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Bahir Dar University, Institute of Technology,

School of Civil and Water Resource Engineering

HIGHWAY ENGINEERING III


(CENG 5173)

By:Girmaw Belete
(B.Sc. in Civil Engineering and M.Sc. in Civil Engineering /Geotechnical Engineering)
email:bkidanz@gmail.com

!)9 2017

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
By: Girmaw Belete Road Construction
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Highway Engineering III (CENG 5173)
Contents

• Chapter 1 Road Construction


0 Introduction
• Preconstruction Basics in Roads
1.1 Earthwork
• Site Clearance/Clearing and Grubbing
• Subgrade preparation
• Roadway Excavation, Embankments Construction
1.2 Drainage Structure Construction
1.3 Construction of sub-bases
1.4 Construction of Gravel Roads
1.5 Road base Construction
1.6 Construction of Stabilized Layers
1.7 Construction of Bituminous pavement,
• Hot Mix Asphalt Concrete Construction
• Cold Mix Asphalt concrete Construction
• Surface Bituminous Treatment
1.8 Construction of Cement By:Concrete/Rigid
Girmaw Belete pavement
Road Construction
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Highway Engineering III (CENG 5173)
Road Construction
0. Introduction
• Basics in Road construction
• Contract documents
• Complete set of Drawings/data
• Plan /profile: Showing natural ground levels: horizontal and vertical curve details;
drainage; cross sections; side drains and etc.
• Details of drainage and bridge Design, location of material site for construction of bench
marks and survey beacons contour lines and other relevant information on the format
determined
• Centerline data every 20m at tangents and 10m at curves, setting out data, earthwork
volume pavement material volume at 20m interval.
• Setting out data(Horizontal and Vertical)
• Drainage drawings(Minor and Major structures)
• Pipe culvert (bedding, rebar detail, section details, inlet and out let)
• Slab Culverts and Box culverts
• Bridges (plan, elevation, abutment and wing wall detail, Rebar)
• Standard drawings/Working drawings
• Road junction drawings
• Traffic Sign post
• Station,size,qty and plan
By: Girmaw Belete Road Construction
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Highway Engineering III (CENG 5173)
Road Construction
0. Introduction
• Cross drainage and ditch
• Culverts schedule
• Ditch schedule
• Typical section
• Rural and town sections
• Slope ratio,widening development,superelevation development

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
0. Introduction
• Specifications:
• Describes in detail the works to be executed, the character and quantity of
material and workmanship
• Also describes the material requirements,
• Division of Specifications
• Standard /ERA 2014 Standard Specification for Road Works
Series 0000: Method of Measurement
Series 1000: General
Series 2000: Site Clearance
Series 3000: Drainage Structures
Series 4000: Earthworks and Material Stabilization
Series 5000: Sub-Base, Road Base and Gravel Wearing Course .
Series 6000: Bituminous Surfacing's and Road Base
Series 7000: Rigid Pavements
Series 8000: Structures
Series 9000: Ancillary Works
Series 10000: Testing Materials and Workmanship

• Particular/Project specific

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
0. Introduction

• Bill of Quantity: list of items giving brief description of and


estimated quantities of the work.
• ..\References\Sample BoQ.xlsx
• Conditions of Contract
• defines the term under which the works to be carried out, the
relationship between the employer and the contractor,the power of the
Engineer and terms of payment
• General conditions of contract: PPA, FIDIC,MoWUD
• Particular conditions of contract: Particularly modified and prepared for
that particular project

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork
• Earthwork-portion of highway construction required to convert the RoW from its natural
condition and configuration to the sections and grades prescribed in the plan.
• Setting out
• Prior to construction, the exact location of the road needs to be established
through a detailed survey. The position of the road center line provides the
main reference for the setting out of all other key positions relating to the
various components and structures that form part of the road.

• The limits of Earth work ( Embankment /Excavation) shall be set out true to
lines, Curves and marked by fixing batter pegs on both sides at regular
intervals as guides before commencing the earthwork (Embankment
/Excavation).
• Various phases of Earthwork includes
• clearing and grubbing,
• Roadway excavation
• Borrow or special classes of excavation(such as removal of or restitution, trenching
for subsurface drainage or utility lines)
• Embankment construction and finishing

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Site clearance
Clearing and Grubbing
• clearing of the Site and grubbing necessary for the construction of the
permanent Works
• the removal and disposal of materials resulting from clearing and grubbing.
• the preservation from injury or defacement of all vegetation and objects designated to
remain.

Clearing shall consist of the removal of all trees, brush, other vegetation, rubbish,
fences and all other undesirable material including the disposal of all material resulting
from the clearing and grubbing to a maximum depth of 150mm, except for boulders.

Grubbing: all stumps and roots larger than 75mm in diameter shall be removed to a
depth of not less than 500mm below the subgrade level and a minimum of 300mm
below the cleared original ground level.

All holes, ruts or other surface deformation remaining after clearing and grubbing should
be backfilled and compacted as directed by the Engineer to prevent the ponding of water
except for borrow pits.
By: Girmaw Belete Road Construction
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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Site clearance

Execution of Work

The portions of the road reserve that fall within the limits of
the road prism as well as certain borrow areas may require to
be cleared and/or grubbed.
The areas to be cleared shall be the area on each side of the
road width, plus 3m and 1.5m in rural and town sections
respectively beyond the catch-point in cut and fill

• Measurement - in Hectare(Ha)
• Equipments: dozer,hand tools

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Site clearance
• Demolition, Removal, Disposal, Storage or Cleaning
of Existing Structures and Installations

• Demolition of Structures
• Existing structures and installations shall be carefully
demolished as described in the Contract
• Demolition of Existing Road Pavements
• Existing road pavements shall be demolished by excavation,
scarifying or milling using appropriate equipment approved by
the Engineer

• Cleaning of Existing Drainage Structures


• The work involves the cleaning of open drains and other
open structures, or the cleaning of piped or box-type drainage
structures and their inlets and outlets
By: Girmaw Belete Road Construction
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Highway Engineering III (CENG 5173)
1.1 Earthwork…..Road Bed Preparation
Preparation of Road Bed
• Comprises of preparation of the roadbed for cut and fill situation
and selected/capping layers prior to the construction of the
pavement layers.
• Roadbed on Suitable Material
In-situ material that is classified as suitable material but with a
density of less than 93% or 95% of the maximum dry density,
as required, determined in accordance with AASHTO T-180 shall
be scarified to a minimum depth of 200mm that yields a minimum
compacted layer thickness of 150mm,watered and re-compacted to
the specified density.
• Roadbed on Unsuitable Material
Any materials exposed in the preparation of the roadbed that are
considered to be unsuitable shall be removed and shall be
backfilled with approved imported material compacted to the
required density .
By: Girmaw Belete Road Construction
• Highway Engineering III (CENG 5173)
12
Road Construction
1.1 Earthwork…..Road Bed Preparation
• Materials for backfilling
Excavated areas shall be
backfilled with approved imported
materials with the following
Prepared road bed in cut section properties:
• The CBR shall not be less than 5%
at 95% of Modified AASHTO
(T180) and where no capping or
selected layer is specified shall have
a minimum soaked Californian
Bearing Ratio (CBR) of 8% at 95%
of Modified AASHTO (T180); and
• A swell value of not more than 2.0%
(with appropriate surcharge weights)
when determined in accordance with
AASHTO T-193

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Road Bed Preparation
• Unsuitable Material consists of:
• Peat and other organic materials from swamps, marshes
and bogs that contain compressible soils and excessive
amounts of degradable organic matter such as decomposing
wood and other vegetation.
• Clay material having a Liquid Limit (LL) > 60; or a Plasticity
Index (PI) > 30;or CBR value < 3% at 95% of modified
AASHTO compaction (AASHTO method T-180) after 4 days
soaking; Clay
• Clay having a swell value > 3% (with two surcharge rings) when
determined in accordance with AASHTO T-193 at 95% of
modified AASHTO compaction.

• Other problem soils such as expansive clays

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Road Bed Preparation
Rock Sub-grade Preparation
• Remove all loose rock from the surface.
• Excavation in solid rock shall be minimum 150mm below the bottom level of the sub-
base
• Rock shall be undercut neatly to the required elevation and sections shown on the
Drawings or as directed by the Engineer. Transverse and longitudinal profile checked by
template shall be accurate to the Specifications.
• Any cuts made below the sub-base level shall be backfilled with selected material of
sub-base quality as shown on the Drawings at the cost of the Contractor. Performance
of this work shall not be paid for under this Division but by the Contract prices for pay
items.
• All rock surfaces shall be prepared so that water cannot accumulate at any point. This
shall be achieved by constructing subgrade drains to connect depressions to the storm
water system or to longitudinal subsoil drains.
• Subgrade drains shall be at least 150mm wide and shall be cleared of all earth and
debris. All depressions and subgrade drains shall be backfilled with course filter
medium.

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow Excavation
• Roadway excavation-excavation
and grading of roadway as
ditches,intersections,benches,removig
unsuitable, excavating Underhill fills

• Common (Normal or Soft)


Excavation
Common excavation shall be excavation in
material which can be efficiently removed
or loaded by any of the following
equipment:
• A bulldozer with a mass of at least 25 tone
and an engine developing approximately
180 kW at the flywheel; or
• A track-type front-end loader with a mass
of at least 27 tonne and an engine
developing 175 kW at the flywheel.
• A bulldozer with a mass of at least 35
tonne, fitted with a single tine ripper, and
an engine.
By: Girmaw Belete Road Construction
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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow Excavation
• Rock (Hard) Excavation
The following shall be classified as rock
excavation:
• Excavation in material which cannot be
efficiently ripped by equipment as specified in
Sub clause 4204(a)(Iv).
• Large boulders encountered in excavation
which, in the opinion of Engineer cannot be
removed by mechanical excavator and can only
be removed with the use of compressor and
pneumatic breaker equipment or blasting.
• Isolated volumes of artificial hard material or
rock occurring within other material to be
excavated. This material shall only be
measured separately when its volume exceeds
1m3 and complies with the specified
requirement in 4204(b)(ii).

• In short, excavation in material


which requires drilling and blasting
or the use of hydraulic or pneumatic
jackhammers to be loosened and to
be loaded for transportation

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow
Excavation

Rock excavation

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow
Excavation

• The dimensions of cuttings shall be in accordance with the cross-


sections and details shown on the Drawings and further amended
during the course of construction, as instructed by the Engineer.

• All cuttings excavated below the specified levels shall be backfilled


with suitable material and compacted to the satisfaction of the
Engineer

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow
Excavation

• Use of Excavated Materials

• All material excavated from the road prism shall, in so far as is


practical and in line with the requirements of these Specifications, be
used for the construction of
• embankment fills,
• pavement layers ,
• Slopes
• shoulders,
• bedding
• backfill and for such other purposes as shown on the Drawings or as directed
by the Engineer.

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Back
slope
Side ditch Road bed

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow
Excavation

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
The road was completely blocked with mud after
the earthwork operation was completed?
How do you treat this slide?

Slide edge

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow
Excavation

• Construction requirements for


drilling and shooting,blasting
• Is performed to break rock so
that it can be quarried for
processing in an aggregate
production or to excavate
roadway.
• Is accomplished by discharging
an explosive

• Drilling using Wagon drill are used


to drill holes
• Place charges /explosives to holes
• Detonators are used for charging

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Roadway and Borrow
Excavation
Borrow Excavation:
• Excavation conducted outside RoW to produce materials required
for the construction of embankments, backfill,subbase or other
use for which the material is intended
• borrow material shall meet specifications for the purpose intended

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Embankment construction
• Embankment Construction
• Comprises of placing an embankment material and backfill material excavated on
roadway or approved borrow material.
• Material requirement
• The minimum grading modulus(The cumulative percentages by mass of material in a
representative sample of aggregate, gravel or soil retained on the 2.00mm, 0.425 mm
and 0.075 mm sieves, divided by 100) for material to be used for capping or
selected layers shall be 0.75
• CBR :minimum soaked CBR of not less than 5% and a swell value of not more
than 2% (with two surcharge rings)
• liquid limit not exceeding 60 and a plasticity index not exceeding 30
• Lower layers of embankment fill constructed on the prepared roadbed shall
have minimum densities of 90, 93 or 95% of modified AASHTO density

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Embankment construction
• Construction Requirements for General Embankment Fills
• The dimensions of fills shall be in accordance with the typical cross-sections
shown on the Drawings; or as amended during the course of construction

• Fill, other than rock fill, shall be deposited in layers not exceeding 200mm after
compaction. Each layer shall extend over the full width of the embankment and
shall be placed in successive layers approximately parallel to the final road surface
• The material shall then be sprayed with water, mixed and compacted as described
hereafter.
• Prior to compaction, the material shall be thoroughly mixed by grader or other
suitable plant so as to obtain an even mix of the fine and coarse material
throughout the mixture.
• Compaction shall be carried out in a series of continuous operations covering the
full width of the layer concerned.
• The length of any section of a layer being compacted shall, wherever possible, be
not less than 150 m or more than a distance that can be properly compacted with
the available equipment.

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.1 Earthwork…..Embankment construction

•Benching :Where the slope of the existing ground, in any


direction is greater than 20%, the existing ground shall be excavated
to form horizontal benches which shall be a minimum of 1m wide.

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
By: Girmaw Belete Road Construction
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Highway Engineering III (CENG 5173)
Road Construction
1.2 Structural works
• Drainage structures
• Minor Structure
• Culverts(Pipe,Slab and Box)
• Major Structure
• Bridges
• Side drainage
• Ditches
• Retaining wall construction

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.2 Drainage Structure
Slab Culvert Construction

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Paved ditch construction

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Retaining wall construction

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Comment on the concrete built in 1930s along
Debre Tabor-Ebinat Road ,Mello arch bridge

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.2 Drainage Structure
Pipe Culvert Construction

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.2 Drainage Structure

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.2 Drainage Structure…Bridge Construction

Rebar placing and formwork preparation for


top slab

False work and formwork

Completed bridge
By: Girmaw Belete Road Construction
37
Highway Engineering III (CENG 5173)
Road Construction
1.2 Drainage Structure

•Comment on it?

False work washed away by flood. What do you recommend to


complete the bridge construction

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.2 Drainage Structure…Summary of drainage construction
Please note that the sequence may get varied as per the site condition

Setting out False work and Rebar


• Excavation limit Formworks Cutting, bending and
placing

Structural
Excavation Superstructure
• Soft
Backfill works concrete cast for
• hard Girder
Slab
Hand railing
Footing Sub structure
• Lean concrete Abutment and wing wall
• Rebar placing Masonry/Concrete
• Concrete cast Bearing

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.3 Construction of sub-bases

• Sub base. Layers of specified material thickness placed on a


subgrade to support a base course.
• Material Sources for Sub-Bases
The materials used for the construction of sub-base layers shall be
either:
• Natural Gravel;
• Scoria (Cinder Gravel);
• Weathered Rock;
• Crushed Gravel;
• Crushed Rock or crushed Boulders;
• Recycled Pavement Material.
• Any other granular material complying with the requirements of this Clause
and a combination
of any of the above.

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.3 Construction of sub-bases
Material Requirements Sub-Base
• Gravel material to be used for sub-base shall be obtained from
approved sources in borrow areas, cuttings or existing pavement
layers and shall conform to requirements specified herein.
• The aggregate used for crushed stone sub-base shall be derived
from a parent rock that is hard, sound, durable, and un-
weathered and obtained from an approved quarry or clean sound
boulder

• The minimum Grading Modulus shall be 1.5, except where a


material, having a lower Grading Modulus (but not less than
1.2) is approved for use by the Engineer.
• The flakiness index, determined by testing in accordance with
BS812, Part 105 or ASTM D 3398, shall not exceed 35
By: Girmaw Belete Road Construction
41
Highway Engineering III (CENG 5173)
Road Construction
1.3 Construction of sub-bases

• The plasticity requirement is as shown below on the table

• The minimum dry density to which the material shall be


compacted shall be 95% of the MDD obtained in the
AASHTO T-180 method D
• The minimum soaked Californian Bearing Ratio (CBR) shall
be 30%
By: Girmaw Belete Road Construction
42
Highway Engineering III (CENG 5173)
Road Construction
1.3 Construction of sub-bases
Construction Requirements
• sub-base material shall be spread on the approved sub-grade by mechanical means without
segregation such as grader
• The material shall be loosely spread in layers to give a compacted thickness not
exceeding 200 mm and not less than 100mm. The final compacted layer shall be free
from concentrations of coarse or fine materials.
• The surface of each completed layer shall be moistened prior to the construction of the
succeeding layer.
• The aggregate shall be mixed and the moisture content adjusted to obtain a uniform mixture
with moisture content within 2 per cent of the optimum moisture content. The mixture shall
be spread and shaped on the prepared surface in a uniform layer.
• The material shall be compacted by the use of approved rollers progressing gradually
from the outside towards the center of the layer, except on super-elevated curves, where
the rolling shall begin at the low side and progress to the high side.
• Each layer shall be compacted full width.
• Rolling shall continue until the entire thickness of each layer is thoroughly and uniformly
compacted to a minimum 95 or 97 percent of the modified AASHTO maximum density as
required on the Drawings;
By: Girmaw Belete Road Construction
43
Highway Engineering III (CENG 5173)
Road Construction
1.2 Construction of Subbase

By: Girmaw Belete Road Construction


44
Highway Engineering III (CENG 5173)
Road Construction
1.3 Construction of sub-bases

By: Girmaw Belete Road Construction


45
Highway Engineering III (CENG 5173)
Construction of Gravel Road

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.3 Construction of sub-bases
• Equipment required for sub base construction
• Grader
• Water Truck
• Dump truck
• Roller
• Loader

By: Girmaw Belete Road Construction


47
Highway Engineering III (CENG 5173)
By: Girmaw Belete Road Construction
48
Highway Engineering III (CENG 5173)
Road Construction
1.4 Construction of Gravel Roads
• The gravel wearing course and gravel shoulders shall be constructed to
the dimensions and cross sectional profiles shown on the Drawings.
Material Requirements for Gravel Wearing Course
• The material shall consist of hard durable angular particles produced by crushing rock,
crushing gravel or from natural sources and shall be clean and free from organic
matter, lumps of clay or other deleterious substances.

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.4 Construction of Gravel Roads
Construction Requirements for Gravel Wearing Course
• Gravel wearing course and gravel shoulder material shall be spread by means of graders
• Gravel wearing course and gravel shoulder material shall be compacted by means of self-
propelled or towed steel wheeled rollers.
• Water shall be applied by means of equipment which is capable of distributing the applied
water uniformly over the surface of the layer.
• Oversize Material and Blending
• Methods to reduce oversize
If a significant portion of the gravel material is oversize,
• a portable crusher, or other suitable method as shall be used to reduce the oversize to the maximum size specified.
• In some cases, it may be economic to windrow the oversize material in or adjacent to the borrow pit and reduce the
oversize with a mobile hammer-mill (eg Rockbuster)
• If blending is necessary to achieve the specified shrinkage product or alter the particle size distribution of
the gravel it can be done at the site if proximity exists or at the construction site.
• Alternatively, the mixing shall be done on the road with careful supervision of the dumping and mixing
operations to ensure the correct proportions of materials
• Transport, Placing, Spreading and Compaction
• The material shall be transported in such a way, that no segregation occurs.
• The material shall be placed, spread, broken down, watered not exceeding 200 mm and not less than
100 mm compacted thickness.
By: Girmaw Belete Road Construction
50
Highway Engineering III (CENG 5173)
Road Construction
1.4 Construction of Gravel Roads
• Prior to compaction, the moisture content of the spread material shall be adjusted as necessary either by
the uniform application of water or drying out.
• The material shall be compacted by the use of approved rollers progressing gradually from the outside
towards the center of the layer, except on super elevated curves, where the rolling shall begin at the low
side and progress to the high side. Each succeeding pass shall overlap the previous pass by at least one
third of the roller width.
• Rolling shall continue until the entire thickness of each layer is thoroughly and uniformly
compacted to the specified density,93 or 95% of the maximum dry density
• Testing Frequency
• The minimum testing frequency that will be required from the Contractor in terms of
conditions of contract for the purpose of process control shall be as shown

By: Girmaw Belete Road Construction


51
Highway Engineering III (CENG 5173)
Summary of Gravel Road Construction
Please note that the sequence may get varied as per the site condition

Site Earthwork
Surveying Clearance Road bed preparation
works •Clearing and grubbing
•Roadway excavation
•Embankment
•Removing obstructions like
existing structures,
pavement

Surfacing Works Drainage structure


Wearing course construction Construction
•Culvert(CP,BC and SC)
Sub base construction •Bridge Construction
•Side drainage works

Ancillary works
ROAD FURNITURE AND SIGNAGE

By: Girmaw Belete Road Construction


52
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course

• Base Course. One or more layers of specified material thickness


placed on a sub base or subgrade to support a surface course.

Material Source
• It includes the use of crushed, screened or crushed and screened stones
or gravels, natural gravels, and stabilized base materials.
• The materials used for the construction of road base layers shall be
one of the following as described in the Contract:
• Crushed rock or stone;
• Naturally occurring granular materials and weathered rock,
• either un stabilised or chemically stabilized

By: Girmaw Belete Road Construction


53
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course
• Material Requirements for Crushed Stone
• It is preferable to use crushed aggregate quarry materials GB1 (fresh crushed
rock) as base course materials when available.

• GB2 (crushed gravel or boulder) and GB3 (natural gravels and weathered rock)
may be considered for base course in areas of scarcity of such preferred
materials.

• The material shall be clean and free from organic matter, lumps of clay
or other deleterious substances.

• The material shall be of such a nature that it can be readily


transported, spread and compacted without segregation.

• The flakiness index determined in accordance with BS 812, Part 105


or ASTM D 3398 shall not exceed 30 per cent.

By: Girmaw Belete Road Construction


54
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course
• The fine fraction of a GB1 material shall be non-plastic. If the PI
approaches the upper limit of 6, it is desirable that the fines content
(passing 0.425 mm sieve) be restricted to the lower end of the range
• The in-situ dry density of the placed material should be a minimum of
98% of the maximum dry density
• Crushed stone road base constructed with proper care with GB1 materials
should have CBR values in excess of 100 per cent.

• The strength and durability requirements of crushed stone shall be


assessed using the 10% Fines Aggregate Crushing Test (10% FACT)
(SANS 3001-AG10)
• The modified AIV is the number of blows that yields 5 – 20 %

By: Girmaw Belete Road Construction


55
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course
• The ACV shall be less than 25
• When compacted in the laboratory to 98% of Modified
AASHTO density, the material should have a minimum CBR of
80% after four days immersion in water

By: Girmaw Belete Road Construction


56
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course
Construction Requirements for Crushed Stone Base

• The material shall be laid by a self-propelled paving machine, grader as described in the
Contract .
• Mix the base course materials by one of the following methods to ensure homogeneous
blending and to provide optimum moisture content for compaction:
• Stationary Plant Method. Mix materials in a pugmill. Place the material onto the
roadbed immediately after mixing

• Travel Plant Method. Use a mechanical spreader or windrow-sizing device to place


aggregate. Add and thoroughly mix water with the aggregate using a traveling
mix plant.
• Road Mix Method. Place and mix aggregate on the roadway using motor graders or
similar equipment, adding water during the mixing operation as necessary to provide
optimum moisture content
• The mixing plant shall be either a batch or a continuous type, as approved by the Engineer,
and shall be equipped with satisfactory means of accurately controlling the proportions of
all constituent materials.

By: Girmaw Belete Road Construction


57
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course

Base course watering


Base course mixing with grader

By: Girmaw Belete Road Construction


58
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course

• Compaction shall be carried out using self-propelled 8 – 10 tonnes deadweight


smooth wheeled rollers having a width of roll not less than 450mm; or by multi-
wheeled pneumatic tyred rollers of equivalent mass; or by vibratory rollers of
equivalent compactive performance; or by a combination of these.
• The compacted thickness of each layer should not exceed 200 mm.

By: Girmaw Belete Road Construction


59
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course

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By: Girmaw Belete Road Construction


60
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course
• Each succeeding pass shall overlap the previous pass by at least one third of the
roller width. Rolling shall continue until the entire thickness of each layer is
thoroughly and uniformly compacted to the specified density.

• Any area, which is inaccessible to rolling equipment, shall be compacted by


means of mechanical tampers or other equipment approved by theEngineer.

• Upon completion of compaction, the surface of the completed layer shall be


tightly bound, free from movement under the compaction plant, and free from
laminations, ridges, cracks or loose or segregated material.
• The material shall be of such a nature that it can be readily excavated,
transported, spread and compacted without segregation.

• The material shall be spread in layers not exceeding 200 mm and not less than
100 mm compacted thickness.

By: Girmaw Belete Road Construction


61
Highway Engineering III (CENG 5173)
Road Construction
1.5 Construction of Base Course
• The material shall be compacted by the use of approved rollers
progressing gradually from the outside towards the centre of the layer,
except on super elevated curves, where the rolling shall begin at the low
side and progress to the high side.
• The in-situ density of the completed layer shall not be less than 98% of
the maximum dry density determined in accordance with the
requirements of AASHTO T-180 method D

By: Girmaw Belete Road Construction


62
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization
• It includes stabilization of materials used in the construction
of the roadbed and/or subgrade; sub-base and road base;
• by the addition of a chemical stabilizing agent; or
• by the mechanical modification of the material by mixing various materials; or
• by treating the material with a bituminous stabilizing agent

• Material stabilization is made to improve the properties


materials to be used for road bed and/or subgrade, sub-base
and road base to comply specification requirements.

By: Girmaw Belete Road Construction


63
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization
• Road Bed and/or Subgrade Stabilization
Road bed and/or subgrade materials shall be considered for
stabilization under the following circumstances:

• To establish a dryer construction platform in wet soils to facilitate the


compaction of the upper layers.
• To strengthen a weak soil and restrict the volume change potential of a highly
plastic (expansive) or compressible soil. In this case the modified soil shall
provide a structural component to the pavement.
• Where a thin zone or short length of road bed or subgrade is subject to
improvement, removal and replacement shall be the preferred alternative
unless a suitable replacement soil is not economically available.

By: Girmaw Belete Road Construction


64
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization
(ii) Stabilized Sub-base and Road Base Material
• The stabilization of materials for use as sub-base and road base shall provide a permanent
improvement to the unstabilised materials to meet the requirements the Specifications
• Stabilization is made
• by the addition of a chemical stabilizing agent; or
• by the mechanical modification of the material by mixing various materials; or
• by treating the material with a bituminous stabilizing agent.
• It includes the furnishing, spreading and mixing-in of the stabilizing agent or soil
binder. In the case of chemically stabilized materials the layer is also given a curing
treatment
• Stabilizing Agents
• Ordinary Portland Cement
• Lime
• Soil Binder
• Bituminous Stabilizing Agents
D:\ARRA files\ARRA\Road Resource Adm\2007 budget year\ANYWay\AACRA Bole Secondary School Ring Road Project.wmv

By: Girmaw Belete Road Construction


65
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Chemical Stabilization
Construction
•Preparing the layer
The material to be stabilized using stabilizers shall be prepared and placed as specified in the
respective Divisions for subgrade, sub-base and road base
•Application of Stabilizing Agent
The stabilising agent shall be spread uniformly over the full width of the layer by means of an
approved type of mechanical spreader at the prescribed rate of application in a continuous
operation, or it may be spread by hand After preparation of the layer of soil or gravel
•Mixing in of Stabilizing Agent
• Immediately after the stabilising agent has been spread, it shall be thoroughly mixed
with the material for the full depth of treatment

• Mixing shall be done by grader, disc harrow, rotary mixer or equivalent plant working
over the full area and depth of the layer to be stabilized
• Watering
Immediately after the stabilising agent has been properly mixed with the material, the
moisture content of the mixture shall be determined and the required amount of water
•Compaction
complete the final compaction and finishing within 12 hours of the final mixing
By: Girmaw Belete Road Construction
66
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Chemical Stabilization
• Curing of Stabilized Work
• The stabilized layer shall be protected against rapid drying out for at least seven
(7) days following completion of the layer.
• The stabilizing agent shall only be applied to such an area that all
processing, watering, compacting and finishing can be completed within
the period stated in Table 4503/1:

By: Girmaw Belete Road Construction


67
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Mechanical Modification

• Mechanical modifications: consists of


• the addition of an approved soil binder to material to improve its properties, or
• the mixing of material originating from various sources

• It is an improvement of an available material by blending it with one


or more material in order to improve the particle size distribution
and plasticity characteristics.
• The principal properties affecting the stability of compacted base or

sub-base materials are internal friction and cohesion.

By: Girmaw Belete Road Construction


68
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Mechanical Modification

• Modifying Soil and Gravel by the Addition of a Soil Binder


This process involves the addition and mixing of an approved soil binder as specified
in Subclause 4502(b)(iii), which shall not exceed 20% by mass of the total mixture, to
the material to be improved.
The material to be treated shall be prepared and spread to the required loose
thickness as specified inthe respective Divisions for sub grade, sub-bases and bases.

• Mixing Materials from Various Sources

• The mixing of materials from various sources requires the material from the first
source to be dumped
onto the road, prepared, broken down and spread in a layer of uniform thickness,
after which it is
lightly rolled with a steel-wheeled roller.
The material from the second source shall then be dumped onto the road, prepared,
broken down and
evenly spread across the first layer, following which, the two materials shall be
thoroughly mixed.

By: Girmaw Belete Road Construction


69
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Bituminous Stabilisation

• Bituminous materials are used as stabilizers to retard or completely


stop moisture absorption by coating soil or aggregate grains in the soil-
aggregate mixture in cohesive soils.

• Bituminous stabilization is used with non- cohesive granular materials-


where the bitumen adds cohesive strength; and with cohesive materials
–where the bitumen “waterproofs” the soil thus reducing loss of
strength with increase in moisture content.

• The bituminous materials that are used for stabilization


works are mostly penetration grade bitumen and
cutback bitumen

By: Girmaw Belete Road Construction


70
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Bituminous Stabilisation

• Both effects take place partly from the formation of bituminous film
around the soil particles which bonds them together and prevents the
absorption of water, and partly from simple blocking of the pores,
preventing water from entering the soil mass.

• The purpose of using bitumen as a stabilizer in cohesive soils is to


waterproof them as a means to maintain them at low moisture contents
and high bearing capacities.
• In the non-cohesive granular materials, bitumen serves as a bonding or
cementing agent between particles.

By: Girmaw Belete Road Construction


71
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Bituminous Stabilisation

• Bituminous stabilized materials:

• Methods of mixing soil-bitumen materials are generally the same as those


previously described. An additional step, of course, involves the application of
the necessary bituminous material and its uniform distribution through the
mixture.

• In the case of road mixing, the bituminous material which is moderately


heated to the specified temperature for application is applied in a measured
amounts by a pressure distributor, along with water applied separately, and
the entire mix thoroughly blended by motor graders disk harrows, rotary
speed mixers, and so on.

• Where a travelling or central mixing plant is used, the measured


amount of binder is incorporated in the plant.

By: Girmaw Belete Road Construction


72
Highway Engineering III (CENG 5173)
Road Construction
1.6 Material Stabilization…Bituminous Stabilisation
• Preparing the Material

• Mixing in of Active Filler


• Where an active filler (lime or cement) has been, or if so required by the
Engineer, to assist the extraction of water phase from the bitumen emulsion to
facilitate the breaking of the emulsion, it shall first be spread and mixed in

• Heating and Diluting the Bituminous Stabilising Agent

• Applying the Stabilizing Agent


• After preparing the material, the stabilising agent shall be uniformly applied by an
approved binder
distributor in a continuous process
• at the prescribed rate of application over the full area of the layer.
• Compaction

By: Girmaw Belete Road Construction


73
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement
• Surface Course. Pavement structure layer(s) designed to accommodate the traffic load. The top layer
resists skidding, traffic abrasion, and the disintegrating effects of climate and is sometimes called the
Wearing Course
• Hot Mix Asphalt Concrete Construction

By: Girmaw Belete Road Construction


74
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

By: Girmaw Belete Road Construction


75
Highway Engineering III (CENG 5173)
By: Girmaw Belete Road Construction
76
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement
Prime Coat
• bituminous binder to a non-bituminous granular pavement layer or chemically stabilised layers as a preliminary treatment prior to the
application of a bituminous base or surfacing.
• Why Bituminous Prime Coat ?
• Temporary waterproofing
• To coat and bond loose mineral particles on the surface of the base
• to plunge capillary voids
• Promotes bond between base and HMA
• Hardens or toughens the surface
• Bind the finer particles in the upper portion of the granular material to accommodate light
construction traffic for a short period until the new surfacing can be placed if approved by the
Engineer

Prime coat material


• MC 30 cutback bitumen complying with AASHTO M 82 or SANS 4001-BT2;
• Invert bitumen emulsion complying with SANS 4001-BT5 (previously SABS 1260).
• Invert emulsion are distinct from normal bitumen-dispersed-in-water emulsion in that
the water is
dispersed in the binder phase. These types of emulsions are manufactured with cutback
bitumens and shall have water contents of less than 20%.
• At least 48 h before paving
• Should be absorbed completely in 24 h
• If not absorbed, blot with sand and prevent it from being picked by under traffic
• All loose sand should be swept from the base prior to placing additional asphalt courses
By: Girmaw Belete Road Construction
77
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement

• Mineral Aggregate for Blinding


The Aggregate used for blinding the primed surface shall
consist of crushed rock or river sand, with 100% passing the
6.7 mm sieve and not more than 10% passing the 2.36 mm
sieve
• Equipment
• Bitumen Binder Distributor;
• Water sprinkler;
• Mechanical sweepers;
• Air blowers;
• Other equipment such as hand brooms, reinforced paper for joints, string,
nails, and all other ancillary equipment required to carry out the
operation efficiently and neatly.

By: Girmaw Belete Road Construction


78
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement
• No prime shall be applied under the following adverse
conditions:
• During foggy or wet conditions;
• When rain is imminent;
• When wind is sufficiently strong to cause uneven spraying;
• When the surface of the layer is wet, i.e. more than damp;
• When at any position the moisture content of the top 25 mm of the layer
to be primed is greater than 70% of the optimum moisture content of the
material in the layer;
• When the temperature of the surface immediately prior to commencing
the application of the prime is below or, in the opinion of the Engineer,
likely to fall below 100 C;
• After sunset.

By: Girmaw Belete Road Construction


79
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement
• All superficial laitance or “biscuit” layers of fine material and animal droppings shall
be removed and may require the use of water, brooms and spades

• Not more than 24 hours before spraying, the layer to be primed shall be broomed and
cleaned of all loose or deleterious material by means of a rotary broom and hand
brooms
• A light spray of water, sufficient to dampen the surface, shall be applied uniformly to
the layer immediately before the application of the prime.
• the application rates selected shall render a net residual binder of 0.35 kg/m². This
equates to a spray rate of 0.7 l/m² for MC 30 and 0.95 l/m² for inverted bitumen
emulsion.
• After the prime has penetrated sufficiently, surplus prime shall be covered with damp
crusher sand, which shall be worked into it by means of hand brooms in order to
absorb the surplus prime. As soon as it is saturated with prime, the crusher sand shall
be swept off the primed surface. The process shall be repeated until no surplus prime
remains on the primed surface.

By: Girmaw Belete Road Construction


80
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement

Primed based course


By: Girmaw Belete Road Construction
81
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement
• Tack Coat –an application of bituminous binder to an existing surface to
ensure bond between new and old surface
• Objective of tack coat
• Promotes necessary bond between old surface which is dry and hungry and new
treatment which is thin.
• Thin carpets have a tendency to peel of under excessive tangential stress unless bonded
to the old surface.
• Too much of tack coat-may create plane of slippage between pavement courses i.e
may act as lubricant than as adhesive. It may create Fat Spots or bleeding on the
surface of the new pavement.
• Typical spray In general, for a stable grade emulsion diluted to have a 30%
bitumen content, the rate of application of tack coat shall be 0.2 to 0.6 litre/m2
depending on the surface to be treated with tack coat;
• Twine-reinforced paper or other suitable approved material shall be used at all
joints at the beginning and end of all sprays in order to obtain a neat start and cut-
off lines
• The tack coat shall not be applied more than 24 hours before the paving is done
By: Girmaw Belete Road Construction
82
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement
• The commonly practiced Bituminous pavements in Ethiopia are
• Hot Mix Asphalt Concrete Construction
• Surface Bituminous Treatment
• sometimes Cold Mix Asphalt concrete
• Hot Mix Asphalt-consists of a combination of aggregate uniformly mixed and coated
with asphalt cement
• Are prepared at an asphalt mixing plant
• Aggregates are blended, heated and dried, and mixed with asphalt cement to produce
a hot asphalt paving mixture
• Operations of batching mixing plant
• Cold aggregate storage
• Proportioning
• Drying/heating
• Screening
• Hot aggregate storage
• Measuring and mixing aggregates with mixing
• Discharging in to trucks, storage silo or surge bin
By: Girmaw Belete Road Construction
83
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement

By: Girmaw Belete Road Construction


84
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement

By: Girmaw Belete Road Construction


85
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement

By: Girmaw Belete Road Construction


86
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement

By: Girmaw Belete Road Construction


87
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement

By: Girmaw Belete Road Construction


88
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

• Obtained from hot mix plant which provides heating aggregates(to avoid
all traces of moisture and improve adhesion property. Preheating of
aggregates ensures final mix is heat)
• Proportion of ingredients determined in laboratory, job mix formula-
usually two job mix formula,viz:for the cold aggregates feed and hot bin
• Aggregates are heated to temperature of 155-163oc,depending up on heat
loss from the dryer to roadside
• Binder generally heated 150-177
• Filler not heated
• Dry materials first introduced in to mixer and mixed dry for 15 seconds
• Binder then introduced and mixing continued for another 30-45 seconds

By: Girmaw Belete Road Construction


89
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA
• Trucks for transporting asphaltic mixes
• The asphaltic mixes shall be transported from the mixing plant to the spreader
in trucks having cargo trays with beds and sides, which are clean and smooth,
without gaps, holes or openings.
• The bed and sides shall be treated to prevent adhesion of the mixture to the
truck bodies. A thin film of soapy water or vegetable oil may be used to
prevent adhesion but petroleum products shall not be used for this purpose.
• All trucks used for transporting hot asphalt shall be equipped with waterproof
canvas covers, insulated metal sheets or other suitable approved covers to
minimize temperature loss from the asphaltic mix.
• Such covers shall be securely fixed over the hot asphaltic mix from the time of
loading at the mixing plant until immediately prior to the discharge of the
asphaltic mix into the paver

By: Girmaw Belete Road Construction


90
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA
Spreading
• (i) Paver
• The asphalt paver spreads the mixture in a uniform layer of
desired thickness and shape, or finishes the layer to the
desired elevation and cross section, ready for compaction
• Place a layer less than 25mm to 250mm in thickness over a
width of 1.8m-9.8m
• All pavers shall be fitted with automatic electronic screed controls to
maintain the required levels, cambers and cross-falls .
• Paving shall, if possible, commence at the bottom of the grades and the
lower edges of super elevated curves. Paving shall be carried out up the
grade on grades steeper than 5%.

By: Girmaw Belete Road Construction


91
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

By: Girmaw Belete Road Construction


92
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA

By: Girmaw Belete Road Construction


93
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA

By: Girmaw Belete Road Construction


94
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA

By: Girmaw Belete Road Construction


95
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA
Compaction
• Break down rolling-
• best accomplished with steel-wheeled rollers
• Compacts material compaction beyond the compaction imparted by the pavet

• Finish rolling-removes roller marks and other blemishes left from previous rolling
• Accomplished with Pneumatic rollers
The following requirements shall apply to rolling and compacting generally:
• The material shall not be excessively displaced in a longitudinal or transverse direction
especially when changing gears, stopping or starting rollers.
• No cracks or hair cracks shall be formed and the bond with the underlying layer shall not be
broken.
• The density shall be uniform over the whole area of the layer and extend over the full depth
ofthe layer.
• Rollers shall not be left standing on the asphalt layer before it has been fully compacted and
before the layer surface temperature has dropped below 60ºC.
• In restricted areas where the specified rollers cannot be used, compaction shall be carried out
with hand-operated mechanical compaction equipment or approved smaller vibratory rollers.
The prescribed density requirements remain applicable throughout over the full layer
thickness irrespective of the method of compaction.
By: Girmaw Belete Road Construction
96
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA
• The rolling starts from the edge of the pavement and proceeds to the crown, overlapping
on successive trips by the width of the rear wheel for the three wheel rollers and by half
the width of the wheel for a tandom roller.
• For super elevated curves, rolling should start at inner side o the curve and proceeds
towards the outer side.
• Number of passes of roller determined by the required density

By: Girmaw Belete Road Construction


97
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

By: Girmaw Belete Road Construction


98
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA

By: Girmaw Belete Road Construction


99
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA

By: Girmaw Belete Road Construction


100
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

By: Girmaw Belete Road Construction


101
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA

Compaction

By: Girmaw Belete Road Construction


102
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement…HMA

Compaction

By: Girmaw Belete Road Construction


103
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

By: Girmaw Belete Road Construction


104
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

By: Girmaw Belete Road Construction


105
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

By: Girmaw Belete Road Construction


106
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…HMA

• Field test
• Most common field test-density test-
Core test required
• Nuclear density meters are being
employed in modern practice. But
needs calibration on bituminous
mix. It is reduces time usage.
• Degree of compaction-ratio between
density achieved in the field and
reference density
• Degree of compaction=field
density/reference density*100
• Other common test-layer thickness,
again checked by measuring test
cores obtained by drilling.
• Unevenness checked by 3m long
straight edge and the transverse
profile by camber board

By: Girmaw Belete Road Construction


107
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…Cold Mix

• Cold Mix Asphalt concrete Construction


• Mixes made with emulsified or cut back asphalt
• Mixing may be along the roadway or in a stationary mixing facility
• Mix spread and compacted at atmospheric temperature
• Suitability
• May be used for surface,base or sub base courses if the pavement structure properly designed
• Cold surface courses suitable for light and medium traffic
• Construction methods
• Road bed preparation
• road bed must be shaped and compacted
• The surface must be swept with power broom to remove dirt and other foreign matter
• Depending on the condition prime coat may be necessary.The procedure as indicated in
the above slides
• Windrows
• Aggregate is windrowed for road mix construction
• Adding asphalt
• Add asphalt either with pressure distributer ahead of mixing process or in case of travel
mixers, during the mixing process.

By: Girmaw Belete Road Construction


108
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…Cold Mix
• Method of cold mix preparation
• Blade mixing
• Accomplished with motor graders
• Aggregate first air dried by manipulating across the road with grader to expose it to
the and air
• The windrow flattened or spread uniformly over half the roadway
• Asphalt then applied from distributor an about two or three spraying passes
• Up on receiving full predetermined asphalt amount ,the mix will be worked back
and forth across the roadway with blade till aggregates are coated and the mix has
uniform appearance
• After mixing and aeration have been made,the windrow is manipulated to one side
of the area to be surfaced in preparation for spreading
• Travel plant mixing
• Self propelled pugmill plant that mix aggregates with asphalt,appled at a controlled
rate as they move along the road
• Stationary mixing facility

By: Girmaw Belete Road Construction


109
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement…Cold Mix
• Aeration/Spreading/Compaction
• Proper aeration required for mixes made with cutback bitumen
• Point of adequate aeration is often made by experience and judgment
• Mixures are spread and shaped to the desired cross section by
successive passes with motor grader
• Roller should follow directly behind the motor grader to eliminate
wheel tracks
• Compaction should not be attempted till there is a moisture reduction.
• For a smooth finish riding surface,the motor grader should be used to
trim and level as the rollers complete compaction of the lift

By: Girmaw Belete Road Construction


110
Highway Engineering III (CENG 5173)
Base Course

Sub base

By: Girmaw Belete Road Construction


111
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface Treatment
• Surface treatment/Surface seals
• Also called surface dressing
• surface seals refer to the wearing surface of a road using a thin layer or layers of bitumen and
mineral aggregate to improve the functional aspects of a
• surfaced road in terms of waterproofing the underlying pavement layers from
water ingress;
• improved riding quality;
• and improved skid resistance.
• provide no structural strength component to the pavement
• Single surface treatment-
• used as a wearing and water proofing course
• Consists of a sprayed application of asphalt immediately covered by a single layer
of aggregates of uniform size.
• Multiple Surface treatment-
• Used for increasing traffic thickness may reach 1.5inch(3.81cm)

• Provides also a wearing and water proofing course and graeter durability than
single surface treatment
• May add some strength to the pavement
• Consists two or more alternate applications
By: Girmaw Belete of asphalt and aggregate
Road Construction
112
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface Treatment
• (a) Bituminous Binders
• The selection of bituminous binders is dictated by several factors.
• These include the material that has to be bound together;
• prevailing environmental conditions of climate and traffic both in service
and during construction;
• geographic location;
• topography;
• traffic loading;
• costs and budgets;
• specified construction methods; and various other specific requirements imposed by the
Client
• Penetration Grade Bitumen (Based on SANS 4001-BT1) ; 70/100 and 150/200
• Cutback Bitumen (Based on SANS 4001-BT2, previously SANS 308) :MC3000
• (b) Aggregate Chippings for Surface Seals
The chippings used in surface seals should be:
• Strong, durable and sound;
• Single sized within a practical tolerance;
• Clean and free from dust;
• Cubical in shape, not rounded or flaky;
• Not susceptible to the polishing action of traffic
By: Girmaw Belete Road Construction
113
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface Treatment
• Construction Equipment:
• Bitumen Distributor
• Mechanical Sweepers or Broom
• Air blowers
• Chip Spreaders
• Chip spreaders, whether self-propelled or truck-mounted shall be capable of:Spreading
the stone uniformly, both transversely and longitudinally, over widths from 1.5m to
4.0m;
• Adjustment to permit variation of the rate of application;
• Stopping and starting without forming a joint line; and Keeping pace with the binder
distributor.
• At least two chip spreaders shall be provided, one of which shall be self-propelled.
Rollers
• Pneumatic-tyred Rollers
• Rubber-soled Flat Rollers
• Steel-tyred Flat Rollers
Trucks for Transportation of Chippings

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement….Surface Treatment
Chip spreader

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface
Treatment
• Sand seal-application of asphalt material covered with fine aggregate
• The fine aggregate may be clean sand or screenings
• May be used to improve skid resistance of slippery pavements
• Or to seal against air and water infiltration
• Construction procedure similar to single surface treartment
• Typically, asphalt is sprayed on to the surface to be treated followed by application of sand

• Construction Sequence
1. Prime coat-used to treat an untreated base for an asphalt surface
• Usually MC-30,1-1-.2 litres/m2
• Asphalt distributer with attached heating bituminous material required
• Asphalt distributer shall have clean spray nozzle, included with tachometr,pressure
gauges accurate measuring devices or calibrated tanks and thermometer for
measuring temperatures in the tanker
• No traffic on the primed surface till it penetrated and dried. If required to
pass,blotter material shall be sprayed to allow traffic at a speed less than 20kph
2. Clearing the existing Surface
• To be cleaned with power broom or power blower if dictated so that all
loose dirt and objectionable material be cleaned and removed away
• If necessary light application of water may be made to moisten the
remaining dust from cleaning and absorption of prim coat
By: Girmaw Belete Road Construction
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Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface
Treatment
3. Spraying the binder/Asphalt
• Spray asphalt at a specified rate
• Line should be placed along the edge of the road to guide the driver of the distributor truck
• Application of bitumen can be manually or mechanical sprayers
• The heated binder is sprayed longitudinally along the road not transversally through nozzles
spaced along a horizontal pipe, to avoid corrugations.
4. Spreading the aggregate-at a specified rate behind the asphalt application
• Can be spread with mechanical or self propelled machine.
• The cover aggregates are usually spread by manual, dump trucks or Chip spreaders.
• These are calibrated and flow of aggregate can adjusted
• A quick check of rate application-laying 1m2 of cloth or aluminum sheet metal on the
pavement and by passing over it with the spreader and measuring the weight.
5. Rolling-
• to seat the particles in the asphalt thus promotes the bond necessary to resist traffic stresses
• Pneumatic tyred roller recommendable since it gives uniform pressure over the entire area.
• Rolling continues till aggregate is properly seated in the asphaltic membrane
• As soon as the asphalt has definite set or hardening, rolling discontinued to prevent bond
between the surface and aggregate from being broken by the roller.
• Rolling begins at lower edge of treatment and proceeds in a longitudinal direction, working
towards the center of the road. Each tip should overlap the previous one by about one-half the
width of the front wheels.

By: Girmaw Belete Road Construction


117
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface
Treatment
• Construction procedure for Multiple surface treatment is essentially
the same as the single surface treatment except that the process is
repeated either two or three times
• Example procedure for DBST
• Place the first course asphalt
• Place the first course aggregate
• Rolling the first aggregate
• Placing the second course asphalt
• Placing the second course aggregate
• Rolling the second course aggregate
• There should be proper curing periods between each treatment,
about 24hrs and the same will be for opening the road to traffic

By: Girmaw Belete Road Construction


118
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous
pavement….Surface Treatment

Chip spreading using Dump truck

By: Girmaw Belete Road Construction


119
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface
Treatment

Self propelled chip spreader

By: Girmaw Belete Road Construction


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Highway Engineering III (CENG 5173)
By: Girmaw Belete Road Construction
121
Highway Engineering III (CENG 5173)
Road Construction
1.7 Construction of Bituminous pavement….Surface
Treatment

By: Girmaw Belete Road Construction


122
Highway Engineering III (CENG 5173)
Summary of AC Road Construction
Please note that the sequence may get varied as per the site condition

By: Girmaw Belete Road Construction


123
Highway Engineering III (CENG 5173)
Road Construction
1.8 Construction of Cement Concrete/Rigid pavement
• Rigid pavement construction is a surface course of Portland cement concrete, with or without
reinforcement, and includes, inter alia, the specifications for materials, the placing and compacting
of concrete, applying the surface texture, and constructing the joints.

• Concrete pavements have not been used extensively in most tropical countries including
Ethiopia. This is mainly due to a lack of tradition and experience in their design and construction.

• Rigid pavements have often been considered only for heavily trafficked roads because of their initial
high cost and their excellent traffic carrying capacity construction of a surface course of Portland
cement concrete, with or without reinforcement.
• Rigid pavements have the following advantages:

• It is feasible to design rigid pavements for very long design lives, up to 60 years and
deterioration is usually very slow.
• Little maintenance is generally required.
• Rigid pavements do not deform under traffic.
• A relatively thin pavement slab distributes the load over a wide area due to its high
rigidity.
• Concrete is very resistant to abrasion making the anti-skidding surface texture last
longer.
• In the absence of deleterious materials (either in the aggregate or entering the concrete in
solution from an external source)By:and unlike
Girmaw Belete flexible pavements, concrete does not suffer 124
Road Construction
Highway Engineering III (CENG 5173)
significant deterioration from weathering. Neither its strength nor its stiffness is significantly
Road Construction
1.8 Construction of Cement Concrete/Rigid pavement

Rigid pavement construction at Woreta-Woldia Junction

By: Girmaw Belete Road Construction


125
Highway Engineering III (CENG 5173)
1.8 Construction
of Cement
Concrete/Rigid
pavement
A rigid concrete pavement
comprises the
• concrete slab supported
by its foundation which
may be a sub base
constructed directly over
the subgrade.
• In the case of low
strength subgrades, the
foundation may include
a capping layer
separating the sub base
from the subgrade.
Rigid pavement structure
By: Girmaw Belete Road Construction
126
Highway Engineering III (CENG 5173)
Road Construction
1.8 Construction of Cement Concrete/Rigid pavement
•Material for Concrete
(a) Cement
(b) Water
(c) Admixtures to concrete
(d) Air-entraining admixtures
(e) Aggregates (Fine and Coarse)
(f) Materials for joints -Joint Sealers, Preformed Expansion Joint
Filler
(g) Materials for reinforcing steel, tie-bars and dowels
(h) Curing materials -Liquid membrane , Waterproof paper
(i)Separation membrane

By: Girmaw Belete Road Construction


127
Highway Engineering III (CENG 5173)
Road Construction
1.8 Construction of Cement Concrete/Rigid
pavement
• Concrete strength
• ERA 2013:minimum compressive strength after 28 days of 30 MPa up
to a maximum of 50 MPa.
• Min cement content:320kg/m3
• The water:cement ratio, including moisture on the aggregates, shall be
not more than 0.53 .
• Mix design is required

By: Girmaw Belete Road Construction


128
Highway Engineering III (CENG 5173)
Road Construction
1.8 Construction of
Cement Concrete/Rigid
pavement
The basic steps involved in
the construction of a rigid
pavement can be
summarized as follows:
(1) prepare the foundation
for the slab;
(2) place the forms (if
fixed-forms are to be used);
(3) install the joint
assemblies;
(4) batch the cement
and aggregates and mix and
transport them to the site;
(5) lay and finish the
concrete; and
(6) cure the concrete.
By: Girmaw Belete Road Construction
129
Highway Engineering III (CENG 5173)
Road Construction
1.8 Construction of Cement Concrete/Rigid pavement
• Preparing the Underlying Layers
(a) Preparation of sub-base
• The sub-base shall include an area 900 mm in width extending beyond the edges of the road base or
pavement unless shown otherwise on the Drawings.
• When kerb and gutter is constructed contiguous with the pavement, the sub-base shall include an area
610 mm in width extending beyond the back of the curb and gutter.
• The Sub-base shall be completed for at least 800 metres in advance of concrete placing operations
when this distance is available.

Applying a bituminous prime coat or placing a separating membrane


Unless specified in the project specification prime coat shall be used
Before any pavement concrete is placed, the bituminous prime coat shall be checked and any areas
having deficient or poor coverage, or where the bituminous coating has been damaged, shall be
repaired as directed by the Engineer. The sprayed surface shall then be thoroughly cleaned.
The bituminous prime coat shall be dry before any reinforcing steel, tie bars, dowels or concrete may be
placed.

Separation membranes, to be used between jointed reinforced concrete surface slabs or unreinforced
concrete surface slabs and the sub-base, shall be laid flat without creases. Where an overlap of plastic
sheets is necessary, this shall be at least 300 mm.
By: Girmaw Belete Road Construction
130
Highway Engineering III (CENG 5173)
Road Construction
1.8 Construction of Cement Concrete/Rigid
pavement
• Transport of the concrete

• Sufficient trucks must be available


to continuously supply the paving
machines

By: Girmaw Belete Road Construction


131
Highway Engineering III (CENG 5173)
Road Construction
1.8 Construction of Cement Concrete/Rigid pavement
• PLACING THE CONCRETE

• Fixed-form concrete paving


Setting up the side forms
• In order to place the side forms properly the alignment of the road has to
be staked out carefully
• accomplished by driving
iron rods firmly into the subgrade soil or the base at a spacing of
maximum 5 m
• After the elevations corresponding to the top of the
forms have been marked on the rods, they are connected with a
string line that represents the top of the forms
Equipment
manual needle vibrators and vibrating screed, equipment for floating the
concrete surface, for applying the curing compound, for sawing the joint

By: Girmaw Belete Road Construction


132
Highway Engineering III (CENG 5173)
አመሰግናለሁ ! ! !
እሴብሆ ! !
Thank you!
By: Girmaw Belete Road Construction
133
Highway Engineering III (CENG 5173)
Questions???

By: Girmaw Belete Road Construction


134
Highway Engineering III (CENG 5173)

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