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PUNJ LLOYD LIMITEDBelgaumMaharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY DENSE BITUMINOUS MACADAM (AND BM, SDBC, BC)

A. Scope:

A1.The activity of Dense Bituminous Macadam shall be executed as base / binder course for flexible pavement. This work shall consist of construction in a single or multiple layers of Dense Bituminous Macadam on a previously prepared base or sub-base. The thickness of single layer shall be between 50mm and 100mm. The Dense Bituminous Macadam shall be executed both as overlay over existing pavement and also as a fresh layer on reconstruction stretches of flexible pavement.

B. Materials:

B1.Bitumen: The bitumen shall be pavement bitumen of penetration grade 60/70 complying with IS:73. The bitumen shall be procured in Bulk from reputed manufacturers such as IOCL, HPCL etc.

B2.Coarse Aggregate: The Coarse Aggregate shall be obtained by crushing basalt rock in integrated stone crushing plant installed on the project. The crushed aggregate shall be tested for all physical properties as per technical specifications.

B3.Fine Aggregate: Fine Aggregate to be used in Dense Bituminous Macadam shall be crushed stone dust. However as an alternative in the event of shortage of crushed stone dust, naturally occurred mineral material i.e. sand may also be used as fine aggregate. The fine aggregate shall be clean, hard, durable, dry and free from any inorganic or other deleterious material.

B4.Filler: Filler, if required, shall be used. It is proposed to use rock dust, hydrated lime or cement as filler.

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C.Mix Design and Quality Control:

C1. Job Mix Formula for Dense Bituminous Macadam:C1.1 Job Mix Design shall be conducted in the Field Laboratory using Marshall method. The materials shall be collected directly from the stockyard / storage tank and shall be checked for various physical / strength requirements. The job mix design has already been conducted and submitted for approval. Once the job mix design is approved by Engineer, planned trial shall be conducted and mix shall be tested for various properties. The mix shall be tested for following requirements:

Minimum stability (kN at 600C)9.0

Minimum flow (mm)2

Maximum flow (mm)4

Compaction level (Number of blows)75 blows on each of the two faces of the specimen

Percent air voids3 6

Percent voids in mineral aggregate (VMA)12 corresponding to 4% Air voids & 25mm nominal aggregate.

Percent voids filled with bitumen (VFB)65 75

C2.Binder content: Binder content shall be as per MOST Technical Specifications. Minimum Binder Content shall be 4.25% by weight of total mix.

D.Construction:

D1.Equipment:

D1.1Batch type Hot Mix Plant of 120T / Hr. or 160T / Hr. capacity has been installed at Camp-B & C and shall be used for producing Hot Mix. 160TPH Plant of Porker make has been installed at Camp-B and 160TPH Plant of Gujarat Appollo (NIGATA) make have been installed at Camp-B on the Project.

D2. Transportation: Transportation shall be done in rear tipping Tippers of 10T and higher capacity. The dumpers shall be covered with Tarpaulin to control loss of temperature.

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D3.Paving: Paving shall be done with Asphalt Paver having hydraulically extensible screed capable of maintaining both longitudinal and lateral grades. Pavers of DYNAPAC make, capable of paving upto 11m width have been mobilised on the Project. These Pavers shall be used for full width paving on Main Carriageway. Bitumen paving on Service Road shall be done with Paver capable of paving upto 5.5m width. These are of Gujarat Apollo make.

D4.Compaction: Compaction shall be done with a combination of 10T Double Drum Tandem Vibratory Roller and matching Pneumatic Tyre Roller of 15T capacity (ballasted).

D4.1Breakdown rolling shall follow immediately behind Paver and shall be started not later than temperature of Hot Mix is 1200C. Rolling shall be completed well before temperature of Hot Mix falls to 800C.

E.Sequence of Operation:

E1.Check Hot Mix Plant for its functions.

E2.Check stock of all materials including bitumen filler etc.

E3.Check the burners of Drier Drums and stock of LDO / HSD.

E4.Keep dumpers ready after cleaning and applying lubricants on the inside face of dumper body.

E5.Clean primed surface of any debris, loose particles etc. with compressed air.

E6.Mark the boundary of paving width with lime powder after marking proposed centerline of the road.

E7. Fix pegs @ 10mm center to center on both sides at a fixed distance from pavement edge.

E8.Fix string line at a fixed height above proposed pavement surface.

E9.Position Paver at the starting point.

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E10.Screed shall rest on wooden slippers on height equal to the proposed thickness of Dense Bituminous Macadam before start of compaction.

E11.Check availability of tools and plants such as Rakers etc. at site.

E12.Check Tandem Roller and Pneumatic Tyre Roller for availability of water and also for functioning of all light fixtures for Roller and Paver.

E13.Keep ready lighting arrangement for night working at site.

E14.Start production of Hot Mix from Hot Mix Plant.

E15.Check the first Batch for any uncoated materials and in case of presence of uncoated materials, discard the mix.

E16.Collect samples from the Hot mix produced at plant from dumpers at the plant location before dispatch to site.

E17.Cover the dumper with Tarpaulin.

E18.Reverse the dumper at site upto Paver hopper.

E19.Unload material into Paver hopper and start paving after drawing material from hopper on the rear side and for full width of paving.

E20.Start sensors after Paver has moved for 1m to 2m.

E21.Remove wooden sleepers from the ground after Paver has moved away.

E22.Check layer thickness and top level of paved surface for any variation from desired level.

E23.Start breakdown rolling immediately behind Paver by plain pass.

E24.Rolling shall be started from lower end to upper end.

E25.Compaction by Pneumatic Tyre Roller shall be started after three passes of Tandem Roller.

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E26.Ensure that compaction of bituminous layer is completed by the time temperature falls below 800C.

E27.Traffic shall be allowed on bituminous surface only after temperature of the mix has come down to ambient temperature.

E28.Next days work shall be started by making a vertical cut along the full width at the end of the previous days work.

E29.Hot bitumen to be applied at the vertical surface for better joint.

E30.Cores shall be taken from the work executed with Asphalt Core cutting machine and all necessary tests shall be conducted to check conformance of the work done with specifications.

Similar procedure shall be followed for Bituminous Macadam / Semi Dense Bituminous Macadam / Bituminous Concrete. However, Design Mix shall be conducted separately as per requirement of these activities.

F.Trial Stretch:

F1. Trial stretch of Dense Bituminous Macadam layer shall be laid outside the working stretch to demonstrate the capability of various equipments and testing the material laid for various parameters as per technical specifications.

G. Opening to traffic:

G1.The newly laid surface shall be opened to traffic until and unless the temperature of mix has reached ambient temperature or after 24 Hours, whichever is earlier.

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