Civil Project

DEPARTMENT OF CIVIL ENGINEERING 2010-2014
1. INTRODUCTION:-
A highway pavement is a structure consisting of superimposed layers of
processed materials above the natural soil sub- grade. The payment
structure should be able to provide a surface of acceptable riding quality,
adequate skid resistance, favourable light reflecting characteristics, and low
noise pollution. The ultimate aim is to ensure that the transmitted stresses
due to wheel load are sufficiently reduced so that they will not exceed
bearing capacity of the sub-grade. Two types of pavements are generally
recognized as serving this purpose, namely flexible pavements and rigid
pavements. This chapter gives an overview of pavement types, layers, and
their functions, and pavements failures. Improper design of pavements leads
to early failure of pavements affecting the riding quality.
2. TYPE OF PAVEMENTS:-
The pavements can be classified based on the structural performance into
two, flexible pavements and rigid pavements. In flexible pavements. Wheel
loads are transferred by grain-to-grain contact of the aggregate through the
granular structure. The flexible pavement, having less flexural strength, acts
like a flexible sheet (e.g. bituminous road). On the contrary, in rigid
pavements, wheel loads are transferred to sub-grade soil by flexural strength
of the pavements and the pavements are also available. A thin layer of
flexible pavement over rigid pavement is an ideal pavement with most
desirable characteristics. However, such pavements are rarely used in new
construction because of high cost and complex analysis required.
2.1 Flexible Pavements
Flexible pavements will transmit wheel load stresses to the lower layers by
grain-to-grain transfer through the points of contact in the granular
structure (see Figure).
S.K.D ENGINEERING COLLEGE

Load transfer in granular structure
2.2 Deflection on flexible pavement
The wheel load acting on the pavement will be distributed to a wider area,
and the stress decreases with the depth. Taking advantage of these stress
distribution characteristic, flexible pavements normally has many layers.
Hence, the design of flexible pavement uses the concept of layered system.
Based on this, flexible pavement may be constructed in a number of layers
and the top layer has to be of best quality to sustain maximum compressive
stress, in addition to wear and tear. The lower layers will experience lesser
magnitude of stress and low quality material can be used. Flexible
pavements are constructed using bituminous materials. These can be either
in the form of surface treatments (such as bituminous surface treatments
generally found on low volume roads) or, asphalt concrete surface courses
(generally used on high volume roads such as national highways). Flexible
pavement layers reflect the deformation of the lower layers on to the surface
layer (e.g., if there is any undulation in sub-grade then it will be transferred
to the surface layer), In the case of flexible pavement, the design is based on
overall performance of flexible pavement, and the stresses produced should
be kept well below the allowable stresses of each pavement layer.

2.3 Types of Flexible Pavements
The following types of constructiowhave been used in flexible pavement:
Conventional layered flexible pavement,
Full - depth asphalt pavement, and
Contained rock asphalt mat (CRAM).
2.3.1 Conventional flexible pavements are layered systems with high
quality expensive materials are placed in the top where stresses are high. aud low
quality cheap materials are placed in lower layers.
2.3.2 Full - depth asphalt pavements are constructed by placing
bituminous layers directly on the soil sub-grade. This is more suitable when there
is high traffic and local materials are not available.
2.3.3 Contained rock asphalt mats are constructed by placing dense/open

graded aggregate layers in between two asphalt layers. Modified dense graded
asphalt concrete is placed above the sub-grade will significantly reduce the vertical
compressive strain on soil sub-grade and protect from surface Waler.
2.4 Typical layers of a flexible pavement
Typical layers of a conventional flexible pavement includes seal coat, surface
course, tack coat, binder course, prime coat, base course, sub-base course,
compacted sub-grade, and natural sub- grade.
2.4.1 Seal Coat
Seal coat is a thin surface treatment used to water-proof the surface and to
provide skid resistance.
2.4.2 Tack Coat
Tack coat is a very light application of asphalt, usually asphalt emulsion
diluted with water. It provides proper bonding between two layers of binder

course and must be thin, uniformly cover the entire surface, and set very
fast.
2.4.3 Prime Coat
Prime coat is an application of low viscous cutback bitumen to an absorbent
surface like granular bases on which binder layer is placed. It provides
bonding between two layers. Unlike tack coat, prime coat penetrates into the
layer below, plugs the voids, and forms a water tight surface.
2.4.4 Surface course
Surface course is the layer directly in contact with traffic loads and generally
contains superior quality materials. They are usually constructed with
dense graded asphalt concrete (AC). The functions and requirements of this
layer are:
It provides characteristics such as friction, smoothness, drainage, etc. Also
it will prevent the entrance of excessive quantities of surface water into the
underlying base, sub-base and sub-grade,
It must be tough to resist the distortion under traffic and provide a smooth
and skid resistant riding surface,
It must be water proof to protect the entire base and sub-grade from the
weakening effect of water.
2.4.5 Binder course
This layer provides the bulk of the asphalt concrete structure. Its chief
purpose is to distribute load to the base course. The binder course generally
consists of aggregates having less asphalt and doesnt require quality as high
as the surface course, so replacing a part of the surface course by the
binder course results in more economical design.

2.4.6 Base course
The base course is the layer of material immediately beneath the surface of
binder course and it provides additional load distribution and contributes to
the sub-surface drainage it may be composed of crushed stone, crushed
slag, and other untreated or stabilized materials.
2.4.7 Sub-Base course
The sub-base course is the layer of material beneath the base course and the
primary functions are to provide structural support, improve drainage, and reduce
the intrusion of fines from the sub-grade in the pavement structure If the base
course is open graded. Then the sub-base course with more fines can serve as filler
between sub-grade and the base dourse A sub-base course is not always needed or
used. For example, a pavement constructed over a high quality, stiff sub- grade
may not need the additional features offered by a sub-base course. In such
situations, sub base course may not be provided.
2.4.8 Sub-grade
The top soil or sub-grade is a layer of natural soil prepared to receive the
stresses from the layers above. It is essential that at no time soil sub-grade
is overstressed. It should be compacted to the desirable density, near the
optimum moisture content.

3. INTRODUCTIONS TO THE PROJECT:

Govt. of India through NHAI has taken up the development, maintenance
and management of National Highways under NHDP Phase III programme
of 4/6 lining of 10,000 km length of highways on BOT basis, where the
intensity of traffic has increased significantly and to augment the capacity
for safe and efficient movement of traffic.
National Highway No.18 starts from Cuddapah (km 167.750) to Kurnool (km
356.502) Via Maidukur, Allagadda, Nandyal & Panyam. Total length of
highway is located in Andhra Pradesh, connecting NH: 7 @ Kurnool
Cuddapah - Kurnool (188.75Km) stretch of NH: 18 in Andhra Pradesh one of
the corridors taken up for augment the capacity under NHDP Phase III
programme. The project highway passes through Cuddapah and Kurnool
districts. A sit location map is enclosed in executive summary.

4. PRELIMINARY INVESTUGATION:
4.1 General
The sub grade provides a foundation for supporting the pavement structure.
As a result, the required pavement thickness and performance obtained
From the pavement during its design life will depend largely upon the
strength and uniformity of the sub grade. Therefore, insofar as is
economically feasible, a through investigation of the sub grade should be
made so that design and construction.

Will ensure uniformity of support for the pavement structure and realization
of the maximum strength potential for the particular sub-grade soil type.
The importance of soil and moisture conditions under the pavement cannot
be over-emphasized with respect to frost action.
4.2 Investigation of site

Characteristic of sub grade soils and peculiar feature of the site must be
known to predict pavement performance investigations should determine the
general suitability of the sub grade soils based on classification of the soil,
moisture-density relation, degree to which the soil can be compacted,
expansion charecteristics,susceptibility to pumping, and susceptibility to

detrimental frost action. Such factors as groundwater, surface infiltration,
soil capillarity, topography, rainfall, and drainage conditions also will affect
the future support rendered by the sub grade by increasing its moisture
content and thereby reducing is strength. Past performance of existing
pavements over a minimum of 5 years on similar local sub grades should be
used to confirm the proposed design criteria.
Sub surface investigation and laboratory tests for proposed National
Highway project The objective of the exploration work was to determine the
probable sub surface Conditions such as stratification, denseness or hard
ness of the strata, position of groundwater table etc. and to evaluate
probable range of safe bearing capacity for the structure. To fulfil objective,
the work carried out is comprises of;
Drilling one borehole up to the depth of 10.0m below existing ground

level in order to know the sub surface satratification, conducting
necessary field tests and to collect disturbs and undisturbed soil
samples for laboratory testing.
Testing soil samples in the laboratory to determine its physical and
engineering properties of the soil samples, and
4.2.1 Alignment

The existing 2-lane carriageway alignment has number of sharp horizontal
and vertical curves which require geometric corrections and the existing
gradient of the highway in within acceptable limits, as per IRC: 73 in the
stretch of the highway where it passes through plain terrain. The existing
alignment in the rolling and mountainous terrain stretches from km
306.500 to km 322.000 requires grade correction as per IRC:SP:48-1998
Hill Road manual Widening options of this stretch will be studied in detail
keeping in the movement of existing traffic during construction,
environmental impact if hill is cut for widening purpose etc. The existing
alignment runs bisection the existing irrigation tank at km 351.800 near
Thandrapadu village for approximately 200m length on about 3.0m high

embankment,
Rocky outcrop is close to existing alignment from km 306.500 to km
322.000. This rock may be required to be cut/chipped for widening of
the existing road to 4-lane.

The alignment does not run in high embankment except on
approaches to major bridges, where the height of embankment is up
to 5m. Generally the existing road is on 0.5, to 2.5m high
embankment.
The alignment of project road passes through number of built-up
sections. The list of built-up areas and locations are shown in the
Table 1.



4.2.2 Climate
The climate along the road is generally hot. Annual rainfall for year 2004-
2005@Cuddapah and Kurnool are as below. The average annual rainfall is
less than 1300mm. The weather pleasant during November to January.
Rainfall and temperature Recorded during 2005-2006 are shown below.
4.2.3 Carriageway width
The existing carriageway width is 7.0m expect at built up locations and
approaches to major towns. A brief detail of carriageway width is shown in
Table2.

4.3 Pavement condition
The existing pavement has distressed at number of stretches due to

presence of irrigation water on both sides. Recently overlay/patch has been
carried out to improve the riding quality of the surface. The existing

pavement condition based on visual observation varies from poor to good.

The details of visual observation regarding pavement condition are given in
Table3.


4.4 Major junctions and cross roads
Six state Highways cross/take off from NH: 18. One major junction is at
Nandyal @ km 289.000 with a road to Nandyal and another is with MDR-24
@ panyam(km 303.030).The details of junction are shown in Table4.There is
no signalized junction on this stretch of highway.
4.4.1 Cross-roads

There are number of side roads that take-off/meet NH: 18 from Cuddapah
to Kurnool stretch. The roads include state highways, MDRs, ODRs and
village roads. The details are shown below:
4.4.2 Land use
Type of soil along the project road includes red gravely soil, silty sand, BC
soil with gravel and black soil with gravel. Land use along the highway is
predominantly for agriculture. Majority of the land is being used for wet
crops viz. Paddy, Sugarcane etc. There are number of settlements all along
the road. The Settlements are for Residential, Commercial, Schools,
Hospitals, petrol stations etc. Major settlements are close to the existing
highway at number of locations. Existing highway requires geometric
corrections at Khajipeta, Maidukuru, Chintakunta, Gudipadu and Duvvuru
villages. Alignment is straight in Chagalamarri village and Allagadda town.
Public have encroached existing ROW in Nandyal from Km 285.000 to Km
292.000
4.4.3Traffic flow conditions
Traffic on this section of NH: 18 are of mixed type. Number of passenger
vehicles viz. buses and cars are more than the commercial vehicles & these
vehicles include 2-axle, 3-axle trucks and LCVs. Local traffic is more in the
urban/ semi-urban stretches of the project road. Relatively traffice is more
from Nandyal to Kurnool compared to Cuddapah to Nandyal stretch of NH:
18.
These are no bus-bays and no parking lay-byes for commercial vehicles. It
was observed during reconnaissance survey that a number of commercial
vehicle are being parked from km 282.750 to km 289.000 on Nandyal
bypass creating congestion for smooth flow of traffic.

Bearing capacity of the soil forgiven foundation sizes and necessary
recommendations for foundation design and construction.
4.4.4. Soil Conditions
Soil conditions should be investigated by a combination of a general survey
of sub grade conditions, preliminary subsurface investigations, and soil
borings.
4.5 General Survey of sub grade Conditions

Sources of data should include the landforms, soil conditions in ditches,
and cuts and tests of Both natural and subsurface drainage of the sub grade
must be considered.
4.5.1 Preliminary Subsurface Explorations.
(i) Soil
Soil samples from the preliminary borings should be classified and the data
used to prepare soil profiles and to select representative soils for further
testing. Measurements should include moisture contents which indicate
soft layers in the soil.
(ii) Borrow Areas
Where material is to be borrowed from adjacent areas, subsurface
explorations should these areas and carried 2 to 4 feet below the anticipated
depth of borrow. Samples from the explorations should be classified and
tested for moisture content and compactions characteristics.
5. DESIGN STANDARDS AND GUIDANCE:-

The design of highway and structures will be bases of design standards.
The design features/requirements are in accordance with the TOR and

bases on relevant IRC codes, MORTH & BIS specifications. Details are
mentioned in subsequent sections.
5.1 Design standards for Road
The detailed geometric design will be worked out as er standards and
following design requirements mentioned in below Table. These
requirements will be reviewed further in relation to the design traffice and
capacity of roadway in consultation with NHAI. Typical corss sections for 4-
lane divided carriageway for symmetrical widening, left / right widening and
widening proposal in built-up sections with service roads are prepared as
per IRC:73-1980 and enclosed.




5.2 Design Standards for Structures

All structure will be windened to 3 lane requirements in each direction. The
general design standard to be followed are enclosed in Table6.

In general, IRC standard codes to which the design shall conform to are:
1) IRC:5 (Sec-I) : General features of Design
2) IRC:6 (Sec-II)-2000 : Loads and stresses
3) IRC:SP-13 : Design of small culverts and bridges
4) IRC:18-2000 : Post tensioned concrete
5) IRC:21(Sec III)-2000 : Cement Concrete(Plain and reinforced)
6) IRC:22-1985 : Composite construction
7) IRC:78(Sec VII)-2000 : Foundations and Substructure
8) IS:14268-1995 : Low relaxation strands
9) IS:1893-1984(Reaffirmed1991):Earthquake loads
10) IS: 2911(part I) : Design and construction of board cast

in-situ piles

11) IRC: 83 : Bearings
5.3 Road drainage

Pavement surface drainage, shoulder and open drainage will be designed as
per IRC: SP: 42-1994 (guidelines on Road Drainage) and sub surface
drainage as per IRC: 37(Guidelines for the design of flexible pavements).
5.3.1 signage/pavement marking/pick up bus stops and

Ancillary works
Consultant site reconnaissance/inventory survey indicates need for
improvement in the project road stretch regarding following facilities for safe
and smooth traffic flow:
Provisions of kilometer stones and crash barriers at high
embankment (design basics:IRC:8-1980 & IRC :26-1967)
Provision of reflective thermoplastic pavement markings, cats eye
etc(design basic: IRC :35-1997)
Provision of retro-reflective road (design basic:IRC:67-2001)
Provision of road delineators IRC :79-1981
Solar powered junction lights using 36 volts battery (manufacturers
standard)

6. MATERIALS SPECIFICATIONS:
Materials specifications to be used in the construction of road and
structures will be based on the MORTH Specifications for road and bridge
works (Fourth Revision) 2001 published by IRC.
6.1 General
Materials to be used in the work shall conform to the specifications
mentioned on the drawings, the requirements laid down in this section and
specifications for relevant items of work covered under these specifications.
If any material, not covered in these specifications, is required to be used in
the work, it shall conform to relevant Indian Standards, if there are any, or
to the requirements specified by the Engineer.
6.2 Sources of materials
The Contractor shall notify the Engineer of his proposed sources of material
sprier to delivery. If it is found after trial that sources of supply previously
approved do not produce uniform and satisfactory products, or if the
product from any other source proves unacceptable at any time, the
Contractor shall furnish acceptable material from other sources at his own
expense.
6.2.1 Stones
Stones shall be of the type specified. It shall be hard, sound, free from
cracks, decay and weathering and shall be freshly quarried from an
approved quarry. Stone with round surface shall not be used. The stones,
when immersed in water for 24 hours, shall not absorb water by more than

5 per cent of their dry weight when tested in accordance with IS: I 124.The
length of stones shall not exceed 3 times its height nor shall they be less
than twice its height plus one joint. No stone shall be less in width than the
height and width on the base shall not be greater than three-fourth of the
thickness of the wall nor less than 150 mm.
6.2.2 Cement
Cement to be used in the works shall be any of the following types with the
prior approval of the Engineer:
a) Ordinary Portland cement, 33 Grade, conforming to IS: 269.
b) Rapid Hardening Portland cement, conforming to IS: 8041.
c) Ordinary Portland cement, 43 Grade, conforming to IS: 8112.
d) Ordinary Portland cement, 53 Grade, conforming to IS: 12269.
e) Sulphate Resistant Portland cement, conforming to IS: 12330.
Cement conforming to IS: 269 shall be used only after ensuring that the
minimum required design strength can be achieved without exceeding the
maximum permissible cement content of 540 kg/cu. m. of concrete.
Cement conforming to IS: 8112 and IS: 12269 may be used provided the
minimum cement content mentioned elsewhere from durability
considerations is not reduced. From strength considerations, these cements
shall be used with a certain caution as high early strengths of cement in the
I to 28-day range can be achieved by finer grinding and higher constituent
ratio of C3S/C2S. where C3S is Tn calcium Silicate andC2S is Di calcium
Silicate. In such cements, the further growth of strength beyond say 4weeks
may be much lower than that traditionally expected. Therefore, further

strength tests shall be carried out for 56 and 90 days to fine tune the mix
design from strength considerations. Cement conforming to IS: 12330 shall
be used when sodium sulphate and magnesium sulphate are present in
large enough concentration to be aggressive to concrete. The recommended
threshold values as per IS: 456 are sulphate concentration in excess of 0.2
percent in soil sub-strata or 300ppm (0.03 percent) in ground water. Tests to
confirm actual values of sulphate concentration are essential when the
structure is located near the sea coast. chemical factories and agricultural
land using chemical fertilizers and sites where there are effluent discharges
or where soluble sulphate bearing ground water level is high. Cement
conforming to IS: 12330 shall be carefully selected from strength

considerations to ensure that the minimum required design strength can be
achieved without exceeding the maximum permissible cement content of
540 kg/cu.m. of concrete .Cement conforming to IS: 8041 shall be used only
for precast concrete products after specific approval of the Engineer.
Total chloride content in cement shall in no case exceed 0.05 per cent by
mass of cement.
6.2.3 Coarse aggregates
For plain and reinforced cement concrete (PCC and RCC) or pre stressed
concrete(PSC) works, coarse aggregate shall consist of clean, hard, strong,
dense, non-porous and durable pieces of crushed stone, crushed gravel,
natural gravel or a suitable combination thereof or other approved nert
material. They shall not consist pieces of disintegrated stones, soft, flaky,
elongated particles, salt, alkali, vegetable matter or other deleterious
materials in such quantities as to reduce the strength and durability of the
concrete, or to attack the steel reinforcement. Coarse aggregate having
positive alkali-silica reaction shall not be used. All coarse aggregates shall
conform to IS: 383 and tests for conformity shall be carried out as per IS:

2386, Parts Ito Viii. The contractor shall submit for the approval of the
Engineer, the entire information indicated in Appendix A of IS: 383.
Maximum nominal size of coarse aggregate for various structural
components in PCC, RCC or PSC.The maximum value for flakiness index for
coarse aggregate shall not exceed 35 per cent. The coarse aggregate shall
satisfy the following requirements of grading:
6.2.4 Sand/fine aggregates
For masonry work, sand shall conform to the requirements of IS: 2116. For
plain and reinforced cement concrete (PCC and RCC) or pre stressed
concrete (PSC) works, fine aggregate shall consist of clean, hard, strong and
durable pieces of crushed stone, crushed gravel, or a suitable combination
of natural sand, crushed stone or gravel. They shall not contain dust,
lumps, soft or flaky, Materials, mica or other deleterious materials in such
quantities as to reduce the strength and durability of the concrete, or to
attack the embedded steel. Motorized sand washing machines should be
used to remove impurities from sand. Fine aggregate having positive alkali-
silica reaction shall not be used. All fine aggregates shall conform to IS: 383
and tests for conformity shall be carried out as per IS :( Parts I to VIII). The
Contractor shall submit to the Engineer the entire information indicated in
Appendix A of IS: 383. The fineness modulus of fine aggregate shall neither

be less then 2.0 nor greater than 3.5.SandJfine aggregate for structural
concrete shall conform to the following grading requirements:
6.25 Steel
The use of cast steel shall be limited to bearings and other similar parts.
Steel for castings shall conform to Grade 280-520N of IS: 1030. In case
where subsequent welding is unavoidable in the relevant cast steel
components, the letter N at the end of the grade designation of the steel
casting shall be replaced by letter W. 0.3 percent to 0.5 per cent copper may
be added to increase the corrosion resistance properties.

7. EMBANKMENT TOP LAYER:-

7.1 General
These Specifications shall apply to the construction of embankments
including sub-grades, earthen shoulders and miscellaneous backfills with
approved material obtained from roadway and drain excavation, borrow pits
or other sources. All embankments, sub-grades, earthen shoulders and
miscellaneous backfills shall be constructed in accordance with the
requirements of these Specifications and in conformity with the lines, and
cross-sections shown on the drawings or as directed by the Engineer.
7.2 Materials and General Requirements
7.2.1 Physical requirements
The material used in embankments, sub-grades, earthen shoulders and
miscellaneous backfills shall be soil, morum, gravel, a mixture of these or
any other material approved by the Engineer. Such materials shall be free of
logs, stumps, roots, rubbish or any other ingredient likely to deteriorate or
affect the stability of the embankment/sub-grade.

The following types of material shall be considered unsuitable for
embankment:
(a) Materials from swamps, marshes and bogs;

(b) Peat, log, stump and perishable material; any soil that classifies as OL,
OI, OH or Pt in accordance with IS: 1498;

(c) Materials susceptible to spontaneous combustion;
(d) Materials in frozen conditions
(e) Clay having liquid limit exceeding 70 and plasticity index exceeding 45;
and
(f) Material with salts resulting in leaching in the embankment.
Expansive clay exhibiting marked swell and shrinkage properties (free
swelling index exceeding 50 percent when tested as per IS:2720-Part 40)
shall not be used as a fill material. Where expansively clay with acceptable
free swelling index value is used as a fill material, sub-grade and top 500
mm portion of the embankment just below sub-grade shall be non-
expansive in nature. Any fill material with a soluble sulphate content
exceeding 1.9 grams of sulphate (expressed as SO3) per liter when tested in
accordance with BS: 1377, but using a 2:1 water-soil ratio shall not be
deposited within 500 mm or other distance described in Earthwork, Erosion
Control and Drainage the Contract, of concrete, cement bound materials or
other cementations material forming part of the Permanent works.
Materials with a total sulphate content (expressed as SO3) exceeding 0.5 per
cent by mass, when tested in accordance with BS: 1377 shall not be
deposited within 500 mm, or other distances described in the Contract, of
metallic items forming part of the Permanent Works.
The size of the coarse material in the mixture of earth shall ordinarily not
exceed 75 mm when being placed in the embankment and 50 mm when
placed in the sub-grade. However, the Engineer may at his discretion permit
the use of material coarser than this also if he is satisfied that the same will

not present any difficulty as regards the placement of fill material and its
compaction to the requirements of these Specifications.
The maximum particle size shall not be more than two-thirds of the
compacted layer thickness. Ordinarily, only the materials satisfying the
density requirements given in Table shall be employed for the construction of
the embankment and the sub-grade.
Notes :( 1) this is not applicable for lightweight fill material e.g. cinder, fly
ash etc.
(2) The Engineer may relax these requirements at his discretion taken into
account the available of materials for construction and other relevant
factors.
(3) The material to be used in sub-grade should also satisfy design CBR at
the dry unit weigh applicable as per Table10.
7.2.2 Borrow materials
Where the materials are to be obtained from designed borrow areas, the
location, size and shape of these areas shall be as indicated by the Engineer

and the same shall not be opened without his written permission. Where
specific borrow areas are not designed by the Employer/the Engineer,
arrangement for locating the source of supply of material for embankment
and sub-grade as well as compliance to environmental requirements in
respect of excavation and borrow areas as stipulated, from time to time by
the Ministry of Environment and Forests, Government of India and local
bodies, as applicable, shall be sole responsibility of the Contractor.
Borrow pits along the road shall be discouraged. If permitted by the
Engineer, these shall not be dug continuously. Ridges of not less than 8 m
width should be left at not exceeding 300 m. Small drains shall be cut
through the ridges to facilitate drainage. The depth of the pits shall be so
regulated that their bottom does not cut an imaginary line having a slope of
1 vertical to 4 horizontal projected from the edge of the final section of the
bank, the maximum depth in any case being limited to 1.5 m. Also, no pit
shall be dug within the offset width from the toe of the embankment
required as per the consideration of stability with a minimum width of 10 m.
Haulage of material to embankments or other areas of fill shall proceed only
when sufficient spreading and compaction plant is operating at the place of
deposition.
No excavated acceptable material other than surplus to requirements of the
Contract shall be removed from the site Contractor be permitted to remove
acceptable material from the site to suit his operational procedure, then he
shall make good any consequent deficit of material arising there from. Where
the excavation reveals a combination of acceptable and unacceptable
material, the Contractor shall, unless otherwise agreed by the Engineer,
carry out the excavation in such a manner that the acceptable materials are
excavated separately for use in the permanent works without contamination

by the unacceptable materials. The acceptable materials shall be stockpiled
separately.
The Contractor shall ensure that he does not adversely affect the stability of
excavation or fills by the respective samples from each of the identified
borrow areas and have these tested at the size laboratory following a testing
programme approved by the Engineer. It shall be ensured that the sub-grade
material when compacted to the density requirements as in Table10 shall
yield the design CBR value of the sub-grade.
The Contractor shall at least 7 working days before commencement of
compaction submit the following to the engineer for approval:
i) The values of maximum dry density and optimum content obtained
in accordance with Is 2720 (Part 7) or (Part 8) as the case may be,
appropriate for each of the fill material he intends to use.

ii) A graph of density plotted against moisture content from which
each of the values in (i) above of maximum dry density and
optimum moisture content were determined.

iii) The dry density-moisture content-CBR relationships for light,
intermediate and heavy capacitive efforts (light corresponding to IS:
2720 (Part 7), heavy corresponding to IS: 2720 (Part 8) and
intermediate in-between the two) for each of the fill materials he
intends to use in the sub-grade.
Once the above information has been approved by the Engineer, it
shall from the basis for compaction.
7.3 Construction Operations
7.3.1 Setting out
The limits of embankment/sub-grade shall be marked by fixing better
pegs on both sides at regular intervals as guides before commencing the
earthwork. The embankment/sub-grade shall be built sufficiently wider
than the design dimension so that surplus material may be trimmed,
ensuring that the remaining material is to the desired density and in
position specified and conforms to the specified side slopes.
7.3.2 Dewatering
If the foundation of the embankment is in an area with stagnant water, and
in the opinion of the Engineer it is feasible to remove it, the same shall be
removed by bailing out or pumping, as directed by the Engineer and the area

of the embankment foundation shall be kept dry. Care shall be taken to
discharge the drained water so as not to cause damage to the works, crops
or any other property. Due to any negligence on the part of the Contractor,
if any such damage is caused, it shall be the sole responsibility of the
Contractor to repair/restore it to original condition or compensate the
damage at his own cost.
7.3.3 Stripping and string topsoil
In localities where most of he available embankment materials are not
conductive to plant growth, or when so directed by the Engineer, the topsoil
from all areas of cutting and from all areas to be covered by embankment
foundation shall be stripped the specified depths not exceeding 150 mm and
stored in stockpiles of heights not exceeding 2 m for covering embankment
slopes. Cut slopes and other disturbed areas where re-vegetation is desired.
Topsoil shall not be unnecessarily trafficked either before stripping or when
in a stockpile. Stockpiles shall not be unnecessarily trafficked either before
stripping or when in a stockpile. Stockpiles shall not be surcharged or
stripping or otherwise loaded and multiple handle shall be kept to a
minimum.
7.3.4 Compacting ground supporting embankment/sub-grade
Where necessary, the original ground shall be levelled to facilitate placement
of first layer of embankment, scarified, mixed with water and then
compacted by rolling so as to achieve minimum dry density as given in
Table. In case where the difference between the sub-grade level (top of the
sub-grade on which pavement rests) and ground level is less than 0.5 m and
the sub-grade level, watered and compacted in layers in accordance to not
less than 97 per cent of dry density as given in Table. Where so directed by
the Engineer, any unsuitable material occurring in the embankment

foundation shall be removed and replaced by approved material laid in layers
to the required degree of compaction. Embankment or sub-grade work shall
not proceed until the foundations for embankment/sub-grade have been
inspected by the Engineer for satisfactory condition and approved.
Any foundation treatment specified for embankments especially high
embankments, resting on suspect foundation as revealed by borehole logs
shall be carried out in a manner and to the depth as desired by the
engineer.
7.3.5 Spreading material in layers and bringing to appropriate
moisture content
The embankment and sub-grade material shall be spread in layers of
uniform thickness not exceeding 200 mm compacted thickness over the
entire width of embankment by mechanical means, finished by a motor
grader and compacted .The motor grader blade shall have hydraulic control
suitable for initial adjustment and maintain the same so as to achieve the
specific slope and grade. Successive layers shall not be placed until the
Table layer under construction has been thoroughly compacted to the
specified requirements as in and got approved by the Engineer. Each
compacted layer shall be finished parallel to the final cross-section of the
embankment.
Moisture content of the material shall be checked at the site of placement
prior to commencement of compaction; if found to be out of agreed limits,
the same shall be made good. Where water is required to be added in such
constructions, water shall be sprinkled from a water tanker fitted with
sprinkler capable of applying water uniformly with a controllable rate of flow
variable widths of surface but without any flooding. The water shall be

added uniformly and thoroughly mixed in soil by blading, discing or
harrowing until uniform moisture content is obtained throughout the depth
of the layer.
If the material delivered to the roadbed is too wet, it shall be dried, by
aeration and exposure to his sun, till the moisture content is acceptable for
compaction. Should circumstances arise, where owing to wet weather, the
moisture content cannot be reduced to the required amount by the above
procedure, compaction work shall be suspended. Moisture content of each
layer of soil shall be checked in accordance with IS: 2720 (Part 2), and
unless otherwise mentioned, shall he so adjusted, making due allowance for
evaporation losses, that at the time of compaction it is in the range of I per

cent above to 2 per cent below the optimum moisture content determined in
accordance with IS: 2720 (Para 7) or IS: 2720 (Para 8) as the case may be.
Expansive clays shall, however, be compacted at moisture content
corresponding to the specified dry density, but on the wet side of the
optimum moisture content obtained from the laboratory compaction curve.
After adding the required amount of water, the soil shall be processed by
means of graders, harrows. Rotary mixers or as otherwise approved by the
Engineer until the layer is uniformly wet.
Clods or hard lumps of earth shall be broken to have a maximum size of 75
mm when being placed in the embankment and a maximum size of 50 mm
when being placed in the sub-grade.
Embankment and other areas of fill shall, unless otherwise required in the
Contract or permitted by the Engineer, be constructed evenly over their full
width and their fullest possible extent and the Contractor shall control and
direct construction plant and other vehicular traffic uniformly over them.
Damage by construction plant and other vehicular traffic shall be made

good by the Contractor with material having the same characteristics and
strength as the material had before it was damaged.
Embankment and other areas of unsupported fills shall not be constructed
with steeper side slopes, or to greater widths than those shown in the
Contract, except to permit adequate compaction at the edges before
trimming back, 01. To obtain the final profile following any settlement of the
fill and the underlying material. Whenever fill is to be deposited against the
face of a natural slope, or sloping earthworks face including embankments,
cuttings, other fills and excavations steeper than 1 vertical on 4 horizontal,
such faces shall be benched immediately before placing the subsequent fill.
All permanent faces of side slopes of embankments and other as of fill

formed shall, subsequent to any trimming operations, be reworked and
sealed to the satisfaction of the Engineer and tracking a tracked vehicle,
considered suitable by the Engineer, the slope or any other method approved
by the Engineer.
7.3.6 Compaction
Only the compaction equipment approved by the Engineer shall be employed
to compact the different material types encountered during construction.
Smooth wheeled, vibratory, pneumatic tvred, sheep foot or pad foot rollers,
etc of suitable size and capacity as approved by the Engineer shall be used
for the different types and grades of materials required to be compacted
either individually or in suitable combinations. The compaction shall be
done with the help of vibratory roller of 80 to 100 KN Static weight with
plain or pad foot drum or heavy pneumatic tyred roller of adequate capacity
capable of achieving required compaction.
The Contractor shall demonstrate the efficacy of the equipment he intends
to use by carrying out compaction trials. The procedure to be adopted for
these site trials shall first be submitted to the Engineer for approval.

Earthmoving plant shall not be accepted as compaction equipment nor shall
the use of a lighter category of plant to provide any preliminary compaction
to assist the use of heavier plant he taken into account.
Each layer of the material shall be thoroughly compacted to the densities
specified in Table Subsequent layers shall be placed only after the finished
layer has been tested according to accepted by the Engineer. The Engineer
may permit measurement of field dry density by a nuclear moisture/density
gauge used in accordance with agreed procedure and the gauge is calibrated
to provide results identical to that obtained from tests in accordance with IS:
2720 (Part 28). A record of the same shall be maintained by the contractor.
When density measurements reveal any soft areas in the embankmen/lsub-
grade/earthen shoulders, further compaction shall be carried out as
directed by the Engineer. If inspite of that the specified compaction is not
achieved, the material& in the soft areas shall be removed and replaced by
approved material, compacted to the density requirements and satisfaction
of the Engineer.
7.3.7 Drainage
The surface of the embankment/sub-grade at all times during construction
shall be maintained at such a cross fall (not flatter than that required for
effective drainage of an earthen surface) as will shed water and prevent
ponding.
7.3.8 Repairing of damages caused by rain/spillage of water
The soil in the affected portion shall be removed in such areas as directed by
thc Engineer before next layer is laid and refilled in layers and compacted
using appropriate mechanical means such as small vibratory roller, plate
compactor or power rammer to achieve the required density in accordance
with. If the cut is not sufficiently wide for use of required mechanical means

for compaction, the same shall he widened suitably to permit their use for
proper compaction.
Tests shall be carried out as directed by the Engineer to ascertain the
density requirements of the repaired area. The work of repairing the
damages including widening of the cut, if any, shall be carried out by the
Contractor at his own cost, including the arranging of
machinery/equipment for the purpose.
7.3.9 Finishing operations
Finishing operations shall include the work of shaping and dressing the
shoulders/verge/roadded and side slopes to conform to the alignment,

levels, cross-sections and dimensions shown on the drawings or as directed
by the Engineer subject to the surface tolerance described .Both the upper
and lower ends of the side slopes shall be rounded off to improve
appearance and to merge the embankment with the adjacent terrain. The
topsoil, removed and conserved earlier shall be spread over the fill slopes as
per directions of the Engineer to facilitate the growth of vegetation. Slopes
shall be roughened and moistened slightly prior to the application of the
topsoil in order to provide satisfactory bond. The depth of the topsoil in shall
be sufficient to sustain plant growth, the usual thickness being from 75 mm
to 150 mm. Where directed, the slopes shall be surfed with sods in
accordance. If seeding and mulching of slopes is prescribed, this shall be
done to the requirement.
When earthwork operations have been substantially completed, the road
area shall be cleared of all debris, and ugly scars in the construction area
responsible for objectionable appearance eliminated.
7.4 Construction of Embankment and Sub-grade tinder
special Conditions

7.4.1 Earthwork for widening existing road embankment
When an existing embankment and/or sub-grade is to be widened and its
slopes are steeper than I vertical on 4 horizontal, continuous horizontal
benches.
Each at least 300 mm wide, shall be cut into the old slope for ensuring
adequate bond with the fresh embankment/sub-grade material to be added.
The material obtained from cutting of benches could be utilized in the
widening of the embankment/sub-grade. However, when the existing slope
against which the fresh material is to be placed is flatter than I vertical on 4
horizontal, the slope surface may only be ploughed or scarified instead of

resorting to benching. Where the width of the widened portions is
insufficient to permit the use of conventional rollers, compaction shall be
carried out with the help of small vibratory rollers/plate compactors/power
rammers or any other appropriate equipment approved by the Engineer. End
dumping of material from trucks for widening operations shall be avoided
except in difficult circumstances when the extra width is too narrow to
permit the movement of any other types of hauling equipment.
7.4.2 Earthwork for embankment and sub-grade to be placed
against sloping ground
Where an embankment/sub-grade is to be placed against sloping ground,
the latter shall be appropriately benched or ploughed/scarified before
placing the embankment/sub-grade material. Extra earthwork involved in
benching or due to ploughing/scarifying etc. shall he considered incidental
to the work. For wet conditions, benches with slightly inward fall and subsoil
at the lowest point shall be provided as per the drawings. Before the fill is
placed against sloping ground.

Where the Contract requires construction of transverse subsurface drain at
the cut-fill interface, work on the same shall be carried out in proper
sequence with the embankment and sub-grade work as approved by the
Engineer.
7.4.3 Earthwork over existing road surface
Where the embankment is to be placed over an existing road surface, the
work shall be carried out as indicated below
(i) If the existing road surface is of granular or bituminous type and lies
within I m of the new
Sub-grade level, the same shall be scarified to a depth of 50 mm or more if
specified, so as to provide ample bond between the old and new material
ensuring that at least 500 portions below the top of new sub-grade level is
compacted to the desired density.
(ii) If the existing road surface is of cement concrete type and lies within 1 m
of the new sub- grade level the same shall be removed completely.
(iii) If the level difference between the existing road surface and the new
formation level is more than I m, the existing surface shall be permitted to
stay in place without any modification.
7.4.4 Embankment and sub-grade around structures
To avoid interference with the construction of abutments, wing walls or
return walls of culvert/bridge structures, the Contractor shall, at points to
be determined to such structures, until such time as the construction of the
latter is sufficiently advanced to permit the completion of approaches
without the risk of damage to the structure.

Unless directed otherwise, the filling around culverts, bridges and other
structures up to a distance of twice the height of the road from the back of
the abutment shall be carried out independent of the work on the main
embankment. The fill material shall not be placed against any abutment or
wing wall, unless permission has been given by the Engineer but in any case
not until the concrete or masonry has been in position for 14 days.
The embankment and sub-grade shall be brought up simultaneously in
equal layers on each side of the structure to avoid displacement and unequal
pressure. The sequence of work in this regard shall be got approved from the
Engineer.
The material used for backfill shall not be an organic soil or highly plastic
clay having plasticity index and liquid limit more than 20 and 40
respectively when tested according to IS: 2720 (Part 5).
Filing behind abutments and wing walls for all structures shall conform to
the general guidelines given in Appendix 6 of IRC :78 (Standard
Specifications and Code of Practice for Road Bridges-Section VII) in respect
of the type of material, the extent of backfill, its laying and compaction etc.
The fill material shall be deposited in horizontal layers in loose thickness
and compacted thoroughly to the requirements of Table at compaction
required for embankment and sub-grade. Where the provision of any filter
medium is specified behind the abutment, the same shall be laid in layers
simultaneously with the laying requirements for filter medium spelt out in
(B) unless otherwise specified in the Contract.
Where it may be impracticable to use conventional rollers, the compaction
shall be carried out by appropriate mechanical means such as small
vibratory roller, plate compactor or power rammer. Care shall be taken to see
that the compaction equipment does not hit or come too close to any

structural member so as to cause any damage to them or excessive pressure
against the structure.
7.4.5 Construction of embankment over ground incapable of
supporting construction equipment
Where embankment is to he constructed across ground which will not
support the weight of repealed heavy loads of construction equipment, the
first layer of the fill may be constructed b placing successive loads of
material in a uniformly distributed layer of a minimum thickness required to
support the construction equipment as permitted by the Engineer.
The Contractor, if so desired by him, may also use suitable geo-synthetic
material to increase the bearing capacity of the foundation. This exception to
normal procedure will not be permitted where, in the opinion of the
Engineer, the embankments could be constructed in the approved manner
over such ground by the use of lighter or modified equipment after proper
ditching and drainage have been provided where this exception is permitted,
the selection of the material and the construction procedure to obtain an
acceptable layer shall be the responsibility of the Contractor.
The cost of providing suitable traffic conditions for construction equipment
over any area of the Contract will be the responsibility of the Contractor and
no extra payment will he made to him.
7.4.6 Embankment construction under water
Where filling or back fulling is to be placed under water, only acceptable
granular material or rock shall be used unless otherwise approved by the
Engineer. Acceptable granular material shall consist of graded, hard durable
particles with maximum particle size not exceeding 75 mm. The material
should be non-plastic having uniformity co-efficient of not less than 10. The

material placed in open water shall be deposited by end tipping without
compaction.
7.4.7 Earthwork for high embankment
In the case of high embankments, the Contractor shall normally use the
material from the specified borrow area. In case he desires to use different
material for his own convenience, he shall have to carry out necessary soil
investigations and redesign the high embankment at his own cost. The
Contractor shall then furnish the soil test data and design of high
embankment for approval of the Engineer, who reserves the right to accept
or reject it. If necessary, stage construction of fills and any controlled rates
of filling shall be carried out in accordance with the Contract including
installation of instruments and its monitoring.
Where required, the Contractor shall surcharge embankments or other areas
of fill with approved material for the periods specified in the Contract. If
settlement of surcharged fill results in any surcharging material, which is
unacceptable for use in the fill being surcharged, lying below formation level,
the Contractor shall remove the unacceptable material and dispose it as
PCI. Direction of the Engineer. He shall then bring the resultant level upon
formation level; the Contractor shall remove the unacceptable material and
dispose it as per direction of the Engineer. He shall then bring the resultant
level up to formation level with acceptable material.
7.5 Settlement period
Where settlement period is specified in the Contract, the embankment shall
remain in place for the required settlement period before excavating for
abutment, wing wall, retaining wall, footings, etc., or driving foundation
piles. The duration of the required settlement period at each location shall
be as provided for in the Contract or as directed by the Engineer.

7.6 Plying of Traffic
Construction and other vehicular traffic shall not use the prepared surface
of the embankment and/or sub-grade without the prior permission of the
Engineer. Any damage arising out of such use shall, however, be made good
by the Contractor at his own expense as directed by the Engineer.
Test for embankment
Free swelling index.
Free swelling index:
Apparatus:
425 Micron IS Sieve-01 no, & l00ml capacity graduated cylinder-02 nos,
kerosene, water, glass, beakers.
Procedure:
1. Take two nos of 10 grams oven dried sample passing through 425 micron
IS Sieve.
2. Take two nos of 100ml capacity graduated cylinder, one filled with
kerosene and another filled with water up to the mark.
3. Each soil specimen shall he poured in each of the two glass graduated
cylinders of 100ml capacity.
4. After removal of entrapped air, the soil in both the cylinder shall be
allowed to settle for 24 hours.
5. Free swell index=VdVk* 100

Vd=Volume of soil specimen from the graduated cylinder filled with water.
Vk= Volume of soil specimen from the graduated cylinder filled with
kerosene.

8. SUB-GRADE:-
8.1 SCOPE
This work shall consists of laying and compacting an improved sub-grade
/lower sub-base of soil treated with lime on prepared sub-grade in
accordance with the requirements of these specifications and in conformity
with the lines, grades and cross sections shown on the drawings are as
directed by the Engineer. Lime treatment is generally effective for soils,
which contain a relatively high percentage of clay and silty clay.
8.2 Materials:
Except when otherwise specified, the sol used for stabilization shall be the
local clayey soil having a plasticity index greater than 8.
8.2.2 Lime:
Lime for lime-soil stabilization work shall be commercial dry lime slaked at
or pre-slaked lime delivered to the site in suitable packing. Unless otherwise
permitted by Engineer, the lime shall have purity of not less than 70% by
weight of Quicklime (CaO) when tested in accordance with IS: 1514. Lime

shall be properly stored to avoid prolonged exposure to the atmosphere and
consequent carbonation, which would reduce its binding properties.
8.2.3 Quantity of lime in stabilized mix
Quality of lime to be added as percentage by weight of the soil shall be as
specified in the Contract. The quality of lime of different calcium oxide
content, which shall be suitably adjusted to the approval of the engineer so
that equivalent calcium oxide is incorporated in the work. The mix design
shall be done to arrive at the appropriate quantity of lime to be added,
having due regard to the purity of the engineer so that equivalent calcium
oxide is incorporated in the work .The mix design shall be done to arrive3e
at the appropriate quality of lime to be added, having due regard to the
purity of lime, the type of soil, the moisture-density relationship, and the
design CBR/UCS value shall be at least 1.5 times the minimum field value
of CBR/UCS stipulated in the contract.
8.2.4 Water
The water to be used for lime stabilization shall be clean and free from
injurious substances. Potable water shall be preferred.
8.3.1 Weather limitations
Lime-soil stabilization shall not be done when the air temperature in the
shade is less than 10 C.
8.3.2 Degree of pulverization

For lime stabilization, the soil before addition of stabilizer shall be pulverized
using agricultural Implements like dis harrows and ratovators to the extent
that it passes the requirements set out in Table.
8.3.3 Equipment for Construction
Stabilized soil sub-bases shall be constructed by mix-in-place method of
construction or as otherwise approved by the Engineer. Manual mixing shall
be permitted only where the width of lying is not adequate for mechanical
operations, as in small-sized jobs.
The equipment used mix-in-place construction shall be rotavator or similar
approved equipment capable of pulverizing and mixing the soil with additive
and water to specified degree to the full thickness of the layer being
processed, and of achieving the desired degree of mixing and uniformity of
the stabilized material. If so desired by the Engineer, trail runs with the
equipment shall be carried out to establish its suitability for work. The
thickness of any layer to be stabilized shall be not less than 100 mm when
compacted. The maximum thickness shall be 200 mm, provided the plant
used is accepted by the Engineer.
8.3.4 Mix-in-place method of construction
Before deploying the equipment, the soil after it is made free of undesirable
vegetation or other deleterious matters shall be spread uniformly on the
prepared sub-grade in a quantity sufficient to achieve the desired compacted
thickness of the stabilized layer. Where single-pass equipment is to be

employed, the soil shall be lightly rolled at the discretion of the Engineer.
The Equipment used shall either be of single-pass or multiple pass type. The
mixers shall be equipped with an appropriate device for controlling the
depth of processing and the mixing blades shall be maintained or reset
periodically so that the correct depth of mixing is obtained at all times. With
Single-pass equipment the forward speed of the machine shall be so selected
in relation to the speed that the required degree of mixing, pulverization and
depth of processing is obtained. In multiple-pass processing, the prepared
sub-grade shall be pulverized to the required depth with successive passes
of the equipment and the moisture content adjusted to be within prescribe
Limits mentioned hereinafter. The blending or stabilizing material shall then
be spread -uniformly and mixing continued with successive passes until the
required depth and uniformity of pressing have been obtained. The mixing
equipment shall be so set that it cuts slightly into the edge of the adjoining
lane processed previously so as to ensure that all the material forming a
layer has been properly processed for the full width.
8.3.5 Construction with manual means
Where manual mixing is permitted, the soil from borrow areas shall first be
freed of all vegetation and other deleterious matter and placed on the
prepared sub-grade. The soil shall then be pulverized by means of crow-
bars, pick axes or other means approved by the Engineer. Water n requisite
quantities may be sprinkled on the soil for aiding pulverization. On the
pulverized soil, the blending materials(s) in requisite quantities shall be
spread uniformly and mixed thoroughly by working with spades or other
similar implements till the whole mass are uniform After adjusting the
moisture content to be within the limits mentioned later, the mixed material
shall be levelled up to the required thickness so that it is ready to be rolled.

8.3.6Addition of Lime
Lime may be mixed with the prepared material either in slurry form or dry
state at the option of e Contractor with the approval of the Engineer. Dry
lime shall be prevented from blowing by adding water to the lime or other
suitable means selected by the Contractor, with the approval of the
Engineer. The tops of windrowed material may be flattened or slightly
trenched to receive the lime. The distance to which lime may spread upon
the prepared material ahead of the mixing creation shall be determined by
the Engineer. No traffic other than the mixing equipment shall be allowed to
pass over the spread lime until after completion of mixing. Mixing or re-
mixing variations, regardless of equipment used, shall continue until the
material is free of any white breaks or pockets of lime and the mixture is
uniform.
Non uniformity of colour reaction, when the treated material is tested with
the standard phenolphthalein alcohol indicator, will be considered evidence
of inadequate mixing.
8.3.7 Moisture content for compaction
The moisture content at compaction checked vide IS: 2720 (Part 2) shall
neither be less than the optimum moisture content corresponding to IS:
2720 (Part 8) nor more than 2 per cent above it.
8.3.8 Rolling
Immediately after spreading, grading and leveling of the mixed material,
compaction shall be carried out with approved equipment preceded by a few
passes of lighter rollers if necessary. Rolling shall commence at edges and
progress towards centre, except at super elevated portions ire ii shall
commence at the inner edge and progress towards outer edge. During rolling

the re shall be frequently checked for grade and cross-fall (camber) and any
irregularities corrected by losing the material and removing/adding fresh
material. Compaction shall continue until the density achieved is at least 98
per cent of the maximum dry density for the material determined in
accordance with IS: 2720 (Part 8).
Sub-Bases, Bases (Non-Bituminous) and Shoulders Care shall be taken to
see that the compaction of lime stabilized material is completed within three
hours of its mixing or such shorter period as may be found necessary in dry
weather. During rolling it shall be ensured that roller does not bear directly
on hardened or partially hardened treated material previously laid other
than what may be necessary for achieving the specified compaction at the
joint. The final surface shall be well closed, free from movement under
compaction planes, ridges, cracks or loose material. All loose or segregated
or otherwise defective areas shall be made good to the full thickness of the
layer and re compacted.
8.3.9 Curing
The sub-base course shall be suitably cured for a minimum period of 7 days
after which subsequent pavement courses shall be laid to prevent the
surface from drying out and becoming friable. No traffic of any kind shall ply
over the completed sub-base unless permitted by the En2ineer.
8.3.10 Strength
When lime is used for improving the sub-grade, the soil-lime mix shall be
tested for its CBR value. When lime stabilized soil is used in a sub-base, it
shall be tested for unconfined compressive strength (UCS) at 7 days. In case

of variation from the design CBR!UCS, in situ value being lower, the
pavement design shall be reviewed based on the actual CBR/UCS value sJi1
be constructed by the Contractor at his own cost.
8.3.11 Measurements for Payment
Sabi1ized soil sub-base shall be measured as finished work in position in
cubic metres.
8.4 Sub-grade Characteristics and Strengths
97 test pits of size 1.Om x l.0m x 0.75m are dug by the side of existing
pavement edge. Pavement composition and their thicknesses are recorded

from each pit. Sub grade soil sample of approx. 5kgs collected from each test
pit for conducting following tests.
wet sieve analysis for soil classification
Moisture content of Sub grade soil
Atterberg limits to obtain plasticity index value
These results would be made use in applying corrections to BBD test values.
8.4.1 Sub grade CBR value
Maximum dry density (MDD) test is conducted at 20 test pits using sand
replacement method to work out the density of existing sub grade material.
Sub grade sample of approx. 60 kg is collected from each pit for conducting
following tests in the laboratory.

- Wet sieve analysis
- Atterberg limits
- Maximum dry density (MDD) and Optimum moisture content (OMC)
- 4- Days soaked CBR value at three energy levels.
The test results will be utilized in assessing the quality of existing sub grade
and to suggest whether sub-grade replacement is required or not. Also, the
CBR value is used in the preliminary design of flexible pavement. The design
thickness would be used in working out the approximate cost of pavement
per sqm and to arrive at the construction cost of tjme project road.
Tests for sub-grade
California bearing ratio (CBR).
Callifornia bearing ratio(CBR):-
Procedure:-

This ratio expressed in percentage of force per unit area required to
penetrate of soil mass with a circular plunger of 50mm dia @1.25mm/mm.
To that required for corresponding penetration in a standard material. The
ratio is usually determined for penetration of 2.5 and 5.0mm where the ratio
at 5.0mm is used.
Volume of soil specimen : 2250cc
Wt. of compaction rammer : 4.89kg.
No. of layer :5
No. of blows on each layer : 56 blows
Preparation of test specimen:- Take a soil sample pass a 19.0mm sieve
allowance for lesser material shall be replacing by 19.0 pass and 4.75mm
retained material &mix thoroughly with water and compacted in CBR mould
layer by layer after compaction this set up shall undisturbed for 96 hours in
water.
Penetration test:- The specimen allowed to drain downwards for 15mm. The
weights the perforated plate and the top filter paper shall be removed and
the mould shall be weighted.
The mould plwe on the testing machine surcharge wt. sufficient to
procedure shall be place on the specimen.
The plunger shall be seated under a load of four kg. So that full centect is
established between the surface of the specimen and plunger. The gauge
shall then be asset to zero.
Lord shall be applied to the plunger into the soil @ 1 .25mm/mm, Reading
Of the load shall be taken at penetration of 0.5, 1.0, 1.5, 2.0, 2.5, 4.0, 5.0,
7.5, 10.0 & 12.5 mm.

CBR Value = PT/PS*100
Penetration depth (mm) Unit Standard Load (Kg/sq.cm)
Total Standard Load (Kg)
2.5 70 1370
5.0 105 2055

9. GRANULAR SUB- BASE:-
9.1 Scope
This work shall consist of laying compacting well graded material on
prepared sub-grade in accordance with the requirements of these
specifications. The material shall be laid in one or more layers as sub-base
lower sub-base and upper sub base (termed as sub base sub base
hereinafter)as necessary according to lines, grades and cross sections shown
on the drawing or directed by the Engineer.
9.2 Materials
The material to be used for the work shall be natural sand, moorum, gravel,
crushed stone, or combination there of depending upon the grading
required. Materials like crushed slag crushed concrete, brick metal and
kankar may be allowed only with the specific approval of the Engineer.

The material shall be free from organic or other deleterious constituents and
conform to one of the three grading given in table below. While the grading
in below table are in respect of close-graded granular sub base materials,
one each for maximum particle size of 75 mm, 53 mm and 26.5 mm.
The corresponding for the coarse-graded materials for each of the three
maximum particle sizes is given at table. The grading to be adopted for a
project shall be as specified in the contract.
9.3 Physical requirements
The materials shall have a10 per cent fines value of 50 km or more (for
sample in soaked condition) when tested in compliance with bs: (812 part
111). The water absorption value of the coarse aggregate shall be determine
as per IS: 2386 (part 3) ; if this value is greater than 2 per cent, the
soundness test shall be carried out on the material delivered to site as per
IS:383. For Grading II and II materials, the CBR shall be determined at the
density and moisture content likely to be developed in equilibrium
conditions which shall be taken as being the density relating to a uniform
content of per cent.


Note: The Material passing 425 micron (0.425 mm) sieve for all the three
grading when tested according to IS: 2720
(Part 5) shall have liquid limit and plasticity index not more than 25 and 6
per cent respectively.
9.3.1 Strength of Sub-Base

It shall be ensured prior to actual execution that the material to be used in
the sub-base satisfies the requirements of CBR and other physical
requirements when compacted and finished. When directed by the Engineer,
this shall be verified by performing CBR tests in the laboratory as required
on specimens re molded at field dry density and moisture content and any
other tests for the quality of materials, as may be necessary.
9.4 Construction Operation
9.4.1 Preparation of Sub-grade
Immediately prior to the laying of sub base, the sub-grade already finished
to as applicable shall be prepared by removing all vegetation and other
extraneous matter, lightly sprinkled with water if necessary and rolled with
two passes of 80 100 KN smooth wheeled roller.
9.4.2 Spreading and Compacting
The sub-base material of grading specified in the Contract shall be spread
on the prepared sub- grade with the help of a motor grader of adequate
capacity, its blade having hydraulic controls suitable for initial adjustment
and for maintaining the required slope and grade during the operation or
other means as approved by the Engineer.
The Material to be used for the work shall be natural sand, morum, gravel,
crushed stone, or combination thereof depending upon the grading required.
Materials like crushed slag crushed concrete, brick metal and kankar may
be allowed only with the specific approval of the Engineer. The material shall
be free from organic or other deleterious constituents and conform to one of
the three grading given in Table for grading for close-graded granular sub-
base materials. While the grading in Table are in respect of close-graded

granular sub-base materials, one each for maximum particle size of 75 mm,
53 mm and 26.5 mm, the corresponding grading for the coarse-graded
materials for each of the three maximum particle sizes are given at Table for
grading for coarse-graded granular sub-base materials. The grading to be
adopted for a project shall be as specified in the Contract. Mixing shall be
done messianically by the mix-in-place method. Sub-Bases, Bases (Non-
Bituminous) and Shoulders Manual mixing shall be permitted only where
the width of lying is not adequate for mechanical operations, as in small-
sized jobs. The equipment used for mix-in-place construction shall be
rotavator or similar approved equipment capable of mixing the material to
the desired degree. If so desired by the Engineer, trial runs with the
equipment shall be carried out to establish its suitability for the work.
Moisture content of the loose material shall be checked in accordance with
IS: 2720 (Part 2) and suitably adjusted by sprinkling additional water from a
truck mounted or trailer mounted water tank and suitable for applying
water uniformly and at controlled quantities to variable widths of surface or
other me4ans approved by the Engineer so that, at the time of compaction,
it is from I per cent below the optimum moisture content corresponding to
IS: 2720 (Part 8). While adding water, due allowance shall be made for
evaporation losses. After water has been added, the material shall be
processed by mechanical or other approved means like disc harrows,
rotavators until the layer is uniformly wet. Immediately thereafter, rolling
shall start. If the thickness of the compacted layer does not exceed 100 mm,
a smooth wheeled roller of 80 to 100 KN weight may he used. For a
compacted single layer up to 225 mm the compaction shall be done with the
help of a vibratory roller of minimum 80 to 100 KN static weights with plain
drum or pad foot-drum or heavy pneumatic tyred roller of minimum 200 to
300 KN weight having a minimum lyre pressure of 0.7 MN/m2 or equivalent
capacity roller capable of achieving the required compaction. Rolling shall

commence at the lower edge and proceed towards the upper edge
longitudinally for portions having unidirectional cross fall and super-
elevation and shall commence at the edges and progress towards the centre
for portions having cross-fall on both sides.
Each pass of the roller shall uniformly overlap not less than one-third of the
track made in the proceeding pass. During rolling, the grade and cross-fall
shall be checked and any high spots or depressions, which become
apparent, corrected by removing or adding fresh material. The speed of the
roller shall not exceed 5 km per hour. Rolling shall be continued till the
density achieved is at least 98 per cent of the maximum dry density for the
material determined as per IS: 2720 (Part 8). The surface of any layer of
material on completion of compaction shall be well closed, free from
movement under compaction equipment and from compaction planes, ridges
cracks or loose material. All loose, segregated or otherwise defective areas
shall be made good to the full thickness of layer and re-compacted.
Granular sub-base shall be measured as finished work in position in cubic
meters. The protection of edges of granular sub-base extended over the full
formation as shown in the drawing shall be considered incidental to the
work of providing granular sub-base and as such no extra payment shall be
made for the same.
9.4.4 Rate
The Contract unit rate for granular sub-base shall be payment in full for
carrying out the required operation including full compensation for:
(i) Making arrangements for traffic to except for initial treatment to verges,
shoulders and construction of diversions;

(ii) Furnishing all materials to be incorporated in the work including all
royalties, fees, rents where necessary and all leads and lifts;
(iii) All labour, tools, equipment and incidentals to complete the work to the
Specifications; (iv) Carrying out the work in part widths of road where
directed; and
(v) Carrying out the required tests for quality control.
Tests for granular sub-base
Liquid limit and plastic limit.
Grain size analysis.
California bearing ratio (CBR)
Liquid limit and plastic limit:-

Apparatus: liquid limit device, plastic limit device, IS 4.75mm Sieve trays.
Procedure for plastic limit:-
The plastic limit is determined by rolling out a thread of the fine portion of a
soil on a flat, nonporous the procedure is defined in ASTM standard.
If is plastic, this thread will retain its shape down to a very narrow diameter.
The sample can than be remolded and the test repeated. As the moisture
content falls due to evaporation the thread will begin to break apart at larger
diameter. The plastic limit is defined as the moisture content where the
thread breaks apart at a diameter of 3mm (about 1/8).
A Soil is considered non-plastic if a thread cannot be rolled out down to
3mm at any moisture.
Procedure for liquid limit:-
The liquid limit (LL) is the water content at which a soil changes from plastic
to liquid behavior. The original liquid limit test of Atterbergs involved mixing
pat of clay in a round-bottomed porcelain bowl of 10-12cm diameter.
A groove was cut through the pat of clay with a spatula and bowl was then
struck many times against the palm of one hand.
Casagrande subsequently standardized the apparatus and the procedures to
make the measurement more repeatable. Soil is placed into the metal cup
portion of device and a groove is made down its center with a standardized
tool of 13.5mm (0.53 in) width. The cup is repeatedly dropped 10mm onto a

hard rubbed base at a rate of 120 blows per minute, during which the
groove closes up gradually as a result of the impact. The number of blows
for the groove to close is recorded. The moisture content at which it takes 25
drops of the cup to cause the groove to se over a distance of 13.5mm (0.53
in) is defined as the liquid limit. The test is normally run several moisture
contents, and the moisture content which requires 25 blows to close the
groove is interpolated from the test results. The liquid limit test is defined by
ASTM standard test method D 4318. The test method also allows running
the test at one moisture content where 2O and 30 blows are required to
close the groove; then a correction factor is applied to obtain the liquid limit
from the moisture content.
Sieve analysis:-

Apparatus:- IS Sieve 75mm, 53mm, 26.5mm, 9.5mm, 4.75mm, 2.36mm,

0.425mm, 0.075mm, Iron trays.
Procedure:-
A gradation test is performed on a sample of aggregate in a laboratory. A
typical sieve analysis involves a nested column of sieves with wire mesh
cloth (screen). See the separate mesh (scale) page for details of sieve sizing.
A representative weighed sample is poured into the top sieve which has the
largest screen openings. Each lower sieve in the column has smaller
openings than the one above. At the base is a round pan, called the receiver.
The column is typically placed in a mechanical shaker. The shaker shakes
the column, usually for some fixed amount of time. After the shaking is
complete the material on each sieve is weighed. The weight of the sample of
each sieve is then divided by the total weight to give a percentage retained
on each sieve. The size of the average particle on each sieve is then analysed
to get a cut-off point or specific size range, which is then captured on a

screen. The results of this test are used to describe the properties of the
aggregate and to see if it is appropriate for various civil engineering
purposes such as selecting the appropriate aggregate for concrete mixes and
asphalt mixes as well as sizing of water production well screens. The results
of this test are provided in graphical form to identify the type of gradation of
the aggregate. The complete procedure for this test is outlined in the
American Society for Testing and Materials (ASTM) C136 and the American
Association and State Highway and Transportation Officials (AASHTO) T27
A suitable sieve size for the aggregate should be selected and placed in order
of decreasing size, from top to bottom, in a mechanical sieve shaker. A pan
should be placed underneath the nest of Sieves to collect the aggregate that
passes through the smallest. The entire nest is then agitated, and the
material whose diameter is smaller than the mesh opening passes through
the sieves. After the aggregate reaches the pan, the amount of material
retained in each sieve is then weighed.



10. WET MIX MACADAM:-
10.1 Scope
This work shall consist of laying and compacting clean, crushed, graded
aggregate and granular material, premixed with water, to a dense mass on a
prepared sub-grade/sub-base/base or existing pavement as the case may be
in accordance with the requirements in these Specifications. The Material
shall be laid in one or more layers as necessary to lines, grades and cross-
sections shown on the approved drawings or as directed by the Engineer.
The thickness of a single compacted Wet Mix Macadam layer shall not be
less than 75 mm. When vibrating or other approved types of compacting
equipment are used, the compacted depth of a single layer of the sub-base
course may be increased to200 mm upon approval of the Engineer.
10.2 Materials & Aggregates
10.2.1 Physical requirements
Coarse aggregates shall be crushed stone. If crushed gravel/shingle is used,
not less than 90 per cent by weight of the gravel/shingle pieces retained on

4.7mm sieve shall have at least two fractured faces. The aggregates shall
conform to the physical requirements set forth in table 14.
TabIel4. Physical requirements of aggregates for wet mix macadam for sub
base/base courses
* Aggregate may satisfy requirements of either of the two tests.
** To determine this combined proportion, the flaky stone from a
representative sample should first be separated out. Flakiness index is
weight of flaky stone metal divided by weight of stone sample. Only the
elongated particles are separated out from the remaining (non-flaky) stone
metal. Elongation index is weight of elongated particles divided by total non-
flaky particles. The value of flakiness index and elongation index so found
are added up. If the water absorption value of the coarse aggregate is greater
than 2 per cent, the soundness test shall be carried out on the material
delivered to site as per IS: 2386(part-5)
10.3 Grading requirements

The aggregates shall conform to the grading given in Table 15.
Materials finer than 425 micron shall have Plasticity Index (PT) not
exceeding 6.
The final gradation approved within these limits shall be well graded from
coarse to fine and shall not vary from the low limit on one sieve to the high
limit on the adjacent or vice versa.
10.4.1 Provision of lateral confinement of aggregates
While constructing wet mix macadam, arrangement shall be made for the
lateral confinement of wet mix.
This shall be done by laying materials in adjoining shoulders along with that
of wet mix madam layer and following the sequence of operations.
10.4.2 Preparation of Mix

Vet Mix Macadam shall be prepared in an approved mixing plant of suitable
capacity having provision for controlled addition of water and forced/positive
mixing arrangement like pug mill or pan type mixer of concrete batching
plant.
For small quantity of wet mix work, the Engineer may permit the mixing to
be done in concrete mixers. Optimum moisture for mixing shall he
determined in accordance with IS: 2720(Part-8) after replacing the aggregate
fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm
size. While adding water, due allowance should be made for evaporation
losses. However, at the time of compaction, water in the wet mix should not
vary from the optimum value by more than agreed limits. The mixed
material should be uniformly wet and no segregation should be permitted.
10.4.3 Spreading of mix
Immediately after mixing, the aggregates shall be spread uniformly and
evenly upon the prepared sub grade-sub-base/base in required quantities.
In no case should these be dumped in heaps directly on the area where
these are to be laid nor shall their hauling over a partly completed stretch be
permitted. The mix may be spread either by a paver finisher or motor grader.
For portions where mechanical means cannot be used, manual means as
approved by the Engineer shall be used. The motor grader shall be capable
of spreading the material uniformly all over the surface. Its blade shall have
hydraulic control suitable for initial adjustments and maintaining the same
so as to achieve the specified slope and grade.
The paver finisher shall be self-propelled, having the following features:
(i) Loading hopper and suitable distribution mechanism.

(ii) The screed shall have tamping and vibrating arrangement for initial
compaction to the layer as it is spread without rutting or otherwise marring
the surface profile.
(iii) The paver shall be equipped with necessary control mechanism so as to
ensure that the finished surface is free from surface blemishes.
Sub-Bases, Bases (Non-Bituminous) and Shoulders
The surface of the aggregate shall be carefully checked with templates and
all high or low spots remedied by removing or adding aggregate as may be
required. The layer may be tested by depth blocks during construction.
No segregation of large and fine particles should be allowed. The aggregates
as spread should be of uniform gradation with no pockets of line materials.
10.4.4 Compaction
After the mix has been laid to the required thickness, grade and cross
fall/camber the same shall be uniformly compacted, to the full depth with
suitable roller. If the thickness of single compacted layer does not exceed
100 mm, a smooth wheel roller of 80 to 100 KN weight may be used. For a
compacted single layer up to 200 mm, the compaction shall be done with
the help of vibratory roller of minimum static weight of 80 to 100 KN or
equivalent capacity roller. The speed of the roller shall not exceed 5 km/h. In
portions having unidirectional cross fall/super-elevation. Rolling shall
commence from the lower edge and progress gradually towards the upper
edge. Thereafter, roller should progress parallel to the centre line of the road,
uniformly overlapping each preceding track by at least one third width until
the entire surface has been rolled.
Alternate trips of the roller shall be terminated in stops at least 1 m away
from any preceding sop. In portions in camber, rolling should begin at the

edge with the roller running forward and ward until the edges have been
firmly compacted. The roller shall then progress gradually towards the
centre parallel to the centre line of the road uniformly overlapping each of
the reeding tracks by at least one-third width until the entire surface has
been rolled. Any &!cement occurring as a result of reversing of the direction
of a roller or from any other cause all be corrected at once as specified
and/or removed and made good. Along forms, kerbs. Wal1s or other places
not accessible to the roller, the mixture shall be thoroughly compacted with
mechanical tampers or a plate compactor. Skin patching of an area without
scarifying the surface to permit proper bonding of the added material shall
not be permitted. Rolling should not be done when the sub-grade is soft or
yielding or when ii causes a wave-like motion in the sub-base base course
or sub-grade.
If irregularities develop during rolling which exceed 12 mm when tested with
a 3 metre straight edge, the surface should be loosened and premixed
material added - removed as required before rolling again so as to achieve a
uniform surface conforming to the red grade and cross fall. In no case
should the use of unmixed material be permitted to make the depressions.
Rolling shall he continued till the density achieved is at least 98 per cent of e
maximum dry density for the material as determined by the method
outlined in IS: 2720(Part-8).After completion, the surface of any finished
layer shall he well-closed, free from movement under compaction
equipment or any compaction planes, ridges, cracks and loose material. All
Loss, segregated or otherwise defective areas shall be made good to the full
thickness of the re-compacted.
10.4.5 Setting and drying
After final compaction of wet mix macadam course, the road shall be allowed
to dry for 24 hours.

10.4.6 Opening to Traffic
Preferably no vehicular traffic of any kind should be allowed on the finished
wet mix macadam surface till it has dried and the wearing course laid.
10.5 Surface Finish and Quality Control of Work
10.5.1 Rectification of Surface Irregularity
Where the surface irregularity of the wet mix macadam course exceeds the
permissible tolerance or where the course is otherwise defective due to sub-
grade soil getting mixed with the aggregates, the full thickness of the layer
shall be scarified over the affected area, reshaped with added premixed
material or removed and replaced with fresh premixed material as applicable
and recomputed. The area treated in the aforesaid manner shall not be less
than 5 m long and 2 m wide. In no case shall depressions be filled up with
unmixed and ungraded material or fines.
10.5.2 Rates
The Contract unit rate for wet mix macadam shall be payment in full for
carrying out the required operations including full compensation for all
components.
Tests for wet mix macadam
Liquid limit and plastic limit.
Grain size analysis.
Flakiness and elongation.
California bearing ratio (CBR).



Sieve analysis:-
Apparatus:-IS a sieve 75mm, 53mm, 26.5mm, 9.5mm, 4.75mm, 2.36mm,

0.425mm, .O75mm, Iron trays.
Procedure:-
A gradation test is performed on a sample of aggregate in a laboratory. A
typical sieve analysis involves a nested column of sieves with wire mesh
cloth (screen). See- the separate mesh (scale) page for details of sieve sizing.
A representative weighed sample is poured into the top sieve which has the
largest screen opening. Each lower sieve in the column has smaller openings
than the one above. At the base is a round pan, called the receiver.
The column is typically placed in a mechanical shaker. The shaker shakes
the column, usually for some fixed amount of time. After the shaking is
complete the material on each sieve is weighed. The weight of the sample of
each sieve is then divided by the total weight to give a percentage retained
on each sieve.
The size of the average particle on each sieve is then analysed to get a cut-off
point or specific size range, which is then captured on a screen.
The results of this test are used to describe the properties of the aggregate
and to see if it is appropriate for various civil engineering purposes such as
selecting the appropriate aggregate for concrete mixes and asphalt mixes as
well as sizing of water production well screens. The results of this test are
provided in graphical form to identify the type of gradation of the aggregate.
The complete procedure for this test is outlined in the American Society for
Testing rd Materials (ASTM) C136 and the American Association and State
Highway and Transportation Officials (AASHTO) T27

A suitable sieve size for the aggregate should be selected and placed in order
of decreasing size, from top to bottom, in a mechanical sieve shaker. A pan
should be placed underneath the nest of sieves to collect the aggregate that
passes through the smallest. The entire nest is then agitated, ad the
material whose diameter is smaller than the mesh opening passes through
the sieves. After the aggregate reaches the pan, the amount of material
retained in each sieve is then weight.

SHAPE TEST (ELONGATION INDEX):-
Apparatus required: Length gauge, I.S.Sieve
Procedure:
1. The sample is sieved through IS Sieve specified in the table. A minimum
of 200 aggregate pieces of each fraction is taken and weighed.

2. Each fraction is the thus gauged individually for length in a length gauge.
The gauge length is used should be those specified in the table for the
appropriate material.
3. The pieces of aggregate from each fraction tested which could not pass
through the specified language length with its long side are elongated
particles and they are collected separately to find the total weight of
aggregate retained on the length gauge from each fraction.
4. The total amount of elongated material retained by the length gauge is
weighed to an accuracy of at least 0.1% of the weight of the test sample.
5. The weight of each fraction of aggregate passing and retained on specified
sieves sizes are found W1, W2, W3, and the total weight of sample
determined =W1+ W2+W3=Wg. Also the weight of the material from each
function retained on the specified gauge length are found= X1, x2, x3 and
the total weight retained determined x1+x2+x3=X gm.
6. The elongation index is the total weight of the material retained on the
various length gauges, expressed as a percentage of the total weight of the
sample gauged.
(X1+x2+x3+-------)
Elongation index = -----------------------
(w1+w2+w3+-----)

SHAPE TEST (FLAKINESS INDEX):-

Apparatus required: The apparatus consist of a standard thickness

gauge, IS Sieve of size63, 50, 40, 31.5, 25, 20, 16, 12.5, 10 and 6.3 and a
balance to weight the samples.
Procedure
1. The sample is sieved with the sieves mentioned in the table.
2. A minimum of 200 pieces of each fraction to be tested are taken and
weighed (WI gm)
3. In order to separate flaky materials, each fraction is then gauged for
thickness on thickness gauge, or in bulk on sieve having elongated slots as
specified in the table.
4. Then the amount of flaky materials passing the gauge is weighed to an
accuracy of at least 0.1% of test sample.
5. Let the weight of the flaky materials passing the gauge be W1 gm.
Similarly the weights of the fractions passing and retained on the specified
sieves be W1, W2, W3, etc, are weighed and the total weight WI+W2+W3+ =
Wg is found. Also the weights of the materials passing each of the specified
thickness gauge are found =W 1, W2, W3.... And the total weight of the
material passing the different thickness gauges = W1+W2+W3= Wg is
found.
6. Then the flakiness index is the total weight of the flaky material passing
the various thickness gauges expressed as a percentage of the total weight of
the sample gauged.
(w1+w2+w3+----)
Flakiness index = ----------------------- X 100
(w1+w2+w3+----)



11. PRIME COAT OVER GRANULAR BASE:-
11. 1 Scope
This work shall consist of the application of a single coat of low viscosity
liquid bituminous material to a porous granular surface preparatory to the
superimposition of bituminous treatment or mix.
11.2 Materials
11.2.1 Prime
The choice of bituminous prime shall depend upon the porosity
characteristics of the surface to be primed as classified in IRC: 16. These
are:
(1)Surface of low porosity; such as wet macadam and water bound
macadam,
(2)Surface of medium porosity; such as cement stabilized soil base,

(3)Surface of high porosity; such as a gravel base.
11.2.2 Prime viscosity
The type and viscosity of the primer shall comply with requirements of IS:
8887, as sampled and tested for bituminous primer in accordance with
these standards .Guidance on viscosity and rate of spray is given in Table16.
Table16. Viscosity requirements and quantity of liquid bituminous primer
11.2.3 Choice of primer
The primer shall be bitumen emulsion, complying with IS: 8887 of a type
and grade as specified in the Contract or as directly by the Engineer. The
use of medium curing cutback as per IS: 217 shall be restricted only for

sites at subzero temperatures or for emergency application as directly by the
Engineer.
11.2.4 Weather and Seasonal Limitations
Bituminous primer shall not be applied to a wet surface or during a dust
storm or when the weather is foggy, rainy or windy or when the temperature
in the shade is less than 100C. Surfaces which are to receive emulsion
primer should be damp, but no free or standing water shall be present.
11.3 Construction
11.3.1 Equipment
The primer distributor shall be a self-propelled or towed bitumen pressure
sprayer for spraying the material uniformly at specified rates and
temperature. Hand spraying of small areas, inaccessible to the distributor,
or in narrow strips shall be sprayed with a pressure hand sprayer, or as
directed by the Engineer.
11.3.2 Preparation of road surface
The surface to be primed shall be prepared in accordance with and as
appropriate. Immediately prior to applying the primer the surface shall be
carefully swept of dust and loose particles, care being taken not to disturb
the interlocked aggregate. This is best achieved when the surface layer is
slightly moist (lightly sprayed with water and the surface allowed to dry) and
the surface should be kept moist until the primer is applied.
11.3.3 Application of bituminous primer

The viscosity and rate of application of the primer shall be as specified in
the contract, or as determined by site trials carried out as directed by the
Engineer. Where a geosynthetic is proposed for use, the requirements and
shall apply. The bituminous primer shall be sprayed uniformly in
accordance with. The method for application of the primer will depend on
type of equipment to be used, size of nozzles, pressure at the spray bar and
speed of forward movements. The contractor shall demonstrate at spraying
trial, that the equipment and method be used is capable of producing a
uniform spray, within the tolerances specified.
11.3.4 Curing of primer and opening to traffic
A primed surface shall be allowed to cure for at least 24 hours or such other
period as is found to be necessary to allow all the volatiles before any
subsequent surface treatment or mix is laid.
Any unabsorbed primer shall first be blotted with an application of sand,
using the minimum quantity possible. A primer surface shall not be opened
to traffic other than the necessary to lay the next course. A very thin layer of
clean sand may be applied to the surface to lay prevent the primer picking
up under the wheels of the paver and trucks delivery bituminous material to
the paver.
11.3.5 Measurement for payment
Prime coast shall be measured in terms of surface area of application in
square meters.
11.3.6 Rate
The contract unit rate for prime coat with adjustment as describe in shall
payment in full for carrying out the required operation including full
compensation for all components listed and as applicable to the work

specified in the Specification. Payments shall be on the basis of the
provision of prime coat at the application rate of 0.6 kg per square meter,
with adjustment, plus or minus, for the variation between this amount and
the actual amount by the Engineer after preliminary trails.
12. DENSE BITUMINOUS MACADAM:-
12.1 Scope
This clause specifies the construction of Dense Graded Bituminous
Macadam, (DBM), for use mainly, but not exclusively, in base/binder and
profile corrective courses. DBM is also intended for use as road base

material. This work shall consist of construction in a single or multiple
layers of DBM on a previously prepared base or sub base. The thickness of a
single layer shall be 50 to 100mm.
12.2 Materials
12.2.1 Bitumen
The bitumen shall be paving bitumen of Penetration Grade complying with
Indian Standard Specifications for Paving Bitumen IS: 73, and of the
penetration indicated in Table for dense bitumen macadam, or this bitumen
as modified by one of the methods specified, or as otherwise specified in the
Contract. Guidance on the selection of an appropriate grade of bitumen is
given in The Manual for Construction and Supervision of Bituminous Works.
The coarse aggregates shall consist of crushed rock, crushed gravel or other
hard material retained on the 2.36 mm sieve. They shall be clean, hard, and
durable, of cubical shape, free from dust and soft or friable matter, organic
or other deleterious substances. Where the Contractors selected source of
aggregates have poor affinity for bitumen, as a condition for the approval of
that source, the bitumen shall be treated with an approved anti-strippiig
agent, as per the manufacturers recommendations, without additional
payment. Before approval of the source, the aggregates shall be tested for
stripping.
The aggregates shall satisfy the physical requirements specified in below
Table, for dense bituminous macadam. Where crushed gravel is proposed for
use as aggregate, not less than 90 % by weight of the crushed material
retained on the 4.75 mm sieve shall have at least two fractured faces.

12.2.3 Fine aggregates
Mineral material, or a combination of the two, passing the 2.36 mm sieve
and retained on 75 micron sieve. They shall he clean, hard, durable, dry and
free from dust, and soft or friable matter. organic or other deleterious matter.
The fine aggregate shall have a sand equivalent alue of not less than 50
when tested in accordance with the requirement of IS: 2720 (Part 37). The
plasticity index of the fraction passing the 0.425 mm sieve shall not exceed
4. When tested in accordance with IS: 2720 (Part 5).
Notes: 1. IS: 2386 Part 1 5. IS: 2386 part 5
2. IS: 2386 part 2 6. IS: 2386 part 6
(The elongation test to be done only on non-flaky aggregated in the sample)
3. IS: 2386 part 4* 7. IS: 6241

4. IS: 2386 part 4* 8. AAASHTO T 283*
* Aggregate may satisfy requirements of either of these two tests.
** The water sensitivity test is only required if the minimum retained coating
in the stripping test is less than 95%
12.2.4 Filler
Filler shall consist of finely divided mineral matter such as rock dust,
hydrate lime or cement approved by the engineer. The filler shall be grated
within the indicated in Table 18.
The filler shall be free from organic impurities and have a Plasticity Index
not greater than 4. The Plasticity Index requirement shall not apply if filler is
cement or lime. When the coarse aggregate is gravel, 2 per cent by weight of
total aggregate, shall be Portland cement or hydrated lime and the
percentage of fine aggregate reduced accordingly. Cement or hydrated lime is
not required when the limestone aggregate is used. Where the aggregates fail
to meet the requirements of the water sensitivity test in then 2 percent by
total weight of aggregate. Of hydrated lime shall be added without additional
coat.
12.2.5 Aggregate grading and binder content

When tested in accordance with IS: 2386 Part 1 (wet sieving method), the
combined grading of the coarse and fire aggregates and added filler for the
particular mixture shall fall within the limits shown in Table 19, for dense
bituminous macadam grading 1 or 2 as specified in the Contract. The type
and quality of bitumen, and appropriate thickness, are also indicated for
each mixture type.
Note: The combined aggregate grading shall not vary from the low limit on
one sieve to the high limit on the adjacent sieve.
12.3 Mixer Design
12.3.1 Requirement for the mixer
Apart from conformity with the grading and quality requirement for
individual ingredients, the mixer shall meet requirement set out in Table 20.

Notes: 1. the nominal maximum particle size is one size larger than the firt
sieve to retain more than 10 percent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for
design air voids value between both listed.
12.3.2 Binder content
The binder content shall be optimized to achieve their requirements of the
mixture set out in Table and the traffic volume specified in the Contract. The

Marshall method for determining the optimum binder content shall be
adopted as described in the Asphalt Institute Manual MS-2, replacing the
aggregates retained on the 26.5 mm sieve by the aggregates passing the 26.5
mm sieve and retained on 22.4 mm sieve, where approved by the Engineer.
Where 40 mm dense bituminous macadam mixture is specified, the
modified Marshall method described in MS-2 shall be used. This method
requires modified equipment and procedures; particularly the minimum
stability values in Table shall be multiplied by 2.25 and the minimum flow
shall be 3 mm.
12.3.3 Job mix formula
The Contractor shall inform Engineer in writing, at least 20 days before the
start of the work, of the job mix formula proposed for be used in the works,
and shall give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materials expressed as follows where each is applicable:
(a) Binder type, and percentage by weight of total mixture;
(b) Coarse aggregate/Fine aggregate/Mineral filler as percentage by weight of
total aggregate including mineral filler;
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The individual grading of the individual aggregate fractions, and the
proportion of each in the combined grading.
(v) The results of tests enumerated in below Table as obtained by the
Contractor;
(vi) Where the mixer is a batch mixer, the individual weights of each type of
aggregate, and binder per batch, (vii) Test results of physical characteristics

of aggregates to be used; (viii) Mixing temperature and compacting
temperature. While establishing the job mix formula, the Contractor shall
ensure that it is based on a correct and truly representative sample of the
materials that will actually be used in the work and that the mixture and its
different ingredients satisfy the physical and strength requirements of these
Specifications. Approval of the job mix formula shall he based on
independent testing by the Engineer for which samples of all ingredients of
the mix shall he furnished by the Contractor required by the Engineer. The
approved job mix formula shall remain effective unless and until a revised
Job Mix Formula is approved.
12.3.4 Plant trials - permissible variation in job mix formula
Over the laboratory job mix formula is approved, the Contractor shall carry
out plant trials at the mixer to establish that the plant can be set up to
produce a uniform mix conforming to the Base and approved job mix
formula. The permissible variations of the individual percentages of the
various ingredients in the actual mix from the job mix formula to be used
shall be within the limits as specified in below Table.

Once the plant trials have demonstrated the capability of the plant. And true
trials are approved. The laying operation may commence. Over the period of
the first month of production for laying on the works. the Engineer shall
require additional testing of the product to establish the reliability and
consistency of the plant.
12.3.5 Laying Trials
Once the 1)1 ant trials have been successfully completed and approved, the
Contractor shall carry out laying trials, to demonstrate that the proposed
mix can be successfully laid, and compacted. The laying trial shall be
carried out on a suitable area which is not to form part of the works. unless
specifically approved in writing, by the Engineer. The area of the laying trials
shall he a minimum of 100 sq. m. of construction similar to that of the
project road, and it shall be in all respects, particularly compaction, the
same as the project construction, on which the bituminous material is to be
laid.
The Contractor shall previously inform the Engineer of the proposed method
for laying and compacting the material. The plant trials shall then establish
if the proposed laying plant, compaction plant, and methodology is capable
of producing satisfactory results. The density of the finished paving layer
shall be determined by taking cores, no sooner than 24 hours after laying,
or by other approved method.
Once the laying trials have been approved, the same plant and methodology
shall be applied to the laying of the material on the project, and no variation
of either shall be acceptable, unless approved in writing by the Engineer,
who may at his discretion required further laying trials.

12.4.1 Preparation of base
The surface shall be thoroughly swept clean by a mechanical broom, aid the
dust removed by compressed air. In locations where mechanical broom
cannot access, other approved methods shall be used as directed by the
Engineer.
12.4.2 Rolling
The compaction process shall be carried out by the same plant, and using
the same method, as approved in the laying trials, which may be varied only
with the express approval of the Engineer in writing.
The newly laid surface shall not be open to traffic for at least 24 hrs after
laying and completion of compaction, without the express approval of the
Engineer in writing.
12.4.4 Measurement for Payment
Dense Graded Bituminous Materials shall be measured as finished wok
either in cubic metres, tons or by the square metre at a specified thickness
as detailed on the Contract drawings. or documents, or as directed by the
Engineer.
12.4.5 Rate
The rate shall include the provision of bitumen, 4.25 per cent by weight of
the total mixture. The variance in actual percentage of bitumen used will be
assessed and the payment adjusted. up or down, accordingly.
Tests for Dense bituminous macadam
Aggregate impact value

Flakiness and elongation
Marshal test
Aggregate impact value:
Apparatus required: Impact testing machine, cylinder, tamping rod, IS

Sieve 125.mm, 10mm and 2.36mm, balance.
Procedure:
The test sample consist of aggregate passing 12.5mm sieve and retained on
10mm sieve and dried in an oven for four hours at a temperature 100C to
110C and cooled. Test aggregates are filled up to about one-third full in the
cylindrical measure and tamped 25 times with rounded end of the tamping

rod. Further quantity of aggregate is than added up to two-third in the
cylinder and 25 stocks of the tamping rod are given. The measure is now
filled with the aggregate to over flow, tamped 25 times. The surplus
aggregate are struck off using the tamping rod as straight edge. The net
weight of the aggregate in the measure is determined to the nearest gram
and this weight of the aggregate is used for carrying out duplicate test on
the sample material. The impact machine is placed with its bottom plate flat
on the floor so that the hammer guide columns arc vertical. The cup is fixed
firmly in position on the base of the machine and the whole of the test
sample from the cylindrical measure is transferred to the cup and
compacted by tamping with 25 strokes.
The hammer is raised until its lower face is 380mm above the upper surface
of the aggregate in the cup, and allowed to fall freely on the aggregates. The
test sample is subjected to a total 15 such blows, each being delivered at an
interval of not less than one second. The crushed aggregate is then removed
from the cup and the whole of it sieved on the 2.36mm sieve until no further
significant amount passes.
The fraction passing the sieve is weighted accurate to 0.1gm. The fraction
retained on the sieve is also weighed and if the total weight of the fraction
passing and retained on the sieve is added it should not be less the original
weight is less than the original weight of the specimen by more than one
gram, if the total weight is less than the original by over one gram the result
should be discarded and a fresh test made.



Marshal Test:-

Apparatus required:
Mould assembly, sample extractor, compaction pedestal and hammer,
breaking head, loading machine flow meter, thermometers water bath and
oven
Procedure: -
1. The coarse aggregates, fine aggregates and mineral filler material
should be proportioned and mixed in such a way that final mix after
blending has the graduation within the specified range.
2. Approximately 1200 grams of aggregates and filler are taken and
heated to a temperature of 175oC to 1950 C.
3. The compaction mould assembly and rammer are cleaned and kept
pre- heated to a temperature of 100oC to 145oC. The bitumen is
heated to temperature of l2loC to 138oC and the required quantity of
first trial percentage of bitumen is added to the heated aggregate and
thoroughly mixed using a mechanical mixer or by hand mixing with
trowel.
4. Then the mix is heated and a temperature of 150o to l6OoC is
maintained and then the mix is transferred into the pre-heated mould
and compacted by giving seventy five blows on each side.
5. The specific gravity values of different aggregates, filler and bitumen
used are determined first. The theoretical specific gravity of the mix is
determined.
6. Soon after the compacted bituminous mix specimens have cooled to
room temperature, the weight, average thickness and diameter of the

specimen are noted. The specimens are weighted in air and then in
water.
7. The bulk density value of the specimen if calculated from weight and
volume
8. Then the specimen to be tested is kept immersed under water in a
thermostatically controlled water bath maintained at 60o l0C for 30
to 40 minutes.
9. The specimens are taken out one, placed in the marshal lest and the
marshal stability value and flow are noted.
10. The corrected Marshall Stability value of each specimen is
determined by applying the appropriate correction factor, i9f the
average height of the specimen is not exactly 63.5mm.
11. Five graphs are plotted with values of bitumen content against
the values of density, Marshall Stability, voids in total mix, flow value,
voids filled by bitumen.
12. Let the bitumen contents corresponding to maximum density be
B 1, corresponding to maximum stability be B2 and that
corresponding to the specified voids content (at 4.0%) be B3.
Then the optimum bitumen content for mix design is given by: Bo= (BI
+B2+B3)/3.

13. TACK COAT:-
13.1 SCOPE
This work shall consist of the application of single coat of low viscosity liquid
bituminous material to an existing bituminous road surface prepare to the
superimposition of a bituminous mix, when specified in the contrite or
instruction by the Engineer.
13.2 Material
13.2.1 Binder
The binder used for tack coat shall be a bitumen complying with IS : 8887 of
a type and grade as specified in the contrite or as directly by the engineer.
The use of emergency application as directed by the Engineer.
13.2.2 Weather and seasonal Limitations

Bituminous material shall not be applied to a wet surface or during a dust
storm or when the weather is foggy, rainy or windy or when the temperature
in the shade is the less than 100c. Where coat is of cutback bitumen, the
surface shall be dry.
13.3 Construction
13.3.1 Equipment
The tack coat distributor shall be a self- propelled or towed bitumen
pressure sprayer, equipped for spraying the material uniform at specified
rate. Hand spraying of small areas, inaccessible to the distributor, or in
narrow strips shall be sprayed with a pressure hand sprayer, or as directed
by the engineer.
The surface on the tack coat is to be applied shall be and from dust, dirt
and any extraneous material, and be otherwise prepared in accordance with
requirements of appropriate.
Immediately before the application of the tack coat the surface shall be
swept clean with a mechanical broom and high pressure air jet or by other
means as directed by the Engineer.
13.3.3 Application of task coat
The application of task coat shall be rate specified in the contrite , and shall
be applied uniformly. If rate application of tack coat is not specified in the
contract then it shall be at the rate specified in the below table. The normal

range of spraying temperature for a bituminous emulsion shall be 200c to
700c and for a cutback 500to 800c if rc-70/MC-70 is used. Where a
geosynthetic is proposed for use the provisions shall apply. The method of
application of the tack coat will depend of forward movement. The contractor
shall demonstrate at a spraying trial that the equipment and method to be
used is capable of producing a uniform spray, within the tolerance specified.
Where the material to receive an overlay is a freshly laid bituminous layer
that has not been subjected to traffic or contaminated by dust a tack coat is
not mandatory where the overlay is completed within two days.
13.3.4 Curing of task coat
The task coat shall be left to cure until the entire have approved before any
subsequent construction is started. No plant or vehicles shall be allowed on
the task coat other than those essential for the construction.
13.3.5 RATE
The contrite unit rate for granular sub-base shall be payment in full for
carrying out required operation including full compensation for.
1) Making arrangement for traffic to except for intial treatment to verges
shoulder and construction of diversions.

2) Furnishing all materials to be incorporated in the including all
royalties, fees, rent where necessary and all leads and lifts.
3) All labour tools equipment to completed the work to the specification;
4) Carrying out the work in the part widths of road where directed and;
5) Carrying out the required test for quality.
(1)To (5) and as applicable to the work specified in these specification.
The rate shall cover the provision of task 0.2 kg square meter, with in
provision that the variance in actual quantity of bitumen used will be
assessed and the payment adjusted accordingly.
14.BITUMINOUS CONCRETE:-

14.1 Scope
This clause specifies the construction of Bituminous Concrete, for use in
wearing and profile corrective courses. This work shall consist of
construction in a single or multiple layers of bituminous concrete on a
previously prepared bituminous bound surface. A single layer shall be
25mm to 100 mm in thickness.
14.2 Materials
14.2.1 Bitumen
The bitumen shall be paving bitumen of Penetration Grade complying with
Indian Standard Specification for Paving Bitumen, IS: 73 and of the
penetration indicated in below Table, for bituminous concrete, or this
bitumen as modified by one of the methods specified , or as otherwise
specified in the Contract. Guidance on the selection of an appropriate grade
of bitumen is given in The Manual for Construction and Supervision of
Bituminous Works.

The coarse aggregates shall be generally as specified. Except that the
aggregates shall satisfy the physical requirements in below Table.
14.2.3 Fine aggregates
Fine aggregates consist of crushed or naturally occurring mineral material
or a combination of the two, passing the 2.36 mm sieve and retained on 75
micron sieve. They shall be clean, hard, durable, dry and free from dust, and
soft or friable matter, organic or other deleterious matter.
The fine aggregate shall have a sand equivalent value of not less than 50
when tested in accordance with the requirement of IS: 2720 (Part 37). The
plasticity index of the fraction passing the 0.425 mm sieve shall not exceed
4. When tested in accordance with IS: 2720 (Part 5)
14.2.4 Filler
Where the aggregates fail to meet the requirements of the water sensitivity
test in below Table then 2 per cent by total weight of aggregate, of hydrated
lime shall be added without additional cost
14.2.5 Aggregate grading and binder content
When tested in accordance with IS: 2386 Part 1 (wet sieving method), the
combined grading of the coarse and fine aggregates and added filler shall fall
within the limits shown in below Table for grading
1 or 2 as specified in the Contract.
14.3 Mixture Design
14.3.1 Requirements for the mixture

Apart from conformity with the grading and quality requirements for
individual ingredients, the mixture shall meet the requirements set out in
below Table. The requirements for minimum per cent voids in minemal
aggregate (VMA) are set out in TabIe24.
14.3.2 Binder content
The binder content shall be optimized to achieve the requirements of the
mixture set Out in below Table and the traffic volume specified in the
Contract. The Marshall method for determining the optimum binder content
shall be adopted as described in The Asphalt Institute Manual MS-2.
Replacing the aggregates retained on the 26.5 mm sieve by the aggregates

passing the 26.5 mm sieve and retained on 22.4 mm sieve, where approved
by the Engineer.
14.3.3Job mix formula
The procedure for formulating the job mix formula shall be generally and the
results of tests enumerated in Table24, as obtained by the Contractors.

Notes: 1. IS: 2386 part 1 6. IS: 2386 part 5
2. IS: 2386 part 1 7.IS: 2386 part 3
(The elongation test to be done only on non-flaky aggregated in the
sample)
3. IS: 2386 part 4* 8.AASHTO T283*
4. IS: 2386 part 4* 9.IS:6241
5. BS: 812 part 114
*Aggregated may satisfy requirements of either of these two tests.

**The water sensitivity test is only required if the minimum retained coating
in the stripping test is less than 95%.
Note: 1.The combined aggregate grading shall not very from the low limit on
one sieve to the high limit on the adjacent sieve.
2. Determined by the marshal method.

The surface on which the Bituminous Concrete is to be laid shall be
prepared in accordance with appropriate, or as directed by the Engineer. The
surface shall be thoroughly swept clean by mechanical broom and dust
removed by compressed air. In locations where a mechanical broom cannot
access, other approved methods shall be used as directed by the Engineer.
14.3.5 Geosynthetics
Where Geosvnthetics are specified in the Contract this shall be in
accordance with the requirements stated.
14.3.6 Stress absorbing layer
Where a stress absorbing layer is specified in the Contract, this shall be
applied in accordance with the requirements.
14.3.7 Tack coat

Where specified in the Contract, or otherwise required by the Engineer, a
tack coat shall be applied in accordance with the provisions.
14.3.8 Mixing and transportation of the mixture
Pre-mixed bituminous materials, including bituminous macadam, dense
bituminous macadam, semi-dense bituminous concrete and bituminous
concrete, shall be prepared in a hot mix plant of adequate capacity and
capable of yielding a mix of proper and uniform quality with thoroughly
coated aggregates. Appropriate mixing temperatures can be found of these
Specifications; the difference in temperature between the binder and
aggregate should at no time exceed 14C.
In order to ensure uniform quality of the mix and better coating of
aggregates, the hot mix plant shall be calibrated from time to time.
If a continuous mixing plant is to be used for mixing the bituminous bound
macadam, the Contractor must demonstrate by laboratory analysis that the
cold feed combined grading is within the grading limits specified for that
bituminous bound material, in the case of a designed job mix, the bitumen
and filler content shall be derived using this combined grading. Further
details are available in the Manual for Construction and Supervision of
Bituminous Works.
Bituminous materials shall be transported in clean insulated vehicles, and
unless otherwise agreed by the Engineer, shall be covered while in transit or
waiting tipping. Subject to the approval of the Engineer, a thin coating of
diesel or lubricating oil may be applied to the interior of the vehicle to
prevent sticking and to facilitate discharge of the material.
14.4 Spreading

Except in areas where a mechanical paver cannot access, bituminous
materials shall be spread, levelled and tamped by an approved self-propelled
paving machine. As soon as possible after arrival at site. The materials shall
be supplied continuously to the paver and laid without delay.
The rate of delivery of material to the paver shall be regulated to enable the
paver to operate continuously. The travel rate of the paver, and its method of
operations, shall be adjusted to ensure an even and uniform flow of
bituminous material across the screen, free from dragging, tearing, and
segregation of the material. In areas with restricted space where a
mechanical paver cannot be used, the material shall he spread, raked and
levelled with suitable hand tools by experienced staff, and compacted to the
satisfaction of the Engineer.
The minimum thickness of material laid in each paver pass shall be in
accordance with the minimum values given in the relevant parts of these
Specifications. When laying binder course or wearing course approaching an
expansion joint of a structure, machine laying shall stop 3mm short of the
joint. The remainder of the pavement up to the joint, and the corresponding
area beyond it, shall be laid by hand, and the joint or joint cavity shall be
kept clear of surfacing material.
Bituminous material, with a temperature greater than 1450C, shall not be
laid or deposited on bridge deck waterproofing systems, unless precautions
against heat damage have been approved by the Engineer. Hand placing of
pre-mixed bituminous materials shall only be permitted in the following
circumstances:
(1) For laying regulating courses of irregular shape and varying thickness.
(ii) In confined spaces where it is impracticable for a paver to operate. (iii) For
footways.

(iv) At the approaches to expansion joints at bridges, viaducts or other
structures.
(v) For laying mastic asphalt.
(vi) For filling of potholes.
(vii) Where directed by the Engineer.
Manual spreading of pre-mixed wearing course material or the addition of
such material by hand-spreading to the paved area, for adjustment of level,
shall only be permitted in the following circumstances:
(i) At the edges of the layers of materials and at gullies and manholes.
(ii) At the approaches to expansion joints at bridges, viaducts or other
structures. (iii) As directed by the Engineer.
14.5 Rolling
Compaction of bituminous materials shall commence as soon as possible
after laying. Compaction shall be substantially completed before the
temperature falls below the minimum rolling temperatures stated in the
relevant part of these Specifications. Rolling of the longitudinal joints shall
be done immediately behind the paving operation.
After this, rolling shall commence at the edges and progress towards the
center longitudinally except that on super elevated and unidirectional
cambered portions, it shall progress from the lower to the upper edge
parallel to the center line of the pavement. Rolling shall continue until all
roller marks have been removed from the surface. All deficiencies in the
surface after laying shall he made good by the attendants behind the paver,
before initial rolling is commenced. The initial or breakdown rolling shall he
done with 8 10 tonnes dead weight smooth-wheeled.

The intermediate rolling shall be done with 8 10 tonnes dead weight or
vibratory roller or with a pneumatic tyred roller of 12 to 15 tonnes weight
having nine wheels, with a tyre pressure of at least 5.6 kg/sqcm. The finish
rolling shall be done with 6 to 8 tonnes smooth wheeled tandem rollers.
The newly laid surface shall not be open to traffic for at least 24 hours after
lying and the completion of compaction, without the express approval of the
Engineer in writing.
14.5.2 Surface Finish and Quality Control
The surface finish of the completed construction shall conform to the
requirements. All materials and workmanship shall comply with the
provisions set out in of this Specification.
Dense Graded Bituminous Materials shall be measured as finished wok
either in cubic metres, tons or by the square metre at a specified thickness
as detailed on the Contract drawings, or documents, or as directed by the
Engineer.
14.5.4 Rate
The contract unit rate for Dense Graded Bituminous Macadam shall be
payment in full for carrying out the all required operations as specified, and
shall include, but not necessarily limited to all components. The rate shall
include the provision of bitumen, 4.25 per cent by weight of the total
mixture.
The variance in actual percentage of bitumen used will be assessed and the
payment adjusted, up or down. accordingly, except that the rate shall

include the provision of bitumen at 5.0 per cent, by weight of the total
mixture. The variance in actual percentage of bitumen used will be assessed
and the payment adjusted up or down, accordingly.
Tests for bituminous concrete
Marshal test

15. SURFACE DRESSING:
15.1 Scope
This work shall consist of the application of one coat or two coats of surface
dressing, each coat consisting of a layer of bituminous binder sprayed on a
previously prepared base, followed by a cover of stone chips rolled in to form
a wearing course to the requirements of these Specifications. For
information on the Design of Surface Dressing refer to the Manual for
Construction and Supervision of Bituminous Works.
15.2 Materials
15.2.1 Binder

The binder shall have a kinematic viscosity lying in the range 1 x 104 to 7 x
105 centistokes at the expected range of road surface temperatures at the
construction site during the period of laying. The type of binder to be used
will be stated in the Contract documents and shall comply with one of the
following:
Paving Bitumen IS: 73 Bitumen Emulsion IS: 8887
15.2.2 Aggregates
(i)Coarse aggregates
The coarse aggregates shall consist of crushed rock, crushed gravel or other
hard material retained on the 2,36 mm sieve. They shall be clean, hard, and
durable, of cubicle shape, free from dust and soft or friable matter. organic
or other deleterious matter. Where the Contractors selected source of
aggregates have poor affinity for bitumen, as a condition for the approval of
that source. The bitumen shall be treated with approved anti-stripping
agents, as per the manufacturers recommendations, without additional
payment. Before approval of the source, the aggregates shall be tested for
stripping.
Except that their water absorption shall be restricted to a maximum of I per
cent and they shall have a Polished Stone Value, as measured by the method
given in BS: 812 (Part 114), of not less than 60. The chips shall be single
sized, clean. hard, durable, of cubical shape, free from dus: and soft or
friable matter, organic or other deleterious matter and conforming to one of
the grading given in below Table.
15.2.3 Rates of spread of binder and chips
For the purpose of pricing the Bill of Quantities the rates of spread given in
Table27, shall be priced.

15.2.4 Anti-stripping agent
Where the proposed aggregate fails to pass the stripping test then an
approved adhesion agent (Appendix 5 for details) may be added to the binder
in accordance with the manufacturer s instructions. The effectiveness of the
proposed anti-stripping agent must be demonstrated by the Contractor,
before approval by the Engineer. Dust removed in the process shall be blown
off with the help of compressed air.
15.2.5 Pre-coated chips
As an alternative to the use of an adhesion agent the chips may be pre-
coated before they are spread except when the sprayed binder film is a
bitumen emulsion. Pre-coating the chips may be carried out in any one of
the two methods:
(a) Mixing them with 0.75 to 1.0 per cent of paving bitumen by weight of
chips in a suitable mixer, the chips being heated to 1600C and the bitumen
to its application temperature. The precoated chips shall be allowed to cure
for at least one week or until they become non sticky and can be spread
easily.

(b) Spraying the chips with a light application of creosote. Diesel oil or
kerosene at ambient temperature. This spraying can be done in a concrete
mixer or on a belt conveying the chips from stockpile to gritting Lorries.
15.3 Construction operations
15.3.1 Weather and seasonal limitations
Laying shall be suspended while freestanding water is present on the
surface to be covered, or during rain, fog and dust storms. After rain, the
bituminous surface, prime or tack coat shall be blown off with a high
pressure air jet to remove excess moisture, or the surface left to dry before
laying shall start. Laying of bituminous mixtures shall not be cal Tied out
when the air temperature at the surface on which it is to be laid is below
l00C or when the wind speed at any temperature exceeds 40 km/h at 2 m
height unless specifically approved by the Engineer.

The base on which the surface dressing is to laid shall be prepared, shaped
and conditioned to the specified lines, grade and cross section in accordance
as directed by the Engineer. Prime coat.
Where needed, shall be provided directed by the Engineer. Where the
existing surface shows signs of fatting up, the excess bitumen shall be
removed by burning off, or manually, as specified. In the Contract or
directed by the Engineer. The bituminous surface to be dressed shall be
thoroughly cleaned either by using a mechanical broom and /or compressed
air, or any other approved equipment/method as specified in the Contract or
by the Engineer. The prepared surface shall be dust free, clean and dry,
(except in the case of cationic emulsion where the surface shall be damp).
15.3.3 Application of binder
The equipment and general procedures shall all be in accordance with the
Manual for Construction and Supervision of Bituminous Works. The
application temperature for the grade of binder used shall be as given in
below Table.
15.3.4 Application of stone chips
The equipment and general procedures shall all be in accordance with the
Manual for Construction and Supervision of Bituminous \Vorks. For
relatively small areas of surface dressing, carefully application of chips by
hand may be acceptable if approved by the Engineer. The rate of application
of chips shall be as determined by the procedure given in the Manual for
Construction and Supervision of Bituminous Works. Immediately after the
application of binder, clean, dry chips (in the case of emulsion binder the
chippings may be damp) shall be spread uniformly on the surface so as to
cover the surface completely with a single layer of chips.

15.3.5 Rolling
Rolling of the chips should preferably be carried out by a pneumatic tyred
roller. Traditional steel wheeled rollers tend to crush the aggregates and if
their use cannot be avoided their weight should be limited to 8 tones. Rolling
shall commence at the edges and progress towards the centre except in
super elevated and unidirectional cambered portions where it shall proceed
from the lower edge to the higher edge. Each pass of the roller shall
uniformly overlap not less than one-third of the track made in the preceding
pass. While rolling is in progress additional chips shall be spread by hand in
necessary quantities required to make up irregularities. Rolling shall
continue until all aggregate particles are firmly embedded in the binder and
present a uniform closed surface.
15.3.6 Application of second coat of surface dressing
Where surface dressing in two coats is specified, the second coat should not
be applied until the first coat has been open to traffic for 2 or 3 weeks. The
surface on which the second coat is laid must be clean and free of dust. The
construction operations for the second coat shall be the same as described.
15.3.7 Opening to traffic

Traffic shall not be permitted to run on any newly surface dressed area until
the following day. In special circumstances, however, the Engineer may allow
the road to be opened to traffic immediately after rolling, hut in such cases
traffic speed shall be limited to 20 km per hour until the following day.
15.3.8 Surface Finish and Quality Control of Work
All works performed shall conform to the lines, grades, cross sections and
dimensions shown on the drawings or as directed by the Engineer, subject to
the permitted tolerances described hereinafter.
For control on the quality of materials and works carried out, the relevant
provisions shall apply.
15.3.9 Arrangements for Traffic
During the period of construction. arrangements for traffic shall be made in
accordance with 1he Contractor shall at all times carry out work on the
highway in a manner creating least interference to the flow of traffic while
consistent with the satisfactory execution of the same. For all works
involving improvements to the existing highway, the Contractor shall, in
accordance with the directives of the Engineer, provide and maintain, during
execution of the work, a passage for traffic either along a part of the existing
carriageway under improvement, or along a temporary diversion constructed
close to the highway. The Contractor shall take priot approval of the
Engineer regarding traffic arrangements during construction.
Each coat of surface dressing shall be measured as finished work, for tire
area instructed to he covered, in square meters.
15.3.11 Rate

The Contract unit rate for surface dressing, based on the notional rates of
spread for binder and each size of chippings, which shall be adjusted, plus
or minus, for the, difference between the notional rates of spread and the
rates of spread determined as described in the Manual for Construction and
Supervision of Bituminous Works, and approved by the Engineer, multiplied
by the rates entered in the Bill of Quantities for binder and each size of
chipping.
The contract unit rate for premixed bituminous material shall be payment in
full for carrying out the required operations including full compensation for,
but not necessarily limited to:
(i) Making arrangements for traffic to except for initial treatment to verge,
shoulders and construction of diversions;
(ii) Preparation of the surface to receive the material.
(iii) Providing all materials to be incorporated in the work including
arrangement for stock yards. all royalties, fees, rents where necessary and
all leads and lifts;
(iv) Mixing, transporting, laying and compacting the mix, as specified.
(v) All labour, tools, equipment, plant including installation of hot mix plant,
power supply units and all machinery, incidental to complete the work to
these Specifications;
(vi) Carrying out the work in part widths of the road where directed; (vii)
Carrying out all tests for control of quality; and
(viii) The rate shall cover the provision of bitumen at the rate specified in the
contract, with the provision that the variation in actual percentage of
bitumen used will he assessed and the payment adjusted accordingly.

(ix) The rates for premixed material are to include for all wastage in cutting
joints etc.
(x) The rates are to include for all necessary testing, mix design,
transporting and testing of samples, and cores. If there is not a project
specific laboratory, the Contractor must arrange to carry out all necessary
testing at an outside Laboratory. Approved by the Engineer, and all costs
incurred arc deemed to be included in the rate quoted for the material.
(xi) The cost of all plant and laying trials as specified to prove the mixing and
laying methods is deemed to be included in the Contractors rates for the
material.
16. SEPARATOR:-
16.1 Scope
The work shall consist of constructing footpaths and/or separators at
locations as specified in the drawings or as directed by the Engineer. The
lines levels and dimensions shall be as per the drawings. The scope of the
work shall include provision of all drainage arrangements as shown in the
drawings or as directed.
16.2 Materials

The footpaths and separators shall be constructed with any of the following
types:
(a)Cast-in-situ cement concrete of Grade M20 as per Section 1700 of the
specifications:
(b)Precast cement concrete blocks/tiles of Grade M20 as per section 1700 of
the specifications. The minimum thickness of the cement concrete block/tile
shall be 25 mm and minimum size shall be 300 mm x 300 mm.
(c) Natural stone slab cut and dressed from stone of good and sound quality,
uniform in texture, free from defects and at least equal to a sample
submitted by the contractor and approved by the Engineer. The minimum
thickness of the natural stone slab shall be 25 mm and minimum size shall
be 300mm x 300 mm.
Drainage pipes below the footpath originating from the kerbs shall be first
laid in the required slope and connected to the drains/sumps/storm water
drain/drainage chutes as per provisions of the drawings, or as specified.
Portion on back side of kerbs shall be filled and compacted with granular
sub-base material of the specifications in specified thickness. The base shall
be prepared and finished to the required lines, levels and dimensions as
indicated in the drawings with the following:-
(a) Minimum 150mm thick, compacted granular sub-base material of the
Specifications, and Minimum 25mm thick cement concrete of Grade M
15.
16.3.1 Precast Cement concrete blocks/tiles/natural/stone slab
The blocks/tiles/slabs shall be set on a layer of average 12 mm thick
cement-sand mortar (1:3) laid on prepared base in such a way that there is

not rocking. The gaps between the blocks/tiles/slabs shall not be more than
12 mm and shall be filled with cement-sand mortar (1:3).
16.3.2 Cast-in-situ cement concrete
The minimum thickness of the cement concrete shall be 25 mm and it shall
be cast on the prepared base in panels of specified size in a staggered
manner. Construction joints shall be provided for the specifications.
Footpaths and separators shall be measured in sq.metre between inside of
kerbs.
16.3.4 Rates
Contract unit rates shall be inclusive of full compensation of all labour,
materials, tools, equipment and incidental to construction of footpaths. Cost
of providing pipes and arrangements for their discharge into appropriate
drainage channels shall be incidental to the construction of footpaths.
17. References:-
1. Design of flexible pavements for a typical cross section on National
highway (NH-18) by NHAL.
2. Alignment for the existing gradient of the highway by ( Indian Road
Congress ) IRC:73& IRC: SP : 48-1998.
3. Design standards for flexible pavements in accordance with TOR and
based on relevant IRC codes, MORTH&H (Minister of road Transport &
Highway ) and BIS(Bureau of Indian standards ) specifications.

4. Design standards for structure accordance with IRC: 5- 1998, IRC: 38,
IRC:73,IRC:38,IRC:6-2000, IRC:6-2000 and IS: 1893-1984, MORTH
specification &IRC: sp:13.
5. Indian standards for road drainage by IRC: SP:42-1994,IRC:37.
6.Material specification by IS:1077 for bricks IS:1124 for stones ,IS:210 for
cast iron, IS:8112,IS:12269&IS:12230for cement IS:383&IS:2386 for corse
aggregate parts 1to 7,IS:2116 for fine aggregate,IS:1030for steel.
7. Free swelling index exceeding 50 percent when tested as per IS:2720-
part40(BS-British standards)BS:1377.
8. Optimum moisture content compaction& rolling obtained in accordance
with IS:2720(part).
9. For granular sub-base the water absorption value of the coarse aggregate
shall be determined as per IS:2386(part3);BS:812 (part111) and the
soundness test shall be carried out on the material delivery to site as per
IS:383.
10. For prime coat the porosity characteristics of the surface to be primed as
classified in IRC:16. And viscosity of the primer shall comply with
requirements of IS: 8887 & for bituminous temperature in the shade is less
than 100c.
11. For task coat shall be a bituminous emulsion complying with IS:888 &
use of cutback bitumen as per IS:217.

12. for wet mix macadam the soundness test shall be carried out on the
material delivery to site as pr IS: 2386(part-5).

13. For dense bituminous macadam Indian standard specifications for
Paving Bitumen IS: 73 & the Asphalt Institute Manual MS-2.

14. For bituminous concrete temperature between thew binder and
aggregate should at no time exceed 14c.

15.For seal coat (surface dressing) Except that their water absorption shall
be restricted to a maximum of 1 per cent and they shall a polished stone
value, as measured method given in BS:812(part114),of not less than 60.
18. Conclusion:-
Pavement from the basic supporting structure in highway transport
each layer of pavement has a multiple of functions to perform which
has to be considered during the construction process.
Improper construction of pavement loads to early failure of pavements
affecting the riding quality also.
In the construction of flexible pavement the quality control of material
used in the construction is most important.
Mainly the material used in the construction will decided by the
national highway of authority (NHAI).
To maintain the quality control we can avoid the damage of highway
and the life of flexible pavements (highway road) will also increases.
Finally to include that we have studied the details and construction of
flexible pavement and we can say that highway can be useful for the
advancement of the community economics prosperity and general
development of the country.

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DEPARTMENT OF CIVIL ENGINEERING 2010-2014

A highway pavement is a structure consisting of superimposed layers of

structure should be able to provide a surface of acceptable riding quality,

adequate skid resistance, favourable light reflecting characteristics, and low

bearing capacity of the sub-grade. Two types of pavements are generally

recognized as serving this purpose, namely flexible pavements and rigid

pavements. This chapter gives an overview of pavement types, layers, and

their functions, and pavements failures. Improper design of pavements leads

to early failure of pavements affecting the riding quality.

The pavements can be classified based on the structural performance into

two, flexible pavements and rigid pavements. In flexible pavements. Wheel

loads are transferred by grain-to-grain contact of the aggregate through the

like a flexible sheet (e.g. bituminous road). On the contrary, in rigid

pavements, wheel loads are transferred to sub-grade soil by flexural strength

flexible pavement over rigid pavement is an ideal pavement with most

desirable characteristics. However, such pavements are rarely used in new

construction because of high cost and complex analysis required.

2.1 Flexible Pavements

grain-to-grain transfer through the points of contact in the granular

structure (see Figure).

S.K.D ENGINEERING COLLEGE

Load transfer in granular structure

2.2 Deflection on flexible pavement

distribution characteristic, flexible pavements normally has many layers.

Based on this, flexible pavement may be constructed in a number of layers

magnitude of stress and low quality material can be used. Flexible

pavements are constructed using bituminous materials. These can be either

in the form of surface treatments (such as bituminous surface treatments

(generally used on high volume roads such as national highways). Flexible

layer (e.g., if there is any undulation in sub-grade then it will be transferred

overall performance of flexible pavement, and the stresses produced should

be kept well below the allowable stresses of each pavement layer.

S.K.D ENGINEERING COLLEGE

2.3 Types of Flexible Pavements

The following types of constructiowhave been used in flexible pavement:

Conventional layered flexible pavement,

Full - depth asphalt pavement, and

Contained rock asphalt mat (CRAM).

2.3.1 Conventional flexible pavements are layered systems with high

quality cheap materials are placed in lower layers.

2.3.2 Full - depth asphalt pavements are constructed by placing

is high traffic and local materials are not available.

2.3.3 Contained rock asphalt mats are constructed by placing dense/open

compressive strain on soil sub-grade and protect from surface Waler.

2.4 Typical layers of a flexible pavement

Typical layers of a conventional flexible pavement includes seal coat, surface

compacted sub-grade, and natural sub- grade.

2.4.1 Seal Coat

provide skid resistance.

2.4.2 Tack Coat

Tack coat is a very light application of asphalt, usually asphalt emulsion

S.K.D ENGINEERING COLLEGE

2.4.3 Prime Coat

Prime coat is an application of low viscous cutback bitumen to an absorbent

surface like granular bases on which binder layer is placed. It provides

2.4.4 Surface course

contains superior quality materials. They are usually constructed with

It provides characteristics such as friction, smoothness, drainage, etc. Also

underlying base, sub-base and sub-grade,

and skid resistant riding surface,

weakening effect of water.

2.4.5 Binder course

as the surface course, so replacing a part of the surface course by the