CONSTRUCTION STEPS OF FLEXIBLE PAVEMENT

Introduction

Pavement construction is a part of the total pavement management process, which includes planning,
design, construction, maintenance, evaluation, and rehabilitation. Conventional flexible pavements are
layered systems with better materials on top where the intensity of stress is high and inferior materials
at the bottom where the intensity is low. Adherence to this design principle makes possible the use of
local materials and usually results in a most economical design. This is particularly true in regions where
high-quality materials are expensive but local materials of inferior quality are readily available.

Aim

Construction Steps

Layers of Flexible Pavement

Natural Sub-grade

The top soil or sub-grade is a layer of natural soil prepared to receive the stresses from the layers above.

Purpose

The purpose of the subgrade is to provide a platform for construction of the pavement and to support
the pavement without undue deflection that would impact the pavement's performance. For pavements
constructed on-grade or in cuts, the subgrade is the natural in-situ soil at the site.

Materials Used

natural soil

Quality Control

It is essential that at no time soil sub-grade is overstressed. It should be compacted to the desirable
density, near the optimum moisture content.

Process/Method

The upper layer of this natural soil may be compacted or stabilized to increase its strength, stiffness,
and/or stability.

Compacted Sub-grade

Purpose/Function

For pavements constructed on embankment fills, the sub-grade is a compacted borrow material. 

Thickness
6’’

Materials Used

Compacted sub-grade may be a layer of selected material.

Process/Method

The compacted sub-grade is constructed by spreading the loose soil and compacting the same at
optimum moisture content of the soil in layer. The maximum compacted thickness of each layer is
generally limited to 200 mm.

Time Require

Quality Control

Sub-Base Coarse

The subbase is a layer or layers of specified or selected materials of designed thickness placed on a sub-
grade to support a base course. The sub-base layer is usually of somewhat lower quality than the base
layer. In some cases, the sub-base may be treated with Portland cement, asphalt, lime, flyash, or
combinations of these admixtures to increase its strength and stiffness. A subbase layer is not always
included, especially with rigid pavements. A subbase layer is typically included when the subgrade soils
are of very poor quality and/or suitable material for the base layer is not available locally, and is,
therefore, expensive. Inclusion of a subbase layer is primarily an economic issue, and alternative
pavement sections with and without a subbase layer should be evaluated during the design process.

Purpose/Function

To serve as an effective drainage layer to drain off the water entering into the pavement layers, leading
to the longitudinal road side drains such that only a very small proportion of water enters into the sub-
grade. To serve as a structure component of the flexible pavement structure by distributing the wheel
load stresses transmitted through the surface course and base course.

Thickness

4’’-12’’

Materials Used

1. Crushed stone aggregates 2. Gravel 3. Coarse sand

Process/Method

The sub-base material is spread to uniform thickness and specified cross slope using a motor grader by
adjusting the blade of grader. The moisture content of the material is checked and the additional
quantity of the water required to bring up to OMC is sprinkled. The loose GSB layer is compacted by
rolling. Rolling is continued till at least 98% of maximum density of the material.

Time Require

Quality Control

Minimum of one moisture content test is to be carried out per 250 m2 area and minimum of density
test per 500 m2 area on each compacted area.

Base Course

The base is a layer or layers of specified or select material of designed thickness placed on a subbase or
subgrade (if a subbase is not used) to provide a uniform and stable support for binder and surface
courses. The base layer typically provides a significant portion of the structural capacity in a flexible
pavement system 

Purpose/Function

Base course is considered as the most important component of flexible pavement layer which sustains
the wheel load stresses and disperses through larger area on the sub-base layer below. It provides
additional load distribution and contributes to the sub-surface drainage and frost resistance.

Thickness

6’’-8’’

Materials Used

Durable aggregate( crushed stone , crushed slag), Water Bound Macadam(WBM).

Process/Method

Base course is prepared by depositing high quality aggregate like crushed stone, on a prepared surface
by hauling vehicles, spreading and mixing with a motor grader, watering and compacting with a
vibratory roller.

Time Require

Quality Control

Los Angeles abrasion value: less than 40% Or Aggregate impact value: less than 30%, Combined flakiness
and elongation index : less than 30%, Plasticity index of material finer than 0.425 mm sieve : less than 6
Minimum of one set of aggregate impact, flakiness index and elongation index tests are to be conducted
per 200 m3 of aggregate and minimum of one density test per 500 m2 on each compacted layer.
Prime Coat

Purpose/Function

It is essential to provide an appropriate type of interface treatment before laying any type of bituminous
layer over another layer. A prime coat is an application of low-viscosity cutback asphalt to an absorbent
surface, such as an untreated granular base on which an asphalt layer will be placed. Its purpose is to
bind the granular base to the asphalt layer. Penetrate deep into the surface and seal the void on the
surface. 

Thickness

Materials Used

Process/Method

Prime coat is applied by spraying liquid bituminous binder of low viscosity.

Time Require

24 to 72 hours

Quality Control

Binder Course

Purpose/Function

This layer provides the bulk of the asphalt concrete structure. There are two reasons that a binder
course is used in addition to the surface course. First, the HMA is too thick to be compacted in one layer,
so it must be placed in two layers. Second, the binder course generally consists of larger aggregates and
less asphalt and does not require as high a quality as the surface course, so replacing a part of the
surface course by the binder course results in a more economical design.

Thickness

3” normaly

Materials Used

Aggregate having low quality and less asphalt

Process/Method

The surface is thoroughly cleaned free of dust. Prime coat is applied by spraying liquid bituminous
binder of low viscosity. After curing of the prime coat, a tack coat is applied by spraying liquid
bituminous binder of low viscosity. Crushed aggregate and bituminous binder heated and mixed in a hot
mix plant at specified temperature, transported to the site, laid with mechanical paver and compacted
by roller.

Time Require

The bituminous macadam shall be covered with either the next pavement course or wearing course, as
the case may be, within a maximum of forty-eight hours.

Quality Control

Bituminous materials shall be laid and compacted in layers, which enable the specified thickness, surface
level, regularity requirements and compaction to be achieved.The initial or breakdown rolling shall be
done with 8- 10 tonne static weight smooth-wheel rollers. The intermediate rolling shall be done with 8-
10 tonne static weight or vibratory roller or with a pneumatic tyre roller of 12 to 15 tonne weight, with a
tyre pressure of at least 0.56 Mpa. The finish rolling shall be done with 6 to 8 tonne smooth wheel
tandem rollers. Rolling shall continue until the specified compaction is achieved.

Tack Coat

Purpose/Function

A tack coat is a very light application of asphalt used to ensure a bond between the surface being paved
and the overlying course.

Thickness

Materials Used

Asphalt emulsion diluted with water.

Process/Method

spray applications.

Time Require

Quality Control

Surface Course
Purpose/Function

Surface course is the layer directly in contact with traffic loads and generally contains superior quality
materials. It provides characteristics such as friction, smoothness, drainage, etc. Also it will prevent the
entrance of excessive quantities of surface water into the underlying base, sub-base and sub-grade.

Thickness

1’’-2’’

Materials Used

They are usually constructed with dense graded asphalt concrete (AC) or dense graded HMA.

Process/Method

Time Require

Quality Control

Seal Coat

Purpose/Function

Seal coat is a thin asphalt surface treatment used to waterproof the surface or to provide skid resistance
where the aggregates in the surface course could be polished by traffic and become slippery.

Thickness

½ ‘’(12 mm)

Materials Used

Crushed stone dust, course sand, bitumen

Process/Method

Time Require

Quality Control

Conclusion