By: HIRALAL AGRAWAL

EXECUTIVE ENGINEER
TYPICAL CROSS-SECTION OF A FLEXIBLE
PAVEMENT
 SECTION-1
Embankment/Sub-grade Construction
 The construction of embankments including Sub-grades, earthen
shoulders etc. is governed by Clause 305 of MORT & H
Specification for Roads & Bridge Works (5th revision).
A) Physical Requirements of Materials:
The materials used for construction of embankments/sub-grades/
earthen shoulders/Backfills shall be soil/earth, moorum, fly ash or a
mixture of these or any other materials as approved by the Engineer.
The following types of materials shall be considered unsuitable:-
 Materials from swamps, marshes etc.
 Clay having Liquid Limit (LL) > 50 and Plasticity Index(PI) > 25.
 Expansive Clay exhibiting marked swell & shrinkage properties with
Free Swelling Index > 50.
B) Other Requirements:
(i) The size of the coarse materials/particle in the earth shall
ordinarily not exceed 75mm, when placed in the embankment and
50mm, when placed in the sub-grade.
(ii) Ordinarily, only the materials satisfying the density requirements
given in Table 300-1 of MORT&H spec., 5th Revn shall be used for the
construction of the embankment/sub-grade/shoulders etc.
TABLE 300-1: Density Requirements of Embankment & Sub-
grade Materials
Type of Work Max. dry density (MDD) when tested
in lab as per IS: 2720 (Part-8)
Embankments up to 3m height, not Not less than 1.52gm/cc or
subjected to extensive flooding. 15.2 KN/cum
Embankments exceeding 3m height or Not less than 1.60gm/cc or
embankments of any height subject to 16.0KN/ cum
long periods of inundation.
Sub-grade/Earthen Shoulders/ Not less than 1.75gm/cc or 17.5KN/cum
Backfill

NOTE: 1) The above table is not applicable for lightweight fill materials. e.g.
Fly-ash, etc.
2) The material to be used in Sub- grade shall be non-expansive and
shall satisfy the design CBR.
iii) It shall be ensured prior to actual execution that the
material to be used in the Sub-grade satisfies the
requirements of design CBR.

iv)The field/actual CBR of the constructed sub-

grade shall be determined on remoulded samples,
compacted to the field density at the field moisture
content and tested for 4 days’ soaked condition at Lab.

C) The materials used for embankment construction

shall be tested for sieve analysis, LL/PL, MDD/
OMC, CBR etc. at Lab & got approved from the
Engineer prior to use.
D) The following routine tests on representative samples of earth
shall be carried out for every 3000 cum for each source during
construction as per Section 900 of MORT&H Specification, 5th
Revision.
 Sand Content/Sieve Analysis = 2 tests [As per IS:2720, Part-4]
 Atterberg Limits (LL/PL)tests = 2 tests [As per IS:2720, Part-5]
 Density test (MDD/OMC) = 2 tests [As per IS:2720, Part-8]
 Moisture Content test = 2 tests [As per IS:2720, Part-2]
 CBR tests = 1 test [As per IS:2720, Part-16]
E) Compaction Control at Field:
Field Density shall be conducted on each finished layer by taking
at least one set of 10 measurements of density for each 3000 sqm of
compacted area or closer in accordance with IS: 2720 (Part-28)
[Sand Replacement Method]. Test locations shall be chosen only
through random sampling techniques.
The acceptance criteria shall be subject to the condition that the
Average Mean density is not less than the Specified Density
Plus [1.65 – 1.65/ (No. of samples) 0.5] times the standard
deviation (S.D). If the no. of density measurement/ samples=10,
then the average mean density should not be less than the specified
density plus 1.13 times the S.D.
 SECTION-2
CONSTRUCTION OF GRANULAR SUB-BASE (GSB)
1) The construction of GSB is governed by Clause 401 of MORT&H
Specifications for Road & Bridge Works (5th Revision).
2) The materials to be used for GSB work shall be natural sand,
Crushed stone, Crushed Slag or combination thereof depending
upon the grading required.
3)The type of grading of GSB to be adopted in a particular work shall be
clearly specified in the BOQ/Contract and accordingly required
materials to be used in GSB are decided.
4) As per MORT&H Specification,4th Revision, which is also mostly
being used today, there are 6 types of GSB
 Close-graded GSB- Gr-I, Gr-II, Gr-III
 Coarse-graded GSB- Gr-I, Gr-II, Gr-III
5) As per MORT&H Specification, 5th Revision, there are 6 types of
GSB, namely Grading I, II, III, IV, V & VI. Grading III & IV shall
preferably be used in lower sub- base, and Grading V & VI shall
be used as a sub-base cum drainage layer. The grading requirements
of these GSBs are given in Table 400-1 of MORT&H Specification, 5th
Revision.
6)Other physical Requirements for Materials for GSB
Test Test Method as per Requirements
Aggregate Impact Value IS: 2386 (Part- 4) Maximum 40%
(AIV)
Liquid Limit (LL) IS: 2720 (Part- 5) Maximum 25
Plasticity Index (PI) IS: 2720 (Part- 5) Maximum 6
Water absorption of IS: 2386 (Part- 3) Maximum 2%
Aggregates
CBR (at 98% of MDD, IS: 2720 (Part- 5) Minimum 30%
determined as per IS: 2720,
Part-8)

7)The mix design of GSB to be done at laboratory prior to

execution of the work to arrive at the proportions of various
materials to be used/ Job-Mix Formula (JMF). The GSB work is to be
carried out strictly as per the JMF prescribed by the LAB.
8) GRADING for GSB Materials (Table 400-1 of MORTH, 5th
Revision)
IS Sieve Gr I Gr II Gr III Gr IV Gr V Gr VI
75.0mm 100 - - - 100 -
53.0mm 80-100 100 100 100 80-100 100
26.5mm 55-90 70-100 55-75 50-80 55-90 75-100
9.50mm 35-65 50-80 - - 35-65 55-75
4.75mm 25-55 40-65 10-30 15-35 25-50 30-55
2.36mm 20-40 30-50 - - 10-20 10-25
0.85mm - - - - 2-10 -
425mic 10-15 10-15 - - 0-5 0-8
75mic <5 <5 <5 <5 - 0-3
9) At the time of compaction, the moisture content of the GSB mix shall
be so adjusted that it lies from 1 to 2% below the Optimum Moisture
Content (OMC).Rolling shall be continued till the density
achieved is at least 98% of the Maximum Dry Density (MDD),
determined at LAB as per IS: 2720 (Part-8). The %age/ degree of
compaction of the compacted layer of GSB to be tested at field as per
IS: 2720 Part-28 (Sand Replacement Method), generally using
Bigger Sand Pouring Cylinder.
10)Various Routine Quality Control Tests as prescribed in Table 900-3
of MORT&H Specification (5th Revision), shall be carried out during
execution of GSB, some of which are given below:

Test Frequency(Minimum)
Gradation 1 test per 400 cum.
Atterberg Limits 1 test per 400 cum.
Moisture content prior to compaction 1 test per 400 cum.
Density of compacted Layer 1 test per 1000 sqm.
 SECTION-3
CONSTRUCTION OF BASE (NON-BITUMINOUS)
1) WATER BOUND MACADAM(WBM) (Popularly known as
Metalling)
i) The construction of WBM is governed by Clause 404 of
MORT&H Specification, 5th Revision & consists of crushed/
broken aggregates (popularly known as ‘Metals’), mechanically
interlocked by rolling and bonding together with stone screening,
binding materials (wherever necessary) and water, laid on a
properly prepared Sub-grade/Sub-base/ base or existing pavement
as the case may be.

ii) Materials for WBM

a) Screenings
It shall generally consist of stone screenings. However, in some
cases we can allow moorum/ gravel, provided Liquid Limit(LL) and
Plasticity Index (PI) of such materials are below 20 and 6
respectively and also fraction passing 75 mic. Sieve does not exceed
10%. The grading requirement of Screening is given in Table 400-10
of MORT&H Specification, 5th Revision.
b) Coarse Aggregates (‘Metals’)
These shall be either crushed/broken stones, crushed slag etc. of suitable
quality, the physical requirements of which are given in table 400-8 of MORT&H
Spec., 5th Revn and reproduced below:-
Physical Requirements of Coarse Aggregates for WBM
Test Test Method Requirements
Los Angeles Abrasion (LA) Maximum 40%
Value IS:2386 (Part-4)
or
Aggregate Impact
Value(AIV) Maximum 30%
Flakiness & Elongation
Index IS:2386 (Part-1) Maximum 35%
(FI & EI) (Total)
Water Absorption IS:2386 (Part-3) Maximum 2%

NOTE: - If the water absorption value is greater than 2%, Soundness test
shall be done as per IS: 2386 (Part-5).
 Grading Requirements of Coarse Aggregates for WBM (Table 400-9)
Grading No. Size Range IS Sieve Cum %age passing
1 63 to 45mm 75mm 100
63mm 90-100
53mm 25-75
45mm 0-15
22.4mm 0-5
2 53 to 22.4mm 63mm 100
53mm 95-100
45mm 65-90
22.4mm 0-10
11.2mm 0-5

NOTE: - The compacted thickness for a WBM Layer shall be 75mm.

iii) Routine Quality Control Tests for WBM during execution:
Tests Frequency (Minimum)
Aggregate Impact Value (AIV) 1 test per 1000 cum of Aggregates
Grading of Aggregates 1 test per 250 cum of Aggregates
 2)WET MIX MACADAM (WMM)
1) The construction of WMM is governed by Clause 406
of MORT&H Specifications, 5thRevn. WMM
consists of laying and compacting clean, crushed,
graded aggregates & granular materials, mixed with
water &thoroughly mixed up in a Wet Mix Plant.
2) Generally 40mm, 20mm, 10mm, 6mm, Crusher/Stone
dust is used for preparation of WMM Mix.
3)WMM can be laid in one or more layers. The thickness
of a single compacted layer of WMM shall not be less
than 75mm. However we can go up to 150mm
thickness, if vibratory roller is used.
4) The physical requirements of Coarse Aggregates are
same as in case of WBM.
 GRADING REQUIREMENTS OF WMM
IS Sieve Cum % by weight passing the sieve
53.0 mm 100
45.0 mm 95-100
26.5 mm -
22.4 mm 60-80
11.2 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600 mic 8-22
75 mic 0-5
NOTE:
1)Materials finer than 425 mic sieve shall have PI < 6.
2)The final gradation for WMM shall be such that it shall not vary from
the low limit on one sieve to the high limit on the adjacent sieve or vice
versa.
5)Mix design of WMM is to be done at laboratory before
execution to find out the Job- Mix Formula (JMF)/
proportioning of various materials to be used and also
MDD/OMC. The WMM work is then done strictly as
per the JMF.
6)The moisture content of the WMM mix at the time of
compaction should be 1-2% less than the
corresponding OMC, found out at Lab.
7)Rolling shall be continued till the density achieved is
at least 98% of the MDD determined at Lab as per IS:
2720 Part-8.
8)No vehicular Traffic, other than construction
equipments, shall be allowed on the finished WMM
surface.
9)Routine Quality Control Tests of WMM during execution.
Tests Frequency (Minimum)
Aggregate Impact Value (AIV) 1 test per 1000 cum of
aggregates
Grading of Aggregates and Atterberg 1 test per 200 cum of
Limits. aggregates
Combined Flakiness & Elongation Index 1 test per 500 cum of
aggregates
Density of compacted layer/ Field 1 set of 3 tests for 1000 sqm
Density
10)In case it is found that there is appreciable variation in gradation and
other properties of aggregates being used in the work from those tested
during mix- design at Lab, the JMF is to be suitably revised in Lab and then
used in the work.
11)The acceptance criteria for density tests in WMM shall be same as that in
case of embankments/ sub- grade construction.
12)The detailed procedure of construction of WMM is given in Clause 406.
 SECTION-4
CONSTRUCTION OF BASE COURSE(BITUMINOUS)
 The frequently used bituminous base course/ Binder Course are
Bituminous Macadam (BM) / Dense Bituminous Macadam
(DBM).
 The general requirements for construction of bituminous pavement
layers/ courses are covered in Section 500 of MORT&H Specifications,
5th Revision.
1)BITUMINOUS MACADAM (BM) :
 The construction of BM is governed by Clause 504 of MORT&H Spec.,
5th Revn.
 BM consists of construction of single course of 50-100 mm thickness
or multiple courses of compacted crushed aggregates premixed with
bitumen, prepared/ mixed up in a Hot-Mix Plant (HMP) and laid
usually over a prepared base or existing BT surface through paver.
 Materials for BM
 Bitumen (Paving grade conforming to IS:73)
 Coarse Aggregates, consisting of crushed stone retained on 2.36
mm sieve.
 Fine aggregates, consisting of crushed mineral materials, passing 2.36
mm sieve & retained on 75 mic sieve.
 In general, 20mm, 10mm, 6mm & crusher dust along with Bitumen
is used for preparing BM Gr-II mix and 25mm, 20mm, 10mm, 6mm
& crusher dust along with bitumen is used for BM Gr-I Mix.
Important Physical Properties of Coarse Aggregates for BM
Property Test Requirements
Strength LA Value Maximum 40%
Or
AIV Maximum 30%
Particle Shape Combined FI & EI Maximum 35%
Durability Soundness Test (5 cycles)
Sodium Sulphate Maximum 12%
Magnesium Sulphate Maximum 18%
Porosity Water Absorption Maximum 2%
Stripping Coating & Stripping of Minimum retained
Bitumen Aggregate coating 95% (IS:6241)
Aggregate Grading & Bitumen Content for BM
Grading 1 2
Nominal Max aggregate 37.5mm 19mm
Size
Layer thickness 80-100mm 50-75mm
IS Sieve Size Cum %age passing Cum %age passing
45mm 100 -
37.5mm 90-100 -
26.5mm 75-100 100
19.0mm - 90-100
13.2mm 35-61 56-88
4.75mm 13-22 16-36
2.36mm 4-19 4-19
300mic 2-10 2-10
75mic 0-8 0-8
Bitumen content 3.3% 3.4%
 The mix design is to be done at Lab to determine Job-Mix
Formula (JMF) i.e. proportioning of various materials & the
density of the mix. Then the work is to be executed strictly
as per the JMF.

 The bitumen temperature, aggregate temperature,

mix temperature, laying and rolling temperature,
shall be 150- 165, 150-170, 150-165, 140 minimum and
900 C minimum respectively when VG- 30 grade bitumen
is used.

 Rolling must be completed before the mat cools down to

900 C and shall be continued until the desired density is
achieved or there is no further movement of mix under the
roller.
 Routine Quality Control Tests for BM during execution
Tests Frequency (Minimum)
Grading of aggregates 2 tests per day
Bitumen Content 2 tests per day per plant
Other physical properties such At regular interval, at least 1 test
as AIV, FI & EI, etc. for each source.
Mix temperature at the time of At regular intervals.
laying & compaction and also at
HMP.
 In case, it is found that there is appreciable/ large variation in
gradation & other properties of aggregates being used from
those tested during the mix design at Lab, the JMF is suitably
revised and a fresh density is also determined at Lab and
accordingly the work is executed.
 The detailed procedure of construction of BM is given in
Clause 504 of MORT&H Specification, 5th Revision.
2)DENSE BITUMINOUS MACADAM (DBM)
 The construction of DBM is governed by Clause 505 of MORT&H Spec.
for Road & Bridge Works, 5thRevn.
 DBM is mostly used in Base/Binder course and is laid in a single or
multiple layers on a previously prepared base or sub-base. The
thickness of a single layer shall be 50mm to 100mm.
 DBM consists of a mixture of crushed aggregates of various sizes
premixed with bitumen, prepared/ mixed up in a Hot- Mix Plant
(HMP) and laid with a paver machine.

 Materials for DBM

 Bitumen (Paving grade conforming to IS:73)
 Coarse Aggregates, consisting of crushed rock/stone retained on 2.36
mm sieve.
 Fine aggregates, consisting of crushed mineral materials, passing 2.36
mm sieve & retained on 75 mic sieve.
 Filler, consisting of finely divided mineral matter such as crushed
stone/dust, hydrated lime or cement, 100% passing in 600 mic
sieve, 95-100% passing in 300 mic sieve & 85-100% passing in 75 mic
sieve.
 Physical Requirements for Coarse Aggregates for DBM
Same as that in case of BM, except the LA & AIV value. The maximum
LA value & AIV in case of DBM is 35% & 27% respectively.
 Aggregate Gradation & Bitumen Content for DBM (Table 500-10)
Grading 1 2
Nominal maximum 37.5 mm 26.5 mm
aggregate size
Layer thickness 75-100 mm 50-75 mm
IS Sieve Cumulative %age passing Cumulative %age passing
45mm 100 -
37.5mm 95 -100 100
26.5 mm 63- 93 90-100
19.0 mm - 71-95
13.2 mm 55-75 56-80
4.75mm 38-54 38-54
2.36mm 28-42 28-42
300 mic 7-21 7-21
75 mic 2-8 2-8
Bitumen Content Minimum 4% Minimum 4.5%
 NOTE:
 The combined aggregate grading shall not vary from the low limit on one sieve to the
high limits on the adjacent sieve and vice versa.
 The bitumen content indicated above is minimum only and the actual bitumen
content is to be found out at Lab by doing Mix-design (Marshall Method).
 The fines to bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.
Mix Requirements for DBM (Table 500-11)
Properties In case of Viscosity grade paving In case of Modified bitumen (Hot
bitumen Climate)
Compaction level 75 blows on each face of the Marshall 75 blows on each face of the Marshall
Specimen. Specimen.
Minimum Marshall Stability (at 600c) 9KN or 900Kg 12KN or 1200Kg

Marshall Flow (mm) 2-4 2.5-4

Marshall Quotient (Stability/ Flow) 2-5 2.5-5
%age air voids 3-5 3-5

%age voids filled up with Bitumen 65-75 65-75

(VFB)
Coating of aggregates 95% minimum 95% minimum

%age voids in Mineral Aggregates 12% for DBM Gr-II 12% for DBM Gr-II
(VMA) & &
11% FOR DBM Gr-I 11% for DBM Gr-I
 Before execution of the DBM work, mix-design is to be done at
laboratory and a Job-Mix Formula (JMF) is to be found out/
proposed for use in the works. The JMF should be based on a correct
and truly representative sample of materials that will actually be used
in the work. The work should be executed strictly as per the laboratory
JMF.
 Whenever there is a change in source of materials to be proposed, a
new JMF shall be worked out at Lab through a revised mix-design.
 Once the Lab JMF is approved, plant trials should be done at HMP site
so as to ensure that the plant can produce a uniform mix conforming to
the approved JMF with the permissible variations as per Table 500-13.
 The temperatures to be maintained in bitumen, aggregates, mix and
the laying and compacting temperature etc. are same as in case of BM
and to be strictly ensured during execution of the DBM work.
 Rolling shall continue until the desired density i.e. 92% of GMM
 (Approximately 95-96% of Lab Density) is achieved at field. It is to
be checked by taking 150mm size cores from the compacted layer of
DBM through core cutter machine.
 Rolling must be completed before the mat cools down to 900 C.
  Routine Quality Control Tests for DBM during execution
Test Frequency (Minimum)
Grading/Sieve Analysis 1 set for individual constituents & mixed
And aggregate from dryer for each 400 tons of
Bitumen Content DBM mix subject to minimum of 2 tests
per day per plant.
AIV and FI & EI etc. 1 test per 350 cum of aggregates for each
source & whenever there is change in
source/ quality of aggregates.
Stability and voids analysis 3 tests for stability/ flow value, density
and air voids etc. for each 400 tons of mix
subject to minimum of 2 tests per day per
plant.
Temperature of DBM mix at the time of
laying & compacting & also in HMP. At regular intervals.
• In case it is found that there is appreciable variation in gradation & other properties
of aggregates being used from those tested during mix design at lab, the JMF is
suitably revised & a fresh mix design is done at lab and then the work is executed as
per the revised JMF.
• The detailed procedure of construction of DBM is given in Clause 505 of MORT&H
Specification, 5th Revision.
 SECTION-5
CONSTRUCTION OF BITUMINOUS WEARING COURSE
The frequently used bituminous wearing courses are Semi- Dense
Bituminous Concrete (SDBC), Bituminous Concrete (BC), Open
graded premium surfacing [popularly known as Pre Mix Carpet
(PMC)] along with seal coat (SC), close - graded Premix Surfacing
[Mixed Seal Surfacing (MSS)].
1) Semi- Dense Bituminous Concrete (SDBC)
 The construction of SDBC is governed by Clause 508 of MORT&H
Specification for Roads & Bridges, 4th Revision and IRC: 111-
2009.
 SDBC is laid in single layer of 25mm to 40mm.
 It generally consists of a mixture of crushed aggregates of various
sizes & bitumen, premixed in a Hot- Mix Plant (HMP) & laid with a
paver machine.
 Materials for SDBC
Coarse aggregates, Fine aggregates, filler, etc.
 Physical properties of Coarse Aggregates for SDBC are same as
that in case of DBM, except additional requirement of Polished
Stone Value, which should be minimum 55%.
 Aggregate grading and binder Content for SDBC
(Table: 500-15 of MORT&H Specification, 4th Revision)
Grading Gr-I Gr-II
Nominal Max Aggregate 13.2mm 9.5mm
Size
Layer Thickness 40mm 25mm
IS Sieve Cum %age passing Cum %age passing
19.0mm 100 -
13.2mm 90-100 100
9.5mm 70-90 90-100
4.75mm 35-51 35-51
2.36mm 24-39 24-39
1.18mm 15-30 15-30
3oo mic 9-19 9-19
75 mic 3-8 3-8
Bitumen Content Minimum 4.5% Minimum 5%
 Mix Requirements of SDBC
Same as that in case of DBM except the VMA which is 14% for SDBC Gr- I & 15%
for SDBC Gr-II.
 Before execution of the SDBC works, mix design is to be done at lab and a Job-
Mix Formula (JMF) is to be found out/proposed for use in the works. The JMF
should be based on a correct and truly representative sample of materials that
will actually be used in the work. The work should be executed strictly as per
the lab JMF.
 Whenever there is a change in source of materials, a new JMF shall be worked
out at lab through a revised Mix Design.
 Once the lab JMF is approved, plant trials should be done at HMP site so as to
ensure that the plant can produce a uniform mix conforming to the approved
JMF with the permissible variation as per Table 500-13 of MORT&H
Specification, 4th Revision.
 The temperature and compaction requirements are the same as in case of
DBM.
 The routine quality control tests for SDBC to be done at field lab during
execution of the work are almost the same as in case of DBM.
 In case, it is found that there is appreciable variation in gradation & other
properties of aggregates being used from those tested during mix design at lab,
the JMF is suitably revised & a fresh mix design is done at lab and then the
work is executed as per the revised JMF.
 The detailed procedure of construction of SDBC is given in Clause 508 of
MORT&H Specification, 4th Revision.
2) Bituminous Concrete (BC)
 The construction of BC is governed by Clause 507 of
MORT&H Specification of Roads & Bridges, 5th Revision.
 BC is laid in single layer of 30mm / 40mm/ 50mm.
 It generally consists of a mixture of crushed aggregate of
various sizes and bitumen, premixed in a HMP and laid
with a paver machine.
 Materials for BC
Bitumen, Coarse aggregates, Fine aggregates, filler, etc. as
in case of DBM / SDBC.
 The physical properties of Coarse Aggregates for BC
are same as in that in case of SDBC, except the LA & AIV
requirement. The maximum LA & AIV in case of BC is 30%
& 24% respectively.
Aggregate grading and Binder Content for BC (Table 500-17)
Grading 1 2
Nominal Max Aggregate Size 19mm 13.2mm
Layer Thickness 50mm 30-40mm
IS Sieve Cum %age passing Cum %age passing
26.5mm 100 -
19.0mm 90-100 100
13.2mm 59-79 90-100
9.5mm 52-72 70-88
4.75mm 35-55 53-71
2.36mm 28-44 42-58
1.18mm 20-34 34-48
6oo mic 15-27 26-38
300 mic 10-20 18-28
150 mic 5-13 12-20
75 mic 2-8 4-10
Bitumen Content Minimum 5.2% Minimum 5.4%
 The mix requirements of BC such as stability, flow, air voids, etc.
are same as that in case of DBM/ SDBC except the VMA, which is
13% for BC Grade-I
 The other requirements such as temperature, compaction &
routine quality control tests, etc. are almost same as in case of
DBM/SDBC.
 Before execution of the BC works, mix design is to be done at
lab and a Job- Mix Formula (JMF) is to be found out for use in
the works. The JMF should be based on a correct and truly
representative sample of materials that will actually be used in
the work. The work should be executed strictly as per the lab
JMF.
 Whenever there is a change in source of materials, a new JMF
shall be worked out at lab through a revised Mix Design.
 Once the lab JMF is approved, plant trials should be done at
HMP site so as to ensure that the plant can produce a uniform
mix conforming to the approved JMF with the permissible
variation as per Table 500-13 of MORT&H Specification, 5th
Revision.
OPEN- GRADED PREMIX SURFACING (Popularly known as PMC)
 It is an open-graded mix of 20mm thickness, composed of stone
aggregates of nominal size 13.2mm(passing 22.4mm and retained
on 11.2mm sieve) (67%) and 11.2mm (passing 13.2mm and retained
on 5.6mm sieve) (33%), premixed with bitumen (@1.46Kg/m2) and
prepared in a hot mix plant (HMP) and laid over a prepared base.
 The construction of PMC is governed by Clause- 510 of MORT&H
Specification, 5th Revision.
 The physical requirements of Aggregates are same as that in case of
BM except that the water absorption value shall not be more than
1% and stone polished value shall not be less than 55.
 If the loose density/ specific gravity of the above 2 aggregates i.e.
13.2 and 11.2mm are almost same, then the above proportions of
67% and 33% by volume can also be taken as same proportion by
weight also. In that case, one tentative combined grading limits of
PMC mix has been developed empirically in lab, which is given in
the next slide:
 IS Sieve Cum %age passing by weight of total
aggregates
22.4mm 100
11.2mm 25-35
5.6mm 0

 Routine quality control tests are to be done during

execution in accordance with Table 900-4 of MORT&H
Specification, 5th Revision.
 Seal coat (SC) is to be applied to the PMC surface
immediately after laying the PMC.
 No traffic shall be allowed on the PMC surface until the
seal coat is laid. The traffic may be allowed soon after final
rolling when the premixed SC materials has cooled down to
the surrounding temperature. However, in case of Type-A
sealcoat, traffic should not be permitted until the next day.
 SEAL COAT (SC)
 It is applied for sealing the voids on the PMC surface so
as to make the finished surface less permeable to
water.
 There are 2 types of SC, namely Type A (Liquid SC)
using stone chips of 6.7mm size (100% passing 11.2mm
& retained on 2.36mm) & Bitumen; Type B (Premixed
SC) comprising sand or crusher dust passing 2.36mm
sieve and retained on 180 mic sieve & Bitumen.
 Premixed SC is generally mixed/ prepared in Hot Mix
Plant.
 The details of SC is given in Clause 511 of MORT&H
Specification, 5th Revision.
 CLOSE-GRADED PREMIX SURFACING (MSS)
 It is a close graded mix of 20mm thickness, composed of graded aggregates
premixed with Bitumen, prepared in a HMP.
 It is generally used as a wearing course on light-trafficked road and high rainfall
areas and is of 2 types i.e. Type A or Type B.
 The physical requirements of coarse aggregates for MSS are same as in case of
Open Graded Premix Surfacing (PMC).
 Aggregate Gradation for MSS (Table 500-19)
IS Sieve Cum %age passing for Type A Cum %age passing for Type B
13.2mm - 100
11.2mm 100 88-100
5.6mm 52-88 31-52
2.8mm 14-38 5-25
90 mic 0-5 0-5
Bitumen 2.2Kg/sqm 1.9Kg/sqm

• Routine Quality Control Tests to be done are same as in case of PMC work.
• Traffic may be allowed after completion of the final rolling when the mix has
cooled down to the surrounding temperature.
THANK YOU