TCS Q 113 01 R0

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TCSQ11301R0/SZA
TRANSMISSION CONSTRUCTION STANDARD
TCS-Q-113.01, Rev. 0
Date of Approval: April 10, 2006

TABLE OF CONTENTS
1.0 SCOPE

2.0 CONFLICTS AND DEVIATIONS

3.0 REFERENCE STANDARDS

3.1 Company Standards
3.2 Industry Standards
3.3 ASTM Specifications and Test Methods
3.4 AASHTO Standards and Test Methods

4.0 GENERAL REQUIREMENTS

4.1 On-Site Requirements
4.2 Material Requirements
4.3 Safety Requirements

5.0 DESIGN REQUIREMENTS

5.1 Specific Requirements
5.2 Operational Requirements
5.3 Miscellaneous/Minor Works

6.0 EARTHWORKS

6.1 Clearing and Preliminary Works
6.2 Sub-grade
6.3 Sub-base and Base Course Materials
6.4 Construction

7.0 PRIME AND TACK COAT REQUIREMENTS

7.1 Prime Coat
7.2 Tack Coat
7.3 Precautions and Maintenance of Bituminous Coating

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8.0 ASPHALT CONCRETE AND PAVING

8.1 Materials
8.2 Asphalt Concrete Mix Design
8.3 Equipment
8.4 Preparation of Asphalt Concrete
8.5 Placement of Asphalt Concrete Mixture
8.6 Tolerances
8.7 Quality Control
8.8 Miscellaneous Works

9.0 FINAL CLEANUP

10.0 APPENDIX

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1.0 SCOPE

This Standard covers the minimum mandatory requirements for the construction of Asphalt
concrete pavement for the Saudi Electricity COMPANY works and includes, but not limited
to, sub-grade preparation, installation of sub-base, base course and asphalt concrete paving,
sampling, testing and inspection of materials, and equipment.

2.0 CONFLICTS AND DEVIATIONS

2.1 Any conflicts between this Standard and other applicable Saudi Electricity
COMPANY (SEC) Standards, Industry Standards, Codes, and forms shall be
resolved in writing by the COMPANY Representative.

2.2 Any request to deviate from this Standard shall be directed to the Manager,
Transmission Standards and Specifications Department.

3.0 REFERENCE STANDARDS

The latest revisions of the following Codes and Standards shall be applicable for the
equipment/material covered in this TCS. In case of conflict, the vendor/ manufacturer may
propose equipment/material conforming to one group of Industry Codes and Standards
quoted hereunder without jeopardizing the requirements of this TCS.

3.1 COMPANY Standards

3.1.1 TCS-Q-113.02 Construction Standard for Earthworks

3.1.2 No. 6.483 Special Manual for Industrial Security (Construction Safety
Manual)

3.2 Industry Standards

3.2.1 AASHTO Guide for Design of Pavement Structures.
American Association of State Highway and Transportation Officials, 1993

3.2.2 The Asphalt Institute, Manual Series

1. MS-1 Thickness Design -Asphalt Pavements for Highways and Streets

2. MS-2 Mix design methods for asphalt concrete and other hot mix types

3. MS-8 Asphalt Paving Manual

4. MS-16 Asphalt in paving Maintenance

5. MS-17 Asphalt overlays for Highways and Street Rehabilitation

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3.2.3 Ministry of Communication (MOC):-General Specification for Road and
Bridge Construction

3.2.4 General Specifications For Building Construction in Kingdom of Saudi
Arabia- Latest Edition

3.3 ASTM Specifications and Test Methods

3.3.1 Soil Materials

1. ASTM D 1556 Test Method for Density and Unit Weight of Soil in
place by the Sand Cone Method

2. ASTM D 1557 Test Method for Laboratory Compaction Characteristic
of soil using modified effort 56000 ft-lbs/ft
3
(2700 kN-
m/m
3
)

3. ASTM D 1883 Test Method for CBR (California Bearing Ratio) of
laboratory-compacted soils

4. ASTM D 2419 Test Method for Sand Equivalent Value of Soils and
Fine Aggregate

5. ASTM D 2922 Test Method for Density of Soil and Soil Aggregate in
place by the Nuclear Method (Shallow Depth)

6. ASTM D 4253 Test Method for Maximum Index Density and Unit
Weight of Soil using a Vibratory Table

7. ASTM D 4254 Test Method for Minimum Index Density and Unit
Weight of Soils and Calculation of Relative Density

8. ASTM D 4318 Test Method for liquid limit, Plastic limit, and
Plasticity Index of Soil.

3.3.2 Aggregate Materials

1. ASTM C 88 Test Method for Soundness of Aggregates by Use of
Sodium Sulfate or Magnesium Sulfate

2. ASTM C 117 Test Method for Materials finer than 75-m (No. 200)
Sieve in Mineral Aggregates by washing

3. ASTM C 131 Test Method for Resistance to Degradation of Small
Size Coarse Aggregate by Abrasion and Impact in the
Los Angles Machine

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4. ASTM C 136 Method for Sieve Analysis of Fine and Coarse
Aggregates

5. ASTM D 692 Specification for Coarse Aggregate for Bituminous
Paving Mixtures

6. ASTM D 1073 Specification for Fine Aggregate for Bituminous
Paving Mixtures

7. ASTM D 4791 Test Method for flat particles, elongated particles, or
flat particles and elongated particles in coarse
Aggregate

3.4. AASHTO Standards and Test Methods

3.4.1. Bituminous Materials

1. AASHTO M-20 Specification for Penetration-Graded Asphalt Cement
(for use in Pavement Construction)

2. AASHTO M-81 Specification for Cut-back Asphalt (Rapid-Curing Type)

3. AASHTO M-82 Specification for Cut-back Asphalt (Medium-Curing
Type)

4. AASHTO M-156 Specification for Mixing Plants for Hot Mixed, Hot
laid Bituminous paving mixtures

5. AASHTO M-320 Standard Specification for Performance Grade Asphalt
Binder.

3.4.2. Test Procedures

1. AASHTO T-37 Specification for Mineral Filler for Bituminous Paving
Mixtures

2. AASHTO T-49 Test Method for Penetration of Bituminous Materials

3. AASHTO T-99 The Moisture Density Relations of Soils Using a 5.5
lb. Rammer and 12-Inch Drop

4. AASHTO T-180 The moisture-Density Relations of Soils Using a 10-lb.
Rammer and 18-inch Drop

5. AASHTO T-209 Test Method for Theoretical Maximum Specific
Gravity and Density of Bituminous Paving Mixtures

6. AASHTO T-275 Test Method for Bulk Specific Gravity and Density of
Non absorptive Compacted Bituminous Mixtures

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4.0 GENERAL REQUIREMENTS

4.1 On-Site Requirements

4.1.1 All works performed and all materials furnished shall be in conformity with
the lines, grades, cross-sections, dimensions, and material requirements,
including tolerances, shown on the SEC approved plans/ drawings or
indicated in the SEC specifications.

4.1.2 All existing underground utilities which may be exposed/ uncovered or
otherwise be affected by the excavation work shall be properly protected, by
shoring, bracing, and supporting, etc., as needed.

4.1.3 Care shall be taken to protect aerial, surface or underground utilities around
the site.

4.1.4 Adequate dewatering equipment to remove and dispose all surface and ground
water entering the excavations and other parts of the work, shall be provided
at site and maintained properly.

4.1.5 Sub-grades or bottom of excavation for structures shall be firm, dense and
thoroughly compacted as specified under Construction Requirements. It shall
be free from mud and muck, and sufficiently stable to remain firm and intact
under the feet of the workmen.

4.2 Material Requirements

4.2.1 All materials shall meet or exceed the appropriate AASHTO, ASTM, or other
Standards and specifications as required by the SEC approved plans/ drawings
or as indicated in the SEC specifications, but in no case shall be less than the
requirements of this Standard.

4.2.2 No material, regardless of its source, shall be incorporated in the Work until
representative samples taken and tested and have been reviewed and approved
by the COMPANY Representative.

4.2.3 Field and laboratory tests required to determine compliance with the
requirements of this Standard before and during the work shall be done by an
Independent Agency approved by the COMPANY.

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4.3 Safety Requirements

4.3.1 All the required safety provisions of Construction Safety Manual shall be
strictly followed.

4.3.2 Excavation by the use of explosives shall be with prior written approval from
the COMPANY.

4.3.3 The stability of adjacent structures or facilities including public safety shall
not be impaired or endangered by excavation work.

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5.0 DESIGN REQUIREMENTS

Design shall be as per AASHTO Guidelines for Design of Pavement Structure, along with
the requirements and guideline as given in the following sections.

The thickness of Asphalt Concrete Pavement shall be dependent upon operational
requirement as determined by COMPANY Design Engineer. The design shall be submitted
to the COMPANY for checking and approval. The parameters for the calculation of the
thickness of pavement shall be as given in the following sections.

5.1 Specific Requirements:

5.1.1 The traffic analysis period shall be twenty (20) years.

5.1.2 Axle loads shall be based on a load meter survey, truck and equipment
manufacturer's technical data or the maximum axle loads allowed by the
Ministry of Communications, Kingdom of Saudi Arabia. See Table I for
maximum legal Saudi Arabia truck loads.

Table I: Wheel Loads

Maximum Legal Saudi Arabia Truck Loads (per MOC)

Steerable axle

6000 kg

Single axle

13,000 kg

Tandem axle

20,000 kg

5.1.3 A Terminal Serviceability Index of 2.5 shall be used for all COMPANY
designated access (pavement) roads and 2.0 for parking and storage lots.

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5.1.4 The Structural Layer Coefficient for each pavement component shall be per
Table II below:

Table II Structural Layer Coefficients

PAVEMENT COMPONENT Coefficient per cm.
Hot mix Asphalt (High
Stability)

0.16

Base Course

0.06

Sub-base Course

0.04

5.1.5 Traffic Equivalence Factor shall be based on a structural number (SN) of 5.

5.1.6 The equivalent 18000 lb. (EAL) loads shall be determined from Table III if a
traffic count cannot be made.

Table III: EAL Loads

EQUIVALENT PAVEMENT
CATEGORIES
TRAFFIC AND LOAD 18000 lb
(EAL) Loads
Access Roadways Sedans to Truck up to 20
Tons/Axle

1X 10
5

Designated Roadways inside
S/S yards
Sedans to Truck up to 20
Tons/Axle

IX 10
5

Undesignated areas inside S/S
yards
Sedans to Truck up to 20
Tons/Axle

I X 10
4

Parking and Storage Lots

Sedans and small trucks

I X 10
5

Parking and Storage Lots

Heavy Traffic (Truck Material
Yard)

I X 10
6

Plant Areas

Occasional Heavy Loads

I X 10
6

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5.2 Operational Requirements

If the designed pavement thicknesses as per Section 5.1 are lesser than the values per
Table-IV, then, the values as shown in the Table IV shall be adopted.

Table IV Thickness of Pavement Components

Minimum Thickness of
Base Course (mm)
(1)

Minimum Thickness of Combined
Binder and Wearing Courses (mm)
(2)

PAVEMENT CATEGORIES
CLASS A & B CLASS A CLASS B & C

Access Roadways

150

80

100
Designated Roadways inside
Substation

150

80

100
Undesignated pavement inside
Substation

150

65

80
Parking & Storage lots for
Sedans and small trucks

150

80

100
Substations with provision for
Mobile units

300

-

100
Parking and Storage Lots for
Heavy Traffic (Material Yard)

230

120

140
Power Plants Areas
Occasional Heavy Loads

230

120

140

Note: (1). Base Course Classes A & B as per TCS-Q-113.02

(2). Asphalt Binder Course Classes A & B and Wearing Course Classes
A, B & C as per Table VI

5.3 Miscellaneous/Minor/Reinstatement Works

If the area to be asphalted is small, such as for utility trenches, and non-traffic areas,
the minimum base course and pavement thickness shall be as shown in Table IV
with grading limits shown in Table VI.

For all these works, the finish shall be better or at least same as before the start of
work. Also, protection and treinstatement shall be done for all markings, affected
structures and shoulders to the satisfaction of COMPANY and MOC Representative.

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6.0 EARTHWORKS

6.1 Clearing and Preliminary Works

6.1.1 Clearing site and rough grading shall be per relevant clauses of TCS-Q-
113.02. Scarification shall be done if required as per COMPANY
Representative instructions.

6.1.2 Protection of bench marks, existing structures, roads, sidewalks, pavings and
kerbs shall be done against damage from vehicular traffic or personnel at the
existing utilities during cleaning / compaction of sub-grade.

6.1.3 Designated temporary roads, walkways and detours, for vehicles, pedestrians
and working personnel shall be maintained properly.

6.2 Sub-grade

6.2.1 The rough grading for sub-grade shall be completed prior to construction of
the surfacing. The sub-base/ base course material shal not be placed on loose,
soft and undesirable materials under any circumstances. All soft and yielding
spots shall be removed till hard and sound strata are available.

When the top soil consists of loose, soft (sand or clay) or otherwise
undesirable materials and if there is any inter bedded soil layer of loose, soft
(sand or clay), where disclosed underlying the firm/dense layer of soil, then
such material shall be completely removed until firm soils are encountered
and replaced with select fill material per TCS-Q-113.02.

The following soil parameter values shall be considered as soft/loose and
hence undesirable:

Table V: Parameters for Unsuitable Soils

Granular Soils
Standard penetration
resistance (SPT) N values

Less than 10
Standard penetration
resistance (SPT) N values

Less than 4 Cohesive
Soils
The unconfined
compression strength, (Cu)

Less than 1.0 kg/cm
2

Other portions of the sub-grade, which will not compact easily, when rolled
or tamped, shall be removed, and all loose rock or boulders, embedded rocks,
abandoned concrete etc., found in the excavation shall be removed or broken
off to a depth of not less than 150 mm below the surface of the sub-grade.

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6.2.2 All holes, ruts, soft places, and other defects shall be corrected. Irregularities
or depressions that develop during the compaction should be corrected to the
specified grade by loosening the material at these places and adding,
removing, or replacing the material.

Where sub-grade is soil, levelling shall be achieved by using select fill
materials. In case of rock, the levelling shall be done by concrete of same
strength as the rock or 5500 psi, as directed by the COMPANY
Representative. The soft and loose spots shall be removed and filled woth
selet fill material/concrete as applicable.

Compaction is then done until the surface is smooth, and uniform. In no case,
shall the sub-base or base course be placed on soft or unstable material, or
over areas that are not properly drained. If the sub-grade is dusty or muddy,
operations shall be delayed until it is in a condition satisfactory to the
COMPANY Representative.

The compaction requirements for sub-grade shall be as follows:

a. For Substations, the entire sub-grade in the yard shall be compacted to
95% of the maximum density.

b. Unpaved and other vacant areas in Substations shall be compacted to
90% of the maximum density.

6.2.3 The sub-grade shall be formed so that after compaction it will conform to the
alignment, grade, and cross-section shown on the drawings, and as required
by the COMPANY Representative.

6.2.4 Where rolling of the sub-grade is required, any areas which are inaccessible
to a roller shall be compacted either by a mechanical or hand tamper meeting
the approval of the COMPANY Representative.

6.2.5 Equipment of such weight, used in such a way, as to cause a rut in the
finished sub-grade of 50 mm or more in depth, shall be removed from the
WORK, or the rutting otherwise prevented.

6.2.6 The sub-grade shall be kept drained during placing and compaction of the
sub-base, base course, binder and/or surface course. If berms of earth are
deposited along the area upon which the succeeding course is being placed,
provision shall be made for surface drainage by cutting lateral ditches
through the berm of earth.

6.2.7 The finished sub-grade shall be maintained in a smooth and compacted
condition until the sub-base, base course, binder and/or surface course is
placed.

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Where existing sub-grade materials are of poor quality, with California
Bearing Ratioo (CBR) value less than 5 after 4-day soaking., sub-grade
modification shall be accomplished to improve the CBR to a minimum value
of 15. Prior approval of the COMPANY shall be obtained for any
modification.

In case CBR test values are not available, test shall be conducted from the top
0.5 m of soil.

Sub-grade modification shall be done by one or more of the following
methods:

a. Addition of aggregate such as crushed stone or coarse screenings

b. Replacement of the sub-grade soil with sub-base material with
minimum CBR of 15 and shall be minimum thickness of 200 mm.

c. Chemical stabilization/treatment with lime or cement

d. Asphalt stabilization

e. Use of geotextiles and/or geogrids

The minimum compacted thickness of the improved layer shall be 200 mm.
CBR tests shall be conducted after the modification to verify the minimum
requirements.

6.2.8 Developing of Sabkhah area shall be in accordance with the applicable
Sections of TCS-Q-113.02.

6.2.9 At locations where grounding grid is to be installed below the asphalt level,
following requirements shall be satisfied:

a. The backfill materials shall have a maximum thermal resistivity less
than 1.2 K-m/W.

b. The Thermal Resistivity of the backfill materials shall be lesser than
that of the existing soil.

6.3 Sub-base and Base Course Materials

Minimum thickness of combined binder and wearing courses depends upon the type
of sub-base. Hence, sub-base / base course materials shall be well-graded of the class
or classes shown on the approved drawings or specifications. In addition, the
following requirements are to be satisfied;

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6.3.1 All materials shall be free from organic matter, shale or other deleterious
matter and shall be of such quality that it will bind readily to form a firm
stable base for placement of flexible pavement.

6.3.2 Gradation and physical properties for base and sub-base materials shall
conform to the requirements of TCS-Q-113.02.

6.3.3. Class C materials shall not be used for base course for COMPANY Utilities.

6.3.4. Class C and Class D materials for Sub-base shall be as per TCS-Q-113.02.

6.4 Construction

6.4.1 General Requirements

Prior to placement of the sub-base or the next layer of fill, the sub-grade or
sub-base shall be inspected and approved by the COMPANY Representative
for conformity to lines, grades, and typical sections shown on the approved
construction drawings.

6.4.2 CBR values for each class of fill materials shall be as per TCS-Q-113.02.

6.4.3 Placing / Spreading

Base or sub-base materials shall be spread on the approved sub-grade in
layers not exceeding 150 mm in compacted thickness. Spreading shall be
done by means of approved mechanical spreader, distributing the materials to
the required loose thickness. Where the required base or sub-base thickness is
greater than 150 mm, the materials shall be placed in layers of equal
thickness. In no case shall a layer be less than 75 mm thick. Under no
circumstances shall any soil materials be dumped in a pile on the sub-grade.
When base or sub-base course is constructed more than one layer, the
previously compacted layer shall be cleaned of loose and foreign matter.

The materials shall be handled so as to avoid segregation. Segregated
materials shall be remixed until uniformity is attained. Suitable precautions
shall be taken to prevent rutting of the sub-base or sub-grade during the
spreading of fill materials. No hauling or placement of materials will be
permitted when in the judgment of the COMPANY Representative, the
weather or road conditions are such that the hauling operations will cause
cutting or rutting of the sub-base or sub-grade or cause contamination of the
fill materials. The water content of the fill material shall be maintained at the
optimum moisture content ( 2%) as determined by ASTM D 1557 or
AASHTO T-180, as obtained from soil investigation reports.

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6.4.4 Compaction

a. The sub-base or base materials shall be compacted, keeping the
moisture content between ( 2%) of optimum moisture content, with
equipment capable of obtaining the desired density to the full depth of
the respective layer.

The rolling shall continue until the sub-base or base are compacted to
not less than 95% of the maximum laboratory density as determined
by ASTM D 1557 or AASHTO T-180 Method for soils containing
more than 15% materials passing the 75 micron (# 200) sieve or
compacted to 85% of relative density as determined by ASTM D
4253 and ASTM D 4254 for free draining soils containing less than
15% non-plastic materials passing the 75 Microns (#200) sieve unless
otherwise specified as per other approved methods.

b. Base and sub-base materials shall be compacted by means of
approved compaction equipment, progressing gradually from the
outside towards the center with each succeeding pass uniformly
overlapping the previous pass. Rolling shall continue until the entire
thickness of each layer is thoroughly and uniformly compacted to the
specified density. Rolling shall be accompanied by sufficient blading
in a manner approved by the COMPANY Representative, to insure a
smooth surface free from ruts or ridges and having the proper section
line and grade.

c. All areas inaccessible to normal compaction equipment shall be
compacted by means of mechanical tampers until satisfactory
compaction is obtained.

d. Each layer of base/sub-base material must be completely compacted,
tested and approved by the COMPANY Representative prior to
delivery of materials for a succeeding layer. Frequency of testing
shall be in accordance with TCS-Q-113.02.

6.4.5 Finishing

The surface of the compacted materials shall be finished by blading or with
automated equipment especially designed for this purpose and rolled with a
steel-wheeled roller. In no case shall thin layers of fine materials be added to
the top layer of the base course in order to meet the required elevation. The
surface of the completed base course shall not show any deviation in excess
of 4 mm when tested with a 4 meter straightedge. The completed thickness of
the base shall be within 5 mm of the thickness indicated, and the average
thickness shall not be less than the design thickness.

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7.0 PRIME AND TACK COAT REQUIREMENTS

Asphalt work including primer application and placing of asphalt concrete mixtures shall be
done only when the atmospheric temperature is 4C or above and when the weather is not
foggy or rainy and when the existing surface is free from moisture.

7.1 Prime Coat

7.1.1 Materials

The prime coat shall be of medium-curing type cutback asphalt consisting of
asphaltic base fluxed with suitable petroleum distillates. The product shall be
free of water, show no separation prior to use, shall not foam when heated to
application temperature and shall conform to the requirements of Grade MC-
70 or MC-250 of ASTM D 2027.

Emulsified asphalt MS-1 or SS-1 conforming to ASTM D 977 may also be
used after getting approval from the COMPANY.

7.1.2 Surface Preparation

The surface shall be cleaned of all loose dirt and other objectionable
materials by means of approved mechanical sweepers or blowers and or hand
brooms prior to the application of the prime coat.

7.1.3 Application

Prime coat shall be applied uniformly to the base course using a pressure
distributor at a rate between 1.0 to 1.75 liters per square meter. Excess
application of primer shall be blotted by using clean and natural sand. The
application temperature shall be within the ranges of 50C to 80C for MC-
70 between 65C to 105C for MC-250. The primer shall be applied to a
width of at least 300 mm greater on each side of the specified width of the
finished surface. Surfaces in contact with the asphalt are to be primed up to
the asphalt thickness. The surfaces of manholes, catch basins, etc., which
need to remain free of asphalt, shall be protected with oil to prevent asphalt
adhesion.

Prime coat shall be applied only when the surface to be treated is dry and
when the weather is not foggy or rainy.

7.1.4 Curing

The prime coat shall be cured until the penetration into underlying surface
has been approved by the COMPANY Representative. It shall be fully set
and cured for not less than 24 hours before placing an asphalt concrete
mixture on the base.

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7.2 Tack Coat

7.2.1 Materials

Tack coat shall be of rapid-curing type cutback asphalt consisting of asphalt
base fluxed with suitable petroleum distillates. The product shall be free of
water, show no separation prior to use, shall not foam when heated to
application temperature and shall conform to the requirements of Grade RC-
800 of ASTM D 2028.

Emulsified asphalt RS-1 conforming to ASTM D 977 or CRS-1 conforming
to ASTM D 2397 may also be used after getting approval from the
COMPANY.

7.2.2 Application

Tack Coat shall be applied on top of the binder course and damaged surfaces
that are being overlaid by means of bitumen distributor from 0.5 to 1.0 liters
per square meter or as directed by COMPANY Representative. This shall be
uniformly applied over the entire surface of the area to be covered. The
temperature shall be between 95C to 120C.

Tack coat shall not be placed during rainy weather, sand storm or stormy
weather, or when the moisture on the surface to be paved would prevent
proper bond. If application of the surface course is delayed by more than
three days, dirt or sand and other impurities have contaminated the tack coat,
then a new tack coat shall be applied thinly after the original one has been
swept clean.

7.3 Precautions and Maintenance of Bituminous Coating

7.3.1 Protection of adjacent structures

When primers are being applied, the surfaces of all structures, guard rails,
curbs and gutters, and other roadway appurtenances shall be protected in a
manner approved by the COMPANY Representative, to prevent them from
being splattered with primer or marred by equipment operation.

7.3.2 Maintenance of Bituminous Coating

Prime and tack coats shall be maintained intact until they are covered by the
succeeding course. Any area where prime coat or previous course has been
damaged by traffic or by equipment or personnel shall be cleaned of all loose
materials, the defective surfaces are to be repaired to the satisfaction of
COMPANY Representative and the prime coat or tack coat shall be re-
applied. In case of rain after the application of the primer, the surface shall be
scraped and allowed to dry to the condition prior to the application before re-
applying the primer.

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8.0 ASPHALT CONCRETE AND PAVING

8.1 Materials

8.1.1 Asphalt Cement shall be homogenous, Performance Grade 60-70, 85-100 or
150-200, free of water, shall not foam when heated to 177C, and conforming
to the requirements of ASTM D 946.

8.1.2 Mineral aggregates shall consist of coarse aggregates, fine aggregates, and
filler material all complying with the following requirements:

a. When tested according to ASTM C 117 and ASTM C 136, the
combined mineral aggregates shall conform to the gradation, shown
on Table VI below.

Table VI: Gradation for Combined Aggregates

Sieve Size
Asphalt Binder
Course
Asphalt Wearing Course

mm/micron(US) Class A Class B Class A Class B Class C

38.0

100

-

-

-

25

100

80-100

-

-

-

19.0

80-100

70-90

100

100

12.5

------

------

80-95

80-100

100

9.5

60-80

55-75

------

------

80-100

4.75 (No. 4)

45-65

44-62

48-62

50-70

55-75

2.0 (No. 10)

30-50

33-48

32-45

32-47

32-47

425 micron (No. 40)

15-32

16-27

16-26

16-26

16-26

212 micron (No. 80)

-

-

8-18

10-18

10-18

75 micron (No. 200)

3-10

3-10

4-8

4-10

4-10

The job mix formula grading may be varied within the specified limits on
the basis of Marshall tests to obtain optimum stability, percent air voids,
and voids in mineral aggregates of the compacted bituminous paving
mixture.

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b. The combined mineral aggregates for asphalt binder course
and asphalt wearing course shall consist of crushed rock or
crushed gravel. These shall be clean, hard, tough, durable and
sound and shall be of uniform quality, free from soft and
friable materials and shall conform to the physical
requirements as per Table VII.

c. Mineral filler shall be finely ground particles of limestone,
hydrated lime or other mineral dust approved by the
COMPANY, free of clay, silt, or other organic or deleterious
materials, passing 600 microns, with a maximum retention of
20% on 75 micron (# 200).

Table VII: Physical Requirements

Tests Specified

ASTM

Requirement

Sand Equivalent

D2419

45 minimum

Binder course

3 Maximum
Plasticity Index

Wearing course

D4318

6 Maximum

Binder course

50% Maximum Loss by Abrasion

Wearing course

C131

40% Maximum

Fine aggregates

12% Maximum Loss by Sodium
Sulphate test.

Coarse aggregates

C88

15% Maximum

Fine aggregates

18% maximum Loss by Magnesium
Sulfate Soundness Test

Coarse aggregates

C88

20% maximum
Thin and elongated pieces, by weight (larger
than 25 mm, thickness less than 1/5 length)

D 4791

5% maximum

Moisture Content
0.25%
Maximum

Soft and friable materials

Nil

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8.2 Asphalt Concrete Mix Design

8.2.1 Mix Design Methods

Asphalt concrete mix shall be designed by satisfying any one of the following
methods.

8.2.1.1 Marshall Test Method

This method is used in this document as guideline for the mix design.

8.2.1.2 SHRP (Superpave) System

This method of design has been explained in Appendix. The
parameters to be obtained and other details are also included.

8.2.1.3 HVEEM Test Method

This method can be adopted for design of asphalt pavement for the
SEC system upon approval by the COMPANY Design Engineer.

8.2.2 The asphalt concrete mix design shall be submitted for review and approval
by the COMPANY at least thirty (30) days prior to start production of plant
mix. The design shall be a combination of mineral aggregates and asphalt
cement in such proportion as to produce a mixture conforming to the
composition limits by weight per Table VIII.

Table VIII

Mineral Aggregate

Percent

Total Mineral

93-96

Asphalt cement

4-7

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When tested according to the Marshall Method, the Asphalt Concrete mixture
shall conform to the requirements of Table IX:

Table IX

Binder Course Wearing Course

Flow (mm)

2.4-5.0

2.0-4.0

Stability (kg)

820 min.

820 min.
Loss of Marshall stability by
submerging (ASTM D1559). (see note)

25% max.

20% max.

Voids in total mix (%)

3.0-7.0

3.0-5.0

Voids filled with Bitumen (%)

60-75

70-80
Class A- 13 % Class A- 14 %
ClassB - 12 % Class B- 15 %
Voids in mineral aggregate (VMA)
ASTM D2041
(Minimum)
Class C -16 %

Note: Loss of Marshall Stability is measured by submerging specimens in water at
60C for 24 hours as compared to stability measured after submersion in
water at 60C for 20 minutes. (ASTM D 1559)

A compaction effort of 75 blows per ASTM D 1559 shall be used for the mix
design of all asphalt mixtures for SEC works.

8.2.3 After receiving the COMPANY approved asphalt mix design, the
proportioning of the individual aggregates, mineral filler and asphalt cement
shall be done so as to produce a final mix that, when compared to the asphalt
mix design, shall be within the tolerance limits of Table X.

Table X Mix Design Tolerances

Materials

Tolerance

Aggregate sieve size 4.76 mm (No.4) and larger

5.0
Aggregate sieve size 2.0 mm (No.10) and retained
on sieve size 75 microns (No.200)

5.0
Aggregate sieve size 75 microns (No.200) and
smaller

1.5

Asphalt content

0.3

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The Asphalt concrete mix shall be tested periodically for conformity to the
approved asphalt mix design. If, during production, the grading of the
aggregates alters, the mixture shall be redesigned and the plant to be
readjusted.

8.3 Equipment

8.3.1 All the construction and asphalt batching plant equipment shall conform to
the requirements of Ministry of Communication (MOC), General
Specification for Road and Bridge Construction.

8.3.2 In addition to the above requirements, trucks used for hauling Asphalt
Concrete Mixture shall have tight, clean, smooth metal beds which have been
thinly coated with a minimum amount of paraffin oil, lime solution (1:3 with
water), or other approved material to prevent the mixture from adhering to
the beds. Each vehicle shall be equipped with a canvass, tarpaulin cover, or
other suitable material of such size to protect the mixture from the weather.
No petroleum derivatives shall be used to coat the truck beds.

8.3.3 Rolling equipment shall be self-propelled. The wheels on the rollers shall be
equipped with adjustable scrapers and the rollers shall have water tanks and
sprinkling apparatus which shall be used to keep the wheels wet and prevent
the surface material from sticking.

Weights of two-axle tandem steel rollers, three-axle tandem steel rollers,
three-wheel steel rollers and self propelled pneumatic tired rollers shall be as
specified in MOC General Specification for Road and Bridge Construction.
The total weight of the pneumatic tired roller shall be varied to prevent
displacement of the asphalt concrete mixture.

8.4 Preparation of Asphalt Concrete

8.4.1 Asphalt cement shall be heated within a temperature range of 135C to
163C at the time of mixing. All materials reheated more than 42C above
the maximum shall be considered overheated and shall be rejected until the
materials can be re-sampled and tested. The reacceptance or rejection shall be
made on the same requirements as established for the original materials.
Asphalt cement received from the refinery at temperatures in excess of
163C, but not exceeding 191C, may be used.

Note: If polymers are used, these may require higher mixing temperatures.
Mixing temperature range should be determined to be the temperature at
which the asphalt binder has viscosity of 0.170 0.020 pa-s while
compaction temperature range should be determined to be the temperature at
which the asphalt binder has viscosity of 0.280 0.030 pa-s. The limits can
be determined from temperature-viscosity plot as developed by Rotational
Viscometer.

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8.4.2 Each aggregate ingredient shall be heated and dried at such temperatures that
the temperature recorded in the hot fines bin after screening shall not exceed
163C. If the aggregates contain sufficient moisture to cause foaming in the
mixture, or if their temperature is in excess of 163C, they shall be removed
from the bins and returned to their respective stockpiles.

Immediately after heating, the aggregates shall be screened into at least three
(3) sizes and conveyed into separate bins ready for batching and mixing with
asphalt cement. When the aggregates furnished are of such size and grading
that separating into three (3) bins is impractical, the number of required
separations may be reduced to two (2) with the approval of the Engineer. The
efficiency of the screening operations shall be sufficient to produce, at plant
operating capacity, gradations in each of the sizes of heated and dried
aggregates, which are reasonably uniform and result in the production of a
mixture complying with the limits specified for the asphalt concrete mixture.

8.4.3 Dried aggregates as specified for asphalt concrete pavement construction and
prepared as prescribed above shall be combined in the plant in the
proportionate amounts as approved. Asphalt cement shall be introduced into
the mixture in the proportionate amount all according to the COMPANY
approved asphalt concrete mix design.

The temperature of the asphalt, except for temporary fluctuations, shall not
be lower than 14C below the temperature of the aggregate at the time the
two materials enter the mixer or pug mill.

During drying operations of aggregates for batch and continuous mixing
plants to produce central plant hot-mixtures, the moisture content of mineral
aggregates shall not exceed 0.25 percent.

8.5 Placement of Asphalt Concrete Mixture

8.5.1 Placing/Spreading

a. The Asphalt Concrete Mixture shall be placed without delay on
completion of 24 hours after priming the base course.

b. All asphalt concrete mixtures shall be delivered to the site covered
with tarpaulin prior to loading on the pavers at a temperature between
139
0
C to 163
0
C. Mixtures delivered at other than these temperatures
shall be rejected. No placement of asphalt concrete shall be permitted
if the atmospheric temperature is below 4
o
C, when the weather is
foggy or rainy, and when the existing surface is not free from
moisture.

If polymers are used which may require higher mixing temperatures,
(see note in clause 7.4.1), mixing and laying temperature range should
be determined and used.

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c. The Asphalt Concrete Mixture shall be spread and finished true to
line and grade by automatically controlled bituminous paver. The
maximum lift for any layer shall be 75 mm. Asphalt Concrete
mixtures may be spread and finished by hand methods only where
machine methods are impractical as determined by the COMPANY
Representative.

d. Asphalt concrete binder course shall be spread in a placement
thickness so that after rolling, the nominal thickness after compaction
will not exceed 75 mm or less than 50 mm per layer.

e. The automatically controlled paver shall spread the Asphalt Concrete
mixture without tearing the surface and shall strike a finish that is
smooth, true to cross section, uniform density and texture and free
from hollows, transverse corrugations and other irregularities. The
joints made during the work shall be vertical, straight, clean, and free
of broken or loose materials. All vertical joints are shall be primed to
ensure proper bond.

f. The paver shall be operated at a speed which will give the best result
and which coordinates satisfactorily with the rate of delivery of the
mixture to the paver so as to provide a uniform rate of placement
without intermittent stoppages.

g. Asphalt concrete wearing course shall be made flush with rain gutters,
if any, adjacent to the pavement.

8.5.2 Compaction of Mixtures

a. After spreading and strike-off of asphalt mixture and as soon as
possible, mixture shall be thoroughly and uniformly compacted.

b. Rollers shall be of the steel/pneumatic tire type, shall be of good
condition capable of reversing without backlash, and shall be operated
at speeds slow enough to prevent displacement of the mixture. The
number and weight of rollers shall be sufficient to compact the
mixture to the required density while it is still in a workable
condition. Use of equipment, which results in excessive crushing of
the aggregates shall not be permitted.

c. Compaction shall be carried out in three passes sequence operations.
Each pass of roller shall overlap the previous pass to ensure smooth
surface free of roller marks. Rollers shall be operated by competent
and experienced operators and shall be kept in operation
continuously, if necessary, so that all parts of the pavement will
receive substantially equal compaction within the time desired.

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d. The initial or breakdown rolling shall be done by means of a tandem
power steel roller or three (3) wheeled power steel roller followed by
rolling with a pneumatic-tired roller. Final compacting and finish
rolling shall be done by means of pneumatic tired roller. The wheels
of the rollers shall be kept properly moistened with water to prevent
adhesion of the mixture to the rollers. Excessive water shall not be
permitted. For other equipment, see section 8.3.

e. Hand tamping or plate compactor may be used where the area is
inaccessible to the rolling equipment.

f. The surface of the compacted asphalt pavement shall be true to lines,
grades and elevations indicated and shall be free from any
depressions. The paving machine shall be fitted with an automatic
screed control operating from an independent grade line or with a
long ski (traveling reference) for leveling the courses. The binder
course shall be laid with utmost accuracy so that there are fewer
chances of deformations in the wearing course.

g. The compacted density of asphalt concrete pavement shall be equal or
greater than 96% of the Marshall Density of each day's production.

8.6 Tolerances

8.6.1 Weighing Scales

The accuracy of the weighing devices for mineral aggregates and bituminous
materials shall be within 1.0% of the actual weight being measured per
ASTM D 995.

8.6.2 Thickness of Asphalt Concrete

The total thickness of the asphalt concrete pavement shall be measured in a
separate operation for each course. Measurement of any core sample shall not
be deficient by 5 mm or 7% of the designed thickness whichever is less.

Core samples shall be taken from the binder course prior to placement of the
wearing course. Core sampling for the wearing course shall be taken as near
as possible to the location where the core sample for binder course was taken.
The placement thickness of the wearing course shall be adjusted when the
average thickness of the binder course is deficient by more than 5 mm.

If the total thickness of asphalt is found deficient, additional cores at intervals
of not more than 25 meters apart for parking/storage lots and at every 100
linear meters for roadways taken parallel to the centerline in each direction to
determine the average thickness of the pavement. Deficiency in average
thickness exceeding the specified tolerance shall be corrected without
additional compensation from the COMPANY.

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Correction shall be done by total removal of deficient materials and replacing
them with new materials. The deficient thickness area shall be removed by
saw cutting to the full depth of wearing and binder courses, forming parallel
and perpendicular lines to the architectural features where practical. Same
procedure will be done for all the areas to be repaired.

Application of additional thin layers of fine materials to the top of wearing
course shall be permitted in order to achieve the required thickness or
specified tolerances.

8.6.3 Surface Tolerance

The asphalt concrete surface shall be tested either by the straightedge test
method or by the water flooding test method as directed by COMPANY
Representative at his option:

a. Roadways

i. The variation of the asphalt surface from the testing edge of
the four {4) meter straightedge between any two (2) contacts
with the surface shall at no point exceed 4.0 mm when placed
on or parallel to the centerline of the roadway or 3.0 mm when
placed perpendicular to the centerline of the roadway.

ii. For water flooding test, the finished asphalt concrete surface
shall not have evidence of water ponding greater than 5.0 mm.

b. Large Areas

Surface tolerances for large areas, such as substation yards, storage
yards, parking areas, etc., are specified below;

i. The variation of the asphalt surface from the testing edge of
the four (4) meter straightedge between any two (2) contacts
with the surface shall at no point exceed 4.0 mm when placed
in any direction.

ii. Water flooding of the asphalt concrete surface shall be done to
check proper drainage and water ponding and the following
conditions shall be adhered to:

(a) The finished surface shall not show any water ponding.
(b) The finished surface shall not have any depression.

All humps and depressions exceeding the specified tolerances
shall be corrected by removing the defective work and
replacing it with new material as directed by the COMPANY
Representative conforming to Asphalt Manual MS-16.

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8.7 Quality Control

8.7.1 A Quality Control Program shall be prepared and submitted for review and
approval by the COMPANY which shall include, but not limited to, material
and equipment checks, construction, inspection and testing of finished
asphalt concrete pavement.

8.7.2. The asphalt concrete batching plant shall also maintain a Quality Control
Program which includes the following material tests and frequencies:

a. Materials

Test Frequency

Penetration of Asphalt Cement

1/week or 1/lot
Gradation of Fine, Coarse
Aggregates & Filler materials

1/week or 1/lot

Specific Gravity of Aggregates

l/week

Resistance to Abrasion (LA)

l/month

Sulfate and Magnesium soundness

l/month

Sand equivalent

l/month

Plasticity Index

l/month

b. Uncompacted Asphalt Concrete

Samples for extraction, gradation and Marshall Properties shall be
taken daily at the following rates of production

0 to 500 tons 1 per 100 tons
500 to 800 tons 1 per 150 tons
800 and above tons 1 per 200 tons

c. Compacted Asphalt Concrete

Cores for density and thickness shall be taken daily from previous
day's work at the following rates of placement

Less than 4000 m
2
1 per 400 m
2

4,000 to 20,000 m
2
1 per 900 m
2

20,000 and above m
2
1 per 1200 m
2

For minor Asphalt Works, the sampling for Marshall Properties and
Cores shall be taken as directed by the COMPANY Representative.

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8.7.3 The independent laboratory must provide upon request, valid calibration
certificates of all testing equipment and the results of all Quality Control
(QC) tests on materials and asphalt concrete mixtures to the COMPANY.

Validity period for Calibration Certificates shall be 4 (four) months and the
calibration shall be done by COMPANY approved laboratory.

COMPANY Representative shall be given full access to the testing
laboratory facilities, the asphalt concrete batch plant, and the job site for his
inspection. All testing and production records shall be made available upon
request.

8.7.4 Protect the newly compacted section of asphalt concrete from traffic by
providing barricades or approved suitable method until it has hardened
properly.

8.8 Miscellaneous Works

Suitable and appropriate methods as directed by the COMPANY Representative
from Asphalt Institute Manuals MS-16 and MS-17 shall be adopted for the following
works:

Preventive maintenance, including Drainage maintenance, Fog Seal

Routine Maintenance like crack sealing, Pot Holes and Patching, etc.

Major Maintenance, including Surface Treatment, Distortions, Slurry Seals, Surface
recycling, etc.,

9.0 FINAL CLEANUP

Upon completion of the work and before final acceptance, the project site including adjacent
properties defaced, damaged or occupied by the equipment and personnel in connection with
the work shall be cleaned of all rubbish, excess materials, false work, temporary structures
and equipment and the damages repaired to the satisfaction of the COMPANY
Representative. The project site and all parts of the work shall be left in a neat and
presentable condition.

10.0 APPENDIX

Superpave (SHRP) Method of design has been explained in th Appendix.

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SUPERPAVE (SHRP) METHOD OF PAVEMENT DESIGN.

1.0 SELECTION OF DESIGN LEVEL

Superpave analysis and design method being more complex than those in current use, the
extent of its use depends on the traffic level or functional classification of the pavement for
which it is being used. Consequently, three levels of superpave mixture design and analysis
are being used. Their extent of use and testing requirements are:

Table-I

Traffic, ESALs

Design level

Testing requirements*

10
6

Mix Design

Volumetric design

10
6
< ESALs 10
7

Intermediate mix design
Volumetric design+
Performance prediction tests

ESALs>10
7

Complex mix analysis
Volumetric design+ Enhanced
performance prediction tests

* In all cases, moisture susceptibility must be evaluated using AASHTO T-283.

For SEC facilities, referring to Table III in TCS-Q-001, the design level is to be limited to
option # 1 in the above table, corresponding to the traffic Level of up to ESALs 1X10
6
.

2.0 TERMS AND DEFINITIONS

TERMS SYMBOL DEFINITIONS

2.1 Air Voids P
a
or V
a
Total Volume of small air pockets between coated
aggregates particles expressed as Percentage of the bulk
volume of the compacted paving mixture

2.2

Voids in
Mineral
Aggregates

VMA

The volume of inter granular void space between the
aggregate particles of a compacted paving mixture that
includes the air voids and effective asphalt content
expressed as Percentage of the total volume of the
compacted paving mixture

2.3

Effective
Asphalt
content

Pbe

The total asphalt content of the paving mixture less the
portion of asphalt binder that is absorbed by the aggregate
particles expressed as Percentage of the total weight of the
compacted paving mixture
2.4 Voids filled
with Asphalt
Pfa or
VFA
The portion of the VMA that contains asphalt binder
expressed as Percentage of the total volume of mix or
VMA

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TERMS SYMBOL DEFINITIONS

2.5 Aggregate
Bulk specific
gravity
G
sb
The ratio of the mass in air of a unit volume of aggregate,
including permeable and impermeable voids, to the mass of
an equal volume of water, both at the same temperature
2.6 Aggregate
effective
specific
gravity

G
se

The ratio of the mass in air of a unit volume of aggregate,
excluding voids permeable to asphalt, to the mass of an
equal volume of water, both at the same temperature
2.7 Asphalt
binder
specific
gravity
G
b
The ratio of the mass in air of a given volume of asphalt
binder, to the mass of an equal volume of water, both at the
same temperature
2.8 Mixture Bulk
specific
gravity

G
mb

The ratio of the mass in air of a given volume of compacted
HMA to the mass of an equal volume of water, both at the
same temperature

2.9
Theoretical
maximum
specific
gravity of the
mix

G
mm

The ratio of the mass of a given volume of HMA with no
air voids to the mass of an equal volume of water, both at
the same temperature
2.10 Volume of
absorbed
asphalt
V
ba
The volume of the asphalt binder that has been absorbed
into the pores of the aggregate

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3.0 VOLUMETRIC MIX DESIGN

For design of the asphalt concrete mix, the following steps to be adopted:

3.1 Selection of aggregates
3.2 Selection of binders
3.3 Selection of a design aggregate structure (Trial Blend Analysis)
3.4 Selection of Design Asphalt Binder Content
3.5 Moisture Sensitivity
3.6 Performance Based tests

3.1 Selection of Aggregates

3.1.1 Properties of Aggregates

Table-II gives the tests and the requirements for the aggregates for use in
Superpave for SEC facilities.

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Table-II

All tests are for ESALs 0.3-1x10
6

Tests

ASTM

AASHTO

Requirements

Remarks

Coarse Aggregate
angularity*

75% top 100 mm
50% lower than
100 mm

(At least one
crushed faces)

Fine Aggregate angularity*

40%

Flat and elongated pieces,
by weight (larger than 25
mm, thickness less than 1/5
length)
D 4791 10% max

Sand Equivalent

D 2419

T 176

45% min

Los Angeles Abrasion
Limits

T 96

45% max
For Wearing &
binder Courses
Specific Gravity for Coarse
Aggregates

C 127

Depends on
local material
Specific Gravity for Fine
Aggregates

C128
Depends on
local material

Deleterious Materials

T 112

Nil
For Wearing &
binder Courses
12% max Fine
aggregates
Loss by Sodium Sulphate
test.

C88

T 104
15% max Coarse
Aggregates
18% max Fine
aggregates
Loss by Magnesium Sulfate
Soundness Test

C88

T 104

20% max
Coarse
Aggregates

Moisture Content

0.25% Max.

* For Surface Course depth <100 mm and Base Course depth >100 mm.

3.1.2 Gradation And Restricted Zone

a. The control points for the Superpave mixtures gradation are as
follows:

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Table-III

Percentage Passing For Mixture Types Sieve Size
(mm)
SP375 SP250 SP190 SP125 SP95
50 100
37.5 90-100
25.0 90-100 100
19.0 90-100 100
12.5 90 90-100 100
9.5 90-100
2.36 15-41 19-45 23-49 28-58 32-67
0.075 0-6 1-7 2-8 2-10 2-10

b. Restricted Zones

The combined aggregate gradation shall pass between control points
and should not pass through the restricted zone as shown in the table
IV and as plotted on a 0.45 power chart. Mixtures passing through this
zone will be considered only if the mixture satisfies all other
requirements.

Table-IV

Percent passing limits for Restricted Zone Sieve Size
(mm)
SP375 SP250 SP190 SP125 SP95
4.75 34.7 39.5
2.36 23.3-27.3 26.8-30.8 34.6 39.1 47.2
1.18 15.5-21.5 18.1-24.1 22.3-28.3 25.6-31.6 31.6-37.6
0.600 11.7-15.7 13.6-17.6 16.7-20.7 19.1-23.1 23.5-27.5
0.300 10 11.4 13.7 15.5 18.7

3.2 Selection of Binders

Asphalt binder shall be selected based on AASHTO MP-1 specification
Performance-Graded Asphalt Binder to meet Performance Grade (PG) of at least
76-10. The selected Binder should meet the testing requirements shown in table V.
The contractor should present testing certificate from an acceptable testing agency to
certify that the selected asphalt meets the requirements of Table V. Polymer additive
may be required to meet the PG 76-10 requirements.

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Table V: Performance-Graded Asphalt Binder Specification

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3.3 Selection of a Design Aggregate Structure (Trial Blend Analysis)

3.3.1 Selection of Trial Blend

For the selection of the trial blend, at least three sets of aggregate blends
consisting of varying stockpile percentages of each aggregate size are taken.
The sieve analysis is conducted for each of the blends. A plot of percentage
passing and sieve size raised to power 0.45 is done. It is recommended that
the plot passes below the restricted zone and must be within the control
points.

3.3.2 Estimation of Aggregate Blend Properties

The aggregate blend properties shall be calculated mathematically from
calculated values as follows with the limits as shown in Table II.

3.3.3 Evaluation of trial blends

Two specimens are made with each of the blends using Superpave Gyratory
Compactor and volumetric properties are determined. The trial asphalt binder
content is determined for each trial blend by estimating the effective specific
gravity of the blend using the formula below:

a. Bulk specific gravity

G
se
= G
sb
+ Y (G
sa
-G
sb
)

Where, Y= 0.7 to 0.8 depending on the absorption of the aggregate

The Bulk specific gravity of the combined aggregate (G
sb
)
G
sb
= (P
1
+ P
2
+P
3
)
P
1
P
2
P
3

G
1
G
2
G
3

Where Pi =Percent by mass of each component aggregate in blend
Note: (P
1
+ P
2
+P
3
) = 100
G
i
= G
sb
of each component aggregate in blend

b. Volume of asphalt binder (V
ba
)

Calculate the volume of asphalt binder (V
ba
) absorbed into the
aggregates by using the following equation:
+ +

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V
ba
= P
s
x (1-V
a
) x 1 1
P
b
Ps G
sb
G
sc

G
b
G
se

Where, V
ba
= volume of absorbed binder, cm
3
/cm
3
of mix
P
s
= Percent of aggregates
V
a
= volume of air voids
G
b
= specific gravity of binder
P
b
= Percent of binder

c. Volume of effective binder (V
be
)

Calculate the Volume of effective binder (V
be
) for the blend using the
following formula:

(V
be
) = 0.081 0.02931 x {In(S
n
)} cm
3
/cm
3
of mix

where S
n
= The nominal maximum sieve size of the aggregate
blend (in inches)

d. Initial trial asphalt binder (P
bi
)

Calculate the initial trial asphalt binder (P
bi
) using the following
formula:

P
bi
= G
b
x (V
be
+ V
ba
) x 100
G
b
x (V
be
+ V
ba
)
W
s

Where P
bi
= Percent (by weight of mix) of binder
W
s
= weight of aggregate (grams)

Where W
s
= P
s
x (1 V
a
)
P
b
+ P
s

G
b
G
se

e. Maximum theoretical specific gravity of the mixture

Two specimens are prepared for the determination of Maximum
theoretical specific gravity of the mixture. Two other samples are
made for each trial blend using Superpave Gyratory Compactor
(SGC). AASHTO T-209 gives the minimum size of sample required
for various mixtures.
+
-

PAGE NO. 38 OF 40
TCSQ11301R0/SZA
TCS-Q-113.01, Rev. 0

The number of gyrations for initial compaction, design compaction
and maximum compaction shall be determined from Table VI
following AASHTO MP-2 specification.

Densification is done for the sample specimens and SGC data
obtained. Plots are drawn for %G
mm
versus the logarithm of the
number of gyrations.

Also, the percent of air voids and voids in the mineral aggregates
(VMA) are determined from these tables, using the following
equations:

% Air Voids = 100 - % G
mm
@ N
design

% VMA = 100- (%G
mm
@N
design
x G
mm
xP
s
)
G
sb

Keeping 4% air voids at N
design
, the asphalt binder is estimated for
each trial blend using the empirical formula as given below:

P
b,estimated
= P
bi
0.4x (4- V
a
))

Where, P
b,estimated
= Estimated percent binder
P
bi
= Initial (trial) percent binder
V
a
= percent air voids at N
design

From all the three trial blends, the effective asphalt binder is
determined as follows:

P
be,estimated
= - (P
s
x G
b
) x ( G
se
-G
sb
) + P
b,estimated

G
se
x G
sb

Calculation of dust proportion is as follows:
DP = P
0.075

P
be,estimated

The values of dust proportion shall be between 0.6 to 1.2.

The trial blend satisfying the criteria shown in Table VI (AASHTO
MP-2) shall be selected as the design aggregate structure.

PAGE NO. 39 OF 40
TCSQ11301R0/SZA
TCS-Q-113.01, Rev. 0

Table VI: Superpave Volumetric Mixture Design Requirements

(1) Design ESALs are anticipated project traffic level expected on the design lane over a
20 years period. Regardless of the actual design life of the roadway, determine the
design ESALs for 20 years and choose appropriate Ndesign level.
(2) For 9.5 mm nominal maximum size mixtures the specified VFA range shall be 73%
to 76% for design traffic levels > 3 million ESALs.
(3) For 25.0 mm nominal maximum size mixtures the specified lower limit of the VFA
shall be 66% for design traffic levels <3 million ESALs.
(4) For 37.5 mm nominal maximum size mixtures the specified lower limit of the VFA
shall be 63% for all design traffic levels

3.4 Selection of Design Asphalt Binder Content

Once the design aggregate structure is selected, specimens are compacted at varying
asphalt binder contents. The mixture properties are then evaluated to determine
design asphalt binder content.

A minimum of two specimens are compacted at each of the following asphalt
contents:

a. Estimated binder content

b. Estimated binder content 0.5% and

c. Estimated binder content + 1.0%

Four asphalt binder contents are a minimum in Superpave mixture design.

Voids in Mineral Aggregate
(VMA)
(Minimum Percent)
Required Density
(Percent of G
mm
)
Nominal Maximum Aggregate
Size (mm)
Design
ESALs
(1)

(Millions
)
N
initial
N
desi
gn

N
max
37.5 25.0 19.0 12.5 9.5

Voids Filled
with Asphalt
(VFA)
(Minimum
Percent)

Dust-
to-
Binder
Ratio
< 0.3

< 91.5 70-80
(3)
0.3 to <
3

< 90.5 65-75
(2)
3 to <10
10 to <
30
> 30

< 89.0

96.0

< 98.0

11
(4)

12.0

13.0

14.0

15.0
65-75
(2)

0.6-1.6

PAGE NO. 40 OF 40
TCSQ11301R0/SZA
TCS-Q-113.01, Rev. 0
Minimum of two specimens are also prepared for determination of maximum
theoretical Specific gravity at the estimated binder content. Specimens are prepared
and tested in the same manner as the specimens from the section. 3.3. above.

The test results are tabulated for each trial asphalt binder content. Densification
curves for each trial asphalt binder content shall be plotted, the average densification
curve taken from the two specimens for each asphalt content plotted on the same
plot.

Mixture properties are evaluated for the selected blend at the different asphalt binder
contents, by using the densification data at N
initial
, N
design
, and N
maximum
.

The volumetric properties are calculated at the design number of gyrations (N
design
)
for each trial asphalt binder content. From these data points, graphs of air voids,
VMA, and VFA versus asphalt binder content are generated.

The design asphalt binder content is established at 4.0% air voids. The design
asphalt binder content corresponding to 4.0% air voids at N
design
is adopted as the
design asphalt binder content. All other mixture properties are checked at the design
asphalt binder content to verify that they meet criteria.

3.5 Moisture Sensitivity

The final step in the Superpave mixture design process is to evaluate the moisture
sensitivity of the design mixture. This is accomplished by performing AASHTO T-
283 testing on the design aggregate blend at the design asphalt binder content.
Specimens are compacted to approximately 7% air voids. One subset of three
specimens are considered control specimens. The other subset of three specimens is
the conditioned subset. The conditioned subset is subjected to vacuum saturation
followed by an optional freeze cycle, followed by a 24 hour thaw cycle at 60
0
C. All
specimens are tested to determine their indirect tensile strengths. The moisture
sensitivity is determined as a ratio of the tensile strengths of the conditioned subset to
the tensile strengths of the control subset.

The minimum criterion for tensile strength ratio is 80%. The design blend, if it
exceeds the minimum requirement, is the Superpave mixture.

3.6 Performance Based tests:

The Performance Based tests for Superpave mix design are optional, as the traffic
level is 10
6
ESALs, where only volumetric mix design is considered sufficient.

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