Pavement Construction Technology t i

y h a
r a
Instructor dha u w
u
o gy G
Dr. Rajan Choudhary C h l o
a n
jProfessorch n o
R a e
o f .
Department T
off Civil Engineering
r o
P ute of Technology Guwahati
Indian Institute
t i t
E-mail: [email protected]

In s
i a n
In d
Module Content
a t i
Course/Module Contents ar y a h
h u w
d
u process G
Lecture 16: Construction equipmentoand
h g y for bituminous bound
C
courses comprising there: production, l o
laying,
o and compaction
Module 7 j a n h n
Lecture 17: Field tests R a e
to ensure c construction quality of bituminous
bound courses o f . f T
r
P ute o
t i t
In s
i a n
In d
2 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 a t i
y
r w a h
a
h Gu
d
u graphs,
I acknowledge the use of texts, information,
h o g y and images
C o l o
sourced from various textbooks, j a n h n
codal standards, journal
R a e c
o f . T
f public domain searches.
articles, reports, newsletters,
r
P ute oand

t i t
In s
i a n
In d
3 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Bituminous Bound Courses
• Bituminous bound courses are a t i
y
r w a h
extensively used in the base, binder,
h a u
and wearing courses of flexible u d G
h o g y
pavements.
C o l o
• Dense-graded bituminous mixes are aj a n h n
R e c
commonly employed for the
o f . f T
r
P withute
construction of these courses,
o
t i t
the binder and wearing courses
I n s Specifications Guidelines Guidelines for Specifications
for road & for selection, for
Pocketbook
for road

a n
typically laid over a previously
ilayer.
bridge works bituminous operation
MoRTH, 2013 macadam & maintenance
dense graded
bituminous
construction
equipment,

In d
prepared bituminous IRC: 27, of hot mix plant mixes IRC: 111,
2009 IRC: 90, 2010 2009
IRC, 2018

4 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology

 Bituminous Bound Courses
• The binder course primarily functions as the a t i
Bituminous Surface course

intermediate layer between the bituminous base course ar y a h Bituminous Binder course

h u w Bituminous base course

and the bituminous wearing course. u d G Granular base course

h o gy Granular sub base course

C
Type of Dense Graded Bituminous Mixes,nTheir Use,o l o
Number of Layer and Layer Thicknessa(IRC: ja 111-2009)
h n Subgrade

R e c
Specification
f
Purpose
o . f T Number of Thickness of each
r
PBase/Binder e o Layers Layer (mm)
Dense Bituminous macadam
t u t Course/Overlay Single or 50 – 100
(DBM)
s i
fortStrengthening Multiple
Semi Dense Bituminous In Wearing Course Single 25 – 40
Concrete (SDBC)
i a n
In d
Bituminous Concrete (BC) Wearing Course Single 25 /40 /50
5 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Construction Steps for Bituminous Bound Courses
• Important steps involved in the construction of bituminous bound courses are
a t i
(MoRTH:2013) : y
r w a h
h a u
➢Preparation of Base u d G
h o gy
➢Application of Prime Coat or Tack Coat C o l o
j a n h n
➢Mixing and Transportation of Mix R
a e c
o f . f T
r
P ute
➢Laying of the Bituminous Mix o
t i t
➢Compaction/Rolling
In s
i a
➢Arrangement for Trafficn
In d
6 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Construction Operation: Preparation of Base
• This work mainly consist of preparing the existing granular or
a t i
black-topped surface for laying the bituminous course. It is to be y
r w a h
carried out over the widths and lengths shown in the drawings. a
h Gu
d
u y
h o
The existing surface has to be firm and clean, & shall be treated
g
with a prime coat or tack coat as specified. C o l o
• a n n
The surface on which the bituminousj work ishto be laid is cleaned of all loose &
R a
extraneous matter mainly means .of a mechanical e c
o f T
f sealed.
broom and air jet. Any potholes and/or
r
cracks need to be first properly repairedoand
P u t e
•
i t
A profile-correcting course, intended
t to rectify the existing pavement profile, may be
n
provided either as a separate
I s layer or as a composite layer of varying thickness. When
the maximum thickness
i a n of the profile-correcting course is less than 40 mm, it can be laid

In d
as an integral part of the overlying layer.
7 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Construction Operations: Prime Coat Application
• Priming is the application of a low-viscosity bituminous
a t i
material to the surface of a non-bituminous granular base y
r wa h Standard
specifications &

course in preparation for placement of a bituminous layer. a

h Gu code of practice
d
u y for prime & tack
➢ The objectives of priming a granular surface are o
coat, IRC:16-2008
h
C and o g
as follows:
l plug
✓ To penetrate the granular course nsurface o
a j a h n
capillary voids.
R e c
✓ To coat and bond loose mineral
o f. T
particles
f on the granular
base course surface.
P r e o
✓ To seal surface pores and tmake u t the surface of the base
course water-resistant. s t i
In
✓ To enhance adhesion
i a n between the base & the next

In d
bituminous course, in conjunction with a tack coat.
8 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 Construction Operations: Prime Coat
• Note: The prime coat shall not be considered Typical Quantity of Bitumen Emulsion for
a t i
a substitute for the tack coat, whose
y a
Various Types of Granular Surfaces
r w h
primary purpose is to ensure proper bonding a
h Gu Rate of
between the surface to be paved and the new u yd
Type of Surface Spray
h o g (kg/sq. m)
bituminous course placed over it.
C o
WMM/WBMl o 0.7-1.0
• For priming usually a cationic bitumen j a n h n
R a e c Stabilized Soil Base, Lime/Cement
Stabilized Soil, Lime Cement Base
0.9-1.2
emulsion SS1 grade (IS:8887) .or medium T
r o f o f
P uistpreferred.
curing cutback bitumen (IS:217) e
t
• Usual quantity of SS1 grade bitumeni t emulsion
n s
applied for various types ofI granular surfaces are
a n
i16-2008 & MoRTH:2013).
d
shown in table (IRC:
In
9 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 Construction Operations: Prime Coat
• Usual quantity of cutback bitumen for Type and Quantity of Cutback Bitumen for
a t i
various types of granular surface are y a h
Various Types of Granular Surface
r Type
given in table (IS:217, IRC:16-2008 & h a u w of Rate of Spray
u d
Type of Surface
GCutback (kg/sq. m)
MoRTH:2013).
h o g y
• Primer distributor shall apply primer WMM/WBM C o l o MC 30 0.6-0.9

j a n
at specified rates & temperatures. Hand Mechanically
h n
stabilized soil
spraying with a pressure sprayer R is abase,
e
limecstabilized soil, soil MC 70 0.9-1.2
permitted only for small or narrowo f . f T
cement, & lime cement base
r
P ute
areas (<3 m) where the distributor
o
cannot access.
t i t
s
n should be such that it can be
• The correct quantity of Iprimer
i
absorbed by the surface a n without causing run-off of excessive
n
primer & to achieve
I d desired penetration of about 8-10 mm.
10 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Construction Operations: Tack Coat Application

• Tack coat is a light application of low- a t i

y
r wa h
viscosity bituminous material applied to a
h Gu
d
u y
existing bituminous, cement concrete, or
h o g
primed granular surfaces to ensure bonding C o l o
a n
j ch n
with the overlaying course.
R a e
• It is not intended to penetrateo f . f T
P r o
the pavement
e
t
layer/course, so the applicationumust be very
t
s t i
In
light to provide an effective bond between
layers.
i a n
In d
11 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 Construction Operations: Tack Coat
• The binder preferred for tack coat is either Cationic bitumen
a t i
emulsion (RS 1) complying with IS:8887 or suitable low viscosity
r y a h
paving bitumen of VG 10 grade conforming to IS:73. h a u w
u d G
• Cutback bitumen RC:70 (IS:217) use is restricted
h o for sites
g y at
C o l o
a n
sub-zero temperatures or for emergency applications.
j be heated
h n
• Paving bitumen if used for tack coat shall
R a e c to appropriate temperature in bitumen
boilers to achieve viscosity less thanf2. poise. f T
r
P uteo o
• Typical application
t
rates i t of
emulsion as tack coat are I s
n given in
the table (IRC: an16-2008 and
MoRTH:2013) n d i
12
I NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 Construction Operations: Mixing
• Dense graded bituminous mixes are mainly Typical Mixing, Laying and Rolling Temperatures for
a t i
produced in a hot mix plant to ensure a uniform,
y
Bituminous Mixes (Degree Celsius)
r w a h
mix with thoroughly coated aggregates.
h a u
• The table provides the recommended mixing, u d G
h o g y
laying, and rolling temperatures for dense graded
mixtures (MoRTH-2013 and IRC:111-2009). n
C o l o
a j a h n
R
• For modified bitumen, mixing and compaction e c
* Rolling must be completed before the mat cools

o
temperatures are usually higher than f. f
for pavingT to these minimum temperatures
bitumen, depending on the typeP r e
and amounto of
u t
modifier used. Typically, the ttemperatures
s t i
In
recommended by the manufacturer are followed.
• Temperature difference n
d a between the binder &
i not exceed 14°C.
13
In
aggregate should preferably
NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Production/Mixing, Laying & Compaction of Bituminous Mixes

a t i
Standard Equipment Used for Bituminous Bound Courses
y
r w a h
Description of Work/Activity Equipment a
h Gu
u
✓ Hot mix plant, Front-endd
Bituminous macadam/Dense
h o gy loader or
bituminous macadam/Bituminous C
Backhoe loader,
o o
Tipper ltruck, Paver
a n
j vibratoryh n
concrete/Standard asphalt base
a
Finisher,
R e c roller or smooth
course
o f . T
wheeled roller
f or pneumatic roller
r
P ute o
t i t
In s
i a n
In d
14 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 Hot Mix Plant
• Hot mix plant (HMP) is a central mixing facility of
a t i
adequate capacity being capable of producing hot
y
r wa h
bituminous mixes with uniform quality and thoroughly a
h Gu
coated aggregates. A hot mix plant should allow: d
u y
a) Blending of different aggregate sizes in specified h o g
C o l o
proportions
a n
j ch n
R a
b) Drying and heating of aggregates at specified
e
temperature
o f . f T
r o
c) Uniform heating and addition of bitumen (in specified
proportions) P ute
t i t
d) Thorough/Uniform mixing of aggregates and bitumen
In s
to get a homogeneous mix at the specified temperature
a n Guidelines for
e) Safe, environmentally friendly, and reliable operation selection, operation
i
Pocketbook for road Specifications for
construction bituminous

In d
to ensure accurate and consistent processing.
& maintenance of hot equipment, IRC, 2018
mix plant IRC: 90, 2010
macadam,
IRC: 27,2009

15 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology

Hot Mix Plant Key Features
A Hot Mix Asphalt (HMA) plant should ideally include
a t i
provisions for:
r wa h
Based on methodology of preparation
y
i) Controlled feeding and blending of aggregates in a
of hot mix, HMP are of two types:
h Gu
d
u y• Batch Type HMP
specified proportions
ii) Drying and heating aggregates to the C
o
h log
required
• Continuous/Drum Type HMP

temperature
j a n n o
a c
iii) Uniform heating of bitumen Rat the especified
h
temperature
o f . f T
r o
P uandtefiller in specified
iv) Controlled feeding of bitumen
amounts
t i t
s
v) Forced mixing of allIncomponents to produce a
a n
consistent, homogeneous mix at the specified
i to the job mix formula.
d
temperature according
In
16 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Production of Bituminous Bound Courses
• Bituminous bound courses are a t i
y
r w a h
extensively used in the base, binder,
h a u
and wearing courses of flexible u d G
h o g y
pavements.
C o l o Guidelines on

• Hot mix plant (HMP) is a central aj a n h n

compaction equipment
for road works

R e c IRC:SP:97-2013

mixing facility of adequate capacity

o f . f T
r
P hot e o
being capable of producing
t u t
bituminous mixes with uniform
s t i Specifications Guidelines Guidelines for Specifications Pocketbook

In coated for road & for selection, for for road

quality and thoroughly
i a n bridge works
MoRTH-2013
bituminous operation
macadam & maintenance
dense graded construction
bituminous equipment,
aggregates.
In d IRC:27-2009 of hot mix plant
IRC:90-2010
mixes
IRC:111-2009
IRC-2018

17 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology

Hot Mix Plant: Batch Mix Type
a t i
y
r wa h
a
h Gu
d
u y
h o g
C o l o
a n
j ch n
R a e
o f . f T
r
P ute o
t i t
In s
i a n
Ind Typical Features of Batch Type Hot Mix Plant
18 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 Components of Batch Mix Type HMA Plant
Cold Bins:
a t i
✓Cold Bin feeder typically consists of 3 to 4 bins y
r wa h Cold
a
h Gu feed bin
to hold aggregates of different sizes. d
u y
h o g
✓Each bin gate has a graded scale to control the
C o l o
gate opening and regulate aggregate flow. a n
j ch n Oversize
✓A single-deck vibratory screen is oftenR a e screen

o f . T
installed
f to
r
at the discharge end of the gathering
P ute o
conveyor
remove oversize aggregates.
t i t
✓The cold elevator or cold
In sfeed conveyor (also Slinger

a n
called a slinger conveyor)
i transfers aggregates
conveyor

n
from the gathering
I d conveyor to the dryer drum.
19 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Key Components of Batch Mix Type HMA Plant
Dryer Drum
a t i
• The dryer drum is a revolving cylindrical drum (usually of y
r w a h
a
h Gu
d
diameter 1.5-3 m and length 6-12 m) placed in an inclined position
u y
h o
and includes a burner and a blower fan, which provides primary
g
C
air for combustion of fuel, and an exhaust fan to create a draft
o l o
through the dryer. a n
j ch n
• R a e
The drum is fitted with longitudinal
o f . T
channels called flights
f lift the aggregates and
mounted with bolts and nuts. r The o
flights
drop it in veils through theP t e
t i t u
burner flame and hot gases.
• The dwell time (retention time
I s for aggregates in dryer drum) mainly
ndrum, its revolutions per minute, diameter,
i a n
depend on slope of the dryer

I n d
length, number of flights & their arrangement, & efficiency of burner.

20 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology

Key Components of Batch Mix Type HMA Plant
• Normally, dryers are designed to heat and dry the
a t i
aggregates having about 4 to 6% moisture content. y
r wa h
a
h Gu
• If moisture content of aggregates increases, the feeding
u d
of aggregates into dryer drum is reduced, resulting o in drop y
C h l o g
in hourly production capacity of plant.
a n
j can n o
• The aggregates heated at high temperature a e c hharden
the bitumen during mixing. R while Tunderheated
aggregates cannot get a proper
r o f o f of bitumen.
coating
Aggregates should be therefore P utheated e uniformly at
appropriate temperature to achieve
t i t homogenous mix.
Fuel In s
a
• In India, light dieselioilnor furnace oil is primarily used as fuel
In
for burners of hot d
mix plants.
21 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Key Components of Batch Mix Type HMA Plant
Primary pollution/dust control/collection device:
a t i
• Its main function is to remove any undesirable y
r w a h
amount of dust coming from the exhaust. a
h Gu
• It is cyclonic in shape, in which dust is collected o and
d
u y
removed/added to dry aggregates, if required. Ch l o g
j a n n o
• It is fitted at the rear of dryer drum. The fuel
the dryer drum pass through these dustR a gases
separators.e c h
leaving

o f . f T
Exhaust stack:
r
P through e o
• The exhaust gases are eliminated
t u t the plant exhaust stack. These gases further pass
through the secondary pollution
s t i control device, a bag house filter, for further filtration.
Hot elevator: In
• The aggregates after i a n
heating and drying are carried by a hot elevator (bucket conveyor
In d
system) to the gradation unit.
22 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Key Components of Batch Mix Type HMA Plant
Screening unit
a t i
y
r w a h • The secondary gradation
a
h Gu
of aggregates, in hot
d
u y
condition, is carried out

h o g in screening unit.
C o l o • Thus also known as second
a n
j ch n gradation control unit of

R a e hot batch type mix plant

o f . f T (IRC:90-2010).
r
P ute o Hot bins
• These are used to
t i t
In s store the heated and
screened aggregates
i a n of various sizes

Ind temporarily.
23 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Key Components of Batch Mix Type HMA Plant
Weigh hopper
a t i
• The aggregates are withdrawn
y
r wa h from hot bins in desired quantity
a
h Gu
d
u y
through load cell and

h o g
accumulated in weigh hopper.
C o l o • Aggregates, thus collected in

a n
j ch n weigh hopper are transferred into

R a e
pugmill where these are blended

o f . f T with desired quantity of bitumen.

r
P ute o Bitumen unit
• The unit mainly consists of
t i t bitumen tank, heating system,

In s bitumen pump and delivery pipe.

i a n Bitumen is weighed separately in

weigh bucket before being inducted
Ind into pugmill (IRC 90-2010).
24 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Key Components of Batch Mix Type HMA Plant
Pug mill
a t i
y
r w a h It is the chamber in which
a
h Gu bitumen and aggregates are
d
u y mixed thoroughly to achieve
h o g homogenous mix (IRC: 90-2010).
C o l o
j a
Mixing in n n
the Pugmill
h and Transfer to Storage Silos:
R a e c
o f . f T
r
P ute o
t i t
In s
i a n
Ind
25 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Key Components of Drum Mix Type HMA Plant
• In drum mix plant, aggregates gradation is
a t i
controlled at cold feed end and aggregates heating, y
r wa h
a
h Gu
drying and bitumen mixing are done in same drum. d
u y
It is popular for its features like (IRC:90-2010): h
o g
C o l o
✓Portability
a n
j ch n
✓Higher efficiency
R a e
✓Economy in basic cost
o f . f T
✓Lower fuel consumptionP r e o
t u t
✓Reduction in manpower and
s t i maintenance
cost
✓Ability to produce n
In
large quantity of mix at
relatively low d ia
temperature and
26
In
NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 Key Components of Drum Mix Type HMA Plant
• The drum mix plant are mainly either Parallel flow type or Counter flow type.
a t i
• In Parallel flow type drum mix plant, aggregates & hot r y a h
gases flow in same direction inside the same drum. d h a u w
u
o& hot gy G
• In Counter flow type drum mix plant, aggregates
C h l o
gases flow in opposite direction within the same
j a n o
drum.
n
These may be of two types:
a e c h Parallel flow type

• First one where drying and mixing

f. R of Taggregates and
bitumen takes place in samerdrum. of
o
P
• Second one, also known as tdual u t e drum plant, where
drying of aggregates takes s t i
dried aggregates are n In place in first drum & then the
transferred to another drum where
Counter flow type

d i
mixing of aggregates a & bitumen takes place.
27
In NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Key Components of Drum Mix Type HMA Plant
Components of Conventional Drum Mix Plant
a t i
(Parallel Flow Type)
y
r w a h
a
h Gu
d
u y
h o g
C o l o
a n
j ch n
R a e
o f . f T
r
P ute o
t i t
•
I n s
Some key attractions/advantages of drum mix plant:
a n
• Cost (operation & maintenance) of plant is less
toimodify and comparatively less space required for installation
• Portable, easyd
28
In NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 HMA Construction: Transportation of Mix
• Bituminous materials shall be transported in clean insulated
a t i
and covered vehicles.
y
r w a h
• An asphalt release agent, such as soap or lime water, may bea
d h G u
applied to the interior of the vehicle to prevent sticking
o u and
y
to facilitate easy discharge of the material.
C h l o g
a n
j ch n o
R a e
o f . f T
r
P ute o
t i t
In s
a n
i water
In d
Spraying of soap Loading of mixture Cover for asphalt mix

29 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology

 HMA Construction: Laying of Mix
Weather & Seasonal Limitations:
a t i
Laying is preferably suspended under following situations: y
r w a h
a
h Gu
✓ In presence of standing water on the surface; d
u y
✓ When rain is imminent, and during rains, fog or o
✓ When the base/binder course is damp; C h l o g
dust storm;

j a n n o
✓ When the wind speed at any temperature
a h
exceeds
e c the 40 km per
hour at 2 m height
f . R T
o
✓ When the air temperature onrthe o
surface f on which it is to be laid is less than 10°C for
mixes with neat bitumen &Pis less u t e
than 15°C for mixes with modified bitumen
t
Preparation of Surface: sConsisti t of preparing an existing granular or black-topped
In course. The work shall be performed on such widths and
surface for laying bituminous
a
lengths as shown on ithendrawings. The existing surface shall be firm & clean, and treated
n d
I as per requirement.
with Prime/Tack coat
30 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 HMA Construction: Laying of Mix
• A Paver Finisher is quite popular in flexible pavement construction for laying non-
a t i
bituminous as well as bituminous mixes. Main functions r y a h
To lay and spread the mix to attain specified surface. d h a of a Paver Finisher are :
u w
•
o u y G
• To facilitate attainment of specified surface
C h l o g
quality and correct grade/level/finish to a n
j ch
meet n o
R a e
o f.
the design specifications for a safe ride.
f T
• To achieve specified camber &rsuper
P ute o
elevation.
•
t t
To achieve required thickness, iuniform degree
of compaction, homogeneousI s
n quality of mix
during laying. i a n
In d
31 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 HMA Construction: Laying of Mix
Key Features/Components of Pavers for Bituminous Construction (IRC:27-2009):
a t i
• Paver finisher should have loading hoppers and a suitable y
r wa h
a
h Gu
distributing mechanism. d
u y
o
• Shall have an electronic sensor for automatichlevellinggand
C o l o
profile control within specified tolerances.
j a n h n
• Should have a hydraulically extendableR a e c
screed
o f . T
f arrangement
• The screed shall have an internal
P r o
heating
e Screed Plate Adjustment in Super
• The screed shall be equipped with
t u t tamping and vibrating Elevation Crown Position

s
mechanisms to achieve initialt i compaction (about 85%) as
In
the layer is spread,n without causing surface rutting. It
d i a
should feature adjustable amplitude and variable frequency. Screed Plate Adjustment in

32
In NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Positive Crown Position
HMA Construction: Laying/Spreading
Laying/Spreading of the HMA Mix:
a t i
• It is important to regulate the material delivery rate so to ensure y
r w a h
a
h Gu
continuous operation of the paver. d
u y
h o g
• The paver speed and operating method should C be so
o l o
adjusted so
a n
that the bituminous material spreads jevenly across h n the screed,
R a e c
f .
without dragging, tearing, or segregation.
o f T
r
P where
• In restricted or irregular areas e o
t u t pavers cannot be used (such
i
as confined spaces, footways of tirregular shape and varying thickness,
s
approaches to expansionn
n
I etc.), trained staff shall spread, rake,
joints,
d i a
33
In
and level the material
NPTEL
using appropriate hand tools.
| Indian Institute of Technology Guwahati | Pavement Construction Technology
HMA Construction: : Compaction Steps
✓ Bituminous materials shall be laid and compacted in layers
a t i
to achieve the specified thickness, surface level, uniformity, y
r wa h
and required compaction. a
h Gu
d
u y
▪ Compaction shall begin immediately after laying.
h o g
C
▪ Longitudinal joints must be rolled directly behind o l o
j a n h nthe paver.
• Rolling should proceed from the edges
R a e c
toward the center,
except on super-elevated orf. unidirectionally T
r o o f cambered
P ute the lower to upper edge
sections, where it shall progress from
parallel to the centerline.
t i t
I
• Rolling shall continue until
s
n all roller marks are removed, &
i a n
compaction is substantially complete before the temperature
falls below then
I d
minimum rolling temperature.
34 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
HMA Construction: Compaction Steps
Breakdown rolling: It is performed immediately behind the paver screed
a t i
and achieves the highest density gain.
r y a h
▪ Mainly done using a 3-wheeled static roller to attain the density h a withinuw
the temperature constraints and in sync with the pavero
d
u yG
speed.
▪ With a three-wheeled static roller, the operation C
h l
should always o g proceed
with the rear (drive) wheel moving forward jin a nthe pavingn odirection.
a e c h
Intermediate rolling: It supplements
f . R
breakdownT rolling to achieve the
r
required density and should be performedo o
whilefthe asphalt is still plastic.
P u t e
• It further compacts the mat and reorients
t i t the aggregates for improved compaction.
• Pneumatic-Tired Rollers (PTR):
I n s PTRs are preferred as they provide uniform compaction, enhance
surface sealing to reducenlayer permeability, and orient aggregates for greater stability, similar to
the effect of traffic d
i a
35
I n over time.
NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
HMA Construction: Compaction Steps
• The finish rolling is done to provide a smooth mat surface.
a t i
It is mainly accomplished with 6-8 ton tandem or tandem y
r wa h
a
h Gu
d
vibratory (without using vibration) while the material is still
u y
warm enough for removal of roller marks.
h o g
• In order to provide complete and uniformCmat compaction,
o l o
a n n
j chspeed.
R a
rollers should be operated at a slow, constant
e
f.
Typical roller speed ranges
o T
(IRC:SP:97-2013)
f
Type of Roller r o
P uteIntermédiate Finish
Breakdown
Static 3.2-5.6it 4.0-6.5 4.8-8.0
n s t
Pneumatic
n I 4.0-6.5
Vibratory
d i a 2.0-6.5

36
InNPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
HMA Construction: Compaction Steps
Rolling Pattern (IRC: SP: 97-2013):
a t i
• The rolling pattern should provide uniform y
r w a h
coverage of lane being paved. a
h Gu
d
u y
• The best rolling pattern for each roller should be
h o g
worked out and followed to obtain uniform C o l o
compaction across the lane. a n
j ch n
R a Rolling pattern behind the Paver on roads without kerb
e • The rolling pattern not
o f . f T
r
P ute o only includes the number
of passes, but also the
t i t location of the first pass,
In s the sequence of succeeding

i a n passes, and the overlapping

In d
Rolling pattern behind the Paver on roads with a kerb between passes.
37 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
HMA Construction: Compaction & Traffic Opening
• Where joints are made, the material shall be fully a t i
compacted and the joint made flush with the y
r wa h
a
h Gu
previously laid surface.
u d
• In multi-layer construction the longitudinal joint h o g y
in one layer shall offset the jointn in theo
C l o
underneath layer by about 150 mm. a j a h n
R e c
o
• Transverse joints in the successivef . f
and T
adjoining
r
P uoffset o
e of 2 m.
layers should have a minimum
t t
s t
• It shall be ensured that traffic i is not allowed on
I
the surface until the paved
nmat has cooled below a
a n
i in its entire depth.
d
temperature of 60°C
In
38 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Checks & Field Tests for Bituminous Construction
• Bituminous-bound layers constitute the primary
a t i
structural components of flexible pavements,
r y a h
contributing significantly to their overall strength h a u w
u d G
and performance. Ensuring quality during their
h o gy
production and construction is essential C to lo Specifications for dense Specifications for road

j a n n o graded bituminous & bridge works

safeguard the structural integrity and
a e c h
long-term mixes IRC: 111- 2009 MoRTH-2013

durability of the pavement.

f . R T
r o
• In recent years, the needPfor stringent o f
u t e checks and
quality control measures
t i t has increased Handbook of Manual for Guidelines

substantially, driven byIn s

escalating traffic volumes
Quality
Control for
Construction
quality
control in
road &
on measuring
road
roughness

i
and the growing demanda n for enhanced service life
of Roads &
Runways IRC:
bridge works
IRC: SP: 112-
and norms
IRC: SP: 16-

and durability n d
Iof roads.
SP: 11-2003 2017 2019

39 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology

Horizontal Alignment of Road
a t i
y
r wa h
a
h Gu
d
u y
h o g
C o l o
a n
j ch n
R a e
o f . f T
r
P ute o
t i t
• In s
C/W: Carriageway-width
•
a n
C/L: Center line
i
•
•
Ind
P/S: Paved shoulder
ROW: Right of Way
40 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Typical Cross Section of Pavement
a t i
y
r wa h
a
h Gu
d
u y
h o g
C o l o
a n
j ch n
R a e
o f . f T
r
P ute o
t i t
In s
i a n
Ind
41 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Check of Alignment, Level & Surface Regularity
Horizontal Alignment
a t i
• The horizontal alignment is to be ensured with reference to the y
r w a h
roads centre line as indicated in the approved plans and drawings. a
h Gu
d
u y
This process involves verifying both the roadway geometry and the edges
h o g
of the various pavement layers against the design centre line.
C o l o
• Adequate control of the horizontal alignment
a n isnpossible
j ch pillars placed if the
centre line is precisely marked in the fieldausing reference
. R T e
r o f
on both sides of the centre line at regular
f
intervals.
o
• To ensure adherence to thePdesign, the e
t u t edges of each pavement layer shall be ensured in
relation to the centre line before
s t i construction, using pegs, strings, or other tools.
• The edges of the carriageway In as constructed shall be correct within a tolerance of ± 10
i n
mm therefrom. The acorresponding tolerance for edges of roadway & lower layers of
pavement shall bed± 25 mm.
42
In NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Check of Alignment, Level & Surface Regularity
Surface levels
a t i
• The levels of the constructed bituminous bound course y
r wa h
shall not vary from those calculated with reference to a
h Gu
d
uon y
the longitudinal and cross-profile of the road shown
h o g
C
the drawings or as directed by the Engineer beyond the
o l o
tolerances mentioned in the Table (MoRTH, a n
j ch2013). n
R a e
Tolerances in surface
o f. levels
f T
P r
Base course for flexible o
pavement
e
t
Bituminous base/binder tu ± 6 mm
t i
Wearing course forsflexible pavement
• Machine laidn
In ± 6 mm
• Manuallyd i a
laid ± 10 mm
43
In NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Check of Alignment, Surface Level & Surface Evenness
• The negative tolerance for wearing course shall not be permitted in conjunction with
a t i
y
r w a h
the positive tolerance for base course, if the thickness of the former is thereby reduced
by more than the following limits: a
h Gu
u d
• 4 mm for bituminous wearing course of thicknessh o
40 mm org y
more
• 3 mm for bituminous wearing course of thicknessC l
less than
o o 40 mm
j a n h n
• For checking compliance with R a c
the eabove
o f . f T
requirement for bituminous
r
P levels o
wearing
e
courses,
measurements of the surface
t u t shall be taken
i
on a grid of points placedt at 6.25 m along the
s
n
length and 0.5 m from Ithe edges and at the center
of the pavement. ia
n
In d
44 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Check of Surface Evenness/Regularity
• The measurement & checking of surface unevenness is mainly done by a 3 m straight edge. a t i
• As per IRC:111-2009, the maximum permissible surface unevenness r y a h
is 6 mm for SDBC and
h a u w
5 mm for BC in the longitudinal profile, and 4 mm for both
u d in the transverse profile.
G
• The maximum permissible frequency of surface unevenness
h o giny300 m length in longitudinal
profile (IRC:111-2009) is shown in the Table. C
o l o
j a n h n
• Where the surface unevenness R a
falls e c
Maximum Permissible Frequency of Unevenness

outside the tolerance, in eithero f . case

T
f Type
Maximum Number of Surface Unevenness

i.e. the surface is low or P

r e o of Unevenness,
NS/SH
MDR & Lower
high, the
t u t full surface mm category

i
depth of the layer shall bet removed
s
SDBC 4-6 mm 20 40

and replaced with fresh Inmaterial and

BC 3-5 15 30

a n
compacted to the ispecification.
SDBC: Semi-dense bituminous concrete; BC: Bituminous concrete

In d
45 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Surface Regularity Check of Bituminous Bound Courses
• The maximum allowable difference between the road surface
a t i
and underside of a 3 m straightedge when placed parallel
r y a h
with, or at right angles to the centre line of the road shall be:h a u w
• 3mm: for a bituminous pavement surface and ou
d G
h g y
• 6mm for bituminous base courses (as per MoRTH-2013) C o l o
j a n n
• As per MoRTH 2013, the longitudinal ch a
profile, when checked with fa. 3-metre
R T e
r o o f
P utalong
straightedge or moving straightedge e the
t
middle of each traffic lane parallel i t to the
n s
centre line, shall conformI to the permissible
surface irregularitiesiaasnspecified in the table.
I n d
46 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Rectification of Bituminous Bound Courses
• As per MoRTH-2013 for bituminous course other than wearing
a t i
course, where the surface is low, the deficiency is corrected by
y
r wa h
adding fresh material over a suitable tack coat, and compacted a
h Gu
as per specifications. d
u y
h o g
• Where the surface is high, the extra thickness C in the
o l o
affected
layer is preferably removed and replacedan n
with fresh material
a j c h
and compacted to specifications.
R
. isf high e
T or low, the full
•
r f
For wearing courses, where theosurface
o
depth of the layer shall bePremoved t e and replaced with fresh
t i t u
material and compacted to specifications.
• In all cases where the I s
nremoval and replacement of a
a n the area treated shall not be less
bituminous layer isiinvolved,
n d
I and not less than 3.5 m in width.
than 5 m in length
47 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Check for Road Roughness
• Road roughness refers to irregularities in the pavement surface
a t i
that negatively impact vehicle ride quality and user experience.
y
r fuel wa h
• It influences not only comfort but also vehicle delays, h a u
consumption, and maintenance costs. u d G
h o g y
• The term “smoothness” is often used interchangeably
C o l o with
“roughness”, as both describe the same pavement
j a n n
characteristic.
h
• Road roughness is mainly a result R a e c
of either the built-in
o . f T
irregularities due to constructionfdefects/deficiencies, or may also
appear on road surface due P e o
torconsolidation
t (IRC: SP:16-2019).
tu surface roughness requirements, in terms of Bump
• Where the project specifies tthe
s i
I n
Integrator value, the roughness is measured by a calibrated Bump Integrator.
•
i
The measurements shall a n
be taken at the center line of each lane for a minimum completed

In
length of one Km. d
48 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Check for Road Roughness
• The typical maximum permissible t i
Maximum Permissible Values of Roughness (mm/km) for
a
y
r Condition a h
Surface with Dense Graded Bituminous Mixes [IRC: 111-2009]

values of surface roughness measured Type of

h a u w of Road
determined through a bump integrator Surfaceu d G Surface (mm/km)
h o Good g y Average Poor
for surfaces with dense graded
C l o
bituminous concrete mixes are given inanSDBC no <2500
a j c h 2500-3000 >3500
the Table 12 (IRC: 111-2009).
. R T e
BC <2000 2000-3000 >3000

r o f o f SDBC: Semi-dense bituminous concrete;

P ute BC: Bituminous Concrete

t i t • The newly constructed surfaces are expected to give

In s roughness values corresponding to the Good category.

i a n • While the Average and Poor categories indicate the level

In d of service and the intervention criteria.

49 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Checks for Bituminous Works (MoRTH, 2013)
One set for individual constituent &
a t i
Mix grading
r w a h
mixed aggregate from dryer for each
y
a
400 tonnes of mix subject to minimum
h Gu
d
of two tests per day per plant
u flow yvalue,
Stability and voids analysis of
h o
Three tests for stability,
g
mix including theoretical density and Cvoid l o
contents
o for each
maximum specific of loose mix 400 tonnes a n n
of mix subject to minimum
j tests perchmix day per plant
R a
of two
e
Moisture susceptibility of mix f.One testffor T each mix type whenever
(AASHTO T 283) P r o o
there is change in the quality or
u t e
source of coarse or fine aggregate
Density of compacted layerst
i t
In One test per 700 sq. m area

i a
Binder Content
n One set for each 400 tonnes of mix subject

In d to minimum of two tests per day per plant

50 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
Check of Bituminous Mix Density and Composition
• The acceptance criteria for test on density  1.65 
a t i
y
r w a h
(N =3 minimum) & Marshall stability (N=2 1.65 − (No. of samples)0.5  times the standard deviation
minimum) shall be subjected to the a
h Gu
u yd
condition that the mean value of N samples Permissible variation from Job mix formula
h o
Description g Permissible Variation
is not less than the specified value plus:
C o l o
• Checks are conducted at plant to ensure j a n Average
h npassing DBM SDBC/BC

production of a uniform mix according R a e

to the 13.2cmm/9.5mm
19 mm or larger ± 8% ± 7%

o f . T
f 4.75 mm
± 7% ± 6%

r
job mix formula. Typical permissible
P ute
are shown in table (IRC:111-2009).
o
variations
2.36 mm, 1.18 mm, 0.6 mm
± 6%
± 5%
± 5%
± 4%
t i t
In s 0.3 mm, 0.15 mm
0.075 mm
± 4%
± 2%
± 3%
± 1.5%

i a n Binder content ± 0.3% ± 0.3%

I n d Mixing temperature ± 10°C ± 10°C

51 NPTEL | Indian Institute of Technology Guwahati | Pavement Construction Technology
 a t i
y
r wa h
a
h Gu
d
u y
h o g
C o l o
a n
j ch n
R a e
o f . f T
r
P ute o
t i t
In s
i an
Ind