CONSTRUCTION OF

BITUMINOUS ROADS
By
Girish Sharma
(Sr. Technical Officer)

Flexible Pavement Division

Central Road Research Institute
New Delhi
Highway construction specifications are
meant to achieve quality
Their objective is to provide the road user with an
adequate and economical pavement on which
vehicles can move easily and safely
A practical specification is one that is designed
to ensure adequate performance at minimum
cost; a realistic specification takes account of
variations in materials and construction that are
inevitable and characteristic of the best
construction possible today
 With this type of specification, the methods to be
used in constructing a section of pavement are
stated by the agency

If the contractor adheres to the methods

prescribed and adherence is verified by the
inspector, 100 percent payment to the contractor
is ensured

A major deficiency of method specifications is that

price adjustments for contractor non conformance
are often arbitrary and based solely on the
judgment of the agency inspector or engineer
 Thus the increased use of QC/QA specifications
signifies a shift in the burden of choosing the
proper construction methods and in the
responsibility for QC from the agency to the
contractor
The focus is on QC/QA under both types of
specifications
First, QC and QA are defined. Method
specifications and QC/QA specifications are then
reviewed in turn
It should be noted that within these two broad
classes of specifications there are many detailed
variations, depending on the owner, and that
most actual specifications combine features of
both types
METHOD SPECIFICATIONS

Method specifications were probably the most

widely used type of specification in highway
construction until the mid-1980s.
As noted earlier, with this type of specification,
the agency directs the contractor to use specific
methods, including materials, proportions, and
equipment. The placement process is also
explicitly defined, with each step being either
controlled or directed, and in some cases actually
performed by a representative of the agency
To illustrate, for HMA compaction, the agency
might tell the contractor what equipment to use,
when to roll, and how many passes to make with
each roller.
Method specifications have evolved with
experience and reflect a lack of quick acceptance
tests for assessing the quality of materials and
construction.
Day-to-day plant control and tests
Stockpile or cold-feed gradations
Hot-bin gradations (for batch plants)
Cold-feed adjustments
Hot-bin weight adjustments (for
batch plants)
Bitumen content tests
Gradation of aggregate in mix
Adjustments of mixing time and
temperature
Preparation of Marshall specimens
for applicable testing of
- Voids
- VMA
- VFA
- Density
- Flow (Marshall only)
- Stability
Field Control of Placement

QC must be exercised during placement and

monitored by individual tests and
measurements.
The success of QC during placement depends
on making corrections while the mix is hot
and when a problem can be actively
corrected.
One step in producing a quality product is to
construct a test strip at the start of the
project.
The following listing of placement controls
should be closely monitored by the
contractor:
Application of tack coat
Rate of HMA delivery
Paver speed
Paver adjustments
Grade control
Thickness control
 MAT DEFECTS
Segregation Bleeding
Rough Mat Non-uniform
Mat Tears Texture
Checking Screed Marks
Shoving Roller Marks
SEGREGATION
Separation of the Coarse and
Fine Aggregate Particles
Typical Loading Practice

Not recommended for segregation-

segregation-prone
mixes!
Sequence for Longer
End Dump Trucks

3
2 1
Sequence for Shorter
End Dump Trucks

2 1
End Dump Truck Operation

Raise bed, but keep tailgate closed

until mix slides against it
End Dump Truck Operation

Open gate and continue to raise bed

End Dump Truck Operation
Empty mix
in
one smooth,
continuous
discharge
End Dump Truck Operation

Lower bed before pulling away

RANDOM SEGREGATION
or ROCK POCKETS
LONGITUDINAL SEGREGATION
Centerline Segregation
LONGITUDINAL SEGREGATION
Side-To-Side Segregation
LONGITUDINAL SEGREGATION
One-Sided Segregation
TRANSVERSE SEGREGATION
Truck-To-Truck Segregation
 ROCK POCKETS
Improper Handling of Aggregates
Random Dumping of Wings at Paver
LONGITUDINAL SEGREGATION
Improper Loading of Haul Truck
Improper Transfer of Delivery of Mix into
the Silo
Improper Discharge of Mix from Batcher or
Silo to Truck
 TRUCK-TO-TRUCK
Segregation
Improper Loading of Haul Trucks
Continual Dumping of the Wings of the
Hopper
Depleting the Hopper between Trucks
MATERIAL TRANSFER
DEVICE
MTV/SHUTTLEBUGGY
 ROUGH MAT
Short Waves or Ripples
Long Waves
 FLOW GATE FLOW GATE

Gates too HIGH - augers overloaded

FLOW GATE
FLOW GATE

Gates too LOW - insufficient material supply

FLOW GATE FLOW GATE

Correct adjustment - uniform material volume flow

 MIX FACTORS RELATED
TO RIPPLES

Tender Mixes
Changes in Mix Temperature
Improper Operation of
Compaction Equipment
 CAUSES OF LONG
WAVES
Incorrectly set slat conveyor
Continually changing thickness
Sag in Stringline
Truck driver riding brakes
Bumping paver with truck
Changes in mix temperature
Improperly operating compaction
equipment
ROUGH MAT SOLUTION

Defect Cured only by Preventing

the Formation of the Waves
During Placement
DETERMINATION OF
CAUSES FOR LONG
WAVES

Observe the Placement and

Compaction Operations
 ROUGH MAT
Effects on Pavement Performance

Increases Dynamic Load on

Pavement Surface
More Variations (Non-uniform) in
Density Levels
Increased Roughness
MAT TEARS CAUSED BY:
Improper Paver Condition
Insufficient Mix Temperature
 TYPES OF MAT TEARS
Center Tears - Lack of lead crown in
paver screed or lack of mix at the
center of auger chamber
Edge Tears - Improper flow gate
settings or incorrect installation of
screed extensions
Full Width Tears - Paver operated too
fast, using warped or worn out screed
plates, insufficient mix temperatures,
use of tender mixes or mixes with
large aggregate
 MAT TEARS
Effects on Pavement Performance

Increase variability of air voids and

density
More susceptible to moisture
infiltration into mix
Increased potential for raveling
Less fatigue resistant
 CHECKING

Short transverse cracks spaced at 1 to 3

inches apart that develop after
compaction equipment passes over mat
Excessive deflections of
pavement under compaction
equipment
Deficiency in mix properties
High mix temperatures
 MIX PROPERTIES
RELATED TO CHECKING
Excess fluids in mix (asphalt and/or
water)
Excess middle size sand (hump in the
gradation curve)

Characteristic of Mix that is Susceptible

to Checking - Mix Shoves under Roller
CURES FOR CHECKING

A wrong cure is to delay

breakdown rolling

A proper cure is to change the

mix characteristics
 Density control
Temperature of air and mixture
Roller type
Rolling pattern and coverage
Roller speed
Control of yield thickness
Control of smoothness
 BITUMINOUS PAVEMENT
CONSTRUCTION
Bituminous construction are classified
into four categories

Interface Treatments
Thin Bituminous Surfacing
Bituminous Surface Courses
Bituminous Binder Courses
 INTERFACE TREATMENTS

Prime Coat
Tack Coat
Crack Prevention Courses
Stress Absorbing Membrane (SAM)
Stress Absorbing Membrane Interface
(SAMI)
INTERFACE TREATMENTS
 PURPOSE OF PRIMING

To plug the capillary voids

To coat and bond loose materials on
the surface
To harden or toughen the surface
To promote adhesion between
granular and the bituminous layer
 REQUIREMENT FOR PRIMING
MATERIAL
Porosity Type of Viscosity at Quantity
Surface 600 C per 10 m2
(centistokes) (Kg)
Low WMM, 30-60 6-9
WBM
Medium Gravel 70-140 9-12
base
High Stabilised 250-500 12-15
base
 TACK COAT

Purpose of Tack Coat:

To ensure a bond between the new
construction and the old surface
Use of Cutback:
It should be restricted for sites at
subzero temperatures or for
emergency applications
 RECOMMENDED QUANTITIES
OF MATERIAL FOR TACK COAT
Type of Surface Quantity in kg
per m2 area
Bituminous Surface 0.20 to 0.25
Dry and hungry bituminous 0.25 to 0.30
surfaces
Primed granular surface 0.25 to 0.30

Cement concrete pavement 0.30 to 0.35

WRONG PRACTICE OF TACK COAT
CRACK PREVENTION COURSES
Stress Absorbing Membrane (SAM)
is an elastomeric bitumen-rubber
membrane, which is laid over a
cracked road surface, together with
a covering of aggregate chips
It can be laid as a single coat or a
double coat.

Contd..
CRACK PREVENTION COURSES
Stress Absorbing Membrane
Interface (SAMI)
It may be a material similar to SAM
It may consist of bitumen-
impregnated geo-textiles
MATERIALS REQUIRED FOR 10 m2 FOR
STRESS ABSORBING MEMBRANE
Type and width of crack Specification of SAM Quantity Quantity of
to be applied of binder chipping
kg/10 m2

Hair cracks and map Single coat SAM or 8-10 0.10 cum of
cracks up to 3 mm width 2nd coat of two coat 5.6 mm chips
SAM
Map cracks or alligator Single coat SAM 10-12 0.11 cum of
cracks 3 mm to 6 mm 5.6 mm chips
width
Map cracks or alligator Two coat SAM 0.12 cum of
cracks 6 mm to 9 mm 1st coat 12-14 5.6 mm and
width 2nd coat 8-10 11.2 mm
chips in 1:1
ratio

Contd..
 Materials Required for 10 m2 for
Stress Absorbing Membrane
Type and width of crack Specification of SAM Quantity Quantity of
to be applied of binder chipping
kg/10 m2

Cracks above 9 mm width Two coat SAM

and cracked area above 50 1st coat 14-16 0.12 cum of
per cent 11.2 mm chips
2nd coat 8-10 0.10 cum of 5.6
mm chips
All types of cracks with Single Coat SAM 8-10 0.1 cum of 5.6
crack width below 6 mm mm chips
All types of cracks with Single Coat SAM 10-12 0.10 cum of
width above 6 mm 11.2 mm chips
BITUMINOUS SURFACE DRESSING
(BSD)
BSD is provided over an existing bituminous
or granular surface to serve as thin wearing
coat. This may be one coat or two coats.

The main functions of BSD are:

To serve as a thin wearing course of
pavement
To prevent infiltration of surface water
To provide dust free pavement surface
 QUANTITIES OF AGGREGATE AND
BINDER PER 10 m2

Type of Normal Specification Quantity of Quantity of

construction Size of of Aggregate Aggregate Bitumen /
Chipping (mm) (Cum/10sqm) (Emulsion)
(mm) kg/10m2
First coat 19 19.0-13.2 0.10 10 (11*)

Second coat 13 13.2-9.5 0.08 9 (18*)

* Quantity of emulsion per 10 m2 area, where

emulsion is used
 GRADING REQUIREMENTS FOR
BSD
IS Sieve Cumulative % by wt. of total aggregate passing for
mm the following nominal sizes (mm)
19 13 10 6
26.5 100 - - -
19 85-100 100 - -
13.2 0-40 85-100 100 -
9.5 0-7 0-40 85-100 100
6.3 - 0-7 0-35 85-100
4.75 - - 0-10 -
3.35 - - - 0-35
2.36 0-2 0-2 0-2 0-10
0.6 - - - 0-2
0.075 0-1.5 0-1.5 0-1.5 0-1.5
SEAL COAT
A. Liquid Seal Coat: comprising of a layer of
binder followed by a cover of stone
chipping

B. Premixed Seal Coat: a thin application of fine

aggregates premixed with bituminous
binder

The quantity of bitumen shall be 9.8 kg and

6.8 kg per 10 m2 area for type A and type B
seal coat respectively
 CLOSELY GRADED PREMIX
CARPET/MIXED SEAL SURFACING
Close-graded premix carpet is a fairly
open graded mix

It is an alternative to the open graded

premix carpet and a seal coat

It may be constructed in one operation

AGGREGATE GRADATION FOR MSS

IS Sieve Cumulative % by wt. of total

mm aggregate passing
Type A Type B
13.2 - 100
11.2 100 88-100
5.6 52-88 31-52
2.8 14-38 5-25
0.09 0-5 0-5
QUANTITY OF AGGREGATES AND
BITUMEN
The total quantity of aggregates
used shall be 0.27 cum per 10 m2
area

The quantity of binder shall be

22.0 kg and 19.0 kg for 10m2 area for
Type A and Type B surfacing
respectively
BITUMINOUS SURFACE COURSES
EQUIPMENTS REQUIRED
MODERN PAVER
Bitumen Batch Mix Plant
SMOOTH WHEELED ROLLER
PNEUMATIC-TYRED ROLLER
BITUMINOUS CONCRETE (BC)
BC is a Dense Graded Bituminous
Mix used as Wearing Course for
Heavily Trafficked Roads

Stress
 BITUMINOUS CONCRETE (BC)
BC Mix consists of Coarse
Aggregates, Fine Aggregates, Filler
and Binder blended as per Marshall
Mix Design
 GRADING REQUIREMENTS OF BC
Sieve Size I II
mm 50-65 mm 30-45 mm
26.5 100 -
19 79-100 100
13.2 59-79 79-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 42-58
0.60 15-27 26-38
0.30 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content per cent 5.0-6.0 5.0 7.0
by mass of total mix
 BITUMINOUS CONCRETE (BC)
Quality control operations involved are:
Design of mix in laboratory, and
control of mixing, laying and
rolling temperatures
Density, Marshall Stability, Flow,
Air Voids, Retained Stability,
Bitumen Content, Gradation of
aggregates are controlled
Riding quality is a control
 Bituminous Concrete

Used as a wearing course for heavily

trafficked
highways
Composed of thoroughly compacted dense
graded bituminous mixture of very well
graded
coarse and fine aggregates with filler and
relatively higher amount of bitumen
compared
to DBM and SDBC
Construction in a single or multiple layers
 Bituminous Concrete
Design Requirement
Selection of gradation based on the
thickness of the layer
Ingredients of the mixture shall meet
their
respective physical requirements
Binder content shall be optimized
following the Marshall method of mix
design
Mixture at optimum binder content
shall
 DESIGN REQUIREMENTS FOR BC
Minimum Stability (kN at 60C) 9.0
Flow 2-4
Compaction Level (Number of blows) 75 on each face
Per cent air voids 3-6
Per cent voids in mineral aggregate VMA Table
(VMA)
Per cent voids filled with bitumen 65-75
(VFB)
Loss of stability on immersion in Minimum 75 %
water at 60C (ASTM D 1075)
 Bituminous Concrete
Critical Points During Construction
Initial rolling shall be carried out with static
roller
and followed by intermediate rolling with
vibratory
roller and final rolling shall be with static
roller or
vibratory roller with no vibration
Roller speeds are kept low to avoid surface
distress like rippling as the combination of
high
frequency and low speed results in low
impact
spacing
Rolling shall be completed in all respects until
the
 SEMI DENSE BITUMINOUS
CONCRETE (SDBC)
Wearing course on roads carrying
moderate traffic, generally less than
10 msa
Lesser binder content when
compared to BC
 Semi Dense Bituminous Concrete

Used as a wearing course on roads carrying

lower
traffic
It is variant of BC, the difference being a
lower
binder content and the aggregate used being
less
dense graded
Construction in a single or multiple layers on a
previously prepared bituminous bound surface
Single layers shall be 25mm to 40mm in
THE GRADING REQUIREMENTS OF SDBC
Grading I II
Nominal Aggregate Size 13.2 mm 10 mm
Layer Thickness 35-40 mm 25-30
mm
IS Sieve (mm) Per cent Passing
19.0 100 -
13.2 90-100 100
9.5 70-90 90-100
4.75 35-51 35-51
2.36 24-39 24-39
1.18 15-30 15-30
0.6 - -
0.30 9-19 9-19
0.15 - -
0.075 3-8 3-8
Bitumen content per cent by wt of total Min 4.5 Min 5.0
mix
 Semi Dense Bituminous Concrete

Work shall be carried as per section 508 of

MORTH specifications for Road and Bridge
Works or IRC :95-1987
Design requirements of the mix are similar
to
BC except that the requirement of minimum
stability is less as compared to BC
Construction and quality control
requirements
are same as described in BC
 DESIGN REQUIREMENTS FOR SDBC

Minimum Stability (kN at 60C), 8.2

Flow 2-4
Compaction level (Number of blows) 75 on each
face
Per cent air voids 3-5
Per cent voids in mineral aggregate VMA Table
(VMA)
Per cent voids filled with bitumen 65-78
(VFB)
Loss of stability on immersion in Minimum 75 %
water at 60C (ASTM D 1075)
 COMPACTION OF BITUMINOUS
MIXES

Lack of adequate compaction in field

leads to reduce pavement life

Inadequate compaction of hot mix

leads to early oxidation, ravelling,
cracking and disintegration before its
life expectancy is achieved
 COMPACTION OF MIXES
contd
Lack of attention to the air voids
requirement of compacted dense graded
bituminous mixes is the most common
cause of poor pavement performance

Laboratory compaction produces more

density, hence 95-98% of laboratory
density or 92% of theoretical density is
preferred in the field
BITUMINOUS BINDER COURSE
 BUILT-UP SPRAY GROUT

Two Layer Composite Construction

of Compacted Coarse Aggregates
Application of Binder after each
layer
Key aggregates on top of each
layer
Thickness = 75 mm
Single Course in Pavement Structure
 BUILT-UP SPRAY GROUT
IS SIEVE CUM % PASSING
(mm) COARSE KEY
53 100 -
26.5 40-75 -
22.4 - 100
13.2 0-20 40-75
5.6 - 0-20
2.8 0-5 0-5
 BUILT-UP SPRAY GROUT

Preparation of Base to the Required

Camber and Shape
Application of Primer
Application of Tack Coat
Spreading and Rolling First Layer of
Coarse Aggregates (0.5 cu.m/10 sq.m)
Application of Binder - First Spray
(15 kg/10 sq.m)
 BUILT-UP SPRAY GROUT

Spreading and Rolling of Coarse

Aggregates for the Second Layer
Application of Binder - Second Spray (15
kg/10 sq.m)
Application of Key Aggregates (0.13
cu.m/10 sq.m)
Roll and Apply Additional key
aggregates, if required
Cover with a Seal Coat before opening to
Traffic
 BITUMINOUS MACADAM (BM)
BM is carried out in a Hot Mix
Plant, laid and compacted
mechanically
There are two sets of grading,
Grade I & II
Quality control measures involves
percentage of Bitumen & Mixing,
Laying and Compaction temperature
GRADATION REQUIREMENTS FOR BM
Grading I II
Nominal 40 mm 19 mm
Layer Thickness 75-100 mm 50-75 mm
IS Sieve (mm) Per cent Passing
45.0 100 --
37.5 90-100 --
26.5 75-100 100
19.0 -- 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.300 2-10 2-10
0.075 0-8 0-8
Bitumen, per cent by 3.1 to 3.4 3.3 to 3.5
weight of mix
Bitumen Grade S 35-90 S 35-90
DENSE BITUMINOUS MACADAM (DBM)
DBM is Closely Graded
DBM is used as a Binder Course for
pavements subjected to heavy
traffic
Hydrated Lime or Cement shall be
used as filler, if the mix fails to
meet the water sensitivity
requirement
 PHYSICAL REQUIREMENTS OF
COARSE AGGREGATES FOR DBM
Test Test Method Requirement
Los Angeles Abrasion Value* IS: 2386 (Part-4) 35 % Max
Aggregate Impact Value * IS: 2386 (Part-4) 27 % Max
Flakiness and Elongation IS: 2386 (Part-1) 30 % Max
Indices (Total)
Coating and Stripping of IS: 6241 Min Retained
Bitumen Aggregate Mixture Coating 95%
Soundness IS: 2386 (Part-5)
Loss with Sodium Sulphate 5 Cycle 12 % Max
Loss with Magnesium sulphate 5 Cycle 18 % Max
Water Absorption IS: 2386 (Part-3) 2 % Max
Retained Tensile Strength AASHTO T283 Min 80 %

* Either of the two is required

GRADATION REQUIREMENTS FOR DBM
Grading I II
Nominal Aggregate Size 40 mm 25 mm
Layer Thickness 75-100 mm 50-75 mm
IS Sieve (mm) Percent Passing
45.0 100 -
37.5 95-100 100
26.5 63-93 90-100
19.0 - 71-95
13.2 55-75 56-80
9.5 - -
4.75 38-54 38-54
2.36 28-42 28-42
1.18 - -
0.6 - -
0.30 7-21 7-21
0.15 - -
0.075 2-8 2-8
Bitumen content per cent by wt of total mix Min 4.0 Min 4.5
Bitumen Grade S 65-90 S 65-90
 DESIGN REQUIREMENTS FOR DBM
Minimum Stability (kN at 60C) 9.0

Flow 2-4

Compaction Level (Number of blows) 75 on each face

Per cent air voids 3-6

Per cent voids in mineral aggregate VMA Table

(VMA)

Per cent voids filled with bitumen 65-75

(VFB)
 TEMPERATURE

Grade Bitumen Agg. Mix Laying Rolling

65 150 - 165 150 - 170 165 Max 125 Min 90 Min

90 140 - 160 140 - 165 155 Max 115 Min 80 Min

CORE CUTTING IN PROGRESS
CORE SAMPLES OF SDBC FOR TESTING
 High Performance Mix
(Stone Mastic Asphalt, Porous Asphalt & warm
mixes)

101
 Conventional Dense Asphalt Mix
General Failure
Observed is Rutting
due to Heavy Wheel
Loads Plying on the
Road

Use of mixes which

can resists rutting
due to heavy wheel
loads is the only
option

Rutting Observed on the Wheel Path due to Heavy Wheel Load

Stone Matrix Asphalt (SMA) is one such Rut Resistant Asphalt Mix

102
STONE MATRIX ASPHALT (SMA)

SMA is a gap graded aggregate

asphalt mix that maximizes the
asphalt cement content and coarse
aggregate fraction
SMA provides a stable stone on
stone skeleton that is held together
by a rich mixture or asphalt cement,
filler and stabilizing additive
103
COMPONENTS OF SMA

104
COMPARISON OF SMA AND DENSE GRADED
MIXES

Dense Graded Mix

SMA Mix 105
COMPARISON OF SMA AND DENSE GRADED
MIXES

106
 Cellulose/Jute/Polymer FIBRES
Retards Drain Down of Binder

Commercially
Available Cellulose
Fibres
107
 Function of FIBRES in SMA

Fibres helps in forming a

matrix to hold the high 108
binder in SMA
 Characteristics Properties

High content of chippings High stability

(temperature independent)

Bitumen: Supporting the stability

modified Bitumen

Thick Bitumen-/ Better aging behavior

mortarcoatings

Stabilising additives Prevention of the draindown of

(Cellulose Fibres) the Bitumen during
transportation 109
 Testing of Aggregate
Test Description` Test Method
Bulk Specific Gravity
(i) 13.0mm IS:2386 (Part 4)
(ii) 10mm
(iii) Stone Dust
(iv) Lime
Aggregate Impact Value , % IS:2386 (Part 4)

Flakiness and Elongation Index, IS:2386 (Part 1)

%
Water Absorption, % IS:2386 (Part 3)

Soundness, % IS:2386 (Part 5)

Sodium Sulphate
Magnesium Sulphate
Stripping, % IS:6241 110
Specification of SMA by IRC SP:79-2008
SMA Designation Wearing Course Binder(Intermediate
) Course
Nominal Aggregate 13mm 19mm
Size
Nominal Layer 40-50mm 45-75mm
Thickness
Sieve Size,mm % Passing % Passing
26.5 - 100
19 100 90-100
13.2 90-100 45-70
9.5 50-75 25-60
4.75 20-28 20-28
2.36 16-24 16-24
1.18 13-21 13-21
0.600 12-18 12-18
111
0.300 10-20 10-20
 SPECIFIED GRADATION FOR BC
Mix Designation Grading 1 Grading 2
Nominal Aggregate Size 19 mm 13 mm
Layer Thickness 50 65 mm 30 45 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
26.5 100 -
19 79 100 100
13.2 59 79 79 100
9.5 52 72 70 88
4.75 35 55 53 71
2.36 28 44 42 58
1.18 20 34 34 48
0.6 15 27 26 - 38
0.3 10 20 18 28
0.15 5 13 12 20
0.075 2-8 4 10
Bitumen Content, % by 5.0 6.0 5.0 7.0
weight of total mixture
 SMA MIX REQUIREMENTS
S.NO PROPERTIES LIMITS

1. Air Voids Content, Percent 4.0 Min.

2. Bitumen Content, % 5.8 Min

3. Voids in coarse aggregate in total Less than VCA,

Mix VCA, mix per cent (dry rodded)

4. Voids in Mineral Aggregate (VMA) 17 Min.

5. Tensile Strength Ratio (TSR) 85 Min.

percent

6. Asphalt Draindown @ production

0.3 Max.
temperature percent 113
 Gradation of Aggregate
Sieve 13.2 mm 10.0 mm Stone Lime Gradation Limits
Size Dust Adopted
(mm)
Percent 31 45 15 9
19 100 100 100 100 100 100
13.2 70 100 100 100 91 90-100
9.5 2 88 100 100 64 50-75
4.75 0 12 84 100 27 20-28
2.36 0 3 66 100 20 16-24
1.18 0 0 52 100 17 13-21
0.600 0 0 27 100 14 12-18.
0.300 0 0 25 100 13 10-20.
0.075 0 0 8 84 9 8-12.
114
Gsb 2.640 2.639 2.638 2.800
 Preparation of Marshall/Rutting
Specimen

At various bitumen content, (5.5, 6.0,

6.5 and 7.0%)
Compactive Effort (50 Blows on each
face of the specimen)
Preparation of Rutting Slab for Hamburg
Wheel Tracking Test
115
 Laboratory Testing

Asphalt Drain Down Test

Volumetric Analysis
Indirect Tensile Strength Test
Creep Test
Wheel Tracking Test
Tensile Strength Ratio Test

116
 Volumetric Properties
VCAdrc = ((Gcaw-s)/Gcaw)100 .
Where,
VCAdrc=voids in coarse aggregates in dry rodded condition
s=unit weight of the coarse aggregate fraction in the dry
rodded condition (kg/m---3),
w=unit weight of water (998kg/m3), and
Gca =bulk specific gravity of the coarse aggregate
Va=100 (1-Gmb/Gmm)
VCAmix=100-((Gmb/Gca)Pca),
VMA=100-((Gmb/Gsb)Ps),
Where,
Ps= percent of aggregate in the mixture,
Pca= percent of coarse aggregate in mix by weight of total mix,
Gmm= theoretical maximum specific gravity of mix,
Gmb= bulk specific gravity of mix,
Gsb= bulk specific gravity of the total aggregate,
Gca= bulk specific gravity of the coarse aggregate 117
 Volumetric Properties Contd..
Type of Binder
Binder Content (%) Density(gm. Vca Mix VCA drc
Voids (%) VMA (%)
cc) (%) (%)

5.50 2.312 36.04 5.40 17.78

6.00 2.327 35.63 4.14 17.86
PMB-40 39.52
6.50 2.343 35.18 2.83 17.47
7.00 2.328 35.61 2.83 18.45
5.50 2.297 36.20 6.03 18.24

60/70 with 6.00 2.335 35.74 3.85 17.35

39.52
Topcel 6.50 2.326 35.94 3.58 18.10
7.00 2.316 36.14 3.34 18.87
5.50 2.303 36.20 5.79 18.03

60/70 with 6.00 2.338 35.74 3.72 17.24

39.52
Genicel 6.50 2.324 35.94 3.66 18.17
118
7.00 2.315 36.14 3.38 18.91
Indirect Tensile Strength Test

119
Properties Studied for Laboratory Performance
of PMB
1) Indirect Tensile Strength Test

St =2 p / d t Conditioned Specimens

Dry Specimens

2) Moisture Susceptibility

Tensile strength ratio which is

the ratio of un-
un-soaked tensile
strength to soaked tensile
strength
Creep Testing Machine

121
 Wheel
Tracking Test
Equipment
Rutting Characteristics
The test involves determining the rut depth of the mix
using Hamburg wheel tracking device

Slabs after Testing for Rutting

 Porous Asphalt
OPEN-
OPEN-GRADED FRICTION COURSES
(OGFC)
are thin, permeable asphalt
mix that increases pavement
friction, particularly in wet
weather..
weather With extremely
permeable voids (18 18-
-22
22%
%),
acts as good drainage
layer
layer ..
..

124
 .Criteria for use
Where not to Use ?

Roads that are frequently soiled

Low-volume or slow traffic roads

Areas where the pavement subjected to very

high tangential loads

As a overlay in Tunnel Roads, to drain out

seepage water

Urban Arterials, to reduce noise

 TERMINOLOGY
Porous Asphalt : in UK, South Africa
Flusterasphalt (whispering) : Germany
Drainasphalt : France
Popcorn Mix : some states of USA
 Cross Sectional View

Porous bituminous pavement Dense grade pavement

Rainwater Rainwater

Bituminous
wearing
course

Bituminous
base

Design percentage of air

voids

20%
Schematic Diagram Describing Porous
Asphalt
 Texture of Porous Asphalt
Surface Immediately
after Construction

View Showing Pouring of

Water on Porous Asphalt
Surface Immediately after
Construction
 Features of Porous Asphalt Mixtures

Mixtures with 20 percentage air void

Materials
uniform grading of aggregates with 50 to 60 %
of the aggregates particles of the same size
Limited amount of fines and filler (filler
content between 2 to 5 percent)
Asphalt content of the mixtures slightly
higher than that of dense graded mixtures
 Characteristics Properties

High content of chippings High stability (Temperature

Independent)

Bitumen: Modified Bitumen

Supporting the Stability

Thick Bitumen/ Mortar Better Aging Behavior

Coatings

Prevention of the Drainage of

Stabilising Additivs
the Bitumen of the Mix During
(Fibers/DAMA)
transportation from Batch Mix
Plant to the Construction Site
 FIBERS
Fibers mixed in asphalt mixtures
New experience in India
Fibers prevent drain down which occurs during
mixing, transportation and paving operations
What are the effects of texture on ...

Surface friction
Safety
Roadside noise
Rolling resistance
Splash and spray
Spray on a
Dense
Graded Mix

Spray on an Open
Graded Friction
Course Mix
Visibility of Porous Asphalt Surface During
Rains

BC Road surface reflection during

Rains

Porous Asphalt Road surface

reflection during Rains
 Noise Walls
Effective only for those in line-of-sight.

Does not reduce noise a

source.
 Noise Reduction
Open vs Dense Graded Mixes
Sound Pressure, dB(A)

12mm Dense
82
12mm Dense
80
12mm Porous
78
8mm Porous
76 18-22% voids

74 8mm Porous
>22% voids
0 2 4 6
Age, in years
Source: NCHRP 284
 Experience in India
In abroad (Europe, Korea, Japan and
South Africa) the Atmospheric
Temperature is Approximately 27oC and
Pavement Temperature is 35 oC
In India, Porous Asphalt has been laid in
Delhi at Dhaula Kuan (NH-8). The outer
lane of the test section is no longer a
permeable layer as compared to Inner
Lanes
This has happened due to high pavement
temperature (57oC) and more dust in the
 Aggregate Gradation
Percent Passing
IS Sieve Size
South Adopted
US
Africa for India
19.0mm
(3/4 inch)
- 100 100
13.2mm
(1/2 inch)
100 95-100 95-100
9.5mm
(3/8 inch)
95-100 40-60 40-60
4.75mm
(No. 4)
30-50 10-26 10-20
2.36mm
(No. 8)
5-15 9-20 5-15
0.075m
(No. 200)
2-5 3-5 2-5
 Gradation Chart
100
South African-LowerLlimit
90
South African Upper Limit
80
Georgia-DOT-Upper Limit
70
P e r c e n t P a s s in g

60 Georgia-DOT-Lower Limit

50

40

30

20

10

0
19 12.5 9.5 4.75 2.36 0.075

S ie v e S iz e , m m
 Gradation of Aggregate
Sieve Size 13.2 mm 10.0 mm Stone Lime Gradation Limits
(mm) Dust Adopted

Percent
43 43 12 2 100

19 43 43 12 100 100 100

100
13.2 38 43 12 95 95-100
100
9.5 1 38 12 53 40-60
100
4.75 0 5 12 19 10-26.
100
2.36 0 2 10 14 9-20.
0.075 0 0 1 84 3 3-5.
Gsb 2.640 2.639 2.638 2.800
MIXTURE DESIGN
 Mix Design Criteria for the OGFCs

Maximum Draindown 0.3 percent of total mass of

the mix
Abrasion Loss in Cantabro Test 25 percent (Max.)
(Unaged) 30 percent (Max.)
Abrasion Loss in Cantabro Test (aged) 18 - 22 percent
Per cent air voids 30 40 percent
Per cent voids in coarse aggregate 28 32 percent
(VCA) 30 45 percent
Per cent voids in mineral aggregate 400 -750 l/day.
(VMA) 0.425 0.70 mm/sec.
Per cent voids filled with bitumen (VFB) 50 blows on only one face
Permeability : Water discharge rate of the specimen
 Optimum Binder Content
Abrasion Loss Air Voids

30.0 Min. 2 21.5

Min. 1
(abrasion) (Optimum) Max. 2
(draindown) 21.0
25.0
Max. 1
20.5
(voids)
20.0
Abrasion Loss, %

20.0

Air Voids, %
15.0 19.5

19.0
10.0
18.5
5.0
18.0

0.0 17.5
4.5 5.0 Binder Content, % 5.5 6.0
 TESTS ON OGFC

Sample before Cantabro

Abrasion Test

Cantabro Abrasion Test

Sample after Cantabro

Abrasion Test
Cantabro Abrasion Test Results of the OGFC-Mixes

Cantabro Abrasion Loss (%) of Unaged

Binder Type Specimens*,
at the Binder content

3.5% 3.8% 4.1% 4.4%

CRMB-60 89.68 79.24 55.09 36.25

CRMB-70 86.9 75.67 56.2 54.5

CRMB-80 26.1 58.41 47.17 29.33

Permeability Test
 Permeability Co-efficient of the OGFC-Mixes

Permeability Property of the OGFC

Mixes,
Binder Type Units***
at the Binder content -
3.5% 3.8% 4.1% 4.4%
t, sec 2.46 2.97 3.59 4.1
CRMB-60 L/Day 2326 1926 1594 1396
CRMB-70 t, sec 2.94 3.21 3.91 5.38
L/Day 1946 1783 1463 1063
t, sec 3.87 6.35 7.1 40
CRMB-80
L/Day 1478 9012 80806 476
EXPERIMENTAL
WORK

TESTS ON AGGREGATES
PHASE I
TESTING OF
MATERIALS TESTS ON BITUMEN

Bitumen Percentages
PHASE II Mix of Bitumen,
Aggregates, Filler and Filler Percentages
MIX DESIGN
Fibres

Voids Percentages

PHAE III HAMBURG WHEEL TRACKING TEST

PERFORMANCE TESTS
ON DESIGNED MIX

PERMEABILITY TEST

SKID RESISTANCE TEST

 Wheel
Tracking Test
Equipment
Creep Testing Machine
Indirect Tensile Strength Test Equipment
Permeability Test
Indirect Tensile Strength Test
 Indirect Tensile Strength Test
Indirect
Type of Binder Load in Dia in cm Height in Tensile
Binder Content Kg cm Strength in
(%) kg/cm2
CRMB 60 5.1 542 10 7.5 4.6

CRMB 70 5.2 705 10 7.5 5.99

CRMB 80 5.3 837 10 7.6 7.11

8.00
7.00
6.00
ITS (kg)

5.00
4.00
3.00 Series1
2.00
1.00
0.00
CRMB 60 CRMB 70 CRMB 80
Type of Binder
British Pendulum