Irc 111-2009 dense graded bituminous mixes

this is civil engineering code regarding dense graded bitumen mixes

1. IRC:111-2009

SPECIFICATIONS
FOR
DENSE GRADED BITUMINOUS MIXES

INDIAN ROADS CONGRESS
2009

3. mt

IRC:111-2009

SPECIFICATIONS
FOR
DENSE GRADED BITUMINOUS MIXES

Published by
INDIAN ROADS CONGRESS
Kama Koti Marg,

Sector 6, RK Puram,

New Delhi-110022

2009

Price Rs. 300%
(Packing and Postage charges eut)

4. IRC: 111-2009

‘ins Published = Tune, 2000
Reprinted: December, 2009

Ai Ragas Reserved No par ofthis publication shal be reproduced.
tained os thanmited many form os y any means vathout dhe
‘permission af the Indian Roads Congress)

Pre at 1G Printers Por Lid New Dell
copies)

110020

5. CONTENTS

Specifications and Standards Commitee

Designof Mix

‘Construction Operation
Conos
Annex A

Annex B

TRCALI 2009

Page No.

o

7. 10
u
2
13
15
16

7
18

19.
20

a

IRCA 2009

PERSONNEL OF THE HIGHWAYS SPECIFICATIONS AND

‘Sinks, VK.
(Convenor)

Singh, Nümali
(Co-Convenor)
Sharma, Aran Kumar.
(Member-Secreary)
Abluwalia, HS,
Bahadın AP.

Paso, SB
Chandrasekhar, Dr BP.
Datta, PK

Desa, IP.

Deshpande, DB
Dhingso, Di SL.
Gupta, DP

Gupta, K K
Sain, NS

hia, RK
hain, Dr SS

Kadiyali, De LR
Kandasany, €

Krishna, Prabhat
Kuro, BP.

Kuma, Anil

STANDARDS COMMITTEE.
(As on 23rd November, 2008)

Adal. Directo: General, Ministry of Shipping Road
Transport & Highways, New Delhi

‘Adal Director General, Minisuy of Sipping Rood
“Transport & Highways, New Delhi

‘Chief Engineer (R) SAR, Ministry of Shipping, Road
Transport & Highways, New Delhi

Members.

Chief Engineer (Re), Minis of Shipping, Road Transport
& Highways, New Delhi

‘Chief Engincer(Retd), Ministry of Shipping, Road Transport
& Highways, New Delhi

Chief Engincer(Rerdj, Ministry of Shipping, Road Transport &
Highsays, New Delhi

Director (Tech), National Rural Roads Development Agency
(Minis of Rural Development). New Delhi

Executive Director, Consulting Engg Services) Pvt Ltd, Now
Debi

‘St Vice-President (ech Ses). Gajrat Ambuja Cement Lid,
Ahmedabad

Secrelaty, Mahatashus PWD, Mumbai

Professor, nian Instiutoof Technology, Mumbai

DG (RD) (Retd.), Minisuy of Shipping, Road Transport &
Highways, New Delhi

Chief Engine (Reid) Haryana, PWD

Chief Engineer, Minisuy ot Shipping, Road Transport &
Highways, New Delhi

Chiet Engineer (Reid), Haryana PWD, Sonepat

Professor & Coordinaton,

Rooıkee

Chief Executive, LR. Kaiya & Associates, New Delhi
Chief Engineer, Minisuy of Shipping, Road Transport &
Highways, New Delhi

(Chief Engineer Reid), Mi
& Highways, New Delhi
(Chief General Manager, Nations! Highways Authority of Indi,
New Delhi

Chief Engineer (Retd ),CDO, Road Constn Deptt. Ranchi

sty of Shipping, Road Transport

w

8. 2009,
Kama, Kamlesh
Liansanga

Mina, I,
Momin,S$

Nando, Di PK.
Rathore, 88
Ready, Di TS

Das, SN

Ses, OWN.

Stoke RS.
nha, AV

Srivastva, HK

Velsyudkan, TP

President, RC

Disector General
‘oad Development)
Secretary General

Borgo, VB.
Justo, Di CEG

Keita, MD
Merani NV

Chief Engineer, Minisuy of Shipping, Road 1
Tighways, Now Delhi
Engincer-in-Chiel & Secretary, PWD, Mizoranı, Aizwal
‘Member, Rajasthan Public Service Commission, Aine
Former Member, Maharashita Public Service Commission,
Mumbai

Director (Ret), Cental Road Research Insütute New Delhi
Secreta tothe Govt of Gujaat, PWD, Gandhinagar

Senior Vice-President, NMSEZ Development Corporation Pvt
Li Mumbai

Chief Engineer, Minis
Highways, New Delhi
Engineer-in-Chief (R&B), Andhra Pradesh PWD,
Secunderahad

DGIRD) & AS, MORT&H (Reid), New Delhi
Ditestor,AIMI., New Delhi

Ex Scientist, ena! Road Research Insite, New Delhi
Chief Engineer, Ministy of Skipping, Road Trasspost &
Highways, New Delhi

Dies: (Projects), Netonal Rural Rosds Development Agency.
Ministry of Rural Developmen), New Delhi

Addl DGBR, Disoctorate General Border Roads, Now Delh

Ex-Officio Members

(Mins, HL), Member, Rajasthan Public Service Commission,
Ajmer
+ Ministry of Shipping, Roud Transport & Highway,
New Delhi
(ANN. Dhodapkan, Indian Roads Congress, New Delhi

‘of Shipping, Road Transpost &

Corresponding Members

Past President, IRC, Secretary (Reid), Maharashıra PWD,
Maui

nevus Fellow, Bangalore University, Bangalore
Exocutive Director, Hindustan Construction Co Lid, Mumbai
Principal Secretary, Maharashta PWD (Reid). Mumbai

9. SPECIFICATIONS FOR DENSE GRADED
BITUMINOUS MIXES

1 INTRODUCTION

“The Indian Roads Congress published three specifications for dense grad bituminous mixes
under ties Bituminous Concrete (IRC:29), "Dense Bituminous Macadam (IRC:94) and “Semi

Dense Bituminous Concrete (IRC: 99) The Flexible Pavement Committee (FPC) in its meeting,
held on 22" April, 2006 decided to revise the specifications to keep pace with the changes i the
technology endimprovements inte consuvetion procedures as well as quality conta expectations
I was also decide to combine ll he documents rlstedto dense graded bituminous mixes into a
comprebensive document and authorized Si R K Pandey o finalize the ral with technica input
from Prof PS Kandhal Ie finalized draft was sent to all EPC members for comments The FPC
in its meeting on 9° September, 2006 discussed all comments in detail The vevised dat was
published in he February, 2007 issue ofthe “Indian Highways to solici mote comments trom
ers atlarge. These additional comment were reviewed by the KPC in ite meeting on 5” May,

2007 ‘The FPC authorized Prot PS Kandhal o incorporate all comments and Finalize the ral.

‘Duat finaized by Prot P'S Kendal was discussed by the Flexible Pavement Committe in ts
_mceting held on 27" July, 2008 whtcin Committee authorized Convenor, Flexible Pavement
‘Committee ro modify the draft in he light ofthe discussions held and submit to the High

‘Specifications and Standards (HSS) Committes HSS Committee considered the diatin its fit
meeting held on 23% November 2008. Dral modified by the Convenor, IISS Committee was
approved by the Executive Committee in its meeting held on 30° November, 2008, at New Delhi
and bythe Council in its meeting held on 13° December, 2008 st Kolkata subjceto the incorporan.
fmodificaions keeping in view the comments of members and approval by the Convenor, HSS.
Commitee The names of the Personnel of Flexinle Pavement Committe (H-2) are given below

Singh, Nirmal Tit = Convenor

Shukla, RS = Co-Convenor

Nisa, SK Member Secretary
Members

Agarwal, Dr Sanjcew Kachroo, De PN

Bhanvala, Col RS Kandhal, Prof. PS

Bose, Dr Sunil Kino, RRD.

Das, Da Animes Krishna, Prabhat

Jain, RK Mina, HT

Jain, Rajesh Kumar Pandey, RK

hain, Dr SS Rathore, $$

10. IRC111.2009

Rawat, MS Singh, Mabavir
Raza, Md. Asif Taiwan, LN,
Roychaudhai, Pina ‘Tyagi. BR
Sharma, SC Director, HRS

Corresponding Members
Bhattacharya, CC Issae, Prof PK
Doagre, Dr Rij Justo, De CEG

Reddy, Dr. KS
Ex-Officio Members
President, IRC Mina, HL)
Director General (RD), MOSRTRH —
Secretary General, IRC (AN Dhodapkar)
2 SCOPE

24 This specification deals with the basic outline for the design, construction and comtols
needed while laying den

+ rade bituminous mixes in base course, binder course and wearing

22 Dense graded bituminous mixes shall consist of mineral aggregate and appropriate
bituminows binder, mixed ina hot mix plant and lad with a mechanized paver Dense graded
bituminous mixes, such as binder and wearing courses are usually laid om a previously prepared!
Pitominous layer Binde: course is the intermediate layer hetween bituminous base course and
biwuainous wearing course Three diferent specifications for dense graded bituminous mives ate
available for use for highways, Purpose, layer thickness and number of layers allowed fo these
specifications are given in Table.

Table 1 Types of Dense Graded Bituminous Mixes, thely Use,
Number of Layers and Layer Thickness

[Specification Purpose Number of | Thickness of
_ Layers | each Layer

[Dense Bituminous |Base/Binder Cause/Overly for [Single oe | SO mm 100mm

IMacadam (DBM) | Strengthen u Multiple

Sena-Deose Riuminous |Westing Cowsc single | 2sum- 40mm

[Concrete (SDRC)

[Bicuminous Concrete | Wearing Comse Single | 25 mm/do mm

umo | Som

11. IRC:L1 2009

3 MATERIALS
34 Bitumen

3.11 Tae bitumen for dense graded bituminous mixes shall comply with Indian Standar
Specification for viscosity-graded peving bitumen, IS: 73 0: modified bitumen complying with

the IS: 15462 Guidelines for selection of grade of viscosty-gtaded paving bitumen and modifica
bitumen are given in Tables 2104.
“Table 2 Viscosity Graded (VG) Bitumens and thelr General Applications
Viscosity Grade General Applications
ver
VGA Une in gi) seid can uch a thse fn inersecions, near ol
(40.60 pet booth, und tuck pking ts lic fold 3040 penetration grade
ve ‘Use or pvingin most ol Inn in is of old 6070 peneuation re
(50.70 peneuation) E
von neo: pvingin col laa high te regions of Nah India,
{6080 peneuation)
vo ‘Use nay ing aplicanonsand for paving in very old cline in
(40-100 peneuaion) | igs of ld 8/100 poncuaton girde

312. ‘Thetype and grado of bitumen to be used shall he specified in the Contact

313. Both the highest ily mean air temperature and thelowest daily mean at temperatures
‘mentioned in Tables 3 and 4 can be obtain forthe weather station nearest to the project site
rom the Indian Meteorological Organization (IMO). The IMO has data on daily mean high
temperature for all 365 days ina yeu forall weather stations based on historial records ofthe las
30-40 or move years This daily mean high temperature on «specie day is Ihe same as daily
“normal” high temperatur for hat day as usualy reported in some newspapers. The highest of the
365 deily mean high air temperatures (which usually cuts on some day in May o Tune) used in
Inbles 3 and. Likewise, the lowest da temperature (which usually occus on some
ay in January) can also be obtained from the IMO

‘Table3 Selection Criteria for Viscosity-Graded (VG) Paving
‘Bitumen Based on Climatic Conditions

= Tier tan tre] 2010306 [ore tan 30

Air Temperature, "© |

Meta wc | von vom Y
I NG-10 vG10

WC où ower

12. IRCALL-2009
‘Tabled Selection Criteria for Grade of Modified Bitumen
Highest Dally Mean Ait Temperature, °C

[Lowest Dally Mean Air [Less than oc 20 to 400 More than 306
Temperature, € Grade of Modified Bitumen
‘Mow tam 100 PAGARMB 120 | PMB/NRMB 10 |PMBVNRMB 40
CRM 50 RMB SS [Cams oo
10 Cat lower PMBINRMB 20 | PMBINRMB 120 [PMBINRMB 70
RMB 50 CRMB 50 [can ss

PMB_ = Polymer Modited Bitemen
NRMB = Natutal Rubber Modified Bitumen
CRMB = Ciumo Rubber Modified Bitumen

Note + When commercial vehicles exceeds 2000 per day pr lane and the highest daly mean
temperatine exceeds 40°C, VG-40 01 modified bitumen of equivalen süllness se

recommended for bituminous concrete and top avers of dense bituminous macadam

32 Coarse Aggregate

421 Thecoanse aggregate shall consis of crushed sock, crushed grave o other hard mater
retinedon 2 36mm sieve It shall be clean, hard, durable and have cubical shape, fee from dust
and soft organic:
potesity The coarse aggregate shall tif tr physica) requirements specified in Table 5

other deleterious substances The aggregate should preferably be of low

322. Where crushed gravel is proposed as aggregate, not less than 95% and 90% by weight ot
{he crushed material retained on 4 5 mm sieve shall bave atleast wo factues faces for ituminous
‘concrete and DBMISDRC tespectvely

33 Fine Aggregate

33.1. Fine aggregate shall consist of crushed os natually occursing minesal material, ora
‘combination of to, passing 2 M6 mm sieve and ctancd on 0075 mm sive. No natural sand will
beallowedin the binder and weaing courses and no mote than 5O percent natural sand will be
silowedin the base courses Ihe fine aggregate shall be clean, hard durable, dry and fice from
stand soft organic ant othe: de

value not less than SO when tested in accordance with the requitement of IS: 2720 Patt 37. The
plasticity index of ths traction passing the 0.425 mam sieve shall rot exceed 4 when tested in
accordance with LS: 2720 Psat 5

ous substances Fine aggregate shall have a sand equivalent

13. IRC:111-2009
‘Table $ Physical Properties of Coarse Aggregate

Properly Test [Requirement | Test method
‘Cleanliness | Grain size analyte Mas 5% passing | 15: 2386 Pun T
0075 men
Panicle Shape | FiaKines and Elongation Index | Max 35% TH 280 ra
combined
Sage | Los angeles Abrasion Vales | BO-Max 30% | 18:2386 Pan TV
eus Mex 356
Aggregate Tap Vale Max 26% [1872586 Pan IV
Obra Max. 27%
Poli Polished Stone Yale Min. $8 ETT
arabes | Soundness (Eher Sodium or Magresiun Sulphate) + eyes
Soaium Selphato | Man 128 [ETE
Magnesium Sulphaie 15: 2386 Par y
Wa Water Absoniion 18: 2386 Pat Im
Absorption
Sinon waa
Water Min 40% ASIETO 253
senti
Notes ~
© The aggregate may sait citer of ths two teste
+= Only for wearing courses
6 Te te minimum tained teni sucngt als below 80%, ne of antstpping age
recommend 10 mec he minimum requsements
54 Fille
34.1 Hillecshallconsistof finaly divided mineral mater such a tock dust, o ydrated ime or
cement apjuoved by th Engines The ase of hydrate lines encouraged because fis ety

goodan
inTibleó

wippinz and antioxidantpropetis “The filler shall be graded wihin the Tmt indicated

“table 6 Grading Requitement of Mineral Fille

Were Canale pa by veo
fo) a total aggrete
a rc
33 5510
GE Som” .
vi
we

14. 12009

342 Tnefilershallbe inet material fre ftom o ganic impurities and have plasticity index not
rents han 4. Plasticity index requrement will ot ap i fillers ychted me ot cement Where
complete bituminous minute slo satisfy equrementof Moisture Susceptibility est(AASHTO
7283 wit freeze & thaw option), 2% by toral weight of aggregate of hydrated lime shall be used
and percentage of (ne aggregate reduced according See Annex A forthe outline of AASHTO
Pi

35 Aggregnte Grading and Bitumen Content

351 Thecombined greding ofthe coarse agguegste, fine aggregato and filler, when tested in
accordance with IS 2386 Pat 1, wetsieving method, ball confou tits given in Table 7

352. Taecombinod aggıegate grating shall not vay from the lower limit on one sieve to the
higher mit onthe adjacent sieve to avoid gap grading

"Table? Aggregate Grading and Bitumen Content

Soon Toi sone RC
Cr T T EZ a 7
ome aa Fon O
yee Tika A a]
tele nn) Cure Percent y TIRE FE
8 i ~
7 a
35 os mt m
Ll E 7 — mr SO
BT = Js tem ter D Rem
ES a an To EA
2 EN EN psss
a aa hea LE Pew — ear
an E E eer
> at SB per LE
= : = [Ear
= = TE 3 ES
EI a LE fer E] EN EL

* Nominal moximnn aggregate size is he lange specified sieve size upon which any of

he aggregate muleil I time

** Conesponds to specific suit of the Aggregate hing 27. Incase aggregate have
specific gly mo than 2.7. bitumen contest ean bo reduced proportionately Further,
fo regions whet highest day mean ar temperature is 30°C 02 lower am lowest daly
‘van air temperate fs 10°C or lower, the blumen content may he increased by ca
much 26 0 porc

15. IRC.1L1.2009.

353 Bitumen content indicatedin Table 7 sche minimum only. The exact bitumen content
required shall be determined following the Marshall Mix Design procedure contained inthe Asphalt:
Institute Manual MS-2 (Sixth Edition)

354 The fines tobitumen (F/B) retioby weight of tote! mix shall ange from 0 6t0 1 2 forall
mixes in Table

4 DESIGN OF MIX
41 Mix Requirements
4.1.1 Besides conforming othe sequirementof ging and quality for individual ingrecientshe
mix shall met the requirement set out in Tables depending upon the typeof bindet

‘Table Requirement of the Dense Graded Bituminous Mix Using
Viscosity. Graded (VG) Paving/ Modified Bitumen

Properties ‘Viscosity Grade [Modified Bitumen [fest Method
Paving Bitumen [Hot [Cold
Climate | Climate
Compacta 75 bows on such fe ofthe specimen
(Surber of blows)
Minimum sai 30 y y AASHTO TES
GN at 0)
Marshal flow (ann) Ex TN DESEAS
Marshal Quote pS 253
(ability)
Ar Vous 35 MST ane
ASEM DIO
EAU SF MSD
bitumen (VER)
“Tensile Stength Rate _ | HI Minimum) AASHTO TS
Coating of Aggrepae SR en [8:0
Particles with bitumen
Vain Mineral agrege VR,
or Maxima Bin S VIA related to designed A
Partio sine os) Pros
7 7 5
33 Ei [u ía
12 IE = 1s
DE a icy m
ES] in = 1
am © i E

Fo Intermediate valu of designed percentage ai voids interpola the MA

16. IRC:111-2009
42. Binder Content

42.1. ‘Thebinder coment shallboselectodto obtain percent voids nthe mix design and shall
‘eet allrequiremen's given in Table $ The Mahal Method for designing the mix shal be adopted as
<escrbedin the sn edition ofthe Asphal institute Manual MS-2

422 Where maximum size ofthe aggregate is more than 26 5 mon, modified Meshell method
sing 150 mun (inches) diameter specimen descibedinthe Asphalt lsttute Manual MS-2 (Sith
Edition) and ASTM DSS81 shal be used. Tais test method requises modified equipment and
procediue When the modified Marshall testis used, he specified minimum stability valves and the
specitied flow values given in Table shall be multiplied by 225 and | 5, respectively

43 JobMix Formula

43.1 Thetaboratory mix design gives the proportion ofthe mineral aggregate combination in
teams ol individual sieve sizes. fw actual operational purpose inthe fet, blending ofthe two o more
sacs of aggregaes (ac size having wii range oindvidual seve size) would be receseay Tas
blendingraos obiined ona weight buss giving pescen weight of the corso sega, fine acute
and file needed to give tho time gradation his mineral aggregate combination together wi the
oespondine optimum bien contentas eterna in the laboratory, consi the job mia fama
{a implementation during constction The ob mix formula proposed or he sein the work shall
give te elowing decis

1 Somee and location of al materials

2. Proportions of all materials

3. Binder type and percentage by weight ot total mixture

4 Coase aggregatc/line aggregates/minezal fills as percentage by weight of toral
aggregate including mineral ile.

A single definite percentage passing euch sieve fox the mis aggregate

© Theindividual grading of the individual agercgate faction and the propontion ofeach
in ho combined grading

‘The testresults of mix design such as maximum specii gravity of loose mix (Gm),

‘compacted specimen densities, Marshall stability, flow, at voids, YMA, VEB and

related graphs, and test results of AASHTO 7283 Moistue Susceptibility Test

8 Incase of Dich miter, eindivial weight ofeach typeof agregate a binder er batch

9 Testresuls of aggregates

10, Mixing and compacting tempera

432 Appovalot the job mix formula salle based ou independent resting bythe Enginccn
the sumples funished by the Contactor It shoold be ensued that i is based on the wuly
representative samples ofthe material that wil be used forthe work Nes job mix forma shall be
otapproved whenever theres change in the material used fo the work

17. IRC: 11-2009
44 Plant Hal

44.1 Plant shal be canid auto establish atthe plant can produce uniform mix conforming
tote job mix formula The permissible variation ofthe various ingredients nthe actual mix om
‘the job mis formula sll be within the limits as given in Table 9. These veritions are intended to
apply to individual specimen taken or quality contol test in accordance with Claus 6

‘fable 9 Permissible Variatlon from the Job Mix Form

Deserpilon Pare Variation
DEN DECTEC
Ragone pang
19 mm or langer = =e,
ATADO EJ = 6%
175mm = 6% ie
EU se 3
03 mm, 0-15 mm = =e
‘OFF Ena PEGI
Binder Content 30 0
ing Temperate Fans 100

45 LayingTrials

45 1. Laying tials are cated out establish thatthe proposed mix can be success id amd
‘compacted, The laying trial shall be cate out in an aca, which does no forma past ofthe work
‘Te minimum are for laying tal shall be 100 qu This shall be similar t the project area on
‘whic the bituminous layer i to he laid Methodology, equipinen ud mix shall also be similar to
(hose proposed tor the project

452 The ils establish that the proposed laying plan, compaction plan. and methodology
we capable of producing satisfactory results The density of finished paving let should not be
Less than the 92% of the average deusity (Sample size N=2) based on theoretical maximum

specie gravity ofthe Love min (Ganz) obtained on the day of tal following ASTM D2041
See Annex fo he outline of ASTM D2041
5 CONSTRUCTION OPERATION
54 Preparation of Base
51.1 Cleaning of the surface: The suce shall be clemed al loose extraneous mater by

ucans of mechanical broom and high-pressure ar jet from compressor or any other approved

equipmentimetion

18. IRC111-2009

5.12. Fillingup of potholes and sealing of cracks: Any potholes andfr cracks shall be
repaired and sealed

5.13 Geosynthetics or stress absorbing layers: Where required, layer of geosymthetics!
Stress absorbing material shall be laid

514 Profile correcting course: Depending upon requitement, profile-conecting course for
correcting the existing pavement profil shall be nic either as a separate layer o as a composite
layer with varying thickzess. Whore the maximun thickness ofthe profile coroctivo courses Less
(an 40 mm, the profil coneotive couse shall be ai as an integral pat ol the overlaying layer In
other cases the profile conecte couse shall be constructed as a separate layer When itis ais
separate layer, type of material forthe use a the profile corrective course may dife

52 Tack Coat

521. ack oat: Tack Cost sal be ws per IRC:16 “Standard Specification and Code of Practice
Los Prime and Tack Coa"

Mixing

53.1 Dense gud bituminous mixes hall be prepszedin «hot mix plant of adequate capacity
and capable of yielding a mix of proper and uniform quality with thorougaly costedaggregate The
essential features of the hot mix plant ae given in Annex A of RC:27 “Specifications or Ritumen
“Macadam”, Table 10 gives the mixing. laying, and oli temperatures fr dense raded mixtes
Incase of modified bitnsen, the temperature o mixing nd compsetin sul o higher thaa the mi
\withconventional bitumen as binden The exact temperature depends upon the type and amount of
modifier used and shall be adopted as pe the recommendations of the manufacture In onder lo
ensure unitoun quality of mix the plant shal be calibrated fom tine to time

Table 10 Mixing, Laying and Rolling Temperatures for
Dense Mixtures (Degree Celcius)
Bitumen [Bitumen | Aggregate [Mined | Laying

Viscosity | Temperature | Temperature | Material | Temperature | Temperature
‘Temperature

160-170 160175 | 160-120 1soxin | 10Min.
150.168 130.170 | 130.168 roma, | o0min,
sss | uso | masias 135 Min. | ss min
140-160 moss | 140160, no in | soni

“Rolling must Be complete beiove the at cols to these minimum tempera

19. IRC:11-2009
84 Transportation
5461 Bituminous material shall be transported in clan, insulated covered vehicles An asphalt

release agent, which does nr adverscy affoet the bituminous mix may be applied tothe interior of
{he vehicle to prevent sticking nd to facilito dischaygeof the material

ss

551 Dense graded bituminous mixes shall not heli:

+ im presence of standing water un the surface,
+ when rain imminent and during rans, fog, u dust tou
+ when the haserbinder course is damp,

+ when the it temperature on te surface un which isto be lai is lessthan 10°C for
‘mix with conventional hitumen as hinder and is ess ihn 15°C fr mix with notified
bitomenas Binder

“+ When the wind specda amy temperature exceed the 40 kavh a 2 m eight

552 Preparation of the base: Base shall be prepared by canying out all or some of the
operations as per Cause 51, depending upon the site conditions.

553. Spreading: Exseptinacas ho paver cannotaccess, bituminous material shall be spread,
Teveled und tamped by sell-proplled hydrostatic paves finisher prfershly with sensor As soon as
possible after arrival at ste the material shall be supplied continuous tothe paver aná aid without
delay The rate of delivery of material othe paver shall be regulated to enable the pave o erate
comtinaosly The travel te of paverand the method of operation sll be adjusted 1 ensu

nl unifoam flou of bituninous mater across the sree fe from din, wing and caen

LResticted areas (such as confined space, footways, inegular shape and varying thickness,
apptoaches fo expansion joins te) where paver cannot be used, the material shall be spt
ak and loved with suitable hand tol by tained staff

Whoa laying dense graded binsminous mixes neat expansion joint, he machine laying shell be
stopped about 300 ana short of joint Ihe remainder of the pavement up o the join snd the
‘comesponding wa beyondt hal be id mally Ji 10 givesthe minimum laying temperatures.

emperatue greater than 145°C shall not be laid or deposited on bridge
deck waterproofing system unless precautions against the heat damags have been taken

Bisuminous material, wi

20. IRC:111-2009
56 Compaction

561 Compaction shall commence as soon as possible ae laying and shall be completed before
‘the temperature falls below the minimum rolling temperatures given in Table 10 Rolling ofthe
Jongitudial joints shall be done immediately behind the paving operation Alle this the rolling shall
commence at the edge and progress towards the center longitudinally except at sections with
‘unidiectional camber, where it shall progress from lower edge to upper edge parallel to centrline
ofthe pavement.

562 Alldeficieniesinthe sutace aftr laying shall be made good bythe atendaat behind the
paver, before nial lings commenced The initial or breaklown vollig shall be dane withthe 8
to 10tonnes dead weight ox vibratory steel wheel role The intermediate olin shall be done wits
¡Sto 10 tomes dead weight or vibrator tlle où with a pneumatic roller of 12015 tonnes, wit
ative pressuze of at least 0 56 MPa The finished tolling sal be done with 6 to 8 tonnes smooth
‘whet oer, Rolling shall continue ill sl the role marks are removed from he surface and the
minimum specified Field density teieved

563 The dense grated biruninous mises shall be roled in he longitudinal inetion with the
roller as lose as possible tothe paver. The overlap on successive passes should be at least one

ind ofthe wicth ofthe rea rol ot inthe case of pneumatic wheeled olles, at east the nominal
‘width of 300 mn, The roll: should move at spood of wo mote than km hour The roc hall
not be permitted to stand on payement, wich has not been fully compacted A preceuiins shall
bo taken prevent dropping ot ol, reas, petrol or other foreign material ou ie pavement The
hel ofthe roles shall be hept mois withthe water or spray system provided with the machine
‘oprevent the mixture fron alheringtothe wheels Minimum avis to prevent adhesion betwen
‘wheels and mistae shall be used ands plus water shall not be allowed to stand onthe patty
complet pavement,

564 ‘The density ofthe finished paving layer shall be determined by taking 150 nm diameter
cotes The density of finished paving layer shall at be less than the 92% of he average (sample
size N=2)theovetical maximus specific gravity ofthe loose mix (Gizan) obtained on tha day in
accordance with ASTM D204 See Annex B for the ouline of ASTM D2041

57 Joints
57.4 Where joints ese made, the material hal be fully commpacted and the joint made fash in

‘one ofthe following ways,

3) Alljoints hailbe cu vertical othe ull thickness ofthe previously Id mix Alllousened
material shal be discarded ard the vesical face be coated with any viscosity grate bitumen,
‘or coldappliedemolsiio bite While spreading the sated

21. IRC: 11-2000

spread shall overlap 25 mm to 50 mm on the previously aid mix beyond the vertical face
ofthe joint The thickness ofthe loose overlap material should be approximately a quaser
‘more than the final compacto thickness, The overlapped mix should be dragged back to
the hot lane so that the olle can press the small excess ino the hot ide of the jointto
‘obtain high joint density

b) By using oo move pavers in echelon, where thisis practicable and insufficient proximity
for adjacent width tobe filly compacted by continuous rolling

5.72. Inmulilayes construction the longitudinal joint in one layers
‘underneath ley by about 150 mm

oferte joint in the

573. For transveise joists method 2) above can apply Tiansverse joins in he successive and
adjoining layers should have a minima offset of 2m

58 Arrangement or Traffic

581 _shll be ensured ha tati isnoz allowed on the surface until the paved mat has cooled
below a temperature of SOC in its entire depth

6 CONTROLS
64 SurfaceFinish

G11 Thelevel of the dense grade bituminous mixes shall ot vary fom those calculated with
reference to longitudinal and cross profile of the roads as pet the Contact beyond
+6 mm provided that the negativo tolerance shall not be permed in conjunction withthe postive
tolerance forthe base course ifthe thickness of the formers theeby reduced by moe than 6 mm

612. For checking the compliance with the above requitement measurements ofthe surface
[evel shall be taken ona grid of points spaced 6 25 m along the length und O 5m tom the edges
and atthe centre ofthe pavement ‘The compliance shall be deemed to be met fr the final read
sutace only ifthe tolerance given above is sallied fr any point om the suríace

61.3 Incase where surface levels fll outside the specified tolerance, the Contsctor shall e
Tiable vo rootify these by replacing the full depth o! layer In all cases of replacement the ca
taeated shall not be les than Sm in lengt and not ess than 3 Sin width,

62 Surtuco Evemness

62.1 Thomensurementand checking of surtuco unevenness shall be done by a Im straight
‘edge in accordance with the procedures in IRC:SP:16

13

22. IRCAN-2009

622 Themaximum permissible surface unevenness in longitudinal profil shall be 6 mm for
SDBC and 5 mm for BC. The maximum permisible unevenness in transverse rofl shall be 4 mm
for both SDBC «nd BC

623 Themaximum permissible frequency of suface unevennessin 300 m length in fongtudinal
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
m tegony
inDenve Bituminous Conc = EN 2
Bituminous Concrete 3s is En

62.4 Where the surface unevenness falls outside the tolerance in ithe cese the surface is
low or high, the full dept ofthe layer shal be removed and replaced with fresh mat
compacted tothe specification

novel and replacement the area treated hall not be less than S min lengt

63 Surface Roughness

63.1 Surface roughness shall be checked in accordance with provedues in IRC:SP:16,

632 The maximum permissible valves surface roughness ensure with a bump integtato:
ace given in Table 12 Newly constructed surface are expected % give roughness value
coutesponding to Good category While the Average and Poor categories indicate level of service
andthe intervention criteria

‘Table 12 Maximum Permissible Values of Roughness (mm) for
Surface with Dense Graded Bituminous Mixes

SNo | Type or Sec Condition of Road Surface (nm 7 km)
L Good Average Poor
1 sone 2500 2500-3500 | > 3500
2 ac 2000 2000-3000 | > 3000

64 Quality Control during Construction

64.1 Tae material supplic andthe work shall conform tothe specifications pescribed in the
receding Clauses Tense the quali ofthe material a the work, conto tesis shall be conducted

23. IRC1N1-2000

duringthe execution ofthe paving projet The tests and minimum frequency for each ests indicated

in Table 13
‘Table 13 Control Tests for Dense Graded Bituminous Mixes
‘and their Minima Frequency
En Test Frequen:
T | Guay oF acer Funiber of samples per lo sad ens per TS
73 0 RC:SP. 53
FT sg pre vastos One tent per 350 m oT aggregate Tor sach

Angeles Ahasion value

source and whenever thete is change in the
quality of aggregte

3] meras ‘One test per 350 m° o aggregate foreach sonne
and whenever there is change in the quality of
aggregate

3 | Soares Godina ist for each somo and whenever here

Magsesium Sulphate txt) is change inte quality of apgregate

FT Water absorption of aprons T test for each source and whenever there 2
change in the quality of aguveyate

ST San oat Text Tor exch souree mud whenever Were Te
change in the quality of agaveeate |

7 | Piast Inder 1 test Tor each source and whenever There TS
change in ne quality of agregate

3 | Polished sone value T test for each source and whenever Were Te
change in the quality of prete

3 Percent of Farad Tr One ssi por 80 mo of agregue Whew
_piavel is use |

To | Higos ‘One set Tor individual constituent and mixed
regal fom yes fo each 400 tonnes of mix
ubjecto minimum of two teste pr day pe plan

TS al valde ayaa Fest Tor sibility, Tow value, density and

tixinchading theoretical maxima | void contents for each 400 tonnes of mix
specific guaviy of loose mix Subject to minimum of two tests per day pet
plan

ES test Tor each mix (ype wherever Tre Te

(AASHTO 128%) change in he qui on somce of coase a Fine
| sggregate

15 | Temperatur of binder m baller] ETS

agategat in dryer and mix athe
ime of laying and compaction

“Ge ao Tor eae 200 Tones oF ma aio
nim of to tests pet day pe pane

res

Rate of spread of ik material

“Aer every 8° rück ead

16

Denain of compared a

“One test per 200 mares

24. TRC:111.2009
65 Acceptance Criteria

651 Theacceptance criteria for teston density (N=3 minimum) and Massa! stability (W=2
minimum) shall bs subjected toe condition that ne can value of N samples ot less than the
specified value plus[1 65~ 165/(No of samples)» standatd deviation

652. Table 9 will vernthe peumisible variation inthe mix and temperate

16

25. IRCATI-2009

ANNEX A.
(Clause 342)

Outline of AASHTO 7283, “Resistance of Compacted Asphalt
Mixtures to Moisture-Induced Damage”

‘A. Scope and Summary of st Method

‘This method covers preparation of compacted bitumizous mixtures and the measurement ofthe
change of diametro tensile strength resulting rom the effect ol water satrston laboratory
Accelerated stipping phenomenon with freeze-thaw cycle, The result may be used to predict
Tongo stuipping suscep o bituminous mixture and evaluate quid anti tiping aditivos
that are added bitume or pulvetized mineral materials such as hydraed lime, which are added!
tothe mineral agregate

‘bach st of 6 compacted specimens is dividedimotwo equal subsets One subsetis tested cy
condition Sor indzect tensile strength The orhr subset is subjected to vacuum setisation anda
‘ceae-h ele (having in a hot water hat) before testing fu diner easlostengih Numerical
indices of retained indirect tensile strength properties ae calclated fom Ue tes det obained bs
testing the two suhses: dy and conditioned

B. Testing Equipment

1 Vacuum contains, vacuum pump, uanomeler, and tbe accessories as speciiedin ASTM
12061, “Theoretical Maximum Specific Gravity and Density of Bituminous Pavi
Mixtires”

2 Balance or scale accurate 100.1 percent ofthe test load
3 Two water baths capable of maintaining temperatures of 60°C and 25°C #0 SC
4 Freezes maintained a 18°C FC
5, 10m graduate eytinder
6

Loading jack and sing dynamometer (Marshal stability testing machine can be used) 10
provide a vetical rte of deformation of 50 mm (2 inches) pet minute and capable of
reading the maximum faire oad

7. Stet loading sips with aconcave suface having a adius oqual othe normal radins of
the test specimen. The loading strips shall 12 7 mun (0.5 incl) wide Lo spacimeas 100
ram (inches) in ameter The loading stip ox 150 mm ( inches) diameter specimens
shall be 19 0S mm (07 inch) wide The length of te loading sips shall exceed the

26. IRea11-2009,

thickness of ho specimens Steel stip are provided atthe top and bottom of specimens
uring indircttensil testing

©. ‘Test Procedure

1. Make atleast 6 compacted specimens fo each mixture, 310 be tested dry and 3 tobe
‘ested after pasta saturation and ooistute conditioning witha freeze-thaw cycle. Some
extra specimens will need to be made to establish compaction procedures in order to
‘obtain specified st void contents in the test specimens by rial and ext

2. Compact the 6 specimens with a Marshal compacto, sot the compacted specimens
have ait voids of 7.0 05 percent. This level of high ait voids can be obtained by
adjusting the number of Marshall blows applied on cach side of the specimen by trial and
ator (start at about 10 blows as a stating point) Air Void content must he calculated
‘hom he bulk specific gravity ofthe 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 de loose bituminous mixture obtained by ASTM D2041

‘Separate the 6 specimens into subses so thatthe average air voids of the two Subsets
arwapproximately equal

4 One set will be ested dry Keep itat room temperature and then placein a 25°C 2.0 $C
‘water bath os 2 hous prot Co determining thet indirect tensile strength

5 The oe: subset will be condiionedas follows:

8) Place and submerge the 3 specimens inthe vacuum container filled with water at
room tempetatare Apply a vacuum of 13-67 Pa absolute pressure (10-26 inches
Hi partial pressure) for 30 minutes Remove the vacuum and leave the specimens
submerged in water for $ to 10 minutes [Note: The water saturation procedure
noted above deviates ftom AASHTO T283, which obtains a specified degree of
saturation The above procedure keeps the time of saturation constant }

b) Wrap aplastic ilmaround each saturated specimen snd place the mapped specimen
in aplastic bag containing 10m of water and seal the plastic bag Place the plastic.
haginaficezc temperature of -IRC= VC for a minimum ol 16 hours. Remove
the spocimens from de ficezer

©) Place the spcimensin a water hath maintain a 60°C °C for 24 hours. Remove
the plastic bag and the plastic im from each specimen after placing the specimens
under water

4) Remove the specimens fom bot waterbath and place in water hath maintained at
25020. for 2 hows

27. IRCAAMI-2009
9 Remove the conditioned specimens and et for indirect tensile streng

Determine the indizect tensile stength ofthe 3 dry and 3 conditioned specimens 25°C
:205"C ae removing fiom waterbath Fürst, measure their mean thicknesses (0 Then
place the wo ste! loading strips on the bottom and top ofthe specimens across diameter
and ple in the Marshall testing machine o a compression-tsting machine Apply load
{othe specimens diametally ata vertical rate of $0 mm (2 inches) pet minute

Record the maximum compressive strength noted on the testing machine and continue,
louding und a vertical rack appear in he specimen Remove he cracked specimen
from the machine and visually estimate Ut approximate depte of moistre damage extent
of stripped or bare aggregate) onthe fuctured faces othe specimen ona sale of 0105
(being he moststipping)

CCaleulate the tensile strength of each specimenas follows in I uit:

Si=2000 Pi ned
Where,
St = tensile strength Pa
P= maximum loads,
Lo = specimen thickness, mm
d = speeimendiamster. mam

[Express the numerical index of resistance of bituminous mixture tothe detrimental eects
‘of water asthe ratio ofthe original eng thas etinod afer accelerated moisture and
{reere-thawe conditioning,

Caleulate the tensile stength ato (TSR) as follows:

‘Tensile strength rato (TSR) = S,/

werage tensile strength ofthe dry subset, kPa

etage tensile strength ofthe conditioned subst, KPa

28. TREALL-2009

ANNEX B
Clause 452)
Outline of ASTM 2041, “Theoretical Maximum Specific Gravity and
Density of Bituminous Paving Mixtures”

A. Soopeand Summary of the Test Method

Tis test mea eovers the determination of Ue theoretical maximum specii gravity and density
of uncompacted bituminous paving mixtures at 25°C. The theoretical maximum specific gravity
(Geum) is usod:(a) Lo callate at voids in compacted bituminous mixtures, (b) o calculae the
amount of bitumen absorbed hy the aggregate, and (c)to provide target value forthe compaction
of paving mistros nd field

A sample of louve paving mixture is placed in a red vacuum vessel Water at 25°Cis added to.
‘compleelysobmerge the sample A specified amount of vacuum is gradually applied to remove the
aicbubbles entapped between aphull mix particles Alte the vacuum is seleased. the volume of
the sample ofthe voidies paving mixture is obtained by either immersing the vacuum container
With he sample ina wate bath and wcighing or by filling the calibcted vacuum container level fll
‘of water and weighing in ir

B. Testing Equipment

1 Container (ihn or below)

2) Vacuum bows the a metal or plastic bow with diameter ranging rom 180
10260 mun and a bowl height fa least 160 mu The bow shall he equipped with
aff, snspent cover ited wäh rubber gasket and connection os the vacant
Tine. The hose connection shall be covered wit a small pice of fine wie mesh to
ninia loss of ny ine material rom tbe mix

5) Vacuum flask for weighing in air only ~A thick-walled votumettic glass Mask
with a capacity of approx 4000 rl fte with a 1ubber stoppe
fox the vacuum ine The hose connection shall be covered with a small piece of ine
‘vive mesh to imine los ofany ine material fromthe mis

2 Balance capable of being send tothe nearest 1 gram If weighing isto be done under
‘wale, suitable suspension aungeiment shal be provided lor weighing the simple while
uspemded fiom the centr af the balance

3 Vacuum pump, capable of eracuting from the vac container toa residual presse
of 40kPa(30mm of Ig) or les. Provide suitable nap between the pump and container
o minimize water vaponsentsing the vacuum pump

29. o

IRC:111.2009.

4 Residual pressure manomete or calibrated absolute pressure gauge with a bleed valve to
adjust the vacuum level

5 Water bith capable of maintaining a constant temperature of 25 & 1°C and suitable for
immersion of the suspended contains

Calibration of Containers

1. Bowls ~ Deteumino the mass (B) ofthe container immersed in water at 251°C. T the
‘bow! is used for weighing in air, pace the volumettc lid on the bowl while under water
Remove the water-filled how! withthe li in place and dy pros to detuning the combined
‘massof the how, id and water Repeat 3 mcs and average the 3 masses Designate the
average mass as D

2 Flasks ~ Calibrate the volume ask by accurately deiermining the mass ofthe flask
filled with waterat 25 IC, Use a glas cover plat to ensue the lack completely full,

“Test Procedure

1 Separate the particles of the loose paving mixture (while itis warm) by and so tha the
Parties ste not large than about 6 mm, Don’t feaetite the aggregate. Place the mix
‘sample directly into the tred bowl ot flask Weigh the contac withthe sample and
designate the net mass of the sample only as À [Note The ninizmum sample size shall be
15005 for mixes with uominl maximun aggregate sizes of 12 5 mim or small; and shal
1b: 2800g fr mixes with nominal maximum aggregate sizes ftom 1910 25 mm)

2. Add suificient wate at 25°C to cover the sample completely Place the coves (bowls) os
stopper flasks) an the continers

3. Place the container with the sample and water ona mechanical agitation device ur atte
manual a frequent interval (210 3 minutes). Begin removing entrapped at by gradually
applying vacuum and increasing the vacuum pressure unl the residual manometer ads
37203 kPa(27 942 5 mmo! Hy) Alte achieving his evel within 2 minutes, continue
the vacuum and agitation for 18 2 minutes Gradually release the vacıım with he bled.
vale

4 Weighing in water — Suspend the bowl (without lid) and content in water for 10: 1
minutes anden determine mass Designate the mass under water ofthe bowl and sample
ac

5 Weighinginait

8) Bowl —Submerge the boul and sample slowly inthe 25 °C waterbath, Keep it there
{or 104 minutes Immerse he lid in water and slide ¡tonto the howl without temoving

30. IRC:A11-2009

‘water from the bow so that no ars uspped inside ie bowl Remove the bowl with he
lid in place from the waterbath Dy the bowl and id with dy cloth Determine the moss
‘ofthe bow, sample, and id and designate tas E.

1) Flask File flask slowly with water ensuring not itroduce any ario the sample
Place the flask in water bath for 10 1 minutes to stabilize the temperature at 25°C
without submerging the top ofthe ask Completely ill the ask with water sing a covet
plate without entrapping ai beneath the cover plate Wipe the exterior ofthe flask and
‘cover plate Determine th mas of the las, plate and is contents completely filled wits
water Designate this mass as.

6 Cuculaons

follows

Cateuat the maximum specifi gravity of te sample oflonse paving minute:
a) Bowls Used Under Water Determination:
Ginm=A/(A{C-B))

Wer,
Gus = msimmspeicgaviy tense
À = massofthedsy sample in aie PA
B mass of bowl under water, g À
N
u A a
bos emi: ee)
Gimme ADD ae
asst id and bowl wit wat 25g
nsf, ol samp a wat a 2g
o) Fisk Determination
mel 1D
Mas,
du. = diente
a isfy samp dy
D 2 mentor pie mel vi vera 258
S 2 miennes Des

32. (The Official amendments to this document would be published by
the IRC in its periodical, “Indian Highways? which shall be
code/guidelinesmanual,

ete. from the date specified therein)