SECTION 7.1 : SUBBASE AND SUBBALLAST1 General1.1 Scope1.1.1 This Section specifies the furnishing, installation and compaction of subbase for roads and other paved areas, and for subballast of all running tracks, loops and sidings of the railway on a prepared and accepted subgrade in accordance with these Specifications, and the lines, levels, grades, dimensions and cross sections shown on the Drawings and as required by the Employer’s Representative.1.1.2 This work shall also include, if specified in the Contract, construction of a sand layer cushion in conjunction with concrete pavement construction to the thicknesses and dimensions shown on the typical cross-section.2 Materials2.1 General2.1.1 “Particle Size Distribution Curves” shall show a well graded material with a distribution curve approximately parallel to the curves for the grading limits. Materials not showing a graded particle size distribution curve will not be accepted.2.1.2 Simultaneous supply from more than one source shall not be allowed.2.1.3 Non complying material shall not be used in the Works and shall be removed from the Site at the Contractor’s expenses.2.2 Properties2.2.1 Material for subbase shall be the type indicated on the Drawings. If no type is indicated, the Contractor may select material of Type I or Type II as described below, according to the conditions of use.2.2.2 The subballast is required to provide a filter medium which is less permeable than the ballast but more permeable than the subgrade. The subballast is also required to withstand and spread the static and dynamic track loads without appreciable deteriorations. 2.2.3 The general characteristics required of the subbase or subballast are:- bearing strength CBR > 25% when tested in accordance with AASHTO Test Method T193.- with compaction 98% of modified procter density, as determined by AASHTO Test Method T180.2.2.4 The grading of the subballast shall approximate to the following rules:- D15 (subballast) - D50 (subballast) Additionally, where drainage of water from the subgrade is anticipated:- D15 (subballast) (where Dn is the particle size for which a percent by weight is finer)2.2.5 The material used for a sand cushion underneath a concrete pavement shall be coarse sand having hard and durable particles without any clay lumps or deleterious material. The percentage by weight passing the 3/8 inch sieve shall be 100% and that the passing the 200 sieve shall not exceed 10%.2.3 Type I MaterialsShall consist of naturally occurring sand or gravels, free from vegetable matter and excess clay and other deleterious matter and shall meet the following requirements.(1) The grading shall conform to grading envelopes A, B, C or D in Table 7.1-1. The fraction passing the No.200 sieve shall be not greater than 2/3 of the fraction passing the No.40 sieve.(2) The portion of aggregate passing the No.40 sieve shall, if it is plastic, have a Liquid Limit not greater than 25% and a Plasticity Index not greater than 6% for subbase under rigid pavements and railway tracks and a Liquid Limit not greater than 35% and a Plasticity Index not greater than 11% for subbase under flexible pavement.(3) The coarse part of the material sampled and tested in accordance with AASHTO Test Method T96 or equivalent shall have a percentage of wear not greater than 50%.(4) The materials shall consist of sound durable particles which do not breakdown under compaction or repeated wetting/drying cycles.(5) In certain case, the Employer’s Representative approval may be given to gradings outside the limits specified in Table 7.1-1.2.4 Type II Materials2.4.1 Shall be material having the same characteristic as Type I except that the grading shall be D, E or F and the Liquid Limit and Plasticity Index shall be limited to 25% and 6% respectively, regardless of the use as subbase or subballast.2.4.2 There will be no requirement for the percentage of wear given by AASHTO Test Method T96.Table 7.1-1 Particle Size Distribution for Subbase and Subballast MaterialsSieve Designation Percentage by Weight Passing Square Mesh Sieves GradingA GradingB GradingC GradingD GradingE GradingF2 inch 100 100 – – – –1 inch – 75 – 95 100 100 100 1003/8 inch 30 – 65 40 – 75 50 – 85 60 – 100 – –No. 10 15 – 40 20 – 45 25 – 50 40 – 70 40 – 100 55 – 100No. 40 8 – 20 15 – 30 25 – 45 20 – 50 30 – 70 40 – 100No.200 2 – 8 5 – 20 5 – 15 5 – 20 6 – 20 8 – 253 Execution3.1 Construction Methods3.1.1 General(1) Work shall be performed in accordance with these Specifications, and the lines, levels, grade, dimensions and cross sections show on the Drawings and as required by the Employer’s Representative.(2) The subbase and subballast shall extend to the side slopes and shall, after compaction and completion, be of the thickness shown on the Drawings and as directed by the Employer’s Representative with due allowances being made for the construction of shoulders as shown on the Drawings and as directed by the Employer’s Representative.(3) The subballast should be placed onto the compacted and shaped subgrade immediately before the placing of the ballast and track. 3.1.2 Preparation of Subgrade(1) Before construction of subbase or subballast is commenced, the subgrade or existing surface shall be shaped and compacted in conformity with the provisions of SECTION 2.6 : EMBANKMENT.(2) Notwithstanding any earlier approval of subgrade, any damage to or deterioration of subgrade shall be made good before subbase is laid.3.1.3 Spreading Subbase and SubballastSubbase or subballast shall be spread in layers, with uncompacted thickness up to 250 mm, and the layers shall be as nearly equal in thickness as possible. Care shall be taken to prevent segregation into fine and coarse materials. Patches or pockets of fine material shall be removed and made good at the Contractor’s own expense.3.1.4 Sprinkling, Rolling and Compacting(1) Immediately after each layer has been spread and shaped satisfactorily, each layer shall be thoroughly compacted with suitable and adequate compaction equipment approved by the Employer’s Representative.(2) Rolling operations shall begin from the outer edge of road bed toward the center, gradually in a longitudinal direction; except on superelevated curves, while rolling shall begin at the low side and progress toward the high side. Subbase or subballast of sandy material shall be compacted by use of vibrating equipment.(3) During construction of subbase or subballast, the Contractor shall take all necessary precautions to ensure that the layers are efficiently drained.(4) The subbase shall be compacted to at least 98% of modified procter density as determined by AASHTO Test Method T180. The in-place dry density shall be tested in accordance with AASHTO Test Method T191. One density determination shall be made for each 500 m2, or less, on each layer of compacted subbase.(5) Material which does not contain sufficient moisture to be compacted in accordance with the requirements of this Section shall have water added to produce the required moisture content so that proper compaction can be achieved. The Contractor shall supply the necessary water at his own cost.(6) Material containing excess moisture shall be dried prior to or during compaction to the required moisture content so that proper compaction can be achieved. Drying of wet material shall be performed by methods approved by the Employer’ Representative, at the expense of the Contractor. 3.1.5 Surface Tolerances(1) Railway Formation AreasThe finished subballast surface shall at no point deviate more than 15 mm from the designed surface level and the design shape and drainage falls must be constructed correctly.(2) Road SubbaseThe finished subbase shall not vary more than 15 mm above or below the planned grade at any point. The thickness of the finished subbase shall be on average not less than the required thickness and not thinner than 15 mm less than the required thickness at any point. The average of 5 thickness measurements in any 100 m of road shall be not thinner than 10 mm less than the required thickness. Subbase which does not conform to the above requirements shall be reworked, watered, and throughly recompacted to conform at the expense of the Contractor.3.1.6 SamplingSuitable samples of the sources of subbase materials shall be submitted to the Employer’s Representative not less than 30 days before commencing the construction and additional samples shall be furnished during construction, as required, upon request. Method for obtaining material for tests shall conform to the requirements of the Employer’s Representative. The Employer’s Representative reserves the right to test the gradation of the material after compaction to ensure compliance. Materials rejected on this basis shall be removed and replaced at the expense of the Contractor.3.1.7 Repair of Defects(1) Work exceeding thickness tolerances shall be reduced to within tolerance by approved methods.(2) Work less than design tolerance shall be built up by approved methods to within conforming requirements.3.1.8 MaintenanceAfter construction is completed the subbase shall be maintained throughout except where portions of the succeeding course are under construction thereon. Maintenance shall include drainage, rolling, shaping, and watering as necessary to maintain the course in proper condition. Deficiencies in thickness, composition, construction, smoothness or density which develop during the maintenance shall be corrected to conform to the requirements specified above. Sufficient moisture shall be maintained at the surface to prevent a dusty condition, by light sprinkling with water.END OF SECTION
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