Technical Specificationssec.2

Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications
SECTION 2 : CIVIL WORKS
2.00 GENERAL FOR CIVIL WORKS
(1) Description
This Specification sets forth the basic requirements of the works to design, manufacture,
furnish, install and construct various civil structures, inclusive of modification, changing or
removal of existing structure, described herein. The works shall also include temporary work,
switch-over work and removal work of existing civil utilities thereof.
The Drawings shall be referred to for detailed designing and the Contractor shall be required
to revise based on the findings and site surveys and to submit the detailed drawing for
approval of the Engineer.
(2) Scope of Work
(a) Contract Limits

Unless otherwise specified in this Specification, construction of civil structure shall be
carried out in accordance with the Drawings.
(b) Installation and Modification Limits

Under the Contract, construction of civil structures shall be subject, but not limited to:
- Demolition
- Earthwork and Drainage
- Concrete Bridge and Structure
- Steel Bridge and Structure
- Miscellaneous Civil Work for Fencing, Pavement and Sodding etc.
- Temporary Work
(c) Works to be Coordinated

Throughout the Contract Period, due consideration shall be taken for close coordination
with other section of works.
(3) Quality Assurance
(a) Contractor’s Responsibility

Types and numbers of civil structure shown on the Drawings shall be confirmed by the
Contractor through site surveys and the Contract. Any incorrect information, if any on
the Drawings, shall not relieve the Contractor from responsibility of performing all site
work under the Contract. Prior to preparing detailed work programmes and during
execution of the work, the Contractor shall coordinate with other related works.
(b) Work Coordination with PT. KAI

The Contractor shall be responsible to coordinate with PT. KAI for train operation and
safety procedure to be required by site civil works or any other works under train
operation.
(4) Survey and Design
The Contractor shall be required to execute site survey and soil condition analysis and to
submit detailed design of main civil structure and system for approval of the Engineer in
accordance with this Specification.
The Contractor shall be required to confirm bearing stratum and depth of underground
structure for abutment and any others. If it is different from the Drawings, the Contractor shall
revise the structure design for submission of the Shop Drawings.
Section 2 – Civil W orks Page 1 of 137

Design and drawing provided by the Employer are for reference only and the Contractor shall
be completely responsible for preparation of detailed structural analysis, calculation of civil
structures, Shop Drawings and additional Detailed Drawings of all civil structures and facilities
and shall be required to submit all calculation results and drawings to the Engineer for
approval.
(5) Materials
Materials for civil works shall be in accordance with this Specification and be approved by the
Engineer before procurement.
(6) Construction
The Contractor shall be required to construct various civil structures under PT. KAI train
operation and work procedure in accordance with this Specification.
The Contractor shall be required to perform monitoring of the site situation in deformation of
existing railway and other structure and the safety condition throughout the construction area.
(7) Test Procedure
The Contractor shall be responsible for carrying out required tests in accordance with this
Specification.
(8) Documentation
The Contractor shall submit three (3) copies of each of the following drawings and documents
to the Engineer according to the time schedule or as otherwise directed by the Engineer.
(a) Manufacturing Drawings

The Contractor shall submit to the Engineer for approval prior to manufacturing the
drawings and documents of the equipment or materials to be delivered in accordance with
the applicable provision in each section of this Specification. Manufacturing drawings and
documents shall contain the general assembly and main parts of equipment or materials.
(b) Shop Drawings

The Contractor shall submit the shop drawings to the Engineer for his approval prior to
installation of equipment or materials as required by the Engineer.
(c) Material Test Reports

Material factory test reports performed at the time of completion of manufacturing in
manufacturer’s factory, including description of test method, shall be submitted in booklet
form. Reports shall show test results performed to prove compliance with the specified
test criteria.
(d) Final As-Built Drawings

The Contractor shall submit as-built drawings of the completed civil facility according to
the final track alignment. Final as-built drawings shall be submitted to the Engineer
before Provisional Hand-Over under this Contract.

2.01 DEMOLITION
(1) Description
This work shall consist of removal wholly or in part, disposal of masonry, buildings, fences,
structures, old pavements, platforms and other obstructions indicated to be demolished,
except items to be removed and disposed of under other Specification, furnishing of all labor,
supervision, transport, tools, supplies, materials and equipment to carry out demolition of all
structures identified in the Drawings for demolition, salvage of identified items and materials,
removal of resulting rubbish and debris from the project area daily, unless otherwise directed,
to avoid accumulation at demolition site. Materials that cannot be removed daily shall be
stored in areas specifically identified by the Engineer.
The work shall include, but is not limited to, salvaging of designated materials and backfilling
of resulting trenches, holes and pits. Provision and maintenance of safety protection,
including hoardings, temporary footpath surfaces, road traffic protection, warnings and
canopies for protection of the public, shall be required, including protection of existing work
that will remain in place.
(2) Scope of Work
(a) General
Items for demolition works shall include all structures existing at site and being removed
from site for construction works in accordance with the Drawing. The Contractor shall be
responsible for confirming all items for demolition works by survey at site aboveground
and underground in addition to structure removal shown in the Drawings.
(b) Major Structures for Demolition

Major structures for demolition works are listed below for reference only and the
Contractor shall be required to confirm the detailed items.
Area and Section Structure Item

Manggarai Station Station Building, Platform, Fence, Water Tank, etc.
Manggarai – Jatinegara Ciliwung and Matraman Bridges
Jatinegara Station Jatinegara Locomotive Depot Building, Station Building,
Platform, Pedestrian Bridge, Fence, etc.
Cipinang Yard Station Building, Bridge Depot Building, Bridge Maintenance
Facility, Fence, Signal Cabin etc.
Klender Station Station Building, Signal Hut, Fence, etc.
Cakung Station Station Facility, Platform, Signal Hut, Fence, etc.
Rawa Bebek Station Station Facility, Platform, Fence, etc.
Kranji Station Platform, Fence, etc.
Bekasi Station Station Building, Platform, Signal Cabin, Fence, etc.
Tambun Station Station Building, Platform, Fence, etc.
Cibitung Station Station Platform
Cikarang Station Station Building, Platform, Signal House, Fence, etc.
(3) Construction
(a) Preliminary Activity

1) The Contractor shall ensure that all demolition works shall be carried out in a
controlled manner under the management of experienced and competent supervision.
Before demolition commences all relevant notifications shall need to be given to the
local authorities and media.
2) Prior to any demolition commencing, a survey shall be conducted to identify if there
are any hazardous materials present, for example presence of materials such as
asbestos and lead. If any hazardous materials are found, then consideration shall be
given as to whether they shall need to be removed by Specialist Agency responsible
prior to main demolition works commencing.

3) Demolition adjacent to any railway line and other works shall only take place after the
requirements of General Safety have been applied to the work.
4) Measures for protection of the public shall be required to give protection from any
possible falling debris and dust generation.
5) All power supplies and other services shall be disconnected before any demolition
work commences.
6) The Contractor shall record all demolished items and locations.
7) If any obstructive item is discovered at site, the Contractor will demolish it after
(b) Demolition of Buildings

1) Existing structures indicated shall be removed to underside of foundations. Interior
walls other than retaining walls and partitions shall be removed to the top of floor slab
on the ground. Basement slabs and floor slabs shall be broken and removed.
2) Existing structures to be partly demolished only shall be taken down with care to
avoid damage to the portion that is to remain. The Contractor shall take care to
demolish only that portion of buildings designated for removal and shall ensure the
stability of remaining structure. Damage to remaining portions and ends of remaining
sections shall be made good and ends of protruding portions shall be neatly dressed
without unsightly condition.
(c) Removal of Concrete or Reinforced Concrete Structures

Existing concrete or reinforced concrete structures designated for removal including
foundations shall be broken into convenient sized pieces by appropriate equipment for
removal and disposal as approved by the Engineer. Any operation necessary for removal
of a structure that may damage a new structure shall be completed prior to placing of new
work, unless otherwise provided in the Contract.
(d) Removal of Masonry

1) Existing masonry designated in the Drawings for removal shall be broken down into
original or convenient sizes for removal and stockpiled at locations or otherwise
disposed as approved by the Engineer.
2) Remaining and exposed ends shall be dressed in a suitable manner to be left in a
neat and workmanlike manner, without jagged or unsightly condition. Contractor shall
backfill holes, cavities and dress slopes as necessary to leave the ground in a safe
and tidy condition.
(e) Removal of Pavements, Curbs, Gutters and Street Light Bases

Irrespective of thickness, all asphalt concrete or concrete pavements except platforms,
shall be broken down into pieces and removed and stockpiled at locations or otherwise
disposed as approved by the Engineer. Existing pavements designated for removal shall
be saw cut at abutting sections designated to remain and removed down to the top of
sub-base if so required. Removal of any ballast or base course shall be considered as
Common Excavation and applied by Clause 2.08 “SOIL DISPOSAL”.
(f) Utilities.
Existing Utilities shall be removed as indicated in the Drawings. When utility lines are
encountered that are not indicated on the Drawings, the Engineer shall be notified prior to
further work in that area.
(g) Removal of Fencing

Existing fences made of steel rail, steel net or steel post and wire designated for removal
shall be taken down and removed, complete with foundations and stockpiled for disposal
or re-use as directed by the Engineer.
(h) Removal of Steel Structures

1) Steel structures shall be removed as complete units or portions of original structure.
Sections may be of structural steel or built-up beams and trusses and may include
cladding.

2) Steel structures shall be carefully dismantled and carried to store as directed by the
Engineer. Steel sections shall be neatly stockpiled to satisfaction of the Engineer.
3) Structures designated to remain and form part of a new structure shall be cut as
neatly as possible by saw leaving a small surplus for grinding and filling or attachment
to new construction as directed by the Engineer.
(i) Removal of Existing Platforms

This work shall include removal of platform walls, surfacing and platform fill, including any
structures founded in platform. All work shall be performed under the requirements of
General Safety. After removal the site of platform shall be compacted to conform with the
requirements in Clause 2.08 “SOIL DISPOSAL”.
(j) Filling
Holes, open basements, trenches and other hazardous openings shall be filled in
accordance with Clause 2.07 “GRANULAR BACKFILL”.
(k) Disposal of Material

1) Title to unsalvageable material recovered from demolished buildings and structures
except salvage, scrap and historic items, is vested in the Contractor, unless the
Employer designates otherwise.
a) The Contractor shall salvage items and material to the maximum extent possible.
This shall particularly apply to ferrous and non-ferrous materials. Remove to
store salvaged materials and equipment designated for the Employer, or
indicated for reuse or relocated, to prevent damage and reinstall as the work
progresses.
b) Salvaged items belonging to the Employer shall be removed in a manner to
prevent damage and packed or crated to protect the items from damage or theft
while in storage or during shipment. Items damaged during removal or storage
shall be repaired or replaced to match existing items. Containers shall be
properly identified as to contents. The Engineer will advise the Contractor of the
locations of storage for salvaged material.
c) Material salvaged for the Contractor shall be stored as approved by the Engineer
and shall be removed from the project site prior to completion of the Contract.
Material salvaged for the Contractor shall not be sold at site.
d) Historic items shall be removed in a manner to prevent damage. Skilled
craftsmen shall refurbish items scheduled for reuse, prior to re-installation.
2) Concrete Masonry, and other non-combustible material, except concrete permitted to
remain in place, shall be disposed of in a disposal area off-site and approved by the
Engineer. Fill in disposal area shall be placed as required by the operators of land-fill
site. Otherwise, fill in disposal area shall remain below ground level and uniformly
graded to drain after disposal is completed. Combustible material shall be disposed
of in land-fill site by burning.
3) The Contractor may dispose the demolished materials upon approval of the
Employer.
(l) Clean Up
Debris and rubbish shall be removed from basements and similar excavations. Debris
shall be removed and transported in a manner that prevents spillage on streets or
adjacent areas. Local regulations regarding haulage and disposal shall be applied.
(4) Method of Measurement
The quantity to be measured for payment shall be on the basis of a lump sum for the whole
works completed and accepted to the satisfaction of the Engineer.

(5) Basis of Payment
The quantity determined, as provided above, will be paid for at the Contract unit price for the
pay item listed below. The payment shall be considered as full compensation for all costs
necessary or usual for the proper completion of the work described in this Clause. All the
work and furnishing all labor, materials, tools, equipment and incidentals necessary to carry
out the work and stockpiling and disposal of the resulting materials as specified in this Clause
or as directed by the Engineer.
Pay Item No. and Name Unit of Measurement
201 Demolition lump sum

2.02 CLEANING AND GRUBBING
(1) Description
This work shall consist of all necessary work for clearing and grubbing, including top soil
stripping, removing and disposing of all debris, including rocks, boulders, old concrete, timber,
rubble, metal objects etc at and within 50cm of existing ground level within the limits of works
as described below except such objects as are designated to remain in place or are to be
removed in accordance with other Clauses of this Specification.
(2) Scope of Work
(a) General
The Engineer will establish the limits of work and designate all trees, shrubs, vegetation
plants and other things to remain or to be removed. The Contractor shall preserve all
items designated to remain or shall replace them at his own expense to satisfaction of the
Engineer.
(b) Clearing and Grubbing and Tree Removal

All surface objects and debris as described above and all trees, timber, rotten wood,
stumps, roots, snags, brush, other vegetation, rubbish, and other protruding obstructions,
not designated to remain or to be replaced, shall be cleared and grubbed, including
disposal off site as required.
In areas under embankment, from which top soil or suitable materials are to be removed
or which are designated to be compacted, all stumps and roots shall be removed to a
depth of at least 50cm below the original ground surface.
In cut areas, all stumps and roots shall be removed to a depth of at least 50cm below the
finished sub-grade level. Clearing and grubbing of pits, channel changes, ditches and
ponds etc will be required only to the depth necessary for excavation within those areas.
(c) Topsoil Stripping

In areas under embankment or where designated by the Engineer, the Contractor shall
remove topsoil and dispose of it as directed by the Engineer. Removal of topsoil shall
include only the removal of soil which is sufficiently fertile to encourage or sustain a
growth of vegetation. Removal of topsoil over any designated area shall be executed to
the depth as directed by the Engineer and topsoil shall be kept separate from other
excavated material.
(d) Protection of Areas Designated to Remain

In areas designated by the Engineer the Contractor shall be responsible for protection
and routine maintenance of existing shrubs, trees and grassed areas. On completion of
the works these areas will be returned to the Employer in the same condition as before
and any damage due to the work operation by the Contractor shall be repaired at his own
expense.
(e) Disposal of Cleared Material

The Contractor shall have the right to use unsaleable timber or saleable timber, when
permission is granted in writing by the appropriate Government agency or authority for his
own purposes in connection with the work, provided that the Contractor ascertained and
complied with the requirements of the appropriate Government agency or authority.
Saleable timber shall be neatly stored in an approved accessible place within or near the
Right-of-Way as directed and shall be trimmed and stacked in accordance with the
requirements of the appropriate Government agency.
All the timber, except to be used, and all brush, stumps, roots, Iogs, debris and other
rubbish and refuse from the clearing and grubbing operation shall be disposed of at
locations provided by the Contractor. Cleared site and adjacent areas shall be left with a
neat and finished appearance in preparation for subsequent common excavation

earthworks. No accumulation of debris shall remain on or adjacent to the Right-of-Way.
(f) Horizontal and Vertical Alignment

The Drawings will indicate the properties of horizontal and vertical curves, together with
rates of super elevation, transitions, etc. where required. The Contractor shall prepare
cross-sections based upon the above properties, submit for approval of the Engineer and
stake out before proceeding with construction. If in the opinion of the Engineer, any
modification of the line or grade is required, either before or after stake-out, the Engineer
will issue detailed instruction to the Contractor for such modifications and the Contractor
shall revise the stake-out for further approval.
The quantity to be measured for payment shall be the actual number of square meters of
clearing and grubbing which shall be deemed to include clearing and grubbing, top soil
stripping, removal of all debris and rubbish etc and the disposal of same all as mentioned
above in this Clause . The work shall only be measured for those areas designated by the
Engineer to be cleared and grubbed to allow construction of the works and shall not include
disposal sites, material sites, imported borrow pit sites, haul roads and all temporary
construction when these are outside the designated areas.
pay item listed below. The price and payment shall be full compensation for all costs
necessary for the proper completion of the work prescribed in this Clause, including furnishing
ail labor, materials, tools and equipment etc. and all incidentals necessary to carry out the
work, stockpiling and disposal of the resulting materials as previously specified in this Clause
or as directed by the Engineer.
Pay Item No and Name Unit of Measurement
202 Clearing and Grubbing square meter

2.03 EXCAVATION
(1) Description
This work shall consist of all necessary work for excavation works as described below.
(a) Common Excavation

Common Excavation shall consist of all excavation within the limits of the Right-of-Way
except Structural Excavation, removal, handling and proper utilization or disposal of all
excavated materials and shaping of excavation and preparation of exposed surfaces of
excavation for entire length of trackbed or roadway in accordance with this Specification
and the lines, Ievels, grades, dimensions and cross-sections shown on the Drawings and
as required by the Engineer.
(b) Structural Excavation

Structural Excavation shall consist of excavation in earth without sheeting, or with
sheeting, struts and wales, within the limits of the work as specified herein or as shown on
the Drawings for structures. Any excavation which can be defined under any other Clause
of this Specification shall not be considered to be Structural Excavation.
Structural Excavation shall be limited to excavation for foundation of concrete structures

unless otherwise noted in this Specification. It shall include backfilling with suitable
material accepted by the Engineer, incorporating surplus material in the fill area as
described in Clause 2.04 "EMBANKMENT" and disposing of waste material.
(c) Structural Excavation with Ground Anchor

"Structural Excavation with Ground Anchor" shall be same construction to "Structural
Excavation" for Ground Anchor.
(2) Scope of Work

1) Use of Excavated Material
Suitable material excavated under this Clause shall be incorporated into the
permanent works in accordance with Clause 2.04 "EMBANKMENT" or excavated
material shall, if directed by the Engineer, be considered as waste and dealt with in
accordance with Sub-Clause 2.02(6) "Waste" in this Specification.
2) Removal and Disposal of Unsuitable Material
When so directed in writing by the Engineer, the Contractor shall remove material
unsuitable for use in embankment and shall dispose of it as provided in Sub-Clause
2.02(6) “Waste” in this Specification.
Where excavation reveals a combination of suitable and unsuitable materials, the

Contractor shall, unless otherwise agreed by the Engineer, carry out excavation in
such a manner that the suitable materials are excavated separately for use in the
works without contamination by the unsuitable materials.
When unsuitable material below sub-grade or embankment foundation level is

removed, soil left in place after removal of unsuitable material shall be compacted to
a density of 90 percent of maximum dry density determined according to AASHTO
T180. Backfilling shall be by suitable material compacted to 90% of maximum dry
density determined according to AASHTO T 180.
3) Conglomerate or Soft Rock
When material in cut is soft or weathered rock, such that in the opinion of the
Engineer it is not firmly consolidated as to require drilling and blasting, the Contractor
shall use an excavator with suitable steel tines or other appropriate equipment for
ripping for its removal. Such ripping work shall be considered as Common
Excavation.

(b) Structural Excavation

On completion of structure, excavated areas shall be backfilled with approved material to
the level of finished ground surface. Unless otherwise approved by the Engineer, all
backfill shall be carried out in accordance with the requirements of Clause 2.04
"EMBANKMENT ".
All material surplus to the requirement of this Clause shall, if instructed by the Engineer,
be considered as waste and treated in accordance with Sub-Clause 2.02(6) "Waste" in
this Specification.
(c) Structure Excavation with Ground Anchor

Ground Anchors shall be standard manufacturer’s product designed for the purpose to
which they shall be used. The Contractor shall provide full manufacturer’s data and
descriptions of previous applications of the product.
(3) Groundwater
(a) Measures for Groundwater

Whenever groundwater is encountered during structural excavation, the Contractor shall
take such measures as described in this Clause to ensure that excavation and
subsequent footing or bottom slab construction are kept free of water. Further, preventive
measures shall be taken to prevent the entry of surface water into the excavation area by
covering during rain and diverting surface flow by means of dykes, etc.
(b) Cofferdams or Cribs

Suitable watertight cofferdams shall be used or other effective water control systems
wherever water bearing strata are encountered significantly above the elevation of
excavation bottom. Upon request, the Contractor shall submit drawings and data showing
work method of water control needed for proper construction to the Engineer for approval.
Cofferdams or cribs for foundation construction shall be constructed to a depth well below
the bottom of footings and shall be well braced and as watertight as practicable. Interior
dimensions of cofferdams shall be such as to give sufficient clearance for construction of
forms and inspection of exteriors and to permit pumping outside of forms.
Cofferdams or cribs, which are tilted or moved laterally during process of sinking, shall be
righted or enlarged so as to provide the necessary clearance. In any case, safety of
excavation shall be the primary consideration together with construction under "dry"
conditions. Cofferdams shall be designed and constructed to be safe against sudden
rising of water and to prevent damage to foundation. No timber or bracing shall be left
permanently in excavation. All cofferdams or cribs, with all sheeting and bracing involved
therewith, shall be removed by the Contractor after completion of substructure. Removal
shall be effected in such a manner as not to disturb or damage any finished work.
Any pumping that is permitted from interior of any foundation enclosure shall be done in
such a manner as to preclude the possibility of any portion of concrete materials being
carried away. Any pumping required during placing of concrete, or for a period of at least
24 hours thereafter, shall be done from a suitable pump located outside concrete forms.
(4) Excavation
(a) Requirements for Structure Excavation

Prior to starting excavation in any area, the Contractor shall be required to:
1) Take steps on his own initiative to regulate the natural drainage of water flowing on
the ground surface in order to prevent it running into the excavations area.
2) Ensure that all necessary structure removal and clearing and excavation in the area
performed in accordance with this Specification.
3) Notify the Engineer sufficiently in advance of beginning of any excavation so that
cross-sectional elevations and measurements are taken of the undisturbed ground.

Existing ground adjacent to structures shall not be disturbed without permission of the
Engineer. Trenches or foundation pits for structures or structure footings shall be of
sufficient size to permit placing of structures or structure footings of the full width and
length shown. Sides of trenches or pits shall be adequately supported with sheet piles or
soldier type sheeting together with H-beams planking wales and struts at all times, if
necessary.
(b) Work Method for Structural Excavation

Elevations of footings bottom as shown on the Drawings shall be considered as
approximate only and the Engineer will order, in writing, such changes in dimensions or
elevations of footings as deemed necessary to secure a satisfactory foundation.
Boulders, Iogs and any other unsuitable material encountered in excavation shall be
removed from the site and shall not be used for backfilling purposes.
After each excavation is completed, the Contractor shall notify the Engineer to that effect,
and no footing or bedding material shall be placed until the Engineer has approved the
depth of excavation and the character of foundation material.
Excavation to final grade shall not be made until just before the footing is to be placed
and foundation material shall be compacted to 95 % of maximum dry density as
determined in accordance with AASHTO T180, or as otherwise specified, for direct
bearing structures. In case of foundations the final grade shall be thoroughly compacted
using mechanical tampers. This foundation fill shall be placed and properly compacted in
15 cm layers up to foundation elevation to 95 % of maximum dry density as determined in
accordance with AASHTO T180. Source and suitability of fill material shall be as
approved by the Engineer.
If, in the opinion of the Engineer, foundation material is unsuitable solely because of the
Contractor's failure to maintain the bottom of excavation in a dry condition, the Contractor
shall:
1) carry out at his own expense removal and replacement described above; or
2) suspend work in that excavation until such time as foundation material becomes
suitable.
All excavated suitable material, which is approved by the Engineer, shall be utilized as
backfill or embankment, or shall be removed from site if surplus to requirements.
Where a box culvert or pipe culvert is to be located or extended in embankment

excavation shall be performed after embankment has been constructed to the proposed
subgrade level or to at least 10 cm above the top surface of culvert and compacted
sufficiently.
(5) Ground Anchor
(a) Materials of Ground Anchor

1) The Engineer will approve materials, equipment, methods and procedures used by
the Contractor for installation of ground anchors.
2) Drill holes shall have diameters recommended by the supplier or as designed by the
Contractor and approved by the Engineer.
3) Anchors shall be thoroughly cleaned and be free from loose rust, scale, dirt, grease
or any other coating before they are inserted into the drill holes. Anchor bars shall be
at least dia. 25 mm bars of a type to which the Engineer will issue the approval.
Anchors shall be installed in accordance with the manufacturer’s recommendations
and be prestressed as directed by the Engineer.
(b) Work Method of Ground Anchor

1) Anchors shall normally be grouted in over the design length with a grout consisting of
cement and water with or without addition of sand. Cement grout for anchors shall be
a pumpable mixture. Aluminum powder shall be added to the mix for expansion of

the grout at the rate of 0.005 % of the cement content by weight. Grout shall be
mechanically mixed for a minimum 3 minutes. Minimum compressive strength shall
be 12 MPa at 24 hours and be determined in tests at frequencies directed by the
Engineer. Additives may be used subject to the Engineer's approval after site trials
conducted by the Contractor in the presence of the Engineer.
2) Grouting shall be carried out in a manner preventing formations of voids or air
pockets. Composition of grout and grouting procedures shall be subject to approval
of the Engineer.
3) Prestressing force shall be achieved by using jacks imposing a direct pull. Protruding
end of bolts shall be provided with rolled or cut threads for fixing of anchor plates by
nut and washer.
4) All tensioned ground anchors shall be tested between 7 and 10 days after installation.
If tension has not been maintained, such bolts shall be re-tensioned to the working
load. Bolts, which have lost more than 30 % of their load, shall be considered
defective and shall be replaced at the Contractor's expense. The Engineer may, for
all or any bolts, direct further testing and re-tensioning.
(6) Waste
(a) Waste Material

Material shall be designated as “Waste” in the following cases.
1) When material resulting from excavation is declared in writing by the Engineer to be
unsuitable for use in embankment or other work. Normally, highly organic clays and
silts, peat, soil containing large amounts of roots, grass and other vegetable matter,
domestic or industrial waste such as vinyl sacks and refuse are unsuitable. Materials
that are soft or unsuitable merely because they are too wet or dry are not to be
classified as unsuitable unless otherwise directed by the Engineer.
2) When material resulting from excavation is surplus to the amount required for
construction of embankment, provided, however, it is not material rendered surplus
by reason of the Contractor having opened borrow pits solely for his own
convenience as provided in Clause 2.05 “BORROW MATERIAL” of this Specification.
Material proposed for wasting shall not be wasted until approved or directed in writing by
the Engineer.
(b) Work Requirements

Unsuitable material shall be excavated below subgrade and embankment foundation
level to the depth shown on the Drawings or directed by the Engineer. Where unsuitable
material is excavated below normal subgrade level or below embankment foundation or
for benching under embankments, excavation shall be back filled with suitable material.
Waste shall be removed and disposed of in waste areas provided by the Contractor in
such manner as to present a neat appearance and not to obstruct drainage of any
railway, street or property, injury to railway public works or property. If it becomes
necessary for the Contractor to locate or relocate any waste areas, they shall be
approved by the Engineer prior to spreading any waste.
Waste areas shall be left in a smooth, neat and drainable condition, as directed by the
Engineer and all waste material shall be placed in such manner that adjacent property will
not be damaged or endangered.

The quantity of common excavation to be measured for payment shall be the actual
number of cubic meters of material excavated and measured in its original position and
shall be computed as described below. Volume of material excavated for temporary
diversion roads constructed by the Contractor for his own use not shown on the
Drawings, or where the Contractor constructs a greater width than that of a specified
temporary road, will not be measured for payment.

(b) Structural Excavation and Structural Excavation with Ground Anchor

The quantity of structural excavation to be measured for payment shall be the actual
number of cubic meters of material excavated for structures and measured in its original
position and shall be computed as described below.
Depth of structural excavation shall be to the bottom of blinding or footing, if blinding not
used, from the agreed ground level after the work has been performed in accordance with
Clause 2.02 “CLEANlNG AND GRUBBING" and no allowance shall be made to
compensate for anticipated swell or additional material resulting from slides, slips, cave-
ins, silting or filling whether due to the action of elements or to operations by the
Contractor. Horizontal limits for structural excavation shall be within vertical faces parallel
with the outermost horizontal dimensions of footing, base slab, rubblestone or other
structure to be constructed or installed in the excavated space, unless otherwise
described or specified in other Clauses of this Specification.
Where the Engineer orders or the Contract requires the excavation to be made after the
embankment has been placed, this extra excavation in the embankment will be measured
for payment as structural excavation as provided in this Specification. Structural
excavation shall include bracing, sheeting, cribs, cofferdams when required, and pumping
and water control, placing and compacting backfill, restoration of ground surface, disposal
of waste and all necessary materials and equipment for keeping the excavation free of
surface water run-off and groundwater.

The quantities determined, as provided above, will be paid for at the Contract unit price
per unit of measurement for the pay items listed below, which payment shall be full
compensation for all costs necessary or usual for the proper completion of the work as
directed by the Engineer, including all labor, equipment, tools, materials, items and
incidentals.
Performance of this work shall include all work involved in performing excavation,
including excavating, removal, haulage, placing and compaction or satisfactory disposal
of material from excavation, shaping and completion of all surfaces and furnishing all
labor, materials, tools, equipment and incidentals to complete the work as shown on the
Drawings, specified in this Specification and as directed by the Engineer.
(b) Structural Excavation and Structural Excavation with Ground Anchor

The quantities determined, as provided above, will be paid for at the Contract unit price
per unit of measurement for the pay items listed below, which payment shall be full
compensation for all costs necessary or usual for the proper completion of the work as
directed by the Engineer, including all labor, equipment, tools, materials, items and
incidentals.
203(1) Common Excavation cubic meter

203(2) Structural Excavation cubic meter
203(3) Structural Excavation with Ground Anchor cubic meter

2.04 EMBANKMENT
(1) Description
This work shall consist of construction of embankment and backfill not specified elsewhere by
furnishing, placing, compacting and shaping suitable material of acceptable quality obtained
from approved sources in accordance with this Specification and to the lines, Ievels, grades,
dimensions and cross-sections shown on the Drawings and as required by the Engineer.
(2) Material
Material for embankment shall consist of suitable material approved by the Engineer and
excavated under the provisions of Clause 2.03 “EXCAVATION” of this Specification. Borrow
material shall only be used under the provisions of Clause 2.05 "BORROW MATERIAL".
Surplus or unsuitable material shall be disposed of as provided in Sub-Clause 2.03(6)
“WASTE”.
(3) Construction
(a) Compaction of Foundation of Embankment
After site clearing, when ordered by the Engineer, the Contractor shall excavate turf,
decayed vegetable matter, or other unsuitable matter to such depth as the Engineer will
require. This work shall be considered as Common Excavation in accordance with Sub-
Clause 2.03(1).
Before beginning construction of embankment, the Contractor shall fill all holes, etc.
within all areas which have been cleared and grubbed and such areas shall be suitably
Ievelled at the level resulting after removal of topsoil. Fill material shall be approved by
the Engineer. This work shall not be paid for directly but shall be considered a subsidiary
obligation of the Contractor covered by the Contract Price for Pay Item 2.03 (1) of this
Specification.
Before construction of embankment, the Engineer may order the compaction of cleared
surface or that resulting after removal of topsoil, in which case density after compaction
shall conform to the requirements of Section (d) of this Clause.
(b) Placing and Compaction

1) Material for embankments, obtained and approved as provided above, shall be
placed in horizontal layers of uniform thickness over a width determined by the
Engineer and in conformity with the lines, grades, sections and dimensions shown on
the Drawings.
Layer of loose material other than rock shall be not more than 20 cm thick, unless
compacting equipment used is capable of compacting a depth greater than 20 cm to
a uniform density through the full depth which is acceptable to the Engineer, in which
case the Contractor shall place and compact the material other than rock, in layers of
the thickness approved by the Engineer. After adjustment of the moisture content to
that required obtaining maximum density, loose material shall be compacted to the
required density.
2) If the material deposited as fill at optimum moisture content cannot be compacted in
accordance with the requirements of this Specification, the Contractor shall at the
Contractor’s expense either:
a) Remove the material to a convenient place for reconditioning or mixing with other
material until it is suitable for re-use and replace it on embankment.
b) Make good the material in-place by mechanical or chemical means; or
c) Cease work on the material until its physical condition by drying cut becomes
such that it can be compacted as described in this Specification.
3) Where embankments are located on hillsides, or where new fill is to be compacted
against existing embankments or where fill is constructed on half width at a time, the
original slope of hillside, of the old or of the first half width fill, shall be cut into a
distance sufficient to accommodate the width of compacting equipment as the new fill

is placed in horizontal layers and this material cut shall be incorporated and
compacted with the new fill.
In measurement of the work no allowance shall be made for volumes of material cut
from the hillside or from the old or from the first half width fill to accommodate the
compacting equipment but shall be calculated only on the net volume of fill placed
against the original hillside, the old embankment or the first half width fill.
4) To avoid interference with construction of bridge abutments, wing walls and box
culverts, the Contractor shall, at points to be determined by the Engineer, suspend
work on embankments forming the approaches to any such structure until such time
as construction of the latter is sufficiently advanced to permit the completion of
approaches without the risk of interference or damage to bridge works. Cost of such
suspension of work shall be included in the Contract unit prices for "Cleaning and
Excavation", and "Borrow Material ".
5) Material for embankment at points inaccessible to normal compacting equipment
shall be placed in horizontal layers of loose material not more than 10 cm thick and
thoroughly compacted by use of mechanical rammers.
6) In carrying embankments up to or over culverts, the Contractor shall bring
embankments up equally on both sides. If conditions require placing backfill or
embankment appreciably higher on one side than on the opposite side, additional
material on the higher side shall not be placed until permission is given by the
Engineer and preferably not until structure has been in place 14 days and tests made
by the laboratory under supervision of the Engineer establish that the structure has
attained sufficient strength to withstand any pressure created by the methods used
and materials placed without damage or strain beyond a safe factor.
Where special materials for filling adjacent to structures are described in the Contract,
filling may proceed over widths less than the full width of embankment and in steps
not exceeding the depth of one layer above adjoining area of fill. In rock fill
embankments materials shall be carefully packed for such distance from structure as
is described in the Contract.
Special care shall be taken to prevent any wedging action against structure and all
slopes bounding or within the areas to be filled shall be benched or serrated to
prevent wedge action. Placing of embankment and benching of slopes shall continue
in such a manner that at all times there shall be a horizontal berm of thoroughly
compacted material for a distance at least equal to the height of abutment or wall to
be backfilled against except in so far as undisturbed material intrudes upon these
areas.
(c) Compaction Trials

Before starting formation of embankment the Contractor shall construct trial lengths for
compacting as directed by the Engineer. Soils used in trials shall be those encountered
along railway and compacting equipment shall be same equipment that the Contractor will
use for main work and has been accepted by the Engineer.
Object of these trials will be to determine the optimum moisture content and relationship
between number of passes of compacting equipment and density obtained for soil types
under trial. No separate payment will be made for this work, which will be regarded as a
subsidiary obligation of the Contractor covered under the other clauses of this
Specification.
(d) Required Density

Required densities to which embankment layers shall be compacted are described below.
1) Layers more than 20 cm below subgrade level shall be compacted to 90 percent of
the maximum dry density determined according to AASHTO T180. For all soils,
except rock fill materials, containing more than 10 percent oversize material retained
on a 19.0 mm (3/4 inch) sieve, the maximum dry density thus obtained shall be
adjusted for such oversize material as directed by the Engineer. Subsequent layers
shall not be placed and compacted unless the previous layer has been properly

compacted and accepted by the Engineer.

2) Layers 20 cm or less below subgrade level shall be compacted to 95 percent of the
maximum dry density determined according to AASHTO T 180.
(e) Moisture Content

Embankment material that does not contain sufficient moisture to obtain the required
compaction shall be given additional moisture by means of approved sprinklers, water
trucks, etc. and mixing. Drying of wet material may be expedited by dicing or other
approved methods.
Compaction of the embankment shall be carried out at the optimum moisture content. In
forming the embankment the Contractor shall take steps to ensure that the work can be
drained free of rain water and shall make due allowance in the height and width of the
work for swelling or shrinkage.
(f) Mixed Material in Fill

When materials of widely divergent characteristics, such as clay and chalk or sand, drawn
from different sources, are to be used in the embankment, they shall be deposited in
alternate layers over the full width of the embankment to depths approved by the
Engineer.
When material used for fill is of variable quality, the Contractor shall schedule and
execute the works so that material designated as better quality by the Engineer, is used
in the upper layers of fill. Rock, clay or other material shall be broken up and no
accumulation of lumps or boulders at the toe of the embankment shall be permitted.
(g) Levelling of Existing Embankment

Before fill is placed and compacted on an existing railway, existing embankment and
pavement will be levelled by cutting, rooting, or scarifying with approved mechanical
means to a level to be determined by the Engineer. Earth, old asphalt, or other material
obtained as a result of this operation will be declared by the Engineer to be either suitable
or unsuitable for use in the embankment. In the first case it shall be used in the adjacent
embankment as directed by the Engineer, subject to the provisions in Clause 2.03
"EXCAVATION". In the second case the material shall be disposed of as provided in Sub-
Clause 2.03(6) "WASTE".
(h) Finishing Trackbed or Roadbed

1) Final Grade Level
When an embankment requires the addition of material to a depth of not more than
20 cm to bring it up to the required grade level, top of the embankment shall be
thoroughly scarified and recompacted before the additional material is placed.
Final grade level, to the profile indicated and adjusted for super elevation where
required, shall conform to the provisions of Sub-Clause 2.02(2) "Horizontal and
Vertical Alignment" of this Specification. Prior to adding any material to raise the level
of any low spots, existing surface shall be scarified.
2) Slopes
Side slopes shall be neatly trimmed to the lines and slopes shown on the Drawings
as directed by the Engineer and finished work shall be left in a neat and acceptable
condition.
3) Stability
The Contractor shall be responsible for stability of all embankments and shall replace
any portions that have been damaged or displaced due, in the opinion of the
Engineer, to carelessness or neglect on the part of the Contractor, or to such natural
causes as storms. The Contractor will not be responsible for damage caused by
unavoidable movements of the natural ground upon which the embankment is made.
During construction the embankment shall be kept shaped to drain at all times. When
unsuitable material has been placed in the embankment by the Contractor, the
Contractor shall remove it and replace it using suitable material and without extra
payment therefor. Any deformation of embankment during the construction period

shall be repaired by the Contractor, including the additional embankment works

before Provisional Hand-Over without extra payment.
(4) Density Testing
Density testing shall be undertaken by the Contractor to ensure compliance with this
Specification and frequency of testing shall be as shown below.
- Layer : Number of Field Density Tests

- Fill : 3 tests per 750 m2 or part of thereof
- Subgrade : 3 tests per 500 m2 or part of thereof
The Engineer will increase or reduce frequency of testing at his discretion depending on the
initial test results.
The quantity to be measured for payment shall be the actual number of cubic meters of
embankment constructed according to the Drawings or as instructed by the Engineer,
compacted, tested and accepted by the Engineer.
The quantity to be measured for payment will be computed by the alignment and cross
section approved by the Engineer in accordance with the Shop Drawings.
The quantity determined, as provided above, will be paid for at the Contract unit price per unit
of measurement for the pay item listed below. The price and payment shall be full
compensation for all costs necessary or usual for the proper completion of the work in
accordance with this Specification and as directed by the Engineer, including all labor,
equipment, tools, items and incidentals.
Material for embankment will be provided and paid for under Clause 2.03 “EXCAVATION”.
Embankment constructed by using borrow material shall be measured and paid for under
Clause 2.5 “BORROW MATERIAL”.
204 Embankment cubic meter

2.05 BORROW MATERIAL
(1) Description
This work shall consist of clearing and stripping of borrow pits, excavating and hauling,
spreading and compacting of borrow materials obtained from approved sources for
constructing embankment, subgrade and other parts of the work as required by the Contract
or by the Engineer.
(2) Applicable Provisions
The applicable provisions of Clause 202 “CLEARING AND GRUBBING, Clause 203
“EXCAVATION” and Clause 204 “EMBANKMENT” shall be read into and become part of this
Clause.
(3) Materials
Borrow material shall be selected to meet the requirements and conditions of the particular fill
or embankment for which it is to be used. Materials shall be free from detrimental quantities of
organic material such as leaves, grass, roots and sewage. Any material classified by the
Unified Soil Classification System as OL, OH or Pt shall not be used. Other satisfactory
material may be used with the prior written approval of the Engineer, with or without any tests
required as directed by the Engineer. The required minimum CBR of borrow materials shall
be 5 % per AASHTO T 193.
(4) Use of Borrow Pits
Borrow material shall be obtained from approved private sources. Permission to open borrow
pits, including advice as to its suitability, shall first be obtained in writing from the Engineer.
Nevertheless, total amount of surplus material from common excavation and structural
excavation of this Specification, after deduction of the material declared unsuitable by the
Engineer, shall be considered to be available for use in embankment and any borrow material
resulting from the Contractor having used borrow pit in place of surplus material shall not be
measured for payment under this Specification.
Distance of borrow pits from the work site shall not be grounds for extra payment or revision
of the Contract Price. The Contractor shall visit the site and form an estimate of the haulage
costs on the basis of survey of possible nature and locations of borrow pits.
(5) Construction
Suitable borrow material shall be constructed and incorporated in the permanent works in
accordance with Sub-Clause 2.04(3) “Construction”.
(6) Payment to Others
Consent of the landowner and tenant for digging and taking of material for borrow materials
shall be secured by the Contractor, who shall, if required, pay for such concession. Pit shall
be left in a condition acceptable to the owner and to the Engineer. Any fees payable for
permission to cut or haul the borrow material shall be at the Contractor's expense and shall
be deemed to be included in the unit price for this pay item.
The quantity to be measured for payment shall be the actual number of cubic meters of the
earthworks borrow material required, compacted and completed to the lines, grades and
cross-sections shown on the Drawings and as directed by the Engineer. The quantity to be
measured for payment will be computed by the alignment and cross section approved by the
Engineer in accordance with the Shop Drawings. No allowance will be made for shrinkage in
borrow material between cutting at borrow pit and incorporation in permanent work.

compensation for all cost of searching for and finding borrow pits, acquiring right to occupy
the sites and extract materials, cost of any negotiation in connection with borrow pits, cost of
obtaining right of access, cost of establishing and maintaining access, any fees, Iicenses, or
royalties in connection with borrow pits, clearing, grubbing, sloping, draining and cleaning up
of pits, for furnishing, excavating, hauling, placing and compacting material from borrow pits
and constructing embankment and for providing all labor, equipment, tools and incidentals
necessary for the works.
205 Borrow Material cubic meter

2.06 SUB-BALLAST
(1) Description
This work shall consist of supplying, placing and compacting sub-ballast material, (not asphalt
treated), which shall consist of sandy gravel between sub-grade and this asphalt treated base
course for roads and ballast for track areas, in accordance with this Specification and in
conformity with the lines, grades, thickness and typical cross-sections shown on the Drawings
or instructed by the Engineer. Whenever "sub-ballast" is shown on the Drawings or is ordered
by the Engineer, all requirements shall be those corresponding to "sub-ballast" as provided
for in this Specification.
(2) Materials
The Contractor shall provide the Engineer at least 14 days prior to the scheduled beginning of
sub-ballast works with a complete statement of origin and composition of all aggregates to be
used in constructing sub-ballast works. All material shall comply with the requirements of this
Specification.
Deleterious substances shall not be contained in sub-ballast materials more than the
indication as described below.
Soft and friable pieces (ASTEM PC 235) : 5.0%

Clay Lumps (ASTEM C 142) : 0.5%
Sub-ballast material, when tested in accordance with ASTM C 136, shall consist of well-
graded sand-gravel conforming to the following requirements and standards.
Sieve Designation (mm) Percentage Passing by Weight

Passing 50mm (2”) 100%
Passing 25mm (1”) 90% to 100%
Passing 9.5mm (2/8”) 50% to 84%
Passing 2mm (No.10) 26% to 50%
Passing 0.425mm (No.40) 12% to 30%
Passing 0.075mm (No.200) 0% to 10%
Maximum size 4mm
Sieve shall conform to the requirements as described below.
Liquid Limit (ASTEM D 423) Less than 35%

Plasticity Index (ASTEM D 424) Less than 9%
(3) Construction
(a) Preparation of Sub-ballast

Sub-ballast shall be constructed prepared and finished as provided under this
Specification before placing sub-base material. Minimum California Bearing Ratio (CBR)
for sub-ballast shall be 8% for roads.
(b) Spreading
The Contractor’s method of spreading sub-ballast shall be subject to the approval of the
Engineer.
(c) Compaction
Immediately following final spreading and smoothing, each 15cm layer shall be
compacted to full width by means of smooth wheel power rollers, pneumatic tired rollers
or other approved compaction equipment. Rolling shall progress gradually from the low to
the high point of cross section parallel to the centerline of carriage-way and shall continue
until entire sub-ballast surface has been rolled.

Any irregularities or depressions that develop shall be corrected by loosening material at

these places and adding or removing material until surface is smooth and uniform. At all
places not accessible to the roller, material shall be compacted thoroughly with approved
tampers or compactors. Material shall be both graded and rolled until a smooth and even
surface has been obtained.
During performance of the work, thickness of each course shall be accurately controlled
to attain the required thickness after compaction. Where surface fails to meet the
tolerance requirement the Contractor shall remove and replace sub-ballast as directed by
the Engineer without any additional cost. Sub-ballast material shall be compacted to
produce the required density through the full depth of each layer of at least 95 percent of
maximum density determined in accordance with AASHTO T 180, method D. In place
field density determinations will be made in accordance with AASHTO T 191. The
Engineer will make measurements of test holes at random during progress of the work to
confirm compliance with this Specification.
Cutting the test holes and refilling with materials properly compacted shall be done by the
Contractor under supervision of the Engineer at the Contractor's expense.
(d) Tolerances
Following tolerances for sub-ballast construction after completion of the work shall not be
exceeded. The Engineer will waive certain requirements and apply other tolerances as
necessary and as are appropriate for the case at hand.
Alignment (horizontal control) + 20 mm to - 20 mm

Profile and Elevations (vertical control)
Top of compacted sub-base course + 20 mm to - 20 mm
Thickness of compacted granular sub-base + 10% to – 5%
When a 3 meter straight edge is laid on the surface parallel to and perpendicular to the
centerline, surface variation from lower edge of straight edge shall not exceed:
Compacted sub-base course 8 mm
The quantity to be measured for payment shall be the actual number of cubic meters of sub-
ballast furnished for roads or under tracks and laid according to the Drawings or as instructed
by the Engineer, compacted, tested and accepted by the Engineer. The quantity to be
measured for payment will be based on the nominal dimensions and shape shown on the
Drawings and the actual length measured along center line of survey.
compensation for furnishing all materials, hauling, placing, compacting, sprinkling, proof
rolling, finishing and shaping and for all labor, equipment, tools and other incidentals
necessary to complete the work as specified herein.
Pay item No. and Name Unit of Measurement
206 Sub-Ballast cubic meter

2.07 GRANULAR BACKFILL
(1) Description
This work shall consist of furnishing, placing and compacting granular backfill adjacent to
structures. The areas in which this material is to be placed is the "Influence Zone" of certain
structures and this shall be as shown on the Drawings or as instructed by the Engineer.
(2) Material
Material shall be well graded crushed or uncrushed gravel, stone, rockfill of natural sand or a
well mixed combination of any of these. Grading requirements for material are as shown
below.
Maximum size : 10cm

Passing No. 4 sieve : 25% to 90%
Passing No. 200 sieve : 0% to 10%
Plasticity : 10 max.
(3) Construction
Granular backfill shall be placed in layers not exceeding 15cm and compacted to a density of
95% of maximum dry density determined according to AASHTO T 180. Construction of
granular backfill is placed in box culvert, abutment, retaining wall and others.
granular backfill supplied, compacted, tested and accepted by the Engineer and in
accordance with this Specification. Material shall be required to be placed when filling within
the influence zone of certain structures and any material placed outside the specified zone
will not be measured for payment.
Any existing material within the influence zone, which is removed because of the Contractor's
working method shall be replaced by granular backfill at the Contractor's expense. Where
excavation within the influence zone is instructed under any Clause of this Specification,
back-filling shall be carried out with granular backfill and the work shall be measured for
payment under this Clause.
pay item listed below. The price and payment shall be full compensation for the work
described in this Clause, including furnishing, hauling, placing and compacting the material.
207 Granular Backfill cubic meter

2.08 SOIL DISPOSAL
(1) Description
This work shall consist of treating soil designated as unsuitable material and disposing it as
“Waste”.
(2) Applicable Provisions
The applicable provisions of Clause 2.03 “EXCAVATION” shall be read into and become part
of this Clause.
(3) Material for Disposal
When so directed in writing by the Engineer, the Contractor shall treat soil unsuitable for use
in the embankment and shall dispose of it as provided in Sub-Clause 2.03(6) “Waste”.
The quantity to be measured for payment shall be the actual number of cubic meters of soil
disposal which shall be deemed to include all required
The quantity deemed, as provided above, will be paid for at the Contract unit price per unit of
measurement for the pay item listed below. The price and payment shall be full compensation
for all costs necessary for the proper completion of all the work prescribed in this Clause.
208 Soil Disposal cubic meter

2.09 SODDING
(1) Description
This work shall consist of furnishing grass sods as required and planting them to give a
healthy, stable covering of grass which will maintain its growth in any weather and prevent
erosion of surface soil in which it is planted.
(2) Material
Grass shall be of species native to West Java, harmless and inoffensive to people and
animals and not of a kind recognized as a nuisance to agriculture. It shall be rapid spreading,
free of disease and noxious weeds and shall be deep rooted. The Contractor shall notify the
Engineer not less than 3 days before cutting of sods begins. Source of sods shall be
approved by the Engineer before cutting and delivery to site. Sods shall be planted with their
root system substantially undamaged and cut into blocks with moist earth in which they have
grown. Sods shall be laid within 5 days of cutting. Sod blocks shall be hauled and stored in
such manner that they will be protected from direct sunrays, provided with air circulation and
prevented against drying.
(3) Construction
Surface on which sod blocks are to be placed shall be scarified and shaped after removing
debris, gravel and weeds. Surface below sods shall be made up as necessary with good
quality topsoil so as to ensure that the sod and topsoil together form a finished thickness of 15
cm. The Contractor shall be responsible for ensuring a healthy growth in sodded areas and
necessary fertilizer used before or after sodding shall be at the Contractor's own expense.
Sod blocks shall be placed so as to cover 50% of the surface by forming sod strips at an
interval of 30 cm (this will be called "Strip sodding"), or to cover entire surfaces (which shall
be called "Solid sodding") as noted in the Drawings or directed by the Engineer. In either case
joints shall be staggered to form a broken bond and joints between adjacent sod blocks shall
not exceed I cm. Sod blocks shall be placed in smooth finish and compacted by a roller of 100
kg weight or by tamper plate. Sufficient bamboo stakes shall be used to prevent the sod
blocks slipping when sodding is provided on slopes. Top soil shall be uniformly spread
between sods to provide a smooth surface and the entire surface sprinkled lightly with water
free from objectionable impurities. For at least six months after completion of sodding, the
Contractor shall maintain watering and other incidental operations. Sodded areas shall be
subject to special checks, two (2) and twelve (12) months after they have been laid. Any
areas in which sods are not maintaining a healthy growth shall be refurnished and resodded
at the Contractor’s expense. The Contractor shall be responsible for cutting and keeping
clean all sodded areas until Provisional Hand-Over.
The quantity to be measured for payment shall be the actual number of square meters of
treated surface measured on the slope including unsodded areas between strip sods,
completed and accepted in accordance with the Drawings, this Specification and as directed
by the Engineer.
The quantity, determined as provided above, will be paid for at the Contract unit price per unit
compensation for furnishing all materials, Iabor, equipment, tools including preparation of
surface, sodding, protection and maintenance, and other incidentals to complete the work in
accordance with the Drawings, this Specification and as directed by the Engineer.
209 Sodding square meter

2.10 PRECAST CONCRETE PILES
(1) Description
This work shall consist of furnishing and installing precast concrete pile furnished and driven
in accordance with the requirements of JIS A 5335-85, Standard for Prestressed Spun
Concrete Piles, this Specification and in conformity with the requirements shown on the
Drawings.
(2) Materials
(a) General
1) Precast concrete piles shall be constructed in accordance with the provisions of
Clause 2.14 “CONCRETE WORKS” as shown on the Drawings and as described in
this Specification.
2) Concrete
a) Reinforced Concrete Piles
Concrete shall be as a minimum Class K-300, in accordance with Clause 2.14
“CONCRETE WORKS” with a minimum cement content in any mix not less than
3.30 kN/m3.
b) Pre-stressed Reinforced Concrete Piles
Concrete shall be as a minimum Class (AA) K-600, Design Strength is 50N/mm2
by cylinder test with a minimum cement content in any mix not less than 4.14
KN/m3.
3) Reinforcing Bar
Reinforcing bar shall be in accordance with Clause 2.15 “REINFORCING BAR”.
Main longitudinal reinforcement not exceeding 12 m in length shall be in one
continuous length unless specified otherwise.
For exceeding 12 m in length joints will be permitted in the main longitudinal bars.
Joints in adjacent bars shall be staggered at least 1m apart along the length of pile.
Method of jointing reinforcing bar shall be subject to prior approval of the Engineer.
(b) Concrete Pile

1) Pile Shoes
Shoe bases where used shall be made from "chilled hardened" high duty cast iron to
ASTM A48 and shall be free from sand, honeycombing or porous places, air holes or
other defects. Straps shall be of mild steel or wrought iron cast as an integral part of
shoe.
2) Dimensions
Cross sectional dimensions of pile shall be not less than those specified and shall not
exceed them by more than 10 mm. Any face of a pile shall not deviate by more than 6
mm from a straight edge 3 m long laid on face, and centroid of any cross section of
pile shall not deviate by more than 1/1000 of the pile length from the straight line
connecting centroids of the end faces of pile. Head of each pile shall be square to the
longitudinal axis. Corners of head and corners of pile shaft for a distance of 30 cm
from head shall be chamfered 25 mm x 25 mm
3) Casting
Cylindrical piles shall be centrifugally cast in steel forms. Ends of piles shall be
square to the longitudinal axis. Other pile shapes shall be cast in a horizontal
position. Special care shall be taken to place the concrete so as to produce a pile free
from any air pockets, honeycombing or other defects. Concrete shall be placed
continuously and shall be compacted by vibrating or by other means satisfactory to
the Engineer. Forms shall be slightly overfilled, surplus concrete screened off, and
top surfaces finished to a uniform, even texture similar to that produced by forms.
4) Tensioning Procedure
a) As used here the word "tendon" shall be defined as any single prestressing
element used to apply prestressed forces to the concrete. For pretensioning this
shall be each strand or straight wire. All tendons to be stressed in a group shall
be brought to a uniform tension of approximately 500 kilograms per tendon prior

to being given their full tension. After this initial stressing the group shall be
stressed to a total tension as required on the Drawings by means of hydraulic
jacks or other approved appliances equipped with gauges graduated to read
directly to 1% of the total load applied and calibrated to measure accurately the
stress induced in the steel. The induced stress shall be measured by elongation
of the tendons and checked by gauge pressure. The results obtained shall be
within 5% of each other.
Means shall be provided for measuring the elongation to an accuracy of one

millimeter in twenty meters of length between jacking heads. In the event of
apparent discrepancies of more than five percent between stresses indicated by
gauge pressure and elongation, the entire operation shall be checked carefully
and the source of error determined and corrected before proceeding further. The
Contractor shall submit theoretical extension calculations based on actual tendon
areas and moduli. Measured extensions shall be within 5% of the agreed,
calculated values.
Independent references shall be established adjacent to each anchorage to

indicate any yielding or slippage that may occur between the time of initial
stressing and final release of the tendons. The tendon stress shall be maintained
between anchorages until the concrete has reached a compressive strength
equal to the "Transfer Strength" specified on the Drawings. Tensioning operations
may be inspected by the Engineer at the factory.
b) Release
Tendon stress shall be maintained between anchorages until concrete has
reached a compressive strength equal to the "Transfer Strength" specified on the
Drawings. After strength requirements are attained, tension in the tendons shall
be gradually and simultaneously released and the tendons cut off as required in
such a way as to prevent shock. It shall be the Contractor's responsibility to
transfer the prestress safely and to the Engineer's satisfaction in all respects.
c) Finish
At the ends of piles a recess shall be cut around each tendon to allow cutting off
the tendon and filling the recess with grout so that cover to the end of tendon is
not less than 20 mm. Piles shall present a true, smooth, even surface free from
any surface blemishes and true to the dimensions shown on the Drawings within
the tolerance limits.
5) Handling and Storage
Method and sequence of lifting, handling, transporting and storing piles shall be such
that piles are not damaged. Only the designated lifting and support points shall be
used. During transportation and storage piles shall be stored on adequate supports
located under the lifting points of piles.
Concrete shall at no time be subjected to loading, including its own weight, which will
induce a compressive stress exceeding 33% of its strength at the time of loading or of
the specified strength, whichever is lesser. For this purpose assessment of strength
of concrete and of stresses produced by loads shall be subject to approval of the
Engineer. All piles within a stack shall be in groups of the same length. Packings of
uniform thickness shall be provided between piles at the lifting points.
6) Marking of Piles
After a pile has been cast, date of casting, reference number, length, diameter and
prestressing force shall be clearly inscribed on the top surface of pile and also clearly
and indelibly marked on the head of pile. In addition, each pile shall be marked at
intervals of 250 mm along top 3 m of its length before being driven.
(3) Construction
(a) Driving Piles

1) Strength of Piles
Piles shall not be driven until concrete has achieved the specified 28 day strength.

2) Leaders and Trestles

At all stages during driving and until incorporation in the superstructure pile shall be
adequately supported and restrained by means of leaders or other guide
arrangements to maintain position and alignment and to prevent buckling. These
arrangements shall be such that damage to pile does not occur. Leaders shall be of
sufficient length to make use of followers unnecessary.
3) Driving Equipment
Before any piling work is commenced the Contractor shall submit to the Engineer full
details of pile driving equipment and method he intends to use in carrying out the
work. Piles shall be driven with diesel hammers or gravity hammers. When diesel
hammers are used, they shall be calibrated by load tests if necessary.
Driving equipment shall be of a modern type which assures that the energy needed to
penetrate pile to the required depth is transmitted to pile head without damaging pile.
Efficiency factor of hammer, i.e. the relation between theoretical energy developed by
hammer and energy submitted to pile, shall be a minimum of 0.7.
When gravity hammers are used for driving concrete piles, drop of hammer shall not
exceed 1.0 m and hammer shall have a weight of not less that 80% of weight of pile
and driving head. Fall shall be regulated so as to prevent injury to pile. Minimum
energy developed by other types of hammers shall be the same as specified for
gravity hammers.
4) Driving Procedure and Redrive Checks
Each pile shall be driven continuously until the specified or approved set and depth
has been reached, except that the Engineer may permit the suspension of driving if
the Engineer is satisfied that rate of penetration prior to cessation of driving shall be
substantially re-established on its resumption or if the Engineer is satisfied that
suspension of driving is beyond control of the Contractor.
The Contractor shall inform the Engineer without delay if an unexpected change in
driving characteristics is noted. A detailed record of driving resistance over full length
of the nearest available pile shall be taken if required. The Contractor shall give
adequate notice and provide all facilities to enable the Engineer to check driving
resistances. A set shall be taken only in presence of the Engineer unless otherwise
approved. Re-drive checks, if required, shall be carried out to an approved procedure.
5) Final Set
Final set of each pile shall be recorded either as penetration in millimeters per 10
blows or as number of blows required to produce a penetration of 25 mm. When a
final set is being measured, following requirements shall be met.
a) Exposed part of pile shall be in good condition without damage or distortion.
b) Dolly and packing, if any, shall be in sound condition.
c) Hammer blow shall be in line with pile axis and impact surfaces shall be flat and
at right angles to pile and hammer axis.
d) Hammer shall be in good condition and operating correctly.
e) Temporary compression of pile shall be recorded if required.
6) Driving Sequence and Piles subject to heave
Piles shall be driven in an approved sequence to minimize the detrimental effects of
heave and lateral displacement of ground. When required, levels and measurements
shall be taken to determine the movement of ground or any pile resulting from driving
process. When a pile has “heaved” as a result of adjacent piles being driven, the
Contractor shall submit to the Engineer the work method for correcting this and
avoidance of it in subsequent work.
(b) Length of Piles

1) Lengths of piles shown on the Drawings are based on information which has been
obtained from a site investigation prior to driving of any piles.
2) Before pile lengths are finally settled, the Contractor shall construct pilot piles to the
lengths shown on the Drawings as may be found necessary and these piles shall be
driven in the positions specified by the Engineer to whom the Contractor shall inform
in advance of the driving. The Contractor shall furnish the Engineer daily with a

detailed record of the driving of pilot piles throughout the full depth of driving. After
attaining the approved set, driving shall be continued until the Engineer directs that it
shall cease. Driving of pilot piles beyond the point at which the approved set is
obtained shall be called for to demonstrate that driving resistance continues to
increase. The Contractor shall then furnish the remainder of piles in the structure. In
determining the lengths of piles the Contractor shall base the order list on the lengths
assumed to remain in the completed structure. The Contractor at his own expense
can increase the lengths to provide for fresh heading and for such lengths as may be
necessary to suit the method of operation.
(c) Cut Off and Extension

Precast concrete piles shall be cut off at such elevation that they shall extend into the cap
or footing as indicated in the Drawings.
(d) Damage to Adjacent Structures

If during the execution of the work damage is, or is likely to be caused to main structures,
or adjacent structures, the Contractor shall submit to the Engineer the work method for
repair or avoidance of such damage.
(e) Records
The Contractor shall keep records as indicated below of installation of each pile and shall
submit two signed copies of these records to the Engineer not later than noon of the next
working day after pile is installed. Signed records shall form a record of the work.
The following data is required:
1) Pile location
2) Pile reference number
3) Pile type
4) Nominal cross-sectional dimensions or diameter
5) Length of pile
6) Date and time of driving or re-driving
7) Pile toe level
8) Ground level (msl)
9) Type, weight, drop and mechanical condition and serial number of hammer and
equivalent information for other equipment
10) Number and type of packing used and type and condition before and after driving of
dolly used during driving pile
11) Condition of pile head before and after driving
12) Set of pile in mm per 10 blows or number of blows per 25 mm of penetration
13) All information regarding obstructions delays and other interruptions to the
sequence of work and observations of occurrences such as ground heave.
(f) Tolerances
1) Setting Out
Setting out shall be carried out from the main grid lines of the proposed structure.
Immediately before installation of pile, the pile position shall be marked with suitable
identifiable pins or markers.
2) Position
For a pile cut off at or above ground level the maximum permitted deviation of pile
center from the center point shown on the setting out drawing shall be 75 mm in any
direction.
3) Verticality
Maximum permitted deviation of finished pile from the vertical shall be 1 in 50.
4) Rake
Where raking piles are specified, piling rig shall be set and maintained to attain the
required rake. Maximum permitted deviation of finished pile from specified rake shall
be 1 in 25.

(g) Defective Piles

Procedure of driving of piles shall not subject them to excessive and undue abuse
producing crushing and spalling of concrete, injurious splitting, splintering and brooming
of wood or deformation of steel. Manipulation of piles to force them into proper position,
considered by the Engineer to be excessive, shall not be permitted. Any pile damaged by
reason of internal defects, or by improper driving or driven out of its proper location shall
be corrected at the Contractor's expense by one of following methods approved by the
Engineer for pile in question:
1) Pile shall be withdrawn and replaced by a new pile.
2) A second pile shall be driven adjacent to the defective pile.
3) Pile shall be spliced or built up as otherwise provided herein or a sufficient portion of
footing extended to properly embed pile.
(h) Repair of Damaged Pile Heads

When repairing the head of pile, head shall be cut off square and all loose particles shall
be removed by wire brushing, followed by washing with water. If pile is to be subjected to
further driving, head shall be replaced with concrete of an approved grade. If driving of
pile has been accepted but pile is below the cut-off level, pile shall be made good to the
cut-off level with concrete of a grade not inferior to that of pile concrete. Repaired piles
shall not be driven until the added concrete has reached the specified characteristic
strength of pile concrete.
(i) Pilot Piles

Any pilot pile, completed and accepted, shall be made at the same rates as for working
piles of the same size and type. Additional costs associated with pilot piles shall be
deemed to have been distributed over the total length of working piles for each size and
each location. No payment shall be made for unauthorized, defective, unsound or
unsatisfactorily driven piles or for any costs incurred by the Contractor for such piles.
(4) Testing of Piles
(a) Preliminary Test

Preliminary pile test shall be carried out on test piles of the same type and dimensions to
permanent piles. Definite locations of the preliminary pile tests shall be designated during
construction period. Cost of these preliminary tests shall be incidental to the piling works
and shall be included in the relevant costs. The Engineer will instruct such pile tests as
necessary.
(b) Proof Loading Test

First pile of any group of the same size and type shall be subjected to a proof load test of
150% of the specified working load for 24 hours. Settlement of the pile shall be monitored
at intervals as directed by the Engineer by reference to a datum point well clear of the
influence zone of pile being tested and of any other work in progress. Total settlement
shall not exceed 15 mm, nor residual settlement 10 mm, for piles supporting buildings.
Total settlement shall not exceed 10 mm, nor residual settlement 5 mm, to piles
supporting structures.
Rate of proof load testing shall be one (1) test for every two hundred (200) piles and all
costs of testing shall be included in the costs of providing, furnishing and installing piles.
The Engineer will instruct such pile testing as may be required.
(a) Prescast Concrete Piles Furnished

The quantity to be measured for payment shall be the actual linear meters of precast
concrete piles, furnished in compliance with material requirements of this Specification,
driven, tested and accepted by the Engineer. Lengths of the satisfactorily driven piles will
be measured from tip to footing bottom. Total length of concrete pile with cut off will not
be measured for payment. No allowance will be made for the length of concrete piles
furnished by the Contractor to replace piles previously accepted by the Engineer that are

subsequently lost or those that are damaged prior to completion of the Contract while in
stockpile or during handling or driving and are ordered by the Engineer to be removed or
disposed from site. Capping footing concrete and reinforcements will be measured and
paid for under other pay items in this Specification.
of measurement for the pay items listed below. The price and payment shall be full
compensation for construction of precast concrete piles prescribed in this Clause, including
furnishing all materials, labor, tools and equipment, installing and driving piles at site,
including incidentals necessary for the works.
210 (1) Precast Concrete Piles (Dia. 600mm) linear meter

210 (2) Precast Concrete Piles (Dia. 300mm) linear meter

2.11 CAST-IN-PLACE CONCRETE PILE
(1) Description
This work shall consist of furnishing and installing cast-in-place concrete pile, constructed in
close conformity with the lines, grade and dimensions shown in the Drawings. All work,
material and performance related to cast-in-place concrete pile shall conform to this
Specification and related specifications and standards.
The Contractor shall be required to confirm depth of bearing stratum by boring survey in site
before starting work and designing concrete pile and substructure by boring survey data.
(2) Construction
(a) General
The work shall consist of excavating, boring, digging, shoring, sleeving, pumping, placing
reinforcing steel, mixing, placing, vibrating and heating concrete in accordance with this
Specification or as described below.
(b) Construction Methods

1) Location and Alignment of Piles
Piles shall be placed in the positions shown on the Drawings or as directed by the
Engineer. Deviation of axis of any finished pile shall not differ by more than 1% from
vertical. When deviation is not acceptable by the Engineer, the Contractor shall
reinforce the structure with reinforcing method designed by the Contractor and
accepted by the Engineer without any additional cost.
2) Excavation
Excavations for piles shall be made with equipment designed to remove a core of the
diameter shown on the Drawings. Upon reaching the required elevation, bottom of
bore shall be cleaned and, if called for, belled out to the required dimensions and
elevations as shown on the Drawings or as directed by the Engineer. Excavated
material shall be removed by the Contractor from the Right-of-Way.
Upon completion of belling out and cleaning out of the bottom to satisfaction of the
Engineer, reinforcement shall be set in place and concrete poured immediately.
Under no circumstances shall a hole be left to stand open after boring has been
completed. If any hole is condemned because of caving, it shall be filled with lean-mix
concrete and a new hole bored as near as possible to the location shown on the
Drawings. Payment shall not be made for condemned piles.
3) Sleeving
Timber or steel sleeving shall be used to temporarily line the bore to prevent bulging
or caving of the walls and to protect labor at work in the bore. Sleeving shall be
designed and constructed to resist all forces which may tend to distort it. Sleeving
shall be withdrawn as concrete is placed in the bore. Sleeving shall extend at least 1
m below top of the freshly deposited concrete at all times. Clearance between face of
the bore hole and sleeving shall not exceed 75 mm. If the Contractor places piles
close to the existing railway, the Contractor shall take necessary measures to avoid
collapse of the bore.
4) Inspection of Bores
Concrete shall not be placed in a bore until the bore has been inspected and
accepted by the Engineer. The Contractor shall have available suitable light for the
inspection of each bore throughout its entire length and shall also have available a
means for the Engineer to descend to the bottom of bore for inspection. All improperly
set sleeving, bore, bell or bottom shall be corrected to satisfaction of the Engineer.
5) Placing Reinforcing Steel
Reinforcement shall be placed in accordance with the details shown on the Drawings,
rigidly fastened together and lowered into the bore intact before concrete is placed.
Spacers shall be utilized to properly locate reinforced steel cage in the bore.
6) Mixing and Placing Concrete
Mixing and placing concrete shall be done in accordance with this Specification

where applicable. Concrete shall not have a free fall of more than 2.0 m and shall be
placed so that aggregates will not separate or segregate. Slump of concrete shall not
exceed 125 mm. Concrete shall be placed to the elevations as shown on the
Drawings. Laitance on top of pile shall be removed before placing of the pile cap.
Concrete shall be vibrated throughout the entire length of pile. Shaft and bell shall be
free of water prior to placing of concrete. Concrete shall not be placed in or through
water unless authorized by the Engineer. In event that tremie concrete is allowed by
the Engineer, concrete shall be placed as specified herein.
7) Tremie Concrete
Shaft of pile shall be pumped clear of water so that bottom can be cleaned and
belled. Pumping shall then be stopped and water shall be allowed to come into bore
until state of equilibrium is reached. Concrete shall then be placed by means of
tremie pipe. Tremie pipe shall have a suitable gate in bottom to prevent water from
entering pipe. Bottom of pipe shall be maintained below surface of the freshly placed
concrete. Pipe shall be capable of being raised or lowered quickly in order to control
the flow of concrete. Tremie concrete shall only be poured up to top of bell or as the
Engineer directs. Pumps shall then be lowered into bore and excess water pumped
out. Laitance which forms on top of tremie shall then be removed and remainder of
concrete shall be placed in the dry.
8) Log Borings
Soil information, if any available, is only for reference and no guarantee. The
Contractor shall be responsible for survey and design of soil bearing capacity.
(3) Testing of Piles
(a) Quality Control and Testing

1) Quality control and testing shall be in accordance with JIS A1115, JIS A1107 as
appropriate.
2) Testing of fresh concrete shall be in accordance with the requirements described
below.
a) Inspection and testing shall be performed in presence of the Engineer or
authorized representative either on site or in the approved Testing Laboratory
hired by the Contractor.
b) Testing of cement and aggregate shall be performed to ensure conformance with
specified requirements.
c) The Contractor shall provide and maintain on site steel molds and facilities in
good condition at all times.
d) Three (3) concrete test samples shall be taken for every 30 or less cubic meters
of concrete placed and test sample will be either of cube or cylindrical form.
e) One (1) slump test shall be taken for each set of test samples taken.
f) The Contractor shall cooperate with Testing Laboratory to facilitate their work.
The Contractor shall provide and arrange for access to concrete mixing plant for
Testing Laboratory. The Contractor shall notify Testing Laboratory and the
Engineer at least 24 hours in advance of placing concrete at plant and at field and
for inspection of formwork and reinforcement. The Contractor shall provide for
Testing Laboratory at site an insulated locked box of sufficient size to store
equipment and cylinders or cube and whatever labor is required in preparation of
test samples. Actual making, handling, transporting and curing of test samples
shall be by Testing Laboratory only.
g) Plant test and inspection, including but not limited to:
- Sampling and testing concrete ingredients
- Reviewing and checking Contractor’s proposed design mixes
- Inspecting plant and equipment for measuring, mixing and delivery concrete
- Inspecting batching and mixing operations
- Inspecting concrete mix
- Checking delivery tickets of plants mixed concrete
h) Field test and inspection, including but not limited to:
- Checking delivery tickets of plant mixed concrete
- Checking amount of water added to concrete mix, if permitted, in field
- Making slump test

- Making samples for Laboratory Testing of compressive strength

- Taking temperatures of as-mixed concrete, of as-deposited concrete and of
concrete during curing period
- Taking air temperatures during placing and curing of concrete
- Checking concrete placing and curing procedures
i) Not withstanding anything in this Clause, the Engineer may at any time request
samples for testing at an Independent Laboratory at expense of the Contractor.
(b) Loading Test

1) In order to determine the required pile length at each location, the Contractor shall
carry out the loading test on the working pile instructed by the Engineer according to
ASTM D114-73 or other international standards. Number of testing piles shall be as
listed below.
Location Number of Tested Pile
Manggarai 1
Manggarai – Jatinegara 1
Bekasi Bridge 1
Cikarang Bridge 1
2) The Contractor shall submit Quality Assurance and Procedure of loading test for
approval of the Engineer prior to loading test. Procedure shall fully describe test
methodology, including tested pile, loading, testing arrangement and set up. Test
Reports shall be submitted to the Engineer together with evaluation fully describing
engineering properties and load bearing characteristics of pile, including soil bearing
capacity and other interaction affects by the professional engineer hired by the
Contractor. When the test fails, the Contractor shall investigate the reasons by
additional soil survey, coring through pile, vibration and shock test, sonic coring test
and shall bear the cost.
3) Pile so tested shall be considered to be failed if:
a) Residual settlement after removal of test load exceeds 6.50 mm; or
b) Total settlement under Design Load exceeds 12.5 mm; or
c) Total settlement under twice Design Load or Test Load, whichever bigger,
exceeds 25.0mm or 10% of pile diameter whichever lower value.
(a) Cast-in-place Concrete Piles

The quantity to be measured for payment shall be the actual number of linear meters of
cast-in-place concrete pile, furnished in compliance with instructions of the Engineer and
material requirements of this Specification. Capping footing concrete and reinforcements
will be measured and paid for under other pay items in this Specification.
No separate payment shall be made for “Concrete” if method of measurement or basis of

payment for another pay item calls for inclusion of this cost in that respective pay item. No
separate payment shall be made for any increased cement content, admixtures or
finishing surface of any concrete. Where with permission of the Engineer the Contractor
will choose to use a stronger class of concrete than that shown on the Drawings,
measurement and payment shall be made for the class of concrete shown or specified
and not that actually used. The quantities of reinforcing bar and other items which are
included in the completed and accepted structure shall be measured for payment as
described for in the separate items involved.
(b) Loading Test

The quantities of loading test of cast-in-place concrete piles to be measured for payment
shall be the actual number of lots for location executed by loading test and accepted by
the Engineer. Locations of the satisfactorily loading test shall be accounted at respective
sites.

of measurement for the pay items listed below. The payment for cast-in-place concrete pile
shall be full compensation for construction of cast-in-place, including concrete, reinforcing bar,
furnishing, temporary working stage and scaffolding and for all labor, tools, equipment,
hauling and all other incidentals necessary to complete the work as shown on the Drawings
and described in this Specification, including boring and design of substructure and concrete
piles.
211 (1) Cast-In-Place Concrete Pile (Dia.1200mm) linear meter

211 (2) Cast-In-Place Concrete Pile (Dia.1000mm) linear meter
211 (3) Concrete Pile Load Test lot

2.12 CONCRETE SHEET PILES
(1) Description
This work shall consist of furnishing and driving corrugated prestressed concrete sheet pile in
accordance with this Specification and in reasonably close conformity with the requirements
on the Drawings.
(2) Materials
(a) General
Corrugated prestressed concrete sheet piles shall be constructed in accordance with this
Specification and as shown on the Drawings and to the requirements of JIS A 5373,
Prestressed Concrete (PC) Sheet Pile.
(b) Concrete
Concrete shall comply with Clause 2.14 “CONCRETE WORKS” and shall be as a
minimum Class (AA) K-725, Design Strength of 60N/mm2 by cylinder test.
(c) Reinforcing Bar

Reinforcing bar shall comply with Clause 2.15 “REINFORCING BAR” and shall be
positioned as shown on the Drawings.
(d) Prestressing Steel

High tensile steel prestressing wire shall conform to the requirements of JIS G 3536 Class
SWPR 1 135/155.
(e) Certificate
The Contractor shall submit a certificate by the manufacturer to the Engineer for approval
prior to furnishing pretensioned corrugated concrete sheet piles.
(3) Construction
(a) Preparation for Driving (Water Jet Type)

1) The Contractor shall install guide frame for concrete sheet piles. Usual method of
guide frame installation is to provide two horizontal runs of steel section secured at
adequate convenient intervals. Structure of guide frame shall be of adequate
proportion to ensure that concrete sheet piles are rigidly supported during driving.
2) Connect top of jetting pipe, which is installed inside concrete sheet pile, with delivery
hoses of water jet, ensure that pipes and nozzle in good condition.
3) Concrete sheet pile, which has been connected to water jet cutter, is lifted and slotted
in position. Hold pile tip at about 25 cm above driving ditch or ground. Then secure
pile by using lever block.
4) Start water jet cutter machine and check water pressure at certain level.
5) Connect vibro hammer on upper part of concrete sheet pile, check grip pressure,
activate vibro then drive. Check vertically and longitudinal alignment during driving by
lead or theodolite.
6) Driving shall be terminated when top of concrete sheet pile reaches the design level.
Water Jet cutter shall be stopped at 0.5 ~ 1 m before reaching final level of concrete
sheet pile.
7) Release vibro hammer and disconnect delivery hoses of water jet cutter from jetting
pipes in concrete sheet pile and start all over again.
(b) Handling, Pitching and Driving

1) When raising or transporting sheet piles the Contractor shall provide slings and other
equipment necessary to prevent any appreciable bending of pile.
2) Main setting out for piles is to be completed prior to commencement of driving.
Secondary or individual pile setting out is to be completed and agreed not less than 8
hours prior to commencing work on the piles concerned. All main setting out points,
lines and areas are to be maintained safe and undisturbed until the work is complete.

3) Sheet piles shall be pitched accurately in position and driven to the lines shown on
the Drawings or fixed by the Engineer. Sheet piles deflected from the vertical or
proper line shall, where ordered by the Engineer, be withdrawn and repitched until the
proper line is obtained.
4) No forcible method of correction of position or line of any pile shall be permitted. Any
pile damaged by reason of improper driving or driven out of its proper location or
driven below the elevation fixed by the Drawings or by the Engineer shall be
corrected at the Contractor’s expense by one of the following methods approved by
the Engineer for the pile in question.
(c) Water Supply

1) Concrete corrugated sheet pile shall be driven using water jet to open soil
beneath pile tip to avoid friction against concrete sheet pile, so that concrete
sheet pile does not compact the soil and penetration shall be easier.
2) In hard soil, water jet shall break out particle or soften soil to let concrete sheet
pile hammer the layer.
3) Mud and fine particle shall flow out from concrete sheet pile side due to vibration
(pumping action of vibro hammer). Water consumption shall be at about 20 ~ 30
m3 /day according to soil condition.
4) Driving ditch shall be constructed accordingly to accommodate mud, fine particle
and waste-water.
5) Mud and waste-water will not be higher than guide frame.
6) Water pressure (low/high) shall be 70 ~ 150 Kg/cm2.
7) The Contractor shall not cut off concrete sheet piles less than that shown on the
Drawings.
(a) Sheet Piles Furnished

The quantity to be measured for payment shall be the actual linear meters of corrugated
prestressed concrete sheet pile, furnished in compliance with instructions of the Engineer
and material requirements of this Specification and accepted by the Engineer. Lengths of
the satisfactorily driven piles shall be measured from tip to ground soil. Total length of
sheet pile with cut off section will not be measured for payment. No allowance will be
made for the length of sheet piles furnished by the Contractor to replace piles previously
accepted by the Engineer that are subsequently lost or those that are damaged prior to
completion of the Contract while in stockpile or during handling or driving and are ordered
by the Engineer to be removed from site or disposed otherwise. Capping beam concrete
and reinforcement will be measured and paid for under the other pay items in this
Specification.
The quantity measured, as provided above, will be paid for at the Contract unit price per unit
of measurement for the particular pay items listed below. The price and payment shall be full
compensation for all materials, including prestressing, reinforcement and high pressure pipes,
water jet equipements, hardware, furnishing, driving, guide beam, support frames, jetting,
welding and all related tools, rigs, cranes, boilers, hammers, jets, labor and other incidental
equipment and work. No payment shall be made for unauthorized, defective, unsound or
unsatisfactorily driven piles or for any costs incurred for such piles.
Pay item No. and Name Unit of Measurement
212 (1) Concrete Sheet Piling (Wid. 450mm) linear meter

212 (2) Concrete Sheet Piling (Wid. 300mm) linear meter

2.13 RUBBLE STONE FOUNDATION
(1) Description
This work shall consist of placing rubble stones and sand for purpose of strengthening
excavated areas before arrangement of reinforcing bars and placing of foundation concrete or
ground slabs.
(2) Material
Material to be used for rubble stone shall be a cube of hard and durable limestone or andesite
or granite of the size ranging from 10 cm to 15 cm or other appropriate size approved by the
Engineer. Sand shall be of the same quality as given for “Fine Aggregate” in Sub-Clause
2.14(3) (a) 4).
(3) Construction
(a) Rubble Stone

After area has been excavated, soil left in place shall be compacted thoroughly with
mechanical tampers to satisfaction of the Engineer and shall be compacted to 95 % of the
maximum dry density as determined in accordance with AASHTO T180 for directly
bearing foundations. After this has been completed, rubble stones shall be neatly laid
over the compacted surface to the thickness shown on the Drawings. These rubble
stones shall then be compacted with mechanical tampers and any depressions or voids
filled with smaller crushed gravel or rock. Surface shall again be compacted to the
horizontal layer as shown on the Drawings.
(b) Sand
After area has been excavated, soil left in place shall be compacted thoroughly with
mechanical tampers to satisfaction of the Engineer and shall be compacted to 95 % of the
maximum dry density as determined in accordance with AASHTO T180 for directly
bearing foundations. After this has been completed, sand shall be spread to the specified
thickness as shown on the Drawings. Sand shall be compacted with mechanical tampers
and any depressions or voids filled to leave a perfectly hard smooth surface.
The quantity to be measured for payment shall be the actual number of cubic meters of rubble
stone or sand completed in place and accepted in accordance with the Drawings or
instructions of the Engineer. Excavation shall be paid for separately under other pay items.
No separate measurement shall be made for compaction associated with this work, as they
are considered as subsidiary obligations of the work. Levelling concrete shall be paid under
Clause 2.14 "CONCRETE WORKS".
The quantity, as determined above, will be paid for at the Contract unit price per unit of
for all costs necessary or usual for the proper completion of the work, including labor and
equipment described in this Clause.
213 Rubble Stone Foundation cubic meter

2.14 CONCRETE WORKS
(1) Description
This work shall consist of furnishing and installing massive concrete and reinforced concrete.
The work also shall include, but is not limited to, concrete materials and workmanship to be
adopted in casting concrete that is related to “Civil Works” and “Building Works”.
(2) Scope of Work
(a) Quality Assurance

The Contractor shall maintain adequate records in accordance with the requirements of
quality assurance programme. These records shall be required to provide the objective
evidence of compliance with the requirements of this Specification. Class of concrete to
be used in each part of the works shall be shown in the Drawings or the relevant sections
of this Specification or as directed by the Engineer.
Classification of Concrete
Design Stregth
Class of (N/mm)
Application
Concrete
(1) (2)
A K 500 40 Prestressed concrete for main girder.
B K 350 30 Prestressed concrete for slab and cross beam;
rigid frame structure; composite concrete H beam;
cast-in-place piles: precast concrete structure.
C K 300 24 Cast-in-place reinforced concrete slab and girder;
box culvert; abutment; pier; retaining wall; cable
trench; cable trough; connection box; parapet;
manhole.
D K 250 21 Drainage structure.
E K 225 18 Plain concrete for gravity type retaining walls; pipe

bedding; and surrounds.
F K 175 14 Levelling concrete.
Notes : (1) Minimum compressive strength at 28 days by cube test (N/mm2)

(2) Minimum compressive strength at 28 days by cylinder test (N/mm2)
Class A is special concrete mixes for special applications. Design strength shall conform
to the requirements of minimum compressive strength at 28 days by cylinder and cube
test. Class of concrete to be used for any structure not clearly indicated above shall be
as shown on the Drawings or as directed by the Engineer.
(b) Construction Tolerances

Variation in alignment, grade and dimensions of structure from established
alignment, grade and dimensions shown on the Drawings shall be within the
tolerances specified below. Concrete work that exceeds the tolerance limits specified
herein shall be remedied or removed and replaced by the Contractor.
1) Elevation and positions

a) Top of clean concrete under foundations +10 mm to 20 mm
b) Plan position of substructures 10 mm
c) Span length -30 mm to + 25 mm
2) Verticality
a) Verticality of substructures and walls 0,2 %
3) Appearance of Exposed Vertical Surfaces
a) Tolerance for offset at form joints 5 mm
b) Tolerance for flatness 5 mm over 2 m

4) Appearance of Exposed Vertical Surface

a) Tolerance for joint offset 2 mm (nominal)
b) Tolerance for flatness 5 mm over 2m
5) Dimensions
a) Tolerance for dimensions of piers 10 mm
b) Wall , abutments, slabs etc.
6) Flatness of Slabs
a) Bridge deck slabs and top and bottom 10 mm over 4 m
b) Slabs of box culverts.
7) Concrete Cover and Spacing for Reinforcing Steel
a) Concrete cover for super structures -0 mm to + 5 mm
b) Concrete cover for other structures -0 mm to + 10 mm
c) Spacing +10 mm to –10 mm
(c) Submittals
Beside general requirements for submission of Shop Drawings, the Contractor shall
submit to the Engineer for approval as described below.
1) The Contractor shall submit in writing to the Engineer concrete mix designs
proportioned by weight and based on trial mixes. Each grade and class of concrete is
denoted by the minimum 28 days cylinder strength as described below. Concrete
cylinder strength tests shall also be carried out at 7 days on trial mixes and results
shall correspond to 70 % of 28 day compressive strength value.
2) Mix design shall be accompanied by all relevant data including, but not limited to the
following :
a) Type and source of cement
b) Source of aggregate, together with results of test in relevant paragraphs
c) Grading details, in tabular and graphical form, of fine and coarse aggregate
d) Grading details, in tabular and graphical form, of combined aggregate together
with details of proportions in which fine and coarse aggregates are to be
combined
e) Aggregate and cement ratio by weight
f) Water and cement ratio by weight
g) Workability in terms of slump and compacting factor having due regard to final
location and dimension of concrete
h) Manufacturer’s water and cement ratio to strength graph for cement to be used
3) Approval to mix design shall be based upon the results of tests carried out on
preliminary tests cylinder or cubes and assessed against the minimum criteria
specified below.
Mix Design Criteria of Concrete

Class of Concrete K350 K300 K250 K175
Maximum Size of Coarse Aggregate (mm) 25 25 25 40
Slump (cm) 7,5 7,5 7,5 7,5
(1) +/- 2.5 +/- 2.5 +/- 2.5 +/- 2.5
Water Cement Ratio W/C (%) 50 55 60 70
Water Content (kN/m3) 1.81 1.81 1.81 1.75
Cement Content (kN/m3) 3.66 3.30 3.00 3.00
Fine Aggregate (kN/m3) 8.19 8.20 8.85 9.05
3
Coarse Aggregate (kN/m ) 10.44 10.39 10.39 10.30
Note: (1) Slump is determined in accordance with JIS A 1101
4) No concrete work shall commence before mix design has been approved in writing by
the Engineer.
5) Should, in opinion of the Engineer, a previously approved mix design become
unsatisfactory for any reason, the Contractor shall submit a revised mix design for
approval as previously described.

(d) Characteristic Strength

1) Standard Deviation
Characteristic strength of various classes of concrete shall be determined as soon as
the first 20 test results of each class become available, in accordance with
Indonesian Standards for Concrete (PBI).
Characteristic strength shall be calculated by equation:

X0 = X - KS
Where :
X0 = characteristic strength
X = mean or average of series of results
K = a factor depending on percentage of results allowed to fall below
characteristic strength.
S = standard deviation given by equation.
½
S= X–X
N–1
Where:
X = individual result
N = total number of results
Value of K factor are:
Value of K factor
Percentage of Results Allowed to Value of K
Fall Below Minimum
< 0.6 3.09
0.6 2.50
1.0 2.33
2.5 1.96
5.0 1.64
If characteristic strength so determined falls below the minimum site working strength, the
Contractor shall increase cement content as specified herein until such time as
adjustment are made in mix proportions or improvements made in quality control
measures to raise the average strength or reduce variation to satisfaction of the Engineer.
2) Compressive Strength Failure to Comply.

In the event that compressive strength results do not comply with the strength
requirements of this Clause or in the event of doubtful results, the Contractor shall prove
to the Engineer by performing a simple compression strength check by means of crushing
tests performed on tests specimens taken with a rotary core bore at suitable points
indicated by the Engineer on the structure in question. Sampling and testing shall be
made in accordance with JIS A 1107. Such tests shall be carried out by an agreed
authority having suitable test facilities. If such tests show strength in compliance with
requirement herein specified, concrete shall be considered satisfactory. If such tests do
not comply with the requirements, the Engineer may direct the Contractor to cut out and
make good the defective work at the Contractor expense.
(3) Materials and Equipment
(a) Materials
1) Cement
a) Cement shall conform to the requirements of JIS R 5210 or SII 0013-81 or
AASHTO M 85 or ASTM C 150-81, Portland Cement Type I, III or V.
b) Type I cement shall be used for ordinary concrete.

c) Type III cement shall be subject to approval of the Engineer in each particular
case. No additional payment shall be allowed for use of one or other type of
cement.
d) Type V cement shall be used where sulphate concentrations in soil or water, in
opinion of the Engineer, are found detrimental to concrete.
e) Cement shall be stored in damp proof warehouse with a floor raised at least 30
cm above the ground, with easy access for inspection. Bagged cement shall not
be piled more than 13 sacks high. Cement, which is damp, lumpy or otherwise
not in proper condition, shall not be used. Cement stored by the Contractor for a
period longer than 60 days shall require approval of the Engineer before being
used in the works. Subject to approval of the Engineer, use of cement of
different brands, type or from different mills shall be stored separately. Use of
cement reclaimed from discarded or used bags shall not be permitted
2) Water
a) Water to be used in mixing or curing concrete shall be tested according to
AASHTO T26-79. Water shall be clean and free from silt, oil or acid, vegetable or
other substance injurious to the finished product.
b) Sources of water shall be maintained at such a depth and water shall be
withdrawn in such a manner as to exclude silt, mud, grass or other foreign
materials.
3) Coarse Aggregates
a) Coarse aggregates shall consist of one or more of crushed stone, crushed gravel,
blast furnace slag or other approved inert materials of similar characteristic
having clean hard durable pieces. It shall be free from objectionable quantities of
flat or elongated particles, organic matter, chlorides or other deleterious matter.
Coarse aggregates, which is “alkali aggregate reaction” with Portland Cement,
shall not be used.
b) The Engineer may, in certain cases as prescribed, allow the designated
maximum size of coarse aggregate to be reduced from 31.5 mm to 25 or 20 mm
according to the spacing of reinforcement bars.
c) Percentage of particles having certain proportions between their largest and
smallest dimensions (i.e. the largest distance the particles can fill out between
two parallel planes and the smallest distance between two parallel planes that will
permit the particle to pass) shall be determined in the following way:
- From a sample of coarse aggregate all particles passing No. 4 sieve are
eliminated. Sample shall be so big that at least 100 particles remain.
- By means of a sliding calliper the largest and smallest dimensions, as defined
above, are determined for each particle and its proportion calculated (with
one decimal).
- Total weights of particles, having the proportions 5.0 or less, are determined
and their percentages in relation to the total sample are calculated.
d) Coarse aggregate shall be uniformly graded and shall meet the grading
requirements described below:
Grading of Coarse Aggregate

Sieve Size Percentage Passing By Weight
(mm) Type 1 Aggregate Type 2 Aggregate
37.5 100 -
25 90 - 100 100
19 - 90 - 100
12.5 25 - 60 30 – 70
4.75 0 - 10 0 - 10
Notes: Type 1 aggregate shall generally be used for reinforced concrete
construction.
Type 2 aggregate shall generally be used for post-tensioned concrete
construction and for reinforced concrete work where specified in
the Drawings.
Sieve analysis of coarse aggregates shall be made in accordance with JIS A

1102 (Method of Test for Sieve Analysis of Aggregate).

e) Amount of deleterious substance in coarse aggregate shall not exceed the limit
prescribed below. Treatment of other deleterious substance, which are not shown
below, shall be determined by the Engineer.
Limits for Deleterious Substance in Coarse Aggregates

Item Maximum Percentage by Weight
Clay lumps 0.25
Soft particles 5.0
Material finer than 0.075 mm size 1.0 (1)
Material floating on liquid having 1.0 (2)
Specific gravity of 1.95
Notes: (1) In case of crushed aggregate, if material greater than 0.075 mm
sieve consists of dust of fractured rock and is essentially free
from clay or shale, this percentage may be increased to 1.5.
(2) This requirement does not apply to manufactured aggregate
produced from blast furnace slag.
f)Test of material finer than 0.07 mm sieve shall be made in accordance with JIS A
1103 (Method of Test for Amount Material Passing Standard Sieve 0.07 mm in
Aggregate). Test for soft particles shall be made in accordance with JIS A 1126
(Method of Test for Soft Particles in Coarse Aggregate by use of Scratch Tester).
g) Testing of Aggregates
Before use, results of foregoing tests on aggregate from each source shall be
submitted to the Engineer. Further tests on aggregates in use shall be made as
and when required by the Engineer. Percentage of wear of aggregate shall not
be greater than 50 % as determined by SNI 03-2417 – 91 or AASHTO T 96.
h) Pre-molded expansion joint filler and composition joint filler
Expansion joint filler shall conform to the requirements of AASHTO M 33 or
ASTM D 994. Filler for each joint shall be furnished in a single piece for full depth
and width required for joint unless otherwise authorized by the Engineer. When
more than one piece is authorized for a joint the abutting ends shall be fastened
securely and held accurately to shape by stapling or other positive fastening
satisfactory to the Engineer.
4) Fine Aggregate
Fine aggregate shall consist of natural sand or, subject to approval of the Engineer,
other inert materials with similar characteristic, having clean, hard and durable
particles and free from objectionable quantities of dust, silt, clay, organic matter and
other impurities. Marine sand containing soluble chlorides shall not be used in
prestressed concrete work, nor in ordinary reinforced concrete work unless otherwise
approved in writing by the Engineer.
a) Fine aggregate shall be uniformly graded and meet the grading requirements as
shown below.
Grading of Fine Aggregate
10.0 100
5.0 90 – 100
2.5 80 – 100
1.2 50 – 90
0.6 25 – 65
0.3 10 – 35
0.15 2 – 10
Sieve analysis of fine aggregate shall be made in accordance with JIS A 1102.
Grading requirements given above are extreme limits to be used in determining
suitability of material from all possible sources of supply. Grading of material from
any one source shall not vary in composition beyond the range of values that
governs the selection of source of supply. For purpose of determining degree of
uniformity, a fineness module determination shall be made upon representative
samples, submitted by the Contractor from such sources to be used.

b) If fineness modules of fine aggregate varies by more than 0.20 from the value
used in selecting concrete proportions, fine aggregate shall be rejected unless
suitable adjustment of mix proportion are made with approval of the Engineer.
c) Amount of deleterious substances in fine aggregate shall not exceed the limit
shown below. Treatment of other deleterious substances, which are not shown
below, shall be determined on directions by the Engineer. Test for material finer
than 0.075 mm sieve shall be made in accordance with JIS A 1103.
Limits for Deleterious Substances in Fine Aggregate

Item Maximum Percentage by Weight
Clay lumps 1.0
Material finer than 0.075 mm sieve 5.0 (1)
Material coarser than 0.300 sieve 0.5 (2)
floating on a liquid having a specific
gravity of 1.95
Notes: (1) In case of crushed aggregate if material finer than 0.075 mm consists
of dust of fracture essentially free from clay or shale, these
percentages may be increased to 5 and 7 percent, respectively.
(2) This requirement does not apply to manufactured sand produced
from blast furnace slag.
d) All fine aggregate shall be free from a deleterious amount of organic impurities.
Approximate determination of presence of injurious organic impurities in natural
sand shall be in accordance with JIS A 1105, or ASTM C 40 (Method of Test for
Organic Impurities in Sand). Aggregate subjected to color metric test for organic
impurities and producing a color darker than the standard shall be rejected.
However, any sand that fails to meet the above requirement, may be used
provided that compressive strength of mortar specimens using the same sand is
more than 95% of that of mortar specimens using the same sand washed by a 3
% solution of sodium hydroxide and then by water and approved by the Engineer.
Testing age of mortar specimens shall be 7 days and 28 days for normal Portland
Cement. Compressive strength of mortar specimens shall be determined by JIS A
5308 or ASTM C 109.
e) Each size of Coarse and Fine Aggregate shall be stored separately and in such a
manner to prevent contamination by foreign material, maintain the moisture
content as uniformly as possible, prevent segregation and provide protection from
the different sources of supply and shall be stored separately and not mixed
except with approval of the Engineer.
5) Admixtures
a) Unless agreed by the Engineer neither admixtures nor cements containing
additives shall be used. The Contractor shall submit samples of any additive or
admixture designated to use to the Engineer at least 35 days prior to the date of
commencement of construction of particular structure or portion of structure on
which intended to use such admixture or additive. Trial mixes or any other tests
incorporating designated admixture additive shall be made by the Contractor and
the results shall be approved by the Engineer before use in the works. Any
approval given under this Clause shall in no way relieve the Contractor of the
obligation to produce concrete with the specified strength, workability and
durability as required under this Specification.
b) Approved admixtures shall be introduced into the mix at the time of adding water
by a method ensuring an even and accurate dispersion throughout the mix.
c) Air Entraining Agent
The Contractor shall produce a stable amount of entrained air in the mortar mix
and shall conform to the requirements of ASTM C260–77 Air-Entraining
Admixtures for Concrete.
6) Reinforcement
All reinforcements shall comply with the requirements in Clause 2.15 “REINFORCING
BAR”.

(b) Plant and Equipment

1) General
Equipment and tools necessary for handling materials and performing the work, and
satisfactory to the Engineer as to design, capacity, and mechanical condition, shall be
at site before the work is started.
2) Batching Plant and Equipment
a) Free Water Contained in Aggregate
Water content of aggregates shall be determined before mixing is commenced on
every day that concrete is to be produced. Samples for determining water content
shall be taken from those stocks of aggregate which shall be used during the day.
When no rain occurs, water content of aggregates shall be checked once more
during the day, after such time as the Engineer shall agree. During rain, water
content shall be checked every two hours unless otherwise directed. Weighed
quantity of aggregates shall be such that correct weight of dry aggregates is
taken into the batch mix and the amount of water added to each batch shall take
into account water content of aggregates. All testing for water content, frequency
of testing and calculations of batch proportions shall require approval of the
Engineer.
b) General
All material in the mix shall be proportioned wholly by weight. Batching plant shall
include bins, weighing hoppers and scales for fine aggregate and for each
separate size of coarse aggregate. If cement is used in bulk, a bin, hopper and
scales for cement shall be included. Container shall be watertight. Provision,
satisfactory to the Engineer, shall be made for batching other components of the
mix, at the batching plant or at the mixer as may be necessary. Batching plant
may be either of stationary or mobile type. It shall be always properly levelled
within the accuracy required for proper operation of weighing mechanisms.
c) Bins and Hoppers
Bins with adequate separate compartments for fine aggregate and for each
required size of coarse aggregate shall be provided in the batching plant. Each
compartment shall discharge efficiently and freely into the weighing hopper.
Means of control shall be provided so that as the quantity desired in the weighing
hopper is being approached and material may be added slowly and shut off with
precision. A port or other opening for removing an overload of the several
materials from the hopper shall be provided.
d) Weighing hoppers shall be constructed so as to discharge fully.
e) Scales for weighing aggregates and cement shall be of either beam type or
spring less-dial type. They shall be accurate within 0.5 percent under operating
conditions throughout the range of use. Ten 25 kg weights shall be available for
checking accuracy. All exposed fulcrums, clevises, and similar working parts of
scales shall be kept clean. When beam-type scales are used, provision shall be
made for indicating to the operator that the required load in the weighing hopper
is being approached. The device shall indicate at least the last 100 kg of load up
to 25 kg overload. All weighing and indicating devices shall be in full view of the
operator charging the hopper and he shall have convenient access to all controls.
f) Cement may be measured by weight or in standard sacks considered to weigh 50
kg net. When measured by weight a separate, satisfactory scale and hopper shall
be provided together with a boot or other approved device to transfer the cement
from the weighing hopper. Satisfactory methods of handling shall be employed.
g) Batching shall be so conducted as to result in the weights of material required,
within tolerances of :
- Cement : 1% 0.3% of the weight required in batch
- Aggregate : 2% of weight required in batch
- Water : 1% of weight required in batch
- Admixtures : 1%0.3% of amount required in batch
3) Vibrators
a) Unless otherwise directed concrete shall be consolidated with approved
mechanical vibrators operating within concrete. When required, vibrating shall be
supplemented by hand spading with suitable tools to ensure proper and adequate
compaction.

b) Vibrator shall be of a type approved by the Engineer, with a minimum frequency

of 3500 impulses per minute and shall be capable of visibly affecting a properly
designed concrete with 20 mm slump over a circular area of 450 mm radius.
(c) Forms and False Works

1) Materials
a) Formwork shall be constructed of sound well-seasoned timber and plywood. Use
of steel forms or forms made of other materials shall be permitted. Metal forms
shall be of regular uniform size with make-up sections arranged in a manner
approved by the Engineer. Metal form shall conform in all relevant respects with
the requirements specified for timber formwork. All timber shall be sound, free
from warps and twists, sap, shakes, large or loose knots, waney edges or other
defects affecting the strength or appearance of finished structure
b) Molds shall be of steel or plywood panels or panels of other materials approved
by the Engineer and shall be rigidly assembled so that no displacement or
deformation can take place during casting. Formwork shall be designed so that it
can be removed without shock or damage to the concrete and it must be braced
and held in position in such a way as to avoid any holes or fastenings through the
member.
c) Falsework shall be constructed from well-seasoned timber, hot rolled steel
sections or other approved materials suitable to support the loads to be carried.
2) Fabrication
a) Formwork
- Formwork shall be constructed so that the side forms of members can be
removed without disturbing the soffit forms and, if props or falsework are to
be left in place when the soffit forms are removed, these props or falsework
shall not be disturbed during striking.
- For prestressed units, soffit forms shall accommodate deformation of
member when the prestress is applied.
- All formwork shall be removed without damage to concrete in appearance,
strength or durability.
b) Falsework
- All falsework shall be designed and constructed to provide the necessary
rigidity and to support the loads without significant settlement or deformation.
- Falsework that cannot be founded on solid footings must be supported by
ample falsework piling, which shall be spaced, driven, and removed in a
manner approved by the Engineer.
- Arch centering shall be so constructed as to permit its lowering gradually and
uniformly.
- Beams and slabs shall have a camber of 1/1000 of their span after removal
of forms, unless otherwise stated on the Drawings or instructed by the
Engineer.
3) Construction
a) Shape, strength, rigidity, water tightness and surface smoothness of reused
formwork shall be maintained at all times. Any warped or bulged timber must be
resized before being reused. Formwork that is unsatisfactory in any respect shall
not be reused.
b) Internal ties shall be so arranged as to permit their removal to a depth of at least
25 mm from the concrete face without injury to concrete. No permanently
embedded metal shall have less than 25 mm cover to finished concrete surface.
c) Formwork shall be so constructed that easy cleaning out of any extraneous
material inside formwork can be achieved without disturbing formwork already
checked and approved by the Engineer.
4) Finishes
a) Concealed Surfaces
Rough timber may be used for surfaces that shall not be exposed in finished
structure. Surface shall be dense and sound and free from excessive
irregularities or blemishes. Finish shall be left as struck but major irregularities
shall be rectified as required by the Engineer.

b) Exposed Surfaces
Formwork shall be lined with a material approved by the Engineer providing a
smooth finish of uniform texture and appearance of curbs, parapets, edge beams,
soffit of deck slab, prestressed girders and beams, columns, cross heads, wing
walls and abutments of all bridges and internal faces of vehicular, pedestrian, and
drainage box culverts. Lining material shall leave no stain on concrete and shall
be so joined and fixed to its backing that it imparts no blemishes.
c) It shall be of the same type and obtained from the same source throughout one
structure. Arrangement of panels shall be agreed with the Engineer. Any
imperfections shall be made good as required by the Engineer.
d) Unless otherwise shown in the Drawings, all formwork joints in exposed surfaces
of concrete finish shall form a regular pattern with horizontal and vertical lines
continuous throughout each structure and all construction joints shall coincide
with these horizontal and vertical lines.
(4) Construction
(a) Preparation
1) Formwork, Falsework and Centering
Before concrete is placed, the Engineer will inspect all formwork, falsework and
centering and no concrete shall be placed until the Engineer has inspected and
approved such formwork, falsework, and centering. Such approval shall not relieve
the Contractor of any responsibilities for successful completion of the structure.
2) Reinforcement
The Engineer will inspect and approve all reinforcement in place, before concrete is
placed. An experienced steel fixer shall be present while all concrete is placed to
ensure that no reinforcement becomes displaced during placing and if it does to
reposition such reinforcement before placing continues.
(b) Mixing Concrete

1) Concrete shall be mixed in batch mixers unless otherwise authorized by the
Engineer. Concrete shall be mixed at construction site, at central batching plant and
truck mixing. No concrete shall be mixed, placed or finished when natural light is
insufficient unless an adequate and approved artificial lighting system is operated.
Entire content of mixer shall be removed from drum before materials for a succeeding
batch are placed therein. No mixer having a rated capacity of less than a 1-bag batch
shall be used nor shall a mixer be charged in excess of its rated capacity.
2) Mixing time shall be required below. Batch shall be so charged into mixer that a
portion of approximately 10 % of water will enter in advance of cement and
aggregates. Flow of water shall be uniform and all water shall be in drum by the end
of first 15 seconds of mixing period. Concrete shall be mixed until a uniform color
and consistency is obtained. All concrete shall be mixed for a period of not less than
1.5 minutes after all materials, including water, are in mixer. During period of mixing,
mixer shall operate at the speed for which it has been designed.
3) First batch of concrete materials placed in mixer shall contain sufficient excess of
cement, sand and water to coat the inside of drum without reducing the required
mortar content of mix. Upon cessation of mixing for a considerable period, mixer
shall be thoroughly cleaned. Concrete mixed as specified above is not to be modified
by addition of water or in any other manner to facilitate handling or for any other
reason. Concrete shall be mixed only in the quantity required for immediate use.
4) Central Plant Mixing
In addition to the requirement under Sub-Clause 3) above, central plant mixers which
have a capacity of not less than 2 m3 but not more than 5 m3 and mixers having a
capacity greater than 5 m3 may be permitted a minimum mixing time of 90 seconds
and 120 seconds respectively, provided a mixing analysis and tests of the job
materials indicates such produced concrete is equivalent in strength and uniformity to
that attained by batch mixing. Mixed concrete may be transported from central mixing
plant to site in agitator or non-agitator truck with approval of the Engineer.

Agitator trucks shall be equipped with a watertight, revolving drum and shall be
capable of transporting and discharging concrete without segregation. Agitation
speed of drum shall be between 2 and 6 revolutions per minute. Volume of mixed
concrete permitted in drum shall not exceed 70% of the manufacturer’s rated gross
volume of drum. Upon approval of the Engineer, truck mixers may be used instead of
agitator trucks for transportation of plant mixed concrete. Interval between
introduction of water into mixer drum and final discharge of concrete from agitator
shall not exceed one hour. During this interval, mixer shall be agitated continuously.
Placing of concrete shall be completed within 30 minutes after introduction of mixing
water into cement and aggregates. Uniformity of mix shall be deemed satisfactory if
samples from one-quarter and three-quarter points of load do not differ more than 2.5
cm in slump.
5) Mixing at Site of Construction
Job-site mixers, shall be operated at a drum speed of not less than 15 or more than
20 revolutions per minute. Batched materials shall be so charged into drum that a
portion of water shall enter in advance of cement and aggregates and water shall
continue to flow into drum for a minimum time of 5 seconds after all cement and
aggregates are in drum. Mixing time shall be measured from the time all materials
except water are in drum and shall, in case of mixers having a capacity of 1 m3 or
less, not be less than 50 seconds or more than 70 seconds. In case of dual drum
mixers, mixing time shall not include transfer time. Contents of an individual mixer
drum shall be removed before a succeeding batch is emptied therein. Any concrete
mixed less than specified minimum time shall be discarded and disposed of by the
Contractor.
6) Truck Mixing
a) Truck mixers, unless otherwise authorized by the Engineer, shall be of the
revolving drum type, watertight, and so constructed that concrete can be mixed to
ensure a uniform distribution of materials throughout the mass. All solid materials
for concrete shall be accurately measured and charged into drum at the
proportioning plant. Except as subsequently provided, truck mixer shall be
equipped with a tank for carrying mixing water. Only the prescribed amount of
water shall be placed in tank unless tank is equipped with a device by which
quantity of water added can be readily verified. Mixing water may be added
directly to batch, in which case a tank shall not be required. Truck mixers may be
required to be provided with means by which mixing time can be verified by the
Engineer.
b) Amount of mixing shall be designated in number of revolutions of mixer drum.
When a truck mixer is used for complete mixing, each batch of concrete shall be
mixed for not less than 70 or more than 100 revolutions of drum or blades at the
rate of rotation designated by the manufacturer of the equipment as "mixing
speed". Such designation shall appear on a metal plate attached to mixer. If
batch is at least 0.5 m3 less than guaranteed capacity, number of revolutions at
mixing speed may be reduced to not less than 50. Mixing in excess of 100
revolutions shall be at the agitating speed. All materials, including mixing water,
shall be in mixer drum before actuating the revolution counter which will indicate
number of revolutions of drum or blades.
c) When wash water (flush water) is used as a portion of mixing water for the
succeeding batch, it shall be accurately measured and taken into account in
determining the amount of additional mixing water required. When wash water is
carried on truck mixer, it shall be carried in a compartment separate from the one
used for carrying or measuring the mixing water. The Engineer will specify the
amount of wash or flush water, when permitted, and may specify a "dry" drum if
wash water is used without measurement or without supervision.
d) When a truck mixer is used for complete mixing at batch plant, mixing operation
shall begin within 30 minutes after cement has been added to aggregate. After
mixing, truck mixer shall be used as an agitator for transporting concrete at the
speed designated by the manufacturer of the equipment as agitating speed.
Concrete discharge to its final position shall be completed within 60 minutes after
addition of cement to aggregates. Each batch of concrete delivered at site shall
be accompanied by a time slip issued at batching plant, bearing the time of

departure therefrom. When truck mixer is used for complete mixing of concrete at
site, mixing operation shall begin within 30 minutes after cement has been added
to aggregates.
e) Rate of discharge of plastic concrete from mixer drum shall be controlled by the
speed of rotation of drum in discharge direction with discharge gate fully open.
(c) Transport of Concrete

Concrete shall be transported from mixer to formwork as soon as practicable by a method
which shall prevent segregation or loss of any ingredients and maintain the necessary
workability. Intervals between delivery of batches shall not exceed 30 minutes. Time shall
be counted from the moment when concrete is discharged from mixer to its deposition.
The Contractor shall submit to the Engineer for approval details of method for transporting
concrete. Such method shall be compatible with the approved mix designs.
(d) Placing Concrete

1) General
a) Placing of Concrete
No structural concrete shall be placed in the works until the relevant mix design
has been approved by the Engineer.
b) Premature Stiffening
Approved means shall also be provided to avoid premature stiffening of concrete
placed in contact with hot, dry surfaces. Surfaces including reinforcement against
which concrete is to be placed shall be shielded against the direct rays of the sun
and shall be sprayed with water to prevent excessive absorption by surfaces of
water from fresh concrete.
c) All concrete shall be placed within the times specified in Sub-Clauses herein.
Concrete shall be placed in such a manner as to avoid segregation and
displacement of reinforcing bars and shall be spread in horizontal layers where
practicable. Concrete shall be placed where necessary inside forms by hand
shovels and in no instance shall vibrators be so manipulated to transport concrete
inside formwork. Care shall be taken to prevent mortar from spattering on forms
and reinforcing steel and from drying ahead of the final covering with concrete.
Where spattering has occurred, forms and steel shall be cleaned with wire
brushes or scrapers before concrete is placed around steel, or in forms which
have been spattered.
d) Troughs, pipes, or short chutes used as aids in placing concrete shall be
positioned in such a manner that segregation of concrete will not occur. All
chutes, troughs, and pipes shall be kept clean and free from coating of hardened
concrete or mortar.
e) Concrete shall not be dropped freely over a vertical distance of more than 1.5 m.
f) Concrete shall be placed continuously throughout each section of the structure,
or between indicated joints if shown on the Drawings, or as directed by the
Engineer. If, in emergency, it is necessary to stop placing concrete before a
section is completed, bulkheads shall be placed as the Engineer may direct and
the resulting joint shall be deemed a construction joint.
g) All concrete shall, during placing and final finishing of surfaces, be protected
against direct sunshine.
h) Concrete when deposited shall have a temperature of not more than 32C. It shall
be compacted in its final position within 30 minutes of discharge from mixer
unless carried in purpose made agitators, operating continuously, when time shall
be within 1.5 hours of introduction of cement to mix and within 30 minutes of
discharge from agitator.
i) Records
The Contractor shall maintain records, in a form to be agreed by the Engineer, of
all tests on aggregates, cement, water, fresh concrete and hardened concrete.
Records shall be kept at site and shall identify tests with section of work to which
they relate and shall be promptly submitted to the Engineer. The Contractor shall
keep records giving class code, cement content used, number of batches and
position of concrete deposition in respect of each class of concrete used in the
Permanent or Temporary Works and shall submit such records to the Engineer

on the day following that during which concrete is placed. Details of all test
cylinders with their reference numbers which are taken from batch of each class
of concrete shall also be included in the records.
2) Concrete Columns
Concrete in columns or bents shall be placed in one continuous operation unless
otherwise permitted by the Engineer.
3) Concrete Slab and Girder Spans
a) Concrete in T-Beam or deck girder spans having spans of 12 m or less shall be
placed in one continuous operation unless otherwise stated on the Drawings.
Concrete preferably shall be deposited by beginning at the center of span and
working from the center toward the ends.
b) Concrete in slab spans shall be placed in one continuous operation and in one
layer for each span.
c) Concrete in girders spanning more than 12 m may be placed in two operations,
first operation being the placing of concrete in the girder stems to bottom of slab
haunches or bottom of slab whichever is applicable.
d) Shear keys shall be provided for by inserting oiled timber blocks to a depth of
about 4 cm in fresh concrete at top of each girder stem. A sufficient number of
blocks shall be used to cover uniformly about one-half top surface of girder stem
and blocks shall be removed as soon as concrete has set sufficiently to retain its
shape.
e) A period of at least 24 hours shall elapse between completion of placing concrete
in girder and commencement of placing concrete in slab.
f) Before placing concrete in slab, top surface of the previously placed concrete
shall be hammered with a sharp hand tool until aggregate is exposed, cleaned
and immediately before placing concrete a small quantity of neat cement slurry
added.
g) The Contractor shall check all falsework for shrinkage and settlement and shall
tighten all wedges to ensure minimum deflection of all formwork.
4) Walls, Piers etc.
a) Where walls, piers, columns, struts, posts and other such structural members
allow horizontal construction joints, concrete shall not be placed on top of other
concrete which has not been allowed to set for 12 hours or more.
b) Work shall not be discontinued within 45 cm of the top of any face, unless
provision has been made for a coping less than 45 cm thick, in which case, if
permitted by the Engineer, construction joint may be made at the underside of
coping.
5) Culverts
a) Slabs of box culverts shall be placed for their full depth in one mass or layer and
allowed to set not less than 12 hours before any additional work is done on them.
b) For culverts of exceptional length under high embankment details of construction
joints are shown on the Drawings. Entire length of slabs between indicated
construction joints shall be placed for their full depth or layer and allowed to set
for not less than 12 hours before any additional work is done on these lengths.
c) Before concrete is placed in sidewalls, bottom slabs shall be cleaned of all
shavings, sticks, sawdust and other extraneous material.
d) The Contractor shall submit to the Engineer for approval the method for pouring
culvert walls before commencing culvert construction. Concrete shall not be
placed in layers more than one meter high relative to the concrete already placed.
Deposition shall proceed in a systematic manner.
6) Depositing Concrete Under Water
a) Concrete shall not be deposited in water except with approval of the Engineer
and under immediate supervision of the Engineer and in this case the method of
placing shall be as defined herein.
b) To prevent segregation, it shall be carefully placed in a compact mass, in its final
position, by means of a tremie tube or pipe, or a bottom-dump bucket and shall
not be disturbed after being deposited. Special care must be exercised to
maintain still water at the point of deposit. Concrete shall not be placed in
running water. Method of depositing concrete shall be so regulated as to produce
approximately horizontal surfaces.

c) Concrete seals shall be placed in one continuous operation.

When a tremie tube or pipe is used, it shall consist of a tube or pipe not less than
25 cm in diameter. All joints in the tube shall be watertight. The means of
supporting the tremie tube shall be such as to permit free movement of discharge
end over the entire top of concrete and to permit being lowered rapidly when
necessary to choke off or retard the flow. Tremie tube shall be filled by a method
that will prevent washing of concrete. Discharge end shall be completely
submerged in concrete at all times and tremie tube shall be kept full.
d) When concrete is placed with a bottom-dump bucket, bucket shall have a
capacity of not less than 0.5 m3 and top of bucket shall be open. Bottom door
shall open freely downward and outward when tripped. Bucket shall be
completely filled and slowly lowered to avoid backwash. It shall not be dumped
until it rests on surface upon which concrete is to be deposited and when empty
be withdrawn slowly until well above concrete. Slump of concrete used shall be
maintained between 10 and 20 cm.
e) Dewatering shall proceed only when concrete seal is considered strong enough to
withstand any pressures to be exerted upon it. This time will be determined by the
Engineer.
f) All laitance or other unsatisfactory material shall be removed from the exposed
surface by scraping, jetting, chipping or other means which will not injure the seal
unduly.
7) Construction Joint
a) Construction joints shall be located where shown on the Drawings or permitted
or instructed by the Engineer. Construction joints shall be perpendicular to
the principal lines of stress and shall be located at points of minimum shear.
b) Horizontal Joints
Unless otherwise agreed or directed by the Engineer, exposed faces of concrete
at the joint shall be thoroughly brushed with wire brushes or by other approved
means so as to remove laitance and expose coarse aggregates. Care shall be
taken to ensure that no disturbance or loosening of aggregate, or cracks or other
defects in concrete are caused.
c) Vertical Joints
Where vertical construction joints are necessary, reinforcing bars shall
extend across the joint in such a manner as to make structure
monolithic. Special care shall be taken to avoid construction joints through
panelled wing walls or other large surfaces which are to have an architectural
finish.
d) Cleaning
Immediately before placing fresh concrete against faces of previously placed and
hardened concrete, surface of construction joints shall be thoroughly cleaned and
wetted.
e) Expansion Joints
Expansion, contraction and other movement joints shall be provided in the
locations and according to the details and dimensions shown on the Drawings or
as directed by the Engineer. Exposed edges of joints shall be sealed within an
approved synthetic rubber or similar resilient sealing compound.
f) Watertight Joint
Unless otherwise specified or shown on the Drawings, joints in water retaining
structures shall be formed with a continuous waterproof material and the work
method shall be approved by the Engineer.
8) Bridge Abutments
Bridge abutments adjacent to earth embankments shall be directly supported on
bored piles. The Contractor shall submit a method of construction, for approval of the
Engineer, which avoids embankment settlement imparting negative friction into bored
piles, otherwise piles shall be bored through embankment only after embankment has
reached its accepted settlement. Proposed method of construction shall also be such
that installation of adjacent bearing slab driven piling does not cause displacement of
abutment and its bored piles.

(e) Compaction of Concrete

1) General
Concrete shall be thoroughly compacted by vibration or other approved methods. The
Contractor shall submit details of work methods and rate of placing and compacting
concrete to the Engineer for approval. Such details shall include number and size of
vibrators to be used and number of standby vibrators that will be kept available and
shall be submitted in sufficient time prior to concreting to enable the Engineer to
consider and agree the compacting methods without delay to commencement of
concreting.
2) Use of Vibrators
a) Vibration shall not be applied by way of reinforcement. Where vibrators of the
immerse type are used, contact with reinforcement and all inserts shall be
avoided, so far as is practicable.
b) Internal vibrators shall be capable of producing not less than 10,000 cycles per
minute and external vibrator not less than 3,000 cycles per minute.
3) Concrete shall not be subjected to vibration between 4 and 24 hours after
compaction.
4) Damage to Freshly Set Concrete
If during concreting a previously placed layer or edge concrete has set before a
subsequent layer has been placed, concreting shall be stopped and the placed
concrete cut back to a sound face at the Contractor's cost.
(f) Finishing Concrete

All concrete surfaces exposed in the completed work shall comply with the requirements
below except where the Drawings indicate otherwise.
1) Concrete Decks
a) Immediately after placing concrete, concrete decks shall be struck off with
templates to provide proper crowns and shall be finished smooth to correct levels.
Finish shall be slightly but uniformly roughened by brooming.
b) Finished surface shall not vary more than 3 mm from a 3 m straight edge placed
parallel to center line and 3 mm from a transverse template cut to true cross-
section.
2) Curb and Sidewalk Surface
Exposed faces of curbs and sidewalks shall be finished true to lines and grades. Curb
surface shall be wood floated to a smooth but not slippery finish. Sidewalk surfaces
shall be slightly but uniformly roughened by brooming.
3) Ordinary Finish
a) Finish left on a surface after removal of forms when all holes left by form ties have
been filled, and any minor surface defects have been repaired. Surface shall be
true and even, free from depressions or projections.
b) Concrete in bridge seats, caps and tops of walls shall be struck off with a straight
edge and floated to true grade except for bridge seat with drain grade of two point
five percent (2.5%) as shown on the Drawings. Under no circumstances shall use
of mortar topping for concrete surfaces be permitted.
4) Rubbed Finish
a) After removal of forms rubbing of concrete shall be started as soon as its condition
will permit. Immediately before starting this work concrete shall be kept
thoroughly saturated with water for a minimum period of three hours. Sufficient
time shall have elapsed before wetting down to allow the mortar used in patching
to have thoroughly set.
b) A medium coarse carborundum stone shall be used for rubbing a small amount of
mortar on face. Mortar used shall be composed of cement and fine aggregate
mixed in the same proportions as those used in concrete being finished. Rubbing
shall be continued until all form marks, projections, and irregularities have been
removed, all voids filled and a uniform surface has been obtained. Paste
produced by this rubbing shall be left in place at this time.
c) Final finish shall be obtained by rubbing with a fine carborundum stone and water
until entire surface is of a smooth texture and uniform color.

d) After final rubbing has been completed and surface dried, burlap shall be used to
remove loose powder. Final surface shall be free from unsound patches, paste,
powder and objectionable marks.
(g) Curing and Protection

1) Approval
The Contractor shall submit the work method for curing and protecting each section
of the work for approval of the Engineer before placing any concrete or any precast
units are cast. For areas likely to be affected by sea water or salt water spray,
proposals describing how concrete is to be effectively protected therefrom up to the
time when it has sufficiently hardened shall also be submitted for approval.
2) Curing Period
All concrete shall be properly cured to satisfaction of the Engineer. Concrete shall be
protected from harmful effects of sunshine, drying winds, rainfall, running water and
shock. It shall be prevented from drying out for at least 4 days for concrete made of
"Type I cement and 7 days for concrete made of Type V cement” or as directed by
the Engineer.
3) Curing Compound
If the Engineer approves use of a curing compound it shall be applied in manner and
at the rate recommended by the manufacturer. Where spraying equipment is used, it
shall be maintained in a thoroughly clean condition and shall not be used for any
material other than the approved curing compound. Curing compound shall be
applied to surface of concrete as soon as it has been finished. Any free water shall be
allowed to dry out before compound is applied. Care shall be taken not to damage
surface during application. If period for drying out exceeds one hour or if for any other
reason curing compound can not be applied alternative methods of curing described
below shall be used. The Contractor shall have an alternative approved method of
curing concrete available for use at any time. The Contractor's work method for use of
liquid membrane curing compound shall be subject to approval of the Engineer.
4) Wetted Absorbent Covering
Where a wetted absorbent covering is used, the Contractor shall ensure that covering
is kept continually damp and that in no circumstances shall alternate wetting and
drying occur. The Engineer will prohibit use of wetted absorbent coverings where
surface being protected is likely to be cooled excessively by drying winds and in such
cases, the Contractor shall submit alternative proposals to the Engineer for approval.
5) Curing after Removal of Formwork
Where formwork is removed from concrete before sufficient time has elapsed for
proper curing, curing protection shall be immediately applied to surface.
6) The Contractor shall take steps to prevent any damage to newly cast surfaces.
Suitable barriers and warning notices shall be erected to prevent access over
concrete which has been recently placed and no plant, equipment and the like shall
be placed thereon until surface is hard enough to bear such loads without damage.
Edges, corners and other areas shall be adequately protected against accidental
damage.
7) All concrete surfaces shall be kept wet for at least 7 days after placing. Salt or
brackish water must not be used for curing. Bridge deck and sidewalk slabs shall be
covered with wet burlap immediately after final finishing of surface. This material shall
remain in place for full curing period or may be removed and replaced with sand
when concrete has hardened sufficiently to prevent marring. In both cases materials
shall be kept thoroughly wet for entire curing period. All other surfaces, if not
protected by forms, shall be kept thoroughly wet, either by sprinkling or by use of wet
burlap until end of curing period. If wood forms are allowed to remain in place during
curing period, they shall be kept moist at all times to prevent openings at joints.
8) Removal of Formwork
a) Notice
The Contractor shall give adequate notice to the Engineer of intention to strike
any formwork.
b) Age and Strength
Concrete must be of sufficient age and strength at the time of striking for it to
withstand effects of striking including effect of thermal shock or loss of surface

durability upon premature exposure and shall be able to carry stresses acting
without adverse effects.
c) Removal of Falseworks and Forms
In determination of the time for removal of falseworks and forms, consideration
shall be given to location and character of structure, weather and other conditions
influencing the setting of concrete and materials used in mix. If field operations
are not controlled by cylinder or beam test the following periods for removal of
forms and supports may be used as a guide.
Minimum Time for Removal of Formwork and Falsework

Description Standard Early Strength Percentage
Concrete Concrete Design Strength
Concrete beams 14 days 7 days 80 %
Slabs 14 days 7 days 70%
Walls 3 days 12 hours -
Piers and Abutments 2 days 1 day -
Side of beams and all other 3 days 12 hours -
Vertical surfaces
d) Partial Removal
Formwork shall be constructed so that side forms of members can be removed
without disturbing soffit forms and if props are to be left in place when soffit forms
are removed, these props shall not be disturbed during striking.
e) Prestressed Units
For prestressed unit, soffit forms shall accommodate deformation of member
when prestress is applied or as approved by the Engineer.
f) Removal without Damage
All formwork shall be removed without damage to concrete in appearance,
strength or durability.
g) No loading or pressure by earth fill or water shall be carried to any part of a
structure until permission is given by the Engineer.
h) Cleaning
Where it is intended to reuse formwork it shall be cleaned to satisfaction of the
Engineer.
The quantities to be measured for payment shall be the actual number of cubic meter of the
various classes of concrete, installed in place, completed and accepted by the Engineer. In
computing the quantities the dimensions used shall be those shown on the Drawings or
ordered in writing by the Engineer but measurement shall not include any concrete used for
construction of temporary works. No deduction from the measured quantity shall be made for
the volume occupied by pipes or piles less than 20 cm in diameter nor for reinforcing steel,
including steel piling encased in concrete. Measurement shall not include any concrete used
in construction of cofferdams or falsework or volume of forms or falsework.
No separate payment will be made for “Concrete” if method of measurement or basis of

payment for another pay item calls for inclusion of this cost in that respective pay item.
No separate payment shall be made for any increased cement content, admixtures or finishing
surface of any concrete. Where with permission of the Engineer the Contractor has chosen to
use a stronger class of concrete than that shown on the Drawings, measurement and
payment will be made for the class of concrete shown or specified and not that actually used.
The quantities of reinforcing bar and other pay items which are included in the completed and
accepted structure shall be measured for payment as described for the separate items
involved.

compensation for the works prescribed in this Clause, including furnishing and placing all
materials, labor, tools, equipment, formwork, falsework (scaffolding, supports and piling),
mixing, placing, curing and finishing concrete, precasting, delivery of mixed concrete to site
and installation, including cement mortaring, concrete blocks for platform construction and H-
beam for composite concrete bridge as shown on the Drawings and all other incidental works,
including provision of drainage slopes and systems, weepholes, expansion joints, joint fillers
and water stops etc. Supply, fixing and finishing of reinforcing bars will be paid for separately
under other Clauses.
214 (1) Concrete Class A cubic meter

214 (2) Concrete Class B cubic meter
214 (3) Concrete Class C cubic meter
214 (4) Concrete Class D cubic meter
214 (5) Concrete Class E cubic meter
214 (6) Concrete Class F cubic meter

2.15 REINFORCING BAR
(1) Description
This work shall consist of finishing, installing and placing reinforcement bars of the grade,
type and size in accordance with this Specification and in conformity with the requirements
shown on the Drawings.
(2) Materials
(a) Reinforcing Bar

1) Reinforcing bar shall conform to the requirements of U 24 (PBI) and SR 235 (JIS) for
plain round bars of 9 mm in diameter or less and U40 (PBI) and SR390 for high yield
strength deformed bars of 10mm or more.
2) Where these standards are not applicable, reinforcing bar shall conform to this
Specification for deformed and plain billet-steel bars, AASHTO M31, Grade 40.
3) Twisted or redrawn bars shall not be used.
4) Yield stress and tensile strength shall be as listed below.
Allowable Stress and Strength
Indonesian Japanese Yield Stress Tensile Strength

2
Standard Standard (N/mm2) (N/mm )
U 24 SR 235 235 380

U 40 SD 390 390 560
5) Weight and section area of reinforcing bar shall be as shown below.
Deformed Bar
Bar No. Weight (kg/m) Section Area (cm2) Perimeter (cm)
D 10 0.617 0.780 3.14
D 13 1.042 1.327 4.08
D 16 1.578 2.011 5.03
D 19 2.226 2.835 5.97
D 22 2.984 3.801 6.91
D 25 3.853 4.909 7.85
D 29 5.185 6.605 9.11
D 32 6.313 8.042 10.05
Plain Bar
Bar No. Weight(kg/m) Section Area (cm2) Perimeter(cm)
Ø7 0.220 0.28 1.88
Ø8 0.395 0.50 2.51
Ø9 0.617 0.79 3.14
(b) Binding Wire

Binding wire shall be best black annealed mild steel wire, approximately 1.6 mm in
diameter. Unless otherwise permitted by the Engineer, all intersecting bars shall be tied
together and ends of tying wire turned into main body of concrete.

(c) Cover Blocks

Cover blocks shall be as small as possible consistent with their purpose, designed not to
overturn when concrete is placed, and of a shape acceptable to the Engineer. If cover
blocks are made of concrete, they shall have 10 mm aggregate size and the same mix
proportions so as to produce the same strength to adjacent concrete. Cover blocks of
other materials may be used with prior written approval of the Engineer.
(3) Construction
(a) Cutting and Bending

1) Bars shall be cut and bent cold, unless otherwise permitted by the Engineer, to
dimension and shape as shown on the Drawing. Bars partially embedded in concrete
shall not be site bent without approval of the Engineer.
a) Stirrups and tie bars in Grade SR 24 shall be bent around a pin having a diameter
not less than four times minimum thickness of bar.
b) Bends for other bars shall be made around a pin having a diameter not less than
12 times minimum thickness except for bars larger than 30 mm in which case
bends shall be made around a pin of eight bar diameters.
c) Hooks shall conform to American Concrete Institute Standard Building Code
Requirements for reinforced concrete (ACI 318), Section 906, or as shown on the
Drawings.
2) High tensile steel reinforcing bar must not be re-bent or straightened on site.
(b) Placing, Supporting and Fastening

1) Reinforcing bars before being positioned shall be cleaned and free from rust, dirt,
mud, loose scale, paint oil or other foreign substance that destroys or reduces the
bond.
2) All bar reinforcement shall be placed, supported and secured before beginning of
concreting operations. Reinforcement shall be checked and approved by the Engineer
before placement of concrete begins. Relation between minimum spacing of bars and
maximum size of aggregate shall be as described below unless otherwise stated by
the Engineer. Minimum clear distance between two bars in a beam or column shall not
be less than diameter of bar or 25 mm or largest size of aggregate plus 10 mm
whichever is greater. Laying or driving bars into concrete after placement shall not be
permitted.
3) All horizontal reinforcement shall be supported on metal supports or mortar blocks of
approved shape with wires embedded in them. Supports which are in contact with
external face of concrete shall all be mortar blocks. Use of small stones or wood
blocks shall not be permitted.
(c) Splicing
1) No splicing shall be made in reinforcement except where shown on the Drawings and
Shop Drawings approved by the Engineer. Splicing of steel bar reinforcement shall be
made in accordance with ACI 315.
2) Reinforcement shall be furnished in the lengths indicated on the Drawings. Lap
splicing except where shown on the Drawings shall not be permitted without written
approval of the Engineer and if additional lap splices are used, additional weight
occasioned by such lap splices shall not be included in measurement of reinforcing
bar for payment.
3) All splices shall have a lap length of not less than that shown on the Drawings or 40
diameters of bars for tensile reinforcement and 32 diameters for compressive
reinforcement wherever no dimension is shown on the Drawings. Lap splices shall
generally be located at points of minimum tensile strength. Except where otherwise
shown on the Drawings lap splices shall be made with bars placed in contact and
wired securely together.
4) Welding of reinforcing steel may be done only if approved in writing by the Engineer.
Before the Engineer will approve welding, the Contractor shall submit such samples
as the Engineer may require for testing and make allowance for time elapsing before
test results are available.

5) Use of mechanical couplers (e.g. crimped type) shall only be used with prior written
(d) Substitution
1) Substitution of different size bars shall be permitted only with specific authorization by
the Engineer. If steel is substituted, it shall have a cross-sectional area equivalent to
design area or larger. Additional weight occasioned by such substitution shall not be
included in measurement of reinforcing bar for payment.
2) The Contractor shall provide, in case of substitutions for approval of the Engineer
Shop Drawings of all reinforcement accompanied by bending schedules and copies
of orders placed for bars.
(e) Inspection
Immediately before concreting, reinforcing bar shall be examined for accuracy of placing
and cleanliness and corrected if necessary. No concreting shall take place before
inspection and approval of reinforcing bar by the Engineer.
(f) Cover to Reinforcement

Unless otherwise indicated on the Drawings or approved by the Engineer, concrete cover
to reinforcing bar nearest to surface shall not be less than:
1) top bars in slabs : 50 mm
2) bottom bars in slabs : 30 mm
3) main bars in all other structures : 50 mm
4) stirrups, links and ties in all other structures : 30 mm
The quantity to be measured for payment shall be the actual number of kilograms of
reinforcing bar installed in place, completed and accepted by the Engineer. In computing the
quantities the dimensions used shall be those shown on the Drawing or ordered by the
Engineer in writing.
Length and area to be taken in calculating weight for the purpose of payment shall be shown
on the Drawings or ordered in writing by the Engineer. No measurement or payment will be
made for splices added by the Contractor for convenience after approval of Shop Drawings or
for splices which are not shown on the Drawings and are not approved by the Engineer. Clip
ties or other material used for positioning and fastening reinforcing bars in place shall not be
measured for payment but the cost thereof shall be included in the price per kilogram of
reinforcing bars.
No separate payment will be made for “Reinforcing Bar” if method of measurement or basis of
payment for another pay item calls for inclusion of this cost in that respective pay item.
compensation for the works prescribed in this Clause, including furnishing all labor, equipment
and materials necessary for fabricating, bending, assembling, installing, transporting and
unloading at the specific location, storing and handling of reinforcing bar.
215 Reinforcing Bar kilogram

2.16 PRESTRESS CONCRETE WIRE
(1) Description
This work shall consist of furnishing, placing of prestressed concrete wire and completing the
work for pretensioning or posttensioning methods. The work shall be in accordance with the
details shown on the Drawings and as specified herein. “Pretensioning” is defined as any
method by which tension wire is tensioned before concrete is placed. “Posttensioning” is
defined as any method by which tension wire is tensioned after concrete is placed.
(2) Materials
(a) Steel for Prestressing

Steel for prestressing used shall be as specified in JIS G 3109 for bars and JIS 3536 for
wire and strand or equivalent. Type and minimum strength of prestressing steel are as
shown below.
Steel for Prestressing

Yield Stress Tensile Strength
Type Category (N/mm2) (N/mm2)
PC Wire G 3536 (8mm) 1275 1470
PC Strand G 3536 SWPR A
(12.4mm×7) 1465 1720
(15.2mm×7) 1470 1730
G 3536 SWPR B
(12.7mm×7) 1580 1855
(15.2mm×7) 1600 1880
PC Bar G 3109 Type B 930 1080
(b) Structural Steel

Structural steel shall conform to Grades SS400, SM400, SM490 and SM520 or equivalent
without any special applications.
(c) Ducts
1) Ducting for internal tendons shall be interlocked, mortar and grout tight and fabricated
from corrugated galvanized sheet steel or semi-rigid conduit of a type approved by
the Engineer. Duct diameter shall be at least 6 mm larger than nominal diameter of
strand, wire or bar and cross sectional area shall be at least 2.5 times that of net
tendon area. Duct thickness shall be as described below.
a) 26 gauge for duct dia. less than or equal to 67 mm
b) 24 gauge for duct dia. greater than 67 mm
c) 31 gauge for bar tendons
Ducts shall have grouting connections at each end and shall have vent/drains at all
intermediate high and low points to approval by the Engineer.
2) Corrugated sheathing is to be delivered to site, coiled on to large diameter wooden
drums, securely fastened and protected from damage or other approved methods.
3) Corrugated sheathing is to be stored on site under cover from weather and shall be
protected from damage, rusting, staining by oil or any other deleterious matter and
shall be clean and free from all such matter before being used in the works.
(d) Anchorages for Prestressing Reinforcement

Anchorages shall be of a proprietary type and material which, through tests and practice,
has verified its safe mode of operation and its strength and breaking characteristics.

(3) Construction
(a) Design and Shop Drawings

The Contractor shall be responsible for detailed design of prestressed concrete structural
elements, including determination of prestressing arrangements and prestressing forces
in accordance with this Specification. The Contractor shall prepare detailed design and
fabrication drawings and erection procedures and shall submit to the Engineer for
approval before any prestressed concrete units are produced in accordance with this
Specification.
(b) Precautions
1) Prestressing and subsequent grouting operations required shall be carried out
under direction of a competent supervisor and by personnel who have approved
previous experience in use of tensioning equipment, all of which shall be subject to
2) The Contractor shall be entirely responsible for safe execution of tensioning
operations. Special precautions against accident shall be taken when working with
or near tendons which have been tensioned or are in process of being tensioned.
(c) Construction of Units

1) Fabrication
a) Prestressing cables shall be manufactured on site from coils of wires or strands.
b) Cable consisting of a number of high-tensile strength steel wires or strands shall
be formed in the manner as directed by the Engineer.
c) In estimating length of all cables, extra allowance must be made for attaching
either one or two tensioning jacks as required or as instructed by the Engineer.
d) Sheathing shall be carefully examined prior to use and any damaged lengths
shall be cut away and rejected.
e) Joints in corrugated sheathing shall be formed by use of couplers and by
wrapping joints with suitable tape. They shall be so designed as to prevent
ingress of water, cement, concrete or other material during casting.
f) All joints in sheathing shall be approved by the Engineer.
g) Sheathing shall be provided with suitable outlets with plugs to prevent air locks.
h) Tendons shall be carefully handled so as to avoid sudden bends or kinks and
threaded into the flexible sheathing before this is placed in formwork.
i) Sheathing with prestressing tendon shall be rigidly supported in its exact position
as shown on the Drawings so that no movement can take place during casting of
structural component.
j) Anchorages shall be placed accurately in accordance with the Drawings and
firmly fixed to resist displacement during vibration of concrete. Each anchorage
shall be fixed so as to have its axis coinciding with axis of tendon in question and
to remain so throughout casting of component.
k) Tendons after being placed in ducts or sheaths shall be so arranged as to allow
an unrestricted flow of grout through ducts and it shall be ensured that tensioned
tendons are completely embedded and ducts effectively filled, unless specific
instructions are given on the Drawings as to tendons being left unbonded.
Treatment of unbonded tendons shall be approved by the Engineer.
(d) Prestressing
1) The Contractor shall provide all equipment necessary for prestressing.
Prestressing shall be done with approved jacking equipment.
a) If hydraulic jacks are used, they shall be equipped with accurate readable
pressure gauges.
b) Combination of jack and gauge shall be calibrated and a graph or table showing
calibration shall be furnished to the Engineer.
2) No tensioning of prestressing tendons shall take place until directed or approved
by the Engineer.
a) The Contractor shall carry out test tensioning of cables if and as instructed by the
Engineer. Cost of this shall be considered incidental to the works and included in
the relevant unit rates or costs.

b) Final tensioning shall take place as directed by the Engineer at the time decided
by the Engineer as ascertained from compression tests on specimens cured
under the same conditions as concrete of structural component.
c) Before final stressing of single wires or strands, wires or strands in each cable
shall be of equal length and tension.
d) Before initial tensioning anchorages shall be carefully cleaned on all surfaces.
3) Amount of tension given to each tendon shall conform to a tensioning schedule to
be supplied by the Engineer and confirmed by the Contractor and will be based on
test data for prestressing steel.
a) Order and sequence of tensioning shall be as specified on the Drawing or as
instructed by the Engineer.
b) After tensioning, wires or strands shall be secured in position and cut off as
directed.
c) Measuring of stressing force shall be done using an accurate gauge indicating
the force on hydraulic jack and also by ascertaining the elongation of tendon,
after allowing for any initial slip in wedges or jaws of pulling grips.
4) Approval shall be obtained from the Engineer before each tendon is anchored.
Tensioning procedure shall be recorded by the Contractor on tensioning
schedules, a copy of which shall be supplied to the Engineer.
a) Prestressing force shall be applied from one or both ends as specified on the
Drawings or by the Engineer.
b) If tensioning does not proceed as scheduled, the Contractor shall be liable to re-
tension or to replace the reinforcement.
c) Each wire, pair of wires, cable or strand, shall be placed, shaped and pulled in
such a manner as to ensure that elongation is uniform in its length. Should any
tensioned steel or anchorage break or be damaged it shall be replaced if so
ordered.
d) Throughout all tensioning operations one or more spare jacks capable of
maintaining the designated load shall be available.
5) Those employed shall be experienced in this class of work. A cable under stress
can cause serious injuries to persons or damage to equipment in case of failure of
cable, anchor or jack. All reasonably practicable precautions shall be taken to
avoid such injury and damage.
(e) Grouting
1) After tensioning and anchorage are approved by the Engineer, all cable ducts shall
be grouted.
a) No grouting shall take place until directed or the Engineer has given approval.
b) Immediately before grouting each duct shall be carefully cleaned by pumping
clean water through it and ducts shall subsequently be blown through with clean
compressed air until water is expelled. Compressed air shall be tested to ensure
that no oil is carried over from compressor unit.
2) Method of mixing and injecting grout shall be approved by the Engineer.
a) Pressure at which grout is to be pumped into duct shall be approved by the
Engineer and shall not normally exceed 1 N/sq. mm.
b) Grout shall be a lean cement grout with a water cement ratio not exceeding 0.4,
or cement mortar (1:1 by weight).
c) An expanding plasticising admixture should be used in accordance with the
manufacturer's recommendations.
d) Admixture shall be of manufacture approved by the Engineer. Admixtures or sand
containing chlorides, nitrates or sulphates shall not be used.
e) Grout should be fluid (the consistency of thick paint) but should be proportioned
so that free water will not separate out of the mix.
f) Care shall be taken to avoid lumps in cement and sieving shall be carried out
before mixing the grout.
g) It is essential to prepare a quantity of grout sufficient for a particular duct
immediately prior to its injection and to use only this batch on the duct.
3) Grouting shall be carried out continuously and discharge from consecutive air
holes before their plugging being observed throughout.
a) Mixer shall be thoroughly cleaned before grouting is commenced.

b) A complete spare grouting plant shall be available for immediate use in case of
an emergency breakdown of equipment in operation.
c) During grouting operation, grout shall be continuously added to bucket from
which grout is being pumped and bucket shall not be changed.
d) Duct shall be plugged when grout is issuing freely from outlet end and once
plugged pressure shall be gradually reduced to prevent blowbacks or air pockets.
e) Pump shall then be removed and inlet end of duct likewise plugged.
f) After grouting, ends of anchorages and any projecting ends of cut-off tendons
shall be covered by epoxy resin and a 1:1 mix mortar shall be packed hard into
recess around these ends.
The quantity to be measured for payment shall be the actual number of kilograms of prestress
concrete wire installed in place, completed and accepted by the Engineer. In computing the
quantities the dimensions used shall be those shown on the Drawing or ordered by the
Engineer in writing.
Length and area to be taken in calculating the weight for purpose of payment shall be as
shown on the Drawings or ordered in writing by the Engineer. No measurement or payment
will be made for splices added by the Contractor for convenience after approval of Shop
Drawings or for splices which are not shown on the Drawings and are not approved by the
Engineer.
Clip ties or other material used for positioning and fastening prestress concrete wires in place
shall not be measured for payment but the cost thereof shall be included in the price per
kilogram of prestress concrete wires.
No separate payment will be made for “Prestress Concrete Wire” if method of measurement or
basis of payment for another pay item calls for inclusion of this cost in that respective pay
item.
compensation for the works prescribed in this Cause, including furnishing all materials, labor,
tools and equipment, delivery to site and installation (with scaffolding, supports and piling),
including grouting, prestressing and incidentals necessary for the works.
216 Prestress Concrete Wire kilogram

2.17 PRESTRESSED CONCRETE BRIDGE SEGMENT
(1) Description
This work shall consist of constructing, furnishing, placing of prestressed concrete bridge
segment and completing the work for pretensioning or posttensioning methods. The work
shall be in accordance with the details shown on the Drawings and as specified herein. Type
of concrete bridge segment shall be consist of “Box Girder” and “I-Beam”.
“Pretensioning” is defined as any method by which tension reinforcement is tensioned before

concrete is placed. “Posttensioning” is defined as any method by which tension reinforcement
is tensioned after concrete is placed. “Prestressed reinforcement” is defined as any
reinforcement to which stress is applied by posttensioning or pretensioning. “Non-prestressed
reinforcement” is defined as any reinforcement to which no stressing tension is applied
externally.
(2) Materials
(a) Cement shall conform to Clause 2.14 “CONCRETE WORKS”
(b) Water shall conform to Clause 2.14 “CONCRETE WORKS”
(c) Admixtures
1) Admixtures or any other additions shall not be used without written approval of the
Engineer.
2) The Contractor shall submit specifications and samples of any admixtures or additive
to use to the Engineer at least 28 days before commencement of construction or
manufacture of particular structure on which to use such admixtures.
3) Any tests, the Engineer will require on concrete mixes to use additives, shall be
carried out by the Contractor.
(d) Coarse aggregate shall conform to Clause 2.14 “CONCRETE WORKS”
(e) Fine Aggregate shall conform to AASHTO Standard Specification M6.
(f) Approval to mix design shall be based upon results of tests carried out on preliminary
tests cylinder or cubes and assessed against minimum criteria specified below.
Mix Design Criteria of Concrete
Class of Concrete K 500 K 350
Maximum Size of Coarse Aggregate (mm) 20 25
7,5 7,5
Slump (cm)
+/- 2.5 +/- 2.5
Water Cement Ratio W/C (%) 40 50
Water Content (kN/m³) 1.84 1.81
Cement Content (kN/m³) 4.60 3.66
Fine Aggregate (kN/m³) 7.57 8.19
Coarse Aggregate (kN/m³) 10.03 10.44
(g) Ducts
1) Ducting for internal tendons shall be interlocked, mortar and grout tight and fabricated
from corrugated galvanized sheet steel or semi-rigid conduit of a type approved by
the Engineer. Duct diameter shall be at least 6 mm larger than nominal diameter of
strand, wire or bar and cross sectional area shall be at least 2.5 times that of net
tendon area. Duct thickness shall be as listed below.
a) 26 gauge for duct diameter less than or equal to 67 mm
b) 24 gauge for duct diameter greater than 67 mm
c) 31 gauge for bar tendons
Ducts shall have grouting connections at each end and shall have vent and drain at

all intermediate high and low points to approval of the Engineer.

2) Corrugated sheathing is to be delivered to site coiled on to large diameter wooden
drums, securely fastened and protected from damage or other approved methods.
3) Corrugated sheathing is to be stored on site under cover from weather and shall be
protected from damage, rusting, staining by oil or any other deleterious matter and
shall be clean and free from all such matter before being used in the works.
(h) Anchorages for Prestressing Reinforcement

Anchorages shall be of a proprietary type and material which, through tests and practice,
is verified its safe mode of operation and its strength and breaking characteristics.
(i) Molds shall be of steel or plywood panels or panels of other materials approved by the
Engineer and shall be rigidly assembled so that no displacement or deformation can take
place during casting. Formwork shall be designed so that it can be removed without
shock or damage to concrete and it must be braced and held in position in such a way as
to avoid any holes or fastenings through the member.
(3) Construction
(a) Design and Shop Drawings

The Contractor shall be responsible for detailed design of prestressed concrete structural
elements, including determination of prestressing arrangements and prestressing forces
for segments division and segments key in accordance with this Specification. The
Contractor shall prepare detailed design and fabrication drawings and erection
procedures and shall submit to the Engineer for approval before any prestressed
concrete units are produced in accordance with specified requirements.
(b) Preparation
Approval of the Engineer for the method of manufacturing and manufacturer shall be
obtained before the work is started. When method and manufacturer are approved, no
changes shall be made without written approval of the Engineer. The Contractor shall
inform the Engineer in advance of date of commencement and location of manufacture
of each type of member and no work of concreting shall be permitted without prior
approval of the Engineer. All concreting operations shall be performed in presence of
the Engineer unless otherwise agreed in writing by the Engineer.
(c) Tests
1) A copy of all 28 days cylinder test results and any tests to establish transport strength
shall be submitted to the Engineer immediately after testing.
2) Where the Engineer requires tests to be performed on members or their material
constituents, no members to which such tests relate shall be despatched to site until
such tests have been satisfactorily completed and all members accepted by the
Engineer.
(d) Precautions
1) Prestressing and subsequent grouting operations required shall be carried out
under direction of a competent supervisor and by personnel who have had
approved previous experience in use of proposed equipment, all of which shall be
subject to approval of the Engineer.
2) The Contractor shall be entirely responsible for safe execution of tensioning
operations. Special precautions against accident shall be taken when working with
or near tendons which have been tensioned or are in process of being tensioned.
(e) Construction of Units

Fabrication shall comply with the requirement in Clause 2.16 “PRESTRESS CONCRETE
WIRE”. Concrete shall not be deposited in the forms until the Engineer has inspected the
placing of reinforcement, corrugated sheathing, anchorages and prestressing steel and
has given approval thereof. Concrete shall be vibrated internally or externally, or both, as
directed by the Engineer. Vibrating shall be done with care in such a manner as to avoid
damage to, or displacement of, reinforcement, sheathing, anchorages or wires.

(f) Identification and Marking

All prestressed girders shall be marked to indicate location in bridge span, top surface
and date of fabrication. Identification marks shall correspond to the placing plan. All
members shall be indelibly marked to show member mark, production line on which they
were manufactured, date on which concrete was cast. If they are symmetrical sections,
face which will be uppermost when member is in its correct position in the works shall be
marked TOP. All markings shall be located so that they are not visible when member is in
its final position in the works.
The quantities to be measured for payment shall be the actual number of cubic meter of Class
“A” of completed concrete segment structure, installed in place and accepted by the Engineer.
In computing the quantities the dimensions used shall be those shown on the Drawings or
ordered in writing by the Engineer but measurement shall not include any concrete used for
construction of temporary works. No deduction from the measured quantity shall be made for
volume occupied by pipes or piles less than 20 cm in diameter nor for reinforcing steel,
including steel piling encased in concrete. Measurement shall not include any concrete used
in construction of cofferdams or falsework or volume of forms or falsework.
No separate payment shall be made for any increased cement content, admixtures or
finishing surface of any concrete. Where with permission of the Engineer the Contractor has
chosen to use a stronger class of concrete than that shown on the Drawings measurement,
and payment will be made for class of concrete shown or specified and not that actually used.
The quantities of reinforcing bar and other items which are included in the completed and
accepted segment structure shall be measured for payment as described by respective pay
items.
compensation for the works prescribed in this Clause, including furnishing concrete, mold, all
materials, labor, tools and equipment, delivery to site and installation of concrete bridge
segment (with scaffolding, supports and piling), including incidentals necessary for the works.
217 Prestressed Concrete Bridge Segment cubic meter

2.18 PRESTRESSED CONCRETE BRIDGE ERECTION
(1) Description
This work shall consist of furnishing all equipment and plant, hauling, erecting and
constructing concrete bridge in accordance with this Specification and the lines, levels,
grades, dimensions and designs as shown on the Drawings and as required by the Engineer.
The Contractor shall be responsible for all errors of detailing, fabrications and correct fitting of
concrete bridge segments.
(2) Materials
(a) Concrete
1) Cement shall comply with the requirements of Clause 2.14 “CONCRETE WORKS”.
2) Aggregates shall comply with the requirements of Clause 2.14 “CONCRETE
WORKS”.
3) Water shall comply with the requirements of Clause 2.14 “CONCRETE WORKS”.
4) Reinforcing bar shall comply with the requirements of Clause 2.15 “REINFORCING
BAR”
(b) Surface Finishes

Surface finishes shall be compatible with use of steel formwork except as shown
otherwise. In particular for precast beams some surfaces, which will be bonded to insitu
concrete, shall have all laitance removed and coarse aggregates shall be exposed.
(c) Prestress Concrete Wire

Prestress concrete wire shall be provided under Clause 2.16 “PRESTRESS CONCRETE
WIRE”.
(d) Prestressed Concrete Bridge Segment

Prestressed concrete bridge segment shall be provided under Clause 2.17
“PRESTRESSED CONCRETE BRIDGE SEGMENT”.
(3) Construction
(a) Preparation
Approval of the Engineer for method of erection work shall be obtained before the
work is started. When method of erection work are approved, no changes shall be
made without written approval of the Engineer. The Contractor shall inform the
Engineer in advance of date of commencement and location of erection work and no
work of concreting shall be permitted without prior approval of the Engineer. All
concreting operations shall be performed in presence of the Engineer unless
otherwise agreed in writing by the Engineer.
(b) Rejection of Segments

Any segment considered by the Engineer to be substandard shall be rejected and
replaced at the Contractor's expense by an acceptable segment.
(c) Erection
1) Precast girders and beams shall be adequately braced and supported during
erection to ensure proper alignment and structural integrity until permanent
connections are completed.
2) Bridge beams shall be arranged that the largest camber are placed at or near
longitudinal center line of bridge. Bridge beams shall not be placed in final positions
in bridge until the Engineer has approved beams and location and alignment of
bearings or bearing pads on substructure.
3) Bearing Surface
Where precast girders are to be placed in the works without compressible bearing
strip on unyielding surface of bearings, bearing shall be carefully screeded to the
specified level on a layer of 10 mm nominal thickness of epoxy mortar bedding and

left for seven days prior to placing segments.

4) Dressed Surface
Surfaces of precast members which will be bonded to cast-in-situ concrete are
designated as "Dressed Surfaces". Such surfaces shall be treated as construction
joints as stipulated in Clause 2.14 “CONCRETE WORKS”
When beams are being placed in position, they shall be braced independently
against overturning or any other movement before being released by crane or other
lifting device. When placing insitu concrete over precast members in bridge decks, it
shall be placed in such a sequence that advancing edge of freshly placed concrete
over full deck width or between longitudinal construction joints is approximately
parallel to the deck supports. Longitudinal construction joints shall be parallel to
precast members and located between adjacent top flanges of two adjacent
members.
The quantities to be measured for payment shall be the actual number of cubic meter of
concrete bridge segment, erected, installed in place, completed and accepted by the
Engineer. In computing the quantities the dimensions used shall be those shown on the
Drawings or ordered in writing by the Engineer but measurement shall not include any
concrete used for construction of temporary works. No deduction from the measured quantity
shall be made for volume occupied by pipes or piles less than 20 cm in diameter nor for
reinforcing steel, including steel piling encased in concrete. Measurement shall not include
any concrete used in construction of cofferdams or falsework or volume of forms or falsework.
compensation for the works prescribed in this Clause, including furnishing concrete, surface
finishes, all materials, labor, tools and equipment, delivery to site and erection of concrete
bridge (with scaffolding, supports and piling), including incidentals necessary for the works.
218 Prestressed Concrete Bridge Erection cubic meter

2.19 CONCRETE BRIDGE BEARING
(1) Description
This work shall consist of furnishing and installing elastomeric concrete bridge bearings as
shown on the Drawings and described in this Specification.
(2) Scope of Work
(a) Quality Assurance

The Contractor shall maintain adequate records in accordance with the requirements of
quality assurance and the records shall be submitted to the Engineer.
(b) Tolerances
On plain and laminated bearings, permissible variation from dimensions and
configuration shall be as required below.
1) Overall Vertical Dimensions mm
- Average total thickness 32 mm or less -0,+3.2
- Average total thickness over 32 mm -0,+6.4
2) Overall Horizontal Dimension
- 1 m and less -0,+6.4
- Over 1 m -0,+12,7
3) Thickness of Individual Layers of Elastomer +3.2
(Laminated Bearing Only)
4) Variation from a Plane Parallel to Theoretical Surface
(as determined by measurements at edge of bearings)
- Top 3.2
- Sides 6.4
- Individual Non-Elastic Laminates 3.2
5) Position of Exposed Connection Members 3.2
6) Edge Cover of Embedded Laminates or Connection Members -0,+3.2
7) Size of Holes, Slots or Inserts +3.2
8) Position of Holes, Slots or Inserts +3.2
(c) Submittals
The Contractor shall submit to the Engineer the following data for approval.
1) Epoxy Mortar Bearing Plinths
- Method statement
- Details of supervisor’s experience
- Composition and mix proportions of epoxy mortar
- Test results
2) Bearings
- Method statement for installation
- Manufacturer’s technical brochures
- Model of bearing system
- Test results of components
(2) Materials
(a) Elastomer Bearing

1) Materials for bearings shall conform to the requirements of the following codes.
- Carbon Steel shall conform to JIS G 5101, SC 450 and SC 480.
- Cast Steel shall conform to JIS G 5102, SCW 410 and SCW 480
- High tensile Carbon steel shall conform to JIS G 5111, SCMn 1A, 2A
- Cast iron shall conform to JIS G 5501 , FC 250
- Stainless steel shall conform to JIS G 4305, SUS 304
2) Elastomer portion of elastomeric compound shall be 100 percent virgin chloroprene
(neoprene), meeting the requirements described below, as shown on the Drawings.
Elastomeric bearing shall be laminated layer type units comprising alternative layer

thickness as shown on the Drawings or encapsulated type such that all perimeter
edges of metal plate layers are protected by a covering of elastomer.
3) Compound of nominal hardness between values shall be used and test requirements
interpolated.
4) When test specimens are cut from finished product a 10 percent variation in "Physical
Properties" will be allowed.
(b) Laminate
Laminates shall be rolled mild steel sheets conforming to AASHTO M183 (ASTM A36),
Grade C or D (JIS code) unless otherwise specified by the Engineer.
(c) Dowel Bars

Dowel Bars shall be of SS400 grade steel, straight with clean cut ends and of diameters
and lengths shown on the Drawings and be galvanized.
Chloroprene
Testing Method Physical Properties Standard Value
of JIS Standard
JIS K 6254 Static shear modulus 0.78+ 0.1 N/mm2
(8+ 1.0 kgf /cm2)
JIS K 6253 Hardness 50 + 5
JIS K 6251 Ultimate elongation, Min. 400%
JIS K 6258 Fuel resistant, Max. (Volume change ratio) +120%
JIS K 6257 Accelerated aging 25% elasticity stress ratio -10% ~ +100%
Elongation ratio, Min. -50%
JIS K 6262 Compression set, Max. 35%
JIS K 6259 Ozone resistance No Cracks

JIS K 6256 Bond made during vulcanization, Min. 7(N/mm)
7(kgf/cm)
(3) Construction
(a) Epoxy Mortar Bearing Plinths

1) Epoxy mortar plinths shall be formed under direction of competent supervisor
experienced in use of material. The work shall be carried out preferably in dry
weather. Air temperature around the joint shall be not less than 100C.
2) Concrete surfaces upon which plinth is to be formed shall be dry, sound and free from
laitance. Before application of priming coat, loose material and dust shall be removed
by an air jet and tested to ensure that no oil is carried over from compressor.
3) A priming coat of unfilled epoxy resin composition shall be well worked in by brush to
all surfaces with which plinth will be permanently in contact at a uniform rate of not
less than 250 g/sq.m. Mortar shall then be applied as quickly as possible while
priming coat is still tacky.
4) Composition and mix proportions of epoxy mortar shall be submitted for prior
approval of the Engineer. Aggregate shall be either silica sand, calcined bauxite or
other approved synthetic or natural aggregate of suitable grading not exceeding one-
fourth of thickness of joint to be grouted. Particle size distribution shall be that which
produces a mortar with adequate workability and minimum void volume. Aggregates
shall be clean and completely dry.
5) Whichever type of aggregate is used, epoxy mortar components shall be thoroughly
mixed in a suitable mechanical mixer. Sequence, duration and temperature of mixing

shall be in accordance with the manufacturer's instructions.

6) Mortar shall be placed in position within time recommended by manufacturer. It shall
be well worked against primed surfaces and trowelled flush to form a dense mortar to
profiles described in the Drawings or special provisions.
(b) Dowel Bars

1) Dowel bars shall be firmly supported in the positions shown on the Drawings so that
they remain accurately parallel and are not displaced during casting of concrete. After
concrete has hardened and after formwork has been removed, the projecting end
shall be cleaned and painted with two coats of bituminous paint. The Contractor shall
take care to protect the projecting ends of dowel bars from bending or other damage.
The quantities to be measured for payment shall be the actual number of lot for rubber
bearing installed in place, completed for concrete bridge and accepted by the Engineer. A lot
shall include all pieces of rubber bearings to be installed for one concrete bridge structure
assembled and erected by various concrete segments. In computing the quantities and the
dimensions of all pieces used for each concrete bridge assembled and erected shall be those
shown on the Drawings or ordered in writing by the Engineer.
compensation for the works prescribed in this Clause, including furnishing bridge bearing, all
materials, labor, tools and equipment, delivery to site and installation of concrete bridge
bearing, including non-shrinkage mortar, anchor bar, anchor cap and incidentals necessary
for the works.
219 Concrete Bridge Bearing lot

2.20 PLATFORM WALL
(1) Description
This work shall consist of construction of concrete platform wall, including base and
foundation, backfilling, embankment, setting precast concrete platform plate and pavement at
location as shown on the Drawings or instructed by the Engineer.
(2) Materials
Platform wall shall be reinforced precast concrete. Concrete for wall shall be Class “D”. Base
and foundation shall be of concrete Class “E”. Filling concrete inside wall shall be Class “ E”.
All concrete shall meet the requirement of Clause 2.14 “CONCRETE WORKS” of this
Specification.
Reinforcing bar shall comply with Clause 2.15 “REINFORCING BAR” and shall be positioned
as shown on the Drawings. Concrete used for precast concrete platform plate shall be Class
“A”. Reinforcing bar used for precast concrete platform plate shall comply with Clause 2.15
“REINFORCING BARS” and shall be positioned as shown on the Drawings. Ceramic tiles
shall be 100mm X 200mm. Mortar used for bedding and joining shall be 1 cement: 3 sand
conforming with the requirements of Clause 2.14 “CONCRETE WORKS”.
Precast concrete platform plate used for edge of platform shall conform to requirements as
shown on the Drawings and surface shall have a ceramic tile embedded parallel to edge of
plate as shown on the Drawings.
(3) Construction
The Contractor shall submit manufacturer’s specification for platform wall and platform plate
to the Engineer for approval. Precast concrete platform plate shall be placed before executing
pavement. Plate shall be installed on concrete slab edge using a stiff mortar as shown on the
Drawings and at 1.6 meters from final track center in straight sections but that distance shall
be changed in curved sections as directed by the Engineer.
The quantity of platform wall to be measured for payment shall be the actual number of linear
meters of constructed wall at condition of constructed concrete platform plate completed in
place, furnished, installing mortar for bed and jointing and accepted by the Engineer and in
accordance with the Drawings.
This work measured, as provided above, will be paid for at the Contract price per unit of
measurement for the pay items listed below. The payment for platform wall shall be full
compensation for construction of platform wall and plate, including concrete, reinforcing bar,
furnishing, fabrication, installation of tile block, including mortar for bed and joints and for all
labor, tools, equipment, hauling and all other incidentals necessary to complete the work as
shown on the Drawings and described in this Specification.
220(1) Platform Wall (hei. 840mm) linear meter

220(2) Platform Wall (hei. 950mm) linear meter

2.21 PEDESTRIAN BRIDGE
(1) Description
This work shall consist of constructing substructure and superstructure of pedestrian bridge at
location indicated on the Drawings or as directed by the Engineer. The work shall include all
required concrete foundations, columns, bridges, stairs, handrails and roofs as well as
aligning, fabricating, erecting and painting of handrail and roof material and everything
necessary to complete the work as described in the Drawings and this Specification.
(2) Materials
Pile for foundation shall be precast concrete pile as specified in Clause 2.10 “PRECAST
CONCRETE PILE” of this Specification. Concrete to be used for foundation, column, bridge
and stair shall be concrete Class “C” and “B” as specified in Clause 2.14 “CONCRETE
WORKS” of this Specification.
Steel plate and angle shall conform to SS 400 as specified in JIS G 3101 (Rolled Steel for
General Structure). Gauge Steel to be used for post shall conform to SSC 400 as specified in
JIS G 3550 (Light Gauge Steel for General Structure). Steel netting shall conform to Z-G# as
specified in JIS G3552 (Chain Link Wire Netting). Bolt and nuts shall conform to the
requirements as specified in JIS B 1180 and JIS 1181 respectively. Steel posts shall be as
shown on the Drawings. Paint shall conform to the requirement as specified in Clause 2.22
“STEEL STRUCTURE WORKS” in this Specification.
(3) Construction
(a) Steel materials shall be carefully handled and stored in a manner so as not to be in
contact with the ground and shall be protected from corrosion. Materials shall be kept free
from dirt, oil, grease and other foreign matter. All nuts and caps on steel materials shall
be spot-welded.
(b) After setting of concrete foundations, holes shall be backfilled with excavated material.
Backfill material shall be thoroughly compacted to same degree of compaction as the
adjacent soil.
(c) Steel not galvanized shall be painted in accordance with the requirements of Clause 2.22
“STEEL STRUCTURE WORKS”
bridge and stair with handrail and roof, completed in accordance with the Drawings and this
Specification and accepted by the Engineer.
(5) Basis for Payment
The quantity determined, as provided above, will be paid for at the Contract unit prices per
unit of measurement for the pay items listed below. The price and payment shall be full
compensation for furnishing all materials, labor and equipment necessary for construction of
concrete bridge, steel bridge, handrail, roof and for other incidentals necessary to complete
the work, including piling, excavation, compaction, backfill, drainage system, cobble stone,
concrete, reinforcing bar, welding, galvanizing and painting in accordance with the Drawings,
this Specification and as directed by the Engineer.
221(1) Pedestrian Bridge Concrete-Type linear meter

221(2) Pedestrian Bridge Steel-Type linear meter

2.22 STEEL STRUCTURE WORKS
(1) Description
This work shall consist of supply, fabrication, delivery to site and installation of structural
steels and other steel members in accordance with this Specification and Drawings or as
instructed by the Engineer. All workmanship shall be of the highest standard and where
necessary this Specification shall be supplemented by the relevant clauses from appropriate
Indonesian Standards for Steel Structure (PPBBI).
(2) Material
Structural steel members shall comprise "H" and "I" shaped steel plate, "L" shaped steel and
channel steel, all of which shall conform to the requirements of this Specification or equivalent
as shown on the Drawings. High strength friction type bolts shall be used for all bolted
connections and they shall conform with the requirements of JIS B 1186. Prior to use of any
materials, the Contractor shall submit the technical data from the manufacturers for approval
of the Engineer.
(3) Erection
Prior to starting any fabrication work the Contractor shall submit for approval the Shop
Drawings and material take-off sheets. Drawings should show full details of all proposed joints
and include clear instructions for fixing of anchor bolt locations. Splices and field connections
shall only be made as shown on the approved Drawings. Welded and riveted connections
shall be by high tension bolts. Fasteners shall be installed as directed by the Engineer.
(a) Anchor Bolts and Anchors

They shall be properly located and built into connection work. Bolts and anchors shall be
presented by use of templates or such other methods as may be required to locate
anchors and anchor bolts accurately.
(b) Column Bases and Bearing Plates

They shall be provided under columns, beams, girders and trusses resting on walls or
footings. Base and bearing plates shall be attached as approved on Shop Drawings.
Base plates and bearing plates shall be supported and aligned on steel wedges or shims.
After supported members have been plumbed and properly positioned and anchor nuts
tightened, entire bearing area under plate shall be dry-packed solidly with bedding mortar.
Wedges and shims shall be cut off flush with edge of column base and bearing plate and
shall be left in place.
(c) Welding
All procedures of welding works shall conform to the requirements as prescribed in AWS,
DI.1-81 (Structural Welding Code). The Contractor shall prepare a detailed programme
for quality control of welds in consultation with the Engineer. This programme shall fulfill
the requirements of the above Code and the Contractor shall not deviate from the
programme without approval of the Engineer. Butt welds shall be terminated at the ends
of a joint in a manner that will ensure their soundness. Where possible, this should be
done by use of extension bars or run-off plates. Extension bars or run-off plates, if used,
shall be removed upon completion of the weld and the ends of weld made smooth and
flush with the abutting parts. Where required, multiple-layer welds may be peened with
light blows from a power hammer, using a roundnose tool. Peening shall be done after
weld has cooled to a temperature warm to the hand. Care shall be exercised to prevent
scaling or flaking of weld and base metal from over-peening.
(d) Bolting
Bolts shall be driven accurately into holes without damaging thread. Bolt heads shall be
protected from damage during driving. Bolts heads and nuts shall rest squarely against
metal. Where selflocking nuts are not furnished, bolt threads shall be set to prevent nuts
from backing off.

(e) Unfinished Bolts Transmitting Shear

It shall be treated to such a length that not more than one thread will be within grip of
metal. Bolts shall be of length that will extend entirely.
(4) Field Assembly
After assembly, various forming parts of a completed frame or structure shall be aligned and
adjusted accurately before being fastened. Bearing surfaces and surfaces that will be in
permanent contact shall be cleaned before members are assembled. As erection progresses,
the work shall be accurately fastened to take care of all dead load, wind, and erection
stresses. Splices will be permitted only where indicated. Poor matching of holes shall be
corrected by drilling to the next larger size. Welding for redrilling will not be permitted.
(a) Driftpins
Driftpins may be used only to bring together several parts and shall not be used in such
manner as to distort or damage the metal.
(b) Gas Cutting

Use of a gas-cutting torch in field for correction of fabrication errors will not be permitted
on any major member in structural framing. Use of gas-cutting torch will be permitted only
on minor members, when member is not under stress and then only after written approval
of the Engineer has been obtained.
(5) Painting
All work on painting shall be done only under direct control of qualified supervisors and in
accordance with manufacturers recommendations. Only the highest standard of painting
workmanship will be accepted by the Engineer. Structural steel to be encased in concrete
shall be power brushed clean immediately before pouring concrete. All other steel shall be
painted and surfaces shall be clean and dry when paint is applied. Except as otherwise
specified, structural steel shall be power brushed and given a shop coat of zinc phosphate
primer, immediately after completion of any cutting, drilling or welding. Steel that is subject to
mill and shop inspection shall not be painted until after such inspection has been made or
waived. Welded areas shall be subject to special treatment before painting and contact
surfaces in bolted joints will require special cleaning but no painting. Immediately after
erection, all damaged areas of structural steel work shall be repaired and entire structure
given a second coat of primer. After second primer has been applied, all structural steel
members shall be painted with two coats of chlorinated rubber paint approved by the
Engineer. Any damage to or disfiguration of paintwork up to the time of Provisional Hand-over
will be repaired by the Contractor at his own expense.
The quantity to be measured for payment shall be the actual number of kilograms of structural
steel members installed, completed in place and accepted by the Engineer. Bolts and rivets
will be weighed and included in the quantity for payment but no allowance or payment will be
made for welds. The work shall include painting and other incidentals and no separate
measurement thereof shall be made.
of measurement for the pay item listed below. This price and payment shall be full
compensation for all costs necessary or usual for the proper completion of the work
prescribed in this Clause. Structural steel works required for electrical, signalling and
telecommunication etc. work shall not be included in this Pay Item.

222 Steel Structure Works kilogram

2.23 RAIL FIXING
(1) Description
This work shall consist of construction and installation of rail fixings Types A and B, including
lighting fixture work as shown on the Drawings at the following locations in Cipinang Depot.
Type A in "Locomotive Monthly and Daily Inspection Pits"

Type B in "Locomotive and Coach Daily Inspection Pits"
(2) Materials and Construction
Rails shall be Type R54 conforming to Clause 4.01 "RAIL R54" of this Specification. Steel
beams, anchor bolts and other steel members shall conform to Clause 2.22 "STEEL
STRUCTURE WORKS" of this Specification. All construction and installation shall be in
accordance with the Drawings and instructed by the Engineer. Material of lighting fixtures
shall be in conformity with Clause 3.41 "LIGHTING FIXTURES".
The quantity to be measured for payment shall be the actual number of linear meter of rail
fixing measured one time along the center line of the track completed and accepted in
accordance with the Drawings and this Specification and as directed by the Engineer for each
type of rail fixing mentioned above, excluding the actual R54 rails which are to be measured
and paid for by Clause 4.01 "RAIL R54" of this Specification. Type A and B, lighting fixture
work inclusive of cable, power supply and other necessary accessories to complete the work
shall be included in the respective pay items herewith.
of measurement for the pay items listed below This price and payment shall be full
compensation for all costs necessary for the proper completion of the work prescribed in this
Clause, including lighting fixture work. Actual R54 rails are not included in these pay items but
shall be paid for under Pay Item 4.01 “RAIL R54”.
223 (1) Rail Fixing Type A linear meter

223 (2) Rail Fixing Type B linear meter

2.24 STEEL BRIDGE SUPERSTRUCTURE FABRICATION
(1) Description
This work shall consist of furnishing materials, equipment and plant and constructing steel
structures and steel structure portions of composite structures for bridge construction and
temporary structures in accordance with this Specification and the lines, levels, grades,
dimensions and designs shown on the Drawings and as required by the Engineer. The
Contractor shall be responsible for all errors of detailing, fabrications and for correct fitting of
structural members.
Design and drawings provided by the Employer are for reference only and the Contractor
shall be completely responsible for preparation of detailed structural analysis, calculation of
substructures and superstructures, Shop Drawings and additional Detailed Drawings of
substructures and superstructures and shall be required to submit all calculation results and
Drawings to the Engineer for approval.
The work shall include, but is not limited to, all fabrication drawings, furnishing all equipment,
tools, labor, and materials in connection with fabricating, hauling, welding, galvanizing and
shop painting of structural metals for incorporation in railway bridges. Structural metals shall
include structural steel, bolts, welding, special and alloy steels, steel forgings and castings,
and iron castings. This work shall also include any incidental metal construction not otherwise
provided for all in accordance with this Specification and the Drawings.
(2) Materials
Materials for steel bridge superstructure shall conform to the requirements of the following
codes and standards or equivalent.
(a) Structural Steel

1) Japanese Industrial Standards (JIS)
JIS B 1180 Bolts
JIS B 1181 Nuts
JIS B 1186 Sets of High Strength Hexagon Bolt, Hexagon Nut and Plain Washer
for Friction Grip Joints.
JIS G 3101 Rolled steel for general structures
JIS G 3106 Rolled steel for welded structures
JIS G 3114 Hot-rolled Atmospheric Corrosion Resisting Steel for Welded
Structure.
JIS G 3191 Dimension, weights
JIS G 3192 Dimensions, Mass and Permissible Variations or Hot Rolled Steel
Sections.
JIS G 3193 Dimensions, Mass and Permissible Variations of Hot Rolled Steel
Plates, Sheets and Strip.
JIS G 3194 Shape, Dimension Weight and Tolerance for Hot Rolled Flat Steel.
JIS G 3444 Carbon steel tubes for general structural purposes
JIS G 3452 Carbon steel pipe for ordinary piping
JIS G 3466 Carbon steel square pipes for structures
JIS G 4303 Hot rolled stainless steel plate sheet strips
JIS G 4305 Cold rolled stainless steel plate sheet strips
JIS G 5101 Carbon steel casting
JIS G 5102 Steel castings for welded structure
JIS G 5111 High tensile strength carbon steel casting and low alloy steel casting
for structural purpose
JIS G 5501 Grey Iron Castings
JIS H 3100 Copper/alloy sheets, plates, strip and coiled sheets
JIS K 1105 Argon gas
JIS K 1106 Liquid carbonic acid
JIS Z 3211 Covered Electrodes for mild steel
JIS Z 3212 Ditto for high tensile strength steel

JIS Z 3213 Ditto for low alloy high strength tensile steel
JIS Z 3311 Wires for submerged arc strength
JIS Z 3312 Wires for CO2 gas shielded arc welding
JIS Z 3801 Non-destructive testing of welds
2) American Society for Testing and Materials (ASTM)

A 6-85 General Requirements for Rolled Steel, Plates, Shapes, Sheet Piling,
and Bars for Structural USE.
A 36-84a Structural Steel
3) American Institute of Steel Construction (AISC)

Code of Standard Practice for Building and Bridges.
Specification for Design, Fabrication and Erection of Structural Steel for Buildings.
The Contractor shall provide materials required for structural steel in accordance with
this section and as shown on the Drawings.
4) Standard Strength of Structural Steel

JIS G 3106, JIS G 3101 and JIS G 3106 as required
5) Security Fastening Bolts

All bolts shall conform to the following with respect to providing a security fastening
device or other equal or approved by the Engineer. All fasteners and bolts
throughout this Specification defined as “high strength bolts” shall be in accordance
with the requirements herein.
- Fastener shall be high tensile carbon steel with mechanical and chemical
properties which meet or exceed the relevant JIS specifications.
- Fastener shall have a manufactured round head similar to a rivet, smooth shank,
annular locking grooves, (not helical), a pintail, a breakneck and a smooth bore
locking collar in free state.
- When installation is completed, pintail shall be separated from fastener by
“tension” only
- Once installed, smooth bore locking collar shall prevent fastener from being
removed by conventional tools.
- After installation, fastener shall require visual inspection only, to determine if it is
installed correctly and that it meets the specifications of manufacturer and
relevant standards.
-
6) High Strength Bolts
Bolts shall comply with JIS B 1186.
(b) Paint
1) Japan Industrial Standards (JIS)
JIS K0050 General Rules for Chemical Analysis
JIS K2381 Recommended Practice for Weathering Test
JIS K 5400 Test Method for Paints
JIS K 5407 Test Method for Paint Components
JIS K5410 Panels for Testing of Paints
JIS K 5551 Epoxy Resin Paint
JIS K 5552 Zinc Rich Primer.
JIS K 5553 High Build type Zinc Rich Paint
JIS K 5657 Polyurethane Resin Paint for Steel Structures
JIS K 2381 Recommended Practice for Weathering Test.
2) Japan Railway Technical Research (RTRI)

Manual of Painting Design and Application for Steel Structures, 2005
(c) Welding
1) Japanese Industrial Standards (JIS)
JIS Z 3211 Cover Electrodes for mild steel
JIS Z 3212 Ditto for high tensile strength steel

JIS Z 3213 Ditto for low alloy high strength tensile steel
JIS Z 3311 Wires for submerged arc strength
JIS Z 3312 Wires for CO2 gas shielded arc welding
JIS K 1106 Liquid carbonic acid
JIS K 1105 Argon gas
JIS Z 3801 Non-destructive testing of welds
2) American Welding Society (AWS)

AWS D1.1 (1998) Structural Welding Code – Steel
3) Welding electrodes shall be standard commercial products for Structural Steel.

All welding equipment, electrodes, welding wire, and fluxes shall be capable of
producing satisfactory welds when used by qualified welder or welding operator
performing qualified welding procedures. If, in a special case selection of a proper
electrode is critical to the design, the Engineer may specify electrode to be used in
this or other sections. In special cases, it may also be necessary to specify the
welding process.
(3) Quality Assurance
(a) JIS Specifications and AISC requirements for design, fabrication and erection of structural
steel for bridges shall govern the work.
(b) The Contractor shall define and make available for approval of control methods and
functions to qualify in accordance with AWS D1.1 and maintain permanent records of all
pertinent information of all component parts, such as material specifications, mill test
reports, welding procedures, welder’s and tacker’s identification and qualifications, types
of inspections, inspector’s test results and records of all visual and non-destructive
testing.
(4) Tolerances
(a) Tolerances for Dimensions of Bridge Members

Item Tolerance Remarks
1 Span ± (5 + 0.15 L) In case of a cantilever
L = span length in meters bridge, span of a
whole set is taken.
2 Distance between centers of main girders ± (3 + 0.5 B)
or main trusses B = distance between centers of main
girders or main trusses in meters
3 Difference between centers of main 2 + 2B
girders or main trusses B = distance between centers of main
girders or main trusses in meters
4 Height of main girder or main trusses + (4 + 0.5 H)
H = height of main girders or main
trusses in meters
5 Inclination of main girders or main δ=3+H
trusses H = height of main girders or main
trusses in meters
6 Difference of elevation of supports 5 mm
7 Camber at Plus δ 3 + 0.15 L
Absolute value δ =
span center Maximum: 20 mm
{ (measured camber)
in shop L = span length in meters
– (specified camber) },
Minus δ 3 + 0.05 L
where no dead load is
Maximum : 6 mm
applied
L = span length in meters
8 Difference of In bridge axial direction 5 mm
elevation of Between right and left Single track 5 mm
truss panel trusses Double track 7 mm
points
9 Horizontal alignment of bridge between Deflection at center - δ = 3 + 0.1 L
support Maximum : 12 mm.
L = span length in meters
10 Horizontal alignment of bridge in Deflection at center of any portion of
intermediate portion 20 m in length δ = 5

11 Difference of Elevation of right and left 1/400 of distance between centers of

elevation of sleeper bearing faces sleeper bearing faces on right and left
sleeper sides
bearing Elevation of upper faces 3
faces of adjacent sleeper
bearers in a through
girder
Distance between upper ±3
face of flange and top
face of sleeper bearer in a
through girder
12 Width of Amount of lack
flange 1+ W
1000 W = Width of flange in
Amount of excess meters
1.5 W
2+
1000
13 Tolerance for angle between web plate W = Width of flange in
W
and flange in welded I shape structure δ = 2000 meters
14 Deviation from straightness of flange At centers of any portion of 1.5 m in

edge, except for upper flange of length: δ = 2
composite beam
15 Deviation from straightness of main L
members, measured at center of any δ = 1000
portion Maximum : 8 mm
L = Any arbitrary length in meters
16 Deviation from flatness of web plate of H/250 or 2t/3
plate girder Whichever is smaller H = Height of web
t = thickness of web plate plate
17 Deviation Between web plates: W1 W1 / 150 or t, whichever is smaller
from flatness t = thickness of web plate
of flange Between web plates and
W2
plate of box rib or between ribs: W2 δ2 =
girder 150
(b) Tolerances for Shape and Size of Weld Bead

No Item Tolerance Limit
1 Unevenness of bead surface Less than 2 mm in any portion of 25 mm along weld
Line
2 Tolerance for leg length (except for front filled) Between +2 and 0. However, a tolerance between +4
mm and –1 mm is allowed for a total length up to 10%
of weld line.
3 Difference in length between vertical and Less than 2 mm. However, a tolerance of 3 mm max.
horizontal legs of any cross section is allowed for a total length up to 10% of weld line.
4 Tolerance for through thickness at any cross Between +1.5 mm and 0. However, a tolerance
section between +3 mm and –0.7 mm is allowed for a total
length up to 20% of weld line.
5 Depth of undercoat. Main member side Less than 0.3 mm, but a tolerance of 0.5 mm max. is
When finishing is not allowed for a total length up to 20% of weld line.
specified
Secondary member side Less than 0.5 mm, but a tolerance of 0.7 mm max. is
allowed for a total length up to 10% of weld line.
6 Reinforcement unless finishing specified b < 15 -----------h < 3
15 < b < 25 ----h < 4
25 < b -----------h < 4b/25
7 Difference in throat Main member side Less than 2 mm For weld between main member
thickness at position and secondary member, value
of changing rods and for main member is applied if it
at round the corner is in direction of stress of main
weld Secondary member side Less than 3 mm member, while value for
secondary is applied if it is
normal to above.
8 Concavity or convexity of bead at any cross Less than 2 mm.

section

(5) Submittals

The Contractor shall submit the following documents to the Engineer for approval.
Certified copies of mill test reports shall be furnished for structural steel. Certification that
each welder is qualified in accordance with welding requirements.
1) Except as otherwise specified, the Contractor shall submit drawings and data for
each type of steel structure.
a) Dimensional Drawings
At least 80 days prior to fabrication of materials, the Contractor shall submit, for
approval, dimensional drawings showing geometric arrangements and controlling
dimensions, including anchor bolt embedded material dimensions. Approval of
these drawings shall be obtained prior to further detailing of steel structure.
b) Detail Drawings and Data
At least 40 days prior to fabrication of materials, the Contractor shall submit, for
approval, detail drawings and data as described below.
c) Erection Diagrams
Include controlling dimensions, marking and position of each member in structure
and, for each joint, number, size, and length of bolts and number of and thickness
of fills and size, type, location, and any special requirements for all site welds.
Keep member designations to the minimum practicable, for example, designate
members of identical size and detail with the same designation regardless of
position in structure.
d) Shop Drawings
Detail members and connections, anchor bolts and embedded materials. Detail
members in place where practicable, drawings consisting totally of individual
members will not be acceptable. Establish “Y” dimensions prior to submittal of
detail drawings and data. Show the controlling dimensions for each structure and
type and grade of material and type of finish and edge planning and preparation
detail for all shop and site welds.
The Contractor shall prepare and submit to the Engineer fabrication, Shop
Drawings and erection procedures for review and approval. Shop Drawings
require approval of the Engineer before any steel fabrication is begun. Shop
Drawings shall be prepared in accordance with instruction of the Engineer.
The Contractor shall furnish to the Engineer as many prints of drawings as may
be necessary to carry out the work. The Contractor shall be responsible for the
correctness and completeness of the drawings, regardless of any review by the
Engineer. Any work performed or material ordered prior to approval by the
Engineer shall be at sole risk of the Contractor. During preparation of the Shop
Drawings, the Contractor shall check all general dimensions of the steel work and
shall report any discrepancies to the Engineer for revision and correction before
fabrication is begun. No allowance shall be made to the Contractor for material
fabricated to incorrect dimensions. Shop Drawings shall indicate type and grade
of steel used in each of fabricated members. Shop Drawings shall indicate
number, length, grip and location of all shop and site fasteners.
All welding shall be fully detailed. One copy of welding procedures giving
complete details for each type and thickness of joint to be used whether
prequalified or subject to qualification tests, shall be submitted to the Engineer for
approval prior to submitting Shop Drawings. Shop Drawings submitted for final
approval shall indicate the welding procedure to be used for each joint. Welding
symbols shall be those shown in the latest edition of American Welding Society
(AWS) Publication A2.4, “Symbols for Welding and Non-Destructive Testing”.
Special conditions including location joints subject to non-destructive testing and
type of non-destructive testing shall be fully explained by added notes or details.

e) Bill of Materials
Show number of pieces required in structure, description of each piece including
mark number, size, length, and weight, and drawing number for shop detail of
that piece. Summarize weights into a subtotal for structural components, a
subtotal for bolts, nuts, locknuts, and fills and a total weight for structure. Detail
drawings and data may be submitted as they are completed for a particular type
of structure, rather than as a single package covering all structure types. Submit
new or original positive reproducible detail drawings and data.
f) Final Drawings and Data
Within 30 days after shipment of materials, submit final drawings and data
consisting of detail shop drawings, erection diagrams and bills of material. Show
all revisions and changes made up to the time fabrication is completed. Sepia
reproducibles are not acceptable.
g) Test Reports
At least 45 days prior to shipment of materials, submit, for approval and use,
certified mill test reports of chemical analyses and physical tests of structural
steel. Show customer and mill order and weights or quantities of materials
furnished represented by such tests.
2) The Contractor shall submit Method Statements to include, but not limited to:
a) Job management, personnel and organization
b) Fabrication facilities
c) Materials intended for use and material manufacturers and suppliers
d) Evidence of material compliance
- Mill ladle analysis reports for main members
- Fabricators certificate for secondary members
- Reports of tensile properties and bend tests for steel, plates shapes and bars
- Certificates of conformance for structural steel tubing and steel bar grating
- Reports of mechanical tests of high strength bolts
e) Shop drawing procedures and schedules
f) Measuring tapes intended for use
g) Quality control methods and procedures
h) Production fabrication, including marking, cutting, bending, drilling, milling and
treatment of frictional surfaces for high strength bolt connections
i) Shop assembly facilities and procedures
j) Proposed welding details. Proposed manufacturers for flux, gas, welding rods and
wire together with manufactures recommendations for storage.
k) Method of embedding anchor bolts and setting bearings. Installation procedures
and allowable tolerances of anchor-bolt locations.
l) Inspections
- Organization of fabrication shop inspection
- Type of inspection, including full size drawing inspection, material inspection,
material marking, drawing inspection, groove inspection, assembly
inspection, welding inspection, product inspection, radiographic and
ultrasonic inspection of welds and inspection of shop assemblies
- Criteria for acceptance
- A copy of the Contractors inspection record pro-forma
Inspection record form shall be attached.
m) Proposed methods of correction and repair of faulty work
n) Method of paint application
o) Marking component and assemblies
p) Storage at plant yard and site
q) Transporting facilities and route from shop to site
r) Qualifications of welders and other specialist
s) Radiographic and Ultrasonic inspection
- Name of inspection company
- Organization chart
- Inspection equipment
- Calibration of equipment
- Personnel
- Operation methods

- Point and numbers of inspection

- Pre-treatment of inspected surfaces
- Criteria for safe or unsafe judgement
- Inspection records form
3) As the work progresses, the Contractor shall maintain the following records of
structural steel fabrication erection prepared for the following items. They should be
maintained for each individual structure and methods and results of tests and
inspections should be indicated as described below.
a) Material tests
b) Methods of examination of welders skills
c) Test of welding work
d) Coefficient of friction test for high strength bolts
e) Inspection for shop made products (welds, shape, dimensions, appearance, and
others)
f) Records of tests, inspection and corrections required by the Engineer
g) Photograph of each section of the work
All the above completed records shall be submitted to the Engineer.
(b) Painting
The Contractor shall submit the following information of painting to the Engineer for
approval.
1) Product Data
Before ordering paint the Contractor shall submit to the Engineer for approval a full
specification of paints to be used, together with name of manufacturer and one-liter
samples for test panels. All paints forming part of any one painting system shall be
obtained from the same manufacturer and the Contractor shall submit to the Engineer
data sheets for all paint material to be used, together with any identifying codes. No
paint shall be used without prior approval of the Engineer.
2) Finishes
a) Surface finish to all items to be protected shall be submitted to the Engineer for
approval.
b) Surface finish proposed for any surface not specifically mentioned herein shall be
submitted to the Engineer for approval.
c) Galvanized surfaces to be painted shall receive suitable primer before being
coated with normal undercoats.
3) Systems
a) Painting schedule for site-painting work.
b) Manufacturer's specification for each paint coating included in schedule.
c) Manufacturer's detailed thinning and application instructions for each type of paint
d) Manufacturer's specification for all shop-applied surface finishes.
e) Copies of Manufacturer's Certified Test results of specular reflectance value.
(c) Welding
The Contractor shall submit the following information of welding to the Engineer for
approval.
a) Quality control methods and procedures
b) Welding Procedure Qualifications
c) Welders, welding operator, and tacker qualifications
e) Shop assembly facilities and details
f) Proposed welding details
g) Welding procedures
h) Welding supervision and inspection
i) Test results
j) Test criteria
(6) Delivery, Handling and Storage

The Contractor shall be required to treat structure steel as described below.

1) Delivery
Transport all structural steel with care to avoid bending or damage, including damage
to painting.
2) Handling
Handle fabricated steel with care and avoid damage to paint. Use structure materials
bent in handling only if they can be straightened without injury to painting. Replace
pieces bent beyond repair by and at the expense of the Contractor. Repaint material
on which the painting has been damaged unless the damage is local and can be
repaired at site in accordance with the requirements.
3) Storage
Storage of fabricated steel at job site shall be the responsibility of the Contractor.
Store material at job site in manner that does not overload the existing or newly-
constructed structures. Protect materials against excessive deflection, corrosion or
deterioration. When temporary storage is necessary, place steel items on timber
blocking to prevent ground or surface water contact.
(b) Paint
The Contractor shall be required to treat paint as described below.
1) Delivery
Deliver all surface finish materials for site application in original, new and unopened
containers bearing the manufacturer's name and label showing at least the following
information:
a) Name of material
b) Manufacturer's stock number
c) Manufacturer's name
d) Thinning instructions
f) Application instructions
Deliver all factory-finished paint in protective packaging to minimize damage to
finished surfaces.
2) Handling
Paint, which has not been used within its “shelf life”, shall be discarded and replaced.
3) Storage of materials:
Provide proper storage to prevent damage to and deterioration of paint materials and
factory applied finishes. All paints shall be stored in cool dry conditions and used in
the same order in which they are delivered. All paint and thinner should be stored in a
locked separate building or room that is well ventilated and free from excessive heat,
sparks, flame or direct rays of the sun. All containers, which have been opened, shall
be used first. Paint that has livered, gelled, or otherwise deteriorated during storage
shall not be used. Thixotropic materials, which may be stirred to attain normal
consistency, are satisfactory.
4) Protection
Use all means necessary to protect materials and finishes, during and after
installation and to protect the work and materials of all other trades.
5) Replacements
In event of damage to surface finishes prior to issue of the Provisional Acceptance
Certificate, immediately make all repairs and replacements necessary to approval of
the Engineer.
(7) Fabrication
(a) Steel Girders

The Contractor shall be required to fabricate steel girders as described below.
Where the drawing does not cover details of design fabrication or specifications, fabricate
in accordance with the applicable requirements of AISC-02. Edge plane or flame-cut
plates or built-up members with mechanically guided torches and ground smooth.
Provide square and true plates after the above operation. The Contractor may elect to
flame-cut and grind the edges of web plates wherever edge planning is shown or noted
on the Drawings.
1) Master Tape
Whole work shall be of the highest class of workmanship and finish. Greatest

accuracy shall be observed in the design, manufacture and erection of every part of
the work to ensure that all parts will fit accurately together on erection. The Contractor
shall maintain a master steel tape of approved make, which has been duly calibrated
and shall supply a certificate of accuracy to the Engineer. The master tape shall not
be used for any purpose other than checking or calibrating other tapes, and in case of
damage, shall be promptly replaced with another.
2) Inspection
a) The Contractor shall give the Engineer at least fifteen (15) days notice prior to the
beginning of work at mill or shop, so that the required inspection may be made.
Term “mill” means any rolling mill, shop, or foundry where material for the work is
to be manufactured or fabricated. No material shall be rolled or fabricated until
said inspection has been provided. The Contractor shall furnish all facilities for
inspection and the Engineer will be allowed free access to the mill or shop and
premises at all times. The Contractor shall furnish, without charge, all labor,
machinery, material and tools necessary to prepare test specimens. The cost of
this shall be regarded as incidental to the costs of fabrication and included in the
rates.
b) Inspection at the mill or shop is intended as a means of facilitating the work and
avoiding errors and it is expressly understood that it will not relieve the Contractor
from any responsibility for imperfect material or workmanship and necessity for
replacing same. Acceptance of any material or finished member at the mill or
shop by the Engineer shall not preclude their subsequent rejection if found
defective before final acceptance of the work.
c) The Contractor shall furnish the Engineer with copies of certified mill reports of the
structural steel, preferably before but not later than delivery of steel to the job site.
3) Straightening Material
Provide structural materials that are straight and free from sharp kinks and bends and
clean of all rust and dirt. If straightening is necessary, do it by methods that will not
injure the metal.
4) Shearing and Cutting
Perform shearing and cutting accurately and finish all portions of the work that will be
exposed to view after completion neatly. Fillet copes and re-entrant cuts before
cutting.
5) Holes
Holes, other than those shown on the steel structure drawings or approved Shop
Drawings, shall not be permitted. All holes in structural steel less than 20mm thick
may be punched to full size unless otherwise noted on the Drawings. Drill or sub-
punch and ream holes shown on the Drawings as drilled holes and all holes in
structural steel 20mm or more in thickness. Clean cut all holes without torn ragged
edges. Remove all burrs resulting from reaming or drilling with a tool making a 1.5mm
bevel. Provide holes cylindrical and perpendicular to the member.
6) Punching
For punching to full size, use punch with the nominal diameter of hole and use die
with diameter of not more than 1.5mm larger than the diameter of punch. For sub-
punching, use punch with diameter 6mm smaller than the nominal diameter of hole
and use die with diameter of not more than 2.5mm larger than the diameter of punch.
Use sub-punch for reamed work such that after reaming no punched surface will
appear in the periphery of hole.
7) Accuracy of Punching, Reaming and Drilling
Space holes accurately in accordance with the Drawings and locate on the gauge
lines. Do not exceed a maximum allowable variation of 0.5 mm in hole spacing from
that indicated on the Drawings for all boltholes.
8) Welding
Use welding symbols shown on the Drawings that comply with AWS symbols. Use a
shielded arc-welding process. Make all welds as shown on the Drawings, continue
unless otherwise noted and in such a manner that residual shrinkage stresses will be
reduced to a minimum. Make all welds full penetration through the material, unless
otherwise shown on the Drawings. No stress-relieving treatment is required.
a) General
All welding equipment, electrodes, welding wire and fluxes shall be capable of

producing satisfactory welds when used by qualified welder or welding operator

performing qualified welding procedures. All welding shall be performed in a
fabrication shop in accordance with the requirements stipulated herein and in the
Drawings. All welding shall be done by approved competent and experienced
fully qualified welders. Welding operator shall place identification mark with
crayon or paint near the welds made by him.
In assembling and joining parts of a structure or a built-up member and in welding

reinforcing parts to existing members, procedure and sequence of welding shall
be to avoid distortion and minimize shrinkage stresses. Peening to reduce
residual stress of multi layer welds may be used only if authorized and ordered by
the Engineer. Care shall be exercised to prevent over-peening which may cause
overlapping, scaling, flecking or excessive cold working of weld and base metal.
Welds to be galvanized shall be treated to remove every particle of slag. Painting
shall not be done until welding work has been accepted as being in accordance
with this Specification. Surface to be painted shall be cleaned of spatter, rust,
loose scale, oil and dirt. Slag shall be cleaned from all welds.
b) Quality Control
All welders shall have valid and current licences. The Contractor shall provide the
Engineer with certification that all welders, welding operators and tackers have
passed qualification test using procedures covered in codes acceptable to the
Engineer. If required by the Engineer, the Contractor shall submit test pieces
made by any welder, welding operator or tacker whose workmanship is in
question.
On completion of welding works, inspection shall be carried out by an Inspector

appointed by the Engineer. Size and contour of welds shall be measured with
suitable gauge. Inspector shall identify with a distinguishing mark all welds
inspected and accepted as required below.
- On-Destructive Testing of Welds
Inspect and test all welds in accordance with this Specification
- Complete inspections and tests as the work progresses, in presence of
Inspector and in accordance with AWS D1.1
When any welds are found to be defective by AWS Standards, repair the
welds in accordance with Standard and re-examine the welds to ensure
adequacy of repair
- Visual Inspection
In addition to the testing required below, visually inspect all welds following
the procedures, technique and Standards of AWS D1.1
- Ultrasonic and Radiographic Testing
Perform ultrasonic or radiographic testing of the entire length of all complete
penetration shop and field welds
- Magnetic Particle and Dye Penetrant
Perform magnetic particle or dye penetrant testing on all partial penetration
joint welds and all fillet welds. Use technique and procedure for magnetic
particle testing in accordance with AWS. Use technique and procedures for
dye penetrant testing in accordance with AWS. Use standards of acceptance
for both types of testing in accordance with AWS D1.1
c) Defective Welds
The Contractor shall require any welder, welding operator or tacker to retake the
test when, in opinion of the Engineer, there is reasonable doubt as to proficiency
of such a workman. Tests, when required, shall be conducted at no additional
expense to the Employer and reinstatement of an offending welder, welding
operator or tacker shall only be acceptable on the successful outcome of retest.
When inspection or testing indicates defects in the weld joints, they shall be
repaired using a qualified welder or welding operator as applicable. Corrections
shall be in accordance with the requirement of AWS D1.1 and the specifications.
- Defects shall be repaired in accordance with procedures which have approval
of the Engineer.

Defects discovered between passes shall be repaired before additional weld

-
material is deposited. Wherever a defect is removed and repair by welding is
not required, affected area shall be blended into surrounding surface to
eliminate sharp notches, crevices or corners.
- The Contractor shall remove and replace or correct as instructed, all welds
found defective or deficient. The Contractor shall also replace all methods
found to produce inferior results, with methods which will produce satisfactory
work.
- In event that faulty welding or removal for rewelding of faulty welding shall
damage the base metal, the Contractor shall remove and replace the
damaged component.
- Sections of weld found to be defective shall be chipped or cut out to base
metal and properly rewelded before proceeding with the work. Should any
two test pieces of any welder show strength less than that of the base metal
then this shall be considered evidence of negligence or incompetence and
the welder, welding operator or tacker shall be removed from the works
forthwith and not reinstated.
- When test pieces are removed from any part of the structure, members cut
shall be repaired, at no additional cost to the Employer, in a neat and
workmanlike manner to satisfaction of the Engineer. Joints shall be cut, as
necessary or required, to relieve residual stress.
d) Repair of Welds
After a defect is thought to have been removed and before rewelding, the area
shall be examined by suitable methods to ensure that defect has been eliminated.
Repair welds shall meet the inspection requirements for original welds. Any
indication of a defect shall be regarded as a defect, unless re-evaluation by non-
destructive methods or by surface conditioning shows that no unacceptable
defect is present
The following defects shall be deemed unacceptable.

Cracks, incomplete functions, slag intrusions, blowholes, overlaps, craters, pits
exceeding 0.3 mm diameter, scratches, notches, unevenness, mis-shapen bolt
holes, etc. The Contractor shall submit method of rectification of the above to the
Engineer for approval. All methods of rectification of welding defects shall be
submitted to and approved by the Engineer.
Notwithstanding the unacceptable defects outlined above, the list should not be
considered exhaustive and the Engineer may, if the works are deemed
unacceptable, identify alternative methods of rectification. The Contractor shall
comply with the requirements of the Engineer and undertake such steps as are
necessary at no extra cost.
Correction of distortion caused by welding shall be required as described below.
- Distortion caused by welding shall be corrected by mechanical processes or
heating processes, provided that characteristics of both weld and base metal
shall not be impaired.
- In case of correction by heating, the preferable upper limit of heating
temperature shall be 850°C.
- In case of correction by heating is prescribed, water cooling shall not be
carried out until temperature comes down to 650°C for rolled steel for welded
structures
9) Measurements
Make measurements with a steel tape or rule. Make measurements when steel
members and steel tape or rule are within 5.556 °C of the ambient temperature.
10) Marking
Mark anchor bolts, embedded material, stub angles and tees with the designation
shown on the Drawings. Mark all other individual pieces with the designation shown
on the approved erection diagrams. Stamp markings prior to galvanizing or painting.
Use numerals or letters 12mm-minimum height, clearly legible after galvanizing or
painting and circled or bracketed with black paint. Anchor bolts may be identified by
tagging.

11) Base Plates

Provide base plates that are straight and true and square cut. Grind edges cut by
torch straight and smooth.
12) Finish
Where the type of finish is not specified, use the type of finish most suitable for the
part to which it applies and average or rough as defined herein. Where an average
finish is required, produce smooth surfaces but slight toolmarks will be allowed.
Where a rough finish is required, rough machining sufficient only to produce a plane
surface true to dimensions will be allowed. Provide an average finish for surface in
permanent contact where a tight joint and rough finish for all other machine surfaces.
Where the finish is called for on the Drawings, finish members true to line and free
from twists, bends and open joints in accordance with the noted degree of finish.
13) Compression Joints
Face the surfaces of compression joints depending on contact bearings so as to have
full contact bearing when aligned and welded.
(b) Composite Girders

The Contractor shall prepare design calculation and drawings of suspended formworks to
be used for concreting of composite girder and shall submit to the Engineer for approval
prior to commencement of the work. Girder length more than 15m shall equip cross
beams. Compute required amount of camber of composite girder and shall be shown on
the Drawings for approval of the Engineer.
(8) Painting
Painting shall comply with “Manual of Painting Design and Application for Steel Structure,
2005” of RTRI, Japan.
(a) Protection of Areas not to be Painted

Items not to be painted which are in contact with or adjacent to painted surfaces shall be
removed or protected prior to surface preparation and painting operations. Items
removed prior to painting shall be replaced when painting is completed.
(b) Surface Preparation

Steel plate shall be processed by blasting of rolled sheet and steel plate coated by
inorganic zinc-rich primer shall be used.
After temporary assembly, inorganic zinc-rich primer, rust and other substances injurious
for coating shall be removed by blasting after make up just before coating from the
surface of steel plate and surface preparation (Preparation grade-1) shall be made until
basic material of steel fully comes out.
Blasting work shall be done indoors and shall not be made when relative humidity is 80%
or more. 1st coating shall be made within 3 hours after completion of blasting. During that
time, steel plate shall not be exposed to rain and dew.
(c) Painting for Touching Surface

Touching surface of friction joints shall be coated by high build type inorganic zinc-rich
paint. On other hand, only blasting shall be made to touching surface of high-strength bolt
joints which are tightened at shop.
(d) Painting Schedule

Coating system shown below shall be applied according to type of bridge and part to be
painted, including name of paint, standard coverage and coating interval for each coating
system.
Coating work shall not be done when temperature and humidity exceed the limit value
presented below.

Shop painting shall be made by airless spray and prior coating shall be made by paint
brush. Field painting shall use paint roller and paint brush at the same time or paint brush
only.
When paint film is damaged during transportation and erection, it shall be repaired in
accordance with “Repair Painting” of the Manual of RTRI, Japan.
Coating System Application

Type of bridge Part to be Painted Shop Painting Field Painting
Outside surface of piece J-2
Outside surface of splice plate J-3
Inside surface of box section (hand hall) LN-2 L-3
Truss High build type
Touching surface of friction joints inorganic zinc-rich
paint
Touching surface of sleeper receiver S-2
Outside surface of piece J-2
Outside surface of splice plate J-3
Inside surface of box section LN-2 WW-3
High build type
Plate Girder
Touching surface of friction joints inorganic zinc-rich
paint
End girder where recoating is difficult R-2
Touching surface of sleeper receiver S-2
Outside surface of lower flange L-2
Concrete Girder with High build type
Touching surface of friction joints outside
Steel Beam Encased inorganic L-3
surface of splice plate
zinc-rich paint
J-2 Coating System (1)

Standard Coating Coating
Process Name of Paint Coverage Thickness Interval
2
(g/m ) (μ) (20℃)
After temporary assembly remove inorganic zinc-rich primer, rust and
Surface
other substances injurious for coating by blasting after make up Within day
Preparation
(Preparation grade-1) of blasting
st High build type epoxy resin zinc-rich
1 Spray 700 75
paint
2 days ～ 3
nd Mist coat（50％ dilution for 3
rd months
2 Spray 150
painting）
16hours ～2
rd Under coat of high build type epoxy days
Shop 3 Spray 300 60
resin based paint
Painting 24 hours
th Under coat of high build type epoxy ～15 days
4 Spray 300 60
resin based paint 24hours
th Intermediate coat of polyurethane ～15days
5 Spray 160 30
resin paint 24hours
th
～15 days
6 Top coat of polyurethane resin paint Spray 140 30
Note: (1) When under coat of high build type epoxy resin paint and intermediate coat of
polyurethane resin paint are used under temperature of 10 degree or lower, those for low
temperature shall be used.

L-2 Coating System (2)

2
(g/m ) (μ) (20℃)
Surface
other substances injurious for coating by blasting after make up Within day
Preparation
(Preparation grade-1) of blasting
st
1 Inorganic zinc-rich primer Spray 200 20
2 days～1
High build type modified months
nd
2 Spray 300 90
Shop epoxy resin paint 24hours～7
Painting days
rd High build type modified
3 Spray 300 90
epoxy resin paint 24hours～7
th Finish coat of high build type days
4 Spray 300 90
modified epoxy resin paint
Note: (1) When high build type modified epoxy resin paint are used under temperature of 10 degree
or lower, those for low temperature shall be used.
LN-2 Coating System (3)

2
(g/m ) (μ) (200C)
After temporary assembly, rust shall be removed from rusted part by
Surface
partial blasting and white rust and other materials shall be fully
Preparation
removed from other part, then 1st coating shall be made on same day. Within day
of blasting
st High build type modified epoxy
1 Spray 300 90
resin paint
24hours ～
Shop 7days
Painting nd High build type modified epoxy resin
2 Spray 300 90
Paint
24hours ～7
rd Finish coat of high build type modified days
3 Spray 300 90
epoxy resin paint
Notes:(1) Steel plate(shop steel plate) coated by inorganic zinc-rich primer is used due to fabrication
process. White rust is sometimes seen on surface. In this case white rust shall be fully
removed.
(2) When high build type modified epoxy resin paint is used under temperature of 10 degree or
lower, that for low temperature shall be used.
Painting of Touching Surface of Friction Joints (1)

2
(g/m ) (μ) (200C)
Surface
other substances injurious for coating by blasting after make up
Preparation
(Preparation grade-1) Within day
Shop High build type inorganic zinc-rich 75 of blasting
st
1 Spray 700
Painting paint (60～90)
Note: (1) Coating material shall be used, the sliding coefficient of which has been confirmed to be
0.4 or more by sliding test.

R-2 Painting of Touching Surface of Friction Joints (2)

2
(g/m ) (μ) (200C)
Surface
Preparation
of blasting
st
1 Dedicated primer Note 1
Note 1
Shop
Painting nd Super high build type epoxy resin
2 Spray 1200 300
paint
24hours～1
rd 5 days
3 Top coat of polyurethane resin paint Spray 140 25
Note: (1) Dedicated primer shall be coating material, standard coverage and coating interval that
coating manufacturing company recommends.
S-2 Painting of Touching Surface of Friction Joints (3)

2
(g/m ) (μ) (200C)

Surface
Preparation
of blasting
st
1 Dedicated primer Note 1
Note 1
Shop
nd
Painting 2 Glass flake paint Spray 1200 500
24 hours～
rd
7 days
3 Glass flake paint Spray 1200 500
Note: (1) Dedicated primer shall comply with specification of manufacturing company of glass flake
paint.

J-3 Painting of Touching Surface of Friction Joints (4)

2
(g/m ) (μ) (200C)
Surface
Shop st of High build type inorganic
1 Spray 700 75
Painting splice zinc-rich paint
plate
Surface On part of splice plate where red rust is seen, surface
of preparation (Preparation grade 3) shall be made by using Within
splice manual or power tools and then 2nd painting shall be made 12 month
Surface plate on same day.
Prepar-
On part of bolt, nut and flat washer where flaw has occurred
ation
Bolt, Nut by tightening and rust is seen, rust shall be fully removed
Washer and then 2nd painting shall be made on same day.
Within day
of blasting
Undercoat of high build
nd Paint brush
2 type epoxy resin based 60
Field 240
paint 24hours
Painting
Undercoat of high build ～15 days
rd Paint brush
240 24hours
paint
Undercoat of high build ～15 days
th Paint brush
240 24hours
paint
～15 days
th Intermediate coat of Paint brush
5 30
polyurethane resin paint 130 24hours
th Top coat of polyurethane Paint brush ～15 days
6 25
resin paint 110
Notes: (1) When undercoat of high build type epoxy resin paint and intermediate coat of polyurethane
resin paint are used under temperature of 10 degree or lower, those for low temperature
shall be used.
(2) When same coating is recoated, color shall be changed to a certain degree.

L-3 Painting of Touching Surface of Friction Joints (5)

2
(g/m ) (μ) (200C)
Surface
Shop st of High build type inorganic
1 Spray 700 75
Painting splice zinc-rich paint
plate
Surface On part of splice plate where red rust is seen, surface

of preparation (Preparation grade 3) shall be made by using Within
splice manual or power tools and then 2nd painting shall be made 12 month
Surface plate on same day.
Prepar
-ation
On part of bolt, nut and flat washer where flaw has occurred
Bolt, Nut
by tightening and rust is seen, rust shall be fully removed
Washer
and then 2nd painting shall be made on same day.
Within day
Field of blasting
Painting nd High build type modified Paint brush
2 60
epoxy resin paint 200
24hours
～7days
rd High build type modified Paint brush
3 60
epoxy resin paint 200 24hours
th High build type modified Paint brush ～7days
4 60
epoxy resin paint 200 24hours
Finish coat of high build ～7days
th Paint brush
5 type modified epoxy 60
200
resin paint
Notes: (1) When high build type modified epoxy resin paint are used under temperature of 10
degree or lower, those for low temperature shall be used.
(2) When same coating is recoated, color shall be changed to a certain degree.
WW-3 Painting of Touching Surface of Friction Joints (6)

2
(g/m ) (μ) (200C)
Surface of High build type
Shop st
1 splice inorganic Spray 700 75
Painting
plate zinc-rich paint
On part of splice plate where red rust is seen, surface

Surface of
preparation (Preparation grade 3) shall be made by
splice
using manual or power tools and then 2nd painting shall Within
plate
Surface be made on same day. 12 month
Prepar
-ation
On part of bolt, nut and flat washer where flaw has
Field Bolt, Nut occurred by tightening and rust is seen, rust shall be fully
Painting Washer removed and then 2nd painting shall be made on same
day.
Within day
Non-solvent type of blasting
nd Paint brush
2 modified 120
300 2days～7d
epoxy resin paint
Non-solvent type ays
rd Paint brush
3 modified 120
300
epoxy resin paint

Limit of Temperature and Humidity at Time of Coating

0
Name of Paint Temperature( C) Humidity（％）
Inorganic zinc-rich primer 2 or less 50 or less
High build type inorganic zinc-rich paint 2 or less 50 or less
High build type epoxy resin zinc-rich paint 5 or less 85 or more
Undercoat of high build type epoxy resin based paint 10 or less 85 or more
Undercoat of high build type epoxy resin based paint for low 2 or less or 20 or
85 or more
temperature more
Intermediate coat of polyurethane resin paint 10 or less 85 or more
Intermediate coat of polyurethane resin paint for low 2 or less or 20 or
85 or more
temperature more
Top coat of polyurethane resin paint 2 or less 85 or more
High build type modified epoxy resin paint and finish coat 10 or less 85 or more
High build type modified epoxy resin paint for low 2 or less or 20 or
85 or more
temperature and finish coat more
10 or less or 30 or
Non-solvent type modified epoxy resin paint 85 or more
more
Super high build type epoxy resin paint 5 or less 85 or more
Dedicated primer of glass flake paint 5 or less 85 or more
Glass flake paint (epoxy resin paint) 5 or less 85 or more
Glass flake resin paint (polyester or vinylester) 2 or less 85 or more
Note: (1) As dedicated primer uses coating specified by coating manufacturing company, values
instructed by manufacturing company shall be applied.
(e) Inspection and Testing

1) Paints shall be tested in accordance with JIS K 5400 and JIS K 5407
2) Results of paint thickness shall be submitted to the Engineer. Thickness shall be
measured using electro-magnet thickness meter and points to be measured shall be
1 point per 10 m2 and points shall be selected to substitute overall positions of
structural types and shapes.
(9) Shop Assembly
(a) Fitting for Bolting

1) Surfaces of metal in contact shall be cleaned before assembling. Parts of a member
shall be assembled, well pinned and firmly drawn together with bolts before reaming
is commenced. Assembled pieces shall be taken apart, if necessary, for removal or
burrs and shavings produced by the reaming operation. Member shall be free from
twists, bends, and other deformation.
2) End connection angles and similar parts shall be carefully adjusted to correct
positions and bolted, clamped, or otherwise firmly in place until final connection is
made.
3) Parts not completely bolted in shop shall be properly secured to prevent damage in
shipment and handling.
(b) Shop Assembling

1) Site connection of main members of trusses, arches, continuous beam spans, bents,
towers (each face), plate girders and rigid frames shall be assembled in shop with
milled ends of compression members in full bearing and then shall have their sub-
size holes reamed to specified size while connections are assembled. Assembly
shall be “Full Truss or Girder Assembly” unless “Progressive Truss or Girder
Assembly”, “Full Chord Assembly”, “Progressive Chord Assembly” or “Special
Complete Structure Assembly” is specified on the Drawings.
2) Check assemblies with Numerically Controlled Drilled Site Connections shall be in
accordance with the provisions below.
3) Each assembly, including camber, alignment, accuracy of holes and fit of milled
joints, shall be approved by the Engineer before reaming is commenced or before an
N/C drilled check assembly is dismantled.
4) A camber diagram shall be furnished to the Engineer by the Contractor showing the
camber at each panel point in cases of trusses or arch ribs and at the location of site
splices and fractions of span length (1/4 points minimum, 1/10 points maximum) in

case of continuous beam and girders or rigid frames. When shop assembly is “Full
Truss”, “Girder Assembly” or “Special Complete Structure Assembly”, camber
diagram shall show camber measured in assembly. When any of other methods of
shop assembly is used, camber diagram shall show calculated camber.
(c) Method of Assembly shall be as described below.

1) Full, Truss or Girders Assembly shall consist of assembling initially for each truss,
arch rib, bent, tower face, continuous beam line, plate girder, or rigid frame at one
time.
2) Progressive Truss or Girder Assembly shall consist of assembling initially for each
truss, continuous beam line, plate girder, or rigid frame all members in at least three
continuous shop sections or panels but not less than number of panels associated
with three contiguous chord lengths (i.e., length between site splices). At least one
shop section or panel or as many panels as are associated with a chord length shall
be added at the advancing end of assembly before any member is removed from the
rearward end so that assembled portion of structure is never less than that specified
above.
3) Full Chord Assembly shall consist of assembling with geometric angles at the joints,
full length of each chord or each truss or open spandrel arch, or each leg of each
bent or tower, then reaming their site connection holes while members are assembled
and reaming the web member connection to steel templates set at geometric (not
cambered) angular relation to the chord lines. Site connection holes in web member
shall be reamed to steel templates. At least one end of each web member shall be
milled or shall be scribed normal to the longitudinal axis of member and templates of
both ends of member shall be accurately located from one of the milled ends or
scribed lines.
4) Progressive Chord Assembly shall consist of assembling contiguous chord members
in the manner specified for Full Chord Assembly and in the number and length
specified for Progressive Truss or Girder Assembly.
5) Check Assemblies with Numerically-Controlled Drilled Site Connections. A check
assembly shall be required for each major structural type unless otherwise
designated on the Drawings and shall consist of at least three contiguous shop
sections or, in a truss, all members in at least three contiguous panels but not less
than number of panels associated with three contiguous chord lengths (i.e., length
between site splices). Check assemblies should be based on the proposed order of
erection, joints in bearings, special complex points and similar considerations. Such
special points could be portals of skewed trusses, etc.
6) Use of either geometric angles (giving theoretically zero secondary stresses under
dead load conditions after erection) or cambered angles (giving theoretically zero
secondary stresses under no-load conditions) should be designated on the Drawings.
7) Check assemblies shall preferably be the first such section of each major structural
type to be fabricated.
8) No match making and no shop assemblies other than check assemblies shall be
required.
9) If check assembly fails in some specific manner to demonstrate that the required
accuracy is being obtained further check assemblies may be required by the
Engineer. Cost of all check assemblies shall be considered incidental to the cost of
assembly and shall be included in the rates.
(10) Assembly Marking
(a) Bridge members to the assembled at site shall have assembly marks painted at a position
easily seen. With respect to members which are prohibited for painting tags or other
suitable means of assembly marking shall be used.
(b) Members heavier than two tonnes per piece shall have their weight and position of center
of gravity indicated with paint at a positions easily seen.
(c) Paint used for assembly marks and position of center of gravity shall not be of such a
character as to cause detrimental effect on the paint to be applied later at site.

The quantities to be measured for payment shall be the actual weight of kilogram of the
fabricated steel bridge superstructure, installed in place and accepted by the Engineer. In
computing the quantities the dimensions used shall be those shown on the Drawings or
ordered in writing by the Engineer but measurement shall not include any steel used for
construction of temporary works. The work shall include painting and other incidentals and no
separate measurement thereof shall be made.
The quantities determined, as provided above, will be paid at the Contract unit price for the
pay item listed below. The price and payment shall be full compensation for the works
prescribed in this Clause, including furnishing all steel bridge materials, labor, tools,
equipment and plant, fabrication, delivery to site and arrangement for installation of steel
bridge superstructure, including incidentals necessary for the works.
224 Steel Bridge Superstructure Fabrication kilogram

2.25 STEEL BRIDGE SUPERSTRUCTURE ERECTION
(1) Description
This work shall consist of furnishing equipment and plant, erecting and constructing steel
structures and the steel structure portions of composite structures for steel bridge
construction and temporary structures in accordance with this Specification and the lines,
levels, grades, dimensions and designs shown on the Drawings and as required by the
Engineer. The Contractor shall be responsible for all errors of detailing, fabrication and correct
fitting of structural members.
The work shall include, but not limited to, all erection drawings, furnishing all equipment, tools,
labor and materials in connection with hauling, erecting and field painting of structural metals
for incorporation in railway steel bridges. This work shall also include any incidental metal
construction not otherwise provided for in accordance with this Specification and the
Drawings.
(2) Tolerances
Tolerances applied for dimensions of steel bridge members erection shall conform to the
requirements in Clause 2.24 “STEEL BRIDGE SUPERSTRUCTURE FABRICATION”.
(3) Submittals
In addition to the general requirements for submission of the Shop Drawings, the Contractor
shall submit the following documents to the Engineer for approval.
(a) Erection Diagrams

Include controlling dimensions, marking and position of each member in structure and, for
each joint, number, size, length of bolts, number and thickness of fills and type, location
and any special requirements for all site welds. Keep members of identical size and
detail with the same designation regardless of position in structure.
(b) Method Statements

1) Job management, personnel and organization
2) Fabrication facilities
3) Materials intended for use and material manufacturers and suppliers
4) Evidence of material compliance
- Fabricators certificate for secondary members
- Certificates of conformance for structural steel tubing and steel bar grating
- Reports of mechanical tests of high strength bolts
5) Shop drawing procedures and schedules
6) Measuring tapes intended for use
7) Quality control methods and procedures
8) Method of embedding anchor bolts and setting bearings. Installation procedures and
allowable tolerances of anchor-bolt locations.
9) Inspections
- A copy of the Contractor’s inspection record pro-forma
Inspection record form shall be attached.
10) Proposed methods of correction and repair of faulty work
11) Method of paint application
12) Marking component and assemblies
13) Storage at site
14) Transporting facilities and route from shop to site
(c) Information
1) Structural Steel Erection
- Plan of erection equipment and all temporary work method
- Detail of any crane foundations, hard standing and removal
- Where necessary, details of safety measures to protect railway whilst in use

- Temporary storage yard and handling methods

- Temporary electrical supply
- Erection sequence
- Erection tolerances and methods for maintenance
- Equipment and procedures for tightening erection bolts and high-strength bolts
- Site welding equipment and methods
2) Setting anchor bolts, bearings and grouting
3) Painting
4) Site inspection
5) Safety measures proposed
(d) As the work progresses, maintain the following records of structural steel erection
prepared for the following items. They should be maintained for each individual structure
and methods and results of tests and inspections should be indicated as described below.
1) Coefficient of friction test for high strength bolts
2) Inspection for shop made products (welds, shape, dimensions, appearance, and
others)
3) Inspection of work performed at site (welds, tightening of high strength bolts, erecting
tolerance, root gaps of site welds and others)
4) Test report of bearing mortar
5) Tolerances of anchor bolts and bearings
6) Records of tests, inspection and corrections required by the Engineer
7) Photograph of each section of the work
All the above completed records shall be submitted to the Engineer.
(4) Delivery, Handling and Storage
(a) Storage
Storage of fabricated steel at job site shall be the responsibility of the Contractor. Store
material at the job site in manner that does not overload the existing or newly-constructed
structures. Protect materials against excessive deflection, corrosion, or deterioration.
When temporary storage is necessary, place steel items on timber blocking to prevent
ground or surface water contact.
(5) Erection
(a) General
The Contractor shall provide the falsework and all tools, machinery and appliances,
including driftpins and fitting-up bolts, necessary for expeditious handling of the work and
shall erect the steelwork, remove the temporary construction and do all work necessary to
complete the structure as required by the Engineer and in accordance with the Drawings
and this Specification.
(b) Handling and Storing Materials

Materials to be stored shall be placed on skids above the ground. They shall be kept
clean and properly drained. Girders and beams shall be placed upright and shored. Long
members, such as columns and chords, shall be supported on skids placed near enough
together to prevent damage from deflection. The Contractor shall be responsible for loss
of any material while in his care, or of any damage caused to it after being received.
(c) Falsework
Falsework shall be properly designed and substantially constructed and maintained for
the loads which will come upon it. The Contractor shall prepare and submit to the
Engineer for approval, working drawings for falsework and working drawings for changes
in any existing structure and for maintaining traffic if necessary.
(d) Method and Equipment

Before starting the work of erection the Contractor shall inform the Engineer fully as to the
method of erection to follow and the amount and character of equipment to use, which

shall be subject to approval of the Engineer. Approval of the Engineer shall not be
considered as relieving the Contractor of the responsibility for safety of the method or
equipment or from carrying out the work in accordance with the Drawings and this
Specification. No work shall be done until such approval of the Engineer has been
obtained.
(e) Straightening Bent Materials

Straightening of plates, angles, other shapes and built-up members, when permitted by
the Engineer, shall be done by methods that will not produce fracture or other damage.
Distorted members shall be straightened by mechanical means or, if approved by the
Engineer, by the carefully planned and supervised application of limited amount of
localized heat, except that heat straightening of special steel members shall be done only
under rigidly controlled procedure, each application subject to approval of the Engineer.
In all other steels, temperature of the heated area shall not exceed 650°C (a dull red) as
controlled by temperature indicating crayons, liquids or bimetal thermometers.
Temperature shall not exceed 510 0C within 1500 mm of weld metal. Parts to be heat-
straightened shall be substantially free of stress and from external forces, except stresses
resulting from mechanical means used in conjunction with the application of heat.
Following straightening of a bend or buckle, surface of metal shall be carefully inspected
for evidence of fracture.
(f) Assembling Steel

Parts shall be accurately assembled as shown on the Shop Drawings and any match
marks shall be followed. Material shall be carefully handled so that no parts are bent,
broken, or otherwise damaged. Hammering which will damage or distort the members
shall not be done. Bearing surfaces and surfaces to be in permanent contact shall be
cleaned before the members are assembled. Unless erected by the cantilever method,
truss spans shall be erected on blocking so placed as to give the trusses proper camber.
Blocking shall be left in place until tension chord splices are fully connected with
permanent fasteners and all other truss connections pinned and erection bolted. Splices
of butt joints of compression members, that are milled to bear, and of railing, shall not be
permanently fastened until spans have been swung, except that such permanent
fastening may be accomplished for truss members at any time that joint holes are fair.
Splices and field connections shall have one-half of holes filled with erection bolts and
cylindrical erection pins (half bolts and half pins) before placing permanent fasteners.
Splices and connections carrying traffic during erection shall have three-fourths of the
holes so filled, unless otherwise permitted by the Engineer. Fitting-up bolts shall be of the
same nominal diameter as permanent fasteners and cylindrical erection pins shall be 0.75
mm larger.
(g) Pin Connections

Pilot and driving nuts shall be used in driving pins. The Contractor shall furnish them
without charge. Pins shall be so driven that members take full bearing on them. Pin nuts
shall be screwed up tight and threads burred at the face of nut with a pointed tool.
(h) Welding
Unless otherwise designated on the Drawings no field welding for reinforcement, handling
or jigs for erection on steel bridge shall be allowed. Such welding shall be executed at the
shop.
(i) Field Painting

1) Steel structures shall be painted as soon as practicable after erection. Metal which
has been shop coated shall be touched-up with the same type of paints as shop coat.
This touch-up shall include cleaning and painting of field connections, welds, rivets
and all damaged or defective paint and rusted areas. The Contractor shall, at his
option, apply an overall coat of primer in place of touch-up spot painting.

2) Surfaces (other than contact surfaces), which are accessible before erection but
which will not be accessible after erection, shall receive all field coats of paint before
erection.
3) If possible the final coat of paint shall not be applied until all concrete work is finished.
If concreting or other operations damage any paint, surfaces shall be cleaned and
repainted. All cement or concrete spatter and dripping shall be removed before any
paint is applied.
4) Wet paint shall be protected against damage from dust or other detrimental foreign
matter to the extent practicable.
5) Maximum practicable time shall be allowed to dry before recoating or exposure. No
drier shall be added to paint on the job unless specifically called for in this
Specification for paint. No painted metal shall be subjected to immersion before paint
is dried through. Paint shall be protected from rain and condensation until dry, to the
fullest extent practicable.
(6) Setting Shoes and Bearings
Shoes and bearings shall not be placed on bridge seat bearing areas that are improperly
finished, deformed, or irregular. They shall be set level in exact position and shall have full
and even bearing. Shoes and bearing plates shall be properly supported and fixed with non-
shrink grout. No load shall be placed on them until grout has set for at least 96 hours,
adequate provision being made to keep grout well moistened during this period. Grout shall
be non-shrink mortar approved by the Engineer. Location of anchor bolts in relation to the
slotted holes in expansion shoes shall correspond with temperature at the time of erection.
Nuts on anchor bolts at the expansion ends shall be adjusted in free movement of span.
(7) Testing and Inspection
Testing and inspection shall be made in accordance with the requirements in Clause 2.24
“STEEL BRIDGE SUPERSTRUCTURE FABRICATION”.
(8) Clean Up
Upon completion and before final acceptance, the Contractor shall remove all falsework and
falsework piling down to at least 1.0 m below the finished ground line, excavated or unused
materials, rubbish and temporary buildings. The Contractor shall replace or renew any fences
damaged and restore in an acceptable manner all property, both public and private which
may have been damaged during prosecution of the work and shall leave the work site and
adjacent railway in a neat and presentable condition, satisfactory to the Engineer. All
excavated material or falsework placed in stream channels during construction shall be
removed by the Contractor before final acceptance.
The quantities to be measured for payment shall be the actual weight of kilogram of fabricated
steel bridge superstructure erected, installed in place, completed and accepted by the
Engineer.
In computing the quantities the dimensions used shall be those shown on the Drawings or
ordered in writing by the Engineer but measurement shall not include any steel used for
construction of temporary works. Bolts will be weighed and included in the quantity for
payment but no allowance or payment will be made for welds. The work shall include painting
and other incidentals and no separate measurement thereof shall be made.

pay item listed below. The price and payment shall be full compensation for the works
prescribed in this Clause, including furnishing all materials, labor, tools, equipment and plant,
delivery to site and erection of steel bridge superstructure, including incidentals necessary for
the works.
225 Steel Bridge Superstructure Erection kilogram

2.26 STEEL BRIDGE BEARING
(1) Description
This work shall consist of furnishing and installing steel bridge bearings inclusive of shoe
foundation mortar works, anchoring, grouting and dry packing works to be provided as shown
on the Drawings and described in this Specification. The Contractor shall furnish all labor,
materials, tools and equipment to complete the work. Steel bridge bearing shall be
manufactured in accordance with this Specification and in conformity with dimensions shown
on the Drawings and manufacturer’s production standards.
(2) Material
(a) Codes and Standards

Materials for steel bridge bearings work shall conform to the requirements of the following
codes and standards.
- Carbon steel : JIS G 5101, SC 450 and SC 480
- Cast steel : JIS G 5102, SCW 450 and SCW 480
- High tensile carbon steel : JIS G 5111, SCMn 1A, 2A
- Cast iron : JIS G 5501, FC 15 and FC 250
(b) Quality
The following codes and standards are an acceptable level of quality for materials and
products. The Contractor shall submit alternative codes and standards provided they give
an equivalent degree of quality as the referenced codes and standards to the Engineer
for approval in advance.
- American Association of State Highway and Transportation Officials (AASHTO)
- American Society for Testing and Materials (ASTM)
- Japanese Industrial Standards (JIS)
- Japanese Railway Standards (JRS)
(3) Submittals
(a) Submittals shall be made in accordance with the requirements in this Specification.
(b) The Contractor shall submit a certificate of compliance at testing that the material
conforms to the standards specified herein. Certified copies of mill test reports shall be
furnished.
(c) The Contractor shall submit the design calculations for approval of the Engineer.
(d) Shop Drawings shall be submitted for approval of the Engineer. Drawings shall include all
shop and erection details. Any portion of bearings not shown on the Drawings shall be
detailed by the Contractor and indicated on the Shop Drawings.
(4) Delivery and Storage
(a) Delivery
Transport with care to avoid any damage.
(b) Storage
Storage of fabricated bridge bearing at site shall be the responsibility of the Contractor.
Protect materials against excessive deflection, corrosion or deterioration. When
temporary storage is necessary, place bridge bearing on timber blocking to prevent
ground or surface water contact.

(5) Execution
(a) Anchoring, Grouting and Dry Packing

1) Anchor bolts shall be carefully installed by use of templates to permit true positioning
of bearing plates and assemblies. All bearing plates and bearing assemblies shall be
set level to the elevation shown on the Drawing. These shall be shimmed with
approved means and grouted to ensure full bearing on the supporting substructure
regardless of tolerances otherwise permitted. Grout shall be mixed and placed as per
manufacturer’s instruction. Air pockets in grout packing shall be avoided.
2) Anchoring bars and sleeves shall be carefully installed by use of templates to permit
true position as shown on the Drawings and shall be accurately retained at the
installed position until placement of concrete.
3) Sleeves shall be completely filled with grout in advance of placing concrete. Grout
shall be mixed and placed as per manufacturer’s instruction.
(b) Shoe Foundation Mortar

1) Material shall be mixed, cured, or otherwise handled in accordance with
manufacturer’s instructions and shall be placed to the dimensions required, uniformly
and accurately formed and finished off smooth at the elevations indicated on the
Drawings and all exposed edges shall be uniformly struck off smooth, straight and
beveled. Completed mortar work shall be free from any air pockets, voids, pits or
other irregularities.
2) Shoe foundation mortar shall be either portland cement with special additives or a
pre-mixed type material, either of which is especially formulated to produce a
compressive strength at 28 days, shrink free mortar. Materials shall be as
determined by the Contractor for approval of the Engineer in advance but shall not be
a material containing ferrous elements or otherwise which would cause any staining
over any length of time.
The quantities to be measured for payment shall be the actual number of each counting for
steel bridge bearing, installed on steel bridge substructure, completed and accepted by the
Engineer. In computing the quantities and the dimensions used shall be those shown on the
Drawings or ordered in writing by the Engineer
pay items listed below. The price and payment shall be full compensation for the works
prescribed in this Clause, including furnishing steel bridge bearing, all materials, labor, tools,
equipment, delivery to site and installation, including non-shrinkage mortar for shoe
foundation, anchor bar, bearing plates and assemblies and incidentals necessary for the
works.
226 (1) Steel Bridge Bearing Type A each

226 (2) Steel Bridge Bearing Type B each
226 (3) Steel Bridge Bearing Type C each
226 (4) Steel Bridge Bearing Type D each

2.27 STEEL BRIDGE OVERSEAS INSPECTION
(1) Description
This work shall consist of arrangement and execution of overseas inspection performance
with supply of all necessary arrangement for international and local transportation, testing
tools, materials and equipment necessary for inspection activity by the representatives of the
Employer and the Engineer at the place of manufacturer or factory for steel bridge
superstructure material and bearing to be provided by the Contract.
(2) Scope of Work
The Contractor shall carry out the inspection test for steel bridge materials to be provided by
the Contract in the presence and supervision of the representatives of the Employer and the
Engineer. The Contractor shall provide all transportation and traveling arrangement to the
locations and furnish all labor and facility for carrying out the test.
(3) Method of Work
(a) The Contractor shall make a schedule for overseas inspection for steel bridge materials
to be produced at overseas manufacturer or factory in accordance with this Specification.
(b) The factory inspection test shall be in accordance with this Specification and the
Contractor shall prepare test procedure and technical requirements complied with this
Specification before commencement of the inspection.
(c) Factory test report shall be documented including the test results and acceptance by the
inspection representatives of the Employer and the Engineer.
(4) Inspection Programme
An overseas inspection programme shall be established for one (1) week period for five (5)
inspectors from the representatives of the Employer and the Engineer. Inspection shall be
executed at the original manufacturer or factory of steel bridge materials after production and
before shipment. The Contractor shall complete all the necessary arrangement for
international traveling, domestic transportation, accommodation and lodging, inspection
activities and reporting documentation etc.
(5) Submittals
The Contractor shall submit in writing one (1) month advance notice to the Engineer of the
overseas inspection schedule when Contractor is ready to make the inspection test.
The quantity to be measured for payment will be on the basis of a lump sum for all the
overseas inspection and testing carried out and completed to satisfaction of the Engineer.
Payment for inspection will be made on completion of the required work but this payment will
not relieve the Contractor of his responsibility to complete all these works defined herein.
compensation for all costs necessary for the proper completion of the work prescribed in this
Clause.

227 Steel Bridge Overseas Inspection lump sum

2.28 U-DITCH DRAINAGE
(1) Description
This work shall consist of furnishing and installing of U-ditch drainage for various types in
locations, across track and road in accordance with this Specification and in conformity with
the lines, grades and dimensions as shown on the Drawings and as instructed by the
Engineer.
(2) Scope of Work
Types and characteristics of drainage structures shown on the Drawings and total quantities
estimated shall be subject to detailed design by the Contractor due to survey results of site
condition and preparation of the Shop Drawings for drainage system. The Contractor shall
undertake a survey at site to confirm or to determine the location, U-ditch, pipe or channel
size, invert level and estimated discharge of all storm water or foul sewer flows entering the
site. On basis of survey result the types, lines, characteristics and quantities designed by the
Contractor will be approved by the Engineer in relation to the work schedule submitted by the
Contractor. Responsibility for accurately locating all existing flow shall be by the Contractor.
The Engineer will reserve the right to inspect and test all precast concrete items before
delivery to site and at any time prior to and during laying.
(3) Method of Work
The Contractor shall schedule construction of drainage works that discharge of run-off from
rain or other sources, both during and after construction, is properly provided for. To avoid
damage to work in course of construction the Contractor shall provide in due time adequate
means of protection, including all necessary temporary outlet ditches, dams, or diversion
channels. Culverts or other drainage works for discharge of run-off water either during or after
construction shall not be built until adequate facilities for inflow and outflow of water have
been completed and they shall be kept clear of all obstructions that might impede flow of
water. All culverts and other drainage works shall be fully operative before work is begun on
construction of subgrade, sub-base or shoulders. Where new drainage connects to existing,
the existing drainage shall be thoroughly cleaned out before final connection is made. All
requirements herein shall be met without additional payment and all costs thereof shall be
included in the unit price for the pay item being installed or constructed.
(4) Materials
Material shall be as shown on the Drawings and shall comply with the relevant Clauses of this
Specification.
(5) Construction
(a) Excavation
Excavation shall be performed in accordance with the relevant requirements of Clause
2.03 ”EXCAVATION" and Sub-Clause 2.03(1) (b) “Structure Excavation”.
The Contractor shall place a temporary steel rail bundle bridge across excavation of
adequate strength to support train loads when necessary during drainage system
construction or other means to carry train loads as approved by the Engineer.
(b) Foundation
Foundation shall be prepared in accordance with Clause 2.03 " EXCAVATION" and
Clause 2.13 "RUBBLE STONE FOUNDATION" or as shown on the Drawings.
(c) Layout
All work on standardized concrete drainage, conduits, catch basins, manholes and
transverse drainage shall be carefully set out and constructed with due recognition being
taken of the fact that upper surfaces must be incorporated smoothly into curbs, sidewalks

etc. The Engineer will reject any item of work under this Clause when upper surfaces do
not meet the tolerances for curb and sidewalk given elsewhere in this Specification.
Cast-in-place concrete for drainage, conduits, inlet and outlet of waterways, shall be
constructed to the requirements of this Clause and Clause 2.35 "PAVEMENT WORK" of
this Specification. All structures shall be constructed as shown on the Drawings and as
directed by the Engineer.
Top portions of catch basins or inlets and concrete drainage on which covers are to be
placed shall be set accurately and carefully and smoothly finished. To ensure uniformity
in horizontal and vertical alignment of curb, the Engineer will instruct that work on upper
sections of inlets, catch basins, channels and drainage shall be deferred and carried out
immediately before or during work on the adjacent curb. Any additional expense incurred
in complying with this instruction shall be deemed to be already included in the unit price
for this work.
(d) Covers and Gratings

Reinforced concrete covers shall be constructed in accordance with the Drawings.
Concrete for covers shall be Class "C" in Clause 2.14 "CONCRETE WORKS. Gratings
shall be fabricated and installed in accordance with the Drawings and instructions given
by the Engineer. Gratings shall be galvanized for finishing.
(e) Backfill and Reinstatement

Backfill shall be performed in accordance with the requirements of Clause 2.03
”EXCAVATION" of this Specification. Backfill shall be carefully made so as to obtain a
bearing capacity equal to the adjacent subgrade. In compacting backfill material in
contact with drainage structures, rammers or small compactors shall be used and care
taken to prevent damage to the adjacent structures. Backfill shall be carefully constructed
so as to prevent erosion by overflow of drain water or rain.
On completion of backfilling, the area excavated shall be reinstated to its original

condition but the Engineer will waive or modify this requirement if the area is to be
overlaid or reconstructed under other Clauses of this Specification.
In case U-Ditch Drainage is installed near concrete sheet pile at cutting area, U-Ditch
Drainage shall be provided with drain hole at wall part and geotextile between U-Ditch
and sub-ballast layer as shown in the Drawings.
The quantity to be measured for payment shall be the actual number of linear meters of U-
ditch drain for respective types furnished, installed, completed in place in accordance with the
Drawings and accepted by the Engineer. The quantity of each type of U-ditch drain will be
measured along the centerline of completed drainage. Length will be measured to the outside
face of any inlet or catch basins.
Measurement for U-ditch drain will be independent of depth and unit price will be deemed to
cover any depth shown on the Drawings. No additional measurement will be made for joints
between inlets or catch basins and U-ditch drain. Any additional expense involved in forming
joints or junctions between individual pay items, will be deemed to be included in the cost of
pay items. Installation of gratings shall not be measured directly for payment but shall be
considered a subsidiary obligation of the Contractor covered by the Contract unit prices for
the various types of U-ditch drain.
of measurement for the pay items listed below. The price and payment will be full
compensation for all the work in accordance with the Drawings, this Specification and
instructions of the Engineer and will include for clearing and excavation and structural

excavation, concrete, reinforcing bars, removal of existing manhole, foundations, construction

and backfill. No separate payments will be made for expansion joints, gratings, concrete
covers, step irons, joints, benching or any such similar work which is shown in the Drawings
or described in this Specification. Any extra costs resulting from working on small areas will
be deemed to be included in the pay items below.
228(1) U-Ditch Drain Type A linear meter

228(2) U-Ditch Drain Type B linear meter
228(3) U-Ditch Drain Type C linear meter
228(4) U-Ditch Drain Type D linear meter
228(5) U-Ditch Drain Type E linear meter
228(6) U-Ditch Drain Type F linear meter
228(7) U-Ditch Drain Type G linear meter
228(8) U-Ditch Drain Type H linear meter
228(9) U-Ditch Drain Type I linear meter
228(10) U-Ditch Drain Type J linear meter

2.29 PIPE DRAINAGE
(1) Description
This work shall consist of furnishing and installing pipe drainage for various types in locations,
across track and road in accordance with this Specification and in conformity with the lines,
levels and other details as shown on the Drawings and as instructed by the Engineer based
on the Contractor's survey results mentioned in Clause 2.28 "U-DITCH DRAINAGE".
(2) Material
All pipe drainage shall be constructed in accordance with the details shown on the Drawings
and to the requirements of JIS A 5303, SII standards or PBI 71. Centrifugal spun reinforced
concrete pipes shall be Type B as specified by JIS A 5303 or SII standards, unless otherwise
modified by the Engineer. Concrete for pipe drainage shall be Class "D" and levelling
cocnrete shall be Class "F" as designated in Clause 2.14 "CONCRETE WORKS" of this
Specification. Reinforcing bars shall comply with PBI 71 U-24 and U-39 and shall be
positioned as shown on the Drawings.
(3) Construction
(a) Excavation
Prior to starting excavation the Contractor shall take all necessary measures to keep
excavation free from surface water or surface water run-off. The Contractor shall place a
temporary steel rail bundle bridge across excavation of adequate strength to support train
loads when necessary during drainage system construction or other means to carry train
loads as approved by the Engineer.
Sides of pits and trenches shall be thoroughly supported at all times. Excavation
undertaken within 2.5 meters of any track shall be fully and continuously supported and
the method to be used shall not extend above ground level excessively. Support systems
shall be sheet piles, wales and adjustable struts or planking, soldiers, wales and
adjustable struts. Supports shall be left in pits or trenches only if approved by the
Engineer. Excavation shall be performed in accordance with the relevant requirements of
Sub-Clause 2.03(1) (b) "Structure Excavation". All excavated material not required for
backfilling shall be dealt with in accordance with Clause 2.04 "EMBANKMENT".
Soft spots in the bottom of drainage excavation shall be removed and the resulting void
immediately backfilled and compacted with suitable material. When the Engineer instructs
this treatment it will be paid for under the relevant clauses of this Specification. Where the
Engineer considers that soft spots are due to the Contractor's failure to fulfill the
obligations under any clause of this Specification then the Contractor shall, at his own
expense, undertake the additional excavation and replacement with suitable material to
satisfaction of the Engineer.
Any suitable material below level of concrete pipe bed which is removed unnecessarily
shall be replaced at the Contractor's expense. In case an additional drainage pipe is
required by the Engineer where the filling has been completed, excavation shall be
carried out so as to minimize damage to the existing surface.
(b) Bedding, Laying and Surrounding of Pipes

All pipes shall be laid, using cradles if necessary, to the true line and level as directed by
the Engineer. Joints shall be sealed with 1:2 cement mortar, except where otherwise
specified, so that water will not leak. Inside of joint shall be wiped and finished smooth
and outside shall be protected and cured for two days or as otherwise directed by the
Engineer to prevent cracking.
After the Engineer has checked and approved the pipes and joints, the Contractor shall
complete the concrete bedding and haunching or surrounding as instructed by the
Engineer. Concrete shall be thoroughly compacted below and around the pipe to the

dimensions shown on the Drawings but special care should be taken to avoid dislodging
the pipes or damaging the joints. Surrounding concrete for all pipes shall be Class "D".
(c) Backfilling and Reinstatement

Backfilling shall not commence until, in opinion of the Engineer, concrete has achieved
sufficient strength. Backfilling shall be carried out in accordance with the requirements of
Clause 2.04 "EMBANKMENT", except that maximum thickness of loose material shall not
exceed 15 cm.
Where insufficient suitable material is available from any particular pipe excavation,
surplus material from any other excavation shall be used. On completion of backfilling the
area excavated shall be reinstated to its original condition but the Engineer will waive or
modify this requirement if the area is to be overlaid or reconstructed under other Clauses
of this Specification.
reinforced concrete pipe drainage for respective types measured along the centerline of pipe,
between inside faces of headwalls, catch-basins or concrete ditches, as installed in
accordance with this Specification and instruction of the Engineer. Pipes will be measured
and paid for according to the particular type and diameter, all details of which shall be as
shown on the Drawings.
Measurement for pipe drain will be independent of depth and unit price will be deemed to
cover any depth shown on the Drawings.
instructions of the Engineer and will include for furnishing, hauling and installing the various
types of pipe drain, including cradles if necessary, jointing, concrete surround, reinforcement,
cobble stone, Ievelling concrete, clearing and excavation and structural excavation to any
depth, including temporary steel bridge, sheeting and backfilling, maintaining the excavation
free of groundwater, breaking into any existing manholes or channels to form a connection,
maintenance of existing drainage, working in and dealing with water, temporary drainage, and
for all labor, tools, equipment and incidentals necessary to complete the work as described in
this Specification. Any extra costs resulting from working on small areas will be deemed to be
included in the pay items below.
229(1) Pipe Drain Type A linear meter

229(2) Pipe Drain Type B linear meter
229(3) Pipe Drain Type C linear meter
229(4) Pipe Drain Type D linear meter

2.30 TRAVERSE DRAINAGE
(1) Description
This work shall consist of furnishing and installing traverse drainage at right angles to railway
in accordance with this Specification and in conformity with the lines, Ievels, grades and
dimensions shown on the Drawings and as directed by the Engineer based on the
Contractor’s survey results mentioned in Clause 2.28 “U-DITCH DRAINAGE”.
(2) Materials
Specification.
(3) Construction
(a) Excavation
2.03 "EXCAVATION". The Contractor shall place a temporary steel rail bundle bridge
across excavation of adequate strength to support train loads when necessary during
drainage construction or other means to carry train loads as approved by the Engineer.
(b) Foundation
Foundation shall be prepared in accordance with Clause 2.03 "EXCAVATION" and
(c) Backfill and Reinstatement

On completion of backfilling, excavated area shall be reinstated to its original condition

but the Engineer will waive or modify this requirement if the area is to be overlaid or
reconstructed under other Clauses of this Specification.
The quantity to be measured for payment shall be the actual linear meters of traverse drain
for respective types furnished, installed and completed in place in accordance with the
Drawings and as accepted by the Engineer. The quantity of each type of traverse drainage
will be measured along the center line of completed drainage. Length will be measured to the
outside face of any inlet or catch basin.
Measurement for traverse drainage will be independent of depth and unit price will be
deemed to cover any depth shown on the Drawings. No additional measurement will be made
for joints between inlets or catch basins and traverse drainage. Any additional expense
involved in forming joints or junctions between individual pay items, will be deemed to be
included in the cost of pay items. Installation of gratings shall not be measured directly for
payment but shall be considered a subsidiary obligation of the Contractor covered by the
Contract unit prices for the various type of traverse drain.


and backfill. No separate payments will be made for expansion joints, gratings, concrete
covers, step irons, joints, benching or any such similar work which is shown in the Drawings
or described in this Specification. Any extra costs resulting from working on small areas will
be deemed to be included in the pay items below.
230(1) Traverse Drain Type A linear meter

230(2) Traverse Drain Type B linear meter

2.31 FRENCH DRAIN
(1) Description
This work shall consist of furnishing and installing french drains in locations, across track and
road in accordance with this Specification and in conformity with the lines, levels and other
details as shown on the Drawings and as instructed by the Engineer based on the
Contractor's survey results mentioned in Clause 2.28 “ U-DITCH DRAINAGE”.
(2) Material
Pipes for french drains types A, B, C, D and E shall be PVC in accordance with JIS K 6742 to
the details as shown on the Drawings. Geotextile for french drains of all types shall be
nonwoven film for filter material in accordance with JIS L 1908 and JIS1218.
(3) Construction
(a) Excavation
Prior to starting excavation the Contractor shall take all necessary measures to keep
excavation free from surface water or surface water run-off. Sides of pits and trenches
shall be thoroughly supported at all times. Excavation shall be performed in accordance
with the relevant requirements of Clause 2.03 ”EXCAVATION". All excavated material not
required for backfilling shall be dealt with in accordance with Sub-Clause 2.03(1) (b)
"Structure Excavation of this Specification”.
Soft spots in the bottom of drainage excavation shall be removed and the resulting void
immediately backfilled and compacted with suitable material. When the Engineer instructs
this treatment it will be paid for under the relevant clauses of this Specification. Where the
Engineer considers that soft spots are due to the Contractor's failure to fulfill the
obligations under any clause of this Specification then the Contractor shall, at his own
expense, undertake the additional excavation and replacement with suitable material to
satisfaction of the Engineer.
Any suitable material below level of pipe bed which is removed unnecessarily shall be
replaced at the Contractor’s expense. In case an additional drainage pipe is required by
the Engineer where the filling has been completed, excavation shall be carried out so as
to minimize damage to the existing surface.
(b) Bedding, Laying and Surrounding of Pipes

All pipes shall be laid, using cradles if necessary, to the true line and level as directed by
the Engineer. Joints shall be sealed joint pipe, except where otherwise specified, so that
water will not leak. Inside of joint shall be wiped and finished smooth and the outside shall
be protected and cured as otherwise directed by the Engineer to prevent cracking.
Granular materials for french drains shall be as shown on the Drawings.
(c) Backfilling and Reinstatement

Backfilling shall not commence until, in opinion of the Engineer, concrete has achieved
sufficient strength. Backfilling shall be carried out in accordance with the requirements of
Clause 2.04 “EMBANKMENT”.
Where insufficient suitable material is available from any particular pipe excavation,
surplus material from any other excavation shall be used. On completion of backfilling the
area excavated shall be reinstated to its original condition but the Engineer will waive or
modify this requirement if the area is to be overlaid or reconstructed under other Clauses
of this Specification.

The quantify to be measured for payment shall be the actual number of linear meters of
french drains for respective types measured along the centerline of drain, between inside
faces of headwalls, catch basins or concrete ditches as installed in accordance with this
Specification and instruction of the Engineer. Pipes and french drains will be measured and
paid for according to the particular type and diameter, all details of which shall be as shown
on the Drawings.
Measurement for french drain will be independent of depth and unit price will be deemed to
cover any depth shown on the Drawings.
instruction of the Engineer and will include for furnishing, hauling and installing the various
types of french drain, including cradles if necessary, jointing and structural excavation to any
depth, sheeting and backfilling, maintaining the excavation free of groundwater, breaking into
any existing channels to form a connection, and for all labor, tools, equipment and incidentals
necessary to complete the work as described in this Specification. Any extra costs resulting
from working on small areas will be deemed to be included in the pay items below.
231(1) French Drain Type A linear meter

231(2) French Drain Type B linear meter
231(3) French Drain Type C linear meter
231(4) French Drain Type D linear meter
231(5) French Drain Type E linear meter

2.32 CATCH BASIN
(1) Description
This work shall consist of furnishing and installing catch basins in locations, across track and
road in accordance with this Specification and in conformity with the lines, Ievels, grades and
dimensions shown on the Drawings and as instructed by the Engineer based on the
Contractor’s survey results mentioned in Clause 2.28 “U-DITCH DRAINAGE”.
(2) Materials
Specification.
(3) Construction
(a) Excavation
2.03 “EXCAVATION".
(b) Foundation
Foundation shall be prepared in accordance with Clause 2.03 “EXCAVATION" and
(c) Layout
All work on standardized catch basins shall be carefully set out and constructed with due
recognition being taken of the fact that the upper surfaces must be incorporated smoothly
into curbs, sidewalks etc. The Engineer will reject any item of work under this Clause
when upper surfaces do not meet the tolerances for curb and sidewalk given elsewhere in
this Specification.
Cast-in-place concrete for catch basins shall be constructed to the requirements of

Clause 2.35 ”PAVEMENT WORK" of this Specification. All structures shall be constructed
as shown on the Drawings and as directed by the Engineer. Top portions of catch basins
or inlets and concrete drainage on which covers are to be placed shall be set accurately
and carefully and smoothly finished.
To ensure uniformity in horizontal and vertical alignment of curb, the Engineer will instruct
that work on upper sections of inlets, catch basins, channels and drainage be deferred
and carried out immediately before or during work on the adjacent curb. Any additional
expense incurred in complying with this instruction shall be deemed to be already
included in the unit price for this work.
(d) Backfill and Reinstatement

On completion of backfilling, excavated area shall be reinstated to its original condition

but the Engineer will waive or modify this requirement if the area is to be overlaid or
reconstructed under other Clauses of this Specification.

The quantity to be measured for payment shall be the actual number of catch basins for
respective types furnished, installed and completed in place in accordance with the Drawings
and accepted by the Engineer. The quantity of each type of catch basins will be measured by
each for installed location. Measurement for catch basins will be independent of depth and
unit price will be deemed to cover any depth as shown on the Drawings.
and backfill. No separate payments will be made for concrete covers, step irons or any such
similar work which is shown in the Drawings or described in this Specification. Any extra costs
resulting from working on small areas will be deemed to be included in the pay items below.
232(1) Catch Basin Type A each

232(2) Catch Basin Type B each
232(3) Catch Basin Type C each
232(4) Catch Basin Type D each
232(5) Catch Basin Type E each

2.33 STONE MASONRY
(1) Description
This work shall consist of constructing stone masonry for slope protection in retaining walls for
both cut and embankment sections in minor structures and in other places where called for on
the Drawings or directed in writing by the Engineer. Stone masonry shall be constructed on a
compacted soil bed in accordance with this Specification and specifications for other work
items involved and in conformity with the lines, grades, sections and dimensions shown on
the Drawings or required by the Engineer.
(2) Material
(a) Stone
Stone shall be sound and of good quality, have sufficient strength and no seams and
shall be resistant to weathering. Quality of stone shall be approved by the Engineer prior
to use. Stone shall be flat wedge or convex shaped. Base surface shall be not less than
1/16 of front surface and shorter length of base surface shall be more than 1/10 of longer
length.
(b) Mortar
Mortar shall be in accordance with this Specification and approved by the Engineer.
(c) Free Draining Material

Free draining material for backfill shall be in hard, clean, crushed rock or gravel complying
with the following grading.
Sieve Size Passing by Weight
63 mm 100 %
37.5 mm 85 -100 %
19 mm 0 - 20 %
9.5 mm 0-5 %
(3) Construction
(a) Excavation
Excavation shall be in strict accordance with cross sections, grades and lines shown on
the Drawings after staking has been inspected and approved by the Engineer. W hen
excavation method and dimensions are not specified, method shall be selected by the
Contractor and approved by the Engineer. Excavation and backfill shall be made in
accordance with the requirements of Clause 2.03 ”EXCAVATION" of this Specification.
(b) Compaction
Prior to placing stone, soil bed shall be compacted in accordance with Clause 2.04
“EMBANKMENT” of this Specification.
(c) Backfill
"Free Draining Material" shall be placed as shown on the Drawings and this Specification
or as directed by the Engineer. Backfill material shall only be placed to such heights as
adequately compacted.
(d) Placing
Placing of stone masonry shall not begin until finishing stakes set according to design
have been inspected and approved by the Engineer. Stones shall be washed with water
before placing. A mortar bed shall be spread on the sides of adjacent stones before next
stone is laid. Thickness of mortar shall be minimum necessary to ensure that there is no
direct contact between stones. Stones shall be thoroughly hammered into place and any
stone whose face is deviating more than 20 mm from true face or more than 30 mm from
face of adjacent stone, shall immediately be made good by lifting and relaying. Face
joints between stones shall be flush-pointed as work proceeds.

(e) Weep Holes

Walls of stone masonry shall be provided with weep holes. Unless otherwise shown on
the Drawings or directed by the Engineer, weep holes shall be spaced at one for every 1
square meter and shall be PVC pipe 50 mm in diameter.
(f) Coping
Coping shall be as shown on the Drawings and upper surfaces of masonry shall be
mortared and finished smoothly by wooden float.
(g) Joints
Expansion joints shall be formed at a maximum spacing of 20 meters. Joints shall be 10
mm in width and shall extend through complete wall including footing. Stones used for
joint forming shall be selected so as to form a clean vertical joint of the dimension
specified above.
(h) Cohesive Soil

Cohesive soil shall be installed on top of free draining material as shown on the Drawings.
(i) Curing
Masonry shall be satisfactorily protected from sun and shall be kept wet for a period of at
least three days after completion.
The quantity to be measured for payment shall be the actual number of cubic meters of stone
masonry laid in accordance with the Drawings and accepted by the Engineer. In computing
the quantity for payment, the dimensions used shall be those shown on the Drawings or
instructed in writing by the Engineer. No deductions shall be made for weep holes, drain pipes
or other openings of less than 1.0 square meter in area. Any coping provided shall be
included in measurement to the dimensions stated on the Drawings.
Volume of free draining material behind stone masonry walls will not be measured in
computing the quantity for payment as this shall be considered a subsidiary obligation of the
Contractor for which full payment shall be included in the Contract unit price for stone
masonry work.
Volume and cost of structural excavation that may be necessary for construction of actual
cross sectional area of stone wall, coping, cohesive soil and free draining material, according
to the dimensions on the Drawings, shall not be measured separately for payment but shall
be included in the Contract unit price for this work. Any over excavation behind stone
masonry wall shall be backfilled with free draining material suitably compacted and all at no
extra cost.
of measurement for the pay item listed below. All excavation and backfilling for this pay item
should comply with the requirements of Clause 2.03 “EXCAVATION" of this Specification,
except as otherwise mentioned in this Clause. The price and payment will be full
compensation for structural excavation and furnishing and placing all materials, including
stone, free draining material behind walls, geotextile, coping, expansion joints, mortar
finishing, preparation of bed and all foundation works for stone work and all other necessary
work as specified for proper completion of all work as described in this Specification.
233 Stone Masonry cubic meter

2.34 GABION
(1) Description
This work shall consist of furnishing and installing stone filled wire mesh gabions for ballast
protection and riverbank slope protection at locations and in accordance with details shown
on the Drawings and as instructed by the Engineer.
(2) Materials
Material shall be provided as specified herein or as specified by the manufacturer of gabion

basket and all details shall be submitted to the Engineer for approval before commencement
of any work.
Gabion basket shall incorporate factory fixed diaphragm wire mesh to form cells having
widths and lengths as indicated on the Drawings. Diameter and quality of diaphragm shall
conform to wire mesh used for forming gabion basket.
Cobbles used for fill shall be clean, hard and durable stone, rounded and angular in shape.
No rock particles or boulders shall exceed the maximum size indicated below and at least
85% by weight of the particle shall have a size equal to or larger than the minimum size.
Cobble stone size for gabion steel net shall range from 100 - 300 mm.
Reinforcement bar shall conform to SR 235. JIS G 3112.
Lacing, bending and all other wires shall be in accordance with the manufacturer’s
recommendation as approved by the Engineer.
(3) Fabrication, Assembly and Installation
(a) Fabrication
Gabion fabrication shall be in accordance with the manufacturer's instructions and the
requirements specified herein. Gabion shall be mechanically pre-fabricated in such a
manner that the side, ends and lids shall be assembled at the construction site into
rectangular baskets of the standard sizes shown on the Drawings. Steel bars shall be
used to maintain the wire mesh gabion in a rectangular shape.
(b) Gabion Assembly and Installation

Assembly and installation of gabions shall be in accordance with the manufacturer's
instructions and as specified herein.
Open and unfold the gabion on a hard surface. Press out creases in the mesh and kinks
in the selvedge wires as these are not intended to indicate the corners of the unit.
Lift up the sides, ends and diaphragms into a vertical position to form an open box shape.
Ensure the tops of corners are level and then join together with projecting thick selvedge
wire, then lace the corners.
Manual lacing shall be carried out in a continuous wiring operation, not with individual ties
or twists. Single and double twists shall be required alternately at approximately 100 to
150 mm spacing. A manageable length of binding wire shall be a complete turn from the
coil as supplied.
Place a number of empty gabions in position and securely lace adjoining units together
before they are tensioned and tilled. A cable winch shall be used to tension the units.
Keep the gabion stretched and under tension longitudinally during filling to give a good
alignment and finish.

Do not treat gabions individually by adding to the structure and filling gabions one at a
time, which is time consuming, detrimental to the finished appearance and may lead to a
loss of structural integrity of the finished structure.
Minimize number of voids by using a well graded stone and avoid large stones in order to
achieve a dense and compact compartment.
Overfill the gabion by approximately 45-50 mm to allow for natural settlement.
All excavation and foundation compaction shall be performed in accordance with Clause
2.03 "EXCAVATION".
gabion protection installed in position and completed in accordance with this Specification.
Cost of excavation shaping and compaction of soil foundation shall be paid for separately by
Pay Item 2.03 "EXCAVATION"
Any excavation behind or below the gabion protection shall be backfilled and compacted with
suitable material at no extra cost.
The quantity determined, as provided above, will be paid for at the Contract price per unit of
for furnishing and placing all materials, including all labor, tools, equipment and incidentals
necessary to complete the work as shown on the Drawings and described in this
Specification.
234 Gabion cubic meter

2.35 PAVEMENT WORK
(1) Description
This work shall consist of executing all necessary work for construction of asphalt pavement,
concrete pavement and interlocking pavement, including provision of materials and
installation to the lines, grades and locations shown on the Drawings or instructed by the
Engineer and in accordance with the tolerances, material requirements and all other
requirements as hereinafter specified.
(2) Scope of Work
This work shall include and be divided into the following scopes, which are hereinafter
described in detail under separate headings below.
(a) Asphalt Pavement

Work shall consist of supplying, placing and compacting sub-base material, (not asphalt
treated), which shall consist of sandy gravel between subgrade and asphalt treated base
course in accordance with this Specification and in conformity with the lines, grades,
thickness and typical cross-sections shown on the Drawings or instructed by the
Engineer. Asphalt pavement will be composed by the following works.
1) Sub-Base.
2) Prime Coat and Tack Coat.
3) Asphalt Concrete Surface Course, Asphalt Binder Course and Asphalt Treated Base
Course.
(b) Concrete Pavement

Work shall consist of supplying, placing and compacting sub-base material and concrete
slab in accordance with this Specification and in conformity with the lines, grades,
thickness and typical cross-sections shown on the Drawings or instructed by the
Engineer.
(c) Interlocking Pavement

Work shall consist of supplying, placing and compacting sand-bed material and
interlocking concrete blocks in accordance with this Specification and in conformity with
the lines, grades, thickness and typical cross-sections shown on the Drawings or
instructed by the Engineer.
(3) Sub-Base
(a) Materials
The Contractor shall provide to the Engineer prior to beginning of sub-base work a
complete statement of origin and composition of all aggregates to be used in constructing
sub-base. All material shall comply with the requirements as described below.
1) Sub-Base Material
Materials shall consist of well-graded sand-gravel conforming to the following
requirements and standards.
1 ½ in (37.5) 100 %
No. 10 (2.00) 80 % max
No.200 (0.075) 15 % max
Liquid Limit (AASHTO T89) 25 % max
Plasticity Index (AASHTO T90) 6 % max
Sand Equivalent (AASHTO T176) 25 % max
Loss by Abrasion (AASHTO T96) 50 % max
2
Minimum Dry Density (AASHTO T180) 2.0 g/cm

(d) Construction
1) Spreading
Work method of spreading granular sub-base shall be subject to approval of the
Engineer.
2) Compaction
Immediately following final spreading and smoothing, each layer shall be compacted
to full width by means of smooth wheel power rollers, pneumatic tired rollers or other
approved compaction equipment. Rolling shall progress gradually from low to high
point of cross section parallel to the center line of carriage-way and shall continue
until all surface has been rolled.
Any irregularities or depressions that develop shall be corrected by loosening material

at these places and adding or removing material until surface is smooth and uniform.
At all places not accessible to roller, material shall be compacted thoroughly with
approved tampers or compactors. Material shall be both graded and rolled until a
smooth and even surface has been obtained.
During performance of the work, thickness of each course shall be accurately

controlled to attain the required thickness after compaction. Where surface fails to
meet the tolerance requirement, the Contractor shall remove and replace sub-base
as directed by the Engineer without any additional cost.
Sub-base material shall be compacted to produce the required density through full
depth of each layer of at least 95 percent of the maximum density determined in
accordance with AASHTO T 180, method D. In place field density determinations
shall be made in accordance with AASHTO T 191. The Engineer will make
measurements of test holes at random during progress of the work to confirm
compliance with this Specification.
Cutting test holes and refilling with materials properly compacted shall be done by the
Contractor under supervision of the Engineer at the Contractor’s expense.
3) Tolerances
The following tolerances for subgrade and pavement construction after completion of
the work shall not be exceeded. The Engineer will waive certain requirements and
apply other tolerances as necessary and appropriate for the case at hand.
- Alignment (horizontal control) + 20 m to – 20 mm
- Profile and Elevations (vertical control)

- Top of compacted sub-base course + 20 m to – 20 mm
- Thickness of compacted granular subbase + 10 % to – 5%
When a 3 meter straight edge is laid on surface parallel to and perpendicular to the
center line, surface variation from lower edge straight edge shall not exceed the
condition below.
- Compacted sub-base course 8 mm
(4) Prime Coat and Tack Coat Work
(a) General
Work shall consist of furnishing and applying bituminous materials to a previously
prepared base course surface or an existing pavement surface in accordance with this
Specification and to the width as shown on the Drawings or as instructed by the Engineer.
(b) Materials
Bituminous materials shall conform to the requirements of this Specification listed below.

1) Prime Coat
Medium-curing cut back asphalt : AASHTO M 82
Grade (with temperatures of application in degress C) shall be MC-70 (43 °C - 85°C).
If blotter material is required, when directed by the Engineer, dry sand or stone
screenings free from dirt or cohesive material shall apply.
2) Tack Coat
Rapid-curing cut-back asphalt : AASHTO M 81
Grade (with temperatures of application in degress C) shall be RC-250
(60°C – 100°C)
(c) Construction
1) Weather Limitations
Prime coat shall be applied only with approval of the Engineer. Surface to be treated
shall be dry or slightly damp. No application of these materials shall be allowed when
surface is very wet.
2) Equipment
Equipment to be used for application of material shall be approved by the Engineer
prior to commencement of the works.
3) Preparation of Surface
Immediately before applying prime coat material all loose dirt and other objectional
material shall be removed from surface. When so ordered by the Engineer a light
application of water shall be made just before application of bituminous materials.
Before applying tack coat material the existing pavement surface shall be patched
and cleaned and shall be free from irregularities to provide a reasonably smooth and
uniform surface to receive treatment.
Edges of existing pavements, which are to be adjacent to new pavement, shall be

cleaned to permit adhesion of bituminous materials. Treated area shall be approved
by the Engineer prior to application.
4) Application of Material
Prime coat material shall be applied to the width of section to be primed by means of
a bitumen distributor in a uniform and continuous spread. Rate of application shall
usually be in range of 1.0 to 2.5kg/m2 and the Engineer will determine the rate to be
applied.
Tack coat material shall be uniformly applied with a bitumen distributor within 24
hours preceding placement of covering course. The Engineer will specify the rate of
application which will usually be in range of 0.4 to 0.8 kg/m2.
Care shall be taken that application of bituminous material at the junction of spreads
is not in excess of the specific amount. Excess bituminous materials shall be
squeegeed from the surface. Skipped areas or deficiencies shall be corrected.
(5) Asphalt Concrete Surface Course, Asphalt Binder Course and Asphalt Treated Base
Course Work
(a) General
Work shall consist of aggregate and bituminous material mixed in a central plant and
spread and compacted on a prepared surface in accordance with this Specification and in
close conformity with the lines, grades, thicknesses and typical cross sections shown on
the Drawings or instructed by the Engineer.
(b) Material
1) Composition of Mixtures
Bituminous material shall be composed of a mixture of aggregate, filler and hydrate

lime, if required, and asphalt cement. Several aggregate fractions shall be sized,
uniformly graded and combined in such proportions that resulting composite blend
meets job-mix formula and the following index of retained strength as determined in
accordance with AASGTO 245.
Item Asphalt Treated Asphalt Concrete Binder

Base Course and Surface Course
Stability (kg) 700 900
Flow (mm) 2.5 – 4.0 2.5 – 4.0
Voids in total mix (%) 4–6 3–5
Voids filled with asphalt (%) 65 – 75 75 – 85
In calculating void characteristics of mixture the Contractor shall allow for asphalt
absorbed by aggregate and use effective specific gravity of aggregate and maximum
specific gravity of loose paving mixture (AASHTO T209).
Several aggregate and filler fractions for mixture shall be sized, graded and combined
in such proportions that resulting composite blend meets one of the grading
requirements listed below.
Grade A shall be used for asphalt treated base course.

Grade B shall be used for asphalt binder course.
Grade C shall be used for asphalt surface course.
Sieve Designation Percentage Passing by Weight

(mm) Grade A Grade B Grade C
2” (50.0) 100 – –
1 ½” (37.5) 95 – 100 – –
1” (25.0) 70 – 90 100 –
¾ (19.0) – 95 – 100 100
½ “ (12.5) 45 – 70 68 – 86 95 – 100
3/8” (9.5) – 56 – 78 74 – 92
No. 4 (4..75) 25 – 50 38 – 60 48 – 70
No. 8 (2.36) 17 – 40 27 – 47 33 – 53
No. 16(1.18) – 18 – 37 22 – 40
No. 30 (0.600) 7 – 22 11 – 28 15 – 30
No. 50 (0.300) – 6 – 20 10 – 20
No. 200 (0.075) 0–6 0–8 4–9
Before stockpilling aggregate the Contractor shall submit a job-mix formula in writing
for approval of the Engineer in setting job-mix to be used with the materials. Formula
submitted shall give definite single values for the following data.
- Percentage of aggregate passing each specified sieve
- Percentage of bituminous material to be added on total aggregate basis
- Temperature of mixture leaving mixer
- Temperature of mixture delivered on road
- Grade of bituminous material
Values shall be proposed within the limits specified for particular type of bituminous
concrete called for.
The Engineer will determine a job-mix formula with single values for the above-
mentioned and so notify the Contractor in writing.
Mixture furnished by the Contractor shall conform to job-mix formula within grading
ranges previously listed and within the following range of tolerances.

Item Tolerance
Aggregate passing No.4 (4.75 mm) + 7 % to – 7 %
And larger sieve
Aggregate passing No.8 (2.36 mm) + 4 % to – 4 %

Through No. 50 (0.300 mm) sieve
Aggregate passing No. 200 (0.075 mm) + 2% to – 2 %

sieve
Bituminous material + 0.4 % to – 0.4 %
Temperature leaving mixer +6C–6C
Temperature delivered on road +6C–6C
When unsatisfactory results make it necessary, the Engineer may establish a new
job-mix formula and so notify the Contractor in writing. Should a change in sources of
material be proposed, a new job-mix formula shall be established before new material
is used.
Plant mixed material will be tested after blending or mixing at plant or prior to final
incorporation in the work.
2) Coarse Aggregate
Coarse aggregate (retained on the 2.36 mm sieve) shall consist of clean, tough,
durable fragments free from an excess of flat, elongated, soft or disintegrated pieces
and free from stone coated with dirt or other objectionable material. Percentage of
wear when tested according to AASHTO T 96, shall be as required below.
- For use in asphalt base course : not more than 50 %
- For use in asphalt surface course : not more than 40 %
Sodium sulphate soundness loss shall not exceed 9 percent and magnesium
sulphate soundness loss shall not exceed 12 percent. When crushed gravel is used,
not less than 50 percent of particles by weight retained on 4.75 mm sieve shall have
at least one fractured face.
3) Fine Aggregate
Fine aggregate (passing No.8 sieve) shall have general characteristics and
soundness in accordance with AASHTO M 29.
4) Filler
Mineral filler, when required, shall consist of limestone dust, portland cement or other
non plastic mineral matter from sources approved by the Engineer. Mineral filler shall
be dry, free flowing, free from lumps and other objectionable material and when
tested by means of laboratory sieve, shall meet the following gradation requirements.

No. 30 (0.600) 100 %
No. 100 (0.150) 95 – 100 %
No. 200 (0.075) 65 – 100 %
5) Asphalt Cement
Asphalt Cement shall be of penetration grade 60–70 and shall conform with the
requirements of AASHTO M 20.

(c) Equipment
Unless specified elsewhere or approved by the Engineer, equipment used in the work for
asphalt concrete pavements shall comply with the following requirements.
1) Bituminous Mixing Plant
Sufficient storage space shall be provided for each size of aggregate. Different
aggregate sizes shall be kept separated until they have been delivered to cold
aggregate feeding system. Storage yard shall be maintained neat and orderly and
separate bins shall be readily accessible for sampling.
Plant used for preparation of bituminous mixtures shall conform to all requirements
under a) except that scale requirements shall apply only where weight proportioning
is used. In addition, batch mixing plants shall conform to the requirements under b)
and continuous mixing plants shall conform to the requirements under c).
a) Requirements for All Plant

Mixing plants shall be of sufficient capacity and coordinated to adequately handle
bituminous construction.
i) Plant Scales
Scales shall be accurate to 0.5 percent of any load that may be required and
sensitive to one half the minimum gradation, which shall not be greater than 3.5
kg. Poises shall be designed to be locked in any position to prevent
unauthorized change of position. In lieu of plant and truck scales, the Contractor
shall provide an approved automatic printer system which will print weight of
material delivered, provided the system is used in conjunction with an approved
automatic batching and mixing control system. Such weights shall be evidenced
by a weight ticket for each load. Public weighing facilities shall be used if tested
and sealed by local authority, subject to approval by the Engineer of the
weighing procedures.
ii) Equipment for Preparation of Bituminous Material

Tanks for storage of bituminous material shall be equipped to heat and hold
material at the required temperatures. Heating shall be accomplished by steam
coils, electricity, or other approved means so that no flame shall be in contact
with tank. Circulating system for bituminous material shall be designed to
ensure proper and continuous circulation during operating period. Provision
shall be made for measuring and sampling storage tanks.
iii) Feeder for Drier

Plant shall be provided with accurate mechanical means for uniformly feeding
aggregates into drier so that uniform production and uniform temperature will be
obtained.
iv) Drier
Plant shall include a drier or driers which continuously agitate aggregates during
heating and drying process. For cold-type bituminous mix, equipment for
mechanical cooling of dried aggregate to the temperature prescribed for cold
mixtures shall be provided, if required, and shall be capable of supplying
prepared material for mixer to operate at full capacity.
v) Screens
Plant screens, capable of screening all aggregates to the specified sizes and
proportions and having normal capacities in excess of full capacity of mixer,
shall be provided.
vi) Bins
Plant shall include storage bins of sufficient capacity to supply mixer when it is
operating at full capacity. Bins shall be divided into at least 3 compartments and
shall be arranged to ensure separate and adequate storage of appropriate
fractions of mineral aggregates.

Separate dry storage shall be provided for filler or hydrated lime when used the
plant shall be equipped to feed such material into mixer or weighing hopper.
Each bin shall be provided with overflow pipes of such size and at such location
as to prevent backing up of material into other compartments or bins. Each
compartment shall be provided with its individual outlet gate, constructed so that
when closed there shall be no leakage. Gates shall cut off quickly and
completely. Bins shall be so constructed that samples can be readily obtained.
Bins shall be equipped with adequate tell-tale devices to indicate the position of
aggregates in the bins at lower quarter points.
vii) Bituminous Control Unit

Satisfactory means, either by weighing or metering, shall be provided to obtain
proper amount of bituminous material in the mix within the tolerance specified.
Means shall be provided for checking quantity or rate of flow of bituminous
material into mixer.
viii) Thermometric Equipment

An armored thermometer of adequate range in temperature reading shall be
fixed in the bituminous feed line at a suitable location near charging valve at
mixer unit. Plant shall also be equipped with either an approved dia-scale,
mercury-actuated thermometer, an electric pyrometer, or other approved
thermometric instrument so placed at discharge chute of drier as to register
automatically or indicate temperature of the heated aggregates. The Engineer
may require replacement of any thermometer by an approved temperature-
recording apparatus for better regulation of temperature of aggregates.
ix) Dust Collector

Plant shall be equipped with a dust collector discharging to waste or returning
uniformly to hot elevator all or any part of material collected as directed, without
escape of objectionable dust into atmosphere.
x) Truck Scale
Bituminous mixture shall be weighed on approved scales furnished by the
Contractor or on public scales at the Contractor’s expense. Such scales shall be
inspected and sealed as often as the Engineer deems necessary to ensure their
accuracy.
xi) Safety Requirements

Adequate and safe stairways to mixer platform and sampling points shall be
provided and guarded ladders to other plant units shall be placed at all points
where accessibility to plant operations is required. Accessibility to the top of
truck bodies shall be provided by a platform or other suitable device to enable
the Engineer to obtain sampling and mixture temperature data. A hoist or pulley
system shall be provided to raise scale calibration equipment, sampling
equipment and other similar equipment from the ground to mixer platform and
return. All gears, pulleys, chains, sprockets and other dangerous moving parts
shall be thoroughly guarded and protected. Ample and unobstructed space shall
be provided on mixing platform. A clear and unobstructed passage shall be
maintained at all times in and around truck loading area. This area shall be kept
free from drippings from mixing platform.
b) Requirements for Batching Plants

i) Weigh Box or Hopper
Equipment shall include a means for accurately weighing each size of
aggregate in a weigh box or hopper suspended on scales and of ample size to
hold a full batch without hand raking or running over. Gate shall close tightly so
that no material is allowed to leak into mixer while a batch is being weighed.

ii) Bituminous Control

Equipment used to measure bituminous material shall be accurate to plus or
minus 0.5 percent of any load that may be required and be sensitive to one half
the minimum gradation, which shall be not greater than 2 kg. Bituminous
material bucket shall be a non-tilting type with a loose sheet metal cover.
Length of discharge opening or spray bar shall be not less than ¾ length of the
mixer and it shall discharge directly into mixer in the manner specified below.
Bituminous material bucket, its discharge valve or valves, and spray bar shall be
adequately heated. Steam jackets, if used, shall be efficiently drained and all
connections shall be so constructed that they will not interfere with the efficient
operation of bituminous scales.
Capacity of bituminous material bucket shall be at least 15 percent in excess of

weight of bituminous material required in any batch. Plant shall have an
adequately heated quick-acting, non-drip, charging valve located directly over
bituminous material bucket. Indicator dial shall have a capacity of at least 15
percent in excess of quantity of bituminous material used in a batch. Controls
shall be constructed so that they may be locked at any dial setting and will
automatically reset to that reading after addition of bituminous material to each
batch. Dial shall be in full view of mixer operator.
Flow of bituminous material shall be automatically controlled so that it will begin

when dry mixing period is over. All of bituminous material required for one batch
shall be discharged in not more than 15 seconds after flow has started. Size and
spacing of spray bar opening shall provide a uniform application of bituminous
material the full length of mixer. Section of the bituminous line between charging
valve and spray bar shall be provided with a valve and outlet for checking meter
when a metering device is substituted for a bituminous material bucket.
iii) Mixer
Batch mixer shall be an approved type capable of producing a uniform mixture
within job-mix tolerance. If not enclosed, mixer box shall be equipped with a
dust hood to prevent loss of dust. Clearance of blades from all fixed and moving
parts shall not exceed 2.5 cm unless maximum diameter of aggregate in mix
exceeds 3.0 cm, in which case clearance shall not exceed 3.8 cm.
iv) Control of Mixing Time

Mixer shall be equipped with an accurate time lock to control operations of a
complete mixing cycle. It shall lock weigh box gate after charging of mixer until
closing of mixer gate at completion of cycle. It shall lock bituminous material
bucket throughout dry wet mixing periods. Dry mixing period is defined as
interval of time between opening of weigh box gate and start of introduction of
bituminous material. Wet mixing period is the interval of time between start of
introduction of bituminous material and opening of mixer gate. Control of timing
shall be flexible and capable of being set at intervals of 5 seconds or less
throughout a total cycle of up to 3 minutes. A mechanical batch counter shall be
installed as a part of timing device and shall be so designed as to register only
completely mixed batches.
Setting of time intervals shall be performed in presence and at direction of the

Engineer who will then lock the case covering timing device until such time as a
change is to be made in timing periods.
c) Requirements for Continuous Mixing Plants

i) Aggregate Proportioning
Plant shall include means for accurately proportioning each size aggregate.
Plant shall have a feeder mounted under each compartment bin. Each
compartment bin shall have an accurately controlled individual gate to form an
orifice for volumetrically measuring the material drawn from each compartment.

Feeding orifice shall be rectangular with one dimension adjustable by positive

mechanical means provided with a lock. Indicators shall be provided for each
gate to show the respective gate opening in inches or centimeters.
ii) Weight Calibration of Aggregate Feed

Plant shall include a means of calibration of gate openings by weighing test
samples. Provision shall be made so that materials fed out of individual orifices
may be bypassed to individual test boxes. Plant shall be equipped to
conveniently handle individual test samples weghing not less than 75 kg.
Accurate scales shall be provided by the Contractor to weigh such test samples.
iii) Synchronization of Aggregate Feed and Bituminous Material Feed

Satisfactory means shall be provided to afford positive interlocking control
between flow of aggregate from bins and flow of bituminous material from meter
or other proportioning device. This control shall be accomplished by interlocking
mechanical means or by any other positive method satisfactory to the Engineer.
iv) Mixer
Plant shall include a continuous mixer of an approved type, adequately heated
and capable of producing a uniform mixture within job-mix tolerances. It shall be
equipped with a discharge hopper with dump gates which will permit rapid and
complete discharge of mixture. Paddles shall be adjustable for angular position
on shafts and reversible to retard flow of the mix.
Mixer shall have a manufacturer’s plate giving net volumetric contents of mixer
at several heights inscribed on a permanent gauge. Charts or other approved
means shall be provided showing rate of feed of aggregate per minute at plant
operating speed.
2) Hauling Equipment
Trucks used for hauling bituminous mixtures shall have tight, clean, smooth, metal
beds which have been thinly coated with approved material to prevent mixture from
adhering to beds. Each truck shall have a cover of canvas or other suitable material
of such size as to protect mixture from weather. When necessary, so that mixture will
be delivered on road at the specified temperature, truck beds shall be insulated and
covers shall be securely fastened. The Engineer will determine the tare weight for
each vehicle used in hauling mixtures to road, as often as necessary, but in no case
less than once during each work shift.
3) Bituminous Pavers
Bituminous pavers shall be self-contained, power-propelled units, provided with an
adjustable activated screed or strike-off assembly, heated if necessary and capable
of spreading and finishing courses of bituminous plant mix material in lane widths
applicable to the specified typical section and thicknesses shown on the Drawings.
Pavers used for shoulders and similar construction shall be capable of spreading and
finishing courses of bituminous plant mix material in widths shown on the Drawings.
Paver shall be equipped with a receiving hopper having sufficient capacity for uniform
spreading operation. Hopper shall be equipped with a distribution system to place
mixture uniformly in front of screed.
Pavers shall employ mechanical devices such as equalizing runners, straightedge

runners, evener arms, or other compensating devices, to maintain trueness of grade
and to confine edges of pavement to true lines without use of stationary side forms.
Equipment shall include blending or joint leveling devices for smoothing and adjusting
longitudinal joints between lanes. Screed or strike-off assembly shall effectively
produce a finished surface of the required evenness and texture without tearing,
shoving or gouging the mixture. When laying mixtures, paver shall be capable of
being operated at forward speeds consistent with satisfactory laying of mixture.

The Contractor shall furnish all necessary small tools and provide means for keeping
them free from accumulation of bituminous material. The Contractor shall provide and
have ready for use at all times enough tarpaulins or covers, as may be necessary, for
use in any emergency such as rain, chilling wind, or unavoidable delay, for purpose of
covering or protecting any material that may have been dumped, or spread but not
compacted.
4) Rollers
Rollers shall be of steel wheel and pneumatic tire types and shall be in good
condition, capable of reversing without back-lash and shall be operated at speeds
slow enough to minimize displacement of bituminous mixture. Number and weight of
rollers shall be sufficient to compact mixture to the required density while it is still in a
workable condition. Use of equipment which results in excessive crushing of
aggregate shall not be permitted.
5) Power Broom and Blower

A rotary power broom and power blowers shall be provided and maintained in good
working order for any cleaning of any of surface to be treated with bituminous
material.
(d) Construction
1) Equipment
Mixing plant and all equipment used for hauling and laying bituminous mixture shall
comply with the requirements of (c) Equipment of this Clause.
2) Preparation of Bituminous Material

Bituminous material shall be heated to the specified temperature in a manner that will
avoid local overheating and provide a continuous supply of bituminous material to
mixer at a uniform temperature at all times. Maximum temperature of asphalt cement
delivered to mixer shall not be more than 2 0 C above the temperature as specified in
(c) hereof for aggregate. Asphalt cement shall not be used while it is foaming nor
0
shall it be heated above 175 C at any time.
3) Preparation of Aggregates
Aggregates for mixture shall be dried and heated to the required temperature. Flames
used for drying and heating shall be properly adjusted to avoid damage to aggregate
and to avoid soot on aggregate. Immediately after heating and drying, aggregates
shall be screened into three or more fractions as specified and conveyed into
separate compartments ready for batching and mixing with bituminous material.
When asphalt cement is used, temperature of aggregates as introduced into mixer,
including the tolerance permitted by job-mix formula, shall not exceed that at which
asphalt cement has a Saybolt Furol viscosity of 100 seconds, determined by
AASHTO T 72. It shall not be lower than is required to obtain complete coating and
uniform distribution of aggregate particles and to provide a mixture of satisfactory
workability.
4) Mixing
Dried aggregate shall be combined in mixer in amount of each fraction of aggregates
required to meet job-mix formula. Bituminous material shall be measured or gauged
and introduced into mixer in amount specified by job-mix formula.
After the required amounts of aggregate and bituminous material have been
introduced into mixer, unless otherwise specified, materials shall be mixed until a
complete and uniform coating of particles and a thorough distribution of bituminous
material throughout aggregate is secured. Wet mixing time will be determined by the
Engineer for each plant and for each type of aggregate used.
For plant mix bituminous pavement, mixture shall be produced as closely as
practicable to the lowest temperature that will produce a workable mix within the
specified temperature range.

5) Transporting, Spreading and Finishing

Mixture shall be transported from mixing plant to point of use in vehicles conforming
to the requirements of section (3) of this Clause. No loads shall be sent out so late in
the day as to prevent completion of spreading and compaction of mixture during
daylight hours unless with the Engineer’s approval and satisfactory illumination is
provided. Each vehicle shall be weighed after each loading at mixer and a record
shall be kept of gross weight, tare, net weight, and time of day of each load operation.
Mixture shall be delivered at a temperature between 1250 C and 1600 C for asphalt
mix.
Mixture shall be laid upon an approved surface, spread and struck off to the grade
and elevation established. Bituminous pavers shall be used to distribute mixture
either over the entire width or over such partial width as may be practical.
Longitudinal joint in one layer shall be offset from that in layer immediately below by
approximately 15 cm, however, the joint in the top layer shall be at center line of
pavement if roadway comprises two lanes of width, or not lane lines if roadway is
more than 2 lanes in width, unless otherwise directed.
On areas where irregularities or unavoidable obstacles make use of mechanical

spread and finishing equipment impracticable, mixture shall be spread, raked and
luted by hand tools. For such areas mixture shall be dumped, spread and screeded to
give the required compacted thickness. When production of mixture can be
maintained and when practical, pavers shall be used in echelon to place the surface
course in adjacent lanes.
The Contractor shall carry out such tests as are necessary to determine the
uncompacted thickness of mixture to be laid for compaction to conform to the
required finished depths. Uncompacted material immediately behind paver shall then
be measured at frequent intervals and adjustments made to ensure comformity with
nominal depths.
6) Compaction
After bituminous mixture has been spread, struck off and surface irregularities
adjusted, it shall be thoroughly and uniformly compacted by rolling. Specific gravity of
consolidated mixture, as determined by AASHTO T 230 shall be not less than 95
percent of specific gravity of laboratory compacted specimens composed of the same
materials in like proportion.
Laboratory specimens shall consist of cylinders of mixture compacted by procedures

of AASHTO T 167. For aggregates containing particles with diameters over 1 inch, 6
inch by 6 inch cylinders shall be used and procedures of T 167 modified to employ 10
repetitions of a molding load of 85 kg per square cm with no appreciable holding time
after each application of full load.
Surface shall be rolled when mixture is in proper condition and when rolling does not
cause undue displacement, cracking or shoving.
Number, weight and type of rollers furnished shall be sufficient to obtain the required
compaction while mixture is in a workable condition. Sequence of rolling operations
and selection of roller types shall provide the specified pavement density.
Unless otherwise directed, rolling shall begin at sides and proceed longitudinal
parallel to road center line, each trip overlapping one-half roller width, gradually
progressing to crown of road.
When paving in echelon or abutting a previously placed lane, longitudinal joint should
be rolled first followed by regular rolling procedure. On super elevated curves rolling
shall begin at low side and progress to high side by overlapping of longitudinal trips
parallel to the center line. Rollers shall move at a slow but uniform speed with drive

roll or wheels nearest paver. Rolling shall be continued until all roller marks are
eliminated and at least the minimum density indicated above has been attained. Care
shall be exercised in rolling not to displace the line and grade of edges of bituminous
mixture. To prevent adhesion of mixture to rollers, wheels shall be kept properly
moistened with water or water mixed with very small quantities of detergent or other
approved material. Excess liquid will not be permitted. Along forms, headers, walls
and other places not accessible to rollers, mixture shall be thoroughly compacted with
hot hand tampers, smoothing irons or with mechanical tampers. On depressed areas,
a trench roller may be used or cleated compression strips may be used under roller to
transmit compression to the depressed area. Any mixture that becomes loose and
broken, mixed with dirt, or is in any way defective shall be removed and replaced with
fresh hot mixture, which shall be compacted to conform to the surrounding area. Any
area showing an excess or deficiency of bituminous material shall be removed and
replaced. No traffic shall be permitted on the final course in less than 12 hours after
completion unless authorized by the Engineer.
7) Joints, Trimming Edges and Clean-up

Placing of bituminous paving shall be as continuous as possible. Rollers shall not
pass over the unprotected end of a freshly laid mixture unless authorized by the
Engineer. Transverse joints shall be formed by cutting back on the previous run to
expose the full depth of course. Where pavers are not used in echelon to place the
surface course in adjacent lanes and where the edges of previously laid wearing
course are, in opinion of the Engineer, in such condition that quality of completed joint
shall be effected, longitudinal joints shall be trimmed to a vertical face and to a neat
line. Exposed edges of the completed mat shall be cut off true to the required lines.
Material trimmed from edges and any other discarded or rejected bituminous mixture
shall be removed from roadway and disposed of by the Contractor as instructed by
the Engineer. When directed by the Engineer, a brush coat of bituminous material
shall be used on contact surfaces of joints just before additional mixture is placed
against previously rolled material.
8) Surface Tolerance
Variation of surface from testing edge of a straight edge between any two contacts
with surface shall not exceed allowable tolerances stipulated below. For base course,
the test for conformity shall be made immediately after initial rolling and variation shall
be corrected by removing or adding materials as may be necessary.
Rolling shall then be continued as specified. Removal or addition of material to

surface course will not be permitted after rolling has commenced. Work on surface
course shall be carefully controlled to ensure that material as laid will conform with
allowable tolerances stipulated below.
Following tolerances for pavement construction after completion of the work shall not
be exceeded. The Engineer will waive certain requirements and apply other
tolerances as necessary and appropriate for the case at hand.
Alignment (horizontal control) + 20 mm to – 20 mm

Profile and Elevations (vertical control)
- Top of compacted asphalt treated base course + 15 mm to – 15 mm
- Top of compacted asphalt concrete surface course + 10 mm to – 10 mm
When a 3 meter straight edge is laid on surface parallel to and perpendicular to

center line, surface variation from lower edge of straight edge shall not exceed:
- Compacted asphalt treated base course 6 mm

- Compacted asphalt concrete surface course 4 mm
9) Overlay and Regulating

Where the Contract requires overlay of an existing pavement this shall be carried out
strictly in accordance with instructions of the Engineer. The Engineer will instruct that

a layer of the pavement shall be laid over a partial over width or to a restricted length
if this is necessary to facilitate the regulation of levels.
10) Frequency of Tests

Control of bituminous mixture and acceptance, sampling and testing shall be carried
out in accordance with instructions of the Engineer.
(6) Concrete Pavement Work
(a) General
Work shall consist of sub-base and concrete slab. Sub-base shall be described in Sub-
Clause 2.35(3) “Sub-Base Work” and concrete slab shall be described in Clause 2.14
“CONCRETE WORKS”.
(b) Material
Concrete for slab shall be Class “C” and reinforcing bar shall comply with this
Specification and shall be positioned as shown on the Drawings.
(c) Construction
Construction requirements shall conform to Clause 2.14 “CONCRETE WORKS” for
concrete structures and Sub-Clause 2.35(3) “Sub-Base Work” for sub-base.
Construction joints shall be located by 10m pitch in longitudinal and cross directions. Vinyl
sheets shall be sat on sub-base to prevent water from leaking. Concrete curbs shall be
placed at end of pavement.
(7) Interlocking Pavement Work
(a) General
Work shall consist of preparation of subgrade with compaction, furnishing and laying of
sand bedding and interlocking concrete blocks to the lines, grade and locations shown on
the Drawings or instructed by the Engineer.
(b) Material
Sand for bed shall be uniformly graded, hard, dense, durable and shall be free from
deleterious materials such as clay, organic matters, etc. Silt content shall be less than 3%
and percentage passing a 4.75 mm sieve shall be 95-100%.
Sand filler shall be hard, durable, free of deleterious materials with silt content less than
10% and percentage passing a 2.36 mm sieve shall be 95-100%.
Interlocking blocks shall be 8x10.5x21 cm colored and in accordance with the

requirements of SII.
(c) Construction
Interlocking blocks shall be placed on a 10 cm compacted screeded sand bed to the
nominated laying pattern and shall be placed to achieve gaps nominally 2 to 4 mm wide
between adjacent blocks such that all joints are correctly aligned.
As soon as practical after laying interlocking blocks, sand for filling the joints shall be
spread over pavement. Filling sand shall be broomed to fill joints until all the joints are full
with sand. After sand filler is spread, pavement shall be compacted to achieve
consolidation on sand bedding and brought to design levels and profiles by not less than
two or three passes of a suitable plate vibrator. Compaction shall continue until lipping
has been eliminated between adjoining blocks.
All work within one meter of laying face must be left fully compacted at completion of each
day's laying. Any blocks which are structurally damaged during compaction shall be
immediately removed and replaced at the Contractor's expense.

Pavement will be measured as the actual number of square meters placed on the site and
approved by the Engineer and will be calculated as the actual area of the finished asphalt
surface course as shown on the Drawings or instructed by the Engineer.
The quantities determined, as provided above, will be paid for at the Contract unit price per
unit of measurement for the pay items listed below, completed in place and accepted by the
Engineer. The price and payment will be full compensation for all the work of this Clause,
including all the work described in this Specification.
235(1) Asphalt Pavement square meter

235(2) Concrete Pavement square meter
235(3) Interlocking Pavement square meter

2.36 PRECAST CONCRETE PATHWAY
(1) Description
This work shall consist of fabricating and installing precast concrete pathway plates between
and along depot yard tracks in accordance with the Drawings or as directed by the Engineer.
(2) Materials
Concrete used for precast concrete pathway plate shall be Class "B" in accordance with
Clause 2.14 "CONCRETE WORKS" of this Specification. Reinforcing bar shall comply with
PBI U-24 and U-39 and shall be positioned as shown on the Drawings and shall comply with
Clause 2.15 "REINFORCING BAR" of this Specification.
Sand used for bedding and jointing shall conform to the requirements of Sub-Clause 2.35 (7)
"Interlocking Pavement Work". Precast concrete pathway plates used shall conform to the
requirements as shown on the Drawings and surface shall be finished also as shown on the
Drawings.
(3) Construction
The Contractor shall submit Shop Drawings and fabrication details for pathway plate to the
Engineer for approval prior to commencement of fabrication.
The quantity to be measured for payment shall be the actual number of square meters
constructed concrete pathway plates, completed in place, furnished, installed pathway plates
and sand for bed and accepted by the Engineer in accordance with the Drawings.
The quantities determined, as provided above, will be paid for at the Contract price per unit of
measurement for the pay item listed below The payment for precast concrete pathway plate
shall be full compensation for construction of the concrete pathway plate, including furnishing
concrete, reinforcing bar, sand for bed, joints and all labor, tools, equipment, hauling and all
other incidentals necessary to complete the work as shown on the Drawings and described in
this Specification.
236 Precast Concrete Pathway square meter

2.37 CONCRETE CURB
(1) Description
This work shall consist of constructing concrete curbs of various shapes, including base and
foundation at locations as shown on the Drawings and instructed by the Engineer.
(2) Materials
Curbs shall be non-reinforced and precast concrete. Concrete for precast curbs shall be
Class "D" and any base and foundation shall be of concrete Class "E" or blinding stone as
shown on the Drawings. All concrete shall meet the requirements of Clause 2.14
"CONCRETE WORKS" of this Specification.
(3) Construction
Construction of curbs shall conform to Clause 2.14 "CONCRETE WORKS" for concrete
structures. Before placing the exposed section of curb all lines and levels shall be approved
by the Engineer.
Precast curbs shall be set on a concrete base with an adjusting mortar bed for Type A and on
a rubble stone base with an adjusting mortar bed for Type B as shown on the Drawings.
When at a driveway entrance crossing a transition section of curb is indicated on the

Drawings or ordered by the Engineer, the Contractor shall furnish concrete curb with the
required modification.
Precast curbs shall be cast in mortar-tight metal molds. Molds shall be sufficiently rigid to
prevent any deformation of curb. Precast curbs shall be removed from molds as soon as
possible and shall be kept damp for a period of at least 7 days. During this period they shall
be protected from sun and from wind. Any curbs that show cracking or soft or damaged
corners or surfaces shall be rejected.
Curbs shall be carefully handled, transported and off-loaded so as to avoid damage. Any
curbs which become chipped, marred or cracked before or during placing shall be rejected.
Bedding and joint mortar for precast curbs shall comply with the requirements of Clause 2.14
"CONCRETE WORKS". Precast curb units shall not be more than 80 cm long. Special units
shall be cast for radii of less than 5.0 m.
Tolerance for dimensions of curbs shall be±10 mm. Flatness of surfaces as measured using
a 3 meter straight edge laid on top or face of curb or on surface of gutters shall not vary more
than 3 mm from edge of straight edge, except at grade changes or curves. On completion of
curb installation the Contractor shall backfill and tidy up the work to satisfaction of the
Engineer.
The quantity to be measured for payment shall be the actual number of linear meters of curbs
measured along the face of curb. No additional allowance will be made for curbs constructed
on curves. No deduction in length will be made for drainage structures installed in the curb
section but payment for these structures will be deemed to be full compensation for finishing
the structures to the same standard and tolerance as the adjacent curb and for providing
expansion joints between the units and the adjacent curbs.

compensation for the work of precast concrete curbs as shown on the Drawings, including
concrete, excavation in any material, provision of base or foundation of the various types as
shown on the Drawings or instructed by the Engineer, including adjusting bedding mortar
between base and precast curb, jointing of precast curbs, backfill and disposal of all surplus
material and all other materials, Iabor or equipment necessary to complete the work as
described in this Specification.
Pay Item No, and Name Unit of Measurement
237 (1) Concrete Curb Type A linear meter

237 (2) Concrete Curb Type B linear meter

2.38 CONCRETE FENCE
(1) Description
This work shall consist of furnishing and installing specified type of precast concrete fence at
locations indicated on the Drawings or as directed by the Engineer. The work shall include all
required concrete foundations, posts, precast plates, fixtures and fastenings, beams and
attachments as well as aligning, fabricating, erecting and all necessary to complete the work
as described in the Drawings and this Specification.
(2) Materials
Concrete to be used for foundation of all specified types of fence and precast concrete
columns and plates for concrete fence shall be concrete Class "D" as designated in Clause
2.14 "CONCRETE WORKS" of this Specification.
(3) Construction
(a) Fencing shall be constructed to the lines and grades and in the exact positions shown on
the Drawings or as directed by the Engineer.
(b) After setting of concrete foundations, holes shall be backfilled with the excavated
material. Backfill material shall be thoroughly compacted to the same degree of
compaction as the adjacent soil as a minimum.
concrete fence completed and accepted by the Engineer in accordance with the Drawings
compensation for furnishing all materials, Iabor and equipment necessary for construction of
concrete fences and for other incidentals necessary to complete the work, including
excavation, compaction, backfill, cobble stone, concrete, reinforcing bar in accordance with
the Drawings and this Specification and as directed by the Engineer.
238(1) Concrete Fence Type A linear meter

238(2) Concrete Fence Type B linear meter

2.39 STEEL FENCE
(1) Description
This work shall consist of furnishing and installing specified type of steel fence at locations
indicated on the Drawings or as directed by the Engineer. The work shall include all required
concrete foundations, posts, nets, steel plates and angles, fixtures and fastenings, beams and
attachments as well as aligning, fabricating, erecting and painting of galvanized steel fence
and all necessary to complete the work as described in the Drawings and this Specification.
(2) Materials
Concrete to be used for foundation of all specified types of fence shall be concrete Class "D"
as designated in Clause 2.14 "CONCRETE WORKS" of this Specification. Steel plate and
angle shall conform to SS 400 as specified in JIS G 3 101 (Rolled Steel for General
Structure). Gauge steel to be used for post shall conform to SSC 4CO as specified In JIS G
3350 (Light Gauge Steels for General Structure). Steel netting shall conform to Z-G3 as
specified in JIS G 3552 (Chain Link Wire Netting). Bolts and nuts shall conform to the
requirements designated in JIS B 1 180 and JIS B 1 181 respectively. Steel posts shall be
101 mm diameter and 3.2 mm wall thickness. Paint shall conform to the requirements as
specified in Clause 2.22 "STEEL STRUCTURE WORKS" in this Specification.
(3) Construction
from dirt, oil, grease and other foreign matter. All nuts and caps on steel fence shall be
spot welded.
(b) Fencing shall be constructed to the lines and grades and in the exact positions shown on
the Drawings or as directed by the Engineer.
(c) After setting of concrete foundations, holes shall be backfilled with the excavated
(d) Steel not galvanized shall be painted in accordance with the requirements of Clause 2.22
"STEEL STRUCTURE WORKS".
The quantity to be measured for payment shall be the actual number of linear meters of steel
fence, completed and accepted by the Engineer in accordance with the Drawings and this
Specification.
steel fences and for other incidentals necessary to complete the work including excavation,
compaction, backfill, cobble stone, concrete, reinforcing bar, spot welding, galvanizing and
painting in accordance with the Drawings and this Specification and as directed by the
Engineer.

239(1) Steel Fence Type A linear meter
239(2) Steel Fence Type B linear meter

2.40 ENTRANCE GATE
(1) Description
This work shall consist of furnishing and installing specified type of entrance gate at locations
indicated on the Drawings or as directed by the Engineer. Work shall include all required
concrete foundations, posts, nets, steel plates, angles, fixtures and fastenings, beams and
attachments as well as aligning, fabricating, erecting and painting of galvanized entrance gate
and all necessary to complete the work as described in the Drawings and this Specification.
(2) Materials
Concrete to be used for foundation of all specified types of fence shall be concrete Class "D"
as designated in Clause 2.14 "CONCRETE WORKS" of this Specification. Steel plate and
angle shall conform to SS 400 as specified in JIS G 3 101 (Rolled Steel for General
Structure). Gauge steel to be used for post shall conform to SSC 4CO as specified In JIS G
3350 (Light Gauge Steels for General Structure). Steel netting shall conform to Z-G3 as
specified in JIS G 3552 (Chain Link Wire Netting). Bolts and nuts shall conform to the
requirements designated in JIS B 1180 and JIS B 1181 respectively. Steel posts shall be 101
mm diameter and 3.2 mm wall thickness. Paint shall conform to the requirements as specified
in Clause 2.22 "STEEL STRUCTURE WORKS” in this Specification.
(3) Construction
from dirt, oil, grease and other foreign matter. All nuts and caps on entrance gate shall be
spot welded.
(b) After setting of concrete foundations, holes shall be backfilled with the excavated
(c) Steel not galvanized shall be painted in accordance with the requirements of Clause 2.22
"STEEL STRUCTURE WORKS".
(d) Entrance gate shall be installed at the exact positions shown on the Drawings or as
directed by the Engineer. Gates shall be locked with approved locks.
The quantity to be measured for payment shall be the actual number of entrance gates of
respective types, completed and accepted by the Engineer in accordance with the Drawings
entrance gates and for other incidentals necessary to complete the work, including
excavation, compaction, backfill, cobble stone, concrete, reinforcing bar, spot welding,
galvanizing and painting in accordance with the Drawings and this Specification and as
directed by the Engineer.

240(1) Entrance Gate Type A each
240(2) Entrance Gate Type B each

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Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

SECTION 2 : CIVIL WORKS

2.00 GENERAL FOR CIVIL WORKS

(2) Scope of Work

(a) Contract Limits

(b) Installation and Modification Limits

(c) Works to be Coordinated

(3) Quality Assurance

(a) Contractor’s Responsibility

(b) Work Coordination with PT. KAI

(4) Survey and Design

Section 2 – Civil W orks Page 1 of 137

(7) Test Procedure

(a) Manufacturing Drawings

(b) Shop Drawings

(c) Material Test Reports

(d) Final As-Built Drawings

Section 2 – Civil W orks Page 2 of 137

(2) Scope of Work

(b) Major Structures for Demolition

Area and Section Structure Item

(a) Preliminary Activity

Section 2 – Civil W orks Page 3 of 137

(b) Demolition of Buildings

(c) Removal of Concrete or Reinforced Concrete Structures

(d) Removal of Masonry

(e) Removal of Pavements, Curbs, Gutters and Street Light Bases

(g) Removal of Fencing

(h) Removal of Steel Structures

Section 2 – Civil W orks Page 4 of 137

(i) Removal of Existing Platforms

(k) Disposal of Material

(4) Method of Measurement

Section 2 – Civil W orks Page 5 of 137

(5) Basis of Payment

Pay Item No. and Name Unit of Measurement

201 Demolition lump sum

Section 2 – Civil W orks Page 6 of 137

2.02 CLEANING AND GRUBBING

(2) Scope of Work

(b) Clearing and Grubbing and Tree Removal

(c) Topsoil Stripping

(d) Protection of Areas Designated to Remain

(e) Disposal of Cleared Material

Section 2 – Civil W orks Page 7 of 137

earthworks. No accumulation of debris shall remain on or adjacent to the Right-of-Way.

(f) Horizontal and Vertical Alignment

(3) Method of Measurement

(4) Basis of Payment

Pay Item No and Name Unit of Measurement

202 Clearing and Grubbing square meter

Section 2 – Civil W orks Page 8 of 137

(a) Common Excavation

(b) Structural Excavation

Structural Excavation shall be limited to excavation for foundation of concrete structures

(c) Structural Excavation with Ground Anchor

(2) Scope of Work

(a) Common Excavation

Where excavation reveals a combination of suitable and unsuitable materials, the