GOVERNMENT OF ANDHRA PRADESH

OFFICE OFTHE DEPUTY EXECUTIVE ENGINEER (PR) Vig& QC SUB-DIVISION, NALGONDA.

Ci !"#$ N%.AEE&'BM&VQC N#g&()*+.D$,-./ *).)*.()*0.

Sub:-WBM - Construction of Water Bound Macadam Roads in Rural Areas Certain guidelines communicated for meticulous execution of WBM Pavement La ers in Rural Roads - Reg!

" " "

#t is observed during t$e ins%ection of t$e various roads b t$e &C Wing in t$e district t$at man of t$e 'ield (ngineers are not constructing t$e WBM Roads s stematicall as %er t$e %rocedures laid do)n in t$e #RC Codes! *$e follo)ing common defects are observed in construction of WBM roads! +, Camber Board never seen on t$e roads! *$e re-uired camber .!/01 .!201 3!20 res%ectivel for WBM1 B*1 CC surfaced roads 4 #RC SP-32-3223, are not found an )$ere! 3, Su%er (levations5(xtra Widening5Curves are not %rovided on $ori6ontal turnings! ., *$e coarse and fine aggregates are $a%$a6ardl mixed and s%read )it$out an control over t$e -uantit of fine aggregates 7, (xcess or less a%%lications of Screening 8 Binding materials 4(xcess 9ravel,! /, :ns stematic %rocedure of rolling resulting in less com%action of la ers! ;, #nade-uate measures for s$oulder confinements1 t$ereb increasing in )idt$ of t$e carriage )a 8 decreasing t$e -uantum of coarse aggregates! #n vie) of t$e above1 t$e guidelines for t$e scientific %rocess of construction of WBM Roads as sti%ulated in #RC codes 8 ot$er materials are re-iterated for guidance of field engineers for ado%tion and better construction %ractices! *$e relevant #RC Codes for ma<ing WBM roads are $ere )it$ communicated to all field engineers for guidance1 ado%tion 8 furt$er discussions! R-1- -2!- M$2"$#3// 4i, #RC-+=-322/-Standard S%ecifications 8 Code of Practice for WBM! 4ii, #RC-SP-32-3227-Rural Roads Manual! 4iii, #RC-+2=-+==>-9uidelines for Wet Mix Macadam! 4iv, #RC-SP-+;-3227-9uidelines for Surface (venness of ?ig$)a Pavements! G-2- $# G"i.-#i2-3 & P %!-." - 1% '$,- B%"2. M$!$.$4/ P -$45#-// Water Bound Macadam 4WBM, consist of crus$ed coarse aggregates mec$anicall interloc<ed b rolling and voids t$ere of filled )it$ screenings and binding material )it$ t$e assistance of )ater1 laid on a %re%ared sub-base!

WBM s$ould not be laid directl over a silt or cla e sub-grade!

P673i!$# R-8"i -4-2,3// P$ sical re-uirements of coarse aggregates for WBM as %er #S: 3.@; or #S: /;72 are1 i, Los Angeles Abrasion Aalue 720 4Max,1 ii, Aggregate #m%act Aalue .20 4Max,1 iii, 'la<iness #ndex +/0 4Max,1 iv, Combined 'la<iness 8 (longation #ndices .20 4Max,! G $.i2g -8"i -4-2,3 %1 !%$ 3- $gg -g$,-3 ( T$5#- ( %1 IRC-*9-()):) G $.i2g N%. 9r!## Si;- R$2gIS 3i-<- .-3ig2$,i%2 ;. mm to 7/ mm =2 mm ;. mm /. mm 7/ mm 33!7 mm /. mm to 33!7 mm ;. mm /. mm 7/ mm 33!7 mm ++!3 mm = 57 >-ig6, ?$33i2g +22 =2-+22 3/->/ 2-+/ 2-/ +22 =/-+22 ;/-=2 2-+2 2-/

9r!###

S! --2i2g3/ Screenings to fill voids in t$e coarse aggregates s$all be of t$e same material as t$e coarse aggregate1 if not feasible1 some ot$er non-%lastic material1 suc$ as1 moorum or gravel $aving LL 8 PL index belo) 32 and ; res%ectivel ma be used %rovided fraction %assing >/ micron sieve does not exceed +20!
* %e A Screenings are recommended for WBM 9r! #8##1 * %e B Screenings are recommended for WBM 9r!##89r!###! G $.i2g 1% 3! --2i2g3 9rading Class Si6e of Screenings * %e A +.!3 mm #S sieve designation +.!3 mm ++!3 mm /!; mm +@2 micron ++!3 mm /!; mm +@2 micron 0 b )eig$t +22 =/- +22 +/-./ 2-+2 +22 =2- +22 +/-./

* %e B

++!3 mm

Bi2.i2g M$,- i$# Binding material to be used for WBM as filler s$all consist of a fine grained material %assing +220 t$roug$ 73/ micron sieve and P# value less t$an ;! Binding material need not be used if t$e la er is to serve as base or is to receive blac< to%%ing1 or )$ere crus$able t %e of screenings1 li<e1 moorum is used!
Q"$2,i,i-3/ 'or t$e WBM la er of >/mm com%act t$ic< %er +2 s-m of road surface! C%$ 3- Agg -g$,-3/ S! --2i2g3 * %e A for WBM 9r!## 2!=+ to +!2> cum 2!+3 to 2!+/ cum

* %e B for WBM 9r!## * %e B for WBM 9r!### Bi2.i2gM$,- i$#

2!32 to 2!33 cum 2!+@ to 2!3+cum 2!2; to 2!2=cum

G-%4-, i! S,$2.$ .3//

*$e Standard Road Wa Widt$ is >!/2M for BCR5AR Roads and ma be reduced to ;!2M )$ere t$e traffic intensit is less t$an +22 motor ve$icles for a da ! *$e Standard Carriage Wa Widt$ for BCR5AR Roads is .!>/M 8 ma be restricted to .!2M1 )$ere t$e motori6ed ve$icles %er da is less t$an +22 4*able 3!; of #RC SP-323223,! *$e Carriage )a )idt$ at ?ori6ontal Curves ma be increased b 2!;2M to 2!=2M based on Radius! *$ic<ness of a com%acted la er s$ould be >/ mm for WBM 9r!##59r!###! *$e Camber in WBM s$all be .!/0 for WBM Surface roads1 .!20 for B* surface roads1 3!20 for CC Surface roads!4*able 3!++ of #RC SP-32-3223, *$e S$oulder )idt$ is one $alf t$e difference bet)een t$e road )a )idt$ 8 carriage )a )idt$!

PROCEEDURE OF 'BM MA@ING:: *$e existing surface s$all be %re%ared to t$e re-uired grade1 camber1 cross-section and cleaned of all dust! Wea< %laces s u c $ a s ruts1 de%ressions and %ot$oles made good )it$ suitable material before s%reading t$e coarse aggregates for WBM! *$e lengt$ of t$e road to be laid on a da s$all be mar<ed on bot$ sides5edges )it$ Line t$read and Muggu s$all be a%%lied! *$e coarse aggregate s$ould be s%read uniforml and evenl on t$e %re%ared sub-base b using )ooden tem%lates %laced across t$e road about ; m a%art! *$e si6e of tem%lates ma be of ;22mm x +22mm x +22mm or )ooden cubes of +22 x +22 x +22mm si6e 4min = nos, ma be used and %laced at .!2m interval i!e!1 for ;!2m lengt$ of road to receive one tractor load of metal! Arrangements for lateral confinement of aggregates must be %rovided! *$is can be done b raising t$e s$oulders in stages e-ual in t$ic<ness to eac$ la er of WBM! Br else1 t$e side s$oulders ma be constructed in advance to a t$ic<ness e-ual to t$e com%acted la er of t$e WBM course! Rolling s$all not be done )$en t$e sub grade is soft or ielding or )$en it causes a )ave-li<e motion in t$e s u b - base course! #f irregularities develo% during rolling1 )$ic$ exceed +3mm )$en tested )it$ a .m straig$t edge1 t$e surface s$all be loosened and aggregates added or removed as re-uired before rolling again so as to ac$ieve all uniform surface conforming to t$e desired cross section1 camber and grade! *$e surface s$all also be c$ec<ed transversel b Camber Board for re-uired camber and an irregularities corrected in t$e manner described above! #n no case s$all t$e use of screenings to ma<eu% de%ressions be %ermitted! (xce%t on su%%er elevated %ortions1 )$ere t$e rolling s$ould %roceed from inner edge to outer edge1 rolling s$ould begin from t$e edge graduall %rogressing to)ards centre! Successive %asses s$ould uniforml overla% t$e %roceeding b at least one $alf )idt$!

 Continue rolling till a smoot$ uniform surface is ac$ieved and all roller mar<s are eliminated! 'or ac$ieving max! densit of t$e la er1 maintain no! of %asses bet)een . to 7! C%4?#-,- %##i2g i3 i2.i!$,-. 57 $ #%%3- 3,%2- ?i-!- g-,,i2g ! "36-. "2.- ,6- %##>i,6%", 3i2Ai2g!

A??#i!$,i%2 %1 S! --2i2g3/ After t$e coarse aggregates $ave been dr rolled1 t$e screenings s$all be a%%lied graduall 8 uniforml in successive t$in la ers at a slo) rate in t$ree or more a%%lications as necessar b s%reading motion of $and s$ovels!Cr rolling s$all be done )$en t$e screenings are being s%read so t$at vibrations of t$e roller cause screenings to settle into t$e voids of coarse aggregate!*$is s$all be accom%anied b rolling and brooming! *$ese o%erations s$ould continue until no more screenings can be forced into t$e voids of coarse aggregate!

#n no case s$all t$ese screenings be a%%lied so fast and t$ic< as to form ca<es or ridges on t$e surface ma<ing t$e filling of voids difficult or %reventing t$e direct bearing of roller on t$e coarse aggregates! Cam% and )et screenings s$all not be used in an circumstances! After t$e a%%lication of screenings1 t$e surface s$all be co%iousl s%rin<led )it$ ) a t e r 1 s)e%t and rolled! ?and brooms s$all be used to s)ee% t$e )et screenings into voids and to distribute t$em evenl ! *$e s%rin<ling1 s)ee%ing and rolling o%erations s$all be continued and additional screenings a%%lied )$ere necessar until t$e coarse aggregates are )ell bonded t$oroug$l <e ed and firml set in its full de%t$ and a grout of screenings and )ater forms a$ead of t$e )$eels of t$e roller! A??#i!$,i%2 %1 Bi2.i2g M$,- i$#

After t$e a%%lication of screenings and binding material 4P# D ;, s$all be a%%lied at an uniform and slo) rate in t)o or more successive t$in la ers! After eac$ a%%lication of binding material1 t$e surface s$all be co%iousl s%rin<led )it$ )ater and t$e resulting slurr s)e%t in )it$ $and brooms 5 mec$anical brooms so as to fill t$e voids %ro%erl ! *$e s%reading of binding material1 s%rin<ling of )ater1 s)ee%ing )it$ brooms and rolling s$all continue until t$e slurr of binding material and )ater forms a )ave a$ead of t$e )$eels of moving roller! S-,,i2g $2. D 7i2g

After final com%action of t$e course1 t$e la er s$all be allo)ed to dr overnig$t! Eext morning1 $ungr s%ots s$all be filled )it$ screenings or binding material1 lig$tl s%rin<led )it$ )ater and rolled! Eo traffic s$all be allo)ed till t$e macadam sets! *$e com%acted WBM Course s$all be allo)ed com%letel dr and set before t$e next %avement course is laid! #f t$e dr 8 )et rolling is done s stematicall 1 t$e WBM la er )ill a%%ear solid li<e mass and 0 of fine aggregates )ould not more t$an 3/0 of volume of coarse aggregates!

S6%"#.- 3//
S$oulder gives ade-uate side su%%ort to t$e %avement and also drains off surface )ater from t$e carriage)a to t$e road side drain! *$e construction s$all be done in la ers eac$ matc$ing t$e t$ic<ness of adFoining la er! Bnl after a la er of WBM1 s$oulder s$all be laid and com%acted! Eext corres%onding la ers in %avement s$all be ta<en u% after t$e com%letion of first la er of WBM and s$oulder! *$is %rocedure s$all be follo)ed u%to t$e surface course! #n t$e case of bituminous courses1 )or< on s$oulder s$all start onl after t$e %avement course $as been laid and com%acted! 4Cl!@!;!+ of #RC-SPG32-3223,! *$e cross fall for eart$ s$oulders s$ould be at least 2!/ 0 stee%er t$an t$e slo%e of t$e %avement subFect to a minimum of 70! Bn su%er elevated sections1 t$e s$oulders s$ould normall $ave t$e same crossfallas t$e %avementto drain off surface )ater! *$e com%action re-uirement of eart$en s$oulder is +220 of Standard Proctor Censit 4 #S-3>32-+=@2,!

QUALITY CONTROL//
(*) P673i!$# P %?- ,i-3 & G $.i2g -8"i -4-2,3/ *$e P$ sical %ro%erties and 9rading re-uirement of Aggregates s$all be as sti%ulated in t$e above %aras! (() S" 1$!- E<-22-33 %1 'BM C%" 3-//

*$e surface unevenness of com%leted WBM course in longitudinal and transverse directions s$all be )it$ in t$e limits s%ecified in*able; of #RC:SP:+;-3227 H9uidelines for Surface (venness of ?ig$)a PavementsI! *able ;: Permissible Surface :nevenness for WBM Courses Sl! Eo! Si6e Range of Coarse Aggregates Longitudinal Profile measured )it$ a .- *ransverse Profile Metre Straig$t (dge Max!Permissibl Max! Permissible Maximum Eo! Bf e Surface :n- undulations %ermitted in variation from s%ecified evenness! an .22M lengt$1 %rofile under camber exceeding +2mm! tem%late! +3 mm +3 mm .2 Eos .2 Eos @ mm @ mm

+ 3!

WBM 9r!## ;.-7/mm

WBM 9r!###/.-33!7mm

(+) R-!%<- 7 1% U2.- 3i;-. M-,$# 4 As %er (EC R8B Cir!Memo Ct!3+!7!322@, D-1i!i-2!7 (i2 P- !-2,$g-) U2.- Si;- Agg -g$,-3. 2-/ /-+2 +2-+/ J+/ R-!%<- 7 Bne *ime Recover *)o *ime Recover *$ree *ime Recover ReFection

 (0) R-!%<- 7 1% S6% ,1$## i2 T6i!A2-33 & Q"$2,i,7 & '-ig6, for all items of road )or<s 4Aide 9ovt! in PR8RC Ce%t Memo Eo!+/.325A#9!#5322/-+1 dated +3!/!322;, S6% ,1$## i2 T6i!A2-33 & Q"$2,i,7 & '-ig6, :%to +20 +2-320 J32 R-!%<- 7 *)ice t$e Agr! Rates *$rice t$e Agr! Rates ReFection 8 Redone!

(:) O<- 3i;- %1 4-,$#/ 49ovt! in R8B Ce%t! Cir! Memo dt! +>!+2!322;, W$enever graded metal is used1 Eo oversi6e )ill be allo)ed over and above t$e range s%ecified as %er in t$e first sieve 4to% sieve,! Bver si6e in sieves ot$er t$an to% sieve t$e difference in t$e rates of t$e metal of t$e s%ecified si6e and next $ig$er si6e in t$e s%ecified grade s$ould be recovered for t$at -uantit of oversi6e metal! ?o)ever if t$e over si6e in an sieve ot$er t$an to% sieve is found to be above .201 metal collected s$ould be reFected! (B) R-3?%23i5i#i,7 1% ,6- #$?3-3/ I1 A<- $g- %1 $## D-1i!i-2!i-3 1%"2. More t$an +20 More t$an +/0 More t$an 320 R-3?%23i5#A(( A(( 8 C (( A(( 1 C ((8 ((

M$i2,-2$2!- %1 'BM '-$ i2g C%" 3-3/

*$e successful %erformance of WBM as a surfacing course de%ends on timel maintenance! Maintenance measures considered under t$ree $eads: 4a, Periodic %atc$ing of %ot $oles along )it$ removal of ruts and de%ressions1 4b, Blinding of t$e surface%eriodicall and 4c, Surface rene)als for )orn out5large amount of %ot $oles! All t$e 'ield Bfficers are re-uested to go t$roug$ t$e above instructions and it is ex%ected a fla)less s stematic %rocess of WBM Construction meticulousl 1 $ere after in res%ect of all items involved in t$e %rocess of WBM construction!!

4 Eeela<antes$)ar Kedla, neela<ant edlaLgmail!com C ! (xecutive (ngineer1 4PR, Aig8 &C Sub-Civision1 Ealgonda! (ncl:+, Relevant #RC Codes! 3, 'lo) C$art of WBM Ma<ing Procedure! ., 'lo) C$art for Pot$ole 'illing (co-Met$od!

7, Some of t$e relevant P$otogra%$s of WBM ma<ing! *o1 *$e (xecutive (ngineer 4PR, P#: 5PR# Ealgonda 8 PR# Mir alaguda )it$ a re-uest to communicate t$e same to all field (ngineers under t$eir control! Co% to all C ((Ms 5A((Ms t$roug$ ((Ms concerned! C5S to t$e (xecutive (ngineer 4PR, Aig 8 &C Civision ? derabad for favour of information!

FLOW CHART

WATER BOUND MACADAM

PROCESS
SPREADING COARSE AGGREGATES > SECTIONING & LEVELLING > DRY ROLLING > APPLYING SCREENINGS > BROOMING > WATER SPRINKLING > SWEEPING > ROLLING > APPLYING BINDER > SPRINKLING WATER > SWEEPING > ROLLING > OVER NIGHT DRYING > FILLING HUNGRY SPOTS WITH SCREENINGS OR BINDER > WATER SPRINKLING > ROLLING > SETTING & DRYING.

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FLOW CHART POTHOLE FILLING ECONOMICAL METHOD

CLEANING & TRIMMING THE POTHOLE TO REGULAR SHAPE > WATER SPRINKLING > FILLING COARSE GRADED

AGGREGATES FOR FIRST LAYER > APPLYING CHIPS & STONE DUST > SPRINKLING WATER > RAMMING > FILLING COARSE GRADED AGGREGATES FOR SECOND LAYER > APPLYING CHIPS & STONE DUST > SPRINKLINGWATER > RAMMING > CLEANING > APPLYING TACK COAT > SPREADING 12.5 MM CHIPS > RAMMING.
NOTE: The above illustration is for a two layer thick patch work. Similar procedure may be adopted for potholes of different sizes and thicknesses. Fordoing intensive patchwork, CC mixer and roller may be used. The most important point to be kept in mind is that use of gravel shall be avoided in pothole filling.