Mastic Asphalt Design (Without Ca)

NS2/BOT/TN - 03 From Start of Proposed Flyover at Namakkal (Km. 248.
625) to
Start at Karur Bypass (Km. 292.600) in the state of Tamilnadu
Client : National Highways Authority of India
Independent Consultant : M/s. Intercontinental Consultants and Technocrats Pvt. Ltd.,
Project Company : M/s. NK Toll Road Ltd.,
EPC Contractor : M/s. Reliance Innoventures Pvt. Ltd.,
Construction Contractor : M/s. Gannon Dunkerley & Co Ltd.,
WATER ABSORPTION TEST
TEST METHOD : IS 2386 PART - III
20.07.07
Sample No. 1 Date of Sampling
21.07.08
Location 282+400 RHS Date of Testing
Source of Material Thaneerpandal Puthur Quarr Proposed use Mastic Asphalt
Type of Material Hot Bin Aggregates Size of Agg 3mm down
Trial No
Determination Average
1 2 3
Wt of Saturated Surface Dry Aggregates in Air (A gm)

695.0 727.0 740.0
Weight of Oven Dried Aggregates in Air (D gm)

690.0 722.0 735.0
Water Absorption (%) = 100 (A - D)/D

0.7246 0.6925 0.6803 0.70
Remarks :
Contractor's Rep. Concessionaire's Rep. I.C. Rep.

Date
Date Date
NS2/BOT/TN - 03 From Start of Proposed Flyover at Namakkal (Km. 248.625) to Start at
Karur Bypass (Km. 292.600) in the state of Tamilnadu
PENETRATION TEST
(TEST METHOD : IS 1203)
Sample No 1 Date of Sampling 20.07.08
Location @ Crusher Lab Date of Testing 20.07.08
Bitumen Grade 10/20 Source of material STP,CHENNAI
Observation No: 1 2 3
Test Load (gms) 100 100 100
Test Temp (0C) 25 25 25
Time For Penetration (Sec) 5 5 5
Penetration 15 14.0 16
Average Penetration 15
Acceptance Creteria : As per MoRT&H,TABLE : 500 - 29 15+/- 5

Date Date Date
NS2/BOT/TN - 03 From Start of Proposed Flyover at Namakkal (Km. 248.625) to Start at Karur
Bypass (Km. 292.600) in the state of Tamilnadu

SOFTENING POINT TEST
(TEST METHOD : IS 1205)
Lab. Sample No : 1 Date of Sampling 21.07.08
Type of material Binder for mastic Asphalt Date of Testing 21.07.08
Source of material STP,CHENNAI
Apparatus Used : Ring and Ball Apparatus
Period of Cooling at Room Temperature (min) : 30 0C
Period of Cooling in Water bath (min) : 15 Min @ 50C
Description Ball No 1 Ball No 2 Softening Point Mean Value
Temperature at which sample

69.00 70.00 69.50
touches the bottom Plate
Acceptance Creteria : As per MoRT&H,TABLE : 500 - 29 65+/-10 0C
Remarks

Date Date Date
INDIVIDUAL GRADATION FOR MASTIC ASPHALT
Source of material :M/s Pakkiyam Lime Works Date of Sampling 21.07.08
Location : Crusher Lab Date of Testing 21.07.08
Type of material Fine Aggregates - 3 mm down Total Weight (gm) 1000
Sample No 1
Weight Retained Cumulative Cumulative % Cumulative %

I.S.Sieve (mm) Remarks
(gm) Wt.Retained (gm) Retained Passing
2.360 0.0 0.0 0.00 100.00
0.600 340.0 340.0 34.00 66.00
0.212 430.0 770.0 77.00 23.00
0.075 200.0 970.0 97.00 3.00
PAN 30.0 500.0 100.00 0.00
Sample No 2 Weight of Sample Taken (gms) : 1000
2.360 0.0 0.0 0.00 100.00
0.600 330.0 330.0 33.00 67.00
0.212 430.0 760.0 76.00 24.00
0.075 217.5 977.5 97.75 2.25
PAN 20.0 997.5 99.75 0.00
2.360 0.0 0.0 0.00 100.00
0.600 360.0 360.0 36.00 64.00
0.212 420.0 780.0 78.00 22.00
0.075 185.0 965.0 96.50 3.50
PAN 35.0 1000.0 100.00 0.00

Date Date Date
Type of material Fine Aggregates - 3 mm down Total Weight (gm) 1000
Sample No 4
2.360 0.0 0.0 0.00 100.00
0.600 350.0 350.0 35.00 65.00
0.212 410.0 760.0 76.00 24.00
0.075 202.5 962.5 96.25 3.75
PAN 37.5 1000.0 100.00 0.00
2.360 0.0 0.0 0.00 100.00
0.600 330.0 330.0 33.00 67.00
0.212 440.0 770.0 77.00 23.00
0.075 202.5 972.5 97.25 2.75
PAN 27.5 1000.0 100.00 0.00
2.360 0.0 0.0 0.00 100.00
0.600 330.0 330.0 33.00 67.00
0.212 450.0 780.0 78.00 22.00
0.075 190.0 970.0 97.00 3.00
PAN 30.0 1000.0 100.00 0.00

Date Date Date

Type of material Filler (Lime Powder) Total Weight (gm) 500
Sample No 1
2.360 0.0 0.0 0.00 100.00
0.600 0.0 0.0 0.00 100.00
0.212 0.0 0.0 0.00 100.00
0.075 0.0 0.0 0.00 100.00
PAN 500.0 500.0 100.00 0.00
2.360 0.0 0.0 0.00 100.00
0.600 0.0 0.0 0.00 100.00
0.212 0.0 0.0 0.00 100.00
0.075 0.0 0.0 0.00 100.00
PAN 500.0 500.0 100.00 0.00
2.360 0.0 0.0 0.00 100.00
0.600 0.0 0.0 0.00 100.00
0.212 0.0 0.0 0.00 100.00
0.075 0.0 0.0 0.00 100.00
PAN 500.0 500.0 100.00 0.00

Date Date Date
Type of material Filler (Lime Powder) Total Weight (gm) 500
Sample No 4
2.360 0.0 0.0 0.00 100.00
0.600 0.0 0.0 0.00 100.00
0.212 0.0 0.0 0.00 100.00
0.075 0.0 0.0 0.00 100.00
PAN 500.0 500.0 100.00 0.00
2.360 0.0 0.0 0.00 100.00
0.600 0.0 0.0 0.00 100.00
0.212 0.0 0.0 0.00 100.00
0.075 0.0 0.0 0.00 100.00
PAN 500.0 500.0 100.00 0.00
2.360 0.0 0.0 0.00 100.00
0.600 0.0 0.0 0.00 100.00
0.212 0.0 0.0 0.00 100.00
0.075 0.0 0.0 0.00 100.00
PAN 500.0 500.0 100.00 0.00

Date Date Date

AVERAGE INDIVIDUAL GRADATION FOR MASTIC ASPHALT
Source of material : Thaneerpanthal Pudur Pupose of material: Mastic Asphalt Mix design
FINE AGGREGATES (3mm Down Grade)
IS Sieve in mm Sample - 1 Sample - 2 Sample - 3 Sample - 4 Sample - 5 Sample - 6 Average
2.300 100.00 100.00 100.00 100.00 100.00 100.00 100.00
0.600 66.00 67.00 64.00 65.00 67.00 67.00 66.00
0.212 23.00 24.00 22.00 24.00 23.00 23.00 23.17
0.075 3.00 2.25 3.50 3.75 2.75 2.75 3.00
FILLER (LIME)
IS Sieve in mm Sample - 1 Sample - 2 Sample - 3 Sample - 4 Sample - 5 Sample - 6 Average
2.300 100.00 100.00 100.00 100.00 100.00 100.00 100.00
0.600 100.00 100.00 100.00 100.00 100.00 100.00 100.00
0.212 100.00 100.00 100.00 100.00 100.00 100.00 100.00
0.075 100.00 100.00 100.00 100.00 100.00 100.00 100.00
Contractor's Rep. Concessionaire's Rep. IC' Rep

Date Date Date
Construction Contractor : M/s. Gannon Dunkerley & Co Ltd., DATE ; 13.08.08
FINE AGGREGATE GRADATION FOR MASTIC ASPHALT
TEST METHOD : MORT&H TABLE 500 - 31
Cumulative % of Passing
I.S.Sieve (mm)
3mm Down Lime
2.360 100.00 100.00
0.600 66.00 100.00
0.212 23.00 100.00
0.075 3.00 100.00
Mix Proportion 60.0 40.0 100.00

Cum % % of Limits (MoRTH
Cum % Retained wt.retained Table 500 -31)
I.S.Sieve (mm) 3mm Down Lime Passing
2.360 60.00 40.00 100.00 0.00 0.00 0
0.600 39.60 40.00 79.60 20.40 20.40 0 - 25
0.212 13.80 40.00 53.80 46.20 25.80 10 - 30
0.075 1.80 40.00 41.80 58.20 12.00 10 - 30
Remarks :

Date Date Date
COMBINED GRADATION FOR MASTIC ASPHALT MIX
TEST METHOD : MORT&H TABLE 500 - 18
Sample No 1 Date Sampled 16.08.08
Location/Source Thaneerpanthal Pudur Quarry Date Tested 16.08.08
Type of Material Mastic Ashpalt Mix Tested by Jointly with Consultant
Total Wt (gms) 1000
Specificaion
I.S.Sieve (mm) Weight Retained % Wt Retained JMF
limits
2.360 0 0.00 0 0.00
0.600 210 21.00 0 - 25 20.40
0.212 264 26.40 10 - 30 25.80
0.075 122.0 12.20 10 - 30 12.00
Contractor's Rep. Concessionaire's Rep. IC'Rep
Date Date Date

1000
100 100 100 0.0 100 1000 1000 0 1000
79 100 89.5 20.4 80 796 -204 12 -192
59 79 69 25.8 74 742 -54 12 -42
52 72 62 12.0 88 880 138 12 150

MASTIC ASPHALT MIX PREPRATION
TEMPERATURE
STAGE DESCRIPTION OF WORK PERIOD
RANGE
1 COOKING OF FILLER 1 HOUR 1700C TO 2100C
1 HEATING OF BINDER REQUIRED TIME 1700C TO 1800C
SOME TIME (MIN

2 COOKING OF FILLER + HALF QTY OF BINDER 1700C TO 2100C
15 min)
COOKING OF FILLER + BALANCE HALF QTY OF BINDER+FINE
3 1 HOUR 1700C TO 2100C
AGGREGATES
CAUTION :
TEMPERATURE SHALL NOT EXCED 2100C
REMARKS :
Date Date Date

HARDNESS NUMBER FOR MASTIC ASPHALT MIX

TEST METHOD : IS 1195 -1978
Sample No 1 Date of Casting 16.08.08
Location at Crusher Lab Date of Testing 17.08.08
Bitumen(%) 14 Test Temperature 250C
MIX PROPORTION OF MASTIC ASPHALT :
SL NO MATERIAL NAME FA & FILLER FA ,FILLER & BITUMEN
1 COARSE AGG 0.0 0.0
2 FINE AGG 60.0 51.6
3 LIME 40.0 34.4
4 ASPHALT 0.0 14.0
TOTAL 100.0 100.0
HARDNESS NUMBER OF MASTIC ASPHALT MIX
AVERAGE HARDNESS
TRIAL NO HARDNESS NUMBER LIMITS
NUMBER
1 7.70
2 7.90
3 8.00 7.92 10 - 20
4 8.10
5 7.90

Date Date Date

2 FINE AGG 60.0 51.0
3 LIME 40.0 34.0
4 ASPHALT 0.0 15.0
TOTAL 100.0 100.0

AVERAGE HARDNESS
NUMBER
1 8.80
2 8.90
3 9.10 9.08 10 - 20
4 9.10
5 9.50
Date Date Date


2 FINE AGG 60.0 50.4
3 LIME 40.0 33.6
4 ASPHALT 0.0 16.0
TOTAL 100.0 100.0

AVERAGE HARDNESS
NUMBER
1 12.50
2 13.00
3 13.50 12.94 10 - 20
4 12.90
5 12.80
Date Date Date


2 FINE AGG 60.0 49.8
3 LIME 40.0 33.2
4 ASPHALT 0.0 17.0
TOTAL 100.0 100.0

AVERAGE HARDNESS
NUMBER
1 9.00
2 8.70
3 8.20 8.90 10 - 20
4 9.10
8.90 10 - 20
5 9.50
Date Date Date

ABSTRACT OF HARDNESS NUMBER FOR MASTIC ASPHALT MIX
Fine Binder Hardness

SL NO Trial No Filler (%) Remarks
Aggregate(%) Content (%) Number
1 1 51.6 34.4 14 7.92
2 2 51.0 34.0 15 9.08
3 3 50.4 33.6 16 12.94
4 4 49.8 33.2 17 8.90
Remarks : Acceptance creteria as per MoRT&H Specification - Hardness Number : 10 - 20

Date Date Date

HARDNESS NUMBER FOR MASTIC ASPHALT MIX AT OPC

2 FINE AGG 60.0 50.4
3 LIME 40.0 33.6
4 ASPHALT 0.0 16.0
TOTAL 100.0 100.0

AVERAGE HARDNESS
NUMBER
1 12.90
2 12.80
3 13.25 12.99 10 - 20
4 12.50
5 13.50
Date Date Date


MIX DESIGN REPORT FOR MASTIC ASPHALT

TEST METHOD : MORT&H SECTION 500 - 15
Mix Proportion By Total Aggregates

Fine
Material Name Filler Binder TOTAL
Aggregate
Mix Propotion By FA & Filler (%) 60 40 0 100
Mix Propotion By Total Mixture (%) 50.40 33.60 16.00 100
Properties of Mixutre
Test
Sl.No Description of the Test Specification Limit
Results
1.0 Optimum Bitumen Content By weight of mix (%) 16.00 14.0 % - 17.0%
2.0 Hardness Number (IS 1195 - 1978)
2.1 At the time of Laying at 25 0 C 12.94 10 to 20
Properties of Materials
1.0 Physical Properties of Binder
1.1 Penetration of Binder 15.0 15+/-5
1.2 Softening Point 69.50 Min 65 0C
1.3 Loss on heating for 5h at 1630C % By Mass Max Max 2%
1.4 Solubility in trichloroethylene, % by Mass Min Min 95 %
1.5 Ash(Mineral matter), % by mass Max 1%
2.0 Physical Properties of Filler (Lime)
2.1 75 mic passing 100.00% 100% Passing

2.2 Calcium Carbonate (%) by total Wt 86.40% Min 80% by Total wt
3.0 Physical Properties of Fine Aggregates
3.1 Water Absorption of Fine Aggregate(%) 0.70% Max 2%

Date Date Date
NS2/BOT/TN - 03 From Start of Proposed Flyover at
Namakkal (Km. 248.625) To Start at Karur Bypass (Km.
292.600) in the state of Tamilnadu
MASTIC ASPHALT MIX DESIGN REPORT
SUBMITTED TO
: M/s. Intercontinental Consultants and Technocrats Pvt. Ltd in

Independent Consultant
Association with M/s Feedback venture Pvt Ltd.
SUBMITTED BY
M/s. Gannon Dunkerley & Co Ltd.,

(Construction Contractor)

Mastic Asphalt Design (Without Ca)

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NS2/BOT/TN - 03 From Start of Proposed Flyover at Namakkal (Km. 248.

Client : National Highways Authority of India

Independent Consultant : M/s. Intercontinental Consultants and Technocrats Pvt. Ltd.,

Project Company : M/s. NK Toll Road Ltd.,

EPC Contractor : M/s. Reliance Innoventures Pvt. Ltd.,

Construction Contractor : M/s. Gannon Dunkerley & Co Ltd.,

WATER ABSORPTION TEST

TEST METHOD : IS 2386 PART - III

Source of Material Thaneerpandal Puthur Quarr Proposed use Mastic Asphalt

Type of Material Hot Bin Aggregates Size of Agg 3mm down

Wt of Saturated Surface Dry Aggregates in Air (A gm)

Weight of Oven Dried Aggregates in Air (D gm)

Water Absorption (%) = 100 (A - D)/D

Contractor's Rep. Concessionaire's Rep. I.C. Rep.

Client : National Highways Authority of India

Independent Consultant : M/s. Intercontinental Consultants and Technocrats Pvt. Ltd.,

Project Company : M/s. NK Toll Road Ltd.,

EPC Contractor : M/s. Reliance Innoventures Pvt. Ltd.,

Construction Contractor : M/s. Gannon Dunkerley & Co Ltd.,

Sample No 1 Date of Sampling 20.07.08

Location @ Crusher Lab Date of Testing 20.07.08

Bitumen Grade 10/20 Source of material STP,CHENNAI

Test Load (gms) 100 100 100

Test Temp (0C) 25 25 25

Time For Penetration (Sec) 5 5 5

Acceptance Creteria : As per MoRT&H,TABLE : 500 - 29 15+/- 5

Contractor's Rep. Concessionaire's Rep. I.C. Rep.

Client : National Highways Authority of India

Construction Contractor : M/s. Gannon Dunkerley & Co Ltd.,

SOFTENING POINT TEST

(TEST METHOD : IS 1205)

Lab. Sample No : 1 Date of Sampling 21.07.08

Type of material Binder for mastic Asphalt Date of Testing 21.07.08

Source of material STP,CHENNAI

Apparatus Used : Ring and Ball Apparatus

Period of Cooling at Room Temperature (min) : 30 0C

Period of Cooling in Water bath (min) : 15 Min @ 50C

Description Ball No 1 Ball No 2 Softening Point Mean Value

Temperature at which sample

Acceptance Creteria : As per MoRT&H,TABLE : 500 - 29 65+/-10 0C

Contractor's Rep. Concessionaire's Rep. I.C. Rep.

Independent Consultant : M/s. Intercontinental Consultants and Technocrats Pvt. Ltd.,

Project Company : M/s. NK Toll Road Ltd.,

EPC Contractor : M/s. Reliance Innoventures Pvt. Ltd.,

Construction Contractor : M/s. Gannon Dunkerley & Co Ltd.,

INDIVIDUAL GRADATION FOR MASTIC ASPHALT

Source of material :M/s Pakkiyam Lime Works Date of Sampling 21.07.08

Location : Crusher Lab Date of Testing 21.07.08

Type of material Fine Aggregates - 3 mm down Total Weight (gm) 1000

Weight Retained Cumulative Cumulative % Cumulative %

2.360 0.0 0.0 0.00 100.00

0.600 340.0 340.0 34.00 66.00

0.212 430.0 770.0 77.00 23.00

0.075 200.0 970.0 97.00 3.00

PAN 30.0 500.0 100.00 0.00