(JKR/SPJ/1998)

SECTION 3 DRAINAGE
3.1

GENERAL
This work shall consist of the construction of surface drains, subsoil drains, pipe culvert, box
culvert, sumps and other drainage structures in accordance with this Specification or as
directed by the S.O. Drainage works shall be constructed to the lines, levels, grades and
cross-sections shown on the Drawings or as directed by the S.O.

3.2

EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS

3.2.1

Description
This work shall consist of excavation for the construction of surface drains, subsoil drains,
cast in situ box culverts, and other drainage structure, except pipe culverts, not otherwise
provided for this Specification, and shall include furnishing, placing, compacting and shaping
foundation bedding materials, backfilling excavations against completed structure with
suitable material or granular backfilling excavations against completed structure with suitable
material or granular backfill where specified, and the removal and disposal of all excess
excavated material, in accordance with this Specification and as shown on the Drawings and
as required by the S.O.
Excavation and backfill for pipe culverts and precasts shall be in accordance with the
provisions of Sub-Section 3.9.

3.2.2

Materials

3.2.2.1 Excavation
Material excavated shall be classified as common excavation or rock as defined in Section 2
of this Specification.
3.2.2.2 Granular Bedding Material
Granular bedding material for the foundations of structures shall be suitably graded broken
rubble, crushed stone, crushed gravel, sand or other material as specified on the Drawings or
as required by the S.O.
3.2.2.3 Concrete Bedding
Concrete bedding or blinding for the foundations of structures shall conform to the
requirements of Section 9 of this Specification for the class of concrete specified on the
Drawings or required by the S.O.
3.2.2.4 Ordinary Backfill Material
Ordinary backfill material shall be suitable material as defined in Section 2 of this
Specification. The maximum particle size of the backfill material shall be 50mm.
3.2.2.5 Granular Backfill Material
Granular backfill material shall be send, crushed stone, crushed gravel or a mixture of
crushed and natural aggregates, shall be essentially free from vegetative and other organic
matter and clay, and shall not contain literate or concretionary materials.
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The material shall conform to the following physical and mechanical quality requirements:(i)
(ii)

the fines shall be non-plastic;

sand shall have a gradation conforming to the envelope shown in Table 3.1 ;
TABLE 3.1 GRADING LIMITS FOR SAND BACKFILL

iii)

B.S Sleve Size

% Passing By Weight

10.0 mm

100

5.0 mm

90 100

1.18 mm

45 80

300 um

10 30

150 um

2 10

material other than sand shall have a gradation conforming to one of the envelopes
shown in Table 3.2

TABLE 3.2 GRADING LIMITS FOR GRANULAR BACKFILL OTHER THAN SAND
B.S
Sieve Size

% Passing By Weight
A

37.5 mm

100

28.0 mm

70 - 100

100

20.0 mm

60 - 90

70 - 100

100

10.0 mm

45 - 75

45 - 75

5.0 mm

30 - 60

35 - 65

45 75

2.0 mm

20 - 50

25 - 50

30 60

425 mm

10 - 30

10 - 30

15 35

75 mm

0-2

0-2

02

3.2.2.6 Concrete Backfill

Concrete backfill where specified shall be of the grade as shown on the Drawings and shall
conform to Section 9 of this Specification.

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3.2.3

Excavation
The contractor shall notify that the S.O sufficiently in advance of the beginning of any
excavation so that cross-section elevations and measurements may be taken of the
undisturbed group. The natural ground adjacent to the structure shall not be disturbed
without permission of the S.O.
Trenches and foundation pits for structure and structure footing and under drains shall be
excavated to the lines, grades and elevations shown on the Drawings or as directed by the
S.O. Excavations must be kept free from water and temporary drains, sumps and pumps
shall be provided when necessary. The rate of excavation and back-fill shall be approved by
the S.O. The elevations of the bottoms of footing shown on the Drawings are approximate
only and the S.O may order in writing such changes in the dimensions or elevations of
footings as may be deemed to secure a satisfactory foundation.
Boulders, logs and other objectionable materials encountered in excavation shall be
removed.
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 has approved the depth of
excavation and the character of the foundation material.
Rock and other hard foundation material shall be cleared of all loose material and cut to a
firm surface, either level or stepped or serrated, as specified or shown on the Drawings or
directed by the S.O. All seems and crevices shall be cleared out and grouted with Portland
cement grout at the time the footing is placed.
All loose and disintegrated rock and thin strata shall be removed. When the footing is to rest
on material other than rock, special care shall be taken not to disturb the bottom of the
excavation, and excavation to final grade shall be deferred until just before the footing is to be
placed. When, in the opinion of the S.O., the foundation material is soft or mucky or
otherwise unsuitable, the Contractor shall remove the unsuitable material and insert
foundation fill material or concrete as specified or shown on the Drawings or directed by the
S.O. If foundation fill material is required it shall be placed and compacted in layers not more
than 150 mm thick as directed by the S.O. The degree of compaction shall be equivalent to
that of the surrounding foundations.
All excavation surfaces and surfaces of backfill material against which concrete is to be
placed shall be even and firm and true to line and level.
All excavated material, so far as suitable, shall be utilized as backfill or embankment. The
surplus material, whether or not temporarily allowed to be placed within a stream area, shall
be finally disposed of in such a manner as not to obstruct the stream nor otherwise impair the
efficiency or appearance of the works, nor is it to endanger the partly finished structure.
Excavated material suitable for use as backfill may be deposited by the Contractor in storage
piles at points convenient for re handling of the material during the backfilling operation.
Excavated material shall be deposited in such places and in such manner as not to cause
damage to highway, services or property either within or outside the road reserve and so as
to cause no impediment to the drainage of the Site or surrounding area.

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3.2.4

Backfilling with Ordinary or Granular Backfill Material

All spaces excavated under this Specification and not occupied by a permanent structure
shall be backfilled. Backfilled material shall be free from large lumps, woods and other
extraneous material.
Backfill not within the embankment areas shall be placed in layers not more than 250 mm in
depth (compacted measurement) and shall be compacted to a density comparable with the
adjacent undisturbed material.
Backfill within the embankment areas shall be made with approved material placed in uniform
layers not to exceed 150 mm in depth (compacted measurement) and each layer shall be
constructed in accordance with Section 2 of this Specification except that mechanical
tampers may be used for compaction. Each layer of backfilled shall be wetted uniformly as
necessary and compacted to the same requirement as the adjacent earthwork as specified in
Section 2 of this Specification. Unless otherwise approved by the S.O., hand tamping will not
be accepted.
In placing and embankment, the material shall be placed as possible to approximately the
same height on both sides of the structure. If conditions require backfilling appreciably higher
on one side, the additional material on the higher side shall not be placed until permission is
given by the S.O or until the S.O is satisfied that the structure has enough strength to
withstand any pressure created.
Backfill for embankment shall not be placed behind the walls of box culverts until the top slab
is placed for the required time and not less than three days. Backfilled and embankment
behind abutments held at the top by superstructure shall be carried up simultaneously behind
opposite abutments and side walls.
No backfilling shall be placed against any structure until permission shall have been given by
the S.O. Jetting of fill or other hydraulic methods involving or likely to involve, liquid or semiliquid pressure shall be prohibited.
Special care shall be taken to prevent any unduly high pressure against the structures.
The placing of the embankment and the benching of slopes shall continue in such a manner
that at all times there will be horizontal beam of thoroughly compacted material for a distance
at least equal to the height of the abutment or wall to be backfilled.

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3.3

CHANNEL EXCAVATION
3.3.1

Description
This work shall consist of excavation for waterway channels both inside and outside the road
reserve as shown on the Drawings or directed by the S.O., and shall include all required
excavation for widening, training or permanently diverting rivers, streams and irrigation and
drainage channels other than the drains and ditches appurtenant to the roadway, except
excavation of topsoil for use in the works and excavation required for clearing and grubbing.
This work shall also include the backfilling of old channels, haulage to their points of
utilization in the Works or the removal and disposal of all excavated materials, the
construction of appurtenant bunds, dikes and beams, and the shaping and finishing of all
earthworks involved in the construction of channels in accordance with the required lines,
levels, grades and cross-sections.

3.3.2

Materials
Channel excavation shall be classified as common excavation or rock as specified in Section
2 of this Specification.

3.3.3

Construction Methods
All suitable removed from channel excavations shall be used for backfilling waterways to be
abandoned and constructing bunds, dikes and other earth appurtenances as required.
Surplus suitable materials shall be used as far as is practicable in constructing the roadway.
The Contractor shall provide borrow of satisfactory quality and approved by the S.O., should
this be necessary to complete the work. Borrow which is required to replaced suitable
excavated materials needed for construction which the Contractor elects to waste shall not be
paid for.
Excavated suitable material, suitable material surplus to that needed for construction and
suitable material that the Contractor elects to waste, shall be disposed of at designated areas
in such manner as to present a neat appearance and not obstruct flow in any channels,
ditches or drains, nor cause damage to highway works or property, all to the satisfaction of
the S.O.
During construction, channel excavations shall be kept drained as far as is practicable and
the work shall be carried out in a neat and workmanlike manner.
All channels and appurtenances shall be excavated and constructed to the lines, level,
grades and cross-sections shown on the Drawings or as directed by the S.O. Excavated
beyond the limits required shall not be paid for and shall be backfilled at the Contractors
expense as directed by the S.O. should be deem it necessary.
Sections of channel abandoned owing to diversions shall be backfilled as directed by the S.O.

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3.4

SURFACE DRAINAGE
3.4.1

Surface Drainage Type

Surface drains of the type shown on the Drawings shall be constructed to the lines, levels,
grades and cross-section as specified or as directed by the S.O. Surface drains shall include
interceptor drains, roadside drains, embankment toe drains, shoulder drains, bench drains,
median drains, outfall drains, cascade drains, etc.
Any of the above drains may be constructed either unlined or lined using cast in situ concrete,
precast or porous concrete drain sections, or stone pitching.

3.4.2.1 Unlined Drains

Excavation for unlined drains shall be trimmed to form a smooth, firm surface to the required
lines, levels, grades and cross-sections as shown on the Drawings or as required by the S.O.
Any areas of over excavation shall be made good to the satisfaction of the S.O., all at the
Contractors expense.
3.4.2.2 Cast in Situ Concrete Drains
Excavation shall be carried out to the lines and levels as specified and as shown on the
Drawings. Templates which may be of timber or steel shall then be provided to ensure the
thickness and shape of the concrete drains. The concrete shall be poured in Sections not
exceeding 2 m in length and shall be carried out between end forms in alternate bays.
Construction joints shall not be formed in the inverts.
All concrete shall be grade 20/20 concrete unless otherwise specified and shall conform to
the requirements of Sections 9 of this Specification. Weep holes shall be cast in situ as
shown on the Drawings or as directed by the S.O.
3.4.2.3 Precast Concrete Drain Sections
Precast concrete block inverts shall be of the shapes and dimensions as shown on the
Drawings and shall be of grade 20/20 concrete conforming to the requirements of Section 9
of this Specification or of porous concrete unless otherwise specified. The precast concrete
drain sections shall be round and have smooth 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.
Samples of ready made drain sections shall be submitted to the S.O for his approval before
placing of orders. Notwithstanding any approval given by the S.O any defective or broken
drain section shall be replaced by the Contractor at his own expense before or after laying in
position.
Precast concrete drain sections shall be laid on concrete bedding in trenches excavated to
the lines and levels as specified and jointed to produce a neat even alignment and gradient.
The joint shall be grouted with 1:3 cement mortar complying with Sub-Section 3.5.2.2 and
weep holes shall be provided as shown on the Drawings or as directed by the S.O.

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Porous concrete shall comply with the requirement of porous concrete for pipes as described
in M.S 525. Cement and aggregates used in the manufacture of the porous concrete drain
sections shall conform to the requirements of section 9 of this Specification.
Mass concrete for bases shall be of grade 10/25 concrete or as specified and to the
dimensions and thickness as shown on the Drawings.

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3.4.2.4 STONE PITCHING
3.5.1

Description
This work shall consist of the construction of all structure or parts of structures to be
composed of stone pitching either grouted or ungraouted as shown on Drawings or as
directed by the S.O. including erosion protection pavements and aprons, drain likings, culvert
inlets and outlets, etc. The work shall be carried out all in accordance with the Specification
and to the lines, levels, grades, dimensions and cross-sections shown on the Drawings and
as required by the S.O.

3.5.2

Materials

3.5.2.1 Stone
Stone shall be rough quarry stone, or pit or river cobbles, or a mixture of any of these
materials, and shall be essentially free from dust, clay, vegetative matter and other
deleterious materials. Individual pieces of stone shall be approximately cubical or spherical
and shall have least dimensions in the range 100 to 150 mm and a maximum dimension of
250mm, maximum, unless otherwise specified. The stone shall be hard, tough, durable and
dense, resistant to the action of air and water, and suitable in all respects for the purpose
intended.
3.5.2.2 Cement Mortar
Cement mortar, unless otherwise specified, shall contain 1 part ordinary Portland cement to 3
parts fine aggregate by volume. Water shall be added to the mix to produce a suitable
consistency for the intended use, all to the satisfaction of the S.O. The constituent materials
of the mortar shall comply with the appropriate requirements of Section 9 of this Specification.
The ingredients for mortar shall be measured in proper gauge boxes and mixed on a clean
boarded platform or in an approved mechanical batch mixer.
All mortar shall be used within 30 minutes of mixing and no reworking of mortar shall be
permitted thereafter.
3.5.3

Construction Methods

3.5.3.1 Grouted Stone Pitching

Prior to constructing grouted stone pitching, the surfaces against which it is to be placed shall
have been finished in accordance with the appropriate provision of this Specification.
Notwithstanding any earlier approval of these finished surfaces, any damage to or
deterioration of them shall be made good to the satisfaction of the S.O. before grouted stone
pitching is placed.
Construction of grouted stone pitching shall commence at the lowest part of each structure or
section of a structure or section of a structure and continue progressively upward. Long
structure such as drain linings and slope protection pavements shall be constructed in
sections of practicable length, to the satisfaction of the S.O . The surface against which the
work is to be placed shall be moistened with clean water a little in advance of construction,
and covered with a layer of cement mortar about 50 mm thick. Stone pitching is placed.

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Construction of grouted stone pitching shall commence at the lowest part of each structure or
section of a structure and continue progressively upward. Long structure such as drain
linings and slope protection pavements shall be constructed in sections of practicable length,
to the satisfaction of the S.O. The surface against which the work is to be placed shall be
moistened with clean water a little in advance of construction, and covered with a layer of
cement mortar about 50 mm thick. Stones shall then be firmly set by hand into the mortar,
densely packed against adjacent stones and built up to form a stone structure of more or less
uniform thickness which shall nowhere be less than 150 mm (measured perpendicularly to
the surface covered). All the while that stones are being placed, all voids in the structure
shall be packed solidly with mortar and stone spells; however the surfaces of stones in the
exposed faces and edges shall not be covered with mortar. The exposed surfaces and edge
of the structure shall be constructed such that they have as large a proportion as practicable
composed of stone faces. Weep holes shall be provided as shown on the Drawings or as
directed by the S.O
Mortar which has been mixed for more than 30 minutes shall not be used in the works. Nor
shall mortar be laid against the supporting surface more than 2 minutes before pitching stone
and building up the structure to full thickness is commenced on any section of the work, as
the construction advances.
The work shall be carried out and finished all to the satisfaction of the S.O.
3.5.3.2 Ungrouted Stone Pitching
Where shown on the Drawings, un grounded stone pitching shall be hand set to provide
maximum interlocking effect. The stones, the largest of which shall be used at the bottom,
shall be well bedded on a 75 mm layer of gravel or aggregate rammed to an even surface.
The whole work shall be finished to the satisfaction of the S.O.

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3.6

GABIONS
3.6.1

Description
This work shall consist of the construction of miscellaneous erosion protection and retaining
structure to be composed of stone filled wire mesh gabions. The work shall be carried out all
in accordance with this Specification and as shown on the drawings and/or as approved by
the S.O.

3.6.2

Materials

3.6.2.1 Wire Mesh Gabions

Gabions shall be rectangular baskets of the required dimensions as shown on the Drawings
or ordered by the S.O. Unless otherwise specified, they shall be of the following standard
dimensions :i)

width

1.00 metre

ii)

length

1.00, 2.00 or 3.00 metres;

iii)

height

0.50 or 1.00 metre.

Gabions longer than 1.00 shall be divided into compartment of equal length not exceeding
1.00 m by wire mesh diaphragms securely tied along all edges. Each gabion or compartment
of a gabion shall be provided with at least 4 cross-connecting wires if its height is 0.50 m or
less, and with at least 8 cross-connecting wires if its height is in range 0.50 to 1.00 metre.
Gabion shall be fabrcated from steel wire manufactured in accordance with B.S. 1052 and
galvanished in accordance with M.S 407, or such similar standards as the S.O shall approve.
The galvanished wire sizes used shall be in accordance with Table 3.3
TABLE 3.3 GALVANISED WIRE SIZES FOR GABIONS
Type of Wire
Selvage (perimeter) wire
Mesh Wire
Tying and connecting wire

Minimum Diameter
3.50 mm
2.70 mm
2.20 mm

Gabion mesh shall be triple twisted and shall have a uniform hexagonal pattern with openings
of 100 x 120 mm or less. The mesh shall be securely tied to sevage wire to form rectangular
panels which shall be securely wired together to form the completed gabion baskets. The
ties and connections for each gabion basket shall be securely tied to selvage wires to form
rectangular panels which shall be securely wired together to form the completed gabion
basket shall comprise not less than 8 % of its total weight, and the fabrication shall be all to
the satisfaction of the S.O.

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3.6.2.2 Polyvinyl Chloride Coating

When specified on the drawing, all wire used in the fabrication of gabions and in the wiring
operation during construction shall, after galvanishing, have extruded on to it a coating of
polyvinyl (PVC). The PVC coating, not inclusive of galvanishing, shall nowhere be less than
0.55 mm in thickness.
3.6.2.3 Stone
Stone fill for gabions shall be clean rough quarry stone, or river cobbles, or a mixture of any
of these materials, and shall be essential free from dust, clay, vegetative and other
deleterious materials. Individual pieces of stone shall have least dimensions not less than 20
mm larger than the gabion mesh openings and greatest dimensions not more than 250 mm.
The stone shall be hard, tough, durable and dense, resistant to the action of air and water,
and suitable in all aspects for the purpose intended. The material shall be approved by the
S.O.
3.6.3

Construction Methods
Prior to placing gabions, the surface on and against which they are to be constructed shall
have been prepared and finished in accordance with the relevant provisions of the
appropriate Sections of this Specification. Notwithstanding any earlier of these finished
surface, any damage to or deterioration of them shall be made good to the satisfaction of the
S.O. before gabions are placed.
Each gabion basket shall be put in its turn, completely fabricated except for the fastening
down of the lid, stretched to the correct shape and dimensions and fastened securely to all
baskets along each edge with tying wire. The basket shall then be tightly packed with
approved stone by hand in such a manner that voids are kept to a practicable minimum and
are uniformly distributed in the stone mass. Finally the lid of the basket shall be securely
fastened down with tying wire along all hitherto unfastened edges, all to the satisfaction of the
S.O. In no case shall the weight of the finished gabion be less than 1300 kg per cubic metre.
As a gabion structure is built up, backfilling against finished gabions shall be carried out as
necessary for proper progressive construction, all in accordance with the relevant provisions
of the appropriate Sections of this Specification. Unless otherwise specified, vertical joints
between gabions shall be staggered in gabion structure in a pattern similar to the joints in
running bond brickwork.

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3.7

BRICKWORK
3.7.1

Description
This work shall include the laying of brickwork to the lines, levels and grades shown on the
Drawings and/or as directed by the S.O.

3.7.2

Materials

3.7.2.1 Common Bricks

Common bricks shall be sound, hard, well burnt, of proper size and clean and shall give a
clear ring when struck. They shall be Class 3 standard format complying with the
requirements of M.S. 76. Brick shall be obtained from manufacturers approved by the S.O.
3.7.2.2 Cement Mortar
Cement mortar for brickwork shall comply with the requirements of Sub-Section 3.5.2.2
3.7.3

Construction Methods

3.7.3.1 Brick Laving

Brickwork shall be executed with cement mortar and shall be of the thickness and bonds as
shown on the Drawings. Bricks shall be kept damp until used and shall be laid on a full bed
of mortar. The brickwork shall be true to line and plumb, and courses shall be kept truly level.
The thickness of mortar joints shall not exceed 10 mm and shall be such that 4 course of
brickwork forms a height of 300 mm. Newly laid brickwork shall be protected from the
harmful effects of sunshine, rain, running and surface water and shocks. Any brickwork that
is damaged shall be taken down and rebuilt and the joints raked out and pointed as directed
by the S.O. Any such remedial work shall be at the Contractors own expense.
3.7.3.2 Plastering Brickwork
All exposed brickwork surface shall be plastered. The plastered shall be applied in 2 coats
generally to a total thickness of 20 mm and shall be finished with a steel trowel for internal
surfaces and with a wooden float for external surfaces.
Plain plaster shall consist of 1 part masonry cement complying with M.S 794 to 3 parts of
sand by volume. Where ordinary Portland cement is used, plasticiser of a type approved by
the S.O may add to the mix in accordance with the manufacturers instructions.
Ordinary Portland cement and water shall comply with the appropriate requirements of
Section 9 of this Specification.
Weep holes shall be provided as shown on the Drawings or as directed by the S.O.

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3.8

SUBSOIL DRAINS
3.8.1

Description
This work shall include the supply and installation of subsoil drains constructed in accordance
with this Specification at the locations and in accordance with the lines, levels and grades as
shown on the Drawings and/or directed by the S.O.

3.8.2

Materials

3.8.2.1 Pipes
Porous concrete pipes for subsoil drains shall comply with M.S 525.
Clay pipes for subsoil drains shall comply with B.S. 1196
Polyvinyl Chloride (PVC) pipes for subsoil drains shall comply with Australian Standard
Specification 2439 or B.S 3656.
3.8.2.2 Filter Material
Filter material used in the construction of subsoil drains shall consist of hard, clean sand
confirming to the grading limits given in the Table 3.4. The material passing the 425 um
sleve shall be non-plastic when tested in accordance with B.S. 1377.
TABLE 3.4 GRADING LIMITS FOR FILTER MATERIAL
B.S Sleve Size

% Passing By Weight

10.0 mm
5.0 mm
2.36 mm
1.18 mm
600 um
300 um
150 um

100
90 - 100
75 - 100
55 90
35 59
8 30
0 10

3.8.2.3 Filter Cloth

The synthetic filter cloth shall be a non-woven type of approved manufacture having the
following properties ;(a)

Chemical Composition Requirements

Fibres used in the manufacture of the engineering fabric shall consist of a long chain
synthetic polymer, composed of at least 58% by weight of polypropylene, -ethylene,
-estermide or vinylidene chloride and shall contain stabilizers and/or inhibitors added to the
base plastic (as necessary) to make the fabric resistant to deterioration from ultraviolet and
heat exposure.

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(b)

Physical Property Requirements

The physical properties of the filter cloth shall comply with Table 3.5.
TABLE 3.5 PHYSICAL PROPERTY REQUIREMENTS FOR FILTER CLOTH
Grab Strength
(ASTM D1682)

0.9

Puncture Strength
(ASTM D3787 80a)

0.4

kN

Burst Strength
(ASTM D3786 80A)

2100

kN/sq.m

(c)

kN

Filtration Requirement

Equivalent opening size of the filter cloth determined by sieving as described in ASTM D422
shall be less than the eight-five percentage size of the adjacent soil.
(d)

Permeability Requirement

The equivalent Darcy Permeability of the filter cloth shall be greater than 10 times in Darcy
Permeability of the soil to be drained.
3.8.2.4 Cement Mortar
1:3 cement mortar for use in pipe joints shall comply with Sub-Station 3.5.2.2
3.8.3

Construction Methods
Excavation for subsoil drains shall be carried out all in accordance with the appropriate
provisions of Sub-Section 3.2.
Filter material as described in Sub-Section 3.8.2.2 above shall be placed and uniformly
compacted by a suitable method approved by the S.O, to form a firm, even bedding for the
pipe drain as shown on the Drawings.
The pipe section shall be set firmly against the filter material bedding with the flow lines in the
design position. For pipe with mating joints, the receiving ends shall be upgrade, and the
pipe joints shall be fully mated, and the collars properly centered over the joints.
Joint shall be spot mortared as necessary to hold the pipe sections correctly centered and
aligned, but not so as to unduly restrict the infiltration of water through the joints.
Slotted or perforated pipes shall be tightly wrapped in filter cloth such that the entire length of
the mortared pipe by at least 2 layers of cloth. All joints in both layers shall have an overlap
of at least 100 mm and joints in the

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outer layer shall be offset by at least 300 mm from joints in the inner layer, all to the
satisfaction of the S.O.
After pipe laying and, if appropriate, wrapping has been approved by the S.O, the remainder
of the filter material shall be placed and uniformly compacted by a suitable method approved
by the S.O to form a dense, even surround to the pipe as shown on the Drawings. Care shall
be taken that the pipe is neither damage nor displaced.

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3.9

R.C PIPE CULVERTS

3.9.1

Description
This work shall comprise the supply and installation of reinforced concrete pipe culverts,
inclusive of excavation, backfilling, jointing, bedding, construction of headwalls, wingwalls,
aprons and sumps and channel protection works, all in accordance with this specification and
the details shown on the drawings.

3.9.2

Materials

3.9.2.1 Pipes
Reinforced concrete pipes shall conform to the requirements of M.S. 881 and shall be
supplied by manufacturers approved by the S.O.
Rebated pipes of diameter 600 mm and above shall be internally rebated.
Collars shall be precast with grade 25 concrete and shall be suitable reinforced all in
accordance with Section 9 of this Specification. The width of the collar shall be not less than
150 mm and the minimum thickness shall be 50 mm.
Rubber rings for spigot and socket pipes shall comply with the requirements of Type 2 as
specified in B.S. 2494.
3.9.2.2 Cement Mortar
1:3 cement mortar for jointing of reinforced concrete pipes shall conform to the requirements
of Sub-Section 3.5.2.2
3.9.2.3 Bedding Material
Type A bedding shall consist of grade 20/20 concrete complying with Section 9 of this
Specification.
Type B bedding shall consist of clean, natural sand or gravelly sand of suitable gradation and
quality, approved by the S.O. The material shall have a maximum particle size of not more
than 12 mm.
3.9..3.1 Excavation
(a)

General

Unless otherwise directed by the S.O., prior to construction of a pipe culvert, the earthworks
at the required location shall have been constructed to a level at least 600 mm above the top
of culvert design levels or to the top of sub grade levels, whichever is lower.
Pipe culvert specified to be constructed in trench conditions shall be excavated in accordance
with Sub-Section 3.9.3.1 (b) below.
Where drainage conditions or other circumstances so require, the S.O. may direct the
Contractor to construct the pipe culvert without first constructing the

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earthwork to the level specified above, in which case excavation and foundation preparation
shall be in accordance with Sub-Section 3.9.3 (c) below.
(b)

Trench Method

The trench to receive a culvert pipe shall be of sufficient width and depth to enable the
placing of bedding material and construction of pipe joints in accordance with this
Specification, and the bottom of the trench shall be trimmed to a suitably smooth plane
surface which shall be kept free from water, all to the satisfaction of the S.O. Where rock or
other hard unyielding foundation material is encounted in the trench, it shall be excavated to a
depth below the bottom of pipe design levels of at least 300 mm or 12.5 meter 300 mm of fill
to be placed over the top of the pipe, whichever is greater, up to a maximum of 75 % of the
internal diameter of the pipe. The hard material so excavated shall be replaced with suitable
material uniformly compacted in layers of not more than 150 mm compacted thickness to
provide satisfactory support for the pipe, all to the satisfaction of the S.O
(c)

Open Ground Method

Where existing ground levels are above top of bedding material design levels and firm
foundation materials are encounted, excavation and foundation preparation shall be similar to
that described in the trench method above. Otherwise a firm foundation plane shall be
prepared, which shall be essentially free draining along the line of the culvert, by trimming the
existing ground, or such fill as it is necessary to place and compact, over a width sufficient to
permit satisfactory construction of the pipe bedding, all to the satisfaction of the S.O. hard
materials shall be excavated from the pipe foundation over a width equal to the outside
diameter of the pipe to the same depth as specified in the trench method, and shall be
replaced with suitable material uniformly compacted in the layers of not more than 150 mm
compacted thickness to provide satisfactory support for the pipe, all to the satisfaction of the
S.O.
Where soft or unstable soil is encounter in the foundation, it shall be excavated over width of
at least 1.5 times the outside diameter of the pipe on each side of the culvert center-line top
the depth directed by the S.O, and replaced with suitable material uniformly compacted in
layers of not more than150 mm compacted thickness to provide satisfactory for the pipe, all to
the satisfaction of the S.O.
3.9.3.2 Backfilling against reinforced concrete pipe culvert and their appurtenant structure shall be
carried out in accordance with the construction methods described in Sub-Section 3.2.4,
using material conforming to the requirements of Sub-Section 3.2.2.5. Special care shall be
taken to properly compact backfill against the undersides of culvert pipes without disturbing or
damaging the pipes and joints. Backfill shall be built up evenly on both sides of each pipe
culvert along its entire length.
Heavy plant and equipment shall not operate within 1.5 m of any pipe culvert until backfilling
and. Where appropriates, pavement construction has advanced to a stage which provides at
least 600 mm of cover to the culvert. Subject to the approval of the S.O., light compaction
equipment may be operated above pipe culvert after a minimum of 300 mm of cover has
been placed and compacted.

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3.10

R.C. PIPE CULVERTS

3.9.1

Description
This work shall comprise the supply and installation of reinforced concrete pipe culverts,
inclusive of excavation, backfilling, jointing, bedding construction of headwall, wing wall,
aprons and sumps and channel protection works, all in accordance with this Specification and
the details shown on the Drawings.

3.9.2

Material

3.9.2.1 Pipes
Reinforced concrete pipes shall conform to the requirements of M.S 881 and shall be
supplied by manufacturers approved by the S.O.
Rebated pipes of diameter 600 mm and above shall be internally rebated.
Collars shall be precast with grade 25 concrete and shall be suitably reinforced all in
accordance with Section 9 of this Specification. The width of the collar shall be not less than
150 mm and the minimum thickness shall be 50 mm.
Rubber rings for spigot and socket pipes shall comply with the requirements of Type 2 as
specified in B.S. 2494.
3.9.2.2 Cement Mortar
1:3 cement mortar for jointing of reinforced concrete pipes shall conform to the requirement of
Sub-Section 3.5.2.2
3.9.2.3 Bedding Material
Type A bedding shall consist of grade 20/20 concrete complying with Section 9 of this
Specification.
Type B bedding shall consist of clean, natural sand or gravelly sand of suitable gradation and
quality, approved by the S.O. The material shall have a maximum particle size of not more
than 12 mm
3.9.3

Excavation and Backfilling for

R.C Pipe Culverts

3.9.3.1 Excavation
(a)

General

Unless otherwise directed by the S.O., prior to construction of a pipe culvert, the earthworks
at the required location shall have been constructed to a level at least 600 mm above the top
of culvert design levels or to the top of sub grade levels, whichever is lower
Pipe culvert specified to be constructed in trench conditions shall be excavated in accordance
with Sub-Section 3.9.3.1 (b) below.
Where drainage conditions or other circumstances so require, the S.O.
Contractor to construct the pipe culvert without first constructing the

may direct the

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earthwork to the level specified above, in which case excavation and foundation preparation
shall be in accordance with Sub-Section 3.9.3.1 below.
(b)

Trench Method

The trench to receive a culvert pipe shall be of sufficient width and depth to enable the
placing of bedding material and construction of pipe joints in accordance with this
specification, and the bottom of the trench shall be trimmed to a suitable smooth plane
surface which shall be kept free from water, all to the satisfaction of the S.O. Where rock or
other hard unyielding foundation material is encounted in the trench, it shall be excavated to a
depth below the bottom of pipe design levels of at least 300 mm or 12.5 mm per 300 mm or
12.5 mm per 300 mm of fill to be placed over the top of the pipe, whichever is greater, up to a
maximum of 75 5 of the internal diameter of the pipe. The hard material so excavated shall
be replaced with suitable material uniformly compacted in layers of not more than 150 mm
compacted in layers of not more than 150 mm compacted thickness to provide satisfactory
for the pipe, all to the satisfaction of the S.O.
(c)

Open Ground Method

Where existing ground levels are above top of bedding material design levels and firm
foundation materials are encounted, excavation and foundation preparation shall be similar to
that in the trench method above. Otherwise a firm foundation plane shall be prepared, which
shall be essentially free draining along the line of the culvert, by trimming the existing ground,
or such fill as it is necessary to place and compact, over a width sufficient to permit
satisfactory construction of the pipe bedding, all to the satisfaction of the S.O. Hard materials
shall be excavated from the pipe foundation over a width equal to the outside diameter of the
pipe to the same depth as specified in the trench method, and shall be replaced with suitable
material uniformly compacted in layers of not more than 150 mm compacted thickness to
provide satisfactory for the pipe, all to the satisfaction of the S.O.
Where soft or unstable soil is encountered in the foundation, it shall be excavated over a
width of at least 1.5 times the outside diameter of the pipe on each side of the culvert centerline to the depth directed by the S.O., and replaced with suitable material uniformly
compacted in layers of not more than 150 mm compacted thickness to provide satisfactory
support for the pipe, all to the satisfaction of the S.O.
3.9.3.2 Backfilling
Backfilling against reinforced concrete pipe culvert and their appurtenant structures shall be
carried out in accordance with the construction methods described in Sub-Section 3.2.4,
using material conforming to the requirements of Sub-Section 3.2.2.5. Special care shall be
taken to properly compact backfill against the undersides of culvert pipes without disturbing or
damaging the pipes and joints. Backfill shall be built up evenly on both sides of each pipe
culvert along its entire length.
Heavy plant and equipment shall not operate within 1.5m of any pipe culvert until backfilling
and, where appropriate, pavement construction has advanced to a stage which provides at
least 600 mm of cover to the culvert. Subject to the approval of the S.O., light compaction
equipment may be operated above pipe culvert after a minimum of 300 mm of cover has
been placed and compacted.

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3.9.4

Installation of R.C Pipe Culverts

3.9.4.1 General
The type, size and class of pipe to be installed at each location shall be as shown on the
Drawings or as directed by the S.O. Culverts shall not be installed at any location until the
type of pipe, the exact location, the lines, levels and grades, the length of pipe and details of
inlet and outlet structures have been confirmed by the S.O. In addition, special requirement
recommended by the manufacturer with respect to assembly and installation shall be
complied with. Especially where elliptically reinforced pipe sections are used, care shall be
taken to ensure that the loading axes are positioned exactly vertically.
3.9.4.2 Butt Ended Pipe Culvert with
Precast Concrete Collars
The pipe 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 correct levels and grades on precast concrete spacing blocks
of the same class as the bedding material and of sufficient to animate any risk of settlement
of the pipe before or during concreting.
All joint shall be fully mortared with 1:3 cement mortars before concreting of the cradle, all to
the satisfaction of the S.O. The concrete cradle shall be cast as one monolithic unit.
Alternatively, part of the concrete cradle below the underside of the pipe may be constructed
monolithically at least 24 hours before the assembly and mortaring up of the pipe sections
and collars, on condition that shear connectors are provided across horizontal construction
joints to the satisfaction of the S.O
During installation, the ends of the pipes shall be butted and the collar centered about the
joint using wedges or other approved means. The annular shall be completely filled with 1:3
cement mortar with only sufficient water added to ensure adequate workability and the
wedges removed before finally fairing the joint. Special care shall be taken to ensure that
excess mortar is neatly cleaned off. For pipes over 900 mm in diameter the jointing space
shall be fill from inside the pipe after completion of embankment construction using 1:3
cement mortar. When installed the clearance between the outer diameter of pipe and the
inner diameter of collar shall be at least 20 mm.
Following pipe assembly and mortaring up as above, the remainder of the cradle shall be cast
monolithically, all to the satisfaction of the S.O.
Where vertical construction joints in the concrete cradle are un avoidable due to
circumstances on Site, transfer bars shall be provided to the satisfaction of the S.O.
Special care shall be taken when placing the concrete cradle to avoid the entrapment of air
underneath the pipe. To elimate this possibility, concrete shall be placed to one side of the
pipe only until only such time as the level of the concrete surface rises above the underside of
the pipe on the side remote from the on which concrete is being placed. The concrete shall
then be brought up at the same level on both sides of the pipe.

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3.9.4.3 Rebate Pipe Culverts

The pipe shall be laid on Type A bedding in conformity with the dimensions shown on the
Drawings.
The method of construction shall follow that described in Sub-Section 3.9.4.2 for butt ended
pipe culvert except for the exclusion of precast concrete collars.
The rebate joint shall be internally flush and fully mortared with 1:3 cement mortar, all to the
satisfaction of the S.O
3.9.4.4 Spigot and Socket Pipe Culverts
The pipes shall be laid on Type B bedding in conformity with the dimensions shown on the
Drawings. The bedding material shall be accurately shaped by a template to fit the lower part
of the pipe exterior for a height of at least 10% of the outside diameter of the pipe. Gaps shall
be left in the bedding material and recesses dug in the earth foundation of sufficient width and
depth to accommodate the socket without it resting on the bottom of the recess. The widths
of the recesses in the foundation and the bedding shall both exceed the width of the socket
by more than 50 mm.
Jointing of the pipes shall be carried out strictly in accordance with the manufacturers
recommendations, all to the satisfaction of the S.O.
Concrete pipes as specified above shall be laid true to line, each pipe being separately boned
between sight rails. Pipes shall be laid in an upstream direction with the sockets towards the
inlet and shall rest on even foundations for the full length of the barrel. Rubber rings joints
shall be installed strictly in accordance with the manufacturers instructions. Prior to jointing,
rubber rings and jointing surfaces shall be cleaned off all contaminants except for specified
lubricants. The spigot of each pipe shall be inserted concentrically in the socket of the one
previously laid, and the pipe then adjusted and fixed in its correct position with the spigot
correctly entered in the socket.
Care shall be taken to see that the rubber ring is adequately compressed to seal the joint. All
pipes shall be laid to the satisfaction of the S.O

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3.10

CORRUGATED METAL PIPE CULVERTS

3.10.1 Description
This work shall comprise the supply and installation of bolted, corrugated metal pipe culverts
inclusive of excavation, backfilling, jointing, bedding, construction of headwalls, wing walls,
aprons and sumps and channel protection works, all in accordance with this specification and
the details shown on the Drawings.
3.10.2 Materials
3.10.2.1

Pipes
The pipe section shall be fabricated from zinc-coated (galvanished) steel sheets
conforming to AASHTO M218 or from structural plates conforming to AASHTO M167
depending on the pipe size requirements.
The dimension of the pipes shall conform to AASHTO M36. All pipes shall be clearly
identified by marking on each section the following information :i)
ii)
iii)
iv)

name of manufacturer;
diameter of pipe;
gauge number;
date of manufacture.

The above marking shall have been marked by the manufacturer.

The contractor shall submit to the S.O., the material test certificates from the
manufacturer showing the chemical composition and mechanical properties of the base
metal and the amount of zinc coating for every lot of pipes supplied. The S.O may order
further tests in the sections supplied to Site at the rate of not more than 1 in 100.
All cost on such tests shall be borne by the contractor.
3.10.2.2

Bitumen Coating
Where specified, the pipe sections or plates shall be coated with an approved bitumen
coating at the factory by the hot-dip process for Type A as specified in AASHTO M190.
Before coating, any damage to the galvanizing shall be made good in a manner approved
by the S.O

3.10.2.3

Bolts and Nuts

All bolts and nuts shall be of high strength carbonated steel meeting the provisions of
ASTM A449 and ASTM A563 Grade C respectively. The galvanizing on bolts and must
meet the requirements of ASTM A153.
Diameter of bolts holes in the longitudinal seams, except those at the plate corners, shall
not exceed the bolt diameter by more than 3 mm. The bolt holes in the circumferential
seams, including those at the plate corners, shall not exceed the bolt diameter by more
than 6 mm. The minimum distance from the center of a hole to the edge of a plate shall
be 1.75 times the diameter of the bolt.

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For pipe material conforming to AASHTO M218 (corrugation 68 mm pitch x 13 mm depth)

with diameters of 1500 mm or smaller, 12 mm diameter bolts shall be used. Bolt holes
circumferential seams shall have spacing of not more than 314 mm.
For pipe material conforming to AASHTO M167 (corrugation 150 mm pitch x 50 mm
depth) with diameters of 1500 mm or larger, 19 mm diameter bolts shall be used. Four
bolt holes per 300 mm of longitudinal seam shall be provided and these be staggered in
rows 51 mm apart with holes in one row in the through and holes in the other row in the
crest of the corrugation. Bolt holes in the circumferential seams shall have spacing of not
more than 254 mm.
Notwithstanding the above, the Contractor shall satisfy the S.O as to the adequacy of all
bolted connections.
3.10.2.4

Cement Mortar
1:3 cement mortar shall comply with the requirements of Sub-Section 3.5.2.2

3.10.2.5

Bedding Material
Corrugated metal pipe culverts shall be bedded on Type B bedding as specified in SubSection 3.9.2.3

3.10.3

Excavation and Backfilling for

Corrugated Metal Pipe Culverts
Unless otherwise directed and/or approved by the S.O., the pipe culvert shall be laid in a
trench excavated in accordance with Sub-Section 3.9.3.1 (b)
Where the open ground method is approved, the work shall comply with Sub-Section
3.9.3.1 (c).

3.10.4 Installation of
Corrugated Metal Pipe Culverts
3.10.4.1

General
The culvert sections shall be assembled, strutted, and protected during construction in
accordance with the manufacturers instructions. Special attention shall be given to the
sequence of tightening bolts and the specified torque to be applied during assembly.
After assembly the bitumen coating shall, where damaged, be repaired and made good
with further application of the bitumen coating.

3.10.4.2

Mortar Lining
For corrugated metal pipe culverts of 1800 mm diameter or more, or where directed by
the S.O. for pipe of smaller diameter, a 1:3 cement mortar lining shall cover the invert of
the pipes to a thickness of 25 mm above the crest of the corrugations over a minimum of
one third of the circumference centrally placed along the entire length of the culvert. The
lining shall be constructed after completion of earthworks and wing walls.

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3.11

PRECAST BOX CULVERT

3.11.1

Description
This work shall comprise the supply and installation of precast box culverts inclusive of
excavation, backfilling, jointing, bedding, construction of headwalls, wingwalls, aprons and
sumps and channel protection works, all in accordance with this Specification and the details
shown on the drawings.

3.11.2.1 Materials
3.11.2.1 Precast Box Culverts
Precast box culvert shall be of approved manufacture complying with Australian Standard
Specification 1597 Part 1, or any equivalent alternative standard acceptable and approved by
the S.O.
3.11.2.2 Cement Mortar
1:3 cement mortar for jointing of precast box culvert sections shall conform to the
requirements of Sub-Section 3.5.2.2
3.11.2.3 Bedding Material
Precast box culverts shall be bedded on Type B bedding as specified in Sub-Section 3..9.2.3.
3.11.2.4 Excavation and Backfilling
3.11.2.5 Excavation for Precast Box Culverts
Unless otherwise directed by the S.O., prior to construction of a precast box culvert, the
earthworks at the required location shall have been first constructed to a level at least 600
mm above the top of the culvert design levels or to the top of subgrade levels, whichever is
lower, and the precast box culvert shall then be constructed in a trench excavated in
accordance with Sub-Section 3.9.3.1 (b).
Where drainage condition or other circumstances so require, the S.O may direct the
Contractor to construct the precast box culvert without first constructing the earthworks to the
level specified above, in which case excavation and foundation preparation shall be in
accordance with Sub-section 3.9.3.1 (c)
3.11.2.6 Backfilling
Backfilling against precast box culvert and their appurtenant structure shall be carried out in
accordance with the construction methods described in Sub-Section 3.2.4 using material
conforming to the requirement of Sub-Section 3.2.4, using material conforming to the
requirement of Sub-Section 3.2.5.5. Special care shall be taken to properly compact backfill
without disturbing or damaging the precast box culvert sections. Backfill shall be built up
evenly on both sides of each box culvert along its entire length.
Unless otherwise approved by the S.O., heavy plants and equipment shall not operate within
2.0 m of any precast box culvert until backfilling and, where appropriate, pavement
construction has construction has to a stage which provide at least 300 mm of cover to the
culvert.
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3.11.3 Installation of Precast Box Culverts

The type and size of precast box culvert to be installed at each location shall be as shown on
the Drawings or as directed by the S.O. Precast box culverts shall not be installed at any
location until the exact location, the lines, levels and grades, the length of culvert and details
of inlet and outlet structure s have been confirmed by the S.O. In additional, special
requirement recommended by the manufacturer shall be complied with

Precast box culvert shall be laid on Type B bedding as specified in Sub-Section 3.9.4 in
conformity with the dimensions shown on the Drawings. Where specified on the Drawings or
directed by the S.O., Type B bedding shall be laid on a layer of crushed aggregate of
maximum particle size not exceeding 50 mm
All joint shall be fully mortared with 1:3 cement mortar, all to the satisfaction of the S.O. In
addition, a 3 mm layer of 1:3 cement mortar shall be spread on top of the legs of the invert in
order to ensure uniform bearing between the invert and lid.
Lifting holes shall be filled with 1:3 cement mortar.

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3.12

EXTENSION OF CULVERTS
3.12.1 Extension of Pipe Culverts
The existing wingwalls, aprons and concrete bedding shall be demolished wherever indicated
on the Drawings to expose the existing pipe culvert on the side(s) to be extended. The end of
the existing pipe culvert to be extended shall then be wire-brushed or some other means
employed to give a clean pipe end.
Extension joints shall be formed as shown on the Drawings by injecting Thioflex 600 Gun
Grade (manufactured by Expandiet or its equivalent to a thickness of not less than 25 mm in
the 1.5 mm 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.
3.12.2 Extension of Box Culverts
The existing wingwalls, aprons and concrete bedding shall be demolished wherever indicated
on the Drawings to expose the existing box culvert on the side (s) to be extended. The end of
the existing box culvert to be extended shall then be wire-brushed or some other means
employed to give a clean surface.
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 box culvert and the new box culvert section. 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.

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