METHODOLOGY OF ROAD MARKING

APPLICATION AT SITE
1. Scope:
 This work shall consist of application of thermoplastic paint with glass beads in
accordance with the lines, thickness as per clause number 803 of MORTH & shown-
mentioned in the drawings, LOI /work order.
2. References:
 MoRT&H specifications clause No: 803 and technical specification of contract,
LOI/Work order.
 Codes & Specification for QA/QC/Testing:-
i) IS:-164 - For colour checking.
ii) ASTM :-D 36 - For softening point.
iii) BS:-3262(Part-1) & BS:-6088 – For Gradation, Roundness, Refractive index &
Glass beads amount in the compound.
iv) BS:-3262(Part-3) – For thickness checking(Appendices B & C).
v) BS:- 6044 – For skid resistance.
vi) AASHTO:-M 249 – For Luminance of white material & Flow resistance,
Yellowness index.
3. Equipments:
 Mixing Unit:-Proper Heating with thermostat control, Circulation, Mixing, Storage for
Homogeneous production.
 Application Unit:- Automatic/Manual screeding machine with uniform laying in line with
temperature/thickness/alignment/shape/dimension/levelled surface.
 Transportation Unit:- Suitable means of transportation of raw material with all other
resources for site execution.
 Moulds & Templates:- For different size of arrow, dotes, signs & other shapes as per
approved etc.
4. Tools:-
 All equipment must be Calibrated from NABL accreditation & Digital thermometer for
temperature checking ,Digital vernier for thickness control checking, All sieves as per
MoRTH803.4.3.3, Refractive index testing meter, Glass plates, Camera, hammer, chisel,
steel scale, Measuring tape, Sampling bag/box, line rope, or any other tool required for
site inspection as per instruction of client/consultant/contractor.

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5. Materials:
 Thermoplastic paint materials: This shall approved grade and approved source, to
achieve the desired specification requirement & as per clause no-803.4.2 of MoRTH
specification. The performance of paints will be checked for Composition, Basic
Properties like Luminance, Drying time, Skid resistance, Cracking resistance at low
temperature, Softening, Flow resistance, Yellowness index, Reflectorisation & all points
from I to VI of clause number 803.4.2.2(As per Approved attached ITP)
 Glass beads: This shall approved grade & approved source, to achieve the desired
specification requirement & as per clause no-803.4.3 of MoRTH specification Type-2
,table no-800-4 with make of Potters Australia/UK. The performance of glass bead will
be checked for Gradation, Roundness/Refractive index/Free flow at both either Internal or
Third party(NABL approved) laboratory.
6. Procedure:
a) Material control:
 Stock & Consumption:- All material as well as paint/glass bead will received L & T store
first. Material issue for site will be given by lab authorized person by taking proper
indent. This process will control of incoming and outgoing of material.
 Pre Inspection:-Before unloading & taking material in stock at store ,material will
checked and verified by lab authorized person regarding Quality control & Quality
assurance. Authorized person suppose to check MTC, qty, Packing, handling condition or
other requirement as per clause no-803.4.2.2(iii) & (V) of MoRTH.
 Sampling Testing:- The material shall be checked ,sampled & tested as per applicable
ASTM/BS method. If the material is not satisfying the specification requirement than
material shall be replaced by manufacturer / Supplier/ Contractor. ITP for the above
material & activity is attached for ready reference. For third party testing agency either
will be NTH or given by Quality in-charge for NABL accreditation, testing charge will be
born by you(M/s Global). In case of cross check of doubt at any time QA/QC authorized
person can ask for third party test. Agency has to bring all necessary equipment which is
required for site testing on his cost before start of work.
b) Mixing control:
 The materials shall be mixed in a mechanized controlled batching unit consisting heating
device with thermostat control, Mechanical stirrer for homogenous heating & mixing with
proper outlet system. For mixing temperature manufacturer will give the approved
method statement for mixing process.

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  Manufacture has to give the method of mixing for heating process ,that is minimum time
for heating and mixing of material so that at the time of application material can spread at
uniform thickness without any surface and inbuilt defect in final product.
c) Laying/Application control
 The traffic will be diverted by placing proper safety barricades/safety cones/flag man.
 Median filling and shoulder work shall be completed prior to Road marking.
 The BC surface shall be thoroughly cleaned of all dust, dirt, grease, oil and all other
foreign matter before application of paint.
 The thermoplastic powder is put in to the container of machine and it is to be heated.
The material is mixed uniformly by operating the mechanical agitator in the container.
The thermostat is adjusted to a temp of 180-200 0C( or As mentioned by agency). The
material is added to the container to its full capacity and melted till it achieves smooth
consistency.
 Thermoplastic materials shall be applied in hot condition either by screeding or
extrusion process.
 After transferring the thermoplastic paint to the laying apparatus, the material shall be
laid at a temperature within the range of 180 to 200 degree centigrade( or As
mentioned by agency).
 The application properties of the thermoplastic material shall be such that it shall
readily get screed or extrude at applied temperature.
 The paint shall be applied with a thickness of 2.5 mm exclusive of surface glass
beads. The width shall be as per drawing.
 The Glass beads shall be applied at the rate of 250 grams per square meter area.
 The finished lines shall be free from ruggedness on sides and ends. The upper surface
of the lines shall be level, uniform and free from streaks.
 Traffic shall be allowed after 60 minutes of application at specified temperature.

d) Addional Precautionary Measures & Care required Before-during execution-application

of paint at site:-

 Pavement temperature during application should not be less than to 10 degree Centigrade.
 The upper surface of the lines shall be level, uniform & free from streak.
 The material shall not be maintained in a molten condition for not more than 4 hours.
 After transferring to laying machine ,the material shall be maintained at specified
temperature by suitable means of heating.

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  The material upon heating to application shall not exude fumes.
 Before taking out paint from mixing/heating unit and laying work starting of each
prepared lot of material, site engineer has to assure & verify for minimum time duration is
completed which is recommended by manufacture for he material heating& mixing
process.
 Before start of work at site agency has to submit the organization chart for man power
planning to compliance the screening process of Administration department and
machinery detail for site programme & Safety compliances.

7. Material Inspection Test plan:-

 Both the material as well as Thermoplastic paint & Glass beads with Final laid surface
will undergo following test & inspection before, during, after execution at site.
SI Method of Frequency Reference Required
Detail Nature of check/Test
NO check /Quantum of check Documents specification
A Thermoplastic paint

) Material
One test/lot
Inspectio 300-400
1 Reflectivity (min 10 AASHTO M249
n mcd/lx/m2
location)
Inspectio 45 degree-
2 Day light-Luminance One test/ lot AASHTO M249
n 75%
102.5+-
3 Softening point Lab test One test/ lot ASTM D 36
9.5degree
4 Specific gravity Lab test One test/ lot ASTM D 153 2.15
Inspectio
5 Bond strength One test/ lot ASTM T 250  
n
Inspectio
6 Impact resistance One test/ lot ASTM T 250  
n
Inspectio Not more
7 Flow resistance One test/ lot AASHTO M 249
n than 25%
Inspectio
8 Adhesive shear strength One test/ lot ASTM T 250  
n
Inspectio not less than
9 Skid resistance One test/ lot BS 6044
n 45 degree
Not more
10 Yellowness index Lab test One test/ lot AASHTO M 249
than 0.12
cracking resistance at low Inspectio AS per MORTH
11 One test/ lot  
temperature n 803.4.2.2
12 Physical test MTC for every Sec.
MTC  consignment 803.4.2.2(vi) of
and MORT&H Spec.
independent

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 testing
randomly
TC for every
Sec.
consignment
MTC & 803.4.2.2(i)
and
13 Chemical Composition Third ,table no-800-3
independent
party test of MORT&H
testing
Spec.
randomly
Colour, width & layout of Measure IRC 35,
14 All
Paint ment Drawings.
By As per supplier 180 to 200 C
Temperature range(Boiler At least hourly
15 Inspectio recommendati
and Laying machine) basis
n on
803.4.2.2(iii) of
16 Storage life for one year MTC  All MORT&H
Specification
Three test per
By As per 803.6.3 Min 2.5mm
Thickness of laid surface day or one test
17 inspectio of MoRTH excluding
at site for each location
n specification glass beads
per day
layer
B) Glass beads    
AS per MORTH
1 Spherical (roundness) One lot/1test 70%min
803.4.3.3
Gradation One lot/1test  
Sieve size Type -2  
850 micron 0 to 5  
min15%
600 micron 5 to 20
AS per MORTH (retained)
2
table no-800-4 min55%
300 micron 30 to 75
(retained)
min18%
180 micron 10 to 30
(retained)
below 180 micron 0 to 15  
AS per MORTH
3 Reflective index One lot/1test 1.5min
803.4.3.3
AS per MORTH
4 Free Flow Test One lot/1test  
803.4.3.4
As per MORTH
5 Drop of glass beads 4 times/per day 250 grm/sqm
803.6.3
All TC for every
Conforming to specific
consignment
requirements of
and Sec. 803 of
6  gradation, roundness, MTC 
independent MORT&H Spec.
refractive index, free
testing
flowing properties
randomly
Properties of finished Inspectio
 C) All IS 356
road marking n

8. Trial length:

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  A trial length of 20m shall be made as per approved drawing, for each type continues line.
 For dotted and other type line one sample consist of 3 nos qty ,will do for trail purpose.
 For junction marking like arrow, sign, other marking one sample consist of 3 nos qty will
do for trail purpose.
9. Properties of finished Road marking:
 Strip shall not be slippery when wet in condition.
 Strip shall not be lift from pavement in freezing weather.
 After application and proper drying ,the strip shall show no appreciable deformation or
dislocation under traffic and under road temperature up to 60 degree C.
 Marking shall not be deteriorate by contact with sodium chloride, calcium chloride or oil
drippings from traffic.
 Note:- No slippage, hair cracks ,bubbles ,undulation shall not allowed in finished
marking, otherwise rework have to do for this type of defects in final product.
 After site testing or performance of paint regarding reflectivity and luminance test, if
required above required/specified value can increase to comply the site requirement
without any other condition changing in any respect.

10. Records/Reports/Documents to be maintained:-

 In lab all test record maintained with signature of L & T staff with the contractor
representative in lab itself. Copy of this daily testing have to keep by site
engineer/Contractor for each lot.
 All site record maintained by site execution engineer, like temperature record, thickness,
glass beads rate of spread record in proper registered/format with duly signed by site
engineer and contractor representative.
 Calibration of report of any measuring equipment (Temperature Dial gauge in boiler,
Digital thermometer, Digital weighing scale of specified capacity in BS/ASTM etc) shall
be maintained by contractor at site always.
 Material consumption record has to do & check on daily basis for reconciliation of
material with duly signature of site engineer, contractor, planning engineer for billing
point of view.
 Daily site progress has to given by site engineer in proper format to concern planning/lab
engineer, for better control in issue of material.
 Man power/Machine availability at site record has to maintain by site engineer/contractor
to smooth operation of execution in respect of planned programme.

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  Material reconciliation will be certified by quality in-charge first than either site in-charge
or may planning in-charge.
11. Safety requirements:
 All vehicle & machine shall be provided with reverse horn & lighting.
 Wherever required, Flagman shall be provided
 The speed of vehicles plying in stretch shall be restricted to 30kmph.
 All workmen at work area shall wear PPE’s and reflective jackets.
 During night work will not allowed.
 Hand gloves shall be used while loading-unloading & during application.
 Wherever the road marking is under process the area shall be properly barricated by
means of Cone, safety ribbon, Flags ,Direction sign boards etc.