IRC: 19-1977

STANDARD SPECIFICATIONS
AND
CODE OF PRACTICE
FOR
WATER BOUND MACADAM
(SecondRevision)
THE INDIAN ROADS CONGRESS
1988
<<
IRC: 19-1977
STANDARD SPECIFICATION
AND
CODE OF PRACTICE
FOR
WATER BOUND
MACADAM
(Second Revision)
Published by
THE INDIAN ROADS CONGRESS
Jamanagr House, Shahjahan Road,
New Delhi-110 011
1988
Price Rs. 80/-
(Plus Packing & Postage)
<<
!RC : 19-1977
First published in April, 1966
Reprinted : February, 1970
Reprinted May, 1972
First Revision November, 1972
Second Revision: May, 1977
Reprinted : September. 1982
Reprinted March, 1987 (incorporates amendment No. I &
corrected Sieve sizes)
Reprinted May, 1988
Reprinted
Reprinted
March, 1999
October, 2000
(Rights of Publication and of Translation are reserved)
Printed at Dee Kay Printers, New Delhi
(500 copies)
<<
IRC: 19-1977
STANDARD SPECIFICATION AND CODE OF
PRACTICE FOR WATER BOUND MACADAM
1. INTRODUCrION
1.1. This standard was originally published in 1966. The
revised standard was considered and approved by the Specifications
and Standards Committee in their meeting held on the 29th & 30th
September, 1972 and by the Executive Committee in their meeting
held at Gandhinagar on the 25th November, 1972. Later, it was
approved for publication as the finafised standard by the Council in
their 79th meeting also held at Gandhinagar on the 25th November,
1972.
1.2. Following the decision of the IRC Council at its meeting
held on the 28th August 1976, the tolerances of surface evenness
have been revised on the basis of IRC Special Publication 16 Sur-
face Evenness of Highway Pavements.
1.3. The Standard is intended to indicate what is consi-
dered to be a good practice for the construction of water
bound macadam and surface treated water bound macadam.
2. DESCRIPTION
2.1. Water bound macadam shall consist of clean crushed
coarse aggregates mechanically interlocked by rolling, and voids
thereof filled with screening and binding material with the assistance
of water, laid on a prepared subgrade, sub-base, base or existing
pavement as the case may be. Water bound macadam may be used
as a sub-base, base course or surfacing course. In each case, it shall
be constructed in accordance with the specifications given below
and in conformity with the lines, grades and cross-sections shown
on the drawings or as otherwise directed.
3. MATERIALS
3.1. Coarse AggregatesGeneral Requirements
3.1.1. Coarse aggregates shall be either crushed or broken
stone, crushed slag, overburnt brick metal or naturally occurring
aggregates such as kankar or laterite of requisite quality as stated
hereinafter, The aggregates shall conform to the physical require-
ments set forth in Table 1.
3.1.2. Crushed or broken stone: Crushed or brokcn stone
shall be hard, durable and generally free from flat, elongated, soft
I
<<
IRC 19-1977
and disintegrated particles. It shall also not have excess of dirt
or other objectionable matter.
TABLE 1. PHYsICAL REQunIEMENT5 OF Co.s~ssAGORFOATES FOR
WATERBOUND MACADAM
Si .
No.
Typeof Test t
construction
Test Requirement
method
1. Sub base Los Angeles IS : 2386 Max. 60%
Abrasion (Part IV)
Value
or
Aggregate iS 2386 Max. 50%
impact (Part IV)
Value or
IS : 5640
2. Base course (a) Los Angeles IS : 2386 Max. 50%
with Abrasion (Part IV)
bituminous Value
surfacting or
Aggregate IS 2386 Max. 40%
Impact Value (Part IV)
or
IS : 5640
(b) Flakiness IS 2386 Max. 15%
Index (Part 1~
3. Surfacing (a) Los Angeles IS 2386 Max. 40%
Course Abrasion (Part IV)
Value
Or
Aggregate IS : 2386 Max. 30%
Impact Value (Part IV)
or
IS : 5640
(b) Flakiness IS : 2386 Max. 15%
Index (Part I)
Note: Aggregates may satisfy therequiremens of either the Los Angeles
test or Aggregate Impact Value Test.
Aggregates like brick metal, kankar and laterite which get softened
in presence of water, should invariably be tested for impact value
under wet conditions in accordance with IS: 5640.
The requirement of Flakiness Index shall be enforced only in the
case of crushed/broken stone and crushed slag,
t Samples for tests shall be representative of the materials to be
used and collected In accordance with the procedure set forth In
IS: 2430.
2
<<
IRC: 19-1977
3.1.3. Crushed slag: Crushed slag shall be manufactured
from air-cooled blast furnace slag. It shall be of angular shape,
reasonably uniform in quality and density, and generally free
from any thin, elongated and soft pieces, dirt or other objectionable
matter. Crushed slag shall not weigh less than 1120 kg per
m
3 and the percentage of glassy material in it shall not be in excess
of 20. Water absorption [IS : 2386 (Part III)] of slag shall not
exceed 10 per cent.
3.1.4. Overburut brick metal : Brick metal shall be made
out of overburnt bricks or brick bats and be free from dust and
other foreign matter.
3.1.5. Kankar: Kankar shall be tough having a blue
almost opalescent fracture. It shall not contain any clay in
the cavities between nodules.
3.1.6. Laterite: Laterite shall be hard, compact, heavy and
of dark colour. Light coloured sandy laterities as also those con-
taining a good bit of ochreous clay shall not be utilised.
3.2. Coarse AggregatesSize and Grading Requirements
3.2.1. As far as possible, coarse aggregates shall conform to
one of the gradings given in Table 2. Grading 1 is more suitable
for sub.base courses, but it is not tenable for a compacted layer
thickness of less than 90 mm.
3.2.2. The size of aggregates to be used in a given case would
depend on the type of aggregates available and compacted
thickness of the layer. The use of grading I shall, however, be
restricted to sub-base courses only.
3,2.3. For crushable type aggregates like brick metal, kankar
and laterite, the gradings given in Table 2 are not so relevant and
need not be strictly enforced but the material should generally be
within the size range indicated.
3
<<
IRC :19-1977
TABLE 2. Sizs AND GRADING REQUIRFMENT5 OP CoARsE
AGGREGATES ma WBM
Grading
No.
Size range Sieve
designation
(IS : 460)
Per cent by weight
passing the sieve
I, 90mmto45mm 125mm
90mm
63 mm
45 mm
22.4 mm
100
90100
2560
015
05
2. 63 mm to 45 mm 90mm
63mm
53 mm
45mm
lL4mm
100
90100
2575
015
05
3. 5 3 mm to 22.4 mm
63 mm
53 mm
45 mm
22.4 mm
11.2mm
100
95100
6590
010
0S
3.3. ScreenIngs
3.3.1. Screenings to fill voids in the coarse aggregates shall
generally be of the same material as the coarse aggregates. How-
ever, from economic considerations, predominantly non-plastic
material such as kankar nodules, moorum or gravel (other than
river-borne rounded aggregate) may also be utilised for this pur-
pose provided that the liquid limit and plasticity index of such
material is below 20 and 6 respectively and the fraction passing 75
micron sieve does not exceed 10 per cent.
3.3.2. As far as possible, screenings shall conform to the
gradings shown in Table 3. Screenings oftype A in Table 3 shall be
used in conjunction with coarse aggregates of grading I in Table 2,
and of type B with coarse aggregates of grading 3. With coarse
aggregates of grading 2, either type A or type B screenings may be
used. For screenings like moorum and gravel, the gradings given
in Table 3 shall not be regarded as binding.
3.3.3. The use of screenings may be dispensed with in the
case of crushable type coarse aggregates such as brick metal,
kankar and laterite.
4
<<
11W: 19-1~fl
TABLE 3. GRADING RECIUIRFMENTS OP ScREININOS
FOR WATER BOUND MACADAM
Gradingj
Classifica..
tion
Size of
screenings
Sieve
designation
(IS : 460)
Per cent by weight
passing thesieve
A 13.2 mm 13.2 mm
11.2 mm
5.6mm
180 micron
100
95100
1535
010
B 11.2mm 11.2mm
5.6 mm
l80mlcron
100
90100
1535
3.4. Binding Material
3.4.1. Binding material to prevent ravelling of water bound
macadamshall consist of a fine grained material passing 100 per
cent through 425 micron sieve and possessing P.!. value of 49
when the WBM is to be used as a surfacing course, and upto 6
when the WBM is being adopted as a sub-base/base course with
bituminous surfacing. If limestone formations are available
nearby, limestone dust or kankar nodules may be usefully
employed for this purpose.
3.4.2. Application of binding material may not be necessary
where the screenings consist of crushable type material like moo-
rum or gravel. However, for WBM used as a surfacing course,
where the P.!. of crushable type screenings is less than 4, applica-
tion of a small amount of binding material having P.!. of 49
would be required at the top. The quantity of screenings could be
reduced slightly on this account.
3.5. Quantities of Material
3.5.1. Approximate quantities of coarse aggregate and
screenings required for 100 mm compacted thickness of WBM sub-
base course are shown in Table 4. Likewise, rough quantities of
materials for WBM base or surfacing course for a compacted
thickness of ~5 mm are given in Table 5.
3.5.2. The quantity of binding material where it is to be used
(see para 3.4.), will depend on the type of screenings and function
of WBM. Generally, the quantity required for 75 mm compacted
thickness will be 0.060.09 m
8/lOm2 in the case of WBM
5
<<
1RC :19-1977
TABLE4. APPRoxIMATE QUANTITIrs Op Co~as~AGGREGATES AND
SCREENINGS REQUIRED FOR 100 mmCOMPACTED
THIcKNEsS OF WUM SUB-BAsE Couase ma 10 m
Coarse Aggregates
Screenings
Classi- Size Loose
fication range quantity
Ston
e screen~
Crushable type such
as moorum or gravel
Gradlng( Loose
classifica- quantity
tion &
size
Grading/ Loose
classifica- quantity
tion &
size
6 7
1 2 3
4 5
Grad- 90 to 1,21 to Type A 0,27 to Not 0.30 to
jag 1 45 mm 1.43 m~ 13.2 mm 0,30 m uniform 0.32 m
TAll.! 5. APPRoXIMATE QUANTITIES OP COARSE AOGRE0ATES AND
ScREENINGs REQUIRED FOR 75 mm CoMPAcTEDTHicK-
NESS OF WBM BASE COURSE~SURPACINOCouasama 10 m
1
Coarse Aggregates Screenings
Classi- Size Loose
fication range quantity
Stonescreenings
Crushable type
such as tnoorum
or gravel
Grading/ All
classifi- cases
cation
& size
7 8
1 2 3
Grading For For
classifi. WBM WBM
cation base surfa-
& size course cing
course
4 5 6
Grad- 63 to 0.91 Lo Type A 0.12 to 0.10 to Not 0.22 to
jag 2 45 mm 1.07 m 13.2 mm 0.15 & 0.12 m uniform 0.24 m
-do~ -do- -do- Type B 0.20 to 0.16 to -do- -do-
11.2mm 0.22m 0.18m
Grad- 53 to -do- -do- 0.18 to 0.14 to -do- -do-
ing 3 22.4 mm 0.21 m 0.17 m
Quantities in col. 6 are 80 per cent of those in col. 5 as a larger quantity of
binding material will need to be used when the WBM is to act as a surfacing
course (see para 3.52.)
Seepars 3.4.2.
6
<<
IRC: 19.1977
sub-base/base course and 0.10-0.15 m
8f10 m2 when the WBM is to
function as a surfacing course. For 100 mm thickness, the quantity
needed respectively will be 0.080.l0 m3/10 m2 and 0.120.16 m3/
10 m2.
3.5.3. The above mentioned quantities should be taken as a
guide only, for estimation of quantities for construction etc.
4. CONSTRUCTION PROCEDURE
4.1. Preparation of Foundation for Receiving
the WBM Course
4.1.1, The subgrade, sub-base or base to receive the water
bound macadam course shall be prepared to the required grade
and camber and cleaned of all dust, dirt and other extraneous
matter. Any ruts or soft yielding places that have appeared due
to improper drainage, service under traffic or other reasons shall
be corrected and rolled until firm.
4.1.2. Where the water bound macadam is to be laid on an
existing unsurfaced road, the surface shall be scarified and re-
shaped to the required grade and camber as necessary. Weak
places shall be strengthened, corrugations removed and depressions
and potholes made good with suitable material before spreading
the coarse aggregates for WBM.
4.1.3. Where the existing road surface is black-topped,
50 mm x 50 mm furrows shall be cut in the existing surface at
1 metre intervals at 45 degree to the centre live of the carriageway
before proceeding with the laying of coarse aggregates.
4.1.4. In all cases, the foundation shall be kept well-drained
during the construction operations.
4.2. Provision of Lateral Confinement of Aggregates
4.2.1. Before starting with WBM construction, necessary
arrangements shall be made for the lateral confinement of aggrega-
tes. One method is to construct side shoulders in advance to a
thickness corresponding to the compacted layer of the WBM
course. After shoulders are ready, their inside edges may be
trimmed vertical and the included area cleaned of all spilled
material thereby setting the stage for spread of coarse aggregates.
The practice of constructing WBM in a trench section excavated
in the finished formation must be completely avoided.
7
<<
ZRC :19-1977
4.3. SpreadIng Coarse Aggregates
4.3.1. The coarse aggregates shall be spread uniformly and
evenly upon the prepared base in required quantities from stock-
piles along the side of the road or directly from vehicles. In no
case shall these be dumped in heaps directly on the area where
these are to be laid nor shall their hauling over a partly completed
base be permitted. The aggregates shall be spread to proper pro.
file by usingtemplates placed across the road about 6 metre apart.
Where possible, approved mechanical devices shall be used to
spread the aggregates uniformly so as to minimise the need for
their manipulation by hand.
4,3.2. The WEM course shall normally be constructed in
layers of not more than 75 mm compacted thickness. However,
for aggregates of grading No. 1 in Table 2, the compacted thick-
ness of layer may go up to 100 mm. Each layer shall be tested by
depth blocks. No segregation of large or fine particles shall be
allowed; the coarse aggregates as spread shall be of uniform
gradation with no pockets of fine material.
4.3.3. The coarse aggregates shall normally not be spread in
lengths exceeding three days average work ahead of the rolling
and bonding of the preceeding section.
4.4. Rolling
4.4.1. After the laying of coarse aggregates, these shall be
compacted to full width by rolling with either three wheel power
roller of 6 to 10 tonnes capacity or an equivalent vibratory roller.
The weight of the roller shall depend on the type of the coarse
aggregates.
4.4.2. The rolling shall begin from edges with roller
running forward and backward until the edge have been firmly
compacted. The roller shall then progress gradually from edges
to the centre, parallel to the cenire line ci the road and lapping
uniformly each precding rear wheel track by one ball width and
shall continue until the entire area of the course has been rolled
by the rear wheel. Rolling shall continue until the road metal
is thoroughly keyed and the creeping of stone ahead of the roller
is no longer visible. Slight sprinkling of water may be done, if
required.
8
<<
IRC :19-1977
4.4.3. On superelevated portions of the road, rolling shall
commence fromthe lower edge and progress gradually towards
the upper edge of the pavement.
4.4.4. Rolling shall not be done when the subgrade is soft or
yielding nor when it causes a wave-like motion in the base course
or subgrade. If irregularities develop during rolling which exceed
12 mm when tested with a 3~metrestraight edge, the surface shall
be loosened and aggregates added or removed as required before
rolling again so as to achieve an uniform surface conforming to the
desired cross section and grade. The surface shall also be checked
transversely by template for camber, and any irregularities correc-
ted in the manner described above. In no case shall the use of
screenings to make up depressions be permitted.
4.5. Application of Screenings
4.5.1. After coarse aggregates have been rolled as per para
4.4, screenings to fill the interstices shall be applied gradually
over the surface. Dry rolling shall be done when the screenings
are being spread so that the jarring effect of roller causes them
to settle into the voids of the coarse aggregates. The screenings
shall not be dumped in piles but applied uniformly in successive
thin layers either by the spreading motion of hand shovels,
mechanical spreaders, or directly from trucks. Trucks plying
over the base course to spread screenings shall be equipped with
pneumatic tyres and so operated as not to disturb the coarse
aggregates.
45.2. The screenings shall be applied at a slow rate in three
or more applications as necessary. This shall be accompanied by
rolling or brooming. Either mechanical brooms/hand brooms or
both may be used. In no case shall the screenings be applied so
fast and thick as to form cakes or ridges on the surface making
the filling of voids difficult or preventing the direct bearing of roller
on the coarse aggregates. The spreading, rolling and brooming of
screenings shall be taken up on sections which can be completed
within one days operation. Damp and wet screenings shaH not
be used in any circumstances.
4.6. Sprinkling and Grouting
4.6.1. After application of screenings, the surface shall be
copiously sprinkled with water, swept and rolled. Hand brooms
shall be used to sweepthe wet screenings into the voids, and to
distribute them evenly. The sprinkling, sweeping and rolling
operations shall be continued and additional screenings applied
where necessary until the coarse aggregates are well-bonded and
9
<<
IRC :19-1977
firmly set and a grout of screenings and water forms ahead of the
wheels of the roller. Care shall be taken that the base or subgrade
does not get damaged due to addition of excessive quantites of
water during the construction.
4.7. Application of Binding Material
4.7.1. After the application ofscreenings as per paras 4.5.
and 4.6., binding material where it is required to be used (see para
3.4.), shall be applied at an uniform and slow rate in two or more
successive thin layers. After each application of binding material,
the surface shall be copiously sprinkled with water and the resul-
ting slurry swept in with hand brooms/mechanical brooms or both
so as to fill the voids properly. This shall be followed by rolling
with a 6.10 tonne roller during which water shall be applied to the
wheels to wash down the binding material that may get stuck to
them. The spreading of binding material, sprinkling of water,
sweeping with brooms and rolling shall continue until the slurry
of binding material and water forms a wave ahead of the wheels of
moving, roller.
4.8. Setting and Drying
4.8.1. After final compaction of the course, the road shall
be allowed to cure overnight. Next morning, hungry spots shall
be filled with screenings or binding material, Iigtly sprinkled with
water if necessary, and rolled. No traffic shall be allowed till the
macadam sets.
4.8.2. In the case of water bound macadam base course to
be provided with bituminous surfacing, the latter shall be laid only
after the WBM course is completely dry and before allowing any
traffic on it,
4.9. Plying of Construction Traffic
4.9.1. In general, construction traffic may ply over comple-
ted portions of the WBM course provided vehicles move over its
full width avoiding any rutting or uneven compaction. However,
the Engineer-in-Charge shall have full authority to stop the passage
of construction traffic when in his opinion this is leading to exces-
sive damage.
5. SURFACE EVENNESS OF WBM COURSE
5.1. The surface evenness of completed WBM course in
longitudinal and transverse directions shall be within the tolerances
indicated in Table 6.
10
<<
IRC :19-1977
TABLr 6, PERMrrrED TouRA?~cFsOF SURFACE EvENNESs FOR
WBM Couasrs
SI,
No,
Size range of
coarse aggregates
Longitudinal profile measured
with a 3 metre straight edge
Cross profile
Max. permissible Maximum num-
undulaiion ber of undula
tions permitted
in any 300
metre length,
exceeding
Max. permissible
variation from
specified profile
under a camber
template
mm 12mm 10mm mm
I. 90-45mm 15 30 12
2. 63-45 mm
or 53-22.4 mm
12 30 8
5.2, The longitudinal profile shall be checked with a 3 metre
long straight edge at the middle of each traffic lane along a line
parallel to the centre line of the road. The transverse profile shall
be checked with a series of three camber boards at intervals of 10
metre. For detailed guidance in this respect, reference may be
made to IRC Special Publication 11 Handbook of Quality Control
br Construction of Roads and Runways (Second Revision).
6. RECTIFICATION OF DEFECTIVE
CONSTRUcTION
6.1. Where the surface irregularity of the WBM courses
exceeds the tolerances given in Table 6 or where the course i-
otherwise defective due to subgrade soil mixing with the aggre
gates the layer to its full thickness shall be scarified over the
affected area, reshaped with added material, or removed and
replaced with fresh material as applicable, and recompacted in
accordance with para 4. The area treated in the aforesaid manner
shall not be less than 10 m~. In no case shall depressions be filled
up with screenings or binding material.
7. CONSTRUCTION OF WBM OVER
NARROW WIDTHS
7.1. Where the WBM course is to be constructed in narrow
widths for widening an existing pavement, the following sequence
of operations should be adopted
(i) The existing shoulders should be excavated to their full
11
<<
IRC: 19-1977
depth and width upto the subgrade level except where the wide-
ning specifications envisage laying of a stabilised-soil sub-base using
in situ operations in which case the same should be removed only
upto the sub-base level.
(ii) Before proceeding with the laying of WBM course, the
shoulders should be rebuilt inlayers in reduced width depending
on the extent of widening. The compacted thickness of each layer
should correspond to the compacted layer of WBM course to be
laid adjacent to it. After compaction, the inside edges of shoulders
should be trimmed vertical and the included are a cleared of all
spilled material; and
(iii) The construction of WBM layer should then follow in
the usual manner.
8. MAINTENANCE OF WBM
WEARING COURSES
8.1. The successful performance of WBM as a surfacing
course depends to a large extent on timely maintenance. Mainten-
ance measures for this can be considered under three heads: perio-
dic patching of pct-holes along with removal of ruts and depres-
sion; blinding of the surface; and surface renewal.
8.2. Patching of Pot-boles Along with Removal of Ruts and
Depressions
8.2.1. Pot-holes, ruts andother depressions should be drained
of water and cut to regular shape with vertical sides. All the loose
and disintegrated material shall be removed and the exposed sur-
faces swept clean. The holes/depressions shall then be filled with
salvaged coarse aggregates mixed with sufficient quantity of fresh
aggregates and recompacted as normal WBM to operations
described in para 4 so that the patched area merges with the
adjoining surface. Where the area so treated is small, hand ram-
mers may be used for compaction instead of rollers.
8.3. BlindIng of Surface
8.3.1. Blinding of the surface shall be resorted to periodi-
cally as soon as the blinding material applied earlier has been
eroded away due to a traffic or weather action and the surface has
started showing signs of ravelling. Blinding operations shall consist
of application of binding material in thin layers and grouting in
accordance with the procedure given in para 4.7.
12
<<
IRC: 19-1977
8.4. Surface Renewal
8.4.1. WBM wearing course shall be renewed when the
surface is worn out, is corrugated and badly ravelled or has a pro-
fusion of potholes and depression which cannot be treated econo-
mically with patching or blinding operations.
8.4.2. For renewal, the existing surface shall be scarified to
a depth of 50-75 mm and the resulting material removed to berms
for screening to salvage the usable coarse aggregates. The exposed
pavement shall be scarified again at high spots so as to ensure
proper grade and camber. The salvaged coarse aggregates mixed
with sufficient quantity of fresh aggregates (usually between one
half to one third of the quantity of salvaged aggregates) shall then
be used to construct a new WBM course in accordance with
para 4.
13 <<