DOC NAME:

WSM
ROAD WORKS VERSION
PEPL/WSM/0.1/2016

DEFINITION:

 The part of a road intended for the movements of vehicles, in contrast to the pavement or verge.

 The part of a bridge or railway used by traffic.

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Road works activity comprises of following steps

1. Different types of roads

2. Before road works
3. During road works
4. Kerbs
5. After road works
6. Related IS codes
7. Stages of checking

1. DIFFERENT TYPES OF ROADS:

Different types of roads based on the material used like

a. Water Bound Macadam roads

b. Asphalt roads (Bituminous roads)
c. Concrete roads

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a. Water Bound Macadam road:
Water bound macadam (WBM) roads are constructed as follows:

 Sub grade preparation

 Preparation of existing surface
 Spraying of binder
 Spreading of stone aggregates
 Rolling of first coat
 Application of binder and aggregates for second coat
 Rolling of second coat (if required)
 Opening to traffic

b. Bituminous road:
Bituminous road are constructed as follows:

 Base coarse preparation

 Application of Tack coat
 Placing of pre-mix
 Compaction of bituminous macadam
 Sand spraying
 Opening to traffic

c. Cement Concrete road:

Cement concrete roads are constructed as follows:

 Preparation of surface
 Fixing of forms
 Mixing and laying of concrete
 Compaction and finishing
 Curing
 Opening to traffic

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2. BEFORE ROAD WORKS:

 All the necessary latest GFC drawings and

specification details should be available at site.
 Proper inspections chambers should be planned
and provided for the sewage lines at suitable
locations.
 Any necessary cutting with respect to the level of
the roads should be done.
 All unwanted material has to be removed.
However, fertile soil can be stocked suitably and can be used for landscaping along the
sides or on the median of the roads.
 The entire area where the road shall be aligned should be free from debris.
 Trees shall be transplanted and loss of vegetation should be minimized.
 Before proceeding with the construction of the road section, the underlying sub grade
has to be compacted. The sub-grade is prepared to the required level.
 The compacted sub grade to be ensured the strength given by the consultant.

3. DURING ROAD WORKS:

 The proposed road areas have to be surveyed

to establish the ROW of the road sections
according to the GFC drawings.
 Establish bench mark pillars along the length
of the road on either side at intervals of 5 to
10m.
 The underlying cut areas have to be scarified
and then given the rough profile of the road during the compaction process using a
single drum roller. 98 % of the maximum dry density of the soil should be the
achieved by compaction and a minimum of 8% CBR.
 Compaction testing to be conducted by any of the following suitable methods like:
a) Sand Replacing Test
b) DCP Test
c) LWD Test

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  The compacted soil should be able to take up the loads as per design.
 After completion of sub-grade work, all the underground utilities, ducts, culverts, etc
should be installed.
 Road crossing drain pipes & other crossing utilities are executed after sub-grade
compaction, because there may high chances of this utilities getting damaged during
compaction of sub-grade, if laid prior to compaction and moreover the crossing
utilities pipe will be almost at the sub-grade level.
 Electrical, sewage/water line, which crosses the alignment of the road, should be
completed as per requirement.
 The water lines should be above the sewage lines with proper separation layer between
the two lines.
 In the required places sub grade material should be placed in layers of not more than
150mm height and it should be compacted. Up to the desired level sub grade filling has
to be done.
 A layer of granular sub base (GSB) should be laid in a maximum thickness of 150mm
(after compaction) per layer and compacted to the required level.
 After spreading the granular sub base, it should be watered.
 By using the single drum roller compaction to be done.
 The aggregates should be slightly wet during this process (5% to 7% moisture
content).
 While laying the granular sub-base, the camber and profile of the road has to be
maintained as per the GFC drawings.
 Upon the completion of the GSB layer, gutters & Kerb stone are fixed to line and level
as per the GFC drawings, before laying the wet mix macadam.
 Wet Mix Macadam (WMM) consisting of graded and granular, material which is
premixed with water, is laid in one or more layers not exceeding 150mm each (after
compaction).
 WMM levelled with a grader and compacted with vibrating soil compactor.

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3.1 ASPHALTIC FINISH (BITUMINOUS FINISH):

 The top of this layer should have the profile and

slope as per GFC drawings.
 On the complete layer of wet mix macadam, prime
coat should be applied using a bitumen sprayer at
the rate of 0.8- 1.2 litre/m². Ensure that the Kerb
stone & Gutter are covered before spraying prime
coat.
 If a bituminous emulsion is being used as per a primer, then Dense Bituminous
Macadam (DBM) works can successively continue.
 Then bitumen is heated to 180ºC and mixed with well-graded aggregates of size 20mm
in a bituminous concrete batching plant to get DBM
 DBM is transported and fed into the paver machine.
 The paver machine will lay the DBM to the required thickness, level, alignment and
width.
 At the time of laying and rolling the temperature of the asphalt base course should not
less than 120ºC.
 For further compaction double drum vibratory rollers are used.
 By using a pneumatic roller finishing to be done.
 Above this asphalt base course, a layer of tack coat (at the rate of 0.4-0.6 litre/m²) is
sprayed with a bitumen sprayer. Ensure that the Kerb stones & Gutter are covered
before spraying tack coat.
 The Semi-Dense Bituminous Concrete (SDBC) is then laid using a paver machine and
rolled with double drum vibratory rollers. This is also called as the seal coat.
 A pneumatic roller is used for the compaction of this layer.
 After laying no vehicular traffic should be allowed for a minimum of 12 hours.

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3.2 CONCRETE FINISH:

 A separation membrane shall be used between the concrete slab and the sub base.
Separation membrane shall be impermeable plastic sheeting 125 microns thick laid flat
without creases.
 The location and type of joint is provided as per the drawings.

JOINTS:

EXPANSION JOINT CONTRACTION JOINT-1

CONTRACTION JOINT-2 LONGITUDINAL (WARPING) JOINT

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Expansion Joint:

 The dowel bars are adequate and are as per required length and diameter
 Expansion joints are commonly spaced at distances equal to 24 to 30 times the road thickness.
Joint spacing that is greater than 15 feet require the use of load transfer devices (dowels or
diamond plates
 Dowel bars are typically 32 to 38 mm (1.25 to 1.5 inches) in diameter, 460 mm (18 inches)
long and spaced 305 mm (12 inches) apart.
 Expansion joints on each side of the longitudinal joint shall be in line with each other
and of the same type and width.
 The filler board shall be positioned vertically with the prefabricated joint assemblies
along the line of the joint within the tolerances
 The adjacent sides shall be completely separated from each other by providing joint
filler board. Space around the dowel bars, between the sub-base and the filler board
shall be packed with a suitable compressible material to block the flow of cement
slurry
 Expansion joints shall be placed whenever concreting is completed after a day’s work
or is suspended for more than 30 minutes. These joints shall be provided at the regular
location of contraction joints using dowel bar
 Expansion joints shall consist of a joint filler board and dowel bars as detailed in the
drawings.
 All transverse joints in surface slabs shall be sealed using sealants. Joints shall not be
sealed before 14 days after construction.

Contraction Joints:

 The Contraction joints are using dowel bars and they are made as butt type joints.
 Dowel bars are typically 32 to 38 mm (1.25 to 1.5 inches) in diameter, 460 mm (18
inches) long and spaced 305 mm (12 inches) apart.
 The Contraction joints should be cut as soon as the concrete undergoing initial
hardening is hard enough to bear the load of sawing machine without causing damage
to the slab.
 Contraction joints shall consist of a mechanical sawn joint groove, 3 to 5 mm wide and
1/4 to 1/3 depth of the slab ± 5 mm or as stipulated in the drawings.

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Longitudinal Joints (Warping joint)

 Tie bars are provided at the longitudinal joints as per dimensions and spacing shown in
the drawing
 Longitudinal differential vertical movement between the slabs is prevented by fixing
mild steel tie bars of generally 12mm in diameter.
 The Longitudinal joints shall be cut as soon as the concrete has undergone initial
hardening and is hard enough to take the load of joint sawing machine without causing
damage to the slab
 The longitudinal joints shall be saw cut as per details of the joints shown in the
drawing. The groove may be cut after the final set of the concrete. Joints should be
sawn to at least 1/3 the depth of the slab ± 5 mm as indicated in the drawing

 There are two types of concrete mixer is using construction

o Batching mixer-used for small road construction
o Continues mixer-used large construction
 Two types of generally used in placing of concrete
o Alternate bay method
o Continues bay method
 After placing the concrete, floating is done as per the requirement for the finishing
purpose of concrete.
 After completion of the finishing operation, the surface of pavement should be entirely
covered with wet hessian cloth.
 All grooves shall be cleaned of any dirt or loose material by air blasting with filtered,
oil-free compressed air. The groove shall be cleaned and dried at the time of priming
and sealing.

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3.3. PAVING:

Concrete block paving is a high performance

construction and for this reason, all that is
required to achieve the above should be done
with care and caution. The major parameters
considered for a durable, quality pavement are
as follows:

3.3.1 THE BASE, SUB-BASE & COMPACTION:

 The materials used for the base construction consists of graded granular material or
lean mixed concrete, constructed and compacted in layers not exceeding 225mm.
 The sub-base surface should have reasonable slope and fails. Compaction should be
carried by mechanical vibrating compactors to specified CBR. It is a must to use
proper kerbing before beginning to lay paving segments.

3.3.2 LAYING OF BLOCKS:

 Blocks should be laid to the specified

pattern with joint width of approximately
2-5mm with the assistance of a string tied
across, in order to maintain line and level.
 Blocks should be laid hand-tight.
 Always avoid using cut pieces smaller than
1/3rd size.
 Colour variations cannot be avoided in the manufacturing process and therefore it is
always advisable to mix and use the pavers from different bundles to provide a
natural appearance.

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3.3.3 LAYING COURSE (SAND BEDDING):

 These materials consist of 6mm D/S natural sand. Thickness of laying course should
be between 25 and 50mm.
 In certain areas, like around the manholes, it is suggested to use lean cement mortar
(one part of cement to ten part parts of sand) instead of plain sand.

3.3.4 FILLING OF JOINTS:

 Once the pavers are laid, dry, coarse and clean sand should be used to fill the paver
joints.
 The sand can be brushed or broomed into the joints.
 A vibrating compactor should help to complete the job efficiently.

4. KERBS:

4.1 INSTALLATION OF KERBS:

 A good and reasonable mix of concrete

should be laid, measuring at least
100mm in height, on which the kerbing
/edging units are fixed so that the
pavement is joined with the kerbs. The
concreting is done to ensure that the
kerbs are fixed at proper level.
 To ensure proper alignment, kerbs
should be fixed by using a string line,
tied properly. This method allows a good level and straightness.
 A concrete Haunching on the back of the kerbing is absolutely necessary to provide
lateral support. The width of the haunched concrete should be minimum 75mm to
maximum 150mm depending on whether it’s a pathway or a medium trafficked
driveway or highways. The Haunching has to be finished well.

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5. AFTER ROAD WORKS:

 After completion of the road construction, the pavement marking, fixing of road signs,
markers, reflectors, convex mirrors, painting of kerb stones, should be done.
 The walking area next to the road has to be done.
 Poles for street lights, signals and other signage’s should be installed and all electrical
works should be done.

6. RELATED IS & IRC CODES:

1. IS: 73-1992-Paving Bitumen Specification (Second Revision)

2. IS: 2720-Methods of Test for Soils

3. IS: 217-1988-Cutback Bitumen-Specification (Second Revision)

4. IS: 702-1988-Industrial Bitumen (Second Revision)

5. IS: 6241-197-Methods of Test for Determination of Stripping Value of Road

Aggregates
6. IS: 8887- 1995-Bitumen Emulsion for Roads (Cationic Type)-Specification (First
Revision)
7. IRC: 35-1997 -Code of Practice for Road Markings (with Paints) (First Revision)
8. IRC: 64-1990 -Guidelines for Capacity of Roads in Rural Areas (First Revision)
9. IRC: 65- 1976- Recommended Practice for Traffic Rotaries
10. IRC: 67-2001 -Code of Practice for Road Signs (First Revision)
11. IRC: 78-2000 -Standard Specifications and Code of Practice for Road Bridges, Section VII-
Foundations & Substructure (Second Revision)
12. IRC: 99-1988 -Tentative Guidelines on the Provision of Speed Breakers for Control of
Vehicular Speeds on Minor Roads
13. IRC: 103-1988 -Guidelines for Pedestrian Facilities
14. IRC: 108-1996 -Guidelines for Traffic Prediction on Rural Highways
15. IRC: SP: 11-1988 Handbook of Quality Control for Construction of Roads and Runways
(Second Revision)
16. IRC: SP: 19-2001 -Manual for Survey, Investigation and Preparation of Road Projects
(Second Revision)

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 17. IRC: SP: 21-1979- Manual on Landscaping of Roads
18. IRC: SP: 53-2002 -Guidelines on Use of Polymer and Rubber Modified Bitumen in Road
Construction (First Revision)

7. STAGES OF CHECKING:

1. Before start of the work

2. During the work

3. After the work

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