10/063/003-FGS-1600-

OMV (YEMEN BLOCK S2) EXPLORATION GMBH TG Doc. No.

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OMV (YEMEN BLOCK S2) EXPLORATION GMBH

CONTRACT NO.: OMV/S2/DEV/WELLHEAD/2009/035

ENGINEERING SERVICES AGREEMENT

FLEXIBLE ROADS AND PAVING - MATERIALS AND

CONSTRUCTION SPECIFICATION

Prepared by TG Engineering

Revision History

Rev Description Date TG Review & Approval Client

(dd/mm/yyyy) By Reviewed Approved Approval

Z IDC 28-DEC-10 KA/AH TR SG

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SHEETS INDEX AND REVISIONS

Rev. Section Revision Description

Note: Revision Table to be used on Post-AFD Issues

HOLDS

Hold
Section Description
No.

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TABLE OF CONTENTS

1.0 INTRODUCTION ......................................................................................................... 5

1.1 Overview .......................................................................................................... 5
1.2 Definitions ....................................................................................................... 5
1.3 Abbreviations .................................................................................................. 5
2.0 APPLICABLE CODES & STANDARDS, REGULATIONS AND REFERENCES ........ 7
2.1 General ............................................................................................................. 7
2.1.1 International Codes & standards........................................................... 7
2.1.2 Project Specifications .......................................................................... 9
3.0 ROADS....................................................................................................................... 10
3.1 Off-Plot Patrol Roads ..................................................................................... 10
3.2 Road along Pipeline Route ............................................................................ 10
4.0 BITUMINOUS CONCRETE PAVING .......................................................................... 11
4.1 General .......................................................................................................... 11
4.2 Materials ........................................................................................................ 11
4.3 Testing ........................................................................................................... 12
4.4 Sub-Grade ..................................................................................................... 14
4.4.1 Preparation of Sub-Grade .................................................................. 14
4.4.2 Protection of Sub-grade...................................................................... 15
4.5 Sub-Base ....................................................................................................... 15
4.5.1 Preparation of Sub-base .................................................................... 15
4.5.2 Material .............................................................................................. 16
4.5.3 Construction ....................................................................................... 16
4.6 Bituminous Concrete Design & Laying ........................................................... 17
4.7 Types of Bituminous Concrete Mixes ............................................................. 18
4.8 Design Criteria ............................................................................................... 19
4.9 Job Mix Formula and Allowable Tolerances ................................................... 20
4.10 Sampling and Testing of Bituminous Concrete Mixes..................................... 21
5.0 CONCRETE PAVING ................................................................................................ 22
5.1 Granular Sub-base......................................................................................... 22

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5.2 Joints in Concrete Paving .............................................................................. 23

5.3 Quality Control ............................................................................................... 23
5.4 Tolerances ..................................................................................................... 23
5.5 Buried Cable Routes ...................................................................................... 24
6.0 GRAVEL ROAD ......................................................................................................... 25
6.1 General ........................................................................................................... 25
6.2 Material Requirements ................................................................................. 25
7.0 CONSTRUCTION TOLERANCES .............................................................................. 27
8.0 ROAD SHOULDERS .................................................................................................. 28
9.0 QUALITY CONTROL .................................................................................................. 29
10.0 SETTING OUT............................................................................................................ 30
11.0 PIPE TRACK AND RIG CROSSINGS ......................................................................... 31
12.0 ROAD MARKINGS AND ROAD SIGNS ...................................................................... 32
13.0 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS .................................. 33

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1.0 INTRODUCTION

1.1 Overview

OMV (Yemen Block S2) Exploration GmbH (OMVY) wishes to realize a

Development at Al Uqlah Block S2 in the Republic of Yemen. As part of this
development there is a Field Gathering System (FGS) Project. This document
provides the Specification for Material and Construction of Flexible Roads and
Paving connected with the project.

1.2 Definitions

Within this specification the following definitions shall apply:

COMPANY OMV (Yemen Block S2) Exploration GmbH

CONTRACTOR The COMPANY appointed to undertake the
Construction and related works for the FGS

“Shall” Indicates a mandatory requirement

“Should” Indicates a recommendation

1.3 Abbreviations

Abbreviations Description
AASHTO American Association of State Highway and
Transportation Officials
BS British Standards
C40 Specified Compressive Strength Of Concrete At 28
Days Of Cube Age.
CPF Central Processing Facility
CPU Central Processing Unit
Dia. Diameter
FGS Field Gathering System
Kg Kilogram
kPa Kilo Pascal
kN KiloNewton
m Metre

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Abbreviations Description
max. maximum
MDD Maximum Dry density
Min. minimum
mm Millimetre
N Newton
OMVY OMV (Yemen Block S2) Exploration GmbH

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2.0 APPLICABLE CODES & STANDARDS, REGULATIONS AND REFERENCES

2.1 General

All work shall conform to the latest issue (including revisions, addenda and
supplements) of recognised standards and any local related statutory regulations,
as listed in this specification. In case of conflict between the various Codes and
Standards, and/or this Specification, reference shall be made to the COMPANY
for resolution.
Unless specified otherwise, the international system of metric units (S.I.) shall be
used.
2.1.1 International Codes & standards

BS 434 (Various) Bitumen Road Emulsions

BS 594-1 Hot Rolled Asphalt for Roads and Other Paved Areas.
Specification for Constituent Materials and Asphalt
Mixtures
BS-598(Various Parts) Sampling and Examination of Bituminous Mixtures
for Roads and Other Paved Areas.
BS 812 (Various Testing Aggregates
Parts)
BS 1377 Parts 1 to 9 Methods of Test for Soils for Civil Engineering Purposes
BS 5273 Specification. Dense Tar Surfacing for Roads and Other
Paved Areas.
BS EN 13043 Aggregates for Bituminous Mixtures and Surface
Treatments for Roads, Airfields and Other Trafficked
Areas.
BS EN 1339 Concrete Paving Flags. Requirements and Test Methods.
BS EN 1338 Concrete Paving Blocks. Requirements and Test
Methods.
BS 4987-1 Coated Macadam (Asphalt Concrete) for Roads and
Other Paved Areas. Specification for Constituent
Materials and for Mixtures.
BS 594987 Asphalt for roads and other paved areas–Specification
for transport, laying and compaction and type testing
protocols.
BS 3262 -3 Hot Applied Thermoplastic Road Marking Materials.
Specification for Application of Material to Road
Surfaces.
BS 4483 Steel Fabric for the Reinforcement of Concrete
Specification.

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BS 4449 Steel for the Reinforcement of Concrete Weldable

Reinforcing Steel. Bar, Coil and Decoiled Product
Specification.
AASHTO GDPS-4-M Guide for Design of Pavement Structures and 1998
Supplement.
AASHTO M82 Standard Specification for Cut-Back Asphalt (Medium-
Curing Type).
AASHTO M140 Standard Specification for Asphalt, Emulsified.

AASHTO T166 Standard Method of Test for Bulk Specific Gravity of

Compacted Hot Mix Asphalt (HMA) Surface-Dry
Specimens.
AASHTO M145 Standard Specification for Classification of Soils and
Soil-Aggregate Mixtures for Highway Construction
Purposes.
AASHTO T2 Standard Method of Test for Sampling of Aggregates.

AASHTO T96 Standard Method of Test for Resistance to Degradation

of Small-Size Coarse Aggregate by Abrasion and
Impact in the Los Angeles Machine.
AASHTO T104 Standard Method of Test for Soundness of Aggregate
by Use of Sodium Sulphate or Magnesium Sulphate.
AASHTO T176 Standard Method of Test for Plastic Fines in Graded
Aggregates and Soils by Use of the Sand Equivalent
Test.
AASHTO T89 Standard Method of Test for Determining the Liquid
Limit of Soils.
AASHTO T90 Standard Method of Test for Determining the Liquid
Limit of Soils.
AASHTO T180 Standard Method of Test for Moisture-Density
Relations of Soils Using a 4.54-kg (10-lb) Rammer and
a 457-mm (18-in.) Drop.
AASHTO T191 Standard Method of Test for Density of Soil In-Place by
the Sand-Cone Method
AASHTO T92 Standard Method of Test for Determining the
Shrinkage Factors of Soils.
AASHTO T112 Standard Method of Test for Clay Lumps and Friable
Particles in Aggregate.

AASHTO T193 Standard Method of Test for The California Bearing

Ratio.

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AASHTO T27 Standard Method of Test for Sieve Analysis of Fine and
Coarse Aggregates.
AASHTO T84 Standard Method of Test for Specific Gravity and
Absorption of Fine Aggregate.
AASHTO T11 Standard Method of Test for Materials Finer Than 75-
µm (No. 200) Sieve in Mineral Aggregates by Washing.
AASHTO T88 Standard Method of Test for Particle Size Analysis of
Soils
AASHTO M20 Standard Specification for Penetration-Graded Asphalt
Cement
AASHTO T49 Standard Method of Test for Penetration of Bituminous
Materials
AASHTO T168 Standard Method of Test for Sampling Bituminous
Paving Mixtures
AASHTO T164 Standard Method of Test for Quantitative Extraction of
Asphalt Binder from Hot Mix Asphalt (HMA)
AASHTO T30 Standard Method of Test for Mechanical Analysis of
Extracted Aggregate
ASTM D1883-07 Standard Test Method for CBR(California Bearing Ratio)
of Laboratory-Compacted Soils
ASTM C131-06 Standard Test Method for Resistance to Degradation of
Small-Size Coarse Aggregate by Abrasion and Impact in
the Los Angeles Machine
ASTM C88-05 Standard Test Method for Soundness of Aggregates by
Use of Sodium Sulphate or Magnesium Sulphate
ASTM D2419-02 Standard Test Method for Sand Equivalent Value of
Soils and Fine Aggregate
ASTM D4318-05 Standard Test Methods for Liquid Limit, Plastic Limit,
and Plasticity Index of Soils
ASTM D1556-07 Standard Test Method for Density and Unit Weight of
Soil in Place by the Sand-Cone Method.

2.1.2 Project Specifications

10/063/003-FGS-1001-003 Basis of Design

10/063/003-FGS-1600-002 Specification for Concrete Works

10/063/003-FGS-1600-003 Specification for Site Preparation and Earthworks

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3.0 ROADS

3.1 Off-Plot Patrol Roads

External Patrol Roads are located outside the fence and are peripheral to each
plot. These roads will be used for patrol and will be minimum 4m wide plus 1m
shoulder either side, finished with thickness of 300mm minimum compacted
Gatch. The provision of the same shall be at the discretion of the COMPANY.
The Gatch shall comply with the requirements as outlined in the Specification
for Site Preparation and Earthworks TGE Doc.No.10/063/003-FGS-1600-003.

3.2 Road along Pipeline Route

The extent and the width of the roads running along the pipeline route shall be as
shown in the drawing 10/063/003-FGS-4418. These roads shall be of thickness
500mm minimum compacted Gatch. The Gatch shall comply with the
requirements as outlined in the Specification for Site Preparation and Earthworks
TGE Doc.No.10/063/003-FGS-1600-003.

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4.0 BITUMINOUS CONCRETE PAVING

4.1 General

Earth works shall be carried out in accordance with the Project Earthworks and
Site Preparation– Materials and Construction Specification TGE
Doc.No.10/063/003-FGS-1600-003 Specification for Site Preparation and
Earthworks. Bituminous concrete paving mixes shall be used for surfacing and
base courses of roadways, full depth asphalt concrete design and shall be
constructed using hot-mix; hot-laid mixtures spread and compacted in layers.
4.2 Materials

(a) Existing soil:

To be excavated or backfilled to the levels indicated on drawings, watered and
compacted to 98% MDD to receive sub-grade.
(b) Sub-grade:
This shall be “Gatch” or other sources approved by the COMPANY. It shall
have 35% CBR value (Soaked) at 5mm (Bottom) at 98% MDD. This shall be
minimum 300mm thick layer after compaction.
(c) Sub-base:
This shall be granular material from a source approved by the COMPANY. It shall
have 80% CBR value (Soaked) at 5mm (Bottom) at 98% MDD. This shall be
minimum 300mm thick layer after compaction.
(d) Prime Coat:
Consist of application of asphalt material on the prepared sub-base and the
bituminous material to be used for prime coat shall conform to the following
kind, grade and specifications.
- Medium curing cut back asphalt; grade MC-70, conforming to the
requirements of AASHTO M82.
- Prime coat shall not be applied when the ambient temperature is less than 13°C
nor during rain, fog, dust storms or other unsuitable weather.
- The application temperature for the MC-70 liquid asphalt shall be between
60°C and 85°C.
- The bituminous material for the prime coat shall be applied in quantities
not less than 0.7 litres/m2 and not more than 1.5 litres/m2.
(e) Asphalt base course, asphalt binder course and asphalt wearing course:

- The mineral aggregates shall consist of coarse aggregates, fine aggregates

and filler material (if required). Coarse aggregate is the material retained on an
AASHTO no. 4 sieve and shall consist of crushed rock or crushed gravel. Fine
aggregate is that portion of the total aggregate which passes through

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AASHTO no. 4 sieve and retained on AASHTO no. 8 sieve and should
have at least two mechanical fractured faces.
- When the combined grading of coarse and fine aggregates is deficient in
material passing the AASHTO no. 200 sieve, filler material is used. Each
aggregate ingredient shall be heated and dried at temperature between 160°C to
170°C.
- Asphalt used shall be asphalt cement grade 60-70 and shall conform to the
requirements of AASHTO designation M20. The percentage of asphalt cement by
weight to be added to the aggregate shall be 3.80 ± 0.5% of the total mix for
bituminous base course and 4.20 +/- 0.5% of total mix for wearing course.
Asphalt cement shall be heated within a temperature of 146°C to 156°C at the
time of mixing.
- The bituminous mixture shall be spread and finished to crown and grade by
automatically controlled bituminous pavers. The thickness of the spread shall be
such that after rolling thickness of the compacted bituminous material shall be:
• Base course 40mm

• Wearing course 40mm

(f) Tack Coat:
Tack coat shall not be applied when the ambient temperature is less than 13°C, nor
during rain fog, dust storms or other unsuitable weather. Tack coat consists of
application of bituminous material on the prepared bituminous base course
and binder course. The material to be used for the tack coat shall conform
to the following kind, grade and specifications.
• Emulsion asphalt, grade SS-1H conformity to the requirements of
AASHTO M140.
• The bituminous material for the tack coat shall be applied in quantities
of not less than 0.3litres/m2 and not more than 0.6litres/m2.

4.3 Testing

1- Testing shall be carried out by the CONTRACTOR in accordance with the

standards and as per the instructions of COMPANY which includes, but not
limited to th following :-
2- The minimum type of testing on materials to be used on bituminous concrete
paving is given in the table below. Frequency of testing shall be one sample every
1000m3 for grading, plasticity index, sand equivalent, maximum dry density,
CBR, loss by abrasion.

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Test Standard Limit

Sampling AASHTO T2 -

Classification AASHTO M145 -

Los Angeles Abrasion AASHTO T96 (ASTM 40 max.

C131)
Soundness (Sodium Sulphate AASHTO T104 12max.
Solution) (ASTM C88)

Soundness(Magnesium AASHTO T104 16 max.

Sulphate Solution)
Sand Equivalent for Aggregate AASHTO T176 (ASTM 40 max.25 min
Sub-base D2419)

Liquid Limit AASHTO T89 (ASTM 25 max.

D4318)

Plasticity Index AASHTO T90 6 max.

(ASTM D4318)
Test for Organic Materials BS 1377 Test 8 No organic

Classification AASHTO M145 -

Los Angeles Abrasion AASHTO T96 (ASTM C131) 40 max.

Moisture-Density Relationship AASHTO T180 As specified hereinafter

Field Density AASHTO T191 (ASTM D1556) 100% min.

Linear Shrinkage AASHTO T92 3% max.

Friable Particles AASHTO T112 0.25% max.

Sulphate Content BS 1377 0.5% max.

Chloride Content BS 812 1% max.

Flakiness Index BS 812 35% max.

Elongation Index BS 812 35% max.

AASHTO T180 As specified hereinafter

Compaction test
CBR at 100% of best proctor AASHTO T193(ASTM D1883) As specified hereinafter
density (96 hr. soaked)
Modified

Sieve Analysis AASHTO T27 As specified

T11, T88
hereinafter

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3) Testing of Sub-grade and Sub-base

- Moisture density test in accordance with AASHTO T180 method D to
determine the maximum density.
- Compacted density which shall not be less than 98% of MDD.
4) Testing of Bituminous paving
• Bituminous Material:
The CONTRACTOR shall supply the COMPANY with a current test
certificate from the suppliers with each consignment of asphalt cement showing
that it complies with the requirements of AASHTO Standard Specification
M20. In addition at least one penetration test in accordance with
AASHTO Standard Specification T49 and one ring ball test shall be carried out
on site on each consignment. If any of these tests shows that the asphalt
cement does not comply with the specified requirements, the entire consignment
shall be rejected.
• Aggregates:
One sample for each stockpile every 1,000 m3 shall be taken and all the tests
mentioned in the table above shall be performed.
• Bituminous Mixtures:
One sample mixture of each day’s production or at every 200 tons shall be
tested for extraction, grading, density and stability.
Loss of Marshall Stability shall be tested at least every 10,000 tons.
Depth of paving taken from 10cm diameter core samples at every 300 meter length
of road in accordance with AASHTO T166.
Road density to be tested from 10cm diameter core samples at every 300 meter
length of road which shall be equal or greater than 98% of the marshall density.
4.4 Sub-Grade
4.4.1 Preparation of Sub-Grade

Sub-grade shall be free of unsuitable materials and compacted to an even firm

foundation. The finished formation shall be to the levels, falls and shape
required, be kept free of surface water wherever practicable, and be free of ruts
and ridges and all deleterious matter.
Prior to placing fill or after cutting to level, the sub-grade shall be proof-rolled for
the full extent of the road width including any embankments.
Any soft spots, irregularities or depressions that develop in the surface of any
layer, shall either be corrected by loosening the surface of such areas and adding
further material, or by removing the material in such areas and replacing with
further approved material, and re-compacting so that the surface is smooth and
uniform and follows the profile of the finished formation.
At all locations of roadway cut where, in the opinion of COMPANY, unsuitable
material is found, or where the sub-grade is not homogeneous, roadway cuts shall
be excavated to a minimum depth of 300mm below sub-grade elevations. The cut

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foundation shall be compacted to a depth of 300mm to achieve 98% of the MDD.

Sub-grade material (gatch or granular material) shall be placed on the cut
foundation and compacted to the required density. After compaction, the sub
grade surface shall conform to the grade and typical section shown on the
drawings.
The surface of the grading plane at any point shall not vary more than 2cm above
or below the grade established for 3 locations maximum each 100m interval.
In the event of “heave” (i.e. visible movement of the sub-grade immediately in
front of the compaction roller) occurring during compaction, caused by excessive
moisture, one or more of the following procedures shall be adopted subject to
approval by the COMPANY.
Sufficient time shall be allowed to elapse enabling the excess moisture to
dissipate prior to further construction or compaction being carried out.
The affected material shall be removed and approved alternative
construction layers substituted.
Any surface area of the layer which is too high shall be graded off, scarified
and re-compacted to the full depth of the affected layer. Any surface area of the
layer which is too low shall be scarified and corrected by the addition of suitable
material of the same classification and moisture content or other approved material
laid and compacted in accordance with the above.
Sub-grade that does not conform to all the above requirements shall be reshaped
to conform to the specified tolerances, and re-compacted at the CONTRACTOR’s
expense. Where material fails to meet the required (98% MDD) density the sub-
grade shall be improved by replacement.
Frequency of testing shall be to discretion of the COMPANY, but not less than one
in situ density test per each 1000m2.

4.4.2 Protection of Sub-grade

The prepared sub-grade shall be protected from all forms of traffic during
construction and any damage to the sub-grade shall be made good by
CONTRACTOR prior to laying the sub-base.
The sub-grade once prepared and ready to receive the sub-base must be kept dry
at all times. Rainfall, if any must be cleared promptly into suitable temporary
drains and the prepared sub-grade covered with waterproof sheeting.

4.5 Sub-Base

4.5.1 Preparation of Sub-base

The sub-base shall consist of crushed stone base laid on sand and gravel bedding
compacted to not less than 98% of the maximum density determined in
accordance with BS 1377 and shall have a soaked California Bearing Ratio
(CBR) of at least 80% when tested in accordance with ASTM D1883.
Frequency of testing shall be to discretion of the COMPANY, but not less than one
in situ density test per each 500m2.

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The surface on completion of compaction shall be well closed, kept free from
movement under compaction plant and free from ridges, cracks or loose
material.
The finished surfaces of the sub-base shall not vary at any point more than 10mm
above or below the grade established. The sub-base shall be maintained in a
condition satisfactory to receive any subsequent base or surfacing material.
Sub-base which does not conform to all the above requirements shall be reshaped
or reworked, watered and thoroughly re-compacted to confirm to the specified
requirements at the CONTRACTOR’s expense.
Thickness and extent of the sub-base shall be in accordance with the standard
drawings.

4.5.2 Material

The bedding layer material shall be sand and gravel mixture and the base
material shall comprise crushed stone. Material for sub-base shall conform to the
following gradation.

US Sieve Size mm % Passing

¾ inch 19.05 90 – 100

3
/8inch 9.52 50 - 80

No. 4 4.76 35 – 55
No. 30 0.595 10 – 30
No. 200 0.074 2-9

4.5.3 Construction

The bedding material shall be laid to level but not compacted. The formation of the
sub-base will be by placing 300mm granular material obtained from source
approved by the COMPANY over the sub-grade.
The sub-base shall be placed and compacted in two layers, each layer not
exceeding 150mm compacted thickness. Levelling, grading and compaction shall
be carried out for the full width from the sides to the centre.
Under no circumstances, the sub-base shall be dumped in a pile on the sub-
grade.
All material to be handled so as to avoid segregation, segregated materials shall
be remixed until they become uniform.
Rolling should be carried out with watering (approximately 15-25 litres per
square metre).As a general guide line, compaction shall be carried out as
outlined in the table below.

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Minimum Number of
Type of Roller Weight Tonne Passes Base Material Minimum Number of Cement
Passes Blinding Layer
**

Rubber Tyred 16 10 20
Combined 16 6 12
Vibrating 16 4 8

** - Shall be based on the result of field compaction trials.

The top layer of base material shall be blinded with small nominal sized crushed
stone and shall be compacted, using a 10-12 tonne smooth wheeled roller.
The surface of the top layer of base material should be sprayed with a bitumen
prime coat at a rate of 2-3 litres per square metre, prior to laying the blinding
layer.
4.6 Bituminous Concrete Design & Laying

1. CONTRACTOR to design Bituminous Concrete mix on the basis of Marshall

Test procedure.
2. The job mix formula in line with the grading tables indicated below shall be
prepared by the CONTRACTOR in Laboratory under the supervision of the
COMPANY.
3. All mixtures shall conform to the approved job mix formula.
4. Paint contact edges of abutting concrete walls, catch basins, concrete
curbs, up to the top of elevation of the asphalt surface course with a thick coat
of joint painting material before paving mixture is placed against them.
5. Apply bituminous prime coat before asphalt base course is laid.
6. Asphalt cement shall be heated within a temperature of 146°C to 156°C at the
time of mixing.
7. Asphalt concrete mix shall be transported in clean vehicle and shall be
covered.
8. All mixtures shall be delivered to the automatically controlled pavers at a
temperature of not less than 146°C.
9. The mixed material shall, as soon as possible after arrival on site, be
supplied to the pavers and laid out without delay.
10. The rate of delivery of material to the pavers shall be so regulated as to
enable the pavers to be operated continuously.
11. Materials shall be laid in accordance with the laying recommendations in BS
594.
12. Uniformly compress asphalt mixture by rolling as soon after being spread, as it

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will bear the roller.

13. The layers shall be compacted by means of approved compacting
equipment progressing gradually from the outside towards the centre with each
succeeding pass uniformly overlapping the previous pass. Rolling shall
continue until the entire thickness of each layer is thoroughly and uniformly
compacted to the specified density. Rolling shall be accompanied by
sufficient grading in a manner to ensure a smooth surface free from ruts or
ridges and having the proper section and crown.
14. Placing of mixture shall be as continuous as possible.
15. Carefully construct, form, bond and seal longitudinal, transverse and other
joints to provide a smooth riding surface. Carefully join the work of successive
days to insure a thorough and continuous bond between the two surfaces.
16. Except when a board or canvas rope is used to form transverse joints, cut back
the edge of the previously laid coarse to its full depth to expose a fresh surface,
paint the contact edge of asphalt with a thin coat of joint painting material, after
which the hot mixture shall be placed and raked to a proper depth and grade.
17. Carefully employ hot smoothers and tampers to heat up the laid pavement
sufficiently, and without burning, to insure a proper bond. Before placing new
mixture against laid pavements, contact surfaces of joints shall be painted
with a thin uniform and continuous coating of joint painting material.
18. Consolidate asphalt paving by rolling with a three wheeled or rando power
driven roller of not less than 4.5tons (5 tons).
19. Before laying asphalt wearing coarse, bituminous tack coat shall be
applied.
20. Pavement edges shall be trimmed and tamped to a clean straight line. If
screeds are used, adequately stake in place in order to provide straight, neat,
clean and curved lines as shown. Remove same after pavement is laid and
make good sod or grounds, up to the edge of the new paving.
21. Surface of finished pavement shall be free from depressions in excess of 3mm
(1/8”) as measured by a 3m (10 foot) straight edge.

4.7 Types of Bituminous Concrete Mixes

The types of bituminous concrete mixes shall be as specified on the drawings and
shall conform to the compositions shown in table.
A minimum of 1.5% hydrated lime (by weight of total aggregate) shall be added
to all types of asphalt concrete mix aggregates. The actual amount of hydrated
lime and water to be added shall be established in the approved Job Mix Design.
A minimum of 40% of the fine aggregate used in Wearing Course mixes shall be
crushed sand.
The aggregate material for bituminous concrete shall be combined so as to be
well graded within the limits given in table below of these specifications.

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Combined gradations which approach maximum limits on some sieves and

minimum limits on other sieves are not acceptable

Table for Composition of Asphalt Concrete Mixes

Percent by passing weight

Type 1 Base Type II Binder or Type III Wearing

Course leveling course Course

1 – ½ inch 100 - -
1 inch 72 -100 100 -
3/4 inch 60 - 89 82 - 100 100
½ inch 46 - 76 60 – 84 66 – 95
3/8 inch 40 -67 49 – 74 54 - 88
No. 4 30 - 54 32 -58 37 - 70
No. 8 22 – 43 23 – 45 26 – 52
No. 16 15 - 36 16 – 34 18 - 40
No. 30 10 - 28 12 – 25 13 – 30
No. 50 6 - 22 8 – 20 8 - 23
No. 100 4 – 14 5 – 13 6 – 16
No. 200 2-8 4-7 4 – 10
Asphalt 3.5 – 5.0 4.0 – 6.5 4.5 – 6.5
Cement ( % by
weight of total
aggregate)

4.8 Design Criteria

The Marshall Method Mix Design (Asphaltic Institute Manual Series MS-2) shall
be used in designing the bituminous concrete mixes. Mechanically
operated compaction equipment shall be used. The indicated number of
blows is for equipment which rotates the sample during compaction. Additional
blows giving equivalent results will be necessary for a compaction unit having
satisfactory base which does not rotate the sample during compaction. All of
the criteria shown in table below, not stability alone, shall be considered in
designing and evaluating each type of mix. The optimum bitumen content
determined by the Marshall Method shall be used in prepared specimens
for the Immersion Compression (AASHTO T165) test.

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Properties Bituminous Bituminous Bituminous

Base Course Binder Wearing Course
Course
Number of Compaction
blows each end of 75 75 75
specimen by freely held
Marshall hammer
Stability (Marshall) minimum kg
900 1300 1500

Flow (Marshall) mm 2-4 2-4 2-4

Stiffness minimum Kg/mm 400 450 450

Percent air voids 4-8 4-8 4-8

Percent voids in mineral
aggregate, minimum % 13 13 13
(V.M.A)
Percent voids filled with
asphalt cement 60 – 70 60 – 70 60 – 70
Loss of Marshall Stability by
submerging specimens in
water at 60 degrees
centigrade for twenty four
(24) hours as compared to Max 25% Max 25% Max 25%
stability measured after
submersion in water at 60
degrees C for twenty (20)
minutes

4.9 Job Mix Formula and Allowable Tolerances

The CONTRACTOR shall submit for approval a proposed Job Mix Formula
together with all applicable design data at least one month prior to commencement
of the work. The Job Mix Formula shall give a combined gradation showing a
single definite percentage passing each sieve as well as a percentage of each
material to be used in the mix.
The Job Mix Formula will also establish the mixing temperature and compaction
reference density.
The COMPANY will test samples of the materials proposed for use in order to
check their quality and to check the proposed mix design.
No asphalt works will be allowed to commence before the CONTRACTOR receives
written approval from the COMPANY for his Job Mix Formula.
Approval by the COMPANY on the Job Mix Formula shall in no way relieve the

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CONTRACTOR of his responsibilities and obligations stipulated in the Contract,

and the CONTRACTOR shall be responsible for the soundness of the asphalt
paving mixes and the satisfactory execution and performance of the asphalt
paving courses.
After the Job Mix Formula has been established and approved, all mixes furnished
shall conform thereto within the following tolerances:
• Passing Sieve No. 4 and larger: ± 5.0%
• Passing Sieve between No.4 and No. 200: ± 4.0%

• Passing Sieve No. 200: ± 1.5%

• Ashpalt Cement: ± 0.4%

• Temperature of Mix when emptied from mixer: 10°C

4.10 Sampling and Testing of Bituminous Concrete Mixes

Samples of loose bituminous concrete mix shall normally be taken behind the
pavers before compaction and shall be obtained in accordance with AASHTO
T168. Samples of compacted bituminous concrete shall be obtained by coring in
accordance with Method B of AASHTO T230. Determination of Bitumen Content
and extraction gradation may be performed on either loose or compacted
samples in accordance with AASHTO T164 and AASHTO T30 except that the
mass of mineral matter in the total volume of the extract shall be determined using
a bituminometer or other equipment and procedures which give equally
satisfactory results. The presence of a satisfactory amount of hydrate lime shall
be determined in accordance with “Test Procedure for Detection of Hydrated
Lime in Loose Asphalt Mixes or Cores”. The specific gravity of the compacted
asphalt concrete cores will be measured in accordance with AASHTO T166.

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5.0 CONCRETE PAVING

Reinforced concrete pavings shall be provided in areas where movement of
vehicles/spillage of liquid is expected. The requirement of such paving will be
shown in the relevant project drawings.
All concrete materials and workmanship shall be in accordance with the
Specification for Concrete Works TGE Doc.No.10/063/003-FGS-1600-002.
Concrete grade shall be C40 with fabric.
Mesh fabric reinforcement shall comply with BS 4483. The overlap between mats
of fabric shall not be less than 250mm.
If deformed bars to BS 4449 are used for reinforcement, they shall be spaced at
not more than 150mm centres, and end laps shall be not less than 40 bar
diameters.
Steel fibre reinforcement may be used with the agreement of the COMPANY, and
in accordance with manufacturer’s instructions.
The sub-grade shall be prepared and compacted as mentioned in this document.

5.1 Granular Sub-base

A granular sub-base, minimum 300mm thick shall be provided on top of the sub
grade.
The granular material shall be natural sands, gravels, crushed rock or crushed
slag. The material shall be well-graded and lie within the following grading
envelope:

Sieve Size passing % by mass

75 mm 100
37.5 mm 85-100
20 mm 60-100
10 mm 40-70
5 mm 25-45
600 microns 8-22
75 microns 0-10

The material passing the 425micron sieve, tested in accordance to BS 1377, shall
have a plasticity index of less than 6.
The sub-base shall be compacted in layers to an average density of 98% of
maximum dry density in accordance with the project Specification for Site
Preparation and Earthworks with no individual test achieving less than 90% of
maximum dry density.
A 0.25mm thick polythene sheeting shall be laid flat, without creases, on the
sub-base. Overlaps shall be at least 300mm.
Foundation plinths penetrating the paving shall be isolated from the paving by
30mm thick pre-moulded joint filler, caulked with elastomeric oil resistant
sealant.

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5.2 Joints in Concrete Paving

Expansion joints shall be placed at locations proposed by the

CONTRACTOR and agreed with the COMPANY. Maximum spacing of
expansion joints shall be 12m.
Expansion joints shall be provided with load transfer dowels installed in
accordance with the project drawings. All expansion joints shall be made
up with a maximum of 30mm thick pre-moulded joint filler and an
elastomeric oil resistant sealant.
Expansion joints shall be straight and vertical through the full thickness of
the slab and shall occur at high points of paving where possible.
The pre-moulded joint filler shall be securely held in position during
spreading and compaction of the concrete.
Construction and contraction joints shall be at locations proposed by the
CONTRACTOR and agreed with the COMPANY.Construction/contraction
joints shall be placed at maximum spacing of 4m.
Contraction joints may be wet formed or sawn after concreting.
Before sealing joints, any accumulated dust or grit shall be removed from
the groove. Joint sealing compound shall be prepared and applied in
accordance with the manufacturer’s instructions and shall fill the groove
completely.
To minimise the opening of lateral movement joints due to shrinkage of
concrete during curing, alternate slabs shall be initially cast and cured.
On completion of curing, the remaining slabs can be cast to fill in the
spaces between the slabs.

5.3 Quality Control

Concrete work Quality Control shall be in accordance with the Project Specification
for Concrete Works.Earthworks Quality Control shall be in accordance with
the Project Specification for Site Preparation and Earthworks.

5.4 Tolerances

Except where otherwise shown on drawings, the following tolerances after

completion of the concrete work represent acceptable limits. All work beyond
these limits may be rejected.

Type of Irregularity Tolerance (mm)

Departure from line ±5

Departure from level ±5

Deviation from 3m straight edge on section ±5

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5.5 Buried Cable Routes

The routes of direct buried cables if any through concrete paved areas shall be
identified by red concrete. The latter shall be made by sprinkling an approved
pigment on top of the wet concrete.

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6.0 GRAVEL ROAD

6.1 General

The work consists of furnishing, placing and compacting gravel surface, base and
subbase courses in conformity with the lines, grades, thicknesses and typical
sections shown on the plans, or as determined by field conditions for Off-Plot patrol
roads and road along pipeline route.

6.2 Material Requirements

Provide materials for the road gravel surface, base, and subbase courses that
consist of Sand and Gravel, approved Blast Furnace Slag or Stone that meet
the requirements contained herein. Provide materials well graded from coarse to
fine, and free from organic or other deleterious materials.Any gravel material will
be rejected if it is determined to contain any unsound or deleterious materials.
Gradation - Perform sieve analysis in accordance with the AASHTO procedures T
27, T 88 or T 311. Report the following sieves for all tests: 75μm, 425μm, 6.3
mm, 12.5 mm, 19.0 mm, 25.0 mm, 37.5 mm, 50 mm, 75 mm.
Provide material meeting the gradation limits from Table 1.

Table 1: Percent passing by weight of gravel materials

A
Sieve B (Base) C (Sub-base)
(Surface)
75 mm (3”) - - 100
50 mm (2") - 100 -
37.5 mm (1.5”) - 85-100 70-100
25.0 mm (1") 100 - -
19.0 mm (3/4") 85-100 - -
6.3 mm (1/4") 50-75 30-50 30-55
425 μm (#40) 15-35 5-20 5-25
75 μm (#200) 8-15 0-5 0-8

Soundness - Material for the road gravel surface, base, and subbase courses
will be accepted on the basis of Magnesium Sulfate Soundness Loss after four (4)
cycles performed according to Table 2.

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Plasticity - Determine plasticity using either of the following methods:

1 . Plasticity Index : The Plasticity Index of the material passing the #40 mesh
sieve shall meet the values in Table 2. Determine plasticity using AASHTO tests
T 89 and T 90.
2. Sand Equivalent -: The sand equivalence of the granular material shall meet
the values in Table 2. Determine sand equivalence using AASHTO test T 176.

Table 2: Test and control limits of gravel materials

Material A B
C (Sub-base)
Properties (Surface) (Base)
Maximum
20 20 25
Soundness loss (%)

Plasticity Index 2-9 0-5 0-8

Sand Equivalent 25-40 >40 >35

Elongated Particles : Not more than 30 percent, by weight, of the particles retained
on a 12.5 mm sieve shall consist of flat or elongated particles. A flat or
elongated particle is defined herein as one which has its greatest dimension more
than 3 times its least dimension. Acceptance for this requirement will normally be
based on a visual inspection.

Fractured Faces : When the COMPANY elects to test for this requirement,
Type A material shall have at least two fractured faces on 50 percent of the stone
particles larger than 12.5 mm or at least one fractured face on 75 percent of the
particles larger than 12.5 mm. Type B material shall have at least one fractured
face on 50 percent of the stone particles larger than 12.5 mm.

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7.0 CONSTRUCTION TOLERANCES

The completed work and the work at each stage shall not deviate from the
levels, falls, thicknesses and alignments required by the drawings or
specifications by more than the following tolerances:

Sub-grade Level +20 mm /-30mm

Sub-base Level ±15 mm
Base course,Binder course
and Wearing course Levels ±6 mm

Local irregularities in Levels for Wearing not more than 3 mm in 3 m Course.

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8.0 ROAD SHOULDERS

The road shoulder shall be constructed using enriched sand/gravel and crushed
stone mixture. Roadway shoulder should be 2’ wide with 2% maximum slop
towards the swale.For all roads, a shoulder area extending from the back of the
curbing to the right-of-way line shall be excavated to a depth of at least 6 inches,
and then backfilled and final graded with not less than 6 inches of topsoil.The
shoulder areas shall be graded so as to slope toward the centerline of the road
where the road is in cut, and away from the centerline of the road where the road
is in fill.The road shoulder layers shall be laid and compacted after each layer of
sub-base has been constructed. After compaction the surface shall be protected
from erosion by spraying with bitumen emulsion.

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9.0 QUALITY CONTROL

1. The moisture content of the material shall be adjusted prior to compaction, by

watering with approved sprinkler trucks or by drying out, as directed by the
COMPANY,to obtain the specified density. Sub-grade/Sub-base shall be
compacted to 98% percent of the maximum dry density as determined
according to AASHTO T180 Method.
2. The moisture content of the sub-grade/sub-base at the time of compaction
shall be within the moisture range of +/-3 of the Optimum Moisture Content.
3. The layers shall be compacted by means of approved compacting equipment.
Any areas inaccessible to normal compaction equipment shall be compacted
by means of mechanical tampers until satisfactory compaction is obtained.
4. Each layer of sub-grade/sub-base course must be completely compacted and
approved by COMPANY prior to the delivery of materials for succeeding layer
of sub-grade/sub-base.
5. Field compaction trials shall be undertaken.

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10.0 SETTING OUT

The basis of setting out will be survey stations, monuments and centreline points
handed over to the CONTRACTOR by the COMPANY not less than 10 days
before the works have begun.
Not less than 48 hours notice shall be given in writing by the CONTRACTOR to the
COMPANY, of intention to set out the works to enable checking arrangements to
be made.
The check shall in no way absolve the CONTRACTOR from his responsibility
of setting out the works correctly.
Where construction of new works requires closure or diversion of existing roads,
details of methods and schedules shall be submitted for approval to the relevant
regulatory authorities, before commencement of the work.

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11.0 PIPE TRACK AND RIG CROSSINGS

At culvert and pipe track crossings the road width shall be continuous. The hard
shoulders shall generally be reduced to 0.5 m on each side of the culvert or pipe
crossing as detailed on the drawings. Safety barriers shall be provided.
The casing pipe shall be so manufactured so as to prevent leakage of any material
except at ends where the ends are left open. The pipe should be installed with
sufficient slack so that it is not in tension.
Casing pipe thickness shall be checked with respect to external loads. The casing
pipe shall be designed to approved Load given by “COMPANY” Casing pipe shall
pipe checked for construction stage stresses also.
Care should be taken to isolate the pipeline crossing installation from
underground conduits carrying electrical wires.
All casing pipes, except those laid longitudinally, shall be sloped not less that 0.3%.

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12.0 ROAD MARKINGS AND ROAD SIGNS

Road markings, where shown on the drawings, shall be hot-applied thermoplastic

road marking. Road signs and markings where required shall be as shown
on the drawings.
Road signs shall be in accordance with the drawing: “Typical details for Road
Marking & Signage”.
Supply and install road signs at locations conforming to Yemen Traffic
Administration Regulation Standards.
Posts shall be minimum 75mm dia. galvanised steel pipes (3mm wall
thickness) fixed on reinforced concrete foundations.
Signs are to be made from aluminium thickness conforming to ASTM B209,
6061 T6.
All borders shall be red non-reflective colour except otherwise shown.
All backgrounds shall be white reflective colour except otherwise shown.
All messages shall be of black non reflective colour except otherwise shown.
Posts are to be painted with alternate black & white, 300mm strips.

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13.0 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS

All works shall be undertaken in a manner such as to eliminate or mitigate risk, so

far as is reasonably practicable, to health and safety of personnel carrying out the
work and to others who may be affected by the work, including the public.
To achieve this, risk assessments must be undertaken and safety precautions
must be put in place and followed in practice.
All personnel carrying out the work must be equipped with appropriate personnel
protective equipment such as safety helmets, safety gloves, safety goggles, eye
protection, overalls and safety boots, etc.
The CONTRACTOR shall ensure that appropriate safe systems of work
are provided, installed and properly maintained.
The CONTRACTOR shall be fully responsible for all safety aspects, including
training of personnel, provision of general and specialist safety etc.
The COMPANY can perform HSE audits to verify the compliance with OMV
HSE standards and procedures.

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