LARSEN & TOUBRO LIMITED - ECC DIVISION

Name Of Project Jaipur - Kishangarh Expressway

Job Procedure for Methodology For Dense Bituminous

Macadam As per Table 500-10 Grading-2
Job Procedure No S. No. – 017

CONTENTS

S. No. DESCRIPTION PAGE NO.

1 Scope 2

2 Reference 2
2
3 Method

4 Tolerance 2

5 Documentation

(a) Inspection & Test Plan (ITP) 2

(b) Formats
2

00 18-09-03. (JKS/ VKC) (RS) (RP)

Rev. Date Prepared By Reviewed By Approved by

Page 1 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)
 LARSEN & TOUBRO LIMITED
ENGINEERING, CONSTRUCTION AND CONTRACTS
PROJECT QUALITY PLAN
SITE: JAIPUR KISHANGARH EXPRESSWAY PROJECT
QUALITY MANGEMENT KM 273.500 TO 313.500 KM

METHODOLOGY FOR CONSTRUCTION OF

DENSE BITUMINIOUS MACADAM
S. No. DESCRIPTION
1 Scope Construction of Dense Bituminous Macadam Layer
(Grading-2)
2 Reference Clause- 507 of MORT&H Revision- 4 drawing no. GE-
1004 A, GE-1002 B, GE- 1003 B
3 Method Production of mix as per design in hot mix plant.
4 Tolerance + 6mm to – 6mm
5 Documentation
(a) Inspection & test plan ITP No. 7 B
(b) Formats JKEW/L&T/QC/00, 21, 25, 36,10 and 26A

REQUIRED EQUIPMENTS WITH ESSENTIAL FEATURES:

1. Bitumen Sprayer (For emulsion tack):
Features: Self propelled sprayer equipped with valve system that controls
the flow of binder, a pump with pressure gauge spraying bar with nozzles with
constant volume and thermostat control of temperature to maintain the
material temperature constant with heating arrangement (Appolo make).
2. Asphalt Paver: 1 Nos.
features: Electronic sensor, hydraulically extendable screed, tamping and
vibrating arrangement.
3. Tandem Roller: 2 Nos.
Features: 8 to 10 Mt static weight tandem vibratory roller with low and
high- frequency & amplitude control.
4. Tractor With Compressor: 160 Cpm capacity.
5. Linhoff Hot Mix Plant 120 TPH: Electronic load sensor to weigh
aggregates with variable speed drive motors for each bin. Bitumen feeding
control with solenoid valve, infrared sensing device for measuring temp of

Page 2 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)
 mix.
6. Auto Level
7. Water Tanker
8. Edge Cutter
10.Core Cutting Machine/ Pavement Quality Indicator
11. Tippers (as required for transporting the mix)
12. Mechanical Broom
13. Hand Set/ Mobile Phone
14. Staff Vehicle
15. Camber-Board And Straight Edge: 3.0-m length straight aluminum
section with camber board for checking of surface irregularities.
16. List of other hand tools: Shovels, crowbar, rakes, wheelbarrows, sensor
pegs, pavement breaker, hand gloves. Safety cone- digital thermometers, wire
brush, concrete nails, measuring tape, steel scale.
Man Power Requirement
1. Asphalt Plant In charge
2. QA/QC Asphalt In charge
3. Asphalt Laying In charge
4. Section In charge
5. Surveyor (With Team)
6. Operators, Supervisors and Laying labours
Safety Measures/ Precantions
A. Safety helmet, Safety jacket, Reverse horn, Red Flag, Hand Gloves,
Safety Shoes will be provided wherever required.
B. Two signalman with red flag will be deputed at both end to guide the
traffic. Safety jacket will be provided to all the asphalt laying team
(Workmen).

Page 3 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)
S.No
Procedure
.

Page 4 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)
Preparation of base
The surface will be thoroughly swept clean free from dust and
foreign matter using tractor compressor. Laying shall be suspended
while free standing water is present on the surface to be covered,
1. or during rains, fog and dust storm. Laying of bituminous mixture
shall not be carried out when the air temperature at the surface on
which it is to be laid is below 10°C or when the wind speed at any
temperature exceeds 40km/h at 2m height.
Tack coat (Rapid Setting Emulsion) Will be applied as per clause-
503 of MORTH Rev. 4 over BM surface at the rate of 0.20-0.5
2. Kg/Sqm. (For existing bituminous surface tack coat at the rate of
0.25-0.3 kg Sqm will be applied) tack coat will be provided with
calibrated bitumen sprayer just before Laying BM.
Preparation And Transportation of Mix
Asphalt mix (Dense Bituminous macadam DBM) will be prepared in
the hot mix plant (Calibrated) for getting proper and uniform
quality mix. The job mix formula (JMF) will be in accordance with
3. clause- 507 of MORTH Rev. 04 (Ref. Table 500-10, Grading-2). The
proposed job mix formula to be used is 20mm: 43.8%, 10mm:
9.5%, Crusher Dust: 40% ; lime 2% with 4.7% of 60/70 grade
bitumen by Wt of total mix.
Temperature of binder at the time of mixing will be in the range of
150°C-165°C and that of aggregate will be in the range of 150°C to
4.
170°C and the difference in temperature between the binder and
aggregate at no time will exceeds 14°C.
Mixing will be done in calibrated LINHOFF plant as per job mix
formula, to obtain a homogenous mixture in which all the particles
of aggregates are uniformly coated. Regular record of temperature
5.
of bitumen, aggregates and mix will be maintained by using the
temperature measuring devices attached with plant. Mix temp will
be maintained less than 165°C.
6. The mix will be transported form the hot mix plant to the site with
Page 5 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)
 suitable tipper vehicles covered with tarpaulin so that mix is not
exposed to surrounding environment.
Spreading & Compaction:
The transported mix from the hot mix plant to the site will be
7. spread by means of senor asphalt paver finisher to the specified
grade, lines and cross-section.
However, the mix will be laid manually in the restricted locations
8.
and in narrow widths.
The temperature of mix at the time of laying will be minimum
125°C. The temperature of the mix at the time of transportation
9. from plant, at the time of reaching at laying site and during laying
at site- will be recorded. Bituminous material with a temperature
greater than 145°C shall not be laid or deposited on bridge becks.
Longitudinal joints and edges will be constructed true to the
10.
delineating lines parallel to the centerline of the road.
11. Longitudinal joints will not be allowed to fall within the wheel path.
All transverse joints will be cut vertically to the full thickness of
previously laid mix with asphalt cutter/pavement breaker and the
12. surface painted with emulsion tack before placing fresh material.
While starting the day work, previous day joint will be cut vertically
and emulsion tack will be applied on the joint.
Longitudinal joints will be painted with emulsion tack (after
13. removing the loose material) before laying adjacent layer. (Total
width 7.0 Mtrs will be done at a time)
After the spreading of mix, rolling will be done immediately with
14. speed not more than 5km per hour with due care to avoid unduly
roughening of the pavement surface.
Initial break down rolling will be done with 8-10 tonne smooth
15.
wheeled tandem roller or with PTR (two passes).
16. The intermediate rolling Three passes will be done with 8-10 tone
static weight vibratory roller. Two passes will be given with PTR of
12 to 15 tones weight having nine wheels with a tyre pressure of at
Page 6 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)
 least 5.6kg/Sq.cm.
The finish rolling will be done with 6-8 ton weight smooth wheeled
17.
tandem roller. (one pass).
During the initial and finish rolling, no vibratory compaction will be
18.
resorted to.
The wheels of roller will be kept moist to prevent the mix from
19. adhering to them, however no excessive water will be poured on
the wheels.
Rolling of the longitudinal joints will be done immediately behind
the paving operations. After this, the rolling operations will be
commenced longitudinally from edges and proceeded towards the
center, except that on super elevated and unidirectional cambered
portions, where it will be progressed from the lower to upper edge
20.
parallel to the center line of the pavement. The roller shall first
compact material adjacent to joints and then work from the lower
to the upper side of the layer, overlapping on successive passes by
at least one-third of the width of the roller or in case of a
pneumatic- tyred roller, at least the nominal width of 300mm.
Rolling operations will be completed before the temperature of the
21.
mix falls below 90°C.
However if required extra passes will be given till the specified
22.
density is achieved.
Traffic will be allowed on DBM surface when the mix/surface cooled
23.
down to the surrounding temperature.
Density of compacted layer will be checked by PQI regularly (And
24.
some time by core cutting method).
Level of surface will be checked as per table 900-1 and surface
25.
regularity will be checked as per 900-2.

Note: Loose thickness of layer (Trial stretch) ~ 64mm. Compacted

thickness 55mm and laying width is 7.0 Mtr.

Page 7 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)
The following persons were present during the trial
stretch of DBM on 18.09.03.

S.No. Name Company Name

1. Mr. S. K. Jha Of IC (Highway
Engineer)
2. Mr. Anil Nagabode Of IC (Material Engineer)
3. Mr. Prabhaker Of LASA
4. Mr. S. Prakash Of LASA
4. Mr. Himanshu Of LASA
5. Mr. R. Srinivas of L&T
6. Mr. Chakravarthy Of L&T
7. Mr. Satender Singh Of L&T
8. Mr. V.P. Shukla Of L&T
9. Mr. Ravi chandra Of L&T
10. Mr. Kalim Of L&T
11. Mr. Santosh Of L&T
12. Mr. Bullu Pani Patra Of L&T
13. Mr. Hussain Of L&T
14. Mr. Rajumu Of L&T

Page 8 of 13
D:/ISO Records/Kuldeep/GSR/Work Method…/…(017)