Bitumen

A black viscous mixture of hydrocarbons obtained naturally or as a residue from petroleum distillation.

 Types of Bitumen:
1. Cutback Bitumen
2. Emulsified Bitumen
1. Cutback Bitumen:
Cutback Bitumen (Liquid Bitumen) is Bitumen that is dissolved in a solvent . Typical
solvents include Naptha, gasoline and kerosene, white spirit etc.

 Cutback Classification
Cutbacks are divided into two classifications, depending on the solvent used.
I. Rapid-Curing (RC)
II. Medium-Curing (MC)
III. Slow curing

 Rapid-Curing (RC)
Rapid curing (RC) asphalt cement is a combination of light diluents of high volatility,
generally in the gasoline or naphtha.

 Medium-Curing (MC)
Medium curing (MC) asphalt cement uses medium diluents of intermediate volatility
generally in the kerosene.

 Slow curing
Slow curing (SC) asphalt cement and oils of low volatility generally in the heavy distillate
slow curing (SC) cutback asphalts are often called road oils and are used primarily in
road-mixing and dust-laying applications. This term originated in earlier days when
asphalt residual oil was used to give roads a low-cost, all-weather surface. SC cutback
asphalts are also used for stockpile patching mixes, plant-mixed with graded aggregates
and occasionally for priming.

2. Emulsified Bitumen
Bitumen emulsion is a mixture of fine droplets of bitumen and water. But as the
bitumen is a petroleum product it doesn’t mix with water and as it is sticky in nature, it
doesn’t easily gets disintegrated into fine droplets. To overcome this problem an
emulsifier is used.
Emulsifier can be defined as a surface-active agent. Emulsifier keeps the bitumen in its
fine droplet state by disallowing it to mix with other droplets. As the droplets are very
fine they suspend in water.

“Therefore, bitumen emulsion is a dispersed liquid consisting of three products, i.e.

water, bitumen and emulsion”.
The bitumen emulsion is classified into 3 types based on setting time:
a. Slow setting emulsion
b. Medium setting emulsion
c. Rapid setting emulsion

a) Slow setting emulsion

In this type of emulsion, a special type of emulsifier is used to slow the process of water
evaporation. These types of emulsifier are relatively stable.

b) Medium setting emulsion

This type of bitumen emulsion doesn’t break as when applied on aggregate. The process
of evaporation starts when the fine dust of mineral are mixed with the aggregate
emulsion mix.

c) Rapid setting emulsion

This type of bitumen emulsion breaks down rapidly as it comes with contact with
aggregate helping in fast setting and rapid curing.

Comparison of Tar and Bitumen

Bitumen and Tar have black to dark brown colour. But bitumen is a petroleum product
whereas Tar is produced by the destructive distillation of coal and wood. The chemical
constituents of bitumen and tar are quite different. Tar coat aggregates more easily and
retains it better in pressure of water than bitumen. But the tar is considered to have
much inferior weather resisting property.
 Pavement
 Types of Pavements
There are two types of pavements:
1. Flexible Pavements
2. Rigid Pavements
1. Flexible Pavements
Flexible pavement can be defined as the one consisting of a mixture of asphaltic or
bituminous material and aggregates placed on a bed of compacted granular material of
appropriate quality in layers over the subgrade.
2. Rigid Pavements
A rigid pavement is constructed from cement concrete or reinforced concrete slabs.
Grouted concrete roads are in the category of semi-rigid pavements.
The design of rigid pavement is based on providing a structural cement concrete slab of
sufficient strength to resists the loads from traffic. The rigid pavement has rigidity and
high modulus of elasticity to distribute the load over a relatively wide area of soil.

Sl.
Flexible Pavement Rigid Pavement
No.

It consists of a series of layers with the highest

It consists of one layer Portland cement concrete
1. quality materials at or near the surface of
slab or relatively high flexural strength.
pavement.

It reflects the deformations of subgrade and It is able to bridge over localized failures and area of
2.
subsequent layers on the surface. inadequate support.

Its stability depends upon the aggregate interlock, Its structural strength is provided by the pavement
3.
particle friction and cohesion. slab itself by its beam action.

Pavement design is greatly influenced by the Flexural strength of concrete is a major factor for
4.
subgrade strength. design.

It functions by a way of load distribution through It distributes load over a wide area of subgrade
5.
the component layers because of its rigidity and high modulus of elasticity.

Temperature variations due to change in

Temperature changes induce heavy stresses in rigid
6. atmospheric conditions do not produce stresses in
pavements.
flexible pavements.

Flexible pavements have self-healing properties Any excessive deformations occurring due to
7. due to heavier wheel loads are recoverable due to heavier wheel loads are not recoverable, i.e.
some extent. settlements are permanent.
 Asphalt
Asphalt is a heterogeneous mixture of three substances:
 Bitumen (Binding material)
 Aggregates
 Filler
The binding agent is a bituminous pitch produced by refining petroleum.
The aggregates are crushed stone.
The fine aggregates or Filler are sand typically those particles that are caught in a number 200
sieve (0.0029 inch or 0.074 mm in diameter).

 Asphaltic Materials
 Asphaltic Base Course Plant Mix
 Asphaltic Concrete Wearing Course Plant Mix
 Bituminous Surface Treatment and Seal Coat
 Bit - Mac
 Hot Recycling of Asphalt Concrete
  Asphaltic Base Course Plant Mix
This work shall consist of furnishing of plant, labour, equipment and material and
performing all operations in connection with the construction of an asphaltic plant-mix
base course on a previously constructed and accepted subgrade, sub base or base
course.
 MATERIAL REQUIREMENTS
Mineral Aggregate Mineral aggregate for bituminous base course shall consist of coarse
aggregate, fine aggregate and filler material.
All conforming to the following requirements:
Crushed rock crushed gravel or crushed boulder. It shall be clean, hard, tough, sound, durable,
and free from decomposed stones, organic matter, shale, clay lump or other deleterious
substances. Rock or boulders, from which coarse aggregate is obtained, shall be of uniform
quality throughout the quarry.
The crushing shall be so regulated with at least two (2) mechanically fractured faces.
The coarse and fine aggregates shall meet the following applicable requirements:

Los Angeles Abrasion test (AASHTO T not be more than 40%

96)
Sodium Sulphate Soundness test shall be less than twelve 12%
(AASHTO T 104)
Sand Equivalent (AASHTO T 176) shall not be less than 45%

liquid limit AASHTO T 89 and T-90 not more than 25

Plasticity Index AASHTO T-89 and T-90. not more than 6

  Classes of Asphalt Base Course
Combined Aggregate Grading Requirements
Mix Designation Class A Class B

Use Leveling/Base Leveling/Base

Compacted Thickness 70 - 90 mm 50 - 80 mm

Asphalt Content weight percent of total mix 3 min 3 min

U.S. Standard Sieve Size Percent passing by weight

2" (50 mm) 100 ------

1.1/2" (38 mm) 90-100 100

3/4" (19 mm) 56-75 65-80

1/2" (12.5 mm) ----- 55-70
Plant Temperature 163 C 163 C
Site Temperature 160 C – 135 min 160 C – 135 min
 Construction Steps
 Plants used for the preparation of bituminous mixtures shall be "Batching Plants"
conforming to AASHTO M 156.Plant shall have minimum three cold bins and at least
3.5 decks of hot sieves.
 Asphalt cement shall be heated within a temperature range of hundred and thirty
five to hundred and sixty three (135-163) degrees centigrade at the time of mixing.
Asphalt cement heated above maximum shown shall be considered overheated and
shall be rejected and removed from job site.
 Dump truck used for hauling bituminous mixtures shall have tight, clean, smooth
metal beds which have been thinly coated with an approved material to prevent
adhering of material to the beds.
 Each truck shall have a cover of canvas or of other suitable material of sufficient size
as to protect the mixture from the weather.
 The mixture will be delivered on the road at temperature not less than hundred and
thirty (130) degree C.
 Drivers of dump trucks will ensure that while reversing the vehicles, paver is not
pushed back producing a hump.
 Bituminous pavers shall be self-contained, power-propelled units, provided with an
automatically controlled activated screed or strike-off assembly, heated if necessary,
capable of spreading and finishing courses of bituminous plant mix material in lane
widths applicable to the specified typical section and thickness shown on the plans.
 Before spreading materials, the surface of base shall be conditioned by application of
a prime or tack coat as specified.
 After a prime coat is applied, it shall be left undisturbed not less than twenty four
(24) hours.
 All mixtures shall be spread at a temperature of not less than hundred and thirty
(130) degree C and all initial rolling or tamping shall be performed when the
temperature of the mixture is such that the sum of the air temperature plus the
temperature of the mixture is between 165 degree C and 190 degree C.
 Compaction
After spreading rolling to be performed without excessive shoving or tearing as soon
as possible. The rolling process shall be longitudinally beginning at the low side of the
spread of material and proceeding towards high side of spread reason is that asphalt
mixture when hot tends to migrate towards the side under the action of roller.

There are three steps of rolling required for compaction of asphalt:

S.No Steps or types Equipment No. of passes

1 Breakdown or Initial Tandem Roller 4
2 Intermediate PTR 8-12
3 Finishing Tandem Roller 4

 Initial or breakdown rolling shall be done by means of either a tandem steel roller or
three wheeled steel roller. In no case shall the temperature be less than hundred and
twenty (120) degree C. for initial break down rolling.

 Intermediate rolling with a pneumatic tyre roller shall be done behind the initial rolling.

 Final rolling shall also do by tandem roller which eliminates marks from previous rolling.

 For intermediate and final compaction operations shall be completed before the
temperature drops down to hundred and ten (110) degree C.
 Rollers shall move at a slow but uniform speed.

 Rolling shall be continued until all roller marks are eliminated and a minimum density of
Ninety seven (97) percent of a laboratory compacted specimen made from asphaltic
material obtained for daily Marshall Density is achieved.
 Frequency of Testing for Cores
 One core shall be taken for each 100 linear meter of each lane of Asphaltic Base.
 If the core so taken is failed against the specified 97% density, then two (2)
additional cores shall be taken in the longitudinal alignment of the road at an
interval of three (3) meters on either side with respect to the failing core and shall
be tested against field density.
 If all the three cores give an average of 97% compaction, and the individual
compaction of the core is not less than ninety five (95) percent, then the
compaction is acceptable.
 If average of the cores further fails against compaction, then retake the cores at a
distance of fifteen (15) meters on either side and compaction shall be checked for
all the five cores in the same fashion. If average of five cores is 97%, the area will
be accepted.
 In case average is ninety six 96% or more, then Engineer may withhold the
payment in full or partly and observe behavior during maintenance period, for the
release of payment or otherwise.
 In case of failure of the average of these five cores giving average compaction of
less than 96%, the failed area shall be removed and subsequently be replaced by
specified mix in an approved manner at the expense of contractor.
 ASPHALT CONCRETE WEARING COURSE - PLANT MIX
This work shall consist of furnishing aggregates and asphalt binder at a central mixing
plant, to a specified mixing temperature, transporting, spreading and compacting the
mixture in an approved manner on primed or tacked base, sub base, subgrade, bridge
deck or concrete pavement.
 MATERIAL REQUIREMENTS
The Aggregates shall consist of coarse aggregates, fine aggregates and filler material and
shall be clean, hard, tough, durable and sound particles of uniform quality, geology,
petrology and free from decomposed material, vegetable matter, soil, clay, lumps and
other deleterious substances. Coarse aggregate crushed rock or crushed gravel having
two (2) faces mechanically crushed. The type of source shall be uniform throughout the
quarry location from where such a material is obtained. The coarse aggregates shall be
free from an excess of flat or/and elongated particles.
The coarse and fine aggregates shall meet the following requirements:

The coarse and fine aggregates shall meet the following applicable requirements:

Los Angeles Abrasion test (AASHTO T 96) not be more than 30%

Sodium Sulphate Soundness test (AASHTO T shall be less than 12%

104) twelve
Sand Equivalent (AASHTO T 176) shall not be less 45%
than
liquid limit AASHTO T 89 and T-90 not more than 25

Plasticity Index AASHTO T-89 and T-90. not more than 4

Combined Aggregate Grading Requirements foe Wearing Course
Mix Designation Class A Class B

Use Wearing/Finishing Wearing/Finishing

Compacted Thickness 50 - 80 mm 35 - 60 mm

Asphalt Content weight percent of total mix 3.5% min 3.5% min

U.S. Standard Sieve Size Percent passing by weight

25 mm or 1 in 100 ----

19mm or 3/4 in 90-100 100

12.5 or 1/2 in ---- 75-90

0.075 or No. 200 2-8 3-8
Plant Temperature 163 C 163 C
Site Temperature 160 C – 135 min 160 C – 135 min
 Construction Steps
 Plants used for the preparation of bituminous mixtures shall be "Batching Plants"
conforming to AASHTO M 156.Plant shall have minimum three cold bins and at least
3.5 decks of hot sieves.
 Asphalt cement shall be heated within a temperature range of hundred and thirty
five to hundred and sixty three (135-163) degrees centigrade at the time of mixing.
Asphalt cement heated above maximum shown shall be considered overheated and
shall be rejected and removed from job site.
 Dump truck used for hauling bituminous mixtures shall have tight, clean, smooth
metal beds which have been thinly coated with an approved material to prevent
adhering of material to the beds.
 Each truck shall have a cover of canvas or of other suitable material of sufficient size
as to protect the mixture from the weather.
 The mixture will be delivered on the road at temperature not less than hundred and
thirty (130) degree C.
 Drivers of dump trucks will ensure that while reversing the vehicles, paver is not
pushed back producing a hump.
 Bituminous pavers shall be self-contained, power-propelled units, provided with an
automatically controlled activated screed or strike-off assembly, heated if necessary,
capable of spreading and finishing courses of bituminous plant mix material in lane
widths applicable to the specified typical section and thickness shown on the plans.
  Before spreading materials, the surface of base shall be conditioned by application of
a prime or tack coat as specified.
 After a prime coat is applied, it shall be left undisturbed not less than twenty four
(24) hours.
 All mixtures shall be spread at a temperature of not less than hundred and thirty
(130) degree C and all initial rolling or tamping shall be performed when the
temperature of the mixture is such that the sum of the air temperature plus the
temperature of the mixture is between 165 degree C and 190 degree C.

 Compaction
After spreading rolling to be performed without excessive shoving or tearing as soon
as possible. The rolling process shall be longitudinally beginning at the low side of the
spread of material and proceeding towards high side of spread reason is that asphalt
mixture when hot tends to migrate towards the side under the action of roller.

There are three steps of rolling required for compaction of asphalt:

S.No Steps or types Equipment No. of passes

1 Breakdown or Initial Tandem Roller 4
2 Intermediate PTR 8-12
3 Finishing Tandem Roller 4

 Initial or breakdown rolling shall be done by means of either a tandem steel roller or
three wheeled steel roller. In no case shall the temperature be less than hundred and
twenty (120) degree C. for initial break down rolling.

 Intermediate rolling with a pneumatic tyre roller shall be done behind the initial rolling.

 Final rolling shall also do by tandem roller which eliminates marks from previous rolling.

 For intermediate and final compaction operations shall be completed before the
temperature drops down to hundred and ten (110) degree C.
 Rollers shall move at a slow but uniform speed.

 Rolling shall be continued until all roller marks are eliminated and a minimum density of
Ninety seven (97) percent of a laboratory compacted specimen made from asphaltic
material obtained for daily Marshall Density is achieved.
 Frequency of Testing for Cores
 One core shall be taken for each 100 linear meter of each lane of Asphaltic Base.
 If the core so taken is failed against the specified 97% density, then two (2)
additional cores shall be taken in the longitudinal alignment of the road at an
interval of three (3) meters on either side with respect to the failing core and shall
be tested against field density.
 If all the three cores give an average of 97% compaction, and the individual
compaction of the core is not less than ninety five (95) percent, then the
compaction is acceptable.
 If average of the cores further fails against compaction, then retake the cores at a
distance of fifteen (15) meters on either side and compaction shall be checked for
all the five cores in the same fashion. If average of five cores is 97%, the area will
be accepted.
 In case average is ninety six 96% or more, then Engineer may withhold the
payment in full or partly and observe behavior during maintenance period, for the
release of payment or otherwise.
In case of failure of the average of these five cores giving average compaction of less
than 96%, the failed area shall be removed and subsequently be replaced by
specified mix in an approved manner at the expense of contractor.
  Pavement Thickness and Tolerances
 The asphalt concrete wearing course shall be compacted to the desired level
and cross slope. The tolerances in compacted thickness of the wearing course
shall be +3mm from the desired thickness.
 For determination of thickness one (1) core per hundred meters of each lane
will be taken. If the thickness so determined is deficient by more than three (3)
mm, but not more than ten (10) mm, payment will be made at an adjusted
price as specified in table.
 The surface of the wearing course shall be tested by the Engineer using a 5
meters straightedge at selected locations. The variation of the surface from
the testing edge of the straightedge between any two contacts, longitudinal or
transverse with the surface shall at no point exceed five (5) millimeters.
 A tolerance of + three (3) mm shall be allowed in compacted thickness of
wearing course. However, any asphalt in excess of 3 mm shall not be paid and
any layer deficient by more than 3 mm but not exceeding 10 mm.
Deficiency in thickness as determined by Proportional Rate of contract Price
cores allowed.
0.0 mm to 3.0 mm 100%
3.1 mm to 5.0 mm 90%
5.1 mm to 10.0 mm 80%