R REFERENCE ONLY IRC:111-2009 For NOT FOR ISSUE SPECIFICATIONS FOR DENSE GRADED BITUMINOUS MIXES LIBRARY & DOCUMENTION CENTRE tro. IMANAPAKKAM, CHENNAY - 640 089 Received on : Ace. No. : Published by INDIAN ROADS CONGRESS Kama Koti Marg, Sector 6, R.K. Puram, New Delhi-110022 2009 Price Rs. 300/- * (Packing and Postage charges extra)IRC : 111-2009 First Published : June, 2009 Reprinted: December, 2009 | (All Rights Reserved. No part of this publication shall be reproduced, | translated or transmitted in any form or by any means without the permission of the Indian Roads Congress) | | Printed at I G Printers Pvt, Ltd, New Delhi-110020 | (500 copies) |IRC:111-2009 CONTENTS Page No. Personnel of the Highways Specifications and Standards Committee 0 1. Introduction 1 2. Scope 2 3. Materials 3 4, DesignofMix 7 5. Construction Operation 9 6. Controls | 13 AnnexA 17 Annex B 2010. il. 12. 13. 14, 15. 16. 17. 18. 20. 21, TRC:111-2009 PERSONNEL OF THE HIGHWAYS SPECIFICATIONS AND Sinha, V.K. (Convenor) Singh, Nirmalit (Co-Convenor) Sharma, Arun Kumar (Member-Secretary) Ahluwalia, H.S. Bahadur, A.P. Basu, S.B. Chandrasekhar, Dr. B.P. Datta, PK. Desai, JP. Deshpande, D.B. Dhingra, Dr. S.L. Gupta, D.P. Gupta, KK. Jain, N.S. Jain, R.K. Jain, Dr. S.S. Kadiyali, Dr. LR. Kandasamy, C. . Krishna, Prabhat Kukreti, B.P. Kumar, Anil STANDARDS COMMITTEE (As on 23rd November, 2008) Addl. Director General, Ministry of Shipping Road Transport & Highways, New Delhi Addl. Director General, Ministry of Shipping Road “Transport & Highways, New Delhi Chief Engineer (R) S&R, Ministry of Shipping, Road ‘Transport & Highways, New Delhi Members Chief Engineer (Retd.), Ministry of Shipping, Road Transport & Highways, New Delhi Chief Engineer (Retd.), Ministry of Shipping, Road Transport & Highways, New Delhi Chief Engineer(Retd.), Ministry of Shipping, Road Transport & Highways, New Delhi Director (Tech.), National Rural Roads Development Agency (Ministry of Rural Development), New Delhi Executive Director, Consulting Engg, Services (I) Pvt. Ltd., New Delhi Sr, Vice-President (Tech Ser.), Gujarat Ambuja Cement Ltd., Ahmedabad Secretary, Maharashtra PWD, Mumbai Professor, Indian Institute of Technology, Mumbai DG (RD) (Retd.), Ministry of Shipping, Road Transport & Highways, New Delhi Chief Engineer (Retd.), Haryana, PWD Chief Engineer, Ministry of Shipping, Road Transport & Highways, New Delhi Chief Engineer (Retd.), Haryana PWD, Sonepat Professor & Coordinator, Centre of Transportation Engg., IIT Roorkee Chief Executive, LR. Kadiyali & Associates, New Delhi Chief Engineer, Ministry of Shipping, Road Transport & Highways, New Delhi Chief Engineer (Retd.), Ministry of Shipping, Road Transport & Highways, New Delhi Chief General Manager, National Highways Authority of India, NewDelhi Chief Engineer (Retd.), CDO, Road Constn, Deptt., Ranchi @IRC:111-2009 22. 23. 24, 25. 26. 21. 28. 29. 30. 31. 32, 33. 34. 35. 36. AEN Kumar, Kamlesh, Liansanga Mina, H.L. Momin, S.S. Nanda, Dr. P.K. Rathore, S.S. Reddy, Dr. TS, Das, S.N. Sastry, GV.N. Sharma, S.C. Sharma, Dr. V.M. Shukla, R.S. Sinha, AV. Srivastava, LK. Velayudhan, TP. President, IRC Director General (Road Development) Secretary General Borge, VB. Justo, Dr. C-E.G. Khattar, MD. ‘Merani, N.V. Chief Engineer, Ministry of Shipping, Road Transport & Highways, New Delhi Engineer-in-Chief & Secretary, PWD, Mizoram, Aizwal Member, Rajasthan Public Service Commission, Ajmer Former Member, Maharashtra Public Service Commission, Mumbai Director (Retd.), Central Road Research Institute New Delhi Secretary to the Govt. of Gujarat, PWD, Gandhinagar Senior Vice-President, NMSEZ Development Corporatio Pvt. Ltd. Mumbai a Chief Engineer, Ministry of Shipping, Road Transport é& Highways, New Delhi Engineer-in-Chief (R&B), Andhra Pradesh PWD, Secunderabad DG(RD) & AS, MORT&H (Retd.), New Delhi Director, AIMIL, New Delhi Ex-Scientist, Central Road Research Institute, New Delhi Chief Engineer, Ministry of Shipping, Road Transport & Highways, New Delhi Director (Projects), National Rural Roads Development Agency, (Ministry of Rural Development), New Delhi Addl. DGBR, Directorate General Border Roads, New Delhi Ex-Officio Members (Mina, H.L.), Member, Rajasthan Public Service Commission, Ajmer —, Ministry of Shipping, Road ‘Transport & Highways, New Delhi (A.N. Dhodapkar), Indian Roads Congress, New Delhi Corresponding Members Past-President, IRC, Secretary (Retd.), Maharashtra PWD, Mumbai Emeritus Fellow, Bangalore University, Bangalore Executive Diector, Hindustan Construction Co, Ltd., Mumbai Principal Secretary, Maharashtra PWD (Retd.), Mumbai i)IRC: 111-2009 SPECIFICATIONS: FOR DENSE GRADED BITUMINOUS MIX! 1 INTRODUCTION ‘The Indian Roads Congress published three specifications for dense graded bituminous mixes under titles ‘Bituminous Concrete (IRC:29), ‘Dense Bituminous Macadam (IRC:94)' and ‘Semi- Dense Bituminous Concrete (IRC: 95)’. The Flexible Pavement Committee (FPC) in its meeting held on 22 April, 2006 decided to revise the specifications to keep pace with the changes in the technology and improvements in the construction procedures as well as quality control expectations. Ttwas also decided to combine all the documents related to dense graded bituminous mixes into a comprehensive document and authorized Shri R.K.Pandey to finalize the draft with technical input from Prof. PS.Kandhal. The finalized draft was sent to all FPC members for comments. The FPC in its meeting on 9% September, 2006 discussed all comments in detail. The revised draft was published in the February, 2007 issue of the “Indian Highways” to solicit more comments from users at large, These additional comments were reviewed by the FPC in its meeting on 5* May, 2007. The FPC authorized Prof. PS. Kandhal to incorporate all comments and finalize the draft. Draft finalized by Prof, P S Kandhal was discussed by the Flexible Pavement Committee in its meeting held on 27" July, 2008 wherein Committee authorized Convenor, Flexible Pavement Committee to modify the draft in the light of the discussions held and submit to the Highways Specifications and Standards (HSS) Committee, HSS Committee considered the draft init fifth meeting held on 23 November 2008. Draft modified by the Convenor, HSS Committee was approved by the Executive: Committee in its meeting held on 30" November, 2008, at New Delhi and by the Council in its meeting held on 13 December, 2008 at Kolkata subject to the incorporation ‘of modifications keeping in view the comments of members and approval by the Convenor, HSS Committee. The names of the Personnel of Flexible Pavement Committee (H-2) are given below: ‘Singh, Nirmal Jit -- Convenor Shukla, R.S. == Co-Convenor Nirmal, $.K. -- Member-Secretary Members Agarwal, Dr. Sanjeev Kachroo, Dr. PN. Bhanwala, Col. R.S. Kandhal, Prof. P.S. Bose, Dr. Sunil Kirori, R.R.D. Das, Dr. Animesh Krishna, Prabhat Jain, RK. Mina, H.L. Jain, Rajesh Kumat Pandey, RK. Jain, Dr. S.S. Rathore, 8.8.IRC:111-2009 Rawat, M.S. Singh, Mahavir Raza, Md. Asif Tatwani, LN. Roychaudhari, Pinaki ‘Tyagi, BR. Sharma, S.C. Director, HRS Corresponding Members Bhattacharya, C.C. Issac, Prof. P.K. Dongre, Dr. Raj Justo, Dr. CE.G. Reddy, Dr. K.S. f Ex-Officio Members President, IRC (Mina, H.L.) Director General (RD), MOSRT&H = —~ Secretary General, IRC (A.N. Dhodapkar) 2 SCOPE 21 ‘This specification deals with the basic outline for the design, construction and controls needed while laying dense graded bituminous mixes in base course, binder course and wearing course, 2.2 Dense graded bituminous mixes shall consist of mineral aggregate and appropriate bituminous binder, mixed in a hot mix plant and laid with a mechanized paver, Dense graded bituminous mixes, such as, binder and wearing courses are usually laid on a previously prepared bituminous layer. Binder course is the intermediate layer between bituminous base course and bituminous wearing course. Three different specifications for dense graded bituminous mixes are available for use for highways. Purpose, layer thickness and number of layers allowed for these specifications are given in Table 1 ‘Table 1 ‘Types of Dense Graded Bituminous Mixes, their Use, Number of Layers and Layer Thickness [Specification Purpose ‘Number of | Thickness of Layers each Layer Dense Bituminous Base/Binder Course/Overlay for | Single or | 50 mm - 100mm Macadam (DBM) Strengthening Multiple [Scmi-Dense Bituminous | Wearing Course Single 25 mm - 40 mm Concrete (SDBC) [Bituminous Concrete _| Wearing Course Single 25 mm/40 mmn/ (BC) 50mmIRC:111-2009 3 MATERIALS 3.1 Bitumen 3.1.1 The bitumen for dense graded bituminous mixes shall comply with Indian Standard Specification for viscosity-graded paving bitumen, IS: 73 or modified bitumen complying with the IS: 15462, Guidelines for selection of grade of viscosity-graded paving bitumen and modified bitumen are given in Tables 2 to 4. Table2 Viscosity Graded (VG) Bitumens and their General Applications Viscosity Grade General Applications (vG) VG-40 Use in highly stressed areas such as those in intersections, near toll (40-60 penetration) booths, and truck parking lots in teu of old 30/40 penetration grade VG-30 Use for paving in most of India in lieu of old 60/70 penetration grade (50-70 penetration) VG-20 Use for paving in cold climatic, high altitude regions of North India (60-80 penetration) VG-10 Use in spraying applications and for paving in very cold climate in (80-100 penetration) lieu of old 80/100 penetration grade 3.1.2 The type and grade of bitumen to be used shall be specified in the Contract. 3.1.3. Both the highest daily mean air temperature and the lowest daily mean air temperatures mentioned in Tables 3 and 4 can be obtained for the weather station nearest to the project site from the Indian Meteorological Organization (IMO). The IMO has data on daily mean high temperature for all 365 days in a year for all weather stations based on historical records of the last. 30-40 or more years. This daily mean high temperature on a specific day is the same as daily “normal” high temperature for that day as usually reported in some newspapers. The highest of the 365 daily mean high air temperatures (which usually occurs on some day in May or June) is used in Tables 3 and 4, Likewise, the lowest daily mean air temperature (which usually occurs on some day in January) can also be obtained from the IMO, ‘Table 3 Selection Criteria for Viscosity-Graded (VG) Paving Bitumen Based on Climatic Conditions Highest Daily Mean Air Temperature, °C Lowest Daily Mean Less than 20°C 20 to 30°C More than 30°C Air Temperature, °C More than —10°C. VG-10 WG-20 VG-30 -10°C or lower YG-10 VG-10 VG-20 LIBRARY & D pouMENTATIN CENTRI FOUBRO av 7 wee co SS tRUCTION GROUP ‘O,N6. 979, ah i OONAMALLEE R \we\ MO NAPAKKAM. CHENNAI - 600 089IRC:111-2009 Table 4 Selection Criteria for Grade of Modified Bitumen Highest Daily Mean Air Temperature, °C Lowest Daily Mean Air | Less than 20°C 20 to 30°C. More than 30°C ‘Temperature, °C Grade of Modified Bitumen More than -10°C PMB/NRMB 120 PMB/NRMB 70 |PMB/NRMB 40 RMB 50. CRMB 55 CRMB 60 10°C or lower PMB/NRMB 120 PMB/NRMB 120 |PMB/NRMB 70 , CRMB 50 CRMB 50 CRMBSS 7 Polymer Modified Bitumen Natural Rubber Modified Bitumen CRMB = Crumb Rubber Modified Bitumen Note : When commercial vehicles exceeds 2000 per day per lane and the highest daily mean temperature exceeds 40°C, VG-40 or modified bitumen of equivalent stiffness are recommended for bituminous concrete and top layers of dense bituminous macadam. 3.2 Coarse Aggregate 3.2.1 ‘The coarse aggregate shall consist of crushed rock, crushed gravel or other hard material retained on 2.36 mm sieve, It shall be clean, hard, durable and have cubical shape, free from dist and soft organic and other deleterious substances. The aggregate should preferably be of low porosity, The coarse aggregate shall satisfy the physical requirements specified in Table 5. 3.2.2 Where crushed gravel is proposed as aggregate, not less than 95% and 90% by weight of the crushed material retained on 4.75 mm sieve shall have at least two fractured faces for bituminous concrete and DBM/SDBC respectively. 3.3 Fine Aggregate 3.3.1. Fine aggregate shall consist of crushed or naturally occurring mineral material, or a combination of two, passing 2.36 mm sieve and retained on 0.075 mm sieve, No natural sand will be allowed in the binder and wearing courses and no more than 50 percent natural sand will be allowed in the base courses. The fine aggregate shall be clean, hard, durable, dry and free from dust and soft organic and other deleterious substances. Fine aggregate shall have a sand equivalent value not less than 50 when tested in accordance with the requirement of IS: 2720 Part 37. The plasticity index of the fraction passing the 0.425 mm sieve shall not exceed 4 when tested in accordance with IS: 2720 Part 5. | | | | | |‘Table 5 Physical Properties of Coarse Aggregate IRC:111-2009 Property Test Requirement ‘Test method Cleanliness | Grain size analysis Max, 5% passing | 1S: 2386 Part I 0.075 mm. Particle Shape | Flakiness and Elongation Index | Max. 35% IS: 2386 Part I (combined) Strength * Los Angeles Abrasion Value BC-Max. 30% IS: 2386 Part IV Others-Max_ 35% Aggregate Impact Value BC-Max, 24% IS: 2386 Part LV. Others-Max. 27% Polishing ** Polished Stone Value Min. 55 IS: 2386 Part 1V_ Durability ‘Soundness (Bither Sodium or Magnesium Sulphate) 5 eycles Sodium Sulphate. Max. 12% IS: 2386 Part V ‘Magnesium Sulphate ‘Max. 18% IS; 2386 Part V Water ‘Water Absorption Max. 2% 1S: 2386 Part 111 Absorption Stipping ‘Coating and Stripping of Bitumen | Min. Retained 18:6241 Aggregate Mixtures Coating 95% Water Retained Tensile strength*** Min 80% ASHTO 283 sensitivity Notes: * The aggregate may satisfy either of the two tests ** Only for wearing courses + If the minimum retained tensile strength falls below 80%, use of anti-stripping agent is recommended to meet the minimum requirements. 34 Filler 3.4.1 _ Filler shall consist of finally divided mineral matter such as rock dust, or hydrated lime or ‘cement approved by the Engineer, The use of hydrated lime is encouraged because of its very good anti-stripping and antioxidant properti in Table 6. ‘Table 6 Grading Requirement of Mineral Filler ‘The filler shall be graded within the limits indicated 1S Sieve ‘Cumulative % passing by weight (nm) of total aggregate 06 100 03 95 - 100 0.075 85 - 100IRC:111-2009 3.4.2 The filler shall be inert material free from organic impurities and have plasticity index not ‘greater than 4, Plasticity index requirement will not apply if filler is hydrated lime or cement. Where the complete bituminous mixture fails to satisfy requirement of Moisture Susceptibility test (AASHTO 7283 with freeze & thaw option), 2% by total weight of aggregate of hydrated lime shall be used and percentage of fine aggregate reduced accordingly. See Annex A for the outline of AASHTO 7283. 3.5 Aggregate Grading and Bitumen Content 3.5.1 The combined grading of the coarse aggregate, fine aggregate and filler, when tested in accordance with IS 2386 Part 1, wet sieving method, shall conform to limits given in Table 7. 3.5.2 The combined aggregate grading shall not vary from the lower limit on one sieve to the higher limit on the adjacent sieve to avoid gap grading. Table7 Aggregate Grading and Bitumen Content ‘Specification DBM ‘SDBC BC Grading T z T z T z ‘Nominal maximum 375mm 265mm | s2amm—f 9Sma iam | 12mm aggregate size* Layer thickness 75-100mm_ | s0-7Tomm [4mm | mam Som | Sora TS Sieve size (mm) vamulative Percent _by weight of foal aggregate passing cs 100) 373 95-100_ [100 265 6-93 [90-100 100 B = 71-95 [100 90-100 [Too 13z 35-75 [36-80 [90-100_ [100 5979 | 90-100 3S = = 70-90 __[ 90-100 [32-72 [70-88 a7 BESSY 53 35-55_ | SET 235 Dea [24-39-39 Baas Tie = = 15390 [1530 234 [3bas 06 = 7 15-27 [26-38 03 Ta Tat sy oy 10-20 | 18-28 ors = 7 3-3 [12-20 0075 2 2 a8 = 28 +10 Bitumen content (Min)™*] 4% 43% 13% 3% 53% | 54% * Nominal maximum aggregate size is the largest specified sieve size upon which any of the aggregate material is retained, ** Corresponds to specific gravity of the Aggregate being 2.7. In case aggregate have specific gravity more than 2.7, bitumen content can be reduced proportionately. Further, for regions where highest daily mean air temperature is 30°C or lower and lowest daily mean air temperature is -10°C ot lower, the bitumen content may be increased by as much as 0.5 percent,IRC:111-2009 3.5.3 Bitumen content indicated in Table 7 is the minimum only. The exact bitumen content required shall be determined following the Marshall Mix Design procedure contained in the Asphalt Institute Manual MS-2 (Sixth Edition), 3.5.4 The fines to bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2 forall mixes in Table 7. 4 DESIGN OF MIX 4.1 Mix Requirements 4.1.1 Besides conforming to the requitement of grading and quality for individual ingredients the mix shall meet the requirement set out in Tables 8 depending upon the type of binder. Table 8 Requirement of the Dense Graded Bituminous Mix Using Viscosity-Graded (VG) Paving/ Modified Bitumen Properties Viscosity Grade [Modified Bitumen | Test Method Paving Bitumen | Hot Cold Climate_|Climate ‘Compaction level 75 blows on each face of the specimen (Number of blows) Minimum stability 30 io i0 ‘RASHTO 1245 (KN at 60°C) Marshall flow Gam) 24 25-4 [35-3 [AASHTO 1245 Marshall Quotient 25 25-5 (stability/flow) % Air Voids 5 MS-2 and ASTM D2041 % Voids filled with 8-75 MS-2 bitumen (VFB) Tensile Strength Ratio 80% (Minimum) AASHTO T283 Coating of Aggregate 95% (Minimum) TS: 6241 Particles with bitumen % Voids in Mineral aggregate VMA Nominal Maximum Min. % VMA related to designed % air Particle size (mm) voids*** 3 4 3 5 1% 15 16 12 B 4 is 19.0 2 B 4 26.5 1 2 3B 375 10 i 2 +#**For intermediate value of designed percentage air voids interpolate the VMA.IRC;111-2009 42 Binder Content 4.2.1 The binder content shall be selected to obtain 4 percent air voids in the mix design and shall meet all requirements given in Table 8. The Marshall Method for designing the mix shall be adopted as described in the sixth edition of the Asphalt Institute Manual MS-2. 4.2.2. Where maxinwum size of the aggregate is more than 26.5 mm, modified Marshall method using 150 mm (6 inches) diameter specimen described in the Asphalt Institute Manual MS-2 (Sixth Edition) and ASTM DS581 shall be used, This test method requires modified equipmeng and procedure, When the modified Marshall testis used, the specified minimum stability values and the specified flow values given in Table 8 shall be multiplied by 2.25 and 1.5, respectively. 43 Job Mix Formula 4.3.1 The laboratory mix design gives the proportion of the mineral aggregate combination in terms of individual sieve sizes, for actual operational purpose in the field, blending of the two or more sizes of aggregates (each size having within its range of individual sieve size) would be necessary. This blending ratiois obtained on a weight basis giving percent weight of the coarse aggregate, fine aggregate and filler needed to give the ultimate gradation. This mineral aggregate combination together with the conresponding optimum bitumen contentas determined in the laboratory, constitute the job mix formula for implementation during construction. The job mix formula proposed for the use in the work shall give the following details: : 1, Source and location of all materials 2, Proportions of all materials 3, Binder type and percentage by weight of total mixture 4, Coarse aggregate/fine aggregates/mineral filler as percentage by weight of total aggregate including mineral filler. A single definite percentage passing each sieve for the mix aggregate, ‘The individual grading of the individual aggregate fraction and the proportion of each in the combined grading. 7. The test results of mix design such as maximum specific gravity of loose mix (Gmm), compacted specimen densities, Marshall stability, flow, air voids, VMA, VFB and related graphs, and test results of AASHTO T283 Moisture Susceptibility Test. 8 Incase of batch mixer, the individual weight of each type of aggregate and binder per batch. 9, Test results of aggregates. 10. Mixing and compacting temperatures ay 4.3.2. Approval of the job mix formula shall be based on independent testing by the Engineer on the samples furnished by the Contractor. It should be ensured that it is based on the truly representative samples of the material that will be used for the work. New job mix formula shall be got approved whenever there is change in the material used for the work.IRC:111-2009 44 Plant Trial 4.4.1 Plantttial shall be carried out to establish that the plant can produce uniform mix conforming to the job mix formula, The permissible variation of the various ingredients in the actual mix from the job mix formula shall be within the limits as given in Table 9. These variations are intended to apply to individual specimen taken for quality control test in accordance with Clause 6. ‘Table 9 Permissible Variation from the Job Mix Formula Description Permissible Variation DEM SDBC/BC ‘Aggregate passing 19 min or larger = 8% = 7% 13.2 mm/9.5 mm = 1% = 6% 475 mam x 6% = 5% 2.36 mm, 1.18 mm, 0.6 mm = 5% = 4% 0.3 mm, 0.15 mm = 4% + 3% 0.075 mm = 2% = 15% Binder Content = 03% 03% Mixing Temperature = 10C = 10C 4,5 Laying'Trials 4.5.1 Laying trials are carried out to establish that the proposed mix can be successfully laid and compacted. The laying trial shall be carried out in an area, which does not form a part of the work. ‘The minimum area for laying trials shall be 100 sqm. This shall be similar to the project area on which the bituminous layer is to be laid, Methodology, equipment and mix shall also be similar to those proposed for the project. 4.5.2 Thetrials establish that the proposed laying plan, compaction plan, and methodology are capable of producing satisfactory results. The density of finished paving layer should not be Jess than the 92% of the average density (Sample size N=2) based on theoretical maximum specific gravity of the loose mix (Gmm) obtained on the day of trial following ASTM D2041. See Annex B for the outline of ASTM D2041. 5 CONSTRUCTION OPERATION 5.1 Preparation of Base 5.1.1 Cleaning of the surface: The surface shall be cleaned of all loose extraneous matter by means of mechanical broom and high-pressure air jet from compressor or any other approved equipment/method.IRC: 111-2009 5.12 Filling-up of potholes and sealing of cracks: Any potholes and/or cracks shall be repaired and sealed. 5.1.3 Geosynthetics or stress absorbing layers: Where required, layer of geosynthetics/ stress absorbing material shall be laid. 5.1.4 Profile correcting course: Depending upon requirement, profile-correcting course for correcting the existing pavement profile shall be laid either as a separate layer or as a composite layer with varying thickness, Where the maximum thickness of the profile corrective course‘s less than 40 mm, the profile corrective course shall be laid as an integral part of the overlaying layer. In other cases the profile corrective course shall be constructed as a separate layer. When it is laid as a separate layer, type of material for the use as the profile corrective course may differ. 5.2 Tack Coat 5.2.1 Tack coat: Tack Coat shall be as per IRC:16 “Standard Specification and Code of Practice for Prime and Tack Coat”. 5.3 Mixing 5.3.1. Dense graded bituminous mixes 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 aggregate. The essential features of the hot mix plant are given in Annex A of IRC: 27 “Specifications for Bitumen Macadam’, Table 10 gives the mixing, laying, androlling temperatures for dense graded mixtures. Incase of modified bitumen, the temperature of mixing and compaction shall be higher than the mix with conventional bitumen as binder. The exact temperature depends upon the type and amount of modifier used and shall be adopted as per the recommendations of the manufacturer, In order to ensure uniform quality of mix the plant shall be calibrated from time to time. Table 10 Mixing, Laying and Rolling Temperatures for Dense Mixtures (Degree Celcius) Bitumen | Bitumen | Aggregate | Mixed Laying *Rolling | Viscosity | Temperature | Temperature} Material | Temperature | Temperature Grade ‘Temperature vG-40 160-170 160-175 460-170 150 Min, 100 Min, ¥G-30 150-165 150-170 150-165 140 Min. 90 Min, VG-20 145-165 145-170, 145-165, 135 Min. 85 Min. VG-10 140-160, 140-165, 140-160. 130 Min. 80 Min. *Rolling must be completed before the mat cools to these minimum teraperatures. 10IRC:111-2009 5.4 Transportation 5.4.1 Bituminous material shall be transported in clean, insulated covered vehicles. An asphalt release agent, which does not adversely affect the bituminous mix may be applied to the interior of the vehicle to prevent sticking and to facilitate discharge of the material, 5.5 Laying ; 5.5.1 Weather and seasonal limitations: Dense graded bituminous mixes shall not be laid: + inpresence of standing water on the surface, + when rainis imminent and during rains, fog, or dust storm * when the base/binder course is damp, + when the air temperature on the surface on which itis to be laid is less than 10°C for mix with conventional bitumen as binder and is less than 15°C for mix with modified bitumen as binder. = When the wind speed at any temperature exceed the 40 km/h at 2 mheight. 5.5.2 Preparation of the base: Base shall be prepared by carrying out all or some of the operations as per Clause 5.1, depending upon the site conditions. 5.5.3. Spreading: Except in areas where paver cannot access, bituminous material shall be spread, leveled and tamped by self-propelled hydrostatic paver finisher preferably with sensor. As soon as possible after artival at site the material 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 paver and the method of operation shall be adjusted to ensure even and uniform flow of bituminous material across the screed, free from dragging, tearing and segregation. Restricted areas (such as confined space, footways, irregular shape and varying thickness, approaches to expansion joints etc.) where paver cannot be used, the material shall be spread, raked and leveled with suitable hand tool by trained staff. When laying dense graded bituminous mixes near expansion joint, the machine laying shall be stopped about 300 mm short of joint, The remainder of the pavement up to the joint and the corresponding area beyond it shall be laid manually. Tuble 10 gives the minimum laying temperatures. Bituminous material, with temperature greater than 145°C shall not be laid or deposited on bridge deck waterproofing system unless precautions against the heat damage have been taken. 11IRC:111-2009 5.6 Compaction 5.6.1 Compaction shall commence as soon as possible after laying and shall be completed before the temperature falls below the minimum rolling temperatures given in Table 10. Rolling of the {ongitudinal joints shall be done immediately behind the paving operation. After this the rolling shall commence at the edge and progress towards the center longitudinally except at sections with Unidirectional camber, where it shall progress from lower edge to upper edge parallel to centerline of the pavement, 5.6.2 _Alldeficiencies inthe surface after laying shall be made good by the attendant béhind the Paver, before initial rolling is commenced, The initial or breakdown rolling shall be done with the 8 ‘0 10 tonnes dead weight or vibratory steel whee! roller, The intermediate rolling shall be done with 8'o 10 tonnes dead weight or vibratory roller or with a pneumatic roller of 12 to 15 tonnes, with atire pressure of at least 0.56 MPa. The finished rolling shall be done with 6 to 8 tonnes smooth wheel roller. Rolling shall continue till all the roller marks are removed from the surface and the minimum specified field density is achieved, 5.6.3 The dense graded bituminous mixes shall be rolled in the longitudinal divection, with the roller as close as possible to the paver. The overlap on successive passes should be at least one- third of the width of the rear roll or in the case of pneumatic wheeled rollers, at least the nominal width of 300 mm. The roller should move at a speed of no more than 5 kin /hout, The roller shall not be permitted to stand on pavement, which kas not been fully compacted, All precautions.hall be taken to prevent dropping of oil, grease, petrol or other foreign material on the pavement, The Wheel of the rollers shall be kept moist with the water or spray system provided with the machine ‘0 prevent the mixture from adhering to the wheels. Minimum moisture to prevent adhesion between ‘wheels and mixture shall be used and surplus water shall not be allowed to stand on the partially completed pavement, 5.64 The density of the finished paving layer shall be determined by taking 150 mm diameter cores ‘The density of finished paving layer shall not be less than the 92% of the avetage (sample size N=2) theoretical maximum specific gravity ofthe loose mix (Gani) obtained on that day in accordance with ASTM D2041, See Annex B for the outline of ASTM D2041, 5.7 Joints 5.7.1 Where joints are made, the material shall be fully compacted and the joint made flush in one of the following ways. 8) _Alljoints shall be cut vertical to the full thickness of the previously laid mix. All loosened ‘material shall be discarded anc! the vertical face be coated with any viscosity grade bitumen, or cold applied emulsified bitumen, While spreading the material along the joint the material 12IRC:111-2009 spread shall overlap 25 mm to 50 mm on the previously laid mix beyond the vertical face of the joint. The thickness of the loose overlap material should be approximately a quarter more than the final compacted thickness. The overlapped mix should be dragged back to the hot lane so that the roller can press the small excess into the hot side of the joint to obtain a high joint density. b) _Byusing two or more pavers in echelon, where thisis practicable and in sufficient proximity for adjacent width to be fully compacted by continuous rolling. 5.7.2 In multi-layer construction the longitudinal joint in one layer shall offset the joint in the underneath layer by about 150mm. 5.7.3 For transverse joints method a) above can apply. Transverse joints in the successive and adjoining layers should have a minimum offset of 2m. 5.8 Arrangement for Traffic 5.8.1 Itshall be ensured that traffic is not allowed on the surface until the paved mat has cooled below a temperature of 60°C in its entire depth. 6 CONTROLS 6.1 Surface Finish 6.1.1 The levels of the dense graded bituminous mixes shall not vary from those calculated with reference to longitudinal and cross profile of the roads as per the Contract beyond 6 mm provided that the negative tolerance shall not be permitted in conjunction with the positive tolerance for the base course if the thickness of the former is thereby reduced by more than 6 mm, 6.1.2 For checking the compliance with the above requirement measurements of the surface level shall be taken on a grid of points spaced 6.25 m along the length and 0.5 m from the edges and at the centre of the pavement. The compliance shall be deemed to be met for the final road surface only if the tolerance given above is satisfied for any point on the surface, 6.1.3 Incase where surface levels fall outside the specified tolerance, the Contractor shall be liable to rectify these by replacing the full depth of layer. In all cases of replacement the area treated shall not be less than 5 min length and not less than 3.5 m in width. 6.2 Surface Evenness 6.2.1 The measurement and checking of surface unevenness shall be done by a3 m straight edge in accordance with the procedures in IRC:SP:16. 13IRC:111-2009 6.2.2 The maximum permissible surface unevenness in longitudinal profile shall be 6 mm for SDBC and 5 mm for BC. The maximum permissible unevenness in transverse profile shall be 4mm. for both SDBC and BC. 62.3 Themaximam permissible frequency of surface unevenness in 300 m length in longitudinal profile shall be as per Table 11. ‘Table 11 Maximum Permissible Frequency of Unevenness Maximum Number of Surface Unvenness Type of Surface Unevenness, | NH/SH ] MDR and Lower mm Category Semi-Denso Bituminous Concrete 46 2 | 4 (Bituminous Concrete, t 3-5 15 30 6.2.4 Where the surface unevenness falls outside the tolerance, in either case ie. the surface is Jow or high, the full depth of the layer shall be removed and replaced with fresh material and compacted to the specification. 6.2.5. Inall-cases of removal and replacement the area treated shall not be less than Sm inlength and 3.5 min width. 63 Surface Roughness 6.3.1 Surface roughness shall be checked in accordance with procedures in IRC:SP:16, 6.3.2 The maximum permissible values of surface roughness measured with abump integrator ae given in Table 12, Newly constructed surface are expected to give roughness values corresponding to Good category. While the Average and Poor categories indicate level of service and the intervention criteria, ‘Table 12 Maximum Permissible Values of | ‘Roughness (mm/km) for Surface with Dense Graded Bituminous Mixes S.No ‘Type of Surface Condition of Road Surface (mm / km) Good Average Poor SDBC. < 2500 2500-3500, > 3500 2. BC <2000 2000-3000 >3000 64 Quality Control during Construction 64.1 The material supplied and the work shall conform to the specifications prescribed inthe Preceding Clauses. To ensure the quality of the material and the work, control tests shall be conducted 14IRC:111-2009 during the execution of the paving project. The tests and minimum frequency for each testis indicated in Table 13. ‘Table 13 Control Tests for Dense Graded Bituminous Mixes and their Minimum Frequency Test I Frequency ‘Quality of binder ‘Number of samples per lot and tests as por IS: 73 ot IRC:SP: 53 2, | Aggregate impact value/Los ‘One test per 350 m> of aggregate for each Angeles Abrasion value source and whenever there is change in the quality of aggregate 3,_| Flakiness index (One test per 350 m? of aggregate for each source and whenever there is change in the quality of aggregate 4. Soundness test (Sodium and | test for each source and whenever there Magnesium Sulphate test) is change in the quality of aggregate 3. | Water absorption of aggregate 1 test for each source and whenever there is change in the quality of aggregate 6. Sand equivalent test T test for each source and whenever there is change in the quality of aggregate 7,_| Plasticity Index T test for each source and whenever there is change in the quality of aggregate &._| Polished stone value T test for each source and whenever there is change in the quality of aggregate 9. | Percent of fractured Taces ‘One test per 350 mi of aggregate when crushed gravel is used. 70. | Mix grading ‘One set for individual constituent and mixed aggregate from dryer for each 400 tonnes of mix subject to minimum of two tests per day per plant i. Stability and voids analysis of 3 tests for stability, flow value, density and mix including theoretical maximum | void contents for each 400 tonnes of mix specific gravity of loose mix subject to minimum of two tests per day per plant 12. | Moisture Susceptibility of mix T test for each mix type whenever there is (AASHTO 1283) change in the quality or source of coarse or fine aggregate 13. | ‘Temperature of binder in boiler, At regular intervals aggregate in dryer and mix at the time of laying and compaction 14] Binder content ‘One set for each 400 tonnes of mix subject to minimum of two tests per day per plant 15,_| Rate of spread of mix material ‘After every 5® truck load 16. | Density of compacted layer ‘One test per 700 m? area, 15IRC:111-2009 6.5 Acceptance Criteria 6.5.1 The acceptance criteria for test on density (N =3 minimum) and Marshall stability (N= 2 minimum) shall be subjected to the condition that the mean value of N samples is not less than the specified value plus [1.65 — 1.65/(No. of samples)"*] x standard deviation. 6.5.2 Table 9 will govern the permissible variation in the mix and temperature. Me 16IRC:111-2009 ANNEX A (Clause 3.4.2) Outline of AASHTO 1283, “Resistance of Compacted Asphalt Mixtures to Moisture-Induced Damage” A. Scope and Summary of Test Method This method covers preparation of compacted bituminous mixtures and the measurement of the change of diametral tensile strength resulting from the effects of water saturation and laboratory accelerated stripping phenomenon with a freeze-thaw cycle. The result may be used to predict Jong-term stripping susceptibility of bituminous mixtures and evaluate liquid anti-stripping additives that are added to bitumen or pulverized mineral materials such as hydrated lime, which are added to the mineral aggregate, Bach set of 6 compacted specimens is divided into two equal subsets. One subset is tested in dry condition for indirect tensile strength. The other subset is subjected to vacuum satiration and a freeze-thaw cycle (thawing in a hot water bath) before testing for indirect tensile strength, Numerical indices of retained indirect tensile strength properties are calculated from the test data obtained by testing the two subsets: dry and conditioned, B. Testing Equipment 1, Vacuum container, vacuum pump, manometer, and other accessories as specified in ASTM ‘D2041, “Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures”. . Balance or scale accurate to 0.1 percent of the test load . Two water baths capable of maintaining temperatures of 60°C # 1°C and 25°C + 0.5°C . Freezer maintained at -18°C + 3*C . 10-ml graduate cylinder aAARYN . Loading jack and ring dynamometer (Marshall stability testing machine can be used) to provide a vertical rate of deformation of 50 mm (2 inches) per minute and capable of reading the maximum failure load 7. Steel loading strips with a coneave surface having a radius equal to the normal radius of, the test specimen. The loading strips shall be 12.7 mm (0.5 inch) wide for specimens 100 mm (4 inches) in diameter. The loading strips for 150 mm (6 inches) diameter specimens shall be 19.05 mm (0.75 inch) wide. The length of the loading strips shall exceed the 7IRC:111-2009 CG thickness of the specimens. Steel strip are provided at the top and bottom of specimens uring indirect tensile testing. ‘Test Procedure 1. Make at least 6 compacted specimens for each mixture, 3 to be tested dry and 3 to be tested after partial saturation and moisture conditioning with a freeze-thaw cycle. Some. extra specimens will need to be made to establish compaction procedures in order to obtain specified air void contents in the test specimens by trialanderror, 2. Compact the 6 specimens with a Marshall compactor so that the compacted specimens have air voids of 7.0 + 0.5 percent. This level of high air voids can be obtained by adjusting the number of Marshall blows applied on each side of the specimen by trial and error (start at about 10 blows as a starting point). Air void content must be calculated from the bulk specific gravity of the compacted specimen (determined by saturated surface dry method as per procedure given in the Asphalt Institute MS-2) and the maximum theoretical specific gravity of the loose bituminous mixture obtained by ASTM D2041., 3. Separate the 6 specimens into 2 subsets so that the average air voids of the two subsets are approximately equal 4, One set will be tested dry. Keep it at room temperature and then place in a 25°C +0.5°C water bath for 2 hours prior to determining their indirect tensile strength. 5. The other subset will be conditioned as follows: a) Place and submerge the 3 specimens in the vacuum container filled with water at room temperature. Apply a vacuum of 13-67 kPa absolute pressure (10-26 inches Hg partial pressure) for 30 minutes. Remove the vacuum and leave the specimens submerged in water for 5 to 10 minutes. (Note: The water saturation procedure noted above deviates from AASHTO 1283, which obtains a specified degree of saturation, The above procedure keeps the time of saturation constant] b) Wrap aplastic film around each saturated specimen and place the wrapped specimen ina plastic bag containing 10 mi of water and seal the plastic bag, Place the plastic bag in a freezer at temperature of ~18°C :3°C fora minimum of 16 hours. Remove the specimens from the freezer. ©) Place the specimens in a water bath maintained at 60°C + I°C for 24 hours, Remove the plastic bag and the plastic film from each specimen after placing the specimens under water. 4) Remove the specimens from hot water bath and place in a water bath maintained at 25°C # 0.5°C for 2 hours, 18,IRC:111-2009 e) _ Remove the conditioned specimens and test for indirect tensile strength, . Determine the indirect tensile strength of the 3 dry and 3 conditioned specimens at 25°C +4 0.5°C after removing from water bath. First, measure their mean thicknesses (t). Then place the two steel loading strips on the bottom and top of the specimens across diameter and place in the Marshall testing machine or a compression-testing machine. Apply load to the specimens diametrally at a vertical rate of 50 mm (2 inches) per minute, . Record the maximum compressive strength noted on the testing machine and continue loading until a vertical crack appears in the specitnen, Remove the cracked specimen from the machine and visually estimate the approximate degree of moisture damage (extent of stripped or bare aggregate) on the fractured faces of the specimen on ascale of Oto S (S being the most stripping). . Calculate the tensile strength of each specimen as follows in SI units: St = 2000 P/ ntd Where, St = tensile strength, kPa P = maximumloads,N t = _ specimen thickness, mm d= specimen diameter, mm . Express the numerical index of resistance of bituminous mixture to the detrimental effects of water as the ratio of the original strength that is retained after accelerated moisture and freeze-thaw conditioning. Calculate the tensile strength ratio (TSR) as follows: Tensile strength ratio (TSR) Where, S, =average tensile strength of the dry subset, kPa S, = average tensile strength of the conditioned subset, kPa 19IRC:111-2009 ANNEX B (Clause 4.5.2) Outline of ASTM D2041, “Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures” A. Scope and Summary of the ‘Test Method This test method covers the determination of the theoretical maximum specific gravity and density of uncompacted bituminous paving mixtures at 25°C. The theoretical maximum specific:gravity (Gmm) is used: (a) to calculate air voids in compacted bituminous mixtures, (b) to calculate the amount of bitumen absorbed by the aggregate, and (c) to provide target valuc for the compaction, of paving mixtures in the field. ‘A ssample of loose paving mixture is placed in a tared vacuum vessel. Water at 25°C is added to completely submerge the sample. A specified amount of vacuum is gradually applied to remove the airbubbles entrapped between asphalt mix particles. After the vacuum is released, the volume of the sample of the voidless paving mixture is obtained by either immersing the vacuum container with the sample ina water bath and weighing or by filling the calibrated vacuum container level full, of water and weighing in air. B. Testing Equipment 1. Container (either a or b below) a) Vacuum bowls — Either a metal or plastic bow! with a diameter ranging from 180 to 260 mm and a bowl height of at least 160 mm, The bowl shall be equipped with stiff, transparent cover fitted with arubber gasket and a connection for the vacuum line. The hose conection shall be covered with a small piece of fine wire mesh to minimize loss of any fine material from the mix. b) Vacuum flask for weighing in air only ~ A thick-walled volumetric glass flask with a capacity of approx. 4000 mi, fitted with a rubber stopper with a connection for the vacuum line, The hose connection shall be covered with a small piece of fine wire mesh to minimize loss of any fine material from the mix. 2, Balance capable of being read to the nearest 0.1 gram, If weighing is to be done under water, a suitable suspension arrangement shall be provided for weighing the sample while suspended from the center of the balance. 3. Vacuum pump, capable of evacuating air from the vacuum container to a residual pressure of 4.0 kPa (30 mm of Hg) or less. Provide a suitable trap between the pump and container to minimize water vapour entering the vacuum pump. 20IRC:111-2009 4, Residual pressure manometer or calibrated absolute pressure gauge with a bleed valve to adjust the vacuum level. 5. Water bath capable of maintaining a constant temperature of 25 + 1°C and suitable for immersion of the suspended container. Calibration of Containers 1. Bowls — Determine the mass (B) of the container immersed in water at 25 + 1°C. If the owl is used for weighing in air, place the volumetric lid on the bow! while under water. Remove the water-filled bowl with the lid in place and dry prior to determining the combined mass of the bowl, lid and water. Repeat 3 times and average the 3 masses, Designate the average mass as D. 2. Flasks — Calibrate the volumetric flask by accurately determining the mass of the flask filled with water at 25+ 19C. Use a glass cover plate to ensure the flask is completely full. ‘Test Procedure 1. Separate the particles of the loose paving mixture (while it is warm) by hand so that the particles are not larger than about 6 mm, Don't fracture the ageregate, Place the mix sample directly into the tared bowl or flask, Weigh the container with the sample and designate the net mass of the sample only as A. [Note: The minimum sample size shall be 1500g for mixes with nominal maximum aggregate sizes of 12.5 mm or smaller; and shall be 2500g for mixes with nominal maximum aggregate sizes from 19 to.25 mm.} 2, Add sufficient water at 25°C to cover the sample completely. Place the cover (bowls) or stopper (flasks) on the containers. 3. Place the container with the sample and water on a mechanical agitation device or agitate manually at frequent intervals (2 to3 minutes). Begin removing entrapped air by gradually applying vacuum and increasing the vacuum pressure until the residual manometer reads 3.7 #0.3 kPa (27.5 2.5mm of Hg). After achieving this level within 2 minutes, continue the vacuum and agitation for 15 2 minutes, Gradually release the vacuum with the bleed valve, 4, Weighing in water — Suspend the bow! (without lid) and contents in water for 10 + L minutes and then determine mass. Designate the mass under water of the bowl and sample as °C. 5. Weighingin air a) Bowl - Submerge the bow] and sample slowly in the 25 « 1°C water bath. Keep it there for 10+ 1 minutes. Immerse the lid in water and slide it onto the bowl without removing 21IRC:111-2009 water from the bow! so that no air is trapped inside the bowl. Remove the bowl with the lid in place from the water bath. Dry the bowl and lid with a dry cloth. Determine the mass of the bowl, sample, and lid and designate it as E. ) Flask - Fill the flask slowly with water ensuring not to introduce any ait into the sample. Place the flask in water bath for 10 + 1 minutes to stabilize the temperature at 25°C without submerging the top of the flask, Completely fill the flask with water using a cover plate without entrapping air beneath the cover plate. Wipe the exterior of the flask and cover plate, Determine the mass of the flask, plate and its contents completely filfed with water, Designate this mass as E, 6. Calculations Calculate the maximum specific gravity of the sample of loose paving mixture as follows: a) Bowls Used Under Water Determination: Gmm = A/[A-(C-B)] Where, Gmm maximum specific gravity of the mixture mass of the dry sample in air, g mass of bowl under water, g mass of bowl and sample under water, g b) Bowls in Air Determination: Gmm=A/(A+D-E) Where, Gmm = maximum specific gravity of the mixture A mass of dry sample in air, g D mass of lid and bowl with water at 25°C, g B = mass of lid, bowl, sample and water at 25°C, g : ¢) Flask Determination Gmm=A/(A+D-E) Where, Gmm = maximum specific gravity of the mixture A= __ mass of dry sample in air, g D = _mass of cover plate and flask filled with water at 25°C, g E = mass of flask, cover plate, sample, and water at 25°C, g LIBRARY & DOCUMENTATION CENTRE LARSEN & TOUBRO LIMITED ECC CONSTRUCTION GROUP 22 P.O, No. 979, MOUNT POONAMALLEE ROAD MANAPAKKAM, CHENNAI. 800 089