This document discusses quality assurance and quality control procedures for road construction projects. It defines key terms like quality and explains that quality assurance aims to build quality into processes through documentation and reviews, while quality control detects deviations from specifications. It then provides details on material selection criteria, testing procedures for borrow areas, gravel, asphalt and other materials. Frequency of inspections and acceptance criteria are specified for various tests to ensure construction meets specifications. In summary, the document outlines quality management systems and testing plans to systematically control quality during road construction.

1. “QUALITY ASSURANCE & QUALITY
CONTROL IN ROAD
CONSTRUCTION”
Mr. Sunil Kumar Jha
Adani Road Transport Ltd.

2. Define the term Quality
• Degree to which a set of inherent characteristics fulfils requirements”
• Quality can also be expressed by simple formula:
• Q = P / E Where P = Performance of result
• E = Customers Expectations
• When Q = 1 The customer’s expectations are complied with and full customer
satisfaction is attained. This is the ideal situation.

3. Quality Assurance.
• Quality Assurance comprises of planned and systematic activities implemented
within the Quality System and demonstrated as needed, to provide adequate
confidence that an entity (Product service) will fulfill requirements for Quality.
• Quality Assurance establishes the extent to which Quality will be, is being or has
being controlled.
• Quality Assurance has to be built into the process.
• This includes creating records, documenting plans, work instructions, document
specifications and reporting reviews.

4. Quality Control.
• A set of measures taken to ensure that defective product or services are not
produced / delivered and meets the specified requirements.
• Quality Control produces results.
• Quality Control detects deviation.
• Quality Control concerns with the fulfilling specified quality requirements

5. Quality Policy.

6. Material selection Criteria:
Selection of suitable raw materials like Steel, Cement, Bitumen, Emulsion, Admixture:
• During the selection of Materials, proper care has to be taken for procuring from the
standard manufacturers. This has to be finalized after factory visits, inspecting the
manufacturing processes adopted by the companies, quality systems implemented and
followed during the process of manufacturing of that particular elements or items.
Availability of Internal testing facilities complied with relevant codel practices. Facilities for
storage of finished items.

7. Selection of Suitable Stone Quarries.
• Stone Quarries to be selected away from the habitants and the quality of Rock has to be confirmed to
IRC78 by getting done the Petro-graphic analysis and other tests as per IS – 383 & 2386/ MORTH
Specifications. All necessary permits as mentioned in Schedule E of Concession Agreement have to
be acquired from competent Authority. All Safety measures to be followed as per IRC SP 55.

8. Factory Visit – Hume Pipe

9. Steel, Bearing and Prestressed Material Visit.

10. Borrow Area Sampling and Testing.
• The Borrow Areas which are intended for use have to confirm the requirements of IRC10 &
other legal /statuary requirements of different government bodies.
• The borrow area’s shall be divided in to suitable number of grids of size 25 m c/c and soil
samples to be collected for checking the suitability of the soils. Depth of excavation is
restricted to 1.50 m initially and necessary legal persimmon required to obtained for further
depth.
• All necessary permits as mentioned in Schedule E of Concession Agreement are to be
acquired from Competent Authority.

11. Borrow Area Sampling and Testing.

12. Borrow Area Redevelopment

13. ITP

14. Laboratory Test conducted for checking suitability of Borrow area:
Sl. No. Test Test Method Minimum Frequency Specified Value
1. Gradation / Sand content IS: 2720 (Pt 4) 2 test per 3000 cum Max size of particle 75 mm for
Embankment & 50mm for
Subgrade
2. MDD & OMC (by heavy compaction) IS: 2720 (Pt 8) 2 test per 3000 cum --
3. CBR at 97% MDD IS: 2720 (Pt 16) 1 test per 3000 cum Min 10%
4. Liquid Limit & Plastic Limit IS : 2720 (Pt 5) 2 tests per 3000 cum LL< 70 & PI <45
5. Free Swell Index IS : 2720 (Pt 40) 2 tests per 3000 cum FSI < 50
6. Chemical Analysis (SO3) IS : 2720 (Pt 27) &BS1377 1 test per source 0.5 % (expressed as SO3)

15. ITP/QAP For Embankment/Subgrade
S.No
Inspection and Testing
Description
IS Specification Frequency of Inspection / Testing Acceptance Criteria
Acceptance Criteria
Reference
EARTHWORK (Ref. MoRT&H 5th Revision Section 305 & 900)
1 Gradation/Sieve Analysis IS:2720 (Part-4) 2 tests / 3000 m3 D:<75 mm (Embk.) /<50 mm
(Subgrade)
903.2.1 & 305.2.1.4
2
Liquid Limit & Plasticity
Index
IS:2720 (Part-5) 2 tests / 3000 m3
LL<50&PI<25 903.2.1, 305.2.1.1
3 Max. Dry Density & OMC IS:2720 (Part-8) 2 tests / 3000 m3
-
903.2.1 & 305.2.1.5; Table
300-1
4 Deleterious Content IS:2720 (Part-27) As and when required - 903.2.1
5 Moisture Content IS :2720 (Part-2) 1 test / 1500 m3
-2% to +1% of OMC 903.2.1 & 305.3.5.2
6 CBR IS:2720 (Part-16) 1 test / 3000 m3
for Subgrade Min % as per design requirement 903.2.1
7 Free Swell Index IS:2720 (Part-40) 1 test / 3000 m3
< 50% 305.2.1.2
8
Field Density Compaction for
Embankment
IS:2720 (Part-28) 1 Set of 10 test / 3000 m2
Min. 95 % of MDD 903.2.2 & Table 300-2
9
Field Density Compaction for
Subgrade/Shoulder
IS:2720 (Part-28) 1 Set of 10 test / 2000 m2
Min. 97 % of MDD 903.2.2 & Table 300-2
10
Field Density Compaction for
OGL
IS:2720 (Part-28) 1 Set of test / 3000 m2
Min. 95 % of MDD 903.2.2 & table 300-2

16. ITP/QAP for GSB Construction.
S.No
Inspection and Testing
Description
IS Specification
Frequency of Inspection /
Testing
Acceptance Criteria
Acceptance Criteria
Reference
GSB (Ref. MoRTH 5th
Revision Section 401 & 900
1 Gradation/Sieve Analysis
IS:2720 (Part-4) &
IS: 2386 (Part-1)
1 test / 400 m3 As per table 900 - 3 & Table
400-1
MoRT&H table 900 - 3 &
Table 400-1
2
Liquid Limit & Plasticity
Index
IS:2720 (Part-5) 1 test / 400 m3
LL<25% PI < 6%
MoRT&H table 900 - 3 &
Table 400-2
3 Moisture Content IS :2720 (Part-2) 1 test / 400 m3 -2% to +1% of OMC
MoRT&H table 900 - 3 &
Cls. 401.3.2
4 Field Density Compaction IS:2720 (Part-28) 1 set of test / 1000 m2
>98% of MDD
MoRT&H table 900 - 3 &
Cls. 401.3.2
5 Deleterious Content IS:2720 (Part-27) As and when required - As per table 900-4
6 CBR IS:2720 (Part-5) As and when required >30
MoRT&H table 900 - 3 &
Table 400-2
7 Max. Dry Density & OMC IS:2720 (Part-8) As and when required - MoRT&H Clause 401.3.2
8
Water Absorption/ Wet AIV
test
IS:2386 (Part-
3)/IS:5640/IS2386
(Part-4)
Initially on submission < 2/ wet AIV <40.
MoRT&H Clause 401.2.2,
Table 400-2
9
Liquid Limit and Plasticity
Index
IS:2720 (Part-5) As and when required LL< 25, PI<6 MoRT&H table 400-2

17. ITP/QAP for WMM Construction
S.No
Inspection and Testing
Description
IS Specification Frequency of Inspection / Testing Acceptance Criteria
Acceptance Criteria
Reference
WMM (Ref. MoRTH 5th
Revision Section 406 & 900)
1
Aggregate Impact Value/
Los Angeles Abrasion
Value
IS:2386 (Part-4)
/IS5640
1 test / 1000 m3
AIV < 30%, LAA < 40%
MoRT&H table 900 - 3
&
Table 400-12
2 Gradation/Sieve Analysis IS: 2386 (Part-1) 1 test / 200 m3
-
900-3; As per table 400-
13
3
Flakiness Index &
Elongation Index
IS:2386 (Part-1) 1 test / 500 m3
< 35%
MoRT&H table 900 - 3
&
Table 400-12
4 Atterberg Limits IS:2720 (Part-5) 1 test / 200 m3
PI<6
MoRT&H Clause 900-3
& 406.2.1.2
5
Field Density
Compaction
IS:2720 (Part-28) 1 set of test / 1000 m2
>98% of MDD
MoRT&H Clause 900-3
& 406.3.5
6
Max. Dry Density &
OMC
IS:2720 (Part-8) As and when required -
MoRT&H Clause
406.3.5
7 Water Absorption IS:2386 (Part-3) Initially on submission
< 2%, if >2% soundness
test to be carried out.
MoRT&H Clause
406.2.1.1

18. ITP/QAP for Prime Coat
S.No
Inspection and Testing
Description
IS Specification Frequency of Inspection / Testing Acceptance Criteria
Acceptance Criteria
Reference
PRIME COAT (Ref. MoRTH 5th
Revision Section 502 & 900)
1 Quality of Binder IS:8887 1 test / Lot -
IS:73, IS:217 and IS:8887
as applicable
2 Rate of Spread of Binder Three tests / day
0.7-1.0 & 0.9-1.2 Kg/m2
for
WMM & Stabilized soil
bases/Crusher Run
Macadam
MoRT&H Table 500-3
TACK COAT (Ref. MoRTH 5th
Revision Section 503 & 900)
1 Quality of Binder IS:8887 1 test / Lot -
IS:73, IS:217 and IS:8887
as applicable
2 Rate of Spread of Binder Three tests / day
0.20 to 0.30 & 0.25 to 0.30
Kg/m2
for Bituminous surfaces
& Granular surfaces treated with
primer
MoRT&H Table 500-5

19. ITP/QAP for Viscosity Grade Bitumen
S.No
Inspection and Testing
Description
IS Specification Frequency of Inspection / Testing Acceptance Criteria Reference
1 Penetration test @ 25⁰ C. IS: 1203 1 Test per lot IS: 73 Table 1
2
Absolute Viscosity test @ 60⁰
C.
IS: 1206, Part 2
1 Test per lot
IS: 73 Table 1
3
Kinematic Viscosity test @
135⁰ C.
IS: 1206, Part 3
1 Test per lot
IS: 73 Table 1
4 Softening point test IS: 1205 1 Test per lot IS: 73 Table 1
5 Flash Point IS: 1209
1 Test per lot
IS: 73 Table 1
6 Specific Gravity IS: 1202
1 Test per Source and every 1 year per
source
IS: 73 Table 1
7 Test on Residue from TFOT
7.i Viscosity ratio @ 60⁰ C. IS: 1206, Part 2
1 Test per Source and every 1 year per
source
IS: 73 Table 1
7.ii
Ductility @ 25⁰ C. after
TFOT
IS: 1208
1 Test per Source and every 1 year per
source
IS: 73 Table 1
8
Solubility in
Trichloroethylene
IS: 1216
1 Test per Source and every 1 year per
source
IS: 73 Table 1

20. ITP/QAP for Modified Bitumen-PMB
S.No
Inspection and Testing
Description
IS Specification Frequency of Inspection / Testing
Acceptance Criteria
Reference
1 Penetration test @ 25⁰ C. IS: 1203 1 Test per lot IRC SP: 53
2 Viscosity @ 150⁰ C. IS: 1206, Part 2 1 Test per lot IRC SP: 53
3 Softening point test IS: 1205 1 Test per lot IRC SP: 53
4 Flash Point IS: 1209 1 Test per lot IRC SP: 53
5 Elastic Recovery of half thread @ 15⁰ C. IRC: SP 53 1 Test per lot IRC SP: 53
6 Complex Modulus IRC: SP 53
1 Test per Source and As per 15468 2019
IRC SP: 53
7 Separation Difference in Softening Point IRC: SP 53
1 Test per Source and As per 15468 2019 IRC SP: 53
7.i TFOT test and Test on Residue
7.ii Loss in mass IS: 9382
1 Test per Source and As per 15468 2019 IRC SP: 53
8 i Increase in Softening Point IS: 1205
1 Test per Source and As per 15468 2019 IRC SP: 53
8 ii Reduction in Penetration of residue IS: 1203
1 Test per Source and As per 15468 2019 IRC SP: 53
8 iii Elastic Recovery of half thread @ 25⁰ C. IRC: SP 53
1 Test per Source and As per 15468 2019 IRC SP: 53

21. S.No Inspection and Testing Description IS Specification Frequency of Inspection / Testing Acceptance Criteria
Acceptance Criteria
Reference
DBM /BC (Ref. MoRTH 5th
Revision Section 507, 509 & 900)
1 Quality of binder IS: 73 1 test/lot -
MoRT&H Clause 900-4,
505.2.1 & 504.2.1 and Table
500-1 Bitumen complying
with IS 73
2
Aggregate Impact Value / Los Angles
Abrasion Value
IS:2386 (Part-4) & IS:
2386 (Part-3)
1 test / 350 m3
AIV DBM <27%, BC< 24% &
LAAV for DBM <35%, BC
<30%
MoRT&H Table 900-
4,Table 500-8
& 500-16
3 Flakiness Index & Elongation Index IS:2386 (Part-1) 1 test / 350 m3
< 35 %
MoRT&H Table 900-4, 500
8 & 500-16
4 Stripping value IS:6241
One test per source and whenever source will
change
Coating retained >95 %
MoRT&H Table 900-4, 500
8 & 500-16
5 Water absorption of aggregate IS:2386 (Part-3)
One test per source and whenever source will
change
< 2 % for DBM & BC
MoRT&H Table 900-4, 500
8 & 500-16
6
Soundness (Magnesium and sodium
sulphate)
IS:2386 (Part-5)
One test per source and whenever source will
change
Sodium Sulphate <12%
Magnesium Sulphate <18%
MoRT&H Table 900-4, 500
8 & 500-16
7 Sand equivalent test IS:2720 (Part-37)
One test per source and whenever source will
change
>50
MoRT&H Table 900-4,
505.2.3
8 Plasticity Index IS:2720 (Part-5)
One test per source and whenever source will
change
<4%
(passing 0.425mm sieve)
MoRT&H Table 900-4,
505.2.3
9 Mix grading IS 2386 (Part-1)
For each 400 MT of mix subject to a
minimum of two tests per plant per day.
-
MoRT&H Table 900-4, As
per table 500-10 , 500-13

22. S.No Inspection and Testing Description IS Specification Frequency of Inspection / Testing Acceptance Criteria
Acceptance Criteria
Reference
DBM /BC (Ref. MoRTH 5th
Revision Section 507, 509 & 900)
10 Stability of mix
Asphalt Institute Manual
MS-2, AASHTO T245,
ASTM D 2041, IS 6241,
AASHTO T 283
For each 400 MT of mix produced, a set of 3
Marshall specimens to be prepared and tested
for stability, flow value, density and void
content subject to a minimum of two sets
being tested per plant per day.
-
MoRT&H Table 900-4, 500
11, 500-12 & Cls. No.
505.3.1
11
Water sensitivity of mix (Retained
tensile strength)
AASHTO T 283
One test per source and whenever source will
change
>80% , is only required if the
minimum coating retained less
than 95%
MoRT&H Table 900-4,
Table 500-8 & Table 500-
16
12
Control of binder content and grading
of the mix.
Asphalt Institute Manual
MS-2
One test for each 400 tones of mix subject to
a minimum of two tests per day per plant.
-
MoRT&H Table 900-4,
Table 500-13 &500-18
13 Density of compacted layer - 1 test / 700 m2
>=92% of GMM
MoRT&H Table 900-4,
505.3.5 & 507.3.5.
14 Polished Stone Value BS-812 (Part-14) 1 test / source
Min 55 for BC. ( For DBM this
test not required)
MoRT&H Table 900-4 and
Table 500-16
15 Rate of spread of mix material - After every 5th
truck load - 900-4
16
Temperature of binder in boiler,
aggregate in dryer and mix at the time
of laying and compaction
- At regular intervals - 900-4
17 Grain Size Analysis of Aggregates IS 2386 (Part-1) As and When Required Max 5% passing 0.075mm sieve
MoRT&H Table: 500-8 &
500-16

23. Some Important Notes:
• Prior to Implementation of any activity Project Quality Assurance Plan (PQAP) have to
be Submit and Obtained Approval from Client/Consultant
• Review and acceptance of quarry sites for aggregate, quarry spall, GSB Material, Sand,
borrow area, Mix Design for Concrete and Pavement layers and other bought out items
to be used for the project.
• Ensure the Suitable measuring and testing Equipment's is available and calibration of
same is monitored regularly.
• If Any Material for ex. Soil is not Suitable for the works then Detailed Investigation
should be Conducted Prior to Start the work.
• We will Conduct the Free Swell Index test(Max- 50%) and Swelling Pressure Test as per relevant
method, if the value is coming out of Specification Limit then we remove the Material from existing
ground or proceed for Stabilization Process with various Materials like Cement, Lime, Flyash which
is nearby available.

24. Highway Construction

25. Plan and Profile Drawing/Cross Section.

26. Survey.

27. Alignment Fixing:
• The control points of GPS (Global Positioning System) pillar is fixed at every 5 km interval by NHAI (National Highway Authority Of India)
and handed over for execution of survey works. The same GPS pillars are also having the value of coordinate and levels.
• Keeping the same GPS pillar as a reference, traversing of coordinate has been fixed between GPS pillar to GPS pillar (ie. every 5 km
interval). Closing error of traverse has been adjusted by bow-ditch method in between two GPS pillars. The traverse closure was less than
1: 20000
• Horizontal angle was observed by taking minimum of two sets of rounds from different locations. All the observations were logged and
the spread between observed rounds of horizontal angles did not exceed 5 seconds (Two sets of angles agreed within 5 seconds).
• In between GPS pillars at every 250meter interval, along the road alignment, the sub control pillar [Bench Mark Pillar (BMP)] is fixed at
the end of ROW (Right Of Way). The location of benchmark pillar is marked at site by paint identifying location. Benchmark pillars are
concrete pillars. Size of concrete pillar is 150X150X450 mm. 12 mm rod is embedded inside and projected 15mm above the concrete
pillar. During the time of traversing the bearing was recorded on the punch point of rod projected over the benchmark pillar. The
coordinate value of each benchmark pillar was arrived after traverse adjustment by bow-ditch method.
• The project alignment coordinate given by client - NHAI for a length of km ie. km to km is fixed over the existing road by 1 - second
accuracy of total station. The alignment point is marked at every 20mtr interval on the straight portion and 10mtr interval on the curve
portion by round head nail. The same point is marked with yellow point and location (chainage) written on the road for quick reference.
For fixing this alignment for 40 km length, the traversed coordinate of benchmark pillar, fixed at every 250mtr interval along the project
alignment, are used and client has checked the alignment. Detailed copy of coordinate value of benchmark pillar (BMP) along-with
chainage and location is given to clients and site engineers for their reference.

28. Bench Mark Fixing:
• For every 250 mtr interval the concrete bench mark pillar is fixed along the project alignment (from km to km ) at the end of
ROW. Location and chainage is marked at site with paint. The pillar is used for fixing the benchmark.
• GPS pillar to GPS pillar (every 5km interval) the level traversing has been done retaining the RL (Reduced Level) of GPS pillar
(GPS level given by NHAI). During the time of traversing the level, the levels are transferred over every 250mtr interval benchmark
control pillars also. During benchmark level transferring maximum observing distance were 100mtr, keeping the fore sight and back
sight distance equal. The spread between observed ranges of vertical angles did not exceed 10 seconds. The closing error on a level
circuit did not exceed 12 root of K in mm (where K is distance in Km.). The closing error has been distributed to all the bench mark
in network in between GPS to GPS. The benchmark pillar (BMP) levels are checked by client.
• Detailed benchmark list mentioning level, location and chainage is issued to client and site engineers for their reference.
Toe Line Fixing:
• The toe line is fixed for the every layer by means of calculating the thickness of pavement layer multiplied by percentage of given
formation slope. The toe distance will be measured from given alignment nail. The cross section drawings also can be followed
for toe line marking.

29. C &G – Clearing and Grubbing.

30. Clearing and Grubbing:
• The vegetation is completely cleared and tree stumps are extricated along with roots for girth less than 300mm.
• The useful materials shall be stockpiled and all other objectionable materials are disposed as per directions of Engineer.
• Top soil shall be stripped and removed if found unsuitable and useful material is stockpiled. The details for the topsoil removal
should be provided as per design requirement of crust.
• Levels shall be taken after stripping / clearing and prior to filling and documented.
• The measurements are recorded as per the provision of agreement and submitted for verification documentation.
Shifting of Utilities:
Clear and shift utilities like electrical poles, cables, telephone and water supply lines, trees, drainage structures etc.
Preservation of Property/Amenities:
• Roadside trees, shrubs, any other plants, pole lines, fences, signs, monuments, buildings, pipelines, sewers and all highway
facilities within or adjacent to the highway which are not to be disturbed shall be protected from injury or damage. Contractor
shall provide and install suitable safeguards approved by the Independent Engineer for this purpose.
• During clearing and grubbing, ITNL shall take all adequate precautions against soil erosion, water pollution, etc., and where
required, undertake additional works to that effect vide Clause 306. Before start of operations, ITNL shall submit to the
Independent Engineer for approval, his work plan including the procedure to be followed for disposal of waste materials, etc.,
and the schedules for carrying out temporary and permanent erosion control works.
Disposal of Materials:
All materials arising from clearing and grubbing operations shall be taken over and shall be disposed of by Contractor with all leads
and lifts. The transportation of cut trees and stumps will be carried out as per permission/guidelines/ estimates of State Forest
Department.

31. Embankment/Subgrade Construction

32. Embankment/Subgrade Construction.
• The toe line and centre line are marked and pegs will be driven.
• The material shall be dumped in site at respective location.
• The material shall be spread in layers of uniform thickness not exceeding 250 mm compacted thicknesses over the entire width of the
subgrade by mechanical means and will be graded with grader to the required camber. Moisture content of the material shall be checked and
extra required will be added.
• The moisture content of each layer shall be checked and it should be with in the range of OMC +1% to OMC -2 percent. If moisture
content is found out of these limits the same will be brought within limits by addition of water or by aeration as the case may be.
• The compaction shall be done with the help of vibratory roller of 8 to 10 ton static weight. Each layer shall be thoroughly compacted to the
densities specified in the specifications which are mentioned at the end of this document for reference. The rolling pattern will be finalized in
trial stretch.
• On compaction of the particular stretch necessary field testing shall be carried out Field density shall be done in the manner and frequency as
specified below.
• If the required field density is not achieved, compaction shall be continued till required density is achieved.
• Loose pockets if any will be removed and replaced with approved material.
• The above stages shall be repeated till the top level of the subgrade is reached to the specified levels and grades. The top levels shall be
checked and shall be within +20mm to -25mm of designed level.
• In case the original ground is in subgrade level or is in cutting and if the density after compaction is not 97% minimum for Subgrade and 35
% for Embankment the ground will be loosened upto a depth of 250mm and will be compacted in accordance with 305.3.5 and 305.3.6 of
technical specifications.

33. GSB Construction.

34. GSB Construction
• The toe line and Centre line are marked and pegs will be driven.
• The material shall be dumped in site at respective location.
• The material shall be spread in layers of uniform thickness not exceeding 200 mm compacted thicknesses over the entire width of the
subgrade by mechanical means and will be graded with grader to the required camber.
• Moisture content of the material shall be checked and extra required will be added.
• The moisture content of each layer shall be checked and it should be with in the range of OMC +1% to OMC -2 percent. If moisture
content is found out of these limits the same will be brought within limits by addition of water or by aeration as the case may be.
• The compaction shall be done with the help of vibratory roller of 8 to 10 ton static weight. Layer shall be thoroughly compacted to the
densities specified in the specifications which are mentioned at the end of this document for reference. The rolling pattern will be finalized
in trial stretch.
• On compaction of the particular stretch necessary field testing shall be carried out Field density shall be done in the manner and frequency
as specified below.
• If the required field density is not achieved, compaction shall be continued till required density is achieved.
• Loose pockets if any will be removed and replaced with approved material. The top levels shall be checked and shall be within +10mm to -
20mm of designed level.
• All relevant QA and QC documents will be maintained for all stages of GSB Construction.

35. WMM Construction.

36. WMM Construction
Preparation of Mix:
• The individual materials gradation shall be checked combined, proportions shall be fixed and combined gradation confirming to
table 400-11 shall be arrived. The individual bins of wet mix plant shall be calibrated for the particular size of material. Material shall be
fed to the mixing plant bins provided for individual sizes of aggregates to meet the required gradation. Mixing plant shall be of suitable
capacity having provision for controlled addition of water. While adding water, loss due to evaporation shall be taken in account. Water
in the wet mix shall not vary from the optimum by more than in the limits of +l/-1 of OMC.
Preparation of Base:
• The sub base shall be checked for proper lines and levels. It shall be made free from dust. Before the laying starts it should be made
slightly wet and shall be given one plain pass. The lateral confinement for wet mix shall be provided by placing material in the adjoining
shoulder portion.
Laying of Wet Mix Macadam:
• The wet mix shall be transported from the mixing plant to the site with trippers. The mix shall be laid with Grader or paver finisher.
The paver shall have suitable loading hoppers and distribution mechanism. The mix shall be laid manually in places where the paver
movement is not possible. High or low spots shall be rectified by adding or removal of materials as the case may be. The material shall
be uniform and shall be free of pockets of fine material.
• The compaction of wet mix shall be done as per clause 406.3.5. The rolling shall be done with 80-100KN vibratory roller. The
rolling pattern shall be established in the trial stretch. Care shall be given at every stage so that there will not be any segregation.
• The finished layer shall be checked for compaction in accordance to the specifications given below. The top shall be checked for level
control and shall be within +10mm and -10mm of designed level.

37. Prime Coat & Tack Coat

38. • Prime Coat:
 The material shall be such that it can penetrate deep into base course about 10 mm and conforming to IS-8887-2004(SS-1).
 The surface to be primed shall be swept clean, free from dust and shall be dry.
 Before laying the primer the surface shall be made to the required profile using compactor and template.
 The prime coat shall be provided on the granular surface with Bitumen Emulsion complete as per MOSRT&H specification
at the rate of 7.0 kg to 1.0 kg per 10 sqm.
 The primer shall be spread uniformly to cover the dry surface using primer distributor equipped with self propelled or
towed pressure sprayer with self heating arrangement and spraying bar with nozzles having constant volume or pressure
system.
 The rate of spray of prime and tack coat is checked at site by keeping iron plate of 200 mm x 200 mm size and 20 mm
depth and weight, on the surface where primer is to be applied.
 After application the weight of the plate is taken and the rate of spray is determined.
 Primed surface shall be allowed to cure for at least 24 hours. No traffic shall be permitted other than that necessary to lay
the next course.

39. • Tack Coat:
 The material shall be bitumen emulsion complying with IS-8887-2004(RS-1).
 The surface to be tack coated shall be swept in, free of dust and shall be dried using Mechanical Broom.
 The temperature of emulsion should be in range of 20-70 o C at time of spraying.
 The rate of emulsion shall be 2 to 3.0 kg per 10 sqm. on bituminous surface and shall be 2.5 to 3 kg/10 m2 for
granular surface treated with primary/secondary bituminous surface.
 After the application of Tack Coat at the specified rate of the spray, the subsequent bituminous layer (DBM/BC)
shall be laid. Quality control test to be done as per MOSRT&H Clause 903.4

40. DBM/BC Construction

41. • Mix Design -The mix design shall be carried out according to MS-2 of Asphalt Institute. The optimum bitumen content and job mix formula are
arrived. The physical requirements of the aggregate shall confirm to table 500-17 and job mix shall confirm to grading 1 of table 500-18 of technical
specifications. The mix properties shall confirm to table 500-19 of technical specifications. The permissible variations from the job mix formula shall be
according to table 500-13.
• Preparation and Transportation of Mix:
• The individual bins of hot mix plant shall be calibrated for the particular size of material. Material shall be fed to the mixing plant bins provided for
individual sizes of aggregates to meet the required gradation. The temperature of binder and aggregate at the time of mixing shall be as per IRC 111-
2009.The difference between and the aggregate temperature shall not exceed 14'C any time. The mix shall be transported to the site with trippers properly
covered with tarpaulins.
• Preparation of Base:
• The base shall be checked for proper lines and levels. The surface shall be swept free from dust with air compressor. The tack coat shall be done if the
DBM surface was old for quite some time.
• Laying of Bituminous Concrete:
• The mix shall be laid with paver finisher. The paver shall have suitable loading hoppers and distribution mechanism. The paver shall have electronic
sensor paver and string wire shall be run on steel pegs driven on both sides at 10m interval in straight portions and 5m interval in curved portions. The mix
shall be laid manually in places where the paver movement is not possible.
• The compaction of BC shall be done as per clause 501.6 and 501.7. The rolling shall be done with 80-100KN smooth wheeled tandom roller, 12-15
tonnes pneumatic tyred roller. The rolling pattern shall be established in the trial stretch.
• The finished layer shall be checked for compaction. The compaction shall be checked by taking cores for every 700sq.m area and the % compaction shall
not be less than 92% of lab GMM of loose mix. The top shall be checked for level control and the levels shall be within ±6mm of designed level.

43. Hot Mix Plant.

45. Checklist for Hot mix Plant.
• Stock piles of aggregate (coarse and fines) shall not be intermingled
• Cold feeders shall be calibrated in accordance with the job mix formula.
• Burner temperature shall be maintained as per manufacturer guideline (Approx 1400
OC)
• Mixing time shall be as per manufacture guidelines
• Thermometer and aggregate weighing scales to be calibrated.
• No Blockage in the Bitumen Flow Line
• Hot Bin sieves shall be in good condition(no holes)
• Hot Bin overflow chute shall be fixed.
• Choking of Bag House filter or no working properly

46. Checklist Before Laying.
• Auger of Paver
• Screed Heater(Pre Heating): Heater used to preheat the screed to Hot Mix temperature (usually about 10-15 min)
• Screed Vibrator Initial Compaction done by screed weight and vibration.
• Screed Plate The Flat bottom portion of the screed assembly that flattens and compresses the Hot Mix.
• Paver sensor & string Line.
• Paving Speed shall be maintained a as per manufacturer guidelines. (Generally paver speed will be 20m/min).
• Paving speed shall be in line with Hot Mix feeding rate.
• leakage of fuel, oil etc due to parking of equipment over tha laid asphalt layer.
• Rollers shall be in good condition.
• Vibrations shall be as per requirments. Sometime vibrations not functioning properly, operator may hide to the execution team.
• Vibrations shall be as per requirments. Sometime vibrations not functioning properly, operator may hide to the execution team
• tyre pressure of PTR shall be 0.56 Mpa(5.6 kg/cm2)
• Water sprinkler in PTR to be working condition.
• Rolling speed shall be not more than 5 kmph. All the above parameters of rollers shall be checked before compaction Bituminous
Layer

47. Temperature of various Stage
Stage of Work Indicated Temperature (o
C)
Binder at Mixing 160 - 170
Aggregate at Mixing 160 - 175
Mix at Mixing Plant 160 - 170
Mix at Laying 150 Minimum
Rolling at Laying Site 100 Minimum

48. THANK YOU.