Methodology

for

9.0 Bituminous Concrete (BC)

 9.0 Methodology for Bituminous Concrete

Methodology of works

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 9.0 Methodology for Bituminous Concrete

Table of Content: -

1. SCOPE OF WORK

2. REFERENCE DOCUMENTS.

3. MATERIALS.

4. MIX DESIGN.

5. PLANTS & EQUIPMENTS.

6. CONSTRUCTION OPERATIONS.

7. ARRANGEMENT FOR TRAFFIC

8. QUALITY CONTROL.

9. ENVIRONMENTAL CONTROL

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 9.0 Methodology for Bituminous Concrete

1. SCOPE OF WORKS

This work shall consist of laying in a single course a 40 mm – thick

layer of BC on a previously approved DBM Layer, as per specified
lines & grades and in accordance with clause 507 of MORTH
specification.

2. REFERENCE

I) Ministry of Road Transport & Highway

Specifications.
II) Technical Specifications
III) Relevant Drawings.
IV) Relevant Codes.

3. MATERIALS :(Morth fifth edition clause no- 502)

The source and test report of all material will be submitted to the
Engineer for approval before using the material.

3.1 Bitumen :(Morth fifth edition clause no- 504.2.1)

Bitumen shall be CRMB Grade 60 as manufactured by Indian Oil

Corporation or Hindustan Colas Limited as approved by the Engineer.

3.2 Coarse Aggregates :( Morth fifth edition clause no- 507.2.2)

Coarse aggregate shall be obtained from the approved quarry and

crusher. The coarse aggregates shall satisfy the specification
requirement as set out in 509.2.2 of MORTH specification.

Physical requirement of Coarse Aggregates for BC.

Property Test Specification

Cleanliness Grain size analysis Max 5% passing
0.075 mm sieve
Particle shape Flakiness and Elongation Index Max 35%
(Combined)
Strength* Los Angeles Abrasion Value Max 30%
Aggregate Impact Value Max 24%

Durability Soundness eighter :

Sodium Sulphate Max 12%
Magnesium Sulphate Max 18%

Polishing Polished Stone Value Min 55

Water Absorption Water absorption Max 2%
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 9.0 Methodology for Bituminous Concrete

Stripping Coating and stripping of Minimum retained

Bitumen Aggregate Mixtures coating 95%
Water Sensitivity Retained Tensile Strength Min 80%

3.3 Fine Aggregate :( Morth fifth edition clause no- 505.2.3)

Fine aggregates shall be crushed or naturally occurring mineral
material, or a combination of the two, passing the 2.36mm sieve and
retained on the 75 micron sieve. They 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 nun sieve shall
not exceed 4. When tested in accordance with IS: 2720 (Part 5)

3.4 Filler :(Morth fifth edition clause no- 505.2.4)

Filler shall be finely divided mineral matter such as rock dust, hydrated
lime or cement approved by the Engineer.

The filler shall be graded within the limits indicated in Table 500-9 of
MORTH Specification.

3.5 Aggregate Grading and Binder Content

When tested in accordance with IS: 2386 Part 1 (wet sieving method), the combined
grading of the coarse and fine aggregates and added filler for the particular mixture
shall fall within the limits shown in Table 500-17 of Morth fifth edition clause no-
507.2.5, grading 2 for MCW BC works and grading 2 for service road BC works.

4. MIX DESIGN

4.1 Requirement of Mix :( Morth fifth edition clause no- 505.3.1)

Apart from conformity with the grading and quality requirements for
individual ingredients, the mixture shall meet the requirements set out
in Table 500-19 of MORTH Specification.
TABLE -7 REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS
(As per IRC-SP-53) 2002

Minimum stability (at 60 o C) kg, min 1200

Minimum flow (mm) 2
Maximum flow (mm) 4
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 9.0 Methodology for Bituminous Concrete

75 blows on each of the two faces of the

Compaction level (Number of blows)
specimen
Per cent air voids 3-6
Per cent voids in mineral aggregate
See Table 500-12 below
(VMA)
Per cent voids filled with bitumen
65-75
(VFB)
Loss of stability on immersion in
Min. 75 per cent retained strength
water at 60oC (ASTM D 1075)
Stability / Flow ratio 250 - 500

The requirements for minimum per cent voids in mineral aggregate

(VMA) are set out in Table 500-12.

TABLE 500-12 MINIMUM PER CENT VOIDS IN MINERAL AGGREGATE (VMA)

Nominal Maximum Minimum VMA, Per cent Related to Design Air Voids, Per
Particle Size1 (mm) cent2
3.0 4.0 5.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
37.5 10.0 11.0 12.0

1. 4.2. Binder content :(Morth fifth edition clause no- 505.3.2)

The binder content shall be optimised to achieve the requirements of
the mixture set out in Table 500-19 and the traffic volume as specified
in the Contract. The Marshall method for determining the optimum
binder content shall be adopted as described in the Asphalt Institute
Manual MS-2, replacing the aggregates retained on the 26.5mm sieve
and retained on the 22.4mm sieve, where approved by the Engineer.

4.3. Job mix formula :(Morth fifth edition clause no- 505.3.3)
The procedure for formulating the job mix formula shall be generally as specified in
Clause 507.3.3 mix design will be established jointly and all testing will be conducted
jointly.

The result thus obtained will be submitted to the Engineer for the
approval and trial stretch will be laid based on the submitted JMF.

4.4 Plant trials – After completion of JMF at lab trial will be carried
out to establish that the plant can be set up to produce a uniform mix
conforming to the approved job mix formula. The permissible variation
in job mix formula will be as per Table 500 – 18 of MORTH.

TABLE 500-13 PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA 500-15

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 9.0 Methodology for Bituminous Concrete

Description Permissible Variations

Base/binder course Wearing course
Aggregate passing 19mm sieve or larger ± 8% ± 7%
Aggregate passing 13.2mm, 9.5mm .± 7% ± 6%
Aggregate passing 4.75mm ± 6% ± 5%
Aggregate passing 2.36mm, 1.18mm, ± 5% ± 4%
Aggregate passing 0.3mm, 0.15mm ± 4% ± 3%
Aggregate passing 0.075mm ± 2% ± 1.5%
Binder content ± 0.3% ± 0.3%
Mixing temperature ± 10°C ± 10°C

4.5. Laying trials :

To demonstrate that the proposed mix can be successfully laid and
compacted, the trial laying shall be carried out on a suitable area. The
area of the laying trials shall not be a less than 75 m.

The density of the finished paving layer shall be determined by taking

cores, no sooner than 24 hours after laying, or by other approved
method. No of passes of roller will be determined during the trials and
same number of passes will be followed during the actual work.

5. PLANTS & EQUIPMENTS

 Crusher of required capacity

 Hot Mix Plant
 Paver with sensor arrangement and capable of paving 9
meter width of mat.
 Steel Tandem Rollers with required weight
 Pneumatic Roller with required weight
 Bitumen Sprayer
 Dumpers
 Air compressor
 Pegs for putting levels
 Broom
 Straight edge
 Thermometer
 Gauge for checking thickness
 Survey Kit / instrument
 Measuring top (metal)
 Core cutting Assembly.

6. CONSTRUCTION OPERATIONS

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 9.0 Methodology for Bituminous Concrete

6.1 Weather and Seasonal Limitations :( Morth fifth edition clause no-
505.1.1)

The work of laying shall not be taken up during rainy or foggy weather/
the base course is damp or wet or during dust storm or when the
atmospheric temperature in shade is 10 deg. or less as specified in the
MORT&H specifications.

6.2 Preparation of Base

The DBM surface on which the bituminous concrete is to be laid shall

be clean, and treated with Tack coat. The surface shall be thoroughly
swept clean by broom and dust removed by compressed air. Core
density / thickness record to be got approved duty signed by consultant
for DBM layer with surface irregularity / tolerance sheet.

6.3 Tack Coat :(Morth fifth edition clause no- 504.4.6)

The binder for tack coat shall be CCS-1 Grade Emulsion and shall be
applied with rate / 10sq m.

6.4 Preparation and Transportation of Mix:( Morth fifth edition

clause no-501.3, 501.4.7 &504.4.7)

BC shall be prepared in batch in Hot Mix Plant. The mixing will be

done in a twin shaft pugmil, which will produce a homogeneous mix.

The mixture shall be transported from the batching plant in tippers

covered with tarpaulin (if required) so as to maintain the temperature,
over spillage and dust and environment hazard.

6.5 Spreading :(Morth fifth edition clause no- 501.6 & 501.7)

The mix shall be transported to the site by the dumpers, which shall
slowly discharge the mix in the paver hopper, while both the tipper and
paver will move forward steadily and slowly. The automatic sensor
shall ensure that the mix is being laid to the proper line and grade and
level. The direction of the paver will be guided by the string lines fixed
with the stack & arms on both sides of the edges 0.5 m away from the
edge. The temperature of the mix at the time of laying shall be between
130 0 c to 150 0 c (as per IRE-SP-53, Table-8)

Transverse joints shall be cut vertically with asphalt cutter and a coat
of hot bitumen shall be applied before placing materials.

6.6 Compaction

As soon as the mix has been laid to the paver, compaction shall be done
with the help of a set of rollers moving at a speed not exceeding 5

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km/hour following close to the paver. Rolling sequence will be as

under or as established during laying trial stretch.

Compaction subsequently completed before the temperature falls below

the minimum rolling temperatures. Rolling of the longitudinal joints
shall be done immediately behind the paving operation. After this,
rolling shall commence at the edges and progress towards the centre
longitudinally except that on super elevated and unidirectional
cambered portions, it shall progress from the lower to the upper edge
parallel to the centre line of the pavement. Rolling shall continue until
all roller marks have been removed from the surface.

i) Initial or breakdown rolling shall be done with 80-100 KN dead

weight smooth wheeled rollers.
ii) Intermediate rolling shall be done by 8-10 tons dead weight or
vibratory roller or with a pneumatic tired roller of 12 to 15 tons
weight having nine wheels, with a tire pressure of at least 5.6
kg/sq cm. The finish rolling shall be done with 6 to 8 tons
smooth wheeled tandem rollers and the no. of passes required
shall be decided after laying a trial bed.

During rolling, wheels of rollers shall be kept moist by sprinkling

water from the water storage fitted with the roller to prevent the mix
from adhering to the wheels. The roller shall proceed on the fresh
material with rear or fixed wheel leading so as to minimize the pushing
of the mix.

In portions in camber, rolling should begin at the edge with the roller
forward and backward until the edges have been firmly compacted. The
roller shall then progress gradually towards the center parallel to the
center line uniformly overlapping each of the preceding tracks by one-
third width until the entire surface has been rolled.

Along forms, kerb and walls where rolling cannot be done by rollers,
shall be compacted with mechanical tampers or a plate compactor or
rammers as may be feasible.

Any undulations / displacement found as a result of reversing of the

direction of a roller or due to some other reasons shall be rectified as
specified or removed and made good to the satisfaction of the Engineer.

All the field tests such as checking of compaction by core cutting,

surface irregularity by using a straight edge and checking of cross
slope by taking level, rate of spray of tack coat / prime coat using
trays, temperature of mix using digital thermometer. Depth of the layer
using thickness gauge etc. shall be carried out as per the requirements.
(As per MORT&H clause 501.7) Sr.no-I, ii and iii

7. ARRANGEMENT FOR TRAFFIC

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 9.0 Methodology for Bituminous Concrete

The works shall be so executed that there is a minimum disturbance to

the traffic. The traffic shall be diverted by making proper diversions at
suitable locations and in accordance with clause 112 of MORTH.
Signboards indicating the locations of these diversions shall be fixed at
desired positions.

Traffic will not be allow to move after 24 hours.

8. QUALITY CONTROL

A) Following are the list of Control Tests to be carried out in the laboratory prior
construction on BC Materials:

 Pre-Construction test for Aggregates

I
S. No. Test Methods Specification
Test
a. Aggregate Impact Value IS: 2386 Max 24 %
Part IV
b. Grading of Aggregates and IS: 2386 Grading 1 of Table 400 – 18
Screening Part I
c. Flakiness and Elongation IS: 2386 Max 30 %
Index of Aggregates Part – I
(Combined)
d L.A.A. IS 2386 Part 4 Max 30 %
e Soundness Test – Sodium IS 2386 Part 5 Max 12 %
Sulphate
Soundness Test – Max 18 %
Magnesium Sulphate
f Water Absorption IS 2386 Part 3 Max 2 %

g. Stripping value of IS: 6241 Minimum retained 95 %

Aggregate

 Pre-Construction test for Filler

II
S. No. Test Methods Specification
Test
a. Grading Table 500 – 9
b. Plasticity Index PI < 4

B) Frequency of tests to be performed during Construction of BC

III
S. No. Test Test Method Minimum Desirable
Frequency
a. Quality of Binder IRC-SP- (IRC-SP-53) Number of samples per lot
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 9.0 Methodology for Bituminous Concrete

53 and IS: 1201 to 1220 and IS: 8887 (for

MS-20 Emulsion – ccss-1)
d. Flakiness Index of IS: 2386 One test per 50 cum
Aggregate Part I
e. Water Absorption of IS: 2386 Initially one set of 3
Aggregate Part 3 representative specimens for
each source of supply.
Subsequently when
warranted by changes in the
quality of aggregates
f. Grading of all in Aggregates IS: 2386 One set of tests on
Part I individual constituents and
mixed aggregate from the
dryer for each 400 tones of
mix subjected to a minimum
of two tests pre plant per
day.
g. Temperature of Binder of Regularly and as directed by
Laying and Rolling the Engineer.
h. Binder Content Extraction Test One test for each 400 tones
with specified of mix subject to a
solvent minimum of two tests per
day per plant.
i. Rate of Spread of Premix Regular Control through
Checks on Materials and
Thickness
j. Density of Compacted By N.DG or from One test per 250 Sq.m
Layer cores cut by core
Cutting Machine

C) Allowable surface finish level BC Wearing Course: Post Construction:

Tolerance in Surface Level : +6 mm

Max. Permissible undulation (with 3 m straight edge) : 6 mm

9. ENVIRONMENTAL CONTROL

The work shall be executed with the least disturbance on environment.

a) The excess material and any other excess materials shall be disposed suitably
without polluting streams, water courses.
b) Vehicles tracks shall be kept moist to prevent flying of dust particles with the
vehicle movement.
c) The smoke and dust at plant will be controlled by adopting suitable method.

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