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BFC HIGHWAY ENGINEERING Lecturer: Mustafa Kamal bin Shamshuddin

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Presentation on theme: "BFC HIGHWAY ENGINEERING Lecturer: Mustafa Kamal bin Shamshuddin"— Presentation transcript:

1 BFC 31802 HIGHWAY ENGINEERING Lecturer: Mustafa Kamal bin Shamshuddin
MATERIALS

2 Materials which involved in highway industry: Soil Sand
BFC HIGHWAY ENGINEERING Lecturer: Mustafa Kamal bin Shamshuddin Materials which involved in highway industry: Soil Sand Crushed rock aggregates Lime Portland Cement Bituminous materials

3 SOIL 2.1 Properties and testing of soils, aggregates, lime,
BFC HIGHWAY ENGINEERING Lecturer: Mustafa Kamal bin Shamshuddin 2.1 Properties and testing of soils, aggregates, lime, Portland cement and Bituminous Materials SOIL Sub-grade is the part of embankment or natural soil under the sub-base or lower sub-base of road and road shoulder. First part of the road constructed The surface of sub-grade - formation level.

4 Sustain load from the top surfaces
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Formation level - soil surface after the earthwork, consolidation, compaction and stabilization works Sustain load from the top surfaces Selection of suitable soils is important

5 The strength of the sub-grade should remain along the design period.
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin PROPERTIES: Good sub-grade Should be stable under the varieties of vehicle load and climatic condition. The strength of the sub-grade should remain along the design period. The ability to drain water. The Loss on Ignition Test is designed to measure the amount of moisture or impurities lost when the sample is ignited.

6 Not good (Unsuitable materials-USM)
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin PROPERTIES: Not good (Unsuitable materials-USM) Soils which consists of organic clays or silts. The value of Liquid Limits (LL) > 80 % or Plasticity Index (PI) > 55 % The value of Loss on Ignition (LOI) > 2.5 % Soils consist of roots, grass or other plants, toxic, peat or mud. The Loss on Ignition Test is designed to measure the amount of moisture or impurities lost when the sample is ignited.

7 The tests which are usually conducted to the soils for sub
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin TESTING The tests which are usually conducted to the soils for sub grade and road embankment are listed as follows: Loss On Ignition (LOI) – BS 1377: Part 3: 1990 Liquid Limit (LL) and Plastic Limit (PL) – BS 1377: Part 2: 1990 Compaction – BS 1377: Test 13: 1975 (Part 4: 1990) California Bearing Ratio (CBR) – BS 1377: Test 16: 1975 (Part 4: 1990) Field density test – sand replacement method – BS 1377

8 SAND 1. Used for the sub-base layer. 2. Features: Must drain readily.
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin SAND 1. Used for the sub-base layer. 2. Features: Must drain readily. Sustain smaller load pressure. 3. The functions: To sustain road base layer and distribute load from the vehicle. Act as a drainage layer (if the materials used capable to drain the water)

9 Can be used as a temporary road during the construction
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Can be used as a temporary road during the construction To protect the sub-grade from the failure due to the climatic effect. As a barrier layer to avoid the mixing of sub-grade and road base materials.

10 Have small proportion of plastic or non plastic fines
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin PROPERTIES: Have small proportion of plastic or non plastic fines Free from vegetative and other organic matter Free from expansive clay minerals and lumps of clay The liquid limit shall be not more than 25%. The plasticity index shall be not more than 6%. The aggregate crushing value shall be not more than 35%. CBR value of 30 or more when compacted to 95% of the maximum dry density The gradation shall conform to one of the envelopes shown in Table 1

11 Aggregate Crushing Value California Bearing Ratio
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin TESTING Atterberg Limits Aggregate Crushing Value California Bearing Ratio Gradation (Sieve test)

12 B.S.Sieve Size (mm) % Passing By Weight A B C D E F
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Table 1: Gradation Limits for Sub-base Material from Specification of Roadworks (Jabatan Kerja Raya, 1988) B.S.Sieve Size (mm) % Passing By Weight A B C D E F 50.0 25.0 9.5 4.75 2.0 425 μm 75 μm 100 - 25 – 55 15 – 40 8 – 20 2 – 8 79 – 95 40 – 75 30 – 60 20 – 45 15 – 30 5 – 20 50 – 85 35 – 65 25 – 50 60 – 100 40 – 70 25 – 45 55 – 100 40 – 100 20 – 50 6 – 20 70 – 100 30 – 70 8 – 25

13 AGGREGATE Aggregates must be hard, durable, clean and essentially free
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin AGGREGATE Aggregates must be hard, durable, clean and essentially free from clay and other deleterious materials. PROPERTIES: The plasticity index shall be not more than 6. The aggregate crushing value shall be not more than 30. The flakiness index shall be not more than 30. Not less than 80% of particles retained on the B.S 4.75mm sieve shall have at least one fractured face. The plastic limit (PL) is the water content where soil starts to exhibit plastic behavior. The liquid limit (LL) is the water content where a soil changes from plastic to liquid behavior. The plasticity index (PI) is a measure of the plasticity of a soil. The plasticity index is the size of the range of water contents where the soil exhibits plastic properties. The PI is difference between the liquid limit and the plastic limit (PI = LL-PL). Soils with a high PI tend to be clay, those with a lower PI tend to be silt, and those with a PI of 0 tend to have little or no silt or clay.

14 BFC 31802 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin The weighted average loss of weight in the sodium sulphate soundness test (5 cycles) shall be not more than 12%. The material shall have a CBR value of not less than 80 when compacted to 95% of the maximum dry density. The gradation shall comply with the envelope shown in Table 2 for type specified.

15 Aggregate Impact Value (AIV) Flakiness Index (FI) Soundness
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin TESTING Aggregate Impact Value (AIV) Flakiness Index (FI) Soundness California Bearing Ratio (CBR) Sieve

16 B.S Sieve % Passing by Weight Type I Type II
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Table 2: Gradation limit for crushed aggregate road base from Spesification of Roadworks (Jabatan Kerja Raya, 1988) B.S Sieve % Passing by Weight Type I Type II 50.0 mm 37.5 mm 28.0 mm 20.0 mm 10.0 mm 5.00 mm 2.36 mm 2.00 mm 600 µm 425 µm 75 µm 100 95 – 100 - 60 – 80 40 – 60 25 – 40 15 – 30 8 – 22 0 – 8 85 – 100 70 – 100 60 – 90 40 – 65 30 – 55 20 – 40 10 – 25 2 – 10

17 LIME AND PORTLAND CEMENT
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin LIME AND PORTLAND CEMENT Mix with crushed rock aggregate for road base construction Combined with aggregate for asphalt to serve an adhesion and anti stripping agent Add for 2% by weight of combined aggregate (Jabatan Kerja Raya, 1988)

18 Properties shall conform to the requirements of MS 522
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin TESTING Properties shall conform to the requirements of MS 522 Shall be dry, free flowing and free from agglomerations at the time of use For anti stripping purposes, stripping test need to be conducted according to AASHTO T Coated area with bitumen at the end of the mixture’s period of immersion in water shall be not less than 95%. The result will indicated that the effectiveness of the lime or Portland cement used as anti stripping agent.

19 Asphalt (Asphalt cement)
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin BITUMINOUS MATERIALS Term of bitumen and tar Term USA United Kingdom Bitumen Asphalt (Asphalt cement) Bitumen + aggregate Asphaltic concrete Asphalt p/s – Tar previously used as a binder to produce mixture. Sources from coal mine.

20 Withstanding high tyre pressure
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Bituminous surface layer which the combination of aggregates and binder. The surface layer consists of two layers which known as the binder course and the wearing course. Capable of: Withstanding high tyre pressure Resisting the abrasive force due to traffic Providing a skid-resistance driving surface Preventing the penetration of surface water

21 surface to construct the wearing course.
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Binder Course This layer is used to distribute load to the road base and provide the flat surface to construct the wearing course. The maximum size of aggregate used is 28 mm and mixed with percentage of bitumen ranging from 4 – 6 %. Wearing Course Top layer with the main function to the safety of the road users. The other functions of wearing course are listed as follows: Provide skid resistance Protect the road surface Provide a safe and comfortable riding surface Sustain abrasion from traffic As a drainage system by providing a waterproof layer, and drain surface run-off to the side drain. The maximum size of aggregate is 20 mm and mixed with bitumen with the percentage ranging from 4.5 – 7 %.

22 Bitumen – binder material which binds the aggregates to produce a
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin The materials used to construct this mixture are aggregates, bitumen and filler. 1. Aggregates – provide interlocking structure, sustain load and distribute to the layer beneath. Bitumen – binder material which binds the aggregates to produce a strong and stable mixture. Filler – to fill the voids in the mixture and improve the elasticity of the bitumen to produce a durable mixture and to reduce bleeding in bituminous mixture.

23 Percentage Content (%)
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin BITUMEN In Malaysia, the term of bitumen refers to the binder material, which produces from refinery of crude oil. The mixture of bitumen and aggregate is called asphaltic concrete. The chemical compositions of bitumen (Table 3) Table 3: Chemical composition of bitumen Minerals Percentage Content (%) Carbon 80 – 85 Hydrogen 10 Sulfur 1 – 5 Nitrogen 1 Oxygen < 1

24 Bitumen can be obtained from two main sources which are:
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Bitumen can be obtained from two main sources which are: Natural sources – located in geological stratum and can be obtained in the hard and soft form. Petroleum bitumen – bitumen in colloidal obtained from refinery process of crude oil and has been widely used in the road construction. Bitumen can be classified into four types as listed as follows: 1. Penetration bitumen 2. Cutback bitumen 3. Emulsified bitumen 4. Blown bitumen

25 Solvent will be evaporated
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin 1. Penetration Bitumen The grade is classified according to the penetration test ranging from 40 – 300 while based on the viscosity test ranging from 5 – 40. 2. Cutback Bitumen Produced based on the bitumen with the percentage ranging from 50 – 80 % mixed with the petroleum-based solvents. Solvent will be evaporated According to the rate of evaporation, this kind of bitumen can be classified into three groups: Rapid Curing (RC) Medium Curing (MC) Slow Curing (SC)

26 Produced by mixing the bitumen with petrol.
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Rapid Curing (RC) Produced by mixing the bitumen with petrol. Used for the tack coat and surface treatment. Medium Curing (MC) Produced by mixing the bitumen with kerosene. Used for the prime coat and cold mix for the patching work. Slow Curing Produced by mixing the bitumen with the diesel. Used especially for the prime coat, cold mix for patching work and dust control.

27 types of are as follows: 1. Anionic
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin 3. Emulsified Bitumen Produced by mixing the bitumen (55 – 65 %) with water and emulsifier in the colloidal rotor. This situation will reduce the viscosity of bitumen and allow them to be used at the low temperature. The type of bitumen depends to the emulsifying agent that is used. The two types of are as follows: 1. Anionic Contains the negative bitumen globule. Produced with positive emulsifying agent is used - alkali. Suitable to be used with the aggregates which have positive charge like limestone.

28 Contains the positive bitumen globule.
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Cationic Contains the positive bitumen globule. Produced when negative emulsifying agent is used – acid. It is suitable to be used with the aggregates which have negative charge like sand, quartz and silica.

29 Emulsified bitumen can be classified into three groups:
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Emulsified bitumen can be classified into three groups: 1. Rapid Setting (RS) Used for surface treatment and tack coat 2. Medium Setting (MS) Used for Macadam penetration and open graded cold mix 3. Slow Setting (SS) Used for tack coat, dense grade cold mix, crack patching and slurry mixture

30 the several factors as follows:
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Emulsified bitumen is most widely used compared to cutback bitumen due to the several factors as follows: 1. Environmental regulation – emulsified bitumen contains water while cutback bitumen contains materials which can evaporate and pollute the air when it has been used. 2. The wastage of petroleum – cutback bitumen uses petroleum solvents. 3. Safety – emulsified bitumen is safer to be used. 4. Low temperature of mixing – this situation can reduce the cost of fuel consumption. Besides that, emulsified bitumen can be used on damp surfaces while cutback bitumen needs dry condition.

31 Produced by heating the bitumen at high temperature and air is allowed
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin 4. Blown Bitumen Produced by heating the bitumen at high temperature and air is allowed through the bitumen and it makes the bitumen become harder. Basically, this type of bitumen is used for building materials especially for roofs.

32 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin TESTING In order to ensure the bitumen that be used fulfill the specification, series of testing can be conducted as follows: Penetration Softening Point Ductility Flash and Fire Point Viscosity Loss on Heating Thin Film Oven Test Specific Gravity Solubility

33 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin AGGREGATES Most of the aggregates used in the road construction were the natural aggregates. However, there was also widely used the artificial aggregates such as the waste material from the process of tin ore. In road construction, the aggregates can be classified into three groups according to the size as follows: 1. Coarse aggregates – retained on the sieve 2.36 mm. 2. Fine aggregates – passing sieve 2.36 mm and retained at 75 m sieve size. 3. Filler – the dust passing sieve size 75 m (eg. quarry dust and Portland cement).

34 Coarse aggregates shall be: screened crushed hard rock
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Coarse aggregates shall be: screened crushed hard rock angular in shape free from dust, clay, vegetative and other organic matter and other deleterious substances. Quality requirements: The aggregated crushing value shall be not more than 30. The weighted average loss of weight in the sodium sulphates soundness test (5 cycles) shall be not more than 12%. The flakiness index shall be not more than 30 The water absorption shall be not more than 2%. The polished stone value shall be not less than 40 (only applicable to aggregates for wearing course)

35 Fine aggregates shall be: clean natural sands non-plastic
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Fine aggregates shall be: clean natural sands non-plastic free from clay, loam, aggregations of material, vegetative and other organic matter and other deleterious substances. screened quarry fines or mining sand. Mining sand shall be thoroughly washed before use. Physical and mechanical quality requirements: The weighted average loss of weight in the sodium sulphate soundness test (5 cycles) shall be not more than 12%. The water absorption shall be not more than 2%. Notwithstanding compliance with the requirements, limestone aggregates shall not be permitted for use in wearing course.

36 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin The gradation of the combined course and fine aggregates, together with ordinary Portland cement added as an adhesion and anti-stripping agent and if necessary any other mineral filler shall conform to the appropriate envelope shown in Table 4. Table 4: Gradation limit for surface layer mixture (after Jabatan Kerja Raya, 2008) Mix Type Wearing Course Binder Course Mix Designation ACW 14 ACB 14 ACB 28 B.S. Sieve Size % Passing By Weight 37.5 mm 28.0 mm 20.0 mm 14.0 mm 10.0 mm 5.0 mm 3.35 mm 1.18 mm 425 µm 150 µm 75 µm - 100 80 – 95 68 – 90 52 – 72 45 – 62 30 – 45 17 – 30 7 – 16 4 – 10 70 – 95 56 – 81 40 – 65 32 – 58 20 – 42 12 – 28 6 – 16 4 – 8 80 – 100 72 – 93 58 – 82 50 – 75 36 – 58 30 – 52 18 – 38 11 – 25 5 – 14 3 – 8

37 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin SOIL STABILISATION Soil for sub-grade which has CBR value < 2% need to be replaced with better import material Increase construction cost Stabilize in-situ to increase the strength – reduce the construction cost Methods – chemical stabilisation and mechanical stabilization

38 HOT MIX ASPHALT CONCRETE MIX DESIGN
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin HOT MIX ASPHALT CONCRETE MIX DESIGN

39 Density & Voids Calculation STEP 4
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Aggregate Selection determine physical properties perform blending calculations to achieve aggregate gradation STEP 1 STEP 2 Binder Selection determine appropriate binder Sample Preparation 5 blends with 3 samples each mixing and compaction STEP 3 Density & Voids Calculation Bulk density, Theoretical Max. SG VTM, VFB & VMA STEP 4 STEP 5 Stability Determination Marshall stability and flow test Optimum Binder Content Selection based on the combined results of Marshall stability and flow, density analysis and voids analysis OBC is determined through graphical method STEP 6

40 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin MARSHALL MIX DESIGN The most used method for hot mix asphaltic concrete mixture design is the Marshall Method (ASTM D 1559). The objective of the Marshall design: to determine the mixing ratio of aggregates and optimum bitumen content produce the durable, stable and adequate of voids, workable, flexible, economy and quality. The most common method used to determine the optimum bitumen content is the method proposed by the Asphalt Institute. The procedure of this method is given as follows: a. Determine - Bitumen content for the maximum stability - Bitumen content for the maximum density - Bitumen content at the median of the specification of VTM - Bitumen content at the median of the specification of VFB

41 b. Calculate the mean value from these 4 values
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin b. Calculate the mean value from these 4 values c. Based on this mean value, determine the values from the Marshall properties curve as listed below: Stability (S) Flow (F) Stiffness (S/F) Void in Total Mix (VTM) Void Filled with Bitumen (VFB) Compare the values obtain from (c) with the specification values (Table 5). IMPORTANT !!! If it fulfills the specification, the bitumen can be considered as the optimum bitumen content. If it does not fulfill the requirement, the mixture needs to be redesigned.

42 Typical curve of Marshall properties
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Typical curve of Marshall properties

43 Parameter Wearing Course Binder Course
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Table 5: Test and Analysis Parameters for Asphaltic Concrete (after Jabatan Kerja Raya, 2008) Parameter Wearing Course Binder Course Stability Flow Stiffness Air voids in mix (VTM) Voids in aggregates filled with bitumen (VFB) >500kg >2.0mm >250kg 3.0%-5.0% 75-85% >450kg >225kg 3.0%-7.0% 65-80%

44 For more information on Marshall Mix Design, visit this website:
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Conventional bitumen content ranges used for mix design Wearing Course ACW 14 5.0 – 7.0% ACW 20 4.5 – 6.5% Binder Course ACB 14 ACB 20 4.0 – 6.0% ACB 28 For more information on Marshall Mix Design, visit this website:

45 EXAMPLE % AC Density Stability Flow Stiffness VTM VFB 4.0 2.259 1339.2
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin EXAMPLE % AC Density Stability Flow Stiffness VTM VFB 4.0 2.259 1339.2 2.62 511.8 6.49 57.96 4.5 2.270 1469.3 2.79 526.0 5.33 65.50 5.0 2.289 1551.0 3.19 486.2 3.86 74.59 5.5 2.272 1321.3 3.25 407.0 3.89 76.06 6.0 2.260 1196.7 3.70 323.1 78.40

46 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin

47 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Average = ( ) / 4 = 4.85 %

48  Optimum Binder Content, OBC = 4.85%
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin Parameter Results Specification (Binder course, JKR 1988) Remarks Stability Flow Stiffness VTM VFB 1530 kg 3.04 mm 495 kg/mm 4.42 % 71.1% > 450 kg > 2.0 mm > 225 kg/mm 3.0 – 7.0% 65 – 80% OK  Optimum Binder Content, OBC = 4.85%

49 COLD MIX ASPHALT CONCRETE MIXTURE DESIGN
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin COLD MIX ASPHALT CONCRETE MIXTURE DESIGN Produced by emulsifying the asphalt in water with (essentially) soap prior to mixing with the aggregate. While in its emulsified state the asphalt is less viscous and the mixture is easy to work and compact. The emulsion will break after enough water evaporates and the cold mix will, ideally, take on the properties of cold HMAC. Cold mix is commonly used as a patching material and on lesser trafficked service roads.

50 BFC 31082 HIGHWAY ENGINEERING Lecturer: Mr
BFC HIGHWAY ENGINEERING Lecturer: Mr. Mustafa Kamal bin Shamshuddin The End


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