Subgrade, ETB and Asphalt Site Organisation construction procedure-2.pptx

Construction Procedures and Site
Organization for:
Subgrade, Sub-base, Base (ETB) and AC Cold
Mix
MINISTRY OF ROAD AND TRANSPORT
KENYA INSTITUTE OF HIGHWAYS AND BUILDING
TECHNOLOGY

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2
Work organization is to arrange and distribute the construction
work between the gangs of workers in such a way that, the best use
is made of the available labour, materials, tools and equipment.
To be able to do this the Contractor/Site supervisor must know:
In which order the operations and activities of the work should
follow each other, (construction sequence);
 How big the various gang should be?(gang size);
How to motivate the worker by using incentives like task work;
The appropriate task rates for the different construction
activities;
How instructions should be given and received correctly in order
to avoid misunderstandings.
LVSR Construction Site Organization

PREPARATION OF SUBGRADE
Construction tolerances
 The subgrade must be prepared to conform with the construction
tolerances in terms of:
 CBR min 15%
 Camber 3% and be of a uniform roof shape (of crossfall)
 Evenness, both transverse and longitudinal (i.e. no
unnecessary sags or humps due to inaccurate
construction)
 Correct width in order to accommodate the base layer and
shoulders as illustrated below
Base half width
4.25 m (4.0m)
Sub-base half width
4.825m (4.0m)

 The sub-grade must be pre-shaped, i.e. spread evenly of the width
of the road.
 If lime is required to reduce the Plasticity Index (PI) of the material,
bags of lime are spread out in a pattern to ensure the right amount
of lime will be mixed into the sub-base.
 The lime must be thoroughly mixed into the material by blading
before any water is added.
 When the mixing of the lime is satisfactory, the material is again
preshaped over the width of the road.
 Water is now added by a waterbowser and the material mixed to
Optimun Moisture Content (OMC) by blading.
 Depending on the in-situ moisture content of the material, several
passes of the water bowser may be required to reach OMC.
 Care must be taken not to apply too much water since this will
prohibit compaction.
 If that happens, the sub-base must be allowed to dry out before it is
compacted.
Reshaping, and watering

 To guide the grader operator in the final shaping to 3% camber,
stakes must be erected at say 5 m distance from the centre line.
 Centre line levels are set out with profiles 1 m above finished sub-
base.
 This allows for checking and correction of minor humps and sags in
the vertical alignment.
 The levels 1 m above the finished sub-base are transferred to and
marked on the stakes.
 For checking the camber, the stakes are marked again at 5 m x 3%
= 0,15 m above and below the 1 m level mark.
Final shaping and compaction
4.5 m 4.5 m
1.0 m
0,15 m
0,15 m

4.5 m
 During final shaping, the grader operator must be assisted by three
workers. Two workers hold a string line tightly from the high mark on
one side to the low mark on the other side such that the string is
parallel to the 3% camber on the side that the grader is working.
 The third person checks the height from the string line to the
surface to tell the grader operator whether to cut or to fill.
 To allow for compaction, the level after the final cut to uniform
camber at 3%, should be approx. 20-30 mm higher than finished
level.
4.5 m
1,0 m
0,15 m
0,15 m
0,97-0.98 m
Final shaping and compaction

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*
Emulsion Treated Base (ETB) has been shown to have
numerous advantages over natural or cement treated
granular bases, both in long term performance as well
as during construction.
ETB eliminates or minimizes some of the major
problems during construction, especially where space is
limited and by-passes cannot be provided in that:
–Traffic can be allowed to use the base before the surfacing
is applied with no damage to the base
–ETB base will not be damaged by inclement weather.
–Curing, which is a big problem for cement treated bases, is
eliminated.
–The ETB base can be used as a working and clean storage
platform during construction operation

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*
ETB base is “Waterproof”, i.e. is less sensitive to
any moisture ingress in the base.
Construction of ETB and Cold Mix Asphalt is
eminently suitable for labour-based methods and do
not require heavy and/or specialized equipment.
 The work methods for both ETB base and Cold mix
asphalt are easily taught and applicable by agency
staff and are equally applicable for future
maintenance operations.

*
Reasons for use of shutters
To ensure accurate control of thickness of layer
To ensure accurate control of compaction of the layer
To ensure accurate control of a smooth and even finished riding surface
To ensure minimal wastage of materials by avoiding spill over.
Spacer plate
The use of a spacer plate on top of a compacted adjacent layer is needed so as to
allow for the compaction of the materials from its loose state to compacted
state.
Shutters must be accompanied with the following:
Screeding bars
Steel pins
Hammers
Strings
Line and level
Tape measures
Squegees
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Notes:
Before setting out shutters on the road formation, ensure that all
the formation works have been inspected, tested and approved by
the Engineer.
Avoid walking on the spread of un-compacted gravel as this will
result in differential compaction and uneven final surface
Shutters should consist of the following lengths:
1m
2m
3m and height of 150mm.
Compaction
Material compaction is important for three main reasons:
* To increase the strength of the material.
* To reduce the permeability, thus reducing moisture content changes
* To reduce settlement and increase resistance to deformation 1/23/2024
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Moisture content
 The degree to which compaction can be achieved is governed by moisture content, if the
material is too dry, friction between particles prevents close packing, if the material is to
wet the water between particles prevent close packing.
Optimum moisture content is the moisture at which maximum density is achieved. As a
rule of thumb OMC of a material can be checked in the field by squeezing a sample in the
hand:
* If the material is too dry it will not stick together and must be thoroughly mixed with
water before compaction
* If the water runs out the material, it is too wet and should not be compacted but left
to dry out until the moisture content is reduced
* If the material is wet enough to stick (you can form a ball), it has optimum moisture
content and is suitable for compaction,
Site Organization and Productivity Rates
 Setting out dumping distance for or spotting of gravel should be done in a manner to allow
passage of traffic in cases where deviations are not possible.
Assuming a lorry of 5m³ loading capacity is used, the material is spread within 5m full road
length on a carriageway width of 5.4m.
Since the shutters are placed on half road section the 5m³ 1/23/2024
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*
Note:
Spreading distance = Volume of gravel
Carriageway width x Gravel layer thickness
Productivity
 Normally the task rates which have been issued for spreading loose gravel are 12 –
16m³/wd
Considering the activities involved i.e. watering and processing to attain the proper OMC
the task rate should be lowered to 5 – 7m³/wd
Team composition
Mixing and placing of gravel - 4No.
Water supply - 1No.
Setting of shutters and screeding -
3No.
Total team - 8No.
Finishing/edge treatment
After a day’s work a work day should be engaged to place material on edge of shoulders
after removal of shutters and tidying up of the works
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 The construction method using shutters has been developed to facilitate
construction of structural pavement layers to the same standard specifications
used for conventional, machine based operations.
 The method ensures even layer thickness, smooth riding surface and facilitates
good quality control.
 By mixing the ETB in small 60 ltr
batches a uniform mix is easily
achieved which has the correct
amount of cement, emulsion
and water.

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 When using concrete mixers, the batch can be increased to 90-120 ltr, but mixing in
purpose made mixing trays is preferred.
 The trays are easy to clean, easy to transport and production can easily be scaled up
by increasing the number of mixing trays.
 The mixers need to be cleaned out
regularly due to caking of fines in
the drum.
 If not watched carefully, the mixers
will not give the same uniform mix
as the mixing trays.
 Two concrete mixers will have
approximately the same daily
output as five mixing pans.

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 At the end of the day, the shutters are set out to be ready for the next
day’s production.
Base construction

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 Initially Steel shutters were procured.
 Due to the cost, a new design using locally available hardwood and angle irons,
was developed
 The picture shows both
types of shutters.
 The Steel shutter
incorporates a 50mm
bulking rail that rides on
top of the base shutter
and can be used for a
composite ETB, whereas
the hardwood model in
its present form is all in
one piece and an only be
used for a full 100mm
ETB.

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 The loose ETB is wheel-barrowed to the front of the construction and screeded off
level with the top of the shutters.
 A tarpaulin is used to cover the loose ETB to prevent moisture loss, until
compaction can take place.

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*
.
 The tarpaulin is rolled up for the section ready for compaction.
 Normally 10-15 m sections are compacted at a time.

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Compaction of ETB layer

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*
.
 After the first pass of the
roller in light vibratory
mode, most of the
settlement has already
taken place.
 Some corrections are
usually necessary
particularly on the joints
between adjacent sections
to smooth out humps on
the surface.
 This is easily done with a
steel squeegee when the
material is still moist.
 Any surface corrections
after final compaction is
nearly impossible.

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*
.
 Compaction is done until refusal, i.e. when the roller drum no longer leaves
a mark on the surface.
 At that point the 150 mm loose ETB has compacted to 100 mm with good
accuracy.
 The picture below
shows the final
compaction being equal
to the height of the
bulking rail or 50 mm.

3.5 m (3.0m/2.5m)
Lane open for traffic
End of
previous
days’
production
Daily production target
3.5 m width -> 34.3m
3.0 m width -> 40 m
2.5 m width -> 48 m
Direction of
wheelbarrow
movement
Mixing
trays
Emulsion
stand
Cement
Site organisation for ETB production – Production Set-up
Base
material
stockpile
24 m3

3.5 m
3.5 m width -> 30m Teach team
Mixing
trays
Emulsion
stand
Cement
Site organisation for ETB production – Production Set-up
Base
material
stockpile
24 m3
Team 1 Team 2
Mixing
trays
Emulsion
stand
Cement

End of
previous days’
production
Daily production target per team:
3.5 m width -> 34.3m
3.0 m width -> 40 m
2.5 m width -> 48 m
Direction of
wheelbarrow
movement
Mixing
trays
Emulsion
stand
Cement
Site organisation for ETB production
Production Setup and Sequence using 5 mixing pans
Base material
stockpile 20 m3
Team 1: 3 days x 34,3
m
Daily production target with three teams:
Width 3.5 m -> 102,9 m
Width 3.0 m -> 120 m
Width 2.5 m -> 144 m
m
m
102,9 m 102,9 m 102,9 m
Direction of
work
m
m
m
On a 7,5 m cross-section, the three team are spaced out 102,9 m apart, all
working in the same lane and in the same direction. Over a six day week a total
of 308,7 m full width can be produced.
Water
drums or
cart

End of
previous days’
production
Daily production target per team:
3.5 m width -> 34.3m
3.0 m width -> 40 m
2.5 m width -> 48 m
Direction of
wheelbarrow
movement
Concrete
Mixers
Emulsion
stand
Cement
Production Setup and Sequence using 2 concrete mixers
Base material
stockpile 20 m3
m
Daily production target with three teams:
Width 3.5 m -> 102,9 m
Width 3.0 m -> 120 m
Width 2.5 m -> 144 m
m
m
102,9 m 102,9 m 102,9 m
Direction of
work
m
m
m
On a 7,5 m cross-section, the three team are spaced out 102,9 m apart, all
working in the same lane and in the same direction. Over a six day week a total
of 308,7 m full width can be produced.
Water
drums or
cart

Production Setup and Sequence using 4 Teams
100m
Team 2day 1
Team 1 day 1
Team 4day 1
Team 3 day 1
traffic
traffic
40m 40m 10m 80m
traffic
100m

ETB Team
composistion
Duties No of
workers
Tools requirements
Base material supply
Screen out oversize, load into
measuring buckets, load wheelbarrows,
remove oversize from road
2
6 x shovels
9 x 20 litre measuring buckets
Mixing and placing base
Collect base material from stockpile,
add cement, emulsion and water, mix
and place base
3 x 3 = 9
9 x spades
5 x wheelbarrows
5 x mixing pans
Emulsion supply
Measure out required quantities of
emulsion, supply mixing teams as
required
1
1 x drum stand
1 x ball valve
5 x measuring containers
Cement supply
cement, supply mixing teams as
required
1
5 x measuring containers
1 x scoop
Water supply
Measure out required quantites of
water, supply mixing teams as required
1
5 x water buckets
1 x measuring container
Screeding
Level and screed base material between
shutters, cover base with plastic,
recover base material falling outside
shutters
3
1 x spade
1 x steel squeegee
1 x screed
1 x 25 m roll of plastic material for
covering base
1 x (50mm x 50mm x 3 m) wood
Shoulders, misc. tasks
Place gravel on edge of shoulders after
removal of shutters, tidying up etc. 1
1 x shovel
1 x wheelbarrow
1 x (50mm x 50mm x 3 m) wood
Total ETB team 18
Team Composistion using 3 mixing pans
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Site organisation for ETB production – Job Descriptions
Position Duties
Site Supervisor Being overall responsible for organisation and management of the ETB production site comprising of
three ETB production teams, each headed by one Assistant Site Supervisor/ Team Leader and having
43 workers spread out among the different tasks described in the ETB Team Composition Sheet.
The Site Supervisor’s specific duties include the following:
a) Organising timely and adequate supply of construction materials (gravel, emulsion, cement,
water), tools and equipment as well as fuel and drinking water
b) Controlling that the consumption of construction materials, particularly emulsion and cement, is in
accordance with the prescribed design mix and rate of production
c) Organise the teams in accordance with the Team Composition Sheet, request additional workers as
required, keep the muster roll and compile the Daily Activity Report.
d) Train the Work Force and check that good standard of workmanship is achieved at all levels, in
particular regarding mixing of the ETB, screeding and compaction.
e) The day before production of a particular section, set out the shutters, check for correct camber,
make corrections on the sub-base to ensure that this layer is within construction tolerances, set
out the team production target, ensure that the correct amount of gravel for the base is dumped in
the correct locations, remove left over material from the last days production, check consumption
of cement and emulsion
f) Attend to disciplinary problems and report to Site Engineer.
Assistant Site
Supervisor/
Team Leader
Being responsible for one ETB Construction Team under the guidance of the Site Supervisor.
The Assistant Site Supervisor/ Team Leaders specific duties include:
a) Organise the team as directed by the Foreman and request additional workers as required
b) Ensure that all the requisite hand tools and equipment are in place and in good working order,
request replacements or repairs as required
c) Assist the Site Supervisor in the training of the workers , supervise the team and check that good
standard of workmanship is achieved, in particular regarding the mixing of the ETB , screeding and
compaction
d) Assist the Site Supervisor in the preparations for the next days production as described under point
e) above
e) Report disciplinary problems to the Site Supervisor.
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Base
material
MDD (kg/m3
Emulsion Volume EV(ltr) per 60 ltr mix (1 pan)
EC 1,5% of MDD EC 2,0% of MDD EC 2,5% of MDD
1900 1,1 ltr 1,5 ltr 1,9 ltr
ltr
EC
MDD
EV
100
04
,
0
(%) 


To calculate the volume of emulsion in the mix, use the formula below:
Where:
EV = Emulsion volume in litres
EC(%) = the percent of emulsion of MDD by weight
The factor 0,04 takes account for the fact that 60 litres of loose gravel
compacts to 40 litres at OMC
The EC(%) to be used will be determined by testing and relyed to the
site staff by the Site Engineer.
Example:
Calculation of the volume of emulsion per 60 ltr mix (1 mixing pan)
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Base
material
MDD (kg/m3
Emulsion Volume EV(ltr) per 60 ltr mix (1 pan)
CC 1,0% of MDD CC 1,5% of MDD CC 2,0% of MDD
1900 0,5 ltr 0,75 ltr 1,0 ltr
ltr
CC
MDD
CV
100
67
,
0
04
,
0
(%) 



To calculate the volume of cement in the mix, use the formula below:
Where:
CV = Cement volume in litres
CC(%) = the percent of cement of MDD by weight (usually 1%)
The factor 0,04 takes account for the fact that 60 litres of loose gravel
compacts to about 40 litres at OMC
The factor 0,67 converts the weight of the cement in kg to volume in
litres
The CC(%) to be used will be determined by testing
Example:
Calculation of the volume of cement per 60 ltr mix (1 mixing pan)
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1. At the start of the day, load a representative sample of 60 ltr of gravel into
a mixing pan. The sample should in your view have the same moisture as
content as the remainder of the stockpile to be used for the day.
2. Add meaured volumes of water until the trial mix has reached OMC.
Make a note of the total volume of water added.
3. Subtract from this volume, 40% of the volume of emulsion to be used for
a 60 ltr mix (since the emulsion contains 40% water and 60& bitumen).
This will be the amount of water to be added to the mix.
4. Make sure the Assistant Site Supervisors and the workers handling the
water and emulsion knows exactly how much water is to be added to
each mix for that day and that they have the required measuring
containers available.
Example:
Water added to the trial mix: 3,5 ltr
- Volume of water in emulsion: 1,5 ltr x 40% = 0,6 ltr
=Compaction water 2,9 ltr
Practical on-site determination of volume of compaction water to be used
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1. Load correct volume of gravel into wheelbarrows and haul to the mixing
pan. The volume should be measured by 20 ltr buckets or as struck
volume in the wheelbarrow.
2. Add the required volume of cement and mix thoroughly
3. Add approximatly 2/3 of the compaction water to the mix and mix until the
water is uniformly distributed in the mix.
4. Add the rest of the compaction water to the measured volume of
emulsion.
5. While the mixing is continuing, slowly pour the emulsion over the mix
making sure that the emulsion is spread evenly over the mix
6. Mix until the emulsion has been evenly distributed throughout the whole
mix and load into wheelbarrows.
With three labourers mixing, the mixing process should take approx. 4,5 - 5
minutes.
Example:
Compaction water = 2,9 ltr
Add approx. 2 ltr to the mix and add the remaining 0.9 ltr to the measured
volume of emulsion.
Procedure for mixing ETB with mixing pans
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1. Load correct volume of gravel into 20 ltr measuring buckets and place
next to mixer.
2. Measure out correct volumes of cement, emulsion and water and place
next to mixer.
3. Add the required volume of cement and mix thoroughly
4. Add approximatly 2/3 of the compaction water to the mix and mix until
the water is uniformly distributed in the mix.
5. Add the rest of the compaction water to the measured volume of
emulsion.
6. While the mixing is continuing, slowly pour the emulsion into the mixer.
7. Mix until the emulsion has been evenly distributed throughout the whole
mix and discharge into wheelbarrows
The mixing process should take approx. 4 minutes.
Example:
Compaction water = 2,9 ltr
Add approx. 2 ltr to the mix and add the remaining 0.9 ltr to the measured
volume of emulsion.
Procedure for mixing ETB with concrete mixers
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37
Bill – Natural Gravel
Bases
What to check: Required Quality: Allowed
Tolerance:
Checking using:
12-50-001(a)
– Hand Packed stone paving
a) Stone quality
b) Width of pavement
c) Camber
d) Thickness
e) Longitudinal
evenness
f) Compaction
a) As per specifications
b) Every 20m, a.p. drawing
c) Every 20m, 3%
d) Every, 150mm comp.
e) Over 3m in any direction
f) Continuous, No. of
passes
a) N/A
b) +/-50mm
c) +/-1%
d) -10mm
e) +/-20mm
f) N/A
a) Visual and/or Lab tests
b) Tape Measure
c) Camber Board and Spirit
level
d) Tape measure
e) Straight edge and spirit
level
f) Counting passes
Note: Approval from Engineer required before you can continue with any other work item, e.g. Composite ETB Work
12-50-002
Composite Emulsion Treated
Base Works
a) Gravel quality
b) Dumping distances
c) Placing shutters
d) Width of base layer
e) Camber
f) Thickness
g) Longitudinal
evenness
h) Mix proportions
i) Compaction density
a) Grading PI and CRB
b) Depend on haul capacity
c) Width and level
continuous
d) Every 20m, a.p. drawing
e) Every 20m, 3%
f) Every, 100mm (a.p.
specs.)
g) Continuous
h) Uniform and correct
quantities, random
i) Every, 100mm, 98%
T180 modified AASHTO
a) As per Specs.
b) N/A
c) Same as for d)
d) +/-250mm
e) +/-0.5%
f) -5mm
g) Over 3m = +/-
6mm
h) No tolerance
i) Not below
98%
a) Visual and/or Lab tests
b) Tape Measure, spirit level
c) Camber Board and Spirit
level
d) Tape measure
e) Test hole, Tape measure
f) 3m Straight edge and Tape
measure
g) Visual - correct size of
measuring containers,
mixing process
h) DCP, and or sand
replacement method
Note: Approval from Engineer required before you can continue with Bills 15 and 16; Bituminous Surface Treatments and Mixes
ROADS 2000 CONRACTOR’S QUALITY CONTROL CHECKLIST FOR LOW – VOLUME SEALED ROAD
(Check yourself the quality of work before the Engineer checks it!)
1/23/2024

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*
.
 The same mixing trays used for the ETB, is used also for the Cold Mix
Asphalt.

39
Bill – Bituminous
Surface Treatments
What to check Required Quality Allowed
Tolerance
Checking using
15-50-002
Prime
a) Mixture
b) coverage
 1:6(Emulsion :
Water)
 Total and equal
(no ‘empty’
spots)
 None
 None
 Visual →→correct size of
mixing process
 Visual
Bill 16 - Bituminous
Mixes
What to Check: Required Quality: Allowed
Tolerance:
Checking Using:
16-60-002
Cold Mix Asphalt
Surfacing
 Aggregate quality
 Emulsion &
cement quality
 Mix proportions
 Surface texture,
coverage, joints
and thickness
 Bleeding
 Grading,
hardness
 As per Specs and
from certified
supplier!
 Uniform and
correct
quantities,
random
 Uniform
compacted
thickness of
14mm, no ‘holes’
 No bleeding
spots
 As per
Specs
 None
 No
tolerance
 None
 None
 Laboratory tests
 Visual →ensure correct
type of emulsion, no
foam when opening
drum/cement without
lumps
 Visual →correct size of
mixing process
 Visual, straight edge
 Visual
Note: Approval from Engineer required before you can continue with Bills 20 – Road Furniture
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*
.
 First the 20x20 mm
Guide rails are set out.
 On a 3.5m width the
asphalt will be laid in
three strips of 0,92 m.

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*
.
 Prior to the mixing,
the base must be
primed with a 1:8
diluted SS60
emulsion.
 The prime is applied
as thin layer in
order to cure
quickly, by means of
a watering can and
brooms

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 Add 40 ltr of 6-12 mm and
10 ltr of 1.5-6 mm stone
 Add just enough water to
moisten the aggregates
and mix
 Add the 8 ltr of emulsion
by pouring it slowly over
the entire surface of the
aggregates while the
mixing takes place
 Quickly spread and level
the mix to the top of the
guide rails.

43
Bill 16 - Bituminous
Mixes
What to Check: Required Quality: Allowed
Tolerance:
Checking Using:
16-60-002
Cold Mix Asphalt
Surfacing
 Aggregate quality
 Emulsion & cement
quality
 Mix proportions
 Surface texture,
coverage, joints and
thickness
 Bleeding
 Grading, hardness
 As per Specs and
from certified
supplier!
 Uniform and
correct quantities,
random
 Uniform
compacted
thickness of
14mm, no ‘holes’
 No bleeding spots
 As per Specs
 None
 No tolerance
 None
 None
 Laboratory tests
 Visual → ensure correct
type of emulsion, no foam
when opening
drum/cement without
lumps
 Visual →correct size of
mixing process
 Visual, straight edge
 Visual
Note: Approval from Engineer required before you can continue with Bills 20 – Road Furniture
1/23/2024

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*
 When the emulsion
has broken (the colour
has turned from dark
brown to black), the
strip of asphalt is
rolled with the roller in
vibratory mode

Width of ETB
3.5 m (3.0m/2.5m)
End of
previous
days’
production
using one tray:
100 mixes -> approx. 240 m2
Place 3 nos 3,0 m
20 x 20 mm guide rails
each side for first strip
Mixing tray,
moved forward
for each mix
Emulsion stand,
moved forward
with production
Site organisation for Asphalt production – Production Set-up
Stone aggregate stockpiles:
2 m3 of 6-12 mm stone
0,5 m3 of 1,5 - 6 mm stone
Width of Asphalt 3,0 m / 2,76 m
Make 3 equal strips of 1,0 m / 0,92 m
First strip
Second strip
Third strip
3, 0 m long
20 x 20 mm
guide rail
Material consumption:
Stone 6-12 mm = 4 m3
Stone 1,5-6 mm = 1 m3
Cathionic CMS65 = 780 ltr (4 drums)
Anionic SS60 (diluted 1:8) = 24 ltr
First stockpile just beyond half way,
e.g. at 45 m
Second stockpile just beyond end of daily production,
e.g. at 90 m

Asphalt production – Longitudinal joint details
First strip
Comp. thickness = 14 mm
Guide rail 3 m long
20 x 20 mm square tube
Guide rail 3 m long
20 x 20 mm square tube
Second strip
Loose thickness = 20 mm
3 m long 50 x 6 mm flat bar
First strip
Loose thickness = 20 mm
1/23/2024
46

Asphalt production – Getting an even surface
d
Specification: d <= 6 mm measured with a 3 m straight edge
For d <= 6 mm, the uneven base surface is corrected with the asphalt.
When spreading the asphalt, do not put weight on the guide rail, otherwise this
will deflect and the surface of the asphalt will follow the suface of the base
For d > 6 mm, the uneven base surface may be corrected with slurry before
application of the the asphalt.
d
Slurry
1/23/2024
47

The trials have shown the following mix to give a good quality,
dense asphalt:
 12 ltr of 6-10 mm stone
 28 ltr of 0-6 mm stone
 3 ltr of 0-2 mm fine sand
 Water as required to moisten the aggregates before
adding emulsion. For a mix of 40 ltr, approx. 0,75 ltr of
water can be added if the aggregates are dry, less if
these are already moist
 8 ltr of Cathionic Emulsion K3-65
Output:
 The above mix of 40 ltr of aggregates will yield an output
of approximately 2,4 m2, i.e. for 1.2 m wide strip approx.
2,0 m length.
Asphalt design mix (1 mixing pan)
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48

 With the Cathionic medium setting emulsion K3-65, the time available
for mixing, placing and leveling the asphalt in between the guide rails, is
very limited, approx. one minute, before the asphalt gets sticky and
difficult to spread.
 It is therefore important that the workers are properly trained, the site is
well organised, clean and tidy and that only the correct tools in good
working order are used.
1. Pour the coarse and fine aggregates into the mixing pan.
2. Add just enough water to moisten all the aggregates and mix
thoroughly
3. Add emulsion by pouring it evenly over the entire surface of
the aggregates in the pan
4. Mix quickly and efficiently to ensure that all aggregates are
coated with bitumen
5. Scoop the mix out of the pan using shovels and place in
between the guide rails as directed
6. Use the specially designed squeegee or spreader to quickly
level the asphalt when it is still flowing easily. Ensure proper
filling along the guide rails and against the previous batch
The mixing and placing process
1/23/2024
49

Asphalt Team
composistion
Duties
No of
workers
Tools requirements
Aggregate supply
Provide stockpiles in correct
positions for the days production.
Load into gauging boxes , load
wheelbarrows and cart to mixing tray
2
2 x shovels
2 x 20 litre gauging boxes (6-12 mm
stone)
1 x 10 litre gauging box (1,5-6 mm
stone)
2 x Wheelbarrows
Emulsion and
water supply
emulsion and water, supply mixing
teams as required 1
1 x drum stand
1 x ball valve
1 x measuring container for emulsion
1 x water bucket
1 x measuring container for water
Mixing and placing
asphalt
Mix coarse and fine stone
aggregates, add water and mix so
that all aggregates are moist, add
emulsion and mix thoroughly and
quickly just until all aggregates are
coated, place in between guide rails
as directed
3
3 x spades for mixing
3 x shovels for scooping asphalt out of
pan
1 x mixing pan
Screeding
Set out guide rails, spread and level
asphalt between guide rails, recover
asphalt falling outside guide rails, tidy
up, backfill joints where required
2
1 x spade
1 x steel squeegee / spreader
1 x tarpaulin for covering asphalt in
case of rain
6 x 3 m long 20 x 20 mm guide rails
2 x 3 m long 50 x 6 mm flat bar
Total Asphalt team 8
Site organisation for Asphalt production
Team Composistion using 1 mixing pan
1/23/2024
50

Asphalt Site setup Duties No of workers Tools requirements
1 x Asphalt Team See description for Asphalt Team 8 See description for Asphalt Team
Setting out, correcting
base if required, priming
with 1:8 diluted anionic
emulsion SS60
Correcting base to within tolerances where
required, applying 1:8 diluted emulsion on
base, demarkating start and end of daily
production target
1 x Foreman (shared with
closest ETB Team)
1 x Asst. Foreman / Team
leader
2 x Workers (screeding team)
1 x carpentry hammer
Box of 1 ½ inch nails
Guide rails and flat bars:
6 x 3 m long
guide rails 2 x 3 m long flat
bar
5 m tape measure
30 m tape measure
1 x Watering can w/rose head
3 x brooms
1 x Bomag vibr. Roller
1 x 3 m steel straight edge for
base correction
1 x Empty drum for water
Hino Tipper truck
Traffic cones
Compaction Compact asphalt as directed 1 x Bomag operator
Stockpiling aggregates
Hauling aggregates by tipper truck to asphalt
production site, dumping on ETB base as
directed
Emulsion supply
Certify amount of emulsion used, moving
drum to correct position for the next day,
supply new drums as required by end of the
day
Water supply
Placing empty drum in correct position, filling
with water
Handling of tools, guide
rails and construction
equipment, maintain site
tidyness
Inspecting condition of tools, supply new
tools as required, collect and clean guide
rails, squeegees etc, bring back to store at
end of day
Direction of traffic Direct traffic
Total AsphaltB Site
setup
1 x Foreman (shared)
1 x Asst. Foreman / Team
Leader
1 x Bomag operator (shared)
8 x Workers
Site organisation for Asphalt production
Site Setup using 1 team with 1 mixing pan
1/23/2024
51

Site organisation for Asphalt production – Job Descriptions
Position Duties
Site Supervisor Being overall responsible for organisation and management of the Asphalt production site comprising of 1
Asphalt production team headed by one Assistant Site Supervisor/Team Leader and having 8 workers
spread out among the different tasks described in the Asphalt Team Composition Sheet.
The Site Supervisor’s specific duties include the following:
a)Organising timely and adequate supply of construction materials (aggregates, emulsion, water), tools
and equipment as well as fuel and drinking water
b)Controlling that the consumption of construction materials, particularly emulsion and aggregates, is in
accordance with the prescribed design mix and rate of production
c)Organise the teams in accordance with the Team Composition Sheet, request additional workers as
required, keep the muster roll and compile the Daily Activity Report.
d)Train the Work Force and check that good standard of workmanship is achieved at all levels, in
particular regarding mixing of the Asphalt, screeding and compaction.
e)The day before production of a particular section, make corrections to base to ensure that this layer is
within construction tolerances, clean the base and prime with diluted 1:8 Anionic SS60 emulsion, set out
the team production target, ensure that the correct amount of aggregates is dumped in the correct
locations, remove left over material from the last days production, check consumption of aggregates and
emulsion
f)Attend to disciplinary problems and report to Site Engineer.
Assistant Site
Supervisor/ Team
Leader
Being responsible for one Asphalt Construction Team under the guidance of the Site Supervisor.
The Assistant Site Supervisor/ Team Leaders specific duties include:
g)Organise the team as directed by the Foreman and request additional workers as required
h)Ensure that all the requisite hand tools and equipment are in place and in good working order, request
replacements or repairs as required
i)Assist the Site Supervisor in the training of the workers , supervise the team and check that good
standard of workmanship is achieved, in particular regarding the mixing of the Asphalt , screeding and
compaction
j)Assist the Site Supervisor in the preparations for the next days production as described under point e)
above
k)Report disciplinary problems to the Site Supervisor.
1/23/2024
52

*
THANK YOU
1/23/2024
53

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