ROAD CONSTUCTION

METHODs

Road construction methods:Various method under this heading are: Earth road method.
Gravel road method.
Water Bound Macadam method.
Bituminous method.
Concrete Cement road method.

PAVEMENT TYPES
The selection of base course and the surface course
depends upon the following factors:
Type and intensity of traffic
Funds available
Sub grade soil and drainage conditions
Availability of construction materials at site
Climatic conditions
Plants and equipment available
Time available

Earth road method

It mainly consist of mainly earth as raw

material which is to be compacted.

It is the cheapest type of road prepared from
natural soil.
It has high camber to avoid erosion due to
water in rainy season.

Material Specifications

Base Course
Clay Content

<5%

Wearing
Course
10%18%

Silt Content

9%32%

5%15%

Sand Content

60%80%

65%80%

Liquid Limit
Plasticity Index

<35%

<35%

<6 %

4%10%

The highway construction project may be

broadly divided in two phases

Earthwork and preparation of sub grade

Pavement structure

Construction Procedure
It consist of :Clearing of site .
Excavation and construction of fills to bring the road to a desired grade.
Shaping the sub grade.
Then the borrowed soil is dump on the sub grade and well compacted
,depth not exceed 10 cm .
Make the soil up to O.M.C level.
Pavement Constructionmixed soil is spread out in layer sand
compacted with compacted thickness not exceeding 10 cm.
Desirable to have at least 95% Dry Density
Steep camber1 in 20 to 1 in 33

After this it is allowed to dry for few days before opening to traffic.

Merits
It has following merits:It is cheap.
It has easy construction.
It can be build with less skill.

Demerits of Earth Road

Its demerits contains: It has low bearing capacity .
Mainly for poor places.
It get eroded vary quickly.
It become slippery when wet.

Gravel road method

It mainly consist of crushed stone as their raw

material.
It is superior to earth road .
It consist of two method:

A.Feather edge type:-

In this the sub

grade is uneven and the construction is done
over it to obtain the desired cross slope.

B. Trench type:-

In this sub grade is

prepared by excavating a shallow trench.

Procedure for construction

It consist of the : Clean the area.
Make the sub grade up to desired cross slope.
Crushed gravel aggregates are placed carefully
in the trench so as to avoid segregation .
Provide proper camber.
Some water may be used to make there
compaction effective.
Left for few days before opening.

The gravel used consists of varying amount

of crushed stone, sand, and fines. Fines are
silt or clay particles smaller than .075
millimetres , which can act as a binder.

Demerits
Its demerits are: It does not provide comfortable ride.
It become detereoted very soon.
It can not hold very heavy traffic.
It can not hold rain.

Merits
Its merits are: It is superior to earth road.
It does not become slippery when wet.
It maintenance coat is low.
It can hold medium traffic.
It is easily constructed.
It is cheap.

Water Bound Macadam

Road Method
By John Macadam
Made of crushed or broken aggregate

mechanically interlocked by rolling and the voids

filled with screening and binding material with the
assistance of water
Used as a Sub-base, base course or surface

course
Thickness ranges from 10 to 7.5 cm depending on

the size and gradation of the aggregates used

SPECIFICATIONS
Type of Course aggregates
Generally consists of hard varieties of crushed
aggregates or broken stones

Requirements for pavement layer

Property

Sub-base Base
course

Surfacing
course

Losangeles abrasion 60

50

40

Impact value

50

40

30

Flakiness index

15

15

Size and grading of coarse aggregate

Grading
No.

Size
range,mm

Sieve size
mm

% passing the sieve by

wt.

90 to 45

125
90
63
45
22.4

100
95-100
25-60
0-15
0-5

63 to 45

90
63
53
45
22.4

100
90-100
25-75
0-15
0-5

50 to 22.4

63
53
45
22.4
11.20

100
95-100
65-90
0-10
0-5

SCREENINGS
Used to fill up the voids in the compacted

layer of coarse aggregates

Non plastic materials like Moorum or gravel
LL
< 20%
PI
< 6%
* Portion of material passing 0.075 mm < 10%

The grading of screenings for WBM construction

Grading

Size of
screening
Mm

Sieve
size mm

% passing
the sieve,
wt

13.2

13.2
11.20
5.60
180 micron

100
95-100
15-35
0-10

11.2

11.20
5.60
180 micron

100
90-100
15-35

Binding material
Fine grained material is used to prevent

ravelling of the stones.

P.I 4 % 9% for surface course
P.I
<6%
for base course

Note: If the screenings used consists of

crushable material like moorum or soft
gravel, there is no need to apply binding
material.

Construction procedure
Preparation of foundation for receiving the WBM course
Maybe either sub grade or base or subbase course

Provision of Lateral confinement

Done by construction the shoulders for a thickness equal to that of WBM layer

and trimming the inner side vertically

Spreading of Coarse aggregatesWBM course compacted thickness of 7.5cm

RollingCompactionrollersstarting from edge sand then shifted to the centre
Application of screenings
Sprinkling and Grouting- Water is sprinkled, swept and rolled Additionally

screenings till coarse aggregates are well bonded and firmly set
Application of Binding Material
Surface is sprinkled with water and rolling is done
Setting and Drying

Merits
It has following merits:
It provide base coarse for top surface.
It can be used with little care.
It is a cheap method.
It introduce the concept of sub-base drainage.

Demerits
It has following demerits: It detereoted very easily.
It can not be used without surface

covering.
It aggregates get loose when water loose
from them.

Bituminous Pavements
It is the most common type of road construction.
It main purpose is to protect the sub-base coarse from
wearing and tearing and to provide a smooth riding
comfort.

Types of bituminous concrete

Interface Treatments prime coat &tack coat

Surface Dressing and Seal Coat
Grouted or penetration type constructions
penetration macadam, Builtup Spray grout
Premix Bituminous bound macadam, carpet,
Bituminous Concrete, Sheet Asphalt or rolled
asphalt, Mastic Asphalt

Interface Treatment
Thin layer of bituminous binderto provide bond
between old and new layers
Prime Coat
First application of low viscosity liquid
bituminous material over an existing porous or
adsorbent pavement material like WBM base
course
Objective is to plug the capillary voids and bond
loose material using a binder of low viscosity
Allowed to cure for at least 24 hours

Tack Coat
Application of bituminous material over an

existing pavement surface that is relatively

impervious
Promo test bond between old and new
surface
Binder does not penetrate into the layer
&remains at the surface

Bituminous Surface Dressing (BSD)

Thin film of bituminous binder is sprayed on the
road surface covered by a coat of aggregates
and rolled
Functions
Thin wearing course of pavement and protect
base course
Water proof the pavement surface and
prevent surface water infiltration
Provide dust free surface in dry weather and
mud free surface in wet weather

Seal Coat

- Top coat over pervious bituminous pavements

such as
premixed carpet and grouted macadam
- Thin surface treatment or single coat dressing
applied
over an existing black top surface
Functions
Seal surfacing against water ingress
Develop skid resistant texture

Builtup Spray Grout (BUSG)

Two layer composition of compacted crushed
aggregate sand application of binder after each
layer for bonding and finished it aggregates at
the top
Total Thickness75 mm
Suitable for strengthening of existing

bituminous pavements
Wearing course is provided over this layer

Penetration Macadam
Used as binder or base course
Coarse aggregates are spread and compacted

and then hot bituminous binder of high

viscosity is spread at the top
Bitumen penetrates the void sand binds the
aggregates together

Premix methods
Aggregate sand binder are mixed before

spreading and compacting

Classified based on gradation of aggregates
chosen as
Bituminous Macadam
Bituminous Carpet
Bituminous Concrete

Bituminous Macadam
Consist of one or more courses of compacted
aggregates premixed with binder, laid
immediately after mixing
Laid in compacted thicknesses of 75mm or
50mm
Essentially a base course or binder course and
should have surfacing
Superior to other base course materials w.r.t
load dispersion and durability

Bituminous Premixed Carpet

Coarse aggregates of 12.5 mm and 10mm size
premixed with binder and compacted to thickness
of 20 mm to serve as a base course
Should be covered by a sealcoat
Semidense carpetWell graded aggregate is
used for construction of bituminous carpet of
thickness 20 or 25mm

Bituminous Concrete
Dense graded premixed bituminous mix that
is well compacted to form a pavement surface
course
Mixture of coarse aggregates, filler and fine
aggregates
Thickness4075mm
IRCspecification40mm thick
AC surface course for highway pavements

Sheet Asphalt
Dense sand bitumen pre mix used as

wearing coursecompacted thickness of

25mm
Well graded coarse to fine sand without
coarse aggregate sand bitumen
Laid over cement concrete pavement
Protects joints and helps in reduction in
warping stresses

Mastic Asphalt

Mixture of bitumen, fine aggregate sand

filler
When cooled results in a hard, stable and
durable
layer that withstands heavy traffic
Absorbs vibrations
Suitable surfacing material for bridge deck
slabs

Bituminous Construction Procedures

Surface Dressing
Grouted or Penetration Macadam
Builtup Spray Grout
Bitumen bound Macadam
Bituminous Carpet
Bituminous Concrete

Surface Dressing (BSD)

Done in either single coat or in two coats over an existing
pavement for renewal or as a wearing course over a WBM road
Bitumengrades80/100

Construction Steps
Surface Preparation
Application of binder
Application of stone chippings
Rolling of first or final coat
Application of binder and stone chippings
for
second coat
Rolling of second coat
Finishing and opening to traffic after 24
hours

Bituminous Concrete Construction

Proper design of mixesessential
Dense grading of coarse aggregates, fine
aggregate sand mineral fillet coated with
bitumen binder
Prepared in a hotmix plant
Thickness depends on traffic and quality of
base course

 Construction Steps
Preparation of existing base course layer
Application of tack coat 6 7.5kg of

bitumen per10 m2area

Preparationand placing of premix
Bitumen heated to1500C1770C
&aggregate temperature should not differ by
over 140C from binder temperature
Spreadatatemperatureof1210C1630C

 Rolling Initial 8 12 trolled &intermediate 15

30t ; final 8 12t roller

Quality Control Bitumen grade, temperature of
aggregate, temperature during mixing and compaction
Marshall Tests conducted
1 sampleoutofevery100tofmixdischarged is tested
Forevery100 m2of compacted surface, one field density
test is done
Variation in thickness6mm per 4.5mofconstruction
Finished surfacechecked for longitudinal
undulations not greater than 8mm.

Cement Concrete Pavements

Excellent riding surface &pleasing appearance
Longer life
Design on rational basis
Cost saving and excellent performance
High initial investment
Jointsplanes of weakness
Curing periodnecessary

Construction of Cement Concrete

Pavement Slab
Cement grouted layerSuitable for base course
Rolled concrete layer
Cement Concrete slab
Cement grouted layer
Opengradedaggregatemixwithaggregateshavingmaximumsize1825mmdryrolled
Cement grout is applied on the surface

Rolled Concrete layer

Lean mix concrete issued

Methods of Construction
Alternate Bay Methodconstructing a bay or one slab in alternate succession leaving the next to

immediate bay to follow up after a gap of a week

Advantages
Working convenience for slab laying
Joint construction easier Disadvantages
Large no of transverse joints to be provided
Complete diversion of traffic necessary
Continuous Bay Method preferred

Material Specifications
Cement OPC or Rapid Hardening Cement
Aggregates
Max size not greater than one fourth slab thickness
Gradationofcoarseaggregate50 to4.75 mm or 40 to
4.75 mm in two size ranges, one below and the other above 20mm
Crushing value 30%max
Impact value30%max
Los Angeles Abrasion value35% max as per IRC Fine aggregate natural sand or crushed stone

ConcreteMin Modulus of Rupture of

40kg/cm2 after 28 days of curing or

compressive strength of280 kg/cm2

Plants &Equipments required

Concrete Mixer &Batching Device
Vibrating Screed

Construction Steps
Preparation of Sub grade and Subbase
Uniformly compacted sub grade extending

30cmoneithersideofwidthtobeconcreted
Properly drained
Min k value of 5.54 kg/cm2
To be kept in moist condition
Water proof paper to be placed in case concrete is placed directly
over sub grade

Placing of Forms
Steel or wooden forms
Batching of material and Mixing
Transporting and Placing of concrete
Compaction and Finishing
Floating and Straight Edging
Belting, Brooming and Edging
Curing

Bituminous Road Method

It is the most common type of road

construction.
It main purpose is to protect the sub-base
coarse from wearing and tearing and to
provide a smooth riding comfort.
It has no. of method. They are:1. Bituminous surface dressing:- It
is provided over an existing surface to
serve as thin wearing coat. It serve as
water proof pavement. Dust proof in wet
season and mud proof in wet season.

2.

Penetration Macadam: It is used as a base or

binder coarse. In this bitumen is used as a cementing
material to bind the aggregates and as a filler to fill the
void.

3. Built up spray grout: It consist of two layer

composite construction of compacted crushed aggregates
with application of bituminous binder after each layer for
bonding and finished with key aggregates at the top to
provide a total compacted thickness of 75mm.

4. Bituminous Macadam: it is premixed construction

method consisting of one or more coarse of compacted
crushed aggregates premixed with bituminous binder . It
consist of thickness of 75mm. It should be cover with
suitable cover.

5.

Bituminous Premixed carpet: It consist

of coarse aggregates of 12.5 and 10mm size
premixed with bitumen and composed to a
thickness of about 20mm. It should be covered
by a suitable seal coat. It aggregates consist of
size between 20mm to 6.3mm.

6. Bituminous Concrete: it is a dense

graded premixed bituminous mixture which is
well compacted to form a high quality pavement
surface course. Thickness ranges from 90 to
75mm. IRC has provided specification for 40mm
thick bituminous concrete surface coarse for
highway construction.

Construction Procedure
All method has nearly same construction

procedure. Common steps to all the methods are:Preparation of existing surface .

Spreading of coarse aggregates.
Rolling .
Seal coat / Track coat.
Surfacing finishing .
Opening of traffic.

Merits
It has following merits: It is cheap.
It provide good riding comfort.
It hold the aggregates well.
It prevent the wearing of sub-base.

Demerits
It has following demerits: It get detereoted.
It design life in not long.
It require frequent maintenance for heavy

traffic.

Concrete and cement road

method
It mainly consist of concrete & cement in its

construction.
It has nearly same concept of laying road slab as
in the building slab.
CC construction can be divided into :1. Construction of pavement slab:- In this we
are concern about the construction of the road
slab.
2. Construction of joints:- In this we are concern
about the construction of the joints between the
road the slab.

CC has two modes of construction which are:-

1.Alternate bay method :-

In
this we make alternate block of CC on the
both lane in the same time , leaving gaps
between them. It is usually not prefer
today's.

2.Continuous bay method :In this we make a lane upto certain length
and the next lane is completed afterward.
This is now days in practice.

Construction Procedure
It has the following steps: Preparation of subgrade & sub-base

. It

include1. Moist the sub-base in advance of placing

concrete.
2. Sub-base should be well compacted and
does not contain any soft spot.
3. It should have proper drained facility.
. Placing of forms- Steel and wooden
forms should be properly connected to the
slab.

 Placing of concrete in this the concrete is

properly placed over the sub-base.

Compacting and Finishing in this concrete is
compacted with the help of vibrator. It has two
methodA. Floating and Straight edges.
B. Belting, Brooming and Edging.
.Curing in this concrete is kept moist for about

28 days. It has two types:A. Initial curing.

B. Final curing

Merits
It give best riding comfort.
It is long design life.
Further all the characteristic of road can be

easily predicted.
It can bear any type of load.
It does not get easily detereoted.
It has sufficient friction both in wet and dry
condition.

Demerits
It
It
It
It
It

has high initial cost.

maintenance coast is high.
require time for completion.
require great skill.
maintenance time is also large.

Thank you