CONSTRUCTION OF BITUMINOUS

LAYERS

Dr. Anjaneyappa
RV College of Engineering
anjaneyappa@rvce.edu.in
 Balancing Production

HMA Paving
Facility

Trucking Compaction

Delivery Construction 2
Flexible Pavements / Bituminous Pavements
1. Fill/ Subgrade - Soil Layers
2. Granular Layers ( Subbase & base layer) -GSB, WBM,
WMM, CRM
3. Bituminous Layers
3.1 Interface treatments
3.2 Thin Surface Layers
3.3 Thick Surface layers
4. Bituminous Binder Courses & Surface Courses
5. Functional & Structural Layers
Bituminous Layers _ Thick Layers
• Grouted / Penetration / Sprayed
Built Up Spray Grout
Penentration Macadam
• Bituminous Precoated Layers
Bituminous Macadam
Dense Bituminous Macadam
Bituminous Concrete
Bituminous Thin Layers - Structural Layer
• Semi Dense Bituminous Concrete - 25 mm

Bituminous Thin Function Layers

• Pre Mix Carpet with Seal Coat
• Mix Seal Surfacing
Hot Mix Asphalt, HMA

Asphalt

Aggregate

Types and Uses

 Time vs. Temperature

1 hour
60 C

1 hour 10 hours
25 C
 Stiffness (Response to Load)

elastic

viscous
elastic fluid
solid
viscous

-30 25 60 135
Temperature, C
Grading DBM – Grade I DBM – Grade 2 BC – Grade 1 BC – Grade 2
Nominal Size (mm) 40 25 19 13
Layer Thickness 80-100 mm 50-75 mm 50-65 30-45
(mm)
Sieve Size (mm) % Passing
45 100 -
37.5 95-100 100
26.5 63-93 90-100 100
19 - 71-95 79-100 100
13.2 55-75 56-80 59-79 79-100
9.5 - - 52-72 70-88

4.75 38-54 38-54 35-55 53-71

2.36 28-42 28-42 28-44 42-58
1.18 - - 20-34 34-48
0.6 - - 15-27 26-38
0.3 7-21 7-21 10-20 18-28
0.15 - - 5-13 12-20
0.075 2-8 2-8 2-8 4-10
Bitumen content (%) Min.4 Min 4.5 5.2 5..4
Grade of Bitumen 65-90 65-90 65 65
 Materials
 Bitumen – Shall be as per IS 73
 Aggregates –
 Coarse Aggregates( retained on 2.36mm)
 clean, hard, durable
 fulfil the physical requirements
 Fine Aggregates
 Passing 2.36 and retained on 0.075 mm
 Hard, durable, dry and free from dust
 Physical Requirements of Aggregates
Property Test DBM BC

Cleaniness Grain size Analysis Min.5% passing 0.075 Min.5% passing 0.075
mm mm
Particle Shape Flakiness & Max. 35% Max. 30%
Elongation
Strength LAA Max. 35% Max. 30%
AIV Max. 27% Max. 24%
Durability Soundness Max.12% ( Sod.Sul) Max.12% ( Sod.Sul)
Max .18% (Mg Sul) Max .18% (Mg Sul)

Polishing Polished Stone Value Min. 55

Water Obsorption Water Obsorption Max. 2% Max. 2%

Stripping Coating & Stripping Min retained 95% Min retained 95%

Water Sensitivity Retained Tensile Min. 80% Min.80%

Strength
 Blending of Aggregates
 Aggregates are crushed and sieved to separate
sizes
 40 mm, 20 mm, 12/10 mm, 6mm and dust
 Need to blend to get required gradation
 Control points for
Percent Passing, % 12. 5 nominal max. size
100
90
Gradation B
80
70
60
50
40
30
20 Gradation A
10
0
0.075 0.3 1 .18 4.75 9.5 12.5 19
Sieve Size, mm

Blending Stockpiles 13 Aggregates

A View of Pug Mill - Wet Mix Macadam
A View of Hot Mix Plant - Weigh Batch Type
 Permissible Variations by Job Mix Formula

Description Permissible Variation

Base / Binder course Wearing Course
Passing 19 mm / larger +/- 8 % +/ - 7%
Passing 13.2 mm, 9.5 mm +/ - 7% +/ - 6%
Passing 4.75% +/- 6% +/- 5%
Passing 2.36,1.18 & 0.6 +/-5 % +/- 4%
mm
Passing 0.3 mm & 0.15 mm +/- 4% +/- 3%
Passing 0.075 mm +/- 2% +/- 1.5%
Binder content % 0.3% 0.3%
Mixing temperature +/- 10 Deg +/- 10 Deg
 Requirements of Mix
Property DBM BC

Stability Min.kN 9.0 9.0

( at 60 degrees)
Flow (mm) 2 -4 2-4

Compaction 75 75
( # of blows)
Air Voids (%) 3-6 3-6

VMA (%) See Table See Table

VFB (%) 65-75 65-75

Loss of Stability on Min.75%

Immersion in water at 60
degrees
 Requirements of VMA

Nominal size Minimum VMA (%) related to air voids

(mm)
3.0 % 4.0 % 5.0 %

9.5 14 15 16

12.5 13 14 15

19.0 12 13 14

25.0 11 12 13

37.5 10 11 12
 Requirements of Mix – modified bitumen
Properties Requirement

Hot Climate Cold Climate High Rainfall

Marshall stability 12 kN 10kN 12 kN

Flow (mm) 2.5 -4 3.5-5 3-4.5

Marhall Quotient 250-500

(Kg/mm)
Voids % 3-5

Binder Content % BC Grade 1- 5.4 Grade 2 – 5.6

SDBC Grade1 4.7 Grade 2 - 5.2
DBM Grade 1 – 4.3 Grade 2 – 4.7
Retained stability 90 95 100
%
Coating of 95 95 100
Aggregates %
 Seggregation

 Segregation is the separation and consolidation

of large size aggregate from the finer particles
 May Occur
 Mixing plant
 During transportation

 Deficiencies in Paving
 Segregation at Plant
 Hang –up of feeders in bins ( moisture)

 Inadequate mixing time in pugmill

 Lack of replacement of broken/ twisted/ ineffective

paddles
 Level of material in pug mil

 Mix in motion ( free fall to hopper / truck)

 Segregation in Transport
 During movement coarser materials roll down

 Small batch in large truck

 During discharging in to paver hopper if rear gate does

not open fully . Partial openings prevent smooth flow,
cause hang up
 Seggregation on both sides of truck & material being
droped in paver in same condition
 Segregation in Paver Finisher
 Insuffcient material in hopper

 Material above the level of auger

 Corser mixes / lean mixes are more prone to

seggregation
 Weather and Seasonal Limitations
 Laying shall be suspended while free standing water is
present on surface / during rain/ dust storms
 Laying shall not be carried out when air temperature at
surface is below 10 deg or when the wind speed
exceeds 40 kmph
 Construction Operations

 Preparation of the receiving layer

 Cleaning
 Interface treatment
 Preparation of Mix
 Transportation of Mix
 Spreading
 Compaction
 Surface Finish Check
 Preparation of Receiving Surface

 Preparation of Existing Granular surface

 Remove loose material / Dust
 Careful on compaction on Compacted Layers

 Patching of potholes & sealing of cracks

 Cleaning

 Remove dust / loose material

 Interface Treatments

 Prime Coat
 Tack Coat
 Crack Prevention Courses
 Purpose of Priming

• To plug the capillary voids

• To coat and bond loose materials on the surface
• To harden or toughen the surface
• To promote adhesion between granular and the
bituminous layer
 Requirement for Priming Material

Porosity Type of Quantity per

Surface (Kg /sqm)

Low WMM, WBM 0.7-1.0

High Stabilised 0.9-1.2

base
 Tack Coat

Purpose of Tack Coat:

 To ensure a bond between the new
construction and the old surface
Use of Cutback:
 It should be restricted for sites at subzero
temperatures or for emergency applications
 Recommended Quantities of
Material for Tack Coat
Type of Surface Quantity in kg per
m2 area
Bituminous Surface 0.20 to 0.30

Primed granular surface 0.25 to 0.30

Cement concrete pavement 0.30 to 0.35

Preparation of Mix
 Manufacturing & Rolling Temperature

Bitumen Bitumen Aggregate Mixed Laying Rolling

Mixing mixing ( Material 9 ( Degrees) ( Degrees)
(Degrees) Degrees) Degrees)

VG40 160-170 160-175 160-170 150 min 100 min

VG 30 150-165 150-170 150-165 140 min 90 min

VG 20 145-165 145-170 145-165 135 min 85 min

VG 10 140-160 140-165 140-160 130 min 80 min

 Temperature Requirements for modified binders

Stage of Work Indicated temperature

(Degrees)
Binder at mixing 165-185

Aggregate temperature 165-185

Mix at mixing plant 150-170

Mix at Laying 130-160

Rolling 115-155
 Transportation of Mix

Delivery Construction 41
 Tarping Loads

Delivery Construction 42
 Laying of Mix

Delivery Construction 43
Delivery Construction 44
 Tracto
r
Hopper
Depth
Crank

Screed

Push
Rollers Tow Point Conveyors Augers
Side Arm

Construction Placement 47
 Correct Depth of
Mat Maintained

Constant Head of Material Volume

Screed Rises Due to

Excess Material Forced
Under Nose of Screed

Head of Material Volume Too High

Screed Settles Due to

Inadequate Supporting
Material

Head of Material Volume Too Low

Construction Placement 48
 Auger
Correct Overloaded Auger
Elevation Underloaded

Construction Placement 49
Construction Placement 50
Construction Placement 51
 Compaction

 Improve Mechanical Stability

 Improve Resistance to Permanent Deformation
 Reduce Moisture Penetration
 Improve Fatigue Resistance
 Reduce Low-Temperature Cracking Potential

Construction Compaction 52
 Types of Rollers

 Static Steel Wheel

 Pneumatic – Rubber Tired
 Vibratory

Construction Compaction Equipment 53

RASTA
Center for Road Technology

Static Steel Wheel Roller

Static Pressure
Weight
Speed Weight
Thickness
Temperature
Roller
Pneumatic Tired Rollers
 Wheel load
 Inflation pressure

 Contact area

Drum -Vibratory roller

Compacted high spots Uncompacted low spots

Front tires

Road surface
Vibratory Rollers
 Load
 Amplitude
 Frequency
 Impact Spacing
 Operation

Construction Compaction Equipment 57

 Low Frequency High Frequency

Impact Spacing

FREQUENCY
DIRECTION OF TRAVEL

Construction Compaction Equipment 58

 AMPLITUDE

Construction Compaction Equipment 59

Construction Compaction 60
Construction Compaction 61
 Construction of Joints

 Transverse joint
 Preferably Vertical Joint
 Staggering of joints at least by 2 meters
 Spraying of bitumen on face
 Heating of Screed
 Longitudinal Joint
 Not be located on same line
 At 150 mm offset
 Vertical face
 Overlap of 25 to 50 mm with previously laid surface
 Rolling operations

 Depends on
 Thickness
 Speed

 Length of rolling zone

 Number of rollers
 Rolling Sequence

 Transverse Joint
 Longitudinal Joint
 Overlap of 150-175 mm
 Lower to Higher edge
 Rolling Operation

 Break down rolling

 Intermediate Rolling
 Finish Rolling
 Breakdown Rolling
 Use smooth wheel rollers/ Static passes
 Breakdown rolling must achieve majority of required
compaction
 An ineffective first pass may make final pass difficult to
achieve
 Compaction is achieved by imparting vertical movement
to mix through roller load
 There should not be any horizontal movement of mix
 Horizontal movement will cause heaving of material
 Crawling of mixture ahead of roller and formation of
ridges
 When movement of mix is observed allow the mix to
cool ( break down temperature)
 Compaction helps in retaining the heat

 Rolling zone at 50 m
 Intermediate Rolling
 After breakdown rolling when mix still in plastic
state
 Pneumatic rollers more suitable
 Pneumatic rollers may not increase the density
substantially
 It does increase the stability of mix by kneading and
reorientation of particles
 More uniform compaction
 Sealing of layer ( tire pressure 0.7 to 0.9 Mpa)
 Finish Rolling
 Carried out while material still in warm condition
 For removal of tire marks
 Precautions for Rolling

 Uniform speed
 Never allow compactor to stand
 Jerky start , sudden braking, sharp changes not
to be made
 Change of lane to made only on already
compacted surface
 Steel wheels / pneumatic wheels cause loss of
heat
 Small amount of detergent / Vegetable oil
Laying of DBM Binder Course -
Compaction by Vibratory Roller and
Pneumatic Roller in Progress
 High

Passing
Density
Density

Low
1 2 3 4 5 6
Roller Passes
Construction Compaction Equipment 73
 Dense Bituminous Madacam/ Semi Dense Bituminous
Concrete/ Bituminous Concrete
Quality of Binder Two Samples per lot to be
subjected to all or some tests as
directed by the Engineer
Aggregate Impact Value One Test per 350 m3 of Aggregate

F I and E I of Aggregates One Test per 350 m3 of Aggregate

Soundness 1 test per Source

Water Absorption of - do -
Aggregates
 Marshall test and binder content for each 400
tonnes of mix subject to minimum two test per
day
 Density for every 700 sqm area
Construct trail stretch for Project Conditions
and fix up guidelines
 Not to adopt the guidelines of constructions
adopted for projects constructed elsewhere /
others
 MAX. PERMISSIBLE ROUGHNESS VALUES (mm/km) –
IRC:SP-16 : 2004

Surface Good Average Poor

Type
CC < 2200 2200 - 3000 > 3000
BC < 2000 2000 - 3000 > 3000

PMC/ MSS < 3000 3000 - 4000 > 4000

SD < 3500 3500 - 4500 > 4500
 Construction of Bituminous layers
 Over heating
 Heating for Longer duration
 Improper gradation
 Improper gradation in spite of fulfilling the required gradation
 Exposure of DBM layer for heavy axle traffic and rainy
conditions for longer duration
 Paving for shorter stretches
 Compaction of Bituminous Layers
 High vibration
 Compaction at lower temperature
 Bituminous Layers
 Preparation of Receiving Layer
 Attending all distresses
 Cleaning & Interface treatment
 Loading of Bituminous mix in to trucks at HMP
 Covering of Mix during transportation using Tarpaulins
 Quantity of Mix in Paver
 Width / lane marking for Paving
 Rolling on Bituminous Layers
 Vibration on asphalt layers
 Static / pneumatic rolling on thin layers
 Labour is Keyman
Best Materials ,Best Design, Best Engineering
Expertise, Best Equipment,

Handled & Executed by Skilled / Unskilled Labour

& Trained / Untrained Operators

Need to Train Labours

Attract and retention of labours in the industry
Results in better product / savings in money
 Construction Cost Break Up
 Materials = 50%
 Plants and Machinery = 15-20%
 Human Resources = <10%

Optimization of these Resources important ( optimum

utalisation, Increase time efficiency)
Small % saving results in huge money
Thank you for Your Valuable Time