Introduction

Road pavement construction procedure can be simply as below. Structural part

of a road construction is separated from others.

Embankment construction (if required) Sub grade preparation

Aggregate base course Sub base filling

Prime coat Asphalt binder course

Asphalt wearing course Tack coat

1 Embankment construction

The purpose of constructing the embankment is to provide the base for above layers or to
increase the existing ground level at the shoulder area protecting the ABC or Asphalt layers
as a side retaining structure.

1.1 Borrow pit

Borrow pit is the place where the excavation of the soil materials is occurring for
embankment construction or for sub base layer. This place has the abundance of the required
soil materials such as sub bases, gravel materials for the soil work. It should be close enough
to the construction site when consider the time and cost for the Transportation.

Borrow pit
1.2 Surface preparation for the Embankment

There should be a suitable surface for the filling for the embankment layers. It is important to
well compact this existing ground surface after removing top soil layer of organic matters and
other hazardous materials such as some roots and boulders. Motor Grader or back-hoe loader
is the most suitable machine for the surface preparation at the site.

Filling of an Embankment by
using motor grader

1.3 Setting out the design level

Before the borrow material transported to the site the surveyor set out the line of embankment
fill and finished levels would be marked on the temporary pegs fixed to spreading the soil
material by using motor grader. Leveling instrument is used to set out these design value
nearly for each layer.

1.4 Filling of the Embankment

Filling for the embankment is done layer by layer approximately having 200 mm thickness.
The compacted thickness is around 150mm for each layer. Benching of sloping surface is
carried out where the existing ground has slop. Benching means the cutting of the existing
slop as steps for better filling and compaction. The height of the one cutting steps is nearly
150mm.
 Existing Road Surface
Existing ground
Designed slope

Bench cutting

1.5 Compaction

Compaction should be done before laying the gravel on the ground surface by using 5-10 ton
vibratory rollers for some passes according to their weight. After the laying of each soil layer
the compaction should be carried out by using these rollers as well. If the material is too dry,
water would be added manually before the compaction.

Weight of the roller (ton) Passes for one section of the area
1-3 20-12
5-10 6-4

1.6 Sand cone test

Sand cone test is used to find the in-situ density of the compacted soil layer. The density of
this compacted soil layer should not be less than 95%-98% of the maximum dry density.

Compaction of an embankment
by using roller vibrator
2 Sub grade preparation

It is the soil layer below the sub base and most location it may be naturally occurring soil or
in some places it becomes embankment layer. When the placing of sub base occurs at the
pavement the below sub grade surface should be well compacted and free from other
hazardous. If the exposed layer of soil unsuitable for sub grade, these layers would be
excavated up to the required depth by using a back-hoe loader.

There are some places of water stagnation which mainly affect for the Boggy area. It seems
like sponge of soil layer if that kind of place found, it should be excavated deeper and filled
with boulders, ABC or using sand.

2.1 Sub base construction

Sub base is the base for the Aggregate Base Course (ABC) and the above asphalt layers. This
soil material has high dry density and bearing strength relatively to the embankment material.
Placing of this layer is more important in to some area where the settlement can occur. The
nature of the sub base layer is different according to the design cross section. Sometimes it is
placed in to whole road surface when increase the ground level or in to the pavement above
the sub grade layer for the widening of the road.

2.2 Sub base filling

Before placing the sub base layer, the design level should be marked on the temporary
wooden pegs fixed at the edge of the pavement to spread by using motor grader.

2.3 Compaction

Compaction of the sub base layer should be carried out by using 5 or 8 ton vibratory rollers.
Maximum compacted thickness of a sub base layer should not exceed the 150mm. If water is
required before compaction, the water bowser fitted with sprinklers is used to add the water
evenly for the laid soil material. Sand cone test is used to find the in-situ density of the
compacted soil layer. The density of this compacted soil layer should not be less than 98% of
the maximum dry density.
3 Aggregate Base Course (ABC)

Aggregate Base Course is a composition of course aggregate and quarry dust. It is the base
layer of the binder course. ABC is highly stable for the settlement due to heavy loads
applying on the above road surface and has a high bearing strength than other soil materials.
Normally the thickness of this layer is about 200mm and the maximum aggregate size does
not exceed 40mm.

Aggregate Base Course

(ABC)

3.1 Layering

➢ First the ABC laying is done up to the shoulder level and then evenly spread this
course over the one side of the road which is already allocated for the construction.
➢ This first ABC layer is laid up to the 150 mm thickness because if the layer thickness
is below than 100mm the required compaction cannot be achieved.
➢ Then again ripping should be done by using motor grader for spreading the rest of
ABC.
➢ The final level for the ABC is given by using steel pegs. The design level which is
given by the surveyor is fixed by using the hammer.
➢ Cutting or filling of final ABC layer is done according to these design levels by using
motor grader.
 Unloading of ABC from
Dump Truck

3.2 Compaction

Finished ABC should be regular and smooth because it is the base for the asphalt layer. So
the compaction should be in proper manner and finished level of the ABC course should be
nearly at the design level. 8 or 12 ton vibratory rollers are used for this compaction process.
ABC must be wetted well while roller passing occurs. Field density of compacted ABC must
exceed 98% from maximum dry density. Here sand cone test is used to find the in situ
density.

4 Prime coat

Prime coat is a protective covering for the Aggregate Base Course on which this coat will
apply. Normally MC-30 is used as the prime coat. It consists of medium curing cutback
bitumen at between 25% – 45% and kerosene. There should be a proper surface which is free
of all dust and other loose particles before apply the coat. It is because this coated surface is
the base for the binder layer.

Spraying temperature of MC 30 – (40 0C -70 0C)

Penetration of MC30 – (7mm-10mm) so it act as bonding material of ABC

Spread rate for MC30 – (0.9 -1.1) l/m2. This rate is checked by using the tray test.
4.1 Procedure

➢ Prime area should be allocated assuring the safety from the traffics.
➢ Broomer and Air compressor are used for the cleaning of ABC surface and it should
be dry surface for better coating.
➢ Then surface checking is done whether there are some base failures or settlement
occurs or not.
➢ Before allowing for traffic Sand sealing is done after 24 hours to absorb excess
bitumen from the surface.

5 Asphalt Concreting

The asphalt material compose basically of graded crushed coarse aggregate, fine aggregate,
filler, penetration grade bitumen (60-70). Simply it is the mixture of bitumen and aggregate.

There are two main types of asphalt layers.

1. Binder course
2. Wearing course

5.1 Binder course

Binder course is the initial layer of asphalt concreting and also it is the bed of the wearing
course. So it can provide the strength to the road. Normally the maximum size of the
aggregate particle is 20 mm and the bitumen content should be between 3.5 - 5.5 percentages
of the total weight of the mixture.

5.2 Wearing course

The final layer of the asphalt concreting and also the whole road pavement is the wearing
course. As it is the finish surface of the road, it should be highly concerns that the smoothness
and the quality of the road surface. So it contains quite little amount of bitumen than in binder
course. Normally the percentage of bitumen content by the total weight of mixture is between
4.5% and 5.5%. Wearing course also provides the additional strength to the road further
more.
 Laying Binder Course by
using Asphalt Paver

5.3 Asphalt concrete mixture

Asphalt mixture consists of graded crushed aggregate according to the mix design and
penetration grade bitumen (60 -70). Mixing process is carried out at the asphalt batching
plant. These graded crushed aggregates are mixture of four ranges of sizes which are 0-5mm
size, 5-10mm size, 10-16mm size and 16-20mm.

5.4 Temperatures of the mixture

The temperature of the mixture after batching of asphalt should exceed 145 º C. But normally
it is between 160 º C to 150 º C. Sometimes there was over heated asphalt mixture having
some bituminous dust among the aggregate. These overheated mixes were not used for the
paving as the materials tend to be segregation. Also when the mixture delivers to the paver
machine the mix temperature should not less than 135 º C.

5.5 Tack coat

Cationic rapid setting 1(CRS 1) is applied as tack coat between two asphalt layers before
constructing surfacing as bonding layer. Spraying should be at the rate between 0.25 – 0.5
l/m2. If this rate is high the bleeding of bitumen from the asphalt surface can occur. Tray test
is carried out to find this spraying rate.
5.6 Procedure of asphalt surfacing

5.6.1 Surface preparation

The existing ABC surface is cleaned by using broomer and air compressor. Sometimes there
are some soil particles and dusts in holes of the ABC surface. These extraneous materials
should be removed before laying as it mainly affect for the bond of asphalt layers with the
bed. In such an occasion this unclean surface is washed by using little amount of water as
over wetting of the ABC surface causes lot of damages to the below bed.

5.6.2 Transportation

Asphalt mixture is transported from batching plant to the construction place by using dump
truck. This mixture should be covered with canvas or tent to prevent the reduction of
temperature, addition of dust and other extraneous matters.

5.6.3 Setting out the design level

➢ Before start the paving of asphalt design level values should be given to the steel
string which is fixed in steel pegs. These pegs are normally fixed at the distance of
10m intervals to mark the level values.
➢ After marking of levels on the pegs, the steel string is used to connect these levels.
The purpose of this string is to run the electronic sensor which is attached to the
paver.

Steel peg to fix the steel cable Steel Plate to avoid the sagging of the Cable
5.6.4 Asphalt Paving

Paving of asphalt is the process of spreading of bituminous and aggregate mixture on the
ABC surface. Asphalt paver is the machine use for the paving of this concrete. This asphalt
mixture comes as a smooth regular layer from the paver. Asphalt paver machine has
electronic sensors to keep the required level which is already given to the steel cable.
According to the sensor level the screed of the paver will adjust automatically.

Manual controlling of the screed

to get the even width of Asphalt
layer

Electronic Sensor is moving on

the steel cable

Asphalt Paving

Before commence the paving the screed should be heated to avoid the reduction of
temperature of the mix due to conduction. Otherwise the asphalt tends to stick on the screed
of the paver machine. The three pin steel roller and pneumatic rollers should be arranged
respectively for final compaction.

C-channels are used at the centre of the road to avoid the edge damages until other side of the
wearing course laying. Normally these steel channel sections has the thickness of 50mm.

Install the C channel to

laying the wearing course
5.6.5 Compaction

There are two type of compaction as initial and final compactions apply on the asphalt
surface. The initial compaction is applied by the vibration and tamping of the paver machine.
Final compaction is done by using the three pin roller and the pneumatic tire rollers. To
commence the final compaction, layer temperature must be lower than the 135 0C. Otherwise
asphalt tries to stick to the roller and due to that surface get damaged or whole layer try to roll
outwards. When the roller passing the surfaces of the roller tires should always wet to avoid
the stickiness of asphalt. As initial rolling three pin roller is used with four passes for uniform
compaction and pneumatic tire rollers are used for the kneading of the asphalt mixture and
for smooth compaction. Crack propagating on the asphalt surface happens as rollers passing
occur when mix is cooling below the temperature of 90 º C. Speed of steel wheel roller must
be kept in approximately 3kmph and pneumatic tyre roller is 5kmph. 1 ton double drum
rollers are used to compact joints. It is a more useful compaction machine when the
compaction area is quite small than other area or some area where other rollers cannot be
used.

Triple drum Roller is using

for compaction
6 Road structures

6.1 Introduction

Structure is the very important part of any Civil Engineering construction. Road construction
structures are varying according to the place to place. We can divide main structures of a road
project as below.

➢ Bridge & Culvert

➢ Line drain
➢ House access
➢ Retaining wall
➢ etc

6.2 Bridges

6.2.1 Introduction

Bridge is the structure which construction across the river, steam or lake etc comparatively
more water pass through it. There are two type of bridges which are major and minor. Here
we are going to discus about minor bridge construction. Because of major bridge
construction is a huge part.

Main part of bridge

➢ Base
➢ Abutment wall
➢ Wing wall
➢ Drop wall
➢ Deck slab
➢ Up rights & Hand rails
❖ Base
Base is the very important part any Civil Engineering structure. All the loads of
bridge are bearing from the base. Its main propose is to distribute the load to the
ground uniformly. In our project base is introduce as bottom slab in drawing. Because
of the cross section shape is rectangle and base like slab.

❖ Abutment
This structure is constructed to bear the load which comes from the Deck slab and
protect road side from the erosion. The entire deck slab loads transfer to the base from
abutments. Therefore abutment has to be highly strength due to live loads and dead
loads are very high.

❖ Wing wall
Wing wall is constructed to protect abutments from obstruction and erosion. It is
perpendicular or angle to the abutment. We can see most of time wing wall are 45
degree angle to the abutment.

❖ Drop wall
Major propose of placing drop wall is to provide protection to the structure when
water entering to it.

❖ Deck slab
Deck slab is main part of the bridge because of asphalt layering is place on that.
Design levels of deck slab should be very accurate otherwise asphalt design level
can’t control. Deck slab is connected to the abutment walls are.

❖ Up rights & Hand rails

Up rights & Hand rails are used as a protection fence, helps to things and lives which
is moving on the Bridge that can fall into the steam.
6.3 Culverts

Culver is the structure which construction across the low water passes.

There are two main types of culverts in this project.

❖ Cylindrical or Pipe culvert

❖ Box culvert

6.3.1 Cylindrical or Pipe culvert

It’s also call as concrete pipe culvert or hume pipe culvert. Pipe diameter varies according to
the flow rate, flood level. It will be 600mm, 900mm, 1200mm & etc. Concrete pipe culvert
also can be tow type.
1. End casing type
2. Caddle type

This difference is occurring because of the height from the top surface of the road to the
concrete pipe. When the pipe is too bottom from the top then filling material was used to be
cost effective structure. When the height difference between top surface and top of pipe it
will fill from concrete.

Sub base

Concrete Concrete

End casing type Caddle type

 ❖ Culvert construction
• First excavation is done up to the required level
• Screed concrete layer is laid by grade 15 concrete thickness will be 50mm or
75mm

• Base is normally constructed by grade 25 concrete. Reinforcement size and

arrangement vary with the design.
• After that RRM and other construction is done ( RRM-Random Rubble
Masonry )

”Construction of random rubble masonry”

6.3.2 Box culvert

 ❖ Culvert construction
• First excavation is done up to the required level
• Screed concrete layer is laid by grade 15 concrete thickness will be 50mm or
75mm
• Base is constructed by grade 25 concrete.
• After that RRM and other construction is done ( RRM-Random Rubble
Masonry )
When the abutment wall is RRM.There is concrete beam to fit the deck slab to the
abutment wall. That is called as capping beam. Propose is to give a connection to the
deck slab and abutment wall.

Use of porker vibrator Use of truck mixture to pouring

concrete

6.4 Line drain

Lined drain is construction for the drainage system.

There are three mail types of lined drains.

1. Normal duty lined drain

2. Heavy duty lined drain

3. Special type lined drain

 ❖ Normal duty lined drain
It is used when the heavy loads are not applied.

150mm 150mm

Grade 25 concrete
750mm

Grade 15 concrete

900mm

50mm thick screed

6.4.1 Construction of line drain

➢ First cleared the site and the removed disposal material into suitable place. Clearing
thickness around 150mm.
➢ Marked the line drain edge according to the design offset.
Note: - Edge is marked with providing working area.
➢ Excavated up to the required depth.
➢ Placed the 50mm screed (Grade 15) after preparation the bed surface.
➢ Laid the steel bars according to the drawing and place 40mm covering from the bed
level.
➢ Constructed the formwork for line drain wall and laid the concrete.

Note: - Expansion joints are placed for every 6m interval.

6.5 Pre-cast concrete cover slab

❖ Pedestrian type cover slabs.

This type of cover slabs are used for cover the normal duty type lined drains and
access drains. Load bearing capacity of this type of cover slabs is relatively low.
Hence this type is not use for the vehicular paths.

100mm

“Pedestrian cover slab”

125 mm

450 mm

900 mm

“Plan view of cover slab”

7 Machineries and Equipment

➢ Backhoe Loader
➢ Mortar Grader
➢ Excavator
➢ Concrete Truck Mixture
➢ Dump Truck
➢ Asphalt Paver Machine
➢ Vibrating Rollers
➢ Pneumatic Tire Rollers
➢ Air Compressor
➢ Broomer
➢ Tractor
➢ Rotary core driller
➢ Bitumen Distributer
➢ Loader
➢ Mini Loader
➢ Water Bowser
➢ Plate Vibrator
➢ Asphalt cutter
Asphalt Paver Machine

Asphalt paver is used for lay Binder and wearing

course, it provides a good surface finish and initial
compaction before rolling to the asphalt and wearing
course. It has a container to unload the Asphalt directly
from the tipper. Two sides of this container, the width
and thickness of the lay can be adjusted. The
temperature of the asphalt can be kept without
dropping through the operation in the paver. The paver
can easily handle asphalt and all asphalt mixes, coated
and uncoated materials, crushed stones and dry lean
concrete, in fact all road making materials other than
wet concrete it Should be equipped with electronic
sensor devices to achieve the cross sectional shape.

Triple drum roller

Provide 100% coverage under the wheel

These type rollers used to give the initial

compaction to the asphalt layer. They must
have following requirements.

➢ Minimum weight – 8 ton

➢ Must have capability to reverse and
equipped with power steering, dual
control to operate from either left or right
side and must have water tanks with
sprinkle system to wetting the roller.
Pneumatic Tire Rollers

Pneumatic tyre roller must have more

minimum of 7 wheels (3 in front and 4 in
rear) fitted with smooth thread compactor
tyres of equal size. Wheels must equally
spaced and free to move independently.

Concrete Truck Mixture

Concrete Truck Mixture is used to

transport the Concrete mixture preventing
the mix from external hazardous

Mini Loader

The Mini Loader is used to place soil for

small areas of structural backfilling. This
machine can be easily controlled within a
small area.
Excavator

The Excavator is very important

machinery used in site constructions.
Because of the long arm of this
machinery, this is normally used in
structural excavations. This can travel in
any irregular land by using its chain wheel
set.

Asphalt cutter

Asphalt cutter is used to cut the edges of the

existing asphalt layer. It is mechanically
operated cutter. Breaker is also used for the
above purpose. But it is operated by
pneumatic power.

Motor Grader

Motor grader has been specifically

developed for spreading and leveling of the
sub grade, sub base, ABC surface on the
surface on the road. it can be used to level
the surface horizontally or with slop using
the blade in required plane. Skilled operator
is needed to control the machine.
Concrete core drilling driver

Used to recover the core of asphalt

concrete

Maximum core Diameter – 200mm

Maximum depth of drilled core – 400mm

Angular velocity – 800 r.p.m-1200 r.p.m