PROBLEM- Design the pavement for construction of a new flexible

pavement with the following data:

DATA (i) Four lane divided carriageway
(ii) Initial traffic in the year of completion of construction = 5000 CV/day
(Sum of both directions)
(iii) Traffic growth rate per annum = 6.0 per cent
(iv) Design life = 20 years
(v) Vehicle damage factor = 5.2 (Based on axle load survey)
(vi) CBR of soil below the 500 mm of the subgrade = 3 per cent
(vii) CBR of the 500 mm of the subgrade from borrow pits = 10 per cent
Using IRC 37
PROBLEM:
Design the pavement for construction of a new bypass with the
following data:
1. Two lane carriage way
2. Initial traffic in the year of completion of construction = 1000CVPD
(sum of both directions)
3. Traffic growth rate = 7.5 %
4. Design life = 15 years
5. Vehicle damage factor based on axle load survey = 2.5 standard axle
per commercial vehicle
6. Design CBR of subgrade soil = 4%.
MoRTH SPECIFICATIONS :

SECTION 100 : GENERAL.

SECTION 400 : SUB-BASES, BASES (NON BITUMINOUS).

SECTION 500 : BASE & SURFACE COURSE (BITUMINOUS).

SECTION 600 : CONCRETE PAVEMENT.

SECTION 700 : GEOSYNTHETICS.

SECTION 900 : QUALITY CONTROL FOR ROAD WORKS.

SECTION 112 : ARRANGEMENT OF TRAFFIC DURING CONSTRUCTION .

SECTION 121 : FIELD LABORATORY.

SECTION 400 SUB-BASES, BASES ( NON BITUMINOUS).

401 : GRANULAR SUB-BASE.

402 : LIME TREATED SOIL FOR IMPROVED SUB-BASE.

403 : CEMENT TREATED SOIL SUB-BASE / BASE.

404 : WATER BOUND MADACAM SUB-BASE / BASE.

405 : CRUSHED CEMENT CONCRETE SUB- BASE / BASE.

406 : WET MIX MACADAM SUB-BASE / BASE.

407 : SHOULDERS, ISLANDS AND MEDIAN.

2
408 : CEMENT CONCRETE KERB AND KERB WITH CHANNEL.

409 : FOOT PATHS AND SAPERATORS.

410 : CRUSHER-RUN MACADAM BASE.

3
SECTION 500: BASE AND SURFACE COURSES
(BITUMINOUS).
501 : GENERAL REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS.

502 : PRIME COAT OVER GRANULAR BASE.

503 : TACK COAT.

504 : BITUMINOUS MACADAM.

505 : BITUMINOUS PENETRATION MACADAM.

506 : BUILT-UP SPRAY GROUT.

507 : DENSE GRADED BITUMINOUS MACADAM.

4
508 : SEMI-DENSE BITUMINOUS CONCRETE .

509 : BITUMINOUS CONCRETE.

510 : SURFACE DRESSING.

511 : OPEN-GRADED PREMIX SURFACING.

512 : CLOSE GRADED PREMIX SURFACING / MIXED SEAL SURFACING.

513 : SEAL COAT.

514 : SUPPLY OF STONE AGGREGATES.

5
515 : MASTIC ASPHALT .

516 : SLURRY SEAL.

517 : RECYCLING OF BITUMINOUS PAVEMENT.

518 : FOG SPRAY.

519 : BITUMINOUS COLD MIX

520 : SAND ASPHALT BASE COURSE.

521 : MODIFIED BINDER.

522 : CRACK PREVENTION COURSES .

6
• 112 Arrangement of Traffic during construction.
• 200 mm GSB
• 250 mm WBM, 20 mm MSS
• 121 Field laboratory
• General equipment
• For Soil & Aggregate
• For Bitumen & Bituminous concrete
• For cement & cement concrete
• 305 Embankment construction
• Density of compacted layer 1.52 to 1.75 gm/cc
 401 GSB
• Natural sand, Moorum, gravel, crushed
stone or combination.
• Grading – 75mm- 0.075 mm, Grading I, II
& III.
• PI < 6%, LL < 25%
• Up to to 100 mm- Smooth wheeled
roller of 80- 100 KN
• Up to 225 mm- Vibratory roller.
GRADING FOR CLOSE GRADED GRANULAR SUB-BASE MATERIALS

IS Sieve Designation Per cent by weight passing the IS sieve

Grading I Grading II Grading III
75.0 mm 100 - -
53.0 mm 80-100 100 -
26.5 mm 55-90 70-100 100
9.50 mm 35-65 50-80 65-95
4.75 mm 25-55 40-65 50-80
2.36 mm 20-40 30-50 40-65
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
CBR value 30 25 20
(minimum)
GRADING FOR COARSE GRADED GRANULAR SUB-BASE MATERIALS

IS Sieve Per cent by weight passing the IS sieve

Designation
Grading I Grading II Grading III
75.0 mm 100 - -
53.0 mm - 100 -
26.5 mm 55-75 50-80 100
9.50 mm - - -
4.75 mm 10-30 15-35 25-45
2.36 mm - - -
0.425 mm - - -
0.075 mm <10 <10 <10
CBR value 30 25 20
(minimum)
STEPS:-
1. Construction Operation-
i)- Preparation of sub base.
ii)- Spreading and compacting
2. Surface finish and quality control
of work
3. Arrangement of traffic
4. Measurement of for payment
5. Rates
 404 WBM
• I.V.- 30% (Max.), Combined FI & EI
30% (Max.)
• Thickness of each layer 100 mm
• G1 (90mm–45mm)
G2(63-45mm) G3(53-22.4mm)
• Screening A&B
13.2mm (A),11.2mm (B)
Materials:
•Coarse aggregate
•Screenings
•Binding material
•water
GRADING REQUIERMENTS OF COARSE AGGREGATES (FOR WBM)
Grading No. Size range IS Sieve Designation Per cent by weight passing

1. 90 mm to 45 mm 125 mm 100
90 mm 90-100
63 mm 25-60
45 mm 0-15
24.4 mm 0-5
2. 63 mm to 45 mm 90 mm 100
63 mm 90-100
53 mm 25-75
45 mm 0-15
22.4 mm 0-5
3. 53 mm to 22.4 mm 63 mm 100
53 mm 95-100
45 mm 65-90
22.4 mm 0-10
11.2 mm 0-5
GRADING FOR SCREENINGS FOR WBM
Grading Size of IS sieve Per cent by
classification screenings designation weight
passing the
IS sieve
A 13.2 mm 13.2 mm 100
11.2 mm 95-100
5.6 mm 15-35
180 micron 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180micron 15-35
STEPS:
1. Preparation of base
2. sub-surface drainage layer
3. Lateral confinement of aggregates
4. Spreading coarse aggregates
5. Rolling
6. Application of screenings
7. Sprinkling of water and grouting
8. Setting and drying
 406 WMM:
• Work 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 requirement of these specifications.
• Single compacted WMM layer shall not be less then 75 mm.
• When vibrating or other approved types of compacting
equipment are used, the compacted depth a of single layer
of the sub-base course may be up to 200mm with the
approval of the engineer.
GRADING REQUIREMENT OF A AGGREGATES FOR WMM

IS SIEVE DESIGNATION PER CENT BY WEIGHT

PASSING THE IS SIEVE
53.00 mm 100
45.00 mm 95-100
26.50 mm -
22.40 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-8
 502 PRIME COAT

• Work consist of application of single coat of

low viscosity liquid bituminous material.
• The primer shall be cationic bitumen emulsion
SS1 grade conforming to IS:8887 or medium
curing cutback bitumen conforming to IS;217 or
as specified in contract.
VISCOSITY REQIUREMENT AND QUANTITY OF LIQUID BITUMINOUS PRIMER

Type of surface Kinematics viscosity Quality of liquid

of Primer at 60 C Bituminous
(Centistokes) Material per 10
Sq.m.
(kg)
Low porosity 30-60 6 to 9
Medium porosity 70-140 9 to 12
High porosity 250-500 12 to 15
 503 Tack coat

• To ensure bond between new & old construction.

• Cationic bitumen Emulsion (RS1) as per IS 8887 or
suitable low viscosity paving bitumen of VG 10 grade as
per IS:73.
TYPE OF SURFACE RATE OF SPRAY OF BINDER IN kg/sq.m
Bituminous surface 0.20-0.30

Granular surface treated with primer 0.25-0.30

Cement concrete pavement 0.30-0.35

CONSTRUCTION-
1.Equipment
2.Preparation of base
3.Application of tack coat
4.Curing of tack coat
MANUFACTURING & ROLLING TEMPERATURES
Bitumen Bitumen Aggregate Mixed Rolling Laying
Penetration Mixing Mixing Material ( C) ( C)
( C) ( C) ( C)

35 160 - 175 160 – 175 170 Maximum 100 Minimum 130 Minimum
65 150 – 165 150 – 170 165 Maximum 90 Minimum 125 Minimum
90 140 - 160 140 - 165 155 Maximum 80 Minimum 115 Minimum
 504 BM
• Work shall consist of construction in a single
course having 50 mm to 100 mm thickness
or in multiple courses of compacted crushed
aggregates premixed with a bituminous
binder on the previously prepared to the
requirement of these specifications.
Materials:
• Bitumen
• Coarse aggregate
• Fine aggregate
Construction:
• Weather and seasonal limit.
• Preparation of base
• Tack coat
• Preparation and transportation of the mix
• Spreading
• Rolling
Aggregate Grading and Bitumen Content
Grading 1 2
Nominal max agg. size 40 mm 19 mm
Layer thickness 80-100 mm 50-75 mm
IS Sieve size (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.3 2-10 2-10
0.075 0-8 0-8
Bitumen content percent by 3.3 3.4
mass of total mix
 505 DBM
• DBM is used mainly, but not exclusively, in base/binder and
profile corrective courses.
• The work shall consist of construction in a single layer or multiple
layer of DBM on a previously prepared base or sub-base.
• The thickness of single layer shall be 50 mm to 100 mm.
Materials:
• Bitumen (VG paving bitumen as per IS:73)
• Coarse aggregate
• Fine aggregate
• Filler
 Grading 1 2

Composition Nominal agg. Size

Layer thickness
37.5 mm
75-100 mm
26.5 mm
50-75 mm
of Dense IS Sieve (mm) Cumulative % by weight of total aggregate passing
48 100
Graded 37.5 95-100 100
26.5 63-93 90-100
Bituminous 19 - 71-95
13.2 55-75 56-80
Macadam 9.5 - -
4.75 38-56 38-56
2.36 28-42 28-42
1.18 - -
0.6 - -
0.3 7-21 7-21
0.15 - -
0.075 2-8 2-8
Bitumen content % by mass Min 4.0 Min 4.5
of total mix
Grading requirement for mineral filler:
IS Sieve (mm) Cumulative percent passing by weight of
total aggregate
0.6 100

0.3 95-100

0.075 85-100
REQUIREMENT FOR DENSE GRADED BITUMINOUS MACADAM

Minimum stability(Knat 60 C) 9.0

Minimum flow(mm) 2
Maximum flow (mm) 4
Compaction level (number of blows) 75 blows of the two faces of the specimen
Per cent air void 3-6
Per cent void in mineral aggregate (VMA)
Per cent void filled with bitumen(VFB) 11-18 %
65-75
COMPOSITION OF SEMI DENSE BITUMINOUS CONCRETE PAVEMENT LAYE
Grading 1 2
Nominal aggregate size 13 mm 10 mm
Layer thickness 35-40 mm 25-30 mm
IS Sieve(mm) Cumulative % by weight of total aggregate passing
45 - -
37.5 - -
26.5 - -
19 100 -
13.2 90-100 100
9.5 70-90 90-100
4.75 35-51 35-51
2.36 24-39 24-39
1.18 15-30 -15-30
0.6 - -
0.3 9-19 9-19
0.15 -
0.075 3-8 3-8

bituminous content % by mass of total mix Min 4.5 Min 5.0

Bitumen grade (pen) 65 65

REQUIREMENT FOR SEMI DENSE BITUMINOUS PAVEMENT LAYERS

Minimum stability(Knat 60 C) 8.2

Minimum flow(mm) 2
Maximum flow (mm)compaction level 4
(number of blows) 75 blows of the two faces of
Per cent air void the specimen
Per cent void in mineral aggregate 3-5
(VMA)
Per cent void filled with bitumen(VFB) 11-18 %
65-78
 507 BITUMINOUS CONCRETE
• The work shall consist of construction of Bituminous concrete, for use
in wearing and profile corrective courses, over a prepared bituminous
bond surface in a single layer.
• A single layer shall be 30/40/50 mm thick.
MATERIALS:
• Bitumen
• Coarse aggregate
• Fine aggregate
• Filler
 Grading 1 2
Nominal aggregate size 19 mm 13 mm

COMPOSITION Layer thickness

IS Sieve(mm)
50-65 mm 30-45 mm
Cumulative % by weight of total aggregate
OF 45 -
passing
-
BITUMINOUS 37.5
26.5
-
100
-
-

CONCRETE 19
13.2
79-100
59-79
100
79-100

PAVEMENT 9.5
4.75
52-72
35-55
70-88
53-71

LAYERS 2.36
1.18
28-44
20-34
42-58
34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10

bituminous content % by mass 5.0-6.0 5.0-7.0

of total mix
Bitumen grade (pen) 65 65
 REQUIREMENT FOR BITUMINOUS PAVEMENT LAYERS

Minimum stability(Kn at 60 C) 9.0

Minimum flow(mm) 2
Maximum flow (mm) 4
Compaction level (number of blows) 75 blows of the two faces of the specimen
Per cent air void 3-6
Per cent void in mineral aggregate (VMA)
Per cent void filled with bitumen(VFB)
Loss of stability on immersion in water at 60
c (ASTM D 1075) 11-18 %
65-75
Min 75per cent retained strength
CONSTRUCTION:
• Weather and seasonal limitations
• Preparation of base
• Geosynthetics
• Stress absorbing layer
• Tack coat
• Mixing and transporting mix
• Spreading
• Rolling
 511 SEAL COAT
• The work shall consist of the application of a seal coat for sealing the
voids in a bituminous surface laid to the specified levels, grade and
cross fall.
• Seal coat shall be of two type:
A. Liquid seal coat comprising of a layer of bituminous binder followed
by a cover of stone chips.
B. Premixed seal coat comprising of a thin application of fine
aggregate premixed with bituminous binder.
Materials:
• Binder
• Stone chips for type A seal coat
• Aggregate for type B seal coat

CONSTRUCTION:
• Weather and seasonal limit
• Preparation of surface
• Construction of type A seal coat
1. Application of binder
2. Application of stone chips
3. Rolling
• Construction of type B seal coat
i. Using paving bitumen
1. Weather and seasonal limit
2. Preparation of surface
3. Tack coat
4. Preparation of premix
5. Spreading and rolling
ii. Using Emulsion
1. Weather and seasonal limit
2. Preparation of surface
3. Preparation of binder
4. Tack coat
5. Preparation of premix
6. Spreading and rolling
 512 SLURY SEAL
• The work consist of design and laying a mixture of mineral aggregate, slow
setting cationic bitumen emulsion, water and additives, if needed
proportioned, mixed and uniformly spread over a previously prepared surface.
• The finally laid slurry seal shall have a homogenous mat, adhere firmly to the
prepared surface and provide friction resistance surface texture throughout its
surface life.
MATERIALS:
• Bitumen emulsion ( cationic slow setting type as per IS:8887)
• Aggregate
• Filler
• Water
• additives
Types of Slurry Seals and application:
Items Type I (2-3 mm) Type II (4-6 mm) Type III (6-8 mm)
Application Filling of hair Filling of surface Filling of surface
cracks cracks 1-3 mm cracks 3-6 mm
and and
preventive/renew preventive/renew
al treatment ( up al treatment (up
to 450 CVCD) to 1500 CVCD)
Quantity of slurry 4.3 to 6.5 8.4 to 9.8 10.1 to 12
(kg/sq.m)
Residual binder 10 to 16 7.5 to 13.5 6.5 to 12
( % by weight of
dry aggregate)
 Aggregate grading for slurry seal:
Sieve Size ( mm ) Percentage by mass passing (minimum layer thickness)
Type I Type II Type III
( 2-3 mm ) ( 4-6 mm ) ( 6-8 mm )

9.5 - - 100
6.3 - 100 90-100
4.75 100 90-100 70-90
2.36 90-100 65-90 45-70
1.18 65-90 45-70 28-50
0.600 40-65 30-50 19-34
0.300 25-42 18-30 12-25
0.150 15-30 10-21 7-18
0.075 10-20 5-15 5-15
Construction:
• Weather and seasonal limitations
• Surface preparation
• Application of tack coat
• Application of slurry seal
• Rolling
 513 FOG SPRAY
• Work covers a very light application of low viscosity bitumen emulsion
for purpose of sealing cracks less then 3 mm wide or incipient fretting
or disintegration in an existing bituminous surfacing, and to help
reduce loosening of chips by traffic on newly finished surface
dressing.
MATERIAL:
The bitumen emulsion shall be as specified in the contract or as
instructed by the engineer. The emulsion shall be SS-1 complying with
the requirement of IS:8887
CONSTRUCTION:
• Equipment ( self propelled or towed bitumen pressure sprayer)
• Preparation of surface
• Application
 516 MASTIC ASPHALT
• Mastic asphalt is an intimate homogenous mixture of selected well
graded aggregates, filler and bitumen in such proportions as to yield a
plastic and void less mass, which when applied hot can be trowelled
and floated to for a very dense impermeable surfacing.

MATERIALS:
• Binder
• Coarse aggregate
• Fine aggregate
• Filler
Grade and thickness of mastic asphalt paving and grading of
coarse aggregate:

Application Thickness Nominal Coarse aggregate

range, mm size of content, % by
coarse mass of total mix
aggregate,
mm
Roads and bridge decks 25-50 13 40±10
Heavily stressed areas i.e. 40-50 13 45±10
junctions and toll plazas
Nominal size of coarse aggregate 13 mm
IS Sieve (mm) Cumulative % passing by
19 weight
13.2 100
2.36 88-96
0-5
Grading of fine aggregate ( inclusive of Filler)

IS Sieve Percentage by weight of aggregate

Passing 2.36 mm but retained on 0-25
0.600 mm
Passing 0.600 mm but retained on 10-30
0.212 mm
Passing 0.212 mm but retained on 10-30
0.075 mm
Passing 0.075 mm 30-55
Construction:
• Weather and seasonal limitations
• Preparation of base
• Tack coat
• Preparation of mastic asphalt
• Spreading
• Joints
• Surface finish
Pre-mixed carepet
1. Closed graded premix carpet
2. Open graded premix carpet
 508 Close-Graded premix surfacing
• The work shall consist of the preparation, laying and compaction of a
close graded premix surfacing material of 20 mm thickness composed
of graded aggregate premixed with a bituminous binder on a
previously prepared surface.
• Close graded premix surfacing shall be of Type A or Type B as
specified in the contract documents.
• Type A grading is recommended for use in areas having rainfall more
then cm per year.
• In other areas Type B grading may be used.
Materials:
• Binder
• Coarse aggregate
• Fine aggregate
Aggregate gradation:
IS Sieve Cumulative % by weight of total
Designation, mm aggregate passing
Type A Type B
13.2 - 100
11.2 100 88-100
5.6 52-88 31-52
2.8 14-38 5-25
0.090 0-5 0-5
Construction:
• Weather and seasonal limitation
• Preparation of surface
• Tack coat
• Preparation of premix
• Spreading and rolling
510 OPEN GRADED PREMIX SURFACING
A. Open graded premix surfacing using viscosity grade paving bitumen.
• This work shall consist of preparation, laying and compaction of an
open graded premix surfacing material of 20 mm thickness composed
of small sized aggregate premixed with bituminous binder on a
previously prepared base.
MATERIALS:
• Binder
• aggregate
Construction:
• Weather and seasonal limitation
• Preparation of surface
• Tack coat
• Preparation of premix
• Spreading and rolling
• Seal coat
B. Open graded premix surfacing using cationic Emulsion.
• This work shall consist of the preparation, laying and
compaction of an open graded premix surfacing of 20 mm
thickness composed of small-sized aggregate premixed with
a Cationic bitumen emulsion on a previously prepared
surface.

MATERIALS:
• Binder
• Aggregate