SERIES 2600 MISCELLANEOUS

1 March 1998 MANUAL OF CONTRACT DOCUMENTS FOR HIGHWAY WORKSVOLUME 1 SPECIFICATION FOR HIGHWAY WORKSSERIES 2600 MISCELLANEOUSC ontentsClauseTitle Page2601 Bedding Mortar22602 Concrete for Ancillary Purposes52603 Porous No Fines Concrete62604 Plastic Coating to Fencing Posts,Gates and Ancillaries62605 Plastic Coated High Tensile Wire62606 Cored Thermoplastic Node Markers 72607 Granolithic Concrete Renderingand Screed71 Volume 1 Specification for Highway WorksSeries 2600 MiscellaneousMISCELLANEOUS2601 Bedding MortarGeneral1 Bedding mortar shall satisfy the followingperformance requirements:(i)Unless otherwise described in Appendix 26/2,bedding mortar shall have a compressivestrength not less than 50 N/mm when testedin accordance with sub-Clause 4(iv) or 4(v) ofthis Clause.(ii) The flow characteristics shall be such that thevolume of the bed or plinth as shown on theDrawings is completely filled withhomogeneous material when placed within therange of ambient temperature between 5 Cand 25 C, or as otherwise described inAppendix 26/2.

2 (iii) The physical and chemical properties shall becompatible with those of all stress in the mortar shall not exceed that defined inAppendix 21/1 for bridge bearings and Appendix 26/2for other applications. Where the mortar is required toresist stress before attaining its 28-day strength thecompressive strength shall be confirmed by tests onmortar cubes stored under conditions that simulate thefield (i)(11/03) The maximum aggregate size inbedding mortar shall be mm.(ii) Proprietary materials shall be stored asfollows:(a) The materials shall be stored in a dryenvironment at a temperature of between10 C and 27 C.(b) The containers shall be damp-proof, leak-proof and readily emptied of theircontents.(c) Containers shall be marked with the batchreference number, componentidentification, manufacturer s name, netweight and such warnings or precautionsconcerning the contents as are required.(iii) The material shall not be removed from thestore for use in the Works until immediatelyprior to mixing.

3 (iv) Material shall not be used more than sixmonths after the date of manufacture or anylesser period specified by the manufacturer orsupplier.(v) The Contractor shall supply with each batchor part of a batch of the material delivered tothe Site, certificates furnished by the supplieror manufacturer stating the following:(a) Manufacturer s name and address.(b) Manufacturer s agent s name and addresswhere applicable.(c) Description of material and brand name.(d) Batch reference number, size of batch,and number of containers in the deliveryorder.(e) Date of manufacture.(f) The chloride ion content, expressed as apercentage by mass of cement.(vi) Calcium chloride or admixtures containingchloride salts shall not be used and the totalchloride ion content shall not exceed ofthe mass of cement.(vii)(11/03) Portland cement CEM I shall complywith BS EN 197-1.(viii)(11/03) The total acid-soluble sulfate content ofthe mortar mix, as SO4 shall not exceed 5% ofthe mass of cement in the mix.

4 The acid-soluble sulfate (AS) shall be determined inaccordance with Test No. 2 in TRL Report447. The sulfate content shall be calculated asthe total from the various constituents of themix.(ix)(11/03) If water for the Works is not availablefrom a water company s supply, theContractor shall ensure that the water complieswith the guidance given in BS EN from a water company supply may beused without testing. Where testing isrequired, the sulfate content of the water shallbe tested in accordance with Test No. 1 inTRL Report 447. The water shall not be usedAmendment - November 20032 Volume 1 Specification for Highway WorksSeries 2600 Miscellaneousif the sulfate content exceeds g of sulfate(as SO4) per litre. Water from the sea or tidalrivers shall not be used.(x) Resinous bedding mortars shall be based onthermosetting organic polymers consisting ofstable fluid and/or solid components which onmixing react chemically to form a hardenedsolid mass. Products shall be formulated fromepoxide, polyester, polyurethane or acrylicresin systems.

5 Fillers or aggregates to beincorporated in accordance with themanufacturer s recommendations, to extend ormodify the properties of the resinouscomposition, shall be pre-bagged, dry andfactory proportioned. The addition of otherfillers or aggregates shall not be Mixing, Placing and Curing3(i)Mixing, placing and curing of proprietarybedding mortar shall be carried out inaccordance with the manufacturer s writteninstructions together with the following:(a) The material shall not be mixed or placedin the Works at ambient temperatures ofless than 5 C. If for 24 hours before,during or after placing, the ambienttemperature falls below 5 C theContractor shall maintain the temperatureof the substrate and other adjoiningsurfaces at not less than 5 C for theduration of the curing periodrecommended by the manufacturer.(b) For cementitious bedding mortars thewater/cement ratio shall not exceed water content shall be confirmedduring the approval tests, and maintainedwithin a tolerance of 1 per cent inmortars placed in the Works.

6 (c) Only full packs of mortar as suppliedshall be mixed. On-site proportioningshall not be permitted.(d) The temperature of the mortar oncompletion of mixing shall be between5 C and 25 C.(ii) For cementitious bedding mortars , thesubstrate shall be flushed clean with watertwo hours before placing and maintained wetuntil placing commences. Any free water onthe surface of the substrate shall be removedbefore placing the mortar. The underside ofthe base plate shall be clean and free fromloose rust and loose mill scale at the time ofbedding. The mortar shall be placed in itsfinal position within 25 minutes ofcommencement of mixing. Immediately aftercasting, the mortar shall be protected toprevent evaporation for at least three days.(iii) For resinous bedding mortars the substrateshall be dry, free from loose dirt and dust andshall meet the conditions specified by themanufacturer. The underside of the base plateshall be clean and free from loose rust andloose mill scale at the time of bedding.

7 Themortar shall be placed in its final positionwithin one hour, or lesser period specified bythe manufacturer, of commencement ofmixing.(iv) The mortar shall be poured in one corner ofthe plinth. The addition of mortar to the sidesof the plinth shall only be permitted after themortar has flowed completely under theplinth.(v) No internal metal shims shall be allowed toremain in the hardened bedding mortar exceptwhere described in Appendix 26 Approval Tests4(i)GeneralEvery batch of mortar to be used in the Worksshall be tested by the Contractor. Where morethan one batch of mortar is to be used in theWorks the Elastic Stability Test may beomitted from the testing regime subsequent tothe initial laboratory approval Contractor shall state the water content tobe used, expressed as a percentage by weightof the material. Mixing shall be carried out inaccordance with the manufacturer s writteninstructions.(ii) Flow Cone Test, Calibration of Flow(a)(11/03) The flow characteristics of themortar shall be determined by the FlowCone Test method described in ASTMS tandard C939-02.

8 (b) Tests shall be conducted at ambienttemperatures of 5 C and 20 C within 15minutes of commencement of mixing.(c) For the test at 5 C the temperature of theflow cone and the mixer shall be 5 C, thetemperature of the dry material 10 C, andthe temperature of the water whererequired, 20 C.(d) For the test at 20 C the temperature of theflow cone, the mixer, the dry material andthe water where required shall be 20 - November 20033 Volume 1 Specification for Highway WorksSeries 2600 MISCELLANEOUS (e) For each temperature at least two testshaving times of efflux within 5% shallbe made and the average time of efflux tothe nearest second shall be reported.(iii) Flow Between Glass Plates(a) The flow characteristics of the mortarbetween glass plates shall be determinedusing the apparatus shown in HCDD rawing Number K2.(b) Tests shall be conducted at ambienttemperatures of 5 C and 20 C.(c) The temperature of the apparatus, drymaterial and water for each test shallcomply with sub-Clause 4(ii)(c) and (d)of this Clause.

9 (d) The mortar shall be poured in one cornerof the apparatus commencing between 18minutes and 20 minutes aftercommencement of mixing.(e) A satisfactory flow shall be achievedwhen the mortar flows under the glassplate and rises at least 10 mm above theunderside of the top plate at all positions,without signs of segregation, bleeding,effervescence or air inclusions.(iv) Compressive Strength (Cementitious)(a) The compressive strength of cementitiousbedding mortars shall be carried out onsix 70 mm cubes at an age of 28 days.(b) The temperature of the mixer, the drymaterial, the water and the moulds shallbe 20 C.(c)(11/03) The 70 mm cube moulds shallcomply with BS EN 12390-1. Testspecimens shall be made by filling themoulds carefully through a funnel toproduce a void-free mortar. The mouldsshall be covered by a steel plate toprevent expansion of the mortar.(d)(11/03) There shall be no shall be damp-cured for thefirst 24 hours, removed from the mouldsand then water cured. Curing shallcomply with BS EN 12390-2.

10 (e)(11/03) Testing shall comply withBS EN 12390-3.(f) The strength requirement shall besatisfied if none of the compressivestrengths obtained is lower than50 N/mm and the difference between thehighest and lowest values is not morethan 20% of the average. All results shallbe reported.(v) Compressive Strength (Resinous)(a) The compressive strength for resinousbedding mortars shall be carried out onsix 40 mm cubes at an age of 24 hours.(b) The 40 mm cube moulds shall complywith BS 6319 : Part 1 and shall becarefully filled using a funnel to ensurevoid-free cubes. There shall be nocompaction.(c) Testing shall comply withBS 6319 : Part 2.(d) The strength requirement shall besatisfied if none of the compressivestrengths obtained is lower than50 N/mm and the difference between thehighest and lowest values is not morethan 20% of the average. All results shallbe reported.(vi) Expansion Test(a)(11/03) Short term expansion shall bedetermined by the method described inASTM Standard C827-01a.