Prime Coat Over Granular Base

Prime Coat Over Granular Base

Single coat of low viscosity liquid bituminous material

Materials:
Cationic bitumen emulsion SS1 grade
Medium curing cutback bitumen

Quantity of bitumen emulsion for various types of granular surfaces (Table 500-3)
Type of surface Rate of Spray (kg/sq.m)
WMM/WBM 0.7-1.0
Stabilized soil bases/Crusher Run Macadam 0.9-1.2

Type and Quantity of Cutback bitumen for various types of granular surfaces (Table 500-4)

Type of surface Type of Cutback Rate of Spray (kg/sq.m)

WMM/WBM MC 30 0.6-0.9
Stabilized soil bases/Crusher Run Macadam MC 70 0.9-1.2

Desired penetration requirement: 8-10 mm

Tack Coat
 Tack Coat

Single coat of low viscosity liquid bituminous material to existing bituminous, cement
concrete or primed granular surface.

Materials:
Cationic bitumen emulsion RS1 grade
Low viscosity paving bitumen of VG 10 grade
Cutback bitumen RC 70: Shall be restricted for sites at sub-zero temperatures

Rate of application of Tack Coat (Table 500-5)

Type of surface Rate of Spray (kg/sq.m)

Bituminous surfaces 0.20-0.30
Granular surfaces treated with primer 0.25-0.30
Cement concrete pavement 0.30-0.35
Bituminous Macadam
 Bituminous Macadam, BM
Single course having 50-100 mm thickness
Multiple courses on crushed aggregates premixed with bituminous binder
Open Graded
May trap water
Hence, proper drainage is required on shoulders

Binder: Viscosity Grade (IS 73)

Coarse Aggregate: Should have at-least two fractured faces and satisfy requirements stated in Table
below:
Property Test Requirement Test method
Cleanliness Grain size analysis Max. 5% passing 0.075 IS: 2386 Part I
micron
Particle shape Combined Flakiness & Elongation Indices Max. 35% IS: 2386 Part I
Strength Los Angeles Abrasion Value or Aggregate Max. 40% IS: 2386 Part IV
Impact Value Max. 30% IS: 2386 Part IV
Durability Soundness 5 cycles
Sodium Sulphate Max. 12% IS: 2386 Part V
Magnesium Sulphate Max. 18% IS: 2386 Part V

Water Absorption Water Absorption Max. 2% IS: 2386 Part III

Stripping Coating and Stripping of bitumen aggregate Min. Retained Coating 95% IS:6241
Water sensitivity Retained Tensile strength Min. 80% AASHTO 283

If min. Tensile Strength is less than 80%, use of antistripping agent is recommended.
 Grading 1 2
Nominal maximum aggregate size 40 mm 19 mm
Layer Thickness 80-100 mm 50-75 mm
IS Sieve size (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.3 2-10 2-10
0.075 0-8 0-8
Bitumen content** percent by mass of total mix 3.3** 3.4**

** Corresponds to specific gravity of aggregate 2.7

• In case aggregates have specific gravity more than 2.7, bitumen content can be reduced
proportionately.
• For regions where highest daily mean air temperature is 30°C or lower and lowest daily mean
air temperature is -10°C or lower, the bitumen content may be increased by 0.5 percent.
Dense Bituminous Macadam
 Dense Bituminous Macadam

Single course or Multiple course having 50-100 mm thickness.

Binder: Viscosity Grade (IS 73)
Coarse Aggregate: Should have at-least two fractured faces.
Fine Aggregate: Sand Equivalence value (IS:2720) ≥50
Plasticity Index should not exceed 4.

Physical Requirements for Coarse Aggregate (Table 500-8)

Property Test Requirement Test method
Cleanliness Grain size analysis Max. 5% passing 0.075 IS: 2386 Part I
micron
Particle shape Combined Flakiness & Elongation Indices* Max. 35% IS: 2386 Part I
Strength Los Angeles Abrasion Value or Aggregate Max. 40% IS: 2386 Part IV
Impact Value Max. 30% IS: 2386 Part IV
Durability Soundness either: Sodium Sulphate or Max. 12%
Magnesium Sulphate Max. 18% IS: 2386 Part V
IS: 2386 Part V

Water Absorption Water Absorption Max. 2% IS: 2386 Part III

Stripping Coating and Stripping of bitumen aggregate Min. Retained Coating 95% IS:6241
Water sensitivity Retained Tensile strength** Min. 80% AASHTO 283

If min. Tensile Strength is less than 80%, use of antistripping agent is recommended.
 Grading Requirements for
Gradation of DBM
Mineral Filler
Grading DBM 1 DBM 2
IS Cumulative Percent Passing by
Nominal maximum 37.5 mm 26.5 mm Sieve Weight of Total Aggregate
aggregate size (mm)
Layer Thickness 75-100 mm 50-75 mm 0.6 100
IS Sieve size (mm) Cumulative % by weight of total 0.3 95-100
aggregate passing 0.075 85-100
45 100 -
37.5 95-100 100
26.5 63-93 90-100 Filler: Cement, rock dust,
19 - 71-95 hydrated lime.
13.2 55-75 56-80 It should be free from organic
9.5 - - impurities.
4.75 38-54 38-54 PI<4
2.36 28-42 28-42
1.18 - -
0.6 - -
0.3 7-21 7-21
0.15 - -
0.075 2-8 2-8
Bitumen content** percent Min 4** Min 4.5**
by mass of total mix
 Requirements for DBM Mix (Table 500-11)

Properties Viscosity Modified bitumen Test Method

Grade Paving
Bitumen Hot Climate Cold Climate

Compaction level 75 blows on each face of the specimen

Min. Stability (kN at 60°C) 9 12 10 AASHTO T245
Marshall flow (mm) 2-4 2.5-4 3.5-5 AASHTO T245
Marshall Quotient 2-5 2.5-5 MS-2 and ASTM
(Stability/Flow) D2041
% air-voids 3-5
% Voids Filled with 65-75
Bitumen (VFB)
Coating of aggregate 95% min. IS:6241
particle
Tensile Strength Ratio 80% min. AASHTO T 283
Fines to Bitumen (F/B) 0.6-1.2
 % Voids in Mineral Aggregate (VMA) (Table 7.3 MS-2)

NMAS Minimum VMA Percent Related to Design Percentage Air Voids

mm 3 4 5
1.18 21.5 22.5 23.5
2.36 19 20 21
4.75 16 17 18
9.5 14 15 16
12.5 13 14 15
19 12 13 14
25 11 12 13
37.5 10 11 12
50 9.5 10.5 11.5
63 9 10 11

Note: Interpolate min. VMA for design percentage air-voids

For Maximum Aggregate Size > 26.5 mm, modified Marshall method is recommended
Minimum Stability 2.25 times the min. stability for Marshall Method
Minimum Flow 3 mm
For example, if Min. Stability with Marshall is 9 kN, the Min. Stability for mix with
aggregate size > 26.5 mm will be 9*2.25 = 20.25 kN
Bituminous Concrete
 Bituminous Concrete
Single course with 30 mm/ 40 mm/ 50 mm thickness.
Coarse Aggregate: Should have at-least two fractured faces.
Fine Aggregate: Sand Equivalence value (IS:2720) ≥50
Plasticity Index should not exceed 4.
Physical Req. for Coarse aggregate
Property Test Requirement Test
Grading Requirements for method
Mineral Filler
Cleanliness Grain size analysis Max. 5% passing IS: 2386
0.075 micron Part I

IS Cumulative Percent Passing by Particle Combined Flakiness & Max. 35% IS: 2386
Sieve Weight of Total Aggregate shape Elongation Indices Part I
(mm)
Strength Los Angeles Abrasion Value Max. 40% IS: 2386
0.6 100 or Aggregate Impact Value Max. 30% Part IV

0.3 95-100 Durability Soundness Max. 12%

Sodium Sulphate Max. 18% IS: 2386
0.075 85-100 Magnesium Sulphate Part V

Water Water Absorption Max. 2% IS: 2386

Absorption Part III
Stripping Coating and Stripping of Min. Retained IS:6241
Filler: Cement, rock dust, bitumen aggregate Coating 95%
hydrated lime.
Water Retained Tensile strength Min. 80% AASHTO
It should be free from organic sensitivity 283
impurities.
PI<4
 Gradation for BC

Grading BC 1 BC 2
Nominal maximum aggregate size 19 mm 13.2 mm
Layer Thickness 50 mm 30-40 mm
IS Sieve size (mm) Cumulative % by weight of total aggregate passing
45
37.5
26.5 100
19 90-100 100
13.2 59-79 90-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content** percent by mass of total mix Min 5.2* Min 5.4**
 Requirements for BC Mix

Properties Viscosity Grade Modified bitumen Test Method

Paving Bitumen
Hot Climate Cold Climate

Compaction level 75 blows on each face of the specimen

Min. Stability (kN at 9 12 10 AASHTO T245
60°C)
Marshall flow (mm) 2-4 2.5-4 3.5-5 AASHTO T245
Marshall Quotient 2-5 2.5-5 MS-2 and ASTM
(Stability/Flow) D2041
% air-voids 3-5
% Voids Filled with 65-75
Bitumen (VFB)
Coating of aggregate 95% min. IS:6241
particle
Tensile Strength Ratio 80% min. AASHTO T 283
Fines to Bitumen (F/B) 0.6-1.2
 % Voids in Mineral Aggregate (VMA) (Table 7.3 MS-2)

NMAS Minimum VMA Percent Related to Design Percentage Air Voids

mm 3 4 5
1.18 21.5 22.5 23.5
2.36 19 20 21
4.75 16 17 18
9.5 14 15 16
12.5 13 14 15
19 12 13 14
25 11 12 13
37.5 10 11 12
50 9.5 10.5 11.5
63 9 10 11

Note: Interpolate min. VMA for design percentage air-voids

For Maximum Aggregate Size > 26.5 mm, modified Marshall method is recommended

Minimum Stability 2.25 times the min. stability for Marshall Method
Minimum Flow 3 mm

For example, if Min. Stability with Marshall is 9 kN, the Min. Stability for mix with aggregate size > 26.5 mm will be 9*2.25
= 20.25 kN
Close-Graded Premix Surfacing/Mixed Seal Surfacing
 Close-Graded Premix Surfacing/Mixed Seal Surfacing

Consist of preparation, laying and compaction of close-graded premix surfacing material

of 20 mm thickness composed of graded aggregates premixed with bituminous binder

Physical Req. for Coarse aggregate

Property Test Requirement Test
method
Binder: Viscosity Grade (IS 73) Cleanliness Grain size analysis Max. 5% passing IS: 2386
Coarse Aggregate: 0.075 micron Part I
Should have at-least two fractured Particle Combined Flakiness & Max. 35% IS: 2386
faces. shape Elongation Indices Part I
Polished stone value > 55 Strength Los Angeles Abrasion Value Max. 40% IS: 2386
or Aggregate Impact Value Max. 30% Part IV
Fine Aggregate: Crushed rock,
natural sand or mixture of both. Durability Soundness Max. 12%
Sodium Sulphate Max. 18% IS: 2386
Shall be free from Soft or flaky Magnesium Sulphate Part V
particles and organic or deleterious
Water Water Absorption Max. 1% IS: 2386
substance. Absorption Part III
Stripping Coating and Stripping of Min. Retained IS:6241
bitumen aggregate Coating 95%
Water Retained Tensile strength Min. 80% AASHTO
sensitivity 283
 Aggregate Gradation
IS Sieve (mm) Cumulative Percent by Weight of Total Aggregate Passing
Type A Type B
13.2 mm - 100
11.2 mm 100 88-100
5.6 mm 52-88 31-52
2.8 mm 14-38 5-25
0.090 mm 0-5 0-5

No Structural Strength
Surface Dressing
 Surface Dressing
Application of one coat or two coats of surface dressing.
Coat consist of a layer of bituminous binder sprayed on prepared base followed by stone chipping

Physical Req. for Coarse aggregate (Table 500-8)

Property Test Requirement Test method
Aggregate Cleanliness Grain size analysis Max. 5% passing IS: 2386 Part I
Polished stone value > 60 0.075 micron
Particle shape Combined Flakiness & Max. 35% IS: 2386 Part I
Elongation Indices
Binder: Strength Los Angeles Abrasion Value Max. 35% IS: 2386 Part IV
Bitumen conforming to or Aggregate Impact Value Max. 27%
IS:73 or Durability Soundness Max. 12%
Sodium Sulphate Max. 18% IS: 2386 Part V
Magnesium Sulphate
Rapid setting cationic
bitumen emulsion (RS-2) Water Water Absorption Max. 1% IS: 2386 Part III
Absorption

Grade of bitumen Stripping Coating and Stripping of Min. Retained IS:6241

bitumen aggregate Coating 95%
depends on climate
condition Water Retained Tensile strength Min. 80% AASHTO 283
sensitivity

Selection criteria for VG paving bitumen based on climate condition (Table 500-1)
Lowest Daily Mean Air Temperature, °C Highest Daily Mean Air Temperature, °C
Less than 20°C 20°C to 30°C More than 30°C
More than -10°C VG-10 VG-20 VG-30
-10°C or lower VG-10 VG-10 VG-20
 Recommended NMAS (mm)

Type of Surface Traffic Intensity in Terms of Number of Vehicles Per Day in the
Lane Under Consideration

1000-2000 200-1000 20-200

Very hard 10 6 6
Hard 13 10 6
Normal 13 10 6
Soft 19 13 13
Very Soft 19 13
 Grading requirements for aggregates used for Surface Dressing

IS Sieve Cumulative Percent by Weight of Total Aggregates Passing for the

Designation Following NMAS
(mm)
19 13 10 6

26.5 100
19 85-100 100
13 0-40 85-100 100
9.5 0-7 0-40 85-100 100
6.3 0-7 0-35 85-100
4.75 0-10
3.35 0-35
2.36 0-2 0-2 0-2 0-10
0.60 0.2
0.075 0-1.5 0-1.5 0-1.5 0-1.5
Min. 65% by Passing 19 and Passing 13.2 Passing 9.5 and Passing 6.3 and
weight of Retained on and Retained Retained on 6.3 Retained on
aggregate 13.2 on 9.5 3.35
 Approximate Rate of Application of Binder and Aggregates (Table 500-22)

Nominal Binder (Kg/m2) Aggregate

Aggregate Uncoated Aggregates Coated Cu.m/m2
Size, mm Aggregates
Bitumen Emulsion Bitumen

19 1.2 1.8 1 0.014-0.015

13 1.0 1.5 0.8 0.009-0.011
10 0.9 1.3 0.7 0.007-0.009
6 0.75 1.1 0.6 0.003-0.005

Note: Bitumen for coated aggregates excludes quantity of bitumen required for coating
Open Graded Premix Surfacing
 Open Graded Premix Surfacing
Thickness: 20 mm
Binder: Viscosity Grade (IS 73)
Selection criteria for VG paving bitumen based on climate condition (Table 500-1)
Lowest Daily Mean Air Temperature, °C Highest Daily Mean Air Temperature, °C
Less than 20°C 20°C to 30°C More than 30°C
More than -10°C VG-10 VG-20 VG-30
-10°C or lower VG-10 VG-10 VG-20

Coarse Aggregate: Should have at-least two fractured faces and Polished Stone Value > 55

Physical Properties of Coarse Aggregate (Table 500-6)

Property Test Requirement Test method
Cleanliness Grain size analysis Max. 5% passing 0.075 IS: 2386 Part I
micron
Particle shape Combined Flakiness & Elongation Indices Max. 35% IS: 2386 Part I
Strength Los Angeles Abrasion Value or Aggregate Max. 40% IS: 2386 Part IV
Impact Value Max. 30% IS: 2386 Part IV
Durability Soundness 5 cycles
Sodium Sulphate Max. 12% IS: 2386 Part V
Magnesium Sulphate Max. 18% IS: 2386 Part V

Water Absorption Water Absorption Max. 1% IS: 2386 Part III

Stripping Coating and Stripping of bitumen aggregate Min. Retained Coating 95% IS:6241
Water sensitivity Retained Tensile strength Min. 80% AASHTO 283
 Proportioning of Material

Quantities of materials required for 10 m2 of road surface for 20 mm Thick

open-graded Premix Surfacing (Table 500-23)

Materials Quantity
Aggregates
a Nominal Stone size 13.2 mm (passing 22.4 mm sieve 0.18 m3
and retained on 11.2 mm sieve)
b Nominal Stone size 11.2 mm (passing 13.2 mm sieve 0.09 m3
and retained on 5.6 mm sieve)
Total 0.27 m3
Binder
a For 0.18 m3 of 13.2 mm nominal size stone of 52 kg 9.5 kg
bitumen per m3
b For 0.09 m3 of 11.2 mm nominal size stone of 56 kg 5.1 kg
bitumen per m3
Total 14.6 kg
Open Graded Premix Surfacing Using
Cationic Bitumen Emulsion
 Open Graded Premix Surfacing Using Cationic Bitumen Emulsion

Thickness: 20 mm

Binder: Cationic Bitumen Emulsion of Medium Setting (MS) grade

Quantities of aggregate for 10 m2 Area (Table 500-24)

Materials Quantity
Aggregates
a Coarse aggregate nominal 13.2 mm size (passing 0.18 m3
22.4 mm sieve and retained on 11.2 mm sieve)
b Coarse aggregate nominal 11.2 mm (passing 13.2 0.09 m3
mm sieve and retained on 5.6 mm sieve)
Binder 20-23 kg
Seal Coat
 Seal Coat

Application of Seal coat for sealing the voids in a bituminous surface

Seal Coat

Liquid seal coat comprising of Premixed seal coat comprising

an application of a layer of of thin application of a layer of
bituminous binder followed fine aggregate premixed with
by cover of stone chips bituminous binder.

Binder: Viscosity Grade (IS 73)

Selection criteria for VG paving bitumen based on climate condition (Table 500-1)
Lowest Daily Mean Air Temperature, °C Highest Daily Mean Air Temperature, °C
Less than 20°C 20°C to 30°C More than 30°C
More than -10°C VG-10 VG-20 VG-30
-10°C or lower VG-10 VG-10 VG-20

Coarse Aggregate: Should have at-least two fractured faces and Polished Stone Value > 55
 Physical Properties of Coarse Aggregate (Table 500-8)
Property Test Requirement Test method
Cleanliness Grain size analysis Max. 5% passing 0.075 IS: 2386 Part I
micron
Particle shape Combined Flakiness & Elongation Indices Max. 35% IS: 2386 Part I
Strength Los Angeles Abrasion Value or Max. 35% IS: 2386 Part IV
Aggregate Impact Value Max. 27% IS: 2386 Part IV
Durability Soundness 5 cycles
Sodium Sulphate Max. 12% IS: 2386 Part V
Magnesium Sulphate Max. 18% IS: 2386 Part V
Water Absorption Water Absorption Max. 1% IS: 2386 Part III
Stripping Coating and Stripping of bitumen aggregate Min. Retained Coating 95% IS:6241
Water sensitivity Retained Tensile strength Min. 80% AASHTO 283

Quantity of Binder per 10 m2 Quantity of Bituminous Emulsion per 10 m2

For Type A Seal Coat: 9.8 kg For Type A Seal Coat: 15 kg
For Type B Seal Coat: 6.8 kg For Type B Seal Coat: 10.5 kg
Stone Chips for Type A Seal Coat
Shall be 6.7 mm size defined as 100 % passing through 11.2 mm sieve and retained on 2.36
mm sieve.
Quantity used for spreading: 0.09 m3 per 10 m2 area.

Physical Requirements for Stone chips (Table 500-8)

Property Test Requirement Test method
Cleanliness Grain size analysis Max. 5% passing 0.075 IS: 2386 Part I
micron
Particle shape Combined Flakiness & Elongation Indices* Max. 35% IS: 2386 Part I
Strength Los Angeles Abrasion Value or Aggregate Max. 40% IS: 2386 Part IV
Impact Value Max. 30% IS: 2386 Part IV
Durability Soundness either: Sodium Sulphate or Max. 12%
Magnesium Sulphate Max. 18% IS: 2386 Part V
IS: 2386 Part V

Water Absorption Water Absorption Max. 1% IS: 2386 Part III

Stripping Coating and Stripping of bitumen aggregate Min. Retained Coating 95% IS:6241
Water sensitivity Retained Tensile strength** Min. 80% AASHTO 283

If min. Tensile Strength is less than 80%, use of antistripping agent is recommended.

Aggregate for Type B Seal Coat

Aggregate shall pass 2.36 mm sieve and retained on 180 micron sieve.
Quantity used for Premixing shall be 0.06 m3 per 10 m2 area.
Slurry Seal
 Slurry Seal

Consists of design and laying a mixture of mixture of mineral aggregate, slow

setting cationic bitumen emulsion, water and additives.
Types of Slurry Seals and Applications
Items Type I (2-3 Type II (4-6 mm) Type III (6-8 mm)**
mm)
Application Filling of Filling of surface cracks 1-3 mm Filling of surface cracks 3-6 mm
hair cracks and preventive/renewal and preventive/renewal
treatment (upto 450 CVPD)*** treatment (upto 1500 CVPD)***
Quantity* 4.3-6.5 8.4-9.8 10.1-12
of slurry
(kg/m2)
Residual 10-16 7.5-13.5 6.5-12
binder (%
by weight
of dry
aggregate)

*In Terms by weight of dry aggregate

** Indicative only
***CVPD: Commercial Vehicles per day
Material
Bitumen Emulsion: Cationic slow setting type SS2
Aggregate shall satisfy the requirements mentioned in Table below:

Properties of Aggregate (Table 500-26)

Properties Test Method Specification

Sand Equivalent Value IS:2720 (Part 37) Min 50%
Water Absorption* IS:2386 (Part 3) Max 2%
Soundness with IS:2386 (Part5)
Sodium sulphate Max 12%
Magnesium sulphate Max 18%

* In case water absorption exceeds 2% but is less than 4%, same may be
permitted subject to conformity of soundness test and wet stripping test
 Aggregate Gradation (Table 500-27)

Sieve Size Percentage by Mass Passing (Minimum Layer Thickness)

(mm)
Type I (2-3 mm) Type II (4-6 mm) Type III (6-8 mm)

9.5 - - 100
6.3 - 100 90-100
4.75 100 90-100 70-90
2.36 90-100 65-90 45-70
1.18 65-90 45-70 28-50
0.600 40-65 30-50 19-34
0.300 25-42 18-30 12-25
0.150 15-30 10-21 7-18
0.075 10-20 5-15 5-15
Tolerance for Slurry Seal (Table 500-28)
Description Tolerance
Filler: Ordinary
Aggregate passing 4.75 mm ±5% Portland Cement
Aggregate passing 2.36 mm, 1.18 mm, 0.6 mm ±5% Quantity of filler: 0.5 to
2% by weight of dry
Aggregate passing 0.3 mm ±4%
aggregate
Aggregate passing 0.15 mm ±3% Water: pH range of
Aggregate passing 0.075 mm ±2% water 6-7

Mix Design Criteria for Slurry Seal Mix

Requirement Specifications Test Methods

Mix Time, min 180 s Appendix 1 IRC:SP:81
Consistency, max 3 cm Appendix 3 IRC:SP:81

Wet cohesion, pass % min 20 kg.cm Appendix 4 IRC:SP:81

Wet stripping, pass % min 90 Appendix 5 IRC:SP:81
Wet Track abrasion loss (1 h soak), max 800 g/m2 Appendix 6 IRC:SP:81
 Indicative quantity of ingredients (Table 500-30)

Ingredients Limits (% by weight of dry

aggregate)
Cationic Bitumen Emulsion 10-16 for type I
7.5-13.5 for type II
6.5-12 for type III
Water 6-12
Filler 1-2
Additive 0.5-2
Fog Spray
 Fog Spray

Purpose: Light application of low viscosity bitumen emulsion for purposes of sealing
cracks less than 3mm wide or incipient fretting or disintegration in an existing
bituminous surfacing , and to help reduce loosening of chips by traffic on newly finished
surface dressing

Material
Bitumen Emulsion: SS1

Note: Spraying shall not take place when temperature is below 10°C

Fog seal application rate: 0.5-1 litres/m2

Stone Matrix Asphalt (SMA)
 Stone Mastic Asphalt (SMA)

Single or multiple layer of fibre-stabilized SMA for use as wearing course/binder course.
For wearing course of 13 mm SMA, Nominal Layer Thickness shall be 40-50 mm.
For binder course of 19 mm SMA, Nominal Layer Thickness shall be 45-75 mm.
Binder: Viscosity Grade (IS 73)
Fine Aggregate: Sand Equivalence value (IS:2720) ≥50
Shall be non-plastic.

Property Test Requirement Test method

Cleanliness Grain size analysis <2% passing 0.075 micron IS: 2386 Part I
Particle shape Combined Flakiness & Elongation Indices* <30% IS: 2386 Part I
Strength Los Angeles Abrasion Value or <25% IS: 2386 Part IV
Aggregate Impact Value <18% IS: 2386 Part IV
Durability Soundness either: 5 cycles
Sodium Sulphate or <12% IS: 2386 Part V
Magnesium Sulphate IS: 2386 Part V

Water Absorption Water Absorption <2% IS: 2386 Part III

Polishing Polished Stone Value >55% IS:2386 (P-114)
Grading Requirements for Mineral Filler
IS Sieve Cumulative Percent Passing by Composition of SMA
(mm) Weight of Total Aggregate
0.6 100 Grading 13 mm SMA 19 mm SMA
0.3 95-100 Course where used Wearing Binder
0.075 85-100 Course (Intermediate
course)

NMAS 13 mm 19 mm
Layer Thickness 40-50 mm 30-40 mm
Filler: Cement, rock dust, hydrated lime. IS Sieve size (mm) Cumulative % by weight of total
It should be free from organic impurities. aggregate passing
PI<4 26.5 - 100
Mix Design Parameter Req.
19 100 90-100
Air void content 4 13.2 90-100 45-75
Bitumen content 5.8 min. 9.5 50-75 25-60
Celluloid fibres 0.3% min by wt. 4.75 20-28 20-28
of total mix
2.36 16-24 16-24
VMA Min. 17
1.18 13-21 13-21
Voids in coarse aggregate Less than VCA
0.6 12-18 12-18
Asphalt drain down (ASTM D 0.3 max.
6390) 0.3 10-20 10-20
0.075 8-12 8-12
Tensile Strength Ratio 85% min.

Air void of compacted SMA mat <6%.

MASTIC ASPHALT
 Mastic Asphalt

Consist of Single layer of mastic asphalt wearing course for road pavements and bridge
decks
Binder Requirement

Property Req. Test Methods

Penetration at 25°C 15±5* IS:1203
Softening point, °C 65±10 IS:1205
Loss on heating for 5h at 163C, % by 2 IS:1212
mass Max.
Solubility 95 IS 1216
Ash, % bt mass Max. 1 IS 1217

*In cold climate, temp<10°C, VG 40 may be used.

 Physical Req. for Coarse aggregate
Property Test Requirement Test method
Cleanliness Grain size analysis Max. 5% passing 0.075 micron IS: 2386 Part I
Particle shape Combined Flakiness & Elongation Indices Max. 35% IS: 2386 Part I
Strength Los Angeles Abrasion Value or Max. 40% IS: 2386 Part IV
Aggregate Impact Value Max. 30%
Durability Soundness 5 cycles IS: 2386 Part V
Sodium Sulphate Max. 12%
Magnesium Sulphate Max. 18%
Water Absorption Water Absorption Max. 2% IS: 2386 Part III
Stripping Coating and Stripping of bitumen aggregate Min. Retained Coating 95% IS:6241
Water sensitivity Retained Tensile strength Min. 80% AASHTO 283

The percentage and grading of coarse aggregate depends on thickness of finished course
Application Thickness NMAS coarse Coarse aggregate content,
Range (mm) aggregate (mm) % by mass of total mix
Roads and bridge deck 25-50 13 40±10
Heavily stressed areas i.e., Junctions and toll plazas 40-50 13 45±10
Nominal size of coarse aggregate 13 mm
(IS Sieve, mm) Cumulative % passing by weight
19 100
13.2 88-96
2.36 0-5
Fine Aggregate:
Consist of crusher run screening, natural sand or mixture of both.
Filler:
Shall be limestone powder passing 0.075 mm sieve and shall have a CaCO3 content not
less than 80% by weight

Grading of fine aggregate (inclusive of filler)

IS Sieve Percentage by weight of aggregate

Passing 2.36 mm, retained 0.600 mm 0-25
Passing 0.600 mm, retained 0.212 mm 10-30
Passing 0.212 mm, retained 0.075 mm 10-30
Passing 0.075 mm 30-55
 Mix Design

Hardness Number (IS:1195-1978)

50 to 70 at the time of manufacture at 25C
10 to 20 at 25C at the time of laying

Binder Content
14-17 percent of total mix

Composition of mastic asphalt blocks without coarse aggregate

IS Sieve Percentage by weight of mastic asphalt

Min. Max.
Passing 2.36 mm, retained 0.600 mm 0 22
Passing 0.600 mm, retained 0.212 mm 4 30
Passing 0.212 mm, retained 0.075 mm 8 18
Passing 0.075 mm 25 45
Bitumen content % by mass 14 17
Bituminous Cold Mix
 Bituminous Cold Mix

Aggregate Grading and binder content

NMAS 9.5 13.2 19

Allowable 25-35 36-50 51-75
Thickness, mm
IS Sieve size (mm) Cumulative % by weight of total
Single layer: 25-75 mm aggregate passing
Binder: Slow/medium setting bitumen 37.5 - - -
emulsion or medium curing cut-back
26.5 - - 100
Coarse Aggregate:
19 - 100 90-100
Should have at-least two fractured faces.
Fine Aggregate: 13.2 100 90-100 -
Sand Equivalence value (IS:2720) ≥50 9.5 90-100 - 60-80
Plasticity Index should not exceed 4. 4.75 60-80 45-70 35-65
2.36 35-65 25-55 20-50
0.3 6-25 5-20 3-20
0.075 2-10 2-9 2-8
Binder content, percent by weight of
total mix
Cutback 4-6
Emulsion 7-10
 Mix Design Requirements

Parameter Emulsion1 Cutback2

Minimum Stability 2.2kN at 22.2°C 2.2kN at 25°C for maintenance,
for paving 3.3kN at 25°C for paving
Percent max. stability loss on soaking 503 244
Min. Flow (mm) 2 2
Compaction level (no. of blows) 50 75
% air voids 3-55 3-5
% min. coating6 50

1
Using Marshall method for emulsified asphalt-aggregate cold mix design (Appendix F, MS-14
2
Using Marshall method for cut-back asphalt-aggregate cold mix design (Appendix H, MS-14
3
With vacuum saturation and immersion
4
Four days soak at 25C
5
Refers to voids in the mix occupied by air and water
6
Coating Test, Appendix F, MS-14
 Minimum VMA

NMAS (mm) Min. VMA (%)

9.5 16
12.5 15
19 14
25 13
37.5 12

The binder content shall be determined by the modified Marshall Test.

Sand Asphalt Base Course
 Sand Asphalt Base Course

Consist of base course composed of a mixture of sand, mineral filler (where req.)
and bituminous binder
Binder: VG30 or VG20
Sieve Size (mm) Cumulative Percentage by weight of total aggregate passing
9.5 100
4.75 85-100
2.36 80-100
1.18 70-98
0.60 55-95
0.30 30-75
0.15 10-40
0.075 4-10
PI (%) 6 max.
Sand Equivalence 30 min.
LA Abrasion Value 40 max.

Max. thickness for sand asphalt 80 mm

Grading Requirements for Mineral Filler
IS Sieve Cumulative Percent Passing by Weight of
(mm) Total Aggregate
0.6 100
Filler: Cement, rock dust, hydrated lime.
0.3 95-100
It should be free from organic impurities.
0.075 85-100
PI<4

Mix Design
Requirement Mix Design

Parameter Requirement
Min. stability (kN at 60C) 2
Min. Flow (mm) 2
Compaction level 150
% air voids 3-5
VMA (min) 16
VFB 65-75
Micro-Surfacing
 Micro-Surfacing
Composed of modified bitumen emulsion, mineral aggregate, water and necessary
additives, proportioned, mixed and uniformly spread over a properly prepared surface
for surface treatment.

Micro-surfacing is applied on an existing pavement surface which is structurally sound

but surface shows sign of premature ageing, aggregate loss, cracking, high degree of
polishing etc.

Used as surface sealing treatment to improve skid resistant, surface durability, to seal fine
and medium cracks and for preventive maintenance and periodic renewal treatment on
low and medium traffic roads.
Types of Micro-surfacing and Rate of Application (Table 500-31)
Items Type II (4 to 6 mm)** Type III (6 to 8 mm)**
Application Preventive and Renewal Preventive and Renewal
Treatment for Roads carrying < Treatment for Roads carrying
1500 CVPD < 1500 to 4500 CVPD
Quantity of mix* (kg/m2) 8.4-10.8 11.1-16.3
Residual binder (% by 6.5-10.5 5.5-10.5
weight of dry aggregate)
 Requirement of Modified Bitumen Emulsion for Micro-Surfacing (Table 500-32)
Requirements Specifications Method of test
Residue on 600 micron IS sieve (% by mass) max. 0.05 IS:8887
Viscosity by Say bolt Furol Viscometer, at 25C in sec. 20-100 IS:8887
Coagulation of emulsion at low temperature Nil IS:8887
Storage stability after 24 h (168 h), % max. 2(4) IS:8887
Particle charge, +ve/-ve +ve IS:8887
Test on residue
Residue by evaporation, % min 60 IS:8887
Penetration at 25C 40-100 IS:1203
Durability at 27C, cm, min. 50 IS:1208
Softening Point, C, min. 57 IS:1205
Elastic Recovery*, %, min. 50 IS:15462
Solubility in tri-chloroethylene, % min. 97 IS:1216

*In case, elastic recovery is tested for Torsional Elastic Recovery as per Appendix-8 of
IRC:81, the min. value shall be 20%.
 Properties of Aggregate (Table 500-26)

Properties Test Method Specification

Sand Equivalent Value IS:2720 (Part 37) Min 50%
Water Absorption* IS:2386 (Part 3) Max 2%
Soundness with IS:2386 (Part5)
Sodium sulphate Max 12%
Magnesium sulphate Max 18%

* In case water absorption exceeds 2% but is less than 4%, same may be
permitted subject to conformity of soundness test and wet stripping test
 Aggregate Gradation (Table 500-27)

Sieve Size (mm) Percentage by Mass Passing (Minimum Layer Thickness)

Type II (4-6 mm) Type III (6-8 mm)
9.5 - 100
6.3 100 90-100
4.75 90-100 70-90
2.36 65-90 45-70
1.18 45-70 28-50
0.600 30-50 19-34
0.300 18-30 12-25
0.150 10-21 7-18
0.075 5-15 5-15
 Filler: Ordinary Portland Cement
Quantity of filler: 0.5 to 2% by weight of dry aggregate
Water: pH range of water 6-7
Mix Design Criteria for Micro-surfacing Mix (Table 500-33)
Requirement Specifications Test Methods (IRC:SP:81)
Mix Time, min 120 s Appendix 1
Consistency, max 3 cm Appendix 3
Wet cohesion, within 30 min, min. 12 kg.cm Appendix 4
Wet cohesion, within 60 min, min. 20 kg.cm Appendix 4
Wet stripping, pass % min 90 Appendix 5
Wet Track abrasion loss (1 h soak), 538 g/m2 Appendix 6
max

Indicative ingredients in mix (Table 500-34)

Ingredients Limits (% weight of aggregate)
Residual bitumen 6.5-10.5 for type II and 5.5-10.5 for type III
Mineral filler 0.5-3.0
Additive As needed
Water As needed
Crack Prevention Courses
 Crack Prevention Courses

One or two coats of an elastomeric rubber membrane known as Stress Absorbing

Membrane (SAM) over a cracked surface, followed by covering of aggregate chips, and
Stress Absorbing Membrane Interlayer (SAMI) which is similar to SAM or which consists of a
bitumen impregnated geotextile.

Binder: Modified binder complying to IS:15462 and IRC:SP:53,

except that VG10 complying with requirements of IS:73 in case of bitumen impregnated
geotextile.

Aggregate:
Polished Stone Value requirement does not apply in case of SAMI.
Aggregates shall be pre-coated by mixing them with 0.75-1% of paving bitumen by weight of
chips

Application for Modified Binder: 160-170°C

Binder quantity for bitumen impregnated geotextile: 0.9-1.2 lit./m2

Where a two coat SAM or SAMI is required, the second coat shall be applied within 90 days
of the first coat.
 Quantity of materials required for 10 sq.m of road surface for
Stress Absorbing Membrane (Table 500-43)

S.N Type and Width of Crack Specification of SAM to be Quantity of Quantity of chipping
applied binder kg/10m2
1 Hair cracks and map Single Coat SAM or 2nd coat of 8-10 0.10 m3 of 5.6 mm chips
cracks upto 3 mm width two coat SAM
2 Map cracks or alligator Single Coat SAM 10-12 0.11m3 of 5.6 mm chips
cracks 3 mm to 6 m width
3 Map cracks or alligator Two coat SAM
cracks 6 mm to 9 m width 1st coat 12-14 0.12m3 of 5.6 mm chips and
2nd coat 8-10 11.2 mm chips in 1:1 ratio
0.10 m3 of 5.6 mm chips

4 Cracks above 9 mm width Two coat SAM

and cracked area above 1st coat 14-16 0.12 m3 of 11.2 mm chips
50% 2nd coat 8-10 0.10 m3 of 5.6 mm chips

5 All types of cracks with Single Coat SAM I 8-10 0.10 m3 of 5.6 mm chips
crack width below 6 mm
6 All types of cracks with Single Coat SAM I 10-12 0.10 m3 of 11.2 mm chips
crack width above 6 mm
Recycling of Bituminous Pavement
Recycling of Bituminous Pavement