SP17 Data Book

CHAPTER XVII
ROAD WORK
CHAPTER-XVII
CHAPTER XVII
ROAD WORK
(A) ROAD WORK – SUB-BASE COURSE (NON-BITUMINOUS LAYER)
1701 GRANULAR SUB BASE
1702 LIME STABILISED SOIL SUB-BASE
1703 CEMENT STABILISED SOIL SUB-BASE
1704 WATER BOUND MACADAM SUB-BASE/BASE COURSE
1705 WET MIX MACADAM SUB-BASE/BASE COURSE
1706 SHOULDER AND MEDIAN
(B) ROAD WORK BASE AND WEARING COURSES (BITUMINOUS-LAYER)
1707 PREPARATION OF BASE
1708 PRIMER COAT OVER GRANULAR BASE
1709 TACK COAT
1710 BITUMINOUS MACADAM
1711 BITUMINOUS PENETRATION MACADAM
1712 DENSE BITUMINOUS MACADAM
1713 SURFACE DRESSING
1714 OPEN-GRADED PREMIX CARPET
1715 SEMI DENSE BITUMINOUS CONCRETE
1716 BITUMINOUS CONCRETE
1717 SEAL COAT
1718 SUPPLY OF MINERAL AGGREGATES FOR PAVEMENT COURSES
1719 BITUMEN MASTIC
1720 QUALITY CONTROL OF ROAD WORK
N. B:Source is Minisistry of surface transport specification for

road and bridge work.
Dy.CE/conversion/tmp/scratch/432106482.doc ii
CHAPTER-XVII
XVII-ROAD WORK
LIST OF BUREAU OF INDIAN STANDARDS CODES (ISI)
S.No. IS CODE NO. SUBJECT
1. 73-1992 Specification for paving bitumen (2nd Revision)
2. 164-1981 Ready mixed paint for road marking, (1st

Revision) (Reaffirmed 1991)
3. 217-1988 Specification for cut back bitumen (2nd Revision)
4. 334-1982 Glossary of terms relating to bitumen and tar

(2nd Revision) (Reaffirmed 1991)
5. 1195-1978 Specification for Bitumen mastic for flooring

(2nd Revision) (Reaffirmed 1990)
6. 1203-1978 Method of testing tar and bituminous material.

Determination of penetration (Amendments 3)
(Reaffirmed 1990)
7. 1205-1978 -Do-,Determination of softening point (Reaffirmed

1988)
8. 1208-1978 -Do-, Determination of ductility, (Reaffirmed

1988)
9. 1212-1978 -Do-, Determination of loss on heating

(Reaffirmed 1988)
10. 1216-1978 Do-, Determination of solubility in carbon

disulphide trichoroethylene (Amendment 1)
(Reaffirmed 1988)
11. 1834-1984 Specifications for hot applied sealing compound

for joint in concrete (1st Revision) (Reaffirmed
1990)
12. 1838(Pt.I) Specifications for reformed fillers for expansion

1983 joint in concrete pavements and structures (Non
extruding and resilient type) Part 1 bitumen
impregnated fiber (1st Rev.) (Reaffirmed 1990)
13. 5317-1987 Specification for Bitumen mastic for bridge

decking and roads (1st Revision) (Reaffirmed
1991)
14. 6241-1971 Methods of test, for determination of stripping

value of road aggregates (Reaffirmed 1993)
Dy.CE/conversion/tmp/scratch/432106482.doc i
CHAPTER-XVII
XVII - ROAD WORK

IRC STANDARDS
S.NO. IRC CODE NO. SUBJECT
1. 10-1961 Recommended practice for borrow pits for road,

embankments constructed by manual operation
2. 29-1988 Specification for bituminous concrete for road

pavements
3. 36-1970 IRC Recommended practice for construction of

earth embankments for road works
4. 60-1976 Tentative guidelines for the use of lime fly

ash concrete as pavement base or sub-base
5. 88-1984 IRC Recommended practice for lime fly ash

stabilised soil base/sub base in pavement
eeostruetten
6. 107-1992 Tentative specifications for bitumen mastic

wearing courses.
Dy.CE/conversion/tmp/scratch/432106482.doc ii
CHAPTER-XVII
XVII-ROAD WORK
LIST OF MANDATORY TESTS
Material/ Test Field/ Test Minimum Frequency of

Work Procedure Quantity testing
Laboratory /Value
1 2 3 4 5 6
Coarse 1. Los Angeles Laboratory IS 2386 Per 200 m3
-
Aggregate (PartIV)
2.Abrasion Valueor IS 2386
Nil
aggregate Impact (Part V)
Value
3. Flakiness Index Field IS 5640

Nil
Grading requirment IS 2386 Per 100 m3
(Part I) IS
2386 (Part
I)
Fine As required
Deleterious Laboratory IS 2386 Nil
Aggregate by the
material (Part III)
Engineer
incharge.
As required
Bitumen As prescribed in IS Laboratory As Nil
by the
73 prescribed
Engineer
in IS 73
incharge.
Embankmen 1.Moisturecontent Laboratory IS 2720(Part Nil
Per 250 m3
t under II)
(O M C
condition
)
2. Density Field IS 2720(Part Nil

Per 250 m3
XXVIII)
3. control test on
borrow pits
(a) Gradation IS 2720(Part Nil

One to two
IV)
test Per 8000
Laboratory m3
(b) Plasticity Laboratory IS 2720(Part Nil -Do-
IV)
(c) Proctor test Laboratory IS 2720(Part Nil -Do-

IV)
(d) Deleterious Laboratory IS 2720(Part Nil As required

contents IV) by Engineer
(e) Moisture Laboratory Nil 250 cum.

contents
Dy.CE/conversion/tmp/scratch/432106482.doc iii
CHAPTER-XVII
1 2 3 4 5 6
Bitumen 1. Binder Field IS 73 Nil As required
Macadam by the
Enginee r-in-
Charge.
2. Aggregate Laboratory IS 2386(Part Nil Per 100 m3 of

Abrasion Impact IV) aggregate
value or Los asrequired by
Angeles Value the Engineer-
in- Charge.
3. Flakiness Index Laboratory IS:2386(Part Nil —Do—

I)
4. Stripping Value Laboratory IS 6241 Nil —Do-
5. Grading of Field or IS 2386(Part Nil Two test per

Aggregate Laboratory I) day per plant
Semi 1. Los angeles Laboratory IS 2386(Part Nil For every 100

Dense Abration IV) m3
Asphaltic value/Aggregate
concrete impact value
2. Flakiness Index Laboratory IS 2386(Part —Do-

I)
3. Stripping Value Laboratory IS 6241 —Do-
4. Mix Grading Field IS 2386(Part One sert of

/Laborator I) test on
y individual
constituents
and mixed
aggregate
from dryer
for each 100
tonnes of mix
subject to
minimum pof
two sets per
plant per
day.
Dense 1. Quality of Laboratory IS 73 Nil As required

asphaltic Binder
concrete
using hot
mix plant
power
equipment
.
2. Los angeles Laboratory IS 2386(Part Nil 100 m3
Abration IV)
value/Aggregate
impact value
3. Stripping Value Laboratory IS 6241 Nil 100 m3
Dy.CE/conversion/tmp/scratch/432106482.doc iv
CHAPTER-XVII
4. Water Absorption Laboratory IS 2386(Part Nil 100 m3

III)
5. Flakiness Index Laboratory IS 2386(Part Nil One test

I) for100 m3
6. Sieve analysis Laboratory IS 2386(Part Nil One test for

for Filler I) each
consignment
subjected to
mionimum one
set per cum.
7. Mix Grading Laboratory IS 2386(Part Nil

I)
8. stability of Mix Laboratory ASTM D 1559 Nil
9. Binder content Field Nil
10. Thickness, Field Appendix ‘B’ Nil

Density of
compacted layer
Bitumen Same as above Same as Same as Nil Same as for

Macadam except Test No. above above asphaltic
(Under 6&7. concrete.
controlle
d
condition
)
Cement Coarse aggregate Laboratory IS 2386(Part - Before

concrete I) approval of
pavement 1. Flakiness Index the quarry
under and every
controlle subsequent
d change in the
condition sourse of
s supply and
one test per
100 cum
2. Impact Value Laboratory IS 2386(Part - —Do-

IV)
3. Los angeles Laboratory IS 2386(Part - —Do-

Abration value IV)
4. Deleterious Laboratory IS 2386(Part - Before

Material II) approval of
the quarry
and every
subsequent
change in the
sourse of
supply
Dy.CE/conversion/tmp/scratch/432106482.doc v
CHAPTER-XVII
5. Moisture content Laboratory IS 2386(Part - Regularly as

III) required
subject to a
minimum one
test per day
Fine aggregate
1. Silt content Field As per CPWD - One test per

specificatio 15 cum
ns Vol. II.
2. Gradation of Field IS 2386(Part - - DO-

sand II)
3. deleterious Field IS 2386(Part - Before

material II) approval of
the quarry
and every
subsequent
change in the
sourse of
supply
4. Moisture content Field IS 2386(Part - Regularly as

III) required
subject to a
minimum one
test per day
5. mix aggregate Field IS 2386(Part - One test per

I) 15 cum of
concrete.
6. flexural Laboratory IS 526 - One test

strength consisting of
8 specimen
for 30 cum of
concrete.
Dy.CE/conversion/tmp/scratch/432106482.doc vi
CHAPTER-XVII
SPECIFICATION NO. 1701
GRANULAR SUB-BASE
1. Scope
2. Materials
3. Construction Operation
3.1 Preparation of subgrade
4. Surface Finish and Quality Control of Work
5. Strength of Sub-base
Dy.CE/conversion/tmp/scratch/432106482.doc 1
CHAPTER-XVII
GRANULAR SUB-BASE
Scope Specifica
1. This work shall consist of laying -tionfor
road and
and compacting, well-graded material on bridge
prepared subgrade in accordance with the works by
MOST
requirements of these specifications. The
material shall be laid in one or more
layers as sub-base or lower sub-base and
upper sub-base (termed as sub-base
hereinafter) as necessary according to
lines, grades and cross sections shown on
the drawings or as directed by the
Engineer.
Material
s 2.1 The material to be used for this
work shall be natural sand, moorum,
gravel, crushed stone, crushed slag,
crushed concrete, brick metal, laterite,
kankar, etc., or combinations thereof
depending upon the grading required. The
mixed material shall be free from organic
or other deleterious constituents and
conform to one of the three gradings given
in Table 1
TABLE 1
GRADING FOR GRANULAR SUB-BASE MATERIALS
Sieve Percent by weight passing the

Designation sieve
Grading 1 Grading 2 Grading 3
90 mm 100 100 100
63 mm 90-100 90-100 90-100
5.6 mm 39-72 44-91 53-100
75 micron 0-20 0-25 0-30
Note:-
The material passing 425 micron sieve
for all the three gradings
When tested according to IS : 2720

(Part V) shall have liquid limit and
Plasticity index of not more than 25
percent and 6 percent respectively.
*The material for lower sub-base may

have a minimum CBR value of 10.
CHAPTER-XVII
Physical
Requirement 2.2 The fraction of material passing
s
22.4 mm sieve shall give a CBR value as
specified in Table 1 or more as specified
in the Contract, when tested in
accordance with IS:2720 (Part XVI) after
preparing the samples at maximum dry
density and optimum moisture content
corresponding to IS : 2720 (Part VII) and
soaking the same in water for 4 days.
Constructio
n Operation 3.1 Immediately prior to the laying of
sub-base, the subgrade shall be prepared
by removing all vegetation and other
extraneous matter, lightly sprinkled with
water if necessary and rolled with one
pass of 8-10 tonne smooth wheeled roller.
Spreading
and 3.2 The sub-base material of grading
compacting
specified in the contract shall be spread
on the prepared subgrade with the help of
a motor grader of adequate capacity, its
blade having hydraulic controls suitable
for initial adjustment and maintain the
required slope and grade during the
operation or other means as approved by
the Engineer. The thickness of loose
layers shall be so regulated that the
maximum thickness of the layer after
consolidation does not exceed 150 mm.
Moisture content of the loose material

shall be checked in accordance with IS:
2720(Part-II) and suitably adjusted by
sprinkling additional water from a truck
mounted or trailer mounted water tank and
suitable for applying water uniformly and
at controlled quantities to variable
widths of surface or other means approved
by the Engineer so that at the time of
compaction it is from 1 percent above to
2 percent below the optimum moisture
content corresponding to IS : 2720 (Part
VII). While adding water, due allowance
shall be made for evaporation losses.
After water has been added, the material
shall be processed by mechanical or other
approved means if so directed by the
Engineer until the layer has uniformly
wet.
Immediately thereafter, rolling shall
CHAPTER-XVII
be started with 8 to 10 tonne smooth
wheeled rollers or other approved
equipment. Rolling shall commence at the
edges and progress towards the centre
longitudinally from compaction planes,
ridges, cracks or loose material. All
loose, segregated or otherwise defective
areas shall be made good to the full
thickness of layer and recompacted.
Surface
Finish and 4. The surface finish of construction
Quality
Control of
shall conform to the requirements of para
Work 2 of sub-chapter 1720.Control on the
quality of materials and works shall be
exercised by the Engineer in accordance
with sub-chapter 1720.
Strength of
Sub-base 5. Lower Sub-base and/or sub-base shall
be tested for the CBR value actually
obtained in-situ. In case of variation
from the designed CBR, in-situ value
being on lower side, prior to proceed
with laying of sub-base/base-course on
it, as the case may be, the pavement
design shall be reviewed for actual CBR
Value. The extra pavement thickness
needed on account of lower CBR shall be
constructed by the Contractor at his own
cost.
CHAPTER-XVII
LIME STABILISED SOIL SUB-BASE
1. Scope
2. Materials
2.1 Soil
2.2 Lime
2.3 Quantity of lime in stabilised mix
3. Construction Operations
3.1 Weather limitations
3.2 Degree of pulverisation
3.3 Equipment for construction
3.4 Mix-in-place method of construction
3.5 Construction with manual means
3.6 Addition of lime
3.7 Moisture content for compaction
3.8 Rolling
3.9 Curing
4. Surface finish and quality control of work
5. Strength
CHAPTER-XVII
LIME STABILISED SOIL SUB-BASE
Scope
1. This-work shall consist of laying and
compacting a sub-base of soil stabilised
with lime on prepared subgrade, in
accordance with the requirements of these
specifications and in conformity with the
lines, grades and cross-sections shown on
Engineer.
Material
s- Soil 2.1 Except when otherwise specified, the
soil used for stabilisation shall be the
local soil.
Lime
2.2 Lime for lime-soil stabilisation
work shall be commercial dry lime slaked
at site or pre-slaked lime delivered to
the site in suitable packing. Unless
otherwise permitted by the Engineer, the
lime shall have a purity of not less than
70 per cent when tested in accordance with
IS:15l4.
Quantity
of lime 2.3 Quantity of lime to be added as
in
stabilis
percentage by weight of the dry soil shall
ed mix be specified in the Contract. This
quantity of lime used shall be related to
its calcium oxide content which shall be
specified. Where the lime of different
calcium oxide content is to be used, its
quantity shall be suitably adjusted to the
approval of the Engineer so that
equivalent calcium oxide is incorporated
in the work.
Construc
tion 3.1 Lime-Soil Stabilisation shall not be
Operatio
ns-
done when the "air temperature in the
Weather shade is less than 10C.
limitati
ons
Degree
of 3.2 For lime stabilisation, the soil
pulveris
ation
before addition of stabilizer, shall be
pulverised to the extent that it passes
the requirements set out in Table 2 .
CHAPTER-XVII
TABLE 2.
SOIL PULVERISATION REQUIREMENTS FOR LIME STABILISATION
Sieve designation Minimum per cent by weight passing
the sieve
for black-cotton other soils
soil
26.5 mm 100 100
5.6 mm 55 63
Equipmen
t for 3.3 Stabilised soil sub-bases shall be
construc
tion
constructed by mix-in-place method of con-
struction or as otherwise approved by the
Engineer. Manual mixing shall generally be
permitted only where the width of laying
is not adequate for mechanical operations.
The equipment used for mix-in-place

construction shall be capable of
pulverising the soil to specified degree
to the full thickness of the layer being
processed, and of achieving the desired
degree of mixing and uniformity of the
stabilised material. If so desired by the
Engineer trial runs with the equipment
shall be carried out so as to establish
its suitability for work.
The thickness of any layer to be

stabilised shall be not less than 100 mm
when compacted. The maximum thickness may
be as high as 200 mm, provided the plant
used is accepted by the Engineer as
capable of meeting the specification
requirements.
Mix-in-
place 3.4 Before deploying the equipment, the
method
of
soil after it is made free of undesirable
construc vegetation or other deleterious matter
tion
shall be spread uniformly on the prepared
subgrade in a quantity sufficient to
achieve the desired compacted thickness of
the stabilized layer. Where single-pass
equipment is to be employed, the soil
shall be lightly rolled as the direction
of the Engineer.
The equipment used shall either be of

single-pass or multiple-pass type. The
mixers shall be equipped with an
appropriate device for controlling the
CHAPTER-XVII
depth of processing and the mixing blades
shall be maintained or reset periodically
so that the correct depth of mixing is
obtained at all times.
With single-pass equipment the forward

speed of the machine shall be so selected
in relation to the rotor speed that the
required degree of mixing, pulverization
and depth of processing is obtained.
In multi-pass processing, the soil on

the prepared subgrade shall be pulverized
to the required depth with successive
passes of the equipment and the moisture
content adjusted to be within prescribed
limits mentioned hereinafter. The blending
or stabilizing material shall then be
spread uniformly and mixing continued with
successive passes until the required depth
and uniformity of processing has been
obtained.
The mixing equipment shall be so set

that it cuts slightly into the edge of the
adjoining lane processed previously so as
to ensure that all the material forming a
layer has been properly processed for the
full width.
Construc
tion 3.5 Where manual mixing is permitted,
with
manual
the soil from borrow areas shall first be
means freed of all vegetation and other
deleterious matter and placed on the
prepared sub grade. The soil shall then be
pulverised by means of crow-bars, pick
axes or other means approved by the
Engineer. Water in requisite quantities
may be sprinkled on the soil for aiding
pulverisation. On the pulverised soil, the
blending material(s) in requisite
quantities shall be spread uniformly and
mixed thoroughly by working with spades or
other similar implements till the whole
mass is uniform. After adjusting the
moisture content to be within the limits
mentioned later, the mixed material shall
be levelled up to the required thickness
so that it is ready to be rolled.
Addition
of lime 3.6. Lime may be mixed with the prepared
CHAPTER-XVII
material either in slurry form or dry
state at the option of the Contractor with
the approval of the Engineer.
Dry lime shall be prevented from blowing

by adding water to the lime, or other
suitable means elected by the Contractor,
with the approval of the Engineer.
The tops of windrowed material may be

flattened or slightly trenched to receive
the lime. The distance to which lime may
be spread upon the prepared material ahead
of the mixing operation will be determined
by the Engineer.
No traffic other than the mixing

equipment will be allowed to pass over the
spread lime until after completion of
mixing.
Mixing or remixing operations,

regardless of equipment used, shall
continue until the material is free of
streak or pockets of lime and the mixture
is uniform.
Non-uniformity of colour reaction, when

the treated material is tested with the
standard phenolphthalein alcohol
indicator, will be considered evidence of
inadequate mixing.
Moisture
content 3.7 The moisture content at compaction
for
compacti
checked vide IS : 2720 (Part II) shall not
on be less than the optimum moisture content
corresponding to IS : 2720 (Part VII) nor
more than 2 percent above it.
Rolling
3.8. Immediately after spreading,
grading and levelling of the mixed
material, compaction shall be carried 8 to
10 tons smooth wheel rollers or other
approved equipment preceded by a few
passes of lighter rollers if necessary.
The rolling shall commence at edges and
progress towards the centre, at
superelevated portions where it shall
commence at the edge and progress towards
outer. During rolling the surface shall be
frequently checked for grade and crossfall
CHAPTER-XVII
(camber) and irregularitites corrected by
loosening the material and removing fresh
material. Compaction shall continue until
the dry density achieved is at least 100
percent of the maximum dry density for the
material determined in accordance with
IS : 2720. Care shall be taken to see that
the compaction of lime material is
completed within three hours of its
mixing. Shorter period as may be found
necessary in dry weather.
During rolling it shall be ensured that

compaction equipment shall bear directly
on hardened or partially hardened treated
or previously laid other than what may be
necessary for compacting the specified
compaction at the joint.
The final surface shall be well closed,

free from movement compaction equipment
compaction planes, ridges, cracks i.e.
material. All loose or segregated or
otherwise defective shall be made good to
the full thickness of the layer and acted.
Curing
3.9. The sub-base course shall be
suitably for 7 days or less if so desired
by the Engineer soon after subsequent
pavement courses shall be laid to prevent
from drying out and becoming friable. No
traffic of any ply over the completed sub-
base unless permitted by the Engineer-in-
charge.
Surface
finish 4. The finish of Work of construction
and
quality
shall conform to the required para 2.1 of
control sub-chapter 1720.
of work
Control on the quality of materials and

works shall be exercised by the Engineer
in accordance with sub-chapter 1720.
Strength
5. Lime stabilised soil sub-base shall
obtained in-situ. In case of variation
from the designed CBR, in-situ value being
on lower side, prior to proceeding with
laying of base course on it, the pavement
design shall be reviewed for actual CBR
value. The extra pavement thickness needed
CHAPTER-XVII
on account of lower CBR shall be
constructed by the Contractor at his own
cost.
CHAPTER-XVII
CEMENT STABILISED SOIL SUB-BASE
1. Scope
2. Materials
2.1 Material to be stabilised
2.2 Cement
2.3 Quantity of cement in stabilised mix
3.1 Weather limitations
3.2 Degree of pulverisation
3.3 Spreading and mixing
3.4 Moisture content for compaction
3.5 Rolling
3.6 Curing
4. Surface Finish and Quality Control of Works
5. Strength
CHAPTER-XVII

CEMENT STABILISED SOIL SUB-BASE
Scope
1.This work shall consist of laying and
compacting a sub-base of soil, stabilised
with cement on prepared subgrade, in
lines, grades and cross-sections shown on
Engineer.
Material
s- 2.1 The material used for stabilisation
Material
to be
shall be soil including sand and gravel,
stabilis laterite, kankar, brick aggregate, crushed
ed
rock or slag or any combination of these.
The material shall be well-graded with a
coefficient of uniformity not less than 5
capable of producing a well closed surface
finish to the compacted layer and have a
grading finer than the limit shown in
Table 3. If the material passing the 500mm
sieve is plastic it shall have a liquid
limit not greater than 45 percent and a
plastic limit not greater than 20 per cent
determined in accordance with IS : 2720
(Part V).
TABLE 3. grading limit

Sieve Designation Percentage of
weight passing
the sieve
53 mm 100
45 mm 98
22.4 mm 55
11.2 mm 37
5.6 mm 27
600 micron 8
300 micron 5
75 micron 0
Cement
2.2.Cement for cement stabilisation
shall comply with the requirements of IS:
269, 455 or 1489.
Quantity
of 2.3.The quantity of cement to be added
cement
CHAPTER-XVII
in
stabilis as per percent by weight of the dry soil
ed mix
shall be specified in the Contract.
Construc
tion 3.1 Stabilisation shall not be done when
Operatio
ns
the air temperature in the shade is less
than 10C.
3.2 For stabilisation, the soil before

addition of stabilizer, shall be
pulverised, where necessary, to the extent
that it passes the requirements as set out
in Table 4.
TABLE 4.
SOIL PULVERISATION REQUIREMENTS FOR CEMENT STABILISATION
Sieve designation Minimum per cent by weight

passing the sieve
26.5 mm 100
5.6 mm 80
3.3. Para s 3.3 to 3.5. of specification

No.1703 shall apply as regards spreading and
mixing the stabiliser except that cement
shall be used as the stabilising material.
Moistur
e 3.4 The moisture content at compaction
content
for
checked vide IS: 2720 (Part II) shall not be
compact less than the optimum moisture content
ion
corresponding to IS: 2720 (Part VII) nor
more than 2 percent above it.
Rolling
3.5 para 3.8. of sub-chapter shall apply
except that care shall be taken to see that
the compaction of cement stabilised material
is completed within two hours of its mixing
or such shorter period as may be found
necessary in dry weather.
Curing
3.6. The sub-base course shall be suitably
cured for 7 days. Subsequent pavement
courses shall be laid soon after to prevent
the surface from drying out and becoming
friable. No traffic of any kind shall ply
over the completed sub-base unless permitted
by the Engineer.
Surface
Finish 4. The surface finish of construction
and
CHAPTER-XVII
Quality
Control 2.1 of sub-chapter 1720.
of
Works
works shall be exercised by the Engineer in
accordance with chapter 1720.
Strengt
h 5. Cement stabilised soil sub-base shall
obtained in situ. In case of variation from
the designed CBR, in situ value being on
lower side, prior to proceeding with laying
of base course on it, the pavement design
shall be reviewed for actual CBR value. The
extra pavement thickness needed on account
of lower CBR shall be constructed by the
contractor at his own cost.
CHAPTER-XVII
SPECIFICATION NO 1704
WATER BOUND MACADAM SUB-BASE BASE COURSE
1. Scope
2. Materials-Coarse aggregates
2.1 General requirements
2.2 Crushed or broken stone
2.3 Crushed slag
2.4 Overburnt (Jhama) brick aggregates
2.5 Grading requirement of coarse aggregates
2.6 Screenings
2.7 Binding material
3.1 Preparation of base
3.2 Inverted choke
3.3 Spreading coarse aggregates
3.4 Rolling
3.5 Application of screenings
3.6 Sprinkling of water and grouting
3.7 Application of binding material
3.8 Setting and drying
CHAPTER-XVII
SPECIFICATION NO 1704
WATER BOUND MACADAM SUB-BASE BASE COURSE
Scope
1.1. This work shall consist of clean,
crushed aggregates mechanically
interlocked by roiling and bonded together
with screening, binding material where
necessary and water laid on a properly
prepared subgrade/subbase/base or existing
pavement, as the case may be and finished
in accordance with the requirements of
these specifications and in close
conformity with the lines grades, cross
sections and thickness as per approved
plans or as directed by the Engineer.
1.2. It is, however, not desirable to

lay water bound macadam on an existing
thin black topped surface without
providing adequate drainage facility for
water that would get accumulated at the
interface of existing bituminous surface
and water bound macadam.
Material
s-Coarse 2.1.1 Coarse aggregates shall be either
aggregat
es-
crushed or broken stone, crushed slag,
General overburnt (Jhama) brick aggregates or any
requirem
ents
other naturally occurring aggregates such
as kankar, laterites of suitable quality
(which shall be used in sub-base courses
only). The aggregates shall conform to the
physical requirements set forth in Table
5. The type and size range of the
aggregate shall be specified in the
Contract or shall be as specified by the
Engineer.
TABLE 5.
PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR
WATER BOUND MACADAM/OR SUB-BASE/BASE COURSES
Test Test Method Requirement
Los Angelses IS : 2386(Part—IV) 50 per cent(Max)
Abrasion value
Or *Aggregate IS : 2386 (Part- 40 per cent(Max)
Impact value IV) or IS: 5640**
Flakiness Index*** IS : 2386 (Part—1) 15 per cent(Max)
*Aggregate may satisfy requirements of
CHAPTER-XVII
either of the two tests.
**Aggregates like brick metal, kankar

laterite etc. which get softened in
presence of water shall be tested for
Impact value under wet conditions in
accordance with IS : 5640.
***The requirement of flakiness index

shall be enforced only in the case of
crushed broken stone and crushed slag.
Crushed
or 2.2.The crushed or broken stone shall be
broken
stone
hard. Durable and free from excess flat,
elongated, soft and disintegrated
particles, dirt and other deleterious
material.
Crushed
slag 2.3. Crushed slag shall be made from air-
cooled blast furnace slag. It shall be of
angular shall be reasonably uniform in
quality and density and generally free from
thin Elongated and soft pieces, dirt or
other deletarious materials. The weight of
the crushed slag shall not be less than
1120 kg/cubic metre and the percentage of
glossy material shall not be more than 20.
It should also comply with the following
requirements.
(i) Chemical stability:To comply with

requirements of appendix of BS:1047
(ii) Sulphur content:Maximum 2 percent
(iii)Water absorption:Maximum 10 percent

Overburn
t 2.4.Jhama brick aggregates shall be made
(Jhama)
brick
from overburnt bricks or brick bats and be
aggregat free from dust and other objectionable and
es
deleterious materials.
Grading
requirem 2.5. The coarse aggregate shall conform
ent of
coarse
to one of the gradings given in Table 6 as
aggre- specified, provided, however, the use of
gates
grading No. 1 shall be restricted to sub-
base courses only.
CHAPTER-XVII
TABLE 6.
GRADING REQUIREMENTS OF COARSE AGGREGATES
Grading No. Size range Sieve Percent by

designation weight
passing
1. 90MM TO 45 MM 125 MM 100
90 MM 90-100
63 MM 25-60
45 MM 0-15
22.4 MM 0-5
2. 63 TO 45 90 MM 100
63 MM 90-100
53 MM 25-75
45 MM 0-15
22.4 MM 0-5
3. 53 TO 22.4 63 MM 100
53 MM 95-100
45 MM 65-90
22.4 MM 0-10
11.2 0-5
Note : The compacted thickness for a layer with Grade I shall be

100mm while for layer with other grades i.e. 2 and 3, it shall be 75
mm.
Screening
s 2.6. Screenings to fill voids in the
coarse aggregate shall generally consists
of the same material as the coarse
aggregate. However, where permitted
predominantly non-plastic material such as
moorum or gravel (other than rounded river
borne material) may be used for this
purpose provided liquid limit and
plasticity index of such material are
below 20 and 6 respectively and fraction
passing 75 micron sieve does not exceed 10
percent.
Screenings shall conform to the gradings

set forth in Table 7. The consolidated
details of quantity of screenings required
for various grades of stone aggregates are
given in Table 8. The table also gives the
quantities of materials (loose) required
for 10 m2 for subbase/base compacted
thickness of 75/100 mm.
CHAPTER-XVII
The use of screenings shall be omitted
in the case of soft aggregates such as
brick metal, kankar, laterites, etc. as
they are likely to get crushed to a
certain extent under rollers.
TABIE 7.
GRADING FOR SCREENINGS
Grading Size of Sieve Percent by

Classification Screening designation Wt passing
the Sieve
A 13.2 mm 13.2 mm 100
11.2 mm 95-100
5.6 mm 15-35
180 microns 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180 micron 15-35
Binding
material 2.7. Binding material to used for water
bound macadam as a filler material meant
for preventing ravelling, shall comprise
of a suitable material approved by the
Engineer having a plasticity Index (PI)
value of less than 6 is determined in
accordance with IS : 2720 (Part—V).
TABLE 8.
APPROXIMATE QUANTITIES OF COARSE AGGREGATES AND SCREENING
RFQUIRED FOR 100/75 MM COMPACTED THICKNESS OF WATER BOUND MACADAM
(WBM) SUBBASE/BASE COURSE/FOR 10 SQM.
Coarse Aggregates Screenings

Class Size Comp Loose Stone Screening Crushable Type such
ifica Rang acte Quantit as Moorum or Gravel
tion e d y Gradin For WBM Grading/C Loose
Thic g /sub- lassifica quantity
knes Classi Base/Base tion and
s ficati course Size
on (Loose
and Quantity)
Size
Grad 90- 100 1.21 TO Type 0.27 to Not 0.3 to
e-I 45 MM 1.43 A 0.3 cubic uniform 0.32
MM SQ.M 13.2 m cubic m
mm
CHAPTER-XVII
Coarse Aggregates Screenings
Class Size Comp Loose Stone Screening Crushable Type such
ifica Rang acte Quantit as Moorum or Gravel
tion e d y Gradin For WBM Grading/C Loose
Thic g /sub- lassifica quantity
knes Classi Base/Base tion and
s ficati course Size
on (Loose
and Quantity)
Size
Grad 63- 75 0.91 to Type 0.12 to Not 0.22 to
e-2 45 mm 1.07 A 0.15 uniform 0.24
MM cubic m 13.2 cubic m cubic m
mm
e-2 45 mm 1.07 A 0.22 uniform 0.24
MM cubic m 11.2 cubic m cubic m
mm
e-2 22.4 mm 1.07 A 0.21 uniform 0.24
MM cubic M 11.2 cubic m cubic m
mm
The quantity of binding material where

it is to be used, will depend on the type
of screenings. Generally, the quantity
required for 75 mm compacted thickness of
water bound macadam will be 0.06—
0.09m3/10m2 and 0.08—0.1 Om3/10m2 for iOO
mm compacted thickness.
The above mentioned quantities should be

taken as a guide only, for estimation of
quantities for construction, etc.
Application of binding materials may not

be necessary when the screenings used are
of crushable type such as moorum or
gravel.
Construc
tion 3.1. The surface of the sub-grade/sub-
Operatio
ns:
base/base to receive the water bound
Preparat macadam course shall be prepared to the
ion of
base
specified lines and crossfall (camber) and
made free of dust and other extraneous
material. Any ruts or soft yielding places
shall be corrected in an approved manner
and rolled until firm Sub-Base/base
surface irregularities, where predominant,
shall be made good by providing
appropriate type of profile corrective
course (levelling course) to para 1707 of
CHAPTER-XVII
these specifications.
As far as possible, laying water bound

macadam course over an existing thick,
bituminous layer may be avoided since it
will cause problems of internal drainage
of the pavement at the interface of two
courses. It is desirable to completely
pick out the existing thin bituminous
wearing course where water bound macadam
is proposed to be laid over it. However,
in exceptional cases, where the intensity
of rain is low and the interface drainage
facility is efficient water bound macadam
can be laid over the existing thin
bituminous surface by cutting 50 mm x 50
mm. furrows at an angle of 45 degrees to
the centre line of the pavement at one
metre intervals in the existing road. The
directions and depth of furrows shall be
such that they provide adequate bondage
and also serve to drain water to the
existing grannular base course beneath the
existing thin bituminous surface.
Inverted
choke 3.2. If water bound macadam is to be
laid directly over the sub-grade, without
any other intervening pavement course, a
25 mm coarse or screenings (Grading B) or
coarse sand shall be spread on the
prepared subgrade before application of
the coarse aggregates is taken up. In case
of a fine sand or silty or clayey
subgrade, it is advisable to lay 100 mm
insulating layer of screening or coarse
sand on top of fine grained soil, the
gradation of which will depend upon
whether it is intended to act as a
drainage layer as well. Alternatively,
appropriate geosynthetics performing
functions of separation and drainage may
be used over the prepared subgrade as
directed by the Engineer.
Spreadin
g coarse 3.3. The coarse aggregates shall be
aggregat
es
spread uniformly and evenly upon the
prepared subgrade subbase/base to proper
profile by using templates placed across
the road about 6 m apart, in such
quantities that the thickness of each
compacted layer is not more than 100 mm
CHAPTER-XVII
for grading 1 and 75 mm for grading 2 and
3, as specified in para 1704.2.5. Wherever
possible, approved mechanical devices
shall be used to spread the aggregates
uniformly so as to minimise the need for
manual rectification afterwards.
Aggregates placed at locations which are
inaccessible to the spreading equipment,
may be spread in one or more layers by any
approved means so as to achieve the
specified results.
The spreading shall be done from

stockpiles along the side of the roadway
or directly from vehicles. In no case
shall the aggregates be dumped in heaps
directly on the surface prepared to
receive the aggregates nor shall hauling
over uncompacted or partially compacted
base be permitted. No segregation of large
or fine aggregates shall be allowed and
the coarse aggregate as spread shall be of
uniform gradation with no pockets of fine
material.
The surface of the aggregates spread

shall be carefully checked with templates
and all high or low spots remedied by
removing or adding aggregates as may be
required. The surface shall be checked
frequently with a straight edge while
spreading and rolling so as to ensure a
finished surface as per approved plan.
The coarse aggregates shall not normally

be spread more than 3 days in advance of
the subsequent construction operations.
Rolling
3.4. Immediately following the spreading
of the coarse aggregate, rolling shall be
started with three wheeled power rollers
of 8 to 10 tonne capacity or tandem or
vibratory rollers of approved type. The
type of roller to be used shall be
approved by the Engineer based on trial
run.
Except on superelevated portions where

the rolling shall proceed from inner edge
to the outer, rolling shall begin from the
edges gradually progressing towards the
CHAPTER-XVII
centre. First the edge/ edges shall be
compacted with roller running forward and
backward. The roller shall then move
inwards parallel to the centre line of the
road, in successive passes uniformly
lapping preceding tracks by at least one
half width.
Rolling shall be discontinued when the

aggregates are partially compacted with
sufficient void space in them to permit
application of screenings. However, where
screenings are not to be applied, as in
the case of crushed aggregates like brick
metal, laterite and kankar, compaction
shall be continued until the aggregates
are thoroughly keyed. During rolling,
slight sprinkling of water may be done, if
necessary. Rolling shall not be done when
the subgrade is soft or yielding or when
it causes a wave-like motion in the
subgrade or sub-base course.
The rolled surface shall be checked

transversely and longitudinally, with
templates and any irregularities corrected
by loosening the surface, adding or
removing necessary amount of aggregates
and re-rolling until the entire surface
conforms to desired crossfall (camber) and
grade. In no case shall the use of
screenings be permitted to make up
depression.
Material, which crushed excessively

during compaction or becomes segregated
shall be removed and replaced with
suitable aggregates.
It shall be ensured that shoulders are

built up simultaneously along with water
bound macadam courses as per para
1706.4.1.
Applicat
ion of 3.5. After the coarse aggregate has been
screenin
gs
rolled to para 1704.3.4 screenings to
completely fill the interstices shall be
applied gradually over the surface. These
shall not be damp or wet at the tims of
application. Dry rolling shall be done
while the screenings are being spread so
CHAPTER-XVII
that, vibrations of the roller cause them
to settle into the voids of the coarse
aggregate. The, screenings shall not be
dumped in piles but be spread uniformly in
successive thin layers either by the
spreading motions of hand shovels or by
mechanical spreaders, or directly from
tipper with suitable grit spreading
arrangement. Tipper operating for
spreading the screenings shall be so
driven as not to disturb the coarse
aggregate.
The screenings shall be applied at a

slow and uniform rate (in three or more
applications) so as to ensure filling of
all voids. This shall be accompanied by
dry rolling and brooming with mechanical
brooms, hand-brooms or both. In no case
shall the screenings be applied so fast
and thick as to form cakes of ridges on
the surface in such a manner as would
prevent filling of voids or prevent the
direct bearing of the roller on the coarse
aggregate. These operations shall continue
until no more screenings can be forced
into the voids of the coarse aggregate.
The spreading, rolling, and brooming of

screenings shall be carried out in only
such lengths of the road which could be
completed within one day's operation.
Sprinkli
ng of 3.6.After the screenings have been
water
and
applied, the surface shall be copiously
grouting sprinkled with water, swept and rolled.
Hand brooms shall be used to sweep the wet
screenings into voids and to distribute
them evenly. The sprinkling, sweeping and
rolling operation shall be continued, with
additional screenings applied as necessary
until the coarse aggregate has been
thoroughly keyed, well-bonded and firmly
set in its full depth and a grout has been
formed of screenings. Care shall be taken
to see that the base or subgrade does not
get damaged due to the addition of
excessive quantites of water during
construction.
Applicat
ion of 3.7. After the application of screenings
CHAPTER-XVII
binding
material in accordance with para 1704.3.5 and
1704.3.6. the binding material where it is
required to be used (para 1704.2.7) shall
be applied successively in two or more
thin layers at a slow and uniform rate.
After each application, the surface shall
be copiously sprinkled with water the
resulting slurry swept in with hand
brooms, or mechanical brooms to fill the
voids properly, and rolled during which
water, shall be applied to the wheels of
the rollers if necessary to wash down the
binding material sticking to them. These
operations shall continue until the
resulting slurry after filling of voids,
forms a wave ahead of the wheels of the
moving roller.
Setting
and 3.8. After the final compaction of water
drying
bound macadam course, the pavement shall
be allowed to dry overnight. Next morning
hungry spots shall be filled with
screenings or binding material as
directed, lightly sprinkled with water if
necessary and rolled. No traffic shall be
allowed on the road until the macadam has
set. The Engineer shall have the
discretion to stop hauling traffic from
using the completed water bound macadam
course, if in his opinion it would cause
excessive damage to the surface.
The compacted water bound macadam course

should be allowed to completely dry and
set before the next pavement course is
laid over it.
Surface
and
Quality
Control 2.1 of the sub-chapter 1720.
of Work
CHAPTER-XVII

WET MIX MACADAM SUBBASE/ BASE COURSE
1. Scope
2. Materials
2.1 Grading requirements
3.2 Inverted choke
3.3 Provision of lateral confinement of aggregates
3.4 Mixing water
3.5 Spreading of aggregates
3.6 Rolling
3.7 Setting and drying
4. Opening to Traffic
5.1 Surface evenness
6. Rectification of Surface Irregularity
CHAPTER-XVII
SPECIFICATION NO.1705
WET MIX MACADAM SUBBASE/ BASE COURSE
Scope
1. This work shall consist of laying and
compacting clean, crushed, graded aggregate
and granular material, premixed with water,
to a dense mass on a prepared
subgrade/subbase/base or existing pavement
as the case may be in accordance with the
requirements of these specifications. The
material shall be laid in one or more layers
as necessary to lines, grades and cross-
sections shown on the approved drawings or
as directed by the Engineer. The thickness
of a single compacted wet mix layer shall
not be more than 100 mm when adopted as a
subbase and 75 mm as base.
Materia
ls- 2 Para 2.1 of sub-chapter 1704 shall
apply.
Grading
require 2.1 The aggregates shall conform to one of
ments
the gradings given in Table 9.
TABLE 9.
GRADING REQUIREMENTS OF AGGREGATES FOR
WET-MIX-MACADAM
Sieve Designation Per cent by weight passing the sieve
Grading 1 Grading 1
53 mm 100 -
45 mm 95-100 -
26.5 mm - 100
22.4 mm 60-80 5-100
11.2 mm 40-60 -
4.75 mm 25-40 35-55
2.36 mm 15-30 -
600 micron 8-22 10-30
75 micron 0-8 2-9
The nominal size of aggregate to be used

in a given case would depend on
availability. While buth the gradings can be
used for base/sub-base courses, course using
grading No. I shall not be laid over the
CHAPTER-XVII
course using grading No. 2.
Constru
ction 3.1 Para 3.1 of sub-chapter 1704 shall
Operati
on-
apply.
Prepara
tion of
base
Inverte
d choke 3.2 Para 3.2 of sub-chapter 1704 shall
apply.
Provisi
on of 3.3. Before starting with wet-mix macadam
lateral
confine
construction, necessary arrangements should
ment of be made for the lateral confinement of wet
aggrega
tes
mix. This could be done by constructing side
shoulders in advance to a thickness
corresponding to the compacted layer of the
wet-mix macadam course. After the verge/
shoulders are ready, their inside edges
should be trimmed vertical and the included
area cleaned of all spilled material,
thereby setting stage for spread of the wet-
mix.
Mixing
water 3.4 Aggregates for wet-mix macadam shall
be mixed with the requisite quantity of
water in a power mixer of suitable capacity.
Optimum moisture for mixing shall be
determined in accordance with IS:2720 (Part-
VII) after replacing the aggregate fraction,
retained on 22.4 mm sieve with material of
4.75 mm to 22.4mm size. While adding water
due allowance should be made for evaporation
losses. However at the time of compaction,
water in the wet mix should not vary from
the optimum value by more than 0.5 per cent.
The mixed material should be uniformly wet
and no segregation should be permitted.
Spreadi
ng of 3.5.Immediately after mixing, the
aggrega
tes
aggegates shall be spread uniformly and
evenly upon the prepared subgrade/subbase,
base in required quantities. In no case
should these be dumped in heaps directly on
the area where these are to be laid nor
shall their hauling over a partly completed
stretch be permitted. The aggregates should
be spread to proper profile by using
templates placed across the road about 6
metre apart. Where possible approved
mechanical devices may be used for this
purpose.
CHAPTER-XVII
The surface of the aggregate shall be
carefully checked with templates and all
high or low spots remedied by removing or
adding aggregate as may be required. The
layer may be tested by depth blocks during
construction. No segregation of larger and
fine particles should be allowed. The
aggregates as spread should be of uniform
gradation with no pockets of fine materials.
Rolling
3.6. After aggregates have been laid to
the required thickness, grade and cross-fall
(camber) these should be compacted to the
full width by rolling with either three-
wheeled power roller of 8 to 10 tonnes
capacity or an equivalent vibratory roller
of approved type.
Except in superelevated portions, the

rolling should begin at edges with the
roller running forward and backward until
the edges have been firmly compacted. The
roller should then progress gradually
towards the centre parallel to the centre
line of the road, uniformly over-lapping
each preceding rear wheel track by at least
one half width.
On superelevated portions of the road,

rolling should commence from the lower edge
and progress gradually towards the upper
edge of the pavement.
Rolling should not be done when the

subgrade is soft or yielding or when it
causes a wave-like motion in the sub-base/
base course/sub-grade. If irregularities
develop during rolling which exceed 12 mm
when tested with a 3 metre straight edge,
the surface should be loosened and premixed
material added or removed as required before
rolling again so as to achieve a uniform
surface conforming to the desired grade and
crossfall. In no case should the use of
unmixed material be permitted to make up the
depressions.
Rolling should be continued till the

density achieved is at least 100 per cent of
the maximum dry density for the material as
determined by the method outlined in IS :
CHAPTER-XVII
2720-Part VII. After completion the surface
of any finished layer should be well-closed,
free from movement under compaction
equipment or any compaction planes, ridges,
cracks and loose material. All loose,
segregated or otherwise defective areas
should be made good to the full thickness of
the layer and recompacted.
Setting
and 3.7. After final compaction of wet-mix
drying
macadam course, the road shall be allowed to
dry overnight.
Opening
to 4. Preferably no vehicular traffic of any
Traffic
kind sliould be allowed on the finished wet-
mix macadam surface till it has dried and
the wearing course laid. In exceptional
cases, construction traffic may be allowed
with approval of the Engineer for short
durations once the course is completely dry
provided vehicles move over the full width
avoiding any rutting or uneven compaction.
Surface
Finish 5.1 The surface finish of construction
and
Quality
of
Work-
Surface
evennes
s
5.2. Control on the quality of materials

and works shall be exercised by the Engineer
in accordance with chapter 1720.
Rectifi
cation 6. Where the surface irregularity of the
of
Surface
wet-mix macadam course exceeds the
Irregul permissible tolerances or where the course
arity
is otherwise defective due to sub-grade soil
getting mixed with the aggregates, the full
thickness of the layer shall be scarified
over the affected area re-shaped with added
premixed material or removed and replaced
with fresh premixed material as applicable
and recompacted in accordance with para
1706.3. The area treated in the aforesaid
manner shall not be less than 5 m long and 2
m wide. In no case shall depressions be
filled up with unmixed and ungraded material
or fines.
Arrange
ment 7. During the period of construction,
for
CHAPTER-XVII
Traffic
arrangement of traffic shall be done as per
para 112 of the specificationfor road and
bridge works by MOST.
Measure
ment 8. Wet mix macadam shall be measured as
for
Payment
finished work in position in cubic metres.
CHAPTER-XVII
SHOULDERS AND MEDIAN
1. Scope
2. Materials
3. Size of Shoulder/Median
4.1 Shoulder
4.2 Median
5. Surface Finish and Quality Control of Works
CHAPTER-XVII
SHOULDERS AND MEDIAN
Scope
1. This work shall consist of
constructing shoulder (earthen/ hard) on
either side of the pavement and/or median
in the road dividing the carriageway into
separate lanes in accordance with the
requirements of these specifications and
in conformity with the lines, grades and
cross sections shown on the drawings or as
Material
s 2.Shoulder on either side of the road
may be of selected earth/granular material
conforming to the requirements of para
1701 and the median may be of selected
earth conforming to the requirements of
para 305 of the specification . Median
when raised shall be kerbed at the
perimeter and the enclosed area filled
with earth and suitably covered with grass
turf/shrubs as per para 307 or tiles/slabs
as per the specifications published by
MOST.
Size of
Shoulder 3.Shoulder (earthen/hard) dimensions
/Median
shall be as per their functional
requirements. Median width shall depend
upon the availability of land and if
provided shall neither be less than 1.70 m
nor more than 5.00 m.
Construc
tion 4.1.Except in the case of bituminous
Operatio
ns-
constructions, shoulders shall be
Shoulder constructed in advance of the courses. The
compacted thickness of the layer of
shoulder shall correspond to the compacted
layer of the pavement course to be laid
adjacent to it. After compaction, the
inside edges of shoulders shall be trimmed
vertical and included area cleaned of all
spilled material before proceeding with
the construction of the pavement layer.
In the case of bituminous courses, work

on shoulder (earthen/ hard) shall start
only after the pavement course has been
CHAPTER-XVII
laid and compacted.
During all stages of shoulder

(earthen/hard) construction the required
crossfall shall be maintained to run off
surface water.
Regardless of the method of laying, all

shoulder construction material shall be
placed directly on the shoulder. Any
spilled material dragged on to the
pavement surface shall be immediately
removed, without damage to the pavement,
and the area so affected thoroughly
cleaned.
Median
4.2.Median shall be constructed in a
manner similar to shoulder upto the road
level. Thereafter the median if raised,
shall be raised at least 300 mm by using
kerb stones of approved material and
dimensions and suitably finishing it and
painted as directed by the Engineer. If
not raised, the median shall be
differentiated from the shoulder/pavement
as the case may be, as directed by the
Engineer. The confined area of the median
shall be filled with local earth or
granular material or any other approved
material. The confined area after filling
with earth shall be turfed with grass or
planted with shrubs and in case of
granular fill it can be finished with
tiles/slabs as directed by the Engineer.
Surface
Finish 5. The surface finish of construcrion
and
Quality
Control 2.1 of sub-chapter 1720.Control on the
of Works
excercised by the Engineer in accordance
with sub-chapter 1720.
CHAPTER-XVII
PREPARATION OF BASE
1. Scope
2. Materials
2.1 For scarifying and re-laying the granular base course
2.2 For patching potholes
2.3 For profile corrective course
2.3.1 Types of Profile Corrective Course material and their
application
2.3.2.Profile Corrective Course is classified under the
following broad categories of materials
2.3.3.Application- Over existing bituminous surfaces
2.3.4 Profile corrective course
2.4.5 Assessment of Profile Corrective Course
CHAPTER-XVII
PREPARATION OF BASE
Scope MOST
1. This work shall consist of preparing specific
ation
an existing water bound macadam, wet mix
macadam or black-topped surface to
specified lines, grades and cross-sections
in advance of laying a bituminous course.
The work shall be performed on such widths
and lengths as may be directed by the
Engineer and may consist of scarifying and
relaying the granular base course, filling
of potholes and/or application of a
profile corrective course (leveling
course) as necessary.
Material
s- For 2.1 The materials used shall be coarse
scarifyi
ng and
aggregates salvaged from scarification of
re- the existing base course supplemented by
laying
the
fresh coarse aggregates and screenings
granular corresponding to sub-chapter 1704 water
base
course
bound macadam or sub-chapter 1706 wet mix
macadam as the case may be.
For
patching 2.2 For patching potholes, the materials
potholes
used shall be coarse aggregate, screening,
stone chippings, bitumen cationic bitumen
emulsion or a combination thereof as
specified, conforming to the quality
requirements of these materials given
elsewhere in these Specifications
depending upon the site requirements.
For
profile 2.3 A profile corrective course
correcti
ve
(levelling course) is essential for a
course pavement base material course for
correcting the existing pavement profile
which has either lost its shape or has to
be given a new shape to meet the
requirement of specified lines, grades and
cross-sections.
It shall be differentiated from the

strengthening course or other type of
structural pavement course needed as a
remedial measure against inherent
deficient and/or distressed pavement. It
is meant to remove the irregularity in the
CHAPTER-XVII
existing section only.
Types of
Profile 2.3.1. The type of material for Profile
Correcti
ve
Corrective Course shall be decided based
Course on its thickness and the type of pavement
material
and
surface over which it is required to be
their placed for its suitability to work in
applicat
ion
conjunction with the existing pavement
course material.
Profile
Correcti 2.3.2.1 Premixed bituminous material
ve
Course
conforming to sub-chapter 1714. Open
is graded premix carpet, excepting the seal
classifi
ed under
coat.
the
followin
g broad
2.3.2.2 Premixed bituminous material
categori confroming to sub-chapter 1710 with binder
es of content of 3 per cent by weight of total
material
s mix. The aggragate may conform to grading
in Tables 3 and 4 of sub-chapter 1710
depending upon the thickness requirement.
2.3.2.3 Water bound macadam

corresponding to grading 3 of Table 6
(sub-chapter 1704).
2.3.2.4 Wet Mix macadam conforming to

sub-chapter 1706.
Applicat
ion- 2.3.3.1 Type A mix shall be used
Over
existing
normally where the irregularities to be
bitumino made up are of non-uniform character and
us
surfaces
of thickness between 20 to 40 mm making
the use of Type B mix not practicable.
However, where profile corrective course
thickness works out to be less than 20 mm
and the overlay course consists of a plant
laid bituminous material, no separate
Profile Corrective Course shall be
prescribed and the requirement shall be
made up as the integral part of the
overlay course.
2.3.3.2 Type B mix shall be adopted

where the thickness of Profile corrective
course is more than 40 mm. The mix shall
usually be hot mixed and hot laid with
mechanical paver in accordance with sub-
chapter 1710, except in isolated locations
or where the work is to be carried out in
narrow widths where laying by other means
CHAPTER-XVII
may be permitted by the Engineer.
Over
granular 2.3.3.3 Type C/D mix shall be provided
surfaces
over existing WBM or any other granular
surface. The mix should preferably be of
the same material as that of existing
surface or having superior engineering
properties. The thickness of Type C/D
Profile Corrective Course shall be 75 mm
(compacted) in a single lift.
2.3.4. Normally the requirement of

Profile Corrective Course exceeding 75 mm
thickness should not arise. The
requirement in excess of 75 mm should not
be catered for under Profile Corrective
Course, in exceptional circumstances where
the requirement is for a specific purpose
such as making up the super elevation of
the horizontal curves, existing two lane
road to be provided with uni-directional
crossfall (camber) to form a part of 4
lane highway, localised short sags or
depressions as described in para 3.4. of
sub-chapter 1707. These requirements
varying from zero thickness to 75 mm
should preferably be met using type A/B
mix depending on condition of the road
surface. Normally, the loss of profile to
such a large extent i.e. in excess of
average 75 mm may not take place, unless
there is some sort of a basic deficiency
or design inadequacy in the road structure
and materials used in it or in its
construction. For this Profile Corrective
Course is not the right answer. The remedy
lies in establishing the causes for such a
situation through investigation and
providing suitable and adequate remedial
measures to overcome the deficiency.
However, where it is conclusively

established that the irregularities
needing more than 75 mm are not due to any
structural deficiency. Profile Corrective
Course requirement may be split into two
layers, treating the top layer of uniform
thicknes is a structural layer and the
bottom layer of varying thickness as
Profile Corrective Course wherever
applicable. The Profile Corrective Course
CHAPTER-XVII
could be of any type A to D but where it
is of type C/D, it shall be ensured that
the top layer of bituminous surface, if
existing, shall be completely removed
prior to laying of the Profile Conective
Course and the underneath disturbed
existing WBM base course duly rectified
and also drainage requirement duly
provided for the internal pavement layer.
If isolated high splits (humps/bumps)

projecting over pavement surface do exist,
the same shall be cut to minimise the
Profile Corrective Course requirement.
Assessme
nt of 2.3.5. Assessment of Profile Corrective
Profile
Correcti
Course shall be done by plotting the
ve existing road profile by taking levels at
Course
close intervals, the actual interval for
levels required for the purpose may be
decided by the Engineer keeping in view
the site situation in each individual case
and superimposing over it the Profile
Corrective Course profile which is derived
from the final road profile, which is
decided and fixed from other
considerations independent of Profile
Corrective Course after accounting for the
thickness of the stipulated superimposed
course (s) over Profile Corrctive Course.
A judicious and cautious work back of
Profile Corrective Course profile is
essential. Profile Corrective Course
profile shall not normally be fixed first
and the final road profile decided
thereafter.
Construc
tion 3.1 The existing bituminous surface
Operatio
ns
shall be removed, where it has been
envisaged so, by method as approved by the
Engineer. After removing it, the
underneath aggregate base which would have
been disturbed in the removal process,
shall be loosened to a depth of 50 mm or
so. The resulting material shall be
removed and screened to salvage coarse
aggregate for use in the Profile
Corrective Course type C/D alongwith the
fresh material. Local high spots on the
exposed surface, if any, shall be
corrected. The salvaged aggregate mixed
CHAPTER-XVII
with requisite quantities of fresh
aggregates shall be spread on the prepared
exposed surface and compacted as water
bound macadam or provided as wet mix
macadam to a thickness 75 mm in accordance
with relevant sub-chapter 1704 and 1706
for these courses.
3.2. Before providing Profile Corrective

Course on the existing pavement, pot holes
if any shall be drained of water, cut to
regular shape with sides vertical upto the
affected depth and slightly beyond the
limits of affected area and dried. All
loose and disintegrated materials from it
shall be removed. The pot holes shall then
either be filled with (i) coarse aggregate
and screenings conforming to sub-chapter
1704, where the pot hole depth extends in
the water bound macadam base coarse, and
compacted with heavy hand rammers/
approved mechanical tampers.
Alternatively, type D could also be used
upto water bound macadam base course
surface and the balance depth with
premixed material to sub-chapter 1714
excepting seal coat after painting the
sides and bottom of the pot holes with
thin application of hot bitumen/emulsion
or (ii) premixed material to sub-chapter
1714 excepting seal coat only where the
pot holes depth lies within the bituminous
course itself, after painting the sides
and bottom of potholes with a thin
application of hot bitumen/emulsion and
compacted with roller or other approved
means. All loose and/or surplus materials
on the surface after making good the pot
holes shall be removed.
3.3 After filling the pot holes to para

3.2. of sub-chapter 1707 the surface on
which Profile Corrective Course is to be
laid shall be thoroughly swept and scraped
clean of dust and any other extaneous
material. The specified type of Profile
Corrective Course shall then be laid and
compacted to the requirement of the
respective specifications. In case of type
A/B, tack coat conforming to sub-chapter
1709 shall be applied prior to laying
CHAPTER-XVII
Profile Corrective Course.
3.4. In specific situation of short sags

or depressions in the pavement, it may
become necessary to provide corrective
course in the form of flat wages.
Normally, layers in maximum thickness at

any point more than 75 mm should not be
provided. In placing multiple lifts, the
lift of shortest length (at the lowest
portion of the sag/depression) should be
provided first, with successive lifts
extending over and fully covering
underneath layer. This will preclude
developments of a series of joints on the
top surfaces, in case lifts are provided
in reverse way i.e. the shortest at the
top, which otherwise would cause roughness
in riding besides a weak structural
composition.
Fig. 1
Fig. 2
For proper appreciation of what is

stated above, two illustrative sketches
are given as Figs. 1 and 2.
3.5 Work of Profile Corrective Course
CHAPTER-XVII
shall be so planned that it shall be
covered by the designed base/wearing
course at the earliest, before opening to
traffic.
Surface
Finish 4. Relevent Provisions of Section 300 of
and
Quality
the specificationfor road and bridge works
Control by MOST shall be exercised by the
of Work
Engineer.
CHAPTER-XVII
PRIMER COAT OVER GRANULAR BASE
1. Scope
2. Materials
3. Weather and Seasonal Limitations
4. Construction
4.1 Equipment
4.2 Preparation of road surface
4.3 Application of bituminous primer
4.4 Curing of primer and opening to traffic
4.5 Laying of bituminous course over primed surface
5. Quality Control of Work
CHAPTER-XVII
PRIMER COAT OVER GRANULAR BASE
Scope
1. This work shall consist of application
of single out of low viscosity liquid
bituminous material to an absorbant
granular surface preparatory to any
superimposed bituminous treatment or
construction.
Materials
2 The choice of a bituminous primer shall
depend upon the porosity characteristics
of the surface to be primed as classified
in Paras 3.1. to 3.3. of IRC: 16-I965
These are : i) Surfaces of low porosity;
ii) Surfaces of medium porosity;
(iii) Surfaces of high porosity.
2.2. The different ranges of viscosity

requirements for the primers to be used for
the different types of the surfaces to be
primed, as classified in 2.1 of sub-
chpater 1708, are given in Table 10.
TABLE 10.
VISCOSITY REQUIREMENT OF PRIMERS
Type of surfaces Standard tar
viscosity of
Primer at 60°
Low Porosity 0-5
Medium Porosity 6-12
High Porosity 16-32
2.3. The bituminous primer shall be Medium

curing (MC) or Slow curing (SC) cut backs as
per ISI : 217/61. Apart from bitumen cut
backs, emulsions, coal tar-pitch, creosote,
etc. also can be used, subject to the
viscosity and surface requirements as in
Table 10 being adhered to.
Weathe
r and 3. The bituminous primer shall not be
Season
al
applied on a wet surface or during dust
CHAPTER-XVII
Limita
tions storm or when the weather is foggy or rainy.
The prime coat for surface treatment should
not be applied when the temperature in the
shade is less than 10°C
Constr
uction 4.1. The primer distributor shall be
-
Equipm
equipped for spraying the material uniformly
ent: at the specified rates and temperatures.
Prepar
ation 4.2 The surface to be primed shall be
of
road
swept clean, free from dust and shall be
surfac dry. It shall be shaped to the specified
e
grades and section. It shall also be free
from ruts, any other irregularities and
segregated materials. Minor depressions and
pot holes may be ignored until the surface
is primed, alter which they shall be patched
with a suitable premix material prior to the
surface treatment.
Applic
ation 4.3. The bituminous primer shall be
of
bitumi
sprayed/distributed uniformly over the dry
nous surface as prepared as per para 4.2. of sub-
primer
chapter 1708 using either self propelled or
towed pressure sprayer with self heating
arrangement and spraying nozzle capable of
spraying primer at specified rates and
temperature so as to provide a uniformly
unbroken spread of primer. The primer shall
be applied at the rate as specified in Table
11.
TABLE 11.
QUANTITY OF BITUMINOUS PRIMERS

Grade of Primer Quantity per 10
sq.m. kg
Primer for surfaces 7.3 to 9.8
of low Porosity
of medium Porosity
of high Porosity
Temperature of application of a primer

need only be high enough to permit the
primer to be effectively sprayed through
the jets of the spray bar and to cover the
granular base surface uniformly.
CHAPTER-XVII
The temperature of the bituminous
cutback primer at the time of application
may vary from 40° to 80°C and that of
bitumen emulsion between 10° to 60°C. The
quantity of primer as given in Table 2 can
vary ±1.5 kg as directed by Engineer where
specifically required.
Any pool of excess primer left on any

part of the surface should be swept out
over the adjacent surface and then a light
spreading of sand or stone grit shall be
applied.
The primer coat shall be applied only on

the top most water bound macadam or any
granular layer, over which the bituminous
base course/wearing course is to be laid.
Curing
of 4.4 It shall always be ensured that
primer
and
while opening to any kind of traffic, the
opening primed surface is fully cured and is not
to
traffic
sticky to avoid being picked up by
traffic. Normally, the primed surface
shall be allowed to cure for not less than
24 hours and during this period no traffic
of any kind shall be permitted.
Laying
of 4.5. Bituminous base course or wearing
bitumin
ous
course shall be laid over the primed water
course bound macadam or any other granular base
over
primed
course, in the usual manner as per
surface relevant specification for the same
including the requirement of tack coat as
per sub-chapter 1709.
Quality
Control 5. Control on the quality of materials
of Work
and work shall be exercised by the
Engineer in accordance with chapter 1720.
CHAPTER-XVII
TACK COAT
1. Scope
2. Materials-Binder
3.2 Application of binder
4. Quality Control of Work
CHAPTER-XVII
TACK COAT
Scope
application of a single coat of low
viscosity liquid bituminous material to an
existing road surface preparatory to
another bituminous construction over it.
Material
s-Binder 2. The binder used for tack coat shall
be bitumen of a suitable grade appropriate
to the region, traffic, rainfall and other
environmental conditions as directed by
the Engineer and conforming to IS: 73, 217
or 454, as applicable, or any other appr-
oved cutback.
Construc
tion 3.
Operatio
n
Preparat
ion of 3.1. The surface on which the tack coat
base
is to be applied shall be cleaned of dust
and any extraneous material before the
application of the binder, by using a
mechanical broom or any other approved
equipment/ method as specified by the
Engineer.
Applicat
ion of 3.2. Binder shall be heated to the
binder
temperature appropriate to the grade of
bitumen used and approved by the Engineer
and sprayed on the base at the rate
specified in Table 12. The rate of spread
is in terms of straight run bitumen.
TABLE 12. rate of application of tack coat

Type of Surface Bitumen quantity in kg per
10 sq. metre area
(i) Normal bituminous 5 to 5.5
surfaces
(ii) Dry and hungry 6.0 to 7.5
bituminous surfaces
(iii) Granular surfaces 6.0 to 7.5
CHAPTER-XVII
treated with primer
(iv) Non bituminous
surfaces
(a) Granular base (not 10.0
primed)
(b)Cement concrete 7.5
pavement
Note: There is no need to apply a tack coat on a freshly laid
bituminuuA. course if the subsequent bituminous course is overlaid
immediately without opening it to traffic.
3.2.2. The binder shall be applied

uniformly with the aid of either self
propelled or towed bitumen pressure
sprayer with self heating arrangement and
spraying nozzles arrangement capable of
spraying bitumen at specified rates and
temperature so as to provide a uniformly
unbroken spread of bitumen.
The tack coat shall be applied just

ahead of the oncoming bituminous
construction.
Quality
4. Control on the quality of materials
Control
and works shall be exercised by the
of Work
CHAPTER-XVII
SPEICFICATION NO. 1710
BITUMINOUS MACADAM
1. Scope
2. Materials
2.1 Bitumen
2.2 Aggregates
2.3 Proportioning of materials
2.4 Variation in proportioning of material
3.1 Weather and seasonal limitations
3.2 Preparation of the base
3.3 Tack coat
3.4 Preparation and transport of mix
3.5 Spreading
3.6 Rolling
CHAPTER-XVII
SPEICFICATION NO. 1710

BITUMINOUS MACADAM
Scope
1.The work shall consist of
construction, in a single course, of 50
mm/ 75mm thickness of compacted crushed
asgregates Premixed with a bituminous
binder, to serve as base/binder course,
laid immediately after mixing, on a base
prepared previously in accordance with the
requirement of these specifications and in
conformity with the requirement of these
line, grades and cross sections shown on
the drawing or as directed by the
Engineer.
Materials-2
Bitumen
2.1 The bitumen shall be paving bitumen
of suitable penetration grade within the
range S 35 to S 90 or A 35 to A 90 (30/40
to S O/100) as per Indian Standards
Specifications for "Paving Bitumen" IS:
73-1961. The actual grade of bitumen to be
used shall be decided by the Engineer
appropriate to the region, traffic,
rainfall and other environmental
conditions.
Aggrega
tes 2.2.1. The aggregates shall consist of
crushed stone, crushed gravel/shingle or
other stones. They shall be clean, strong,
durable of fairly cubical shape and free
from disintegrated pieces, organic or
other deleterious matters and adherent
coating. The aggregates shall preferably
be hydrophobic and of low porosity. If
hydrophillic aggregates are to be used the
bitumen shall preferably be treated with
anti stripping agents of approved quality
in suitable doses. The aggregates shall
satisfy the physical requirements set
forth in Table 13.
CHAPTER-XVII
TABLE 13.
physical requirements of aggregates for bituminous macadam
S.No. Test Test Method Requirement
1 Los Angeles Abrasion IS:2386 40% Maximum
Value* (Part-IV)
2. Aggregate Impact IS:2386 30% Maximum

Value (Part-IV)
3. Flakiness Index IS:2386 35% Maximum
(Part-I)
4. Stripping Value IS:6241 25 % Maximum
5. Soundness :
(i) Loss with sodium 12 %
sulphate 5 cycle
(ii) Loss with 18%
Magnesium sulphate 5
cycle
6. Water Absorption IS:2386 22%
(Part-II)
•Aggregates may satisfy requirements of either of the two tests.

Note: If crushed slag is used. para 1704.2.3 shall apply.
2.3.2. The aggregate for bituminous

macadam for different thicknesses shall
conform to the Grading given in Tables 14
and 15.(The actual grading to be used
shall be specified in the contract).
TABLE 14. AGGREGATE GRADING FOR 50 mm COMPACTED
CHAPTER-XVII
Sieve Designation (IS) Percent by weight
passing the sieve
26.5 mm 100
22.4 mm 75-100
11.2 mm 50-85
5.6 mm 20-40
2.8 mm 5-20
90 micron 0-5
TABLE 15. AGGREGATE GRADING FOR 75 mm COMPACTED
THICKNESS OF BITUMINOUS macadam

Sieve Designation (IS) Percent by weight
passing the sieve
45 MM 100
26.5 mm 75-100
22.4 mm 60-95
11.2 mm 30-55
5.6 mm 15-35
2.8 mm 5-20
90 micron 0-5
Proporti
oning of 2.3 The bitumen content for premixing
material
s
shall be 4 percent by weight of the total
mix except when otherwise directed by the
Engineer.
The quanitities of aggregates to be used

shall be sufficeint to yield the specified
thickness after compaction.
Variatio
n in 2.4 The Contractor shall have the
proporti
oning of
responsibility for ensuring proper
material proportioning of materials and producing a
uniform mix. A variation in binder content
± 0.3 percent by weight of total mix
shall, however, be permissible for
individual specimens taken for quality
control tests vide chapter 1720.
CHAPTER-XVII
-Weather
and 3.1. The work of laying shall not be
seasonal
limitati
taken up during rainy or foggy weather or
ons when the base course is damp or wet, or
during dust storm or when the atmospheric
temperature in shade is 15°C or less.
Preparat
ion of 3.2. The base on which bituminous
the base
macadam is to be laid shall be prepared,
shaped and conditioned to the specified
lines, grades and cross sections in
accordance with para 1707, and a priming
coat where needed shall be applied in
accordance with para 1708 as directed by
the Engineer.
Tack
coat 3.3. A tack coat as per sub-chapter 1709
shall-be applied over the base.
Preparat
ion and 3.4. Bituminous macadam mix shall be
transpor
t of mix
prepared in a hot mix plant of adequate
capacity and capable to yield a mix of
proper and uniform quality with thoroughly
coated aggregates. The plant may be either
a weigh batch or. Volumetric proportioning
continuous or drum mix type. The plant
shall have coordinated set of essential
units capable of producing uniform mix
within the job mix formula such as
(a) Cold aggregate feed system for

providing blended aggregate in the correct
proportion(called Cold Binfeed
arrangement).
(b) Rotating cylindrical dryer drum

fitted with suitable burner capable of
heating the aggregate to the required
temperature without any visible unburnt
fueol or carbon residue on the
aggregateand to reduce the moisture
content of the aggregate to specified
minimum level.
(c) The dryer units shall be fitted with

approved type of thermometric instruments
at appropriate places so as to indicate or
automatically record/register the
temperature of heated aggregate before
CHAPTER-XVII
adding/ mixing the binder.
Gradatio
n (d) Except in case of Drum Mix Plant,
control
other two types of plants mentioned above
shall have :
(i) A screening unit for accurate sizing

of hot aggregate and feeding the same to
mixing unit by weight or volume control as
per the specified job mix, formula.
(ii) Paddle Mixer unit shall be capable

of producing a homogenous mix with uniform
coating of all panicles of the mineral
aggregate with binder.
(e) In case of Drum Mix Plant, the cold

feed system shall have variable speed belt
conveyors/or other suitable devices for
regulating the accurate proportioning of
aggregate into an even feed flow automa-
tically from a Central operating/control
cabin.
Bitumen
control (f) Capable of measuring/metering and
unit
spraying required quantity of bitumen at
specified temperature with automatic
synchronisation of bitumen and aggregate
feed.
Filler
system g) A fines feeder system suitable 10
receive bagged or bulk supply of filler
material and its incorporation to the mix
in the correct quantity shall be a
necessary auxiliary.
Dust
control (h)A suitable built in dust control
equipment for the dryer to contain the
exhaust of fine dust into atmosphere for
environmental control, wherever so
specified by the Engineer.
(i) Suitable Auxiliary Bitumen Boiler of

adequate capacity with self heating
arrangement and temperature control
device. The boiler should be fitted with
temperature indicating instruments.
CHAPTER-XVII
The temperature of binder at the time of
mixing shall be in the range of 150° to
165° C and that of the aggrgate in the
range of 125° tu 150° C, provided that the
difference in temperature between the
binder and aggregate at no time exceeds
25° C.
Mixing shall be thorough to ensure that

a homogeneous mixture is obtained in which
all particles of the aggregates are coated
uniformly, and the discharge temperature
of mix shall be between 130° C to 160° C.
The mixture shall be transported from

the mixing plant to the point of use in
suitable tipper vehicle. The vehicles
employed for transport shall be clean and
be covered over in transit if so directed
by the Engineer.
Spreadin
g 3.5.The mix transferred from the tipper
at site to the paver shall be spread
immediately by means of self propelled
mechanical paver with suitable scieeds
capable of spreading, tamping, and
finishing the mix true to the specified
lines, grades and cross sections. The
paver finisher shall have the following
essential features :
(a) Loading hoppers and suitable

distributing mechanism.
(b) All drives having hydrostatic

drive/control.
(c) The machine shall have a

hydraulically extendable screed for
appropriate width requirement.
(d) The screed shall have tamping and

vibrating arrangment for initial
compaction to the layer as it is spread
without rutting or otherwise marring the
surface. It shall have adjustable
amplitude and infinetely variable
frequency.
CHAPTER-XVII
(e) The paver shall be equipped with
necessary control mechanism so as to
ensure that the finished surface is free
from surface blemishes.
(f) The paver shall be filled with an

electronic sensing device for automatic
levelling and profile control within the
specified tolerances.
g) The screed shall have (he internal

heating arrangement.
However, in restricted locations and in

narrow widths where the available plant
cannot be operated in the opinion of the
Engineer, he may permit manual laying of
the mix.
The temperature of the mix at the time

of laying shall be in the range of 120° to
135°C. In multi-layer construction the
longitudinal joint in one layer shall
offset that in the layer below by about
150 mm. However, the joint in the top most
layer shall be at the centre line of the
pavement.
Longitudinal joint and edges shall be

constructed true to the delineating line
parallel to the central line of the read.
All jcints shail be cut vertical to the
full thickness of the previously laid mix
and the surface painted with the hot
bitumen befcre placing fresh material.
Rolling
3.6. After the spreading of mix rolling
shall be done by 8 to 10 tonne power
rollers or other approved equipment.
Rolling should start as soon as possible
after the material has been spread.
Rolling shall be done with care to keep
from unduly roughening the pavement
surface.
RoIIing of the longitudinal joints shall

be done immediately behind the paving
operation.
CHAPTER-XVII
After this the rolling shall commence at
the edges and progress towards the centre
longitudinally except that on
superelevated portions it shall progress
from the lower to the upper edge parallel
to the central line of the pavement.
The initial or break down rolling shall

be done, with 8 to 12 tonnes three wheel
steel roller, as soon as it is possible to
role the mix without cracking the surface
or having the mix pick up on the roller
wheels. The second or intermediate rolling
shall follow the break down rolling as
closely as possible and be done while the
paving mix is still at a temperature that
will result in maximum density. The final
rolling shall be done while material is
still workable enough for removal of
roller marks with 8 to 10 tonne tandem
roller. All the compaction operations i.e.
break down rolling, intermediate rolling
and final rolling can be accomplished by
using a vibratory roller of 8 to 10 tonnes
static weight. During the initial or
break down rolling and final rolling,
vibratory system shall be switched off.
The joints and edges shall be rolled with
a 8 to 10 lonne static roller.
When the roller has passed over the

whole area once, any high spots or
depressions which become apparent shall be
corrected by removing or adding mix
material. The rolling shall then be
continued till the entire surface has been
rolled to compaction, there is no crushing
of aggregates and all roller marks have
been eliminated. Each pass of the roller
shall uniformly over-lap not less than
one-third of the track made in the
preceding pass.. The roller wheel shall be
kept damp if necessary to avoid bituminous
material from sticking to the wheels and
being picked being picked up. In no case
shall fuel lubricating oil be used for
this purpose nor excessive water poured on
the wheels.
CHAPTER-XVII
Rolling Operations shall be completed in
every respect before the temperature of
the mix fall below 80ºC.
Roller (s) shall not stand on newly laid

material while there is a risk that it
will be deformed thereby. The edges
along and transverse of the bituminous
macadam laid and compacted earlier shall
be cut to their full depth so as to expose
fresh surface which shall be painted with
a thin surface coat of appropriate binder
before the new mix is placed against it.
Surface
and
Quality
Control 2.1 of sub-chapter 1720.Control on the
of Work
with chapter 1720.
5. The bituminous macadam shall be

covered with either the next pavement
course or wearing course, as the case may
be, without any delay. If there is to be
any delay, the course shall be covered by
a seal coat to the requirement of sub-
chapter 1717 before allowing any traffic
over it.
CHAPTER-XVII
BITUMINOUS PENETRATION MACADAM
1. Scope
2. Materials
2.1 Bitumen
2.2 Aggregates
2.3 Quantities of materials
3.3 Spreading and compacting coarse aggregates
3.4 Rolling
3.5 Application of bituminous material
3.6 Application of key aggregates
4. Surface Finish and Quality Control
CHAPTER-XVII
Scope
1. The work shall-consist of
construction of one or more layers of
compacted layer coarse aggregates with
alternate applications of bituminous
binder and key aggregates in accordance
with the requirements of these
specifications to serve as base/binder
course and in conformity, with the lines,
grades and cross-sections shown on the
drawings or as directed by the Engineer.
Thickness of an individual course shall
not exceed 75 mm.
Materia
ls 2.1. The binder shall be paving bitumen
-Bitume
n
of suitable penetration grade within the
range of S-35 to S-90 or A-35 to A-90
(30/40 to 80/100) as per Indian Standards
Specifications for "Paving Bitumen" IRC :
73-1961. The road tar grade RT-4/RT-5 or
approved cut backs satisfying the
requirements of IS : 73. 215, 217 or 454.
The actual grade of bitumen tar or cut
backs to be used shall be decided by the
Engineer, appropriate to the region,
traffic, rainfall and other environmental
conditions.
Aggrega
tes 2.2.1. The aggregates shall satisfy the
physical requirements set forth in sub-
chapter 1710.2.2.1 and Table 13.
2.2.2 The coarse aggregates shall

conform to the gradings given in Table 16.
Quantit
ies of 2.3 The quantites of materials used fro
materia
ls
this work shall be as pecified in Table
17.
CHAPTER-XVII
TABLE 16.
GRADING REQUIREMENTS OF COARSE AGGREGATES AND KEY AGREGATES FOR
Sieve Percent by weight passing the sieve
designa For 50 m compacted For 75 mm compacted
tion thickness thickness
Coarse Key Coarse Key
aggrega aggregate aggrega aggregate
te te
63 mm - - 100 -
53 mm 100 - - -
45 mm - - 58-82 -
26.5 mm 37-72 - - 100
22.4 mm - 100 5-27 50-75
13.2 mm 2-20 50-75 - -
11.2 mm - - - 5-25
5.6 mm - 5-25 - -
2.8 mm 0-5 0-5 0-5 0-5
TABLF 17.
QUANTITIES OF MATERIAL REQUIRED FOR 10 SQ. M. OF ROAD SURFACE FOR
BITUMINOUS PENETRATION MACADAM BASE/BINDER COURSE
Compact Binder Coarse Key
ed Straigh Road Aggregate aggregate
thickne t run Tar RT-
ss bitumen 4/RT-9
50 mm 50 kg 60-65 0.60 cubic 0.15 cubic
kg m m
75 mm 68 kg 82-88 0.90 cubic 0.18 cubic
kg m m
Construc
tion Sub-chapter 1710.3.1 shall apply.
Operatio
ns-
Weather
and
seasonal
limitati
ons
Preparat
ion of 3.2.The base on which the Penetration
the base
Macadam Course is to be laid shall be
CHAPTER-XVII
prepared, shaped and conditioned to the
specified lines, grades and sections to
para 1707 or as directed by the Engineer.
A priming coat where needed shall be
applied over the base in accordance with
para 502 or as directed by the Engineer. A
tack coat as per sub-chapter 1709 shall be
applied.
Spreadin
g and 3.3 The coarse aggregate in a dry and
compacti
ng
clean form shall be spread uniformly and
coarse evenly at the rate specified in Table 8
aggregat
es
preferably with the help of a self
propelled or towed aggregate spreader
capable of spreading aggregate niformly at
the specified rates over the required
widths. The surface of the layer shall be
carefully checked with camber templates
and all high and low spots remedied by
removing or adding aggregates as may be
required.
The spreading shall be carried no

further in advance of the rolling and
penetrating operations than can be
completed in one average day's work.
Segregated aggregates or aggregates mixed
with earth or other foreign substances
shall be removed and replaced with graded
aggregates.
Rolling
3.4 After the spreading of coarse aggre-
gates. dry rolling shall be done by 10
tonne smooth wheeeled steel roller.
Rolling shall be done by 10 tonne smooth
wheeled steel roller. Rolling shall start
as soon as possible after the material has
been spread. The rolling shall commence at
the edges, parallel to the centre line of
the road overlapping the verge shoulder at
least 300 mm and progress towards the
centre longitudinally except on
progress from the lower to the upper edge
after the edges have been rolled. For
superelevatedportions the overlapping
should be approximately one third of the
width of the rear wheel on each trip.
After the initial dry rolling, the

surface shall be checked with a crown
CHAPTER-XVII
template and a 3 metre straight edge. The
surface shall not vary more than 12 mm
from the template or straight edge. All
surface irregularities exceeding the above
limit shall be corrected by removing or
adding aggregates as required.
The rolling shall be done until the

compacted coarse aggregate has a firm
surface true to the cross section shown on
the plans and that it has a texture that
will allow free and uniform penetration of
the bituminous material.
Applicat
ion of 3.5 After the Coarse aggregate has been
bitumino
us
rolled and checked, the bituminous Binder
material shall be applied at specified temperatures
The rate of application shall be as

specified in the table 17.
At the time of applying the binder, the

aggregates shall be surface dry for full
depth of the layer.
The bituminous material shall preferably

be applied by a pressure distributor
uniformly over the surface at the
specified rate. Over small areas, where
the use of a spray bar is impracticable,
the bituminous material shall be applied
by the nozzle attachment. Only when
permitted, pouring pots may be used
according to the directions of the
Engineer.
Applicat
ion of 3.6. Immediately after the first
key
aggregat
penetration of bitumen, the key aggregates
es in a clean and dry state chamber shall be
spread uniformly over the surface bymeans
of an approved mechanical spreader or by
approved manual methods at the rate
specified in Table 17.
If necessary, the surface shall be

broomed to ensure uniform application of
the key aggregates. The entire surface
shall then be rolled with 8-10 tonne
smooth Steel wheel roller (along with
vibratory roller if available) to the
specifications conforming to para 3.4.
CHAPTER-XVII
Surface
and
Quality
shall conform to the requirement of para
Control 2.1 of sub-chapter 1720.
Controls on the quality of materials and

4.1 The Penetration macadam shall be

provided with final surfacing (binder
wearing course) without any delay. If
there is to be any delay, the course shall
be covered by a seal coat to the
requirements of sub chapter 1717 before
allowing any traffic over it.
CHAPTER-XVII
DENSE BITUMINOUS MACADAM
1. Scope
2. Materials
2.1 Binder
2.2 Coarse aggregates
2.3 Fine aggregates
2.4 Filler
2.5 Aggregate gradation
3. Mix Design
3.1 Requirement of mix
3.2 Binder content
3.3 Job mix formula
3.4 Permissible variation from job mix formula
4.3 Tack coat
4.4 Preparation of mix
4.5 Spreading
4.6 Rolling
CHAPTER-XVII
DENSE BITUMINOUS MACADAM
Scope
1.The work shall consist of
construction, in a single course of -10
to' 75 mm thick base/hinder course to the
following specifications on a previously
prepared base.
Material
s 2.1 Para 2.1. of sub-chapter 1710 shall
-Binder
apply.
Coarse
aggregat 2.2.shall conform to 2.2.1. of sub-
es
chapter 1710.
Fine
aggregat 2.3.Fine aggregates shall be the
es
fraction passing 2.8 mm sieve and
retained on 90 mm sieve, consisting of
crusher run screenings, natural sand or a
mixture of both. these shall be clean,
hard, durable, uncoated, dry and free
from any injurious, soft or flaky pieces
and organic or other dele-terious
substances.
Filler
2.4.The filler shall be an inert
material, the whole of which pass through
710 micron sieve atleast 90 % passing
micron sieve and not les than 70 %
passing 90 micron sieve. The fiiier shall
be stone dust, cement, hydrated lime, fly
ash or any other non-plastic mineral
matter approved by the Engineer.
Aggregat
e 2.5 The mineral aggregates including
gradatio
n
mineral filler shall be so graded or
combined as to conform to the gradings
set forth in Table 18. For 40-50 mm
compacted layer thickness grading I and
for 51-75 mm compacted layer thickness
Grading shall be used.
TABLE 18.
AGGREGATE GRADATION ROR DENSE BITUMINOUS MACADAM
Sieve Percentage passing by weight
designation
Grading-1 Grading-2
37.5 mm 100 100
26.5 mm - 85-100
CHAPTER-XVII
32.4 mm 93-100 79-98
13.2 mm 63-82 58-82
11.2 mm 57-78 55-78
5.6 mm 43-59 39-54
2.8 mm 31-47 30-45
710 micron 16-29 16-29
355 micron 9-23 9-23
180 micron 6-16 6-16
90 micron 3-10 3-10
Mix
3.1.Apart from conformity with grading
Design-
and quality icquirements of individual
Requireme
nt of mix
ingredients, the mix shall meet the
requirements set out in Table 19.
TABLE 19.
REQUIREMENTS OR DENSE BITUMINOUS MACADAM MIX
Sl.No. Description Requirement
1. Marshall stability (ASTM 340 kg.
Designation D 1559)
determined on Marshall
specimens compacted by 50
compaction blows on each end
2. Marshall flow-(mm) 2-4
3. Percent voids in mix 5-10
4. Percent voids in mineral 55-75
aggregaates filled with
bitumen
5. Binder content % by weight of 4.5-6.0
total mix.
Binder
content 3.2. The binder content shall be so
fixed as to achieve the requirements of
the mix set out in Table 19. For
aggregates gradings. Table 18, Marshall
method for arriving at the binder content
shall be adopted. The bitumen content for
grading 2, Table 18, shall be determined
by Marshall method replacing the
aggregates retained on 26.5 mm sieve by
the aggregates passing 26.5 mm sieve and
retained on 19.0 mm sieve.
Job mix
formula 3.3.The contractor shall intimate to
the Engineer in writing, at least 20 days
CHAPTER-XVII
before the start of the work, the job mix
formula proposed to be used by him for
the work and shall give the following
details :
(i) Source and location of all

materials.
(ii) Proportions of all materials

expressed as follows where each is
applicable
Binder as percentage by weight of total

mix
Coarse aggregate percentage by

weight of total
Fine aggregate aggregate including
mineral filler
Mineral filler
(iii) A single definite percentage

passing each sieve for the mixed
aggregate.
(iv) The results of test enumerated in

Table 19 as obtained by the contractor.
(v) Test results of physical

characteristics of aggregates to be used.
While working out the job mix formula,

the contractor shall ensure that it is
based on a correct and truly
representative sample of the materials
that will actually be used in the work
and that the mix and its different
ingredients satisfy the physical and
strength requirements of these
specifications.
Approval of the job mix formula shall

be based on independent testing by the
Engineer for which samples of all
ingredients of the mix shall be furnished
by the contractor as required by the
former.
The approved job mix formula shall

remain effective unless and until
modified by the Engineer. Should a change
in the source of materials be proposed, a
CHAPTER-XVII
new job mix formula shall be established
and got approved from the Engineer before
actually using the materials.
Permissi
ble 3.4.It shall be the responsibility of
variatio
n from
the contractor to produce a uniform mix
job mix conforming to the approved job mix
formula
formula subject to the permissible va-
iations of the individual percentages of
the various ingredients in the actual mix
from the job mix formula to be used
within the limits as specified in Table
20. These variations are intended to
apply to individual specimens taken for
quality cental test vide chapter 1720.
TABLE 20.
PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA
Sr.No. Description of ingredients Permissible
variation by
weight of
total mix—in
per cent
1 Aggregate passing 13.2 mm sieve ±8
and larger
and 4.75 mm sieve
and 1.18 mm sieve
4 Aggregate passing 600 micron ±5
sieve and 300 micron sieve
sieve
sieve
7 Binder ±0.5
Construc
tion 4.1.Para 3.1.of sub-chapter 1710 shall
Operatio
ns-
apply.
Weather
and
seasonal
limitati
ons
Preparat
ion of 4.2.The base on which Dense Bituminous
base
Macadam is to be laid shall be prepared,
lines,grades and cross sections in
CHAPTER-XVII
accordance with sub-chapter 1707 or as
directed by the Engineer. A priming coat
where needed, shall be applied in
accordance with sub-chapter 1708 or as
Tack
coat 4.3. A tack coat over the base shall be
applied as per sub-chapter 1709.
Preparat
ion of 4.4. Hot mix plant of adequate capacity
mix
and capable of producing a proper and
uniform quality mix shall be used for
preparing the mix. The plant may be
either a weigh batch type or volumetric
proportioning continuous or drum mix
type. The plant shall have coordinated
set of essential units capable of
producing uniform mix as per the job mix
formula such as spelt out in para 3.4 (a)
to (i) 0f sub-chapter 1710.
The temperature of binder at the time

of mixing shall be in the range of 150°—
l77"C and of aggregates in the range of
155-163. Provided also that at no time
shall the difference in temperature
between the aggregates and binder exceed
14 degree centigrade.
Mixing shall be thorough to ensure that

a homogeneous mixture is obtained in
which all particles of the mineral
aggregates are coated uniformly.
The mix shall be transported from the

mixing plant to the point of use in
suitable tipper vehicles. The vehicles
employed for transport shall be clean and
be covered in transit if so directed by
the Engineer.
Spreadin
g 4.5. The mix transported from the hot
mix plant to the site shall be spread by
means of a self-propelled mechanical
paver with suitable screeds capable of
spreading, tamping and finishing the mix
to specified grade, lines and cross
section. Paver Finisher shall have the
essential features as spelt out in 3.5.
of sub-chapter 1710. However, in
restricted locations and in narrow width
CHAPTER-XVII
where the available equipment cannot be
operated in the opinion of the Engineer,
he may permit manual laying of the mix.
The temperature of mix at the time of

laying shall be in the range of 120°—
160°C.
Longitudinal joints and edges shall be

constructed true to the delinerting lines
parallel to the centre line of the road
Longitudinal joint shall be offset by
atleast from those in the lower course.
All joints shall be cut vertical to the
full thickness of the previousy laid mix
and the surface painted with hot bitumen
before placing fresh material.
Rolling
507.4.6 After the spreading of mix by
paver, it shall be thoroughly compacted
by rolling with a set of rollers more
than 5 km per hour, immediately following
close to the paver. The initial or
breakdown rolling following 8 to 12 tonne
three wheeled steel roller_and the
finished rolling with 8 to 10 tonne
tandem roller. Before finishing with the
tandom roller, breakedown rolling shall
be preferably followed by an
intermmediate rolling with a smooth wheel
pneumatic roller of 15 to 30 tonne having
a tyre pressure of 7 ke/cm2. All the
compaction operations i.e. breakdown
rolling, intermediate rolling and
finished rolling can be accomplished by
using vibratory roller of 8 to 10 tonne
static weight. During the initial or
breakdown rolling and finished 'rolling,
the vibratory system shall be switched
off. The joints and edges shall be rolled
with a 8 to 10 tonne three wheeled static
roller.
The wheels of roller shall be kept

moist to prevent the mix from adhering to
them. But in no case shall
fuel/lubricating oil be used for this
purpose nor excessive water poured on the
wheels. Rolling shall commence
longitudinally from edge and proceed
towards the centre, except that on
CHAPTER-XVII
superelevated portions, it shall progress
from the lower to upper edge parallel to
the centre line of the pavement. The
roller shall proceed on the fresh
material with rear or fixed wheel leading
so as to minimise the pushing of the mix
and each pass of the roller shall o
verlap the preceding one by half the
width of the rear wheel. Rolling shall
be continued till the density achieved is
atleast 95 per cent of that of laboratory
Marshall Specimen and all roller marks
are eliminated. Rolling operations shall
be completed in all respect before
temperature of the mix falls below 100
degree centigrade.
Opening
to 5. Traffic may be allowed after
Traffic
completion of the final rolline
when the mix has cooled down to the

surrounding temperature. The Dense
Bituminous macadam shall be provided with
an appropriate wearing course without
delay prior to regular opening to normal
traffic.
Surface
Finish 6.The surface finish of construction
and
Quality
shall conform to the requirements of
Control para 2.1 of the sub-chapter 1720.
of Work

CHAPTER-XVII
SURFACE DRESSING
1. Single and Two Coat Surface Dressing using Bitumen

1.1 Description
1.2. Material
1.2.1Binder
1.2.2Stone chippings
1 1.2.3Quantities of materials
1.3 Construction Operations
1.3.1Weather and seasonal limitations
1.3.2Preparation of base
1.3.3Application of binders
2 1.3.4Application of stone chippings
3 1.3.5Rolling
1.3.6Application of second coat of surface dressing
4 1.4 Opening to traffic
1.5 Surface finish and quality control of work
2. Two Coat Surface Dressing Using Cationic Bitumen Emulsion.

2.1 Scope
2.2 Material
2.2.1Binder
2.2.2Aggregate
2.3 Construction Operations
2.3.1Weather limitations
2.3.3Preparation of binder
2.3.4First Coat
2.3.5Second coat
2.4 Opening to traffic
3. Surface Dressing with Precoated Aggregate Using Bitumen

3.1 Scope
3.2 Materials
3.2.1Binder
3.2.2Aggregate
3.2.3Quantities of materials
3.2.4Precoating
3.3 Construction operations
3.3.1Weather and seasonal limitations
3.3.3Application of binder
3.3.4Application of stone chippings
3.3.5Rolling
CHAPTER-XVII
3.4 Application of second coat of surface dressing
CHAPTER-XVII
SURFACE DRESSING
Single
and Two 1.1. This work shall consist of the
Coat
Surface
application of one coat or two coats of
Dressing surface dressing, each coat consisting of
using
Bitumen-
a layer of bituminous binder sprayed on a
Descript base prepared previously, followed by
ion
cover of stone chippings properly rolled
to form a wearing course to the
requirement of this specification.
Material
s- 2.1 The binder shall be straight run
Binder
bitumen of a suitable grade appropriate
to the region, traffic, rain-fail and
other environmental conditions as
directed by the Engineer and conforming
to IS: 73.
Stone
chipping 1.2.2. The stone chippings siiall
s
conform to 2.2.1.of sub-chapter 1710.
They shall conform to the quality
requirments of Table 4 except that the
Flakiness Index and water absorption
shall be restricted to a cent and 1 per
cent respectively. the size of stone
chippings shall be in accofdahcewith
Table 21.
TABLE 21.
SIZE REQUIREMENT OF STONE CHIPPINGS FOR SURFACE DRESSING USING
BITUMEN
Sl. Type of Construction Nominal Specifications
No. size of
stone
chippin
gs
1 Single coat surface 13.2 mm 100 per cent passing
dressing or the first through 22.4 mm sieve &
coat of two coat retained on 11.2 mm
surface dressing sieve.
2 Second coat of two 11.2 mm 100 per ceflt passing
coat surface dressing through 13.2 mm sieve &
CHAPTER-XVII
Sl. Type of Construction Nominal Specifications
No. size of
stone
chippin
gs
(also used as a retained on 5.6 mm
renewal coat) sieve.
Quantiti
es of 1.2.3. The quantities of material used
material
s
for this work shall be as specified in
Table 22.
TABLE 22.
QUANTITIES OF MATERIALS REQLIRED FOR 10 SQ.M. M ROAD SURFACE FOR
SURFACE DRESSING USING BITUMEN
Sl. No. Type of Construction Binder Stone
Chipping
1. Single coat surface 18 kg 0.15 sqm
dressing or the first coat
of the two coat surface
dressing
2. Second coat of two coat 11 kg 0.10 sqm
surface dressing (also
used as a renewal coat)
Construc
tion 3.1 Para 3.1. of sub-chapter 1710 shall
Operatio
ns-
apply.
Weather
and
seasonal
limitati
ons
Preparat
ion of 3.2.The base on which the surface
base
dressing is to be laid shall be prepared,
lines, grade and cross section in
accordance with para 1707 and as directed
by the Engineer. Priming coat, where
needed, shall be provided as per para 502
and as dTrectecT by the Engineer. Where
the existing surface shows signs of
fatting up, this shall be rectified. The
bituminous primed surface to be dressed
shall be thoroughly cleaned either by
using a mechanical broom or any other
approved equipment/method as specified by
Engineer.
CHAPTER-XVII
Dust removed in the process shall be
blown off with the help of the compressed
air.
Applicat
ion of 1.3.3 Bitumen shall be heated to- 163°—
binders
177°C and sprayed on the dry surface in a
uniform manner preferably with the help
of self propelled mechanical sprayers
having self heating arrangement and
bitumin pressure pump and spreay nozzle
bar capable of spraying buitumen
unoformly at the rates specified in Table
22 and above mentioned temperature.
Excessive deposits of binder caused by
stopping or starting of the sprayer or
through leakages or any other reason
shall be suitably corrected before the
stone chippings are spread.
Applicat
ion of 1.3.4.Immediately after the application
stone
chipping
of binder stone chippings in a dry and
s clean state shall be spread uniformly on
the surface, by means of a self
propelled or towed mechanical grit
spreader capable of praying uniformly at
rates specified in Table 22 so as to
cover the surface completely. If
necessary, the surface shall be broomed
to ensure uniform spread of chippings.
Rolling
1.3.5 Immediately after the application
of the cover material, the entire surface
shall be rolled with a 8-10 tonne smooth
wheeled steel roller, suitable vibratory
roller, or other approved equipment.
Rolling shall commence at the edges and
progress towards the centre except in
proceed from the inner edge to the outer.
Each pass of the roller shall uniformly
overlap not less than one third of the
track made in the preceding pass. While
rolling is in progress additional
chippings shall be spread by hand in
necessary quantities required to make up
irregularities. Rolling shall continue
until all aggregate particles are firmly
bedded in the binder and present a
uniform closed surface.
Applicat
ion of 1.3.6. Where surface dressing in two
CHAPTER-XVII
second
coat of coats is specified, the second coat shall
surface
dressing
be applied immediately after laying of
the first coat. The construction
operations for the second coat shall be
the same as described in Paras 1.3.3, to
1.3.5of sub-chapter 1713.
Opening
to 1.4. Traffic shall not be permitted to
traffic
run on any newly surface dressed area
until the following day. In special
circumstances, however, the Engineer may
open the road to traffic immediately
after rolling, but in such cases traffic
speed shall be limited to 16 km per hour
till the following day.
Surface
finish 1.5.The surface finish of construction
and
quality
control para 2.1 of the sub-chapter 1720.
of work

2. Two Coat Surface Dressing Using Cationic Bitumen

Emulsion.
Scope
2.1. This work shall consist of two
coat surface dressing each coat
consisting of a layer of cationic bitumen
emulsion binder sprayed on a base
prepared previously followed by a cover
of stone aggregate, properly rolled to
form a wearing course to the requirements
of these specifications.
2.1.2. It shall, however, not be

applicable to a single coat surface
dressing using cationic bitumen emulsion.
Material-
Binder 2.2.1.The binder shall be of cationic
type bitumen emulsion of Rapid Setting
(RS) grade complying with IS:8887-1978
and having bitumen content 60 percent
minimum by weight.
Aggregate
2.2.2. para 1.2.2.of sub-chapter 1713
(A)
General shall be as given except the size
Requireme requirement which is 15.
nts
CHAPTER-XVII
Wet aggregate can be used for surface
dressing with cationic bitumen emulsions
an'd wheifaggregates are dusty, they
should be cleaned by washing or by
sprinkling water copiously.
Size
(B) : The aggregates shall conform to
the sizes given in Table 23.
TABLE 23
1. For first coat 13.2 mm size Passing 22.4 mm
sieve and
retained on 11.2
mm sieve
2. for second coat 6.7 mm sizes Passing 9.5 mm
sieve and
retained on 2.36
mm sieve
Quantiti
es of (C) The quantities of materials used
material
for this work shall be as given in Table
24.
TABLE 24
Material For 10 square metre
For For Second
First Coat Coat
Cationic Bitumen 12 to 14 kgs 16 to 18
Emulsion kgs
Aggregate 0.10 to 0.12 0.06 to 0.08
c.m. c.m.
Construc
tion 2.3.1. Cationic bitumen emulsions
Operatio
ns-
should not normally be stored below 6°C.
Weather However, surface dressing with cationic
limitati
ons
bitumen emulsion should be carried out
only when the atmospheric temperature is
above 10°C. The work can be carried out
when the base is damp. All standing water
in depressions shall, however, be
removed.
Preparat
ion of 2.3.2. The existing base on which
base
surface dressing is to be laid shall be
prepared, shaped and corrected to a
uniform grade and camber in accordance
with para 1707.
CHAPTER-XVII
The surface shall be cleaned to remove
all loose particles, is preferable to
spray water on the surface to settle the
loose dust and also to expose clean
surface of aggregates in the case of
granular base courses.
Preparat
ion of 2.3.3. Before opening, the cationic
binder
bitumen emulsion, drums, should be
rolled, at slow speed, to and fro, for a
distance of about 10 metres, 5 to 6 times
to mix the contents properly.
First
Coat- 2.3.4. (A)Cationic bitumen emulsions
Applicat
ion of
binder can be applied on wet road
Binder surface. Cationic bitumen emulsion should
be sprayed uniformly on the prepared base
by mechanical sprayers. In exceptional
cases spraying from a spraying may be
resorted to as directed by the Engineer.
The spraying can should have 6 mm
diameter holes spaced 30 mm apart to
prevent clogging. An emulsion tank of 30-
litre capacity pressurised by compressed
air from a hand pump and a 12-mm flexible
pipe with a spray nozzle is a simple and
efficient arrangement for spraying.
Applicat
ion of (B)Immediately after spraying of
aggregat
e
cationic emulsion, aggregate of 13.2 mm
size shall be spread uniformly and evenly
by mechanical means to cover the surface
completely and evenly. Any oversize
aggregate, if seen, should be removed.
Rolling
(C)Immediately after the application of
cover material the surface shall be
rolled with 6 to 8 tonne roller
preferably by smooth wheeled tandem type.
The rolling shall begin at the edge and
proceed towards the centre parallel to
the centre line except in superelevated
portions where it shall proceed from the
inner edge to the outer edge. While
rolling, aggregates shall be added or
removed so as to ensure a uniformly
covered surface. Each pass of roller
shall uniformly overlap not less than one
third of the track made in the preceding
pass. Rolling shall continue for just
enough time to embed the aggregates in
CHAPTER-XVII
the binder and present a uniform closed
surface. Excessive rolling, resulting in
crushing of aggregates should be avoided.
Second
coat 2.3.5. (A) The second coat of surface
-Time
interval
dressing should be applied on the same
day as the first coat but at least not
earlier than one hour after finishing the
rolling of the first coat.
Applicat
ion of (B) Traffic should not be allowed on
emulsion
the first coat before, the application of
second coat. If the aggregates of the
first coat appear to be loose and
unbonded in few spots, the same should
not be disturbed.
The cationic bitumen emulsion for

second coat should sprayed by mechanical
sprayer or in exceptional cases by using
pouring can with the approval of the
Engineer, taking care not to disturb the
first layer while walking over it.
Applicat
ion of (C) Immediately after the application
aggregat
e
of emulsion, 6.7 mm size chips should be
spread uniformly by mechanical means to
cover the whole surface evenly.
Rolling
(D) Rolling shall start soon after
spreading the aggregates and all
operations carried out as per para
2.3.4(C)of this chapter to achieve a
uniform closed surface.
Finishin
g (E)After one pass of the roller,
depressions should be filled with 6.7 mm
size aggregate. If excess of aggregate is
found in isolated spots, the bigger size
aggregates should be removed to give a
uniform surface. Finish rolling on the
next day helps to give a firm surface.
Opening
to 2.4. The road may be opened to traffic
traffic
4 hours after completing rolling of the
second coat, but preferably the next day
after 24 hours.
Where the road width is single lane,

traffic can be allowed at slow speed of
not more than 10 km per hour making sure
CHAPTER-XVII
to add aggregates and emulsion wherever
the surface has been picked up by
traffic.
Surface
finish 2.5. The surface finish of construction
and
quality
control 2.1 of sub-chapter 1720.
of work

works shall exercised by the Engineer in
accordance withchapter 1720.
Arrangem
ents for 2.6. During the period of construction,
traffic
arrangement of traffic shall bed one
topara 112 of the specificationfor road
and bridge works by MOST.
Measurem
ents for 2.7.Two coat of surface dressing shall
payment
be measured as a finished work in square
metres.
3. Surface Dressing with Precoated Aggregate Using Bitumen

Scope
3.1 The work shall consist of_
Application of either a single coat or
two-coats, of surface dressing over a
previously prepared base each coat
consisting of application of bituminous
binder sprayed on a base previously
prepared followed by a cover of precoated
materials properly roli.ed to form a
wearing course to the requirements of
these specifications.
3.1.2. This specification may be

adopted in lieu of the conventional
surface dressing to para 1 of this
chapter, in situations where better
adhesion is required between the
aggregates and binder during construction
and later in service. The technique, is
basically the same as conventional-
surface dressing except that a small
quantity of binder is used for precoating
the aggregates. However, it is quite
different from premix construction.
CHAPTER-XVII
Material
s-Binder 3.2.1.The binder shall be straight run
bitumen of a suitable grade appropriate
to the region, traffic and other
environmental conditions and as directed
by the Engineer and conforming to IS: 73.
Aggregat
e 3.2.2. The aggregate shall conform to
2.2. of sub-chapter 1710. They shall
conform to the quality requirements of
Table 4 except that the Flakiness index
and water absorption shall be restricted
to a maximum of 25 per cent & 1 per cent
mark, respectively.
The size of the stone chippings shall

be in accordance with Table 21
Quantiti
es of 3.2.3.The quantity of materials used
material
s
for this work shall be as specified in
Tables 21 and 22.
Precoati
ng 3.2.4. The aggregates shall be pre-
coated with 0.75 to 1.00 per cent of its
weight with binder and shall not be
percoated simultaneously with the
painting operation. The precoated
aggregates shall be allowed to cure for
atleast one week so that they become non
sticky to facilitate easy spreading like
normal uncoated aggregate. The aggregate
free of dust or fine particles shall be
preheated to 60 degree centigrate for
precoating and then mixed with bitumen
binder (0.75 to 1.00 percent weight of
aggregates) heated to its application
temperature. The aggregate and binder
shall be thoroughly mixed in a mixer of
approved_type till the aggregates are
uniformly coated.
Construc
tion 3.3.1.Para 3.1. of sub-chapter 1710
operatio
ns-
shall apply.
Weather
and
seasonal
limitati
ons
Preparat
ion of 3.3.2. Para 1.3.2. of this sub-chapter
base
shall apply.
CHAPTER-XVII
Applicat
ion of 3.3.3 After deducting the binder
binder
quantity, consumed in precoating
aggregates for first coat in terms of
para 3.2.4 of this sub-chapter from the
quantities specified remaining binder of
first coat shall be heated to 163°—177°C
and sprayed on the clean and dry surface
in a uniform manner preferably with the
help of mechanical sprayers having self
heating arrangement, bitumen pressure
pump and spray nozzle bar capable of
spraying bitumen uniformly at the rates
and temperatures specified above.
Excessive deposits of binder caused by
stoppage or starting of sprayer or
through leakage or any other reason shall
be corrected before stone chippings are
spread.
Applicat
ion of 3.3.4. Immediately after the
stone
chipping
application of binder, stone chiprings in
s a dry and clean state shall be spread
uniformly on the surface preferably by
means of a mechanical gritter capabL of
spraying uniformly at the rates specified
in Table 22 so ns ro cover the surface
completely. If necessary, the surface
shall be broomed mechanically or manually
to ensure uniform spread of chippings.
Rolling
3.3.5.Para 1.3.5. of this sub-chapter
shall apply.
Applicat
ion of 3.4.The second coat of surface dressing
second
coat of
where specified shall be applied
surface immediately after the first coat or soon
dressing
after depending upon the conditions at
site and type of binder used. The
construction operations for the second
coat shall be the same as described in
para 3.3.3. to 3.3.5 of this sub-chapter
except that the rate of application of
aggretate and binder for second coat
shall be as specified in Table 22 after
deducting binder consumed for precoating
the aggregate required for second coat
vide para 3.2.4 of this sub-chapter.
CHAPTER-XVII
Opening
to 3.5.Para 1.4. of this sub-chapter Shall
traffic
apply.
Surface
finish 3.6. The surface finish of construction
and
quality
control 2.1 of sub-chapter 1720.Control on the
of work
with chapter 1720.
CHAPTER-XVII
OPEN-GRADED PREMIX CARPET
1. Using Bitumen
1.1 Scope
1.2 Materials
1.2.1 Binder
1.2.2 Aggregates
1.2.3 Proportioning of materials
1.3 Construction operation
1.3.1 Weather and seasonal limitations
1.3.2 Preparation of base
1.3.3 Tack coat
1.3.4 Preparation of premix
1.3.5 Spreading and rolling
1.3.6 Seal coat
2. 20 mm Thick Premix Carpet using Catio-nic Bitumen Emulsion
2.1 Scope
2.2 Materials
2.2.1 Binder
2.2.2 Coarse aggregates
2.2.3 Fine aggregate
2.3 Quantities of materials required
2.3.1 Aggregates
2.4 Construction operation
2.4.1 Weather limitations
2.4.2 Preparation of base
2.4.3 Preparation of binder
2.4.4 Tack coat
2.4.5 Preparation of premix
2.4.6 Spreading of mix
2.4.7 Rolling
2.4.8 Seal coat
2.6 Surface finish and quality control
CHAPTER-XVII
OPEN-GRADED PREMIX CARPET
Using
Bitumen- 1.1. This work shall consist of laying
Scope
and compacting an open-graded carpet of
20 mm thickness in a single course
composed of suitable small sized
aggregates premixed with a bituminous
binder on a previously prepared base, in
specifications, to serve as a wearing
course.
Materials
- Binder 1.2.1. The binder shall be bitumen of a
suitable grade appropriate to the region,
traffic, rainfall and other environmental
conditions, as directed by the Engineer
and satisfying the requirements of IS :
73,217,454 or other approved cut back as
applicable.
Aggregate
s 1.2.2. The coarse aggregate shall
conform to 2.2. of sub-chapter 1710.
The aggregates shall satisfy the

quality requirements set forth in Table 4
except that the Flakiness Index and water
absorptions shall be limited to a maximum
of 30 per cent and 1 per cent
respectively.
Proportio
ning of 1.2.3. The materials shall be
materials
proportioned as per quantities given in
Table 25.
TABLE 25.
QUANTITIES OF MATERIALS REQUIRED FOR ROAD SURFACE 20 MM THICK OPEN-
GRADED PREMIX CARPET USING BITUMEN
Aggregates for Carpet
(a) Stone chippings—13.2 mm size; passing 22.4 0.18
mm sieve and retained on 11.2 mm sieve
(b) Stone chippings—11.2 mm size; passing 13.2 .09
mm sieve and retained on 5.6 mm sieve
Total .27
Binder for Premixing (quantities in terms of
straight run bitumen)
CHAPTER-XVII
(a) For 0.18 m* of 13.2 mm size stone chippings 9.5
at 52 kg per m3
(b) For 0 09 m* of 11.2 mm size stone chippings 5.1
at 56 kg per m'
Total : 14.6 Kg
Construc
tion 1.3.1.Para 3.1.of sub-chapter 1710
operatio
n-
shall apply.
Weather
and
seasonal
limitati
ons
Preparat
ion of 1.3.2.The underlying base on which the
base
bituminous carpet is to be laid shall be
specified lines, grade and cross section
in accordance with sub-chapter 1707. A
primer coat where needed shall be applied
in accordance with sub-chapter 1708 as
Tack
coat 1.3.3. A tack coat complying with sub-
chapter 1709 shall be applied over the
base preparatory to laying of the carpet.
Preparat
ion of 1.3.4. Mixers of approved type shall be
premix
employed for mixing the aggregates with
the bituminous binder.
The binder shall be heated to the

temperature appropriate to the grade of
bitumen approved by the Engineer, in
boilers of suitable design avoiding local
overheating and ensuring a continuous
supply.
The aggregates shall be dry and

suitably heated to a temperature as
directed by the Engineer before these are
placed in the mixer. After about 15
seconds of dry mixing, the heated binder
shall be distributed over the aggregates
at the rate specified.
The mixing of binder with chippings

shall be continued until the chippings
are thoroughly coated with the binder.
The mix shall be immediately transported
CHAPTER-XVII
from the mixer to the point of use in
suitable vehicles or wheel barrows. The
vehicles employed for transport shall be
clean and the mix being transported
covered in transit if so directed by the
Engineer.
Spreadin
g and 1.3.5. The premixed material shall be
rolling
spread on the read surface with rakes to
the required thickness and cross-fall
(camber) or distributed evenly with the
help of a drag spreader, without any
undue loss of time. The crossfall shall
be checked by means of camber boards and
inequalities evened out. On large scale
works use of a mechanical paver finisher
shall be preferable.As soon as sufficient
length of bituminous material has been
laid, rolling shall commence with 8 to 10
tonne power rollers, preferably of smooth
wheel tandem type, or other approved
equipment.Rolling shall begin at the
edges and progress toward the centre
longitudinally, except that on the super-
elevated portions it shall progress from
the lower upper edge parallel to the
centre line of the pavement.
When the roller has passed over the

whole area once, any high spots or
depressions, which become apparent, shall
be corrected by removing or adding
premixed materials. Rolling shall then be
continued until the entire surface has
been rolled to compaction and all the
roller marks eliminated. In each pass of
the roller, preceding track shall be
overlapped uniformly by at least 1/3
width. The roller wheels shall be kept
damp to prevent the premix from adhering
to the wheels and being picked up. In no
case shall fuel/lubricating oil be used
for this purpose. Excess use of water for
this purpose shall also be avoided.
CHAPTER-XVII
Rollers shall not stand on newly laid
material while there is a risk that it
wili be deformed thereby.
The edges along and transverse of the

carpet laid and compacted earlier shall
be cut to their full depth so as to
expose fresh surface which shall be
painted with a thin surface coat of
appropriate binder before the new mix is
placed against it.
Seal
coat 1.3.6. A seal coat conforming to para
513 shall be applied to the surface
immediately after laying thu carpet.
Opening
to 1.4.No traffic shall be allowed on the
traffic
road till the seal coat has been laid.
After the seal coat is laid, the road
shall be opened to traffic according to
Para 4 of sub-chapter 1718.
Surface
finish 1.5 The surface finish of construction
and
quality
of work

in accordance withchapter 1720.

CHAPTER-XVII
2. 20 mm Thick Premix Carpet using Catio-nic Bitumen Emulsion
Scope
2.1.This work shall consist of laying
and compacting an open graded premix
carpet of 20 mm thickness with seal coat
composed of suitable small sized
aggregate premixed with cationic bitumen
emulsion placed on a previously prepared
base in accordance with the requirements
of these specifications to serve is a
wearing course.
Material
s-Binder 2.2.1. The binder shall be cationic
bitumen emulsion of Medium Setting {MS.)
grade complying with I.S. 8887-1978 and
having bitumen content 60 percent minimum
by weight. For liquid seal coat MS
grade can be used, but it is preferable
to use Rapid Setting (F.S) grade_of
cationic bitumen emulsion. However, for
premix seal coat Slow Setting (SS) grade
cationic bitumen emulsion shall be used.
Coarse
aggregat 2.2.2. sub-chapter 1714.1.2.2. shall
es
apply. Aggregates should be cleaned by
"ashing or by sprinkling water
copiously”.
The coarse aggregate shall satisfy the

quality requirement set forth in Table 4,
except that the Flakiness Index and water
absorption values shall be limited to a
maximum of 30 per cent and 1 per cent
respectively. Stripping value is not to
be considered unless directed by the
Engineer. Water absorption upto 2 per
cent may be permitted in exceptional
cases only.
Fine
aggregat 2.2.3. Fine aggregate for seal coat
e
shall be crushed stone chips or coarse
sand, clean, uncoated and free from clay,
dust and other deleterious matter.
Quantiti
es of 2.3. The materials shall be
material
s
proportioned as per quantities given in
required Tables 26 and 27.
TABLE 26. QUANTITIES or AGGREGATES

Sr.No. Item Per 10
sq.m area
CHAPTER-XVII
(A) For Premix Carpet
(a)Coarse aggregate—13.2 mm size
passing IS 22.4 mm sieve and retained 0.18
on IS 11.2 mm sieve
(b) Coarse aggregate 11.2 mm size 0.09
passing IS 13 2 mm sieve and retained
on IS 5.6 mm sieve.
(B) For Seal Coat
(a) Liquid Seal Coat: Crushed fine 0.06
aggregates 6.7 mm size passing IS 9.5
mm sieve and retained on IS 2.36 mm
sieve
(b) Premix Seal Coat :Coarse sand or 0.06
stone grit passing 2.36 mm sieve and
retained on 180 micron sieve.
Binder 2.3 2.The binder shall be added as per

given in table 27.
TABLE 27. QUANTITIES OF BINDER
(A) For Tack Coat
(a) On water bound macadam surface 6.5 to 7.5 kg
(b) On existing black top surface 4.5 to 5.5 kg
(B) For Premix Carpet 20 to 23 kg
(C) For Seal Coat
(a) For Liquid Seal Coat 12 to 14 kg
(b) For Premix Seal Coat 10 to 12 kg
Construc
tion 2.4.1.Cationic bitumen emulsions should
operatio not normally be stored below 0°C.
n-
Weather However, prernix carpet work with
limitati cationic emulsion should be carried out
ons
only when the atmospheric temperature is
above 10°C.
Preparat
ion of 2.4.2.The underlying base on which the
base premix carpet is to be laid shall be
specified lines, grades and cross
sections in accordance with para 1707.
The cleaned surface can be finally washed
with water, if it is readily available.
2.4.3. para 2.3.3 of sub-chapter
1713 shall apply.
Preparat
ion of 2.4.4. para 2.3.4.(A) of sub-chapter
binder-
Tack 1713 shall apply. Tack coat should be
coat applied not earlier than 10 minutes
CHAPTER-XVII
before spreadig the premix. On water
bound macadam surface, water should be
sprayed to make the surface damp before
applying tack coat.
Preparat
ion of 2.4.5. Premixing of cationic bitumen
premix emulsion and aggregates can be done in a
suitable mixer such as cold mixing plant
as per IS: 5435 (Revised) or concrete
mixer or by shovels in exceptional cases
with the approval of the Engineer.
However, for large works, continuous
mixing operation can be done either in
batch or continuous mixer units suitable
for emulsion mixes.
When using concrete mixer for preparing
the premix, 0.135 m3 (0.09 m3 of 13.2 mm
size and 0.045 m3 of 11.2 mm size) of
aggregates per batch may be used as this
quantity will cover 5 sqm of road surface
with 20 mm average thickness.
The aggregates required for patch
should be kept ready near the mixer. The
aggregate should be cleaned free from
dust and dirt, if any, by dipping or
washing or copiously sprinkling water.
First the coarse aggregate of 13.2 mm
size should be charged into the mixer
followed by 5 to 6.5 kg of eationic bitu-
men emulsion and then add 11.2 mm size
aggregates, followed by 5 to 6.5 kg of
cationic bitumen emulsion. After the
materials have been mixed  should be
avoided as it may unload the mix from the
mixer and immediately transport to the
laying site in suitable vehicles. Too
much mixing should be avoided as it may
result in decoating of aggregates.
Because of ease of mixing, cationic
bitumen emulsion and aggregates can be
mixed manually by shovels when mechanical
mixer is not available or when the work
is too small with the approval of the
Engineer. 0.06 m3 of aggregates can be
conveniently mixed in one heap, with
appropriate quantity of emulsion. It is
preferable to make the aggregates damp
before mixing, as it reduces the effort
required for mixing and also helps to get
CHAPTER-XVII
better coating of aggregates. The 13.2 mm
size aggregates and emulsion are mixed
first and then the 11.2 mm size
aggregates and remaining quantity of
emulsion are added and mixed. Too much
mixing should be avoided, as it will
result in decoating of aggregates.
Spreadin
g of mix 2.4.6. The premixed cationic bitumen
emulsion and aggregates shall be spread
within 10 minutes of applying the tack
coat. The mix is easily workable for
about 20 minutes after mixing and hence
all levelling, raking, etc. should be
completed within this time for easy
workability.
The mix should be spread uniformly to
the desired thickness, grades and
crossfall (camber) making due allowance
for extra quantity required to fill up
depressions, if any. The crossfall should
be checked by means of camber boards and
inequalities evened out. Too much use of
blades or rakes should be avoided.
Rolling
2.4.7. The rolling shall start at
least half an hour after laying the
premix and in no case the commencement of
rolling delayed beyond four hours after
laying. Smooth wheeled tandom roller
delayed beyond four hours after laying.
Smooth wheeled tandem roller of 8 to 10
tonne shall be used preferably three
wheeled steel roller of equivalent
capacity can also be used. While rolling
should be clean and kept moist to prevent
the premix from adhering to the wheels
and being picked up. In no case shall
fuel/lubricating oil be used for this
purpose. Excessive use of water for this
purpose shall also be avoided.
Rolling shall commence at the edges and
progress towards the centre
longitudinally except in case of
superelevated sections where rolling
shall be done from inner edge towards the
outer edge of the curve parallel to the
centre line of the road.
After one pass of roller over the whole
area, depressions or uncovered spots
should be corrected by adding premix
CHAPTER-XVII
material. Rolling should be continued
until the entire surface has been rolled
to compaction and all the roller marks
eliminated. In each pass of the roller,
preceding track shall be overlapped
uniformly by at least 1/3 width.
Rolling shall be continued until the
entire surface has been rolled to
compaction and all the roller marks
eliminated. Roller(s) shall not stand
on newly laid material while there is a
risk that it will be deformed thereby.
At joints, the edges along the transverse
of the the carpet laid and compacted
earlier shall be cut to their full depth
so as to expose fresh surface which shall
be painted with a thin surface coat of
binder before the new mix is placed
against it.
Seal
coat 2.4.8. A seal coat, liquid or premix
type, shall be applied 4 to 6 hours after
laying the premix carpet.
Liquid
Seal Quantities of the materials required
Coat ar;- given in Tabks 26 and 27.
For application of binder para 2.3.4.
(A) of sub-chapter 1713 shall apply.
Immediately after spraying emuis.nn,
stons: chips in a clean state shall be
spread uniformly preferably by means of a
mechanical gritter, otherwise manually so
as to cover the surface completely. Start
rolling with 6 to 8 tonne roller soon
after spreading the chips. The rolling
operation shal be indicated in 509.2.4.6,
as far as applicable.
Premix
Seal The quantities of aggregate and binder
Coat to be used shall be as given in sub-
chapter 1714.2.3. Tables 18 and 19. Grit
or sand used for premix seal coat should
be made thoroughly wet with water before
mixing with emulsion of slow setting
grade.
The mixing, spreading and rolling etc.
shall be carried out as per sub-chapter
1714.2.4.4. to 509.2.4.6. except for the
quantities and materials which shall be
for premix seal coat. Rolling shall be
continued till the premix material
CHAPTER-XVII
completely seals the voids in the premix
carpet and smooth uniform surface is
obtained.
Opening
to 2.5. Traffic should not be allowed over
traffic the premix surface with or without seal
coat for 6 to 8 hours after rolling. In
case of single lane roads, traffic may be
allowed at slow speed not exceeding 10 km
per hour. If any premix material gets
picked up by vehicle tyres, the spot
shall be filled up by new mix. It is
preferable to open the road to traffic
the next day after 24 hours.
Surface
finish 2.6.The surface finish of construction
and shall conform to the requirements of
quality
The control on the quality of materials
and works shall be exercised by the
CHAPTER-XVII
SEMI-DENSE BITUMINOUS CONCRETE
1. Scope
2. Materials
2.1 Binder
2.2 Coarse aggregate
2.3 Fine aggregate
2.4 Filler
3. Mix Design
3.2 Binder content
3.3 Job mix formula
3.4 Permissible variation from job mix formula
4.3 Tack coat
4.5 Spreading of mix
4.6 Rolling
6. Surface Finish and Quality Control oi Work
CHAPTER-XVII
SEMI-DENSE BITUMINOUS CONCRETE
Scope
construction in a single course of 25
mm/40 mm thick semi-dense bituminous
concrete on a previously prepared
bituminous base to the requirements of
these Specifications, to serve as a
wearing course.
Material
s- 2.1. Para 2.1. of sub-chapter 1710
Binder
shall apply.
Coarse
aggregat 2.2. Para 2.2. of sub-chapter 1710
e
shall apply. The aggregates shall satisfy
the physical requirements as given in
Table 4 except that the maximum values of
flakiness index and water absorption
shall be 30 per cent and I per cent
respectively. However, water absorption
upto a maximum of 2 per cent may be
permitted in exceptional cases only.
Fine
aggregat 2.3. para 2.3. of sub-chapter 1712
e
shall apply.
Filler
2.4. para 2.4. of sub-chapter 1712
shall apply.
Aggregat
e 2.5. The mineral aggregates including
gradatio
n
iilier shall be so graded or combined as
to conform to the gradings set fortli in
Table 28.
TABLE 28.
AGGREGATE GRADATION FOR SEMT-DENSE BITUMINOUS CONCRETE
Sieve Percent by weight passing the sieves
Designation
Grading 1 Grading 2 Grading 3
22.4 - 100 100
13.2 100 85-100 79-100
11.2 88-100 70-92 68-90
5.6 42-64 42-64 33-55
2.8 22-38 22-38 22-38
710 MICRON 11-24 11-24 6-22
355 MICRON 7-18 7-18 4-14
180 MICRON 5-13 5-13 2-9
CHAPTER-XVII
90 MICRON 3-9 3-9 0-5
Mix
Design- 3.1. Semi-dense bituminous concrete mix
Requirem
ent of
shall be properly designed so as to
mix satisfy the critcrm laid down in Table
29.
TABLE 29.
REQUIREMENTS OF SEMI-DENSE BITUMINOUS CONCRETE MIX
S.No. Test Limits
1. Marshall Stability (ASTM 340 Kg.
Designation : D 1559) 340 Minimum
kg Minimum determined on
Marshall Specimens
compacted with 50
compaction blows on each
and
2. Marshall flow (mm) 2-4
3 Percentage voids in mix 5-10
4. Percentage voids in mineral 55-75
aggregates filled with
bitume n
5. Binder content per cent by 4.5-6.0
weight of mix
Notes
1. Higher stability values consistant
with other requirements should be
achieved as far as possible.
2. At bus stops, parking areas and

roundabouts near minimum flow value
should be adopted.
3. Attempt should be to have well

graded aggregate and the percent voids in
the mix closer to the lower limit.
Binder
the mix set forth in Table 29. Marshall
Method for arriving at the binder content
shall be adopted.
Job mix
formula 3.3. para 3.3. of sub-chapter 1712
shall apply except that the requirement
of semi-dense bituminous concrete mix
shall be as per Table 29.
CHAPTER-XVII
Permissi
ble 3.4.The Contractor shall have the
variatio
n from
responsibility of ensuring proper
job mix proportioning of materials in accordance
formula
with the approved job mix formula and
producing a uniform niix. The permissible
variations of the individual percentuges
of tise various, ingredients in the
actual mix from the job mix formula may
be within the limits as specified in
TABLE 30. These variation are intended to
apply to individual specimens taken for
quality control test vide sub-chapter
1720.
TABLE 30. PERMISSIBLE VARIATION FROM JOB MIX FORMULA

Sl.No. Description of Permissible
ingredient vaiiation by
weight of tolal
mix in
percentage
1. Aggregate passing 13.2 ±8
mm and larger
2. sieve and larger ±7
Aggregate passing 11.2
3. mm sieve and
Aggregate 5.6 mm
passing 2.8 mm ±6
sieve and 1.40 mm sieve
4. Aggregate passing 710 ±5
micron sieve and 355
5. micron sieve
Aggregate passing 180 ±4
(im sieve
6. Aggregate passing 90 m ±3
sieve
7. Bitumen ±0.3
Weather
and 4.1.Para 3.1. Of sub-chapter 1710 shall
seasonal
limitati
apply.
ons
Preparat
ion of 4.2. The base on which semi-dense
base
bituminous concrete is to be laid shall
be prepared, shaped and conditioned to
the specified lines, grades and cross
sections in accordance with para 1707 or
as directed by the Engineer.
CHAPTER-XVII
Tack
coat 4.3. A tack coat as per sub-chapter
1709 shall be applied on the base.
Preparat
ion of 4.4. para 4.4. Of sub-chapter 1712
mix
shall apply.
Spreadin
g of mix 4.5. para 4.5. Of sub-chapter 1712
shall apply.
Rolling
4.6 para 4.6. Of sub-chapter 1712
shall apply except that the density
achieved for semi-dense bituminous
concrete shall be at least 98 per cent of
that of laboratory Marshall Specimen.
Opening
to 5. Traffic may be allowed after
Traffic
completion of the final rolling when the
mix has cooled down to the surrounding
temperature.
Surface
and
Quality
shall conform to tlic requirements of
oi Work

CHAPTER-XVII
BITUMINOUS CONCRETE
1. Scope
2. Materials
2.1 Bitumen
2.3 Fine aggregate
2.4 Filler
3. Mix Design
3.2 Binder content
3.3 Job mix formula
3.4 Permissible variations from the job mix formula
4.3 Tack coat
4.5 Spreading
4.6 Rolling
CHAPTER-XVII
BITUMINOUS CONCRETE
Scope
constructing a single layer of 25 mm/40
mm thick bituminous concrete (Asphaltic
concrete) on a previously prepared
bituminous base to the requirement of
these Specification, to serve as a
wearing course.
Material
s- 2.1 2.1 of sub-chapter 1710 shall
Bitumen
apply.
Coarse
aggregat 2.2. Para 2.2. of sub-chapter 1710
e
shall apply. The aggregates shall satisfy
the physical requirements as given in
Table 13 except that the maximum values
for the flakiness index and water
absorption shall be 30 per cent and 1 per
cent respectively. However, water
absorption upto a maximum of 2 per cent
may be permitted in exceptional cases
only.
Fine
aggregat 2.3. para 2.3. of sub-chapter 1712
e
shall apply.
Filler
2.4 para 2.4 of sub-chapter 1712 shall
apply.
Aggregat
e 2.5. The mineral aggregates, including
gradatio
n
mineral filler shall be so graded or
combined as to conform to the gradings
set forth in TABLE 31. For compacted
layer thickness of 25 mm. grading 1 shall
be used and for 40 mm grading 2 can also
be used.
TABLE 31.
AGGREGATE GRADATION FOR BITUMINOUS CONCRETE
Sieve Percent by weight passing
Designation the sieve
Grading 1 Grading 2
22.4 - 100
13.2 100 80-100
11.2 90-100 75-95
5.6 60-80 55-75
2.8 40-55 40-55
CHAPTER-XVII
710 MICRON 20-30 20-30
355 MICRON 15-25 15-25
180 MICRON 10 20 10 20
90 MICRON 5-11 5-11
Mix
design- 3.1 Apart from conformity with the
Requirem
ent of
grading and quality requirements of
mix individual ingredients, the mix shall
meet the requirements set forth in TABLE
32
Binder
the mix set forth in TABLE 32. Marshall
method for arriving at the binder content
shall be adopted.
Job mix
formula 3.3. para 3.3. of sub-chapter 1712
shall apply.except that the requirement
of Bituminous Concerte mix shall be as
per TABLE 32.
TABLE 32.
REQUIREMENTS OF BITUMINOUS CONCRETE MIX
Sl. No. Description Require
ment
1. Marshall stability (ASTM Designation 340 kg
D 1559) determined on Marshall (Minimu
specimens compacted by 50 compaction m)
blows on each end
Marshall flow ( mm ) 2—4
Per cent voids in mix 3—5
Per cent voids in mineral aggregate 75-85
filled with bitumen
Binder content per cent by weight of 5-7.5
mix
Permissi
ble 3.4 The contractor shall have the
variatio
ns from
responsibility of ensuring proper
the job proportioning of materials in accordance
mix
formula
with the approved job mix formula and
producing a uniform mix. The permissible
variations of the individual percentages
of the various ingredients in the actual
mix from the job mix formula may be
within the limits as specified in TABLE
33. These variations are intended to
CHAPTER-XVII
apply tc individual specimens taken for
quality control tests vide chapter 1720.
TABLE 33. PERMISSIBLE VARIATIONS FROM THE JOB Mix FORMULA

Sl. Description of ingredients Permissible
No. variation by
weight of
total mix in
percentage
1. Aggregate passing 5.6 mm sieve ±5.0

sieve larger
2. 2.8 mm sieve ±4.0
3. 710 micron ±3.0
4. 180 micron sieve ±1.0
and 90 micron
5. Binder +0.3
Weather
and 4.1. para 3.1 of sub-chapter 1710 shall
seasonal
limitati
apply.
ons
Preparat
ion of 4.2. The base on which bituminous
base
concrete is to be laid shall be prepared,
levels, grade and crossfall (camber) in
accordance with para 1707 or as directed
by the Engineer. The surface shall be
thoroughly swept and scraped clean and
free of dust and other foreign matter
Tack
coat 4.3. A tack coat complying with sub-
chapter 1709 shall be applied over the
base.
Preparat
ion of 4.4. para 4.4 of sub-chapter 1712 shall
mix
apply.
Spreadin
g 4.5. para 4.5 of sub-chapter 1712 shall
apply.
Rolling
4.6. para 4.6 of sub-chapter 1712 shall
apply except that the density achieved
for Bituminous Concrete shall be at least
98 per cent of that of laboratory
Marshall specimen.
CHAPTER-XVII
Opening
to 5.Traffic may be allowed immediately
Traffic
after completion of the final rolling
when the mix has cooled down to the
surrounding temperature.
Surface
Finish 6.The surface finish of construction
and
Quality
of Work

CHAPTER-XVII
SEAL COAT
1. Scope
2. Materials
2.1 Binder
2.2 Stone chippings for type A seal coat
2.3 Aggregate for type B seal coat
3.2 Construction of type A seal coat
3.3 Construction of type B seal coat
CHAPTER-XVII
SEAL COAT
Scope
1.1. This work shall consist of
application of a seal coat for sealing
the voids in a bituminous surfaace laid
to the specified levels, grade and cross
fall (camber).
1.2. Seal coat shall be of either of

the two types as specified below :
Type A : Liquid seat coat comprising of

an application of a layer of bituminous
binder followed by a cover of stone
chippings.
Type B : Premixed seal coat comprising

of a thin applicaticn of fine aggregate
premixed with bituminous binder.
Material
s- 2.1. The quantity of binder to be
Binder
utilised, in terms of straight run
bitumen shall be 9.8 kg and 6.8 kg per 10
square metre area for Type A and Type B
seal coat respectively.
Stone
chipping 2.2. The stone chippings shall consist
s for
type A
of angular fragments of clean, hard,
seal tough and durable rock of uniform quality
coat
throughout. They should be free of
elongated or flaky pieces, soft or
disintegrated stone, organic or other
deleterious matter. Stone chippings shall
be of 6.7 mm size defined as 100 per cent
passing through 11.2 mm sieve and
retained on 2.36 mm sieve. The quantity
used for spreading shall be 0.09 cubic
metre per 10 square metre area. The
chippings shaft satisfy the quality
requirements spelt out in Table 13 except
that the upper limits for Flakiness Index
and water absorption values shall be 30
per cent and 1 per cent respectively.
Aggregat
e for 2.3. The aggregate shall be sand or
type B
seal
grit and shall consist of clean, hard,
coat durable, uncoated dry particles and shall
be free from dust, soft or flaky
material, organic matter or other
deleterious substances. The aggregate
CHAPTER-XVII
shall pass 2.36-mm sieve and be retained
on 180-micron sieve. The quantity used
for premixing shall be 0.06 cubic metre
per 10 square metre area.
Construc
tion 3.1. The seal coat shall be aJgJJijed
Operatio
ns-
immediately after the laying of
Preparat bituminous course, which is required to
ion of
base
be sealed. Before application of seal
coat materials, the surface shall be
cleaned free of any dust or other
extraneous matter.
Construc
tion of 3.2. The binder shall be heated in
type A
seal
boilers of suitable design, to the
coat temperature appropriate to the grade of
bitumen approved by the Engineer, and the
seal coat applied in accordance with the
construction operations described in para
1.3.3 of sub-chapter 1713 through para
1.3.5 of sub-chapter 1713.
Construc
tion of 3.3 Mixers of approved type shall be
type B
seal
employed for mixing the aggregates with
coat the bituminous binder.
The binder shall be heated in boilers

of suitable design to the temperature
appropriate to the grade of bitumen
approved by the Engineer. Also the
aggregates shall be dry and suitably
Treated to a temperature directed by the
Engineer before the same are placed in
the mixes. Mixing of binder with
aggregates to the specified. Proportions
shall be continued till the latter are
thoroughly coated with the former.
The mix shall be immediately

transported from the mixing plant to the
point of use and spread uniformly on the
bituminous surface to be sealed.
As soon as sufficient length has been

covered with the pre-mixed material, the
surface shall be rolled with 6-9 tonne
smooth wheeled power rollers. Rolling
shall be continued till the pre-mixed
material completely seals the voids in
the bituminous course and a smooth
uniform surface is obtained.
CHAPTER-XVII
Opening
to 4. In the case of Type B Seal coat,
Traffic
traffic may be allowed soon after final
rolling when the premixed material has
cooled down to the surrounding
temperature. However, as regards Type A
seal coat. para 1.4 of sub-chapter 1713
shall apply.
Surface
and
Quality
of Work

CHAPTER-XVII
SUPPLY OF MINERAL AGGREGATES FOR PAVEMENT COURSES
1. Scope
2. Sizes of Mineral Aggregates
3. Stacking
4. Quality control of Materials
CHAPTER-XVII
SUPPLY OF MINERAL AGGREGATES FOR PAVEMENT COURSES
Scope
1. These specifications shall apply to
works where it is intended only to
collect, transport and stack the mineral
aggregates and mineral filler for use in
pavement courses. The actual work of
laying the courses shall, however, be
governed by the Specifications for the
same given elsewhere in these
Specifications. The size and quantities
of the aggregates to be supplied shall be
so selected by the Engineer such that the
grading requirements set forth in these
Specifications for the courses for which
the supply is intended are satisfied.
All the materials shall be procured

from approved sources and shall conform
to the physical requirements, specified
in the respective specifications for the
individual items given elsewhere in these
Specifications.
Sizes of
Mineral 2. The Mineral aggregates shall be
Aggregat
es
designated by their standard sizes in the
Contract and shall conform to the
requirements set forth in TABLE 34.
Stacking
3. Only the aggregates satisfying the
Specification requirements shall be
conveyed to the roadside and stacked.
Each size of aggregate shall be stacked
separately.Likewise, materials obtained
from different quarry sources shall be
stacked separately.
TABLE 34.
SIZE REQUIREMENTS FOR MINERAL AGGREGATES
Sl. Standard size Designation of Designation of sieve on
No. 0f aggregate sieve through which the aggregate shall
which the wholly be retained
aggregate shall
wholly pass
CHAPTER-XVII
1. Coarse
2. Aggregate
(i) 75 mm 106 mm 63 mm
(ii) 63 mm 90 mm 53 mm
(iii) 45 mm 53 mm 26.5 mm
(iv) 26.5mm 45 mm 22.4 mm
(v) 22.4mm 26.5 mm 13.2 mm
(vi) 13.2 mm 22.4mm 11.2 mm
(vii) 11.2 mm 13.2 mm 6.7 mm
(viii) 6.7 mm 11.2 mm 2.8 mm
Fine As given in relevant specifications
Aggregate
The aggregates shall be stacked

entirely clear of the roadway on even
ground, or platform prepared in advance
for the purpose by the Contractor at his
own cost and in a manner that permits of
correct and ready measurement. Materials
shall not be stacked in locations liable
to inundation or floods.
The dimensions of the stacks and their

location shall be as approved by the
Engineer. Where the material is
improperly stacked, the Engineer shall
have the right to order complete
restacking of the materials to
specifications at the cost of the
Contractor.
Mineral filler shall be supplied in dry

state in bags or other suitable
containers approved by the Engineer and
shall be protected from weather,
dampness, etc., so as to prevent
deterioration in quality.
Quality
Control 4. The Engineer shall exercise control
of
Material
over the quality of the materials so as
s to ascertain their conformity with the
Specification requuirement, by carrying
out tests for the specified properties.
Testing shall be to the following

frequencies and the Engineer shall have
the right to modify these according to
the needs.
CHAPTER-XVII
Coarse and fine One test for each
aggregates specified property
per 50 sq.m Of
material.
Mineral filler One test for each

specified property
for every five tonne
subject to a minimum
of one test for each
consignment.
Materials not conforming to the

Specification requirements shall not be
brought to the work site.
CHAPTER-XVII
BITUMEN MASTIC
1. Scope
2. Materials
2.1 Bitumen
2.3 Fine aggregate
2.4 Filler
3. Mix Design
3.1 Hardness number
3.2 Binder content
3.3 Job mix formula
4.3 Tack coat
4.4 Preparation of bitumen mastic
4.5 Spreading
4.6 Joints
4.7 Surface finish
5 Opening to Traffic
6 Quality Control of Work
CHAPTER-XVII
BITUMEN MASTIC
Scope
1.1. This work shall consist of
constructing a single layer of 25 mm to
50 mm thick Bitumen Mastic wearing course
for road pavements and bridge decks and
20 mm to 25 mm thick for footpaths of
bridges. The bitumen mastic shall be laid
over a Dense Bituminous Macadam base in
case of road pavements and over a Cement
Concrete base in bridge decks.
1.2. The Bitumen Mastic is a homogenous

mixture of selected well graded
aggregates and bitumen in such
proportions as to yield a plastic and
voidless mass, which when applied hot can
be trowelled and floated to form a very
dense impermeable surfacing.
Material
s- 2.1. The binder shall be straight run
Bitumen
bitumen of a suitable grade satisfying
the requirements of IS: 73. It shall be
paving bitumen of grade S 35 or any other
appropriate grade as directed by the
Engineer. The requirements of physical
properties of bitumen are as given in
TABLE 35.
TABLE 35.
REQUIREMENTS OF PHYSICAL PROPERTIES OF bitumen
S. Characteristic Requirement Method of
No. tests
1 Penetration at 25°C 20 to 40 IS : 1203-
( in 1/100 cm) 1958
2 Softening point (Ring 50°C to 80°C IS : 1205-
and Ball Method) 1958
3 Ductility at 27°C 10 cms IS : 1208-
(Minimum) 1958
4 Loss on heating, 1 percent IS: 1212-1958
(Maximum)
5 Solubility in CS 99 Percent IS : 12l6-
(Minimum) 1958
Coarse
aggregat 2.2. The coarse aggregate shall consist
e
CHAPTER-XVII
of hard durable crushed stones, which
shall be clean, strong, free of
disintegrated pieces, organic and other
deleterious matter and adherent coatings.
They shall be hydrophobic and of low
porosity and shall satisfy the physical
requirements, given in Table 13 except
that the maximum values offlakinessmdex
and water absorption shall be 25 per cent
and 1 per cent respectively.
The percentage and grading of the

coarse aggregate to be incorporated in
the bitumen mastic depending upon the
thickness of the finished course shall be
as in Table 36.
TABLE 36.
AND PERCENTAGE OF COARSE AGGREGATE
GRADING
S.No. Type of Thickness Percentage Grading Coarse
work of of Coarse Aggregate
Finished Aggregate Passsing Percentag
Course I.S. e
(mm) Sieve
1. Wearing (a) 25-40 (a) 30-40 19mm 100
course 13.2 mm 88-96
for (b)41-50 (b) 40-50 2.36mm 0-5
pavement
and deck
2. Footpath 20-35 15-30 6.7mm 100
600 0-15
micron
Fine
aggregat 2.3. The fine aggregate shall be the
e
fraction passing 2.36 mm and retained c.T
75m sieve,_consisting of crusher run
screenings, natural sand or a mixture of
both. These shall be clean, hard,
durable, uncoated, dry and free from any
injurious soft or flaky pieces and
organic or deieterious substances.
Filler
2.4. The filler shall be the lime stone
powder passing, 75 micron sieve and shall
have a calcium carbonate content of not
less than 80 percent by weight when
determined in accordance with the method
specified by the relevant Indian
standards.
CHAPTER-XVII
The grading of the fine aggregate
inclusive of filler shall be as given in
Table 37.
TABLE 37.
GRADING OF FINE AGGREGATE
(INCLUSIVE OF FILLER)
S.NO. I.S. Sieve Percentage
by weight
1. 6.7 mm 2.36 -
2. 2.36 600 0—25
3. 600 212 5—35
4. 212 75 10—20
5. 75 - 30—50
Mix
Design- 3.1. The Bitumen Mastic shall have a
Hardness
number
hardness number of 60 to 80 at 25"C
without coarse aggregates and 10 to 20 at
25°C after adding coarse aggregate. The
hardness number shall be determined in
accordance with the method specified in
IS : 1195.
Binder
the mix set forth in para 3.1 of this
sub-chapter and shall be in the range of
14 to 17 per cent by weight of total mix
as indicated in Table 37.
Job mix
formula 3.3. The Contractor shall intimate the
Engineer in writing at least 20 days
before the start of the work, the job mix
formula proposed to be used by him for
the work indicating the source and
location of all materials, proportions of
all materials such as binder and
aggregates, single definite percentage
passing each seivc for the mixed
aggregate and results of the tests
recommended in various Tables and paras
of this specification.
4. Construction Operations-
Weather
and 4.1. Para 3.1. of sub-chapter 1710
seasonal
limitati
shall apply.
ons
Preparat
ion of 4.2. The base on which bitumen mastic
the base
CHAPTER-XVII
is to be laid shall be prepared, shaped
and conditioned to the specified levels,
grade and crossfall (camber) in
accordance with para 1707 or as directed
by the Engineer. In case of a cement
concrete base, the surface shall be
thoroughly swept and scraped clean and
free of dust and other deleterious
matter. Under no circumstances should
bitumen mastic be spread on a base
containing a binder which will soften
under high application temperatures. If
any such spots or area are there, the
same shall be cutout and repaired before
the bitumen mastic is laid.
Tack
coat 4.3. A tack coat as per sub-chapter
1709 shall be applied on the base or as
Preparat
ion of 4.4. Preparation of bitumen mastic
bitumen
mastic
consists of two stages. The first stage
shall be mixing of filler and fine
aggregates and then heating the mixture
to a temperature of 170°c to205°C.
Required quantity of bitumen shall be
heated to 170°c to 180°C and added io the
heated aggregate. They shall be mixed and
cooked in an approved type of
mechanically agitated mastic cooker for
some time till the materials are
thoroughly mixed. Initially the filler
alone is to be heated in the cooker for
an hour and then half the quantity of
binder is added. After heating and mixing
for some time, the fine aegregate and the
balance of binder are to bs added and
further cooked for about one hour. The
second stage is incorporation of coarse
aggregates and cooking the mixture for a
total period of 3 hours. During cooking
and mixing, care should be taken to
ensure that the contents in the cooker
are at no time heated to a temperature
exceeding 205°C.
In case where the material is not

required for immediate use it shall be
cast into blocks with filler, fine
aggregates and binder, weighing about 25
kgs each. These blocks when required to
CHAPTER-XVII
be used, have to be reheated in the
mechanically agitated cooker to a
Imperative of not less than 170°C and not
more than 205°C, poroughly incorporated
with the requisite quantity of coarse
Bggregatcs and mixed continuously for not
less than an hour. ekixiag shall be
continued until laying operations are
completed |o as to maintain the coarse
aggregates in suspension. At no Btass
during the process of mixing shall the
temperature exceed 205°C.
The bitumen mastic blocks (without

coarse aggregates) shall show on analysis
a composition within the limits as given
in Table 38.
TABLE 38.
COMPOSITION OF BITUMEN MASTIC BLOCKS
I.S. Sieve Percentage by weight
Passing Retained Minimum Maximum
2.36 mm 600 micron 0 22
600 micron 212 micron 4 30
212 micron 75 micron 8 18
75 micron - 25 45
Bitumen Content 14 17
The mix shall be transported to the

laying site in a towed mixer transpoiter
having arrangement for stirring and
keeping hot the mix during
transportation.
Spreadin
g 4.5. The bitumen mastic shall be
deposited directly on the prepared base
immediately in front of the spreader
where it is spread uniformly by means of
wooden floats to the required thickness.
The mix shall be laid in one metre width
contained between angis iron of sizes
suitable to retain the required
thickness. The temperature of the mix at
the times of laying shall be l70ºC to
205ºC. In case blowing takes place while
laying the bitumen mastic, ths bubbles
shall be punctured while it is hot and
the surface treated well.
CHAPTER-XVII
Joints
4.6. It should be ensured that all con-
struction joints are properly and truly
made. These joints shall be made by
warming the existing bitumen mastic by
the application of excess quantity of the
bitumen mastic mix which afterwards shall
be trimmed offto make it flush with the
surfaces on either side.
Surface
finish 4.7. As the bitumen mastic surface can
be slippery after floating to provide
resistance to skidding, the bitumen
mastic after spreading while still hot
and in plastic condition shall be covered
with a layer of stone aggregate of 9.5 mm
size (passing 13.2 mm sieve and retained
on 6.7 mm sieve) granite stone chips of
approved quality precoated with bitumen
at the rate of two per cent of S-65 to S-
90 penetration grades at 25"C at the rate
of 0.05 m3 per 10 m2 and rolled or other-
wise pressed into the surface of the
mastic layer when the temperature of
bitumen mastic is between 80º and lOOºC.
Opening
to 5. The traffic may be allowed after
Traffic
completion of the work when the bitumen
mnstic has cooled down to the sorrounding
temperature.
Quality
Control 6. The type of grade of bitumen, this
of Work
quality, grade and percentage of coarse
and fine aggregates and filler the
temperature control for heating the
materials, mix, laying, floating and com-
pacting, hardness number of the bitumen
mastic, etc. should be strictly followed
as indicated in the various Para s of
this specification or as directed by the
Engineer.
The quality control tests for coarse

and fine aggregates, shall be exercised
by the Engineer in accordance with
Section 900, For mineral filler one test
for each property for every 5 tonne
Subject to a minimum of one test for each
consignment shall be carried out.
The surface of the bitumen mastic

tested with a straight edge 3.0 m long
CHAPTER-XVII
placed parallel to the centre line of the
carriageway shall have no depression
greater than 4 mm. The same limit shall
also apply in case of transverse profile
when tested with a camber template.
CHAPTER-XVII
QUALITY CONTROL FOR ROAD WORKS
1. General
2. Control of alignment and surface regularity
2.1 General
2.2 Horizontal alignments
2.3 Longitudinal profile
2.4 Surface Regularity of Subgrade & Pavement Courses
2.5 Rectification
2.5.1 Subgrade
2.5.2 Granular Sub-base
3. Surface evenness requirements
3.1 Quality control tests during construction-General
4. Tests on Earthwork for Embankment and Subgrade Construction-
Borrow material
5. Compaction control
6. Tests on Sub-bases and Bases(excluding bitumen bound bases)
CHAPTER-XVII
QUALITY CONTROL FOR ROAD WORKS
General
1.1 All materials incorporated and all
works performed shall be strictly in
conformity with the Specification
requirements, and the Contractor shall be
responsible for the quality of the work
in the entire construction within the
Contract. He shall, therefore, have his
own independent and adequate set-up for
ensuring the same.For this purpose, the
Contractor should set up his own
laboratory at locations approved by the
Engineer. The laboratory should be
equipped with sufficient number of modern
and efficient equipment suitable to carry
out the tests prescribed for different
materials and work according to the
Specification. The list of equipment to
be procured and facilities to be provided
shall be got approved by the Engineer.
1.2. The Contractor's laboratory should

be manned by a qualified Material
Engineer assisted by experienced Techni-
cians, and the set-up should be got
approved by the Engineer.
1.3. The Contractor shall carry out

quality control tests on the materials
and work to the freqency stipulated in
subsequent paragraphs. In the absence of
clear indications about method and or
frequency of tests for any item, the
direction of the Engineer shall be
followed.
1.4. For satisfying himself about the

quality of the materials and work,
quality control tests will also be
conducted by the Engineer (by himself, by
hi& Quality Control Units or by any other
agencies deemed fit by him), generally to
the frequency set-forth hereinunder.
Additional tests may also be conducted
where in the opinion of the Engineer need
for such tests exists.
1.5. The Contractor shall provide

necessary co-operation and assistance in
CHAPTER-XVII
obtaining the samples for test and
carrying out the field test as required
by the Engineer from time to time. This
may include provision of labour,
attendance, assistance in packing and
dispatching and any other assistance
considered necessary in connection with
the test.
1.6. For the work of embankment,

subgrads and pavement, constructioa of
subsequent layer of same or other
material over the finished layer shall be
dons after obtaining permission from the
Engineer. Similar permission from the
Engineer shall be obtained in respect of
all other items of works prior to
proceeding with the next stage of
construction.
1.7. The Contractor shall carry out

modification in tns procedure of work, if
found necessary, as directed by the
Engineer during inspection. Works falling
short of quality shall be rectified by
the Contractor at his own cost as
1.8. The Contract rate quoted for

various items of works in the Bill of
Quantities or the lumpsum amount tendered
shall be deemed to be inclusive of all
costs of the quality control test and
operations necessary for ensuring quality
of the material and work so as to be in
conformity with the Specification
requirement.
Control
of 2.1. All works performed shall conform
alignmen
t and
to the lines, grades, cross sections and
surface dimensions shown on the drawings or as
regulari
ty-
directed by the Engineer subject to the
general permitted tolerances described herein-
after.
Horizont
al 2.2. Horizontal alignments shall be
alignmen
ts
reckoned with respect to the centre line
of the carriageway as shown on the
drawings. The edges of the carriageway as
constructed shall be correct within a
tolerance of ±25 mm thereform. The
CHAPTER-XVII
corresponding tolerance for edges of the
roadway and lower layers of pavement
shall be + 40 mm.
Longitud
inal 2.3. The levels of the oubgrade and
profile
dicerent pavement courses as constructed,
shall not vary from those calculated with
reference to the longitudinal and cross-
profile of the load shown on the drawings
or as directed by the Engineer beyond the
tolerances mentioned below :
Subgrade ± 25 mm
Sub-base ± 20 mm
Base course +15 mm
Wearng course +10 mm
Provided, however, that the negative

tolerance for wearing course shall not be
permitted in conjunction with the
positive tolerance for bass course if the
thickness of the former is thereby
reduced by more than 6 mm.
Surface
Regulari 2.4. The surface regularity of
ty of
Subgrade
completed subgrads, sub-bases, base
& Pave- courses and wearing surfaces in the
ment
Courses
longitudinal and transverse directions
shall be within the tolerances indicated
in Table 39.
The longitudinal profile shall be

checked with a 3 metre long straight
edge, at the middle of each traffic lane
along a line parallel to the centre line
of the road. The transverse profile shall
be checked with a set of three camber
boards at intervals of 10 metres.
Rectific
ation 2.5. Where the surface irregularity of
subgrade and the various. pavsment
courses fall outside the specified
tolerances, the Contractor shall be
liable to rectify these in the manner
described below and to the satisfaction
of the Engineer.
CHAPTER-XVII
Subgrade
2.5.1 Where the surface is high, it
shall be trimmed and suitably compacted.
Where the same is low, the deficiency
shali be corrected by adding fresh
material.
Granular
Sub-base 2.5.2 Same as at (1) above except that
the degree of compaction and the type of
material to be used shall conform to the
requirements of sub-chapter 1701.
TABLE 39.
PERMITTED TOLERANCES OF SURFACE REGULARITY FOR SUBGRAOE AND PAVEMENT
COURSES
S. Type of Longitudinal profile Cross profile
NO. construction with 3 metre straight
edge
Max. Maximum number Maximum
Permi of undulations permissible
ssibl permitted in any variaiion from
e 300 metres specified profile
undul length exceeding under camber
ation mm template mm
mm 18 12 10 6
1 2 3 4 5 6 7 8
1. Earthen subgrade 24 30 — — - 15
2. Granular/Lime/Cem 15 - 30 - - 12
ent/
stabilised
subbase
3. Water bound 15 - 30 - - 12
macadam with over
size metal
(45.90 mm size)
4. Water Bound 12 - - 30 - 8
Macadam with
normal size
metal(22.4-53 mm
and 45-63 mm
size), Wet mix
macadam bitu-
minous
penetration
macadam or built-
up spray grout
5. Surface dressing 12 - - 20 - 8
** (two coat)
over WBM (22.4-53
mm or 45-63 mm
CHAPTER-XVII
S. Type of Longitudinal profile Cross profile
NO. construction with 3 metre straight
edge
Max. Maximum number Maximum
Permi of undulations permissible
ssibl permitted in any variaiion from
e 300 metres specified profile
undul length exceeding under camber
ation mm template mm
mm 18 12 10 6
size metal),
bituminous
penetration
macadam or
built-up spray
grout
6. Open graded 10 - - - 30 6
premix carpet,
mix-seal
surfacing
7. Bituminous 10 - - - 20 6
macadam @@
8. Dense bituminous 10 - - - 20 6
Macadam @@
9. Semidense 10 - - - 20 6
bituminous @@
Concrete
10. Bituminous 8 - - - 10 4
concrete @@
(Asphahic
concrete)
Notes:
1. For surface dressing in all other
cases, the standards of surface evenness
will be the same as those for the
surface receiving the surface dressing.
2. These are for machine laid

surfaces. If laid manually due to
unavoidable reasons, tolerance upto 50
per cent above these values in this
column may be permitted at the
discretion of the Engineer. However,
this relaxation does not apply to the
values of maximum undulation for
longitudinal and cross profiles
mentioned in columns 3 and 8 on the
table.
CHAPTER-XVII
3. Surface evenness requirements in
respect of both the longitudinal and
cross profile should be simultaneously
satisfied.
Lime/Cemen
t (iii) For lime/cement treated
Stabilized
Soil Sub-
materials where the surface is high, the
base same shall be suitably trimmed while
taking care that the material below is
not disturbed due to this operation.
However, where the surface is low, the
same shall be corrected as described
herein below.
For cement treated material, when the

time elapsed between detection of
irregularity and the time of mixing of
the material is less than 2 hours, the
surface shall be scarified to a depth of
50 mm supplemented with freshly mixed
material as necessary and recompacted to
the relevant specification. When this
time is more than 2 hours, the full
depth of the layer shall be removed from
the pavement and replaced with fresh
material to specification. In either
case, the area treated shall not be less
than 5 metres long by 2 metres wide.
This shall also apply to lime treated
material except that the time criterion
shall be 3 hours instead of 2 hours.
Water
Bound (iv) Where the surface is high or low,
Macadam/We
t Mix
the top 75 mm shall be scarified, re-
Macadam shaped with added material as necessary
Base
and recompacted to para 1704. The area
treated at a place shall not be less
than 5 metres long and 2 metres wide.
This »hall also apply to wet mix macadam
to sub-chapter 1706.
Bituminous
Constructi (v) For bituminous construction other
ons
than wearing course, where the surface
is low, the deficiency shall be
corrected by adding fresh material and
rccompicting to specifications. Where
the surface is high, the full depth of
the layer shall be removed and replaced
with fresh material and compacted to
specifications.
CHAPTER-XVII
For wearing courae, where the surface
is high or low, the full depth of the
layer shall be removed and replaced with
fresh material and compacted to
specifications. In all cases where the
removal and replacement of a bituminous
layer is involved, the area treated
shall not be less than 5 metre long and
not less than 1 lane wide.
Quality
control 3.1. The materials supplied and the
tests
during
works carried out by the Contractor
constructi s'nai'i conform to the specifications
on-
General
prescribed in the preceding Para s.
For ensuring the requisite quality of

construction, the materials and works
'ihall be subjected to quality control
tests, as described hereinafter. The
testing frequencies set forth ars the
desirable minimum and the Engineer shall
have the full authority to carry out
tests as frequently as he may deem
necessary to satisfy himself that the
materials and works comply with the
appropriate specifications.
Test procedures for the various

quality control tests are indicated in
the respective Sections of these
Specifications or for certain tests
within this Section. Where no specific
testing procedure is mentioned, the
tests shall be carried out as per the
prevalent accepted engineering practice
to the directions of the Engineer.
Tests on
Earthwork 4. Following are the test should be
for
Embankment
conducted.
and
Subgrade
Constructi
(a) Sand Content [IS: 2720 (Part IV)]
on- Borrow
material 1-2 tests per 8000 cu. Metres of soil.
(b) Plasticity Test [IS : 2720 (Part

V)1
Each type to be tested, 1-2 tests per

8000 cu. metres of soil.
(c) Density Test [IS : 2720 (Part
CHAPTER-XVII
Vll)]
Each soil type to be tested, 1-2 tests

per 8000 cubic metres of soil.
(d) Daleterious Content Test [IS :

2720 (Part XXV11)]
As and when required by the Engineer.
(e) Moisture Content Test [IS : 2720

(Part 1151 One test for every 250 cubic
metres of soil.
(f) CBR Test on materials to be

incorporated in the subgrade on
soaked/unsoaked samples [IS : 2720
(PartXVl)]
One test for every 3000 cum atleast or

closer as and when required,by the
Engineer.
Compaction
control 5. Control shall be exercised by
taking at least one measurement of
density for each 1000 square metres of
compacted area, or closer as required to
yield the minimum number of test results
for evaluating a day's work on
statistical basis. The deterrGinafkm of
density shail be in accordance with
IS:2720 (Part XXVIII). Test locations
shall be chosen only through random
sampling techniques. Control snail not
ba based on the result of any one test
but on the mean value of a' set of 5-10
density determinations. The number of
tests in one set of measurements shall
be 5 as long as it is felt that
sufficient control over borrow material
and the method of compaction is being
exercised. If considerable variations
are observed between individual density
results, the minimum number of tests on
one set of measurement shall be
increased to 10. The acceptance of work
shall be subject to the condition that
the mean dry density equals or exceeds
the specified density and the standard
deviation for any set of results is
below 0.08 gm/cc.
CHAPTER-XVII
However, for earthwork in shoulders
(earthen) and in top 500 mm portion of
the embankment below the subgrade, at
least one density measurement shall be
taken for every 500 square metres of the
compacted area provided further that the
number of tests in each set of
measurements shall be at least 10. In
other respects, the control shall be
similar to that described earlier.
Tests on
Sub-bases 6. The tests and their frequencies for
and
Bases(excl
the different types of bases and sub-
uding bases shall be as given in Table 40. The
bitumen
bound
evaluation of density results for
bases) compaction control shall be on lines
similar to those set out in para
903.2.2.
TABLE 40.
CONTROL TESTS AND THEIR FREQUENCY FOR SUB-BASES AND BASE* (EXCLUDING BHUMEN
BOUND BASES)
S.No. Types of Test Frequency

construction
1. Granular base (i) Gradation One test per

course 200 cubic m
(ii) Atterbergs --do--

limit
(iii) Moisture One test per

content prior to 250 cubic m
compaction
(iv) Density of One test per

compacted layer 500 cubic m
(v) Deleterious As required

constituents
(vi) C.B.R. As required
CHAPTER-XVII
S.No. Types of Test Frequency
construction
2. Lime/Cement (i) Purity of One test for

Stabilised lime (for lime- each
soil sub-base soil consignment
Stabilization) subject to a
minimum of one
test per 5
tonnes of lime
(ii) Lime/Cement Regularly

content through
procedural
checks
(iii) Degree of Periodically

pulverisation as considered
necessary
(iv) CBR test on As required

a set of 3
specimens
(v) Moisture con- One test per

tent prior to 250 sq. m
compaction
(vi) Density of One test per

compacted layer 500 sq. m
(vii) Deletcrious As required

constituents
3. Water bound (i) Aggregate Imp One test per

Macadam and act Value 200 cubic m of
wet mix aggregate
macadam
(ii) Grading One test per
100 cubic m of
aggregate
(iii) Flakiaess One test per

Index 200 cubic m of
aggregate
(iv) Atterbergs One test per

limits of binding 25 cubic m of
material (for WBM binding
only) material
CHAPTER-XVII
Test on
Bituminous The tests and their frequencies for
constructi
ons
the different types of bituminous works
shall be as given in Table 41.
TABLE 41.
CONTROL TESTS AND THEIR. FREQUENCY FOR BITUMINOUS WORKS
S.No. Type of Test Frequency
construction
1. Prime (i) Quality of As required
coat/Tack binder
coat
(ii)Binder At regular close
temperature for intervals.
application
(iii) Rate of Two tests per
spread of binder day.
2. Seal (i) Quality of As required
Coat/Surfaces binder
Dressing
(ii)Aggregate One test per 50
Impact Value sq. m of area
(iii) Flakiness —do—
Index
(iv)Stripping value Initially, one
of aggregates set of 3
(v)Water absorption representative
of aggregates specimens for
each source of
supply.
Subsequently
when warranted
by changes in
the quality of
aggregates.
(vi)Grading of One test per 25
aggregates cubic m of
aggregate.
(vii) Temperature At regular close
of binder at intervals
Application
(viii) Rate of One test per 500
spread of materials cubic m of
aggregate.
3. Open- (i) Quality of As required.
graded Premix binder
(ii) Aggregate One test per 50
Impact Value m2 of area.
(iii) Flakiness —do—
CHAPTER-XVII
Index of aggregates
(iv) Stripping Same as
Value and water mentioned under
absorption of serial no.2
aggregates
(v) Grading of One test per 25
aggregates cubic metre of
aggregate.
(vi) Temperature of At regular close
binder at intervals.
application
(vii)Binder content Two tests per
(vide ASTM : D- day.
2172)
(viii) Rate of Regular control
spread of mixed through checks
material on materials and
layer thickness.
4. Bitumen (i) Quality of As required.
Macadam binder
(ii)Aggregate One test per 50-
Impact 100 cubic metre
Value of aggregate.
(iii) Flakiness --do--
Index of aggregates
(iv)Stripping Value Same as
mentioned under
serial no.2
(v) Grading of Two tests per
aggregates day per plant
both on the
individual
constituents and
mixed aggregates
from the dryer.
(vi) Binder content Periodic subject
(vide ASTM :D-2172) to minimum of
two tests per
day per plant.
(vii)Control of At regular close
temperature of intervals.
binder and agg-
regate for mixing
and of the mix at
the time of laying
and rolling
(viii) Rate of Regular control
spread of mixed through checks
material on layer
thickness
CHAPTER-XVII
5 Bituminous (i) Quality of As required
Penetration binder
Macadam
Built-up
Spray-Grout
(ii)Aggregate One test per 200
Impact cubic metre of
Value aggregate.
(iii) Flakinesa --do--
Index of aggregates
(iv)Stripping Value Same as
mentioned under
serial no.2
(v)Aggregate One test per 100
grading cubic metre of
aggregate.
(vi)Temperature of At close
binder at intervals.
application
(vii) Rate of One test per 500
spread square metre of
of binder area.
6. Dense (i) Quality of As required.
Bituminous binder
Macadam/Semi-
Dense
Bituminous
Macadam
(ii)Aggregate One test per 50-
Impact 100 cubic metre
Value of aggregate.
(iii)Flakinesa --do--
Index of aggregates
(iv)Stripping Value --do--
(v)Mix Grading One set of tests
on individual
constituents and
mixed aggregates
from the dryer
for each 100
tonnes of mix
subject to a
minimum of two
sets per plant
per day.
CHAPTER-XVII
(vi)Stability of For each 100
mix (Vide ASTM D- tonnes of mix
1559) produced, a set
of 3 Marshall
specimens to be
prepared and
tested for
stability, flow
value. Density
and void
content subject
to a minimum of
two sets being
tested per plant
per day.
(vii) Control of At regular close

temperature of intervals.
binder in boiler,
aggregate in the
dryer and mix at
the time of laying
and rolling
(viii)Control of One test for
binder content and each 100 tonnes
gradation in the of mix subject
mix to a minimum
ofiwo tests per
day per plant.
(ix) Rate of spread Regular control
of mixed malerial through checks
on layer
thickness.

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CHAPTER XVII

1701 GRANULAR SUB BASE

1702 LIME STABILISED SOIL SUB-BASE

1703 CEMENT STABILISED SOIL SUB-BASE

1704 WATER BOUND MACADAM SUB-BASE/BASE COURSE

1705 WET MIX MACADAM SUB-BASE/BASE COURSE

1706 SHOULDER AND MEDIAN

(B) ROAD WORK BASE AND WEARING COURSES (BITUMINOUS-LAYER)

1707 PREPARATION OF BASE

1708 PRIMER COAT OVER GRANULAR BASE

1709 TACK COAT

1710 BITUMINOUS MACADAM

1711 BITUMINOUS PENETRATION MACADAM

1712 DENSE BITUMINOUS MACADAM

1713 SURFACE DRESSING

1714 OPEN-GRADED PREMIX CARPET

1715 SEMI DENSE BITUMINOUS CONCRETE

1716 BITUMINOUS CONCRETE

1717 SEAL COAT

1718 SUPPLY OF MINERAL AGGREGATES FOR PAVEMENT COURSES

1719 BITUMEN MASTIC

1720 QUALITY CONTROL OF ROAD WORK

N. B:Source is Minisistry of surface transport specification for

LIST OF BUREAU OF INDIAN STANDARDS CODES (ISI)

S.No. IS CODE NO. SUBJECT

1. 73-1992 Specification for paving bitumen (2nd Revision)

2. 164-1981 Ready mixed paint for road marking, (1st

3. 217-1988 Specification for cut back bitumen (2nd Revision)

4. 334-1982 Glossary of terms relating to bitumen and tar

5. 1195-1978 Specification for Bitumen mastic for flooring

6. 1203-1978 Method of testing tar and bituminous material.

7. 1205-1978 -Do-,Determination of softening point (Reaffirmed

8. 1208-1978 -Do-, Determination of ductility, (Reaffirmed

9. 1212-1978 -Do-, Determination of loss on heating

10. 1216-1978 Do-, Determination of solubility in carbon

11. 1834-1984 Specifications for hot applied sealing compound

12. 1838(Pt.I) Specifications for reformed fillers for expansion

13. 5317-1987 Specification for Bitumen mastic for bridge

14. 6241-1971 Methods of test, for determination of stripping

XVII - ROAD WORK

S.NO. IRC CODE NO. SUBJECT

1. 10-1961 Recommended practice for borrow pits for road,

2. 29-1988 Specification for bituminous concrete for road

3. 36-1970 IRC Recommended practice for construction of

4. 60-1976 Tentative guidelines for the use of lime fly

5. 88-1984 IRC Recommended practice for lime fly ash

6. 107-1992 Tentative specifications for bitumen mastic

LIST OF MANDATORY TESTS

Material/ Test Field/ Test Minimum Frequency of

3. Flakiness Index Field IS 5640

2. Density Field IS 2720(Part Nil

(a) Gradation IS 2720(Part Nil

(c) Proctor test Laboratory IS 2720(Part Nil -Do-

(d) Deleterious Laboratory IS 2720(Part Nil As required

(e) Moisture Laboratory Nil 250 cum.

2. Aggregate Laboratory IS 2386(Part Nil Per 100 m3 of

3. Flakiness Index Laboratory IS:2386(Part Nil —Do—

4. Stripping Value Laboratory IS 6241 Nil —Do-

5. Grading of Field or IS 2386(Part Nil Two test per

Semi 1. Los angeles Laboratory IS 2386(Part Nil For every 100

2. Flakiness Index Laboratory IS 2386(Part —Do-

3. Stripping Value Laboratory IS 6241 —Do-

4. Mix Grading Field IS 2386(Part One sert of