Section 132 Airfield Pavement

SECTION 132 AIRFIELD PAVEMENT
132.1 ABBREVIATION AND TERMINOLOGY
132.1.1 ABBREVIATION
The following abbreviations are used in this General Materials and

Workmanship Specification .
AASHTO : American Association of State Highway and

Transportation Officials
ACI : American Concrete Institute
ASTM : American Society for Testing and Materials Method and
Standards
BS : British Standards
CABC : Crushed Aggregate Base Course
CASB : Crushed Aggregate Sub Base
CBR : California Bearing Ratio
CS1 : Construction Standard CS1
CSBC : Cement Stabilised Base Course
DCP : Dynamic Cone Penetrometer
DLC : Dry Lean Concrete
DSR : Dynamic Shear Rheometer
EN : Euro Norm
EI : Elongation Index
FI : Flakiness Index
FOD : Foreign Object Damage
GMWS : General Materials and Workmanship Specification
IDD : In-situ Dry Density
ISO : International Organisation for Standardisation
ITFT : Indirect Tensile Fatigue Test
ITS : Indirect Tensile Strength
ITSM : Indirect Tensile Stiffness Modulus
LAA : Los Angeles Abrasion
LL : Liquid Limit
MABC : Marshall Asphalt Base Course
MAWC : Marshall Asphalt Wearing Course
MDD : Maximum Dry Density
MMDD : Maximum Modified Dry Density
OMC : Optimum Moisture Content
PAV : Pressurized Aging Vessel
PFA : Pulverised Fuel Ash
General Materials & Workmanship Specification 1/243 April 2019

Issue No. 6a, Volume 4 - Airfield Works
Section 132 – Airfield Pavement
PI : Plasticity Index
PMABC : Polymer Modified Marshall Asphalt Base Course
PMAWC : Polymer Modified Marshall Asphalt Wearing Course
PQC : Pavement Quality Concrete
PTS : Particular Technical Specification
RC : Relative Compaction
TAI : The Asphalt Institute
TFV : Ten per cent Fines Value
UV : Ultraviolet
WLC : Wet Lean Concrete
132.1.2 TERMINOLOGY
(a) Pavement courses forming the various pavement types are

designated as follows:
(i) Flexible pavement (Figure 132.1): Polymer Modified

Marshall Asphalt Wearing Course, Marshall Asphalt Base
Course, Primed Crushed Aggregate Base Course, Crushed
Aggregate Sub-Base;
(ii) Rigid pavement (Figure 132.2): Pavement Quality Concrete

and Dry Lean Concrete / Wet Lean Concrete; and
(iii) Block pavement (Figure 132.3): Block Paving including

bedding sand and geotextile interlayer, Cement Stabilised
Base Course, Crushed Aggregate Base Course and
Crushed Aggregate Sub-Base.
Figure 132.1 – Flexible Pavement
Polymer Modified Marshall Asphalt Wearing Course

Marshall Asphalt Base Course
Primed Crushed Aggregate Base Course
Crushed Aggregate Sub-Base
Subgrade
Figure 132.2 – Rigid Pavement
Pavement Quality Concrete

Dry Lean Concrete / Wet Lean Concrete
Subgrade

Figure 132.3 – Block Pavement
Block Paving including bedding sand and

geotextile interlayer
Cement Stabilised Base Course
Crushed Aggregate Base Course
Crushed Aggregate Sub-Base
Subgrade
(a) The term 'ex-pavement' shall mean 'from the completed pavement
layer'.
(b) The term modified proctor in relation to compaction testing shall

mean the determination of the Maximum Dry Density (MDD) in
accordance with BS 1377 : 1990 Part 4 Method 3.6 (Heavy
compaction - 4.5 kg hammer in CBR mould).
(c) The relative compaction (RC) shall be calculated from the

equation:
RC = IDD/MDD x 100%
Where IDD is the in-situ dry density and MDD is the maximum
dry density.
132.2 CRUSHED AGGREGATE SUB-BASE
132.2.1 GLOSSARY OF TERMS
132.2.1.1 Crushed aggregate sub-base
The sub-base shall consist of crushed aggregates constructed in one

or more layers on a prepared subgrade in accordance with this GMWS.
132.2.1.2 Type B and type C subgrade
Type B and Type C subgrade are earthwork materials which comply

with Sections 132.10.3.1 (b) and 132.10.3.1 (c) of this GMWS
respectively.
132.2.1.3 Marine Sand and Public Fill subgrade
Marine Sand (Types S1 and S2) and Public Fill subgrade are earthwork
materials used on the Third Runway System and comply with Sections
132.10.3 of this GMWS.

132.2.2 MATERIALS
132.2.2.1 Sub-base material
(a) Aggregate shall be produced by crushing material from sources

which have been reviewed without objection by the Project
Manager and shall consist of clean, sound, durable particles of
crushed rock substantially the same as the reference sample.
Gravel or crushed gravel shall not be permitted.
(b) Aggregate may be mixed or blended with fine sand, stone dust, or
other similar binding or filler materials produced from permitted
sources. The blended material must be uniform and shall comply
with the requirements of this GMWS.
(c) The combined material shall be capable of being compacted into

a dense and stable sub-base and shall be free from weathered
material, vegetable matter, lumps of clay, disintegrated or friable
matter and other deleterious substances.
(d) The sub-base material shall have the properties stated in Table
132.1.
Table 132.1: Properties of sub-base material
Property Requirement
Ten Percent Fines Value >120 kN
Plasticity Index Non-plastic
California Bearing Ratio >30%
Magnesium Sulphate Soundness <5% loss after 5 cycles
(e) The ex-pavement grading of the sub-base material shall be within

the limits shown in Table 132.2.

(f) The particle size distribution shall be determined in accordance
with the requirements of Table 132.2. Table 132.2 is the particle
size distribution to be achieved ex-pavement following
compaction. The Contractor shall determine the degree of
material breakdown following rolling and shall determine a
stockpile particle size distribution to suit.
Table 132.2: Ex-pavement particle size distribution for sub-base

material
BS Sieve Size Percentage by mass passing

(mm)
75 100
37.5 85-100
20 60-85
10 40-70
5.0 25-45
0.600 8-22
0.075 4-10
(g) The material shall be well graded from coarse to fine and shall not
vary between the lower third of the range on one sieve to the
upper third of the range on each adjacent sieve. The fraction of
the material that passes the 75 micron sieve shall not exceed 60%
of the fraction passing the 600 micron sieve.
132.2.2.2 Geogrid
Geogrid shall be manufactured from synthetic durable polymers, and

shall comply with the following requirements:
(a) Weight: greater than 0.3 kg/m2
(b) Tensile strength: 15 kN/m minimum
(c) Load at 2% strain
Transverse: greater than 12 kN/m
Longitudinal: greater than 7 kN/m
(d) UV susceptibility: greater than 90% strength retention after 25

years exposure to sunlight.
(e) The aperture size shall be between 20 mm and 40 mm.
(f) The rib shall be at least 0.8 mm thick at junctions.
(g) It shall be resistant to all chemicals normally found in pavement

construction and shall not be susceptible to biological attack.
(h) The geotextile shall be durable enough to maintain its integrity for
at least 50 years when installed.

132.2.2.3 Water
Water for use in sub-base layers shall be in accordance with the

following requirements:
(a) be tested and comply with the requirements of BS EN 1008:2002;
(b) be clean, free from harmful matter, and available in such

quantities as necessary to complete the Permanent Works to the
specified requirements;
(c) be protected from contamination by wind-blown dust or other

material; and
(d) not exceed the limits given in Table 132.3.
Table 132.3: Water quality standards
Criterion Permissible Limit

(ppm)
Chloride as NaCl 800
Sulphate as SO3 1,000
Alkali HCO3/CO3 1,000
Total Dissolved Solids 2,000
Suspended Solids 2,000

132.2.3 SUBMISSIONS
132.2.3.1 Particulars of aggregates
At least 30 days prior to scheduled construction of the trial area, the

Contractor shall submit to the Project Manager for review without
objection, a statement of the origin and method of extraction of all
aggregates proposed for the Permanent Works. The Contractor shall at
the same time provide evidence demonstrating that an adequate supply
of uniform material can be produced. The Contractor shall submit test
results showing that the material meets the specified requirements.
132.2.3.2 Representative samples of aggregate
At the same time as the particulars detailed in Section 132.3.1 of this

GMWS are submitted, a reference sample from each different
aggregate source, taken after tertiary crushing, shall be submitted to
the Project Manager for review without objection. The sample, which
shall be a minimum of two 50 kg samples, shall be accompanied by a
full petrological and mineralogical description to the requirements of
ASTM C295/C295M-12 (2012).
132.2.3.3 Particulars of the geogrid
(a) At least 30 days prior to scheduled commencement of the trial

area, the Contractor shall submit manufacturer's literature and
certificates for the geogrid to the Project Manager for review. They
shall show the manufacturer's name, the date and place of
manufacture and that the geogrid complies with the requirements
stated in this GMWS.
(b) The Contractor shall establish a Quality Control Point at this

juncture
132.2.3.4 Representative samples of geogrid
At the same time as the particulars of the geogrid are submitted, the
Contractor shall submit a representative sample of the geogrid to the
Project Manager for review.

132.2.3.5 Particulars of mixes for sub-base material and methods of
construction
The following particulars shall be submitted to the Project Manager for

review without objection at least 20 days prior to scheduled construction
of the trial area.
(a) the source and type of aggregates;
(b) target particle size distribution details in tabular and graphical form
for the sub-base in the stockpile and ex-pavement;
(c) details of each mixing plant proposed;
(d) details of methods of construction; and
(e) details of maximum dry density and optimum moisture content

conducted to either BS 1377 and/or BS 5835.
132.2.4 TRIALS
132.2.4.1 Trial areas
(a) The Contractor shall construct, for each sub-base material source
and on each subgrade type, a trial area of at least 300 m2.
(b) Trial areas shall be used to determine the adequacy of the

Contractor’s equipment to achieve the specified density and finish
requirements. It shall also be used to determine appropriate loose
material depths, placement methods and the relationship between
the number of compaction passes and resulting field density. A
placement and compaction methodology shall be established and
shall form the basis of the Compaction Procedure.
(c) Trial areas shall be carried out on completed underlying type B

and type C subgrade courses (and underlying General Fill
Material sub-base course if used because type B or type C
material is not available or permitted in Section 132.10.9(c)) and
marine sand and public fill subgrades that meet the requirements
of this GMWS with the materials and plant intended for use in
constructing the Permanent Works. The trial areas shall be
constructed in an area considered by the Project Manager to be
non-critical to airport operation and may form part of the
Permanent Works if accepted.
(d) The Contractor shall notify the Project Manager at least 48 hours
before construction of a trial area begins. Results of laboratory
compaction studies (where appropriate) shall be forwarded to the
Project Manager prior to the commencement of trials.
(e) The Project Manager shall be kept fully informed without delay
throughout the trial of any difficulties, anomalies or changes
identified and the consequences of these items.

132.2.4.2 Testing: trial area
(a) Ten in-situ density tests shall be carried out on each layer of sub-
base in the trial area. The tests shall be carried out in accordance
with Section 132.2.13.1(b) of this GMWS.
(b) Three samples of sub-base shall be taken from the trial area and
tested to determine the maximum dry density in accordance with
BS 1377 Part 4 1990 Method 3.6 or BS 5835. The highest and
lowest results shall be discarded and the average of the
remainder reported.
(c) The trial area shall be tested for thickness and level in accordance
with Section 132.2.12.1 of this GMWS.
(d) Two samples of sub-base material shall be taken from the trial
area after placing and compacting. One sample shall be tested for
particle size distribution in accordance with BS EN 933-1 2012
and the other shall be tested for soaked CBR in accordance with
BS 1377: Part 4: 1990, Section 7, Method 3. The CBR tests shall
be carried out with the specimen compacted to 100% modified
Proctor maximum dry density.
(i) Both ends of the sample shall be tested and both results
reported to the Project Manager for his assessment of
compliance; or
(ii) Both ends of the sample shall be tested and the average
value shall be greater than 30% CBR; or
(iii) The Contractor may decide whether to test only the top, or
both ends, of the sample in order to achieve 30% CBR on
either end of the sample.
(e) Any damage to the sub-base caused by taking samples shall be

repaired by the Contractor using a method which has been
reviewed without objection by the Project Manager.

132.2.4.3 Compliance criteria: trial area
The results of tests on the trial area shall comply with the following
requirements:
(a) The result of each in-situ density test shall be at least 100% of the
average maximum dry density determined from the three
laboratory compaction tests.
(b) The surface level shall comply with Section 132.2.11.1 of this
GMWS.
132.2.4.4 Non-compliance: trial area
(a) If the result of any test on the trial area does not comply with the
specified requirements for the trial area, particulars of proposed
changes to the materials, methods of production or methods of
construction shall be submitted to the Project Manager for review
without objection. Further trial areas shall be constructed until the
result of every test on the trial area complies with the specified
requirements for the trial area.
(b) If the CBR or particle size distribution do not comply with the
requirements of Tables 132.1 and 132.2 respectively then two
samples shall be taken from each lot within the trial area and
tested in accordance with Sections 132.2.14.1(b) and (c) of this
GMWS.
(c) If the result of any of the additional tests does not comply with the
specified requirements then the non-complying sub-base lot shall
be removed by the Contractor and replaced using fresh material
at the Contractor’s own cost.
(d) Trial areas which do not comply with the specified requirements
for the trial area shall be rejected and removed.
132.2.4.5 Commencement of sub-base placement
(a) Sub-base shall not be placed in the Permanent Works, other than
in a trial area, until the result of every test on the trial area
complies with the specified requirements for the trial area.
(b) On satisfactory completion of the trial area, and before placement

of the Permanent Works, the Contractor shall submit the
Compaction Procedure to the Project Manager for review without
objection. The Compaction Procedure shall form an integral part
of the Quality System.
(c) Sub-base material may not be placed in the Permanent Works

until all test results and the Compaction Procedure have been

132.2.4.6 Changes in materials and methods of construction
The materials, methods of production and methods of construction used

to produce a trial area which complies with the specified requirements
shall not be changed without the permission of the Project Manager.
132.2.4.7 Submission of test results
The Contractor shall provide production and field test summaries on an

on-going daily basis (or other agreed period) to monitor compliance and
trends in test results and submit these promptly to the Project Manager.
The format of the test summaries shall be agreed with the Project
Manager. The Contractor shall take appropriate action as required
(including raising non-conformance report etc.) to ensure compliance
with the GMWS.
132.2.5 STORAGE OF MATERIALS
(a) If the Contractor proposes to stockpile any sub-base materials,

the stockpiles shall be constructed in the manner and at locations
(b) The Contractor shall be responsible for ensuring the stockpile

pads are prepared so as to prevent contamination of the stockpile
material. As a minimum, prior to stockpiling of materials, the
storage sites shall be cleared, drained, levelled and surfaced with
at least 50 mm thickness of material of equal quality and type to
that being stockpiled.
(c) Material from different sources or with different particle size

distributions shall be stockpiled separately.
(d) Materials shall be stockpiled in such a manner as to avoid

segregation or contamination by foreign materials, and shall be
removed from stockpiles in such a manner as to maintain their
uniformity and avoid segregation. Where segregation is apparent,
the material shall be re-mixed before use.
(e) The surfacing layer shall not be disturbed until completion of the
Permanent Works at which time it shall be removed to spoil and
the area reinstated.

132.2.6 MIXING OF SUB-BASE MATERIAL
(a) The mixing plant shall be stationary and so designed and

constructed as to thoroughly mix constituent materials without
degradation of the aggregate. Mixers shall be designed, and
operated to produce uniform material. Each plant shall have
sufficient production capacity to meet the contract requirements.
The plant shall be equipped with feeding and metering devices,
which will add the various materials into the mixer in the specified
or required quantities.
(b) The separate size fractions of the coarse and fine aggregates, or
any combination thereof, and/or materials to be blended, shall be
proportioned by mass or by volume in such quantities that the
specified particle size distribution requirements will be met after
the sub-base has been placed and compacted. Water measured
by mass or volume shall be incorporated during the mixing
operation so that the moisture content of the material during
spreading and compaction shall be within the range specified.
Mixing operations shall produce satisfactory uniform blending.
Discharge into haulage vehicles shall be in a manner that will not
produce segregation.
132.2.7 PRELIMINARY WORK
132.2.7.1 Installation of utilities
(a) Pipes, cables, manholes, chambers, gullies and other utilities

below the sub-base shall be completed and fill material shall be
deposited and compacted in trenches before the total thickness of
pavement placed and compacted exceeds 225 mm. Openings to
manholes, chambers and gullies shall be protected by temporary
covers.
(b) Box-outs shall be formed in the sub-base for covers, frames and
other hardware.
(c) Where trenching occur through the first layer of sub-base, the line
of the trench including the area within 2 m either side of the trench
shall be proof rolled to the method of Sections 132.2.9 (b) to (i) of
this GMWS.

132.2.7.2 Preparation of underlying course
(a) The Contractor shall only place material on a subgrade that is

undamaged and is clean and free from foreign material. The
Contractor shall not place material until all the specified
requirements for the subgrade, at the time of placing, have been
met and the subgrade has been reviewed without objection by
the Project Manager.
(b) The subgrade shall be lightly watered prior to placement of sub-

base. Watering shall be controlled to minimise loss of moisture
from the sub-base and loss of fines from the surface of the
subgrade.
132.2.8 PLACING AND COMPACTING SUB-BASE
132.2.8.1 General
(a) Sub-base material shall be processed in a stationary mixing plant.

The sub-base material shall be thoroughly mixed with the
required amount of water. Water added during mixing shall be
sufficient such that during placing, spreading and compaction,
the moisture content is at the optimum established from the
Compaction Procedure.
(b) After the mixing is complete, the material shall be transported to,
and spread on, the underlying layer without delay. Storage of
mixed sub-base material in stockpiles will not be permitted. The
material shall be handled in a manner so as to prevent
segregation, contamination or degradation.
(c) Material contiguous with the sub-base shall be placed and

compacted (as specified in the appropriate section of this GMWS)
such that the level of the surface of the contiguous material is
never more than 150 mm below or above the surface level of the
compacted sub-base.
(d) Whenever possible, sub-base placement shall begin along the

centre line of crowned sections or on the high side of pavements
with a one-way slope.

132.2.8.2 Placing sub-base material
(a) The sub-base course shall be constructed in one or more layers.

Any layer shall be not less than 100 mm or more than 225 mm
compacted thickness. Layers of unequal thickness shall be laid
with the thinnest uppermost. The initial layer of sub-base shall be
a uniform layer of not less than 150 mm compacted thicknesses.
(b) The surface of each layer shall be kept free of deleterious matter
and debris.
(c) Material from different sources shall be laid in discrete areas. The
first layer of sub-base shall be placed directly on the subgrade
using a self-propelled tracked mechanical paver designed for the
purpose of spreading granular material. Delivery and spreading of
the first layer of sub-base course shall be carried out in a manner
that does not disturb or rut the subgrade. Where a type C or
marine sand subgrade exists, delivery vehicles shall not be
permitted to travel on the finished subgrade and suitable side
loading facilities shall be provided for discharging the sub-base
material into the paver. The subgrade shall be subject to
inspection and approval by the Project Manager prior to placing of
sub base material.
In areas where paver spreading cannot be achieved, end tipping

and dozer spreading will be permitted. Spreading by motor grader
will not be permitted.
(d) Subsequent layers of sub-base shall be placed by self-propelled

mechanical pavers designed for the purpose of spreading
granular material, without segregation across the full width of the
paving lane and to a uniform loose thickness and shall be fitted
with a tamping or vibrating screed. Pavers shall have a capacity
to spread at least 200 tonnes of material per hour.
(e) Sub-base material, as laid, shall be of uniform gradation without

segregation. The sub-base shall not be laid more than 1,000 m2
in advance of rolling. During placing, the incorporation of
subgrade or foreign material in the sub-base course mixture shall
not occur. Should the incorporation of subgrade or foreign
material in the sub-base course mixture occur, the layer shall be
completely removed and replaced. The moisture content shall be
maintained at ± 1% of the optimum field moisture content
determined as part of the Compaction Procedure or as
subsequently reviewed without objection by the Project Manager.
(f) Water shall not be added in such a manner or quantity that free
water will reach and weaken the underlying layer.

132.2.8.3 Compaction of sub-base material
(a) Immediately after placing, the sub-base material shall be

thoroughly and expeditiously compacted according to the
Compaction Procedure by rolling. Sufficient rollers as determined
in the Compaction Procedure shall be used to adequately handle
the rate of placing and spreading of the sub-base course.
(b) Vibrating and pneumatic tyred rollers shall not be operated at

excessive speeds sufficient to cause damage or disruption to the
surface. Speeds shall be controlled such that the full compact
effort of the equipment is mobilised.
(c) In places inaccessible to rollers, the sub-base material shall be

tamped with mechanical or hand tampers to the required density.
(d) The Compaction Procedures for the top layer of sub-base shall
include a minimum of six passes of a heavy vibrating roller which
has the following salient features:
(i) static mass on each vibrating drum – 15 t minimum
(ii) static mass per metre length of each vibrating drum - 6.5 t
minimum
(iii) Frequency of vibration 20 Hz minimum
(iv) Nominal amplitude 2 mm minimum
132.2.9 PROOF ROLLING
(a) At completion of the compaction of each layer of sub-base

material and immediately following field density testing, the layer
shall be proof rolled by the Contractor in the presence of the
Project Manager. The Contractor shall notify the Project Manager
at least 24 hours before proof rolling is carried out.
(b) Prior to an area being proof rolled the moisture content shall be
maintained at +0, -3 % of the placement moisture content.
(c) Proof rolling shall include for at least eight coverages with a
pneumatic tyred roller with a wheel load of 120 kN. A tyre pressure
of 600 kPa shall be used when proof rolling the top layer of sub
base and 500 kPa for the first placed layer of sub base.
(d) The proof roller shall operate at a speed of 3 to 6 km/hr to allow
an observer walking beside the roller to note the surface
deflections of the pavement layer.
(e) Guide markers and counting systems shall be established by the

Contractor on the pavement area to control the line and number
of coverages of the proof roller. The Contractor shall submit his
method of control and logging as part of his Quality System.

(f) The proof roller shall roll along marked lines such as to apply the
specified number of coverage’s uniformly to all parts of the
pavements area.
(g) Not more than four coverages of the proof roller shall be applied
on any one line before the roller is moved to the next line.
(h) The Contractor shall observe the behaviour, stability and

deflections of the surface of the sub-base course during each
coverage of the proof roller.
(i) Any areas of the surface which exhibit behaviour different from the
remainder of the layer or deflect excessively, rut, yield or show
any signs of instability under the final coverage of the proof roller
shall be marked and the area shall be investigated by the
Contractor in the presence of the Project Manager. Following the
investigation, the Contractor shall carry out remedial works
including any works required to lower layers, that have been
reviewed without objection by the Project Manager and shall then
re-proof roll the area.
132.2.10 MAINTENANCE AND PROTECTION
(a) Following completion of any layer of sub-base, the Contractor

shall perform all Maintenance Work necessary to keep the layer
in a satisfactory condition meeting the specified requirements.
The surface shall be kept clean and free from foreign material.
The sub-base shall be properly drained at all times.
(b) The surface of the sub-base shall be kept moist by sprinkling to

prevent dusting and loss of fines until such time as the bond coat
has been applied.
(c) Trafficking of the layer shall be restricted to that necessary to

place the succeeding layer or course.
(d) If damage such as ruts, ridges, tracks, loose material, pot holes
or other defects to the sub-base layer or any underlying layer
occurs, from trafficking the course or by any other reason, causing
it to fall outside of the specified requirements, the affected area
shall be removed to spoil and replaced by the Contractor.

132.2.11 TOLERANCES
132.2.11.1 Tolerances: thickness, level and regularity
(a) The elevation of the finished surface shall not vary by more than
+0, -25 mm from the required level. The finished surface shall not
vary by more than 10 mm when tested with a 3.0 m straightedge.
(b) The finished surface shall also not vary by more than 10 mm per
3 m length of surface when tested with a profilometer
(c) The thickness of the sub-base shall not be less than the thickness
indicated on the Employer’s Drawings.
(d) Subject to the requirements of the PS Section 10.2, the tolerances

for the thickness and finished surface level of sub-base may be
revised by the Project Manager.
132.2.12 TESTING: SURFACE LEVEL
132.2.12.1 Testing: thickness and level
(a) Levelling of the surface of each finished layer shall be performed

by the Contractor. The frequency of levelling shall accurately
represent the surface of the finished layer and shall be carried out
at cross sections for review and without objection by the Project
Manager, and shall be taken across each cross section at all
changes of grade and at intermediate points not greater than 10
m spacing.
(b) The thickness of each finished layer shall be determined at the

location of each in-situ density test which is carried out on the sub-
base. The method of measurement used shall have been

132.2.12.2 Non-compliance: thickness and level
(a) Any deviation of the finished levels or thickness outside of the

specified tolerances, shall be corrected by the Contractor in a
manner reviewed without objection by the Project Manager.
(b) The addition of thin layers of sub-base material in order to meet

level requirements will not be permitted.
(c) Any deviations outside the -25 mm limit shall be corrected by

removing material and replacing and finishing fresh material in
accordance with this GMWS. The minimum area removed shall
be at least 2 m wide and 5 m long in the direction of paving. The
minimum thickness of replaced material shall be 100 mm.
132.2.13 TESTING: RELATIVE COMPACTION
132.2.13.1 Testing: relative compaction
(a) Each area of sub-base which contains sub-base material of the

same type and the same mix, produced at the same mixing plant,
and which is laid and compacted in a single layer in one day shall
be divided into lots. Each lot shall be of a maximum size of 1,000
m2.
(b) Nuclear density testing to BS 1377 will not be accepted as a

substitute for the sand or water replacement density tests, but it
may be used for the Contractor’s information.
(c) Alternatively, nuclear density testing to BS 1377 at a frequency of

not less than there for one and to a work plan reviewed without
objection by the Project Manager may be substituted for the sand
or water replacement density tests.
(d) The tests shall be carried out at positions which are representative
of the lot as a whole.
(e) A sample of sub-base material shall be taken from a location

adjacent to each insitu sand replacement density test or the sub-
base recovered from the water replacement test. The samples of
up to six lots taken from an area of sub-base as defined in Section
132.2.13.1(a) of this GMWS shall be combined and the peak (dry)
bulk density shall be determined by carrying out a compaction test
in accordance with BS 5835. The test result shall be deemed to
be the average maximum dry density from the laboratory
compaction test for the combined lots when determining
compliance with Section 132.2.13.3 of this GMWS. The
determination of maximum dry density and optimum moisture
content by modified Proctor: BS 1377 Part 4: 1990 Method 3.6
shall be the subject of review without objection by the Project
Manager.
(f) Any damage caused by testing shall be repaired by the Contractor

using a method which has been reviewed without objection by the
Project Manager.

132.2.13.2 Compliance criteria: relative compaction
The in-situ density shall be at least 100% of the modified Proctor

maximum dry density determined from either laboratory compaction
test.
132.2.13.3 Non-compliance: relative compaction
(a) If the result of any test for relative compaction in a lot does not
comply with the specified requirements then the lot shall be re-
compacted and two in-situ density tests shall be carried out and
the relative compaction recalculated.
(b) If the relative compaction still does not comply with the specified
requirements then the non-complying sub-base lot shall be
removed by the Contractor and replaced using fresh material.
132.2.14 TESTING: CBR AND PARTICLE SIZE DISTRIBUTION
132.2.14.1 Testing: CBR and particle size distribution
(a) Two samples of sub-base material shall be taken from each area
representing a maximum of five lots of sub-base as defined in
Section 132.2.13.1 of this GMWS after placing and compacting.
(b) One sample shall be tested for particle size distribution in

accordance with BS EN 933-1 2012 and the other shall be tested
for soaked CBR in accordance with BS 1377: Part 4: 1990,
Section 7, Method 3. The CBR tests shall be carried out with the
specimen compacted to 100% modified Proctor maximum dry
density.
compliance; or
(iii) The contractor may decide whether to test only the top, or
(c) Any damage to the sub-base caused by taking samples shall be


132.2.14.2 Non-compliance: CBR and particle size distribution
(a) If the CBR or particle size distribution do not comply with the
requirements of Tables 132.1 and 132.2 respectively then two
samples shall be taken from each lot within the area and tested in
accordance with Sections 132.2.14.1(b) and (c) of this GMWS.
(b) If the result of any of the additional tests does not comply with the
specified requirements then the non-complying sub-base lot shall
be removed by the Contractor and replaced using fresh material
at the Contractor’s own cost.
132.2.15 TESTING: TEN PERCENT FINES VALUE AND PLASTICITY INDEX
132.2.15.1 Batch: ten per cent fines value and plasticity index
For projects with less than 20,000 tonnes of CASB, the batch of sub-
base material is a quantity not exceeding 1,000 tonnes of sub-base
material of the same type and obtained from the same source. For
projects with greater than 20,000 tonnes of CASB, the batch of sub-
base material is a quantity not exceeding 10,000 tonnes of sub-base
material of the same type and obtained from the same source.
132.2.15.2 Testing: ten per cent fines value and plasticity index
(a) Each batch of sub-base material shall be tested ex-stockpile for

ten per cent fines value and plasticity index.
(b) The method of testing for ten percent fines value shall be in
accordance with BS 812: Part 111; 1990, except that the sample
shall be soaked in water at room temperature for 24 hours and
shall not be oven-dried before testing.
(c) The method of testing for plasticity index shall be in accordance

with BS 1377: Part 2: 1990. Sample preparation shall be by wet
sieving the material over a 425 micron BS test sieve.
(d) Four sets of test results shall be submitted with the particulars
detailed in Section 132.2.3.1 of this GMWS. Thereafter, three set
of tests shall be carried out for every batch of sub-base material.
132.2.15.3 Non-compliance: ten percent fines value and plasticity index
If the result of any test does not comply with the requirements specified
in Table 132.1 then four additional sets of tests shall be carried out. The
continued use of the material source shall depend on the results of
these additional tests being reviewed without objection by the Project
Manager.

132.2.16 TESTING: STOCKPILES
132.2.16.1 Testing stockpiles
(a)All materials supplied to the project shall be sampled and tested on

a daily basis during production to determine their compliance with
the specified properties. The frequency of sampling and testing
shall be such as to ensure that changes in quality of the materials
are detected sufficiently in advance of the materials being
incorporated in the Permanent Works to reject, verify or otherwise
take action to avoid the inclusion of non-complying materials in
the Work.
(b)The minimum rate of testing the target stockpile particle size

distribution shall be one test per 500 tons of material for projects
up to 20,000 tonnes of CASB. For projects greater than 20,000
tonnes of CASB, the minimum rate of testing the target stockpile
particle size distribution shall be one test per 1,000 tonnes of
material.
132.2.16.2 Compliance Criteria: Stockpiles
(a)All materials tested shall comply with the requirements of Section

132.2 of this GMWS.
(b)The tests on stockpile particle size distribution shall confirm that the
stockpile particle size distribution is achieved.
132.2.16.3 Non-Compliance: Stockpiles
Any material not complying with the requirements of Section 132.2.16.2

of this GMWS shall not be used in the Permanent Works.

132.2.17 CASB HOLD AND CONTROL POINTS
The Contractor shall include the Control and Hold Points shown in Table
132.3A in his Construction Quality Plan or Inspection & Test Plan.
In addition, the Contractor shall prepare and update daily, control charts
or graphs for the results of all process quality control tests. A separate
control chart or graph shall be kept for the results of relative compaction.
Updated control charts shall be submitted to the Project Manager each
week or as requested.
Table 132.3A: CASB Hold and Control Points
Section Hold Point Control Point

132.2.2 Materials
132.2.3 Initial approval submission Submissions (in particular:
aggregate sources,
aggregate samples, method
of construction and
batching plant)
132.2.4 Trials
132.2.5 Storage of materials
132.2.7.2 Preparation of underlying
course
132.2.8.2 Placing sub-base material
132.2.9 Completion of Proof Rolling Proof Rolling
– submission/compliance
assessment of each lot
132.2.12 Testing: Surface Level –
submission/compliance
132.2.13 Testing: Relative
Compaction –
132.2.14 Initial approval submission Testing: CBR and Particle
Size Distribution –
132.2.15 Testing: Ten Per Cent
Fines Value and Plasticity
Index –
assessment of each batch
132.2.16 Testing: Stockpiles –

132.3 CRUSHED AGGREGATE BASE COURSE
The CABC shall consist of crushed aggregates constructed in one or

more layers on a prepared underlying course in accordance with this
GMWS.
132.3.2 MATERIALS
132.3.2.1 Aggregates
(a) CABC material shall be produced by crushing material from

sources which have been reviewed without objection by the
Project Manager and shall consist of clean, sound, durable
particles of crushed rock substantially the same as the reference
sample. Gravel and crushed river aggregate shall not be permitted.
Blending of sand or other similar binding or filling material will not
be permitted.
(b) The CABC material shall be capable of being compacted into a
dense and stable CABC and shall be free from weathered material,
vegetable matter, lumps of clay, disintegrated or friable matter and
other deleterious substances.
(c) The CABC material shall have the properties stated in Table 132.4.
Table 132.4: Properties of CABC Material

Water Absorption <2%
Los Angeles Abrasion <20% wear after 500 revolutions
Magnesium Sulphate <5% loss after 5 cycles
Soundness
Flakiness Index <25%
Elongation Index <25%
Liquid Limit <25%
Sand Equivalent >45

(d) The particle size distribution shall be determined in accordance
compaction. The Contractor should determine the degree of
material breakdown following rolling and shall determine his target
Table 132.5: Ex-Pavement Particle Size Distribution for CABC
BS Sieve Size Percentage by mass passing

(mm)
37.5 100
28 90 – 95
20 65 – 90
10 40 – 70
5 30 – 50
0.600 12 – 30
0.075 4–8
(e) The material shall be well graded from coarse to fine. It shall not
vary between the lower third of the range on one sieve to the
upper third of the range on each adjacent sieve. The fraction of
the material that passes the 75 micron sieve shall not exceed 60%
of the fraction passing the 600 micron sieve.
132.3.2.2 Water
Water for use in CABC shall be in accordance with the following

requirements:
(a) be tested and comply with the requirements of BS EN 1008:2002;
(b) be clean and free from harmful matter and shall be available in
such quantities as necessary to complete the Permanent Works
to the specified requirements;
(c) be protected from contamination by wind-blown dust or other
material; and
(d) not exceed the limits given in Table 132.6.
Table 132.6: Water Quality Standards

Criterion Permissible Limit
(ppm)
Chloride as NaC1 800
Sulphate as SO3 1,000
Alkali HCO3/CO3 1,000
Total Dissolved Solids 2,000
Suspended Solids 2,000

132.3.2.3 Geogrid
Geogrid for use in CABC shall be in accordance with Section 132.2.2.2.
132.3.3 SUBMISSIONS
132.3.3.1 Particulars of aggregates
At least 30 days prior to scheduled construction of the trial area, the

Contractor shall submit to the Project Manager for review without
objection, a statement of the origin and method of extraction of all
aggregates proposed for the Permanent Works. The Contractor shall at
the same time provide evidence demonstrating that an adequate supply
of uniform material can be produced. The Contractor shall submit test
results showing that the aggregate meets the specified requirements.
At the same time as particulars detailed in Section 132.3.3.1 of this

GMWS are submitted, a reference sample from each different
ASTM C295/C295M-12 (2005).
132.3.3.3 Particulars of mixes for CABC and methods of construction
The following particulars shall be submitted to the Project Manager for

review without objection at least 20 days prior to scheduled construction
of the trial area:
(a) source and type of aggregates;
(b) target particle size distribution details in tabular and graphical
form for the CABC in the stockpile and ex-pavement. The
target particle size distribution shall be expressed as a single
percentage passing each sieve size;
(c) details of each mixing plant proposed;
(d) details of methods of construction; and
(e) details of BS 1377 maximum dry density and optimum
moisture content and / or BS 5835 peak (dry) bulk density and
optimum moisture content.

132.3.4 TRIALS
132.3.4.1 Trial area
(a) The Contractor shall construct, for each CABC material source, a
trial area of at least 500 m2.
(b) The trial area shall be used to determine the adequacy of the
Contractor's Equipment to achieve the specified density and finish
requirements. It shall also be used to determine appropriate loose
material depths, placement methods and the relationship between
the number of compaction passes and resulting field density. A
placement and compaction methodology shall be established and
shall form the basis of the Compaction Procedure.
(c) The trial area shall be carried out on a completed underlying sub-
base course which meets the requirements of this GMWS and
shall be constructed with the materials and plant intended for use
in constructing the Permanent Works. The trial area shall be
before construction of a trial area begins. Results of laboratory
studies (where appropriate) shall be forwarded to the Project
Manager prior to the commencement of trials.
(a) Ten in-situ density tests shall be carried out on each layer of
CABC in the trial area. The tests shall be carried out in accordance
with Section 132.3.13.1 (b) of this GMWS.
(b) Five samples of CABC material shall be taken from the trial area
and tested to determine the peak (dry) bulk density in accordance
with BS 5835. The determination of maximum dry density and
optimum moisture content by modified Proctor: BS 1377 Part
4:1990 Method 3.6 shall be the subject of review without objection
by the Project Manager. The highest and lowest results shall be
disregarded and the average of the remainder reported.
(c) The trial area shall be tested for regularity, levels and thickness in
accordance with Section 132.3.13.1 of this GMWS.
(d) Three samples of CABC material shall be taken from the trial area
and tested for particle size distribution, flakiness index, elongation
index and CBR in accordance with Section 132.3.14.1(c) of this
GMWS.

requirements:
(a) The result of each in-situ density test shall be at least 100% of the
average maximum dry density determined from the five laboratory
compaction tests;
(b) the regularity, levels and thickness of the CABC shall be within the
specified tolerances; and
(c) the particle size distribution, flakiness index, elongation index and
CBR shall comply with Section 132.3.14.2 of this GMWS.
(b) Trial areas, which do not comply with the specified requirements
for the trial area shall be rejected and removed.
132.3.4.5 Commencement of CABC placement
(a) CABC shall not be placed in the Permanent Works, other than in
a trial area, until the result of every test on the trial area complies
with the specified requirements for the trial area.
objection. The Compaction Procedure shall form an integral part
of the Contractor's Quality System.
(c) CABC material may not be placed in the Permanent Works, until
all test results and the Compaction Procedure have been
The materials, methods of production and methods of construction used

to produce a trial area which complies with the specified requirements

The Contractor shall provide production and field test summaries on

and on-going daily basis (or other agreed period) to monitor compliance
and trends in test results and submit these promptly to the Project
Manager. The format of the test summaries shall be agreed with the
Project Manager. The Contractor shall take appropriate action as
required (including raising non-conformance report etc.) to ensure
compliance with the GMWS.
(a) If the Contractor proposes to stockpile any materials to be used in

the production of CABC, the stockpiles shall be constructed in the
manner and at locations reviewed without objection by the Project
Manager.
(b) The Contractor shall be responsible for ensuring the stockpile
pads are prepared so as to prevent contamination of the stockpile
material. As a minimum, prior to stockpiling of materials, the
storage sites shall be cleared, drained, levelled and surfaced with
at least 50 mm thickness of material of equal quality and type to
that being stockpiled.
(c) Material from different sources or with different particle size
distributions shall be stockpiled separately.
(d) Materials shall be stockpiled in such a manner as to avoid
segregation or contamination by foreign materials, and shall be
removed from stockpiles in such a manner as to maintain their
uniformity and avoid segregation. Where segregation is apparent,
the material shall be remixed before use.
(e) The surfacing layer shall not be disturbed until completion of the
Permanent Works at which time it shall be removed to spoil and
the area reinstated.

132.3.6 MIXING OF CABC MATERIAL
(a) The separate size fractions of the coarse and fine aggregates, or
any combination thereof, and/or materials to be blended, shall be
proportioned by mass or by volume in such quantities that the
specified particle size distribution, liquid limit and plasticity index
requirements will be met. Water measured by mass or volume
shall be incorporated during the mixing operation so that the
moisture content of the material during spreading and compaction
shall be within the range specified. Mixing operations shall
produce satisfactory uniform blending. Discharge into haulage
vehicles shall be in a manner that will not produce segregation.
(b) The mixing plant shall be stationary and so designed and

constructed as to thoroughly mix constituent materials without
degradation of the aggregate. Mixers shall be designed, and
operated to produce uniform material. Each plant shall have
sufficient production capacity to meet the contract requirements.
The plant shall be equipped with feeding and metering devices
which will add the various materials into the mixer in the specified
or required quantities.

below the CABC shall be completed and fill material shall be
deposited and compacted in trenches before the CABC is
constructed. Openings to manholes, chambers and gullies shall
be protected by temporary covers.
(b) Box-outs shall be formed in the CABC for covers, frames and
other hardware.
(a) The Contractor shall notify the Project Manager before CABC is
placed in any part of the Permanent Works and shall allow the
Project Manager sufficient time to inspect the underlying course.
(b) The Contractor shall only place material over sub-base material
that is undamaged and is clean and free from foreign material.
The Contractor shall not place CABC material until all the
specified requirements for the underlying sub-base, at the time of
placing, have been met and the sub-base has been reviewed
without objection by the Project Manager.
(c) The underlying course shall be lightly watered prior to placement
of CABC. Watering shall be controlled to minimise loss of moisture
from the CABC and loss of fines from the surface of the underlying
course.

132.3.8 PLACING AND COMPACTING CABC
132.3.8.1 General
(a) CABC material shall be processed in a stationary mixing plant.

The CABC material shall be thoroughly mixed with the required
amount of water. Water added during mixing shall be sufficient
such that during placing, spreading and compaction, the moisture
content is at the optimum established for the Compaction
Procedure.
(b) After the mixing is complete, the material shall be transported by
sheeted haulage vehicles to, and spread on, the underlying layer
without delay. Storage of mixed CABC material in stockpiles will
not be permitted. The material shall be handled in a manner so as
to prevent segregation, contamination or degradation.
(c) Material contiguous with the CABC shall be placed and

compacted (as specified in the appropriate section of this GMWS)
such that the level of the surface of the contiguous material is
never more than 150 mm below or above the surface level of the
compacted CABC.
(d) Whenever possible, CABC placement shall begin along the centre
line of crowned sections or on the high side of pavements with a
one-way slope.
132.3.8.2 Placing CABC
(a) The CABC shall be constructed in layers. Any layer shall be not
less than 100 mm nor more than 200 mm compacted thickness.
Layers of unequal thickness shall be laid with the thinnest
uppermost.
and debris.
(c) Material from different sources shall be laid in discrete areas.
(d) CABC material shall be deposited by suitable paving machine in
uniform layers, without segregation on the prepared, moistened
underlying layer. It shall be placed to such loose depth that, when
compacted, the layer will have the required thickness. The paving
machine shall spread the aggregate so as to avoid or minimise
the need for hand manipulation and shall be fitted with a vibrating
or tamping screed. Hauling over un-compacted base course and
dumping from vehicles in piles will not be permitted. Spreading by
motor grader will not be permitted. Pavers shall have a capacity
to spread at least 200 tonnes of material per hour.

(e) The CABC shall not be laid more than 750 m2 in advance of rolling.
During placing, the incorporation of subgrade or foreign material
in the CABC mixture shall not occur. The moisture content shall
be maintained at ±1 per cent of the optimum field moisture content
determined as part of the Compaction Procedure or as
subsequently reviewed without objection by the Project Manager.
(f) Water shall not be added in such a manner or quantity that free
water will reach and weaken the underlying layer.
132.3.8.3 Compaction of CABC material
(a) Immediately after placing, the CABC material shall be thoroughly

and expeditiously compacted according to the Compaction
Procedure by rolling. Sufficient rollers as determined in the
Compaction Procedure shall be used to adequately handle the
rate of placing and spreading of the CABC course.
(b) Vibrating and pneumatic tyred rollers shall not be operated at
surface. Speeds shall be controlled such that the full compactive
(c) In places inaccessible to rollers, the CABC material shall be
tamped with mechanical or hand tampers to the required density.
(d) The Compaction Procedure for the top layer of CABC shall include,
a minimum of six passes of a heavy vibrating roller which has the
following salient features:
(i) static mass on each vibrating drum – 15 t minimum
(ii) static mass per metre length of each vibrating drum - 6.5 t
minimum
(iii) Frequency of vibration 20 Hz minimum
(iv) Nominal amplitude 2 mm minimum
(e) The finished surface of the CABC shall present a uniform tightly
interlocked stone mosaic appearance and shall be fully
compacted, and free from loose stones.
132.3.9 PROOF ROLLING
(a) At completion of the compaction of each layer of CABC material

as the case may be, and immediately following field density
testing, the layer shall be proof rolled by the Contractor in the
presence of the Project Manager. The Contractor shall notify the
Project Manager at least 24 hours before proof rolling is carried
out.
(b) Prior to an area being proof rolled, the moisture content shall be
maintained at +0, -3 % of the placement moisture content.
(c) Proof rolling shall consist of eight coverages with a pneumatic
tyred roller with a wheel load of 120 kN and a tyre pressure of
1,100 kN/m2.

(d) The proof roller shall operate at a speed of 3 to 6 km/hr to allow
an observer walking beside the roller to note the surface
deflections of the pavement layer.
Contractor on the pavement area to control the line and number
of coverages of the proof roller. The Contractor shall submit his
method of control and logging as part of his Quality System.
(f) The proof roller shall roll along marked lines so as to apply the
specified number of coverages uniformly to all parts of the
pavement area.
(g) Not more than two coverages of the proof roller shall be applied
on any one line before the roller is moved to the next line.
(h) The Contractor shall observe the behaviour, stability and
deflections of the surface of the CABC during each coverage of
the proof roller.
(i) Any areas of the surface which exhibit behaviour different from the
remainder of the layer or deflect excessively, rut, yield or show
any signs of instability under the final coverage of the proof roller
shall be marked and the area shall be investigated by the
investigation, the Contractor shall carry out remedial works that
have been reviewed without objection by the Project Manager and
shall then re-proof roll the area.
(a) Following completion of any CABC layer, the Contractor shall

perform all maintenance work necessary to keep the CABC layer
in a satisfactory condition meeting the specified requirements.
The surface shall be kept clean and free from foreign material.
The CABC shall be properly drained at all times.
(b) The surface of the CABC shall be kept moist by sprinkling to
prevent dusting and loss of fines until such time as the prime coat
has been applied.
(c) Trafficking of the CABC layer shall be restricted to that necessary
to place the succeeding layer or course.
(d) If damage such as ruts, ridges, cracks, loose material, pot holes
or other defects to the CABC layer or any underlying layer occurs,
from trafficking the course or by any other reason causing it to fall
outside of the specified requirements, the affected area shall be
removed to spoil and replaced by the Contractor.

132.3.11 TOLERANCES
+0, -15 mm from the required level.
(b) The finished surface shall not vary by more than 7 mm when
tested with a 3.0 m straightedge. The finished surface shall also
not vary by more than 7 mm per 3 m length of surface when tested
with a profilometer.
(c) The thickness of the CABC shall not be less than the thickness
indicated on the Employer's Drawings.
(d) Subject to the requirements of the PS Section 10.2, the tolerances
for the thickness and finished surface level of CABC may be
revised by the Project Manager.
132.3.11.2 Tolerances: particle size distribution
The tolerances for target grading shall be as detailed in Table 132.7.
Table 132.7: Tolerances for Target Gradings

BS Sieve Size Tolerances (percentage by mass
passing)
37.5 0
28 ±2
20 ±8
10 ±8
5 ±8
0.600 ±5
0.075 ±2

132.3.12 TESTING: THICKNESS, LEVEL AND REGULARITY
132.3.12.1 Testing: thickness, level and regularity
(a) Levelling of the surface of each finished layer shall be performed

represent the surface of the finished layer and shall be carried out
at cross sections agreed with the Project Manager, and shall be
taken across each cross section at all changes of grade and at
intermediate points not greater than 10 m spacing.
(b) The full width of the finished surface shall be tested for regularity
perpendicular to the main axis of the pavement by using a 3.0 m
straight edge. The tests shall be carried out at intervals not
exceeding 10 m.
(c) The finished surface shall be tested for regularity along lines at 5
m intervals and parallel to the main axis of the pavement by using
a profilometer which produces a continuous computerised printout
of the surface profile for visual reading and surface record.
(d) The thickness of each finished layer shall be determined at the
location of each in-situ density test which is carried out on the
CABC. The method of measurement used shall have been
(e) Any damage to the CABC course caused by testing shall be
132.3.12.2 Non-compliance: thickness, level and regularity
(a) Any deviation of the finished thickness, level or regularity outside

the specified tolerances, shall be corrected by the Contractor in a
manner reviewed without objection by the Project Manager.
(b) The addition of thin layers of CABC material in order to meet level
requirements will not be permitted.
(c) Any deviations outside the -15 mm limit shall be corrected by
removing material and replacing and finishing fresh material in
accordance with this GMWS. The minimum area removed shall
be at least 2 m wide and 5 m long in the direction of paving. The
minimum thickness of replaced material shall be 100 mm.

132.3.13.1 Testing relative compaction
(a) Each area of CABC which contains CABC material of the same
type and the same mix, produced at the same mixing plant, which
is laid and compacted in a single layer in one day shall be divided
into lots. Each lot shall be of a maximum size of 1,000 m2.
(b) Two in-situ density tests shall be carried out on each lot. The tests
shall be carried out in accordance with BS 1377: Part 9: 1990
Method 2.3 (water replacement) or BS 1377: Part 9: 1990 Method
2.2 (sand replacement).
(c) Nuclear density testing to BS 1377 will not be accepted as a
substitute for the sand or water replacement density tests, but it
may be used for the Contractor’s information.
(d) The tests shall be carried out at positions which are representative
of the lot as a whole.
(e) A sample of CABC material shall be taken from a location adjacent
to each in-situ sand replacement density test or the CABC
material recovered from the water replacement test. The samples
of up to six lots taken from an area of CABC as defined in Section
132.3.13.1(a) shall be combined and the maximum dry density or
peak (dry) bulk density as appropriate shall be determined by
carrying out a compaction test in accordance with BS 1377 : Part
4 :1990 Method 3.6 or in accordance with BS 5835. The test result
shall be deemed to be the average modified Proctor maximum dry
density from the laboratory compaction tests for the combined lots
when determining compliance with Section 132.3.13.2 of this
GMWS.
(f) Any damage caused by testing shall be repaired by the Contractor
Project Manager.
The average in-situ density of ten consecutive results shall be at least

100.0% of the modified Proctor maximum dry density determined from
either laboratory compaction test with no individual result being less
than 99.0%.
(a) If the result of any test for relative compaction in a lot does not
comply with the specified requirements then the lot shall be
recompacted and two insitu density tests shall be carried out and
the relative compaction recalculated.
(b) If the tests for relative compaction still does not comply with the
specified requirements then the non-complying CABC layer shall
be removed by the Contractor and replaced using fresh material.

132.3.13.4 Testing: degree of saturation
Prior to placing any bituminous layers on the CABC, the Contractor shall
inspect the surface of the CABC with the Project Manager. If any areas
of the CABC appear to be saturated in the opinion of the Project
Manager, the Contractor shall test the CABC to determine the degree
of saturation. This shall be determined in accordance with Test Method
Q146 (Queensland Main Road Specification MRTS05-2017) at a
frequency of at least one test per 10,000m². Where areas of CABC are
found to have a degree of saturation greater than 65%, the Contractor
shall allow adequate time for the CABC to dry out. Placement of the
bituminous layers on the CABC may proceed when the degree of
saturation is less than 65%.
132.3.14 TESTING: SAMPLES TAKEN EX-PAVEMENT
132.3.14.1 Testing: samples taken ex-pavement
(a) One sample of CABC material shall be taken from each area
representing a maximum of five lots of CABC after placing and
compacting. The sample shall be large enough to enable all of the
tests detailed in this section to be carried out.
(b) Any damage caused to the CABC by taking the sample shall be
(c) Each sample shall be tested to determine the properties stated in
Table 132.8. The method of testing shall be as stated in Table
132.8. Each of the tests shall be carried out on a separate sub-
sample.
Table 132.8: Testing Samples Taken Ex-Pavement
Property Method of testing
Particle Size Distribution BS EN 933-1 2012

California Bearing Ratio BS 1377: Part 4 : 1990, Section 7,
Method 3
Flakiness Index BS EN 933-3 2012
Elongation Index BS 812: Part 105.2

(d) The CBR tests shall be carried out on samples which have been
soaked and compacted to 100% modified Proctor maximum dry
density.
compliance; or
(iii) The Contractor may decide whether to test only the top, or
132.3.14.2 Compliance criteria: samples taken ex-pavement
The results of tests for flakiness index, elongation index and CBR shall
comply with the requirements stated in Table 132.4. The results of tests
for particle size distribution shall comply with Table 132.5 and shall be
within the specified tolerance of the ex-pavement target grading.
132.3.14.3 Non-compliance: samples taken ex-pavement
(a) If the result of any test does not comply with the specified
requirements then two samples shall be taken from each lot in the
area and tested in accordance with Section 132.3.14.1(c) for the
non-complying property.
(b) If the result of any of the additional tests fails to comply with the
specified requirements then the non-complying CABC lot shall be
removed by the Contractor and replaced using fresh material at
contractor own cost.
132.3.15 TESTING: MATERIAL FOR THE PRODUCTION OF CABC
132.3.15.1 Batch: CABC material
For projects with less than 20,000 tonnes of CABC, the batch of base
material is a quantity not exceeding 1,000 tonnes of base material of
the same type and obtained from the same source. For projects with
greater than 20,000 tonnes of CABC, the batch of base material is a
quantity not exceeding 10,000 tonnes of base material of the same type
and obtained from the same source.
132.3.15.2 Samples: materials for the production of CABC
(a) Four samples shall be taken from the source for initial testing and
thereafter three sample shall be taken per batch.
(b) Each sample shall be large enough for all of the tests detailed in
this section to be carried out.

132.3.15.3 Testing: materials for the production of CABC
(a) Each sample of materials for the production of CABC shall be

tested to determine the properties stated in Table 132.9. The
method of testing shall be as stated in Table 132.9.
Table 132.9: Testing CABC Material

Ten Percent Fines Value BS 812: Part 111/BS EN
1097-2:2010
Plasticity Index BS 1377: Part 2: 1990
Water Absorption BS 812: Part 2/BS EN 1097-
3:2010
Los Angeles Abrasion ASTM C131/C131M-14:2006
Magnesium Sulphate Soundness BS812: Part 121: 1989
(b) The samples to be tested for ten percent fines value shall be
soaked in water at room temperature for 24 hours and shall not
be oven-dried before testing.
132.3.15.4 Non-compliance: CABC material
in Table 132.4 then four additional sets of tests shall be carried out on
the same batch of material. The continued use of the material source
shall depend on the results of these additional tests being reviewed
132.3.15.5 Testing: stockpile gradings
The minimum rate of testing the target stockpile particle size distribution
shall be one test per 500 tonnes of material for projects up to 20,000
tonnes of CABC. For projects greater than 20,000 tonnes of CABC,
the minimum rate of testing the target stockpile particle size distribution
shall be one test per 1,000 tonnes of material.
132.3.15.6 Compliance criteria: stockpiles
The tests on stockpile particle size distribution shall confirm that the
target stockpile particle size distribution is achieved within the
tolerances listed in Table 132.7.
132.3.15.7 Non-compliance: stockpiles

shall not be used in the Permanent Works.

132.3.16 CABC HOLD AND CONTROL POINTS
In addition, the Contractor shall prepare and update daily, control charts
or graphs for the results of all process quality control tests. A separate
control chart or graph shall be kept for the results of ten per cent fines
value; plasticity index and relative compaction. Updated control charts
shall be submitted to the Project Manager each week or as requested.

Table 132.9A: CABC Hold and Control Points

132.3.2 Materials
132.3.3 Initial approval Submissions (in particular
submission aggregate sources,
aggregate samples, method
of construction and batching
plant)
132.3.4 Trials (including
Production Trial Report)
132.3.5 Storage of material
132.3.7.2 Preparation of underlying
course
132.3.8 Placing and Compacting
CABC
132.3.9 Completion of Proof Proof Rolling
Rolling –
132.3.12 Testing: Thickness, Level
and Regularity –
Compaction –
132.3.13.4 Testing: Degree of
Saturation –
132.3.14 Testing: Sample Taken
Ex-Pavement –
132.3.15 Testing: Material for the
Production of CABC –
assessment of each
batch

132.4 DRY LEAN CONCRETE
132.4.1.1 Dry Lean Concrete
The DLC course shall consist of crushed aggregates, cement and water
constructed in one or more layers on a prepared subgrade in
accordance with this GMWS.
Type B and type C subgrade are earthworks materials which comply

with Section 132.10.3.1 (b) and 132.10.3.1 (c) of this GMWS
respectively.
132.4.1.3 Marine sand and public fill subgrade
Marine sand (Types S1 and S2) and public fill subgrade are earthworks
materials which comply with Section 132.10.3.1 of this GMWS.
132.4.2 GENERAL
132.4.2.1 General requirements
The works and materials specified in Sections 132.4.2.2, 132.4.2.3,

132.4.2.4, 132.4.2.5, 132.4.2.6, 132.4.3.1 and 132.4.3.2 of this GMWS
shall comply with the sections stated, unless otherwise stated in this
section.
132.4.2.2 Formwork and finishes
Formwork and finishes for the DLC course shall comply with Section
18 of the GMWS.
132.4.2.3 Concrete
Concrete for the DLC course shall comply with Section 20 of the GMWS.
132.4.2.4 Curing compound
Curing compound for the DLC course shall comply with Section
132.5.1.5 of this GMWS.
132.4.2.5 Water
Water for the DLC shall comply with Section 132.3.2.2 of this GMWS.
132.4.2.6 Aggregate


(b) Aggregate may be mixed or blended with fine sand, stone dust,
or other similar binding or filler materials produced from permitted
with the requirements of the GMWS.
(c) The combined material shall be free from weathered material,

vegetable matter, lumps of clay, disintegrated or friable matter
and other deleterious substances.
The aggregate shall have the properties stated in Table 132.10.
Table 132.10: Properties of Aggregate
Magnesium Sulphate Soundness <5% loss after 5 cycles
(d) The ex-pavement grading of the aggregate shall be within the

limits shown in Table 131.11.
(e) The particle size distribution shall be determined in accordance

with the requirements of Table 132.11. Table 132.11 is the
particle size distribution to be achieved ex-pavement following
Table 132.11: Ex-pavement Particle Size Distribution for
Aggregate
BS Sieve Size Percentage by mass

(mm) passing
75 100
37.5 85 – 100
20 60 – 85
10 40 – 70
5.0 25 – 45
0.600 8 – 22
0.075 4 – 10
(f) The material shall be well graded from coarse to fine and shall
not vary between the lower third of the range on one sieve to
the upper third of the range on each adjacent sieve. The fraction
of the material that passes the 75 micron sieve shall not exceed
60% of the fraction passing the 600 micron sieve.

132.4.2.7 PFA
PFA for use in the DLC shall be in accordance with BS 3892: Part 1:
1997 (or BS EN 450-1:2012).
132.4.3 MATERIALS
132.4.3.1 Geogrid
Geogrid shall be manufactured from synthetic durable polymers and

shall comply with the following requirements:
(a) Weight: greater than 0.3 kg/m2
(b) Tensile strength:15 kN/m minimum
(c) Load at 2% strain
Transverse: greater than 12 kN/m
Longitudinal: greater than 7 kN/m
(d) UV susceptibility: greater than 90% strength retention after 25

years exposure to sunlight.
(e) The aperture size shall be between 20 mm and 40 mm.
(f) The rib shall be at least 0.8 mm thick at junctions.
(g) It shall be resistant to all chemicals normally found in pavement

construction and shall not be susceptible to biological attack.
(h) The geotextile shall be durable enough to maintain its integrity for
at least 50 years when installed.
132.4.3.2 DLC mix
(a) In each cubic metre of fully compacted DLC the minimum

cementitious content shall be 120kg/m³ with a maximum
aggregate/cement ratio of 15:1 by mass such that the average 7
day compressive strength shall be between 7.0 N/mm² to 10.0
N/mm² at density condition such that air voids are not more than
5%. With the approval of the Project Manager the
aggregate/cement ratio may be changed to 20:1 by mass.
(b) Where PFA is used in combination with Portland cement, the

proportion of PFA by mass to the total cementitious content
shall be between 15 and 25%.

132.4.4 SUBMISSIONS
132.4.4.1 Particulars of materials for DLC
(a) At least 30 days prior to scheduled construction of the trial area,

the Contractor shall submit to the Project Manager for review, a
statement of the origin, and method of extraction of all
aggregates proposed for the permanent works. The Contractor
shall at the same time provide evidence demonstrating that an
adequate supply of uniform material can be produced and that
the aggregate meets the specified requirements.
(b) At least 20 days prior to scheduled construction of the trial area,

the Contractor shall submit the particulars detailed in Section
20.6.1 (a) and 20.6.1 (c) of the GMWS to the Project Manager for
review.
At the same time as the particulars detailed in Section 132.4.4.1 are

submitted, a reference sample from each different aggregate source,
taken after tertiary crushing, shall be submitted to the Project Manager
for review. The sample, which shall be a minimum of two 50 kg
samples, shall be accompanied by a full petrological and
mineralogical description to the requirements of ASTM C295/C295M-
12 (2012)..
132.4.4.3 Particulars of DLC mix and methods of construction
The following particulars of each proposed design DLC mix shall be

submitted to the Project Manager for review at least 20 days prior to
scheduled construction of the trial area:
(a) Quantity of each constituent per cubic metre;
(b) Target grading details in tabular and graphical form for the
aggregate ex-pavement. The target grading shall be expressed
as a single percentage passing each sieve size;
(c) Type and source of cement and PFA; and
(d) Method of construction.
132.4.4.4 Particulars of batching and mixing plant
Particulars of the proposed batching and mixing plant to be used,

including a layout plan and output of the plant, shall be submitted to
the Project Manager for review at least seven days before the plant is
delivered to the Site.

132.4.4.5 Particulars of geogrid

area, the Contractor shall submit manufacturer's literature and
certificates to the Project Manager for review. They shall show
the manufacturer's name, the date and place of manufacture and
that the geogrid complies with the requirements stated in the
Specification.
(b) The Contractor shall establish a Quality Control Point at this

juncture.
132.4.4.6 Representative sample of geogrid
At the same time as the particulars of the geogrid are submitted, the
Contractor shall submit a representative sample of the geogrid to the
Project Manager for review.
132.4.5 TRIALS
132.4.5.1 Trial mix DLC
(a) The Contractor shall prepare trial mixes in advance of

constructing the permanent works.
(b) Using an aggregate/cement ratio within the limit specified in

Section 132.4.3.2 of this GMWS, the Contractor shall make trial
mixes at water contents ranging from 5% to 7%, by weight of the
dry materials, at 0.5% intervals.
132.4.5.2 Testing: trial mix DLC
From each of the mixes a set of three 150 mm cubes shall be made
and cured in accordance with BS EN 12390-2:2009. At seven days
the mean dry density of the cubes shall be determined in accordance
with BS EN 12390-7:2009, and the compressive strength shall be
determined in accordance with BS EN 12390-3:2009.
132.4.5.3 Compliance criteria: trial mix DLC
(a) Providing that the mean compressive strength of the three cubes
from the same set is between 7 N/mm² and 10 N/mm², and no
individual cube strength in the set is less than 6.5 N/mm² nor
more than 12 N/mm² the mix shall be considered to be
satisfactory.
(b) The satisfactory mix with the highest dry density shall be chosen
as the job mix.

132.4.5.4 Non-compliance: trial mix DLC
If the test results fail to satisfy the strength requirements, the Contractor
shall repeat the whole test sequence, using mixes with a different
aggregate/cement ratio, until a satisfactory mix has been designed
which meets the strength requirements specified in Section 132.4.5.3
of this GMWS.
(a) The Contractor shall construct, for each DLC material source and
on each subgrade type, a trial area of at least 750 m². This shall
comprise at least two runs of a minimum length of 50 m and shall
contain at least one transverse and one longitudinal joint. The
widths of each run shall be between 3.75 and 7.5 m unless agreed
otherwise with the Project Manager.
(b) Trial areas will be used to determine the adequacy of the

Contractor's Equipment, loose material depth measurements,
placement methods and the relationship between number of
compaction passes and resulting field density. A placement and
compaction methodology shall be established to optimise field
density and shall form the basis of the Placement Procedure.
(c) Trial areas shall be carried out on completed underlying type C,

type B, marine sand and public fill subgrade courses which meets
the requirements of the specification and shall be constructed with
the materials and plant intended for use in constructing the
permanent works. The trial areas shall be constructed in an area
considered by the Project Manager to be non-critical to airport
operation and may form part of the permanent works if accepted.
before construction of a trial area begins.
(a) At least 10 cores to the full depth of the DLC shall be cut from the
trial area to determine the density of the DLC. The cores shall be
cut when the DLC is not less than four days old. The cutting of
cores shall be in accordance with CS1.
(b) The cores shall be tested for density in accordance with BS EN

12390-7:2009. For a two layer DLC course only the top layer shall
be tested for density. The cores shall also be used to determine
the course thickness.
(c) The trial area shall be tested for surface level and regularity in
accordance with Section 132.4.14.1 of this GMWS.

(d) At least six 150 mm DLC cubes shall be made and cured in
accordance with BS EN 12390-2:2009The cubes shall be tested
after seven days in accordance with BS EN 12390-3:2009.
(e) Three samples of DLC shall be taken from the trial area after
placing and compacting, and shall be tested in accordance with
BS EN 933-1 2012.
(a) The results of tests on the trial area shall comply with the following
requirements:
(b) The thickness, regularity and levels of the DLC shall comply with
Section 132.4.13.1 of this GMWS.
(c) The density of cores shall comply with Section 132.4.15.2 of this
GMWS.
(d) The compressive strength of the DLC cubes shall comply with
Section 132.4.15.2 of this GMWS.
(e) The particle size distribution shall comply with Section 132.4.17.2
of this GMWS.
changes to the materials, mix design, methods of production or
methods of construction shall be submitted to the Project
Manager for review. Further trial areas shall be constructed until
the result of every test on the trial area complies with the
specified requirements for the trial area. Further trial mixes shall
be made unless non-compliance of the trial area was not due to
the DLC mix.
(b) Trial areas which do not comply with the specified requirements
shall be removed.

132.4.5.9 Commencement of DLC placement
(a) DLC shall not be placed in the permanent works, other than in a
trial area, until the result of every test on the trial area complies

of the permanent works, the Contractor shall submit the
Placement Procedure to the Project Manager for review. The
Placement Procedure shall form an integral part of the
Contractor's Quality System.
(c) DLC may not be placed in the permanent works, until all the above
requirements have been met and the Placement Procedure has
been reviewed without objection by the Project Manager.
The materials, mix design, methods of production and methods of

construction used to produce a trial area which complies with the
specified requirements shall not be changed without the permission
of the Project Manager.
The Contractor shall provide production and field test summaries on an

on-going daily basis (or other agreed period) to monitor compliance and
trends in test results and submit these promptly to the Project Manager.
The format of the test summaries shall be agreed with the Project
Manager. The Contractor shall take appropriate action as required
(including raising non-conformance reports etc) to ensure compliance
with the GMWS.
(a) Storage of materials shall be in accordance with Section 20.7.1,

20.7.2 and 20.7.3 of the GMWS.
(b) The storage of aggregates for DLC shall be arranged so that, as

far as possible, rapid drying out in hot weather is prevented in
order to avoid sudden fluctuations in water content. Storage of
fine aggregates shall be arranged so that they can drain
sufficiently before use in order to prevent fluctuations in water
content of the DLC.


below the DLC course shall be completed and fill material shall
be deposited and compacted in trenches before the DLC course
is constructed. Openings to manholes, chambers and gullies shall
(b) Box-outs shall be formed in the DLC course for covers, frames
and other hardware.
(a) The Contractor shall notify the Project Manager before DLC is
placed in any part of the permanent works and shall allow the
Project Manager sufficient time to inspect the subgrade.
(b) DLC material shall only be placed if the subgrade is undamaged

and clean and free from foreign material, and has been reviewed
(c) The subgrade shall be lightly watered prior to placement of DLC.

Watering shall be controlled to minimise loss of moisture from the
DLC and loss of fines from the surface of the subgrade.
132.4.8 FORMWORK
(a) Straight side forms shall be made of steel or sealed plywood.
(b) Formed surfaces shall have a class F2 finish.
132.4.9 FORMING JOINTS
(a) At the end of each day's run a transverse construction joint shall
be formed by a stop end or by cutting back into the compacted
material to form a true transverse vertical face. These faces shall
be protected by banking damp material against them or by other
suitable methods. The protection method provided shall permit
the placing and compacting of subsequent material without
damage to previously laid material.
(b) Care shall be exercised to ensure thorough compaction of the

DLC material immediately adjacent to all construction joints.
(c) Before depositing new material against compacted material, the

surface of the joint shall be cleaned, roughened and moistened.
(d) Joints in DLC shall be offset from joints in PQC by a minimum of

0.3 m and a maximum of 0.6 m.

132.4.10 PLACING AND COMPACTING DLC
(a) No activity or work shall be carried out on the DLC course during
rain or when there is standing water on the DLC or subgrade.
Placement of DLC in hot and cold weather conditions shall be
subject to the limitations noted within Section 132.5.10 of this
GMWS.
and debris.
(c) The DLC layer shall be placed directly and spread on the
subgrade using a self-propelled tracked mechanical paver
designed for the purpose of spreading granular material. The
width of the DLC run shall be between 3.75 and 7.5 m unless
agreed otherwise with the Project Manager. Spreading of DLC
shall be carried out in a manner that does not disturb the
subgrade. DLC shall be placed in one layer without segregation
where a type C or marine sand subgrade exists, delivery vehicles
shall not be permitted to travel on the finished subgrade and
suitable side loading facilities shall be provided for discharging
the sub-base material into the paver. The material shall be
spread so as to avoid or minimise the need for hand manipulation.
Hauling over previously completed DLC will not be permitted.
Material shall not be placed in piles or windrows nor will
spreading by motor grader be permitted.
(d) In areas where paver spreading cannot be achieved, end tipping

and dozer spreading will be permitted. The first layer shall be
placed 75 mm thick by end tipping and dozing to the correct
profile. It shall be lightly rolled. The second layer shall be placed
immediately thereafter. It shall be placed, without segregation to
such loose depth that, when compacted, the layer will have the
required thickness. The material shall be spread so as to avoid
or minimise the need for hand manipulation. Hauling over the
second DLC layer shall not be permitted. Material shall not be
placed in piles or windrows nor will spreading by motor grader be
permitted.
(e) The DLC shall be spread by mechanical means between levelling

forms not more than 10 m apart or by suitable slip form paver. In
either case the spreading equipment and supply of DLC mixture
shall permit the continuous spreading of material for construction
and compaction to the proper thickness and contours.

(f) Material from different sources shall be laid in discrete areas that
have been inspected by the Project Manager.
(g) Immediately after placing, the DLC shall be thoroughly and

expeditiously compacted in accordance with the Placement
Procedure by rolling. Sufficient rollers, as determined in the
Placement Procedure, shall be used to compact adequately the
material that has been placed. Care shall be exercised in routing
construction equipment to avoid the formation of unnecessary
ridges due to wheel tracks or tractor treads.
(h) Vibrating and pneumatic-tyred rollers shall not operate at

(i) In places inaccessible to rollers, the DLC material shall be tamped

to the specified density with mechanical tampers, and finished
with hand-guided vibratory rollers with a minimum compactive
effort equivalent to 750 kg/m roll to – 1,500 kg/m roll when in
vibratory mode.
(j) Rolling shall continue until the specified requirements for density
have been met.
(k) No more than 90 minutes shall elapse between the time that water
is added to the cement and the time the DLC is deposited in place,
unless the DLC is batched on the airport where this time limit shall
be reduced to 60 minutes
(l) No more than 120 minutes shall elapse between the time that
water is added to the cement and the time the DLC, including DLC
in any overlying layers, is compacted to its final position, unless
the DLC is batched on the airport where this time limit shall be
reduced to 90 minutes. No water shall be added to the DLC after
batching and before final compaction.

132.4.11 CURING DLC
(a) After compaction of the DLC has been completed as specified it

shall be protected for a period of seven days against drying out
by covering with polyethylene sheeting or by the application of an
appropriate bitumen emulsion which shall be reviewed without
objection by the Project Manager. Alternatively, a curing
compound may be applied by s pray meeting the requirements
of Section 1 3 2 . 5 of this GMWS. Curing application shall begin
as soon as possible after the completion of finishing operations.
The finished DLC shall be kept moist continuously until the curing
material is placed.
(b) Where polyethylene sheeting is used, the surface of the DLC

course shall be entirely covered by sheeting weighted to remain
in contact with the material. Joints in the sheeting shall overlap
by at least 300 mm and be set to prevent egress of water.
(c) The curing material shall be maintained and applied as needed

by the Contractor during the seven day protection period so that
all of the DLC will be covered effectively during this period.
(a) Following completion of the DLC course, the Contractor shall

perform all maintenance work necessary to keep the DLC in a
satisfactory condition meeting the specified requirements. The
surface shall be kept clean and free from foreign material. The
DLC course shall be properly drained at all times.
(b) Trafficking of DLC course by construction plant or other vehicles

shall not be permitted until at least seven days have elapsed from
the time of placing. After that time traffic shall be restricted to that
necessary to place the succeeding layer or course.
(c) If damage such as ruts, ridges, cracks, loose material, pot holes
or other defects to the DLC course or any underlying layer occurs,
from trafficking the course or by any other reason, causing it to
fall outside of the GMWS requirements, the affected area shall be
removed to spoil by the Contractor and replaced using fresh
material.

132.4.13 TOLERANCES
(a) The finished surface shall not vary by more than 7 mm when
tested with a 3.0m straight edge. The finished surface shall also
(b) The elevation of the finished surface shall not vary by more than
(c) The thickness of the DLC course shall not be less than the
thickness indicated on the Employer's Drawings.
The tolerance on the ex-pavement target grading shall be as detailed

in Table 132.7.
132.4.14 TESTING: SURFACE LEVEL AND REGULARITY
132.4.14.1 Testing: surface level and regularity
(a) Levelling of the surface of the finished course shall be performed

by the Contractor at all changes of grade and on a grid which has
an interval of up to 10 m in two mutually perpendicular directions.
(b) The DLC course shall be tested for surface regularity parallel and
transverse to the directions of placing along parallel lines not less
than 5 m apart.
(c) Where the DLC course extends for more than 30 m in a given
direction, the finished surface shall be tested for regularity using
a profilometer which produces a continuous computerised
printout of the surface profile for visual reading and surface record.
(d) Where the DLC course extends for less than 30 m in a given
a 3.0 m straight edge.
132.4.14.2 Non-compliance: surface level and regularity
Any deviation of the finished thickness, level or regularity outside the

specified tolerances, shall be corrected by the Contractor by removing
material and replacing and finishing fresh material in accordance with
the GMWS.

132.4.15 TESTING: ROUTINE DLC TESTS
132.4.15.1 Testing: routine DLC tests
(a) The Contractor shall cut at least one core from each 500 m2 of
DLC course after the DLC has been cured for four days. The
method of taking the cores shall be in accordance with CS1.
When the Contractor can demonstrate to the Project Manager,
uniformity in production and continued compliance with the
GMWS, the Contractor may submit for review to the Project
Manager a request to reduce the frequency of coring to one core
from each 1,000 m2 of DLC course. However, at least two cores
shall be cut from each day's work. The cores shall be 150 mm in
diameter and shall be the full depth of the DLC. Holes formed by
taking DLC cores shall be reinstated using fresh DLC, which shall
be placed and compacted in 50 mm layers.
(b) Each core shall be tested for density in accordance with BS EN

12390-7:2009. For a two layer DLC course only the top layer shall
be tested for density.
(c) Each core shall be inspected to determine the thickness of the

DLC course.
(d) 150 mm DLC cubes shall be made and cured in accordance with
BS EN 12390-2:2008At least three cubes shall be made per
1,000 m2 of DLC course and not less than six cubes shall be made
per day. The cubes shall be tested after seven days in
accordance with BS EN 12390-3:2009.
132.4.15.2 Compliance criteria: routine DLC tests
(a) The cube specimens shall be used to determine compliance with

compressive strength. The DLC course represented by the three
cubes shall be deemed to satisfy the specified compressive
strength requirements if the conditions given in both (i) and (ii) are
achieved.
(i) The average strength determined from any group of four

consecutive test results is between 7 N/mm² and 10 N/mm².
(ii) The strength determined from any test result is not less
than 6.5 N/mm².
(b) The density of the DLC shall be such that the air voids are not
more than 5%. The air voids shall be derived from the difference
between the theoretical maximum dry density of the DLC
calculated from the specific gravities of the constituents of the mix
and the average density determined from any group of three
consecutive cores.

132.4.15.3 Non-compliance: routine DLC tests
(a) If the result of any test on the cubes fails to meet the requirements
of this GMWS then the areas of DLC which are represented by
them shall be removed by the Contractor and replaced using fresh
material.
(b) If the result of any test on the cores fails to meet the requirements
of this GMWS then additional cores shall be taken 5 m on each
side of the defective core to determine the limit of the defective
area of DLC. The defective area shall be removed by the
Contractor and replaced using fresh material.
132.4.16 TESTING: AGGREGATE SAMPLES TAKEN PRE- STOCKPILING
(a) Aggregate shall be tested in accordance with the following

requirements.
(i) Batch: ten per cent fines value (TFV) and plasticity index
(PI)
(ii) A batch of aggregate is a quantity not exceeding 2,500

tonnes of aggregate of the same type and obtained from
the same source.
(b) Testing: ten per cent fines value and plasticity index
(i) Each batch of aggregate shall be tested ex-stockpile for

ten per cent fines value and plasticity index.
(ii) The method of testing for ten per cent fines value shall be
in accordance with BS 812: Part 111/BS EN 1097-2: 1996,
except that the sample shall be soaked in water at room
temperature for 24 hours and shall not be oven-dried
before testing.
(iii) The method of testing for plasticity index shall be in

accordance with BS 1377: Part 2: 1990. Sample
preparation shall be by wet sieving the material over a 425
micron BS test sieve.
(iv) Four sets of test results shall be submitted with the

particulars detailed in Section 132.4.4.1 of this GMWS.
Thereafter, three set of tests shall be carried out for every
batch of aggregate.
(c) Non-compliance: ten per cent fines value and plasticity index
(i) If the result of any test does not comply with the
requirements specified in Table 132.10 then four additional
sets of tests shall be carried out. The continued use of the
material source shall depend on the results of these
additional tests being reviewed without objection by the
Project Manager.

132.4.17 TESTING: AGGREGATE SAMPLES TAKEN EX-PAVEMENT
132.4.17.1 Testing: aggregate samples taken ex-pavement
(a) Each area of DLC course which contains DLC material of the
same type and the same mix, produced at the same mixing plant,
which is laid and compacted in a single layer in one day shall be
divided into lots. Each lot shall be a maximum size of 2,500 m2.
(b) One sample of DLC material shall be taken from each lot of DLC
after placing and compacting. The sample shall be large enough
to enable all of the tests detailed in this Section to be carried out.
(c) Any damage caused to the DLC course by taking the sample
shall be repaired by the Contractor using a method which has
(d) Each sample shall be tested to determine the particle size

distribution in accordance with BS EN 933-1: 2012.
132.4.17.2 Compliance criteria: aggregate samples taken ex-pavement
The results of tests for particle size distribution shall comply with Table
132.11 and shall be within the specified tolerance of the ex- pavement
target grading.

132.4.17.3 Non-compliance: aggregate samples taken ex-pavement
If the result of any test does not comply with the specified requirements
then three additional samples shall be taken from the lot and tested for
the non-complying property. If the result of any of these additional tests
fails to comply with the specified requirements then the non-complying
lot shall be removed by the Contractor and replaced using fresh
material.
132.5 PAVEMENT QUALITY CONCRETE COURSE
132.5.1 GENERAL
(a) The works and materials specified in Sections 132.5.1.2 to

132.5.1.8 of this GMWS shall comply with the sections stated
including all testing requirements, unless otherwise stated in this
section.
(b) The Contractor shall provide production and field test summaries
on an on-going daily basis (or other agreed period) to monitor
compliance and trends in test results (in particular, flexural
strength, compacting factor, air content and density) and submit
these promptly to the Project Manager. The format of the test
summaries shall be agreed with the Project Manager. The
Contractor shall take appropriate action as required (including
raising non-conformance reports etc) to ensure compliance with
the GMWS.
Formwork and finishes to the PQC course shall comply with Section 18
of the GMWS.
132.5.1.3 Reinforcement
Steel reinforcement for the PQC course shall comply with Section 19 of
the GMWS.
132.5.1.4 Pavement quality concrete
All requirements of Section 20 of the GMWS shall apply unless

otherwise stated in this section.
Curing compound for the PQC course shall comply with Section 20 of
the GMWS, and shall also comply with ASTM C-309 (Type 2).
132.5.1.6 Admixtures
No admixtures other than air entraining agents and super-plasticisers

shall be used. The admixture for the PQC course shall comply with
Section 20 of the GMWS, and shall be no more than 6 months old at
time of use.

132.5.1.7 Water
Water for the PQC course shall comply with Section 132.3.2.2 of this
GMWS.
132.5.1.8 Aggregates and cement
Aggregates and cement for the PQC course shall comply with Section
20 of the GMWS and additional requirements for aggregates as noted
in Section 132.5.2.3.
132.5.1.9 PFA
PFA for use in PQC shall be in accordance with BS 3892: Part 1: 1997
(or BS EN 450-1: 2012).
132.5.2 MATERIALS
132.5.2.1 Reinforcement, dowel bars, tie bars and cradles
(a) Fabric reinforcement shall be fabric type A252 complying with BS

4483:2005. The fabric shall be manufactured from steel wire
which complies with BS 4482:2005 and which has a type 2 bond
classification.
(b) Dowel bars, cradles and tie bars for cradles shall be Grade 250
plain round steel bars complying with BS 4449:2005 + A3:2016.
Dowel bars shall be straight; both ends of dowel bars shall be
sawn square with all burrs removed. Cropping and/or the use of a
guillotine to cut dowel bars shall not be permitted.
(c) Tie bars shall be Grade 460 type 2 deformed high yield steel bars
complying with BS 4449:2005 + A3:2016.
(d) The deformation from the true shape of dowels shall not exceed
1 mm on the diameter of the dowel, and shall not extend more
than 1mm from the end of the dowel.
(e) Dowels shall be clean and free from mill scale, loose rust or oil.

132.5.2.2 Cement mortar for cradles
Cement mortar for supporting cradles shall consist of one part of

cement to three parts of fine aggregate together with the minimum
amount of water necessary to achieve a consistency suitable for the
required work. Fine aggregates shall be sand or crushed rock to BS
1200 1976/BS EN 13139:2002 and shall pass a 5 mm BS test sieve.
132.5.2.3 Aggregates
(a) Coarse aggregates shall consist of clean, sound, durable particles

of crushed granite rock and shall be free of disintegrated material,
friable material, weathered material, lumps or balls of clay, organic
matter or other deleterious materials. Gravel, crushed gravel and
natural sand shall not be permitted as coarse aggregates.
(b) The flakiness index of the coarse aggregate shall not exceed 30%.
(c) The ten percent fines value of the coarse aggregate shall be at
least 120 kN.
(d) The coarse aggregate shall be a graded aggregate complying with
Table 3 of BS EN 12620:2002.
(e) The coarse aggregate shall have a water absorption of less than
2% and have a magnesium soundness value of less than 5% after
five cycles.
(f) Natural sand fine aggregate shall be non-plastic and have a
magnesium soundness value of less than 5% after five cycles.
(g) The Fineness Modulus of the fine aggregate shall be between
2.50 and 3.40 when tested in accordance with ASTM C33.
(h) Aggregates shall, if necessary, be washed before use to remove
any deleterious coatings and dust.
(i) A full petrological and mineralogical analysis of the aggregate
shall be carried out in accordance with ASTM C295/C295M-12
(2012)).
(j) Coarse and fine aggregate shall be tested separately for reactivity
in accordance with ASTM C1260. The aggregates shall be
considered innocuous if the expansion of the test specimens does
not exceed 0.10% at 28 days.
132.5.2.4 Polyethylene sheeting
Polyethylene sheeting used under the PQC shall be impermeable and

shall have a nominal thickness of 0.25 mm.

132.5.2.5 Joint filler
(a) The joint filler shall be a proprietary type reviewed without

objection by the Project Manager and shall be firm, compressible,
single-thickness and non-rotting.
(b) The joint filler shall comply with the requirements of Section 20 of
the GMWS except that each of the four specimens in the
compression and recovery test shall have a recovery value of at
least 80% and the extrusion of the free edge of the specimen shall
not exceed 4 mm as determined by the extrusion test.
132.5.2.6 Joint sealant
(a) The joint sealant shall be of a grade suited to the climatic

conditions of Hong Kong and shall perform effectively over a
temperature range of 0°C to 60°C.
(b) The joint sealant shall be Fosroc Colpor 200PF or similar
equivalent and shall be reviewed without objection by the Project
Manager.
(c) The joint sealant shall be an elastometric based sealant, cold
poured, two-part, polymer-based, and jet fuel resistant sealant
complying with BS 5212, Type F.
(d) Primer for use with joint sealant shall be a proprietary type
recommended by the joint sealant manufacturer and reviewed
(e) For flexible pavement joints an epoxy primer shall be used. The
epoxy primer for use with joint sealant shall be a proprietary type
132.5.2.7 Bond breaker tape and Backer rod
(a) Bond breaker tape shall be a proprietary type recommended by

the joint sealant manufacturer and reviewed without objection by
the Project Manager. The tape shall be a polyethylene film with
adhesive applied on one side and shall be the full width of the
groove.
(b) Backer rod shall be a proprietary type recommended by the joint
sealant manufacturer and reviewed without objection by the
Project Manager. The rod shall be a closed cell, expanded
polyethylene rod and oversized such that it fits tightly in the joint.

132.5.2.8 Groove forming strip
(a) Where shown on the Employer’s Drawings, groove forming strip

shall be a proprietary type reviewed without objection by the
Project Manager. The strip shall be a firm compressible strip of
either ethylene vinyl acetate foam with a density of at least 90
kg/m3 or synthetic rubber. The strip shall have the same
dimensions as those detailed on the Employer's Drawings for the
groove.
(b) The groove forming strip shall be sufficiently rigid to remain in
position during concreting without deforming or stretching.
(c) Adhesive for groove forming strip shall be a proprietary type
recommended by the groove forming strip manufacturer and
132.5.2.9 Sleeves for dowel bars
Sleeves for dowel bars shall be PVC and shall have a nominal wall
thickness of 5 mm. The sleeves shall fit tightly to the bars.
132.5.2.10 Epoxy resin grout
Epoxy resin grout shall be a proprietary type reviewed without objection

by the Project Manager.
132.5.3 PAVEMENT QUALITY CONCRETE
132.5.3.1 PQC mix
(a) The PQC shall be supplied as a designed mix, batched, mixed

and transported in accordance with Section 20 of the GMWS. The
PQC shall comply with the relevant clauses of BS 8500-2:2012 +
A1:2016.
(b) The concrete shall have a characteristic flexural strength at 28
days of 4.5 N/mm2.
(c) The nominal maximum size of aggregate shall be 40 mm.
(d) PFA shall be used in combination with Portland cement. The
proportion of PFA by mass to the total cementitious content shall
be between 15 and 25%.
(e) The weight of fine aggregate shall be between 30 and 35% of the
total weight of aggregate.
(f) A minimum of 25% of the combined aggregate (by weight) shall
be retained on the 20 mm sieve.
(g) A maximum of 3% of the combined aggregate (by weight) shall
pass the 0.15 mm sieve.
(h) The target compacting factor shall be between 0.82 and 0.85
when measured in accordance with BS EN 12390-4:2000 using
the large apparatus.
(i) The maximum free water/cementitious material ratio shall be 0.45.

(j) The air content of the mix, based on measurements in accordance
with BS EN 12390-7:2009 made on the concrete immediately after
discharge from the mixer shall be uniform and able to permit the
requirements of Section 132.5.10(p) of this GMWS to be met.
132.5.3.2 Cementitious content of PQC
(a) The minimum cementitious content of PQC shall be 350 kg/m3.

(b) The maximum cementitious content of PQC shall be 420 kg/m3.
(c) The temperature of the cement when batched shall not exceed
60°C.
132.5.4 SUBMISSIONS
132.5.4.1 Particulars of materials for joints
The following particulars of the proposed materials for joints in the PQC
course shall be submitted to the Project Manager for review without
objection at least 20 days prior to scheduled construction of the trial
area:
(a) manufacturer's literature and a certificate for joint filler
showing the manufacturer's name, the date and place of
manufacture and showing that the joint filler complies with the
requirements and including results of tests for:
(i) disintegration and shrinkage;
(ii) recovery value and reduction in mass;
(iii) extrusion; and
(iv) manufacturer's literature for joint sealant, including details of
the method and time required for mixing the different
components, and a certificate showing the manufacturer's
name, the date and place of manufacture and showing that
the sealant complies with the requirements and, where
applicable, results of tests for:
 application life;
 tack-free time;
 resistance to flow;
 recovery;
 adhesion and cohesion in tension and compression;
 resistance to heat ageing;
 manufacturer's literature and a certificate for groove
forming strip showing the manufacturer's name, the date
and place of manufacture and showing that the groove
forming strip complies with the requirements and
including results of tests for density; and
 particulars of primers for joint sealant, adhesive for
groove forming strip, bond breaker tape, backer rod and
sleeves for dowel bars.

132.5.4.2 Representative samples of materials for joints
Representative samples of the following proposed materials shall be

submitted to the Project Manager at the same time as particulars of the
material are submitted:
(a) polyethylene sheeting;
(b) joint filler;
(c) bond breaker tape;
(d) backer rod;
(e) groove forming strip; and
(f) sleeves for dowel bars, including compressible filler.
132.5.4.3 Particulars of materials for PQC
(a) At least 40 days prior to scheduled construction of the trial area

the Contractor shall provide the Project Manager with a statement
of the origin, and method of extraction of all aggregates proposed
for the Permanent Works. The Contractor shall also provide
evidence demonstrating that an adequate supply of uniform
material can be produced.
(b) At least 40 days prior to scheduled construction of the trial area
the Contractor shall submit the particulars detailed in Sections
20.6.1 (a) to 20.6.1 (c) of the GMWS.
At the same time as the particulars detailed in Section 132.5.4.3 (b) are
for review without objection. The sample, which shall be a minimum of
two 50 kg samples, shall be accompanied by a full petrological and
12 (2012).

132.5.4.5 Particulars of PQC mix and methods of construction
(a) The following particulars of each proposed designed PQC mix

shall be submitted to the Project Manager for review without
objection at least 40 days prior to scheduled construction of the
trial area.
(i) quantity of each constituent per cubic metre of
compacted PQC.
(ii) type and source of cement and PFA.
(iii) type and quantity of admixture.
(iv) type and source of fine and coarse aggregates.
(v) grading details in tabular and graphical form of coarse
and fine aggregates, including combined grading curves
and details of the proportions in which the fine and
coarse aggregates are combined.
(vi) workability in terms of target compacting factor.
(vii) method of construction.
(viii) test or trial mix data, including 28 days beam flexural test
results, carried out on mixes that validate the proposed
mix constituents.
(b) The test results from all test mixes shall be submitted to confirm
the nominated mix has been optimised.
(a) Particulars of the proposed batching and mixing plant to be used

including a layout plan and the output of the plant and details of
the methods used to measure and control materials in each batch,
objection.
(b) The proposed batching and mixing plant shall not be located in an
airside area in order to prevent any potential FOD (Foreign Object
Damage).
132.5.5 TRIALS
132.5.5.1 Production Trials
(a) For each different nominated design mix of PQC the Contractor
shall prepare three separate batches of PQC using the materials
and mixing plant which he proposes to use for the Permanent
Works.
(b) On completion of the trials the Contractor shall submit a detailed
Production Trial Report (refer to Section 132.5.5.9 (c)).

132.5.5.2 Testing: production trials
(a) Two large apparatus compacting factor tests shall be carried out
on each batch in accordance with BS EN 12390-4:2000.
(b) Three 150 mm x 150 mm x 750 mm long test beams and three
150 mm diameter x 300 mm long test cylinders shall be cast from
each batch. The making, curing and testing of all test specimens
shall comply with the requirements of the relevant parts of BS EN
12390.
(c) The three cylinders from each batch shall be tested for
compressive strength at seven days and the three beams shall
be tested at 28 days for flexural strength. The density of all test
specimens shall be determined in accordance with BS EN
12390-7:2009 before they are tested.
(d) One grading shall be determined by wet analysis per batch. Also,
one air content in accordance with BS EN 12390-7:2009 shall be
determined per batch.
132.5.5.3 Compliance criteria: trial mix PQC
(a) Each compacting factor test shall be within ± 0.02 of the target
compacting factor.
(b) The mean flexural strength of the three beams from the same
batch shall be 5.1 N/mm2 or greater and no individual beam
strength shall be less than 4.5 N/mm2.
(c) The gradings shall comply with Section 132.5.14.2 of this GMWS.
(d) The air content shall be uniform and no result shall vary by more
than 1% from the mean.
132.5.5.4 Non-compliance: trial mix PQC
If any of the test results fail to satisfy the specified requirements the
Contractor shall repeat the whole test sequence with a different mix.
(a) Prior to commencement of PQC operations for the Permanent

Works, the Contractor shall construct, a trial area to be reviewed
without objection by the Project Manager but not less than 750
m2 for each different PQC mix and for each different thickness of
PQC course. The trial will be used to determine the adequacy of
the Contractor's Equipment, loose material depth measurement,
placement methods and the resulting field density.
(b) The trial area shall comprise at least two runs of minimum length
of 50 m and shall contain at least one construction and
contraction joint. The trial area shall contain an area of hand laid
PQC and also an area containing fabric reinforcement. The trial
area shall be carried out on completed underlying DLC / WLC
courses which meet the requirements of the GMWS.

(c) The trial area may form part of the Permanent Works if it meets
all the requirements of this GMWS. Materials used to construct
the trial area shall be those which have been reviewed without
objection for use in PQC and equipment shall be that intended
for use in constructing the Permanent Works.
(f) The Contractor shall structure his construction trial to
demonstrate the capacity and ability of his concrete mix plant,
delivery vehicles, respective paving spreads and personnel to
produce concrete paving which meets the requirements of this
GMWS including:
(i) setting up forms
(ii) edge thickening
(iii) formation of a block-out
(iv) compaction
(v) finishing
(vi) texturing
(vii) curing
(viii) protection of plastic concrete
(ix) construction of construction and contraction joints
(a) At least ten cores shall be cut from the trial area to determine the
thickness of the slab, the density of the PQC, the positions of the
reinforcement and joint components, the amount of segregation
of the constituents and the presence of voids. The method of
taking, preparing, inspecting and testing PQC cores shall be in
accordance with CS1. The cores shall be cut when the PQC is
not less than four days old. The cores shall be tested for density
and 7 day compressive strength in accordance with BS EN
12390-7:2009 and BS EN 12390-1:2012 respectively.
(b) All core holes shall be filled and compacted with fresh PQC to
achieve the required density and air content. The finished
surface of the reinstated core shall be flush with the adjacent
pavement surface after curing.
(c) One pair of 150 mm x 150 mm x 750 mm long test beams and
one pair of 150 mm diameter x 300 mm long cylinders shall be
cast for each 75 m2 of the trial area. The beams shall be tested
for flexural strength at 28 days. The making, curing and testing
of all test specimens shall comply with the requirements of BS
EN 12390.

(d) The trial area shall be tested to determine the accuracy of the
alignment and level, the surface regularity and the texture depth.
The method of testing the surface regularity shall be as stated in
Section 132.5.15.1 of this GMWS. The method of testing the
texture depth shall be as stated in Section 132.5.16.1 of this
GMWS.
requirements:
(a) The regularity, levels and thickness of the PQC course shall
comply with Section 132.5.14.6 of this GMWS.
(b) The texture depth shall comply with Section 132.5.16.2 of this
GMWS.
(c) The positions of the reinforcement and joint components shall
comply with Sections 132.5.14.3, 132.5.14.4 and 132.5.14.5 of
this GMWS.
(d) PQC cores shall not show evidence of segregation. The extent
of voids in the core shall be "few" in accordance with Table 4 of
CS1 and there shall be no honeycombing.
(e) The density of cores shall confirm the requirements of Section
132.5.10(q) of this GMWS.
(f) The flexural strength of the test beams shall comply with Section
132.5.17.2(a) of this GMWS.
Manager for review without objection. Further trial areas shall be
constructed until the result of every test on the trial area complies
with the specified requirements for the trial area. Further trial
mixes shall be made unless non-compliance of the trial area was
not due to the PQC mix.
shall be removed.

132.5.5.9 Commencement of PQC placement
(a) PQC shall not be placed in the Permanent Works, other than in
a trial area, until the result of every test on the trial area complies
with the specified requirements for the trial area, except as noted
in Section 132.5.5.9 (b).
(b) PQC may be placed in the Permanent Works before the results
of tests for flexural strength of the trial area are available provided
that the result of every other test on the trial mix and trial area
complies with the specified requirements for trial mix PQC and
for the trial area.
(c) On satisfactory completion of the trial area, and before placement
of the Permanent Works, the Contractor shall provide the Project
Manager with a Production Trial Report with specific details of
the Placement Procedure, which shall form an integral part of the
Quality System for the Project. The Production Trial Report
shall provide details of the mix design used and test results
achieved and details of the plant and procedures used to meet
the requirements of this GMWS.

specified requirements shall not be changed without the permission of

(a) Joint sealant, primer for joint sealant and adhesive for groove
forming strip shall be stored in sealed containers marked to
identify the contents and protected from exposure to conditions
which may adversely affect the material. The materials shall be
stored in accordance with the manufacturers' recommendations
and shall not be used after the recommended shelf life has been
exceeded.
(b) Polyethylene sheeting, joint filler, bond breaker tape, backer rod,
groove forming strip and sleeves for dowel bars shall be stored
in accordance with the manufacturers' recommendations in a dry,
weatherproof store with a raised floor. Joint filler shall be stored
in sealed plastic bags and shall not be exposed to moisture or air.
(c) Aggregates shall be handled and stored at the mixer site in such
a manner as to avoid degradation, segregation or contamination
by foreign materials. Sites for stockpiles shall be prepared and
maintained in such a manner as to prevent the inclusion of
foreign materials with the aggregate. The stockpile base shall be
paved so that the area is trafficable during wet weather by the
delivery trucks and equipment using the areas, such that
contamination of the aggregates does not occur. Aggregate shall
be deposited in stockpiles and removed therefrom in such
manner as to avoid segregation. The stockpiling shall be carried
out in such a manner that a continual turnover of aggregates is
achieved. When segregation is apparent, the aggregate shall be
remixed before use. Each size of aggregate from each source
shall be stored separately in free-draining stockpiles, and shall
be handled in such manner that the different sizes will not
become mixed.
(d) The Contractor shall establish a monitoring system reviewed
without objection by the Project Manager to ensure that at the
point of delivery to the batching plant the moisture content
variation of samples on any day do not exceed 1.5% by mass for
coarse aggregate and 2.5% by mass for fine aggregates.
(e) Bulk cement shall be delivered in weather-tight carriers and shall
be unloaded into the storage facilities by means of weather-tight
conveyors or other suitable means that will protect the cement
completely from moisture. Immediately upon receipt, cement
shall be stored in an approved dry weather-tight and properly
ventilated structure with adequate provisions for prevention of
absorption of moisture. Details of the storage structures shall be
submitted to the Project Manager for review without objection.


below the PQC course shall be completed and fill material shall
be deposited and compacted in trenches before the PQC course
is constructed. Openings to manholes, chambers and gullies
shall be protected by temporary covers.
(b) Box-outs shall be formed in the PQC course for covers, frames
and other hardware, the covers, frames and other hardware shall
be fixed in position after the main slab has been concreted and
before the infill slab is concreted.
(a) The Contractor shall notify the Project Manager before PQC is
(b) The underlying layer shall be undamaged, clean and free from
foreign material and shall have been reviewed without objection
(c) A separation layer, consisting of a single layer of 0.25 mm thick
polythene sheet shall be placed on the DLC or WLC course. It
shall be laid flat and shall have laps of 150 mm. It shall butt
against the side forms or adjacent lanes on either side without
gaps. It shall be laid such that joints are staggered and it shall be
kept flat by securing it to the DLC or WLC course using felt nails.
Polythene sheets which are torn or otherwise damaged shall not
be used.
132.5.8 FORMWORK
(a) Straight side forms shall be made of steel of a thickness capable

of supporting the PQC and shall be in sections not less than 3 m
in length.
(b) Forms shall have a depth equal to the specified edge thickness
of the PQC, without horizontal joint. Shims shall be used to level
the forms. Forms shall not be embedded in the DLC or WLC base.
(c) Where dowel bars and tie bars are required in construction joints,
the forms shall have adequate provision for their insertions and
for rigidly supporting them in the correct alignment. Where the
Employer’s Drawings show thickening of slab edges, forms may
be built up with metal or wood. In this instance the depth of the
forms may be increased up to 25% by securely bolting or welding
to the bottom thereof a metal section of the required thickness or
by securely bolting wood planks to the bottom of the steel form.
The metal section or wood planks shall completely cover the
underside of the base of the steel form, and shall extend beyond
the edge of the form a sufficient distance to provide the
necessary stability against movement of the vertical face.

(d) Forms shall be free of warps, bends or kinks. The top surface of
a form shall not vary from a straight edge by more than 3 mm in
3 m. The face of the form shall not vary more than 3 mm from
vertical. Forms with damaged top surfaces or distorted faces or
bases shall not be used and shall be removed from the Site.
Forms shall be cleaned and oiled each time before PQC is to be
placed. All forms shall be inspected by the Contractor prior to
commencement of concreting operations.
(e) Formed surfaces shall have a Class F3 finish.
(f) Formwork shall be set and checked at least one day prior to
placing PQC. Forms when set ready for paving shall be mortar
tight and maintained in that condition during the paving process.
(g) The Contractor shall provide and operate a scratch template to
check the shape and level of the DLC or WLC course and to
confirm the minimum thickness of concrete specified will be
achieved between the forms. The template shall be capable of
riding on the forms.
(h) The Contractor shall check and confirm that the design gradient
of the PQC can be achieved within the specified tolerance for the
PQC prior to commencing any PQC works.
132.5.9.1 General
(a) Joints shall be of the type, and in the position, indicated on the
Employer's Drawings. The joint layout shall not be altered without
the permission of the Project Manager, except that construction
joints shall be used instead of contraction joints when required
by Section 132.5.9.4 of this GMWS.
(b) All joints shall be constructed with their faces perpendicular to
the surface of the pavement.
(c) Materials for joints in the PQC course shall be used in
accordance with the manufacturers' recommendations.
(d) Grooves in the PQC course for joint sealant shall be straight,
shall have parallel sides and shall be perpendicular to the top
surface of the slab. The bottom of the groove shall be flat and
shall be parallel to the top surface of the slab.
132.5.9.2 Sealing joints
(a) Before permanent sealing, grooves in the PQC course shall be

protected from contamination by a temporary sealing strip or
nylon cord.
(b) The permanent sealing of joints in the PQC course shall be
carried out at least seven days after concreting.

(c) Immediately before permanent sealing, temporary seals, dirt and
loose material shall be removed from the groove and the sides of
the groove shall be cleaned and roughened by water jetting or
abrasive blasting. The groove shall be clean and surface dry at
the time of applying the primer and joint sealant.
(d) Where recommended by the sealant manufacturer, bond breaker
tape or a backing rod shall be fixed continuously and evenly
along the bottom of the groove for the full width and length of the
groove.
(e) Primer and joint sealant shall be applied in accordance with the
manufacturer's recommendations.
132.5.9.3 Dowels and tie bars
(a) Dowel bars and tie bars shall be perpendicular to the joint.
(b) Dowel bars and tie bars shall be of the size, spacing and in the
location shown on the Employer's Drawings.
(c) Tie bars shall not be painted, greased, coated with asphalt or
enclosed in sleeves.
(d) Sleeves shall be provided for each dowel bar as indicated on the
Employer's Drawings. The sleeves shall fit the dowel bars tightly,
and the closed ends shall be watertight and substantial enough
to prevent collapse. For expansion joints the closed end of the
dowel sleeve shall contain 50 mm of compressible filler.
(e) Individual dowel and tie bars shall be omitted where the centre of
the dowel or tie bar will be located within 300 mm of a transverse
joint.
132.5.9.4 Contraction joints
(a) Contraction joints shall be perpendicular to the centre-line of the

paving lane and shall extend the full width of the slab.
(b) An initial groove shall be sawn as soon as the PQC has hardened
sufficiently to permit cutting without chipping, spalling or tearing,
but not later than 15 hours after the PQC has been compacted.
The initial groove shall be at least one quarter of the depth of the
slab.
(c) If uncontrolled cracking of an area of the PQC bounded by joints
occurs, the PQC within this area shall be removed and reinstated.
(d) The final groove shall be sawn to the width and depth specified
on the Employer's Drawings not less than seven days after
concreting. The centre lines of the initial and final grooves shall
coincide.

132.5.9.5 Expansion and isolation joints
Grooves shall be formed by using formers shown on the Employer’s

Drawings or other formers reviewed without objection by the Project
Manager and shall not be formed by raking out the joint filler. The
grooves shall be located over the joint filler such that the upper surface
of the joint filler is entirely contained in the groove.
132.5.9.6 Construction joints
(a) Construction joints shall be installed at the locations shown on

the Employer's Drawings and when it is necessary to suspend
the PQC placement for more than 30 minutes. Location of
construction joint shall be reviewed without objection by the
Project Manager.
(b) When the installation of a transverse construction joint can be
planned in advance, it shall be located at a contraction or
expansion joint. The joint shall not be allowed within 2.5 m of a
contraction joint shown on the Employer's Drawings. If the
pouring of the PQC has been stopped, causing a joint to fall
within this limit, the fresh PQC shall be removed to the previously
spaced regular joint.
(c) The groove can be sawn or formed. If sawn, the cut shall be
made not less than seven days after concreting. If formed, a
groove forming strip shall be used and it shall be fixed to the
existing slab using groove forming strip adhesive.

132.5.10 PLACING AND COMPACTING PQC
(a) All standing water shall be removed prior to placing PQC.

(b) Mixing and concreting operations shall be discontinued when a
descending air temperature in the shade and away from artificial
heat reaches 5°C and shall not be resumed until an ascending
air temperature in the shade and away from artificial heat
reaches 2°C.
(c) The temperature of the PQC shall not be less than 10°C at the
time of placement.
(d) The temperature of the concrete at the time of placing in the
forms shall not exceed 32°C.
(e) Where the ambient temperature is greater than 32°C full hot
weather concreting techniques as described in ACI document
ACI 305R-10, shall be implemented.
(f) The Contractor shall provide adequate artificial lighting facilities
for night pouring.
(g) All PQC sections, except those detailed in Section 132.5.10(l) of
this GMWS, shall be carried out by a self-propelled concrete train
or modified slip form paver in conjunction with fixed side forms.
(h) Concrete paving trains shall consist of at least a concrete
spreader, a surface compaction plate, a compactor finisher and
a diagonal levelling finisher or other similar finishing equipment.
The spreader shall deposit the concrete in a substantially uniform
layer over the full width of the lane. Vibrating equipment used in
compacting the concrete shall be an approved surface type with
vibrating pans or vibrating beam or beams of combinations
thereof. Equipment necessitating poker or internal vibrators
drawn through plastic concrete will not be permitted.
(i) Modified slip form pavers shall be a machine which has the side
conforming plates removed or rendered ineffective and travels
over preplaced fixed forms. The paver shall achieve a similar final
concrete pavement as that which would be achieved by the use
of fixed form concrete paving trains.
(j) All construction traffic shall be propelled in such a way that it does
not cause damage to the DLC or WLC course or PQC course. If
damage does occur which causes the course to fall outside this
GMWS requirements then the affected area shall be removed by
the Contractor and replaced using fresh material.
(k) The mixed PQC shall be placed and distributed evenly over the
base by means of spreaders. The mix shall not be deposited
direct on the base by lorry, skip, by hand, or in any way which
might cause uneven compaction or segregation of the mix.
(l) The PQC shall either be placed against fixed forms or against
adjacent PQC slabs which have been in place for at least 24
hours. PQC shall not be placed against excavated surfaces or
kerbs.

(m) PQC areas which have irregular dimensions or are inaccessible
to self-propelled machines shall be placed by hand as described
in Section 132.10.1(m) of this GMWS. Where it is necessary to
lay the pavement over an area which has a group of manholes
or pits closely placed, the area may be concreted by hand.
Submission to do so shall be forwarded to the Project Manager
for review without objection.
(n) Hand laid PQC shall be placed and distributed evenly over the
base by means which will ensure uniformity and continuity of
spread and shall not cause uneven compaction or segregation of
the mix. Hand laid PQC shall be compacted by internal
mechanical vibration or hand manipulated vibrating tampers.
Vibrators shall not be dragged through the PQC nor used to
spread or transport concrete.
(o) Vibrators used in either hand or machine placed concrete shall
not contact joint fillers, dowels, tie bars, reinforcement or the DLC
or WLC course and any immersion vibrators shall not be dragged
horizontally.
(p) The fabric reinforcement shall be positioned 100 mm below
finished surface level and shall extend over for the full area of the
slab, except that it shall not be placed within 100 mm of the sides
of the slab or within 75 mm of dowel bars or tie bars.
(q) The concrete shall be uniformly compacted including adjacent to
the forms and joints to a density that gives air voids of not more
than 3% when derived from the difference between the
theoretical maximum dry density of the PQC calculated from the
specific gravities of the constituents of the mix and the average
density determined from any cores. The Contractor shall
establish an operating procedure to achieve this and shall
continually monitor and report on the procedure to the Project
Manager. Cores need only be taken where adherence to the
procedure cannot be verified.
(r) Concreters shall not work within the formwork during placement
and compaction of PQC. A stable and safe working platform shall
be erected on the slip form system for access such that the PQC
can be properly compacted without segregation.
(s) No more than 90 minutes shall elapse between the time that
water is added to the cement and the time the PQC is deposited
in place. Where PQC is batched on the airport, this time limit
shall be reduced to 60 minutes.
(t) No more than 120 minutes shall elapse between the time that
water is added to the cement and the time that the PQC, including
PQC in any overlying layers, is compacted and finished to its final
position. Where PQC is batched on the airport, this time limit shall
be reduced to 90 minutes. This period shall be reviewed should
weather conditions cause an earlier initial set.

132.5.11 SURFACE FINISH
132.5.11.1 General
(a) Finishing operations shall comprise transverse finishing,

longitudinal straight-edge finishing, floating and broom finishing,
in that order and shall be started immediately after compaction of
the PQC and completed as soon as possible.
(b) Where a paving train is used, the finisher shall not operate more
than 35 m behind the spreader.
132.5.11.2 Finishing and Texturing
(a) Fine finishing of machine placed PQC shall be carried out using
equipment with an orthogonal or diagonal type machine which
shall be capable of fine finishing the PQC pavement to the
specified cross section and longitudinal profiles and to within
specified surface tolerance, and such as to produce a dense
smooth surface true to shape and level. Manipulation of the PQC
which results in an excess of mortar or water being brought to
the surface shall be avoided.
(b) Fine finishing of hand placed PQC shall be by at least two passes
of a mechanical vibrating screed or counter rotating tube screed.
(c) After fine finishing of the surface is completed, but before

texturing and initial curing and while the PQC is still plastic, minor
irregularities and score marks in the pavement surface shall be
eliminated by means of long handled, hand operated straight-
edges used in conjunction with long bladed, long handled hand
operated floats. The blades of the straight-edges shall be not less
than 3 m long. Floats shall be at least 1.2 m wide. When
necessary, excess water and laitance shall be removed from the
surface transversely by means of the float. The hand operated
float shall be used to smooth and fill in open textured areas in the
pavement surfaces.
(d) The surface shall also be tested for trueness with a 3 m straight-
edge held in successive positions parallel and at right angles to
the centreline of the pavement or any other direction and in
contact with the surface and the whole area covered as
necessary to detect variations. The straight-edge shall be
advanced along the pavement in successive stages of not more
than one-half the length of the straight-edge.
(e) After the PQC course has been compacted and before the curing
compound is applied, the surface, other than the surface of
channels and edges of slabs which do not require to be textured,
shall be textured by brushing with a wire broom at right angles to
the direction of paving.
(f) The Contractor shall use suitable wire brooms to achieve a
consistent quality of brush finish meeting the requirements of
Section 132.5.16.2.

(g) The wire broom shall be at least 450 mm wide and shall have two
rows of tufts. The rows shall be 20 mm apart and the tufts in each
row shall be at 10 mm centres and in line with the centre of the
gaps between the tufts in the other row. The tufts shall contain
an average of 14 wires, each of 32 gauge and initially 100 mm
long. The broom shall be replaced if any tuft wears down to a
length of 90 mm.
(h) The surface texture shall be produced by brushing evenly across
the slab in one direction. Brushing shall be carried out after the
moisture film has disappeared from the PQC surface and before
the initial set is complete.
(i) The marks in the pavement surface shall be uniform in
appearance without disfiguring marks.

132.5.12 CURING PQC
(a) Concrete shall be cured by protection against loss of moisture

and rapid temperature changes for a period of not less than
seven days from the completion of the finishing operations.
(b) Curing shall comprise of initial curing followed by moist curing for
at least 24 hours and then followed by more membrane curing.
(c) Immediately after the finishing operations have been completed
and until the concrete has set sufficiently to prevent marking of
the surface, the surface of the concrete shall be kept
continuously damp by a combination of a water fog or mist
applied with spraying equipment and protective tentage which
has been reviewed without objection of the Project Manager.
(d) When the concrete has set sufficiently to prevent marking of the
surface, the entire surface of the newly placed concrete shall be
moist cured for a period of not less than 24 hours. During moist
curing the entire surface of the newly placed concrete shall be
kept wet for the 24 hours period. The method of moist curing shall
have been reviewed without objection by the Project Manager.
(e) On completion of the moist curing and for the remainder of the
curing period the entire exposed surface of the concrete shall be
uniformly coated with a curing compound that has been reviewed
without objection by the Project Manager. The concrete shall not
be allowed to dry out before the application of the membrane.
(f) The curing compound shall be of such type that it will become
stable and impervious to evaporation of water from the PQC
surface within 60 minutes of application and shall have an
efficiency index of 90% when tested in accordance with BS
7542:1992.
(g) Standby facilities for all curing processes shall be provided.
(h) If the curing compound membrane is damaged by any cause, the
damaged parts shall be repaired immediately.
(i) Forms shall not be removed from the PQC until at least 15 hours
after placing the PQC. The formed finished shall be reviewed
without objection by the Project Manager as soon as the
formwork has been removed. The vertical faces of the PQC shall
immediately be coated with curing compound of RC-2 bituminous
material.

(a) After completion of the PQC course the Contractor shall perform
all maintenance work necessary to keep the PQC in a
satisfactory condition.
(b) If damage occurs to the PQC from trafficking the course or by
any other reason, or if a crack of any kind occurs in the PQC then
all bays which contain an affected area shall be removed by the
Contractor and replaced with fresh material meeting the
requirements of Section 132.5 of this GMWS.
(c) Loads which are not essential to construction of the PQC course
shall not be applied to the PQC course until at least 14 days after
concreting has been completed and until all grooves at joints
have been temporarily or permanently sealed or protected.
(d) Metal wheels shall not be allowed to run on the PQC at any time.
132.5.14 TOLERANCES
132.5.14.1 Tolerances: formwork
(a) The line of formwork for the PQC course shall be within 5 mm of
the specified line.
(b) The level of the top of the formwork shall be within 3 mm of the
specified level of the PQC course.
(c) Abrupt irregularities in the line of the formwork and in the level of
the top of formwork shall not exceed 3 mm.

132.5.14.2 Tolerances: PQC Mix
The production mix shall not vary from the nominated PQC Mix by more
than the tolerances listed below:
Combined Aggregate Grading Percent Passing Sieve
Aggregate passing 5 mm Sieve or ±4

larger
Aggregate passing BS Sieves from ±3
2.36 mm to 0.6 mm
Aggregate passing 0.3 mm BS Sieve ±2
Aggregate passing 0.15 mm BS ±2
Sieve
Material Percent of Mix Design

Quantity
Cement ±1
Air Entraining Admixture ±3
Water Shall not exceed nominated
PQC mix percentage
132.5.14.3 Tolerances: dowel bars, tie bars and reinforcement
(a) Dowel bars at joints in the PQC course shall be within ± 6 mm of

the specified vertical position, and evenly spaced along the
formwork to within ± 25 mm of the specified spacing.
(b) Dowel bars shall be perpendicular to the joint, both vertically and
horizontally, to within a tolerance of 2.5 mm per 250 mm length
of bar. The error in parallelism between any two consecutive bars
shall not exceed 3 mm.
(c) Tie bars shall be perpendicular to the joint, both vertically and
horizontally, to within a tolerance of 30 mm per 600 mm length of
bar.
(d) The cover to fabric reinforcement in the PQC course shall be
within 10 mm of the specified cover.
132.5.14.4 Tolerances: grooves
Unless otherwise recommended by the manufacturer of the joint

sealant the depth of grooves for joint sealant in the PQC course shall
be within 3 mm of the specified depth.

132.5.14.5 Tolerances: alignment of joints
Joints in the PQC course shall be within 5 mm of the specified line and
shall be continuous across intersections of joints to within 5 mm.
132.5.14.6 Tolerances: thickness, level and regularity of PQC course
 3 mm from the required level.
(b) Discontinuities in level across joints shall not exceed 3mm
subject to the requirements of Section 132.5.14.6(c) also being
met.
(c) The finished surface shall not vary by more than 3 mm when
tested with a 3.0 m straight edge on a uniform slope. The finished
surface shall also not vary by more than 5 mm per 3 m when
tested with a profilometer. The finished surface level shall not
pond water.
(d) The thickness of the PQC course shall not be less than the
(e) The finished surface levels shall produce a grade within ± 0.1%
of the specified gradient when comparing adjacent levels
obtained in accordance with Section 132.5.15.1(a) of this GMWS.
(f) The finished surface shall not pond water.

(b) The finished surface shall be tested for surface regularity parallel
and transverse to the direction of placing along parallel lines not
less than 5 m apart.
(c) Where the PQC extends for more than 30 m in a given direction,
the finished surface shall be tested for regularity using a
profilometer which produces a continuous computerised printout
(d) Where the PQC extends for less than 30 m in a given direction,
the finished surface shall be tested for regularity using a 3.0 m
straight edge.
(e) The surface shall be inspected for honey-combing.

(a) Isolated spots, not exceeding 2 m2, which do not comply with the
specified tolerances shall be ground down if the total area does
not exceed 10 m2 in any 1,000 m2 of surfacing. Any isolated high
spots where grinding is permitted shall on completion be finished
with a uniform grooving operation to provide a texture
approximately 1.5 mm in depth. When the non-compliance
cannot be corrected using this procedure, or the total area
exceeds 10 m2 in any 1,000 m2 of surfacing, the Contractor shall
remove the entire bays which contains the defect and replace
them with fresh material in accordance with this GMWS.
(b) If any areas of PQC exhibit honey-combing on the surface then
the Contractor shall remove the entire bay which contains the
defect and replace it with fresh material in accordance with this
GMWS.
132.5.16 TESTING: TEXTURE DEPTH
132.5.16.1 Testing: texture depth
The texture depth of the PQC surface shall be determined by the sand
patch test detailed in Appendix A10.1 of the GMWS. Tests shall be
carried out at least four days after the surface texturing has been carried
out and before the area is used by the Contractor's Equipment or other
vehicles. One test shall be carried out per 250 m2 of pavement.
132.5.16.2 Non-compliance: texture depth
(a) Areas with an average texture depth less than 0.7 mm shall be
grooved using 3 mm by 3 mm grooves at 32 mm spacing.
(b) The average texture depth shall not be less than 0.7 mm, and
(c) Not more than one out of ten successive measured texture
depths shall be less than 0.6 mm.
(d) The maximum texture depth shall not be more than 1.2mm.

132.5.17 TESTING: ROUTINE PQC TESTS
132.5.17.1 Testing: routine PQC tests
(a) 150 mm x 150 mm x 750 mm long PQC beams shall be made,

cured and tested in accordance with BS EN 12390-2:2009. At
least three beams shall be made per 500 m2 of PQC slab and not
less than six beams shall be made each day. The beams shall
be tested for flexural strength after 28 days in accordance with
BS EN 12390-5:2009.
(b) The workability shall be determined by the large apparatus
compacting factor test in accordance with BS EN 12390-4:2000.
A minimum of one test shall be carried out per 250 m2 of slab laid
or 10 times per day, whichever is the greater. The tests shall be
carried out at the point of placing.
(c) For each production shift the Contractor shall confirm the mix
proportions. In addition one grading by wet analysis and one test
for air content shall be carried out for each production shift.
(d) The temperature of every batch of concrete at the time of placing
shall be measured.
132.5.17.2 Compliance criteria: routine PQC tests
(a) The beam specimens shall be used to determine compliance with

flexural strength. Compliance shall be assumed if the conditions
given in both (a) and (b) are met:
consecutive test results exceeds 4.8 N/mm2.
than 4.5 N/mm2.
(b) The compacting factor shall be maintained at ± 0.03 of the target
compacting factor. Any alteration to the optimum workability
necessitated by a change in conditions shall have been reviewed
(c) The grading of the mix shall comply with Section 132.5.14.2 of
this GMWS.
(d) The air content shall be within 1% of the mean air content
established in the production trials
(e) All concrete batches at time of placing shall meet the
requirements of Section 132.5.10(c) of this GMWS.
132.5.17.3 Non-compliance: routine PQC tests
(a) When test specimens do not comply with the flexural strength
requirements the production represented by the test results shall
be rejected and removed from the Site.
(b) If any determination of workability gives a result outside the
tolerance, a further test shall be made immediately on the next
available load of PQC. The average of the two consecutive

results and the difference between them shall be calculated. This
load shall not be discharged if the average is not within the
tolerance or the difference between readings from the two loads
is greater than 0.06. Further samples shall be taken from
subsequent delivery vehicles, which shall not be allowed to
discharge into the Permanent Works until compliance with this
GMWS has been established.
(c) Should the mix proportions used in a shift not meet the
requirements of Section 132.5.14.2 of this GMWS the Contractor
shall not place any PQC in the Permanent Works until the
method of rectification has been reviewed without objection by
the Project Manager and been implemented.
(d) Should the air content not meet the requirements of Section
132.5.17.2(d) of this GMWS the Contractor shall modify his
compaction procedure to achieve the requirements of Section
132.5.10(p) of this GMWS. The hardened concrete shall then be
tested by coring to determine compliance with Section
132.5.10(p) of this GMWS. Concrete not meeting the
requirements of Section 132.5.10(p) of this GMWS shall be
removed from the Permanent Works.
(e) Batches of concrete not meeting the requirements of Section
132.5.10(c) of this GMWS shall be removed from the Permanent
Works.
132.5.18 TESTING: ALIGNMENT OF DOWEL BARS AND TIE BARS
132.5.18.1 Testing: alignment of dowel bars and tie bars
(a) For every 100 m length of construction and expansion joint, a 6

m length shall be selected following the stripping of formwork
within which the alignment of every dowel bar and tie bar shall
be measured relative to the PQC slab by the Contractor, in the
presence of the Project Manager. The measurements shall be
carried out before the adjacent slab is poured.
(b) All dowel bars and tie bars shall also be visually checked for
alignment and straightened to suit.
132.5.18.2 Compliance criteria: alignment of dowel bars and tie bars
(a) Dowel bars shall comply with Section 132.5.14.3(b) of this

GMWS.
(b) Tie bars shall comply with Section 132.5.14.3(c) of this GMWS.

132.5.18.3 Non-compliance: alignment of dowel bars and tie bars
(a) If more than one 6 m length fails to comply in any group of four
consecutive tests then the Contractor shall revert to the
construction of trial areas and make any necessary alterations
until the method of ensuring dowel bar and tie bar alignment has
(b) Misaligned dowels or tie bars in hardened concrete shall be sawn
off and a replacement dowel/tie bar drilled and set into the
concrete using materials and methods that have been reviewed
132.5.19 TESTING: MATERIALS FOR JOINTS
132.5.19.1 Batch: joint filler, joint sealant
A batch of joint filler or joint sealant shall comply with Section 20.8.24
of the GMWS.
132.5.19.2 Samples: joint filler, joint sealant
Samples of joint filler or joint sealant shall comply with Section 20.8.25
of the GMWS.
132.5.19.3 Testing: joint filler, joint sealant
Testing of joint filler and joint sealant for joints in the PQC course shall
be as stated in Sections 20.8.26 (a) and 20.8.26 (b) of the GMWS
except as stated in Sections 132.5.2.5 and 132.5.2.6 of the GMWS.
132.5.19.4 Testing: joint sealant
Each sample of joint sealant shall be tested to determine the application

life, tack-free time, resistance to flow, recovery, adhesion and cohesion
in tension and compression and resistance to heat ageing. The method
of testing shall be in accordance with BS 5212.
132.5.19.5 Testing: PFA, Admixtures, Cement, Aggregate and Curing

Compounds
Sampling and testing shall be as per Section 20 of the GMWS.

132.6 POLYMER MODIFIED MARSHALL ASPHALT WEARING COURSE
AND MARSHALL ASPHALT BASE COURSE
132.6.1 INTRODUCTION
(a) Polymer modified Marshall asphalt wearing course (PMMAWC)

shall consist of mineral aggregate, filler and polymer modified
binder mixed in a mixing plant and placed on a prepared
underlying course in accordance with this GMWS.
compliance and trends in test results and submit these promptly
to the Project Manager. The format of the test summaries shall
be agreed with the Project Manager. The Contractor shall take
appropriate action as required (including raising non-
conformance reports etc) to ensure compliance with the GMWS.
(c) Where shown on the Employer’s Drawings, the Marshall Asphalt
Wearing Course (MAWC) used on runway and taxiway shoulders
and RESAs does not require a polymer modified binder. In lieu
of the polymer modified binder, a 60 - 70 penetration grade
bitumen to ASTM D946 shall be used. The MAWC mix shall
fully meet the requirements of PMAWC except for the
Deformation Resistance; Hamburg Wheel Tracking; Stiffness
Modulus and Flow Number properties contained in Table 132.18.
(d) The asphalt mixing plant shall have sufficient production capacity
to meet the contract requirements.
132.6.2 MATERIALS
132.6.2.1 General
(a) Aggregates, filler and bitumen for use in the construction of
polymer modified Marshall asphalt wearing course shall meet the
requirements of this GMWS.
(b) The Contractor shall submit full details including the proposed
manufacturing plant, quality control procedures and source
material information for any polymer modified binder supplier
who is intended to manufacture the polymer modified binder on
the Site.
(c) If material is obtained from more than one source each must
meet the requirements of this GMWS. The Contractor shall
supply evidence demonstrating that each material source can
meet the requirements of this GMWS. This evidence shall be

132.6.2.2 Polymer Modified Binder
(a) The polymer modified binder shall be procured from suppliers
and delivered to the Site in Bitutainers or equivalent containers.
The procurement details shall be reviewed without objection by
material information for any polymer modified binder that is to be
manufactured on the Site.
(c) The polymer modified binder shall be one of the following: BP
Olexobit AB5, Shell Cariphalte PG76 or Ooms Avenhorn
Sealoflex 5-50 (JR) and shall meet the requirements stated in
Table 132.12. The polymer modified binder used for runway
works shall have added fuel resistant capabilities.
(d) All pre-blended polymer modified binder shall be stored in
accordance with a quality control procedure which follows the
manufacturer’s instructions detailing the mode of circulation or
agitation in the storage tank necessary to ensure homogeneity is
maintained.
(e) The susceptibility of pre-blended polymer modified binder to
separation or instability during prolonged storage at high
temperatures shall be tested prior to the commencement of the
Works in accordance with Appendix A132.6.1 and shall meet the
requirements of Table 132.12. Alternative storage temperatures
may be proposed to the Project Manager for review without
objection by submitting a letter of recommendation from the
polymer modified binder manufacturer/supplier, which shall
demonstrate that the proposed polymer modified binder is
storage stable at the respective temperature.
(f) When the Contractor proposes to blend polymer modified binder
on the Site, on-Site blending of polymer modified binder shall be
carried out in accordance with the manufacturer’s
recommendations. The Contractor shall supply evidence
demonstrating that each production meets the requirements of
Table 132.12.
(g) If binder modifiers are partially insoluble when analysis is carried
out to determine the soluble binder content in accordance with
ASTM D2172/D2172M-11, then test results shall be submitted
that:
(i) establish the degree of insolubility of the modifier; and
(ii) determine the adjustment to the measured soluble binder
content that will be necessary. If requested by the Project
Manager, analysis of the polymer content of polymer
modified material shall be carried out in accordance with a
method recommended by the polymer supplier or other
agreed analysis method.

Table 132.12: Required properties of polymer modified binder
Property Test Method Unit Requirement Note
Penetration at ASTM D5 0.1mm Reported -

25oC
Softening Point ASTM D36 °C Reported -
Viscosity at ASTM Pa.s <3 -
135oC D4402
Dynamic Shear, AASHTO kPa > 1.00 -
G*/ sin δ, at 70oC TP5
and 10 rad/s
Flash Point ASTM D92 °C > 230 -
Rolling Thin Film AASHTO - - -
Oven Test T240
(RTFOT)
Mass Loss AASHTO % < 1.0 After
T240 RTFOT
Dynamic Shear, AASHTO kPa > 2.20 After
G*/sin δ, at 70oC TP5 RTFOT
and 10 rad/s
Increase in ASTM D36 °C < 10 -
Softening Point
Pressure Ageing AASHTO °C 100 -
Vessel (PAV) PP1
Test
Dynamic Shear, AASHTO kPa < 5000 After
G*/ sin δ, at 34 oC TP5 PAV
and 10 rad/s Test
Storage Stability Appendix - - -
A132.6.1
Difference in ASTM D5 0.1mm <9 After
Penetration Storage
Stability
Difference in ASTM D36 °C <5 After

Softening Point Storage
Stability
Multiple Stress AAHSTO kPa-1 <0.25 at Target

Creep Recovery TP70 64°C values
(MSCR) Jnr3.2 <0.5 at 70°C
<1 at 76°C
Multiple Stress AAHSTO % To be tested To be
Creep Recovery TP70 at 64°, 70°C reported
(MSCR) Jnrdiff and 76°C only

132.6.2.3 Aggregate
(a) Aggregate shall be obtained from a source which has been

(b) Aggregate shall consist of clean, hard, durable particles of
crushed granite rock blended if necessary with sand or other inert
finely divided mineral aggregate. Gravel or crushed gravel shall
not be permitted. Aggregate shall be uniform, have an affinity for
bitumen and be capable of being coated evenly. Aggregate shall
be free from weathered material, vegetable material,
disintegrated or friable matter, clay, organic matter, and other
deleterious substances.
(c) The portion of the material retained on the 2.36 mm sieve shall
be known as coarse aggregate, the portion passing the 2.36 mm
sieve and retained on the 0.075 mm sieve as fine aggregate, and
the portion passing the 0.075 mm sieve as filler.
(d) Coarse aggregate shall have the properties stated in Table
132.13.
Table 132.13: Properties of coarse aggregate
Los Angeles Abrasion ≤30% wear after 500

revolutions
Magnesium Soundness ≤5% loss after five cycles
Ten Per Cent Fines Value (TFV) ≥180kN
Flakiness Index (FI) ≤20%
Elongation Index ≤25%
Water Absorption ≤2%
Material finer than 0.075 mm in ≤2%
Aggregates (by washing)
Note: Alternatively FI < 25% if tested to BS EN 933-3 2012

(e) Coarse aggregate for each asphalt mix required shall be supplied
in not less than the following number of fractions:
(i) 20 mm and 28 mm nominal maximum size mix – three
fractions
(ii) 14 mm nominal maximum size mix - two fractions
The grading for each fraction shall be submitted to the Project
Manager for review without objection.

(f) Fine aggregate shall consist of clean, hard, durable, angular
particles produced by crushing rock meeting the requirements for
wear and soundness specified for coarse aggregate. If necessary,
to obtain the required mixed aggregate grading and required
workability, natural sand may be used. In this case the
percentage of sand shall be below 15% by weight of the total
mixture.
(g) Fine aggregates shall comply with the requirements of Table
132.14.
Table 132.14: Properties of fine aggregate
Water Absorption:
. crushed aggregate Not more than 2.5%
. uncrushed aggregate Not more than 2.0%
Material finer than 0.075 mm in
Aggregates: (by washing)
. sand aggregate Not more than 5.0%
. combined aggregate Not more than 5.0%
Magnesium Soundness Not more than 5% after 5

cycles
Sand Equivalent to ASTM D 2419 Not less than 45
Methylene Blue Value (MBV) to Not more than 5mg/g

ISSA Technical Bulletin No 145
132.6.2.4 Filler
(a) Added filler shall consist of hydrated lime to ASTM C 1097 or BS

EN 459-1: 2010. It shall be in accordance with the limits given in
Table 132.15.
Table 132.15: Grading requirements for filler
Sieve Size (mm) Percent by mass passing
0.6 100
0.3 95 – 100
0.075 70 – 100
(b) The reclaimed dust extracted from the aggregates during asphalt
production may also be used as filler, subject to the requirements
of Sections 132.6.2.4(a) and 132.6.2.5(b)(ii) being met.
(c) Filler shall be stored in dry conditions.

132.6.2.5 Combined aggregate and filler
(a) Combined aggregate and filler for polymer modified Marshall

asphalt wearing course shall conform to the grading shown in
Table 132.16 and shall not vary from the low limit on one size of
sieve to the high limit on an adjacent sieve, or vice versa. The
Contractor shall initially target the centre of the grading band to
produce the combined aggregate grading. This grading shall be
adjusted should the specified polymer modified Marshall asphalt
requirements be demonstrated as not achievable.
Table 132.16: Combined aggregate grading for polymer modified

Marshall asphalt
Percent by mass
Percent by mass passing
passing
Sieve Size Polymer Modified
(mm) Polymer Modified
Marshall Asphalt
Marshall Asphalt Wearing
Wearing Course
Course Taxiway
Grooved Runway
40 -- --
28 100 --
20 90 – 100 100
14 76 – 90 96 – 100
10 67 – 84 78 – 86
5 50 – 70 56 – 64
2.36 35 – 53 41 – 47
1.18 25 – 40 30 – 36
0.6 19 – 33 22 – 28
0.3 13 – 25 13 – 19
0.15 8 – 16 8 – 12
0.075 4–6 4–6
(b) The combined aggregate and filler shall also conform to the
(i) The material passing the 0.3 mm sieve shall be non-plastic
when tested in accordance with BS 1377: Part 2: 1990;
and
(ii) Between 1% and 1.5% by mass of the combined
aggregate and filler shall be hydrated lime filler.
132.6.2.6 Bond coat
Bond coat to be applied to existing bituminous surfaces shall comply

with Section 132.8 of this GMWS.

132.6.2.7 Pavement reinforcement mesh
The pavement reinforcement mesh shall be a knitted, glass fibre strand

with the following characteristics:
(a) Tensile strength shall be at least 100 kN/m in two mutually
perpendicular directions
(b) Weight shall be greater than 0.4 kg/m²
(c) Elongation at break shall be a maximum of 4%
(d) Melt point shall exceed 1,000°C
(e) Mesh shall be self-adhesive with sufficient bond to allow normal
construction traffic and paving machinery operations.
132.6.3 DESIGN OF POLYMER MODIFIED MARSHALL ASPHALT
132.6.3.1 General
(a) The Contractor shall notify the Project Manager at least seven
days before carrying out the mix designs and associated tests.
(b) The mix design process shall be repeated each time that there is
a change in sources of material.
132.6.3.2 Polymer modified Marshall asphalt mix design
(a) Polymer modified Marshall asphalt shall be designed in

accordance with the Marshall Method of Mix Design stated in The
Asphalt Institute Handbook "MS-2 Mix Design Methods for
Asphalt Concrete and other Hot-mix Types" (TAI MS-2).
(b) In carrying out the tests mechanically operated compaction
equipment shall be used. This equipment shall deliver the same
compactive effort per blow as the standard Marshall compaction
hammer. The compaction shall be 75 blows each side and three
test specimens shall be prepared for each polymer modified
binder content used.
(c) The mix shall meet the grading requirements of Table 132.16 and
shall attain the properties given in Table 132.17. When plotted,
the particle size distribution of the aggregates, determined in
accordance with BS EN 933-1:2012, shall give a smooth curve
within the specified aggregate grading as listed in Table 132.16
and shall not vary from the low limit on one size of sieve to the
high limit on an adjacent sieve nor vice versa.
(d) The laboratory manufactured samples for all polymer modified
Marshall asphalt wearing course shall comply with the
requirements given in Table 132.17 at the target binder content
when determined for each mixture in accordance with the
procedures stipulated in TAI MS-2. In addition the polymer
modified Marshall asphalt wearing course shall meet the
performance requirements described in Table 132.18.

(e) The Contractor shall make arrangements for the polymer
modified Marshall asphalt core samples which are required for
the performance related testing described in Table 132.18 to be
tested at an accredited laboratory reviewed without objection by
the Project Manager. If the testing facilities are not available in
HOKLAS credited laboratories, the same can be undertaken at
the laboratories in the Universities in Hong Kong or in any other
overseas accredited laboratories reviewed without objection by
(f) At the target polymer modified binder content, the Loss of
Stability, shall not be greater than 10 %.
Table 132.17: Marshall design criteria
Test Required Property
Number of blows each side 75

Minimum Stability (kN) 12.0
Flow (mm) 3.0 – 4.0*
Air voids (%) 3.0 – 5.0
Minimum Voids in Mineral Aggregate (%) 14.0 (Runway)
13.0 (Taxiway)
Polymer Modified Binder Content (percent) 5.0 – 6.0
Minimum Bitumen Film Thickness 7.5
(microns)
* Alternative values may be agreed with the Project Manager subject

to the Contractor submitting a letter of recommendation from the
Material Supplier.

Table 132.18: Additional performance requirements for polymer
modified Marshall asphalt
Property Test Test Specification Compliance

Condition
Indirect AASHTO 25oC (dry Average of 3 > Job Mix,

Tensile T283 sub-set) 1.0MPa Trial
Strength Minimum Sample,
(ITS) individual > Laid Material
0.75MPa
AASHTO After freeze Job Mix,
T283 thaw cycles Average of 3 > Trial
(wet sub-set): 0.80MPa Sample,
> 16 hours at Minimum Laid Material
-18oC, then individual >
0.65MPa
24 hours at
60oC, then ITSRatio (ITSwet
divided by
> 3 hours at
ITSdry) > 0.80
25oC
Fatigue BS EN Temperature Average of 2 > Job Mix
Life * 12697-24: 20oC 4,000 load
2012 Initial tensile repetitions
strain 300 Minimum
individual > 3,500
load repetitions
Deformation BS 598- Temperature Rut Depth < 7mm Job Mix
Resistance 110: 1998 60oC (Average of 6) Trial Sample
Rate of Rutting <
5mm/hour
(Average of 6)
Hamburg BS EN Temperature Target maximum Job Mix
Wheel 12697-22 60oC (water rut depth of Trial Sample
Tracking bath) 4.0mm at 60,000 Thereafter,
60,000 passes for each twice during
passes specimen. the project.
(30,000 Stripping Inflection If the Job
cycles) Point to be Mix is
98% Marshall reported. changed
Density additional
Minimum two testing shall
samples be
undertaken.

Condition
Stiffness BS EN Temperature Between 3 and 6 Job Mix

Modulus 12697-26: 32oC GPa. Trial
(ITSM) 2012 Sample.
Thereafter,
additional
one test per
25,000
tonnes of
asphalt laid.
Flow Number AASHTO Temperature Less than 20,000 Job Mix,
T79-13 60oC microstrain at Trial
2,000 cycles Sample.
* Prior to testing, specimens shall be subjected to the laboratory

ageing test in accordance with Appendix A132.6.2.
Requirement for number of samples for testing:
1. Job Mix (Section 132.6.3.2(d)/Table 132.18):
1.1 Indirect Tensile Strength (ITS) = one set of six number

100mm diameter cores
1.2 Fatigue Life (ITFT) = one set of two number 100mm
diameter cores
1.3 Deformation Resistance = one set of six number 200mm
diameter cores
2. Trial Sample (samples removed from trial panel):
2.1 Indirect Tensile Strength (ITS) = one set six number 100mm
diameter cores
2.2 Deformation Resistance = one set of six number 200mm
diameter cores
3. Laid Material (samples removed from the main construction,

Section 132.6.14.1(a)-(b)):
3.1 Indirect Tensile Strength (ITS) = one set of six number 100
mm diameter cores, per area of up to 2,000 m².
(g) The proportions of the mix produced by this design shall be
known as the Design Mix Formula.

(h) The Design Mix Formula shall be submitted to the Project
Manager for review without objection at least 14 days prior to the
start of trial paving operations and shall give the percentage of
each sieve fraction of aggregate, the percentage of filler and
polymer modified binder and the temperature of the completed
mixture when discharged from the mixer. All test data used to
develop the Design Mix Formula shall also be submitted
including a graphical presentation of the mix design.
132.6.3.3 Job Mix
(a) The Contractor shall optimize the properties of the design mix
using the ‘Range Method’ as described in the method for design
of the asphalt mix specified in Section 132.6.3.2.
(b) The Loss of Stability test shall be carried out on the Job Mix as
follows:
(i) determine Marshall Stability of specimens submerged in
water at 60°C for 30 minutes - result (a);
(ii) determine Marshall Stability of specimens submerged in
water at 60°C for 24 hours - result (b); and
(iii) loss of stability is ((a-b)/a) x 100% .
(c) If the Loss of Marshall Stability of the Job Mix is more than 10%,
the aggregates shall be rejected or the polymer modified binder
shall be treated with an anti-stripping agent which has been
reviewed without objection by the Project Manager. The
measures taken shall be such that a Job Mix with a loss of less
than 10% of the Marshall Stability is produced.
(d) The Contractor shall satisfy himself that when laid in the trial area
the Job Mix Formula will meet the criteria for wheel track rut
resistance and indirect tensile strength detailed in Section
132.6.5.4 of the GMWS.
(e) The Job Mix Formula shall include the percentage of combined
aggregate passing each sieve, the percentage of polymer
modified binder, and the temperature of the completed Job Mix
when discharged from the mixer.

132.6.4 SUBMISSION
132.6.4.1 Particulars of aggregate, filler and polymer modified binder
(a) The following particulars of the proposed aggregate, filler and

polymer modified binder shall be submitted to the Project
Manager for review without objection at least 40 days prior to
scheduled construction of the trial area.
(b) A certificate from the manufacturer for each type of filler showing
showing that the filler complies with the requirements stated in
Section 132.6.2.4 of the GMWS, including results of tests for
grading.
(c) A certificate from the manufacturer for polymer modified binder
showing the manufacturer’s name, the date and place of
manufacture, proof of Quality Assurance registration to
BS/EN/ISO 9000:2015 with an appropriate scope of registration
for the supply of polymer modified binder, and showing that the
polymer modified binder complies with the requirements stated
in Section 132.6.2.2 of the GMWS.
(d) A statement of the origin and method of extraction of all
aggregates proposed for the Works. The Contractor shall provide
material can be produced. Four sets of test results showing that
the aggregate meets the requirements stated in Section 132.2.3
of the GMWS shall also be submitted. Test results shall be
provided for each type and size fraction to be used.
(e) Further certificates showing that the materials comply with the
GMWS shall be submitted at intervals reviewed without objection
132.6.4.2 Particulars of mixes
(a) The following particulars of each Job Mix Formula shall be

submitted to the Project Manager for review without objection at
least 20 days prior to construction of the trial area:
(i) Source and type of constituent materials;
(ii) Percentage of each sieve fraction of aggregate, for each
aggregate size fraction and added filler;
(iii) Percentage of polymer modified binder;
(iv) Temperature of the completed mixture when discharged
from the mixer;
(v) Marshall test properties (graphical format);
(vi) Performance test properties (for polymer modified
Marshall asphalt); and
(vii) Bulk density and volumetric properties.
(b) Evidence shall be provided to demonstrate that the Job Mix
Formula can achieve the requirements detailed in Section

132.6.4.3 Particulars of supplier of polymer modified Marshall asphalt
(a) All operations in the procurement of component materials and

batching of bituminous materials shall be carried out by a
Contractor (or supplier on his behalf) who has a Quality
Assurance accreditation to BS/EN/ISO 9000:2015 for the
operations.
(b) The name of the supplier and the location and details of each
plant from which the Contractor proposes to obtain polymer
modified Marshall asphalt shall be submitted to the Project
commencement of the trial area. The Contractor shall provide
documented evidence of asphalt plant calibration including
recent calibration graphs for cold aggregate feeders for the
aggregates proposed for use.
132.6.4.4 Particulars of methods of laying and compacting polymer

modified Marshall asphalt
The following particulars of the proposed methods of laying and

compacting polymer modified Marshall asphalt shall be submitted to the
Project Manager for review without objection at the same time as the
particulars of the supplier are submitted.
(a) Details of contractor’s equipment, and
(b) Programme and rate of working.
132.6.4.5 Representative samples of aggregate, filler and polymer modified

binder
A representative sample of each type of aggregate, filler and polymer

modified binder shall be submitted to the Project Manager for review
without objection at the same time as the particulars of these materials
are submitted. The aggregate sample shall be a minimum of two 50 kg
samples and shall be accompanied by a full petrological and
mineralogical description to the requirements of ASTM C295.

132.6.5 TRIALS
(a) Prior to commencement of polymer modified Marshall asphalt

operations for the Works, the Contractor shall construct three trial
pavements, one of at least 525 m2 for polymer modified Marshall
asphalt wearing course mix and the remaining two, for two
taxiway fillets. The trial for the main polymer modified Marshall
asphalt wearing course mix shall comprise at least two adjacent
paver runs each of a minimum length of 70 m placed in echelon
and contain at least one 50 m continuous length of longitudinal
joint and at least 3.75 m of transverse joint. The runs shall be
between 3.75 and 7.5m in width unless agreed otherwise with
the Project Manager. The paving screed should be equipped with
90°, 60° or 45° confining side plates to ensure that neat and
stable pavement edges are formed. The sizes of the two taxiway
fillets shall be agreed with the Project Manager.
(b) The trial areas will be used to determine the adequacy of the
Contractor’s equipment, loose material depth measurements and
the relationship between number of compaction passes and
resulting density. The trials should demonstrate how the required
density and insitu air voids will be achieved. The taxiway fillet trial
areas should also demonstrate how the required surface levels
will be achieved. On completion of the trials, the Contractor shall
submit a Construction Trial Report in an agreed format to the
Project Manager. The Report shall contain details of the asphalt
mix design; plant employed; the placement and compaction
procedure and test results obtained.
(c) The trial areas shall be constructed off the Site over a sound and
stable asphalt pavement or on-site over previously completed
underlying course which meets the requirements of the GMWS
and shall be constructed with the materials and equipment
intended for use in constructing the Works. This shall include the
selected bituminous spray at the appropriate application rate,
trialled as described in Section 132.8.4.1 of the GMWS. Trial
areas constructed on-site shall be constructed in an area
considered by the Project Manager to be non-critical to Airport
operation and may form part of the Works if accepted.

(f) Based on the following techniques a methodology shall be
established which shall form the basis of the Asphalt Compaction
Procedure:
(i) Rollers shall be of the steel wheel and pneumatic-type and
shall be in good condition, capable of reversing without
backlash and shall be operated at speeds slow enough to
avoid undue displacement of asphalt material. They shall
be equipped with roll scrapers, absorbent mats and tanks
connected to spray pipes on both front and rear rolls to
ensure a uniform minimal application of water or parting
fluid. The number and weight of rollers shall be sufficient
to compact the mix to the required density and surface
finish while it is still in a workable condition;
(ii) A minimum of three rollers, two steel wheel, one of which
shall be vibrating, and one pneumatic-tyre type shall be
used with each spreading operation;
(iii) The sequence of rolling the first paving lane shall be to
proceed in the direction of laying and to roll the lower edge
of the lane first and then proceed towards the higher edge.
On adjoining paving lanes rolling shall begin by
overlapping the joint by 150 to 200 mm and shall progress
gradually to the opposite edge of the lane;
(iv) The speed of the roller shall, at all times, be sufficiently
slow and uniform to avoid displacement of the hot mixture,
and shall at no time exceed 5 km/h. Any pronounced
change of direction shall be made on stable material. The
line of rolling shall not be suddenly changed or the
direction of rolling suddenly reversed, thereby displacing
the mix. Any displacement occurring as a result of
reversing the roller or from any other cause shall be
corrected at once by raking and applying fresh mixture;
(v) To prevent adhesion of the mixture to the roller, the wheels
shall be kept properly moistened, but excessive use of
water/soap solution will not be permitted. A water bowser
shall be provided alongside each spreading unit to ensure
that rolling continues with the minimum interruption. The
tyres of pneumatic tyred rollers may be operated dry and,
if required to prevent pick-up, vegetable oil may be applied
to the tyres;
(vi) Rollers shall be operated by competent and experienced
drivers and shall be kept in operation continuously, if
necessary, so that all parts of the layer receive equal
compaction;
(vii) Use of equipment which results in crushing of the
aggregate will not be permitted. All rollers shall be
reviewed without objection by the Project Manager;

(viii) Breakdown rolling of the mixture shall comprise a
maximum of two passes and shall begin as soon after
spreading as the mixture will bear the roller without undue
displacement or cracking. The breakdown roller shall be
steel wheeled and shall be operated with the drive wheel
nearer to the paver. In no case shall the mix temperature
be allowed to drop below 155°C prior to commencement
of breakdown rolling;
(ix) For surface courses the compaction procedure shall
include kneading rolling. Pneumatic tyred rolling shall be
undertaken to knead the surface of the asphalt either
during or after compaction. This rolling shall consist of a
minimum of four coverages of a pneumatic tyre roller
having a wheel load not less than 2 tonnes and tyre
pressure not less than 850 kPa. Kneading rolling shall be
undertaken before the temperature of the mix falls below
140°C;
(x) Rolling shall continue until all roller marks are eliminated,
the surface is of a uniform texture and true to grade and
cross section, and the required density is achieved;
(xi) Final compaction and finish rolling shall be carried out by
means of a steel wheel roller unless otherwise designated.
Cross rolling shall be permitted up to a maximum of two
passes;
(xii) The asphalt surface appearance shall be consistent and
the surface texture depth shall be between 0.3 and 0.6 mm
when measured by the sand patch test; and
(xiii) Asphalt shall be compacted prior to the temperature of the
mix falling below 140°C.
(g) On completion of compaction of the polymer modified Marshall
asphalt wearing course, the Contractor shall demonstrate a
procedure for cooling the completed layer to 35°C (measured at
mid-depth) at least one hour before the Airfield is due to be
operational.
132.6.5.2 Samples: trial areas
(a) During construction of the trial areas three samples of polymer

modified Marshall asphalt mix shall be taken from each type of
mix at the mixing plant in accordance with BS EN 12697: Part 27:
2001.
(b) Ten 150 mm diameter cores shall be taken from each of the trial
areas in accordance with BS EN 12697: Part 27: 2001. At least
three of these cores shall be taken from joints.
(c) In addition, six 200 mm diameter cores and six 100mm diameter
cores shall be taken from the trial area in accordance with BS EN
12697: Part 27: 2001.

132.6.5.3 Testing: trial areas
(a) The loose polymer modified Marshall asphalt mix shall be

subjected to analyses of aggregate/filler grading and polymer
modified binder content in accordance with ASTM C136/C136M-
2014 and ASTM D2172/D2172M-11 respectively. The polymer
modified Marshall asphalt mix samples shall be tested in
accordance with Table 132.24.
(b) The bulk density and air voids of the ten 150 mm diameter
polymer modified Marshall asphalt cores taken from the trial
areas shall be determined as described in Sections 132.6.15.1(b)
and (c) of the GMWS.
(c) The wheel tracking rut depth and rut rate of the six 200 mm
diameter cores shall be determined at 60°C in accordance with
BS 598: Part 110 and the indirect tensile strength of the six
number 100mm diameter samples shall be determined to
AASHTO T283.
(d) Six sand patch tests shall be undertaken on each of the trial
areas in accordance with either ASTM E965; BS598 Part 3
Method 7 or Hong Kong CEDD Appendix 10.1 to determine the
surface texture depth.
132.6.5.4 Compliance criteria: trial areas
(a) The tests on polymer modified Marshall asphalt mix samples

shall comply with the Job Mix Formula and the requirements of
Section 132.6.11.1 of the GMWS.
(b) The bulk density and air voids tests on polymer modified Marshall
asphalt cores shall comply with the relevant requirements of
(c) The wheel tracking rut depth and rut rate, and the indirect tensile
strength, of the polymer modified Marshall asphalt cores shall
comply with the requirements stated in Table 132.18.
(d) The asphalt surface appearance shall be consistent and the
surface texture depth shall be between 0.3 and 0.6 mm when
measured by the sand patch test.

132.6.5.5 Non-compliance: trial areas
(a) If the result of any test on the trial areas does not comply with the
constructed until the result of every test on the trial areas
complies with the specified requirements for the trial areas.
(b) Trial areas, or parts of trial areas, which do not comply with the
specified requirements for the trial areas shall be removed.
132.6.5.6 Commencement of polymer modified Marshall asphalt placement
(a) Polymer modified Marshall asphalt shall not be placed in the

Works other than in a trial area, until the result of every test on
the trial areas complies with the specified requirements for the
trial areas.
(b) On satisfactory completion of the trial areas, and before
placement of the Works, the Contractor shall submit the Asphalt
objection. The Asphalt Compaction Procedure shall be clearly
documented in a Method Statement and shall form an integral
part of the Contractor's Quality System.
(c) Polymer modified Marshall asphalt shall not be placed in the
Works, without the permission of the Project Manager.
The material, mix design, methods of production and methods of


132.6.6 HANDLING, STORAGE AND TRANSPORT OF MATERIALS
132.6.6.1 Storage of polymer modified binder
(a) Polymer modified binder shall be closely monitored during hot

storage.
(b) Polymer modified binder shall not be stored at temperatures
higher than 180C for more than three days. A specialised
temperature controlled storage tank with a stirring facility to
maintain the homogeneity of the polymer modified binder during
hot storage shall be used. Any polymer modified binder left after
this period has elapsed shall be disposed. Following this disposal,
the storage tank shall be completely cleaned prior to being used
for storing a new batch of polymer modified binder.
(c) For each batch of polymer modified binder, a representative
sample (1 to 2 kg) shall be taken daily (from Day 0 to Day 3) in
accordance with ASTM D140/D140M-16 and the polymer
modified binder penetration and softening point (and other
properties listed at Table 132.14) shall be determined from a sub-
sample of the representative sample on the same day of
sampling. The remaining sub-sample shall be kept in a closed,
air tight container and adequately labelled for future reference.
One batch is defined as the quantity of material prepared and/or
produced in one operation or each delivery if produced off-site.
(d) The determined penetration and softening point values shall not
differ from those determined initially (at Day 0) by more than
9dmm and 5C respectively.
(e) In case of non-compliance, the polymer modified binder shall be
rejected and the Project Manager shall be made aware of
whether the polymer modified binder has actually been used for
asphalt manufacturing on that particular day. The Project
Manager shall have the right to refuse the respective polymer
modified Marshall asphalt mixture. For all polymer modified
Marshall asphalt laid using the rejected material, the Contractor
shall remove and replace such polymer modified Marshall
asphalt wearing course at its own cost without compensation of
any kind.
(f) Records showing batch number, storage temperature and
duration, and associated quality test results shall be prepared by
the Contractor and shall be available for inspection by the Project
Manager.

132.6.6.2 Handling, storage and transport of materials
(a) Polymer modified Marshall asphalt shall not be stored in heated

surge bins for more than eight hours or in transport vehicles for
more than three hours.
(b) Polymer modified Marshall asphalt shall be delivered to the paver
within 20oC of the Job Mix Formula temperature. Material
delivered to the paver outside of these limits shall be rejected.
(c) The Contractor shall follow the access routes reviewed without
objection by the Project Manager for delivery of polymer modified
Marshall asphalt.
(d) Each truck load of polymer modified Marshall asphalt shall be
accompanied by a ticket issued at the mixing plant by the
Contractor stating the truck number, time despatched and
temperature.
(e) The plant mixtures shall be transported without delay to the
laying sites from the mixing plant or from hot storage bins taking
care to prevent segregation. The vehicles shall be double
sheeted during transit and while waiting to prevent loss of heat,
contamination and wetting. All vehicles shall be mechanically
sound and roadworthy and shall be suitable for the spreading
equipment in use and shall have insulated bodies.
(f) The internal surfaces of the truck bodies shall be smooth, clean
and uniformly coated with a suitable non-hydrocarbon based
release agent to prevent adhesion of the mixture to the bodies.
Particular care shall be taken to ensure that pools of release
agent do not remain on the bottom of the bodies or are removed
before trucks are loaded with polymer modified Marshall asphalt.
(g) Loads that are below the minimum temperature, that have crusts
of cold unworkable material, that have been wetted by rain or
have been contaminated with other material shall be rejected.
(h) Hauling over freshly placed material shall not be permitted until
the material has been fully compacted and allowed to cool to
atmospheric temperature.

132.6.7 MIXING OF POLYMER MODIFIED MARSHALL ASPHALT
132.6.7.1 Mixing of polymer modified Marshall asphalt
(a) Each production unit or depot involved in the work shall be

registered under a Quality Assurance Scheme to BS/EN/ISO
9000:2015. The quality policy manual(s) for the supply of
component materials and batching of bituminous materials,
together with other relevant records and certificates, are to be
submitted prior to commencement of works on the Site.
(b) The Contractor shall be responsible for all testing for the supply
of bituminous materials and providing the Project Manager with
a written copy of the results, in accordance with the requirements
of Section 132.6 of the GMWS.
(c) All documentation relevant to the works, including records of
temperature control during mixing and test results, shall be
available at the plant or the depot for inspection. The
documentation, including worksheets, shall be stored in an easily
retrievable form for a minimum of three years.
(d) Polymer modified binder shall be heated within a temperature
range as recommended by the manufacturer; as a guide, a
temperature range of 170°C to 180C at the time of mixing is
applicable for any of the following binders, BP Olexobit AB5,
Shell Cariphalte PG76 or Sealoflex 5-50 (JR). Polymer modified
binders heated above 185°C shall not be used. The polymer
modified binder used for runway works shall have added fuel
resistant capabilities.
(e) Mixing, delivery, laying and compaction temperatures for
polymer modified Marshall asphalt are summarised in Table
132.19 below:
Table 132.19: Mixing, delivery, laying and compaction temperatures
for polymer modified Marshall asphalt
Binder Binder Binder Mixing Delivery Paver Compaction

Grade Temp Temp (Max) (Min) - Out (Min)‡
(Min) (Max) (Min)
Polymer 170°C 180°C 180°C 160°C 155°C 140°C

Modified
Binder
‡ This is the mid-layer temperature at which compaction shall

have been substantially completed.
* For guidance only; these values are applicable for BP
Olexobit AB5, Shell Cariphalte PG76 and Sealoflex 5-50 (JR).

(f) Each aggregate ingredient shall be thoroughly heated and dried
at such temperature that the temperature as recorded in the hot
fines bin after screening shall not exceed 180°C for asphalt
containing polymer modified binder. The Contractor shall carry
out moisture tests as detailed in Table 132.20 at least once a
week to check the effectiveness of the drying processes. If at any
time the tests specified indicate that the drying facilities are
inadequate as indicated by the criterion in Table 132.21 mixing
shall cease until the Contractor has improved his drying
capability to the satisfaction of the Project Manager.
(g) Immediately after heating, aggregate shall be screened in at least
three sizes and conveyed into separate bins ready for batching
and mixing with bituminous material. When the aggregates are
of such size and grading that separating into five bins is
impractical the number of required separations may be reduced
to four with permission of the Project Manager. The efficiency of
screening operations shall be sufficient to produce, at plant
operating capacity, gradations in each of the sizes of heated and
dried aggregates which are uniform and result in the production
of a mix complying with the limits specified for the Job Mix
Formula tolerances.
(h) Initial mixing time will be determined by the Contractor but shall
not be less than 30 seconds. Mixing time shall be increased if
additional time is necessary to obtain a homogeneous mixture
and satisfactory coating. On batch plants, the mixing time shall
begin at the start of the introduction of bitumen into the pug mill.
(i) The mixing time shall not allow significant hardening of the
polymer modified binder to occur.
(j) After mixing is complete the material shall be transported to and
placed on the underlying layer without delay. The material shall
be handled in a manner so as to prevent segregation or
contamination.
(k) Polymer modified binder content shall be calculated by weight of
total mixture.
(l) Alternative mixing using a drum mix plant will be reviewed by the
Project Manager subject to the Contractor demonstrating a
confirmed consistent source of uniformly graded single sized
material.

(a) Where new pavement is required to be constructed, pipes,

cables, manholes, chambers, gullies and other utilities below
airfield pavements shall be completed and fill material shall be
deposited and compacted in trenches before the pavement is
(b) Finishing around pits, chambers, gullies and other utilities shall
be carried out using polymer modified Marshall asphalt as part of
the paving process. Hand work and manually operated
equipment shall be used as required when working in confined
areas not accessible to normal paving machines. Contact
surfaces of manholes, light fitting bases and similar fixtures shall
be painted with a thin uniform coating of bituminous material
which has been reviewed without objection by the Project
Manager.
(c) Where required, and as shown on the Employer’s Drawings, light
fittings and their associated bases shall be removed prior to cold
milling of the surrounding pavement. The removed items shall be
stored until they are reinstated and protected from damage.
Following completion of cold milling and cleaning operations, the
bases or parts thereof shall be removed to the required level and
fitted with blanking plates to protect the lighting equipment from
contamination by hot asphalt, as detailed on the Employer’s
Drawings. At the completion of placement and sufficient cooling
of the asphalt, the asphalt shall be cored and the lighting can be
reinstalled to the correct line and level. The light fitting shall then
be reinstalled and reconnected.
(a) The existing asphalt wearing course shall be removed (if required)
by cold milling using a purpose built cold milling machine having
a drum width of not less than 2 m. The Contractor shall not apply
water during the milling operation. The depth of cutting shall be
controlled and shall be in accordance with the depths shown on
the Employer’s Drawings. In any case, the residual thickness of
the existing wearing course shall not be less than 25 mm. All
edges shall be cut by saw cut or other methods reviewed without
objection by the Project Manager to present a vertical clean edge.

(b) Cleaning of the milled surface shall be carried out by vacuum
sweeping, supplemented with hand brooms where necessary,
shovels and compressed air to remove adhering and compacted
cutting fines. The Contractor shall not apply water to clean the
milled surface.
(c) Bituminous sprays shall be applied to the cleaned underlying
course in accordance with Section 132.8 of the GMWS prior to
commencement of polymer modified Marshall asphalt placement.
(d) The Contractor shall notify the Project Manager before polymer
modified Marshall asphalt is placed in any part of the Works and
shall allow the Project Manager sufficient time to inspect the
underlying course.
(e) Where new pavement is required to be constructed, the
underlying layer treated with a bituminous spray in accordance
with Section 132.8 of the GMWS shall be undamaged, clean and
free from foreign material. The Contractor shall not commence
placement of the polymer modified Marshall asphalt until the
underlying treated layer has been reviewed without objection by
(f) The quantity of milled pavement shall not exceed the quantity of
asphalt stored in the batch plant surge bins plus delivery vehicles.
(g) The Contractor shall provide sufficient sweepers to clean the
existing pavement surrounding the milled surface to ensure no
deleterious material or debris being pick-up by the asphalt
delivery lorries and deposited onto the bond coated surfaces.
132.6.9 LAYING AND COMPACTION
132.6.9.1 General
(a) Asphalt shall be placed on a surface which is dry and only after
the applied bond coat has fully broken into polymer modified
binder and water and the water has evaporated.
and debris.
(c) The bituminous mixture shall not be placed when the surface
temperature of the underlying course is less than 5°C or
inclement weather is forecast.
(d) The asphalt surface appearance shall be consistent and the
surface texture depth shall be between 0.3 and 0.6 mm when
measured by the sand patch test.
(e) For the polymer modified Marshall asphalt, the Contractor shall
include the use of a Material Transfer Vehicles (MTVs) between
the delivery vehicle and the paving machine. The MTVs shall be
a purpose-built, pneumatic tyred, self-propelled mechanical
device capable of receiving hot asphalt from delivery vehicles,
storing and re-mixing the asphalt, and delivering the asphalt to
the hopper of the paver machine. The MTVs shall have a
minimum storage capacity of 20 tonnes.

(f) The polymer modified Marshall asphalt should be laid over areas
as large as possible to minimize the extent of cold joints and that
the laying arrangements shall be reviewed without objection by
the Project Manager. The arrangements for laying of polymer
modified Marshall asphalt should ensure that cold longitudinal
joints shall be avoided along the runway and taxiway centreline.
132.6.9.2 Laying of polymer modified Marshall asphalt
(a) Placing of polymer modified Marshall asphalt shall, whenever

possible, begin on the low side of pavements, and shall be
completed to the high point by the end of each work shift or when
inclement weather is forecast. The surface shall be left free
draining.
(b) Surface wearing courses shall, wherever possible, be placed by
pavers (with a capacity of not less than 100 tonnes per hour)
working in echelon and may be placed using level averaging
devices and joint matching devices should the Contractor
demonstrate that the tolerance requirement of Section
132.6.11.1 can be met.
(c) Polymer modified Marshall asphalt material shall be deposited by
suitable paving machine in uniform layers, without segregation
on the prepared, underlying layer to achieve a consistent surface
appearance. Unless agreed otherwise by the Project Manager,
paver widths shall be between 3.75 and 7.5 m. Where 3.75m
paver widths are adopted, the material shall be laid by echelon
paving methods. With the approval of the Project Manager, the
Contractor may elect to use a smaller paver width for use on
taxiway fillets. Material shall be placed to such loose depth that,
when compacted, the layer will have the thickness specified on
the Employer’s Drawings. The paving machine shall spread the
material so as to avoid or minimise the need for hand
manipulation.
(d) Upon arrival at the point of placement, the mixture shall be
spread to the full width by a suitable bituminous paver. The speed
of the paver shall be regulated to eliminate pulling and tearing. It
shall be operated at a speed which coordinates satisfactorily with
the rate of delivery of the mixture to the paver so as to provide a
uniform rate of placement without intermittent operation.
(e) The mix shall be delivered at a temperature of not less than
160oC. The moisture content of the mix shall not exceed 0.5%.
(f) Polymer modified Marshall asphalt from different mixing plants
shall be placed in separate lots as referred to in Section
132.6.14.3(a) of the GMWS. Polymer modified Marshall asphalt
from different mixing plants shall not be delivered to the same
paving machine whilst it is on a particular paving run. A paving
run is defined as a single layer of asphalt placed continuously,
excluding pauses not exceeding 30 minutes, between two
transverse joints.

(g) Paving in echelon shall be arranged so that the leading half shall
not be in advance of the trailing half by more than the minimum
amount necessary to ensure that full compaction at the joint is
achieved.
(h) Hand work shall be permitted to remove excess and/or
segregated material to waste, to correct minor surface
irregularities and to work in areas inaccessible to pavers. Under
no circumstances shall material be broadcast or fanned over the
surface of the spread material.
132.6.9.3 Joints in polymer modified Marshall asphalt
(a) The formation of all joints shall be made in such a way that a
continuous bond between old and new sections of the course is
ensured. All joints shall have the same texture, and shall be
smooth, tight and fully compacted, and surface regularly as other
sections of the course or layer. The density of cores taken from
the area of the joint shall comply with Section 132.15.2 of the
GMWS. Joints shall be constructed as either cold joints or warm
joints unless paving in echelon where the mat shall be
considered continuous.
(b) Warm joints may be used where the temperature of the edge of
the previously placed lane is above 140°C and the edge has
been formed while hot to a straight, vertical tight face using metal
lutes or similar equipment.
(c) Longitudinal and transverse cold joints require the edge of the
previously placed lane to be cut back a minimum of 75 mm or a
minimum of one and a half times the layer thickness, whichever
is greater, to remove all segregated or out of shape material.
Edges shall be cut with a cutting wheel or other means reviewed
without objection by the Project Manager to expose a clean
straight and vertical face for the full depth of the layer. The edge
face shall be thoroughly cleaned of all adherent material and
coated with bond coat prior to placement of the adjoining lane.
The bond coat shall completely and uniformly cover the exposed
edge for its full depth to the satisfaction of the Project Manager.
Excess material to the top and base of the joints, streakiness and
blobs shall be avoided.
(d) The longitudinal joint shall be made by overlapping the screed of
the paver on the previously laid material for a width of between
30 to 50 mm and depositing a sufficient amount of material so
that the joint formed will be smooth, tight and fully compacted.
(e) The longitudinal joint in one layer shall be staggered from the
joint in the layer immediately below by at least 600 mm. The
longitudinal lane joints shall be in straight lines which are
continuous for the full length of the pavement (including the
pavement to be reinstated), or in smooth curves around bends.
(f) If during laying, the paver stands at one location for more than
thirty minutes, a transverse joint shall be constructed in
accordance with the GMWS.

(g) Transverse joints in a layer shall be staggered by at least 600
mm from transverse joints in the previous layer and shall be
perpendicular to the direction of placing. Transverse joints in
adjacent lanes shall be staggered by a minimum of 3 m. Joints
shall be cut back for at least 300 mm to the full depth and width
of the layer and shall receive a complete and uniform coat of
bond coat in accordance with Section 132.6.9.3(c) of the GMWS
before placing the fresh mixture.
132.6.9.4 Compaction of polymer modified Marshall asphalt
(a) Immediately after placing, polymer modified Marshall asphalt

shall be thoroughly compacted by rolling. Sufficient rollers, as
determined in the Asphalt Compaction Procedure, shall be used
to compact adequately the material that has been placed.
(b) In places inaccessible to rollers, material shall be tamped to the
required level of compaction with mechanical tampers, and
finished with hand-guided vibratory rollers with a minimum
compactive effort equivalent to 750 kg/m roll to 1,500 kg/m roll
when in vibratory mode.
(c) Rolling shall continue until the requirements of the GMWS are
met.
(d) Where new pavement is required to be constructed, while the
surface is being compacted and finished, the Contractor shall
trim and compact the edges of the pavement to the specified
alignment.
(e) The finished surface shall present a tightly bonded, closed
textured surface of uniform appearance and shall be free from
cracks, segregation, open textured areas, drag marks and loose
stones.

(a) Plant and equipment shall not be permitted to traffic the polymer
modified Marshall asphalt wearing course until it has cooled to a
maximum temperature, measured at the mid-depth of the layer,
of 35°C.
(b) If damage to polymer modified Marshall asphalt wearing course
occurs due to fuel spillage, or from trafficking or from any other
reason causing it to fall outside of the GMWS requirements it
shall be removed and replaced with fresh material in accordance
with the GMWS.
132.6.11 TOLERANCES
(a) The elevation of the finished surface of each course shall not vary
by more than 5 mm from the required level shown on the
Employer’s Drawings.
(b) The finished surface of each course shall not vary by more than
4 mm per 3 m when tested with a profilometer on a uniform slope
parallel to the major axis of the pavement or 3 mm when tested
with a 3.0 m straight edge perpendicular to the major axis of the
pavement. Up to 3% of measurements with the 3.0 m straight
edge may exceed the tolerance by another 2 mm. Up to five
irregularities per 100 m may exceed the tolerance by up to 2 mm
when the surface is tested with the profilometer.
(c) The thickness of the wearing course shall not be less than the
thickness indicated on the Employer’s Drawings.
(d) Subject to the requirements of the PS Section 10.2, the
tolerances for the thickness and finished surface level of wearing
course may be revised by the Project Manager.
132.6.11.2 Tolerances: Job Mix Formula
The tolerances shown in Table 132.20S shall be applied to the Job Mix
Formula, and all mix placed shall be within the tolerance specified.

Table 132.20: Job mix formula tolerances
Material Tolerance
Each individual sieve 2.36 mm or greater ± 4.0%
Each individual sieve 1.18 mm or smaller ± 3.0%
(excluding 0.075 mm)
Aggregate passing 0.075 mm sieve ± 1.0%
Polymer modified binder content ± 0.3%
Temperature of mix ± 10oC
Percentage voids filled with polymer modified ± 5.0%
binder
Percentage air voids ± 1.0%
Marshall Stability ≥ 12.0 kN
Marshall Flow To be between
2.0
and 4.0 mm
VMA Not less than
13.5%
(Runway) Not
less than
12.5%
(Taxiway)
Bitumen Film Thickness Not less than
7.5 microns
Hamburg Wheel Tracking Target rut
depth to be not
more than 4.0
mm
Note: Alternative values may be reviewed without objection by the

Project Manager, subject to the Contractor submitting a letter of
recommendation from the material supplier.
132.6.12 TESTING: SURFACE LEVEL, REGULARITY AND TEXTURE
132.6.12.1 Testing: Surface Level, Regularity and Texture

represent the surface of the finished course and as a minimum
shall be carried out at not greater than 5 m spacing.
(b) Parallel to the main axis of the pavement the surface regularity
shall be tested along lines at 5 m intervals using a profilometer
which produces a continuous computerised printout of the
surface profile for visual reading and surface record.

(c) Perpendicular to the main axis of the pavement the full width of
the finished surface shall be tested for regularity using a 3 m
straight edge. The tests shall be carried out at intervals not
exceeding 5 m.
(d) The surface texture depth shall be measured at a frequency of at
least test per 800 m². Additional testing at the Contractor’s
expense may be required if the Project Manager considers areas
to be too coarse or segregated.
(e) For information purposes only, the Contractor shall measure the
surface friction level of the grooved PMAWC for the runway.
The friction testing shall be undertaken by a Griptester in
accordance with ICAO Annex 14 requirements and shall be
carried out at a speed of 65 km/hour on a dry runway surface
using a self-watering device giving a controlled depth of 1 mm of
water. Testing shall be undertaken for the full length of both
runways at +/-3 m and +/- 6 m offsets from the centreline. Test
results in both a tabular and graphical format shall be submitted
to the Project Manager within five days of the test.
132.6.12.2 Non-compliance: surface level, regularity and texture
(a) The full depth of polymer modified Marshall asphalt shall be

removed and replaced with fresh material in all areas which do
not comply with the specified tolerances for surface level and
regularity. Areas so treated shall be at least 15 m long and the
full width of the paving laid in one operation. Any damage caused
to the underlying layer shall be repaired before replacing the
polymer modified Marshall asphalt.
(b) Where the texture depth requirement is not met by being too
coarse or segregated, any localised areas may be treated with a
proprietary polymer emulsion based seal coat approved by the
Project Manager.
132.6.13 TESTING: AGGREGATES, FILLER AND POLYMER MODIFIED

BINDER
132.6.13.1 Batch: aggregates, filler and polymer modified binder
(a) A batch of aggregate, filler or polymer modified binder is any

quantity of aggregate, filler or polymer modified binder of the
same type, manufactured or produced in the same place,
covered by the same certificates and delivered to the Site at any
one time.
(b) The Contractor shall establish batch sizes for testing so as to
ensure that changes in properties of the ingredient materials are
detected significantly in advance of materials being incorporated
in asphalt production. A batch of aggregate shall not exceed
1,000 tonnes for projects with up to 20,000 tonnes of asphalt. For
projects in excess of 20,000 tonnes of asphalt the batch size shall
not exceed 5,000 tonnes.
(c) The minimum batch size for PMB shall be 50 tonnes and tested
as noted it Table 132.22.

(d) The minimum batch size for filler shall be 100 tonnes and tested
as noted it Table 132.22.
132.6.13.2 Sample: aggregates, filler and polymer modified binder
(a) One sample of each type of aggregate, filler and polymer

modified binder shall be provided from each batch.
(b) The minimum size of each sample and the method of sampling
shall be as stated in Table 132.21.
Table 132.21: Size of samples and method of sampling for
aggregates, filler and polymer modified binder
Material Minimum Method of sampling

size of
sample
Aggregate, nominal 25 kg BS EN 932-1: 1997

maximum aggregate size
10 mm to 32 mm
less than 10 mm
Filler 5 kg BS EN 932-1: 1997
Polymer modified binder 5 kg ASTM D140: 2016
132.6.13.3 Testing: aggregates, filler and polymer modified binder
(a) Each sample of aggregate and filler and polymer modified binder
shall be tested to determine the properties stated in Table 132.22.
The method of testing shall be as stated in Table 132.22. All test
results shall be reported, including failures.

Table 132.22: Testing aggregates, filler and polymer modified
binder
Material Property Method of Frequency
testing
Coarse Los Angeles BS EN 1097: Each batch

aggregate Abrasion Part 2; 2010
Magnesium BS EN 1367: Each batch
Soundness Part 2 : 2009
Flakiness Index BS EN 933: Each batch
Part 3: 2012
Water Absorption BS EN 1097: Each batch
Part 6: 2013
Particle Size BS EN 933: Each batch
Distribution Part 1 :: 2012
Material < 0.075 BS EN 933: Each batch
mm Part 1 : 2012
Ten Percent Fines BS EN 1097 Each batch
(TFV) Part 2 : 2010
Elongation Index BS 812:Part Each batch
105.2
Fine Magnesium BS EN 1367: Each batch
aggregate Soundness Part 2:2009
(tests on Los Angeles BS EN 1097: Each batch
sample of Abrasion Part 2 :2010
material Water Absorption BS EN 1097: Each batch
before Part 6:2013
crushing) Particle Size BS EN 933: Each batch
Distribution Part 1 : 2012
Material < 0.075 BS EN 933: Each batch
mm Part 1 :2102
Filler Particle Size BS EN 933: Each batch
Distribution Part 10:2009
Moisture Moisture Content Oven drying Weekly
content of (see
aggregates Subsection
at/after (b)
mixing below)
Polymer Penetration at ASTM Each
modified 25°C D5/D5M-13 batch/daily
binder Softening Point ASTM basis
Other properties D36/D36M-14
as listed at Table As listed at
132.12 Table 132.12

(b) The moisture content of aggregates at/after mixing (i.e., on
completion of mixing but without the addition of polymer modified
binder) shall be determined using the procedure described in BS
EN 1097: Part 5: 2008, modified by weighing samples, drying in
a ventilated oven at 175  2°C for 24 hours and then weighing
again.
(c) As noted at Section 132.6.1.1 (b) for all materials, in addition to
supplying test results, the Contractor shall prepare and submit a
summary of test results in the form of a graphical “trend” chart.
132.6.13.4 Compliance criteria: aggregates, filler and polymer modified

binder
The result of each test shall comply with Table 132.23.

Table 132.23: Compliance criteria for aggregates, filler and
polymer modified binder
Material Property Compliance Criteria

Coarse Los Angeles Abrasion ≤ 30% wear after 500
aggregate Magnesium Soundness revolutions
Flakiness index < 5% loss after 5 cycles
Elongation Index < 20%
Water Absorption < 20%
Percentage <0.075mm < 25%
Ten Percent Fines < 2%
Value (TFV) < 180kN
Fine Los Angeles Abrasion < 30% wear after 500
aggregate revolutions
Magnesium Soundness < 5% loss after 5 cycles
Water Absorption ≤ 2.5% (crushed aggregate)
≤ 2.0% (uncrushed
aggregate)
Percentage <0.075mm ≤ 10.0% (crushed
aggregate)
≤ 5.0% (sand and/or
Plastic Index combined aggregate)
Non-plastic
Sand Equivalent >45
Filler Sieve size (mm) Percentage by mass
0.6 passing
0.3 100
0.075 95 – 100
70 – 100
Moisture Moisture Content ≤ 0.5%
content of
aggregates
at/after mixing
Polymer Penetration difference ≤ 9dmm of initial value (Day
modified at 25°C 0)*
binder Softening Point ≤ 5oC of initial value (Day
difference 0)*
Other properties as
listed at Table 132.12 Values listed in Table
132.12
* For each batch of polymer modified binder sampled from the hot
storage tank, up to Day 3, as described in Section 132.6.6.1 of the
GMWS.

132.6.13.5 Non-compliance: aggregates, filler and polymer modified binder
(a) If any test result fails to meet the requirements of Table 132.23
then four further samples shall be taken from the relevant batch
and tested in accordance with Table 132.22 for the non-
complying property.
(b) If any of the additional tests fail to meet the compliance criteria
then the batch shall not be permitted for use in the Works.
132.6.14 TESTING: POLYMER MODIFIED MARSHALL ASPHALT MIX
132.6.14.1 Samples: polymer modified Marshall asphalt mix
(a) Following trials, each mix, per production plant per work shift
shall be as follows:
For the first 100 tonnes per production plant per work shift –
minimum two samples.
For each subsequent 100 tonnes, or part thereof, per plant, per
work shift, one further sample is to be taken.
(b) The samples shall be taken from the delivery truck prior to
leaving the mixing plant and shall be obtained in accordance with
BS EN 12697: Part 27.
(c) The Contractor shall submit all test results to the Project Manager
within 24 hours of mixing and placement.
132.6.14.2 Testing: Polymer Modified Marshall Asphalt Mix
Each sample shall be tested in accordance with Table 132.24.
Table 132.24: Testing polymer modified Marshall asphalt mix
Particle size distribution BS EN 933: Part 1: 2012 or

ASTM C136/C136M- 2014
Polymer modified binder content ASTM D2172/D2172M- 11
Marshall properties TAI MS 2 Chapter 5

132.6.14.3 Non-compliance: polymer modified Marshall asphalt mix
(a) If any of the test results fail to comply with the job mix formula
described in Sections 132.6.3.2 and 132.6.3.3 of the GMWS and
the associated level of tolerances as given in Table 132.20 or the
Marshall properties do not comply with those specified in Table
132.17, then four further samples of polymer modified Marshall
asphalt mix shall be taken immediately from any remaining
production or four additional tests shall be conducted on the in-
situ cores having been reviewed without objection by the Project
Manager.
(b) If the result of any of the additional tests does not comply with
the requirements of the GMWS then the Contractor shall provide
the Project Manager with justification, rationale and details of
corrective action taken for acceptance of such materials.
However, in all cases of non- compliance, the Project Manager
reserves the right to reject the material, instruct the Contractor to
remove and replace at their own cost, the full extent of the area
concerned, and make whatever changes are necessary to
produce a mix which complies with the GMWS.

132.6.15 TESTING: POLYMER MOFIFIED MARSHALL ASPHALT CORES
132.6.15.1 Samples: polymer modified Marshall asphalt cores
(a) Each area of polymer modified Marshall asphalt, up to 2,000 m2,

which contains polymer modified Marshall asphalt of the same
mix produced at the same mixing plant and which is laid and
compacted in a single layer in one day shall be designated as a
lot. Each lot shall be divided into four equal sub-lots.
(b) A pair of 100 mm diameter cores shall be taken from three of the
four sub-lots in accordance with BS EN 12697: Part 27: 2001.
The location of sampling sites for the polymer modified Marshall
asphalt layer will be advised by the Project Manager on site.
(c) In addition to the cores described in Section 132.6.15.1(b), cores
shall also be taken on the longitudinal lane joint at a frequency of
one core per 250 m of joint or a minimum of two cores per day.
The cores shall be taken in the first-laid (older) mat, with the
circumference of the core not greater than 30 mm or less than 10
mm away from the joint.
(d) The Contractor shall paint the walls and base of all test holes with
hot bitumen or bond coat complying with Section 132.8 of the
GMWS, fill with suitable hot asphalt and compact with a vibrating
hammer in lifts not exceeding 50 mm.
132.6.15.2 Testing: polymer modified Marshall asphalt cores
(a) Each polymer modified Marshall asphalt core shall be measured

to determine the compacted layer thickness. The thickness shall
be measured to an accuracy of the nearest 1 mm.
(b) The density of the polymer modified Marshall asphalt cores shall
be determined in accordance with BS EN 12697: Part 6: 2012,
Procedure B (Saturated Surface Dry method).
(c) For each pair of 100 mm diameter polymer modified Marshall
asphalt cores, one core shall be subjected to the indirect tensile
strength test as a dry subset sample and the other core shall be
subjected to the same test but as a wet subset sample as
described in Table 132.18.
(d) In-situ air voids shall be determined for each polymer modified
Marshall asphalt core in accordance with BS EN 12697: Part
8:2003 and the test results shall be submitted to the Project
(e) The Contractor shall submit all test results to the Project Manager

132.6.15.3 Compliance criteria: polymer modified Marshall asphalt cores
(a) The average compacted layer thickness for the lot shall comply
with Section 132.6.11.1 of the GMWS. The ‘Reference Density’
to be used for the determination of compaction and air voids of
polymer modified Marshall asphalt cores shall be the rolling
average compacted (bulk) density of all polymer modified
Marshall asphalt specimens prepared from production asphalt
during this and the previous four work shifts in which the asphalt
from which the polymer modified Marshall asphalt cores were
taken was placed.
(b) The average mat density determined from all polymer modified
Marshall asphalt cores from the same lot shall not be less than
98.0% nor more than 100.0% of the ‘Reference Density’ and no
individual mat density test shall deviate by more than 1.8% from
the average density of the lot or exceed 101.0% of the ‘Reference
Density’.
(c) The density of individual polymer modified Marshall asphalt cores
taken with the circumference of the core not more than 30mm or
less than 10mm away from the joint shall not be less than 97.0%
of the ‘Reference Density’.
(d) The average air void content of all polymer modified Marshall
asphalt cores obtained for a lot, except cores taken on the
longitudinal joint, shall not deviate from the range 3.0% to 6.0%,
when determined in accordance with Chapter 5 of TAI MS-2.
Individual air void contents shall be between 2.5 and 7.5%.
(e) The indirect tensile strength test results of samples removed from
each lot shall comply with the requirements stated in Table
132.18.
(f) For each polymer modified Marshall asphalt core, the fresh
overlying course and existing underlying course shall be well
bonded; their physical detachment into two separate layers shall
not be permitted.

132.6.15.4 Non-compliance: polymer modified Marshall asphalt cores
(a) If the result of any individual polymer modified Marshall asphalt

core density test does not comply with the requirements of the
GMWS then four additional polymer modified Marshall asphalt
cores shall be taken from the same sub-lot, at locations which
are evenly spaced throughout the sub-lot. The additional polymer
modified Marshall asphalt cores shall be tested in accordance
with Section 132.6.15.2 of the GMWS. In all cases where non-
compliance is noted, the Contractor shall provide the Project
Manager with justification, rationale and details of corrective
actions taken for acceptance of such materials. In all cases
where the average air void content of any set of retest cores is
outwith the range of 2.5% to 7.5% and thickness of the core is
not conforming to the requirement shown in the drawings, the
Contractor shall offer to remove and replace at their own cost,
the full extent of the area represented by the related core.
However, in all cases of non-compliance this Section of the
GMWS, the Project Manager reserves the right to reject the
material, and instruct the Contractor to remove and replace at
their own cost, the full extent of the area concerned.
(b) If the indirect tensile test results do not comply with the
requirements stated in Table 132.18, then a further removal of
three pairs of 100 mm diameter polymer modified Marshall
asphalt cores shall be taken from the same lot. The additional
polymer modified Marshall asphalt cores shall be tested in
accordance with Section 132.6.15.2 of the GMWS. If any of the
additional polymer modified Marshall asphalt cores fail to meet
the requirements of the GMWS then the non-complying layer of
polymer modified Marshall asphalt shall be removed over the
whole lot and shall be replaced with fresh material.
(c) If any individual polymer modified Marshall asphalt core indicates
that the fresh overlying course and existing underlying course are
physically detached into separate layers then four additional
polymer modified Marshall asphalt cores shall be taken from the
same sub-lot, at locations which are evenly spaced throughout
the sub-lot. If any of the additional polymer modified Marshall
asphalt cores fail to meet the requirement of Section 132.6.15.3
(f) then the non-complying layer of polymer modified Marshall
asphalt shall be removed over the whole sub-lot and shall be
replaced with fresh material.
(d) Any fresh material installed to replace non-compliant lots or sub-
lots shall be tested in accordance with Section 132.6.15.2 of the
GMWS and shall comply with the criteria stated in Section
132.6.15.3 of the GMWS.

132.6.16 MARSHALL ASPHALT BASE COURSE
132.6.16.1 Introduction
(a) Marshall asphalt base course shall consist of mineral aggregate,

filler and 60 – 70 penetration grade bitumen to ASTM D946
mixed in a mixing plant and placed on a prepared underlying
course in accordance with the GMWS.
conformance reports etc.) to ensure compliance with the GMWS.
(c) Where shown on the Employer’s Drawings, the Polymer Modified
Marshall Asphalt Base Course (PMABC) shall be used in lieu of
MABC. In lieu of the 60 - 70 penetration grade bitumen to
ASTM D946, a polymer modified binder as detailed in Section
132.6.2.2 shall be used. The PMABC mix shall fully meet the
requirements of the MABC with the additional performance
requirements for the Deformation Resistance; Hamburg Wheel
Tracking; Stiffness Modulus and Flow Number properties
contained in Table 132.18 to be met
(d) The asphalt mixing plant shall have sufficient production capacity
to meet the contract requirements.
132.6.17 MATERIALS
132.6.17.1 General
(a) Aggregates, filler and bitumen for use in the construction of

Marshall asphalt base course shall meet the requirements of the
GMWS.
material information for the Works.
(c) If material is obtained from more than one source each must
meet the requirements of the GMWS. The Contractor shall
supply evidence demonstrating that each material source can
meet the requirements of the GMWS. This evidence shall be
132.6.17.2 Bituminous Binder
(a) Bituminous binder shall be 60 - 70 penetration grade bitumen to

ASTM D946. The procurement details shall be reviewed without
objection by the Project Manager .
material information for any bituminous binder that is to be
manufactured on the Site.

(c) Bituminous binder shall be 60 - 70 penetration grade bitumen
conforming to the requirements in ASTM D946 Table 2. The
viscosity at 60°C of the bitumen shall be a minimum of 250 Pas
when measured in accordance with ASTM D2171.
(d) Bituminous binder shall be stored in accordance with a quality
control procedure which follows the manufacturer’s instructions
detailing the mode of circulation or agitation in the storage tank
necessary to ensure homogeneity is maintained.
132.6.17.3 Aggregate
(a) Aggregate shall be obtained from a source which has been

(b) Aggregate shall consist of clean, hard, durable particles of
crushed granite rock blended if necessary with sand or other inert
finely divided mineral aggregate. Gravel or crushed gravel shall
not be permitted. Aggregate shall be uniform, have an affinity for
bitumen and be capable of being coated evenly. Aggregate shall
be free from weathered material, vegetable material,
disintegrated or friable matter, clay, organic matter, and other
deleterious substances.
(c) The portion of the material retained on the 2.36 mm sieve shall
be known as coarse aggregate, the portion passing the 2.36 mm
sieve and retained on the 0.075 mm sieve as fine aggregate, and
the portion passing the 0.075 mm sieve as filler.
(d) Coarse aggregate shall have the properties stated in Table
132.25.
Table 132.25: Properties of coarse aggregate
Los Angeles Abrasion ≤30% wear after 500

revolutions
Magnesium Soundness ≤5% loss after five cycles
Ten Percent Fines Value ≥180kN
Flakiness Index (FI) ≤20%
Water Absorption ≤2%
Material finer than 0.075 mm in ≤2%
Aggregates (by washing)
Note: Alternatively FI < 25% if tested to BS EN 933-3 2012
(e) Coarse aggregate for each asphalt mix required shall be supplied
in not less than the following number of fractions:
(i) 20 mm and 28 mm nominal maximum size mix – three
fractions
(f) The grading for each fraction shall be submitted to the Project

(g) Fine aggregate shall consist of clean, hard, durable, angular
particles produced by crushing rock meeting the requirements for
wear and soundness specified for coarse aggregate. If necessary,
to obtain the required mixed aggregate grading and required
workability, natural sand may be used. In this case the
percentage of sand shall be below 15% by weight of the total
mixture.
(h) Fine aggregates shall comply with the requirements of Table
132.26.
Table 132.26: Properties of fine aggregate
Water Absorption:
. uncrushed aggregate Not more than 2.0%
Material finer than 0.075 mm in
Aggregates: (by washing)
. sand aggregate Not more than 5.0%
. combined aggregate Not more than 5.0%
Magnesium Soundness Not more than 5% after 5 cycles
Sand Equivalent to ASTM D Not less than 45
2419
Methylene Blue Value (MBV) to Not more than 5mg/g
ISSA Technical Bulletin No 145
132.6.17.4 Filler
(a) Added filler shall consist of hydrated lime to ASTM C 1097 (or BS
EN 459-1: 2010). It shall be in accordance with the limits given in
Table 132.27.
Table 132.27: Grading requirements for filler
Sieve Size (mm) Percent by mass passing
0.6 100
0.3 95 – 100
0.075 70 – 100
(b) The reclaimed dust extracted from the aggregates during asphalt
production may also be used as filler, subject to the requirements
of Sections 132.6.17.4 (a) and 132.6.17.5 (b)(ii) being met.
(c) Filler shall be stored in dry conditions.

132.6.17.5 Combined aggregate and filler
(a) Combined aggregate and filler for Marshall asphalt base course
shall conform to the grading shown in Table 132.28, and shall not
vary from the low limit on one size of sieve to the high limit on an
adjacent sieve, or vice versa. The Contractor shall initially target
the centre of the grading band to produce the combined
aggregate grading. This grading shall be adjusted should the
specified Marshall asphalt requirements be demonstrated as not
achievable.
Table 132.28: Combined aggregate grading for Marshall asphalt
Percent by mass passing

Sieve Size
Marshall Asphalt Base Course
(mm)
40 100
28 90 – 100
20 75 – 95
14 60 – 85
10 50 – 75
5 35 – 55
2.36 23 – 40
1.18 15 – 30
0.6 12 – 25
0.3 8 – 18
0.15 5 - 12
0.075 3-6
(b) The combined aggregate and filler shall also conform to the
(i) The material passing the 0.3 mm sieve shall be non-plastic
when tested in accordance with BS 1377: Part 2: 1990.
(ii) Between 1% and 1.5% by mass of the combined
aggregate and filler shall be hydrated lime filler.
132.6.17.6 Bituminous Sprays
Bituminous sprays to be applied to existing bituminous surfaces shall

comply with Section 132.8 of the GMWS.
132.6.18 DESIGN OF MARSHALL ASPHALT
132.6.18.1 General
(a) The Contractor shall notify the Project Manager at least seven
days before carrying out the mix designs and associated tests.
(b) The mix design process shall be repeated each time that there is
a change in sources of material.

132.6.18.2 Marshall asphalt mix design
(a) Marshall asphalt shall be designed in accordance with the

Marshall Method of Mix Design stated in The Asphalt Institute
Handbook "MS-2 Mix Design Methods for Asphalt Concrete and
other Hot-mix Types" (TAI MS-2).
(b) In carrying out the tests mechanically operated compaction
equipment shall be used. This equipment shall deliver the same
compactive effort per blow as the standard Marshall compaction
hammer. The compaction shall be 75 blows each side and three
test specimens shall be prepared for bituminous binder content
used.
(c) The mix shall meet the grading requirements of Table 132.28.
When plotted, the particle size distribution of the aggregates,
determined in accordance with BS EN 933-1:2012, shall give a
smooth curve within the specified aggregate grading as listed in
Table 132.28 and shall not vary from the low limit on one size of
sieve to the high limit on an adjacent sieve nor vice versa.
(d) The laboratory manufactured samples for all Marshall asphalt
base course shall comply with the requirements given in Table
132.29 at the target binder content when determined for each
mixture in accordance with the procedures stipulated in TAI MS-
2.
Table 132.29: Marshall design criteria
Test Required Property
Number of blows each side 75

Minimum Stability (kN) 12.0
Flow (mm) 2.0 – 4.0*
Air voids (%) 3.0 – 5.0
Minimum Voids in Mineral Aggregate 12.0
(%)
Bituminous Binder Content (%) 4.5 – 6.0
Minimum Bitumen Film Thickness 7.5
(microns)
* Alternative values may be agreed with the Project Manager subject

to the Contractor submitting a letter of recommendation from the
Material Supplier.

Condition
Deformation BS 598- Temperature Rut Depth < 7mm Job Mix, Trial
Resistance 110: 1998 60oC (Average of 6) Sample.
Rate of Rutting < Thereafter,
5mm/hour additional
(Average of 6) one test per
25,000
tonnes of
asphalt laid.
Stiffness BS EN Temperature Between 3 and Job Mix,
Modulus 12697-26: 32oC 6GPa. Trial Sample.
(ITSM) 2012 Thereafter,
additional
one test per
25,000
tonnes of
asphalt laid.
* Alternative values may be agreed with the Project Manager subject to

the Contractor submitting a letter of recommendation from the Material
Supplier.
(e) The proportions of the mix produced by this design shall be

known as the Design Mix Formula.
(f) The Design Mix Formula shall be submitted to the Project
Manager for review without objection at least 14 days prior to the
start of trial paving operations and shall give the percentage of
each sieve fraction of aggregate, the percentage of filler and
bituminous binder and the temperature of the completed mixture
when discharged from the mixer. All test data used to develop
the Design Mix Formula shall also be submitted including a
graphical presentation of the mix design.

132.6.18.3 Job Mix
(a) The Contractor shall optimize the properties of the design mix
using the ‘Range Method’ as described in the method for design
of the asphalt mix specified in Section 132.6.18.2.
(b) The Loss of Stability test shall be carried out on the Job Mix as
follows:
(i) determine Marshall Stability of specimens submerged in
water at 60°C for 30 minutes - result (a);
(ii) determine Marshall Stability of specimens submerged in
water at 60°C for 24 hours - result (b); and
(iii) loss of stability is ((a-b)/a) x 100%.
(c) If the Loss of Marshall Stability of the Job Mix is more than 10%,
the aggregates shall be rejected or the bituminous binder shall
be treated with an anti-stripping agent which has been reviewed
without objection by the Project Manager. The measures taken
shall be such that a Job Mix with a loss of less than 10% of the
Marshall Stability is produced.
(d) The Job Mix shall include the percentage of combined aggregate
passing each sieve, the percentage of bituminous binder, and the
temperature of the completed Job Mix when discharged from the
mixer.
(e) The Contractor shall satisfy himself that when laid in the trial area
the Job Mix will meet the criteria for stiffness as detailed in
132.6.19 SUBMISSION
132.6.19.1 Particulars of aggregate, filler and bituminous binder
(a) The following particulars of the proposed aggregate, filler and

bituminous binder shall be submitted to the Project Manager for
review without objection at least 20 days prior to scheduled
construction of the trial area.
(b) A certificate from the manufacturer for each type of filler showing
showing that the filler complies with the requirements stated in
Section 132.6.17.4 of the GMWS, including results of tests for
grading.
(c) A certificate from the manufacturer for bituminous binder showing
the manufacturer’s name, proof of Quality Assurance registration
to BS/EN/ISO 9000 with an appropriate scope of registration for
the supply of bituminous binder, and showing that the bituminous
binder complies with the requirements stated in Section
132.6.17.2 of the GMWS.

(d) A statement of the origin and method of extraction of all
aggregates proposed for the Works. The Contractor shall provide
material can be produced. Four sets of test results showing that
the aggregate meets the requirements stated in Section
132.6.17.3 of the GMWS shall also be submitted. Test results
shall be provided for each type and size fraction to be used.
(e) Further certificates showing that the materials comply with the
GMWS shall be submitted at intervals reviewed without objection
132.6.19.2 Particulars of mixes
(a) The following particulars of each Job Mix Formula shall be

submitted to the Project Manager for review without objection at
least 20 days prior to construction of the trial area:
(i) Source and type of constituent materials;
(ii) Percentage of each sieve fraction of aggregate, for each
aggregate size fraction and added filler;
(iii) Percentage of bituminous binder;
(iv) Temperature of the completed mixture when discharged
from the mixer;
(v) Marshall test properties (graphical format); and
(vi) Bulk density and volumetric properties.
(b) Evidence shall be provided to demonstrate that the Job Mix
Formula can achieve the requirements detailed in Section
132.6.20.4 of the GMWS.
132.6.19.3 Particulars of supplier of Marshall asphalt
(a) All operations in the procurement of component materials and

batching of bituminous materials shall be carried out by a
Contractor (or supplier on his behalf) who has a Quality
Assurance accreditation to BS/EN/ISO 9000:2005 for the
operations.
(b) The name of the supplier and the location and details of each
plant from which the Contractor proposes to obtain Marshall
asphalt shall be submitted to the Project Manager for review
without objection at least 20 days prior to commencement of the
trial area. The Contractor shall provide documented evidence of
asphalt plant calibration including recent calibration graphs for
cold aggregate feeders for the aggregates proposed for use.

132.6.19.4 Particulars of methods of laying and compacting Marshall asphalt
The following particulars of the proposed methods of laying and

compacting Marshall asphalt shall be submitted to the Project Manager
for review without objection at the same time as the particulars of the
supplier are submitted.
(a) Details of contractor’s equipment, and
(b) Programme and rate of working.
132.6.19.5 Representative samples of aggregate, filler and bituminous binder
A representative sample of each type of aggregate, filler and bituminous

binder shall be submitted to the Project Manager for review without
objection at the same time as the particulars of these materials are
submitted. The aggregate sample shall be a minimum of two 50 kg
samples and shall be accompanied by a full petrological and
12 (2012).
132.6.20 TRIALS
(a) Prior to commencement of Marshall asphalt operations for the

Works, the Contractor shall construct a trial pavement of at least
375 m2 for Marshall asphalt base course mix.
(b) The trial area will be used to determine the adequacy of the
Contractor’s equipment, loose material depth measurements and
the relationship between number of compaction passes and
resulting density.
(c) The trial area shall be constructed off the Site over a sound and
stable CABC or on-site over previously completed underlying
course which meets the requirements of the GMWS and shall be
constructed with the materials and equipment intended for use in
constructing the Works. This shall include the selected
bituminous spray at the appropriate application rate, trialled as
described in Section 132.8.4.1 of the GMWS. Trial areas
constructed on-site shall be constructed in an area considered
by the Project Manager to be non-critical to Airport operation and
may form part of the Works if accepted.

(f) Based on the following techniques a methodology shall be
established which shall form the basis of the Asphalt Compaction
Procedure:
(i) Rollers shall be of the steel wheel and pneumatic-type and
shall be in good condition, capable of reversing without
backlash and shall be operated at speeds slow enough to
avoid undue displacement of asphalt material. They shall
be equipped with roll scrapers, absorbent mats and tanks
connected to spray pipes on both front and rear rolls to
ensure a uniform minimal application of water or parting
fluid. The number and weight of rollers shall be sufficient
to compact the mix to the required density and surface
finish while it is still in a workable condition;
(ii) A minimum of three rollers, two steel wheel, one of which
shall be vibrating, and one pneumatic-tyre type shall be
used with each spreading operation;
(iii) The sequence of rolling the first paving lane shall be to
proceed in the direction of laying and to roll the lower edge
of the lane first and then proceed towards the higher edge.
On adjoining paving lanes rolling shall begin by
overlapping the joint by 150 to 200 mm and shall progress
gradually to the opposite edge of the lane;
(iv) The speed of the roller shall, at all times, be sufficiently
slow and uniform to avoid displacement of the hot mixture,
and shall at no time exceed 5 km/h. Any pronounced
change of direction shall be made on stable material. The
line of rolling shall not be suddenly changed or the
direction of rolling suddenly reversed, thereby displacing
the mix. Any displacement occurring as a result of
reversing the roller or from any other cause shall be
corrected at once by raking and applying fresh mixture;
(v) To prevent adhesion of the mixture to the roller, the wheels
shall be kept properly moistened, but excessive use of
water/soap solution will not be permitted. A water bowser
shall be provided alongside each spreading unit to ensure
that rolling continues with the minimum interruption. The
tyres of pneumatic tyred rollers may be operated dry and,
if required to prevent pick-up, vegetable oil may be applied
to the tyres;
(vi) Rollers shall be operated by competent and experienced
drivers and shall be kept in operation continuously, if
necessary, so that all parts of the layer receive equal
compaction;
(vii) Use of equipment which results in crushing of the
aggregate will not be permitted. All rollers shall be
reviewed without objection by the Project Manager;

(viii) Breakdown rolling of the mixture shall comprise a
maximum of two passes and shall begin as soon after
spreading as the mixture will bear the roller without undue
displacement or cracking. The breakdown roller shall be
steel wheeled and shall be operated with the drive wheel
nearer to the paver. In no case shall the mix temperature
be allowed to drop below 125oC prior to commencement
of breakdown rolling;
(ix) For surface courses the compaction procedure shall
include kneading rolling. Pneumatic tyred rolling shall be
undertaken to knead the surface of the asphalt either
during or after compaction. This rolling shall consist of a
minimum of four coverages of a pneumatic tyre roller
having a wheel load not less than 2 tonnes and tyre
pressure not less than 850 kPa. Kneading rolling shall be
undertaken before the temperature of the mix falls below
90oC;
(x) Rolling shall continue until all roller marks are eliminated,
the surface is of a uniform texture and true to grade and
cross section, and the required density is achieved;
(xi) Final compaction and finish rolling shall be carried out by
means of a steel wheel roller unless otherwise designated.
Cross rolling shall be permitted up to a maximum of two
passes; and
(xii) Asphalt shall be compacted prior to the temperature of the
mix falling below 95oC.
132.6.20.2 Samples: trial area
(a) During construction of the trial area three samples of Marshall

asphalt mix shall be taken from each type of mix at the mixing
plant in accordance with BS EN 12697: Part 27.
(b) Ten 150 mm diameter cores shall be taken from the trial area in
accordance with BS EN 12697: Part 27. At least three of these
cores shall be taken from joints.
(a) The loose Marshall asphalt mix shall be subjected to analyses of

aggregate/filler grading and bituminous binder content in
accordance with ASTM C136/C136M-2014 and ASTM
D2172/D2172M-11 respectively. The Marshall asphalt mix
samples shall be tested in accordance with Table 132.36.
(b) The bulk density and air voids of the ten 150 mm diameter
Marshall asphalt cores taken from the trial area shall be
determined as described in Sections 132.6.30.2(b) and (d) of the
GMWS.
(c) The Indirect Tensile Stiffness Modulus (ITSM) at 20°C of six of
the 150 mm diameter cores (not including those taken from the
joints) shall be determined in accordance with BS EN 12697: Part
26:2012, Annex C.

(a) The tests on Marshall asphalt mix samples shall comply with the
Job Mix Formula and the requirements of Section 132.6.26.2 of
the GMWS.
(b) The bulk density and air voids tests on Marshall asphalt cores
shall comply with the relevant requirements of Section 132.6.30.3
of the GMWS.
(c) The stiffness modulus (ITSM) of the Marshall asphalt cores shall
comply with the requirements in Table 132.30 below.
Table 132.30 : Stiffness of Marshall asphalt base course
Stiffness (ITSM) (GPa) at 20°C
Grade Characteristic Minimum Minimum

Value (5th Moving Mean Individual
Percentile) of 6 Values Value
2.5 2.5 3.0 2.0
(d) The characteristic stiffness value is the value below which only
5% of all measurements are expected to lie.
(b) Trial area, or parts of trial area, which do not comply with the
specified requirements for the trial area shall be removed.
132.6.20.6 Commencement of Marshall asphalt placement
(a) Marshall asphalt shall not be placed in the Works other than in a
of the Works, the Contractor shall submit the Asphalt Compaction
Procedure to the Project Manager for review without objection.
The Asphalt Compaction Procedure shall be clearly documented
in a Method Statement and shall form an integral part of the
Contractor's Quality System.
(c) Marshall asphalt shall not be placed in the Works, without the
permission of the Project Manager.

The material, mix design, methods of production and methods of

132.6.21 HANDLING, STORAGE AND TRANSPORT OF MATERIALS
(a) Marshall asphalt shall not be stored in heated surge bins for more
than 12 hours or in transport vehicles for more than five hours.
(b) Marshall asphalt shall be delivered to the paver within 14oC of
the Job Mix Formula temperature. Material delivered to the paver
outside of these limits shall be rejected.
(c) The Contractor shall follow the access routes reviewed without
objection by the Project Manager for delivery of Marshall asphalt.
(d) Each truck load of Marshall asphalt shall be accompanied by a
ticket issued at the mixing plant by the Contractor stating the
truck number, time despatched and temperature.
(e) The plant mixtures shall be transported without delay to the
laying sites from the mixing plant or from hot storage bins taking
care to prevent segregation. The vehicles shall be double
sheeted during transit and while waiting to prevent loss of heat,
contamination and wetting. All vehicles shall be mechanically
sound and roadworthy and shall be suitable for the spreading
equipment in use and shall have insulated bodies.
(f) The internal surfaces of the truck bodies shall be smooth, clean
and uniformly coated with a suitable non-hydrocarbon based
release agent to prevent adhesion of the mixture to the bodies.
Particular care shall be taken to ensure that pools of release
agent do not remain on the bottom of the bodies or are removed
before trucks are loaded with Marshall asphalt.
(g) Loads that are below the minimum temperature, that have crusts
of cold unworkable material, that have been wetted by rain or
have been contaminated with other material shall be rejected.
(h) Hauling over freshly placed material shall not be permitted until
the material has been fully compacted and allowed to cool to
atmospheric temperature.
132.6.22 MIXING OF MARSHALL ASPHALT
(a) Each production unit or depot involved in the work shall be

registered under a Quality Assurance Scheme to BS/EN/ISO
9000:2015. The quality policy manual(s) for the supply of
component materials and batching of bituminous materials,
together with other relevant records and certificates, are to be
submitted prior to commencement of works on the Site.
(b) The Contractor shall be responsible for all testing for the supply
of bituminous materials and providing the Project Manager with
a written copy of the results, in accordance with the requirements
of Section 132.6 of the GMWS.

(c) All documentation relevant to the works, including records of
temperature control during mixing and test results, shall be
available at the plant or the depot for inspection. The
documentation, including worksheets, shall be stored in an easily
retrievable form for a minimum of three years.
(d) 60 – 70 penetration grade bitumen shall be heated within a
temperature range of 135°C to 163°C at the time of mixing; 60 –
70 penetration grade bitumen heated above 163°C shall not be
used.
(e) Mixing, delivery, laying and compaction temperatures for
Marshall asphalt are summarised in Table 132.31 below:
Table 132.31: Mixing, delivery, laying and compaction

temperatures for Marshall Asphalt
Bitumen Binder Binder Mixing Delivery Paver- Compaction

Grade Temp Temp (Max) (Min) Out (Min)‡
(Min) (Max) (Min)
60 - 70 135°C 163°C 163°C 135°C 125°C 95°C
Pen
‡ This is the mid-layer temperature at which compaction shall have

been substantially completed.
(f) Each aggregate ingredient shall be thoroughly heated and dried
at such temperature that the temperature as recorded in the hot
fines bin after screening shall not exceed 163°C for asphalt
containing Grade 60/80 Pen bitumen. The Contractor shall carry
out moisture tests as detailed in Table 132.34 at least once a
week to check the effectiveness of the drying processes. If at any
time the tests specified indicate that the drying facilities are
inadequate as indicated by the criterion in Table 132.35 mixing
shall cease until the Contractor has improved his drying
capability to the satisfaction of the Project Manager.
(g) Immediately after heating, aggregate shall be screened in at least
five sizes and conveyed into separate bins ready for batching and
mixing with bituminous material. When the aggregates are of
such size and grading that separating into four bins is impractical
the number of required separations may be reduced to two
without objection of the Project Manager. The efficiency of
screening operations shall be sufficient to produce, at plant
operating capacity, gradations in each of the sizes of heated and
dried aggregates which are uniform and result in the production
of a mix complying with the limits specified for the Job Mix
Formula tolerances.
(h) Initial mixing time will be determined by the Contractor but shall
not be less than 30 seconds. Mixing time shall be increased if
additional time is necessary to obtain a homogeneous mixture
and satisfactory coating. On batch plants, the mixing time shall
begin at the start of the introduction of bitumen into the pug mill.

(i) The mixing time shall not allow significant hardening of the
bituminous binder to occur.
(j) After mixing is complete the material shall be transported to and
placed on the underlying layer without delay. Hot storage of the
material shall only be permitted in bins designed and equipped
to prevent oxidation of the bituminous binder. The material shall
be handled in a manner so as to prevent segregation or
contamination.
(k) The bituminous binder content shall be calculated by weight of
total mixture.
(l) Alternative mixing using a drum mix plant will be reviewed by the
Project Manager subject to the Contractor demonstrating a
confirmed consistent source of uniformly graded single sized
material.
(a) Where new pavement is required to be constructed, pipes,

cables, manholes, chambers, gullies and other utilities below
airfield pavements shall be completed and fill material shall be
deposited and compacted in trenches before the pavement is
(b) Finishing around pits, chambers, gullies and other utilities shall
be carried out using Marshall asphalt as part of the paving
process. Hand work and manually operated equipment shall be
used as required when working in confined areas not accessible
to normal paving machines. Contact surfaces of manholes, light
fitting bases and similar fixtures shall be painted with a thin
uniform coating of bituminous material which has been reviewed
(c) Where required, and as shown on the Employer’s Drawings, light
fittings and their associated bases shall be removed prior to cold
milling of the surrounding pavement. The removed items shall be
stored until they are reinstated and protected from damage.
Following completion of cold milling and cleaning operations, the
bases or parts thereof shall be removed to the required level and
fitted with blanking plates to protect the lighting equipment from
contamination by hot asphalt, as detailed on the Employer’s
Drawings. At the completion of placement and sufficient cooling
of the asphalt, the asphalt shall be cored and the lighting can be
reinstalled to the correct line and level. The light fitting shall then
be reinstalled and reconnected.

(a) The existing asphalt wearing course and base course shall be
removed (if required) by cold milling using a purpose built cold
milling machine having a drum width of not less than 2 m. The
Contractor shall not apply water during the milling operation. The
depth of cutting shall be controlled and shall be in accordance
with the depths shown on the Employer’s Drawings. In any case,
the residual thickness of the existing wearing course or base
course shall not be less than 25 mm. All edges shall be cut by
saw cut or other methods reviewed without objection by the
Project Manager to present a vertical clean edge.
(b) Cleaning of the milled surface shall be carried out by vacuum
sweeping, supplemented with hand brooms where necessary,
shovels and compressed air to remove adhering and compacted
cutting fines.
(c) Prime coat shall be applied to the cleaned underlying course in
accordance with Section 132.8 of the GMWS prior to
commencement of Marshall asphalt placement.
(d) The Contractor shall notify the Project Manager before Marshall
asphalt is placed in any part of the Works and shall allow the
(e) Where new pavement is required to be constructed, the
underlying layer treated with a bituminous spray in accordance
with Section 132.8 of the GMWS shall be undamaged, clean and
free from foreign material. The Contractor shall not commence
placement of the Marshall asphalt until the underlying treated
layer has been reviewed without objection by the Project
Manager.
(f) The quantity of milled pavement shall not exceed the quantity of
asphalt stored in the batch plant surge bins plus delivery vehicles.
(g) The Contractor shall provide sufficient sweepers to clean the
existing pavement surrounding the milled surface to ensure no
deleterious material or debris being pick-up by the asphalt
delivery lorries and deposited onto the bond coated surfaces.
132.6.24 LAYING AND COMPACTION
132.6.24.1 General
(a) Asphalt shall be placed on a surface which is dry and only after
the applied bond coat has fully broken into bituminous binder and
water and the water has evaporated.
and debris.
(c) The bituminous mixture shall not be placed when the surface
temperature of the underlying course is less than 5°C or
inclement weather is forecast.

(d) For the Marshall asphalt, the Contractor shall include the use of
a Material Transfer Vehicles (MTVs) between the delivery vehicle
and the paving machine. The MTVs shall be a purpose-built,
pneumatic tyred, self-propelled mechanical device capable of
receiving hot asphalt from delivery vehicles, storing and re-
mixing the asphalt, and delivering the asphalt to the hopper of
the paver machine. The MTVs shall have a minimum storage
capacity of 20 tonnes.
(e) The Marshall asphalt should be laid over areas as large as
possible to minimize the extent of cold joints and that the laying
arrangements shall be reviewed without objection by the Project
Manager. The arrangements for laying of Marshall asphalt should
ensure that cold longitudinal joints shall be avoided along the
runway and taxiway centreline.
132.6.24.2 Laying of Marshall asphalt
(a) Placing of Marshall asphalt shall, whenever possible, begin on

the low side of pavements, and shall be completed to the high
point by the end of each work shift or when inclement weather is
forecast. The surface shall be left free draining.
(b) The Marshall asphalt base course shall be placed using fixed
string lines, or a combination of fixed string lines and a joint
matching device or electronic devices equivalent to string lines
that have been reviewed without objection by the Project
Manager.
(c) Marshall asphalt material shall be deposited by suitable paving
machine (with a minimum capacity of not less than 100 tonnes
per hour) in uniform layers, without segregation on the prepared,
underlying layer. It shall be placed to such loose depth that, when
compacted, the layer will have the thickness specified on the
Employer’s Drawings. The paving machine shall spread the
material so as to avoid or minimise the need for hand
manipulation.
(d) Upon arrival at the point of placement, the mixture shall be
spread to the full width by a suitable bituminous paver. The speed
of the paver shall be regulated to eliminate pulling and tearing. It
shall be operated at a speed which coordinates satisfactorily with
the rate of delivery of the mixture to the paver so as to provide a
uniform rate of placement without intermittent operation.
(e) The mix shall be delivered at a temperature of not less than
135oC. The moisture content of the mix shall not exceed 0.5%.
(f) Marshall asphalt from different mixing plants shall be placed in
separate lots as referred to in Section 132.6.30.1(a) of the
GMWS. Marshall asphalt from different mixing plants shall not be
delivered to the same paving machine whilst it is on a particular
paving run. A paving run is defined as a single layer of asphalt
placed continuously, excluding pauses not exceeding 30 minutes,
between two transverse joints.

(g) Paving in echelon shall be arranged so that the leading half shall
not be in advance of the trailing half by more than the minimum
amount necessary to ensure that full compaction at the joint is
achieved.
(h) Hand work shall be permitted to remove excess and/or
segregated material to waste, to correct minor surface
irregularities and to work in areas inaccessible to pavers. Under
no circumstances shall material be broadcast or fanned over the
surface of the spread material.
132.6.24.3 Joints in Marshall asphalt
(a) The formation of all joints shall be made in such a way that a
continuous bond between old and new sections of the course is
ensured. All joints shall have the same texture and surface
regularly as other sections of the course or layer. The density of
cores taken from the area of the joint shall comply with Section
132.6.30.2 of the GMWS. Joints shall be constructed as either
cold joints or warm joints unless paving in echelon where the mat
shall be considered continuous.
(b) Warm joints may be used where the temperature of the edge of
the previously placed lane is above 95°C and the edge has been
formed while hot to a straight, vertical tight face using metal lutes
or similar equipment.
(c) Longitudinal and transverse cold joints require the edge of the
previously placed lane to be cut back a minimum of 300 mm or a
minimum of three times the layer thickness, whichever is greater,
to remove all segregated or out of shape material. Edges shall
be cut with a cutting wheel or other means reviewed without
objection by the Project Manager to expose a clean straight and
vertical face for the full depth of the layer. The edge face shall be
thoroughly cleaned of all adherent material and coated with bond
coat prior to placement of the adjoining lane. The bond coat shall
completely and uniformly cover the exposed edge for its full
depth to the satisfaction of the Project Manager. Excess material
to the top and base of the joints, streakiness and blobs shall be
avoided.
(d) The longitudinal joint shall be made by overlapping the screed of
the paver on the previously laid material for a width of at least 30
mm and depositing a sufficient amount of material so that the
joint formed will be smooth, tight and fully compacted.
(e) The longitudinal joint in one layer shall be staggered from the
joint in the layer immediately below by at least 600 mm. The
longitudinal lane joints shall be in straight lines which are
continuous for the full length of the pavement (including the
pavement to be reinstated), or in smooth curves around bends.
(f) If during laying, the paver stands at one location for more than
thirty minutes, a transverse joint shall be constructed in

(g) Transverse joints in a layer shall be staggered by at least 600
mm from transverse joints in the previous layer and shall be
perpendicular to the direction of placing. Transverse joints in
adjacent lanes shall be staggered by a minimum of 3 m. Joints
shall be cut back for at least 300 mm to the full depth and width
of the layer and shall receive a complete and uniform coat of
bond coat in accordance with Section 132.6.24.3(c) of the
GMWS before placing the fresh mixture.
132.6.24.4 Compaction of Marshall asphalt
(a) Immediately after placing, Marshall asphalt shall be thoroughly

compacted by rolling. Sufficient rollers, as determined in the
Asphalt Compaction Procedure, shall be used to compact
adequately the material that has been placed.
(b) In places inaccessible to rollers, material shall be tamped to the
required level of compaction with mechanical tampers, and
(c) Rolling shall continue until the requirements of the GMWS are
met.
(d) Where new pavement is required to be constructed, while the
surface is being compacted and finished, the Contractor shall
trim and compact the edges of the pavement to the specified
alignment.
(e) The finished surface shall present a tightly bonded, closed
textured surface of uniform appearance and shall be free from
cracks, segregation, open textured areas, drag marks and loose
stones.
(a) Following placement of Marshall asphalt base course, the

Contractor shall perform all work necessary to protect and
maintain the Marshall asphalt base course in a satisfactory
condition for receiving the polymer modified Marshall asphalt
wearing course.
(b) Plant and equipment shall not be permitted to traffic the Marshall
asphalt base course until it has cooled to a maximum
temperature, measured at the mid-depth of the layer, of 35°C.
(c) If damage to Marshall asphalt base course occurs due to fuel
spillage, or from trafficking or from any other reason causing it to
fall outside of the GMWS requirements it shall be removed and
replaced with fresh material in accordance with the GMWS.

132.6.26 TOLERANCES
(a) The elevation of the finished surface of each course shall not vary
by more than 5 mm from the required level shown on the
(b) The finished surface of each course shall not vary by more than
4 mm per 3 m when tested with a profilometer on a uniform slope
parallel to the major axis of the pavement or 3 mm when tested
with a 3 m straight edge perpendicular to the major axis of the
pavement. Up to 3% of measurements with the 3 m straight edge
may exceed the tolerance by another 2 mm. Up to five
irregularities per 100 m may exceed the tolerance by up to 2 mm
when the surface is tested with the profilometer.
(c) The combined thickness of the Marshall asphalt base course and
polymer modified Marshall asphalt wearing course shall not be
less than the thickness indicated on the Employer’s Drawings.
(d) Subject to the requirements of the PS Section 10.2, the
tolerances for the thickness and finished surface level of base
course and may be revised by the Project Manager.
(e) Subject to the requirements of the PS Section 10.2, the
tolerances for the thickness and finished surface level of wearing
course and base course may be revised by the Project Manager.

132.6.26.2 Tolerances: Job Mix Formula
The tolerances shown in Table 132.32 shall be applied to the Job Mix
Formula, and all mix placed shall be within the tolerance specified.
Table 132.32: Job mix formula tolerances
Material Tolerance
Each individual sieve 2.36 mm or greater ± 5.0%

Each individual sieve 1.18 mm or smaller ± 4.0%
(excluding 0.075mm)
Aggregate passing 0.075 mm sieve ± 1.5%
Bituminous binder content ± 0.3%
Temperature of mix ± 14.0oC
VMA - 1%
Percentage air voids ± 1.0%
Marshall Stability ≥ 12.0 kN
Marshall Flow Between 2.0
and 4.0 mm
Note: Alternative values may be reviewed without objection by the

Project Manager, subject to the Contractor submitting a letter
of recommendation from the material supplier.
Levelling of the surface of the finished course shall be performed by the

Contractor. The frequency of levelling shall accurately represent the
surface of the finished for regularity using a 3 m straight edge. The tests
shall be carried out at intervals not exceeding 5 m.
The full depth of Marshall asphalt shall be removed and replaced with
fresh material in all areas which do not comply with the specified
tolerances for surface level and regularity. Areas so treated shall be at
least 5 m long and the full width of the paving laid in one operation. Any
damage caused to the underlying layer shall be repaired before
replacing the Marshall asphalt.

132.6.28 TESTING: AGGREGATES, FILLER AND BITUMINOUS BINDER
132.6.28.1 Batch: aggregates, filler and bituminous binder
(a) A batch of aggregate, filler or bituminous binder is any quantity

of aggregate, filler or bituminous binder of the same type,
manufactured or produced in the same place, covered by the
same certificates and delivered to the Site at any one time.
(b) The Contractor shall establish batch sizes for testing so as to
ensure that changes in properties of the ingredient materials are
detected significantly in advance of materials being incorporated
in asphalt production. A batch of aggregate shall not exceed
1,000 tonnes for projects with up to 20,000 tonnes of Marshall
base course. For projects in excess of 20,000 tonnes of
Marshall base course the batch size shall not exceed 5,000
tonnes.
132.6.28.2 Sample: aggregates, filler and bituminous binder
(a) One sample of each type of aggregate, filler and bituminous

binder shall be provided from each batch.
(b) The minimum size of each sample and the method of sampling
shall be as stated in Table 132.33.
Table 132.33: Size of samples and method of sampling for

aggregates, filler and bituminous binder
Material Minimum size Method of sampling

of sample

exceeding 32 mm
10 mm to 32 mm
less than 10 mm
Filler 5 kg BS EN 932-1: 1997
Bituminous binder 5 kg ASTM D140/D140M

132.6.28.3 Testing: aggregates, filler and bituminous binder
(a) Each sample of aggregate and filler and bituminous binder shall
be tested to determine the properties stated in Table 132.34. The
method of testing shall be as stated in Table 132.34. All test
results shall be reported, including failures.
Table 132.34: Testing aggregates, filler and bituminous binder
Material Property Method of testing Frequency

Coarse Los Angeles Abrasion BS EN 1097: Part 2 Each batch
aggregate Magnesium Soundness BS EN 1367: Part 2 Each batch
Flakiness Index BS EN 933: Part 3 Each batch
Water Absorption BS EN 1097: Part 6 Each batch
Particle Size Distribution BS EN 933: Part 1 Each batch
Material < 0.075 mm BS EN 933: Part 1 Each batch
Ten Percent Fines Value BS EN 1097 Part 2 Each batch
(TFV)
Fine Magnesium Soundness BS EN 1367: Part 2 Each batch
aggregate Los Angeles Abrasion BS EN 1097: Part 2 Each batch
(tests on Water Absorption BS EN 1097: Part 6 Each batch
sample of
Particle Size Distribution BS EN 933: Part 1 Each batch
material
Material < 0.075 mm BS EN 933: Part 1 Each batch
before
crushing)
Filler Particle Size Distribution BS EN 933: Part 10 Each batch
Each batch
Moisture Moisture Content Oven drying (see Weekly

content of Sub-section (b)
aggregates below)
at/after
mixing
Bituminous Penetration at 25°C BS EN 1426 (or Each batch
binder ASTM D5) /daily
Viscosity at 60°C ASTM D2171 Each batch
/daily
(b) The moisture content of aggregates at/after mixing (i.e., on

completion of mixing but without the addition of bituminous binder)
shall be determined using the procedure described in BS EN
1097: Part 5:2008, modified by weighing samples, drying in a
ventilated oven at 175  2°C for 24 hours and then weighing
again.

132.6.28.4 Compliance criteria: aggregates, filler and bituminous binder
The result of each test shall comply with Table 132.35.
Table 132.35: Compliance criteria for aggregates, filler and

bituminous binder
Material Property Compliance Criteria
Coarse Los Angeles Abrasion ≤ 30% wear after 500
Flakiness Index < 20%
Water Absorption < 2%
Percentage <0.075 mm < 2%
Ten Percent Fines Value < 180kN
(TFV)
Fine Los Angeles Abrasion < 30% wear after 500

Water Absorption ≤ 2.5% (crushed aggregate)
≤ 2.0% (uncrushed
aggregate)
Percentage <0.075 mm ≤ 10.0% (crushed
aggregate)
≤ 5.0% (sand and/or
combined aggregate)
Filler Sieve size (mm) Percentage by mass
0.6 passing
0.3 100
0.075 95 – 100
70 – 100
Moisture Moisture Content ≤ 0.5%
content of
aggregates
at/after
mixing
Bituminous Penetration at 25°C 70  10
binder Viscosity at 60°C Minimum as noted in
Section 132.6.17.2

132.6.28.5 Non-compliance: aggregates, filler and bituminous binder
(a) If any test result fails to meet the requirements of Table 132.35
then four further samples shall be taken from the relevant batch
and tested in accordance with Table 132.34 for the non-
complying property.
(b) If any of the additional tests fail to meet the compliance criteria
then the batch shall not be permitted for use in the Works.
132.6.29 TESTING: MARSHALL ASPHALT MIX
132.6.29.1 Samples: Marshall asphalt mix
Following trials, each mix, per production plant per work shift shall be
as follows:
(a) For the first 100 tonnes per production plant per work shift –
minimum 2 samples.
(b) For each subsequent 150 tonnes, or part thereof, per plant, per
work shift, one further sample is to be taken.
(c) The Contractor shall submit all test results to the Project
Manager within 24 hours of mixing and placement.
132.6.29.2 Testing: Marshall asphalt mix
Each sample shall be tested in accordance with Table 132.36.
Table 132.36: Testing Marshall asphalt mix
Particle size distribution BS EN 933 : Part 1: 2012 or

ASTM C136/C136M-2014
Bituminous binder content ASTM D2172/D2172M-11
Marshall properties TAI MS – 2 Chapter 5
132.6.29.3 Non-compliance: Marshall asphalt mix
(a) If any of the test results fail to comply with the job mix formula
described in Section 132.6.18.2 of the GMWS and the associated
level of tolerances as given in Table 132.32 or the Marshall
properties do not comply with those specified in Table 132.29,
then four further samples of Marshall asphalt mix shall be taken
immediately from any remaining production or mix.

(b) If the result of any of the additional tests does not comply with
the requirements of the GMWS then the Contractor shall provide
the Project Manager with justification, rationale and details of
corrective action taken for acceptance of such materials.
However, in all cases of non-compliance, the Project Manager
reserves the right to reject the material, instruct the Contractor to
remove and replace at their own cost, the full extent of the area
concerned, and make whatever changes are necessary to
produce a mix which complies with the GMWS.
132.6.30 TESTING: MARSHALL ASPHALT CORES
132.6.30.1 Samples: Marshall asphalt cores
(a) Each area of Marshall asphalt, up to 2,000 m2, which contains

Marshall asphalt of the same mix produced at the same mixing
plant and which is laid and compacted in a single layer in one
day shall be designated as a lot. Each lot shall be divided into 4
equal sub-lots.
(b) A pair of 100 mm diameter cores shall be taken from three of the
four sub-lots in accordance with BS EN 12697: Part 27. The
location of sampling sites for the Marshall asphalt layer will be
advised by the Project Manager on site.
(c) In addition to the cores described in Section 132.6.30.1(b), cores
shall also be taken on the longitudinal lane joint at a frequency of
one core per 250 m of joint or a minimum of two cores per day.
The cores shall be taken in the first-laid (older) mat, with the
circumference of the core not greater than 30 mm or less than 10
mm away from the joint.
(d) The Contractor shall paint the walls and base of all test holes with
hot bitumen or bond coat complying with Section 132.8 of the
GMWS, fill with suitable hot asphalt and compact with a vibrating
hammer in lifts not exceeding 50 mm.
(e) The Contractor shall submit all test results to the Project Manager

132.6.30.2 Testing: Marshall asphalt cores
(a) Each Marshall asphalt core shall be measured to determine the

compacted layer thickness. The thickness shall be measured to
the nearest 1 mm.
(b) The density of the Marshall asphalt cores shall be determined in
accordance with BS EN 12697: Part 6, Procedure B (Saturated
Surface Dry method).
(c) In-situ air voids shall be determined for each Marshall asphalt
core in accordance with BS EN 12697 Part 8 and the test results
objection.
132.6.30.3 Compliance criteria: Marshall asphalt cores
(a) The average compacted layer thickness for the lot shall comply
with Section 132.6.26.1 of the GMWS. The ‘Reference Density’
to be used for the determination of compaction and air voids of
Marshall asphalt cores shall be the rolling average compacted
(bulk) density of all Marshall asphalt specimens prepared from
production asphalt during this and the previous four work shifts
in which the asphalt from which the Marshall asphalt cores were
taken was placed.
(b) The average mat density determined from all Marshall asphalt
cores from the same lot shall not be less than 98.0% nor more
than 100.0% of the ‘Reference Density’ and no individual mat
density test shall deviate by more than 1.8% from the average
density of the lot or exceed 101.0% of the ‘Reference Density’.
(c) The density of individual Marshall asphalt cores taken with the
circumference of the core not more than 30 mm or less than 10
mm away from the joint shall not be less than 97.0% of the
‘Reference Density’.
(d) The average air void content of all Marshall asphalt cores
obtained for a lot, except cores taken on the longitudinal joint,
shall not deviate from the range 3.0% to 6.0%, when determined
in accordance with Chapter 5 of TAI MS-2. Individual insitu air
void contents shall be between 2.5 and 7.5%.
(e) For each Marshall asphalt core, the fresh overlying course and
existing underlying course shall be well bonded; their physical
detachment into two separate layers shall not be permitted.

132.6.30.4 Non-compliance: Marshall asphalt cores
(a) If the result of any individual Marshall asphalt core density test
does not comply with the requirements of the GMWS then four
additional Marshall asphalt cores shall be taken from the same
sub-lot, at locations which are evenly spaced throughout the sub-
lot. The additional Marshall asphalt cores shall be tested in
accordance with Section 132.6.30.2 of the GMWS. In all cases
where non-compliance is noted, the Contractor shall provide the
Project Manager with justification, rationale and details of
corrective actions taken for acceptance of such materials. In all
cases where the average air void content of any set of retest
cores is outwith the range of 2.5% to 7.5% and thickness of the
core is not conforming to the requirement shown in the drawings,
the Contractor shall offer to remove and replace at their own cost,
the full extent of the area represented by the related core.
However, in all cases of non-compliance this Section of the
GMWS, the Project Manager reserves the right to reject the
material, and instruct the Contractor to remove and replace at
their own cost, the full extent of the area concerned.
(b) If any individual Marshall asphalt core indicates that the fresh
overlying course and existing underlying course are physically
detached into separate layers then four additional Marshall
asphalt cores shall be taken from the same sub-lot, at locations
which are evenly spaced throughout the sub-lot. If any of the
additional Marshall asphalt cores fail to meet the requirement of
Section 132.6.30.3(e) then the non-complying layer of Marshall
asphalt shall be removed over the whole sub-lot and shall be
replaced with fresh material.
(c) Any fresh material installed to replace non-compliant lots or sub-
lots shall be tested in accordance with Section 132.6.30.2 of the
GMWS and shall comply with the criteria stated in Section
132.6.30.3 of the GMWS.

132.6.31 REFERENCES
British Standards Institution

Standard Title Superseded or
complimentary
BS
BS 598-100 Methods of sampling and analysis n/a
BS 598-102 Sampling and examination of bituminous n/a
mixtures for roads and other paved areas.
Part 102. Analytical test methods
BS 598- Sampling and examination of bituminous n/a
110:1998 mixtures for roads and other paved areas.
Part 110. Method of test for the determination
of wheel-tracking rate and depth
BS 812- Testing aggregates. Methods for Partially replaced

111:1990 determination of ten percent fines value by BS EN 1097-
(TFV) 2:1998
BS EN 932- Tests for general properties of aggregates. BS 812-102
1:1997 Part 1. Methods for sampling
BS EN 933-1: Tests for geometrical properties of BS 812-103.1
2012 aggregates. Part 1. Determination of particle
size distribution. Sieving method
BS EN 933-3: Tests for geometrical properties of BS 812-105.1
2009 aggregates. Part 3. Determination of particle
shape of aggregates. Flakiness index
BS EN 933-10; Tests for geometrical properties of n/a
2009 aggregates. Part 10. Determination of fines.
Grading of fillers (air jet sieving)
BS EN 1097-2: Tests for mechanical and physical properties BS 812-111
2013 of aggregates. Part 2. Methods for the
determination of resistance to fragmentation
2008 of aggregates. Part 5. Determination of water
content by drying in a ventilated oven
2013 of aggregates. Part 6. Determination of
particle density and water absorption
BS EN 1367-2: Tests for thermal and weathering properties BS 812-121
2009 of aggregates. Part 2. Magnesium sulphate
test
BS 1377-2 Methods of test for soils for civil engineering Partially replaced
purposes. Part 2. Classification tests

complimentary
BS
BS EN 1426: Methods of test for petroleum and its BS 2000-49
2015 products. BS 2000-49: Bitumen and
bituminous binders-Determination of needle
penetration
BS EN 12591: Bitumen and bituminous binder. Specification BS3690-1

2009 for paving grade bitumens
BS EN ISO Quality management systems. Fundamentals n/a
9000: 2015 and vocabulary
BS EN 12697- Bituminous mixtures. Test methods for hot BS 598-104
6: 2012 mix asphalt. Part 6. Determination of bulk
density of bituminous specimens
BS EN 12697- Bituminous mixtures. Test methods for hot
22: 2003 mix asphalt. Wheel tracking
BS EN 12697- Bituminous mixtures. Test methods for hot
24: 2012 mix asphalt. Part 24. Resistance to Fatigue.
BS EN 12697- Bituminous mixtures. Test methods for hot BS DD 213
26: 2012 mix asphalt. Part 26. Stiffness
BS EN 12697- Bituminous mixtures. Test methods for hot BS 598-100
27: 2001 mix asphalt. Part 27. Sampling
BS DD AWF Methods for determination of the fatigue n/a
characteristics of bituminous mixtures under
indirect tensile fatigue

American Society for Testing and Materials
Standard Title
ASTM C295 Standard practice for petrographic examination of aggregates for
concrete
ASTM D5: 2013 Test method for penetration of bituminous materials
ASTM D36: Standard test method for softening point of bitumen (ring and ball
2014 apparatus)
ASTM D92 Flash and Fire Points by Cleveland Open Cup
ASTM Standard Test Method for Sieve Analysis of Fine and Coarse
C136/C136M: Aggregates
2014
ASTM Standard practice for sampling of bituminous materials
D140/D140M:
2016
ASTM Standard Test Methods for Quantitative Extraction of Bitumen
D2172/D2172M - From Bituminous Paving Mixtures
11
ASTM D4402: Viscosity Determinations of Unfilled Asphalts Using the
2015 Brookfield Thermosel Apparatus
The Asphalt Institute
Standard Title
TAI MS2 Mix design methods for asphalt concrete and other hot-mix types
(Seventh
Edition) (2015)
American Association of State Highway and Transportation Officials
Standard Title
AASHTO TP5: Rheological Properties of Asphalt Binder Using Dynamic Shear
1998 Rheometer (DSR)
AASHTO T240: Test method for effect of heat and air on asphalt materials (rolling
2013 thin film oven test)
AASHTO T283: Resistance of bituminous mixtures to moisture induced damage
2014
AASHTO PP1 Practice for accelerated aging of asphalt binder using a
pressurized aging vessel (PAV)

132.6.32 PMAWC AND MABC HOLD AND CONTROL POINTS
The Contractor shall include the Control and Hold Points shown in
Table 132.36A in his Construction Quality Plan or Inspection & Test
Plan.
Table 132.36A: PMAWC and MABC Hold and Control Points

132.6.2 Materials Materials (in particular: PMB,
bitumen, aggregates and
filler)
132.6.3.1 Design of Polymer Modified
Marshall Asphalt - General
132.6.3.2 Design of Polymer Modified Design of Polymer Modified
Marshall Asphalt – Design Marshall Asphalt – Design
Mix Formula Mix Formula
132.6.4 Initial approval submission Submissions (in particular
aggregate sources,
aggregate samples, PMB,
method of construction and
batching plant)
132.6.5 Trials (including Construction
Trial Report)
132.6.7 Mixing of Polymer Modified
Marshall Asphalt
132.6.8.2 Preparation of Underlying Preparation of Underlying
Course Course
132.6.9 Laying and Compaction
132.6.12 Testing: Surface Level,
Regularity and Texture –
132.6.13 Testing: Aggregates, Filler
and PMB –
132.6.14 Testing: Polymer Modified
Marshall Asphalt Mix –
132.6.15 Testing: Polymer Modified
Marshall Asphalt Cores –

132.6.17 Materials – Materials (in particular,
submission/compliance bitumen, aggregates and
assessment of each lot filler)
132.6.18.2 Design of Marshall Asphalt – Design of Marshall Asphalt –
Design Mix Formula Design Mix Formula
132.6.19 Initial approval submission Submissions (in particular;
aggregate sources,
aggregate samples, bitumen,
asphalt mix design, method
of construction and batching
plant)
132.6.20 Trials (including Asphalt
Compaction Trial Procedure)
132.6.22 Mixing of Marshall Asphalt
132.6.23.2 Preparation of Underlying Preparation of Underlying
Course Course
132.6.24 Laying and Compaction
132.6.27 Testing: Surface Level and
Regularity –
132.6.28 Testing: Aggregates, Filler
and Bituminous Binder –
132.6.29 Testing: Marshall Asphalt Mix
– submission/compliance
132.6.30 Testing: Marshall Asphalt
Cores –

APPENDIX A132.6.1 TEST METHOD FOR STORAGE STABILITY OF POLYMER
MODIFIED BINDERS
A132.6.1.1 Scope
This test determines the susceptibility of a pre-blended modified binder
to separation or instability during prolonged storage at high temperature.
A132.6.1.2 Apparatus
(a) Cylinder, made of heat resistant glass, of minimum height 160
mm and of internal diameter between 30 mm and 60 mm having
a removable lid, flush fitting to exclude air when the cylinder is
filled with binder, and provided with three drain-cocks, one at the
base, the other two spaced equally down the side of the cylinder,
to allow the sample to be divided into three equal portions as in
Sections A132.6.1.3 (g) or A132.6.1.3 (h) of this Appendix.
Alternatively, a thin-wall sheet metal tube or similar vessel such
as a 500 ml beverage can, of similar dimensions to the glass
cylinder, and having a similarly removable lid, fitted either with or
without drain-cocks.
(b) Oven, electrically heated, fan assisted, and capable of
maintaining a temperature of 180 ± 5C, having interior
dimensions not less than 330 mm from the top of the heating
element to the top of the chamber and not less than 305 mm in
width and depth.
(c) Tube holder, made of metal, which will hold either the glass
cylinder or sheet metal can, in a vertical position, such that the
base of the cylinder or can is not in direct contact with the oven
floor.
(d) Apparatus for determining the penetration at 25oC and softening
point of bitumen in accordance with ASTM D5: 2013 and D36:
2014 respectively.
(e) Transfer dishes (3), made of metal, each of a capacity sufficient
to hold at least one third of the test sample.

A132.6.1.3 Procedure
(a) The bulk sample of modified binder shall be obtained by sampling
in accordance with ASTM D140.
(b) Place the bulk sample of modified binder and the glass cylinder
(or metal tube or equivalent vessel) in the preheated oven at 180
± 5C for a period not exceeding three hours.
(c) Remove the bulk sample from the oven and thoroughly mix by
stirring to ensure obtaining a representative test sample.
(d) Remove the glass cylinder (or metal tube or equivalent vessel)
from the oven and completely fill with the modified binder test
sample to allow no air space when the lid is fitted.
(e) Support the filled cylinder in a vertical position in the holder and
transfer to the oven which shall be controlled at a temperature of
180 ± 5C and allow to stand undisturbed for a period of 72 ± 1
hours. (Note: Alternative storage temperature may be proposed
to the Project Manager for his review without objection by
submitting a letter of recommendation from the binder
manufacturer/supplier).
(f) If a vessel having drain-cocks has been used for the test,
proceed using Method A below, otherwise proceed using Method
B.
(g) Method A
(i) Remove the glass cylinder (or alternative approved vessel
reviewed without objection by the Project Manager) from
the oven, keeping the cylinder vertical.
(ii) Open the upper-most drain-cock and run off the top third
portion of the test sample into a transfer dish for testing.
(iii) Open the middle drain-cock and run off the middle third
portion of the test sample into a suitable container and
discard.
(iv) Open the lower drain-cock and run off the bottom third
portion of the test sample into a transfer dish for testing.

(h) Method B
(i) Remove the tube or vessel containing the test sample from
the oven and allow it to cool at room temperature for 2 ±
0.25 hours whilst maintaining the vessel vertical in the
holder.
(ii) When the vessel of modified binder has cooled to ambient

temperature, remove it from the tube holder and make two
cuts through the vessel and the sample at positions one-
third and two-thirds of the length from, and parallel to, the
base.
(iii) Retain the top and bottom thirds of the test sample for
further testing and discard the middle third.
(i) Determine the penetration at 25oC and softening points of the top
and bottom thirds of the test sample, in accordance with ASTM
D5 and D36 respectively.
A132.6.1.4 Reporting
For both the top and bottom thirds of the test sample the following shall
be reported:
(a) The penetration at 25oC, ASTM D5 to the nearest 0.1 mm.
(b) The softening point, ASTM D36, to the nearest 0.2oC or 0.5C
when using ASTM thermometer 15oC (15F) or 16oC (16F)
respectively.
(c) Whether Method A or Method B was used.
(d) The location and date of obtaining the bulk sample, and the dates
of test.

APPENDIX A132.6.2 STANDARD PRACTICE FOR LONG-TERM OVEN AGEING
OF COMPACTED ASPHALT MIXES
A132.6.2.1 Scope
This standard practice is used to simulate the long-term ageing of
compacted bituminous mixtures. Long-term aging considers the
hardening of the bitumen in the mixture subsequent to construction. The
practice should result in aging representative of five to ten years for
dense-graded mixtures.
A132.6.2.2 Definitions
(a) Ageing refers to the hardening or embrittlement of the bitumen
in bitumen-aggregate mixtures as a result of compositional
changes in the bitumen due to many factors such as time,
temperature, oxidation, steric hardening, ultraviolet radiation,
etc.
(b) Long-term ageing refers to the hardening or embrittlement of the

bitumen in bitumen aggregate mixtures, subsequent to
construction of the pavement layer incorporating the bituminous
mixture.
A132.6.2.3 Apparatus
(a) Oven: forced-draft oven which is thermostatically controlled and
capable of being set to maintain any desired temperature from
room temperature to 260C with an accuracy of ± 1C or less.
(b) Digital thermometer capable of measuring temperatures from

room temperature to 260C and having an accuracy of + 1C or
less.
(c) Wire mesh, of sufficient rigidity to support the compacted

specimens without bending or flexing appreciably, having an
open area to total area ratio of at least 75%.
A132.6.2.4 Procedure
(a) Place the specimen on the wire mesh in the forced-draft oven for
120 ± 0.25 hours at a temperature of 85 ± 1C.
(b) After 120 hours, turn off the oven, open the door and allow the
specimen to cool to room temperature (24 hours should be a
sufficient cooling period).
(c) After the specimen has cooled to room temperature, remove it

from the oven. The specimen is now ready for testing as required.

132.7 BLOCK PAVING
132.7.1.1 Block Paving
Block paving is a flexible surfacing consisting of paving blocks on

a laying course.
132.7.1.2 Laying Course
A laying course is a layer of sand on which paving blocks are

bedded.
132.7.1.3 Open laying face
An open laying face is a working edge of block paving at which

laying of paving blocks is taking place and which is orientated as
indicated in Figure 3 of BS 7533-3:2005 + A1:2009.
132.7.2 GENERAL
132.7.2.1 Scope of section
This section covers the requirements for the construction of block

paving.
132.7.3 MATERIALS
132.7.3.1 Paving blocks
(a) Paving blocks shall be 80 mm thick, natural colour, interlocking

precast concrete paving blocks conforming to BS EN
1338:2003.
(b) The paving blocks shall have a chamfer around the top edge
to an angle of approximately 45o and of a size between 4 and
7 mm.
(c) Paving blocks shall have spacing nibs on the vertical faces.
The size, number and location of the nibs shall be such as to
separate all paving blocks to achieve a joint spacing as
required in Section 132.7.8.2(k) of the GMWS. Nibs shall not
be located at corners of blocks.
(d) Nibs shall consist of integrally cast projections on the paving
blocks units and shall not extend to within 25 mm of the surface.
(e) Paving blocks shall have a surface texture depth, when tested
in accordance with Appendix A132.7.1, not greater than 0.11
mm before installation nor 0.16 mm after compaction.
(f) The blocks shall key into each other and their plan geometry,
when keyed together shall resist the spread of joints parallel to
both the longitudinal and transverse axes of the block. The
block size shall be such that 40 to 50 units are required to make
up one square metre.

(g) The manufacturing tolerance must be such as to ensure the
blocks can be laid to achieve the joint spacing specified.
(h) The manufacturer shall certify that the blocks are free from risk
of alkali aggregate reaction.
132.7.3.2 Bedding sand
(a) Bedding sand shall be natural silica sand.

(b) The particle size distribution of the bedding sand when tested
in accordance with BS EN 933-1 2012 shall comply with the
requirements of Table 132.37.
(c) Bedding sands shall be washed free of soluble salts or other
contaminants, which can cause or contribute to efflorescence.
(d) Bedding sand shall comply with the requirements of Section
132.7.13.1 of the GMWS.
TABLE 132.37: Grading requirements for bedding sand

Sieve Size (mm) Percentage Passing by
Mass
10.0 100
5.00 95 – 100
2.36 75 – 100
1.18 50 – 90
0.600 10 – 35
0.300 0 – 20
0.150 0 – 10
0.075 0–3
(e) Bedding sand shall not contain more than 10% acid soluble
material.

132.7.3.3 Joint filling sand
(a) Joint filling sand shall be a washed, specially graded kiln dried
silica sand with a target particle size distribution, when tested
in accordance with BS EN 933-1 2012, complying with Table
132.38.
Table 132.38: Target grading for jointing sand

Sieve Size (mm) Percentage Passing by
Mass
1.18 100
0.60 55 – 75
0.30 12 – 20
0.15 0 – 10
0.075 0–3
(b) Masonary and beach sand shall not be used.
(c) The joint filling sand shall either be mixed with binding additives
that when activated give a cohesive cross particle linked,
flexible mass throughout the depth of the joint or a sealer shall
be applied.
(d) Sealer for stabilizing joint sand shall be an urethane, or equal,
capable of 100% elongation in accordance with ASTM D 2370
(2010). The sealer or binding additive shall have demonstrated
acceptable performance in similar airfield paving application
for a minimum of two years. The sealer shall penetrate the
joint filling sand to a depth of at least 30 mm. The sealer shall
be applied in strict accordance with manufacturer's
recommendations. The sealer or binding additive shall be
proven to stabilize the joint filling sand to resist repeated blasts
from jet engines and propeller wash and shall prevent the
ingress of water through the joint filling sand. The sealed joint
shall also be resistant to jet fuels, aviation gasoline and
hydraulic fluids.
(e) Joint filling sand and the binder or sealer shall be reviewed

132.7.3.4 Geotextile
Geotextile shall be non-woven and shall have the following minimum

properties:
(a) Mass per unit area 200 g/m2

(ASTM-D-1910)
(b) Thickness (at 2kPa 0.8 mm

applied Pressure)
(c) Tensile strength 10 kN/m

(both directions)
(B.S. 6906, Part 1)
(d) Elongation
longitudinal 50%
transverse (ASTM-D-4632) 50%
(e) Permeability 150 litre/sec/m2

(BS EN 12958: 2010)
(f) CBR Push Through Force 1,000N

(BS EN 12236: 2006)
132.7.4 SUBMISSIONS
132.7.4.1 Particulars of materials

area, the Contractor shall submit the following particulars to the
Project Manager for review without objection:
(i) Manufacturers' literature and certificates for paving

blocks, joint filler sand, binder or sealer and geotextile
showing the manufacturer's name, the date and place
of manufacture and showing that the material complies
with the requirements.
(ii) A statement of the origin, method of production and

proposed grading of the bedding sand. The Contractor
shall also provide evidence demonstrating that an
adequate supply of uniform material can be produced.
(b) At least 40 days prior to scheduled commencement of the

manufacture of the blocks, the Contractor shall produce and
submit for review to the Project Manager a computer simulation
of the herringbone laying pattern using the block size and
production tolerances proposed. The simulation shall
demonstrate that the joint spacing requirements can always be
achieved. The simulation shall be accompanied by a statement
by the block manufacturer on methods of controlling block
dimensions including the proposed rate of replacement of
moulds due to wear.

132.7.4.2 Representative samples of materials
At the same time as the particulars of materials are submitted, the

Contractor shall submit the following representative samples to the
Project Manager:
(a) paving blocks;

(b) joint filling sand;
(c) bedding sand; and
(d) geotextile.
132.7.4.3 Particulars of methods of construction
At least 20 days prior to scheduled commencement of the trial area,

the Contractor shall submit particulars of the proposed methods of
construction to the Project Manager for review without objection.
The Contractor shall provide production and field test summaries on

an on-going daily basis (or other agreed period) to monitor compliance
and trends in test results and submit these promptly to the Project
Manager. The format of the test summaries shall be agreed with the
Project Manager. The Contract shall take appropriate action as
required (including raising non-conformance reports etc) to ensure
compliance with the GMWS.
132.7.5 TRIALS
(a) Prior to commencement of block paving construction, the

Contractor shall construct a trial area of at least 500 m 2. The
trial will be used to determine the adequacy of the Contractor's
equipment, placement methods and ability to meet the specified
tolerances.
(b) The trial area shall contain at least one manhole or similar
obstacle.
(c) Materials and equipment used to construct the trial area shall
be those intended for use in constructing the Permanent Works.
The trial area may form part of the Permanent Works if
accepted.
(d) The Contractor shall notify the Project Manager at least 48
hours before construction of a trial area begins.

(a) The trial area shall be tested for surface level and regularity in
accordance with Section 132.7.11.1 of the GMWS.
(b) The trial area shall be tested for paving block alignment in
accordance with Section 132.7.12.1 of the GMWS except that
the frequency of testing shall be one 1 m x 1 m test area per 50
m2 of block paving.
The results of all tests shall comply with Sections 132.7.10 and
132.7.12.2 of the GMWS.
(a) If the results of any test on the trial area fail to comply with the
specified requirements for the trial area, particulars of
proposed changes to the method of construction shall be
submitted to the Project Manager for review without objection;
further trial areas shall be constructed until the result of every
test on the trial area complies with specified requirements for
the trial area.
132.7.5.5 Commencement of block paving construction
(a) On satisfactory completion of the trial area, and before

construction of further Permanent Works, the Contractor shall
provide the Project Manager with details of the Construction
Procedure, which shall form an integral part of the Contractor's
Quality System.
(b) Construction of the Permanent Works, other than the trial area,
may not commence until the Construction Procedure referred
to in Section 132.7.5.5(a) has been reviewed without objection
The materials and methods of construction used to produce a trial

area which complies with the specified requirements shall not be
changed without being first reviewed without objection by the Project
Manager.
Joint filling sand shall be stored in accordance with the

manufacturer's recommendations.

(a) The Contractor shall notify the Project Manager before work
commences on the block paving for each part of the
Permanent Works and shall allow the Project Manager
sufficient time to inspect the primed underlying course.
(b) All loose foreign materials shall be removed from the surface
and work shall not proceed until the underlying course
conforms to the requirements of the GMWS, and has been
132.7.7.2 Laying of geotextile
(a) Prior to placing the geotextile course the Contractor shall apply
a layer of bond coat to the requirements of Section 132.8 of the
GMWS but at an application rate determined by trials and
previously reviewed without objection by the Project Manager,
to the underlying layer.
(b) When the bond coat has dried to a suitable condition of
tackiness the Contractor shall lay a geotextile onto the
underlying course. The method of laying shall ensure that the
geotextile is in continuous contact with the surface on which it
is placed. It shall not be stretched or bridged over humps or
hollows.
(c) Adjacent sheets or strips of geotextile shall be overlapped by
at least 300 mm. Geotextile shall be brought up the vertical
faces of all edge restraint and structures (including kerbs,
footings, retaining walls, cable draw pits, manholes, etc.) to
ensure that sand does not flow down the side of the edge
restraint and structures.
(d) Geotextile shall also cover the entrance to all associated sub-
surface drainage outlets.
(e) The geotextile shall be rolled with a roller which has a wheel
load of at least 0.5 tonnes and the Contractor shall ensure that
the geotextile sticks to the bond or tack coat.
(f) A further application of bond or tack coat shall be applied to the
geotextile at a rate determined by trials.
(g) Traffic, except equipment necessary to construct the block
paving, shall not be permitted to run on the geotextile.

132.7.8 CONSTRUCTION OF BLOCK PAVING
132.7.8.1 Construction of block paving: general
(a) No activity or work shall be carried out on block paving when

there is standing water on any of the component layers or the
underlying layer.
(b) The surface of each layer shall be kept free of deleterious
matter and debris.
132.7.8.2 Placement of block paving
(a) Bedding sand shall be placed in a uniform layer and at a

uniform moisture content and shall be rolled with two passes
of a smooth drum steel wheel roller having a drum mass of at
least two tonnes per linear metre of drum.
(b) The rolled sand layer shall be screeded to remove all ridges
and hollows.
(c) The top 5 mm of sand shall then be carefully raked to loosen
the surface to aid in bedding of the block.
(d) The nominal compacted thickness of bedding sand is 20 mm.
The compacted thickness of the bedding sand shall nowhere
exceed 25 mm nor be less than 15 mm.
(e) Placement of paving blocks shall pave uphill wherever possible
to avoid downhill creep in incomplete area and shall not
commence until a sufficient area of laying course is ready to
permit work to proceed in a continuous systematic fashion.
(f) Paving blocks shall be placed on the screeded bedding sand
in a herringbone pattern.
(g) The first row shall be located next to an edge restraint,
previously completed paving, or an established straight line.
The paving blocks shall be aligned at a suitable angle to
achieve the required orientation in the completed pavement.
(h) The pattern alignment shall be checked on a 5 m x 5 m grid
and minor adjustments shall be made as necessary. A 5 m x 5
m string line grid shall be established to facilitate this checking.
(i) Block laying shall follow an order which maintains an open
working face and does not trap paving blocks.
(j) Specially manufactured edge paving blocks with nibs shall be
used. Alternatively edge blocks shall be cut using a power saw.
Cut blocks shall consist of not less than 25% of a full unit.
Specially manufactured half blocks with nibs shall be used
adjacent to the first row to facilitate the herringbone pattern.
Gaps against restraints greater than 5 mm shall not be
permitted.
(k) Joint widths between adjacent paving blocks shall be within the
range of 1.5 mm to 4 mm.
(l) Adjacent paving blocks shall be placed level with each other.

(m) The paving block shall not be placed on saturated bedding
sand. The bedding sand should be at or near optimum
moisture content to gain the highest degree of sand
compaction when the paving blocks are vibrated by the plate
compactors. If there is too much water, either the saturated
sand must be left to dry or be replaced with new sand.
(n) At the end of the shift, the open working face of incomplete
works shall be temporarily sealed with cement sand mortar
which then shall be removed prior to subsequent blocks being
laid.
132.7.8.3 Initial compaction
(a) After placement of the paving blocks and before joint filling, the
block paving shall be fully compacted using a plate compactor
with a plate, area of not less than 0.25 m2, transmitting an
effective force of not less than 88 kN/m2 of plate at a frequency
of vibration in the range 75 Hz to 100 Hz. Alternatively,
compacting equipment which will achieve the same degree of
compaction and which will not damage the block surface, may
be used.
(b) Compaction shall be carried out as soon as possible after
laying but not within 2 m of any laying face or such greater
distance necessary to prevent spreading (opening) of joints if
this is evident. Apart from this edge strip, no block paving shall
be left un-compacted at the completion of a work shift.
(c) Paving blocks which are adjacent to edge restraints shall not
be compacted until the edge restraint has gained sufficient
strength.
(d) Any paving blocks which are damaged during initial
compaction shall be removed and replaced.
132.7.8.4 Joint filling
(a) After initial compaction, dry joint filling sand shall be spread
over the pavement by brooming or other means to effectively
ensure all joints are filled to their full depth. Joint filling shall not
take place whilst the paving blocks are damp.
(b) The pavement shall then receive one pass of the vibrating plate
compactor and the joints re-filled with joint filling sand to their
full depth. Excess sand shall be removed. This process shall
be repeated until the joint filling sand is fully compacted.
(c) The pavement shall be subjected to not less than four
coverages of a heavy pneumatic tyred roller having wheel
loads of 5,000 kg at tyre pressures of 800 kPa.
(d) At the completion of the rolling, joints are to be topped up by
adding more joint filler sand such that the joints are left filled.

(e) Where a gap of more than 5 mm occurs against a restraint, the
joint shall be filled with a dry sand cement mix of proportions
3:1 to within 20 mm of surface. After final compaction of the
pavement, the top 20 mm shall be sealed with an elastomeric
joint sealant meeting the requirements of Sections
132.7.8.4(f)-(i) and installed to the manufacturers’
requirements.
(f) The joint sealant shall be of a grade suited to the climatic
conditions of Hong Kong and shall perform effectively over a
temperature range of 0oC to 60oC.
(g) The joint sealant shall be Fosroc Colpor 200PF or similar
equivalent and shall be reviewed without objection by the
Project Manager.
(h) The joint sealant shall be an elastometric based sealant, cold
poured, two-part, polymer-based, and jet fuel resistant sealant
complying with BS 5212, Type F.
(i) Primer for use with joint sealant shall be a proprietary type
(a) After completion of the block paving the Contractor shall

perform all maintenance work necessary to keep the block
paving in a condition complying with the GMWS.
(b) If damage occurs to the block paving from trafficking the course,
or by any other reason, then the affected area shall be
removed by the Contractor and replaced with fresh material
complying with the GMWS.
132.7.10 TOLERANCES
(a) The elevation of the finished surface shall not vary by more
than +/-5 mm from the required level.
tested with a 3.0 m straight edge on a uniform slope. The
finished surface shall also not vary by more than 7 mm per 3
m length of surface when tested with a profilometer.
(a) Levelling of the finished course shall be performed by the

Contractor at all changes of grade and on a grid which has an
interval of up to 5 m in two mutually perpendicular directions.
(b) The block paving course shall be tested for surface regularity
on a grid layout agreed with the Project Manager.

(c) Where the block paving extends for more than 30 m in a given
direction, the finished surface shall be tested for regularity
using a profilometer which produces a continuous
computerised printout of the surface profile for visual reading
and surface record.
(d) Where the block paving course extends for less than 30 m in a
given direction, the finished surface shall be tested for
regularity using a 3.0 m straight edge.
(a) Any areas which do not comply with the requirements of the
GMWS shall be corrected by the Contractor by removing the
defective work and replacing it with fresh material.
(b) If more than 3% of measurements do not comply with the
requirements of the GMWS then the Contractor shall revert to
constructing trial areas and make any necessary alterations
until the surface level and regularity are satisfactory.
132.7.12 TESTING: PAVING BLOCK ALIGNMENT
132.7.12.1 Testing: paving block alignment
(a) All paving blocks shall be visually inspected to ensure that no

joint spacing or differences in level between adjacent paving
blocks exceed the absolute maximum specified.
(b) One 1 m x 1 m area shall be marked out per 250 m2 of block
paving. Within this area the joint spacing and difference in level
shall be measured between each adjacent paving block.
132.7.12.2 Compliance criteria: paving block alignment
(a) No more than 5% of joint widths shall exceed 4 mm. No joint

space shall be less than 1.5 mm nor more than 5 mm.
(b) The difference in level between adjacent paving blocks shall
not exceed 4 mm with not more than 3% exceeding 2 mm.
132.7.12.3 Non-compliance: paving block alignment
(a) If any 1 m x 1 m area fails to comply with the requirements of

the GMWS then a 3 m x 3 m area adjacent to the non-
complying test area shall be tested as described in Section
132.7.12.1 of the GMWS.
(b) If the 3 m x 3 m test area does not comply with Section
132.7.12.2 of the GMWS then the Contractor shall revert to
constructing trial areas and make any necessary alterations
until the paving block alignment is satisfactory.
(c) All defects in. the 1 m x 1 m test area and the 3 m x 3 m test
area shall be corrected by the Contractor.

132.7.13 TESTING : BEDDING SAND
132.7.13.1 Testing: bedding sand
(a) All sands shall be tested for susceptibility to degradation using

the Micros Deval test described below (and in general
accordance with ASTM D 7428-15).
(b) One 1.4 kg sample shall be randomly sampled from each 100
tonnes of sand. The sample shall be dried for 24 hours at
115oC to 121oC. Three sub-samples each weighing 0.2 kg shall
be produced from the sample and the grading of each
subsample shall be determined.
(c) Each sub-sample shall then be remixed and placed in a
nominal litre capacity porcelain jar with two 25 mm diameter
steel ball bearings weighing 75 +/- 5 grams each. Each jar shall
be rotated at 50 rpm for six hours after which the grading shall
be repeated. The individual and average grading shall be
recorded.
132.7.13.2 Compliance criteria : bedding sand
(a) The increase in percentage of sand particles passing the 0.6

mm, 0.3 mm and 0.15 mm sieves shall be limited to 10%, 8%
and 5% respectively.
(b) The increase in percentage of sand particles passing the 0.075
mm shall be limited to 2%. Under no circumstances shall the
percentage passing the 0.075 sieve exceed 3%.
132.7.13.3 Non-compliance: bedding sand
Bedding sand which does not comply with Section 132.7.13.2 of the
GMWS shall not be used in the Permanent Works.
132.7.14 TESTING: PAVING BLOCKS
132.7.14.1 Testing: blocks
(a) Testing shall be carried out in accordance with BS EN

1338:2003 but at the frequency specified below.
(b) Paving block lots shall be divided into five subsets and three
blocks selected and tested from each subset. A lot shall consist
of not greater than 50,000 paving blocks.
132.7.14.2 Compliance criteria: blocks
Paving blocks shall comply with BS EN 1338:2003 and the plan

dimensional tolerances shall also comply with those nominated in the
laying pattern computer simulation reviewed without objection by the
Project Manager.

132.7.14.3 Non-compliance: blocks
Any blocks not complying with BS EN 1338:2003 shall not be used in

the Permanent Works.
132.7.14.4 Testing: surface integrity of blocks
(a) The Contractor shall test the first lot of paving blocks in
accordance with Appendix A132.7.1
(b) The Contractor shall test sufficient blocks to enable the sample
boards described in the following section to be prepared.
(c) Based on the above testing, three sample boards shall be
prepared which show the following ranges of surface texture
depth:
Acceptable 0.07 to 0.10mm
Marginal 0.10 to 0.13mm
Rejected 0.13 to 0.20mm
(d) The sample boards and associated test results shall be

(e) After sample boards have been reviewed without objection by
the Project Manager they shall be used to form a basis for
visual acceptance or rejection of blocks on the Site.
(f) The Contractor shall recommence testing using Appendix
A132.7.1 if requested by the Project Manager.
132.7.14.5 Compliance criteria: surface integrity of blocks
When tested in accordance with Appendix A132.7.1 paving blocks

shall have a surface texture depth not greater than 0.11 mm before
installation nor greater than 0.16 mm after compaction.
132.7.14.6 Non-compliance: surface integrity of blocks
Blocks with a surface texture depth greater than that specified in

Section 132.7.14.5 shall be rejected and removed from the Site.

APPENDIX A132.7.1 DETERMINATION OF SURFACE TEXTURE
A132.7.1.1 DEPTH OF INTERLOCKING CONCRETE BLOCKS
A132.7.1.1.1 Scope
This test method details the method of test for determining the
surface texture depth of paving blocks.
A132.7.1.1.2 Limitations
This method of test cannot be undertaken on paving blocks in-situ in

the pavement. It is intended for use in the laboratory only.
A132.7.1.1.3 Apparatus
The following apparatus is required:
(a) A graduated glass cylinder of at least 100 mm internal depth and

20 mm internal diameter, capable of reading to the nearest 1
cubic millimetre.
(b) A flat wooden disc 65 mm diameter with a hard rubber disc also
of 65 mm diameter and 2 mm thick fixed to one face, the reverse
face being provided with a handle.
(c) Dry natural sand with a rounded particle shape all of which will
pass a 0.30 mm BS sieve and be retained on the 0.15 mm BS
sieve.
(d) A metre rule, graduated in millimetres.
(e) A soft hair or nylon brush.
A132.7.1.1.4 Procedure
The procedure shall be as follows:
(a) Before commencing the test, check the top surface of the paving
block for rough and ragged projections which may prevent
spreading the sand flush with the block face.
(b) Ensure the paving block to be measured is dry, including the
voids therein.
(c) Estimate the average surface texture depth of the paving block
and calculate the approximate volume of sand required. Measure
out approximately twice the required volume of sand and
carefully pour it into two conical heaps on the top surface of the
paving block to be tested.

(e) Holding the handle of the wooden disc between the thumb and
fore-finger, and with vertical pressure on the disc, spread the
sand in a spiral motion from the centre of the heaps so that the
sand is spread over the entire surface of the paving block. Care
must be taken to maintain the face of the disc horizontal at all
times. Ensure that excess sand is worked off the surface and
over the edge of the chamfer.
(f) Continue to spread the sand using a spiral motion until all the
surface depressions are filled with sand to the level of the surface
peaks and all excess sand is removed.
(g) Carefully brush excess sand off the chamfer and any caught on
the side of the paving block.
(h) Invert the paving block over a suitable tray (funnel or clean sheet
paper) and by tapping the block edges ensure all the sand is
collected.
(i) Transfer the sand to the graduated cylinder taking care not to
lose any and consolidate by tapping until a constant volume
reading is obtained.
A132.7.1.1.5 Calculation
(a) Calculate the average surface texture depth of the paving

block using the formula:
Average Surface Texture Depth = Volume of Sand (mm3)

Area of Block Surface (mm2)
Note: The area of the paving blocks to be tested shall be calculated

from the manufacturer's nominal dimensions for the
appropriate block type.
(b) The area shall be that encompassed by the inner edge of the
chamfer.
(c) The area so calculated, shall be agreed between the

Contractor and the Project Manager prior to testing
commencing.
A132.7.1.1.6 Report
Report the average surface texture depth to the nearest one

hundredth of a millimetre.

132.8 BITUMINOUS SPRAYS
132.8.1 GENERAL
132.8.1.1 General: Prime Coat
Prime coat is a cutback bitumen spray that shall be applied to the

surface of the crushed aggregate base course (CABC) and the
cement stabilised base course.
132.8.1.2 General: Tack Coat
Tack coat is an emulsion bitumen spray that shall be applied to the

surface of existing bituminous surfaces to ensure a bond between
the existing surface and the overlying layer. Unless agreed with the
Project Manager, there is no requirement to apply tack coat to the
surface of a bituminous layer which will be overlaid within three days
of placement, unless the surface becomes contaminated by dust or
other foreign material in which case the surface shall be thoroughly
cleaned and tack coat applied. At least 90% of the tack coat shall
have “broken” prior to placement of any asphalt.
132.8.1.3 General: Bond Coat
Bond coats are proprietary materials, usually polymer modified

(sometimes referred to as polymer modified tack coat) and formulated
to enable application at heavier spread rates than are possible with
tack coats and to provide greater cohesion. They shall be applied
following the trials described in Section 132.8.4.1 of the GMWS. Bond
coat shall be applied to all asphalt surfaces to receive overlaying
asphalt courses.
132.8.2 MATERIAL
132.8.2.1 Material: Prime Coat
The prime coat material shall be one of the types detailed in Table
132.39 and shall comply with the stated Specification.
Table 132.39: Requirements for prime coat
Type and Grade Specification Application

Temperature
MC-70 for dense bases ASTM D 45° - 105°C
2027/2027M-13
RC-70(RC-1)
ASTM D 50° - 75°C
2028/2028M-15
RC-250(RC-2)
ASTM D 2028/2028- 65° - 95°C
15

132.8.2.2 Material: Tack Coat
The tack coat shall be one of the types detailed in Table 132.40 and
shall comply with the stated Specification.
Table 132.40: Requirements for tack coat

Temperature
SS-1, SS-1h ASTM D 977-13e1 25° - 55°C
ASTM D
CSS-1, CSS-1h 2397/2397M-13 25° - 55°C
K1-40 BS434: Part 1: 1984 25° - 55°C
132.8.2.3 Material: Bond Coat
The bond coat shall be one of the types detailed in Table 132.41 and
shall comply with the stated Specification.
Table 132.41: Requirements for bond coat

Temperature
SS-1, SS-1h ASTM D 977-13e1 25° - 55°C
CSS-1, CSS-1h, CRS-1 ASTM D 25° - 55°C

2397/2397M-13
132.8.2.4 Material: Blinding Sand
Blinding sand to be used for absorbing excess primer shall be dry,

crushed or natural sand containing only sound, hard, dense, durable
and clean particles, free from clay, organic matter, or other foreign
material. The sand shall be non-plastic. The particle size distribution of
the sand shall comply with the limits given in Table 132.42.
Table 132.42: Particle size distribution of blinding sand
Sieve Size Percent Passing by Mass

(mm)
10.0 100
5.0 85 to 100
1.18 40 to 100
0.3 10 to 40
0.075 0 to 5

132.8.3 SUBMISSIONS
(a) At least 10 days before a bituminous spray is used on the Site,

the Contractor shall submit the following particulars to the Project
(i) A certificate from the manufacturer of the bituminous spray

showing the manufacturer's name, the date and place of
manufacture and showing that the material complies with
the requirements stated in the GMWS.
(ii) A statement giving details of the proposed method and rate
of application, the proposed equipment and the target
application temperature.
(iii) A certificate to demonstrate that the spraying device has
been tested for rate of spread and accuracy of spread,
using the product to be used, not more than six weeks
before commencement of the work. The tolerances
achieved shall comply with the requirement of Section
(b) Further certificates showing that the materials comply with the
GMWS shall be submitted at intervals of not less than one
sample per 100 tonnes.

132.8.4 TRIALS
(a) At least seven days prior to the commencement of spraying

operations, a field trial shall be conducted on a trial area for each
different combination of bituminous spray and underlying
material. The trial area shall be a minimum of 225 m2.
(b) The trials shall be carried out on a completed underlying course

which meets the requirements of the GMWS. The trials shall be
carried out using the materials, methods and equipment which
have been proposed for the Works.
(c) The trials shall be used to determine the optimum rate of

application of spray. This shall be within the limits specified in
Table 132.43 and shall be such that prime coat takes between
six hours and 48 hours to soak in.
Table 132.43: Maximum and minimum application rates
Bituminous Spray Application rate (l/m2)

Minimum Maximum
Prime Coat
Crushed aggregate base 0.5 1.5
course
Other surfaces As determined from field

tests
Tack Coat (residual bitumen) 0.1 0.2
Bond Coat (residual bitumen) 0.1 0.2

(d) The required application rate is dependent on the binder content
of the upper layer and the binder content and condition of the
lower layer/existing surface. Recommended application rates for
bond coat are given in Table 132.44.
Table 132.44: Recommended target rates of application of bond

coat in kg/m² of residual bitumen for existing surfaces
Nature of lower layer/existing surface (refer to
Binder
Note)
content upper
layer Fretted/binder
Planed asphalt Binder rich
lean/ concrete
≥ 5.1% 0.50 0.40 0.25

4.1-5.0% 0.60 0.50 0.35
≤ 4% 0.60 0.60 0.40
Note: “Binder lean” is regarded as asphalt estimated to have less than

4% binder content or where a surface to be treated has partly
coated exposed aggregate or where there is some evidence of
cracking.
(e) The proposed rate of application of spray determined from the

trials shall be reviewed without objection by the Project Manager.
(f) The Contractor shall demonstrate that a minimum bond strength

(using pull-off, shear or torque bond testing as reviewed without
objection by the Project Manager) of 0.5 MPa at 20 ± 5°C can be
achieved, when tested within seven days of spray application.
132.8.4.2 Commencement of application of bituminous spray
Bituminous spray shall not be applied to the Works, other than in a trial
area, until the results of the trial have been reviewed without objection
132.8.4.3 Changes in materials, methods and rates of application
The materials, methods and rates of application used to produce a trial

area which has been reviewed without objection by the Project Manager
132.8.5 MIXING AND HEATING OF BITUMINOUS SPRAY
132.8.5.1 Mixing bitumen emulsion
Bitumen emulsion for use as bond coat shall not be diluted with water.
Suitable equipment for mixing, as recommended by the emulsion
supplier, shall be used.

132.8.5.2 Heating of bituminous sprays
(a) Heating shall be with equipment which has been reviewed

without objection by the Project Manager. The use of any method
of agitation or heating that introduces free steam or moisture into
bituminous spray shall not be permitted.
(b) Materials heated to temperatures above 28°C higher than the
maximum application temperature specified shall be considered
as overheated and shall be rejected.
132.8.6.1 Preparation of underlying course: Prime Coat
(a) Immediately prior to application of the prime coat, all loose

material shall be removed from the surface by means of
approved mechanical sweeper, blowers and/or hand brooms. No
prime coat shall be applied until the swept surface has been
(b) The cleaned surface shall be given a light application of water
using a suitable sprinkler and allowed to dry to a surface dry
condition before the prime coat is applied.
132.8.6.2 Preparation of underlying course: Tack Coat
(a) Immediately prior to application of the tack coat, all loose material
shall be removed from the surface by means of approved
mechanical sweeper, blowers and/or hand brooms. The
Contractor shall ensure that the surfaces to be tack coated shall
be in a clean and dry condition.
(b) Where a tack coat is to be applied to a concrete surface all
expansion joints shall be cleaned and sealed with asphaltic joint
sealing material, or as otherwise shown on the Employer's
Drawings.
132.8.6.3 Preparation of underlying course: Bond Coat
(a) Immediately prior to application of the bond coat, all loose

material shall be removed from the surface by means of
mechanical sweepers, blowers and/or hand brooms reviewed
without objection by the Project Manager. The Contractor shall
ensure that the surfaces to be bond coated shall be in a clean
and dry condition.
(b) Where a bond coat is to be applied to a concrete surface all

expansion joints shall be cleaned and sealed with asphaltic joint
sealing material, or as otherwise shown on the Employer's
Drawings.
132.8.6.4 Inspection of underlying course
The Contractor shall notify the Project Manager before bituminous

spray is applied to any part of the Works and shall allow the Project
Manager sufficient time to review the prepared underlying course.

132.8.7 APPLICATION OF BITUMINOUS SPRAY
(a) The bituminous material shall be applied by means of a

distributor at the rate and temperature determined as part of the
trials and in accordance with ASTM D 2955. The application
rates shall be within +/-10% of the agreed application rate.
(b) The distributor shall be designed, equipped, maintained, and
operated so that bituminous material at even heat may be applied
uniformly on variable widths of surface at the specified rate.
(c) Distributor equipment shall include a tachometer, pressure
gauges, column-measuring devices or a calibrated tank, and a
thermometer for measuring temperatures of tank contents.
(d) The distributor shall be self-powered and shall be equipped with
a power unit for the pump and full circulation spray bars
adjustable laterally and vertically.
(e) Hand sprays will be allowed only for priming small patches or
inaccessible areas.
(f) Spraying of bond coat shall not commence when the temperature
at the surface is below 3°C, during rain, fog, or other unsuitable
weather.
(g) The prime coat shall only be applied when the temperature of the
course to be primed is at least 15°C and is expected to remain in
excess of 15°C.
(h) Bond coating shall be carried out not less than 30 minutes prior
to the spreading of asphalt. The asphalt shall not be spread until
the bond coat has broken into bitumen and water (i.e. turned from
brown to black), and the water has evaporated. Any emulsion
accumulating in hollows shall be dispersed by brushing and
allowed to break before it is overlaid.
(i) Care shall be taken to avoid over application of prime coat during
overlap at the joints. Excess shall be blotted from the surface with
clean fine sand.
(j) The Contractor shall protect all light fittings, manholes, pits, kerbs
or other structures by covering with paper or plastic sheet to
avoid splashing or spraying them with bituminous materials.
Immediately after the completion of the spraying the Contractor
shall remove the protective coverings and dispose of them.
(k) The Contractor shall be responsible for removing any bituminous
material which has adhered to fittings or structures as a result of
the Contractor's operations.
(l) If it is not possible to remove the bituminous material, the
Contractor shall replace and make good the splashed or sprayed
part.

132.8.8.1 Prime Coat
(a)Following application of prime coat the surface shall be allowed to

dry for a period of 48 hours without being disturbed, or for such
time as may be necessary to permit the drying out of the prime
coat until it will not be picked up by equipment placing
subsequent layers. The surface shall then be maintained by the
Contractor until the subsequent layer has been placed.
(b)Appropriate precautions shall be taken by the Contractor to protect
the primed surface against damage during this period, including
supplying and spreading any sand necessary to blot up excess
bituminous material.
132.8.8.2 Tack Coat
(a) After application of a tack coat, the surface shall be allowed to

dry until it is in a suitable condition of tackiness to receive the
next layer. Tack coat shall be overlaid on the same day as it is
applied. The Contractor shall protect the tack coat from damage.
(b) If the tack coat is damaged by rain, dust or other means, it shall
be cleaned and if required by the Project Manager a subsequent
light application of tack coat applied to the surface.
132.8.8.3 Bond Coat
(a) After application of a bond coat, the surface shall be allowed to

dry until it is in a suitable condition of tackiness to receive the
next layer. Bond coat shall be overlaid on the same day as it is
applied. The Contractor shall protect the bond coat from damage.
(b) If bond coat is damaged by rain, dust or other means, it shall be
cleaned and if required by the Project Manager a subsequent
light application of bond coat applied to the surface.
132.8.9 TOLERANCES
(a) The application rate shall be within +/-10% of the rate determined
in the trials.
(b) The coefficient of variation of the transverse distribution of the

spray bar shall not exceed 15%.

132.8.10 TESTING
132.8.10.1 Sampling
The rate of spread of bituminous spray material shall be determined for

each area where bituminous spray is applied.
132.8.10.2 Testing
(a) The Vialit Pendulum Cohesion of the residual binder from the
bond coat material shall be determined in accordance with BS
EN 13588: 2008.
(b) The rate of spread of bituminous spray material shall be

determined by weighing a lightweight rigid plate of minimum size
300 mm x 300 mm before and after the passage of the binder
distributor.
(c) The accuracy of transverse distribution of the spray bar used to

apply bituminous spray material shall be determined by
discharging binder from each spray bar nozzle into identically
sized compartments in a suitably sized tray of sufficient length
and volume to encompass the output of the entire spray bar,
when operated over 60 seconds in a static condition. The
average rate of spray during this period shall then be calculated
for each spray bar nozzle by dipping each compartment with a
suitable measuring instrument. Alternatively, the method
specified in BS EN 12272-1:2002, which assesses the ability of
the spray bar in real working conditions and may be carried out
quickly using the correct binder shall be carried out.
132.8.10.3 Compliance criteria
(a) The minimum peak cohesion of bond coat material shall be 1.0
Joules/cm2.
(b) The rate of spread of bituminous spray material shall comply with
the application rate determined in the trials and the tolerances in
Section 132.8.9(a) of the GMWS.
(c) The accuracy of spread of the spray bar shall comply with the
tolerances in Section 132.8.9(b) of the GMWS.
(d) Where the application rates fallout with the tolerances stated in
Section 132.8.9 of the GMWS, the Contractor shall submit a
rectification methodology for the approval of Project Manager for
further works. The decision taken by the Project Manager on the
rectification methodology shall be final and binding.

132.8.11 REFERENCES
British Standards Institution

complimentary
BS
BS 12272-1: Surface dressing. Test methods. Part 1. n/a
2002 Rate of spread and accuracy of spread of
binder and chippings
BS EN Bitumen and bituminous binders. n/a
13588: 2008 Determination of cohesion of bituminous
binders with pendulum test
American Society for Testing and Materials
Standard Title
ASTM D977 Standard specification for emulsified asphalt

ASTM D2028 Standard specification for cutback asphalt (rapid-curing
type)
ASTM D2397 Standard specification for cationic emulsified asphalt
132.8.12 BITUMINOUS SPRAYS HOLD AND CONTROL POINTS
Table 132.44A: Bituminous Sprays Hold and Control Points

tack coat, bond coat, prime
coat and spraying devices)
132.8.4 Trials
132.8.6 Preliminary Work and in Preliminary Work
particular, Preparation of
Underlying Layer
132.8.7 Application of Bituminous
Spray –
132.8.10 Testing –

132.9 AIRFIELD PAVEMENT MARKINGS
Airfield pavement markings shall be an approved water based paint and

shall be placed on a suitably prepared surface in accordance with this
GMWS. The application rate shall be within 10% of the rate determined
in the trials.
132.9.2 TRIALS
(a) Prior to commencement of line marking works, the Contractor

shall conduct a trial of line marking painting operation at an off-
site area.
(b) The trial for line marking painting shall include painting of at least
one 20 m long and 0.15 m wide trial strip for each colour of paint
involved in the Works. The purpose of the trial shall be to verify
the compliance of the workmanship to Section 132.9.1 of this
GMWS and to determine the application rate to be adopted
during the actual site works.
(c) The application rate for all temporary and permanent line marking
on the Site shall be within 10% of the rate determined in the trials.
132.9.3 MATERIALS
(a) Paint for airfield pavement markings shall be pre-mixed water

based, shall comply with Federal Specification TT-P-19522E
Type I or Type III (to be advised by the Project Manager) unless
specified otherwise and shall be specifically designed for
pavement markings.
(b) The colour of the paint shall be as indicated on the Employer's
Drawings. Paint colours shall be to US FAA AC150/5370-10G P-
620 (i.e. White – 37925; yellow – 33538; Red -31136: Black –
37038).
(c) The paint shall be supplied fresh and ready for use in sealed
containers.
(d) The paint shall be of a consistency suitable for application by
spraying.
(e) The no-pick-up-time of the paint, as defined by ASTM
D711/ASTM D711-10 (2015), shall not exceed 20 minutes.
(f) The paint when applied to the pavement shall show a uniform
colour which will not yellow (in the case of white) or dull
appreciably for a minimum of six months.
(g) The paint shall have no reaction with or effect on bitumen and
there shall be no discolouration of the paint film following
application on bituminous surfaces.

(h) The dry film of paint shall have a non-gloss finish.
(i) The painted surface shall have a coefficient of friction of the same
order as the surrounding unpainted pavements.
(j) The paint when applied shall give a durable finish which shows
resistance to weathering, chipping, abrasion and erosion when
tested in accordance with ASTM D713 and D913. The paint shall
be resistant to jet blast and scuffing under normal aircraft
operations.
(k) Glass beads shall not be used.
132.9.4 SUBMISSIONS
132.9.4.1 Particulars of airfield pavement markings paint
(a) At least 30 days prior to scheduled application of airfield

pavement markings, the Contractor shall submit paint certificates
to the Project Manager for review without objection. The
certificates shall show the manufacturer's name, the date and
place of manufacture and the fact that the material complies with
the requirements.
(b) At the same time the Contractor shall supply a two litre sample
of each type of paint and colour they propose to use.
132.9.4.2 Particulars of methods of preparation and application
At the same time as the particulars of airfield pavement markings paint

are submitted, the Contractor shall submit particulars of the proposed
methods of preparation and application to the Project Manager for
review without objection.

Paint shall be stored in accordance with the manufacture's

recommendations.
132.9.6 PREPARATION, APPLICATION AND PROTECTION OF AIRFIELD

PAVEMENT MARKINGS
132.9.6.1 Preparation of surfaces
(a) The pavement shall be prepared in accordance with BS 3262

Part 3 1989 and FAA AC150/5370-10G – Item P-620.
(b) Curing compound shall be removed from the surface of PQC
pavement on which apron markings will be applied by wire
brushing or by other methods reviewed without objection by the
Project Manager.
(c) After preparation of the surface and before application of airfield
pavement markings, the Contractor shall make the area available
to the Project Manager for inspection. Paint shall not be applied
until the surface has been reviewed without objection by the
Project Manager.
132.9.6.2 Application of airfield pavement markings
(a) A time interval as recommended by the paint manufacturer shall

elapse between the laying time of the PQC, Marshall asphalt or
the concrete block paving and the time of application of the apron
marking, but shall not be less than two days for asphalt
pavements.
(b) A bond coat or sacrificial layer of paint shall be applied to the
pavement in order to overcome any bleeding of oils through the
paint which may lead to discoloration of the marking. Where
black surround markings are required these shall be provided by
extension of the areas to be tack coated.
(c) Airfield pavement markings shall only be applied to surfaces
which are clean and dry.
(d) Paint shall be applied to produce a crisp even line without side
splatter and shall be uniform and free from streaks.
(e) Longitudinal markings shall be applied by mechanical means
Manager.
(f) Light assemblies, and other utilities, positioned in or near areas
marked out for painting, shall be covered during application.
(g) Paint shall not be poured onto the pavement surface and spread
with rollers, brushes or brooms.
(h) Markings shall be applied to clean and dry surfaces and the hot
and cold weather limitations noted in FAA AC150/5370-10G
(620-3.1) shall be followed .

132.9.6.3 Protection of airfield pavement markings
(a) After application of the paint, all markings shall be protected from
traffic, both vehicular and pedestrian, and from injury or damage
of any kind.
(b) A second coat of paint shall be applied no earlier than seven days
after the first coat and no earlier than 60 days before opening of
the area to aircraft traffic.
132.9.7 TOLERANCES
132.9.7.1 Tolerances: airfield pavement markings
(a) The lengths, thicknesses and widths of airfield pavement

markings shall comply with the following requirements:
(i) The dry film thickness shall be not less than 120
microns and not more than 150 microns for each coat.
(ii) The length and width shall be within ± 5% or 20 mm,
whichever is smaller, of the specified dimension.
(b) The position of airfield pavement markings shall be within 25 mm
of the position shown on the Employer's Drawings.
132.9.7.2 Removal of existing and temporary markings
Existing paint markings shall be removed to the extent indicated by grit

blasting on concrete surfaces and hot-air torch; cold planing; controlled
water cutting on bituminous surfaces or such other method as may be
reviewed without objection by the Project Manager. Temporary
markings shall be removed using mechanical wire brushing or other
approved methods reviewed without objection by the Project Manager.
132.9.8 AIRFIELD PAVEMENT MARKINGS HOLD AND CONTROL POINTS
Plan.
Table 132.44A: Airfield Pavement Markings Hold and Control Points

132.9.2 Trials Trials
132.9.4 Initial approval submission Submissions
132.9.6 Preparation of Surfaces Preparation of Surfaces
132.9.7.1 Tolerances – including

132.10 PREPARATION OF FORMATION FOR AIRFIELD PAVEMENTS
132.10.1.1 Formation
Formation is that part of the earthworks final surface on which a

pavement is constructed.
132.10.1.2 Earthworks material
Earthworks material is material of a soil, rock or artificial material of any

kind which is on or below the Site at the commencement of the Works.
132.10.1.3 Rigid pavement area
A rigid pavement area is an area of formation which the Employer’s

Drawings indicate will be overlain by pavement consisting of Pavement
Quality Concrete and DLC / WLC.
132.10.1.4 Flexible pavement area
A flexible pavement area is an area of formation which the Employer’s

Drawings indicate will be overlain by pavement other than rigid
pavement.
132.10.2 GENERAL
(a) Section 132.10 covers the requirements for the preparation of

formations for airfield pavements, including use of different types
of earthworks materials, compaction requirements and
completion of the formation.
(b) The works and materials specified in Sections 132.10.2.2 to
132.10.2.3 of the GMWS shall comply with the sections stated,
unless otherwise stated in this section.
(c) The Contractor shall provide production and field test summaries
132.10.2.2 Site clearance
Site clearance shall comply with Section 3 of the GMWS.
132.10.2.3 Earthworks
Earthworks shall comply with Section 7 of the GMWS.

132.10.3 MATERIALS
132.10.3.1 Classification of earthworks materials
(a) Type A material shall be well graded hard and durable material
with the following grading:
Size (mm) 2000 1000 300 125 37.5 2 0.063

Percentage
by mass 80- 40-
100 0-95 0-70 0-30 0-5
passing the 100 100
size shown
(b) Type B material shall consist of well graded decomposed granite

material which has the following grading :
Size (mm) 300 37.5 2 0.063 0.002

Percentage
by mass
100 70-100 30-100 0-50 0-25
passing the
size shown
(c) Type C material shall be sand which has the following grading :
Size (mm) 100 37.5 10 2 0.063

Percentage
by mass
100 80-100 60-100 30-100 0-20
passing the
size shown
(d) For imported Type C sand the percentage passing the 425
micron sieve shall not exceed the following plasticity
characteristics:
(i) LL - 45%
(ii) PI - 25%
(e) Marine sand Type S1 consists of coarse sand being hard, clean
and durable material free from organic and other deleterious
material; with a carbonate content of less than 5% by mass and
which has the following grading:
Size (mm) 75 37.5 20 0.6 0.063

Percentage
by mass 100 100 - - 0-10
passing the
size shown

(f) Marine sand Type S2 consists of coarse sand being hard, clean
and durable material free from organic and other deleterious
material; with a carbonate content of less than 5% by mass and
which has the following grading:
Size (mm) 75 37.5 20 0.6 0.063

Percentage
by mass 100 100 - - 0-20
passing the
size shown
(g) Suitable public fill material is material not containing any of the
following:
(i) Material exceeding 250 mm in size (retained on Mesh No
60)
(ii) Material susceptible to volume change including marine
mud, soil with a Liquid Limit exceeding 65% or a Plasticity
index exceeding 35%
(iii) Swelling clays and collapsible soils
(iv) Peat, vegetation, timber, organic, soluble or perishable
material
(v) Dangerous or toxic material
(vi) Materials susceptible to combustion
(vii) Metal, rubble, plastic or synthetic material.
(h) Stabilised subgrade is a uniform mixture of Type C earthworks
material, PFA and cement complying with the following
requirements:
(i) The proportion of stabilising agent by mass to the total
mass of dry mixture shall be at no time less than 1.5%.
Further, the total amount of PFA in the cement/PFA mix
shall not exceed 25%.
(ii) The Contractor shall achieve a minimum soaked insitu
CBR of 30%.
(i) Type A/B material has the same grading as Type A material
except 100% is less than 900 mm.

132.10.3.2 Use of different types of earthworks materials
(a) Where Type A or Type A/B material is within 1200 mm of the

formation under pavements, it shall be excavated and removed.
(b) Mixing of Type B and Type C material shall not be permitted.
(c) Where materials similar to Type B material are encountered: any

fill materials to be placed above such layers shall be Type B, but
shall also have the following characteristics:
(i) Passing 75m: < 25%

(ii) Passing 425m Plasticity Characteristics
 LL>45%
 PI>25%
(d) Type B material shall not be used over material similar to Type C
material.
Geotextile shall be durable, non-decaable, oil and sea-water stable, of

nonwoven needle-punched mechanically bonded staple fibre
manufactured from polyester fibres and be in the form of permeable
membranes.
Geotextile shall have the following minimum properties:
(a) Mass per unit area 300 g/m2
(ASTM-D1910)
Thickness (at 2kPa 3 mm
applied pressure)
Tensile strength 10 kN/m
(both directions)
(BS EN 10319: 1996)
Elongation
longitudinal 50%
transverse 50%
(ASTMD-4632)
Permeability
(BS EN 12958: 2010) 10 litre/sec/m2
CBR Push Through Force
(BS EN 12236:2006) 1,000N

132.10.4 SUBMISSIONS
132.10.4.1 Particulars of methods of construction
(a) The following particulars of the proposed methods of construction

for earthworks shall be submitted to the Project Manager for
review without objection at least 20 days prior to commencement
of preparation of the formation.
(i) details of Contactor's Equipment including haulage
vehicles,
(ii) methods of excavation including deposition and
compaction of earthworks material,
(iii) use of different types of material,
(iv) arrangement for stockpiling and for disposing of
earthworks material,
(v) methods of controlling the moisture content of earthworks
material,
(vi) methods of controlling surface water and groundwater and
of protecting earthworks and earthworks materials from
damage due to water and from weather conditions which
may affect the earthworks or earthworks material,
(vii) methods of dealing with existing water courses so as to
maintain existing drainage paths,
(viii) any special methods/sequence of work for earthworks
adjacent to structures, and
(ix) method of preparing the surface of the earthworks
materials to receive the geotextile, method of laying
geotextile, method of jointing of geotextile and method of
placing and compacting fill on top of the geotextile.
(b) Where the Contractor proposes to form temporary slopes or
proposes any form of temporary support to earthworks, then he
shall submit full supporting calculations and the provisions of
Section 1 of the GMWS shall apply.

132.10.4.2 Particulars of geotextile
(a) At the same time as the particulars of methods of construction

are submitted, the Contractor shall submit the following
particulars of the geotextile to the Project Manager for review
without objection:
(i) Manufacturer's certificate which should include:
 Name of the manufacturer
 Product name and type
 Product composition and information on the raw
material used such as type of fibre, their proportions
and the type of connection between individual layers
in a case of composites.
(ii) Test certificate which should include:
 weight per unit area
 thickness
 strip tensile strength (longitudinal/transverse)
 elongation (longitudinal/transverse)
 effective opening size O90
 coefficient of water permeability k
 Tear (Trapezoidal) strength
 CBR Push Through Force
 UV stability
 resistance to perforation (cone drop test)
Tests shall be carried out in accordance with the
recommendations of Codes of Practice which have been
(b) Calculations to substantiate that the geotextile can fulfil its
function as a separator between different material types shall be
(c) For each delivery of geotextile the Contractor shall submit a
delivery note containing the manufacturer's certificate, the roll
number and test certificates.

132.10.5 TRIALS
132.10.5.1 Preliminary work trial areas
(a) The Contractor shall construct preliminary work trial area(s) to

the satisfaction of the Project Manager to demonstrate that the
Contractor's Equipment and methods of construction are
adequate to carry out the preliminary work detailed in Section
132.10.7.1 of the GMWS without causing damage to the
geotextile.
(b) A 20 m x 10 m trial area shall be constructed for each different
type of geotextile and each different type of contiguous
earthworks material. The trial area may form part of the
(c) Each trial area shall be constructed using the method detailed in
Section 132.10.7.1 (b) - (f) of the GMWS. The test panel of
geotextile shall include a full joint constructed as proposed for the
Permanent Works.
(d) The Contractor shall then place the next layer of type C material
onto the geotextile to the same loose depth thickness as he
proposes to use for the Permanent Works. Compaction of this
layer shall be carried out using the same equipment and method
that are proposed for the Permanent Works.
(e) The layer of type C material shall then be carefully removed over
an area of 5 m x 5 m so that the geotextile is exposed, including
a joint between adjacent sheets of geotextile.
(f) The geotextile shall be inspected for damage and to determine
the effectiveness of the joint.
132.10.5.2 Compliance criteria: preliminary work trial areas
There shall be no sign of damage either to the geotextile or to the joint.
132.10.5.3 Non-compliance: preliminary work trial areas
(a) If any trial area does not comply with the specified requirements
for the trial area, particulars of the proposed changes to materials
or methods of construction shall be submitted to the Project
constructed until a trial area complies with the specified
for the trial area shall be removed.
132.10.5.4 Commencement of preliminary work
(a) The preliminary work detailed in Section 132.10.7.1 of the

GMWS shall not be carried out for any part of the Permanent
Works, other than in trial areas, until a trial area which complies
with the requirements of the GMWS has been completed.

(b) On satisfactory completion of the trial areas, and before
construction of the Permanent Works, the Contractor shall submit
the preliminary works procedure to the Project Manager for
review without objection. The Preliminary Works Procedure shall
form an integral part of the Contractor's Quality System.
(c) The Contractor shall not commence preliminary works until the
Preliminary Works Procedure has been reviewed without
objection by the Project Manager.
132.10.5.5 Compaction trial areas
(a) The Contractor shall compact, for each subgrade type and
specified density profile, a trial area to be agreed without
objection by the Project Manager but not less than 500 m2.
(b) The trial area shall be used to determine the adequacy of the
Contractor's Equipment to achieve the specified density and
finish requirements. It shall also be used to determine
appropriate loose material depths, placement methods and the
relationship between number of compaction passes, moisture
and resulting field density. A placement and compaction
methodology shall be established and shall form the basis of the
Compaction Procedure. Trials shall be conducted to indicate that
the Contractor’s method of working and plant can consistently
exceed end product requirements.
(c) The trial area shall be constructed with the plant intended for use
in constructing the Permanent Works to determine its adequacy
and to provide the basis of a work procedure which shall be
reviewed by the Project Manager. The trial area shall be
before construction of the trial area begins.
(e) The Project Manager shall be kept fully informed throughout the
trial.
132.10.5.6 Testing: compaction trial area
(a) For information purposes only, Dynamic Cone Penetrometer

(DCP) tests shall be undertaken in accordance with BS1377-
9:1990 (or ASTM D6951-03) and the CBR value at depth
intervals of 100mm shall be determined using an established
DCP (blows/100mm) to CBR formula. DCP testing shall be
undertaken to a depth of 1.2m from both (i) the top of subgrade
and (ii) the top of the first layer of CASB, each at a frequency of
one test per 50 m².
(b) For information purposes, material shall be collected to
determine the laboratory CBR and compaction/moisture values.
Three tests shall be carried out in accordance with BS1377: Part
4: 1990 Section 7 with the samples compacted to 100% modified
Proctor MDD and soaked for four days.

(c) For information purposes only, insitu CBR tests shall be
undertaken in accordance with BS1377-9:1990 and the CBR
value at depth intervals of 300mm shall be determined. Insitu
CBR testing shall be undertaken in each test pit to a depth of 1.2
m from both (i) the top of subgrade and (ii) the top of the first layer
of CASB, each at a frequency of one test per 100m2.
(d) For information purposes only, at the trial stage, Static Plate Load
Tests (using 30 inch (762mm) diameter plate) shall be
undertaken in accordance with ASTM D1196 and AASHTO
T222-81 to determine the modulus of subgrade reaction (k) at
various levels of compaction.
As instructed by the Project Manager, Static Plate Load testing
shall be undertaken on top of the subgrade which has been
compacted to a depth of 600mm to (i) 95% MMDD; (ii) 98%
MMDD and (iii) 100% MMDD. For each plate diameter, three (3)
tests shall be undertaken for each of the 95% MMDD and 98%
MMDD compaction levels and a minimum of six (6) tests at 100%
MMDD compaction level. The top of the subgrade shall be
prepared to seat the plate and supporting deflection
measurement dial gauges in accordance with ASTM D1196.
Separate trials shall be undertaken for each type of subgrade.
The location and size of the trial area(s) shall be agreed with the
Project Manager to accommodate these additional Static Plate
Load Tests.
132.10.5.7 Compliance criteria: compaction trial area
requirements.
(a) The result of each density test shall comply with the relative
densities specified on the Employer's Drawings for the relevant
subgrade type and density profile.
(b) The surface level shall comply with Section 132.10.11.1 of the
GMWS.
132.10.5.8 Non-compliance: compaction trial area
If the result of any test on the trial area does not comply with the
changes to the methods of compaction shall be submitted to the Project
compacted until the result of every test on the trial area complies with
the specified requirements for the trial area.
132.10.5.9 Commencement of subgrade compaction
(a) Subgrade compaction shall not be carried out for any part of the
formation, other than in a trial area, until a trial area which
complies with the requirements of the GMWS has been
completed.

(b) On satisfactory completion of the trial area, and before
compaction of the remaining formation, the Contractor shall
submit the Compaction Procedure to the Project Manager for
132.10.5.10 Changes in methods of construction
The methods of construction used to produce trial areas which comply

with the specified requirements shall not be changed without the
permission of the Project Manager.
Geotextile shall be delivered in black polyethylene sheetings and stored

such that it is protected from physical damage and from the effects of
light and weather. If the black wrapping is damaged during handling the
wrapping shall be repaired immediately by the Contractor using
additional black polyethylene sheeting. Geotextile shall not be
uncovered between manufacture and incorporation in the Permanent
Works. Temporary exposure of the geotextile shall not exceed 14 days.
(a) Where, at the commencement of the Works, Type A or Type A/B

material is present within the subgrade compaction zone below
formation as shown on the Employer’s Drawings, preliminary
work shall be carried out as detailed in this section.
(b) The Type A or Type A/B material shall be excavated for the whole
depth of the subgrade compaction zone as shown on the
(c) A layer of stabilized subgrade material, as defined in Section
132.10.3.1 of the GMWS and agreed without objection by the
Project Manager, shall be placed on the Type A or Type A/B
material to the thickness and extent as proposed by the
Contractor and reviewed without objection by the Project
Manager, such that a flat, uniform surface, without protruding
boulders, is achieved.
(d) The surface of the stabilised subgrade material shall be
compacted by 10 coverages of a steel-wheeled vibrating roller
with the following specifications.
(i) Static mass per metre length of vibrating drum of at least
50 kN.
(ii) Minimum frequency of vibration of 25 Hz
(iii) Nominal amplitude of vibration of at least 1.5 mm
(e) If existing geotextile is present at the top of the Type A or Type
A/B material, the surface of the stabilised subgrade material shall
be prepared to receive new geotextile to lap onto the existing
geotextile.
(f) The new geotextile shall be placed onto the prepared surface. If
adjacent sheets of geotextile are to be joined by overlapping then
the overlap shall be at least 300 mm.

(g) The necessary fill material shall then be placed onto the new
geotextile and compacted in such a way that it does not cause
any damage to it.
(h) In areas where geotechnical investigations by others in the
location of pavements or within 10 m of the pavement edge have
caused known damage to the any existing geotextile present
(whether previously repaired or not), the Contractor shall expose
the geotextile by excavating a 2 m x 2 m pit without further
damaging the geotextile.
(i) A 1.8 m x 1.8 m patch of geotextile meeting the requirements of
Section 132.10.3.3 of the GMWS shall then be stitched to the
geotextile and the excavation backfilled.
(j) Should the damage to the geotextile extend beyond the limit of
the patch, the excavation and the patch shall be extended to
cover the extent.
132.10.8 COMPACTION
(a) The formation shall be compacted such that the relative

compaction of the earthworks material shall be equal to or
greater than the relative compaction specified on the Employer's
Drawings at the specified depths below formation level. If
necessary the Contractor shall excavate the earthworks material
and carry out compaction in layers. Where samples in variable
materials are required to conduct laboratory studies to establish
target parameters or where materials are of a nominal particle
size larger than 37.5mm BS 1377 Part 9 :1990 Method 2.3 (water
replacement) shall be used.
(b) In areas where permanent utilities or permanent services have
already been installed the formation shall only be compacted to
a depth of 300 mm and to a density of at least 98% maximum
modified Proctor density. The method of compaction shall be
such that no damage occurs to the underlying utility or service.
132.10.9 COMPLETION OF FORMATION
(a) The formation shall be completed as soon as practicable after

compaction of the earthworks material has been completed.
(b) The formation shall be completed to smooth alignments.
(c) Subgrade material shall be proof rolled after compaction of the
formation. The Project Manager shall be notified at least 48
hours prior to proof rolling each section of formation.
(d) Proof rolling shall be conducted after application of the first layer
of sub-base. It shall consist of eight coverages with a pneumetic
tyred roller with a wheel load of 120 kN, and a type pressure of
500 kPa. The proof roller shall operate at a speed of 3 to 6
km/hour to enable an observer walking beside the roller to note
the surface deflections of the compacted layer.

Contractor to control the line and number of coverages of the
proof roller. The Contractor shall submit his method of control
and logging as part of his Quality System.
(f) Any areas of the surface which exhibit behaviour different from
the remainder of the layer or deflect excessively, rut, yield or
show any signs of instability under the final coverage of the proof
roller shall be marked and the area shall be investigated by the
investigation, the Contractor shall carry out remedial works
including any works required to lower layers, that have been
reviewed without objection by the Project Manager and shall then
re-proof roll the area.
(a) Formations shall be maintained in a stable condition and shall be

protected from damage due to water or any other causes and
from exposure to conditions which may adversely affect the
surface. Any damage which occurs to the formation shall be
repaired by the Contractor using methods which have been
(b) Formations shall not be used by Contractor's Equipment or
vehicles other than those which are essential to construct the
subsequent works.
132.10.11 TOLERANCES
(a) The elevation of the formation shall not vary by more than +0, -
40 mm form the required level.
(b) Preliminary works as described in Section 132.10.7 of the GMWS
shall be finished to within a tolerance of +0 to -250 mm of the
required level.
(c) Subject to the requirements of the PS Section 10.2, the
tolerances for the thickness and finished surface level of
formation may be revised by the Project Manager.
132.10.12 TESTING: OPTIMUM MOISTURE CONTENT, MAXIMUM DRY

DENSITY
132.10.12.1 Samples: optimum moisture content, maximum dry density
The Contractor shall take three samples per batch of earthworks

material.
(d) A batch of earthworks material is a quantity of earthworks
material of the same type and which has similar properties
throughout. A batch shall have a maximum area of 4,000 m2.
(e) Samples shall be taken after the earthworks material has been
deposited in its final position. The samples shall be
representative of the batch as a whole and locations of individual
samples recorded.

132.10.12.2 Testing: optimum moisture content, maximum dry density and
CBR
(a) A portion of each sample of earthworks material taken as stated

in Section 132.10.12.1 of the GMWS shall be tested to determine
the optimum moisture content and maximum dry density. The
tests shall be carried out in accordance with BS 1377: Part 4:
1990 Method 3.5 or 3.6 as appropriate to the grain size of the
earthworks material.
(b) Sufficient material shall be collected from one location per batch
and shall be tested to determine laboratory CBR and
compaction/moisture content values. The tests shall be carried
out in accordance with BS 1377: Part 4: 1990 Section 7 with the
sample compacted to 100% modified Proctor MDD and soaked
for four days.
132.10.12.3 Consistency: optimum moisture content, maximum dry density
If the result of any test for optimum moisture content or maximum dry
density of earthworks material indicates that the batch contains material
which differs to such an extent that subsequent tests for relative density
may be affected, the batch shall be divided into smaller batches, each
of the smaller batches shall comprise material with similar properties
throughout. Additional samples shall be provided from each of the
smaller batches and additional tests for optimum moisture content and
maximum dry density shall be carried out to the satisfaction of the
Project Manager.
132.10.12.4 Testing: DCP
For information purposes only, Dynamic Cone Penetrometer (DCP)

tests shall be undertaken in accordance with BS1377-9:1990 (or
ASTM D6951-03) and the CBR value at depth intervals of 100mm
shall be determined using an established DCP (blows/100mm) to CBR
formula. DCP testing shall be undertaken to a depth of 1.2m from
the top of the first layer of CASB (after compaction and proof rolling) at
a frequency of one test per 1,000 m². With the agreement of the
Project Manager the frequency of testing may be reduced to one test
per 2,500 m² when consistent results are obtained.
132.10.12.5 Testing: Insitu CBR
For information purposes only, insitu CBR tests shall be undertaken in

accordance with BS1377-9 and the CBR value at depth intervals of
300 mm shall be determined. Insitu CBR testing shall be undertaken
to a depth of 1.2 m from the top of the first layer of CASB (after
compaction and proof rolling) at a frequency of one test per 1,000 m².
With the agreement of the Project Manager the frequency of testing
may be reduced to one test per 2,500 m² when consistent results are
obtained.

132.10.12.6 Testing: Static Plate Load Test
For information purposes only, Static Plate Load Tests shall be

undertaken in accordance with ASTM D1196 and AASSHTO T222-81
to determine the modulus of subgrade reaction (k). Static Plate Load
testing shall be undertaken on top of the subgrade after the
placement, compaction and proof rolling of the first layer of CASB,
each at a frequency of one test per 50,000 m² or as instructed by the
Project Manager. A localised area of CASB shall be carefully
removed to accommodate the plate, and the top of the subgrade shall
be prepared to seat the plate and supporting deflection measurement
dial gauges in accordance with ASTM D1196. Following the test, the
removed CASB shall be reinstated by the Contractor using a method
which has been reviewed without objection by the Project Manager.
132.10.13.1 Testing: relative compaction (Type B material and General Fill

Material if used because type B or type C material is not available)
Each batch of earthworks material shall be tested to determine

the relative compaction. Tests shall be carried out after the
material has been deposited and compacted in its final position
and the test location recorded. The number of tests on each
batch shall be as stated in Table 132.45.
Table 132.45: Number of samples of material to be tested for
relative compaction per batch
Depth below formation level

Type of
pavement area 0 - 300 300 - 600 600 - 900 900 - 1,200
mm mm mm mm
Flexible 4 2 2 2
pavement area
Concrete block 4 2 0 0
pavement
(c) When material is excavated, and replaced and compacted in

layers, the tests for relative compaction may be carried out upon
completion of each layer and before overlying layers are placed.
(d) The tests shall be carried out at positions which are
representative of the batch of compacted material as a whole.
(e) The insitu dry density tests shall be carried out in accordance
with BS 1377: Part 9: 1990 Method 2.3.

(f) The relative compaction (RC) shall be calculated using the
following values:
(i) IDD is the in-situ dry density, determined as stated in
Section 132.10.13.1(d).
(ii) MDD is the maximum dry density, determined as stated in
132.10.13.2 Testing: Relative compaction (Marine sand - Type C, Type S1 and

Type S2 materials)
(a) The Contractor shall carry out insitu dry density tests in
accordance with B.S. 1377: Part 9: 1990 Method 2.3. The
number of tests on each batch shall be as stated in Table 132.45.
(b) The relative compaction shall be calculated as specified in
Section 132.10.13.1 of the GMWS .
(c) Where the Contractor’s Compaction Procedure regularly
demonstrates that the relative compaction requirements of the
GMWS are consistently being met, the batch size may be
increased to an area of 8,000 m2, subject to review without
132.10.13.3 Reinstatement of Test Pits
Where test pits or dry density holes are excavated during the course of
the works, they shall be refilled with similar material and the area
recompacted using the approved Compaction Procedure.
(a) If the result of any test for relative compaction of earthworks

material does not comply with the specified requirements for
relative compaction, testing as described in Section 132.10.13.1
of the GMWS for relative compaction shall be carried out on
every batch within the area.
(b) If the result of any of the additional tests for relative compaction
do not comply with the specified requirements for relative
compaction then the earthworks material in that batch shall be
further compacted and tested until a complete set of test results
show compliance with the specified requirements.
132.10.14 TESTING: FORMATION LEVEL
132.10.14.1 Testing: formation level
Levelling of the formation shall be performed by the Contractor at all

changes of grade and on a grid which has an interval of up to 10 m in
two mutually perpendicular directions.
132.10.14.2 Non-compliance: formation level
Areas not complying with Section 132.10.11(a) of the GMWS shall be

rejected.

132.10.15 PREPARATION OF FORMATION FOR AIRFIELD PAVEMENT
HOLD AND CONTROL POINTS
Table 132.45A: Preparation of Formation for Airfield Pavement

Hold and Control Points
132.10.4 Initial approval Submissions (in
submission particular: proposed
method of construction
for each subgrade type,
geotextile)
132.10.5 Trials including
assessment of trial area
132.10.7 Preliminary Works
132.10.8 Compaction
132.10.9 Completion of Formation Completion of Formation
– Proof Rolling – Proof Rolling
132.10.10 Maintenance and
Protection
132.10.11 Tolerances – including
132.10.12 Testing: Optimum
Moisture Content,
Maximum Dry Density
including laboratory CBR
and insitu DCP/CBR –
including
Compaction – including
132.10.14 Testing: Formation Level
– including

132.11 CEMENT STABILISED BASE COURSE
CSBC shall consist of CABC material meeting the requirements of

Section 132.3 of the GMWS mixed with cement and water and
constructed in one or more layers on a prepared underlying layer. The
use of a mix with 20 mm maximum aggregate size shall be permitted
subject to approval by the Project Manager.
132.11.2 GENERAL

appropriate action as required (including raising non-conformance
reports etc.) to ensure compliance with the GMWS.
132.11.2.2 Cement/PFA Mixture
Cement shall comply with Section 20 of the GMWS. PFA shall comply
with BS 3892: Part 2: 1996.
Curing compound for the CSBC shall comply with Section 132.5 of the
GMWS.
132.11.2.4 Water
Water for the CSBC shall comply with Section 132.3.2.2 of the GMWS.
Aggregate for the CSBC shall comply with Section 132.3 of the GMWS.
132.11.3 CEMENT STABILISED BASE MIX
(a) The Contractor shall design the cement stabilised base mix with
sufficient Ordinary Portland Cement by weight of the dry un-
stabilised material added to achieve a compressive strength
(target) of between 7 N/mm² and 10 N/mm² at 28 days, 100%
MDD and at OMC less 1%.
(b) If PFA is used in combination with Portland cement, the
be between 15 and 25%, provided always that the compressive
strength requirements specified above are met.

132.11.4.1 Particulars of materials for CSBC

the Contractor shall submit to the Project Manager for review
without objection, a statement of the origin, and method of
extraction of all aggregates proposed for the Permanent Works.
The Contractor shall at the same time provide evidence
demonstrating that an adequate supply of uniform material can
be produced and that the aggregate meets the specified
requirements.
the Contractor shall submit the particulars detailed in Section
20.6.1(a) of the GMWS for review.
At the same time as the particulars detailed in Section 132.11.4.1 (a) of

the GMWS are submitted, a reference sample from each different
ASTM C295-85/C295-13 (2012).
132.11.4.3 Particulars of CSBC mix and methods of construction
The following particulars of each proposed design CSBC mix shall be

submitted to the Project Manager for review without objection at least
20 days prior to scheduled construction of the trial area.
(a) quantity of each constituent per cubic metre;
(b) target grading details in tabular and graphical form for the
aggregate ex-pavement. The target grading shall be expressed
as a single percentage passing each sieve size;
(c) type and source of cement and PFA; and
(d) method of construction.

including a layout plan and output of the plant, shall be submitted to the
Project Manager for review without objection.

132.11.5 TRIALS
132.11.5.1 Trial mix CSBC
(a) The Contractor shall prepare trial mixes in advance of

constructing the Permanent Works.
(b) The Contractor shall make trial mix at water contents ranging
from 5% to 7%, by weight of the dry materials, at 0.5% intervals.
132.11.5.2 Testing: trial mix CSBC
From each of the mixes a set of three 150 mm cubes shall be made and
cured in accordance with BS EN 12390-1 (2012) and -2 (2009). At
seven days the mean dry density of the cubes shall be determined in
accordance with BS EN 12390-7:2009, and the compressive strength
of the cubes shall be determined in accordance with BS EN 12390-3:
2009.
132.11.5.3 Compliance criteria: trial mix CSBC
(a) Providing that the mean compressive strength of the three cubes
from the same set is 3.5 N/mm2 or more, and no individual cube
strength in the set is less than 2 N/mm2, the mix shall be
considered to be satisfactory.
(b) The satisfactory mix with the highest dry density shall be chosen
as the job mix.
132.11.5.4 Non-compliance: trial mix CSBC
which meets the strength requirements specified in Section 132.11.5.3.
(a) The Contractor shall construct, for each CSBC material source,
a trial area of at least 750 m2. This shall comprise at least two
runs of a minimum length of 50 m and shall contain at least one
transverse and one longitudinal joint.
(b) The trial area will be used to determine the adequacy of the
compaction passes and resulting field density. A placement and
compaction methodology shall be established to optimise field
density and shall form the basis of the Placement Procedure.
(c) The trial area shall be carried out on completed underlying
crushed aggregate base or sub-base courses which meet the
requirements of the GMWS and shall be constructed with the
materials and plant intended for use in constructing the
Permanent Works. The trial area shall be constructed in an area
considered by the Project Manager to be non-critical to airport
operation and may form part of the Permanent Works if accepted.

(a) Ten in-situ density tests shall be carried out in the trial area in
accordance with BS 1924: 1990 Part 2 Section 3.3.
(b) Three samples of CSBC material shall be taken from the trial
area and tested to determine the maximum dry density in
accordance with BS 1924: 1990 Part 2 Section 2.1.4.
(c) The trial area shall be tested for regularity, levels and thickness
in accordance with Section 132.11.14.1 of the GMWS.
(d) Ten 150mm cubes shall be made, stored and tested for
compressive strength at 28 days, all in accordance with GMWS
Section 20.
requirements:
(a) The result of each in-situ density test shall be at least 100% of
the average maximum dry density determined from the three
laboratory compaction tests.
(b) The regularity, levels and thickness of the CSBC course shall be
within the specified tolerances.
(c) The flakiness index, elongation index, particle size distribution
and CBR shall comply with Section 132.3.2.1 of the GMWS
suitably revised to allow 20mm mix when permitted.
(d) The average compressive strength of the cubes taken shall be
between 7 N/mm² and 10N/mm² at 28 days with no result outside
these limits.
requirements for the trial area. Adjustment to the trial mix shall
be made unless non-compliance of the trial area was not due to
the CSBC mix.

132.11.5.9 Commencement of CSBC placement
(a) CSBC material shall not be placed in the Permanent Works,

other than in a trial area, until the result of every test on the trial
area complies with the specified requirements for the trial area.
Placement Procedure to the Project Manager for review without
objection. The Placement Procedure shall form an integral part
of the Contractor's Quality System.
(c) CSBC material may not be placed in the Permanent Works until
all the test results and the Placement Procedure referred in
Section 132.11.5.9(b) above has been reviewed without

specified requirements shall not be changed without the proposed
changes being reviewed without objection by the Project Manager.
(a) Storage of cement and PFA materials shall be in accordance with

Sections 20.7.1 of the GMWS.
(b) The storage of aggregates for CSBC shall be in accordance with
Section 132.3 of the GMWS.

below the CSBC shall be completed and fill material shall be
deposited and compacted in trenches before the CSBC is
(b) Box-outs shall be formed in the CSBC for covers, frames and
other hardware.
(a) The Contractor shall notify the Project Manager before CSBC is
(b) The Contractor shall only place material over underlying layers
that are undamaged and clean and free from foreign material.
The Contractor shall not place CSBC material until all the
specified requirements for the underlying layer, at the time of
placing, have been met and the underlying layer has been

(c) The underlying course shall be lightly watered prior to placement
of CSBC. Watering shall be controlled to minimise loss of
moisture from the CSBC material and loss of fines from the
surface of the underlying course.
132.11.8 FORMWORK

(b) Formed surface shall have a class F2 finish.
(a) At the commencement of each day's run a transverse

construction joint shall be formed in the previously placed
material by cutting back into the compacted material to form a
true transverse vertical face.
(b) When a longitudinal construction joint is required it shall be
formed by cutting back into the compacted material to form a true
vertical edge. Longitudinal construction joints shall be formed
where material is placed by paver without forms.
(c) Care shall be exercised to ensure thorough compaction of the
CSBC material immediately adjacent to all construction joints.
(d) Before depositing new material against compacted material, the
surface of the joint shall be cleaned, roughened and thoroughly
moistened.
132.11.10 MIXING, PLACING AND COMPACTING CSBC
(a) Mixing of CSBC shall be in accordance with Section 132.3.6 of

the GMWS, except that the pug mill shall be fitted with a cement
silo with appropriate feeding mechanisms to ensure consistency
of cement content.
(b) No activity or work shall be carried out on the CSBC during rain
or when there is standing water on the CSBC or underlying
course.
(c) The surface of each layer shall be kept free of deleterious matter
and debris.
(d) CSBC material shall be transported in sheeted plant and in such
a manner that no degradation of the material shall be evident,
particularly with respect to segregation and moisture content.
(e) The CSBC material shall be placed in accordance with Section
(f) Material from different sources shall be laid in discrete areas that
have been reviewed without objection by the Project Manager.
CSBC material may be constructed in layers which have a
compacted thickness of between 80 mm and 100 mm. If two layer
placement is undertaken then a cement slurry shall be applied to
the surface of the bottom layer of CSBC where the top layer is
laid more than 24 hours later. Each layer shall be subject to the
requirements of Section 132.11.10 of the GMWS.

(g) Immediately after placing, the CSBC shall be thoroughly and
expeditiously compacted in accordance with the Placement
Procedure by rolling. Sufficient rollers, as determined in the
Placement Procedure, shall be used to compact adequately the
material that has been placed. Care shall be exercised in routing
construction equipment to avoid the formation of unnecessary
ridges due to wheel tracks or tractor treads.
(h) Vibrating and pneumatic-tyred rollers shall not operate at
(i) In places inaccessible to rollers, the CSBC material shall be
tamped to the specified density with mechanical tampers, and
(j) Rolling shall continue until the specified requirements for density
have been met.
(k) The compaction procedure shall be in accordance with that
approved by the Project Manager and subsequently proven
through trials as described under Section 132.11.5.5 of the
GMWS.
(l) The finished surface of the CSBC shall present a uniform tightly
interlocked stone mosaic appearance and shall be fully
compacted and free from loose stones.
(m) No more than 30 minutes shall elapse between the time that
water is added to the cement and the time the CSBC material is
deposited in place.
(n) No more than 90 minutes shall elapse between the time that
water is added to the cement and the time the CSBC, including
CSBC in any overlying layers, is compacted to its final position.
(o) Over rolling of the CSBC (to induce micro cracking) shall consist
of eight passes of a pneumatic tyred roller with a wheel load of
120 kN and a tyre pressure of 1,000 kN/m² immediately after
density testing and within 24 hours of placement.
132.11.11 CURING CSBC
After compaction of the CSBC, the layer shall be cured as per Method
3 or 4 of Section 20.7.15 of the GMWS for four days or until the bond
coat is applied. Bond coat shall be applied in accordance with the
requirements of Section 132.8 of the GMWS.

(a) Following completion of the CSBC, the Contractor shall protect

the CSBC from damage. The surface shall be kept clean and free
from foreign material. The CSBC shall be properly drained at all
times.
(b) Trafficking of CSBC by construction plant or other vehicles shall
not be permitted. Trafficking shall be restricted to that necessary
to place the succeeding layer or course, or maintain the existing
layer.
(c) If damage to the CSBC occurs, from traffic or by any other reason,
causing it to fall outside of the GMWS requirements, the affected
area shall be removed by the Contractor and replaced using
fresh material.
 5mm from the required level.
tested with a 3.0 m straight edge. The finished surface shall also
not vary by more than 7 mm per 3 m length of surface when
tested with a profilometer. The surface of the CSBC shall at all
times be free draining.
(c) The thickness of the CSBC shall not be less than the thickness
indicated on the Employer's Drawings.
The tolerance on the ex-pavement target grading shall be as detailed in

Table 132.7, suitably revised to permit mix with maximum aggregate
size of 20 mm when permitted.

132.11.14 TESTING: THICKNESS, LEVEL AND REGULARITY
132.11.14.1 Testing: thickness, level and regularity
(a) Levelling of the finished course shall be performed by the

Contractor at all changes of grade and on a grid which has an
interval of up to 10 m in two mutually perpendicular directions.
(b) The CSBC shall be tested for surface regularity parallel and
transverse to the direction of placing along parallel lines not less
than 5 m apart.
(c) Where the CSBC extends for more than 30 m in a given direction
the finished surface shall be tested for regularity using a
profilometer which produces a continuous computerised printout
(d) Where the CSBC extends for less than 30 m in a given direction
the finished surface shall be tested for regularity using a 3.0 m
straight edge.
(e) The thickness of the completed course shall be checked by
carefully excavating test pits through the full depth of the CSBC.
The course thickness shall be determined at the location of each
in-situ density test.
(f) Any damage to the CSBC caused by testing shall be repaired by
the Contractor using a method which has been reviewed without
132.11.14.2 Non-compliance: thickness, level and regularity
Any deviation of the finished thickness, level or regularity from the

the GMWS. The minimum area removed shall be at least 2 m wide and
5 m long in the direction of paving. The minimum depth of material
removed shall be 100 mm.

132.11.15.1 Testing: relative compaction
(a) Each area of CSBC which contains CSBC material of the sample
type and the same mix, produced at the same mixing plant, which
is laid and compacted in a single layer in one day shall be divided
into lots. Each lot shall be of a maximum size of 1,000 m2.
(b) Two in-situ density tests shall be carried out on each lot
immediately following compaction and prior to initial set of the
CSBC. The tests shall be carried out in accordance with BS 1924:
1990 Part 2 Section 3.3.
(c) The tests shall be carried out at positions which are
representative of the lot as a whole.
(d) A sample of CSBC material shall be prepared and its maximum
dry density determined by carrying out a compaction test in
accordance with BS 1924:1990 Part 2 Section 2.1.4. One
maximum dry density test shall be carried out for every twelve
insitu density tests.
The in-situ density as measured in Section 132.11.15.1(d) of the GMWS

shall be at least 100% of the modified Proctor maximum dry density
determined from the laboratory compaction test.
If the result of any test for relative compaction does not comply with the
specified requirements then three additional tests shall be carried out
on the lot. If the result of any of these additional tests fails to comply
with the specified requirements then the non-complying lots shall be
removed by the Contractor and replaced using fresh material.
132.11.16 TESTING: CSBC MATERIALS
132.11.16.1 Testing: Samples Taken Ex-Pavement
Testing of the CSBC material ex-pavement shall be in accordance with

Section 132.3.14.1 of the GMWS except that no CBR testing is required
and compressive strength testing shall be in accordance with the
requirements of GMWS Section 20.
132.11.16.2 Compliance Criteria: Samples Taken Ex-Pavement
Compliance criteria for CSBC material ex-pavement shall be in

accordance with Section 132.3.14.2 of the GMWS with the exception
that no CBR testing will be conducted. Compliance criteria for
compressive strength tests shall be such that no result shall be outside
the range 7 N/mm² to 10N/mm² at 28 days.

132.11.16.3 Non Compliance: Samples Taken Ex-Pavement
The procedures for non-compliance shall be in accordance with Section

132.3.14.3 of the GMWS.
132.11.16.4 Testing: CSBC Material
Testing of the CSBC material shall be in accordance with Sections

132.3.15.1, 132.3.15.2 and 132.3.15.3 of the GMWS.
132.11.16.5 Compliance Criteria: CSBC Material
Compliance criteria for CSBC material shall be in accordance with

132.11.16.6 Non Compliance: CSBC Material
The procedures for non-compliance shall be in accordance with Section

132.3.15.4 of the GMWS.
132.11.16.7 Testing: Stockpiles
Testing of CSBC material in stockpile shall be in accordance with

132.11.16.8 Compliance Criteria: Stockpiles
Compliance criteria for material in stockpile shall be in accordance with

132.11.16.9 Non Compliance: Stockpiles

of the GMWS shall not be used in the Permanent Works.
132.12 WET LEAN CONCRETE
132.12.1.1 Wet lean concrete
The WLC course shall consist of crushed aggregates, cement and

water constructed in one or more layers on a prepared subgrade in
Type B and type C subgrade are earthworks materials which comply

with Sections 132.10.3.1 (b) and 132.10.3.1 (c) of the GMWS
respectively.
132.12.1.3 Marine sand and public fill subgrade
Marine sand (Types S1 and S2) and public fill subgrade are earthworks
materials which comply with Sections 132.10.3.1 of the GMWS.

132.12.2 GENERAL

Formwork and finishes for the WLC course shall comply with Section
18 of the GMWS.
132.12.2.3 Concrete
Concrete for the WLC course shall comply with Section 20 of the
GMWS.
Curing compound for the WLC course shall comply with Section 132.5
of the GMWS.
132.12.2.5 Water
Water for the WLC shall comply with Section 132.3.2.2 of the GMWS.

(b) Aggregate may be mixed or blended with fine sand, stone dust,
or other similar binding or filler materials produced from permitted
with the requirements of the GMWS.
(c) The combined material shall be free from weathered material,
vegetable matter, lumps of clay, disintegrated or friable matter
and other deleterious substances.

(d) The aggregate shall have the properties stated in Table 132.46.
Table 132.46: Properties of Aggregate

Magnesium Sulphate Soundness <5% after 5 cycles
(e) The ex-pavement grading of the aggregate shall be within the

limits shown in Table 132.47.
(f) The particle size distribution shall be determined in accordance
Table 132.47: Ex-pavement Particle Size Distribution for Aggregate

Sieve Size Percentage by Mass Passing
(mm)
75 100
37.5 85 – 100
20 60 – 85
10 40 – 70
5.0 25 – 45
0.600 8 – 22
0.075 4 – 10
(g) The material shall be well graded from coarse to fine and shall not
vary between the lower third of the range on one sieve to the upper
third of the range on each adjacent sieve. The fraction of the
material that passes the 75 micron sieve shall not exceed 60% of
the fraction passing the 600 micron sieve.
132.12.2.7 PFA
PFA for use in the WLC shall be in accordance with BS 3892: Part 1:
1997 (or BS EN 450-1:2012).

132.12.2.8 WLC mix
(a) In each cubic metre of fully compacted WLC the minimum

cementitious content shall be such that the average 7 day
compressive strength shall be between 7.0 N/mm² to 10.0 N/mm².
(b) PFA shall be used in combination with Portland cement. The
be between 15 and 25%.
132.12.3.1 Particulars of materials for WLC

the Contractor shall submit to the Project Manager for review
without objection, a statement of the origin, and method of
extraction of all aggregates proposed for the Permanent Works.
The Contractor shall at the same time provide evidence
demonstrating that an adequate supply of uniform material can be
produced and that the aggregate meets the specified
requirements.
the Contractor shall submit the particulars detailed in Sections
20.6.1 (a) and 20.6.1 (c) of the GMWS to the Project Manager for
At the same time as the particulars detailed in Section 132.12.3.1(a) are

for review without objection. The sample, which shall be a minimum of
two 50 kg samples, shall be accompanied by a full petrological and
mineralogical description to the requirements of ASTM C295/295M-12
(2012).
132.12.3.3 Particulars of WLC mix and methods of construction
The following particulars of each proposed design WLC mix shall be

submitted to the Project Manager for review without objection at least
20 days prior to scheduled construction of the trial area.
(a) quantity of each constituent per cubic metre;
(b) target grading details in tabular and graphical form for the
aggregate ex-pavement. The target grading shall be
expressed as a single percentage passing each sieve size;
(c) type and source of cement and PFA; and
(d) method of construction.


including a layout plan and output of the plant, shall be submitted to the
Project Manager for review without objection.
132.12.4 TRIALS
132.12.4.1 Trial mix WLC
The Contractor shall prepare trial mixes in advance of constructing the

Permanent Works using the materials and batching and mixing plant
which he proposes to use for the Permanent Works and following the
requirements specified in Section 132.12.2.7 of the GMWS.
132.12.4.2 Testing: trial mix WLC
From each of the mixes a set of three 150 mm cubes shall be made and
cured in accordance with BS EN 12390-2:2009. At seven days the
mean dry density of the cubes shall be determined in accordance with
BS EN 12390-7:2009, and the compressive strength shall be
determined in accordance with BS EN 12390-3:2009.
132.12.4.3 Compliance criteria: trial mix WLC
Providing that the mean compressive strength of the three cubes from
the same set is between 7 N/mm² and 10 N/mm2, and no individual cube
strength in the set is less than 6.5 N/mm2 nor more than 12 N/mm² the
mix shall be considered to be satisfactory.
132.12.4.4 Non-compliance: trial mix WLC
which meets the strength requirements specified in Section 132.12.4.3
of the GMWS.
(a) The Contractor shall construct, for each WLC material source and
on each subgrade type, a trial area of at least 750 m2. This shall
comprise at least two runs of a minimum length of 50 m and shall
contain at least one transverse and one longitudinal joint.
(b) Trial areas will be used to determine the adequacy of the
compaction passes and resulting field density.

(c) Trial areas shall be carried out on completed underlying sub grade
courses which meet the requirements of the GMWS and shall be
constructed with the materials and plant intended for use in
constructing the Permanent Works. The trial areas shall be
(a) At least 10 cores to the full depth of the WLC shall be cut from the
trial area to determine the density of the WLC. The cores shall be
cut when the WLC is not less than four days old. The cutting of
cores shall be in accordance with CS1.
(b) The cores shall be tested for density in accordance with BS EN
12390-7:2009. The resulting average density of the cores shall be
taken as the Target Density. The cores shall also be used to
determine the course thickness.
(c) The trial area shall be tested for surface level and regularity in
accordance with Section 132.12.13.1 of the GMWS.
(d) At least six 150 mm WLC cubes shall be made and cured in
accordance with BS EN 12390-2:2009. The cubes shall be tested
after seven days for compressive strength in accordance with BS
EN 12390-3:2009.
requirements:
(a) The thickness, regularity and levels of the WLC shall comply with
Section 132.12.12 of the GMWS.
(b) The compressive strength of the WLC cubes shall comply with

methods of construction shall be submitted to the Project Manager
for review without objection. Further trial areas shall be
with the specified requirements for the trial area. Further trial
mixes shall be made unless non-compliance of the trial area was
not due to the WLC mix.
(b) Trial areas, which do not comply with the specified requirements
shall be removed.
132.12.4.9 Commencement of WLC placement
(a) WLC shall not be placed in the Permanent Works, other than in a
Placement Procedure to the Project Manager for review without
objection. The Placement Procedure shall form an integral part of
the Contractor's Quality System.
(c) WLC may not be placed in the Permanent Works, until all the
above requirements have been met and the Placement Procedure
has been reviewed without objection by the Project Manager.

(a) Storage of materials shall be in accordance with Sections 20.7.1,

20.7.2 and 20.7.3 of the GMWS.
(b) The storage of aggregates for WLC shall be arranged so that as
far as possible rapid drying out in hot weather is prevented in order
to avoid sudden fluctuations in water content. Storage of fine
aggregates shall be arranged so that they can drain sufficiently
before use in order to prevent fluctuations in water content of the
WLC.


below the WLC course shall be completed and fill material shall
be deposited and compacted in trenches before the WLC course
is constructed. Openings to manholes, chambers and gullies shall
(b) Box-outs shall be formed in the WLC course for covers, frames
and other hardware.
(a) The Contractor shall notify the Project Manager before WLC is
Project Manager sufficient time to inspect the subgrade.
(b) WLC material shall only be placed if the subgrade is undamaged
and clean and free from foreign material, and has been reviewed
(c) The subgrade shall be lightly watered prior to placement of WLC.
Watering shall be controlled to minimise loss of moisture from the
WLC and loss of fines from the surface of the subgrade.
132.12.7 FORMWORK

(b) Formed surfaces shall have a class F2 finish.
(a) At the end of each day's run a transverse construction joint shall
be formed by a stop end to form a true transverse vertical face.
These faces shall be protected by banking damp material against
them or by other suitable methods. The protection method
provided shall permit the placing and compacting of subsequent
material without damage to previously laid material.
(b) Care shall be exercised to ensure thorough compaction of the
WLC material immediately adjacent to all construction joints.
(c) Before depositing new material against compacted material, the
surface of the joint shall be cleaned, roughened and moistened.
(d) Joints in the WLC and the PQC shall be staggered by at least 0.6
m.

132.12.9 PLACING AND COMPACTING WLC
(a) No activity or work shall be carried out on the WLC course during
rain or when there is standing water on the WLC or subgrade.
and debris.
(c) Placement of WLC in hot and cold weather conditions shall be
subject to the limitations noted within Section 132.5.10 of this
GMWS.
(d) The WLC layer shall be placed directly and spread on the
subgrade using a slip form paver or between forms where hand
laying is permitted as described in Item (g) below. Spreading of
WLC shall be carried out in a manner that does not disturb the
subgrade. WLC shall be placed in one layer without segregation.
Delivery vehicles shall not be permitted to travel on the finished
subgrade and suitable side loading facilities shall be provided for
discharging the material into the paver. Hauling over previously
completed WLC will not be permitted.
(e) The slip form paver shall compact the concrete, shape it between
sliding side forms and shall be adequate to enable the concrete to
be laid consistently to the required levels and profiles within the
tolerances permitted in the GMWS. The concrete shall be
deposited, without segregation, in front of the slip form paver,
across its whole width. Finishing behind the slip form paver shall
be carried out mechanically. The concrete surface shall not be
overworked. Hand floating shall be kept to an absolute minimum.
(f) Immediately after placing, the WLC shall be thoroughly and
expeditiously compacted by vibration. Vibrating equipment used
in the compaction of WLC shall be an approved surface type with
vibrating pans or vibrating beam (or beams) or combinations
thereof. Equipment needing poker or internal vibrators drawn
through the WLC will not be permitted.

(g) In areas where slip form paver spreading cannot be achieved,
WLC may be laid by hand subject to the prior agreement of the
Project Manager. Hand laying shall be between forms not more
than 7 m apart. The forms shall provide the required class F2
finish, with no horizontal lip. The forms shall be kept free from dirt,
mud, and other deleterious matter. They shall have adequate
devices for secure setting so that, when in place, they will
withstand, without springing or settlement, the impact and
vibration of the spreading, compacting and finishing plant and
equipment. The line and level of the forms shall enable the
resulting joints and pavement surface level to comply with the
GMWS and shall be grout tight. The forms shall be inspected to
see that they are generously coated with form releasing fluid to
facilitate easy removal. The Contractor shall operate a scratch
template or dip from string lines to check the shape and level of
the WLC course and to confirm the minimum thickness of WLC
specified will be achieved between the forms. WLC shall be
deposited in such a manner as to avoid segregation. It shall not
be vibrated into place. Internal and surface vibration shall be
utilised to ensure the WLC is fully compacted over the full width
and depth. After internal vibration the WLC shall be struck-off at
sufficient level above the forms to ensure that during surface
vibration the concrete is everywhere in contact with the
compacting beam. It shall not be overworked. Forms shall not be
removed until at least twelve hours after finishing the WLC.
Surplus mortar packing along the vertical edges of the finished
WLC course shall be broken down and removed.
(h) Material from different sources shall be laid in discrete areas that
have been inspected by the Project Manager.
(i) No more than 90 minutes shall elapse between the time that water
is added to the cement and the time the WLC is deposited in place.
This time limit shall be reduced to 60 minutes where WLC is batch
on the airport.
(j) No more than 120 minutes shall elapse between the time that
water is added to the cement and the time the WLC, including
WLC in any overlying layers, is compacted to its final position. This
time limit shall be reduced to 90 minutes where WLC is batch on
the airport.

132.12.10 CURING WLC
(a) After compaction of the WLC has been completed as specified it

shall be protected for a period of seven days against drying out by
covering with polyethylene sheeting or by the application of an
appropriate bitumen emulsion which shall be approved by the
Project Manager. Alternatively, a curing compound may be
applied by spray meeting the requirements of Section 132.5 of the
GMWS. Curing application shall begin as soon as possible after
the completion of finishing operations. The finished WLC shall be
kept moist continuously until the curing material is placed.
(b) Where polyethylene sheeting is used, the surface of the WLC
course shall be entirely covered by sheeting weighted to remain
in contact with the material. Joints in the sheeting shall overlap by
at least 300 mm and be set to prevent egress of water.
(c) The curing material shall be maintained and applied as needed by
the Contractor during the seven days protection period so that all
of the WLC will be covered effectively during this period.
(a) Following completion of the WLC course, the Contractor shall

perform all maintenance work necessary to keep the WLC in a
satisfactory condition meeting the specified requirements. The
surface shall be kept clean and free from foreign material. The
WLC course shall be properly drained at all times.
(b) Trafficking of WLC course by construction plant or other vehicles
shall not be permitted until at least seven days have elapsed from
the time of placing. After that time traffic shall be restricted to that
necessary to place the succeeding layer or course.
(c) If damage occurs to the WLC course or any underlying layer
occurs, from trafficking the course or by any other reason, causing
it to fall outside of the GMWS requirements, the affected area shall
be removed to spoil by the Contractor and replaced using fresh
material.
(a) The finished surface shall not vary by more than 7 mm when
tested with a 3.0 m straight edge. The finished surface shall also
(b) The elevation of the finished surface shall not vary by more than
(c) The thickness of the WLC course shall not be less than the


(b) The WLC course shall be tested for surface regularity parallel and
transverse to the directions of placing along parallel lines not less
than 5 m apart.
(c) Where the WLC course extends for more than 30 m in a given
a profilometer which produces a continuous computerised printout
(d) Where the WLC course extends for less than 30 m in a given
a 3.0 m straight edge.
Any deviation of the finished thickness, level or regularity outside the

the GMWS.
132.12.14 TESTING: ROUTINE WLC TESTS
132.12.14.1 Testing: routine WLC tests
(a) The Contractor shall cut at least one core from each 375 m2 of
WLC course after the WLC has been cured for four days. The
method of taking the cores shall be in accordance with CS1. When
the Contractor can demonstrate to the Project Manager,
uniformity in production and continued compliance with the
GMWS, the Contractor may submit for review to the Project
Manager a request to reduce the frequency of coring to one core
from each 750 m2 of WLC course. However, at least two cores
shall be cut from each day's work. The cores shall be 150 mm in
diameter and shall be the full depth of the WLC. Holes formed by
taking WLC cores shall be reinstated using fresh WLC.
(b) Each core shall be tested for density in accordance with BS EN
12390-7:2009.
(c) Each core shall be inspected to determine the thickness of the
WLC course.
(d) 150 mm WLC cubes shall be made and cured in accordance with
BS EN 12390-2:2009. At least three cubes shall be made per 600
m2 of WLC course and not less than six cubes shall be made per
day. The cubes shall be tested after seven days for compressive
strength in accordance with BS EN 12390-3:2009.

132.12.14.2 Compliance criteria: routine WLC tests
(a) The cube specimens shall be used to determine compliance with

compressive strength. The WLC course represented by the three
cubes shall be deemed to satisfy the specified compressive
strength requirements if the conditions given in both (a) and (b)
are achieved.
consecutive test results is between 7 N/mm2 and 10 N/mm2.
than 6.5 N/mm2.
(b) The density of the WLC shall be determined from the cores. The
density of any core not be less than 98.0% of the Target Density
determined during the testing of the trial area and defined in
Section 132.12.4.6.
132.12.14.3 Non-compliance: routine WLC tests
(a) If the result of any test on the cubes fails to meet the requirements
of the GMWS then the areas of WLC which are represented by
them shall be removed by the Contractor and replaced using fresh
material.
(b) If the result of any test on the cores fails to meet the requirements
of the GMWS then additional cores shall be taken 5 m on each
side of the defective core to determine the limit of the defective
area of WLC. The defective area shall be removed by the
Contractor and replaced using fresh material.
132.12.15 TESTING: AGGREGATE SAMPLES TAKEN PRE- STOCKPILING
132.12.15.1 Testing and compliance: aggregate samples taken pre-stockpiling
Aggregate shall be tested in accordance with the following

requirements.
132.12.15.2 Batch: ten percent fines value and plasticity index
A batch of aggregate is a quantity not exceeding 2,500 tonnes of

aggregate of the same type and obtained from the same source.

132.12.15.3 Testing: ten percent fines value and plasticity index
(a) Each batch of aggregate shall be tested ex-stockpile for ten

percent fines value (TFV) and plasticity index.
(b) The method of testing for ten percent fines value (TFV) shall be
in accordance with BS 812: Part 111/BS EN 1097-2; 1996,
except that the sample shall be soaked in water at room
temperature for 24 hours and shall not be oven-dried before
testing.
(c) The method of testing for plasticity index shall be in accordance
with BS 1377: Part 2: 1990. Sample preparation shall be by wet
sieving the material over a 425 micron BS test sieve.
(d) Four sets of test results shall be submitted with the particulars
detailed in Section 132.12.3.1 of the GMWS. Thereafter, three
set of tests shall be carried out for every batch of aggregate.
132.12.15.4 Non-compliance: ten percent fines value and plasticity index
in Table 132.46 then four additional sets of tests shall be carried out.
The continued use of the material source shall depend on the results of
these additional tests being reviewed without objection by the Project
Manager.

132.13 RUNWAY GROOVING
132.13.1 GENERAL
(a) Where indicated on the Employer’s Drawings, the polymer

modified asphalt wearing course shall be grooved by saw
cutting, using a method which has been reviewed without
objection by the Project Manager, to provide 6mm wide by 6 mm
deep continuous channels at 32 mm centres.
(b) Where indicated on the Employer’s Drawings, the polymer

modified Marshall asphalt wearing course shall be grooved by
saw cutting, using a method which has been reviewed without
objection by the Project Manager, to provide trapezoidal
grooves being 12mm wide at the top and 6mm wide at the
bottom by 6 mm deep continuous channels at 57 mm centres
Particulars of the proposed method of grooving and cleaning after

grooving shall be submitted to the Project Manager for review at least
20 days prior to scheduled grooving of the trial area.
132.13.3 TRIALS
132.13.3.1 Trial Area
(a) A trial area shall be grooved to demonstrate that the proposed

method of grooving and cleaning will produce a finished surface
which complies with the specified requirements.
(b) The trial area shall be at least 750 m2 and may form part of the
Works if reviewed without objection by the Project Manager. The
trial area shall contain a 600 mm un-grooved corridor to
demonstrate that the requirements of Section 132.13.5(d) can be
met.
(c) The Contractor shall notify the Project Manager at least 48 hours
before grooving the trial area.
132.13.3.2 Testing: Trial Area
The trial area shall be tested in accordance with Section 132.13.8.1

except that the frequency of testing shall be one test per 75 m2.

132.13.3.3 Compliance Criteria: Trial Area
(a) The results of tests for texture depth shall comply with Section
132.13.8.2.
(b) All results of measurements of groove size and spacing shall

comply with the specified dimensions and tolerances.
(c) The trial area shall be cleaned of all arising and residual slurry.
132.13.3.4 Non-compliance: Trial Area
(a) If the trial area does not comply with the specified requirements
then the Contractor shall submit particulars of the proposed
changes to the Project Manager for review.
(b) Further trial areas shall be grooved until the specified

requirements have been met.
(c) Should any of the compliance test data relating to the

measurements of the grooves within the trial area be found to be
outwith the specified tolerances, the whole area of the trial shall
be removed to the full depth of the asphalt laid and replaced at no
additional cost to the Employer.
132.13.4 COMMENCEMENT OF GROOVING
(a) Grooving of the Works, other than in a trial area, shall not
commence until a trial area which complies with the GMWS has
been completed.
(b) Grooving of the Works shall not commence until the results of the
trial area have been reviewed without objection by the Project
Manager.
132.13.5 PARTICULAR REQUIREMENTS
(a) Grooving shall not be undertaken until at least 42 days after the
laying of the Marshall asphalt wearing course.
(b) The extent of the grooving shall be as shown on the Employer’s

Drawings.
(c) Grooves shall not be cut within 300 mm of airfield ground lighting.
(d) Grooves shall be perpendicular to the centre line of the runway.

132.13.6 CLEANING OF GROOVED SURFACE
(a) The grooving plant used shall be capable of efficiently collecting

the grooving arising by suitable vacuum recovery apparatus
integral with the grooving machine.
(b) The Contractor shall use a vacuum road sweeper in order to pick
up any remaining arising.
(c) All grooving arising shall be disposed off the Site.
(d) All residual slurry within the grooves shall be removed by water
jetting before the end of each working period.
(e) On completion of cleaning operations, the Contractor shall make

the grooved area available to the Project Manager for inspection.
132.13.7 TOLERANCES
(a) The width and depth of the grooves shall be within 1 mm of the
specified dimensions.
(b) The spacing of the grooves shall be within 2 mm of the specified

dimension.
132.13.8 TESTING: GROOVE SIZE AND SPACING
132.13.8.1 Testing: Groove Size and Spacing
(a) Each test shall consist of a series of 10 measurements of depth,

width and spacing. The results of each set of ten measurements
(depth, width and spacing) shall be averaged to produce one test
result of depth, width and spacing.
(b) The groove depth, width and spacing shall be measured at a rate
of three tests per work shift where grooving took place,
irrespective of the area grooved.
132.13.8.2 Non-compliance: Groove Size and Spacing
If any test result is found to be outwith specified tolerances, the asphalt

within the affected area shall be removed and replaced to the full
asphalt depth and be replaced at no extra charge to the Employer.
132.13.8.3 Texture Depth Measurement
(a) Texture depth measurements shall be carried out by the sand

patch method in accordance with BS EN 13036-1:2010.
(b) Testing shall take place on a frequency of one test per 2,000 m2
per work shift, irrespective of the size of area grooved. The result
of each test shall not be less than 1.5 mm.

132.13.9 RUNWAY GROOVING HOLD AND CONTROL POINTS
Plan.
Table 132.47A: Runway Grooving Hold and Control Points

132.13.2 Initial approval submission Submissions (in
particular: method of
grooving, grooving
plant and method of
cleaning)
132.13.3 Trials including
assessment of trial mix
and trial area
132.13.4 Commencement of
Grooving
132.13.6 Cleaning of Grooved
Surface
132.13.8 Testing: Groove Size and
Spacing – including
assessment of each set
132.13.8.3 Testing: Texture Depth –
including
assessment of each work
shift
132.14 PREPARATION OF GRADED AREA
132.14.1.1 Graded Area
The graded area is the area of earthworks adjacent to the runways.

There are three different types of preparation for the graded area, Type
1, Type 2 and Type 3. The extent of each type of preparation is detailed
on the Employer’s Drawings.
132.14.1.2 Pulverised-fuel ash
PFA is solid material extracted by electrostatic and mechanical means

from the flue gases of furnaces fired with pulverized bituminous coal.

132.14.1.3 Classification of earthworks material
Earthworks materials shall be classified in accordance with Section

132.10.3.1.
132.14.1.4 Stabilised subgrade mix
Stabilised subgrade mix is a uniform mixture of either Type C, Type S1

or Type S2 marine sand fill/earthworks material, PFA and cement.
132.14.2 MATERIALS
132.14.2.1 Cement/PFA Mixture
Cement shall comply with Section 16 of the GMWS. PFA shall comply
with BS 3892: Part 2: 1996.
132.14.2.2 Water
Water for the stabilized subgrade shall comply with Section 132.2.2.3.
132.14.2.3 HDPE cellular paving system
(a) The heavy duty cellular (honeycomb) paving system used for the
run up slabs shall be of UV stabilised HDPE material and shall
comply with the following requirements:
(i) Thickness: 40mm minimum
(ii) Wall thickness: 4mm minimum
(iii) Mass: 4kg/m² minimum
(iv) Cell size: 50 mm by 50 mm minimum
(v) Shall be durable enough to maintain integrity for at least

50 years when installed.
(b) Details of the proprietary system shall be submitted to the Project

construction of the run up slabs.
132.14.3 STABILISED SUBGRADE MIX
The stabilised subgrade mix shall comply with the following

requirements:
(a) The proportion of stabilising agent by mass to the total mass of

dry mixture shall be at no time less than 1.5%. Further, the total
amount of PFA in the cement/PFA mix shall not exceed 25%.
(b) The Contractor shall achieve a minimum soaked insitu CBR of 30%
when tested to BS 1924: Part 2: 1990.

132.14.4.1 Particulars of PFA
(a) The following particulars of the proposed PFA shall be submitted

to the Project Manager for review at least 40 days prior to
commencing preparation of the graded area:
(b) A certificate which is applicable to the material to be supplied and

not older than six months for PFA showing the source of the PFA
and showing that the PFA complies with the requirements stated
in the Specification and including results of tests for:
(i) chemical composition
(ii) fineness
(iii) moisture content.
132.14.4.2 Particulars of stabilised subgrade mix and method of construction
The following particulars of each proposed stabilised subgrade mix

shall be submitted to the Project Manager for review at least 40 days
prior to commencing preparation of the graded area:
(a) Quantity of each constituent per cubic metre.
(b) Type and source of PFA.
(c) Results of a laboratory stabilisation study conducted in

accordance with BS1924 Parts 1 and 2 and demonstrating
compliance with the requirements of Section 132.14.3(b) shall be
forwarded to the Project Manager for review. An appropriate
target strength / margin, subject to the Project Manger’s review,
will be applied to ensure a 95% success rate is maintained.
(d) Proposed method of construction.
PFA shall be stored in accordance with Section 20.7.1 of the GMWS.

(a) For graded area Types 1 and 2, the top 500mm of the underlying
subgrade below the stabilised subgrade mix shall be compacted
to 95% modified Proctor maximum dry density and tested and
finished in accordance with Section 132.10. For graded area Type
3 the top 750 mm of the subgrade shall be compacted to 95%
modified Proctor maximum dry density and finished and tested in
accordance with Section 132.10.
(b) Where type A material or fragmented rock is within the zone to be

compacted, the preparation requirements shall be adjusted in
accordance with the Employer's Drawings. Where these
requirements include excavation of type A material and placement
of geo-membrane the work shall be in accordance with Section
132.10.7.1.
(c) The relative compaction of the underlying subgrade shall be

tested in accordance with Section 132.10.
132.14.7 MIXING OF STABILISER AND SUBGRADE
The method of mixing the stabiliser and subgrade shall be plant mixed
and submitted for review to the Project Manager and shall ensure a
uniform mixture.
132.14.8 PLACING AND COMPACTING STABILISED SUBGRADE MIX
(a) The stabilised subgrade mix shall be placed by a tracked paving

machine and compacted in layers to give a compacted thickness
of no more than 200 mm per layer.
(b) The method of laying shall not cause segregation of the mix.
(c) The stabilised subgrade mix shall be compacted to 95% modified

Proctor maximum dry density in accordance with Section 132.10.
(a) The stabilised subgrade mix shall be kept continuously wet until
placement of the subsequent layer.
(b) After the placement and testing of the stabilised subgrade mix the
Contractor shall fill the area to the required levels with Soil-mix as
shown on the Employer’s Drawings and in accordance with
Section 133 Airfield Landscaping Works.
(c) After completion and testing of the stabilised subgrade mix the
Contractor shall protect the works from damage.
(d) If damage occurs to the surface of the graded area or stabilised

subgrade mix from trafficking, or by any other reason, then the
affected area shall be removed to spoil by the Contractor and
replaced with fresh material complying with the requirements of
the Specification.

132.14.10.1 Tolerances: surface level
The level of the finished surface shall not vary by more than ± 30 mm
from the required level.
132.14.10.2 Tolerances: thickness of compacted stabilised subgrade
The thickness of the compacted stabilised subgrade mix shall not be

less than the thickness detailed on the Employer's Drawings.
132.14.11 TESTING: SURFACE LEVEL
132.14.11.1 Testing: surface level
Levelling of the graded are finished surface and surface of the stabilized
subgrade mix shall be performed by the Contractor at all changes of
grade and on a grid which has an interval of not more than 25 m in two
mutually perpendicular directions.
132.14.11.2 Non-compliance: surface level
Areas which do not comply with the specified requirements shall be

corrected by the Contractor using a method which has been reviewed
132.14.12 TESTING: OPTIMUM MOISTURE CONTENT AND MAXIMUM DRY

DENSITY
132.14.12.1 Samples: optimum moisture content, maximum dry density
(a) A batch of stabilised subgrade mix is a quantity of stabilised

subgrade mix of the same type and which has similar properties
2
throughout. A batch shall have a maximum area of 3,000 m .
(b) Samples to be tested for optimum moisture content and maximum

dry density shall be taken after the stabilised subgrade mix has
been deposited in its final position. The samples shall be
representative of batch as a whole.
(c) Three samples shall be taken per batch.
132.14.12.2 Testing: optimum moisture content, maximum dry density
(a) Each sample of stabilised subgrade mix taken as stated in Section

132.14.12.1 shall be tested to determine the optimum moisture
content and maximum dry density. The tests shall be carried out
in accordance with BS 1924: Part 2: 1990 Section 2 Section 2.1.4.
(b) The results for the three tests shall be averaged to determine the
mean maximum dry density for the batch.

132.14.12.3 Consistency: optimum moisture content, maximum dry density
If the result of any test for optimum moisture content or maximum dry
density of stabilised subgrade mix indicates that the batch contains
material which differs to such an extent that subsequent tests for
relative density may be affected, the batch shall be divided into smaller
batches, each of the smaller batches shall comprise material with
similar properties throughout. Additional samples shall be provided from
each of the smaller batches and additional tests for optimum moisture
content and maximum dry density shall be carried out.
132.14.13 TESTING: RELATIVE COMPACTION AND COURSE THICKNESS
132.14.13.1 Testing: relative compaction and course thickness
(a) As soon as practicable after compaction, one in-situ density test

2
shall be carried out per 1,000 m of stabilized subgrade mix. The
tests shall be carried out in accordance with BS 1924: Part 2: 1990
Method 3.3.
(b) The relative compaction (RC) shall be calculated using the

following values:
(i) IDD is the in-situ dry density, determined as stated in

Section 132.14.13.1(a).
(ii) MDD is maximum dry density of the corresponding batch

determined as stated in Section 132.14.12.2.
(c) The thickness of the stabilised subgrade mix layer shall be

measured at the location of each in-situ density test by carefully
excavating test pits.
(d) Any damage to the stabilised subgrade mix caused by testing

shall be repaired by the Contractor using a method which has
132.14.13.2 Non-compliance: relative compaction and course thickness
(a) If the result of any test for relative compaction or layer thickness
does not comply with the specified requirements then three
additional tests shall be carried out close to the non-complying
test, at locations selected by the Project Manager.
(b) If any of the three additional tests fail to comply with the specified
requirements then the Contractor shall carry out remedial works
Project Manager. This method shall include a schedule of further
testing to verify that the specified requirements have been met.

132.14.14 TESTING: IN-SITU CBR
132.14.14.1 Testing: in-situ CBR
(a) At 28 days one in-situ CBR test shall be carried out per 2,000 m2
of stabilised subgrade mix.
(b) The in-situ CBR tests shall be in accordance with BS 1924: Part
2: 1990 with the addition that the ground shall be wetted by
ponding water for 24 hours prior to testing.
(c) Any damage to the graded area caused by testing shall be

132.14.14.2 Non-compliance: in-situ CBR
(a) If the result of any test for in-situ CBR does not comply with the
specified requirements then three additional tests shall be carried
out close to the non-complying test, at locations selected by the
Project Manager.
(b) If any of the three additional tests fail to comply with the specified
requirements then the Contractors shall carry out remedial works
Project Manager. This method shall include a schedule of further
testing to verify that the specified requirements have been met.

132.14.14.3 PREPARATION OF GRADED AREA HOLD AND CONTROL POINTS
Table 132.48A: Preparation of Graded Area Hold and Control

Points
132.14.2.3 HDPE Cellular Paving
System
132.14.3 Stabilised Subgrade Mix Stabilised Subgrade Mix

PFA, results of laboratory
stabilisation study,
proposed method of
construction, mixing plant)
132.14.6 Preliminary Works Preliminary Works
including preparation of including preparation of
underlying course underlying course
132.14.7 Mixing of Stabiliser and Mixing of Stabiliser and
Subgrade Subgrade
132.14.8 Placing and Compacting
Stabilised Subgrade Mix -
– including
132.14.9 Maintenance and
Protection – including
132.14.11 Testing: Surface Level –
including

132.14.12 Testing: Optimum
Moisture Content and
Maximum Dry Density –
including

Compaction and Course
Thickness – including
132.14.14 Testing: Insitu CBR –

including

132.15 INSPECTION, TESTING AND COMMISSIONING
132.15.1 PARTICULAR REQUIREMENTS FOR INSPECTION, TESTING AND

COMMISSIONING WORKS FOR EDGE OF PAVEMENT
All pavement works constructed in this contract will be integrated into

works undertaken in succeeding Works Contract. The Contractor shall
therefore make provision for the succeeding Works Contractor to attend
all inspection, testing and commissioning sessions on completed works
adjacent to the works boundary which will be integrated into works
constructed in succeeding Works Contract. The inspection, testing and
commissioning works shall be undertaken in a manner such that the
succeeding Works Contractor would agree to take over the works
completed in this contract and integrate them into works undertaken in
the succeeding Works Contract.
The Contractor shall send the followings to the succeeding Works

Contractor:
(i) One complete set of Inspection, Testing and Commissioning

Records.
(ii) One complete set of approval and certification documents

received from the Statutory Authorities on completed works for
subsequent submissions (if any) required under the succeeding
Works Contract (if applicable).
(iii) Any documentation required to be sent to the Project Manager.


Section 132 Airfield Pavement

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SECTION 132 AIRFIELD PAVEMENT

132.1 ABBREVIATION AND TERMINOLOGY

The following abbreviations are used in this General Materials and

AASHTO : American Association of State Highway and

General Materials & Workmanship Specification 1/243 April 2019

(a) Pavement courses forming the various pavement types are

(i) Flexible pavement (Figure 132.1): Polymer Modified

(ii) Rigid pavement (Figure 132.2): Pavement Quality Concrete

(iii) Block pavement (Figure 132.3): Block Paving including

Figure 132.1 – Flexible Pavement

Polymer Modified Marshall Asphalt Wearing Course

Figure 132.2 – Rigid Pavement

Pavement Quality Concrete

General Materials & Workmanship Specification 2/243 April 2019

Block Paving including bedding sand and

(b) The term modified proctor in relation to compaction testing shall

(c) The relative compaction (RC) shall be calculated from the

132.2 CRUSHED AGGREGATE SUB-BASE

132.2.1 GLOSSARY OF TERMS

132.2.1.1 Crushed aggregate sub-base

The sub-base shall consist of crushed aggregates constructed in one

132.2.1.2 Type B and type C subgrade

Type B and Type C subgrade are earthwork materials which comply

132.2.1.3 Marine Sand and Public Fill subgrade

General Materials & Workmanship Specification 3/243 April 2019

132.2.2.1 Sub-base material

(a) Aggregate shall be produced by crushing material from sources

(c) The combined material shall be capable of being compacted into

Table 132.1: Properties of sub-base material

(e) The ex-pavement grading of the sub-base material shall be within

General Materials & Workmanship Specification 4/243 April 2019

Table 132.2: Ex-pavement particle size distribution for sub-base

BS Sieve Size Percentage by mass passing

Geogrid shall be manufactured from synthetic durable polymers, and

(a) Weight: greater than 0.3 kg/m2

(b) Tensile strength: 15 kN/m minimum

(c) Load at 2% strain

Transverse: greater than 12 kN/m

Longitudinal: greater than 7 kN/m

(d) UV susceptibility: greater than 90% strength retention after 25

(e) The aperture size shall be between 20 mm and 40 mm.

(f) The rib shall be at least 0.8 mm thick at junctions.

(g) It shall be resistant to all chemicals normally found in pavement

General Materials & Workmanship Specification 5/243 April 2019

Water for use in sub-base layers shall be in accordance with the

(a) be tested and comply with the requirements of BS EN 1008:2002;

(b) be clean, free from harmful matter, and available in such

(c) be protected from contamination by wind-blown dust or other

(d) not exceed the limits given in Table 132.3.

Table 132.3: Water quality standards

Criterion Permissible Limit

General Materials & Workmanship Specification 6/243 April 2019

132.2.3.1 Particulars of aggregates

At least 30 days prior to scheduled construction of the trial area, the

132.2.3.2 Representative samples of aggregate

At the same time as the particulars detailed in Section 132.3.1 of this

132.2.3.3 Particulars of the geogrid

(a) At least 30 days prior to scheduled commencement of the trial

(b) The Contractor shall establish a Quality Control Point at this

132.2.3.4 Representative samples of geogrid