Method Statement for laying of BC Contractor :

(with RAP Material

1.0 PURPOSE :
The methodology provides the method adopted for construction of Bituminous Wearing Course,
a thoroughly controlled, hot mixed, hot laid, plant mix of well-graded reclaimed and new
aggregates, filler and bitumen that, when compacted, forms a dense layer. This work consists of
constructing in a single layer Bituminous Wearing Course as per the specified requirements.

2.0 SCOPE

The scope of this methodology will cover the following activities :

 Collection of RAP material from the scarified pavement and testing

 Identification of Sources, Bitumen & Aggregates for BC mix, materials selection, testing,
approval of all materials and finalization of mixing proportions, trials etc
 Survey and Setting out Works
 Laying of BC mix with sensor paver, compacting and testing as per Specifications
 Recording of all results / inspection data etc. in relevant Inspection and Test formats and
controlling of all inspection / test records / files as per existing Internal Document Control
System for identification and traceability

3.0 CONSTRUCTION METHODOLOGY :

3.1 Materials :

The materials used for preparation of BC mix will satisfy the specified requirements as stated
below :

RAP Material : The reclaimed material shall be tested for the following and evaluated to find the
optimum blend meeting the mixture requirement. Mechanical sieve analysis (IS:2386, Part I,
wet sieving method) shall be performed on the aggregate portion of the reclaimed bituminous
pavement sample to determine the grading. After selecting the proportion of reclaimed
materials to be recycled, the grading of the mixture to be adjusted to meet specification
requirements by the addition of selected aggregate sizes.

 Bitumen Extraction Test as per Clause 519.2.3

 Impact Test
 Shape Test
 Aggregate Stripping Value Test
 Aggregate Crushing Test
 Soundness or Durability Test
 Crushing Test
 Water Absorption Test
 Specific Gravity Test

Fresh Material :

 Bitumen: The type & grade of bitumen shall be as specified in the CA or VG 40 / VG 30

conforming to IS 73

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 Method Statement for laying of BC Contractor :
(with RAP Material

 Coarse Aggregates: The coarse aggregates shall consist of crushed rock, crushed gravel or
other hard material retained on 2.36 mm sieve. It shall be clean, hard, durable and cubical
shape, free from dust and soft organic and other deleterious substances. The aggregate shall
satisfy the physical requirements specified in Table 500-16 of MORTH specifications.
 Fine Aggregates: Fine aggregates shall be either crushed or naturally occurring mineral
material, or a combination of the two, passing the 2.36 mm sieve and retained on the 75
micron sieve. These shall be clean, hard, durable, dry and free from dust, and soft or friable
matter, organic or other deleterious matter. The fine aggregate shall have a sand equivalent
value of not less than 50 when tested in accordance with the requirement of IS: 2720 (part
37). The plasticity index of the fraction passing the 0.425 mm sieve shall not exceed 4, when
tested in accordance with IS: 2720 (Part 5).
 Filler: This shall conform to Clause 505.2.4 of MORTH specifications. Filler shall consist of
finely divided mineral matter such as rock dust, hydrated lime or cement. The filler shall be
graded within the limits indicated in Table 500-9 of MORTH specifications.

When the amount of reclaimed bituminous materials to be used in the mixture exceeds 10%, the
penetration value of the recovered binder from the reclaimed bituminous material, before
mixing, shall exceed 15 pen, after recovery of binder in accordance with the requirements of
BS:2000:Part 397, when tested in accordance with IS:1203.

After mixing with recycled material, the binder recovered from the mixture shall have a
recovered penetration value not less than the value specified in Table 500-48 of MoRTH.

The combined aggregate grading shall be checked for resistance to stripping as specified in Table
500-17

3.2 Mobilization of Plant & Equipment :

The following construction machinery will be used for the execution of the Work.

 Hot Mix Plant (Batch Type) of 160 TPH capacity with DG Set along with RAP Arrangement
 Sensor Paver Finisher
 Front End Loader
 Tippers of required capacity and numbers
 Smooth Wheeled Tandem Roller
 Vibratory Roller
 Pneumatic Tyred Roller
 Emulsion Pressure Distributor
 Milling Machine
 Air Compressor
 Mechanical Broomer
 Water Tanker
 Core cutting machine

3.3 Mix Design :

The combined grading and binder content shall be in accordance with Clause 507

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 Method Statement for laying of BC Contractor :
(with RAP Material

3.4 Procedure or Construction of BC Mix :

3.4.1 Site Trials :

The full scale laying and compaction trials will be carried out on BC mix materials for the
permanent works using the plant and methods proposed. The trials will be carried out in the
presence of Independent Engineer. The program will be conveyed vide e=mail prior to trial.

The trials will be done to demonstrate the suitability of the 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.

The trial of pavement layer shall be undertaken ahead of the proposed work to commence full-
scale work. The data retrieved from the trials i.e. temperature of the mix, composition, grading,
bitumen content, marshal parameters, rolling pattern, laying temperature and other test results
which will be submitted separately.

3.4.2 Preparation of Base :

The base on which BC mix is to be laid will be prepared, shaped and conditioned to the specified
lines, grade and cross sections in accordance with Clause 501 or as directed by the Engineer.
The surface shall be thoroughly swept clean free from foreign matter; loose materials and dust
removed by thorough brushing with mechanical brooms and / or blown off by compressed air or
other acceptable methods. Any defects like rutting, bleeding and cracks on the surface will be
made good by milling for initial 40mm to be done by mechanical milling machine. If the further
cracks are observed in DBM after milling, then again the milling to be done or further 40mm
shall be re-laid with dense bituminous macadam prior to laying of BC and cleaning the surface. A
tack coat as needed will be applied in accordance with Clause 503 of MoRTH Rev-5.

3.4.3 Preparation of Mix :

The BC mix will be prepared in a mixing plant complying with Clause 507.4.6. It will be equipped
with at least four cold bins, four deck vibratory screen, hot bins for the storage of the heated
aggregates and a separate bin for filler. Precaution will be taken to prevent the ingress of
moisture.

The mixing plant will be of the batch-mix type and shall be capable of regulating the composition
of the mixture to within the tolerances specified by Table 500-18 of the Specification and / or as
instructed by the Engineer.

The dryer is of the rotating drum type capable of heating the aggregates to the temperatures set
forth in this Specification. Bitumen will be heated to the specified temperature in tanks and
delivered to the mixing plant via insulated pipes such that heat losses are minimized. The
minimum mixing period will be adopted to get the suitable mix. The mixing cycle times will
range from 30 to 40 seconds. Plants shall have automatic controls that co-ordinate the
proportioning, timing and discharge of the mix.

The Bitumen will be heated in the range of 160˚C to 170˚C so that it can be distributed
uniformly. The aggregate will be heated so that they are mixed within the temperature range of

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 Method Statement for laying of BC Contractor :
(with RAP Material

160˚C to 175˚C. The difference in temperature between the binder and the aggregate shall at no
time exceed 14˚C. The mixing will be thorough to ensure that a homogeneous mixture is
obtained in which all particles of the aggregates are coated uniformly and the discharge
temperature of mix shall be between 160˚C to 170˚C.

Bituminous mixes will be kept free of contamination and segregation during transportation.
Trucks used for hauling asphalt mixture will be adequately free of petroleum oils, solvents or
other materials that adversely affect asphalt mixture. The hot mix will be supplied in accordance
with the specified standard mix formula. The temperature of mix when laying at place will be
minimum 150˚C.

3.4.4 Laying of Bituminous Mix :

The BC mix will be laid by a self-propelled spreader finished equipped with a hopper, delivery
augers and capable of spreading, tamping and finishing the mix to specified grade, lines and
cross section. 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.

Immediately after receiving the transported materials from hot mix plant to the site, it will be
spread on prepared surface, the mixture will be spread to line and level by the Sensor Paver
without segregation or dragging. The temperature of mix at the time of laying will be minimum
150˚C. BC mix is very sensitive and the mix material to be fed to the paver at all times
continuously. Therefore, a steady dedicated fleet of dumper will be provided for doing BC. The
mixture will be placed in full width of the pavement. The compacted thickness of any layer shall
be as per specification. The paver shall be capable of operating at forward speeds consistent
with uniform and continuous laying of the mixture. The condition will be seen to avoid continual
stop and start fashion. The speed of the paver will be coordinated with the feed limiting to no
drag condition.

Paver 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 0.1%. 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 will be operated manually for the remaining period of the
normal working day, provided that the specified requirements are met.

3.4.5 Compaction of the laid Mix :

Sufficient rollers (minimum 2 No.) will be provided of appropriate type sizes and weights to
achieve the specified compaction. Rollers shall be self-propelled and of steel wheel, pneumatic
tyre and vibratory types, including combinations thereof, capable of reversing without shoving
or tearing the mixture.

Immediately after spreading the bituminous mixture, the mix will be compacted thoroughly and
uniformly by rolling. The laid mix will be rolled so that 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.

Rolling, in compliance with the general procedures outlined below, shall continue until the layer
under compaction has attained the specified requirements initial static rolling with a steel

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 Method Statement for laying of BC Contractor :
(with RAP Material

tandem roller as per Clause 507.4.8. The rollers shall be operated with the drive roll nearest the
laying plant, at a uniform speed not exceeding 5 km/hr. Rolling shall normally commence from
the outer edge and proceed longitudinally parallel to the centerline, each pass overlapping the
previous pass by one half of the roller width. On super elevated curves, rolling shall begin at the
low side and progress to the high side. Where laying carried out care shall be taken to prevent
the entrapment of water. Intermediate vibratory rolling with steel tandem roller shall follow
immediately upon initial rolling.

Intermediate rolling with pneumatic tyred roller as per Clause 507.4.8 having 0.56 MPa tyre
pressure will be done. In case of failure of pneumatic tyred roller at site during operation any
one type of roller shall substitute the other for the days work to obtain the specified
requirement. Final static rolling with a steel wheel roller shall be used to eliminate marks from
previous rolling. The roller wheels and drums shall be kept lightly moistened with water to
prevent adhesion of the mixture to the rollers. All rolling operations shall be completed in all
respects before the temperature of the mix falls below 90˚C. Rolling pattern will be determined
from trials and adopted for the full work. The general pattern shall be as follows :

a) Initial rolling 1 Static passes with vibratory roller

b) Intermediate rolling 3 passes with PTR
2 vibratory passes
c) Final rolling 1 static pass

One pass shall include both forward and reverse movement of roller

3.4.6 Finishing of edges :

Any mixture that becomes loose or broken, mixed with dirt or foreign matter or defective will be
removed and it will be replaced with fresh hot mixture and compacted. The edges of the course
will be rolled concurrently with or immediately after the finishing. In rolling the edges, roller
wheels will extend 50mm to 100mm beyond the edge.

Any fresh mixture on the existing work shall be removed carefully sweeping it back on to
uncompacted work, so as to avoid formation of irregularities at the previous face.

3.4.7 Surface Finish :

The surface finish of construction shall be conformed to the requirements of Clause 902

3.4.8 Limitation to construction :

The work will not be carried out in adverse weather conditions.

Bituminous material will not be applied to wet or frozen surface or when weather conditions
otherwise prevent the proper handling and finishing of the mixture. The bituminous material
will be placed when both the ambient temperatures and road surface temperatures are greater
than 10 ˚C with rising trend.

4.0 INSPECTIONS :

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 Method Statement for laying of BC Contractor :
(with RAP Material

The finished layer shall be checked for compaction. The compaction shall be checked by taking
cores after 24 hours of laying at the rate of 1 No. per 2 lane km and the degree of compaction
shall not be less than 98% of lab Marshal Density or as specified.

5.0 QUALITY CONTROL CHECK :

All relevant QA and QC documents will be maintained as per section 900 of MoRTH for all stage
construction.

6.0 DIVERSION OF TRAFFIC SAFETY :

The detailed traffic diversion and control plan shall be prepared as per MoRTH clause 112 prior
to commencement of work. The plan shall contain details of temporary diversion, details of
arrangement for construction under traffic, details of traffic arrangement after cessation of work
each day, safety measures for transportation of materials and arrangement of flagman. Special
consideration shall be given for safety of pedestrians and workers at night. The changes in traffic
routes, conditions and pedestrian access arrangements shall be informed to road users by
providing suitable traffic signs and signals as per IRC:SP:55-2001.

Traffic will be allowed after completion of the final rolling when the mix has cooled down to the
surrounding temperature. Speed restrictions shall be imposed at initial stages.

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