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FOR INTERNAL USE ONLY Standard Specification For Road Works

SECTION 3

DRAINAGE WORKS

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 50


FOR INTERNAL USE ONLY Standard Specification For Road Works

SECTION 3 - DRAINAGE WORKS

Page

3.1 GENERAL S3-54

3.2 EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS S3-54

3.2.1 Description S3-54

3.2.2 Materials S3-54


3.2.2.1 Excavation S3-54
3.2.2.2 Granular Bedding Material S3-54
3.2.2.3 Concrete Bedding S3-54
3.2.2.4 Ordinary Backfill Material S3-54
3.2.2.5 Granular Backfill Material S3-54
3.2.2.6 Concrete Backfill S3-55

3.2.3 Excavation S3-55

3.2.4 Backfilling with Ordinary or Granular Backfill Material S3-56

3.3 CHANNEL EXCAVATION S3-57

3.3.1 Description S3-57

3.3.2 Materials S3-57

3.3.3 Construction Methods S3-58

3.4 SURFACE DRAINAGE S3-58

3.4.1 Surface Drainage Types S3-58

3.4.2 Surface Drain Construction S3-58


3.4.2.1 Unlined Drains S3-58
3.4.2.2 Cast In Situ Concrete Drains S3-59
3.4.2.3 Precast Concrete Drain Sections S3-59

3.5 STONE PITCHING S3-60

3.5.1 Description S3-60

3.5.2 Materials S3-60


3.5.2.1 Stone S3-60
3.5.2.2 Cement Mortar S3-60

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FOR INTERNAL USE ONLY Standard Specification For Road Works

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3.5.3 Construction Methods S3-60


3.5.3.1 Grouted Stone Pitching S3-60
3.5.3.2 Ungrouted Stone Pitching S3-61

3.6 GABIONS S3-61

3.6.1 Description S3-61

3.6.2 Materials S3-61


3.6.2.1 Wire Mesh Gabions S3-61
3.6.2.2 Polyvinyl Chloride Coating S3-62
3.6.2.3 Stone S3-62

3.6.3 Construction Methods S3-63

3.7 BRICKWORK S3-63

3.7.1 Description S3-63

3.7.2 Materials S3-63


3.7.2.1 Common Bricks S3-63
3.7.2.2 Cement Mortar S3-63
3.7.3 Construction Methods S3-63
3.7.3.1 Brick Laying S3-63
3.7.3.2 Plastering Brickwork S3-64

3.8 SUBSOIL DRAINS S3-64

3.8.1 Description S3-64


3.8.2 Materials S3-64
3.8.2.1 Pipes S3-64
3.8.2.2 Filter Material S3-64
3.8.2.3 Filter Cloth S3-65
3.8.2.4 Cement Mortar S3-65
3.8.3 Construction Methods S3-65

3.9 R.C. PIPE CULVERTS S3-66

3.9.1 Description S3-66

3.9.2 Materials S3-66


3.9.2.1 Pipes S3-66
3.9.2.2 Cement Mortar S3-66
3.9.2.3 Bedding Material S3-66

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FOR INTERNAL USE ONLY Standard Specification For Road Works

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3.9.3 Excavation and Backfilling for R.C. Pipe Culverts S3-67


3.9.3.1 Excavation S3-67
3.9.3.2 Backfilling S3-68

3.9.4 Installation of R.C. Pipe Culverts S3-68


3.9.4.1 General S3-68
3.9.4.2 Butt Ended Pipe Culverts with Precast Concrete Collars S3-68
3.9.4.3 Rebated Pipe Culverts S3-69
3.9.4.4 Spigot and Socket Pipe Culverts S3-70

3.10 CORRUGATED METAL PIPE CULVERTS S3-70

3.10.1 Description S3-70

3.10.2 Materials S3-70


3.10.2.1 Pipes S3-70
3.10.2.2 Bitumen Coating S3-71
3.10.2.3 Bolts and Nuts S3-71
3.10.2.4 Cement Mortar S3-71
3.10.2.5 Bedding Material S3-71

3.10.3 Excavation and Backfilling for Corrugated Metal Pipe Culverts S3-72

3.10.4 Installation of Corrugated Metal Pipe Culverts S3-72


3.10.4.1 General S3-72
3.10.4.2 Mortar Lining S3-72

3.11 PRECAST BOX CULVERTS S3-72

3.11.1 Description S3-72

3.11.2 Materials S3-72


3.11.2.1 Precast Box Culverts S3-72
3.11.2.2 Cement Mortar S3-72
3.11.2.3 Bedding Material S3-72

3.11.3 Excavation and Backfilling S3-73


3.11.3.1 Excavation for Precast Box Culverts S3-73
3.11.3.2 Backfilling S3-73
3.11.4 Installation of Precast Box Culverts S3-73

3.12 EXTENSION OF CULVERTS S3-74

3.12.1 Extension of Pipe Culverts S3-74


3.12.2 Extension of Box Culverts S3-74

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 53


FOR INTERNAL USE ONLY Standard Specification For Road Works

SECTION 3 - DRAINAGE WORKS 3.2.2 Materials

3.2.2.1 Excavation

3.1 GENERAL Material excavated shall be


classified as common excavation
This work shall consist of the or rock as defined in Section 2 of
construction of surface drains, subsoil this Specification.
drains, pipe culverts, box culverts,
sumps and other drainage structures in 3.2.2.2 Granular Bedding Material
accordance with this Specification or
as directed by the S.O. Drainage works Granular bedding material for the
shall be constructed to the lines, levels, foundations of structures shall be
grades and cross-sections shown on the suitably graded broken rubble,
Drawings or as directed by the S.O. crushed stone, crushed gravel,
sand or other material as
specified on the Drawings or as
3.2 EXCAVATION AND required by the S.O.
BACKFILLING FOR DRAINAGE
WORKS 3.2.2.3 Concrete Bedding

3.2.1 Description Concrete bedding or blinding for


the foundations of structures shall
This work shall consist of excavation conform to the requirements of
for the construction of surface drains, Section 9 of this Specification
subsoil drains, cast in site box for the class of concrete specified
culverts, and other drainage on the Drawings or required by
structures, except pipe culverts, not the S.O.
otherwise provided for in this
Specification, and shall include 3.2.2.4 Ordinary Backfill Material
furnishing, placing, compacting and
shaping foundation bedding Ordinary backfill material shall
materials, backfilling excavations be suitable material as defined in
against completed structures with Section 2 of this Specification.
suitable material or granular backfill The maximum particle size of the
where specified, and the removal and backfill material shall be 50 mm.
disposal of all excess excavated
material, in accordance with this 3.2.2.5 Granular Backfill Material
Specification and as shown on the
Drawings and as required by the Granular backfill material shall
S.O. be sand, crushed stone, crushed
gravel or a mixture of crushed
Excavation and backfill for pipe and natural aggregates, shall be
culverts and precast box culverts essentially free from vegetative
shall be in accordance with the and other organic matter and clay,
provisions of Sub-Section 3.9. and shall not contain lateritic or
concretionary materials.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

The material shall conform to the 3.2.2.6 Concrete Backfill


following physical and
mechanical quality requirements:- Concrete backfill where
specified shall be of the
i) the fines shall be non-plastic; grade as shown on the
Drawings and shall con
ii) sand shall have a gradation form to Section 9 of this
conforming to the envelope Specification.
shown in Table 3.1;
TABLE 3.1 - GRADING LIMITS FOR SAND 3.2.3 Excavation
BACKFILL
The Contractor shall notify the S.O.
B.S. Sieve Size % Passing By Weight sufficiently in advance of the
beginning of any excavation so that
cross-section elevations and
10.0 mm 100 measurements may be taken of the
5.0 mm 90 - 100 undisturbed ground. The natural
1.18 mm 45 - 80 ground adjacent to the structure shall
not be disturbed without permission
300 um 10 - 30 of the S.O.
150 um 2 - 10
Trenches and foundation pits for
structures and structure footings and
iii) material other than sand shall underdrains shall be excavated to the
have a gradation conforming lines, grades and elevations shown
to one of the envelopes shown on the Drawings or as directed by
in Table 3.2. the S.O. Excavations must be kept
free from water and temporary
TABLE 3.2 - GRADING LIMITS FOR drains, sumps and pumps shall be
GRANULAR BACKFILL OTHER THAN provided when necessary. The rate of
SAND excavation and backfill shall be
approved by the S.O. The elevations
of the bottoms of footings shown on
B.S. % Passing By Weight the Drawings are approximate only
Sieve A B C and the S.O. may order in writing
Size such changes in the dimensions or
elevations of footings as may be
37.5mm 100 - - deemed necessary to secure a satis
28.0mm 70 –100 100 - factory foundation.
20.0mm 60 – 90 70 - 100 100
10.0mm 45 – 75 45 - 75 - Boulders, logs and other
5.0mm 30 – 60 35 - 65 45 – 75 objectionable materials encountered
2.0mm 20 – 50 25 - 50 30 – 60 in excavation shall be removed.
425um 10 – 30 10 - 30 15 – 35
75um 0–2 0–2 0–2 After each excavation is completed
the Contractor shall notify the S.O.
to that effect and no footing,
bedding material or structure shall be
placed until the S.O.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

to that effect and no footing, All excavated material, so far as


bedding material or structure shall be suitable, shall be utilized as backfill
placed until the S.O. has approved or embankment. The surplus
the depth of excavation and the material, whether or not temporarily
character of the foundation material. allowed to be placed within a stream
area, shall be finally disposed of in
Rock and other hard foundation such a manner as not to obstruct the
material shall be cleared of all loose stream nor otherwise impair the
material and cut to a firm surface, efficiency or appearance of the
either level or stepped or serrated, as works, nor is it to endanger the
specified or shown on the Drawings partly finished structure.
or directed by the S.O. All seams
and crevices shall be cleared out and Excavated material suitable for use
grouted with Portland cement grout as backfill may be deposited by the
at the time the footing is placed. Contractor in storage piles at points
convenient for rehandling of the
All loose and disintegrated rock and material during the backfilling
thin strata shall be removed. When operation.
the footing is to rest on material
other than rock, special care shall be Excavated material shall be
taken not to disturb the bottom of the deposited in such places and in such
excavation, and excavation to final a manner as not to cause damage to
grade shall be deferred until just highway, services or property either
before the footing is to be placed. within or outside the road reserve,
When, in the opinion of the S.O., the and so as to cause no impediment to
foundation material is soft or mucky the drainage of the Site or
or otherwise unsuitable, the surrounding area.
Contractor shall remove the
unsuitable material and insert 3.2.4 Backfilling with Ordinary or
foundation fill material or concrete Granular Backfill Material
as specified or shown on the
Drawings or directed by the S.O. If All spaces excavated under this
foundation fill material is required it Specification and not occupied by a
shall be placed and compacted in permanent structure shall be
layers not more than 150 mm thick backfilled. Backfill material shall be
or as directed by the S.O. The free from large lumps, wood and
degree of compaction shall be other extraneous material.
equivalent to that of the surrounding
foundations. Backfill not within the embankment
areas shall be placed in layers not
All excavation surfaces and surfaces more than 250 mm in depth
of backfill material against which (compacted measurement) and shall
concrete is to be placed shall be be compacted to a density
even and firm and true to line and comparable with the adjacent
level. undisturbed material.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

Backfill within the embankment Special care shall be taken to prevent


areas shall be made with approved any unduly high pressures against
material placed in uniform layers not the structures.
to exceed 150 mm in depth
(compacted measurement) and each The placing of embankment and the
layer shall be constructed in benching of slopes shall continue in
accordance with Section 2 of this such a manner that at all times there
Specification except that mechanical will be a horizontal berm of
tampers may be used for thoroughly compacted material for a
compaction. Each layer of backfill distance at least equal to the height
shall be wetted uniformly as of the abutment or wall to be back
necessary and compacted to the filled.
same requirements as the adjacent
earthwork as specified in Section 2 3.3 CHANNEL EXCAVATION
of this Specification. Unless
otherwise approved by the S.O., 3.3.1 Description
hand tamping will not be accepted.
This work shall consist of excavation
In placing backfill and embankment, for waterway channels both inside
the material shall be placed insofar and outside the road reserve as
as possible to approximately the shown on the Drawings or directed
same height on both sides of the by the S.O., and shall include all
structure. If conditions require required excavation for widening,
backfilling appreciably higher on one training or permanently diverting
side, the additional material on the rivers, streams and irrigation and
higher side shall not be placed until drainage channels other than drains
permission is given by the S.O. or and ditches appurtenant to the
until the S.O. is satisfied that the roadway, except excavation of top
structure has enough strength to soil for use in the Works and
withstand any pressure created. excavation required for clearing and
grubbing. This work shall also
Backfill for embankment shall not be include the backfilling of old
placed behind the walls of box channels, haulage to their points of
culverts until the top slab is placed utilization in the Works or the
for the required time and not less removal and disposal of all
than three days. Backfill and excavated materials, the construction
embankment behind abutments held of appurtenant bunds, dikes and
at the top by superstructure shall be berms, and the shaping and finishing
carried up simultaneously behind of all earthworks involved in the
opposite abutments and side walls. construction of channels in accor
dance with the required lines, levels,
No backfilling shall be placed grades and cross-sections.
against any structure until permission
shall have been given by the S.O. 3.3.2 Materials
Jetting of fill or other hydraulic
methods involving, or likely to Channel excavation shall be
involve, liquid or semi-liquid classified as common excavation or
pressure shall be prohibited. rock as specified in Section 2 of this
Specification.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

3.3.3 Construction Methods Sections of channel abandoned


owing to diversions shall be back
All suitable materials removed from filled as directed by the S.O.
channel excavations shall be used for
backfilling waterways to be
abandoned and constructing bunds, 3.4 SURFACE DRAINAGE
dikes and other earth appurtenances
as required. Surplus suitable 3.4.1 Surface Drainage Types
materials shall be used as far as is
practicable in constructing the Surface drains of the types shown on
roadway. The Contractor shall the Drawings shall be constructed to
provide borrow of satisfactory q the lines, levels, grades and cross-
quality and approved by the S.O. sections as specified or as directed
should this be necessary to complete by the S.O. Surface drains shall
the work. Borrow which is required include interceptor drains, roadside
to replace suitable excavated drains, embankment toe drains,
materials needed for construction shoulder drains, bench drains, berm
which the Contractor elects to waste drains, median drains, outfall drains,
shall not be paid for. cascade drains, etc.

Excavated unsuitable material, Any of the above drains may be


suitable material surplus to that constructed either unlined or lined
needed for construction and suitable using cast in situ concrete, precast or
material that the Contractor elects to porous concrete drain sections, or
waste, shall be disposed of at stone pitching.
designated areas in such a manner as
to present a neat appearance and not 3.4.2 Surface Drain Construction
obstruct flow in any channels,
ditches or drains, nor cause damage 3.4.2.1 Unlined Drains
to highway works or property, all to
the satisfaction of the S.O. Excavation for unlined drains
shall be trimmed to form a
During construction, channel smooth, firm surface to the
excavations shall be kept drained as required lines, levels, grades and
far as is practicable and the work cross-sections as shown on the
shall be carried out in a neat and Drawings or as required by the
workmanlike manner. S.O.

All channels and appurtenances shall Any areas of over excavation


be excavated and constructed to the shall be made good to the
lines, levels, grades and cross- satisfaction of the S.O., all at the
sections shown on the Drawings or Contractor's expense.
as directed by the S.O. Excavation
beyond the limits required shall not
be paid for and shall be backfilled at
the Contractor's expense as directed
by the S.O. should he deem it
necessary.

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3.4.2.2 Cast In Situ Concrete Drains Ready made precast concrete


drain sections may be used
Excavation shall be carried subject to the approval of the
out to the lines and levels as S.O. Samples of ready made
specified and as shown on the drain sections shall be submitted
Drawings. Templates which to the S.O. for his approval
may be of timber or steel shall before placing of orders.
then be provided to ensure the Notwithstanding any approval
thickness and shape of the given by the S.O., any defective
concrete drains. The concrete or broken drain section shall be
shall be poured in sections not replaced by the Contractor at his
exceeding 2 m in length and own expense before or after
shall be carried out between laying in position.
end forms in alternate bays.
Construction joints shall not Precast concrete drain sections
be formed in the inverts. shall be laid on concrete bedding
in trenches excavated to the lines
All concrete shall be grade and levels as specified and
20/20 concrete unless otherwise jointed to produce a neat even
specified and shall conform to the alignment and gradient. The joint
requirements of Section 9 of this shall be grouted with 1:3 cement
Specification. Weep holes shall mortar complying with Sub-
be cast in situ as shown on the Section 3.5.2.2 and weep holes
Drawings or as directed by the shall be provided as shown on the
S.O. Drawings or as directed by the
S.O.
3.4.2.3 Precast Concrete Drain
Sections Porous concrete shall comply
with the requirements of porous
Precast concrete block inverts concrete for pipes as described in
shall be of the shapes and M.S. 525. Cement and
dimensions as shown on the aggregates used in the
Drawings and shall be of manufacture of the porous
grade 20/20 concrete conforming concrete drain sections shall con
to the requirements of Section 9 form to the requirements of
of this Specification or of Section 9 of this Specification.
porous concrete unless otherwise
specified. The precast concrete Mass concrete for bases shall be
drain sections shall be of grade 10/25 concrete or as
manufactured using good quality specified and to the dimensions
moulds and the finished product and thicknesses as shown on the
shall be round and have smooth Drawings.
inside surfaces all to the approval
of the S.O. Ready made precast
concrete drain sections may be
used subject to the approval of
the S.O.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

3.5 STONE PITCHING 3.5.2.2 Cement Mortar

3.5.1 Description Cement mortar, unless otherwise


specified, shall contain 1 part
This work shall consist of the ordinary Portland cement to 3
construction of all structures or parts parts fine aggregate by volume.
of structures to be composed of stone Water shall be added to the mix
pitching either grouted or ungrouted to produce a suitable consistency
as shown on the Drawings or as for the intended use, all to the
directed by the S.O. including satisfaction of the S.O. The
erosion protection pavements and constituent materials of the
aprons, drain linings, culvert inlets mortar shall comply with the
and outlets, etc. The work shall be appropriate requirements of
carried out all in accordance with Section 9 of this Specification.
this Specification and to the lines,
levels, grades, dimensions and cross- The ingredients for mortar shall
sections shown on the Drawings and be measured in proper gauge
as required by the S.O. boxes and mixed on a clean
boarded platform or in an
3.5.2 Materials approved mechanical batch
mixer.
3.5.2.1 Stone
All mortar shall be used within
Stone shall be clean rough quarry 30 minutes of mixing and no
stone, or pit or river cobbles, or a reworking of mortar shall be
mixture of any of these materials, permitted thereafter.
and shall be essentially free from
dust, clay, vegetative matter and 3.5.3 Construction Methods
other deleterious materials.
Individual pieces of stone shall be 3.5.3.1 Grouted Stone Pitching
approximately cubical or
spherical and shall have least Prior to constructing grouted
dimensions in the range 100 to stone pitching, the surfaces
150 mm and a maximum against which it is to be placed
dimension of 250 mm, shall have been finished in
maximum, unless otherwise accordance with the appropriate
specified. The stone shall be provisions of this Specification.
hard, tough, durable and dense, Notwithstanding any earlier
resistant to the action of air and approval of these finished
water, and suitable in all respects surfaces, any damage to or
for the purpose intended. deterioration of them shall be
made good to the satisfaction of
the S.O. before grouted stone
pitching is placed.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

Construction of grouted stone building up the structure to full


pitching shall commence at the thickness is commenced on any
lowest part of each structure or section of the work, as the con
section of a structure and struction advances.
continue progressively upward.
Long structures such as drain The work shall be carried out and
linings and slope protection finished all to the satisfaction of
pavements shall be constructed in the S.O.
sections of practicable length, to
the satisfaction of the S.O. The 3.5.3.2 Ungrouted Stone Pitching
surface against which the work is
to be placed shall be moistened Where shown on the Drawings,
with clean water a little in ungrouted stone pitching shall be
advance of construction, and hand set to provide maximum
covered with a layer of cement interlocking effect. The stones,
mortar about 50 mm thick. the largest of which shall be used
Stones shall then be firmly set by at the bottom, shall be well
hand into the mortar, densely bedded on a 75 mm layer of
packed against adjacent stones gravel or aggregate rammed to an
and built up to form a stone even surface. The whole work
structure of more or less uniform shall be finished to the
thickness which shall nowhere be satisfaction of the S.O
less than 150 mm (measured per
pendicularly to the surface 3.6 GABIONS
covered). All the while that
stones are being placed, all voids 3.6.1 Description
in the structure shall be packed
solidly with mortar and stone This work shall consist of the
spalls; however the surfaces of construction of miscellaneous
stones in the exposed faces and erosion protection and retaining
edges shall not be covered with structures to be composed of stone
mortar. The exposed surfaces filled wire mesh gabions. The work
and edges of the structure shall be shall be carried out all in accordance
constructed such that they have with this Specification and as shown
as large a proportion as on the Drawings and/or as approved
practicable composed of stone by the S.O.
faces. Weep holes shall be
provided as shown on the 3.6.2 Materials
Drawings or as directed by the
S.O. 3.6.2.1 Wire Mesh Gabions

Mortar which has been mixed for Gabions shall be rectangular


more than 30 minutes shall not be baskets of the required
used in the works. Nor shall dimensions as shown on the
mortar be laid against the Drawings or ordered by the S.O.
supporting surface more than 2 Unless otherwise specified, they
minutes before pitching stone and shall be of the following standard
dimensions :-

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 61


FOR INTERNAL USE ONLY Standard Specification For Road Works

i) width - 1.00 metre; Gabion mesh shall be triple


twisted and shall have a uniform
ii) length - 1.00, 2.00 or 3.00 hexagonal pattern with openings
metres; of 100 x 120 mm or less. The
mesh shall be securely tied to
iii) height - 0.50 or 1.00 metre. selvage wires to form rectangular
panels which shall be securely
Gabions longer than 1.00 m shall wired together to form the
be divided into compartments of completed gabion baskets. The
equal length not exceeding 1.00 ties and connections for each
m by wire mesh diaphragms gabion basket shall comprise not
securely tied along all edges. less than 8% of its total weight,
Each gabion or compartment of a and the fabrication shall be all to
gabion shall be provided with at the satisfaction of the S.O.
least 4 cross-connecting wires if
its height is 0.50 m or less, and 3.6.2.2 Polyvinyl Chloride Coating
with at least 8 cross-connecting
wires if its height is in the range When specified on the Drawings,
0.50 to 1.00 metre. all wire used in the fabrication of
gabions and in the wiring
Gabions shall be fabricated from operation during construction
steel wire manufactured in shall, after galvanising, have
accordance with B.S. 1052 and extruded on to it a coating of
galvanised in accordance with polyvinyl chloride (PVC). The
M.S. 407, or such similar PVC coating, not inclusive of
standards as the S.O. shall galvanising, shall nowhere be less
approve. The galvanised wire than 0.55 mm in thickness.
sizes used shall be in accordance
with Table 3.3. 3.6.2.3 Stone

TABLE 3.3 - GALVANISED WIRE SIZES Stone fill for gabions shall be
FOR GABIONS clean rough quarry stone, or pit
or river cobbles, or a mixture of
any of these materials, and shall
be essentially free from dust,
Type of Wire Minimum Diameter
clay, vegetative matter and other
deleterious materials. Individual
pieces of stone shall have least
Selvage (perimeter) wire 3.50 mm dimensions not less than 20 mm
larger than the gabion mesh
openings and greatest dimensions
Mesh wire 2.70 mm not more than 250 mm. The stone
shall be hard, tough, durable and
Tying and connecting 2.20 mm dense, resistant to the action of
air and water, and suitable in all
wire aspects for the purpose intended.
The material shall be approved
by the S.O.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

3.6.3 Construction Methods 3.7 BRICKWORK

Prior to placing gabions, the surface 3.7.1 Description


on and against which they are to be
constructed shall have been prepared This work shall include the laying of
and finished in accordance with the brickwork to the lines, levels and
relevant provisions of the appropriate grades shown on the Drawings
Sections of this Specification. and/or as directed by the S.O.
Notwithstanding any earlier approval
of these finished surfaces, any 3.7.2 Materials
damage to or deterioration of them
shall be made good to the 3.7.2.1 Common Bricks
satisfaction of the S.O. before
gabions are placed. Common bricks shall be sound,
hard, well burnt, of proper size
Each gabion basket shall be put in and clean and shall give a clear
place in its turn, completely ring when struck. They shall be
fabricated except for the fastening Class 3 standard format
down of the lid, stretched to the complying with the requirements
correct shape and dimensions, and of M.S. 76. Bricks shall be
fastened securely to all contiguous obtained from manufacturers
baskets along each edge with tying approved by the S.O.
wire. The basket shall then be tightly
packed with approved stone by hand 3.7.2.2 Cement Mortar
in such a manner that voids are kept
to a practicable minimum and are Cement mortar for brickwork
uniformly distributed in the stone shall comply with the
mass. Finally, the lid of the basket requirements of Sub-Section
shall be securely fastened down with 3.5.2.2.
tying wire along all hitherto
unfastened edges, all to the 3.7.3 Construction Methods
satisfaction of the S.O. In no case
shall the weight of the finished 3.7.3.1 Brick Laying
gabion be less than 1300 kg
per cubic metre. Brickwork shall be executed with
cement mortar and shall be of the
As a gabion structure is built up, thickness and bonds as shown on
backfilling against finished gabions the Drawings. Bricks shall be
shall be carried out as necessary for kept damp until used and shall be
proper progressive construction, all laid on a full bed of mortar. The
in accordance with the relevant brickwork shall be true to line
provisions of the appropriate and plumb, and courses shall be
Sections of this Specification. Unless kept truly level. The thickness of
otherwise specified, vertical joints mortar joints shall not exceed 10
between gabions shall be staggered mm and shall be such that 4
in gabion structures in a pattern courses of brickwork forms a
similar to the joints in running bond height of 300 mm.
brickwork.

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FOR INTERNAL USE ONLY Standard Specification For Road Works

Newly laid brickwork shall be 3.8 SUBSOIL DRAINS


protected from the harmful
effects of sunshine, rain, running 3.8.1 Description
and surface water and shocks.
Any brickwork that is damaged This work shall include the supply
shall be taken down and rebuilt and installation of subsoil drains
and the joints raked out and constructed in accordance with this
pointed as directed by the S.O. Specification at the locations and in
Any such remedial work shall be accordance with the lines, levels and
at the Contractor's own expense. grades as shown on the Drawings
and/or as directed by the S.O.
3.7.3.2 Plastering Brickwork
3.8.2 Materials
All exposed brickwork surfaces
shall be plastered. The plaster 3.8.2.1 Pipes
shall be applied in 2 coats
generally to a total thickness of Porous concrete pipes for subsoil
20 mm and shall be finished with drains shall comply with M.S.
a steel trowel for internal surfaces 525.
and with a wooden float for
external surfaces. Clay pipes for subsoil drains shall
comply with B.S. 1196.
Plain plaster shall consist of 1
part masonry cement complying Polyvinyl Chloride (PVC) pipes
with M.S. 794 to 3 parts of sand for subsoil drains shall comply
by volume. where ordinary with Australian Standard
portland cement is used, Specification 2439 or B.S. 3656.
plasticiser of a type approved by
the S.O. may be added to the mix 3.8.2.2 Filter Material
in accordance with the
manufacturer's instructions. Filter material used in the
construction of subsoil drains
Ordinary Portland cement and shall consist of hard, clean sand
water shall comply with the conforming to the grading limits
appropriate requirements of given in Table 3.4. The material
Section 9 of this Specification. passing the 425 um sieve shall be
non-plastic when tested in
Weep holes shall be provided as accordance with B.S. 1377.
shown on the Drawings or as
directed by the S.O. TABLE 3.4 - GRADING LIMITS FOR
FILTER MATERIAL

B.S. Sieve % Passing By


Size Weight

10.0mm 100
5.0mm 90 - 100
2.36mm 75 - 100
1.18mm 55 - 90
600um 35 - 59
300um 8 - 30
150um 0 - 10

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3.8.2.3 Filter Cloth (c) Filtration Requirement

The synthetic filter cloth shall be Equivalent opening size of the


a non-woven type of approved filter cloth determined by sieving
manufacture having the following as described in ASTM D422 shall
properties :- be less than the eighty-five
percentage size of the adjacent
(a) Chemical Composition soil.
Requirements
(d) Permeability Requirement
Fibres used in the manufacture of
the engineering fabric shall The equivalent Darcy
consist of a long chain synthetic Permeability of the filter cloth
polymer, composed of at least shall be greater than 10 times
85% by weight of the Darcy Permeability of the
polypropylene, -ethylene, - soil to be drained.
esteramide or -vinylidene
chloride and shall contain 3.8.2.4 Cement Mortar
stabilisers and/or inhibitors added
to the base plastic (as necessary) 1:3 cement mortar for use in pipe
to make the fabric resistant to joints shall comply with Sub-
deterioration from ultraviolet and Section 3.5.2.2.
heat exposure.
3.8.3 Construction Methods
(b) Physical Property
Requirements Excavation for subsoil drains shall
be carried out all in accordance with
The physical properties of the the appropriate provisions of Sub-
filter cloth shall comply with Section 3.2.
Table 3.5.
Filter material as described in Sub-
TABLE 3.5 - PHYSICAL PROPERTY Section 3.8.2.2 above shall be placed
REQUIREMENTS FOR FILTER CLOTH and uniformly compacted by a
suitable method approved by the
S.O. to form a firm, even bedding for
Grab Strength 0.9 kN the pipe drain as shown on the
Drawings.
(ASTM D1682)
The pipe sections shall be set firmly
Puncture Strength 0.4 kN against the filter material bedding
(ASTM D3787 - 80a) with the flow lines in the design
position. For pipes with mating
joints, the receiving ends shall be
Burst Strength 2100 kN/sq.m upgrade, and the pipe joints shall be
(ASTM D3786 - 80a) fully mated. For butt jointed pipes
with collars, the pipe sections shall
be fully contiguous, and the collars
properly centred over the joints.

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Joints shall be spot mortared as 3.9.2 Materials


necessary to hold the pipe sections
correctly centred and aligned, but not 3.9.2.1 Pipes
so as to unduly restrict the infiltration
of water through the joints. Reinforced concrete pipes shall
conform to the requirements of
Slotted or perforated pipes shall be M.S. 881 and shall be supplied
tightly wrapped in filter cloth such by manufacturers approved by
that the entire length of the mortared the S.O.
pipe is covered by at least 2 layers of
cloth. All joints in both layers shall Rebated pipes of diameter 600
have an overlap of at least 100 mm mm and above shall be internally
and joints in the outer layer shall be rebated.
offset by at least 300 mm from joints
in the inner layer, all to the Collars shall be precast with
satisfaction of the S.O. grade 25 concrete and shall be
suitably reinforced all
After pipe laying and, if appropriate, in accordance with Section 9 of
wrapping has been approved by the this Specification. The width of
S.O., the remainder of the filter the collar shall be not less than
material shall be placed and 150 mm and the minimum
uniformly compacted by a suitable thickness shall be 50 mm.
method approved by the S.O. to
form a dense, even surround to the Rubber rings for spigot and
pipe as shown on the Drawings. Care socket pipes shall comply with
shall be taken that the pipe is neither the requirements of Type 2 as
damaged nor displaced. specified in B.S. 2494.

Backfill shall then be placed and 3.9.2.2 Cement Mortar


compacted in accordance with the
appropriate provisions of Sub- 1:3 cement mortar for jointing of
Section 3.2.4. reinforced concrete pipes shall
conform to the requirements of
3.9 R.C. PIPE CULVERTS Sub-Section 3.5.2.2.

3.9.1 Description 3.9.2.3 Bedding Material

This work shall comprise the supply Type A bedding shall consist of
and installation of reinforced grade 20/20 concrete complying
concrete pipe culverts, inclusive of with Section 9 of this
excavation, backfilling, jointing, Specification.
bedding, construction of headwalls,
wingwalls, aprons and sumps and Type B bedding shall consist of
channel protection works, all in clean, natural sand or gravelly
accordance with this Specification sand of suitable gradation and
and the details shown on the quality, approved by the S.O.
Drawings. The material shall have a
maximum particle size of not
more than 12 mm.

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3.9.3 Excavation and Backfilling for R.C. Where rock or other hard
Pipe Culverts unyielding foundation
material is encountered in the
3.9.3.1 Excavation trench, it shall be excavated to
a depth below the bottom of
(a) General pipe design levels of at least
300 mm or 12.5 mm per 300
Unless otherwise directed by mm of fill to be placed over
the S.O., prior to construction the top of the pipe, whichever
of a pipe culvert, the earth is greater, up to a maximum
works at the required location of 75% of the internal
shall have been constructed diameter of the pipe. The
to a level at least 600 mm hard material so excavated
above the top of culvert shall be replaced with suitable
design levels or to the top of material uniformly compacted
subgrade levels, whichever is in layers of not more than 150
lower. mm compacted thickness to
provide satisfactory support
Pipe culverts specified to be for the pipe, all to the
constructed in trench satisfaction of the S.O.
conditions shall be excavated
in accordance with Sub- (c) Open Ground Method
Section 3.9.3.1 (b) below.
Where existing ground levels
Where drainage conditions or are above top of bedding
other circumstances so material design levels and
require, the S.O. may direct firm foundation materials are
the Contractor to construct the encountered, excavation and
pipe culvert without first foundation preparation shall
constructing the earthworks to be similar to that described
the level specified above, in in the trench method above.
which case excavation and Otherwise a firm foundation
foundation preparation shall plane shall be prepared, which
be in accordance with Sub- shall be essentially free
Section 3.9.3.1 (c) below. draining along the line of the
culvert, by trimming the
(b) Trench Method existing ground, or such fill as
it is necessary to place and
The trench to receive a culvert compact, over a width
pipe shall be of sufficient sufficient to permit
width and depth to enable the satisfactory construction of
placing of bedding material the pipe bedding, all to the
and construction of pipe joints satisfaction of the S.O. Hard
in accordance with this materials shall be excavated
Specification, and the bottom from the pipe foundation over
of the trench shall be trimmed a width equal to the outside
to a suitably smooth plane diameter of the pipe to the
surface which shall be kept same depth as specified in the
free from water, all to the trench method, and shall be
satisfaction of the S.O. replaced with suitable

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material uniformly compacted Heavy plant and equipment shall


in layers of not more than 150 not operate within 1.5 m of any
mm compacted thickness to pipe culvert until backfilling and,
provide satisfactory support where appropriate, pavement
for the pipe, all to the construction has advanced to a
satisfaction of the S.O. stage which provides at least 600
mm of cover to the culvert.
Where soft or unstable soil is Subject to the approval of the
encountered in the foundation, S.O., light compaction equipment
it shall be excavated over a may be operated above pipe
width of at least 1.5 times the culverts after a minimum of 300
outside diameter of the pipe mm of cover has been placed and
on each side of the culvert compacted.
centre-line to the depth
directed by the S.O., and 3.9.4 Installation of R.C. Pipe Culverts
replaced with suitable
material uniformly 3.9.4.1 General
compacted in layers of not
more than 150 mm The type, size and class of pipe to
compacted thickness to be installed at each location shall
provide satisfactory support be as shown on the Drawings or
for the pipe, all to the as directed by the S.O. Culverts
satisfaction of the S.O. shall not be installed at any
location until the type of pipe, the
3.9.3.2 Backfilling exact location, the lines, levels
and grades, the length of pipe and
Backfilling against reinforced details of inlet and outlet
concrete pipe culverts and their structures have been confirmed
appurtenant structures shall be by the S.O. In addition, special
carried out in accordance with the requirements recommended by
construction methods described the manufacturer with respect to
in Sub-Section 3.2.4, using assembly and installation shall be
material conforming to the complied with.
requirements of Sub-Section
3.2.2.5. Special care shall be Especially where elliptically
taken to properly compact reinforced pipe sections are used,
backfill against the undersides of care shall be taken to ensure that
culvert pipes without disturbing the loading axes are positioned
or damaging the pipes and joints. exactly vertically.
Backfill shall be built up evenly
on both sides of each pipe culvert 3.9.4.2 Butt Ended Pipe Culverts with
along its entire length. Precast Concrete Collars

The pipes shall be laid on Type A


bedding in conformity with the
dimensions shown on the
Drawings. Before placing any
concrete bedding, the pipes shall
be assembled complete with
precast concrete collars to the

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correct levels and grades on precast Following pipe assembly and


concrete spacing blocks of the same mortaring up as above, the
class of concrete as the bedding remainder of the cradle shall be
material and of sufficient size to cast monolithically, all to the
eliminate any risk of settlement of satisfaction of the S.O.
the pipes before or during
concreting. Where vertical construction joints
in the concrete cradle are
All joints shall be fully mortared unavoidable due to circumstances
with 1:3 cement mortar before on Site, transfer bars shall be
concreting of the cradle, all to the provided to the satisfaction of the
satisfaction of the S.O. The concrete S.O.
cradle shall be cast as one monolithic
unit. Alternatively, part of the Special care shall be taken when
concrete cradle below the underside placing the concrete cradle to
of the pipe may be constructed avoid the entrapment of air
monolithically at least 24 hours underneath the pipe. To
before the assembly and mortaring eliminate this possibility,
up of the pipe sections and collars, concrete shall be placed to one
on condition that shear connectors side of the pipe only until such
are provided across horizontal time as the level of the concrete
construction joints to the satisfaction surface rises above the underside
of the S.O. of the pipe on the side remote
from that on which concrete is
During installation, the ends of the being placed. The concrete shall
pipes shall be butted and the collar then be brought up at the same
centred about the joint using wedges level on both sides of the pipe.
or other approved means. The
annular shall be completely filled 3.9.4.3 Rebated Pipe Culverts
with 1:3 cement mortar with only
sufficient water added to ensure The pipes shall be laid on Type A
adequate workability and the wedges bedding in conformity with the
removed before finally fairing the dimensions shown on the
joint. Special care shall be taken to Drawings.
ensure that excess cement mortar is
neatly cleaned off. For pipes over The method of construction shall
900 mm in diameter the jointing follow that described in Sub-
space shall be filled from inside the Section 3.9.4.2 for butt ended
pipe after completion of pipe culverts except for the
embankment construction using 1:3 exclusion of precast concrete
cement mortar. When installed, the collars.
clearance between the outer
diameter of pipe and the inner The rebated joint shall be
diameter of collar shall be at least internally flush and fully
20 mm. mortared with 1:3 cement mortar,
all to the satisfaction of the S.O.

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3.9.4.4 Spigot and Socket Pipe Culverts Care shall be taken to see that the
rubber ring is adequately
The pipes shall be laid on Type compressed to seal the joint. All
B bedding in conformity with the pipes shall be laid to the
dimensions shown on the satisfaction of the S.O.
Drawings. The bedding material
shall be accurately shaped by a 3.10 CORRUGATED METAL PIPE
template to fit the lower part of CULVERTS
the pipe exterior for a height of at
least 10% of the outside diameter 3.10.1 Description
of the pipe. Gaps shall be left in
the bedding material and recesses This work shall comprise the supply
dug in the earth foundation of and installation of bolted, corrugated
sufficient width and depth to metal pipe culverts inclusive of
accomodate the socket without it excavation, backfilling, jointing,
resting on the bottom of the bedding, construction of headwalls,
recess. The widths of the wingwalls, aprons and sumps and
recesses in the foundation and the channel protection works, all in
bedding shall both exceed the accordance with this Specification
width of the socket by more than and the details shown on the
50 mm. Drawings.

Jointing of the pipes shall be 3.10.2 Materials


carried out strictly in accordance
with the manufacturer's recom 3.10.2.1 Pipes
mendations, all to the satisfaction
of the S.O. The pipe sections shall be
fabricated from zinc-coated
Concrete pipes as specified above (galvanised) steel sheets
shall be laid true to line and level, conforming to AASHTO M218
each pipe being separately boned or from structural plates
between sight rails. Pipes shall conforming to AASHTO M167
be laid in an upstream direction depending on the pipe size
with the sockets towards the inlet requirements.
and shall rest on even
foundations for the full length of The dimensions of the pipes shall
the barrel. Rubber ring joints conform to AASHTO M36. All
shall be installed strictly in pipes shall be clearly identified
accordance with the by marking on each section the
manufacturer's instructions. Prior following information :-
to jointing, rubber rings and
jointing surfaces shall be cleaned i) name of manufacturer;
of all contaminants except for ii) diameter of pipe;
specified lubricants. The spigot iii) gauge number;
of each pipe shall be inserted iv) date of manufacture.
concentrically in the socket of the
one previously laid, and the pipe The above markings shall have
then adjusted and fixed in its been marked by the
correct position with the spigot manufacturer.
correctly entered in the socket.

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The Contractor shall submit to For pipe material conforming to


the S.O. the material test AASHTO M218 (corrugation 68
certificates from the manufacturer mm pitch x 13 mm depth) with
showing the chemical diameters of 1500 mm or smaller,
composition and mechanical 12 mm diameter bolts shall be
properties of the base metal and used. Bolt holes along
the amount of zinc coating for circumferential seams shall have
every lot of pipes supplied. The spacings of not more than 314
S.O. may order further tests in the mm.
sections supplied to Site at the
rate of not more than 1 in 100. For pipe material conforming to
AASHTO M167 (corrugation
All costs on such tests shall be 150 mm pitch x 50 mm depth)
borne by the Contractor. with diameters of 1500 mm or
larger, 19 mm diameter bolts
3.10.2.2 Bitumen Coating shall be used. Four bolt holes per
300 mm of longitudinal seam
Where specified, the pipe shall be provided and these shall
sections or plates shall be coated be staggered in rows 51 mm a
with an approved bitumen apart with holes in one row in the
coating at the factory by the hot- trough and holes in the other row
dip process for Type A as in the crest of the corrugation.
specified in AASHTO M190. Bolt holes in the circumferential
Before coating, any damage to seams shall have spacings of not
the galvanising shall be made more than 254 mm.
good in a manner approved by
the S.O. Notwithstanding the above, the
Contractor shall satisfy the S.O.
3.10.2.3 Bolts and Nuts as to the adequacy of all bolted
connections.
All bolts and nuts shall be of high
strength carbonated steel meeting 3.10.2.4 Cement Mortar
the provisions of ASTM A449
and ASTM A563 Grade `C' 1:3 cement mortar shall comply
respectively. The galvanising on with the requirements of Sub-
bolts and nuts must meet the Section 3.5.2.2.
requirements of ASTM A153.
3.10.2.5 Bedding Material
Diameters of bolt holes in the
longitudinal seams, except those Corrugated metal pipe culverts
at the plate corners, shall not shall be bedded on Type B
exceed the bolt diameter by more bedding as specified in Sub-
than 3 mm. The bolt holes in the Section 3.9.2.3.
circumferential seams, including
those at the plate corners, shall
not exceed the bolt diameter by
more than 6 mm. The minimum
distance from the centre of a hole
to the edge of a plate shall be
1.75 times the diameter of the
bolt.
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FOR INTERNAL USE ONLY Standard Specification For Road Works

3.10.3 Excavation and Backfilling for placed along the entire length
Corrugated Metal Pipe Culverts of the culvert. The lining
shall be constructed after
Unless otherwise directed and/or completion of earthworks and
approved by the S.O., the pipe wingwalls.
culvert shall be laid in a trench
excavated in accordance with 3.11 PRECAST BOX CULVERTS
Sub-Section 3.9.3.1 (b).
3.11.1 Description
Where the open ground method
is approved, the work shall This work shall comprise the supply
comply with Sub-Section and installation of precast box
3.9.3.1 (c). culverts inclusive of excavation,
backfilling, jointing, bedding,
3.10.4 Installation of Corrugated Metal construction of headwalls,
Pipe Culverts wingwalls, aprons and sumps and
channel protection works, all in
3.10.4.1 General accordance with this Specification
and the details shown on the
The culvert sections shall be Drawings.
assembled, strutted, and
protected during construction 3.11.2 Materials
in accordance with the
manufacturer's instructions. 3.11.2.1 Precast Box Culverts
Special attention shall be
given to the sequence of Precast box culverts shall be of
tightening bolts and the approved manufacture complying
specified torque to be applied with Australian Standard
during assembly. After Specification 1597 Part 1, or any
assembly the bitumen coating equivalent alternative standard
shall, where damaged, be acceptable and approved by the
repaired and made good with S.O.
further application of the
bitumen coating. 3.11.2.2 Cement Mortar

1:3 cement mortar for jointing of


3.10.4.2 Mortar Lining precast box culvert sections shall
conform to the requirements of
For corrugated metal pipe Sub-Section 3.5.2.2.
culverts of 1800 mm diameter
or more, or where directed by 3.11.2.3 Bedding Material
the S.O. for pipes of smaller
diameters, a 1:3 cement Precast box culverts shall be
mortar lining shall cover the bedded on Type B bedding as
inverts of the pipes to a specified in Sub-Section 3.9.2.3.
thickness of 25 mm above the
crest of the corrugations over
a minimum of one third of the
circumference centrally

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3.11.3 Excavation and Backfilling Backfill shall be built up


evenly on both sides of each
3.11.3.1 Excavation for Precast Box box culvert along its entire
Culverts length.

Unless otherwise directed by Unless otherwise approved by


the S.O., prior to construction the S.O., heavy plant and
of a precast box culvert, the equipment shall not operate
earthworks at the required within 2.0 m of any precast
location shall have been box culvert until backfilling
first constructed to a level at and, where appropriate,
least 600 mm above the top pavement construction has
of the culvert design levels or advanced to a stage which
to the top of subgrade levels, provides at least 300 mm of
whichever is lower, and the cover to the culvert.
precast box culvert shall then
be constructed in a trench 3.11.4 Installation of Precast Box
excavated in accordance with Culverts
Sub-Section 3.9.3.1 (b).
The type and size of precast box
Where drainage conditions or culvert to be installed at each
other circumstances so location shall be as shown on the
require, the S.O. may direct Drawings or as directed by the
the Contractor to construct S.O. Precast box culverts shall
the precast box culvert not be installed at any location
without first constructing the until the exact location, the lines,
earthworks to the level levels and grades, the length of
specified above, in which culvert and details of inlet and
case excavation and outlet structures have been con
foundation preparation shall firmed by the S.O. In addition,
be in accordance with Sub- special requirements
Section 3.9.3.1 (c). recommended by the
manufacturer shall be complied
3.11.3.2 Backfilling with.

Backfilling against precast Precast box culverts shall be


box culverts and their laid on Type B bedding as
appurtenant structures shall specified in Sub-Section 3.9.4 in
be carried out in accordance conformity with the dimensions
with the construction shown on the Drawings. Where
methods described in Sub- specified on the Drawings or
Section 3.2.4, using material directed by the S.O., Type B
conforming to the bedding shall be laid on a layer of
requirements of Sub-Section crushed aggregate of maximum
3.2.2.5. Special care shall be particle size not exceeding 50
taken to properly compact mm.
backfill without disturbing or
damaging the precast box
culvert sections.

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All joints shall be fully mortared 3.12.2 Extension of Box Culverts


with 1:3 cement mortar, all to the
satisfaction of the S.O. In The existing wingwalls, aprons
addition, a 3 mm layer of 1:3 and concrete bedding shall be
cement mortar shall be spread on demolished wherever indicated
top of the legs of the invert in on the Drawings to expose the
order to ensure uniform bearing existing box culvert on the side(s)
between the invert and lid. to be extended. The end of the
existing box culvert to be
Lifting holes shall be filled with extended shall then be wire-
1:3 cement mortar. brushed or some other means
employed to give a clean sur
face.Extension joints shall be
3.12 EXTENSION OF CULVERTS formed as shown on the
Drawings by injecting Thioflex
600 - Gun Grade (manufactured
3.12.1 Extension of Pipe Culverts by Expandite) or its equivalent to
a thickness of not less than 25
The existing wingwalls, aprons and mm in the 15 mm wide gap
concrete bedding shall be between the existing box culvert
demolished wherever indicated on and the new box culvert section.
the Drawings to expose the existing The remaining space in the gap
pipe culvert on the side(s) to be shall then be filled with Flexcell
extended. The end of the existing Expansion Filler.
pipe culvert to be extended shall then
be wire-brushed or some other Bakau piles shall be installed as
means employed to give a clean pipe shown on the Drawings, unless
end. otherwise directed by the S.O.

Extension joints shall be formed as


shown on the Drawings by injecting
Thioflex 600 - Gun Grade
(manufactured by Expandite) or its
equivalent to a thickness of not less
than 25 mm in the 15 mm wide gap
between the existing pipe and the
new pipe. The remaining space in
the gap shall then be filled with
Flexcell Expansion Filler.

Bakau piles shall be installed as


shown on the Drawings, unless
otherwise directed by the S.O.

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 74

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