GENERAL REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS

500.1.1. General - Bituminous pavement courses shall be made using the materials described in the
following specifications.
The use of machinery and equipment mentioned in various clauses of these specifications is
mandatory. Details of the machinery and equipment are available in the Manual for Construction and
Supervision of Bituminous Works. Equipment mandatory for any particular project shall be in
accordance with the contrast specification for that project. A number of IRC codes are extracted and
enclosed as Annexures for the benefit of the field engineers.
500.1.2. Materials
500.1.2.1 Binder - The binder shall be an appropriate type of bituminous materials complying with the
relevant Indian Standard (IS), as defined in the appropriate clauses of these specifications, or as
otherwise specified herein. The choice of binder shall be stipulated in the contract or by the engineer.
Where penetration grades of bitumen are specified, they are referred to by a single-figure designation
in accordance with IS: 73. (Annexure 500-A.1) Thus bitumen grade 35 refers to bitumen in the
penetration range 30 to 40. Where modified binder is specified, the clause 500.21 of these
specifications shall apply.
500.1.2.2. Coarse aggregates - The coarse aggregates shall consist of crushed rock, crushed gravel
or other hard material retained on the 2.36-mm sieve. They shall be clean, hard and durable, of
cubical shape, free from dust and soft or friable matter, organic or other deleterious matter. Where the
contractor’s selected source of aggregates have poor affinity for bitumen, as a condition for the
approval of that source, the bitumen shall be treated with approved anti-stripping agents, as per the
manufacturer’s recommendations, without additional payment. Before approval of the source, the
aggregates shall be tested for stripping. The aggregates shall satisfy the physical requirements set
forth in the individual relevant clause for the material in question. Where crushed gravel is proposed
for use as aggregate, not less than 90% by weight of the crushed material retained on the 4.75 mm
sieve shall have at least two fractured faces.
500.1.2.3. Fine aggregates
Fine aggregates shall consist of crushed or naturally occurring material, or a combination of the two,
passing 2.36 mm sieve and retained on the 75 micron sieve. They shall be clean, hard, durable, dry
and free from dust, and soft or friable matter, organic or other deleterious matter.
500.1.2.4. Source of material
The source of all materials to be used on the project must be tested to the satisfaction of and be
expressly approved by the engineer. The engineer from time to time withdraws approval of a specific
source, or attaches conditions to the existing approval. Any change in aggregate source for
bituminous mixes will require a new mix design, and laying trials, where the mix is based on a job mix
design. Stockpiles from different sources approved or otherwise, shall be kept separate, such that
there is no contamination between one material and another. Each source submitted for approval
shall contain sufficient material for at least 5 days work.
500.1.3. Mixing
Pre-mixed bituminous materials. Including bituminous macadam, dense concrete, shall be prepared in
a hot mix plant of adequate capacity and capable of yielding a mix of proper and uniform quality with
thoroughly coated aggregates. Appropriate mixing temperatures can be found in Table 500-5 of these
specifications; the difference in temperature between the binder and aggregates should at not exceed
140C. In order to ensure uniform quality of the mix and better coating of aggregates, the hot mix plant
shall be calibrated from time to time. If a continuous mixing plant is to be used for mixing the
bituminous bound macadam, the contractor must demonstrate by laboratory analysis that the cold
feed combined grading is within the grading limits specified for that bituminous bound material. In the
500-1
case of a designed job mix, the bitumen and filler content shall be derived using this combined
grading.
500.1.4. Transporting - Bituminous materials shall be transported in clean insulated vehicles, and
unless otherwise agreed by the engineer, shall be covered while in transit or awaiting tipping. Subject
to the approval of the engineer, a thin coating of diesel or lubricating oil may be applied to the interior
of the vehicle to prevent sticking and to facilitate discharge of the material.
500.1.5. Laying
500.1.5.1. Weather and seasonal limitations - Laying shall be suspended while free standing water
is present on the surface to be covered, or during rain, fog and dust storms. After rain, the bituminous
surface, prime or tack coat shall be blown off with a high-pressure air jet to remove excess moisture,
or the surface left to dry before laying shall start. Laying of bituminous mixtures shall not be carried
out when the air temperature at the surface on which it is to be laid is below 10 0C or when the wind
speed at any temperature exceeds 40 km/h at 2m height unless specifically approved by the engineer.
500.1.5.2. Cleaning of surface
The surface on which the bituminous work is to be laid shall be cleaned of all loose and extraneous
matter by means of a mechanical broom or any other approved equipment/method as specified in the
contract. The use of a high pressure air jet from a compressor to remove dust or loose matter shall
be available full time on the site, unless otherwise specified in the contract.
500.1.5.3. Spreading
Except in areas where a mechanical paver cannot access, bituminous materials shall be spread,
levelled and tamped by an approved self-propelled paving machine. As soon as possible after arrival
at site, the materials shall be supplied continuously to the paver and laid without delay.
The rate of delivery of material to the paver shall be regulated to enable the paver to operate
continuously. The travel rate of the paver, and its method of operations, shall be adjusted to ensure
an even and uniform flow of bituminous material across the screed, free from dragging, tearing and
segregation of the material. In areas with restricted space where a mechanical paver cannot be used,
the material shall be spread, raked and leveled with suitable hand tools by experienced staff, and
compacted to the satisfaction of the engineer. The minimum thickness of material laid in each paver
pass shall be in accordance with the minimum values given in the relevant parts of these
specifications. When laying binder course or wearing course approaching expansion joint of a
structure, machine laying shall stop 300 mm short of the joint. The remainder of the pavement up to
joint, and the corresponding area beyond it, shall be laid by hand, and the joint or joint cavity shall be
kept clear of surfacing material.
Bituminous material, with a temperature greater than 1450C, shall not be laid or deposited on bridge
deck waterproofing systems, unless precautions against heat damage have been approved by
engineer. Hand placing of pre-mixing bituminous materials shall only be permitted in the following
circumstances:
(i) For laying regulating courses of irregular shape and varying thickness. (ii) In confined spaces
where it is impracticable for a paver to operate. (iii) For footways. (iv) At the approaches to expansion
joints at bridges, viaducts or other structures. (v) For laying mastic asphalt in accordance with clause
500.15. (vi) For filling of potholes. (vii) Where directed by the engineer
Manual spreading of pre-mixed wearing course material or the addition of such material by hand-
spreading to the paved area, for adjustment of level, shall only be permitted in the following
circumstances.
(i) At the edges of the layers of material and at gullies and manholes. (ii) At the approaches to
expansion joints at bridges, viaducts or other structures (iii) as directed by the engineer.
500.1.5.4. Cleanliness and overlaying

500-2
Bituminous material shall be kept clean and uncontaminated. The only traffic permitted to run on
bituminous material to be overlaid shall be that engaged in laying and compacting the next course or,
where a binder course is to be sealed or surface dressed, that engaged on such surface treatment.
Should any bituminous material become contaminated the contractor shall make it good to the
satisfaction of the engineer, in compliance with clause 500.1.8.
Binder course material shall not remain uncovered by either the wearing course or surface treatment,
whichever is specified in the contract, for more than three consecutive days after being laid. The
engineer may extend this period, by the minimum amount of time necessary, because of weather
conditions or for any other reason. If the surface of the base course is subjected to traffic, or not
covered within three days, a tack coat shall be applied, as directed by the engineer.
500.1.6. Compaction - Bituminous materials shall be laid and compacted in layers which enable the
specified thickness, surface level, regularity requirement and compaction to be achieved.
Compaction of bituminous materials shall commence as soon as possible after laying. compaction
shall be substantially completed before the temperature falls below the minimum rolling temperatures
stated in the relevant part of these specifications. Rolling of the longitudinal joints shall be done
immediately behind the paving operation. After this, rolling shall commence at the edges and
progress onwards the centre longitudinally except that on super elevated and unidirectional cambered
portions, it shall progress from the lower to the upper edge parallel to the centre line of the pavement.
Rolling shall continue until all roller marks have been removed from the surface. All deficiencies in the
surface after laying shall be made good by the attendants behind the paver, before initial rolling is
commenced. The initial or breakdown rolling shall be done with 8 – 10 tonnes dead weight smooth-
wheeled rollers. The intermediate rolling shall be done with 8-10 tonnes dead weight or vibratory roller
or with a pneumatic tyred roller of 12 to 15 tonnes weight having nine wheels, with a tyre pressure of
at least 5.6 kg/sqcm. The finish rolling shall be done with 6 to 8 tonnes smooth wheeled tandem
rollers. Where compaction is to be determined by density of cores the requirements to prove the
performance of the rollers shall apply in order to demonstrate that the specified density can be
achieved. In such cases the contractor shall nominate the plant, and the method by which he intends
to achieve the specified level of compaction and finish at temperatures above the minimum specified
rolling temperature/. Laying trials shall then demonstrate the acceptability of the plant and method
used. Bituminous materials shall be rolled in a longitudinal direction, with the driven rolls nearest the
paver. 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 rear
roll or, in the case of pneumatic tyred roller, at least the nominal width of 300 mm.
In portions with super-elevated and uni-directional camber, after the edge has been rolled, the roller
shall progress from the lower to the upper edge.
Rollers should move at a speed of not more than 5 km per hour. The roller shall not be permitted to
stand on pavement which has not been fully compacted, and necessary precautions shall be taken to
prevent dropping of oil, grease, petrol or other foreign matter on the pavement either when the rollers
are operating or standing. The wheels of rollers shall be kept moist with water, and the spray system
provided with the machine shall be in good working order, to prevent the mixture from adhering other
wheels. Only sufficient moisture to prevent adhesion between the wheels of rollers and the mixture
should be used. Surplus water shall not be allowed to stand on the partially compacted pavement.
500.1.7. Joints
Where longitudinal joints are made in pre-mixed bituminous materials, the materials shall be fully
compacted and the joint made flush in one of the following ways; only method (iii) shall be used for
transverse joints:
(i) By heating the joints with an approved joint heater when the adjacent width is being laid,

500-3
but without cutting back or coating with binder. The heater shall raise the temperature of the full depth
of material, to within the specified range of minimum rolling temperature and maximum temperature at
any stage for the material, for a width not less than 75 mm. The contractor shall have equipment
available, for use in the event of a heater breakdown, to form joints by methods (iii).
(ii) By using two or more pavers operating in echelon, where this is practicable, and in sufficient
proximity for adjacent widths to be fully compacted by continuous rolling;
(iii) By cutting back the exposed joint, for a distance equal to the specified layers thickness, to vertical
face, discarding all loosened material and coating the vertical face completely with 80/100 penetration
grade hot bitumen, or cold-applied bitumen, or polymer modified adhesive bitumen tape with a
minimum thickness of 2 mm, before the adjacent width is laid.
All joints shall be offset at least 300 mm from parallel joints in the layer beneath or as directed, and in
a layout approved by the engineer. Joints in the wearing course shall coincide with either the lane
edge or the lane marking, which is appropriate. Longitudinal joints shall not be situated in wheel track
zones.
500.1.8. Preparation of surface
500.1.8.1. Scope - This work shall consist of preparing an existing granular or black-topped surface
bituminous course. The work shall be performed on such widths and lengths as shown on the
drawings or as instructed by engineer. The existing surface shall be firm and clean, and treated with
prime or tack coat as shown on the drawings as otherwise stated in the contract.
200.1.8.2. Materials
500.1.8.2.1. For scarifying and re-laying the granular surface - The material used shall be coarse
aggregate salvaged from the scarification of the existing granular base course supplemented by fresh
coarse aggregate and screenings so that aggregates and screenings thus supplemented correspond
to clause 400.4: Water Bound Macadam or clause 406.6Wet Mix Macadam of the Ministry’s
Specification for Road and Bridge Works (third revision) 1995.
500.1.8.2.2. For patching potholes and sealing cracks - Where the existing surface to be overlaid
is bituminous, any existing potholes and cracks shall be repaired and sealed in accordance with
clauses 3000.4.2 and 3000.4.3, or as directed by the engineer.
500.1.8.2.3. For profile corrective course - A profile corrective course for correcting the existing
pavement profile shall be laid to varying thickness as shown on the drawings, or as indicated in the
contract documents. The profile corrective course shall be laid to tolerances and densities as
specified for wearing course if a single layer, or base course, if it is to be covered with a wearing
course layer.
500.1.8.2.4. Profile corrective course and its application - The type of material for use as profile
corrective shall be as shown on the drawings or as directed by the engineer. While it is to be laid as
part of the overlays/strengthening course, the profile corrective course material shall be of the same
specification as that of the overlay/strengthening course. However, if provided as a separate layer, it
shall be of the specification and details given in the contract drawings.
(i) Any high spots in the existing surface shall be removed by a milling machine or other approved
method, and all loose material shall be removed to the satisfaction of the engineer. (ii) Where the
maximum thickness of profile corrective course will be not more than 40 mm, the profile Corrective
course shall be constructed as an integral part of the overlay course. In other cases, the Profile
corrective course shall be constructed as a separate layer, adopting such construction procedure and
using such equipment as approved by the engineer, to lay the specified type of material , to
thickness and tolerance as specified, for the course, to be provided.
500.1.8.3. Construction operations
500.1.8.3.1. Preparing existing granular surface - Where the existing surface is granular, all loose
materials shall be removed, and the surface lightly watered where the profile corrective course to be
500-4
provided as a separate layer is also granular. Where the profile corrective course of bituminous
material is to be laid over the existing granular surface, the latter shall, after removal of all loose
material, be primed in accordance with clause 500.2.
The surface finish of all granular layers on which bituminous works are to be placed, shall, unless
otherwise specifically instructed by the engineer, be free from dust. All such layers must be capable
of being swept, after the removal of any non-integral loose material, by means of a mechanical broom,
without shedding significant quantities of material and dust removed by air jet, washing, or other
means approved by the engineer.
After cleaning the surface shall be correct to line and level, within the tolerances specified for base
course.
500.1.8.3.2. Scarifying existing bituminous surface - Where specified or shown on the drawings,
the existing bituminous layer in the specified width shall be removed with care and without causing
undue disturbance to the underlying layer; by a suitable method approved by the engineer. After
removal, all loose and disintegrated material, the underlying layers that might have been disturbed
should be suitably reworked and compacted to line and level. After supplementing the base material
as necessary with suitable fresh stone, the compacted finished surface shall be primed in accordance
with clause 500.2. Reusable materials shall be stacked as directed by the engineer within 1000 m of
their origin.
500.1.8.3.3. Patching of potholes and sealing of cracks - Where the existing surface to be overlaid
is bituminous, any existing potholes and cracks shall be repaired and sealed in accordance with
clauses 3000.4.2. And 3000.4.3., or as directed the engineer.
500.1.8.3.4. Laying the profile corrective course
500.8.3.4.1. Laying on granular base - After preparing the granular surface in accordance with
clauses 500.1.8.3.1 and 500.1.8.3.2, the profile corrective course shall be laid using material as
described in Clauses 500.1.8.2.3 and 500.1.8.2.4, or otherwise described in the contract, and
compacted to the requirements of the particular specifications.
500.1.8.3.4.2. Laying on existing bituminous surface - The existing bituminous surface shall be
prepared in accordance with clause 500.1.8.3.3, and after applying a tack coat conforming to clause
500.3, the bituminous profile corrective course shall be laid and compacted to the requirements of the
particular specification.
500.1.8.3.4.3. Correction of local depression - Where local sags or depressions occur in the
existing pavement, a specific filling operation shall be instructed by the engineer, which should be laid
in accordance with Figure 1. Normally, the maximum layer thickness at any point should not exceed
100 mm. In placing multiple lifts, they should be arranged according to the correct method as
illustrated.
For correction of camber or super-elevation of the existing carriageway, the method showed in Figure.
500-2 shall be adopted, depending on the profile of the existing carriageway.
500.1.8.3.5. Covering the profile corrective courses - Profile corrective course particularly shall be
so planned that the layer shall be covered by the designed base/wearing course at the earliest
opportunity, before opening to regular traffic.
500.1.8.4. Surface finish and quality control of work - The relevant provisions of section 900 shall
apply.
Note: Profile corrective course material to be in accordance with the lift thickness
500.1.8.5. Arrangements for traffic - During construction operations, arrangements for traffic shall
be made in accordance with the provisions of clause 100.12.
500.1.8.6. Environmental protection - The provisions of clause 100.11 of the Ministry’s Specification
for Road and Bridge Works (third revision) 1995 and the provision of Appendix A to clause 500.1 shall
apply.
500-5
 (A) Correct method

(A) Incorrect method

Fig. 1 Method for providing corrective course for short sags and depressions

Appendix ‘A’
SPECIFICATIONS FOR PROTECTION OF THE ENVIRONMENT
1. General
1.1. This section of the specifications sets out limitations on the contractor’s activities specifically
intended to protect the environment.
1.2. The contractor shall take all necessary measures and precautions and otherwise ensure that the
execution of the works and all associated operations on site or off-site are carried out in conformity
with statutory and regulatory environmental requirements including those prescribed elsewhere in this
document.
1.3. The contractor shall take all measures and precautions to avoid any nuisance or disturbance
arising from the execution of the works. This shall wherever possible be achieved by suppression of
the nuisance at source rather than abutment of the nuisance once generated.
1.4. In the event of any spoil, debris, waste or any deleterious substance from the Site being
deposited on any adjacent land, the contractor shall immediately remove all such material and restore
the affected area to its original state to the satisfaction of the engineer.
2. Water quality
2.1. The contractor shall prevent any interference with the supply to or abstraction from, and prevent
any pollution of, water resources (including underground percolating water) as a result of the
execution of the works.

500-6
2.2. Areas where water is regularly or repetitively used for dust suppression purposes shall be laid to
fall to specially constructed settlement tanks to permit sedimentation of particulate matter. After
settlement, the water may be re-used for dust suppression and rinsing.
2.3. All water and other liquid waste products arising on the site shall be collected and disposed of at
a location on or off the site and in a manner that shall not cause either nuisance or pollution.
2.4. The contractor shall not discharge or deposit any matter arising from the execution of the works
into any waters except with the permission of the engineer and the regulatory authorities concerned.
2.5. The contractor shall at all times ensure that all existing stream courses and drains within, and
adjacent to, the site are kept safe and free from any debris and any materials arising from the works.
2.6. The contractor shall protect all watercourses, waterways, ditches, canals. drains, lakes and the
like from pollution as a result of the execution of the works.
3. Air quality
3.1. The contractor shall devise and arrange methods of working to minimise dust, gaseous or other
air-borne emissions and carry out the works in such a manner as to minimise adverse impacts on air
quality.
3.2. The contractor shall utilise effective water sprays during delivery manufacture, processing and
handling of materials when dust is likely to be created, and to dampen stored materials during dry and
windy weather. Stockpiles of friable materials shall be covered with clean tarpaulins, with application
of sprayed water during dry and windy weather. Stockpiles of material or debris shall be dampened
prior to their movement, except where this is contrary to the specification.
3.3. Any vehicle with an open load-carrying area used for transporting potentially dust-producing
material shall have properly fitting side and tailboards. Materials having the potential to produce dust
shall not be loaded to a level higher than the side and tail boards, and shall be covered with a clean
tarpaulin in good condition. The tarpaulin shall be properly secured and extend at least 300 mm over
the edges of the side and tailboards.
3.4. In the event that the contractor is permitted to use gravel or earth roads for haulage, he shall
provide suitable measures for dust palliation, if these are, in the opinion of the engineer, necessary.
Such measures may include spraying the road surface with water at regular intervals.
4. Noise
4.1. The contractor shall consider noise as an environmental constraint in his planning and execution
of the works.
4.2. The contractor shall take all necessary measures so that the operation of all mechanical
equipment and construction processes a on and off the site shall not cause any unnecessary or
excessive noise, taking into account applicable environment requirements. The contractor shall use
all necessary measures and shall maintain all plant and silencing equipment in good condition so as
to minimise the noise emission during construction works.
5. Control of wastes
5.1. The contractor shall control the disposal of all forms of waste generated by the construction
operations and in all associated activities. No uncontrolled deposition or dumping shall be permitted.
Wastes to be so controlled shall include, but shall not be limited to, all forms of fuel and engine oils, all
types of bitumen, cement, surplus aggregates, gravel’s, bituminous mixtures etc. The contractor shall
make specific provision for the proper disposal of these and any other waste products, conforming to
local regulations and acceptable to the engineer.
6. Emergency response
6.1. The contractor shall plan and provide for remedial measures to be implemented in the event of
occurrence of emergencies such as spillage of oil or bitumen or chemicals.

500-7
6.2. The contractor shall provide the engineer with a statement of the measures he intends to
implement in the event of such an emergency, which shall include a statement of how he intends to
provide personnel adequately, trained to implement such measures.
7. Measurement
7.1 No separate measurement shall be made in respect of compliance by the contractor with the
provisions of this section of the specification. The contractor shall be deemed to have made
allowance for such compliance with these provisions in the preparation of his prices for items of work
included in the Bills of Quantities and full compensation for such compliance will be deemed to be
covered by them.
500.2. SPECIFICATIONS FOR PRIME COAT OVER GRANULAR BASE.
500.2.1. Scope - This work shall consist of the application of a single coat of low viscosity liquid
bituminous material to a porous granular surface preparatory to the superimposition of bituminous
treatment or mix.
500.2.2. Materials
500.2.2.1. Primer - The choice of a bituminous primer shall depend upon the porosity characteristics
of the surface to be primed as classified in IRC: 16, (Annexure 500-A.2) these are:
(i) Surfaces of low porosity, such as wet mix macadam and water bound macadam, (ii) Surfaces of
medium porosity; such as cement stabilised soil base, (iii) Surfaces of high porosity; such as a gravel
base.
500.2.2.2. Primer viscosity - The type and viscosity of the primer shall comply with the requirements
of IS 8887, as sampled and tested for bituminous primer in accordance with these standards.
Guidance on viscosity and rate of spray is given in Table 1.
Table1. Viscosity requirement and quantity of liquid bituminous primer
Kinematic viscosity of Primer at 600C Quantity of Liquid Bituminous Material
Type of surface (Centistokes) per 10 Sq.cm. (kg)
Low porosity 30-60 6 to 9
Medium porosity 70-140 9 to 12
High porosity 250-500 12 to 15
500.2.2.3. Choice of primer - The primer shall be bitumen emulsion, complying with IS 8887 of a
type and grade as specified in the contract or as directed by the engineer. The use of medium curing
cutback as per IS 217 (Annexure 500- A.3) shall be restricted only for sites at sub-zero temperatures
or for emergency applications as directed by engineer.
500.2.3. Weather and seasonal limitations - Bituminous primer shall not be applied to a wet surface
(see 500.2.4.2) or during a dust storm or when the weather is foggy, rainy or windy or when the
temperature in the shade is less than 10 0C. Surfaces, which are to receive emulsion primer, should be
damp, but no free or standing water shall be present.
500.2.4. Construction
500.2.4.1. Equipment - The primer distributor shall be a self-propelled or towed bitumen pressure
sprayer equipped for spraying the material uniformly at specified rates and temperatures. Hand
spraying of small areas, inaccessible to the distributor, or in narrow strips shall be sprayed with a
pressure hand sprayer, or as directed by the engineer.
500.2.4.2. Preparation of road surface - The surface to be primed shall be prepared in accordance
with clauses 500.1.8 and 900.2 as appropriate. Immediately prior to applying the primer the surface
shall be carefully swept clean of dust and loose particles, care being taken not to disturb the
interlocked aggregate. This is best achieved when the surface layer is slightly moist (lightly sprayed
with water and the surface allowed to dry) and the surface should be kept moist until the primer is
applied.
500.2.4.3. Application of bituminous primer- The viscosity and rate of application of the primer shall
be as specified in the contract or as determined by site trials carried out as directed by the engineer.
500-8
Where a geosynthetic is proposed for use, the requirements of clauses 700.4.3. and 704.4.4. shall
apply. The bituminous primer shall be sprayed uniformly in accordance with clause 500.1. The
method for application of the primer will depend on the type of equipment to be used, size of nozzles,
pressure at the spray bar and speed of forward movement. The contractor shall demonstrate at a
spraying trial, that the equipment and method to be used is capable of producing a uniform spray,
within the tolerances specified.
500.2.4.4. Curing of primer and opening to traffic - A primed surface shall be allowed to cure for at
least 24 hours or such other period as is found to be necessary to allow all the volatiles to evaporate
before any subsequent surface treatment or mix is laid. Any unabsorbed primer shall first be blotted
with an application of sand, using the minimum quantity possible. A primed surface shall not be
opened to traffic other than the necessary to lay the next course. A very thin layer of clean sand may
be applied to the surface of the primer, to prevent the primer pricking up under the wheels of the paver
and the trucks delivering bituminous materials to the paver.
500.2.4.5. Tack coat - Over the primed surface, a tack coat should be applied in accordance with
clause 500.3.
500.2.5. Quality control of work - For control of the quality of materials supplied and the works
carried out, the relevant provisions of section 900 shall apply.
500.2.6. Arrangements for traffic - During construction operations, arrangements for traffic shall be
made in accordance with the provisions of clause 100.12.
500.2.7. Measurement for payment - Prime coat shall be measured in terms of surface area of
application in square metres
500.2.8. Rate - The contract unit rate for prime coat with adjustments as described in clause 500.2.7.
shall be payment in full for carrying out the required operations including full compensation for all
components listed in clause 401.8(I) to (v) and as applicable to the work specified in these
specifications. Payment shall be made on the basis of the provision of prime coat at an application
rate of 0.6 kg per square metre, with adjustment, plus or minus, for the variation between this amount
and the actual amount approved by the engineer after the preliminary trials referred to in clause
500.2.4.3.
500.3. SPECIFICATIONS FOR TACK COAT
500.3.1 Scope - This work shall consist of the application of a single coat of low viscosity liquid
bituminous material to an existing bituminous road surface preparatory to the superimposition of a
bituminous mix, when specified in the contract or instructed by the engineer.
500.3.2. Materials
500.3.2.1. Binder - The binder used for tack coat shall be bitumen emulsion complying with IS 8887
(Annexure 500-A.4) of a type and grade as specified in the contract or as directed by the engineer.
The use of cutback bitumen as per IS 217 (Annexure 500-A.3) shall be restricted only for sites at sub-
zero temperatures or for emergency applications as directed by the engineer.
500.3.3. Weather and seasonal limitations - Bituminous material shall not be applied to a wet
surface or during a dust storm or when the weather is foggy, rainy or windy or when the temperature
in the shade is less than 10 0C. Where the tack coat consists of emulsion, the surface shall be slightly
damp, but not wet. Where the tack coat is of cutback bitumen, the surface shall be dry.
500.3.4. Construction
500.3.4.1. Equipment - The tack coat distributor shall be a self propelled or towed bitumen pressure
sprayer, equipped for spraying the material uniformly at a specified rate. Hand spraying of small
areas, inaccessible to the distributor, or in narrow strips, shall be sprayed with a pressure hand
sprayer, or directed by the engineer.
500.3.4.2. Preparation of base - The surface on which the tack coat is to be applied shall be clean
and free from dust, dirt, and any extraneous material, and be otherwise prepared in accordance with
500-9
the requirements of clauses 500.1.8 and 900.2 as appropriate. Immediately before the application of
the tack coat, the surface shall be swept clean with a mechanical broom, and high-pressure air jet, or
by other means as directed by the engineer.
500.3.4.3. Application of tack coat - The application of tack coat shall be at the rate specified in the
contract, and shall be applied uniformly. If rate of application of tack coat is not specified in the
contract then it shall be at the rate specified in Table 2. The normal range of spraying temperature for
a bituminous emulsion shall be 20 0C to 700C and for a cutback, 500C to 800C if RC-70/MC-70 is used.
Where a geosynthetic is proposed for use, the provisions of section 700 shall apply. The method of
application of the tack coat will depend on the type of equipment to be used, size of nozzles, pressure
at the spray bar, and speed of forward movement. The contractor shall demonstrate at a spraying
trial, that the equipment and method to be used is capable of producing a uniform spray, within the
tolerances specified.
Where the material to receive an overlay is a freshly laid bituminous layer that has not been subjected
to traffic, or contaminated by dust, a tack coat is not mandatory where the overlay is completed within
two days.
Table 2. Rate of application of tack coat
Sl.No Type of Surface Quantity of liquid bituminous material in Kg.per sq.m.area
i. Normal bituminous surfaces 0.20 to 0.25
ii. Dry and hungry bituminous surfaces 0.25 to 0.30
iii. Granular surfaces treated with primer 0.25 to 0.30
iv. Non bituminous surfaces
a) Granular base (not primed) 0.35 to 0.40
b) Cement concrete pavement 0.30 to 0.35
500.3.4.4. Curing of tack coat - The tack coat shall be left to cure until all the volatiles have
evaporated before any subsequent construction is started. No plant or vehicles shall be allowed on
the tack coat other than those essential for the construction.
500.3.5. Quality control of work - For control of the quality of materials supplied and the works
carried out, the relevant provisions of section 900 shall apply.
500.3.6. Arrangements for traffic - During the period of construction, arrangements for traffic shall
be made in accordance with the provisions of clause 100.12.
500.3.7. Measurement for payment - Tack coat shall be measured in terms of surface area of
application in square metres.
500.3.8. Rate - The contract unit rate for tack coat shall be payment in full for carrying out the required
operations including for all components listed in clause 400.1.8 (I) to (v) and as applicable to the work
specified in these specifications. The rate shall cover the provision of tack coat at 0.2 kg per square
metre, with the provision that the variance in actual quantity of bitumen used will be assessed and the
payment adjusted accordingly.
500.4. SPECIFICATIONS FOR BITUMINOUS MACADAM
500.4.1. Scope - This work shall consist of construction in a single course having 50mm to 100 mm
thickness or in multiple courses of compacted crushed aggregates premixed with a bituminous binder
on a previously prepared base to the requirements of these specifications. Bituminous macadam is
more open graded than the dense graded bituminous materials described in clauses 500.7., 500.8.
and 500.9.
500.4.2. Materials
500.4.2.1. Bitumen - The bitumen shall be paving bitumen of penetration grade complying with Indian
Standard specifications for “Paving Bitumen” IS: 73, and of the penetration indicated in Table 500-4.
500.4.2.2. Coarse aggregates - The coarse aggregates shall consist of crushed rock, crushed gravel
or other hard material retained on the 2.36 mm sieve. They shall be clean, hard, durable, of cubical
shape, free from dust and soft or friable matter, organic or other deleterious matter where the
500-10
contractor’s selected source of aggregates have poor affinity for bitumen, as a condition for the
approval of that source, the bitumen shall be treated with approved anti-stripping agents, as per the
manufacturer’s recommendations, without additional payment. Before approval of the source, the
aggregates shall be tested for stripping. The aggregates shall satisfy the physical requirements set
forth in Table 3.
Table 3 Physical requirements for coarse aggregates for bituminous macadam
Property Test specification
Grain size analysis1 Max 5% passing 0.075 mm
Cleanliness
sieve
Particle shape Flakiness and Elongation Index Combined)2 Max 30%
Los Angeles Abrasion Value3 Max 40%
Strength*
Aggregate Impact Value3 Max 30%
Soundness:4
Durability Sodium sulphate Max 12%
Magnesium sulphate Max 18%
Water absorption Water absorption5 Max 2%
Coating and Stripping of Bitumen Minimum retained coating
Stripping
Aggregate Mixtures6 95%
Water Sensitivity7 Retained Tensile Strength Min 80%
Notes: 1. IS: 2386 Part 1 4. IS: 2386 Part 5
2. IS: 2386 Part 1 5. IS: 2386 Part 3
(The elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4* 6. IS: 624c1
7. IS: the water sensitivity test is only to be carried out if the minimum retained coating in the stripping
test is less than 95%.
* Aggregate may satisfy requirements of either of these two tests.
Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of the crushed
material retained on the 4.75 mm sieve shall have at least two fractured faces.
500.4.2.3. Fine aggregates - Fine aggregates shall consists of crushed or naturally occurring
material, or a combination of the two, passing 2.36 mm sieve and retained on 75 micron sieve. They
shall be clean, hard, durable, dry and free from dust, and soft or friable matter, organic or other
deleterious matter.
500.4.2.4. Aggregate grading and binder content - When tested in accordance with IS: 2386 Part 1
(wet sieving method), the combined aggregate grading for the particular mixture shall fall within the
limits shown in Table 500-4 for the grading specified in the contract. The type and quantity of
bitumen, and appropriate thickness, are also indicated for each mixture type.
500.4.2.5. Proportioning of material - The aggregates shall be proportioned and blended to produce
a uniform mixture complying with the requirements of Table 4. The binder content shall be within a
tolerance of  0.3 per cent by weight of total mixture when individual specimens are taken for quality
control tests in accordance with the provisions of section 900.
500.4.3. Construction operations
500.4.3.1. Weather and seasonal limitations - The provisions of clause 500.1.5.1 shall apply.
Table 4 Composition of bituminous macadam
Mix designation Grading 1 Grading 2
Nominal aggregate size layer 40 mm 19 mm
thickness 80-100 mm 50-75 mm
IS: Sieve (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100

500-11
 13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.3 2-10 2-10
0.075 0-8 0-8
Bitumen content, % by weight 3.1 – 3.4 3.3 – 3.5
of total mixture.
Bitumen grade 35 to 90 35 to 90
Notes: 1. Appropriate bitumen contents for conditions in cooler areas of India may be up to 0.5%
higher subject to the approval of the engineer.
500.4.3.2. Preparation of the base - The base on which bituminous macadam is to be laid shall be
prepared, shaped and compacted to the required profile in accordance with clauses 500.1.8 and
900.2.3. as appropriate, and a prime coat, shall be applied in accordance with clause 500.2 where
specified, or as directed by the engineer.
500.4.3.3. Tack coat - A tack coat in accordance with clause 500.3 shall be applied as required by the
contract documents, or directed by the engineer.
500.4.3.4. Preparation and transportation of the mixture - The provisions of clauses 500.1.3 and
500.1.4. shall apply.
500.4.3.5. Spreading - The provisions of clauses 500.1.5.3 shall apply.
Table 5. Manufacturing and rolling temperatures
Bitumen Bitumen Aggregate Mixed Material Rolling Laying
Penetration Mixing (0C) Mixing (0C) (0C) (0C) (0C)
35 160-170 160-175 170 Maximum 100 Minimum 130 Minimum
65 150-165 150-170 165 Maximum 90 Minimum 125 Minimum
90 140-160 140-165 155 Maximum 80 Minimum 115 Minimum

500.4.3.6. Rolling - Compaction shall be carried out in accordance with the provisions of clauses
500.1.6. and 500.1.7.
Rolling shall be continued until the specified density is achieved, or where nod density is specified,
until there is no further movement under the roller. The required frequency of testing is defined in
clause 900.3.
500.4.4. Surface finish and quality control of work - The surface finish of the completed
construction shall conform to the requirements of clause 900.2. for control of the quality of materials
supplied and the works carried out, the relevant provisions of section 900 shall apply.
500.4.5. Protection of the layer - The bituminous macadam shall be covered with either the next
pavement course or wearing course, as the case may be, within a maximum of forty-eight hours. If
there is to be any delay, the course shall be covered by a seal coat to the requirement of clause
500.13. before opening to any traffic. The seal coat in such cases shall be considered incidental to
the work and shall not be paid for separately.
500.4.6. Arrangements for traffic - During the period of construction, arrangements for traffic shall
be made in accordance with the provisions of clause 100.12.
500.4.7. Measurement of payment - Bituminous macadam shall be measured as finished work in
cubic metres, or by weight in metric tonnes, where used as regulating course, or square metres at the
specified thickness as indicated in the contract or shown on the drawings, or as otherwise directed by
the engineer.
500.4.8. Rate - The contract unit rate of bituminous macadam shall be payment in full for carrying out
the required operations as specified. The rate shall include for, all components listed in clause
500.1.8.8.2.(i) to (xi).

500-12
500-13