Four Laning and Strengthening of Existing Two Lanes of NH-7 From Madurai To Kanyakumari Km 80.

000
(New Chainage Km 87.651) To Km 120.000 (New Chainage Km 126.884) in the State of Tamilnadu, Contract
Package No. NS-41 (TN).

METHODOLOGY FOR DENSE BITUMINOUS MACADAM

The work shall consist of construction in double course having 110mm in two layers (55mm
each) Thickness of compacted crushed aggregate premixed with bituminous binder on a
previously prepared non-bituminous / existing bituminous surface based to the Requirements as
per specifications.

SCOPE:

 The scope of this methodology is limited to work of Madurai to kanyakumari road project
(km:87+651 to km:126+884)
 The Methodology presented in this paper is based on certain assumptions. In case of
actual execution likely are the changes that this methodology may vary to certain limited
extent.

PURPOSE:

 The purpose of this methodology is to outline the guideline for laying of Dense
Bituminous Macadam at site
 To generate records to show compliance as per Requirements
 To make the operation Process clear with out leaving any void for ambiguity

PREPARATION OF BASE:

 The base on which DBM to be laid is to be prepared shaped and conditioned to Specific
lines and grades in accordance with specified permissible limits and the surface cleaned
from dust and any loose material to removed. After cleaning the surface prime coat is to
be applied and primed surface is allowed to cure for not less than 24 hours. Before laying
of DBM Tack shall be applied as per specified rates.

MIXING AND TRANSPORTING:

 Premixed Dense Bituminous material (DBM) shall be prepared in PARKER Batch mix
plant of adequate capacity (120TPH) and capable of yielding a mix of proper and uniform
quality with thoroughly coated aggregate. The mix design of bituminous works finalized
as per Hot bin aggregate gradation. The grading control unit having four decks vibratory
screen for sizing of hot aggregate and storing them in separate bins. Proper Arrangement
for accurate weighing of each size of aggregate from the control panel before mixing. in
HMP the weighing hopper of aggregate, bitumen and filler shall be calibrated before the
plant operation. The mix from Asphalt mixing plant will be transported to site with
approved JMF.The temperature of binder at the time of mixing shall be 150 to 165 0C and
 that of aggregate in range of 150 to 1700C provided that the difference in temperature
between the binder and aggregate at no time exceed 14 0C.
The bituminous mix shall be transported in insulated vehicles to the site. Thin Coating of
diesel or lubricating oil to the interior of vehicle to prevent sticking and to facilitate the
discharge of material or as suggested by you.
Four Laning and Strengthening of Existing Two Lanes of NH-7 From Madurai To
Kanyakumari Km 80.000 (New Chainage Km 87.651) To Km 120.000 (New Chainage Km
126.884) in the State of Tamilnadu, Contract Package No. NS-41 (TN).

SPREADING AND ROLLING OF MIX:

After priming the surface with prime Coat and Tack coat DBM will be laid with the help of
sensor paver of screed width 9.0m.After arrival of material from HMP the Material will be
supplied continuously to the paver and laid with out delay. Before unloading of the material
the temperature of mix will be checked and will be recorded at no time the mix temperature
should not be less than 1250C.If the temperature is found less it has to be re heated in the
paver to the required temperature.
The rate of delivery of the material to the paver will be regulated to able the paver to operate
continuously. The travel rate of the paver will be adjusted to ensure an even flow of
bituminous material across the screed, free from dragging, tearing and segregation of the
material.
After DBM has been laid to the specified thickness it is to be compacted before the
temperature falls below 900C.Rolling of the longitudinal joints will be done immediately
behind the paving operation. After this, the rolling operation will commence at the edges and
progress towards the centre except on the super elevated portion and unidirectional cambered
portion it will progress from the lower edge to upper edge parallel to the centerline of the
pavement. The rolling sequence with 10MT Smooth wheel vibratory rollers will be as
follows

 2Plain passes
 2Medium passes
 1High pass
 2medium passes
 2Plain passes
care is to be taken that the rolling temperature at no point is not less than 90 0C.After the rolling
operation is completed with smooth wheel roller the surface with rolled pneumatic tyre roller for
about 45Min so that all the voids percent are closed

PRECAUTION TO BE TAKEN WHILE OPERATION:

 Care should be taken to ensure that the minimum temperature of the mix is maintained
while rolling and laying operation.
 The speed of the roller should not be more than 5Kmph
 The roller should not be permitted to stand on the fresh laid pavement
 Care should be taken to ensure that there is no dropping of oil grease, petrol or other
foreign matter on the pavement either when the roller are operating or are standing still
 The wheel of the roller is to be kept moist with water
Four Laning and Strengthening of Existing Two Lanes of NH-7 From Madurai To
Kanyakumari Km 80.000 (New Chainage Km 87.651) To Km 120.000 ( New Chainage Km
126.884) in the State of Tamilnadu, Contract Package No. NS-41 (TN).

CONTROL TESTS AT LAB:

 Gradation of aggregate from hot bins

 Extraction test for Bituminous mix
 Gradation of individual and combined aggregates
 Temperature of the mix at loading and un loading point
 Core cutting from the laid quantity of DBM
 Any other test prescribed as per MoRTH section 900

PLANT AND MICHENERY FOR BITUMINOUS WORK:

 PARKER Asphalt Batch mix plant (120TPH) : 1No

 Sensor paver VOGLE make : 1No
 Pneumatic tyre roller : 1No
 Smooth wheel tandem vibratory roller : 2No
 Truck mounted Bitumen Sprayer : 1No
 Tippers : 20No
 Straight Edge : 1No
 Mechanical core cutting Machine : 1No
 Leveling instrument along with staff : 3No
 Thermometer for measuring the temperature of mix : 2No

RECORDS AT SITE:

 Level sheets for DBM

 Measurement book
 Site instruction book
IVRCL / NH-7 / NS-41/ SWIPL / /2007-08
Date: 18.08.2007

To,
The Resident Engineer,
Scott Wilson India Pvt Ltd.,
5/88-C - Vinayaga Nagar,
Inam maniyachi
Kovilpatti-628 503
Kind Attn. Mr.T.Rajalingam.

Sub: Widening and strengthening of existing 2-lane road from Km 87+651 to Km

126+884 Proposed Chainage. (NS-41) of Madurai - Kanyakumari section.
: BM Trial stretch test results with DMI HMP @126+440 RHS . : Reg
Dear Sir,

With reference to the above subject please find enclosed here with the
Methodology of laying, site reports & test reports for BM Trial Stretch @ Km: 103+750 to
103+860 RHS. Conducted with DMI HMP@126+440 RHS.

This is for your Kind approval.

Thanking you,

Yours faithfully,
For IVRCL Infrastructures & Projects Ltd.,

(V.Durairaj)
Sr.Manager (Projects)

Encl: 1. BM Test Reports

2. Level Sheets
3. Methodology

CC: The Team Leader SWIPL Madurai

 METHODOLOGY FOR BITUMINOUS MACADAM
The work shall consist of construction in single course having 50mm Thickness of compacted
crushed aggregate premixed with bituminous binder on a previously prepared non-bituminous /
existing bituminous surface based to the Requirements as per specifications.

SCOPE:

 The scope of this methodology is limited to work of Madurai to kanyakumari road project
(km:87+651 to km:126+884)
 The Methodology presented in this paper is based on certain assumptions. In case of
actual execution likely are the changes that this methodology may vary to certain limited
extent.

PURPOSE:

 The purpose of this methodology is to outline the guideline for laying of Dense
Bituminous Macadam at site
 To generate records to show compliance as per Requirements
 To make the operation Process clear with out leaving any void for ambiguity

PREPARATION OF BASE:

 The base on which DBM to be laid is to be prepared shaped and conditioned to Specific
lines and grades in accordance with specified permissible limits and the surface cleaned
from dust and any loose material to removed. After cleaning the surface prime coat is to
be applied and primed surface is allowed to cure for not less than 24 hours. Before laying
of DBM Tack shall be applied as per specified rates.

MIXING AND TRANSPORTING:

 Premixed Dense Bituminous material (DBM) shall be prepared in PARKER Batch mix
plant of adequate capacity (120TPH) and capable of yielding a mix of proper and uniform
quality with thoroughly coated aggregate. The mix design of bituminous works finalized
as per Hot bin aggregate gradation. The grading control unit having four decks vibratory
screen for sizing of hot aggregate and storing them in separate bins. Proper Arrangement
for accurate weighing of each size of aggregate from the control panel before mixing. in
 HMP the weighing hopper of aggregate, bitumen and filler shall be calibrated before the
plant operation. The mix from Asphalt mixing plant will be transported to site with
approved JMF.The temperature of binder at the time of mixing shall be 150 to 165 0C and
that of aggregate in range of 150 to 1700C provided that the difference in temperature
between the binder and aggregate at no time exceed 14 0C.
The bituminous mix shall be transported in insulated vehicles to the site. Thin Coating of
diesel or lubricating oil to the interior of vehicle to prevent sticking and to facilitate the
discharge of material or as suggested by you.
Four Laning and Strengthening of Existing Two Lanes of NH-7 From Madurai To
Kanyakumari Km 80.000 (New Chainage Km 87.651) To Km 120.000 (New Chainage Km
126.884) in the State of Tamilnadu, Contract Package No. NS-41 (TN).

SPREADING AND ROLLING OF MIX:

After priming the surface with prime Coat and Tack coat DBM will be laid with the help of
sensor paver of screed width 9.0m.After arrival of material from HMP the Material will be
supplied continuously to the paver and laid with out delay. Before unloading of the material
the temperature of mix will be checked and will be recorded at no time the mix temperature
should not be less than 1250C.If the temperature is found less it has to be re heated in the
paver to the required temperature.
The rate of delivery of the material to the paver will be regulated to able the paver to operate
continuously. The travel rate of the paver will be adjusted to ensure an even flow of
bituminous material across the screed, free from dragging, tearing and segregation of the
material.
After DBM has been laid to the specified thickness it is to be compacted before the
temperature falls below 900C.Rolling of the longitudinal joints will be done immediately
behind the paving operation. After this, the rolling operation will commence at the edges and
progress towards the centre except on the super elevated portion and unidirectional cambered
portion it will progress from the lower edge to upper edge parallel to the centerline of the
pavement. The rolling sequence with 10MT Smooth wheel vibratory rollers will be as
follows

 2Plain passes
 2Medium passes
 1High pass
 2medium passes
 2Plain passes
care is to be taken that the rolling temperature at no point is not less than 90 0C.After the rolling
operation is completed with smooth wheel roller the surface with rolled pneumatic tyre roller for
about 45Min so that all the voids percent are closed

PRECAUTION TO BE TAKEN WHILE OPERATION:

 Care should be taken to ensure that the minimum temperature of the mix is maintained
while rolling and laying operation.
 The speed of the roller should not be more than 5Kmph
 The roller should not be permitted to stand on the fresh laid pavement
 Care should be taken to ensure that there is no dropping of oil grease, petrol or other
foreign matter on the pavement either when the roller are operating or are standing still
  The wheel of the roller is to be kept moist with water

Four Laning and Strengthening of Existing Two Lanes of NH-7 From Madurai To
Kanyakumari Km 80.000 (New Chainage Km 87.651) To Km 120.000 ( New Chainage Km
126.884) in the State of Tamilnadu, Contract Package No. NS-41 (TN).

CONTROL TESTS AT LAB:

 Gradation of aggregate from hot bins

 Extraction test for Bituminous mix
 Gradation of individual and combined aggregates
 Temperature of the mix at loading and un loading point
 Core cutting from the laid quantity of DBM
 Any other test prescribed as per MoRTH section 900

PLANT AND MICHENERY FOR BITUMINOUS WORK:

 PARKER Asphalt Batch mix plant (120TPH) : 1No

 Sensor paver VOGLE make : 1No
 Pneumatic tyre roller : 1No
 Smooth wheel tandem vibratory roller : 2No
 Truck mounted Bitumen Sprayer : 1No
 Tippers : 20No
 Straight Edge : 1No
 Mechanical core cutting Machine : 1No
 Leveling instrument along with staff : 3No
 Thermometer for measuring the temperature of mix : 2No

RECORDS AT SITE:

 Level sheets for DBM

 Measurement book
 Site instruction book
IVRCL / NH-7 / NS-41/ SWIPL / /2007-08
Date: 31.08.2007

To,
The Resident Engineer,
Scott Wilson India Pvt Ltd.,
5/88-C - Vinayaga Nagar,
Inam maniyachi
Kovilpatti-628 503
Kind Attn. Mr.T.Rajalingam.

Sub: Widening and strengthening of existing 2-lane road from Km 87+651 to Km

126+884 Proposed Chainage. (NS-41) of Madurai - Kanyakumari section.
: BM Trial stretch test results with DMI HMP @126+440 RHS . : Reg
Dear Sir,

With reference to the above subject please find enclosed here with the
Methodology of laying, site reports & test reports for BM Trial Stretch @ Km: 103+750 to
103+860 RHS. Conducted with DMI HMP@126+440 RHS.

This is for your Kind approval.

Thanking you,

Yours faithfully,
For IVRCL Infrastructures & Projects Ltd.,

(V.Durairaj)
Sr.Manager (Projects)

Encl: 1. BM Test Reports

2. Level Sheets
3. Methodology

CC: The Team Leader SWIPL Madurai

IVRCL / NH-7 / NS-41/ SWIPL / /2007-08
Date:

To,
The Resident Engineer,
Scott Wilson India Pvt Ltd.,
5/88-C - Vinayaga Nagar,
Inam maniyachi
Kovilpatti-628 503
Kind Attn. Mr.T.Rajalingam.

Sub: Widening and strengthening of existing 2-lane road from Km 87+651 to Km

126+884 Proposed Chainage. (NS-41) of Madurai - Kanyakumari section.
: PCC(with DBM Material)Trial stretch test results with PARKER HMP
@126+440 RHS . : Reg

Dear Sir,

With reference to the above subject please find enclosed here with the site
reports & test reports for PCC (with DBM Material) Trial Stretch @ Km: 116+900 to
117+000 RHS. Conducted with PARKER HMP@126+440 RHS.

This is for your Kind approval.

Thanking you,

Yours faithfully,
For IVRCL Infrastructures & Projects Ltd.,

(V.Durairaj)
Sr.Manager (Projects)

Encl: 1. Test Reports

2. Site Reports
CC: The Team Leader SWIPL, Madurai