Asphalt Pavement Construction Guide
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143Asphalt Pavement Construction Guide
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143ASPHALT PAVEMENT CONSTRUCTION
1. Improved Subgrade:
Prior to the placement of the first course, the entire width of the vehicular and pedestrian pavement shall
be cleared of brush, weeds, vegetation, grass, and all other debris. All depressions or ruts which may
contain storm water shall be drained. If the 45cm below the subgrade elevation of earth cut is found to be
incapable of compaction, CBR less than 15%, such subgrade material shall be removed and replaced.
Improved subgrade must have CBR greater than 30%, moisture content is 3% of the OMC and maximum
allowable particle size must be 75mm. The compaction test should be conducted 1 in 600m2 for
carriageway.
In case of cut areas, the excavation is carried out up to the formation level and then scarified 20cm-25cm,
plough mix water and compact up to the specified density i.e. 95%. If the material is not suitable then it
should be removed up to 20cm depth and is replaced with borrow material. Limitations for the borrow
material depends upon the following AASHTO and ASTM standards.
Sieve Analysis T-27, T-11, T-88
Liquid Limit T-89
Plastic Limit & Plasticity Index T-90
Moisture Content T-265, T-217
Moisture - Density Relationship T-180
Sand Equivalent T-176
Specific Gravity T-100, T-85
California Bearing Ratio (CBR) T-193
Classification M-145
2. Geotextile Fabric:
Geotextile fabric shall be placed on the prepared roadway subgrade and at other locations prepared for its
use to restrain soil movement, to provide for drainage and to prevent soil erosion. The width of fabric
supplied on each roll shall be such as to minimize the development of longitudinal and transverse
overlaps. Where longitudinal overlaps are required, the width of fabric used shall be not less than 4.5m. A
narrower width may be used if the number of longitudinal overlaps is the same as would be developed
using the minimum fabric width of 4.5m. Where transverse overlaps are required, the minimum length of
fabric on a roll shall be 90m. Shorter lengths of fabric may be employed provided that the number of
overlaps resulting there from is the same as that developed using the specified 90m minimum length rolls.
Properties and feature of the fabric must meet the following requirements.
Description Geotextile Requirements
Fabric weight 135 g/m² Min.
Grab Tensile Strength 750 N Min.
Grab Failure Strain > 50 %
Puncture Resistance 990 N Min.
Tear Strength 275 N Min.
3. Granular Sub base:
The need for a Sub base granular material placed on a prepared subgrade depends on the frequency of
heavy traffic. It is mandatory for major highways or totally depends on the design requirement. Sub base
is seldom required for light-duty pavements. Major requirements for the sub base layer are shown in the
table below.
Description Limitation
CBR 30% at 95 of MDD
Density Test 3 no. in 1500mm2
Moisture content 2% of OMC
Surface tolerance 10mm
Layer thickness 15cm
Compaction required 95% of MDD
4. Aggregate road base:
All aggregate road base material shall be free from dirt, shale or other deleterious matter and shall be of
such quality that it will bind readily to form a stable aggregate road base. Aggregate road base shall
consist of uniform mixtures of gravel or crushed gravel with sand, silt and clay conforming to the
specified gradation limits. Some of the requirements for the aggregate road base are given in following
table.
Tests Standards Limits
Liquid Limit BS1377 Part2 Test4.5 25% Max
Plasticity Index BS1377 Part2 Test 5 06 Max
Sand Equivalent ASTM D - 2419. 40% Min
Max particle size - 50mm
Moisture content - MC = 2% of OMC
Los Angeles Abrasion. ASTM C-131 ORC-535 30% Max
Flakiness Index (Coarse Aggregate) BS812 Part 105.1 35% Max
Elongation Index ( Coarse Aggregate) BS812 Part 105.2 35% Max
Soundness ( MgSO3 Sol. -5cycles) ASTM C88 12% Max
Organic Impurities. BS1377 Part3 Method 3 0.2% Max
Acid soluble Chloride- Combined BS 812 Part 117 0.1% Max.
Agg.
Acid soluble Sulphate - Combined BS 812 Part 118 0.5% Max
Agg.
Max. Dry Density BS 1377 Part 4 Test 3.6 2% gr/cc Min
C.B.R on remoulded samples after 4 BS 1377 Part 4 Test 7 80% Min.
days soaking at 100% of the max.dry
density.
Three in-situ Density tests shall be made per 900 m2 of aggregate road base. Straight edge is limited to
10mm and surface tolerance is 12mm.
5. Wet Mix:
It totally depends upon the design, loading requirements and types of vehicles whether to use wet mix or
aggregate road base.
The features of road base are in the following.
Tests Standards Limits
Liquid Limit BS1377 Part2 Test4.5 25% Max
Plasticity Index BS1377 Part2 Test 5 06 Max
Sand Equivalent ASTM D - 2419. 45% Min
Max particle size - 50mm
Moisture content - MC = 1% of OMC
Los Angeles Abrasion. ASTM C-131 ORC-535 30% Max
Flakiness Index (Coarse Aggregate) BS812 Part 105.1 30% Max
Elongation Index ( Coarse Aggregate) BS812 Part 105.2 30% Max
Soundness ( MgSO3 Sol. -5cycles) ASTM C88 12% Max
Organic Impurities. BS1377 Part3 Method 3 0.2% Max
Acid soluble Chloride- Combined Agg. BS 812 Part 117 0.1% Max.
Acid soluble Sulphate - Combined Agg. BS 812 Part 118 0.5% Max
C.B.R on remoulded samples after 4 BS 1377 Part 4 Test 7 80% Min.
days soaking at 100% of the max.dry
density.
Three in-situ Density tests shall be made per 750 m2 of each layer of carriageway. Sieve analysis shall be
carried out on the material recovered from 5 consecutive field density tests.
Wet Mix Macadam Road base is laid and compacted in layers maximum thickness of 150mm normally.
6. Prime coat:
Quality of Primer should be as per BS1707 or 1S:217, IS: 454 and IS: 8887. Immediately before applying
the prime coat, the full width of the surface shall be cleaned with compressed air.
i) The bituminous material for the prime coat shall be applied by means of bitumen spray tankers.
ii) This shall be applied in a single layer at the rate of 0.7 – 1.5 liters/sq.m and at a temperature not
exceeding 70oC. This surface shall be cured for 24 hours.
7. Asphalt base coarse:
This layer usually comes in the thickness of 6cm-10cm with the max size of particle is 39mm. The
compaction requirement is range from 97%-101%.
8. Tack coat:
Tack coat is normally needed for binding two surfaces of asphalt. If the duration between the two asphalt
layers is less than 48 hour then tack coat is not required. Minimum curing time is 2 hours. This shall be
applied in a single layer at the rate of 0.2 – 0.6 liters/sq.m and at a temperature not exceeding 70oC.
9. Asphalt binder coarse:
This layer usually comes in the thickness of 5cm-8cm with the max size of particle is 25mm. The
compaction requirement is range from 97%-101%.
10. Asphalt wearing coarse:
This layer usually comes in the thickness of 4cm-6cm depends upon the design with the max size of
particle is 25mm. The compaction requirement is range from 97%-101%.
The coarse aggregate properties for asphalt layers are given in following table.