HighwayConstruction&Maintenance

Lecture II

Contents

ConstructionofEarthRoads
ConstructionofWaterBoundMacadamRoads
BituminousPavements
BituminousConstructionProcedures
CementConcretePavements

ConstructionofEarthRoads
Cheapesttypeofroadfromnaturalsoil
Dependsontypeofsoilavailableatsite
Steepcamber 1in20to1in33
MaximumCrossslope 1in20
3

MaterialSpecifications
Base Course

Wearing Course

ClayContent

<5%

10%18%

SiltContent

9% 32%

5% 15%

SandContent

60% 80%

65% 80%

LiquidLimit

<35%

<35%

PlasticityIndex

<6 %

4% 10%

ConstructionProcedure
Material
Location FixingC/L
SubgradePreparation

SiteClearing
Excavationandconstructionoffills
Shapingthesubgrade
PavementConstruction mixedsoilisspreadout
inlayersandcompactedwithcompactedthickness
notexceeding10cm.

Desirabletohaveatleast95%DryDensity

OpeningtoTraffic
5

ConstructionofWaterBound
MacadamRoads
Macadam pavementbasecoursemadeof
crushedorbrokenaggregatemechanically
interlockedbyrollingandvoidsfilledwith
screeningandbindingmaterialwiththe
assistanceofwater
Maybeusedassubbase,basecourseor
surfacingcourse
Thicknessofeachlayer 10to7.5cmdepending
onsizeandgradationofaggregatesused
6

MaterialSpecifications
CoarseAggregates crushedaggregatesor
brokenstones
Shouldbehard,durable,acceptableshape,
freefromflakyandelongatedparticles
Property

Requirements forPavementlayer
Subbase

BaseCourse

SurfaceCourse

LosAngelesAbrasion
value(%)

60

50

40

AggregateImpact
value(%)

50

40

30

15

15

FlakinessIndex(%)

MaterialSpecifications
Screenings
Usedtofillupthevoidsincompactedlayerof
coarseaggregates
Consistofsmallsizedcoarseaggregates
Nonplasticmaterialslikekankar,moorumetc
LL<20%,PI<6%&Proportionoffinespassing
0.075mm<10%

MaterialSpecifications
BindingMaterial
Usedtopreventravellingofstone
Finegrainedmaterial kankar nodules,limedust
PI 4%9%inWBMsurfacecourseconstruction
&<6% WBMlayersasbasecourseandsubbase
course

ConstructionProcedure
Preparationoffoundationforreceivingthe
WBMcourse
Maybeeithersubgradeorbaseorsubbase
course
Ifexistingsurfaceisabituminoussurface,furrows
ofdepth50mmandwidth50mmarecutat1m
intervalsandat450 toCLbeforelayingcoarse
aggregate

10

 ProvisionofLateralConfinement
Donebyconstructingtheshouldersforathickness
equaltothatofWBMlayerandtrimmingtheinner
sidesvertically

SpreadingofCoarseAggregates
WBMcourse compactedthicknessof7.5cm

Rolling
Compaction rollers startingfromedges
andthenshiftedtothecentre

11

 ApplicationofScreenings
Dryrolling

SprinklingandGrouting
Waterissprinkled,sweptandrolled
Additionalscreeningstillcoarseaggregatesarewell
bondedandfirmlyset

ApplicationofBindingMaterial
intwoormoresuccessivelayers
surfaceissprinkledwithwaterandrollingisdone

SettingandDrying
12

BituminousPavements
Pavementlayers WearingCourse
Types
InterfaceTreatments primecoat&tackcoat
SurfaceDressingandSealCoat
Groutedorpenetrationtypeconstructions
penetrationmacadam,Built upSpraygrout
Premix Bituminousboundmacadam,carpet,
BituminousConcrete,SheetAsphaltorrolled
asphalt,MasticAsphalt
13

InterfaceTreatment
Thinlayerofbituminousbinder toprovide
bondbetweenoldandnewlayers
PrimeCoat
Firstapplicationoflowviscosityliquidbituminous
materialoveranexistingporousoradsorbent
pavementmateriallikeWBMbasecourse
Objectiveistoplugthecapillaryvoidsandbond
loosematerialusingabinderoflowviscosity
Allowedtocureforatleast24hours
14

 TackCoat
Applicationofbituminousmaterialoveran
existingpavementsurfacethatisrelatively
impervious
Promotesbondbetweenoldandnewsurface
Binderdoesnotpenetrateintothelayer&
remainsatthesurface

15

BituminousSurfaceDressing(BSD)
Thinfilmofbituminousbinderissprayedon
theroadsurfacecoveredbyacoatofmineral
aggregatesandrolled
Functions
Thinwearingcourseofpavementandprotect
basecourse
Waterproofthepavementsurfaceandprevent
surfacewaterinfiltration
Providedustfreesurfaceindryweatherandmud
freesurfaceinwetweather
16

SealCoat
Topcoatoverperviousbituminouspavements
suchaspremixedcarpetandgrouted
macadam
Thinsurfacetreatmentorsinglecoatdressing
appliedoveranexistingblacktopsurface
Functions
Sealsurfacingagainstwateringress
Developskidresistanttexture

17

Built upSprayGrout(BUSG)
Twolayercompositionofcompactedcrushed
aggregatesandapplicationofbinderafter
eachlayerforbondingandfinishedwith
aggregatesatthetop
TotalThickness 75mm
Suitableforstrengtheningofexisting
bituminouspavements
Wearingcourseisprovidedoverthislayer
18

PenetrationMacadam
Usedasbinderorbasecourse
Coarseaggregatesarespreadandcompacted
andthenhotbituminousbinderofhigh
viscosityisspreadatthetop
Bitumenpenetratesthevoidsandbindsthe
aggregatestogether
19

Premixmethods
Aggregatesandbinderaremixedbefore
spreadingandcompacting
Classifiedbasedongradationofaggregates
chosenas
OpenGraded
Semidenseanddensemixes

Commontypesare
BituminousMacadam
BituminousCarpet
BituminousConcrete
20

BituminousMacadam
Consistofoneormorecoursesofcompacted
aggregatespremixedwithbinder,laid
immediatelyaftermixing
Laidincompactedthicknessesof75mmor50
mm
Essentiallyabasecourseorbindercourseand
shouldhavesurfacing
Superiortootherbasecoursematerialsw.r.t
loaddispersionanddurability
21

BituminousPremixedCarpet
Coarseaggregatesof12.5mmand10mmsize
premixedwithbinderandcompactedto
thicknessof20mmtoserveasabasecourse
Shouldbecoveredbyasealcoat
Semidensecarpet Wellgradedaggregateis
usedforconstructionofbituminouscarpetof
thickness20or25mm

22

BituminousConcreteorAsphaltic
Concrete
Densegradedpremixedbituminousmixthatis
wellcompactedtoformapavementsurface
course
Mixtureofcoarseaggregates,fillerandfine
aggregates
Thickness 4075mm
IRCspecification 40mmthickACsurface
courseforhighwaypavements
23

SheetAsphalt
Densesand bitumenpremixusedas
wearingcourse compactedthicknessof
25mm
Wellgradedcoarsetofinesandwithout
coarseaggregatesandbitumen
Laidovercementconcretepavement
Protectsjointsandhelpsinreductionin
warpingstresses
24

MasticAsphalt
Mixtureofbitumen,fineaggregatesandfiller
Whencooledresultsinahard,stableand
durablelayerthatwithstandsheavytraffic
Absorbsvibrations
Suitablesurfacingmaterialforbridgedeck
slabs
25

BituminousConstruction
Procedures

SurfaceDressing
GroutedorPenetrationMacadam
Built upSprayGrout
BitumenboundMacadam
BituminousCarpet
BituminousConcrete

26

SurfaceDressing(BSD)
Doneineithersinglecoatorintwocoatsover
anexistingpavementforrenewalorasa
wearingcourseoveraWBMroad
Bitumengrades 80/100

27

 ConstructionSteps
SurfacePreparation
Applicationofbinder
Applicationofstonechippings
Rollingoffirstorfinalcoat
Applicationofbinderandstonechippingsfor
secondcoat
Rollingofsecondcoat
Finishingandopeningtotraffic after24hours

28

BituminousConcreteConstruction
Properdesignofmixes essential
Densegradingofcoarseaggregates,fine
aggregatesandmineralfilletcoatedwith
bitumenbinder
Preparedinahotmixplant
Thicknessdependsontrafficandqualityof
basecourse

29

 ConstructionSteps
Preparationofexistingbasecourselayer
Applicationoftackcoat 6 7.5kgofbitumenper
10m2 area
Preparationandplacingofpremix
Bitumenheatedto1500 C 1770C&aggregate
temperatureshouldnotdifferbyover140Cfrombinder
temperature
Spreadatatemperatureof1210C1630C
30

 Rolling Initial 812troller&intermediate

1530t;final 812troller
QualityControl Bitumengrade,temperatureof
aggregate,temperatureduringmixingand
compaction
MarshallTestsconducted
1sampleoutofevery100tofmixdischargedis
tested
Forevery100m2 ofcompactedsurface,onefield
densitytestisdone
Variationinthickness 6mmper4.5mof
construction
Finishedsurface checkedforlongitudinal
undulations notgreaterthan8mm.
31

CementConcretePavements

Excellentridingsurface&pleasingappearance
Longerlife
Designonrationalbasis
Costsavingandexcellentperformance
Highinitialinvestment
Joints planesofweakness
Curingperiod necessary
32

ConstructionofCementConcrete
PavementSlab
Cementgroutedlayer
Rolledconcretelayer
CementConcreteslab

Suitableforbasecourse

Cementgroutedlayer
Opengradedaggregatemixwithaggregateshaving
maximumsize 1825mm dryrolled
Cementgroutisappliedonthesurface

RolledConcretelayer

Leanmixconcreteisused
33

MethodsofConstruction
AlternateBayMethod constructingabayorone
slabinalternatesuccessionleavingthenextto
immediatebaytofollowupafteragapofaweek
Advantages
Workingconvenienceforslablaying
Jointconstructioneasier
Disadvantages

Largeno.oftransversejointstobeprovided

Completediversionoftrafficnecessary

ContinuousBayMethod preferred
34

MaterialSpecifications
Cement OPCorRapidHardeningCement
Aggregates
Maxsizenotgreaterthanonefourthslabthickness
Gradationofcoarseaggregate 50to4.75mmor40to
4.75mmintwosizeranges,onebelowandtheother
above20mm
Crushingvalue 30%max
Impactvalue 30%max
LosAngelesAbrasionvalue 35%maxasperIRC
Fineaggregate naturalsandorcrushedstone

Concrete MinModulusofRuptureof40kg/cm2after28
daysofcuringorcompressivestrengthof280kg/cm2
35

Plants&Equipmentsrequired
ConcreteMixer&BatchingDevice
VibratingScreed

36

Plants&Equipmentsrequired

InternalVibrators
StraightEdge
Belt
FibreBrush
EdgingTool

37

ConstructionSteps
PreparationofSubgradeandSubbase
Uniformlycompactedsubgrade extending30cm
oneithersideofwidthtobeconcreted
Properlydrained
Minkvalueof5.54kg/cm2
Tobekeptinmoistcondition
Waterproofpapertobeplacedincaseconcreteis
placeddirectlyoversubgrade

38

 PlacingofForms
Steelorwoodenforms

BatchingofmaterialandMixing
TransportingandPlacingofconcrete
CompactionandFinishing
FloatingandStraightEdging
Belting,BroomingandEdging
Curing

39

ThankYou

40

References
HighwayEngineering,S.K.Khanna&C.E.G.
Justo,NemChand&Bros.,2001.
PrinciplesofTransportationEngineering,
ParthaChakraborty&Animeshdas,Prentice
HallofIndiaPrivateLtd,2003.
PavementDesignandMaterials,A.T.
Papagiannakis&E.A.Masad,JohnWiley&
Sons,2007
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