SECTION B3400: PAVEMENT LAYERS OF GRAVEL MATERIAL 3 Book 2 of... · C3-92 SECTION B3400: PAVEMENT LAYERS OF GRAVEL MATERIAL B3401 SCOPE Add the following: “This section also covers

C3-92

SECTION B3400: PAVEMENT LAYERS OF GRAVEL MATERIAL

B3401 SCOPE

Add the following:

“This section also covers the construction of pavement drainage layers. The scope includes the work and constraints as described in Part C4: Site Information.”

B3402 MATERIALS

(a) General

Add the following at the end of the second paragraph:

“For chemically stabilised layers the material shall conform to the requirements in table B3402/5.” Add the following after the second paragraph:

“Distinction shall be made between crushed and natural G4, G5 and G6 materials. Where the crushing and/or screening of these materials has been specified, the combined grading shall conform to the grading limits specified for G4 class material in table B3402/1. Material used to construct all stabilised subbase layers shall be of crushed G5 quality and the combined grading shall conform to the grading limits specified for G4 class material in table B3402/1. The same shall apply for all materials obtained from commercial sources.” Add the following:

“Natural gravel material may also be obtained from commercial sources as provided for in the schedule of quantities and where such material is to be used in chemically stabilised pavement layers it shall be capable of achieving the requirements stated in table B3402/5 for C3 and C4 with not more than 3% cement. When materials from different sources are mixed together in a lot the uniformity of the mixed material shall be determined from the CBR values of at least six samples taken randomly, by expressing the calculated standard deviation value of the set of CBR values as a percentage of the calculated mean value of the same set of results. The variation value so determined shall not be greater than 30% for the G7 material in the selected subgrade layer, and not greater than 25% for the G5 material in the to be stabilised subbase layer.” Replace the grading section in Table 3402/1 with:

Grading

Nominal aperture size of

sieve (mm)

Percentage passing through sieve by mass

The percentage

by mass passing

the 2,00mm

sieve shall not be less than 20% not more than 70%

Crushed material Nominal max size

Uncrushed material

37,5 mm 28 mm 53 100 50 95 - 100

37,5 100 85 – 100 28 86 - 95 20 73 - 86 87 - 96 61 - 91 14 61 - 76 73 – 86 5 37 - 54 43 - 61 31 - 66 2 23 – 40 27 – 45 20 – 50

0,425 11 – 24 13 – 27 10 – 30 0,075 4 - 12 5 - 12 5 - 15

Note: Refer to standard COLTO table for COLTO grading if required

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Replace table 3402/5 with:

“Table B3402/5

Requirements for Chemically Stabilised Layers

Classification C1 C2 C3 C4 Material before treatment

At least G2 quality

At least G4 quality

At least G5 quality, (but with

G4 grading)

At least G6 quality

PI after treatment Non-plastic Non-plastic 6 max. *(1) 6 max. *(1) UCS (MPa) *(2) 6 min. 4 min. 1,5 min 0,75 min. ITS (kPa) *(3) - - 250 min. 200 min. WDD (% loss) 5 max. 10 max. 20 max. 30 max.

Note: * (1) For materials derived from the basic crystalline rock group, the Plasticity Index after stabilisation

shall be non-plastic. * (2) Unconfined Compressive Strength @ 100% Mod. AASHTO density at 7 days * (3) Indirect tensile Strength @ 100% Mod. AASHTO density at 7 days * (4) Wet/Dry Durability according to Method B 8110”

Add the following after the last paragraph: “With the in-situ reconstruction of the pavement layers, the existing pavement layers may be broken up in part or completely and mixed together with additional imported material. The existing pavement layers and imported material does however contain isolated hard boulders with sizes varying up to the layer thicknesses of the existing pavement layers and more. The Contractor shall do the necessary investigation prior to in-situ reconstruction of any pavement layer in order to verify that his choice of equipment can cope with the existing pavement layer types and conditions without the risk of damage to his construction equipment. The cost of this investigation shall be deemed to be included in the tendered rates of sections 3300 and 3400. No claim for additional payment for damage to equipment as a result of construction equipment incapable of coping with the existing pavement layer types and conditions shall be considered.” (b) Compaction requirements

Amend the compaction requirements as follows:

“The minimum in-situ dry density of sand and gravel material on this project shall be as specified hereinafter for the respective layers in terms of a percentage of modified AASHTO density.

Selected layer: Lower Selected layer (G9) 93% (100% for sand: see B3402(e) and Table B3402/7) Granular upper Selected layer (G7) 95% (Not sand) Subbase (Crushed G5): 97% for material not chemically stabilized 97% for chemically stabilized (C3 / C4) material Gravel Shoulders (G5) & Wearing course (Type 2) 97% Drainage layer 95%” The minimum densities specified shall be attained throughout the full depth of the layer including the upper 50 mm. For layers constructed in thicknesses of 200 mm and thicker the density of the upper and lower half of the layer shall be measured and evaluated separately.”

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Add the following clauses:

“(d) Drainage material

Material for a drainage layer shall comply with the following requirements:

The Plasticity Index shall not exceed 6. The gradation of the material in the completed drainage layer, measured after compaction shall comply with the limits stated in table B3402/6. Table B3402/6

GRADATION OF DRAINAGE MATERIAL

Sieve Size (mm) Percentage by mass passing

53,0 100 37,5 74 - 100 28,0 57 - 98 14,0 41 - 69 5,00 25 - 37 2,00 15 - 20

0,425 4 - 9 0,075 0 - 4

(e) Defining sand and compaction requirements

Material within the limits as described in table B3402/7 below will be classified as sand. Table B3402/7

DEFINING SAND

PROPERTY LIMIT

Grading percentage passing: 5,00 mm, (minimum) 0,425 mm, (minimum) 0,075 mm, (maximum)

Plasticity Index

96 50 20

Non-plastic “Notwithstanding the above criteria, the compactibility of a material shall be assessed by means of trials and if it is found that it compacts readily to a density of 100% of modified AASHTO and is non-plastic, it shall henceforth be classified as sand for the purposes of the density and CBR at 100% modified AASHTO.”

B3403 CONSTRUCTION

Requirements applying prior to the construction of the layer

Delete the third paragraph which starts with “Where the in situ material .......”.

Add the following:

“The contractor shall note the requirements of clause B3307(d)” (b) Placing and compaction

Insert the following paragraph after the 1st paragraph:

“All in-situ density determinations shall be measured using two individual nuclear density gauges that have been calibrated/validated according to the guidelines described in the manuals for each type of nuclear gauge. The reading taken by each nuclear gauge shall be calculated to obtain a density and a moisture content. Both density results shall then be average to obtain a single result. This result will then represent the density achieved of the spot being tested as the accepted value.

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The minimum densities specified shall be attained throughout the full depth of the layer including the upper 50 mm. For layers constructed in thicknesses of 200 mm and thicker the density of the upper and lower half of the layer shall be measured and evaluated separately.” (ii) Shoulders

Add the following:

"Where the existing unsurfaced shoulder has to be temporarily surfaced to accommodate traffic it shall be constructed to the width shown on the drawings or directed by the engineer. If material is to be added to the base layer of the shoulder in order that the final compacted inner edge may be level with the adjacent roadway with a cross-fall of 3%, it shall be done with G5 quality gravel material. Having flattened and spread any imported material, the base layer shall be ripped or scarified over the required width to a depth of 150 mm, watered, mixed, shaped and compacted to 95% of modified AASHTO density. If so ordered by the engineer, the shoulder shall be stabilised with the addition of cement as specified in section 3500. The contractor shall take care to ensure that despite the restricted working width, the material is well mixed with a uniform moisture content and that a neat and well compacted joint is formed between the shoulder and the adjacent pavement and shall grade the shoulder such that with the surfacing to follow, surface water will drain without ponding on the roadway.” (e) Classification of layers for payment purposes

Replace the first paragraph with the following:

“Payment for pavement layers constructed from gravel material, shall distinguish between layers constructed with material from cuts, or from existing pavement layers, or from commercial sources, or in situ reprocessed layers with or without the use of additional material.”

Add the following subclauses:

“ (f) Utilisation of existing pavement materials

When the road to be constructed overlaps the existing road prism, the materials from the existing pavement layers including the surfacing, shall be utilised as specified or as instructed by the engineer, and if not to be spoiled, shall be used either in fill or in selected subgrade layers of the new road. In the case of half-width construction the contractor shall take care and use suitable techniques for cutting the existing surfacing in a neat line along the inner edge of the working width. Excessive over break of the surfacing extending into the roadway of adjacent traffic shall be reinstated at the contractor's own cost to the satisfaction of the engineer. (g) Stormwater drainage

The contractor shall, at no additional payment, apply sound constructional principles to protect the works and keep pavements dry as specified in clause 1217. In the case of partial-width construction where on account of the box construction, accumulation or ponding of stormwater may occur in the low spots, special measures will be required to provide temporary drainage. The contractor shall allow for all such special measures in the tendered rates and no additional payment shall be made on account of delays or remedial work having to be done where layer material has become too wet under circumstances which, in the opinion of the engineer, is due to the neglect of the contractor to take the necessary precautions.”

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B3405 CONSTRUCTION TOLERANCES

(a) Level

Replace the table in the sub-sub-clause with the following:

“H90

Hmax

Selected layers 25 mm 33 mm Sub-base layers 15 mm 20 mm Base layers 12 mm 15 mm Shoulders 25 mm"

Add the following:

“Level control for the various pavement layers shall be done at least at the following intervals in the longitudinal direction:

Layer Interval

Selected layer, shoulders and wearing course 20 m

Subbase and Base 10 m

(b) Layer thicknesses

Replace the table in the sub-sub-clause with the following:

“D90 Dmax

Dave

Selected layers 25 mm 35 mm 8 mm Sub-base layers 18 mm 24 mm 5 mm Base layers 15 mm 22 mm 5 mm Shoulders 30 mm 0 mm"

(f) Surface regularity

Replace the subclause with the following:

“For new base layers and rehabilitation of existing base layers where the layer or part thereof (in depth) is required to be reworked or recycled over a length of 600 m or more and over the full width of a traffic lane or shoulder wider than 2.0 m (to be surfaced) the roughness of the base layer will be determined by using a inertial laser profilometer capable of producing a class 1 vertical measurement resolution, and a class 3 longitudinal sampling distance as defined in ASTM standard (E950-09). If the inertial laser profilometer is unavailable the roughness of the base layer can be determined by using a ARRB Walking Profiler or Face Dipstick® Profiler. However, these latter instruments are not suitable for mass measurements. Shoulders less than 2.0 m wide (to be surfaced), will be assessed according to measurements obtained from the adjacent lane. The inertial laser profilometer, ARRB Walking Profiler or Face Dipstick® Profiler shall be used to record the longitudinal profile in both wheel tracks of each traffic lane or shoulder wider than 2.0 m, as determent according to the final line markings that will be applied on road surface after completion of construction. For Inertial laser profilometer three repeated runs will be required, for the ARRB Walking Profiler or Face Dipstick

® Profiler only single measurement will be required per wheel track. The two

wheel tracks shall be 1,75 m apart. Should the two tracks not be measured simultaneously during the same pass, then procedures shall be implemented to ensure that the longitudinal profile data recorded for the two wheel tracks are at the same longitudinal location on the road. The measured longitudinal profiles will then be processed using the Quarter-Car simulation model with parameter values as defined in ASTM standard (E1170-97) for Ride Meter-Vehicle Mounted. The simulated suspension mentioned will then be linearly accumulated and divided by the length to yield 100 m IRI (International Roughness Index) values in units of mm/m or m/km for each wheel track. The last 50 metres and the joining first 50 metres of adjacent sections will be evaluated as a 100 m section in the direction of vehicle travel. For inertial laser profilometer measurements the left and the right

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100 m IRI values from the three runs for each measured lane will then be averaged to produce the average IRI as follows: Run1 IRI 100m Ave = (100m IRI Left wheel track + 100m IRI Right Wheel track) / 2 Run2 IRI 100m Ave = (100m IRI Left wheel track + 100m IRI Right Wheel track) / 2 Run3 IRI 100m Ave = (100m IRI Left wheel track + 100m IRI Right Wheel track) / 2 Average IRI 100m = (Run1 IRI 100m Ave + Run2 IRI 100m Ave + Run3 IRI 100m Ave) / 3 For the ARRB Walking Profiler or Face Dipstick Profiler measurements the Average IRI will be calculated as follows: Average IRI 100m = (100m IRI Left wheel track + 100m IRI Right Wheel track) / 2 The Average IRI 100m values is then evaluated and judged according to table B3405/1 to determine whether the 100 m section needs corrective work or payment adjustments. Table B3405/1

PAYMENT ADJUSTMENT FOR BASE LAYER

Average IRI 100 m (m/km) New Pavement Construction

<1.30 1.050

1.31 to 1.40 1.050

1.41 to 1.50 1.025

1.61 to 1.70 1.010

1.71 to 1.80 1.000

1.81 to 1.90 0,990

1.91 to 2.00 0,975

2.01 to 2.10 0,955

2.11 to 2.20 0,930

2.21 to 2.30 0,900

2.31 to 2.40 0.865

2.41 to 2.50 Reject

2.51 to 2.60 Reject

2.61 to 2.70 Reject

2.71 to 2.80 Reject

2.81 to 2.90 Reject

2.91 to 3.00 Reject

>3.01 Reject

Any adjustment to the payment for the base will be made by multiplying the full payment value for each 100 m section, for payment items B36.01, by the payment adjustment factor derived from table B3405/1. The payment adjustment shall apply to the total base layer width placed over the 100 m section in question. Surfaced shoulders less than 2 m wide will be assumed to have the same roughness measurements as the adjacent lane and the quantity of material in the shoulder shall be added to the quantity of material of the adjacent lane for determination of the payment adjustment factor.

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On sections where the Average IRI 100 m is worse than the cut-off value listed in table B3405/1 the section is rejected and corrective work will be necessary. Any corrective work required shall be made by the removal of the total base layer width placed over the 100 m section in question, followed by reinstatement. Surfaced shoulders less than 2.0 m wide will be treated similar to the adjacent slow lane. Corrective work shall not commence until the engineer has approved the contractor’s method statement. If the contractor proposes any other corrective procedure he shall apply to the engineer for the employer’s approval of his proposal. Corrective work shall be done at the contractor’s expense and shall be completed prior to determining pavement thickness. After completion of the corrective work, the 100 m sections shall be re-evaluated according to the specifications. The longitudinal profile and the 100 m International Roughness Index (IRI) values shall be determined using an inertial laser profilometer or an ARRB Walking Profiler or Face Dipstick® Profiler furnished and operated by the contractor or on his behalf in the presence of the engineer. Prior to using an inertial laser profilometer it shall have successfully completed a validation trial against the Instrument of Reference (Face Dipstick

®) used by the employer.

As an absolute minimum the longitudinal profile shall be measured as soon as a 2000 m section of lane or shoulder is completed. Where shorter than 2000 m sections of a layer is required to be constructed the section as a whole will be measured as soon as it is completed. The contractor will be paid for these measurements under payment item B81.05. No additional payment will be made to the contractor for additional measurement and analysis of profiles if ordered for his own assessment purposes, or if additional surveys are required as a result of any remedial/corrective work identified and subsequently completed. For new base layers and rehabilitation of existing base layers where the layer or part thereof (in depth) is required to be reworked or recycled over a length of less than 600 m and over the full width of a traffic lane or shoulder the roughness of the layer will be determined by using a rolling straight edge as described in subclause 8111(c), the number of surface irregularities shall not exceed those given below:

(i) the average number of irregularities per 100 m equal to or exceeding 5 mm when taken in the wheel paths over 300 – 600 m lengths: 3 (ii) the number of irregularities equal to or exceeding 5mm when taken in the wheel paths over 100 m lengths: 4 The maximum value of any individual irregularity measured with the rolling straight-edge or a 3 m straight-edge shall not exceed 10 mm. The measurements with a rolling straight edge or 3 m straight-edge shall be done in each wheel path of each lane or shoulder over the full length of the section. Where a 3 m straight-edge is used it shall be placed in such a way that for a measured line each measurement shall overlap by at least 500 mm with the previous measurement.”

B3406 QUALITY OF MATERIALS AND WORKMANSHIP

Replace the second paragraph with the following:

“Test results and measurements will be assessed in accordance with the provisions of Section 8200.”

B3407 MEASUREMENT AND PAYMENT

Add the following at the beginning of this clause: ”Rates tendered under section 3400 shall cover all additional costs involved in initially placing and compacting the pavement layers in areas larger than theoretically required (in order to achieve compaction and level control) and later cutting back into the compacted layer when the rest of the road

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is constructed and no additional payment will be made for this activity. The quantities of the subbase layer for payment shall be calculated from the authorized dimensions of the completed layer as shown on the drawings or prescribed by the Engineer.” Replace the item description of item 34.01 with the following:

“Item Unit

B34.01 Processing of gravel pavement layers”

Add the following subitem:

“(i) Drainage layer compacted to 95% of modified AASHTO density (state layer thickness) ........................................................................................... cubic metre (m3)”

Add the following to the first paragraph:

“For half-width construction the measured quantities shall not include for having to cut back into previously constructed layers.” Delete the second paragraph (payment paragraph) of this item and substitute with the following:

“The tendered rates shall include full compensation for mixing, watering, placing and compacting the material supplied under item B34.03, the protection and maintenance of the layer, the conducting of control tests and the trimming and removal of surplus material, all as specified. In addition the tendered rate for subitem (g): gravel shoulders, shall, when combined with item B34.03, include full compensation for reworking the existing shoulders as specified in subclause B3403(b)(ii). ” Replace the description of item 34.02 with the following:

“Item Unit

B34.02 Extra over item B34.03(a) for excavation of material in:”


“Measurement shall be as for item 33.03.” Replace item 34.03 with the following:

“Item Unit

B34.03 Supply of material for pavement layers

(a) Gravel taken from cut or borrow including free-haul up to 1,0 km .................. cubic metre (m3) (b) Non-cemented material reworked in situ ....................................................... cubic metre (m3) (c) Non-cemented material taken from pavement layers, including free-

haul up to 1,0 km .......................................................................................... cubic metre (m3) (d) Commercial sources (including unlimited free-haul) (i) G9 quality material ...................................................................................... cubic metre (m³) (ii) G7 quality sand ............................................................................................ cubic metre (m³) (iii) G7 quality gravel (not sand) .......................................................................... cubic metre (m³) (iv) G5 quality material ....................................................................................... cubic metre (m³) (v) G5 quality (with a G4 grading) crushed material (37.5 mm nominal

size) (not Laterite, not bituminous) ................................................................ cubic metre (m³) (vi) Crushed stone drainage layer material ......................................................... cubic metre (m³) (vii) Wearing course material (Type 2) ................................................................. cubic metre (m³) (e) Milled bituminous material in stockpile .......................................................... cubic metre (m³)

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In general the unit of measurement shall be the cubic metre of compacted pavement layer, and the quantity shall be calculated from the authorised dimensions of the completed layer unless otherwise specified hereinafter. For half-width construction the measured quantities shall not include for having to cut back into previously constructed layers. For subitem (a) the tendered rate shall include full compensation for procuring, as if from soft excavation or pits, transporting the material for a distance of 1,0 km, for off-loading and spreading, breaking down, and for the removal, disposal and transporting for a distance of 1,0 km, of up to 5% by volume of oversize material, all as specified. For subitem (b) the tendered rate shall include full compensation for ripping and breaking up non-cemented existing pavement material intended to be reworked in situ and for mixing and redistributing the material transversely to obtain an even mix of uniform thickness over the width of the layer, all as specified. It shall also include for longitudinal redistribution where this can be done by grader. The ripping and breaking-down of the existing surfacing, where applicable, shall be measured and paid for separately under item B38.16. For subitem (c) the tendered rate for non-cemented material supplied from excavation in existing pavements shall include full compensation for the excavation of pavement materials, including any previously broken-down surfacing, in any layer thickness to the depth ordered by the engineer, for breaking down, loading, transporting for an unlimited free-haul distance, off-loading and spreading of the material, all as specified. It shall also include full compensation for controlling the depth of excavation as specified in subclause B3805(a). For subitem (d) the tendered rates shall include full compensation for procuring and furnishing the material from a commercial source, for transporting the material for an unlimited free-haul distance, off-loading and spreading, all as specified. For subitem (e) the tendered rates shall include full compensation for loading the material from stockpile, for transporting the material for a distance of 1,0 km, off-loading and spreading, all as specified.

General:

(1) The tendered rates for the respective subitems when combined with that of item B34.01, shall include full compensation for all the work involved in pavement layers constructed from materials taken from various and any combination of sources as specified. The addition of a soil binder or the mixing of materials from two or more different sources in a new layer shall comply with the requirements of clause 3504 and provided the addition and mixing of materials from different sources has been instructed by the engineer, additional payment under item B35.03 shall be made.

(2) The measured quantity of material to be added to a layer to make up a shortfall in the

available volume of existing in situ pavement material shall be computed by subtracting the quantity of material determined for subitem (b) from the total quantity for the layer as calculated from the authorised dimensions of the completed layer. The in situ volume of pavement materials shall therefore be assumed to be equal to its compacted volume.

(3) Where materials supplied to a particular layer section are to be measured and paid for under

two or more of the relevant subitems and cannot readily be measured separately in the compacted layer, the individual compacted quantities may be calculated from the ratio of material imported as measured loose in the hauling vehicles.

(4) For subitem (c), and in the event of it having to be stockpiled temporary, on the instruction of

the engineer, the material so stockpiled will be paid for at 50% of the tendered rate and the balance will be paid when it has been finally placed and measured in the intended layer. The quantity to be paid for in stockpile shall be calculated from the volume measured loose in the hauling vehicles and converted with a bulking factor of 1,5. If any material is left over in a stockpile on completion of the project, no further payment will be made for it. If the

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engineer decides that the stockpile area has to be cleared and the remaining material moved elsewhere or to spoil, such work will be paid for on a daywork basis.”

Delete items 34.04 and 34.06 in total.

Replace item 34.05 with the following:

“Item Unit

B34.05 Extra over item B34.01 for processing gravel pavement material mixed with bituminous surfacing material ................................................ cubic metre (m

3)

The unit of measurement shall be the cubic metre of gravel pavement layer constructed with recovered pavement material mixed with existing bituminous surfacing material. The tendered rate shall be extra over the rates tendered for item B34.01 and shall include full compensation for all additional costs and incidentals for placing and compacting material mixed with more than 10% by volume of bituminous surfacing material. This item is not applicable to the C3/C4 stabilised subbase layers.” Note that items 34.09 will not apply to this contract.”

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SECTION B3500: STABILIZATION

B3501 SCOPE

Add the following as a 3rd paragraph:

“The use of recyclers for cold in situ recycling purposes is also covered in this section, which includes cement, lime, emulsion and foam stabilisation of base and subbase layers consisting of gravel and/or crushed stone material as described in sections 3400 and 3600.”

B3502 MATERIALS

(a) Chemical stabilizing agents

Delete sub-clauses (ii) Ordinary Portland cement and (iii) Portland blast-furnace cement and replace with the following:

“Cement shall comply with the relevant requirements of SANS 50197-1:2000. The use of strength classes greater than 32,5 shall not be permitted. The stabilizing agent for this contract shall be CEM II/A-L 32.5 or CEM II 32.5 A-S or composite CEM II/B-M (L-S) 32.5. The preferred stabilising agent will be based on performance tests results obtained on insitu materials by site laboratory trials.”

B3503 CHEMICAL STABILIZATION

(a) Preparing the layer

Insert the following before the first paragraph:

“Moisture content tests shall not be undertaken more than one day in advance of in situ stabilization operations. Care shall be taken to ensure that samples are representative of the in situ material. Checks shall be conducted when wet weather occurs between initial testing and work commencing on any section.” Add the following: “The material shall then be spreaded in a uniform layer over the full half width under construction before additional granular material is added, if required. After the layer has been cut to level, the surface of the layer to be stabilized shall be watered and rolled to obtain a smooth compacted surface without loose or coarse patches in order to ensure a uniform application of stabilizing agent or agents. Payment for preparing the layer surface to these standards shall be deemed to be included in the tendered rates of sections 3400 and 3500.” (b) Applying the stabilizing agent


“Application of the stabilizing agent using a bulk supply truck will not be permitted.” Replace the second sentence of the second paragraph with the following:

“Spreading shall only commence when the engineer is satisfied that the correct quantity of stabilizing agent has been placed on the layer and has given permission that the stabilizing agent may be spread uniformly over the entire surface to be treated.” Add the following: "The minimum rate of application shall be a total of 2,0% by mass of the specified stabilizing agents. The Engineer may order a variation in the rate of application. The spreading of stabilizing agent/s shall be done by placing bags along the road and spreading by hand using rubber squeegees to obtain a uniform layer of stabilizing agent/s. Bags which have become damaged or wet shall not be used and

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such bags shall be replaced at the Contractor’s cost. No additional payment other than the scheduled payment items shall be considered if more than one type of stabilizing agent is used for the stabilization of a layer.” (d) Mixing in the stabilizing agent Add the following: ”Where chemically stabilized pavement layers are constructed, no stabilizing agent may be spread or mixed beyond the specified width. The Contractor shall not mix material for stabilization on adjacent bituminous surfaces. Where existing and new works are joined (longitudinal joints and others), the material shall be satisfactorily mixed and compacted without any permeable or loose patches.” (f) Compaction Add the following at the end: “The entire layer, regardless of its thickness, shall be processed within the time limitations stipulated in sub-clause B3503(i).” The minimum densities specified shall be attained throughout the full depth of the layer including the upper 50 mm. For layers constructed in thicknesses of 200 mm and thicker the density of the upper and lower half of the layer shall be measured and evaluated separately.” (h) Curing the stabilized work

Replace the first paragraph with the following: "The stabilized layer shall be protected against rapid drying out by being kept continuously wet or damp by watering at frequent intervals until one of the methods of protection listed below is put into effect. Stabilized layers which are not kept continuously wet or damp but is subjected to consecutive wet-dry cycles, may be rejected by the Engineer should he consider the layer to have been adversely affected. Method (iii) and (iv) shall not be applicable." For method (i) amend the second sentence to read as follows: “This method shall be applied for an initial period of at least 48 hours, but thereafter one of methods (ii) or (v) shall be applied.” For method (ii) add “after the initial 48 hour period” after “layer” in the second line. Add the following to method (ii): “The covering material shall be placed by end-tipping, spread, and not compacted until the underlying layer has cured for at least 7 days.” Add the following to paragraph: “Method (iii) and (iv) shall not be applicable.” Add the following: “The contractor shall take note of this clause and in particular the requirement that notwithstanding the method of curing used, the stabilized layer shall be kept continuously wet or damp for seven days.”

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Amend the final paragraph to read: "No additional payment will be made for curing as described above." (i) Construction limitations

Replace the fourth paragraph starting with “No stabilization ...” with the following: “No stabilization shall be done during windy conditions, wet weather or with falling air temperatures (7°C and dropping), or during rising air temperatures (when the air temperature is below 5°C). The surface temperature of a compacted stabilized layer shall not be allowed to fall below 1°C during the first three (3) days after stabilization. The contractor shall be responsible for taking the necessary precautions to prevent the layer from freezing. All stabilized layers damaged by rain, frost or by the formation of ice in the layer shall be removed and replaced by the contractor at his own expense. The contractor shall make allowance for these requirements in his construction programme.” Add the following: “Under no circumstance shall traffic be allowed to travel on layers of cement stabilised material for a period of at least 7 days. Moisture content tests shall not be undertaken more than one day in advance of in-situ stabilisation operations. Care shall be taken to ensure that samples are representative of the in-situ material. Checks shall be conducted when wet weather occurs between initial testing and work commencing on any section.” In table 3503/1, delete “8 hours” for Ordinary Portland cements and cement blends and replace with “6 hours”.

B3506 TOLERANCES

(b) Uniformity of mix (chemical stabilisation)

For this project method (ii) shall apply.


Add the following after the second paragraph:

“The test results and measurements will be judged in accordance with the provisions of Section 8200. Add the following paragraphs:

“The engineer shall be notified in good time to enable him to conduct tests himself. Sample preparation and testing for cement stabilization content shall be done by means of the Rapid Cure Method as described in clause B8110. The stabilized material sampled from the layer for the compaction of modified AASHTO briquettes, shall be prepared according to SANS 3001; GR54; i.e. discard material coarser than a 37,5 mm test sieve, and compacted according to SANS 3001; GR31. Any delamination of the completed layer (biscuiting), identified by the hollow sound caused when a chain is dragged over the stabilized layer, shall be removed and repaired prior to the construction of subsequent layers. The repair method shall be approved by the engineer. No payment will be made for repairs.”

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“For this project only the areas as defined under clause B3407 shall be deemed to be restricted areas.

Item Unit

B35.01 Chemical stabilization (layer thickness indicated) extra over unstabilized compacted layers (layer to be stabilized indicated) ........................... cubic metre (m)

In the fifth line of the second paragraph, add “for at least 48 hours” after “sections”.

Item Unit

B35.02 Chemical stabilizing agent

Replace the full stop at the end of the third paragraph with the following:

“and layer dimensions. ” Item Unit

B35.03 Mechanical modification (extra over untreated layer):

Add the following to the payment clause:

“The procurement and furnishing of the material to be added or mixed from different sources shall be measured and paid for under item B34.03 or B33.02 as the case may be.”

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SECTION B3600: CRUSHED-STONE BASE B3602 MATERIALS (a) Requirements for crushed aggregate After the first sentence delete the remainder of the paragraph and replace with the following: “The aggregate shall not contain more than 0,1% by mass of unwanted material such as wood, coal or similar organic material. Aggregates containing mica, such as granite, gneiss, mica schist, pegmatite, sandstone shall not contain more than 2% by mass of free mica, especially muscovite, when assessed by visually separating the particles, or more than 4% by volume when assessed by means of microscopic slides. Aggregate containing easily detectable quantities (more than 1%) of olivine, serpentine and sulphide minerals such as pyrites and marcasite, must be considered with caution, and may warrant additional evaluation to the satisfaction of the engineer. Argillaceous rocks may only be used if specified in the project specifications, or with the engineer’s written approval. Soft or weathered particles shall be controlled by the Durability Mill Index values specified in B3602(e) Durability. Provision has been made in clause B8108(b)(iii), calculation, for the determination and calculation of the apparent density for aggregates with a total water absorption greater than 1,5%, when total water absorption is determined according to TMH1 methods B14 and B15.” (c) Grading requirements Replace entire clause with the following: “The target grading, after compaction, shall be as near as possible to the mean of the specified grading envelope listed in table B3602/1 and shall be continuous with no marked gaps or excessive quantities of any particular size. The mean grading of each lot (minimum of 4 but preferably 6 test points per lot) shall conform to the approved target grading plus or minus the tolerances specified in table B3602/4. However, no target grading plus tolerance can be set such that the original grading envelope in table B3602/1 is exceeded. ” Table 3602/1 In table 3602/1 delete “85% of bulk relative density” and replace with “88% of Apparent Relative Density". Replace the grading section in table 3602/1 with:

GRADING

Nominal aperture size of sieve (mm)

Percentage passing through sieve by mass

Nominal max size

G1 G2 G3

37.5mm 37.5mm 37,5 mm 28 mm

37,5 100 100 100

28 86 - 95 86 - 95 86 - 95

20 73 - 86 73 - 86 73 - 86 87 - 96

14 61 - 76 61 - 76 61 - 76 73 – 86

5 37 - 54 37 - 54 37 - 54 43 - 61

2 23 – 40 23 – 40 23 – 40 27 – 45

0,425 11 – 24 11 – 24 11 – 24 13 – 27

0,075 6 - 10 6 - 10 6 - 10 5 - 12

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Replace table 3602/4 with:

Table B3602/4

Sieve size (mm)

Permissible deviations by mean values (% by mass)

Permissible deviations by individual values (% by mass)

Nominal maximum size (mm) 37,5 26,5 37,5 28

28 ± 5 ± 5 20 ± 5 ± 5 ± 7 ± 7 14 ± 5 ± 5 ± 7 ± 7 5 ± 5 ± 5 ± 7 ± 7 2 ± 4 ± 4 ± 5 ± 5

0,425 ± 3 ± 3 ± 5 ± 5 0,075 ± 2 ± 2 ± 3 ± 3 Note: Refer to standard COLTO table for COLTO grading if required

Add the following sub-clause:

“(e) Durability

The durability property of aggregates derived from the basic crystalline group shall be assessed by means of the Ethylene Glycol Durability Index. When tested in accordance with the method prescribed in B8105(g) the durability index shall not exceed four. In addition, the 10% FACT value obtained after soaking in ethylene glycol for four days shall not be less than 50% of that obtained on the unsoaked sample. Where any values are obtained that fall outside the above requirements, a detailed assessment of the quarry shall be undertaken together with a specialist mineralogical evaluation of both the coarse as well as fine fractions in order to assess the long-term durability properties of the material. For basic crystalline rocks, arenaceous rocks, argillaceous rocks and diamictites the durability mill index (DMI) shall be less than 125. For all other rock types the durability mill index (DMI) shall not be more than 420, subject to the % passing the 0,425 mm sieve not increasing by more than 8 percentage points during the durability mill test.”

B3604 CONSTRUCTION

(b) Compaction

Replace that last sentence of the first paragraph with:

“The density of the layer shall be tested at each third of the layer thickness.” Add the following: “All insitu density determinations shall be measured using two individual nuclear density gauges that have been calibrated/validated according to the guidelines described in the manuals for each type of nuclear gauge. The reading taken by each nuclear gauge shall be calculated to obtain a density and a moisture content. Both density results shall then be averaged to obtain a single result. This result will then represent the density achieved of the spot being tested as the accepted value.”

The minimum densities specified shall be attained throughout the full depth of the layer including the upper 50 mm.”

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(c) Surfacing preparation of the base

Replace the final paragraph in subsubclause 3604(c)(i) with:

“Slushing of the base, is compulsory and shall be carried out within 48 hours after completion of the compaction. Even if the specified density is achieved without slushing or before completion of the slushing process, the full slushing process must still be completed.” Delete subsubclause (ii) Multi-stage process (water or slurry rolling). B3605 PROTECTION AND MAINTENANCE Add the following to the end of the second sentence: “as determined according to TMH 1 method A7.” B3607 QUALITY AND WORKMANSHIP Delete “or 8300” in the second paragraph. Add the following at the end of the first paragraph:

“All crushed-stone base material shall be subjected to the tests and their frequencies specified in Table 3602/5. The material may only be placed on the road when all of the specified tests have been

completed and have passed”.

TABLE 3602/5: TEST FREQUENCIES OF BASE

Test Description

Frequency

(test / m3 of base material) 10% Fines Aggregate Crushing Values

5 000

(i) Ethylene glycol durability testing

5 000

(ii) Atterberg Limits:

PI –0,425

1 000

PI –0,075

2 000

(iii) Soluble salts

10 000

Grading

10 000

(iii)+(iv) Durability Mill Index

5 000

(i) Test method B8116 durability shall not exceed 5.

(ii) PI -0,425 = Plasticity Index determination on - 0,425 mm material. PI -0,075 = Plasticity Index determination on - 0,075 mm material. (iii) Durability mill index shall be less than 125. Replace the last paragraph with the following: “Test results and measurements shall be assessed in accordance with the provisions of Section 8200 (Ls = 88,0% or 89,0% as ordered).” B3608 MEASUREMENT AND PAYMENT Add the following at the beginning of this clause:

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”Rates tendered under Section 3600 shall cover all additional costs involved in initially placing and compacting the base in areas larger than theoretically required (in order to achieve compaction and level control) and later cutting back into the compacted layer when the rest of the road is constructed and no additional payment will be made for this activity. The quantities of the base layer for payment shall be calculated from the authorised dimensions of the completed layer as shown on the drawings or prescribed by the Engineer.” Delete the first paragraph and replace it with the following: “Note: No additional or extra over payment shall be made for work in restricted or confined areas.” Item Unit

B36.01 Crushed-stone base In the description of subitem (a) replace "88% of apparent relative density" with "89% of apparent relative density". In the description of subitem (c) replace "85% of bulk relative density" with "88% of bulk relative density".

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SECTION B3800: BREAKING UP EXISTING PAVEMENT LAYERS B3801 SCOPE Add the following: “The scope includes the work and constraints as described in Part C4: Site Information.” B3804 PLANT AND EQUIPMENT (a) Milling equipment Add the following: “No payment shall be made for moving the milling machine onto or within the site.” (b) General Add the following: “Compressed air for cleaning the milled surface shall be delivered by a mobile compressor capable of producing at least 3 m3/minute compressed air at 750 kPa, equipped with the necessary filters to ensure clean air. The compressor shall be free of oil and diesel leaks.” B3805 CONSTRUCTION (a) General Amend the first paragraph to read as follows: “Where the engineer instructs that all or a part of the existing surfacing material is to be reprocessed together with the underlying layer either in place or elsewhere in fill or new pavement layers, the surfacing shall be properly broken down and mixed thoroughly with the underlying material to the depth instructed by the engineer. Fragments of the bituminous material shall be broken down to sizes not exceeding 37,5 mm.” Add the following to the second paragraph: “The contractor shall use methods and procedures which will result in the surfacing being removed with the minimum amount of base material lost. Bituminous material so removed shall be classified as bituminous material excavation as specified in subclause 3803(a).” Amend the fourth paragraph to read as follows: “The existing pavement material shall be broken down to the depth specified or ordered by the engineer and removed, or reprocessed in place, whichever may be required. The underlying layers may not be damaged, and material from one layer may not be mixed with that from another layer unless so instructed by the engineer. Where such unauthorised mixing occurs or where the material is contaminated in any other way by the actions of the contractor, he shall remove such material and replace it with other approved material, all at his own cost.” Add the following: “For material classified as non-cemented material, the contractor's method of excavating the pavement material and his control over the depth of excavation shall be such that when instructed to remove a particular layer as defined by the quality of the material, the material is not contaminated as specified herein above. Similarly, when the depth of excavation is defined to be to the top of a specific layer in the new pavement, then any over or under excavation resulting in a shortfall or surplus of material when such a layer is subsequently processed in situ, will be made good at the contractor's own cost.

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The work is proposed to be executed in sections as described in Part A of the specifications and which may necessitate the de-establishment and re-establishment of certain plant items. Payment for the moving of plant onto or from site, or from one location to another on site, shall only be made as may explicitly be provided for in the schedule of quantities and the contractor shall provide for all additional expenditures in this regard in his tendered rates. ” (b) Milling (iv) Milling in restricted areas Delete this paragraph. No separate payment will be made for having to mill in narrow widths. (vi) General Add the following: “The exposed floor of the excavation shall be lightly sprayed with water to identify cracks. The engineer shall be given the opportunity to inspect the milled surface for cracks and loose patches and any cracks or loose patches shall be repaired in accordance with the relevant sections of the specification. The floor of the milled excavation shall, before the application of the tack coat, be cleaned of all loose material by brooming, blowing with compressed air or vacuuming or any other method that will produce an exposed surface that is closely-knit, firm and stable, free of nests of segregated materials, laminations or corrugations. Where milling is to be done at existing structures, care shall be exercised to avoid damage to concrete elements, expansion joints, nosings to expansion joints, manholes, catch pits etc. Damage caused to any element forming part of the permanent works shall be repaired at the contractor’s cost. Milled excavations shall not be left open to traffic unless longitudinal and transverse joints have been treated. Where the difference in level between the floor of the milled excavation and the existing road surface exceeds 25 mm, joints shall be treated as follows: Transverse steps shall be tapered off at a slope of 1 vertical to 20 horizontal (1:20) and longitudinal joints exposed to traffic shall be tapered to a slope of 1 vertical to 5 horizontal (1:5). An alternative method using a compacted asphalt wedge of the same dimensions is acceptable.” (c) Treatment of pavement excavation floor Replace the paragraph with the following: “After removal of the bituminous surfacing layer, the floor of the milled area shall be cleared in the conventional manner of all loose material. In the case where a skin of bituminous material has remained and which is not well bonded to the underlying base layer, it shall be carefully scraped off by hand and removed. If so ordered it shall thereafter be cleaned further using compressed air to remove any remaining loose fragments and dust so that the surface may be inspected by the engineer for cracks and other defects. When using compressed air passing vehicles shall be protected from flying particles which may cause damage by strictly controlling the compressed air nozzle direction, or when this is in the opinion of the engineer, not sufficient, by providing a suitable mobile screen to contain any flying particles.”

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B3807 MEASUREMENT AND PAYMENT (a) General (v) Measurement for excavating existing pavement material and underlying fill Add the following: “Where deemed more appropriate, the quantity will be computed by the method of average end areas from levelled cross-sections taken before and after the excavation.” Replace paragraph (c) with the following: “(c) Items 38.05 and 38.06 will not apply to this project and payment for working in restricted

areas shall be allowed for in the tendered rates.” Item Unit

B38.02 Milling out existing bituminous material with an average milling

depth: ........................................................................................................ cubic metre (m³) Insert as a new fourth paragraph the following: “The rates shall also include for transverse saw-cutting at the start and end of sections prior to the commencement of the milling operations.” Add the following at the end of this clause: “Note: Where material under this section requires haulage in excess of 1 km, item B16.02 shall be

included in this section of the schedule of quantities to make provision for overhaul to stockpile except where the material is specified for immediate re-use in which case overhaul shall be paid under the relevant construction payment section(s).”

Item Unit B38.08 Sawing or cutting asphalt or cemented pavement layers: Amend subitem (a) to read as follows: “(a) Sawing bituminous surfacing to an average depth: (i) Not exceeding 30 mm..............................................................................................metre (m) (ii) Exceeding 30 mm but not exceeding 60 mm............................................................metre (m) (iii) Exceeding 60 mm.................................................................................................. metre (m)” Replace the second payment paragraph with: “Payment will distinguish between the various depths of sawing, irrespective of the number of separate cuts which may be required to saw the bituminous layer.” Item Unit B38.14 Providing the milling machine on site Replace the first paragraph with the following: “No payment for this item shall be made under this contract. All costs related to the provision of a milling machine on site shall be deemed to be included in the other pay items in this section.”

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Item Unit

B38.15 Moving the milling machine on the site


“No payment for this item shall be made under this contract. All costs related to the moving of the milling machine on site shall be deemed to be included in the other pay items in this section.” Add the following item:

“Item Unit

B38.16 Breaking-down existing surfacing intended for re-use, with an average thickness of: (state thickness)..................................................... square metre (m2)

The unit of measurement shall be the square metre of existing surfacing broken down on the instruction of the engineer in order for it to be reprocessed and re-used together with the under lying layer. The tendered rates shall include full compensation for ripping and breaking down to the maximum aggregate size specified, for removing by hand or other means lumps of bituminous material that cannot be broken down and disposing thereof, and for mixing of the broken-down surfacing with the underlying layer(s) and/or material added to it so as to obtain a uniform mixture containing not more than 30% bituminous material. ”

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SECTION B3900: PATCHING AND REPAIRING EDGE BREAKS

B3901 SCOPE

Add the following to the first sentence:

“This section also covers the repair of potholes which are generally defined to be patching of a local failure with a surface area less than 2 m².” B3904 PATCHING (c) Excavating pavement material

Add the following after the first paragraph:-

“Excavated material to be spoiled must be removed and dumped on a suitable site on the same day it is excavated.” Replace the last paragraph with the following:

“For this contract patching shall refer to surfacing repair and base repair. For surfacing repair the depth of excavation shall be nominally 40 mm. For base repair the depth of excavation shall be as directed by the engineer up to the full thickness of the existing asphalt layer which is nominally 100 mm. After completion of the initial excavation to the depth ordered, the engineer shall be afforded the opportunity to examine it to determine whether the excavation depth shall be increased. When no further layer materials are to be removed the floor of the excavation shall be cleaned of all loose and uncompacted material.” (d) Backfilling excavations

Add the following as new paragraph one for subparagraph (i):

“The backfilling of excavations must be done in layers. Every layer must be compacted before the next layer is placed. The following layer thickness limits shall be applied:- Minimum

Maximum

Gravel 75 mm 75 mm Crushed stone 75 mm 75 mm Asphalt base 50 mm 75 mm

Asphalt wearing course 30 mm 60 mm Base patching shall be effected with a continuously graded asphalt base mix as specified in section 4200 and the project drawings. Where asphalt material is used for patching, special cognisance must be taken of the requirements of section 4200 as it pertains to the material that will be used for patching. Where instructed by the engineer, after completion of the trimming and finishing of the patch, its circumference up to 100 mm beyond the edges, shall be sealed by applying a diluted bitumen emulsion (e.g. Colseal) or an approved equivalent to seal the joints. Where needed, an approved crack sealant is to be applied along the joints between the patch and the existing road pavement. The cost of sealing the patch shall be deemed to be included in pay item 42.20.” Replace subparagraph (ii) with the following:

“The contractor shall place and spread the material with mechanical equipment or by hand in layer thicknesses matching the capability of the compaction equipment that can be used, “building up” until the full depth is obtained. To achieve a level patch that gives a smooth ride the base shall be

C3-115

screeded off using a board or rails or a different method approved by the engineer. Once the backfilling has been done to the level of the adjacent base layer, the final compaction should be done with a heavy vibratory and/or pneumatic roller. As soon as it is feasible the area around the patch shall be washed off to remove all surplus slush and other contaminants which will affect the subsequent reinstatement of the asphalt wearing course Before placing the surfacing, a tack coat shall only be applied where directed by the engineer. Application of prime or tack coat shall be paid under payment item 42.15. Any consolidation of the patch under traffic shall be made good by the contractor at his own expense. Where the engineer is satisfied with the structural capability of the patch, the depression may be corrected by replacing the asphalt surfacing.” (e) Restrictions

Replace the first sentence with the following :

“All excavations for localised isolated patching shall be backfilled on the same day. Where a number of patches and/or other repairs are required, subject to the approval of the engineer, a half width length of the road not greater than 500 m may be closed to traffic.” Add the following new subclauses:

“(f) Spreading and compaction equipment to be used with patching

The compaction equipment for patching areas (surfacing repairs) of more than 2,0 m² (where the width of the patch is equal to or exceeds 1,0 m) shall comply with the same standards as that for asphalt bases and surfacing, as described in section 4200. In this regard special emphasis is placed on the use of the prescribed spreading equipment when placing the asphalt mixture. This requirement is necessary to ensure that the requirements for construction tolerances and finish requirements are as set out in section 4200. (g) Potholes

A pothole shall be defined as a failure of the existing pavement layers where the surfacing and/or base materials no longer exist over a relative small area (less than 2,0 m2). Pothole repair shall consist of trimming away any ravelled edges and loose material to the full depth of the pothole and the backfilling thereof with asphalt as follows: (i) Excavation and preparation

The existing material shall be removed in a neat rectangle to sound base, with a minimum dimension of 200 mm x 200 mm and a minimum depth of 60 mm. Prior to backfilling the areas with asphalt the excavation shall be cleaned of all fine material, and lightly watered and tacked with an invert emulsion complying with the requirements of SABS 1260 and shall be applied at a rate of 0,7 litre/m². (ii) Backfilling

The backfilling of potholes shall be done with asphalt which shall be obtained from commercial sources. The asphalt supplied from commercial sources shall be as detailed in section 4200, table 4202/7 for medium continuously graded. The medium grade continuously graded asphalt shall be placed and well compacted in layers not exceeding 60 mm after compaction. The contractor shall use suitable compaction equipment and shall ensure that adequate compaction is applied for the mix used to produce a dense asphalt layer which will not deform under traffic. (iii) Trimming and finishing

The edges of the reinstated pothole shall not be above the existing surface by more than 3 mm. Nowhere shall the edges be below the existing surface. The surface of the repaired area shall be a continuation of the existing road cross-fall.

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Surplus material resulting from the repairs shall be suitably disposed of and the drainage systems cleared of any spoil. (iv) Sealing

Immediately on completion of the trimming and finishing of the reinstated pothole, its total area and up to 100 mm beyond the edges, shall be sealed by applying a diluted bitumen emulsion (e.g. Colseal) or an approved equivalent to render the repaired area impermeable. The cost of sealing the patch shall be deemed to be included in pay item B42.21.”


Add the following payment item:

“Item Unit

B39.06 Repairing potholes in the existing surfacing with a bituminous mixture ........................................................................................................ cubic metre (m³)

The unit of measurement for repairing potholes shall be the cubic metre measured to the nearest 0,001 cubic metre of bituminous mixture placed in accordance with the specifications. The tendered rate shall include full compensation for all excavation and spoiling of the excavated material. The tendered rate shall also include full compensation for all transport, handling, labour, plant, supply and mixing of all materials, preparation of the area to be repaired, the placing and compaction of the bituminous mixture and all incidentals necessary for completing the work.” Add the following clause:

“B3908 CONSTRUCTION TOLERANCES, FINISH REQUIREMENTS AND RESTRICTIONS

The final riding surface on any particular point on patches or between the patch and existing surface shall not deviate more than 5 mm from the bottom of a 3 m long straight edge.”

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COLTO SERIES 4000: ASPHALT PAVEMENTS AND SEALS

SECTION B4100: PRIME COAT

B4102 MATERIALS

(a) Priming material

Add “(such as MSP 1)” to the definition of invert bitumen emulsion

(b) Aggregate for blinding

Add the following sentence:

“Blinding of the primed surface with aggregate shall only be permitted to facilitate vehicular access to adjoining properties”

B4104 WEATHER AND OTHER LIMITATIONS

Replace paragraph (g) with the following: “(g) When at any position within the layer the moisture content of a granular base layer is more than 50% of the optimum moisture content determined according to TMH 1, Method A7. In the event of rain after priming, the base shall be allowed to dry out to meet the above moisture content requirement prior to surfacing.” Add the following paragraph: “(h) When the moisture content of a granular base layer during the periods May to August is more than 2%.

B4106 APPLICATION OF THE PRIME COAT

Replace paragraph (c) with the following:

“The type of prime and application rate best suited for the base shall be determined during construction. The contractor shall provide about 20ℓ of each prime and apply it at different application rates with a brush on the base. The engineer will then instruct the type of prime and application rate to be used. No payment shall be made for tests to determine the type of prime. Unless directed otherwise by the engineer or indicated on the drawings, the edges of the primed surface shall be 150 mm wider than the edges of the surfacing.” Add the following to subclause (e):

“Areas showing a deficiency in prime shall be made good, and areas with excessive prime shall be blinded before opening to traffic, all at the contractor’s cost. However, blinding material ordered by the engineer for primed areas where prime has been applied at the specified rate of application, shall be paid for under payment item B41.02.” Add the following sub-clause:

“(j) Application in areas treated by reworking and construction of a new base shall be primed using a mechanical distributor complying with sub-clause 4103(a). The edges of the previously constructed or existing surfacing shall be adequately protected by approved means to ensure that an overlap of prime not exceeding 50 mm is sprayed onto the previously constructed or existing surfacing.”

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B4108 TOLERANCES


“The actual spray rates measured at spraying temperature shall not deviate by more than 8.0% from that ordered by the engineer. The engineer may, at his discretion, conditionally accept application rates falling outside this tolerance at reduced payment in accordance with table B4108/1.

Table B4108/1

PAYMENT REDUCTION FACTORS FOR CONDITIONALLY ACCEPTED PRIME COAT

Deviation specified spray rate at spraying temperature. (%)

Payment reduction factor of tendered rate.

±8,0 1.00 ±9,0 0.97

±10,0 0.95 ±11,0 0.90 ±12,0 0.85 ±13,0 0.80

Any deviation outside these limits shall not be paid for, however, the engineer shall have the right to instruct the contractor to make up any deficiency, or blind excessive prime without additional payment. Where so instructed, the material for blinding shall consist of approved, but shall consist of screened 5 mm nominal single size aggregate. The use of crusher dust for blinding shall not be permitted. If under-spraying occurs, and it is accepted by the engineer, only the actual quantities applied shall be paid for.”

B4109 TESTING

Add the following:

“No payment will be made if this condition is not adhered to. The contractor shall provide, at his cost, representative samples of every batch of prime delivered onto site.”


Item Unit

B41.01 Prime coat

Replace the description of subitem (e) with the following:

“(e) Invert bitumen emulsion (MSP 1) .................................................................................... litre” Add the following subitem:

“(f) Emulsion based prime i.e. Colprime E ............................................................................. litre” Add the following at the end of the payment paragraph:

“The prime coat may have to be applied in restricted areas. The tendered rate shall apply for all applications of the prime coat irrespective of the size of the area where it has to be applied. Making good of deficiency in prime, and blinding of excessive prime shall be for the cost of the contractor.” Item Unit

B41.02 Aggregate for blinding ............................................................................. square metre (m²)

Add the following to the payment paragraph:

“Blinding of areas with excessive prime as a result of an application rate deviating from the specified application rate, shall not be measured for payment.”

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SECTION B4200: ASPHALT BASE AND SURFACING

B4201 SCOPE

Add the following to sub item (a):

“(viii) Continuously graded asphalt surfacing with modified binder Add the following sub item:

(d) The work as described in Part C4: Site Information”

B4202 MATERIALS

(a) Bituminous binders

(i) Conventional binders

Add the following:

“The binders to be used shall be as follows:

(a) Continuously graded surfacing -: 50/70 penetration grade bitumen (b) Continuously graded base: 50/70 penetration grade bitumen”. (iii) Homogeneous modified binders

Replace the last sentence with:

“The modified binder to be used on this project shall be A-E2. The homogeneous modified binder shall be manufactured according to the guidelines contained in “Technical Guideline: The use of Modified Bituminous Binders in Road Construction (TG 1-2007): Asphalt Academy”. The base bitumen shall conform to SANS 4001-BT1:2012, or a blend of SANS 4001-BT1:2012 grades. The type as well as percentage of modifier is not prescribed, however the contractor shall indicate in the Pricing Schedule what polymer he shall be using. The properties of the homogeneous modified binder shall comply with the relevant requirements for binder class A-E2 as listed in table B4202/12.”

Table B4202/12

PROPERTIES OF POLYMER-MODIFIED BINDER FOR HOT-MIX ASPHALT

Property Unit Test Method Binder Class

A-E1 A-E2 A-P1

Softening Point1 °C MB-17 55-65 65-85 63-73

Dynamic Vicosity@165°C Pa.s MB-18 ≤0.6 ≤0.6 ≤0.55

Force Ductility @ 5°C N EN 13703 Report*3 Report*

3 Report*

3

Elastic Recovery @ 15°C % MB-4 >50 >60 >30

Storage Stab @ 160°C) °C MB-6 ≤5 ≤5 ≤5

Flash Point °C ASTM: D93 ≥230 ≥230 ≥230

Creep Stiffness MPa AASHTO:TP1 Report Report Report

Properties after ageing (RTFOT) MB-3

Diff in Softening Point °C MB-17 -2 to +8 -2 to +8 -2 to +8

Elastic Recovery @ 15°C % MB-4 >40 >50 Report*2

Mass change % MB-3 ≤1.0 ≤1.0 ≤1.0

Dynamic Viscosity @ 165°C

Pa.s MB-18 Report*2 Report*2 Report*2

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* Notes: 1. The prescribed test method is based on not using stirrers although it has been reported that the

use of stirrers has shown no difference in test results. For referencing purposes no stirrers should be used.

2. No limits are given and the values should be recorded for reporting purposes only as they may be used in future specifications.

3. No values given but the test can be used to rank various binders according to their low temperature cohesion properties

(b) Aggregates

Add the following paragraph to the introductory description:

“Asphalt mixes shall be manufactured using different individual single size coarse aggregates fractions and crushed fine aggregates blended to conform to the specified grading requirements. The use of natural sands shall only be permitted if approved by the engineer and shall be limited to a maximum of 5% for continuously graded mixes. All aggregate in excess of 4,75 mm shall consist of individual nominal single sized aggregate. For stone mastic asphalt mixes all aggregate fractions in excess of 2,36 mm shall consist of individual single size fractions. The Contractor shall note that commercial suppliers may not be able to supply all the required single size aggregates, in which instance arrangements will have to be made for additional on-site screening. No additional payment shall be made for screening aggregate. The use of run of crusher type materials shall not be permitted.” (v) Absorption

Add the following sentence:

“In addition, the total binder absorption of the combined coarse and fine aggregate blend shall not exceed 0,5%.” (viii) Grading

Delete the second paragraph commencing with "The target grading…" and add the following paragraphs

“The grading limits for the combined aggregate grading for the asphalt base shall be as specified in table 4202/6: Continuously graded 26,5m maximum. The grading limits for the combined aggregate grading for the asphalt surfacing shall be as specified in table 4202/7: Continuously graded medium grade.” Add the following:

“The engineer may request a reconsideration of a blend to achieve any grading within the given envelope to improve certain properties.” (x) Rolled-in chippings

Replace Table 4202/11 with:

Table B4202/11

Sieve size (mm) Chip size - Percentage passing by mass 20 mm 14 mm

20,0 100 14,0 0 – 20 100 10,0 0 – 5 0 – 20 7,1 0 – 1 0 – 5

0,425 0,5 max 0,5 max Note: Refer to standard COLTO table for COLTO grading if required

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Add the following new sub-items:

“(xi) Moisture content

The moisture content of aggregates, sampled from the cold feed belt, shall not exceed the following limits at the time that it is introduced into the mix:

Coarse aggregate 2% Fine aggregate 4%

(xii) Deleterious materials

The presence of deleterious material in both coarse and fine aggregates to be used in the asphalt mixes shall be determined from the following tests:

SABS Method 1243: 1994: Deleterious clay content of the fines in aggregate (methylene blue adsorption test). The methylene blue value of the materials shall not exceed a maximum of 5 %.” (c) Fillers

Delete the second last sentence of the first paragraph and replace with:

“Not more than 2% by mass of active filler be used in the mixes.” Add the following after the last paragraph:

“For tender purposes the active filler shall be hydrated lime” (h) General

Add the following after the second paragraph:

“Sufficient aggregate for a minimum of 3 days production shall be separately stockpiled and tested for conformance and uniformity prior to use. The test results shall be presented to the engineer” Add the following:

“The contractor shall inform the engineer at least three (3) weeks before any shortage of bitumen develops, of the circumstances surrounding the impending shortage. He shall indicate the expected tonnage to be imported, shall demonstrate that every local source and facility has been or will be exhausted and shall obtain the engineer’s written permission to import standard penetration grade bitumen. A pay item (B42.23) has been provided for in the schedule of quantities for the additional cost of importation of bitumen on the written instruction of the engineer to cover shortfalls of SABS standard penetration grade bitumen arising at the local refinery, local sources and facilities during this contract.”

B4203 COMPOSITION OF ASPHALT BASE AND SURFACING MIXTURES

In the first paragraph, third last line, after “or active filler content” add:

“or aggregate content” Replace the fifth paragraph with the following:

“The design of the asphalt mixes shall be in accordance with “Interim Guidelines For The Design Of Hot-Mix Asphalt In South Africa (June 2001)”, and appropriate research results. The mix properties and requirements shall be as specified in the project specifications” The relevant asphalt mixes for the base and surfacing layers shall comply with the requirements in table B4203/1.

C3-122

In the fifth paragraph, delete “guidelines of TRH 8” and replace with “Interim Guidelines for the Design of Hot-Mix Asphalt in South Africa and the design criteria specified in B4203”.

In the last sentence of fifth paragraph replace “table 4203/1” with “table B4203/1”

Add the following:

“The design of the asphalt surfacing mix shall be in accordance with the design criteria at 100% Marshall density (2 x 75 blows) Additional joint permeability criteria will also apply. Mix design proposals and parameters shall be finalised between the contractor and the engineer before commencement of paving work.” Replace Table 4202/6 with:

Table B4202/6

Sieve size (mm)

Maximum nominal size (mm)

Semi-gap Continuously

graded 37,5 28 37,5 28

Percentage passing sieve by mass 37,5 100 100 28 87 – 100 100 86 – 95 100 20 77 – 96 93 – 100 73 – 86 87 - 96 14 83 – 94 61 – 76 73 - 85 10 61 – 81 73 – 88 52 - 68 64 - 79 7,1 62 – 77 5 46 – 61 51 – 65 37 – 54 43 – 61 2 39 – 51 39 – 51 23 - 40 28 - 44 1 35 - 46 35 – 46 17 - 32 20 - 35

0,600 32 – 42 32 – 42 15 – 30 0,300 22 – 35 22 – 35 9 – 21 11 – 24 0,150 10 – 20 10 – 20 6 – 17 8 – 19 0,075 4 - 10 4 – 10 4 - 12 5 - 12

Nominal Mix Proportions by Mass

when Bitumen is Used

Aggregate 93,5% 95% 94,5% Bitumen (grade

according to project specifications)

5,5% 4% 4,5%

Active filler* 1,0% 1,0% 1,0% * Active filler for tender purposes to be hydrated lime.

Notes: 1. For recycled asphalt the nominal mix ratios of recovered asphalt, new aggregate,

new bituminous binders, and active mineral filler to be used for tender purposes, shall be as specified in the project specifications.

2. Refer to standard COLTO table for COLTO grading if required

C3-123

Table B4202/7

Continuously graded Coarse Medium Fine

PE

RC

EN

TA

GE

T

HR

OU

GH

SIE

VE

BY

M

AS

S

28 100 20 88 – 100 14 73 – 86 100 10 64 – 77 85 – 100 100 5 44 – 62 56 – 77 66 – 89 2 27 – 45 33 – 48 42 – 59 1 21 - 35 25 - 40 31 - 51

0,600 16 – 28 18 – 32 24 – 40 0,300 12 – 20 11 – 23 16 – 28 0,150 8 – 15 7 – 16 10 – 20 0,075 4 - 10 4 - 10 4 - 12

NO

MIN

AL

PR

OP

OR

TIO

NS

BY

M

AS

S

AGGREGATE 93,5% 93,5% 93,0%

BITUMEN (GRADE ACCORDING TO

PROJECT SPECIFICATIONS)

5,5% 5,5% 6,0%

ACTIVE FILLER 1,0% 1,0% 1,0%



Table B4203/1

ASPHALT MIX REQUIREMENTS: BASE AND SURFACING

Property Continuously

graded base mixes

Continuously graded surfacing

mixes

Marshall Stability (kn) 8 – 18 8 – 18

Marshall Flow (mm) 2 – 6 2 – 6

Stability /Flow (kN/mm) >2,5 > 2,5

VMA (%) > 14 > 15

VFB (%) 65 – 75 65 – 75

Air voids (%) 4 – 6 4 – 6

Indirect tensile strength @ 25°C (kPa) > 1000 > 1000

Dynamic Creep Modules @ 40°C (MPa) > 20 > 20

Modified Lottmann @ 7% voids (TSR) > 0,7 > 0, 8

Air permeability @ 7% voids (cm2) < 1 x 10

–8 < 1 x 10

–8

Binder film thickness (microns) 5,5 – 8,0 5,5 – 8,0

Filler bitumen ratio 1 – 1,5 1 – 1,5

Immersion index (%) - -

Marvil penetration on joints (litre/h) - <3

Add the following:

“The contractor shall within 14 days of handing over of site, provide the engineer with his proposed asphalt mix designs as well as samples of the materials he intends to use in the asphalt, to ensure the timely approval of the asphalt mixtures.”

C3-124

B4204 PLANT AND EQUIPMENT

(b) Mixing plant

(i) Conventional binder

Add the following after the third paragraph:

“The manufacturer’s rated capacity of the mixing plant shall be adequate to meet production requirements for the work. The rate of production shall not exceed manufacturer’s rated capacity of the plant.” (c) Spreading equipment

(i) Paver

Add the following

“Asphalt base with a surface area of > 5 m² and equal or wider than 1.0 m shall be placed by means of a paving machine. Each paver must be capable to be operated at forward speeds consistent with satisfactory placement and compaction of the relevant mixture. The paver must also be capable of screeding a smooth asphalt finish of uniform texture." (d) Rollers

(i) General requirements

Add the following:

“No vibratory compaction may be used on bridge decks and within 5 m of any designated water main or high voltage cable.” (f) Vehicles


“To minimize temperature loss all vehicles used for transporting asphalt to the site shall be fitted with thermal asphalt covers (canvas covers not acceptable) irrespective of the prevailing climatic conditions or distance of transport.” Add the following

“Plant and vehicles used at the laying site shall be free from oil, fuel, and hydraulic fluid leaks. Any item of plant or vehicle showing signs of these leaks shall immediately be removed from the site.” Add the following subclause:

“(h) Transfer of mix to paver

Asphalt shall be transferred from the haul trucks to the paver by means of a materials storage and transfer vehicle (“shuttle buggy”) and no material shall be transferred directly from the haul vehicle into the paver. The material storage and transfer vehicle must be able to store and transfer hot-mixed asphalt material from a truck to a paver to ensure continuous paving. It must contain an anti-segregation auger which remixes materials just before they are delivered to the asphalt paver.”

B4205 GENERAL LIMITATIONS AND REQUIREMENTS AND THE STOCKPILING OF MIXED MATERIAL

(b) Moisture

Add the following at the end of the second last paragraph after “engineer”

“even if the underlying layer has been previously primed.”

C3-125

Amend the last paragraph as follows:

Insert “and/or primed base” after “surfacing” in the third line of the first sentence. Replace the last sentence with “In such case the base shall be allowed to dry out to meet the above

moisture content requirement prior to placing the surface layer.”

(c) Surface Requirements

(iii) Tack Coat

Add the following after the third paragraph:

“A tack coat consisting of 60% stable grade emulsion shall be applied to the exposed edges of the bituminous layers in milled-out excavations prior to placing abutting layers. The tack coat shall be applied by brush at a nominal application rate of 2,0 ℓ/m².” Add the following paragraph:

“Hand spraying shall only be permitted on areas approved by the engineer. The binder distributor shall be capable to apply the binder evenly over the full area. The equipment shall comply with clause 4103. Tack coat shall be applied to all transverse and longitudinal joints by hand utilizing a paint brush.”

B4206 PRODUCING AND TRANSPORTING THE MIXTURE

(a) Mixing and storage temperatures of binder

Add the following at the end of the paragraph:

“The temperature-time limits for hot polymer modified binders as provided in table B4203/1a are for tender purposes only. The selected supplier of the homogeneous modified binder shall provide information with respect the type of modifier used and storage and handling characteristics of the product, to the contractor prior to commencement of the works. The selected supplier shall also advise on the applicability of table B4203/1a to his product. Table B4203/1a TYPICAL TEMPERATURE / TIME LIMITS FOR HOT POLYMER MODIFIED BINDERS

Binder class

Short term handling Storage Spraying / Asphalt mixing Max.

Temp. (oC)

Max. Holding Time (h)

Max. Temp.

(ºC)

Max. Holding

Time (h)

Max. Temp.

(ºC)

Min. Temp.

(ºC)

Max. Holding time (h)

S-E1 and S-E2 180 24 150 240 200 185 8

A-E1, A-E2, A-P1 180 24 140 240 170 160 36

To prevent the development of any "hot spots" within the product, or possible separation, a circulation/stirring system shall be in place, even for periods of short-term storage. Many long chain polymers have low shear stability and can be degraded by the action of a high shear rate pump such as a close tolerance gear pump. Due to the cost of these premium products, storage tanks shall be fitted with slow stirrers or augers, which, while assisting in keeping modified blend homogeneous, also ensures no localized build-up of heat in the vicinity of the flue pipes. The SBS binder shall be handled according to the TG1of November 2007 guidelines and shall also include the following:

(1) Storage tanks on site must be able to maintain a constant temperature between 160 °C and 170 °C. A constant recording device must be installed to monitor the storage temperatures.

(2) The testing frequency on modified binders will be according to TG1 Guidelines November 2007 Table 19 as published by the Asphalt Academy. ”

C3-126

(b) Production of the mixture

(ii) Using drum-type mixer plants

Add the following:

“Pre-blending of aggregate fractions shall not be permitted and the contractor shall ensure that sufficient cold-feed bins are installed to accommodate each individual aggregate fraction, including the filler.” (c) Transporting the mixture

Delete the second sentence in this paragraph.

Add the following paragraph:

“Special precautions shall be taken by the contractor to ensure that the temperature of the total mass of asphalt does not decrease by more than 10 º C from point of despatch to the point where it is to be paved. The contractor shall ensure that trucks used to haul asphalt are not overloaded and the legal axle loads are not exceeded. Before any asphalt can be transported, the contractor must provide the engineer with the certified carrying capacity of each truck intended for the purpose of transporting the mix. The contractor shall provide the engineer with a weighbridge ticket before discharging into the paver hopper. ANY truck that is overloaded shall not be allowed to discharge its load and shall return to the depot/batching plant for adjustment of the load. ” Add the following subclause:

“(f) Approval of asphalt mixture

Before any asphalt is placed on the road, the engineer shall approve the mix design. The approval process shall be as follows: The contractor shall prepare and submit a laboratory design mix with test results at four different bitumen contents. The design mix shall be submitted on the prescribed form D3 of TMH 10: “Instruction for the Completion of As-Built Materials Data Sheets” with all the necessary test results completed. In addition, the proposed asphalt mixture shall be subjected to gyratory testing. All the expenses in preparing and submitting the laboratory design mix shall be to the contractor’s cost. The proposed design, as well as samples of all aggregate and bitumen intended for use, shall be submitted with the laboratory design mix to enable the engineer to carry out check design testing as necessary. The above design and aggregate shall be submitted to the engineer at least six weeks before it is intended to commence with any asphalt production. The contractor shall check his mix design proposal thoroughly before submitting it to the engineer. The engineer may request tests to be repeated at the expense of the contractor if the results do not make sense and this will delay the approval process. The engineer shall not be liable for this delay. After approval is obtained for the laboratory design mix, a plant mix at varying binder contents of approximately 5 to 10 tons each shall be produced. The purpose of the plant mix is for the contractor to prove that the laboratory design mix can be produced successfully. The engineer shall conduct the necessary testing on the plant mix. The plant mix shall not be placed on the road. During the production of the plant mix, the engineer shall be afforded the opportunity to inspect the asphalt plant. After the plant mix is approved, permission shall be given for laying a trial section at varying binder contents in accordance with the requirements of section 4211 of the specifications. The engineer may require that the mix be further assessed by means of CSIR Wheel Tracking or MMLS testing, the cost of which will be borne by the employer. Mass production of asphalt shall only commence after approval of the trial section, which should be given within a maximum of ten days.

C3-127

The engineer may instruct the contractor at any time to halt his paving process and to review the whole or part of the above process should a change of aggregate properties occur, the specified asphalt requirements not being met and/or a consistent asphalt mixture not be produced.”

B4207 SPREADING THE MIXTURE

Add the following to clause sub-clause (a):

“For base repairs, the existing base shall be excavated to a depth as instructed by the engineer (but not exceeding 150 mm) with the side of the excavation stepped back by 100 mm from the milled edge of the asphalt surfacing. Where instructed, asphalt base is to be placed in layers of at least 50 mm thick but not exceeding 75 mm thickness.”

B4208 JOINTS


“Saw-cutting of the longitudinal joints on newly placed asphalt will not be allowed and hence the wheel-cutting shall be done as soon as possible after completion of compaction. In the case of a joint between adjacent phases the removal of the material that has been cut loose may be delayed to protect the edge from damage. If, in the opinion of the engineer, the edges are nevertheless damaged, the affected area shall be cut back further. When, on account of the age of the asphalt, this cannot be done effectively with a cutting wheel, paving breakers shall be used in an expert manner.” Add the following to the fourth paragraph:

“The cut edges of all asphalt joints, longitudinal and transverse, shall receive a tack coat before the adjacent asphalt is placed against it.” Replace the fifth paragraph with the following:

“The density of asphalt at the joint locations and the assessment thereof shall be as specified in clause B4210 and the water permeability of the surfacing layer shall be assessed as specified in clause B4213(g). In order to meet the permeability requirement at the joints, all joints in the surfacing layer shall be treated along a strip with width 200 mm either side of the joint, with an approved diluted bitumen emulsion (e.g. Colseal). Transverse joints shall be cut back in a neat straight line to approximately nought comma three metre (0,3 m) to the full depth and over the full paved width of the layer. The cut line shall be determined with a straight edge to eliminate the tapering asphalt layer thickness at the end. Longitudinal joints may be cut back up to 1,5 times the nominal layer thickness without the wastage being deemed excessive. All joints shall be marked out with chalk lines prior to cutting. There shall be no deduction in payment for the asphalt removed and spoiled when forming transverse joints and for cutting longitudinal joints unless the engineer considers the wastage to be excessive, and his decision shall be final. Asphalt removed and spoiled at unplanned transverse joints or from trimming the outside edge of the completed asphalt wearing course along the shoulder, shall be regarded as excessive wastage.” Add the following to this clause:

“Temporary transverse joints shall be rolled smooth to the engineer’s satisfaction. There shall be a perfectly smooth joint between existing and new surfacing. Where the engineer so directs, an asphalt fillet shall be placed along the edge of the completed asphalt course. Unless otherwise directed, the fillet shall be 150 mm wide. Separate payment will be made for the placing and subsequent removal of the fillet.

C3-128

The contractor, having due regard for his responsibilities in terms of clause 17.2 of the conditions of contract, shall form, protect and treat temporarily exposed longitudinal joints in a manner which will minimise traffic risks. The minimum requirement shall be that the edges be rolled-over prior to opening to traffic and that they subsequently be cut back before continuing with the adjacent asphalt layer. Unless explicitly otherwise stated the cost of all joint construction activities (temporary and permanently, transverse and longitudinal joints) is to be included into the relevant asphalt layer rates. Where the difference in level between the new work and the existing road surface exceeds 25 mm, joints shall be treated as follows: Transverse steps at the end of a day’s work shall be tapered off at a slope of 1 vertical to 20 horizontal (1:20) to tie in with the existing surface. The tapered section shall be removed before surfacing is recommenced and a joint formed in accordance with clause 4208 of the specification. Longitudinal joints exposed to traffic shall be provided with a taper of compacted asphalt material over the full length of the exposed joint. The width of the taper shall be at least 5 times the difference in level between the old and new work. All costs involved in the provision and removal of these temporary ramps shall be deemed to have been included in the rates tendered for the relevant asphalt payitem.”

B4209 PRE-COATED CHIPPINGS FOR ASPHALT SURFACING

Replace the first sentence of the fifth paragraph with the following:

“The pre-coated chippings used shall be 14 mm size aggregate.” In the last sentence of the fifth paragraph, delete “between 0,6 and 1,0 mm” and replace with:

“minimum 0,8 mm”.

B4210 COMPACTION

Add the following to the sixth paragraph:

“ The asphalt base shall have a maximum density of 96,5%, and the asphalt surfacing a maximum of 96%, of the theoretical maximum (Rice’s) density of the material. In addition hereto the compaction within the zone up to 200 mm away from the joint plane shall be done in a manner to ensure densities not less than the minimum specified - less 2% (including all hot and cold joints). Joint densities shall be determined from cores taken not closer than 70 mm to the joint plane and not further away than 200 mm and they shall be assessed by treating the cores from each of the 200 mm zones as separate lots for acceptance and payment purposes.” Replace subclause (e) with the following:

“In restricted areas, or on bridge decks, where the specified rollers cannot be used, compaction shall be carried out with hand operated mechanical compaction equipment, approved smaller vibratory rollers or static rollers (bridge decks). The revised compaction procedure shall be predetermined and approved during the laying of trial sections and, if required, a relaxed density specification shall be applicable as determined by the engineer.” Add the following:

"Rolling must continue until all roller marks have been eliminated and the specified minimum density has been obtained, but not after the mat has cooled to 90º C or below. Vehicular traffic shall not be allowed on the newly compacted surface before the mat has cooled to 50°C or lower.”

C3-129

B4211 LAYING OF TRIAL SECTION


"Before the contractor commences with the construction of any asphalt surfacing, he shall demonstrate, by laying a trial section of between 300 m2 and 600 m2 in an area as ordered, his ability to reproduce in practice a mix, the properties of which conform with that of the recommended mix design, and that the equipment and processes that he proposes to use, will enable him to construct the particular asphalt course in accordance with the specified requirements.” Replace the fifth paragraph with the following:

“Only when such a trial section has been satisfactorily laid, finished and tested, and complies with all the specified requirements, will the contractor be allowed to commence with construction of the permanent work.” Add the following to the end of the first paragraph:

“As the purpose is not to calibrate any equipment, etc., the contractor shall calibrate the equipment and refine the mix design at his own cost.”

B4213 CONSTRUCTION TOLERANCES AND FINISH REQUIREMENTS

(a) Construction tolerances

(iii) Thickness

Add the following tolerance:

“Davg+ surfacing = 3 mm” (v) Surface regularity


“For the lanes and surfaced shoulders wider than 2.0 m of the through road as well as interchange ramps and cross roads the roughness of the surfacing will be determined by using an inertial laser profilometer capable of producing a class 1 vertical measurement resolution, and a class 3 longitudinal sampling distance as defined in ASTM standard (E950-09). Surface shoulders less than 2.0 m wide, will be assessed according to measurements obtained from the adjacent slow lane. The inertial laser profilometer shall be used to record the longitudinal profile in both wheel tracks of each traffic lane or shoulder wider than 2.0 m, as determent according to the final line markings that will be applied after construction. Should the two tracks not be measured simultaneously during the same pass, then procedures shall be implemented to ensure that the longitudinal profile data recorded for the two wheel tracks are at the same longitudinal location on the road. The measured longitudinal profiles will then be processed using the Quarter-Car simulation model with parameter values as defined in ASTM standard (E1170-97) for Ride Meter-Vehicle Mounted. The simulated suspension mentioned will then be linearly accumulated and divided by the length to yield 100 m IRI (International Roughness Index) values in units of mm/m or m/km for each wheel track. The last 50 metres, and the joining first 50 metres of adjacent sections will be evaluated as a 100 m section in the direction of vehicle travel. For each measured lane the left and the right 100m IRI values from the three runs will then be average to produce the Average IRI as follows: Run1 IRI 100m Ave = (100 m IRI Left wheel track + 100 m IRI Right Wheel track) / 2 Run2 IRI 100m Ave = (100 m IRI Left wheel track + 100 m IRI Right Wheel track) / 2 Run3 IRI 100m Ave = (100 m IRI Left wheel track + 100 m IRI Right Wheel track) / 2 Average IRI 100m = (Run1 IRI 100 m Ave + Run2 IRI 100 m Ave + Run3 IRI 100 m Ave) / 3 The Average IRI100m values is then evaluated and judged according to table B4213/2 to determine whether the 100m section needs corrective work or payment adjustments.

C3-130

For the asphalt base the values in payment bracket 6 in table B4213/2 shall be applied as the payment adjustment factors for the asphalt base on the contract or section. For the asphalt surfacing, the applicable payment bracket in table B4213/2 for the measured lanes and shoulders will be determined as follows: 1. Calculate the applicable Target IRI100m Ave for full payment as follows,

Target IRI100m Ave = greater of 1.05 or [IRIb Ave * {1-(NAT/100)}[ Where: IRIb Ave = Average IRI100m before the construction of the asphalt surfacing as determined from:

i The Average IRI100m as calculated from measurements performed for the UTFC

section to be milled and replaced, prior to commencement of the milling, or ii The Average IRI100m as calculated from the measurements performed as part of the

assessment of the new constructed base (refer B3405(f) for granular base and B4213(a) for asphalt base).

NAT = Total New Asphalt Surface Thickness as specified (measured in mm) applied over a section as

part of this contract. For example, should 40mm AC be applied followed by 18mm UTFC, then NAT = 58mm.

2. Using the Target IRI100m Ave calculated under 1 above, find the matching Target IRI100m Ave

range in the first column of table B4213/2 into which the value fits. Then read horizontally to the relevant Full Payment Bracket column in which the unit value (1.000) appears. The values in this column shall then be applied as the payment adjustment factors for the contract or section. For example should the Target IRI100m Ave be 1.33, then the Full Payment Bracket will be No 4.

Should the Total New Asphalt Thickness (NAT) as specified vary over the contract length, then a Payment Bracket will need to be calculated for each of these uniform NAT sections.

Any adjustment in the payment for asphalt base or asphalt surfacing will be made by multiplying the full payment value for each 100 m section, for payment items 42.01, B42.02, 42.09 and B42.11 by the payment adjustment factor derived from table B4213/2. The payment adjustment shall apply to the total asphalt layer width placed during a single pass by the paver over the 100m sections in question. Surfaced shoulders less than 2 m wide will be assumed to have the same roughness measurements as the adjacent lane and the quantity of material in the shoulder shall be added to the quantity of material of the adjacent lane for determination of the payment adjustment factor. On sections where the Average IRI100m is worse than the cut-off value listed in table B4213/2 the section is rejected and corrective work will be necessary. Any corrective work required shall be made by the removal, through milling of the total asphalt layer width placed during a single pass of the paver over the 100 m section in question, followed by reinstatement. The contractor shall submit his method statement for any corrective work to the engineer for approval, prior to commencing with any corrective work. Corrective work shall be done at the contractor’s expense and shall be completed prior to determining pavement thickness. After completion of the corrective work, the 100 m sections shall be re-evaluated according to the abovementioned procedure. The longitudinal profile and the 100 m International Roughness Index (IRI) values shall be determined using a profilometer furnished and operated by the contractor or on his behalf in the presence of the engineer. Prior to using the inertial laser profilometer it shall have successfully completed a validation trial against the Instrument of Reference (Face Dipstick®)used by the Employer.

C3-131

As an absolute minimum, measurements shall be provided to the engineer after 10%, 50% and 100% of the surfacing area of the project has been completed. The contractor will be paid for these measurements under payment item B81.03(c). No additional payment will be made to the contractor for additional measurement and analysis of profiles. On all road sections and in areas where the use of a profilometer is not possible, the rolling straight-edge specification as indicated below shall apply.” (c) Gradings


Table B4213/1

AGGREGATE GRADING TOLERANCES

Size of aggregate passing Sieve size (mm)

Permissible deviation from target grading (%)

28 ± 5 20 ± 5 14 ± 5 10 ± 5 7,1 ± 5 5 ± 4 2 ± 4 1 ± 4

0,600 ± 4 0,300 ± 3 0,150 ± 2 0,075 ± 1*

* When statistical methods are applied the permissible deviation for the 0,075 fraction is ± 2%.

C3-132

Table B4213/2

PAYMENT ADJUSTMENT FACTORS FOR ASPHALT BASES AND ASPHALT SURFACINGS

Target IRI100m

Ave (m/km)

PAYMENT ADJUSTMENT FACTORS

Full Payment

Bracket 1

Full Payment

Bracket 2

Full Payment

Bracket 3

Full Payment

Bracket 4

Full Payment

Bracket 5

Full Payment

Bracket 6

Full Payment

Bracket 7

Full Payment

Bracket 8

< 0.80 1.050 1.050 1.050 1.050 1.050 1.050 1.050 1.050

0.81 to 0.90 1.025 1.050 1.050 1.050 1.050 1.050 1.050 1.050

0.91 to 1.00 1.010 1.025 1.050 1.050 1.050 1.050 1.050 1.050

1.01 to 1.10 1.000 1.010 1.025 1.050 1.050 1.050 1.050 1.050

1.11 to 1.20 0,990 1.000 1.010 1.025 1.050 1.050 1.050 1.050

1.21 to 1.30 0,975 0,990 1.000 1.010 1.025 1.050 1.050 1.050

1.31 to 1.40 0,955 0,975 0,990 1.000 1.010 1.025 1.050 1.050

1.41 to 1.50 0,930 0,955 0,975 0,990 1.000 1.010 1.025 1.050

1.51 to 1.60 0,900 0,930 0,955 0,975 0,990 1.000 1.010 1.025

1.61 to 1.70 0.865 0,900 0,930 0,955 0,975 0,990 1.000 1.010

1.71 to 1.80 Reject 0.865 0,900 0,930 0,955 0,975 0,990 1.000

1.81 to 1.90 Reject Reject 0.865 0,900 0,930 0,955 0,975 0,990

1.91 to 2.00 Reject Reject Reject 0.865 0,900 0,930 0,955 0,975

2.01 to 2.10 Reject Reject Reject Reject 0.865 0,900 0,930 0,955

2.11 to 2.20 Reject Reject Reject Reject Reject 0.865 0,900 0,930

2.21 to 2.30 Reject Reject Reject Reject Reject Reject 0.865 0,900

2.31 to 2.40 Reject Reject Reject Reject Reject Reject Reject 0.865

>2.41 Reject Reject Reject Reject Reject Reject Reject Reject

C3-133

(e) Voids

Add the following:

“The void content shall not deviate from the approved production mix void content by more than 1%." Add the following subclause:

“(g) Permeability

The water permeability of the continuously graded asphalt base and surfacing layer shall be tested using the falling head (MARVIL) apparatus as described in clause 8109(d). The engineer shall determine the number and location of test points and no single result shall exceed a value of 3 litres per hour. In the case of all joints the permeability of the surfacing layer up to 200 mm either side of the joint, shall not exceed 1 litre per hour. Refer to clause B4208 for the specified standard treatment of joints prior to testing for permeability. Areas of asphalt surfacing which meets all the stated specifications except for the permeability requirement, shall be demarcated and treated (retreated in the case of joints) with an approved water proofing agent e.g. a diluted emulsion (Colseal), at the contractor’s cost and re-tested for conformance. All permeability testing which prove non-conformance shall be for the contractor’s account as per clause B1143. The water proofing agent shall be suitably diluted with water and applied by roller in a manner which facilitate penetration and sealing of the layer without undue enrichment of the surface or alteration of the surface texture.”

B4214 QUALITY OF MATERIAL AND WORKMANSHIP

(b) Coring of asphalt layers

Add the following:

“A suitable coring machine shall be available on a daily basis when asphalt paving is taking place. Cores shall only be drilled, when the road temperature is 20°C or less. Core holes shall be filled with hot mix asphalt and compacted, all within 24 hours of the core being drilled. Coring shall be carried out within 48 hours after the paving has been completed and supplied to the engineer. The test results of cores shall be submitted to the engineer within 24 hours after coring. Cores may only be drilled when the road temperature is 20ºC or less. Core holes must be dried out, tacked and backfilled as soon as possible with hot mix asphalt. Coring shall be carried out within 48 hours after the paving has been completed. The process control core test results and material testing results shall be submitted to the engineer not later than 24 hours after coring and sampling respectively” (c) Routine inspection and tests

Add the following paragraphs:

“The contractor shall keep accurate records of:

(i) The position where every truckload of asphalt is paved (chainage, lane, time and date). (ii) The temperatures of the asphalt in the trucks both at the mixing plant and at the paving

equipment immediately prior to discharging the load. (iii) The truck and load number from which control samples are taken. All samples taken shall be

appropriately numbered. Quality Control Scheme 1 given in Section 8200 will apply to the asphalt paved on this contract.” Add the following subclause:

“(d) Special tests

n-Heptane-Xylene Equivalent (Spot test) (AASHTO-T102)

C3-134

If the engineer suspects that bitumen or asphalt has been overheated, he may order that the bitumen, or the bitumen recovered from the asphalt, be subjected to the Spot Test. Recovery of binder for use in the Spot Test shall be carried out according to an approved method. Any bitumen having an n-Heptane-Xylene equivalent in excess of 36, or in excess of the manufacturers test result on the dispatched stock, shall be considered to have been overheated and shall be deemed to be rejected unless proven otherwise. ”



“No additional or extra over payment shall be made for work in restricted or confined areas.”. Item Unit

B42.02 Asphalt surfacing

Add the following to the first payment paragraph:

“The tendered rates shall also include for all joint construction activities as specified including the backfilling of cores holes, sealing of all joints with an approved diluted bitumen emulsion, and for having to cut back into existing surfacing as specified on the drawings.” Amend the following payment item:

“Item Unit

B42.08 100 mm cores in asphalt paving ................................................................... number (No)”

Amend the 1st sentence by adding the following after the word “drilled….”. “irrespective of depth of core.” Add to the second paragraph” “The tendered rate shall also include full compensation for the traffic accommodation required to drill and recover the cores.”

Item Unit

B42.11 Asphalt constructed for rehabilitation purposes in accordance with the provisions of subsubclause B4213(f)(ii) and B4213(f)(iii) ......................... ton (t)

Insert the following paragraphs after the 1st paragraph:

“The unit of measurement for subitem (a) shall be the ton of asphalt base placed in compacted layer thickness not exceeding 60 mm, and measured according to certified weighbridge tickets issued in respect of the mixture used. The unit of measure for subitem (b) shall be the ton of asphalt overlay placed to the nominal thickness specified if placed in terms of B4213(f)(iii) and placed to the specified level if placed ito B4213(f)(ii), and measured according to certified weighbridge tickets issued in respect of the mixture used. No payment shall be made for excess width and wastage of asphalt, and the mass of such excess or wasted material shall be deducted from the recorded delivery for payment purposes. For layers constructed in terms of clause B4213(f)(iii) no payment shall be made for asphalt in excess of the mean spread rate(s), which shall be determined as follows:

S = 1000 m2/ton where,

AXB S = Mean spread rate in m

2/ton

A = Average bulk relative density achieved on the road in ton/m3

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B = (specified asphalt thickness in mm) + 5mm”

Add the following to the 3rd paragraph:

“The tendered rate shall also include full compensation for joint forming, temporary ramping of construction joints between paving operations when new work is opened to traffic (including ramping material), breaking up and disposal of temporary ramps and waste material, weighing the material on the specified weighbridge and cleaning the surface.” Add the following payment item:

“Item Unit

B42.14 Extra over item 42.04 for applying tack coat by hand .................................................. litre

The unit of measurement shall be litre of 30% stable-grade emulsion applied by hand. The tendered rate shall include full compensation for additional costs for applying the tack coat by hand.” Add the following payment items:

“Item Unit

B42.21 Aggregate variations ................................................................................................. ton (t)

The unit of measurement in respect of increases or decreases in the aggregate content from that specified in the nominal mix shall be the ton. Payment for variations shall be made as specified for clause 1213. Item Unit

B42.22 Apply diluted bitumen emulsion (e.g. Colseal) to joints on circumference of patches .............................................................................................. litre

The unit of measurement shall be the undiluted litre of emulsion applied to the joints at the instruction of the engineer. The tendered rate shall include full compensation to procure and apply the emulsion as specified and instructed. Item Unit

B42.23 Extra over items 42.01, B42.02, 42.09, 42.10 and B42.11 for the transportation cost of bitumen binder supplied by a refinery outside the Western Cape Province ....................................................................... ton (ton)

Where bitumen that meets the requirements of the specification is not available from a refinery in the Western Cape Province the engineer may agree that material be imported from other sources. The unit of measurement shall be the ton of net cold bituminous binder and shall be calculated from the average binder content of the asphalt placed for a day’s work or the actual volume of prime, tack and binder sprayed. The tendered rate shall include full compensation for the additional cost of transporting bituminous binder which meets all the requirements of the specification from a refinery outside the Western Cape Province. Any difference in the “ex refinery” price of bitumen shall be compensated for by means of the special material adjustment formula.”

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SECTION B4300: SEALS: MATERIALS AND GENERAL REQUIREMENTS

B4301 SCOPE Add the following paragraph: “The contractor shall take and submit samples of materials and/or mixtures to the engineer who must approve designs before construction work can commence.” B4302 MATERIALS Add the following to the first paragraph: “Any tests referred to in the publication “Technical Guideline: TG1 The Use of Modified Bituminous Binders in Road Construction (TG 1-November-2007): Asphalt Academy”, shall supersede those specified in the COLTO Standard Specifications for Road and Bridge Works for State Road Authorities (1998 edition). This document is available from the Asphalt Academy.”

a) Bituminous binders (ii) Non-homogeneous (heterogeneous) modified binders (summer grade) (4) Diluent Add the following sentence: “The addition of a diluent or cutter to the blend shall not be permitted unless approved by the engineer.” (iv) Homogenous cold applied modified binders Replace the entire sub-sub-clause with the following: “(1) Base bitumen The cationic emulsion shall be manufactured from bitumen complying with the requirements of SANS 4001-BT1:2012. (2) Polymer The contractor shall indicate, in the relative payitem in the Pricing Schedule, the type of polymer to be used in the blend. (3) Polymer modified emulsion blend All blending shall be done at the factory. The modified binder for this project shall be Binder Class SC-E2 (65-68)(t) and SC-E2 (70-73)(t), where “(t)” indicates that no fluxing agent or cutter is allowed in the binder. The binder shall comply with the requirements in table B4302/5. The recovered binder residue shall be obtained using either the rotary vacuum evaporation or simple evaporation method. If there is any discrepancy in the test results then the results on recovered binder obtained from the rotary vacuum evaporation method shall be binding. The use of a volatile solvent flux added to the bitumen shall not be permitted unless approved by the engineer.”

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TABLE B4302/5: PROPERTIES OF POLYMER MODIFIED EMULSIONS FOR SURFACE SEALS

Property Unit Test Method Modified Binder Class

SC-E1 SC-E2

Modified Binder Content (%) MB-22 65-68 70-73 65-68 70-73

Saybolt Furol Viscosity @ 50°C Second MB-21 51-200 51-400 51-200 51-400

Residue on sieving

4

(/100ml)

710µm sieve g MB-23

≤0,1 ≤0,1

150µm sieve ≤0,5 ≤0,5

Particle charge - MB-24 Positive Positive

Sedimentation after 60 rotations °C SANS 309 Nil Nil

Properties of recovered binder residue (MB-20)1

Softening Point2 °C MB-17 ≥48 ≥55

Elastic recovery @ 15°C % MB-4 ≥50 ≥55

Force Ductility @ 5°C N EN 13703 Report3 Report

3

Notes:

1. Either the rotary vacuum or the simple evaporation method can be used. For on site testing the simple method is more practical and is thus recommended. The simple method retains a very small portion of the fluxing oils whereas these are removed in the rotary vacuum method. The latter method renders a better indication of the binder properties after in-service curing.

2. The prescribed test method is based on not using stirrers although it has been reported that the use of stirrers has shown no difference in test results. For refereeing purposes no stirrers should be used.

3. No values given but the test can be used to rank various binders according to their low temperatures cohesion properties. The properties listed as “Report” will only be determined on instruction of the engineer. The contractor will not be liable for the cost of such testing.

4. Pour the emulsion through the larger sieve to remove the skin and larger particles before passing the emulsion through the finer sieve.

(v) Homogeneous hot applied polymer modified binders (summer grades) Replace the entire sub-sub-clause with the following: “(1) Base bitumen The base bitumen or blends thereof, shall comply with the requirements of SANS 4001-BT1:2012 . In addition, the chemical composition of the bitumen shall be such as to permit blending with the proposed polymer to form a stable product. (2) Polymer The type and percentage of polymer to be blended with the bitumen is not prescribed, however the contractor shall indicate, in the relevant payitem in the Pricing Schedule, the type of polymer to be utilized. (3) Polymer modified blend The polymer modified bitumen shall be blended at the factory. The polymer modified bitumen to be used on this project shall be Binder Class S-E2 and shall comply with the requirements of table B4302/7. The binder for the day’s production shall be tested on site to determine the softening point before any seal work is commenced with. No claim for delays due to this requirement shall be considered. As a control, a hand held spindle viscometer shall be used to monitor the viscosity of the binder at the spray temperature.”

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TABLE B4302/7 PROPERTIES OF POLYMER MODIFIED BINDERS FOR HOT SEALING APPLICATIONS

Property Unit Test Method Binder Class

S-E1 S-E2

Softening Point1 °C MB-17 50-60 60-80

3

Dynamic Viscosity @165°C Pa.s MB-18 ≤0,55 ≤0,60

Force Ductility @ 5°C N EN 13703 Report2 Report2

Elastic Recovery @ 15°C % MB-4 >50 >70

Flash Point °C ASTM:D93 ≥230 ≥230

Stability (R&B diff. @ 160°C) °C MB-6 ≤5 ≤5

Properties after ageing (RTFOT)

Difference in Softening Point °C MB-17 -2 to +8 -2 to +8

Elastic Recovery @ 15°C % MB-4 >40 >50

Mass Change % MB-3 ≤1.0 ≤1.0

Notes:

1. The prescribed test method is based on not using stirrers although it has been reported that the use of stirrers has shown no difference in test results. For refereeing purposes no stirrers should be used.

2. No values provided but the test can be used to rank various binders according to their low temperature cohesion properties

3. The softening point values obtained for bitumen modified with SBS will tend to fluctuate over time and on reheating.

* Note: The properties listed as “Report” will only be determined on instruction by the engineer. The contractor will not be liable for the cost of any such testing. b) Aggregates (i) Aggregates for seals Add the following at the end of the sentence: “and durability.” (1) Grading Add the following: “Only grade 1 aggregate shall be used for the construction of seals on this project.” (3) Shape Add Table B4302/13 and the following paragraph: “Ninety five (95%) percent of the particles shall have at least three fractured faces. The Average Least Dimension (ALD) of the relevant nominal aggregate sizes shall comply with the requirements of Table B4302/13.” TABLE B4302/13: MINIMUM ALD REQUIREMENTS

Nominal Aggregate Size (mm) Minimum ALD (mm)

20 12,0 14 8,0 10 5,5 7 4,0

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Replace Table 4302/8 with: TABLE B4302/8



TABLE B4302/9

Sieve sizes (mm) Percentage passing by mass 5 95 minimum

0,425 50 minimum 0,075 20 maximum

Plasticity index = Non-plastic

Note: Refer to standard COLTO table for COLTO grading if required Replace Table 4302/10 with:

TABLE B4302/10

Nominal size of aggregate (mm)

Maximum flakiness index (%) Grade 1 Grade 2

20 25 30 14 25 30 10 30 35 7 30 35


Sieve size (mm)

Grade

Percentage by mass passing

Nominal size (mm)

28 20 14 10 7 5 2

37,5

1 & 2

100

28 85 – 100 100

20 0 – 30 85 – 100 100

14 0 - 5 0 – 30 85 – 100 100

10 0 - 5 0 – 30# 85 – 100 100

7 0 – 5## 0 – 30# 85 – 100 100

5 0 – 5##

0 – 30# 85 - 100 100

3,35 0 – 30

2,0 0 – 5## 0 - 5 0 – 100

3 Gradings shall comply with the requirements for Grades 1 and 2 with the following exceptions: # 0 – 50, ## 0 – 10

Fines content: passing

0,425 mm sieve

1 0,5 0,5 0,5 0,5 0,5 1,0 15

2 1,5 1,5 1,5 1,5 1,5 2,5 15

3 N/A N/A 2,0 2,0 3,0 3,5 15

Dust content: passing

0,075 mm sieve

1 N/A N/A N/A N/A N/A N/A 2,0

2 0,5 0,5 0,5 0,5 1,0 1,0 2,0

3 N/A N/A 1,5 1,5 1,5 1,5 2,0

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Replace Table 4302/11 with: TABLE B4302/11


Delete Table 4302/12 without replacement Add the following sub-sub-clause: “(4) Durability Aggregate used in seals and asphalt shall show a durability index of less than 4 as determined by the test method specified in Clause B8105 paragraph (g)." (ii) Aggregate for slurry seals In the first paragraph, add the following after the first sentence: “The engineer may order the addition of an approved natural sand or additional cement to improve either the permeability or workability of the slurry.” Add the following sub-sub-clause: “(iii) Aggregate for blinding The aggregate used for blinding the single seal shall consist of 2,00mm to 5mm crushed aggregate or river sand. The aggregate shall be clean, hard and free from clay, silt or other deleterious matter." d) Hydrophilic aggregates (i) Precoating of aggregate for stockpiling or for immediate use: In the second paragraph, delete “12 litre” in the second sentence, and add the following sentence: “Precoating fluid shall be manufactured from petroleum based products. The use of tar based precoating fluids will not be permitted. For tender purposes the nominal quantity of precoating fluid for the relevant nominal aggregate sizes is specified in table B4302/14.”

Sieve size (mm)

Percentage passing sieve by mass

Fine slurry Coarse slurry

Fine grade Medium grade Coarse grade Type 1 Type 2

14 100

10 100 86 – 100

7 100 100 87 – 100 71 – 91

5 100 84 – 100 72 – 91 72 – 91 62 – 82

2 84 – 99 51 - 90 40 – 64 40 - 63 36 – 56

1 60 - 90 33 – 68 25 - 46 22 – 41 22 - 41

0,600 42 – 72 22 – 50 19 – 34 15 – 30 15 – 30

0,300 23 – 48 15 – 37 12 – 35 10 – 20 10 – 20

0,150 10 – 27 7 – 20 7 – 18 6 – 15 6 – 15

0,075 4 - 12 4 - 12 2 - 8 4 - 10 4 - 10

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TABLE B4302/14: NOMINAL APPLICATION RATES FOR PRECOATING FLUID

Nominal aggregate size (mm) Nominal precoating application rate (ℓ/m³)

20 12 14 16 10 19 7 22

Add the following sub-clauses: “e) Water for diluting emulsions Water used for the dilution of emulsions on site shall be suitable potable water, and each source of water used shall be tested for compatibility with the emulsion before it is added to the bulk emulsion. f) Testing of polymer modified bitumen/emulsion Testing shall be in accordance with the methods described in “Technical Guideline: The use of Modified Bituminous Binder in Road Construction (TG 1-November-2007): Asphalt Academy”. During spraying of each batch, the contractor shall draw off at least three test samples of the modified bitumen/emulsion product and submit them to the engineer for acceptance testing purposes. The supplier shall submit all his tests results to the engineer for correlation purposes, failing which the engineer’s results shall be binding in terms of acceptance or rejection of the product.” B4303 PLANT AND EQUIPMENT b) Binder distributor Add the following: "Prior to the commencement of any work, a calibration certificate, not older than 12 months, for the binder distributor shall be presented to the engineer for approval. The binder distributor shall be capable of spraying the binder at the specified application rates and to the satisfaction of the engineer. The pump of the distributor shall be capable of delivering the binder at the spray bar nozzles at the correct pressure to obtain the specified application rates, irrespective of the viscosity properties of the prescribed binder. The spray bar of the distributor shall be fitted with fishplates at the outside edge of the bar to prevent over spraying onto gravel shoulders or staining of concrete elements on the edge of the surfacing of the road In addition, the transverse distribution of the spray bar shall be field-verified by means of SANS 3001-BT24: Civil engineering test methods Part BT24: Measurement of transverse distribution (‘Bucket test’) for a binder distributor. The maximum permissible tolerance permitted between the troughs (excluding the outer 300mm) is dependent on the viscosity of the binder type being applied and shall be as follows:

Emulsions, cutback and penetration grade bitumens - 5% Homogeneous modified bitumens - 7% Non- homogeneous binders (bitumen rubber) - 10%

The spray bar shall be of such design as to allow for any adjustments to be made in order to meet the above tolerances. This procedure shall be carried out each time the distributor is first established on site and once a week thereafter or when a problem with transverse distribution is suspected. The binder distributor shall thus have a set of troughs available in order to allow the execution of the test. For limited quantities of spray-work, the engineer may accept the results of a recently completed distribution test that has been recorded and approved by an independent supervisor on the distributor's test log book. The binder distributor shall be fitted with a suitable valve or other access gate for taking of samples of the binder for testing purposes.”

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c) Chip spreaders Add the following at the end of the first paragraph: “The chip spreader shall be capable of delivering a proper and uniform transverse distribution of chips across the conveyor belts. The chip distribution shall be tested by means of canvas patches, each 1,0m by 1,0m and placed side by side. The mass of chips spread onto each individual canvas patch shall not deviate by more than 10% from the calculated average spread per canvas patch.” Add the following to the last paragraph: "A non-self-propelled chip spreader may only be used in the event of a breakdown of the self-propelled chip spreader during a pull, and shall be limited to the completion of that pull. No further application of binder shall be permitted until such time as the self-propelled chip spreader is repaired or replaced.” B4304 GENERAL LIMITATIONS AND REQUIREMENTS a) Weather limitations Add the following: “Seal work using bitumen rubber or hot applied polymer modified binder shall not be permitted during the months of May to August (inclusive). Winter grade binders shall not be used in any seal work and the contractor’s program shall reflect this limitation.” b) Moisture content Replace “reseal” with “seal” in the second line of the second sentence. Insert “and/or primed base” after “surfacing” in the third line of the second sentence. Replace the last sentence with “In such case the base shall be allowed to dry out to meet the above moisture content requirement prior to placing the seal layer.” (i) General Add the following: “Seal work shall not be permitted on granular base layers if the moisture content in the upper 50mm exceeds 50% of the optimum moisture content, determined in accordance with TMH1 Method A7. This limitation shall apply even if the layer has been previously primed. Sealing work shall not commence until the engineer has approved all other works ordered on that section of road.” e) Demarcation of the working areas (i) New work Add the following: “Before the tack coat and first application of aggregate may be applied, the centreline of the road shall be demarcated by means of a clearly visible weatherable fibre rope, pegged down with nails driven into the existing surface at intervals of 15m on straight sections and 3m apart on curves. The demarcating rope shall be removed prior to the application of the tack coat and aggregate on the adjacent lane.’

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B4305 HEATING AND STORAGE OF BITUMINOUS BINDERS d) Homogeneous cold applied modified binders Add the following: “The requirements for short term handling, storage and application of these binders shall comply with the requirements listed in table B4305/5:” TABLE B4305/5: TEMPERATURE/TIME LIMITS POLYMER MODIFIED EMULSIONS

Binder Class

Short term handling Storage Spraying

Max Temp (°C)

Max Time (hrs)

Max Temp (°C)

Max Time (hrs)

Max Temp (°C)

Min Temp (°C)

Max Time (hrs)

SC-E11

SC-E21

70 24 Ambient 240+ 80 50 2

CC-E1 Ambient 240+ Ambient 240+ Ambient 240+

Notes: 1. This applies to modified emulsions with a binder content of approximately 70% m/m. For emulsions with a

binder content of approximately 65% m/m the maximum short term handling and maximum spraying temperature limit shall be reduced by 10°C.

e) Homogeneous hot-applied binders (summer grade) In the second paragraph, replace table 4305/3 with “table B4305/3”: TABLE B4305/3: TEMPERATURE/TIME LIMITS FOR HOT POLYMER MODIFIED BINDERS

2

Binder Class

Short term handling

Storage Spraying/Asphalt

Mixing/Application

Max Temp (°C)

Max Holding

Time (hrs)

Max Temp (°C)

Max Holding Time

1

(hrs)

Max Temp (°C)

Min Temp (°C)

Max Holding

Time (hrs)

S-E1 (SBR) 180 24 150 240 210 190 8

S-E1 (SBS) 180 24 150 240 185 175 12

S-E2 180 24 150 240 185 175 12

A-E1 (SBR) 180 24 150 240 190 175 8

A-E1 (SBS) 180 24 150 240 180 170 12

A-E2 180 24 150 240 180 170 12

A-P1 180 24 150 240 170 150 24 C-E1 160 24 140 240 180 160 8

Notes: 1. If the recommended maximum holding time has been exceeded then resample and test the binder to

ensure compliance with the specification. 2. In the event of non-polymer modified binders being used, refer to the supplier for guidelines on handling

and application temperatures. B4306 STOCKPILING OF AGGREGATE a) General Add the following: "The contractor shall heed the environmental requirements of Part C of this volume in the preparation, operation and closure of stockpile sites. The positions for stockpiling of aggregate and the proposed operation methods shall be approved by the engineer before delivery of the aggregate can commence. After application of the seal all loose stones swept off the road surface are to be heaped either in the drain or gravel shoulder, whichever is applicable, and removed in one operation. No sweepings are to

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be left on site for more than 24 hours. No sweepings are to be heaped or stored on the vegetated areas of the road reserve. No loose stone is to be spoiled in the road reserve.” B4307 CONSTRUCTION OF SEAL b) Single and double aggregate seals (i) Application of tack coat and aggregate Replace the last sentence of the fourth paragraph with the following: "The contractor shall so place the strips when constructing the seal that the joint between two adjacent aggregate applications shall be located along the centreline and at 3,7m from the centreline." Add the following to the fourth paragraph: “Joints shall be straight and aggregate shall be broomed back in a neat straight line before the next spray. String lines shall be used to demarcate joint edges. All stone-loss and "tram-lining/roping" shall be made good by the contractor at no additional cost.” (ii) Initial rolling of aggregate Replace the second sentence with the following: "In the case of modified emulsions, initial rolling by means of self-propelled 5-ton flat steel wheel rollers shall only be permitted if crushing of aggregate does not occur. Pneumatic-tyred rolling shall be delayed until the emulsion has been allowed to break sufficiently to firmly secure the aggregate. Rolling shall be postponed if there is any pick-up of aggregate on the tyres of the pneumatic type roller." (iii) Broom drag and final rolling of aggregate Add the following after the first paragraph: “The contractor shall provide a back-chipping team, together with a pneumatic-tyred roller, of sufficient capacity to ensure that back-chipping and rolling of aggregate shall be completed within thirty minutes after initial application of the aggregate.” Replace third paragraph with the following: "After completing the spreading of the aggregate, final rolling shall consist of a minimum of four passes utilizing a 15-ton to 20-ton pneumatic-tyred roller, followed by one or two passes of a 6-8 ton flat steel wheel roller." iv) Joints between binder sprays Add the following at the end of the paragraph: "The protective sheets shall be made of reinforced building paper." (v) Protection of kerbs, channels etc. Add the following: "Where bitumen binder is to be sprayed directly adjacent to existing concrete kerbs, channels, side drains, concrete edge beams and bridge balustrades, or over bridge joints, such concrete elements shall be covered with an approved reinforced building paper.” Add the following sub-sub-clause:

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“(vi) Trial section Before the contractor commences with the construction of any seal work he shall demonstrate that the equipment and processes he proposes to use will enable him to construct the seal in accordance with the specified requirements. At the commencement of the surfacing operation, a 200m half-width section shall be considered as a trial. After completion of each phase of the seal on this 200m section, the engineer will review and then approve/reject the work method. If approval is granted for a specific operation i.e. application of tack coat, aggregate, fog or slurry, the contractor may proceed with that approved operation. Should the contractor at any stage fail to deliver an acceptable product he shall rectify the problems at his own cost and demonstrate with a further trial section that he can carry out the operation successfully. No specific payment shall be made for conducting these trials and the cost thereof shall be deemed to be included in the tendered rates of sections 4400, 4500 and 4600.” B4308 RATES OF APPLICATION In the first sentence of the first paragraph, delete the following after "conventional": "or homogeneous modified" Add the following at the beginning of the second sentence: "Homogeneous and" In the second paragraph, replace 4314 with: "B4314" Add the following at the end of the second paragraph: “In the case of single seals the engineer may, at his discretion, permit the application of a diluted emulsion fog spray in instances where application rates are below the minimum allowable tolerances. In such instances no additional payment over and above the unit rate tendered for the accepted seal, plus or minus any variation from the nominal, will be made. In the case of sand seals or graded seals the engineer may accept, at his discretion, an application of binder sprayed above the allowable tolerance subject to the contractor, at his own cost, applying and rolling any additional sand/aggregate necessary as a result of such over application.”

B4314 TOLERANCES AND FINISH REQUIREMENTS c) The rate of application Replace the first paragraph with the following: "The maximum permissible variation from the rates of application of aggregate or slurry, as ordered by the engineer, shall be plus or minus 5%. For binders, the maximum permissible variation from that specified shall be 5% for conventional bitumen and all emulsions (measured net cold), and 5% for hot applied modified binders (measured at spray temperature). Provided he is satisfied that the seal will perform satisfactorily, the engineer may, at his discretion, conditionally accept out of tolerance variations at the reduced rates of payment listed in Table B4314/1 below. However, variations in total binder application rates in excess of those tabled shall be deemed rejected. Rejected sprays will not be considered for payment unless corrected to the satisfaction of the engineer. A lot for acceptance control purposes shall be at least 2000 litres. Lots smaller than 2000 litres shall be combined with succeeding lots until a combined lot not less than 2000 litres is obtained. “

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TABLE B4314/1: PAYMENT REDUCTION FACTORS FOR CONDITIONALLY ACCEPTED BINDER APPLICATION RATES

Conventional bitumen and emulsion. Deviation from specified spray rate

Net cold bitumen. (%)

Hot applied homogeneous and non-homogeneous modified bitumen.

Deviation from specified rate. At spray temperature. (%)

% Payment of tendered rate for seal

±5,0

±6,0

±7,0

±8.0

±9,0

±10.0

±5,0

±6,0

±7,0

±8,0

±9,0

±10,0

100%

97,5%

95%

90%

85%

80%

Add the following at the end of the last paragraph: "The completed surfacing shall be of uniform texture without gaps or patches and shall be free from longitudinal and transverse corrugations and any loose aggregate or binder spillage. The edges of the completed bituminous surfacing shall be true to line." d) Conditional acceptance Delete the entire sub-clause

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SECTION B4600: BITUMINOUS SINGLE SEAL WITH SLURRY (CAPE SEAL) B4602 GRADES OF BINDER TO BE USED a) Tack coat (iii) Homogeneous modified binders Delete “(1) 5% latex cationic emulsion” and replace with: “Binder Class SC-E2 (65-68)(t) or (70-73)(t) where “(t)” indicates that the binder being applied shall contains no diluents (cutters).” (b) Second application of binder The second application of bituminous binder, as directed by the engineer shall consist of the following: (1) 35% polymer modified spray-grade emulsion of Class SC-E2 (1 part 70% emulsion mixed with 1 part of water).” B4603 CONSTRUCTION BEFORE SLURRY APPLICATION a) Application of tack coat and aggregate Add after the first paragraph: “The Engineers may instruct the pre-coating of the 20mm aggregate of the first layer with a bituminous based pre-coating fluid, at 12ℓ/m

3 as specified in sub-clause 4302(d).

A second application of 35% cationic bitumen emulsion shall be applied to the surface of the 20mm aggregate. The aggregate to be used with the tack coat shall conform to the grading requirements for a 20mm nominal size Grade 1 surfacing aggregate.” b) Initial rolling Replace “sub-sub-clause 4307(b)(ii)” with: “Sub-sub-clause B4307(b)(ii)” c) Broom drag and final rolling of aggregate Replace “sub-sub-clause 4307(b)(iii)” with: “Sub-sub-clause B4307(b)(iii)” B4604 SLURRY c) Composition of slurry Add the following: “The aggregate used for slurry shall comply with the requirements of Table 4302/11. The first slurry shall be a fine slurry "coarse” to “medium grade" and the second slurry shall be fine slurry "medium grade". For tender purposes the mix proportions of the slurry shall be based on mass.” After the second paragraph add the following:

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"The slurry consistency when measured in accordance with ASTM D3910 Section 6.1 shall be between 30mm and 40mm." e) Application of slurry In the first sentence of the third paragraph insert the words "one or" before "two layers". Replace the fifth and sixth paragraphs with: "The measurement of slurry application rate shall be the dry mass of aggregate in kg/m² applied per m² of surfacing and the total nominal rate of application shall be 13 kg/m2 if only the 1st slurry layer is applied, and 15 kg/m2 in total if the 1st and 2nd slurry layers are applied. Payment for slurry application variations shall be based only on the actual total rate of slurry application of the completed Cape Seal.” Add the following after the eighth paragraph (now the seventh paragraph): "Both the first and second layer of slurry shall be spread to the full final width of the primed surface." Change the eighth line of the tenth paragraph as follows: “… pneumatic-tyred roller. However, each layer of slurry shall be ….” B4605 MEASUREMENT AND PAYMENT Item Unit B46.01 Bituminous seal with 20mm aggregate and slurry In the heading to this item add the words: "(excluding 2nd application of binder)." Delete the unit and add the following subitems: "(a) Single 20mm seal with first (coarse to medium grade) slurry layer with a tack coat comprising (i) 70% polymer modified cationic spray-grade emulsion of Class SC-E2……………………………………………………………………….square metre (m

2)

(b) Extra over (a) for 2nd (fine) slurry layer ................................................... square metre (m2)" In the measurement paragraph delete the word "complete", and after the word "slurry" insert; "(excluding 2nd application of binder)". Add the following at the end of the payment clause for this item: "The cost of providing the slurry seal over the final primed width shall be included in the rate for providing the seal with slurry over the bituminous surfaced width." Item Unit B46.03 Bituminous binder variations Amend (l) to read: "(l) Polymer modified spray grade emulsion of SC-E2 (70-73) ........................................ litre (ℓ)"

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Add the following items: “Item Unit B46.09 Extra over items B46.01(a) and (b) and 46.06 for the addition of natural sand from commercial sources to the aggregate of the slurry…………………….. ton (t) The unit of measurement shall be the ton of natural sand from commercial sources added to the slurry aggregate calculated from the proportion of natural sand ordered by the engineer and the actual measured application of the slurry. The tendered rate shall include full compensation for all additional cost for procuring and furnishing the sand from commercial sources, transporting the sand over an unlimited free-haul distance, and the mixing of the sand into the slurry aggregate. Item Unit B46.11 Second application of binder consisting of 35% spray grade cationic emulsion……………………………………………………………………………….. litre (ℓ) The unit of measurement shall be the litre of emulsion sprayed as specified and measured of the application temperature. The tendered rate shall include full compensation for procuring and furnishing the binder and applying the second application of binder as specified."

Item Unit

B46.12 Extra over items B46.01 and B46.11for the transportation cost of bitumen binder supplied by a refinery outside the Western Cape Province ................................................................................................................... ton (ton)

Where bitumen that meets the requirements of the specification is not available from a refinery in the Western Cape Province the engineer may agree that material be imported from other sources. The unit of measurement shall be the ton of net cold bituminous binder and shall be calculated from the average binder content of the asphalt placed for a day’s work or the actual volume of prime, tack and binder sprayed. The tendered rate shall include full compensation for the additional cost of transporting bituminous binder which meets all the requirements of the specification from a refinery outside the Western Cape Province. Any difference in the “ex refinery” price of bitumen shall be compensated for by means of the special material adjustment formula.”

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COLTO SERIES 5000: ANCILLARY ROADWORKS

SECTION B5100: PITCHING, STONEWORK AND PROTECTION AGAINST EROSION

B5102 MATERIALS

(a) Stone

Replace the 2nd paragraph with the following:

“Unless suitable stone can be located on site, the stone for pitching shall come from commercial sources but, from whatever source, its use shall be subject to the prior approval of the engineer.” (c) Sand

(ii) Sand for bedding

Replace this sub-sub-clause with the following:

“Sand for bedding used for paving blocks shall not contain any deleterious impurities and shall comply with the requirements given in table B5102/1.

Table B5102/1

Sieve size (mm) Percentage passing 10 100 5 95 – 100 2 73 – 86 1 43 - 78

0,600 25 – 60 0,300 10 - 30 0,150 5 – 15 0,075 5 - 10


B5106 SEGMENTAL BLOCK PAVING

(d) Edge beams


“Where concrete edge beams are constructed the relevant specifications under section 2300 shall apply."

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SECTION B5400: GUARDRAILS

B5402 MATERIALS

(a) Guardrails

At the end of the 1st sentence delete the full stop and add “or SANS 51317 and carry the SABS mark.”

(b) Guardrail posts

(ii) Steel posts

Replace the paragraph with the following:

“Where offered or instructed to be used, steel posts shall be part of an approved guardrail system as tested and complying with SANS 51317, and galvanized in compliance with the requirements of SABS 763 for type A1 articles, shall be used. Where guardrails are placed on concrete retaining walls or concrete structures, the steel posts shall be of the type and size shown on the drawings or described in the project specifications.”

B5403 CONSTRUCTION

(a) Erection

Replace the 7th paragraph with the following:

“Steel posts placed on concrete retaining walls or concrete structures shall be erected and fixed as shown on the drawings. For all other applications, wooden posts shall be erected and fixed in compliance with the approved guardrail system as tested and approved in terms of SANS 51317.”

B5405 REMOVING, RENOVATING AND RE-ERECTING GUARDRAILS

(a) Removing the guardrails

In the 3rd line of the 1st paragraph, after “150mm layers,” delete the full stop and add “of suitable material (not less than G7 quality material).”


Replace item 54.01 with the following:

“Item Unit

B54.01 Guardrails on 3.81 m spaced posts

(a) Complete galvanised system on: (i) Timber posts .......................................................................................................... metre (m) (b) Extra over 54.01(a) for the following: (i) Type A - Bridge terminal flared end treatment with combination of

single and double guardrail sections ................................................................... number (No) (ii) Type B - Bridge terminal flared end treatment with double guardrail

sections.............................................................................................................. number (No) (iii) Type E1 - Bridge terminal end treatment with combination of single

and double rail section ....................................................................................... number (No) (iv) Type F1 - Bridge terminal end treatment with double guardrail

sections.............................................................................................................. number (No) (v) Bridge connect treatments with double guardrail sections ................................... number (No) (vi) End wing ............................................................................................................ number (No) (vii) Guardrail adapters.............................................................................................. number (No)

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(viii) Bullnoses WCG detail......................................................................................... number (No) (ix) Type G – WCG detail end treatment approach end ............................................. number (No) (x) Type G – WCG detail end treatment departure end ............................................ number (No) The unit of measurement for (a) shall be the metre of guardrail as erected, (including length of end treatments and curved guardrails). The unit of measurement for (b)(i) to (b)(x) shall be the number of end treatments, connect treatments, adaptors and steel posts of each type installed. The tendered rates shall include full compensation for furnishing all materials and labour for erecting and galvanizing the guardrails, complete with posts, spacer blocks, bolts, nuts, washers and reinforcing plates, and excavating holes in all classes of material, concrete, backfilling and removing any surplus material. It shall also include full compensation for incidentals in respect of supplying and erecting curved guardrails, end treatments, connect treatments, adaptors and turned down sections. Reflective plates and drilling and blasting will be paid for separately under items 54.06 and 54.12 respectively.” Replace item 54.02 with the following:

“Item Unit

B54.02 Guardrails on 4.0 m spaced posts

(a) Complete galvanised system on: (i) Steel posts ............................................................................................................. metre (m)

(b) Extra over 54.02(a) for the following (i) Type A - Bridge terminal flared end treatment with combination of

single and double guardrail sections ................................................................... number (No) (ii) Type B - Bridge terminal flared end treatment with double guardrail

sections.............................................................................................................. number (No) (iii) Type E1 - Bridge terminal end treatment with combination of single

and double rail section........................................................................................ number (No) (iv) Type F1 - Bridge terminal end treatment with double guardrail

sections.............................................................................................................. number (No) (v) Bridge connect treatments with double guardrail sections ................................... number (No) (vi) End wing ............................................................................................................ number (No) (vii) Guardrail adapters.............................................................................................. number (No) The unit of measurement for (a) shall be the metre of guardrail system (complying with SANS 51317) as erected (including length of end treatments and curved guardrails). The unit of measurement for (b)(i) to (b)(vii) shall be the number of end treatments, connect treatments and adaptors of each type installed. The tendered rates shall include full compensation for furnishing all materials and labour for erecting and galvanizing the guardrails, complete with posts, spacer blocks, bolts, nuts, washers and reinforcing plates, and excavating holes in all classes of material, concrete, backfilling and removing any surplus material. It shall also include full compensation for incidentals in respect of supplying and erecting curved guardrails, end treatments, connect treatments, adaptors and turned down sections. Reflective plates and drilling and blasting will be paid for separately under items 54.06 and 54.12 respectively.”

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Delete items 54.03, 54.04 and 54.05 without replacement Item Unit B54.07 Removing existing guardrails ............................................................................. metre (m) Add the following: “The tendered rate shall also include for the backfill of the holes with suitable G7 quality material.” Add the following payitems: “Item Unit

B54.14 Nailing of gang nail plates on top of timber guardrail posts ........................ number (No) The unit of measurement shall be the number of gang-nail plates supplied and fixed as specified. The tendered rate shall include full compensation for supplying all materials and labour and for fixing to the top of the sealed guardrail post. Item Unit

B54.15 Proprietary H4B containment level with a working width of 2.5 m

guardrail system complying with SANS51317 ................................................... metre (m) The unit of measurement shall be the metre of guardrail erected including end treatments. The tendered rate shall include full compensation for furnishing all materials and labour, and erecting, painting and galvanising the guardrail, complete with posts, spacer blocks, bolts, nuts, washers and reinforcing plates, and excavating the holes in all classes of material and backfilling the post holes, including concrete backfill, and removing any surplus excavated material.”

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SECTION B5500: FENCING B5501 SCOPE Add the following: “This section also covers the repairing of existing fences that form part of the permanent work and/or routine maintenance” B5502 MATERIALS Add the following new sub-clauses: (k) Type 2 Fence - Pedestrian fence welded mesh Pedestrian fence welded mesh shall be constructed using 2.5mm diameter wire that is fully hot dip galvanized and of the quality as shown in drawing J01802-01-10-905. Aperture sizes shall be 100mm by 50mm centre to centre. (l) Type 3 Fence – Anti – dazzle screen welded mesh Anti – dazzle screen welded mesh shall be a mesh with aperture size of 100mm by 20mm and of 4mm diameter wires and shall be in accordance with drawing J01802-01-10-906. All wire shall be fully hot dip galvanized. B5503 TYPES OF FENCING In the 1

st paragraph add the following subclauses:

“(f) Anti – dazzle screen” B5508 ERECTING DIAMOND MESH OR WIRE NETTING Change the heading to “B5508 ERECTING DIAMOND MESH, WELDED MESH OR WIRE NETTING” In the 2nd line of the 1st paragraph, after “wire netting” add “, welded mesh” B5514 MEASUREMENT AND PAYMENT Item Unit B55.02 Supply and erect new fencing material for new fences and

supplementing material in existing fences which are being repaired

Add the following item under the subsubitem (ii) Inclined of subitem (i) Straining posts, stays and anchors: Add the following items: (j) Type 2 Fence (Pedestrian) - Pedestrian fence welded mesh 1.8m in

height (aperture size 100mm x 50mm x 2.5mm dia). Fully galvanized…………………… ................................................ ……………… square metre (m2)

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B55.03 New gates

Add the following items:

“(a) Type 1 Fence (Stockproof) - Double leaf 7.2m wide stock proof fence gate, manufactured from 42.9mm ɸ X2.6mm mild steel tubing complete with hinges, washers, bolts and locking chain. Fully hot galvanized. ………… ...................................................................................... ….number (No)

“(b) Type 1 Fence (Stockproof) - Single leaf 3.6m wide stock proof fence gate, manufactured from 42.9mm ɸ X2.6mm mild steel tubing complete with hinges, washers, bolts and locking chain. Fully hot galvanized. ………… ...................................................................................... ….number (No)

(c) Type 2 Fence (Pedestrian) - Double leaf 5m wide pedestrian fence gate, manufactured from 42mm ɸ X 2mm mild steel tubing frame 21.4mm ɸ X 2mm mild steel tubing bracing complete with hinges, washers, bolts and locking chain. Fully hot dip galvanized. …………… .... ……….number (No)

B55.04 Moving existing fences and gates

Add the following item under subitem (a) Fences:

“ (v) Moving private property fences and walls. … ............................................ ….provisional sum”

B55.05 Dismantling existing fences

Add the following item under subitem (a) Fences:

“(v) Vibacrete walls. ………………………………. ................................................. .kilometre (km)” Add the following items:

“Item Unit

B55.10 Repairing existing fences ............................................................................ kilometre (km)

The unit of measurement for repairing existing fences shall be the kilometre of existing fence repaired on the instruction of the engineer. The tendered rate shall include full compensation for untying the existing fence (where necessary) and reinstating it, tying of droppers and repairing and re-aligning of standards to the satisfaction of the engineer as well as for coiling and stacking material unsuitable for re-use. Fencing material replaced shall be paid for under items 55.02 and 55.03. If the existing fence is damaged by the contractor’s construction activities, the contractor shall repair the fence at his own cost.” B55.11 Type 3 Fence (Anti – Dazzle Screen) – Anti – dazzle screen

complete as per drawing J01802-01-10-906. All steel fully hot dip galvanized............................................................................................................. metre (m)

The unit shall be the metre of anti – dazzle screen installed measured from centre of post to centre of post complete as per drawing J01802-01-10-906. The tendered rate for each metre of anti – dazzle screen shall include full compensation for providing all materials, including all concrete, bolts, washers and nuts, back plates, anti – dazzle mesh, posts, connection plates, excavation or drilling of holes, erecting all posts, fixing all mesh, incidentals and the complete putting up of the fence as specified and shown on the drawing.”

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SECTION B5600: ROAD SIGNS

B5601 SCOPE

Replace “South African Road Traffic Signs Manual” in the second paragraph with:

“SADC Road Traffic Signs Manual”

B5603 MANUFACTURING OF ROAD SIGN BOARDS AND SUPPORTS

(a) Road signboards

Add the following:

“The contractor shall make every effort to ensure that signboards are correct in all respect and before dispatching the boards from the manufacturer’s factory shall provide the engineer with a 100 mm x 150 mm colour photograph of each sign face for approval of the correctness of the legend. Such approval will not imply final acceptance of the board. If the contractor is in any doubt as to the correctness of the sign detail, the sign designer shall be contacted for verification.” (ii) Steel profile road signboards

Add the following:

“Chromadek section shall be assembled in accordance with the details on drawings. Where the letter or legends cross the horizontal joints of the sign panels, the letter shall be cut on the joint and both ends folded around the radius. Retro-reflective material to adjoining Chromadek panels on a sign shall be practical visual match of the specified colour.”

B5604 ROAD SIGN FACES AND PAINTING

Add the following subclause:

“(e) Application of retro-reflective material

All sign faces shall be faced with retro-reflective material. Painted front sign faces shall not be used. Where applied to Chromadek sections, retro-reflective material shall be applied as specified for aluminium section in clause 5603(d) of the standard specification, and of clause B5603(a)(ii) of this project specification.”

B5605 STORAGE AND HANDLING

Add the following:

“The following shall not be allowed on the sign face:

Drilling of holes, except for the fastening of overlays Application of any form of adhesive Cleaning with any chemicals that are not specifically approved by the manufacturer of the retro-

reflective material. Covering the sign face with an impermeable material that does not allow free circulation of air.”

B5606 ERECTING ROAD SIGNS

(b) Excavation and backfilling

Add the following:

“Where posts are to be backfilled with concrete or soilcrete the lower 50 mm of the post shall protrude into the in-situ material if it is of a free draining nature, alternatively, a 50 mm thick layer of imported free draining material shall be placed around the foot of the post before placing the concrete or soilcrete.”

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(c) Erection

Add the following:

“After erection the signboard shall be thoroughly cleaned with a cleaning agent approved by the retro-reflective material’s manufacturer. All vegetation obstructing the new or replaced sign board shall be removed and disposed of as instructed by the engineer.”

B5608 DISMANTLING, STORING AND RE-ERECTING EXISTING ROAD SIGNS

Add the following:

“Existing road signs that are being replaced by new signs shall be dismantled and disposed of by the Contractor. Where possible the dismantling of the signs shall not be before the replacement sign is erected and displayed. Where dismantling of the sign is required before erection of the replacement sign, the dismantling shall not take place until immediately before work is to commence on the replacement, and the replacement shall be completed and the new sign displayed as soon as possible thereafter (within 72 hours). Dismantling shall include sign panels and ground mounted sign supports. Ground mounted sign supports shall be cut off just below ground level. Material excavated for removal of buried poles shall be replaced, and any depression made good using excess material from excavation for new signs. Payment items are provided in the Pricing Schedule. Payment will differentiate between different types of sign panels.”


Item Unit

B56.01 Road sign boards with painted or coloured semi-matt background. Symbols, lettering, and borders in semi-matt black or in Class I retroreflective material, where the sign board is constructed from:

Amend the last two lines of the second paragraph to read:

“completion, delivery, installation of the road sign board complete as specified, and the removal and disposal of all vegetation obstructing the motorists’ view of the new or replaced sign board.”

Item Unit

B56.02 Extra over item B56.01 for using:

(a) Background of retro-reflective material: Add the following subitem:

“ (iv) Diamond grade: Class IV .......................................................................... square metre (m²)” (b) Lettering, symbols, numbers, arrows, emblems and border of retro-reflective material: Add the following subitem:

“(iii) Diamond grade: Class IV .......................................................................... square metre (m²)”

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Add the following payment items:

“Item Unit

B56.10 Danger plates at culverts/structures (800 mm x 200 mm) .............................. number (No)

The unit of measurement shall be the number of danger plates provided and erected in accordance with the drawings. The tendered rate shall include full compensation for all labour and material, painting, posts, excavation, backfilling with soil etc., as may be necessary for completing the work in accordance with the details shown on the drawings.

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SECTION B5700: ROAD MARKINGS

B5701 SCOPE Replace “South African Road Traffic Signs Manual” in the second paragraph with: “SADC Road Traffic Signs Manual” Replace the words “ordinary road marking paint” with “solvent borne road marking paint”. Replace “BS 3262” with “EN 1436”. Replace “Hot melt plastic road marking” with “thermoplastic road marking”. B5702 MATERIALS Insert the following before subclause (a) Paint: “The selection of the appropriate road marking paint and materials for permanent road markings to ensure conformance with the requirements of this specification rests with the contractor. Such paint and material shall have technical characteristics (brightness, luminance, skid resistance, durability) equal to or greater than road marking paint and materials specified in subclauses 5702(a), (b) and B5702(c). Where plastic road-marking material (hot-melt plastic (also known as thermoplastic) and two-component (also known as cold plastic)) is used, the contractor shall obtain an approved guarantee from the manufacturer that the paint complies with the specification. This shall be submitted to the engineer on request.” (a) Paint (i) Road marking paint Replace the subclause with the following: “Road marking paint shall be Type 1 as specified in SANS 731-1. Only paint, manufactured in a SANS approved and accredited facility shall be accepted. The no-pick-up time of road-marking paint shall comply with the Class 1 requirement in accordance with SANS 731-1. The paint shall be delivered at the site in sealed containers marked in accordance with SANS 731-1. The viscosity of the paint shall be such that it can be applied without being thinned down.” Replace subclause (iii) with the following:

“(iii) Thermoplastic road marking material

Thermoplastic road marking material shall comply with the requirements of EN 1436, and EN 1423: 1998 for drop-on glass beads for road marking and anti-skid aggregates and mixtures thereof. Blending of thermoplastic road marking material and glass beads shall comply with EN 1424: 1998. The binder shall be an elasticized synthetic resin and the material shall be reflectorized by mixing in 25% by mass Class A glass beads in accordance with EN 1424: 1998. An additional topping of glass beads shall be applied to the hot surface of the material for instant retro-reflectivity. The white road marking material shall contain 6% by mass minimum titanium dioxide content and shall have a skid resistance of 45 S.R.T. – units or higher. SABS Method 1248: 1995 shall be used for determination of traffic wear index; indication of durability.

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The following minimum lumination values are required for the completed product:

250 mcd/m2.lux & 120 mcd/m2.lux for white & yellow lines respectively, at 30 days after application. 200 mcd/m2.lux & 100 mcd/m2.lux for white & yellow lines respectively, at 6 months after application.

Determination of coefficient of retro-reflected luminance by means of portable retro-reflectometer shall be carried out using SANS 6261: 2008. Application of the permanent roadmarking will thus have to be performed within the first 6 months of the 12 month defects liability period to allow for the second measurement to fall within the contract dates. Should the application of the permanent road-marking fall outside the first half of the defects liability period for whatever reason, the settlement of the retention money will be delayed until the second measurement of luminance can be performed at the stipulated time and the required adjustment can be made to the tendered rate (if required). Two-component cold plastic road marking material shall be used for symbols, arrows and letters (hand painted markings) unless otherwise instructed by the engineer.” Add the following subclauses:

“(v) Cold plastic road marking material

Cold plastic road marking material shall be used for symbols, arrows and letters (hand painted markings) and shall consist of a solvent-free reactive acrylic resin, stuffing, beads and pigment to which a hardener shall be added. Application is carried out using a trowel. Material applied by paint brush shall not be used. Cold plastic road marking material shall be reflectorized by mixing in 25% by mass (or 400 g/m2) Class A glass beads in accordance with EN 1424: 1998. An additional topping of glass beads is applied to the wet surface of the material after application and will comply with EN 1423: 1997. (vi) Epoxy Primer applied to Kerb Markings

The primer to be applied to the kerbs shall be SigmaCover 280 manufactured by Sigma Coatings or similar approved.” (b) Roadstuds

Replace the second sentence with the following:

“All square roadstuds shall have a footprint of 100 mm x 100 mm and a height of at least 20 mm. Round roadstuds shall be 100 mm in diameter and not less than 20 mm in height.” Add the following subclause:

“(c) Retro-reflective beads

Retro-reflective glass beads shall be applied to the wet paint, thermoplastic and cold plastic. The beads shall comply with Class A beads in accordance with EN 1424: 1998, with the following requirements or as approved by the engineer:

colour : crystal clear

roundness : > 80%

size range of : 14 – 200 US Mesh (75 – 1400 Microns)

refractive index : > 1.5

specific gravity : ± 2.5

granulometry :

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CUMULATIVE RETAINED MASS SIEVE MINIMUM MAXIMUM 1700 0 2 1400 0 10 1180 5 30 850 40 80 600 70 100 425 80 100 355 90 100 212 95 100 PAN 100 100

The beads shall be delivered to the site in sealed bags, marked with the name of the manufacturer, the batch number and an inspection seal of SANS, confirming that the beads form part of a lot tested by SANS and comply with the requirements of EN 1424: 1998. Alternatively, the contractor shall at all times have a SANS certificate on the site, identifying the batches to which the inspection seals apply and certifying that they have been tested by SANS, and comply with the requirement of EN 1424: 1998.”

B5704 MECHANICAL EQUIPMENT FOR PAINTING

Add the following sentence at the end of the first paragraph:

”The road-marking machine shall be fitted with a device to guide the operator to the centre of the line to be painted. This device shall be used at all times of operation.”

B5705 SURFACE PREPARATION

Add the following at the end of the second paragraph:

“The onus is on the contractor to ensure that the surface on which the road markings are to be applied is sufficiently clean and dry to ensure that the quality of the road markings will not be adversely affected. The contractor is also responsible for protecting road studs from being painted over, and the subsequent cleaning thereof if such over-painting did occur.” Add the following new paragraph after the fourth paragraph:

“Where permanent road markings are specified on kerbs or on concreted surfaces, as instructed by the Engineer, the surface shall first be cleaned in order to remove any dust and traces of mould release oils. The surface is to be prepared to a wood floated (etched) finish by applying light sandblasting or by any other approved means. An approved epoxy primer shall then be applied to the concrete surface to ensure good adhesion of the paint with the concrete surface. The epoxy primer shall be compatible with road marking paint. Once the primer has dried, the specified road marking colour paint shall be applied as a top coat at the specified application rate.”

B5707 APPLYING THE PAINT


“The contractor’s establishment on site and general obligation shall be deemed to fully include the establishment of the road-marking team, irrespective of the number of times the road-marking team is required to be on site or is required to move within the site. Provision is also made under item 57.07 for de-establishment and re-establishment in the contract or maintenance period if such action is required by delays not attributable to the contractor and/or ordered by the engineer.” Replace the sixth paragraph with the following:

“Solvent borne road marking paint shall be applied at a nominal rate of 0, 42 ℓ/m2 or as directed by the engineer. Thermoplastic road marking shall be applied at a nominal rate of 2,5 kg/m

2 to achieve a

minimum thickness of 1,25 mm to 1,5 mm or as directed by the engineer. The two-component road marking material shall be applied by hand by means of a trowel. The desired symbol or line shall be marked with a tape or a template on the road surface. Thereafter apply the required volume of

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material and spread uniformly over the entire area. When dry/set, remove the tape or template. A spreading rate of 4,5 kg/m2 is estimated to achieve a 2,0 mm material thickness. In order to ensure proper coverage on all types of surfaces the engineer may order an increase in the above nominal application rates. Payment for these variations in application rates shall be made under item 57.04. A daily log-sheet, provided by the employer, shall be completed and signed by the contractor and the engineer’s representative, recording the quantities of paint and glass beads used on that day and shall be available for inspection at all times. The completed and signed log-sheet for the period covered by a payment certificate shall be attached to the payment certificate.” Replace the last paragraph with the following:

“Solvent-based road marking as specified by the engineer shall be carried out within 14 days of opening the road full width to traffic after the completion of the surfacing. If in the in the opinion of the engineer, conditions are unsafe, the centre-line shall be painted immediately after 2,0 km of continuous road has received a new asphalt layer, or 4,0 km of continuous road has received a new seal surfacing.”

B5708 APPLYING THE RETRO-REFLECTIVE BEADS

In the first paragraph, replace the nominal application rate of 0,8 kg/litre with “400 g/m2”.


“The thermoplastic road marking material and two-component road marking material shall contain insitu glass beads of minimum content of 25% in order to obtain night visibility (reflectivity). The contractor shall immediately apply additional glass beads at 400 g/m2 to obtain immediate reflectivity. The beads shall be sprayed onto the road marking layer by means of a pressure sprayer. Where letter, symbol, traverse line and island road marking is undertaken by hand, the glass beads may be applied by hand if approved by the engineer. Prior to any hand application work, the contractor shall first request approval from the engineer.” Add the following:

“Beads shall be applied in accordance with EN 1424.”

B5710 TOLERANCES

Add the following paragraphs to subclause (c) Alignment of markings:

”When an unbroken line and a broken line are painted alongside each other, the beginning and the end of the unbroken line shall coincide with the beginning of one broken line and the end of another broken line. When existing lines are repainted, the new markings shall not deviate more than 100 mm in the longitudinal direction or 10 mm in the transverse direction from the existing marking. The alignment of the road studs shall not deviate from the true alignment by more than 10 mm and shall be positioned so that the reflective faces are within 5 of a right angle to the centre line of the road.” Add the following subclause:

“(e) Testing

(1) Plant

Before painting any permanent road markings, the contractor shall satisfy himself and the engineer, by painting test lines on a section of pavement other than the section required to be marked:

(i) that the painting machine is in good working order and properly adjusted; (ii) that the operator is fully experienced; and

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(iii) that the machine sprays at the specified rate of paint application. The contractor shall bear the cost of all materials and workmanship required for the above plant tests. In addition, the contractor shall conduct random paint thickness tests and dip/spread tests as required by the engineer.”

B5711 GENERAL

Insert the following into the last sentence of the last paragraph between “black paint” and “or chemical paint remover”:

“, bituminous emulsion, slurry” Add the following to the last paragraph:

“Where black paint is used, it shall be matt.” Add the following paragraph:

”The contractor shall provide temporary traffic control facilities in accordance with section 1500 to ensure traffic safety where work is being executed. Property and/or road signs damaged by the contractor, his personnel, his agents or subcontractors shall be repaired or restored to their condition prior to the damage at his own cost.”

B5712 FAULTY WORKMANSHIP OR MATERIAL

Add the following paragraphs to this item:

“The durability of the roadstuds supplied and the installation thereof shall be guaranteed for 12 months after installation. Defective or lost roadstuds shall be replaced by the contractor at his own cost. Excluded from this guarantee is damage or faults originating from vandalism or extreme mechanical damage. The contractor shall rectify in an acceptable manner and at his own costs; all markings that do not comply with the specified requirements. While work is in progress, tests shall be carried out on materials and/or the quality of work to ensure compliance with the specified requirements. The sampling methods are specified in SANS 731-1. The sampling methods described in TMH5 shall be followed where applicable.”

B5713 PROTECTION

Add the following paragraph

”Traffic cones shall not be smaller than 750 mm in height and shall be placed on the road not further than 48 m apart. Cones shall not be removed before the paint on the road has hardened to such an extent that it will not be damaged by traffic and the adhesive of the road studs has hardened to such an extent that the studs will not turn or become loose. All marks on the road caused by traffic driving over wet paint shall be removed by the contractor at his own cost.” Add the following clause: “B5715 REMOVAL OF EXISTING ROAD STUDS The existing road studs shall be removed from the road surface prior to milling.”

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B5714 MEASUREMENT AND PAYMENT Item Unit B57.01 Road-marking paint “(g) Kerb markings (any colour) ......................................................................... square metre (m²)

Add the following to this pay item: “The colour to be applied shall be as per the details given in the Southern African Development Community Road Traffic Signs Manual (SADC RTSM), Volume 1, Chapter 7. The unit of measurement for applying the road marking paint to concrete kerb surfaces shall be the actual area painted. The undercoat and top coat shall not be measured separately but as a single layer. The tendered rate per square metre shall include full compensation for procuring and furnishing all labour, materials and equipment including all costs associated with cleaning and preparing the surface to receive both the undercoat and topcoat paint applications. The tendered rate shall also include for applying the undercoat and topcoat layers (as per the manufacturers specifications).” Amend the heading for item B57.03 as follows: “B57.03 Thermoplastic road-marking paint

(a) White lines (broken or unbroken) (width of line indicated) .................................kilometre (km) (b) Yellow lines (broken or unbroken) (width of line indicated) .............................. kilometre (km)” Add the following after the third paragraph: “Full payment of the tendered rate will be applicable upon completion of the application of the road-marking paint. However, should the coefficient of retro-reflected luminance fall below the required minimum levels as specified in clause B5702 above, payment will be reduced on the following sliding scale : White lines: Below 250 mcd/m2.lux at 30 days : minus 10 % of the tendered rate Below 200 down to 180 mcd/m2.lux at 6 months : minus 10% of the reduced rate Below 180 down to 160 mcd/m2.lux at 6 months : minus 20% of the reduced rate Below 160 down to 140 mcd/m2.lux at 6 months : minus 30% of the reduced rate Yellow lines: Below 120 down at 30 days: minus 20 % of the tendered rate Below 100 down to 80 mcd/m2.lux at 6 months: minus 20% of the reduced rate The reduction in the tendered rate applicable for failing to meet the specified minimum luminance level at the 30 days and 6 months measurement dates shall be applied accumulative in the certificate immediately following the date of measurement.” Amend item B57.05 as follows:

“Item Unit

B57.05 Roadstuds installation and maintenance (type stated) ................................. number (No)”

Add the following after the first sentence of the second paragraph:

“No additional payment will be made should temporary or permanent road studs be replaced if lost or broken during the construction period or during the Defects Notification Period.”

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Item Unit

B57.08 Removal of existing, temporary or permanent road markings by:


“(c) Black Stamark removable roadmarking tape ............................................. square meter (m²)” Add the following items:

“Item Unit

B57.10 Cold plastic road marking material

(a) White lettering and symbols ....................................................................... square metre (m2)

(b) Yellow lettering and symbols ..................................................................... square metre (m2)

(c) Transverse lines, painted island and arrestor bed markings (any colour) ....................................................................................................... square metre (m2)

The unit of measurement for applying the roadmarking material for the lettering, symbols, transverse lines, islands and arrestor bed markings shall be the square metre, and the quantity to be paid for shall be the actual surface area of the lettering, symbols, transverse lines, islands and arrestor bed markings, completed in accordance with the instructions of the engineer. The tendered rate per square metre for applying the road marking material shall include full compensation for procuring and furnishing all material, including the retro-reflective beads and all necessary equipment, and for applying, protecting and maintenance as specified, including the setting out of lettering, symbols, transverse lines, islands and arrestor bed markings.

Item Unit

B57.11 Re-establishing the painting unit on instruction of the engineer during the construction period ...................................................................... number (No)

The unit of measurement shall be the number of times the painting unit is re-established on site on instruction of the engineer. The contractor’s establishment on site and general obligation shall be deemed to fully include the establishment of the road-marking team, irrespective of the number of times the road-marking team is required to be on site or is required to move within the site. Provision is made under payment item 57.07 for de-establishment and re-establishment in the contract or maintenance period if such action is required by delays not attributable to the contractor and/or ordered by the engineer. The tendered rate shall include full compensation for re-establishing the complete painting unit on the site and the subsequent removal of all special equipment, personnel, etc., for painting the road-traffic markings during the construction period.

Item Unit

B57.12 Retro-reflective removable road marking tape

(a) White lines (broken or unbroken) (width of line indicated) ................................ kilometre (km) (b) Yellow line (broken or unbroken) (width of line indicated) ..................................kilometre (km)

The unit of measurement for applying the temporary road making tape shall be a km of each specified width of line and the quantity paid shall be the actual length of line applied in accordance with the instructions of the engineer, excluding the length of gaps in broken lines. The tendered rate per km shall include full compensation for procuring and furnishing all material and the necessary equipment, and for applying, protecting and maintenance as specified but excluding setting out and pre-marking the lines.”

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SECTION B5800: LANDSCAPING AND PLANTING PLANTS

B5801 SCOPE AND DEFINITION

Delete this paragraph and replace with

“This section includes all areas affected by construction activities. It includes landscaping, grassing, rehabilitation, erosion protections and planting trees and shrubs. (b) Definition

WEEDS

Delete the following:

“(as listed in bulletin 413 issued by the Department of Agriculture, Directorate of Agricultural Information)” and replace it with:

“(as listed in the Conservation of Agricultural Resources Act)”

B5802 MATERIALS

(c) Grass seeds

Add the following:

“The grass seed mixture and soil additives shall be as follows:

(i) Seed mixtures

Locally harvested seed mix of suitable indigenous plants for areas under consideration (5 kg/ha). Refer to EMPr Rehabilitation Plan in Part C3 Section C.

(ii) Mulch

Straw mulch (250 kg/ha)

(iii) Fertiliser

Organic fertiliser weed free (250 kg/ha)

(iv) Soil binder

Earthbound (250 kg/ha) (e) Grass sods

Delete “until they are placed” and add “once placed for planting”.

(i) Nursery-grown sods

Add the following:

“The sods shall be free of weeds, weed seeds, insects and fungal diseases.” (ii) Veld sods

Add the following:

“The sods shall be free of weeds, weed seeds, insects and fungal diseases.” (f) Anti-erosion compounds

Add the following to the end of the paragraph:

“Straw bales harrowed into the sand fill slopes is also recognized as a supplementary measure for stabilising the slopes and suppressing dust.”

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(g) Topsoil

Add the following at the end of the first paragraph:

“The contractor shall be responsible for the control of any germination of weed seeds within topsoil used on site.” Add the following at the end of the second paragraph:

“Areas such as stockpiles, borrow pits and spoil sites shall be stripped of all topsoil before work may commence within the area. Should a larger site for any of the above be required during construction, the contractor shall refer to the DEO for best practice methods on ensuring the preservation of the additional stripped topsoil.” Add the following paragraph:

“The topsoil shall be kept free of all foreign material generated during construction. This shall include all stone and bituminous products. Topsoiling shall not be accepted should it contain any of the above material.”

B5804 PREPARING THE AREAS FOR PLANTS

(b) Areas which do not require topsoil

Replace “50 mm” with “20 mm“ and “150 mm” with “20 mm”

Add the following:

“In areas with large natural rock, i.e. not blasted or excavated rock, these rocks may be placed so as to look like a natural part of the landscape” Add the following sub-clause:

“(g) Removal of undesirable vegetation

During the course of the contract the engineer may instruct the contractor to physically remove undesirable vegetation from within the road reserve. Such an operation will take place before the flowering stage of the undesirable vegetation upon written instruction from the engineer, but shall not relieve the contractor of his obligation towards weeding sodded, grassed areas as described under 5806(a) and any area directly affected by any construction activity. Should the contractor fail to respond to the written instruction from the engineer for the removal of the aforementioned undesirable vegetation before flowering, the contractor shall be held contractually responsible for any growth or seeding of said vegetation for a period of not less than twenty four (24) months in the affected area.”

B5805 GRASSING

(a) Planting grass cuttings

2nd paragraph – remove “be covered with 30 mm of approved soil”. Replace with:

“have the root system of the grass cuttings thoroughly planted within the topsoil layer to ensure good growth. No part of the grass root system shall be left protruding from the topsoil”. Remove “and, when sufficiently dry, shall be rolled with a light agricultural roller”

(b) Sodding

Add the following:

“Grass sods obtained from a commercial grass farm shall be used for the following:

A 1m wide strip shall be placed next to the road edge where no gravel shoulder exists.

A 0,5 m wide strip shall be placed adjacent to all concrete-lined drains. Full sodding must be used for grass-lined drains. This sodding shall extend over the entire drainage channel, including the tops of the sides. The use of grass sods will commence from the point of acceptance of water, up to the safe discharge of water. No area shall be left without grass sods within the drainage channel should it provide a risk of erosion.

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A minimum of a 1 m wide strip shall be placed over the shoulder breakpoint for all fill slopes.

Full sodding to be used for all slopes steeper than 1:2. Any slope that exceeds 3 m in width shall be sodded, the type of which shall be determined by the slope.”

(f) Sowing by hand

Delete the following:

“If approved by the engineer,” Replace the second sentence with:

“The top 20 mm of prepared topsoil shall be raked away in sections, the seed shall then be spread uniformly within the prepared area. The top 20 mm topsoil shall then be raked over the seedbed, ensuring an even thickness. This method is to be systematic, and where applicable, follow the contours of any slopes.” Add the following:

“The thickness of the topsoil layer shall be as specified by the engineer. The preparation of the soil of the soil for areas to be grassed is to include scarifying just before sowing the grass seed. Should erosion of any kind (by animal, wind or rain) have occurred before the contractor applies the grass seed, the slope shall be re-instated, at the contractor’s cost, to its original, erosion free state before seeding. The types and mixtures of seeds to be used shall be as specified in the project specifications. The contractor shall be solely responsible for establishing an acceptable grass cover, and any approval by the engineer of seed mixtures intended for use by the contractor shall not relieve him of his responsibility”.

B5807 TREES AND SHRUBS

(a) Positions of trees and shrubs

Add the following:

“(x) No median shall be planted with shrubs, should the median width be less than 10 m wide.”

B5808 GENERAL

Add the following subclauses:

“(f) Weeding

The contractor shall maintain all areas affected by construction activities free of all undesirable plant species. They shall be removed before the flowering stage of each species. Should the contractor fail to remove the alien plant species before flowering he shall be held responsible for alien plant removal within the affected area, for an additional period of one year, over and above the contractual one year defects liability period. The method for the removal of undesirable plant species shall be either by hand, which shall include the removal of the complete root system, or by chemical means, through the use of a registered selective herbicide. A registered, licensed pest control operator, licensed for the industrial application of herbicides, shall only administer the application of the herbicide. (g) Establishment of vegetation within areas disturbed by construction activities

The engineer shall assess any area within the construction boundaries that has been disturbed by construction activities, but which is not scheduled for formal re-vegetation within the contract. The assessment shall include whether re-vegetation is required. These disturbed areas, none the less remain the contractor’s responsibility for the removal of alien vegetation (see 5807(e)).”

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Item Unit

B58.03 Preparing the areas for grassing

(e) Providing and applying chemical fertilisers and/or soil-improvement material


(vii) gypsum ........................................................................................................................ ton (t) Amend subitem (f) to read as follows:

“(f) Stockpiling topsoil where the following applies: (i) topsoil stored at a stockpile site agreed with by the engineer (free haul

1.0 km) ........................................................................................................ cubic metre (m3) (ii) topsoil pushed or bladed into heaps next to area from which it was

taken ......................................................................................................... cubic metre (m3)” (f) Stockpiling the topsoil

Delete the 2nd paragraph and replace with the following:

“The volume of topsoil removed shall be measured in cut, calculated from the difference in cross-sections of the natural ground level before the commencement of clearing to cross-sections taken after the removal of the topsoil.

The contractor shall constantly liaise and agree with the engineer as to the depth of topsoil to be removed. Where, in the opinion of the engineer, material that would normally be classed as topsoil has also been excavated, the excavation shall be backfilled and compacted with selected material at the contractor’ expense. Should material that is deemed by the engineer not to be topsoil, be removed and stockpiled together with material classed as topsoil, the contractor shall be responsible for the removal of this unsuitable soil from the stockpile and the replacement of the quantity of topsoil contaminated by the unsuitable material at his cost. The quantity of topsoil to be replaced shall be determined by the engineer.

The rates tendered shall include for the excavation of the topsoil and where required, the loading and hauling thereof to temporary stockpile, placing in stockpile, maintaining of the stockpile until re-use of the material as well as any payment to private owners for the use of the stockpile area. The rates tendered shall also include for all supervision required to ensure that only topsoil is removed.”

Item Unit

B58.04 Grassing

Amend sub item (f) as follows:

“(f) Straw stabilisation ...................................................................................... square metre (m2)

The unit of measure shall be the square metre of sand fill slope that is straw stabilised at a rate of one bale per 10 m

2 and harrowed into the top 100 mm of the top material. This item is not intended as

payment for any measures for which the contractor is liable for as mentioned under clause 5808(c), but rather intended for the use at the engineer discretion where an accommodation of traffic safety risk exists due to unavoidable dust generation.” Add the following to the end of the first paragraph of the item 58.10 Extra work for landscaping:

“The provisional sum shall also allow for the provision and planting of new trees, the establishment of landscaped beds and the appointment of a landscaping or horticultural specialist for the sole use of the engineer.”

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SECTION B5900: FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD ROADS

B5901 SCOPE

In the first line of the second paragraph, insert the following after ‘this section’

“…distinguishes between new construction and renewal construction. When construction is new, as in the case of new alignments for example, then this section”

B5902 FINISHING THE ROAD AND ROAD RESERVE

Retain the existing paragraphs as subclause: “(a) New construction”

Replace the sixth paragraph with:

“All materials resulting from the finishing operations shall be disposed of at approved spoil sites.” Add the following clause:

“(b) Renewal construction

After completing construction work within the site, the contractor shall ensure that all construction generated or related material that may have been swept, windrowed, stockpiled, stored or spread beyond the road surface is removed. This shall be done before any other rehabilitation work is undertaken, including shaping, top soiling and grassing. Should, during the removal of construction generated or related material, existing vegetation or topsoil be disturbed or destroyed, the contractor shall, at his own cost, re-instate the road reserve to its original state. This shall include ripping, should the construction material have compacted the existing surface. Culvert in lets and outlets, culvert barrels, and open drains shall be cleared of debris, soil, silt and other material generated from the construction activities. The surfacing shall be cleared of all dirt, mud and foreign objects. Dragging, pushing or scraping material across the finished surfacing shall not be permitted. All junctions, intersections, islands, kerbing and other elements making up the completed works shall be neatly finished off. The contractor shall ensure that all undesirable plants have been removed from the road reserve and borrow pit areas. All materials resulting from the finishing operations shall be disposed of at approved spoil sites.”

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COLTO SERIES 6000: STRUCTURES

SECTION B6100: FOUNDATIONS FOR STRUCTURES

B6103 GENERAL

(a) Subsurface Data

Add the following:

“It is expressly understood that, while all subsurface information is given in good faith, the correctness of the information furnished is not guaranteed. Where the actual foundation conditions encountered are considerably at variance with conditions visualised and described in the contract documents and those terms for which the rate or price provided for in the contract is rendered unreasonable or inapplicable, such other rate or price consistent with the rates set out in the contract shall be fixed as set out in clause 13 of the FIDIC Conditions of Contract subject always to a founding depth variation not exceeding 2.5 m in any foundation component (except piling depth) of the permanent structure not, by itself, being held to constitute cause for variation for the contract rates or prices. If required and instructed by the engineer, additional foundation investigations shall be conducted by an appointed sub-contractor.” Add the following sub-item

(j) Plum Concrete

Plum concrete shall consist of mass concrete and plums. Mass concrete shall comply with the requirement of Section 6400. The water cement ratio shall be adjustable, within approved limits, to maintain the appropriate viscosity of concrete to fill all the interstices between plums. The stone size to be used for plums shall be between 200 and 300 mm. The stone shall be veld or quarry stones of such quality that they will not disintegrate on exposure to water or weathering with a minimum crushing strength of 20MPa. The stones shall be free from soil, shale or organic material. Neither the breadth nor thickness of a single stone shall be less than one-third its length. The proportion of plums shall not exceed 60% of total volume of plum concrete. Not more than 10% of the total volume of plums shall consist of stones with a size of less than 0.5 times the specified size. Not more than 10% of the total volume of plums shall consist of stones with a size of more than 2 times the specified size.

B6104 ACCESS AND DRAINAGE

(c) Drainage

Add the following:

“Where dewatering and keeping dry of excavations has not been billed separately as per item 61.03 “Access and Drainage”, it shall be deemed to be included in the rates tendered and paid for under excavation and backfill.”

B6105 EXCAVATION

(a) General

Add the following:

“Excavation required for diverting, channelling or widening streams within 5.0 m of concrete structures shall be measured and paid for under item 61.02. Excavations beyond the 5.0 m limit shall be measured and paid for under the appropriate items in Sections 2100 and 3300. Excavation in the vicinity of existing structures shall be performed with due care and diligence. The contractor shall take special care not to disturb the founding material of the existing foundations. The contractor shall provide complete details of the proposed shoring system or temporary earth retaining system including a design by a registered professional engineer for any location where the appropriate system is required and shall submit these to the engineer for his approval at least 30 days

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before commencement of the excavation or fill. Any additional costs shall be included in the appropriate payment items under B61.51.” (c) Excavation

Add the following paragraphs:

“Where excavation is in soft material, the final 0.75 m and in the case of hard material, the final 0.25 m of material shall be removed using suitable hand tools such as pick and shovel or pneumatic tools. Where the excavation forms part of an existing fill, the excavated material shall be measured under the appropriate mass earthwork items in Section 3300 up to the natural ground level. A typical example would be where large portions or the whole of the fill at bridge abutments are removed.” During construction of river bridges the contractor will only be permitted to construct, subject to the approval of the Directorate of Water Affairs, low level causeways to access the rivers that cause negligible backing up; and cofferdams around the piers and abutments for the construction of the foundations using material excavated in the road prism consisting of natural alluvial deposits of sand boulders, etc. These obstructions must be removed at the end of the contract and the river and banks restored to their original condition. (g) The safety of excavations


“The design for shoring, signing of the drawings and inspection prior to construction of the permanent works of excavations to ensure it is safe shall be undertaken by the contractor’s competent person, who shall be a professional engineer with the relevant experience. The contractor shall ensure that all temporary works undertaken shall comply with the relevant sections of the Occupational Health and Safety Act and the Construction Regulations”.

B6106 FOUNDING

Add the following clause at the end of the last paragraph:

“Where foundation slabs or pile caps are cast directly against the face of the excavations, the volume of concrete measured for payment shall be the total volume of concrete placed or the volume based on the plan dimensions detailed on the drawings plus a 100 mm allowance for overbreak on each applicable side whichever is the lesser. No formwork to the footing shall be measured when the concrete is cast against the face of the excavations”.

B6109 FOUNDATION FILL

Add the following after the 4th paragraph:

“Foundation fill consisting of plum concrete shall be constructed in uniform layers not exceeding 600mm above adjoining work. The plums shall be laid in layers using concrete as mortar and flowable concrete to fill all the interstices. Plums shall extend beyond each layer to prevent slip planes between layers. Plum concrete shall be maintained wet for at least 7 days.” In the 5th paragraph, 7th line delete “60” substitute “45”.

Add the following after the 6th paragraph:

“Concrete blinding shall extend 100 mm all round beyond the horizontal dimensions of all formed footings to facilitate placing of the formwork, unless otherwise directed by the engineer. In the case of structures where excessive ground water is encountered, the blinding layer may extend over the full plan area of the base of the excavation and beyond the edge of the foundation where required. Payment shall be made for the quantity of concrete calculated as the product of the specified thickness of blinding layer and the actual area of blinding placed subject to a maximum distance of 500 mm beyond the edge of the foundation.”

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B6113 FOUNDATION PILING

(p) Determining pile lengths

Add the following:

“It is required that the top section of each pile has a minimum length of 2,5 m below the pile cap before the coupler or such greater length as specified by the engineer. The contractor shall submit to the engineer for approval the minimum length he proposes to use.” (u) Load test

(i) General

Insert the following as a first paragraph at the beginning of this clause:

“The engineer may require that a trial pile(s) be installed and load tested prior to the commencement of the piling works proper. The engineer may require that the installation of such trial pile(s) be measured and paid for separately, thus not forming part of the working piles installed later on.“ Insert the word “working“ between the words “selected“ and “piles” in the first sentence of the next paragraph.

(x) Nuclear integrity testing

Delete this subclause and replace it with the following:

“(x) Pile integrity testing (PIT)

(i) Calibration piles

Before piling on any site is commenced with, the contractor shall (per pile construction site) construct a 5.0 m long calibration pile of the same pile type, same method of construction as the piles in the bridge or structure or wall, same diameter, and same concrete mix and reinforcing. The location of this calibration pile (at any particular site) will be selected in agreement with the engineer. (ii) Provisions with regard to pile cap construction

Results from integrity tests on the piles for each pile cap must be evaluated and submitted to the engineer for approval, before any work on the pile cap itself may commence. Tests on the calibration pile must be done at the same time or before tests on the first working pile are undertaken. (iii) Pile integrity test method

The purpose of integrity testing is to prove that the construction techniques employed to create a bored or augured pile is satisfactory in terms of quality assurance with respect to aspects such as necking of concrete in the pile shafts, checking concrete cover to reinforcement, checking for honeycombing or grout loss, segregation of aggregate inclusion and for large cracks or voids. (1) Cross-Hole Sonic Logging (CSL) and optional Base Integrity Test

(aa) Overview

This method is used to verify the integrity of the pile shaft particularly in the case of larger diameter piles. By sending ultrasonic pulses through concrete from one probe to another (probes located in parallel tubes), the CSL procedure inspects the drilled shaft structural integrity and extent and location of defects, if any. At the receiver probe, pulse arrival-time and signal strength are both affected by the concrete. For equidistant tubes, uniform concrete yields consistent arrival times with reasonable pulse wave speed and signal strengths. Non-uniformities such as contamination, soft concrete, honeycombing, voids, or inclusion exhibit delayed arrival times with reduced signal strength. An optional Base Integrity Test (in order to establish the quality of the pile base/end bearing contact via the CSL tubes) specification is included at the end of this section.

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(bb) Personnel Requirements

The CSL consultant shall have a registered professional engineer supervising the testing and interpretation of results. The CSL consultant shall be an independent testing agency with at least 3 years’ experience in CSL testing. The consultant’s qualifications and the specifications for the equipment used shall be submitted to the engineer for approval prior to beginning bored or augured pile shaft installation. (cc) Equipment requirements

A Cross Hole Analyser (CHA) that meets the following minimum requirements:

(1) Computer based CSL data acquisition system for display of signals during data acquisition, with a minimum 12 bit A/D converter with a sampling frequency of at least 500 000Hz, and recording of all pulse signals for full analysis and individual inspection.

Note: Converting signals with low noise using high A/D resolution and sampling rates is

important to obtain quality data and allow proper full data interpretation. (2) Ultrasonic transmitter and receiver probes capable of producing records at a minimum

frequency of 50 000Hz with good signal amplitude and energy through good quality concrete. The probes shall be less than 28mm in diameter and shall freely descend through the full depth of properly installed access tubes in the drilled shafts.

(3) Two depth sensors to independently determine transmitter and receiver probe depths. (4) Triggering of the recording system time base with transmitted ultrasonic pulse.

(dd) Access tube preparation

The access tubes in each drilled shaft are indicated on the drawings. Every drilled shaft shall be equipped with access tubes to permit inspection by CSL. All permanent drilled shafts are to be tested by CSL. 50 mm (minimum) nominal diameter 3mm wall thickness mild steel tubes are specified for access for the probes in each drilled shaft. Typically 3 to 4 tubes are used, although up to 6 may be used in larger piles. Round tubes with regular internal diameter free of defects and obstructions, including any tubes joints, to permit the free, unobstructed passage of the probes shall be used. Tubes shall be watertight and free from corrosion with clean internal and external faces to ensure a good bond between the concrete and tubes. Tubes may be extended with mechanical couplings. Duct tape or other wrapping materials to seal the joints and butt welding of joints are prohibited. Tubes shall be installed by the contractor such that the CSL probes will pass through the entire length of the tube without binding. Ensure that the access tubes are plumb and verify that unobstructed passage of the probes is achievable before the CSL consultant arrives. Note: If an existing pile does not contain access tubes, access holes can be installed by coring a borehole in the concrete. Locate cored holes about 150 mm inside the reinforcement cage. Log core holes and include descriptions of any inclusions or voids. For pile drilled shafts with access tubes that do not allow the probe to pass through the entire length of the tube due to poor workmanship, replacement access holes may be provided by core drilling. Fit the tubes with watertight shoe in the bottom and a removable cap on the top. Secure the tubes at regular intervals not to exceed 1,0 m to the interior of the reinforcement cage. Install the tubes uniformly and equidistantly around the circumference such that each tube is spaced parallel for the full length and at the maximum distance possible from each adjacent tube. Tubes should be spaced as far as possible from the main axial reinforcing steel. Extend the tubes to within 300 mm of the bottom of the pile, and at least 1,0 m above the drilled shaft tops, and at least 0,6 m, but no more than 1,5 m above the ground surface. Do not damage the tubes during installation of the reinforcement cage. Note: Do not allow the tube to rest on the bottom of the drilled shaft excavation. After placement of the reinforcement cage, fill the access tubes with clean fresh water as soon as possible but within at the latest one hour of concrete placement. Cap the tube tops to prevent debris

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from entering the access tubes. Do not apply excessive torque, hammering or other stresses that could break the bond between the tube and concrete when removing caps from the tubes. Note: The tubes should preferably be filled with water prior to concrete placement, but MUST be filled with water within at most 4 hours after placing concrete to prevent debonding of the access tubes due to differential temperatures. (ee) Test sequence

Test the drilled shaft no sooner than 3 calendar days after placement of all concrete in any drilled shaft, but within 10 days after placement and prior to loading for test drilled shafts, or within 45 days after placement on production drilled shafts. Note: CSL testing can be performed any time after concrete installation, although 2 days is usually the minimum acceptable wait. Because the concrete strength and quality generally increases as the concrete cures, longer wait times are usually desirable, particularly if minimum pulse wave speeds are specified or to reduce result variability between drilled shafts or even as a function of depth in a single drilled shaft. However, if PVC tubes are used, long wait times increase the tube debonding, which is detrimental to the test. Production of drilled shaft installation and subsequent construction influence the dates of CSL testing. After all CSL testing has been completed, and after acceptance of the drilled shaft by the engineer, the contractor shall remove the water in the tubes, place grout tubes extending to the bottom of the access tube, and fill all access tubes in the drilled shafts with grout. (ff) Test procedures

Prior to CSL testing, the contractor shall provide the engineer and CSL consultant with a record of all drilled shaft lengths with elevations of the top and bottom, and installation dates of all drilled shafts. The access tubes shall be clearly labelled for identification by the CSL consultant.

The CSL testing shall be performed with the transmitter and receiver probes in the same horizontal plane in parallel tubes unless test results indicate potential defects, in which case the questionable zone may be further evaluated with angled tests (source and receiver vertically offset in the tubes). Using the labelling established for the tubes, perform CSL testing between all adjacent perimeter access tube pairs and across at least two major diagonals within the drilled shafts with more than four tubes, additional logs in other diagonal tube pairs may be required to estimate the extent of the defect. Lower the probes from the top, effectively measuring the access tube lengths. Pull the probes simultaneously, taking CSL measurements at intervals of 50 mm or less from the bottom to the top of the drilled shaft. Defects indicated by late pulse arrival times and significantly lower amplitude/energy signals shall be immediately reported to the engineer. Additional tests such as the offset elevation CSL testing may be required by the engineer to further evaluate the extent of such defects. If debonding between the access tube and the concrete is indicated by the CSL results, an alternative test method will be required to determine the integrity of the concrete in the debonded region. Note: In case defects are detected, additional tests or analysis options may include CSL tomography, Gamma-gamma nuclear density logging, sonic echo or impact response tests, high strain dynamic pile testing, static load testing, or concrete coring. If the drilled shaft is cored, an accurate log of the cores that include depth and core recovery shall be kept, and core and coring logs shall be properly identified and given to the engineer. (gg) Results

Present the results of the CSL in a written report within five (5) working days of completion of testing. The report shall include presentation of CSL logs for all tested tube pairs including:

(1) Presentation of the traditional signal peak diagram as a function of time plotted versus depth.

(2) Computed initial pulse arrival time or pulse wave speed versus depth.

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(3) Computed relative pulse energy or amplitude versus depth.

A CSL log shall be presented for each tube pair. Defect zones, if any, shall be indicated on the logs and their extent and location discussed in the report text. Defect zones are normally (see Note below also) defined by an increase in arrival time of more than 20% relative to the arrival time in a nearby zone of good concrete, indicating a slower pulse velocity. Note: Because the tubes might not be perfectly straight or even parallel, a fixed absolute limit of a wave speed value cannot be used for evaluation. It should also be noted that if the referenced good concrete exceeds the specifications, then a concrete with a local 20% wave speed reduction might still exceed the specifications. The log for each tube pair shall be clearly identified and oriented relative to the structure. The engineer shall have five (5) working days to evaluate the results and determine whether the drilled shaft construction is acceptable or not. The contractor shall not perform any load testing or other construction associated with these drilled shafts until after acceptance by the engineer. If the drilled shaft is accepted by the engineer, the contractor may then proceed with construction. If the engineer determines the drilled shaft is not acceptable, the drilled shaft must be cored, repaired or replaced by the contractor at the contractor’s expense and with no increase in contract time. (hh) Base integrity test

In order to establish the quality of the pile/base rock contact, a base integrity test shall be performed. This shall be accomplished in the following manner:

(1) The 85 mm diameter tubes for the “Cross Hole Sonic Logging” shall be installed to within 300 mm of the base pile of the pile. The base of the tubes shall be sealed square with a water tight seal.

(2) NX (55 mm) diameter cores shall be drilled within 85 mm diameter tubes, through the

remaining 300 mm of pile concrete and for a distance of 1200 mm into the rock at the toe of the pile. The core shall be carefully retrieved with drill string lengths and datums noted. This core shall be marked and carefully placed inside a plastic sheath such that the actual condition of the interface between pile and rock is not disturbed. The core shall be temporarily stored in a core box for later inspection.

At the completion of the test, and when instructed by the engineer, the complete assembly to the top of the pile shall be filled with non-shrink grout of at least 30 MPa strength. The hole shall be filled from the bottom up. The basis of payment shall be in accordance with payitems 61.37, 61.38 and 61.39.


Delete payitem 61.01 and replace it with the following:

“Item Unit

B61.01 Additional founding investigation

(a) Provisional sum allowed for additional founding ............................................. provisional sum (b) Handling cost and profit in respect of subitem B61.01 (a) ................................ percentage (%) The provisional sum allowed under subitem (a) shall be expended to cover the actual costs of the appointed sub-contractor for the additional founding investigation. The tendered percentage of subitem (b) is a percentage of the amount actually spent under the subitem (a) and shall include full compensation for all charges and incidental costs of the contractor, profit and overheads in connection therewith”.

C3-177

Item Unit

61.08 Foundation fill consisting of:


(f) Plum concrete (class indicated) ................................................................... cubic meter (m

3)

Delete payitem 61.50 and replace it with the following items for Pile Integrity Testing (PIT):-

“Item Unit

B61.50 Pile Integrity Testing on bored/augured piles

(a) Constructing 4.0 m long reinforced concrete/grout calibration bored piles of (indicate diameter(s)) inclusive of the required number of 85 mm diameter mild steel tubes ............................................................................ number (No)

(b) Providing and installing 85 mm diameter mild steel tubes used for

“Cross Hole Sonic Logging” in all designated piles (per pile construction site) .................................................................................................... metre (m)

(d) Cross-Hole Sonic Logging tests and interpreted results (per pile

diameter and per pile construction site) ....................................................... metre of pile (m) The unit of measurement shall be the number of cores logged. The tendered rate shall include full compensation for the log of the core data by a qualified person, who shall be approved by the engineer. The core logging shall be done in general accordance with the “Guidelines for soil and rock logging” compiled by the Geotechnology Workshop and published by SAICE in 1990. (f) Grouting up all CSL tubes after successful testing ....................................... cubic metre (m3) The unit of measurement shall be the volume of grout used to fill all the tubes used for sonic testing and the cores. The tendered rate shall include full compensation for the grout, equipment and all labour used to fill the tubes and cores. The grout shall have a compressive strength of at least 30 MPa. The unit of measurement for subitem (a) shall be the number of 4.0 m long calibration reinforced concrete bored piles provided complete with the required number (and length) of 85 mm mild steel tubes to facilitate CSL testing and constructed similarly to the proposed working piles. The unit of measurement for subitem (b) for the 85 mm nominal diameter mild steel tubes shall be the metre of approved 3 mm thick tubes provided and installed into all designated piles of various diameters in accordance with the specification. The unit of measurement for subitem (d), i.e. the CSL tests, shall be the metre of pile shaft fully tested (for all designated piles) using the Cross-Hole Sonic Logging method, and shall include full compensation for establishment and removal of all specialised equipment and expert personnel as well as for all materials, for the preparation and conducting and supervising the tests as well as full compensation for the proper evaluation and reporting of the results as well as the interpreted findings/conclusions/recommendations to the engineer by the CSL consultant”. Add the following items:

Item Unit

B61.51 Lateral support to:

(a) Excavation or fill at Location 1: (i) 0 to 5m depth ............................................................................................. square meter (m

2)

(ii) 5 to 10m depth .......................................................................................... square meter (m2)

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(b) Excavation or fill at other locations The unit of measurement shall be the square meter of lateral support at a specific location over the successive depth ranges. The depth ranges shall be measured down from the level where shoring is required at each location and agreed with the Engineer. The rate shall include full compensation for design, supply, fabrication, installation, removal (if required), and for all labour, materials, equipment, plant and incidentals to provide the complete lateral support to the excavated or filled faces. The rate shall also include the inspections, supervision by the safety officer and for the maintenance of the lateral support. The lateral support shall remain in position for as long as required and only removed with the approval of the Engineer.”

C3-179

SECTION B6200: FALSEWORK, FORMWORK AND CONCRETE FINISH

B6204 DESIGN

(a) General

Add the following:

“The contractor shall submit to the engineer at least 4 weeks before the structure is scheduled for construction a detailed analysis showing the effect of the stresses that will be induced by the contractor’s chosen method of construction. The cost of any additional prestressing, reinforcing steel, concrete, etc, required as a result of the contractor’s chosen method of construction shall be to the contractor’s account. No construction shall commence until the engineer has given his written approval.” (b) Falsework

“Unless instructed otherwise by the engineer, the contractor shall submit his design criteria and detailed drawings of the staging to the formwork. The design, signing of the drawings and inspection of the falsework prior to construction of the permanent works shall be undertaken by the contractor’s competent person, who shall be a registered professional engineer with the relevant experience.”

B6205 CONSTRUCTION

(b) Formwork

(i) General

Add the following:

“Formwork to faces of structures with a gradient equal to or greater than ten vertical to one horizontal shall be classified as vertical formwork. Formwork to faces of structures with a gradient less than ten vertical to one horizontal, or equal to or greater than one vertical to ten horizontals, shall be classified as inclined formwork. Formwork to faces of structures with a gradient of less than one vertical to ten horizontal shall be classified as horizontal formwork.” (ii) Formwork to exposed surfaces

Add the following:

“The formwork at construction joints shall have moulding strips 25 mm x 25 mm neatly butted and set at the position of the construction joint”.

B6207 FORMED SURFACES: CLASSES OF FINISH

(d) Class F3 surface finish


“The use of steel forms shall be permitted to form surfaces for which Class F3 surface finish has been specified, provided that only undamaged forms shall be used for such work and that the forms shall be subject to the approval of the engineer. Formwork comprising of steel faced panels shall have minimum face plate thickness of 5mm. Particular careful attention is required for preparation and execution of steel plate to form fillet roundings and aesthetic details.”


“(g) Making good tie holes

All openings resulting from the use of ties shall be made good in an approved manner such that the colour matches that of the adjoining concrete, there is no shrinkage or slumping and the finished surface is flush with the adjoining concrete. All formwork tie holes shall be repaired to full depth of tie

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hole, including the complete removal of all embedded plastic components. Removal of plastic form tie linings shall be conducted by drilling 3mm oversize holes, to suitably roughen the concrete surface to assist with bonding of cementitious repair materials used to fill the remaining void. The procedure shall be proven by the contractor submitting a sample completed hole for approval which shall then be regarded as the minimum acceptable standard for all other holes. (h) Formed surface finish

This surface finish shall be the specified indentations formed in the concrete surface as shown. The surface shall first be given a class U2 surface finish and after the concrete has hardened sufficiently, it shall be shaped and finished as specified without torn and unduly loosened coarse aggregate. "


Item Unit

B62.04 Inclined Formwork to provide (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable)

Delete the entire note at the end of this item.

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SECTION B6300: STEEL REINFORCEMENT FOR STRUCTURES

B6306 PLACING AND FIXING

Replace the second and third paragraphs with the following:

“The concrete cover for all structural concrete shall be within the acceptance ranges shown in table B6404/6. Prior to fixing the steel, samples of the proposed cover and spacer blocks shall be submitted to the engineer along with a written statement for in situ manufacture, if applicable, for approval. Overlap of steel reinforcement bars shall be such that the cover to the lapped bars remains constant at the specified cover.”

B6307 COVER AND SUPPORT

Amend the second paragraph as follows:

Replace the second sentence, commencing with ”Where no cover is indicated…shown in table 6306/1” with the sentence “Where no cover is indicated, the contractor shall inform the engineer who shall after consultation with the design engineer indicate the required cover in writing and the as-built drawings shall indicate such cover”.

Add the following to the end of the fifth paragraph:

“Proprietary micro-concrete cover- and spacer-blocks of reputable high-quality are preferred for this contract. Plastic- (or equal) -type positioners shall not be permitted. Non-proprietary concrete cover block and spacer blocks shall be made using the same cement and aggregate type as the main concrete with the same water/ cement ratio so that differences in shrinkage, thermal movements and strain are minimised. Cover- and spacer-blocks shall be water cured by submersion for a minimum of 7 days and thereafter kept submerged in water until immediately before fixing onto reinforcing steel. Where concrete cover- and spacer-blocks, subsequent to fixing, have visually dried out they shall be remoistened by an appropriate method so that they are damp before the placing of concrete. Where fixing wire is inserted into cover- and spacer-blocks, it shall be galvanised Class A wire in accordance with SANS 675. Cover and spacer blocks manufactured from other materials e.g. plastic or wood, shall not be permitted. All cover blocks regardless of the type of material manufactured from, shall not be visible on exposed concrete surfaces Delete Table 6306/1 in its entirety.


“Where the concrete cover specified has not been achieved after cover tests have been carried out in accordance with clause B8106(j), reduced payment as determined under clause B8212 shall be applied to all the relevant payitems under section 6300.”

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Item Unit

B63.01 Steel reinforcement for: ...................................................................... ton (t) / kilogram (kg)


“Where hot-dip galvanized steel reinforcement is indicated, the steel reinforcement shall be paid under Item 63.01. The additional costs associated with the hot-dip galvanizing shall be included in the extra over payment item B63.04.

Add the following items:

“Item Unit

B63.04 Extra over item B63.01 for hot-dip galvanizing steel reinforcement ............................................................................. ton (t) / kilogram (kg)

The unit of measurement shall be the kilogram of hot-dip galvanized steel reinforcement. The tendered rate shall include only the costs associated with the hot-dip galvanizing to the required specifications.

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SECTION B6400: CONCRETE FOR STRUCTURES

B6401 SCOPE


“The contractor shall take and submit samples of materials and/or mixtures to the engineer who must approve mix designs before construction work can commence.”

B6402 MATERIALS

(a) Cement

Replace the colon at the end of the first paragraph with a comma, and add the following:

“taking into account the adoption of the new SANS 50197-1: 2013 code for common cements: (refer to Concrete Institute website (www.theconcreteinstitute.org.za). All common cements shall hold certification in the form of a valid Letter of Authority (LoA) issued as certified approval pursuant to Compulsory Specification for cement as published by Government Notice R544 (Government Gazette No. 30023) of 6 July 2007 and shall be included in the latest version of the National Regulator for Compulsory Specifications’ cement database (www.ncrs.org.za). In order to promote resource sustainability principles, common cements shall have a maximum average emission value of 950 kg CO2e per ton.” Add the following paragraphs:

“The type of cement to be used in any concrete element shall take into account the environmental conditions and durability requirements at the location of the site of the works, and shall be as approved by the engineer. With the exception of the standard SANS approved cement blends supplied by the primary cement producers, the blending of proprietary cements and supplementary cementitious materials (extenders) shall not be permitted unless specifically approved by the engineer on the basis of an acceptable quality assurance procedure. The quality assurance procedure shall ensure that the ternary blending of common cements containing a proportion of supplementary cementitious materials shall not be further extended with supplementary cementitious materials of a different generic type or nature. supplementary cementitious materials accepted for use as cement extenders shall include: Slag, conforming to SANS 1491-1; Fly ash, conforming to SANS 1491-2; Silica fume, conforming to SANS 1491-3 and Supplementary Cementitious Materials, conforming to SANS 1491-4. Wherever durability (W-class) concrete is specified, the cementitious binder system shall comprise of the following permitted blends:

75% CEM II A-L 52,5N (PPC W.Cape OPC) and 25% fly ash, or 50% CEM II A-L 52,5N (PPC W.Cape OPC) and 50% Ground Granulated Corex Slag, or 81% CEM III A-S 42.5N (PPC W.Cape Surebuild) and 19% Ground Granulated Corex

Slag, or 70% CEM I 42.5 N (or greater strength class supplied by a SANS 50197 approved cement

manufacturer) and 30% fly ash. 50% CEM I 42.5 N (or greater strength class supplied by a SANS 50197 approved cement

manufacturer) and 50% Ground Granulated Corex Slag.” (b) Aggregates

Delete the remainder of the sentence after “exceed” in subclause (i)(1)and replace with the following:

“150% of that of the reference norite aggregate or any of the other three reference aggregates” Delete the remainder of the sentence after “exceed” in subclause (i)(2) and replace with the following:

“200% and of the coarse aggregate 175% of that of the reference norite aggregate or any of the other three reference aggregates”

C3-184

Delete the remainder of the sentence after “exceed” in the first paragraph of subclause (i)(3) and replace with the following:

“235% of that of the reference norite aggregate or any of the other three reference aggregates” Delete the entire last paragraph of subsubsubclause (i)(3) commencing with “The drying shrinkage of concrete…”

Add the following subsubclause:

“(vi) The maximum chloride ion content of fine aggregate shall be 0,03% by mass of aggregate as specified by SANS 1083:2002. Where concrete is situated in a chloride environment the value shall be reduced from 0,03% to 0,01%.” (d) Water

Add the following:

“Water utilised to mix concrete shall comply with SANS 51008. Water for concrete other than prestressed concrete, shall not contain chlorides, calculated as sodium chloride, in excess of three thousand parts per million (3000ppm) nor sulphates, calculated as sodium sulphate, in excess of two thousand parts per million (2000ppm). Water for curing concrete shall not contain impurities in sufficient amount to cause discolouration of the concrete or produce etching of the surface. No sea-water or water containing salts shall be used. No water shall be added on site to ready mix concrete prior to placing to improve workability. All concrete delivered to site shall be checked for workability using the slump cone test and slump measured outside of the limit set from the design mix shall be rejected. The maximum permitted mix water content per cubic meter of concrete shall be 190 litres.” (e) Admixtures

Replace the following subclauses:

“(i) All admixtures shall be used in liquid form and shall be batched in solution in the mixing water by mechanical batcher capable of dispensing the admixture in quantities accurate to within 2% by mass of the desired quantity. (ii) All admixtures shall comply with the requirements of ASTM C494, EN 934-2, or AASHTO M194 and shall be of an approved brand and type suited to the cementitious binder system.” Add the following subclauses:

“(v) Admixtures, which have a retarding effect on the rate of hydration of the cement, may not be used when the concrete temperature is below 20°C. (vi) A retarding admixture shall be used if the temperatures of concrete mixes using cements of strength class 42.5 or higher is between 20 to 30°C or where the ambient temperature is between 20 to 30°C.” Add the following:

“Note: Only admixtures of the type that do not increase the water content of the mix will be considered by the engineer. In addition, no admixtures shall be added on site to ready mix concrete prior to placing to improve workability.”

C3-185

B6403 STORING THE MATERIALS

(a) Cement

Insert the following paragraph after the third paragraph:

“Where hot weather concreting conditions exist, the bulk cement silos shall be painted white with high solar reflectance paint to reduce any temperature rise in the stored cement. Furthermore, the sides and tops of silos shall be insulated with 4 mm Alucushion double sided aluminium foil insulation which shall be wrapped around silos, and kept in position with galvanized steel hoop straps. Alucushion insulation material shall overlap by at least 100 mm at joints.” (b) Aggregates

Insert the following paragraph after the first paragraph:

“Where hot weather concreting conditions exist, the both the coarse- and fine-aggregate stockpiles shall be the aggregate shall at all times be stored in a cool environment and be shaded from the sun by means of 80% shade netting. When the ambient temperature reaches and exceeds 30°C, only the coarse aggregate shall be sprayed with water to assist cooling. Water shall be delivered by means of an approved water droplet sprayer system. The Contractor shall ensure adequate drainage of the coarse aggregate stockpile area.” Insert the following subclause:

“(e) Water

“Where hot weather concreting conditions exist, the sides and tops of water tanks for mixing water, including pipework leading to and from tanks, shall be insulated with 4 mm Alucushion double sided aluminium foil insulation which shall be wrapped around silos, and kept in position with galvanized steel hoop straps. Alucushion shall overlap by at least 100 mm at joints. The burying of pipework at sufficient depth below ground will be permitted only if it can be demonstrated that temperature of mixing water remains below 20 ̊C when added to the concrete mix.”

B6404 CONCRETE QUALITY

(a) General

Insert the following paragraph after the second paragraph:

“When structural concrete prefixed ‘W’ is shown on the drawings, it shall, in addition to the strength requirement, comply with the durability requirements specified in subclause 6404(h), ‘W’ class concrete shall not apply to minor structural elements such as side drains and catch pits except in very severe environmental conditions of exposure. Requirements for concrete quality (including any durability requirements) for concrete pavements are found in Section 7100 of the specifications.” (b) Strength concrete

Replace the sixth paragraph with the following:

“Where concrete is designated by the prefix “W”, e.g. class W30/20, such designations shall denote concrete achieving the durability criteria specified in the relevant tables under subclause B6404(h).” Add the following subclauses:

“(h) Concrete durability

(i) General

Concrete designated by the prefix ‘W’ shall, in addition to the requirements of subclause 6404(b) comply with the durability parameters described below. Durability is influenced by the materials used in the concrete, their mix proportions, transporting, placing, compacting and, in particular, curing of the finished cover concrete (concrete layer between the outermost layer of steel reinforcement and the exposed outer surface of the concrete element). The tests required to prove durability performance of the placed concrete are given under sub-clause B8106(i).

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It is the engineer’s responsibility to approve the component materials and their mix properties, however it is the contractor’s responsibility to utilise acceptable component material and to achieve mix properties complying to the specifications. It is the contractor’s responsibility to design and blend materials to produce concrete of the specified quality (ii) Durability parameters

Water sorptivity: Sorptivity is sensitive to surface effects and may be used to assess the effectiveness of initial curing.

Oxygen permeability: Permeability is sensitive to changes in the coarse pore fraction and thus

a means of assessing compaction of concrete. It is used to quantify the microstructure of the concrete and sensitive to macro-defects such as voids and cracking.

Chloride conductivity: Chloride conductivity provides a method of characterisation of concretes

in the marine environment and is used to assess the chloride resistance of concrete.

Cover concrete/covercrete: Cover concrete (covercrete) is the outer concrete layer that protects

reinforcing steel. Concrete cover is a requirement for all concrete whether specified as durability concrete (Class “W”) or strength class (normal) reinforced concrete.

Individual Cover Depth Individual cover depth measurement determined Measurement (CDM): by an electromagnetic cover meter, complying with BS 1881, Part 204. Individual mean cover: The arithmetic mean of at least 24 individual CDM’s per 600mm by

600mm grid (or 0.36m² area) determined using the grid or block method on a clearly identified area.

Overall Cover: The arithmetic mean cover determined for the total scan area per

element or structure. Scan Area: Total areas of approximately 1m², represented by at least 3 individual

mean cover randomly distributed over the entire element or structure. The total scan area per structure shall represent at least 2% of total surface area (formed and unformed, internal and external surfaces) for that structure.

Individual bar reading: A minimum of 3 linear CDM’s, spaced at 100mm intervals, representing a

single bar of reinforcement. Capped CDM: The value applied to all CDM’s in excess of the maximum allowed CDM,

determined by the engineer (e.g. 40mm (specified cover) + 25mm (upper limit) = 65mm) or

Capped Value: A value in mm, assigned to a cover reading where the raw reading

exceeds the specified cover plus a value (mm) specified by the engineer (eg. the greater of 25mm or 2,0*bar diameter).

Quick/Linear Scan: This method shall not be used for this contract unless the normalisation

procedure is strictly followed and approved in writing by the Engineer. For evaluation of cover depth measurements taken perpendicular to closest rebar in a line covering required area to be scanned. Each scan area to exceed 0,36m2).

C3-187

Image/Block/Grid Scan: Provides an overview of rebar layout. Measurements taken over a square meter clearly indicating position of first and second layer of rebar. Each scan area to exceed 0,36m2).

Cover: Cover is a dimensional indicator of covercrete depth and it varies

according to the requirements of the different environmental exposure classes.

Notes: 1. Water sorptivity and Oxygen Permeability tests are required to assess carbonation resistance 2. Water sorptivity, permeability and chloride conductivity tests are required to assess chloride

resistance When tested in accordance with the test protocols described in B8106 for each potential durability parameter, the concrete shall meet the limits listed in tables B6404/4 and B6404/6. (iii) Cement content

In order to meet the durability criteria, the proportions of cementitious binder used shall be determined to suit the fine and coarse aggregate and cement type used in order to achieve the durability limits specified in tables B6404/4 and B6404/6 under the Acceptance Category of “Concrete made, cured and tested in the laboratory.” In order to avoid the possibility of Alkali Silica Reaction (ASR), the following shall be taken into account when designing the mixes:

(1) Where aggregates are tested in accordance with ASTM C227-03 and the expansion at 14 days determined as equal to or more than 0.20% and are categorised as ‘rapidly expansive’, the maximum permitted equivalent sodium monoxide (Na2Oeq) of the concrete mixture shall be 2,1kg/m

3

of concrete. (2) Where aggregates are tested in accordance with ASTM C227-03 and expansion at 14 days determined as equal to or more than 0,10% but less than 0,20% and are categorised as ‘slowly expansive’, the maximum permitted equivalent sodium monoxide (Na2Oeq) of the concrete mixture shall be 2,8 kg/m3 of concrete. (3) Where aggregates are tested in accordance with ASTM C227-03 and expansion at 14 days determined as less than 0,10% and are categorised as ‘innocuous’, the maximum permitted equivalent sodium monoxide (Na2Oeq) of the concrete mixture shall be 4,0 kg/m

3 of concrete.

(4) The contractor shall prior to the use of cement provide test certificates from an approved laboratory confirming the equivalent sodium monoxide (Na2Oeq) content of the batch of cement proposed for use. (5) Special literature should be consulted e.g. Fulton’s Concrete Technology. For tendering purposes a cementitious binder content of 400 kg/m3 shall be used in order to meet the durability criteria. If the actual cementitious contents fall below 400 kg/m3, the mix will not be subject to the reduction mentioned under clause B1213(b) and shall be to the contractors benefit providing all durability requirements are met. Notwithstanding what is indicated above, should the contractor wish to increase cementitious content above limits stated for reasons not related to durability, such as the need for early strengths, then the additional costs shall be borne by the contractor. (iv) Environmental classes of exposure

For this project, the environmental classes for carbonation and chloride exposure for the different structural elements are as shown below in table B6404/3.

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Table B6404/3

ENVIRONMENTAL CLASSES OF EXPOSURE FOR ELEMENTS OF STRUCTURE

Element Carbonation Environment (OPI) Foundations XC2 Substructures XC3 Superstructures XC4

(v) Acceptance ranges

Table B6404/4

DURABILITY PARAMETERS ACCEPTANCE RANGES

Acceptance Category

Test No./ Description/ Unit

Water

Sorptivity

(mm/ h)

Oxygen Permeability

(log scale)

Parapets Super-

structures Sub-

structure Foundation

s

Concrete made, cured and tested in the laboratory using Trial Panels

<10.0 >9.60 >9.30 >9.10 N/A

Full acceptance of in situ using Test Panels

<10.0 >9.60 >9.30 >9.10 N/A

Conditional acceptance of in situ concrete based on results of Test Panels

Not applicable 2

9.20 - 9.60 9.29 - 9.00 9.09 - 9.0 N/A

Rejection based on results of Test Panels

Not applicable 2

<9.20 <9.00 <9.00 N/A

Notes: 1. A value has been given, but the value to be adopted shall be based on the results from design mixes. 2. Although no value has been given due to ongoing research, values above 12 are regarded as poor

quality concrete. 3. For purposes of interpretation, substructure is deemed to be all supporting elements below the deck

(superstructure), including buried lengths of columns, etc, but excluding foundation elements like bases and spread footings.

Table B6404/6

DURABILITY PARAMETERS ACCEPTANCE RANGES: Cover for all concrete types

Test No. Description

of Test

Specified Cover (mm)

Acceptance Range

Min Max Overall cover

Individual bar

Overall cover Individual bar

B8106(g) (iv)

Concrete cover to reinforce-ment (mm)

40 to 75

85% of specified cover

75% of specified cover

Specified cover + 15mm or where member depth is less than 300mm the limit accepted in writing by Design Engineer.

Specified cover + 25mm or where member depth is less than 300mm the limit accepted in writing by Design Engineer.

(vi) Site testing

To ensure that the concrete has been placed, compacted and cured correctly, a number of tests shall be carried out on the concrete by an approved laboratory. (vii) Non-compliance with specified criteria

The contractor should also note that there is specific provision made for curing of concrete under payment item B64.07 of the project specification. The amount priced under this item will be subject to reduced payments should the durability tests indicated under B8106(h) fail to meet the required targets. Similarly, failure to achieve the required durability test results will be sufficient cause to apply partial payment factors for all the payitems of the elements of the structure under sections 6300 and 6400 of the standard and project specifications or in some cases the removal of the rejected concrete.

C3-189

(i) Mix design approval procedures

(i) General

The compressive strength achieved on ‘W’ class concrete shall generally exceed the characteristic strength class structurally required. The contractor shall note that the process of finalising ‘W’ class mix designs could take up to two months. In order to expedite the process, the contractor must submit samples of aggregate and cement to an approved laboratory within seven days of the commencement date. Should ‘W’ class concrete be required before the mix design is finalised, the engineer will approve a preliminary mix design in consultation with the contractor. (ii) Laboratory designs and site tests based on trial panels

Good mix design practice is essential and the following criteria shall be taken into consideration when pricing and determination of the mix design:

(1) Selection of sands and aggregates to achieve a good grading is important if the desirable concrete density and durability have to be achieved. (2) The selection and use of the correct cement grade and type for the environmental conditions (and not based solely on costs) is fundamental (3) Water: cement ratios are critical, dictating both the structural strength and the durability requirements Mix proportions for the concrete to be used on site need to be determined by an approved laboratory, cylindrical specimens, 70 ± 2 mm in diameter shall be made or cored from a trial panel during the laboratory trial mix for performance of tests B8106(g)(i), (ii) (if required). Note that concrete cubes are not cored for durability testing during design trial mix stage or during the construction stage. Testing for approval purposes shall be carried out by an accredited laboratory approved by the engineer, the costs of which are deemed to be included in the contractor’s rates for structural concrete. Concrete as designed shall satisfy the limits set out in table B6404/4 under the heading “Concrete made, cured and tested in the laboratory, using Trial Panels”. It is therefore a requirement that the trial panels be cast on the site and the cores extracted and tested in the laboratory as part of the mix design approval process. Where the site is remote from the laboratory, the trial panels may be cast at the laboratory in accordance with the requirements of subclause B8106(g). It will be necessary for the contractor to establish a target mean strength with a margin above the minimum requirement so that small fluctuations due to material changes or workmanship can be accommodated. In general, mean target strength = characteristic strength + 1,645xSn. Once the mix is approved, the target mean compressive strength for quality control purposes for durability class concrete shall be the mean compressive strength obtained from the mix that satisfies the durability requirements.”

B6405 MEASURING THE MATERIALS

Add the following sub-clause:

“(d) Admixture

All admixtures shall be dosed at an accuracy of 2% by mass. The dosing unit shall be checked daily for accuracy using a nominal dispensing volume, typically 2 litres, as recommended by the dosing unit manufacturer/supplier. At least once a week, the dosing unit shall be checked for accuracy using a typical dispensing volume suited to the concrete mixing procedures employed on site, typically for 6m

3

concrete batch mixed by a standard ready mix truck.”

C3-190

B6407 PLACING AND COMPACTION

Add the following:

“(b) Placing

Casting of the in situ parapets or placing of precast parapets shall only commence after removal of the deck staging, and in addition, in the case of prestressed decks, the stressing must be complete. Where specified on the drawings the top of the parapets after placing shall follow the pre-camber levels specified on the drawings to allow for future creep effects. This is of particular importance on the edges of very long skew decks and prestressed simply supported decks. The levels of the top rail of each panel of the balustrades/parapets shall be confirmed in writing by the design engineer Subject to the approval of method statements for particular concrete pour operations, the maximum height concrete will be permitted to free-fall shall be limited to 3.0m. Preventative measures to avoid segregation shall be employed whenever deemed necessary, particularly for concrete pours exceeding 2.4m high.”

B6408 CONSTRUCTION JOINTS

(a) General

Add the following:

“No construction joints other than those indicated on the drawings will be permitted without the written approval of the engineer. In all cases the proposed method of forming the joint shall be discussed and agreed with the engineer and approved as a particular method statement.”

B6409 CURING AND PROTECTION

Delete the content of subclause 6409(c) and replace with the following:

“Covering it with mats, made from moisture retaining material, and waterproof or plastic sheeting firmly anchored and sealed at the edges and joints. The moisture retaining material must be kept wet for the duration of the curing period.” Add the following to the end of subclause 6409(f):

“Where a curing compound is used, it shall consist of an approved water based low viscosity clear wax emulsion applied in accordance with the manufacturer’s instructions.” Add the following paragraphs to the end of this subclause:

“Where curing by retention of formwork is used as the only method of curing the concrete, it must be left in place for the minimum period specified in table 6206/1 but in no instance shall it be less than 7 days. The materials used for formwork shall take into account properties such as thermal insulation and moisture absorption when assessing the suitability of the material, to the approval of the engineer. If impermeable curing membranes are to be used as a curing method, they shall be installed at the same time as formwork is removed and no portion of a concrete surface may be left unprotected for a period in excess of 2 hours. If the surface is an unformed finish e.g. top of deck slab, then the surface must be protected immediately by appropriate methods approved by the engineer after it is finished, without damage to that surface, since it is vulnerable to plastic shrinkage cracking due to high rates of evaporation while the concrete is still in a plastic state. Plastic shrinkage and settlement shall not be permitted on any of the structural elements since it compromises the durability of the concrete. In order to prevent early settlement and shrinkage of the concrete, the concrete placed shall be re-vibrated after initial compaction while the concrete is still in a plastic state. Any remedial measures shall be as approved in writing by the engineer. On bridge decks, the top surface shall be cured using the method described in clause 6409(c) or 6409(d.) For all concrete, curing shall be excluded from the make-up of rates for measurement under items B64.01 and B64.02 and will be paid for separately under pay item B64.07. Where the application of a

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curing compound is used, the type and nominal application rate thereof shall be as specified in the schedule of quantities or to the manufacturer’s nominal specified rates. For parapets, retain formwork in place for 72 hours to avoid cracking”

B6410 ADVERSE WEATHER


“(d) Temperature and hydration of concrete

Site batched concrete: The temperature of concrete delivered to site shall be within the range 10°C to 30°C. Concrete which has a temperature outside of this range shall not be placed in the structure. Ready mix concrete: In the case of ready mix concrete the temperature limits at point of delivery shall be as specified in SANS 878 2004 unless the engineer has specified other limits due to specific design requirements. If slump loss occurs at concrete temperatures of over 30°C and or more than two hours after mixing has elapsed, the concrete shall be rejected. Also if after addition of recovery packs the concrete begins to stiffen again such as to place in doubt that full compaction and finishing can be achieved, the concrete shall be rejected. Care must also be taken not to cast concrete onto hot steel shutters as this might induce cracking. Where thinner concrete elements are to be cast in steel shutters, such as parapets, the contractor shall make the necessary arrangement to shield the shutters from direct sunlight during the full casting and curing period(s). The rate of hydration of the cement in the concrete shall be such that the concrete can be placed and properly compacted within 2 hours after the addition of water to the mix ingredients. The initial set of the concrete shall not be unduly delayed due to inappropriateness of admixtures or cement type, which could promote bleeding.”

B6413 PRECAST CONCRETE

Add the following final paragraph:

"Precast concrete units shall comply with the requirements of the latest SANS 986:2006 specification. Prior to the manufacture of any units the manufacturer shall submit his quality plan to be approved by the engineer. The quality plan must incorporate all requirements and frequency for durability index testing i.e. sorptivity, oxygen permeability, chloride conductivity (if required) and cover testing. As part of the quality plan submitted for approval, copies of calibration certificates of both gauges used for proof loads and cover meters used at the factory shall be supplied to the engineer. The originals of these certificates shall at all stages also be available for inspection at the factory premises. The manufacturer shall check each precast unit for cover compliance, and random checking of units shall not be permitted. The engineer's representative may visit the factory at any stage to ascertain adherence to the quality plan including test results from the durability index testing as well as to check covers before delivery to site. Any substandard cover shall result in the applicable structural element or part thereof being rejected. Should the manufacturer not be adhering to their quality plan the engineer may exercise the right to reject the use of products from the manufacturer concerned. The employer shall also be informed in all such cases. For durability requirements due to the reduced cover provided for precast culverts, all such durability testing shall be done in accordance with clause B6404(h). "


(a) Criteria for compliance with the requirements

Add the following paragraphs after the first paragraph:

“The cores shall be taken from the trial panels cast using the design mixes made in the laboratory. Where the site is remote from the laboratory, the trial panels may be cast at the laboratory in accordance with the requirements of sub-clause B8106(g).

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In the event that for ‘W’ classed concrete strength requirements the actual achieved average cube strengths of an element are less than 85% of the target mean strength needed to meet durability requirements or less than 100% of the target mean strength to meet strength requirements, it may result in the durability parameters not meeting the prescribed targets and the engineer will instruct the taking of cores from the test panel and structure for additional testing. The cost of these in situ tests shall be borne by the contractor. The approved quality control criteria for process control testing for durability concrete shall be coring and testing of test panels. The frequency of manufacture and coring of test panels shall be as ordered by the engineer and indicated in tables B8106/1 and B8106/2. Tests B8106(g)(i), (ii) and (iii) (when required), shall be conducted on cores extracted from the test panels when the concrete reaches the age of at least 28 days. To allow for variability in the material potential, the type of chloride conductivity values shall be limited to 110% of the values indicated in table B6404/5. Test no. B8106(g)(iv) shall be conducted to confirm that the specified depth of concrete cover has been achieved. The frequency of these tests shall be as described under item B8106(g). The test results shall be accepted or rejected on the criteria set out in table B6404/4 and B6404/5 based on the following categories: (i) Full acceptance

Concrete shall be accepted unconditionally and full payment shall be made. (ii) Conditional acceptance

Concrete may be accepted, based on the cube strength and durability index results with a warning that construction methods be examined to improve the durability criteria. A reduced payment shall be applied to all the relevant payitems of the specific element under B6300 where the cover requirements are not achieved and B6400 where the oxygen permeability and strength requirements are not achieved for the non-conforming element or concrete pour as set out in tables B8212/1 and B8212/2. The decision to accept the substandard concrete at reduced payment shall rest solely with the employer. Should the test result(s) indicate conditional acceptance of the element tested, the contractor shall have the option of carrying out additional tests (on 4 extracted cores) on that element of the structure, at his own expense to confirm or disapprove the original test result(s). These cores shall be extracted within 56 days from the date of the element being cast. Should the additional test confirm the original test result, then the original test result shall serve to determine payment in accordance with tables B8212/1 and B8212/2. Should the additional test show that the structure meets the targets, the penalty shall be halved.” (iii) Rejection

The concrete shall be removed and replaced with fresh concrete at the expense of the contractor, as directed by the engineer.


Add the following at the beginning of clause 6416:

"Note that items B64.01, B64.02 and B64.07 below are only applicable to durability concrete prefixed ‘W’."

Item Unit

B64.01 Cast in situ concrete

Amend the descriptions of subitems 64.01(a) and (b) to read as:

"(a) Durability concrete (Class W) ..................................................................... cubic metre (m3)

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(i) Indicate part of structure and strength e.g. Piers (W30/20)) (ii) Etc for other parts of structure (b) Normal concrete ......................................................................................... cubic metre (m3) (i) Indicate part of structure and strength e.g. Blinding (15/20) (ii) Etc for other parts of structure In the case of cast in situ concrete, delete “curing and protecting the concrete,” in the sixth line of the description of the tendered rate for item 64.01. Add the following after the second paragraph in the rate make-up:

“The contractor shall note that the strengths indicated above are to meet structural requirements only. In order for the durability criteria to be achieved, it may result in higher strengths being required. Target mean strengths to be achieved for durability purposes may therefore be higher than those shown above, as discussed under subclauses B6406(b) and B6404(h)(ii). All durability testing costs required for process control testing shall be included in the rate make-up for durability class concrete.”

Item Unit

B64.02 Manufacturing precast concrete members (description of member with reference to drawing) ................................................................................ number (No)

In the case of precast concrete, delete “curing and" in the second line of the description of the tendered rate for item 64.02.

Item Unit

B64.06 Demolishing existing concrete

Amend the payment paragraph as follows:

“The tendered rate shall include full compensation for all labour, plant (including access and craneage) and equipment (including concrete cutters) required to demolish the existing concrete (irrespective of strength) and the disposal of the product of the demolishing to a borrow pit within a free-haul distance of 15 km. The tendered rate shall also include full compensation for any necessary measures to ensure no debris falls into rivers or surfaces where damage is possible and for any debris that has fallen into rivers to be recovered. Payment shall distinguish between plain and reinforced concrete. For the purposes of this item, reinforced concrete is defined as concrete containing at least 0,2% of steel reinforcement measured by volume.” Add the following payment items:

“Item Unit

B64.07 Curing of concrete:

(a) (Indicate structural element and surface to be cured) (Tenderer to specify method of curing) .......................................................................... square metre (m

2)

(b) Etc. for various elements (Tenderer to specify method of curing) .............. square metre (m2) The unit of measurement shall be the square metre of completed concrete element cured using an approved method as described in clause B6409 of these project specifications. The tendered rates shall include full compensation for providing the curing agent and applying it to the fresh concrete surface by means of an approved pressure distributor (or other approved methods of application) in accordance with the manufacturer’s specified nominal rates of application. Wet fine mist spray curing is also permitted providing it is done for 7 days. Payment will also be made under this item if this is the preferred method to be used. Should no curing method be specified at time of

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tender then it will be assumed wet fine mist spray curing is to be done. Partial payment shall be applied in the event that the engineer allows conditional acceptance.

Item Unit

B64.08 Hot weather concreting ....................................................................................... lump sum

The tendered lump sum shall include full compensation for all measures specified in clause B6410(d) required to ensure that the temperature of the concrete placed will not exceed the temperature specified under clause B6410(f) of these specifications. Payment will be made pro-rata to the quantity of all structural concrete, which is placed on the contract. Payment will only be made if all the necessary measures required to ensure that the concrete is placed at the temperature specified are implemented”.

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SECTION B6500: PRESTRESSING OF STRUCTURES

B6505 TECHNICAL DATA

(h) Bursting reinforcement


“The contractor shall design the bursting reinforcement for his proposed prestressing system and submit drawings to the engineer for approval in accordance with clause 6507. The price for the steel and fixing shall be included in the rate tendered for stressing.”

B6510 POST-TENSIONING

(b) Fabrication

Add the following after the sixth paragraph:

“Vent pipes shall also be installed at all low points of the prestressing ducts to facilitate grouting.” (d) Concrete strength

Add the following after the first paragraph:

“Notwithstanding the concrete strength provisions above, permanent prestressing cables shall not be stressed within 7 days after completion of the last concrete pour unless the method and sequence of construction is based on a method of assessing the in situ concrete strength, such as match casting, which demonstrates that adequate strength has been attained. The proposed method shall be described in a method statement which shall be submitted to the engineer for approval at least 28 days before construction of that part of the works commences. When determining concrete strengths at which stressing operations can safely commence, due regard shall be taken of the tensile strength in addition to compressive strength, to prevent undesirable cracking in tendon anchorage zones. In this regard, tests shall be carried out to determine the rate of gain of both tensile and compressive strengths before the above method statement is submitted to the engineer for approval”.


Item Unit

B65.01 Prestressing tendons:

(a) Longitudinal tendons ................................................................. meganewton-metre (MN-m) Add the following to the paragraph describing the unit of measurement:

“The cross-sectional area of the tendon used in the calculations shall be the area of the minimum number of strands necessary to develop the jacking force.”

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SECTION B6600: NO-FINES CONCRETE, JOINTS, BEARINGS, PARAPETS AND DRAINAGE FOR STRUCTURES

B6603 JOINTS IN STRUCTURE

(a) Materials

(i) General

Add the following after the last paragraph:

“It is a firm requirement that all contracts have full Agrément certification for bridge deck joints, with the target date for new applications for Agrément assessment one year from receipt and acceptance by Agrément South Africa of each application. Proof of original acceptance of application by Agrément is required in such a case. (1) current Agrément assessments: 1 September 2010. (2) new applications for Agrément assessment one year from receipt and acceptance by

Agrément South Africa of each application. Proof of original acceptance of application by Agrément is required in such a case.”

(ii) Joint filler


“ The specifications for generic products used on this project are shown below in table B6603/1

Table B6603/1

GENERIC PRODUCT SPECIFICATIONS

Description on drawing Specification

20 mm thick polyethylene joint former Closed cell, cross-linked expanded Polyethylene joint former with thickness of 20 mm.

10 mm thick polyethylene joint former Closed cell, cross-linked expanded Polyethylene joint former with thickness of 10 mm.

Synthetic-fibre filter fabric Non-woven synthetic fibre fabric impregnated and coated with a neutral compound based on saturated petroleum hydrocarbons and inert silaceous fillers, with a nominal thickness of 1.15mm and mass per unit area of 1.44 kg/m2.

“ (iii) Sealants


“The specifications for generic products used on this project are shown below in table B6603/2

Table B6603/2



Silicone sealant One component, gun grade, low modulus, neutral cure silicone sealant that complies with ASTM D5893, does not require a primer and has resistance against temporary fuel spillage.

Composite asphalt and polypropylene mesh membrane

Composite membrane incorporating rubberised asphalt and polypropylene reinforcing mesh, 2.0 mm thick, with self-adhering properties and inclusive of substrate primer, for use under hot asphalt wearing course or in direct contact with road fill material.

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(g) Installing the expansion joints

Delete the first paragraph and replace with the following:

“All deck expansion joints shall be installed by approved specialist subcontractors only. Installed deck expansion joints shall have the following guarantees:

Proprietary joints - 15 years Asphalt plug type joints - 10 years Concrete nosings (replacement) - 10 years Joint sealant - 5 years All deck expansion joints will only be considered for use on this contract if the manufacturer has obtained Agrément certification. New applications for Agrément assessment takes up to one year from receipt to acceptance by Agrément South Africa.”

B6604 BEARINGS FOR STRUCTURES

(a) Materials

Add the following after paragraph (a)(ii):


Table B6604/1



3 Ply asphaltic waterproof membrane Asphaltic waterproofing membrane with a fibre felt carrier with nominal thickness of 2.0 mm and nominal mass per unit area 2.20 kg/m

2.

(e) Proprietary Bearings

(v) Construction

Delete the final three (3) paragraphs of subclause (e)(v)(7) and replace with the following:

“Applying two coats of epoxy MIO paint, with each coat a minimum of 75 micrometers of dry-film thickness and of a dark grey colour. Applying a semi-gloss, acrylic polyurethane (2 pack) finish with a minimum of 50 micrometers of dry-film thickness and of light grey colour. Surfaces in contact with concrete shall be sprayed with zinc, but not painted, so that it complies with the requirements of SABS 1391 part 1 for type Zn 150 surfacing.”

B6606 DRAINAGE FOR STRUCTURES

Add the following after paragraph (d):

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Table B6606/1


Description on drawing Specification 200 mm wide composite band drain strips

Pre-manufactured composite band drain for vertical and near-vertical inclined surfaces comprising a heavy duty, extruded HDPE geospacer, wrapped in needle-punched, non-woven, continuous filament, polyester geotextile of minimum tensile strength of 11 kN/m in the machine diection with nominal band width of 200 mm.

100 mm diameter drainage pipe HDPE drainage pipe with typically 70% open area with nominal 100 mm diameter and nominal 4 mm wall thickness.

65 mm diameter drainage pipe HDPE drainage pipe with typically 70% open area with nominal 65 mm diameter and nominal 3 mm wall thickness.

Polyester geotextile Needle-punched, non-woven, continuous filament, polyester geotextile with typical tensile strength of 22 and 19 kN/m in the machine and transverse direction respectively, determined in accordance with SANS 10221.

“ B6608 MEASUREMENT AND PAYMENT

Item Unit

B66.05 Expansion Joints

(a) (Description of joint measured in metre) ............................................................ metre (m)

Add the following to the measurement clause of subitem (a):

“The tendered rate for a complete buried type joint shall include the G1/G2 material, Asphalt base, tack coat and fibreglass pavement reinforcement as specified on the drawings.” (b) (Description of joint measured per number) ................................................. number (No)

Add the following to the measurement clause of subitem (b):

“The joint measured shall be the complete joint shown on the drawings including termination details and recesses at balustrades and cover plates and fixings.” Add the following to the end of the second paragraph:

“The tendered rate for subitems (a) and (b) shall also include for water test required to prove the joint. The water shall be ponded and maintained to a minimum depth of 150 mm above the top of the joint for a period of one hour each. Testing should follow the installation of the various sections of joints to take advantage of the existing traffic accommodation and each test shall cover the length of each joint installed (generally half width of bridge)”.

Item Unit

B66.06 Filled Joints ......................................................................................................... metre (m)

Add the following to the end of the second paragraph:

“The tendered rate for subitems (a) and (b) shall also include for water test required to prove the joint. The water shall be ponded and maintained to a minimum depth of 150 mm above the top of the joint for a period of one hour each. Testing should follow the installation of the various sections of joints to take advantage of the existing traffic accommodation and each test shall cover the length of each joint installed (generally half width of bridge)”.

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Item Unit

B66.15 Concrete parapets ............................................................................................... metre (m)

Add the following to this clause:

“The tendered rate shall include for sealing of joints between balustrade units as shown on the drawings. Add the following payment items:

“Item Unit

B66.28 Drainage strips (Type and position) .................................................................... metre (m)

The unit of measurement shall be the linear metre of drainage strips as shown on the drawing. The tendered rate shall include full compensation for all material, labour, and equipment to supply and install the strips as shown.

Item Unit

B66.29 Perforated drainage pipes – 100mm diameter drainage pipe wrapped in polyester geotextile ....................................................................................... metre (m)

The unit of measurement shall be the linear metre of perforated drainage pipes placed behind the earth faces as shown on the drawing. The tendered rate shall include full compensation for all material, labour, and equipment to supply and install the perforated pipes as shown including the 200mm wide by 75mm thick concrete screed class 15/20 under the core.

Item Unit

B66.30 Joint protection plates ........................................................................................ metre (m)

The unit of measurement shall be the linear metre of specified width installed. The tendered rate shall include full compensation for supplying all materials, including fastening or adhesives, for galvanizing and installation, including all labour and equipment, and for any wasted material.

Item Unit

B66.31 Additional water tests for joints ordered by the engineer ............................ number (No)

The unit of measurement shall be the number of additional water tests for proving the expansion joints, as ordered by the engineer. The test shall be executed by ponding water to a minimum depth of 150 mm deep above the top of the joint for a period of one hour each. Testing should follow the installation of the various sections of joints to take advantage of the existing traffic accommodation and each test shall cover the length of each joint installed (generally half width of bridge). The tendered rate shall include full compensation for providing the pond of water and maintaining its minimum depth of 150mm for the full one hour period, and clearing away the ponding materials on completion.

Item Unit

B66.32 Service ducts (type, size and location indicated) .............................................. meter (m)

The unit of measurement shall be the linear metre of specified type and size installed. The tendered rate shall include full compensation for supplying all materials, including fastening, installation and all labour and equipment, and for any wasted material”

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COLTO SERIES 7000: SUNDRY STRUCTURES

SECTION B7200: REINFORCED EARTH

Delete the entire Section 7200 Reinforced Earth, and replace with the following:

“SECTION B7200: MECHANICALLY STABILISED EARTH WALLS (MSEW)

B7201 SCOPE

This section covers the construction of (vertical) MSEW structures. In broad terms this consists of a fill material with horizontal layers of reinforcing elements which may take the form of sheets, grids, meshes, strips, bars, rods etc. The reinforcing elements, which are either metallic or polymeric, are capable of sustaining tensile loads and the effects of deformation developed in the fill, with a positive connection to the clad face. The outer, clad face of the fill shall, for this project, be vertical and consist of concrete panels with a high aesthetic finish. All cladding, soil reinforcement and fastener materials shall be sourced from a single MSEW supplier who will be responsible for the internal stability of the structure. The MSEW supplier shall have suitable professional indemnity insurance cover. The engineer assumes overall responsibility for the structure regarding foundation analysis and design criteria.

B7202 MATERIALS

(a) General

All materials used in constructing the MSEW, shall be subject to the approval of the engineer. When requested by the engineer, the contractor shall submit test certificates from an approved independent testing authority to show that the respective materials comply with the specified requirements, or where applicable the certificates from the patent holders or licensees certifying that the manufactured items comply in all respects with the relevant product specifications. (b) Concrete panels

Concrete panels shall be manufactured from materials which comply with the relevant requirements of sections 6200, 6300 and 6400. (c) Concrete bases and foundations for earth retaining systems

All materials for concrete bases and foundations for earth retaining systems shall comply with the relevant requirements of sections 6200, 6300 and 6400. (d) Metallic soil reinforcements

Metallic soil reinforcement shall be made from materials having a certain resistance to corrosion when buried and may take the form of sheets, grids, meshes, strips, bars, rods, ladders etc. and shall comply with section 6.2.2, Table 6 and Table 7 of the latest edition of SANS 207:2006 Galvanizing shall comply with the requirements of SANS 121 for bars and SANS 675 for wire up to 5mm. (e) Fasteners between the facing and reinforcing elements

The fasteners between the facing and the reinforcing elements shall comply with section 6.4 of the latest edition of SANS 207:2006. The facing shall have a positive connection to the reinforcing elements. (f) Polymeric soil reinforcements and joints

Polymeric soil reinforcements and joints shall comply with section 6.2.3 and section 6.2.4 of the latest edition of SANS 207:2006.

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(g) Accessory proprietary products

Any accessory proprietary products, elements or fittings necessary for the construction of the MSEW structure shall comply with the appropriate, accepted standards or specifications. (h) Fill Materials

All material which is used as fill behind MSEW cladding panels shall comply with the grading and chemical requirements specified below in addition to all the requirements of series 3000. (i) Grading

The material which is used as fill in reinforced earth structures shall fall within the unshaded section of graph 7202/1 and shall also comply with the requirements of table 7202/1.

Table 7202/1

MATERIAL SUITABLE FOR USE IN MSEW STRUCTURES

Percentage passing through an 80 µm sieve

Percentage finer than 20

µm Plasticity Index Type

< 12% - - Granular 12 to 35% < 10%

> 10%

-

PI < 30 Intermediate > 35% < 40%

Table 7202/2

MATERIAL SUITABLE FOR USE IN MSEW STRUCTURES

100

Pebbles Gravel Coarse Sand

Fine Sand

Silt Clay

90

80

70

60

50 GRANULAR SUITABLE

40 40

INTERMEDIATE CONDITIONALLY

SUITABLE

30

20

10 10 0

10

00

50

0

25

0

20

0

10

0

50

20

10

5

2

1

0,5

0,2

0,1

50

µm

20

µm

10

µm

5 µ

m

2 µ

m

1 µ

m

0,5

µm

0,2

µm

(j) Chemical and electro-chemical properties

Except in the case of structures which will come into contact with salt water, in which case the requirements will be set out in the project specifications, fill material shall comply with the following chemical requirements: Class A Class B Resistivity (Ohm.mm) >- 10 000 >- 30 000 pH 5 to 10 5 to 10 Chlorides (ppm) <200 <100

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Sulphates (ppm) <1000 <500 Sulphides (ppm) <300 <100 The resistivity shall be determined in accordance with the method prescribed by the patentee. Class B requirements shall apply. Intermediate materials may be utilised on sections of the walls shallower than 5 m, and only if the plasticity index is less than 20. A copy of all the results of the tests conducted on the material by the contractor or his supplier shall be submitted to the engineer. Material which does not comply with these specifications shall not be used without the written permission of the engineer.

B7203 MANUFACTURING AND HANDLING THE CLADDING PANELS

(a) Concrete panels

Concrete panels shall be manufactured in accordance with the dimensions and details shown on the drawings, and, where necessary, these details shall be adapted to suit joining onto existing structures, inclined foundations, varying heights or similar conditions. The concrete panels shall be manufactured in accordance with the provisions of sections 6200, 6300 and 6400, and shall have an off-shutter class F2 surface finish. Concrete panels shall be between 140 mm and 180 mm thick. Selected panels shall have a protruding patterned effect. The date of manufacture and the classification of every panel shall be clearly marked on the back of such panel. The concrete panels may be removed from the mould once the concrete has attained a cube compressive strength of 7 MPa. The concrete panels shall not be stacked more than five panels high during storage. The bottom concrete panels shall be supported off the ground by means of timber blocking, and adjacent concrete panels shall be separated by timber blocks packed between the tie strips to prevent any forces from being transmitted onto the tie strips. (b) Accessories

Any accessory proprietary products, elements or fittings shall be manufactured in accordance with the dimensions and details shown on the drawings. The accessories shall be handled in accordance with the supplier’s recommendations.

B7204 CONSTRUCTION

(a) Excavations

All excavations for the bases of the earth retaining systems shall be done in accordance with the provisions of section 6100. The contractor shall not commence with the construction of the bases before the excavations have been properly cleaned by the contractor and inspected and approved by the engineer. (b) Foundation

The foundation plane for the MSEW structure shall be graded for a width equal to the length of soil reinforcement and to the heights shown on the drawings, and compacted to a minimum of 93% modified AASHTO density in accordance with the requirements of clause 3305. All foundation soils found to be unsuitable shall be removed and replaced with compacted, approved granular material. Measurement and payment for this work will be paid for under the relevant items of section 3300.

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A concrete footing, conforming to the correct line and level, shall be provided in accordance with the details shown on the drawings, or as may be directed by the engineer. (c) Construction of MSEW

The construction of the MSEW structure shall conform to the procedures specified by the wall system supplier. Concrete panels may be installed once the concrete reaches the cube compressive strength of 18 MPa. The bottom row of cladding panels shall be carefully aligned on the foundation footing in accordance with the details provided. These panels shall be properly braced to prevent movement during the placing of the first layers of fill. Each cladding panel shall be individually checked after having been placed to confirm that the panel is correctly aligned to line, levels and inclinations shown on drawings within the stipulated tolerance. The fill material behind the cladding panels shall be placed and compacted in accordance with the provisions of section 3200 and 3300 of the specifications to at least 93% modified AASHTO density, except that the layer thickness may vary slightly to suit the position of the soil reinforcement. The fill should be deposited, spread, levelled and compacted in horizontal layers of appropriate thickness. The deposition and compaction should be carried out so that all layers of soil reinforcing elements are fixed at the specified levels on top of compacted fill. The fill should be placed such that it slopes away from the face at 2% to ensure that rainwater is kept away from the face of the MSEW structure during construction. The deposition, spreading, levelling and compaction of the fill should be carried out generally in a direction parallel to the facing and should be executed in stages to alternate with the placing and fixing of the reinforcing elements and facing. Fill shall not be placed right up to the cladding panels before the underlying reinforcing has been covered, for sufficient length from the centre of the fill, with compacted earth so as to anchor the reinforcement adequately to keep the cladding panel in position. The filling shall be made from the end of the reinforcement to the cladding panels. Care should be taken to ensure that the reinforcing elements are not damaged or displaced beyond the specified tolerance during the process of filling and compacting. Filling should be arranged so that no machines or vehicles run on the reinforcing elements. All vehicles and construction equipment weighing more than 1500 kg should be kept at least 2 m away from the cladding. Suitable compaction equipment weighing less than 1500 kg can be used within 2 m of the cladding

B7205 PATENT RIGHTS AND DESIGN

The license holder shall be responsible for the design by a professionally registered engineer (ECSA), manufacture and supply of the cladding panels, reinforcing elements and accessories and for providing technical assistance during construction. The contractor shall negotiate direct with the patent holders or licensees in connection with royalties payable for the use of the patented systems. The contractor shall arrange for technical assistance by the patent holders or licensees before and during construction. The patent holders or licensees shall design each wall, and full details shall be submitted to the engineer for scrutiny and approval not later than (20) days prior to the commencement of construction of any part of the wall(s). No construction work shall be carried out in accordance with any drawings if the official approval of the licence holder has not been clearly indicated on it.

B7206 QUALITY ASSURANCE

(a) General

The quality of the various materials covered in this section of the specifications must be monitored and the results recorded to ensure that they comply with the requirements of the general or project specifications. Series 8000 of the specifications provide tests and quality control procedures that

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cover a variety of materials and finishes. The standards given on the wall system supplier’s drawings need to be checked for compliance. (b) Cladding panels

The quality of the various cladding panels covered in this section of the specifications must be monitored to ensure that they comply with the requirements of this specification. All results should be recorded for quality assurance purposes. (c) Materials and components not covered in the specifications

For testing procedures not covered by this specification reference shall be made to section 6.5 of the latest edition of SANS 207:2006.


The tendered rates shall also include for all incidentals necessary to carry out the works, specifically, labour, transport, equipment, tools, all measures necessary for the safety of workers on the walls and supervision.

Item Unit

B72.01 Cladding panels and reinforcement elements

(a) Concrete panels (F2 surface finish) ............................................................ square metre (m2)

(b) Special panels (i) Corner panels ........................................................................................... square metre (m2) (ii) Patterned recessed panels ....................................................................... square metre (m2) (iii) Steel mesh panels lined with geotextile ..................................................... square metre (m2) The unit of measurement shall be the square metre of each type of cladding panel supplied. The quantity shall be calculated on the basis of the specified dimensions on the surface which will be visible in the completed structure. The front surface of the panel only shall be measured in respect of special panels (e.g. corner elements) This item shall also specifically include the supply of the required reinforcement elements behind the wall according to the MSEW and patent holders design. The tendered rates shall include full compensation for the labour, the supplying of all materials, including tie strips, dowels and tubes, bolts and nuts, lifting devices and the necessary jointing material, for manufacturing, storing, loading, transporting and off-loading and all appurtenant work which may be necessary for providing the cladding panels on the site, also for all royalties, design costs and technical assistance.

Item Unit

B72.02 MSEW structures..................................................................................... square metre (m2)

The unit of measurement shall be the square metre of the front vertical face of the earth retaining system placed in position as shown on the drawings. The front vertical face shall be measured from the top of the base including embedment to the top of the earth retaining systems and include the surface area of nominal panel joint openings and wall penetrations such as pipes and other utilities. The tendered rate shall also include full compensation for procuring, furnishing, transporting, handling and placing all materials including the reinforcement elements (strip, grids, etc.) and any additional costs required for placing the panels and reinforcement elements into position complete as specified.

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Item Unit

B72.03 Excavation for concrete bases for earth retaining systems

(a) In soft material ............................................................................................ cubic metre (m³) Measurement and payment for excavation shall be as specified for item 61.02 except that no additional excavation shall be measured where formwork is required.

Item Unit

B72.04 Concrete bases for earth retaining systems (Class 25 MPa/19) .............. cubic metre (m³)

The unit of measurement shall be the cubic metre of concrete cast in the concrete bases for earth retaining systems, calculated in accordance with the net approved dimensions of the concrete bases. The tendered rate shall include full compensation for supplying and placing the concrete and constructing the concrete bases, including any formwork which may be necessary, and for all steel reinforcement, complete.

Item Unit

B72.05 Infill concrete and finishing on top of the wall (Class 30 MPa/19) ............ cubic metre (m³)

The unit of measurement shall be the cubic metre of infill concrete placed on top of the wall. The tendered rate shall include full compensation for all labour, material, formwork and construction equipment necessary for placing infill concrete and for finishing off the top of the wall.

Item Unit

B72.06 Borrow to fill G6 material from approved commercial source ............... cubic metre (m3)

The unit of measure shall be the cubic metre of granular G6 fill material according to the relevant provisions of section 3400 measured in the compacted fill, calculated from the authorised dimensions. The tendered rate shall include full compensation for procuring from an approved commercial source, furnishing and placing the material, for transporting of the material, for preparing, processing, shaping and compacting the materials to the densities or in the manner specified.

Item Unit

B72.07 Extra over items B72.06, 33.01(a)(i) and 33.01(a)(ii) for backfill behind MSEW compacted in layers of 150mm to min. 93% MOD AASHTO density at optimum moisture content ...................................... cubic meter (m

3)

The unit of measure shall be the cubic metre of fill placed between the geotextile or strip reinforcement in accordance with approved dimensions of the MSEW fills bounded by reinforcing elements. The tendered rate shall include full compensation for the additional costs of constructing the fills containing geotextile or strip reinforcement, and for any adjustments to normal backfilling methods as may be necessary for placing the backfill material as specified, including the trimming of layer planes for providing intimate contact with reinforcement elements.

Item Unit

B72.08 Filter Fabric (State Grade) ...................................................................... square metre (m2)

The unit of measurement shall be the square metre area covered with filter fabric placed in position as indicated.

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The tendered rate shall include full compensation for the supply of the filter fabric, for cutting, waste, placing, jointing, overlapping and securing the fabric in position as per the MSEW design requirements. Note: Pay item 64.02 shall apply to the manufacture of prefabricated concrete coping and pay item 64.03 to its transport and erection. These pay items shall be listed under section 7200 in the schedule of quantities. ”

SECTION B7800: SHOTCRETING SPECIFICATION

B7801 SCOPE

This specification covers the supply and application of shotcrete to cut and soil nail faces and other areas as directed by the engineer. It shall include the supply and installation/application of the shotcrete and the mesh.

B7802 SHOTCRETE AND MESH

(a) Aggregate

The aggregates employed shall be of such quality as to meet the strength requirements specified and shall comply with the requirements of Section 6400 of the Standard Specifications. Fine aggregate shall be stored in such a manner that the moisture content is kept constant at all times. The moisture content should not exceed 5% by weight when a dry mix process for shotcrete application is to be used. The aggregate particles shall be spherical or cubical in shape. Natural river aggregates are ideal. Where crushed aggregates are used the crushing process shall be aimed at producing aggregate of the specified size from the outset. Aggregates which are screened off during the manufacture of larger sizes generally contain an excess of flaky and elongated particles and are not acceptable for shotcrete unless otherwise approved by the engineer. (b) Cement

Cement should be either Cem 1 (42.5) or Cem 2 (42.5) complying with Section 6400 of the Standard Specification. (c) Additives

Proposed additives shall be submitted to the engineer for approval prior to the commencement of work. The use of additives containing chloride will not be permitted. Additives shall have no deleterious effects on the steel reinforcement or the shotcrete. Once an additive has been approved, its use shall not be discontinued nor the agreed quantities per batch varied, nor another additive substituted without the prior consent of the engineer. Where different additives are included in the same batch, they shall be chemically compatible. Additives shall be metered into the batch in such a way that uniform dispersal throughout the mix is achieved. The engineer may require the contractor to apply test sections of shotcrete to prove the adequacy of the proposed additives prior be starting on the specified work. Test sections shall be at contractor’s cost. (d) Mesh

All steel employed shall conform to Section 6300 of the standard specification. The mesh to be used in the shotcrete on plane surfaces shall be welded steel mesh R395. (e) Mix design

The contractor shall submit details of the mix proportions he proposes to adopt 14 days prior to commencing the work. The contractor shall demonstrate to the engineer the suitability of the mix proportions, the competence of each operator and method of application by shotcreting test sections prior to commencing work. Such test sections shall not be carried out on a cut face requiring being

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shotcreted. Only when the mix suitability, the competence of each operator and method of application have been demonstrated to the satisfaction of the engineer shall the contractor be permitted to commence production. (f) Mixing and batching

All constituents shall be thoroughly mixed before they are discharged into the shotcrete pump. All constituents for each batch shall be accurately measured each time a fresh batch is prepared. Weight batching is preferred but volume batching will be permitted if accurately made gauge boxes of an approved design are employed, all subject to the engineers discretion. Where volume batching is permitted, the bulking factor of the sand shall be determined and taken into account. Cement shall be measured by weight. Prepared batches shall be discharged through the nozzle within 30 minutes of mixing. (g) Strength requirement

The required minimum cube strength of test specimens shall be 5; 8 and 30 MPa at 8 hours; 24 hours and 28 days respectively. Test cubes are to be made by blowing shotcrete into prepared cube moulds using the same technique as for application of shotcrete onto the rock face (i.e. the cube mould shall be placed on its side and shotcrete shot into it horizontally). The cube mould itself shall be protected by means of a suitable template. A set of three test cubes shall be required to be made for every 100 m² of shotcrete applied or as directed by the engineer and at the cost of the contractor. (h) Thickness required and measurement

The nominal thickness required is 25; 150 and/or 175 mm. The thickness shall be determined by means of random test holes drilled by the contractor at positions indicated by the engineer. At least one thickness measurement shall be taken every 10 m². The basis of acceptance shall be that in any area of 100 m², the arithmetic mean thickness at all the points checked shall be equal to or greater than the specified thickness. In addition, at no point checked should the thickness be less than 80% of the specified thicknesses. Where the thickness is not acceptable, the engineer may order an additional layer of shotcrete to be applied. All test holes shall be filled with mortar after the engineer has approved the thickness of the shotcrete. (i) Sequence of applying shotcrete

All soil or rock to be covered with shotcrete shall be cleaned thoroughly with compressed air as ordered by the engineer, to remove all loose pieces of rock and soil. Where soft material is to be covered, only obviously loose material shall be removed and boulders shall be thoroughly cleaned with compressed air. Shotcrete shall be applied as an initial layer of approximately 20 to 50 mm thick (depending on specified thickness). The steel mesh shall then be fixed over this initial layer and the shotcrete completed to the final specified thickness. (j) Method of fixing mesh reinforcement

The reinforcing mesh shall be securely fixed over the initial shotcrete layer by fastening to the dowels as shown in Drawing J02173-01-11-3104 with wire ties or other approved fixings. The mesh shall be fixed so that it lies snugly against the initial shotcrete layer and will not vibrate during application of the second layer of shotcrete. Where sudden concave or convex surfaces preclude this, the mesh may be cut so that smaller pieces of mesh can be formed into the curved surfaces. All sheets of mesh shall overlap at junctions by at least 150mm. No additional payment shall be made for overlaps. (k) Application of shotcrete

Equipment used for the application of shotcrete shall be of approved manufacture and in good condition. The operating crew shall be skilled in the use of this equipment. Care shall be taken to ensure that the strands of mesh reinforcement are completely covered with the second layer of shotcrete and that voids are not formed between shotcrete layers. The operations shall be carried out in such a manner that rebound material falls clear of future working areas, wherever possible. At all times the engineer may suspend shotcreting operations if in his opinion either the equipment used becomes defective and results in a deterioration in the quality of the resulting shotcrete work, the operator applying the shotcrete is incompetent or if adverse weather conditions preclude the application of good shotcrete.

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(l) Rebound material

Rebound material shall not be re-used. Rebound material shall be removed from all future working areas and may not be covered up by subsequent applications of shotcrete. Rebound material shall also be cleaned from the surface of any finished work. (m) Weep holes

Weep holes comprising of 75mm nominal diameter PVC piping, as shown in Drawings J02137-01-11-3103 and J02137-01-11-3104, shall be installed at those positions indicated or as requested by the Engineer. The pipe shall protrude with sufficient length to allow for the cladding to be constructed in front of the shotcrete without requiring a joint in the pipe, and have its inner end wrapped with a single layer of geofabric. Weep holes shall be positioned in the no fines layer wrapped in geotextile, as shown in Drawing J02137-01-11-31003, prior to shotcreting with the geofabric end The outer ends of the tubes shall be adequately protected against shotcrete. (n) Detail of edge of shotcrete

Detail of the finishing off of shotcrete at the brow of cuttings is illustrated in Drawing 2 which shall be provided by the client. Where boulders or outcrop occur on the brow of the cut, no cut off is required and the shotcrete shall be neatly stopped on top of the rock. As an alternative, the contractor may submit details for approval of other proposed methods to terminate the shotcrete at the edge and the top of the cutting so as to prevent surface water from undermining the shotcrete. (o) Curing

The finished shotcrete shall be adequately cured by an approved curing compound applied within half an hour of application of the shotcrete. Where the shotcrete is applied in two layers hanging hessian over the face and keeping the hessian wet for a period of 24 hours shall cure the first layer. (p) Blasting restriction

In order to reduce damage to the shotcrete no blasting shall be carried out within 50 m of a shotcreted section within 72 hours of application of the shotcrete. (q) Procedure in event of failure of shotcrete

In the event that test samples do not achieve the specified minimum strength, the engineer may order the contractor to carry out additional tests to determine new mix proportions. If the engineer considers that the low strengths of the applied shotcrete may reduce the safety of the Works and persons he may order that the following action be taken: Either

(i) Remove the defective shotcrete in strips or panels in such a way that the safety of the Works and persons is not endangered and replace with shotcrete that is acceptable. This may also require replacement of the mesh; or (ii) Apply an additional layer of shotcrete not exceeding the specified thickness originally required. In neither case will payment be made for the defective shotcrete already applied, nor for the work involved in removing the defective shotcrete from the areas where it has been applied, nor for any mesh that must be replaced, nor for any costs involved in removing the resultant rubble and spoiling it in an approved site. Any additional laps required for mesh that must be replaced shall be to the Contractor's cost. Payment shall only be made for placed and accepted shotcrete.

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Measurement and payment for the mesh shall be based on the square metre of rock slope covered with mesh measured on the plane of the slope. No extra payment shall be made for overlap of the mesh.

Item Unit

B78.01 Establishment on site ......................................................................................... lump sum

The unit of measurement shall be a lump sum and shall be payable in two instalments as follows:

(i) 50% of the tendered sum in the payment certificate following establishment of the necessary equipment (to the engineer's satisfaction) on site. (ii) 50% of the tendered sum after the work has been accepted and the installation team has left the site. The tendered rate shall include full compensation for the establishment and subsequent removal from site of all the equipment, transport, plant, scaffolding, materials and personnel necessary to carry out the specified work.

Item Unit

B78.02 Supply and Installation of Reinforcing

(a) Welded steel fabric Mesh Ref. 395. ................................................................... kilogram (kg) The unit of measurement shall be the square metre of mesh actually incorporated into the shotcrete. Overlaps shall not be measured. The tendered rate shall include full compensation for the supply and installation, including all equipment, plant, materials, labour and incidentals necessary to carry out the specified work and including specifically, the supply and installation of pins, wire ties, gun nails and any other approved fastenings for the completion of the work to the satisfaction of the Engineer.

Item Unit

B78.03 Shotcrete of specified thickness applied in one, two or more layers as necessary

(i) 30Mpa 25mm thick (unreinforced) flash coat ............................................. square metre (m²) (ii) 30Mpa 150mm thick final coat retained faces less than 3m high ................ square metre (m²) (iii) 30Mpa 175mm thick final coat retained faces 3m to 4.5m high................... square metre (m²) The unit of measurement shall be the square metre of face measured in the plane of the cutting face, which is protected by shotcrete of the specified thickness, installed to the satisfaction of the engineer. No separate allowance shall be made for an uneven surface when measuring the area over which shotcrete has been applied. The tendered rate shall include for everything necessary to carry out the specified work to the satisfaction of the engineer and shall include the following: (1) Supplying all materials, including additives (if any), mixing and applying shotcrete including

test sections as ordered by the engineer, either to prove the adequacy of the additives or the shotcrete methods and materials, mix design and the competence of operators.

(2) Cleaning down the cutting face with air as ordered, and the removal of all resulting soil and

rock debris from the site to an approved spoil site, including all loading and transport (3) Applying the shotcrete in one, two or more layers as directed by the engineer. (4) Checking the thickness in the manner specified.

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(5) Cleaning off all rebound and excess material and the disposal of thereof at an approved spoil site.

(6) Making, curing and testing test specimens as specified. The tendered rate shall include any extra over payment for the instalment of the weep holes through the shotcrete as shown in Drawings J02137-01-11-3103 and J02137-01-11-3104. The payment of the piping for the weep holes will be done under Item 12/66.19, the no fines concrete under Item 12/66.01 and the geotextile fabric under Item 12/66.21. No separate or additional payment shall be made for shotcrete applied to a thickness greater than specified and required, nor shall any additional payment be made for shotcrete whether applied in one or more layers.

Item Unit

B78.04 Finishing off of shotcrete along brow of cut face .............................................. metre (m)

The unit of measurement shall be the linear metre of the top of cut face where the shotcrete is finished off in the manner as detailed on the drawings or any other equivalent method, all to the satisfaction of the engineer. The tendered rate shall include full compensation for excavation and spoiling of material from cut off trenches, bending of mesh/netting, application of shotcrete irrespective of the volume involved as well as all equipment, labour, transport and other incidentals necessary to complete the specified work.

Documents

SECTION B3400: PAVEMENT LAYERS OF GRAVEL MATERIAL 3 Book 2 of... · C3-92 SECTION B3400: PAVEMENT LAYERS OF GRAVEL MATERIAL B3401 SCOPE Add the following: “This section also covers