CONSTRUCTION OF BITUMINOUS

LAYERS

Dr. Anjaneyappa
RV College of Engineering
anjaneyappa@rvce.edu.in
 Balancing Production

HMA Paving
Facility

Trucking Compaction

Delivery Construction 2
Flexible Pavements / Bituminous Pavements
1. Fill/ Subgrade - Soil Layers
2. Granular Layers ( Subbase & base layer) -GSB, WBM,
WMM, CRM
3. Bituminous Layers
3.1 Interface treatments
3.2 Thin Surface Layers
3.3 Thick Surface layers
4. Bituminous Binder Courses & Surface Courses
5. Functional & Structural Layers
Bituminous Layers _ Thick Layers
Grouted / Penetration / Sprayed
Built Up Spray Grout
Penentration Macadam
Bituminous Precoated Layers
Bituminous Macadam
Dense Bituminous Macadam
Bituminous Concrete
Bituminous Thin Layers - Structural Layer
Semi Dense Bituminous Concrete - 25 mm

Bituminous Thin Function Layers

Pre Mix Carpet with Seal Coat
Mix Seal Surfacing
Hot Mix Asphalt, HMA

Asphalt

Aggregate

Types and Uses

 Time vs. Temperature

1 hour
60 C

1 hour 10 hours
25 C
 Stiffness (Response to Load)

elastic

viscous
elastic fluid
solid
viscous

-30 25 60 135
Temperature, C
Grading DBM Grade I DBM Grade 2 BC Grade 1 BC Grade 2
Nominal Size (mm) 40 25 19 13
Layer Thickness 80-100 mm 50-75 mm 50-65 30-45
(mm)
Sieve Size (mm) % Passing
45 100 -
37.5 95-100 100
26.5 63-93 90-100 100
19 - 71-95 79-100 100
13.2 55-75 56-80 59-79 79-100
9.5 - - 52-72 70-88

4.75 38-54 38-54 35-55 53-71

2.36 28-42 28-42 28-44 42-58
1.18 - - 20-34 34-48
0.6 - - 15-27 26-38
0.3 7-21 7-21 10-20 18-28
0.15 - - 5-13 12-20
0.075 2-8 2-8 2-8 4-10
Bitumen content (%) Min.4 Min 4.5 5.2 5..4
Grade of Bitumen 65-90 65-90 65 65
 Materials
Bitumen Shall be as per IS 73
Aggregates
Coarse Aggregates( retained on 2.36mm)
clean, hard, durable
fulfil the physical requirements
Fine Aggregates
Passing 2.36 and retained on 0.075 mm
Hard, durable, dry and free from dust
 Physical Requirements of Aggregates
Property Test DBM BC

Cleaniness Grain size Analysis Min.5% passing 0.075 Min.5% passing 0.075
mm mm
Particle Shape Flakiness & Max. 35% Max. 30%
Elongation
Strength LAA Max. 35% Max. 30%
AIV Max. 27% Max. 24%
Durability Soundness Max.12% ( Sod.Sul) Max.12% ( Sod.Sul)
Max .18% (Mg Sul) Max .18% (Mg Sul)

Polishing Polished Stone Value Min. 55

Water Obsorption Water Obsorption Max. 2% Max. 2%

Stripping Coating & Stripping Min retained 95% Min retained 95%

Water Sensitivity Retained Tensile Min. 80% Min.80%

Strength
 Blending of Aggregates
Aggregates are crushed and sieved to separate
sizes
40 mm, 20 mm, 12/10 mm, 6mm and dust
Need to blend to get required gradation
 Control points for
Percent Passing, % 12. 5 nominal max. size
100
90
Gradation B
80
70
60
50
40
30
20 Gradation A
10
0
0.075 0.3 1 .18 4.75 9.5 12.5 19
Sieve Size, mm

Blending Stockpiles 13 Aggregates

A View of Pug Mill - Wet Mix Macadam
A View of Hot Mix Plant - Weigh Batch Type
 Permissible Variations by Job Mix Formula

Description Permissible Variation

Base / Binder course Wearing Course
Passing 19 mm / larger +/- 8 % +/ - 7%
Passing 13.2 mm, 9.5 mm +/ - 7% +/ - 6%
Passing 4.75% +/- 6% +/- 5%
Passing 2.36,1.18 & 0.6 +/-5 % +/- 4%
mm
Passing 0.3 mm & 0.15 mm +/- 4% +/- 3%
Passing 0.075 mm +/- 2% +/- 1.5%
Binder content % 0.3% 0.3%
Mixing temperature +/- 10 Deg +/- 10 Deg
 Requirements of Mix
Property DBM BC

Stability Min.kN 9.0 9.0

( at 60 degrees)
Flow (mm) 2 -4 2-4

Compaction 75 75
( # of blows)
Air Voids (%) 3-6 3-6

VMA (%) See Table See Table

VFB (%) 65-75 65-75

Loss of Stability on Min.75%

Immersion in water at 60
degrees
 Requirements of VMA

Nominal size Minimum VMA (%) related to air voids

(mm)
3.0 % 4.0 % 5.0 %

9.5 14 15 16

12.5 13 14 15

19.0 12 13 14

25.0 11 12 13

37.5 10 11 12
 Requirements of Mix modified bitumen
Properties Requirement

Hot Climate Cold Climate High Rainfall

Marshall stability 12 kN 10kN 12 kN

Flow (mm) 2.5 -4 3.5-5 3-4.5

Marhall Quotient 250-500

(Kg/mm)
Voids % 3-5

Binder Content % BC Grade 1- 5.4 Grade 2 5.6

SDBC Grade1 4.7 Grade 2 - 5.2
DBM Grade 1 4.3 Grade 2 4.7
Retained stability 90 95 100
%
Coating of 95 95 100
Aggregates %
 Seggregation

Segregation is the separation and consolidation

of large size aggregate from the finer particles
May Occur
Mixing plant
During transportation

Deficiencies in Paving
 Segregation at Plant
Hang up of feeders in bins ( moisture)

Inadequate mixing time in pugmill

Lack of replacement of broken/ twisted/ ineffective

paddles
Level of material in pug mil

Mix in motion ( free fall to hopper / truck)

 Segregation in Transport
During movement coarser materials roll down

Small batch in large truck

During discharging in to paver hopper if rear gate does

not open fully . Partial openings prevent smooth flow,
cause hang up
Seggregation on both sides of truck & material being
droped in paver in same condition
 Segregation in Paver Finisher
Insuffcient material in hopper

Material above the level of auger

Corser mixes / lean mixes are more prone to

seggregation
 Weather and Seasonal Limitations
Laying shall be suspended while free standing water is
present on surface / during rain/ dust storms
Laying shall not be carried out when air temperature at
surface is below 10 deg or when the wind speed
exceeds 40 kmph
 Construction Operations

Preparation of the receiving layer

Cleaning
Interface treatment
Preparation of Mix
Transportation of Mix
Spreading
Compaction
Surface Finish Check
 Preparation of Receiving Surface

Preparation of Existing Granular surface

Remove loose material / Dust
Careful on compaction on Compacted Layers

Patching of potholes & sealing of cracks

 Cleaning

Remove dust / loose material

 Interface Treatments

Prime Coat
Tack Coat
Crack Prevention Courses
 Purpose of Priming

To plug the capillary voids

To coat and bond loose materials on the surface
To harden or toughen the surface
To promote adhesion between granular and the
bituminous layer
 Requirement for Priming Material

Porosity Type of Quantity per

Surface (Kg /sqm)

Low WMM, WBM 0.7-1.0

High Stabilised 0.9-1.2

base
 Tack Coat

Purpose of Tack Coat:

To ensure a bond between the new
construction and the old surface
Use of Cutback:
It should be restricted for sites at subzero
temperatures or for emergency applications
 Recommended Quantities of
Material for Tack Coat
Type of Surface Quantity in kg per
m2 area
Bituminous Surface 0.20 to 0.30

Primed granular surface 0.25 to 0.30

Cement concrete pavement 0.30 to 0.35

Preparation of Mix
 Manufacturing & Rolling Temperature

Bitumen Bitumen Aggregate Mixed Laying Rolling

Mixing mixing ( Material 9 ( Degrees) ( Degrees)
(Degrees) Degrees) Degrees)

VG40 160-170 160-175 160-170 150 min 100 min

VG 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

 Temperature Requirements for modified binders

Stage of Work Indicated temperature

(Degrees)
Binder at mixing 165-185

Aggregate temperature 165-185

Mix at mixing plant 150-170

Mix at Laying 130-160

Rolling 115-155
 Transportation of Mix

Delivery Construction 41
 Tarping Loads

Delivery Construction 42
 Laying of Mix

Delivery Construction 43
Delivery Construction 44
 Tracto
r
Hopper
Depth
Crank

Screed

Push
Rollers Tow Point Conveyors Augers
Side Arm

Construction Placement 47
 Correct Depth of
Mat Maintained

Constant Head of Material Volume

Screed Rises Due to

Excess Material Forced
Under Nose of Screed

Head of Material Volume Too High

Screed Settles Due to

Inadequate Supporting
Material

Head of Material Volume Too Low

Construction Placement 48
 Auger
Correct Overloaded Auger
Elevation Underloaded

Construction Placement 49
Construction Placement 50
Construction Placement 51
 Compaction

Improve Mechanical Stability

Improve Resistance to Permanent Deformation
Reduce Moisture Penetration
Improve Fatigue Resistance
Reduce Low-Temperature Cracking Potential

Construction Compaction 52
 Types of Rollers

Static Steel Wheel

Pneumatic Rubber Tired
Vibratory

Construction Compaction Equipment 53

RASTA
Center for Road Technology

Static Steel Wheel Roller

Static Pressure
Weight
Speed Weight
Thickness
Temperature
Roller
Pneumatic Tired Rollers
Wheel load
Inflation pressure

Contact area

Drum -Vibratory roller

Compacted high spots Uncompacted low spots

Front tires

Road surface
Vibratory Rollers
Load
Amplitude
Frequency
Impact Spacing
Operation

Construction Compaction Equipment 57

 Low Frequency High Frequency

Impact Spacing

FREQUENCY
DIRECTION OF TRAVEL

Construction Compaction Equipment 58

 AMPLITUDE

Construction Compaction Equipment 59

Construction Compaction 60
Construction Compaction 61
 Construction of Joints

Transverse joint
Preferably Vertical Joint
Staggering of joints at least by 2 meters
Spraying of bitumen on face
Heating of Screed
Longitudinal Joint
Not be located on same line
At 150 mm offset
Vertical face
Overlap of 25 to 50 mm with previously laid surface
 Rolling operations

Depends on
Thickness
Speed

Length of rolling zone

Number of rollers
 Rolling Sequence

Transverse Joint
Longitudinal Joint
Overlap of 150-175 mm
Lower to Higher edge
 Rolling Operation

Break down rolling

Intermediate Rolling
Finish Rolling
 Breakdown Rolling
Use smooth wheel rollers/ Static passes
Breakdown rolling must achieve majority of required
compaction
An ineffective first pass may make final pass difficult to
achieve
Compaction is achieved by imparting vertical movement
to mix through roller load
There should not be any horizontal movement of mix
 Horizontal movement will cause heaving of material
Crawling of mixture ahead of roller and formation of
ridges
When movement of mix is observed allow the mix to
cool ( break down temperature)
Compaction helps in retaining the heat

Rolling zone at 50 m
 Intermediate Rolling
After breakdown rolling when mix still in plastic
state
Pneumatic rollers more suitable
Pneumatic rollers may not increase the density
substantially
It does increase the stability of mix by kneading and
reorientation of particles
More uniform compaction
Sealing of layer ( tire pressure 0.7 to 0.9 Mpa)
 Finish Rolling
Carried out while material still in warm condition
For removal of tire marks
 Precautions for Rolling

Uniform speed
Never allow compactor to stand
Jerky start , sudden braking, sharp changes not
to be made
Change of lane to made only on already
compacted surface
Steel wheels / pneumatic wheels cause loss of
heat
Small amount of detergent / Vegetable oil
Laying of DBM Binder Course -
Compaction by Vibratory Roller and
Pneumatic Roller in Progress
 High

Passing
Density
Density

Low
1 2 3 4 5 6
Roller Passes
Construction Compaction Equipment 73
 Dense Bituminous Madacam/ Semi Dense Bituminous
Concrete/ Bituminous Concrete
Quality of Binder Two Samples per lot to be
subjected to all or some tests as
directed by the Engineer
Aggregate Impact Value One Test per 350 m3 of Aggregate

F I and E I of Aggregates One Test per 350 m3 of Aggregate

Soundness 1 test per Source

Water Absorption of - do -
Aggregates
 Marshall test and binder content for each 400
tonnes of mix subject to minimum two test per
day
Density for every 700 sqm area
Construct trail stretch for Project Conditions
and fix up guidelines
Not to adopt the guidelines of constructions
adopted for projects constructed elsewhere /
others
 MAX. PERMISSIBLE ROUGHNESS VALUES (mm/km)
IRC:SP-16 : 2004

Surface Good Average Poor

Type
CC < 2200 2200 - 3000 > 3000
BC < 2000 2000 - 3000 > 3000

PMC/ MSS < 3000 3000 - 4000 > 4000

SD < 3500 3500 - 4500 > 4500
 Construction of Bituminous layers
Over heating
Heating for Longer duration
Improper gradation
Improper gradation in spite of fulfilling the required gradation
Exposure of DBM layer for heavy axle traffic and rainy
conditions for longer duration
Paving for shorter stretches
Compaction of Bituminous Layers
High vibration
Compaction at lower temperature
 Bituminous Layers
Preparation of Receiving Layer
Attending all distresses
Cleaning & Interface treatment
Loading of Bituminous mix in to trucks at HMP
Covering of Mix during transportation using Tarpaulins
Quantity of Mix in Paver
Width / lane marking for Paving
Rolling on Bituminous Layers
Vibration on asphalt layers
Static / pneumatic rolling on thin layers
 Labour is Keyman
Best Materials ,Best Design, Best Engineering
Expertise, Best Equipment,

Handled & Executed by Skilled / Unskilled Labour

& Trained / Untrained Operators

Need to Train Labours

Attract and retention of labours in the industry
Results in better product / savings in money
 Construction Cost Break Up
Materials = 50%
Plants and Machinery = 15-20%
Human Resources = <10%

Optimization of these Resources important ( optimum

utalisation, Increase time efficiency)
Small % saving results in huge money
Thank you for Your Valuable Time