Ch09 Road Construction

Technology

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 Road Construction Technology

 A branch of engineering that deals with:

 All activities for changing existing ground to

the desired shape and slope

 Providing all necessary facilities for traffic

operation

 Reconstruction/Maintenance of existing roads

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 Activities and techniques
used in road construction

 Earthwork and site clearance

 Site clearance

 Earthwork in filling for embankment

 Excavations for cutting

 Excavations for borrow pit

 Excavations for structural foundation

 Disposal of surplus earth

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 Activities and techniques
used in road construction

 Drainage works  Protection works

 Minor bridges  Site clearance
 River training works
 Culverts
 Gully control works
 Cause ways
 Landslide stabilization works
 Side drains
 Bridge protection works

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 Activities and techniques
used in road construction

 Pavement  Miscellaneous works

works  Road ancillaries
 Traffic sign/signal/marking etc
 Sub grade works
 Bioengineering works
 Sub base works
 Base works
 Surface works

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 Tools
 A tool is a simple piece of equipment that use to do a
particular kind of work in construction, usually holding
in hand.
 Wheelborrow,
 Shovel, Chisel and hammer, Pick Axe
 Level pipe, Spirit level
 Trowel
 Plumbbob
 String, crowbar, Hoe, Doko, Tape, Sickle etc.
 Important for labor based construction

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 Equipment
 All appliances for the execution, completion, operation or
maintenance of the road work, but which will not become
a permanent part.

 Used for executing complex tasks in even the most

unfavorable topography

 15% to 40% of total project cost

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 Equipment – Earth Moving
 Earth-moving (Excavating) equipment covers a broad
range of machines that can excavate soil and rock

 Earth movers help to speed not only earth work but

also materials handling, demolition, and construction

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 Equipment – Earth Moving
1) Dozers:
 Used for shallow Excavation, Hauling the earth for short
distance, pushing earth (front & sideways) & uprooting
trees.
 Either Crawler or Wheeled Dozer
 Types: Bull dozer, Angle dozer, Tree dozer

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 3.2.2 Equipment – Earth Moving
2) Scraper :
 Attached to tractor and is used for scraping, carrying and
spreading of the earth on the site.
 a cutting edge for scraping and bucket for loading.
 The cutting edge excavates earth and collected in bucket
by it self

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 Equipment – Earth Moving
3) Loader
 Primarily used to load material (such as debris,
gravel, rock, sand etc.) into or onto another
type of machinery (such as a dump truck).

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 Equipment – Earth Moving
4) Excavators
 They are heavy construction equipment consisting of a

boom, stick, and cab on a rotating platform.

 The house sits atop an undercarriage with tracks or

wheels.
 Excavators are used for digging, pipe laying, ditch

cleaning etc.

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 Equipment – Earth Moving
5) Backhoe
 a excavator which draws towards itself a
bucket attached to a hinged boom
 Used for digging and loading materials

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 Equipment – Earth Moving
6) Dragline
 Drag line is used to
excavate soft earth and
to deposit in nearby
banks.
 The bucket is thrown out
from the dragline on the
top of the earth to be
excavated and then
pulled back towards the
base of the machine.

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 Equipment – Earth Moving
7) Clam Shell
 Clam shell consists of special types of bucket of two

halves hinged together at top.

 Used for dredging and digging operation

 It may be used by attaching with shovel crane or

boom of drag line.

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Equipment – Earth Moving

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 Equipment – Compacting
1) Smooth Wheeled Roller
 Consists of smooth wheels especially of steels.
 Hand/animal driven has only one drum where as power

driven roller has two axles or three axles

 They are suitable for compacting gravel, sand, crushed

rock, where crushing action is required.

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 Equipment – Compacting
2) Sheep’s foot roller
 It consists steel cylindrical drum with projection
extending radial direction outward from surface of
cylinder.
 It is suitable for silty & clay sand, medium & heavy clay.

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 Equipment – Compacting
3) Pneumatic tyred roller
 It gives kneading action as well as compression to the
soil underneath.
 It has a set four on one axle and five on the other
 It is suitable for moderately cohesive silty soils, clayey
soils, gravelly and clayed sand.

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 Equipment – Compacting
4) Vibrating Roller
 Steel wheel rollers equipped with vibratory drums.

 Drum vibration adds a dynamic load to the static roller

which enable to achieve high compaction

 Vibrating roller used to compact pavement layers and

sub grade to a high degree of density.

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 Equipment – Compacting
5) Rammers
 It has a large vibrating base plate used for
compaction
 Suitable for compacting small area and where rollers

cant operate such as compaction of trenches

foundation and slopes.

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 Equipment – Leveling
1) Grader
 It is self propelled or towed machine motor grader

 It has blade supported on machine frame work and

capable of turning, tilting.

 It shapes the ground and spreads the loose material.

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 Equipment – Lifting
1) Crane
 A crane is used both to lift and lower materials and to
move them horizontally.
 It is mainly used for lifting heavy things and transporting

them to other places.

 Cranes may be stationary, mobile, overhead gantry, tower

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 Equipment – Lifting
2) Hoist:
 Commonly used on large scale

construction projects, such as

high-rise buildings

 It is used to carry personnel,

materials, and equipment
quickly between the ground
and higher floors
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 Equipment – Lifting
3) Forklift Truck
 designed to lift or move objects

 The truck equipped with an attached prolonged platform

helps to pick an object laying on or below the ground

and move it to the destination.

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 Equipment – Paving
1) Bitumen Spreader (distributor)
 Bitumen distributors are used to apply prime or tack

coats on a surface in preparation for paving.

 It consists of an insulated tank with a heating

system, a spray bar and unique control system.

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 Equipment – Paving
2) Aggregate Spreader
 Used to
distribute aggregate
evenly over the film of
asphalt sprayed by the
asphalt distributor

 Thickness of spread
aggregate is controlled
by speed and material
feed
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 Equipment – Paving
3) Bituminous paver
 Pavers are self-propelled
machines designed to place
hot mix asphalt concrete or
premix carpet on the roadway
 The tractor unit provides
moving power for the pavers.
 Thickness of mat is controlled

by pavers speed, material

feed

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 Equipment – Paving
3) Cement concrete Mixer
 A device that homogeneously combines cement,
aggregate such as sand or gravel, and water to form
concrete.
 A typical concrete mixer uses a revolving drum to mix

the components.
 Portable concrete mixers are used for small volume

work
 Truck mixers are used to transport concrete to site for

large volume work

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 Equipment – Paving
3) Cement concrete Mixer

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 Equipment – Paving
4) Cement concrete Paver
 Cement concrete pavers

are self-propelled
machines to place
cement concrete mix on
the roadway to a specific
depth
 Thickness of mat is
controlled by pavers
speed, material feed
rate.
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 Equipment – Paving
5) Concrete vibrators
 For compacting the concrete after its placement concrete
vibrator is used.
 e.g. needle vibrators, surface vibrators

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 Equipment – Transport
1) Haul Truck - Haul trucks are used for transporting HMA,
aggregates and con from the place of production to the
construction site.
2) Tipper - A truck or lorry the rear platform of which can
be raised at the front end to enable the load to be
discharged by gravity also called tip truck..

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 Equipment – Transport
4) Dump trucks - These are used for earth transporting
purpose. It may be side or rear dump trucks.

3)Trailer - A trailer is generally an unpowered vehicle

pulled by a powered vehicle. Commonly, used for
transport of goods and materials.

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 3.2.3 Equipment – Transport
5) Mini Dumper - They are high speed pneumatic wheeled
trucks of short chassis and strong bodies. Fast loading,
hauling and dumping. They are suitable for short hauls on
rough roads.
6) Concrete Transport Truck - Made to transport and mix
concrete up to the construction site. They can be charged
with dry materials and water, with the mixing occurring
during transport.

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Plant
1) Stone Crusher
• To reduce large rocks into smaller rocks or rock dust.
• To differentiate pieces of different composition

https://manufactor.wordpress.com/category/stone-crusher-plant/

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 Plant

2) Asphalt Mixing Plant

• It may be hot mix plant or cold mix plant.
• Function of asphalt mixing plant includes
heating and drying aggregate, screening &
measuring aggregate, the filler and bitumen
and mixing the aggregate & bitumen in
proportion to produce homogenous mix.

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Plant
2) Asphalt Mixing Plant
https://commons.wikimedia.org/wiki/File:Lb-asphalt-batching-plant-structure.jpg

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 Plant
 Continuous mix plant: the aggregates are dried and
mixed at the same time in the drums. The advantage of this
type of process is that the machines used are of simple built
reducing the investment costs.

 Batch mix plant: the aggregates are first weighed and

then passed to the drying drums. After the aggregates get
dried they are all mixed along with the binder in the mixer.

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 Plant
3) Cement Concrete Mixing Plant
• Cement concrete mixing plant mixes different
ingredients (coarse aggregate, fine
aggregate, admixture, cement and water) in
required proportion.
• It consists of storage bins for storing
materials like cement and admixtures.
• Aggregate is mix in it with the help of a
hopper which is fixed in plant.
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 Plant Cement Storage

http://www.getbusinesses.org
Belt converyor
Cement Delivery

Weigh Hoper
Agg. Storage
Water Storage
Mixer

Control room

Agg. Delivery

Concrete loading
Reclaimed Agg

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 Preparation of Road Bed
 All operation before the pavement could be
laid over it

 It includes:
 Site clearance,
 Earth work in embankment (filling),
 Earth work in cutting (excavation)

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 Site Clearance
 Clearing of bushes and shrubs at least covering
toe width
 Removal of existing trees, stumps and roots
along the alignment
 Removal of existing structures along the
alignment
 a minimum of 1 to 3 m from the top of the cut
or toe of the fill

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 Earth Works
 All the operations required to convert the natural land to
the sections and grades as in plans

 May be excavation or fill

 To decide limits of economical haul and lift

 It is advantageous to plot a mass haul diagram

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 Earth Works in Excavation (Cut)
 Cutting and removing the earth, rocks from its
original position, transporting and dumping

 Required when the natural ground level is

higher than the designed level

 Also construction of side drain requires

excavation

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 Earth Works in Excavation (Cut)
 Equipment:

 Excavation Equipment's (Dozers, scrappers,

loaders, drag line, clamshell etc.).

 Tools for Small work (e.g. Spade, Shovel, Pick-

axe etc.)

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Earth Works in Excavation (Cut)
Design:
 Depth,

 Stability of foundation,

 Stability of slope, and

 Requirement of side drains etc.

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 Earth Works in Embankment (Fill)
 The filling of earth/soil to achieve the desired
formation level

 Required when the natural ground is below the

formation level

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 Earth Works in Embankment (Fill)

 Formation level is raised due to :

 To maintain the vertical alignment

 To keep the sub grade above the high ground

water table

 To prevent damage to pavement due to

surface and capillary rise

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Earth Works in Embankment (Fill)
Design Elements:
 Height of fill,
 Fill materials,
 Settlement of embankment,
 Stability of foundation,
 Stability of slopes

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 Embankment construction
 Site clearance

 Filling the site with earth from borrow pits

 Mixing with water up to optimum moisture

content

 Levelling and compacting the first layer. The

thickness of layer may vary between 10 – 30 cm
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 Embankment construction
 Check the side slope after finish compacting
first few layers (max. slope upto 1.5)

 Continue filling embankment with earth

followed by compaction up to formation level

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 Mass Haul Diagram
 It is diagrammatic representation of earthwork
volumes involved in road construction along a
linear profile

 horizontal stationing is plotted along the X-axis

 Net cut values are plotted above the X-axis

(positive Y value) & Net fill values are plotted
below the X-axis (negative Y value)
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 Construction of Mass Haul
Diagram
 Compute the net earthwork values for each station,
applying the appropriate shrink factor

 Net cuts have a positive value, net fills have a negative

value

 The value at the first station (origin) = 0

 Plot the value of each succeeding station which equals

the cumulative value to that point

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Mass Haul Diagram

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 Characteristics of Mass Haul
Diagram
 The accumulated volume of earthwork at start is 0

 The ordinate at any station along the curve

indicates summation of cut and fill (earthwork
quantity accumulated up to that point)

 The maximum (+) ordinate indicates a change

from cut to fill, the minimum (-) ordinate indicates
a change from fill to cut
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 Characteristics of Mass Haul
Diagram
 A rising curve indicates an excess cut whilst a
falling curve indicates the fill.

 Steep slopes indicates heavy cuts or fill, flat

slopes indicates small earthwork

 Convex loop - haul from cut to fill is from left to

right, where as, Concave loop - haul is from
right to left.
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 Characteristics of Mass Haul
Diagram
 The curve starts with zero-accumulated
earthworks

 The baseline is the zero balance line

 A line that is drawn parallel to the baseline so as

to cut a loop is called a 'balancing line’

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 Characteristics of Mass Haul
Diagram
 The two intersection points on the curve are called
‘balancing points’ as the volumes of cut and fill are equal.

 A negative value at the end of the curve indicates that

borrow is required to complete the fill whereas positive
value means waste

 The area between a balance line and the mass-haul curve

is a measure of the haul (in station.m3 ) between the
balance points.

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 Definitions
 Haul: Distance over which material is moved.
Earthwork quantities are Haul Volume-distance (m3 .m
or m3 .sta.)
 Free-Haul Distance (FHD): - The distance within
which a contractor is paid a fixed amount per cubic
meter of material irrespective of actual distance price.
 Over-Haul Distance (OHD):- Distance beyond free-
Haul for which extra charges are paid for each unit of
haulage
 Limit of Economical Haul Distance (LEHD): - The
maximum Over-Haul distance plus Free Haul distance
beyond which it is more economical to waste & borrow
than to pay for over hauling. 60
 Definitions
 Shrinkage
 Volume of the compacted embankment is less than

the borrow area volume, called Shrinkage

 Shrinkage factor depends on the soil type and vary

between 10 – 20%.

 Swell:
 Excavated soil/rock occupy a larger volume, called

swell
 Swell may vary from 20 – 40%

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 Earthen roads
 Cheapest road
 It utilize existing or immediately adjacent
materials along an alignment
 Selection of Materials :
Base Course Wearing Course
Clay content (%) <5 10 – 18
Silt content (%) 9 – 32 5 – 15
Sand content (%) 60 – 80 65 – 80
Liquid Limit (%) < 35% < 35%
Plastic Limit (%) < 6% 4 to 10%

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 Earthen roads
 Tools & Equipments :
o hand tools such as spade, pick, shovels,
rammers etc

o Equipments such as dozer, scrapper, graders,

compactors, tippers etc.

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 Earthen roads
 Construction Procedure
 Soil survey to find borrow pit material within

economic haulage distance

 Centerline with wooden pegs and reference pegs are

fixed

 Sub grade preparation: clearing site, cut or fill to the

desired grade, shaping of sub grade and compaction

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 Earthen roads
 Construction Procedure (continued)
 The borrowed soil are dumped and mixed with additional
water if necessary to bring it up to OMC. (Too wet
material, dried by aeration and exposure to the sun)
 Soil mixed with water spread, first by dozer and later
grader for precise grading, and rolled in layers up to
compacted thickness 15 cm.
 Camber of final compacted pavement is 1 in 20 to 1 in
25
 Provide suitable side drains on both edges
 After few days, road is opened to traffic

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 Earthen roads

 Quality control
 Material specification
 Moisture content 90 – 95% of OMC
 Dry density – 95% of MDD
 Plasticity index <40%

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 Gravel roads
 Superior to earthen road & can carry heavy traffic loads
 Many natural gravels such as colluvial, alluvial, lateritic,
calcite and weathered hard rock materials
 May be trench type or feather edge type

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 Gravel roads
 Selection of Materials :

Base Course Wearing Course

% Gravel ( passing 80 mm & 50-70% 50-70%
retained on IS4.75 mm sieve)
% Sand (passing 4.75 & retained on 25 – 40% 25 – 40%
75 micron)
% Slit & Clay (passing 75 micron) Max. 5% 8 – 15%
Liquid Limit (%) < 35%
Plastic Limit (%) <6% - 15%
PI value of Binding material less than 6 (approx. quantity required for 75 mm
compacted thickness is 0.06-0.09 m3/10m2 )

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 Gravel roads
 Tools & Equipments :

o hand tools such as spade, pick, shovels,

rammers etc

o Equipments such as dozer, scrapper,

graders, compactors, tippers etc.

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 Gravel roads
 Construction Procedure
 Location of gravel source
 Clearing and preparing the surface
 For trench type, trench of suitable depth and width
equals to width of road is formed
 The gravel course materials are placed on prepared
surface
 Spreading of gravel material – first by dozer and then
by graders in a uniform layer
 Adjustment of the moisture content by watering with
sprinkler trucks or by manually, if dry

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 Gravel roads
 Construction Procedure (continued)
 Compaction by means roller gradually edge to centre

(<150mm compacted thickness)

 Continue Rolling to uniform dry density (98% for
base) or 95% for sub-base & Shoulder)
 Open the traffic after 24 hours

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 Gravel roads

 Quality control
 Material specification
 Moisture content 90 – 105% of OMC
 Dry density – 98% of MDD, 95% for
subbase and shoulder
 Plasticity Index 6 for base course and 5 to
10 for surface course

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 Water Bound Macadam Roads
 pioneered by Scottish Engineer John Loudon McAdam
around 1820

 Made of crushed gravel, hard stones etc.

 The broken stones are mechanically interlocked by rolling

 the voids filled with screening and binding material with

the assistance of water

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 Water Bound Macadam Roads

 Selection of Materials :
 Angular and cubical shape, nominal size 35 – 50 mm, LA
value upto 40% (base) & 45% (subbase), AIV upto 30%
(base), & 40% (subbase) and combined flakiness &
elongation index less than max. 35%.
 Screening materials (Grading 1 – 13.2 mm, & Grading 2 –
11.2 mm) of LL < 20% , PL <9%
 Filler (Binding) materials fine grained material, Plasticity
index less than 6% (approx. quantity required for 75 mm
compacted thickness is 0.06-0.09 m3/10m2 )

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Water Bound Macadam Roads

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 Water Bound Macadam Roads

Equipments:
 Water tanker, dump truck, grader, compaction

equipments

Construction Procedure :
 material with 20% extra broken stones are
stocked along the roads
 preparation of sub grade to required grade and
camber
76
 Water Bound Macadam Roads
Construction Procedure :
 Provision of lateral confinement

 Spreading of coarse aggregate

 Dry rolling – roller 8 to 10 tonnes (Compacted thickness <

7.5cm) three wheeled power rollers or tandem or
vibratory rollers
 Dry screening is applied gradually over the surface to fill

the voids
 The surface is sprinkled with water and wet rolling to fill

about 50% of total voids

 Application of binding material at a uniform and slow rate

at two and more thin layers

 Opening of traffic after few days of construction
77
 Water Bound Macadam Roads

 Quality control
 Material specification
 LAA, AIV, Flakiness and Elongation Index
 90 – 105% of OMC
 Dry density – 98% of MDD, 95% for subbase
and shoulder
 Plasticity Index 6 for base course and 5 to 10
for surface course

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 Soil Stabilization
Soil Stabilization

 It is the process of improving the strength of

the soil by proportioning and/or mixing with
other materials and compaction.

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 3.4.4 Soil Stabilization
 Advantages
 Increase bearing capacity of soil

 Increase shear strength of soil

 Avoid changes in soil characteristics due to

changes in moisture content

 Prevent cracks in soil

 Good drainage, less frost susceptibility

80
 Soil Stabilization Methods

1. Mechanical Soil Stabilization

2. Soil-Cement Stabilization
3. Soil-Lime Stabilization
4. Soil-Bitumen Stabilization

81
Factors affecting Mechanical Soil
Stabilization

 Mechanical strength of aggregate

 Gradation
 Properties of soil
 Presence of salts and mica etc.
 Compaction

82
Desirable properties Stabilized Soil

 Strength
 Incompressibility
 Stability with variation in moisture
content
 Good drainage
 Less frost susceptibility
 Ease of compaction
83
 Factors affecting Mechanical
Soil Stabilization
 Recommended gradation for granular sub base

84
 Construction of Mechanical Soil
Stabilized Roads
 Equipments:
 Laboratory facilities for mix design
 motor grader or rotavator for mixing
 Compaction equipment such as 3 tone
vibrating roller
 Hand tools and equipments for labor based
construction

85
 Construction of Mechanical Soil
Stabilized Roads
 Material Selection:
 Crushed stone or screened stone with less than 20%
passing from 12 mm sieve and more than 85% passing
from 40 mm sieve or Sand

 Max. size 60 mm, CBR Min. 25%, Density 95%

maximum,

 Liquid Limit 25% for Base and 35% for surface

 PI 6 for base and 5 to 10 for surface course

86
 Construction Procedure for
Mechanical Soil Stabilization
 Preparation of sub grade or sub base
 Pulverization of soil
 Application of required proportion of material and mixing
 Spreading and grading
 Compaction by smooth wheeled roller

87
 Soil Cement/lime Stabilization
 Addition of cement and water

 Stabilization is due to bond between cement and soil

particle and Reduction in plasticity (Lime is suitable for
clay)

 normally 2-12% (4-8% for lime) by weight is usually

mixed on-site

 Curing for about 7 days (14 days for Lime)

 % of cement is ascertained through laboratory test

88
 Soil Cement Stabilization
 Design of soil-cement mix
 Based on compressive strength of specimen cured

for 7 days

 Specimen prepared with different cement content in

5 cm diameter and 10 cm height moulds and
compacted up to OMC

 Design cement content corresponding to 17.5

kg/cm2 and 35 kg/cm2 for medium and high traffic

89
 Construction of Soil cement
stabilized roads
 Equipments:
 Mix in place – manually or simple equipments
such as rotovator
 Plant mix – large mixing plants, cement truck
mixer,
 compacting equipment

90
 Construction of Soil cement
stabilized roads
 Selection of Materials:
 Materials passing 4.75 mm >50%
 Material Passing 75 micron >50%
 Liquid limit >40%
 Plasticity limit >18%
 Cement content 5 to 14% by volume

91
 Construction of Soil cement
stabilized roads
 Procedure:
 Preparation of sub grade or sub base

 Pulverization of soil

 Application of cement and dry mixing

 Addition or spraying water and remixing

 Spreading and grading

 Compaction by smooth wheeled roller

 Moist curing either by preventing the moisture to

escape or by covering with moist soil

92
 Construction of Soil cement
stabilized roads
 Field controls:
 Checking moisture content
 Degree of pulverization
 Cement content
 Compressive strength test
 Determination of dry density
 Surface regularity

93
 Soil Lime Stabilization
 Design of mix
 No standard method of mix design

 lime content is decided based on lime

fixation limit or amount required to reduce
plasticity index or swelling value to desired
limit

94
 Construction of Soil Lime
stabilized roads
 Equipments:
 For scarifying, pulverizing, mixing, and

compacting equipment

 Selection of Materials:
 consistent quality slaked or hydrated lime,

calcium hydroxide - Ca(OH)2,

 Fresh water for compaction moisture control

and curing.
95
 Construction of Soil Lime stabilized
Procedure: roads
 Preparation of Sub grade
 Pulverization of the soil to be stabilized
 Addition of part of lime as dry powder or as slurry with
water and mixing
 Allowing mixture to age for a day and remixing when
pulverization becomes easy
 Addition rest of the lime and water if necessary and
remixed
 Spreading to desired grade and shape
 Compaction with sheep foot roller and then smooth
wheeled roller
 Curing – soil lime is protected from drying out and 96
allowed moist curing for 14 days
 Construction of Soil Lime
stabilized roads
 Field Control:
 Checking moisture content at the time of

compaction
 Determination of dry density after

compaction
 Surface regularity

97
 Soil Bitumen Stabilization
 Addition of bitumen

 Bitumen emulsion is an effective option for

strengthening non plastic sandy materials.

 Normally 4-8% residual bitumen is usually mixed

 Specimens are prepared at lab with various

bitumen contents and are tested for stability and
water absorption.
98
 Soil Bitumen Stabilization
 Design of mix
 No standard method of mix design

 specimens are prepared with various

bitumen contents and are tested for stability
and water absorption

 CBR test may be conducted

99
 Construction of Soil Bitumen
stabilized roads
 Equipments:
 For scarifying, pulverizing, mixing, and
compacting equipment

100
 Construction of Soil Bitumen
stabilized roads
 Selection of Materials:
 Local sandy soil compatible with emulsion
modification.
 Slow Setting emulsion.
 Soil properties (passing 4.75 sieve – 50%,
passing 0.425 sieve – 35 to 100%, passing
0.075% sieve – 10 to 50%, LL – 40%, PL –
18%)

101
 Construction of Soil Bitumen
stabilized roads
 Procedure:
 The soil to be stabilized is pulverized
 Addition of water to soil and mixed
 Addition of cut back or emulsion and mixed
 Spreading of the mix to desired grade and
compaction
 The compacted layer is allowed for curing –
moisture and volatile elements evaporated

102
 Construction of Soil Bitumen
stabilized roads
 Field Control:
 Checking of pulverization
 Checking moisture content and bitumen
content
 Determination of dry density after compaction

103
 Bituminous Roads

 Classification based on construction

techniques:
 Interface treatment like prime coat and tack
coat
 Seal coat, Surface dressing, Otta Seal
 Grouted or penetration macadam
 Premix construction like Bitumen bound
macadam, bituminous carpet, bituminous
concrete
104
Bituminous Roads
Factors affecting selection of Type
 Traffic Volume

 Riding Quality Required

 Operational Factor

 Safety

 Environmental Considerations

 Construction and Maintenance

 Properties of Available Aggregate

 Construction Cost

 Required Service Life

105
 Interface Treatment – Prime Coat

 A low viscosity liquid bituminous material

and is applied to the existing bases of the
previous surface

106
Interface Treatment – Prime Coat

Purpose
 To promote a bond between the existing base
and bituminous layer
 To plug the voids and make water proof

 To coat and bond loose material

 To harden the surface and make dust free

107
 Construction of Prime coat
Material Selection:

 MC cut back bitumen or SS1 grade bitumen

emulsion

 Rate of apply 0.6 – 0.15 kg/m2 depending on

type of surface (high for high porosity)

108
 Construction of Prime coat
 Equipment:
 Manual or mechanical broom

 Bitumen distributor (self propelled or towed

pressure sprayer)

109
 Construction of Prime coat

 Preparation of surface
 Clean surface by sweeping with mechanical

broom
 Remove any loose materials

 Spraying of prime coat at the specified rate

 The primed surface shall be allowed to cure

for at least 24 hours

 After 24 hrs, if bitumen fails to penetrate,

blinding material is sprayed to absorb any

excess bitumen 110
 Interface Treatment – Tack Coat
 It is high viscosity bitumen applied over
the relatively impervious pavement such as
existing bituminous pavement, concrete
pavement etc.

Source: www.hincol.com
111
 Interface Treatment – Tack Coat
Purpose

 To promote the bond between old and new

pavement layers
 To prevent slippage between pavement layers
 To improve structural performance
 To be able to work all layers together

112
 Interface Treatment – Tack coat
Material Selection:

 Cationic Bitumen Emulsion (RS-1), paving

bitumen of VG10 or cut back bitumen RC-70 (if
temp < 0oC)

 Application rate = 0.5 (existing black top

surface) – 1.0 kg/m2 (over pervious surface)

113
 Interface Treatment – Tack coat
 Equipment:
 Manual or mechanical broom

 Bitumen distributor (self propelled or towed

pressure sprayer)

114
 Construction Tack coat

 Preparation of surface
 Surface is cleaned by sweeping with
mechanical broom
 Loose materials shall be removed
 Spraying of tack coat at the specified rate

115
 Seal Coat

A very thin surface treatment which is applied as

final step in the construction of bituminous
surface or on existing surface
 Liquid seal-coat - Liquid bitumen is sprayed and
covered with coarse aggregates
 Premix seal-coat – the mix of aggregates and
bitumen is spread over premix carpet and
compacted

116
 Seal Coat
Purpose

 To seal surface to make water proof

 To increase resistance to skidding
 To improve structural performance (strength and
bearing capacity)

117
 Seal Coat
Material Selection:

 Aggregates passing 12.5 mm and retained on 6

mm size sieves.
 Bitumine of 60/70 or 80/100 penetration grade
 Application rate = 0.68 (existing black top
surface) – 0.98 kg/m2 (over pervious surface)

118
 Seal coat
 Equipment:
 Manual or mechanical broom

 Bitumen distributor (self propelled or towed

pressure sprayer)
 Aggregate

119
 Construction of Seal Coat

 Construction Procedure
 Surface cleaning by sweeping with mechanical

brooms
 Prime/tack coat is sprayed on to it at the

specified rate and allowed to cure for 24 hours

 A thin aggregate is spread over the asphalt

material and compaction

120
 Surface Dressing (Surface
Treatment)
Surface dressing is the application of bituminous emulsion
over the prepared road base followed immediately by
covering with single sized stone aggregate chippings that
are lightly rolled.

Types
 Single Bituminous Surface Treatment (SBST) - One

application of bituminous material and aggregate

 Double Bituminous Surface Dressing (DBST) - Two

applications of bituminous material and aggregate
121
Surface Dressing (Surface
Treatment)

122
Surface Dressing (Surface
Treatment)

Equipment:
 Equipment for heating bitumen

 Manual/self-bitumen spreader

 Manual chip spreader/a truck chip spreader

 Roller (5- to 8-ton), Pneumatic tire roller

 Mechanical brooms or hand brushes etc.

123
 Surface Dressing (Surface
Treatment)

Material Selection:
 FI ≤ 20%, LAA <35%, AIV <30%, stripping
value <25%,
 Water absorption <1%

 Nominal size of chippings 12 mm for first coat,

9 mm for second coat,
 Bitumen of 80/100 penetration grade

124
 Surface Dressing (Surface
Treatment)

 Construction Procedure (SBST)

 Surface cleaning by sweeping with
mechanical brooms
 The edges of road surface is marked out and

prime/tack coat is sprayed on to it at the

specified rate
 The primed surface is allowed to cure for at

least 24 hours, during which period no traffic

is allowed
125
 Surface Dressing (Surface
Treatment)
 Construction Procedure (SBST)
 An bitumen is applied from a spray truck to the surface
of the existing pavement
 A aggregate cover of uniform gradation is spread over
the bitumen before it has set.
 A pneumatic tire roller is used to push the aggregate
into the asphalt material.
 Excess chipping should be removed within 24 – 48
hours

126
 Surface Dressing (Surface
Treatment)
Construction Procedure (DBST)
 Construct a single surface treatment (SBST) same as
before
 Sweep away loose aggregate so that subsequent layers

will bond together.

 Apply binder (bituminous) material about one-third or one-

half of the first layer

 Apply the aggregate which is about one-half the diameter

of that used in the first application

 A roller (usually a pneumatic tire roller) is used to push

the aggregate into the asphalt material.

 Excess chipping should be removed within 24 – 48 hours
127
 Surface Dressing

 Quality Control
 Temperature of binder,

 Tests on aggregates (LAA, FI, Impact value,

Plasticity Index (PI),

 gradation test,

 rate of application of binder and aggregate,

 test on bitumen (penetration, viscosity,

ductility etc.)

128
 Grouted or Penetration
Macadam

 Penetration macadam consists of 3 layers of successively

finer broken or crushed rock interspersed with
applications of heated bitumen to grout voids and
eventually seal the surface.

 Full grout - Bitumen penetrates up to full depth of

aggregate
 Semi-grout - Bitumen penetrates up to half the depth

 Recommended for thickness of 50 to 75 mm

129
 Grouted or Penetration
Macadam
Material Selection:
 Aggregate - FI ≤ 25%, LAA ≤ 40%, Impact
value ≤ 30%, stripping at 40oC ≤ 25%, loss
withNA2SO4≤ 25%, Coarse aggregate (<63 mm
for 7.5 cm thick, <50 mm for 5 cm thick), key
aggregates (<25 mm for 7.5 cm thick , <19mm
for 5 cm thick, stone chipping or fine (<10 mm )

 Bitumen grade 80/100, 60/70, 30/40 (5-6.7

kg/m2 for first application, second application 2-3
per m2)
130
 Grouted or Penetration
Macadam
Equipment:
 Hot bitumen spray equipment;

 Roller,

 Aggregate spreader,

 Mechanical brooms,

 Hand tools such as shovels, wheelbarrows, and

hard brooms etc.

131
 Grouted or Penetration
Macadam
Construction Procedure
 Preparation of existing surface and recondition it
as necessary
 Spreading of Coarse aggregates

 Rolling – 10 tonnes

 Apply the first layer of bituminous material 5-6.7

kg/m2

132
 Grouted or Penetration
Macadam

Construction Procedure
 Spreading of key aggregates

 Rolling by 10 tonnes but excessive rolling

avoided
 Apply the second layer of bituminous material.

 Apply stone chippings.

 Drag-broom, roll, and hand-broom the surface

 Opening of traffic – After 24 hours

133
 Grouted or Penetration
Macadam

Quality Control
 Temperature of binder,

 Tests on aggregates (LAA, FI, Impact value,

Stripping test etc,
 gradation test,

 rate of application of binder and aggregate,

 Test on bitumen (penetration, viscosity,

ductility etc.)

134
 Bitumen Bound Macadam

 It is an open graded mixture of mineral

aggregate and appropriate binder, mixed in a
hot mix plant
 It is laid in a single course or in a multiple
layers
 Thickness of single layer is 50 mm to 75 mm.
 It may trap water or moisture vapor within the
pavement system

135
 Bitumen Bound Macadam

Material Selection:
 Aggregate
 For Binder course - FI ≤ 25%, LAA ≤ 40%, Impact
value ≤ 30%, stripping at 40oC ≤ 25%, loss
withNA2SO4≤ 12%
 For Base Course - FI ≤ 15%, LAA ≤ 50%, Impact
value ≤ 35%, stripping at 40oC ≤ 25%, loss
withNA2SO4≤ 12%
 Bitumen grade 80/100, 60/70, 30/40 penetration, RT-4
tar, bitumen content 3 to 4.5% by weight

136
 Bitumen Bound Macadam

Equipment:
 Hot bitumen sprayer;

 Mechanical or hand mixer,

 Mechanical paver,

 Bitumen heating device,

 Hot mix plant,

 Pneumatic Roller,

 Mechanical brooms etc.

137
 Bitumen Bound Macadam

 Construction Procedure
 Preparation of existing layer

 Tack Coat or prime coat application – 4 to 7.5

kg/10m2 for black top; 7.5 to 10 kg/10m2 for

WBM layer
 Premix Production – temperature tolerance of

+- 10oC

138
 Bitumen Bound Macadam

 Construction Procedure
 Placement of the mix at site with paver or

grader or manual
 Rolling compaction by 8 to 10 tone pneumatic

roller
 Application of seal coat

 Opening to traffic

139
 Bitumen Bound Macadam
 Quality Control
 Temperature of binder,

 Tests on aggregates (LAA, FI, Impact value,

Stripping test etc,

 gradation test,

 rate of application of binder

 Spread of mix material

 test on bitumen (penetration, viscosity, ductility

etc.)
 Density of compacted layer
140
 Premix Bituminous Carpet

 It is an open graded premix of stone chipping

of size 10~12 mm with bitumen or tar binder

 Being open graded, it should be covered with

sand seal or chip seal

 Thickness of single layer is 20 mm to 25 mm.

141
 Premix Bituminous Carpet

 Equipment: Hot bitumen sprayer;

mechanical paver, bitumen heating device,
Pneumatic Roller, mechanical brooms etc.

142
 Premix Bituminous Carpet

Material Selection:
 Coarse aggregate - Angular, clean, hard,
tough, durable ≤ 16 mm for 40 mm thick and ≤
10 mm for 20 mm thick
 LAA value 40% (max), Aggregate Impact value –
35%(max), Flakiness index – 30%(max)
 Sand - clean, hard, durable

 Bitumen grade 80/100 penetration

143
 Premix Bituminous Carpet
Construction Procedure
 Preparation of the existing surface

 Application of tack coat or prime coat

 Premix is prepared by heating both bitumen and aggregate

up to the required temp and mixed in mechanical mixer

 Mix is taken out and spread with thickness 15 cm using

paver
 Rolling is done with Tandem or Pneumatic roller of 6 to 9

tonnes
 Premix sand seal coat or chip seal is applied and light

tandem roller is rolled

 Open to traffic after 24 hours

144
 Premix Bituminous Carpet
Quality Control
 Temperature of binder,

 Tests on aggregates (LAA, FI, Impact value, Stripping test

etc,
 Gradation test,

 Rate of application of binder

 Spread of mix material

 Test on bitumen (penetration, viscosity, ductility etc.)

 Density of compacted layer

145
 Bituminous Concrete
 Highest quality of construction among
bituminous pavement

 It is carefully proportioned mix of coarse, fine

and mineral fillers with bitumen binders

 Thickness of single layer is 50 mm to 100 mm

 Durable, impervious, better riding quality and

load carrying capacity 146
 Bituminous Concrete

 Material Selection:
 Coarse aggregate - LAA value ≤ 40%,
Aggregate Impact value ≤ 30%, Flakiness index
≤ 30%, stripping ≤ 25%, water absorption ≤
1%, Loss with Na2SO4 ≤ 12%, dense grading

 Bitumen grade 30/40, 60/70, 80/100

penetration

147
 Bituminous Concrete

Equipment:
 Hot bitumen sprayer;

 Mechanical paver,

 Hot mix plant,

 Tandem/Pneumatic Roller,

 Mechanical brooms etc.

148
 Bituminous Concrete

Construction Procedure
 Preparation of the existing surface - sweeping,
correcting irregularities such as pot holes

 Application of tack coat at the rate of 6.0~7.5

kg/102m

 Production of mix from hot mix plant

149
 Bituminous Concrete

Construction Procedure
 Hot mix bituminous concrete is transported to site
and spread by mechanical paver to the required
grade and shape
 The mix is thoroughly rolled. Rolling first two
passes by either 8 tonnes smooth wheel roller, 4
tones vibro roller and then with 8 to 12 tonnes
pneumatic roller
 Open to traffic

150
 Bituminous Concrete
Quality Control
 Temperature of bituminous mix, aggregate

 Tests on aggregates (LAA, FI, Impact value,

Stripping test etc,
 gradation test,

 rate of application of tack coat

 Spread of mix material

 test on bitumen (penetration grade, viscosity,

ductility etc.)
 Marshal test for compacted layer 151
 Cement Concrete Pavement

Two Types of construction:

 Cement Grouted layer – an open graded
compacted aggregate (18 to 25 mm) laid
mixture of cement and sand (1:1.5:2.5) is
spread over it.
 Rolled Concrete layer – Aggregate, sand,
cement and water with less plasticity is used
and compacted.

152
 Cement Concrete Pavement

Plant and equipment:

 Concrete mix plant,

 Concrete truck mixer,

 Concrete mixture,

 Batching device, wheel barrow, needle vibrators,

brush, finishing tools etc.

153
 Cement Concrete Pavement

Material Selection:
 Portland cement,

 Coarse aggregates with Crushing Value≤30%,

Aggregate Impact Value≤30%, LAA≤16%,
Soundness Value≤12% in Na2SO4 and ≤16%
MgSO4
 Fine aggregate (natural sand),

 M30 concrete or higher in 28 days

154
 Cement Concrete Pavement

Construction Procedure
 Preparation of Sub Grade and sub base

 All formwork are placed and well secured to resist

the tamping forces
 Coarse aggregate, fine aggregate, cement and
required amount of water are either mixed on site
in batch mixer or transported from mixing plant.
 Concrete is transported to the site and deposited
on the sub base to the required depth
155
 Cement Concrete Pavement
Construction Procedure
 Compaction is carried out using a mechanical
poker (needle) vibrator.
 The surface is textured with an approved long
handled steel or fiber brush.
 Curing of cement Concrete: surface is with jute
mat for 24 hours, Upon the removal of wet covers,
the slabs cured by ponding for 14 days.
 Concrete road is opened to traffic after 28 days

156
Cement Concrete Pavement

157
Cement Concrete Pavement
Expansion Joint construction
 Expansion joints are provide at 140 m interval,

width 20 to 25 mm

158
Cement Concrete Pavement

Contraction Joint construction

 Contraction joints are provided at 4.5 m
interval for plain and 14 m for reinforced

159
 Cement Concrete Pavement
Longitudinal Joint construction
 Longitudinal joints are provided if slab width

more than 4.5 m

 Allow shrinkage and swelling and warping of

slab. It acts as hinge

160
 Cement Concrete Pavement
Construction Joint
 Provided at only when the concreting has to be
suspended due to unforeseen reasons.

161
 Cement Concrete Pavement

Quality Control
 Ordinary Portland cement or rapid hardening
type
 Max size of aggregate = ¼ of slab thickness

 Tests on aggregates (LAA, FI, Impact value,

soundness)
 gradation test,

 Proportioning of concrete

162