QUALITY ASPECT IN ROADS

Quality Assurance and Management Plan

in R&B Department.
• In this Scenario, it is imperative that the roads are
built and maintained to the standards as specified in
the respective contracts. With a view to achieve the
required standards in road construction and
maintenance, uniformly and consistently, it is
necessary to have all the required standards,
construction methods, quality control procedures and
tests at one place in the form of a document.

•This quality Assurance/Management plan is developed

with an intention to aid the personnel responsible /
involved in construction and maintenance to achieve the
required standards.
• This QA/MP is a tool or method, aimed to
achieve the required standards and specifications
in a Roads,Bridges and Buildings.
• The QA/M Plan consists of two main parts i.e.,
– (i) Quality Control and (ii) Quality Audit.
– The first part is very important one where in it helps in
achieving a specified quality product.
– The second part evaluates quality standards of the
final product. This plan is developed with main focus
on Road and Bridge Projects.
– This plan, once implemented will help in achieving
uniform and consistent standards in all projects across
the state.
 The quality assurance and quality
control in work execution is achieved
by adopting.
• Correct work methodology for each item of work
• Selection / Approval of specified material based on initial
material testing.
• Design Mix wherever necessary.
• Use of right plant and machinery during the construction.
• By using RFI and OK card system.
• Conducting necessary QC Test during construction to satisfy
the material requirements.
• Testing, passing final product and final quality Audit.
• Proper documentation/recording of the above activities.
• Quality assurance and quality control is achieved in
three stages
• Material selection stage:
• The field Engineer shall conduct the tests required
as per the frequency specified for each item of work.
The item of work which are not within the specified
limit shall be rejected or rectified as specified by the
Engineer-in-charge.
• Inspection of specified plant and machinery /
approvals.
• Construction Stage
• Each activity of construction shall be associated with RFI and OK card
system i.e right from setting out to final completion. The contractor shall
first establish TBM shall be accompanied by the abstract of TBM Values /
Test Results / Levels, etc.
• Raise an RFI for verification of TBMs. The Engineer-in-charge shall verify &
approve the TBMs if correct. If TBMs are not correct then redirect to
establish them afresh.
• This methodology shall be continued for each item of road work like
setting out, C&G, Earth work excavation, Formation of embankment,
Subgrade, Granular Sub Base, Wet Mix Macadam, Prime coat, Tack coat
and BT layers ie BM/DBM/BC construction / execution of each item of
work as per specification.
• Final Stage
• Final Quality Audit and Payment
 Model of RFI (Request For Inspection)
Name of the Project:

Name of Agency
Description of Works:

Location/chainage:

BOQ Item No.

Approx Quantity

Submitted by: Desig. Sign:

Inspection Required on: Date: Time:

Engineer-in-charge
Received by Engineer’s representative Sign. Date/Time:

Inspection:
AEE/AE Fiedl Engineer Comments:
Tests /Levels Conducted/verified
Satisfactory/Non-Compliance
Checked by DEE/EE comments:-

Inspection Required on:

Tests /Levels Conducted/verified
Satisfactory/Non-Compliance
Approved/Not approved for the following reasons
Two lane typical cross section for new road

Not to scale
Widening road typical cross section
 Activities involved in Road Construction in Brief

• Setting out alignment /levels

• C&G Stage
• Earth work
• Granular Sub base(GSB)
• Wet Mix Macadam
• Prime coat
• Tack coat
• BT layers (BM/DBM/BC)
Setting out alignment and C&G Stage
• Setting out allignment involves centre line
marking and establishing TBMs as per
drawings
• In Clearing &Grubbing is done up to the
widths as specified or up to toe line/edge of
formation or excavation.
• Taking of Pre-levels & verification.
 Earth Work
• Earth work involves earth work excavation, formation of
embankment, Sub-grade and Earthen shoulders.
• Materials used for embankment shall confirm the specificiations of
Clause:305 of MoRTH.

• Selection of earth i.e., from borrow areas

• The borrow materials requirements
• For embankment up to 3M height MDD shall not be less than 1.52
gm/cc
• For embankment above 3M height MDD shall not be less than 1.60
gm/cc
• The soil with Liquid Limit >50 and Plasticity Index >25 & Pree
Swelling Index (FSI)>50 shall not be used.
• Further lumps/coarse material of size >75mm shall not be used.
• MDD shall not less than 1.75 gm/cc for Sub
grade and Earthen shoulders and soil with
Liquid Limit>40 and Plasticity Index >20 shall
not be used. Further lumps/coarse material of
size >50mm shall not be used for sub grade.
• Embankment / sub grade shall be compacted
in layers of 250mm compacted thickness, if
vibratory rollers / vibratory earth compactors
are used. It shall be 200mm if static rollers are
used.
• Control of Compaction
• Relative Compaction shall not be less than
95% of Lab MDD for embankment and not less
than 97% for Sub grade and earthen
shoulders.
• And the surface level tolerances for Sub grade
with reference to the longitudinal and cross
profile + 20 mm
 Quality control test for embankment/Subgrade
ITEM CLAUSE TEST RQUIRED FREQUENCY RELEVANT I.S CODE LIMITS
(Min)

EMBANKMENT 305 Plasticity 2 tests per 3000 IS:2720(pt-V) LL≤50,PI ≤25

cum

MDD and OMC --do— IS:2720(pt-VIII) Up to 3M≥1.52kN/cum

Above 3m,≥1.6kN/cum

≤50
Free Swelling Index --do— IS:2720(pt-40)

Natural moisture content

-- do— IS:2720(pt-II)
Moisture content just before
compaction
2-3 test for every IS:2720(pt-II) -2 to +1% of
250 cum of loose OMC
soil
Field density

1 test for 1000sqm

Subgrade ≥95% MDD of heavy
IS:2720(pt-28) compaction for embankment

≥97%of MDD of heavy

compaction for sub grade&
earthen shoulders
 Granular Sub Base(GSB)
• This work shall consist of laying and compacting well graded material (On prepared
sub grade)in accordance to the Section 400 & Clause 401 of MORT&H.
• The compacted individual layer thickness of GSB shall not be more than 200mm.
• Spreading and compacting as per design mix.
• Sub base material of grading specified in the contract and water shall be mixed
mechanically by suitable mixer equipped with a provision for controlled addition of
water and mechanical mixing so as to ensure homogeneous and uniform mix. Mix
shall be spread on the prepared sub grade with the help of motor grader of
adequate capacity and blade having hydraulic controls for maintaining required
slope and grade or other means as directed by the Engineer-in-charge.
• Control of Compaction
• Rolling shall be continued till the density achieves 98% of the MDD Lab. And the
surface level tolerances for Granular Sub base with reference to the longitudinal
and cross profile + 10 mm
 Table 400-1:Grading for Granular Sub base material

Percentage by Weight Passing the IS sieve

IS Sieve
Designation Grading I Grading II Grading Grading Grading V Grading
III IV VI
75.0 mm 100 - - - 100 -

53.0 mm 80 – 100 100 100 100 80-100 100

26.5 mm 55 – 90 70- 100 55 – 75 50 – 80 55 – 90 75 – 100

9.50 mm 35 – 65 50 – 80 - - 35 -65 55 – 75

4.75 mm 25 – 55 40 - 65 10 – 30 15 – 35 25 – 50 30 – 55

2.36 mm 20 – 40 30 – 50 - - 10 – 20 10 – 25

0.85 mm - - - - 2 -10 -

0.425 mm 10 – 15 10 – 15 - - 0–5 0 -8

0.075 mm <5 <5 <5 <5 - 0-3

 Required Quality Control tests for GSB as tabulated below .
FREQUENCY RELEVANT
CLAUSE TEST REQUIRED LIMITS
ITEM (Min) IS CODE

(1) Granular Sub- 401 Gradation 1 test per 400cum IS 2386(pt-IV) As per table 401-1 of
base (Maximum MORTH
compacted thickness
of layer to be ≤200 Atterberg limits of --do – IS 2720 (pt-V) LL≤ 25, PI≤6
mm) aggregates passing
425 micron sieve

Field density test 1 test per 1000sqm IS 2720 (pt-28) ≥98% of MDD(Heavy
compaction)
-1to-2 of OMC
Moisture content 1 test per 400sqm IS 2720 (pt- II)
prior to compaction

Deleterious
constituents As required IS 2720 (pt-XXVIII)

CBR As required IS 2720 (pt-XVI) ≥30

Water absorption As required IS 2386 (pt – III) ≤2%

 Machinery required for GSB
• Motor grader 3.35M blade @ 50 cum/hr
• Tractor – Rotavator/Mechanical Mixer
• Water Tanker – 6 KL
• Vibratory Roller – 8 T
• Tippers for conveyance
 WET MIX MACADAM(WMM)
• This work shall consist of laying and
compacting clean crushed, graded aggregate
and granular material premixed with water
to a dense mass on prepared Sub grade/Sub
base /base or on existing pavement in
accordance to the Section 400 & Clause 406
of MORT&H.
• The compacted individual layer thickness of
WMM shall not be less than 75mm and more
than 200mm.
• WMM shall be prepared as per design mix in an
approved mixing plant of suitable capacity having
provision for controlled addition of water and mixing
arrangement like Pugmil or Pan type mixer of
concrete batching plant consisting of 4-bin feeders
with variable speed motor, vibrating screen for
removal of over sized aggregate, conveyor belt and
premixing the material at OMC and laying at site
uniform layer with paver finisher to lines, grades and
cross sections as shown in the drawings and shall be
compacted to achieve at least 98% of MDD (Heavy
compaction).
• After final completion WMM shall be allowed to dry
for 24 hours.
• No traffic shall be allowed on WMM surface.
• Forming of shoulder/ berms should be done
simultaneously along with WMM layer.
• Surface level tolerances for Wet Mix Macadam with
reference to the longitudinal and cross profile + 10
mm.
Grading requirements of aggregate for
WMM
IS Sieve Designation Percentage by weight passing the IS
Sieve
53.00 mm 100
45.00 mm 95-100
26.50 mm -
22.40 mm 60 - 80
11.20 mm 40 – 60
4.75 mm 25 – 40
2.36 mm 15 – 40
600.00 micron 8 – 22
75.00 micron 0-5
 Machinery requirement of WMM
• Wet mix plant(Pugmill) of 60T/hr (minimum)
• Electrical generating set 125 KVA.
• Front end loader 1 cum capacity
• Mechanical paver finisher at 100 Tph
• Vibratory Roller – 8 to 10 Tonnes
• Water Tanker
• Tippers for conveyance.
 Required quality control tests to WMM
ITEM CLAUSE TESTS REQUIRED FREQUENCY RELEVANT I.S. LIMITS
(Min) CODE
Wet Mix 406 Aggregate 1 test per IS 2386 (pt-IV) ≤ 30
Macadam Impact value 1000cum.

Grading 1 test per IS 2720 (pt-IV) As per table

200 cum. 400-13 of
Flakiness and MORTH
Elongation Index 1 test per IS 2386 (pt-I) ≤35%
500 cum.
P.I limits (on
material finer 1 test per IS 2720 (pt-V) ≤6
than 425μ) 200 cum.

Field Dry 1 set of IS 2720 (pt- ≥98% of

Density 3tests per VIII) MDD(Heavy
1000 sqm. compaction)
Water
absorption As required IS 2720 (pt-II) ≤2%
 Prime Coat
• Prime coat applied on prepared Granular Surface on
which bituminous layer is going to be laid as per
Section 500 and Clause 502 of MORT&H
• Primer shall be bitumen emulsion SS1 grade
conforming IS-8887 or as specified in the contract.
• Rate of spray on WMM surfaces 0.7-1.0 Kg/Sqm.
• Laying Prime coat with bitumen emulsion (medium
setting) using emulsion pressure distributor on
prepared surface of Granular base including cleaning of
road surface and spaying emulsion with required rate
of spray.
• The frequency of test for rate of spread of binder – 3
tests/day.
 Tack Coat
• Tack coat applied on prepared Granular Surface or on
a bituminous surface is going to be next layer of
bituminous layer laid as per Section 500 and Clause
503 of MORT&H
• Tack coat material shall be as specified in Agreement
i.e. VG10 or bitumen emulsion etc.
• Rate of spray on bituminous surfaces 0.2-0.3Kg/Sqm.
• Laying Tack coat with bitumen emulsion (medium
setting) using emulsion pressure distributor on
prepared surface of Granular base including cleaning of
road surface and spaying emulsion with required rate
of spray..
• The frequency of test for rate of spread of binder – 3
tests/day.
 Bituminous Macadam(BM)
• Procedure for mixing laying compacting for BM/DBM and
BC
• Mixing:
• The ingredients of BM i.e. (i) Bitumen, (ii) Coarse
aggregate and (iii)Fine aggregates shall be as per relevant
MORTH classes.
• The mix of aggregate and binder shall be prepared in
Hot Mix Plant of specified type and capacity. The mix shall
be uniform and mixed at specified temperatures as
indicated in respective clauses and extracted here in QAP.
• The difference in temperature between the binder and
aggregate shall not exceed 140 C. The Hot Mix Plant shall
be calibrated from time to time to produce the desired mix.
 Mixing, Laying and Rolling Temperatures
for Bituminous mixes(Degree Celsius)

Bitumen Bitumen Aggregate Mixed Laying Rolling Penetration

Viscosity Temperature Temperature material Tempe Temperat Grade
Grade temperature rature ure Bitumen

VG-40 160-170 160-175 160-170 150 100 Min 30/40,

Min 40/50
VG-30 150-165 150-170 150-165 140 90 Min 60/70
Min
VG-20 145-165 145-170 145-165 135 85 Min
Min
VG-10 140-160 140-165 140-160 130 80 Min 80/100
Min
• Laying:
• Spreading/laying mix shall be avoided (i) when standing water is
present (ii) when rain is imminent, (iii) when the course on which
the mix is going to be laid is damp, (iv)when the course on which
the mix is going to be laid is having temperature < 100 C for
conventional bitumen and < 150 C for modified bitumen. (v) when
wind speed exceeds 40 kmph at 2m height. Spreading shall be by
specified type of paving machine. Mix soon after arrival at the site
shall be supplied continuously to the paver and laid without delay.
Paver speed shall be adjusted to ensure even and uniform flow, free
from dragging, tearing and segregation. Where paver can’t reach,
the material shall be spread, raked and levelled with suitable hand
tools. The bitumen mix shall be spread on surface cleaned of all
loose and extraneous matter by means of a mechanical broom and
air jet. The equipment for applying a high pressure air jet shall be
available full time at the site.
• Compaction
• Compaction shall commence as soon as possible after laying. Rolling shall
be completed before the temperature falls below specified temperature.
Rolling of the longitudinal joints shall be done immediately behind the
paving operation. After rolling of longitudinal joint, rolling shall
commence from edges and shall progress towards centre. In super
elevated or unidirectional camber rolling shall progress from lower edge to
upper edge. Rolling shall continue until all roller makes have been
removed from the surface. Rolling shall be in three stages: (i) The initial or
break down rolling with 8-10 t static weight smooth wheeled rollers (ii)
The intermediate rolling with 8 - 10 t static weight or vibratory roller or
with 12 to 15 t PTR with a tyre pressure of at least 0.56MPa, (iii)Finish
rolling shall be with 6 – 8 t smooth wheel tandem rollers. Each pass of
roller shall overlap with the previous pass by 1/3rd of the roller width and
in case of PTR by 300mm. Roller speed shall not be more than 5 Kmph.
• Joints
• All joints shall be cut vertical to the full thickness of the previously
laid mix. All loosened material shall be discarded and the vertical
face coated with a suitable viscosity grade hot bitumen. The
material/mix shall be spread along the joint with a overlap of 25mm
to 50mm. The thickness of the loose overlap shall be ~ ¼ of final
compacted thickness. The overlap shall be dragged back to hot
lane and rolled to give a high density joint. Longitudinal joints shall
not be in wheel tract zones.

• Transverse joints in successive layers shall be with a minimum

off set of 2m.
• All joints shall be made flush.
 The requirements of grading, binder content, mix for
BM, DBM & BC shall be as detailed below.

• Bituminous Macadam: compacted thickness

of single layer- 50mm to 100mm
• Bitumen- As per contract specifications.
• The BM layer shall be protected with next
layer of pavement course or W.C within a
maximum period of forty eight hours. If there
is any delay it shall be covered by seal coat.
• The grading requirement and content of
bitumen shall be as given below.
The grading requirement and content of bitumen shall
be as given below.
Grading 1 2

Nominal Maximum aggregate 40mm 19mm

Size*
Layer thickness 80 -100mm 50-75mm
IS Sieve size (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4 – 19 4 – 19
0.3 2 – 10 2 – 10
0.075 0–8 0–8
Bitumen content ** percent by 3.3** 3.4**
mass of total mix
 The required physical properties of aggregate shall be as
specified below.

Property Test Requirement Test method

Cleanliness(dust) Grain size analysis Max. 5% passing 0.075 IS: 2386 Part I
micron
Particle shape Combined Flakiness and Max. 35% IS: 2386 Part I
Elongation indices
Strength Los Angeles Abrasion Max. 40% IS: 2386 IV
Value or Max. 30% IS: 2386 IV
Aggregate Impact value
Durability Soundness (Sodium or 5 Cycles
Magnesium) Max. 12% IS: 2386 Part V
Sodium Sulphate Max. 18% IS: 2386 Part V
Magnesium Sulphate
Water absorption Water absorption Max. 2% IS: 2386 Part III

Stripping Coating and Stripping of Min. Retained coating 95% IS: 6241
Bitumen Aggregate
Water sensitivity Retained Tensile Strength* Min. 80% AASHTO 283
 The other tests to be conducted on B.M are as follows
Bituminous i) Quality of binder
Macadam
ii) Aggregate Impact value or Los Angeles
Abrasion Value
iii) Combined Flakiness and Elongation
indices
iv) Stripping value
v) Water absorption of aggregates
vi) Water sensitivity of mix
vii) Grading of aggregates
viii)Soundness (Magnesium
sulphate/Sodium sulphate)
ix)Percentage of fractured faces
x) Binder content
xi) Control of temperature of binder and
aggregate for mix and of the mix at the
time of laying and rolling
xii)Density of compacted layer
.
Depending on the lot size, the no.of representative containers are
selected. Samples are drawn from each of such selected container.
On each of these samples viscosity, flash point and ductility tests are
conducted.
Remaining tests are done on samples obtained by mixing together of
bitumen from all individual samples proportionately.
One test per 200 cu.m. of each source and whenever there is change
in the quality of aggregate.
One test per 350 cu.m for each source
One test of each source and whenever there is change in the quality
of aggregate
- do -
- do -
2 tests per day
One test of each source and whenever there is change in the quality
of aggregate
1 test per 100cum of aggregate
Two tests per day per plant
At regular intervals
One test per 700 sq.marea
 DENSE GRADED BITUMINOUS MACADAM(DBM)

• The thickness of single layer shall be from

50mm to 100mm.
• The combined grading and bitumen content of
DBM shall be as fallows.
 Combined grading and Bitumen content of DBM shall be as follows
Grading 1 2
Nominal aggregate Size* 37.5mm 26.5 mm
Layer thickness 75 -100mm 50-75 mm
IS Sieve size (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
9.5 - -
4.75 38 – 54 38 – 54
2.36 28 – 42 28 – 42
1.18 - -
0.6 - -
0.3 7 – 21 7 – 21
0.15 - -
0.075 2–8 2–8
Bitumen content % by mass of total Min. 4.0** Min. 4.5**
mix
• The nominal maximum particle size is the largest specified
sieve size upon which any of the aggregate is retained.

• Corresponds to specific gravity of aggregates being 2.7. In

case aggregate have specific gravity more than 2.7, the
minimum bitumen content can be reduced proportionately.
Further the region wherein highest daily mean air
temperature is 300 C or lower and lowest daily air
temperature is - 100 C or lower, the bitumen content may
be increased by 0.5 percent.
 The physical properties of aggregates shall be as follows.

Property Test Specification Method of Test

Cleanliness (dust) Grain size analysis Max. 5% passing IS: 2386 Part I
0.075mm sieve
Particle shape Combined Flakiness and Max. 35% IS: 2386 Part I
Elongation indices*
Strength Los Angeles Abrasion Max. 35% IS: 2386 IV
Value or Max. 27%
Aggregate Impact value
Durability Soundness either: Sodium IS: 2386 Part V
Sulphate or Max. 12%
Magnesium Sulphate Max. 18%
Water absorption Water absorption Max. 2% IS: 2386 Part III

Stripping Coating and Stripping of Minimum retained IS: 6241

Bitumen Aggregate Mix coating 95%
Water sensitivity Retained Tensile Min. 80% AASHTO 283
Strength*
• To determine this combined proportion, the flaky stone
from a representative sample should first be separated out.
Flakiness index is weight of flaky stone metal divided by
weight of stone sample. Only the elongated particles be
separated out from the remaining (non-flaky) stone metal.
Elongation Index is weight or elongated particles divided by
total non-flaky particles. The values of flakiness index and
elongation index so found are added up.

• If the minimum retained tensile test strength falls below 80

percent, use of anti stripping agent is recommended to
meet the requirement.
 Apart from grading and quality of individual ingredients, the mix of DBM shall satisfy
the following requirements.
Properties Viscosity Grade Modified bitumen Test Method
paving Bitumen Hot climate Cold climate

Compaction level 75 blows on each face of the specimen

Minimum stability 9.0 12.0 10.0 AASHTO T245
(kN at 600 C)
Marshall flow 2–4 2.5 – 4 3.5 – 5 AASHTO T245
(mm)
Marshall Quotient 2–5 2.5 - 5 MS-2 and ASTM
Stability D2041
Flow
% Air Voids 3.5
% Voids Filled 65 – 75
with Bitumen
(VFB)
Coating of 95% minimum IS: 6241
aggregate particle
Tensile Strength 80% Minimum AASHTO T 283
ratio
 Q.C Tests for DBM Layer
ITEM CLAUSE TESTS REQUIRED FREQUENCY (Min) RELEVANT I.S. LIMITS
CODE
Dense 505 Density of 1 test per 700sq.m 92% of Gmm
Graded compacted layer area
Bituminous Quality of Binder . IS:1203-1220 As per IS 73
Macadam
Plasticity Index As required IS: 2720 part 5 ≤4%

Combined 1 set of test per 400 IS:2386,part-II As per MOST

gradation tons subjected to a table
minimum of two test
per plant per day
Bitumen content One test for 400 ASTM D-2172 Min 4%by
tonnes of mix weight of total
subject min of two mix for Grd-1
tests per plant per Min 4.5%for
day Grd-II
Temperature of At regular close 150oC to 1650C
Bitumen intervals
Temperature of --do-- 1500C to 1700C
Aggregate
Temperature of 150oC to 1650C
mixed material
ITEM CLAUSE TESTS REQUIRED FREQUENCY RELEVANT LIMITS
(MIN) IS CODE
Temperature of --do-- 1500C to 1700C
Aggregate
Temperature of mixed 150oC to 1650C
material
Temperature of laying At regular close VG.30=140
intervals VG.20=135
Temperature of Rolling --do-- VG.30=90
VG.20=85
Stability at 600C One set of test per ASTM D1559 <9 KN
400 tons subjected
to a minimum of two
test per plant per
day
Flow 2-4mm
Percent Air Voids 3-5
Percent Voids in mineral As per the table
aggregates
Percent Voids filled with 65-75
Bitumen
Temperature of Mix At regular close
intervals
 MINIMUM PERCENT VOIDS IN MINERAL AGGREGATE

Minimum VMA, percent related to design air voids present

Nominal Maximum Particle

size(mm) 3.0 4.0 5.0

26.5 11.0 12.0 13.0

37.5 10.0 11.0 12.0

 PERMISSIBLE VARIATIONS IN THE JOB MIX FORMULA
Subjected to the condition that final gradation shall remain within respective gradation band

DESCRIPTION BASE / BINDER COURSE WEARING COURSE

Aggregate passing 19mm sieve ±8% ±7%
or larger
Aggregate passing 13.2, 9.5 ±7% ±6%
mm sieve
Aggregate passing 4.75mm ±6% ±5%
sieve
Aggregate passing ±5% ±4%
2.36,1.18,0.6mm sieve
Aggregate passing 0.3,0.15mm ±4% ±3%
sieve
Aggregate passing 0.075mm ±2% ±1.5%
sieve
Binder content ±0.3% ±0.3%
Mixing Temperature ±100C ±100C
• Compaction
• The compactive layer of dense bitumen
Macadam(DBM) shall have a minimum field
density equal to or more than 92% of average
theoretical maximum specific gravity
obtained on the day of compaction in
accordance with ASTM D-2041.
 BITUMINOUS CONCRETE(BC)
• The thickness of single layer shall be from
50mm to 100mm.
• The combined grading and bitumen content of
DBM shall be as fallows.
 Physical requirements for Coarse Aggregate for Bituminous Concrete

Property Test Specification Method of test

Cleanliness(dust) Grain size analysis Max 5% passing I.S 2386PartI

0.0075mm sieve
Particle shape Combined Flakiness and Max 35% I.S 2386PartI
Elongation indices
Strength Los Angeles Abrasion Max30% I.S 2386PartIV
Value or Aggregate Impact Max24%
Value
Durability Soundness either: Sodium Max12% I.S 2386PartV
sulphate or Max18%
Magnesium Sulphate
Polishing Polished stone Value Min 55 BS:812-114

Water absorption Water Absorption Max2% I.S 2386Part III

Stripping Coating and Stripping of Minimum retained IS:6241

Bitumen Aggregate Mix coating 95%
Water Sensitivity Retained Tensile Strength Min 80% AASHTO 283

Plasticity Index Max 4%

 Composition of Bituminous Concrete Pavement Layer
Grading 1 2
Nominal aggregate size 19mm 13.2mm

Layer thickness 50mm 30-40mm

IS Sieve (mm) Cumulative % by weight of total aggregate passing

45

37.5

26.5 100

19 90-100 100

13.2 59-79 90-100

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 mass of total mix Min 5.2* Min 5.4**

• Note:
• The nominal maximum particle size is the largest
specified sieve size up on which any of the aggregate is
retained
• Corresponding to specific gravity of aggregate being
2.7 .In case aggregate have specific gravity more than
2.7, the minimum bitumen content can be reduced
proportionately. Further the region where highest daily
mean air temperature is 300 C or lower and lowest
daily air temperature is – 100 C or lower, the bitumen
content may be increased by 0.5 percent.
 Other Quality Control Tests on B.C are as fallows .
RELEVANT
ITEM CLAUSE TESTS REQUIRED FREQUENCY (Min) LIMITS
I.S. CODE
Bitumino 507 Quality of Binder Depending on the lot size, the
us no. of representative containers As per IS 73
Concrete are selected. Samples are drawn
from each of such selected
container. On each of these
samples viscosity, flash point and
ductility tests are conducted.

Remaining tests are done on

samples obtained by mixing
together of bitumen from all
individual samples
proportionately.

Binder Content One set of test per 400 tons

subjected to a minimum of two
test per plant per day
Combined One set of test per 400 tons IS:2386,part As per MOST
gradation/mix subjected to a minimum of two -II table
grading test per plant per day
Density of One test per 700 sq.m area 92% of Gmm
 RELEV
TESTS ANT
ITEM CLAUSE FREQUENCY (Min) LIMITS
REQUIRED I.S.
CODE
Plasticity Index One test for each source
and whenever there is
change quality of
aggregate
Temperature of At regular close intervals IS:1203 150oC to 1650C
Bitumen mix
Aggregate One test for350 cum of
impact value/los aggregate for each source
angeles abraison and whenever there is
change in quality of
aggregate.
Temperature of --do-- 1500C to 1700C
Aggregate Mix
Temperature of At regular close intervals VG 30 = 140
laying VG 20 = 135
Temperature of --do-- VG 30 = 90
Rolling VG 20 = 85
Flakiness and One test for350 cum of
Elongation index aggregate for each source
and whenever there is
Table:500-18: Permissible allowable variations in plant mix from
the job mix formula

DESCRIPTION WEARING COURSE

Aggregate passing 19mm sieve or ±7%
larger
Aggregate passing 13.2, 9.5 mm ±6%
sieve
Aggregate passing 4.75mm sieve ±5%
Aggregate passing ±4%
2.36,1.18,0.6mm sieve
Aggregate passing 0.3,0.15mm ±3%
sieve
Aggregate passing 0.075mm sieve ±1.5%
Binder content ±0.3%
Mixing Temperature ±100C
• Compaction
• The compactive layer of bitumen Concrete
shall have a minimum field density equal to or
more than 92% of average theoretical
maximum specific gravity obtained on the day
of compaction in accordance with ASTM D-
2041.
 Concrete/Rigid pavements
• Rigid pavements are usually constructed on a sub base
consisting of (a) Granular material OR (b) stabilized soil
OR(c) Semi Rigid material, usually DLC.
• Below this sub base, the sub grade shall have the following
properties.
• No soft spots are present in the sub grade
• It shall be coarse grained material
• The top 150mm thick layer of sub grade shall have drainage
property.
• When the DLC is used it shall be for 100mm thickness.
• The grading of aggregate (combined grading of fine and
coarse aggregates) shall be as follows
Aggregate Gradation for Dry Lean Concrete

Sieve designation Percentage by weight passing the sieve

26.50mm 100

19.0mm 75-95

9.50mm 50-70

4.75mm 30-55

2.36mm 17-42

600µ 8-22

300µ 7-17

150µ 2-12

75µ 0-10