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PAVEMENT MATERIALS AND CONSTRUCTION 10CV763

SYLLABUS

Subcode: 10CV763 IA Marks: 25

No of lecture hour/week: 04 Exam hours: 03
Total no of lecture hours: 52 Exam marks: 100
PART - A

PAVEMENT MATERIALS

UNIT - 1

AGGREGATES: Origin, classification, requirements, properties and tests on road

aggregates, concepts of size and gradation – design gradation, maximum aggregate size,
aggregate blending
to meet specification. 6 Hours

UNIT - 2

BITUMEN AND TAR: Origin, preparation, properties and chemical constitution of

bituminous
road binders; requirements. 4 Hours

UNIT - 3

BITUMINOUS EMULSIONS AND CUTBACKS: Preparation, characteristics, uses and tests.

Adhesion of Bituminous Binders to Road Aggregates: Adhesion failure, mechanism of stripping,
tests and methods of improving adhesion. 8 Hours

UNIT - 4

BITUMINOUS MIXES: Mechanical properties, dense and open textured mixes, flexibility and
brittleness, (no Hveem Stabilometer & Hubbar – Field Tests) bituminous mix, design methods
using Rothfuch‟ s Method only and specification using different criteria- voids in mineral
aggregates, voids in total mix, density, flow, stability, percentage voids filled with bitumen.

6 Hours

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PART - B

PAVEMENT CONSTRUCTION

UNIT - 5

EQUIPMENT IN HIGHWAY CONSTRUCTION: Various types of equipment for excavation,

grading and compaction – their working principle, advantages and limitations. Special
equipment for bituminous and cement concrete pavement and stabilized soil road construction.
6 Hou

UNIT - 6

SUBGRADE: Earthwork grading and construction of embankments and cuts for roads.
Preparation of subgrade, quality control tests. 6 Hours

UNIT - 7

FLEXIBLE PAVEMENTS: Specifications of materials, construction method and field control

checks for various types of flexible pavement layers. 8 Hours

UNIT - 8

CEMENT CONCRETE PAVEMENTS: Specifications and method of cement concrete

pavement construction; Quality control tests; Construction of various types of joints.

8Hours

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LIST OF CONTENTS

UNIT TOPIC PAGE NO

1 AGGREGATES 4
2 BITUMEN AND TAR 14
3 BITUMINOUS EMULSIONS AND CUTBACKS 17
4 BITUMEN MIXES 23
5 EQUIPMENT IN HIGHWAY CONSTRUCTION 29
6 SUBGRADE 36
7 FLEXIBLE PAVEMENTS 40
8 CEMENT CONCRETE PAVEMENTS 60

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Unit -1: AGGREGATES

Aggregates form the major portion of pavement structure and they form the prime materials used
in pavement construction.

1.1 Origin:
 
 Most of the aggregates are prepared from natural rock
 
 Gravel aggregates are obtained from river beds.
 
 Sand in fine aggregates from weathering of rock.


 natural rocks are classified as igneous, sedimentary
Based on the origin,
 and metamorphic.

1.2 Classification:


The aggregates are specified based on their grain size, shape, texture and  its
 gradation and it is specified by various agencies like ASTM, BSI, ISI and IRC.

Based on strengthproperty, the coarse aggregates are divided into hard aggregates and
 soft aggregates.

1.3 Requirements:

Aggregates have to bear stresses occurring due to the wheel loads on the pavement. It

has to resist wear due to abrasive action of traffic on the surface course.

It should resist disintegration due to the action of weather.

1.4 Properties of aggregates:

Strength:
 
 The aggregates should be strong to withstand the stresses due to traffic wheel load.

Aggregates used in top layers of pavements I.e. wearing course have to be capable  of
 withstanding high stresses in addition to wear and tear hence should posses resistance to

crushing.

Hardness


The aggregate used in surface course are subjected to constant rubbing or abrasion due
to moving traffic.

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 
 They should be hard enough the wear due to abrasive action of traffic.
 
 Heavy wheel loads can also cause deformation on some types of pavements.


The mutual rubbing of stones is called attrition which also cause little wear in the
aggregates.

Toughness
 
 Aggregates in pavements are subjected to impact due to moving wheel loads.

 hammering is seen when heavily loaded steel tyred vehicles move
Severe impact like
on WBM roads.
 
 Jumping of steel tyred wheels from one stone to another cause severe impact.

The magnitude of impact  increases with the roughness of load surface, speed of the
vehicular characteristics.

Durability
 
 They should be durable and should resist disintegration due to action of weather.
 
 The property of the stones to withstand adverse action of weather is called soundness.


The aggregates are subjected to physical and chemical action of rain and ground
weather and hence road stones should be sound enough to withstand weathering action.

Shape of aggregates


Flaky and elongatedaggregates will have less strength compared with cubical, angular or
 rounded particles.

 as
Rounded aggregates are preferred in cement concrete mix due to better workability where
 these materials are not preferred in granular base course, water bound macadam and

 bitumen construction. In such cases angular particles are used.

Highly angular flaky andelongated aggregates have more voids in comparison
with rounded aggregates.

Adhesion with Bitumen

The aggregates used in bituminous pavements should have less affinity with water or
else bituminous coating on the aggregate will be stripped off in presence of water.

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1.5 Test for road aggregates:

1. Crushing test
2. Abrasion test
3. Impact test
4. Soundness test
5. Shape test
6. Specific gravity and water absorption test
7. Bitumen adhesion test
1. Aggregate crushing test:

The aggregate crushing value provides a relative measure of resistance to crushing under
gradually applied crushing load. The test consists of subjecting the specimen of aggregate in
standard mould to a compression test under standard load conditions (Figure 1). Dry
aggregates passing through 12.5 mm sieves and retained 10 mm sieves are filled in a cylindrical
measure of 11.5 mm diameter and 18 cm height in three layers. Each layer is tampered 25 times
with at standard tamping rod. The test sample is weighed and placed in the test cylinder in three
layers each layer being tampered again. The specimen is subjected to a compressive load of 40
tonnes gradually applied at the rate of 4 tonnes per minute. Then crushed aggregates are then
sieved through 2.36 mm sieve and weight of passing material (W2) is expressed as percentage

of the weight of the total sample (W1) which is the aggregate crushing value.

A value less than 10 signifies an exceptionally strong aggregate while above 35 would
normally be regarded as weak aggregates.

Aggregate Crushing value= (W1/W2) X 100

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2. Abrasion test

Abrasion test is carried out to test the hardness property of aggregates and to decide whether
they are suitable for different pavement construction works. Los Angeles abrasion test is a
preferred one for carrying out the hardness property and has been standardized in India (IS:2386
part-IV). The principle of Los Angeles abrasion test is to find the percentage wear due to relative
rubbing action between the aggregate and steel balls used as abrasive charge.

Los Angeles machine consists of circular drum of internal diameter 700 mm and length 520 mm
mounted on horizontal axis enabling it to be rotated (see Figure 2). An abrasive charge
consisting of cast iron spherical balls of 48 mm diameters and weight 340-445 g is placed in the
cylinder along with the aggregates. The number of the abrasive spheres varies according to the
grading of the sample. The quantity of aggregates to be used depends upon the gradation and
usually ranges from 5-10 kg. The cylinder is then locked and rotated at the speed of 30-33 rpm
for a total of 500 -1000 revolutions depending upon the gradation of aggregates.

After specified revolutions, the material is sieved through 1.7 mm sieve and passed fraction
is expressed as percentage total weight of the sample. This value is called Los Angeles
abrasion value.

A maximum value of 40 percent is allowed for WBM base course in Indian conditions. For
bituminous concrete, a maximum value of 35 is specified.

Figure 2: Los Angeles abrasion test setup

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3. Impact test

The aggregate impact test is carried out to evaluate the resistance to impact of aggregates.
Aggregates passing 12.5 mm sieve and retained on 10 mm sieve is filled in a cylindrical steel cup
of internal dia 10.2 mm and depth 5 cm which is attached to a metal base of impact testing
machine. The material is filled in 3 layers where each layer is tamped for 25 number of blows.
Metal hammer of weight 13.5 to 14 Kg is arranged to drop with a free fall of 38.0 cm by vertical
guides and the test specimen is subjected to 15 number of blows. The crushed aggregate is
allowed to pass through 2.36 mm IS sieve. And the impact value is measured as percentage of
aggregates passing sieve (W2) to the total weight of the sample (W1).

Figure 3: Impact test setup

Aggregates to be used for wearing course, the impact value shouldn't exceed 30 percent. For
bituminous macadam the maximum permissible value is 35 percent. For Water bound macadam
base courses the maximum permissible value defined by IRC is 40 percent

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4. Soundness test

Soundness test is intended to study the resistance of aggregates to weathering action, by

conducting accelerated weathering test cycles. The Porous aggregates subjected to freezing and
thawing are likely to disintegrate prematurely. To ascertain the durability of such aggregates,
they are subjected to an accelerated soundness test as specified in IS:2386 part-V. Aggregates of
specified size are subjected to cycles of alternate wetting in a saturated solution of either sodium
sulphate or magnesium sulphate for 16 - 18 hours and then dried in oven to a constant weight.
After five cycles, the loss in weight of aggregates is determined by sieving out all undersized
particles and weighing. And the loss in weight should not exceed 12 percent when tested with
sodium sulphate and 18 percent with magnesium sulphate solution.

5. Shape tests

The particle shape of the aggregate mass is determined by the percentage of flaky and elongated
particles in it. Aggregates which are flaky or elongated are detrimental to higher workability
and stability of mixes.

The flakiness index is defined as the percentage by weight of aggregate particles whose least
dimension is less than 0.6 times their mean size. Test procedure had been standardized in
India (IS:2386 part-I)

Figure 4: Flakiness gauge

The elongation index of an aggregate is defined as the percentage by weight of particles

whose greatest dimension (length) is 1.8 times their mean dimension. This test is applicable to

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aggregates larger than 6.3 mm. This test is also specified in (IS:2386 Part-I). However there are
no recognized limits for the elongation index.

Figure 5: Elongation gauge

6. Specific Gravity and water absorption

The specific gravity and water absorption of aggregates are important properties that are required
for the design of concrete and bituminous mixes. The specific gravity of a solid is the ratio of its
mass to that of an equal volume of distilled water at a specified temperature. Because the
aggregates may contain water-permeable voids, so two measures of specific gravity of
aggregates are used: apparent specific gravity and bulk specific gravity.

Apparent Specific Gravity, , is computed on the basis of the net volume of aggregates i.e

the volume excluding water-permeable voids. Thus

(1)

where, is the dry mass of the aggregate, is the net volume of the aggregates

excluding the volume of the absorbed matter, W is the density of water.

Bulk Specific Gravity, , is computed on the basis of the total volume of aggregates

including water permeable voids. Thus

(2)

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where, is the total volume of the aggregates including the volume of absorbed water.

Water absorption, The difference between the apparent and bulk specific gravities is nothing
but the water-permeable voids of the aggregates. We can measure the volume of such voids by
weighing the aggregates dry and in a saturated, surface dry condition, with all permeable voids

filled with water. The difference of the above two is . is the weight of dry

aggregates minus weight of aggregates saturated surface dry condition. Thus

(3)

The specific gravity of aggregates normally used in road construction ranges from about 2.5 to
2.9. Water absorption values ranges from 0.1 to about 2.0 percent for aggregates normally used
in road surfacing.

7. Bitumen adhesion test

Bitumen adheres well to all normal types of road aggregates provided they are dry and free from
dust. In the absence of water there is practically no adhesion problem of bituminous construction.
Adhesion problem occurs when the aggregate is wet and cold. This problem can be dealt with by
removing moisture from the aggregate by drying and increasing the mixing temperature. Further,
the presence of water causes stripping of binder from the coated aggregates. This problems occur
when bitumen mixture is permeable to water. Several laboratory tests are conducted to arbitrarily
determine the adhesion of bitumen binder to an aggregate in the presence of water. Static
immersion test is one specified by IRC and is quite simple. The principle of the test is by
immersing aggregate fully coated with binder in water maintained at temperature for 24
hours. IRC has specified maximum stripping value of aggregates should not exceed 5%

1.6 Aggregate gradation

The properties of the bituminous mix including the density and stability are very much
dependent on the aggregates and their grain size distribution. Gradation has a profound effect on
mix performance. It might be reasonable to believe that the best gradation is one that produces
maximum density. This would involve a particle arrangement where smaller particles are packed

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between larger particles, thus reducing the void space between particles. This create more
particle-to-particle contact, which in bituminous pavements would increase stability and
reduce water infiltration. However, some minimum amount of void space is necessary to:
 
 provide adequate volume for the binder to occupy,
 
 promote rapid drainage, and


provide resistance to frost action for base and sub base courses. A dense mixture may be
obtained when this particle size distribution follows Fuller law which is expressed as:
n
p = 100 [d/D]

where, p is the percent by weight of the total mixture passing any given sieve sized, D is the size
of the largest particle in that mixture, and n is the parameter depending on the shape of the
aggregate (0.5 for perfectly rounded particles). Based on this law Fuller-Thompson gradation
charts were developed by adjusting the parameter n for fineness or coarseness of aggregates.
Practical considerations like construction, layer thickness, workability, etc, are also considered.
For example Table 25:1 provides a typical gradation for bituminous concrete for a thickness of
40 mm.

1.6.1 Proportioning of aggregates

After selecting the aggregates and their gradation, proportioning of aggregates has to be done
and following are the common methods of proportioning of aggregates:

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1. Trial and error procedure: Vary the proportion of materials until the required
aggregate gradation is achieved.
2. Graphical Methods: Two graphical methods in common use for proportioning of
aggregates are, Triangular chart method and Rotfuch's method. The former is used when
only three materials are to be mixed.

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