APPENDIX 0/1 ADDITIONAL CLAUSES, TABLES AND FIGURES 185 AK Night Work Night work will only be permitted as detailed in Appendix 1/85. 186 AK Sectional Completion The Contractor shall comply with the requirements described in Appendix 1/86. 187 AK Site Safety In the interests of Site Safety, where there is a foreseeable risk, safety helmets and high visibility warning clothing shall be worn on the Site by all Site personnel at all times. The high visibility warning clothing shall be as described in Clause 117.18. 188 AK Sustainability The Contractor shall comply with the requirements described in Appendix 1/87. 586 AK Existing Drainage Renewal of Filter Drains 1. The Contractor shall locate the ends of the existing filter pipe where it has been built into catchpits or the concrete surround to gully connections. These pipes shall be protected during the excavation of the existing drain and surround. The new filter pipe shall connect positively to the existing pipe using a method approved by the Overseeing Organisation. Invert and Pipe Details of Replacement Drainage 2. All replacement pipe sizes and inverts shall be as existing. 3. Following agreement of the temporary bench mark values and before the drainage work is commenced, invert and existing ground levels above drain runs shall be agreed with the Overseeing Organisation. 587 AK Deep Bored Soakaways 1. Deep bored soakaways shall be constructed in the position and to the depths shown in Appendix 5/1. 2. The borehole shall not be greater than 250mm in diameter and temporary casing shall be used over its full length to uphold the sides prior to backfilling. 3. The borehole liner shall have an internal diameter, not less than 150mm. It may be in PVC-U in accordance with BS 4962 or other durable material agreed with the Overseeing Organisation. It must be capable of insertion in the borehole without risk of breakage or damage to the joints. APPENDIX 0/1 4. Perforated slotted or screened pipe shall only be used in that section where soakage is intended. The apertures in such a pipe shall be smaller than any aggregate placed between the liner and the borehole wall. 5. After installation of the lining tube, rounded 5mm to 10mm pea gravel shall be placed in the annulus between the borehole wall and the lining tube to a level 1 metre above the perforated pipe as the casing is withdrawn. Care must be taken to ensure that the level of the aggregate is maintained just above the bottom of the casing to prevent collapse of the borehole. In addition, excessive heights of aggregate above the bottom of the casing will jam casing withdrawal and lift the liner to the detriment of the installation. 6. A bentonite seal shall be placed on top of the aggregate to a depth of 2.0 metres. Care must be taken to prevent contamination of the gravel. 7. As the casing is withdrawn the remaining annulus shall be filled with suitable material as directed by the Overseeing Organisation. 588 AK Adjustment of Ironwork 1. Where the adjustment or replacement of existing frames and covers or gratings to service boxes, service valves and the like is required, such adjustment or replacement shall be in accordance with Clause 507.18. 685 AK Stone Pitching 1. The type of stone and locations of Stone Pitching shall be as described in Appendix 6/85. 2. The stone shall not be liable to damage by frost. 3. The individual pieces of stone shall be selected to fit roughly together. They shall then be securely wedged in position by stone spalls and small gaps in the top 50mm shall be filled with broken stone or gravel or dry mortar. 4. Selected heavy stones shall be used to prevent displacement at the top and bottom. 686 AK Geosynthetics The type of geosynthetic and location shall be as described in Appendix 6/86. 687 AK NOT USED 688 AK NOT USED 689 AK Performance Categorised Capping Layer Material 1 Performance Categorised Capping Layer Material shall satisfy the requirements of Clause 613 except as amended below. 2 For the purpose of this clause ‘cement’ includes Portland cement CEM I and cementitious (hydraulic) binders including PFA and ground granulated blast APPENDIX 0/1 furnace slag. Selected granular materials include recycled aggregates, for example: crushed concrete, demolition waste and asphalt, incinerator ash and asphalt planings but excluding unburnt colliery spoil. Type Approval 3 Material shall achieve a minimum CBR of 30% when tested in the laboratory in accordance with BS 1377-4 Cl. 7 when compacted to 95% of the maximum achieved by BS 1377 Test 14 and at saturation moisture content using 3 annular surcharge rings. Alternatively, the material shall satisfy an in-situ Stiffness Modulus measured by Portable Dynamic Plate, of 60MPa when tested in the Laboratory for approval purposes in accordance with Clause 890AK using the Portable Dynamic Plate 4 At least 2 weeks before the laying of material is to commence, details shall be submitted to the Overseeing Organisation of the sources of material and the methods intended to be used. Main Works 5 Chalk shall have a saturation moisture content not exceeding 20% and shall be compacted in homogeneous layers not exceeding 225mm to achieve a maximum air voids of 5% 6 Capping layer materials shall be compacted with vibrating rollers so that when tested they achieve an in-situ Stiffness Modulus measured by Portable Dynamic Plate of 40MPa maintained until carriageway construction is complete. Tests shall be carried out every 10m of carriageway which may be reduced in frequency if there is no result less than 80MPa after 5 tests 10m apart. 7 Unless otherwise stated in Appendix 7/1, when used in the carriageway the materials shall not be frost susceptible if used within 450mm of the designed final surface when tested in accordance with Clause 801.8. 888 AK Performance Categorised Unbound Mixture for Subbase 1. Performance Categorised Unbound Mixture for Subbase shall be selected granular materials complying with this clause including materials complying with the 800 series of the Specification and other recycled and secondary aggregates for example: crushed concrete, demolition waste, asphalt planings, furnace bottom, fuel and incinerator ash, slag but excluding unburnt colliery spoil. 2. The material shall have a Los Angeles coefficient of LA when tested in 55 accordance with BS EN 1097-2, Determination of resistance to fragmentation by the Los Angeles test. 3. The material shall contain no gypsum plaster, putrescent or soluble material and not more than a total of 2% by mass, timber, plastic, steel or other degradable material. The maximum dimension of any such material shall not exceed 25mm. APPENDIX 0/1 4. The material at time of compaction shall be at an appropriate moisture content between +1% and –2% of the optimum moisture content as determined by BS 1377-4 or a recognised field identification test. 5. The material shall satisfy the requirements of Table 8/88 below when tested in the Laboratory for approval purposes using the Portable Dynamic Plate in accordance with Clause 890 AK. 6. In addition after installation the material should have sufficient mechanical interlock not to rut under construction traffic. If necessary this should be demonstrated by a field trial. The material shall not exhibit a rut depth exceeding 20mm after 100 passes of an 8 tonne axle. 7. When tested in-situ it shall achieve a Stiffness Modulus measured by Portable Dynamic Plate described in Clause 889 AK, as given by Table 8/88 measured at a rate of 1 test per 50 linear metres of carriageway 8. Unless otherwise stated in Appendix 7/1, when used in the carriageway the materials shall not be frost susceptible if used within 450mm of the designed final surface when tested in accordance with Clause 801.8. Table 8/88 Stiffness of granular materials Stiffness at top of layer In-situ Laboratory Category A material 100 MPa 150 MPa Category B material 70 MPa 105 MPa Category C material 50 MPa 75 MPa 9. Materials shall be compacted with vibrating rollers without drying out or segregation so that when tested they achieve 95% of the density when compacted in accordance with BS 1377-4 Method 3.7. This shall be measured in-situ using a calibrated nuclear density meter at a rate of 1 test per 50 linear metres of carriageway. 10. Prior to laying the bituminous material the surface of the subbase shall satisfy the surface tolerance requirements of clause 702. 11. At least 2 weeks before laying of material is to commence, details shall be submitted to the Overseeing Organisation of the sources of material and the methods intended to be used. 889 AK Portable Dynamic Plate Test 1. The Portable Dynamic Plate Test shall be carried out using equipment which has been properly calibrated to the manufacturer’s specification and subject to a validation check prior to use. 2. The equipment shall be capable of delivering a total load pulse of peak magnitude 6-8kN, of total duration 15-40 milliseconds, to a rigid circular plate APPENDIX 0/1 of 300mm diameter. Both the applied load and the transient deflection shall be measured. 3. The dynamic modulus shall be determined at each point tested using the following formula:- Dynamic Modulus, Evd (MPa) = P(l-v²) 0.3y Where P is the peak applied load (kN) y is the peak deflection (mm) v is the Poissons Ratio; a value of 0.35 shall be used in the absence of any other data 4. The stiffness modulus shall be obtained using the following formula:- Stiffness Modulus, G (MPa) = Evd / 0.6. 5. The full technical specification of the Portable Dynamic Plate Test apparatus is published by the German Federal Ministry of Transport, Road Construction Department in TP BF-StB Part B 8.3, 1992 (in German). 890 AK Materials approval using Portable Dynamic Plate Test 1. The material shall be compacted into a box dimensions: 610mm x 610mm x 420mm deep, with a 75Kg Vibrating Plate Compactor in 3 layers with 6 passes on each layer. 2 The moisture content shall satisfy the requirements for the particular material being approved. 3. The density shall be checked with a calibrated nuclear density gauge in direct transmission mode to ensure a minimum compaction of 95% of wet density achieved in BS 1377-4 Method 3.7. 4. The materials shall be tested using the Portable Dynamic Plate Test in accordance with Clause 889 AK. 5. The mean Stiffness modulus shall satisfy the requirements of the relevant Clause for the material. 989 AK Geotextile Surface Dressing The Geotextile Fabric 1. The membrane shall be a non-woven, 100% polypropylene fabric with the following characteristics: (a) Tensile strength BS EN 10319 9.0kN/m minimum (b) Elongation at Break (md) BS EN 10319 55% minimum (c) Melting point ASTM D.276 150°C minimum APPENDIX 0/1 (d) Asphalt retention Task Force 25 Method 8 1.0 kg/m² 2 The fabric shall not be exposed to direct sunlight for a cumulative period exceeding 2 weeks prior to its being overlaid and shall be stored in accordance with the manufacturer's instructions. Surface Preparation 3 The surface of any existing pavement to be overlaid, whether directly with the membrane, or with a regulating course onto which the membrane will subsequently be laid, shall receive the following treatment: (a) All cracks of width greater than 5mm shall be blown clean and dry with hot compressed air and filled with 70 - 100 pen grade filled bitumen incorporating 70 - 75% Limestone filler, using a screed box not exceeding 50mm wide. (b) All potholes, or fretted areas shall be filled with regulating material of aggregate size appropriate for the depth of material laid. (c) The minimum surface temperature shall be 5°C, and the surface shall be dry and swept free from dirt, oil, vegetation and other debris, by mechanical broom. Bond Coat 4. The binder shall be either 160-220 pen bitumen maintained in a tanker/spray at 160ºC ± 5ºC or 70-100 pen maintained at 180ºC ± 5ºC and sprayed at a rate of 0.9 l/m2 ± 0.1 l/m2 or cut back bitumen, sprayed at a rate of 1.0 l/m2 ± 0.1 l/m2. If the surface is porous/pervious the rate shall be increased, with the agreement of the Overseeing Organisation, to allow for the binder lost into the surface. The binder shall be sprayed uniformly over the whole area on which the fabric is to be laid, plus 150mm at each side using pressure jets specifically designed and calibrated for the purpose. Fabric Laying 5. The fabric shall be laid out mechanically immediately after spraying whilst maintained under sufficient light tension to ensure no wrinkling. Should wrinkling in excess of 25mm occur inadvertently, the fold shall be slit and laid flat, permitting only a double thickness of material. Transverse and longitudinal joints shall be butted, joints shall not coincide with longitudinal or transverse cracks. All fabric must be bonded to the substrate with bitumen, and the Overseeing Organisation may permit additional bitumen to be placed manually to ensure this. 6. The fabric shall be brushed with a stiff broom over its whole surface to ensure it is in contact with the bitumen film. If hot binder is used this shall take place before the binder has cooled to a non-tacky state 7. The surface of the fabric shall be rolled with at least one pass of a rubber coated drum roller or pneumatic tyred roller immediately after laying the fabric to press the fabric into the bond coat APPENDIX 0/1 8. The fabric shall be overlaid immediately with the surface dressing if cut back or penetration grade binder is used for the bond coat or as soon as is practicable if bitumen emulsion is used. 9. Construction and emergency traffic may run on the fabric immediately after laying. However, it must be ensured that damage is not caused to the membrane by vehicles turning, braking etc. and it must also be ensured that the membrane is kept clean of mud or other detritus. If damage occurs the affected area shall be patched with bond coat and fabric. If the surface of the fabric becomes tacky with bitumen during construction, this may be blotted if necessary with sand to prevent spreading and pick-up of the fabric. Excess sand shall be removed by sweeping before overlaying Surface Dressing 10. Surface Dressing overlay shall be carried out using polymer modified cut back or polymer modified binder in accordance with Clause 919 treating the site as ‘hard’ and except for the following: a) an additional 0.3 l/m2 bitumen shall be used. b) if a single dressing is used for the main works, any bends, junctions or entrances to premises shall have smaller chippings added to form a racked in system c) compaction shall be carried out using both a vibrating roller with rubber coated drum and a pneumatic tyred roller to ensure the whole surface is fully compacted to produce a stable dressing 11 Unrestricted traffic, turning or braking traffic, shall not use the dressed surface until the binder has gained enough strength and the layer has stabilised to form a mosaic 990 AK Geotextile Reflective Crack Control Membrane The Geotextile Fabric 1. The membrane shall be a non-woven, 100% polypropylene fabric with the following characteristics: (a) Tensile strength ISO 10319/1 8.0kN/m minimum (b) Elongation at maximum load% ISO 10319/1 55% minimum (c) Melting point ASTM D.276 150°C minimum (d) Asphalt retention ASTM D 6140-97 1.1 kg/m² 2 The fabric shall not be exposed to direct sunlight for a cumulative period exceeding 2 weeks prior to its being overlaid and shall be stored in accordance with the manufacturer's instructions. Surface Preparation APPENDIX 0/1 3 The surface of any existing pavement to be overlaid, whether directly with the membrane, or with a regulating course onto which the membrane will subsequently be laid, shall receive the following treatment: (a) All cracks of width greater than 5mm shall be blown clean and dry with hot compressed air and filled with 60 - 80 pen grade filled bitumen incorporating 70 - 75% Limestone filler, using a screed box not exceeding 50mm wide. (b) All potholes, or fretted areas shall be filled with regulating material of aggregate size appropriate for the depth of material laid. (c) The minimum surface temperature shall be 15°C, and the surface shall be dry and swept free from dirt, oil, vegetation and other debris, by mechanical broom. Bond Coat 4. The binder shall be either 200 pen bitumen maintained in a tanker/spray at 160ºC ± 5ºC or 100 pen maintained at 180ºC ± 5ºC and sprayed at a rate of 0.9 l/m2 ± 0.1 l/m2 or cut back bitumen, sprayed at a rate of 1.0 l/m2 ± 0.1 l/m2. If the surface is porous/pervious the rate shall be increased, with the agreement of the Overseeing Organisation, to allow for the binder lost into the surface. The binder shall be sprayed uniformly over the whole area on which the fabric is to be laid, plus 150mm at each side using pressure jets specifically designed and calibrated for the purpose. APPENDIX 0/1 Fabric Laying 5. The fabric shall be laid out mechanically immediately after spraying whilst maintained under sufficient light tension to ensure no wrinkling. Should wrinkling in excess of 25mm occur inadvertently, the fold shall be slit and laid flat, permitting only a double thickness of material. Transverse and longitudinal joints shall be butted, joints shall not coincide with longitudinal or transverse cracks. All fabric must be bonded to the substrate with bitumen, and the Engineer may permit additional bitumen to be placed manually to ensure this. 6. The fabric shall be brushed with a stiff broom over its whole surface to ensure it is in contact with the bitumen film. If hot binder is used this shall take place before the binder has cooled to a non-tacky state. 7. The surface of the fabric shall be rolled with at least one pass of a rubber coated drum roller or pneumatic tyred roller immediately after laying the fabric to press the fabric into the bond coat. 8. Construction and emergency traffic may run on the fabric immediately after laying. However, it must be ensured that damage is not caused to the membrane by vehicles turning, braking etc. and it must also be ensured that the membrane is kept clean of mud or other detritus. If damage occurs the affected area shall be patched with bond coat and fabric. If the surface of the fabric becomes tacky with bitumen during construction, this may be blotted if necessary with sand to prevent spreading and pick-up of the fabric. Excess sand shall be removed by sweeping before overlaying 991AK Cold Recycled Bitumen Bound Material structural grade off site mix 1. Scope a) Cold recycled bitumen bound material shall be designed and produced to form the foundation or main structural layer of the road pavement. The primary aggregate source shall be asphalt milling, pulverised pavement material, processed demolition waste, crushed glass, natural or artificial aggregates, mixed remotely and taken to site. The primary binder (stabilising agent) shall be a foamed penetration grade bitumen or bitumen emulsion, with pfa, cement or lime as an adhesion agent. The aggregate grading may be adjusted by the addition of a filler. b) Prior to commencing the works, the Contractor shall demonstrate, to the satisfaction of the Overseeing Organisation using the results of mix design procedures described in sub-Clauses 32 to 48 of this Clause, that the materials are capable of producing a material that can meet the specified requirements. Aggregates and Fillers 2. The aggregate components comprising asphalt milling, pulverised pavement material, processed demolition waste, crushed glass, natural or artificial aggregates and filler (if used) shall be granular material with not less than 5% and not more than 20% passing the 0.063mm sieve (Zone A graded material). Approval for use of granular material containing up to 35% passing the 0.063mm sieve (Zone B graded material) shall require confirmation by the Overseeing APPENDIX 0/1 Organisation subject to the results of the mixture design procedures described in sub-Clauses 62 to 71 of this Clause. 3. The aggregate components shall contain not more than 2% of organic matter as determined in accordance with BS 1377-3: Clause 3. 4. Using water, the optimum liquid content for the aggregate components shall be obtained in accordance with BS 1377-4 Clause 3.7. If aggregate contains bitumen residues the material shall be dried at a temperature not exceeding 40 oC to constant weight. 5. The particle (or “lump”) size distribution for the aggregate components shall be determined in accordance with BS EN 933-1 (or by an amended method to obtain an early assessment of grading, provided correlation with the standard test method can be demonstrated). Bitumen Binder 6. The primary binder shall be foamed bitumen or bitumen emulsion. The base bitumen shall comply with BS EN 12591 and shall normally be penetration grade 100 - 150. Subject to the results of the mixture design procedures described in sub-Clauses 62 to 71 of this Clause and approval of the Overseeing Organisation, the base bitumen may be a penetration grade in the range 50 to 190. 7. Other than foaming agent(s), bitumen modifiers shall not be used unless approved by the Overseeing Organisation for special purposes or conditions. 8. The binder shall be transported to the plant in tankers capable of maintaining the required temperature and a homogeneous binder consistency and transferred to the plant in a controlled and uniform manner. 9. In the case of foamed bitumen the foaming process shall be carried out within the system of the mixing plant and immediately mixed with the aggregate, at which point the foamed bitumen shall have a volume of not less than 10 times the volume of the base penetration grade bitumen. Cement, Filler and Lime 10. The constituents and required quality standards of hydraulic cement, filler and lime delivered to site shall be certified by the supplier, whose manufacturing and delivery processes shall be implemented using quality management systems in accordance with the BS EN ISO 9001 and certified by an accredited body. 11. Hydraulic cement as a filler or adhesion agent shall be Portland cement CEM I, Portland blast furnace slag cement PBC or Portland pfa cement CEM II/B-V, in accordance with sub-Clause 1001.3. 12. PFA, used as a filler, shall be in accordance with BS 3892: Part 1. 13. Lime shall be either quicklime or hydrated lime, complying with sub-Clause 615.3.