METHOD STATEMENT MS-M-22

Ed 1/Rev.1

ASPHALT MIXTURE
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Code F-SP - 03
 METHOD STATEMENT MS-M-22
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Checked by Site Inspector

Elaborated by Quality Manager

Summary

1. Scope
2. Reference
3. Materials and equipment
4. General information
5. Production proces
5.1. Check the cleanliness for asphalt mixing plant.
5.2. Preparation of asphalt mixture in asphalt mixing plant.
5.3. Tolerances of dosage.
6. Transport
7. Trafic
8. Site preparation
9. Laying and supplying
10. Application of prime coat and tack coat
11. Installation of the finisher and work procedure.
12. Compaction.
13. Compaction technology
14. Joints, Shaping and Edge Cleaning
15. Tolerances on finished work
16. Acceptance of executed layer
17. Weather conditions
18. Responsibilities
19. Resources
20. Reports and records

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1. Scope
This method statement defines the work procedure for preparing, transporting and spreading of asphalt
mixture (binder course and wearing course )

2. Reference
SM STB 1033-2008
GOST 8267-93 - Aggregates Technical requirements,
SNIP 3.06.03-85 - Highways. Construction norms and rules
SM GOST 22245 – 90 Viscous Road Petroleum Bitumen. Specifications
SM GOST 8736 – 93 Sand for construction. Technical Conditions.
SM GOST 16557- 78 Filler for asphaltic-concrete mixtures. Technical requirements
Technical specification – chapter 305 Asphalt concrete for pavements
Traffic management plan

3. Materials and equipment

Asphalt mixing Plant AMMANN UB 269,
Vogel or similar
Emulsion spreader,
Steel roller similar
Rubber roller
Trucks
Water tank
Brushing machine
Vibroplate
Joint cutter

Crushed Sand (granite) 0-4mm

Crushed Aggregates (granite) 4-8, 8-16 and 16-31 mm
Natural filer
Bitumen BND 60/90
Fiber
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Prime coat - cationic emulsion type EBK1 (0,8-1,0 kg/m2)

Tack coat - cationic emulsion type EBK1 (0.25-0.4 kg/m2)

4. General information
All aggregates, crushed stones 4/8, 8/16, 16/31, crushed sand 0/4, bitumen BND 60/90, filler material,
prime coat/tack coat -bituminous emulsion type EBK1, fiber, are delivered from approved sources only
and inspected by Engineer. A stockpile is done at the asphalt mix plant yard in Cîșlița-Prut necessary to
cover production for at least one day or planned production amount. The stockpiles will be inspected by
Engineer and approved through the system of “MAR”.
Type of asphalt mixture which we will make in our asphalt plant will be in accordance with the
Technical Specification and the project, like :
- Binder SKVPG -I
- Binder SKBG II 2,3
- Wearing course ȘMCC-I 2,2
Trials sections. The contractor will carry out trials sections on a minimum 200m length to determine for
JMF (job mix formula) the optimum method of use and sequence of operation for laying and number of
passes for rollers and check the adequacy of the equipment used. The works will be in compliance with
Technical Specifications chapter 305.

5. PRODUCTION PROCESS
5.1. Check the cleanliness for asphalt mixing plant.
The plant will be inspected each day before commencement of production. The inspection consist of:
- Checking the cold bins for aggregate
- Checking the operation of each electrical engine
- Checking the operation of each electrical pump for water or hydro oil.
- Checking of the software of the computer
All aggregates for execution of asphalt mixture comply to the norms and standards (see requirements
and methods in and TS 305)

5.2. Preparation of asphalt mixture in asphalt mixing plant.

Asphalt mixing plant has a rated output of 260 t/h. The plant is equipped with two system of adding the
aggregates. The first system is volumetric. Through this system the aggregate will be adjusted according
to the job mix for gradation. The weighing system is for mass dosages. It is programmed through the
computer installed on the plant. In the software the job mix for dosing is stored. The software follows all
the process and gives to the operator visual information for process of work. The process of work is
fully automated. The weighing system is calibrated. As soon as the system is loaded, the production
could start, pressing the knob START.
Before introduction into the mixer, the aggregates must be heated and dried to the
correct temperature, between 155 and 170 deg C.
The aggregate moisture content at the moment of introduction to the mixer shall in no circumstances
exceed 1%. The burners to be used for heating and drying the aggregates shall be so adjusted as not to
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damage or contaminate the aggregates either by overheating or by the deposition of soot, oil or other
residues.
Test and calibrate asphalt mix plant. All aggregates proportions shall be according to JMF of binder
course layer and wearing course layer. Fill cold bins with aggregates, crushed stones 4/8, 8/16, 16/31,
sand 0-4 mm, and transport them for drying and hot screening. The material in the pug mill is added in
the following way: first is added course aggregate then fine and filer and the last is bitumen. The mixer
creates a thorough coating of all ingredients. The mixing time is between 40 – 45 seconds. As soon as
mixing is ready, the material is discharged in the moving bucket. It transport the material over the
trucks, where the gate is open and material flow down in the box. The final product meets the
requirements of JMF (305.13 Supplying and Laying).
The bitumen will be uniformly heated to permit a continuous introduction of bitumen from the storage
tank into the mixer. The temperature of bitumen will be less than 175°C. Bitumen heating shall be
indirect, that means using oil-filled heating coils or other approved systems.

5.3. Tolerances of dosage.

Asphalt plant is calibrated within this tolerance limit :
+/- 2% aggregate size > 15 mm
+/- 1% aggregate size > 5 mm
+/- 0.5% aggregate size < 5 mm
Filler +/-0.5%
Bituminous material +/-0.3%

6. Transport
Mixed asphalt material will be transported from the mixing plant to the laying site in tipping trucks
specially reserved and designated for this purpose.
Trucks shall be metal bodies, insulated and equipped with insulated tarpaulin covers.
Covers shall be deployed at all times when the truck is being used for the transport of
asphalt.
Temperature of asphalt leaving the plant shall be 140-160 ° C.

7. Traffic.
The works will be made in base of the approved Traffic management plan. All arrangements to divert
traffic to only one side of the road, work area will be free of any unauthorized vehicles (use fences,
barricades, signs, traffic light or personnel). Where a diversion road exists work is performed on full
width.

8. Site preparation.
All the surfaces, on which the asphalt is to be laid down, have to be cleaned by mechanical brush and
blow up by compressed air ( TS 305.06 The preparation of the Supporting Surface).

9. Laying and supplying

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The supplying and laying of the asphalt mixture will be done according to SNiP 3.06.03-85.
The materials will be spread, leveled and tamped by an approved self-propelled paving
machine. The asphalt mixture will be supplied continuously to the paver and laid without
delay. The rate of delivery of material to the paver will be regulated to enable the
paver to operate continuously.
The speed of the paver and the maner of working its method of operation shall be adjusted to ensure an
uniform flow of material across the full laying width, avoiding dragging or tearing and without
segregation of material.
In confined areas where irregularities or unavoidable obstacles make the use of
mechanical laying impracticable, the mixture may be spread by hand. Hand spreading
shall be done by staff experienced in the work and the standard of finish of the
completed hand spread asphalt shall not be noticeably inferior to the machine laid areas.
The asphalt will be laid in courses of less than 40 mm thickness unless specifically called for in the
design. Asphalt wearing course shall not be laid in thicknesses greater than 60 mm and asphalt binder
course shall not be laid in thicknesses of more than 80 mm without first obtaining the specific approval
of the Engineer.
When required by the construction drawings, geocomposite,, type 1, must be placed between binder and
wearing cours, The width of geocomposite is about 50 cm and must be placed half over the existing
road and half on the widening.

10. Application of prime coat and tack coat

If the lower layer is CRACP, which is protected by emulsion and it is clean and fresh (not older than 2
days), it is not necessary to apply tack-coat. In another case, the tack-coat has to be applied in quantity
0.25-0.4 kg/m2.
If the lower layer is coated macadam protected with emulsion and it is fresh and surface clean it is not
necessary to apply the tack-coat. In another cases, apply 0.25-0.4 kg/m2 of tack-coat (TS 304.06
Application of Prime and Tack coat). Sufficient time as be given to the emulsion in order to dry. In hot
weather, 2 – 3 hours are quite enough. The tack-coat will not be spread on wet surface.
The tack-coat will be applied when binder course is max seven days old. Other way the tack-coat will
be applied in quantity 0.25 – 0.40 kg/m2/
At laying, the minimum temperature stipulated is necessary to be achieved in accordance to ones
stipulated in the Specification, min 10°C (TS 305.07 Weather Condition).

11. Installation of the finisher and work procedure.

In accordance to norms stipulations, the mixture well be done by mechanical means, with a paver that
has a good pre compaction, and that can follow the designed levels and cross fall.
The screed of the finisher, before beginning, will be warm. The screed is installed on the wooden pieces,
the height 10 – 15% higher the layer thickness. As soon as the finisher is installed on the support, the
side electronic leader devices are installed on the wire and adjusted to zero (0).
The speed of the finisher will be between 9 to 12 m /minute. Where the road has climbing lane, the
whole width will be done in one pass, traffic and climbing lane together.
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The unloading of the trucks and speed of the finisher will be so adjusted to avoid the stoppage of the
finisher.
Only in exceptional cases, the manual laying is permitted (narrow spaces). In this case, the unloading of
mixture is to be done in successive piles. The mixture will be transported with frontal loader, and spread
with shovel (not by throwing). Levelling will be made with rake and the transverse profile achievement
is realised with pattern, which will be moved in the road length supported by the height moulds
adequate height, for verification before compaction. The thickness of layer has to be 20 - 25 % higher
than the requested compacted thickness.

12. Compaction.
Laying and compaction is performed according to the requirements of TS Chapter 305 and SNIP
3.06.03-85. Basically, compaction will start immediately after the spreading;
The temperatures of asphalt mixture have to fulfill the following table requirements:
Bitumen The mixture temperature (C) Temperature during compaction (C)

At the plant At laying At the beginning At the end

BND 60/90 140-160 min. 120 min. 120 min. 80

The compaction is very important because this operation influences directly the layer durability. When
the compaction is performed at 130 - 140°C, good compaction results are obtained. The compaction is
indispensable in the laying mixture to obtain the optimum physical - mechanical characteristics values
and of deformability (apparent specific weight, voids percentage, compression strength, high
temperature stabilizing, deformation and elasticity modulus) and a good road surface, assuring the
quality and durability for the road system.
Basically the compaction has to be performed in straight, longitudinal passes, the changing of rollers
direction must be done on compacted mixture where the roller leaves no traces. Rolling should be
accomplished by diagonal rolls <15 ° from axial direction. The compaction begins with the longitudinal
joint area (on adjacent strips) and then from the edge to the axis and in the climbing sense of the
longitudinal slope. In all cases, the compaction have to be fast executed to obtain the required
compaction in the shortest time.. The temperature of the asphalt mixture will be frequently checked to
obtain a good leveling and compaction.
Compaction of wearing course will commence immediately and will be performed by using exclusively
non-vibrating steel drum rollers to meet density requirements as specified. Pneumatic tyred rollers shall
not be used for wearing course.

13. Compaction technology.

The compaction workshop may include a rubber roller and steel rollers.
The adjustment of one of the indicated compaction equipment will be achieved according to the site
instructions.
The compaction will be performed in the road length from the edge to axis. Each roller pass will be
superposed lateral with 10-30 cm above precedent run.
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On the sections with cross fall, laying begins with the lowest lane (from the edge or shoulder) and then
the following lane till the axis. The roller will execute long passes. First pass will be done with low
speed 2 – 4 Km/h and following passing with higher speed 4 – 6 Km/h.
Direction changes will be progressive effectuated without shocks, to avoid the waving. Stopping in the
road lengths will be staggered between them.
Eventual unevenness, which appears in front of the roller on the asphalt surface, will be corrected
moving transversely with a small roller.
In some cases, it is necessary to start rolling with a rubber roller. The tires of the rollers should be
covered with a thin layer of organic oil to prevent sticking of the mixture.
After first compaction the second compaction will be done by steel vibrating rollers. It will eliminate
longitudinal marks of the rubber roller tires. At low temperature, under 20° C and windy conditions, the
tires will be covered by tarpaulin
When the steel roller should go first, the wheels will be wet with water. Finally if the final rolling will
be done with rubber roller, on the beginning when tires are warm, it will be wet with water.
The number of passes of the roller will be determined by trail sectors, for each type of asphalt mixture.
The criteria for compaction are given in TS 305.14.

14. Joints, Shaping and Edge Cleaning

Longitudinal joints and transversal joints, when it is unavoidable, will be done in following procedure:
- After laying first traffic lane is done and the second lane is done in same day the temperature of
mixture on the joints are not to be lower than minimum prescribed in TS. The length of the first pass
depends of the air temperature and in no case the temperature of the asphalt laid in the first pass will be
under 80 0 C.
- When laying of the second lane is done next day the edge will be cut minimum 150mm. The vertical
edge is primed by emulsion EBK-1 (0.8-1.0 kg/m2). The compaction of the joint will be according to
TS 305.14.
Longitudinal joints will not be over the joint of under layers, the superposing will be minimum 400 mm.
When two finishers are used to cover all width of traffic lane, the distance between each other will be
not more than 10 meters.
The traffic will be opened 4 hours after the end of compaction in order to protect the edge.

15. Tolerances on finished work

After compaction the surface will be checked for tolerance.
Completed asphalt overlay courses shall not be less than the thickness indicated in the drawings and
the final levels of asphalt wearing course shall be within a tolerance of +15mm to 0 mm. The levels
will be checked using a grid stipulated by the Engineer comprising not less than 6 points per 100
sq.m.
A 3meter straight edge will be used to check the final surface for regularity after initial
rolling and while the material is still hot enough for corrections to be made.
Checks will be made at regular intervals, but not less than two checks per lane at 10 meter intervals.
The defective area is an area with surface deviations in excess of 5mm relative to the straightedge.

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16. Acceptance of executed layer

Test procedures needed to satisfy quality, are given in the Quality Control Plan, Compaction rate will be
controlled by extraction of the course, minimum 3 per each day or minimum one sample per 800 m2.
The evenness will be controlled by 3 m straight edge and depression shall be within tolerance of 5mm
(TS 305.16 Tolerances on finished works).

17. Weather conditions

The laying of asphalt mixture will be done at ambient temperatures exceeding 6°C and rising with
an allowable wind velocity of less than 25 km/h and/or at an ambient temperature exceeding 10°C
and rising with an allowable wind velocity of less than 55 km/h or for asphalt with a thickness of
equal or less than 30 mm with an allowable wind speed of 25 km/h. With falling temperatures all
work shall be stopped when the temperature reaches 6°C.
The asphalt mixture will not be laid when the surface is visibly wet or when rain is immenent.
Laying of asphalt in the period 15 October to 15 March will be made only with the consent of Engineer.

18. Responsibilities

The Site Manager is responsible for exact application of the execution documentation (Drawings),
Technical Specifications, Standards and this execution procedure.
The Quality Manager is responsible for exact application of the Drawings, Technical Specifications
provisions, rule and regulations in force, application of this technical execution procedures not correct
preparation of quality records.
The Chief of the working place coordinates the works and provides humans resources, materials
necessary for works execution.
The person in charge for labor protection are responsible for training on compliance with labor
protection regulations and PSI.
The Traffic Manager is responsible of the planning and the execution temporary signs and roads and
the management of traffic problems.
The Head of the laboratory is responsible for performing the examinations and tests required by
specifications before and during the work execution and prepare proper records.
The Head of surveyor is responsible for the setting out and the execution of the survey.

19. Resources

Chief of the Work Place / Workers;

Quality Manager;
Head of surveyor / surveyors;
Head of laboratory / Technicians;

20. Reports and Records

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Minute of hidden works

Laboratory test Report
Request for Inspection - RFI
Protocol survey

Code F-SP - 03