LARSEN & TOUBRO LIMITED ECC DVISION GMR HYDERABAD INTERNATIONAL AIRPORT PROJECT

Construction Quality Plan Bitumen Mastic for TFC Page 1 of 3

Work Procedure No WP B 32 METHODOLOGY OF CONSTRUCTION - BITUMEN MASTIC FOR TRAFFIC FORECOURT Scope:
The work shall consist of application of prime coat, cooking of bitumen mastic and laying of bitumen mastic of 6mm thick single layer as wearing coat course over Traffic Fore Court deck as per approved drawings or specifications.

Reference:
Clause 2702 of MoRT&H specifications

Materials:
Emulsion: Emulsion for prime coat shall confirm to IS8887: 2004 of Rapid Setting type RS-1. Bitumen: The bitumen shall be a penetration grade of 30/40 conforming to IS73. Mineral Filler: The filler shall be hydrated lime having more than 80% calcium content. It shall satisfy the gradation given below. IS sieve size (mm) 0.600 0.300 0.075 . Aggregate: The aggregate shall crushed stone; clean, hard, durable and free from soft, organic or other deleterious substances. The aggregate shall of size 4.75mm and down of crusher run or screenings or natural sand or a combination of both, having Soundness with Sodium Sulphate a maximum of 12%, and water absorption a maximum of 2%. The grading of aggregate inclusive of filler shall be as follows. IS sieve 4.75mm 2.36mm 600microns 300microns 75microns Mix: The bitumen content in the total mixture shall be 15% by the weight of total mixture with 68% of aggregate and 17% of hydrate lime so as to achieve a hardness number of 6-10 at 250C. % Of passing 90-100 75-100 45-80 15-50 0-30 Cumulative % of passing 100 95-100 70-100

Construction procedure:
Hydrated lime is heated in a mechanically agitated mastic cooker up to 170-2100C. The mastic cooker consists of 6 side pockets for heating the fine and coarse aggregates, central compartment for heating bitumen and main compartment for the mix. To the heated hydrated lime half the quantity of heated bitumen (1601700C) is added and mixed thoroughly and cooked for an hour. Then the heated aggregate and the remaining bitumen is added to the mixture and heated to 170-2000C and cooked for three hour.. At no time the contents in the mixture shall cross 2100C. The surface to be coated shall be thoroughly swept clean, free from dust and other deleterious matter. Prime coat with emulsion shall be applied at a rate of 3.5kg per 10sqm at least two hours before the commencement of laying bitumen mastic. To receive the mastic asphalt, angles or wooden strips can be provided to the required thickness. The bitumen mastic shall be transported by wheelbarrows or by pans to the laying area. Hydrated lime may be sprinkled inside the wheelbarrows / pans to avoid sticking of the bitumen mastic. The bitumen mastic shall Revision No Date
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Construction Quality Plan LARSEN & TOUBRO LIMITED ECC DVISION Bitumen Mastic for TFC GMR HYDERABAD INTERNATIONAL AIRPORT PROJECT Page 2 of 3 be laid in single coat at temperature between170-2000C and spread uniformly using wooden floats to the required thickness. All construction joint shall be properly and truly made. These joint shall be warmed by application of hot bitumen mastic in an excess quantity on the existing edge of bitumen mastic, which shall be then trimmed off to leave it flush with the surfaces on the either side.

Quality Control tests and their frequencies:

1. 2. 3. 4. 5. 6. 7. Quality of binder as per IS 73 and IS 8887. Grading at a frequency of 2per day per plant. Water absorption of aggregates at a frequency of 3 representative specimens for each source. Soundness of aggregate as per IS 2386 part5 at a frequency of 1 test of per source. Temperature of mix at regular intervals. Rate of spread of mixed material through regular checks of layer thickness. Hardness number-two tests per 3000sqm of mix as per IS1195:1978.

Safety Requirements:
1. 2. 3. 4. 5. 6. 7. 8. 9. Leather hand gloves shall be used during the hot works Fire extinguisher shall be available near by the mastic cookers Proper area lighting shall be provided if night work is carriedout. Flagman shall be provided at all exit points of the trucks / tippers. All tippers / Tankers shall be provided with reverse horns. The speed of vehicles plying in the work area shall be restricted to 40kMpH maximum. Level staff shall be made of non-electricity conductive materials. Check for the working condition of safety valves of air compressors, if compressed air is being used for cleaning. Face shield shall be worn when working with hot bitumen.

10. First aid boxes shall be provided. 11. The workmen working with hot mixes shall wear shoes.

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LARSEN & TOUBRO LIMITED ECC DVISION GMR HYDERABAD INTERNATIONAL AIRPORT PROJECT

Construction Quality Plan Bitumen Mastic for TFC Page 3 of 3

Format No. T/F74

SIEVE ANALYSIS OF AGGREGATE FOR BITUMEN MASTIC INCLUDING MINERAL FILLER

PROJECT CLIENT CONTRACTOR Laboratory job no. Source Proportion of aggregate and Mineral Filler Representing stretch : Construction of Airside and Landside Works for Hyderabad International Airport : Hyderabad International Airport Limited : Larsen & Toubro Ltd. - ECC Division : : : Date of sampling : Sampled by Date of testing Tested by : : : :

Weight of sample taken W1:

IS Sieve size (mm)

gm.

1 6.0 4.75 2.36 0.600 0.300 0.075

Wt. Retained (gm) 2

Retained on sieve % wt. Retained % of Cumm. Wt. (clo.2/W1) x100 Retained 3 4

% of passing (100 - col.4) 5

Specification requirement 6

100 90-100 75-100 45-80 15-50 0-30

FOR L & T

FOR HIAL

Revision No Date
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