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Grouted or Penetration Macadam
Penetration macadam consists of 3 layers of successively
finer broken or crushed rock interspersed with applications
of heated bitumen to grout voids and eventually seal the
surface.
May be full grout (bitumen penetrates up to full depth of
aggregate) or semi-grout (bitumen penetrates up to half the
depth)
Recommended for thickness of 50 to 75 mm
Grouted or Penetration Macadam Grouted or Penetration Macadam
Construction Procedure
Equipment: Hot bitumen spray equipment; Roller,
Preparation of existing surface and recondition itas
Aggregate spreader, mechanical brooms, Hand tools
necessary
such as shovels, wheelbarrows, and hard broomsetc.
Spreading of Coarse aggregates
Rolling – 10 tonnes
Material Selection:
Apply the first layer of bituminous material – 5-6.7kg/m2
Aggregate - FI ≤ 25%, LAA ≤ 40%, Impact value ≤ 30%,
Spreading of key aggregates
stripping at 40oC ≤ 25%, loss withNA2SO4≤ 25%, Coarse
aggregate (<63 mm for 7.5 cm thick, <50 mm for 5 cm Rolling by 10 tonnes but excessive rollingavoided
thick), key aggregates (<25 mm for 7.5 cm thick , <19mm Apply the second layer of bituminousmaterial.
for 5 cm thick, stone chipping or fine (<10 mm ) Apply stonechippings.
Bitumen grade 80/100, 60/70, 30/40 (5-6.7 kg/m2 for Drag-broom, roll, and hand-broom the surface
first application, second application 2-3 perm2) Opening of traffic – After 24 hours
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Grouted or Penetration Macadam
Quality Control
Temperature of binder,
Tests on aggregates (LAA, FI, Impact value, Stripping
test etc,
gradation test,
rate of application of binder andaggregate,
test on bitumen (penetration, viscosity, ductilityetc.)
6.9 Construction of Different Types of
6.9.1 Bitumen Bound Macadam
Bituminous Premixes
It is an open graded mixture of mineral aggregate
and appropriate binder, mixed in a hot mix plant
Bitumen Bound Macadam
Bituminous premixed carpet It is laid in a single course or in a multiple layers
Bituminous concrete
Thickness of single layer is 50 mm to 75mm.
However, may trap water or moisture vapor
within the pavement system
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6.9.1 Bitumen Bound Macadam 6.9.1 Bitumen Bound Macadam
Equipment: Hot bitumen sprayer; mechanical or Construction Procedure
hand mixer, mechanical paver, bitumen heating device, Preparation of existing layer
hot mix plant, Pneumatic Roller, mechanical brooms Tack Coat or prime coat application – 4 to 7.5 kg/10m2 for
etc. black top; 7.5 to 10 kg/10m2 for WBMlayer
Premix Production – temperature tolerance of +- 10oC
Material Selection: Placement of the mix at site with paver or grader or manual
Aggregate - FI ≤ 25%, LAA ≤ 40%, Impact value ≤ 30%,
Rolling compaction by 8 to 10 tone pneumaticroller
stripping at 40oC ≤ 25%, loss withNA2SO4≤ 12% for Application of seal coat
binder course, FI ≤ 15%, LAA ≤ 50%, Impact value ≤ 35%, Opening to traffic
stripping at 40oC ≤ 25%, loss withNA2SO4≤ 12% for base
course
Bitumen grade 80/100, 60/70, 30/40 penetration, RT-4
tar, bitumen content 3 to 4.5% byweight
6.9.1 Bitumen Bound Macadam 6.9.2 Premix Bituminous Carpet
It is an open graded premix of stone chipping of
Quality Control size 10~12 mm with bitumen or tar binder
Temperature of binder,
Tests on aggregates (LAA, FI, Impact value, Stripping
test etc, Being open graded, it should be covered with
gradation test, sand seal or chipseal
rate of application of binder
Spread of mix material Thickness of single layer is 20 mm to 25mm.
test on bitumen (penetration, viscosity, ductilityetc.)
Density of compacted layer
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6.9.2 Premix Bituminous Carpet 6.9.2 Premix Bituminous Carpet
Equipment: Hot bitumen sprayer; mechanical paver, Construction Procedure
bitumen heating device, Pneumatic Roller, mechanical Preparation of the existing surface
brooms etc. Application of tack coat or prime coat
Premix is prepared by heating both bitumen and aggregate
up to the required temp and mixed in mechanicalmixer
Material Selection:
Mix is taken out and spread with thickness 15 cm using
Coarse aggregate - angular, clean, hard, tough, durable
paver
≤ 16 mm for 40 mm thick and ≤ 10 mm for 20 mm thick
with LAA value 40% (max), Aggregate Impact value – Rolling is done with Tandem or Pneumatic roller of 6 to 9
35%(max), Flakiness index – 30%(max) tonnes
Sand - clean, hard, durable Premix sand seal coat or chip seal is applied and light
tandem roller is rolled
Bitumen grade 80/100 penetration
Open to traffic after 24 hours
6.9.2 Premix Bituminous Carpet 6.9.3 Bituminous Concrete
Highest quality of construction among
Quality Control bituminous pavement
Temperature of binder,
Tests on aggregates (LAA, FI, Impact value, Stripping
test etc, It is carefully proportioned mix of coarse, fine
gradation test,
and mineral fillers with bitumen binders
rate of application of binder
Spread of mix material Thickness of single layer is 50 mm to 100mm
test on bitumen (penetration, viscosity, ductilityetc.)
Density of compacted layer
Durable, impervious, better riding quality and
load carrying capacity
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6.9.3 Bituminous Concrete 6.9.3 Bituminous Concrete
Equipment: Hot bitumen sprayer; mechanical paver, Construction Procedure
hot mix plant, Tandem/Pneumatic Roller, mechanical Preparation of the existing surface - sweeping, correcting
irregularities such as potholes
brooms etc.
Application of tack coat at the rate of 6.0~7.5 kg/102m
Production of mix from hot mixplant
Material Selection: Hot mix bituminous concrete is transported to site and spread by
Coarse aggregate - LAA value ≤ 40%, Aggregate Impact mechanical paver to the required grade and shape
value ≤ 30%, Flakiness index ≤ 30%, stripping ≤ 25%, The mix is thoroughly rolled. Rolling first two passes by either 8
water absorption ≤ 1%, Loss with Na2SO4 ≤ 12%, dense tonnes smooth wheel roller, 4 tones vibro roller and then with 8
grading to 12 tonnes pneumaticroller
Bitumen grade 30/40, 60/70, 80/100 penetration Open to traffic
6.9.3 Bituminous Concrete
Quality Control
Temperature of bituminous mix, aggregate
Tests on aggregates (LAA, FI, Impact value, Stripping
test etc,
gradation test,
rate of application of tack coat
Spread of mix material
test on bitumen (penetration grade, viscosity, ductility
etc.)
Marshal test for compacted layer
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6.10 Cement Concrete Pavement 6.10 Cement Concrete Pavement
Two Types of construction: Plant and equipment: concrete mix plant,
concrete truck mixer, Concrete mixture, batching
Cement Grouted layer – an open graded compacted
device, wheel barrow, needle vibrators, brush,
aggregate (18 to 25 mm) laid mixture of cement and finishing tools etc.
sand (1:1.5:2.5) is spread over it.
Material Selection: Portland cement, coarse
Rolled Concrete layer – Aggregate, sand, cement and aggregates with Crushing Value≤30%, Aggregate
water with less plasticity is used and compacted.
Impact Value≤30%, LAA≤16%, Soundness
Value≤12% in Na2SO4 and ≤16% MgSO4 and fine
aggregate (natural sand), M30 concrete orhigher
6.10 Cement Concrete Pavement 6.10 Cement Concrete Pavement
Construction Procedure Construction Procedure
Preparation of Sub Grade and subbase Curing of cement Concrete: surface is with jute mat for 24
All formwork are placed and well secured to resistthe hours, Upon the removal of wet covers, the slabs cured by
tamping forces ponding for 14 days.
Coarse aggregate, fine aggregate, cement and required Concrete road is opened to traffic after 28 days
amount of water are either mixed on site in batch mixer or Joint construction
transported from mixing plant.
Expansion joints are provide at 140 m interval, width 20
Concrete is transported to the site and deposited on the
to 25 mm
sub base to the requireddepth
Contraction joints are provided at 4.5 m interval for plain
Compaction is carried out using a mechanicalpoker
and 14 m for reinforced
(needle) vibrator.
Longitudinal joints are provided if slab width more than
The surface is textured with an approved longhandled
4.5 m
steel or fiber brush.
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6.10 Cement Concrete Pavement
Quality Control
Ordinary Portland cement or rapid hardeningtype
Max size of aggregate = ¼ of slabthickness
Tests on aggregates (LAA, FI, Impact value, soundness)
gradation test,
Proportioning of concrete
