“Construction and Quality Control of Flexible

Pavement at Harohalli Industrial Area”

UNDER THE GUIDENCE OF:

Dr. G KAVITHA
Associate Professor
RASTA – Center for Road Technology, Bengaluru

PRESENTATION BY:
KEERTHI S
1IR17CHT08
 CONTENTS

 INTRODUCTION
 TASK PERFORMED
 RESULTS
 CONCLUSION
 REFERENCE
 KIADB is proposed to develop an 3rd Phase of Industrial Area at Harohalli, Kanakapura Taluk, Ramanagar
District.

 The area earmarked for the proposed Development of Harohalli Industrial Area is 1316.90 Acre with a project
cost of Rs: 128 Crores.

 Harohalli Industrial area is located at a distance of 40km from Bengaluru and 17km from Kanakapura.
 KIADB has appointed M/s. Alcon consulting Engineers (India) Pvt Ltd. Bangalore for providing the
required consultancy services for Detailed Project Report preparation for industrial area development at
Harohalli Ramanagar District.
 KIADB has appointed RASTA Consulting Service for Quality assurance of the project at Harohalli industrial
area.

 The entire work for the construction of road in this area was made in packages, which are divided in 5, were
each package was awarded for different contractor for the construction and maintains.
 Table 1:- Details of each package works and estimated amount
SL.No. Type of the work Contractor Contract Amount (Rs.)

1 Formation of 30mt wide road,18mt wide road and 15mt wide road including asphalting, P.Venkata Reddy I.N.R.
construction of RCC side drains, RCC Storm water drain, RCC cross drainage works, 27,22,32,311.00
HDPE Water supply pipe line and rain water harvesting at Harohalli industrial area 3rd
phase, Kanakapura Taluk, Ramanagara District (Package-1)
2 Formation of 30mt wide road,18mt wide road and 15mt wide road including asphalting, M/s Santhsosh Buildwel Infra Pvt
construction of RCC side drains, RCC Storm water drain, RCC cross drainage works, Ltd I.N.R.
HDPE Water supply pipe line and rain water harvesting at Harohalli industrial area 3rd 25,08,01,249.36
phase, Kanakapura Taluk, Ramanagara District (Package-2) P.Venkata Reddy (Sub Contractor)

3 Formation of 30mt wide road (Road No. 1), 18mt wide road (Road No. 17,18,21,22 & M/s Shrinivas Constructions
23) and 15mt wide road (Road No. 18A, 18B,18C, 20, 25, 26, 27 & 28) including M/s P. Venkata Reddy (Sub Contra
asphalting, construction of RCC side drains, RCC cross drainage works, RCC storm ctor) I.N.R 25,10,00,000.00
water drain, HDPE Water supply pipe line and rain water harvesting at Harohalli
Industrial area 3rd phase, Kanakapura taluk, Ramanagara District (Package-3).

4 Formation of 30mt wide road (Road No.1 &31), 18mt wide road (Road No.
31,46,49,50, 51 & 52) and 15mt wide road (Road No. 43,4445, 46A & 48) including M/s Govinde Gowder and sons I.N.R.
asphalting, construction of RCC side drains, RCC cross drainage works, RCC storm
water drain, HDPE Water supply pipe line and rain water harvesting at Harohalli 23,60,00,000.00
Industrial area 3rd phase, Kanakapura taluk, Ramanagara District

5 Formation of 30mt wide road,18mt wide road and 15mt wide road including asphalting,
I.N.R.
construction of RCC side drains, RCC cross drainage works, construction of corporate
27,31,10,345.00
office building, HDPE Water supply pipe line, sump tank and rain water harvesting at M/s Amrutha Constructions Pvt Ltd
women Entrepreneurs’ park, Harohalli industrial area 3rd phase, Kanakapura taluk,
Ramanagara District
 Tasks Performed
Construction and Quality control of different layers of Flexible Pavement:
 Subgrade
 Sub-base(Granular sub-base/Drainage layer)
 Base Course (W M M)
 Binder Course (D B M)
 Surface Course (B C)

The study deals with the construction and quality control of the following road:
A 30m wide main Road-1 with 1km length. [Chainage- 2090m to 3090m]
 Layers Thickness
BC-II 40mm
DBM-II 100mm
WMM 250mm
GSB-II 230mm
Subgrade 300mm
 SUBGRADE
Material Specifications for Subgrade as per MoRT&H (V Revision) Specifications
Maximum Particle size Should not be more than 50 mm or should not be more than
2/3rdof compacted layer thickness(whichever is minimum)
Free swell Index Max 50%
Liquid Limit Max 50%
Plasticity Index Max 25%
C.B.R.(4 days soaked) Min % as specified at 97 % MDD
Laboratory test report of Subgrade soil sample
Sieve analysis (% passing) Atterberg limits Compaction CBR (%)
test 4days soaked
Test method-IS-2720 part 4- Test method-IS- 2720 Test method- Test method IS-
1985 part 4-1985 IS-2720 part 8- 2720 part 16-1985
1985
Gravel Sand (%) Silt and CBR (%)
(%) > 4.75 to clay (%) < LL PL PI MDD OMC
4.75mm 0.075mm 0.075mm (%) (%) (%) (g/cc) (%)
1 12.26 72.56 15.18 36.24 21.6 14.58 1.89 11.2 10
Construction of Subgrade:

 The Selected soil in loose condition is spread to the required grade and cross slope in layer of desired
thickness using appropriate equipment such as blade grader, over the prepared surface i.e. top of
embankment or top of prepared cutting. Thickness of loose soil is decided so as to obtain desired
compacted thickness determined during rolling.

 Additional water as required is sprayed so as to obtain OMC of the soil determined from the laboratory
compaction test.

 The soil with the added water is mixed thoroughly using appropriate equipment so that the water gets
distributed in soil layer uniformly the mixed soil is spread again to uniform layer thickness.

 The soil layer is compacted by rolling using the selected equipment so as to obtain the specified density.

 After ensuring that the layer has been compacted to the desired density, the next layer of soil is spread over
these, water added, mixed and compacted as mentioned in steps 1to 4 above . the process is repeated until
the desired compacted thickness sub grade is achieved
Quality control checks of subgrade
 Soil sample collected from selected borrow pits is subjected to laboratory tests, to check the values
of liquid limit, plasticity index, grain size distribution ,if the selected soil fulfils the specified
requirement, the use of this soil is approved for use.

 Laboratory compaction test is carried out to determine the OMC and MDD.

 CBR value of soil is determined in lab , compacted at 97% of MDD.

 Field moisture content soil is determined prior to compaction and extra water is added to bring up
to the OMC is estimated.

 After adding water ,mixed thoroughly and moisture content is again checked by rapid test method
ensure that OMC is achieved.

 After soil layer is rolled adequately, field density and moisture content is determined ,in case dry
density achieved is less than specified value i.e 97% further rolling is carried out until the desired
density is achieved.

 Step 4to 6 is repeated for every layer and finished surface are checked with reference to the
longitudinal and cross profile of the road.
 Wet Sieve Analysis Test Result For Soil(Site)
Road no-1,Ch-2150

Cum wt
Sieve Size Wt retained retained % cum wt % fines
Sl no (mm) (gm) (gm) retained passing
1 4.75 94 94 18.8 81.2
Gravel (%) 18.8
2 2.36 102 196 39.2 60.8 Sand(%) 61.8

3 1.18 85 281 56.2 43.8 Silt and

4 600 78 359 71.8 28.2 Clay(%) 19.4

5 300 32 391 78.2 21.8

6 150 9 400 80 20
7 75 3 403 80.6 19.4
8 pan 1 404 80.8 19.2
Sub grade field density by sand replacement method
Lab OMC(%): 11.2 Lab MDD(g/cc): 1.89

Mean Weight of sand in cone(W2) 395

Volume of calibrating cylinder(V) 1179
Weight of Sand + cylinder (before pouring into the calibrating 6520
container)(W1)
Mean Weight of sand + cylinder(after Pouring into the calibrating 4460
container)(w3)
Weight of sand to fill calibrating container(wa=w1-w2-w3) 1665
Bulk density of sand(Ys=Wa/V) 1.41
Prepared
Road NO 1 subgrade
Chainage (m) 2190rhs
Weight of wet soil from hole w gm 2385
Weight of cylinder + sand before pouring(w1) 6420
Weight of cylinder + sand after pouring(w2) 4384
Weight of sand in conical portion(Wc) 395
Weight of sand in hole(Wh=W1-W2-Wc) 1641
volume of pit (V=Wh/Density of sand) 1161.58
Bulk density=(W/V) 2.05
Rapid moisture meter reading= M 10
Field moisture content (%) by RMM reading 0.1
Field dry density FDD(g/cc) 1.87
Camber check for Subgrade
Sl no Chainage(mt) LHS Camber (%) Chainage(mt) RHS Camber (%)

1 2140 2.6 2090 2.7

2 2200 2.3 2170 2.5
3 2260 2.5 2230 2.4
4 2320 2.5 2290 2.3
5 2380 2.5 2350 2.4
6 2440 2.7 2410 2.6
7 2500 2.4 2470 2.7
8 2560 2.7 2530 2.5
9 2620 2.5 2590 2.5
10 2680 2.4 2650 2.5
11 2740 2.5 2710 2.5
12 2800 2.4 2770 2.7
13 2860 2.7 2830 2.7
14 2920 2.6 2890 2.5
15 2980 2.5 2950 2.5
16 3040 2.4 3010 2.5
Granular Sub-base Course / Drainage Layer
Physical requirements of materials
Maximum limits allowed for GSB materials test results as per MoRT&H (V Revision) Specifications

Aggregate impact value IS 2386 (part-4) 40 % maximum

Liquid limit of material passing Max 25 %

0.425mm
IS 2720(part5)

Plasticity index of fines passing Max 6 %

0.075mm

CBR @ 98% of dry density Min 30% unless otherwise

(at IS:2720-Part 8) specified in contract
Gradation of GSB materials as per MoRT&H (V Revision) Specifications

IS Percent by weight passing the IS sieve

designation Grade Grade Grade Grade Grade Grade
I II III IV V VI
75.0mm 100 - - - 100 -
53.0mm 80-100 100 100 100 80-100 100
26.5mm 55-90 70-100 55-75 50-80 55-90 75-100
9.5mm 35-65 50-80 - - 35-65 55-75
4.75mm 25-55 40-65 10-30 15-35 25-50 30-55
2.36mm 20-40 30-50 - - 10-20 10-25
0.85mm - - - - 2-10 -
0.425mm 10-15 10-15 - - 0-5 0-8
0.75mm <5 <5 <5 <5 - 0-3
Construction of Granular Sub-base layer
The total thickness of GSB was laid in 2 layers thickness confined to GSB materials as per MoRT&H (V Revision)
Specifications
 Toe line and center line are marked and pegs are driven.

 Sub base material is dumped and spread to uniform thickness and specified cross slope using motor grader
by adjusting the blade of the grader.

 The moisture content of the material is checked and the additional quantity of water required to bring up
the OMC is sprinkled at an uniform rate using truck mounted sprinkler.

 The watered material is mixed properly using machinery such as disc harrows and rotavators.

 Mixed material is spread to the desired thickness, grade , and camber of 2.5% using a motor grader with
hydraulic controls of the blade.

 Material is compacted by rolling if the thickness is 100mm or lesser ordinary smooth wheel roller is used
if it is 100 to 225mm compaction is done by vibratory roller of static weight 10tonnes or more.

 Rolling is done starting from lower edge to towards the upper edge with minimum one third of
overlapping. Rolling is continued till at least 98% of maximum density of the material is achieved
Grading of GSB Rolling of GSB
Quality control checks of GSB

 Samples of gsb material is subjected to laboratory test to check the values of liquid limit, plasticity index,
gradation and deleterious constituents.

 Laboratory compaction test is carried out to determine the OMC and MDD.

 CBR value is determined.

 Field moisture content is determined prior to compaction and extra water is added to bring up to the OMC is
estimated.

 After rolling the field density and moisture content determined ,ensure that dry density achieved is not less
than 98%of lab density.

 The above steps are repeated for each subsequent layers and camber is checked for finished GSB layer and
camber of 2.5% should be maintained.
 Grain size analysis of aggregates used in GSB (On Site)
Road no: 1 Sampled at CH: 2150m
Sample Weight (gm) Wx: 10000grams Type of Material: GSB
Offset (from Median): 4.5m RHS

Sieve Size, as Weight Cumulative % of Standard

Sl. per Retained weight Cumulative % Gradation as per
No. MORT&H Retained weight Passing MORT&H Fifth
(gm)
Retained Revision
(mm) (gm)

1 53 mm 0 0 0 100 100

2 26.5 mm 968 968 9.68 90.32 75-100

3 9.5mm 50 - 80
2522 3490 34.9 65.1

4 4.75 mm 40-65
2108 5598 55.98 44.02

5 2.36mm 30-50
1202 6800 68 32
6 0.425mm 1880 8680 86.8 13.2 10-15

7 0.075 mm 878 9558 95.58 2.2 0-5

 Field density check by sand replacement method for Granular Sub-base
Lab OMC(%): 3.7 Lab MDD(g/cc): 2.35
Mean Weight of sand in cone(W2) 949
Volume of calibrating cylinder(V) 3536
Weight of Sand+cylinder (before pouring into the calibrating container)(W1) 17442
Mean Weight of sand+cylinder(after Pouring into the calibrating container)(w3)
11535
Weight of sand to fill calibrating container(wa=w1-w2-w3) 4958
Bulk density of sand(Ys=Wa/V) 1.40
Sl.no Description 1
1 Road NO 1
2 Chainage (m) 2210rhs
3 Weight of wet soil from hole w gm 6104
4 Weight of cylinder+sand before pouring(w1) 15638
5 Weight of cylinder+sand after pouring(w2) 11148
6 Weight of sand in conical portion(Wc) 949
7 Weight of sand in hole(Wh=W1-W2-Wc) 3541
8 volume of pit (V=Wh/Density of sand) 2525.20
9 Bulk density=(W/V) 2.42
10 Rapid moisture meter reading= M 4
11 Field moisture content (%) by RMM reading
0.04
12 Field dry density FDD(g/cc) 2.32
13 Degree of compaction(%) 98.90
Camber check for GSB Layer

Sl.no Chainage(mt) LHS Camber (%) Chainage(mt) RHS Camber (%)

1 2140 2.5 2090 2.6

2 2200 2.7 2170 2.6

3 2260 2.6 2230 2.5

4 2320 2.4 2290 2.4

5 2380 2.3 2350 2.4

6 2440 2.4 2410 2.6

7 2500 2.5 2470 2.6

8 2560 2.7 2530 2.5

WET MIX MACADAM
WMM Gradation as per MoRT&H
Maximum limits allowed for WMM materials test results
(V Revision) Specifications
as per MoRT&H (V Revision) Specification

Sl. Test Test method Requirement IS sieve size inn passing

No mm percent
53.0mm 100
1 Los Angeles Abrasion IS:2386 (PART 4) Max 40%
45.0mm 95-100
value or aggregate Max 30%
impact value 26.5mm -
22.4mm 60-80
2 Combined index IS:2386 (PART 1) Max 35%
11.2mm 40-60
3 Plasticity Index of Max 6% 4.75mm 25-40
material finer than
2.36nm 15-30
0.425mm sieve
0.6mm 8-22
0.075mm 0-5
Construction of WMM
Wet mix macadam of 250mm thickness was laid in two layers of 125mm each to get a compacted
thickness of 250mm.
 Compaction test is carried out in the laboratory using the selected grade of WMM material. The
optimum moisture content of the WMM mix is determined in the laboratory under heavy
compaction.

 The selected WMM mix (with water equal to the optimum moisture content) is prepared in a suitable
mixing plant like the “pug mill‟.

 The WMM mix is transported to the site and is spread using a self propelled type paver-finisher
machine or grader , to the required thickness, grade and cross slope of 2.5%.

 The WMM layer is compacted using a vibratory roller of minimum static wt. of 10 tonnes , the
compacted thickness of each layer should be less than 200mm.

 Rolling is done starting from the lower edge and proceeded towards the centre of the undivided
carriageway or towards the upper edge of the divided carriageway, with a minimum one third overlap
b/w each run of the roller; the rolling speed is limited to less than 5kmph.

 If the total design thickness of WMM base course is say 250mm, the base is constructed in two
layers, each of compacted thickness 125mm. After compaction of the first layer, the second layer is
laid and compacted by a vibratory roller as mentioned in steps (3) and (4) above rolling is continued
till 98% of density is achieved
 The WMM surface is checked for defects, if any and allowed to dry; no traffic shall be allowed before a bituminous
surface course is constructed.
 After the WMM layer is dried for at least 24 hours in dry weather, the preparation for laying a bituminous pavement
layer may start by applying the prime coat.

Grading of WMM

Finished WMM Surface

WMM gradation
 Quality control checks for WMM

 Samples of coarse aggregate are subjected to laboratory test to check los Angeles abrasion value ,
aggregate impact value flakiness and elongation index.

 Plasticity index is checked on the fraction of mixed aggregate that pass 0.425mm sieve.

 Gradation of coarse and fine aggregate is carried out at site.

 Laboratory compaction test is carried out to determine the OMC and MDD.

 The field density and moisture content of the compacted WMM layer are determined to ensure that
the dry density is achieved is not less than98% of std lab density.

 The finished surface levels of WMM base course are checked with reference to desired longitudinal
and cross profile of the road.
Road name: 1 Sampled at CH:2210m
Sample Weight (gm) Wx: 10000grams Type of Material: WMM
Offset (from Median): 3.5m RHS

Weight Cumulative % of Standard

Sieve Size, as Retained weight Cumulative Gradation as per
Sl. No. % Passing
per MORT&H Retained weight MORT&H Fifth
Retained Revision
1 53 0 0 0 100 100

2 45 18 18 0.18 99.82 95-100

3 22.4 3124 3142 31.42 68.58 60-80

4 11.2 2584 5726 57.26 42.74 40-60

5 4.75 1186 6912 69.12 30.88 25-40

6 2.36 722 7634 76.34 23.66 15-30

7
0.6 782 8416 84.16 15.84 8-22.

8 0.075 1020 9436 94.36 5.64 0-8

Field density check by sand replacement method for WMM
Lab OMC(%):4.9 Lab MDD(g/cc): 2.39

Mean Weight of sand in cone(W2) 956

Volume of calibrating cylinder(V) 3542
Weight of Sand+cylinder (before pouring into the calibrating container)(W1) 17520
Mean Weight of sand+cylinder(after Pouring into the calibrating container)(w3) 11535
Weight of sand to fill calibrating container(wa=w1-w2-w3) 5029
Bulk density of sand(Ys=Wa/V) 1.42

Sl.no Description 1
1 Road NO 1
2 Chainage (m) 2280 rhs
3 Weight of wet soil from hole w gm 7190
4 Weight of cylinder+sand before pouring(w1) 16348
5 Weight of cylinder+sand after pouring(w2) 11294
6 Weight of sand in conical portion(Wc) 956
7 Weight of sand in hole(Wh=W1-W2-Wc) 4098
8 volume of pit (V=Wh/Density of sand) 2886.28
9 Bulk density=(W/V) 2.49
10 Rapid moisture meter reading= M 6
11 Field moisture content (%) by RMM reading 0.06
12 Field dry density FDD(g/cc) 2.35
13 Degree of compaction(%) 98.33
Camber check for WMM Layer

Chainage(mt) Chainage (mt)

Sl.no Camber (%) Camber (%)
LHS RHS
1 2140 2.6 2190 2.7
2 2200 2.3 2220 2.5
3 2260 2.5 2280 2.4
4 2320 2.5 2350 2.3
5 2380 2.5 2390 2.4

6 2440 2.7 2460 2.6

7 2500 2.4 2520 2.7
8 2560 2.7 2580 2.5
9 2620 2.5 2640 2.6
10 2680 2.5 2700 2.5
11 2740 2.5 2760 2.4
12 2800 2.4 2820 2.3
13 2860 2.5 2880 2.4
14 2920 2.5 2940 2.5
 Prime Coat

• In the present work RS I at a spaying rate of 0.60 kg /sqm is used.

Rate of spraying the bitumen emulsion on WMM surface is as per MoRT&H (V Revision) Specifications

Type of surface Rate of spray, kg/m2

WMM/WBM 0.7 to 1.0
Stabilized soil bases, crusher run macadam 0.9-1.2

Application of Prime coat

Tests of Prime coat applied for Different Road Stretches

Required Rate of spray is 0.6 Kg/m2 Type of material: RS1 emulsion

Type of coat: Prime-coat
Roads Chainage (m) Offset Wt. of Wt. of tray Wt. of Area of tray Rate of Average
(m) tray + sample sample (m2) Results
(g) (g) application
LHS RHS (g) (kg/m2)
(kg/m2)

Road 1 2170 1 856 918 62 0.0902 0.66 0.66

2260 3.7 864 921 57 0.0876 0.68
2420 6.3 856 915 59 0.0902 0.64

2620 3 864 923 59 0.0876 0.67

2760 6.7 856 914 58 0.0902 0.64

2950 1.5 856 916 60 0.0902 0.67

 Tack Coat:
RS I grade cationic bitumen emulsion satisfying IS 8887 is used or low viscosity grade of bitumen (VG 10
satisfying IS 73) used. In the present work 80/100 (VG 10) with a spraying rate 4 kg / 10sqm is used.
Rate of Application of Tack Coat as per MoRT&H (V Revision) Specifications
Type of surface Rate of spray in kg/m2

Bituminous surface 0.2-0.3

Granular surfaces treated with primer 0.25-0.3
Cement concrete pavement 0.3-0.35

Application of Tack coat

Tests of Tack coat applied for Different Road Stretches

Required Rate of spray is 0.4 Kg/m2 Type of material: VG-10

Type of coat: Tack-coat
Roads Chainage Offset Wt. of Wt. of tray Wt. of Area of tray Rate of Average
(m) (m) tray + sample sample (m2) Results
(g) (g) application
(g) (kg/m2)
LHS RHS (kg/m2)

Road 1 2170 1 856 894 38 0.0902 0.42 0.43

2360 3.7 864 904 40 0.0876 0.45

2420 6.3 856 891 35 0.0902 0.38

2620 3 864 905 41 0.0876 0.47

2760 5 856 894 38 0.0902 0.42

2950 4.5 864 903 39 0.0876 0.44

 Dense Bituminous Macadam
• In present work 60/70 Grade bitumen is used and the thickness of DBM II
• For 100mm thickness, two layers of 66.5mm layer loose thickness adopted to get a compacted thickness of 50mm.
So, the total thickness of DBM is 100mm

Materials
Bitumen:
• The viscosity graded paving bitumen VG-30 satisfying the requirements as per IS 73 was used in the present work.
Selection criteria for viscosity graded paving bitumen based on climatic conditions.

Lowest daily mean air temp Highest daily mean temperature 0C

0C
Less than 20 20-30 More than 30

-100 C or higher VG-10(40-60 VG-20(60-80 VG-30(60-70

penetration) penetration) penetration)
Lower than -100C VG-10(40-60 VG-10(40-60 VG-20(60-80
penetration) penetration) penetration)
 Coarse aggregates:
• The crushed aggregates were used as coarse aggregates in the project.

Physical Requirements for Coarse Aggregates for Dense Bituminous Macadam as per MoRT&H (V Revision)
Specifications
Property Test Specification Testing method

Cleanliness Grain size analysis Max 5% passing through IS 2386 part 1

0.075mm sieve

Particle shape Combined index Max 35% IS 2386 part 1

Strength Loss angle abrasion value Max 35% IS 2386 part 4

Aggregate impact value Max 27%
Durability Soundness IS 2386 part 4
Sodium sulphate Max 12%
Magnesium sulphate Max 18%
Water Water absorption Max 2% IS 2386 part 3
absorption
Stripping Coating and stripping of Min retained coating 95% IS 6241
bitumen aggregate mixture

Water Retained tensile strength Min 80% AASHTO 283

sensitivity
 Fine aggregates:

• In the present work M-sand is used which is free from dust particles and should be hard and durable. The
materials passing through 2.36mm sieve and retained on 75 micron sieve is used.
Aggregate grading and binder content:
Grading 1 2
Nominal max aggregate 37.5mm 26.5mm
size
Layer thickness 75-100mm 50-75mm
IS sieve in mm Cumulative % by weight of total aggregate passing
45 100 -
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
4.75 38-54 38-54
2.36 28-42 28-42
0.3 7-21 7-21
0.075 2-8 2-8
Bitumen content percent Min 4.0 Min 4.5
by mass of total mix
 Lab reports of DBM

For DBM : OBC is 4.8

Material A 40mm down is 18%.
Material B 25mm down is 20%.
Material C 10mm down is 18%
Material D 4.75mm down is 42%
Filler-cement 2%
A : B : C : D = 18% :20% :18% :42%
Construction steps involved for DBM layer:
Preparation and Transportation of Mix

• The Individual bins of hot mix plant should be calibrated for the particular size of material.
• Material is fed to the mixing plant bins provided for individual sizes of aggregates to meet the required gradation.
• The temperature of binder at the time of mixing should be in the range of 160-170 degree centigrade and the
aggregate in the range 150-170 degree centigrade. The difference between the aggregate temperatures shall not
exceed 14 degree centigrade any time.
• The Mixed material temperature should be in the range of 150-165 degree centigrade.
• The mix will be transported to the site with Tippers properly covered with tarpaulins.
Preparation of Base:
• The sub base is checked for proper lines and levels and the surface must be swept free from dust.
• The tack coat is to be provided if the WMM surface was primed and left for 24hours
Laying of DBM:
• The mix will be laid with paver finisher.
• The laying temperature of Mix must be minimum 140 degree centigrade.
• The mix will be laid manually in places where the paver movement is not possible.
• The rolling is done with 80-100 KN smooth wheeled tandem rollers, 12-15 tones pneumatic tyres roller.
Laying of DBM Rolling of DBM Camber check

Temperature check Bitumen extraction Thickness check

Quality control tests for Dense Bituminous Macadam
 Checking of the DBM material for gradation by carrying the material from the Hot Mix Plant it satisfies the
requirement as per MoRT&H specifications.

 In field or in plant the bitumen extraction test is to find out the percentage of bitumen content in the mix as per the
requirement

 The mixing of the DBM material temperature is maintained to 150-165 0C as per specification.

 The minimum laying for DBM mix temperature is 140 0C is maintained.

 The minimum rolling temperature layed on the WMM surface is above 90 0C.

 By using thickness gauge at regular intervals check the thickness of the DBM while laying. The loose thickness is
kept 33% more than the compacted thickness.

 Camber is checked for regular intervals, as per the requirement 2.5% is specified and if any irregularity is found
checked using 3m straight edge.
 Bitumen Extraction Tests for DBM layer
Tested Site,Ch:2200m lhs Type of material: DBM
GRADE -2
Type of work: Bitumen Extraction

Sl.no Description Road 1

2 Total wt. of mix before extraction (g) 500

3 Wt. of mix after extraction (g) 476.9

4 Wt. of filter paper before extraction (g) 8.4

5 Wt. of filter paper after extraction (g) 8.85

9 Bitumen content (%) 4.8

 Gradation at site
Road No- 1 Chainage: 2200m,lhs
Sample Weight: 470g Type of material: DBM
Offset from Median: 4.5m

Sieve Size Weight Cumulative Wt. % Cumulative wt. % Passing Grade II

(mm) retained retained W2 (g) retained W3= (MoRT&H Vth
W1 (g) (W2/Wx) ×100 Revision)

37.5 100
0 0 0 100
26.5 90-100
12 12 2.55 97.45
19 71-95
14.2 26.2 5.57 94.43
13.2 56-80
113.8 140 29.79 70.21
4.75 38-54
132.2 272.2 57.91 42.09
2.36 28-42
53.8 326 69.36 30.64
0.3 7-21
84.6 410.6 87.36 12.64
0.075 4.2 450.8 95.91 4.09
2-8
Camber check for DBM layer

Sl.no Chainage(mt) LHS Camber (%) Chainage(mt) RHS Camber (%)

1 2140 2.6 2190 2.5

2 2200 2.5 2220 2.5
3 2260 2.5 2280 2.3
4 2320 2.4 2350 2.6
5 2380 2.3 2390 2.3
6 2440 2.5 2460 2.4
7 2500 2.3 2520 2.6
8 2560 2.5 2580 2.4
9 2620 2.4 2640 2.3
10 2680 2.3 2700 2.4
11 2740 2.4 2760 2.3
12 2800 2.3 2820 2.4
13 2860 2.5 2880 2.5
14 2920 2.5 2940 2.4
15 2980 2.5 3000 2.5
16 3040 2.6 3040 2.5
Bituminous Concrete
The bituminous concrete surface is the surface which is in direct contact with the tyres of the vehicle. So its
quality should be high as for as possible. In the present work BC II of 40mm thickness was provided.
Materials
Bitumen:

In our project 60/70 penetration grade bitumen is used.

Coarse aggregates:

The crushed aggregates are used as coarse aggregates.

Fine aggregates:

M-sand is used as fine aggregates. Other materials like crushed rocks, natural gavel may be used after
satisfying the MoRT&H specifications.
Filler:

Filler may be cement, lime or rock dust.

 Gradation of BC as per MoRT&H (V Revision) Specifications

Grading 1 2
Nominal aggregate size 19mm 13.2mm
Layer thickness 50 mm 25/40 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45 - -
37.5 -
26.5 100
19 79-100 100
13.2 59-79 79-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content % by mass 5.2 5.4
of total mix
 Lab report of BC

For BC: OBC is 5.8%

Material A 20mm down is 12%.
Material B 12.5mm down is 24%.
Material C 6mm down is 6%
Material D 4.75mm down is 56%
Filler-cement 2%

A : B : C : D = 12% : 24% : 6% : 56%

 Bitumen Extraction Test for BC layer
Tested Site,ch:2370 at rhs Type of material: BC GRADE -2

Type of work: Bitumen Extraction

Sl.no Description Road 1

2 Total wt. of mix before extraction (g) 500

3 Wt. of mix after extraction (g) 469.7

4 Wt. of filter paper before extraction (g) 9.1

5 Wt. of filter paper after extraction (g) 9.6

6 Bitumen content (%) 5.96

 Sample Weight: 475g Type of material: BC
Ch:2370 ar rhs

Sieve Size Weight Cumulative Wt. % Cumulative wt. % Passing Grade II

(mm) retained retained W2 (g) retained W3= (W2/Wx) (MoRT&H Vth
W1 (g) ×100 Revision)

19 0 0 0 100 100
13.2 14.6 14.6 3.24 96.76 79-100
9.5 88.2 102.8 22.84 77.16 70-88
4.75 92.5 195.3 43.40 56.60 53-71
2.36 42.1 237.4 52.76 47.24 42-58
1.18 33 270.4 60.09 39.91 34-48
0.6 41.2 311.6 69.24 30.76 26-38
0.3 38.9 350.5 77.89 22.11 18-28
0.15 39.2 389.7 86.60 13.40 12-20
0.075 41.1 430.8 95.73 4.27 4-10
Camber check for BC layer

Chainage(mt)
Sl.no Camber (%) Chainage(mt) RHS Camber (%)
LHS
1 2140 2.5 2110 2.5
2 2200 2.5 2170 2.3
3 2260 2.5 2230 2.4
4 2320 2.4 2290 2.4
5 2380 2.4 2350 2.4
6 2440 2.4 2410 2.2
7 2500 2.4 2470 2.4
8 2560 2.4 2530 2.6
9 2620 2.4 2590 2.5
10 2680 2.5 2650 2.5
11 2740 2.5 2710 2.5
12 2800 2.5 2770 2.3
13 2860 2.4 2830 2.2
14 2920 2.5 2890 2.4
15 2980 2.5 2950 2.4
16 3040 2.4 3010 2.6
Rolling of BC using Dual Drum Roller Finished pavement
Hot Mix Plant
 CONCLUSION

1.The construction procedure was followed as per MoRT&H( 5th revision) specification.
2. The sub grade was laid and compacted in two layers of 150mm thickness each to the required density of 97% and camber of 2.5%
3.In the present work, two layers of 199.5mm each layer loose thickness was adopted to get a compacted thickness of 150mm (one layer).
So, that the total thickness of sub grade achieved was 300mm.
4. Non plastic material was used for GSB (Grade II) to take care of sub surface drainage
5.GSB was laid in two layers of 130mm (drain to drain) and 100mm compacted thickness confined to Coarse Grade II of GSB materials to
get a compacted thickness of 230mm, the bottom of GSB was connected to 110mm diameter weep holes in the drain.
6.The GSB layers were graded and compacted until density of 98% and camber of 2.5% was achieved with a total thickness of 230mm and
allowed for laying of WMM.
7. The WMM was laid in two layers after checking the gradation in site. Both the layers of 125mm compacted thickness were provided to
get total compacted thickness of 250mm.
8. The WMM layers were compacted to the required thickness, density of 98% and camber of 2.5% and allowed for the application of
prime and tack coat.
9.The DBM laid in 2 layers of each 50mm thickness to total compacted thickness 100mm (75mm is specified as per DPR) and camber of
2.5%.
10.BC layer provided was 40mm compacted thickness and camber 2.5%.The Bitumen extraction test was conducted to check bitumen
content for DBM and BC mix.Temperature during the laying, rolling and mixing was maintained according to MoRT&H specifications.
11. Gradation test was performed at regular intervals before laying of GSB , WMM , DBM and BC in order to check the Gradation of
material.
12. Field Density was checked for subgrade, GSB and WMM by sand replacement method so that compaction was achieved as per
requirements and rapid moisture content test was conducted to determine moisture content by Calcium Carbide method.
 REFERENCES
1. Khanna.S.K, Justo.C.E.G, “Highway Engineering”, New Chand & Bros-2001.
2. MoRT&H, “Ministry of Road Transport & Highway Specification for Road & Bridge Works”, Revision 5.
3. IRC: 37-2012, “Guidelines for Design of Flexible Pavements”.

4. Detailed Project Report of Harohalli Industrial Area.

5. Highway material testing laboratory manual, Khanna.S.K and Justo.C.E.G.

THANKYOU