CHAPTER 1.

INTRODUCTION

1.1General Background

In our study we have included a stretch of the construction of flexible pavement and
strengthening of existing pavement. In this project we studies design, construction methods
and difficulties faced in construction of the flexible pavement . During 7th semester survey,
traffic and design of flexible pavement using IRC: 37-2012 has been completed.

During 8th Semester construction aspects and use of various construction methodology and
machineries have studied in detail. Construction aspects included the use of various
Materials, machines, and Manpower. Also Quality Assurance (QA) & Quality Control (QC),
aspects incorporated in the construction procedure have been studies and these are included
in the project report. Testing of various material is carried out for Quality Assurance and
Quality Control of the flexible pavement.

1.2Objectives of the Project

 The main goal of this study is to get an insight of the design and construction aspects
and problems faced in the expansion/widening of roads. To evaluated the various
tasks, methodologies which are undertaken foe the design and construction of a
Highway pavement.

 To study how to achieve a sound and economical engineering design considering the
various factors VIZ. climate: quality of local materials, construction technology,
environmental condition etc.

 To study the complex design process considering realistic assessment of subgrade

strength, traffic loads & traffic projection, environmental factors and several other
factors.

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 To study the general design procedure has been based on the design of new
pavement structure done as per IRC: 37(Guidelines for the design of flexible
pavement). It includes study of the various design parameters.

 To study the Impact of use of Construction machinery on the construction schedule.

Examining of critical aspects of soil and material testing. To study impact on environmental
aspects due to highway construction.

 To study the various steps taken for completion of the works within estimated budget
and time also maintaining the quality of works as per required specifications.

1.3Main Components of Methodology

The works includes construction of following:-

1 Road works Via: Site Clearance, Survey, Earthwork, Sub Base & Base Course, and
Bituminous Works.

2 Drainage & Protective Work.

.
3 Traffic Sings, Markings and Road Accessories.

4 Miscellaneous and Maintenance of Road.

The methodology includes the use of various equipment’s to carry out the various procedure
such as the site clearance, Earthwork, bituminous works etc. as per the required specifications.

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 CHAPTER 2.
DETAILS OF THE PROJECT
2.1 General
Name of Work BT Road Construction

Name of Division PWD, Chaksu

Name of Road Chaksu To Paghi

Name of Project Missing Link Project

2.2 Brief Specification

1. Earth work for Embankment

2. Granular sub-base for Shoulder & Sub-Base

3. 150mm WBM

4. 20mm PMC with seal coat

5. 50mm BM

6. WBM & PMC patches

7. Road furniture work

2.3 Data Table

CBR Values 4.80%

Annual Growth Rate of Traffic 6%
Design Life 10 Years
Width of Road 5.50m
Shoulders Width 1.50m
Thickness of GSB Shoulders 150mm
Camber 3%
Proposed Thickness of WBM 150mm

Proposed Thickness of BM 50mm

Table 2.3 Pavement Detail

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 CHAPTER 3.
BITUMINOUS ROAD CONSTRUCTION

3.1 Introduction
Road is route or way on land for improved to allow travel by some Convince including a horse,
cart, bicycle, bus, truck and two wheeler. Road is line of communication using a stabilized base
other than rails or air strips open to public traffic, primarily for the use of road motor vehicles
running on their own wheels which includes bridges, tunnels, supporting structures, crossing,
junctions. Road consist of one or two roadways each with one or more lanes and associated
sidewalks and road verges.

The bituminous or flexible pavement is those which on the whole have low or negligible
flexural strength nd rather flexible in their structural action under the loads. The surface of the
bitumen road way is stable and non-yielding to allow the heavy well loads of road traffic to
move with least possible rolling resistance. The bitumen road surface is prepare in four layers
soil sub grade, granular sub-base or drainage layer, granular base course, surface course.

Figure 3.1 Components of Flexible pavement

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3.2 Components of Flexible Pavement

1. Wearing Surface- It performs following functions:

1. Provides a smooth riding quality

2. Provides abrasion resistance

3. Makes road dust proof

4. Prevents water from entering the pavement

2. Base Course- It performs following functions:

1. Withstands the high stresses included by traffic.
2. Distributes load to lower layers

Sub-Base Course- It performs following functions:

1. Two layer tighter distribute the load
2. Helps in draining the water away from the road
3. Prevents intrusion of embankment soil into the pavement

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 CHAPTER 4.
CONSTRUCTION METODS AND EQUIPMENTS
4.1 Major Construction Activities

 Clearing and grubbing

 Excavation

 Embankment and sub-grade construction

 Granular sub-base

 Wet mix macadam.

 Prime coat

 Dense bituminous macadam

 Bituminous conc

4.2 Method Statement for Clearing and Grubbing

Clearing:-
This term is used by civil engineers to denote the falling and removing of tress and brush.
But farmers usually apply the term “clearing” to stumping and burning stumps, as well as to
cutting down tress and brush.

Grubbing:-
Civil engineers use grubbing to denote the removal of stumps and roots, whether by blasting,
pulling, or otherwise; and it is often specified that he term “grubbing” is to include burning
the stumps.

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 Figure 4.1 Grubbing

4.2.1 PROCESS

o Toe line will be marked with the help of survey equipment’s.

o Clearing of top grass bushes &shrubs are done mechanically with Excavator or
Dozer and manually
.
o Stumps and roots are removed by the help of Backhoe and also the top soil up to
150 mm thickness shall be removed.

o The materials arising after clearing and grubbing operational shall be disposed of.
The topsoil will be stocked for future use within provided ROW on other side of
widening area.

o Ditches and pits obtaining from uprooting of trees roots etc. shall be filled by
suitable material.

4.2.1 Clearing Equipment

The use of engineer equipment is the most rapid and efficient method of clearing.
The use of such equipment is limited only by un- usually large tress, stumps, and terrain
that decrease the maneuverability of the equipment and increase maintains requirements.
The type of equipment includes bulldozers; tree-dozer, tractor mounted units; winches;
power saw; rippers; and motor graders.
In addition, pioneer tools are used for some clearing operations.

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Bulldozer:-When clearing an area in dry or temperate foresters, the bulldozer is the most
efficient mechanical equipment foe removing small brush, trees and stumps up to 6 inches in
diameter. Although more time effort are required, bulldozers can also remove trees up to30
inches in diameter when tractor-mounted clearing units and power saws are not available.

Winches:-Towing winches mounted on tractor-dozer units or trucks are limited in use for
clearing operations because of their small capacities in comparison with the tree and stumps-
pulling units.

Felling Equipment:-Filling can be done with hand tools or power equipment. Axes two-
man saws, shovels, pick-mattocks, and machetes are used to chop or saw down standing timber,
dig uproot stumps; and slash grass, vines, and undergrowth.

Grader:-The grader is used 10 cut grass and weeds, remove small brush, and clear the area of
dead vegetation, The terrain must be level and free from boulders and trees.

Used with rippers and bulldozer, graders can windrow the cleared material for later removal by
other equipment.

4.3 Method Statement for Excavation

Earthwork includes the excavation of existing earth material and any placement of fill material
required for constructing the embankment.

Excavation consists of the following:

(1) Roadway excavation

All material excavated from within the right of –way or casement areas, except sub excavation.

Roadway excavation includes all material encountered regardless of its nature or characteristics.

(2) Sub excavation-

Material excavated from below sub grade elevation in cut sections or from below the original
ground line

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 (3) Borrow excavation

Material used for the embankment construction that is obtained from outside the roadway prism.
Borrow excavation includes unclassified borrow, select borrow, and select topping.

Embankment less than 1 meter high over natural ground. Completely break up the cleared
ground surface to a minimum depth of 150 mm by plowing or scarifying.

4.3.1 Excavation Process

 Working area within ROW for excavation is to be fixed according to drawing .

Boundary / toe line points shall mark with lime.

 The excavation shall be done by using manpower, excavator, blasting as per requirement
to avoid minimum disturbance to the existing traffic. The excavated material shall be
done in three categories and stocked / used or spoiled as appropriate.

o Rock / Boulder
o Useful material for embankment, GSB, Backfilling etc.
o Excess Material / unsuitable material

Figure 4.2 Excavation

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  The excavated slope will be trimmed properly and filling of loose material after
completion of work will be taken care.
 Required level will be marked on the each peg to control of excess excavation.
 The Engineer will be informed through RFI for inspection of excavation sites and level
checking.
 After achieving final excavation level next activity will be executed.

4.4 Method Statement for Embankment and Sub-Grade Construction

4.4.1 Embankment Process

 The embankment is constructed by spreading the loose sol and compacting same at the
optimum moisture contained of the soil in layers the compacted thickness of layer.
 Water is add for spread so as to obtain the optimum moisture contained of the soil than
the soil is mixed with water by the different types of equipment’s and then after
sometimes the water get distributed in the soil layers uniformly
 The soil layer is compacted by rolling using vibrator rollers for obtain the specified
density.
 The soil is spread again the already compacted layer and water is added and mix and
again compacted. This process is repeated at the one meter height of the embankment

Figure 4.3 Embankment

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4.4.2 Embankment Equipment

1. Excavator
2. Dozer
3. Tipper Truck
4. Motor Grader
5. Vibro Roller
6. Water Tanker
7. Tractor

4.5 METHOD STATEMENT FOR GRANULAR SUB BASE

Water is present in pavement materials in the form of free water , capillary water ,bound
moisture ,Or water vapor .Free water is the form of most concern because it can decrease the
strength of The pavement and is the only form of water that can be significantly removed by
gravity drainage .The source of water in pavements is atmospheric precipitation. This water can
Enter the pavement through several ways and is removed by an energy gradient such as Gravity
and capillary forces. The free water can be removed by draining vertically through the Subgrade
or laterally through a drainage layer.

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 Figure 4.4 Granular sub-base

A. Materials:-
The material used in GSB should be mixture of natural sand, moorum ,gravel, crused Stone
,shall satisfy grading of MORT&H specification. The required testing will be Done and test
report will be forwarded to the engineer after the tested material satisfied the specification
requirement. The material for GSB shall be obtained from the approved source

B. Preparation of GSB
Prior to laying of GSB, approved sub grade is rolled with two passes by 80-100 KN smooth
wheeled roller with slight sprinkle of water.

C. Spreading and compacting

The granular sub bas (GSB) material is spread with the help of motor grader on the Approved
layer of sub grade. During spreading and mixing by grader in site, water is sprinkled over the
material by water browser mounted on water tanker. Sufficient Water is taken into account of
evaporation losses so that moisture content of the Materials should lie in between 1 to 2% of
optimum moisture content.
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 D. Equipment’s

1. Excavator
2. Dozer
3. Tipper Truck
4. Motor Grader
5. Vibro Roller
6. Water tanker Tractor
7. Tractor

4.6 Method of Statement for Wet Mix Macadam

This is coarse aggregate in required proportion along with the fines. They are
mixed with water in a WMM pug mill of 160tph capacity and brought to the site in
trucks .It is laid in two layers .For the first layer, the material is spread along the
girder. The Second layer is laid with the help of hydrostatic paver with sensor.
Rolling is done with the help of vibrio layers of 10T to 18T to achieve desired
compaction.

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 Figure 4.5 WMM
4.6.1 Construction Procedure

(1) Preparation of base

While constructing wet mix macadam arrangement shall be made for the lateral
confinement of wet mix. This shall be done by laying materials on
Adjoining shoulder along with that of WMM layer.

(2) Preparation and transportation of mix

WMM shall be prepared in the wet mix plant at site. The mixed material shall be
immediately transported to prepared sites by using tipper trucks.
(3) Spreading

The plant mix. WMM at OMC within the variation limits from OMC as will be decided in the
trail mix, be transported to the site in dumpers and shall be spread uniformly upon the
prepared Sub-Base/base in required quantities .The Mix shall be spread either by paver finisher
or motor grader as per site condition. For portion where mechanical means cannot be used,
Manual means as per approved by the Engineer shall be used. The level and gradient will be
controlled by the electronic to the paver or with the level peg.

(3) Compaction

After the mix has been laid on site to the required thickness, on grade and camber, then
compaction is carried out with suitable roller to the full depth. For a compaction up to 200mm

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in a single layer, compaction shall be done with vibratory roller of 80 to 100 KN static weights
with plain drum or equivalent capacity roller. The speed of the rollers shall not exceed 5
km/hour to ensure smooth finish and better compaction.

4.6.2 Plants & Equipment’s

 Wet Mix Plant

 Paver (4.8 m width)
 Grader
 Vibratory Rollers (80/100 kn)
 Dumpers
 Water tanker/ Browser
 Back Hoe cum Loder

4.7 Method of Statement for Laying of Prime Coat

Prime Coat:-
Typically is application of low viscosity bitumen over a granular base, preparing it laying an asphalt
mixture on it. A prime coat performs several important functions.

o Coats and bonds losses materials particles on the surface of the base.
o Hardness or toughness surface of the base.
o Waterproofs the surface of the base by plugging capillary or interconnected voids.

o Provides adhesion or bond between the base and the asphalt mixture.
o Bitumen emulsions used for Prime Coat are Catinic Slow Setting Emulsion 1 and
Cationic Slow Setting Emulsion 2 as per latest MOST specifications.

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 Figure 4.6 Prime Coat

Tack Coat:-
Is very light spray application of diluted asphalt emulsion to create a bond between an asphalt
overlay being placed and the existing surface. The functions performed by Tack Coat are:

o It is essential for good patching operation.

o To avoid skidding of top layer from bottom layer.
o To add strength to both the layers as it makes both layers act as one.

Figure 4.7 Tack Coat

Bitumen emulsion used for Tack Coat as Cationic Setting Emulsion 1 as per latest MOST
specifications.

A. Materials

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The primer used for prims coat shall be bitumen emulsion with IS 8887 and CSS-1 Grade
conforming to ASTM D 2397/AASHTO M 140. The particular grade and test certificate of prime
coat will be submitted to the Engineer for approval .

B. Rate of Spray
The rate of spray shall be 6 to 9kg/10sqm.

C. Equipment
Priming shall be carried out by using self-propelled pressure distributor. The distributor shall
ensure that the

D. Preparation of Base
The Wet Mix Macadam surface to be primed shall be swept clean, made free from dust and be
made dry. It shall be shaped to the specified grades and levels as per drawings. It shall be free
from any ruts, irregularities and segregated materials.

E. Application
The prime coat shall be sprayed uniformly over the WMM surface . The temperature of the
primer during application shall be such that the primer could be sprayed effectively through the
jets of the spray bar.

F. Curing
After the application of the Prime Coat, the surface shall be allowed to be cured for at least 24
hours so as to allow the penetration of the priming Material into the WMM course. During this
curing period no traffic of any kind shall be allowed to ply on the surface.

4.8 Method of Statement for Dense Bituminous Macadam

The DBM (Dense bituminous macadam) is laid with the help of asphalt paver. The mix is
batched in the Marini Mobile HMP of 120 spit capacities and it is brought to the site using
trucks. It is laid using pavers for the desired thickness. This is also laid in two

Layers. The rollers compact it before the temperature cools down. L &T case roller are used for
this purpose and the breakdown rolling is done with pneumatic Tire Rollers if 38T

4.8.1 Construction Operations

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 i. Preparation of Base
The WMM surface already prepared to the specified lines, grades and cross sections shall be
swept clean free from dust and foreign matters using mechanical broom or blown off by
compressed air as specified in the MORT&H specifications.

ii. Prime Coat

A bituminous primer emulsion shall be used per clause 502, MORT&H specifications over the
WMM surface. The range of spraying temperature will be 20 to 60 deg as specified in the
MORT&H specifications.

iii. Tack Coat

The binder for tack coat shall be Rapid Setting Emulsion and shall be applied as per clause 503
of the MORT&H specifications.

iv. Spreading
The mix shall be transported to the site by the dumpers covered with Tarpaulin, which shall
slowly discharge the mix in the paver hopper, while both the tipper and paver will move
forward steadily and slowly. The automatic sensor shall ensure that the mix is being laid to the
proper line and grade and level. The direction of the paver will be guided by the string lines
fixed with the stack & arms on both sides of the edges .5 m away from the edge. The paving will
be done in one go for the width or in two lanes running forward simultaneously. The
temperature of the mix at the time of laying shall be between 120 to 140 deg. C. Transvers
joints shall be cut vertically with asphalt cutter and a coat of bitumen Emulsion shall be applied
before placing materials .In case hot joints cannot be made, cold joints will be provided with
joint heater to attain about 80 deg. C before laying adjacent layer.

v. Compaction
As soon as the mix has been laid to the paver, compaction shall be done with the help of a set
of rollers moving at a speed not exceeding 5 km/hour following close to the paver . Rolling

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sequence will be as under or as established during trial stretch. Initial or breakdown rolling shall
be done with 80-100 KN static weights smooth wheeled rollers. No vibration will be applying
during the operation. Intermediate rolling shall be done with 80-100 KN static weights vibrator
rollers. Vibrations shall be applied during this stage and amplitude of vibration and the no. of
passes required shall be done with 60-80 KN weight smooth wheeled tandem roller as well as a
pneumatic tyre roller of 150-250 KN weight having tyre pressure of .7 MPa No vibration will be
applied in this stage. During rolling, wheels of rollers shall be kept moist by sprinkling water
from the water storage fitted with the roller to prevent the mix from adhering to the wheels.
The roller shall proceed on the fresh material with rear or fixed wheels . The roller shall proceed
on the fresh material with rear of fixed wheel leading so as to minimize the pushing of the mix.

Figure 4.8 DBM

4.8.2 Plants & Equipment

 Hot Mix Plant
 Paver
 Vibratory Roller
 Pneumatic Roller
 Bitumen Sprayer
 Dumpers

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4.9 Method of Statement for Bituminous Concrete
Over the DBM layer, the final BC is put. It gives the road a good riding quality surface the road
marking as done on BC layer. This is also done with the paver .

4.9.1 Materials
The source and test report of all material will be submitted to the Engineer before using the
material.

A. Bitumen

Bitumen shall be ordinary paving bitumen or Modified Bitumen.

B. Course Aggregates

Course aggregate shall be obtained from the aooroved quarry. Three cone crushed shall be
installed at the quarry/camp site. This crusher shall produce aggregates cubical / angular type
so that flakiness and elongation indices are contained within the specified limit .

C. Fine Aggregate
Fine aggregates shall be of the fraction passing 2.36 mm sieve and retained on 75 micron sieve,
consisting of crusher run screening , sand or a mixture of both.

Figure 4.9 Bitumen Concrete

4.9.2 Plants & Equipment

 Hot mix Plant

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  Paver
 Vibratory Rollers
 Pneumatic Roller
 Bitumen Sprayer
 Dumpers

4.9.3 Construction Operations

A. Preparation of Base

The DBM surface already prepared to the specified lines, grades and cross sections shall be
swept clean free from dust and foreign matter using mechanical broom or blown off by
compressed air as specified in the MORT&H specifications.

B. Tack Coat

The binder for tack coat shall be Rapid Setting bitumen Emulsion and shall be applied as per
clause 503 of the MORT&H specifications.

C. Preparation and Transportation of Mix

BC shall be prepared in batch Hot Mix Hot Plant. The mixing will be done in a twin shaft pug
mill, which will produce a homogeneous mix. The mixture shall be transported from the
batching plant in tippers covered with tarpaulin so as to maintain the temperature.

D. Spreading

The mix shall be transported to the site dumpers covered with Tarpaulin, which shall slowly
discharge the mix in the paver hopper, while both the tipper and paver will move forward
steadily and slowly. The automatic sensor shall ensure that the mix is being laid to the proper
line and grade and level. The direction of the layer will be guided by the string lines fixed with
the stack & arms on the both side of the edges 0.5 m away from the edge. The paving will be
done in one go for the full width or in two lanes running forward simultaneously. The
temperature of the mix at the time of laying shall be between 120 to 140 deg. C.

E. Compaction

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As soon as the mix has been laid to the paver, compaction shall be done with the help of a set
of rollers moving at a speed not exceeding 5 km/hour following close to the paver Rolling
sequence will be as under or as established during layer trial stretch.

(a ) Initial or breakdown rolling shall be done with80-100 KN static weight smooth wheeled
rollers. No vibrations n will be applied during the operation

(b) Intermediate rolling shall be done with 80-100 KN. Static weights vibratory roller.
Vibrations shall be applied during this stage and the amplitude of vibration and the no. of
passes required shall decide after laying a trial bed.

(C)) The final and finishing rolling shall be done with 60-80 KN Weights smooth wheeled
tandem rollers well as a pneumatic tyred roller of 150-250 KN weights having tyre pressure of
0.7 MPa. NO. Vibration will be applied in this stage

4.10 Method of Statement Road Marking

(A) General
The color, width and layout of road markings shall be in accordance with the code of practice
and as specified in the drawings or as directed by the Engineer.

(B) Materials
Road markings shall be hot applied thermoplastic compound and the materials shall be meet
the requirements as specified in Clause 803.4

(1) Hot applied thermoplastic compound:

This will be used by marking traffic stripes using a thermoplastic compound in the manner as
outlined below:

 The thermoplastic compound shall be screeded / extruded on to the

pavement surface in a molten state by suitable machine capable of controlled
prepetition and laying with surface application of glass beads at a specified
rate. Upon cooling to ambient temperature, it shall produce an adherent
marking of specified thickness and with and capable of deformation by traffic.

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  The color of the compound shall be white or Yellow as specified in the
drawings or as directed by the Engineer.
 Where the compound is to be applied to cement pavement, a sealing
primer as recommended by the manufacturer, shall be applied to the
pavement in advance to the stripes to ensure proper bonding of the
compound. On new concrete surface any laitance and/or curing
compound shall be removed before the markings are applied.
 Composition of Materials: The thermoplastic material shall be
homogenous composed of pigment, resins and glass reflectorsing
beads

(2) Reflectorsing glass beads: Type 2reflectorsing glass beads as required vide
Table 800-4 of MORT&H Specifications will be used.
(3) Application properties of the thermoplastic material

(a) The material shall be malted in accordance with the manufacture’ in instruction in
a heater fitted with a stirrer to give a smooth consistency of the thermoplastic
material to avoid local overheating. The temperature of the mass shall be within
the range specified by the manufacturer. The molten material should be used as
expeditiously as possible.
(b) After transfer to the laying equipment, the materials shall be maintained within
the temperature range specified by the manufacturer for achieving the desired
consistency for laying.

Figure 4.10 Lane Marking

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 The thermoplastic material shall get screeded / extruded at temperatures specified by the
manufacturer to produce a line of specified thickness which shall be uniform in shape having
clear and sharp edges.

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