METHODOLOGY FOR CONSTRUCTION PROFILE CORRECTIVE COURSE WITH

DENSE –BITUMINOUS MACADAM (Ref: MORTH – Fifth Revision)

1. OBJECTIVE
1.1 To provide and supervise the Profile corrective course with Dense Bituminous macadam
layer.

2. SCOPE
2.1. This work shall consist of preparing of existing road surface to specified lines grades and
cross section in advance of laying a bituminous course as per most specification and
clause no 501.1

3.0. REFERENCE
3.1. Approved drawing supplied by the Engineer.

4.0 PROCEDURES / METHODOLOGY

4.1. MATERIAL
(a) Bitumen:-
The Bitumen shall be paving bitumen of VG-30 as per Indian Standard specification for
paving Bitumen IS: 73.
(b) AGGREGATE
The Course aggregate shall consist of crushed stone which shall be clean , strong ,
durable of fairly cubical shape and free from disintegrated pieces , organic or other
deleterious matter and adherent coating and shall be conforming to the following
physical and graduation requirement as per most specification clause no 505.2.2 table
500.8
(1)
Sl No Test Requirements.
01 Aggregate Impact Value* 27% Maximum
02 Los Angeles Abrasion Value* 35% Maximum
03 Flakiness and Elongation Index 35% Maximum
04 Coating and Stripping of bitumen aggregate Minimum Retained
Coating 95%
05 Soundness
i)Loss with sodium sulphate 5 cycles 12% Maximum
ii)Loss with Magnesium Sulphate 5 Cycle 18% Maximum
06 Water Absorption 02% Maximum
* Aggregate shall satisfy requirements of either of the two tests.

(2) AGGREGATE GRADATION FOR DENCE BITUMINOUS MACADAM AS PER

TABLE 500.10
(3)
Sl No Sieve Designation % Passing the Sieve by weight
01 40 mm 100
02 37.5.mm 95-100
03 26.5 mm 63-93
04 13.2 mm 55 – 75
05 4.75 mm 38 - 54
06 2.36 mm 28 – 42
07 300 Micron 7-21
08 75 Micron 2-8

The aggregate mix shall be in close proximity of adjacent sieves and shall be well graded.

(c ) FILLER

The design mix for DBM carried out in the laboratory caters for the filler material by
way of crushed stone dust used in the formula adopted . No filler material will thus be
used
(d) REQUIREMENT OF DENSE BITUMINOUS MACADAM

As per table 500 – 11 of most specification

The DBM mix shall conform to the following requirement.

Sl No Description Requirements
01 Marshall stability Determined on Marshall 9 KN Minimum
Specimens Compacted by 75 compaction blows
& on each end
02 Marshall Flow (mm) 2–4
03 Percent Air Voids 3–5
 04 Minimum Voids in Mineral Aggregate (VMA) 11% Minimum
05 Percent Void in Mineral aggregates filled by 65 - 75
Bitumen(VFB)
06 Binder content percent by weight of total mix. Not less than 4.0%

(e) BINDER CONTENT

The binder content for grading indicated shall be determined by Marshall Method
replacing the aggregate retained on 26.5mm sieve by the aggregates passing 26.5 sieve
and retained on 22.4 mm sieve.

5. JOB MIX FORMULA

After approval of the material by the engineer, The job mix formula will be designed and
submitted for approval to the Engineers as per most specification and clause no 507.3.3.

6. PRODUCTION OF DBM
Production of DBM for profile corrective course will be done in a 160 TPH batch type
HOT Mix plant, Aggregate of different sizes will be drawn from the stock pile and loaded
in four bins of HOT MIX PLANT with the front End Loader. Thee out flow of aggregate
from the bins will be controlled by adjacent gate opening and will be in accordance with
the Job mix Formula. The aggregate will be further conveyed to dryer unit where it will be
heated to the following range of temperature.

Range of Temperature – 155 to 163 degree centigrade.

The bitumen to be used shall be paving bitumen of VG-30 as per Indian standard
specification for paving bitumen IS: 73. The temperature of binder at the time of mixing
shall be in the range of 150-170 degree centigrade.
The binder duly heated in bitumen tank will be conveyed to mixing unit through pipes to
obtain the mix in approved range of Temperature.
The flow of Bitumen shall be controlled by the bitumen pump. Mixing shall be through to
ensure a homoeogineous mixture so as to coat all particles of mineral aggregate uniformly.
The Mixture shall be further discharged through load –out hopper into waiting dump
truck. The dump trucks shall be clean and these will be covered in transit with tarpaulins
 depending on the weather conditions requiring control temperature as specified above.
The complete operation of Hot Mix Plant shall be exercised. Through computerized panel
installed in the cabin provided for this purpose near the Hot mix Plant.
7 ARRANGEMENT OF TRAFFIC
The traffic arrangements will be made as per the traffic plan ‘P’ attached herewith. One
way traffic shall be introduced and controlled by deployment of men with red green flags.
Who will regulate the vehicular traffic. Battery operated colour light, signals of red and
green indication will also be put on both sides of working area during the night if required.
The traffic shall be so regulated that there is least disturbance to the traveling vehicles.
The total length of road shall be about 5 to 10Km. full width of carriage way of new
highway where laying of DBM shall be carried out in a day . Initially the barricaded
length of road shall be for about 1000 m which will gradually increase to 2000 m or more
as the work of DBM progress during the day.

8 PREPARETION OF BASE
Pot – holes shall be made good before providing profile corrective coarse. These potholes
shall be drained of water. Cut to regular shape with sides vertical up to affected depth and
slightly beyond the limits of affected area and dried. All loose and disintegrated materials
from these portholes shall be removed. The potholes shall be filled with Dance
Bituminous material ( as per clause no 502.4.2) in layers not exceeding 75 mm after
painting the sides and bottom with a thin layer of hot emulsion and each layer shall be
compacted with approved mechanical device and top layer shall be flushed with existing
bituminous surface . All loose surface materials on the surface shall be removed after
making good potholes.
The surface shall be thoroughly swept clean, free from dust and foreign matter using
mechanical broom and dust removed or below off by compressed air.

9. TACK TOAT
The binder to be used for track coat shall be a bituminous emulsion as per specified in the
contracts as specification and clause no 503.2. The Tack coat shall be applied @ 2-2.5 kg
g/10Sqm area on bituminous surface with the help of bitumen pressure sprayer, the
 bitumen sprayer with self heating arrangement and capable spraying bituminous emulsion
at specified rate & temperature appropriate to the grade of bituminous emulsions shall be
used to provide a uniformly unbroken spread of bituminous emulsion.

10 SPREADING
DBM for profile corrective course shall be laid symmetrically astride the centre line of the
road for full width of carriageway. Accordingly the centerline and extent of DBM will be
marked with the help of lime steel pins shall be fixed along with the edge s at 10 m
interval along with sensor wire. Sensor wire would be laid at the levels of the loose
thickness of DBM course being laid which would be 20-25 % more than the finished
level. However the exact depth of un compacted material to achieve the required thickness
of layers shall be determined by field trials.

For Camber / Super elevation correction of the existing carriageway, method as shown in
sketch 500.2 of specification shall be adopted depending on the profile of existing
carriageway. Method for providing corrective course for sags & depressions shall be
adopted as per sketch 500.1A of specification
The mix transported from the Hot Mix Plant to the site shall be spread by means of a self
propelled Electronic Paver with sensor system having suitable screeds capable of
spreading tamping and finishing the mix to specified grade, lines and cross sections. At
the time of unloading, the trucks shall be pushed slowly forward so as to avoid any
spillage of material. Any spillage however will be shoveled into the hopper before the
paver passes though that area. The temperature of the mix at the time of laying shall be in
the range of 120 to 160OC. Longitudinal joints and edges shall be constructed true to the
lines parallel to centerline of the road and all joints shall be cut vertical to the full
thickness of the previously laid mix. The longitudinal and transverse joints shall be
staggered by 250 mm from those in lower courses.

11 ROLLING
After the spreading of mix by paver, the initial or breakdown rolling shall be done with 8-
10 tonnes tandem roller Breakdown rolling preferable shall be followed by intermediate
 rolling with a smooth wheel pneumatic tyre roller having adjustable tyre pressure . Finish
rolling shall be done with 8-10 tonnes weight tandom roller. During breakdown rolling
and finish rolling no vibrator compaction shall be resorted to.

The wheel of roller shall be kept moist by water if necessary. Rolling shall commence
from edge and proceed towards the center except that on super elevated portion it shall
progress from the lower edge to upper edge parallel to the centre line of the pavement.
Rolling shall continue till the density achieved is at least 98% of that laboratory Marshall
specimen and all roller marks eliminated. Rolling operation shall be completed in all
respects before the temperature of the mix falls below 100 degree centigrade as per most
specification clause no 506.4.6

12 SURFACE FINISH AND QUALITY CONTROL OF WORK

The surface finish of construction shall confirm to the requirement of most specification
and clause no 902.4.
In case of low surface the deficiency shall be corrected by adding fresh material and re
compacting during the course of construction to achieve the 98% of field density. If the
surface is high the fill depth of layer shall be removed and replaced with fresh material
and compacted to achieve the above specified density.
The checking of levels o the finished surface will be carried out with a leveling
instrument. The permissible tolerance in levels of base course shall be ±6 mm.

13 OPENING OF TRAFFIC
Traffic will be allowed only after completion of the final rolling when the mix has cooled
down to surrounding temperature.

14 We proposed to be deployed the following equipment for the activity of profile corrective
course.
a) Hot mix plant - 1 No (160TPH)
b) Electronic sensor paver 1 No
c) Tandom Roller - 2 No
d) Pneunatic Tyre Roller - 1 No
e) Bitumen spray tanker - 1 No
f) Dumper/Tripper - 6 Nos.
g) Water Tanker - 1 No
h) Mechanical Broom
With Tractor - 2 No
i) Air Compressor - 2 Nos.
j) Labour - As per requirement