Bituminous Pavement Works

SECTION 800 - BITUMINOUS PAVEMENT WORKS
SECTION 800 - BITUMINOUS PAVEMENT WORKS................................................................................................1

801
SCOPE OF SECTION..........................................................................................................................................3
802
GENERAL REQUIREMENTS...........................................................................................................................3
1)
2)
3)
4)
5)
A BITUMINOUS BINDER STORAGE AND HANDLING................................................................................................ 3

B HEATING OF BITUMINOUS BINDER.................................................................................................................... 3
C ADHESION AGENT........................................................................................................................................... 4
D SAFETY AND ENVIRONMENTAL PRECAUTIONS................................................................................................... 4
E
CONTRACTORS EQUIPMENT............................................................................................................................ 4
General..........................................................................................................................................................................4
Mixing plant..................................................................................................................................................................4
Bitumen distributors....................................................................................................................................................5
Laying equipment.........................................................................................................................................................6
Compaction equipment................................................................................................................................................6
803
A
B
C
D
E
F
G
H
I
804
CONSTRUCTION REQUIREMENTS..............................................................................................................6
SITE TRIALS.................................................................................................................................................... 6
LIMITATIONS ON CONSTRUCTION..................................................................................................................... 6
MIXING OF AGGREGATES AND BITUMEN........................................................................................................... 7
PREPARATION OF SURFACES............................................................................................................................. 8
LAYING THE MIXTURE..................................................................................................................................... 9
COMPACTION OF THE MIXTURE...................................................................................................................... 10
FINISHING, JOINTS, AND EDGES..................................................................................................................... 10
QUALITY CONTROL TESTING.......................................................................................................................... 11
TOLERANCES................................................................................................................................................ 11
DESIGN OF BITUMINOUS MIXES...............................................................................................................12
805 ROAD PAVEMENT

806 CRUSHED-STONE MASTIC MIX
A
Materials
1)
Crushed-stone mastic asphalt concrete mix and asphalt concrete requirements
2)
Raw material requirements
3)
Crushed-stone mastic asphalt concrete mix selection
B
Work execution requirements
1)
Crushed-stone mastic asphalt concrete mix preparation
C
Laying and compaction of crushed-stone mastic asphalt concrete mix
807
ASPHALT CONCRETE.....................................................................................................................................16
A MATERIALS FOR ASPHALT CONCRETE............................................................................................................. 16

1) Penetration Graded Bitumen........................................................................................................................16
2) Aggregate.........................................................................................................................................................16
3) Mineral Filler.............................................................................................! .
B LAYING AND COMPACTION OF ASPHALT CONCRETE..............................! .
808
A
PRIME COAT AND TACK COAT...................................................................................................................27

MATERIALS FOR PRIME COAT AND TACK COAT................................................................................................ 27
1) Tack coat
2) Prime coat
B
PREPARATION OF SURFACES........................................................................................................................... 28
800-1
C
D
E
F
809
SPRAYING OF PRIME COAT AND TACK COAT.................................................................................................... 28

SPRAYING TEMPERATIRE
CURING AND BLINDING OF PRIME COAT......................................................................................................... 29
TOLERANCES................................................................................................................................................ 30
PREPARATION OF EXISTING BITUMINOUS PAVEMENTS. .20
A. PAVEMENT MILLING......................................................................................................................................20
1)
2)
3)
4)
5)
General Requirements...............................................................................................................................................20
Equipment & methods of working............................................................................................................................20
Sequence of operations...............................................................................................................................................20
Re use of bituminous milled material.......................................................................................................................21
Pavement reconstruction............................................................................................................................................21
B. PATCHING..........................................................................................................................................................22
1)
2)
3)
4)
5)
Description..................................................................................................................................................................22
Type 1 Patching...........................................................................................................................................................22
Type 2 Patching...........................................................................................................................................................22
Type 3 Patching...........................................................................................................................................................23
Work procedure..........................................................................................................................................................23
C. CRACK SEALING.......................................................................................................................................... 23
1) Sealing 6 - 15 mm wide cracks in bituminous pavements......................................................................................23
2) Patching cracks greater than 15 mm wide in bituminous pavements...................................................................24
D.
REGULATING
24
1) General Requirements
800-2
801
SCOPE OF SECTION
This Section covers the preparatory works to existing bituminous pavements, application of prime coat, tack
coat, and placement of asphalt concrete.
802
GENERAL REQUIREMENTS
A
BITUMINOUS BINDER STORAGE AND HANDLING
If bituminous binder is delivered in bulk containers, the Contractor shall keep records, in a manner
acceptable to the Engineer, of binder temperature and binder quantity against time for each trip. Any
bituminous binder which fails to meet the requirements of this Specification may be rejected by the
Engineer as unsuitable for use in the Works.
The Contractor shall keep the bitumen storage area and heating station neat and tidy. The storage area
shall be cleared of vegetation. Drums shall be stacked on their sides in small quantities with sufficient
gaps between stacks to minimise the risk of fire.
Bitumen distributors and boilers shall be kept clean at all times. When the grade of bitumen is to be
changed and at the end of each day's work, all boilers and distributors shall be thoroughly cleaned out
with a proprietary non polluting, biodegradable cleaning agent. Diesel and other
similar solvents shall not be used. The flushings from boilers and distributors shall not be
poured over the area indiscriminately, but shall be led via lined drainage channels to
purpose built sumps. The Contractor shall ensure that such flushings do not pollute stormwater
ditches or streams or underground water sources. The Contractor shall empty the sumps periodically
and dispose of the flushings in a safe manner to the approval of the Engineer. Upon completion of the
Works the Contractor shall remove the sumps and drains and reinstate all such areas to the satisfaction
of the Engineer. The Contractor shall keep all boilers, pre-heating pits, tools and equipment
scrupulously clean.
When the bitumen distributor is filled from either boilers or bulk containers, the bitumen shall be
passed through a fine wire gauze filter.
HEATING OF BITUMINOUS BINDER
During storage the temperature of the bituminous binder shall be kept as low as possible, consistent
with a suitable viscosity for pumping.
The Contractor shall only heat bituminous binder in boilers or bulk storage containers that are
equipped with compatible pumps and accurate thermometers. Bituminous binders shall not be heated
in a boiler with a broken or inaccurate thermometer.
Penetration grade bitumen to be used in the Works shall be heated up to a temperature of not more
than 155 oC. If any bitumen is overheated it shall be removed from the Site and disposed of by the
Contractor.
The rates of application of binder specified or instructed by the Engineer refer to volumes of binder
corrected to 15.6 oC.
800-3
C
1.
2.
ADHESION AGENT
If, in the opinion of the Engineer, the risk of heavy rain within a few hours of the proposed
application of surface dressing should be high, the addition of an adhesion agent to the
bituminous binder shall be instructed by the Engineer.
If adhesion of aggregate with the bitumen is less than 95% in comparison with the area of the
aggregate coated with the bitumen, then it is necessary to use an agent increasing adhesion,
which should be added to the bitumen. The adhesion agent and the amount to be added shall be
to the approval of the Engineer and the application shall be in accordance with the
manufacturer's instructions.
SAFETY AND ENVIRONMENTAL PRECAUTIONS
The Contractor shall take all necessary precautions to avoid fire. The Contractor shall ensure that his
operations in respect of bituminous construction work are not hazardous to the health and safety of the
public or his labour. In particular the Contractor shall ensure that:
1)
2)
3)
4)
5)
bitumen is heated only to the temperature required for the particular application,
hot bitumen does not come in contact with water,
suitable protective clothing and gloves are used when handling hot bitumen, and
dust is reduced to a minimum.
bitumen products and solvents are not spilled on to the ground, ditches, or water
courses.
any bitumen products or solvents which are split shall be immediately removed along
with any contaminated soil etc. and disposed of in a place and manner acceptable to
the Engineer such that environmental risks and hazards are negated.
waste or over heated bitumen or solvents shall not be disposed of by burning.
Because of the highly flammable nature of the solvent, great care is required when
using rapid-curing cut-back bitumen, and volatile solvents.
6)
7)
8)
CONTRACTORS EQUIPMENT
1)
General
In accordance with Section 100 of this Specification, full details of the Contractors
Equipment and methods proposed to carry out the Permanent Works shall be submitted by the
Contractor to the Engineer.
The Engineer shall at all times have access to Contractors equipment for the purposes of
inspection. The Contractor shall carry out regular calibration checks in the presence of the
Engineer and shall correct forthwith any faults that are found.
All Contractors equipment used in the mixing, laying and compacting of bituminous mixes
shall be of adequate rated capacity, in good working condition, and shall be acceptable to the
Engineer. No obsolete, worn-out or malfunctioning equipment shall be used in the Works.
2)
Mixing plant
The Contractor shall mix bituminous materials in a mixing plant, which shall be located on
the Site. It shall be equipped with at least three bins for the storage of heated aggregates and a
separate bin for filler. All bins shall be covered to prevent the ingress of moisture.
The mixing plant shall be the batch-mix type or drum mixer and shall be capable of regulating
the composition of the mixture to within the tolerances specified in this Section of the
Specification.
800-4
The bitumen tank shall be capable of maintaining its contents at the specified temperature
within a tolerance of 5 oC and shall be equipped with a thermostat to prevent the
temperature rising above 155 oC and a fixed thermometer easily read from outside the tank.
The Contractor shall remove from the plant and dispose of any bitumen which has been heated
above 155 oC or has suffered carbonisation due to prolonged heating.
3)
Bitumen distributors
Bitumen distributors shall be truck mounted constant pressure distributors, Specifications for
distributors for binder in hot condition for surface treatment. The uniformity of transverse
distribution of spray bars shall comply with the requirements of the "Depot tray test" and the
Contractor shall have spray bars checked at least twice during the construction season or as
directed by the Engineer where it is apparent the bitumen distribution is not uniform.
Bitumen distributors shall have sufficient power to maintain uniform speeds for the proper
application of the binder. The truck shall be equipped with an accurate low range tachometer
showing the driver the speed in metres per minute. The truck shall be fitted with a gauge bar
and chain or any other acceptable device clearly visible to the driver to enable him to follow
the required edge.
The distributor tank shall have a capacity of at least 4,000 litres and shall be fitted with a
device for indicating the quantity in the tank at any time. It shall be equipped with heaters
capable of maintaining temperatures up to 200 oC and be fitted with an accurate thermometer.
A pressure gauge registering the spraying pressure and a temperature gauge shall be fitted to
the spray bar.
The distributor shall have a pumping system capable of circulating hot binder around the tank
and around the spray bar without spraying. A strainer shall be provided on the discharge line
to prevent nozzles from clogging. Before commencing spraying the spray bar and jets shall be
preheated by circulating hot binder. Spray bars shall be available for spraying in widths
varying from 0.5 m to 4 m and shall be adjustable transversely, so that the operator can follow
the required edge independently, and vertically. The spray nozzles, with quick-acting positive
shut off and anti-drip device, shall be arranged to give a uniform fan-shaped spray. The
pressure in the spray bar shall be sufficient to give an even distribution of the binder.
Distributors shall be capable of applying bituminous binder within the limits of 10% of the
specified rate of application over any portion of the surface.
Distributors shall be checked and calibrated before starting any work or when required by the
Engineer. This shall include the calibration of all the metering devices and gauges and
checking the uniformity of the transverse distribution of spray.
All distributors shall be furnished with a calibrated "rate of spray/machine speed" chart.
4)
Laying equipment
The Contractor shall lay bituminous materials by a self-propelled spreader finisher equipped
with a hopper, delivery augers and a heated adjustable vibrating screed. It shall be capable of
laying bituminous materials with no segregation, dragging, burning or other defects and within
the specified level and surface regularity tolerances. Delivery augers shall terminate not more
than 200 mm from the edge plates.
800-5
5)
Compaction equipment
The Contractor shall provide sufficient rollers of appropriate types sizes and weights to
achieve the specified compaction. Rollers shall be self-propelled smooth wheel tandem
vibratory type with 8 - 10 ton having a width of roll of at least 1450 mm and pneumatic tyre
rollers of equivalent mass, including combinations thereof, capable of reversing without
shoving, tearing or marking the laid mixture. Vibratory rollers shall only be used for
breakdown rolling and processed as smooth wheel dead weight rollers. Wearing course and
base course shall always be finished with a smooth wheel dead weight roller. Prior to laying
of bituminous mixes in the Permanent Works the Contractor shall carry out Site trials in
accordance with Section 200 of this Specification to demonstrate the adequacy of his plant
and to determine the optimum method of use and sequence of operation of the rollers.
803
CONSTRUCTION REQUIREMENTS
A
SITE TRIALS
The Contractor shall carry out full-scale laying and compaction trials on all asphalt concrete paving
and bituminous regulating materials and treatments proposed for the Permanent Works using the plant
and methods proposed. The trials shall be carried out with the agreement, and under supervision of the
Engineer at locations approved by the Engineer.
The Contractor shall carry out the trials to demonstrate the suitability of his plant, equipment and
work procedures to provide and compact the material to the specified proportions, density and voids
content and to confirm that the other specified requirements of the completed asphalt pavement can be
achieved.
Each territory where trials are held shall be at least 100 m in length and full width and thickness of
construction layer for specific material. It can form part of Permanent works, given that it corresponds to
requirements of Specifications and is approved by the Engineer. The Contractor removes all materials,
laid during trials from the territory that does not correspond to Specifications.
The Contractor shall allow in his programme, pursuant to the Conditions of Contract, for conducting
Site trials and carrying out the appropriate tests. The trial of any pavement layer shall be undertaken
at least 14 days ahead of the Contractors proposed date to commence full-scale work on that layer.
The Contractor shall compact each section of the trial area over the range of compactive effort he
proposes. He shall record the following data for each level of compactive effort at each Site trial:
1)
2)
3)
4)
5)
6)
7)
8)
the composition and grading of the material including the bitumen content and type
and grade of the bitumen used,
the moisture content of aggregate in the asphalt plant hot bins,
the temperature of the bitumen and aggregate immediately prior to entering the mixer,
and the temperature of the mix on discharge from the mixer, on commencement of
laying, on commencement of compaction and on completion of compaction,
the type, size, mass, width of roller, number of wheels, wheel-load, tyre pressures
and the number of passes of the compaction equipment, as appropriate for each roller
type,
the target voids and other target properties of the mix together with the results of the
laboratory tests on the mix,
the density and voids achieved,
the compacted thickness of the layer including tolerances achieved,
any other relevant information required by the Engineer.
800-6
The Contractor shall, in the presence of the Engineer, carry out at least eight sets of tests on each 100
m length of trial section for each level of compactive effort. The Site trial shall be deemed to be
successful if all eight sets of results over the range of compactive effort proposed by the Contractor
meet the specified requirements for the material. The above data as recorded in the Site trial shall
become the agreed basis on which the particular material shall be provided and processed to achieve
the specified requirements.
If, during the execution of the Works, the construction control tests should indicate that the
requirements for a material are not being consistently met, the Contractor shall cease work on that
layer and investigate the cause. Materials not meeting the relevant requirements shall be removed
from the Works in accordance with Section 300 of the Specification. Such investigations may include
further laboratory and/or Site trials of the material to determine a revised set of criteria and data that,
when approved, shall be the basis on which all subsequent material is provided and processed to
achieve the specified requirements.
In order the Engineer could study the date of trials, which show incompliance with the Specification
requirements, should be recorded in the logbook for works production, at the same time it is necessary
to indicate responsibilities and terms for defects elimination.
LIMITATIONS ON CONSTRUCTION
The Contractor shall not carry out bituminous construction work in adverse weather conditions or
when directed by the Engineer.
Bituminous material shall not be applied to wet or frozen surfaces or when weather conditions
otherwise prevent the proper handling and finishing of the mixture. Provided that the Engineer may
otherwise instruct surfaces to be damped prior to the application of bitumen emulsions and certain
types of prime coat.
The Contractor shall only place bituminous material when both the ambient temperatures and road
surface temperatures are greater than 10 C and rising and the wind velocity is less than 14 metres per
second. The Contractor shall only lay asphalt concrete paving when he can demonstrate that
prevailing conditions in the field allow the specified densities to be achieved by rolling.
MIXING OF AGGREGATES AND BITUMEN
Mixing plants shall conform to the requirements listed below:

1)
2)
3)
4)
5)
6)
the minimum capacity of the mixing plant shall be 120 t/h (tonnes per hour),
the dryer shall be of the rotating drum type capable of heating the aggregates to the
temperatures set forth in this Specification,
bitumen shall be heated to the specified temperature in approved storage tanks and
delivered to the mixing plant via insulated pipes such that heat losses are minimised,
for batching plants, when dry mixing is required, the minimum dry mixing period
shall be 10 seconds and the minimum wet mixing period shall be 30 seconds,
the wet mixing period shall not normally exceed 60 seconds,
batching plants, continuous mixing plants and drum mixing plants shall have
automatic controls that co-ordinate the proportioning, timing, and discharge of the
mix.
The Contractor shall heat the bitumen so that it can be distributed uniformly, and he shall take care not
to overheat it. The temperature of the heated bitumen shall not exceed 155 oC. The maximum
continuous storage temperature for bitumen over a 24 hour period shall not exceed 125 oC.
Temperatures of bitumen and aggregates shall be within the following limits during mixing.
800-7
Grade of Bitumen
Penetration 91-130
Penetration 60-91
Bitumen Temperature
at Mixing ( 0C)
130 150
140 155
Aggregate Temperature
Mixing ( 0C)
130 - 160
150 - 170
The Contractor shall combine the dried aggregates in the mixer in the amount of each fraction required
to give the specified grading and then introduce bitumen into the mixer in the amount specified. The
materials shall then be mixed until a complete and uniform coating of the aggregate is obtained.
Bituminous mixes shall be kept free of contamination and segregation during transportation. Each
load shall be covered with a tightly fitting and firmly secured canvas or similar covering of sufficient
size to overhang the loaded truck box on all sides. Covers shall be used to protect the mixture from
the weather and dust at all times including during the discharging of the load into the paver. Loads not
properly covered shall be rejected. Trucks used for hauling asphalt mixture shall be adequately
insulated with tight, clean, smooth beds that are free of petroleum oils, solvents or other materials that
may adversely affect the asphalt mixture. A thin coating of an approved release agent may be used to
prevent the mixture from adhering to the beds.
The Contractor shall be deemed responsible to ensure that hot mixes are supplied in accordance with
the specified standard mix formula.
PREPARATION OF SURFACES
Irregularities in the surface of the existing pavement, binder course or base shall be corrected before
application of the tack / prime coat. The existing pavements shall be prepared to receive asphalt
surfacing by appropriate milling, patching, crack sealing and regulating in accordance with this
Section of the specification.
Prior to placement of bituminous mixes, the Contractor shall condition the non-bituminous base or
binder course or existing surface by the application of a prime coat or tack coat in accordance with
this Section of the Specification or as otherwise directed by the Engineer.
Tacked or primed surfaces shall be cured prior to the placement of bituminous mixes. The tack coat
shall be applied only as far ahead of the placing of mix as necessary to obtain the minimum curing
period.
The Contractor shall repair damaged areas of tack-coated or primed surfaces before laying bituminous
mixes. Before the Contractor commences the placement of bituminous mixes he shall apply a tack
coat to the surfaces of kerbs, gutters and other structures that will be in contact with the bituminous
mix.
The Contractor shall protect all exposed surfaces of kerbs, posts, buildings, trees and the like from
being splashed or sprayed with bitumen. Any surfaces which are so marked shall be immediately
cleaned to the satisfaction of the Engineer.
The Contractor shall obtain clearance to proceed from the Engineer before commencing laying
operations.
LAYING THE MIXTURE
Immediately after the surface has been prepared and approved, the mixture shall be spread to line and
level by the laying plant without segregation or dragging.
800-8
The Contractor shall place the mixture in widths of one traffic lane at a time, unless otherwise agreed
by the Engineer. The thickness of any layer after compaction should be at least 2.5 times more than the
maximum size of the stone for the surface layer.
Self-propelled asphalt pavers shall be used for laying. Pavers shall be provided and equipped with an
activated screed assembly, heated if necessary, capable of spreading and finishing the asphalt plantmix material in widths applicable to the typical section and thickness, elevations, grades and camber
shown on the Drawings or as instructed by the Engineer. The pavers loading hopper shall have
sufficient capacity to permit uniform spreading and an automatic distribution system that places the
mixture uniformly in front of the strike-off assembly. The screed assembly shall produce the specified
textured surface finish, free from surface irregularities and without tearing, shoving, gouging or
otherwise distorting the mixture.
The paver shall be capable of operating at forward speeds consistent with uniform and continuous
laying of the mixture. The Contractor shall not operate the paver in a continual stop and start fashion.
Pavers shall be equipped with accurate screed controls for maintaining the screed at the specified
longitudinal grade and transverse slope. The controls shall be capable of maintaining the screed at the
specified transverse slope within plus or minus 1 percent. Automatic controls in the paver shall be
backed by manual controls that can be optionally activated.
If the automatic controls fail or malfunction, the equipment may be operated manually for the
remainder of the normal working day, provided that the specified requirements are met.
If the Contractor fails to obtain and maintain the specified surface tolerance, the paving operations
shall be suspended until satisfactory corrections, repairs or equipment replacement are made to the
satisfaction the Engineer.
F
COMPACTION OF THE MIXTURE
Immediately after spreading the bituminous mixture, the Contractor shall compact it thoroughly and
uniformly by rolling.
The Contractor shall roll the layer when the mixture is neither too workable, such that rolling causes
undue displacement or shoving, nor too stiff, offering resistance to the desired degree of compaction.
The number, weight and type of rollers supplied by the Contractor shall be sufficient to obtain the
required compaction while the mixture is in a workable condition. The equipment to be used and
sequence of rolling operations shall be as agreed with the Engineer and proven during Site trials.
Rolling, in compliance with the general procedures outlined below, shall continue until the layer under
compaction has attained the specified requirements.
Initial rolling with a steel tandem vibratory roller or three axles vibratory roller shall follow the paver
as closely as possible. The rollers shall be operated with the drive wheel nearest the paver, at a
uniform speed not exceeding 5 km/h.
Rolling shall normally commence from the outer edge and proceed longitudinally parallel to the
centreline, each pass overlapping the previous pass by one half of the roller width. On superelevated
curves, rolling shall begin at the low side and progress to the high side. Where laying is carried out in
lanes the Contractor shall take care to prevent the entrapment of water.
Intermediate rolling with a pneumatic tired roller shall follow immediately after the initial rolling.
Final rolling with a smooth, steel wheel tandem roller shall be carried out to eliminate marks from
previous rolling.
800-9
The Contractor shall keep roller wheels and drums lightly moistened with water to prevent adhesion of
the mixture to the rollers.
In areas too small for rollers, a vibrating plate compactor may be used to achieve the specified
compaction.
FINISHING, JOINTS, AND EDGES
The Contractor shall remove any mixture that becomes loose or broken, mixed with dirt or foreign
matter, or is in any way defective, and replace it with fresh hot mixture compacted to conform with the
surrounding area.
The Contractor shall spread the mixture in a continuous operation. Where the mixture is to be placed
against previously placed bituminous material he shall form transverse joints by cutting neatly in a
straight line across the previous face to expose the full depth of the course. The vertical face so
formed shall be heated with a propane joint heater and painted lightly with bitumen emulsion
immediately prior to the new mixture being placed against it.
The Contractor shall roll longitudinal joints directly behind the paving operation. The first lane shall
be placed true to line and level and have a vertical face. The mixture placed in the abutting lane shall
then be tightly pressed against the face of the previously placed lane. The paver shall be positioned to
spread material overlapping the joint face by 20 to 30 mm. Before rolling, the excess mixture shall be
raked off and discarded.
When the abutting lane is not placed the same day, or the joint is destroyed by traffic, the Contractor
shall cut back the edge of the lane as necessary, trim it to line, heat it with a propane joint heater and
lightly paint it with hot 90/130 penetration grade bitumen immediately before the abutting lane is
placed.
The Contractor shall remove any fresh mixture that is inadvertently spread on the existing work by
carefully sweeping it back on to the uncompacted work, so as to avoid formation of irregularities at
the joint. The finish at joints shall comply with the surface requirements and shall present the same
uniformity of finish, texture and density as other sections of the surface.
The edges of the course shall be rolled concurrently with or immediately after the longitudinal joint. In
rolling the edges, roller wheels shall extend 50 mm to 100 mm beyond the edge.
QUALITY CONTROL TESTING
During mixing and laying of bituminous materials the Contractor shall carry out control tests on the
constituents and on the mixed material in accordance with his Project Quality Control Plan and
Section 200 of these specifications.
If the results of any tests show a trend towards the constituent materials failing to comply with the
Specification, the Contractor shall identify whatever changes are necessary to the materials and work
procedure to ensure compliance, and obtain the Engineers approval before implementing such
changes.
If the results of more than one test in ten successive tests on the mixed material show that the material
fails to comply with the Specification, the Contractor shall immediately cease laying operations until
he has identified and corrected the reason for the failure. The Contractor shall at his own cost remove
all faulty material and replace it with material complying with this Specification.
800-10
TOLERANCES
The Contractor shall construct surfacing courses and base courses within the geometric tolerances
specified in Section 300 of this Specification
The Contractor shall maintain the composition of the mixture as determined from the standard mix and
Site trials within the tolerances, per single test, set out in Table 8- 1.
Table 8 - 1 Tolerances for Bituminous Mixes

Constituent
Bitumen Content
Passing 5 mm sieve and larger sieves
Passing sieves between 5 mm and 0,63 mm
sieves
Passing sieves between 0,63 mm and 71
m sieves
Passing 71 m sieve
Tolerance
0.3% by total weight of total mix
6% by total weight of dry aggregate including mineral filler
The average amount of bitumen in any length of any layer, calculated as the product of the bitumen
contents obtained from single tests and the weight of mixture represented by each test, shall not be less
than the amount instructed.
The average amount of bitumen for each days production calculated from the check weights of mixes
shall not be less than the amount instructed.
The final average overall width of the upper surface of a bituminous mix layer measured at six
equidistant points over a length of 100 m shall be not less than the width specified. At no point shall
the distance between the centreline of the road and the edge of the upper surface of a bituminous mix
layer be narrower than that specified by more than 30 mm.
804
DESIGN OF BITUMINOUS MIXES
Asphalt concrete mix shall be composed of a mixture of aggregates, bitumen, mineral filler and additives as
specified. A standard mix formula shall be established by the Contractor and approved by the Engineer for
each mixture to be supplied for the Contract. The several aggregate fractions shall be sized, uniformly graded,
and proportioned such that the resulting mixture meets the grading requirements of the standard mix formula.
The standard mix formula, within specific allowable tolerances, shall be within the ranges specified for the
particular type of asphalt concrete mix and shall establish:
i
ii
iii
iv
a single percentage of aggregate passing each required sieve size,

a single percentage of bitumen to be added to the aggregate,
a temperature range within which the mixture is to be mixed,
a recommended temperature range for compaction of the mixture after being laid.
At least 56 days prior to production, the Contractor shall submit to the Engineer in writing a standard mix
formula for each mixture supported by laboratory test data, samples, and sources of the components, and
asphalt concretes plasticity temperature relationships information for approval. The Contractor shall only use
the standard mix formula for the production of each bituminous mixture. No modifications to a standard mix
or changes in the nature or source of the constituent materials shall be made without a written submission by
the Contractor to the Engineer detailing the proposed modifications with relevant supporting data and the
subsequent approval of the Engineer.
If a standard mix formula proves unsatisfactory, a new standard mix formula together with supporting test
data shall be submitted by the Contractor for review and approval by the Engineer prior to production.
800-11
Aggregate shall be conditionally accepted or rejected in the stockpiles at the mixing plant site. Asphalt
concrete mix shall be conditionally accepted or rejected at the mixing plant. The plant-mixed material will be
tested for conformance with the standard mix after laying and before compaction.
If the standard mix formula includes additives, their sources shall be approved by the Engineer. Additives shall
be added at the rate determined by the Contractor and approved by Engineer based on laboratory analysis and
laboratory mix design procedures. The rate of additive addition shall be confirmed by the field laboratory
during production. Appropriate in-line blending or other approved methods for addition of additives to the
mixture shall be used.
The procedures set out above shall be followed in establishing each new standard mix formula.
805
ROAD PAVEMENT
For the wearing course of the pavement it is necessary to use crushed-stone mastic asphalt on bitumen
type BND 60/90 grade, for the binder course of the pavement hot porous coarse grain asphalt
concrete grade 1, for upper layer of the aggregate base course highly porous coarse grain asphalt
concrete.
806
PAVEMENT FROM STONE

MIXTURES
A
MASTIC ASPHALT CONCRETE
Materials
Requirements for stone mastic asphalt concrete mixtures and asphalt concrete
Stone mastic asphalt concrete mixtures and asphalt concrete shall meet the requirements of the GOST
31015
Depending on size of the stone being used the stone mastic asphalt concrete mixtures are divided into
the following types:
SMA -20-with the largest size of the grains up to 20 mm;
SMA-15-
15 mm;
SMA-10-
10 mm.
Mixtures shall be prepared in accordance with the requirements of the GOST 31015 according to the
technological documentation approved in a set order by the manufacturer.
Granular content of the mineral part of the mixtures and asphalt concrete shall correspond to the ones
indicated in the Table 8-2.
Indices of the physical-and-mechanical properties of the asphalt concretes, being used in the certain
road climatic zones, shall correspond to the one indicated in the Table 8-3.
The mixtures shall pass the testing for adhesion of binding agent with the surface of the mixtures
mineral part.
800-12
The mixtures shall be resistant to splitting during the process of transportation and loading-unloading.
Resistance to splitting is determined in accordance with the Appendix B of the GOST 31015 by the
index of binding agents swelling, which shall be no more than 0,20 % by the mass. During preparing
mix design it is recommended to have the index of the binding agents swelling within the limits from
0,07% up to 0,15% by the mass.
The mixtures shall be homogeneous. Homogeneity of the mixtures is checked by the variation
coefficient of the indices of ultimate compression strength at the temperature of 50C, which shall be
no more than 0,18.
Depending on the bitumen binding agent being used the temperature of the mixtures during unloading
and placement shall meet the values indicated in the Table 8-4.
Table 8-2
in % by
Type
of
the
mixtures
and 20
asphalt concrete
SMA -10
SMA -15
SMA -20
10090
15
10
100-90
10090
7050
60-40
42-25
weight
Size of grains, finer, mm
5
2.5
1.25
0.63
4030
3525
3020
2919
2818
2515
26-16
25-15
24-13
0.315
2220-11
13
2220-10
12
21-11 19-9
0.16
0.071
17-10
15-10
16-9
14-9
15-8
13-8
Note At the acceptance testing it is allowed to determine granular content of the mixtures by control sieves in
accordance with the data, marked in bold font.
Table 8-3
Value of the index for road climatic
zones IV, V
Name of the index

Porosity of the mineral part, %
Retained porosity, %
Water Saturation, % by volume:
of the samples, formed from mixtures
core samples of the ready pavement, not more
Ultimate compression strength, MPa, not less:
at the temperature of 20 C
Shear-resistance:
Coefficient of internal friction, not less
adhesion at shear at temperature of 50 C, MPa, not
less
Crack resistance:
Ultimate stretchability strength during splitting at
temperature 0 C, MPa:
800-13
From 15 up to 19
From 2,0 uo to 4,5
From 1,5 up to 4,0
2,5
0,70
0,94
0,20
Not less
Not more
Water resistance at long water saturation, not less
3,0
6,5
0,75
Notes:
1. For SMA-10 it is allowed to reduce the rates of coefficient of internal friction for 0,01 by absolute value.
2. When polymer-bitumen binding agents are used it is allowed to reduce the rates of adhesion at shear and the
rates of ultimate tensile strength at splitting for 20%.
Table 8-4
Depth of the needle penetration, 0,1 mm,
from 40 up to 60 includ.
over 60 up to 90 includ.
over 90 up to 130 includ.
Temperature, C
during loading
From 160 till 175
From 155 till 170
From 150 till 165
During placing, not less

150
145
140
Depending on value of summary specific activity of natural radionuclides (Aeff) in the materials being
used the mixtures and asphalt concrete are used for:
With Aeff up to 740 Bq/kg for construction of roads without limitations;
With Aeff up to 1500 Bq/kg for construction of roads beyond the settlements and zones of
perspective building up.
Requirements for raw materials
Crushed stone from the dense rocks and crushed stone from metallurgical slags, constituent to
mixtures, shall meet the requirements of the GOST 8267 and GOST 3344. To prepare mixtures and
asphalt concrete crushed stone of the following fractions shall be used: 5-10 mm, 10-15 mm, 15-20
mm. Grade of crushability of the crushed stone from igneous and metamorphic rocks shall be not less
than 1200, from sedimentary rocks, gravel and metallurgical slags not less than 1000, grade of the
crushed stone on the abradability shall be I-I. Grade of the crushed stone on frost-resistance shall be
not lower than F50.
Content of plate-like and needle-shaped grains in the crushed stone and gravel shall be not more than
15% by weight.
Content of crushed grains in the used gravel aggregates shall be not less than 85 % by weight.
Sand from the screening of crushing rocks shall meet with the requirements of the GOST 8736; grade
on strength of sand shall be not lower than 1000; content of loamy particles, determined by method of
swelling not more than 0,5 %, at this content of grains finer than 0,16 mm (including dust-like and
loamy particles in this fraction) is not standardized.
Mineral filler shall meet the requirements of the GOST 16557. With corresponding feasibility study it
is allowed to use sifting material finer 0,16 mm from crushing rocks instead of mineral filler at the
quantity of up to 50 %. The content of clayey particles determined by the swelling method, shall be not
more than 0,5 %. Other industrial wastes (ashes, fly-ash, cement dust, etc.) are allowed to use as
mineral filler only after approving their suitability pretesting.
As stabilising agent, cellulose fiber or special granules shall be used, which shall meet the
requirements of the technical specifications of the manufacturer.
800-14
Cellulose fiber shall have tape-like structure with the length of from 0,1 mm up to 2,00 mm. The fiber
shall be homogeneous and shall not include the bunches, concentration of uncrushed materials or the
foreign particles. On the physical-and-mechnical properties the cellulose fiber shall correspond to the
values, which are given in the Table 8-5.
Table 8-5
Description of Index
Moisture, % by mass, not more than
Heat resistance at the temperature of 220 on the mass
changing during heating, %, not more than
Content of fibers with the length of from 0,1 mm up to 2,00
mm, %, not less
Value
8,0
7,0
80
It is allowed to use other stabilizing agents including polymer or other fibers with round or elongated
cross section of the fibers with the length of from 0,1 mm up to 10,00 mm which are capable to
absorb the bitumen at technological temperatures without negative affecting to the binding agent and
mixtures. Suitability of the stabilizing agents and their optimum content in the mixture is defined by
testing the SMA as per the GOST 12801 and by split resistance in the mixture as per the GOST
31015.
As binding agent viscous bitumen for roads shall be used as per the GOST 22245 and also the
modified, polymer-bitumen binding agents (PBBA) and other bitumen binding agents with improved
properties according to the normative and technical documents agreed and approved by the Employer
in a set order.
For the climatic zones IV-V it is recommended to use the bitumen binding agents with the needle
penetration depth (0,1mm) at the temperature of 250C of the type 40-90. At that more viscous
bitumen and polymer-bitumen binding agents are recommended to use for the road with higher traffic
volume.
The raw materials shall be approved by the Engineer.
3.
Mix design for Stone Mastic Asphalt concrete mixtures
Mix design of stone mastic asphalt concrete mixtures shall be done based on the designed thickness of
the layer being placed according to the Table 8-6.
Table 8-6
Types of SMA
Recommended layer thickness, cm
SMA -10
2,0-4,0
SMA - 15
3,5-5,0
SMA 20
4,0-6,0
At the first stage the quality of the raw materials and bitumen binding agent shall be determined
which shall correspond to the requirements and clause 2 of the Specification.
At the second stage the balance of mixtures components shall be selected to give which the
requirements of the clause 1 of the specification.
Preliminarily the mix designs shall be sized in accordance with Table 8-7.
The mineral part shall be selected in a way so that the curve of the granular content was in the zone
limited by ultimate curves and it should be smooth curve.
800-15
During mix designing it is necessary to take into account quantity of the grains finer than 0,071 mm in
the sand from crushing screening as well as conditions of their partial removal from the drying drum
by dust collection system. At dry system it is necessary to provide for batching the cyclone dust into
mixing plant together with the mineral filler; at wet system the dust removed from the mixture shall be
filled by additional quantity of the mineral filler.
800-16
Table 8-7
Material requirements, % by mass SMA
Material
SMA -10
SMA - 15
Fraction, mm:
5-10
10-15
15-20
SMA - 20
60-70
-
15-25
40-60
-
10-15
20-30
30-50
Sand from crushing sifting

Mineral filler
Bitumen or PBBA
Stabilizing agent
10-30
10-20
6,5-7,5
0,2-0,5
5-20
10-20
6,0-7,0
0,2-0,5
5-15
10-20
5,5-6,0
0,2-0,5
Based on the recommendations from the Table 8-7, a trial batch of 3 kg mass shall be prepared in the
laboratory. The sample of the hot mix shall be tested for runoff of the binding agent according to the
method stated in the GOST 31015. If the index of runoff is higher than 0,2% the content of stabilizing
agent shall be increased by 0,05-0,1% or reduced by the bitumen quantity; if the rate is low, 2-3
samples shall be prepared from the produced batch by combined method of compaction a per the
GOST 12801 and according to these samples one shall determine sedimentary porosity and porosity of
the mineral carcase.
If case the sedimentary porosity does not correspond to the standardized value, then according to the
obtained data one shall define required content of the bitumen () (% by mass):
(V - V ) p
pm
Where
V
V
porosity of the mineral part, %

required residual porosity, %
real density of the bitumen, gr/sm3
pm
average density of mineral part,gr/sm3
With the defined bitumen content the mixture shall be prepared, the rate of binding runoff shall be
determined, then from 2-3 samples residual porosity or water saturation of the asphalt concrete shall be
determined. If residual porosity and index of the water saturation is equal to 1,5-3,5 %, then the calculated
quantity of the bitumen is assumed as a basis. Otherwise the procedure of defining content of the binding agent
shall be repeated.
Under the last recipe, a batch shall be prepared, which could be enough for the quantity of the
samples to determine physical-and-mechanical properties of the SMA.
Determination of the physical-and-mechanical properties shall be carried out as per the GOST 12801.
Mix design of the asphalt concrete is considered as completed if all the indices of the asphalt concrete
samples properties meet the requirements set in the Table 8-3. mix design prepared int eh laboratory
shall be tested at the Asphalt Concrete Plant and revised as per the results of testing the trial batches.
Mix design of mixtures shall be approved by the Engineer.
B
Requirements for execution of the works
800-17
Preparation of Stone Mastic Asphalt concrete mixes
SMA mixtures shall be prepared in standard asphalt mixing plants equipped with mixers of forced
mixing by means of mixing aggregates, sand of crushing siftings, mineral filler and bitumen, and also
stabilizing additives in the form of fibers or polymers.
During preparation of the SMA mixture it is necessary to keep the mix design as soon as accurate. The
error of batching components during mix preparation shall not exceed:
- for crushed stone 2 %;
- of the mineral filler and bitumen 1,5 %;
-of adding fibers 5 % out of mass of the corresponding component.
The technological process of preparing the mixture in the mixers of periodical function includes the
following primary operations:
- preparation of mineral materials ( supply and prior batching, drying and heating to the
required temperature, graded proportion);
- supply of cold mineral filler and stabilizing agent, its proportioning prior to adding to the
mixer;
- bitumen preparation (heating and in case of necessity supply from the bitumen pool to the
bitumen melting plant, evaporation of the possible moisture and heating to the working
temperature, in necessary cases adding surface active substances and other improving
additives, portioning prior to supply to the mixer);
- dry mixing of hot mineral materials with cold mineral filler to the stabilizing agent;
- mixing mineral materials with the bitumen and offloading the ready asphalt concrete mixture
to the storage bin or to the trucks.
When the mixture is prepared in the mixer of continuous operation there is no need for separate
batching of hot mineral materials, but heating and mxing mineral materials with the bitumen and
stabilizing agent shall be done in one drying-mixing drum.
Temperature of heating the mixture of sand and aggregates shall be 25-30C higher than the required
temperature for ready asphalt concrete mixes enlisted in the Table 8-4. In comparison with preparation
of traditional asphalt concrete mixtures for dense asphalt concrete one recommends to increase heating
of the mineral materials in the drying drum approximately by 10-20C.
In the case of applying the surface active substances or activated mineral filler one recommends to
decrease the temperature of heating the mineral materials by 10-20C.
Granular hot materials in the mixture shall be batched based on designed grading of the mixture. In
order to convert the design form of the grains of the SMA to the square form of the screen holes it is
necessary to use the conversion table 8-8.
Final content of the fractions being mixed is specified according to the results of testing the trial batch
obtained from the mixing plant.
The stabilizing agent of the cellulose fibers, represented in the form of the bitumen soaked and pressed
granules shall automatically be delivered to the mixer from a silo bin via weighing or volumetric
feeder on a specially equipped line. Cellulose fibers shall be injected directly into mixing chamber
with the help of a compressor, and batching is carried out according to the time of valve opening and
closing.
Table 8-8
Compliance of sieve holes dimensions, mm
800-18
Round
Square
31,5
28,0
24,0
20,0
16,0
12,0
8,0
4,0
40,0
35,0
30,0
25,0
20,0
15,0
10,0
5,0
The stabilizing additive is entered into a mixer of a modern asphalt mixing plant of cyclic operation
onto the heated aggregate or prior to add the mineral filler, or together with it, providing for dry
mixing during 15-20 seconds. During consequent wet batching of the mixture with the bitumen
within 10-20 seconds the stabilizing agent shall be equally spread in the asphalt binding substance.
Duration of batching the mix is defined by technical parameters of the mixing plant, degree of
deterioration of stirring arms (agitators) and finally shall provide for equal distribution of all the
components including fibers, and full bitumen coverage of discrete grains of the mineral materials.
Temperature of the ready asphalt concrete mixtures at exit from the mixer shall comply with the
requirements of the Table 8-4.
The basic criterion for quality assurance during preparation of asphalt concrete mixes for SMA is
observance of mix design, especially bitumen content. The value of water saturation in the samples,
which are formed in the asphalt concrete plant, can serve as indirect factor of the bitumen content.
The second important quality characteristic during preparing mixes is the index of binding agents
running-off. Exceeding of its standardized value can lead to sticking of the asphalt concrete mixture
onto bodies of the trucks.
Laying and compaction of the SMA mixture
Hot SMA mixture shall be laid and compacted as standard mixture by common asphalt pavers and
rollers. It is recommended to lay the mixture for full width of the carriageway as much as it is
possible by caterpillar asphalt pavers, equipped with automatic systems providing evenness and
crossfall.
After passage of the asphalt paver there should not be cracks, popouts, discontinuity and other defects
on the surface of the placed SMA. The noticed defects can be manually corrected prior to start
compaction of the layer by rollers be means of adding and levelling the hot mixture in the noticed
places.
However it is necessary to note that adhesiveness of the SMA mixes is considerably higher
than of the common mixes for dense asphaltic concrete in accordance with the GOST 9128.
For manual works SMA mix is "difficult".
In order to get smooth surface of the layer it is necessary to provide for continuous laying the SMA.
The recommended speed of laying is not less than 2-3 m/mines and depends on delivery of the mixture
to the asphalt pavers.
In case of short breaks in delivery of the mix it is not recommended to work it out completely from the
asphalt pavers bin. The bin shall be always filled for not less than 25 %. In case of forced stoppage of
the paver for 15-20 minutes it is necessary to displace the remained mix from the bin into warmed
screw barrel as during cooling-down the SMA mixes fasten quicker than the common asphalt concrete
mixes.
800-19
In case of long breaks in delivery the mixture from the ACP it is necessary to consume the whole mix
remained in the pavers bin, in the screw barrel and under the plate of the paver.
Special attention shall be paid to cold longitudinal and transverse joints at conjugation of the lanes
being placed. Transverse conjugations shall be perpendicular to the road axis. Edges of the lanes
placed earlier shall be cut vertically and treated with bitumen or bitumen emulsion. Cold transverse
joints shall be heated, the paver shall be put in a way so that the vibrating plate was above the edge of
the earlier placed pavement layer and afterward the screw barrel shall be filled with hot mixture.
For compaction of SMA it is more suitably to use heavy rollers of 8-10 tons weight, the steel rollers of
which shall be wetted by with soap, water kerosene emulsion or water during rolling process. It is not
recommended to use pneumatic rollers as at high temperature sticking of the SMA bitumen to rubber
tyres is possible. Only at final stage of compaction it is possible to use them but with properly
warmed tyres.
The laid SMA layer shall be compacted at maximum temperature by heavy static rollers, which shall
be moving by short divisions with a speed of 5-6 km/h and kept as close to the asphalt paver as
possible.
In case there transverse conjugations and cold longitudinal joints the compaction shall be started with
them. For conjugation of the layer with a cold lane it is necessary the roller to make its first passage
over the earlier placed lane covering the newly placed lane for the width of 2030cm. There always
should be a worker in front of the roller close to the paver whose task is to remove excesses of the
mixture from the cold lane to the newly placed hot mixture being compacted.
During compaction the rollers shall move along the lane being compacted in a shuttle way from the
edge of the lane to the road axis, and then from the axis to the edges overlapping every trace by 20-30
cm.
The first passage shall be started having receded from edge of the pavement for 10 cm. The edges
shall be compacted after the first passage of the roller along the whole length of the lane. The scheme
of rolling shall provide uniform compaction on the whole width of compacted pavement that can be
reached by equal number of rolling passages by one trace.
It is not recommended to compact the SMA layer by the roller with running vibration. When the
temperature of the SMA mix is lower than 100C, and the mixture shall be placed to the rigid base or
under thin layer of the SMA it is forbidden to compact the layer. Layers of an increased thickness are
allowed to compact with vibration only with sufficiently high temperature of the mixture after one
passage of the static roller. For efficient compaction 1-2 passages are enough.
When the temperature is not lower than 80C it is very important to compact the SMA layer quickly,
especially when thin layers of the pavement are constructed as they are cooled down very quickly. As
a rule behind one asphalt paver, there shall be two heavy static rollers. The required level of the SMA
compaction is normally reached after 4 passages of the roller by one trace.
The basic criterion of the SMA quality is water saturation or residual porosity of core samples, which
shall be selected not earlier than in a day after laying and compaction. It is not recommended to define
compaction factor of the SMA layers. In case of calculating the compaction factor on demand of the
Employer, it is necessary to take into account that this factor r is characterized by low frequency and
precision (ISO 572-2-94). Due to small thickness of the layer and high content of aggregates,
heterogeneity of the properties of the reformed laboratory samples increases both on density and on
water saturation indices.
800-20
807
ASPHALT CONCRETE
MATERIALS FOR ASPHALT CONCRETE

1)
Penetration Grade Bitumen
To prepare the mixtures one should use oil road bitumen (BND) viscous, which complies with the
requirements of GOST 22245 of the types BND 90/130 and BND 60/90.
Table 8-9 Norms for Bitumen
Index name
Needle penetration depth, 0,1 mm:
at 25C
at 0C, not less than
Softening point on ring and ball, C,
not lower than
not greater than
Stretchability, cm, not less than:
at 25C
at 0C
Break point, C, not higher than
Flash point, C, not lower than
Change of softening point after
heating, C, not more than
Penetration index
2)
BND 60/90
BND 90/130
02 5612 0112
02 5612 0113
61-90
20
91-130
28
47
43
55
3,5
-18
230
65
4,0
-20
230
5
From -1,0 up to +1,0
Aggregate
Aggregate from dense rocks and gravel, slag aggregate, forming part of the mixture, should comply with the
requirements of GOST 8267 GOST 3344 on gradation, strength, content of flour and clay particles, content
of clay in lumps. Content of plate-like and needle-shaped grains in the crushed stone and gravel shall be not
more than 15% by weight.
Table 8 - 10 Physical Properties for Crushed Stone and Sand

For asphalt
concrete
Grade I
Type B
Index name
Crushed stone
The mark, which should not be lower:
On crushability:
a) crushed stone from igneous and metamorphic rocks
b) crushed stone from sedimentary rocks
On abradability:
a) crushed stone from igneous and metamorphic rocks
b) crushed stone from sedimentary rocks
on frost-resistance for all types of crushed stone and gravel for V
road-climatic zone
Sand
The mark on strength of the sand from siftings of the rocks and
gravel crushing
Content of clay particles being determined by swelling method, %
by weight, not more than
Hot asphalt concrete dense, grade I type B

Retained porosity in dense asphalt concrete is above 2,5 to 5%.
800-21
1200
1000
I1
I2
F 50
800
0,5
The type B contains the crushed stone above 40 to 50%.

Hot asphalt porous, grade I
Retained porosity in dense asphalt concrete is above 5 to 10,0%.
Hot asphalt highly porous, grade I
Retained porosity in dense asphalt concrete is above 10 to 18,0%.
Table 8 - 11 Gradation of Mineral Part of Mixture and Asphalt Concrete for Wearing Courses
Types of dense
asphalt concrete
B
40
90100
20
75100
15
10
64-100
52-100
Size of grains, finer, mm

5
2,5
1,25
40-60
28-60
16-60
0,63
0,315
0,14
0,071
10-60
8-37
5-20
2-8
in % by weight
Note: At acceptance tests it is allowed to determine gradation of the mixtures by redresser sieves
in accordance with the data in bold type.
In asphalt concrete mix design the remainder on the sieve of 5 mm is recommended as 45-55%.
Table 8 - 12 Gradation of Mineral Part of Mixture and Asphalt Concrete for Binder Courses
and Bases
in % by weight
Size of grains,
finer, mm
Porous
Highly Porous
5,0
0,63
0,071
From 40 to 60
From 10 to 60
From 0 to 8
From 40 to 60
From 10 to 60
From 4 to 8
Table 8-13 Physical Properties for IV-V Road Climatic Zones

For asphalt concrete
Coarse grain porous
Fine grain dense, Type
and highly porous
B
Index name
Compression strength under temperature of 50C,
MPa, not less
Compression strength under temperature of 20C,
MPa
Compression strength under temperature of 0C, MPa
Water resistance, not less
At long water saturation
not normal
1,3
not normal
2,5
not normal
13,0
0,70
not normal
Table 8-14 Water Saturation of Dense Asphalt Concrete from Hot Mixtures
Type of asphalt concrete

Type B
Samples formed from mixture

from 1,5 to 4,0
in % by weight
Core samples of ready pavement,
not more
4,5
Porosity of mineral part of hot mixture asphalt concrete shall not be more than
Dense types - 19%
Porous 23%
Highly Porous 24%.
800-22
Table 8-15 Temperature of Hot Mixtures during Shipment to Consumer and Storage Depending on
Bitumen Properties
Temperature of the mixture, C, depending on bitumen properties
Needle penetration with 0,1 mm thickness at 25C, mm
61-90
91-130
from 145 to 155
from 140 to 150
The Contractor shall take such measures necessary to prevent the segregation of aggregates in storage heaps.
Stockpiles shall be built up in horizontal layers and shall not exceed 1.5 m in height.
3) Mineral filler forming part of the mixtures and asphalt concretes shall meet the requirements of ST RK
1276-2004.
Table 8-16
Index name
Gradation, % by weight, not less:
Finer 1,25 mm
Finer 0,,315 mm
Finer 0,071 mm
Porosity, % by volume, not more
Swelling of samples from filler and bitumen mixture, % by volume, not
more:
Containing loamy admixtures in the filler not more than 5%
(one and half oxides Al2O3+Fe2O3 not more than 1,7 by weight)
(one and half oxides Al2O3+Fe2O3 not more than 5% by weight)
Bitumen capacity index, g, not more:
(one and half oxides Al2O3+Fe2O3 not more than 1,7 by weight)
(one and half oxides Al2O3+Fe2O3 not more than 5% by weight)
Moisture, % by weight, not more
Norms for mineral filler

100
95
80
30
1,5
2,5
50
65
0,5
B LAYING AND COMPACTION OF ASPHALT CONCRETE

Asphalt concrete shall be placed according to Section 803E. The Contractor shall carry out rolling in
accordance with this Section of the Specification by a sequence of rollers in such a manner and at such
temperatures as will ensure the full specified compaction of the asphalt concrete layer and produce a
uniform textured surface free from tearing, tracking or other objectionable surface irregularities within
the tolerances laid down in this Specification. The minimum temperature of the mixture at the
commencement of compaction shall be 125 OC and after completion of compaction - 90O.
The binder content of the standard mix shall initially be proposed by the Contractor and amended as
necessary in consultation with and to the approval of the Engineer following laboratory and Site trials.
The field density of each asphalt concrete layer shall be checked from the average density of pairs of
cores cut through the full thickness of the layer at the frequency indicated in the Project Quality
Control Plan subject to a minimum of 1 pair of cores for each calendar day that asphalt concrete work
takes place.
Coefficient of compaction for pavement design layers of dense asphalt concrete from hot mixtures of
the type B shall be not lower than 0,98, dense 0,99.
Site trials shall determine the minimum number, type and condition of rollers required to compact the
mixture to the required density while it is still in a workable condition. At all times during asphalt
concrete laying the Contractor shall ensure that the availability of compaction plant does not drop
below the minimum.
800-23
808
PRIME COAT AND TACK COAT

B
MATERIALS FOR PRIME COAT AND TACK COAT
Prime Coat
The binder for prime coat shall be medium curing Cationic Slow Set bitumen emulsion complying
with Section 200 of this Specification. The depth of penetration of the prime coat shall be between 5 10 mm with thin film left on the surface. Penetration of the prime coat shall be such that the surface is
dry within 24 hours.
Manual for using different by viscosity types and spraying volume are enlisted in Table 8-17
Table 8-17 Manual for Types of Bitumen on Viscosity and Volume of Spraying for Prime Coat
Surface Porosity
Low porosity
Average porosity
High porosity
Standard Materials
Pavement from
optimal
mixture of
aggregate, gravel and stabilized graded
materials
Mechanically stabilized foundation soil with
dusty binder
Any material, which can be compacted up to
dense surface and creates open texture after
compaction
Kinematical
viscosity at 60C
(centistokes)
Volume of
Spraying (l/m)
30-60
from 0,6 to 0,9
70-140
from 0,9 to 1,2
250-500
from 1,2 to 1,5
For very low porosity surfaces viscosities in the range 10 - 15 centistokes at 60 0 C may be necessary
implying the use of special primers. Emulsions for use as primer may also require further dilution
with water at 1: 1 with an increase in the rate of spray and for very low porosity surfaces it may be
necessary to use higher dilutions and make multiple applications at lower rates of spray. Despite the
Table 8-10 provides for general guidance on actual selection, the type of prime coat shall be
determined by site trials to the approval of the Engineer.
Tack Coat
The binder for tack coat shall be a Cationic Rapid Set (CRS-1) bitumen emulsion complying with
Section 200 of this Specification and in accordance with the requirements of GOST 18659. The rate of
application shall be determined by site trials, dependent upon the nature of the existing bituminous
surface, in the range of 0.1 to 0.4 l/m2 residual bitumen with continuous cover.
PREPARATION OF SURFACES
The Contractor shall thoroughly clean the surface to be sprayed by sweeping with mechanical brooms
and/or washing or other approved means. All laitance of soil and loose and foreign material shall be
removed.
All loose material shall be swept clear of the Works to expose the full width of the layer.
800-24
Prime coat and tack coat shall not be applied to a wet surface, or during a dust storm, or when the
weather is rainy, foggy, windy, or the temperature in the shade is less than 10 0 C except that
immediately prior to the application of prime coat on unbound granular materials, the complete
surface of the unbound layer shall be lightly and evenly sprayed with water. Ponding or saturation of
the layer shall be avoided. Water shall be applied to the surface in small increments in order to
achieve the required condition. Any water remaining on the surface shall be allowed to drain away
before the prime coat is applied.
The surface to be sprayed shall be checked for line, camber and level, and the surface corrected, made
good as necessary and approved by the Engineer before any bituminous spray is applied. Immediately
prior to the commencement of all bituminous spraying operations the Contractor shall request the
Engineer's approval of the surface to be sprayed.
SPRAYING OF PRIME COAT AND TACK COAT
As soon as practical after the surface preparation as specified in Section 800 of this Specification has
been carried out to the approval of the Engineer, the prime or tack coat shall be sprayed at the
specified rate. Spraying shall be carried out not later than 4 hours after the surface preparation has
been approved.
The quantity of binder used shall give complete coverage of the surface with a slight trace of run-off in
places. If the specified spray rate should appear to be incorrect, the Contractor shall immediately stop
spraying and inform the Engineer. The Engineer shall instruct an amended spray rate.
The edge of the area to be sprayed shall be marked out with a line of string or wire pegged down at
intervals not exceeding 15 m on straights or 7.5 m on curves.
Bitumen shall be sprayed from a constant pressure distributor of minimum capacity 4,000 litres,
complying with the requirements of Section 800 of this Specification. Hand-spraying shall be
permitted only at the discretion of the Engineer in small areas or to make good defective areas such as
those caused by a blocked nozzle.
Nozzles shall be arranged to give a uniform spray and shall be tested prior to spraying by discharging
on to suitable material (such as building paper, metal sheets, etc.,) or into purpose made troughs.
Testing shall not take place on the road, and any bitumen spilt on the ground shall be cleaned off.
If during spraying, a nozzle becomes blocked or develops a defect, the spraying shall be immediately
stopped. Any area incompletely sprayed shall be made good with a hand-spray. The machine shall be
repaired before further spraying is commenced.
When commencing and stopping spraying, sheets of building paper or metal at least 2 m wide shall be
spread across the full width to be sprayed to give a clean sharp edge.
The metal sheets used for stopping and starting work shall be cleaned after each run and the troughs
used for testing shall be cleaned at the end of each day's work.
During spraying all kerbs, road furniture, culvert headwalls, tree boles and the like which are liable to
be disfigured by splashing of bitumen shall be protected, and any such feature which is accidentally
marred by bitumen shall be cleaned off with a suitable solvent and made good.
TEMPERATURES OF APPLICATION
The minimum pumping temperatures, the range of spraying temperatures, and the maximum heating
temperatures of cut-back bitumen specified for use in the Works are set out in Table 8-18.
Table 8 - 18 Pumping, Spraying & Heating Temperatures of Medium Curing

800-25
Cut-back Bitumen
Temperature (oC ) *
Minimum for Pumping
Binder
SG 30-70
SG 70-130
10
25
Minimum for Spraying

Slot Jets
Atomising Jets
40 - 50
50 - 60
55 - 70
65 - 80
Maximum
Heating
65
85
*
These spraying temperatures are for guidance only. the optimum spraying temperature is dependent upon the
temperature/viscosity relationship of the bitumen, climatic conditions and road conditions and shall be determined by the
contractor subject to the approval of the engineer. for slot jets the viscosity for spraying shall be 70 - 100 centistokes, and for
atomising jets 35 - 60 CENTISTOKES .
CURING AND BLINDING OF PRIME COAT
If, after the application of the prime coat, the bituminous material should fail to penetrate within the
time specified in Section 800 of this Specification or the road must be used by traffic, blinding
material shall be spread in the amount required to absorb any excess bituminous material and to
protect the primed surface.
Blinding material shall consist of clean fine aggregate, sand, or crusher dust free from organic, clayey
or other deleterious materials.
Blinding material shall be spread in such a manner that no wheel shall travel on uncovered bituminous
material.
All loose material on the sprayed surface, including any blinding material, shall be removed before any
further bituminous binder is sprayed.
TOLERANCES
The rate of application of bituminous binder across the width of each spray run shall not vary by more
than 10% of the rate ordered. The average rate of binder for each single run of the spray truck shall
be at least equal to the instructed rate. Tray tests shall be taken at least once a day during priming
operations to check calculations based on dipping of spray trucks.
807 PREPARATION OF EXISTING BITUMINOUS PAVEMENTS

A. MILLING
1)
General Requirements
Where shown on the drawings or otherwise instructed by the Engineer, the Contractor shall
remove existing asphalt by cold planning/milling, scarifying and/or breaking out, stock piled
and reuse as subbase in roadway pavement with additional coarser/finer fractions, as required
to bring it to the requirements of the subbase as per section 700 of the Specifications.
The Contractor shall make the milling/cold planning to the depths required as shown on the
drawings and/or directed by the Engineer.
2)
Equipment & methods of working
The Contractor shall submit detailed proposals/methodology for the Engineers approval for
each type of work and shall carry out such site trials as may be required by the Engineer to
demonstrate the suitability of the proposed equipment and methods of working.
800-26
In cold planing, the milling equipment with its all accessories and working methodology shall
be such that the milled materials are scarified/broken out as close as possible to the subbase
material requirements for re-use as subbase in the pavement structure/carriageway. Before reusing the milled material, additional coarser/finer fractions shall be mixed to meet the
requirements of subbase as per Section 700 of Specification:
equipment must be self propelled with automatic systems for controlling camber,
cross fall, and depth of cut,
all accessories/parts must be attached with the equipment to scarify/break out the
material nearest to the subbase grading requirements.
be capable of accurately establishing profile grades along each edge of the
machine by referencing from the existing pavement,
have an effective means for preventing dust from escaping into the air.
3)
Sequence of Operations
Where asphalt is to be scarified or broken out the asphalt shall be neatly saw cut at the limits
of breaking out or scarifying where necessary to provide a sound construction joint with
subsequent paving materials.
In the case of cold planing, the Contractor shall verify the number of passes and the depth of
each pass required to obtain the total depth of specified cut, subject to approval by the
Engineer. The equipment attached with all required accessories shall be operated at a speed
that produces a surface within the applicable tolerances and material to the Specifications
requirements.
4)
Re use of bituminous milled material
The Contractor shall re use bituminous milled material with additions of coarser/finer
fractions to meet the requirements of subbase as per Section 700 of the Specifications. The
Contractor shall submit proposal/methodology for the Engineers approval including field
trials to demonstrate that the pavement layers properties including bituminous materials are at
least equal to the properties of corresponding materials indicated in the Contract.
5)
Pavement reconstruction
Where existing bituminous pavement is removed/milled to facilitate full depth reconstruction,

the underlying materials shall be excavated/ploughed and compacted to a depth sufficient to
accommodate the typical cross-sections for reconstruction shown on the drawings. The
formation shall be prepared in accordance with specification clause 514 and the pavement
then reconstructed in accordance with the drawings and Sections 700 and 800 of these
specifications.
B. PATCHING
1)
Description
This work consists of repairs to an existing bituminous surface showing local, discontinuous
damage in the form of pot-holes, ravelling, crocodile cracking, or loss of edge support.
Patching work shall be classified into the following categories:
6)
Type 1 Patching
Removal of damaged bituminous surfacing for a depth of up to 75 mm below the surface and
reconstruction in bituminous materials in accordance with Section 800 of these specifications.
800-27
7)
Type 2 Patching
Removal of the damaged bituminous surfacing and base layers for a depth of up to 250 mm
below the surface, and their replacement with corresponding layers of graded crushed stone
base, and bituminous materials in accordance with Sections 700 and 800 of these
specifications.
8)
Type 3 Patching
Removal of the damaged bituminous surfacing, base and subbase layers for a depth of up to
500 mm below the surface, and their replacement with corresponding layers of granular
subbase, graded crushed stone base, and bituminous materials in accordance with Sections
700 and 800 of these specifications. The exposed formation shall be recompacted and
prepared in accordance with specification clause 514 prior to reconstruction.
The pavement areas to be patched and the type of patching for each area shall be instructed by
the Engineer.
9)
Work procedure
Rectangular areas of pavement requiring different types of patching shall be identified by the
Engineer and the Contractor shall demarcate their boundaries in traffic-resistant white paint.
The Contractor shall conduct Site trials to determine the type and combination of excavating,
laying and compacting equipment best suited for each situation where patching is likely to be
required. Excavation, laying and compacting activities shall be carried out to the satisfaction
of the Engineer.
Patching activities shall be carried out according to a programme and in accordance with
safety procedures agreed in advance on a weekly basis with the Engineer. Patching at any
particular time shall not occupy more than one traffic lane.
The marked pavement areas shall be excavated in accordance with their size and the type of
patching instructed. The Contractor shall dispose of excavated material in a manner approved
by the Engineer. The excavated areas shall be regular in shape, having perpendicular sides
and vertical edges. Consecutive layers shall be stepped back by 300 mm on all sides to avoid
the formation of continuous vertical joints in the pavement structure. The bottom of any
excavated area shall have the same cross-fall as that instructed for the finished surface. Water
and pneumatic jets shall be used for cleaning and drying.
After inspection and approval by the Engineer and on the same day as excavation, excavated
areas shall be backfilled in properly compacted layers, as applicable for each pavement layer
and material type. Before placing asphalt the base and the sides of the excavation shall be
treated with prime coat.
If, on inspection prior to backfilling, the Engineer considers that not all sub-standard material
has been removed he may order that the excavation be continued or widened.
CRACK SEALING
1)
Sealing 6 - 15 mm wide cracks in bituminous pavements
Crack sealing activities shall be carried out according to a programme and in accordance with
safety procedures agreed in advance on a weekly basis with the Engineer. Crack sealing at
any particular time shall not occupy more than one traffic lane.
800-28
The Contractor shall, in sections generally of about 1 km in length, identify and demarcate the
extent of cracks in the existing bituminous pavement. Individual cracks shall be denoted by
prominent marks (20 mm * 50 mm) across the crack ends, and at 5 m intervals where the
crack is longer than 10 m, in traffic-resistant white paint. The Contractor shall submit fully
marked sections to the Engineer for his approval prior to commencing crack sealing
operations.
Prior to sealing, the Contractor shall ensure that cracks are clean of all dirt, dust, vegetation,
other loose materials and oils by using wire brushes, mechanical brooms and high-pressure
pneumatic jetting. The cracks shall be dried by blowing with hot oil free compressed air.
After cracks have been thoroughly cleaned and dried they shall be sealed with a medium
curing cut-back bitumen SG 70-130 or MG 130-200 heated to a temperature of 80 - 100 oC
temperature. A spray lance blowing hot oil free compressed air may be used to introduce
bitumen into the crack. Fine sand and cement dust may be mixed with the cutback bitumen, to
the extent that the flow of bitumen into the crack remains unimpeded. Care shall be taken to
ensure that bitumen is not spread over the surface of the road by pouring the bitumen through
a purpose made sheet metal banding shoe, to give a maximum width of 40 mm. A squeegee
board (a stiff rubber or plastic strip fitted to a timber board, or similar) may also be used to
facilitate the entry of the sealant into the crack. When cracks are fully sealed, a blinding layer
of coarse sand shall be applied before the bitumen cools.
2)
Patching cracks greater than 15 mm wide in bituminous pavements
The Contractor shall identify, demarcate the extent of and denote cracks greater than 15 mm
wide in the existing bituminous pavement as indicated above except that traffic-resistant
yellow paint shall be used.
Such cracks shall be trimmed longitudinally for their full depth along the edge of the crack
using powered pavement cutting equipment that shall be subject to the approval of the
Engineer. The edges of such cuts shall be straight vertical and clean. All dirt, dust, loose
materials (including those due to trimming) and vegetation within the crack shall be removed
and cleaned using wire brushes, power brooms and high-pressure pneumatic jets. The cracks
shall be dried by blowing with hot oil free compressed air. The Contractor shall submit fully
marked sections to the Engineer for his approval prior to commencing crack patching
operations.
The trimmed and cleaned crack space shall be painted at the bottom and sides using hot cutback bitumen SG 70-130, MG 130-200. The crack space shall then be patched with hot
asphalt in accordance with Section 800 of this Specification and compacted to the same
standards for the same materials used in other paving work.
D
1)
REGULATING
General
800-29
The Contractor shall identify and visibly delineate on the existing pavement surface all areas
to be regulated for approval by the Engineer. Regulating up to 150 mm in depth shall be in
bitumen macadam regulating material in accordance with this specification. Regulating
exceeding 150 mm in depth shall be in crushed stone in accordance with Specification 700.
The Contractor shall submit working drawings for the Engineers approval showing his
proposed selection and sequence of regulating materials.
The Contractor shall initially lay and compact the bitumen macadam regulating layers with a
minimum overlap of 150 mm in areas to receive crushed stone regulating. The Contractor
shall then saw cut the bitumen macadam to create a vertical construction joint in sound
bitumen macadam against which the crushed stone regulating material can be laid. Prior to
laying crushed stone regulating the Contractor shall cut drainage channels in the existing
asphalt pavement where water could become trapped in existing low spots. The drainage
channels shall be a minimum of 300 mm wide and extend to the outer edge of the
embankment. The minimum depth of channel shall be sufficient to provide a fall for drainage
and shall be backfilled with compacted subbase material in accordance with Specification
700. Crushed stone regulating material shall finally be laid in accordance with Specification
700.
800-30

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SECTION 800 - BITUMINOUS PAVEMENT WORKS

SECTION 800 - BITUMINOUS PAVEMENT WORKS................................................................................................1

A BITUMINOUS BINDER STORAGE AND HANDLING................................................................................................ 3

805 ROAD PAVEMENT

A MATERIALS FOR ASPHALT CONCRETE............................................................................................................. 16

PRIME COAT AND TACK COAT...................................................................................................................27

SPRAYING OF PRIME COAT AND TACK COAT.................................................................................................... 28

PREPARATION OF EXISTING BITUMINOUS PAVEMENTS. .20

BITUMINOUS BINDER STORAGE AND HANDLING

HEATING OF BITUMINOUS BINDER

SAFETY AND ENVIRONMENTAL PRECAUTIONS

MIXING OF AGGREGATES AND BITUMEN

Mixing plants shall conform to the requirements listed below:

LAYING THE MIXTURE

FINISHING, JOINTS, AND EDGES

QUALITY CONTROL TESTING

Table 8 - 1 Tolerances for Bituminous Mixes

DESIGN OF BITUMINOUS MIXES

a single percentage of aggregate passing each required sieve size,

PAVEMENT FROM STONE

MASTIC ASPHALT CONCRETE

Name of the index

During placing, not less

Requirements for raw materials

Mix design for Stone Mastic Asphalt concrete mixtures

Sand from crushing sifting

porosity of the mineral part, %

real density of the bitumen, gr/sm3

average density of mineral part,gr/sm3

Requirements for execution of the works

Preparation of Stone Mastic Asphalt concrete mixes

Laying and compaction of the SMA mixture

MATERIALS FOR ASPHALT CONCRETE

Penetration Grade Bitumen

Table 8 - 10 Physical Properties for Crushed Stone and Sand

Hot asphalt concrete dense, grade I type B

The type B contains the crushed stone above 40 to 50%.

Size of grains, finer, mm

Table 8-13 Physical Properties for IV-V Road Climatic Zones

Type of asphalt concrete

Samples formed from mixture

Norms for mineral filler

B LAYING AND COMPACTION OF ASPHALT CONCRETE

PRIME COAT AND TACK COAT

MATERIALS FOR PRIME COAT AND TACK COAT

from 0,6 to 0,9

from 0,9 to 1,2

from 1,2 to 1,5

SPRAYING OF PRIME COAT AND TACK COAT

Table 8 - 18 Pumping, Spraying & Heating Temperatures of Medium Curing

Minimum for Spraying

CURING AND BLINDING OF PRIME COAT

807 PREPARATION OF EXISTING BITUMINOUS PAVEMENTS

Equipment & methods of working

Re use of bituminous milled material

Where existing bituminous pavement is removed/milled to facilitate full depth reconstruction,

Sealing 6 - 15 mm wide cracks in bituminous pavements

Patching cracks greater than 15 mm wide in bituminous pavements

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