Continental Engineering Corporation

NAME OF THE WORK: FOUR LANING OF HYDERABAD – BANGALORE

SECTION KM. 336.000 TO 376.000 OF NH-7 PACKAGE-ADB-II/C-13

METHOD STATEMENT FOR

BITUMINOUS CONCRETE

CONTENTS

1.0 Objective

2.0 Scope of work

3.0 Reference Documents

4.0 Man Power

5.0 Equipment / Machinery

6.0 Material

7.0 Methodology

8.0 Quality Control

Version Prepared By: Approved By: Date:

CEC/ATP/C-13/N o 1 15.04.09
 BITUMINOUS CONCRETE

1.0 Objective:

This method statement provides Bituminous Concrete. Methodology

adopted by CEC in the ADB-II/C-13 Package

2.0 Scope of work:

This scope of work deals with mixing, laying, spreading and compacting
the approved bituminous mix in accordance with clause 509 of
MOSRT&H.

3.0 Reference Document:

1. Contract documents volume – II Technical Specification.

2. Specification for Road & Building works MORT&H (Fourth Revision)
3. IRC-SP/53
4.0 Man Power:

1. Senior Engineer (Highways) 1 no.

 (Ravi Kumar) Km. @ 336.000 – 348.000
 (Vijaya Ratnam) Km. @ 348.000 – 364.000
 (Ranga Rao) Km. @ 364.000 – 376.000
2. Junior Engineer (Highways) 1 no.
3. Hot Mix Plant operator 1 no.
4. Electrical sensor paver operator 1 no.
5. Un skilled workers 8 no.
6. Supervisor 1 no.
7. Lab staff 1 no.
8. Survey staff 1 no.
9. Quality technician 1 no.
5.0 Equipments / Machinery

1. Hot Mixing Plant 176 TPH 1 no.

2. Electronic sensor paver width
(according to the drawings as specified) 1 no.
3. Dumpers 10 no.
4. Auto level 1 no.
5. Leveling staff 1 no.
6. Measuring tape 1 no.
7. Smooth-wheeled Roller of 8 to 10 tons 2 no.
8. Pneumatic tyred Roller of 12 – 15 tons 1 no.
9. Bitumen sprayer 1 no.
10. Air Compressor 1 no.
11. Water Tanker 1 no.

6.0 Material:

The constituents of the aggregates will be produced by the Crusher @

373.600 LHS. The aggregates satisfy both Los Angels abrasion value &
Aggregate impact value.

The material to be used for construction of Bituminous Concrete will be

satisfying the following requirements.

1. Paving bitumen of grade CRMB-55

2. Coarse aggregates will be of clean, strong, durable, cubical shape and
free from other deleterious matter and adherent coating.
3. Los Angeles abrasion value will not be more than 40% when tested as
per IS: 2386 (Part - 4)
4. Aggregate impact value will be not be more than 27% when tested as
per IS: 2386 (Part – 4)
5. Flakiness and Elongation indices will not be more than 30% when
tested as per IS: 2386 (Part – 1)
6. Stripping value of bitumen aggregate mixtures will be of minimum
retained coating 95% when tested as per AASHTOT 182.
7. Water absorption of the aggregate will not be more than 2% when
tested as per IS: 2386 (Part-5)
8. Plasticity index of the filler (Cement ) will not be grater than 4.
 9. The filler (Cement ) will be graded with the following limits, If lime satisfies as
per IS: 1514 & 712

IS Siive Percent
600 micron 100
300 micron 95-100
75 micron 85-100

10. The BC will be laid in one layer. The total thickness of BC is

50mm,. The aggregate gradation will be satisfying the following limits
35-45mm of Grade-II.

Grade II
Sieve Designation JMF
Percent Passing
19mm 100 100
13.2mm 79-100 88.9
9.5mm 70-88 80.2
4.75mm 53-71 62.6
2.36mm 42-58 49.8
1.18mm 34-48 35.9
600 micron 26-38 27.6
300 micron 18-28 19.6
150micron 12-20 12.8

75micron 4-10 6.9

7.0 Methodology:

1. Weather conditions to be checked

2. The base will be thoroughly swept clean free from dust and foreign
matter by means of compressed air. Marking will be done by adjusting
paver sensor to its line, grades and cross sections. (Full widths)
3. Tack Coat will be applied over the prepared base by using approved
emulsion to the required quantity & delay 24 hours before laying BC.
4. Mix produced from the hot mix plant will be transported to the site by
means of end dumpers covered.
5. The mix will be unloading gently into the paver hoper and paving will
be started uniformly.
 6. The levels will be checked before paving and after compaction with
respect to the designed levels. If there is any variation in the levels,
the same will be adjusted in further paving, after analyse and
agreement with the Engineer.
7. Initial or break down rolling will be carried out immediately following
close to the paver in longitudinal direction from lower edge to upper
edge with 80-100 KN static weight of smooth wheeler roller. The
speed of the roller will be maintained not more than 5 Km/hr.
8. Intermediate rolling will be done with 80-100 KN static weight of
vibratory roller or with a pneumatic tyred roller of 150-250 KN weight
having tyre pressure of at least 0.7 MPa; and it will be continued till
the compaction achieved is at least 98%.
9. Pattern decided after the trail stretch.
10. Traffic will be allowed after completion of the final rolling when
the mix has cooled down to the surrounding temperature.

8.0 Quality Control:

1. The application of tack coat will be checked as per the following table.

Type of Surface Quantity / 10 sq.m

1. Normal Bituminous Surface 2.0 – 2.5

2. Dry and hungry bituminous Surface 2.5 – 3.0

3. Granular surface treated with primer 2.5 – 3.0

4. Non Bituminous Surface
a) Granular base (not primed) 3.5 – 4.0
b) Cement concrete payment 3.0 – 3.5

3. The gradation of the mix will be controlled at plant as per the

approved designed mix.

4. Mix temperature will be controlled at plant with in the range of

140 0 C -160 0 C and the temperature less than 115 0 C will not be used for
paving.
5. The compacted surface will be checked for field density by taking
cross 24 hours after laying at the frequency of 1 test for 250 sq.m.
The degree of compaction should not be less than 98% of Marshall
Density.
The surface will be checked for levels at 5m intervals longitudinally and
transversely and the same will be with in +/-6

Continental Engineering Corporation

 NAME OF THE WORK: FOUR LANING OF HYDERABAD – BANGALORE
SECTION KM. 336.000 TO 376.000 OF NH-7 PACKAGE-ADB-II/C-13

METHOD STATEMENT FOR

DENSE BITUMINOUS MACADAM

CONTENTS

9.0 Objective

10.0 Scope of work

11.0 Reference Documents

12.0 Man Power

13.0 Equipment / Machinery

14.0 Material

15.0 Methodology

16.0 Quality Control

Version Prepared By: Approved By: Date:

CEC/ATP/C-13/N o 2 18.06.08

DENSE BITUMINOUS MACADAM

9.0 Objective:

This method statement provides Dense Bituminous Macadam.

Methodology adopted by CEC in the ADB-II/C-13 Package

10.0 Scope of work:

This scope of work deals with mixing, laying, spreading and compacting
the approved bituminous mix in accordance with clause 507 of MORT&H.

11.0 Reference Document:

4. Contract documents volume – II Technical Specification.

5. Specification for Road & Building works MORT&H (Fourth Revision)
6. IRC 109-1997

12.0 Man Power:

1. Senior Engineer (Highways) 1 no.

 (Ravi Kumar) Km. @ 336.000 – 348.000
 (Vijaya Ratnam) Km. @ 348.000 – 364.000
 (Ranga Rao) Km. @ 364.000 – 376.000
2. Junior Engineer (Highways) 1 no.
3. Hot Mix Plant operator 1 no.
4. Electrical sensor paver operator 1 no.
5. Un skilled workers 8 no.
6. Supervisor 1 no.
7. Lab staff 1 no.
8. Survey staff 1 no.
9. Quality technician 1 no.

13.0 Equipments / Machinery

 12. Hot Mixing Plant 176 TPH 1 no.
13. Electronic sensor paver width
(according to the drawings as specified) 1 no.
14. Dumpers 10 no.
15. Auto level 1 no.
16. Leveling staff 1 no.
17. Measuring tape 1 no.
18. Smooth-wheeled Roller of 8 to 10 tons 2 no.
19. Pneumatic tyred Roller of 12 – 15 tons 1 no.
20. Bitumen sprayer 1 no.
21. Air Compressor 1 no.
22. Water Tanker 1 no.

14.0 Material:

The constituents of the aggregates will be produced by the Crusher @

373.600 LHS. The aggregates satisfy both Los Angels abrasion value &
Aggregate impact value.

The material to be used for construction of Dense Bituminous Macadam

will be satisfying the following requirements.

11. Paving bitumen of grade 60/70

12. Coarse aggregates will be of clean, strong, durable, cubical shape
and free from other deleterious matter and adherent coating.
13. Los Angeles abrasion value will not be more than 40% when
tested as per IS: 2386 (Part - 4)
14. Aggregate impact value will be not be more than 30% when
tested as per IS: 2386 (Part – 4)
15. Flakiness and Elongation indices will not be more than 30%
when tested as per IS: 2386 (Part – 1)
16. Stripping value of bitumen aggregate mixtures will be of
minimum retained coating 95% when tested as per AASHTOT 182.
17. Water absorption of the aggregate will not be more than 2% when
tested as per IS: 2386 (Part-5)
18. Plasticity index of the filler (Lime/Cement ) will not be grater
than 4.
19. The filler (Lime/Cement ) will be graded with the following limits, If lime
satisfies as per IS: 1514 & 712
 IS Siive Percent
600 micron 100
300 micron 95-100
75 micron 85-100

20. The DBM will be laid in two layers. If the total thickness of
DBM is 120mm, 1 s t layer will be laid for a thickness of 60mm and
remaining thickness will be laid in II n d layer. It will be laid in two
equal layers. The aggregate gradation will be satisfying the following
limits 50-75mm, Grade-II for a thickness of 50-75mm.

Grade II
Sieve Designation JMF
Percent Passing
37.5mm 100 100
26.5 90-100 93.9
19.0mm 71-95 84.5
13.2mm 56-80 68.9
4.75mm 38-54 44.7
2.36mm 28-42 34.0
300 micron 7-21 12.8
75 micron 2-8 4.6

15.0 Methodology:

11. Weather conditions to be checked

12. The base will be thoroughly swept clean free from dust and
foreign matter by means of compressed air. WMM will be re-material,
re-compacted and tested before laying RFI.
13. Marking will be done by adjusting paver sensor to its line, grades
and cross sections. (Full widths)
14. Prime Coat on WMM in first.
15. Tack Coat will be applied over the prepared base by using
approved emulsion to the required quantity & delay 24 hours before
laying DBM.
16. Mix produced from the hot mix plant will be transported to the
site by means of end dumpers covered.
 17. The mix will be unloading gently into the paver hoper and paving
will be started uniformly.
18. The levels will be checked before paving and after compaction
with respect to the designed levels. If there is any variation in the
levels, the same will be adjusted in further paving, after analyse and
agreement with the Engineer.
19. Initial or break down rolling will be carried out immediately
following close to the paver in longitudinal direction from lower edge
to upper edge with 80-100 KN static weight of smooth wheeler roller.
The speed of the roller will be maintained not more than 5 Km/hr.
20. Intermediate rolling will be done with 80-100 KN static weight
of vibratory roller or with a pneumatic tyred roller of 150-250 KN
weight having tyre pressure of at least 0.7 MPa; and it will be
continued till the compaction achieved is at least 98%.
21. Pattern decided after the trail stretch.
22. Traffic will be allowed after completion of the final rolling when
the mix has cooled down to the surrounding temperature.

16.0 Quality Control:

2. Prime Coat

3. The application of tack coat will be checked as per the following table.

Type of Surface Quantity / 10 sq.m

1. Normal Bituminous Surface 2.0 – 2.5

2. Dry and hungry bituminous Surface 2.5 – 3.0

3. Granular surface treated with primer 2.5 – 3.0

4. Non Bituminous Surface
a) Granular base (not primed) 3.5 – 4.0
b) Cement concrete payment 3.0 – 3.5

6. The gradation of the mix will be controlled at plant as per the

approved designed mix.
7. Mix temperature will be controlled at plant with in the range of
150 0 C -163 0 C and the temperature less than 120 0 C will not be used for
paving.
8. The compacted surface will be checked for field density by taking
cross 24 hours after laying at the frequency of 1 test for 250 sq.m.
The degree of compaction should not be less than 98% of Modified
Marshall.
The surface will be checked for levels at 5m intervals longitudinally and
transversely and the same will be with in +/-6
 Continental Engineering Corporation

NAME OF THE WORK: FOUR LANING OF HYDERABAD – BANGALORE

SECTION KM. 336.000 TO 376.000 OF NH-7 PACKAGE-ADB-II/C-13

METHOD STATEMENT FOR

BITUMINOUS MACADAM

CONTENTS

1.0Objective

2.0Scope of work

3.0Reference Documents

4.0Man Power

5.0Equipment / Machinery

6.0Material

7.0Methodology

8.0Quality Control

Version Prepared By: Approved By: Date:

20.10.08
CEC/ATP/C-13/N o 1
 BITUMINOUS MACADAM

1.0Objective:

This method statement provides Bituminous Macadam. Methodology

adopted by CEC in the ADB-II/C-13 Package

2.0Scope of work:

This scope of work deals with mixing, laying, spreading and compacting
the approved bituminous mix in accordance with clause 504 Grading-II of
MOSRT&H.

3.0Reference Document:

1.0 Contract documents volume – II Technical Specification.

2.0 Specification for Road & Building works MORT&H (Fourth Revision)

4.0Man Power:

1. Senior Engineer (Highways) 1 no.

 (Ravi Kumar) Km. @ 336.000 – 348.000
 (Vijaya Ratnam) Km. @ 348.000 – 364.000
 (Ranga Rao) Km. @ 364.000 – 376.000
2. Junior Engineer (Highways) 1 no.
3. Hot Mix Plant operator 1 no.
4. Electrical sensor paver operator 1 no.
5. Un skilled workers 8 no.
6. Supervisor 1 no.
7. Lab staff 1 no.
8. Survey staff 1 no.
9. Quality technician 1 no.
5.0Equipments / Machinery

1.0 Hot Mixing Plant 176 TPH 1 no.

2.0 Electronic sensor paver width
(According to the drawings as specified) 1 no.
3.0 Dumpers 10 no.
4.0 Auto level 1 no.
5.0 Leveling staff 1 no.
6.0 Measuring tape 1 no.
7.0 Smooth-wheeled Roller of 8 to 10 tons 2 no.
8.0 Pneumatic tyred Roller of 12 – 15 tons 1 no.
9.0 Bitumen sprayer 1 no.
10.0 Air Compressor 1 no.
11.0 Water Tanker 1 no.

6.0Material:

The constituents of the aggregates will be produced by the Crusher @

373.600 LHS. The aggregates satisfy both Los Angel’s abrasion value &
Aggregate impact value.

The material to be used for construction of Bituminous Macadam will be

satisfying the following requirements.

1.0 Paving bitumen of grade 60/70

2.0 Coarse aggregates will be of clean, strong, durable, cubical shape and
free from other deleterious matter and adherent coating.
3.0 Los Angeles abrasion value will not be more than 40% when tested as
per IS: 2386 (Part - 4)
4.0 Aggregate impact value will be not be more than 30% when tested as
per IS: 2386 (Part – 4)
5.0 Flakiness and Elongation indices will not be more than 30% when
tested as per IS: 2386 (Part – 1)
6.0 Stripping value of bitumen aggregate mixtures will be of minimum
retained coating 95% when tested as per AASHTOT 182.
7.0 Water absorption of the aggregate will not be more than 2% when
tested as per IS: 2386 (Part-5)
 8.0 Captured fines used in filler

IS Siive Percent
600 micron 100
300 micron 95-100
75 micron 85-100

10.0 The BM will be laid in Single layer. If the total thickness of BM is

75mm, The aggregate gradation will be satisfying the following limits 50-
75mm, Grade-II for Service roads profile corrective course. The BM will
be laid in 2 layer if the overall thickness is more than 75mm.

Grade II
Sieve Designation JMF
Percent Passing
26.5 100 100
19.0mm 90-100 93.8
13.2mm 56-88 72.3
4.75mm 16-36 23.4
2.36mm 4-19 16.9
300 micron 2-10 7.8
75 micron 0-8 4.0

7.0Methodology:

1.0 Weather conditions to be checked

2.0 The base will be thoroughly swept clean free from dust and foreign
matter by means of compressed air. WMM/Existing road surface will be
re-material, re-compacted and tested before laying RFI.
3.0 Marking will be done by adjusting paver sensor to its line, grades and
cross sections. (Full widths)
4.0 Prime Coat on WMM in first.
5.0 Tack Coat will be applied over the prepared base by using approved
emulsion to the required quantity & delay 48 hours before laying BM.
6.0 Mix produced from the hot mix plant will be transported to the site by
means of end dumpers covered.
7.0 The mix will be unloading gently into the paver hoper and paving will
be started uniformly.
 8.0 The levels will be checked before paving and after compaction with
respect to the designed levels. If there is any variation in the levels, the
same will be adjusted in further paving, after analyse and agreement with
the Engineer.
9.0 Initial or break down rolling will be carried out immediately
following close to the paver in longitudinal direction from lower edge to
upper edge with 80-100 KN static weight of smooth wheeler roller. The
speed of the roller will be maintained not more than 5 Km/hr.
10.0 Intermediate rolling will be done with 80-100 KN static weight of
vibratory roller or with a pneumatic tyred roller of 150-250 KN weight
having tyre pressure of at least 0.7 MPa; and it will be continued till the
compaction achieved is at least 98%.
11.0 Pattern decided after the trail stretch.
12.0 Traffic will be allowed after completion of the wearing course
(SDBC)
8.0Quality Control:

1.0 Prime Coat

2.0 The application of tack coat will be checked as per the following table.

Type of Surface Quantity / 10 sq.m

1. Normal Bituminous Surface 2.0 – 2.5

2. Dry and hungry bituminous Surface 2.5 – 3.0

3. Granular surface treated with primer 2.5 – 3.0

4. Non Bituminous Surface
a) Granular base (not primed) 3.5 – 4.0
b) Cement concrete payment 3.0 – 3.5

3.0 The gradation of the mix will be controlled at plant as per the
approved designed mix.

4.0 Mix temperature will be controlled at plant with in the maximum

165 0 C and the temperature less than 125 0 C will not be used for paving.

5.0 The surface will be checked for levels at 5m intervals longitudinally

and transversely and the same will be with in +/-6