DURABLE ROAD

INFRASTRUCTURE – OPTIONS
AND RECENT DEVELOPMENTS
 Typical NHDP crust
 Average com. traffic-100 to 150 msa
 Crust Composition
 40 mm BC
 110 to 150 mm DBM
 250 mm WMM
 250 to 300 mm GSB
 Total crust 650 mm to 740 mm
 ROUGH ESTIMATE OF
AGGREGATE CONSUMPTION
 175 m Cu.m of stone aggregates / year
 Cost – Rs. 10,000 Cr.
 Over-exploitation
 Increased cost of aggregates
 Environmental problem
 Depletion of natural resources
Conventional Pavement Design: IRC37

Pavement Thickness for CBR value of 5%

4 August 7th, 2007

 Consumption of Aggregate Quantity
Aggregate Quantity for one km - two lane, in metric tonnes

For a typical 60 km stretch aggregate consumption is about

20-30 lakh tonnes of good aggregates
5
August 7th, 2007
 Road Composition

Vehicle

Black Topping (150+50) mm

Base 250 mm Road

Crust, 430
Granular sub-base 200 mm mm

Subgrade 500 mm

450
Embankment
Ground Level
 Road Composition

Vehicle

Black Topping 150 mm

Roller Cement Concrete- 180 mm Road

Crust, 430
Unbound Granular Drainage Layer mm
100 mm

Stabilised Subgrade 300 mm

450
Embankment
Ground Level
GUIDE TO EFFECTIVE STABILISATION
TYPE Soil Properties

More than 25% passing Less than 25% passing

0.075 mm sieve 0.075 mm sieve
PI < 10 < PI PI > 20 PI < 6 6 < PI < PI > 10
10 < 20 10

Cement Yes Yes ME Yes Yes Yes

Lime ME Yes Yes No ME Yes

Lime - Yes ME No Yes Yes ME

Pozzolan
IS SOIL CEMENT RIGHT?

 Low cost alternative

 A good pavement requires good foundation
 Pavement base provides the thickness and
stiffness necessary to support traffic and
provide long – term performance
 Soil cement provided strength and durability –
outstanding value as a base/sub-base material
SOIL-CEMENT

 Simple. Highly compacted mixture of soil,

portland cement and water
 Cement reacts or hydrate and the mixture
gains strength and improves the engineering
properties of the raw soil
 Variables controlling the properties and
characteristics – type of soil or aggregate
material, proportion of cement, mositure
conditions and degree of compaction
How does cement – based
engineered structure benefit
the pavement structure?

 Distribute the loads

 Eliminates Rutting in Base
 Reduces Moisture Problems
 Reduces Deflection
CEMENT BASED
PAVEMENT MATERIALS
TYPES OF CEMENT – BASED
ENGINEERED SOILS
 Cement Modified Soil (CMS)
 Cement Treated Base (CTB)
 Full – Depth Reclamation (FDR)
CEMENT MODIFIED SOIL

 Problems with silty and cly soils, when

wet
 Soils soft, plastic and difficult to compact
 CMS to improve the engineering
properties and construction
characteristics – reduce plasticity,
enhance compaction and strength
 Add 3-5% of cement by dry weight
PRINCIPAL BENEFITS
 Improved constructability of marginal on-site
soils
 Reduced plasticity and improved strength
 Less susceptible to damaging effect of water
 An all-weather work platform
 Use of on-site soil rather than removal and
replacement with expansive select fill material
 Permanent soil modification (does not leach)
 Fast construction technique
CEMENT TREATED BASE
 Soil cement that meets the project specified
minimum durabilty and strength requirements
 CTB can be mixed in-place like CMS using on-
site soils or mixed in central plants using select
aggregates
 CTB uses more cement than CMS resulting in
strong and durable layer
 Typical cement contents 3- 10%
 7 days UCC – 2.1 to 5.5 MPa
Cement requirements for
AASHO soil groups
FULL DEPTH RECLAMATION

 Aggregate for cement stabilised base is

obtained by pulverizing and recycling an
old asphalt and base material
 FDR commonly uses 4-6% cement
 UCC (7-days) – 2.1 to 2.8 MPa
DESIGN ASPECTS

 Minimum acceptable strength of

stabilized material depends on:
 Position in the pavement
 Level of traffic
 Sufficiently strong to resist traffic stresses
but upper limits of strength are set to
minimise the risk of reflection cracking
FACTORS AFFECTING SOIL CEMENT
STABILIZATION

• Soil
• Cement
• Pulverisation and Mixing
• Compaction
• Curing
• Additives
Soil
THE PHYSICAL PROPERTIES

• Particle Size Distribution

• Clay content
• Specific Surface
• Liquid limit and Plasticity Index

Cement
A increase in cement content generally
causes increase in strength and durability
Pulverisation and Mixing
• Better the Pulverisation and degree of mixing,
higher is the strength
• Presence of un pulverised dry lumps reduces
the strength

Compaction
• By increasing the amount of compaction dry
density of the mix, strength and durability also
increases
Curing
Adequate Moisture content is to be retained in
order to accelerate the strength

Additives
There are some additives to improve properties
• Lime
• Sodium hydroxide
• Sodium Carbonate
• Calcium Chloride
 Design of Soil –Cement Mix
• Soil – Cement specimens are prepared with
various cement contents in constant volumes
moulds
• The compressive strength of these specimens
tested after 7 days of curing
• A graph is plotted Cement content Vs
compressive strength
• The Cement Content Corresponding to a
strength of 17.5 kg/cm2 is taken as design
cement content
MATERIAL REQUIREMENTS

 Well graded
 LL < 45%
 PI < 20 %
 Cement quantity – based on UCS and/or
durability test
 Lab. Strength values = 1.5 times
minimum field UCS value
PULVERISATION

IS SIEVE MIN % BY WT.

PASSING IS SIEVE

26.5 mm 100

5.6 mm 80
Soils pulverized more easily when they
contain proper moisture content and
when proper equipment is used
Pre-wetting helps in
pulverization of dry, hard soils
OTHER ISSUES

 Moisture content during compaction

 Rolling – to be completed within 2 hours
of mixing or lesser
 Curing – 7 days (min)
PROPERTIES OF CEMENT
AND LIME STABILISED
MATERIALS
CODE DESCRIPTION UCC (MPa)

CB1 Stabilized road 3.0- 6.0

base
CB2 Stabilized road 1.5 – 3.0
base
CS Stabilized sub- 0.75 - 1.5
base
SIEVE % by wt. passing
CB1 CB2
53 100 100
37.5 85-100 80-100
20 60-90 55-90
5 30-65 25-65
2 20-50 15-50
0.425 10-30 10-30
0.075 5-15 5-15
LL 25 30
PI 6 10
DESIGN CRITERIA FOR CEMENT
MODIFIED SOIL
 Percentage of cement – 2 to 3 %
Cement content (% by wt. CBR value (soaked)
of dry soil)
0 8
1 20*
2 43*
2.5 60*
3 65*
4 85*
Soil with PI - 5 to 10; % finer than 75 micron < 50%
* Cured for 6 days and thereafter soaked for 4 days
CEMENT TREATED SOIL SUB-BASE / BASE
(MoSRT&H)
IS SIEVE % BY WT. PASSING
SUB-BASE BASE
FINER THAN RANGE
53 mm 100 100
37.5 mm 95 95-100
19 mm 45 45-100
9.5 mm 35 35-100
4.75 mm 25 25-100
600 micron 8 8-65
300 micron 5 5-40
75 micron 0 0-10
 Lime/ Cement Stabilised Soil
Sub-base
Quality of Lime/ Cement One Test for Each
Consignment Subject to a
Minimum of one Test per 5
Tonnes
Lime/Cement Content Regularly, through Procedural
Checks
Degree of Pulverisation 1-2 Tests per 8000 m3 of Soil

CBR or UCC As Required

Density One Test per 500 m2
MIX DESIGN
 Test soil for PI, sand fraction, sulphate/carbonate
concentration and organic content to assess
suitability
 Develop moisture-density relationship
 Pulverise the soil and add different percentages
of cement ;
 Prepare CBR specimens at max. dry density and
OMC
 Cure for 3 days followed by soaking for 4 days
 Select cement content based on the CBR value
CONSTRUCTION ASPECTS

 Spreading the stabiliser

 Mixing
 Compaction
 Curing
 Quality Control
 Mixing

Demonstration road project

Compaction
 Construction of roller
compacted concrete
pavement

Demonstration road project

View of the
demonstration road
stretch after three years
Sheepsfoot roller used to
compact moist soil
CURING

 Ensure that sufficient moisture is retained

in the layer so that the stabilizer can
continue to hydrate
 Reduces shrinkage
 Reduces the risk of carbonisation from
top of layer
CURING

 Curing is more efficient, if a layer of sand, 30 to

40 mm thick is first sprayed on top of the
stabilized layer
 Number of spraying cycles can be reduced;
considerable savings in water
 First apply a light spray of water followed by
either viscous cut-back bitumen or a slow
setting emulsion- continuous bitumen film act
as curing membrane
Thin covering of bituminous
material being used to cure
soil-cement base
FACTORS INFLUENCING
SHRINKAGE
 Loss of water, particularly during the
initial period
 Cement content
 Density of the compacted amterial
 Method of compaction
 Pre-treatment moisture content of the
material to be stablized
Shrinkage Cracking:

Description:
Hairline cracks formed during PCC setting and
curing

Problem: moisture infiltration.

Possible Causes:
 Improper curing technique.
 High early strength
Shrinkage cracks on brand new slabs
Severe shrinkage cracking
Repair:
•mild &moderate condition – seal the crack
•severe situations replace the slab
CONTROL OF SHRINKAGE
CRACKS
 Longer the period of curing, the smaller the
shrinkage when the layer subsequently dries
 Lower cement content – shrinkage cracks at
reduced spacing and material will crack more
readily under traffic- low strength; less durable
 To maximise strength and durability,
compaction to max . density possible; higher
compaction causes shear planes in the surface
of the layer, increased shrinkage cracks
 Higher stabiliser content to get adequately
strong and durable layer
REMEDIES

 Shrinkage cracks are inevitable in the

stabilized layer
 Cover with a substantial thickness of
granular layer to prevent reflection
through the bituminous surfacing
 Use SAMI
Reflection Cracking
Discontinuities in the underlying layers propagate
through the HMA surface due to movement of
cracks

Discontinuities
 Cracks or joints in underlying RCC pavement
 Cracks in soil-cement base course
All types of cracks in the existing HMA pavement

Causes
Thermal (movement of joints/cracks)
Load
 CRACK RETARDING LAYERS

 Stress Absorbing Membrane (SAM)

is an elastomeric bitumen-rubber
membrane, which is laid over a
cracked road surface, together with
a covering of aggregate chips
 It can be laid as a single coat or a
double coat

contd..
 CRACK RETARDING LAYERS

 Stress Absorbing Membrane

Interface (SAMI)
 It may be a material similar to SAM
 It may consist of bitumen-
impregnated geo-textiles
 MATERIALS REQUIRED FOR 10 m2 AREA
STRESS ABSORBING MEMBRANE
Type and width of crack Specification of SAM Quantity Quantity of
to be applied of binder chipping
kg/10 m2

Hair cracks and map Single coat SAM or 8-10 0.10 cum of
cracks up to 3 mm width 2nd coat of two coat 5.6 mm chips
SAM
Map cracks or alligator Single coat SAM 10-12 0.11 cum of
cracks 3 mm to 6 mm 5.6 mm chips
width
Map cracks or alligator Two coat SAM 0.12 cum of
cracks 6 mm to 9 mm 1st coat 12-14 5.6 mm and
width 2nd coat 8-10 11.2 mm
chips in 1:1
ratio
contd..
KUALA LUMPUR
INTERNATIONAL AIRPORT
ALTERNATIVE CRUST DESIGN
FROM KM 126.020 TO 127.020 RHS ON NH-7
 PAVEMENT CRUST DETAILS
Conventional Proposed- Alternate
BC 50 Design
BC 50
DBM 75
DBM 80
BM 75
SAMI 10
WMM 250
CTB 160
GSB 200
DL 100
Subgrade
500 SS 300

Total thickness – 1150mm Total thickness – 700mm

SALIENT FEATURES OF
DIFFERENT PAVEMENT
COURSES
 SAILENT FEATURES
CEMENT STABILIZED SUBGRADE
MATERIALS
 Cement : 3.0% by weight of soil
 Soil (preferably with CBR value 5% - 10% )

PHYSICAL REQUIREMENTS
 Laboratory CBR : 80.0 % (after stabilization)
 Elastic Modulus : 105 MPa (min)
 U.C.S. : 1.0 MPa
 SAILENT FEATURES
DRAINAGE LAYER
 MATERIALS
 Bitumen 60 / 70 grade : 2.0 % by weight of mix
 Aggregate 20 mm :10mm : 6mm :: 30 : 30 : 40

 PHYSICAL REQUIREMENTS
 Elastic Modulus : 700 MPa
 Permeability : 300 – 800 m/ day
 GRADATION
 20mm – 100%
 12.5mm – 75% - 85%
 9.5mm – 65% - 75%
 4.75mm – 45% - 55%
 2.36mm – 25% - 35%
 1.18mm – 0% - 15%
 SAILENT FEATURES
ROLLER COMPACTED LEAN
CONCRETE (RCLC)
 DESIGN 1 (per cu.m.)
 From Ch. 126 + 020 to Ch.126 +  DESIGN 2 (per cu.m.)
390  From Ch. 126 + 390 to
 Cement : 90.0 kg Ch 127+ 020
 MTPS Fly ash : 120.0 kg
 Cement : 60.0 kg
 PHYSICAL PROPERTITES  MTPS Fly ash : 150.0 kg
 Workability : 30 Sec.
 Compressive Strength: 5.0 MPa
(min)
 Modulus of Elasticity: 5000
MPa(min)
 SAILENT FEATURES
STRESS ABSORBING MEMBRANE
INTERLAYER (SAMI)

 MATERIALS
 PMB–40 (1.5 – 2.0 lt / m2)
 Aggregate -13.2 mm to 6mm (15
kg/m2 )
 SAILENT FEATURES
DBM & BC

MATERIALS

 Bitumen 60/70 grade for DBM

 Bitumen PMB – 40 for BC

 CONSTRUCTION
METHODOLOGIES
 CONSTRUCTION METHODOLOGY
CEMENT STABILIZED SUBGRADE

 Sub grade material was spread on the top of Embankment

layer(150mm + 25% loose) and lightly compacted.
 Total work area marked with grids of area required for one bag of
cement (2.5m X 2.5m).
 Cement was spread @ one bag per grid.
 Soil & Cement was mixed by mechanical harrow followed by
tractor mounted rotovator
 Moisture was added (+/- 1% of OMC )
 Grading was done to the required grade & levels.
 Compaction done with vibratory roller (8 – 10 tonnes)
 Quality Control tests conducted as per the frequency
 METHODOLOGY

DRAINAGE LAYER
 The aggregates were proportionately mixed with 2% bitumen
in a hot mix plant
 The mix was transported in tipper trucks.
 The laying was carried out by a mechanical paver
 Compacted the layer with 4 plain passes of 8 – 10 tonne
roller.
 Quality Control test conducted as per the specifications.
 CONSTRUCTION METHODOLOGY
ROLLED COMPACTED DRY LEAN
CONCRETE (RCLC)

 Batching and Mixing was done in batching plant of 30 cu.m. per hour rat
capacity.
 Transportation : tipper trucks
 Laying : Mechanical paver with sensor
 Compaction : Vibratory roller with 8 – 10 tonne capacity
 Curing: Wet curing
 Quality Control test conducted as per the specifications.
 CONSTRUCTION
METHODOLOGY
ROLLED COMPACTED DRY
LEAN CONCRETE (RCLC)
 CONSTRUCTION METHODOLOGY
STRESS ABSORBING MEMBRANE
INTERLAYER (SAMI)

 Aggregate spreading pans (“tagari”)were calibrated

 Markings were given on the kerb at regular intervals to have correct idea of
area covered
 RCLC surface was properly cleaned of dust and undesired materials
 PMB Temperature was maintained at between 180 to 200oC in the sprayer
tank
 PMB was laid @ 1.5 to 2 lts / sq.m.
 Aggregate was spread manually @ 15 kg/ sq.m. using calibrated pans
 Rolling was done by 8-10 tandem roller in static mode
CONSTRUCTION OF DBM & BC
 LESSONS LEARNED
Cement Stabilized Sub Grade
 Mechanised methods will be more effective
Drainage Layer
 1% binder was enough in lab, but 2% was used in plant for proper
coating
 Compaction problems due to very open graded mix
 The mix too weak to tolerate even the construction traffic
RCLC
 Use of pug mill mixing instead of batch type mixing will be more time
and cost effective
SAMI
 Specially designed sprayers shall be used
 Aggregate sprayers will be more effective for large volumes
 Nozzles were require to be changed from 1.35 (for 6 GPM) mm to
2.28 mm slit
 COMPARISON OF NEW CRUST WITH CONVENTIONAL

New Crust Conventional crust Remarks

Sl No. Item description Rate/ sqmt Rate/ sqmt

1 CEMENT TREATED SUBGRADE 126.31 51

2 DRAINAGE LAYER/GSB 250.27 105.704

3 Roller compacted lean concrete 212.82 0

4 Wet mix macadam 0.00 167.80

5 Stress absorbent ( SAMI ) 82.36 0

6 BM 0 276.95

7 DBM 376.06 352.56

8a BC with PMB 283.66 256.82 Conventional with 60/70 Bitumen

8b BC with CRMB 231.28

Total 1331.47 1210.83

% diff 10.0
SUMMARY
 Type of stabiliser to be decided

 Drainage layer is critical for good performance

 CMS and CTB to be designed for the site conditions

 Curing plays an important role in reducing the
shrinkage cracks
 Micro-cracking reduces severity of shrinkage cracks in
the base, regardless of cement content
SUMMARY
 Proper mix design combined with 3 passes of vibratory
roller at high amplitude after 2/3 days cure provided
significant reduction in shrinkage cracks
 Crack relieving layer may be considered at design
stage, but asphalt curing membrane was minimally
effective in reducing cracking problems
 Bituminous mix design and choice of layers play a key
role on performance
 Performance to be monitored periodically
CONCRETE OVERLAYS
Conventional white topping

 A PCC overlay of 200 mm thickness

 Designed and constructed without

consideration of a bond between the CC
overlay and underlying bituminous layer;
similar to freshly laid CCP
Thin White Topping (TWT)

 An overlay of thickness 100 mm and above

and less than 200 mm
 Bond between the overlaid pavement and
underlying BT layer is often a consideration
in most cases
Ultra Thin White Topping (UTWT)

 An overlay of thickness equal or less than 100

mm (50-100 mm)
 For light traffic less than 12 msa
 Bonding between the underlying BT layer and
overlaid PCC layer is mandatory.
 Use of short spacings 60 cm and 1.25 m
 Use of high strength concrete to provide early
opening to traffic; inclusion of synthetic fibres
(steel, polypropylene/polyster) to control plastic
shrinkage and enhance post-cracking behaviour
QUESTIONS?