Guidance

for Asphalt
Paving Operations

Paver

Finished
surface
course
10–15 cm

GUIDELINES
 Guidance for Asphalt Paving Operations
1 Preparation of sub-base .......................................................2
Granular base course ....................................................................2
Bound base course ........................................................................2
2 Orders and release orders for asphalt-mix ....................6
Ordering the asphalt-mix ..............................................................6
Release orders for paving operations..............................................7
3 Mix Transport ..........................................................................8
4 Mix inspection prior to paving operations..........................10
Measuring the mix temperature ..................................................10
Visual inspection of the mix ........................................................11
Flawless mix ..............................................................................11
Excessive cooling of mix ............................................................12
Overheated mix ........................................................................12
How to proceed with mixes that failed the visual inspection ........13
Excessive cooling of mix ............................................................13
Overheated mix ........................................................................13
5 Paving ......................................................................................14
Getting started ............................................................................14
Guidance for paving operations ..................................................16
Tests during paving operations ....................................................17
Manual placement ......................................................................18
Cold weather paving....................................................................19
Paving during wet weather ..........................................................19
6 Compaction of the mix ........................................................20
Guidance for compaction ............................................................20
Getting the rollers ready ..............................................................22
Roller passes ................................................................................23
Guidance for asphalt mix compaction ..........................................23
Compaction mistakes ..................................................................26
7 Skid Resistance.......................................................................28
Paving and compaction process ....................................................28
Guidance ....................................................................................28
8 Design specific guidance ..........................................................29
Compact Asphalt ......................................................................29
Planning the job ........................................................................29
Planning paving operations........................................................29
During paving operations ..........................................................30
8 Design specific guidance…
Porous Asphalt ..........................................................................30
Planning the job ........................................................................30
Planning paving operations........................................................31
During paving operations ..........................................................31
Warm mix asphalt ....................................................................32
Planning the job ........................................................................32
Planning paving operations........................................................32
During paving operations ..........................................................32
Light-colored surface courses ..................................................33
Railway track beds ....................................................................33
Hydraulic applications and landfill construction ....................33
Anti-icing surfaces ....................................................................34
Colored pavements ..................................................................34
9 Joints ........................................................................................35
Guidance ....................................................................................35
Longitudinal joints ......................................................................35
“Hot to hot” technique ............................................................35
“Hot to cold” technique............................................................36
Transverse joints ..........................................................................38
Material finishing/shaping ............................................................40
10 Gap joints ................................................................................41
Guidance ....................................................................................41
Joint faces....................................................................................41
Filling the sealant reservoir ..........................................................41
Application of sealant ................................................................42
Sealing strips ............................................................................42
Application of sealing strips ......................................................43
11 Road Edges..............................................................................44
12 Taking samples to verify quality features..............................46
Sampling......................................................................................46
Documentation ............................................................................47
Guidance ....................................................................................47

Annex
Additional information about the German Asphalt Pavement
Association (DAV) and further DAV-Guidelines ............................48
Publisher

Deutscher Asphaltverband e.V.

(German Asphalt Pavement Association)
Schieffelingsweg 6
53123 Bonn
Tel. +49 228 9 79 65-0
Fax +49 228 9 79 65-11
E-Mail [email protected]
Internet www.Asphalt.de

Author
Bau-Ing. Roland Milster, Regensburg
in cperation with:
Dipl.-Ing. (FH) Walter Emperhoff,
Regensburg;
Dipl.-Ing. Klaus Graf, Leipheim;
Dipl.-Ing. Carsten Lips, Bad Hersfeld;
Dipl.-Ing. Richard Mansfeld, Rodewisch.

Design
Elke Schlüter Werbeagentur, Alfter
Tel. +49 228 64 79 89

2nd edition July 2007,

english translation January 2011
Preface
Asphalt technology has evolved due to new require-
ments, designs and mix materials, thus requiring a
revision of the popular dav guidelines „Guidance for
paving operations“ from 1989/95.

„Guidance for hot mix asphalt

paving operations“
is intended to help practitioners to produce
high-quality asphalt courses by carefully
planning and executing paving operations.
It also discusses specific designs and methods
to make their use easier.

These guidelines are based on the authors’ current

expertise and practical experience and existing pub-
lications. This informa-
tion does not claim to Successful work
be exhaustive. always depends on
a well-organized,
qualified, and well
informed staff

1
 Guidance for Asphalt paving operations

1 1
Preparation Preparation
of sub-base of sub-base
Granular base course The paving foreman must com-
(anti-freeze/ municate any obvious failures
crushed stone base) to the site manager, who will
promptly inform the client.
Producing a smooth, durable,
and adequately compacted base
course to specifications is vital Bound base course
for evenly solid asphalt pave- (Pre-existing bases or
ments.
bases that have been
Acceptance and hand over of laid formerly within the
the sub-base should always be project)
completed in due time before
starting paving operations. Existing bound bases must be
tested for suitability and relea-
Placement can only start if there
sed for use in due time prior to
are no defects in:
the commencement of paving
■ Bearing capacity operations.
■ Evenness The paving foreman must com-
■ Grade and cross-slope municate any obvious failures
■ Contamination to the site manager, who will
■ Required level promptly inform the client.

2
Preliminary works:
■ Thoroughly clean the base
surface of all dust, dirt and
other debris.
■ Ensure that manhole covers,
fire hydrants and utility
covers are at the right level
or adjusted to the required Appropriate mixes
level if required. for leveling courses:
■ Leveling courses or milling: Asphalt- Layer
usually a paver is used to base course thickness
pave the leveling course.
0/32 8,0 to 14,0 cm
Minor areas can be prepared
manually. 0/22 8,0 to 10,0 cm
0/16 3,0 to 8,0 cm
■ The mix should be applied in 0/11 < 6,0 cm
a separate work phase at all
times.
Tack coat:
■ Make sure that the leveling
A tack coat should be applied
course is densely compacted.
to the existing surface in com-
■ Slight irregularities do not pliance with table 1 and 2 of
need a leveling course and the M SNAR* guideline to en-
should be leveled out when sure a bond between the exis-
placing the next layer. ting surface and the new asphalt
overlay, see next page.

* Merkblatt für Schichtenverbund, Nähte, Anschlüsse und Randausbildung von

Verkehrsflächen aus Asphalt (Guidelines for layer bonding, seams, joints and
edging of asphalt roads), 1998 edition, FGSV No. 747.

3
 Preparation of sub-base

Application rate of tack coat based on type

of base....

Table 1: …for heavy traffic categories:

Category SV, I to III (g/m2)
Type and quality of existing surface

Overlay to be applied
Base Binder SMA
PmOB Type C U 60 K PmOB Type C U 60 K x
f
150 to 250 250 to 350
Base

PmOB Type C U 60 K PmOB Type C U 60 K x

m 250 to 350 250 to 350
PmOB Type C U 60 K PmOB Type C U 60 K x
o/d 300 to 400 300 to 500

f – x PmOB Type C U 60 K
150 to 250
Binder

m – PmOB Type C U 60 K PmOB Type C U 60 K

250 to 350 250 to 350

o/d – PmOB Type C U 60 K PmOB Type C U 60 K

300 to 500 250 to 350

The cited quantities have yet to Observe the manufacturer's in-

be matched with the surface structions when using new, re-
qualities since practical expe- fined products.
rience shows that the upper
limits are set at a very high level.

4
 Table 2: …for the categories IV to VI (g/m2)

Overlay to be applied
Base Binder AC SMA
U 60 K U 60 K U 60 K HK x
f
Type and quality of existing surface

150 – 250 250 – 350 150 – 250 200 – 300

U 60 K U 60 K U 60 K HK x
m 250 – 350 250 – 350 250 – 350 200 – 300
Base

U 60 K U 60 K U 60 K x
o/d 300 – 400 300 – 500 250 – 350

– HK HK x
d 200 – 300 200 – 300

x x U 60 K HK U 60 K HK
f
150 – 250 150 – 250 50 – 250 150 – 250

x U 60 K U 60 K HK U 60 K HK
m
Binder

250 – 350 250 – 350 200 – 300 150 – 250 150 – 250

x x U 60 K U 60 K
o/d 300 – 400 250 – 350

x x HK HK
d 200 – 300 200 – 300

Base = Asphalt base course

Binder = Asphalt binder course
AC = Asphalt concrete surface course
SMA = Stone mastic asphalt
f = fresh
m = milled
o/d = very porous structure or disintegration/raveling
d = dusty
x = to be evaluated from case to case
– = should not occur

5
 Preparation of sub-base

2
Ordering and release
orders for asphalt-mix
Guidance for tack coat Ordering the asphalt-mix
application:
■ Apply the tack coat on the Every order should be made in
previous day, if possible. writing and as early as possible.
Allow enough time for set- Orders must comply with the
ting. Cover kerb restraints specifications set forth in the
and ironworks etc. construction contract. The dav
guidelines „How to organise
■ Apply a thin and even layer; quality“ include a form for
avoid fat spots, especially asphalt mixture release orders
when using hand-held de- attached as annex 4. It is re-
vices (avoid slip planes in commended that this order
wet condition). form be used.
■ Use truck mounted spray
bar, whenever possible.

The quality
of the entire overlay
hinges on the base!

6
The order should include Release orders for
the following items: paving operations:
■ Contractor
■ Ensure effective commu-
■ Construction job nication between paving
(cost center, if required) foreman and mix plant

■ Specific features ■ Ensure prompt communica-

of the job site tion in the event of failures

■ Name of mix/ ■ Ensure effective coordina-

type test No. tion regarding the start of
paving operations
■ Desired delivery date
■ Take weather conditions
■ Quantity: Total/daily/ into account.
hourly output
■ Type and size of trucks,
if possible Clear and effective
communication
■ Name and phone number between the
of paving foreman paving foreman
Ask the mix supplier for and the
an order confirmation! mix manufacturer
is vital to ensure
smooth delivery
of the mix!

7
 3
Mix Transport

The number of haul trucks The following points should

should be planned so that be taken into consideration
the transport rate matches for mix delivery:
the paving rate, thus ensuring a
constant supply for the paving
■ Select weight, size and type
job site.
of the trucks to match the
conditions on site. Vehicles
The following factors should
with half-round trailers are
be taken into consideration:
the best choice.

■ Haul distance and haul time ■ The truck bed of the haul
truck is to be thoroughly
■ Traffic holdups, e. g.
cleaned. Only use release
■ other construction sites, agents that are suited for
asphalt when spraying the
■ Traffic jams occurring
truck bed or bitumen im-
every day at certain times
pregnated crushed aggre-
(e. g. rush hour traffic),
gate/sand mixtures.
■ Detours that are required Make sure that there is no
due to weight limits for puddling when using liquid
bridges and certain road release agents.
sections.
■ Heavy and/or unpredic- ■ The use of oils, e.g. diesel oil,
table traffic (congestions can cause severe damage to
and detours) the asphalt layer and is thus
strictly prohibited.
■ Rest periods for drivers
8
■ The mix should not be
hauled to the paving site A continuous
if defects are detected visu- mix supply
ally already during loading for the paver
(e. g. segregation, wrong is vital
temperature, fatting-up or to the evenness
dry mixes). and regularity
of the applied
■ All vehicles must be equip- asphalt layer!
ped with windproof
tarpaulins; the load has
to remain covered during
transport and while the
truck is stationary.

■ Vehicles should stay as close

to the paver as possible du-
ring backups.

The banksman and driver

should always have
visual contact!

9
 Mix Transport

Table: Reference values

Type and grade Asphalt Asphalt Asphalt Stone mastic
of binder base course binder concrete asphalt
in Mix surface c.
Base Binder AC SMA
30/45 130 to 180 130 to 180 – 140 to 180
50/70 120 to 180 120 to 180 130 to 180 140 to 180
70/100 120 to 180 120 to 180 130 to 180 130 to 180
PmB 25 – 130 to 180 – –
PmB 45 – 130 to 180 – 150 to 180
PmB 65 – 120 to 180 130 to 180 140 to 180

For Warm Mix Asphalts, the bottom limit of the regular mix temperature
should be used as reference value based on the additive applied, the process
technology, and the boundary conditions.

The lower limits are applicable to the unloaded mix during paving operations;
the upper limits are applicable to the mix when discharged from the mixing
plant or silo.

4
Mix inspection prior
to paving operations

Measuring the Aspects to be considered:

mix temperature
■ Ensure that you use fast
The mix temperature is decisive response thermometers
when evaluating the workabili- (e. g. probe and radiation
ty and compactability of a thermometer; follow the
given mix. Measuring the tem- manufacturer's instructions!)
perature is an important and
absolutely essential measure ■ As a general rule, the
when evaluating the mix delive- mix temperature must be
10 red to the paving site. measured prior to paving.
for mix temperatures in oC
Combination of Compact Porous Thin overlays
Base and Surface asphalt asphalt - hot applied

BS CA PA TOH
– 130 to 180 130 to 180 130 to 180
120 to 180 120 to 180 130 to 180 130 to 180
120 to 180 120 to 180 130 to 180 130 to 180
– 130 to 180 –
– 130 to 180 130 to 180 130 to 180
– 120 to 180 130 to 180 130 to 180

Refer to the manufacturer's instructions when using special binders

and organic additives to improve workability.

Visual inspection
of the mix

Flawless mix: ■ Slightly steaming (excep-

tion: warm-mix asphalt)
■ Even black coating and
light sheen ■ Does not segregate on the
truck bed or when tipping
■ Load in the truck bed is it into the paver hopper
„topped off“
11
 Mix inspection prior to paving operations

Visual inspection
of the mix

Excessive cooling of mix: Overheated mix:

■ Crusting on top while on ■ Yellow vapour while tipping

the truck bed mix into the hopper

■ No steam when tipping ■ Dull, brownish appearance

mix into the paver hopper
■ Loss of cohesive strength;
(exception: warm-mix
mix can be easily pushed
asphalt)
apart – a typical indicator
■ Generally stiff appearance that the adhesive force of
the binder has declined or
■ Mix builds up chunks when has been entirely lost
tipping it into the hopper

Defective material
may not
be paved!

12
How to proceed with
mixes that failed
the visual inspection

Excessive cooling of mix: The following action should

be taken after identifying
■ Mix may not be dumped defects in the mix delivered:
into the hopper. Contact
the mix plant and agree ■ Inform the mix producer
on how to proceed with
the rejected mix. ■ Retain a sample of the
rejected mix
Overheated mix: ■ Record the defects
■ May not be dumped into ■ Get advice from the mix
the hopper, either. Contact producer on how to pro-
the mix plant and agree on ceed.
how to proceed with the
rejected mix.
■ Overheated mix can be
used, if at all, as granular
base course material,
e. g. as back-up material
for shoulders and slopes.
■ It is advisable to retain
a sample of the mix.

13
 5 5
Paving Paving

Getting started Getting started

The following steps should be ■ Pre-heat the plate on

taken prior to paving operations: the bottom of the screed

The paving rate has to be ad- ■ Type of slope and

justed to the delivered mix. grade control, e. g.
floating beam equipped
Paving speed is of the essence
with shoes, string line,
and is influenced by the width
3D-control, ultrasonic
and thickness of the layer be-
or laser system
ing placed.
■ Adjust augers to the
The paver should be set up maximum width of the
and adjusted in accordance screed.
with the mix that is being
laid. ■ Match screed with
the longitudinal joint
■ Angle of attack for the
screed ■ Ensure that the paver
is ready for operation
■ Choice of compaction
equipment and desired
■ Screeds should be
pre-compaction by
synchronized during
adjusting the screed
pre-compaction when
■ Compliance with using two pavers
tolerance range

14
 Different kinds of pre-compaction
with paver screeds
(Voegele equipment as example)

„Traditional design“ (not to scale)

1st variation 2nd variation
Screed Screed
Vibration

Tamper Tamper

Pressure bar

3rd variation: High compaction (not to scale)

Screed
Vibration

Tamper

2 pressure bars

Options on Base Binder AC SMA BS PA Thin WMA

high-compac- overlay
tion screed
Tamper ++ ++ ++ ++ ++ ++ ++ As with
Vibration ++ ++ • to + • + – – standard
Pressure bars ++ ++ • to + • + – – Placement
++ = especially suited • = suited under certain circumstances
+ = suited – = not very well suited

15
 Paving

Guidance for paving operations

The following points should be considered

during paving operations:
■ The tolerance range is based ■ In the event of stoppages,
on material type, thickness, continue paving until the
pre-compaction and tempe- hopper begins to empty
rature. The tolerance range and the amount of material
has to be verified during the in the screed chamber de-
entire paving operations and creases below normal ope-
adjusted, if required. rating level. Stop the paver
at his point and construct
■ When directing the haul trucks
a transverse joint.
avoid situations where trucks
would approach the paver dia- ■ Cold mix that builds up
gonally or back into the paver. between the baffle and
the screed may not be laid
■ Ensure a constant paving
(to be discarded at the end
speed during the entire
of paving operations).
paving operations to the
greatest extent possible. ■ Adjust the screed settings
(T, V, P) when extending
■ Do not empty the
the paving width.
hopper to the extent
possible (segregation)

16
 Tests during
paving operations

■ As a general rule, narrow The following tests should be

radii (e. g. roundabout) carried out at regular intervals
should be laid with the during paving operations:
standard width of the
■ Mix temperature
screed (pave large widths
with two pavers). ■ Visual inspection of the mix
(appearance, quality)
■ Pave surface courses with-
out automatic grade and ■ Amount of mix being placed
slope controls (with the and layer thickness, ratio
exception of special cases, between maximum aggre-
e. g. utility installations for gate size and layer thickness
buildings).
■ Correct pavement profile
■ Re-adjustments of the and smoothness
screed should be reduced
■ Alignment of edges (correct
to a minimum.
location and true alignment)
■ Especially on surface courses
■ Visual inspection with regard
the spreading out of additi-
to uniform surface condition
onal material to close holes
of the placed layer.
or to level out irregularities
should be avoided. ■ Quality/condition of longi-
tudinal and transverse joint
A record should be kept of the
tests cited above!
17
 Paving

Stop paving operations

at a temperature below

Manual placement

The asphalt mix should be pla- Make sure you have enough
ced by hand only in exceptio- hot mix available when star-
nal cases. Use an extendable ting manual work. As there is
screed to accommodate chan- no screed affording initial com-
ging paving widths. Pave span- paction, the tolerance range
drels manually, while continu- has to be increased. Do not
ing laydown operations with throw the material through the
the paver. Manual work may be air. Instead, deposit the material
required in the following cases: from the shovel on to a small
pile. Verify surface evenness with
■ Very small areas a straight edger before starting
(repairs, excavations) compaction.
■ Cable trenches
Start with compaction immedi-
■ Driveways ately. Lightweight rollers and
■ Spandrels vibratory plate compactors are
ideal for base and binder cour-
It is vital that manual work only
ses when working on excava-
be performed after you have tions and small repair areas. A
completed preliminary work e.g. vibro-tamper or hand tamper
■ Cleaning should be on hand for corners
and side areas.
■ Applying tack coat
adhesive or emulsion Fast and uninterrupted work is
■ Fitting sealing strips or of the essence when surfacing
applying joint sealants by hand.
18
Surface course +5 o C As a general
Binder course 0 oC rule, the lower
Base course –3 o C layer should
Surface tem- not be frozen or wet,
perature of the and should be free
lower layer from snow and ice!

Cold weather paving Paving during wet weather

The ZTV Asphalt bulletin specifies As a general rule, surface layers

that paving operations must stop should not be placed while it is
at the specified air temperatu- raining or when the surface is wet,
re. This might cause problems as this could cause insufficient
in practice. It is, therefore, advi- density and layer bonding.
sable to monitor the surface
temperature of the lower layer. It is possible, however, to place thick
asphalt layers, such as asphalt
base courses, asphalt binders, and
If there are any unfa- bituminous surface treatments, in
vorable weather conditions drizzling rain. Nevertheless, these
you should ensure that works also have to be halted in
heavy rainfall.
■ Additional rollers are on hand
If rain has been forecast, the layer
■ Haul trucks are insulated
should be placed in the sloping
■ Surfaces are pre-heated with direction if possible. In special cases
appropriate heaters, the surface can be dried and/or
if required. the water removed.

Ambient conditions
and the mix type
have a strong impact
on paving operations

19
 6
Compaction
of the mix

Consideration should be Guidance for compaction

given to the following points
■ Initial compaction should
when selecting number and
be matched with the type
types of rollers:
of mix.
■ Type of mix ■ Start with compaction
■ Planned paving rate as soon as possible to
(expressed in m2) ensure that the desired
density is easily attained
■ Thickness of each layer at 80 – 90 Co.
■ Paving width (full or ■ When the layer thickness
half width of the road) is less than 4 cm you
should use the vibratory
■ Temperature of air, mode only for a few
surface and mix passes, if at all.

20
Various types and weights of Static tandem rollers
rollers can be used for the follo-
wing purposes: ■ For breakdown rolling of
asphalt layers,
Static three wheel rollers ■ For compacting asphalt layers
(10–22 t) up to 8 cm in thickness,
■ Used for compacting ■ For compacting edges of the
asphalt layers, edges of lane as well as transverse and
the lane, transverse and longitudinal joints,
longitudinal joints, and ■ For smoothing the layer after
to smooth the layer after the roller passes have been
all roller passes have been completed;
completed.
Tandem vibratory rollers
■ Used for compacting asphalt
layers up to 16 cm in thickness,
■ Never to be used for breakdown
rolling, on engineering structures,
or on thin overlays or porous
asphalt surface courses.

21
 Compaction of the mix

Tandem rollers with oscillation Getting the rollers ready

■ For compacting all asphalt Ensure that the rollers are in
layers; especially suited for good working order before
engineering structures and starting compaction work.
overlays
Careful consideration
Combination rollers should be given to the
■ For universal purposes. With following points:
each subsequent roller pass ■ Check the drum
it is only the smooth drum wetting system,
that increases layer density.
■ Refill the water tank,
Pneumatic-tired rollers ■ Check the vibratory
■ Are only used sporadically; mode when using
especially for rural roads and vibration rollers,
in all cases where thorough, ■ Check and/or adjust
perfect sealing of the sur- tyre pressure when using
face course is required. combination rollers, and
add the release agent.

22
Roller passes

A roller pass is defined as one A rolling lane consists of two

complete coverage of the area roller passes across the width of
to be compacted by the roller. the drum.

Breakdown: Roller pass without vibration

Compaction is • Mix type and temperature
affected by: • Roller type and weight
• Layer thickness
• Number of roller passes
„Smoothing“ the layer Two roller passes, if required
or surface finish:
Edges of • Use rollers with edge restraining devices
paved lanes: to shape and compact the edges
Rolling pattern: • Construct a test strip, e.g. by using
a density gauge or similar device

Guidance for asphalt mix compaction

Compaction consideration of the type of mix,

is always plan- on-site placement conditions,
ned and executed taking due and the season ............

23
 Guidance for asphalt mix compaction

■ Typically, at least 2 rollers should switch off the engine and allow
be on site during placement. the roller to coast down; then
■ Follow the paver as closely as restart the engine right away,
possible during the first roller thus avoiding a surge.
pass (breakdown). ■ When using vibratory rollers
■ Turn the roller slightly when turn off the vibration with
stopping in front of the paver. enough lead time before chan-
ging directions, to avoid vibra-
■ Angle the drive wheel (of single
tory roller marks on the layer
drum rollers) towards the paver
that are unable to be ironed
to avoid bow humps and crak-
out by subsequent rolling.
king (exception: paving opera-
tions on steep sections). ■ Vibratory compaction has to
be consistent with the mix
■ Begin the compaction process
temperature.
on the low side of the pave-
ment lane and proceed up- ■ Moisten the drums regularly
wards towards the centre or with only enough water (e.g. in-
the high side, using the drum termittent water spray system).
width as reference. ■ Assign the longitudinal joint to
■ When compacting curves with a specific roller when paving two
crossfall begin compaction on layers „hot on hot“.
the low side of the road's edge. ■ In no circumstance should the
The lane first paved serves as roller be stopped on the hot lay-
an abutment for the next roller er. After having completed the
passes. required roller passes, remove
■ Always stop rollers on comple- the roller from the cooling
ted asphalt layers and never on asphalt layer and park it out-
a hot layer that is still plastic. side the cold surface.
■ Change directions smoothly; ■ Do not use the vibratory mode
when reversing directions for cold layers!
24
Compaction of the mix

Rollers for different asphalt types

Base Binder AC SMA BS PA Thin WMA
Overlay
Static three-
wheeled roller • • + ++ – + ++ +
Static mode
Tandem roller

smaller 6 tons • • + • + ++ • •
larger 6 tons + ++ ++ ++ ++ ++ ++ ++

vibratory mode
normal ++ ++ + • to + ++ – – • to +
Oscillation ++ ++ ++ • to + ++ – • • to ++
Combi roller + • • – ++ – – –
++ = especially suited
+ = suited
• = suited under certain circumstances
– = not very well suited

Roller compaction: 1st variation 2 nd variation

Finishe
Paver 1 d
surface Paver
course

Paver 2

Mini- 10–15 cm
mum:
15 cm 25
 Compaction

of the mix

An excessive,
initial mix temperature
causes...

…lateral mix displacement outside

the wheelpaths

…a small wave in front of the roller

(excessive shoving)

Compaction ■ Wrong rollers (excessive roller

mistakes load creates shear cracks),
Cracking is caused by ■ Mix tends to shove under roller
an excessive, initial mix loads (too much tack coat, mois-
temperature and by the ture or dirt on the existing surface)
following factors:
■ Yielding subgrade or base.

■ Improper or poor mix design

26
…transverse cracks behind …mix sticking to the roller
the roller drum, drum despite wetting the
roller,

As soon as defects caused by

rolling are identified the root
cause is to be determined as
fast as possible and eliminated.

■ Waves or roller marks are

typically caused by poor
workmanship

Better
a roller too much
than a roller short

27
 7
Skid Resistance

Paving and Guidance

compaction process

Initial skid resistance is ensured, Anti-skid road surfaces ensure

inter alia among other things, the safety of all road users. Paving
with the following methods: operations greatly impact initial
■ Use aggregates with a par- skid resistance. When the gua-
ticle size of 1-5 mm (with rantee period expires, skid resi-
bitumen coating, pre-heated, stance is affected mainly by
de-dusted) for gritting the mix that was used.

■ Spread aggregates as soon Ensuring skid resistance is just

as possible, at the latest as important as all other accep-
after the second roller pass tance criteria. Use the forms
■ Correct metering and even issued in the General Newsletter
spread (ARS No. 2/2002) for your self-
■ Use smooth drum rollers control.
with high line loads
Initial skid resistance is reduced,
for instance, in the following
cases:
■ Fatting up (migration of
bitumen to the surface), The appropriate
■ Premature opening to traffic pavement technology
(cooling time of at least 24 h), ensures
initial skid resistance!
■ Wrong gritting material
(e. g. crushed sand)
28 ■ Uneven spread.
8
Design specific guidance

Consideration should Planning paving operations

be given to the following
■ Check both screeds for
guidelines when applying
camber and cross fall.
a specific design:
■ When constructing trans-
Compact asphalt
verse joints, approaching
Planning the job bridges, etc. both screeds
should use automatic screed
■ Select mix plants based on controls with a string line
their supply rate. Then sort providing elevation input
the plants according to to the paver sensor.
binder and surface course
material. ■ Direct and separate haul
trucks according to the
■ Select one mix plant that type of mix (binder versus
coordinates all the other surface course).
mix plants.
■ Prepare a roller pattern
■ Make sure that the mix based on the total thick-
plant and the paving crew ness, type of mix and
discuss the production, the available roller types.
process, choice of haul
vehicles based on appropri-
ate policies and procedures,
and that clear roles and
responsibilities are assigned.

29
 Design specific

guidance

Compact asphalt Porous asphalt

During paving operations Planning the job

■ Maintain a constant paving ■ Reduce haul distances
speed (if possible > 3 m/min). (excessive cooling of mix).
■ Verify the thickness of both ■ When placing multiple
layers at regular intervals. layers it is not possible to
apply a bituminous binder,
■ Make sure that the tolerance
as this would considerably
range is kept.
reduce the water per-
■ Document the tonnage meability of the mix. Best
placed on an ongoing basis. practice is to place the
■ Inform the mix plant in a layers immediately one
timely manner about the after another (fresh on
remaining material required fresh) to attain sufficient
to complete placement. layer bonding. It is very
important to avoid con-
tamination of the bottom
layer.
■ It might be advisable
to prepare a test strip
to avoid falling short of
the required void content.

30
Planning paving operations During paving operations
■ If the mix is placed on an ■ The tolerance range is
existing surface, ensure considerably lower than
that it is sufficiently sealed. for standard asphalt layers.
■ Special care should be given ■ Also, make sure to use
to preheating the plate on smooth drum rollers only
the bottom of the screed. when compacting the mat.
■ Operate the roller in
■ When paving half of the
static mode.
road width, ensure that
water drainage within the ■ Base courses laid under block
layer is not stopped by a pavements and permeable
sealing strip, etc. The same sports surfaces can also be
applies when repairing compacted under vibratory
road damages. mode.
■ Be especially careful when
the roller moves across the
lane to the next rolling lane.
■ Porous asphalt overlays are
not gritted because the
aggregates would clog the
voids of the porous asphalt
surface course.

31
 Design specific guidance

Warm mix asphalt

walzasphalt

Planning the job During paving operations

■ As warm mix asphalt has ■ Ensure that the asphalt
a lower heat potential it temperature is monitored
makes sense to use in- around the screed area
sulated or heated trucks. during stoppages.
The remaining mix has to
Planning paving operations
be removed at an earlier
■ Special care should be stage than is the case for
taken in preheating the standard asphalts.
plate on the bottom of
the screed. ■ Excess compaction causes
a lower air void content.
■ As this mix is more recep- Typically, the desired densi-
tive to compaction, the ty level is generally reached
initial compaction unit of after the fourth roller pass.
the paver should be reset.
■ Prepare a roller pattern ■ The roadway can usually
based on the total thick- be opened to traffic sooner
ness, type of mix and the than with standard asphalt.
available roller types.

32
Light-colored surface courses

Light-colored surface courses can aggregates can both be used for

be produced with surface dressing this purpose. The aggregates for
and/or by incorporating light-colo- the surface dressing should be
red aggregates into the mixture. embedded right behind the paver
Natural or artificial light-colored with the first roller pass.

Railway track beds Hydraulic applications

and landfill construction

The asphalt base courses for the Asphalt layers serve as water-
solid track bed are laid with the proof sealing for hydraulic and
same technique as in road de- landfill constructions. In such
sign. There is, however, a signi- construction projects the base
ficant difference in the surface and also the embankments
course which is compacted sole- should be rendered waterproof.
ly by the screed without using Asphalts used in these appli-
any rollers. Only when using this cations must have sufficient sta-
technique can the course be laid bility to be laid without sliding
to the specified level. The course down the slope. Specific paving
is laid using the approved equip-
and compaction equipment is
ment and in compliance with
required in addition to a special
the specifications pertaining to
mix design. The applicable con-
the building of solid track beds.
tract specifications should be
The track bed should be placed observed. The construction of
while taking on-site conditions joints and seams requires ad-
adequately into consideration vanced techniques and special
and using equipment modified care.
specifically for this purpose.

33
 Design specific guidance

Anti-icing surfaces Colored pavements

These surface courses are only Colored pavements are manu-

placed on short sections that are factured with the following
particularly susceptible to black methods:
ice formation.

Such sections might include: ■ Colored Binders

■ Bridges ■ Clear binders and dyes/
pigments for fillers
■ Open strips in forests
■ Sections exposed to unfa- It is a good idea to blend aggre-
vorable climatic conditions. gates of the same colour into the
mixture to enhance colouring.
Special salt crystals are incor-
porated into the asphalt mix. The entire equipment (including
The salt manufacturer’s instruc- tools and footwear) should be
tions for placement and com- carefully and thoroughly clea-
paction should be observed. ned prior to paving operations.

Special designs
require
special instructions
and information!

34
9
Joints

Guidance Aspects to be considered:

A joint is the interface between ■ The pavers should follow

two adjacent and parallel HMA each other as closely as
layers (longitudinal joint). possible to ensure that
Joints can occur when paving the edge of the first lane
in echelon („hot to hot“) or paved is still sufficiently hot.
when paving half the width
■ The rollers right behind
of the road („hot to cold“).
each paver should be of
Joints at the end of each day’s the same size. Both rollers
construction are referred to should begin to compact
as transverse joints. the layer from the outer
In all cases it is imperative that edge towards the joint.
a permanent bond be created Compaction ends about
between both sides of the joint 15 cm away from both
to avoid surface water ingress. sides of the longitudinal
joint. The mix across the
joint is only compacted
Longitudinal joints with the last roller pass.
This method produces
„Hot to hot“ technique tight, solid compaction
Paving in echelon with two or and adhesion between
more pavers is the best precau- the two layers
tion to ensure a solid bond bet- (see page 39).
ween the two adjacent mats.
35
 Joints: Not recommended! …Best practice!

„Hot to cold” technique The following guidelines

should be considered:
Joints must be constructed with ■ As a general rule it should
great care if traffic necessitates be ensured that the joint
that paving be performed one is not placed in the area
lane at a time. of road markings or the
wheel path.
■ The required longitudinal
edge (contact face) has
to be constructed while
paving the first lane…

36
 Centerline of the pavement

Asphalt surface course

Asphalt binder course

Asphalt base courses

Longitudinal joint

…The edge should have a To ensure perfect adhesion

70 to 80 degree inclined face. between the two asphalt
Compared to a vertical face lanes, the face should be
this permits a contact area that prepared as follows:
is larger than the layer placed.
This taper is constructed with 1. Thorough cleaning.
a joint taper attached to the The surface adjacent to
paver and/or an edge compac- the joint should also be
tor attached to a roller. It is not cleaned of all debris and
recommended to cut the edge loose particles.
after it has cooled because this 2. Spray or paint vertical face
would create a smooth face. with sufficient adhesive
material. Coatings are
In addition, the cutting ooze con- placed with hot or cold
taminates the existing surface applied materials.
(poor layer bonding).

Remove any
dirt and loose particles!

37
 Joints

Keep the following points Transverse joints

in mind when placing and
compacting the second lane: Transverse joints are built at the
end of each day’s construction, or
■ The second lane is placed if there will be lengthy stoppages.
with a narrow overlap
(2-3 cm) and in compliance
with the specified tolerance The following steps are
range. required to construct a
transverse joint:
■ A poor overlap, or no over-
lap at all, would cause a
■ Run the paver empty.
lack of mix at the joint. This
would lead to poor compac- ■ If the layer thickness is in-
tion and eventually would sufficient, cut back the mix
cause damage to the joint. by hand and construct a
■ If there is an excessive vertical edge.
amount of overlap the paver
■ Place a board with the same
would ride on top of the mix.
thickness next to the joint.
This would cause aggregate
crushing in the overlapping ■ Grit the existing pavement
area and insufficient com- surface of the ramp area
paction across the joint. with a thin layer of sand.
■ Before starting roller com-
■ Construct the ramp by hand
paction the overlapping mix
on the gritted area using
should be looted on to the
the rest of the mix.
new layer.
■ See Chapter 6 for the use ■ Compact the entire area
of rollers. and the ramp with rollers.
38
How to produce joints

splashguard, if required
bituminous material

Overlap (2–3 cm)

push back
Layer placed by paver

roller first roller pass

last roller pass

if completed layer roller
is not passable

roller pass
if completed layer roller
is not passable

39
 Joints

Material finishing/shaping

■ Remove ramp, sand and An overband to seal rough

wooden board before re- areas around the joint can help
suming paving operations. provide additional protection.

■ Use a straight edger to ■ Apply the sealant with

verify whether the old a hand-held banding
layer is level in longitudi- machine equipped with
nal direction. If necessary, a narrow steel squeegee.
cut back the layer.
■ Paint the joint area with
■ Clean the ramp area an appropriate binder and
and tack it with contact then blot the material using
adhesive. crushed sand with low filler
content.
■ Compaction is carried out
using the „hot to cold“
technique.

Transverse joints and longitu-

dinal joints can also be con- The best joint
structed as gap joints (see is no joint at all!
Chapter 10).

40
10
Gap joint
Guidance Gap joint configurations

Gap joints must be built

whenever there are transitions
between layers with different Bituminous heat-bonded
properties. sealing strip

This is the case, for instance, with:

■ Gutters (concrete, block
pavement) Cut channel, filled
■ Kerbs (concrete, natural stone) with hot pour material
■ Concrete slabs
■ Walls
■ Ironworks.
Routed channel with chamfered
Joints can be sealed by mecha- edge, filled with hot pour material
nically creating a reservoir to be
filled with hot pour material or
by using heat-bonded sealing
tape. Overband

Joint faces Filling the gap joint reservoir

Ensure that gap joints Reservoirs/channels can be created

by using the following methods:
■ have the same thickness as
the surface course, ■ Placing an insert,
■ are vertical, ■ Cutting, or
■ are clean and dry. ■ Routing.

41
 Gap joints

Application of sealant Sealing strips

The following steps are impor- Sealing strips are anticipated

tant and should be followed: joint filler. Follow the specific
recommendations provided by
■ Remove any debris with the manufacturer of the sealing
hot air blasting. Flush the strips.
reservoir if necessary.
Application:
■ Dry the reservoir, e. g.
with hot compressed air ■ Sealing strips are pre-fitted
to the vertical face
■ Apply the primer and
allow it to cure ■ Sealing strips are placed as
an overband covering the
■ Carefully prepare the channel.
sealant or filler material
■ Follow the specific recom-
mendations provided by
the manufacturer of the
material.
■ Dispense the material with
an applicator wand or pour
pot
Outsource major jobs in-
volving hot pour material
to specialized firms!
42
Application of sealing strips

The following steps are impor- ■ The cross-section of the

tant and should be followed: sealing strip should be
consistent with the thick-
■ Clean and dry the faces ness of the surface course.
■ Apply the primer and allow ■ Sealing strips placed as
it to cure overband should be fixed
■ Carefully melt the sealing in place by applying a
strip to the cold face by blotter coat.
using a propane torch;
apply and press the strip Sealing strips are less elastic than
immediately to the face hot pour material.
■ If the reservoir is very long,
the strip should be applied
with power equipment.
■ Make sure that there is
no deformation or detach-
ment of the sealing strip Seals and transitions
from the asphalt layer should be permanently
prior to paving waterproof!

43
 11
Road Edges

To prevent the ingress of water,

dirt and roots penetrating the
asphalt from the side, the out-
side road edges should be suffi-
ciently compacted:

■ With edge restraining

devices

■ With joint taper and

edge restraining devices

Additional protection is provided

to the outside edges by spray
coating the edges, e. g. with
hot bitumen or by applying
asphalt slurry or pore filler. Such
treatment is imperative for high
shoulders. The lower edge of
porous asphalt layers should not
be sealed.

Faulty sealing
damages
the asphalt!
44
 ≥ 2,5%
Not required if the layers
are placed immediately
Asphalt surface course
one after another
≥10 cm
Asphalt binder course
≥10 cm
2nd layer
Asphalt base course
≥10 cm
1st layer

45
 12
Taking Samples to
verify quality features

Sampling

Samples should be taken in com- When taking mix it is imperative

pliance with an approved sample that a square-tipped shovel with
drawing plan. Any additional upturned edges be used.
samples are drawn for special
testing (additional compliance Make sure that the receptacles
tests). for samples are the right size
and diameter.
During taking mix samples for
compliance testing the client or Square-tipped shovel with
its representative and the con- upturned edges
tractor should be present. It is also
a good idea for the mix supplier
to be present.
min. 50 mm

The samples to be drawn should

be representative of the areas
allocated to them. Samples
should be drawn in accordance
with applicable specifications.
max. 250 mm

46
Documentation

The sample drawing plan should

be prepared and be available
prior to paving operations. Every Guidance
drawn sample should be put on
record. It should be possible to Samples taken are used to con-
identify the mix sample at any duct follow-up tests describing
time. The following information the quality features of the mix
is required to that end: supplied.

■ Name of job site Mix samples are taken for

the following purposes:
■ Date/time when the sample
was taken ■ Self-monitoring
■ Client and contractor (conducted by paving
■ Suitability test no. contractor/mix supplier)
■ Exact position/lane ■ Compliance tests
■ Mix type (conducted by client)
■ Supplier/mix plant
■ Delivery note no.
■ Mix temperature
■ Sample number/description Taking wrong samples
■ Signatures of client and is a sure-fire way
contractor on record to lose out!

47
 Annex
Notes

Additional information about the

German Asphalt Paving Association (DAV)
and further DAV-guidelines
More information about the German Asphalt Pavement Association
DAV and the German Asphalt Research Institute DAI as well as
an overview of their publications (brochures, guidelines and
research reports) you will find on the internet:
www.asphalt.de

Further publications in English and in other languages

48 www.asphalt.de ➞ Literatur ➞ Download ➞ International
Notes

49
 Notes

More information on the internet:

50 www.asphalt.de
Notes

More information on the internet:

www.asphalt.de 51
 English version sponsored by

J. Rettenmaier & Söhne GmbH + Co. KG

73494 Rosenberg
Germany

Fon +49 7967 152 297 • Fax +49 7967 152 500 151

[email protected] • www.jrs.de
www.sma-viatop.com

Deutscher Asphaltverband e.V. · Schieffelingsweg 6 · 53123 Bonn

Fon +49 228/97 96 5-0 · Fax +49 228/97 96 5-11
E-Mail [email protected] · Internet www.asphalt.de