1.

Introduction to various layers & their function in a Flexible Pavement

2. Sequence of operations – Setting out, clearing & Grubbing..
3. GSB, WMM – Material, Laying, Compaction, Plant & Equipment,
QC, Acceptance Criteria
4. Asphalt Layers (DBM & BC) – Mix Design, Hot Mix Plant, Laying,
Quality Control aspects, Tests, Acceptance Criteria, Troubleshooting
5. Tolerance in surface levels & surface regularity
6. Do’s & Don’ts in Bituminous Works
7. Various distresses in Flexible pavements - Causes, Prevention &
Repair

(IRC: 37- June 2017 Draft, IRC: 82-2015)

Satander Kumar
Ex Scientist, Central Road Research Institute, New Delhi

satander50@yahoo.co.in
09971974477
 Introduction to various layers & their function
in a Flexible Pavement

1. Wearing Course BC/AC

1. Binder Course /binder base course DBM/BM

2. Granular Base Course – WMM (Wet Mix

Macadam), Medium strength Structure layer/
CTB
N = Design Traffic 25 MSA
INPUT
MR = Resilient Modulus 1700 MPa

Reliability Factor, 80% or 90% 2 %

Constant 0.711

Ev = Allowable Micro Strains 210.21 micro strains OUTPUT

 Introduction to various layers & their function
in a Flexible Pavement

1) Granular Sub base (GSB) Course- Low

Strength structural layer/CT Sub base

2) Subgrade – Very low strength structural

layer/Natural Foundation/Top portion of
embankment/Improved Subgrade

600 mm HFL

1) Embankment for HFL/Level/Alignment

FUNCTION OF Sub-base and Base Course

- To Provide Stress Transmitting Medium

- To distribute Wheel Loads

- To Prevent Shear /Deformation and

- Accelerate Consolidation
SHEAR OF Flexible Pavement at EOK, New Delhi
 Asphalt Concrete/DAC/BC
• Traffic and axle configuration are increasing
very much.

• which can meet the above requirements.

• Asphaltic concrete is one which is high dense

graded premix and it is termed as highest
quality pavement surface course.
• Bituminous binder course

• A bituminous-aggregate mixture used as an

intermediate coarse between the base and
surface courses or as the first bituminous layer
in a two-layer bituminous resurfacing. It is
sometimes called a leveling course.
 Seal Coat
Base course is protected from traffic and
moisture by sealing the surface with a thin film
of bitumen aggregate mix, which is structurally
strong surface for pneumatic-tyred traffic. This is
provided on firm and smooth base course after
a tack coat using cutback bitumen or bitumen
emulsions with a penetration of 5 mm
 DURABILITY –
Adequate Strength, Minimum Corrosion, Minimum Air Voids
Consolidation Compaction Densification

Clayey soil Clayey/non-plastic Non plastic

Clayey-silty Concrete Filter media

Static load Mechanical Mechanical

Removal of Water Removal of air Addition of water

AVOID HONEY-COMBING (Honey bee house)

Crack, fracture, fissure

10
 Typical Cross Section of Embankment
with Prefabricated Vertical Band Drains

Initial Sand
Embankment Blanket

Band
Soft drains
Clay
Layer
Firm
Soil
11
 Installation of band drains

Stitcher for installing Close up view of mandrel for

band drains installing band drain
12
Band drains installed above
initial embankment

13
 DURABILITY – CRACKS
Crack, cut, break,

fissure (A fissure is a crack or tear in the skin)

Fracture: Fracture strength, also known as breaking strength, is the stress

at which a specimen fails via fracture.

Fracture: cracking or breaking of a hard object or material,

Basements may have hairline to 1/16 in wide

Concrete road 0.5 mm

Structure 0.3 mm
FP 3 mm

vertical cracks 1/8 in wide - need reviewing. 14

 1. Geotextiles in India – An Introduction
 Geosynthetics are planar products manufactured from polymeric or natural materials used with soil, rock,
or other geotechnical-related material as part of a project or system.

Product Categories

Geotextiles Geogrids Geonets Geomembranes Geocomposites Geocells Others

Continuous Plastic filaments Extruded Continuous Products Relatively • Geomats

sheets of woven, and tapes etc. polymer ribs sheets of manufactured thick, three- • Geo-clayliners
nonwoven, formed into a set in net like impermeable using a dimensional • Geofoam
knitted or stitch- very open, grid fashion with plastic and are combination of networks • Geobags
bonded fibres or like small not textiles. two or more made of strips • Geotubes
yarns. The sheets configuration apertures. Impermeable geosynthetics of polymeric • Geopipes
are flexible and having larger fabric acts as a sheet. The • Erosion Control
permeable and apertures. barrier. strips are Blankets(ECB)
generally have joined • Turf
the appearance together to Reinforcement
of a fabric. form conjoint Mats(TRM)
cells.
• IRC Special Publication No 59 Basal REinforcement

• Reinforced earth walls:IRC:SP:102

• IRC: 113-2013- Guidelines for the Design and Construction

of Geo Synthetic Reinforced Embankment on Soft Soils

• Ministry of Road Transport and Highways- Specification for

Road and Bridge Works (Fifth Revision)- 2013, Section 700-
 Functions of Basel
Reinforcement
Separation

Filtration Natural Soil

Geo-textile
Water Flow Direction

Granular Soil
 Road Composition

Vehicle

Load distribution at 45o

Black Topping 243 % CBR

Base WBM/WMM 81% CBR Road Crust

Sub Base GSB/DL 27% CBR 200

600mm Sub Grade 9% CBR /Permeability 30 m/day

450
Embankment 3% CBR - 1800 mm
Ground Level
1. Agg size 3 time decreases, 2. Permeability 3 times decrease
3. Clay/silt 3 times decreases 4. Thickness 2-3 times decrease
Stress Diagram
• EMBANKMENT AND SUBGRADE
CBR 20%, 10% 5% 2.5%

Size > 2mm 60µ- 2mm 2- 60µ <2 µ

Figure: Indian standard grain size soil classification system

Sand size in concrete and FP < 4.75 mm
 California Bearing Ratio Test
CBR - % of actual load causing penetrations
of 2.5 mm or 5.0 mm to standard loads.
– Load values on standard crushed stones:
– 1370 kg at 2.5 mm, 2055 kg at 5.0 mm
– Water Bound Macadam CBR 100 % - deflection 2.5 mm
load of 1.37 ton
– 5 mm for load of 2.055 ton on WBM
 Standard Proctor Test Modified Proctor Test

Soil passing 20 mm / 37.5 mm Soil passing 20 mm / 37.5 mm

compacted in 3 layers, compacted in 5 layers,

25 blows / 55 blows 25 blows / 55 blows

compaction - 2.6 kg hammer, compaction - 4.9 kg hammer,

31 cm - fall 45 cm - fall

urban areas and village roads NH, SH, MDR

 Field density by sand replacement method

 Sand pouring cylinder, diameter =11.5 cm, length = 38 cm

 Metal tray with hole (tray = 30 cm x 30 cm, hole diameter = 10 cm)

 Calibrating container (diameter = 10 cm, length = 15 cm)

 Volume = 1179 cm3
 Glass plate (45 cm x 45 cm)
 Dynamic
Cone
Penetrometer

8kg hammer =
• E value Modulus of elasticity
from DCP
• DCP Value CBR in %
• 24.6mm 7%
• 19 mm 10 %
• 11 mm 20%
• 3.2 mm 100%

• E in Mpa= 357.87 (DCP in mm/blow)-0.6445

E in Mpa= 357.87 (25)-0.6445 357.87/7.884= 45 Mpa

17.6 * (CBR)0.64 for CBR > 5 61 Mpa

 GEOMETRIC DESIGN STANDARDS (Contd.)

TERRAIN CLASSIFICATION

Terrain Per cent cross slope

classification
Plain 0 to 10

Rolling 10 to 25
Mountainous 25 to 60
Steep Greater than 60
 SOIL - Munsell Color Chart
• Identify soil color - uniformly describe soil composition.

• Desire to fit a contour, such as pyramid, cone, cylinder or cube

• Albert H. Munsell, “A Pigment Color System and Notation”[3]
–
Hematite Iron Oxide Fe2 O3 Red

Iron Sulphide Fe S Black

Dolomite Ca Mg CO3 White

Shrink-swell Potential
• Shrinking and swelling can
buckle roads, crack building
foundations and walls, and
even damage plant roots.
NP 1 Un reinforced (0.07 Mpa 7 m head)
Drainage/irrigation (NP)
(0.07 Mpa 7 m head)
NP 2 Reinforced , Light duty Drainage/irrigation/CD/Culverts
(0.07 Mpa 7 m head)

NP 3 UnRein./Reinforced, medium duty Drainage/irrigation/CD/Culverts

(0.07 Mpa 7 m head)

NP 4 UnRein./Reinforced, heavy duty Drainage/irrigation/CD/Culverts

(0.07 Mpa 7 m head)

P1 Reinforced, medium duty, Pressure Gravity mains, site 0.6* 0.2 MPa
Pressure 0.2 Mpa (20 m head)

P2 Reinforced, medium duty, Pressure Pumping main 0.5* 0.4 MPa

Pressure 0.4 Mpa (40 m head)

P3 Reinforced, medium duty, Pressure Pumping mains, site 0.5* 0.6 MPa
Pressure 0.6 Mpa (60 m head)

PRESSURE and Non Pressure Pipe

Very Severe IS: 458
 Liquid limit
 passing 425 micron

 free fall of cup, depth of soil -10 mm

 Rotating of the crank at the rate of 2 rev. / sec.

 no of blows when bottom of groove meets -10 mm

 test blow-s between 10 and 40 blows

 Casagrande’s liquid limit

 Plastic limit
 20 gm of soil passing 425 micron

 soil ball

 Rolled between fingers, 3 mm

 continued till thread crumble at a 3 mm

 moisture content of soil when thread crumbles

 Plasticity index =Liquid limit – Plastic limit-

 PI = LL - PL
 SLOPE COMPACTOR - Earth Work- Embankment
Embankments ( 95%)

Unsuitable Soil : OI, OL,OH, Pt, > 75 mm

LL >50%
PI >25
FSI > 50%

Density:
1.52gm/cc upto 3 m

39
 Density

S.N Type of work Maximum laboratory dry

o. unit weight when tested
as per IS: 2720 (Part 8)

1. Embankments up to 3 Not less than 15.2 kN/cu.m

metres height, not subjected
to extensive flooding

2. Embankments exceeding 3 Not less than 16.0 kN/cu.m

metres height or
embankments of any height
subject to long periods of
inundation

3. Subgrade and earthen Not less than 17.5 kN/cu.m

shoulders/verges/backfill
 Sand Replacement

Rapid Moisture meter

Density Gauge Nuclear

ASTM =
ASTM 6938, 7759

Surface depth shall depth

41
Compaction - embankment and subgrade

S.No Type of Relative compaction as

. work/material percentage of max. laboratory
dry densiy as per IS: 2720
(Part 8)

1. Subgrade and earthen Not less than 97

shoulders

2. Embankment Not less than 95

3. Expansive clays

(a) Subgrade and Not allowed

500 mm
portion just
below the
Not less than 90
subgrade

(b) Remaining
portion of
embankment
SUBGRADE CAMBER 4% using camber plate

In 10 m = 10000mm *4% = 400 mm down

 Construction Equipments Subgrade Preparation

1. JCB (Joseph Cygril Bam ford) 2. Dozer 3. Motor Grader

4. Rotavator 5. Water Sprinkler 6. Compactor

44
SOIL COMPACTORS
WMM/GSB Plant/Pugmill
• Sequence of operations – Setting out,
clearing & Grubbing..
3. GSB, WMM – Material, Laying,
Compaction, Plant & Equipment, QC,
Acceptance Criteria
4. Asphalt Layers (DBM & BC) – Mix
Design, Hot Mix Plant, Laying, Quality
Control aspects, Tests, Acceptance
Criteria, Troubleshooting
MORTH- DLC

48
49
50
Lower sub base Upper sub base
Filter layer Drainage layer
Common

III - VI
100
100
75
60
30
20
6
4
2

51
52
53
 Components of Asphalt

Asphaltenes: Solid - High viscosity component (black)

Resins- Semi-solid: i) Fluid when heated ii) Brittle when cold

Oils - Soluble in most solvents

56
 IRC:SP:53 Polymer Modified
Bitumen

• IS: 15462-2004 - Modified

Bitumen
 Requirements for Paving Bitumen(IS 73: 2013

S. Characterization Paving Grades Test Ref.

No
VG-10 VG-20 VG-30 VG-40
1 Absolute viscosity 800- 1600- 2400- 3200- IS 1206
at 60 C, poises, min 1200 2400 3600 4800 (Part 2)

2 Kinematic viscosity 250 300 350 400 IS 1206

at 135 C , cSt, min (Part 3)

3 Flash point, C, min 220 220 220 220 IS 1209

4 Solubility in 99 99 99 99 IS 1216
trichloroethylene,
percent, min
5 Penetration at 25 C,100g, 80 60 45 35 IS 1203
5s,0.1mm

6 Softening point, C, min 40 45 47 50 IS 1205

7
Tests on Residue on
Rolling Thin Film

Viscosity at 60 deg Max 4 4 4 4 IS: 1206

part 2
Ductility at 25 C, cm, min,
after thin-film oven test
75 50 40 25 IS 1208
 Industrial Grade Requirements for Grades
Bitumen 85/25 85/40 90/15 115/15 135/10 155/6
Specific gravity at 27°C 1.00- 1.00- 1.01- 1.01- 1.02- 1.02-1.07 IS: 1202-
1.05 1.05 1.06 1.06 1.07 1978
Flash point, cleave land 225 225 225 225 225 225 IS: 1209-
open cup, °C , Min 1978
Softening point, °C 80-90 80-90 85-95 110-120 130- 150-160 IS: 1205-
140 1978
Penetration at 25°C , 20-30 35-45 10-20 8-20 7-12 2-10 IS: 1203-
100 g, 5 sec, 1/10 mm 1978
a. Loss on heating, 0.30 0.30 0.30 0.30 0.30 0.30 IS: 1212-
percent by mass, 1978
Max
b. Penetration of the 60 60 60 60 60 60 IS: 1203-
residue at 25°C, 1978
100g , 5s, percent of
original, Min
Ductility at 27°C, cm, 3 3 2 2 1 0 IS: 1208-
Min 1978
soluble in 99 99 99 99 99 99 IS: 1216-
trichloroethylene, 1978
IS: 73-2013
 Specified Gradation for DBM
Mix Designation Grading 1 Grading 2
Nominal Aggregate Size 40 mm 25 mm
Layer Thickness 80 – 100 mm 50 – 75 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45 100 -
37.5 95 – 100 100
26.5 63 – 93 90 – 100
19 - 71 – 95
13.2 55 – 75 56 – 80
4.75 38 – 54 38 – 54
2.36 28 – 42 28 – 42
0.3 7 – 21 7 – 21
0.075 2-8 2-8
Bitumen Content, % by Min 4.0 Min 4.5
weight of total mixture
 Specified gradation for BC
Mix Designation Grading 1 Grading 2
Nominal Aggregate Size 19 mm (Maximum 26.5 13.2 mm (Max = 19 mm)
mm)
Layer Thickness 50 – 65 mm 30 – 45 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
26.5 100 -
19 79 – 100 100
13.2 59 – 79 79 – 100
9.5 52 – 72 70 – 88
4.75 35 – 55 53 – 71
2.36 28 – 44 42 – 58
1.18 20 – 34 34 – 48
0.6 15 – 27 26 - 38
0.3 10 – 20 18 – 28
0.15 5 – 13 12 – 20
0.075 2-8 4 – 10
Bitumen Content, % by 5.2 min 5.4 min
 OBJECTIVE OF MIX DESIGN

 sufficient bitumen to ensure a durable pavement,

 sufficient strength to resist shear deformation under traffic at higher

temperature,

 sufficient air voids in compacted bitumen to allow for additional

compaction by traffic,

 sufficient workability to permit easy placement without segregation,

 sufficient flexibility to avoid premature cracking due to repeated

bending by traffic,

 sufficient flexibility at low temperature to prevent shrinkage cracks

 Marshall Method of Mix Design
(ASTM D 1559 or MS 2)

•Mix Design Methods for Asphalt Concrete

and Other Hot-Mix Types. Manual Series
No. 2 (MS-2). Asphalt Institute. Lexington
 Mix Design DBM MORTH:
• The bitumen content required shall be determined
following the Marshall mix design procedure
contained in Asphalt Institute Manual MS-2.

• The Fines to Bitumen (FIB) ratio by weight of total mix

shall range from 0.6 to 1.2.
•
• Section 500 Bases and Surface Courses (Bituminous)

• 505.3.1 Requirements for the Mix

• Apart from conformity with the grading and quality
requirements for individual ingredients, the mixture
shall meet the requirements set out in Table 500-11.
 Table 500-11: Requirements for Dense Graded Bituminous Macadam
Properties Viscosity Modified bitumen Test Method
Grade Hot climate Cold climate
Paving
Bitumen
Compaction 75 blows on each face of the specimen
level
Minimum stability 9.0 12.0 10.0 AASHTO
(kN at 600C) T245
Marshall flow (mm) 2-4 2.5-4 3.5-5 AASHTO
T245
Marshall Quotient 2-5 2.5-5 MS-2 and
Stability ASTM D2041
Flow
% air voids 3-5
% Voids Filled with 65 -75
Bitumen (VFB)
 505.3.3 Job Mix Formula
i)
i) Source and location of all materials;

ii) Proportions of all materials expressed as follows:

iii) Binder type, and percentage by weight of total mix;

iv) Coarse aggregate/Fine aggregate/Mineral filler as percentage

by weight of total aggregate including mineral filler;

v) A single definite percentage passing each sieve for the

mixed aggregate;
 505.3.3 Job Mix Formula
ivi)
i) Individual gradings of the individual aggregate fraction, and
proportion of each in the combined grading;

vii) Results of mix design such as maximum specific gravity of

loose mix (Gmm), compacted specimen densities, Marshall

stability, flow, air voids, VMA, VFB and related graphs and

test results of AASHTO T 283 Moisture susceptibility test;

viii) Where mixer is a batch mixer, individual weights of each

type of aggregate, and binder per batch;

ix Test results of physical characteristics of aggregates;

x) Mixing temperature and compacting temperature

 Reasons of Tender Mix:

Causes Effects

Excess bitumen Corrugations, rutting

More medium sand -Tenderness during rolling

Rounded aggregate, Rutting and channeling

 Area Bitumen Aggrega Mixed Laying Rolling
Grade of Temperat te Materia Temperat Temperat
Bitumen ure Temper
ature
l
Temper
ure ure

ature

VG 40 Highly stressed 160-170 160-175 160-170 150 100

40-60 penetration area- Inter Minimum Minimu
section, truck m
parking in liu of
30/40

VG 30 in Place of 60/70 150--165 150-170 150-165 140 90

50-70 penetration penetration Minimum Minimu
m

VG 20 Cold Climatic, 145-165 145-170 145-165 135 85

60-80 penetration high altitude Minimum Minimu
m
VG-10 Spraying and
140-160 140-165 140-160 130 80
80-100 paving in cold
Minimum Minimu
penetration climatic in liu of
m
80/100
 MORTH 2013

Temperature same 10oC less 50oC less

Marshall Hammer

Marshall Stability and

75 Equipment
Flow Test
 DBM Clause 505.3.2
• Where maximum size of the aggregate is more
than 26.5 mm, the modified Marshall method
using 150 mm diametre specimen described in
MS-2 and ASTM D 5581 shall be used. This
method requires modified equipment and
procedures. When the modified Marshall test is
used, the specified minimum stability values in
Table 500-12 shall be multiplied by 2.25, and the
minimum flow shall be 3 mm.
(178 –page)
Filler: Fills the voids, stiffens the binder and
offers permeability. E.g. Rock dust, cement, lime
• The density of the finished paving layer shall
be determined by taking cores, no sooner
than 24 hours after laying, or by other
approved method. The compacted layers of
Dense Graded Bituminous Macadam (DBM)
shall have a minimum field density equal to or
more than 92% of the density based on
theoretical maximum specific gravity (Gmm)
obtained on the day of compaction in
accordance with ASTM D 2041.
 Bulk specific gravity of aggregate

Pca  Pfa  Pmf

Ga 
Pca Pfa Pmf
 
Gca G fa Gmf
P = percentages by weight of aggregates

G = Bulk specific gravities of aggregates

Theoretical maximum specific gravity

100
Gt 
Pca Pfa Pmf Pb
  
Gca G fa Gmf Gb
 Vv , VMA and VFB

Volume of Air Voids in final mix

Vv  100
 Gt  Gmb 
Gt
 Voids in mineral aggregates
Gmb Pa
VMA  100 
Ga
Pa  Pca  Pfa  Pmf
 Aggregate voids filled with bitumen

VFB 100
VMA  Vv 
VMA
 Design of Dense Bituminous Macadam
Marshal Stability Test
Gsb 2.576

Gb 1.02

Proving Ring Factor 4.820

Bitumen Bitumen Agg. by w t Dry w t of Wt of SSD w t Vol. of Bulk density of Air v oids in Total v oids in Voids filled
Max. Sp. Vol of bit. Vol of agg. Dial gauge Stability Corrected Flow
Sr. No by w t of by w t of of mix % specimen specimen in (1 min in w ater) specimen in specimen mix % mineral agg. w ith bit.
Gr. of Mix (I x c)/Gb (I x d)/ Gsb reading Kg stability Kg (mm)
agg.(%) mix (%) (100-c) in air (gm) w ater (gm) gm cc (g-f) gm/cc (e/h) 100*(j-i)/j (100-l) 100*(n-m)/n

Gmb Gmm Va VMA VFB

a b c d e f g h I j k l m n o p q r s

1 4.17 4.00 96.00 1242.5 706.0 1246.0 540.0 2.301 320 1542 1434 2.5

2 4.17 4.00 96.00 1241.5 707.0 1248.0 541.0 2.295 310 1494 1390 2.7

3 4.17 4.00 96.00 1242.5 706.5 1248.0 541.5 2.295 295 1422 1322 2.6

Average 4.17 4.00 96.00 1242.2 706.5 1247.3 540.8 2.297 2.443 9.0 85.6 6.0 14.4 58.4 308 1486 1382 2.60
1 4.44 4.25 95.75 1249.5 714.5 1250.0 535.5 2.333 320 1542 1434 2.8

2 4.44 4.25 95.75 1246.0 712.0 1252.0 540.0 2.307 325 1567 1457 2.8

3 4.44 4.25 95.75 1244.5 711.5 1251.5 540.0 2.305 320 1542 1434 2.7

Average 4.44 4.25 95.75 1246.7 712.7 1251.2 538.5 2.315 2.434 9.6 86.1 4.9 13.9 65.0 322 1550 1442 2.77

1 4.71 4.50 95.50 1245.5 710.0 1247.0 537.0 2.319 320 1542 1481 3.1

2 4.71 4.50 95.50 1246.0 711.0 1247.0 536.0 2.325 315 1518 1458 3.2
3 4.71 4.50 95.50 1246.5 712.0 1248.0 536.0 2.326 320 1542 1481 3.1

Average 4.71 4.50 95.50 1246.0 711.0 1247.3 536.3 2.323 2.425 10.2 86.1 4.2 13.9 69.7 318 1534 1473 3.13

1 4.99 4.75 95.25 1243.5 710.0 1246.0 536.0 2.320 315 1518 1458 3.5

2 4.99 4.75 95.25 1244.5 711.0 1247.5 536.5 2.320 310 1494 1434 3.6

3 4.99 4.75 95.25 1246.0 712.0 1249.0 537.0 2.320 315 1518 1458 3.6

Average 4.99 4.75 95.25 1244.7 711.0 1247.5 536.5 2.320 2.417 10.8 85.8 4.0 14.2 71.8 313 1510 1450 3.57

1 5.26 5.00 95.00 1248.0 712.0 1250.0 538.0 2.320 310 1494 1434 3.9

2 5.26 5.00 95.00 1245.5 709.0 1247.5 538.5 2.313 305 1470 1411 4.0

3 5.26 5.00 95.00 1246.0 708.0 1248.5 540.5 2.305 310 1494 1434 4.1

Average 5.26 5.00 95.00 1246.5 709.7 1248.7 539.0 2.313 2.408 11.3 85.3 4.0 14.7 73.1 308 1486 1427 4.00

OSEPL Representative JAL Representativ

Correction of Stability
Stability vs. Bitumen content

Property Requirement
Minimum Stability (kN 9.0
at 60⁰C)
Marshall Flow 2- 4 mm
Compaction Level 75 blows on each of
(No. of Blows) two faces
Percent Air Voids 3–5
Percent Voids Filled 65 – 75
With Bitumen (VFB)
Unit weight vs. Bitumen content

Property Requirement
Minimum Stability (kN 9.0
at 60⁰C)
Marshall Flow 2- 4 mm
Compaction Level 75 blows on each of
(No. of Blows) two faces
Percent Air Voids 3–5
Percent Voids Filled 65 – 75
With Bitumen (VFB)
% voids in mix vs. Bitumen content

Property Requirement
Minimum Stability (kN 9.0
at 60⁰C)
Marshall Flow 2- 4 mm
Compaction Level 75 blows on each of
(No. of Blows) two faces
Percent Air Voids 3–5
Percent Voids Filled 65 – 75
With Bitumen (VFB)
Flow value vs. Bitumen content

Property Requirement
Minimum Stability (kN 9.0
at 60⁰C)
Marshall Flow 2- 4 mm
Compaction Level 75 blows on each of
(No. of Blows) two faces
Percent Air Voids 3–5
Percent Voids Filled 65 – 75
With Bitumen (VFB)
VFB vs. Bitumen Content

Property Requirement
Minimum Stability (kN 9.0
at 60⁰C)
Marshall Flow 2- 4 mm
Compaction Level 75 blows on each of
(No. of Blows) two faces
Percent Air Voids 3–5
Percent Voids Filled 65 – 75
With Bitumen (VFB)
 Filler to Binder Ratio

Filler to Binder (F/B) ratio -0.6 to 1.2

• If filler = 40 gms
• Binder = 51 gms
• F/B = 0.78, acceptable
Mini Drum Mix Plant
 Construction of BC in Progress

92% density based on theoretical maximum

specific gravity ASTM D2041
505.3.5 Laying Trials

density of the finished paving layer shall be determined

by taking cores, no sooner than 24 hours after laying,

Compacted layers of Dense Graded Bituminous

Macadam (DBM) shall have a minimum field density
equal to or more than 92% of the density based on
theoretical maximum specific gravity (Gmm) obtained on
the day of compaction in accordance with ASTM D 2041.
Tolerance in surface
levels & surface
regularity
6. Do’s & Don’ts in
Bituminous Works
7. Various
distresses in Flexible
pavements -
Causes, Prevention &
Repair
• BI less than 2000 mm/km

• The maximum crack width shall be recorded as at least

50% of length.
 Riding Quality of New Pavement

• IRC:SP 16 2004 BI= 630 (IRI)1.12

Roughness-

Function of faulting, spalling and cracking

> 2000 Av. < 3000

2000 mm /km + 3000 mm
good /km Poor
 100 mm

100 mm

- 9mm - 6 mm
12mm
- 3 mm 0 mm + 3 mm + 6 mm + 9 mm
21 mm 18 mm 15mm 12mm 9 mm 6 mm 3 mm

12 mm
12 mm

3 meter straight Bump I.

100 mm 100 mm
 Max. Irregularity allowed -3 m st. edge
• Longitudinally----

• Irregularity 4mm 7mm

• Length 300m 75 m 300m 75m

• NH 20 9 2 1

• RR 40 18 4 2
Texture Depth = M/D
Area FWD Evaluation
Figure 2: Light Weight Figure 3: Geo-Gauge Figure 4: Dynamic Cone
Deflectometer (ASTM D6758) Penetrometer IRC:SP:72

Figure 5: Benkelman Beam Equipment (IRC:81)

Principle of FWD
MAINTENANCE
IRC:SP:82
 Distress Based Rating for Highways
Defects (type) Range of Distress, %

Cracking (%) <5

Ravelling (%) <1
Potholes (%) <0.1
Shoving (%) <0.1
Patching (%) < 1.0
Settlement and < 1.0
Depression (%)
Rut depth (mm) <5.0
 IS-8887
Types of emulsion

 Cationic ( +ve)
silica agg

 Anionic ( -ve) – lime stone agg

 Requirement of IS:8887- 2004

Properties of Bitumen Emulsion Requirement of IS:8887- 2004

S.No.

RS-1 RS-2 MS SS-2

(i) Residue on 600 micron IS sieve 0.05 max. 0.05 max. 0.05 max. 0.05 max.
(% mass)

(ix) Test on residue :

(a) Residue by evaporation, % 60 min. 67 min. 65 min. 60 min.
(b) Penetration, 250C/100 gm/5 sec. 80-150 80-150 60-150 60-120
(c) Ductility, 270C/cm., 50 min. 50 min. 50 min. 50 min.
(d) Solubility In Trichloroethylene, % 98 min. 98 min. 98 min. 98 min.
 FOG SEAL

COMPOSITION
(IRC: SP:20 p317/ MORTH / IRC:SP:100)

• Slow setting asphalt emulsion.

• Emulsion (SS) is diluted with equal amount of water 1:1 /Diluted

SS2

• Sprayed @ 1 litrev/sqm on old pavement

Slurry seal Clause 4.0
IRC:SP:81-2008
 SLURRY SEAL Clause 512 p 207

Fill cracks
• hair line- 4.3-6.5 kg/m2
• cracks 1-3 mm, 8.4 - 9.8 ,,
• Cracks 3 - 6 mm 10.1 - 12 ,,
• Ravelled
• Smooth
• Hungry
• Provide skid resistance
Micro surfacing clause 5.1

Type 2 < 1500 CVPD Type 3

> 1500 < 4500 cvpd

Thickness 4-6mm 6-8 mm

agg 6.3 mm 9.5mm

Quantity slurry kg/sq m 8.4 to 10.8 11.1 -16.3

Binder residual by wt dry 6.5-10.5 5.5-10.5

agg

Filler by wt dry agg 0.5-2% 0.5-2%

 Properties of modified emulsion

Requirements Test Method Limits

Residue on 600 micron max % 0.05

Test on Residue
Solubility in TCE 97%
Residue by evaporation, %, min. IS:8887 60
Penetration, 0.1mm at 250C IS:1203 40-100
Softening Point, 0C, min. IS : 1205 57
Elastic Recovery, %, min. IRC : SP : 53 50
Ductility at 270C, cm, min. IS:1208 50
Low Severity Fatigue Cracking

Fog seal for cracks < 3 mm

3004.3.2

Compressed air

Scrubber

0.7 litre/sqm

Pressure tank/
spraying

126
 Moderate Severity Fatigue Cracking MORTH 3004.3.3

Crack filling

3 -6 mm

Compressed air

Scrubber
 Rapid cure (RC) (Naphtha or Gasoline)
First Dust passing 2.36 mm,
 Medium cure (MC) (Kerosene)
75 µ 10%

Then slow curing bitumen

 Slow cure (SC) (Low viscosity oil) diesel

127
Clause 501.7 MORTH

Off sett 300 mm Longitudinal.

Off Sett 2 m transverse

Overlap 25 to 50 mm

128
 Edge Cracking

Edge cracking of low severity

Edge cracking of high severity
 Deformation
v
 SMOOTH SURFACE
Remedial
• Resurface with PMC/ SDBC/BC after milling
machine 15- 25 mm

• Slurry seal
 Rutting in Bituminous Surface
Rutting is continues longitudinal depression or groove in the pavement
along the wheel path
 Shoving
.

Shoving of bituminous surface

traffic starts- stops (intersections, bus-stops),
Remedial - Potholes Clause 3004.2.2
IRC : 116/emulsion IRC: 100)

• Removal of failed material

• Trimming Vertical faces

• Upto layer depth

• Tack coat - all faces

• Placing, compaction

• Finishing of patch material

• Emulsified/modified bitumen

• Sealed boundary

• 3 m st edge

134
• IRC:107-2013 Bitumen Mastic Wearing Courses

• IRC:109-2015 Wet Mix Macadam

• IRC:110-2005 Design and Construction of Surface Dressing

• IRC:111-2009 Specifications for Dense Graded Bituminous Mixes

• IRC:112-2011 Code of Practice for Concrete Road Bridges

• IRC:113-2013 Geosystemic Reinforced Embankments on Soft Subsoils

• IRC:114-2013 Silica Fume in Rigid Pavements

• IRC:115-2014 Flexible Road Pavements Falling Weight Deflectometer

• IRC:116-2014 Readymade Bituminous Pothole Patching Mix Using Cut-Back

• IRC:117-2015 Structural Evaluation of Rigid Pavement by FWD

IRC: 7-2017 Numbering of Culverts and Bridges/culverts,

IRC:121-2017 Construction and Demolition waste in roads,

IRC:122-2017 Pre cast Box Culverts/Bridges

IRC:123 -2017 Geo Physical Investigation .

IRC:125-2017 Dozers

IRC: 126-2017 WMM , Wet Mix Macadam Plant

IRC:SP:93-2017 Environmental Clearance

IRC: SP:111-2017 Highway Capacity PCU -Geometric DEsign'

IRC:SP:112-2017 Quality Control of Bridges

THANKS