CHAPTER 3:

ROAD CONSTRUCTION
BY: HARYATI YAACOB
 TOC
1. SURVEY AND ALIGNMENT
2. SITE CLEARING
3. EARTHWORK
4. PAVEMENT WORK
5. DRAINAGE WORK
6. FINISHING
 Aspects to be considered in road
construction?
• Terrain – capacity, cost, speed, earthwork
• Soil properties – cost, treatment
• Environmental impact
• Economy and socio-economy – cost &
benefit, finance
• Politics – involve other country
• Historical – heritage building, cemetery
 1. Survey and Alignment
• 4 major phases:
– Desk study of area- available and existing data i.e maps,
aerial photographs, charts
– Reconnaissance survey- identify feasible route between
two end points, aerial photograph
– Preliminary survey of the best route –each route are
plotted on the base map and compared for suitability.
Economic evaluation, environmental evaluation. Pick the
best route.
– Final location survey – horizontal and vertical allignments.
setting out points on site according to drawings e.g ROW,
alignment, leveling, etc.
 SURVEY AND ALIGNMENT

Maps in highway work:

• Ordnance survey map
• Plans
• Longitudinal sections
• Transverse sections
• Details drawings
• Ordnance survey map
- Scale 1: 50000, 1:25 000, 1:10000, 1: 2500 1:1250
• Plans – larger scale, 1:500, 1:200, 1:100, 1:50
• Longitudinal Section- to show the height or the elevation of the ground along a
line which is the centre line of proposed highway. Same scale as plan & drawn on
the same sheet
• Cross Section- at bigger scale, numbered for reference according to
chainage, compiled together under seperate drawing sheets.
Chainage
• Details Drawing- – showing all details clearly, scale from 1:20
to 1:1, e.g culvert detail, pipe, retaining wall, etc.
Detail Drawing
 CADANGAN MEMBINA JALAN BARU DARI
KAMUNTING KE ANAK KURAU, DAERAH LARUT
MATANG DAN SELAMA,
PERAK DARUL RIDZUAN
 LOCATION PLAN

LOCATION OF
PROJECT
 Kg Anak Kurau
LOCATION OF
PROJECT

Kamunting
 CONCEPTUAL
ALIGNMENT STUDY
Option 1
Kg. Anak Kurau

Kg.
Bukit
Jana
Option 1 – 14 km
Option 2
Kg. Anak Kurau

Option 2 – 13.5
km
Jln. Kamunting
Lama
 Option 3

Kg. Anak
Kurau

Sg. Relong

Option 3 – 11.1
km
 LOCATION OF
TERMINAL END
CONSIDERATION OF ALTERNATIVES
 2. Site Clearing- Rural
Site clearing in rural area composed of three major processes:

Clearing

Grubbing

Stripping
 Clearing
• Above ground level
Clearing
 Grubbing
• Removal 0.5m below ground level.
Grubbing
 Stripping top soil
• remove top soil 100 mm below
ground level
Separate disposable materials
Site Clearing – Urban
Utilities
 TMP
Poor practices of TMP
TRAFFIC MANAGEMENT PLAN
TRAFFIC MANAGEMENT
ZONING PLAN
ZONING

ZONE A ZONE B ZONE C ZONE D ZONE E

ADVANCE WARNING ZONE

Recommended provision of Advance

Warning signages
TRANSITION ZONE
BUFFER ZONE
WORK ZONE
TERMINATION ZONE
Signages
Signages
Detour
Work-Sign
Poor practices of TMP - Consequences
Poor practices of TMP - Consequences
Poor practices of TMP - Consequences
7) Traffic Sign - Check for case of non-standard signs
 Crawler tractor

Scraper
 Wheel digger

Wheel loader
 3. Earthworks
Excavation Backfill

Transportation Stockpiling

Spreading Forming
Compaction embankment

up to the FORMATION LEVEL as

shown on the drawings
 Earthworks- Excavation

Cut and fill

Common excavation – any

material not hard /rock
 Earthworks- Excavation
Silt
Unsuitable
materials
Stumps

Mud

LL>80, PI>55

Peat
 Subgrade
Improvement
Geotextile
Geotextile
PVD
Vertical Drain

Video
• PVD video 2 (refer elearning)

• PVD video 3 ( refer elearning)

 Earthworks- Backfilling

Tests conducted on
Soil need to be All fill metarials - soil , unsuitable (e.g.
replace- suitable organic, marine clay)
formation level materials need to be treated,
remove and
replaced with
suitable material
 Earthworks- Excavation
• Works carried out according to mass-haul
diagram
 Temporary water course
• Provide temporary water course, ditches, drains,
pumps and silt trap to maintains earthworks free
from water.
 Earthworks- Excavation
• Excavation of rock/hard materials – use
appropriate and safe methods.
Rock/hard material
Explosive
Blasting/transportation
Earthworks - Compaction
 Earthworks - Compaction
• Factors affecting compaction – soil characteristics, moisture content,
plants, energy applied
• Conduct lab compaction test (BS 1377, 4.5 kg) to determine ………??
• Field compaction trials carried out as soon as
the material is spread ( 8m x 15m )
• No. of passes, layer thickness, determine
through trial lay at OMC (max thickness
300mm)
• Soil compaction video ( elearning)
 Compactor
Smooth wheel– compaction by dead weight, additional
pressure (ballasted with water/sand), vibrate, for all types of soils (gravel,
sand, clay) and premix.
• Pneumatic – rubber tyre, 12 - 200 ton, pressure on tyre up
to 100lb/in2 for cohesive, sandy soil, premix, surface
dressing.
• Vibratory – rearrange soil grains through
vibration, suitable for coarse grained soil
• Sheep foot – steel drum with protruding and tamping feet (round
and rectangular shape) , drum wheel can be fliled with water,
compact from bottom upwards, 3-27 ton, contact pressure 200-
1000lb/in2, for clay, silt, fine grained soil
Compaction in small area
Field Density Test ( FDT)
FDT: Sand Replacement Method
FDT – Nuclear Gauge
DOC on road layers
Sand replacement
method/ Sand cone

Sand Replacement Method

Sand replacement method video
Derivation and calculation
Worked Example
 EARTHWORKS - Turfing
Protective Vegetation (Erosion Control)
• Topsoil spread and lightly compacted, thickness 50mm
• Block 250 x 250 mm, free of lallang and weeds
• Slope steeper than 1:3, pegged with bamboo stakes
• Seeding/hydroseeding – submit 4 weeks in advance with
proposed method and material
• All turf shall be regularly watered and fertilised
• Dead turf to be replaced with new turf
 4. PAVEMENT WORKS

Consists of:
• Drainage layer
• Subbase
• Roadbase
• Coating
• Surfacing
• Shoulder
 PAVEMENT WORKS – Drainage Layer

Laying and compaction of drainage layer

• Laid on a prepared and accepted subgrade (any damage
or deterioration on subgrade shall be made good before
laying drainage layer).
• Coarse aggregate (screened crushed hard rock), fine
aggregate (screened quarry dust or sand)
• Laid and compacted at MC +1 to -2% of OMC without
drying out or segregation to the required width and
thickness
 PAVEMENT WORKS - Subbase

• Material – natural or artificial mixture of locally available

material such as sand, gravel, crushed aggregate, free from
organic matter, clay lumps and other deleterious materials.
• Spec: CBR soaked  30% (if  10% retained on 20mm, can be
assumed passed), PI  12, TFV  30kN, sand equivalent  45
• Laid in 100 - 200 mm compacted thickness, compacted at
MC +1 to -2% of OMC without drying out or segregation to
the required width and thickness
• Compaction in longitudinal direction, lower edge towards
the crown, in superelevation towards the upper edge to
produce density  95% MDD
Spreading and leveling the sub base
Large scale 5000m2 grader

Small scale bulldozer/ loading

shovel
Pegs and wires
Subbase
 PAVEMENT WORKS - Roadbase

Crushed Aggregate Roadbase

• Material – crusher rock, crushed gravel or a mixture or
crushed rock and gravel
• Spec: PI  6, ACV  25, FI  30, Soundness  18, CBR  80,
sand equivalent  45
• Spread using motor grader or approved spreader at OMC
± 1%, laid in 100 - 200 mm compacted thickness,
maintain uniform gradation, prevent drying out or
segregation to the required width and thickness
• Compaction in longitudinal direction, lower edge
towards the crown, in superelevation towards the upper
edge to produce density  95% MDD
Roadbase – back pusher
Roadbase – grader, paver
Roadbase
 PAVEMENT WORKS - Roadbase

Wet Mix
Material – crusher rock, crushed gravel or a mixture or crushed
rock and gravel
Spec: ACV  25, FI  30, Soundness  18, sand equivalent  45
Spread using paving machine at OMC ± 0.5%, laid in 100 - 200
mm compacted thickness, maintain uniform gradation,
prevent drying out or segregation to the required width
and thickness
Compaction in longitudinal direction, lower edge towards the
crown, in superelevation towards the upper edge to
produce density  95% MDD
 PAVEMENT WORKS - Roadbase

Bituminous Roadbase
Material – conform to the physical and mechanical
quality requirement in asphaltic concrete section
Design, equipment and construction methods as
specified for asphaltic concrete section.
 Coating
Prime Coat Tack Coat

• liquid bitumen, sprayed • bitumen emulsion,

onto clean unbound sprayed onto bituminous
roadbase using pressure layer, rate 0.25 – 0.55
distributor at the rate of liter/m2
0.5 – 1 liter/m2 • RS-1K (25℃ - 45℃ )
• MC-70 (50℃-70℃), SS-
1K (25℃ - 45℃) cured
for 24 hours to achieve
maximum penetration

Carried out in dry, warm weather and dry surface, prevent spattering
adjacent trees, furniture etc, not to be discharged into drains, gutter,
keep traffic off
• Binder course will be laid on the broomed,
clean and prime coated roadbase.
Coating
Prime Coat
 PAVEMENT WORKS - Surfacing
Transporting asphaltic concrete
- Using tip truck not less than 5 tonnes.
- Protect from contamination
- Clean vehicles
- Supply continuously
- Temperature before unloading 130˚C (+ 10˚ C for pen 60-70 bitumen)
 Paver
Laying surfacing materials
Video
• Laying and compacting job shall be carried out in dry weather
• After binder course has been properly compacted, sprayed with tack
coat, wearing course will then be laid and compacted.
• Compated thickness not less than twice the nominal max agg size
(NMAS) and not more 100mm.
 Premix compaction
Consists of:
1. Breakdown/initial – smooth wheel, <5 km/hr
Temperature at the commencement of rolling  120C,
not if < 80 C
Operate longitudinal direction with driven wheels
towards the paver, lower to higher edge
Passes overlapped half width of the roller
2.Intermediate/principal – pneumatic, < 8 km/hr, weight
 15 ton, tyre pressure  0.7 N/m2
3. Final /Finish – smooth wheel, eliminate irregularities,
tyre tracks
 Premix compaction
Joint

Construction joint cut back straight,

brushed on with RS-1K, 10-15
minutes before laying of next
section, no joints along
wheelpaths
Rollers, heavy vehicles shall not be
allowed to stand on newly laid
mix before compaction
completed and thoroughly
cooled and set.

118
Joint

cri-mab8053-2008 119
Joint compaction

120
Compacted surface

cri-mab8053-2008 121
Coring- Core diameter  100mm, 1 sample
every 500 m2
Core Samples
Core thickness & density
Tests (density, thickness, and quality), > 24 hrs
Open to traffic > 4 hrs, < 30 km/hr, no sharp
turning
Compaction requirement – 95, 98% of Marshall
density at OBC
Core Extraction
 PAVEMENT WORKS - Shoulder

Consists of furnishing, compacting and shaping earth,

gravel, or paved shoulder
Paved – constructed as normal bituminous layer
Gravel – using approved material for gravel surfacing
Earth – using suitable material as described in earthwork
section
Thickness of each layer according to the drawing, based
on material used and compacted to the required
minimum density
Top level of shoulder should be level and flushed with
pavement and uniformly free draining away from
carriageway.
Shoulder
 PAVEMENT WORKS - Tolerance

Horizontal Alignment
Determine from the CL of the pavement surface, edge
and all parallel line correct within +50mm and -0mm
Kerb, channel blocks and edge line +25mm and -0mm

Surface levels

Pavement Layer Tolerance

Wearing  5 mm
Binder  5 mm
Roadbase + 0 mm, - 20 mm
Subbase + 10 mm, - 20 mm
 PAVEMENT WORKS - Tolerance

Surface Regularities

Riding quality depends on roughness

Roughness due to – uneven settlement, undulation,
rutting, wide cracking, potholes etc.
IRI used to measure roughness
Lane IRI measured using walking profiler – for the whole
road length and each 100m section < 2.m/km
Surface regularity
Walking profiler
 PAVEMENT WORKS - Defects

Surface defects
Some of the factors contributing to surface defects are:
• Design – wrong material spec, low/substandard spec,
inadequate design thickness
• Mixing and transporting – bad grading, low quality binder,
inadequate binder, temperature, low aggregate quality
• Laying/Paving – uneven or dirty surface, inadequate
coating, low quality workmanship, inadequate
compaction, thickness, plant and equipment not in good
working condition.
 5. DRAINAGE WORKS - Surface
Surface Drainage
• Road surface has to be free of standing water, drains water away to side
drains down to open water course
• Types of surface drains includes interceptor drains, roadside drains,
embankment toe drains, shoulder drains, berm drains, median drains, outfall
drains, cascade drains, etc.
 DRAINAGE WORKS - Subsoil
Subsoil Drains
• To handle ground water so that the level is low enough, avoiding soil from
becoming plastic
• Porous pipe, clay pipe, and PVC pipes used shall comply with the requirement
standard
• Granular filter material shall conform the required grading limits
• Synthetic filter cloth from non-woven type with required strength and properties
 DRAINAGE WORKS - Culvert
Culvert
• Either precast box, PVC, corrugated metal pipe atau reinforced
concrete may be used depending on the drawings.
• Material required depends on type of culvert used and shall meets
the specification
6. Finishing- Guard rail
Finishing- Trafic signs
Finishing-Road marking
Finishing- Street lighting
Finishing- Traffic signal