PAVEMENT MATERIALS AND CONSTRUCTION

MODULE 5

HIGHWAY CONSTRUCTION

Flexible Pavements: Specifications of materials, Construction method and field control checks for various
types of flexible pavement layers.
Cement Concrete Pavements: Specifications and method of cement concrete pavement construction (PQC,
importance of providing DLC as sub base and polythene thin layer between PQC and sub base). Quality
control tests, Construction of various types of joints.

Granular Sub-Base
The work shall consist of laying and compacting well-graded material on prepared subgrade in accordance
with the requirements of the specifications.

Materials

 The material to be used for the work shall be natural sand, crushed gravel, crushed stone, or
combination of these depending upon the grading required.
 The material shall be free from organic or other deleterious constituents and shall conform to the
quality standards as prescribed in the specifications.
 Table 400-1, MORTH prescribes four gradings for Granular Sub-Base (GSB).
a) Gradings I and II are well graded granular sub-base materials. These can be used at locations
where drainage requirement is not predominant.
b) Gradings III and IV are gap graded and addresses to the concern of the drainage requirements and
can be used at location experiencing heavy rainfall, flooding etc.
 Physical requirements:
a) The material shall have a 10 percent fines
b) The water absorption value of the coarse aggregate not exceeding 2 percent.
c) For Gradings II and IV materials, the CBR shall be determined at the density and moisture content
likely to be developed in the field.
d) The material passing 425 microns (0.425 mm) shall have liquid limit and plasticity index not more
than 25 and 6 percent respectively.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Construction Operations

a) Preparation of subgrade

Immediately prior to the laying of sub-base, the subgrade is prepared by removing all vegetation and other
extraneous matter, lightly sprinkled with water, if necessary and rolled with two passes of 80–100 kN smooth
wheeled roller

b) Spreading and Compacting

 The sub-base material of grading specified in the Contract shall be spread on the prepared subgrade
with the help of a motor grader of adequate capacity, its blade having hydraulic controls suitable for
initial adjustment and for maintaining the required slope and grade during the operation or other
means as approved by the Engineer
 Moisture content of the loose material shall be checked and if required suitably adjusted by sprinkling
additional water such that at the time of compaction, moisture content is from 1% to 2% above or
below the optimum moisture. While adding water, due allowance shall be made for evaporation losses.
 Immediately thereafter, rolling shall start. If the thickness of the compacted layer does not exceed 100
mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For a compacted single layer up to

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

200 mm the compaction shall be done with the help of a vibratory roller of minimum 80 to 100 kN
static weight.
 Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for
portions having unidirectional crossfall and super-elevation. Shall commence at the edges and
progress towards the center for portions having crossfall on both sides
 Each pass of the roller shall uniformly overlap not less than one-third of the track made in the
preceding pass. During rolling, the grade and crossfall (camber) shall be checked and any high spots
or depressions which become apparent, corrected by removing or adding fresh material. The speed
of the roller shall not exceed 5 km per hour.
 Rolling shall be continued till the density achieved is at least 98 percent of the maximum dry density
for the material

Quality Control Tests on Granular Sub – Base

Sl. No. Type of Test Frequency [Min]

1 Gradation 3
One test per 200m

2 Atterberg limits 3
One test per 200m

3 Moisture content prior to compaction 3

One test per 250m

4 Density of Compacted Layer 3

One test per 500m
5 Deleterious Constituents As required.
6 CBR As required.

Water Bound Macadam Sub-Base/Base

This work shall consist of clean crushed aggregates mechanically interlocked by rolling and bonding together
with screening, binding material where necessary and water laid on a properly prepared subgrade/sub-
base/base or existing pavement

Materials

a) Coarse aggregates: Coarse aggregates shall be either crushed or broken stone, crushed slag, overburnt
(Jhama) brick aggregates or any other naturally occurring aggregates such as kankar and laterite of
suitable quality.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Table: Physical Requirements of Coarse Aggregates for WBM for Sub-base/Base Courses

Sl. No. Test Requirements

1. Los Angeles Abrasion value 40 percent (Max)

2. Aggregate Impact value 30 percent (Max)

Combined Flakiness and
3. 40 percent (Max)
Elongation Indices (Total) **
4. Water absorption 2 percent (Max)
Table: Grading Requirements of Coarse Aggregates

Grading IS Sieve Per cent by

Size Range
No. Designation weight passing
75 mm 100
63 mm 90– 100
1. 63 mm to 45 mm 53 mm 25– 75
45 mm 0– 15
22.4 mm 0– 5
63 mm 100
53 mm 95- 100
2. 53 mm to 22.4 mm 45 mm 65– 90
22.4 mm 0– 10
11.2 mm 0– 5

b) Screenings: Screenings to fill voids in the coarse aggregate shall generally consist of the same material as
the coarse aggregate. However predominantly of non-plastic material such as moorum or gravel may be used
for this purpose.

 Liquid Limit and Plasticity Index of such material are below 20 and 6 respectively
 Fraction passing 75 microns sieve does not exceed 10 percent

c) Binding material: Binding material to be used for water bound macadam as a filler material meant for
preventing raveling shall comprise of a suitable material having a Plasticity Index (PI) value of less than 6.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Table: Grading Requirements of Screenings

Grading Per cent by weight

Size of Screenings IS Sieve Designation
Classification passing the sieve
13.2 mm 100
11.2 mm 95 – 100
A 13.2 mm
5.6 mm 15-35
180 micron 0 –10
11.2 mm 100
B 1.2 mm 5.6 mm 90 – 100
180 micron 15–35

Construction Operations

a) Preparation of base:

The surface of the sub-grade/sub-base/base to receive the water bound macadam course shall be prepared
to the specified grade and camber and cleaned of dust, dirt and other extraneous material. Any ruts or soft
yielding places shall be corrected in an approved manner and rolled until firm surface is obtained.

b) Inverted choke/sub surface drainage layer

 If water bound macadam is to be laid directly over the sub-grade, without any other intervening
pavement course, a 25mm course of screenings (Grading B) or coarse sand shall be spread on the
prepared sub-grade before application of the aggregates is taken up. In case of sand or silty or clayey
sub-grade, it is advisable to lay 100 mm insulating layer of screening or coarse sand.
 Alternative to inverted choke, appropriate geosynthetics performing functions of separation and
drainage may be used over the prepared sub-grade

c) Lateral confinement of Aggregates

For construction of WBM, arrangement shall be made for the lateral confinement of aggregates. This shall
be done by building adjoining shoulders along with WBM layers.

d) Spreading coarse aggregates

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

 The coarse aggregates shall be spread uniformly and evenly upon the prepared sub-grade/sub-base in
the required quantities from the stockpiles to proper profile by using templates placed across the road
about 6 m apart, in such quantities that the thickness of each compacted layer is not more than 75
mm. Approved mechanical devices such as aggregate spreader shall be used to spread the aggregates
uniformly so as to minimize the need for manual rectification afterwards
 The surface of the aggregates spread shall be carefully checked with templates and all high or low spots
remedied by removing or adding aggregates as may be required.

e) Rolling

 Immediately following the spreading of the coarse aggregates, rolling shall be started with three
wheeled power rollers of 80 to 100 kN capacity or tandem or vibratory rollers of 80 to 100 kN static
weight.
 Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for
portions having unidirectional crossfall and super-elevation shall commence at the edges and progress
towards the center for portions having crossfall on both sides. Each pass of the roller shall uniformly
overlap not less than one-third of the track made in the preceding pass.
 The rolled surface shall be checked transversely with templates and longitudinally with 3 m straight
edge. Any irregularities, exceeding 12 mm, shall be corrected by loosening the surface, adding or
removing necessary amount of aggregates and re-rolling until the entire surface conforms to the
desired camber and grade.

f) Application of screenings

 After the coarse aggregates have been rolled screenings to completely fill the interstices shall be
applied gradually over the surface. These shall not be damp or wet at the time of application.
 The screenings shall be applied at a slow and uniform rate (in three or more applications) so as to
ensure filling of all voids. This shall be accompanied by dry rolling and brooming with mechanical
brooms, hand brooms or both
 Dry rolling shall be done while the screenings are being spread so that vibrations of the roller cause
them to settle into the voids of the coarse aggregates.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

g) Sprinkling of water and grouting

 After application of screenings, the surface shall be copiously sprinkled with water, swept and rolled.
Hand brooms shall be used to sweep the wet screenings into voids and to distribute them evenly.
 The sprinkling, sweeping and rolling operation shall be continued, with additional screenings applied
as necessary until the coarse aggregates have been thoroughly keyed, well-bonded and firmly set in
its full depth.
 Care shall be taken to see that the sub-base or sub-grade does not get damaged due to the addition
of excessive quantities of water during construction.

h) Application of binding material

 After the application of screenings, the binding material where it is required to be used shall be
applied successively in two or more thin layers at a slow and uniform rate.
 After each application, the surface shall be copiously sprinkled with water, the resulting slurry swept
in with hand brooms, or mechanical brooms to fill the voids properly and rolled during which water
shall be applied to the wheels of the rollers if necessary, to wash down the binding material sticking
to them.

i) Setting and drying

After the final compaction of water bound macadam course, the pavement shall be allowed to dry overnight.
Next morning hungry spots shall be filled with screenings or binding material as directed, lightly sprinkled
with water if necessary and rolled. The compacted water bound macadam course shall be allowed to
completely dry and set before the next pavement course is laid.

Quality control tests on Water Bound Macadam Course

Sl. No. Type of Test Frequency (min)

3
1 Aggregate Impact value 1 test per 200m of aggregate

3
2 Grading One test per 100m

3
3 Flakiness Index & Elongation Index One test per 200m aggregate

3
4 Atterberg limits of binding materials One test per 325m of binding material

The evaluation of density results & acceptance criteria for compaction control shall be on lines similar to

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

those subgrade / embankment as we discussed earlier.

Wet Mix Macadam Sub-Base/Base

This work shall consist of laying and compacting clean, crushed, graded aggregate and granular material,
premixed with water, to a dense mass on a prepared sub-grade/sub-base/base or existing pavement as the
case may be in accordance with the requirements of these Specifications. The thickness of a single compacted
Wet Mix Macadam layer shall not be less than 75mm When vibrating or other approved types of compacting
equipment are used, the compacted depth of a single layer of the sub-base course may be upto 200 mm.

Materials

a) Aggregates

Coarse aggregates shall be crushed stone. If crushed gravel/shingle is used, not less than 90 percent by
weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces.

Table: Physical Requirements of Coarse Aggregates for WBM for Sub-base/Base Courses

Sl. No. Test Requirements

1. Los Angeles Abrasion value 40 percent (Max)

2. Aggregate Impact value 30 percent (Max)

Combined Flakiness and
3. 40 percent (Max)
Elongation Indices (Total) **
4. Water absorption 2 percent (Max)

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Table: Grading Requirements of Aggregates for Wet Mix Macadam

Per cent by weight passing the IS Sieve

IS Sieve Designation
Grade 1 layer thickness ≥ 100mm Grade 2<100 mm
53.00 mm 100
45.00 mm 95 – 100
26.50 mm _ 100
22.40 mm 60–80 50-100
11.20 mm 40–60 -
4.75 mm 25–40 35-55
2.36 mm 15–30 -
600.00 micron 8–22 10-30
75.00 micron 0–-5 2-5
**Material finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.

Construction Operations

a) Preparation of base

The surface of the sub-grade/sub-base/base to receive the water bound macadam course shall be prepared
to the specified grade and camber and cleaned of dust, dirt and other extraneous material. Any ruts or soft
yielding places shall be corrected in an approved manner and rolled until firm surface is obtained

b) Provision of lateral confinement of aggregates

While constructing wet mix macadam, arrangement shall be made for the lateral confinement of wet mix.
This shall be done by laying materials in adjoining shoulders along with that of wet mix macadam layer

c) Preparation of mix

 Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity having provision
for controlled addition of water and forced/ positive mixing arrangement like pugmill or pan type
mixer of concrete batching plant.
 Optimum moisture for mixing shall be determined and while adding water, due allowance should be
made for evaporation losses. The mixed material should be uniformly wet and no segregation should
be permitted.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

d) Spreading of mix

 Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the prepared
sub-grade/sub-base/base in required quantities. In no case shall these be dumped in heaps directly
on the area where these are to be laid. The mix may be spread by a paver finisher
 The surface of the aggregate shall be carefully checked with templates and all high or low spots
remedied by removing or adding aggregate as may be required. The layer may be tested by depth
blocks during construction. No segregation of larger and fine particles should be allowed

e) Compaction

 After the mix has been laid to the required thickness, grade and crossfall/camber the same shall be
uniformly compacted to the full depth with suitable roller.
 If the thickness of single compacted layer does not exceed 200 mm, a smooth wheel roller of 80 to
100kN weight may be used. For a compacted single layer upto 200 mm, the compaction shall be done
with the help of vibratory roller of minimum static weight of 80 to 100 kN. The speed of the roller
shall not exceed 5 km/h.
 Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for
portions having unidirectional crossfall and super-elevation shall commence at the edges and
progress towards the centre for portions having crossfall on both sides.
 Each pass of the roller shall uniformly overlap not less than one-third of the track made in the
preceding pass.

f) Setting and drying

After final compaction of wet mix macadam course, the road shall be allowed to dry for 24 hours.

Quality control tests on Water Bound Macadam Course

Sl. No. Type of Test Frequency (min)

3
1 Aggregate Impact value 1 test per 200m of aggregate

3
2 Grading One test per 100m

3
3 Flakiness Index & Elongation Index One test per 200m aggregate

3
4 Atterberg limits of binding materials One test per 325m of binding material

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

The evaluation of density results & acceptance criteria for compaction control shall be on lines similar to
those subgrade / embankment as we discussed earlier.

Types of Bituminous Pavement Layers

Bituminous pavement layers are important part of flexible pavement layer system. Thin bituminous surfacing
is provided on road with less traffic loads; thicker bituminous layers rea provided to withstand heavier traffic
loads with additional bituminous layer in the form of ‘binder course’ before laying the bituminous surface
course.

Number of types and methods are in use for bituminous pavement construction. It is attempted to broadly
classify them here based on the methods of construction. The following construction techniques are in use:

1. Interface treatment like prime coat and tack coat Surface dressing and seal coat
2. Bituminous base courses
i) Penetration Macadam
ii) Built up spray grout
3. Bituminous binder courses
i) Bituminous Macadam (BM)
ii) Dense Bituminous Macadam (DBM)
4. Bituminous surface courses
i) Bituminous surface dressing
ii) Open graded Premix Carpet with seal coat
iii) Close graded Premix Surfacing

Prime Coat

Spraying of liquid bituminous binder of low viscosity over a granular or non-bituminous surface is called
application of prime coat or priming.

Objectives:
1. Penetrate deep into surface and plug or seal voids on the surface
2. Coat and bond loose particles on the surface
3. Render surface of base course water resistant

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

4. Permit the tack coat to be applied over a primed surface to provide proper adhesion between
base and bituminous pavement layer constructed above treated granular base.

Material

The bituminous material to be used as primer shall be such that it can penetrate about 10 mm deep into
base course. Bitumen emulsion SS1 grade or medium curing cutback bitumen conforming can be used as
primer.

When cutback is used as primer, the type and quantity of cutback bitumen for various types of granular
surface shall be as per Table 500-2.

The correct quantity of primer shall be decided by the Engineer and shall be such that the maximum amount
that can be absorbed by the surface without causing run-off of excessive primer and to achieve desired
penetration of 10 mm.

Method of application

 The granular base surface should be swept clean of dust and loose particles and where required,
lightly and uniformly sprinkled with water to moist the surface.
 The primer should be sprayed uniformly over the dry surface of absorbent granular base, using
suitable bitumen pressure distributor or sprayer capable of spraying primer at specified rates and

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

temperature so as to provide a uniformly unbroken spread of primer. Normal temperature range of

spraying emulsion should be 20 °C to 60 °C
 A very thin layer of coarse sand #ay (e applied to the surface of the primer to prevent it from getting
picked up under the wheels of vehicles delivering materials for construction of bituminous layer
 The surface should be allowed to cure preferably for 24 hours, unabsorbed primer should be blotted
with sand using the minimum quantity possible

Quality Control Tests

 Tests on quality of bituminous binder

 Temperature of application of the binder, at regular interval
 Checking rate of application of the binder: 1 test per 1000 m2 area

Tack Coat

Tack coat is application of small quantity of liquid bituminous binder of low viscosity over either primed
granular surface or over an existing bituminous or cement concrete surface.

Objective:
To provide adequate interface bond between the receiving pavement surface and new bituminous layer
being overlaid.

Material
The binder used for tack coat shall be either Cationic bitumen emulsion (RS 1) complying or suitable low
viscosity paving bitumen of VG 10 grade. The type and grade of tack coat shall be as specified in the Contract
or as directed by the Engineer. Specified rate of application of tack coat are as in Table 500-3:
If Paving grade of bitumen (VG 10) used for tack coat, it shall be heated in bitumen boilers to achieve
viscosity less than 2 poise.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Method of application:
 The normal range of spraying temperature for a bituminous emulsion (RS1) shall be 20°C to 70°C and
for a cutback (RC-70/MC-70) is 50°C to 80°C.
 The bituminous emulsion is sprayed uniformly over a clean receiving surface at the rate specified
above.
 It is then allowed curing, for bituminous emulsion to break, indicated by the color tuning from
chocolate brown to black.

Quality Control Tests

 Tests on quality of bituminous binder

 Temperature of application of the binder, at regular interval
 Checking rate of application of the binder: 1 test per 1000 m2 area

Bituminous Macadam (BM)

Bituminous Macadam (BM) consists of crushed aggregates and bituminous binder heated and mixed in a hot
mix plant at a specified temperature. The BM is laid in a compacted thickness of 20 to 100mm.

Materials

Bitumen binder:

Paving bitumen of viscosity grade VG-30 (60-70 penetration value) is recommended in most of the regions in
India. However, in cold region IRC has recommended use of VG-20(70-80 penetration value).

Aggregates:

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material retained on 2.36
mm sieve.
Fine aggregates shall consist of crushed or naturally occurring mineral material, or a combination of two,
passing 2.36 mm sieve and retained on 75-micron sieve It shall be clean, hard, durable and cubical shape,
free from dust and soft organic and other deleterious substances.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

The aggregate shall satisfy the physical requirements specified in Table 500-13.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

The combined grading of the coarse aggregates and fine aggregates, shall conform to limits given in Table
500-14.

Construction Steps

1. The base on which bituminous macadam is to be laid shall be prepared by patching the potholes,
filling up the depression and making profile correction if required.
2. The surface is cleaned with a mechanical broom to remove loose material and dust.
3. The prime coat and tack coat are applied as specified if receiving surface is granular sub-base or base
course; if it is bituminous surface, tack coat alone is sufficient.
4. After ensuing that the prepared surface s dry, the BM mix is prepared in hot mix plant at specified
temperature, depending on the grade of bitumen used. [ recommended temperature is 160 – 170 °C
for VG-10 and 150-165 °C for VG-10]
5. Hot mix ix transported to the construction site in a clean, insulated covered truck.
6. The BM mix is spread using mechanical paver.
7. Rolling is starts soon after laying the mix and compaction is completed before the mix cools down to
a minimum specified temperature of 100 °C in case of VG-10 and 90 °C for VG-20.
8. Compaction: Compaction is done by rolling in three stages
 The initial or breakdown rolling shall be done with 8–10 tonne dead weight smooth-wheeled
rollers
 The intermediate rolling shall be done with 8–10 tonne deadweight or vibratory roller or with
a pneumatic tyred roller of 12 to 15 tonne weight having nine wheels, with a tyre pressure of
at least 5.6 kg/sq.cm
 The finish rolling shall be done with 6 to 8 tonne smooth wheeled tandem rollers.

The rolling speed shall be less than 5 kmph. The rolling shall commence from the edges and
precedes towards the center with a minimum one third overlap of the rear wheel. In case of
unidirectional camber (super-elevated stretch), the rolling shall start from lower edge to upper
edge of pavement. The rolling is continued till 98% of laboratory density is achieved.

9. The surface finish of rolled pavement is checked; the finished surface is corrected after rolling if
necessary. The finished BM layer shall be covered with next pavement layer with in 48 hours.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Quality Control Tests

1. Physical properties of coarse aggregates are tested at a rate of one sample per 50 m3 of aggregate.
2. Bitumen binder supplied from each source is subjected to specified tests to check its suitability as per
recommendations.
3. The temperature of the binder and aggregates are checked at the time of mixing, during laying and
rolling.
4. Binder content and grading of aggregates of BM mix are checked a rate of two tests per day per mixing
plant.
5. Thickness of BM layer just after spreading at regular interval.
6. Density of compacted BM layer is checked at the rate of one test per 250 m2 area.
7. Finished surface levels are checked with reference to the specified longitudinal and cross profile.

Dense Bituminous Macadam (DBM)

Dense Bituminous Macadam is prepared using well graded aggregates, suitable filler material and
appropriate type, grade and bitumen binder under controlled conditions. The DBM mixes are prepared in
laboratory to strictly fulfill the specified properties and requirements that controls stability and durability
under the expected traffic, climate and environmental conditions.

Materials

Bitumen binder:

Paving bitumen of viscosity grade VG-30 (60-70 penetration value) is recommended in most of the regions in
India. However, in cold region IRC has recommended use of VG-20(70-80 penetration value). Modified
bitumen complying with IS:15462 or as otherwise specified in the Contract can also be used.

Aggregates:

Coarse aggregates shall consist of crushed rock, crushed gravel or other hard material retained on 2.36 mm
sieve. It shall be hard, durable, of cubical shape, free from dust and soft or friable matter, organic or other
deleterious substances. Aggregates shall be treated with an anti-stripping agent if it has poor affinity for
bitumen. Physical requirements of coarse aggregates are as in Table 200-7.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Fine aggregates shall consist of crushed or naturally occurring mineral material, or a combination of two,
passing 2.36 mm sieve and retained on 75-micron sieve It shall be clean, hard, durable and cubical shape,
free from dust and soft organic and other deleterious substances.

Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement approved by
the Engineer.

Aggregate grading and binder content

 The combined grading of the coarse and fine aggregates and added filler for the particular mixture
shall fall within the limits given in MORTH Table 500-9 for dense bituminous macadam grading 1 or
grading 2
 The exact bitumen content required shall be determined following the Marshall mix design
procedure.
 The mix design tests are carried out in laboratory. The Requirement of Mix are as follows
a) Marshall stability 820Kg
b) Marshall flow 2 – 4
c) % air voids 3 – 5
d) VMA 10 – 12%
Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT
 PAVEMENT MATERIALS AND CONSTRUCTION

e) VFB 65 – 75
f) Binder Content Not less than 4%

Construction Operation

1. The receiving surface on with DBM is to be laid (such as existing bituminous surface course or base
course/binder coarse) is prepared by patching the potholes, filling up the depression and making
profile correction if required.
2. Geosynthetics and Stress absorbing layer are may be laid if requires.
3. The receiving surface is cleaned with a mechanical broom to remove loose material and dust.
4. The prime coat and tack coat are applied as specified if receiving surface is granular sub-base or base
course; if it is bituminous surface, tack coat alone is sufficient.
5. The DBM mix fulfilling the required gradation is prepared at specified mixing temperature in an
approved hot mix asphalt plant; the hot mix is transported to construction site in insulated covered
vehicle.
6. The mix is spread using hydraulic paver finisher with specified paving temperature.
7. Rolling is starts soon after laying the mix and compaction is completed before the mix cools down to
a minimum specified temperature of 100 °C in case of VG-10 and 90 °C for VG-20.
8. Compaction: Compaction is done by rolling in three stages
 The initial or breakdown rolling shall be done with 8–10 tonne dead weight smooth-wheeled
rollers
Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT
 PAVEMENT MATERIALS AND CONSTRUCTION

 The intermediate rolling shall be done with 8–10 tonne deadweight or vibratory roller or with
a pneumatic tyred roller of 12 to 15 tonne weight having nine wheels, with a tyre pressure of
at least 5.6 kg/sq.cm
 The finish rolling shall be done with 6 to 8 tonne smooth wheeled tandem rollers.
The rolling speed shall be less than 5 kmph. The rolling shall commence from the edges and precedes
towards the center with a minimum one third overlap of the rear wheel. In case of unidirectional
camber (super-elevated stretch), the rolling shall start from lower edge to upper edge of pavement.
The rolling is continued till 98% of laboratory density is achieved.
9. The surface finish of rolled pavement is checked; the finished surface is corrected after rolling if
necessary.

Quality Control Tests

1. Physical properties of coarse aggregates are tested at a rate of one sample per 50 m3 of aggregate.
2. Grading of coarse aggregate, fine aggregate and filler for DBM is checked.
3. Bitumen binder supplied from each source is subjected to specified tests to check its suitability as per
recommendations.
4. Requirement for voids in mineral VMA of dense graded mix is checked.
5. The temperature of the binder and aggregates are checked at the time of mixing, during laying and
rolling.
6. After the mix is spread, rate of spread or average thickness of the layer is checked for every fifth truck
7. Density of compacted BM layer is checked at the rate of one test per 700 m2 area.
8. Finished surface levels are checked with reference to the specified longitudinal and cross profile.
9. After final rolling of 300m stretch, the surface finish is checked with 3m straight edge to check
depressions along longitudinal and transverse direction.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Bituminous Concrete

The work shall consist of construction of Bituminous Concrete, for use in wearing and profile corrective
courses. This work consists of construction in a single layer of bituminous concrete on a previously prepared
bituminous bound surface. A single layer shall be 25mm/40 mm/50 mm thick.

Materials

Bitumen binder:

Paving bitumen of viscosity grade VG-30 (60-70 penetration value) is recommended in most of the regions in
India. However, in cold region IRC has recommended use of VG-20 (70-80 penetration value). Modified
bitumen complying with IS:15462 or as otherwise specified in the Contract can also be used.

Aggregates:

Coarse aggregates shall consist of crushed rock, crushed gravel or other hard material retained on 2.36 mm
sieve. It shall be hard, durable, of cubical shape, free from dust and soft or friable matter, organic or other
deleterious substances. Aggregates shall be treated with an anti-stripping agent if it has poor affinity for
bitumen. Physical requirements of coarse aggregates are as in Table 500-18.

Fine aggregates shall consist of crushed or naturally occurring mineral material, or a combination of two,
passing 2.36 mm sieve and retained on 75-micron sieve It shall be clean, hard, durable and cubical shape,
free from dust and soft organic and other deleterious substances.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement approved by
the Engineer.

Aggregate grading and binder content

 The combined grading of the coarse and fine aggregates and added filler for the particular mixture
shall fall within the limits given in MORTH Table 500-19 for dense bituminous macadam grading 1 or
grading 2
 The exact bitumen content required shall be determined following the Marshall mix design
procedure.
 The mix design tests are carried out in laboratory. The Requirement of Mix are as follows
g) Marshall stability 820Kg
h) Marshall flow 2 – 4
i) % air voids 3 – 5
j) VMA 10 – 12%
k) VFB 65 – 75

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

l) Binder Content Not less than 4%

Construction Operations:

1. Preparation of base: The surface on which the bituminous concrete is to be laid (such as existing
bituminous surface course or base course/binder coarse) is prepared by patching the potholes,
filling up the depression and making profile correction if required. The surface shall be thoroughly
swept clean by mechanical broom and dust removed by compressed air. In locations where a
mechanical broom cannot get access, other approved methods shall be used as directed by the
Engineer.
2. Geosynthetics and Stress absorbing layer are may be laid if requires.
3. The prime coat and tack coat are applied as specified if receiving surface is granular sub-base or base
course; if it is bituminous surface, tack coat alone is sufficient.
4. Mixing and transportation of the mix: The BC mix fulfilling the required gradation is prepared at
specified mixing temperature in an approved hot mix asphalt plant; the hot mix is transported to
construction site in insulated covered vehicle.
5. Spreading: The mix is spread using hydraulic paver finisher with specified paving temperature.
6. Rolling: Rolling is starts soon after laying the mix and compaction is completed before the mix cools
down to a minimum specified temperature of 100 °C in case of VG-10 and 90 °C for VG-20.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

7. Compaction: Compaction is done by rolling in three stages

8. The initial or breakdown rolling shall be done with 8–10 tonne dead weight smooth-wheeled rollers
9. The intermediate rolling shall be done with 8–10 tonne deadweight or vibratory roller or with a
pneumatic tyred roller of 12 to 15 tonne weight having nine wheels, with a tyre pressure of at least
5.6 kg/sq.cm
10. The finish rolling shall be done with 6 to 8 tonne smooth wheeled tandem rollers.
a. The rolling speed shall be less than 5 kmph. The rolling shall commence from the edges and
precedes towards the center with a minimum one third overlap of the rear wheel. In case of
unidirectional camber (super-elevated stretch), the rolling shall start from lower edge to upper
edge of pavement. The rolling is continued till 98% of laboratory density is achieved.
11. The surface finish of rolled pavement is checked; the finished surface is corrected after rolling if
necessary.

Quality Control Tests

1. Physical properties of coarse aggregates are tested at a rate of one sample per 50 m3 of aggregate.
2. Grading of coarse aggregate, fine aggregate and filler for DBM is checked.
3. Bitumen binder supplied from each source is subjected to specified tests to check its suitability as per
recommendations.
4. Requirement for voids in mineral VMA of dense graded mix is checked.
5. The temperature of the binder and aggregates are checked at the time of mixing, during laying and
rolling.
6. After the mix is spread, rate of spread or average thickness of the layer is checked for every fifth truck
7. Density of compacted BM layer is checked at the rate of one test per 700 m2 area.
8. Finished surface levels are checked with reference to the specified longitudinal and cross profile.
9. After final rolling of 300m stretch, the surface finish is checked with 3m straight edge to check
depressions along longitudinal and transverse direction.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Cement Concrete Pavement Construction

Specification of Materials

For concrete slabs cement, coarse aggregates, fine aggregates and water are required. If reinforcement is
provided, steel wire fabrics are used & for construction of joints, joint filler & sealer are used.

1. Cement – Ordinary Portland cement is used. In case of urgency rapid hardening cement is used.
2. Coarse Aggregates – The max size should not exceed 1/4th slab thickness. The gradation may range
from 50 – 4.75 or 40 – 4.75. The aggregates should be free from iron, purities, cola, mica, clay, alkali,
etc., For Physical properties desire limits are –

a) Aggregate Crushing Value: 30% Max

b) Aggregate Impact Value: 30% Max

c) Los Angeles abrasion Value: 30% Max

d) Soundness for sodium sulphate: 12% Max

3. Fine aggregates – Natural sands, crushed stones etc., are used.

4. Proportioning of Concrete – It is proportioned so as to obtain a minimum modulus of rupture of
40Kg/cm2 on field or to develop minimum compressive strength of 280 Kg/cm2 at 28 days.

Construction method

a) Preparation of subgrade and sub base

 No soft pots are present in subgrade or sub base.

 It should extent at least 30cm on either side of width to be connected.
 Subgrade is properly drained; minimum modulus of subgrade reaction is 5.54kg/cm2.
 The layers should be kept moist when cement concrete is placed.
 Water proof paper may also be used when CC is laid directly.

b) Placing of Forms –

 The steel or wooden forms are used.

 The steel forms are M.S. Channel sections and their depts. Is equal to thickness of pavement and
length at least 3m except on curves < 45m radius.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

 Wooden forms are dressed on side, these have minimum base width of 100n for slab thickness or
20cm.
 The forms are jointed neatly and are set with exactness to the required grade and alignment.

c) Batching of Material & Mixing –

 The proportioned mixture is placed into hopper in weigh batching plant.

 All batching of material is done on the basis of one or more whole bags of cement, weifgt of one bag
is 50 kg or unit weight of cement is taken as 1440kg/m3.
 The mixing of concrete is done in batch mixer. So that uniform distribution, uniform is color and
homogenous mix is obtained.
 The batch of cement, fine aggregate and coarse aggregate is led together into the mixer. Water for
mixing is introduced into the drum within fifteen seconds of mixing.

d) Transportation & Placing of Concrete –

 The cement concrete is mixed in quantities required for immediate use.

 It should be seen that no segregation of materials results while transporting.
 Spreading is done uniformly; certain amount of redistribution is done with shovels.

e) Compaction & Finishing –

 The surface of pavement is compacted either by means of power-driven finishing machine or by

vibrating hand screed.
 Areas where width of slab is small, hand consolidation and finishing is adopted.
 The concrete is further compacted by longitudinal float. It is help parallel to carriage way and passed
gradually from one site to other.
 The slab surface is tested for its grade and level with straight edge.
 Just before the concrete becomes hard, the surface is belted with two ply canvas belts.
 Broom finish is given with fiber broom brush and it is done perpendicular to centerline of pavement.
 Before concrete develop initial set, the edges of slab are carefully finished with an edging tool.

f) Curing of cement concrete –

 Initial curing – The surface of pavement is entirely covered with burlap cotton or jute mats prior to
placing it is saturated with water and wet side is placed on pavement.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

 Final curing – Curing with wet soil exposed edges of slabs are banked with soil berm. A blanket of
sandy soil free from stones is placed. The soil is thoroughly kept saturated with water for 14 days.

In impervious membrane method, use of impervious membrane which does not impart a slippery surface to
the pavement is used. Liquid is applied under pressure with a spray nozzle to cover the entire surface with a
uniform film. It hardens within 30 minutes after its application. The liquid applied immediately after surface
finishing.

When the concrete attains the required strength or after 28days of curing the concrete road is opened to
traffic.

Quality Control Tests

a) Quality control tests for materials used –

Physical & Chemical One for each source of supply and

1 Cement
Tests occasionally
(i) Gradation One test for every day work of
Coarse aggregates &
2 (ii) Deleterious each fraction of coarse aggregate
fine aggregates
constituents and fine aggregate
b) Quality control tests for levels, alignment and texture

1 Level Tolerance +5mm

2 Width of pavement & position of paving edges -6mm +-10mm
To be checked @ one joint
3 Alignment of joints, widths, depths of dowel groves
per 400m length
4 Surface regularity both transversely Once a day or one day’s work
5 Alignment of dowel bars and tie bars To be checked in trail length.

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

Joints in CC Pavements

Joints are important components in CC pavements and they have important functions to perform. The Main
purpose of joints is to relieve part of the stresses developed due to the temperature variations in the slabs.

Requirements of Joints:

a) The joint must permit movement of the slab without restraint.

b) The joint should not unduly weaken the slab structurally and the load should be transferred from one
slab to another effectively
c) The joints must be sealed to exclude water, grit and other external matter
d) The riding quality of the pavement should not be impaired
e) The construction of the joints must interfere as little as possible with laying of the concrete.

The joints in CC pavements are provided as:

a) Longitudinal joints
b) Transverse joints
Longitudinal joints

The need of these longitudinal joints is to prevent the shrinkage cracks, happening during the initial period of
curing. Tie bars are provided along the longitudinal joints, in order to prevent opening up of the longitudinal
joints in due course.

The longitudinal joints function as:

a) Contraction joints and prevent development of additional shrinkage cracks in the longitudinal
directions
b) Warping joints and relieve part of warping stresses
c) Lane markings in highways with two or more lanes

Transverse Joints
The transverse joints are subdivided into three categories, based on their purpose:
a) Contraction joints
b) Expansion joints
c) Warping joints
d) Construction joints

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

1. Contraction joints

 The purpose of the contraction joint is to allow the contraction of the slab due to fall in slab
temperature below the construction temperature
 Contraction joints are formed by cutting grooves across the pavement slab at regular intervals
 During the initial period of curing shrinkage cracks formed at regular intervals, when contraction joints
are provided these shrinkage cracks formed below the each groove at the weekend section.

2. Expansion joints
 CC pavement slabs, during the summer get expanded & during winter gets contracted.
To accommodate these variations in length, expansion joints are provided in transverse pavement at
long intervals.

3. Warping Joints:

 Warping joints also known as hinge joints. The joints are intended to relieve warping stresses.
Warping joints can be longitudinal or transvers.
 A major difference between the warping joints and the expansion/ contraction joints is that, in
warping joints appreciable changes in the joint width are prevented. This is achieved by construction
of reinforcing steel through the joint or by the installation of bars across the joint

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT

 PAVEMENT MATERIALS AND CONSTRUCTION

4. Construction Joints:

 A construction joint is necessary when work has to be stopped at a point where there should be
otherwise no other joint.
 It is advisable to plan a day’s work such that the work stops at a contraction or expansion joint
 The reinforcement should be continued across the joint. A groove in the joint is filled with sealing
compared to arrest the entry of foreign matter

Nisarga P, Assistant Professor, Dept. of Civil Engineering, SJBIT