Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road

(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY

CONSTRUCTION

METHODOLOGY

Page 1 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY
METHOD STATEMENT FOR REMOVAL OF EXISTING BITUMINOUS SURFACE

Scope :

Removal of existing bituminous surface as per the drawing approval and approved method where

ever over laying is required.

PROCEDURE

Where specified or shown on the drawings, the existing drawings, the existing bituminous layer in

the specified width shall be removed with care and without causing any disturbance to the under

laying layer, by utilizing a Milling Machine. After removal, all loose and disintegrated material, the

underlying layers which might have been disturbed should be suitable 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 502.

Reusable materials shall be stacked as directed by the Engineer within 1000 m of their origin.

Page 2 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY

METHOD STATEMENT FOR APPLICATION OF TACK COAT

(Acceptance Criteria: Ref. Section 503 of MORT&H)
1. General

This work is consisting of application of a Single Coat Cationic emulsion RS1 confirming to IS
8887.
2. Machinery

For this tack coat distributor of required capacity shall be used. This distributing unit, so
called as tack coat tanker is facilitating pneumatic tyre and self-propelled pressure
distributor for spraying the material uniformly at the rate of 2.0 to 3.0 Kg/10 Sq .m under
200TO 700C temperature and pressures. Sometimes few small patches near junctions, or
narrow space where the primer tanker is not reachable then for those areas spraying of
primer shall be done manually, after approval from the engineer.
3. Preparation of Road Surface
The surface on which the tack coat is to be applied will be cleaned, of dust and extraneous
material before the application of the tack coat.
4. Application of Tack Coat
The tack coat “bituminous emulsion” will be heated to the temperature between 20 0 C to 700
C with the help of self-propelled emulsion pressure Sprayer with self heating arrangement
and spraying bar with nozzles having consistent volume or pressure system, capable of
spraying emulsion at the rate of 0.25 to 0.30 Kg/Sq.m for granular surfaces treated with
primers and 0.20 to 0.3 kg/Sq.m for normal bituminous surfaces. During laying trial the
nozzle openings will be adjusted accordingly to obtain the required rate of spray.

Page 3 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY

Major Equipment and Machinery:

1. Air Compresser
2.Broomer
3 Bitumen Tank with Sprayer

5.CONTROL TESTS FOR PRIME COAT

Type of construction Test Frequency

i)Binder temperature At regular intervals

TACK COAT
ii)Rate of spread of Three tests per day
binder

6.RECORDS AND DOCUMENTS MAINTAINED:

a. RFIs
b. Field test results

7.QUALITY CONTROL PROCEDURES:

To ensure the suitability, compaction of fill/original ground, tests would be conducted at

field/laboratory as per frequency mentioned in the inspection test plan shown below.

METHOD STATEMENT FOR CONSTRUCTION OF BITUMINUS CONCRETE

Page 4 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY
(Acceptance Criteria: Ref. Section 507 of MORT&H)

This item of work deals with construction of Bituminous Concrete with approved materials as per
the specifications of contract agreement.
1. General

This item of work shall be detail in compliance to the clause 507 of specifications.
The construction shall confirm to the specific alignment, lines and grades given in the drawing.

2.Materials

a. Bitumen

Bitumen CRMB 55 conforming to IRC-SP-53-2010 shall be used. The scope of sampling,

sample of criteria for conformation etc. shall be same as those applicable for Bitumen shall
confirm to clause 504.2.1 of MORT&H Specifications.

b.Aggregates

Coarse Aggregates:

The physical requirements of coarse aggregates to be used in bituminous aggregates shall

be as per Table. Coarse aggregates shall be tested for Stone polishing value as per BS 812
(part 111).

Fine Aggregates:
The physical and grading requirements, tests and their frequencies shall be same as those for
Bituminous Concrete.

C. Filler
1 Table 50Error! No text of specified style in document.-9: Gradation of Filler Material
used in BC
I. S. Sieve Per cent Passing By weight
600 micron 100
300 micron 95 - 100
75 micron 85-100

Page 5 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY
The physical and grading requirements, test and their frequencies shall be same as those for
Bituminous Concrete.

Aggregate Gradation

Coarse aggregates, fine aggregates and fillers shall be so blended as to give grading set forth
in grading-2.

Gradation requirement of Coarse Aggregate (Table 500-17 of MoRTH)

Grading 1 2
Nominal aggregate size* 19 mm 13.2 mm
Layer Thickness 50 mm 30 – 40 mm
IS Sieve Cumulative % by weight of total aggregate passing
26.5 100
19 90 - 100 100
13.2 59 - 79 90 - 100
9.5 52 - 72 70 - 88
4.75 35 - 55 53 - 71
2.36 28 - 44 42 - 58
1.18 20 - 34 34 - 48
0.6 15 - 27 26 - 38
0.3 10 - 20 18 - 28
0.15 5 - 13 12 - 20
0.075 2-8 4 - 10
Bitumen content % by mass of total Min 5.2* Min 5.4**
mix
Notes:
* The nominal maximum particle size is the largest specified sieve size up on which any of the
aggregate is retained.
** Corresponds to specific gravity of aggregate being 2.7. In case aggregate have specific gravity
more than 2.7, the minimum bitumen content can be reduced proportionately. Further the
region where highest daily mean air temperature is 30oc or lower and lowest daily air
temperature is - 10oc or lower, the bitumen content may be increased by 0.5 percent.
Permissible variation in job mix formula
Permissible Limits for variation as per Table 500-18 in MORTH

Page 6 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY
2 Permissible Variations in Plant Mix
No. Description Permissible variation
1 Aggregate Passing 19 mm sieve or larger  7%
2 Aggregate Passing 13.2 mm sieve & 9.5  6%
mm sieve
3 Aggregate Passing 4.75 mm sieve  5%
4 Aggregate Passing 2.36 mm, 1.18 mm, 0.6
 4%
mm sieve
5 Aggregate Passing 0.3 mm, 0.15 mm  3%
6 Aggregate passing 0.075 mm sieve  1.5%
7 Binder content  0.3%
8 Mixing Temperature  10o C

4. Procedure
Mix Design
The mix design shall be carried out according to MS-2 of Asphalt Institute. The optimum bitumen
content and job mix formula are arrived. The physical requirements of the aggregate shall confirm to
table 500-16 and job mix shall confirm to grading 2 of table 500-17 of technical specifications. The
mix properties shall confirm to table 500-18 of technical specifications. The permissible variations
from the job mix formula shall be according to table 500-18.
.Preparation and Transportation of Mix:

The individual bins of Hot Mix Batching plant shall be calibrated for the particular size of material.
Material shall be fed to the mixing plant bins provided for individual sizes of aggregates to meet the
required gradation. The temperature of binder at the time of mixing shall be in the range of 165'C-
185'C and the aggregate in the range 150'C to 170'C .The difference between and the aggregate
temperature shall not exceed 14'C any time
The mix shall be transported to the site with trippers properly covered with tarpaulins.

Preparation of Base:

The base shall be checked for proper lines and levels.

Page 7 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY
The surface shall be swept free from dust with air compressor. The tack coat shall be done if the
DBM surface was old for quite some time.

Laying of Bituminous Concrete:

The mix shall be laid with paver finisher. The paver shall have suitable loading hoppers and
distribution mechanism. The paver shall be electronic sensor paver and string wire shall be run on
steel pegs driven on both sides at 10m interval in straight portions and 5m interval in curved
portions. The mix shall be laid manually in places where the paver movement is not possible.

The compaction of BC shall be done as per clause 501.6 and 501.7. The rolling shall be done with 80-
100KN smooth wheeled tandem roller, 12-15 tones pneumatic tyre roller. The rolling pattern shall
be established in the trial stretch. The finished layer shall be checked for compaction. The
compaction shall be checked by taking cores for every 700sq.m area and the degree of compaction
shall be Equal to or more than 92% of the density based on theoretical maximum specific gravity
(Gmm) obtained on the day of compaction in accordance with ASTM D 2041. in technical
specification. The top shall be checked for level control and the levels shall be within ±6mm of
designed level.
All relevant QA and QC documents will be maintained for all stages of construction.

COMPACTION REQUIREMENT FOR BC

Type of Work Relative compaction

/Material
BC Equal to or more than 92% of the density based on theoretical
maximum specific gravity (Gmm) obtained on the day of compaction in
accordance with ASTM D 2041.
Compaction
control 1 Test per 700 m2 area,

Page 8 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY
5. Equipment/Machinery

Hot Mix Plant (Batch Mix Type) : 1 No

Tippers : 10 - 20 No as depending upon quantum of work

Rollers : 80 to 100KN Smooth wheeled tandem rollers 2

No as a minimum & 12-15 Tones PTR 1 No
Minimum

Paver Finisher (Hydraulic) : 1 No

Mechanical broomer/Air Compressor : 1 No

6. RECORDS AND DOCUMENTS MAINTAINED:

a. RFIs
b. Density test results (Laboratory)
c. Material test results (Laboratory)
7. QUALITY CONTROL PROCEDURES:

To ensure the suitability, compaction of fill/original ground, tests would be conducted at

field/laboratory as per frequency mentioned in the inspection test plan shown below.

8. SAFETY MANAGEMENT ACTION PLAN

In order to minimize the occurrence of site accident, the provision of a safe working
environment for workers to work is essential. Our company endeavors to make a zero
accident record in each site. In addition to the above, the following safety precautions must
also be implemented in achieving the minimization of site accidents.

SAFETY MEASURES:

a.Provisions for workmen:

a.It is required that all persons working at the site shall be provided with the safety
equipment, protection means such as safety jackets, hand gloves, safety helmets and
other necessary kinds.
B .All persons working on the site shall be trained by conducting the training course for
safety to ensure that they are fully aware of the contents.

Page 9 of 10
Name of work : Renewal of Wearing Course (Overlay and other works) Salem Ullunderpet Toll Road
(SUTR), Tamilnadu

Client : SALEM ULLUNDURPET TOLL ROAD.

Contractor : M/s. NOTCH INDIA PROJECTS., MADURAI.

METHODOLOGY
b.Provisions for Equipment, Machine:
a.All equipment will be ensured to operate safely, maintained and repaired periodically.
b.All power equipment should be insulated and covered to all exposed
live parts.
c.A competent person shall inspect equipment during shift duty.
c.Provisions for Job Site:
a. Relevant Caution boards and sufficient lighting system shall be installed at the
working area to ensure safety for construction activities at night time.
b. The working area shall be free from hazards before starting the work.
c. Unnecessary materials such as empty bags and rubbish shall be removed periodically

d. Proper safety measures like barricading, guard poles painted with florescent
in alternate bands, flags etc. will be provided prior to the commencement of excavation
operations.
e. Signal man will be placed at heavy traffic locations at the time of Execution.
f. Reflective sign boards will be placed during night near risky locations.
g. All workers shall be educated in the use of excavators, bulldozers, backhoes, graders
and rollers such as the excavator arm & bucket distance and buffer zone in order to
prevent from injuries.
h. Operators would be thoroughly instructed to prevent pushing soil loads into
the main road area if any.
i. Photographs would be taken to disseminate and maintain traffic safety records
j. Working area will be cordon with traffic cones to identify survey setting out to
oncoming traffic on both sides.

9. ENVIRONMENT CONTROL
a. All necessary measures shall be taken to maintain all plants and silencing
equipments in good conditions so as to maintain air and noise emission during
the operation.
b. All necessary measures shall be taken to control the disposal of all forms of
waste generated by the construction operations and in all associated activities.
c. Disposable materials would not be dumped into streams or unauthorized areas.
Every effort would be made not to disturb prevailing surface water runoff.
d. All necessary measures and precautions shall be taken to avoid any nuisance or
disturbance arising from the execution of the work.

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