Highway Material & Construction A. Highway Material 1. Test for Road Aggregate 2. Test for Bitumen 3. Marshall Mix Design B. Symptoms and cause of Defects Pavement Construction A. 1. Test for Road Aggregate G3 1. Crushing Test (For Strength) Specification Osize of Aggregate: 10 to 12 mm Qo of layers: 3 ORRate of Loading: 4T/min Time : 10min Osieve size : 2.36mm Acv= 42. 100 Ww, W: Weight of aggregate passing 2.36mm sieve W,: Total weight of aggregate | QACV + 30% for surface course DACV % 45% for Base Course fs oeA. 1. CONTI 2. Impact Test (For Toughness) | Specification: " Osize of Aggregate: 10 to 12 mm | lm Oheight of fall: 38cm eo L QWeight of hammer: 13.5-14.5 kg QNo of blows: 15 Osieve size : 2.36mm Alv= “2 « 100 Ww, \ 4, W.: Weight of aggregate passing 2.36mm sieve : hy | W,: Total weight of aggregate “ORL Qalv + 30% for surface course alv % 35% for Base Course Before After o — eff of Hardnes A. 1. CONTI... = 20 — + Loss of weight in gram |3. Abrasion Test (For Wear &Tear) Specification: Los Angeles Test ORate : 33rpm No of revolution : 500 Ko OSieve size: 1.7mm “AS Av= “2+ 100 w, W,: Weight of aggregate passing 1.7 mm sieve é W,: Total weight of aggregate eer QAV%30% for surface course ee 3 % Dav 50% for Base Course Cage | BeforeA. 1. CONTI 4. Soundness Test (For Durability & weathering) + Aggregates of specified size are subjected to cycles of alternate wetting in a saturated solution of either Sodium | Sulphate or Magnesium Sulphate at a certain temperature and then drying in air Each cycle involves between 16-18 hrs of submergence in sulphate solution followed by 4 more hr of drying, + After five cycles loss of weight is determined Loss in weight: #12% NazSo4 %18% MgS0x A. 1. CONTI 5. Shape Test (Angularity Number) _ _ 100: | an= (67 — 5) | C: Weight of water to fill the cylinder Gq: Specific gravity of Aggregate QAN=(67 - %Solid Volume) (67% represents volume of solids of rounded Aggregate in well compacted state which would have 33% void. | QaAcceptable range for construction: 0-11 Oit shows degree of packing. QAngularity number measures void excess of 33% Xs For Rounded Aggregate AN=0 OFor Angular Aggregate AN+ 0 V3 W: Weight of Aggregate to fill the cylinder = Angular Rounded ivA. 1. CONTI... 5. Shape Test (Flakiness Index) Usize of Aggregate > 6.3 mm Oflakiness index of aggregate is the percentage by weight of aggregate particles of least dimension of which is less than 0.6 of mean dimension. FI= m 100 eight of Flaky particle Weight of Total Aggregate QIAS PER IRC Fl 25% for Bituminous Concrete Fl 15% for WBM Flaky A. 1. CONTI... 5. Shape Test (Elongation index) Osize of Aggregate > 6.3 mm | Elongation index of aggregate is the percentage by weight of aggregate particles of greatest dimension of which is greater than 1.8 of mean eight of Elongated particle Weight of residual aggregate OAS PER IRC 1 #15% dimension. ElongatedA. 1. CONTI... Ga 6. Water Absorption Test weight of Aggregate. O Water absorption should not be more than 0.6% of 7. Specific Gravity Test Olt measures the quality of strength of material. OSpecific gravity of solids lies between 2.6 to 2.9 A. 2. Bitumen @g Bitumen Tar Manufactured by fractional distillation of crude oil. Manufactured by destructive distillation of coal or Wood. Soluble in CS, and CCl, Soluble in toluene More resistant to water Less resistant to water Free carbon content is less Free carbon content is more Less temperature susceptibility More temperature susceptibilityA. 2. CONTI... ba Bitumen Tar OGrading by VGwiscosity grading) | 1. VG-40:(3200 Poise): Used in high stress area/ toll plaza/truck terminal 2. VG-30:(2400 Poise):used for paving OGrading by RT (Road tar) 1. RT-1:Used for surface dressing in very cold weather condition 2, RT-2:Used for surface dressing under application normal climate condition 3. VG-20:(1600 Poise):used for paving | 3. application in cold climate RT-3:Used for surface dressing & Renewal Coat 4, VG-10:(800 Poise):used for spraying | 4. application RT-4:Used for premix Tar Mecadam 5. RT-5:Used for Grouting A. 2. CONTI. Asphalt Asphalt is produced in a plant that heats, dries and mixes aggregate, bitumen and sand into a composite mix. Cutback Bitumen Cutback bitumen is obtained by|QGrading by RC blending bitumen binder with * RC (Rapid Curing) suitable volatile diluents or solvents MC(Medium Curing) in the required proportion to reduce| * SC (Slow Curing) its viscosity to the desired range. Olt is used for: * Colder region * Tack coat without heat + Bituminous Mixes + Soil Bitumen StabilizationA. 2. CONTI Bituminous Emulsion QA bituminous emulsion is a liquid product in which a substantial amount of bitumen is suspended in a finely divided condition in an aqueous medium and stabilized by means of one or more suitable material. Olypes of Bituminous Emulsion + Anionic Bituminous Emulsion + Cationic Bituminous Emulsion Note: Choice of type depends upon Climate and Environmental Condition OGrading System: + Rapid Setting Type (RS-1/RS-2) + Medium Setting Type (MS) + Slow Setting Type (SS-1/SS-2) A. Test For Bitumen |1, Penetration test Olt represents softness or hardness of bitumen by measuring the depth in 0.1 mm to which a standard needle carrying a weight of 100g penetrates in 5 sec. at temperature 25°C. UGrade of bitumen is decided on the basis of penetration test. | + if grade of bitumen is 80/100 then penetration values lies between 8 to 10mm. If grade of bitumen is A-30 then bitumen is manufactured from Assam petroleum / + If grade of bitumen is $-30 then bitumen is manufactured from other than Assam Petroleum,A. 2. CONTI... 2. Viscosity test Ot measures resistance to flow. Ult is the time taken in sec. by 50mI of bitumen to flow from beaker through a standard orifice under standard test condition. Oit is measured by “Saybolt Furol”. Ostandard temperature for this test is 25° and 50°C. Qviscosity of Tar is measured by “Tar Viscometer”. A. 2. CONTI 3. Float Test Olt is used to measure consistency of material for which penetration & viscosity test can not be conducted. QOTime required by water to inject through bitumen is called “Float Value”. Qhigher the float value stiffer the bitumen. Fhust testA. 2. CONTI... 4. Ductility Test oat eo Qit is the distance in cm to which a] ——— standard briquette of size 10mm X a - 10mmcan be stretched before the waek thread breaks at a __ standard | temperature of 27°C. Min ductility for grade 45 & above is |<) Coll 75cm. A. 2. CONTI... 5. Softening Point Test OSoftening point is the temperature at which the substance attains a particular degree of softening under standard test | condition | OThis test is also known as Ring & Ball test.. OSoftening point of various bitumen grade used in paving jobs varies between 35° to 70°CA. 2. CONTI \6. Flash & Fire Point Test QIFLASH POINT: it is the temperature at which bitumen vapors take fire. Standard Flash point : 175°C QFIRE POINT: it the lowest temperature at which material gets ignited. Uit is measured by “Pensky Martin” A. Marshall Mix Design G3 The mix design determines the Optimum Bitumen Content for evaluation of performance of bituminous mix. UDesirable properties: Stability Flow Value Unit weight Air Void VFB VMA DARWNHK QiMarshall Stability and Flow value determined experimentally and other properties calculated theoretically.A. 3. CONTI.... [O marshall Test 1. Test specimen size: * Diameter: 101.6mm * Thickness: 63.5mm | 2. Rate of deformation: * 51mm/min 3. Temperature: | + 60°C | Q Marshall Stability: it is defined as the max load carried in kg at the standard temperature of 60°C. Q Flow Value: it is defined as the total deformation that marshall test specimen |__ undergoes at the max Load. A. 3. CONTI Properties of Mix 1. Theoretical Specific Gravity(G,) Ws| Gs W,| G, _ (Wit Wr + Wa +W. - “= (Ww mm) males G, * G. * Gs G UA (without considering Air Void) W:) G: 2. Bulk Specific gravity (Gp) (With considering Air Void) Mass Wn = (—_|) We = is the weight of mix in air W,,-Ww. Gn = Volume We : isthe weight ofmix in water (WarWry) + gives the volume of the mixA. 3. CONTI. re) Properties of Mix a Air Void Percentage (V,) 4. Percentage volume of bitumen (Vp) + W. G, — Gm Vesicumen Gy” 100 = ( ={—_——* eee vo = (FE) +100 |. = (Fes 100) = (geteiem =(™“ (@) = wie (& ¥»=(q5* 199) (Z) = Ws %) ) 5. Voids in mineral 6. Voids filled with bitumen (VFB) aggregates (VMA, Vs VMA = (Vv +Vb) vee = (+). 100 Marshall Test Results S gs _ s = a Bitumen (%) Bitumen (%) Bitumen (%) zB a < $ S s s Bitumen (%) Bitumen (%) Bitumen (%)B. Symptoms and Cause of Defects G3 Fatty Surface (surface Defect) * Bitumen binder moves upward and collect as a film of bitumen + Wet in summer & Slippery in cold Symptoms Excessive binder in premix Cause Smooth Surface (surface Defect) E|+ very low skid resistance B+ Very slippery in wet a|* Excessive binder 2|+* Polishing of aggregate under traffic & B. CONTI... Streaking (surface Defect) * Heavy lines of bitumen symptoms + Coreless operation of _ bituminous distribution. + Sometimes mechanical fault Cause Hungry surface (surface Defect) * Careless operation of bituminous distribution. symptoms + Less bitumen in surfacing CauseB. CONTI Hair line cracks (cracks) é &|+ Fine cracks at closed interval e % |* Insufficient bitumen & |+ Improper compaction Alligator cracks (cracks) z + Interconnected cracking forming a series of small blocks. + Excessive deflection of surface over unstable subgrade + overloading/ brittleness of binder. B. CONTI Longitudinal crack (cracks) é §|* Crack in a line between two lanes or at E| edge. %|+ Alternate wetting and drying &|* Weak joint between lanes Edge cracks (cracks) * Cracks parallel to outer edge 0.3m -0.5m inside from the edge Symptoms + Lack of lateral support. * settlement CauseB. CONTI Reflection cracks (cracks) ‘Symptoms * Cracks over joints * Anywhere in overlay on cement concrete pavement Cause * Crack due to pavement layer underneath B. CONTI.... Slippage (veformation) Symptoms + Relative movement between surface layer Cause + Inadequate prime coat or tack coat. + Lack of bond Rutting (Deformation) Symptoms + Longitudinal depression Cause + Heavy channelize traffic + Weak pavement + Improper compactionB. CONTI Corrugation (veformation) é 5 [+ Regular undulation across the bituminous E| surface 2+ Lack of stability in the mix & Shoving (Deformation) é § 3+ Localized bulging of pavement surface 3+ Lack of stability in the mix & = B. CONTI... Shallow depression (veformation) é 5|+ Shallow depression where water will E| normally collect 3 |+ Settlement of lower layer of pavement & Settlement / Upheaval (veformation) + Large deformation + Extremely uncomfortable Symptoms + Inadequate compaction in the fill & | + Excessive moisture in subgradeB. CONTI Stripping (oisintegration) ‘symptoms + Separation of bitumen adhering to the surface of aggregate + Loss of material from the surface Cause + Moisture/ inadequate mix + Ageing of bitumen Raveling (oisintegration) symptoms + Progressive disintegration of the surface due to failure of binder to hold the material together Cause + Inadequate compaction * Construction during cold weather + Insufficient binder B. CONTI Pot holes (oisintegration) symptoms * Bowl shape holes in surface layer Cause * Water into the pavement through the surface course Edge breaking/ Frayed surface (pisintegration) symptoms + Edge of the bituminous surface gets broken , may peel of in large chunks at |. edges Cause + Insufficient side support + Lower layer of pavement not being wider |" than upper layer. Pavement Construction a a Presa C. 1. Construction of Subgrade i Material Used : Soil/ Moorum /gravel/ mixture of these material which are free from organic matter that are likely to deteriorate, UO Requirement of Soil properties : + Liquid limit less than 50% Plasticity index less than 25 + Non expansive soil + Min acceptable CBR Process repeated by desired range of compaction Additional Spreading of waters Compaction Soil sprayed to by PTR/SR obtain OMC Note : As per IRC the specified compaction requirement of highway subgrade is 97% in terms of max dry densityC. 2. Construction of Sub-Base Q Material Used : + GSB (Granular Sub Base} in one or more layer + G58 is made by Crushed Stones/gravel/Coorse Sand/Moorum Q Requirement of material used for GSB: + Liquid limit less than 25% + Plasticity index less than 6 + Min acceptable CBR is 30% Process repeated up to | 98% of max density Compaction by Vibratory Roller Spreading of GSB Note : This layer also acts as a drainage layer. C. 3. Construction of Base Course Ga Q Material Used : (wMM) : + WMM (Wet mix Mecadam) + WMM consist of @ well graded hard crushed aggregates and adequate proportion of water mixed thoroughly in a mixing plant Q Primary function is to provide load distribution and contribution to sub-surface drainage. Preparation of Compaction by anand Spreading vibratory rollerCc. 3. CONTI Q Material Used : (WBM) + WBMIWater Bound Mecadam) binding material, + WBM consists of coarse aggregate, screenings and contribution to sub-surface drainage. Q Primary function is to provide load distribution and Spreading of coarse aggregate and compaction by vibratory roller Dry screening are applied after compaction Water is sprinkled then rolled again Screenings: The material which is used up to fill up the excess voids present in the compacted layer of course aggregate is called as screenings. C. 3. CONTI (4.75-20mm) wMM WBM Stone aggregates are comparatively Stone aggregates are larger in size smaller n size (45-90mm) Stone aggregates and binding materials are premixed in a batching plant Stone aggregates, screening material and binders are overlaid one after another Prepared by stone aggregates and binders. Prepared by stone aggregate, screening and binding material Water is premixed Water is sprinkled on dry material Fast construction Comparatively SlowC. 4. Coatings OPrime Coat: + 1% application of low viscous liquid bituminous material over an existing porous pavement surface like WBM base course. + The main objective of priming is to plug capillary void of porous surface and to bond the loose mineral particles on existing surface. + Only low viscous binders are used so that it can penetrate in to the voids. * Generally, Tar, Low viscous bitumen, MC/SC cutbacks are used P * Primed surface is allowed to cure for at least 24hr during which no traffic is allowed C. 4. Coatings GS QO Tack Coat: * Bituminous tack coat is the application of bituminous material over an existing pavement surface which is relatively impervious like an existing bituminous surface. + It can also be applied to pervious surface like WBM which are already been treated by prime coat + Bituminous material of higher viscosity like hot bitumen is used and in cold state bituminous emulsion may also be applied + It provides the bond between existing layer and new layer of pavement. OSeal Coat: + Seai coat usually recommended as a top coat over certain bituminous pavement which are not impervious such as premixed carpet. + Itcan also be provided over worn out existing bituminous pavement. + The main function are: * Jo seal the surfacing against action of water * To develop skid resistance textureC. 5. Surface Dressing + Bituminous surface dressing is provided over an existing pavement to serve as thin wearing coat + The single coat surface dressing consists of single application of bituminous binder material followed by spreading of aggregate and rolling + The main functions are: + To serve as thin wearing coat and to protect base course + To water proof the pavement surface + To provide dust free pavement surface + To provide mud free pavement in monsoon season Application Spreading of of Bitumen Aggregate Bolling) C. 5. Penetration Mecadam + Penetration mecadam/ grouted mecadam is used as a base of binder course + The coarse aggregates are first spreaded and compacted well in dry state and then hot bituminous binders of relotively high viscosity Is sprayed in fairly large quantity at top + The bitumen penetrates into voids from the surface of compacted aggregate and fill up o part of void and binds aggregate together. + Full grout is adopted in heavy rainfall area + Semi-grout is adopted in moderate rainfall area. A610 FH, BRL Compaction on dry Aggregate Spreading of Bitumen Spreading of AggregateC. 5. Premixed Method + In this method the aggregates and bituminous binders are mixes thoroughly before spreading and compacting. * It is possible to coat each particle of aggregate with binder but stil! quantity of bitumen used is less than penetration mecadam. Depending upon gradation of aggregate premixed construction is classified as: S.No Premixed Method Used For Remarks 1 | Bituminous Mecadam Binder Course Used for heavy Traffic 2 | Bituminous premixed carpets | Wearing Course Economical 3. | Bituminous concrete Wearing Course/BC BC, SDBC 4 _| Sheet Asphait Wearing Course Smooth & Contunuous 5 | Mastic Asphalt Wearing Course Void-less MaterialCBR Test (California Bearing Test) + The CBR test is penetration test meant for the evaluation of subgrade strength of roads and pavements + The results obtained by these tests are used with the empirical curves to determine the thickness of pavement and its component layers. * This is the most widely used method for the design of flexible pavement. * Specification: * Cylindrical diameter:150mm * Height : 175mm + Penetration Plunger Dia: 5¢mm=5cm * Rate of Penetration: 1.25mm/Min Note: Surcharge weights are used to stimulate the effect of overlying pavement. CONTI Ls Test Procedure: + The Specimen may be compacted to max dry density at the optimum moisture content. (heavy compaction is required for high trafficked road like Express Highway). + The specimen is subjected to 4 days(96hr) of soaking and swelling and the water absorption values are noted. + The surcharge weight is placed on the top of specimen in the mould and the assembly is placed under the plunger of loading frame. + The load values corresponding to various penetration values are noted as given in table. Penetration (mm) | 0.0} 05 | 10] 15 | 20|25| 30 | 40) 50 | 7.5 | 100/125 Load (Ka)CONTI. + Load-Penetration graph (CBR Curve) is plotted, Convex throughout + If CBR curve is convex throughout then Load Corresponding to 2.5mm & 5.0mm penetrations are noted from CBR Curve. Lead (ke) + These load values are compared with Standard Load values of Standard Aggregate and CBR Value is found as: Penetration (rom) CBR Pas. 109 25 = 4, CBR Value = at CBRs) = —* 100 axl 2055 CONTI * Generally, CBRz; > CBRso but if CBR; found more then test should be repeated, and after repetition of test which ever found more should be accepted as CBR value. * Standard Load Value on Crushed Stones Aggregate Penetration (mm) Standard Load (Kg) Unit ae load 25 1370 70 5.0 2055 105CONTI.... Initial Concavity in CBR curve * Sometimes Initial Concavity may found in CBR Curve due to following reasons: 1. The top layer of the soaked soil is too soft. 2. The top surface of the soil specimen is not even. 3. The penetration plunger of the loading machine is not truly vertical. (due to which bottom surface of plunger is not horizontal truly) OSE: Original CBR Curve ASE: Corrected CBR Curve Load (ke) Toad (ke) o Penetration (mm) oO An Penetration (mm) Some Important terms from Hilly Roads 1. Resisting Length: 5 The resisting length of road is its effective h length taking into consideration the total 4 A —— by —— work done against the resistance. Suppose two points A & B with elevation| Work done =Wfly +Wh = Wf (0 + difference h and straight line distance Lo are to be connected by means of road. Resisting Length = Lr = (10 ie *) 2. Hair Pin Bends camara eee The curve ina hilly road which changes its) 4" {. B direction through an angle 180° is known a as hair pin curve and the bend formed at the hair pin curve is called hair pin bend. This bend should be located on hill side having min. slope and max stability.Some Important terms from Hilly Roads R= Surcharge Loading Breast Wall Parapet Wall m1 Road Retaining Wall Hill Side Valley Side Some Important terms from Hilly Roads bS 3. Retaining Wall: Retaining walls are the most important structure in hill road construction, it provides adequate stability to the road and to the slope. Retaining walls are constructed on the valley side of the roadway. The main function of this wall is to resist the pressure of earth filling 4. Breast Wall: Breast waills are constructed to support uphill slopes of the road cross section. This wall is constructed when hill side is steep and there is tendency of its sliding down towards the road. 5. Land Slide: The term landslide denotes downward and outward movements of material of hill slope consisting of natural soil or disintegrated rocks. Landslide take place along surface of separation by sliding, falling & flowing.Some Important terms from Hilly Roads 6. Parapet Wall: The wall provided above the formation level of hill road, usually towards the downslope side is known as parapet wall. This wall provides protection to the traffic against falling down of hill slope. It is not constructed continuous but generally constructed with a suitable gap for economy point of view. 7. Weep holes: The holes provided in retaining structure such as retaining wall, Breast wall, Abutment et. to drain off the seepage water are known as weep hole. It is generally provided with square shape in staggered fashion.