Highway construction

Types of highway constructions

Earth road and gravel roads

Water bound macadam roads(WBM)

Cement concrete roads

 Soil survey

◗ The objective of soil survey is to determine the soil types

occurring along alignment and to locate the sources of
borrow soil for embankments
◗ Soil sampling at an interval of 200 m

◗ Soil samples to be evaluated for different geotechnical

properties
 Earthwork for embankment/subgrade
(As per specifications)

• Suitability of materials

– Free from peat, perishable and other organic material

– Should not be spontaneously combustible

– LL should be less than 70, PI should be less than 45

– Soils having salts are not suitable

– Free Swell Index more than 50 % should not be used

Earthwork for embankment/subgrade (contd.)
• Spreading of material in layers and bringing to appropriate

moisture content.

 Maximum compacted layer thickness should not exceed

200 mm

 Moisture content between OMC - 2 % to OMC + 1%

 Expansive soils to be compacted at OMC or on wet side

of optimum
Preparation of sub grade

•The preparation of sub grade includes all operations before the

pavement structure could be laid over it and compacted

•Sub grade would include site clearance , grading (embankment

or cut section) and compaction
 Objectives of soil compaction

• Increase in strength

• Reduction in compressibility

• Reduction in tendency for subsequent changes in

moisture content
• Reduction in erodability

• Reduction in frost susceptibility

Machinery for
earthwork
-Dozers
 JCB
(Backhoe
cum
Loader)

Motor
grader
 Tractor as
grader

Tractor
as
plough
Vibratory
roller
 Tandem
vibratory
roller

Static
roller
 Small
vibratory
roller

Plate
compact
or
Compacted subgrade
 Field control of compaction

• Measurement of dry density

– Core cutter method (IS: 2720 (Part 29) - 1975)

– Sand replacement method (IS: 2720 (Part 28) - 1974)

– Nuclear density & moisture gauge (ASTM D- 2922)

 Field control of compaction (contd.)

• Measurement of moisture content

– Pan drying method

– Speedy moisture meter (IS 2720 (Part 2 - 1973)

– Microwave oven method (ASTM D: 4643-1989)

 High embankment
• Failures within the body of embankment
 Incorrect design practices
 Poor quality fill materials
 Improper construction methods
 Lack of quality control
• Failures involving foundation
 Inadequate subsoil investigation
• Design of high embankment
 Using MoRTH or any other suitable software
 Target FS = 1.25 for economical design
 Earthwork under special conditions

• Earthwork over existing road surface

• Embankment construction in waterlogged areas

• Construction of embankment over soft soils

• Inadequate compaction of backfill material in trenches

dug for services in urban areas

• Low cost roads may cater for 30 t to 200 t per day

Compaction of ground with underlying cables, water pipelines, sewer
lines, etc.

Settlement of pavement due to improper compaction of backfill

material in the trenches
 Effect of earthquake on
embankment

Shallow cracks in road

pavement

Deep and wide cracks in

embankment

• Depth of crack upto 1m

• width of crack 10 cm- 80 cm
 Failures on the side slopes

Sinking of side slopes Severe damage to stone- pitching on

embankment slopes
Major slides/
subsidence
 Erosion control of slopes
 Common methods
 Simple vegetative turfing
 Transplantation of ready made turf of grass
 Straw with cowdung or wood shavings or
sawdust as mulch

 Special techniques
 Asphalt mulch technique
 Use of jute/ coir netting
 Erosion Control of
Slopes

Use of jute geotextile for erosion

control
Stone pitching for slope protection
Construction of gravel roads

Gravel roads are considered superior to earth roads as they can

carry heavier traffic

Camber may be between 1in 25 and 1 in 30

This type of roads can cater for about 100 t of pneumatic tyred
vehicles or 60 t of iron tyred vehicles per day per lane

Hard variety of crushed stones or gravel of specified gradation is

used
Rounded stones and river gravel are not preferable
 Preparation of sub grade : site is cleared and fills
and cuts are completed

Pavement construction : place the crushed gravel aggregates carefully

So that we can avoid seggregation
Aggregates are spread with greater thickness at center and less towards
the edge so as to obtain the desired camber

Opening to traffic
 Sub-base course

• Intermediate layer between sub grade and granular base course

• Essentially a drainage layer

• Distributes the stresses imposed by traffic

 Materials for sub base
• Locally available materials (no specifications for materials)
 Natural sand
 Gravel or moorum
 Kankar
 Crushed stone
 Laterite
 Rounded and river gravel are not preferable

• Industrial waste and other materials

 Steel slag
 Pond ash or Pond-Bottom ash mix
 Crushed concrete
 Brick bats
 Spreading of pond ash

Second Nizamuddin bridge approach embankment

Compaction of pond ash

 Construction operations - GSB
• Preparation of subgrade
• Mixing and preparation of GSB
• Spreading and compacting
Moisture content to be between OMC+1% to
OMC - 2%
Use of static roller (8 to 10ton) for compacted
layer thickness less than 100 mm
Use of vibratory roller for compacted layer
thickness upto 225 mm
• Rolling
Starting from edges going towards center
Speed of roller not to exceed 5 km/h
 Water Bound Macadam

• Materials
 Aggregates
 Screening
 Binding material

• Aggregates
 Crushed or broken stone
 Crushed slag
 Overburnt brick aggregates for sub-base
 Water Bound Macadam

• Aspects to be considered
– Grading of aggregates
– Strength of aggregates
– Shape of aggregates
– Water absorption
– Screening material
– Binding material
Gradation of aggregates for WBM
 Water Bound Macadam
Physical requirements of aggregates for
WBM / WMM / CRM (MORTH)

Physical requirements of aggregates for WBM

(Rural Roads Manual)
 Water Bound Macadam
Quality control tests for WBM (MORTH & Rural roads Manual)

Sl.No. Test Relevant code Frequency of test

1. Aggregate IS:2386 : Part - 4 1 test / 200 m3

impact value or
1 test / 250 m3
Los Angeles
(Only AIV – Rural
abrasion value
Roads Manual)
2. Aggregate IS:2386 : Part - 1 1 test / 100 m3
gradation
1 test / 125 m3
(Rural Roads )
3. Combined IS:2386 : Part - 1 1 test / 200 m3
Flakiness and
1 test / 250 m3
Elongation index
(Only FI – Rural
Roads Manual)
4 Atterberg limits IS:2720 : Part - 5 1 test / 25 m3
of binding
1 test / 50 m3
material
(Rural Roads )
5 Atterberg limits IS:2720 : Part - 5 1 test / 100 m3
of aggregates
finer than 425
micron
 Water Bound Macadam

Gradation of screenings
 Water Bound Macadam
Quantity of materials
 WBM as wearing course

• Only WBM Grade III can be adopted as

wearing course as per Rural Roads
Manual
Plasticity requirements of binding material
for wearing course
 WBM - Construction
• Preparation of sub base to specified
crossfall
• Spreading of coarse aggregates
• Rolling
• Application of screenings
• Watering and brooming
• Application of binding material
• Watering and rolling
• Setting and drying
 WBM Construction

Stone metal for WBM

Spreading of stone metal Spreading of screening

 WBM Construction

Applying binder for WBM

Watering & rolling of WBM Difficulty due to soft subgrade

Close-up View of WBM
CONSTRUCTION OF BITUMINOUS PAVEMENTS
Types of Bituminous Layers

Bituminous construction are classified into four

categories

 Interface Treatments

 Thin Bituminous Surfacing

 Bituminous Surface Courses

 Bituminous Binder Courses

 INTERFACE TREATMENTS

 Prime Coat
 Tack Coat
Prime coat

Application of single coat of low viscosity liquid bituminous

material to a porous granular surface

choice of a bituminous primer - depend upon the porosity

characteristics of the surface to be primed as classified in IRC : 16.

(i) Surfaces of low porosity; such as wet mix macadam &

water bound macadam,,

(ii) Surfaces of medium porosity; such as cement stabilized

soil base,

(iii)Surfaces of high porosity; such as a gravel base .

 PURPOSE OF PRIMING
 To plug the capillary voids
 To coat and bond loose materials on the surface
 To harden or toughen the surface
 To promote adhesion between granular and the bituminous
layer
 REQUIREMENT FOR PRIMING
MATERIAL
Porosity Type of Viscosity at Quantity
Surface 600 C per 10 m2
(centistokes) (Kg)
Low WMM, 30-60 7-12
WBM
Medium Gravel 70-140 9-12
base
High Stabilised 250-500 12-15
base
Prime coat- Slow setting Cationic emulsion as per IS :
8887-2004
Mechanical sprayer at rate of 7.3 to 14.6 kg per 10 m2 area
Prime Coat
Prime coat

Weather and Seasonal Limitations

- primer shall not be applied on a wet surface or during
dust storm or when the weather is foggy, rainy or windy.
-should not be applied when the temperature in the shade
is less than 10oC
Construction
 Equipment:

-pneumatic tyred self-propelled pressure distributor equipped for

spraying the material uniformly at the specified rates and
temperatures
Preparation of road surface:
-swept clean, free from dust and shall be dry .
-shaped to the specified grades and section.
-free from ruts, any other irregularities and segregated materials.
Minor depressions and potholes may be ignored until the surface is
primed, after which they shall be patched with a suitable premix
material prior to the surface treatment.
Application of bituminous primer:
-shall be sprayed/distributed uniformly over the dry surface, prepared
using self-propelled sprayer equipped with self-heating arrangement,
suitable pump, adequate capacity compressor and spraying bar with
nozzles having constant volume or pressure system capable of
supplying primer at specified rates and temperatures so as to provide
a uniformly unbroken spread of primer.

Surface- dry or dusty as to cause freckling of bituminous material, -

sprinkled with water immediately prior to priming; however, the
bituminous material shall not be applied till such time as no surface
water is visible.
Curing of primer and opening to traffic:
Fully cured and is not sticky to avoid being picked up by traffic.

- allowed to cure for not less than 24 hours and during this
period no traffic of any kind shall be not permitted .

- measured in terms of surface area of application in square

metres.
 TACK COAT

Purpose of Tack Coat:

 To ensure a bond between the new construction and the
old surface
Use of Cutback: exceptional cases
 It should be restricted for sites at subzero temperatures or
for emergency applications
 Weather and Seasonal Limitations
 - shall not be applied on a wet surface or during dust
storm or when the weather is foggy, rainy or windy.

Construction Operation
Equipment- self propelled/towed bitumen pressure sprayer
equipped for spraying the bitumen uniformly- inaccessible- Hand
sprayers

Preparation of base: -cleaned of dust and any extraneous material

before the application of the binder, by using a mechanical broom
or any other approved equipment/method as specified by the
Engineer
Application – Rate specified in the contract , unformly to be applied
Surface Cleaning
 TABLE 500-2. RATE OF APPLICATION OF TACK COAT

Type Surface Quantity of liquid

Bituminous material in kg per sq. m.
area

i) Normal bituminous surfaces 0.2 to 0.25

ii) Dry and hungry bituminous 0.25 to 0.30

surfaces
iii) Granular surfaces treated with 1.0.25 to 0.30
primer
iv) Non bituminous surfaces 0.35 to 0.40
a)Granular base (not primed) 0.3 to 0.35
b)Cement concrete pavement

-range of spraying temperature 20 0

C - 60 0
C;
-cutback 50 0 C – 80 0C if RC-70/MC-70 grade is used.
WRONG PRACTICE OF TACK COAT
MECHANICAL SPRAYER FOR TACK COAT
Tack coat is usually applied by spraying bituminous material of
higher viscosity like the hot bitumen at the rate of 4.9 to 9.8 kg
per 10 m2 area
INSUFFICIENT TACK COAT
 Apply Tack Coat

Typical
Application

Does this
look okay?
 Tack Coat Examples

Proper Coverage

Anything
wrong here?
 Tack coat

Curing- left to cure until all volatiles evaporated

Traffic- No traffic including construction vehicles

Measurement for payment- Sq.meters

THIN BITUMINOUS LAYERS
BITUMINOUS SURFACE DRESSING (BSD)

Purpose : One or two coats of bituminous application, each

coat consisting of layer of bituminous binder followed by a
cover of stone chips to serve as wearing course.

The main functions of BSD are:

 To serve as a thin wearing course of pavement
 To prevent infiltration of surface water
 To provide dust free pavement surface
 SURFACE DRESSING
Equipment :
a)Self propelled mechanical sprayer for spraying bitumen.
b)Self propelled or towed mechanical grit spreader to
spread aggregate’s uniformly.
c) Road roller 8-10 Ton smoothed wheeled or static weight
vibratory.
Construction Procedure :
a)Preparation of base course.
b)Bitumen is heated & sprayed with mechanical sprayer.
c)Stone chips is spread with mechanical grit spreader.
d)Surface is rolled with 8-10 ton roller.
e)Application of second coat.
 SURFACE DRESSING

BITUMEN BEING SPRAYED STONE CHIPS BEING SPREAD BY

MECHANICALLY MECHANICAL GRIT SPREADER

Opening to Traffic:
Traffic is not allowed till following day.
POOR CONSTRUCTION
 Tack Coat on
Cracked
Bituminous
Surface

Thin Layer of
MSS over
WBM
Seal Coat

Seal Coat
 SEAL COAT

1.Purpose : This is applied on bituminous surface for sealing the voids.

2.Types :
a)Liquid seal coat (Type A). Application of layer of bituminous binder
followed by layer of stone chips.
b)Premixed seal coat (Type B). Thin application of fine aggregates
premixed with bituminous binder.
 SEAL COAT
3. Materials :

a) Binder : Penetration grade satisfying IS-73.

Qty/10m2
Item
Bitumen (kg) Bituminous
Emulsion (kg)
Type A 9.8 15.0
Type B 6.8 10.5
b) Aggregates . Should be clean, hard, durable and dry.

Size Passing Retained Qty/10m2

Item (mm) Sieve (mm) Sieve (mm) (m3)

Type A 6.7 11.2 2.36 0.09

Type B - 2.36 0.180 0.06
4. Equipment :
a)Self propelled mechanical sprayer for spraying bitumen.
b)Self propelled or towed mechanical grit spreader to spread
aggregate’s uniformly.
c)Road roller 8-10 Ton smoothed wheeled or static weight
vibratory.

5. Construction Procedure ( Type A) :

a)Bituminous surface is cleaned.

b)Bitumen is heated to 150-163о C & sprayed with mechanical

sprayer.

c)Stone chips is spread with mechanical grit spreader.

d)Surface is rolled with 8-10 ton roller.

6. Construction Procedure ( Type B) :
a)Bituminous surface is cleaned.
b)Bitumen and aggregate are mixed thoroughly at suitable
temperature in mixing plant .
c)Mix is transported to site and spread uniformly.
d)Surface is rolled with 8-10 ton roller.

7. Opening to Traffic:
a)Type A. Following day.
b)Type B. Soon after final rolling.
Open Graded Premix Carpet
 OPEN GRADED PREMIX SURFACING

1. Purpose :To serve as wearing course, 20mm thick open graded

premix surfacing material is laid and compacted.

2. Material :
a) Binders.
Paving Bitumen as per IS-73.
Bitumen Emulsion as per IS-8887.
c) Aggregates.
Physical requirement as per table
500-3 MORT&H
specifications for roads.
3. Equipment :
a)Hot mix / cold mix plant for mixing binder and
aggregates.
b)Self propelled or towed mechanical sprayer.
c)Pavers.
d)Air compressor for cleaning.
e)Road roller 8-10 Ton smoothed wheeled or static
weight vibratory.
4. Construction Procedure :
a) Preparation of underlying surface.
b) Tack coat.
c) Preparation of premix in hot/cold mix plant.
d) Spreading of premix by pavers or manually.
e) Rolling with 8-10 ton roller.
f) Application of seal coat.
 OPEN GRADED PREMIX
SURFACING

PREPARATION OF UNDERLYING SPREADING BITUMEN ON PREPARED

SURFACE SURFACE : TACK COAT
 OPEN GRADED PREMIX
SURFACING

PREPARATION AND TRANSPORTATION LAYING THE MIX BY PAVER

OF MIX FROM HOT MIX PLANT

5. Opening to Traffic:
Traffic is not allowed until seal coat is laid.
Close Graded Premix Carpet
 CLOSE GRADED PREMIX SURFACING

1. Purpose :To serve as wearing course, 20mm thick close graded

premix surfacing material is laid and compacted.

2. Material :
a) Binders.
Paving Bitumen as per IS-73.
c) Aggregates.
Physical requirement as per table 500-3 & Gradation
as per table 500-26 MORT&H specifications for roads.
3. Equipment :
a)Hot mix plant for mixing binder and aggregates.
b)Self propelled or towed mechanical sprayer.
c)Pavers.
d)Air compressor for cleaning.
e)Road roller 8-10 Ton smoothed wheeled or static weight
vibratory.

4. Construction Procedure :
a) Preparation of underlying surface.
b) Tack coat.
c) Preparation of premix in hot mix plant.
d) Spreading of premix by pavers or manually.
e) Rolling with 8-10 ton roller.
5.Opening to Traffic:
Soon after final rolling.
Mastic Asphalt

Work- Construction of single layer of mastic asphalt wearing

course for road pavements and bridge decks
- Mixture of well graded aggregates, filler and bitumen- plastic
and voids less mass- impermeable surface

- it cannot be compacted, and is spread rather

than rolled.
- fully waterproof and does not degrade as a result of
weathering
Mastic Asphalt
Mastic Asphalt

Requirements of Binder
Mastic Asphalt

Grade and Thickness of Mastic Asphalt paving and Grading

of Coarse Aggregate

0-5
Mastic Asphalt

Grading of Fine aggregate including Filler

BITUMINOUS BINDER COURSE
504 BITUMINOUS MACADAM

Scope
- consist of construction, in a
single course, of compacted crushed
aggregates premixed with a bituminous
binder, to serve as base/binder course,
laid immediately after mixing, on a base
prepared previously in accordance with
the requirement of these Specifications
and in conformity with the lines, grades
and cross-sections shown on the drawing
or as directed by the Engineer

Core- BM
Materials

Bitumen:
- shall be paving bitumen of suitable penetration grade ( 35 to 90) as per
IS : 73.
-actual grade of bitumen to be used shall be decided by the Engineer
appropriate to the region, traffic, rainfall and other environmental
conditions.
Aggregates

Aggregates - crushed stone, crushed/ other hard material retained on

2.36 mm sieve stones.
-clean, strong, durable, of fairly cubical shape and free from disintegrated
pieces, organic or other deleterious matter and adherent coating.
-poor adhesion- to be treated with anti-stripping agents
Coarse aggregates

Coarse aggregates- many fracture faces

Angular and non- angular aggregates
Bituminous macadam

Fine aggregates- crushed/naturally occurring material

/combination (2.36 to 75 micron)- clean, hard, durable..etc
 TABLE 500-3. PHYSICAL REQUIREMENTS OF AGGREGATES
FOR BITUMINOUS MACADAM

S.No. Test Test Method Requirement

1. Los Angeles Abrasion IS : 2386 (Part-4) 40 per cent Maximum
Value*
2. Aggregate Impact Value * IS : 2386 (Part-4) 30 per cent Maximum
3. Flakiness and Elongation IS : 2386 (Part-1) 30 per cent Maximum
Indices (Total) **
4. Coating and Stripping of AASHTO T 182 Minimum retained
Bitumen Aggregate coating 95 per cent
Mixtures
5. Soundness IS : 2386 (Part-5) 12 per cent Maximum
(i) Loss with Sodium 18 per cent Maximum
Sulphate 5 cycles
(i)Loss with Magnesium
Sulphate 5 cycles
6. Water absorption IS : 2386 (Part-3) 2 per cent Maximum
ABLE 500-4. AGGREGATE GRADING FOR BITUMINOUS MACADAM

IS Sieve Designation Per cent by weight passing the sieve

Grading 1 Grading 2
Nominal size 40 mm 19 mm
Layer thickness 80-100 mm 50-75 mm

45.0 mm 100 -
37.5 mm 90-100 --
26.5 mm 75-100 100
19 mm - 90-100
13.2 mm 35-61 56-88
4.75 mm 13-22 16-36
2.36 mm 4-19 4-19
0.3mm 2-10 2-10
0.075 mm 0-8 0-8

Bitumen % wt of mix 3.1-3.4 3.3 -3.5

BM- Construction Operations

Weather and seasonal limitations

Preparation of the base
-shall be prepared, shaped and conditioned to the specified lines,
grades and cross-sections in accordance with Clause 501.8
(preparation of surface- Profile corrective course) and a priming
coat where needed shall be applied in accordance with Clause 502
as directed by the Engineer
Tack coat
Preparation and transportation of mix
Spreading
Rolling-
Surface finish and quality control check (clause 900)
Protection of layer – another layer/ seal coat
Mixing and compaction Temperature
BM- Construction Operations

Arrangement for traffic

Measurement for payment- cu.m
BITUMINOUS PENETRATION MACADAM

Scope
- consist of construction of one or more layers of
compacted crushed coarse aggregates with alternate applications
of bituminous binder and key aggregates in accordance with the
requirements of these Specifications to serve as base/binder
course and in conformity with the lines, grades and cross-
sections shown on the drawings or as directed by the Engineer.

Thickness of an individual course -not exceed 75 mm.

BITUMINOUS PENETRATION MACADAM

Bitumen: S- 35 to S-90
Aggregates
Quantity of materials
 COMPOSITION OF BITUMINOUS PENETRATION MACADAM

IS Sieve Per cent by weight passing the Sieve

Designati
For 50mm compacted For 75mm compacted
on
thickness thickness
Coarse Key Coarse Key
Aggregate Aggregate Aggregate Aggregate

63 mm - - 100 -
53 mm - - - -
45 mm 100 - 58-82 -
26.5 mm 37-72 - - 100
22.4 mm - 100 5-27 50-75
13.2 mm 2-20 50-75 - -
11.2 mm - - - 5-25
5.6 mm - 5-25 - -
2.8 mm 0-5 0-5 0-5 0-5

Appro. Loose aggre(cu.m/m2) 0.06/0.015 0.09/0.018

Binder (kg/m2) 5 6.8
BITUMINOUS PENETRATION MACADAM
Construction steps

Steps
Weather and seasonal Limitations
Equipment- mechanical broom, compressor, self-propelled/trailed
bitumen distributor, aggregate spreader, rollers
Preparation of base
Spreading coarse aggregate
Compaction
Application of binder material
Application of key aggregates
Surface finish and quality control
Surfacing- other layer/seal coat
Arrangement for traffic
MODIFIED PENETRATION MACADAM
(MPM)

 Grouted/ Penetration type of construction

 It can be laid in 50 mm or 75 mm thickness

 Commonly practiced in Maharashtra

 SIZE AND QUANTITY OF AGGREGATES
FOR MPM

Rate of application for 10 m2 area

Aggregate 75 mm 50 mm
Size
On On On On
Asphalt W. B. M. Asphalt W. B M.
Surface Surface Surface Surface
40 mm size 0.9 cum 0.9 cum 0.6 cum 0.6 cum
hand
broken metal
12 mm size 0.18 cum 0.18 cum 0.18 cum 0.18 cum
chips
Built Up Spray Grout
 Materials to be used

• Bitumen –Bitumen of paving grade complying with IS specifications

for “paving bitumen” IS:73 and of penetration 35-90
• Course aggregate- crushed rock ,crushed gravel or other hard
material retained on 2.36mm sieve.
• They shall be clean, hard, durable, of cubical shape, free from dust
and soft of friable matter, or other deleterious material
• If selected aggregate have poor affinity for bitumen, then the
bitumen is to be treated with anti stripping agent.
• Source aggregate should be tested for stripping.
• If crushed gravel is to be used >90%by weight retained on 4.75mm
sieve shall have two fractured surfaces
Fine aggregate
• Aggregate shall consist of crushed or naturally occurring material,
or combination of two, passing 2.36mm sieve and retained on 75
micron sieve
• Clean, durable, dry and free from dust, and soft or friable matter,
organic or other deleterious matter
 Construction operation
Weather and seasonal limitations
• To be suspended while free standing water is present on the
surface to be covered, or during rain, fog and dust storms.
• After rain, the bituminous surface, prime coat or tack coat ,shall
be blown off with high pressure air jet to remove excess moisture
or surface left to dry.
• Laying not be done when air temperature is less 10°C, wind
speed at any temperature exceeds 40kmph at 2m height

Preparation of base.

• The base on which the built up spray grout course is to laid

shall be prepared, shaped and compacted
• A prime coat where specified shall be applied over the base
• A tack coat shall be applied
Spreading and rolling course aggregate for the first

• Immediately after application of prime coat course aggregate shall

be spread uniformly and evenly by a self propelled or tripper tail
mounted aggregate spreader
• The surface of the layer shall be checked with camber templates
• At places where paver cannot go mix shall be spread, leveled
using suitable hand tools
• Layer thickness should be maintained carefully
 Compaction

•Rolling Should start soon after laying

•Rolling Should be completed before the max temperature
falls below minimum rolling temperature
•Should ensure layer thickness and surface level
•Rolling should commence at edges and progress towards
centre (except at super elevation)
•At super elevated portions progress shall be from lower to
the upper edge
•Should continue till roller marks are removed
•Initial rolling with 8-10 ton smooth wheeled
•Intermediate with 8-10 ton dead weight / vibratory or
pneumatic tyred of 12-15 ton
•Finishing with 6-8 ton smooth wheeled
 Final surfacing

• The built up spray grout shall be provided with final surfacing

within two days.
• A seal coat is to be applied when there is a delay.
 BUILT-UP SPRAY GROUT

 Two Layer Composite Construction of Compacted Coarse

Aggregates
 Application of Binder after each layer
 Key aggregates on top of each layer
 Thickness = 75 mm
 Single Course in Pavement Structure
 BUILT-UP SPRAY GROUT

 Preparation of Base to the Required Camber and Shape

 Application of Primer
 Application of Tack Coat
 Spreading and Rolling First Layer of Coarse Aggregates
(0.5 cu.m/10 sq.m)
 Application of Binder - First Spray (15 kg/10 sq.m)
 BUILT-UP SPRAY GROUT

 Spreading and Rolling of Coarse Aggregates for the

Second Layer
 Application of Binder - Second Spray (15 kg/10 sq.m)
 Application of Key Aggregates (0.13 cu.m/10 sq.m)
 Roll and Apply Additional key aggregates, if required
 Cover with a Seal Coat before opening to Traffic
 BITUMINOUS MACADAM (BM)

 BM is carried out in a Hot Mix Plant, laid and

compacted mechanically
 There are two sets of grading, Grade I & II
 Quality control measures involves percentage
of Bitumen & Mixing, Laying and Compaction
temperature
 GRADATION REQUIREMENTS FOR BM
Grading I II
Nominal 40 mm 19 mm
Layer Thickness 75-100 mm 50-75 mm
IS Sieve (mm) Per cent Passing
45.0 100 --
37.5 90-100 --
26.5 75-100 100
19.0 -- 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.300 2-10 2-10
0.075 0-8 0-8
Bitumen, per cent by 3.1 to 3.4 3.3 to 3.5
weight of mix
Bitumen Grade S 35-90 S 35-90
 SEGREGATION IN MIX

Segregation due to Single Drop

Must Avoid Segregation!
SEGREGATION IN BM MIX
PROPER LOADING
Sequence for Shorter End Dump Trucks

2 1
GOOD PAVEMENT SURFACE
EQUIPMENT REQUIRED
MODERN PAVER
SMOOTH WHEELED ROLLER
 COMPACTION OF BITUMINOUS MIXES

• Lack of adequate compaction in field leads to reduce

pavement life

• Inadequate compaction of hot mix leads to early

oxidation, ravelling, cracking and disintegration before its
life expectancy is achieved
Stopping
 e!
Free Barbecu
 End Dump Truck Operation

Raise bed, but keep tailgate closed

until mix slides against it
 End Dump Truck Operation

Open gate and continue to raise bed

Dense Bituminous Macadam (DBM)
 Dense Graded Bituminous
Macadam
• Used for base / binder course

• Work may require single or multiple layers

• Thickness of a single layer is 50 -100mm

 Materials

• Bitumen

– 60/70 or 80/100 or modified as specified

– Minimum bitumen content by weight of mix

• For NMAS 40mm --- 4.0%

• For NMAS 25mm --- 4.5%

 Aggregates

• Coarse
– Crushed rock / gravel

– Cubical or F.I.+E.I. < 30%

– Retained bitumen coating ≥ 95%

– L.A.V. ≤ 35% & A.I.V. ≤ 27%

• Fine aggregate
– Crushed / naturally occurring
– Free from organic matter
– Sand equivalent ≥ 50%

• Filler

– Generally rock dust/hydrated lime/cement

– For filler other than lime/cement P.I. ≤ 4
– Lime acts as antistripping agent
• If coarse aggregate is gravel

– Lime is added by 2% of aggregate weight

– Fine aggregate is correspondingly reduced

• Aggregate used is relatively well graded

Aggregate requirement

Dense Bituminous Macadam (DBM):

Dense Bituminous Macadam (DBM):

Gradation requirement

bitumen
 Dense Bituminous Macadam (DBM):

Marshall Mix Design-criteria

 Dense Bituminous Macadam (DBM):

Binder content- as per mix design

Agg. retained on 26.5- 26.5 to 22.4

For 40mm- use modified Marshall method- MS 2(AI)

 Dense Bituminous Macadam (DBM):
Plants-trials
 Dense Bituminous Macadam
(DBM):
Steps
Weather and seasonal limitations
Preparation of base
Geosynthetics
Stress absorbing layer
Prime coat
Tack coat
Mixing and transportation of the mixture
….contd
Steps
Spreading
Rolling
Opening top traffic
Surface finish and quality control of work
Arrangements for traffic
Measurements for payment
Bituminous Concrete
Bituminous Concrete

Aggregate requirement
(wet sieving method)
Bituminous Concrete

Gradation
requirement
 Bituminous Concrete

• Used for wearing / profile corrective course

• Work may require single or multiple layers

• Thickness of a single layer is 25-100mm

 Materials
• Bitumen

– 60/70 or modified as specified

– Bitumen content by weight of mix

• For NMAS 13mm --- 5-6%

• For NMAS 19mm --- 6-7%

• Coarse
– Crushed rock / gravel

– Cubical or F.I.+E.I. < 30%

– Retained bitumen coating ≥ 95%

– L.A.V. ≤ 30% & A.I.V. ≤ 24%

• Fine aggregate

– Crushed / naturally occurring

– Free from organic matter
– Sand equivalent ≥ 50%

• Filler

– Generally rock dust/hydrated lime/cement

– For filler other than lime/cement P.I. ≤ 4
– Lime acts as anti stripping agent

Continued…
• If coarse aggregate is gravel

– Lime is added by 2% of aggregate weight

– Fine aggregate is correspondingly reduced

• Aggregate used is relatively well graded

 Mix requirements (Table 500-16)
Min stability (KN at 60°C) 9.0
Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (no. of blows) 75(each face)
Percent air voids 3-6
VMA (NMAS 13mm) 13 - 15
VMA (NMAS 19mm) 12 - 14
VFB 65 - 75
Loss of stability on immersion 60°C Min.75% retain
• Mixing , laying and compaction operations are
similar to them explained for DBM

Opening to traffic

• Traffic shall not be allowed for first 24 hours

after laying & completion of compaction of
the mix
 Thank
you