HINDUSTAN PETROLEUM CORPORATION LIMITED

LONI TERMINAL REVAMPING PROJECT CIVIL WORKS

STANDARD SPECIFICATION FOR WBM AND BITUMEN PREMIX ROADS

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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HINDUSTAN PETROLEUM CORPORATION LIMITED

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CONTENTS

1.0 SCOPE

2.0 REFERENCE CODES AND STANDARDS

3.0 EARTHWORK IN FILLING

4.0 FILLING WITH MURRUM/SAND

5.0 WBM SUB-BASE/BASE COURSE

6.0 CONSTRUCTION OF SHOULDERS OF BERMS

7.0 BITUMEN PREMIX CARPET

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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1.0 SCOPE This specification covers the material and construction details for earthwork in filling for embankments, filling with sand/murrum, WBM sub-base, WBM base course and shoulders for roads and flexible pavements. 2.0 2.1 REFERENCE CODES AND STANDARDS B.I.S. Specifications. IS: 2720 Methods of Test of Soil. 2.2 Indian Road Congress Standards. IRC: 19 Standard Specification and Code or Practice for Water Bound Macadam 3.0 3.1 EARTH WORK IN FILLING Material Only material considered suitable by the Engineer-InCharge shall be employed for the construction and that considered unsuitable shall be disposed off as directed by Engineer-In-Charge at his own cost and no claim for compensation will be entertained. The contractor shall give the samples of earth, he proposes to use for filling along with the following characteristics of the sample to
STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS PAGE 3 OF 26

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Engineer-In-Charge prior to collection and use, for approval. i) Mechanical analysis or gain size analysis as per IS: 2720 Part IV. Liquid limit as per IS: 2720 Part V. Plastic Limit as per IS: 2720 Part V.

ii) iii)

iv) Moisture density relationship as per IS: 2720 Part VIII. The material (murrum) used for filling shall be free from boulders, lumps, tree roots, rubbish or any organic deleterious matter. Murrum having standard proctor laboratory maximum dry density less than 1.8 gm/cc shall not be used. The murrum shall have a Plasticity Index of 5-24(medium Plastic) and not more than 20% Fines i.e., Clay. Care shall be taken to see that unsuitable waste material is disposed off in such a manner that there is no likelihood of its getting mixed with the materials proposed to be used for filling. The work shall be so planed and executed such that the best available material is reserved for the top portion of embankment.
STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS PAGE 4 OF 26

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3.2 3.2.1

Filling for Embankments and Shoulders The area where filling is to be placed must be cleared of all loose material and virgin soil must be exposed. Such exposed surface must be consolidated properly to obtain 90% of maximum laboratory dry density of the soil. All soft patches must be worked out to remove the soft soil and selected approved earth must be filled back and compacted. Payment for the removal of loose top soil as described in clause 3.2.1 above shall be included in the item for earth work in filling. No separate payment for consolidation of exposed ground surface will be made. The rate quoted for the earth fill shall be inclusive of the cost of clearing and stripping, consolidation including watering, testing etc. of the exposed ground. Approved fill material (murrum) shall be spread in uniform layers not exceeding 20 cms in loose depth for embankment filling. Shoulder construction shall be so organized as to keep pace with the construction of different layers of the pavement, which may require fill thickness less than 20cm. All clods, lumps etc. shall be broken before compaction. In general the murrum shall be spread uniformly over the entire width of embankment or shoulders as the case may be. For large embankments, the spreading of soil shall be as directed by the Engineer-In-Charge.
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3.2.2

3.2.3

3.2.4

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

HINDUSTAN PETROLEUM CORPORATION LIMITED

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3.2.5

Successive layers of filling shall not be placed until the layer under construction has been thoroughly compacted to satisfy the requirements laid down in this specification. Prior to rolling, the moisture content of material shall be brought to within plus or minus 2% of the optimum content as described in IS: 2720 Part-VIII. The moisture content shall preferably be on the wet side for potentially expensive soils. After adjusting the moisture content as described in Clause 3.2.6, the layers shall be thoroughly compacted by means of rollers till 95% of modified proctor density is obtained as per IS:2720 Part VIII. Each layer shall be tested in field for density and accepted by Engineer-In-Charge subjected to achieving the required density before laying the next layer. A minimum of one test as per 500 M 2 areas for each layer shall be conducted. All type of rollers that should be employed for compaction shall be as per direction of Engineer-In-Charge.

3.2.6

3.2.7

3.2.8

3.2.9

3.2.10 If the layer fails to meet the required density, it shall be reworked to the material shall be replaced and method of construction altered as directed by Engineer-In-Charge to obtain the required density.

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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3.2.11 The filling shall be finished in conformity with alignment, levels, cross-section and dimensions as shown in the drawings.

3.2.12 Extra material shall be removed and disposed off as by Engineer-In-Charge. 3.2.13 Tolerance Embankment and shoulders for roads, units etc. shall be carried to within a tolerance of cm. from final lines but shall be to required roads and slopes. 3.3 3.4.1 Payment Payment for filling shall be made on cubic meter of volume calculated on the basis of cross-section plotted from the level of the ground surface prepared as described inn clause 3.2 above and from where filling is to be carried out and the levels reached after filling and due consolidation. Rates of embankment shoulder or fill formation shall include cost of breaking clods, watering, consolidation, providing testing apparatus and testing the degree of consolidation, providing and operating, including POL and operator charges of necessary road rollers and other equipment, dressing and leveling of sides and top surfaces etc.
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3.4.2

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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4.0 4.1

FILLING WITH SAND/MURRUM Sand for filling shall preferably the locally available sand, clean and free from any chemical or other impurities. Murrum for filling shall be clean and well graded. Sand/Murrum shall not contain any vegetation, organic, clayey or other material and shall be obtained from a source approved by Engineer-In-Charge. Murrum/Sand shall be spread in layers not exceeding 20 cm in loose thickness over the areas. Each layer shall be uniform in density, quality of material and moisture content as per IS: 2720 Part VIII.

4.2

4.2.1 4.3

In case of pure sand, flooding with water is permissible. Compaction of each layer shall be by mechanical means as per directions of Engineer-In-Charge. Only in accessible reaches shall be worked manually. Each layer shall be uniformly compacted obtain 95% of modified proctor density of the material. If the material fails to achieve the required density, the layer shall be reworked with necessary alteration in compaction, so that the required compaction is obtained. A minimum of one test as per 500 M 2 areas for each layer shall be conducted. Subsequently layers shall be placed only after the layer already laid has been compacted to the required density and approved by Engineer-In-Charge.
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4.4

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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4.5

The finished surfaces must be dressed to required grade and slope. Excess material must be removed from compaction site, as directed by Engineer-In-Charge. Payment Payment for sand/murrum filling shall he made on the basis of volume of fill, after placement and compaction. The rate quoted shall include cost of sand/murrum, royalties, transportation, handling, compacting, watering, testing at various stages, dressing removal of surplus material and any other incidental to this.

4.6

5.0

WATER BOUND MACADAM SUB BASE/BASE COURSE The sub-base course shall consist of one or more layers, each or 100 mm compacted thickness. The base course shall consist of one or more layers, each of 75 mm compacted thickness. Stone Aggregate for WBM

5.1

5.1.1

The coarse aggregate shall be hard, crushed or broken stone metal from quarries approved by Engineer-InCharge, it shall be hard durable and free from flat elongated, Soft and disintegrated particles. It shall not have excess of dirt and other objectionable matter. The quality, size, and grading of the coarse aggregate shall be
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STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

HINDUSTAN PETROLEUM CORPORATION LIMITED

LONI TERMINAL REVAMPING PROJECT CIVIL WORKS

conforming to IRC 19: STD Spec and code of practice for WBM. a) The grading of the coarse aggregate for the sub-base course shall be as follows:

Size Range

90mm to 45mm Grade-1

Sieve Designation(IS: 460) 125 MM 90 MM 63 MM 45 MM 22.4 MM

% by weight Passing the sieve 100 90-100 25-60 0-15 0-5

b) The grading of the coarse aggregate for the base course shall be as follow: Size Range Sieve Designation(IS: 460) 90 MM 63 MM 53 MM 45 MM 22.4 MM % by weight Passing the sieve 100 90-100 25-75 0-15 0-5

63mm to 45mm Grade-2

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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5.1.2 a) Physical requirement of coarse aggregates for sub-base course shall be as below: i)Los Angles Abrasion Value-60% (Maximum) Or ii)Aggregate Impact Value -50% (Maximum)

b)

Physical requirement of coarse aggregates for base course shall be as below:

i)Los Angles Abrasion Value-50% (Maximum) Or Aggregate Impact Valueii) 40% (Maximum)

Flakiness index value -15% (Maximum)

Samples of test shall be representative of the material to be used and collected as per IS: 2430. 5.1.3 The aggregate shall be stacked at the road sided on firm, well drained ground in regular stacks, as directed by Engineer-InCharge. The various grades shall be stacked separately and
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contamination by earth and other extraneous matter shall be prevented effectively.

5.2 Binding Material Murrum 5.2.1 The binding material shall be clean, dry murrum free from leaves, organic matter any deleterious material.

5.2.2 It shall be obtained from quarries approved by Engineer-InCharge. 5.3 Spreading Coarse Aggregates 5.3.1 The sub grade or sub-base to receive WBM coarse shall be prepared to the required grade and camber. Before starting with WBM construction, side shoulders shall be constructed in advance to a thickness corresponding to the compacted layer of the WBM coarse for lateral confinement of aggregate. After shoulders are ready, their inside edge shall be trimmed vertical to receive the aggregate. The practice of constructing WBM in a trench section excavated on the embankment/formation must be avoided. 5.3.2 The coarse aggregate shall be spread uniformly and evenly on the prepared base in required quantities from the stacks. The aggregate shall be spread to proper profiles by using templates across the road about 6m apart.

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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5.3.3 The surface of the aggregate spread shall be carefully, trued up and all high or low sports remedied by removing or adding aggregate as may be required. The surface shall be checked from time to time, during the spreading and rolling of the coarse aggregate to ensure a finished surface without variation greater than 12 mm, when a 3 meter long straight edge is laid parallel to centre line of the road. 5.3.4 The WBM layer shall be tested by depth blocks. No segregation on large or fine particle shall be allowed and the coarse aggregate as spread shall be of uniform gradation with no pocket of fine materials. 5.3.5 The coarse aggregate shall not be spread in lengths more than 3 days average work in advance of the rolling, spreading murrum and bonding o f the preceding section.

5.4 Rolling Road Metal 5.4.1 Immediately following the spreading of the coarse aggregate, it shall be compacted to full width by rolling with either three wheeled power roller of 8 to 10 tone weight or equivalent vibratory roller true to the line and camber as shown inn the drawing. The course shall not be rolled when the sub-grade is soft or yielding or the rolling causes a wave like motion in the base course or sub-grade. When rolling develops irregularities that exceed 12mm when tested with a 3 meter straight edge, the irregular, surface shall be loosened and then aggregate added to or remove from it as required and the area rolled until it gives uniform surface conforming to the desired
STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS PAGE 13 OF 26

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cross-section and grade. The surface shall also be checked transversely by template and any regulates corrected as above. The use of murrum to make up depression shall not be permitted. 5.4.2 The rolling shall begin from edges with roller running forward and backward until the edges have been firmly compacted. The rolling shall then progress gradually from edges to the centre parallel to the centre line of the road lapping uniformly each proceeding rear wheel track by one half widths and shall continue until the entire area of the course has been rolled by the rear wheel. On the super elevated portion of road, the rolling shall commence from the lower edge and progress gradually towards the upper edge of the road. 5.4.3 Rolling shall be discontinued when aggregate are thoroughly keyed and creating of stone wheel of roller is no longer visible partially compacted with sufficient void space in them to permit application of screenings. Slight sprinkling of water may be done if required. 5.5 Screenings 5.5.1 Material Screening to fill the voids in the coarse aggregate shall, as far as possible be the same material as the coarse aggregate. Where it is decided by the Engineer-In-Charge to use other materials, the same shall be predominantly non plastic materials such as Kankar nodules, gravel (other than riverSTANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS PAGE 14 OF 26

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born rounded aggregate) or murrum, provided that the liquid limit and plasticity index of such material is below 20 and 6 respectively, and the fraction passing 75 micron siever does not exceed 10 percent. 5.5.2 Grading requirements of screenings

Size of Screening

Siever Designation (IS:460) 13.2mm 11.2mm 5.6mm 180 micron

Percent by weight passing the sieve 100 95-100 15-35 0-10

13.2mm

This grading however shall not be mandatory, in case either murrum or gravel is used as screenings. 5.6 Application of Screenings 5.6.1 After the coarse aggregate has been rolled as described in Clause 5.3, screenings shall be applied uniformly and gradually over the surface to completely fill the interstices. Dry rolling shall be continued while the screenings are being
STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS PAGE 15 OF 26

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spread so that the jarring effect of the roll will cause them to settle into the voids of the coarse aggregates. 5.6.2 The screening shall not be dumped in piles on coarse aggregate but shall be spread uniformly in successive thin layers either by the spreading motion of hand shovels or by mechanic spreaders.

5.6.3 The screenings shall be applied at a uniform and slow rate (in three or more applications so as to ensure filling of all voids. Rolling and brooming shall continue with the spreading of the screenings. Either mechanical brooms or both may be used. In no case shall the screenings be applied so fast and thick as to form cakes or ridges on the surface making the filling of voids difficult or preventing the direct bearings of the roller on the coarse aggregates. The spreading, rolling and brooming of screenings shall be performed on sections which can be completed within one days operation and shall continue until no more screening can be forced into the voids of the coarse aggregates. Damp and wet screening shall not be used under any circumstances. 5.6.4 The quantity of screenings used shall be such as to fill all voids in the water bound macadam courses. 5.7 Sprinkling and Grouting 5.7.1 After spreading the screenings, the surface shall be copiously sprinkled with water, swept and rolled. Hand brooms shall be used to sweep the wet screening into voids and to distribute
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them evenly. The sprinkling, sweeping and rolling shall be continued and additional screenings applied where necessary until the coarse aggregate are well compacted and grout of screenings and water form a wave ahead of wheels of the roller. Care shall be taken to see that the base of sub-grade does not get damaged due to the addition of the excessive quantity of water during the construction. 5.8 Binding Material 5.8.1 Binding material to prevent reveling of WBM shall consist of fine grained material possessing P.I. Value upto 6. 5.8.2 Application of binding material shall not be necessary where murrum or gravel is used as screenings.

5.8.3

Binding material shall be obtained from quarries/sources approved by the Engineer-Ion-Charge.

5.9 Application of Binding Material 5.9.1 After the application of screenings as described above the binding material shall be applied at a uniform and slow rate (in two or more successive thin layers) so as to ensure filling of all voids. After each application of binding material, the surface shall be copiously sprinkled with water and the resulting slurry swept in with hand brooms/mechanical brooms or both so as to fill the voids properly. This shall be followed by rolling
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with 1 6-10 tonne roller during which water shall be applied to the wheels to wash down the binding material that may get stuck to them. The spreading, rolling and brooming of binding material shall be performed on section which can be completed within one days operation and shall continue until no more binding material can be forced into the voids of the coarse aggregates until the slurry of binding material and water forms a wave ahead of the wheels of moving roller. Damp and wet binding material shall not be used under any circumstances. 5.9.2 The quantity of binding used shall be such as to fill all voids in the water bound macadam. 5.9.3 Payment Payment for laying WBM shall be made on square meter basis of each layer of WBM laid, measured after consolidation and finishing. Rate shall include supply of all materials, royalty, taxes, handling, transportation, stacking, spreading metal in layers, including screening, consolidation by power roller, binding with murrum or other approved binding material, cost of carrying the material from stack to work for all leads and lifts, providing and running roller etc. complete as per specification and satisfaction of Engineer-InCharge.

5.9.4 Subsequent Layers of WBM

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Before laying the subsequent layers of WBM, the surface shall be scarified and reshaped to the required camber and profile and all ruts, depressions pot holes etc. made good. The second layer shall be laid after the surface preparation is approved by Engineer-In-Charge. The specification and mode of measurement for subsequent layers of WBM will be similar to that described before. 5.9.5 Payment Payment for surface preparation, rectification of damaged portions of proceeding layers of water bound macadam and filling in ruts and depressions shall he made in M2 or M3 as per schedule of items. Payment for subsequent layer of WBM shall be made on M2 as per CI.5.9.3 6.0 CONSTRUCTION OF SHOULDERS OR BERMS 6.1 After the WBM course is laid and compacted, the existing surface at side berms or shoulders of the roadway must be scarified. Fresh quantity of approved earth must he spread in layers for building up of berms upto the required level and scope. The earth must be consolidated by at least three passes of an 8-10 tonne road roller. The edges must be well consolidated by suitable means to prevent edge slips and the work properly trimmed and dressed. 7.0 BITUMEN PREMIX CARPET 7.1 Material
STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS PAGE 19 OF 26

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7.1.1 Coarse aggregate The aggregate shall consist of crushed stone of Clean, hard, tough, durable rock of uniform quality and shall be clean, free from excess of dust, flat or elongated pieces, soft or disintegrated stone, clay or other deleterious matter. The size of aggregate shall be as below Coarse aggregate P h y 1. for 35 mm thick s 1st layer) i 2. for 15 mm thick c nd 2 layer) a size Quantity required per 100 m2 of premix bituminous carpet

25 mm and downsize 12 mm and downsize

5.5 m3 2.0 m3

The grading for the coarse aggregates mentioned above for premix carpet shall comply with respective IRC code. Physical requirement of coarse aggregates for premix bituminous carpet shall be as below:

i)Los Angles Abrasion Value-40% (Maximum) Or Aggregate Impact ValueSTANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

35% (Maximum)
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ii)

Flakiness index value -30% (Maximum)

Samples of test shall be representative of the material to be used and collected as per IS: 2430. 7.1.2 Binder The Binder shall be bitumen of penetration 80/100 conforming to IS: 73. The bitumen shall be collected on road side drums. Any drum leaking or damaged shall not be accepted. Quantity of bitumen required per 100 m2 premix carpet will be as given below: Quantity required per 100 m2 of premix carpet 269 kg 110 kg

Bitumen 80/100 grade 1. for 35 mm thick 1st layer 2. for 15 mm thick 2nd layer

7.2. LAYING 7.2.1 Preparation of Road Surface

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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The existing surface shall be thoroughly cleaned of dust, loose materials caked mud and foreign matter with the help of wire brush, chisel, picks etc., before laying the tack course. The cleaning shall be carried out in such a manner as to expose the stone metal to a depth of 1 to 2mm without dislodging the interlocking of the metal. All dust and other material thus removed shall be carried away and dumped at suitable places as directed by the Engineer-in-charge. 7.2.2 If Pot holes or ruts are found on the existing road surface, these irregularities must be filled in with premix chippings and will rammed about a week before the carpet is laid.

7.3 Tack Coat 7.3.1 The bitumen shall be heated in asphalt boiler to 177 188 C and shall be spread uniformly at the rate of 1 kg/m by the means of sprayers. The applied binder shall be evenly spread. The tack coat shall be applied just ahead, keeping pace with laying of premix carpet.

7.3.2

7.4 Preparation of Premix 7.4.1 50 mm thick asphalt bituminous carpet should be laid in two layers of 35 mm and 15 mm thickness with following specifications.

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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Ist Layer (35 mm thick) coarse aggregate 25 mm and downsize @ 5.5m3 and 80/100 grade bitumen @ 269 kg per 100 m2 of premix carpet. II nd Layer (15 mm thick) coarse aggregate 12 mm and downsize @ 2.0 m3 and 80/100 grade bitumen @ 110 kg per 100 m2 of premix carpet. 7.4.2 Mechanical Mixers shall be generally used for preparation of premix improvised hand mixing drums may be used if permitted by the Engineer-in-charge. Stone chippings of specified size shall be thoroughly mixed dry in the Mixer at the rate indicated above. Binder heated at temperature suitable for the grade of bitumen is added to the mixer drum at the specified rate per 100m of surface and thoroughly mixed till the stone chips are completely coated with the Binder. The premix shall be emptied on the wheel barrows or stretchers and carried to work site.

7.4.3

7.4.4

7.5 Spreading of Premix Immediately after applying the tack coat, the premix shall be spread in two layers as mentioned above with rakes to the required thickness land distributed evenly by means of a drag spreader. The camber shall be checked by means of camber board and the unevenness shall be rectified.

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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7.6 Rolling 7.6.1 When the premix has been laid for a length of 15-20 meters, rolling shall be commenced with tandem rollers (8 to 10 tonnes). Rolling should commence from edges and proceed towards center longitudinally. The wheels of roller shall be continuously moistened to prevent the premix adhering to the wheels and being picked up. After the preliminary rolling and honey combing, high spot of depressions shall be rectified by adding or removing the premix as per requirements and the surface shall be rolled again to compaction. Camber shall be checked at every stage and any defects found shall be rectified. Excessive rolling shall be avoided.

7.6.2

7.6.3

7.7 Seal Coat 7.7.1 A liquid seal coat, having following specifications should be applied immediately after laying the carpet and rolled to achieve maximum compaction. seal coats are of two types, 1) Type A: liquid seal coat for high rain fall areas, comprising an application of layer of bituminous binder followed by a cover of stone chippings, and lightly rolled. The quantities of ingredients are as given below
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Quantity required per 100 m2 of seal coat 1. Quantity of binder in terms of straight run bitumen 80/100 grade

98.0 kg

2. Stone chipping (6 mm size all passing through 10 mm sieve and retained on 2.36 mm sieve)

0.9 m3

2) Type B: premix seal coat for low rain fall areas comprising of a thin premixed fine grit or coarse sand. The quantities of ingredients are as given below

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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Quantity required per 100 m2 of seal coat 1. Quantity of binder in terms of straight run bitumen 80/100 grade

68.0 kg

2. Stone chipping (passing through 1.7 mm sieve and retained on 1.18 mm sieve)

0.6 m3

Notes:

1. The combined compacted thickness of asphalt carpet and seal coat shall be minimum 62mm. The combined compacted thickness of two layers of asphalt carpet shall be minimum 50mm. 2. Contractor to procure asphalt 80/100 grade from HPCL only.

STANDARD SPECIFICATION FOR WBM & BITUMEN PREMIX ROADS

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