SHAPOORJI PALLONJI & CO. LTD.

SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

Method statement for Bituminous concrete 25mm thick (BC)

CONTENTS

Sr. No. TITLE

1 INTRODUCTION

2 GENERAL

3 PHYSICAL REQUIREMENTS
4 COMPACTION
5 CONSTRUCTION OPERATIONS
6 SURFACE FINISH & QUALITY CONTROL WORKS

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

1.0 Introduction
This method statement covers all the procedures to be adopted for bituminous concrete consisting of
mixing materials, transportation, spreading and compacting on approved Sub base course. Work shall
consist of single layer of bituminous concrete on a previously laid DBM.
2.0 Abbreviation

CM – Construction Manager
SE - Site Engineer
SEO – Safety & Environmental Officer
ME – Material Engineer
PPE – Personal Protective Equipment
Man Power Equipment
CM Hot Mix Plant
SE Sensor Paver
ME Compactor / Roller (8 to 10 Ton)
pneumatic roller (12-15 tonne) or
vibratory roller
SEO Transport trucks
Lab Technicians & Helpers Level Instruments
Surveyor Safety Inventory
Survey Helpers Sufficient barricade tapes.
Supervisor/Foreman Traffic cones
Driver – Distributor
Driver - Dump Truck
Skilled & Unskilled laborers

3. Material:
Bitumen:
1. Bitumen shall be paving bitumen of penetration grade 60/70 as per IS 73.
Coarse Aggregate:

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

1. Coarse aggregate shall be crushed rock, crushed gravel or hard material retained on 2.36mm sieve.
it shall be clean, hard, durable, cubical shape and free from deleterious material.
2. Physical requirement of coarse aggregate is mentioned in table no 500-17 of MORTH
Specification.
Property Test specification
Cleanliness Grain size analysis Max 5% passing on 75micron sieve

Particle shape Flakiness and elongation index Maximum 30%

combined
strength Los Angeles abrasion value Maximum 30%
Aggregate impact value Maximum 24%

polishing polished stone value min 55

Durability soundness
Sodium sulphate Max 12%
Max 18%
Magnesium sulphate

water water absorption max 2%

absorption

.Aggregate grading and binder content:

1. Combined aggregate grading of grade II for mixture within the limit shown in table 500-18 of
grading 2 of MORTH Specification.
Mix designation Nominal Grading 2
Aggregate size Layer thickness 10 mm
IS Sieve 25 to 30mm

45 -
37.5 -

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

26.5 -
19 100
9.0
13.2 Minimum stability (KN at 60º C)79-100
9.5 70-88 2& 4
Minimum flow(mm) & Maximum flow
4.75mm 53-71
75 blows of each of the two faces of
2.36 Compaction level(number of blows)
42-58 specimen
1.18 34-48
3-6
Per cent air voids
0.6 26-38
AS PER TABLE 500-12
0.3 Percent voids in mineral aggregate(VMA)
18-28
loss of stability on immersion in water at
0.15 60º C
12-20
(ASTM D 1075) Minimum 75% retained strength
0.075 4-10
Binder Content, % by weight of total 5-7.0%
mixture
Bitumen grade 60/70

4. Mixture design: Apart from conformity with grading and quality requirements for individual
requirements, the mixture shall meet following requirement as per table 500-19 of MORTH
Specification.

Table 500-19(Morth specification)

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

5. Construction Process:
Preparation of base:
1. Surface on which the bituminous work is to be laid shall be cleaned of all loose and extraneous
matter by means of a mechanically or manually.
2. Filling of pot holes and patch repairs: each pot hole and patch repair area shall be inspected and all
loose material removed. Area shall be thoroughly cleaned with compressed air or any other
appropriate method.
3. Excavated patch shall be replaced using material equivalent to the original material.
Application of tack coat:
1. Binder used for tack coat shall be LOW VISOCCITY bitumen emulsion
complying of IS 8887.
2. Bituminous primer shall not apply to a wet surface or during a dust storm or in
foggy weather.
3. Surfaces which are to receive prime coat shall be free from stagnant water.
4. Primer distributor shall be self-propelled or towed pressure sprayer equipped for
spraying the material uniformly at specified rates and temperatures.
5. Rate of application of low viscosity tack coat shall be 0.25 to 0.3 kg/sqmt.
6. A tack surface shall not open to traffic other than that of necessary to lay next
course.

Application of Bituminous course

Mixing
1. Pre-mix dense bituminous macadam material shall be prepared in hot mix plant of enough
capacity and capable of yielding a mix of proper and uniform quality with thoroughly coated
aggregate.
2. Appropriate mixing temperature shall be as per table 500-5 of Morth Specification.

Bitumen Bitumen Aggregate Mixed Rolling (ºC) Laying (ºC)

preparation mixing (ºC) mixing (ºC) material (ºC)

35 160-170 160-175 170 max 100 min 130 min

65 150-165 150-170 165 max 90 min 125 min

90 140-160 140-165 155 max 80 min 115 min

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

3. Difference between binder and aggregate should not exceed 14ºC at any time.
Transportation:
1. Bituminous material shall be supplied in clean vehicles.
2. Subject to approval of client, a thin coat of diesel or lubricant may be applied to interior surface of
the vehicle to facilitate smooth discharge.
Laying:
1. Laying shall be suspended while free standing water is present on surface, during rain, fog and
storm.
2. After rain, coated surface shall be blown of with pressure air jet to remove excess moisture, or
surface left to dry before laying bituminous course.
3. Surface on which bituminous concrete is to be laid shall be free from loose material by manually
or mechanical means.
4. As soon as possible, after arrival at site, it shall be continuously supplied to the paver and laid
without delay.
Spreading:
1. Travel rate of the paver, and its method of operations, shall be adjusted to ensure an even and
uniform flow of bituminous material across the screed, free from dragging, tearing and segregation
of material.
2. In areas with restricted space where a mechanical paver cannot be used, the material shall be
spread, raked and leveled with suitable hand tools by experienced staff.
3. Minimum thickness of material laid in one paver pass shall be above 25mm or such that so as to
after compaction it will get compacted 25 mm thickness.
Compaction:
1. Bituminous material shall be laid and compacted in such a manner that it will achieve desire
thickness, surface level, irregularity requirements and proper compaction.
2. Compaction of bituminous material shall start immediately after spreading operation completed.
3. Rolling of the longitudinal joints shall be done immediately behind the paving operation.
4. Roller shall first compact material adjacent to the joint.
5. Rolling shall commence at the edge and progress towards the center, overlapping on successive
passes by at least one third width of the rear roll.
6. Rolling shall continue until all roller marks removed from the surface.
7. All deficiencies in the surface after laying shall be made good by the attendants behind the paver,
before initial rolling is commence.
8. The intermediate rolling shall be done by 8-10 tones dead weight smooth-wheeled surface. The
intermediate rolling shall be done by 8-10 tonnes dad weight or vibratory roller or with a
pneumatic tyre roller of 12-15 tonne weight having nine wheels, with a tyre pressure of at least 5-6
kg/sqcm.
9. Roller move at a speed not more than 5 km/hour.
10. Wheels of rollers shall be kept moist with water, and the spray system provided with the machine
shall be in good working condition, to prevent mixture from adhering to the wheels.
11. Newly laid surface shall not be open to traffic for at least 24 hours after laying and completion of
compaction.

7. Surface Level:
Tolerance in surface level
Wearing course for flexible payment machine laid ±6 mm.

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

For checking the compliance with the above requirements for bituminous wearing course,
measurement of the surface level shall be taken on a grid of points spaced at 6.25 mtr along the
length and 0.5 mtr at the edge and center of the pavement.
8. Surface regularity of pavement course:
Maximum allowable difference between the road surface and underside of a 3 meter straight-edge
when placed parallel with or at right angles to the center line of the road at points for bituminous
course shall be 3 mm.
9. Quality Control test during construction:
Control test and their minimum frequency for bituminous works
Sr. Type of Test frequency
no layer

1 Prime (i)Quality of Binder (I)Two samples per lot

coat/tack (ii)Binder temperature (ii) at regular intervals randomly
coat for application
2. Bituminous
concrete (i)Aggregate impact
value (i)one test per 50 cum of agg at internal
(ii) Flakiness and laboratory
elongation index (ii) –do-
(iii) water absorption
of aggregate (iii) change of source
(iv) sand equivalent
test (iv) as required
(v) stone polishing
value (v) as required for BC
(vi) Mix grading
(vi) One set of test on individual aggregates
and mixed aggregate from the dryer for each
400 tonnes of mix subject a ID a minimum of
(vii) stability of mix two test per day.
(vii) for each 400 tonne of mix produced, a set
of 3 Marshall specimens to be prepared and
tested for stability, flow value, density and
void content subject ot a minimum two sets
(viii) water sensitivity per plat per day.
of mix (viii) as required
(ix) swell test on the
mix (ix) as required
(x) control of
temperature of binder (x) at regular intervals
in boiler, aggregate in
the dryer and mix at
the time of laying and
rolling
(xi) rate of spread of

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

mixed material
(xi) regular control and through checks on the
(xii) Density of weight of mixed material and layer thickness
compacted layer (xii) One test per 250 sqmt area.

10. QUALITY ASSURANCE

1. All the activities shall be in compliance with approved quality plan.

2. ITP shall be provided.
3. Inspection test report shall be generated prior to commencement of the activity,
any short fall shall be attended at earliest and ITR shall be closed.
4. Carrying out of BC shall be in accordance with the check list.
5. The Bituminous surface shall be protected against damage until acceptance by
the engineer.
6. The traffic shall be opened only after completion of activity.

11. HSE – HEALTH, SAFETY AND ENVIRONMENT.

All necessary precautions shall be taken in accordance with HSE Plan

11.1 RISK IDENTIFICATION

During the whole process of work the following risks are foreseen:

1. Chances of vehicle overturning

2. If bituminous course is done, chances of getting air pollution through diesel
machinery.
3. Chances of getting burn.

11.2 RISK MANAGEMENT

SPCL shall comply with all the necessary mitigation measure as stated in Job safety
analysis. The risk management can be separated into general safety consideration and
those that are particularly applicable to the actual work at site.

a. General Safety Considerations:

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

The following safety precautions shall be followed during construction.

1. All the workers shall wear proper personal protective equipment.
2. All the workers & staff personals shall be trained well in works to be
executed at height & precautionary & corrective measures to be taken for
the same.
3. All the workers shall be trained and safety induction shall be imparted to
them before the commencement of work at site.
4. Daily tool box talk shall be carried out for mutual understanding of work.
5. Regular or daily check of equipment prior to use shall be carried out and
shall be recorded.
6. A competent site supervisor shall be present at all times during work.
7. A first aid person shall be present at site and a first aid kit shall be
provided in site office.
8. All record of operator and plant certificate shall be kept on site at all the
times.
9. Emergency call numbers shall be posted on site for contact in emergency.

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati
 SHAPOORJI PALLONJI & CO. LTD. SPCL

FIPL2-1-SPC-QM-CVL-P00-PNT-299012
QUALITY MANAGEMENT

PROJECT PROCEDURE PLAN – FIPL#2, Phase 1

REVISION NO. 1B
DATE 12-04-2013
PREPARED BY Vivek Contractor
(SPCL)
APPROVED BY Mr. B.C Gangavati