CONTENTS

S. No. Title Page No.

I. Introduction 01
II. Classification of Roads 02
III. Different Road Materials Used 06
IV. Execution of Site work 16
a. Site Investigation 16
b. Site Clearance 20
V. Excavation for Cutting 26
VI. Filling for Embankment 29
VII. Sub Soil Drain 31
VIII. Typical Construction of Cross Section
In Highway 42
IX. Laboratory Tests on Field 56
X. Drawings
XI. References 72
Classification of roads as per IRC (Nagpur Plan)

National Highways: These are main highways running through the length and breadth of the
country connecting major ports, foreign highways, state capitals, large industrial and tourist
centers etc.

State Highways: These are arterial routes of states linking direct headquarters and important
cities within the state and connecting them with National Highways or Highways of the
neighboring states.

Major District Roads: These are important roads within a district serving areas of production
and markets, and connecting these with each other or with the main highways.

Other District Roads: These are roads serving rural areas of production and providing them
with outlet to market centers, taluka/tehsil headquarters, block development headquarters, or
other main roads.

Village Roads: These are roads connecting villages or groups of villages with each other and to
the nearest road of higher category.

Geometric Design Standards

The layout and other geometric features of a road have direct influence on the initial cost of its
construction and the efficiency and economy of its use by traffic. The safety of operation is also
significantly affected by geometric design. The geometric design of a highway is influenced
significantly by terrain conditions.
Terrain Classification - The terrain is classified by the general slope of the country across the
highway alignment, for which the criterion given in table followed.

Sl. No. Terrain classification cross Percent

slope of the country
1. Plain 0-10
2. Rolling 10-25
3. Mountains 25-60
4. Steep Greater than 60

Road lane width:

It is also termed the right-of-way is the land acquired for road purposes. Desirable width for
National and state Highways is 45mts in open areas in case of plain and rolling terrain, and
24mts in case of mountainous and steep terrains.

i. Roadway width: the width of the roadway for single and two lane roads in plain and
rolling terrain is 12mts for National and State highways.
ii. Carriageway width: The total width of the carriageway shall be determined in relation
to the design traffic and capacity of the roadway. The standard width shall be as indicated
below.
Single lane 3.75mts

Two lane without raised kerbs 7.0 mts

Two lanes with raised kerbs 7.5mts

Multi lane pavements width per lane 3.5mts

iii. Pavement camber or cross fall: the camber or cross fall on straight sections of roads
should be as recommended in table given below for various types of surfaces. For a given
surface type, the steeper values may be adopted in areas having high intensity of rainfall.

High-type bit surfacing or cement concrete 1.7-2.0 %

(1 in 60 to 1 in 50)

Thin bit surfacing 2.0-2.5 %

(1 in 50 to 1 in 40)

Water bound macadam, gravel 2.5-3.0 %

(1 in 40 to 1 in 33)

Earthen 3.0-4.0 %
(1 in 33 to 1 in 25)
iv. Horizontal alignment: the horizontal alignment should be fluent and blend well with the
surrounding topography. The curves should be sufficiently long and have suitable
transitions to provide pleasing appearance. Curve length should be at least 150mts or a
deflection angle of 5 degrees, and this should be increased by 30 meters for each one
degree decreases in the deflection angle. For deflection angles less than one degree, no
curve is required to be designed.
v. Horizontal curves and super elevation: horizontal curve is a curve with end transitions
to provide change in direction to the centerline of a road. When a vehicle traverses a
horizontal curve, the centrifugal force acts horizontally outwards through the center of
gravity of the vehicle. The centrifugal force acting on a vehicle negotiating a horizontal
curve have a tendency to overturn the vehicle outwards about the outer wheels and
tendency to skid the vehicle laterally, outwards. In order to counteract the effect of
centrifugal force, the outer edge of the pavement is raised with respect to the inner edge
thus providing a transverse slope throughout the length of the horizontal curve. This
transverse inclination to the pavement surface is called “super elevation or cant or
banking”
Super elevation required on horizontal curves should be calculated from the following formula

2
e=V /225R

Where,

e= super elevation in meter per meter

V= speed in km/h
R= Radius in meters
vi. Vertical alignment: Vertical Alignment should provide for a smooth longitudinal profile
consistent with category of the road and lay of the terrain. Grade changes should not be
frequent as to cause kinks sand visual discontinuities in the profile. Desirably there
should be no change in grade with in a distance of 150mts.
a) For plain and rolling terrain 1 in 30 is the ruling gradient and 1 in 15 is
Exceptional gradient.

Vertical curves
Definitions:

i. Vertical Curve: Vertical curves have the shape of a parabola and are used to produce a
gradual change between tangent grades.
ii. Point of Vertical Intersection (PVI): The PVI is the point where the extension of two
tangent grades intersect
iii. Point of Vertical Curvature (PVC). The PVC is the point at which the tangent grade ends
and the vertical curve begins.
iv. Point of Vertical Tangency (PVT). The PVT is the point at which the vertical curve ends
and the tangent grade begins.
v. Grade Slopes (G1 or G2). The grade slope is the rate of slope between two adjacent PVI's
expressed as a percent. The numerical value for percent is the vertical rise or fall in
 feet for each 100 feet of horizontal distance. Upgrades in the direction of stationing are
identified as plus (+). Downgrades are identified as minus (-).

Different road materials used:

The most important pavement materials are soils, mineral aggregates, bituminous binders, and
stabilizers like lime, cement, etc. Mineral aggregates constitute about 90 percent of total volume
of road construction materials used. All roads have to be founded on soil and are required to
make optimum use of the locally available materials, if it is to be constructed economically.
Materials used in the structural layers of the pavement should be selected based on availability,
economy and previous experience.
Soil as road construction material:

Sub grade soil is an integral part of the road pavement structure as it provides support to the
pavement as its foundation. The main function of the sub grade is to give adequate support to the
pavement and for this the sub grade should possess sufficient stability under adverse climatic and
loading conditions. The formation of wave, corrugations, rutting and shoving in black top
pavements are generally attributed to poor sub grade conditions. When soil is used in
embankment construction, in addition to stability, incompressibility is also important as
differential settlement may cause failure. Soil is used in its natural form (gravel and sand) or in a
processed form (stabilized layer) for pavement construction. Soil is also used as a binder in
water-bound macadam layers. Soil is therefore, considered as one of the principal highway
materials. The foundation of other cross-drainage structures (culverts, bridges and retaining
walls) rests on soils and their stability depends on the soil strength, knowledge of soil properties
is necessary to select the embankment material, pavement structure, drainage system and
foundation of structures. When a high embankment rests on soft ground, its stability can be
predicted by studying the properties of soil. Frost action, common in high altitudes, can be taken
care of if the soil properties are well known. Soil consists mainly of minerals matter formed by
the disintegration of rocks, by the action of water, frost, temperature, and pressure or by plant or
animal life. Based on the individual grain size of the soil particles, soil have been classified as
gravel, sand, silt, and clay.

The BIS gives the following limits of particle size.

Gravel 80-4.75 mm
Sand coarse 4.75- 2.00 mm
Medium 2.00-0.475 mm
Fine 0.475-0.075 mm
Silt 0.075- 0.002 mm
Clay <0.002mm
Types of soil: Soils occur in a fairly wide variety in our country. Some of the major soil types
found in the country are:

i. Alluvial soils: These are mostly found in the indo-gangatic plane. Generally, these are
composed of broadly matching fractions of sand, silt, and clay, and make fair to good sub
grade material.
ii. Fine sand: It is confined mostly to desert areas in the north western part of the country.
This soil lacks binder fraction and is not well graded.
iii. Coastal soils: The sands/sandy soils forming the coastal alluvium usually make a good
sub-grade.
iv. B.C soils: Black cotton soils occur in parts of Madhya Pradesh, Maharashtra, Andhra
Pradesh and Karnataka. This soil is characterized by pronounced volume changes
(swelling upon wetting and shrinkage after drying) and low strengths at high moisture
content.
v. Red gravelly soils: The moorums and red gravelly soils are found in various pockets and
are less problematic.
The wide range of soil types as highway construction materials have made it obligatory on the
part of the highway engineer to indentify and classify the different soils. The classification of soil
as per IS nomenclature, the general range of the maximum dry densities of these materials and
their approximate CBR values are given below.
Well graded gravels and gravel sand mixture GW 2.00 – 2.24 60 – 90

(fines<5%)

Poorly graded gravel and gravel sand mixture (fine GP 1.76 – 2.24 25 – 60

< 5%)

Silty gravel and gravel sand mixture (fines>12%) GM 2.08 – 2.22 20 – 80

Clayey gravels and gravel sand silt mixtures GC 1.92 – 2.24 20 – 80

(fines>12%)

Well graded sand and gravelly sand (fines< 5%) SW 1.76 - 2.08 20 – 60

Poorly graded sand and gravelly sand (fines<5%) SP 1.59 - 1.92 10 – 30

Silty sand and sand silt mixtures (fines>12%) SM 1.92 – 2.16 10 – 40

Clayey sands and sand clay mixtures SC 1.68 – 2.08 15 – 50

(Fines >12%)

Inorganic silt, very fine rock floor ML 1.60- 2.00 5 – 20

Clayey silt or fine sand, inorganic clay, gravelly, CL 1.60 – 2.00 5 – 15

sandy or silty.

Organic silt and silty clays OL 1.44 – 1.60 3–8

Inorganic silt elastic and micaceous silts MH 1.28 – 1.60 3–8

Inorganic Fat clays CH 1.44 – 1.76 3–5

Organic silt and clays CH 1.28 – 1.68 2–4

Classification of soils as per IS system

Road aggregates:
These have to bear the stresses due to the wheel loads and hence they should possess sufficient
strength to resist crushing. They should be hard enough to resist wear due to abrasive action of
traffic. The aggregates in the pavement are also subjected to impact hence toughness is another
desirable property of aggregates. The stones used should be durable and resist disintegration due
to action of weather, this property is called soundness.

The following are the most commonly available rocks in India from which road aggregates can
be obtained.
 Type of Rock Properties Suitability
Basalt Hard and durable, resistant to Good for base courses
abrasion, fine grained.
Granite Hard and durable resistant to Very good for bituminous
abrasion, Coarse grained. Courses and WBM
Limestone Reasonably hard, liable to Good for base course
polish to a Smooth surface
under traffic, fine grained and
high water absorption.
Quartzite Hard, durable but is liable to Good for base course
be brittle and adhesion to
bitumen is rather poor.
Sand Stone Moderately hard and durable, Good for road bases
fine to medium grained.

Aggregates may have rounded cubical angular flaky or elongated shape of particles. The flaky or
elongated particles will have less strength and durability hence too flaky and elongated particles
should be avoided. The following are the physical requirements of coarse aggregates used for
WBM as per IS 2386.

Los Angles abrasion value 40 percent (Maximum)

Or
Aggregate impact value 30 percent (Maximum)

Combined flakiness and elongation indices 30 percent (Maximum)

Grading requirements: The WBM is carried out in layers. The coarse aggregates for each layer
should confirm to any of (3) grading below. The use of grading no 1 shall be restricted to sub
base courses only.
 Size and grading requirements of coarse aggregates for water bound macadam.

Grading No. Thickness and Size range IS sieve Percent by

aggregate per designation weight passing
10 sqm. the sieve
1 10 mm 90 mm to 45 mm 125 mm 100
1.21 to 1.13 90 mm 90-100
cums. 63 mm 25-60
45 mm 0-15
22.4 mm 0-5

2 75 mm 63 mm to 45 mm 90 mm 100
0.91 to 1.01 63 mm 90-100
cums. 53 mm 25-70
45 mm 0-15
22.4 mm 0-5
3 75 mm 53 mm to 22.4 63 mm 100
0.91 to 1.07 mm 53 mm 95-100
cums. 45 mm 65-90
22.4 mm 0-10
11.2 mm 0-5

The compacted thickness for a layer with grading no 1 shall be 100 mm while for layer with
other grading i.e. 2&3 shall be 75 mm.
Application of screenings:
To fill voids in the coarse aggregates, screenings are generally necessary and shall consist if the
same material as the coarse aggregate. As far as possible, the screening material should conform
to grading given in the table.

Grading Size of screening IS sieve designation Percent by weight

classification passing the sieve
A 13.2 mm 13.2 mm 100
11.2 mm 95-100
5.6 mm 15-35
180 microns 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180 microns 15-35

Gravel: Non-Plastic material such as moorum or gravel may also be used for filling the voids in
the coarse aggregates provided liquid limit and plasticity index of such material are below 20 and
6 respectively and fraction passing 75 microns sieve doesn’t exceed 10%.

Bituminous material:

Bitumen is a viscous liquid, semisolid or solid material, colour varying from black to dark brown
having adhesive properties consisting essentially hydrocarbons is derived from distillation of
petroleum crude or natural asphalt and soluble in carbon disulphide. Bituminous materials used
for paving purposes are penetration grade bitumen and liquid bitumen (cutbacks & emulsion).

The bituminous binder should possess the following qualities.

¾ Adequate viscosity at the time of mixing and compaction.

¾ Not highly temperature susceptible.
¾ Should not strip from aggregate in presence of water.
Following suitability tests are followed:
1. Consistency Test
• Penetration test
• Viscosity test
• Softening point test
• Ductility test

• Loss on heat test

• Solubility test
• Water content test
• Distillation test
• Spot test

• Varies from 1.00 to 1.28

4. Flash & Fire Point Test
• Safety test to indicate the max temperature to which the bituminous material can be
safely heated.
¾ Measurement of penetration a 100 gm standard steel needle into a bitumen binder kept
into a bitumen binder kept at 25 degrees within 5 sec is known as penetration value.
¾ Viscosity is its important physical property low viscous binder may flow off the
aggregate during transit from mixing plant to site and a high viscous material may
provide an unworkable mix. Viscometer is used to measure the viscosity of the bitumen.
¾ The ductility of a bituminous material is measured by the distance in centimeters to
which it will elongate before breaking when a briquette specimen of the material of the
form is pulled apart at a specified speed (50 mm/min) and specified temperature of 27
degrees- bituminous briquette is subjected to rupture in the testing machine.
Softening point: The temperature at which the bitumen attains the particular degree of softening
under specified condition of test- measured with ring and ball apparatus.
Flash point: It is the lowest temperature at which the vapour of bitumen momentarily takes fire
in the form of a flash under specified condition of test- pensky-martens tester is the apparatus
used to test flash point.
Fire point: It is the lowest temperature at which the material gets ignited and burns under
specified condition of test- measured with pensky-martens tester.
Properties of paving bitumen:

Specific gravity at 27 degrees 1.12-1.28

Water content percent by weight, max 0.50
Flash point in degree centigrade 175
Softening point in degree centigrade 45-60
Penetration at 25 degrees 80-100
Ductility at 24 degrees 75
Loss on heating percent by weight 1

The aggregates used in bituminous works shall satisfy the following physical requirements:

Property Test Specification

Cleanliness (Dust) Grain size analysis Max 5% passing 0.075 mm
sieve
Particle shape Flakiness and elongation Max 30%
index
Strength Los Angeles Abrasion Value Max 35%
Aggregate impact value Max 27%
Durability Soundness
Sodium sulphate Max 12%
Magnesium sulphate Max 18%
Water absorption Water absorption Max 2%
Stripping Coarse and stripping of Min retained coating 95%
Bituminous courses:

Bituminous courses of different specifications are laid on WBM/WMM base or existing BT

surface. A PRIME COAT over macadam base at the rate of 6 to 9 kgs/10 sqms and TACK COAT
of 2 to 3 kgs/sqms over existing BT surface shall precede the bituminous courses. The
specification for different classes of BT work varies with respect to size of aggregates and
quantity of bitumen used. The voids in bituminous surface will be sealed by application of seal
coat.

Requirements before laying bituminous courses:

i. Surface should be clean and dry.

ii. There should be no presence of organic or inorganic substances.
iii. The level of DBM layer should be checked before laying bituminous course and if any
error is found, it should be corrected.
iv. Aggregates used should also be clean and dry.
v. Loose soil if present should be scratched out.
The following table shows the bituminous generally used:

Sl.no Item of Grade Thickness Nominal Bitumen Ref to

work of layer in aggregate content % MOST
mm size by weight specification
1 Premix 20 mm 12 mm 2.8 511
carpet
2 Bituminous Grade 1 80-100 40 mm 3.1 to 3.4 504
macadam
Grade 2 50-75 19mm 3.3 to 3.5 504
3 Dense Grade 1 80-100 40mm 4.0 507
bituminous
macadam Grade 2 50-75 25mm 4.5 507
 4 Semi dense Grade 1 35-40 13 mm 4.5 508
bituminous
concrete Grade 2 25-30 10mm 5.0 508

Apart from conformity with grading and quality requirements individual ingredients the
mix shall meet the requirements of Marshall test.

Minimum stability(kg at 60 degree centigrade) 820 kgs

Flow (mm) 2-4
Compaction level (no of blows) 75 blows on each of two faces of the specimen
Percent air voids 3-5
Percent voids in mineral aggregate (VMA) 8-22

Bituminous
Execution of site work:

Site investigation:

A site investigation report is the basis for all the subsequent decisions regarding cleanup of a
contaminated site. This report describes the findings of the desk study and the field work and
discuss their implications with respect to the proposed development of the site. An assessment is
made in terms of likelihood of the presence of contamination that may affect the feasibility of the
site for the intended use.

The sequence of a site investigation is as follows:

• Desk Study
• Site Reconnaissance
• Preliminary report or feasibility study
• Preliminary Ground Investigation - Planning of main GI
• Preliminary report
• Main Ground Investigation
• Laboratory testing
• Final report

Objectives of site investigation

The principal objectives for a highway design Site Investigation are as follows:

• Suitability: Are the site and surroundings suitable for the highway?
• Design: Obtain all the design parameters necessary for the works.
 • Construction: Are there any potential ground or ground water conditions that would affect
the construction?
• Materials: Are there any materials available on site, what quantity and quality?
• Effect of changes: How will the design affect adjacent properties and the ground water?
• Identify Alternatives: Is this the best location?

In addition to these, it is necessary to investigate existing features such as slopes. If there is a

failure of such a feature then it is necessary to investigate the failure and suggest remedial works.

Desk study:

The desk study is work taken up prior to commencing the work on site and the Ground
Investigation. It should always be the first stage of the Site Investigation and is used to plan the
Ground Investigation. The work involves researching the site to gain as much information as
possible, both geological and historical.

Site reconnaissance:

The Site Reconnaissance phase of a site investigation is normally in the form of a walk over
survey of the site. Important evidence to look for is:

• Hydrogeology: Wet marshy ground, springs or seepage, ponds or streams and Wells.
• Slope Instability: Signs of slope instability include bent trees, hummocks on the ground
and displaced fences or drains.
• Mining: The presence of mining is often signs of subsidence and possibly disused mine
shafts. Open cast mining is indicated by diverted streams replaced or removed
fence/hedge lines.
• Access: It is essential that access to the site can be easily obtained. Possible problems
include low overhead cables and watercourses.

Planning a site investigation:

The main investigation is the full investigation of the site using boreholes and trial pits and
includes the preparation of the site- investigation report with revised plans and sections,
interpretation and recommendations for design.

They consider that there are two aspects to the site investigation .The geological structure and
character of the site and the testing of the soil both in the laboratory and in-situ.
Ground investigation:

Ground investigation is taken to be that other than the information available from the walk over
survey as discussed previously.

There are two principal methods of investigating the ground conditions, trial pits and boreholes.
In addition, the reader should be aware of geophysical techniques such as seismic surveys, which
are not discussed here.

Sampling:

Sampling can be either undisturbed, of which in-situ testing is a form, or disturbed. On our site,
we used both disturbed and undisturbed/representative.

Reporting:

The Site Investigation report for a highway design scheme should answer all the questions set
out in the planning phase of the Investigation. This should include an assessment of the viability
of the proposed route and indication of any alternatives.

Included in the report should be a location of all the boreholes, trial pits, other excavations and
their logs. These logs should give as much information as possible on the soil and rock structure
as it is possible to obtain.

The soil and rock descriptions should be defined and should contain the information described
below:

Soil Description - Often remebered using the acronym MCCSSOW obviously!

• Moisture Content - Dry, slightly moist, moist, very moist or wet. Not the measured value
just the way it appears in the hand.
• Colour - This is an indicator of chemical and mineralogical content. Charts are available
but not often used.
• Consistency - Loose or dense and other descriptions dependant on soil type. An
approximate relationship can be made between stifness and undrained shear strentgh (Cu)
and between
Cu SPT 'N' Value density and
the SPT 'N'
Very Soft <20 Very Loose <4
Values.
Soft 20-40 Loose 4-10
Firm 40-75 Medium dense 10-30
75-
Stiff Dense 30-50
150
Very stiff >150 Very dense >50
 • Structure - Bedding, laminatesfissure, joints, fractures, shear zones etc.
• Soil Type - Given by particle sizes as described in Table
• Origin - Try and identify geological area and stratographic unit. This is difficult and often
impossible
• GroundWater Conditions - Depth to groundwater and any other observations.

Rock Descriptions - The acronym makers came up with CGTSWROS in a moment of inspiration

• Color - Same terminology as for soils with principal and secondary

• Grain Size - Range of sizes present and the dominant sizes.
• Texture & Fabric – Porphyritic, crystalline, granular, glassy, amourphous, homogeneous
and many more as described in BS5930 Table 9.
• Structure - Dependant on the type of rock, reference should be made to BS5930
Table 9. Discontinuities in the rock can be caused by the drilling action,
weathered surfaces indicate natural and clean surface indicate recent fractures.
Point Load
Term Field recognition Cu(MPa) Strength(MPa)

Rocks Ring on hammer

Extremely
blows. >200 >12
Strong
Sparks fly

Lumps only chip by heavy

Very Strong hammer blows. Dull ringing 100-200 6-12
Sound

Lumps or core broken by

Strong 50-100 3-6
heavy hammer blow

Moderately Lump or core broken by light 12.5-50 0.75-3

Strong hammer blow
Site clearance:

General:

Site clearing generally consists of the cutting and/or taking down, removal and disposal of
everything above ground level, including objects overhanging the area to be cleared such as tree
branches, except such trees, vegetation, structures or parts of structures and other things which
are designated in the contract to remain or be removed by others to which the engineer directed
to be left undisturbed.

The material to be cleared usually but not necessarily is limited to trees, stumps, logs, brush,
undergrowth, long grasses, crops, loose vegetable matter and structure.
The entire road area shall be cleared as described above, unless otherwise shown on the drawing
and/or directed by the engineer.

Setting out:

The right of way (R.O.W) shall be surveyed and set out before any site clearance is cleared out.
Wooden pegs usually indicate the surveyed rights of ways.

Procedure for setting out:

1. Fixing of centre line of alignment by using total station, theodelite.

2. Calculating curvature and refractures(for curves and embankment) by using auto levels or
dumpy level.
3. To establish traverse bench mark (TBM) at required intervals adjacent to alignments.
4. Location of levels at major conflict junctions.
5. To mark the longitudinal and cross sectional pavement structure.
6. To make efficient, minimum and desired sight distance at major conflicts and terrain and
also setting out of horizontal curves throughout the alignment was done by using
theodolite and total survey station.
Steps involved in surveying:

Benchmark
Temporary benchmark at regular intervals.
Centre line marking
Road markings
Profile marking (for longitudinal and cross sectional structures)
Establishment of different levels providing gradients as per to design considering
different factors like-
• SSD(STOPPING SIGHT DISTANCE
•
OSD(OVERTAKING SIGHT DISTANCE)
ISD(INTERMEDIATE SIGHT DISTANCE)

Surveying using dumpy level

Plants and equipments:

Site clearing of trees, vegetation, undergrowth, bushes and minor structures are carried out by
dozers and or hydraulic excavators. Trees that cannot be felled by the aforesaid equipment shall
be felled by using saws.

Major structures that cannot practically be cleared by hydraulic excavators and/or dozers, these
demolitions can be carried out using pneumatic tools, explosives and/or other

specialized equipment depending on the size and type of structures. Before commencing
explosive demolition all necessary permits and licenses will be obtained and a blasting plan
detailing the size of charges, locations of holes, system of detonation and safety precaution will
be forwarded to the engineer together with the request sheets.

:Single barrel Asphalt Premix Plant.

Sensor Paver

Aggregate Crusher
 Sequence of works:

Prior to the commencement of the site clearance, the following shall be carried out either
independently or jointly with the Engineer’s Representative.

I. The right of ways (R.O.W) shall be surveyed and set out according to the data stated
in the drawings.
II. Photographs shall be taken of structures, landscaping trees and shrubs, fences,
telephone and electrical poles and other if they are payable under individual measured
item apart from the general site clearance in the bill of quantities.
III. The above site clearance items shall be measured according to the method of
measurement jointly with the Engineer’s Representatives. The location of these items
shall be identified according to the survey data or offsets from the centerline of the
proposed alignment in road construction.
IV. Prior to demolition of existing buildings, liaison with the respective authorities
terminates the utilities supply to the building.
V. Removal of landscaping trees and shrubs shall be carried out with the prior approval of
the concerned authority.
VI. Fencing or others that are to be relocated or salvaged shall be carried out according to
the drawings or as per the instructions given by Engineer.
VII. Obtain confirmation that the employer or relevant authority have acquired the right of
way lands.
VIII. Access roads to the site shall be constructed if required to enable vehicles,
equipment and plants to be brought into the site.
IX. Solid waste dumps sites shall be predetermined within or outside the site for the
dumping of the site clearing materials.
X. The site clearance then shall be proceeded to clear the trees, vegetation,
undergrowth, bushes and minor structures by hydraulic excavators or dozers.
Excavation for cutting:

Construction method:

The excavation of cutting shall be carried out in accordance with the drawings and to the slopes,
levels, depths, widths and heights shown on the drawings. Prior to commencement of works,
surveyor will use the survey data of road alignment and TBM provided by the engineer for
setting out the extent of cutting in accordance with the cross sections and put in such pegs, bars,
sight rails and reference markers necessary to control the works.

A survey team shall monitor and control each stage of work. All the major setting out works will
be carried out jointly with the engineer’s surveyor. At the same time, the cut material below the
top soil level shall be sampled and tested for laboratory compaction, laboratory CBR, grading
and index properties, so that it may be classified as suitable or not for the various categories to
fill. Requests for approvals for use of that material as fill will then be submitted.

Before commencement of cut/fill, it will be ensured that the haul roads have sufficient width for
to and fro traffic and for smooth movement of the plant. The diversion of traffic, warning signs,
flagmen etc to the agreed traffic management plan shall be deployed for the safety of the works,
and all necessary ramps be provided to maintain existing accesses to and off the road.

Before starting the mass excavation the top soil shall be stripped from the area, either to a
thickness agreed from the soil sampling holes, or as directed on site by the engineer or his
designated staff, and afterwards measured by leveling. Requests for approval for commencement
of cutting shall then be submitted.

When approvals are received, the mass excavation shall be started from the top of the high
ground down to the formation levels. At the specified frequency and at any change of
material the engineer will be notified and the material will be sampled and tested for continued
suitability of use. If the changed material is considered to be Hard Rock a request for approval
for re classification will be submitted.
Slopes in cutting shall be trimmed mechanically to neat and even surfaces in accordance with the
designed gradients. The tolerance for widths of excavations shall not exceed the
dimensions shown on the drawings by more than 150mm or specified limits. Erosion protection

measures if desired by the engineer shall be carried out after the completion of trimming.

The construction of side drain shall follow closely to the slope trimming and surface water shall
be regulated to discharge to the side drain.

If directed by the engineer the slope of cutting shall be cleared of all rock boulders or rock
fragments, which move when, pressed by the crowbar.

The formation of sub grade on the cut area shall be sampled and tested for lab compaction, lab
CBR, and grading and index properties. If found to be suitable for sub grade this will be
compacted and tested as to CI.301 and CI.305. Request for approval for placing of sub base will
then be submitted. If there is likely to be a delay in immediately placing the sub base then a
protective layer 300mm thick shall be left in place above the sub grade level for removal at a
later date.

Machinery used:

i. Excavator – J.C.B. or Hitachi EX 100 for bulk excavation, loading on trucks and slope
trimming.

JCB
ii. Dump truck – For transporting cut materials from the cut area.

BMEL BH100 Dump truck

ii. Bulldozer – ripping & loosening of earth and rock mixed soil etc.
iii. Grader for trimming to final level and maintaining the surface parallel to the finished
grade line.

Backholes
Filling for embankment:

Construction method:

The embankment shall be constructed to the level, heights, widths and slopes shown on the
drawing with following procedures.

General:

The area to receive fill shall be sampled and tested below topsoil in accordance with the
specification. If the test results indicate that the material is for suitable to receive fill then a
request of Approval starting compaction of existing ground will be submitted. Before starting the
compaction of the existing ground the topsoil will be stripped from the area, either to a thickness
agreed from the soil sampling holes or as directed on site by the Engineer or his designated staff
and afterwards measured by leveling. After compacting the existing ground to specified standard
density tests will be carried out and a Request for Approval to start filling will be submitted.
Where it is the intention to commence filling will be commence by cutting to firm material, for
cross fill.

Fill materials for use in forming embankments shall be suitable material obtained from
excavation cuttings or borrow pits.
The slope trimming shall be completed after the pavement and shoulders are completed.

The trimmed slope is to be turned, if specified.

Subsoil drain:

General:

This work shall include the supply and installation of subsoil drains constructed in accordance
with the contract specification at the locations and in accordance with the lines, levels and grades
as shown on the drawings and or as directed by the Engineer.

Materials:

CONCRETE PIPES OR Polyvinyl chloride (PVC) pipes for the subsoil drains shall comply with
the relevant contract specification.

Filter material used in the construction of subsoil drains shall consist of hard, clean, crushed rock
or gravel having a grading limits given in the specification. The aggregate crushing value of the
material shall not exceed 30%.
The filler cloth shall be geotextile fabric as specified in the contract.
Construction method:

Excavation of longitudinal and cross trenches shall be carried out all in accordance with the
approximate provisions of specification and drawings. At the completion of excavation, Request for
Approval forms for placing filter materials will be submitted to the Engineer.

Filter cloth shall then be placed to cover the perimeter of the longitudinal trench excavated, with
the top open to facilitate the placement of filter material. Subsoil cross pipe is then laid in the cross
trench at minimum 1% slope, with the inlet face covered with filter cloth and the outlet being free
outfall. The inlet of cross pipe is to be imbedded in the filter material fill placed in the longitudinal
trench. Care shall be taken against damage of filter cloth during the construction stage.

Filter material shall be placed in longitudinal trench and uniformly compacted. The filter cloth shall
be closed at top and backfilled with soil. At the completion of placing filter materials a Request for
Approval for placing compacted backfill will be submitted. During backfilling random field density
check tests will be carried out.
Granular sub-base:

General:

Sub base is the lowest of all the pavement layers consisting of natural sand, mooram, gravel,
crushed stone or combination thereof necessary to comply with the grading requirements of Table
400-1 Grading I.

Materials:

Prior to the laying of sub base, a Request for Approval of Material shall be submitted which will
indicate compliance with the specified properties of sub base material.

a) Fraction of material passing the 22.4 mm sieve shall have a soaked CBR of 30% or greater.
b) The fraction passing the 0.425 mm sieve shall have Liquid Limit not greater than 25 and
a Plasticity Index not greater than 6.
c) The soaked 10% fines value (KN) shall be greater than 50.
d) If the water absorption is greater than 2% the Soundness Test IS 383 shall be carried.
The grading shall be as follows:

SEIVE SIZE (MM) PERCENTAGE PASSING

75 100
53 80-100
26.5 55-90
9.5 35-65
4.75 25-55
2.36 20-40
0.425 10-25
0.075 3-10

Laying equipment:

The following plants are required for the laying of sub-base:-

i. Motor Grader
ii. Tipper Trucks
iii. Vibratory Roller
iv. Water Tanker
Wet mix macadam:

General:
Wet mix macadam (WMM) is a base material in road pavement structure, which is batched from
a mixing plant, and laid in position with a paver.

Materials:

WMM consists of crushed graded aggregate and granular material pre mixed with water.
 Equipments:

Constructional plants required are as follows:-

NO. OF UNIT/TEAM

A) WMM MIXING PLANT 1

B) PAVER 1
C) MOTOR GRADER 1
D) VIBRATORY ROLLER 1
E) TIPPER 3

Procedures:

Work shall commence on site upon Approval and Acceptance of the sub-base layer.

The wet mix macadam shall be plant mixed with moisture content within reasonable limits of the
Optimum Moisture Value, as determined in accordance with IS 2720 (Part 8).

The approved wet mix macadam shall be delivered to site by tipper trucks. To prevent the loss of
moisture, the materials shall be covered, if necessary.

i. The wet mix macadam shall be laid by using a paving machine.

ii. Segregation at localized areas shall be made good by back casting with fines or by
immediate removal and replacement of the freshly laid wet mix macadam.
iii. Transverse joint shall be lapped and longitudinal joints due to stoppage of work will have
the loose removed before paving resumes.
iv. Compaction shall be carried out using vibratory roller and as per specifications.

v. The surface of the wet mix macadam shall be finished to the grade and line as required by
the drawings, and within specified tolerance limits.
vi. On completion of laying and compaction, approval of the Engineer will be obtained for
compliance with the specified requirement, before proceeding with the next layer.
vii. Sampling of mixture shall be carried out at the plant or site.
Dense bituminous macadam:

General:

DBM is a bituminous road base mix consisting of graded aggregates, bitumen and filler. It is
used in main pavement course.

Materials:

DBM consists of the following materials:

i. Road base material complying with IS:2386 (Part- 1,3,4,5) and IS:2720 (Part 37) and
table 500-8 of the MOST specification and the grading shall be within the range shown
below and the design mix shall be approved from the Engineer.
ii. The plasticity index of the fraction passing the 425-micron sieve should not exceed 4.

iii. Bitumen – (6-/70) penetration grade. The quantity will be as specified in the contract and
bitumen 4.0 percent.
iv. Cement lime/stone dust- as specified in the contract.
v. Temperature of materials.
vi. The aggregates shall be surface dry and shall be mixed at 155 o C to 163oC temperature
o o
with binder temperature at 150 C to 163 C. the mixed material as delivered to the laying
site shall be between 120oC to 160o C.

Mixing:

The materials including any added filler, shall be weighed or measured into a mechanical mixer
and thoroughly mixed in such a manner that all particulars of the aggregate are completely and
uniformly coated.
Equipments:

Plant required to produce DBM:

i. Premix Plant
ii. Wheel Loader
Machineries required for laying:

i. Tipper Trucks
ii. Asphalt Paver
iii. Tandem Roller – 80-100 Km
iv. Bitumen Sprayer
Procedure:

Work shall commence on site upon approval and acceptance of the wet mix macadam and prime
coating. Tack coat shall be sprayed on the surface, to receive the DBM.

The dense bituminous macadam shall be plant mixed as specified in design mix.

The approved DBM mix shall be delivered to site by tipper trucks. To prevent the loss of heat,
the mixture shall be covered.

The dense bituminous macadam shall be laid by paver in 50 to 100mm layer as specified in the
contract.

If the laid surface is open-textured, back casting shall be carried out and the bigger size
aggregates removed before rolling.

At the end of the paving operation, the transverse joint shall be feathered down. Lap joint shall
be provided for the next operation of paving.

Compaction shall be carried out using the specified/ equivalent type of compactors and for
rolling pattern shall be as per specifications.

Rolling shall always commence from the lower to the higher side of the carriageway. The
o
minimum rolling temperature shall be 100 C.
The surface of the dense bituminous macadam shall be finished to the grade and line as required
by the drawings, within the specified tolerance limits of +6 mm.

On completion of laying and compaction, checks shall be carried out to verify compliance with
the specified requirements.

Bituminous concrete wearing course

General:

The B.C. wearing course is the final layer of the pavement.

The material quality shall meet the requirements of MORTH Technical specifications.

The aggregate shall be surface dry and shall be mixed at 155 degree Celsius to 163 degree
Celsius temperature. The mix material as delivered to the laying site shall be 120 to160 degrees
Celsius.

Equipments:

Plant required to produce WC shall be:

i. Asphalt Premix Plant

ii. Wheel loader
Machineries required for laying WC:

i. Tipper Trucks
ii. Asphalt Paver
iii. Tandem Roller
iv. Bitumen Sprayer
Procedures:

Trial mix and trial lay shall be carried out to assess the suitability of the mixing, laying and
compacting plant and to establish the sequence of the laying operation.
Works shall commence on site upon approval and acceptance of the asphalt concrete wearing
course.
The surface to receive the Asphalt concrete wearing course shall be freed of all dirt, loose
materials and standing water.
Tack coat of approved bitumen emulsion or cut back shall be applied as per the specifications on
the prepared surface prior to laying of the asphaltic concrete wearing course.
The ACWC shall be plant mixed with bitumen content as established in the Job Standard
Mixture.
The approved asphaltic concrete mixture shall be delivered to site by tipper trucks. To prevent
the loss of heat, the mixture shall be covered if necessary.

The ACWC shall be laid in single layer.

If the said surface is open textured, back casting shall be carried out and the bigger size
aggregates removed before rolling.

At the end of paving operation, the transverse joint shall be feathered down. Vertical joint shall
be provided for the next operation of paving.

Compaction shall be carried out using the specified/equivalent type of compactors and the rolling
pattern shall be as agreed with the Engineer. In our project, every layer was compacted six times,
with first and last compaction, plain and middle four compactions, with vibrations.

Rolling shall always commence from the lower end to the higher side of the carriageway. The
minimum rolling temperature shall be 100 degree Celsius.
The surface of the ACWC shall be finished to the grade and line as required to the drawings
within the tolerance limits.
On completion of laying and compaction, checks shall be carried out to verify compliance with
the specified requirements.

Dry lean concrete:

General:
The work shall consist of construction of dry lean concrete sub base for Cement Concrete
Pavement in accordance with the requirements of MORT&H Specifications. IRC 43-1972 and
IRC 15-1981. The construction shall also be in conformity with lines, grades and cross sections
shown on drawings and/or as directed by the Engineer.
Materials:

All the materials required in the construction will be from the source approved by the Engineer

and according to the relevant clauses of MORT&H specifications mentioned in the contract.

Cement - 601.2.2

Coarse aggregates - 602.2.4.2

Fine Aggregates - 602.2.4.2

Water - 601.2.4

Aggregate gradation given in table 600-1 of MORT&H specifications shall be adopted after
blending the coarse and fine aggregates.

Sieve Designation % passing Proposed by % passing Limits by

Weight Weight
26.50 mm 100 100
19.00 mm 87.4 80-100
9.50 mm 67.6 55-76
4.75 mm 46.1 35-60
600.00 Micron 18.2 10-35
75.00 Micron 5.4 0-8
Aggregates are fed into the cold bins from online storage bins of a 4-stage crusher or from the
approved stacks. Cement is obtained either in bags or bulk and necessary support system will be
employed for feeding the 120-140 MT storage silos of the concrete batching plant.

Mix for dry lean concrete will be appropriately proportioned to achieve the strength requirements
mentioned in the specifications and prior approval shall be taken from the engineer before
adopting for the site trials.

The calibration trial of the batching plant will be undertaken with the approved proportions after
the calibration of the plant. The approved mix will then be used on the trail length already
identified jointly by the representatives of the contractor and the engineer.
Equipment:

The following plants and equipment will be deployed for the construction of DLC:

i. Concrete batching plant (200 Cum/hr) with all the required accessories and storage
facilities.
ii. Tippers
iii. Sensor Paver
iv. Excavator/JCB
v. Vibratory Roller
vi. Water Tankers
vii. Equipment for laboratory and survey
Preparation:

i. The GSB surface already approved will be given a fine sprayed with water and rolled
with the earth compactor giving a couple of passes after a lapse of 2-3 hours of watering.
This will stabilize the loose surface. Prior to watering, loose or dislocated spots, if any,
will be identified and they will be rectified by removing loose material and back filling
with appropriate material and compacting to the required degree of compaction as the
adjoining areas. The GSB surface will be kept ready at least one day in advance of DLC
laying.
ii. Before start of laying, it will be ensured that the guide/sensor wires are in position on
both sides or on one side of the Paver depending upon the paver pressed used for the
work. For SP1600, guide wires will be provided on both sides of the paver. For normal
sensor pavers, guide wires will be provided on one side with slope control provision.
There will be designated entry points for the trucks carrying concrete on to the new
carriageway or prepared GSB layer.
Paving:

i. Paving is kept in position and the concrete is dumped in hopper in case of normal sensor
paver and paving is done by spreading a loose thickness of about 200 mm for achieving
the compacted thickness of 150 mm. the loose thickness is ascertained by
 conducting trial laying of DLC. The paving will be done on the same day matching with
the first lane.
ii. In case of use of SP 1600, the DLC is laid to full width with guide wires fixed on both
sides relative to the line and grade and cross- slope as per the drawings. The concrete is
dumped in front of the paver and it is spread across the width by the spreader.

iii. It will be ensured that traverse and longitudinal construction joints are staggered by 500-
1000 mm and 200-400 mm respectively from the corresponding joints in the overlaying
pavement quality concrete.
Transporting:

The concrete is transported in tippers from the batching plant and to the place of laying. The
tippers are covered with tarpaulins in order to prevent water loss due to evaporation during
transit. It will be ensured that there will be sufficient number of tippers for uninterrupted supply
of material to the paving equipment.

Compaction:

The compaction is carried out immediately after the material is laid and leveled. Rolling shall be
continued on full width till there is no further visible movement under the roller and surface is
compact. The required compaction effort in terms of number of passes is ascertained by
employing one single drum smooth wheeled vibratory roller and one double drum smooth
wheeled vibratory roller on the trail stretch of DLC. After arriving at the efficiency of the
proposed set up in the trial length, depending upon the programmed quantity and period of
laying, additional rollers will be deployed. Initial two passes will be plain passes on order to roll
down the loose DLC. Then vibratory pass will be given followed by plain passes for providing a
finished and closed surface.

Curing:

Curing of the DLC will be done by covering the surface by gunny bags or hessian cloth, which

will be kept continuously moist for seven days by sprinkling water using water tankers.
Testing:

After the construction of the trial length, the in-situ density of freshly laid material will be
determined by sand replacement method with 20 cm diameter density cone. The density will be
taken at three location along the diagonal that bisects the trail length. The locations for testing
will be at least 50 cm from the edges. The average density of three holes will be considered as
100% and the field density of regular work will be compared with this reference density in
accordance with clauses 601.5.5.1 and 903.5.1.2 of MORT&H specifications. Course will be cut
to check segregation or any other deficiency. The routine quality control tests for levels
alignment and material will be exercised as per the frequency norms given in table 900-6. Other
tests will be done at the frequency mentioned therein. If there could be any reduction in total
number tests depending upon the consistency of the results, ration will be taken up with the
Engineer.

Description Frequency
Testing of cubes Each 100 sqm or part there of laid each day from the un-
compacted material
In-situ density Holes at location equally spaced along the diagonal that
bisects each 2000 sqm or part there of laid each day.
Thickness Cores at random

Repairs:

Rectification, if any will be taken up before overlaying PQC. The low spots, loose material, pot
holes etc will be made good by using fresh lean concrete material duly compacting the same as
per specifications. For repairing honey combed surface, and any other spots which cannot be
repaired with DLC material, concrete with aggregates of size 10mm and below will be used after
roughening the surface for proper keying in.
Typical construction of cross section in highway:

Compaction of soils:

The road crust is founded on sub grade and any deficiencies in the stability of earthwork results
in settlements and other distress develop in pavement during service under traffic. Therefore
good stability is necessary for the sub grade. Proper compaction at appropriate moisture is the
most effective and economical way to improve the stability of soils.The density test is the
principal means by which the engineer determines whether or not the specified compaction
requirements have been met.

Moisture density relationship (M.D.D & O.M.C):

 For a given compaction effect as the moisture content is changed density of soil varies and
maximum density is achieved at “optimum moisture”. Soil is compacted in proctor’s apparatus
and dry weight is assessed for different moisture contents. The results are plotted and the
maximum dry weight is the highest point of the curve and is called “proctor’s density of soil”.

Embankment and sub grade formation:

The materials used in embankment shall be soil, moorum, gravel, and a mixture of these. The
materials satisfying the density requirements shall be employed for construction of embankment
and sub grade.

Type of work Max.lab dry unit weight when tested

as per IS 2720
Embankment upto3 meters height not Not less than 1.52 gm/cc
subjected to extensive flooding
Embankment exceeding 3 meters height or Not less than 1.60 gm/cc
Embankment of any height subjected to long
periods of inundation
Sub grade and earthen shoulders/verges Not less than 1.75gm/cc
The size of the coarse material in the mixture of earth shall ordinary not exceed 75mm when
being placed in the embankment and 50mm when placed in the sub grade.

The soil for embankment and sub grade must be tested for compaction requirements.

Type of work/material Relative compaction as % of

maximum lab dry density as per is
2720
Sub grade and earthen shoulders Not less than 97
Embankment Not less than 95
Expansive soils
a> Sub grade and 500mm portion just Not allowed
below the sub grade.
 b> Remaining portion Not less than 90

Clayey soils if any should be removed and replaced by good granular soil.

The embankment and sub grade material shall be spread in layers of uniform thickness not
exceeding 200 mm compacted thicknesses over the entire width of embankment. Successive
layers shall not be placed until the layer under construction has been thoroughly compacted to
the specified requirements. Moisture content of each layer of soil is checked in accordance with
IS-2720.

Determination of field density:

The in situ dry density of soil in the embankment/sub grade must be tested to check the degree of
compaction in the field. The field density of soil can be determined popularly by

1> Core cutter and

2> Sand replacement methods.
Weight of the soil obtained in the core cutter of known volume is determined; moisture content is
assessed and dry density is calculated. In sand replacement method pre-calibrated density of sand
is used to measure the volume of pit dug out from the sub grade and the moisture content is
assessed. Knowing the weight and volume of excavated soil and moisture content the field
density can be calculated which should not be less than 95% and 97% of proctor’s density for
embankment and sub grade respectively.

Nuclear gauges are being used to measure the field density of soils, the principle being gamma
rays emitted into the soil and number of rays returned and counted on a scalar. A low gamma ray
count indicates high density and vise versa.
California bearing ratio (CBR) of soils:

Load carrying capacity of soil is measured from penetration resistance i.e. test conducted on
compacted specimen and expressed as per percentage of a standard crushed rocks specimen and
called as CBR of Soil.CBR 100 Percent (viz) Load of 1360 kg to drive cylindrical plunger of
19.30 sqcms to a distance of 0.250 mm at the rate of 0.125 mm per minute.

Type of Soils CBR

Gravel and sand mixtures 20-90

Sand and Silt mixtures 10-40

Sand and clay mixtures 15-40

Inorganic silt & clay 5-15

Organic silt & clay 3-8

Granular sub base:

This is being practiced to act as transition zone between hard base courses and sub-grade as well a
drainage layer to drain pout the seepage water from base courses and avoid capillary water from
sub-grade.
The CBR requirement for sub base layer is not less than (15) percent. The Material to be used for
the work shall be natural sand, moorum, gravel, Crushed Stone or combination of these. The
material shall be non-plastic i.e. plasticity index of material passing 425 micron sieve shall be less
than (6) and liquid limit less than 20 percent.
If thickness of layer does not exceed 100 mm a smooth wheeled roller of 8 to 10 tons weight
may be used. For compacted single layer of 225mm the compaction shall be done with the help
of a vibratory roller of 8 to 10 tons weight with plain drum or pad foot drum. Rolling shall
commence at the lower edge and proceed towards upper edge longitudinally for portions having
unidirectional cross fall and super elevation. Rolling shall commence at edges and progress
towards the center for portions having cross fall on both sides. The Speed of the roller shall not
exceed 5 kms per hour. Rolling shall be continued till the density achieved is at least 98% of the
maximum dry density for the material as per IS 2720 (Part 8).
Water bound macadam base:
The basic need of WBM base is to distribute the load over a soft sub-grade in such a way that
there will be no sinking of the road crust into the sub-grade. WBM is constructed with hard and
soft metals called aggregates obtained from breaking/crushing of rocks. The aggregates spread in
layers are interlocked by rolling and bonding together with screenings, blinding material and
water.

Road aggregates: These have to bear the stresses due to the wheel loads and hence they
should possess sufficient strength to resist crushing. They should be hard enough to resist wear
due to abrasive action of traffic. The aggregates in the pavement are also subjected to impact
hence toughness is another desirable property of aggregates. The stones used should be durable
and resist disintegration due to action of weather, this property is called soundness. The
following are the most commonly available rocks in India from which road aggregates can be
obtained.

Type of Rock Properties Suitability

Basalt Hard and durable, resistant to Good for base courses
abrasion, fine grained.
Granite Hard and durable resistant to Very good for bituminous
abrasion, Coarse grained. Courses and WBM
Limestone Reasonably hard, liable to Good for base course
polish to a Smooth surface
under traffic, fine grained and
high water absorption.
Quartzite Hard, durable but is liable to Good for base course
be brittle and adhesion to
bitumen is rather poor.
Sand Stone Moderately hard and durable, Good for road bases
fine to medium grained.
Aggregates may have rounded cubical angular flaky or elongated shape of particles. The
following are the physical requirements of coarse aggregates used for WBM as per IS 2386.

Los Angles abrasion value 40 percent (Maximum)

Or
Aggregate impact value 30 percent (Maximum)

Combined flakiness and elongation indices 30 percent (Maximum)

Grading requirements: The WBM is carried out in layers. The coarse aggregates for each layer
should confirm to any of (3) grading below. The use of grading no 1 shall be restricted to sub
base courses only.
Size and grading requirements of coarse aggregates for water bound macadam.

Grading No. Thickness and Size range IS sieve Percent by

aggregate per designation weight passing
10 sqm. the sieve
 1 10 mm 90 mm to 45 mm 125 mm 100
1.21 to 1.13 90 mm 90-100
cums. 63 mm 25-60
45 mm 0-15
22.4 mm 0-5

2 75 mm 63 mm to 45 mm 90 mm 100
0.91 to 1.01 63 mm 90-100
cums. 53 mm 25-70
45 mm 0-15
22.4 mm 0-5
3 75 mm 53 mm to 22.4 63 mm 100
0.91 to 1.07 mm 53 mm 95-100
cums. 45 mm 65-90
22.4 mm 0-10
11.2 mm 0-5
The compacted thickness for a layer with grading no 1 shall be 100 mm while for layer
with other grading i.e. 2&3 shall be 75 mm.

Application of screenings:

To fill voids in the coarse aggregates, screenings are generally necessary and shall consist if the
same material as the coarse aggregate.

.
 Grading Size of screening IS sieve designation Percent by weight
classification passing the sieve
A 13.2 mm 13.2 mm 100
11.2 mm 95-100
5.6 mm 15-35
180 microns 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180 microns 15-35

Gravel:
Non-Plastic material such as moorum or gravel may also be used for filling the voids in the
coarse aggregates provided liquid limit and plasticity index of such material are below 20 and 6
respectively and fraction passing 75 microns sieve doesn’t exceed 10%.

Construction operations:

The coarse aggregates shall be spread uniformly and evenly upon the prepared sub grade/sub
base/base to proper profile by using templates placed at 6 mts apart and all high or low spots
remedied by removing or adding aggregates. Immediately after spreading of coarse aggregates
rolling shall be started with power roller of 8 to 10 tons of capacity or vibration roller of 8 to 10
tons weight. First the edge shall be compacted and move inward parallel to the centre line of the
road duly lapping preceding tracks by at least one half width. Rolling is continued until the
aggregates are well compacted and no waveform is seen when the roller is advancing. Screening
shall be applied gradually brooming and dry rolling is continued until no more screenings be
forced into voids of the coarse aggregates. All this operations shall be carried out in only such
lengths of road, which could be completed within one day. Now the surface be copiously
sprinkled with water, wet screenings swept and rolled until the coarse aggregates has been
thoroughly keyed well bonded and firmly set in its full depth. The binding material shall be
applied successively in 2 or more thin layers and the surface shall be copiously sprinkled with
water, the resulting slurry swept in with brooms to fill the voids. The rolling shall be continued
until the resulting slurry after filling voids forms a wave ahead of wheels of the moving roller.
After final compaction the pavement shall be allowed to dry over night and no traffic is allowed
for 2 or 3 days until the macadam has set. The roads shall be kept watered so that it remains in
damp condition under traffic for about a fortnight.

Wet mix macadam: (WMM)

Graded aggregate and granular material and water are premixed in pug mill and shall be laid in
one or more layers. The thickness of a single compacted layer shall not be less than 75mm and
can be increased to 200mm when compaction is with vibratory roller. The aggregates shall
satisfy the physical requirement of aggregates i.e. impact value of 30 percent (max) and flakiness
index 30 percentage (max).

The aggregates shall confirm to the following grading.

IS sieve % by weight passing

53mm 100
45mm 95-100
22.4mm 60-80
11.2mm 40-60
4.75mm 25-40
2.36mm 15-30
600 micron 8-22
75 micron 0-8

The mix shall be spread uniformly using a paver finishers or motor grader and no segregation of
larger and finer particles be allowed. While constructing WMM confinement of mix against
lateral movement shall be ensured by simultaneous shoulder development. Traffic shall not be
allowed until the mix has dried at least for 24 hours.
Bituminous pavement:

Pavement made of aggregates and bitumen as binding material are smooth, dust free and have
higher load carrying capacity and longer life period of 10 to 15 years; hence most of the roads
are being constructed/converted to black top.
Bituminous material:

Bitumen is a viscous liquid, semisolid or solid material, colour varying from black to dark brown
having adhesive properties consisting essentially hydrocarbons is derived from distillation of
petroleum crude or natural asphalt and soluble in carbon disulphide. Bituminous materials used
for paving purposes are penetration grade bitumen and liquid bitumen (cutbacks & emulsion).

The bituminous binder should possess the following qualities.

Adequate viscosity at the time of mixing and compaction.
Not highly temperature susceptible.
Should not strip from aggregate in presence of water.
The following suitability tests are followed.
Consistency test:

Penetration test

Viscosity test

Softening point test

Ductility test

Compaction test:

Loss on heat test

Solubility test

Water content test

Distillation test

Spot test

Specific gravity test:

Varies from 1.00 to 1.28
Flash and fire point test:
Safety test to indicate the max temperature to which the bituminous material can be safely
heated.
Measurement of penetration a 100 gm standard steel needle into a bitumen binder kept into a
bitumen binder kept at 25 degrees within 5 sec is known as penetration value.

Viscosity is its important physical property low viscous binder may flow off the aggregate during
transit from mixing plant to site and a high viscous material may provide an unworkable mix.
Viscometer is used to measure the viscosity of the bitumen.

The ductility of a bituminous material is measured by the distance in centimeters to which it will
elongate before breaking when a briquette specimen of the material of the form is pulled apart at
a specified speed (50 mm/min) and specified temperature of 27 degrees- bituminous briquette is
subjected to rupture in the testing machine.

Softening point: The temperature at which the bitumen attains the particular degree of softening
under specified condition of test- measured with ring and ball apparatus.

Flash point: It is the lowest temperature at which the vapour of bitumen momentarily takes fire
in the form of a flash under specified condition of test- pensky-martens tester is the apparatus
used to test flash point.

Fire point: It is the lowest temperature at which the material gets ignited and burns under
specified condition of test- measured with pensky-martens tester.

Properties of paving bitumen:

Specific gravity at 27 degrees 1.12-1.28

Water content percent by weight, max 0.50
Flash point in degree centigrade 175
Softening point in degree centigrade 45-60
Penetration at 25 degrees 80-100
Ductility at 24 degrees 75
Loss on heating percent by weight 1
The aggregates used in bituminous works shall satisfy the following physical requirements.

Property Test Specification

Cleanliness (Dust) Grain size analysis Max 5% passing 0.075 mm
Sieve
Particle shape Flakiness and elongation Max 30%
index
Strength Los Angeles Abrasion Value Max 35%
Aggregate impact value Max 27%
Durability Soundness
Sodium sulphate Max 12%
Magnesium sulphate Max 18%
Water absorption Water absorption Max 2%
Stripping Coarse and stripping of Min retained coating 95%
bitumen aggregate mixtures

Bituminous courses:

Bituminous courses of different specifications are laid on WBM/WMM base or existing BT

surface. A PRIME COAT over macadam base at the rate of 6 to 9 kgs/10 sqms and TACK COAT
of 2 to 3 kgs/sqms over existing BT surface shall precede the bituminous courses. The
specification for different classes of BT work varies with respect to size of aggregates and
quantity of bitumen used. The voids in bituminous surface will be sealed by application of seal
coat.
The following table shows the bituminous generally used.

Sl. No Item of Grade Thickness Nominal Bitumen Ref to

work of layer in aggregate content % MOST
mm size by weight specification
1 Premix 20 mm 12 mm 2.8 511
carpet
2 Bituminous Grade 1 80-100 40 mm 3.1 to 3.4 504
macadam
Grade 2 50-75 19mm 3.3 to 3.5 504
3 Dense Grade 1 80-100 40mm 4.0 507
bituminous
macadam Grade 2 50-75 25mm 4.5 507

4 Semi dense Grade 1 35-40 13 mm 4.5 508

bituminous
concrete Grade 2 25-30 10mm 5.0 508
5 Bituminous Grade 1 50-65 19 mm 5 to 6 509
concrete
Grade 2 30-45 13 mm 5 to 7 509
Apart from conformity with grading and quality requirements individual ingredients the
mix shall meet the requirements of Marshall test.

Minimum stability(kg at 60 degree centigrade) 820 kgs

Flow (mm) 2-4
Compaction level (no of blows) 75 blows on each of two faces of the specimen
Percent air voids 3-5
Percent voids in mineral aggregate (VMA) 8-22

Mixing and spreading operation:

The mix for bitumen courses shall be prepared in hot mix plant (HMP). The plant will have cold
aggregate feed system with minimum (4) bins having belt conveyor arrangement and variable
speed drive motors, dryer unit with burner capable of heating the aggregate and bitumen supply
unit capable of heating and spraying of bitumen at specified temperature. The plant should have
centralized control panel cabin to ensure for quality of mix.

The mix from the HMP shall be transported to the site and spread on the road surface using paver
and compacted with suitable rollers. The following temperature shall be maintained during the
process.

Temperature of binder at the time of mixing – 150 to 163 degree centigrade.

Traffic will be diverted until the rolling is finished and the course is well set.
Aggregate blending:

The aggregates from the crusher are stored in BINS. For getting the desired mix three or four
aggregates have to be mixed and proper proportioning of different aggregates is called aggregate
blending.

The following table illustrates aggregates blending of DBM.

Sieves 37.5 26.5 12.5 4.75 2.36 0.3 0.075

Min Pass 100 90 56 29 19 5 1 MOST
Max 100 100 80 59 45 17 7 MOST
Pass

Avg Pass 100 95 68 44 32 11 4

Designed 100 93.2 66.2 48 31.3 8.9 2.1 Blending
Bin- A 100 65.9 .6 .5 .4 .3 .2 20
Bin-B 100 100 33.5 1 .9 .7 .4 21
Bin-C 100 100 100 61.2 9.7 2.9 1.3 29
Bin-D 100 100 100 100 94.1 26.1 5.5 30
100
.

Dry lean concrete (DLC):

Dry lean concrete is used for construction of base course under the concrete pavement. The DLC
general consists M- 10 concrete of thickness not less than 112 mm laid over thin layer of
WBM/WMM. Graded aggregate of size varying from 25 mm to 4.75 mm are used. The mix shall
be proportioned with a maximum aggregate cement ratio of 15: 1 and water cement ratio around
0.70. The minimum cement content shall not be less than 150kgs/cum of concrete and the
average compressive strength shall not be less than 100 kg/cm2 at (7) days.

The mix is produced in the central batching and mixing plant and transported to the paving site
in trucks. Concrete pavers equipped with tampers and vibrators are used for spreading without
segregation. The compacting and finishing shall be within (90) minutes of concrete mixing.
Longitudinal and traverse construction joints shall be provided as per drawing. Curing shall be
done by covering the surface with gunny bags/hessian, which shall be kept continuously for (7)
days by sprinkling water. Initial curing can also be done by spraying liquid curing compound and
wet hessian for 3 days. Light vehicles may be allowed after (7) days of construction. Trial mixes
with varied moisture contents of 5 to 7% shall determine the optimum moisture and trial length
of minimum 60 meters length shall be constructed and dry density of the mix shall be determined
to be used as reference density.

Cement concrete pavement:

This work consists construction of unreinforced, dowel jointed, plain cement concrete pavement.
The thickness of pavement slab, grade of concrete and joint details shall be stipulated in the
drawings. Ordinary Portland cement of 43 Grade or higher is generally used. The coarse
aggregate shall be of crushed stone maximum size not exceeding 25 mm and shall be devoid of
soft flaks, elongated, splintery pieces and water absorption shall not be more than 2%. The fine
aggregate shall be natural sand or crushed stone or combination of the two. The cement concrete
shall not be less than 350 kgs/cum of concrete and water content ratio shall be 0.50. The mix is
produced in mechanized batch mix plant and transported with dumpers or transit mixers. The
mix from the plant shall be transported in trucks/tippers and spreading and finishing shall be
completed within (90) minutes of concrete mixing, curing shall be for (14) days using liquid
curing compound and covering with moist hessian. A separation membrane shall be used
between concrete slab and the sub base. The location and type of joints shall be as shown in the
drawings.

Different laboratory tests on field:

Laboratory test for CBR:(California Bearing Ratio)

Objective: To determine the CBR of soils from the re- moulded specimens by dynamic
compaction method in soaked state at laboratory.

CBR: The ratio of the force per unit area required to penetrate a soil mass with a plunger of
50mm diameter at the rate of 1.25mm/minute to the required corresponding penetration of
standard material.
Generally the ratio is determined for 2.5mm and 5.0mm penetrations, and where the ratio at
5.00mm is consistently higher than that at 2.5mm, the ratio at 5.00mm is considered.
 Apparatus: Cylindrical mould , metal rammer, spacer disc, metal weights, perforated base
plate, metal tripod stand, penetration plunger, loading machine with moving head, sieves,
balances, oven , air tight container, tray, trowel, measuring jar.

Procedure:

i. Take a representative sample to be tested, pour it in the form of a heap and divide into 4 equal
parts by quartering method and mix the material in one of the two diagonals and sieve it
through 19mm sieve, the material retained shall be replaced by the equal amount of passing
through 19mm sieve, but retained on 4.75mm sieve, obtained from the material of the other
two diagonals, so that the passing material shall weigh a minimum of 5500gm.
ii. Place it in a tray and mix with the equal amount of that water required obtaining OMC.
iii. Note the empty weight of the cylindrical mould to the nearest 1 gm.
iv. Place the mould on a solid base, such as concrete floor or plinth.
v. Make the water mixed soil into 5 equal parts, place the spacer disc in the mould and a
filter paper and place one part into the mould fitted with collar.
vi. Compact the soil with the metal hammer by distributing the 55 blows equally on the
surface of the soil.
vii. Continue this process till the fourth layer, make an impression on the fourth layer of the
compacted soil to a depth of 25mm, so that the next layer will plug into this and avoid
separation of the top layer from the previous while removing the collar.
viii. Add fifth layer and compact it with metal hammer by giving 55 blows.
ix. Remove the collar and also remove the excess soil up to the level exactly equal to the
cylindrical mould by using trowel or spatula. Note the weight of the sample with the
mould to the nearest 1 gm.
x. Reverse the compacted mould, tighten the mould on the base plate, place the perforated
disc with surcharge weights of 5kg on the compacted soil specimen with the mould and
soak it in water for 96hours. Maintain constant water level in the tank throughout the
soaking period.
xi. After the soaking period, take out the mould with the soil specimen from the water tank
and allow it to drain free water collected in the mould, downward for 15 minutes.
 Image: CBR apparatus

Grain size analysis of soil:

Objective: To determine the quantitative distribution of grain size distribution of soils.

Apparatus: Wash the sample under water by allowing the washed water through the lowest
size of sieve, balance of 0.1 gm sensitivity, IS sieves of 100mm, 75mm, 19mm, 4.75mm, 425
microns and 75 microns and rubber pestle, water tight trays or a bucket.

Procedure:

i. The soil sample received from the field shall be dried in the oven at 105 to 110 degree
centigrade.
ii. The oven dried sample shall be taken by quartering method to have a minimum weight.
iii. The mass of the sample taken for testing shall be weighed to nearest 0.1gm.
iv. Pour water in the sample with water tight tray and leave it for 2hrs.
v. Wash the sample under water by allowing the washed water to go through the lowest size of
sieve.
vi. Wash bigger size aggregate first by rubbing in between two hands, ensure that the 75 microns
sieve never gets overloaded, since it may get damaged.
 vii. Wash the sample till the water passing the sieve is substantially clean, collect all the material
retained on 75 microns, drain out the excess water and keep it in oven for 24hrs at 105 to 110
degree centigrade.
viii. Allow the sample to cool, and perform dry sieving with the largest size of sieve first and the
next sizes consecutively.
ix. Ensure that the sieving is complete, and the amount of material retained on each sieve shall
be weighed and noted.
x. The cumulative mass of the soil fraction shall be then calculated, and percentage of passing
on each sieve shall then be reported.
xi. The material passing 100mm sieve and retains on 75mm sieve is called ‘Cobble’.
xii. The material passing 75mm sieve and retains on 4.75mm sieve is called ‘Gravel’.
xiii. The material passing 4.75mm sieve and retains on 75 microns is called ‘Sand’.
xiv. The material passing 75 microns sieve is called ‘Silt’.
Determination of free swell index of soil:

To determine the free swell index of soil as per IS: 2720 (Part XL) – 1977. Free swell or
differential free swell, also termed as free swell index, is the increase in volume of soil without
any external constraint when subjected to submergence in water. The apparatus used:

i) IS Sieve of size 425µm

ii) Oven
iii) Balance, with an accuracy of 0.01g
iv) Graduated glass cylinder- 2 nos., each of 100ml capacity

Procedure to determine free swell index of soil:

i. Take two specimens of 10g each of pulverized soil passing through 425µm IS Sieve and
oven-dry.
ii. Pour each soil specimen into a graduated glass cylinder of 100ml capacity.
iii. Pour distilled water in one and kerosene oil in the other cylinder upto 100ml mark.
iv. Remove entrapped air by gently shaking or stirring with a glass rod.
 v. Allow the suspension to attain the state of equilibrium (for not less than 24hours).
vi. Final volume of soil in each of the cylinder should be read out.
Reporting of results:
Free swell index = [Vd - Vk] / Vk x 100%
Where,

Vd = volume of soil specimen read from the graduated cylinder containing distilled water.
Vk = volume of soil specimen read from the graduated cylinder containing kerosene.

Determination of dry density and optimum moisture content of soil:

This test is done to determine the maximum dry density and the optimum moisture content of
soil using heavy compaction as per IS: 2720 (Part 8) – 1983.The apparatus used is
 i. Cylindrical metal mould – it should be either of 100mm dia. and 1000cc volume or
150mm dia. and 2250cc volume and should conform to IS: 10074 – 1982.
ii. Balances – one of 10kg capacity, sensitive to 1g and the other of 200g capacity, sensitive
to 0.01g
iii. Oven – thermostatically controlled with an interior of non corroding material to maintain
o
temperature between 105 and 110 C
iv. Steel straightedge – 30cm long
v. IS Sieves of sizes – 4.75mm, 19mm and 37.5mm

Preparation of sample:
A representative portion of air-dried soil material, large enough to provide about 6kg of material
passing through a 19mm IS Sieve (for soils not susceptible to crushing during compaction) or
about 15kg of material passing through a 19mm IS Sieve (for soils susceptible to crushing during
compaction), should be taken. This portion should be sieved through a 19mm IS Sieve and the
coarse fraction rejected after its proportion of the total sample has been recorded. Aggregations
of particles should be broken down so that if the sample was sieved through a 4.75mm IS Sieve,
only separated individual particles would be retained.

Procedure to determine the maximum dry density and the optimum moisture
content of soil:
A) Soil not susceptible to crushing during compaction:

i. A 5kg sample of air-dried soil passing through the 19mm IS Sieve should be taken. The
sample should be mixed thoroughly with a suitable amount of water depending on the
soil type (for sandy and gravelly soil – 3 to 5% and for cohesive soil – 12 to 16% below
the plastic limit). The soil sample should be stored in a sealed container for a minimum
period of 16hrs.
ii. The mould of 1000cc capacity with base plate attached should be weighed to the nearest

1g (W1). The mould should be placed on a solid base, such as a concrete floor or plinth
and the moist soil should be compacted into the mould, with the extension attached, in
five layers of approximately equal mass, each layer being given 25 blows from the 4.9kg
rammer dropped from a height of 450mm above the soil. The blows should be distributed
uniformly over the surface of each layer. The amount of soil used should be sufficient to
fill the mould, leaving not more than about 6mm to be struck off when the extension is
removed. The extension should be removed and the compacted soil should be leveled off
carefully to the top of the mould by means of the straight edge. The mould and soil
should then be weighed to the nearest gram (W2).
iii. The compacted soil specimen should be removed from the mould and placed onto the
mixing tray. The water content (w) of a representative sample of the specimen should be
determined.
iv. The remaining soil specimen should be broken up, rubbed through 19mm IS Sieve and
then mixed with the remaining original sample. Suitable increments of water should be
added successively and mixed into the sample, and the above operations i.e. ii) to iv)
should be repeated for each increment of water added. The total number of
determinations made should be at least five and the moisture contents should be such that
the optimum moisture content at which the maximum dry density occurs, lies within that
range.

B) Soil susceptible to crushing during compaction:

Five or more 2.5kg samples of air-dried soil passing through the 19mm IS Sieve, should be
taken. The samples should each be mixed thoroughly with different amounts of water and stored
in a sealed container as mentioned in Part A)
C) Compaction in large size mould:
For compacting soil containing coarse material upto 37.5mm size, the 2250cc mould should be
used. A sample weighing about 30kg and passing through the 37.5mm IS Sieve is used for the
test. Soil is compacted in five layers, each layer being given 55 blows of the 4.9kg rammer. The
rest of the procedure is same as above.

Reporting of results:
Bulk density Y(gamma) in g/cc of each compacted specimen should be
calculated from the equation,
Y(gamma) = (W2-W1)/ V
where, V = volume in cc of the mould.

The dry density Yd in g/cc

Yd = 100Y/(100+w)
The dry densities, Yd obtained in a series of determinations should be plotted against the
corresponding moisture contents. A smooth curve should be drawn through the resulting points
and the position of the maximum on the curve should be determined.

A sample graph is shown below:

The dry density in g/cc corresponding to the maximum point on the moisture content/dry density
curve should be reported as the maximum dry density to the nearest 0.01. The percentage
moisture content corresponding to the maximum dry density on the moisture content/dry density
curve should be reported as the optimum moisture content and quoted to the nearest 0.2 for
values below 5 percent, to the nearest 0.5 for values from 5 to 10 percent and to the nearest
whole number for values exceeding 10 percent.

Determination of plastic limit and liquid limit of soil:

This test is done to determine the plastic limit of soil as per IS: 2720 (Part 5) – 1985.The plastic
limit of fine-grained soil is the water content of the soil below which it ceases to be plastic. It
begins to crumble when rolled into threads of 3mm dia. The apparatus used:

i) Porcelain evaporating dish about 120mm dia.

ii) Spatula
iii) Container to determine moisture content
iv) Balance, with an accuracy of 0.01g
v) Oven
vi) Ground glass plate – 20cm x 15cm
vii) Rod – 3mm dia. and about 10cm long

Preparation of sample:
Take out 30g of air-dried soil from a thoroughly mixed sample of the soil passing through

425µm IS Sieve. Mix the soil with distilled water in an evaporating dish and leave the soil

mass for naturing. This period may be upto 24hrs.

Procedure to determine the plastic limit of soil:

i. Take about 8g of the soil and roll it with fingers on a glass plate. The rate of rolling
should be between 80 to 90 strokes per minute to form a 3mm dia.
ii. If the dia. of the threads can be reduced to less than 3mm, without any cracks appearing,
it means that the water content is more than its plastic limit. Knead the soil to reduce the
water content and roll it into a thread again.
iii. Repeat the process of alternate rolling and kneading until the thread crumbles.
iv. Collect and keep the pieces of crumbled soil thread in the container used to determine the
moisture content.
v. Repeat the process at least twice more with fresh samples of plastic soil each time.
Reporting of results:
The plastic limit should be determined for at least three portions of the soil passing through
425µm IS Sieve. The average water content to the nearest whole number should be reported.
This test is done to determine the liquid limit of soil as per IS: 2720 (Part 5) – 1985. The liquid
limit of fine-grained soil is the water content at which soil behaves practically like a liquid, but
has small shear strength. Its flow closes the groove in just 25 blows in Casagrande’s liquid limit
device. The apparatus used :-
i. Casagrande’s liquid limit device
ii. Grooving tools of both standard and ASTM types
iii. Oven
iv. Evaporating dish
v. Spatula.
vi. IS Sieve of size 425µm.
vii. Weighing balance, with 0.01g accuracy.
viii. Wash bottle.
ix. Air-tight and non-corrodible container for determination of moisture content.

Preparation of sample:
i) Air-dry the soil sample and break the clods. Remove the organic matter like tree roots, pieces
of bark, etc.
ii) About 100g of the specimen passing through 425µm IS Sieve is mixed thoroughly with
distilled water in the evaporating dish and left for 24hrs for soaking.
Procedure to determine the liquid limit of soil:

i. Place a portion of the paste in the cup of the liquid limit device.
ii. Level the mix so as to have a maximum depth of 1cm.
iii. Draw the grooving tool through the sample along the symmetrical axis of the cup,
holding the tool perpendicular to the cup.
iv. For normal fine grained soil: The Casagrande’s tool is used to cut a groove 2mm wide at
the bottom, 11mm wide at the top and 8mm deep.
v. For sandy soil: The ASTM tool is used to cut a groove 2mm wide at the bottom, 13.6mm
wide at the top and 10mm deep.
vi. After the soil pat has been cut by a proper grooving tool, the handle is rotated at the rate
of about 2 revolutions per second and the no. of blows counted, till the two parts of the
soil sample come into contact for about 10mm length.
vii. Take about 10g of soil near the closed groove and determine its water content.
viii. The soil of the cup is transferred to the dish containing the soil paste and mixed
thoroughly after adding a little more water. Repeat the test.
 ix. By altering the water content of the soil and repeating the foregoing operations, obtain at
least 5 readings in the range of 15 to 35 blows. Don’t mix dry soil to change its
consistency.
x. Liquid limit is determined by plotting a ‘flow curve’ on a semi-log graph, with no. of
blows as abscissa (log scale) and the water content as ordinate and drawing the best
straight line through the plotted points.

Reporting of Results:
Report the water content corresponding to 25 blows, read from the ‘flow curve’ as the liquid
limit.

A sample ‘flow curve’ is given as:

Flakiness index and elongation index of coarse aggregates:

Aim:
i. To determine the elongation index of the given aggregates.
ii. To determine the flakiness index of the given aggregates.

Apparatus:
The apparatus for the shape tests consists of the following:
i. A standard thickness gauge.
ii. A standard length gauge.
iii. IS sieves of sizes 63, 50 40, 31.5, 25, 20, 16, 12.5,10 and 6.3mm.
iv. A balance of capacity 5kg, readable and accurate up to 1 gm.

Theory:
The particle shape of aggregates is determined by the percentages of flaky and elongated
particles contained in it. For base course and construction of bituminous and cement concrete
types, the presence of flaky and elongated particles are considered undesirable as these cause
inherent weakness with possibilities of breaking down under heavy loads. Thus, evaluation of
shape of the particles, particularly with reference to flakiness and elongation is necessary. The
Flakiness index of aggregates is the percentage by weight of particles whose least dimension
(thickness) is less than three- fifths (0.6times) of their mean dimension. This test is not applicable
to sizes smaller than 6.3mm. The Elongation index of an aggregate is the percentage by weight
of particles whose greatest dimension (length) is greater than nine-fifths (1.8times) their mean
dimension. This test is not applicable for sizes smaller than 6.3mm.
Procedure:
i. Sieve the sample through the IS sieves (as specified in the table).
 ii. Take a minimum of 200 pieces of each fraction to be tested and weigh them.

iii. In order to separate the flaky materials, gauge each fraction for thickness on a thickness
gauge. The width of the slot used should be of the dimensions specified in column (4) of
the table for the appropriate size of the material.
iv. Weigh the flaky material passing the gauge to an accuracy of at least 0.1 per cent of the
test sample.
v. In order to separate the elongated materials, gauge each fraction for length on a length
gauge. The width of the slot used should be of the dimensions specified in column (6) of
the table for the appropriate size of the material.
vi. Weigh the elongated material retained on the gauge to an accuracy of at least 0.1 per cent
of the test sample.
Observations:
Flakiness Index = (X1+ X2+…..) / (W1 + W2 + ….) X 100
Elongation Index = (Y1 + Y2 + …) / (W1 + W2 + ….) X 100
Result:
i. Flakiness Index =
ii. Elongation Index =

Aggregate impact value test:

This test is done to determine the aggregate impact value of coarse aggregates as per IS: 2386
(Part IV) – 1963. The apparatus used for determining aggregate impact value of coarse
aggregates is:
i. Impact testing machine conforming to IS: 2386 (Part IV)- 1963.
ii. IS Sieves of sizes – 12.5mm, 10mm and 2.36mm.
iii. A cylindrical metal measure of 75mm dia. and 50mm depth.
iv. A tamping rod of 10mm circular cross section and 230mm length, rounded at one end and
Oven.
i. Preparation of sample:

The test sample should conform to the following grading:

- Passing through 12.5mm IS Sieve – 100%
- Retention on 10mm IS Sieve – 100%
ii. The sample should be oven-dried for 4hrs. at a temperature of 100 to 110oC and cooled.
iii. The measure should be about one-third full with the prepared aggregates and tamped
with 25 strokes of the tamping rod.
A further similar quantity of aggregates should be added and a further tamping of 25 strokes
given. The measure should finally be filled to overflow, tamped 25 times and the surplus
aggregates struck off, using a tamping rod as a straight edge. The net weight of the aggregates in
the measure should be determined to the nearest gram (Weight ‘A’).

i.
Procedure to determine aggregate impact value:
i. The cup of the impact testing machine should be fixed firmly in position on the base of
the machine and the whole of the test sample placed in it and compacted by 25 strokes of
the tamping rod.
ii. The hammer should be raised to 380mm above the upper surface of the aggregates in the cup
and allowed to fall freely onto the aggregates. The test sample should be subjected to a total
of 15 such blows, each being delivered at an interval of not less than one second.
Reporting of results:
i. The sample should be removed and sieved through a 2.36mm IS Sieve. The fraction passing
through should be weighed (Weight ‘B’). The fraction retained on the sieve should also be
weighed (Weight ‘C’) and if the total weight (B+C) is less than the initial weight (A) by
more than one gram, the result should be discarded and a fresh test done.
ii. The ratio of the weight of the fines formed to the total sample weight should be
expressed as a percentage.

Aggregate impact value = (B/A) x 100%.

iii. Two such tests should be carried out and the mean of the results should be reported

Determination of bituminous content:

i. This test is done to determine the bitumen content as per ASTM 2172. The apparatus
needed to determine bitumen content are:-Centrifuge extractor.

ii. Miscellaneous – bowl, filter paper, balance and commercial benzene.

iii. A sample of 500g is taken.

 Procedure to determine bitumen content:

i. If the m ixture is not soft enough to separate with a trowel, place 1000g of it in a
o
large pan and warm upto 100 C to separate the particles of the mixture uniformly.
ii. Place the sample (Weight ‘A’) in the centrifuge extractor. Cover the sample with
benzene; put the filter paper on it with the cover plate tightly fitted on the bowl.
iii. Start the centrifuge extractor, revolving slowly and gradually increase the speed until
the solvent ceases to flow from the outlet.
iv. Allow the centrifuge extractor to stop. Add 200ml benzene and repeat the procedure.
v. Repeat the procedure at least thrice, so that the extract is clear and not darker than the
light straw colour and record the volume of total extract in the graduated vessel.
vi. Remove the filter paper from the bowl and dry in the oven at 110 + 5oC. After
24hours, take the weight of the extracted sample (Weight ‘B’).

Reporting of results:
i. Bitumen content = [(A-B)/B]×100 %
ii. Repeat the test thrice and average the results.
References:

BSCPL Engineer s book

MORTH
Highway Engineering by S.K. Khanna and C.E.G. Justo
Transportation Engineering by L.R. Kadiyali
Highway Material Manual [JNTU]