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1.0 INTRODUCTION 1
1.1 Definition 1

2.0 SITE CLEARING 1

2.1 Setting Out 2
2.2 Method of Statement 2
2.3 Plant & Equipment 3

3.0 EARTHWORKS 4
3.1 Setting Out 4
3.2 Site Preparation 4
3.3 Method of Statement 5
3.3.1 Cutting Area 5
3.3.2 Treatment For Cutting Area 7
3.3.3 Embankment Fill 7
3.3.4 Excavation of Unsuitable Material (USM) 9
3.4 Preparation Of Formation 10
3.5 Plant & Equipment 11

4.0 TURFING WORKS 12

4.1 General 12
4.2 Method of Statement 12

5.0 GEOTEXTILE 13
5.1 General 13
5.2 Material 13
5.3 Application 14
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5.4 Fill Foundation Reinforcement With Geotextile 14

6.0 DRAINAGE WORKS 15

6.1 Insitu Reinforced Concrete Drain 15
6.1.1 General 15
6.1.2 Material 15
6.1.3 Method of Statement 15
6.1.4 Inspection Test plan 17
6.2 Block Drain 18
6.2.1 General 18
6.2.2 Material 18
6.2.3 Method of Statement 18
6.2.4 Inspection Test Plan 20
6.3 Subsoil Drain 21
6.3.1 General 21
6.3.2 Material 21
6.3.3 Method of Statement 21
6.3.4 Inspection Test Plan 23
6.4 Reinforced Concrete Pipe Culvert 24
6.4.1 General 24
6.4.2 Material 24
6.4.3 Method of Statement 25
6.4.4 Inspection Test Plan 29
6.5 Culvert Headwalls & Wingwalls 30
6.5.1 General 30
6.5.2 Material 30
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6.5.3 Method of Statement 30

6.5.4 Inspection Test plan 32
6.6 Extension Between RCP and CMP 33
6.6.1 General 33
6.6.2 Material 33
6.6.3 Method of Statement 33
7.0 GABION 35
7.1 General 35
7.2 Material 35
7.3 Method of Statement 35

8.0 STREET LIGHTING 37

8.1 General 37
8.2 Material 37
8.3 Method of Statement 38
8.3.1 Cable Routing along PLUS Highway’s Shoulder 38
8.3.2 Cable Routing inside Concrete (bridge deck) 38
8.3.3 Cable Routing Under Road Crossing 38
8.3.4 Erecting the Lighting Column and High mast at 39
Ulu Bernam R&R, Behrang and Tanjung Malim
Lay Bys, Behrang and Slim River Interchanges
8.4 Plant & Equipment 41

9.0 OPTICAL FIBER 42

9.1 General 42
9.1.1 Optical Fiber 42
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9.1.2 Optical Fiber Cable along PLUS Highway 43

9.2 Material 43
9.3 Method of Statement 44
9.3.1 Ducting Works 44
9.3.2 Ducting At Filling Area 45
9.3.3 Ducting At Cutting Area 47
9.3.4 Installation of Hand holes and Cable 48
Duct (ET and OFC)
9.3.4.1 Installation of handholes Type A or B 48
9.3.4.2 Lay 2 ways 100mm UPVC duct 49
9.3.4.3 Install cabinet plinth 49
9.3.4.4 Install emergency telephone plinth 49
9.3.4.5 Install 50mm & 32mm (tied together) sub-duct 50
9.3.4.6 FC, Jointing, Splicing and Testing & 50
Commissioning Of the System
9.4 Plant & Equipment 50

10.0 SOIL NAILS 51

10.1 General 51
10.2 Method of Statement 51
10.2.1 Reinforcement 51
10.2.2 Slope Preparation 52
10.2.3 Temporary Staging 52
10.2.4 Drilling 52
10.2.5 Installation of Reinforcement 52
10.2.6 Grouting 53
10.2.7 Fitting of soil Nails Anchorage 53
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10.2.8 Soil Nails Stressing / Locking 54

10.2.9 Soil Nails Anchorage Protection 54
10.3 Plant & Equipment 54

11.0 PULL OUT TEST 54

11.1 General 54
11.2 Method of Statement 55
11.2.1 Pull Out Test On Soil Nail 55
11.2.2 Choosing of Soil Nail Position 55
11.2.3 Setting Up of Pull Out Test 56
11.2.4 Test Loading Sequence & Cycle 56
11.2.5 Measurement of Displacement 57
11.2.6 Measurement of Applied Load 57
11.2.7 Terminate Test 57
11.3 Plant & Equipment 57

12.0 HORIZONTAL DRAIN 58

12.1 General 58
12.2 Method of Statement 58
12.2.1 Fabrication 58
12.2.2 Slope Preparation 58
12.2.3 Temporary Staging 58
12.2.4 Drilling 59
12.2.5 Installation of Horizontal Drain 59
12.2.6 Chute Drain 59

13.0 TRAFFIC SIGNAGES AND OVERHEAD GANTRY 60

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13.1 General 60
13.2 Method of Statement 61
13.2.1 Signage with bore footing 61
13.2.2 Signage with RC footing 62
13.2.3 Overhead Gantry 62
13.3 Plant & Equipment 63

14.0 BRIDGES 64
14.1 General 64
14.2 Work Sequences 64
14.3 Method of Statement 65
14.3.1 Temporary works 65
14.3.2 Piling 66
14.3.2.1 Caisson Works 66
14.3.2.1.1 Caisson Pile 66
14.3.2.1.2 Hand Dug Construction 67
14.3.2.1.3 Cassion Excavation 68
Safety Precautions
14.3.2.1.4 Caisson Hole Protection 68
14.3.2.1.5 Worker’s Safety 69
14.3.2.1.6 Safety Equipment 69
14.3.2.1.7 Caisson’s Safety Regulations 70
14.3.2.2 Bored Piling 71
14.3.2.2.1 Scope 71
14.3.2.2.2 Materials 71
14.3.2.2.3 Plant & Equipment 72
14.3.2.2.4 Bored Pile Construction 73
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14.3.2.2.5 Pile in The River 77

14.3.2.2.6 Proposal to treat the conditions where 77
caving is encountered or excess water begins
seeping into bored hole during boring.
14.3.3 Protective Pile (KTM Bridge) 79
14.3.3.1 Equipment 79
14.3.3.2 Construction Method 79
14.3.4 Pile Cap Construction 80
14.3.5 Column Construction 82
14.3.6 Cross Beam 83
14.3.7 Bearing setting 83
14.3.8 Beam Launching 84
14.3.9 Diaphragm Beam 84
14.3.10 Deck Slab Casting 85

15.0 PAVEMENT 86
15.1 Method of Statement 86
15.1.1 Setting Out Of Widened Part of Expressway 86
15.1.2 Testing of CBR Under Existing Emergency Lane 88
15.1.3 CBR Sampling 89
15.1.4 Treatment of Subgrade Under existing 89
Emergency Lane
15.1.4.1 For Cut Area 89
15.1.4.2 For Embankments 89
15.1.4.2.1 Option 1 89
15.1.4.2.2 Option 2 90
15.1.5 Sequencing CBR Under Existing E.L Between 91
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Embankment area & Box Cut area

15.1.5.1 Box Cut 91
15.1.5.2 Embankment Area 91
15.1.5.2.1 Embankment Option 1 91
15.1.5.2.2 Embankment Option 2 91
15.1.6 Removal of Existing subsoil 92
15.1.7 Laying of New Subsoil drain 92
15.1.8 Construction of Temporary Drain 94
15.1.9 Preparation of Subgrade 94
15.1.10 Granular Subbase Type 2 – Lower Subbase 95
15.1.11 Granular Subbase Type 1 – Upper Subbase 96
15.1.12 CRCP saw Cut & CBM3 Removal 96
15.1.12.1 Marking The Line of Cut 96
15.1.12.2 Cutting The CRCP 97
15.1.12.3 Cutting The CBM3 97
15.1.12.4 CBM3 Key Rectification Works 98
15.1.13 Cement Bound Material – CBM 4 99
15.1.13.1 Laying of CBM4 99
15.1.13.2 Field Control 100
15.1.13.2.1 Compaction 100
15.1.13.2.2 Insitu Wet Density 101
15.1.14 Tack Coat 101
15.1.14.1 Spraying Tack Coat 101
15.1.14.2 Field Control – Trial Spray 102
15.1.14.3 Spraying rate 102
15.1.15 Dense Bituminous Macadam – DBM40 102
15.1.15.1 Laying of DBM40 102
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15.1.16 Asphaltic Concrete Binder Course – ACBC 25 103

15.1.17 Asphaltic Concrete wearing Course ACWC 20 104
15.1.18 Stone Mastic Asphalt (SMA) 106
15.1.18.1 Laying of SMA 106
15.1.18.2 Compaction Requirements 107
15.1.19.3 Trial Lay 107
15.2 Plant & Equipment 108
15.2.1 Treatment & Subbase Layers 108
15.2.2 For CBM3 Repair 108
15.2.3 For CBM4 & CBM2 108
15.2.4 For DBM40, ACBC25 & ACWC 20 109
15.2.5 For SMA 109
16.0 ROAD LINE MARKING 110
16.1 General 110
16.2 Method of Statement 110

17.0 SITE RECORDS 111

18.0 SAFETY AND ENVIRONMENTAL 111

1.0 INTRODUCTION
This method statement covers the requirements for overall works from the preparation of
formation level to the finishing works which need to be adopted during the overall
construction activities for widening and strengthening of highways and describes the
controlling elements during the execution of the works.
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1.2 Definition
Project : Third Lane Widening Between Tg. Malim & Slim River (Package 4)
Client : PLUS Expressway Berhad
PMC : Opus International Berhad (Formerly known as Pengurusan Lebuhraya Berhad)

Engineer : Maunsell (M) Sdn. Bhd. (Formerly known as Maunsell, Sharma & Zakaria Sdn. Bhd.)

Contractor : UEM Builders Berhad

2.0 SITE CLEARING

Site clearing generally consists off the cutting and /or taking down, removal and
disposal of everything above ground level, including objects overhanging the areas to
be cleared such as tree branches, except such trees, vegetation, structures or parts of
structures or parts of structure and other things which are designated in the
contract to remain, or be removed by others or which Employer Representative
directs to be left undisturbed.

The material to be cleared usually include but not necessarily be limited to tress,
stumps, logs, brush, undergrowth, long grasses, crops, loose vegetable matter and
structure. The entire road reserve and platform area shall be cleared as described
above, unless otherwise shown on the Drawings and /or directed by the Employer
Representative.
2.1 Setting Out
The right of way (R.O.W) shall be surveyed and set out before any site clearance is
carried out. Wooden pegs shall be used to indicate the surveyed right of way.

2.2 Method of Statement

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 Prior to the commencement of site clearance, the followings shall be carried out
either independently or jointly with the Employer’s Representative
 The right of way (R.O.Ws) shall be surveyed and set out according to the
coordinates stated in the drawings. Refer appendix A.
 Photographs shall be taken for structures, landscaping trees and shrubs, fences.
Telephone and electrical poles and others that are payable under individual
measured item apart from the general site clearance in the bill of quantities.
 The above site clearance items shall be measured according to the method of
measurement jointly with the Employer’s Representative. The location of these
items shall be identified according to the surveyed coordinates or offsets from
the control line (at Emergency Lane) of the proposed alignments in road
construction.
 Prior to demolition of existing buildings (Pump house), a liaison with the
respective authorities to terminate the utilities supply to the buildings shall be
done.
 Prior to removal of landscaping trees and shrubs, a joint inspection shall be
carried out with the local authority.
 Fencing or others that are to be relocated or salvaged shall be carried out
according to the drawings or as per instructions given by the Employer
Representative.
 Solid waste dumpsites shall be predetermined within or outside the site for the
dumping of site clearing materials. The Employer’s Representative or the
relevant authorities shall approve these dumping sites. All burning shall not
allow.
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 All unwanted material shall be piled up and disposed off in a safe tidy manner at
the designated area or outside R.O.W. Maximum distance for dumping area
approximately 5 km from working area. The access road will constructed 4 meter
from working area and will be maintain (graded) within construction period.
 Material designated in the Contract or direct by S.O to be salvaged shall be
carefully removed and stored and shall be the property of the Employer or
Government whichever is specified in the Contract.
 Saleable timber if any shall be trimmed and stacked in accordance with the
requirements of the specification or appropriate Government Agency, in
accessible places within the right of ways.

2.3 Plant & Equipment

A site clearing of trees, vegetation, undergrowth, bushes and minor structure is carried
out by dozers and or hydraulic excavators with dump/licence trucks. Trees that cannot
be felled by the aforesaid equipment shall be felled by using chainsaws.

Major structures that cannot practically be cleared by hydraulic excavators and/or

dozer, these demolition can be carried out using pneumatic tools, explosives and/or
other specialized equipment depending on the size and type of structure.

3.0 EARTHWORKS
3.1 Setting Out
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 Before the commencement of the works, the contractor will be supplied with
information necessary to establish the alignment and levels of the works and need
to re-establishment of any markers found to be missing.
 All survey markers and reference pegs must be preserved except where construction
requires their removal and to be replaced with new reference marker.
 Prior to commencement of any physical work, a licensed surveyor shall be appointed
to carry out demarcation works and establish bench marks on site.

3.2 Site Preparation

 A temporary system for rapid dispersal of water shed on to the earthwork or
completed formation during construction, or which enters the earthworks from any
source shall be devised to prevent water pounding. Where practicable, the water
shall be discharged into an adjacent existing drainage system.
 Adequate means of trapping silt shall be provided on temporary systems discharging
into permanent drainage systems. The arrangements shall be made in respect of all
earthworks including excavation whether for pipe trenches, foundations or cuttings
which will be complying with Environmental Management Plan (EMP).
 When any material is disposed outside from the site, the disposed material shall be
graded to a neat appearance and shall not obstruct natural drainage or cause
damage to highways or property. All precautions shall be taken to prevent any
erosion of the soil on the affected areas.
 All unsuitable material and surplus suitable material shall be run to spoil in tips
approved by the SO.
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 Where the embankment is to be constructed on a slope steeper than 1:10, the

foundation will be excavated in all materials to form benches with horizontal and
vertical faces from which construction of embankment shall proceed. The benching
will be carried out.
 Standard compaction test (Modified Proctor) will be carried out for the proposed
suitable fill material in order to ascertain the maximum dry density (MDD) and
optimum moisture content (OMC).

3.3 Method of Statement

3.3.1 Cutting Area
 The excavation of cutting shall be carried out in accordance with the drawings and
to the slopes, levels, depths, widths and heights shown on the drawings.
 Prior to commencement of the works, our surveyor will use the co-ordinate point of
road alignment and TBM provided by the licensed surveyor for setting out the
extension of cutting in accordance with the cross sections.
 A survey team shall be stationed on site to monitor and control each stage of work.
All the major setting out works will be carried out jointly with the Engineer’s
Surveyor.
 Before commencement of massive cut/fill, the haul roads shall be constructed
based on site requirement and to ensure smooth flow of the plant and to comply as
the requirement as follows :
 Typical construction details of access / haul road
 Schedule of total lengths of access / haul road
 Proposed maintenance of access / haul road
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 The haul proposal to be submitted prior to start work for the approval
 After completion of haul roads, the mass excavation shall be started from the top of
the hills or high ground down to formation levels.
 Slopes in cutting shall be trimmed mechanically to neat and even surfaces in
accordance with the designated gradients. The tolerance for widths of excavations
shall not exceed the dimensions shown on the drawings by more than 300mm.
Erosion protection measures shall be carried out upon completion of each slope.
 The construction of berm drain shall follow closely to the slope trimming and
surface water shall be regulated to the temporary earth drains and eventually
discharged to the silt traps.
 The slope of cutting shall be cleared of all rock boulder or rock fragments which
move when prised by a crow-bar. Any resultant voids in the slope shall be filled up
with class 10/20 concrete or stone pitching.
 Water browser will be used to control the dust to the minimum level on the working
areas and the haul roads.
 Bulk samples of subgrade material shall be obtained in advance of exposure of the
subgrade. The in situ dry density at subgrade level shall be obtained together with
in situ moisture content. The sampling rate shall be 1500m²/point with minimum of
3 per length of cutting.
 A CBR versus moisture content curve shall be plotted for each sample based on the
soaked of CBR of the top face of specimen and compacted with BS 4.5kg hammer in
accordance with the BS 1377 : 1975 Test No. 16. Dynamic compaction method 1 to
achieve the in situ moisture content.
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 The moisture content shall be within range of ±5% of the in situ moisture content
and 5 points one of which shall be the in situ moisture content shall be plotted. The
CBR value for the sample shall be taken as in situ moisture content.

3.3.2 Treatment For Cutting Area

For a length of cutting, the minimum CBR is otained from samples taken and derived as
follows:
 Where the CBR is equal or greater than 5%, no treatment needed to the subgrade.
 Where the CBR is less than 5% but greater than or equal to 3%, the top 300mm of the
subgrade need to remove and replace with selected fill of capping layers in
accordance to Clause 629
 Where the CBR is less than 3% but greater than or equal to 2%, the top 450mm of the
subgrade need to remove and replace with selected fill of capping layers in
accordance to Clause 629
 Where the CBR is less than 2%, the top 600mm of the subgrade need to remove and
replace with selected fill of capping layers in accordance to Clause 629 or as
directed by the Engineer’s Representative.

3.3.3 Embankment Fill

 Fill materials for use in forming embankments shall be the suitable material
obtained from designated excavation area in cuttings or borrow pits.
 Prior to commencement of the works, the selected sample from the source of
cutting or borrow pits shall be sent for laboratory test for Proctor Test (B.S
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1377.713) moisture contain, liquid, limit, plastic limit, Atterberg limits and grading
analysis to determine its suitability for forming embankments.
 Trial compaction shall be carried out at the designated area of the site to determine
the pattern of compaction for each main type of material to be used. This shall
include of compaction plant for each type of material to achieve required
compaction.
 After the required passes for compaction has been accepted, the filling shall be
carried out in layer of the loose depth and shall be compacted by the compaction
plant as used and achieved in the trial areas.
 A CBR versus moisture content curve shall be plotted for each sample based on the
soaked of CBR of the top face of specimen and compacted with BS 4.5kg hammer in
accordance with the BS 1377 : 1975 Test No. 16. Dynamic compaction method 1.
The sampling rate shall be 1500m²/point with minimum of 3 per length of
embankment. The moisture content shall be from ±3% to ±5% of the optimum
determined in above at increments of 2%.
 The CBR value of the sample shall be taken as the minimum derived form its CBR
versus moisture content curve over a range ±3% of the optimum moisture content.
 The degree of compaction will be at least 95% of maximum dry density for the
subgrade final layer (900mm thickness) and 90% of maximum dry density for filling
works below subgrade final layer and it will be determined by using BS 1377.
 The density test shall b carried out in every compacted layer of approx. 250mm
depth and the nos. of test shall be done in accordance with the test plan of the
specification.
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 The requirement for compaction of embankment fill are as follows and shall apply
equally to all clayey, silty, sandy or gravelly materials placed in the embankment.
 The Engineer’s representative will be notified to witness the test and the result sent
to the Resident Engineer for further filling works.
 As for the slope filling works, the filling shall be in layer and with extended one
meter extra for cut back in order to form a compacted slope
 Prior to the commencement of massive cut/fill, the haul roads shall be constructed
with two lanes width traffic and to ensure smooth flow of the plant and machinery
as per item 1.4 Excavation For Cutting.
 Excavators shall be deployed to use for excavation and load the cut material to the
dump trucks for filling. On the filling area, the dump trucks transport the material
to the area and tip from one end. One bulldozer shall be used for spreading the
material in layer and shall not exceed 300mm loose depth as adopted. The vibrating
roller shall be used for compaction.
 On reaching to each berm level, the slope trimming shall be completed prior to
carry out the subsequent filling for the next berm.
 Permanent berm drain needs to be constructed before the access road cut off by the
filling works.
 Erosion protection measures shall be carried out after completion of trimming work
and complying with Environment Management Plan.

3.3.4 Excavation of Unsuitable Material (USM)

 The Engineer has to determine the extension and the depth of soft material to be
replaced before the commencement of the works.
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 Mackintosh probe tests to be used for checking the resistance of the soft ground at
certain interval as directed by the Resident Engineer who shall determine the depth
of soft material to be replaced by the test results.
 A trial pit to be commenced to provide a method of monitoring water table on the
area to determine the top level of granular fill requirement. Dewatering shall be
continued to keep the excavated area dry for filling with granular material.
Minimum period of monitoring water table shall be 24 hours which will be fluctuated
with the wet and dry season.
 The excavator is able to work on the solid bottom of about 4 meter under the soft
ground. The filling is kept close behind the excavation in order to reduce the
possibility or the sides of the excavation slipping in again.
 The excavated material can be dumped outside the embankment with written
consent from land owner approval and within Right of way along the road with
approval from Employer (PLUS).
 Low pressure track bulldozer will be deployed to push the tip granular material in
the required layer for compaction.
 The compaction of all embankment material shall be accordance with the
requirements. All fill material which within 900mm below formation level shall be
compacted to 95% of the maximum dry density as B.S 1377 Test 13 at 500m²/point.
 Before start dumping the excavated unsuitable material at proposed dumping area
(outside R.O.W and inside R.O.W), an approval must be obtained from PLUS.

3.4 Preparation Of Formation

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 Preparation of formation shall be carried out only after completion of any specified
sub grade drainage such as sub-soil drain and table drain.
 Road alignment and level pegs at 10 meter interval to be set out to monitor the
trimming works to the sub grade levels.
 The surface shall be trimmed to the right levels and to the requirement of the
contract.
 The trimmed surface shall be rolled by a few passes of smooth – wheeled roller by a
15 tons vibratory roller.
 All areas of prepare formation shall be approved by the Resident Engineers prior to
the placing of sub – base material. Placing of sub – base shall commence
immediately following such approval.
 The subgrade and formation level for road shall be finished in a neat and workman –
like manner and the widths of embankments and cuts shall be those specified on the
drawings.
 The top surface of the subgrade and formation shall have the required shape, super-
elevation, levels and grades and within plus 10mm and 25mm of the required level.
3.5 Plant & Equipment
i. Excavator - For sample trimming, bulk excavation and loading to
dump truck.
ii. Dump truck- To transport the filling material from the cut area or borrows
pits to from the embankment.
iii. Bulldozer - Ripping and loosening of rock earth. Frequently the
bulldozer is used for pushing and spreading the earth in
layer in layer for compaction.
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iv. Motor Grader - The motor grader can be used spreading of sub grades,
shoulders, ditches and back slopes, maintenance of haul
road.
v. Backhoe - Excavation below existing ground in firm or hard material as in
digging pipe trenches.
vi. Water browser - For dust control on working area.
vii. Compactor - 1) SAKAI CA 25 Vibrating Roller
- Compacting soil
2) DYNAPAC CF 51 Vibrating Roller
- Compacting soil

4.0 TURFING WORKS

4.1 General
Turfing is easiest and most effective way to control and reduce erosion on side slopes of
cut and fill embankment during the earthworks. All turfs shall be cut 300mm square and
75mm thick. They shall consist of healthy dense indigenous cow grass firmly rooted into at
least 50mm of topsoil. The turf shall be free from mimosa, lalang and any other
objectionable plants.

4.2 Method of Statement

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 Topsoil shall be spread and lightly compacted to an even thickness of 50mm.

 Prior to turfing and approved pre-turfing fertilizer with N:P:K of 10:15:10% shall be
worked into the top 50mm of soil.
 Turf shall be delivered for use within 36 hours of cutting.
 The prepared areas shall be closed turfed with no gaps between the turves and
lightly beaten. On the areas require spot turfed, the spot turfed with turves set at
500mm centres in line spaced 500mm apart. The turves in alternating lines shall be
staggered to give a diamond pattern.
 Turf applied on the slopes exceeding 1 on 4 each turf shall be secured with a
wooden peg at least 230mm long driven into ground flush with the top of the turf.
 Regular watering at newly laid turf during dry weather until such time as it is firmly
established.
 Grass cutting shall be carried out when the grass has reached 75-100mm high.

5.0 GEOTEXTILE
5.1 General
Geotextiles have been employed in a variety of ways to reinforce soil or pavement and
provide drainage and erosion control for both highways and railroads.
They serve the following functions :-
i. Filter
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They retain soil in place while allowing water to escape easily to be carried
away by some from of drain.
ii. Drainage
Heavy geotextiles themselves provide channels for carrying water away
from the soil to be drain.
iii. Separator
They prevent dissimilar materials from mixing.
iv. Reinforcement
They add mechanical strength to the soil or pavement system.
v. Armor
They protect the soil from surface erosion or attractive forces.

5.2 Material
 Geotextiles are porous fabrics manufactured from synthetic materials such as
polypropylene, polyster, polyethylene, nylon, polyvinyl chloride, glass and various
mixtures.
 They come in thicknesses ranging from 10 to 300 mils, in widths up to 30ft, and with
permeabilities comparable in range from coarse gravel to fine sand.
 Important difference in properties include specific gravity, strength, strain at
failure, modulus of elasticity, creep resistance to ultraviolet light, chemicals and
biological effects.

5.3 Application
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 Geotextiles can be used in filtration and drainage systems which are used in trench
drains, base course drains, structural drains and pipe wrappings.
 Between natural foundation soils and stone aggregate for paved and unpaved roads,
railroads, parking lots, staging areas, sideworks etc.
 In earth dams to separate rip-rap from shell soil, shell soil from core wall soil, core
wall soil from drainage soils.
 As a waterproofing agent to prevent cracks in existing asphalt pavements from
propagating through the asphalt overlays. Geotextiles have found significant use in
this area of preventing crack.
 For our construction of the highway at the treatment area ,we will using the KET 9
(Mass Kiara) non woven geotextile.

5.4 Fill Foundation Reinforcement With Geotextile

Geotextile can be used to advantage in the construction of low fills over swampy or marshy
areas. It is placed on the weak foundation and overlain with the embankment fill. This
increases the bearing capacity of the foundation and allows a higher fill to be constructed
on it. The use of a fabric in such circumstances has several advantages:-
1) It permits construction of embankments on suitable foundations.
2) It eliminates lost construction line due to failures and delays inherent in
soft ground construction.
3) It result in consideration savings of fill material compared to displacement
construction methods.

6.0 DRAINAGE WORKS

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6.1 Insitu Reinforced Concrete Drain

6.1.1 General
Insitu reinforced drains shall include interceptor or berm drains, roadside roadside drains,
side embankment toe drains, shoulder drains, bench drains, median drains, outfall drains,
cascade drains etc. which are constructed either unlined or lined using cast insitu
concrete.
6.1.2 Material
The concrete shall be grade 25/20 concrete unless otherwise specified and shall confirm to
the requirements of the contract specification.
The reinforcement shall be BRC A6 mesh or otherwise stated in the drawings or
specification.

6.1.3 Method of Statement

 The alignment and levels of the drains shall be provided by surveyor and dimensions
need to be checked by site supervisor.
 Excavation shall be carried out by a backhoe or hydraulic excavator to the required
lines, levels, grades and cross-sections as shown on the drawings or as required by
the Employer’s Representative. Rate of excavation not too far from concreting
works.
 Templates which may be timber or steel and to be provided to ensure the thickness
and slope of the concrete drains. The concrete shall be poured in sections not
exceeding length as specified in the specification and shall be carried out between
end forms in alternate bays. Construction joints shall not be formed in the inverts.
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 All concrete shall be grade 25/20 concrete unless otherwise specified and shall be
batched at the site using concrete mixer or supply by ready – mix batching plants.
Contractor to ensure BRC placed at the right depth and to be laid on spacer blocks.
 Weep holes shall be identified location effected and surface need to be smoothened
or as directed by the Employer’s Representative.
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6.1.4 Inspection Test plan

Point Of
Inspection Responsibilit Criteria / Rate Of Verifying
No Inspection Action
/ Test y Reference Testing Document
/ Test
Alignment Surveyor and UEM /
1. Setting out Clause 108 - Survey record
and level Site Supervisor MSZ
Drawing No : SUBCON
Size / Depth and Construction
2. Site Supervisor W/TMS/4/DG/ - / UEM /
Dimension width Drawing
1.2-1.10 MSZ
Drawing No : SUBCON
BRC / Wire Construction
3. Type Site Supervisor W/TMS/4/DG/ - / UEM /
mesh Drawing
1.2-1.10 MSZ
Drawing No : SUBCON
Concrete Construction
4. Design mix Site Supervisor W/TMS/4/DG/ - / UEM /
grade Drawing
1.2-1.10 MSZ
Lab Drawing No : SUBCON
Mix Construction
5. Concrete Technician / W/TMS/4/DG/ / UEM /
Proportion Drawing
Site Supervisor 1.2-1.10 MSZ
Before Lab SUBCON
Based on design Drainage
6. Slump test pouring the Technician / - / UEM /
mix checklist
concrete Site Supervisor MSZ
Lab
Technician / CSL /
Every day 50cu.m /
7. Cube test Site Clause 2908 Specification UEM /
of batching 50 batch
Supervisor / MSZ
QAQC
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Material Cement Lab Approval SUBCON

8. for Aggregate Technician / Clause 1602 of Specification / UEM /
concreting Sand Site Supervisor material MSZ
6.2 Block Drain
6.2.1 General
Block material shall consist of precast concrete block inverts on mass concrete bases with
brick walls at the site and close turfing on slopes for open drains, or with bricks wall at the
sides and precast concrete cover slabs for closed drains as shown in the drawings.

6.2.2 Material
 Precast concrete block inverts shall be of the slopes and dimensions as shown on the
drawings and shall be of grade 30/10 concrete or unless otherwise specified.
 Mass concrete for bases shall be grade 20/40 concrete or as specified and to the
dimensions and thickness as shown on the drawings.
 Brick walls shall be constructed of approved common bricks lain in mortar. All
exposed faces of brick wall shall be provided with a 19mm thick rendering trowelled
to a smooth hard finish.
 Precast concrete cover slabs shall be cast with class 30/10 concrete to the
dimensions and thickness shown on the drawings. The cover slabs shall be reinforced
as specified in the drawings.
 The sample of material shall be submitted to Consultant for approval.

6.2.3 Method of Statement

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 The precast concrete inverts shall be manufactured using good quality moulds and
the finished product shall be sound and have smooth inside surfaces all to the
approval of the Employer’s Representative.
 Ready made precast concrete inverts maybe used subject to the approval of the
Employer’s Representative.
 Excavation of the trenches shall be carried out by backhoe or hydraulic excavator,
to the required lines, levels, grades and cross-sections as shown in the drawings or
as required by the Employer’s Representative. Rate of excavation not too far from
laying process and base shall be subsequently compacted by plate compactor.
 Mass concrete bases shall be constructed of the dimensions and thickness shown on
the drawings in the excavated trenches and shall be constructed with class 20/40
concrete or as specified. This mass concrete can be either batched by concrete
mixer at site or directly supply from the ready mix batching plants.
 Precast concrete block inverts shall then be laid on the mass concrete bases in
trenches excavated to the lines and levels as specified and jointed to produce a
neat even alignment and gradient. The joints shall be grouted in 1:3 cement/sand
mortar.
 Brickwalls for the sides of block drains shall be constructed of approved common
bricks laid to the thickness and dimensions shown on the drawings. All exposed faces
of brick walls shall be provided with a 19mm thick mortar rendering trowelled to a
smooth hard finish.
 Weep holes and r.c struts shall be installed in the brickwalls as shown in the
drawings.
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 Precast concrete cover slabs shall be laid on the brickwalls of the block drains as
specified on the drawings.

6.2.4 Inspection Test Plan

Point Of
Responsibili Criteria / Rate Of Verifying
No Test Inspection Action
ty Reference Testing Document
/ Test
Alignment Surveyor and Survey UEM /
1. Setting out Clause 108 -
and level Site Supervisor record MSZ
CMP/RC
Supplier
Size / Depth and Drawing No : culvert/ VB
2. Site Supervisor - / UEM /
Dimension width W/TMS/4/DG/SD/1.20 culvert
MSZ
checklist
Lab Technician
Approval Supplier
/ Site
3. Material Precast Block Clause 1602 of Specification / UEM /
Supervisor &
material MSZ
QA/QC
Lab Technician Approval Supplier
Concrete
4 Design Mix / Site Clause 514 of Specification / UEM /
Grade
Supervisor material MSZ
5. Bricks Type Lab Technician Drawing No : Approval Construction Supplier
/ Site W/TMS/4/DG/SD/1.20 of Drawing / UEM /
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Supervisor material MSZ

Subcon /
Compaction & Surveyor and Drawing No : Before Construction
6. Bedding UEM /
Level Site Supervisor W/TMS/4/DG/SD/1.20 laying Drawing
MSZ

6.3 Subsoil Drain

6.3.1 General
This work shall include the supply and installation of subsoil drains constructed in
accordance with the contract specification at the locations and in accordance with the
lines, levels and grades as shown on the drawings and or as directed by the Employer
Representative.

6.3.2 Material
 Porous concrete pipes, clay pipes, HDPE corrugated pipes and Polyvinyl chloride
(PVC) pipes for the subsoil drains shall comply to the relevant contract
specification.
 Filter material use in the construction of subsoil drains shall consist of hard, clean or
crushed rock. The aggregate crushing value of the material shall not exceed 30
percent.
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 The filter cloth shall be geotextile fabric (separator) as specified in the contract
specification.

6.3.3 Method of Statement

 The alignment and levels of the sub soil drains shall be provided by surveyor while
dimensions and grades need to be checked by site supervisor.
 Excavation for subsoil drains shall be carried out all in accordance with the
appropriate provisions of specification.
 Filter cloth shall then be placed to cover the perimeter of the trench excavated,
with the top open to facilitate the placement of filter material and subsoil pipe.
Care shall be taken against damage of filter cloth during the construction stage.
 Filter material shall be placed and uniformly compacted by plate compactor /
rammer and wrapped by geotextile.
 Joints shall be spot mortared as necessary to hold the pipe sections correctly
centered and aligned, but not so as to unduly restrict the infiltration of water
through the joints.
 Slotted or perforated pipes shall be tightly wrapped in filter cloth such that the
entire length of the mortared pipe is covered by at least 2 layers of cloth. All joints
in both layers shall have an overlay of at least 100mm and joints in the outer layer
shall be offset by at least 300mm from joints in the inner layer, all to the
satisfaction of the Employer’s Representative.
 After pipe laying and, if appropriate, wrapping has been approved by the Employer’s
Representative, the remainder of the filter material shall be placed and uniformly
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compacted by a suitable method approved by the Employer’s Representative, to

form a dense, even surround to the pipe as shown on the drawings.
 On completion of filling with filter material, the filter cloth shall be folded on the
top with the required lap. Care shall be taken against contamination of the filter
material during the filling operation and also ensure that the pipe is neither
damaged not displaced.
 Backfill above the filter material shall then be placed and compacted in accordance
with the appropriate provisions of the contract specification.

6.3.4 Inspection Test Plan

Point Of
Inspection Responsibi Criteria / Rate Of Verifying
No Inspection Action
/ Test lity Reference Testing Document
/ Test
Surveyor and
Alignment Survey UEM /
1. Setting out Site Clause 108 -
and level record MSZ
Supervisor
CMP/RC
Drawing No : Supplier
Size / Depth and Site culvert/ VB
2. W/TMS/4/DG/SD/1. - / UEM /
Dimension width Supervisor culvert
11 MSZ
checklist
3. Subsoil pipes Size / Type Site Drawing No : Before CMP/RC Supplier
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culvert/ VB
W/TMS/4/DG/SD/1. / UEM /
Supervisor laying culvert
11 MSZ
checklist
Material
Lab Drawing No :
a) Granular Const. Subcon
4. Technician / W/TMS/4/DG/SD/1. Before
b) Geotextile Drawing / UEM /
For Approval Site 11 laying
c) Subsoil Specification MSZ
Supervisor Clause 2642
pipe
Lab
a) Grading Subcon
Granular Technician / Clause 517
5. b) Specification / UEM /
material Site Properly compacted
compaction MSZ
Supervisor
Drawing No : Subcon
Site Before Const.
6. Geotextile Lapping W/TMS/4/DG/SD/1. / UEM /
Supervisor laying Drawing
11 MSZ

6.4 Reinforced Concrete Pipe Culvert

6.4.1 General
This work comprises the supply and installation of reinforced concrete pipe culverts,
inclusive of excavation, backfilling, jointing, construction of headwalls, wingwalls, aprons
and sumps and channel protection works, all in accordance with the contract specification
and the details shown on the drawings.

6.4.2 Material
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 Reinforced concrete pipes used for the construction of culverts shall meet the
requirements of BS 5911 or Australian Standard Specification A1342 and rubber ring
shall meet the requirement of BS 2494 which to be supplied by same pipe
manufacturer.
 Rebated pipe of diameter 600mm and above shall be internally rebated or otherwise
specified.
 Collars shall be precast with grade 30 concrete and shall be suitably reinforced all in
accordance with the contract specification. The width of the collar shall be not less
than 150mm and the minimum thickness shall be 50mm.
 Rubber rings for spigot and socket pipes shall comply with the requirements of the
contract specification.
 A ratio of 1:3 cement mortar for jointing of reinforced concrete pipes shall conform
to the requirement of the contract specification.
 Bedding material shall consist of grade 15/20 concrete or otherwise specified in the
contract specification.

6.4.3 Method of Statement

 The quality of materials used and the process of manufacture of precast concrete
pipes shall be subject to inspection and approval by the Employer’s Representative.
Pipes shall be subject to rejection if they fail to comply with any of the specified
requirements and in addition if they exhibit any of the following defects at the time
and place of installation:
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i. Fractures or cracks, except for a single crack which does not extend
through the full thickness of the wall.
ii. Defects that indicate imperfect proportioning of the constituent
materials.
iii. Surface defects indicating honey combing or open texture.
iv. Damaged ends or distortion which would prevent making of a satisfactory
joint.
 At the discretion of the Employer’s Representative occasional imperfections
occurring in manufacture or as a result of accidental damage during handling may
be accepted if suitable repairs are carried out with the approval of the Employer’s
Representative and the repaired pipe conforms to the requirements of the contract
specifications.
 Precast concrete pipes for testing shall be selected at random by the Employer’s
Representative. The manufacturer shall carry out the tests in accordance with the
contract specification.
 Pipe culverts which are to be constructed at existing ground level and under an
embankment shall have the fill constructed and compacted to a height of at least
600mm above the top of the pipe or to subgrade level, whichever is the lower, and
then a trench shall be excavated to receive the culvert.
 In areas of soft, spongy or unstable soil where the removal of unsuitable material is
indicated in the drawings, constructed culverts at the existing ground level prior to
the construction of an embankment and in such cases the procedure shall be as
follows.
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i. The unstable shall be excavated to a depth directed by the Employer’s

Representative and over a width of at least 1.5 time of pipe diameter or
either side of the pipe. The excavated area shall be backfilled with
approved granular material compacted to give adequate support to the
pipe unless other special construction methods are indicated on the
drawings. The prepared surface shall provide a firm foundation of uniform
density throughout the length of the culvert to receive the pipe bedding.
ii. Culverts which are to be constructed below existing ground level shall be
laid in a trench excavated from that level. Excavation of the trench shall
be to the width shown on the drawings and this width shall not be
exceeded below a level of 300mm above the crown of the pipe. Above
that level the trench may be battered subject to the Employer’s
Representative’s approval. The trench bottom shall be trimmed true to
line and level and soft spots and any over break dealt with as described in
the contract specification. Particular care shall be taken where excavation
is in rock to ensure an even surface to the bottom of the trench.
 Where granular bedding is specified the granular bedding material shall be laid on
the prepared trench bottom or foundation to the height of the underside of the
pipe, forming depressions where necessary to accommodate the pipe spigots when
spigot and socket point are used. The material shall be carefully compacted and the
culvert assembled and jointed to line and level.
 Pipe shall not be laid until their class, size and length called for at each location
have been approved by the Employer’s Representative.
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 Concrete pipe shall be laid to line and level, each pipe being separately aligned.
Pipes shall be laid in an upstream with the sockets leading upstream and shall rest
an even foundation for the fill length of the barrel with socket holes being formed in
the bottom of the trench foundation.
 Rubber ring joint shall be installed strictly in accordance with the manufacturer’s
instructions. Prior to jointing, rubber rings and jointing surfaces shall be cleaned of
all contaminants.
 The spigot of each pipe shall be inserted concentrically in the socket of the one
previously laid, and the pipe adjusted and fixed in its correct position with the
spigot accurately centered in the socket care shall be taken to see that the rubber
ring is adequately compressed to seal the joint.
 All culverts constructed in trench, backfilling with suitable material or bedding
material as specified placed in even layers equally on either side of the pipe to a
height of 600mm above the crown of the pipe.
 This shall be placed in layers not exceeding 150mm thick and duly compacted where
culverts are constructed at existing ground level in the open the surround material
shall be placed and compacted in layers not exceeding 150mm brought up evenly on
both sides of the pipe to a height of 600mm above the crown of the pipe as shown
on the drawings.
 Above this level suitable material shall be placed in accordance with the contract
specification and FDT has to be taken randomly.
 Heavy earth moving and compacting equipment shall nor be permitted to operate
closer to the culvert than 1.8 metres until a minimum of 600mm of backfill, sub
base or base course has been placed and compacted over the crown of the pipes or
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otherwise specified. Light vehicles and compacting equipment may operate within
this limit subject to 300mm cover being maintained around the pipe and subject to
the approval of the Employer’s Representative.
 The alignment, skew, gradient and levels to be peg by surveyor. Survey works should
be carried out to determine the longitudinal profile and layout of the stream which
need to be plotted and superimposed with the cross section of the proposed road
and it will be submitted to Engineer’s Representative for perusal and approval.
 An excavator need to be deployed for excavation of culvert and for lifting purposes.
 In order to maintain dry working area during construction, the contractor need to
pump out all stagnant water and temporary water channel need to provide.
 The foundation of existing structure will not be disturbed and if any disturbance
during construction, the contractor need to replace 1m extended foundation from
the disturbed area.
 Any extension of culvert need to be hacked (if any) by hacking machine or hand
breaker or saw cutting.
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6.4.4 Inspection Test Plan

Point Of
Inspection Criteria / Rate Of Verifying
No Inspection / Responsibility Action
/ Test Reference Testing Document
Test
Alignment and Surveyor and Site
1. Setting out Clause 108 - Survey record UEM / MSZ
level Supervisor
CMP/RC
Drawing No :
Diameter / culvert/ VB Supplier /
2. Type Site Supervisor W/TMS/4/DG/ -
Class culvert UEM / MSZ
GE/1.1 – 1.3
checklist
Material – Clause 519
Site Supervisor / Before SUBCON /
3. RCP, Rebars, Approval Clause 2629 Specification
lab technician commencement UEM / MSZ
Concrete Clause 1602
Drawing No :
Size & As required by Construction SUBCON /
4. Rebars Site Supervisor W/TMS/4/DG/S
dimension Engineer drawings UEM / MSZ
D/1.8 – 1.23
Drawing No :
Site Supervisor / Before Construction SUBCON /
5. Concrete Design mix W/TMS/4/DG/S
lab technician commencement drawings UEM / MSZ
D/1.8 – 1.23
1) Slump
Clause 2908 Before casting
2)compaction SUBCON /
6. Conc. Works Clause 1610 During casting Specification
3)Mixing UEM / MSZ
Clause 1602 Before casting

Cement As required by SUBCON /

7. Design mix Site Supervisor Clause 2618 Specification
Mortar grade Engineer UEM / MSZ
Cube Site Supervisor / 20m³ or 20 SUBCON /
8. Strength Clause 2908 Specification
sampling lab technician batch/sample UEM / MSZ
Drawing No :
Bedding Construction SUBCON /
9. For Approval Site Supervisor W/TMS/4/DG/S
Material drawings UEM / MSZ
D/1.17
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Drawing No :
Size, Type & Construction SUBCON /
10 RCP Site Supervisor W/TMS/4/DG/S Before laying
Jointing drawings UEM / MSZ
D/1.17
Drawing No :
1) Size Construction SUBCON /
11 Rubber Ring Site Supervisor W/TMS/4/DG/S Before laying
2) installation drawings UEM / MSZ
D/1.17

6.5 Culvert Headwalls & Wingwalls

6.5.1 General
This work shall include the supply of all materials, labour and machineries required for the
construction of the headwall / wingwalls / apron at each end of the culvert in accordance
with the contract specification, at the locations, to the lines, levels, grades and
dimensions as shown on the drawings and / or as directed by the Employer’s
Representative.

6.5.2 Material
 The grade of concrete shall be as specified on the drawings and shall conform to the
requirements to the contract specification.
 Reinforcement bars shall be according to the drawings and shall conform to the
requirements of the contract specification.

6.5.3 Method of Statement

 Construction of headwalls shall not commence until two weeks after the completion
of the embankment fill to formation level or unless otherwise approved by the
Employer’s Representative.
 Reinforcement shall be cut and bend according to the confirmed bending schedule
of bars, drawings and requirement of contract specification.
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 Reinforcement shall be placed and maintained in the positions indicated in the

drawings, to the required tolerances. Reinforcement binding wire shall be No. 16
gauge soft annealed iron wire unless otherwise specification.
 All bar reinforcement shall be placed, supported and secured before the beginning
of concreting operations.
 The reinforcement shall be checked and approved by the Employer’s Representative
before placement of concrete begins.
 Formwork shall be constructed to the correct position shape, profile and dimensions
as designated and approval by the Engineers and Employer’s Representative
respectively.
 The formwork shall be carried out according to the requirements of the contract
specification and drawings.
 Concrete shall be mixed by machine at site or directly supply from ready mix
batching plants. The concrete shall be deposited carefully in its intended position as
quickly as possible after being mixed.
 All concrete shall be compacted by the use of poker type vibrators until a dense
solid mass without voids is obtained.
 The formwork shall be dismantled and removed from the cast concrete after such
period as required by the condition of the maturing concrete the specification.
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6.5.4 Inspection Test plan

Point Of
Inspection Criteria / Rate Of Verifying
No Inspection Responsibility Action
/ Test Reference Testing Document
/ Test
Alignment Surveyor and Survey UEM /
1. Setting out Clause 108 -
and level Site Supervisor record MSZ

Drawing No : CMP/RC
Supplier
Size / Depth and W/TMS/4/D culvert/ VB
2. Site Supervisor - / UEM /
Dimension width G/SD/1.12, culvert
MSZ
checklist
1.18 – 1.19
Drawing No :
As required SUBCON
Size & W/TMS/4/D Construction
3. Rebars Site Supervisor by / UEM /
dimension G/SD/1.12, drawings
Engineer MSZ
1.18 – 1.19
4. Concrete Design mix Site Supervisor Drawing No : Before Construction SUBCON
commence drawings / UEM /
/ lab W/TMS/4/D
ment MSZ
technician G/SD/1.12,
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1.18 – 1.19
Cement As required SUBCON
5. Mortar Design mix Site Supervisor Clause 2618 by Specification / UEM /

grade Engineer MSZ

Site Supervisor 20m³ or 20 SUBCON

Cube
6. Strength / lab Clause 2908 batch/sam Specification / UEM /
sampling
technician ple MSZ

6.6 Extension Between RCP and CMP

6.6.1 General
The work comprises supply of all materials, labour, machineries required for the
installation of reinforced concrete pipe culverts, construction of junction box, headwalls,
wingwall, aprons, sump and channel protection works.

6.6.2 Material
 Reinforced concrete pipes used shall be supplied by manufacturers approved by
Employer’s representative. Rebates pipes of 600mm diameter and above shall be
internally rebated or otherwise specified.
 Rubber rings for spigot and socket pipes shall comply with the requirements of the
contract specification. Cement mortar of 1:3 ratio, for jointing of reinforced
concrete pipes shall confirm to the requirement of the contract specification.
 Bedding material shall consist of grade 15/20 concrete or otherwise specified.
Reinforced bars provided shall be according to the construction drawings.
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6.6.3 Method of Statement

 Existing headwall receiving new concrete surface to be roughened and drilled
150mm depth, to install 8mm diameter, 305mm length rebar at 200mm spacing both
side.
 The rebar installation shall be done according to the Hilti Rebar Fastening Guide.
The rebar shall be fastened with Hilti HIT-HY150 system which shall be done strictly
to the manufacturer’s instruction.
 After the curing process is complete and SO’s confirmation, the junction box
concreting shall be commenced in according to the drawing and specification.
 To insert joint rubber ring for spigot and socket to the existing pipe culverts.
 Existing wingwall remain un-demolish unless obstructing pipe culvert installation or
water flow.
 The base and apron will not removed. The base hacked to from depressions where
necessary to accommodate the pipe spigots, when spigots and socket joint are used.
 Bedding material shall be laid on the base. All backfill material shall be carefully
compacted and the culvert assembled and jointed in line to the required level and
length.
 Pipes shall be laid upstream with the socket leading upstream and shall rest on even
foundation for the fill length of the barrel.
 Socket holes shall be formed at the bottom of the trench or foundation.
 Prior to jointing, rubber rings and jointing surfaces shall be cleaned of any debris.
 The spigot of each pipe shall be inserted concentrically in the socket of the one
previously laid.
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 Backfilling with suitable material or bedding specified, which shall be placed in even
layers equally on either side of the pipe to a height of 600mm above the crown of
the pipe. This shall be placed in layers not exceeding 150mm thick and duly
compacted.
 Where culverts are constructed at existing ground level in the open, surround
material shall be placed and compacted in layers not exceeding 150mm brought up
evenly on both sides of the pipe to a height of 600mm above the crown of the pipes.
Above this level suitable material shall be placed in accordance with the contract
requirement.
 Heavy, earth moving machines and compacting equipment shall not be permitted to
operate at a distance of 1.8m from culvert, until a minimum of 600mm of backfill,
subbase or base course has been placed and compacted over the crown of the pipes
or otherwise specified.
 Light vehicles and compacting equipment may operate within this limit, subject to
300mm cover being maintained around the pipe and subject to the approval of the
SO.Pipe shall not be laid until their class, size and length called for at each location
have been approved by the SO.

7.0 GABION
7.1 General
Gabions are baskets made of hexagonal woven wire mesh commonly referred to as triple
twist wire mesh. Gabions are filled with rock at the project site to form flexible,
permeable, monolithic structures such as retaining walls, channels linings and weirs for
erosion control projects.
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7.2 Material
 The steel wire used in the manufacture of the gabion is heavily zinc coated. If
required, a PVC coating is extruded over the galvanized wire to provide added
protection for use in aggressive environments such as acidic soils and water, in salt
water, in water carrying a high abrasive sediment load or wherever the risk of
corrosion is present. The PVC coating has a nominal thickness of not less than
0.55mm.
 In order to reinforce the structure, all mesh panel edges are selvedge with a wire
having a greater diameter than the mesh wire. The gabion is divided into cells by
means of diaphragms positioned at approximately 1m centres.

7.3 Method of Statement

 After completion of site clearing operation, cross-section survey of the excavation
area to be done and the limit of excavation will be set out accurately by the
surveyor. In the area of shallow excavation where foundation treatment is required
as shown on the construction drawing, Mackintosh Probes will be carried out to
indicate the depth of excavation required. A joint inspection shall be arranged to
check the wall alignment by clerk of work/ ARE.
 Exposed slope and existing highway embankment shall be protected if necessary.
 Sheet piles shall be used for temporary protection if necessary.
 Excavation to be carried out by excavator/backhoe or manually to the required level
(300-400mm depth) to form flat strata for a length of not more than 20.0 m by
maintaining survey control pegging.
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 The surplus excavated suitable material will be stockpiled at site for reused or cut
away if necessary; the base formation will be compacted using portable compactor.
 The gabions must then be filled with rock ranging between 100mm and 250mm. The
range in sizes may allow for a variation of 5% oversize and / or 5% undersize rock,
provided it is not placed at the exposed surface.
 In all cases oversize rock shall not be larger than 300mm and the undersize rock
shall not be smaller than 100mm as per PLUS specification (Section 532, Clause
523.4.1).
 Rock shall be hard, angular to round, durable and such quality that they shall not
disintegrate on exposure to water or weathering during the life of the structure.
 Care should be taken when placing stone to assure that the PVC coating on gabions
will not be damaged and to ensure tying of the wire is properly fastened.
 All visible faces should be carefully hand-placed for appearance purposes.
 In place of lacing wire, lacing operations can be made by using Spenax tools
together with stainless steel rings.
 Spacing of the rings or loops must not exceed that shown in Figure 6B. Timber
framing shall be introduced to obtain square gabion.
 In the meantime, preparation of cages will be going on for a length of Gabion Wall
not more than 20.0 m.

 After the laying or stacking of gabion wall is completed, a layer of geo-fabric will be
applied before the granular backfilling be preceded.

 Backfilling behind the gabion shall be laid in layers and compact by using plat
compactor.
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8.0 STREET LIGHTING

8.1 General
 This method statement describes the method and procedures for Street Lighting
installation at PLUS Third Lane Widening Project.
 This document shall show the necessary requirement and correct measures for the
proper installation method statement associated with street lighting works.

8.2 Material
The main materials are as following:

 Cables (Cooper cable)

 Lighting pole
 Street lantern (Philips brand)
 Feeder pillar
 Time switch
 Ducts

8.3 Method of Statement

8.3.1 Cable Routing along PLUS Highway’s Shoulder
 Cable route shall be pegged according to the drawings. Any changes made shall be
subjected to Engineer’s approval.
 A trench with nominal depth of 750 mm and 350 mm wide shall be cut with the
centre of the trench at approximate distance of 1.5m from the paved shoulder.
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 The new one number of 16mm sq/2c pvc/swa/pvc copper cable and one number
new 25mm sq/4c pvc/swa/pvc copper cable shall be laid directly underground
following consultant’s typical installation.
 Protective PVC duct tiles will be laid above the sand filling along the cable route.
The trench shall then be backfilled and compacted in layers.
 Relocation detail shall follow the latest Construction Drawing issued by the
consultant.
 If cable is cut during the course of the installation, the open ends shall be sealed
immediately by means of heat shrink joints or a self adhesive PVC tape in order to
form an air tight joint to prevent the ingress of moisture between the cores.

8.3.2 Cable Routing inside Concrete (bridge deck)

 Cable route encased inside concrete shall be as per the drawings.
 The cables shall be inserted into the 100 mm  PVC duct encased inside the parapet
wall on the bridge deck or between the beams under the bridge deck.

8.3.3 Cable Routing Under Road Crossing

 Cable route shall be pegged according to the drawings. Any changes made shall be
subjected to Engineer’s approval.
 Where 150 mm dia. GI duct (Class B) is specified, the method of laying and
backfilling of the trench shall be as per item 4.1. Where 100 mm dia. HDPE duct to
be used, duct will be concrete surrounded before backfilling.

8.3.4 Erecting the Lighting Column and High mast at Ulu Bernam R & R, Behrang and
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Tanjung Malim Lay Bys, Behrang and Slim River Interchanges

 The quantities involved as per below:-
Street Lightings:
i. Ulu Bernam R&R and Behrang Lay By (SB) - 43 numbers.
ii. Behrang and Tanjung Malim Lay Bys (NB) – 45 numbers.
iii. Behrang and Slim River Interchanges (NB & SB) – 124 numbers.

High Masts
i. 20 numbers all together to be relocated and reused and provision of
new plinths.

Feeder Pillar
i. 11 numbers of feeder pillar shall be installed and provision of new
plinths for this Package 4.

 The lighting and high mast columns are assembled as close as possible to its
installation site.

 Setting-out and Macintosh Probe Test shall be carried out to determine the location
and soil bearing capacity of the highmast plinths.

 Wirings within the column and the mounting of the street lantern will be carried out
simultaneously. All wiring between the terminal block in the luminaries and the
components in the base of the column shall be PVC insulated cable. All cables shall
be correctly color coded according to PLUS requirement.
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 The erection of the column is aided by the used of a crane and the verticality of the
poles or columns shall be checked by mean of plum bulb, spirit level or theodolite.

 There are two types lighting column: flanged mounted type to be installed at
concrete structures and planted-type to be installed in the ground.

 For lighting column located at parapet wall, a Galvanized steel plate shall be bolted
to the parapet wall.

 All street lighting poles and lanterns shall be new and all existing under ground
pvc/swa/pvc cables shall be replaces with new 2c 16mm2 pvc/swa/pvc cables.

 The relocation works should not cause any black outs to the system. The
termination, connection and activation shall be executed in the day time and shall
be completed in 4 days for each high mast.

 The detail working schedule is as per attachment (Appendix A). The new relocated
high mast will be maintained working by providing the temporary cable connecting
to the existing working cable.

 The existing street lightings shall be maintained in operation until the new street
lighting systems is energized.

 Philips brand shall be used for lighting bulbs as per PLUS requirement.

 Energisation or commissioning schedule shall be submitted after all the installation

of equipment and cabling works are completed.

 The existing old street lighting equipment shall then be stored at designated storage
as per PLUS requirement.
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 For the High Mast, the existing shall be relocated and reused after the location or
formation is ready for them and shall take 4 days duration per high mast. Temporary
lightings shall be installed during the 4 days relocation exercise.

 Removal of existing cables and installation of cable markers shall be carried out
after the new system is activated (if any provision).

 The temporary flood lights shall be provided with individual generator in case the
new relocated highmast is not working due to unexpected error.

 The methodology of relocation works shall conform to the Traffic Management Plan
as attach in Appendix B. Stage 1 of the relocation works will commence at both
ramps (SB and NB) of the interchange.

 After completion of relocation work and system is activated at the ramps, Stage 2 of
the relocation works will be executed at the main line of the highway at the
interchange.

 Stage 3 will be carried out after Stage 2 relocation work is completed and the
system is activated to avoid any blackouts.

8.4 Plant & Equipment

 1 unit of back hoe (Excavator)
 Steel bar bender
 Plate compactor
 Mobile crane / Sky lift
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9.0 OPTICAL FIBER

9.1 General
9.1.1 Optical Fiber
 Optical fibers, with the exception of some types of communication fiber, are all
composed of two distinct and different types of optically conducting material. For
simplicity, the term glass will be used for all types of fiber.
 The center or CORE of the fiber is the portion that actually carries light and is the
glass with the higher index of refraction. A thin layer of glass with a lower index of
refraction, called the CLAD, surrounds the core and is fused to it, creating a totally
reflecting barrier at the interface of the glasses.
 A typical glass fiber for most light carrying applications will be in the range of .001
to .003 inches (25-75 microns) in diameter. It will have 83% of its area composed of
core and 17% of the area will be clad.

Figure 1: Typical Optical Fiber Cable

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 Optical fibers are commonly produced from glass, plastic and synthetically fused
silica, often called silica or quartz fiber.
 Each type has its own advantages and drawbacks. For data communication
applications, silica fiber is the overwhelming choice.

 For illumination and sensing applications, glass fiber is the better choice for cost
and NA reasons, while plastic excels for ease of assembly in applications that do not
require operating temperatures above 175 degrees F. (70°C).

9.1.2 Optical Fiber Cable along PLUS Highway

 For Package 4 (Tanjong Malim to Slim River), existing Optical Fiber Cable (OFC) is
laid along the highway behind the guard rail at the verge area toward the North
Bound. OFC is the most critical activity to be looking at. It covers more than 90 % of
overall utilities relocation works.
 The depth of the duct which contain OFC are varies from 300mm to 500mm. The
alignment of the duct can easily be seen at site since the OFC handholes are only
230m to 250m apart.
 To lay OFC at it new route, a 4 km clear stretch of platform is required before the
ducting work can be carried out.

9.3 Material
 Ducting
 Main Duct: 100mm UPVC according to Engineer’s specification or equivalent
 Sub Duct: 1 x 50mm HDPE and 2 x 32mm HDPE according to Engineer’s specification
or equivalent
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 Sub Duct Preparation: 1 x 50mm HDPE and 2 x 32mm HDPE will be tied together with
PVC tape at 2m interval for securing sub duct formation.

 Handhole: Pre-cast hand holes Type A and B

Estimated quantity of hand holes for this package: Type A (138 nos.), Type B (15
nos.)
Estimated quantity for Type 1 cabinet plinth (15 nos.)
Estimated quantity for emergency telephone plinths (30 nos)
 Cables
Optical Fiber Cables – for globally telecommunication
Copper Cables – for locally emergency telephones

9.3 Method of Statement

9.3.1 Ducting Works
 Before the relocation can be carried out, ideally the formation of 2.0 km is required
for ducting work. Two categories of the formation identified: Filling and Cutting
areas.
 The arrangement of ducting work at both filling and cutting area can be referred to
Figure 2.
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1400

500 377

50mm Top Soil

Suitable backfill material
(2nd layer)
Varies
250 Suitable backfill
material (1st layer) Spaces between Ducts
1200 Are Filled With Sand
150mm Sand
Spare duct
50mm Sand
Maximum Trench Depth to
Top Of Upper Sub-base Layer

1000 350

Figure 2: Sub-duct Arrangement (Refer drawing no: W/TMS4/UT/TL/SD/1.5)

9.3.2 Ducting At Filling Area

Sequence of work at filling area is as follows:
 Filling works will be executed layer by layer according to the earthwork
specification to the specified formation level as per construction drawing.
 After the backfilling work reach the subgrade level, new hand holes will be installed
(200-250m apart) and located near to existing hand holes (which are to be
dismantled and removed).
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 Trenching works will follow where trenching depth is varying (300-720mm) according
to the formation level at the particular area.
 A layer of sand then is laid and compacted to receive cable ducts.
 After cable duct be laid, another layer of sand is laid and compact to helps maintain
fiber's usefulness over the long term of period.
 A suitable material then be used to backfill the opened trench and properly compact
and keep ambient or stray light from creating signal noise (for sensor applications).

Widening area Existing Lanes

Existing OFC
3
1
Step 1:
Fill the new embankment area
New OFC Step 2:
Install hand holes
Step 3:
Excavate and lay new OFC ducting

Figure 3: Ducting at filling area

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9.3.3 Ducting At Cutting Area

Sequence of work at cutting area is as follows:
 Piloting of the existing OFC is to be carried out prior to the excavation work. The
recommended pilot pit is between 50 to 100 meters apart depending on the site
condition.
 The existing OFC cable route then be identified and peg.
 The excavation work for formation level can ONLY be carried out after the pegging
work completed to a minimum 4 km stretch. Any construction activity near the OFC
alignment must be away from OFC at least by 1m from the peg. This is to avoid any
damage to the existing OFC.
 After the cutting work reach the subgrade level, new hand holes will be installed
(200-250m apart) and located near to existing hand holes (which are to be
dismantled and removed).
 Trenching works will follow where trenching depth is varying (300-720mm) according
to the formation level at the particular area.
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Widening area Existing Lanes

2 5

Step 1:
Slope will be cut 4 3 6
Step 2:
Existing OFC
Construct toe drain
to be removed
Step 3:
Cut to formation
New OFC
Step 4:
Install handholes
Step 5:
Excavate & lay OFC ducts Figure 4: Ducting at cut area
Step 6:
Box cut for pavement works

9.3.4 Installation of Hand holes and Cable Duct (ET and OFC)
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9.3.4.1 Installation of handholes Type A or B

 To provide of existing services information and pilot holes record to
ensure that no other underground utilities at the proposed handhole
location.
 Excavate at location of proposed handhole once the position and type
of handhole is confirmed
 Placed the precast handhole and ensure the orientation is correct
 Site clearance of debris and excess materials
9.3.4.2 Lay 2 ways 100mm UPVC duct
 To provide existing services information and pilot hole location of duct
route to be laid to ensure that no underground utilities.
 Open trench to a required depth and width according to Construction
drawing- properly compacted
 Spread 50mm thick sand bedding
 Lay 2 ways 100mm UPVC duct
 The laid 100mm UPVC duct should be backfilled with excavated
material and compact.
 Site clearance of debris and excess materials.

9.3.4.3 Install cabinet plinth

 Peg and confirmed position
 Excavation and putting blinding concrete on the base
 Installed cabinet plinth including 100mm UPVC bend and mild steel
plates
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 Site clearance of debris and excess materials

9.3.4.4 Install emergency telephone plinth

 Peg and confirm positions
 Excavation and putting blinding concrete on the base
 Installed telephone plinth including 100mm UPVC bend and mild steel
plates
 Site clearance of debris and access materials

9.3.4.5 Install 50mm & 32mm (tied together) sub-duct

 Mandrel test the laid duct as per construction drawing

9.3.4.6 FC, Jointing, Splicing and Testing & Commissioning Of The System
 Roding work along the 4 km distance is to be carried out before
activity on cabling to be started. This is to ensure that all duct save in
good condition. Laying OFC to be carried out upon Roding work
completed.
 Jointing and splicing work basically is an intensive activity which to be
carried out fast and complete within a limited time frame (system
transfer time) given by TT dot.com.
 Request for system transfer shall be submitted a month earlier before
the system transfer is carried out.
 The system will be tested and commissioned
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9.4 Plant & Equipment

 unit of back hoe
 1 unit hack saw
 Plate compactor

10.0 SOIL NAILS

10.1 General
Soil nails at Ch12+500 NB to Ch12+660 NB had been introduced in order to minimize and
strengthened the cut slope due to PLUS R.O.W which is encroached into Filati Lastex Sdn
Bhd mill area.

10.2 Method of Statement

A joint inspection shall be held in order to confirm the grid location of soil nails. Soil
nailing works shall be commenced from the top to downwards. This method statement is
intended to be step by step sequential order of all the operations entailed in fabrication,
installation, grouting and stressing of soil nails.

10.2.1 Reinforcement
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 The effective reinforcement for soil nails comprise of one length of high yield steel
bar or the Engineer’s specification of other types of reinforcement either
manufactured by local steel mill or specially imported types confirming to all the
relevant standards.
 The surfaces of the reinforcement shall be free from loose rust.
 Should the length of the reinforcement used be longer than the standard 12m long
steel bar, the splicing of the reinforcement shall be either using the standard splice
(hydraulically pressed types) or the threaded couplers whereby the ends of the
reinforcement are necessary.

10.2.2 Slope Preparation

 Localised uneven slope surfaces shall be trimmed when necessary.
 To prevent excessive disturbance to the existing slope, large scale slope trimming
shall be discouraged and only absolutely necessary.

10.2.3 Temporary Staging

 The type of drilling machine used shall be dependent on the slope profile, height,
spacing and the availability of working platform.
 Temporary staging shall be erected along the slope side so as to enable drilling of
the soil nails by small portable drilling machine and also as a platform for workers.
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 Temporary staging shall be erected from bracing pipes fastened together by pipes
clamps.
 Rigidity of the whole frame are enhanced by having extra diagonal bracing and
firmness of the ground on which the supports stand must be ensured.

10.2.4 Drilling
 A minimum 100mm nominal diameter bore holes are drilled at the required locations
with either rotary percussive drilling machines to the required depth and
inclinations.
 Temporary casings are to be used to ensure the stability of the bore holes.

10.2.5 Installation of Reinforcement

 Prior to any insertion of any reinforcement, the bore holes are to be flushed clean
with either water or air.
 Install together with 50mm Ø corrugated HDPE pipe.
 Centralizer is required to provide minimum grout cover.
 The insertion of the reinforcement shall be either be by crane or manually. During
the insertion of the reinforcement, no excessive force shall be allowed.
 In case of any refusal, the reinforcement shall be removed from the bore hole and
the borehole shall be re-flushed with air or water.

10.2.6 Grouting
 Grouting shall be carried out as soon as possible after the insertion of the
reinforcement in order to avoid drilled hole collapsed.
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 The grout shall be mixed in a high speed grout mixer with optional of high speed
colloidal mixer (1000r/min) or peddle mixer (150r/min) and pump into the bore
holes by tremie pressure injection method through a PVC grout hose.
 Grouting shall continue until neat cement grout flows out from the bore holes.
 If temporary casings are used, they shall be withdrawn immediately after grouting is
completed.
 Upon full withdrawal of the temporary casings, the grout column shall be topped up
where necessary.
 Pull out test shall be carried out after 7 days grouted nails and to achieve the design
strength (Grade 25). The contractor to submit the report to consultant.

10.2.7 Fitting of soil Nails Anchorage

During the curing period, preparations shall be made to receive the soil nail anchorage.
The type of anchorage shall be as per Engineers Specifications.

10.2.8 Soil Nails Stressing / Locking

 Stressing or locking of the soil nails shall only commence after cementitious grout
has attained a crushing strength at least 25N/mm.
 Stressing or locking shall be by either a hydraulic jack or simply by a torque wrench
to the required load.
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10.2.9 Soil Nails Anchorage Protection

Steel bearing plates, locknuts and the short length of the reinforcement shall be protected
from the elements by either painting with anti-rust, galvanizing as per construction
drawing (200mm x 1000mm concrete pad).

10.3 Plant & Equipment

Air Compressor 1no.
Drilling Rig 1no.
Grouting Machine 1no.
Staging 1 set

11.0 PULL OUT TEST

11.1 General
The pull out test is intended to investigate the geotechnical capacity of the design as well
as to demonstrate the behavior and performance of the working soil nail and to prove the
quality and adequacy of the design. This report is to describe the proposed method
statement for the pull out test on 9m long soil nail as specified on the drawing no.
T/TMS/4/GT/CS/1.5.

11.2 Method of Statement

11.2.1 Pull Out Test On Soil Nail
 The details of test soil nail are outlined as below:-
a) One (1) no 9m length Y25 high tensile deformed bar
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b) Permissible structural load of soil nail is taken as 10T based on Grade 460 Y25
deformed bar (FS=2.0)
c) Mean thread diameter of Y25 deformed bar ≈ 22mm for lock nut
d) Size of drilled hole approximately 100mm nominal diameter
e) Grade 25 Ordinary Portland cement grout with water cement ratio ranging
from 0.45 - 0.5
f) Pull out test shall be carried out to the specified maximum load at 1.5 times
working load of 40kN (4ton). The maximum test load is 60kN (6ton).

11.2.2 Choosing of Soil Nail Position

The soil nail position is generally to be decided by the Engineer’s Representative. When
the proposed test soil nail point is decided, the test equipment shall be set up by tester.

11.2.3 Setting Up of Pull Out Test

Attachment 1 shown the approximate setting up of the pull out test assembly.
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11.2.4 Test Loading Sequence & Cycle

The proposed test loading sequence taken to maximum 150% of the working load is
enclosed. Two (2) cycle test with the maximum observation time of 15 minutes.

11.2.5 Measurement of Displacement

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The actual displacement of the soil nail shall be measured by dial gauge. The dial gauges
shall be seated on steel plate at the top of the hydraulic jack and supported by
independent frame. Position of measurement shall be always at two perpendicular
directions in between ram and bearing plate.

11.2.6 Measurement of Applied Load

The applied load to the soil shall be by a center hole single cylinder of hydraulic jack. The
reinforcement bar will be stressed accordingly to each loading stress. Applied load shall be
read by pressure gauge adapted to maximum test load.

11.2.7 Terminate Test

Test termination upon completion of two cycle test or testing encounter displacement
greater than 25mm of specify load, whichever is reached earlier.

11.3 Plant & Equipment

 Hydraulic jack
 Stopper or lock nut
 Dial gauge
 Digital read out unit c/w module
 Load cell
 Bearing plate
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12.0 HORIZONTAL DRAIN

12.1 General
 This method statement in intended to be a step by step sequential order of
all the operations entailed in the fabrication and installation of Horizontal
Drain.

12.2 Method of Statement

12.2.1 Fabrication
The fabrication of the pipe itself is as follows:
a) Make slotted horizontal holes at nominated spacings on 75mm diameters
perforated PVC pipe.
b) Install end cap to the pipe.
c) The PVC pipe shall also be wrapped with 2 layer geotextile fabric type D and
mound with MS Wire at 100 pitch with accordance to the construction drawing.

12.2.2 Slope Preparation

Localized uneven slope surfaces shall be trimmed when necessary. To prevent excessive
disturbance to the existing slope, large scale slope trimming shall be discourage and only
absolutely necessary.

12.2.3 Temporary Staging

 The types of drilling machines used shall be dependent on the slope profile, height,
spacing and the availability of working platform.
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 Temporary staging shall be erected along the slope side so as to enable drilling of
the soil by small portable drilling machine and also as a platform for workers.
 Temporary staging shall be erected from bracing pipes fastened together by pipes
clamps.
 Rigidity of the whole frame are enhanced by having extra diagonal bracings and
firmness of the ground on which the supports and stands must be ensured.

12.2.4 Drilling
 A minimum 100mm diameter bore holes are drilled at the required locations with
either rotary percussive drilling machines to the required depth and inclinations.
 The drilling machine is powered by air compressor and connected to a hydraulic
power pack.

12.2.5 Installation of Horizontal Drain

 Prior to the insertion of the PVC pipe, the bored hole is to be flushed clean with air.
 The insertion of the pipe shall either be carried out by crane or manually.
 During the insertion, no excessive force shall be allowed.
 In case of any refusal, the pipe shall be removed from the bored hole and the its
shall be re-flushed.
 Pipe shall be leaved 100mm protruted outside bored hole.
 The duct shall be leaved 100mm protruted outside the PVC pipe.

12.2.6 Chute Drain

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 A small chute drain of concrete mortar shall be installed at the discharge point of
the horizontal drain.
 The chute drain will prevent erosion underneath the outlet.

13.0 TRAFFIC SIGNAGES AND OVERHEAD GANTRY

13.1 General
 This method statement describes the method and procedures for installation of
permanent Traffic Sign and Overhead Gantry which accordance to the T1 standard.
 The scope of works shall include:
i) Site survey to establish the location, levels and all necessary control points
ii) Mobilization of machinery to site
iii) Piloting to determine the location of services
iv) Installation of signboard

13.2 Method of Statement

13.2.1 Signage with bore footing
 Site Inspection and confirmation of location by main consultant and client’s
representative.
 Boring machine will be used if the size of post exceeding 165mm while for the post
less than 165mm, manual excavation will be used.
 Installation of signage post will be installed by skill workers and supervised by site
supervisor.
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 Concreting of signage footing using site mix will be done manually by 2 concreter
and supervised by one site supervisor using portable concrete mixer
 Installation of signage post and other accessories as per constructions drawing.
 Painting works for the post will be carried out upon completion of signboard
installation.
 Site clearing — all surplus debris will be removed after completion of works.

13.2.2 Signage with RC footing

 Piloting will be done by a backhoe .The piloting works shall be done based on
services location drawings provided by the Main Contractor.
 Unsuitable material shall be excavated, placed in lorries and carted away from site
to the approved dumping area. Depth of excavation shall be accordance to the
construction drawing.
 After excavation and prior to filling operation, the excavated area shall be surveyed
to determine the necessary reduced levels.
 50mm lean concrete will be applied for the installation of reinforcement.
 Concrete grade 30 (ready-mix) will be used for base footing.
 A formwork for concrete stump after holding down bolt fixed (for footing required
holding down bolt). A grade 30N concrete will be used for concreting the stump.
 Formwork will be removed before backfilling.
 Upon completion of gantry and signboard, touching up using paint will be applied to
the post.
 Site clearing — all surplus debris will be removed after completion of works.
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13.2.3 Overhead Gantry

 Piloting will be done by using backhoe.
 Unsuitable material shall be excavated, placed in lorries and carted away from site
to approved dumping area. Depth of excavation shall be as instructed by the
consultant.
 After excavation and prior to filling operation, the excavated area shall be surveyed
to determine the necessary reduced levels.
 50mm lean concrete will be applied for the installation of reinforcement.
 A formwork for concrete stump after holding down bolt fixed (for footing required
holding down bolt). A grade 30N concrete will be used for concreting the stump.
 Formwork will be removed before backfilling.
 Upon completion of gantry and signboard, touching up using paint will be applied to
the post.
 Site clearing — all surplus debris will be removed after completion of works.
 1(one) 25tan mobile crane will be used for lifting and installation of gantry.
 Site clearing — all surplus debris will be removed after completion of works.

13.3 Plant & Equipment

Back Hoe 1no.
Lorry 1no.
25ton Crane 1no.
Boring Machine 1 set
Vibrator Poker 1no.
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14.0 BRIDGES
14.1 General
This procedure outlines and describes the scope of work, construction sequence and
method, materials, testing, safety, and other related items generally applicable for the
construction of :
No Bridge Location Chainage Length (m)
1 Access Road Slim Village Ch 24,380.077 SB and Ch 24,380.077 NB 48.41
2 Underbridge Sungai Slim Ch 24,172.223 NB and Ch 24,172.223 SB 90.53
3 Underbridge Sungai Bernam Ch 3,996.86 NB and Ch 6,996.86 SB 60.41
4 Underbridge Sungai Behrang Ch 14,241.914 NB and Ch 14,214.914 SB 60.41
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 The bridge design consist of pre-cast M3 beams for span 1, 2 and 3. Bored pile of
600mm Ø are used through out.
 Construction of a new 3-span under bridge inclusive of 600mm bored pile,1100mm
R.C column, cross beam, M3 beams, bridge deck slab and all related work as
described in construction drawing.
 The new 3 spans bridge will be jointing up with the existing PLUS bridge at the
southbound and northbound of the PLUS expressway.

14.2 Work Sequences

General sequence of construction shall be as following:
 Surveyor to demarcate extent of bridge to be widened.
 Site clearing, construction of access road and working platform.
 Install bore pile.
 Audit survey for bored pile positions and approval for as-built pile positions shall be
obtained.
 Construct pile caps and abutments
 Cast precast beams
 Construct pier column and cross head
 Remove and hack existing parapet and past of deck to keep gap for closure
concreting
 Launch precast beams
 Cast diaphragm beam and deck slab
 Cast parapet wall/install railing
 Stitch to existing deck slab-closure concrete
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 Fill approach slab and cast approach slab

 Slope protection
 Bridge joint
 Pavement overlay

14.3 Method of Statement

14.3.1 Temporary works
Construction of access road to Pier 1 and Pier 2 and also to the abutment A and B the
access shall be from the out site R.O.W
Piling platform will be prepared for the movement of bored piling machine
Construct working platform at abutments, Pier 1 and Pier 2.

14.3.2 Piling
14.3.2.1 Caisson Works
14.3.2.1.1 Caisson Pile
 The caisson shall carry out in a proper sequence of steps so as to ensure quality and
safety of workers and adjacent structures.
 Leveling working platform and setting out caisson pile position. Excavate a pilot
hole with depth not exceeding 1000 mm and diameter around 200 mm – 300 mm
larger than the caisson diameter.
 Inside the pilot hole a circular steel mould, which has an inner diameter equals to
caisson diameter, is set up in the exact position of the caisson to be constructed.
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 Pour concrete of grade 25 around the gap between the mould and the vertical soil
surface
 After the concrete has gained the required strength the circular steel mould
dismantled. A concrete caisson lining is thus formed to prevent collapse of soil.
 Before further excavation is continued, a supporting frame about 3.0 m high is
erected in the ground surface above and cross the caisson opening. This temporary
frame supports an electrical chain block, which is used to transport excavated
material from the caisson bottom to the ground surface.
 A safety barrier is then set up on top of the caisson opening.
 Continue to excavate not more than the ring mould depth of soil each time and
subsequent concrete lining is again formed with the steel mould by lowering down
from the upper ring.
 If underground water or seepage is encountered or soil strata are found different
from the soil investigation at time during the excavation, the designer shall be
notified immediately for necessary design review, and necessary dewatering shall be
done by means of a water pump installed at the bottom of the caisson.
 Continue excavation and concreting of lining until after reaching the designed
bottom, level of caisson or socketing into the bedrock formation as required by
Engineer.
 If the termination is confirmed, the caisson base shall be cleaned and follow by
either lowering down the steel cage into the caisson or fabricating the steel cage
inside the caisson.
 The caisson shaft is then concreted with the reinforcement in place. The caisson
shaft shall be pump to dry prior to concreting and concrete poured in continuous
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operation though a hopper and with trunking extending down to the caisson shaft. If
the concrete of caisson shaft is placed in ‘wet’ tremie pipe method shall be used.
 During the excavation, there is always a worker on top of the caisson guiding the
hoist and removing the excavated soil.
 The excavation work is carried out by means of manual digging using hand tools and
pneumatic tools such as pick hammer and jack hammer if hard materials are
encountered. Manually rock splitting will be used if encounter boulders or socketing
to bedrock.

14.3.2.1.2 Hand Dug Construction

Caisson is defined as a structure that is sunk though ground or water for the purpose of
excavating and placing work at the prescribed and which subsequently becomes an integral
part of the permanent work. In this context, the caisson is constructed by hand excavation
method. This method is normally being used for ground conditions where obstructions in
the form of large boulders or tree trunks could prevent the operation of mechanical plant
or where the area is inaccessible by large machine.

The caisson work is being carried out with the following sequence:
a) Excavation
 An excavation / backhoe will be used to start the excavation third ring of the shaft
it is unreachable
 The first ring should be elevated at least 6 inches above commencement level to
prevent entry of surface washer or falling debris.
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 All the excavated material is lifted thought the shaft by chain hoist with a steel
made bucket.

b) Concrete Ring Lining

 Each stage of excavation is taken out for the depth to which the soil stand
unsupported to max 5’.
 A tapered circular mould is placed at the bottom of each stage of excavation as a
supporting formwork for fresh concrete lining.
 Every stage of excavation is lined with a minimum of 75 mm thickness of concrete.

c) Hard Level / Bed Rock Level

 Upon reaching hard layer/bed rock level or boulders, the pneumatic tools such as
jack hammer, pick hammer, rock driller and rock splitter shall be used to break it
into pieces and disposed out.
 The excavation will continue until the socket depth of hard layer/bed rock as
required by consultant.

d) Installation of Steel reinforcement

 A prefabricated steel cage will be lowered to the shaft. The on site welding for the
lapping length of reinforcement would be required if the full length of steel bar is
insufficient.
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 The center location of the steel cage and the minimum concrete cover is maintained
by placing spacers along the steel cage peripheral.

e) Shaft Concreting
 Concreting is carried out by direct method though a concreter hopper. The hopper
shall be extended with an 8” diameter pipe until at least 5’ above the founding level
for dry hole.
 Tremie concreting is only introduced for caisson hole where the ground water
couldn’t be pumped to reasonably dry condition.

14.3.2.1.3 Cassion Excavation Safety Precautions

 Caisson excavation work involves in a high degree of risk due to the unexpected
under ground situation caisson, such as leakages of underground gas, careless act of
worker of worker or fallen object from high level. Therefore, the work is always
being carried with highly cautions and equipped with sufficient safety equipment.

14.3.2.1.4 Caisson Hole Protection

 The top caisson ring should be elevated at least 6 inches above the commencing
level to prevent entry of surface water and falling debris.
 Construct 2 feet height toe-boards or timber around the top caisson ring to prevent
debris or equipment from failing into caisson hole, especially at the lope area.
 Construct 3 feet height hand-guard rails around the top of all caisson excavation to
protect workers from falling into caisson hole.
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14.3.2.1.5 Worker’s Safety

 All caisson workers must wear safety helmet, whistle, work shoe and proper
clothing.
 Workers inside caisson holes must be attended with a hoist controller on top and
shall be alert at all times.
 Smoking is prohibited caisson holes.
 Worker must be careful when going down or up, ascending or descending
equipments or excavated material during the caisson construction.
 Workers drilling in rock inside caisson holes must wear nose mask, goggle and
earplug.
 Adequate lighting and fresh air supply must be provided all times to workers inside
caisson holes, standby lamps and air blowers must also be provided
 A 1” diameter rope with 2’ spacing knot must be provided down the full height of
each caisson hole as a an emergency escape aid. In addition, spare ropes and safety
belts must also be provided for emergency use.
 While lifting the soil bucket, the workers in the caisson shall stand under a steel
overhead protection.

14.3.2.1.6 Safety Equipmet

 All equipment and tools must be regularly inspected and properly maintained by
workers and supervisors.
 The supporting wood or steel frames must be stably erected and should be leveled
and aligned in the central position of the caissons.
14.3.2.1.7 Caisson’s Safety Regulations
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 All employees must have a sense of responsibility of safety

 Safety is achieved through teamwork
 Explain to workers the regulated posted at the caisson.
 All workers inside caisson must be provided with all the necessary Personal
Protective Equipments (PPE) at all times.
 Workers ascending or descending must use safety belt and must hold on to the
safety rope provided.
 The safety rope must be in the caisson hole all the time while the work is
progressing.
 Safety rope must be knotted at every 2 feet with at least 1” in diameter
 Before starting work, the fresh air need to be blower into the hole for at least 5 min
by using air blower.
 The air blower must be positioned 5 feet above the first ring to prevent the duct
from being recycled.
 The plastic air hose must go directly into caisson so as to have maximum airflow.
 All compressed air hose joining must be tied with wire to prevent them from coming
apart.
 All caissons must be fitted with proper lighting.
 All caisson to have daily housekeeping.
 Workers to check and maintain their tools daily.
 All electrical appliances shall have proper wiring.
 All caissons shall be barricaded when not in use.
 Smoking is prohibited in the caisson.
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14.3.2.2 Bored Piling

14.3.2.2.1 Scope
This method statement specifically describes the procedure involved in construction of
bored piles to ensure that the works is completed in accordance with the specification and
applicable Standard Codes of Practice and that the activities are documented. The scope
of work shall include :
 Mobilization and delivery of piling equipment and accessories.
 Setting out of piling points.
 Construction of cast in-situ bored piles 900 mm diameter. It shall be installed by use
of mechanical and/or hydraulic-powered machine and cast within reinforced
concrete.
 Carry out sonic logging test, load test and cavity treatment.
 Obtaining all necessary approvals from Engineers.

14.3.2.2.2 Materials
Materials to be used will be :
 Water
Potable water shall be used in preparing the slurry suspension and concrete.
 Bentonite / Polymer Slurry Suspension
During excavation of the borehole, pile shaft stability shall be maintained, if
required, by the introduction into the hole of a stable suspension medium of
bentonite or polymer drilling fluid.
 Concrete
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The ready mixed concrete (G40 Tremmie Mix T2) for piling will be supplied by the
supplier approved by SE. the concrete shall be in accordance with the Specification.
 Steel Reinforcement
The steel reinforcement will have both a main supplier and a back-up supplier. The
reinforcement cages for the piles shall be high tensile deformed steel bars. They
shall de delivered to site in straight lengths of 12 metres. All delivery will be
accompanied by Mill Test Certificate.

14.3.2.2.3 Plant & Equipment

 The basic configuration required for the construction if 1500mm diameter bored
piles are:-
a) Hydraulic Piling Rig
b) 1 no. of either BG14/BG22/BG30 as appropriate.
c) Service crane
d) 1 no.crawler crane (45t, 50t or 60t)
e) Casing vibrators (vibro hammer) and segmental casing
f) Bentonite mixing/storing plant.
g) Grout mixing and pumping mixing
h) Rock / soil auger, digging/cleaning buckets and core barrels

 Ancillary equipment will include :-

a) EX 200 hydraulic excavator or equivalent
b) Lorries for removing spoil materials
c) Water silos, pump, pipework, settling tank
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d) Air compressors, generator, welding set.

e) Airlift, tremie, concrete skip, jet washer
f) Toolbox container for small tools and spares
g) Lifting chains, slings and beams.
14.3.2.2.4 Bored Pile Construction
a) Formation of Bored Hole
 Joint survey to check the setting out of pile position from control point by the
surveyor will be carried out before commencement of the drilling work.
 Setting out of the first pile point and subsequent selected pile points shall be
confirmed by Engineer.
 Drilling rig shall be stationed on stable ground. Steel plate shall be provided if
required.
 The pile position set by the surveyor shall be offset in two perpendicular directions.
 The boring plant will be moved to the pile point intended for excavation. The Kelly
bar mounted with an auger is placed just above the pile point.
 The vertically of the bar should be checked by means of a spirit level. Adjustment
should be made so as to enable the Kelly bar to be as vertical as possible. Then the
position of the auger is checked against the pile point.
 Adjustments should be made so that the centre of the auger is nearest to the pile
point. The auger is the lowered and boring operation commence.
 Reasonable care should be taken so that the pile position and vertically are
constructed within the specified tolerance i..e 75mm and 1 in 75 respectively.
Plumb bob shall be used to check the verticality as boring is in progress.
 During the course of boring, the following checks shall be made :-
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 If boring encounters unstable stratum or boring hole starts to collapse, temporary

casing to depth will be installed.
 Where casing cannot penetrate further down, the vibro hammer shall be used if
necessary to drive the casing down.
 If unsuitable stratum is encountered below the casing depth, one of the following
methods shall be applied to stabilize the bore hole :-
 Extent and install further the casing to prevent collapse.
 Stabilize with water if workable.
 The drop chisel will be used if it is found that the coring cannot be continued due to
hard strata.
 Boring will stop when the required depth is reached. Soil sample to be taken
whenever soil strata changes during the course of drilling and shall be properly
labeled.
 All boring activity shall be accompanied by a Borelog record which will indicate the
description and changes in the soil strata revealed during the boring exercise.
 After reaching the required depth, a cleaning bucket will be used to clean up the
bottom of the borehole and the cleanliness of the for is checked by the weigh tie to
the measuring tape. A joint measurement of the depth should be made before
lowering of reinforcement and concreting.
 For dry borehole, each hole shall be inspected by Engineer prior to the placing of
concrete in it. The inspection shall be carried out from the ground surface in the
case where borehole diameter is less than 750 mm. Torches or other approved
means of lighting, measuring tapes and a means of measuring verticality shall be
provided. Where the borehole diameter exceeds 750mm, adequate equipment
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conforming to BS 5573 shall be provided to enable descending into the borehole for
inspection.
 For wet boreholes, i.e holes filled with drilling fluid water, a suitable probe shall be
provided to ascertain the evenness and cleanliness of the pile case. The water or
drilling fluid in the bored hole shall be checked for its specific gravity and sand
content.
 Soil sample shall be taken whenever soil strata changes during the course of drilling,
and shall be properly labeled.
 Reinforcement for bored piles will be pre-fabricated in the reinforcement yard and
transported to the borehole for placing.
 After fabrication by the bar benders, the helical links will be tack welded to the
main reinforcement. Laps (50D or 1.25m) are also to be welded sufficiently so that
they are intact during transportation.
 100mm diameter round concrete spacers will be fixed to the reinforcement to
provide the 50mm cover as required to the reinforcement against the soil during
concreting.
 The reinforcement will be lowered to the completed borehole, prior to concreting,
by means of a service crane and to be adjusted to the correct level.

b) Concreting
i) Dry hole method
 When the hole is practically dry, ready mix concrete shall be discharged directly
into the through a 1.5m length funnel hoper.
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 The funnel hopper shall be guided to ensure that the concretes falls centrally to
the full depth without striking the reinforcement steel on the sides of the pile
excavation, by attaching a 10 inch pipe. The length of the pipe shall be made to
suit the borehole depth such that the free fall of the concrete is restricted to
3m.
 The concrete level shall be cast at least 0.5m above the cut-off level.
 Casing shall be withdrawn immediately if temporary casing is required for
forming the bore hole.
 Concrete slump for dry hole method shall be between 100-200mm.

ii) Partially dry hole method

 In core where water is less than 500mm and without substantial water seepage
from the side of borehole, 2(two) nags of cement shall be discharged
immediately into the hole thorough a funnel hopper.
 Method of construction shall be the dry hole method.
 If there is water in the bored hole, tremie pipe shall be used for concreting.

iii) Wet hole (Tremie method)

 In bore hole with more than 1.0 m of water and continuous seepage to such an
extent that the borehole cannot be dewatered, tremie method shall be applied.
 Tremie pipe sections of minimum 150mm diameter shall be joined progressively
until the pipe reaches the toe.
 Concrete will be poured continuously until fresh concrete is ‘flushed out’.
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 The trimmie pipe shall be dismantled progressively after the concrete had been
discharge into the pipe. Trimmie pipe shall have at least 3m embedded in the
concrete all the time.
 As the trimmie pipe extends to the base of the bore hole, a sliding plus on
barrier shall be placed in the pipe to prevent direct contact between the first
change of concrete in the trimmie and the water on the drilling fluid.The
concrete level shall be cast at least 1m above the cut-off level.Casing shall be
withdrawn immediately if temporary casing is required for forming the borehole.
 Temporary casing shall be extracted within 2 hours of placing concrete.
Extraction of casing shall be done by vertical lift, continually plump and shall
proceed in such a manner as to allow continuous observations of the interior
slumping of the concrete.
 Concrete slump for tremie method shall be between 175-225mm.
14.3.2.2.5 Pile in The River
 The method for bored pile in the river is the same as the method discussed above.
 Permanent casing will be applied to case the construction of pier column.
 The following precautions will be taken for bored pile in the river.
 All bored pile shall be cast to a level of at least 1 metre above the required cut-off
level to avoid concrete mixed with laitance accrued from the boring process. This
excess length shall be hacked off before continuing with cast in-situ column
extension or cross-beam construction.
 sets of plumb-lines will be set perpendicular to each other to monitor the verticality
of the casing during installation as well as extraction. This will ensure the verticality
of the bored pile shaft.
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 Steel casing will be used to stabilize the bored hole in the river and bentonite will
not be used. A water/mud pump will be used to discharge the sludge and slurry on
dry ground to prevent any sludge discharge into the water-course.

14.3.2.2.6 Proposal to treat the conditions where caving is encountered or excess

water begins seeping into bored hole during boring.
a) Cavity Grouting
 If any pile affected by the presence of cavities, cavity treatment will be conducted
either before the boring works commence at the particular pile location or after the
pile has been constructed.
 If required, bentonite will be used to stabilize the existing soils during boring works
to prevent collapse or unstable soils.
 If boring encounters unstable stratum or boring hole starts to collapse, temporary
casing to depth will be installed.

b) Sonic Tubes
Upon acceptance of sonic test results, the tubes shall be backfilled with a cement water
mix appropriate composition, through the following steps :
a. Tremie tubes (20 mm poly pile) shall be lowered.
b. Sonic tubes shall be flushed with clear water.
c. Cement mix shall be grouted from the bottom to the top until uncontaminated grout
mix comes out from other circuit.
d. Grout tubes shall be capped and protected until setting of grout
mix.
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Three test cubes will be taken for each set of sonic tubes.

c) In-Situ Test
The test of the bored pile shall consist of either sonic coring, integrity test, static load test
or other load tests instructed or approved by S.E. Detail for the sonic coring and integrity
testing are as detailed below :
i) Sonic Coring
 Sonic tubes shall be fixed to the interior of the reinforcing cage. The sonic tubes
range from 2’ to 5’ and shall extend from 300mm above the toe of the pile. The
number of sonic tubes per pile be as per specification.
 The sonic tubes shall be capped during concreting. The sonic
ii) Integrity Testing
iii) Load Testing

14.3.3 Protective Pile (KTM Bridge)

The following materials shall be used to construct to protect :
Material vibration from railway track (If nessaccery)
12m-long FSP Type 111 sheetpiles shall be utilised for the cofferdam. They shall be
installed vertically by a vibro hammer to resist lateral earth force. The cut of level of the
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sheetpiles shall be 24.00 m. Where sheetpiles protrude out beyond the level after refusal,
oxy-acetylene will be used to cut these shetpiles if they obstruct machinery movement.

14.3.3.1 Equipment
The proposed machinery to be utilised shall be as the following :
1. Crawler crane (minimum 20 M ton)
2. 3 – 7 tons Hydraulic vibro-hammer c/w power pack (Depending on site conditions)
3. Welding set
4. Oxy-acetylene cutter
5. Excavator

14.3.3.2 Construction Method

a) Preliminary Work
 Preparation works preceed piling activities.
 The site shall be levelled to allow safe operation of heavy machinery.
 Steel plates will be provided at locations where the ground is soft and unable to
support the machinery.
 Fabrication and stocking of material such as sheetpiles, walers and PC strands will
be within the bridge ROW. Exact location will be subject to site constraints.
 Gas palettes and welding machines will be located close to the place of work.

b) Sheet piling Sequence of Work

The following sequence will be used during sheet pile installation:-
 Surveyor locates centre of sheet pile wall.
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 Appropriate reference line and offset point to the centre of piles to be set out
 Arrange the piles at each point with the use of timber frame to ease and maximise
installation.
 Use vibro-hammer to install piles, a plump wiyh string will be used to ensure
verticality of the sheet pile wall. A excavator will be used to guide and correct the
pile verticality.
 Piling will continue until the desired depth is attained.
 Repeat steps 3-6 for the next sheet pile and steps 1-6 for every new sheet pile wall.

14.3.4 Pile Cap Construction

 After completion of piling work, excavation of pile cap then carried out. Precaution
shall be taken to avoid any damage to the piles. The size of excavation shall take
into account for working space.
 The surveyor shall mark the require cut off level before cutting the piles using
pneumatic hammer. Saw cut a groove before hacking the piles using pneumatic
hammer to prevent propagation of micro cracks. After all the pile has been cut, as
built survey shall be carried out. The survey data shall be submitted to the
consultant for approval to proceed the pile cap construction.
 The bottom of the excavated area then prepared as platform for the pile cap and
levelled (150mm below cut off level) and compacted. Lean concrete of 50mm thick
then poured.
 The reinforcement bars for the pile cap and column starter bars then installed. All
bars shall be firmly tied using steel wires to enable then to maintain its position
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under its weight, concrete and vibration. The complete work shall be inspected and
approved by the consultant before proceeding with further works.
 All formwork shall be fixed in perfect alignment according to the relevant pile cap
drawings. There shall be braced to adequately withstand the weight of concrete,
vibration and forces due to the movement of workers and machineries.12mm thick
plywood shall be used together 2” x 4” timber as struts. G.I pipes shall be used as
horizontal brace. All formwork joint shall be plugged with sponges to prevent
leakage of cement mortar.
 Sufficient number of spacer blocks shall be installed to achieve the required
concrete cover.
 The formwork shall be inspected and approved by the consultant before concreting
can proceed. Cleanliness shall be observed by ensuring the lean concrete is free of
construction debris, dirt/mud and standing water.
 Concreting will only proceed immediately after obtaining Approval from the
consultant. However, if for some reason concreting does not take place within 24
hours; a new inspection shall be called again.
 Ready mix concrete of grade 40/20 N shall be used. The concrete shall be
compacted using vibrator poker. Concreting bucket and crane shall be taken to
ensure it is clean.
 The discharge of concrete shall be continuous where sufficient number of trucks for
transportation shall be utilized. The concrete shall be placed in horizontal layers to
a compacted depth not exceeding 450mm.
 Slump test shall be carried out for all loads. Four (4) concrete cube samples shall be
taken for every 20 cubic meter of concrete. Cube samples shall be transported to
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proper curing tank within 24 hours. In the meanwhile, they shall be covered with
plastic and gunnysacks. A trained technician shall carry out both slump test and
preparation of the cube samples.
 Curing compound shall be applied after concrete set or after dismantling formwork.
 Post concreting check shall be carried out after stripping formwork.
 Saw cutting a groove before hacking the pile using pneumatic hammer to prevent
propagation of micro crack.

14.3.5 Column Construction

 Reinforcement bar shall be bent to the required shape and dimension. It will be
installed for column height using temporary scaffolding. Consultant inspection will
be called before erecting the steel mould.
 Steel mould shall be thoroughly oiled with mould oil before erection.Verticality
check shall be carried out using Plumb bob if instructed by the consultant, surveyor
shall be assigned to check the verticality.
 Excavation and cutting of piles
 Laying of 50 mm thick blinding concrete
 Fix formwork and pile cap’s rebar
 Cast the pile cap
 Remove formwork after acquired strength.
 Repeat the procedures for column and cross beam.
 Scaffolding to be erected to support cross beam construction.
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14.3.6 Cross Beam

 Scaffold shall be erected with the supervision of competent scaffolder.Safety
requirement such as ladders, landing and handrails shall be given due attention.
 The soffit if cross beam shall be installed first using 2”x4”, 2”x3” timber and 12mm
plywood. Triangular strips are used to form chamfer corners at the bottom.
 Reinforcement bar then lifted using crane and installed into position.
 After consultant’s approval side formwork shall be erected. The plywood shall be
used.
 Ready mix concrete of grade 40/20 N.

14.3.7 Bearing setting

 The seating position shall be marked by the surveyor. This portion shall be inspected
by the consultant for approval.
 This position shall be then hacked to roughen its surface. The roughen surface shall
be thoroughly clean, sound and free from oily grease laitance and loose adhering
particles.
 A steel mould shaped and dimensioned as per the required seating then placed.
Sponge will be used to plug in the joints. The surface then sprayed with water to
damp the area.
 Epoxy mortar then prepared for pourable consistency as per manufacture
specification.
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 The prepared epoxy grout then poured into steel mould and levelled to the required
level.
 The test cube sample will be prepared with using same epoxy mixture.
 The epoxy plinth shall be left to cure it up with damped gunny sacks.
 Laying 50 mm thick blinding concrete.
 Proposed rubber bearing shall be tested of its property and strength.
 Rubber bearing then is put on the plinth before the beams launching.

14.3.8 Beam Launching

 This beam will be launched using 1x50 ton and 1x70 ton cranes.
 Access to the site, beam transporters parking area and cranes launching position
shall be inspected and prepared if necessary.
 Cranes shall be used to lift the beams from transporters and in a coordinated
movement, manoeuvre the beams its final position.
 After the entire beam have been launched, Y-20 reinforcement bars will be welded
as tie rod to ensure the beams stay in it position until the construction of the
diaphragm beam and deck slab.

14.3.9 Diaphragm Beam

 Fix diaphragm beam formwork and rebar
 Cast the diaphragm beam
 Remove formwork after acquiring concrete strength
 Spray curing compound
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14.3.10 Deck Slab Casting

 The permanent form work shall be fixed at the between beam and beam.
 Reinforcement bars shall be laid as per construction drawing.
 The top levels of concrete shall be marked along the side formworks. Steel rod
indicating the deck slab level shall also be provided at suitable spacing covering the
entire deck slab.
 Concreting shall be carried out using crane and bucket.
 Curing shall be done by spraying curing compound or wet gunnysacks.
 Hogging in pre-cast beams shall be considered within the tolerance and shall be
accommodate with extra thickness of the slab at the ends.
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15.0 PAVEMENT
15.1 Method of Statement
15.1.1 Setting Out Of Widened Part of Expressway

Groove Line
200mm (W) 150mm (W) 200mm (W)
3.75m

3.65m
3.76m

3.65m 3.75m
Existing Fast Lane Existing slow Lane

EXISTING ROAD LINE MARKING

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Existing Fast Lane Existing slow Lane

3.75m 3.76m Base line

Groove Line
7.10m
Existing White Line O/S
3.70m 3.00m 2m

New Slow lane New Emergency Lane

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SETTING OUT AT SITE

 Joint survey and joint inspection will be held to confirm new alignment
 Base line shall be taken from edge of existing white line
 Alignment peg will be offset 2m away from edge of new subbase
 Alignment control and levels shall be based from existing expressway

200mm (W) 150mm (W) 150mm (W) 150mm (W) 200mm (W)

3.65m 3.65m 3.65m 3.00m

New Fast Lane New Middle Lane New Slow Lane New Emgcy Lane

THIRD LANE WIDENING COMPLETED

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15.1.2 Testing of CBR Under Existing Emergency Lane

CBR sample shall be taken at every 500m interval. For area cut and fill within the same
range, another sample shall be taken to differentiate between cut and fill area. Generally
4 type will be carried out at the Existing Emergency Lane.
a) Field Density Test
b) Soaked CBR (from sample)
c) Moisture Content (from sample)
d) Dynamic Cone Penetration at every 50m (to determine length of treatment)

15.1.3 CBR Sampling

 The contractor will determine the effected location. Back hoe swill be used to
excavate the existing emergency lane till subgrade layer.
 Sample shall be taken approximately 70kg to CSL Laboratory
 A soaked CBR value and moisture content will be determined accordingly to the
BS1377
 The result will be finalized after 6-7 days

15.1.4 Treatment of Subgrade Under existing Emergency Lane

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Treatment of subgrade below existing existing emergency lane shall be applied if the
soaked CBR value is less than 5%

15.1.4.1 For Cut Area

The treatment of subgrade for the cut area shall be as follows:
a) CBR value 3% to 5% : 300mm depth of granular fill
b) CBR value 2% to 3% : 450mm depth of granular fill
c) CBR value < 2% : 600mm depth of granular fill
The treatment material must be CBR value more than 15%

15.1.4.2 For Embankments

15.1.4.2.1 Option 1
a) The top 900mm of the subgrade below the existing emergency lane shall be
removed and replaced with suitable material which shall have soaked CBR not
less than 5% as per Specification Clause 633.1.
b) This treatment shall be applied in areas where the earthwork for the new
embankment (i.e the widened part for the new emergency lane) have been
completed up to formation level (i.e the finished subgrade level)

15.1.4.2.2 Option 2
a) Remove the existing subgrade below the existing emergency lane and replace
with suitable Capping material which shall have a soaked CBR not less than 15%
b) For subgrade soaked CBR equal to or less than 2%, the thickness of the capping is
600mm, to be compacted in three layers.
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c) For subgrade soaked CBR more than 2% and less than 3%, the thickness of the
capping is 500mm, to be compacted in three layers.
d) For subgrade soaked CBR between 3% and less than 5%, the thickness of the
capping is 300mm, to be compacted in two layers.

For option 2, the following shall apply:

I. This treatment shall be used for areas where the earthwork for the new
embankment (i.e widened part for the new emergency lane) has NOT been
completed up to the formation level. For such areas, the earthwork shall be
carried out up to certain level (below the formation level) leaving a gap to receive
the capping layer.
II. If the capping is not laid immediately, an extra cover (approximately 150mm) shall
be provided on the finished earthwork for protection from rains. The cover shall
consist of well compacted earthwork and it shall be only removed just before the
laying of the capping material.
III. The capping layers shall be extended across both the existing emergency lane and
the new emergency lane. The capping layers shall be day-lighted.
The selection of the options is subject to the approval from the Engineer depending on the
site conditions.

15.1.5 Sequencing CBR Under Existing E.L Between Embankment area & Box Cut area
15.1.5.1 Box Cut
 For box cut area, advisable to wait for CBR under existing emergency lane result
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 If treatment under existing emergency lane is deeper than new slow lane,
contractor need to provide cross drain in order to drain out the trapped water into
subsoil drain.
 The size, interval and length of the cross drain shall be confirmed by Engineers

15.1.5.2 Embankment Area

15.1.5.2.1 Embankment Option 1
 The filling works for the new emergency lane shall proceed without waiting for the
CBR result under existing emergency lane.

15.1.5.2.2 Embankment Option 2

 For the in-completed embankment fill, advisable to wait for CBR under existing
emergency lane result.
 If treatment under existing emergency lane is deeper than new slow lane,
contractor need to provide cross drain in order to drain out the trapped water into
subsoil drain.
 The size, interval and length of the cross drain shall be confirmed by Engineers

15.1.6 Removal of Existing subsoil

 The existing subsoil drains which located parallel to the edge of existing emergency
lane need to be removed in order to prevent water from subgrade trapped into it
upon completion of pavement.
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 There are 2 option for subsoil removal

a) Existing subsoil without outlet to slope:
The existing subsoil will be removed and compacted with suitable
material.
b) Existing subsoil with outlet day-lighted to the slope:
The existing subsoil will be removed and compacted with granular or
material CBR value more than 15% to the end of of and it will be day-
lighted to the new filling slope.

15.1.7 Laying of New Subsoil drain

 Porous concrete pipes, clay pipes and Polyvinyl chloride (PVC) pipes for the subsoil
drains shall comply to the relevant contract specification.
 Filter material use in the construction of subsoil drains shall consist of hard, clean,
crushed rock or gravel having a grading limits given in the specification. The
aggregate crushing value of the material shall not exceed 30 percent.
 The filter cloth shall be geotextile fabric as specified in the contract specification.
 The alignment and levels of the sub soil drains shall be provided by surveyor while
dimensions and grades need to be checked by site supervisor.
 Excavation for subsoil drains shall be carried out all in accordance with the
appropriate provisions of specification.
 Filter cloth shall then be placed to cover the perimeter of the trench excavated,
with the top open to facilitate the placement of filter material and subsoil pipe.
Care shall be taken against damage of filter cloth during the construction stage.
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 Filter material shall be placed and uniformly compacted by a suitable method

approved by the Employer’s Representative, to form a firm, even bedding for the
pipe drain as taken against damage of filter cloth during the construction stage.
 The pipe sections shall be set firmly against the filter material bedding with the
flow lines in the design position. For pipes with mating joints, the receiving ends
shall be fully contiguous, and the collars properly centered over the joints.
 Joints shall be spot mortared as necessary to hold the pipe sections correctly
centered and aligned, but not so as to unduly restrict the infiltration of water
through the joints.
 Slotted or perforated pipes shall be tightly wrapped in filter cloth such that the
entire length of the mortared pipe is covered by at least 2 layers of cloth. All joints
in both layers shall have an overlay of at least 100mm and joints in the outer layer
shall be offset by at least 300mm from joints in the inner layer, all to the
satisfaction of the Employer’s Representative.
 After pipe laying and, if appropriate, wrapping has been approved by the Employer’s
Representative, the remainder of the filter material shall be placed and uniformly
compacted by a suitable method approved by the Employer’s Representative, to
form a dense, even surround to the pipe as shown on the drawings.
 On completion of filling with filter material, the filter cloth shall be folded on the
top with the required lap. Care shall be taken against contamination of the filter
material during the filling operation and also ensure that the pipe is neither
damaged not displaced.
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 Backfill above the filter material shall then be placed and compacted in accordance
with the appropriate provisions of the contract specification.

15.1.8 Construction of Temporary Drain

 A temporary drain shall be provided with offset approximately 200mm from the
edge of new laid subbase. The temporary drain will be constructed for the cutting
area only.
 The trench dimension is approximately 300mm depth (from subgrade level) and
200mm width.
 The outlet of temporary drain will be free flow to the lowest point of OGL.
 The contractor to ensure that the temporary drain working and maintained properly.
 Upon completion of pavement, the temporary drain shall be fill with suitable
material as verge to the expressway.

15.1.9 Preparation of Subgrade

 Preparation of formation shall be carried out only after completion of any specified
sub grade drainage such as sub-soil drain and table drain.
 Road alignment and level pegs at 20 meter interval to be set out to monitor the
trimming works to the sub grade levels.
 The surface shall be trimmed to the right levels and to the requirement of the
contract.
 The trimmed surface shall be rolled by a few passes of smooth – wheeled roller by a
15 tons vibratory roller.
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 All areas of prepare formation shall be approved by the Resident Engineers prior to
the placing of sub – base material. Placing of subbase shall commence immediately
following such approval.
 The subgrade and formation level for road shall be finished in a neat and workman –
like manner and the widths of embankments and cuts shall be those specified on the
drawings.
 The top surface of the subgrade and formation shall have the required shape,
superelevation, levels and grades and within plus 10mm and 25mm of the required
level.
 The contractor must ensure that the minimum compaction for subgrade is 95% and
soaked CBR value 5%. In the event that the CBR value less than 5%, a treatment will
be applied at the particular area.

15.1.10 Granular Subbase Type 2 – Lower Subbase

 Prior to the laying of lower sub-base course, the material shall be approved by the
engineer.
 Works shall be commenced upon the approval and acceptance of the sub-grade
formation layer. The prepared sub-grade formation shall be protected from damages
caused by rains and construction vehicles by preparing temporary drainage at the
edge of the formation and lower sub-base.
 Sub-base course (Type 2) shall be delivered to site by tipper trucks and spread by
motor –grader or back-pusher.
 Density test shall be carried out by sand replacement or other approved methods.
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 Compaction of lower sub-base : To achieve minimum 98% of the maximum dry

density determined in the BS 1377.
 Frequency of compaction test and grading on lower sub-base: At least two
compaction test and grading analysis shall be taken for every 1000 m².

15.1.11 Granular Subbase Type 1 – Upper Subbase

 Works shall be commenced on site upon approval and acceptance of the lower sub-
base layer. The finished lower sub-base shall be protected from damages caused by
rains and construction traffic by providing temporary drainage at the edge of USB.
 Approval USB material shall be delivered to site by tipper trucks.
 Laying and spreading in full width of the USB shall be monitored by using back-
pusher or motor grader
 The moisture content of the upper sub-base material shall be monitored and
compacted by using vibratory roller to not less than 98% of the maximum dry density
determined in the BS 1377.
 The surface of the USB shall be finished to the grade line as required by the
drawings and specification and tolerances.
 On completion of laying and compaction, joint dipping and in-situ density shall be
conducted to check for compliance with the specified requirement.
 At least two compaction test and grading analysis shall be carried ot for every
1000m².

15.1.12 CRCP saw Cut & CBM3 Removal

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Firstly, carry out traffic control to cordon off the road so as to provide safe working
corridor by placing of red/white road barriers along the road.
The road barriers are supplied and delivered to site by others.
Placement of road barriers may be carried out by prior arrangement with contractor.

15.1.12.1 Marking The Line of Cut

White line markers shall be drawn on the road along the lines of cutting. The first line of
cut for the CRCP layer shall be 200mm from the edge of the CRCP. The second line of cut
for the CBM3 layer shall be 200mm away from the first line of CRCP cut. A nylon rope shall
first be laid along the lines of cutting and then marked with white paint dispensed from
aerosol cans. The empty cans shall be collected and discarded to bins.

15.1.12.2 Cutting The CRCP

Cutting of the CRCP layer shall be executed in the following sequence :-
 To mobilization cutting machines with 22” diameter diamond blades to make a
3.6mm to 4mm wide cut down to and through the reinforcement bars to a maximum
depth of 200mm. Watering the cut line is the method to be used for cooling the
cutting blade.
 Just before the removal of CRCP strip, the CRCP is cut to full depth
 The CRCP is then cut diagonally into smaller pieces
 The smaller pieces shall be removed by excavator without damaging the existing
CBM3.
 The production shall be approximately 200 meters distance per day of work.
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 Mobilization of backhoe/excavator and empty trucks to site for removal of CRCP

debris and then cart to disposal dump.
 The remaining 30mm shall be removed upon cut CRCP removal by using smaller
breaker

15.1.12.3 Cutting The CBM3

Cutting of the CBM3 layer shall be executed as follows :-
 To mobilize cutting machines with the appropriate diamond blades to make a 3.2
mm to 4.0mm wide cut to 150mm depth to complete cutting of the CBM3 layer. A
similar method shall be used to cool the cutting blades as per earlier stages of
cutting.
 Mobilization of backhoe and empty trucks to site for removal of CBM3 debris and
then cart to disposal dump.
 This CBM3 cutting shall be targeted to complete of approximately 300 meters
distance per day of work.
The procedures are repeated until completion of road cutting works.

15.1.12.4 CBM3 Key Rectification Works

Upon removal of cut CRCP, some of CBM3 might stick with the CRCP which can cause
damage to the existing CBM3. The contractor to ensure that existing CBM3 must be in
vertically cut in order to introduce a key to the existing CBM3.
Work Sequence
 Formwork to be used for forming vertical shape of 150mm height.
 The face of CBM3 shall be clean from dirt and loose material before concreting
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 The recess of approximately 100mm to be made into the existing CBM3

 Concrete G30/20 is placed to form back the key
 In extremely hot weather, the CBM3 key shall be moistened before concreting
 The concrete shall be compacted using vibrator poker
 cubes shall be taken for each concreting work.
 The formwork shall be removed after 3 hours.

15.1.13 Cement Bound Material – CBM 4

15.1.13.1 Laying of CBM4
 Work shall commence on site upon approval and acceptance of the upper subbase
and saw cutting of existing interfacing CBM.
 Approved CBM4 materials shall be mix-in-plant and delivered to site by tipper trucks
and to prevent loss of moisture content, the mixture shall be covered by tarpaulin.
 The supervisors at site will accept the delivery docket and tipping time will be
recorded.
 CBM shall be laid by paver to a compacted thickness not exceeding 200mm in single
layer.
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 The moisture content of the CBM shall be the optimum, as determined in

accordance with the vibrating hammer method test in BS 1377. Compaction shall be
completed within 2 hours as per specification clause 820.1.
 Protection of completed CBM shall be carried out to avoid any exposure to the
traffic run on CBM until the DBM (170mm thickness) has been laid.
 The surface of the CBM shall be finished to the grade and line as required by the
drawing and specifications, subject to tolerance of ± 10mm.
 At the end of the paving operation, the transverse joint will made by using timber as
vertical forms or diamond cutter to cut back to a straight cut before next operation
of paving.
 On completion of laying and compacted, joint dipping shall be conducted before
proceeding with the next layer.
 Bituminous tack coat shall be sprayed on completed CBM as curing purposed.

15.1.13.2 Field Control

15.1.13.2.1 Compaction
a. Compation shall be carried out using vibratory roller with specifications as given
below :-
Model : Dynapac CA251 or equivalent
Operating Weight, Total : 9,600 kg
Vibration Frequency : 30 HZ
Speed : 3-5 km / hr
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In order to achieve the specified compaction density, compaction using the

vibratory roller as specified / equivalent shall commence only when moisture
content of the CBM material is approximately at the optimum moisture content
value.

b. The rolling pattern applied shall be as follows :-

Breakdown rolling : 2 static passes with 4 vibration using
Dynapac CA251 or equivalent
Intermediate rolling : 6 passes using Dynapac CA 251
or equivalent
Final rolling : 2 static passes with Dynapac CA 251 or
Equivalent

Actual rolling pattern to be established through trial lay to achieve the specified
compaction along the longitudinal and transverse joints for the pavement works.
Full compaction to be achieved along the longitudinal and transverse joints.

15.1.13.2.2 Insitu Wet Density

The wet density at each location shall be determined immediately after compaction
by using sand replacement method as specified in clause 820.4. The average in-situ
wet density shall not be less than 94% of the average wet density from the
respective group of cube specimens.

15.1.14 Tack Coat

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15.1.14.1 Spraying Tack Coat

 Work shall commence at site upon approval and acceptance of the bituminous layer
of beneath or CBM.
 The surface to receive the tack coat ( RS-1K ) shall be power broomed and free from
all dirt, loose material and standing water.
 The approved tack coat ( RS-1K ) will be sprayed by Bitumen Emulsion self-propelled
Distributor evenly or manually to the surface of the bituminous layer.
 The spray should be uniformly at the specified rate without leaving any dry spots.
 The rate for spreading the tack coat shall be as follows :-

Sprayed Rate Remarks

0.4 to 0.6 litres/m² Concrete Surface

0.35 to 0.55 litres/m² CBM Surface

0.15 to 0.30 litre/m² Bituminous Surface

15.1.14.2 Field Control – Trial Spray

 These shall be carried out to assess and determine the rate of spray.
 A tray will be put at the middle of the area to be spraying.
 The tray will be weighed and measured before spray.
 After spraying, the weight of the tray with tack coat will be determined.
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 Hence, the rate of the spread will be determined as follows :-

15.1.14.3 Spraying rate

Rate of spread = (prime coat + tray ) – ( tray )
Density of prime coat X area of spray

15.1.15 Dense Bituminous Macadam – DBM40

15.1.15.1 Laying of DBM40
 Works shall be commenced on site upon approval and acceptance of prime or tack
coating.
 The DBM shall be plant mixed ( Brac 250 TPH Asphalt Plant ) with binder content as
established in the Job standard mixture.
 The approved DBM shall be delivered to site by tipper trucks. To prevent the loss of
heat, the mixture shall be covered by tarpaulin.
 The DBM shall be laid by mechanical sensor paver in single layer of compacted
minimum thickness 90mm.
 If the laid surface is open textured, back-casting shall be carried out and remove
the bigger size aggregates before rolling.
 At the end the paving operation, the transverse joint shall be feathered down. Lab
joint shall be provided for the next operation of paving.
 Compaction shall be carried out using the specified equivalent type of compactors
and rolling pattern shall be as per established during the trial lay.
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 Rolling shall be always commenced from the lower to the higher side of the
carriageway. The temperature of DBM at the completion of rolling shall be not less
than 90°C.
 Full compaction shall be achieved along the longitudinal and transverse joints.
 The surface of the DBM shall be finished to the grade and line as required by the
Drawings.
 On completion of laying and compaction, joint Dipping shall be carried out to check
for compliance with the specified requirement.
 samples per day per plant shall be taken to determine the binder content and
gradation of DBM.
 Frequency of compaction test (field density control) :- Twin samples shall be taken
from every 1000sq.m of DBM. The samples may used to determine the course
thickness and other requirements as per specifications.

15.1.16 Asphaltic Concrete Binder Course – ACBC 25

 Works shall be commenced on site upon approval and acceptance of DBM 40.
 The surface to receive the ACBC shall be freed of all dirt, loose materials and
standing water.
 Tack coat of approved bitumen emulsion shall be applied as per the specification on
the prepared surface prior to laid of the ACBC.
 The ACBC shall be plant mixed with bitumen content as established in the Job
standard mixture.
 The ACBC shall be delivered to site by tipper trucks. To prevent the loss of heat, the
mixture shall be covered by tarpaulin.
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 The approved ACBC shall be laid by mechanical sensor paver in one layer or two.
 If the finish surface is open textured, back-casting shall be carried out and remove
the bigger size aggregate before rolling.
 At the end the paving operation, the transverse joint shall be feathered down.
Vertical joint shall be provided for the next operation of paving.
 Compaction shall be carried out using the specified equivalent type of compactors
and rolling pattern shall be as per established during the trial lay.
 Full compaction shall be achieved along the longitudinal and transverse joints.
 Rolling shall be always commenced from the lower to higher of the carriageway. The
minimum laying temperature shall not be less than 120 degree Celsius while the
minimum rolling temperature at completion of compaction shall be 100 degree
Celsius.
 The surface of the ACBC shall be finished to the grade and line as required by the
Drawings.
 Upon completion of laying and compaction, joint Dipping shall be carried out to
check for compliance with the specified requirement.
 samples per day per plant shall be taken to determine the binder content,
Gradation Analysis and Marshall properties Test.
 Frequency of Marshall Density test (field density control ) :- Twin samples shall be
taken from every 1000sq.m of ACBC. The samples may used to determine the course
thickness and other requirements as per specifications.

15.1.17 Asphaltic Concrete wearing Course ACWC 20

 Works shall be commenced on site upon approval and acceptance of ACBC.
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 The surface to receive the ACWC shall be freed of all dirt, loose materials and
standing water.
 Tack coat of approved bitumen emulsion shall be applied as per the specification
on the prepared surface prior to laid of the ACWC.
 The ACWC shall be plant mixed with bitumen content as established in the Job
standard mixture.
 The ACWC shall be delivered to site by tipper trucks. To prevent the loss of heat,
the mixture shall be covered by tarpaulin.
 The approved ACWC shall be laid by ABG mechanical sensor paver or equivalent in
single layer.
 Regulating of ACWC shall carry out at depression area.
 If the finish surface is open textured, back-casting shall be carried out and remove
the bigger size aggregate before rolling.
 At the end the paving operation, the transverse joint shall be feathered down.
Vertical joint shall be provided for the next operation of paving.
 Compaction shall be carried out using the specified equivalent type of compactors
and rolling pattern shall be as per established during the trial lay.
 Rolling shall be always commenced from the lower to higher of the carriageway.
The minimum laying temperature shall not be less than 125 degree Celsius while
the minimum rolling temperature at completion of compaction shall be 110 degree
Celsius.
 Full compaction shall be achieved along the longitudinal and transverse joints.
 The surface of the ACWC shall be finished to the grade and line as required by the
Drawings.
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 Upon completion of laying and compaction, joint Dipping shall be carried out to
check for compliance with the specified requirement.
 samples per day per plant shall be taken to determine the binder content,
Gradation Analysis and Marshall properties Test.
 Frequency of Marshall Density test (field density control) :- Twin samples shall be
taken from every 1000sq.m of ACWC. The samples may used to determine the
course thickness and other requirements as per specification.

15.1.18 Stone Mastic Asphalt (SMA)

15.1.18.1 Laying of SMA
 Work shall commence on site upon approval and acceptance of the SMA material.
 SMA mix temperatures during mixing, laying and compaction shall be as per
specifications. Compaction shall commence immediately after the SMA laid. Roller
shall immediately follow the paver as closely as possible.
 The surface to receive the asphaltic concrete base course shall be freed of all dirt,
loose materials and standing water by sweeping
 Tack coat of polymer modified binder (PG76) shall be applied as per specifications
on the prepared surface prior to the laying of the SMA
 The approved SMA material shall be delivered to site by tipper trucks. To prevent
the loss heat, the mixture shall be covered by tarpaulin.
 The site supervisor will accept the delivery docket, tipping time and temperature
will be recorded.
 The SMA material shall be laid by sensor paver or equivalent in single layer with
minimum thickness of 40mm.
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 At the end of the paving operation, the transverse joint shall be feathered down.
Roller cutter of diamond saw cutter shall be use to cut back to a vertical face for
the longitudinal and transverse construction joint the next operation of paving.
 Full compaction shall be achieved along the longitudinal and transverse joints.
 Compaction shall be carried out using the specified / equivalent type of compactors
and the rolling pattern shall be established during the trial lay.
 Rolling shall always commence from the lower to the higher side of the carriageway.
The minimum rolling temperature shall not below 130ºC at completion of
compaction.
 On completion of laying and compaction, joint dipping survey shall be carried out to
check for compliance with the specified requirements.

15.1.18.2Compaction Requirements
 Method of compaction to achieve at least to density of 94% of the maximum
theoretical density and to achieve of void content as per specifications.

15.1.18.3 Trial Lay

a) These shall be carried out to access the suitability of the mixing, laying and
compacting plant and to establish the sequence of laying operation.
b) The trials shall also familiarize personnel experience in mixing and placement of
SMA and capable of any mixture adjustment required. Trial lay to be carried out
for each of the CBM, DBM, ACBC, ACWC and SMA materials.
c) Compaction shall be carried out using rollers with specifications as given below :-
Tandem Roller Model : Dynapac CC222 or equivalent
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Weight Of Tandem Roller : 7,000 kg to 12,000kg

Drum Width : 1,450 mm
Speed : 3 – 5 km / hr

15.2 Plant & Equipment

15.2.1 Treatment & Subbase Layers
Motor-grader CAT 12 G or equivalent
Back-pusher Ford 5000 or equivalent
Vibratory Roller Dynapac or equivalent
Water Tanker Isuzu or equivalent
Tipper Trucks Isuzu or equivalent

15.2.2 For CBM3 Repair

Concrete Mixer
Vibrator Poker
Cutting Machine
Formwork

15.2.3 For CBM4 & CBM2

CBM Batch Plant -
Paver Vogelle 1800 or equivalent
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Vibratory Roller Dynapac CA 251 or equivalent

Tipper Trucks Isuzu or equivalent
Milling machine Wirtgen 1900 W
Power Broom Ford 5000 or equivalent

15.2.4 For DBM40, ACBC25 & ACWC 20

Asphalt Mix Plant Brac 250 TPH or equivalent
Wheel loader Caterpillar 950 or equivalent
Paver ABG Titan 411 or equivalent
Vibratory Tandem Roller Dynapac CC21 or equivalent
Pneumatic Tyred Roller Dynapac WP20 or equivalent
Tipper Trucks Isuzu or equivalent
Water Trucks Isuzu or equivalent
Power Broom Ford 5000 or equivalent

15.2.5 For SMA

Asphalt Batch Plant Brac 250 TPH or equivalent
Wheel loader Caterpillar 950 or equivalent
Paver ABG Titan 411 or equivalent
Vibratory Tandem Roller Dynapac CC21 or equivalent
Pneumatic Tyred Roller Dynapac WP20 or equivalent
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Tipper Trucks Isuzu or equivalent

Water Trucks Isuzu or equivalent
Power Broom Ford 5000 or equivalent

However, if the above said plant breakdown, contractor to replace with the equivalent
machine in order to proceed the works.

16.0 ROAD LINE MARKING

16.1 General
This part specifies the requirements for the application of white and yellow thermoplastic
synthetic resin binder materials, which are melt and applied hot, to road surfaces using
screed methods as thin superimposed markings for centre lines, edge lines, stop lines,
chevron hatching, directional arrows and the like.

16.2 Method of Statement

 Since the thermoplastic material is applied hot, a good bond to the road is
normally obtained on standard bituminous surfaces
 The material shall not be laid over loose detritus, mud or similar extraneous matter
of over old flaking marking of paint or thermoplastic material. If the road surface is
wet, it shall be warmed carefully by a road heater so that. When the material is
laid, the surface temperature is above 5˚C and the surface is dry
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 To avoid discoloration and embitterment due to heating at a temperature in excess

of that specified by the manufacturer, the material shall be melted in a heater
fitted with a mechanical stirrer to prevent local overheating.
 A thermometer accurate to within +5˚C at the working temperature of the heater
shall be used during laying to ensure that overheating of the material does not
occur.
 Once molten, hydrocarbon resins shall be used within 6 hours. The materials shall
not exceed 230˚C application temperature during that time and shall be discarded
after that time.
 After transferring to the apparatus, the material shall be laid at a temperature
within the range of 180˚C - 230˚C for the particular method of laying being used.
For places inaccessible to screed machine, hand application shall be used.
 Where surface application of solid beads is required, the additional solid glass beads
shall be distributed from the screed machine at a rate of 300± 100g/m² concurrently
with the laying of the line
 The material shall be laid to the 2.0mm thickness for synthetic resin binder

17.0 SITE RECORDS

 The contractor’s representative in charge of works shall ensure that the site
supervisors continuously supervise and observe the construction works and furnish
the daily site report everyday.
 The site daily sheets shall records the following information :-
 Location of works
 Type of works and operations
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 Plant and equipments used on site

 Material delivered and used on site
 Subcontractor’s personnel and labour resources at site
 Weather condition
 The person in charge shall ensure that the completed works are measured and
recorded in the joint measurement sheets by the site supervisors.

18.0 SAFETY AND ENVIRONMENTAL

The following are part of safety and environmental control measures to be implemented at
work site.
 Work will be carried out according to the Project Safety Plan
 Induction courses shall be conducted to workers before commencement of work
 Banner and signboard shall be provided to warn any oncoming train
 All affected utilities will be protected or relocated prior to commencement of work
 All machinery mobilised to site will be inspected to ensure that it is in safe
operating condition
 Installed sheet piles will also be monitored for possible movement cause by other
construction activities nearby.
 Provide signboards to warn workers and public of dangers associated with
construction works.
 Concrete barriers, where required, will be placed to barricade working area and
prevent public from trespassing into the site.
 Conduct safety awareness to workers.
 Provide PPE to all workers including safety helmet, safety shoe, vest, ear plug, etc.
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 Flagmen will be provided to control traffic where appropriate.

 Ensure machine operators and signalmen are competent to carry out the work.
 Ensure machinery and equipment to be used is inspected and possesses valid
certificates.
 Ensure all affected utilities are relocated or protected prior to commencement of
work.
 Provide water browser to control dust especially during dry period.
 Provide temporary drainage to prevent/minimise pollution of existing waterway
during preparation of earth platform and bore piling.