Presentation-on-Quality control of Roads 01.02.24.pptx Final.pptx

Highways

1. N.ANANDARAJ.M.E., ADE, HIGHWAYS QUALITY CONTROL SUB DIVISION, CHENNAI QUALITY CONTROL OF Flexible pavement

2. Topics

3. SPECIFICATIONS AND CODES In case of any conflict or inconsistency in the provisions of the applicable specifications/Standards/Codes of IRC, Provisions contained in MoRTH specifications shall apply

4. IRC SPECIAL PUBLICATIONS IRC SP 11-1984 IRC SP 57-2000 IRC SP 47-1998 IRC SP 112-2017 QUALITY CONTROL MANUAL

5. QUALITY D e r i v e d f r o m La t i n w o r d ‘ Q ual i t a ’ w hi c h m eans what some thing is really like. Quality costs more, but lack of quality costs even more, so cost of repairing bad quality is high. For Engineers quality refers “meeting the Specifications and Standards set out in full.”

6. QC Vs QA QC focuses on identification of Defects QA focuses on prevention of Defects Planned and systematic working with a view to eliminate non conformities

7. Quality Assurance Quality Assurance Covers Planning Management Execution of Work Selection of Materials Selection of Construction Methods Selection of Equipment and Plant Deployment of Personnel and Supervisory Staff Quality Control – Inspection &Testing Acceptance & NCR

8. QMS QAP QC Total Quality Management Quality Assurance Quality Control Quality Management System

9. Quality Control Systems in TNHD - history Prior to 2004 QC during 2005 – 2010 After 2010 Present system of Quality Control TNHD Major Projects & PPP PROJECTS Metro wing, Projects &( EPC,BOT,DBFOT,Annuity )

10. QUALITY ASSURANCE & RESEARCH (G.O.Ms. No. 323, Highways & Minor Ports (HK-3) Department, Dt. 24.12.2010) Existing system of QMS/QA in TNHD

11. Quality Assurance ( 1 st Stage) ( Field Level Officers AE/ADE/ DE ) Conducting Quality control test as per required Frequency AE-100%, ADE 20%, DE-10% Non bituminous layer quality ensured by field engineers. Testing of material and Obtaining mix design from QC Ensuring Quality of Work during Construction Next layer shall be laid after approval of QC Bituminous and Concrete Work Obtaing JMF for Bituminous work and Design Mix for Concrete Works Recording in field register Ensuring Quality of Work during Construction DE has to verify QC Register

12. Quality Assurance ( 2 nd Stage) (AE/ADE of Quality Control wing ) Non bituminous layer. Testing of material , Evaluation of mix design & Recording Ensuring Quality of Work during Construction Conducting Quality control test as per required Frequency AE-30% Bituminous and Concrete Work CMP – Quality of Mix– Full Responsibility Conducting Tests and making necessary entries in the Register Concrete Works – Surprise Check NON CONFORMATORY works should be Rectified and further work shall be taken up after conducting necessary quality control tests by ADE QC at the rectified locations Submission of monthly Reports to Director through DE QC

13. Quality Assurance ( 3 rd Stage) DE-QC & DE’s other than C&M,NH Inspection & reporting of Quality of ongoing and completed works costing more than 100 lakhs Before execution of Bituminous layers Calibration of central mixing plant Checking working Condition of paver, roller and other machineries Taking actions for the petition received regarding quality of works and Submitting report to the Director

14. Quality Assurance ( 4 th Stage) ( Director, JD, SE’s other than C&M,NH ) Inspecting Quality of ongoing and completed works costing more than 200 lakhs & reporting to DG Verifying Quality Control Reports of first 3 levels Surprise Inspection of completed works Updating and Modifying Methodologies for Future Development

15. LABORATRY SETUP

16. QUALITY CONTROL REGISTER Laboratory register Field register Laboratory register Field register Laboratory register Field register

17. Field laboratory manned by qualified Engineer assisted by Lab technicians shall be provided by the contractor MORTH Section 900 Quality Control for Road works -Highlights Contractor shall carry out QC tests on the materials and works to the stipulated frequency The contractor shall provide necessary cooperation and assistance in obtaining samples for tests and carrying out field tests including lab equipment's, transportation, consumables and personnel. Works found falling short of quality shall be rectified by the contractor at his own cost The cost of the above provisions and services shall be deemed to be incidental to work

18. FIELD LABORATORY- MORTH 120 Quality control requires testing of materials, processes and workmanship Contractor shall arrange , provide and maintain fully furnished & adequately equipped field laboratory Ownership-Contractor Maintenance-Contractor Rate – Not payable

19. RESPONSIBILITIES-QC/QA QA/ QC CONTRACTOR AUTHORITY/ ENGINEER

20. Highlights of IRC: SP 112-2017

21. QUALITY OF WORK

22. 1. Quality Assurance Plan (QAP)_ Selection of the Class of Quality Assurance (As per IRC:SP:112) Depending upon the rigors of control and cross verification, four classes of Quality Assurance (QA) are prescribed;- Q-1: Class for Rural roads Q-2: Class for MDR/ ODR/ Avearage size Projects Q-3: Class for NH, SH, Coastal Roads, Roads at high altitudes/ Roads in high rainfall areas (Annual Av above 2000mm), Large size project on MDR Q-4: Class for Expressways, Tunnel, Elevated highways

23. 2. Personnel SIZE OF PROJECT < RS. 300 CRORES

24. SIZE OF PROJECT > RS. 300 CRORES

25. 5. Quality Requirements for Factory Manufactured Materials, Products and Specialized items Individual Materials(Factory Manufactured Materials) Fly ash, Lime, Cement Steel, Strands, Bolts &Nuts Brik's, Hume Pipes, Sheathing Duct, Wedges, Bitumen, Bitumen emulsion Sign Boards &Sheets, Lane marking paints,Glass beads 26

26. ORDINARY PORTLAND CEMENT T esting requirements Requirement of IS:269 Physical Tests Consistency, Setting Time Fineness (Blaine’s air, dry seiving ) Soundness Density Compressive Strength IS:4031-Part-1 IS:4031-Part-2 IS:4031-Part-3 IS:4031-Part-4 IS:4031-Part-5 IS:4031-Part-6 IS:4031-Part-11 Chemical Tests Lime, Soluble Silica, Alumina Iron Oxide, Total Sulpher Content Tricalcium Aluminate , Magnesia Loss on Ignition, Chloride Content Insoluble Residue, Alkali IS:4032, IS:12423-1988

27. 5. Quality Requirements for Factory Manufactured Materials, Products and Specialized items Factory Manufactured Finished Items Joints and Bearings RPM, Delineators, Crash Barriers, Traffic Cones Geo Synthetics, Tiles, pre formed Joint seals 28

28. ELASTOMERIC BEARING T esting requirements Test facility at field laboratory Requirements of IRC:83 (Pt.-II) Physical Tests Identification of Polymer Polymer Content Sp. Gravity Test Ash Content Hardness Tensile Strength Elongation at Break Compression Set Aceelerated Ageing Adhesion Strength Ozone Resistance of Elastomer , Laminate ASTM:D-3677 ASTM:D-297 IS:3400(P-I, II, IV, X, XIV, XX & XXII) IS:226 IRC:83 (Part-II) No. Test on hole Bearing 1) Shear Modulus, 2) Elastic Modulus, 3) Visual test 4) Dimensional tolerance 5) Axial load on 15 Mpa Deflection under load 5 Mpa 15 Mpa (Ultimate Compressive Strength) 6) Adhesion Strength No.

29. Strip Seal Joints T esting requirements Test facility at field laboratory Requirements of MORT&H Specifications Mild Steel for Reinforcing plates, Inserts and Anchorage Cast Steel for Reinforcing Plates Elastomer Laminates IS:2062 IS:1030 IRC:83 (Pt.-II) IS:3400 (Pt.-I) IS:3400 (Pt.-II) IS:3400 (Pt.-IV) IS:3400 (Pt.-X) IS:3400 (Pt.-XIV) IS:3400 (Pt.-XX) IS:226 No.

30. SINGLE STRIP/MODULAR STRIP SEAL JOINTS Testing requirements Requirements of MORT&H Specifications Edge Beam & Central Beam/Lamella Anchorage Chloroprene Seal Hardness Tensile Strength Elongation at Fracture Tear Propagation Strength Longitudinal transverse Shock Elasticity Abrasion Residual Compression Strain Ageing in Hot air Ageing in Ozone Swelling Behaviour in Oil Cold Hardening Point DIN:17100 ASTM:A-36 ASTM:A-588 IS:2062 ASTM:D-2240 ASTM:D-412 ASTM:D-624 DIN:53504 DIN:53505 DIN:53507 DIN:53512 DIN:53516 DIN:53517, ASTM:D-395 DIN:53508, DIN:53509 DIN:53521, ASTM:D-1043

31. 5. FIELD LABORATORY

32. LABORATORY EQUIPMENTS MORTH TABLE 100-2 GENERAL (Weigh Balance, Oven, Sieves, Stop watches, Trays, etc ) SOIL AND AGGREGATES BITUMINOUS WORKS CONCRETE WORKS CONTROL OF PROFILE AND SURFACE EVENNESS (Total station, Theodolite, Precision staff, 3m straight edge, Camber Board, Tape, Rough meter)

33. FIELD LABORATORY SETUP MAIN LABORATORY EQUIPMENTS

34. CEMENT AND CEMENT CONCRETE TESTING EQUIPMENT High frequency mortar cube vibrator for cement testing Cement motor moulds (70.6 mm W x 70.6 mm L x 70.6 mm H) Vicat needle apparatus for setting time with plungers as per IS:269  Soundness testing apparatus for cement (Le Chattlier ) Weigh Balances 5 -20 kg capacity electronic type – accuracy 1 gm  500 gm capacity electronic type – accuracy 0.01 gm  Electronic 5 kg capacity accuracy 0.5 gm  50 kg capacity electronic type – accuracy 2 gm Concrete mixer power driven, 1 cft capacity

35. f ) Moulds 150 mm x 300 mm ht. cylinder with capping component along with the capping set. Cube 150 mm and 100 mm (each size) g) Apparatus for slump test h) Variable frequency and amplitude vibrating table size 1m x 1m as per the relevant British standard i) Compression and Flexural strength testing machine of 2000 KN capacity with additional dial for flexural testing j) Core cutting machine with 10cm dia. diamond cutting edge k) Lechatelier flask CEMENT AND CEMENT CONCRETE TESTING EQUIPMENT

36. FIELD LABORATORY -Layout

37. General Features of Field Laboratory 7 6 5 4 3 2 1

38. Field Laboratory Amenities Maintenance Consumables Distilled water, Filter paper, Kerosene- Soil Sodium sulphate, Magnesium sulphate-Aggregates Cement, Admixtures, Distilled water – Concrete Bitumen, Benzene, Gas cylinder, Filter paper Payment

39. 6.Calibration of Inspection, Measuring and Testing Equipment's Measuring Devices Proving Rings Extension meters Dial Gauges Temperature Gauges Load cells Accuracy of Measuring devices degrade over time. Changes in accuracy can also caused by electric/Mechanical shock or hazardous working environment Calibration Restores the accuracy of Measuring device

40. 7. Inspection and Testing

41. Inspection Proforma Formwork Inspection Checklist Reinforcement Inspection Checklist Inspection Check list before approval of Concrete Concrete Delivery and Pouring Record Post Concrete Inspection

42. Surveillance Proforma Surveillance form for Material Quality Surveillance form for Product Quality Surveillance form for Pre- Concreting Operations Cube Testing Machine Surveillance form for Workmanship of Concrete Surveillance form for Pavement layers

43. Registers and Records Particulars of work Register of Drawings Cement Register Consumption of Cement for different Items Records of Calibration Daily Progress report Inspection Notes Memos Bitumen Register Prestressing work Grouting Record Cement and Concrete Test Analysis

44. Calibration Proforma Calibration chart for batching of aggregate gage Calibration chart of batching Plant for water meter Calibration Chart of Batching Cube Testing Machine

45. Quality Control of Flexible Pavements

46. Quality Control i n Road Construction Control of Materials Inspection &Testing Procedure Frequency and Extent of Testing Acceptance Criteria Equipment Type & its Calibration Recording of Test Results Training for QC 52

47. Quality Control Test Individual Materials(Natural/Factory Manufactured Materials) Soil, Gravel, Aggregates Fly ash, Lime, Cement Steel, Strands, Bolts &Nuts Briks , Hume Pipes, Sheathing Duct, Wedges, Bitumen, Bitumen emulsion Sign Boards &Sheets, Lane marking paints,Glass beads Factory Manufactured Finished Items Joints and Bearings RPM, Delineators, Crash Barriers, Traffic Cones Geo Synthetics, Tiles, pre formed Joint seals 53

48. Quality Control Test Mixes Gradation of Aggregates, Mix Proportion, Mixed Design Properties During Construction Process Transportation, Laying Compaction Segregation Temperature – (Mixing, Laying, Rolling) 54

49. Quality Control Test Test on Compacted Layer Mixed Proportion (Unbound Layers) Density Mix proportion and Gradation (bound layers after extraction) Finished Surface Longitudinal Profile Transverse Profile Cross Slope Texture 55

50. Typical flow chart for quality control in road works

51. Typical flow chart for quality control in road works- Contd … Undertake Mixing/Batching Carry out test on quality of mix GSB /WMM DBM/BC CONCRETE Improve Quality of Mix Not acceptable yes Acceptable

52. FAILURES ASSOCIATED WITH PAVEMENT DESIGN QUALITY CONTROL AND PAVEMENT FAILURES FAILURES ASSOCIATED WITH MIX DESIGN FAILURES ASSOCIATED WITH QUALITY CONTROL

53. FAILURES ASSOCIATED WITH PAVEMENT DESIGN QUALITY CONTROL AND PAVEMENT FAILURES Fatigue Cracking Rutting Fatigue Cracking

54. FAILURES ASSOCIATED WITH MIX DESIGN Bleeding

55. What are all the failures associated with the lack of Quality Control? Longitudinal Cracking Ruts Pot Holes Frost Heaving Slippage Rutting shoving Cracking Map Cracking Bleeding Ravelling

56. Quality control in Road Construction

57. Horizontal Alignment Permitted tolerances for the edges of the carriageway and for the edges of the roadway The edges of the carriageway shall be correct within a tolerance of ±10 mm. The tolerance for the edges of the roadway and lower layers shall be ± 25 mm

58. Tolerance in Surface Levels Subgrade ± 20 mm Subbase – Flexible Pavement concrete pavement ± 10 mm ± 6 mm Base course for flexible pavement – bituminous base/binder course Granular base Machine Laid Manually Laid ± 6 mm ± 10 mm ± 15 mm Wearing course for flexible Pavements Machine Laid Manually Laid ± 6 mm ± 10 mm - Cement concrete Pavements ± 5 mm

59. Important Point (rider) The negative tolerance for wearing course shall not be permitted in conjunction with the positive tolerance for base course, if thickness of the wearing course is thereby reduced by more than 4 mm for bituminous course of thickness 40 mm or more 3 mm for bituminous course of thickness less than 40 mm 5 mm for concrete pavement slab These limits are 6 mm for flexible pavements and 5 mm for concrete pavements, in case of low volume roads .

60. DBM Level BC Level WMM Level DBM – (-5mm) BC – (- 5mm) DBM – (+5mm) BC – (-5mm) DBM BC In a Flexible Pavement – difference in DBM layer is (-5 mm) and that in BC layer is +5 mm---- ok, permitted If the difference in DBM layer is (+5mm) and that in BC 50 mm layer is -5 mm not permitted

61. How to check compliance For subgrade, subbase and base Take measurements of the surface levels on a grid of points placed at 6.25m longitudinally and 3.5 m transversely. Not more than 1 out of10 measurements taken longitudinally or transversely should exceed the tolerance limit value by 5mm

62. How to check compliance For Bituminous wearing course and CC pavements – take measurements of the surface levels in a grid of points placed at 6.25 m along the length and 0.5 m from the edge and at center of the pavement Tolerance limit value must be satisfied at all points

63. The longitudinal profile to be checked with 3 m straight edge or moving straight edge, at the middle of each traffic lane along centre line of the road. Surfaces of carriageway and paved shoulders Surfaces of laybys, service areas and all bituminous base courses Irregularity 4 mm 7 mm 4 mm 7 mm Length,m 300 75 300 75 300 75 300 75 Number of surface irregularity on NH and Expressways 15 9 2 1 40 18 4 2 Number of surface irregularity on reads of lower category 40 18 4 2 60 27 6 3 Maximum permitted number of surface irregularities Surface regularity of pavement courses

64. Surface Irregularities ( Maximum allowable difference) Sl.No Type of Pavement Layers Tolerances in mm 1 Sub Grade 15 mm 2 Sub Bases and Concrete Pavements 10 mm 3 Granular Sub Base and Base Courses 8 mm 4 Bituminous Base Courses 6 mm 5 Wearing Surface / Cement Concrete 3 mm

65. Rectification For subgrade and Granular Subbase Where the surface is high, trim it and compact suitably When surface is low – scarify the lower layer and add fresh material and recompact to the required density. For WMM base or subbase Where the surface is high or low – top 75 mm will be scarified, reshaped with added material as necessary and recompact as per specification

66. Rectification For Bituminous Construction other than wearing course Where the surface is low - correct it by adding fresh material over a suitable tack coat (if needed) and recompact it. When the surface is high – remove full depth of the layer and replace with fresh material as per specification

67. Rectification For Bituminous Wearing Course Where the surface is high or low – remove dull depth of the layer and replace with fresh material as per specification Area treated should not be less than 5 m in length and 3.5 m in width.

68. FREQUENCY AND TYPE OF TESTS DURING CONSTRUCTION

69. Frequency Testing frequencies set forth in the MoRTH Tables are desirable minimum Engineer shall have the full authority to carryout additional tests as frequently as he may deem necessary, to satisfy himself Number of tests recommended in MoRTH tables may be reduced at the discretion of the Engineer

70. Tests On Borrow Materials Of embankment/ subgrade Test Min. Desirable Frequency Gradation/ Sand Content 2 Tests per 3 000 m 3 of Soil Plasticity Index 2 Tests per 3 000 m 3 of Soil Each type Standard Proctor Test 2 Tests per 3000 m 3 of Soil CBR on a set of 3 Specimens One Set of Test per 3000 m 3 Deleterious Constituents As Required Natural Moisture Content Two Test per 3000m 3 of Soil

71. Frequency of Compaction Tests Particulars Frequency (min) Moisture Content prior to compaction One test for every 250 m 3 of soil subject to min. of 4 tests/day Thickness of layer Regularly Degree of compaction (a) E mbankment At least one set of 10 measurements per 3,000 m 2 for each layer (b) Subgrade and shoulders At least one set of 10 measurements per 2,000 m 2 for each layer

72. Density Requirements Of Embankments And Subgrade Test Min. Desirable Frequency Embankments upto 3 metres height, not subjected to extensive flooding Not less than 15.2 kN / cu.m Embankments exceeding 3 metres height or embankments of any height subject to long periods of inundation Not less than 16.0 kN / cu.m Subgrade and earthern shoulders/ verges/backfill Not less than 17.5 kN / cu.m

73. Compaction Requirements For Embankment And Subgrade Type of Work/ Material Relative Compaction as % of MDD Subgrade and Earthen Shoulders Not less than 97 Embankments Not less than 95 Expansive Clays: Subgrade and 500 mm portion just below the subgrade Not Allowed Remaining Portion of Embankment Not Less than 90

74. ACCEPTANCE CRITERIA Control should be based on the mean value of a set of 10 density measurement for each 3000 sqm of compacted area. The criteria for acceptance shall be subject to the condition that the MEAN DENSITY is not less than the specified density

75. LOCATION OF DENSITY TEST POINTS FOR EARTH WORK

76. Granular Base or subbase Layers Test Frequency as per MoRTH 2013 Gradation One test per 400 m 3 Atterberg Limits One test per 400 m 3 Moisture content prior to compaction One test per 400m 3 Density of compacted layer One test per 1000m 3 Deleterious constituents As required CBR As required

77. Requirement for material for GSB Layer Aggregate Impact Value 40%(maximum) Liquid Limit 25% (maximum) Plasticity Index 6 (Maximum) CBR at 98% dry density 30% (minimum)

78. GSB 1-2 percent below the OMC at the time of compaction -Adjust suitably for loss due to evaporation Rolling should be continued till the density achieved is at least 98 percent of Proctor’s density(IS 2720,Part8)

79. Wet Mix Macadam Test Frequency in MoRTH Aggregate Impact Value One Test per 1000 m 3 of Aggregate Grading One Test per 200 m 3 of Aggregate Flakiness and Elongation Index One Test per 500 m 3 of Aggregate Attenberg Limits of Portion of Aggregate passing 425 micron sieve One Test per 200 m 3 of Aggregate Density of Compacted Layer One set of three Test per 10 00 m 2

80. Requirements For density of Compacted layer 100 percent of Proctor’s density (Part 7) Moisture Content Not less than OMC Not more than 2 percent above OMC

81. Loose Thickness Calculation., Loose thickness required = Compacted thickness x Compaction factor Compaction factor = Maximum Dry Density Blended density of WMM mix Example : Maximum Dry Density = 2.30 g. Blended density of WMM mix - 1.6 g to 2.0 g/ cc Compaction factor = 2.3/ 1.60 = 1.43 For 150 mm. compacted thickness Loose thickness required = 150 X 1.43 = 215 mm.

82. Quality Control of Bituminous Works

83. For Bituminous works Quality of binder Quality of aggregates Requirement of gradation Binder content Temperature of binder and aggregates – mixing Quality of the mix-Stability, density, flow, etc. Finished layer- density and thickness

84. 1. Prime coat, Tack coat & fog spray Test Frequency as per MoRTH 2013 Quality of binder (IS:73,IS217 or IS 8887) As suggested in the IS code Binder temperature for application Regularly Rate of spread of binder 3 tests per day

85. Test for Measurement of spread Take three Aluminum or other light metal plate of 200mm by 200mm of 20mm depth Weight them accurately up to first place of decimal Place them along road in wheel path at an interval of 10m Allow the distributor to move for 50m covering all the three plates Wrap the plates in weighed polythene bags for weighing Similarly transverse distribution is noted by placing three plates at an interval of 50cm in the path of binder spraying equipment

86. Test for Measurement of Spread Calculations to be done Area of Plate=0.20*0.20=0.04m 2 Initial Weight of Tray = A Kg Final Weight of Tray= B Kg Increase in Weight of the Plate = (B-A) Kg Rate of Spray = (Increase in Weight)/(Area of plate) B-A OR 25X(B-A) 0.04

87. Bituminous Macadam Test Frequency as per MoRTH 2013 (section 900) Quality of Binder No of samples as per lot and tests as per IS code Aggregate Impact Value One test per 200m 3 for each source Flakiness Index or Flakiness Elongation Index combined One test per 350m 3 for each source Grading of Aggregates 2 tests per day Binder content 2 tests per day Thickness Regularly Density of compacted layer One per 700m 2 area

88. Physical properties of aggregates for BM (section 500) Property Test Requirement cleanliness Grain size analysis Max.5% passing 0.075micron Particle shape Combined Flakiness and Elongation Indices Max.35% Strength Los Angeles Abrasion value or Aggregate Impact value Max.40% Max.30% Durability Soundness(sodium or Magnesium) Sodium sulphate Magnesium sulphate 5 cycles Max. 12% Max.18% Water absorption Water absorption Max.2% Stripping Coating and stripping of Bitumen Aggregate Min. Retained Coating 95% Water sensitivity Retained Tensile strength Min.80%

89. DBM and BC Test Frequency as per MoRTH 2013 (section 900) Quality of binder (IS:73, IRC SP 53, IS 15462) As suggested in the IS code Tests on aggregates Impact value or LA abrasion& CFI One per 350 m 3 and with change of source Soundness, Sand Equivalent, PI, water absorption, Polished Stone Value One test per source Stability and voids Analysis of mix Three tests for each 400 t of the mix Moisture susceptibility of Mix One for each mix type Binder temperature for application Regularly Binder content One for each 400 t of mix Density of the compacted layer One per 700m 2 area

90. Physical Properties of aggregates for DBM (section 500) Property Test Specification Cleanliness (dust) Grain size analysis Max 5% passing 0.075 mm sieve Particle shape Combined Flakiness and Elongation Indices Max 35% Strength Los Angeles Abrasion value or aggregate Impact value Max 35% Max 27% Durability Soundness either: Sodium sulphate or Magnesium sulphate Max 12% Max18% Water absorption Water Absorption Max 2% Stripping Coating and stripping of Bitumen Aggregate Mix Minimum retained coating 95% Water sensitivity Retained Tensile Strength Min 80%

91. Binder content and density –DBM & BC Binder content within a tolerance of ±0.3 by weight of total mix from JMF, when individual samples are taken Density of the layer as per JMF Acceptance criteria for tests on density Mean value is not less than

92. Density as per JMF =2.270 gm/cm3 Test Number Field density 1 2.268 2 2.277 3 2.292 4 2.290 5 2.268 6 2.301 7 2.289 8 2.278 9 2.292 10 2.288 Mean 2.284 SD 0.011 =2.282 gm/cm 3

93. Permissible variation from JMF Description Base/ Binder course Surface course Aggregate passing 19mm sieve or larger ±8% ±7% Aggregate passing13.2mm,9.5mm ±7% ±6% Aggregate passing4.75mm ±6% ±5% Aggregate passing2.36nmm,1.18mm,0.6mm ±5% ±4% Aggregate passing 0.3mm,0.15mm ±4% ±3% Aggregate passing0.075mm ±2% ±1.5% Binder content ±0.3% ±0.3% Mixing Temperature ±10°C ±10°C

94. DESIGN MIX & COMPACTION Section 500 The compacted Layers of Dense Bituminous Macadam / Bituminous Concrete shall have a minimum filed density equal to or more than 92 % of the average theoriticl maximum specific gravity( G mm ) obtained on the day of Compation What is the value of PQI Reading while checking at site after compaction? 99.9% (or) 100% (or) 105%

95. WHAT IS MIX DESIGN? The mix design is determination of the proportion of bitumen, filler, fine aggregates, and coarse aggregates to produce a mix which is workable, strong, durable and economical. Compaction parameters are determined from Mix Design so as to achieve desired Density during Construction

96. PROCEDURE – BASIC SEVEN STEPS Step -1 – Aggregate evaluation Step -2 – Evaluation of bitumen Step -3 – Marshall sample preparation Step -4 – Density and voids calculations Step -5 – Marshall stability and flow test Step -6 – Analysis of test results Step -7 – Determination of optimum binder content ASTM, AASHTO , IS Asphalt Institute Manual MS2 (Marshal Method for determining Optimum Binder Content) Binder Content Shall be selected to obtain 4% air voids in the Mix design

97. REQUIREMENTS OF BITUMINOUS CONCRETE MIX Test Requirement Test Method Marshall Stability 9 KN at 600 C . AASTHO Marshall Flow 2 – 4 mm AASTHO P er c ent A i r v o i ds i n Mi x 3 – 5 % Min. VMA Percent related to De s i gn A i r V o i d s , % 3.0 - 10-14 % 4.0 - 11-15% 5.0 - 12-16 % P er c ent A i r v o i ds i n Mi neral Aggregates filled by Bitumen (VFB) 65 - 75 Binder content percent by weight of total mix 5- 6 (50-65 mm thick) 5 - 7 (30-45 mm thick) MS-2, ASTM Water Sensitivity Min. 75 % Retained Strength Swell Test 1.5 % Max. LAV

98. S.No. IS Sieve Cumulative % by weight of total aggregate passing Combined Grading Job Grading Job Grading Specification Permissible Variation as per MORTH Final Gradation 1 19.0 mm 100.00 100 100 + 7% 107 - 93 100 100 2 13.2 mm 94.84 95 95 + 6 % 89 - 101 90 - 100 90 – 100 3 9.5 mm 78.93 79 79 + 6 % 73 - 85 70 - 88 73 – 85 4 4.75 mm 58.00 58 58 + 5 % 53 – 63 53 - 71 53 – 63 5 2.36 mm 43.43 43 43 + 4 % 39 – 47 42 - 58 42 – 47 6 1.18 mm 35.26 35 35 + 4 % 31 – 39 34 - 48 34 – 39 7 0.6 mm 27.72 28 28 + 4 % 24 – 32 26 - 38 26 – 32 8 0.3 mm 19.97 20 20 + 3 % 17 – 23 18 - 28 18 – 23 9 0.15 mm 12.79 13 13 + 3 % 10 – 16 12 - 20 12 – 16 10 0.075 mm 5.46 5 5 + 1.5 % 3.5 – 6.5 4 - 10 4 – 6.5

99. IMPORTANCE OF COMPACTION IN QUALITY

100. COMPACTION Soil or Aggregates or Mix is densified through compaction. Loose material + water + Compaction

101. COMPACTION Purpose of Compaction: To improve its Engineering properties by way if increasing its density Properties: Structural strength Load bearing capacity Stability of fills Impermeability Shear resistance

102. COMPACTION OF BITUMINOUS MIXES L ack of adequate compaction in field leads to reduced pavement life Inadequate compaction of hot mix leads to early oxidation, ravelling, cracking and disintegration before its life expectancy is achieved 1% excess voids results in approximately about 10% reduction in life

103. Compaction Sequence SCREED The screed is the first device used to compact the mat and may be operated in the vibratory mode. Approximately 75 to 85 percent of Theoretical Maximum Density (TMD) will be obtained when the mix passes out from under the screed.

104. Compaction Sequence-Contd.. Initial Breakdown Rolling 8 To 10 T Smooth Wheel Roller Intermediate Rolling 8-10 T Dead Wt. Or Vibratory Roller. Pneumatic Tyred Roller –12-15 T Wt. 5.6 Kg/Sq.Cm Pr. Fin al Rolling 6-8 T Smooth Wheel Tandem Roller 113 Commence From Edges And Progress Towards Centre Roller Speed Not More Than 5 Kmph Do Not Permit Rollers To Stand On Pavement Prevent Oil Drop Keep Wheels Just Moist Enough

105. MECHANISM OF COMPACTION Pressure Impact Vibration Kneading/ Manipulation / Rearrangement

106. Rollers SINGLE DRUM DOUBLE DRUM Walk Behind Roller Pneumatic Tyre Roller

107. ROLLER CAPACITY Depends on length of pavement that can be compacted in time influenced by Roller speed No. of passes No. of lapse Overlaps Extension over edge Extra passes for joints

108. EFFECT OF CHARACTERISTICS OF VIBRATORY ROLLER Operating Frequency : Number of impacts per metre between the drum and mat. b). Amplitude of vibration : It is the vertical displacement of the roller drum. Amplitude of vibration is directly linked to the impact force . Higher amplitude Higher thickness &minimum number of passes c). Speed of Travel : Slow speed results in closeness of impacts

109. Conclusion The quality of project is always agreed upon between the contractor and the employer The quality objective is to achieve zero defects with best quality of the project works. Possible only by ensuring quality control at every stages during progress of construction. Quality control system is like human health, If one of its part is weak, the whole system will suffer.

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