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The Jaipur Development Authority (JDA)’s so-called “Readymade Kandhal Pothole Patching Mix” has been adopted in August 2014 as Indian Roads Congress (IRC) Standard Specification IRC: 116-2014. This technical note to highway engineers in India justifies they use this “idiot proof”, economical, unpatented and highly durable readymade pothole patching mix across India to eliminate the menace of potholes throughout the year especially during monsoon season. Necessary nomenclature (G schedule), specifications, and rate analyses have been provided to facilitate its inclusion in highway agencies’ Basic Schedule of Rates (BSR) and calling for tenders.
Titolo originale
Readymade Kandhal Pothole Patching Mix adopted as Indian Roads Congress Standard Specification
The Jaipur Development Authority (JDA)’s so-called “Readymade Kandhal Pothole Patching Mix” has been adopted in August 2014 as Indian Roads Congress (IRC) Standard Specification IRC: 116-2014. This technical note to highway engineers in India justifies they use this “idiot proof”, economical, unpatented and highly durable readymade pothole patching mix across India to eliminate the menace of potholes throughout the year especially during monsoon season. Necessary nomenclature (G schedule), specifications, and rate analyses have been provided to facilitate its inclusion in highway agencies’ Basic Schedule of Rates (BSR) and calling for tenders.
The Jaipur Development Authority (JDA)’s so-called “Readymade Kandhal Pothole Patching Mix” has been adopted in August 2014 as Indian Roads Congress (IRC) Standard Specification IRC: 116-2014. This technical note to highway engineers in India justifies they use this “idiot proof”, economical, unpatented and highly durable readymade pothole patching mix across India to eliminate the menace of potholes throughout the year especially during monsoon season. Necessary nomenclature (G schedule), specifications, and rate analyses have been provided to facilitate its inclusion in highway agencies’ Basic Schedule of Rates (BSR) and calling for tenders.
Subject: Readymade Kandhal Pothole Patching Mix is now Indian Roads
Congress Standard Specification
Dear Highway Colleagues: The Jaipur Development Authority (JDA)s so-called Readymade Kandhal Pothole Patching Mix has recently been adopted as Indian Roads Congress (IRC) Standard Specification IRC: 116-2014. This standard was officially released on 19 August 2014 in New Delhi by Hon. Nitin Gadkari, Minister of Road Transport and Highways (MORTH). This has happened finally after persistent voluntary efforts by the writer for the last 6 years.
It is hoped this idiot proof, economical, unpatented and highly durable readymade pothole patching mix would now be implemented across India to eliminate the menace of potholes throughout the year especially during monsoon season. All government organizations such as State PWDs, Central PWD, MES, BRO, and city municipalities should include this item in their Basic Schedule of Rates (BSR) for easy implementation. Necessary nomenclature (G schedule), specifications, and rate analyses used by JDA are attached to facilitate its inclusion in their BSR and calling for tenders.
The following are background and facts (written in third person) on this highly acclaimed and successful readymade pothole patching mix, which is most suited for India.
This readymade cold pothole patching mix was developed by Prof. Prithvi Singh Kandhal while serving as Chief Asphalt Road Engineer for the US State of Pennsylvania Department of Transportation (Penn DOT). Pennsylvania has the fourth largest highway network in the US. His R&D work on this mix was published by the US Transportation Research Board in Transportation Research Record No. 821, 1981.
This mix was included in the Penn DOT Specification in Section 485 and has been used in Pennsylvania and adjoining states with success for over 30 years. It is used during harsh cold and rainy weather when hot mix cannot be used.
Readymade pothole patching mixes used in the US by different states with their own recipes had mixed field performance and durability. Therefore, under the US Strategic Highway Research Program (SHRP) it was decided to conduct a field performance study of some 10 different pothole patching mixes/applications in 4 different extreme climatic regions of the US. The Kandhal Mix (Section 485 material) was adjudged as the best performing patching mix in the US because 78% patches made with this mix survived after 4 years service in the field. Most other patches had failed miserably to different degrees by that time and so the field study was terminated.
Prof. Prithvi Singh Kandhal attempted to introduce this mix in Jaipur in 2008. Numerous pothole patches were made on city streets with the voluntary assistance of the students and faculty of the Malviya National Institute of Technology at Jaipur. The mix was also tried by IJM, contractor for National Highway 11 (Jaipur- Agra Section). All patches were highly successful. Photograph 1 shows a patch made with the Kandhal Mix on NH 11 after it was subjected to rains and traffic. It simply locks itself in the cavity of the pothole and does not ravel out.
Photograph 1. Kandhal Mix patch on NH 11
This pothole patching mix was then introduced by Prof. Kandhal to Indian national audience by publishing and presenting a technical paper in the Annual Session of the Indian Roads Congress (IRC) held in Kolkata in 2008. This IRC paper titled, A Simple and Effective Method of Repairing Potholes in India was published in the Journal of the IRC, Volume 69-3, October-December 2008. The paper describes all the logical research conducted in the US, which led to its development. The paper can also be accessed and downloaded at the following link:
Faced with severe pothole problem during 2010 monsoon, JDA experimented with this mix in October 2010 with the voluntary technical assistance/guidance of Prof. Kandhal. [JDA has to maintain some 6000 km lane of roads and streets in Jaipur.] Satisfied with its excellent performance even in very adverse circumstances, JDA has been inviting tenders for this so-called Kandhal Readymade Pothole Patching Mix since 2011 (about one crore rupees worth per year). The lowest bidder for this unpatented patching material is awarded the contract. Kandhal Mix is supplied by the local contractors in a 50-kg plastic lined bag (Photograph 2) to the JDA store premises. It has a shelf life of at least 6 months and therefore it is used throughout the year. Once all the supply is obtained before monsoon, JDA awards the contract of laying and compaction of the mix in potholes to another contractor. That is why: two separate specifications and tenders are needed (see attachments).
It has been called an idiot proof mix because it does not require any preparation of the pothole such as squaring and applying tack coat; the mix is simply taken out of the 50-kg bag, leveled, hit with a hand rammer by ordinary laborer (no roller), some light sand or grass/leaves is sprinkled on surface to prevent pick up by vehicle tyres, and opened to traffic right away. If there is water in the pothole simply sweep off the extra water. The patch will outlast the adjacent road area.
Photograph 2. Kandhal Mix 50-kg bag
Kandhal mix can be made in a portable or stationary drum or batch asphalt mixing plants by any contractor using local materials. However, since the MC-800 Cutback bitumen is used which has some kerosene in it, stringent safety measures as given in the specifications need to be followed. Portable asphalt mixing plant as shown in Photograph 3 has been used in Jaipur. Cost of producing this mix can be reduced significantly if a conventional batch or drum plant is used. All these plants are used primarily to dry and warm the aggregate, which is then processed again through the plant to mix with MC-800 Cutback. Under no circumstances, drying/heating and mixing should be done in one operation because MC-800 Cutback has kerosene which can cause explosion when exposed to flame.
Photograph 3. Kandhal Mix production in portable drum plant (burner flame turned off)
Photographs 4 and 5 show typical patches made in Jaipur with the Kandhal Mix.
Photograph 4. Typical patch with Kandhal Mix
Photograph 5. Typical patch with Kandhal Mix (next to divider)
Photographs 6 and 7 show as to how a pothole on Raj Bhawan Road in Civil Lines, Jaipur was simply cleaned, filled with Kandhal Mix, and hit with hand rammer. Photograph 8 taken after several months of rain and traffic dramatically shows the patch was still there but the SDBC hot mix asphalt road surrounding the patch had eroded and was gone.
Rajasthan PWD followed JDA and used the Kandhal Mix successfully in 2012 on state roads and national highways.
Photograph 6. Long pothole bring cleaned in Civil Lines, Jaipur
Photograph 7. Kandhal Mix being placed and compacted in the long pothole in Civil Lines, Jaipur
Photograph 8. Long pothole patch in Civil Lines, Jaipur after rainfall season; Kandhal patch is still there but hot mix road around it is gone
Rate analyses have shown the cost of unpatented, generic Kandhal Mix is about one- third the cost of many patented ready made mixes such as Shelmac available in India. Attached rate analyses show the cost of supplying Kandhal mix to JDA premises to be Rs. 6.72 per kg and cost of laying in potholes and compacting it to be Rs. 0.35 per kg. Thus the total cost in place of the Kandhal Mix including all leads is about 7 rupees per kg based on Rajasthan Basic Schedule of Rates.
Cost analyses have also shown the cost of repairing potholes with readymade cold mix is less than the cost of repairing with hot mix asphalt because the latter is more labour intensive (squaring the pothole), material intensive (binder for tack coat), and equipment intensive (need for roller). Moreover we cannot use hot mix during rainy season any way. If we consider that potholes get larger and deeper during the three months of monsoon and therefore will require much more hot mix, the cost of prompt repair of potholes with cold Kandhal mix may be half that with the hot mix. A stitch in time saves nine. Moreover, what is the cost of injuries/fatalities; vehicle repair costs; and user delays resulting from unfilled potholes? It is very hard to estimate these costs. If we are a civilized country we simply cannot wait and repair potholes after monsoon ends as we have been doing for the last 65 years after independence.
Patches made with the Kandhal mix are also more economical and faster than those made with the so-called automatic patching machines called by fancy names such as road ambulance and road doctor in India. These machines which are really white elephants require major capital outlay and are also difficult to maintain. By the time these machines make one patch, one laborer can make 10 Kandhal Mix patches with a hand rammer only. However, politicians, bureaucrats and technocrats with their own self interest in mind, fool the public and sell them unrealistic dreams by purchasing such machines.
This mix is also very handy for contractors who are responsible for maintaining national highways, state highways or PMGSY roads during the concession or warranty or defect liability period. If there are a few potholes there is no need to arrange hot mix; take some bags of this idiot proof mix and a labourer (with a hand rammer) in a car or pickup and get the potholes repaired. It is also handy for filling test/survey pits made on the road for testing and also for filling utility cuts in city streets.
Kandhal mix can also be manufactured and sold commercially to township developments and housing colonies to fix potholes on their internal roads; fixing potholes with hot mix would be too expensive and cumbersome for them.
Again, nomenclature, specifications, and rate analyses used by the Jaipur Development Authority for the last 4 years are attached for guidance so that highway agencies across India can include this mix in their BSR as soon as possible without doing any home work. Just substitute your organizations name in place of Jaipur Development Authority (JDA). It is that simple!
With all preceding information and encouragement it would be unfortunate if highway agencies and contractors do not adopt this generic, unpatented, economical and effective patching technology to keep roads in India pothole free throughout the year. Moreover, there is no excuse now this being an Indian Roads Congress Standard!
If still there are some excuses, those are really lame excuses from people who do not wish to get the public out of the pothole misery and rut due to their own self interest and/or downright incapability! May God save India from such people who always have 100 excuses not to try new things which are really good for public! [Its good they are not working for ISRO who sent the Mangalyaan and made us proud.]
I am not saying all this because I had the privilege of developing this mix but because I believe this IS the answer to our pothole problems. This mix has been proven in the field in US and India and its performance has been documented. No other certificate in needed. If you have a better and economical alternative please let me know, I would have everybody know about it if it is truly valid and does not serve your own interest.
Sincerely,
Prof. Prithvi Singh Kandhal Jaipur, Rajasthan pkandhal@gmail.com Home page: www.eng.auburn.edu/users/kandhps
American roads are not good because America is rich, but America is rich because American roads are good. - John F. Kennedy
Never doubt that a small group of citizens can change the world. Indeed, it is the only thing that ever has. -Margaret Mead
ABOUT THE WRITER
Prof. Prithvi Singh Kandhal is Associate Director Emeritus of the National Center for Asphalt Technology (NCAT) based at Auburn University, Alabama, U.S.A. NCAT is the largest asphalt (bitumen) road technology center in the world.
Prior to joining NCAT in 1988, Prof. Kandhal served as Chief Asphalt Road Engineer of the Pennsylvania Department of Transportation for 17 years. He is the first person born outside North America, who has held the following three national and international very prestigious positions in the asphalt road technology area:
President, Association of Asphalt Paving Technologists (with members from all continents in the world) Chairman, American Society for Testing and Materials (ASTM) International Committee on Road Paving Standards (responsible for over 200 standards used worldwide) Chairman, Transportation Research Board Committee on Asphalt Roads, U.S. National Academy of Sciences Prof. Kandhal has published over 120 technical papers and has co-authored the first ever textbook on asphalt road technology, which is used by more than 25 universities in the U.S. He has travelled to various countries in South America, Middle East, China, Vietnam, Japan, Singapore, and Australia to provide training and consulting services in asphalt (bitumen) technology. He has been to China three times to train their highway engineers in building world-class roads.
Prof. Kandhal has been a practicing highway engineer in India for 20 years and in the US for 30 years. Recently he has drafted many standards for the Indian Roads Congress including specifications for dense graded bituminous mixes, stone matrix asphalt and readymade pothole patching mix. He was also instrumental single- handedly in introducing viscosity grading of bitumen in India in lieu of penetration grading in 2005.
In August 2011, Prof. Kandhal was inducted on the Wall of Honour established at the largest asphalt road research center in the United States. In April 2012, he received the Lifetime Achievement Award in Asphalt Road Technology from the International Association of Asphalt Paving Technologists during their annual banquet held in Austin, Texas, USA.
Name of Work: Production and Supply of Kandhal Readymade Bituminous Pothole Patching Mix to JDA Zone Number .. Location (Godown) (Rate Contract)
Schedule-G S.N. Particulars Qty. Unit Rate to be quoted Amount 1.
Producing and supply of Kandhal readymade cold bituminous patching mix in 50-kg plastic lined, sturdy bags for repair of potholes in adverse climatic conditions including the bituminous mix with a minimum of 5.6% MC-800 cutback bitumen (containing a suitable anti- stripping agent) by weight of mix and in strict conformance to gradation and other requirements such as 6-month storage life as per the enclosed specification dated 1 February 2013; transfer with all leads and lift complete in all respects as per direction of engineer-in-charge [No. of 50- kg bags] 50-kg bag
Special conditions: 1. Specification for Kandhal readymade bituminous mix dated 1 February 2013 is enclosed. Its strict compliance is required in production and supply. The contractor shall be solely responsible if the mix is not workable and is not usable for a period of 6 months for making durable patches. 2. All 50-kg bags shall be transported to a storage facility designated by the Executive Engineer. Since the mix contains volatile kerosene, sealed bags shall not be stored in a closed building or warehouse. Storage shall be made under an open shed or in a well ventilated warehouse. No open flame or smoking shall be allowed in the vicinity of the stored mix.
Executive Engineer JDA, Jaipur
I/we agree to do the above work on rate as quoted above.
Indian Roads Congress Version as of 1 February 2013 for Rajasthan PWD and JDA
Specification for Kandhal Readymade Bituminous Pothole Patching Mix
1. Scope
The material shall consist of plant mixed readymade pothole patching bituminous mixture composed of mineral aggregate coated with bituminous material. The material shall be capable of being stocked for at least six months without stripping and shall be workable at all times. Unless specified otherwise, this mix shall be supplied in 50-kg plastic lined, sturdy bags. This material is intended for patching potholes up to 75 mm (3 inches) deep. For deeper potholes, patching mix shall be placed and compacted in 75 mm thick layers.
2. Materials
2.1 Bitumen
Medium Curing Cutback Bitumen MC-800 conforming to Indian Standards Specification IS: 217 Specification for Cutback Bitumen shall be used in preparing the patching mix and shall be supplied by a certified manufacturer of this product. For proper mixing, the bitumen shall be heated as specified in Section 3.
MC Cutback Bitumen shall be treated with a proper type and amount of an anti- stripping agent by the approved bitumen supplier so that when combined with the proposed job aggregate the resulting mix shall pass the Wet Coating Test, Static Immersion Test and Stripping Test as given in Annexure I. The antistrip agent shall conform to IS 14982. The contractor shall furnish the sample of the job aggregate each year to the bitumen supplier for these coating and stripping tests and obtain a certificate that the bitumen material has been treated to suit the job aggregate. This yearly certificate must be on file and shall be available at the asphalt mix plant when required by the Engineer. The contractor shall also forward a copy to the Engineer. Under no circumstances, the contractor or the department shall be permitted to manufacture the MC cutback by blending paving bitumen and kerosene.
2.2 Coarse Aggregate
2.2.1 The coarse aggregate shall consist of crushed rock, crushed gravel or other hard material retained on 2.36 mm sieve. It shall be clean, hard, durable and cubical shape, free from dust and soft organic and other deleterious substances. The aggregate shall satisfy the physical requirements specified in Table 1.
2.2.2. Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of the crushed material retained on 4.75mm sieve shall have at least two fractured faces resulting from crushing operation.
TABLE 1. Physical Properties of Coarse Aggregate
Property Test Requirement
Test method Cleanliness Grain size analysis Max. 2% passing 0.075 micron IS 2386 Part I Particle shape Flakiness & Elongation Index (combined) Max. 35% IS 2386 Part I
Strength * Los Angeles Abrasion Value Max. 40% IS 2386 Part IV Aggregate Impact Value Max. 30% IS 2386 Part IV
Durability Soundness (Sodium or Magnesium), 5 cycles Sodium Sulphate Max. 12% IS 2386 Part V
Magnesium Sulphate Max. 18% IS 2386 Part V
Water absorption Water absorption Max. 2% IS 2386 Part III
* The coarse aggregate may satisfy either of the two strength tests.
2.3 Fine Aggregate
Fine aggregate shall consist of crushed mineral material passing 2.36 mm sieve and retained on 75-micron sieve. It shall be clean, hard, durable, and free from dust and soft organic and other deleterious substances. No natural sand shall be permitted.
2.4. Composition of Mixtures
When tested in accordance with IS:2386 Part 1 (wet sieving method), the combined aggregate grading shall fall within the limits shown in Table 2. As far as possible an aggregate with water absorption of 1.0 or less shall be used. The amount of residual bitumen binder (total cutback bitumen minus diluent such as kerosene) in the mix shall be as shown in Table 3. The readymade patching mix shall be rejected if it does not meet the grading (especially the 0.075 mm sieve) and the minimum residual bitumen content. The produced mix shall be tested by an independent approved testing laboratory before its acceptance by the Engineer.
Table 3. Minimum Residual Bitumen Content by Weight of Mix Aggregate water absorption, % Minimum residual bitumen content, % Less than 1.0 4.5 1.1 to 1.5 5.0 1.6 to 2.0 5.5
Based on the characteristics of the aggregate and the performance of the mix, the Engineer can specify amount of residual bitumen higher than that shown in Table 3.
The contractor shall ascertain from the supplier of MC-800 as to how much residual bitumen it contains. For example, if the MC-800 contains 80% bitumen and 20% kerosene and a total of 6.0% MC-800 is used by weight of the mix, the residual bitumen content in the mix will be 4.8 percent.
3. Preparation and Storage of Mixture
The Kandhal readymade patching mix shall preferably be produced in a conventional batch type hot mix plant. However, if a portable or stationary asphalt drum plant is used, under no circumstances drying/heating of aggregates with a burner flame and mixing with MC-800 shall be carried out simultaneously because MC-800 containing volatile kerosene will catch fire and pose a safety hazard. The contractor and the engineer shall ensure there is no open flame inside or outside the drum when MC-800 is added for mixing.
The mix should be such that it can be stocked, handled, placed, and finished without stripping of the bitumen from the aggregate. To help prevent stripping and avoid heat buildup in a stockpile (which may burn the entire stockpile), the mixed material should not be stockpiled no higher than 1.5 m for the first 48 hours. The stockpile then can be raised in height and made conical in shape. Unless specified otherwise, the readymade cold mix shall be placed and sealed in plastic lined, sturdy 50-kg bags on cooling.
The mineral aggregate should be clean and surface dry before mixing. The temperature of aggregate and bituminous material should comply with those shown in Table 4.
Table 4. Temperature Ranges for Producing Stockpile Patching Mix Bituminous material Aggregate temperature, C Bitumen temperature, C MC-800 25 65 75 - 95
Since the range of aggregate temperature is rather low and the maximum aggregate temperature is restricted to 65 C, it may not be possible to dry the aggregate within this temperature range. Therefore, the aggregate can be processed in a dryer at high temperatures and allowed to cool before the bituminous binder is added. Pre-drying the aggregate at high temperatures will also help in reducing the fines (material passing 0.075 mm sieve), which will go into the baghouse. The resulting mix then would have fines less than 2 % as required in the stringent gradation specifications. High aggregate temperature while mixing with the cutback bitumen will not only cause excessive loss of kerosene from the cutback but will also pose a safety hazard in the plant pug mill. Proper and adequate venting of the pug mill is necessary. Under no circumstances there shall be any open flame in the vicinity of MC-800 cutback because it contains volatile kerosene.
Since the mix contains volatile kerosene it is not safe to store the loose mix or sealed bags in a closed building/warehouse. Store under an open shed or in a well ventilated warehouse. No open flame or smoking shall be allowed in the vicinity of the stored mix.
4. Quality Control and Acceptance of Mixture
The composition of the produced mix (gradation and bitumen content) shall be tested by an independent, approved testing laboratory before acceptance by the Engineer. Before conducting the bitumen extraction test to determine residual bitumen content in the Kandhal patching mix, the sample shall be cured completely to remove all kerosene. Curing shall be done as follows. Place the loose mix in an open metal container and heat slowly on a hot plate with frequent stirring until a constant weight is achieved.
The following two tests shall be performed by the contractor (in presence of a Department representative) on the mixture, freshly prepared or taken from a stockpile or sealed bag at any time during its storage life (usually 6 months).
Water Resistance Test (See Annexure I, Test C) Workability Test (See Annexure I, Test D)
The water resistance test would indicate whether the patching mix has a potential for stripping in the pothole in presence of water. If the mix fails this test, it means a proper type and/or amount of an antistrip agent has not been used in the bituminous binder.
If the mix fails in workability it could be due to improper bitumen type, low bitumen content, excessive fines or improper gradation. Even one-half percent lower bitumen content can make the patching mix unworkable and useless.
Stocked patching material may be rejected, at any time during the six month period if, in the opinion of the Engineer, the patching material has stripped (more than 10% uncoated particles) or otherwise become unfit or unworkable for use.
5. Measurement for Payment
The tonnage of the Kandhal readymade pothole patching mix shall be measured and determined from the actual plant batch reports as recorded by a representative of the Engineer assigned to the work. In case the Kandhal mix is supplied in plastic lined, sturdy bags, each bag must weigh at least 50 kg and the number of bags shall be counted for payment. 6. Rate
The Kandhal readymade bituminous patching material shall be paid for at the contract unit price per ton or per 50-kg bag, FOB the asphalt mix plant, at the work site, or at other destination as specified in the contract. A reasonable amount of earnest money will be kept by the Department for 6 months or on depletion of the stockpile, whichever is earlier, to ensure the product is satisfactory for use and meets all tests specified earlier during the life of the product.
ANNEXURE I
A. Wet Coating Test
Heat the unwashed job aggregate, cutback bitumen and distilled water to 40 C in a suitable oven. Weigh 100 g of dry aggregate into a suitable mixing container (such as seamless tin can, 16 oz capacity). Add 3 ml of distilled water. Mix thoroughly with a spatula until the aggregate particles are uniformly wetted. Add cutback bitumen equivalent to 5.0 +/ 0.2 g of bitumen residue. Mix rigorously with the spatula until all aggregate is coated, but not more than 5 minutes. Transfer the contents into a 400 ml beaker containing 150 ml of distilled water (22 32 C). Let stand for 15 minutes and visually determine the percent of retained coating, which should be at least 98 percent.
B. Static-Immersion Test
The coated aggregate as prepared in the preceding wet coating test shall remain immersed in the beaker of distilled water (22 32 C) for 24 hours. At the end of this period, visually determine the percent of retained coating while the sample remains immersed in water, which should be at least 95 percent.
C. Water Resistance Test
Fifty grams of patching mix, whether freshly prepared or taken from the stockpile or a sealed bag, shall be heated at 120 C in a laboratory oven for 1 hour, cooled to 95 C in laboratory air, and then placed in 400 ml of boiling water in a 600-ml glass beaker and stirred with a glass rod at the rate of 1 revolution per second for 3 minutes. The water shall be decanted and the mix shall be spread on an absorbent paper for visual observation of the coating. The aggregate shall be at least 90 % coated with a bituminous film.
D. Workability Test
Approximately 2.5 kg of the patching mix shall be cooled to 7 C in a freezer. After cooling, the mixture shall be capable of being broken up readily with a spatula that has a blade length of approximately 200 mm. This test shall be performed when the mix is produced and thereafter anytime during storage. If the mix is not workable at 7 C, it shall be rejected and the composition of the mix shall be properly modified (for example, by increasing the bitumen content and/or gradation changes). This test is also applicable in areas with hot climate because it amplifies the workability characteristics of the mix by using a lower test temperature.
**************************************
JAIPUR DEVELOPMENT AUTHORITY, JAIPUR
Name of Work: Placing and Compacting Kandhal Readymade Bituminous Patching Mix in potholes on various roads in JDA ZoneArea.. Jaipur (Rate Contract)
Schedule-G
S.N. Particulars Qty. Unit Rate to be quoted Amount
1.
Placing and compacting Kandhal readymade cold bituminous patching mix in potholes in adverse weather as per enclosed specifications including cleaning of potholes; placing and compacting the mix; sprinkling sand to prevent pick up by traffic; and documentation of patches,
[No. of 50- kg bags]
50-kg bag
with all leads and lifts complete in all respects as per attached specifications and direction of engineer-in-charge.
Special conditions: 3. Specification for placing and compacting the Kandhal readymade bituminous mix dated 1 February 2013 is enclosed. Its strict compliance is required.
Executive Engineer JDA, Jaipur
I/we hereby agree to do the above work on rates as quoted above.
Signature of the Contractor With full postal address and Mobile Number
************************************************************* Indian Roads Congress Version as of 1 February 2013 for JDA
Specifications for Placing and Compacting Kandhal Readymade Cold Bituminous Mix in Potholes
1. Scope
These specifications cover placing and compacting the Kandhal readymade patching mix in potholes including transportation of the mix from the designated storage facility to road sites as directed by the engineer. The work involves cleaning and preparation of potholes; placing and compacting the mix; applying sand to prevent pick up by traffic; and documenting the number and sizes of the patches. The Kandhal readymade cold patching mix is suitable for patching potholes only and shall not be used for patching long stretches of deteriorated road surface.
2. Preparation of Potholes
Pothole shall be cleaned with a stiff wire brush and all loose material including dust shall be removed with a soft brush. Pothole need not be dry. However, excess water shall be swept off the pothole.
If the pothole is deep and extends to WMM or granular base, it is recommended to apply a prime coat consisting of MC-30 Cutback before placing the patching mix. If angular aggregate (nominal size 25 mm) is used to partially fill deep potholes, the aggregate should be compacted thoroughly and primed with MC-30 before placing the patching mix. At least 50 mm thick pothole patching mix shall be placed at the top.
3. Placing Kandhal mix in Potholes
The Kandhal mix is intended for patching potholes up to 75 mm (3 inches) deep. For deeper potholes, patching mix shall be placed and compacted in 75 mm thick layers.
Sufficient material shall be placed in the pothole so that after compaction the patch is about 10 mm above the existing road surface.
4. Compacting the Kandhal mix
First the outside edge or periphery of the patch shall be compacted with a hand rammer and then compaction shall proceed inwards. To prevent initial pick up of the loose mix by the hand rammer either continue to wet the hand rammer with water or place empty plastic lined bags on the loose mix.
For deep potholes, place the patching mix and compact in 75 mm thick layers. After compaction, the compacted patch shall be about 10 mm higher than the existing road surface to allow for further compaction by traffic. If there are numerous closely spaced patches, it is preferred to use a small roller rather than a hand rammer.
5. Applying Sand to Prevent Pick up by Traffic
Before opening the compacted patch to traffic, sufficient amount of clean sand shall be sprinkled on the patch to prevent pick up by traffic.
6. Documenting the Number and Sizes of Patches
The contractor shall document and the engineer shall verify the following on a daily basis: (a) Number of 50-kg bags used; (b) Name of road and chainages where patches were made; and (c) Average sizes of potholes patched by measuring their average length, average width and average depth.
7. Measurement for Payment
The total number of 50-kg bags of Kandhal mix placed and compacted by the contractor shall be recorded by the engineer for payment. Payment shall be made at the contract price per 50-kg bag.
***********************************
Cost Analysis of Supplying Kandhal Readymade Bituminous Pothole Patching Mix to Department Godown (Revised 16 March 2013)
Assume one ton (1000 kg) of the mix is to be made and filled in 20 bags of 50 kg each, which will be supplied to Department Godown for use later.
A. Cost of Materials
1. Aggregate of specified gradation; rate of Rs. 300/ton; Add extra cost 10% for special size; total rate is Rs. 330/ton Aggregate 940 kg @ Rs. 330 per ton.. 310.20
2. Bitumen MC-800 Cutback supplied in drums: 60 kg @ Rs. 60,000 per ton. 3600.00
3. Anti Stripping Agent @ 0.3 % by weight of MC-800 1.8 kg @ Rs. 165 per kg. 297.00
Total for A 4,207.20
B. Production Cost
1. Portable Mini Hot Mix Plant with capacity of 8 tons/day Rent for one day = Rs. 1000. Rent to produce one ton will be one-eighth of Rs. 1000, that is, Rs. 125 125.00
2. Fuel costs: 24 liters per day; 3 liters per hour 3 liters @ Rs. 50 per liter 150.00
3. Labour: 8 labourers needed per day to produce 8 tons 1 labourer needed per ton @ Rs. 300 per day. 300.00
Total for B 575.00
C. Packing, Handling and Transport to Department Godown
1. Cost of 50-kg empty bags 20 bags @ Rs. 12 per bag.. 240.00
2. Labour for filling, weighing and sealing bags; 3 labourers can fill 160 bags in one day (20 bags in one hour) Cost of labourers for one day = 3 times Rs. 300 = Rs. 900 Cost of filling 20 bags in one hour = 900/8.. 112.50
3. Transport of bags from plant to department godown (average 10 km lead) 1 ton@ Rs. 200 per ton . 200.00
Total for C 552.50
D. Total of A + B + C. 5,334.70
Contractors overhead @ 10% of D........................................................... 533.47
Royalties, sales tax, income tax etc. @ 4.5% of D....................................... 240.06
Total 6,108.23
Add 10% contractors margin 610.82
Total Cost per ton (20 bags of 50 kg each)..Rs. 6,719.05
Cost per kg..Rs. 6.72
Cost per 50-kg bag..Rs. 335.95
Revised 16 March 2013
**************************************************************** Cost Analysis of Laying Kandhal Readymade Bituminous Pothole Patching Mix (As of 16 March 2013)
Assume Eight (8) tons of the Kandhal mix will be laid in potholes in one day. Costs for one day operation are as follows:
1. 4 Labourers @ Rs. 300 each 1,200.00
2. Transportation of bags from Department Godown to laying site (average one-way lead of 20 km) (a) Rent of tractor = Rs. 600 (b) Cost of diesel = Rs. 400 (tractor will consume one liter per 5 km; 8 liters for 40 km @ Rs. 50 per liter = Rs. 400 Total transportation cost = 600 + 400 = 1000 1,000.00
3. Sand bags for sprinkling sand on patches to avoid pickup:
2 sand bags @ Rs. 10 per bag20.00
Total 2,220.00
Add 10% contractor overhead... 222.00
Add 4.5% for royalty, sales tax, income tax, etc.. 99.90
Total 2,541.90
Add 10% contractor margin.. 254.19
Total 2,796.09
This is the cost for 8 tons.
Cost per ton = Rs. 349.51 Cost per kg = Rs. 0.35 Cost per 50-kg bag = Rs. 17.48