INTRODUCTION

GENERAL:

 The Nizamabad –Jagdalpur NH-63 is passing through major towns i.e. Nizamabad,
Armoor, Metpally, Korutla, Jagtial, Dharmapuri, Laxettipeta, Mancherial, Chennur, and
connecting Maharashtra, Chethisghad, Madyapradesh. The present status of the road
is existing two lane with paved shoulders and two lanes without paved shoulders.
Inview of the bad condition of the road and problems faced by the traffic it was
proposed for strengthening of the road in selected stretches by MORT&H to enhance
the safe and fast movement of the traffic
 The project is mainly strengthening of existing NH-63 Nizamabad Jagdalpur Road from
KM 59/0 tp 173/0 section in selected stretches on EPC mode under NH(o) in the State
of Telangana through Engineering Procurement & Construction (EPC) basis is taken up
by M/S Sree Sai Ram Enterprises heir-in-after called EPC contractor from the Principle
Employer National Highway Department.
 This document heir-in-after referred to as quality assurance procedure/plan (QAP) of
guidelines for quality control and quality monitoring of strengthening of Existing NH-63
Nizamabad-Jagdalpur Road from Km 59/0 to 173/0 in selected stretches under NH(O)
in the state of Telangana.
 The QAP is prepared and formulated as a summary of the quality related activities
required meeting the terms of the contract. the manual set out the management
practices and describes the quality management for this Project and relation-ship with
EPC contractor quality system.

PURPOSE:

The Project Quality Assurance Plan has been prepared and formulated as
summary of quality related activities required meeting the terms of contract. This
manual set out the management practices and describes the quality management for
this project and its relationship with contractor road quality system
The contents of this document are applicable to design, Engineering,
Procurement, Construction, Inspection, Testing Commissioning operation and
 maintenance works in an environ mutually safe manner which are being carried out by
contractor for the Road Project Contract.

Quality Policy, Quality System and Quality Strategy

Quality Policy Concept

The Quality Policy is communicated and made understood at all level of the
organizing ion through awareness. Program an display of the Qua lity Policy boards at all the
Project sites/departments. The Quality Policy shall be reviewed annually for continual
improvement and suitability to the purpose of the division.

Tak ing Quality Policy as guide, the quality objective s are established in related functions and
monitored in the monthly steering committee meetings and periodic Management Review
meet ings.
 Management review includes review of Quality objectives and specific policy statements with
the view to achieve Quality objectives and meeting the requirements of the policy statement.
Quality Policy:

W e aspire to fulfill the expectations of our customer by a dedicated and organized approach,
which is amenable t o s kill and knowledge enhancement.

W e sha ll improve the competence of our Quality management System continually.

Our focus to accomplish this aim shall be on:

 : Effective design

 Effective Implementation of planning and Methodology

 Effective Supplier Management

 Proficient Management of workforce.

 Training and development of Human Resource

 Quality System.

The e Quality System has been designed to ensure that the Quality Policy, objectives and the requirements
o f 1SO 9001:2008 are implemented. The system has been determined in terms of the following main
processes.
1. Estimation, Costing and Tendering

2. Design an d Engineering

3. Quality planning and Control

4. Planning, Monitoring and Control

5. Plant and Machinery provision

6. Project Operation

8. Commercial, Contract and Procurement

9. Personnel and training

10. Finance

Structure of Quality management System d ocumentation

QUALITY POLOCY
 Quality management
System manual

Quality Process
and Procedure
Other Quality Documents
Manual
(Standards, Records, Guidelines, Check lists etc)

Project Quality Plan

Quality Management System Manual:

This quality Management system manual describes the purpose and scope of the Quality

management system. Interaction of functional process and establishment of documented to

fulfill requirements of standard.

Quality Process and Procedure manual:

The Procedures are established to meet the requirements and are included in the quality
process and procedure Manual. These procedures covers control of documents, control of
records, internal quality audit, control of non conforming products and corrective/preventative
actions.
The other functional processes and their inter actions have been identified and detailed in the

quality process and procedure manual. These processes cover the quality and responsibility for each

process steps required for efficient operational execution.

Project Quality plan:

A definite quality plan for every project, detailing there in the activities, Acceptance criteria.
Verifying documents, controlling agency (Organization/Customer) and the type of control and
responsibility for implementing the activity and its control, including resource requirements are
developed before start of the Project.
Other Quality Documents:

Quality records and formats from this level of d0cuments . Other standards, check list

and guidelines are also used for the supports of overall quality syst em structure.

Quality Strategy:

Implementation of the quality Management system and its effectiveness is ascertained by

periodical monitoring as well as by structured internal quality audit and corrective and preventive

action to ensure improvement in effectiveness of the Quality system in operation.

A continuous process of feasible Technology up gradation and value analysis is initially targeted at

persisting unsolved non-conformities to be attended to as well a s potential problems.

Management review of the quality system is conducted periodically, to check for continued

suitability for effectiveness, towards meeting the requirement of the organization's Quality Policy

and objectives.

The integrity of Quality Management System is ensured when changes are planned and implemented.

Planning

This Project Qua lity Manual is the document which details the Quality Sys tem to be planned,
established, implemented and maintained as part of the contract for the road works for the project
The Project Quality Plan consists of the following:

(i) The Project Quality Statement of the company

(ii) Project Specific Details including Organizati0n an System Element Desciptio1
(iii) Inspection and Test Plans (including Construction Process Flowcharts and Quality
Verification Checklists).
(iv) Project t specific Procedures as required by the contract specification / concession
agreement

The Project Quality Manual describes the managerial and technical systems which shall be
implemented to achieve conformance to specified requirements. The systems shall cover all on site

work under the contract. Where necessary the systems shall be extended to include offsite

activities.

The inspection and test plan shall identify necessary inspections and tests to verify

conformance of the work during performance of the identified project tasks. It shall include

acceptance criteria and details for performance of inspection and test activities, as applicable.

Control

Control shall be achieved by implementing the requirements of the Project Quality Manual

including construction process controls, inspection and test plan and audit requirements.

Continuous monitoring and the investigation of timely corrective action shall form the basis of

control. System Element Descriptions shall detail the methods by which the quality system is

controlled. The agreed Inspection and Test Plans shall be used for controlling the work and

detecting nonconformance.

Verification

Verification processes shall be established to ensure that the planning and controls have been

effective and the Quality System and constructed works conform to the specified requirements. The

outcome of a ll verification activities shall be documented and maintained as quality records. R ecords

of conformance shall be available for inspection by the Concessionaire's

Representative / IIE upon request to provide evidence of the outcome of activities undertaken to

achieve conformance.
`

PART-I
QUALITY
MANAGEMENT
 Safety T
Consultant Authority
Engineer

Proof Consultant
Organization Chart EPC Contractor:

PROJECT MANAGER

HIGHWAY ME PLANNING
CONSTRUCTION &BILLING
MANAGER QA/QC DEPARTMENT

SITE ENGINEER LAB TECHNICIAN Asst. QS

 PART –II
QUALITY CONTROL &
QUALITY ASSURANCE
PROCEDURE

Summary of duties and responsibilities

Quality Control Manager I Assurance

 Identifies all material requirement, sources

 Conducts qualification tests for source approval
 Conducts test on materials as Test and Inspection Plan
 I n dents all laboratory equipment, commissions and conducts calibration exercises as per
plans
 Documents all test in standard formats

 Liaison with external labs, third party agency labs

 Conducts laboratory activities independently and reports any potential problems to the
General Manager
 Checks and approves work procedures of Section Engineers based on mock-up results
 Monitors implementation of procedures, record keeping by section through weekly audits
 Reports non-compliance and proposes remedial action to site Staff and Senior Management
 Follows up through remedial measures

QUALITY CONTROL
1.2 Quality control Action Plan
Quality control plan addresses the actions, inspection, and sampling and testing necessary to keep the
production and placement operation in control, quickly determine where and operation has gone out
of control and to respond to correct the situation and bring it back into control. Quality Control Plan
addresses actions needed including the frequency of testing to:

 Keep Process in Control:

 Quickly determine when the process has gone out of control:
 Respond adequately to correct the situation(s) and bring the process back into control

CHAPTER 2
 QUALITY CONTROL

2.1.1 General
Transport is vital infrastructure for the speedy economic growth of developing country. The Govt. of India is
taking very active role in their development since 3 rd 20th Road plan. Their ambition set to change the
construction technologies and also stringent quality control measures.

Scope of the Quality Assurance Manual

 A ‘Quality Plan’ setting out quality practices including Quality Control tests duly documented in standard
formats.
 Quality Assurance, which includes all actions necessary to provide adequate confidence the product will
meet the requirements of quality plan envisaged. The guidelines also suggest a project specific Quality
Assurance r111anual be prepared for adoption by all concerned with the execution of the project. in
conformity with these requirements, this document called the 'Quality Assurance Manual' has been
brought out for adoption in this Project so a s to maintain uniformity in the test procedures and
documentation and reporting the results thereof.

The purpose of this Quality Assurance Document is to put forward good engineering practice and guidance for
the team members of the Contractor as well as the Engineer during construction of the complete project.

Quality Assurance Manual documents the Laboratory’s and field-testing commitment to controlling the
quality of the incoming materials and Process control at field and the quality of the finished product for the
project.

The document describes what is to be done, by whom and how? Manual describes the following:

 Duties and responsibilities of Q.C. staff.

 Organization chart
 Laboratory operational procedure.
 Sampling procedure.
 Testing procedure (if required)
 Filing system
 Calibration procedures.
 Records to be maintained with sample formats
 Acceptance criteria of test result s.

 Staff training.
 Safety measures and first aid tips for general injuries.
 CHAPTER 2
INFRASTRUCTURE & FUNCTIONAL BRIEF

2.2.1 General
Project Main Laboratory is located at Medipally Camp Site Offices compound.

The project Laboratory have been established by the EPC Contractor according to MoRT&H clause 121, to
conduct the testing of materials, including trial mix and acceptance testing.

2.2.1.1 The Laboratories are equipped and staffed by the contractor, to carry out the range of laboratory and
field tests on soil, aggregate, Cement, Bitumen and their mixtures as listed in the MoRT&H Specifications.
The frequency considered to be the minimum Chapter 3 of this manual

2.2.1.2 Providing the land for the construction of the laboratory is the responsibility of the Concessionaire.
For the smooth functioning of the system the Accommodation for the laboratory and office
 Testing equipment
 Technical Library
 Communication facility
 Transport and
 Office equipment

2.2.2 Accommodation

2.2.2.1 Space for the different sections dealing with soil, aggregate, cement/concrete, bitumen/bituminous
mixes, chemical tests, isolated room for hazardous tests.
 Storage of samples and stores/supplies
 Soaking Tanks for CBR, Curing tanks for Concrete Cubes
 Office rooms for Engineer’s Materials engineer, Authority Materials Engineer and Contractors
Materials Engineer and other staff.

2.2.2.2 In Addition to the central field laboratory, it is with essential equipments for the regular frequency
tests.
2.2.3 Testing Equipment
2.2.3.1 However, the contractor will procure all equipment for the proper functioning of the laboratory as per
actual requirement.
Table 2.1 List of equipment to be provided in the field laboratory by the contractor
SL.No. 750 mm Dia G.I Sieves Total availability
1 60 mm 1
2 50 mm 1
3 40 mm 1
4 37.5 mm 1
5 26.5 mm 1
6 22.4 mm 1
7 13.2 mm 2
8 12.5 mm 1
SL.No. 450 mm Dia G.I Sieves Total availability
8 90 mm 1
9 63 mm 1
10 53 mm 3
11 45 mm 2
12 26.5 mm 1
13 22.4mm 1
14 19 mm 2
15 13.2 mm 1
16 11.2 mm 1
17 10 mm 2
18 9.5 mm 2
19 5.6 mm 1
20 2.36 mm 2
21 1.18 mm 1
SL.No. 200 mm BRASS Sieves Total availability
22 4.75 mm 1
23 2.80 mm 1
24 2.36 mm 1
25 1.00 mm 1
26 600 µ 1
27 425 µ 1
28 300 µ 1
29 150 µ 1
30 90 µ 1
31 75 µ 1
32 Flakiness Gauge 1
33 Elongation Gauge 1
34 CBR Moulds 6
Aggregate Crushing
35 1
Value
Bulk Density Test
36 1
apparatus
37 Hot Air Oven 1
PVC Measuring
38 1
cylinder 500ml
PVC Measuring
39 1
cylinder 1000ml
40 Digital Thermo meter 1
41 Glass thermo meter 2
Aggregate Impact
42 1
value
Sand pouring Cylinder
43 2
100 mm dia
Sand pouring Cylinder
44 2
150 mm dia
45 Sampling auger 1
46 Liquid limit device 1
Sand pouring Cylinder
47 2
100 mm dia Hole Tray
Sand pouring Cylinder
48 2
150 mm dia Hole Tray
49 Rapid Moisture Meter 3
Electronic balance
50 1
30Kgs (1gm)
Electronic balance 5
51 1
Kgs (.1 gm)
52 Enamel Tray 24 X 28 3
53 Enamel Tray 30 X 44 4
54 Enamel Tray 46 X 62 3
55 Straight Edge 1
56 Scoop 2
57 Tool Kit 1
58 Vernier Calipers 2
59 Splitter Tool Box 40mm 1
Splitter Tool box 20
60 1
mm
Water Bath (Stainless
61 1
steel)
62 Wooden Hammer 2
Pavement Core drilling
63 1
machine
Marshall Stability Test
64 1
apparatus
65 Marshall moulds 6
 66 Tamping rammer 2
Marshal mould
67 1
remover
Centrifuge type
68 3
Bitumen Extractor
69

2.2.4 Office Equipment & Test recording formats.

The laboratory shall be well equipped to handle needs of maintaining test records and furnishing relevant
reports. EPC Contractor will arrange to print adequate quality test quality test forms for recording test data
and registers for maintaining summary of test results.
2.2.5 Library

A library containing following books/publications shall be ready available in the laboratory copy of MORTH
Specification for Road and Bridge works with amendments in the special specification of the contract

 Relevant standards published by BIS, BS, ASTM, AASHTO and other professional books as
specified in the contract
 Important technical books/ publications pertaining t road and bridge construction for the
efficient functioning of QC/QA works.
2.2.6 Communication system

Prompt attention of the quality control personal is essential for speedy execution of the work. Delay on their
part in turn delays all the execution process and description of work Schedule. To make the system function
effectively, a good communication system is necessary to keep the contractor/consultant materials engineer
and his staff in constant touch with each other. The network should link the laboratory, asphalt mixing plant
site, concrete batching plant site and different work sites where technicians/field engineers are engaged.

2.2.7 Transport: For sample collection, plants inspection and field-testing purpose vehicles will be
provided timely to the laboratory.

CHAPTER 2.3
MANAGEMENT, STAFFING & RESPONSIBILITIES
2.3.1 General
A coherent team of experts from the concessionaire, Consultant and the contractors shall manage the whole
gamut of quality assurance with prime responsibility of contractor staff.
Detailed organization setup of quality control department is given chapter-1

Summary of Duties and responsibilities

QA QC Manager:

 Identified all material requirements, source.

 Conducts qualification tests for source approvals.
 Conducts test on material as per Test and Inspection plan.
 Intends all laboratory equipment, and conducts calibration exercises as per plans.
 Documentation all tests in standard approved formats.
 Liaison with external labs, third party agency labs.
 Conducts laboratory activities independently and reports any potential problems.
 Checks and approves work procedures of section engineer based on field results.
 Monitors QAP implementation and proposes remedial action to site staff.
 Follows up through remedial measures.

Site Engineer

The site engineer is responsible for full time supervision and check for compliance to specifications for
construction procedure and workmanship. These tasks relating to quality assurance is in addition to their other
duties pertaining to project management. In this project the site engineers comprises of Jr. Engineer s
(Highway/bridge, Dy. project Mangers, Project Mangers.

Survey Engineer

The quality assurance team is incomplete without the assistance of the survey engineer. The duties and
responsibilities of the survey engineer relating to quality control are the geometric tolerance checks. The
survey engineer has the dual role of checking, setting out on the ground, the layout for the road and structures
before commencing the work and during the course of the construction as well do the role of checking the
geometric after the construction. In this project the site engineers will do the role of checking geometric
tolerances as part of quality assurance operation.

Laboratory Engineer

The basic duties and responsibilities of Laboratory Engineer are sampling and testing of materials and
finished works at appropriate stages before commencing the work, during the Work and after the
completion of the work. The Laboratory engineers in this project are 01nos. Material engineers, 01nos.
Assistant Material Engineer, 01 nos. of Field Engineers and 02nos. of Sr. lab Technicians, and04 nos. of
Technicians and 06 nos. of Lab Assistants and 12 nos. of lab Helper. They will also obtain the assistance of
field engineers. Laboratory organization chart is shown in fig 2.3.

2.3.2 EPC Contractor Laboratory Staff Responsibilities

2.3.2.1 1 Materials Engineer

The Materials Engineer report to the Project Head and are responsible for all the operations of the laboratory.
The Basic duties and responsibilities of ME are sampling and testing of materials and finished works at
appropriate stages before commencing the work. He is responsible for mix designs, quality control during
the work and after the completion of the work.

• Interacting with ME {Proof Consultant Materials Engineer), keeping him informed of the
work in progress and providing the necessary assistance to Proof Consultant as and when
required;
• Submitting all the design proposals of the various mixers;

• Ensuring the Laboratory conducts its operations according to this manual; "
Ensuring the Laboratory responds promptly to test requests;

• Ensuring the Laboratory's operation is efficient so that samples are tested within a
minimum time period after receipt;

• Ensuring Test Methods are correctly followed , and Ensuring equipment is in

good working condition and calibrated at regular intervals;

• Ensuring all Q.C. tests in the field and lab are conducted to the specified frequency;
• Maintaining daily weather records like max/Min temperature, Rainfall, etc

On behalf of EPC Contractor, M.E has the authority to have a direct interact with the Consultants materials
Engineer. And he is fully authorized to make correspondence with Consultant Materials engineer relating to
laboratory testing design and other quality control aspects, which involves no financial implications. His
powers are further extended to have a full control over the staff working under him. He is fully authorized to
induct or remove any person· working laboratory by taking in to the confidence of the management.
MINIMUM SAMPLE REQUIREMENT

MINIMUM Wt. OF SAMPLE REQUIREMENTS

Sl.N TEST
TEST FOR RELEVANT TESTS (KG)
o METHOD

IS:2386
I Grading (part-1) 2
1963
IS:2386 Quantity of coarse aggregate shall be taken
Flakiness index and Elongation (part-2)
II 1963 sufficient number of 200 pieces of any fraction to
index
be tested.
IS:2386
Deleterious Material and (part-2)
Organic impurities 1963
a. Determination of clay
lumps
1.0
Over 4.75 to 10 mm
2.0
Over 10 to 20 mm
3.0
Over 20 to 40 mm
5.0
Over 40 mm
b. Determination of al and
lignite:
III 40 mm size
5.0
20 mm size
3.0
6.30 mm size
0.2
c. Determination of soft
particles/shale:
Over 10 to 12.5 mm
Over 12.5 to 20 mm 0.2
Over 20 to 25 mm 0.6
Over 25 to 40 mm 1.5
Over 40 to 50 mm 4.5
12.0

Specific Gravity
2.0
Aggregate >40 mm IS:2386
IV Aggregate <40mm>10mm (part-3) 1.0
Aggregate <10mm>4.75mm 1963
1.0
Aggregate <4.75 mm
0.5
 IS:2386
V Bulk Density of Voids (part-3) As required
1963

The quantity of material shall be sufficient to fill following capacity measures as per maximum nominal size
of aggregate.
Max size of Size of Container
Aggregate (mm) Volume (Ltr) Inside Diameter Inside Length (cm) Metal thickness
(cm) (mm)
<=4.75 mm 3 15 17 3.15
>4.75 <40 mm 15 25 30 4.00
>40 mm 30 35 31 5

Storage of Aggregate
Material shall be stored in such manner that segregation of fine and coarse sizes will be avoided. They shall be
stored/stock piled and handled in such a manner that will prevent contamination by foreign materials. Storage
shall be done as per IS:4082.

Test Frequency
All relevant tests shall be carried out on each sub-lot Samples and at least two tests shall be carried out for
each sub-lot sample.

LABORATORY PROCEDURE NO. 1

Test Requests, Sampling Preparation

2.7.l TEST REQUESTS

Test Requests by Contractor All Field testing requested by the Contractor must be accompanied by a
'REQUEST FOR INSPECTION / QUALITY TEST' Form. Testing will only be carried out for the Contractor
upon receipt of this Form by the Resident\ Engineer (RE) I Materials Engineer. who will pass the Request
Form to the Laboratory who have the responsibility for the field testing as determined by the Team Leader.

The Form must be adequately completed when received from the Contractor including as a

1ninin1um:

When the work will ready for test,

Location: chainage, carriageway, elevation.

Name of Engineer submitting request and date.

All the tests hall follow in the order of preference Submitted. Contractor will proceed with the work as per the
test programme submitted. it is the duty of the engineer to deploy his representative to supervise the testing at
stipulated time.
SAMPLES / SAMPLING

Introduction
Correct sampling procedures are essential to the whole process of mechanical testing. Samples need to be
representative of a larger quantity of material, if the test results are to be considered indicative of the
properties of more than the sample.

Safety
In order to prevent Jack injuries the laboratory team shall follow the following

The mass of each bagged sample will be limited to ensure no risk of back injury.

All laboratory staff will instruct in safe lifting practices, particularly to bend the knees and not the
back. in order to lift samples.

Sampling:
Sampling of Soil/Embankment/Borrow Pits

The sampling of soil shall be according to IS: 2720 Fart I - 1983 . Sampling of proposed borrow area or cut
should be done so that 11e samples represent the material in the field, over the area under consider action, and
to the depth required. This can be accomplished by:
Digging sufficient holes over the area. A minimum of 5 holes are suggested, with one hole in each corner plus
one in the centre. Further holes may be required depending on what is found in the first 5 holes dug. The holes
should be dug to the required depth or if this Is not possible 10 the safe limits of the excavation method used.

The holes should be logged so that 1he changes 1n material type with depth are recorded.

Samples should be taken to represent the different material types encountered in the holes ( N B.
these samples should not be mixed prior to testing, unless the materials represented will be mixed as part of
the proposed excavation, or winning operation.}

Sampling of Bitumen (Asphalt)

The Sampling of Bitumen will be according to IS:1201-1978.

For sampling at the bitumen refinery the Asphalt institute's manual series No. 18 (MS-18) ( Sampling
Asphalt products for specification compliance) details sampling frequencies and method s.

LABELLING SAMPLES

All samples must be labeled at the time of sampling. The labels provided to the laboratory should be used
to ensure adequate labeling of sample s I t is essential that adequate information is recorded at the
time or sampling, including giving each sample a number
Registration of samples:

All samples received by the Laboratory will be registered promptly after arrival.
The samples will be registered in one of the sample registers described
Each sample or group of samples received as a unit will be given the same Lab No

The Lab No/sample No will be written on the sample label attached to each sample bag.

Preparation of Samples for Testing

Following registration of samples, they shall be prepared for according to test method requirements. Such
requirements may be documented in separate test methods, or in the method which also describes the test.

After preparing each portion, the Technicians/Helpers should place the card-board 'chit' for the purpose of
identifying. Following sample preparation the Worksheets for each Test Method for every sample should also
be prepared, noting necessary information including Lab. No. and Sample No. (SI. no.).The Worksheets can
then be placed on clipboards kept in the area where the particular test is done.

Preparation of Soil/GSB/WMM

Samples of soil, GSB or WMM will normally be prepared for testing according to AASHTO T 86(1990) 'Dry
Preparation of Soil and Soil Aggregate Samples for Test'. Alternatively soil, GSB or WM M can be prepared
for testing according to AASHTO Tl46-88'Wet Preparation of Disturbed Soil Sample for Test'.

Preparation of Aggregate Samples

Samples of aggregate will be prepared according to: AASHTO T248-89. Preparation of Bituminous
Concrete Samples
The preparation of bituminous concrete samples for testing is described in the relevant test method.

EQUIPMENT

PROCUREMENT

Procurement of all equipment and materials by the laboratory will be according to the
procedure described below

EQUIPMENT PROCUREMENT
All the laboratory test equipments shall be purchased by the EPC Contractor

MATERIALS PROCUREMENT

Density of Sand

Density sand will be purchased locally or by sieving sand collected passing 1.0mmIS Sieve and
retained on 600 micron IS Sieve at laboratory
Chemicals/Solvents
Some chemicals/solvents sufficient quality as desired by consultants ME snail be purchased by Contractor.

Identification
All major items of equipment (i.e. all equipment except minor items such as hammers, chisels. spatulas, etc)
will be given a unique number. which will be inscribed or written on the equipment. This Equipment Number
(E. no.) will be registered and will serve to identify the equipment.

Registration

All major items of equipment will be registered in the Equipment Register described in the 2.7. 2

Equipment Calibration
The Laboratory will operate and maintain equipment which conforms to the requirements of the Test
Methods being performed

The equipment will be calibrated by Laboratory staff, expect for proving rings and concrete compression
machines. The latter will be Calibrated using suitable equipment by experienced Personnel who will visit the
Laboratory when the calibration is due.

To facilitate calibration of laboratory and field testing equipment, the following documents should be used.

i. Calibration Worksheets
ii. Calibration Registers
iii. Calibration Calendar.

The Calibration Worksheets and the Calibration Registers are included rn Annexure of this manual. The
Calibration Calendar is a conventional calendar with sufficient space for recording equipment due for
Calibration.

The Calibration Worksheets + Calibration Registers will be subdivided into the following equipment
categories in alphabetical order:

Balances,

Cones,

Dial gauges

Loading devices,

Miscellaneous,

Moulds,

Rammers,
 Sieves, and

Thermometers

The Laboratory In charge is in-charge of equipment, including calibration. Checking the calibration calendar at
least once per week.

Ensuring all calibrations are completed by the due date (Calibrations should be performed early rather than
late).

On 'rainy' days when lab engineers and technicians are not involved with routine testing due to wet weather
lab-in-charge should organize available staff to conduct calibrations. These calibrations should be conducted
early rather than late.

Mould Calibration

Dimensions of moulds will be measured using the 150mm/300mm vernier calliper. Mould volumes shall be
determined by filling the mould with water then using a glass plate to ensure the mould is full and all air is
removed. Distilled water should be used and the density of the water should be corrected according to its
temperature.

7.3.4.2 Rammer Calibration

Rammers will be calibrated using the equipment noted below:

i) Rammer face diameter: use a vernier calliper.

ii) Fall: use 500mm steel scale to measure the fall.

iii) Mass: use the 10kg Balance. With 0.1kg accuracy

Dial Gauges:

Dial gauges will be mounted in the frame provided before using the thickness gauges also provided, to
calibrate the dial gauge readings.

Balances:

Balances will be calibrated using standard certified weights.

General purpose weighing devices shall conform to the accuracy, readability, and sensitivity indicated based
on principal sample weights.

General Purpose Balances and Scales:

A. Samples shall be weighed on a weighing device conforming to the requirements of the weight
range in which the principal sample weight is located (Note 2).
 B. Accuracy equal to the mass stated or 0 1% of the test load, whichever is greater, throughout the
range of use.

Ovens will be calibrated using thermometers placed in beakers of sand in the four corners of the
oven. This equipment will be left undisturbed, in position in the oven for 4 hours. Then the oven
will be opened and the 4 readings will be taken as quickly as possible.

Thermometers
To calibrate thermometers follow the procedure.
Place working thermometer and standard certified thermometer in a beaker filled with ice. Place the
beaker on the electrical hot plate over sand both.
Allow the temperature of the ice/water to reduce to 0 o C.

Record both readings Switch on the heater observe the reading at every 50 o C increment in standard
thermometer.
Follow the procedure till maximum reading is reached.
If temp range is more than 1000 C use high grade hot oil in place of ice/water.

Calibrate all thermometers as received. If a correction is required the thermometer must be identified in
order for the correction to be applied in all records observed with that.

Measuring Cylinders
Measuring cylinders shall be calibrated using water . The following points shall be observed:
i) Distilled water should be used.

ii) The density of the water will correct according to its temperature.

iii) The bottom of the meniscus should coincide with the relevant mark on the cylinder when
examined with the eye at the level of the mark.

Proving Rings

Proving rings for CBR Machine can be calibrated as described below.

A ring is calibrated by measuring the radial deflection caused by applying known loads. This can be done by
three methods as detailed below.
 CHAPTER 2.5
QUALITY CONTROL IN ROAD WORKS

2.5.1Bitumen Layers

2.5.1.1 Prime Coat

Test Requirements (As per relevant IS codes)

The EPC Contractor, Results for consignment for approval prior to their use comprising of:

Source

Type

Quantity

Test Results

Control during Work

Before the work is started the quality of binder required as per IS: 8887 should be checked by relevant Indian
standards. The atmospheric temperature (in shade) should be checked and no work shall be permitted, if it is
less than 10° C

An effective check on the functioning of bituminous heater, Primer distributor and spray nozzles should be
made to ascertain that at the required temperature the Primer is uniformly spread on the surface to be treated.
(To be tested by Tray Test as specified in the Appendix V of l.R.C. Special Publication No. 11). It is always
advisable to check the rate of spread by weigh measurement.

A control is to be exercised on the heating temperature of the primer on hourly basis; primer need only be
high enough to permit the primer to be effectively sprayed through the jets of the spray bar.

The Wet Mix Macadam surface to be primed shall be free of dust and not wet at the time of priming. The
surface shall be slightly sprinkled with water (care shall be taken that surface should not be wet) just before
swept clean with mechanical broom and any rutting, cut holes, minor depressions shall be made good before
applying further bituminous treatment.

In case of any accumulation of primer in a pool, the Bitumen should be swept evenly on adjacent surface and
clean sand spread lightly over the excess bitumen.
The rate of spray of primer shall be checked at the rate of three tests per day minimum.

2.5.1.2 Tack Coat

Test Requirement (As per relevant IS codes)

The Contractor shall submit the test results for each consignment for approval prior to their use comprising:

Source

Type
Quantity

Test Results

Construction Operation

A thorough check is to be carried on the equipment for heating bituminous material and the pressure sprayer
and nozzles to ascertain their working efficiency.

The normal range of spraying temperature shall be 20°C - 60°C. The rate of spreading of bituminous
material is to be checked by Tray test method as given in Appendix V of l.R .C. Special publication No. 11.
An effort is to be made to maintain this temperature during the work by hourly checking of the temperature of
bituminous material.

The surface on which the tack coat is to be laid is to be free from dust and swept clean of caked mud or any
other extraneous material.

The tack coat spraying shall be controlled within the rate of spreading specified in the contract . Tack coat Is
to be covered immediately with the next bituminous layer.

No tack coat is necessary on freshly laid bituminous surface on the same day without traffic. The quality of
binder shall be checked regularly as per relevant IS code.
2.5.1.3 Bituminous Macadam

Materials
Bitumen
Paving bitumen of VG -40 grades conforming to the requirements of IS: 73 shall be used. The contractor
shall submit for approval prior to use the suppliers certificate comprising:
Source
 Type
Quantity
Test Results

Sampling and Criteria of Conformity

These shall be same as those specified for Paving Bitumen conforming to the relevant IS Specification.

Aggregates
Aggregates shall be of crushed stone, retained on sieve 4.75 mm fairly cubical in shape; 90% two faced
fractured and free from disintegrated pieces, organic and other deleterious materials, adherent coating and
preferably hydrophobic.

Sampling and Test Frequency from Quarry and Stack

Sampling and testing frequency shall be procedure explained in Para 5.2.1.4

The samples of aggregates are to be tested for their physical properties.

Grading Requirements
Grading requirements of aggregates in the final mix for Bituminous Macadam shall conform to the grading
specified in clause 504.2.4.in the MORTH Specification and checked as per IS: 2386 (Part - 1).

2.5.3.4 Dense Graded Bituminous Macadam

Materials
Bitumen
Paving bitumen of viscosity gradeVG-30 conforming to the requirements of IS: 73-2006shall be used. The
procedures for obtaining approval, sampling and criteria of conformity shall be same as those specified for
use in Bituminous Macadam

Aggregates
Coarse Aggregates
Aggregates shall be of crushed stone, retained on sieve 4.75 mm fairly cubical in shape; 90% two faced
fractured and free from disintegrated pieces, organic and other deleterious materials, adherent coating and
preferably hydrophobic.

The physical properties requirements, except grading of aggregate techniques of sampling, frequencies of
test for approval of the material before use in work shall be same as those specified for use in Bituminous
Macadam.

Fine Aggregates:
Fine aggregates passing 2.36 mm sieve and retained on 75 microns shall be crusher run screenings, natural
sand or a mixture of both. Fine aggregates shall be tested for organic and deleterious materials as per IS:
2386 and shall be clean, hard, durable, uncoated dry and free from any injurious, soft pieces organic or other
deleterious materials.

Filler
Fillers used shall consist of finely divided mineral matter like rock dust, or hydrated lime or cement
approved by Engineer; and conforming to the following gradation with a Plastic ity Index of not more
than 4 percent (The Plasticity Index requirement will not apply in case of cement and hydrated lime)
tested as per relevant I.S. specification

I.S. Sieve Per cent Passing By weight

600 micron 100

300 micron 95 - 100

Designing of the mix:

The Designing of the required mix shall be carried out on the basis of Marshall Test Method as per ASTM
- D - 1559

The bitumen content shall be determined by Marshall Method replacing the aggregates retained on 26.5 mm
sieve with an equal quantity of aggregates passing 26.5 mm sieve but retained on 22.4 mm sieve.

The Optimum Binder content requirements for the aggregate grading specified for DBM shall be determined
by based on Asphalt Institute MS 2.

The mix proportion of the different aggregates to be actually mixed shall depend on their individual
gradation. As such it is to be ensured that job mix formula is based on the actual gradation of the
representative materials. Sieve analysis of the blended aggregates is to be carried out to ensure their
conformity with specified gradation.

The aggregate bitumen mix arrived on the basis of Marshall Test shall meet the criteria as given in clause
505.3.l of MORTH specifications .

Works:

Check is to be carried out on the various equipment to be used for the work and their accessories.

Hot mix plant shall be of required capacity to yield a mix of proper and uniform quality. Its accessories such
as aggregate feeder, dryer, weigh batcher, binder heater and binder control unit, filler feeder unit and mixing
unit should be checked for their proper functioning.

Spreader cum paver finisher should be checked for screeds for spreading,tampin11 and finishing the mix true
to grade, line and cross section

A gradation check on the representative sample of the aggregates, fillers at site is to be regularly carried out
to ensure that the combined gradation is achievable with the proposed mix proportion and there is no change
in the source of the material.

In the event there is a change in the material available at site, a fresh job-mix formula shall be arrived at.
In all cases the Job-mix formula shall be within the permissible limits as specified in clause 507.3.4 of
MORTH specifications as given below:

Permissible variation of the individual percentages

of the various ingredients in the actual mix from the
Sl.No. Description of Ingredients
Job-mix formula
Base/ Binder Course Wearing Course
1 Aggregate Passing 19 mm sieve or larger +8 +7
2 Aggregate Passing 13.2 mm ,9.5 mm +7 +6
sieve
3 Aggregate Passing 4. 75 mm sieve +6 +5
4 Aggregate Passing 2.36mm , 1.18 mm, +5 +4
0.6mm
5 Aggregate Passing 0.3 mm , 0.15 mm +4 +3
6 Aggregate Passing 0.075 mm sieve +2 +1.5
7 Binder Content +0.3 +0.3
8 Mixing Temperature +10oC +10oC

(These variations are intended to apply to individual sample taken for Quality Control)

Wet mix macadam/DBM base shall be free from pothole rutting etc., shall be free from dust, caked
mud etc., and dry before applying the tack coat.

The atmospheric temperature (in shade) shall not be less than 10° C at the time of laying Dense
Bituminous Macadam.

The temperature for different operations shall be checked frequently and controlled within the
range given herein:

The density of the Dense Bituminous Macadam can be checked with nuclear density gauge by back-
scattered method and/or by core cutting method. As the later method is pavement distractive testing
method and leaves potential potholes in the newly constructed pavement. It is prefer to do by Density
checking by core cutting Method and shall be at least 92% of Laboratory Gmm prepared on that
 2
days mix density shall be measure at least @ 1test per 700 m area. If NDG is used it shall be 1 test
per 250 m2 area. Core samples may be taken at a rate of 5- 10/KM to cross check the NDG value and to
check the thickness.

Quality of various sizes of aggregates from bins fed to the dryer shall be checked regularly so that
the resulting combination satisfies the required gradation.

Mixing time should be shortest required to get proper homogenous mix without segregation of
aggregates.

To minimize the loss of heat, the mix shall be carried in a tarpaulin covered tipper truck and spread
and compacted as early as possible. To cope up with the spreading, number of rollers may be
increased.

After establishing the design job-mix, a trial run of the hot mix plant should be made to verify the
efficiency of the control system. Even in case of the computerized control, this trial run is necessity.

Stability of mix and f low, (ASTM D-1559) binder content of the mix (ASTM D-2172) and the
grading of the mix shall be checked regularly when the work is in progress. @ 1 test each per 400
tones of mix with a minimum of 2 tests per day and the results noted in a register to be maintained
for the purpose.

In case of any deviation, the feed controls shall be adjusted suitably and preset only after the mix
outputs have been checked for all the parameters.

The surface of the compacted Dense Bituminous Macadam shall be checked for surface regularities
before it is accepted. Permissible surface irregularities are given in the clause 902 of MORTH
specifications and as given below.

Horizontal Alignment

Horizontal alignment of Dense Bituminous Macadam shall be checked with reference to the
centerline as given in clause 902.2 of MORTH specification. The edges of the Dense Bituminous
Macadam after compaction shall be correct within a tolerance of ± 6mm.

Longitudinal Profile

The levels of Dense Bituminous Macadam layer shall be checked with respect to approved drawings
and shall conform to the requirement/tolerance as specified in clause 902.3 and 902.4 of MOST
Specifications. Provided that the positive tolerance of Dense Bituminous Macadam in conjunction
with the negative tolerance of Bituminous Concrete by more than 6 mm.

Job Mix design

Refer Para above, laboratory procedure for Job Mix design of Bituminous concrete .
2.5.3.5 Bituminous Concrete
Materials
Bitumen

Paving Bitumen of VG - 30 conforming to IS: 73shall be used. The scope of sampling, sample of
criteria for conformation etc. shall be same as those applicable for Bitumen to be used for Dense
Bituminous Macadam. (Clause 507of MORTH specifications).

Aggregates
Coarse Aggregates:

The physical requirements of coarse aggregates to be used in bituminous aggregates shall be same
as those for Dense Bituminous Macadam. For BC coarse aggregates shall be tested for Stone
polishing value as per BS 812 (part 111).

The scope of sampling, sample lot and criteria for conformity and their frequencies shall be same
as those for Dense Bituminous Macadam.

Fine Aggregates:
The physical and grading requirements, tests and their frequencies shall be same as those for
Dense Bituminous Macadam.

Filler
The physical and grading requirements, test and their frequencies shall be same as those for
Dense Bituminous Macadam.

Aggregate Gradation
Coarse aggregates, fine aggregates and fillers shall be so blended as to give grading set forth in
clause 507.205 of MORTH Specifications.

The design of job-mix shall conform to the design requirements as given in clause 500.17 of
MORTH Specifications.
Works
Follow as described for Dense Bituminous macadam and in addition to its water sensitivity test on
Bituminous concrete mix shall be conducted as in chapter 7 laboratory procedure 2.

SI.No Operations Range

1 Temperature of Binder at the time of mixing 1 50° C to 165° C
2 Temperature of Aggregate at the time of mixing 1 50° C to 170° C
3 Difference in aggregate & Bitumen <14°C
4 Discharge temperature of mix from the mixer 150° C to 165° C
5 Temperature of mix at the time of laying 140° C Minimum
6 Minimum temperature of mix at the time of rolling 90° c

Horizontal Alignment

Horizontal alignment shall be checked as per clause 902.2 of MORTH Specifications.

Surface Level

The levels of Bituminous Concrete layer shall be checked with respect to approved drawings and shall
conform to the same within a tolerance of ± 06 mm. Provided that the positive tolerance of Dense
Bituminous Macadam in conjunction with the negative tolerance of Bituminous Concrete shall not
reduce the thickness of Bituminous Concrete by more than 6 mm.

Longitudinal Profile

It should be checked as per clause 902.4 of MORTH specification. The maximum allowable
difference between the road surface and the underside of 3m straight edge shall be 3mm.

JOB MIX FORMULA DESIGN FOR DENSE BITUMINOUS MACADAM (DBM) AND
BITUMINOUS CONCRETE (BC)

The Asphalt Institute's MS-2 shall be followed in determining the Job Mix Formulas (JMFs) for DBM
and BC.

Aggregate

Aggregate Sampling of Stockpiles

Sample aggregate in stockpiles by following IS: 2430-1969.

Aggregate Preparation
Prepare aggregate by following AASHTO T-248.

Aggregate Gradation

Determine gradation, by following IS 2386 (Part-I), for aggregate samples from the different stockpiles.

Aggregate Proportions

Determine the % of each different aggregate to satisfy the MORTH grading envelop.

Cold Bin Settings

Adjust the cold bin feed rates to produce a cold mix containing the different aggregate percentages
determined above. Run the plant.

Hot Bin Aggregate Sampling

Sample the aggregates in the hot bins to obtain sufficient material to determine the Job Mix Formula
(JMF).

Preparation of Hot Bin Aggregate Samples

Prepare hot bin aggregate samples according to AASHTO T-248.

Gradation of Hot Bin Aggregate

Determine the gradation of the hot bin aggregates by following IS 2386 (Part I).

Hot Bin Aggregate Proportions

Determine the % of each hot bin aggregate to satisfy the relevant MOST grading envelop.

Aggregate Bulk Specific Gravity

Measure the bulk specific gravity of:

i. Fine aggregate by following ASTM C128-93

ii. Course aggregate by following AASHTO T-85

iii. Filler by following AASHTO T-100

Bulk Specific Gravity of Total Aggregate

Calculate the combined aggregate bulk specific gravity using the formula in MS-2 clause 4.05.

Effective Specific Gravity

Determine the Effective Specific Gravity of the combined aggregate using :

 MS-2, clause 5.lO(c), involving determination of maximum specific gravity for 2 bitumen
contents using ASTM D-2041 and

 The formula in MS-2 clause 4.06.

Maximum Specific Gravity

Determine Maximum Specific Gravity from the formula in MS-2 clause 4.07, for the other bitumen
contents in the JMF design

Bitumen

Bitumen Sampling

Sample the bitumen by following IS: 1201-1978

Bituminous Concrete Mixtures

Follow Asphalt Institute's MS-2 (6th Edition) Chapter 111 {Marshall Method of Mix Design).

Preparation of Aggregates

Prepare aggregates according to MS-2 clause 5.05 (b), and the grading envelope of MORTH Table 500-9
(for DBM) and Table 500-23 (for BC).

Equipment for Testing

Organize and prepare equipment for testing according to MS-2 clauses 5.04 and 5.05(d).

Preparation of Bituminous Mixtures

Prepare the mixtures according to MS-2 clause 5.0S(a) and 5.05(e). The temperature s at mixing (from
MOST clauses 507.4.4., 512.4.4.) shall be:
 For the bitumen 150 - 165°c

For the aggregate 150 - 170° c

The temperature of the mixture at compaction shall be 120-160° C (from MOST clauses 500)

Testing of Compacted Marshall Specimens

Bulk Specific Gravity Testing

Determine the Bulk Specific Gravity of the compacted Marshall specimens using :

• ASTM-D2726 (Bulk Specific Gravity of Compacted Bituminous Mixtures Using Saturated

Surface Dry Specimens)

• Where the water absorption is >2% use ASTM-D1188 (Bulk Specific Gravity of Compacted
Bituminous Mixtures Using Paraffin Coated Specimens).

Marshall Stability and Flow Testing

Determine the Marshall Stability and Flow using ASTM-D1559. The time in the water bath at 60°C
±1°C shall be 30 minutes.

Air Voids

Calculate the Air Voids in the compacted specimens using ASTM D-3203-94 and

 The average Bulk Specific Gravity figure for the Marshall specimens with the same bitumen
content

 The Maximum Specific Gravity from section 6.04.3.1.7.

 The formula in MS-2 clause 4.11.

Voids in Mineral Aggregate (VMA)

Calculate the VMA using:

• The average Bulk Specific Gravity for the Marshall specimens with the same bitumen
content
 • The combined Bulk Specific Gravity of aggregate from section 6.04.3 .1.4.

• The formula in MS-2 clause 4.10.

Analysis of Test Data

Preparation of Test Data

Prepare test data according to MS-2 clause 5.11(a) and (b). Prepare graphs of Test data according to MS-
2 clause 5.11(c).

Check graphical trends against MS-2 clause 5.12

Determination of Optimum Bitumen Content (OBC)

Determine the OBC according to MS-2 clause 5.14.

Water Sensitivity

Compact 6 Marshall Specimens at OBC. Determine Bulk Specific Gravity (Gsb) of specimens Divide
into 2 groups so that the average Gsb for Group I is similar to for Group II too.

Place the Group I specimens in the water bath at 60 ±. 1°C for 30 minutes. Determine the ir stability
according to ASTM D-1559. Calculate the Average Marshall stability for Group I.

Place the Group II specimens in the water bath at 60 ±. 1°C for 24 hours. Determine their stability
according to ASTM D-1559. Calculate the Average Marshall Stability for Group II.

Calculate the Water Sensitivity as the retained stability by the following formula:

Ave rage Marshall Stability (Group II)

------------------------------------------------ X lOO

Average Marshall Stability (Group I)

Swell Test

Prepare and compact the swell test specimens by following MS-2 clause 6.13. Conduct the swell test by
following MS-2 clause 6.18 (Swell Test).
Note: The MOST Specifications require the swell test for Bituminous Concrete but not for DBM.

Analysis of OBC Mix Results

Analysis the test results to check they conform to the requirements of MORTH Table 500-10 (for DBM)
and Table 500-17 (for BC).lf the test results don't conform then the trial mix testing shall be repeated
after analysis of the failure.

Job Mix Formula

The details of the Job Mix Formula (JMF) as determined above shall be provided to the Engineer
according to MORT 7 H clauses 507.3.3.

Permissible Variations to JMF

MORTH Table 500-13 provides the permissible variations to the JMF for:

 Gradation

 Bitumen content

The bituminous mix produced shall lie within the permissible variations to the JMF and Table 500-10
(for DBM) and Table 500-17 (for BC).

Maximum Specific Gravity of DBM

Determine the maximum specific gravity of the DBM according to ASTM D-2041.

Note: The formula in Asphalt Institutes MS-2 (section 4.07), is not to be used for routine determination
of Gmm of production mix DBM.

Compact Marshall Specimens

Compact-DBM according to ASTM D-1559.

Bulk Specific Gravity of Marshall Specimens

Measure the bulk specific gravity of saturated surface dry Marshall Specimens using ASTM 0 2726, or
paraffin coated specimens using ASTM D-1188 where the water absorption is more than 2%.

Marshall Stability & Flow

Follow ASTM D-1559 to measure the Marshall properties of flow and stability of specimens that have
been compacted then placed in the water bath at 60 .:!: 1°C for 30 minutes.

Voids in Mineral Aggregate (VMA)

Calculate the voids in the mineral aggregate (VMA) according to the Asphalt lnstitute's MS-2 usingthe
formula :

GmbPs

VMA = 100 - ------------

Gsb

Air Voids (V)

Calculate % air voids in compacted mixture according to the Asphalt lnstitute's MS-2 using the following
formula :

Gmm - Gmb

Va = --------------- X 100

Gmm

Voids Filled with Bitumen (VFB)

Calculate the % of voids filled with bitumen (VFB) in the compacted mixture using the following
formula:

VMA - Air Voids

VFB = ----------------------- x 100

VMA
TESTING OF BITUMINOUS CONCRETE (BC)

The frequency of sampling and testing shall be as per Table 6.04.3 .

Sampling of BC

Sample the bituminous concrete according to ASTM 0-979-96.

Preparation of Bituminous

Prepare the bituminous concrete samples according to the requirements of the relevant test method.
Quarter the BC to provide the quantities required for each test.

Bitumen Extraction

Extracting the bitumen from the BC sample by centrifuge method by using mechanical or electrical
extraction machine.

Sieve Analysis of Extracted Aggregate

Determine the gradation of the aggregate from which the bitumen has been extracted using AASHTO T-30.

Maximum Specific Gravity of BC

Determine the maximum specific gravity of the BC according to ASTM D-2041.

Compact Marshall Specimens

Compact the BC mixture according to ASTM D-1559.

Bulk Specific Gravity of Marshall Specimens

Measure the bulk specific gravity of saturated surface dry Marshall Specimens using ASTM 0- 2726, or
paraffin coated specimens using ASTM D-1188 where the water absorption is more than 2%.

Marshall Stability & Flow

Follow ASTM 0-1559 to measure the Marshall properties of flow and stability of specimens that have
been compacted then placed in the water bath at 60 + 1°C for
 30 minutes (3 specimens), and
 24 hours (3 specimens).

Water Sensitivity
Compact 6 Marshall Specimens at OBC. Determine Bulk Specific Gravity (Gsb) of specimens. Divide
into 2 groups so that the average Gsb for Group I is similar to the average Gsb for Group 11.

Place the Group I specimens in the water bath at 60 + 1°C for 30 minutes. Determine their stability
according to ASTM D-1559. Calculate the Average Marshall stability for Group I.

Place the Group II specimens in the water bath at 60 + 1°C for 24 hours. Determine their stability
according to ASTM D-1559. Calculate the Average Marshall Stability for Group II.
Calculate the Water Sensitivity as the retained stability by the following formula

Average Marshall Stability (Group 11)

--------------------------------------------------------------------- x 100
Average Marshall Stability (Group I)

Note: The Water Sensitivity test is only required for Bituminous Concrete.

Voids in Mineral Aggregate (VMA)

Calculate the voids in the mineral aggregate (VMA) according to the Asphalt Institute’s MS-2 using
the formula.

Gmb Ps
VMA= 100 - ------------
Gsb

The % compaction of a material shall be determined according to the formula:

Field Dry Density

% Compaction = ------------------------------------- x 100

Maximum Ory Density

Assessment of Compaction Results

Table 7.04.3 lists the minimum % compaction required by the MOST specification. Where a minimum of 6
compaction tests have been conducted, follow sections 7.04.1.9.1. Where < 6 compaction tests have
been conducted, follow section 7.04.1.9.2.
Statistical Assessment of Compaction Results
Calculation of the Characteristic % Compaction (Q) for the lot or reach shall be as follows where the sample
size > 6

Q= x - ks

Where x = arithmetic mean of % compaction for all sub-lots

k = acceptance constant from Table Q.6. (Based on 10% producer's

risk)
Table Q.6: Acceptance Constant k
A lot or reach passes if Q is equal to or greater than the specified minimum % compaction. If Q is
less than the specified lower limit for % compaction then the lot fails.
Note: The lot will normally be one day's work, in a continuous stretch.
Assessment of % Compaction Where Sample Size < 6

Where < 6 % compaction results were determined average method may be followed but in no case

-
density shall less than specified density 3%.

Sand Calibration
The sand used in the field to fill the density holes will be calibrated in the Laboratory, using the
calibration cylinders provided, for the appropriate depth of hole: 10cm, 1Scm, 20cm, and the
appropriate diameter of hole: 15cm or 20cm.

IS 2720 Part 28 requires the density sand to pass the 1.00 mm sieve and be retained on the 600 micron
sieve

The following steps should be followed to prepare the sand for Field Density Tests:

 Screen the sand preferably to pass the 1mm sieve, and be retained on the 600 micron sieve.
Dry the sand in the 110 degree oven, or over a gas burner

 Pour the sand in a manner as similar as possible to the field by:

Using the same sand cone and cylinder.

 Pour the sand into a calibration container of approximately the same depth and diameter as

the FDT holes. Pour the sand on a level surface free of vibration. Place the sand cone and
cylinder over the calibration container then allow the sand to flow into the container. Make a
minimum of 3 sand pours into the calibration container. Record the sand calibration.

 Exclude values varying by > 0.005 g/cc from the other values. Determine the average of 3
acceptable unit weight values as the density sand unit weight in g/cc.

Re-Use of Density Sand

The Test Method (IS 2720 Part 28) requires the use of clean, dry, calibrated sand. Re-used density
sand in the field will be contaminated by moisture and material from the previous FDT holes, even if the
sand is screened after use. Density sand can only be re-used if the procedure below is followed:

Screen the all sand after every day of FDT testing.

Dry the sand in the 110 degree oven or over a gas burner, if necessary.

Conduct a unit weight {density) calibration check daily, and check the mass of sand required to fill the
cone if there is a significant change in the unit weight.

If the unit weight varies by > 1% from the unit weight determined in (7.04.1.10), then screen, dry and
re-determine the unit weight according to 7.04.1.10.

Cone Calibration
Sand cones must be re-calibrated at the intervals specified in 7.3.5, or after any change in shape,
or repair.

Calibrate the cone according to the following steps using, or use the procedure described in IS 2720
(Part 28):

 Fill sand cylinder and cone, and then weigh to the nearest lg.
 Place cylinder and cone or a level place surface free of vibration.
 Allow the sand to flow freely filling the cone.
 Weigh sand residue + cylinder.+ Cone.
 Determine weight of sand in cone.
 Repeat a minimum of 3 times. Exclude sand cone weights varying by > 5g. from the other
values.
 Calculate the average sand cone weight from 3 acceptable values.

Relative Density

For cohesion less materials (sands) to assess compaction it will be necessary to determine:

i) The minimum index density by ASTM D4254-83

ii) The maximum index density by ASTM 04253-83, &

 iii) The field dry density using AASHTO T-191

The relative density (Dd) of the cohesion less material will be determined using the following formula:

Pd max X (Pd-Pd min)

Dd = ------------------------------X 100
Pd x (Pd max –Pd min)

Where
Pd = field dry density (AASHTO T191)
Pd max= maximum index density (ASTM 04253)
Pd min = minimum index density (ASTM D4254)
To relate Relative Density % to % Compaction use the relationship in Table 1below, adopted from the
Saudi Arabian General Specification for Road & Bridge construction (First Edition 1972)

DETERMINATION AND ASSESSMENT OF ASPHALTIC CONCRETE COMPACTION AND

THICKNESS

Sampling and Compaction of Marshall Specimens

Sample from delivery trucks or behind the paver, minimum of 2 samples for each day's paving (at the
frequency of 1/400mt).

Compact a minimum of 6 (DBM) or 9 (BC) Marshall specimens for each day's paving, by
compacting:

For each DBM sample compact:

3 Specimens for stability test immersed in water at 60+ or - 1°c for 30 min.

For one BC sample/day compact:

6 specimens that will comprise: 3 for 30 min stability testing specimens 3 for loss instability test
immersed in water at 60 ±10 C for 24 Hours.

For the other BC samples each day compact: 3 for 30 min stability testing specimens.

Determine the Bulk Specific Gravity of the Marshall specimens by ASTM D-2726 or ASTM D- 1188
(if the water absorption exceeds 2%).

For each sample, using the 6 or 3 specimens: determine the mean Bulk Specific Gravity, and then
exclude all values whose Bulk SG value departs from the mean by > 0.02. Recalculate the mean Bulk
SG if values are excluded.

Coring of DBM & Bituminous Concrete

Test location for coring shall be purely based on random selection of first point. Further all other
locations are based on regular interval as discussed in the following figure.
Divide the paved area in to four sectors. Select the first test chainage and sector (out of four, each 2 m)
randomly.

Add 35 m for the next location and offset it by are sector (c 2m).

Determination of Core Bulk Specific Gravity

Determine core bulk specific gravity according to ASTM D-2726, according to the following weighing
sequence:

i) Weigh in water
ii) Weigh SSD specimen

iii) Weigh in air, after drying in air to constant dry weight.

If water absorption > 1%: determine bulk specific gravity according to ASTM 0-1188 (wax coated
specimens).

Determination of Bituminous Concrete % Compaction

The compaction of the DBM & BC courses in the pavement will be determined according to
AASHTO T-230-68 'Determining Degree of Pavement Compaction of Bitumen Aggregate
Mixtures

Core Bulk Specific Gravity

% compaction = --------------------------------------------------- x 100
Mean Marshall Bulk SG/Gmm

i) The above % compaction formula,

ii) The mean Bulk Specific Gravity for each sample, determined according to 7.04.5.1. If the
mean Bulk SGs for the 2 or more samples taken for the day's work are within 0.02 of each
other, then the mean of the mean Bulk SGs for all the day's samples shall be used as the
denominator in the above equation.
If the mean Bulk SGs for the 2 or more samples taken for the day's work are not within 0.02
of each other, then the 2 or more sections represented by the 2 or more samples, shall have
their
% Compaction determined separately.
iii) Report the % Compaction to nearest 01%.

Determination of Thickness
Determine the DBM and BC layer thickness by measuring the same cores used for determining %
compaction. Core thickness should be determined according to ASTMD 3549-83 (Standard Test Method
of thickness or Height of Compacted Bituminous Paving Mixture Specimens).

Core thickness should be measured by Vernier calipers according to 6.1.2 of ASTM D 3549. The core
thickness should be reported to the nearest mm.

TESTING OF DENSE BITUMINOUS MACADAM (DBM)

Frequency of Sampling and Testing
The frequency of sampling and testing shall be as per Table 6.04.3. Sampling of DBM

Sample the DBM according to ASTM D-979-96. Preparation of DBM

Prepare the DBM samples according to the requirements of the relevant test method. Quarter the DBM to
provide the quantities required for each test.
Bitumen Extraction

Extract the bitumen from the DBM sample by following the method described in the centrifugal method
of bitumen extraction

Sieve Analysis of Extracted Aggregate

Determine the gradation of the aggregate from which the bitumen has been extracted using
AASHTO T-30.

Maximum Specific Gravity of DBM

Determine the maximum specific gravity (Gmm) of the DBM according to ASTM D-2041.

Note: The formula in Asphalt Institutes MS-2 (section 4.07), is not to be used for routine determination
of Gmm of production mix DBM.

Screen +25 mm Material and Replace

Screen +25 mm material from the sampled production mix DBM. Replace the +25 I -37.5 mm DBM
with an equal mass of -25 I +22.4 mm DBM material. Note: This should not be necessary for DBM mix
from this plant as the maximum screen size is 24 mm.

Compact Marshall Specimens

Compact the -25 mm DBM according to ASTM D-1559.

Bulk Specific Gravity of Marshall Specimens

Measure the bulk specific gravity of saturated surface dry Marshall Specimens using ASTM D- 2726, or
paraffin coated specimens using ASTM D-1188 where the water absorption is more than 2%.
Marshall Stability & Flow

Follow ASTM D-1559 to measure the Marshall properties of flow and stability of specimens that have
been compacted then placed in the water bath at 60 + 1°C for 30 minutes.

Voids in Mineral Aggregate (VMA)

Calculate the voids in the mineral aggregate (VMA) according to the Asphalt lnstitute's MS-2 using the
formula:
GmbPs
VMA = ------------
Gsb
Where VMA = voids in mineral aggregate (% of bulk volume)

Gsb = bulk Specific gravity of aggregate

Gmm = Bulk Specific Gravity of compacted mixture

Ps = aggregate, % by total weight of mixture

Air Voids: Calculate % air voids in compacted mixture according to the Asphalt institute’s MS-2 using the
following formula

Gmm-Gmb
Va = 100 X ----------------
Gmm
Where Pa = air voids in compacted mixture, % of total volume

GMM = maximum specific gravity of DBM mixture (ASTM D-2041)

Gmb = bulk specific gravity of compacted mixture

Voids Filled with Bitumen(VFB):

Calculate the % of voids filled with bitumen (VFB) in the compacted mixture using the following formula:
VMA - Air Voids
VFB =------------------------ X100
VMA

TESTING OF BITUMINOUS CONCRETE (BC):

The frequency of sampling and testing shall be as per Table 11.

Sampling of BC

Sample the bituminous concrete according to ASTM 0-979-96.

Preparation of bituminous concrete samples

Prepare the bituminous concrete samples according to the requirements of the relevant test method. Quarter
the BC to provide the quantities required for each test.

Bitumen Extraction

Extract the bitumen from the BC sample by following the method described in the Trox ler oven manual.

Sieve Analysis of Extracted Aggregate

Determine the gradation of the aggregate from which the bitumen has been extracted using AASHTO T-30.

Maximum Specific Gravity of BC

Determine the maximum specific gravity of the BC according to ASTM D-2041.

Compact Marshall Specimens

Compact the BC mixture according to ASTM D-1559.

Bulk Specific Gravity of Marshall Specimens

Measure the bulk specific gravity of saturated surface dry Marshall Specimens using ASTM 0- 2726, or
paraffin coated specimens using ASTM 0-1188 where the water absorption is more than 2%.

Marshall Stability & Flow

Follow ASTM D-1559 to measure the Marshall properties of flow and stability of specimens that have been
compacted then placed in the water bath at 60 + 1°C for :

30 minutes (3 specimens), and

24 hours (3 specimens).

Loss of Stability

Compact 6 Marshall Specimens at OBC. Determine Bulk Specific Gravity (GSB) of specimens . Divide into 2
groups so that the average GSB for Group-I is similar to the average GSB for Group II.

Place the Group I specimens in the water bath at 60 + 1°C for 30 minutes. Determine their stability according
to ASTM D-1559. Calculate the Average Marshall stability for Group I.

Place the Group II specimens in the water bath at 60 + 1°C for 24 hours. Determine their stability according
to ASTM D-1559. Calculate the Average Marshall Stability for Group II.

Calculate the loss of stability as the retained stability by the following formula:

Average Marshall Stability (Group II)

100 x ------------------ --------------------------

Average Marshall Stability (Group I)

Note: The Water Sensitivity test is only required for Bituminous Concrete

Voids in Mineral Aggregate {VMA)

Calculate the voids in the mineral aggregate (VMA) according to the Asphalt lnst1tute 's MS-2 using the
formula

Gmb X Ps
VMA = 100 X ----------------
Gsb
Where: VMA = voids in mineral aggregate (% of bulk volume)

Gsb = bulk specific gravity of aggregate

Gmb = bulk specific gravity of compacted mixture (ASTM D-2726)

Ps = aggregate, % by total weight of mixture.

Air Voids

Calculate % air voids in compacted mixture according to the Asphalt institute’s MS-2 using the
following formula

Gmm X Gmb
Va = 100 X ----------------
Gmm

Where Pa = air voids in compacted mixture, % of total volume

Gmm = maximum specific gravity of BC mixture (ASTM D-2041)

Gmb = bulk specific gravity of compacted mixture (ASTM D-2726)

Voids filled with Bitumen

Calculate the % of voids filled with bitumen (VFB) in the compacted mixture using the following formula

VMA – Air voids

VFB = 100 X --------------------------
VMA