Methology For Traversing To Tackcoat

Essel Ahmedabad Godhra Toll Roads Limited
National Highways Authority of India
CONSTRUCTION METHODOLOGY
The Ministry of Road Transport and Highways (MoRT&H) Government of India has decided to take up
the improvement of various sections of National Highways under NHDP Phase III. The projects are to
be executed as BOT (Toll) project on DBFO Pattern. National Highway No. 59, connecting
Ahmedabad with Indore, is one of the important corridors of the country has been taken up for
feasibility-cum-preliminary study for 4 laning by NHAI.
The details of the project and the associated organizations are given below:-
Project Name & Location Four Lanning of Ahmedabad to Godhra section of NH-59
from Km 4.200 to Km 122.420 in the State of Gujarat on
Design, Build, Finance, Operate and Transfer (DBFOT) Basis
under NHPD Phase –III.
Client National Highways Authority of India
Concessionaire Essel Ahmedabad Godhra Toll Roads Limited
Independent Engineer EGIS BECOM International JV Egis India Consulting

Engineers
Pvt Ltd
Total Project Management Consultant Wilbur Smith Associates Inc.
EPC Contractor Pan India Infrastructures Private Limited.
Contractor Dilip Buildcon Limited
Page 1
TRAVERSING
SCOPE
This work shall consist of fixing of control station points, horizontal and vertical alignment as
per designed coordinates and levels.
INSTRUMENTS
i. Global positioning system (GPS)

ii. Electronic disto meter (Total station- with 2 sec accuracy)
iii. Prism stand
iv. Auto level (1mm accuracy)
v. Leveling staf
vi. Tapes
vii. Nails
viii. Hammers
ix. Marking paint, etc.
METHODOLOGY
i. Minimum two base station points shall be fixed by GPS for every 5Km to control the
manual and instrumental errors.
ii. The control station points shall be fixed for every 200m by traversing.
iii. The station points shall be located at appropriate places and these should be painted
properly for easy identification.
iv. Proposed centerline shall be fixed along the existing road or any firm ground by fixing
the nails with the help of designed coordinates.
v. Proper marking shall be done around the nails by specifying the ofset distance.
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vi. Pre-caste concrete pillars having centered nail shall be fixed on the firm ground along
the roadside for temporary benchmarks (TBM’s) and these should be painted properly
to identify easily.
vii. Every six months control points traversing is required.
viii. Numbering and Chainage shall be given to the benchmark pillars.

ix. Levels shall be shifted to the TBM pillars with the help of auto levels.
x. Monthly TBM list checking, inspection and rectification
xi. TBM checking shall be carried out by two instructions.
PRECAUTIONS
i. Care shall be taken against control station points and temporary benchmark pillars to
not to disturb or damage by any lateral loads.
ii. Maximum allowable error between any adjacent benchmark pillars shall not be more
than 2mm when it is closed.
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METHODOLOGY OF CLEARING AND GRUBBING

GENERAL
This method statement shall consists of site clearing, grubbing, cutting, excavating,
removing & disposing of all material such as trees up to 300mm girth, bushes, stumps,
shrubs & roots of trees up to 300 mm girth, grass weeds , rubbish and top soil up to 150
mm shall be removed. Backfilling with suitable soil into pits resulting from uprooting of
stumps.
MACHINERY & EQUIPMENT
The equipment to be used for site clearing and grubbing shall be done using Hydraulic
Excavators, Grader, Roller, dumpers and labors.
METHOD OF CONSTRUCTION
 The site shall be cleared by Excavators / JCB as per site requirement & conditions. The
pits formed due to uprooting of trees shall be back filled with suitable material &
compacted with power / Vibratory roller to the required compaction or shall be filled by
granular material.
 All unsuitable material arising from clearing and grubbing operation shall be disposed
of and suitable material if any shall be deposited nearer to road side for further use in
Embankment / Sub grade.
 The ground after clearing & Grubbing shall be watered and compacted by vibratory /
power roller for embankment density of 95%, for sub grade density 97% with relative
natural ground density.
TESTING AND ACCEPTANCE PROCEDURES INCLUDING DOCUMENTATION

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All works to be carried out pursuant to the above shall be recorded and verified jointly by
Contractor and Supervision Consultants for record and claim purposes. The sample of
records to be used for the above works are attached as Appendix A and summarized as
per Table 1.
Table 1
Ite Description
m
1 Request For Inspection
2 Request For Sampling
3 Stump Removal Records
4 F.D.D.Checking
5 Leveling Field Book
QUALITY TIPS
i. Excavated material should not be allowed to mix with the material using for road work
or it will spoil homogeneity of the layer.
ii. Proper drainage provision shall be made to avoid ponging or erosion of the cuts due to
water stagnation.
iii. The excavated portion shall be inspected for marshy swamps and water springs, etc.
This should be rectified to the standard of adjacent strata before proceeding for
construction.
SEQUENCE OF CONSTRUCTION
1. Joint Inspection between Contractor and Supervision Consultant to take
measurement and quantities shall be carried out after setting out for the following: -
A. Stumps to be removed.
B. Identification of water logged / slushy areas.
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C. Structures to be dismantled. Etc;

2. Clearing and Grubbing of Road Land up to R.O.W.
3. Marking of Carriage way Center Line (Ref. Methods Statement of SETTING OUT).
4. Recording of Original Ground Levels.
5. Compaction of Original Ground.
6. Testing of original Ground
METHOD OF MEASUREMENT
 Site Clearing will be measured in area Hectare (hectares)
SAFETY MAESURES
All safety precautionary measures shall be taken as stated below: -
i) Cautionary / Warning Signboards shall be placed along the road side.
ii) Moveable signboards shall be placed at area where heavy machineries and survey
works are being carried out. Flagmen shall control the movement of machines and
tippers/dumpers at these areas.
EQUIPMENT DEPLOYMENT
1. Excavator
2. Grader
3. Roller
4. Tippers
DETAILS OF PERSONNEL BOTH FOR EXECUTION AND QUALITY CONTROL OF THE

WORK
Personnel for Execution:
1. Site Engineer
2. Materials Engineer
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3. Surveyor
4. Supervisor
METHODOLOGY OF EMBANKMENT
GENERAL
This work shall consist of laying, spreading and compacting Embankment layer with approved
material in accordance with clause 305 of MoRT&H specification.
Material
As per clause 305.2 of MoRT&H, the material to be used for construction of embankment shall
be satisfying the following requirements.
i. The Particle size of the coarse material shall not be more than 75 mm.
ii. Free swell index of the material shall not be more than 50 percent when tested as per
IS: 2720 (Part-40).
iii. Dry unit weight of the material shall not less than 1.52 gm/cc and 1.6 gm/cc for
embankment up to 3m height and embankment exceeding 3m height when tested as
per IS: 2720 (Part-8).
iv. The values of maximum dry density and optimum moisture content obtained in
accordance with IS: 2720 (Part 8).
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v. Liquid limit shall not be more than 40 percent as per 305.2.1.1 of Tech. Specifications.
vi. Plasticity index shall not be more than 18 percent as per 305.2.1.1 of Tech.
Specifications.
vii. Roots and stumps shall be removed if any while spreading.
viii. Moisture content shall be checked before commencing the compaction, if it is less than
-2% of OMC, water shall be added by sprinkler and if it is more than +1% of OMC, it
shall be dried by aeration and exposure to the sun till to reach the OMC.
ix. Rolling shall be carried out from lower edge to upper edge with 80-100KN vibratory
roller till to achieve the required compaction and no tyre impression or drum
impression on the surface.
APPROVAL OF BORROW AREA

Suitable borrow area are identified field with detail location distance from site field No and
sample taken from the borrow area are tested from suitability in embankment construction
as per technical specification and clause No 903.2.1 The testing of sampling will be 0.5 m ,
1.0 m and 1.5 m depth from ground level. Number of samples will be decided jointly based
on borrow area volumes
Quality control
Quality control for the above work shall be as per table 900-3 of MoRT&H.
i. Moisture content shall be checked before compaction for preceding the work.
ii. The compacted surface shall be checked for field density at the frequency of 1 test per
1000sq.m. The degree of compaction shall not be less than 95%. At High embankment
(exceeding 6mheight) compaction shall not be less than 97%.
iii. The surface shall be checked for levels at 5m/10m intervals longitudinally and
transversely and the same shall be within +20/-25mm.
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Quality tips
i. In the field one can estimate OMC without instrument just by adding water or drying
borrow material until a squeezed handful of soil is deformed with finger marks for
about an average squeeze efort and the molded soil resists breaking apart.
ii. Roots and stumps shall be removed at barrow area before loading.
iii. The area where cracks are developed after compaction shall be removed and it should
be filled with approved material with proper compaction.
iv. The surface can be ensured that it has achieved required compaction by continuing the
rolling until there are no wavy or sponge action.
Construction Procedure:-
Setting out:-
After clearing and grubbing and compaction of ground supporting Embankment, the
limits of Embankment shall be marked on both sides at regular interval of 15 meter for
commencing the work. The Embankment shall be kept minimum 500 mm than
designed dimension, so that surplus material can be trimmed during slope
construction.
Transportation:-
The material for Embankment from the approved source of borrow areas will be
transported in dump truck (Tipper / Dumper) or in some cases by tractor trolley. The
filling of earth in Dumpers shall be done by excavators / JCB. The dumping of materials
shall be done systematically.
SITE RECORDS
Contractor and Supervision Consultants for record and claim purposes. The samples of
records to be used for the above works are summarized as per Table 1.
Table 1
Item Description
Page 9
1. Request For Inspection

2. Sand Test
3. Plasticity Test
4. Density Test
5. Moisture Content
6. CBR Test
7. Field Density Test
SAFETY MAESURES
i) Cautionary / Warning Signboards shall be placed along the road side.
ii) Moveable signboards shall be placed at area where heavy machineries and survey
1. Treatment on ground supporting embankment if any
2. Checking of Toe line and surface.
3. Placing of layers
4. Checking FDD for each layer.
5. Checking of levels for Top Layer of Embankment.
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1. Excavator
2. Tippers
3. Motor grader
4. Vibratory Roller
5. Water Tankers

WORK
1. Site Engineer
2. Materials Engineer
3. Surveyor
4. Supervisor
5. Laborer
SPECIAL PART OF Q.A. PROGRAMME
Test requirement for earthwork on excavation, embankment are as shown in Table 2.

Table 2
Item Description Frequency
1. Sand Test 2 Test per 3000 m3
2. Plasticity Test 2 Test per 3000 m3 per type
3. Density Test 2 Test per 3000 m3 per type
4. Moisture Content 1 Test per 250 m3
5. CBR Test 1 Test per 3000 m3
6. Field Density Test 1 Test per 1000 m2 at every
layer
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METHODOLOGY OF SUBGRADE
SCOPE
This work shall consist of laying, spreading and compacting sub grade layer with approved
material in accordance with clause 305 of MoRT&H specification.
MATERIAL
As per clause 305.2 of MoRT&H, the material to be used for construction of subgrade shall be
satisfying the following requirements.
i. The Particle size of the coarse material shall not be more than 50mm.
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ii. Free swell index of the material shall not be more than 50 percent when tested as per
iii. IS: 2720 (Part-40).
iv. Dry unit weight of the material shall not less than 1.75gm/cc when tested as per IS:
2720 (Part-8).
v. Liquid limit shall not be more than 40 percent as per 305.2.1.1 of Tech. Specifications.
vi. Plasticity index shall not be more than 18 percent as per 305.2.1.1 of Tech.
Specifications.
vii. The values of maximum dry density and optimum moisture content obtained in
accordance with IS: 2720 (Part 8).
viii. As per Tech. Specification “The material to be used in subgrade should satisfy the
requirement of the 4 day soaked design CBR of 10%”.
MACHINERY
i. Excavator
ii. Tippers
iii. Grader
iv. Water tanker
v. Vibratory roller of capacity 80-100KN
vi. Survey kit.
Methodology
i. The Embankment top shall be cleaned of if there is any extraneous material. If the
surface is dry, it should be made wet by sprinkling water.
ii. The approved material from borrow area shall be transported by means of end
dumpers and dumped in the form of heaps.
iii. Material shall be spread by means of motor grader to its loose thickness and specified
grade.
iv. Roots and stumps shall be removed if any while spreading.
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v. Moisture content shall be checked before commencing the compaction, if it is less than
-2% of OMC, water shall be added by sprinkler and if it is more than +1% of OMC, it
shall be dried by aeration and exposure to the sun till to reach the OMC.
vi. Rolling shall be carried out from lower edge to upper edge with 80-100KN vibratory
roller till to achieve the required compaction and no tyre impression or drum
impression on the surface.
vii. The Subgrade shall be kept minimum 500 mm than the design dimension so that
surplus material, Cross fall shall be maintained as per the design.
QUALITY CONTROL
Quality control for the above work shall be as per Clause 900-3 of MoRT&H .
Moisture content shall be checked before compaction for preceding the work. The same
should be –2 % to +1% of OMC.
i. The compacted surface shall be checked for field density at the frequency of 1 test per
500sq.m.
ii. The degree of compaction shall not be less than 97%.
iii. The surface shall be checked for levels longitudinally and transversely as per MoSRTH
clause 902.3 and the same shall be within +20/-25mm.
QUALITY TIPS
i. In the field one can estimate OMC without instrument just by adding water or drying
borrow material until a squeezed handful of soil is deformed with finger marks for
about an average squeeze efort and the molded soil resists breaking apart.
ii. Roots and stumps shall be removed at loading place.
iii. The area where cracks are developed after compaction shall be removed and it should
be filled with approved material with proper compaction.
iv. The surface can be ensured that it has achieved required compaction by continuing the
rolling until there are no wavy or sponge action.
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SITE RECORDS
Table 1
Item Description
1. Request For Inspection
2. Sand Test
3. Plasticity Test
4. Density Test
5. Moisture Content
6. CBR Test
7. Field Density Test
SAFETY MAESURES
a. Cautionary / Warning Signboards shall be placed along the road side.
b. Moveable signboards shall be placed at area where heavy machineries and

survey works are being carried out. Flagmen shall control the movement of
machines and tippers/dumpers at these areas.
1 Treatment on ground supporting embankment if any

2 Checking of Toe line and surface.
3 Placing of layers
4 Checking FDD for each layer.
5 Checking of levels for Top Layer of Embankment and Sub grade.

WORK
Site Engineer
Page 15
Materials Engineer
Surveyor
SPECIAL PART OF Q.A. PROGRAMME
Test requirement for earthwork on excavation, embankment, and sub grade are as
shown in Table 2.
Table 2
Item Description Frequency
1. Sand Test 2 Test per 3000 m3
2. Plasticity Test 2 Test per 3000 m3 per type
3. Density Test 2 Test per 3000 m3 per type
4. Moisture Content 1 Test per 250 m3
5. CBR Test 1 Test per 3000 m3
6. Field Density Test 1 Test per 500 m2 at every
layer
METHODOLOGY OF GRANULAR SUB BASE (GSB)

GENERAL
This work shall consist of laying and compacting approved granular sub base material on
prepared sub grade in accordance with the requirements of Specifications. The material shall
be laid in one layers as sub-base as necessary according to lines, grades and cross-sections
shown on the drawings or as directed by the Engineer
SCOPE
Page 16
This work shall consist of laying and compacting well graded material as per (Table 400-1
Grading I) on prepared Sub Grade in accordance with the most specification.
SOURCE APPROVAL
The Source for raw material are identified accordingly the material at source is tested to as
certain its suitability for use as granular Sub Base. The samples are taken jointly with
Engineers. Representatives and tested for confirmatory tests.
MATERIALS
(a) The material is to be used for work shall be natural / crushed stone / crushed singles or
combination thereof depending upon the grading required. The material shall be free from
organic or there deleterious constituents. The raw material will be brought to the crusher
and will be processed there so as to achieve all in one aggregate in conformity with
specification required for GSB as per most course Grading (Table 400- 1 Grading I).
(b) There after Mix design shall be designed and got approved by the Engineers before
starting the work
CONSTRUCTION OPERATION
The GSB layer will be spread in single layer of 200 mm (Compacted) to achieve over all
thickness. The dumped material will be spread uniformly with the help of motor grader of
adequate capacity. Its blade having hydraulic controls suitable of initial adjustment and for
maintaining the required slope. The required quantity of water added to achieve the moisture
content +1% above to -2% below the OMC as per IS : 2720(Part – 8) . The Layer is thoroughly
mixed and moisture content is checked to ensure that it is within the prescribed limit of OMC.
The layer is then grade and compacted by means of vibratory compactor to achieved MDD.
Rolling shall be continued till the density achieved is at least 98% of Maximum dry Density.
The material determined as per IS: 2720 (Part -8). Normally 6 to 8 passes are required to
achieve desired compaction.
LAYER THICKNESS: - The Compacted thickness of Granular Sub base is 200 mm
SEQUENCEOF CONSTRUCTION
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 Checking of stock pile at source

 Stock pile will be checked jointly with consultants for approval.
 Transportation and Dumping
 The material for Granular Sub base from the approved stock pile shall be transported in
dump truck (Tipper / Dumper). The filling of Granular Sub base in Dumpers shall be
done by excavators / Loader. The dumping of materials shall be done systematically.
SPREADING THE MATERIAL AND COMPACTION

The sub-base material of grading specified in the Contract shall be spread on the prepared
sub grade with the help of a motor grader of adequate capacity its blade having hydraulic
controls suitable for initial adjustment and for maintaining the required slope and grade
during the operation or other means as approved by the Engineer.
Moisture content of the loose material shall be checked in accordance with IS: 2720 (part 2)
and suitably adjusted by sprinkling additional water from a truck mounted or trailer mounted
water tank and suitable for applying water uniformly and at controlled quantities to variable
widths of surface or other means approved by the Engineer so that; at the end of compaction,
it is from 1 per cent above to 2 per cent below the optimum moisture content corresponding
to 15:2720 (part 8). While adding water, due allowance shall be made for evaporation losses.
After water has been added, the material shall be processed by mechanical means until the
layer is uniformly wet.
Immediately thereafter, rolling shall start and rolling shall commence at the lower edge and
proceed towards the upper edge longitudinally for portions having unidirectional cross fall and
super elevation and shall commence at - the edges and progress towards the centre of
portions having on.
Each pass of the roller shall uniformly overlap not less than one third of the track made in the
preceding pass. During rolling, the grade and cross fall (camber) shall be checked and any-
high spots or depressions, which become apparent, corrected by removing or adding fresh
material, the speed of the roller shall not exceed 5 km per hour. Rolling shall be continued till
the density achieved is at least 98 per cent of the maximum dry density for the material
determined as per - 15:2720 (Part 8).
SITE RECORDS
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Table 1
Item Description
1. Request For Joint Checking of Stock Pile
2. FDD Checking
3. Level Checking of Top Layer
4. Moisture Content
METHOD OF MEASUREMENT
Granular sub-base shall be measured as finished work in position in cubic metres.
SAFETY MAESURES
 Cautionary / Warning Signboards shall be placed along the road side.
 Moveable signboards shall be placed at area where heavy machineries and survey
Motor Grader
Vibratory Roller
Dumper/Tripper
Loader
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Water Tanker

WORK
Site Engineer
Materials Engineer
Surveyor
Laborer
METHODOLOGY OF Wet Mix Macadam (WMM)

SCOPE
This work shall consist of laying Work consist of providing, laying and compacting clean,
crushed and graded aggregates premixed with water to be a mass on a prepared granular
Page 20
sub-base layer. Wet Mix Macadam (WMM) shall be laid in two equal layers of 125 mm thick
(compacted thickness) true to line, grade and cross sections.
MATERIAL
Coarse Aggregates for WMM will be used from an approved source satisfying the specification
requirement as per MORT&H Clause 406.2.
PROCEDURES
SOURCE APPROVAL
It is proposed to use crashed stone and dust etc. Available from crushing plants which
are the requirement as per technical specifications. The samples are taken and tested
by contractor, if found suitable, submitted to Engineer, Then sample of various sizes of
materials are taken jointly with Engineers‘s Representative and tested for confirmatory
test in laboratory.
JOB MIX FORMULA

After approval of the source and the sample by the engineer, the job mix formula will
be designed and submitted for approval to the Engineers.
If the material at crushing plant meets the requirements as per clause no 406.2.1.2 and
table no 400-II . The raw material are stacked at mixing yard and again tested to
ensure that the materials are as per most specifications or not. Then only approved
materials are mixed as per job mix formula. The wet mix macadam will be prepared in
mixing plant of adequate capacity having arrangement for controlled addition of water.
MACHINERY
I. WMM Plant with 250 TPH Capacity

II. Grader
III. WMM Paver
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IV. Vibromax
V. Loader
VI. Water Tanker
VII. Dumper/Tripper
VIII. Labour

WORK
Site Engineer
Materials Engineer
Surveyor
Supervisor
Laborer
Quality Control
Quality control for the above work shall be as per table 900-3 of MOST.
i. The gradation and moisture content of the mix shall be controlled at plant as per the
approved design mix.
ii. The compacted surface shall be checked for field density at the frequency of 1 test per
500 sq.m. The degree of compaction should not be less than 98%
iii. The surface shall be checked for levels longitudinally and transversely as per MoSRTH
clause 902.3 and the same shall be within +/- 10 mm.
Quality Tips
i. The mix while transporting can be covered with tarpaulin to avoid moisture loss.
ii. The mix shall be loaded at the plant in three heaps into dumper so as to avoid
segregation.
iii. The hopper of the paver shall not be emptied completely as it may lead to segregation
while paving successive loads.
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iv. The end portions of carriageway shall be confined with hard shoulders or any means if
the mix spreading with grader to avoid end segregation.
v. The surface can be ensured that it has achieved required compaction by continuing
rolling until there is no wavy action or sponge action or impressions of the roller on the
surface.
CONSTRUCTION OPERATION
The material produced from mixing plant are again tested to ensure that the mixed material
conform to specification and job mix formula. The mixed materials shall be uniform no
Segregation shall be allowed. Approved mixed WMM is bought to the site and spread with the
help of Grader/ Paver finisher in a thickness of 125mm (compacted) in two layers so that
overall compacted thickness of 250 mm is achieved. Then the material is compacted by
means of vibratory compactor. Normally 5 to 6 passes are required to achieve desired
compaction. After final compaction spot levels are taken to check the thickness of layers cross
slope and profile. It is ensured that Top level of WMM layer is within +10 mm to -10 mm of the
desired level as per clause 902.3 of most specifications. After ensuring the required tolerance
of the levels density is checked
Enclosures
i. Typical compaction test results
ii. Typical Level check sheet
iii. Typical Surface Regularity sheet
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PRIME COAT
Scope
Work shall consist of application of single coat of low viscosity liquid bituminous material to a
porous granular surface preparatory to the superimposition of bituminous treatment of mix.
The primer shall be low porosity type bitumen emulsion complying with IS:8887 of suitable
grade.
Preparation of Surface
Dried WMM surface, complete in all respect i.e. surface evenness, grade, lines and levels,
shall be considered for priming. The surface to be primed shall be made clean and free from
dust or segregated materials with power broom and/or blower. Hand brooms will also be used
in location where sticky clay type material has coated the surface. Surface shall also be free
from ruts, loose material or any other minor irregularities. Minor depressions potholes
developed on the surface shall be patched by priming. When the completed WMM surface
remains unprimed for long period indicating the presence of unbounded aggregate in certain
locations or it is too much dried causing stresses in mechanical bonding or may cause
freckling of prime material, the surface shall be rolled after sprinkling water to produce proper
mechanical bonding.
Application of Primer
Primer shall not be applied when WMM surface is wet or during dust storm or when the
weather is foggy, rainy or windy. Also when temperature in the shade is less than 10°C, prime
coat shall not be applied.
Primer shall be applied with the help of self-propelled presser distributor equipped for
spraying the material uniformly at the rate of 6 to 9.0 kg per 10 m2. Manual spraying of
primer shall be avoided as far as possible except in unavoidable circumstances. Temperature
of the primer material at the time of spraying shall be in a range of 20° C to 70° C to permit
the primer to be efectively sprayed through the jets of the spray bar and to cover the WMM
surface uniformly.
Curing
After application of primer coat surface shall be allowed to cure for a minimum of 24 hours or
till all the volatiles have been evaporated from the surface. It shall also be ensured that the
penetration of primer has taken place in to the WMM surface.
If primer at any place is not found to be fully absorbed, sand will be spread over the surface
to blot the excess primer, any pools of excess primer left on any part of the surface shall be
swept out over the adjacent surface before spreading sand.
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No vehicle shall be allowed to ply on the primed surface except for laying next course. Prime
coat shall be applied on the primed surface before laying next course.
TACK COAT
SCOPE
Work shall consist of application of a single coat of low viscosity liquid bituminous material to
an existing bituminous road surface or over prime coat preparatory to laying of another
bituminous layer over it. The binder shall be bituminous emulsion complying to IS: 8887 of
suitable type and grade. Use of cutback bitumen shall be restricted for emergency application
only.
Preparation of Surface
The surface planned for providing tack coat shall be properly cleaned of dust or any
extraneous material. Immediately before the application of tack coat, the surface shall be
swept clean by mechanical broom or an air compressor.
Application of tack coat
Tack coat shall not be applied on a wet surface or during a dust storm or when the weather is
foggy, rainy or windy. Also when temperature in the shade is less than 10°C, tack coat shall
not be applied
After ensuring surface cleaning, bituminous emulsion generally at normal ambient

temperature shall be sprayed on the surface at the rate specified in Table 500-2 of the
MORT&H specification. The normal range of spraying bituminous material as per specification
shall be 20° C to 70° C. Tack coat shall be sprayed with the help of self-propelled bitumen
pressure distributor equipped with spray bars with nozzles having constant pressure system
and self-heating arrangement, capable of spraying bituminous emulsion to provide a
uniformly unbroken spread.
Curing
After application of tack coat, it will be allowed to cure until the all the volatiles have
completely evaporated (generally 4 to 6 hrs). Only vehicles necessary for
construction of subsequent bituminous layer shall be allowed to ply on the
tack-coated surface.
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Casting of Cement Concrete Kerb
Scope
This work shall consist of constructing cement concrete Kerbs and kerbs with channel in the
central median and/or along the footpaths or separators in confirmatory with the lines, levels
and dimensions as specified in the drawing with clause 408 of MoSRTH specification.
Materials
The Kerb shall be provided in cement concrete of Grade -M-20 approved mix Design in
accordance with Section 1700 of MOSRTH Specification. It shall be done cast-in-situ
construction with suitable Kerb casting machine in all situations.
Equipments
A continuous Kerb casting equipment of adequate capacity and controls, capable of laying the
Kerb in required cross-sections and producing a well compacted mass of concrete free of
voids and honeycombs, shall be used. After laying the Kerbs and just prior to hardening of the
concrete, saw cut grooves shall be provided at 5 M intervals or as specified by the Engineer.
The vertical and horizontal tolerances with respect to true line and level shall be ± 6mm.
List of Equipments:
1- Kerb Casting Machine; - 01 No.

2- String rod and String Wire; - As per requirement.
3- Auto Level Machine Set. - 01 No.
4- Man Power - As per requirement.
5- Transit Miller - As per requirement.
6- Sprayer with curing compound - As per requirement.
7- Water Tanker - As per requirement.
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DENSE –BITUMINOUS MACADAM
SCOPE
This work shall consist of construction of single course 80-100 mm & 50- 75 mm thick
layer with required grade line and levels as per clause no 507.
REFERENCE
Specification and procedures stipulated in the contract agreement.
Approved drawing supplied by the Engineer.
PROCEDURES
MATERIAL
(a) Bitumen:-
The Bitumen shall be paving bitumen of viscosity grade VG-30 as per Indian Standard
specification doe paving Bitumen IS: 73.
(b) AGGREGATE
The Course aggregate shall consist of crushed stone which shall be clean , strong ,
durable of fairly cubical shape and free from disintegrated pieces , organic or other
deleterious matter and adherent coating and shall be conforming to the following
physical and graduation requirement:-
(1)
Sl. No Test Requirements
01 Aggregate Impact Value* 30% Maximum (Table
400.10)
02 Los Angeles Abrasion Value* 40% Maximum (Table
400.10)
Page 27
03 Flakiness and Elongation Index 30% Maximum (Table

400.10)
04 Coating and Stripping value Minimum Retained
Coating 95%
05 Soundness
i)Loss with sodium sulphate 5 cycles 12% Maximum
ii)Loss with Magnesium Sulphate 5 Cycle 18% Maximum
06 Water Absorption 02% Maximum
* Aggregate shall satisfy requirements of either of the two tests.
TABLE 500-10. COMPOSITION OF DENSE GRADED BITUMINOUS
MACADAM PAVEMENT LAYERS
Grading 1 2
Nominal aggregate size 40mm 25 mm
80-100 mm 50-75 mm
IS Sieve1 (mm) Cumulative % by weight of total aggregate
passing
45 100
37.5 95 - 100 100
26.5 63 - 93 90 - 100
19 - 71 - 95
13.2 55 - 75 56 - 80
9.5 - -
4.75 38 - 54 38 - 54
2.36 28 - 42 28 - 42
1.18 - -
0.6 - -
0.3 7 - 21 7 - 21
0.15 - -
0.075 2-8 2-8
Bitumen content % by
Bitumen grade (pen) 65 or 90 65 or 90
Notes:
1. The combined aggregate grading shall not vary from the low limit on one sieve to the high
limit on the adjacent sieve.
2. Determined by the Marshall method.
The aggregate mix shall be in close proximity of adjacent sieves and shall be well
graded.
(c) FILLER
Page 28
The design mix for DBM carried out in the laboratory caters for the filler material by
way of crushed stone dust used in the formula adopted. However the filler material
shall be used as and when needed as per design nix. The filler material shall be rock
dust hydrated lime or cement and will be meeting the following gradation.
Sl No Sieve % of Passing by weight
01 600 Micron 100
02 300 Micron 95 - 100
03 75 Micron 85 - 100
The filler shall be free from organic impurities and have a plasticity Index not greater
than 4.
(d) REQUIREMENT OF DENSE BITUMINOUS MACADAM
The DBM mix shall conform to the following requirement.
TABLE 500-11. REQUIREMENTS FOR DENSE GRADED BITUMINOUS MACADAM
Minimum stability (kN at 60°C 9.0

Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of blows) 75 blows on each of the two faces of the
specimen
Per cent air voids 3-6
Per cent voids in mineral aggregate
(VMA) See Table 500-12 below
Per cent voids filled with bitumen 65-75

The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in Table
500-12.
TABLE 500-12. MINIMUM PER CENT VOIDS IN MINERAL AGGREGATE (VMA)
Nominal Maximum Minimum VMA, Per cent Related to Design Air Voids, Per
Particle Size1 cent2
(mm)
3.0 4.0 5.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
Page 29
37.5 10.0 11.0 12.0
Notes: 1. The nominal maximum particle size is one size larger than the first sieve
to retain more than 10 per cent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for design .air
voids values between those listed.
(e) BINDER CONTENT

The binder content for grading indicated shall be determined by Marshall method
replacing the aggregate retained on 26.5mm sieve by the aggregates passing 26.5
sieve and retained on 22.4 mm sieve.
JOB MIX FORMULA

After approval of the material by the engineer, The job mix formula will be designed
and submitted for approval of the Engineers.
PRODUCTION OF DBM
Production of DBM will be done in a 124 TPH batch type HOT Mix plant; Aggregate of
diferent sizes will be drawn from the stock pile and loaded in four bins of HOT MIX
PLANT with the front End Loader. The out flow of aggregate from the bins will be
controlled by adjacent gate opening and will be in accordance with the Job mix Formula.
The aggregate will be further conveyed to dryer unit where it will be heated to the
following range of temperature i.e, range of Temperature – 150 to 170 degree
centigrade. The bitumen to be used shall be paving bitumen of Viscosity grade VG-30 as
per Indian standard specification for paving bitumen IS: 73. The temperature of binder
at the time of mixing shall be in the range of 150-170 degree centigrade.
Page 30
The binder duly heated in bitumen tank will be conveyed to mixing unit through pipes to
obtain the mix in approved range of Temperature.
The flow of Bitumen shall be controlled by the bitumen pump. Mixing shall be through to
ensure a homoeogineous mixture so as to coat all particles of mineral aggregate
uniformly. The Mixture shall be further discharged through load –out hopper into waiting
dump truck. The dump trucks shall be clean and these will be covered in transit with
tarpaulins depending on the weather conditions requiring control temperature as
specified above. The complete operation of Hot Mix Plant shall be exercised. Through
computerized panel installed in the cabin provided for this purpose near the Hot mix
Plant.
SPREADING
DBM shall be laid true to the centre lines. Grades and cross section in the thickness of
80 mm the mix transported from the Hot Mix Plants to the site shall be spread by
means of self propelled Electronic Paver with sensor system having suitable screeds
capable of spreading tamping and finishing the mix to specified grade ,lines and cross
section. At the time of unloading the truck shall be pushed slowly forward so as to
avoid any spillage of, material. Any spillage however will be shoveled into the hopper
before the paver passes though that area. The temperature of the mix at the time of
laying shall be Min 125° Longitudinal joints and edges shall be construction true to
lines parallel to center line of the road and all joints shall be cut vertical to the full
thickness of the previously laid mix.
ROLLING
After the spreading of mix by paver, the initial or breakdown rolling shall be done with 8-
10 tonnes tandem roller Breakdown rolling shall be followed by intermediate rolling
with a Tendam Vibratory and pneumatic tyre roller . Finish rolling shall be done with 8-
10 tonnes weight tandom roller during breakdown rolling and finish rolling no vibrator
compaction shall be resorted.
Page 31
The wheel of roller shall be kept moist by water if necessary. Rolling shall commence
from edge and proceed towards the center except that on super elevated portion it shall
progress from the lower edge to upper edge parallel to the centre line of the pavement.
Rolling shall continue till the density achieved is at least 98% of that laboratory
Marshall specimen and all roller marks eliminated. Rolling operation shall be completed
in all respects before the temperature of the mix falls below 90 degree centigrade as
per most specification clause no 507.4.6.
SURFACE FINISH AND QUALITY CONTROL OF WORK

Quality control for the above work shall be as per table 900-4 of MoRT&H .
i. The gradation of the mix shall be controlled at plant as per the approved designed mix.
ii. Mix temperature shall be controlled at plant within the range 165 0C max and the
temperature less than 1250C shall not be used for paving.
iii. The compacted surface shall be checked for field density by taking cores at the
frequency of 1 test for 250 sq.m. The degree of compaction should not be less than
98%.
iv. Paved DBM shall be checked for “Surface Regularity Test”
v. The surface shall be checked for levels longitudinally and transversely as per MoSRTH
clause 902.3 and the same shall be within +/-6mm.
vi. Cores will be collected after satisfactory compaction of the layer using mechanical core
cutting machine and will be tested for the parameters like Thickness, Compaction % of
air voids etc as per the table 500-10 of MoRT&H .
QUALITY TIPS
i. Laying shall not be taken up when atmospheric temperature is less than 10 0C.
ii. The temperature diference between bitumen and aggregate shall not be more than
140C during mixing at plant.
iii. The mix shall be loaded at the hot mix plant in three heaps on dumpers so as to avoid
segregation.
iv. Temperature should not be less than 1250C during paving.
Page 32
v. The hopper of the paver shall not be emptied completely as it may lead to segregation
vi. The rollers should not stand on pavement which has not been fully compacted
vii. The mix while transporting shall be covered with taurpalin to protect from rain and
temperature loss.
MACHINERY
a) Hot mix plant

b) Electronic sensor paver
c) Tandom Roller
d) Pneunatic Tyre Roller
e) Bitumen spray tanker
f) Dumper/Tripper
g) Water Tanker
h) Mechanical Broom With Tractor
i) Air Compressor

WORK
Site Engineer
Materials Engineer
Surveyor
Supervisor
Laborer
Page 33
BITUMINOUS CONCRETE WORK
SCOPE
This work shall consist of constructing in single layer bituminous concrete of thickness
40 mm on dense bituminous layer to the requirement of the most specifications and
clause no 509.
REFERENCES
Specification and procedures stipulated in the contract agreement.
Approved drawing supplied by the Engineer.
PROCEDURE
MATERIALS
(a) BITUMEN:-
Page 34
The Bitumen shall be paving bitumen of viscosity grade VG-30 as per Indian Standard
specification doe paving Bitumen IS: 73.
(b) AGREGATE
The coarse and fine aggregate will be produced at approved quarry and will consist of
crushed stone or fairly cubical shape material shall be free from any organic or
deleterious substances. The coarse and aggregate will confirm to the physical
requirement of clause on 507.2.2 and 507.2.3 of Technical specifications and the water
absorption will not be more than 1%
(c) FILLER
The design mix for bituminous concrete carried out in the laboratory caters for the filler
material by way of crushed stone dust. However the filler material will be used, if
requirement according to the job mix formula and material shall be stone dust,
hydrated lime or any other suitable material prescribed in design mix. The filler
material is used shall be confirmed to clause no 507.2.4 of Technical specification
(e) AGGREGATE GRADATION

Aggregate Gradation for Bituminous concrete as per MoSRTH clause table 500-18 for
grading -2.
Grading 1 2
Nominal aggregate size 19 mm 13 mm
Layer Thickness 50-65 mm 30-45 mm
IS Sieve1 (mm) Cumulative % by weight of total aggregate passing
45
Page 35
37.5
26.5
100
19
79-100 100
13.2
59-79 79-100
9.5
52-72 70-88
4.75
35-55 53-71
2.36
28-44 42-58
1.18
20-34 34-48
0.6
15-37 26-38
0.3
10-20 18-28
0.15
5-13 12-20
0.075
2-8 4-10
Bitumen content % by mass
of total mix2. 5.0 - 6.0 5.0 - 7.0
Bitumen grade (pen)
65 65
TABLE 500-17. PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE FOR
BITUMINOUS CONCRETE PAVEMENT LAYERS
Property Test Specification
Cleanliness Grain size analysis1 Max 5% passing 0.075 mm sieve
Particle shape Flakiness and Elongation Index Max 30%

(Combined) 2
(Combined)2
Strength* Los Angeles Abrasion Value3 Max 30%
Aggregate Impact Value4 Max 24%
Polishing Polished Stone Value5 Min 55
Durability Soundness: 6
Page 36
Sodium Sulphate Max 12%

Magnesium Sulphate Max 18%
Water Absorption Water absorption7 Max 2%

Stripping Coating and stripping of Minimum retained coating
Bitumen Aggregate Mixtures9 95%
Water Sensitivity** Retained Tensile Strength8 Min 80%
(f) REQUIREMENT OF MIX

The grading and quality requirements of Individual ingredients, the mix shall confirm
the requirements as per clause 512.3 of Technical specifications.
TABLE 500-19. REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS

Minimum stability (kN at 60°C) 9.0
Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of blows) 75 blows on each of the two faces of the
specimen
Per cent air voids 3-6
Per cent voids in mineral aggregate
(VMA) See Table 500-12 below
Per cent voids filled with bitumen (VFB) 65-75

Loss of stability on immersion in water
at 60°C (ASTM D 1075) Min. 75 per cent retained strength
JOB MIX FORMULA

Job mix formula will confirm to the clause no 507.3.3 of the Technical Specification
PRODUCTION OF MIX
Production of the bituminous concrete mix will be done in the computer controlled
Batch type Hot Mix Plant. Aggregate of diferent size will be drawn from the stock pile
and loaded in four bins of Hot Mix Plant with the front end loader.
Page 37
The out flow of the aggregate from the bins will be controlled by adjusting gate and will
be in accordance to job mix formula. The aggregate will be further conveyed to dryer
unit where it will be heated to the temperature range of 150-170 degree centigrade.
The bitumen to be used, shall be paving mix with CRMB/ PMB conforming to IRC: 53 as
per Indian standard specification
For paving bituminous IS:73. The Temperature of the binder at the time of mixing shall
be in range of 150-165 degree centigrade. The binder duly heated in bitumen Tank will
be conveyed to mixing unit through pipes to obtain the mix in approved range of
Temperature.
The flow of bitumen shall be controlled by the bitumen pump, mixing shall be through to
ensure a homogeneous mixture so as to coat all particles of mineral aggregates
uniformly, the mixture shall be further discharged throughout load out hopper into
waiting dump trucks. The dump truck shall be clean and these will be covered in transit
with tarpaulins depending on the weather conditions
requiring control temperature as specified above, the complete operation of Hot Mix
Plant shall be exercised through computerized panel installed in the Cabin provided for
this purpose near the Hot Mix Plant.
SPREADING
Bituminous concrete shall be laid true to the specific lines, grades and cross-Section in
the thickness of 40mm. the mix transported from the Hot mix plant to the site shall be
spread by means of self propelled electronic paver with sensor having suitable screeds
capable of spreading, tamping and finishing the mix specified grade. Lines and cross-
section. At the time of unloading, the trucks shall be shoveled into the hopper before
the paver passes through that area. The temperature of the mix at the time of lying
shall be 125° Longitudinal joints and edge shall be constructed true to line parallel to
Centerlines of the road all joints shall be cut vertical to the thickness of the previously
laid mix.
ROLLING
Page 38
After the spreading of mix by paver, the initial or breakdown rolling shall be done with 8-
10 tonnes tandem roller Breakdown rolling shall be followed by intermediate rolling
with a Tendam Vibratory and pneumatic tyre roller . Finish rolling shall be done with 8-
10 tonnes weight tandom roller during breakdown rolling and finish rolling no vibrator
compaction shall be resorted.
The wheel of roller shall be kept moist by water if necessary. Rolling shall commence
from edge and proceed towards the center except that on super elevated portion. It
shall progress from the lower edge to upper edge parallel to the centre line of the
pavement. Rolling shall continue till the density achieved is at least 98% of that
laboratory Marshall Specimen and all roller marks eliminated. Rolling operation shall be
completed in all respects before the temperature of the mix falls below 90 degree
centigrade as per most specification clause no 507.4.6.
OPENING OF TRAFFIC
Traffic will be allowed only after completion of the final rolling when the mix has cooled
down to surrounding temperature.
SURFACE FINISH AND QUALITY CONTROL OF WORK

Quality control for the above work shall be as per table 900-4 of MoRT&H.
i. The gradation of the mix shall be controlled at plant as per the approved designed mix.
ii. Mix temperature shall be controlled at plant within the range of 165 0C and the
temperature less than 1250C shall not be used for paving.
iii. The compacted surface shall be checked for field density by taking cores at the
frequency of 1 test for 250 sq.m. The degree of compaction should not be less than
98%.
iv. Paved be shall be checked for “surface Regularity Test ”
v. The surface shall be checked for levels at 5m intervals longitudinally and transversely
as per MoSRTH clause 902.3 and the same shall be within +/-6mm.
vi. Cores will be collected after satisfactory compaction of the layer using mechanical core
cutting machine and will be tested for the parameters like Thickness, Compaction.
Page 39
QUALITY TIPS
i. Laying shall not be taken up when atmospheric temperature is less than 10 0C.
ii. The mix shall be loaded at the hot mix plant in three heaps on dumpers so as to avoid
segregation.
iii. Temperature should not be less than 1250C during paving.
iv. The hopper of the paver shall not be emptied completely as it may lead to segregation
v. The mix while transporting shall be covered with tarpaulin to protect from rain and
temperature loss.
MACHINERY
j) Hot mix plant

k) Electronic sensor paver
l) Tandom Roller
m) Pneunatic Tyre Roller
n) Bitumen spray tanker
o) Dumper/Tripper
p) Water Tanker
q) Mechanical Broom With Tractor
r) Air Compressor
WORK
Site Engineer
Materials Engineer
Surveyor
Supervisor
Laborer
Page 40
ENCLOSURES
i. Typical Core density sheet.

ii. Typical level check sheet.
iii. Typical Surface Regularity sheet.
Page 41

Methology For Traversing To Tackcoat

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Methology For Traversing To Tackcoat

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Essel Ahmedabad Godhra Toll Roads Limited

National Highways Authority of India

feasibility-cum-preliminary study for 4 laning by NHAI.

Client National Highways Authority of India

Concessionaire Essel Ahmedabad Godhra Toll Roads Limited

Independent Engineer EGIS BECOM International JV Egis India Consulting

EPC Contractor Pan India Infrastructures Private Limited.

Contractor Dilip Buildcon Limited

i. Global positioning system (GPS)

viii. Numbering and Chainage shall be given to the benchmark pillars.

METHODOLOGY OF CLEARING AND GRUBBING

MACHINERY & EQUIPMENT

TESTING AND ACCEPTANCE PROCEDURES INCLUDING DOCUMENTATION

C. Structures to be dismantled. Etc;

All safety precautionary measures shall be taken as stated below: -

i) Cautionary / Warning Signboards shall be placed along the road side.

DETAILS OF PERSONNEL BOTH FOR EXECUTION AND QUALITY CONTROL OF THE

Personnel for Execution:

APPROVAL OF BORROW AREA

1. Request For Inspection

All safety precautionary measures shall be taken as stated below: -

i) Cautionary / Warning Signboards shall be placed along the road side.

DETAILS OF PERSONNEL BOTH FOR EXECUTION AND QUALITY CONTROL OF THE

SPECIAL PART OF Q.A. PROGRAMME

Test requirement for earthwork on excavation, embankment are as shown in Table 2.

a. Cautionary / Warning Signboards shall be placed along the road side.

b. Moveable signboards shall be placed at area where heavy machineries and

1 Treatment on ground supporting embankment if any

DETAILS OF PERSONNEL BOTH FOR EXECUTION AND QUALITY CONTROL OF THE

SPECIAL PART OF Q.A. PROGRAMME

METHODOLOGY OF GRANULAR SUB BASE (GSB)

LAYER THICKNESS: - The Compacted thickness of Granular Sub base is 200 mm

 Checking of stock pile at source

SPREADING THE MATERIAL AND COMPACTION

DETAILS OF PERSONNEL BOTH FOR EXECUTION AND QUALITY CONTROL OF THE

METHODOLOGY OF Wet Mix Macadam (WMM)

JOB MIX FORMULA

I. WMM Plant with 250 TPH Capacity

DETAILS OF PERSONNEL BOTH FOR EXECUTION AND QUALITY CONTROL OF THE

Application of tack coat

After ensuring surface cleaning, bituminous emulsion generally at normal ambient

Casting of Cement Concrete Kerb

1- Kerb Casting Machine; - 01 No.

DENSE –BITUMINOUS MACADAM

03 Flakiness and Elongation Index 30% Maximum (Table

2. Determined by the Marshall method.

Minimum stability (kN at 60°C 9.0

Per cent voids filled with bitumen 65-75

12.5 13.0 14.0 15.0

19.0 12.0 13.0 14.0

25.0 11.0 12.0 13.0

37.5 10.0 11.0 12.0

(e) BINDER CONTENT

JOB MIX FORMULA

SURFACE FINISH AND QUALITY CONTROL OF WORK

a) Hot mix plant

DETAILS OF PERSONNEL BOTH FOR EXECUTION AND QUALITY CONTROL OF THE

BITUMINOUS CONCRETE WORK

(e) AGGREGATE GRADATION

Nominal aggregate size 19 mm 13 mm

Layer Thickness 50-65 mm 30-45 mm

IS Sieve1 (mm) Cumulative % by weight of total aggregate passing

Property Test Specification