1 1. ------IND- 2011 0633 D-- EN- ------ 20120105 --- --- PROJET German Road and Transportation Research Association (FGSV) Commission on Municipal Roads Additional technical terms of contract and guidelines for excavation in traffic areas ZTV A-StB 11 2011 Edition 2 © 2010 German Road and Transportation Research Association (FGSV) e. V., Köln This work is protected by copyright. All rights reserved, in particular the reprinting, translation, presentation, use of illustrations and tables, radio broadcast, microfilming or other methods of copying, and storage in data processing systems, even for partial use. The conditions for remuneration for the reproduction of individual FGSV guidelines or for parts of these for literary purposes can be found in the valid fact sheet from the German Road and Transportation Research Association (FGSV) e. V .German Road and Transportation Research Association (FGSV) Commission on Municipal Roads 3 Additional technical terms of contract and guidelines for excavation in traffic areas ZTV A-StB 11 2011 Edition 4 Commission on Municipal Roads Ad-hoc group: ZTV A-StB revision Director: Dr Maria Kastner, München Collaborators: Mr Uwe Bischoff, Kassel Mr Walter Emperhoff, Regensburg Mr Joachim Germann, Darmstadt Mr Matthias Heuser, Höhr-Grenzhausen Mr Franek Kitowski, Fürth Dr Klaus Krass, Viersen Mr Michael Lintgen, Darmstadt Mr Ulrich Lüthje, München Mr Rudolf Sabatier, Hannover Mr Helmut Schgeiner, Berlin Mr Markus Schmidt, München Mr Hans-Dieter Schulte, Dortmund Mr Frank Schweigert, Hameln Mr Wolfgang Staeckling, Gelsenkirchen Mr Horst Thyes, Stuttgart Preface ZTV A-StB deals with the break-up of road surfaces, the excavation and backfilling of service trenches, as well as the restoration of the superstructure of road surfaces. ZTV A-StB 11 should be a component of the contract between the client and the companies contracted by the client as additional technical terms of contract within the meaning of VOB/B for all building contracts that involve excavation in traffic areas. In addition, the provisions in ZTV E-StB, ZTV SoB-StB, ZTV Asphalt-StB, ZTV Beton-StB, and ZTV PflasterStB shall also apply to excavations unless other provisions are agreed in the contract terms. ZTV A-StB was prepared on the basis of the existing “General technical terms of contract for construction work” (ATV) and the additional technical terms of contract and guidelines, as well as experience in carrying out excavations in municipal roads. The performance description must make special note any deviations from the guidelines in ZTV A-StB that are agreed between the client and the road construction planner. ZTV A-StB 11 replaces ZTV A-StB 97/06. ZTV A-StB 11 has been developed by the German Road and Transportation Research Association (FGSV) in cooperation with the German Gas and Water Industry Association, the German Association of Energy and Water Industries, e.V., the Gütegemeinschaft Leitungstiefbau e.V., and Deutsche Telekom. The obligations under Directive 98/34/EC of the European Parliament and the Council of 22 June 1998 regarding a notification procedure in the field of technical standards and regulations and of rules on Information Society services (OJ L 204 dated 21 July 1998, p. 37), as most recently amended by Directive 2006/96/EC (OJ L 363 dated 20 February 2006, p. 81) must be observed. 5 Contents 1 2 3 4 General ....................................................................................................................................... 8 1.1 Scope ............................................................................................................................ 8 1.2 Definitions..................................................................................................................... 9 1.3 Structural principles .................................................................................................. 12 1.4 Building materials, material mixtures ..................................................................... 14 1.5 1.5.1 1.5.2 1.5.3 1.5.4 Requirements for compaction, deformation modulus, and flatness .................. 14 Compaction degree of the trench backfill .............................................................. 14 Deformation modulus at the subgrade .................................................................. 14 Compaction degree and deformation modulus at the superstructure ............... 14 Flatness ...................................................................................................................... 15 1.6 1.6.1 1.6.2 1.6.2.1 1.6.2.1.1 1.6.2.1.2 1.6.2.1.3 1.6.2.1.4 1.6.2.1.5 1.6.2.2 1.6.2.3 1.6.3 1.6.3.1 1.6.3.2 1.6.4 Testing ........................................................................................................................ 15 General information .................................................................................................. 15 Testing the compaction in earthworks ................................................................... 15 Test procedures ........................................................................................................ 15 Determination of density under DIN 18125 ........................................................... 15 Static plate-loading test as an indirect test procedures ...................................... 16 Dynamic plate-loading test as an indirect test procedures ................................. 16 Testing probe resistance as an indirect test procedures .................................... 16 Monitoring the work process as indirect test procedures ................................... 17 Internal quality control checks ................................................................................. 17 Check tests ................................................................................................................ 18 Testing the superstructure ....................................................................................... 18 Binderless layers ....................................................................................................... 18 Asphalt layers ............................................................................................................ 19 Records regarding layer thicknesses or the installation weight ......................... 19 1.7 Defects ........................................................................................................................ 19 1.8 Acceptance by the road construction planner ...................................................... 19 Removal of the superstructure ............................................................................................. 20 2.1 General ....................................................................................................................... 20 2.2 Asphalt superstructure ............................................................................................. 20 2.3 Concrete superstructure .......................................................................................... 20 2.4 Superstructure with stone pavements or slab pavements .................................. 20 2.5 2.5.1 2.5.2 Other surfaces ........................................................................................................... 20 Binderless top layers ................................................................................................ 20 Green areas and trees ............................................................................................. 21 Removing soil from the excavation ..................................................................................... 21 3.1 General ....................................................................................................................... 21 3.2 Trench shoring ........................................................................................................... 21 3.3 Ground contamination .............................................................................................. 21 Backfilling and compaction of the excavation ................................................................. 21 4.1 General ....................................................................................................................... 21 6 5 4.2 Procedure for sheeted trenches ............................................................................. 21 4.3 4.3.1 4.3.2 Soil types and compactability .................................................................................. 22 Piping zone ................................................................................................................ 22 Fill-in zone .................................................................................................................. 22 Restoring the superstructure ................................................................................................ 22 5.1 Base courses without binder ................................................................................... 23 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 Superstructure with asphalt ..................................................................................... 23 General ....................................................................................................................... 23 Benching..................................................................................................................... 24 Remnants ................................................................................................................... 24 Construction method ................................................................................................ 25 Additional technical regulations .............................................................................. 25 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 Superstructure with concrete .................................................................................. 26 General ....................................................................................................................... 26 Benching..................................................................................................................... 26 Remnants ................................................................................................................... 26 Construction method ................................................................................................ 26 Additional technical regulations .............................................................................. 26 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 Superstructure with stone pavements or slab pavements .................................. 27 General ....................................................................................................................... 27 Benching..................................................................................................................... 27 Remnants ................................................................................................................... 28 Adjustments at manhole covers, built-in parts, and posts .................................. 28 Construction method ................................................................................................ 29 Additional technical regulations .............................................................................. 29 5.5 Other superstructures ............................................................................................... 29 5.6 Overview of benching and remnant widths ........................................................... 30 5.7 Kerbs and drainage gutters ..................................................................................... 31 Annex 1 Reference values for the use of equipment in compacting the fill-in zone ....... 32 Annex 2 Instructions for checking compaction using test compaction and job instructions 33 Annex 3 Excerpt from: Directives for the standardisation of the superstructure of road surfaces (RStO 2001)/2001 Edition ....................................................................... 35 Annex 4 Abbreviations and Guidelines ................................................................................. 41 Excerpts from selected regulations .............................................................................................. 43 Excerpt 1 Excerpt from: Additional technical and contractual guidelines for earthworks in road construction (ZTV E-StB 09), 2009 Edition .................................................. 44 Excerpt 2 Excerpt from: Additional technical and contractual guidelines for the construction of binderless layers in road construction (ZTV SoB-StB 04), 2004 Edition / 2007 Version .............................................................................................. 56 Excerpt 3 Excerpt from: Additional Technical contract conditions and guidelines for the construction of traffic surface pavements made of asphalt (ZTV Asphalt - StB 07), Version 2007 ...................................................................................................... 65 Excerpt 4 Excerpt from: Additional technical contract conditions and guidelines for the construction of base courses with hydraulic binders and driving surfaces made of concrete ................................................................................................................. 79 7 (ZTV Beton - StB 07), Version 2007 ............................................................................................ 79 Excerpt 5 Excerpt from: Additional technical contract conditions and guidelines for the production of sett pavings, slab pavings, and borders (ZTV Pflaster-StB 06), Version 2006 .............................................................................................................. 83 Excerpt 6 Excerpt from: DIN 18299 VOB, Part C: General technical contract conditions for construction works (ATV)—General provisions for all types of construction works, Version 2006 ................................................................................................. 87 Excerpt 7 Excerpt from: DIN 18300 VOB, Part C: General technical contract conditions for construction works (ATV) - Earthworks, Version 2006........................................ 90 Excerpt 8 Excerpt from: DIN 18315 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction – superstructure layers without binder, Version 2006 ................................................................................................ 95 Excerpt 9 Excerpt from: DIN 18316 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction – superstructure layers with hydraulic binders, Version 2006 ............................................................................. 97 Excerpt 10 Excerpt from: DIN 18317 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction – superstructure layers made of asphalt, Version 2006............................................................................................. 106 Excerpt 11 Excerpt from: DIN 18318 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction - Unbound sett pavings and slab pavings, and borders, Version 2006 .................................................................... 108 8 1 General 1.1 Scope The “Additional technical terms of contract and guidelines for excavations on road surfaces”, 2011edition (ZTV A-StB 11), deal with the break-up of road surfaces, the creation and backfilling of service trenches, as well as the restoration of the surfacing. They are set out in such a way that the German Construction Tendering and Contract Regulations (Vergabe- und Vertragsordnung für Bauleistungen), Part C: General technical terms of contract for construction work (ATV) are a component of the building contract, in particular: ATV DIN 18299 “General rules applying to all types of construction work”, ATV DIN 18300 “Earthwork”, ATV DIN 18315 “Road construction - surfacing without binder”, ATV DIN 18316 “Road construction - surfacing with hydraulic binders”, ATV DIN 18317 “Road construction - asphalt surfacing”, ATV DIN 18318 “Road construction - Dry-jointed sett and slab pavements, and surrounds” and ATV DIN 18322 “Underground cable laying work” In addition, the provisions in the valid versions of ZTV E-StB, ZTV SoB-StB, ZTV Asphalt-StB, ZTV Beton-StB, ZTV Pflaster-StB, ZTV BEA-StB, ZTV BEB-StB, and ZTV Fug-StB shall apply to excavations. In the case of contradictions, the provisions in ZTV A-StB shall take precedence. The paragraphs indicated in the text with a line in the margin are “additional technical terms of contract” within the meaning of s. 1 (2d) of the VOB, Part B - DIN 1961 -, if ZTV A-StB is components of the building contract. The paragraphs in the text that are italicised rather than being indicated with a line in the margin are “Guidelines”; the client must observe these in preparing the performance description as well as in the monitoring and acceptance of the construction work. The performance description must make special note any deviations from the guidelines in ZTV A-StB that are agreed between the client and the road construction planner. 9 Products and goods originating from other Member States in the European Union, Turkey, or an EFTA State that is a party to the EEA Agreement that do not meet these technical terms of contract shall be treated as equivalent, including the testing and inspections conducted in the manufacturing state, if the required level of protection with regards safety, health, and durability is consistently achieved. The abbreviations used in the text and the regulations referenced are summarised in Annex 4. 1.2 Definitions The structure of road pavement in a traffic area is divided into Superstructure Substrate (only in embankment area) Subgrade The position and boundaries are shown in Figure 1. Geh-/ Radweg Fahrbahn Unterbau bzw. Untergrund Planum Oberbau Asphaltdeckschicht ggf. mit Asphaltbinderschicht oder Pflasterdecke bzw. Plattenbelag Tragschicht (z.B. Verfestigung) Tragschicht (z.B. Frostschutzschicht) Asphaltdeckschicht, ggf. mit Asphaltbinderschicht Asphalttragschicht Tragschicht (z.B. Verfestigung) Tragschicht (z.B. Frostschutzschicht) Foot/cycle path Road surface Substrate or subgrade Subgrade Superstructure Asphalt surface, where applicable with Asphalt binder course or Stone pavements and slabbed surfaces Base course (e.g. stabilisation) Base course (e.g. frost protection layer) Asphalt surface, where applicable with asphalt binder course Asphalt base course Base course (e.g. stabilisation) Base course (e.g. frost protection layer) Figure 1: Schematic structure of a paved traffic area 10 Benching The benching is the degree to which the bound layers can be cut away after laying the base courses without binder in order to be able to compact the loosened edge areas of the binderless layers. Deckschicht gebundene Tragschicht Tragschicht ohne Bindemittel Verfüllzone Leitungszone a = Grabenbreite b = Wiederherstellungsbreite c = Abtreppung/Rücknahme d = Dicke des Oberbaues Road surface Bound base course Base course without binder Fill-in zone Piping zone a = Trench width b = Width of reconstruction c = Benching/cut-away d = Thickness of the pavement Figure 2: Schematic diagram of benching Asphalt base course The asphalt base course is the bottom layer of the asphalt pavement. It lies beneath a base course without binder or another suitable base (e.g. stabilisation) and consists of asphaltic concrete for asphalt base courses (asphalt base course mixture – AC T). Asphalt binder course The asphalt binder course is an asphalt layer below the asphalt surface and consists of asphaltic concrete for asphalt binder courses (asphalt binder – AC B). Asphalt surface The asphalt surface is the top layer of the asphalt pavement. It consists either of stone mastic asphalt (SMA), asphaltic concrete for asphalt surfaces (AC D), porous asphalt (PA), or melted asphalt (MA). Asphalt combined base and surface layer The asphalt combined base and surface layer is a single-layer asphalt layer. It simultaneously performs the function of an asphalt base course and an asphalt surface and consists of asphaltic concrete for asphalt combined base and surface layers (asphalt combined base and surface layer mixture -AC TD). 11 Excavation Taking up the road surface, excavating mostly subgrade or substrate material (e.g. to install or expose the service lines). Backfilling up to the subgrade and restoration of the superstructure. Also used as a term for the affected area of roadway. Client Within the meaning of ZTV A-StB, the client is the owner or operator of the service lines or buildings, the preparation, modification, repair, or removal of which makes the excavation necessary. Concrete pavements Concrete road surfaces are the upper part of the pavement. They lie on the base course or another suitable substrate. The pavement can be created having one or two courses. Internal quality control check Inspection by the contractor or its agents to determine whether the qualities of the building materials, material mixtures, and the completed performances meet the contractual requirements. Frost protection layer Base course without binder, which is intended to prevent frost damage in the (road) superstructure, and which is composed of frost-resistant material mixtures and/or soil. Check test Check tests are tests performed by the client to determine whether the qualities of the building materials, the material mixtures, and the completed performances meet the contractual requirements; the results are used as a basis for acceptance. Piping zone Zone in which underground lines are stored and embedded with a service trench, the width of which is up to 30 cm over the crown of the pipe. In the case of cables and cable channel systems, the rules of the line owner shall apply. Surface soil Top layer of soil, which, in addition to containing inorganic materials, e.g. mixtures of gravel, sand, silt, and clay, also contains humus and soil organisms: Class 1 in accordance with ATV DIN 18300. Stone pavement Pavement made of paving stones including the pavement beds. Porous lightweight concrete Lightweight concrete with a grain size of 0/2 mm having a high pore content, which is generally used in earthwork for backfilling underground cavities with a consistency of 0.5 N/mm². Remnants Part of the bound paved traffic area between the cut-away edge of an excavation and the edge of the pavement or the nearest joint or seam, or the edge or inner edge of the edging (see Figure 3). 12 vorhandene Fuge Alte Grabung R = Reststreifen Existing joint Old trench R = Remnants Figure 3: Remnants Base courses The base courses are the lower part of the superstructure; they lie directly on the subgrade or on the substrate. They are distinguished according to their composition: - Base courses without binder o o Frost protection layers Gravel and crushed stone base courses - Asphalt base courses - Base courses with hydraulic binders Fill-in zone The space above a service trench above the piping zone up to the subgrade. 1.3 Structural principles Any excavation of a traffic area creates lasting damage to the bedding density, the sequence of layers, and the layer bond of the paved traffic area. For this reason, all efforts should be made to restore an excavated paved traffic area in such a way that it is technically equivalent to its original state. Only qualified companies within the meaning of VOB/A should be contracted for excavation work. 13 Conditions for achieving technical equivalency include especially the following: - Dimensioning should be done in accordance with these additional technical terms of contract and guidelines. In the case of old pavements, the type and scope of the restoration should be determined in consultation with the road construction planner (see Section5). - During acceptance, care should be taken to ensure that there is a proper joint seal between the newly laid course and the existing layers of pavement. - In terms of appearances (especially brightness, colour, and structure), the same types or aggregates, for example, are used in restoring the surface. In order to compact the loosened areas, the bound layers must be cut away (benching) after the base courses have been laid, since otherwise damages such as cracks and subsidence may occur in the surrounding surfaces. The road construction planner and the client may decide to waive the benching on a case by case basis. It is necessary to remove the remnants of the superstructure made of asphalt, concrete, paving stones, or slabs. Before calling for bids on measures, it is necessary to check whether the client, together with the road construction planner, can undertake further road renewal, with the costs being shared by the road construction planner. As a rule, road surfaces are restored during a single building phase, during which the superstructure is restored in one go. In the case of asphalt construction, the restoration can be completed in two phases in exceptional cases, and on consultation with the road construction planner. The following possibilities exist for restoration that is performed in two building phases: - The bound pavement is first laid up to the upper surface of the top layer using an asphalt base course mixture (e.g. paving during the cold season). The asphalt surface is applied at a later point in time, for which the asphalt base course is milled. During milling, over-milling should be avoided (risk of reflective cracking). - The restoration is initially performed by laying a temporarily bound pavement, which connects evenly and flatly, to the existing upper surface of the top layer. During the final restoration, the temporary restoration is removed and replaced with the final pavement (e.g. in especially deep, large-volume trenches in the road surface area, in which subsidence is expected). At the call for bids, attention should be paid to the proper design of joints in asphalt surfaces. This includes a pre-treatment of the cur or milled edges of the asphalt surfaces, since: - They must be waterproof - A covering is needed for materials that are exposed through cutting or milling. The replacement of markings destroyed or damaged by the excavation is part of the restoration, which must be paid for by the client and if necessary, must be included in the performance description accordingly. 14 1.4 Building materials, material mixtures The requirements in ZTV E-StB, ZTV SoB-StB, ZTV Asphalt-StB, ZTV Beton-StB, ZTV Pflaster-StB, ZTV Fug-StB, and ZTV M-StB apply to building materials and material mixtures. In addition, the requirements for pipeline operators must also be observed for the piping zone. The building material mixture for the frost protection layer or the gravel or crushed stone base course must match the accepted aggregate mixture. The use of other aggregates requires the approval of the road construction planner (see Section1.5.1). 1.5 Requirements for compaction, deformation modulus, and flatness 1.5.1 Compaction degree of the trench backfill The requirements in ZTV E-StB apply to the compaction degree that must be achieved in the fill-in zone and in the remaining trench area. If the degree of compaction stipulated in ZTV E-StB cannot be achieved by reusing the excavated soil, the contractor must notify the client of this immediately. If it is known that there are poor soil conditions, the compaction degree of the soil in the service trench up to the subgrade must reach at least the compaction degree of the surrounding soil; this must be coordinated with the construction planner. Minimum trench widths must be maintained (DIN 4124, DIN EN 1610) for proper compaction of the trench backfill. Trench widths of less than 30 cm are only permitted with the approval of the road construction planner. In this case, the building process and the backfill materials, e.g. self-compacting, temporarily fluid backfill material, must be adjusted. The area of the piping and fill-in zone that cannot be properly backfilled and sealed, e.g. close conditions around the sides of the pipes, must be filled with concrete, porous lightweight concrete, soil-binder mixture, or with a self-compacting, fluid backfill material. 1.5.2 Deformation modulus at the subgrade The requirements in ZTV E-StB shall apply to the deformation modulus at the subgrade. If the degree of compaction stipulated in ZTV E-StB cannot be achieved by reusing the excavated, the contractor must notify the client of this immediately. If it is known that there are poor soil conditions, the compaction degree of the soil in the service trench up to the subgrade must reach at least the compaction degree of the surrounding soil. This must be coordinated with the construction planner. 1.5.3 Compaction degree and deformation modulus at the superstructure The binderless layers (frost protection layer, gravel, or crushed stone base course) must be compacted in such a way that the minimum compaction degree and deformation modulus according to ZTV SoB-StB are achieved. If the load values required in ZTV SoB-StB cannot be achieved, for example because of the low layer thickness of the base course without binder or insufficient load - 15 bearing capacity of the bedding layer, the deformation modulus at the surrounding base course without binder must at least be achieved. This must be coordinated with the construction planner. The compaction of the remaining layers of the superstructure must be carried out in accordance with additional technical terms of contract and guidelines (ZTV AsphaltStB, ZTV Beton-StB, and ZTV Pflaster-StB). 1.5.4 Flatness The junction with the existing road pavement must be at the same height. The joints must lie 3 to 5 mm above the surface beside built-in fixtures, and 5 to 10 mm above the gutter beside kerbs and gutters. ZTV Asphalt-StB, ZTV Beton-StB, and ZTV Pflaster-StB shall apply to the limits for longitudinal flatness imperfections. In terms of the flatness in the transverse direction within the excavation, 1.5 % of the width of the reconstruction is considered an acceptable height deviation for mechanised paving, so a maximum of ± 3 mm for a trench width of up to 2.00 m, as long as the edges of the excavation (existing areas) have no greater flatness imperfections. In the case of manual paving, 2.5 %o of the width of reconstruction is considered an acceptable height deviation, so a maximum of ± 5 mm for trench widths of up to 2.00 m. 1.6 Testing 1.6.1 General information The tests required under ZTV E-StB, ZTV SoB-StB, ZTV Asphalt-StB, ZTV BetonStB, ZTV Pflaster-StB, and ZTV Fug-StB must be performed. 1.6.2 Testing the compaction in earthworks 1.6.2.1 Test procedures The procedure for testing the compaction must be coordinated in advance with the road construction planner and must be indicated in the performance description. 1.6.2.1.1 Determination of density under DIN 18125 Studies to test the trench backfill according to DIN 18125-2 (volume replacement procedure) and DIN 18127 (proctor compaction test for soil) or DIN EN 13286-2 (proctor compaction test for base courses without binder) must be conducted. Water content and density can be determined using a radiometric probe. Measurement results correlate to the required proctor density or to the density of the surrounding soil according to ZTV E-StB. When using a consistent backfill soil (same soil parameters), indirect testing procedures may be used for follow-up tests. 16 1.6.2.1.2 Static plate-loading test as an indirect test procedures Instead of testing the compaction degree D Pr using proctor density as a reference value, it is possible instead to test the load-bearing capacity using a static plate-loading test in accordance with DIN 18134 for coarse-grained soils and mixed-grained soils with a fine-grained content of up to 15 mass % if determining the compaction degree DPr is very difficult of time consuming because of the material properties. The static plate-loading test may only be performed on the surface of the trench backfill if the necessary working space is available to set up the counterweight (loaded truck). The deformation modulus using the static plate-loading test may only be determined for trench widths greater than 1.50 m in order to exclude the influence of the trench edges (diameter of the load plate is 30 cm). In so doing, the ratio of the deformation moduli must be Ev2/Ev1 ≤ 2.3, if a compaction degree of DPr ≥ 100 % is required. In the case of a compaction degree DPr of ≥ 98 %, the ratio must be Ev2/Ev1 ≤ 2.5 (see ZTV E-StB). If the Ev1 value has already reached 60 % of the required Ev2 value, higher ratios Ev2/Ev1 are also permissible. The benchmarks for the static deformation modulus E v2 are found in ZTV E-StB. 1.6.2.1.3 Dynamic plate-loading test as an indirect test procedures For coarse and mixed-grained soils with a fine-grained content of up to15 mass %, instead of testing compaction degree DPr using proctor density as a reference value, testing may be conducted using a dynamic plate-loading test in accordance with TP BF-StB, Part B 8.3. In so doing, the scope of testing is to be doubled as compared with the direct test procedures. Testing using the dynamic plate-loading test is especially suited for service trench construction, since this allows the individual layers of the service trench to be quickly tested. Aside from the details in ZTV E-StB, it is possible to use regionally available correlation values for mixed-grained soils with a fine-grained content greater than 15 mass % and fine-grained soils. They should be based on the performance description. The procedure must be coordinated with the road construction planner. 1.6.2.1.4 Testing probe resistance as an indirect test procedures It is also possible to assess the trench backfill with a probe resistance test using dynamic probing or penetration tests in accordance with DIN EN ISO 22476-2, or other devices developed for this purpose. The minimum impact rate for the required compaction degree must be determined according to the soil type being used. Regionally available practical values may be used as a basis; the approach must be coordinated with the road construction planner. When driving in the light penetrometer (TP BF-StB being edited), the soil in the upper area is loosed by displacement. The impact numbers in the upper 50 cm are therefore not comparable. It is advisable to load the base plate with a corresponding dummy load (concrete rings or the like.) in order to obtain comparable values from the top of the backfill. 17 1.6.2.1.5 Monitoring the work process as indirect test procedures For small construction projects, especially for narrow trenches, it is recommended that the work process be determined in coordination with the road construction planer before starting construction. In the case of soil types, for which a test compaction has been performed under the same conditions over the course of prior construction projects, and for which job instructions were created, this should be used as a basis for testing compaction. If there is no past experience for the soil being used based on test compactions, a test compaction should be performed in order to create job instructions (see Annex 2). 1.6.2.2 Internal quality control checks It must be demonstrated that the compaction of the fill-in zone is sufficient. Notwithstanding ZTV E-StB, separate monitoring of the piping zone is dispensed with for shallow and narrow service trenches. If the monitoring of the work process in order to monitor compaction has been agreed, compliance with that process must be recorded. If compliance with the job instructions is in doubt or if it has not been agreed that the work process will be monitored, compaction is to be demonstrated using one of the test procedures in Table 1. 18 Table 1: Number of compaction tests depending on the test procedures and the thickness of the fill-in zone Test procedures Proctor compaction test (Section 1.6.2.1.1), Dynamic plate-loading test (Section 1.6.2.1.3) Static plate-loading test (Section 1.6.2.1.2), Dynamic probing or penetration tests (Section 1.6.2.1.4) A test for fill-in zone thicknesses of up to 2.00 m A test for fill-in zone thicknesses greater than 2.00 m - per installed layer and - per 50 m of - per installed layer and per 25 m of trench length started trench length started - per metre thickness started per metre of thickness of the fill-in of the fill-in zone and zone started and - per 50 m of per 25 m of trench length started trench length started - In addition the uniformity of the compaction should be tested using the light penetrometer (TP BF-StB being edited) per every 25 started. The compaction of shaft excavations must be examined in any case. Testing may be waived in the case of sleeves and head holes. The load-bearing capacity of the subgrade must be tested for every 100 m of trench length for jobs with contiguous surfaces starting at 50 m². It is possible to forego a separate test of the load-bearing capacity if the subgrade loadbearing tests have been performed during the internal quality control checks as indirect test procedures or “monitoring the work process" has been agreed as a testing method. The records from the internal quality control checks are to be presented to the client. These records are to be submitted to the road construction planner upon request. 1.6.2.3 Check tests The extent of the control testing to be carried out by the client should be approximately 30 % of the scope of internal quality control checks. The test records are to be submitted to the road construction planner upon request. It is possible to forego control testing if the client is involved in carrying out the internal quality control check and oversees that it is properly carried out. 1.6.3 Testing the superstructure Testing of the installed layer thicknesses and the compaction of the individual surfacing is to be carried out in accordance with the additional technical terms of contract and guidelines (ZTV). 1.6.3.1 Binderless layers The deformation modulus is to be determined as an internal quality control check in accordance with DIN 18134 for jobs with contiguous surfaces starting at 50 m² for each 100 m of trench length started, if it has not been agreed that the work process will be monitored. 19 The scope of the internal quality control checks may be increased in justified cases. This must be included in the performance description. Section 1.6.2.3 applies to control testing. 1.6.3.2 Asphalt layers The internal quality control checks during paving are to be performed in accordance with ZTV Asphalt-StB. Check tests should be carried out by the client for every layer for jobs with contiguous surfaces starting at 1 000 m². Control testing may also be necessary for smaller areas in justified cases. Grain size distribution, binder content, binder type, void content, and compaction degree must be determined. 1.6.4 Records regarding layer thicknesses or the installation weight In the case of contiguous areas starting at 50 m², records are to be kept of the layer thickness or installation weight of the binderless layers and/or the bound surfacing according to ZTV SoB-StB, ZTV Asphalt-StB, ZTV Beton-StB, and ZTV Pflaster-StB. 1.7 Defects The contractual provisions regarding warranty claims in the respective ZTVs shall apply. 1.8 Acceptance by the road construction planner Acceptance is expected immediately upon completion. Prerequisite or acceptance is the notice of completion and submission of all documents by the client. The road construction planner may refuse acceptance for substantial defects until those defects are remedied. If the date of transfer is not set by the road construction planner within 12 working days after receiving the notice of completion, the restored traffic area shall be considered to have been accepted upon the expiration of this deadline. Special provisions must be agreed for two-step construction methods. The road construction planner may make acceptance contingent upon the performance and submission of additional control testing—even in the case of single excavation. The costs associated with this testing shall be borne by the road construction planner. If the values required in the contract are not achieved, the client must assume these costs and require the contractor to make subsequent improvements. 20 2 Removal of the superstructure 2.1 General As a rule, the condition of the road surfaces around the construction site must be determined and documented with the road construction planner before starting to break up the pavement. Kerbs that are intersected must be carefully removed before the start of the excavation work and stored. Undercutting is only permitted in exceptional cases in coordination with the road construction planner. In the case of service trenches and other excavations, the existing superstructure is to be taken up with care. Material that is to be backfilled without special treatment such as material mixtures from crushed stone base courses and frost protection layers meet the requirements under ZTV SoB-StBare to be temporarily stored separately. The remaining materials are to be recycled wherever possible. If materials containing tar or pitch are encountered when breaking open the pavement, the client must be informed of this immediately. The disposal of this material must be arranged with the road construction planner. 2.2 Asphalt superstructure Before removing the road pavement, the asphalt superstructure in the vicinity of the trench width must be separated using appropriate devices unless it is milled. The edge of the trench should be laid out in parallel to the pipeline route. 2.3 Concrete superstructure The point at which the pavement will be broken up must be demarcated with straight lines and right angles, in accordance with its dimensions. The concrete pavement must be cut through perpendicularly and then broken up above the trench or excavation route approximately in the width of the excavation using suitable equipment. Any plugs or anchors must be removed in order to protect the remaining area. 2.4 Superstructure with stone pavements or slab pavements Before starting construction, it is necessary to clarify with the road construction planner whether the paving stones or slabs are suitable for reuse. Paving stones and slabs that are intended for reuse should be carefully taken up, cleaned, and stored. 2.5 Other surfaces 2.5.1 Binderless top layers The superstructure is to be taken up as part of the excavation. 21 2.5.2 Green areas and trees All excavations in green areas must be agreed with the competent government departments prior to the start of construction. 3 Removing soil from the excavation 3.1 General The removed soil is to be reused during relaying of the pavement as needed and as suitable. For larger construction projects, it is recommended that a soil report be obtained before creating the performance description. In the case of soil that contains silt or clay, the water content should be checked in order to determine whether the soil is suitable for reuse. If the reusable soil is sensitive to the effects of weather, it must be covered with plastic sheeting immediately after excavation or protected against the ingress of water. 3.2 Trench shoring In order to prevent later subsidence, the trench shoring must lie flush with large areas of the trench wall. Cavities that form behind the excavation pit lining must backfilled immediately. 3.3 Ground contamination If contaminated soils are encountered when breaking up the pavement, the client must be informed immediately. The client must coordinate their disposal with the road construction planner. The necessary actions are considered special services. 4 Backfilling and compaction of the excavation 4.1 General Compaction must be done in accordance with ZTV E-StB (see Section1.5.1). 4.2 Procedure for sheeted trenches In the case of service trenches with sheeting, the installation and compaction of the backfill soil should be adjusted for the sheeting being used. The connection between the backfill soil and trench wall must be ensured, regardless of the type of sheeting. 22 In the case of horizontal sheeting and sheeting elements, the sheeting elements must be removed in sections. The backfill soil must immediately be filled into the exposed portion of the excavation pit in layers and compacted. In the case of vertical sheeting, the soil must also be filled into the unsheeted trench in layers and compacted to the required compaction degree. The removal of vertical sheeting components (trench sheets, sheet piling) must be included in the static calculation of the pipes. The removal of shoring panels or boards after backfilling is complete is not permitted. 4.3 Soil types and compactability 4.3.1 Piping zone Filling soils that meet the specifications of the respective pipeline operator must be used for the area around the piping zone. The soil on both sides of the line in the piping zone is to be filled in simultaneously in layers and carefully compacted. In so doing, care should be taken to ensure that the pipeline remains in place. The manhole construction pits must also be backfilled in the same manner. In all cases in which cable protection pipes are laid over one another in multiple layers in road surfaces, cavities must be backfilled with porous lightweight concrete or an equivalent material. If cable protection pipes are laid over one another in multiple layers in foot paths, cycle, and the like, cavities must be backfilled with sand after laying each layer of pipes. 4.3.2 Fill-in zone Reference values (suitability, layer thickness, and transitions) for the use of compactors depending on the type of soil and equipment are summarised in the “Data sheet on the compaction of the subsoil and substrate in road construction”. In Annex 1, practical values are also included with these reference values. The information in Annex 1 can also be consulted when agreeing on a work process according to Section 1.6.2.1.5. The organic and organogenic soils, soils with organic admixtures as well as distinctly plastic, fine-grained soils and especially swelling soils listed in DIN 18196 are not suitable for backfilling service trenches (HN, HZ, F, OU, OT, OK). The soil is to be filled in layers and compacted. The fill height must be determined according to the type of soil and compactor. An approach that differs from Annex 1 may be agreed on with the road construction planner prior to the start of work according to regional needs. 5 Restoring the superstructure The objective in restoration is to restore the superstructure of the excavated traffic area in such a way that it is technically equivalent to its original state. 23 If the restoration of the superstructure with the layer structure encountered is not technically appropriate, the restoration is based on the standard construction methods of the RStO (see Annex 3). If the layer structure encountered significantly exceeds or falls short of the structure required by the composition in accordance with RStO, a construction method based on the existing superstructure must be determined in coordination with the road construction planner. 5.1 Base courses without binder When paving in service trenches, no decomposition of the aggregates may occur. The use of recycled building materials or industrially manufactured aggregates is permitted of the material that complies with the specifications in TL Gestein-StB and TL SoB-StB, and this has been approved by the road construction planner. Paving must comply with ZTV SoB-StB. 5.2 Superstructure with asphalt 5.2.1 General An asphalt pavement may only be restored using a hot application. The composition of the asphalt surface mixture must be matched to the composition of the existing asphalt surface. When manually laying mixtures for asphalt surfaces, insulated containers must be used to transport asphalt mixtures. This is the only way to ensure that the temperatures required under ZTV Asphalt-StB are also maintained for small amounts. Asphalt surfaces made of roller-compacted asphalt with an paving thickness of at least 3 cm may not be laid in air temperatures below +5 °C; asphalt surfaces made of melted asphalt with a thickness of at least 3 cm, asphalt binder courses, asphalt combined base and surface layer, as well as compact asphalt pavements may not be laid at air temperatures below 0 °C; and asphalt base courses may not be laid at air temperatures below –3 °C. Asphalt surfaces with a paving thickness below 3 cm and porous asphalt surfaces may not be laid at an air temperature below +10 °C and bedding layer temperatures below +5 °C. Porous asphalt may not be laid in high winds. Asphalt surfaces made of stone mastic asphalt must be laid using pavers. If this is not possible, the excavation area must be manually sealed using melted asphalt or asphaltic concrete for asphalt surfaces in coordination with the client and in consultation with the road construction planner. The use of small-scale asphalt recycling processors requires the approval of the road construction planner. 24 5.2.2 Benching Benching is to be done parallel to the edge of the trench, at right angles in the case of extensions within the trench (manholes, outcroppings, etc.). As a rule, benching in bound courses is done with sharp edges (see Figure 4). Loose excavation material must be removed. The asphalt surface should be cut or milled. After laying the base courses without binder, the asphalt layers are to be cut back to the extent that the edge areas of the base courses without binder have been loosened, at a minimum, however: by approximately 15 cm for trench depths < 2.00 m by approximately 20 cm for trench depths ≥ 2.00 m. The loosened edge areas of their base courses without binder must then be recompacted. Material must be added to replace missing material. Figure 4: Benching for asphalt construction methods Asphaltdeckschicht ggf. mit Asphaltbinderschicht Asphalttragschicht Tragschicht ohne Bindemittel Verfüllzone Leitungszone a = Grabenbreite b = Wiederherstellungsbreite c = Abtreppung/Rücknahme d = Dicke des Oberbaues 5.2.3 Asphalt surface, where applicable with asphalt binder course Asphalt base course Base course without binder Fill-in zone Piping zone a = Trench width b = Width of reconstruction c = Benching/cut-away d = Thickness of the superstructure Remnants Remnants of the asphalt superstructure beside the cut back bonded layers that are less than 35 cm should be removed. Larger remnants should also be removed if they are visibly loosened or if joint gaps have formed along the edges. Before beginning construction, it should be examined wither it is economically feasible to replace larger widths. 25 5.2.4 Construction method In the event that there are a greater number (n > 4) of subsequent excavations for the client in the road surface (with a distance between them of up to 10 m, e.g. for checking pipe connections), the affected lanes must be given a new asphalt surface at a width equal to the greatest excavation width (see also Section 1.3). In addition, it should also be examined whether it is economically feasible to repair larger areas, where appropriate with cost-sharing by the road construction planner. The cut or milled edges of asphalt pavements must be kept clean and free of dust while preparing to close the excavation. The seam must be formed in the asphalt surface as a joint. The following options for this include: 1. Casting subsequently created joints with joint compound. 2. The use of joint tape. ZTV Asphalt-StB and ZTV Fug-StB apply to the formation of joints. Regardless of the type of joint created, all asphalt layers that are cut through must be completely painted or coated with hot asphalt 160/220, an asphalt emulsion, or a primer containing asphalt. Adhesives should not be used. The surface of the existing asphalt surface may not be contaminated with binder. The asphalt mixture may only be laid when the coating is adequately dry. When laying melted asphalt, water-stops must be installed or joints for draining water are to be formed using flat steel bands. If a joint can be dispensed with in individual, justifiable cases, this may only be done with the approval of the road construction planner. Only up to100 m2 of asphalt surface mixture may be manually installed in contiguous areas with widths greater than 1.50 m. Pavers should also be used for smaller areas. ZTV Asphalt-StB and TL Asphalt-StB apply to the asphalt mixture being used and the installation of asphalt layers. Test procedures and the scope of skid resistance measures on the finished asphalt surface must be coordinated with the road construction planner before starting asphalt road construction. 5.2.5 Additional technical regulations Applicable regulations include: “Technical terms of delivery for asphalt aggregates for the construction of paved traffic area” (TL Asphalt-StB) and the “Technical terms of delivery for joint fillers on road surfaces” (TL Fug-StB) together with “Technical testing regulations for joint fillers on road surfaces” (TP Fug-StB) and “Additional technical terms of contract and guidelines for joint fillers on road surfaces” (ZTV FugStB). In addition, “Additional technical terms of contract and guidelines for the structural maintenance of paved traffic area—Asphalt construction methods” (ZTV BEA-StB) is also applicable. In addition to ZTV Asphalt-StB, “Data sheet on layer bond, seams, joints, and edging of asphalt traffic areasˮ (M SNAR) must also be observed when producing transverse seams and joints. 26 5.3 Superstructure with concrete 5.3.1 General Before laying concrete pavements, the trench edges are to be cut back so that they are straight. As a rule, all edges are to be at right angles to one another. 5.3.2 Benching After laying the base courses without binder, the asphalt layers are to be cut back to the extent that the edge areas of the base courses without binder have been loosened, at a minimum, however: by approximately 15 cm for trench depths < 2.00 m by approximately 20 cm for trench depths ≥ 2.00 m. The loosened edge areas of their base courses without binder must then be recompacted. Material must be added to replace missing material. 5.3.3 Remnants Remnants with a width of less than 120 cm from the edge or the next joint must be removed. A width/length ratio of > 0.4 must be maintained. Larger remnants should also be removed if they are visibly loosened or if joint gaps have formed along the edges. 5.3.4 Construction method ZTV Beton-StB shall apply to the production of concrete pavements. High early strength concrete with a liquefier should be used for all excavations, in which the concrete paving is not is not being done using machines or in which areas cannot be restored as a whole. The joints of the restored concrete pavements at the existing concrete pavements must be forms using compression joints with drilled in dowels or tie bars and then filled with a hot applied sealant or its equivalent at a width of at least 10 mm and a depth of 20 mm once the concrete has hardened. The expansion, contraction, and compression joints already encountered in the excavation site must be restored including the dowel and tie bar. In individual cases, it is possible to deviate from this method with the approval of the road construction planner and, for example, additional transverse joints may be provided or an existing joint may be moved as needed. Test procedures and the scope of measurements of the grip on the finished concrete surface must be coordinated with the road construction planner before starting concrete work. 5.3.5 Additional technical regulations “Technical terms of delivery for joint fillers on road surfaces” (TL Fug-StB), together with “Technical testing regulations for joint fillers on road surfaces” (TP Fug-StB), and “Technical terms of delivery for construction materials and material mixtures for base courses with hydraulic binders and concrete surfacing” (TL Beton-StB), and the 27 “Additional technical terms of contract and guidelines for joint fillers on road surfaces” (ZTV Fug-StB) are applicable. In addition, “Additional technical terms of contract and guidelines for the structural maintenance of road surfaces – concrete construction” (ZTV BEB-StB) shall also apply. The “Data sheet on the structural maintenance of concrete road surfaces” (M BEB) must be observed. 5.4 Superstructure with stone pavements or slab pavements 5.4.1 General The surface being laid again must be matched to the shape and colour of the existing surface. Breakups in stone pavements involving entire stones must be closed again using entire stones of the same colour. Care should be taken to ensure that the paving stones or slabs are laid in those areas, in which they were taken up, in order to preserve the old surface texture, colour of the stones, shape, etc. The call for tenders should specifically note the bound construction method used in the superstructure and an appropriate approach should be agreed with the road construction planner. Replacements for already damaged stones or slabs should be provided upon request, free of charge by road construction planner prior to the start of excavation. The replacement material must be installed in the contiguous areas. If the road construction planner wants work performed on a different surface, he or she must beat the additional costs beyond the cost of restoration. The edges of the remaining surfacing may not be loosened and the new joints may not differ from the adjacent joints. 5.4.2 Benching Benching is to be done parallel to the edge of the trench, at right angles in the case of extensions within the trench (manholes, outcroppings, etc.). As a rule, benching in bound courses is done with sharp edges (see Figure 4). Loose excavation material must be removed. The asphalt surface should be cut or milled. After laying the base course without binder, the anchored layers (surface and, where applicable, the base course) are to be cut back to the extent that the edge areas of the base courses without binder have been loosened, at a minimum, however: by approximately 15 cm for trench depths < 2.00 m by approximately 20 cm for trench depths ≥ 2.00 m. The loosened edge areas of their base courses without binder must then be recompacted. Material must be added to replace missing material. In the event that a bound base course exists under the stone pavement or the slabbed surface, a cut-away proportionate to the loosening and an additional benching “e” from a format width are necessary (see Figure 5). 28 Figure 5: Benching in stone pavements and slabbed surfaces ohne gebundene Tragschicht mit gebundener Tragschicht Pflasterdecke / Plattenbelag gebundene Tragschicht Tragschicht ohne Bindemittel Verfüllzone Leitungszone a = Graben breite b = Wiederherstellungsbreite c = Abtreppung/Rücknähme e = zusätzliche Abtreppung einer Formatbreite 5.4.3 Without a bound base course With a bound base course Stone pavement/slabbed surface Bound base course Base course without binder Fill-in zone Piping zone a = Trench width b = Width of reconstruction c = Benching/cut-away e = Additional benching of a format width Remnants In the case of road surfaces and parking strips, remnants beside the benched surface must be removed if their width to the edge of the pavement is less than 40 cm or in the case of relocating a segment arc, half the width of an arc of paving. In the case of foot and cycle paths, remnants with a format width or a width of up to 20 cm including any existing base course must be removed. Larger remnants should also be removed if they are visibly loosened or if joint gaps have formed along the edges. 5.4.4 Adjustments at manhole covers, built-in parts, and posts During restoration work, only whole to half paving stones and/or slabs or fit plates may be used in the area on either side of the pipes. Otherwise, the areas on either side of the pipes must be closed in consultation with the road construction planner. Street caps or other built-in parts are to be adjusted in consultation with the utility companies and paved in a professional manner. 29 5.4.5 Construction method The restoration work is to be performed according to ATV DIN 18318 and ZTV Pflaster-StB. The aggregates for bedding and joint filler are to be selected in consultation with the road construction planner. 5.4.6 Additional technical regulations The “Technical terms of delivery for joint fillers on road surfaces” (TL Fug-StB) together with “Technical testing regulations for joint fillers on road surfaces” (TP FugStB) as well as the “Additional technical terms of contract and guidelines for joint fillers on road surfaces” (ZTV Fug-StB) are applicable. The “Data sheet on surface pavements with paving and slabs - Part 1: Standard construction method (unbonded construction)” (M FP1) must be observed. 5.5 Other superstructures If out-dated construction methods have been used (e.g. rough-stone pitching, coarse gravel, macadam surfaces), the type and scope of the restoration must be agreed between the client and the road construction planner. In the case of pavements with binderless top layers, benching is omitted. The width of reconstruction is the trench width plus the thickness on each side of the superstructure (see Figure 6). The restoration is done in accordance with ZTV SoB-StB. Deckschicht ohne Bindemittel Tragschicht ohne Bindemittel Verfüllzone Leitungszone a = Grabenbreite b = Wiederherstellungsbreite d = Dicke des Oberbaues Binderless top layer Binderless base course Fill-in zone Piping zone a = Trench width b = Width of reconstruction d = Thickness of the superstructure Figure 6: Restoration of pavement with binderless top layers 30 5.6 Overview of benching and remnant widths Table 2: Benching and remnant widths in the restoration of paved traffic area Benching per side No Superstructure Trench depth Trench depth T < 2.00 m T ≥ 2.00 m 1 2 Asphalt layers: Asphalt surface, asphalt base course (upper asphalt base layer if applicable) Concrete pavements at least 15 cm at least 15 cm at least 20 cm at least 20 cm Stone pavement / slabbed surface 3 With binderless base course at least 15 cm at least 15 cm plus an With bound base additional course format width 4 Out-dated construction method (rough-stone pitching, coarse gravel, macadam surfaces) at least 20 cm at least 20 cm plus an additional format width Remnant widths* (dimensions of paved traffic area to be cut back) < 35 cm From edge of pavement or the nearest joint or seam, or the edge of inner edge of the kerb < 120 cm Up to the edge or to the next joint; the ratio of width to length should not be less than 0.4. Road surfaces and parking strips < 40 cm Up to the edge of the paving or ½ the arc with of the paving Foot and cycle paths Format width or < 20 cm including any bound base course Restoration – Coordination with the road construction planner * Larger remnants should also be removed if they are visibly loosened or if joint gaps have formed along the edges. 31 5.7 Kerbs and drainage gutters If kerbs and drainage gutters are affected by the excavation or are no longer stable or have been undercut by the excavation, they are to be taken up and placed on a concrete foundation according to ATV DIN 18318—in the case of kerbs, they should also be installed again with a concrete backrest—in accordance with Figure 7. The “Data sheet on surface pavements with paving and slabs” (M FP1) must be observed. Figure 7: Schematic representation of a kerbstone border Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. Annex 1 32 Reference values for the use of equipment in compacting the fill-in zone Soil groups Type of equipment Vibratory rammer/plate tamper Vibratory plates/ Place compactor Vibrating rollers single-drum roller/tandem roller + recommended o most suitable Coarse-grained soils (GW, GI, GE, SW, SI, SE) Operating max. 5 M-% grain diameter 0.063 mm und weight Mixed-grain soils (GU, GT, SU, ST) max. 15 M-% grain diameter 0.063 mm Fine-grained soils 1) UL, UM, TL, TM > 40 M-% grain diameter 0.063 mm Mixed-grain soils 1) GU*, GT*, SU*, ST* 5–40 M-% grain diameter 0.0.63 mm kg Suitability Fill height cm No of passes Suitability Fill height cm No of passes Suitability Fill height cm No of passes - 50 o 15–20 3–7 o - 15 3–7 o - 15 2–4 50–80 o 20–30 3–7 o 20–30 3–7 o 10–20 2–4 > 80 o 30–35 3–7 o 30–35 3–7 o 20–30 2–4 - 150 + 15–20 4–6 o - 15 4–6 - - 150 - 400 + 20–30 4–6 o 10–20 4–6 - - > 400 + 30–40 4–6 o 20–40 4–6 o 20–30 6–8 - 3 000 + 15–20 4–8 + 15–20 4–8 + - 152) 4–8 3 000 7 000 + 20–30 4–8 + 20–30 4–8 + 20–30 2) 4–8 > 7 000 + 30–50 4–8 + 30–40 4–8 + 20–30 2) 4–8 Water content 0.9 w Pr < w < 1.1 w Pr 2) with padfoot 1) Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 33 Annex 2 Instructions for checking compaction using test compaction and job instructions 1. Creating a test field in the service trench A field test is to be performed for each type of soil being used for which there is no reference value. The optimum fill height and the required number of compacting passes needed to achieve the compaction requirements are to be determined for the compactor selected. The test compaction may be performed at the start of backfill work at the building site/in the service trench. The length of the test field depends upon the fill height, construction site conditions, and the dimensions of the device, but should be at least 10 m. 2. Test compaction The choice of equipment depends on: Type of soil The designated compaction depth Building site conditions. The equipment used for the test compaction must be the equipment that will also be used for compaction during subsequent construction operations. The equipment and settings for the compactor used must be precisely and comprehensively described in the job instructions. Depending on the type of equipment, the following g information must be provided: For rollers: Smooth-wheeled/sheepsfoot rollers Single wheel/2-wheel/tandem design Self-propelled/drawn Static/dynamic/static and dynamic effect Operating weight Width and diameter of the footpad Vibration frequency Operating speed Vibration direction (vertical/horizontal). For plate compactors: Self-propelled/drawn Operating weight Dimensions of the footprint Vibration frequency Operating speed. For vibratory rammers: Operating weight Dimensions of the footprint Impact frequency/number Upstroke of the ramming plate. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 34 Prior to compaction, the exact heights of the fill layers must be measured and recorded. See ZTV A-StB, Annex 1: Reference values for the use of equipment to compact the fill-in zone. The compaction must be performed in such a way that it corresponds to subsequent construction. The full width of the test fields are compacted using the planned equipment passes, where first the edges and then the middle lanes are treated. 3. Testing the compaction of the test field The compaction degree achieved is tested for a single test position for layers with a thickness of 20 to 30 cm (depending on the type of soil and the compactor being used). Layers with a thickness greater than 30 cm must be tested at various depths. In order to do so, the compacted layer is divided into individual test positions, where a test is performed for every 30 cm started. Compaction is tested using one of the test procedures according to ZTV A-StB, Sections 1.6.2.1.1 through 1.6.2.1.4. 4. Job instructions Based on the results obtained at the test field, it must be possible to give following information in the job instructions: - Type of soil - Type of compactor - Rate of advance or working conditions (e.g. frequency-amplitude) of the compactor - Number of required compacting passes - Maximum allowable fill height (non-compacted) - Permissible water content range for the soil being filled in. The job instructions or the specific type of soil must contain information regarding the compactors selected and the results obtained from the test compaction. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 35 Annex 3 Excerpt from: Directives for the standardisation of the superstructure of road surfaces (RStO 2001)/2001 Edition ….. 2.6 Construction classes and traffic load Road surfaces and other transport areas, with the exception of cycle and foot paths, are assigned to Construction Classes SV and I to VI depending on their traffic load. 2.6.1 Road surfaces ….. If the load, B, that is relevant to the measurements being taken cannot be determined for road surfaces, e.g. in the built-up area, the types of roads can be assigned to the construction classes in accordance with Table 2. At crossings and in junction areas, the load, B, relevant to measurements being taken is the busiest lane on the connecting routes is decisive. Table 1: Type of road and assigned construction class Row Type of road 1 Expressway, industrial access road Construction class SV / I / II 2 Main road, industrial road, road in an industrial zone II / III 3 Residential access road, pedestrian area with cargo traffic Service road, drivable residential path, pedestrian zone (without bus traffic) III / IV 4 V / VI ….. 3.3 3.3.1 Superstructure Construction methods and layer thicknesses Tables 1 to 3 present the standardised construction method with asphalt pavement, concrete pavement, and stone pavement on F2 and F3 soils for the respective construction classes. Section 3.1.2 applies to F1 soils. ….. Tables 1 to 3 indicate the thicknesses of the frost-resistant superstructure on F2 and F3 soils in 10-cm increments. If the thickness of frost-resistant superstructure indicated in Section 3.2 differs from that of these tables, Section 3.2 shall apply. ….. 3.3.6 Special circumstances It may be necessary to deviate from the provisions in Section 3.1 through 3.3.5 if there are special circumstances, for example in the area of the supply or sewage lines, or for technical and economic reasons. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 36 3.4 Additional information for road surfaces in built-up areas The provisions in Sections 3.1 through 3.3 and in Section 4 also apply to roads in built-up areas insofar as the special circumstances of the municipal road allow, and no other claims need to be taken into account. For example, difficulties arise for construction if: – Road width is limited – Construction must be performed under traffic, especially in intersection areas – There are supply and waste lines, valves, manholes, drains as well as specific demands as a result of increased driving without lane changes, and because of limited visibility on the motorway in high-traffic areas. Depending on local conditions, additional measures are needed in addition to the selection of more durable asphalt layers such as laying an additional asphalt base course with aggregate type AO or reinforcing the bound base course taking into account the thickness of the frost protection layer. ….. 5.2 5.2.1 Cycle and foot paths Construction methods and layer thicknesses Table 7 presents the standardised construction methods for cycle and foot paths. The construction methods and layer thicknesses are selected in such a way that recreation service vehicles can drive on these areas. Even occasional use by other vehicles is not considered. Particular attention should be paid to flatness and drainage when selecting the construction method. Soils belonging to frost Susceptibility Class F1 do not require frost protection measures. For soils belonging to frost Susceptibility Classes F2 and F3, a frost-resistant superstructure with a minimum thickness of 30 cm, and of 20 cm in a built-up area is adequate. Unfavourable climatic conditions and water conditions must be taken into account as per local experience. In the vicinity of vehicle crossings, the pavement thickness must be selected in accordance with the traffic load. In a dense sequence of crossings, the construction method and thickness selected for the crossings must also be checked for the areas between these. Construction method using slab pavements are generally not effective in this case. In addition to the construction methods presented in Table 7, thinner pavements or simple construction methods (e.g. binderless top layer) may be adequate. If cycle and foot paths are situated at a deeper lying edge of the road, it is especially useful for drainage reasons to run the subgrade and frost protection layer of the road surface under the pavement of the cycle foot path. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 37 Table 37: Construction method using asphalt pavement for road surfaces on F2 and F3 subgrade/substrate (construction methods on F1 soils, see Section 3.1.2) EV2 minimum values in MN/m2) (Thickness in cm; Row Construction class Equivalent 10-t axel B passages in millions SV I II III IV V VI > 32 > 10–32 > 3–10 > 0.8–3 > 0.3–0.8 > 0.1–0.3 < 0.1 Thickness of frost-resistant superstructure) 55 65 75 85 55 Asphalt base course on frost protection layer 65 75 85 55 65 75 85 45 55 65 75 45 55 65 75 135 45 55 65 35 45 55 65 312) 41 51 233) 35 45 55 293) 39 49 59 332) 43 53 273) 37 47 57 212) 31 Asphalt base course and base course with hydraulic binding agent on frost protection layer or course made of frost-resistant material 41 51 25 35 45 55 163) 26 36 Asphalt surface Asphalt binder course 1 Asphalt base course Frost protection layer Thickness of the frost protection layer Asphalt surface Asphalt binder course 2.1 Asphalt base course Hydraulically bound base course (HGT) Frost protection layer Thickness of the frost protection layer 2.2 - - 104) 204) 342) 44 - 283) 38 48 24 34 44 184) - 302) 40 50 28 38 48 124) - - 342) 44 - 263) 36 46 - 163) 26 36 - Asphalt surface Asphalt binder course Asphalt base course Stabilisation Layer out of frost-resistant material -largely or intermittently - classified according to DIN 18196Thickness of the layer made out of frost-resistant material 30 40 144) 22 32 42 164) 26 36 46 64) 164) 26 36 64) 164) 26 36 27 37 164) 26 36 46 64) 164) 26 36 64) 164) 26 36 263) 36 46 - 183) 28 38 - 202) 30 40 312) 41 - - 232) 33 - 153) 25 35 Asphalt binder course Asphalt base course 2.3 Stabilisation Layer out of frost-resistant material -classified according to DIN 18196Thickness of the layer made out of frost-resistant material 54) 154) 25 35 94) 194) 29 39 134) 23 33 Asphalt base course and crushed stone base course on frost protection layer 3 74) 174) 48 - - Asphalt surface Asphalt binder course Asphalt base course Crushed stone base course17) EV2 ≥ 150(120) Frost protection layer Thickness of the frost protection layer 302) 40 342) 44 Asphalt base course and gravel base course on frost protection layer 4 43 283) 38 322) 42 - Asphalt surface Asphalt binder course Asphalt base course Gravel base course EV2 ≥ 150(120) Frost protection layer Thickness of the frost protection layer 253) 35 293) 39 332) 43 273) 37 Asphalt base course and crushed stone or gravel base course on a layer made out of frost-resistant material 5 - Asphalt surface Asphalt binder course Asphalt base course Crushed stone or gravel base course layer made out of frost-resistant material Thickness of the layer made out of frost-resistant material At 12 cm made of frost-resistant material, the lower residual thickness is offset with the overlying material 1) For different values, the thickness of the frost protection layer or the frost-resistant material is determined by subtraction. See also Table 8. 2) Only use with round-grained aggregates if tested locally. 3) Only use with crushed aggregates and if tested locally. 4) Only use if the frost-resistant material and the material being solidified are laid as a single course. 5) In the case of gravel base course in Construction Classes SV and I to IV with a thickness of 40 cm, in Construction Classes V and VI with a thickness of 30 cm. 6) Combined base and surface layer, see also Section 3.3.3. 7) Alternative: Reduce the Asphalt base course by 2 cm with a 20 cm thick crushed stone base course and EV2≥180 MN/m2 (Construction Classes SV, I to IV) or EV2≥150 MN/m2 (Construction Classes V and VI). Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 38 Table 38: Construction method with concrete pavements for road surfaces on F2 and F3 subgrade/substrate (construction methods on F1 soils, see Section 3.1.2) EV2 minimum values in MN/m2) (Thickness in cm; Row Construction class Equivalent 10 t axel passages in millions SV > 32 B Thickness of frost-resistantpavement1) 55 65 75 > 10–32 85 55 65 75 85 55 II III IV V VI > 3–10 > 0.8–3 > 0.3–0.8 > 0.1–0.3 < 0.1 65 75 85 45 55 65 75 45 55 65 75 35 45 55 65 35 45 55 65 41 - 212) 31 41 273) 37 47 Nonwoven geotextiles and base course with hydraulic binding agent on frost protection layer or course made of frost-resistant material Concrete superstructure Nonwoven geotextiles 1.1 Hydraulically bound base course (HGT) Frost protection layer - - 332) 43 - 253) 35 45 84) 184) 28 38 154) 25 35 45 164) 34) 134) 23 33 104) 20 Asphalt base course on frost protection layer Thickness of the frost protection layer 263) 36 46 - - 273) 37 26 36 46 74) 174) 27 37 30 40 114) 21 31 41 24) 124) 22 32 41 51 322) 42 52 - Concrete pavements Nonwoven geotextiles Stabilisation Layer out of frost-resistant material largely or intermittently classified according to DIN 18196Thickness of the layer made out of frostresistant material Concrete pavements Nonwoven geotextiles Stabilisation Layer out of frost-resistant material classified according to DIN 18196- Thickness of the layer made out of frostresistant material Concrete pavements Asphalt base course Frost protection layer Thickness of the frost protection layer - 293) 39 49 - 312) - - - 332) 43 - 293) 39 49 - 212) 31 Crushed stone base course on a layer made out of frost-resistant material Concrete pavements Crushed stone base course 7) Layer of frost-resistant material Thickness of the layer made out of frostresistant material At 12 cm made of frost-resistant material, the lower residual thickness is offset with the overlying material Frost protection layer Concrete pavements Frost protection layer - 332) 43 53 - 253) 35 45 - Thickness of the frost protection layer 1) For different values, the thickness of the frost protection layer or the frostresistant material is determined by subtraction. See also Table 8. 2) Only use with round-grained aggregates if tested locally 3) Only use with crushed aggregates and if tested locally 4) Only use if the frost-resistant material and the material being solidified are laid as a single course. 7) With requirements according to ARS 37/1997 of the BMV dated 6 October 1997. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 39 Table 39: Construction method with stone pavement for road surfaces on F2 and F3 subgrade/substrate (construction methods on F1 soils, see Section 3.1.2) Ev2 minimum values in MN/m2) (Thickness in cm; Row Construction class Equivalent 10 t axel passages in millions B Thickness of frost-resistant superstructure)) 55 SV 1 i ii iii 1 iv 1 V Vi > 32 > 10–32 > 3–10 > 0.8–3 > 0.3–0.8 > 0.1–0.3 < 0.1 65 75 85 55 65 75 85 55 65 75 85 45 55 65 75 45 55 - - - 322) - - 65 75 35 45 - - 55 65 35 45 - - 44 - 242) 55 65 Crushed stone base course on frost protection layer Stone pavement 8) 1 Crushed stone base course Frost protection layer Thickness of the frost protection layer 293) 39 242) 34 242) 34 Gravel base course on frost protection layer Stone pavement 8) 2 Gravel base course Frost protection layer Thickness of the Frost protection layer Crushed stone- or gravel base course on a layer of frost-resistant material Stone pavement 8) 3 Crushed stone or gravel base course Layer of frost-resistant material Thickness of the layer made out of frostresistant material At 12 cm made of frost-resistant material, the lower residual thickness is offset with the overlying material Asphalt base course on frost protection layer Stone pavement 8) 4 Asphalt base course 15) Frost protection layer Thickness of the frost protection layer - 283) 48 - 322) - - 273) 37 - - - - - - 322) 42 38 52 - 242) - 312) 41 - - 212) 31 - - 212) 31 - - 263) `36 - - 163) 26 - - 163) 26 - 293) 39 - 193) 29 - 193) 42 34 34 44 Asphalt base course and crushed stone base course on frost protection layer Stone pavement 8) Asphalt base course 15) 5 Crushed stone base course Frost protection layer Thickness of the frost protection layer Asphalt base course and gravel base course on frost protection layer Stone pavement 8) Asphalt base course 15) gravel base course 6 Frost protection layer Thickness of the frost protection layer 322) Drain concrete base course on frost protection layer Stone pavement 8) Drain concrete base course (DBT) 15) 7 Frost protection layer Thickness of the frost protection layer 1) For different values, the thickness of the frost protection layer or the frostresistant material is determined by subtraction. See also Table 8. 2) Only use with round-grained aggregates if tested locally. 3) Only use with crushed aggregates and if tested locally. 49 39 8) For different stone thicknesses, see Section 3.3.5. 15) See ZTV P-StB 16) For a gravel base course in Construction Classes III and IV with a thickness of 40 cm, in Construction Classes V and VI with a thickness of 30 cm. 29 39 Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 40 Table 7: Construction methods for cycle and foot paths on F2 and F3 subgrade/substrate (Thickness in cm; Row Construction method with Thickness of frost-resistant superstructure Asphalt pavement Concrete pavements Stone pavement EV2 – minimum values in MN/m2) Flagstone paving 20 30 40 20 30 40 20 30 40 20 30 40 10 20 30 - 18 28 - 19 29 - 19 29 Layer of frost-resistant material Surface 1 Layer made of frost-resistant material Thickness of the layer made out of frostresistant material Crushed stone or gravel base course on layer made out of frost-resistant material Surface 2 Crushed stone or gravel base course Layer made of frost-resistant material Thickness of the layer made out of frostresistant material - - 17 - - 14 - - 14 22 32 - 19 29 - 19 29 Crushed stone or gravel base course on subgrade Surface 3 Crushed stone or gravel base course Thickness of the crushed stone or gravel base course - 6) Combined base and surface layer, see also Section 3.3.3. 14) Lesser thicknesses also possible. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 41 Annex 4 Abbreviations and Guidelines DIN FGSV RStO VOB/B VOB/C ZTV A-StB ZTV Asphalt-StB ZTV BEA-StB ZTV Beton-StB ZTV BEB-StB ZTV E-StB ZTV Fug-StB ZTV M-StB ZTV Pflaster-StB ZTV SoB-StB TL Asphalt-StB TL Beton-StB TL Gestein-StB TL SoB-StB TL Fug-StB TP BF-StB TP Fug-StB RAS-LP 4 M BEB M FPl M SNAR German Institute for Standardisation (Deutsches Institut für Normung e. V.) German Road and Transportation Research Association (Forschungsgesellschaft für Straßen- und Verkehrswesen e. V.) Directives for the standardisation of the pavements of traffic areas German Construction Tendering and Contract Regulations (Vergabe- und Vertragsordnung für Bauleistungen) Part B: German Standard Building Contract Terms - DIN 1961) German Construction Tendering and Contract Regulations (Vergabe- und Vertragsordnung für Bauleistungen) Part C: General technical terms of contract for construction work (ATV) - DIN 18299 et seq. Additional technical terms of contract and guidelines for excavation in traffic areas (FGSV 976) Supplementary technical terms of contract and guidelines for the construction of asphalt pavements (FGSV 799) Supplementary technical terms of contract and guidelines for the structural maintenance of paved traffic areas—asphalt construction methods (FGSV 798) Supplementary technical terms of contract and guidelines for the construction of base courses with hydraulic binders and concrete surfacing (FGSV 899) Supplementary technical terms of contract and guidelines for the structural upkeep of road surfaces concrete constructions (FGSV 898) Supplementary technical terms of contract and guidelines for earthworks in road construction (FGSV 599) Supplementary technical terms of contract and guidelines for joint fillers on road surfaces (FGSV 897/1) Supplementary technical terms of contract and guidelines for markings (FGSV 341) Supplementary technical terms of contract and guidelines for the construction of pavements and slabbed surfaces (FGSV 699) Supplementary technical terms of contract and guidelines for the construction of binderless layers in road construction (FGSV 698) Technical delivery conditions for asphalt mixtures for the construction of asphalt pavements (FGSV 797) Technical terms of delivery for construction materials and material mixtures for base courses with hydraulic binders and concrete surfacing (FGSV 891) Technical terms of delivery for aggregates used in road construction (FGSV 613) Technical terms of delivery for construction material mixes and soil for the construction of binderless layers in road construction (FGSV 697) Technical terms of delivery for bituminous joint sealants on road surfaces (FGSV 897/2/3) Technical test regulations for soil and rock in road construction (FGSV 591) Technical test regulations for joint fillers on road surfaces (FGSV 897/2/3) Guidelines for the construction of roads (RAS); Part: Landscape preservation, Section 4: Protection of trees, vegetation, and animals during building work (FGSV 293/4) Data sheet on the compaction of the subsoil and substrate in road construction (FGSV 516) Data sheet on the structural maintenance of concrete road surfaces (FGSV 823) Data sheet on surface pavements with paving and slabs; Part 1: Standard construction method (unbonded construction) (FGSV 618/1) Data sheet on layer bond, seams, joints, and edging of asphalt traffic areas (FGSV 747) Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. Colour sheet between p. 42 and p. 43!!!!! 42 Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 43 Excerpts from selected regulations As a rule, the regulation that is valid when the contract is concluded is applicable to construction work. Excerpt 1 ZTV E-StB 09, 2009 Edition ........................................Error! Bookmark not defined. Excerpt 2 ZTV SoB-StB 04, 2004 Edition / 2007 Version ...........Error! Bookmark not defined. Excerpt 3 ZTV Asphalt - StB 07, 2007 Edition ............................Error! Bookmark not defined. Excerpt 4 ZTV Beton - StB 07, 2007 Edition ...............................Error! Bookmark not defined. Excerpt 5 ZTV Pflaster-StB 06, 2006 Edition ..............................Error! Bookmark not defined. Excerpt 6 DIN 18299 VOB, Part C: General technical terms of contract for construction (ATV)Error! Bookmark not defined. Excerpt 7 DIN 18300 VOB, Part C: General technical terms of contract for construction (ATV)— earthworks, 2006 Edition ..............................................Error! Bookmark not defined. Excerpt 8 DIN 18315 VOB, Part C: General technical terms of contract for construction (ATV)—Road construction—surfacings without binding agents, 2006 Edition Error! Bookmark not defined. Excerpt 9 DIN 18316 VOB, Part C: General technical terms of contract for construction (ATV)—Road construction—surfacings with hydraulic binders, 2006 Edition . Error! Bookmark not defined. Excerpt 10 DIN 18317 VOB, Part C: General technical terms of contract for construction (ATV)—Road construction—asphalt surfacings, 2006 Edition ...........Error! Bookmark not defined. Excerpt 11 DIN 18318 VOB, Part C: General technical terms of contract for construction (ATV)— Road construction—Dry-jointed sett and slab pavements, and surrounds, 2006 Edition Error! Bookmark not defined. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 44 Excerpt 1 Excerpt from: Additional technical and contractual guidelines for earthworks in road construction (ZTV E-StB 09), 2009 Edition …… 4.3.2 Requirements for compaction Subgrade and substrate of streets and paths are to be compacted in such a way that the requirements specified in Table 2 are met. Table 2: 1 Requirement of a minimum quantile 1) of 10 % for the degree of compaction DPr or at 10 % maximum quantile 2) for the air entrainment na Area Subgrade depth up to 1.0 m for embankments and 0.5 m for through-cuts Soil groups GW, GI, GE DPr in % na in Vol.-% SW, SI, SE 100 - 98 - 97 124) GU, GT, SU, ST 2 1.0 m below subgrade to base of embankment GW, GI, GE SW, SI, SE GU, GT, SU, ST 3 Subgrade to base of embankment and a depth of 0.5 m for through-cuts GU*, GT*, SU*, ST* U, T, OU3), OT3) 1 ) The minimum quantile is the smallest permissible quantile, below which no more than the prescribed percentage of characteristic values (e.g. for the compaction degree) of the distribution is allowed (see also Section 14.2.2 and TP BF-StB, Part E 1). ²) The maximum quantile is the greatest permissible quantile, above which no more than the prescribed percentage of characteristic values (e.g. for thin air entrainment) of the distribution is allowed (see also Section 14.2.2 and TP BF-StB, Part E 1). 3 ) These requirements only apply to soils belonging to Classes OU and OT if their suitability and installation conditions have been separately examined and determined in consultation with the client. 4 ) If the soils are not solidified or qualified as improved (see Section 12), it is recommended that that a requirement of 8 vol.% be stipulated for the 10 % maximum quantile for air entrainment when paving with watersensitive mixed and fine-grained soils, and a corresponding requirement of 6 vol.% when paving using variably solid rock. This should be indicated in the performance description. The requirements for coarse-grained soils also apply to grain mixtures of crushed stone with appropriate grain composition. The requirements in Tab. 2 also apply if the soils and building materials have up to 35 mass % of its grains > 63 mm and < 200 mm. In the case of rock piles in which over 35 mass % of the grain content > 63 mm or a maximum grain size > 200 mm, requirements for compaction and inspection are to be stipulated in the performance description. The requirements in Table 2 also apply to soils and building materials in accordance with TL BuB EStB, each with the respective grain composition. If soils having different compaction requirements are switched within a phase of construction in such a way that separate processing is not possible, the lower value in the table shall apply. In such a situation, the client may determine and set requirements that are appropriate for the serviceability of the structure. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 45 For especially stressed earthworks or sections as well as for special building materials, it may be necessary to set higher compaction requirements such as those in Table 2, based on separate testing. These must be indicated in the performance description. The requirements presented in Table 2 may be reduced if this is demonstrated to be justified by local experience, i.e. when the rinsing method is applied under water. If these kinds of deviations are planned, this should be indicated in the performance description. The requirements are to be indicated in the performance description for backfilling internal surfaces and backfilling residual areas. For compaction requirements for backfilling excavation pits and trenches, see Section 9; for the backfill and covering of structures, see Section 10; for the construction of noise barriers, see Section 11. If the required compaction degree and/or air entrainment cannot be achieved through compaction, the required measures must be indicated in the performance description. A compaction degree DPr of 100 % (minimum quantile) and a porosity n of 22 Vol.-% (upper limiting quantile) must be maintained for washery tailings (WB). In assessing the compaction degree of HMVA [ash from incinerated household waste used in road construction], the water absorption behaviour and the changes in grain composition must be taken into account (see Section 14.3.3). 4.4 Subgrade 4.4.1 The subgrade must be made true to the grade and slope, level, and capable of withstanding a load in accordance with the requirements under Section 4.3.2 and 4.5 (see Section 4.1.2). 4.4.2 The subgrade may not deviate by more than 3 cm or, if a bound base course is planned directly on top of it, no more than 2 cm from the nominal height. 4.4.3 The subgrade may only be driven on if no damaging deformations or barriers to water runoff occur as a result. Where necessary, appropriate, special measures in accordance with Section 4.4.6 must be provided for in the performance description. If driving on the subgrade is included in the contractor’s exclusive arrangements, any necessary measures for the subgrade according to Section 4.4.6 shall not be compensated separately. 4.4.4 If soils are accumulated during road cutting, with which the requirements for the load-bearing capacity can be met, it is preferable that these should be used immediately below the subgrade in the areas to which the contract pertains unless otherwise provided in the performance description. 4.4.5 The transverse slope of the subgrade must be at least 4 % for water-sensitive soils and building materials. After treating soil with a binding agent (soil compaction, qualified soil improvement), the transverse slope of the subgrade must be at least 2.5 %. The distorted areas should be kept as short as possible. The gradient conditions must be set in the performance description taking into account any necessary counter slope on high road surface edges (see ZTV SoB-StB). In coordination with the design of the superstructure, it must be ensured that the roadway drainage is guaranteed at low points in the gradient, especially the first base course (frost protection layer). This can be achieved, for example, through a thicker base course, a special composition of the base course materials or a drainage system below the subgrade. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 4.4.6 46 The finished subgrade should not remain unprotected for an extended period in the case of watersensitive types of soil or rock, especially during rainy periods. The following protective measures in particular should be considered: 1) Soil compaction and qualified soil improvement, 2) Leave or deposit a low-permeable protective layer above the subgrade approximately 0.5 m thick of standing soil, 3) Create a bound base course. (See “Data sheet on the compaction of the subsoil and substrate in road construction”) If no protective measures are taken, compaction must be performed again immediately prior to laying the base course on the subgrade. If the soil is too wet at this point in time for compaction, it must either be improved by mixing in a binding agent, or the soil in the affected area must be removed and replaced with another building material. If it is already anticipated at the outset that there will be a long wait period between the earthworks and the surfacing work, the necessary measures must be provided. If the contractor builds the subgrade and superstructure of a building measure, the protection of the subgrade shall not be separately compensated. 4.5 Deformation modulus 4.5.1 If, according to building contract, both earthworks and work constructing the superstructure are to be carried out, the requirements according to Section 4.5.2 must be met immediately before laying the courses of the superstructure. If the construction work ends with the production of the subgrade, deformation moduli according to Section 4.5.2 must be demonstrated for acceptance. If the subgrade created is overbuilt within the context of another building contract, appropriate measures must be taken (see also Section 4.4.6). 4.5.2 Requirements with respects to the deformation modulus The following requirements pertain to the 10 %-minimum quantile. substrate a deformation modulus of Ev2 = 120 MN/m² or Evd = 65 MN/m², is required for road surfaces belonging to Construction Classes SV and I to IV on a frost-proof subgrade, or a deformation modulus of Ev2 = 100 MN/m² or Evd = 50 MN/m² is required for Construction Classes V and VI. The deformation modulus Ev2 is verified using the static plate-loading test in accordance with DIN 18134 and the deformation modulus E vd is verified using the dynamic plate-loading test in accordance with TP BF-StB, Part B 8.3. If these requirements can only be met through the compaction of the base courses that are to be laid on the subgrade, it is sufficient to use separate testing to verify or determine that there is a deformation modulus on the subgrade of Ev2 = 100 MN/m² or Evd = 50 MN/m² for Construction Classes SV and I to IV on a subgrade and a deformation modulus of Ev2 = 80 MN/m² or Evd = 40 MN/m² for Construction Classes V and VI. In the case of a frost-sensitive subgrade or substrate, a deformation module on the subgrade of Ev2 = 45 MN/m² or Evd = 25 MN/m² is required. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 47 In the case of a frost-sensitive subgrade or substrate, a deformation module on the subgrade of Ev2 = 70 MN/m² is required after completing a qualified soil improvement. The performance description should indicate whether the static or dynamic deformation modulus must be verified. If this information is not included in the performance description, the static deformation modulus should be verified. If the required deformation modulus at the subgrade cannot be achieved through compaction, either (1) the subgrade or substrate must be improved or compacted, or (2) the thickness of the unbound base courses must be increased. The measures taken or the specification of other requirements based on proven regional experience must be indicated in the performance description. 4.6 Water runoff See DIN 18300, Section 3.3 See RAS-Ew; see ZTV Ew-StB 4.6.1 See DIN 18299, Section 4.1.10 The measures needed to channel surface water caused by precipitation without damage and the safety measures that this entails are a prerequisite for all building phases. 4.6.2 See DIN 18300, Section 3.3.3 If the necessary drainage measures are omitted, or if they are performed improperly or not in a timely manner, appropriate measures shall be taken to remedy or replace any building materials made unusable as a result. 4.6.3 The water is not permitted to flow from the excavation slope onto the subgrade. The water must be collected and channelled away by longitudinal drainage installations. Water flowing from the subgrade over the slope of embankment should flow without collection to lower lying areas or to the longitudinal drainage at the base of the embankment. In the case of erosionsusceptible slopes, the water must be collected and channelled through erosion-proof, longitudinal drainage installations at the edges of the subgrade. 4.6.4 For the drainage of construction backfill, see Section 10. …… 9. Excavation pit and service trenches 9.1 Building See DIN 18300, Sections 3.1.3 and 3.10 9.1.1 If detrimental deformations are anticipated as a result of the design of the service trenches or excavation pits, special measures implemented as a result must be indicated in the performance description. 9.1.2 Underpinnings or other safeguards for endangered structures for which the contractor is responsible shall not be separately compensated. The blasting of trenches or excavation pits in bedrock must be performed in such a way that mountains are not damaged (see Sections 4.1.3 and 4.1.4). 9.1.3 Excavated soil should be used for refilling, backfilling, covering, or other refilling work depending on the need and suitability (see Section 4.1.1). 9.1.4 Excavation pits and service trenches should be protected against the inflow of surface water using appropriate measures. In the case of frost and water-sensitive types of soil and bedrock, the bottom of the pit or trench must be protected using suitable measures during periods of freezing and rain. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 48 If long wait periods between the earthworks and subsequent work are anticipated at the outset, the necessary measures should be provided. Measures for keeping excavation pits and service trenches dry of entering groundwater must be indicated in the performance description. 9.2 Backfill See DIN 18300, Section 3.11 9.2.1 The necessary soil parameters must be indicated in the performance description if there are pipes, which require a rated load and deformation analysis for determining their dimensions. 9.2.2 The pipelines must be appropriately dimensioned and protected if there are special loads on them during the construction phase, for example when heavy construction machinery or vehicles are driving over top, or high cover filling. 9.2.3 Appropriate measures should be taken to prevent the service trench from developing into a longitudinal drainage for incoming surface and groundwater after the backfill. An appropriate measure should be provided in the performance description. 9.3 Building materials 9.3.1 Coarse-grained soils and building materials with a maximum grain size of 22 mm should be used in the piping zone. If there are restrictions or expansions for the building materials used with regards to the materials or the dimensions of the pipes, this must be indicated in the performance description (see also Section 3.2). Washery tailings (WB), ashes from incinerated household waste (HMVA), and residual foundry sand (GRS) may not be used in the piping zone. 9.3.2 Outside the piping zone, the excavated soil should be used to backfill the trench or the fill material used in the fill bank should be used in the embankment. 9.3.3 The temporarily stored soil that is suitable for backfilling the service trench is to be kept in a condition that it is suitable for use in that backfill. Excavated soil that is too wet can be reused if necessary after treatment with a binding agent. If it is not possible to separately remove individually suitable soils because of varying soil stratification (for example interbedded coarse and mixed or fine-grained soils), these must be homogenised before replacement. 9.3.4 Temporarily fluid, self-compacting soil-binder mixtures may be used to backfill service trenches, especially in areas that are difficult to access or to compact. The suitability of the soil-binder mixture must be verified through a suitability test. 9.4 Installation and compaction See DIN 18300, Section 3.11 9.4.1 The building material must be installed evenly in layers and carefully compacted in and outside of the piping zone as well as in the backfill spaces of service ducts. In doing so, care should be taken to ensure that the lines remain in position. The building materials and installation methods used may not lead to any damaging deformations or disadvantageous load conditions for the line and the traffic area. Other building materials and/or other installation methods shall be included in the performance description. The backfilling of service trenches must take place immediately after laying the lines, in sections if necessary. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 49 9.4.2 The compaction may only be performed using light compactors in the piping zone and in the area up to 1 m above the pipe crown, with moderately heavy compactors up to 3 m, and with heavy compactors above that. 9.4.3 The slopes of excavation pits or trenches that have slipped down must be dug out. The resulting space should be treated as a part of the piping zone or trench/pit backfill. 9.5 Compaction requirements 9.5.1 Soils and building materials in the fill-in zone for service trenches within the roadway should be compacted in such a way that the requirements under Section 4.3.2 are met. For service trenches inside and outside of the roadway, a requirement a compaction degree of DPr of 97 % for the 10 % minimum quantile shall apply for the piping zone. This requirement also applies to the fill-in zone of service trenches outside of the roadway. For the compaction requirements for excavation pits, see Section 10.3. 9.5.2 Areas in the piping zone, in which the soils or building materials cannot be properly compacted, must be backfilled with other appropriate building materials (e.g. temporarily fluid, self-compacting soilbinder mixture, concrete of suitable quality), unless this would have an adverse effect on the pipe bedding (see Section 9.4.1), the pipelines, and the superstructure. Appropriate measures should be indicated in the performance description. If adverse effects on the road surface from the pipeline are expected, appropriate protective pipes or hemispherical indentations must be provided. Special bulk materials and/or special installation methods should be specified in the performance description. …… 14. Testing the quality achieved 14.1 General In carrying out testing, a distinction must be made between the testing method and test procedures. The term “method“ refers to the systematic procedure by which the planned quality in accordance with the requirements for the compaction parameters prescribed in Section 4, 7, and 9 to 12 are tested. Using “test procedures”, the test characteristics (compaction parameters, e.g. compaction degree in accordance with DIN 18127, or deformation modulus in accordance with DIN 18134) are defined and determined. Test procedures contain the concrete job instructions used to determine the compaction parameters. 14.2 Methods for testing the compaction parameters 14.2.1 General The following methods can be distinguished: Method M 1: Method according to the test plan (Section 14.2.2) Method M 2: Method of applying a comprehensive measurement procedure (Section 14.2.3) Method M 3: Method of monitoring the work process (Section 14.2.4) Each method is based on a decision rule for the clear and objective evaluation of the test results. The application of the decision rule leads to the “acceptance” or “rejection” of the test lot. When deciding on the appropriate method, in particular the type, size, and significance of the earthworks, the type and composition of the earthwork material as well as the use of equipment and required earthwork service must be considered (see Sections 14.2.2 to 14.2.4). The validity of the methods varies, however. Each method provides certain advantages, depending on the application, so that the user can select the most suitable method for the respective conditions. Internal quality control checks and control testing can only be compared with one another if the same method is used for both. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 50 The testing method should be indicated in the performance description. If variant solutions with regards to other than the methods in the tender are desirable, this should be indicated in the performance description. In all three methods, one test lot each is evaluated. A test lot is a layer (= bulk layer) of compacted soil that has been processed under uniform conditions, for which there is a uniform requirement. The area of the test lot should be precisely determined. If one of the aforementioned conditions is not met, the test lot should be divided into several partial areas in which the conditions are met. Each of these partial areas requires its own evaluation as a test lot. Test lots or their test areas should be determined by mutual agreement between the client and contractor. 14.2.2 Method M 1: Procedure according to test plan This procedure complies with Part E 1 the TP BF-StB. In Method M 1, the statistics within a test lot are obtained on a sample basis. Based on the sampling results, a decision is made whether to accept or reject the test lot (see “Data sheet on the compaction of the subsoil and substrate in road construction”). Method M 1 can be used with all types of soil. The application of Method M 1 is especially recommended in the following cases: For large test lots, For test lots, in which the uniformity of the compaction needs to be evaluated, For test lots, on which test procedures should be used that require little time and for which, the results should be immediately available. Method M 1 should also be used for test compactions (see Section 4.3.1.1). Testing is done on a sample basis, whereby the position of the test points in the testing area are random, e.g. determined using a random selection process in accordance with TP BF-StB, Part E 1. The sample size n depends on the test lot size and the test plan used. For a simple test plan, for example, it can be taken from Table 7. The test results x1,...., xn are obtained for the n randomly selected test points. The arithmetic mean x and the standard deviation s are calculated from these results xi of the sample. Arithmetic mean x of the sample with the sample size n: 1 in Xi x = n i 1 (Equation 1) Standard deviation s of the sample: S= in i 1 xi x 2 n 1 (Equation 2) The statistical sample size z is obtained from x and s in the case of a 10 % minimum quantile TM (compaction degree, deformation modulus, see Section 4). Z= x -k·s (Equation 3) The sample size of z is obtained in the case of a 10 %-upper limiting quantile TH for the air entrainment Z= x +k·s whereby k is the acceptance factor in accordance with Table 7. (Equation 4) Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 51 The test lot is accepted if, z TM in the case of a required minimum quantiles and z TH in the case of an upper limiting quantile; otherwise the test lot is rejected. This is then brought up to a condition that meets the requirements by the contractor. If it is rejected, the entire area if the test lot is rejected. Part E 1 of TP BF-StB contains additional sample testing plans, which may lead to a smaller scope of testing than presented in Table 7. Table 7: Sample size and acceptance factor for a simple plan for variable testing depending upon the test lot size Test lot size Area m2 Up to 1 000 Above 1 000–2 000 Above 2 000–3 000 Above 3 000–4 000 Above 4 000–5 000 Above 5 000–6 000 Length of service trench per m of trench depth Sample size n Up to 100 Above 100–200 Above 200–300 Above 300–400 Above 400–500 Above 500 to 600 4 5 6 7 8 9 Acceptance factor k 0.88 0.88 0.88 0.88 0.88 0.88 When using the dynamic plate-loading test to measure the dynamic deformation modulus, the sample size specified in Table 7 should be doubled. …… 14.2.4 Method M 3: Procedure for monitoring the work process This procedure complies with Part E of TP BF-StB. In Method M 3, proof of the suitability of the compaction process being used is generally obtained via a test compaction. Job instructions for the compaction are created based on the results of the test compaction. The compaction work on the earthworks is performed according to the job instructions. Compliance with the job instructions must be documented. Further instructions can be found in the “Data sheet on the compaction of the subsoil and substrate in road construction”. The use of this method requires that a specific work process for laying and the compaction of the respective soil be set (job instructions) using the test compaction (see Section 4.3.1.1) or based on specific results from first-hand experience, and compliance with the work process is documented through self-monitoring by the contractor. The following should be established for the work process in the job instructions: 1. The appropriate compactor, 2. The work method during installation, 3. The number of required compacting passes, 4. The type and class of soil, 5. The maximum thickness of the non-compacted fill layer, 6. The water content during installation permissible for the compaction. The contractor must be able to demonstrate compliance with the job instructions to the client by maintaining a daily report log. At least the following parameters should be recorded therein: 1. Positioning (e.g. construction kilometre point) according to position and height, 2. Fill layer number, width, thickness of the non-compacted fill layer, 3. Number of transitions per fill layer, 4. Compactor with operating parameters (frequency, amplitude, speed) per fill layer, 5. The associated test compaction, 6. The weather conditions during installation, Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 7. 52 The installed type of soil and its water content. If a tachograph, Global Positioning System (GPS), automatic levelling, or radio transmission is used for more precise documentation, the client must indicate the required documentary resources in the performance description. The daily report log also serves as documentation according to Section 15. The client should participate appropriately in the test compaction. In addition to the records in the daily report log, the contractor should also carry out tests in the scope specified in Table 8. Table 8: Minimum number of internal quality control checks Row Area Minimum number 1 per 1 000 m² begun, however, at least 2 tests 1 Subgrade, substrate, subgrade 2 Structure backfill see Section 14.6 3 Structure cover fill 3 within the first metre of the cover fill 4 Service trenches 3 per 150 m length per m of trench depth 5 For municipal roads and for building done in sections 1 per 1 000 m² begin, however, at least per 100 m and at least 2 tests The median value x (see Gl. 1) and the standard deviation s (see Gl. 2) are obtained from the n test results xi. The test results should be evaluated as follows (decision rule): 1. For two test results (n = 2) Acceptance of the test lot if 2. otherwise rejection x - 1.15 s ≥ TM otherwise rejection For three test results (n = 3): Acceptance of the test lot if 3. x - 1.28 s ≥ TM For four or more test results (n = 4): Acceptance of the test lot if x - 0.88 s ≥ TM otherwise rejection If a test lot is rejected, the contractor must bring it up to a condition that meets the requirements. The results of the test compaction, the inspection of the work process (daily report log) to be documented by the contractor as well as the results of the internal quality control checks must be submitted to the client. If compliance with the job instructions is not proved both by maintaining the daily report log and by carrying out individual testing in accordance with Table 8 as described, the compaction must be tested according to Method M1 (see Section 14.2.2). 14.3 Test procedures for determining compaction parameters 14.3.1 Sampling and test procedures The Technical testing regulations for soil and rock in road construction (TP BF-StB) apply to sampling and conducting testing. Measurement uncertainties are not taken into account since the requirements (see Section4, 7, and 9 to 12) refer to measured values. The use of all of the specified indirect test procedures requires prior agreement between the client and the contractor. Planned indirect test procedures should be indicated in the performance description. 14.3.2 Compaction degree DPr Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 53 The ratio of the dry density of the tested sample to the proctor density of that sample is taken to calculate the compaction degree given in per cent (see DIN 18127). For soils and building materials, the associated proctor density must be obtained from the sample from which the density measurement is taken as a reference value and used as a basis for evaluation. For soils and building materials with a consistent composition, the proctor density obtained using either the suitability test or the test compaction may be used as a basis as a reference value for the compaction degree. 14.3.3 Dry density d and porosity n If the proctor density cannot be reliably determined as a reference value of the compaction degree through technical testing (e.g. in the case of variably solid stone, stony and blocky soils, certain industrially manufactured and recycled aggregates) the dry density d or the porosity n may be substituted as a parameter for the compaction. The specification values for the dry density and the porosity must be set by mutual agreement between the client and the contractor based on already existing local experience for the application in question. 14.3.4 Air entrainment na The air entrainment na is calculated from the results of the density measurement in accordance with DIN 18125 and the results of the water content determination in accordance with DIN 18121. In addition, the air entrainment can be set as an additional parameter for the compaction analogously to Section 14.3.3. 14.3.5 Indirect test procedures for the compaction degree As a substitute for determining the compaction degree, the following test procedures may be used for coarse-grained soils and mixed-grained soils with a fine-grained content of less than 15 mass %: 1) Static plate-loading test in accordance with DIN 18 134 2) Dynamic plate-loading test in accordance with TP BF-StB, Part B 8.3 Test procedures to be used in isolated cases are indicated in the performance description. When creating the test field (see Section 4.3.1.1), calibration tests should be used to determine the relationship between the selected indirect test procedures and the compaction degree (see TP BF-StB, Part E 4). The relationship may also be demonstrated by proven first-hand experience or recognised second-hand experience. When using the dynamic plate-loading test as an indirect test procedure for determining the compaction degree, the scope of testing should be doubled as compared with the necessary scope of testing when using direct test procedures according to Section 14.2.2. For coarse-grained soils, the assignments specified in Tables 9 and 10 may be used. Table 9: Benchmarks for assigning the static deformation modulus Ev2 to the compaction degree DPr in coarse-grained soils Soil class GW, GI GE, SE, SW, SI Static deformation modulus Ev2 in MN/m² 100 80 80 70 Compaction degree DPr in % 100 98 100 98 In addition, the ratio of the deformation modulus E v2/Ev1 should be used to evaluate the compaction state. In so doing, Ev2/Ev1 ≤ 2.3 holds true for DPr ≥ 100 % and Ev2/Ev1 ≤ 2.5 holds true for DPr ≥ 98 %. If the Ev1 value has already reached 60 % of the Ev2-value indicated in Table 9, higher Ev2/Ev1 ratios are also permitted. Table 10: Benchmarks for assigning the dynamic deformation modulus Evd to the compaction degree DPr in coarse-grained soils Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. Soil class GW, GI, GE, SW, SI, SE Dynamic deformation modulus Evd in MN/m² 50 40 54 Compaction degree Dpr in % 100 98 In the soil groups GE and SE, the assignments in Tables 9 and 10 should be checked within the context of the test compactions. The following is recommended for testing in service trenches and in confined work spaces: 1) The measurement of probe resistance using special service trench sensors for lengthwise installation or for shallow service trenches (0.7 m in depth), for particularly coarse-grained soils and mixed-grained soils with a fine-grained content of less than 15 mass % 2) The measurement of the probe resistance using penetrometers for deep service trenches and backfill material made up of coarse-grained soils and mixed-grained soils with a fine-grained content of less than 15 mass %. 14.4 Testing the deformation modulus, the correct profile true to line and thickness, and the flatness of the subgrade In order to test the load and deformation behaviour on the subgrade as a bedding layer for the road surface, the applicable requirements for the deformation modulus E v2 or for the dynamic deformation modulus Evd must be verified according to Section 4.5.2. In order to do so, Method M 1 or M 3 according to Section 14.2.2 or Section 14.2.4 should be used. Testing should be performed using the static plate-loading tests in accordance with DIN 18134 or the dynamic plate-loading test in accordance with TP BF-StB, Part B 8.3. When using the dynamic plateloading test, the scope of testing according to Section 14.2.2 and 14.2.4 should be doubled. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 55 Method M 2 in accordance with 14.2.3 may also be used if it is applicable for soil mechanical reasons. The test results obtained using the measuring roller should be calibrated to the deformation modulus Ev2 (see TP BF-StB, Part E 4). The relationship may also be demonstrated by proven first-hand experience or recognised second-hand experience. The correct profile true to line and thickness is tested using conventional surveying methods. The flatness in accordance with Section 12.4.2.7 is tested using a 4 m builder’s square (TP Eben-StB). …… Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 56 Excerpt 2 Excerpt from: Additional technical and contractual guidelines for the construction of binderless layers in road construction (ZTV SoB-StB 04), 2004 Edition / 2007 Version …… 1.2 Definitions …… Binderless layers are: - B i n d e r l e s s t o p l a y e r ( D o B ): Topmost layer of road paving, mainly on rural roads that are built without binders. - B i n d e r l e s s b a s e c o u r s e ( T o B ): Load distributing layer between the road surface or combined base and surface layer and the subgrade, which, when compacted, is sufficiently capable of withstanding a load and is sufficiently permeable to water. Binderless base courses are: - F r o s t p r o t e c t i o n l a y e r ( F S S ): Binderless base course, which helps to avoid frost damage to the (road) superstructure and which is made out of frost-resistant material mixtures and/or soils. - B a l l a s t s u p p o r t i n g l a y e r ( S T S ): binderless base course, which consists of a building material mixture classified by grain size that is primarily made up of crushed aggregates. - G r a v e l s u b s t r a t u m ( K T S ): Binderless base course, which consists of a building material mixture classified by grain size that is primarily made up of crushed aggregates, with the addition of crushed aggregates where necessary. - L a y e r o f f r o s t - r e s i s t a n t m a t e r i a l ( S f M ): Layer on the subgrade or substrate, which may also be arranged below a base course in order that the frost-proof superstructure can achieve an adequate thickness. It must be sufficiently water permeable even in a compacted state. ….. 2 Constructing binderless layers 2.1 General See DIN 18315, Section 3.1. 2.1.1 Production See DIN 18315, Sections 3.3, 4.1.2; 4.2.4; 4.2.5; 4.2.6. The production of binderless layers on a frozen bedding layer is not permitted. Every course of layer of a binderless course must be produced in such a way that its qualities are consistent and the set requirements are met. When producing the courses, the sequence of associated work processes must be performed in rapid succession. In so doing, the performances and the number of required pieces of equipment must be coordinated to one another. The use of courses or layers for the continuation of the work does not change the contractual obligations of the contractors with regards traffic safety and traffic control. 2.1.2 Requirements See DIN 18315, Section 3.3. The requirements specified in Sections 2.2, 2.3, and 2.4 include both the distribution for taking samples and the confidence interval of the test procedures (precision among reproducibility conditions) as well as the work-related non-uniformities, unless other arrangements are made in individual cases. 2.2 Frost protection layer and layer made out of frost-resistant material 2.2.1 Construction principles Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 57 See Section 1.3. The frost protection layer or layer made out of frost-resistant material is to be arranged and constructed in such a way that it can properly drain water from the road in the construction and operational state. It must be run in cut sections up to the lateral drainage installations, and on the fill bank, up to the drain pipes or up to the embankment. The thickness of the frost protection layer or the layer made out of frost-resistant material between the edge of the paved area and the slope or the lateral drainage installations may be reduced if proper drainage is ensured. The layer thickness of the frost protection layer or of the layer made out of frost-resistant material in the gradient basin must thus be increased across the entire subgrade width and additional drainage installations added so that no water build-up occurs. The greater layer thickness must be achieved in a length of 10 m on both sides from the lowest point of the gradient basin. The grain size distribution of the material mixture for the upper 20 cm of the frost protection layer must meet the requirements in Table 4 of the TL SoB-StB. If groundwater can rise to the level of the subgrade, the filter stability between the frost protection layer of the layer made out of frost-resistant material and the subgrade/substrate must be guaranteed, unless it is solidified. Proof can be provided in accordance with RAS Ew-StB. Filter stability can be created in the following ways: - An appropriate grain size distribution of the material mixture or soil of the frost protection layer or the layer made out of frost-resistant material - Arrangement of a geotextiles according to TL Geotex E-StB as a separating layer between the subgrade and frost protection layer or the layer made out of frost-resistant material - Soil improvement or soil compaction the subgrade/substrate. If it cannot be ensured that the requirements for the compaction degree according to Table 1 and/or the deformation modulus are achieved, special measures should be provided in the performance description such as: 2.2.2 - Solidification of the upper course of the frost protection layer with a binding agent - Increasing the thickness of the frost protection layer or the bound base course above it - Replacement of the frost protection layer with an appropriately thicker gravel or crushed stone base course. Material mixtures and soils Material mixtures and soils in accordance with TL SoB-StB, Section 2.2 should be used. 2.2.3 Production See Section 2.1.1. The minimum installation thickness for each course or layer must be as follows when compacted, depending on the grain size: - up to 32 mm 12 cm, - up to 45 mm 15 cm, - up to 56 mm 18 cm, - up to 63 mm 20 cm; For cycle and foot paths, the minimum installation thickness of each course or layer when compacted is 10 cm when using a material mixture with a maximum grain size of up to 22 mm. The frost protection layer or the layer made out of frost-resistant material must be created in such a way that its load and deformation behaviour is as consistent as possible. To this end, the building material mixture or the soil must be unloaded and installed in such a way that no harmful segregation occurs. The building material mixture or the soil should be compacted to the required compaction degree (DPr) with a water content that is conducive to installation and compaction, selected based on the results of the suitability test. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 2.2.4 58 Requirements See Section 2.1.2. 2.2.4.1 Grain size distribution and fine material When installed, the limiting values in the Figures in Annex A shall apply. The proportion of fine material < 0.063 mm may not exceed 7.0 mass % when installed. If groundwater can rise to the height of the subgrade, the lower part of the frost protection layer at a thickness of at least 20 cm must be created in such a way that the proportion of fine material < 0.063 mm does not exceed 5 mass % when installed. 2.2.4.2 Compaction degree and deformation modulus The frost protection layer or layer made out of frost-resistant material must be compacted in such a way that the minimum compaction degree DPr according to Table 1 is achieved. For frost protection layers on road surfaces in built-up areas in which paving is hindered by manholes or the like, a compaction degree of at least DPr = 100 % may be provided in the performance description instead of the compaction degree DPr of greater or equal to 103 % required in accordance with Table 1. If a static plate bearing tests is instead used for frost protection layers in order to indirectly identify the compaction state, the ratio of the deformation moduli E v2/Ev1 for roads belonging to Construction Classes SV, I to V may not be greater than 2.2, if a compaction degree D Pr of greater than or equal to 103 % is prescribed. If a compaction degree DPr below 103 % is required, the ratio Ev2/Ev1 may not be greater than 2.5. Ev2/Ev1 ratios higher than 2.2 or 2.5 are permitted if theE v1 value is at least 0.6 times the required Ev2 value. Table 1: Minimum requirements for the compaction degree DPr of material mixtures and soils in the frost protection layer or layer made out of frost-resistant material Row Areas Material mixtures und soils according to Section 2.2.2 (l) (2) (3) 1 Surface frost protection layer up to 0.2 m deep 0/8 to 0/63 and soils GW and GI 2 Frost protection layer below the area in Row l and layer made out of frost-resistant material All material mixtures and soils in Row l as well as SE, SW, SI, GE, and aggregates 0/2 and 0/5 DPr in % Constructio Constructio n classes n class SV, I to V VI*) (4) (5) 103 100 100 *) Both for cycle and foot paths, and other road surfaces Based on a deformation modulus at the subgrade of at least E v2 = 45 MN/m², a deformation modulus of at least Ev2 = 120 MN/m² must be reached on the frost protection layer for roads belonging to Construction Classes SV, I to IV. In the case of a superstructure, in which these requirements can only be met subsequently through the compaction of a gravel or crushed stone base course installed above the frost protection layer, a deformation modulus at the frost protection layer of at least Ev2 = 100 MN/m² may be provided in the performance description. Based on a deformation modulus at the subgrade of at least E v2 = 45 MN/m², a deformation modulus of at least Ev2 = 100 MN/m² must be reached on the frost protection layer for roads belonging to Construction Classes SV, I to IV according to RStO. In the case of a superstructure, in which these requirements can only be met subsequently through the compaction of a gravel or crushed stone base course installed above the frost protection layer, a Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 59 deformation modulus at the frost protection layer of at least Ev2 = 80 MN/m² may be provided in the performance description. The above requirements for the deformation modulus do not apply to courses made of frost-resistant material. The respective technical regulations apply (e.g. RLW for rural roads) for road surfaces that are not dealt with in RStO. In determining the deformation modulus Ev2 and the dry densities d within the context of selfmonitoring and control testing, the following deviations are permitted: - If the examination of a course or a test layer is based on fewer than five individual values, all of the individual values must reach or exceed the required minimum value. - If the examination of a course or a test layer is based on five or more individual values, in each case one individual value may fall below the minimum value for the deformation modulus by no more than 10 %; when calculating the compaction degree, a deviation in the dry density of 3.0 % may also be permitted in each case for an individual value. The permissible deviations only apply, however, if these individual values belong to the five measurement points in closest proximity to one another. If, in individual cases, shortfalls beyond this are justified, e.g. in the case of very unevenly composed material mixtures or soils, the maximum attainable values should be determined through test compactions and indicated. The verification of the deformation modulus at the frost protection layer may be omitted - if a second binderless layer is arranged and the required deformation modulus is verified for this layer - for other types of road surfaces that are not assigned to a construction class in RStO. Regardless of this, the required compaction degree of the frost protection layer or the layer made out of frost-resistant material according to Table 1 must be verified. 2.2.4.3 True to cross-section, line, and level See DIN 18315, Section 3.3.1.4. The surface of the frost protection layer or the layer made out of frost-resistant material may not deviate from the nominal height by more than ± 2.0 cm. 2.2.4.4 Flatness See DIN 18315, Section 3.3.1.5. 2.2.4.5 Paving thickness See DIN 18315, Section 3.3.1.6. The installation thickness of every course or layer may not fall short of the minimum installation thickness indicated in Section 2.2.3. 2.3 Gravel and crushed stone base courses 2.3.1 Construction principles See Section 1.3. Only material mixtures 0/32 according to TL SoB-StB, Table 5, and Table 9 may be used for roads belonging to Construction Class SV, I to III if a concrete pavement is to be laid immediately on a crushed stone base course. Base courses under stone pavements: In order that no bedding material from the stone pavement can penetrate into the base course, the building material mixture for the binderless base course must be highly graduated. It has proven advantageous when the building material mixture of the base course exhibits a coefficient of uniformity (U = D60/D10) 13. Where: D60 = grain diameter in mm of the base course material, which is 60 mass % of the grain size distribution when passed through a sieve. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 60 D10 = grain diameter in mm of the base course material, which is 10 mass % of the grain size distribution when passed through a sieve. Base course material should be provided, with which it is ensured that the bedding material of the overlying pavement bed will not be flushed into the base course. For this reason, the grain size distribution of the base course material should be adjusted to the grain size distribution of the bedding material, so that the materials can guarantee adequate filter stability. Evidence of filter stability is provided if the following conditions are met: D15/d85 5 D50/d50 25 with D15; D50 = grain diameter [mm] of the base course materials, which is 15or 50 mass % of the grain size distribution when passed through a sieve. d50; d85 = grain diameter [mm] of the bedding material, which is 50 of 85 mass % of the grain size distribution when passed through a sieve. 2.3.2 Material mixtures Material mixtures for gravel and crushed stone base courses in accordance with TL SoB-StB, Section 2.3 should be used. 2.3.3 Production See Section 2.1.1. The minimum installation thickness for each course or layer must be as follows when compacted, depending on the grain size: - up to 32 mm 12 cm - up to 45 mm 15 cm - up to 56 mm 18 cm The base course should be produced in such a way that its load and deformation behaviour is as consistent as possible. To this end, the building material mixture or the soil must be unloaded and installed in such a way that no harmful segregation occurs. Temporary storage at the construction site is not permitted. The building material mixture or the soil should be compacted to the required compaction degree (DPr) with a water content that is conducive to installation and compaction, selected based on the results of the suitability test. The building material mixture should be installed with pavers. The building material mixture may also be installed without pavers in the case of smaller areas and for difficult profile designs as well as numerous fixtures. Installation may be in multiple layers, depending on the installation and compaction equipment used, and in compliance with the minimum installation thickness for the respective building material mixture. Further information can be found in the “Data sheet on the installation of base and top layers without bindingˮ [Merkblatt für die Herstellung von Trag- und Deckschichten ohne Bindemittel]. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 2.3.4 61 Requirements See Section 2.1.2. 2.3.4.1 Grain size distribution and fine material When installed, the limiting values in the Figures in Annex B shall apply. The proportion of fine material < 0.063 mm may not exceed 7.0 mass % when installed for gravel and crushed stone base courses (KTS/STS), and may not exceed 5.0 mass % for crushed stone base courses below concrete pavements (STSuB). 2.3.4.2 Compaction degree and deformation modulus The compaction degree DPr of the base course may not fall below 103 %. For road surfaces in built-up areas in which paving is hindered by manholes or the like, a compaction degree of at least DPr = 100 % may be provided in the performance description. The ratio of the deformation moduli E v2/Ev1 may not be greater than 2.2, if a compaction degree DPr of greater than or equal to 103 % is prescribed. If a compaction degree DPr below 103 % is required, the ratio Ev2/Ev1 may not be greater than 2.5. Ev2/Ev1 ratios higher than 2.2 or 2.5 are permitted if theEv1 value is at least 0.6 times the required Ev2 value. Based on a deformation modulus at the frost protection layer of at least E v2= 120 MN/m², the following deformation modulus E v2 must be reached at the base course for roads belonging to Construction Classes SV, I to IV depending on the layer thickness: Based on a deformation modulus at the frost protection layer of at least Ev2 = 120 MN/m², the following deformation modulus E v2 must be reached at the base course for roads belonging to Construction Classes SV, I to IV depending on the layer thickness: - for gravel base courses 20 cm: Ev2 150 MN/m² 25 cm: Ev2 180 MN/m² - for crushed stone base courses 15 cm: Ev2 150 MN/m² 20 cm: Ev2 180 MN/m². Based on a deformation modulus at the frost protection layer of at least E v2 = 100 MN/m², the following deformation modulus E v2 must be reached at the base course for roads belonging to Construction Classes V to VI depending on the layer thickness: - for gravel base courses 20 cm: Ev2 120 MN/m² 25 cm: Ev2 150 MN/m² - for crushed stone base courses 15 cm: Ev2 120 MN/m² 20 cm: Ev2 150 MN/m². Based on a deformation modulus at the frost protection layer of at least E v2 = 45 MN/m² even in the event that a layer made out of frost-resistant material is used, the following deformation modulus E v2 must be reached at the base course for roads belonging to Construction Classes SV, I to IV depending on the layer thickness: - for gravel base courses 40 cm: Ev2 150 MN/m² - for crushed stone base courses 30 cm: Ev2 150 MN/m². Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 62 Based on a deformation modulus at the frost protection layer of at least Ev2 = 45 MN/m² even in the event that a layer made out of frost-resistant material is used, the following deformation modulus E v2 must be reached at the base course for roads belonging to Construction Classes V and VI depending on the layer thickness: - for gravel base courses 30 cm: Ev2 120 MN/m² - for crushed stone base courses 25 cm: Ev2 120 MN/m². Based on a deformation modulus at the frost protection layer of at least E v2 = 45 MN/m², a deformation modulus of at least Ev2 = 80 MN/m² must be reached at the gravel or crushed stone base course for cycle and foot paths with asphalt or stone pavement or slabbed surface. The following deviations are permissible for the deformation moduli within the context of selfmonitoring and control testing: - If the examination of a course or a test layer is based on fewer than five individual values, all of the individual values must reach or exceed the required minimum value. - If the examination of a course or a test layer is based on five or more individual values, in each case one individual value may fall below the minimum value for the deformation modulus by no more than 10 %. The permissible deviations only apply, however, if these individual values belong to the five measurement points in closest proximity to one another 2.3.4.3 True to cross-section, line, and level See DIN 18315, Section 3.3.1.4. The surface of the base course may not deviate by more than ± 2.0 cm from the nominal height. 2.3.4.4 Flatness See DIN 18315, Section 3.3.1.5. Flatness imperfections in the surface of the base course may not be greater than 2.0 cm within a test section 4 m in length. 2.3.4.5 Paving thickness See DIN 18315, Section 3.3.1.6. The paving thickness may not fall below the paving thickness stipulated in the building contract by more than 10 %. The arithmetic mean of all individual paving thickness values is taken as the paving thickness for the respective course over the entire contract section. In determining the mean value, only excess thicknesses of up to 3.0 cm in individual values over the paving thickness stipulated in the building contract may be taken into account. Regardless the mean value, individual values of paving thickness may not fall below the paving thickness stipulated in the building contract by more than 3.5 cm. 2.4 Binderless top layers 2.4.1 Construction principles See Section 1.3. Binderless top layers are situated on gravel and crushed stone base courses according to Section 2.3. For specific applications, e.g. the construction of semi-natural routes, top layers made of unsorted stone may also find application. The construction of these top layers is described in ZTV LW. 2.4.2 Material mixtures Material mixtures in accordance with TL SoB-StB, Section 2.4 should be used for binderless top layers. For certain fields of application, it may be necessary to limit the grain size 2.4.3 Production Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 63 See Section 2.1.1. The minimum installation thickness for each course or layer must be as follows when compacted, depending on the grain size: - up to 8 mm 3 cm - up to 11 mm 3 cm - up to 16 mm 5 cm - up to 22 mm 7 cm - up to 32 mm 12 cm For paths that are also intended to be used as cycling paths, the largest grain size should not exceed 16 mm. The thickness of the top layers depends on the type of upkeep and the surface structure of the bedding layer. It must be at least 3 cm. The building material mixture should be unloaded and installed in such a way that no harmful segregation occurs. Segregated material may not be installed. The building material mixture should be evenly installed in a layer with a favourable water content, which should be selected on the basis of suitability, and compacted. Compaction should be done in such a way that an even surface finish is guaranteed, as well as quick drainage of surface water in connection with the drainage pattern. Joints on existing components should run smoothly together. Permissible flatness imperfections in the surface must have gradual transitions and may not occur at short regular intervals. In any case, it must be ensured that the surface water is removed without damage. This also applies to flatness in the transverse direction. Puddles may not arise. 2.4.4 Requirements See Section 2.1.2. 2.4.4.1 Grain size distribution and fine material When installed, the limiting values in the Figures in Annex C shall apply. The proportion of fine material < 0.063 mm may not fall below 8.0 mass % and may not constitute more than 17.0 mass %. 2.4.4.2 True to cross-section, line, and level See DIN 18315, Section 3.3.2.4. The surface of the top layer may not deviate by more than ± 2.0 cm from the nominal height. 2.4.4.3 Flatness See DIN 18315, Section 3.3.2.5. Flatness imperfections in the surface of the base course may not be greater than 2.0 cm within a test section 4 m in length. In the case of washboard-liken flatness imperfections, it should be checked whether the flatness imperfections can be eliminated or whether a price reduction should be given. 2.4.4.4 Transverse slope The transverse slope of the surface may not deviate from the stipulated transverse slope by more than an absolute value of 0.5%. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 64 2.4.4.5 Paving thickness, installation weight See DIN 18315, Section 3.3.2.6. The observed mean value for paving thickness or installation weight may not fall below the nominal value by more than 15 %. Regardless of the mean value, individual values of paving thickness may not fall below the nominal value by more than 20 %. As a rule, the determination of the installation weight should be based on the installation weight of the entire contract section for the top layer. The client is also entitled to determine the installation weight for a segment, however. The segment should then meet at least one daily performance; the same requirement applies in this case. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 65 Excerpt 3 Excerpt from: Additional Technical contract conditions and guidelines for the construction of traffic surface pavements made of asphalt (ZTV Asphalt - StB 07), Version 2007 1 General 1.1 Scope The “Additional technical contract conditions and guidelines for the construction of traffic surface pavements made of asphaltˮ, Version 2007 (ZTV Asphalt-StB 07) regulate the construction of traffic surface pavements made of asphalt. …… 1.2 Definitions …… The definitions of bitumen and bitumen preparations correspond to the (abridged) definitions of the TL Bitumen-StB. The definitions of bitumen emulsions correspond to the (abridged) definitions of the TL BE-StB. The definitions of aggregates correspond to the (abridged) definitions of the TL Gestein-StB. The definitions of asphalt aggregate correspond to the (abridged) definitions of the TL Asphalt-StB. A distinction is made between - rolled asphalt, an asphalt aggregate compacted by rolling, and - mastic asphalt, an asphalt aggregate that can be poured and spread in its hot state and does not need to be compacted. An asphalt pavement consists of an asphalt base layer, where appropriate an asphalt binder course, and an asphalt surface course, or in some cases only a supporting asphalt surface course. The asphalt base layer is the lower layer of the asphalt pavement; it lies on a base layer without a binder or other suitable sublayer (e.g. hardening) and consists of asphalt concrete for asphalt base courses (asphalt base layer aggregate - AC T). The asphalt binder course is an asphalt layer below the asphalt upper layer, and consists of asphalt concrete for asphalt binder courses (asphalt binder - AC B). The asphalt surface course is the upper layer of the asphalt pavement. It consists either of stone mastic asphalt SMA, asphalt concrete for asphalt surface courses (asphalt concrete - AC D), porous asphalt (PA), or mastic asphalt (MA). The supporting asphalt surface course is a single-layer asphalt course. It simultaneously fulfils the function of asphalt base layer and asphalt surface course, and consists of asphalt concrete for supporting asphalt surface courses (supporting asphalt surface course aggregate - AC TD). Layer cohesion is the cohesion between the individual layers or coats of traffic surface pavements made of asphalt. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 66 Seams are the contact surfaces produced by the laying of asphalt aggregate with similar properties in adjacent parallel strips (longitudinal seams) as well as within strips in case of interruptions for longer periods (transverse seams). Connections are contact surfaces - between different types of asphalt aggregate with different properties (e.g. rolled asphalt/ mastic asphalt), - between asphalt coats or layers and embedded elements (e.g. kerbstones, revetments, etc.). Joints are planned or contingent gaps between two asphalt layers or between asphalt layers and embedded elements. Edge construction is the fabrication, shaping, and design of the free edges of all asphalt layers as well as their sealing. A compact “hot on hotˮ asphalt pavement consists of an asphalt surface course and an asphalt binder course, constructed in immediate sequence. Here, both layers are compacted in a single operation. …… 2.3 Asphalt aggregate 2.3.1 General See DIN 18317, Section 2.1.4 The asphalt aggregate used for asphalt base, binder, surface, and supporting surface courses shall be in accordance with TL Asphalt-StB. ...... 2.3.4 Transport of asphalt aggregate The loading area of the transport vehicle shall be cleaned before loading with asphalt aggregate. For moistening transport vehicles, only anti-caking agents that do not produce any adverse changes in the asphalt aggregate shall be used. During transport of asphalt aggregate, the temperature limits indicated in Table 5 shall be observed. The asphalt aggregate shall be produced in accordance with the progress of construction. During transport and storage, the asphalt aggregate shall be protected from cooling and addition of air (covering, heated vehicles/containers, etc.). Mastic asphalt shall be continuously stirred in mobile agitator vessels. For mastic asphalt, the following storage times in agitator vessels shall be observed: - no more than 12 hours when using road bitumen, - no more than 8 hours when using polymer-modified bitumen. Mastic asphalt that has been heated for longer or at higher temperatures than given in Table 5 shall not be used for construction. Where mastic asphalt is transferred from agitator vessels to the construction site in buckets, trolleys, tipping buckets, or similar receptacles, such receptacles shall be moistened using only agents that do not produce any adverse changes in the asphalt aggregate. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. Table 5: 67 Minimum and maximum temperature of asphalt mixture in °C*) Type and grade of the binder in the asphalt aggregate 20/30 30/45 50/70 70/100 40/100–65**) 10/40–65 25/55–55 Asphalt concrete for asphalt surface courses, asphalt binder, asphalt base layer aggregate, aggregate for the supporting asphalt surface course 155 to 195 140 to 180 140 to 180 160 to 190 150 to 190 Stone mastic asphalt Mastic asphalt Porous asphalt 150 to 190 140 to 180 150 to 190 210 to 230 200 to 230 210 to 230 200 to 230 140 to 170 - *) The lower limits apply to the asphalt aggregate at delivery to the construction site; the upper limits apply to the asphalt aggregate at production and at leaving the asphalt mixer or silo. **) The instructions given by the manufacturer shall also be observed. 3. Implementation 3.1 General See DIN 18317, Section 3.1 …... Where, in case of precipitation, a continuous water film forms on the sublayer, asphalt aggregate must not be applied. In addition, the sublayer must be clean and free of snow and ice. Mastic asphalt and porous asphalt must not be applied in case of rain. Asphalt surface courses made of mastic asphalt to be applied at a thickness of less than 3 cm without rolling must not be applied on a moist sublayer. Porous asphalt shall not be applied in case of strong winds. The application requirements of Table 6 apply additionally. Table 6: Application requirements Asphalt layers asphalt layer Asphalt binder course asphalt surface course made of rolled asphalt asphalt surface course made of mastic asphalt asphalt surface course made of porous asphalt supporting asphalt surface course compact asphalt pavement *) Temperature of sublayer at least + 5 ° C thickness in cm -3°C X minimum air temperature 0°C + 5° C + 10 ° C X ≥3 <3 ≥3 <3 X X X X X X X Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 68 The specifications shall lay down either the thickness of application or the quantity to be applied per unit of area. The type of asphalt aggregate and the thickness of application or the quantity to be applied per unit of area shall be mutually adjusted as indicated in Tables 9 to 15. For smaller construction projects or for layers where the proposed thickness of application is less than 3.0 cm, the quantity to be applied shall normally be laid down in terms of the quantity per unit of area. The production of compact asphalt pavements shall be done in accordance with the “Fact sheet for the construction of compact asphalt pavementsˮ [Merkblatt für den Bau kompakter Asphaltbefestigungen, M KA). The relative placement, type, and form of seams, connections, and joints shall be laid down in the specifications (see Section 3.3). Asphalt layers shall be produced such that their properties are as homogenous as possible and the given requirements are fulfilled. When producing the layers, all process steps that belong together shall be carried out in a swift, coordinated manner using the required equipment for the proposed operation. Rolled asphalt aggregate shall be applied mechanically using road finishers, and mastic asphalt aggregate using screeds. For smaller areas and difficult road surface profiles, as well as for large numbers of embedded elements, the asphalt aggregate may also be applied manually. When “hot on hotˮ producing compact asphalt pavements, the lower hot layer shall not be driven on. The temperature of the unloaded asphalt mixture at application shall not be less than the lower limits of Table 5. The application shall proceed at an even speed. The type, weight, and number of rollers shall be in line with the type of application, layer thickness, type of asphalt aggregate as well as the weather, season, and local conditions. Specifically Sdesignated stone mastic asphalt aggregate classes shall be compacted using static rollers with high line loads and/or dynamic vibrating rollers. In this case, the vibration compaction must be undertaken only at sufficiently high temperatures of the asphalt aggregate (at least 100 ° C) and only if preceded by a static roller pass. Compaction of porous asphalt must be done only statically. Rollers shall be used such that they do not create any permanent depressions, unevenness or cracks. 3.2 Sublayer See DIN 18317, Sections 3.2 and 4.2.1. The sublayer is the respective area underneath the layer being produced. When producing compact asphalt pavements, the unevenness of the sublayer, either longitudinally or transversely, must not exceed 6 mm on any 4 m section. When producing asphalt surface courses made of porous asphalt, the unevenness of the sublayer, either longitudinally or transversely, must not exceed 4 mm on any 4 m section. In the asphalt layer immediately below it, the unevenness, either longitudinally or transversely, must not exceed 6 mm on any 4 m section. A condition for the production of the layers is that the sublayer must be suitable: specifically, it must have sufficient resistance to deformation, load-bearing capacity, cleanness, trueness to profile, and evenness. These requirements shall be considered to be fulfilled if the sublayer is produced in accordance with the technical regulations applicable to the relevant case. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 69 Markings made of paint or plastics may be built over, provided that adequate cohesion with the new layer is ensured. The specifications shall include a separate paragraph to the effect that markings made of foils shall be removed before applying the next layer. If the sublayer is not suitable, it shall be assessed which specific measures need to be laid down. 3.3 Layer cohesion, seams, connections and joints, edge construction See DIN 18317, Section 3.3 and Sections 4.2.1 and 4.2.3 3.3.1 Layer cohesion There shall be adequate layer cohesion between all asphalt layers. When applying mastic asphalt, the sublayer shall not be sprayed. When applying rolled asphalt on an asphalt layer, it shall be sprayed with a bitumen emulsion. The specifications shall include a separate paragraph to this effect. Spraying shall be done so as to produce an even distribution of the total quantity of binder. The bitumen emulsions must be broken before the next layer is applied. The water in the bitumen emulsion shall have evaporated. A polymer-modified bitumen emulsion C 60 BP 1-S shall be used for Construction Classes SV, I to III, and a solvent-based bitumen emulsion C 40 BF-S for Construction Classes IV to VI. The dosage of the bitumen emulsion for layer cohesion shall be chosen in accordance with Tables 7 or 8 and laid down in the specifications. Table 7: Type and dosage of polymer-modified bitumen emulsion as a function of the sublayer for Construction Classes SV, I to III Type and properties of the sublayer Asphalt course base Asphalt binder course Legend: f gf N/A X f gf N/A f gf N/A = fresh = milled = very porous or worn / pull-out = to be assessed per project = must not occur Asphalt base course Layer to be applied Asphalt binder course asphalt surface course made of stone mastic asphalt or asphalt concrete spraying quantity C60BP1-S in g/m² 150 to 250 250 to 350 X 250 to 350 250 to 350 X 300 to 400 300 to 500 X X 150 to 250 250 to 350 250 to 350 300 to 500 250 to 350 Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. Table 8: 70 Type and dosage of solvent-based bitumen emulsion as a function of the sublayer for Construction Classes IV to VI Layer to be applied Asphalt surface course made of stone mastic asphalt or asphalt concrete spraying quantity C 40 BF 1-S in g/m² 200 to 300 200 to 300 300 to 400 200 to 300 350 to 450 300 to 400 Type and properties of the Asphalt base course sublayer asphalt base layer Legend: f gf N/A f gf N/A = fresh = milled = very porous or worn / pull-out The spraying quantity required for the application shall be determined on site. This quantity shall be the basis for invoicing. Spraying shall be done by means of a spray bar. Hand-held spraying equipment shall be used only in exceptional cases. An even application of the binder film onto the sublayer shall be ensured, particularly near the edges. Adjacent areas, particularly borders and drainage gutters, shall be protected. Sprayed surfaces may only be driven on for purposes of application. 3.3.2 Seams In multi-coat and/or multilayer application, the seams of the individual layers and coats shall be offset by at least 15 cm. This does not apply inside compact asphalt pavements. Where offsetting is not possible, a continuous joint shall be constructed. In case of application in parallel strips, an even, tight connection shall be ensured along the longitudinal seams by taking suitable measures. In case of interruptions to the work on the asphalt binder or asphalt surface course, up to 3 m of the strip being constructed shall be removed. The starting point shall then be edged off across the entire thickness of this layer and, except for asphalt surface courses made of mastic asphalt, evenly plastered or sprayed with road bitumen, polymer-modified bitumen, or bitumen-containing binder, ensuring a smooth junction (transverse seam) between the two sections. The starting point for the individual layers and/or coats shall be offset lengthwise by at least 2 m. Lengthwise seams shall not be placed in tracks or near markings on driving surfaces. …… 3.3.2.2 “Hot to coldˮ application for rolled asphalt The existing asphalt strip shall be true to profile, evenly compacted, and crack-free up to the edges. The side of the seam shall be produced slightly bevelled instead of vertically. The sides of seams in asphalt binder courses and asphalt surface courses shall be covered with bitumen, polymer-modified bitumen, or bitumen-containing binder, in a quantity of at least 50 g of binder per cm of thickness of the layer and per metre of seam. The relevant type of material shall be laid down in the specifications. For compact asphalt pavements, the seam in the asphalt surface course may be constructed as a joint as an alternative. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 71 3.3.2.3 “Hot to coldˮ application for mastic asphalt For layers made of mastic asphalt, joints shall be constructed between asphalt strips. The specifications shall include a separate paragraph to this effect. 3.3.3 Connections and joints The requirements of ZTV Fug-StB shall apply, unless provided otherwise below. Connections of surface layers made of rolled asphalt to mastic asphalt or to embedded elements shall be constructed as joints. This does not apply to connections between asphalt surface courses made of porous asphalt and embedded elements. For layers made of mastic asphalt, the connections shall be constructed as joints. Lengthwise seams shall not be placed in tracks or near markings on driving surfaces. Joints may be constructed by means of grouting or waterstops. The specifications shall include a separate paragraph to this effect, laying down the type of jointing material to be used. Grouting and waterstops shall be in accordance with the TL Fug-StB. The joint width shall be at least 10 mm for both longitudinal and transverse connections. The specifications shall lay down the depth and width of the joint. 3.3.4 Edge construction Where asphalt surface courses or supporting asphalt surface courses are applied adjacent to borders of the same height, the surface of the asphalt surface course or supporting asphalt surface course shall be placed 0.5 to 1.0 cm higher than the border; in case of slant, this applies only to the lower edge. The free edges of all rolled asphalt layers shall be constructed at an inclination not exceeding 2:1, bevelled off in a straight line using suitable devices, and compressed evenly across the surface of the sides. The edges of layers made of mastic asphalt shall be constructed vertically. For mechanical application of mastic asphalt, separate edge strips shall be constructed. The specifications shall lay down the width, mastic asphalt grade, and type of surface finishing for the construction of the edge strips, included in a separate paragraph of the specifications. After producing a traffic surface pavement made of asphalt with a unilateral transverse inclination, the higher edge (both edges in curves) shall be sealed. To that end, the entire side area shall be covered with hot bitumen in a quantity of at least 40 g per centimetre of layer thickness and per metre of asphalt strip. The bitumen shall be applied early enough that the edges are still free from dirt. The side surfaces may only be sealed flush for several asphalt layers at a time if the asphalt layers can be applied immediately afterwards and/or accumulation of dirt can be prevented until construction is resumed. In case of sealing per layer, the adjacent surface of the relevant layer ca. shall be included in the sealing over a width of 10 cm, with a bitumen quantity of at least 150 g per metre of asphalt length. The specifications shall included separate paragraphs for the specified quantities of each binder. The type of binder shall be laid down. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.4 72 Production of asphalt base courses See DIN 18 317, Section 3.3.1 3.4.1 General provisions An asphalt base course consists of asphalt base layer aggregate, which is applied and compacted while hot. Its composition is adjusted to enable creating deformation-proof asphalt base courses whose apparent density and particle size distribution change only slightly under the impact of traffic. 3.4.2 Application Asphalt base courses may be applied on all types of traffic surface pavements. 3.4.3 Material mixtures The asphalt base layer aggregate used shall be in accordance with the TL Asphalt StB 07, Section 3.2.1. When using asphalt granulate and road bitumen with a requirement of 70/100 or 50/70, the contractor may use another binder type in lieu of the tendered binder type, if the suitability certificate shows that its ring-and-ball softening point (TR&Bmix) corresponds to the next-higher hardness grade. This grade will then be deemed to be the required binder class for the material mix. For asphalt base courses underneath concrete pavements, the composition of the mixture shall be chosen such that the Marshall sample has a cavity proportion not exceeding 6.0 % of the volume. 3.4.4 Layer properties The requirements of Table 9 shall apply. Table 9: Requirements for asphalt base courses Layer properties Minimum thickness of application Minimum quantity applied Degree of compaction 1) cm kg/m² % AC 32 T S AC 22 T S 8.0 AC 32 T N AC 22 T N 8.0 AC 32 T L AC 22 T L 8.0 185 97.0 185 97.0 185 97.0 1) For bicycle paths and footpaths as well as for manual application, a sublayer produced without binder shall meet a minimum requirement of 95.0 %. 3.5 Production of supporting asphalt surface courses See DIN 18317, Section 3.3.1 3.5.1 General provisions Aggregate for supporting asphalt surface courses shall consist of an aggregate mixture of graded particle sizes, with road bitumen as the binder. The aggregate for the supporting asphalt surface course shall be applied and compacted while hot. Its composition shall be adjusted to allow the production of robust, safe supporting asphalt surface courses with only a limited cavity proportion, whose degree of compaction and particle size distribution are only slightly affected by traffic. 3.5.2 Application A supporting asphalt surface course may be used as a single-layered pavement on traffic surfaces of minor importance on rural roads and on bicycle paths and footpaths. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.5.3 73 Material mixtures The supporting asphalt base layer aggregate used shall be in accordance with the TL Asphalt StB 07, Section 3.2.2. 3.5.4 Layer properties The requirements of Table 10 shall apply. Table 10: Requirements for supporting asphalt surface courses Layer properties Thickness of application Quantity to be applied Degree of compaction Cavity proportion 3.5.5 AC 16 TD 5.0 to 10.0 125 to 250 96.0 ≤ 6.5 cm kg/m² % Vol.-% Treatment of the surface Supporting asphalt surface courses shall have a roughness commensurate with their intended use. They shall be given an anti-skid treatment to increase the initial grip. The anti-skid treatment can take the form of sprinkling and rolling pure or binder-coated sprinkling material of grade 1/3 or 2/5. Here, the sprinkling material must be applied early enough to the surface of the hot layer so that it will be pressed in by the rollers. Any sprinkling material that is not bound shall be removed. The specifications shall include a separate paragraph for the anti-skid treatment of the surface. The following target values are recommended for the volume of sprinkling material applied: - broken aggregate of grade 1/3: 0.5 to 1.0 kg/m² - broken aggregate of grade 2/5: 1.0 to 2.0 kg/m² 3.6 Production of asphalt binder courses see DIN 18317, Section 3.3.1. 3.6.1 General provisions An asphalt binder course consists of asphalt binder, which is applied and compacted while hot. Its composition shall be adjusted to enable creating deformation-proof asphalt binder courses whose apparent density and particle size distribution change only slightly under the impact of traffic. 3.6.2 Application Asphalt binder courses may be applied on all types of traffic surface pavements. 3.6.3 Material mixtures The asphalt binder used shall be in accordance with the TL Asphalt-StB 07, Section 3.2.3. 3.6.4 Layer properties The requirements of Table 11 shall apply. Table 11: Requirements for asphalt binder courses Layer properties Thickness of application cm Quantity to be applied kg/m² Degree of compaction % 3.7 AC 22 B S 7.0 to 10.0 175 to 250 97.0 AC 16 B S 5.0 to 9.0 125 to 225 97.0 Production of asphalt surface courses made of asphalt concrete see DIN 18317, Section 3.3.1 AC 16 B N 5.0 to 6.0 125 to 150 97.0 Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.7.1 74 General provisions An asphalt surface course made of asphalt concrete for asphalt surface courses consists of an aggregate mixture of graded particle size, with road bitumen or polymer-modified bitumen as the binder. The asphalt aggregate shall be applied and compacted while hot. Its composition shall be adjusted to allow the production of robust, deformation-proof, and safe asphalt surface courses with only a limited cavity proportion, whose apparent density and particle size distribution are only slightly affected by traffic. 3.7.2 Application Asphalt concrete for asphalt surface courses may be used for asphalt surface courses on traffic surface pavements in Construction Classes II to VI as well as on all types of roads. 3.7.3 Material mixtures The asphalt concrete used for asphalt surface courses shall be in accordance with TL Asphalt-StB 07, Section 3.2.4. 3.7.4 Layer properties The requirements of Table 12 shall apply. Table 12: Requirements for asphalt surface courses made of asphalt concrete Layer properties Thickness application Quantity applied Degree compaction to of cm 5.0 to 6.0 4.0 to 5.0 3.5 to 4.5 3.0 to 4.0 2.0 to 3.0 be kg/m² 125 to 150 100 to 125 85 to 115 75 to 100 50 to 75 97.0 97.0 97.0 97.0 96.0 ≤ 6.5 ≤ 6.5 ≤ 5.5 ≤ 5.5 ≤ 5.5 of % Cavity proportion Vol.-% 3.7.5 AC 16 D S AC 11 D S AC 11 D N/L AC 8 D N/L AC 5 D L Treatment of the surface Asphalt surface courses made of asphalt concrete for asphalt surface courses shall have a roughness appropriate for their intended use. They shall be given an anti-skid treatment to increase the initial grip. The anti-skid treatment can take the form of sprinkling and rolling pure or binder-coated sprinkling material of grade 1/3 or 2/5. Here, the sprinkling material must be applied early enough to the surface of the hot layer so that it will be pressed in by the rollers. Any sprinkling material that is not bound shall be removed. The specifications shall include a separate paragraph for the anti-skid treatment of the surface. The following target values are recommended for the volume of sprinkling material applied: - broken aggregate of grade 1/3 0.5 to 1.0 kg/m², - broken aggregate of grade 2/5 1.0 to 2.0 kg/m² When choosing the grade of the sprinkling material, it shall be noted whether any noise-related requirements also need to be observed. If this is the case, grade 1/3 shall be specified. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.8 75 Production of asphalt surface courses made of stone mastic asphalt see DIN 18317, Section 3.3.1. 3.8.1 General provisions An asphalt surface course made of stone mastic asphalt consists of an aggregate mixture with gap grading, of polymer-modified bitumen or road bitumen as the binder, and additives as the binder substrate. The asphalt aggregate shall be applied and compacted while hot. A large proportion of coarse aggregates produces a self-supporting aggregate structure whose cavities are largely filled with asphalt mastic. The simultaneous use of large binder concentrations requires the addition of additives as a binder substrate to prevent demixing during production, transport, application, and compaction of the stone mastic asphalt. Suitable additives include organic and mineral fibrous materials. The composition of the stone mastic asphalt shall be adjusted such that the asphalt mastic permanently ensures the cohesion of the aggregate structure, thereby enabling the production of robust, deformation-proof, and safe asphalt surface courses with only a limited cavity proportion, whose apparent density and particle size distribution are only slightly affected by traffic. 3.8.2 Application Stone mastic asphalt may be used as an asphalt surface course on all types of traffic surface pavements. 3.8.3 Material mixtures The stone mastic asphalt used shall be in accordance with TL Asphalt-StB 07, Section 3.2.5. Asphalt granulate shall not be used. Where the use of asphalt granulate is possible in specific cases, this shall be stated in the specifications. 3.8.4 Layer properties The requirements of Table 13 shall apply. Table 13: Requirements for asphalt surface courses made of stone mastic asphalt 3.8.5 Layer properties SMA 11 S SMA 8 S SMA 8 N SMA 5 N Thickness of application cm 3.5 to 4.0 3.0 to 4.0 2.0 to 3.5 2.0 to 3.0 Quantity to be applied kg/m² 85 to 100 75 to 100 50 to 85 50 to 75 Degree of compaction % 97.0 97.0 97.0 97.0 Cavity proportion Vol-% ≤ 5.0 ≤ 5.0 ≤ 5.0 ≤ 5.0 Treatment of the surface Asphalt surface courses made of stone mastic asphalt shall have a roughness appropriate for their intended use. They shall be given an anti-skid treatment to increase the initial grip. The anti-skid treatment can take the form of sprinkling and rolling pure or binder-coated sprinkling material of grade 1/3. In the case of SMA 11 S, sprinkling material of grade 2/5 may also be used. Here, the sprinkling material must be applied early enough to the surface of the hot layer so that it will be pressed in by the rollers. Any sprinkling material that is not bound shall be removed. The specifications shall include a separate paragraph for the anti-skid treatment of the surface. The following target values are recommended for the volume of sprinkling material applied: - broken aggregate of grade 1/3 0.5 to 1.0 kg/m², broken aggregate of grade 2/5 1.0 to 2.0 kg/m² When choosing the grade of the sprinkling material, it shall be noted whether any noise-related requirements also need to be observed. If this is the case, grade 1/3 shall be specified. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.9 76 Production of asphalt surface courses made of mastic asphalt See DIN 18 317, Section 3.3.2. 3.9.1 General provisions An asphalt surface course made of mastic asphalt is a dense layer made of coarse and fine aggregates, filler and road bitumen, or polymer-modified bitumen or a mixture of road bitumen, with natural asphalt as the binder. The aggregate mixture shall be designed for a low cavity proportion. The binder content shall be adjusted to the cavities in the aggregate mixture, such that these are completely filled upon application, or that even a slight surplus of binder remains. To comply with workplace safety legislation, suitable modified-viscosity binders or viscositymodifying additives shall be used. As an alternative, suitable procedural measures may be taken to reduce the amount of bituminous vapours and airborne particles: the effectiveness of these measures will then need to be demonstrated. The surface structure shall be produced immediately after the application of the mastic asphalt, by applying sprinkling material. On high-incline surfaces (inclination above 7 %), special measures shall be specified for the application of mastic asphalt. The widths of application of mastic asphalt layers shall be laid down in the specifications. 3.9.2 Application Mastic asphalt may be used as a surface course on all types of traffic surface pavements. 3.9.3 Material mixtures The mastic asphalt used shall be in accordance with TL Asphalt-StB 07, Section 3.2.6. 3.9.4 Layer properties See Table 14. Table 14 Layer properties for surface courses made of mastic asphalt Layer properties MA 11 S MA 11 N MA 8 S MA 8 N MA 5 S MA 5 N Thickness of application1) cm 3.5 to 4.0 2.5 to 3.5 2.0 to 3.0 Quantity to be applied1) kg/m² 85 to 100 65 to 85 50 to 75 1) including bound sprinkling material Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.9.5 77 Treatment of the surface Asphalt surface courses made of mastic asphalt shall be roughened with sprinkling material after application. The surface of road shoulders made of mastic asphalt may be roughened with sprinkling material consisting of either coarse or fine aggregate; that of driving lanes and side lanes only with coarse aggregate. Gutters made of mastic asphalt shall normally be anti-skid treated only with fine aggregate. After the asphalt surface course made of mastic asphalt has cooled, any excess sprinkling or anti-skid material shall be removed. After this, the surface shall be even and have a roughness appropriate for the intended use. The specifications shall lay down whether the surface treatment of asphalt surface courses made of mastic asphalt will be done in accordance with Method A, B, or C. A surface treatment according to Method B shall normally be done to a thickness of 2.5 cm. A surface treatment according to Method C is only suitable for anti-skid treatments of road shoulders and gutters. Method A: To produce a rolled surface structure, thinly binder-coated grade 2/5 coarse aggregate shall be mechanically—or optionally manually for small surfaces—sprinkled evenly on the hot surface, in a quantity of 12 to 15 kg/m². The volume of binder shall be chosen to produce a material that is easy to sprinkle. The sprinkling material shall be pressed in using rubber tyre rollers and/or static rollers. Method B: To produce the surface structure, thinly binder-coated coarse aggregate shall be mechanically—or optionally manually for small surfaces—sprinkled evenly on the hot surface, in a quantity of 10 to 12 kg/m² for grade 2/3 aggregate or 11 to 13 kg/m² for grade 2/4 aggregate. The specifications shall include a separate paragraph for the aggregate grade to be used. The volume of binder shall be chosen to produce a material that is easy to sprinkle. The sprinkling material shall be applied such that it that it has sufficient adhesion to the surface. To this end, the sprinkling material shall be produced fresh and applied to the mastic asphalt surface while hot. The sprinkling material shall be transported using thermally insulated vehicles. Driving lanes shall not be rolled. In special cases, the sprinkling material may be pressed using a light roller with static treading and an operational weight not exceeding 2 tonnes for a surface temperature of 80 to 120 °C. The specifications shall include a separate paragraph to this effect. Method C: For the anti-skid treatment, the hot surface of the asphalt surface course made of mastic asphalt shall be sprinkled with 2 to 3 kg/m² defillered dry or thinly binder-coated fine aggregate, which is then rubbed in. 3.10 Production of asphalt surface courses made of porous asphalt 3.10.1 General provisions An asphalt surface course made of porous asphalt shall have such composition that it reduces noise and drains water in its final state. It shall have a very high proportion of interconnected cavities, allowing the passage of water and air. Asphalt surface courses made of porous asphalt shall be laid on top of a tight sublayer. 3.10.2 Application Porous asphalt may be used as an asphalt surface course on all types of traffic surface pavements of Construction Classes SV, I to III. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 78 The Fact sheet for asphalt surface courses made of porous asphalt [Merkblatt für Asphaltdeckschichten aus Offenporigem Asphalt, M OPA] shall be observed. Any individual lot of asphalt surface course made of porous asphalt shall have a length of at least 1 000 m for reasons related to construction, noise, and traffic. Proper operation of asphalt surface courses made of porous asphalt depends on ensuring appropriate drainage. To achieve this, suitable drainage facilities shall be planned particularly for borders and embedded elements, with a separate paragraph for each included in the specifications. Prior to the construction of asphalt surface courses made of porous asphalt, either all excavation, drainage, and preparation shall have been completed, or suitable measures shall be taken to protect the surface; the specifications shall include a separate paragraph for each. 3.10.3 Sealing the sublayer Before applying the sealant, the sublayer shall be cleaned using suitable devices. A water-tight sealing of the sublayer underneath an asphalt surface course made of porous asphalt requires a bituminous layer of sufficient thickness. To achieve this, a quantity of 2.0 to 3.0 kg/m² (depending on the properties of the sublayer) of polymer-modified bitumen 40/100-65 H shall be applied, sprinkled with 5 to 10 kg/m² of a prebituminised grade 8/11 aggregate of category SZ18/LA20, and compressed using rollers where appropriate. Any aggregate that is not bound shall be removed. In light of the thickness of the sealing thus applied to the asphalt binder course, it shall be considered an asphalt surface course made of porous asphalt. 3.10.4 Material mixtures The porous asphalt used shall be in accordance with TL Asphalt-StB 07, Section 3.2.7. 3.10.5 Layer properties The requirements of Table 15 shall apply. Table 15: Requirements for asphalt surface courses made of porous asphalt Layer properties Thickness including sealing cm Degree of compaction % Cavity proportion Vol-% PA 11 PA 8 5.0 to 6.0 4.5 to 5.0 97.0 97.0 22.0 to 28.0 22.0 to 28.0 Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 79 Excerpt 4 Excerpt from: Additional technical contract conditions and guidelines for the construction of base courses with hydraulic binders and driving surfaces made of concrete (ZTV Beton - StB 07), Version 2007 …… 1 General provisions 1.1 Scope These “Additional technical contract conditions and guidelines for the construction of base courses with hydraulic binders and driving surfaces made of concreteˮ, Version 2007 (ZTV Beton-StB 07), contain requirements for the construction of base courses with hydraulic binders and driving surfaces made of concrete, which shall be observed in the production of superstructure layers in the construction of roads and other traffic surfaces. …… 1.2 Definitions …… Base courses with hydraulic binders are: - - Hardening: Operations to increase the strength of unbound base courses under traffic and climate stresses. Here, hydraulic binder and water are added to the soil and/or aggregate mixtures either centrally or on site. The concrete mix is subsequently compacted. The position of the hardening within the superstructure can be seen in Figures 1 and 2. ▪ Site mixing: The mixing device drives on the layer that has been prepared for hardening, cuts it open and mixes the binder and any required additional water into the layer. ▪ Central mixing: The soil or aggregate mixture is mixed with the binder and water (mixing water) in stationary mixing installations, then transported to the construction site and applied there. Hydraulically bound base courses: Hydraulically bound base courses consist of whole and/or broken aggregate mixtures and hydraulic binders. The particle size distribution of the aggregate mixtures shall be within the defined sieve-line range. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. - 80 Concrete base courses: Concrete base courses are base courses made of concrete as defined in DIN EN 206-1 and DIN 1045-2. Driving surfaces made of concrete will be referred to below as pavements or concrete pavements. They are constructed out of concrete in accordance with DIN EN 206-1 and DIN 1045-2. - Concrete pavements: Driving surfaces made of concrete constitute the upper part of the superstructure: they lie on the base layer or another appropriate sublayer. The pavement may consist of either a single layer or two layers. Two layers means that the concrete is composed of two layers of different composition. In this case, the upper layer is referred to as the concrete top layer, the lower layer as the concrete sublayer. Each layer may be applied in one or several coats. Several coats means that concrete of the same composition is applied in several coats. - Washed concrete: Concrete where the surface mortar is specifically removed in its wet or dry state. - Concrete pavements made of concrete with plasticizer: Concrete with plasticizer is easy to process. The following are distinguished in terms of composition: ▪ high-early-strength road concrete with plasticizer (Consistency Class F2 or C2) and ▪ soft road concrete with plasticizer (Consistency Class F3 or C3). Here, the starting concrete is the premixed concrete as supplied to the construction site, before adding the plasticizer. Concrete with plasticizer may be applied in one or two coats. …… 1.3.3 Construction principles 1.3.3.1 Superstructures of traffic surfaces See DIN 18316, Sections 3.3.1.4, 3.3.2.4, 3.3.3.4, or 3.3.4.8 ...... Construction materials and mixtures thereof shall be in accordance with TL Beton-StB. Each layer or coat shall be produced such that its quality characteristics are as homogenous as possible and the given requirements are fulfilled. When producing the layers, operations belonging together shall follow each other in rapid succession. To achieve this, the services provided and the number of devices required to provide them shall be adjusted appropriately. 1.3.3.2 Sublayer See DIN 18316, Section 3.2 The sublayer is the respective area underneath the layer being produced. A condition for the production of the layers in accordance with the ZTV Beton-StB is that the sublayer must be suitable: specifically, it must be stable, true to profile and even, and have sufficient loadbeating capacity. These requirements shall be considered to be fulfilled if the sublayer meets the requirements of the respective technical contract conditions. If the sublayer fails to meet the requirements of the respective relevant technical contract conditions, special measures shall be taken. …… Drainage devices shall be protected from damage and their proper operation shall be maintained. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 81 The production of base courses and pavements on a wet or frozen sublayer shall be prohibited. …… 3.4 Special provisions for pavements made of concrete with plasticizer 3.4.1 Application With respect to pavements made of concrete with plasticizer, two types of applications are distinguished: 3.4.2 - Traffic surfaces which may be subject to high loads from an early date after construction. - Traffic surfaces for which it is not possible or inefficient to use road finishers. Construction principles Where an unbound sublayer or non-woven fabric is present under the pavement, care shall be taken to ensure that the fresh concrete is not damaged by excess water removal. In some cases, the use of a foil sublayer may be expedient. 3.4.3 Implementation 3.4.3.1 Production of the concrete pavement 3.4.3.1.1 Consistency of the concrete and mixing-in of the plasticizer The consistency of the concrete to be chosen depends on the equipment used for the application, the temperature of the fresh concrete at application, and the inclination of the driving lane surfaces. Where the duration of the fluidising effect of the plasticizer is temporary, the plasticizer shall not be mixed in with the starting concrete until immediately before the transfer of the concrete to the place of application, or before it is processed. In this case, the mixing time in the mobile mixer shall be at least 1 minute per m³ of concrete, but not less than 5 minutes. The admixture of the plasticizer shall increase the expansion of soft road concrete with plasticizer by at least 100 mm in comparison to the starting concrete. 3.4.3.1.2 Application of the concrete Concrete with plasticizer shall be fully processed within 30 minutes. The load of the mixer trucks shall be adjusted accordingly. Depending on the specific needs, special measures shall be taken when applying concrete on driving lane surfaces with slopes over 3 %. Such measures may include: Dual-coat application or Removing the surface layer after a specific delay. 3.4.3.1.3 Compacting the concrete Concrete with plasticizer requires a degree of compaction in accordance with its consistency. In case of application on several interconnected areas with widths over 3 m, the compaction devices used shall be mechanically operated and powered. In case of application on several interconnected areas with widths of up to 3 m, as well as for individual fields, hand-held compacting beams may also be used. The compaction devices shall so be designed and operated so as to ensure that the requirements for evenness of the pavement are met. 3.4.3.1.4 Finishing the surface Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 82 The final finishing of the surface shall not be undertaken until the fluidising effect of the plasticizer has subsided enough for the surface structure of the applied concrete to remain intact. 3.4.3.2 Production of the joints For pavements made of high-early-strength road concrete with plasticizer, the more rapid hardening of the concrete requires that the joint grooves be incised at an earlier stage than with normal road concrete. 3.4.4 Requirements for early strength When using high-early-strength concrete, adequate early strength shall be demonstrated in addition to the 28-day compressive strength and bending tensile strength. Unless specified in more detail, the initial inspection after 2 days shall demonstrate a compressive strength of at least 30 N/mm² (average of 3 samples). Here, none of the individual values shall be less than 26 N/mm². The strength shall be demonstrated based on 150 mm cubes (storage under water at 20 °C). 3.4.5 Release for public use For high-early-strength road concrete with plasticizer, the compressive strength shall be tested on separately produced samples that have been stored on-site, before the road is opened to the public. See also Section 3.3.5. …… Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 83 Excerpt 5 Excerpt from: Additional technical contract conditions and guidelines for the production of sett pavings, slab pavings, and borders (ZTV Pflaster-StB 06), Version 2006 1. General provisions …… 1.2 Definitions ……. Set t p a v i n g Upper layer of the superstructure, consisting of setts including their bedding, and the joint filler. Sla b p a vi n g Upper layer of the superstructure, consisting of slabs including their bedding, and the joint filler. Set t s Setts are Setts made of concrete (see Section 1.5.2) Pavement tiles or clinker bricks (see Section 1.5.4) Setts made of natural stone (see Section 1.5.6 in accordance with the TL Pflaster-StB. B o nd ed s ett s Bonded setts are setts whose design creates a special cohesion between the stones, and prevents loosening of individual stones under the impact of traffic loads and forces. Sla b s Slabs for purposes of the present ZTV Pflaster-StB are Slabs made of concrete (see Section 1.5.3) Clinker brick slabs (see Section 1.5.5) Slabs made of natural stone (see Section 1.5.7) In accordance with the TL Pflaster-StB, for rectangular or square shapes the ratio of the total length and thickness (nominal dimensions) is greater than 4. For other shapes, the total length shall be the length of the smallest enclosing rectangle. B ed d i n g Lower part of the sett or slab paving, also referred to as the sett or slab bed. Bedding material Material mixtures without binder, in accordance with the TL Pflaster-StB, used for the lower part of the sett or slab paving, also referred to as the bedding. J o in t s Gap between the setts or slabs, or to the borders at the edges or the elements embedded in the relevant traffic surface. Joint material Material mixtures without binder, in accordance with the TL Pflaster-StB, used to fill the gap (joint) between the setts or slabs, or to the borders at the edges or to the elements embedded in the relevant traffic surface. Bond The geometrical pattern to which the setts, clinker bricks, or slabs are embedded or laid. …… Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 1.4 Construction principles 1.4.1 General provisions 84 Sett pavings may be used to cover all types of traffic surfaces in accordance with the RStO. Slab pavings shall be used only to cover footpaths and bicycle paths, except for crossings, and locations without motor vehicle traffic. ……. 1.4.2 Sublayer See DIN 18 318 The sublayer is the layer underneath the sett or slab paving. A condition for the production of sett or slab pavings is that the sublayer must be suitable: specifically, it must have sufficient load-bearing capacity, water-permeability, trueness to profile, and evenness. These requirements shall be considered to be fulfilled if the sublayer is produced in accordance with the technical regulation applicable to the relevant case. In light of the requirement of even bedding thickness, it is recommended to contractually restrict the maximum unevenness of the sublayer to a maximum of 1 cm over a 4 m section. Where a sublayer is already present, it shall be reworked where necessary. …… The surface of the base course shall have the same inclination as the sett or slab paving. The sublayer of the border is the layer underneath the latterʾs foundation. It shall have sufficient loadbearing capacity, trueness to profile, and evenness. Sett or slab pavings or borders shall not be applied on a frozen sublayer. Frozen bedding or joint material shall not be used. …… 1.5 Construction products Construction products for the production of sett or slab pavings or borders shall meet the requirements of the TL Pflaster-StB. …… 1.5.1.2 Joint material …… Material mixtures 0/4, 0/5, 0/8, or 0/11 shall be used as joint materials. …… 2 Implementation 2.1 General provisions See DIN 18318 For large interconnected surfaces made of bonded setts, if it is expected that the surface will subsequently need to be opened (e.g. to accommodate piping), it is expedient to subdivide the sett surface to enable the subsurfaces to be rebuilt in their entirety. The edges of the subsurfaces may be fitted e.g. with rectangular setts that can be used to compensate for any movement of the edges of the bonded setts (e.g. in case of changes in sett dimensioning or cutting). These measures shall be included in the specifications. 2.2 Bedding See DIN 18318 The bedding material shall be evenly mixed and evenly moistened, with a water content that is conducive to its application and compaction. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 2.3 85 Laying and embedding See DIN 18318 To avoid additional work on setts or slabs made of concrete or on sett bricks or clinker brick slabs, the exact distance to the borders—in relation to the required width—shall be determined beforehand by laying out individual brick rows or slab rows. Additional work shall be avoided by using shaped stones where possible. The same applies to e.g. curved stones. The specifications shall include the relevant provisions as appropriate. Shaped spacers do not determine the regular joint width. For the production of a joint of compliant width when laying/embedding in rows, setts, or slabs made of natural stones they shall be sorted according to their actual dimensions between the upper and lower limits of the permitted variation in dimensions. The sett or slab paving shall normally be vibrated or tamped from the edges towards the centre. This must not affect the designed layout of the joints. Surfaces with unfilled joints shall not be vibrated or tamped. 2.4 Jointing See DIN 18318 Joints shall be filled completely and continuously as the laying or embedding proceeds. The joints shall be closed by applying the joint material to the sett paving, brushing it into the joints, and grouting it while adding a limited amount of water; any excess joint material shall be removed completely. Subsequently and after having dried up sufficiently, the surface shall be vibrated or tamped to achieve its intended stability. After this, the joints shall be filled up if needed. Finally, the joints may be closed by brushing in and grouting, e.g. an aggregate of size 0/2. 2.5 Borders See DIN 18318 The distance from edge restraints to unpaved surfaces shall be at least 15 cm. For edge restraints that may be subjected to frequent high mechanical loads, e.g. in roundabouts or entrance or exit driveways with a small radius, greater widths and higher compressive strength classes may be required. 2.6 Release for public use Sett or slab pavings shall not be released for public use until their bedding and its sublayer have dried up sufficiently after grouting. If any missing joint material needs to be replaced in a sett or slab paving after it has been released for public use, the relevant details shall be included in the specifications. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 2.7 Position, permitted variation 2.7.1 Heights and unevenness 86 See DIN 18318 Any unacceptable unevenness in the base course must not be compensated for by the bedding. 2.7.2 Transverse and longitudinal inclination See DIN 18318 Any transverse inclination, or alternatively longitudinal inclination, of the surface of a sett or slab paving must not be less than the lower limits given in DIN 18318. If local circumstances do not permit this, the contract partners shall conduct prior consultations on the measures to be taken. The surface of the bedding shall have the same inclination as the surface of the sett or slab paving. 2.7.3 Thickness of the bedding See DIN 18318 The thickness of the bedding shall not be more than 1 cm below the minimum given in DIN 18318. The specified maximum dimensions shall not be exceeded. …… Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 87 Excerpt 6 Excerpt from: DIN 18299 VOB, Part C: General technical contract conditions for construction works (ATV)—General provisions for all types of construction works, Version 2006 ..... 1 Scope The ATV DIN 18299, “General provisions for all types of construction works” shall apply to all construction works, including those for which the VOB/C − DIN 18300 to DIN 18451 − does not include a set of general technical contract conditions. Any differing provisions in the general technical contract conditions DIN 18300 to DIN 18451 shall take precedence. 2 Materials and components 2.1 General provisions 2.1.1 The scope shall also include the supply of associated materials and components including unloading and storage at the construction site. 2.1.2 Materials and components provided by the client shall be requested from the latter in time by the contractor. 2.1.3 Materials and components shall be suitable for and tailored to their respective intended use. 2.2 Availability Materials and components which the contractor merely has to make available, without becoming part of the structure, may be new or used at the option of the contractor. 2.3 Delivery 2.3.1 Materials and components which the contractor has to deliver and embed, thereby becoming part of the structure, must be new. Recycled materials shall be deemed to be new if they meet the requirements of Section 2.1.3. 2.3.2 Materials and components for which DIN norms are in force shall meet the relevant DIN quality and dimensioning requirements. 2.3.3 Materials and components which require approval pursuant to regulations of the German authorities, shall be officially approved and meet the requirements of their respective approval. 2.3.4 Materials and components for which the specifications do not contain specific technical requirements may also be used if they comply with norms, technical requirements, or other provisions in force in other countries which ensure the required level of protection with regard to security, health, and fitness for purpose with equal permanence. Where materials and components are under a generic requirement of monitoring, certification, or proof of usability, e.g. in the form of a general construction approval, equivalence may be assumed only if the materials and components bear a relevant inspection or certification mark or the aforementioned proof of usability has been given. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3 88 Implementation 3.1 Where the building site contains any traffic, utility, or waste disposal installations, the regulations and instructions of the competent authorities shall be observed. Where the location of such installations has not been specified beforehand, it must be investigated. Such measures shall be considered special services (see Section 4.2.1). 3.2 Any areas intended to facilitate traffic shall be kept clear. Access to facilities of utility and waste disposal companies, fire departments, post and railways, survey points, and similar facilities must not be beyond hindered except where unavoidable in connection with the implementation. 3.3 If any harmful substances are found, e.g. in soils, water bodies, or components, the client shall be notified immediately. In case of imminent danger, the contractor shall take the necessary protective measures immediately. Any further measures shall be determined in mutual consultation. Any measures taken or subsequently laid down shall be considered special services (see Section 4.2.1). 4 Supplementary services and special services 4.1 Supplementary services Supplementary services are services which are part of the scope of contract even without being specified in the contract (Section 2(1) of the VOB/B). Accordingly, the following constitute supplementary services: 4.1.1 Preparing and clearing the construction site, including equipment, etc. 4.1.2 Making the site facilities available, including equipment, etc. 4.1.3 Measurements for the implementation and settlement of the works, including making available any measuring devices, moulds, markers, etc., keeping the moulds and markers available during construction, and making available the required workforce, but not including services pursuant to Section 3(2) of the VOB/B. 4.1.4 Protection and security measures required under the relevant accident prevention regulations and official regulations, except for services as referred to in Section 4.2.5. 4.1.5 Lighting, heating, and cleaning of the common-use and sanitary areas intended for the contractorʾs employees. 4.1.6 use. Supply of water and energy from the on-site connection points provided by the client to the place of 4.1.7 Supply of fuels. 4.1.8 Making available any minor equipment and tools. 4.1.9 Transport of all materials and components, even if provided by the client, from the on-site storage facilities or transfer locations as stated in the specifications, to the place of use application services, and vice versa where appropriate. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 89 4.1.10 Securing the work against the precipitation that should reasonably be expected, and removal thereof where required. 4.1.11 Removing waste from the contractorʾs working areas, and removing any contaminants attributable to the contractorʾs activities. 4.1.12 Removing waste from the clientʾs working areas, up to a volume of 1 m³, unless such waste is polluted. 4.2 Special services Special services are services which are not considered supplementary services as defined in Section 4.1, and which are not considered part of the scope of contract unless specifically designated as such in the specifications. Special services include the following: 4.2.1 Measures as defined in Section 3.1 and Section 3.3. 4.2.2 Inspecting the services of other entrepreneurs. 4.2.3 Complying with instructions from the client with respect to the planning of the construction project or its coordination pursuant to the Construction Sites Regulation [Baustellenverordnung]. 4.2.4 Protective measures for accident prevention with respect to services provided by other companies. 4.2.5 Special protection and security measures when working in contaminated areas, e.g. monitoring by means of measurements, specific additional equipment for building machines and installations, screened-off working areas. 4.2.6 Special protective measures against weather-induced damage, floods, and groundwater, except for services pursuant to Section 4.1.10. 4.2.7 Insuring the service until the date of acceptance, with the client as the beneficiary, or insuring any exceptional liability risk. 4.2.8 Special inspections of substances and components provided by the client. 4.2.9 Placing, making available, operating, and disposing of facilities to secure and maintain traffic on site, e.g. site fences, security structures, auxiliary structures, lighting, guiding facilities. 4.2.10 Erecting, making available, operating, and disposing of facilities outside the construction site for diverting, regulating, and securing public and local traffic, and obtaining the required traffic approvals and instructions under the Road Traffic Regulation [Straßenverkehrsordnung]. 4.2.11 Making part of the site facilities available to other companies or to the client. 4.2.12 Special measures for reasons of environmental protection, nature conservation, and heritage protection. 4.2.13 Any disposal of waste beyond the scope of Sections 4.1.11 and 4.1.12. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 90 4.2.14 Special protection for the works as required by the client for early commissioning, as well as the maintenance and later removal thereof. 4.2.15 Removing obstacles. 4.2.16 Additional measures for continued working in frost and snow, if the contractor is not already required to take such measures. 4.2.17 Special measures to protect and secure any sensitive building installations and neighbouring plots. 4.2.18 Securing pipes, cables, drains, ducts, boundary stones, trees, plants, etc. Excerpt 7 Excerpt from: DIN 18300 VOB, Part C: General technical contract conditions for construction works (ATV) - Earthworks, Version 2006 ..... 3 Implementation Supplementary to ATV DIN 18299, Section 3, the following applies: 3.1 General provisions 3.1.1 The choice of construction method and procedure, as well as the choice and use of construction equipment, shall be the responsibility of the contractor. 3.1.2 Near any structures, pipes, cables, drains, and ducts, the work shall be carried out with appropriate caution. 3.1.3 Any sensitive building installations shall be secured; DIN 4123 “Building security near excavations, foundations and underpinningsˮ shall be observed. Any protection and security measures shall comply with the instructions given by the owners or other appropriately authorised persons. Such measures shall be considered special services (see Section 4.2.1). 3.1.4 Where the location of any existing pipes, cables, drains, ducts, markings, obstacles, and other building installations cannot be specified prior to construction, they shall be investigated. Such measures shall be considered special services (see Section 4.2.1). 3.1.5 If any unexpected cavities or obstacles are found, e.g. unmarked pipes, cables, drains, ducts, markings, or remainders of structures, the client shall be notified immediately. The measures to be taken shall be considered special services (see Section 4.2.1). 3.1.6 Near any trees, plant populations, and vegetation that must be conserved, the work shall be carried out with appropriate caution. 3.1.7 Any sensitive trees, plant populations, and vegetation shall be protected; DIN 18920 “Vegetation engineering in landscaping; protection of trees, plant populations, and vegetation areas in constructionˮ shall be observed. Such protective measures shall be considered special services (see Section 4.2.1). Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.2 91 Preparing the building site 3.2.1 Any boundary stones and official fixed points shall not be removed except with the consent of the client. Any fixed points specified for the construction project by the client shall be secured by the contractor before disposal. 3.2.2 Any new growth shall not be removed beyond the agreed scope except with the consent of the client. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.3 92 Water discharge 3.3.1 The contractor shall take the necessary drainage measures in a timely fashion. Where the agreed measures for disposal of ground water, deep groundwater, source water, or drainage water, etc. are inadequate, the necessary additional measures shall be determined in mutual consultation; the relevant services shall be considered special services (see Section 4.2.1). 3.3.2 The direction, elevation, and water content of water bodies, seepage channels, and drains shall not be changed during construction except with the consent of the client. 3.3.3 For measures as referred to in Sections 3.3.1 and 3.3.2, the contractor shall ensure that the water can run off unobstructed at all times and will not produce any damages. 3.4 Topsoil work 3.4.1 Topsoil shall be removed from all contractual working areas. Topsoil on storage areas, traffic areas, etc. shall be removed only to the extent as laid down in the specifications. 3.4.2 The removal and incorporation of topsoil shall take place separate from any other groundwork. 3.4.3 Topsoil not used for landscaping but reused as topsoil instead, shall be subject to the following provisions: 3.4.3.1 The quality of the topsoil shall not be affected by any admixtures such as building residues, metals, glass, slag, ashes, plastics, mineral oils, chemicals, and poorly degradable plant residues. 3.4.3.2 Heavy topsoils may only be removed and applied if they have soft to solid consistency. 3.4.3.3 Topsoil that is not immediately reused shall be separated from other types of soil and stored away from the construction work, undivided where possible. It shall not be compacted by driving or other means. 3.4.3.4 Fast-decaying plant cover such as turf shall be treated as topsoil. 3.5 Loosening and loading 3.5.1 The dimensions of the removal cross-sections as defined in the specifications shall not be deviated from except with the consent of the client. The same applies where relying exclusively on expert reports. 3.5.2 Where cross-sections for removal are not defined in the specifications, they may be chosen by the contractor; this applies specifically to the inclination of the embankment. Here, the following shall be observed: - DIN 4124 “Trenches and ditches; embankments, working area width, trench lining,ˮ for the minimum widths of ditches for wastewater pipes and ducts: DIN EN 1610 “Construction and inspection of wastewater pipes and ductsˮ. - 3.5.3 If, in removing the topsoil, soil conditions are found which differ from the specifications, or if Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 93 circumstances arise which make it impossible to observe the agreed removal cross-sections, then the necessary measures shall be determined in mutual consultation; the relevant services shall be considered special services (see Section 4.2.1). 3.5.4 With respect to excavations from escarpments, the contractor shall submit a work plan upon request. 3.5.5 Any unforeseen events, such as lateral afflux, soil buoyancy, layer overflow, and damages to structures, shall be immediately reported to the client by the contractor. The measures to be taken shall be considered special services (see Section 4.2.1). 3.5.6 Any loosening of rock, e.g. by means of blasting, shall be done such that the remaining rock is not loosened where possible. Any rock in embankments that is loosened nevertheless shall be removed. 3.6 Transport 3.6.1 The transport of soil and rock up to 50 m is part of the scope. 3.6.2 The contractor is free to choose the manner of transport. ..... 3.10 Production of trenches and ditches 3.10.1 The design and safeguarding of trenches and ditches, and the working area widths and inner minimum ditch widths shall be subject to DIN 4124; the following also apply: DIN EN 1610 for wastewater pipes and ducts, ATV DIN 18307, Sections 2 and 3, for pressure pipes. Ditches with multiple-section installations as referred to in ATV DIN 18322 shall have a walkable working area. 3.10.2 If the specifications do not lay down the depths of trenches and ditches, the scope shall include the following: - for ditches for wastewater pipes and ducts: up to a depth of 1.0 m, - for ditches for other pipes and foundations: up to a depth of 1.25 m, - for trenches: up to a depth of 1.75 m. 3.10.3 If the specifications require a protective layer to be constructed to protect the foundation slab, this may be not be removed until immediately before the foundation structure, e.g. concrete sublayer, foundation, or pipeline, is constructed. The removal of such a protective layer shall be considered a special service (see Section 4.2.1). 3.10.4 Near the surface of the foundation for the structure or in ditches, the slab shall not be loosened. Soil that is loosened nevertheless shall be restored to its original degree of compaction—through re-compacting— or otherwise to its original load-bearing capacity, through any other suitable means. The slab as support for pipes without additional bedding shall be constructed true to profile and free from any rocks or blocks. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.11 94 Backfilling and covering structures 3.11.1 Before backfilling or covering, any foreign bodies near the structures that could produce damage shall be removed. 3.11.2 The contractor shall be free to choose the material used for backfilling and covering; the pipe zone near wastewater pipes and ducts is subject to DIN EN 1610; the pipe zone near pressure pipes is subject to Sections 2 and 3 of the ATV DIN 18307; in underground cable construction, the pipe zone shall be filled with compactable soil, applied in layers and compacted manually, to a height of 15 cm above the vertices of any pipe or pipe connection. Aggregate size 0/2 mm shall be used for cables, aggregate sizes 0/8 mm for cable ducts. 3.11.3 Backfilling, covering, and compacting shall be carried out such that the structures are not damaged. Care shall be taken to ensure that any pipes remain in their correct location. 3.11.4 If the specifications do not require a particular depth, Section 3.10.2 applies accordingly. 3.11.5 The compaction equipment used as well as the method and layer thickness shall be adjusted to the characteristics of the backfilling or covering material to achieve an even degree of compaction. Grouting shall not be permitted except with the consent of the client. 3.11.6 In underground cable construction, the pipeline zone shall be filled immediately after laying the cable. For cables and cable ducts, mechanical compaction shall take place only from 30 cm above the pipe upwards. 3.11.7 For pipeline ditches, filling shall not be initiated until all pipe connections and -bearings have been secured against the soil pressure and other forces occurring during filling. 3.11.8 Material that could damage the pipes, such as slag or stony soil, shall not be used between the ditch bed and the ditch walls up to a height of 0.3 m above the vertex of the pipeline. With respect to the suitability of materials in the pipe zone near wastewater pipes and ducts, DIN EN 1610 shall be observed. 3.11.9 In the pipe zone, the soil shall be applied and carefully compacted in layers on both sides of the pipe simultaneously. 3.12 Working during and after frost Frozen soil shall not be applied or compacted in earthworks, backfillings, or coverings of structures. Frozen layers of earthworks, backfillings, and coverings may be covered only if no damage can result. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 95 Excerpt 8 Excerpt from: DIN 18315 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction – superstructure layers without binder, Version 2006 3 Implementation Supplementary to ATV DIN 18299, Section 3, the following applies: 3.1 General provisions 3.1.1.1 Superstructure layers without binder shall not be constructed in adverse weather conditions such as frost unless special measures have been taken to ensure that the quality of the service is not affected. 3.1.1.2 Where the location of any existing pipes, cables, drains, ducts, markings, obstacles, and other building installations cannot be specified prior to construction, they shall be investigated. Such measures shall be considered special services (see Section 4.2.1). 3.2 Sublayer After inspecting the sublayer, the contractor shall raise any doubts he or she may have (see Section 4(3) of the VOB/B), particularly with respect to: Insufficient load-bearing capacity or characteristics of the subsurface, Discrepancies with respect to the specified elevation, inclination, or evenness, Harmful contaminations, Absence of necessary drainage facilities, Adverse weather conditions (see Section 3.1.1) Missing points of reference. The client shall present any available proofs to the contractor upon request. 3.3 Production, requirements 3.3.1 Base courses, frost-protection layers, road-bed protection layers 3.3.1.1 Application The concrete mix or soil shall be distributed evenly in order to prevent demixing. 3.3.1.2 Compaction Each layer or coat shall be evenly compacted to a degree corresponding to the intended use, across the entire surface and with an appropriate water content. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 96 3.3.1.3 Surface The surface of individual layers shall be even and shall have adequate transverse inclination for drainage purposes. If a layer is to be driven on immediately, or is to be left unused over winter, additional measures shall be taken where necessary. Such measures shall be considered special services, unless they have become necessary through a fault of the contractor. (see Section 4.2.1). 3.3.1.4 True-to-profile position Layers shall be produced to the correct height and true to the agreed longitudinal and transverse profile. Any discrepancies with respect to the agreed height of the surface shall not exceed 4 cm in any location. 3.3.1.5 Evenness Any unevenness in the surface of a layer shall not exceed 3 cm over a 4 m section. 3.3.1.6 Thickness The minimum thickness of each layer or coat, in its compacted state and depending on the maximum particle size of the cement mix or soil, shall be as follows: - up to 32 mm 12 cm - up to 45 mm 15 cm - up to 56 mm 18 cm - up to 63 mm 20 cm The thickness of any applied layer shall not exceed 30 cm. 3.3.2 Surface courses 3.3.2.1 Application The concrete mix or soil shall be distributed evenly in order to prevent demixing. 3.3.2.2 Compaction The surface course shall be evenly compacted to a degree corresponding to the intended use, across its entire surface and with an appropriate water content. 3.3.2.3 Surface The surface of the surface course shall be dense and even, and shall have adequate transverse inclination for drainage purposes. For a dense surface, fine-grained components of the cement mix or soil may also be used. 3.3.2.4 True-to-profile position Surface courses shall be produced to the correct height and true to the agreed longitudinal and transverse profile. Any discrepancies with respect to the agreed height of the surface shall not exceed 3 cm in any location. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 97 3.3.2.5 Evenness Any unevenness in the surface of a layer shall not exceed 2 cm over a 4 m section. 3.3.2.6 Thickness The minimum thickness of each layer or coat, in its compacted state and depending on the maximum particle size of the cement mix or soil, shall be as follows: - up to 11 mm 3 cm - up to 16 mm 5 cm - up to 22 mm 7 cm Excerpt 9 Excerpt from: DIN 18316 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction – superstructure layers with hydraulic binders, Version 2006 2 Materials and components Supplementary to ATV DIN 18 299, Section 2, the following applies: The relevant DIN norms for the most frequently used standardised materials are given below. 2.1 Requirements 2.1.1 Aggregates DIN 1045-2 Concrete, reinforced, and prestressed concrete structures. Part 2: Concrete— Specification, properties, production and conformity, Application rules for DIN EN 206-1 DIN 4301 Ferrous and non-ferrous metallurgical slag for construction use. DIN EN 206-1 Concrete ─ Part 1: Specification, properties, production, and conformity; DIN EN 12620 Aggregates for concrete; DIN V 20000-103 12620:2003-04 Application of building products in structures, Part 103: Aggregates according to DIN EN DIN EN 13055-1 Lightweight aggregates ─ Part 1: Lightweight aggregates for concrete, mortar, and grout; DIN V 20000-104 Application of building products in structures, Part 104: Lightweight aggregates according to DIN EN 13055-1:2002-08 DIN EN 13242 construction; Aggregates for unbound and hydraulically bound mixtures for engineering and road DAfStb Guideline Technical contract conditions for aggregates in road construction (TL Gestein 2.1.2 Binder Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 98 DIN 1164-10 common cement Special cement ─ Composition, requirements and conformity evaluation for special DIN 18506 Hydraulic road binders ─ Part 10: Composition, specifications, and conformity criteria. DIN EN 197-1 Cement: Composition, specifications and conformity criteria for common cements; DIN EN 197-4 Cement – Part 4: Composition, specifications, and conformity criteria for low early strength blast-furnace cements; German version of EN 197-4:2004 Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 2.1.3 99 Admixtures DIN EN 934-2 Admixtures for concrete, mortar and grout - Part 2: Concrete admixtures - Definitions, requirements, conformity, marking, and labelling DIN V 20000-100 Application of building products in structures - Part 100: Concrete admixtures according to DIN EN 934-2:2002-02 2.1.4 Additives Concrete additives shall meet the requirements of DIN EN 206-1 and DIN 1045-2. 2.1.5 Mixing water DIN EN 1008 Mixing water for concrete ─ Specification for sampling, testing, and assessing the suitability of water, including water recovered from processes in the concrete industry, as mixing water for concrete; Balance water shall not be used for air-entrained concrete. 2.1.6 Material mixtures, concrete DIN EN 14227-1 Hydraulically bound mixtures - Specifications Part 1: Cement-bound granular mixtures; German version EN 14227-1:2004 Hydraulically mixed and bound mixtures Part 5: Hydraulic road-binder bound mixtures; DIN EN 14227-5 The composition of material mixtures and of the concrete shall be the responsibility of the contractor. In doing so, he or she shall observe the requirements with respect to intended use, traffic volumes and types, weather factors, and local conditions. 2.1.6.1 Hardenings as base courses Hardenings shall be produced from construction materials by mixing in hydraulic binders. Tar-containing roadbuilding materials may be used if the hardenings so produced meet the relevant technical and environmental requirements. 2.1.6.2 Hydraulically bound base courses Hydraulically bound base courses are base courses made of hydraulically bound mixtures according to DIN EN 14227-1 and DIN EN 14227-5. Hydraulically bound base courses shall produced from graded mixtures of aggregates (TL Gestein-StB, Annex G) and hydraulic binders. 2.1.6.3 Concrete base courses Concrete base courses are base courses made of concrete as defined in DIN EN 206-1 and DIN 1045-2. Concrete base courses shall be produced from graded mixtures of aggregates (TL Gestein-StB, Annex G) and cement. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 100 Only coarse recycled aggregates from suitable driving-surface concrete may be used for the concrete base course. 2.1.6.4 Concrete pavements Concrete shall be produced in accordance with DIN EN 206-1 and DIN 1045-2. Only coarse recycled aggregates from suitable driving-surface concrete may be used for the lower layer of a concrete pavement. 2.1.7 Steel DIN 488-1 Reinforcing steel ─ Grades, properties, markings DIN EN 10025-1 Part 1: General; Hot-rolled products of non-alloy structural steels - General technical delivery conditions – DIN EN 10060 Hot rolled round steel bars - Dimensions and tolerances on shape and dimensions; 2.1.8 Joint fillers and joint deposits 2.1.8.1 Joint fillers Materials used to seal a joint shall have adequate deformation resistance and adhesion. Where sealing profiles are used, the contact pressure shall prevent moisture penetration even at low temperatures. 2.1.8.2 Joint deposits Permanent joint deposits in expansion joints shall allow the concrete slabs to expand and shall be sufficiently rigid to resist deformation under compaction of the concrete. They shall be water- and alkaliresistant and shall not absorb the water from the freshly-made concrete. Permanent deposits for contraction joints shall not be compressible in the lower part of the pavement. 3 Implementation Supplementary to ATV DIN 18299, Section 3, the following applies: 3.1 General provisions Superstructure layers with hydraulic binders shall not be constructed in adverse weather conditions such as frost unless special measures have been taken to ensure that the quality of the service is not affected. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.2 101 Sublayer After inspecting the sublayer, the contractor shall raise any doubts he or she may have (see Section 4(3) of the VOB/B), particularly with respect to: - Insufficient load-bearing capacity or characteristics of the subsurface, - Harmful cracking, - Discrepancies with respect to the specified elevation, inclination, or evenness, - Harmful contaminations, - Absence of necessary drainage facilities, - Adverse weather conditions (see Section 3.1), - Missing points of reference 3.3 Production, requirements 3.3.1 Hardenings as base courses 3.3.1.1 Processing and curing The construction materials shall be mixed with the binder so as to create an even distribution of the binder. The concrete mix shall be distributed true to profile and compacted evenly. The dry density of the compacted hardening shall not exceed 98 % of the Proctor density. Hardenings shall be kept moist for at least 3 days after production or protected from drying out through other suitable measures. 3.3.1.2 Binder quantity The binder quantity shall be chosen such that the compressive strength after 28 days as found in the suitability test is not less than 5 N/mm². The 28-day strength may be calculated from the 7-day strength proportionately to the ratio of the standard compressive strengths of the hydraulic binder after 28 and 7 days respectively 3.3.1.3 Grooves Hardening under asphalt layers: Hardenings shall be produced with grooves - at intervals not exceeding 5m if the compressive strength as found in the suitability test exceeds 7 N/mm², or any thickness of application exceeds 20 cm, - at intervals not exceeding 2.5 m for layers of asphalt with a total thickness of 14 cm or less. Hardening under concrete pavements: Under concrete pavements, the locations of the grooves shall correspond to the locations of the joints in the concrete pavement. Where a nonwoven textile is placed under the concrete, grooves are not required. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 102 3.3.1.4 Thickness Hardenings shall have a thickness of not less than 10 cm in any location. 3.3.1.5 True-to-profile position Base courses shall be produced to the correct height and true to the agreed longitudinal and transverse profile. Any discrepancies with respect to the agreed height of the surface shall not exceed 3 cm in any location. 3.3.1.6 Evenness Any unevenness in the surface of a hardening shall not exceed 3 cm over a 4 m section. 3.3.2 Hydraulically bound base courses 3.3.2.1 Processing and curing The aggregate mixture shall be thoroughly mixed with the binder and water. The concrete mix shall be spread on a clean sublayer, evenly and without demixing, applied true to profile and compacted evenly. Hydraulically bound base courses shall be kept moist for at least 3 days after production or protected from drying out through other suitable measures. 3.3.2.2 Binder quantity The binder quantity shall be chosen such that the compressive strength after 28 days as found in the suitability test is not less than 5 N/mm². The 28-day strength may be calculated from the 7-day strength proportionately to the ratio of the standard compressive strengths of the hydraulic binder after 28 and 7 days respectively. 3.3.2.3 Grooves Hydraulically bound base course under asphalt layers: Hardenings shall be produced with grooves - at intervals not exceeding 5 m if the compressive strength as found in the suitability test exceeds 7 N/mm², or any thickness of application exceeds 20 cm, - at intervals not exceeding 2.5 m for layers of asphalt with a total thickness of 14 cm or less. Hydraulically bound base courses under concrete pavements: Under concrete pavements, the locations of the grooves shall correspond to the locations of the joints in the concrete pavement. Where a nonwoven textile is placed under the concrete, grooves are not required. 3.3.2.4 Thickness Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 103 Hydraulically bound base courses shall have a thickness of not less than 9 cm in any location. 3.3.2.5 True-to-profile position With respect to true-to-profile position, Section 3.3.1.5 applies. 3.3.2.6 Evenness Any unevenness in the surface of a hardening shall not exceed 2 cm over a 4 m section. 3.3.3 Concrete base course 3.3.3.1 Processing and curing The concrete shall be applied true to profile and compacted evenly. Curing shall be in accordance with DIN 1045-3. 3.3.3.2 Concrete compressive strength classes The compressive strength class of the concrete shall be at least C12/15 according to DIN EN 206-1 and DIN 1045-2. 3.3.3.3 Grooves Concrete base courses shall be produced with grooves. Under concrete pavements, the locations of the grooves shall correspond to the locations of the joints in the concrete pavement. Where a nonwoven textile is placed under the concrete, grooves are not required. 3.3.3.4 Thickness Concrete base courses shall have a thickness of not less than 6 cm in any location. 3.3.3.5 True-to-profile position With respect to true-to-profile position, Section 3.3.1.5 applies. 3.3.3.6 Evenness With respect to evenness, Section 3.3.2.6 applies. 3.3.4 Concrete pavements Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 104 3.3.4.1 Requirements for the concrete The concrete shall fulfil the requirements of exposure class XF 3 in case of high saturation with water without defrosting agent, or exposure class XF 4 for high saturation with water with defrosting agent—according to DIN EN 206-1 and DIN 1045-2. 3.3.4.2 Transport and application of the concrete Fresh concrete shall not come into contact with aluminium surfaces during transport. The concrete shall be applied either across the entire pavement width or in strips determined by the position of the longitudinal joints. Work interruptions shall be permitted only in transverse joints. The concrete pavement shall have vertical sides. The layers of the concrete pavement may have different compositions, if the agreed requirements for concrete are fulfilled. Batches of concrete of the same composition may be applied in a single coat or in multiple coats. The thickness of a coat shall be at least triple the diameter of the largest particle size. In multi-layer concrete pavements, the upper layer shall have a thickness of at least 4 cm. 3.3.4.3 Reinforcement Where surface reinforcement has been agreed, it shall be applied with at least 2 kg/m² of reinforcing steel BSt 500M (IV M). The reinforcement must not affect the operation of the joints. The concrete cover shall be at least 4 cm thick. 3.3.4.4 Joints Concrete pavements shall be made with joints. Joints shall be given a joint gap in the upper part, with a width and depth tailored to the intended joint sealant. The production of joints shall not affect the strength of the concrete or the surface characteristics of the concrete pavement. Joints shall be made timely enough to prevent cracks from forming. 3.3.4.4.1 Contraction joints Contraction joints shall be made in the hardened concrete by cutting into a joint gap to a depth of at least 25 % of the pavement thickness. If it has been agreed that the lower part of the concrete pavement shall contain deposits to reduce the concrete cross-section, these shall be secured against displacement. 3.3.4.4.2 Expansion joints Expansion joints shall be produced such that they separate the concrete slabs from each other across the entire thickness. The joint deposits shall enable the slabs to expand and shall be secured against displacement. The expansion joints shall be produced to a width of at least 12 mm. 3.3.4.4.3 Press joints Press joints shall be made without anti-caking agent. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 105 3.3.4.4.4 Sealing of joints The joint gap shall be sealed using suitable joint fillers. Before any bituminous joint fillers are applied, the joint gap must be dry and clean. 3.3.4.5 Pins Where it has been agreed that pins shall be used to transfer lateral forces and to secure the elevation of the slabs, the pins used shall be corrosion-protected and made of smooth round-bar steel with a diameter of 25 mm and a length of 500 mm. They shall be placed at mid-level in the slab such that they do not impede the expansion of the slabs. 3.3.4.6 Anchors Where it has been agreed that anchors shall be used to prevent concrete slabs from separating, the anchors used shall be made of smooth round-bar steel with a diameter of at least 16 mm and a length of at least 600 mm. They shall be corrosion-protected around the joints. Anchors shall be placed at mid-level within the slab. 3.3.4.7 Curing Fresh concrete shall be protected from weather factors and from drying, such that it eventually reaches its required characteristics. 3.3.4.8 Thickness Concrete pavements shall have a thickness of not less than 10 cm in any location. 3.3.4.9 True-to-profile position With respect to the true-to-profile position of concrete pavements, Section 3.3.1.5 applies. 3.3.4.10 Evenness Any unevenness in the surface of a concrete pavement shall not exceed 1 cm over a 4 m section. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 106 Excerpt 10 Excerpt from: DIN 18317 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction – superstructure layers made of asphalt, Version 2006 ..... 3 Implementation Supplementary to ATV DIN 18 299, Section 3, the following applies: 3.1 General provisions Superstructure layers made of asphalt and surface coats shall not be constructed in adverse weather conditions such as wet weather or low air temperature, unless special measures have been taken to ensure that the quality of the service is not affected. 3.2 Sublayer After inspecting the sublayer, the contractor shall raise any doubts he or she may have (see Section 4(3) of the VOB/B), particularly with respect to: ─ Insufficient load-bearing capacity or characteristics of the subsurface, ─ Discrepancies with respect to the specified elevation, inclination or evenness, ─ Harmful contaminations, ─ Absence of necessary drainage facilities, ─ Adverse weather conditions (see Section 3.1.2) ─ Missing points of reference 3.3 Production, requirements 3.3.1 Asphalt base courses, supporting asphalt surface courses, asphalt binder courses, surface courses made of asphalt concrete, and stone mastic asphalt 3.3.1.1 Application The asphalt shall be distributed evenly on a clean subsurface so as to prevent demixing. The seams of layers and coats shall be offset by at least 15 cm. The seams of a surface course made of asphalt shall be linear, longitudinal seams aligned to the lines of the roads. Suitable measures shall be taken to ensure even, tight connections. There shall be adequate cohesion between the various layers and/or coats. The next layer or coats shall not be applied until the layer below it has gained sufficient stability and loadbearing capacity. 3.3.1.2 Compaction Layers or coats shall be compacted adequately and evenly across the entire surface. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.3.1.3 107 Surface The surface of individual coats shall have even characteristics. The surfaces of the supporting asphalt surface course and the asphalt surface courses shall have an even density and a roughness appropriate for the intended use. 3.3.1.4 True-to-profile position Layers shall be produced to the correct height and true to the agreed longitudinal and transverse profile. Any discrepancies with respect to the agreed height of the surface shall not exceed 3 cm in any location. 3.3.1.5 Evenness Any unevenness in the surface of a layer, as measured with respect to a 4 m section, shall not exceed 2 cm for asphalt base courses, 1.5 cm for supporting asphalt surface courses, and 1 cm for asphalt binder courses and asphalt surface courses. 3.3.1.6 Thickness The following layer thicknesses shall be observed: ─ Asphalt base courses: 6 cm on average, but nowhere less than 4 cm, ─ Supporting asphalt surface courses: 7 cm on average, but nowhere less than 5 cm, ─ Asphalt binder courses: 4 cm on average, but nowhere less than 3 cm, ─ Surface courses made of asphalt: 2.5 cm on average, not less than 1.5 cm anywhere, and at least 2.5 times the largest particle diameter. 3.3.2 Surface courses made of mastic asphalt 3.3.2.1 Application Section 3.3.1.1 applies accordingly. Connections to cold mastic asphalt shall be constructed as joints. 3.3.2.2 Surface The surface of a surface course made of mastic asphalt shall have even characteristics. It shall be roughened or dulled during application. 3.3.2.3 Evenness Any unevenness in the surface of a surface course made of mastic asphalt shall not exceed 1 cm over a 4 m section. 3.3.2.4 Thickness Surface courses made of mastic asphalt shall be produced in a thickness of 2.5 cm on average, but nowhere less than 1.5 cm. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 3.3.3 108 Surface coats Surface coats shall be produced such that they cover the (clean) sublayer completely, and have even characteristics. Sett joints shall be filled up with coarse aggregates up to the top level of the bricks before applying the surface coat. Immediately after spraying the binder, sprinkling material as referred to in Annex F of the TL Gestein-StB shall be sprinkled on evenly and compressed with rollers. 3.3.4 Thin coats in cold applications The aggregate for thin coats in cold applications shall be produced mechanically, and applied in one or several coats or layers. Sections 3.3.1.1 and 3.3.1.3 shall apply accordingly to thin coats in cold applications. 3.3.5 Thin coats in hot applications and asphalt mastic coats Sections 3.3.1.1, 3.3.1.2, and 3.3.1.3 apply accordingly to thin coats made of asphalt concrete and stone mastic asphalt, and Sections 3.3.2.1 and 3.3.2.2 to thin coats made of mastic asphalt and asphalt mastic coats. Thin coats in hot applications shall be produce with 30 kg/m² on average; asphalt mastic coats with 15 kg/m² of mastic and 15 kg/m² of coarse aggregates. 3.3.6 Surface heating of asphalt coats The existing coats as well as any additionally required aggregates, binder, or asphalt shall be suitable for their intended use. The existing coats shall be heated carefully without affecting their properties. Sections 3.3.1.1 to 3.3.1.5 apply accordingly to surface heating. Excerpt 11 Excerpt from: DIN 18318 VOB, Part C: General technical contract conditions for construction works (ATV) - Road construction - Unbound sett pavings and slab pavings, and borders, Version 2006 ..... 2 Materials and components Supplementary to ATV DIN 18299, Section 2, the following applies: The relevant DIN norms, as well as the applicable regulations for further requirements, are given below for the most frequently used standardised materials and components. DIN 18158 Clinker tiles DIN 18500 Cast stones - Terminology, requirements, testing, inspection DIN EN 13198 Precast concrete products - Street furniture and garden products DIN EN 1433 requirements, Drainage channels for vehicular and pedestrian areas. classification, design, and testing marking and evaluation of conformity DIN V 19580 area Drainage channels for vehicular and pedestrian areas. Weathering resistance, mass per unit and third party control DIN 1045-2 Concrete, reinforced, and prestressed concrete structures. Part 2: Concrete; Specification, properties, production, and conformity, Application rules for DIN EN 206-1 DIN EN 206-1 Concrete ─ Part 1: Specification, properties, production and conformity Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 109 General technical delivery conditions for construction products for the production of sett pavings, slab pavings, and borders (TL Pflaster-StB)*). General technical delivery conditions for joint fillers in traffic surfaces (TL Fug-StB)*). ..... 3.3 True-to-profile position, tolerances 3.3.1 Sett and slab pavings shall be produced to the correct height and true to the agreed longitudinal and transverse profile. Any discrepancies with respect to the agreed height of the surface shall not exceed 2 cm in any location. Borders with kerbstones or other stones shall be produced to the specified height and flush. Any discrepancies with respect to the specified height of the surface and the specified distance from the reference axis shall not exceed 2 cm anywhere; any greater differences shall be permitted only if they are needed to avoid excessive cutting and have been agreed with the client before commencing the construction works. The permissible tolerance in the flushness of standing surfaces and front surfaces shall be 2 mm for heading joints of kerbstones and other stones with a flat surface, and 5 mm for kerbstones and other stones with a rough surface. 3.3.2 Any unevenness in the surface, as measured over a 4 m section, shall not exceed 2 cm for surfaces made of natural stone with a split surface, or 1 cm for all other surfaces. 3.3.3 Sett and slab pavings shall be constructed level at the joints. The permissible tolerance for level connections is 2 mm for construction materials with an even surface and 5 mm for construction materials with a rough surface. Connections adjacent to borders and embedded elements shall be constructed 3 mm to 5 mm above the formerʾs surface, connections adjacent to water-carrying gutters 3 mm to 10 mm above the gutter level. 3.3.4 The resultant drainage-relevant inclination of a sett paving or slab paving shall not be less than the respective value given below: - for natural stone with a split or roughly treated surface - on driving lanes: 3.5 %, - other surfaces: 3.0 %, - in all other cases: 2.5 %. Any implementation-related discrepancies with respect to the specified inclination shall not exceed 0.4 %. Drainage gutters shall be constructed to a lengthwise inclination of at least 0.5 %. 3.4 Pavements made of concrete block paving 3.4.1 Bedding The thickness of the bedding shall be 3 cm to 5 cm in its compacted state, or alternatively 4 cm to 6 cm for stones with a nominal thickness of 120 mm and up. The bedding materials used shall be aggregates sizes 0/4 mm, 0/5 mm, or 0/8 mm, or mixtures of aggregates 0/11 mm for stones with a nominal thickness of 120 mm Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 110 and up and a bedding thickness greater than 4 cm. 3.4.2 Laying and embedding Setts shall be laid or embedded on the bedding in an even pattern, in rows with offset joints and joint widths of 3 mm to 5 mm, or joint widths of 5 mm to 8 mm for stones with a nominal thickness of 120 mm and up. The joint axes shall form a smooth trajectory. 3.4.3 Jointing and compacting Joints shall be filled continuously as the laying proceeds. To that end, the joint material shall be applied to the sett paving, brushed into the joints and grouted; any excess joint material shall be removed completely. Subsequently, the surface shall be vibrated or tamped to achieve its intended stability. After this, the joints shall be filled up if needed. For setts with special surfaces (e.g. coloured paving), the surface shall be protected during vibrating or tamping, e.g. with a plastic apron underneath the vibratory plate. 3.5 Pavements made of clinker bricks or pavement tiles 3.5.1 Bedding The thickness of the bedding in its compacted state shall be 3 cm to 5 cm. As bedding materials, mixtures of aggregate sizes 0/4 mm, 0/5 mm, or 0/8 mm shall be used. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 111 3.5.2 Laying and embedding Clinker bricks or pavement tiles shall be laid or embedded on the bedding in an even pattern, in rows with offset joints and joint widths of 3 mm to 5 mm. The joint axes shall form a smooth trajectory. 3.5.3 Jointing and compacting Joints shall be filled continuously as the laying proceeds. To that end, the joint material shall be applied to the sett paving, brushed into the joints, and grouted; any excess joint material shall be removed completely. Subsequently, the surface shall be vibrated or tamped to achieve its intended stability. After this, the joints shall be filled up if needed. The surface shall be protected during vibrating or tamping, e.g. with a plastic apron underneath the vibratory plate. 3.6 Pavements made of natural stone paving 3.6.1 Bedding The thickness of the bedding in its compacted state shall be 3 cm to 5 cm. For stones with a nominal thickness of 120 mm and up, it shall be 4 cm to 6 cm. The bedding materials used shall be aggregates sizes 0/4 mm, 0/5 mm, or 0/8 mm, or mixtures of aggregates 0/11 mm for stones with a nominal thickness of 120 mm and up and a bedding thickness greater than 4 cm. 3.6.2 Embedding and laying The stones shall be embedded firmly or laid on the bedding with the narrowest possible, offset joints. Depending on the nominal thickness of the stones, the following joint widths shall be observed, measured along the upper edge of the stones: - nominal thickness of 60 mm or less max. 6 mm, - nominal thickness from 60 mm up but less than 120 mm max. 10 mm, - nominal thickness of 120 mm and up max. 15 mm, - for treated stones min. 10 mm. Split stones with a nominal thickness of 120 mm and up, as well as treated stones, shall be laid or embedded in rows. Split stones with a nominal thickness of less than 120 mm shall be well as treated stones, shall be laid or embedded in mitre bends. Press joints shall not be permitted; cross-joints shall be avoided. Joints shall form a smooth trajectory. Where the stones are laid or embedded in rows, the joint axes shall form a smooth trajectory. The width of the stones used in each individual row or bend shall have the same width where possible. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 112 3.6.3 Jointing and compacting Joints shall be closed filled continuously as the laying or embedding proceeds. To that end, the joint material shall be applied to the sett paving, brushed into the joints, and grouted; any excess joint material shall be removed completely. Subsequently, the surface shall be vibrated or tamped to achieve its intended stability. After this, the joints shall be filled up if needed. 3.7 Slab pavings 3.7.1 Bedding The thickness of the bedding in its compacted state shall be 3 cm to 5 cm. The bedding materials used shall be aggregates sizes 0/4 mm, 0/5 mm, or 0/8 mm, or mixtures of aggregates 0/11 mm for slabs with a nominal thickness of 120 mm and up and a bedding thickness greater than 4 cm. 3.7.2 Laying and embedding Slabs shall be laid on or embedded in the bedding in an even pattern, parallel to the border or another specified axis, in rows with offset joints. Slabs with a nominal thickness of less than 120 mm shall be constructed with joint widths from 3 mm to 5 mm; slabs with a nominal thickness of 120 mm and up with joint widths from 5 mm to 10 mm. The joint axes shall form a smooth trajectory. 3.7.3 Jointing and compacting Joints shall be filled continuously as the laying proceeds. To that end, the joint material shall be applied to the paving, brushed into the joints, or grouted; any excess joint material shall be removed. Subsequently, the surface shall be vibrated or tamped to achieve its intended stability. After this, the joints shall be filled up if needed. The surface shall be protected during vibrating or tamping, e.g. with a plastic apron underneath the vibratory plate. 3.8 Borders Edge and border stones, and borders made of setts, shall be placed on a 20 cm thick foundation with edge restraints made of concrete of Composition Class C12/15. The foundation and edge restraints shall be compacted. The compressive strength after 28 days of the finished structural element, in accordance with DIN 1048-2, shall be at least 8.0 N/mm² (average) or 6.4 N/mm² (any individual value from at least 3 samples). Kerbstones and edge restraints shall be placed on the foundation concrete while still workable. The edge restraints shall be produced to a thickness of 15 cm in formwork. The upper edge of the edge restraints shall be aligned with the thickness of the adjacent surface pavement. The surface of the edge restraints shall be bevelled slightly towards the outside. The width of the foundation depends on the edging or kerbstone used, as well as the edge restraints and the width of the gutter stone used, as appropriate. Where gutter stones are used, the expansion joints of the drainage gutter shall be constructed to be contiguous in both the foundation and the edge restraints. Edging and border stones shall be embedded with joint of about 5 mm wide, that shall not be joined. Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. 113 Borders in bends with a radius up to 12 m shall be produced using curve stones. For bends with a radius over 12 m, straight stones with a length of 500 mm may be used; for radii from 20 m and up, straight stones with a length of 1 000 mm. 3.9 Drainage gutters Gulley stones, gutter stones, and gutters made of setts shall be placed on a 20 cm thick foundation made of concrete of Composition Class C12/15 and provided with expansion joints. The foundation shall be compacted. The compressive strength after 28 days of the finished structural element, in accordance with DIN 1048-2, shall be at least 8.0 N/mm² (average) or 6.4 N/mm² (any individual value from at least 3 samples). Gulley stones, gutter stones, and setts shall be embedded or laid on the foundation concrete while still workable, with joints of at least 8 mm and no more than 12 mm in width, which shall be jointed using bound joint sealant. Expansion joints shall be produced at intervals not exceeding 12 m, to a width of at least 8 mm and at most 15 mm. They shall be poured with pavement grouting. Where drainage gutters are simultaneously used as borders, they shall be given edge restraints in accordance with Section 3.8. Drainage gutters shall be laid or embedded on a concrete foundation, flush and to the correct height, in accordance with Section 3.3.3 before application of the adjacent surface pavement. ..... Error! Use the Home tab to apply Überschrift 2 to the text that you want to appear here. All circulars in force may be downloaded from www.fgsv-verlag.de Source: FGSV Verlag GmbH Address: Wesselinger Str. 17, 50999 Köln Tel: 02236/384630, Fax: 02236/384640 E-mail: info@fgsv-verlag.de, FGSV 976 Internet: Production and sale: FGSV Verlag GmbH 50973 Köln · Postfach 50 13 62 Telephone: 0221/93 55 73-0 · Fax: 0221/39 37 47 2009 www.fgsv-verlag.de 114 Error! 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