ITP Projek Jalan

INSPECTIONS AND TESTING PLAN FOR ROAD WORKS PROJECT

Disediakan Oleh:Bahagian Jalan Ibu Pejabat JKR Perak Darul Ridzuan Jalan Panglima Bukit Gantang Wahab 30000 Ipoh

CONTENT

1.

EARTHWORKS 1.1

2.

3.

PAGE

BORROW PIT SOURCE

3

FLEXIBLE PAVEMENT 2.1

GRANULAR SUBBASE MATERIAL

4

2.2

QUARRY / AGGREGATE SOURCE

5

2.3

CRUSHER RUN (ROADBASE)

5

2.4

BITUMINOUS PRIME COAT (SK – 1 – SK – 1K)

6

2.5

BITUMINOUS TACK COAT (RS – 1 – RS – 1K)

6

2.6

ASPHALTIC CONCRETE WEARING COURSE

7-8

2.7

ASPHALTIC CONCRETE BINDER COURSE

8-9

CONCRETE 3.1

MINIMUM RATE OF SAMPLING

1

10

APPENDIX:-

1.

TABLE 4.1 -

2.

GRADATION LIMITS FOR CRUSHED ROADBASE

11

GTRADATION LIMITS FOR ASPHALTIC OCNCRETE

12

TABLE 4.9 -

5.

11

TABLE 4.8 -

4.

GRADATION LIMITS FOR SUBBASE MATERIAL

TABLE 4.3 -

3.

PAGE

DESIGN BITUMEN CONTENTS

12

TABLE 9.5 -

PRESCRIBED MIXES FOR GENERAL USE PER CUBIC METRE OF CONCRETE

2

13

1.

EARTHWORKS 1.1

BORROW PIT SOURCE

Activity

Testing

Requirement

Frequency

a). Determine Suitability

i). Lab Compaction Test (Proctor) BS 1377

i). To determine moisture content / dry density relationship

Initial Stage

ii). Soaked CBR

ii). > 3.0 %

Approving Officer Engineer

Remark JKR / SPJ / 1988 Lab test for every different variable materials

Activity

Testing

Requirement

Frequency

b). Earthfilling

i). In Situ Density Test (Top 300 mm)

i). >95% Max. Dry Density / CBR > 5%

i). Minimum 1 test / 500 sq.m of each layer compacted

ii). Below 300 mm

ii). > 90% Max. Dry Density

ii). Ditto

c). Cut Area

i). In Situ Density Test (Top 300 mm)

i). >95% Max. Dry Density / CBR > 5%

i). Ditto but every 300 sq.m

d). Disposal Area / Dumping Ground

i). Field Density Test

i). > 85% Max. Dry Density

i). Min. 1 test / each layer compacted

Approving Officer Engineer / Technician

Remark JKR / SPJ / 1988 CI. 2.2.4 Max. compacted thickness of fill shall be limited to 300 mm

3

2.

FLEXIBLE PAVEMENT 2.1

GRANULAR SUB-BASE MATERIAL

Activity a). Determine Suitability

Testing

Requirement

i). Sieve Analysis

i). Envelope ‘A’ to ‘E’ of Table 4.1

ii). Lab Compaction

ii). For Field Density

iii).Soaked CBR

iii).>30%

iv). Liquid Limit

iv). Not more than 25%

v). Plasticity Index

v). Not more than 6

Approving Officer Engineer

Activity b). Laying

Frequency Initial Stage

Remark JKR / SPJ / 1988 CI. 4.1.2 Based on 1 test / 750 cu.m of material supplied (Envelope dependent on sub-base designed) Testing

Requirement

Frequency

i). Sieve Analysis

i). Envelope ‘A’ to ‘E’ of Table 4.1

i). 1 test / 750cu.m stockpile or laid

ii). In Situ Density Test

ii). > 95% Max. Dry Density

ii). 1 test / 500 sq.m of Each layer laid

Approving Officer Engineer / Technician

Remark JKR / SPJ / 1988 CI. 4.1 Based on 1 test / 750 cu.m of material supplied (Not all sandy material conform to envelope)

4

2.2

QUARRY / AGGREGATE SOURCE

Activity

Testing

c). Determine Suitability

Requirement

i). Flakiness Index

i). Less than 30

ii). Aggregate Crushing Value

ii). Less than 30%

iii).Sodium Sulphate Soundness

iii).Not more than 12%

iv). Los Angeles Abrasion

iv). Less than 40

Approving Officer Engineer 2.3

Frequency i). Initial Stage

Remark JKR / SPJ / 1988 CI. 4.1.1

CRUSHER RUN (ROAD BASE)

Activity a). Determine Suitability

Testing

Requirement

i). Sieve Analysis

i). Type 1 of Table 4.3

ii). Lab Compaction Test

ii). To determine moisture content / dry density relationship

iii).Plasticity Index

iii).Not more than 6

iv). Soaked CBR

iv). >80%

Approving Officer Engineer / Technician

Activity a). Laying

Frequency Initial Stage

Remark JKR / SPJ / 1988 CI. 4.1.4 Based on 1 test / 750 cu.m of material supplied Testing

Requirement

Frequency

i). Sieve Analysis

i). Type 1 of Table 4.3

i). 1 test / 750 cu.m supplied

ii). In Situ Density Test or In Situ CBR

ii). > 95% Max. Dry Density

ii). 1 test / 2500 sq.m of each layer laid or every 100 m laid

Approving Officer Engineer / Technician

Remark JKR / SPJ / 1988 CI. 4.14.2 Based on 1 Test / 750 cu.m of material supplied. Thickness of material laid should be checked together with the in-situ compaction test. 5

2.4

BITUMINOUS PRIME COAT (SS – 1 or SS – 1K)

Activity

Testing

Requirement

Frequency

a). Determine

i). Test Conforming to MS 161

i). MS 159 (Cut Back) to MS 161 (Emulsion)

i). Initial Stage

b). Application

i). Tray Test

i). Between 0.5 to 1.0 litres / sq.m

i). 1 test / 16,000 sq.m covered

ii). Spraying Temperature

ii). Between 25° C to 45° C

ii). Daily Operation covered

Approving Officer Engineer / Technician

2.5

Remark MS 161 JKR/SPJ 1988 CI. 4.2.1

BITUMINOUS TACK COAT (RS – 1 or RS – K)

Activity

Testing

Requirement

Frequency

a). Determine

i). Test Conforming to MS 161

i). MS 161

i). Initial Stage

b). Application on site

i). Tray Test

i). Between 0.25 to 0.55 litres / sq.m

i). 1 test / 16,000 sq.m covered

ii). Spraying Temperature

ii). Between 25° C to 45° C

ii). Daily Operation covered

Approving Officer Engineer / Technician

Remark MS 161 JKR/SPJ 1988 CI. 4.2.2

6

2.6

ASPHALTIC CONCRETE WEARING COURSE

Activity a). Lab Mix Design

Testing

Requirement

i).

Aggregates Grading

i). Table 4.8

ii).

Binder Content

ii). Table 4.9 (5.0 % - 7.0 %0

iii). Marshal Method:- Stability - Flow - Voids in Mix - Voids in aggregate filled with bitumen

-

Approving Officer Engineer

i). At initial stage or any change of aggregate source

>500 kg 2.0 – 3.0 mm 3% - 5% 75% - 85%

Remark JKR/SPJ 1988 C 1.4.1

Activity b). Trial Lay

Frequency

Testing

Requirement

i).

Aggregates Grading

i). Table 4.8

ii).

Binder Extraction

ii). Table 4.9 (5.0 % - 7.0 %0

iii). Marshal Method:- Stability - Flow - Voids in Mix - Voids in aggregate filled with bitumen

-

>500 kg 2.0 – 3.0 mm 3.0% - 5.0% 75% - 85%

iv). Lab Compaction Test

iv). To determine lab density

v). In-situ Density Test

v). > 98% lab density

vi). Rolling Pattern

vi). To select most suitable pattern

Approving Officer Engineer

Remark JKR/SPJ 1988 CI 4.2.2

7

Frequency i). Initial stage or any change of lab mix design

Activity

Testing

b). Laying

Requirement

Frequency

i). Sieve Analysis (Gradation Analysis)

i). Table 4.8

i). 1 test / day of production

ii).

ii). 4 % - 6 %

ii). 1 test / 200 tons produced

Binder Extraction

iii). Marshal Method:- Stability - Flow - Voids in Mix - Voids in aggregate filled with bitumen

-

>500 kg 2.0 mm 3.0% - 5.0% 75% - 85%

iii).1 test / 200 tons produced

iv). In-situ Density Test

iv). To determine lab density

iv). One sample / 500 sq.m of area laid or daily

v). Rolling Temperature (RT)

v). > 98% lab density

v). Every initial rolling

vi). To select most suitable pattern

Approving Officer Engineer / Technician

2.7

Remark JKR/SPJ 1988 CI 4.2.4

ASPHALTIC CONCRETE BINDER COURSE (ACB 28)

Activity a). Lab Mix Design

Testing

Requirement

i).

Aggregates Grading

i). Table 4.8

ii).

Binder Content

ii). Table 4.9 (4 % - 6 % )

iii). Marshal Method:- Stability - Flow - Voids in Mix - Voids in aggregate filled with bitumen

-

Approving Officer Engineer

>450 kg 2.0 mm 3.0% - 7.0% 65% - 80%

Remark JKR/SPJ 1988 CI 4.2.4 8

Frequency At initial stage or any change of aggregates source

Activity

Testing

b). Trial Lay

Requirement

i).

Aggregates Grading

i). Table 4.8

ii).

Binder Extraction

ii). Table 4.9 (4 % - 6 % )

iii). Marshal Method:- Stability - Flow - Voids in Mix - Voids in aggregate filled with bitumen

-

iv). Lab Compaction Test

iv). To determine lab density

v). In-situ Density Test

v). >95% lab density

vi).Rolling Pattern

vi). To select most suitable pattern

Approving Officer Engineer

Frequency

>450 kg 2.0 mm 3.0% - 7.0% 65% - 80%

Remark JKR/SPJ 1988 CI 4.2.4

Activity

Testing

Requirement

Frequency

c). Laying

i). Sieve Analysis (Gradation Analysis)

i). Table 4.8

i). 1 test / day of production

ii).

Binder Extraction

ii). 4 % - 6 %

ii). 1 test / 200 tons produced or each plant operation

Marshal Method:Stability Flow Voids in Mix Voids in aggregate filled with bitumen

-

iii).1 test / 200 tons produced

iii). -

>450 kg 2.0 mm 3.0% - 7.0% 65% - 85%

iv). In-situ Density Test

iv). > 95% lab density

iv). One sample / 500 sq.m of area laid or daily

v). Rolling Temperature (RT)

v). Immediately RT > 110° C

v). Every initial rolling

Approving Officer Engineer

Remark JKR/SPJ 1988 CI 4.2.4 9

3.

CONCRETE

Activity

Testing

Requirement

Frequency

a) Concreting

i).

i)

As per Table 9.5

Strength

Prescribed Mix

28 days strength must satisfy at least one of the foolowing a) fcu of each the two cubes ≥ specified compressive strength b) average fcu of the two cube ≥ specified compressive strength and the different between the two strength > 20% of average strength ii) Designed Mix a) mean of 4 consecutive sample > fcu + 0.5 current margin b) individual sample fcu > 0.85 x specified compressive strength

3.1

MINIMUM RATE OF SAMPLING

Rate

Volume of concrete from which a sample shall be taken

Rate 1 (Pre-stressed Concrete)

Every 10 cu.m or every group of 10 batches*

Rate 2 (Ordinary Structural Concrete)

Every 20 cu.m or every group of 20 batches*

Rate 3 (Mass Concrete)

Every 50 cu.m or every group of 50 batches*

10

i) 3 cube / sample 1 nos – 7 days 2 nos – 28 days

APPENDIX

TABLE 4.1 – GRADATION LIMITS FOR SUBBASE MATERIAL B.S SIEVE SIZE

50.00 mm 25.00 mm 9.50 mm 4.75 mm 2.00 mm 42.50 mm 7.500 mm

% PASSING BY WEIGHT A 100 30 – 65 25 – 55 15 – 40 8 – 20 2 – 8.0

B 100 79 – 95 40 – 75 30 – 60 20 – 45 c 15 – 30 5 – 20

C 100 50 – 85 35 – 65 25 – 50 15 – 30 5 – 20

D 100 60 – 100 50 – 85 40 – 70 25 – 45 5 – 20

E 100 55 – 100 40 – 100 20 – 50 6 – 20

F 100 70 – 100 55 – 100 30 – 70 8 – 25

TABLE 4.3 – GRADATION LIMITS FOR CRUSHED AGGREGATE ROADBASE

B.S SIEVE SIZE

50.00 mm 37.50 mm 28.00 mm 20.00 mm 10.00 mm 5.00 mm 2.36 mm 2.00 mm 600 mm 425 mm 75.00 mm

% PASSING BY WEGHT TYPE 1 100 95 – 100 60 – 80 40 – 60 25 – 40 15 – 30 8 – 22 0 – 8.0

11

TYPPE II 100 85 – 100 70 – 100 60 – 90 40 – 65 30 – 5.0 20 – 40 10 – 25 2 – 10

TABLE 4.8 – GRADATION LIMITS FOR ASPHALTIC CONCRETE MIX TYPE MIX DESIGNATION

WEARING COURSE ACW 14

B.S SIEVE SIZE

BINDER COURSE ACB 14

BINDER COURSE ACB 28

% PASSING BY WEIGHT

37.50 mm 28.00 mm 20. 00 mm 14.00 mm 10.00 mm 5.00 mm 3.35 mm 1.18 mm 425 mm 150 mm 75.00 mm

100 80 – 95 68 – 90 52 – 72 45 – 62 30 – 45 17 – 30 7 – 16 4 – 10

100 70 – 95 56 – 81 40 – 65 32 – 58 20 – 42 12 – 28 6 – 16 4–8

100 80 – 100 72 – 93 58 – 82 50 – 75 36 – 58 30 – 52 18 – 38 11 – 25 5 – 14 3–8

TABLE 4.9 – DESIGN BITUMEN CONTENTS CLASS OFMIX

NORMAL RANGE OF DESIGN BITUMEN CONTENTS BY WEIGHT OF MIX

ACW 14

-

WEARING COURSE

5.0 - 7.0 %

ACW 14

-

BINDER COURSE

4.5 - 6.5 %

ACW

-

BINDER COURSE

4.0 - 6.0 %

12

TABLE 9.5 – PRESCRIBED MIXES FOR GENERAL USE PER CUBIC METRE OF CONCRETE

Grade of concrete

15P

20P

25P

28 days characteristic strength of concrete (N/mm2)

15

20

25

Nominal size of aggregate (mm)

40

20

Workability

Medium

High

Medium

High

Slump limits (mm)

50 – 100

100 – 150

25 – 75

75 – 125

Cement (kg)

250

270

280

310

Total aggregate (kg)

1850

1800

1800

1750

Fine aggregate (kg)

30 – 45

30 – 45

35 – 50

35 – 50

Cement (kg)

300

320

320

350

Total aggregate (kg)

1850

1750

1800

1750

Fine aggregate (kg)

25 – 35

25 – 40

25 – 40

20 – 45

Cement (kg)

340

360

360

390

Total aggregate (kg)

1800

1750

1750

1700

Fine aggregate (kg)

25 – 35

25 – 40

45 – 40

30 – 45

13