Road

Construction
Methods
Topic Outline
Part I Introduction
Part II Preparatory Work
Part III Road Base Preparation
Part IV Formation of the Subgrade
Part V Stabilizing Layers
Part VI Concrete Pavements
Part VII Drainage Structures
Part VIII Slope Protection/Retaining Structures

Part IX Miscellaneous Works

 Part I: Introduction

ROAD DEFINITION
ROAD CLASSIFICATIONS
ROAD COMPONENTS
 Definition
• A road is a structure that link barangays and cities in the
country, and serve as medium in transporting goods and commodities
from one place to another, and as communication link which brings
economic development to a nation.
Classifications of Road
• According to usage
• According to national importance
• According to its surface course
• According to traffic volume
Types of Road According to Usage

• National Road
– Primary National Road - the main highway trunk line system
that is continuous in extent that goes from province to province
and region to region.
– Secondary National Road - connects a provincial or national
road to a public wharf or railway station.
• Provincial Road - connects two municipalities or cities within a
province
• City Road-street within the urban area of the city.
• Municipal Road-street within the poblacion area of a municipality.
• Barangay Road–street located outside the poblacion area of a
municipality or urban area of a city and those outside industrial,
commercial areas or residential subdivisions.
Types of Road According to National
Importance
• Major roads are those roads of national
importance. They are frequently used by
traffic and leads to vital areas such as major
cities and installations. Example of major
roads are the those roads classified as
National Roads or those which are part of the
highway system.

• Minor roads are roads which is local in nature

as it serves only the interest of the locality
such as a street. Minor roads are less
frequently used by traffic.
What is the difference between a street
and a highway?

• Highway - can accommodate greater traffic volume.

• Street or road - serves service area connecting to
highways.
Types of Road According to Surface
Course

• Earth Road
• Gravel Road
• Asphalt Road
• Concrete Road
Earth Road…..
• It is the simplest form of road constructed by shaping and smoothing
the natural soil traversed by the road line.
• A trail that has been developed with use over a number of years can be
purposely converted into a road that has a properly designed and
engineered alignment, cross section and drainage.
• One of the most important aspects of the design of a road is the
provision made for protecting the road from surface water or ground
water.
• The road surface must be constructed so that it drains rainwater away
quickly to drainage ditches.
• The formation of the road must be raised above the level of the local
water table to prevent it from being soaked by ground water.
Gravel Road…..
• Are constructed from natural gravel together with a
sufficient amount of good quality soil to serve as binder.
• It is sometimes termed as an all weather road and are used
to construct Farm to Market Roads which serves to connect
rural and agricultural areas to market towns.
• These routes serve as a better quality road, usually a
highway which allows farmers to transport their products
to market towns and/or distribution centers.
Asphalt Road……
• It is frequently described as flexible pavement implying its
ability to absorb the stresses imposed by traffic and
weather without cracking.
• The tensile strength of an asphalt pavement enables
resistance to displacement and the flexibility to conform to
minor irregularities of the base without failure.
• It is composed of hot-mix combination of asphalt cement,
crushed stone, sand fines and a small amount of air.
PCC Pavement Road……
• It is sometimes termed rigid pavement because it is strong in
resisting compressive load but weak in resisting tensile
stresses.
• Concrete pavement resting on a weak subgrade and base
courses is considered also weak in carrying heavy load
associated with impact forces.
• Portland cement is the essential ingredient in rigid pavements,
and in most structural concrete.
• It is a fine dry powder which, when combined with water,
forms a paste that sets into a stone-like substance.
• This is moderately strong in itself, and has the quality of
binding sand and stones into rigid masses with great strength.
• Cement and water are mixed with clean sand to produce
mortar, which is used chiefly as a binder and filler between
bricks, stones, and blocks; and with sand and graded sizes of
crushed rock or similar material to make concrete.
Part II - Preparatory Work

 Preconstruction Conference /Preliminary

preparations
 As-stake survey
 Temporary facilities
 Access and detour roads (Traffic
Management)
 Preconstruction Conference
• A preconstruction conference between the Contractor’s representative
on the project and the Project Engineer and his staff is required.
• A discussion of the project, specifications, unusual conditions,
Contractor’s plan and schedule of operation, and other pertinent items
is conducive to better job understanding. An understanding should be
reached as to how, and with whom the Project Engineer’s
representatives will communicate within the Contractor’s organization
during inspection of the work. If utility adjustments or removals are
involved in the project, the utility representatives must attend the part
of the conference that would involve that phase of the work.
• At this meeting, the site for the project field office should be
determined, as well as sites for storage of material and equipment.
• All such facilities must be approved by the Administration.
• Any controversy between the Contractor and the Project Engineer that
cannot be resolved at the field level, in accordance with the controlling
Contract Documents and established policies, should be referred to the
District Engineer in written form.
• All important instructions from the Project Engineer to the Contractor
must be either given in writing or confirmed in writing. These
instructions will be made part of the official project file.
Preliminary Preparations
• Before beginning work on any contract, the Project Engineer
should make certain that all of the following items applicable to the
contract are on site.

– Complete contract drawings, including any revisions that have been authorized.
– Cross-sections.
– Standard Specifications, Supplemental Specifications, and Invitation for Bids
– Reference materials.
– Right-of-Way plans, options, entry agreements, entry rights obtained under the
immediate possession law, and a record of properties under condemnation.
– Plans for adjustments to, or relocations of, any utilities that may be affected.
– Notice to Proceed.
– Material test equipment.
– Material test reports and approved sources of supply.
– Sketchbook, report forms, office supplies and field books.
– Surveying notes and equipment.
– Pertinent correspondence.
As - Stake Survey
• Its Importance :
– Determines the actual position of the road
structure based on the plans
– Helps in determining what necessary
deviation should be undertaken

•
Plans That Govern an
Infrastructure Project
•Original Plans
•As-Stake Plans
•As-Built Plans
Temporary Facilities and Equipment
• Client's Side (Facilities for the
Engineer)
• Office, Quarters and Laboratory for
the Engineer
• Vehicle for the Engineer
• Assistance to the Engineer
• Progress photographs
Temporary Facilities and Equipment
Contractor’s Side:
•Office
•Equipment yard
•Fabrication Area/Shop
•Workmen’s quarters
•Storage/warehouse
Contractor’s Equipment Yard
Access and Detour Roads
• In planning the construction work, care must be taken to
see that alternative routes or temporary deviations are
provided for traffic using the route.

• Access to properties along the road must be maintained at

all times and the works must be barricaded where
necessary to protect any passing traffic from accident.
Detour Roads
• Becomes necessary to divert traffic from any existing
roadway whenever the construction operations block the
flow of traffic.

• Are to be planned and maintained so that they will have

sufficient durability to remain in good condition and carry
the required traffic at any weather condition for the entire
period that the detour is required.
Access Roads
• A road by which a job is connected to the highway system
and is generally used in connection with borrow pits.

• Are also built for each isolated piece of job it services.

Part III – Road Base Preparation
• Clearing and grubbing
• Removal of obstruction
Clearing and Grubbing
• It means removing and disposing all surface
objects including vegetation, trees and
other protruding objects not designated to
remain along the roadway.

• It is necessary as a preliminary move in

shaping the ground prior to the start of any
excavation or placing of embankment as
any growth makes earth difficult to handle
and its decay will cause future settlement of
fill
Clearing and Grubbing
• Equipment and Labor Requirement
• Removal of Trees
• Disposal of Debris
Removal of Existing Obstructions
• Prior to actual construction work, obstructions are removed
in order not to hamper the work.
Typical Obstructions Are :
• Existing pavements
• Existing drainage structures
• Underground waterline
• Electrical post and lines
• Cable and telephone lines
• Residential houses and buildings
• Fences
Removal of Existing Pavement Using
Pneumatic Drill
Part IV-Formation of the Subgrade
– The subgrade is the upper layer of natural soil which
may be the undisturbed local materials or soil
excavated elsewhere placed as fill.
– In forming the road subgrade, excess suitable
material located along the upper part of the
designed road profile is excavated and taken as fill
to low lying areas along the road traverse.
– Roads in rolling hills are often engineered to balance
the cuts and fills so that all the material cut out in
high spots is just enough to build up all the low
spots.
– If the material is not enough, borrow materials are
quarried and taken along as fill in order to obtain
the design elevation of the subgrade along the road
project.
– The two components in forming the subgrade
therefore are:
• Roadway excavation
• Embankment fill
Embankment Fill
• Are suitable materials which can be common or
rock which are brought and compacted
together to a specified degree to form a stable
embankment to bring the road to a desired
grade or to elevate it above flood level.

• The most desirable fill is a mixture of two or

more simple type and varying proportion of
clay, silt, sand, gravel and stones. Sand and
gravel are most desirable as embankment fill
when mixed with enough clay or silt to bind
them together.
Quarrying and Hauling

Fill may be obtained by quarrying with bulldozer

from borrow pits opened just to obtain the fill and
loading/hauling same using a loader and dump
trucks.
 Spreading of Embankment

A stable embankment is attained by spreading the

materials into a thin layer then compacted at moisture
content close to optimum.
Compaction

Compaction trial of not less than 500 sq.m. is done to

determine the actual capability of the compaction
equipment and the compatibility of the material to be
used.
The number of passes for the compaction equipment to
attain the specified degree of compaction is recorded
for use as reference in the subsequent layering works
using the same material and compaction equipment.
What Is an FDT ?

FDT is Field Density Test which is conducted on site

in order to determine if the required compaction
specification has been attained to a specific layer.
 Road Widening

Required degree of compaction in road widening is attained by

benching the material for the heavy equipment to gain access
What Do We Mean by Blue Tops?

Blue Tops are painted sticks placed along the side of

the road traverse as guide and reference in the elevation
of the different layering requirements of the road project
Part V - Stabilizing
Layers
AGGREGATE SUB BASE COURSE
AGGREGATE BASE COURSE
As Stabilizers…..
• The subbase course is a structural
layer which accepts greater
compressive stress than the subgrade
and thus reduces the deformation of
the pavement under traffic loading.

• The base course reduces the vertical

compressive stress induced by traffic
in the subbase course and the
subgrade.
In Asphalt Pavements…..

• the base and subbase courses

serves to provide structural
capacity to bituminous concrete
slabs.

• they carry the load and distribute

it to the soil under the layers of
asphalt concrete.
In PCC Pavements….
• the subbase and base courses
spreads the load over the foundation.

• the base course prevents pavement

pumping and provides drainage for
PCCP slabs.
 What Other Purpose of Putting
These Layers Below the Surface
Course?
• Aside from being stabilizing layers, it also serve for
draining purposes

N. G

PCCP
W.T Agg. Base Course
Agg. Sub-Base Course
Subgrade

Water capillary action

What Is the Difference Between the
Two Stabilizing Layers ?
• Material Requirement
– Grading
– CBR
– Plastic Limit
– Liquid Limit

• Balance of Mechanics and Economy

 Stockpile Along the Roadway Side

What certain field condition dictates that materials are first

stockpiled along the roadside before it is spread and
compacted?
 Spreading

The subbase/base materials shall be spread to the

required thickness for compaction.
If the required thickness is 150 mm or less, the
material may be spread and compacted in one layer.
Compaction

Each layer shall be compacted to the full width.

Required degree of compaction is 100%
Part VI -Concrete Pavements
• Portland Cement Concrete Pavement (PCCP)
• Asphalt Concrete Pavement
Purpose of Concrete Pavement
•

• Being the uppermost component of the

roadway, it should provide long lasting,
smooth, clean surface and should spread
the load sufficiently so that the base
material can support them.

• It protects the base against damage by

traffic and weather.
Portland Cement Concrete
Pavement (PCCP)
• PCCP Terminology
• Types of Joint in PCCP
• Types of Re-bar Used in PCCP Joints
• Methodology
 ARY
DICTION

PCCP Terminology
• Workability - concrete ability to be placed in a prepared form
without honeycomb.
• Consistency - measure of fluidity of concrete.
• Water-cement ratio – describes the compressive strength of
concrete mix.
• Admixture - are substances other than aggregates water and
Portland cement that can be added to concrete to improve its
properties and fulfill other special purposes.
• Curing agent - is the treatment or protection applied to
concrete during hardening period to protect against early
shrinkage due to lose of moisture or abrupt changes in
temperature.

•
Types of Joint in PCCP
• Construction Joint
• Contraction Joint
• Longitudinal Joint
• Expansion Joint
Construction Joint
• Also called cold joint.

• Is constructed when there is an

interruption of more than 30 minutes
in the concreting operation which is
placed not within 1.50 m. of an
expansion joint or contraction joint.
Contraction Joint
• Also called weakened-plane joint.

• Are provided to relieve the tensile stresses

due to temperature, moisture, and friction,
thereby controlling cracking.

• If not installed, random cracking would

occur on the surface of the pavement.
Longitudinal Joint

• If the lanes are concreted separately, a

longitudinal construction joints in the form
of a key and keyway is used.

• Deformed steel tie bars of specified length,

size and spacing are placed perpendicular
to this joint.

• The spacing between longitudinal joints is

dictated by the pavement thickness.
Expansion Joint
• Provide space for the expansion of the
pavement, thereby preventing the
development of compressive stresses which
can cause the pavement to buckle.

• Are usually from 19 to 25 mm wide and

extend the full depth of the slab.
Expansion Joint
• The joint space is filled with expansion joint
fillers.
• Dowel bars are normally used in expansion
joints, and their diameter, spacing, and
length would generally be similar to that
indicated for contraction joints.
Types of Re-bar Used in PCCP Joints

• Dowels
• Tie bars
Dowels
• Are load transfer devices in joints to transfer wheel loads
from one slab to another and thus, prevent excessive
deflection at the ends of the slabs.

• Are plain round steel bars generally coated with a thin file
of bitumen to protect them against corrosion and to
facilitate sliding in concrete.

• Their installation midway in the slab should be carried out

accurately so as to have the dowels run parallel to the
surface of the pavement and the center line of the road.
Tie bars
• Are deformed bars used in construction and longitudinal
joints together with keys to tie two slabs together.

• Like the dowels, its installation must be midway in the slab

so that it runs parallel to the surface or centerline of the
pavement.
Methodology
• Setting of forms
• Batching of concrete
• Concrete pouring
• Use of concrete vibrator
• Screeding
• Concrete finishing
• Concrete curing
• Removal of forms and concrete cutting
• Pavement protection
• Sealing of joints
 Setting of Forms

Forms should be made of steel of an approved section

and depth equal to the thickness of pavement.
The base of the forms should be of sufficient width to
provide necessary stability in all directions.
It should be installed firmly in contact with
foundation w/ no deviation from true lines by more
than one (1) cm.
The alignment and grade elevations of forms should
be checked prior to placing of concrete.
 
Batching of Concrete

For large jobs, a Concrete Batching Plant is necessary to provide

a smooth flow of continues supply and transport of materials to
the work.

Periodic calibration of the plant is needed to ensure that only the

approved concrete mix is used for the project.
Concrete Pouring
• Concrete unloaded from truck mixers in a movable chute
for proper distribution into the prepared forms.
• Workers are not allowed to walk on the freshly mixed
concrete with boots or shoes coated with earth or foreign
substances.
• Placing should be continuous and necessary hand
• spreading should be done using shovels not rakes.

•
Use of Concrete Vibrator

Concrete should be thoroughly consolidated along the

faces of all forms by means of vibrators inserted into
concrete.
Vibrators are not allowed to be operated longer than 15
seconds in any single location.
 Screeding

A screeder is used to grade concrete in such manner as

to prevent segregation.
The screed is moved forward on top of the forms with
combined longitudinal and transversal shearing motion.
 Concrete Finishing

Floating- after the concrete has been struck off and consolidated it is
further smoothened by means of a longitudinal float. Any excess water
or soupy material is wasted over the side forms on each pass.

Brooming - is executed by producing a uniform appearance of

corrugations produced in the surface not more than 1.5 mm. in depth.
Concrete Curing
• Is necessary for the hydration to take place so that the
concrete may harden properly and prevent abrupt loss of
moisture during the curing period.
Curing Methods
• Earth or straw may be spread over the surface of the pavement and
kept constantly wet during the curing period.
• Burlap or cotton mats are spread over the surface. The mats are
sprinkled and kept constantly wet.
• Waterproof paper or polytelene sheets may be placed over the slab to
retain the moisture.
• Curing compound - the most popular method which involves the
spray application of light-colored fluid to the entire area of the
wet concrete. The fluid forms a film over the pavement that
prevents moisture loss.
 Removal of Forms and Concrete
Cutting

Forms for concrete shall remain in place

undisturbed within 24 hours after pouring.

Crowbars are used in removing forms pulling out

of nails and pins but cares should be exercised
not to break the pavement edges.
 
Concrete sawing is done within 24 hours after
concrete pouring water using cooled diamond
edge saw blade
 Weakened Plane Joint Using a
Template

An alternative to concrete sawing is the use of a thin

steel template
 Pavement Protection

Against Rain- To protect newly poured concrete pavements against rain it

is required to have available at all times materials for protection or covering
materials such as burlap or cotton mats, curing paper or plastic sheeting
materials.
 
Against Traffic-To protect concrete pavement at its early age, it should be
protected form passing traffic. This includes the posting of watchman to
direct traffic and the posting and maintenance of warning signs, lights,
pavement bridges and crossovers, etc.
 Sealing of Joints

Sealing of joints should be undertaken after

the curing period and before the pavement is
opened to traffic.
Each joint should be clean and dry when the
seal is applied.
Spilling of seal on the surface of the
pavement is not allowed.
 
Part VIII
Slope Protection/Retaining
Structures
• Slope protection/retaining structures are constructed
along the side of the road as protection from erosion or if
there are space constrictions.
Erosion of Side Slope
Some of the Types of Slope
Protection Structures Are :
• Grouted Riprap
• Stone Masonry
• Gabions
• Plain or Reinforced Concrete
Grouted Riprap
• Excavation of Foundation
• Use of Batterboards As Guide
• Laying of Boulders and Grout
• Finishing Work
• Importance of Weep Holes
 Excavation of Foundation

A backhoe is an ideal equipment to use in the excavation

of foundation for grouted riprap.
 Use of Batterboards As Guide

Good workmanship requires a reliable reference to guide

the work up to completion.

The unevenness of the embankment slopes is then

trimmed using shovels and rakes.

The high areas are removed and patched and compacted

to low areas until a flat surface is attained.
Laying of Boulders and Grout

Boulders and grout are placed layer by layer alternately.

Each stone is laid with its longest axis perpendicular to

the slope in close contact with the adjacent stone.
 Laying of Boulders and Grout

The riprap is thoroughly rammed into place and the

finished stone are laid to an even tight surface.

Spaces between stones are filed with cement mortar

sufficient enough to fill completely all the voids.  
 Finishing Work

Cement grout is placed starting from the bottom to the

top of the surface and then swept with a stiff broom.

After grouting, the surface is cured for a period of at least

3 days from the date of installation.
Measurement of Thickness
 What is the importance of weep
holes in slope protection/retaining
structure?

Weep holes are opening provided to permit draining of

water in filter layer or soil layer from behind the
structure.
If no or insufficient weep holes are installed, this will
cause oversaturation of the embankment and the
subsequent failure of the road structure.
Stone Masonry Specifications
• Boulders - thickness of not less than 150 mm, and widths
of not less than one and one-half times their respective
thickness, and lengths of not less than one and one-half
times their respective widths.
•
• Mortar - composed of one part of Portland Cement and two
parts of fine aggregate by volume and sufficient water to
make the mortar such consistency that it can be handled
easily and spread with a trowel.
 Excavating Stone Masonry
Foundation

The foundation bed where the masonry is to be placed

should be firm and normal to the face of the wall.

The bed that will receive the stone should be clean

and moistened before the mortar is spread.  
Use of Batterboards Essential to
Produce Good Workmanship

As in grouted riprap, batter boards are necessary to keep the lines and
grades of the finished stone masonry structure in accordance to the lines
and grades of the plans.
 Laying of Boulders and Grout
• Large stones are used in the corners.
• Bunching of small stones of the same size is not allowed.
• Stones are laid with their longest face horizontal in full
beds of mortar.
• Joints are flushed with mortar.
• The exposed face of the individual stone should be parallel
to the face of the wall in which stones are set.
• The stones are handled carefully so as not to jar or
displace the stones already set.
 Finishing Works

Immediately after laying and while the mortar is still

fresh, all face should be thoroughly cleaned of mortar
stains and should be kept clean until the work is
completed.
Gabion Mattress
• Wire mesh in varying thickness and width which is filled
with boulders in placed to form a slope protection
structure.

• Boulders should be hard and durable rock pieces that will

not deteriorate when submerged in water or exposed to
severe weather conditions.

• Boulder size should be uniformly graded generally ranging

from 10 to 20 cm.

• Filled gabions should have a minimum density of 1,400

kg/cum and voids distributed evenly.
Sample Gabion Mattress
 Installation Procedure
• Only simple tools are needed to assemble this wire
basket such as long nosed fencing pliers and
crowbars.
• Before closing of lids, gabions mattress should be
overfilled by about 25mm to allow for settlement.
• The lids are then stretched over the stone fill and
laced down.
• Corners are secured first to make sure the lid can be
laced down without overstretching the mesh.
• The lids are then laced down securely.
Part IX - Miscellaneous
Structures/Works

• Curb and gutter

• Sidewalk
• Guardrail
• Road signs
Curb and Gutter Defined
• It is the raised rim of concrete which forms the edge of the
sidewalk while the gutter is the horizontal paved portion
slightly inclined.
•
• Both forms the road surface drainage system used to
collect surface run-off water.
Concrete Sidewalk Defined

• It is for use of pedestrians

• It provides safety also to motorists as a good clearance so
that the roadway can be fully utilized.
• It must be wide enough and skid resistant
Types of Sidewalk
• Concrete paved
• Asphalt paved
Guardrails Defined
• They are installed to mark the limit of safe travel and warn
of danger beyond.

• It is used to restrain and guide out-of-control vehicle in a

manner that will cause the least damage and not create
undue hazard to other vehicles.
Material Requirements
• Standard beam type are either galvanized or aluminum
• Post may be concrete, steel or aluminum
Installation Specifications
• Location lay-out
• Post installation
• Beam assembly
• Backfilling of drilled/dug holes
Location lay-out

• The proper location of guardrail is as shown in the plans.

• But most often, its location is left to the discretion of the

Engineer.

• In general, the rail should be located near the shoulder line

to give a maximum width of roadway and shoulder.

• However, the distance form the back of the post line to the
slope should to be less than 0.6 meter in order to give
adequate support against overturning.
Post Installation
• Spacing of posts should be done with accuracy and care.
• Holes are pre-drilled depending on the kind of soil or
presence of rock or boulders.
• Appropriate drilling equipment or hand tools should be
adequate to handle any condition encountered.
Beam Assembly

• Assembly begins at the end farthest from approaching

traffic placing one panel of the rail at a time on the posts.

• Without putting the nut on the long bolt on the post until
the next panel is in place, the two corrugation crests is
placed always towards traffic.

• Then the short splice bolts are inserted and the nuts left
loose. Tightening of all bolts is done during the final
aligning process.
Beam Assembly
• The end piece is installed just like any other panel and
always with the end flared back.
• The lap at all posts should be such that a vehicle does not
strike the end of the metal.
• For curved installation, flex-beam guardrail may be
obtained shop curved to any desired radius 6 meters or
greater.
Backfilling of Drilled/Dug Holes

• Backfilling of dug or drilled holes should not be completed

until the rail is in place and lined up.

• Backfill should consist of dry earth or granular material

well tamped.

• Posts need not be set in concrete unless unusually soft

materials require it.
Concrete Parapet Wall…..

An economical alternative road protection.

Completed Parapet
Road Signs Defined
• Are traffic signs installed along the roadway for
the following purposes :

– For traffic safety

– To remind particular traffic rules
– To inform drivers how to use the roadway
Types of Road Signs
• Warning sign
• Regulatory sign
• Informatory sign
Specifications
• Sign assembly/fabrication
• Surface preparation of sign blanks
• Application of reflectorized sheeting
• Installation