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AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 PROCEDUR E FOR ASPHALT PAVING 1.0 SCOPE This work

AL MUSAIRIE NATIONAL

PRO/2/004

Revision 0

PROCEDURE FOR ASPHALT PAVING

1.0 SCOPE

This work instruction describes the activities associated with the construction of road pavements using granular sub-base and aggregate base course materials, bituminous base and /wearing course construction using hot mix asphalt concrete for roads and construction of culvert and trenches. This document shall be read in conjunction with the relevant Engineering Standards & drawings, Industry codes and any other additional requirement as set forth by the client. Asphalt pavement shall be performed by a specialist vendor having appropriate equipment for the work.

2.0 RESPONSIBILITIES

Project Manager: Ensures compliance by all parties to this procedure, QA/QC manual, inspection plans, project specifications, drawing and industry codes.

Site Engineer: Ensure compliance by all craftsmen to the requirement of this work instruction, relevant Specifications and QC Inspection requirement. Confirm the availability of all resources necessary to complete the pavement construction in a timely manner.

Civil Supervisor: Ensure the correct drawings; approved procedures associated with the construction are available to all personnel in charge of the work. Ensure that all submittals required by the client were duly approved and issued for use. Confirm construction materials are available and comply with the project specification.

Quality Control Inspector: Monitor construction activities and verify compliance to client specifications and inspection plans. Prepare daily QC records and final acceptance documentation where required. Report non-conformances, coordinate all inspection activities and conduct periodic audit of documentation and verification activities.

3.0 PROCEDURE

3.1 Source of material & Storage

All aggregates for use in the construction of the bituminous pavement shall be obtained from approved sources and complying with the project specifications. QC Inspector shall

AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 ascertain the properties of all raw material s intended

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ascertain the properties of all raw materials intended for incorporation into permanent work, through appropriate certification.

The aggregate stockpile shall be prepared by clearing and smoothing and shall be hard ground. The center of the storage area shall be elevated and sloped to the sides so as to provide proper drainage of excess moisture. The material shall be stored in such a way as to prevent segregation and coning to insure proper control of gradations and moisture. All processed materials shall be tested and approved for use before being stored or incorporated to permanent works.

3.2 Granular Subbase

This work shall include the furnishing, placing and preparation of the materials on the road, the mixing of the various materials together and with water, the spreading, compacting and finishing of the materials, the maintenance of the completed subbase course and the dressing of shoulders and slopes. This Work shall consist of furnishing and placing one or more courses of aggregate, including binder soil if required, on a prepared subgrade in accordance with the specifications, in conformity with the lines, grades, thicknesses and typical cross sections shown on the drawings or established by the client.

1. All subbase material shall be free from dirt, organic matter, shale or other deleterious matter and shall be of such quality that it will bind readily to form a firm, stable subbase.

2. The material for "Granular Subbase" shall conform to the requirements specified for the class of subbase noted on the drawings.

3.2.1 Preparation of Subgrade

The formation of the subgrade will vary by either placing the "Granular Subbase" on the roadway/parking area surface as previously constructed or by excavating sufficient material from the roadway/parking area to form the shoulders and placing the "Granular Subbase" on the subgrade obtained thereby. In either case the subgrade shall be brought to the lines, grades, and typical section shown on the drawings for the bottom of the "Granular Subbase."

All soft and yielding material or other portions of the subgrade, which will not compact readily, when rolled or tamped, shall be removed, and all loose rock or boulders found in the excavation shall be removed or broken off. All holes or depressions made by the removal of material, as described above, shall be filled with approved material, and the whole subgrade brought to line and grade and compacted to the density designated on the drawings.

3.2.2 Spreading

Subbase aggregate shall be spread on the approved subgrade layers in a compactable depth. Spreading shall be done by distributing the material to the required width and loose thickness.

AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 The material shall be handled so as to avoi

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The material shall be handled so as to avoid segregation. Segregated materials shall be remixed until uniform. Suitable precautions shall be taken to prevent rutting of the subgrade during the spreading of the subbase material.

3.2.3 Compaction

The moisture content of the subbase material shall be adjusted prior to compaction, by watering or by drying out to that required maximum moisture content to obtain the specified density. The subbase aggregate shall be compacted using suitable compaction equipment progressing gradually from the outside towards the center with each succeeding pass uniformly overlapping the previous pass. Compaction shall continue until the entire thickness of each layer is thoroughly and uniformly compacted to the specified density. Consolidation shall be accompanied by sufficient blading to insure a smooth surface free from ruts or ridges and having the proper section and crown.

Any areas inaccessible to normal compaction equipment shall be compacted by means of mechanical tampers until satisfactory compaction is obtained.

If any layer of subbase material, or part thereof, is permitted to dry out after compaction, or does not conform to the required density or finish rework, watered and re-compact the material to the density specified, before the next layer of subbase or base course is superimposed thereon.

The subbase shall be compacted to the thickness and cross section as shown on the drawings and shall not vary by the permissible tolerances. All humps and depressions and thickness deficiencies exceeding the specified tolerances shall be corrected by removing the defective Work or by adding new material.

3.3 Aggregate Base Course

3.3.1 Subgrade Preparation

Prior to the delivery of materials for the base course, prepare the roadbed surface by sprinkling, blading, rolling, and lightly scarifying where necessary, until the proper crown is obtained.

In the process of shaping the roadbed, the originally compacted crust or top portion of the roadbed shall be disturbed as little as possible.

When completed and ready for base course construction, the roadbed shall be well compacted, smooth, hard and uniform, all irregularities having been bladed out and rolled down.

At existing pavements the subgrade shall be excavated to such depth that the proper thickness of base course may be constructed flush with the existing surface. The transition from normal to special section shall be of sufficient length to present no abrupt

AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 or noticeable change of grade and shall be excavated

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or noticeable change of grade and shall be excavated in accordance with the grades and lines shown on the drawings.

3.3.2 Maintenance of Subgrade

After the roadbed has been prepared, it shall be maintained true to cross section and grade until the base course is completed. Sufficient drains shall be cut through excavated material on the shoulders to drain the roadbed completely at all times. Drains shall be cut through windrowed base course material at sufficient intervals to prevent ponding of water and the windrowed material shall be moved when necessary to permit the subgrade to dry.

3.3.3 Method of Construction.

Combining Aggregates and Water

Aggregates for base course shall be combined into a uniform mixture as per specified grading requirements and water added before final placement of the material. When binder is to be added, it may be combined with the aggregate base by thoroughly mixing separate windrows of binder and aggregate base.

Spreading and Combining Aggregates

Aggregate for base courses shall be delivered to the roadbed as a uniform mixture and shall be placed on the existing roadway, prepared subbase or prepared subgrade, as the case may be, in a uniform layer including any binder that is to be blended on the road. Spreading shall be done by distributing the material to the required width and loose thickness.

The material shall be so handled, as to avoid segregation.

Compaction

Immediately after placing, the base course material shall be compacted. The material shall be compacted to a density of not less than that is specified requirements (See attachment).

Rolling shall be continued until the entire thickness of each layer is thoroughly and uniformly compacted to the density specified.

Rolling shall be accompanied by sufficient blading in a manner to insure a smooth surface, free from ruts or ridges and having the proper section and crown.

The surface of the finished base course will be tested with a three meter straight edge at selected locations.

Prior to placing the succeeding layers of material, the top of the under layer shall be made sufficiently moist to insure bond between the layers.

AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 The edges and edge slopes of the base course

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The edges and edge slopes of the base course shall be bladed or otherwise dressed to conform to the lines and dimensions shown on the drawings and present straight, neat and workmanlike lines and slopes as free of loose material as practicable.

If after the base is compacted, any areas are above or below proper grade and true elevations, such areas shall be loosened and after having had additional materials added or excess material removed, as the case may require, shall be reconstructed as described herein.

If after the base is compacted, any areas fail to meet the specified density and gradation requirements, they shall be loosened or removed.

3.4 Job Mix

The job mix shall be approved prior to production. The job-mix formula shall combine the mineral aggregates and asphalt in such proportion as to produce a mixture conforming to the project requirements. The gradation of the combined aggregate, including the mineral filler shall be within the limits specified in the specification for the class of bituminous course to be used. Any re-proportioning of aggregates, mineral filler and asphalt to produce the final mix shall be within the range specified by the project specification.

3.5 Bituminous Base Course

This Work shall consist of aggregate and bituminous material mixed in a central plant, and spread and compacted on an approved, primed subgrade in accordance with the specifications and in conformity with the lines, grades, thickness and typical cross sections shown on the drawings.

Mineral aggregates for "Bituminous Base Course" shall consist of coarse aggregates, fine aggregates, and filler material, if required.

Asphalt for "Bituminous Base Course" shall be petroleum asphalt cement, conforming to the projects requirements.

Trucks used for hauling bituminous mixtures shall have tight, clean, smooth metal beds which have been thinly coated with a suitable material to prevent the mixture from adhering to the beds.

3.5.1 Preparation of Asphalt Cement

Asphalt cement shall be heated within a temperature range of 135 degrees C to 163 degrees C or as per project specification (see attachment) at the time of mixing. All material reheated more than 42 degrees C above the maximum shown shall be considered overheated and shall be rejected until the material can be resample and tested.

AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 3.5.2 Preparation of Mineral Aggregates Each aggregate ingredient s

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3.5.2 Preparation of Mineral Aggregates

Each aggregate ingredient shall be heated not more than 163 degree C or as specified (see attachment) and dried. If the aggregates contain sufficient moisture to cause foaming in the mixture or their temperature is in excess of 163 degrees C, they shall be removed from the bins and returned to their respective stockpiles.

3.5.3 Preparation of Bituminous Mixture

Dried aggregate as specified for bituminous construction and prepared as prescribed above shall be combined in the plant in the proportionate amounts as approved. Asphalt cement shall be introduced into the mixture in the proportionate amount determined by the job-mix formula.

3.5.4 Preparation of surfaces

When a new surface is constructed on an existing subgrade, base or bituminous surface, the surface shall be cleaned of all foreign material and broomed free of dust.

In addition any loose, broken, or shattered bituminous material along the edges of the existing surface shall be removed, and the exposed subgrade and a sufficient width of the shoulder adjacent to the edge of the existing surface to receive the new bituminous mixture shall be shaped, bladed, compacted and broomed to provide a uniform firm subgrade for the new surface course.

3.5.5 Prime/Tack Coat

Prior to the placing of the bituminous mixture, when designated by the specification, a prime coat shall be applied to the prepared subgrade, base or tack coat to the existing bituminous surfaces using a pressure distributor at the specified rate and cured. The spray bar and spray nozzle shall be adjusted and frequently checked so that uniform distribution is insured.

If the surface is an earth surface or a water-bound base course or subbase, the cleaned surface shall be given a light application of water and allowed to dry to a surface-dry condition before the prime coat.

3.5.6 Placing of the Mixture

Hot bituminous mixtures shall be placed only when the air temperature is four (4) degrees C or above and when the weather is not foggy or rainy and when the existing surface is free from moisture.

Bituminous mixtures may be spread and finished true to crown and grade using a self propelled paver. Manual paving shall be adopted where machine methods are impractical.

The automatically controlled paver shall spread the bituminous mixtures without tearing the surface and shall strike a finish that is smooth, true to cross section, uniform in

and irregularities. density texture and AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 free from hollo ws,

and

irregularities.

density

texture

and

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free

from

hollows,

transverse

corrugations

and

other

The paver shall be operated at a speed which will give the best results for the type of paver being used which coordinates satisfactorily with the rate of delivery of the mixture to the paver.

All mixed material shall be delivered to the paver in time to permit completion of spreading, finishing and compaction of the mixture during daylight hours.

All bituminous mixtures shall be delivered to the paver at a temperature between 139 degrees C to 163 degrees C or as specified (see attachment). Mixtures delivered to the paver at lower temperatures shall be discarded.

The width of surface or top course placements shall conform to traffic lane edges as shown on the drawings. Where successive layers are to be placed, the surface of the existing layer shall be swept clean with a power broom, or by other means and a tack coat applied.

3.5.7 Thickness Cores

Thickness determination shall be made from core drill by cutting samples from the compacted mixture on the road (see attachment).

3.5.8 Compaction of Mixtures

After spreading and as soon as the mix conditions permit the rolling to be performed without excessive shoving or tearing, the mixture shall be thoroughly and uniformly compacted. Rollers shall be of the steel wheel and/or pneumatic-tire type and shall be operated at speeds slow enough to avoid displacement of the bituminous mixture. The wheels of the rolling equipment shall be kept wet to prevent the surface material from sticking.

3.5.9 Joints

Joints between old and new pavements or between successive days' work shall be made so as to insure thorough and continuous bond between the old and new mixtures.

Transverse construction joints in previously laid material shall be constructed by cutting the material back vertically for its full depth so as to expose a fresh surface.

Before placing the fresh mixture against a cut joint or against old pavement, the contact surface shall be primed.

3.5.10 Surface Tolerances

The surface will be tested with a four (4) meter straightedge at selected locations and the variations shall be in accordance with the project specifications. The thickness of the

AL MUSAIRIE NATIONAL PRO/2/004 Revision 0 bituminous base will be determined by aver age caliper

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bituminous base will be determined by average caliper measurement of cores (see attachment).

3.6 Bituminous Wearing Course

This Work shall consist of the construction of bituminous concrete courses on an approved, primed or tacked, base, subbase, subgrade, bridge deck, or concrete pavement in accordance with the specifications and in conformity with the lines, grades, thickness and typical cross sections shown on the approved construction drawings.

Preparation of mineral aggregates, asphalt, Job mix, bituminous mixture, surface preparation, placing, compaction and testing shall be similar to that of bituminous base course described in the preceding sections as per appropriate specification applicable to the project.

3.7 QC Records

The QC inspector should maintain daily record using the report form Asphalt Concrete Paving of the entire day’s operations and progression of construction and should become part of the permanent record of the project. Changes in materials, gradation, methods, proportions, or conditions should be noted and tied into station location.

4.0 SUPPORTING DOCUMENTS

PRO/2/001

Project execution

PRO/4/001

Project Communication

PRO/4/002

Project Plan

FAB/4/005

Equipment Request

NCP/4/006

Quality Check List

PRO/4/004

Daily Report

FAB/4/004

Mixing Ratio

MR/4/008

Corrective and Preventive Action

CIM/2/001

Inspection Measuring & Test Equipments

Prepared by:

QA/QC Manager (Name & Sign)

Date:

Approved by:

Business Development Manager (Name & Sign)

Date: