Irc Gov in SP 011 1984

HANDBOOK OF QUALITY
CONTROL FOR CONSTRUCTION

OF ROADS AND RUNWAYS
(Second Revision)
INDIAN
ROADS CONGRESS
c)igitized by the Internet Archive

in
2014
https://archive.org/details/govlawircy1984sp11_0
IRC:SP:11-1984
HANDBOOK OF QUALITY
CONTROL FOR CONSTRUCTION
OF ROADS AND RUNWAYS
(Second Revision)
Published by
INDIAN ROADS CONGRESS

Jamnagar House, Shahjahan Road,
New
Delhi 110011
1984
Price ^
(Plus packing
300
& postage)
IRC:SP:11-1984
July,
First Published
First
1973
December, 1977
Revision
Reprinted
October, 1983
Second Revision
April, 1984
Reprinted
September, 1989
Reprinted
January, 1994
Reprinted
January, 1997
Reprinted
September, 2000
Reprinted
April,
Reprinted
January, 2003
Reprinted
Reprinted
December, 2004
October, 2005
Reprinted
July,
Reprinted
February, 2008
Reprinted
June, 2009
Reprinted
June,
Reprinted
December, 2012
2002
2006
2010
(Rights of Publication
Printed at
and Translation are reserved)
India Offset Press,
New Delhi
(1000 copies)
- 1
10064
Contents
Page
Introduction
CHAPTER
General
...
CHAPTER 2
Earthwork
...
13
CHAPTER 3
Sub-base Courses
...
23
CHAPTER 4
Base Courses
...
39
CHAPTER 5
Bituminous Surface Courses
...
53
CHAPTER 6
Concrete Pavements
...
65
CHAPTER 7
Control of Alignment, Profile and

...
75
to Quality Control...
85
Surface Evenness
CHAPTER 8
Statistical
Approach
APPENDICES
1.
List of Standards/Specifications of Indian
Roads Congress
referred to in the text
...
97
...
98
Range of equipment required for a testing

central, regional and field laboratories
...
100
4.
Sample forms
...
112
Procedure for certain field control tests

not covered by published standards
...
125
...
128
2.
List
of
test
standards of Bureau of Indian
Standards and other bodies referred to

3.
in the text
and
6.
for quality tests
Procedure for checking surface regularity

using a straight-edge
INTRODUCTION
materials and product is an

improved and uniform standard
of roads. Towards this end, a three-day Symposium on 'Quality
Control in the Construction of Roads and Runways,' was organised
under the joint auspices of the Indian Roads Congress and the
Central Road Research Institute in New iDelhi from 27th to
29th February, 1968. At the concluding Session of this Symposium,
the following resolutions were adopted
Quality control of construction
essential requirements for obtaining
(1) that quality control
of materials and the end product together with

part of construction
involved should form an integral
process
of road and runway projects, and that materials

survey be carried out for each project at the rough estimate stage;
specifications
wherever necessary, the existing specifications be reviewed so

and to provide for adequate quality control
measures fair to all concerned;
(2) that
as to be realistic
(3
be provided in the form of either a

budgetary provision or as a percentage of each project
estimate to meet the expenses of quality control;
that adequate financral outlay
basic
(4) that
all
a Committee of experts be set up to prepare a
the details of quality control code
and
handbook giving
handbook be
that the
reviewed periodically based on experience gained;

(5) that short
term training programmes be organised to provide the
requisite trained personnel for quality control.
In
pursuance of Resolution No.
the following
members was
Committee
consisting of
constituted for drafting the
(1) Shri S.N. Sinha
M.K. Chatterjee
(2) Shri
4,
Convenor
Member
(3) Shri J. Datt

(4)
Dr. M.P. Dhir
(5)
Dr. R.K.
(6) Shri
(7) Dr.
Ghosh
T.K. Natarajan
M.L. Puri
R.P. Sikka
Dr. Bh. Subbaraju
(8) Shri
(9)
(11)
CO.
Swaminathan
Dr. H.L. Uppal
(10) Prof.
Handbook:
Introduction
The above Committee,
in turn,
constituted
tees to prepare drafts of various Sections.
SubcommitCommittee
main tentative
four
Later, the
that, before finalising the Handbook, its

recommendations regarding the quantum of testing, control tests,
acceptable tolerances and method of interpretation of results, in a
summarised form, be placed before the National Seminar on
Roads and Bridges at Bombay in October, 1968 for wider discussion.
For this purpose, a Working Group consisting of
Dr. M.L. Puri, Dr. M.P. Dhir and Shri R.P. Sikka was entrusted
decided
with responsibility of preparing the
required
summary
for circula-
tion to the delegates attending the National Seminar.
The
Recommendations
discussed by the Committee and

ing
Subcommittee
of
the
in light
National Seminar were

of the discussions, a draft-
Prof.
C.G.
Swaminathan,
M.L. Puri was formed to complete
comprising
Shri T.K. Natarajan and Dr.

the draft.
The draft prepared by the Subcommittee was discussed by

Committee in a series of meetings and a Working Group
consisting of Shri R.P. Sikka, Dr. M.P. Dhir and Dr. M.L. Puri
processed the same. It was then considered by the Executive
Committee of the Indian Roads Congress, in its meeting held at
Gandhinagar on 25-11-72. Thereafter, the Council of the Indian
Roads Congress at its meeting held at Gandhinagar on the same
day finally approved the draft of this Handbook of Quality Control
for being published as a Special Publication of the Indian Roads
the
Congress.
The Manual was
revised in 1977 (First
Revision) to incorpo-
rate the new standards on surface evenness approved by the I.R.C.

Council at its Meeting held in Madras on 28.8.76. The second
revision includes the prescribed equipment for different laboratories and the forms to be used for recording the results of
observation/test results by the field officers.
General
1
General
CHAPTER
GENERAL
Need
1.1.
for Quality Control
part of any production

is an essential
highway constructions are no exception. Quality
control is an important requirement for highway construction for
ensuring quality and for creating durable national assets. The
need for quality control on these constructions has increased considerably in recent times due to a significant increase in traffic
intensities, and the level of service expected of highway facilities.
Improved level of service of the highways will result in considerable savings in vehicle operating cost and in favourable road user
reaction and public opinion. Quality control in the form of sensory checks which are intrinsically subjective and qualitative is
grossly inadequate for present-day needs and must instead be based
on proper objective and quantitative measurements.
Quality control
1.1.1.
process and
1.1.2.
It is
common knowledge
improved
leading to constructions of
ensuring a more economical

operation,
transportation
quality
benefits,
is
highly
average project
control
On
just
the
in as
much
as on an
cost of exercising quality
cent of the construction cost.
J to 2 per
direct
extra cost of
fraction of the resulting
economical proposition,
the other hand, the
uniformity, and
The
maintenance.
being only a
estimated that
it is
would be
and
control
end
of materials, also affords a

terms of lower costs of vehicle
utilisation
significant reduction in user costs, in
exercising
that quality control, besides
quality
and
indirect
economic return from
quality control could be of the order of 5 to 10 per cent of the total
construction cost and even more.

Pre-requisites for Quality Control
1.2.
The
tions are
(i)
prc-requisites for effective
control of highway construc-
Construction
specifications
effective quality control.
and
estimates
should
provide
for
General
Adequately trained staff and
control should be set up.
(ii)
equipped
agency for exercising quality
of the quality control data should be made not

implementation during construction but also for effecting
Periodic appraisal
(iii)
only for
improvements
possible
quality
in
and
control
construction
techniques themselves.
Updating of knowledge by on job training
(iv)
1.3.
Organisational Set-op for Quality Control
1.3.1.
The requirements of a quality control organisation will
obviously vary on different projects depending on the departmental
set-up of the concerned highway agency. For. example, the organisation of quality control
work
single centrally situated large
at a
project will need to be on quite different lines than at average sized
scattered projects.
the organisation
discussed.
The
chapter
In this
of quality
actual set-up
of various factors involved.

control set-up in this
only the
control
work
may be
evolved
For the suggested
handbook a
typical
broad guidelines for

road projects are
at
in the
background
pattern of quality
Organisational set-up ha?
been drawn up and shown below:

Organisational Chart of Quality Control Set-up
ENGINEER-IN-CHIEF/
CHIEF ENGINEER
I
DIRECTOR
Head of quality
control, should not be below the rank of S.E.

Located at Head-Quarter or where Central Laboratory Exists
REGIONAL LABORATORIES
Headed by Executive Engineer Q/C
all
will deal with specific cases,

policy matters, training of staff etc.
Field Laboratory
Depending upon the job

routine field tests at
it
with the
of the work
will deal
site
General
1.3.2.
In any organisational set-up, che central agency has
an important role as regards implementation of quality control
standards by way of drafting and constant review of the quality
control criteria included
in
specifications.
The
would normally invo-
construction
the
implementation of quality control
in the field
lve three sub-agencies viz. the construction staff of the
Engineer-in-
Chacge, the constructing agency ^nd the quality control team. The
construction staff and quality control teams must have distinctly
defined functions and inter-relationships so as to avoid possible
The quality control team may consist of staff of regional
conflicts.
laboratories and field laboratories working under the technical
direction of the Central Laboratory.
As
1.3.3.
fed to the
site
engineer,
well as to the
view
Head
of the
ensure
to
specifications in
This
back.
as
the
latter
responsible for ensuring

the data will also
Engineer/Chief Engineer as
Central Laboratory; to the former with
continuity
practice,
and
as
and
well
to the
may be regarded
subject to review
is
In addition,
Superintending
be submitted to the
a
collected
and speed of construction.
quality
concerned, the perby them should be promptly
far as the field laboratories are
iodic quality control data
as
as
compatibility of the
latter for
tentative
modification, as and
purpose of feed-
recommendation,
when experience accu-
mulates.
The expenditure on quality control may be charged

to the works and the staff as well as equipment shifted from project
to project depending upon the requirements.
The quality control
staff should not be on work-charged basis but form part of regular
properly trained for the work they are required to
staff and be
1.3.4.
handle, for which suitable training

the department,
either in
other Laboratory.
suggested that this
work
To provide
may be
should be afforded by
Central Laboratory or any
the cost of quality control, it is
facilities
own
for
included as a distinct item in the various
estimates.
1
.4.
1.4.1.
Types of Quality Control
Over the years, two types of methods
for exercising quality
One
their
is
generally
control
known
during
the
have emerged
construction of works.
as *Process control' and the other as 'End
General
6
rcsuU' type of
control.
former,
In the
the
decisions regarding the type of equipment,
designer makes the
the procedure of con-
and the amount of work required to obtain the desired

*End result* type of control, the construction agency,
which may be a private contractor, has a free hand in the selection
of construction methods and equipment to achieve the desired end
struction
result.
In the
product.
The choice of
1.4.2.
of judgment, depending
either type of control
is
largely a matter
magnitude of the job, different

environmental factors involved, and the available facilities. In
India, gradually the trend is towards *End result* type of working
on highway pavement and embankment construction jobs. But in
several situations, for example on small jobs, or where jnput type
of tests like material gradation and purity of lime are to be carried
out, expediency would be in adopting *Proccss type* of control.
Because of circumstances, a combination of the Process* and *End
result' types of control will continue to be adopted in India, depending on the nature and size of the job.
on
the
In the 'End
1.4.3.
intervals
to
ments or
not.
result*
carry out
responsibility of field personnel

different phases
down
type
of
specification,
the field
on finished work at regular

evaluate whether it meets the specification requireOn the other hand, in Trocess type' control, the
engineering personnel
is
executed
is
in the
tests
make sure that the work in its

manner predetermined and laid
to
in specifications.
1.4.4.
The
tion of ^Process*
details given in this
and 'End
result*
Handbook
arc for a combina-
types of quality control which
is
generally being practised in this country.
1.5.
SpecilBcations for
The handbook draws

Specifications
of
Indian
Work
heavily upon the existing Standards/

Roads Congress by way of abstracting
requirements of construction for the various items of

Reference is given to the relevant Standards at appropriate
places in the Handbook. A complete list of all the standards referred to with their full title is included at Appendix 1.
essential
work.
General
Control of Materials
1.6.
The
1.6.1.
quality control tests on
subsequent chapters, are

the material
brought
materials indicated in the
intended essentially
However,
to site.
and other considerations, some
to be carried out
at times,
on
from practical
be done advantageously at the material source.

e EngineerIn these circumstances,
in-Charge may do additional testing at site as may be found necessary to ensure that the materials being incorporated in the construction are of specified quality.
testing could
"
All the materials
1.6.2.
brought
to the
site shall
be stacked
and stored as specified so as to prevent deterioration or intrusion

by foreign matter and to ensure the preservation of their quality
and fitness for work. Materials which have been improperly stored
or have been stored for long periods shall be re-tested where their
suitability for incorporation in the work is in doubt.
Test Procedures
1.7.
The
procedure for testing of different materials and

accordance with the relevant standards of Indian
Bureau of Standards where these are available. Reference has been
1.7.1.
work
shall be in
drawn
to these standards at appropriate places
consolidated
Appendix
list
of the
standards
in the
with their full
Handbook.
title is
at
2,
Where specific procedure of testing is not indicated, the

be carried out as per the prevalent accepted engineering
practice to the direction of the Engineer-in-Charge.
1.7.2.
tests shall
1 .8.
Frequency and Extent of Testing
The frequency and extent of testing indicated in the Handbook

minimum considered necessary for normal conditions. It is
envisaged that additional testing shall be carried out for abnormal
is
the
conditions where variations
may be
excessive or where circumstan-
ces so warrant otherwise.

1.9.
Acceptance Criteria
Acceptance Criteria for different items of work where

was available have been setforth in the
Handbook in respective chapters. For other items, acceptance
1.9.1.
sufficient
experience
General
8
may be
minimum
based on
values or statistical analysis
as
is
considered judicious.
For
1.9.2.
it
effective control
on quality of materials and work,
usually be necessary to lay
will
down
the acceptance criteria in
the contract documents.
Range of Equipment
1.10.
for
a Central, Regional and Field
Testing Laboratory
Range of equipment required for a central, regional

and control laboratories is indicated in Appenguidance. The list includes such equipment as will
1.10.1.
and
dix 3
testing
field
for
normally be required for quality control operations
Handbook.
Individually, quality control
units
spelt out in the
could be suitably
equipped with the help of this list depending on the type and
volume of work to be controlled. Special equipment as given in the
appendix can be procured depending upon the requirement.
1.10.2.
Testing facilities
Testing
facilities
should comprise
Laboratories at Central, Regional and Field levels.

located
laboratory
facilities for tests
headquarterswill
at
(a)
of specialized nature, (b) act
tory for works circle
(s)
at
headquarters,
The Central
provide
as
testing
regional labora-
(c) act
as
the
nodal
and Central sectors,

(d) bring out manuals for testing procedures.
The Central laboratory headed by the Director, may have for quality control work,
The
scientists from Geology, Chemistry and Physics disciplines.
of suggested equipment to be provided in Central laboratory
list
are avilable at Appendix 3.
laboratory for Research schemes
in the
State
The Regional laboratories located at circle level will be headed by Executive Engineers (Quality Control) assisted by scientists
from Geology, Physics and Chemistry disciplines. Regional laboratories will provide testing support to the (a) Engineers working in
the circles and (b) Research teams from Central and State Highway
R&D
In
institutions.
training
of
all
suggested equipment
given at Appendix
It is
addition they shall provide
all facilities
the Quality Control staff in the Region.

to
be
provided
in
The
for
list
Regional laboratories
of
is
3.
neither feasible nor advisable to send samples for routine
General
tests
way
the
all
to the
Regional laboratories and delay the work
Setting up facilities for basic tests at the

Engineer/Engineering subordinate is therefore necesSome other equipments may have to be provided at sub
sary.
A list of equipment suggested to be
Divisional/Divisional level.
divisional/Divisional
level can be seen at
provided at Site/Sub
for
want of
test results.
level of Junior
Appendix
3.
Recording of the Test Results
1.11.
The
accordance with the standard

in the proformae given
It is desirable
that of the total tests, 70 per cent
at Appendix 4.
arc carried on by the Junior Engineer, 20 per cent by the Assistant/
Deputy Engineer and the remaining 10 per cent by the Executive
The test result record registers shall be presented
Engineer.
with every third runnipg bill so that the payments get linked with
the assured quality of work.
tests shall
be carried out
in
procedures and the results shall be recorded
Training for Quality Control
1.12.
In order to bring awareness in the officers of department
and
knowledge of methods of testing, regular workshops
on quality control should be held. To make the participants aware
to
up date
their
required test acceptance

frequency of testing and methodology of tests for understanding the quality control system and operation of regional/field
The training could be imparted by known road
laboratories.
research institutes or through on job training.
of basic necessities like
specifications,
criteria,
Scope of the Handbook
1.13.
1.13.1.
for the
ctions.
It
is
Handbook is intended to be a handy reference

work of quality control at various highway construnot in any way meant to be a substitute for the rele-
This
general
vant departmental specifications for construction and materials, but

only as a guide to complement these. For certain items, where
need was felt, broad guidelines on salient construction features have

been included in the Handbook. These are for guidance only and
should not be taken to constitute specifications.
Even though the Handbook is intended mainly for

1.13.2.
highway constructions, it will be found equally advantageous for a
number of
facets of
runway constructions
as well.
Earthwork
Earthwork
11
CHAPTICR
EARTHWORK
General
2.1;
2.1.1.
It is
the responsibility of the field engineer
to
ensure
assumed by the designer is achieved at the

expected moisture content. The way to ensure this is to test
samples for moisture and density and to take appropriate corrective measures, as necessary.
The rate of testing on a given project
would depend on several factors, such as the homogeneity or
otherwise of the material from the borrowpits, the nature and
quantum of machinery or manual labour employed, and terrain
conditions, so that the number of particular tests to be conducted
for say 1000 cubic metres of the material involved, would entirely
Therefore, the frequency
be a matter of engineering judgment.
of testing indicated at the end of .this chapter should be regarded
as indicative of the minimum number of tests to be conducted with
full realisation of the fact that the rate of testing would have to be
that
the
increased
density
if
circumstances so warrant.
Discussion of other aspects such as the
2.1.2.
minimum
equipment, thickness
of layer, etc., are considered to be outside the scope of this
chapter.
For guidance in this respect, reference should be made
36-1970 "Recommended
specifications, IRC
to the relevant
densities to be obtained, selection of rolling
Practice
for
Construction of Earth
Embankments
for
Road
Works".
2.2.
Earthwork Materials and Process Selection of Soils
The soil to be used for making up the embankment

shall be free from stumps and root rubbish which might affect the
stability of the embankment.
2.2.1.
2.2.2.
bankment
selection of materials for construction of the embe made after conducting necessary soil surveys
The
shall
and laboratory
investigations, as set out in
IRC
36-1970.
Earthwork
14
2.2.3.
Only approved materials should be
body of the embankment.
2.2.4.
Processing and placement
paction, the
embankment
To
utilised
in
com-
obtain adequate
shall be constructed in
uniform
the
layers.
Due
care shall be exercised to ensure that loose thickness of

each layer does not exceed the specified limits. Successive layers
of embankment shall not be placed until the layer under construction has been thoroughly compactedto satisfy the specified
requirements.
2.2.5.
After adjusting the moisture content whether at the
road side or at borrow area, (making due allowance for evaporation losses), the soil shall be processed by means of graders,
harrows, rotary mixers, other suitable equipment or even manually
if no equipment is available until the moisture distribution is reasonably uniform. Clods or hard lumps of earth where present shall be
broken down to sizes preferably of the order of 5 cm but under

no circumstances shall the maximum size of clods exceed 15 cm
when soil is being placed in the body of the embankment and 6 cm
when it is being placed in the top 50 cm of the embankment.
2.2.6.
Moisture content at the time of compaction : Unless
otherwise specified, the moisture content of each layer of soil at
the time of compaction except in the case of highly expansive soils

should be at optimum moisture content subject to the permitted
tolerances.
Highly expansive soils such as black cotton soil
should be compacted at the specified moisture content which
is usually
on the higher side of the optimum moisture content.
The tolerance
limits for variation
of moisture content from
the specified moisture content are normally
per cent and
per cent.
2.2.*^.
Densities to be aimed at in the compaction process
be chosen with jdue regard to factors such as soil type, height
of embankment, drainage conditions, position of the individual
layers and type of plant available for compaction.
shall
Each compacted layer shall be tested in the field for

and accepted before the operations for the next layer
commence.
2.2.8.
density
Earthwork
15
Compaction
Trial
2.3.
where no previous record or experience

needed number of passes with a particular rolling
In situations
2.3.1.
concerning the
equipment relating
desirable
to
to a particular soil type
conduct
is
available,
it
may
be
on compaction so as to obtain data

planning of compaction operations.
field trials
which would serve as an aid
to
2.3.2.
A test area about 20 m long and 5 m wide is prepared
removing the top soil.
The fill material to be used is spread
over this area, the depth of the loose layer being 25 cm. The
after
mositure
content of the
should be as specified subject to the
soil
tolerance limits indicated.

2.3.3.
The test layer is then compacted with the type of
compaction plant decided upon, and the mean dry desnsity to the
full depth determined over the range of about 4 to 16 passes.
The
number of passes required are dependent upon the weight and type
of rollers employed. The dry density shall be determined in accordance with IS: 2720 (Part-XXVIII) and the mean of 5 determination should be obtained for each compaction condition.
The mean
dry densities are plotted against the number of roller passes. From
graph, the approximate number of passes required for the compaction equipment to obtain the specified dry density is determined.
this
Quality Control of Earthwork
2.4.
2.4.1.
Quality of
fill
material
and
its
compaction
shall
controlled through exercise of checks on the borrow material,
paction
process,
or the
However,
directed.
in
be
com-
end-product, singly or in combination as
every case, the end-product must conform
to the construction specifications.
2.4.2.
Details of control tests
on borrow materials and com-
paction are dealt with in Clauses 2.5. and 2.6.
Control Tests on Borrow Material
2.5.
2.5.1.
The
particular type of tests required to be conducted
on the borrow material and

interplay
of several
factors
their
frequency would depend on
such as the nature of plant or machi-
nery employed on the project, the quantum of manual labour
in-
Earthwork
16
volved, the nature of specifications to be followed whether they call
on borrow
particular tests
for
niat'^rials,
the uniformity or other-
wise of materials coming out of borrowpits,
The recommended frequencies

graphs and
terrain conditions, etc.
indicated in the succeeding para-
Table 2.1. are therefore only to be taken as applicable

These tests are meant to verify during executior
of the work that the material coming to site conforms to specifications, for borrow material and should be regarded as distinct from
the test referred to in Clause 2.2.2. which relate to the initial selecin
to routine cases.
tion of soils for
embankment
construction.
All the tests would not
be applicable on all projects. Depending upon site conditions, etc.,

only particular tests may be found necessary for a particular
The frequency of
project.
the
minimum number
for
each kind of
testing indicated releates generally to
The rate of testing

would have to be stepped up much more than is herein indicated,
depending upon the heterogeneity of the material and the compaction technique adopted in any particular project.
2.5.2.
of tests to be conducted.
2720 Part IV)-1965 At least, one test

Usual rate of testing, 1-2 tests per 8,000 m^
would be necessary only if specifications call for
Gradation (IS:
of soil.
The test
checks using gradation
selecting
be
the
soil.
soil.
or grain-size distribution as a criterion for
However, sand content determinations
carried out invariably, at the rate of 1-2 tests per
2.5.3.
test
m^ of
2720-- Part V)-1970

Usual rate cf testing 1-2
Plasticity index (IS:
each kind of
for
soil.
8000
At
sliould
m^
least,
tests per
one
8000
soil.
2.5.4.
Proctor
test
(IS:
2720 Part V1I>-1965
This test
is
performed to ensure that soil of requisite quality is coming out of

borrow areas as also to provide information on optimum moisture
content and maximum laboratory dry density.
Usual rate of testing, 1-2 tests per
2.5.5.
The
soil
The
m^
of
soil.
Deleterious constituents (IS:
shall
organic matter
tively.
8000
be free of harmful
(permissible
tests will
2720 Part XXVII)-1968
sodium sulphate and

and 1 per cent respec-
salts like
limits) of 0.2
be done as and when required.
Earthwork
17
Natural
2.5.6.
(Second Reyision)
coneent
moistare
One
test for
(IS
every 250
2720 Part
of
soil.
11-1973)
The natural
moisture content of the soil coming out of the borrowpits will have
determined in order to evaluate how far the natural moisture
to be
optimum value and whether further addiwater content would be necessary.
content tallies with the

tion or reduction of
Table
2.5.7.
materials discussed
gives
2.1.
above
along
summary of the tests for borrow

with minimum desirable fre-
quencies.
2.6.
Compaction Control
2.6.1.
Compaction
namely, control of
control mairtly involves two operations,
moisture
content just before compaction and
density of compacted layer.
2.6.2.
Moistare content determinations: Moisture content
determinations for compaction control shall be in addition to those
on borrow material spelt out in Clause 2.5.6. This test is necessary
ensuring proper moisture content at the time of compaction

which significantly influences the density results. Usual rate of
testing should be 2-3 tests per 250 m^ of soil.
for
Except when
otherwise
measurement of density shall be made for
each 1000 m^ of compacted area. Test locations shallbe chosen
only through predetermined random sampling techniques. Control
shall not be based on the result of anyone test but on the mean
value of 5-10 density determinations. The number of tests in one
set of measurements shall be 5 as long as it is felt that sufficient
control over borrow material and the method of compaction was
being exercised. But if there be any doubt about this control, or
2.6.3.
Density
measurements
directed, at the last one
observed between individual density

results, the number of tests in one set of measurement shall forth
with be increased to 10. The acceptance of results shall be subject
to the condition that the mean dry density equals or exceeds the
specified density and the standard deviation for any set of results is
below 0.08 gm per cc.
considerable
variations
are
Earthwork
18
2,6A, In general, the control at top subgrade layers of the

formation shall be more strict than stated above with density measurements being carried out at the rate of 1 test per 500-1000 m^
mean
number of
of compacted area. Further, for the determination of
and standard
deviation
(refer
Chapter
8),
the
density
tests in
of measurements shall not be less than 10. Acceptance of

the work shall be subject to the same conditions as stipulated in
one
set
Clause
2.6.3.
Table 2.2. sets out the

for compaction control.
2.6.5.
of
tests
Table
S.No.
2.1.
minimum
desirable frequency
Control Tests on Borrow Materials
Miniiniim
HeîravOiA
iVllil Jill t4 III Vi
Test
ble frequency
Gradatlon*/Saodcontent
IS:
2.
Plasticity index
IS:
3.
Standard Proctor
IS: 2720 Part
1.
2720 Part IV-1965
1-2 tests per 8000
of
m*
soil
-do-
2720 Part V-1970
-do-
VIM965
Test
4.
GBR
on a set of
specimens**
IS:
2720 Part
XVM965
One
2720 Part
XXVIM968
As
5.
Deleterious constituents
IS:
6.
Natural moisture
content
IS: 2720 Part 11-1973

(Second Revision)
If specifications
call for
such
tests.
For purposes of design only unless otherwise specified.
required
One
of
per 3000 m
test
test
soil
per 250
m*
Earthwork
19
Table
S.
No.
2.2.
Tests for Compaction Control
Minimum
Test method
Test
desirable
frequency
Moisture content
just before
Dry
compaction
density
of compacted layer
IS: 2720 Part II

1973 (Second Revision)
IS: 2720 Part

1966
XXVIII-
2-3 tests per 250

of loose soil.
Generally, one test
per 1000 m* of compacted area for the

body of the embankment to be increased
one
test
per
to
500-1000 m* of compacted area for top
subgrade layers, i.e.
portion
top 500
of the embankment.
mm
Sub-base Courses
3
Sub-base
Courses
21
CHAPTER
SUB-BASE COURSES
3.
General
The following sub-base courses are dealt with
3.1.1.
Chapter
Stone Soling
(i)
Brick Soling
(ii)
(iii)
Water Bound Macadam Sub-base
(iv) Soil-Gravel/
(vii)
(viii)
3.2.
Moorum
Sub-base
Mechanically Stabilized Soil
(v)
(vi)
Lime Stabilized Soil

Cement Modified Soil
Sand-bitumen Mix
StODe Soling
3.2.1.
3.2.1.1.
moded
in this
General
Stone soling, as a rule,
as a sub-base
owing to
its
is
gradually
inferior
becoming
out-
load spreading proper-
poor or slushy subgrades.

and works
should be exercised as described hereunder.
ties as
well as the liability to
However, where
3.2.2.
3.2.2.1.
it is still
sink
Materials
Before incorporation
stone soling shall be checked for

at the
quarry or
3.2.2.2.
into
used, control on the materials
in
the
work, the materials for

requirements either'
specification
at the site.
The stones
shall
be
granite,
limestone,
sandstone,
from laminations, foreign matter,

and be in a clean condition.
fragments
unsound and weathered
etc., as specified, reasonably free
The filler material shall be sand or any

3.2.2.3.
granular material having a plasticity index of not more than
other
6.
Sub-base Courses
24
Processing and construction
3.2.3.
Preparation of subgrade
3.2.3.1.
checked for
line,
All irregularities
The subgrade
shall
be
grade and cross-section as spelt out in Chapter 7.

beyond the permitted tolerances shall be rectified.
Soft and yielding places and
ruts
shall
be
and rolled
corrected
until firm.
Soling work
3.2.3.2.
The following points
shall be kept in
view during execution:

(i)
The stones
shall be laid
and seated properly by hand as
All voids should be filled,
(ii)
filler
by wedging
first
material accompained by
in
spalls
specified.
and then with
sprinkling of water, brooming and
rolling.
Rolling
(iii)
shall
commence
at
the
edges,
progressing
gradually
towards the centre parallel to the centre line *of the road except at
superelevated portions where it shall proceed from the inner edge
to the outer.
The
(iv)
3.2.4.
3.2.4.1.
as their
Table
be checked
finished surface shall
as indicated in Chapter
line,
level
and
regularity
Control tests and their frequency
on materials and work as well

frequency shall be as shown in
Quality control tests
minimum
desirable
3.1.
Table
S.
for
7.
No.
Test
3.1.
Test method
Minimum
desirable
frequency
1.
2.
Aggregate Impact Value/

Los Angeles Abrasion
Value
(Pari IV)
Plasticity index
IS:
of
filler
material
3.
IS: 2386
2720
(Part
test
per 200 m'
One
test
per 25
V) 1963
Control of grade, camber,
Vide
thickness and surface
Chapter 7
finish
One
1963
Regularly
m*
25
Sub'base Courses
Rectification of sorface irregularities
3.2.5.
the tolerances specified
manner
following
When
beyond
Irregularities present in the finished surface
3.2.5.1
Chapter
in
shall
be
rectified
in
the
the finished surface
is
too high or too
low,
the
soling
be dismantled to the full depth and reconstructed as specified.

no case shall the filling of depressions with filler material be
shall
In
permitted.
Brick-Soling
3.3.
General
3.3.1.
may
Bricks for soling works
3.3.1.1.
layers either
flat
be laid in one or
more
or on edge.
Materials
3.3.2.
The quality of bricks
3.3.2.1.
shall
be checked for specfica-
tion requirements before their incorporation in the works.

to be used shall be of full size
and brickbats
shall not
Bricks
be used.
The filler shall be sand or any other material having

index of not more than 6.
3.3.2.2.
a plasticity
3.3.3.
Processing and constmction
3.3.3.1.
Preparation of subgrade:
Clause
3.2.3.1. shall apply.
3.3.3.2.
Soling work
mind while executing the work
:
shall be kept in
(i)
(ii)
The
bricks shall be
hand
laid with
each brick touching the other.
Pattern for laying of bricks, such as herringbone, shall be as speci-
When more than one layer is to be constructed,

should be so laid as to break joints in successive layers.
fied.
(iii)
the bricks
The material used for filling the interstices shall be sand or any other
mineral matter with plasticity index not exceeding 6*.
3.3.4.
3.3.4.1.
Quality control tests on the materials and the work
and their minimum desirable frequency shall be as indicated in
Table 3.2.
26
Sub-base Courses
Tablf. 3.2.
No.
S.
Test
Minimum
method
Test
desirable
frequency
1.
Crushing strength of
IS:
bricks
5 bricks to be tested
3495
(Part
to
IV)- 1973
First Revision
2.
Water absorption of
IS:
bricks
(Parts
to
50,<'Uw'
bricks
3495
i
every
for
-do
One
lest
V) 1973
First Revision
3.
Plasticity
index of
IS:
2720
per 25 m'
(Part V)--1970
material
filler
First Revision
Water Bound Macadam Snb-base
3.4.
bound macadam
shajll be constructed with oversized aggregates of 40-90 mm size. The
materials used and the work shall conform to the requirements of
IRC: 19-1977 and their quality shall be controlled on the same
lines as outlined in Chapter 4 for water bound macadam base
General
3.4.1.
For use
as sub-base water
course.
Soil-Gravel/Moorum* Sub-base
3.5.
3.5.1.
moorum,
General
This type of sub-base
soil-gravel mixtures
is
constructed
using
and similar naturally occurring low-
grade materials.
3.5.2.
Materials
the specifications as laid
3.5.3.
3.5.3.1.
The materials
down.
shall be in
accordance with
Preparation of sabgrade
Moorum is the name
Clause
usually given to
formed by disintegration of rock.
naturally occurring materials
27
Sub-base Courses
Construction of sub-base
3.5.3.2.
shall be kept in
(i)
(ii)
mind during execution of
Before compaction, moisture

brought to the desired level.
Rolling shall
commence
The following
work
the
content
points
the material shall be
of
edges, proceeding gradually towards
at the
the centre parallel to the centre line of the road, except at superele-
vated portions where

outer.
Rolling
proceed from the inner edge to the
shall
it
be
shall
continued
till
the specified
density
achieved.
(iii)
The
from movement
surface after rolling shall be well closed, free
under compaction plant, any compaction planes, ridges, cracks or

loose material.
(iv)
After rolling, the sub-base layer shall be checked for density, the
shall be the same as
Clause 2.6.4. This presupposes that Proctor density is
known through prior testing.
control
and permissible tolerances for which
set out in
(v)
Unless otherwise speci6ed, no trafiSc of any description shall ply

sub base.
directly over the finished
Control tests and their frequency :

Quality control
on materials and work with their minimum desirable
frequency are indicated in Table 3.3.
3.5.4.
tests
Table
S.
No.
3.3.
Minimum
Test
Test
method
1.
Gradation
IS
2720
(Part
Plasticity
IS : 2720
(Part V) 1970
3.
Natural moisture content
IS : 2720
(Part 1 1) -1973
(First Revision)
4.
IS:
5.
Moisture contents prior to

compaction
2720
IS
One
test
per 200 m'
IV) 1965
2.
(Part
desirable
frequency
-do-
One
As
test
per 250 m'
required
XXVII)
2720
One
test
per 250 m'
(Part II)-1973
(Second Revision)
6.
Density of compacted layer
IS 2720
One test per 500
(Part XXVIII) 1966
7.
Control of grade, camber
Vide
Chapter 7
thickness
and surface
m-
Regularly
finish
8.
CB II
test* (on a set of

3 specimens)
IS
* This test, unless specified otherwise in
of design only.
2720
(Part
As
required
XVI)-1965
the Specifications,
is
for the purpose
28
Sub-base Courses
RectilScation of surface irregularities
3.5.5.
Where
3.5.5.1.
layer
fall
irregularities of the finished sub-base
surface
outside the specified
tolerances given
Chapter
in
7, the
same shall be rectified.

If the surface is too high, it shall be
trimmed and suitably compacted. If it is too low, the deficiency
The degree of comshall be corrected by adding fresh material.
paction and the type of material to be used shall conform to the
specification requirements.
Mechanically Stabilized Soil
3.6.
3.6.1.
General
Mechanical stabilization is mainly of three different

namely, stabilization of sandy soils with admixture of clay,
stabilization of clayey soils with admixture of sand and stabilization
3.6.1.1.
types,
with soft aggregates.
3.6.2.
Materials
The blending/grafting
3.6.2.1.
stabilization shall be
3.6.3.
materials used for mechanical

checked for specification requirements.
3.6.3.1.
3.6.3.2.
Mixing and laying of
Clause
stabilized soil
The following
Doints shall be kept in

(i)
out preferably by mechanical means.

be ensured that the plant used and methods
Stabilization shall be carried
In all cases,
it
shall
adopted are capable of pulverising the soil to specified degree to

full thickness of the layer being processed and of achieving the
desired degree of mixing and uniformity of the stabilized material.
(ii)
manual mixing, it shall be ensured that there has

been uniform mixing of various ingredients to the full depth of
In the event of
layer processed.
(iii)
Degree of pulverisation
(iv)
Grading and
shall
plasticity
be checked.
shall be as specified.
index of mixed material, where specified,
29
Sub-base Courses
(v)
Before compaction, moisture content of the mixed material shall
brought to the desired level, which

optimum moisture content.
(vi) In the
general
in
case of stabilization with aggregates,
it
the
is
same
be ensured
shall
be
as the
that
the aggregates are evenly dispersed in the stabilized layer.

(vii)
commence
Rolling shall
the
centre
parallel
proceeding gradually towards

line of the road, except at
shall proceed from the inner edge
at the edges,
the centre
to
superelevated portions where
it
Roiling shall be continued
to the outer.
till
the specified
density
is
reached.
(viii)
surface after rolling shall be well closed, free from movement

under compaction plant, any compaction planes, ridges, cracks or
The
loose material.
(ix)
After rolling, the sub base layer shall be checked
(x)
(xi)
The surface
The
in
(xii)
compaction,
This presupposes that Proctor
as set out in Clause 2.6.4.
known through
for
of which shall be the same
and permissible tolerances
the control
density
is
prior testing.
shall be cured as s^*Cified.
finished surface shall be checked for
accordance with Chapter
level
line,
and
regularity
7.
Unless otherwise specified, no traffic of any description shall ply

directly over the stabilized layer.
3.6.4.
on materials and work with

in Table
Specific tests and their frequencies on soft aggregates where
3.4.
required to be used are also included in Table 3.4. Where for
any test, the procedure of testing is not indicated, the same shall
be performed as per accepted engineering practice.
3.6.4.1.
their
minimum
3.6.5.
desirable frequency shall be as indicated
Rectification of surface irregularities
3.6.5.1.
Where
falls outside the
be
rectified.
suitably
surface irregularity
If the surface
compacted.
If
it is
is
too high,
of material to
requirements.
stabilized
be
it
shall
layer
same shall
trimmed
be
and
7, the
too low, the deficiency shall be correc-
ted by adding fresh material.
type
of the
tolerances mentioned in Chapter
used
The degree of compaction and the

shall conform to the specification
30
Sub-base Courses
Table
S.
No.
3.4.
Minimum
Test
Test
method
Aggregate impact value*
IS
2386
(Part
2.
3.
Water absorption* of
aggregates
IS
One
test
per 200 m*
One
test
per 200
IV) 1963
2386
m*
(Part III) 1963
iîasiiciiy
desirable
frequency
Regularly
iDQcA oi miAeu
IS
material
2720
ly/v
^^rari
One test per
1000 m
(First Revision)
<
6.
OdllU WUUlCUl
material
VII
IS
LUlAvU
Moisture content prior to
compaction
7.
Dry
8.
density of
layer
2720
(rart IV)
compacted
IS
ao
lyOD
IS 2720
(rart 11) ly/i
(Second Revision)
2720
One
test
One
test per
per 250
m*
500 m*
1966
9.
thickness
and surface
CBR
on material**
test
mixed
at site (a set
Vide Chapter 7
Regularly
finish
of 3
IS
2720
(Part
One
test
per 3000 m*
XVI)-1965
specimens)
10.
IS
2720
As required
XXVII)
1968
(Part
Where
This
3.7.
applicable.
test is for the
Lime
purpose of design only unless otherwise specified.
Stabilized
Soil/Moorum
3.7.1.
General: Besides lime stabilized soil, this sub-section
covers constructions involving stabilization with lime of materials
like
moorum.
3.7.2.
Materials
Lime, at delivered at site, shall be
checked for purity and available calcium oxide content as specified.
:
TFe quantity of lime for incorporation in the soil related to its

calcium oxide content, shall be expressed as per cent by weight
of the dry soil. The lime content shall be predetermined on the
basis of laboratory tests.
Sub-base Courses
31
Processing and constrnction
3.7.3,
3.7.3.1.
Clause
3.7.3.2.
Stabilization :
shall be kept in
(i)
Stabilization shall
If single
be carried out preferably by mechanical means.
pass stabilisers are not available, rotavators or agricultural
machinery like ploughs and disc harrows shall be made use of. In
every case, it shall be ensured that the plant used and methods
adopted are capable of pulverising the soil to specified degree over
the full thickness of layer being processed and of achieving the
mixing and uniformity of the stabilized material to desired degree.
(ii)
In the case of
manual mixing,
shall be ensured that there has
it
a uniform mixing of lime and

processed.
(iii)
(iv)
Mixing
(v)
soil
shall be as specified.
be uniform and no streaks of free lime shall be
shall
been
to the full depth of the layer
visible.
After mixing, the lime content of the mix shall be determined.
The
lime content values shall conform to the following (also see foot note
under Table
(a)
3.5)
Moving average of
10 tests not
lo
be
less
than the specified
lime content.
(b)
No
test
value to
L*e
less
than 75 per cent of the specified lime
content.
(vi)
(vii)
Before compaction, moisture content of the mixed material shall be

brought to the desired level, which, in general, is the optimum
moisture content.
(viil)
be ensured that the time interval between mixing of lime with

and compaction does not exceed three hours.
It shall
soil
Rolling shall
commence
at the edges progressing gradually
towards
the centre parallel to the centre line of the road, except at superele-
vated portions where

Rolling
outer.
shall
it
shall proceed from the inner edge to the

be continued till the specified density Is
achieved.
(Ix)
Care
be taken to ensure that during rolling the compaction

does not bear directly on hardened or partially hardened
treated material previously laid except as may be necessary for
achieving the desired compaction at the joints.
plant
shall
32
Sub-base Courses
(x)
The surface after rolling shall be well closed, free from movement
under compaction plant, and any compaction planes, ridges, cracks
or loose material.
(xi)
After rolling, the sub-base layer shall be checked for compaction the
control and the permitted tolerances of which shall be the
out in Clause 2.6.4.
same as set
is known
This presupposes that Proctor density
through prior testing.

(xii)
The
finished
line, level
(xiii)
and
surface shall be checked immediately
after laying for
regularity in accordance with Chapter 7.
The surface on completion shall be cured for 7 days soon after which
subsequent pavement courses shall be laid to prevent the surface
from drying out and becoming
friable.
No
traffic
of any description
shall ply directly over the stabilized layer.
3.7.4.
Quality control
3.7.4.1.
minimum
Where for any
their
same
shall
tests
on materials and work with
frequency are indicated in Table
desirable
3.5.
procedure of testing is not indicated, the

be performed in accordance with accepted engineering
test
the
practice.
3.7.5.
3.7.5.1.
falls
outside
Where
the
the surface irregularity of the stabilized layer
specified tolerances given in
Chapter
7,
the
same
shall be rectified.
3.7.5.2.
suitably
Where
surface
the
is
trimmed while taking care
too high, the same shall be

is not
that the material below
disturbed by this operation.
3.7.5.3.
However,
where the surface
shall be corrected as described hereafter.
is
too low, the same
When
the time elapsed
between detection of irregularity and the time of mixing of the

material is less than 3 hours, the surface shpll be scarified to a
depth of 50 mm, supplemented with freshly mixed material as
necessary and recompacted to the requirements. Where the elapsed
lime is more than 3 hours, the full depth of the layer shall be re-
moved from
specified.
the
pavement and replaced with fresh material as
33
Sub-base Courses
Tablr
Mo
csl
csi
3.5.
rncmua
iviiniiiiuii] ucsiritDic
frequency
Purity of lime and available calcium oxide
1.
IS: 1514-1959
One
test
consignment
to
for each
subject
minimum of one
test
per 5 tonnes of
lime
Lime content immedia-
7.
tely after
3.
4.
Dry density of
ted layer
compac-
2720
(Part II)-1973
(Second Revision)
IS:
One
test
per 250 m^
IS:
ber, thickness
2720
One
test
per 250
One
test
per 500 m"
m'
(Part XXVIII)-1966
Control of grade, cam-
6.
1514@-1959
Regularly
compaction
5.
IS:
mixing
Vide
Chapter 7
Regularly
IS: 2720
One
and surface
finish
CBR
7.
mixed
test
on materials*
at site (a set
of 3
test
per 3000
m^
(Part XVI)-1965
specimens)
Deleterious
of soil
8.
constituents
IS:
As required
2720
(Part
XXVI)-1973
(First Revision)
@This
it
method is inconvenient for wide application in the field. As such,

be desirable to exercise close control over material quantities and their
test
will
processing.
Unless otherwise
3.8.
specified, this test
Cement Modified
is
only for the purpose of design.
Soil
General
3.8.1.
3.8.1.1.
Cement modified
cement content for use
soil is
envisaged to be with
as sub- base, as distinct
lower
from soil-cement
intended to be used for base courses.

Materials
3.8.2.
3.8.2.1.
sulphate
shall
Soil
proposed for cement stabilisation
content of
more than
0.2 per cent.
shall not
have
The cement used
be checked for compliance with the requirements of IS: 2691489-1967 (First Revision)
(1967), 455-1967 (Second Revision) or
applicable.
The quantity of cement for incorporation shall
be expressed as a percentage by weight of dry soil. This shall be
predetermined on the basis of laboratory tests.
as
34
Sub-base Courses
3.8.3.
Clause
3.8.3.1.
3.8.3.2.
Preparing and laying of cement modified
soil
sub-base
The operations involved in processing and construction of cementmodified soil are the same as those for lime stabilized soil except
that the stabilizing material will be cement instead of lime.
As
such,
Clause
3.7.3.2.
apply
shall
but for the
between mixing of cement with

be 2 hours in this case.
interval
shall
3.8.4.
soil
maximum
time
and compaction which
control
Quality
on the materials and the work and their minimum desirable

frequency shall be as indicated in Table 3.6. Where for any test
the procedure of testing is not indicated, the same shall be carried
tests
out as per the prevalent engineering practice.

Table
No.
S.
3.6.
Test method
Test
Minimum
desirable
frequency
1.
IS
2720
(Part
2.
Quality of cement
3.
Cement content immediately after
4.
5.
IS
269/455/1489
As required
XXVII)-1968
-doOne
test
per 250 m*
mixing
Regularly
compaction
IS 2720
(Part II)-1973
Dry density
IS
m^
One
test
per 250
One
test
per 500 m-
(Second Revision)
6.
2720
(Part XXVIII)-1966
Control of grade, camber
thickness
and
surface
Vide
Chapter 7
Regularly
finish
8.
CBR
mixed
test
at
on materials*
site
(a set of 3
IS
2720
One
test
per 3000
(Part XVI)-1965
specimens)
@Under
finalisation with ISI.

This test method is inconvenient for wide appliAs such, it will be desirable to exercise close control over
cation in the field.
material quantities and their processing.
This
test
unless otherwise specified
is
for the purpose of design only.
35
Sub-base Courses
of surface Irregularities
Rectification
3.8.5.
apply except that the

Clause 3.7.5.3. shall be 2 hours
time
shall
Sand-bitumen
3.9.
Clause
spelled
criterion
3.7.5.
out
in
in this case.
Mix
J.9.1.
General : Sand-bitumen can* be used both as subbase and base, the composition being designed accordingly.
Materials
3.9.2.
3.9.2.1.
finer than
Sand
shall
75-micron sieve
The per cent fraction

be non-plastic.
shall be within the range of 5 and 10.
Binder shall be as specified. The per cent binder

the sand-bitumen mix shall be predetermined in the
3.9.2.2.
content in
laboratory.
3.9.3.
shall
3.9.3.1.
Preparation of subgrades
3.9.3.2.
Sand-bitumen
mix
Clause 3.2.3.1. shall apply.
laying
be attenaed to while executing the work

(i)
(ii)
Mix proportions of
Where sand
is
constituent materials shall be as specified.
found to be wet,
it
be dried before mixing with
shall
binder.
(ill)
The means adopted
for mixing shall be as specified and it shall be

ensured that sand pai tides are uniformly and properly coated with
binder.
(iv)
(v)
(vi)
The sand-bitumen mix shall be laid at

back aerated for about 24 hours.
proper camber and rolled.
For
Ibis
The
thickness of individual layer
site
It
and
shall
if
the binder
is
a cut-
then be regarded to
type of construction, edge confinement shall be provided.
of sand-bitumen mix shall be as
specified.
(vii)
Provisions
Clause
(viii)
rolling
After rolling, the compacted

laid
(ix)
regarding
The
in
be the same as described
shall
in
3.7.3.2. (viii-x).
layer
shall
be checked for density as
down.

accordance with Chapter 7.
line,
level
and icgularity
'
Sub-base (Jourses
36
Control tests and
3.9.4.
frequency
their
on the materials and the work and

frequency shall be as indicated in Table
tests
Table
S.
No.
Test
Plasticity index
2.
IS
IS
Quality
minimum
control
desirable
3.7.
3.7.
Test method
Minimum
IS 2720
(Part IV) 1965
As required
Sand fraction finer than

75 micron sieve
1.
their
desirable
frpniipnrv
of sand
IS
731961
2171961
As required
2720
(Part
V) 1970
(First Revision)
-do-
3.
Quality of binder
IS
4.
Binder content of mix
Method, vide
Appendix-4
73/217
One
per 50
test
m'
to a min. of
subject
2 tests per day
sand bitumen
mix by Hubbard-Field
^Stability of
5.
ASTM-D-1138
One
test
IS 2720
(Part XXVIII)
One
test for
50
for
m^
method
6.
Density of compacted mix
7.
500 m"
1966
Vide
Chapter 7
'
thickness and surface
Regularly
finish
*To be performed only when
stability
has been specified as an acceptance
criterion.
3.9.5.
Rectification
of
surface
irregularities
surface irregularity of the sand-bitumen

the specified tolerances as given in
The
rectification shall
be
done while the
7,
Where
sub-base
layer
Chapter
it
mix
is
the
outside
shall be rectified.
is
still
workable.
be suitably trimmed
Where the
while taking care not to disturb the material below.
surface is too low, the depressed areas shall be filled up with
Where
the surface
is
too high, the
same
shall
sand-bitumen mix and rolled according to
specification*.
Base
Cc;
rses
4
Base Courses
37
CHAPTER
BASE COURSES
4.
General
The following base courses
4.1.1.
Chapter
dealt
with
in
this
Water bound macadam:
(a)
(i)
(ii)
(b)
Surfaced
Unsurfaced
BitumiDous penetration
(c) Built-up-spray
(d)
macadam
grout
Bituminous macadam
(e)
Soil-cement base
(f)
Lean concrete
(g)
Lime puzzolana concrete
(h) Sand-
bitumen base
Water Bound Macadam
4.2.
Water bound macadam may be used as a

:
under a surfacing or as a wearing course without any
General
4.2.1.
base
are
course
In either case, the construction
surfacing.
shall
generally
be
in
accordance with IRC: 19-1972.

4.2.2.
v/z.,
Materials
All materials used in
coarse aggregates, screenings and
checked
in
advance of
their incorporation in the
fication requirements, either at the
4.2.3.
4.2.3.1.
WBM
construction,
binding material
quarry or
shall
be
works for speci-
at site.
Preparation of subgrade/sub-base
This
shall
be
checked for line, grade and section in accordance with Chapter 7.

ûts or soft yielding places shall be corrected suitably and rolled
Arrangement of lateral confinement of aggregate shall
until firm.
40
Base Courses
be checked before starting to spread of materials. If necessary, iht
surface
shall
be
scarified
and reshaped
to the required
grade and
camber.
4.2.3.2.
The following
while executing the work

(i)
(ii)
(iii)
points shall be
attended to
carefully
Quantity and uniformity of spread of materials shall be

template (see Chapter 7).
checked by
Segregation of coarse and fine aggregates shall be avoided.

Rolling operations shall begin from edges, proceeding gradually to
the centre while lapping each preceding
rear
wheel track by one
The weight and type of the roller shall be relevant to

At horizontal curves, rolling shall
the type of coarse aggregate.
proceed from the inner edge to the outer. No rolling shall be
carried out when it causes a wave-like motion due to softness of the
half width.
Irregularities that develop during rolling shall

be rectified either by adding or removing aggregate. In no case
shall screenings be added to make up depressions.
Rolling shall be
discontinued when the aggregates are partially compacted with void
subgrade/sub-base.
However, where
space suflScient to permit application of screenings.

screenings are not to be used, compaction shall
be continued
until
the aggregates are thoroughly keyed.

(iv) Screenings shall
be applied in three or more applicaions
the interstices while dry rolling
is
screenings shall be so operated
as
continued.
not
to
Vehicles
disturb
to
fill
carrying
the
coarse
aggregates.
should be ensured
(v) It
damaged due
that
to addition
sub-base/subgrade does
the
not
get
of excessive quantities of water during
construction.
(vi)
be added after the application

be introduced at a uniform rate in two or
more applications accompanied by copious sprinkling of water so
as to form a slurry which could be swept with brooms to fill the
remaining voids. Rolling shall be continued till full compaction is
Binding material,
of screenings.
if
It
required, shall
shall
achieved.
(vii)
No
traflBc shall
treated water
after the
(viii)
The
in
be allowed
till
the
macadam
sets.
bound macadam ^ the surfacing
macadam
base
is
In case of surface
shall
be laid only
completely dried.

line,
level
and
regularity
Base Courses
4.2.4.
on the
4:
materials
and
work and
tiie
frequency shall be as indicated
Table
in
Table
S.
No.
their
minimum
desirable
4.1.
4.1.
Test method
Test
Minimum
desirable
frequency
1.
3.
Los Angeles Abrasion Value/

Aggregate Impact Value
IS:
Grading of aggregate and
IS:
screenings
(Part
Flakiness index of aggregate
IS:
Plasticity of binding material
Rectification
of
V)-1970
Vide
Chapter
surface
test
test
per 200 m
One
IS: 2720
Control of grade, camber, thickness

and surface finish
4.2.5.
I) 1983
per 100 m'
One
2386
(Part
5.
I) 1963
test
per 200
One
2386
(Part
4.
One
2386
(Part IV)--1963
test
per 25 m'
Regularly
7
irregularities:
Where
the
water-bound macadam base are outside

the tolerances mentioned in Chapter 7, the same shall be rectified
by lemoving to full depth the aflected area, which should not be
In no case
less than 10 m-, and relaying with fresh materials.
shall depressions be filled up with screenings or binding material.
surface irregularities of
Bituminous reuerration
4.3.
4.3.1.
macadam
General:
base shall
in
Macadam
Cv)nstruction
general
be
Control over the quality

shall be exercised as set forth hereunder.
IRC: 20-1966.
bituminous
of
penetration
carried out in accordance with
of materials and
work
42
Base Courses
4.3.2.
Materials
Coarse
4.3.2.1.
checked for
IRC: 20-1966.
aggregates
conformity
Bituminous binder
4.3.2.2.
uith
The
the
quality before and during construction as
4.3.3.
be
in
The type and grade of bituminous
The binder
binder shall be as specified.
should
aggregates
requirements stipulated
shall
checked for
be
may be
its
required.
4.3.3.1.
Preparation
of subgrade/sub-base
Clause
4.2.3.1.
shall apply.
4.3.3.2.
course
Construction of bituminous penetration
shall
macadam
be given proper
base
attention
during construction:
(i)
The coarse aggregates

template (see Chapter
(ii)
shall
be spread uniformly and checked by
7).
Provision for rolling and checking of finished surface shall be the
same as in Clause 4.2.3.2. Provided however that rolling shall stop

before the voids are closed to such an extent as to prevent free and
uniform penetration of binder and key aggregates.
(iii)
(iv)
Bituminous penetration macadam work shall not be carried out

when the atmospheric temperature in shade is less than 16C or
when the underlying course is damp or wet.
The
specified
quantity of approved binder shall be sprayed at the
appropriate application temperature,

sprayers.
The ends of
the stretch shall
preferably using mechanical
be covered with thick paper

The rate of spray of
so as to avoid double spraying of binder.
binder shall be frequently checked and regulated to be within 2^ per

Excessive deposits of binder
cent of the specified rate of application.

shall
(v)
Key
be immediately removed.
stones shall
be
uniformly
spread
immediately
application of bituminous binder by mechanical or
The
surface shall be
key stones and
broomed
after
the
manual means.
to obtain a uniform distribution of
rolled.
4.3.4.
Quality control
Control tests and their frequencies
on the materials and the work and their minimum desirable
frequencies shall be as indicated in Table 4.2.
:
tests
43
Base Courses
Table
s.
No.
4.2.
Minimum
Test method
Test
desirable
frequency
1.
Los Angeles Abrasion Value
IS:
One
2386
test
per 200 m
(Part IV\
2.
AcorPDntp ornHiition-
IS:
2386
(Part
3.
VÛw IWol ^CI
IS: 2386
Fiakiness index
(Part
IV/V/ 111
I) 1963
One
test
per 200
One
test
per 200 m'
m'
I) 1963
6241-1971
4.
Stripping value
IS:
5.
Quality of binder
IS: lli2\5ll\llA54,
As reouired
6.
Rale of spread of binder
Method
Regularly
vide
Annendix 4
7.
do-
Rate of spread of key
Regularly
aggregates
8.
Temperature of binder
Regularly
at
application
9.
Vide Chapter 7
Regularly
thickness and surface finish
4.3.5.
4.4.
4.4.1.
Construction of built-up spray grout shall

IRC 47-1972. The quality
General:
of materials and
work
shall
be
Bituminous
General
same lines
macadam.
cuntrolled on the
outlined in Clause 4.3. for bituminous penetration
4.5.1.
4.2.5.
Built-up Spray Grout
generally be done in accordance with
4.5.
Vide Clause
as
Macadam
Construction
of
bituminous
macadam
premix base shall generally be done in accordance with IRC

27-1967.
For ensuring tiie requisite quality of materials and work,
points to be kept in view and the control tests to be
important
the
:
carried out are set forth below.
44
Base Courses
4.5.2.
Materials
The aggregates
Coarse aggregates
requirements spelt out in IRC:27-1967.
4.5.2.1.
for the
Bituminous binder
4.5.2.2.
4.5.3.
checked
Clause 4.3.2.2. shall apply.
4.5.3.1.
shall apply.
first
shall be
Clause
In addition, the surface shall be thoroughly
4.2.3.1.
cleaned,
with wire brushes and finally by dusting with sacks.

4.5.3.2.
Construction of bituminous
macadam
Proper atten-
tion shall be paid to the following points during construction

(i)
(ii)
The bituminous macadam construction shall not normally be

out when the atmospheric temperature (in shade) is less than
when the underlying course in damp or wet.
All mechanical equipment,
shall
(iii)
(iv)
like hot-mix plant, paver

be checked tor their work worthiness.
carried
16''C or
roller,
etc.,
Where specified, a tack coat of bituminous binder shall be applied

on the base/sub-base and control shall be exercised on the rate
uniformity and temperature of its application.
Mix proportions of
the constituent materials shall be as specified.

Binder content with mix shall be checked periodically and controlled
so that there is no variation beyond 0.3 per cent by weight of the
total mix.
(v)
Unless otherwise specified, mixing of aggregates and binder shall be

carried out in hot-mix plant.
(vi)
(vii)
Binder and aggregate temperatures shall be consistent with proper

mixing and laying of the mix and be within the specified limits.
Mix
shall be
spread uniformly preferably
the correct thickness, grade

at the time
(viii)
and camber.
using a paver-finisher to
Temperature of the
mix
of laying and rolling shall be within the specified limits.
proceed on to fresh material with the drive wheel

commence from the edges and progress
towards the centre except on superelevated curves where the rolling
shall commence from the lower edge and progress towards the upper
edge. The rolling shall be continued, with ofif-set of half rear wheel
width, till the layer has been fully compacted. The wheels of the
roller shall be kept moist to prevent the mix from adhering to them
and being picked up but in no case shall fuel/lubricating oil be used
The
roller shall
leading.
Rolling shall
for this purpose.
45
Base Courses
(ix)
Longitudinal
joints
and edges
shall
be constructed true to the
delineating lines parallel to the centre line of the road.

shall
be cut vertical to the
and
the
full
All joints
thickness of the previously laid mix
surface painted with hot bitumen before placing fresh
material.
(x)
Traffic shall
cooled
(xi)
The
down
not be normally allowed on the course
till
the mix has
to the surrounding temperature.
finished surface shall be
checked for
line, level
and
regularity in
7.
4.5.4.
Control tests and their frequencies : Quality control
on the materials and the work and their frequencies shall be
as indicated in Table 4.3.
tests
Table
S.
No.
Test
4.3.
Minimum
Test
method
1.
Quality of binder
IS:
73-1961
desirable
frequency
As required
(Revison)
2.
Los Angeles Abrasion Value/

Aggregate Impact Value
3.
Flakiness index of
aggregate
IS: 2386
(Part rV)-1964
IS:
One test for 50-100

m^ of aggregate
-do-
2386
(Part
I) 1963
4.
Stripping value of
aggregate
IS:
62411971
5.
Mix grading
IS:
2386
(Part
I) 1963
doTwo
tests
on both the
ents
and
per day
consitu-
mixed
aggregate from the

dryer
6.
Control of temperature of
binder and aggregate and
of the mix at the time of
Regularly
laying
7.
Control of binder content

and aggregate gradation
in the
mix
Method
vide
App. 4
Periodic, subject to
minimum
tests
per
plant
8.

thickness
and surface
finish
Vide Chapter 7
Regularly
of two
day per
46
Base Courses
Rectification
4.5.5.
surface
of
surface
irregalarities
macadam
of the bituminous premix
irregularities
course arc outside the tolerances given in Chapter
per procedure given in Clause
rectified as
4.6.
Where
7,
the
base
these shall be
4.2.5.
Soil-Cement Base
4.6.1.
construction
General: As distinct from cement modified soil, this

envisaged to be of base course quality with mix desi-
is
gned as per strength and durability considerations.
4.6.2.
Materials
Clause
shall apply except that the
3.8.2.
materials shall be proportioned to achieve the specified compressive

strength.
4.6.3.

4.6.3.1.
Clause
3.2.3.1.
shall apply.
Preparing
4.6.3.2.
and
base
laying soil-cement
Clause
4.6.4.
on
materials and
shall
work and
be as indicated
dure of testing
is
in
Table
their
4.4.
not indicated, the
minimum

desirable frequency
Where for any test, the procesame shall be carried out as per
prevalent engineering practice.
The strength of
the material
by carrying out cube strength
mixed
at site shall be controlled
shall be ensured that in a

average strength shall be equal to or
more than the specified strength and that not more than one test
shall give a value less than the specified value by more than 10
set
of ten test
results,
tests.
It
the
per cent.
4.6.5.
shall apply.
Rectification
of surface irregularities
Clause
3.8.5.
47
Base Courses
Table
S.
No.
4.4.
Minimum
Test
Test
As rcqu
IS : 2720-1968
(Part XXVII)
Deleterious constituents of
1.
soil
- do
2.
Quality of cement
3.
Cement content
4.
5.

compaction
IS
6.
Dry
IS 2720
(Part XXVIII)-1968
7.
Cube
8.
ials
IS 269/455/
1489
:
One
strength
mixed
per 250 m=
-do-
2720
(Part II)-1973
and surface
test
red
do
density
thickness
desirable
frequency
method
One
test
per 500 m-
Vide Chapter 7
Regularly
IS: 516-1959
One
finish
of mater-
at site (a set
of
of
test for
50 m
mX
2 specimens)
Under
finalisation with IS!.

This this method is inconvenient for wide
application in the field. As such, it will be desirable to exercise close
control over material quantities and their processing.
4.7.
Lean Concrete
4.7.1.
4.7.1.1.
General
This type of construction
is
suitable as
base both
for flexible and rigid pavements.
4.7.2.
Materials
All
materials,
viz.
cen^cnt, sasid, Ci>arsc
aggregates and water used in x:onstruction shall satisfy the relevant
The mix proportions for lean concrete

predetermined in the laboratory so as to obtain the specicompressive strength at 28 days.
specification requirements.
shall be
fied
4.7.3.
4.7.3.1.
Processing and construcfion

Preparation
of
sub-grade/sub-base/base
In addition,
where the lean concrete
CIduse
is
to
be
48
Base Courses
laid over
an absorbent subgrade/sub-base/base, the
kept moist so as to prevent absorption of water from
shall
latter
be
concrete
the
mortar.
Mixing and laying of lean cement concrete
4.7.3.2.
tion should
work
be paid
to the
Atten-
following points while carrying out the
(i)
Unless otherwise permitted, the mix shall be prepared in a powerdriven batch mixer of approved type.
(ii)
Proportioning of constitueDt materials including water shall strictly

be as specified. Due allowance shall be made for the free moisture
content of aggregates.
(iii)
Concrete immediately after mixing shall be transported for placement

in such a manner that segregation or loss of constituent materials
is
(iv)
avoided.
Concrete shall be spread uniformly and the surface struck off with
surcharge over the desired finished level. The amount of surcharge
determined in the field by actual trial. The surcharge shall
be uniform over the entire area and the concrete as spread shall be
shall be
to the
(v)
(yi)
same camber and slope
No joints
as desired in the finished surface.
other than construction joints shall be provided.
Concrete shall be compacted with a suitable roller within the period

which will not exceed 2 hours since mixing of the material.
specified
(vii)
During compaction, the grade and camber of the surface shall

be checked and all irregularities corrected by removing or adding
fresh material.
(viii)
Where
shall
(ix)
lean concrete is to be laid in two layers, the second layer

be placed within one hour of compaction of the lower layer.
A minimum
of 72 hours of curing shall be done before placing the

course. If the next pavement course is not laid
immediately after this period, curing of the lean concrete shall
continue subject to a maximum period of 14 days.
next pavement
of lean c(mcrete shall be controlled by carrying out cube

It shall be ensured that in a set of ten test results,
the average strength shall be equal to or more than the specified
strength and that not more than one test shall give a value less than
the specified value by more than 10 per cent.
(x) Strength
strength tests.
49
Base Courses
4.7.4.
4.7.4.1.
Quality control test on the
and their minimum desirable frequency
Table 4.5.
Table
S.
No.
be as indicated in
4.5.
Minimum
Test method
Test
and the work
materials
shall
desirable
frequency
1.
Quality of cement
18:269-1967/455-1967/
14891967
2.

Value/ Aggregate Impact
IS: 2386 (Part
As required
IV)-1963
One
One
test
per 200
Value
3.
4.
Aggregate Gradation
IS:
2386 (Part
1) 1963
Aggregate moisture
IS:
2386 (Part
III)
IS:
11991959
- 1963
test
per 100
As required
content
5.
Wet
6.
Control of grade,
camber, tiiickness and
analysis of
mix
As required
Vide Chapter 7
Regularly
surface finish
7.
Strength of cubes (2
specimens for each
age of 7 and 28 days)
IS:
One
516-1959
test for
50
m* mix
4.7.5.
The
checked for line, level,

The checking and
grade and surface finish as in Chapter 7.
the
mix is still plastic.
rectification should be effected when
Surface irregularities left in hardened layer will have to be
4.7.5.1.
removed by
finished surface shall be
cutting out suflSciently
patches and relaying to
large
specification.
4.8.
4.8.1.
Lime-Puzzolana Concrete
This type of construction
General:
is
suitable as
base both for flexible and rigid pavements.

4.8.2.
Materials
All
ture, sand, coarse aggregate
materials,
viz.,
and water used
satisfy the relevant specification
requirements.
lime-puzzolana mixconstruction shall
in
The mix propor-
50
Base Courses
tion for the concrete shall be
predetermined
the
in
laboratory
so
as to obtain the specified compressive strength at 28 days.
4.8.3.
4.8.3.1.
Clause
3.2.
.1.
shall apply.
4.8.3.2.
Mixing and laying of lime puzôlana concrete: The
procedure of mixing, transporting, placing, compacting, curing and
strength control shall be the
same
as
that
for
lean concrete vide
Clause 4.7.3.2.
4.8.4.
4.8.4.1.
Quality control tests on the materials and the work
and their minimum desirable frequency shall be as indicated in
Table 4.6.
Table
s.
No.
4.6.
Minimum
Test method
Test
desirable
frequency
1.
IS:
4098-1967
IS:
2386 (Part
Value/Aggregate Impact
Value
1963
Aggregate gradation
IS: 2386'(Part
Quality of lime-
As required
puzzolana mix
2.
3.
IV)-
One
test
I)
One
test
per 200
per 100
1963
4.
Aggregate moisture
content
5.
Control of i^rade,
camber, th ckness and
IS:
2386 (Part III)

1963
As required
Vide Chapter 7
Regularly
surface finish
6.
Strengtli of cubes (2
specimens for each
age of 7 and 28 days)
IS:
4.8.5.
shall apply.
4.9.
Sand-bitumen Base
Clause
3.9. shall
apply.
One
5161959
test for
Clause
50 m
4.7.5.1.
Bituminous
Surface Courses
51
Bituminous
Courses Surface
CHAPTER
BITUMINOUS SURFACE COURSES

The following bituminous surface courses are dealt
5.1.
with in this Chapter
and two coat bituminous surface dressing.
(1) Single
(2)
Surface dressing using pre-coated aggregates.
(3)
Thin bituminous premix carpet.
(4)
Asphaltic concrete surfacing.
Single and Two-coat Bituminous Surface Dressing
5.2.
5.2.1.
in single
laid
down
General: Construction of bituminous surface dressing
or two
in
5.2.2.
IRC
coats
:
shall
generally
follow
the
specifications
17-1965 and 1RC:23-1966 respectively.
Materials
The
namely, aggregates and binder

should be checked for specification requirements stipulated in
IRC:17-1965 or IRC:23-1966 as applicable.
5.2.2.1.
5.2.3.
5.2.3.1.
in the
materials,
Preparation of base
base on which surface dressing
made up and compacted
Any
All
is
depressions
or
potholes
to be laid shall be properly
to the required lines, grade
and
section.
patch on the existing surface shall be corrected. The

surface shall be thoroughly cleaned of any caked earth and other
Where the base is an old
matter before the binder is applied.
fat
bituminous surfacing, the extent and manner of rectification will

Where specified, bituminous prime coat shall
be as indicated.
cured
be applied and
before laying the surface dressing. The edges
to be treated shall be properly defined
The
prepared base shall be checked for line, grade and section in
accordance with Chapter 7 and all irregularities beyond the per-
of the surface
mitted tolerances corrected.
54
Construction of bituminous surface dressing:
5.2.3.2.
While
executing the work, the following points shall be kept in mind
No
surface dressing
a.
atmospheric temperature
(i)
b.
(ii)
base
is
work
be carried out
shall
shade
in
is
less
if
than 16*C, or
damp, or
c.
construction materials are
d.
the weather
is
damp, or
fogey, rainy or dusty.
The work should be so Organised
that
no
traffic
or dust gets on to
the cleaned or bituminous painted base.

(iii)
The specified quantity of approved binder shall be sprayed at the

appropriate application temperature, preferably using mechanical
sprayers. The ends of the stretch shall be covered with thick paper
binder. The rate of spray of
binder shall be frequently checked and regulated to be within 2J per
cent of the specified rate of application. Excessive deposits of binder
so as to avoid double spraying of
shall
(iv)
be immediately removed.
Immediately after application of the binder, cover aggregates of

approved quality shall be spread uniformly at the specified rate. If
necessary, the surface shall be broomed to ensure uniform spreading
of aggregate.
(V)
Cover aggregates
immediately rolled with roller of approved

at the edês progressing gradually
towards the centre paralle! to the centre line of the road except at
superelevated portions where it shall proceed from the inner edge
Rolling operation shall continue till all aggregates
to the outer.
weight.
shall be
Rolling shall
commence
embedded
particles are firmly
in the binder.
Excessive rolling resul-
ting in the crushing of aggregates shall be avoided.

(vi)
The second
coat,
laying of the
(vii)
first
if
specified,
shall
be applied immediately after
coat.
Generally, no
traffic shall
be allowed on the finished surface for
24 hours. If allowed, its speed shall be restricted to 16 km per
hour during this period. If cut-back bitumen has been used, the
finished surface shall be closed to traffic till the binder is adequately
cured.
5.2.4.
tests
shall
Control
tests
and their frequency
on the materials and the work and

be as indicated in Table 5.1.
their
Quality
desirable
control
frequency
55

Table
No.
S.
5.1.
Test
Test
method
Minimum
desirable
frequency
As required
: 73-1961
215-1961. 217-1961
Quality of binder
18
or 454 as applicable
2.

Value/ Aggregate Impact
Value
IS 2386
(Part IV)-1963
3.
Stripping value of
aggregate
IS
4.
Flakiness index of
aggregate
IS 2386
(Part I)-1963
5.
Water absorption of
aggregate
IS : 2386
(Part III) 1963
6.
Grading of aggregate
IS : 2386
(Part I) 1963
7.
62411971
One
test
per 50 m"
-do-
do
doOne
test
per 25
m*
Regularly
at application
8.
Rate of spread of binder
Tray test vide

Appendix 4
One
test
9.
Rate of spread of
Tray test vide

Appendix 4
One
test jper
aggregate
per 500 m*
500 m"
Rectification of surface irregularities : Surface dressing

cannot remove any undulations present in the base or
the surface on which it is applied.
It is therefore essential that
all operations of rectifications to meet the requirements set out in
Chapter 7, be carried out on the receiving surface before the work
of surface dressing is begun.
5.2.5.
by
itself
5.3.
Surface Dressing with Pre-coated Aggregates
Construction of bituminous surface dressing with pre-coated aggregates shall generally be carried out in
48-1972. The construction is similar to
accordance with IRC
conventional surface dressing except that the cover aggregates are
lightly pre-coated with binder.
As such the quality of materials
5.3.1.
General
56
and work
5.2.
shall be controlled
on the same
(i)
Clause
lines as set out in
with additional checks on the following aspects
At (he time of mixing, the binder and cover aggregates

app opriate temperatures.
be at
shall
their
(ii)
(iii)
Coaling of the aggregates with binder shall be unifoim.
The aggregates after coating shall be aerated and cooled properly

before using them in work. During cooling, these shall not be piled
in big heaps and care shall be taken to protect them from dust.
Thin Bituminous Freniix Carpet
"^.4.
General: Thin bituminous premix carpet may be

iiom pen graded or closely graded mixes iis specified.
Where the mix is open graded, the carpet is generally provided v\ ith
The construction for open-graded premix surfacing
a seal coat.
shall be in accordance with IRC: 14-19/0.
5.4
1.
constituted
5.4.2.
Materials
The
materials,
namely, aggregates and
binder should be checked for specificatioji requirements (IRC
14-
1970 or other relevant specification).

5.4.3.
Clause
5.4.3.1.
Preparation of base
5.4.3.2.
Construction of premix carpet
The following
shall be properly attended to during construction of
surfacing
(i)
this
points
type cf
Mix proportion of
constituent materials shall be as specified.
Binder
content in the mix shall be checked periodically and regulated to
be within 2^ per cent of the specified quantity.

(ii)
(iii)
(iv)
Tack coat, where necessary, shall be applied uniformly over the

prepared base at the specified rate.
Mixing
shall preferably
be done in mechanical mixers.
Where
straight-run bitumen is used, the aggregates should be suitheated prior to mixing with binder. The binder heated to
appropriate temperature should be mixed with aggregates until the
ably
latter are
(V)
thoroughly coated.
The mixed
materials shall be spread evenly with rakes or spreaders
to specified thickness
and camber.
57
Biturninous Surface Courses

(vi)
Rolling shall start immediately after the material is spread. The

wheels of the roller shall be kept moist to prevent the premix from
adhering to the wheels and being picked up but in no case shall the
use of fuel lubricating oil be permitted for this purpose.
(vii)
Where
and
a seal coat comprising premix sand or liquid seal
specified,
fine aggregates shall
The
be evenly applied and rolled.
points to
be attended to during application of seal coat shall be the same as

those for Surface Dressing (Clause 5.2.) and Thin Premix Carpet
(Clause 5.4.) \yhen the seal is of liquid type and premix sand respectively.
(viii)
When
straight-run
bitumen
is
used,
carpet has cooled
the
diately
after
rature
but with restricted speed
of 16
However, where cut-back bitumen

ted
(ix)
till
The
the binder
tests
on
for the next 24 hours.
traffic shall
not be permit-
and regularity
and
tests
in
7.
their
and work with
materials
frequency
their
Quality control
desirable frequency are
able 5.2.
Rectification
5.4.5.
KMH
used,
finished surface shall be checked for line, level
Control
indicated in
to the surrounding tempe-
is ciired.
5.4.4.
is
may be allowed imme-
traflSc
down
of surface irregularities
Premix carpets
can improve the
evenness of an existing surface only
way.
if
Therefore,
there
are
large
irregularities
in a limited
in the surface
should be rectified just prior to laying of the carpet. Where

the surface ii regularities of the finished carpet are outside the
these
given
tolerances
out and
filled
here.
7,
If the
these
should
surface
be
rectified in the
too high,
it shall be cut
by fresh materials laid and compacted to speciWhere the surface is too low, the depressed portion shall
is
replaced
fications.
be
Chapter
in
manner described
up by fresh material laid and compacted to specifications.
At times,
it
would be found advantageous/necessary
to
have an
enlarged area for the patch.
5.5.
5.5.1.
ral,
Asphaltic Concrete Surfacing
General
be constructed
29-1968.
in
Asphaltic concrete surfacing shall, in geneaccordance with requirements of IRC
58

Table
No.
S.
5.2.
Minimum
Test method
Test
desirable
frequency
Quality of binder
18:731961,
As required
215-1961, 217- 1961 or
IS:
Value/aggregate Impact
(Part
454 196i
2.
as applicable
One
2386
per 50
test
m*
IV)-1963
Value
18:62411971
3.
Stripping value of
aggregate
4.
Flakiness index of
aggregate
IS:
5.
Water absorption of
IS: 2386
2386 (Part
-do-
I)
-do-
1963
(Pan III) 1963
-do-
aggregate
6.
Grading of
IS:
2386 (Part
I)
-1963
One
per 25
test
m*
aggregates
7.
Regularly
at application
8.
Method
Binder content
Two
vide
tests
per day
Appendix-4
9.
Rate of spread of
premix
Regulav
control
through checks on
materials and layer
thickness
Materials:
5.5.2.
filler
and
fine
requirements laid
5.5.3.
5.5.3.1.
shall
apply.
laid to
carrying out
down
in
IRC
viz.,
bituminous binder,
shall satisfy the specification
29-1968.
Preparation of base:
If
Provisions of Clause 5.2.3.
necessary, a bituminous levelling course
Construction of asphaltic concrete surfacing

this
sliall
be
undulations.
type of construction, the
properly attended to
(!)
materials,
make up
5.5.3.2.
All
and coarse aggregates,
While
following points shall be
Gradation of combined aggregates and binder content

the design criteria of the relevant
IRC
specification.
shall satisfy
59

(ii)
The design mix proportions arrived at in the laboratory shall be

based on representative samples of materials actually available at
In
the site and shall be followed to the maximum extent possible.
the event there is a change in the material available at site, a fresh
job mix formula shall be arrived at. In all cases, variations from
the job-mix formula shall be within the specified limits.
Tack coat where necessary
(iii)
at the specified rate

(iv)
be applied over the prepared base
sha'l
before laying the surfacing.
Mixing plant shall be of adequate capacity to yield a mixture of

proper and uniform quality. It should have the necessary accessories such as
aggregate feeder, dryer, weight or volume batcher,
binder heater, binder measuring unit,
filler
feeder unit and mixing
unit.
of various sizes of aggregates shall be fed to the dryer

proportions that the resulting combination complies with
(v) Quantities
in
such
the job-mix formula.
with
This shall be
no gradation contiol
The temperature of binder
(vi)
strictly
followed on small plants
unit.
at
the time of mixing shall be in the
in the range 155"- 163'C.

Care
should be taken so that the difference in temperature between the
aggregates and the binder does not exceed 14C.
range 150-177X and of aggregates
Mixing time should be shortest possible to obtain uniform
(vii)
bution of the binder and a

(viii)
'
distri-
homogenous mix.
Binder content with mix shall be checked periodically to ensure

that the same conforms to specification.
A variation in binder
content of 0.3 per cent by weight of total mix shall, however, be
permissible.
(ix)
The mix shall be carried to the site by tipper trucks and spread and
compacted to obtain a carpet of required thickness. Spreading shall
be done by self-propelled mechanical pavers provided with screeds
for spreading, tamping and finishing the mix true to grade, line and
The temperature of mix at the time of laying shall
cross-section.
be in the range 121" 163C.
(x)
Soon
after laying of the mix, rolling shall be started with 8 to 10

tonnes rollers at a speed not more than 5 km per hour. Rolling
operation shall progress with the drive wheel of the roller in the
direction of the paving, starting from the low side of the spread
and proceeding towards the high side. The initial breakdown pass
made
as soon as possible,
i.e., as soon as
the roller can be
wheels picking up the mix.
When adjoining
lanes are placed, the same, rolling proceduj;^ shall be followed
after compaction of the fresh mix at the longitudinal joint with 15
shall be
operated without
to 20
cm
its
of the roller width (with the remaining roller width on the

The mix shall be further compacted
previously compacted lane).
60

and surface
The
finished
final rolling shall
tandem rollers.
compacted and
The density shall
with suitable pneumatic and
continue
till
the mix
fully
is
or no roller marks are left on the surface.

not be less than 95 per cent of the laboratory density.
little
During
wheels shall be kept moist to prevent the mix
from adhering to the wheels and being picked up but in no case
shall the use of fuel/lubricating oil be permitted for this purpose.
rolling, the
(xi)
roller
Longitudinal joints and
edges
shall
be constructed true to the
delineating lines parallel to the centre line of the road.

shall
be cut vertical to the
and the surface painted with

material.
bitumen before placing fresh
hot
Transverse joint shall be staggered.
(xii) Traffic shall
final rolling
(xiii)
be allowed on the surface only when the carpet after

has cooled down to the ambient temperature.
The
in
All joints
thickness of the previously laid mix
full

grade and regularity
line,
5.5.4.
Quality ccntrol tests
on the materials and the work and their frequency shall be as
indicated in Table 5.3.
:
Table
S.
No.
5.3.
Minimum
Test method
Test
desirable
frequency
1.
Quality of binder
IS:
73-1961
2.
Los-Angeles Abrasion
Value/Aggregate
Impact Value
IS:
2386
(Pait
As required
One test per
IV) 1963
6241-
3.
Stripping value of
aggregates
IS:
4.
Water absorption of
aggregates
IS: 2386 (Part III)1963
5.
Flakiness index of
aggregates
IS:
6.
Sieve analysis for
filler
-do-
1971
2386 (Part I)
1963
-do-
For each size, one test per

50-100 m* of aggregate
One
-do-
test for
ment
mum
of
7.
Mix-grading
IS: 2386 (Part

1963
50-100 m of
aggregate
I)-
each consignto a mini-
subject
of one
test per 5
m*
filler
One
set
vidual
mixed
of tests on indiconstituents
and
aggregates from
the dryer for each 100
tonnes of mix subject to a
minimum of two sets per
plant per day

8.
Control of temperature
of binder in boiler,
aggregate in the dryer
and mix at the time of
laying
9.
61
and
Regularly
rolling
Stability of
ASTM:
mix
For each 100 tonnes of

mix produced, a set of 3
Marshall specimens to be
prepared and tested for
D-1559
value,
flow
density, and void content
subject to a minimum of
two sets being tested per
stability,
plant per day
Binder content and
Method
gradation in the mix
Appendix-4
Thickness and density

of compacted layer
Appendix-4
5.5.5.
Rectification
Method
'of
One test for each 100

tonnes of mix subject to
minimum of two tests
per day per plant
vide
One
vide
surface
test
irregularities
per 500
m*
Where
the
surface irregularities of the asphaltic concrete are out side the tole-
rances given
in
Chapter
7,
these
procedure given in Clause 5.2.5.
shall
be
rectified
as
per the
Concrete Pavements
6
Concrete
Pavements
63
CHAPTER
CONCRETE PAVEMENTS
6.
General
Construction of concrete pavements shall in general

15-1981 entitled "Standard
IRC
6.1.1.
follow
guidelines given in
the
Code of
Specifications and
Practice for
Construction
of Concrete
Roads."
equipments and appliances required for
the work and for the proper upkeep thereof, reference should be
made to IRC
43-1972 entitled "Recommended Practice for
Tools, Equipments and
for
Appliances
Concrete Pavement
For
6.1.2.
tools,
Construction*'.
Mix
Materials and
6.2.
Proportions
viz., cement, coarse aggregates, fine

water shall be checked for specification requireadvance of their incorporation in the work.
All materials,
6.2.1.
aggregates and
ments
in
Proportioning of different aggregate fractions shall be

so controlled that the combined aggregate grading falls within the
6.2.2.
specified
limits
of gradation.
In
case
of non-compliance,
proportioning of the various aggregate fractions

adjusted
Statistical
based on actual gfadation of the

approach to this problem is explained
Mix proportions
shall
be
dififerent
in
the
suitably
fractions.
Chapter
8.
predetermined
samples of materials proposed
to be actually utilised in the work.
While proportioning, adequate
allowance should be made for the expected strength variations so
as to ensure the specified minimum strength in the field, subject
to the permitted tolerances.
Guidance in this regard can be had
from IRC 44-1972 and IRC 59-1976 for continuously and gap
graded mixes respectively.
6.2.3.
on strength
6.2.4.
used,
Where cement from more than one source
proportions
cement.
for concrete shall be
basis using representative
In
such
for
cases,
is
to
be
mix shall be determined for each

cement from different sources shall be
the
Concrete Pavements
66
stored and used separately and a record of the type or brand

shall
used
be maintained.
worK shall be stored

manner so as to prevent deterioration or intrusion
of foreign matter and to ensure the preservation of its quality and
fitness for the work (Ref. IRC
15-1981).
6.2.5.
and handled
All materials required for the
in
6.2.6.
Quality control tests on the materials as well as their
frequencies shall be as indicated in Table 6.1.

Tabll
Material
6.1.
Minimum
Test method
Test
desirable
frequencies
1.
Cement
Physical and Chemical

Tests
2691967
IS:
445 -1964
1489- 1967
8112
2.
Coarse
and fine
(i)
Gradation
2386
IS:
0-1963
(Pt.
aggregates
(ii)
(iii)
Deleterious
constituents
Moisture content
Once for each source

of supply and occasionally when called for
in case of long and/or
improper storage
One test for 15 ni=^ of

each fraction of coarse
aggregate and fine
aggregate
-do-
IS 2386
(Pt
II)
IS:
(Pt.
-1963
2386
1II)-1963
Regularly as required
subject to a minimum
for
of one test/day
coarse aggregate and
two tests/day for
fine
aggregate
(iv)
do-
Bulking of fine
aggregate (for
volume batching)
Once
for each source

for deriving the mois-
turecontent
relati.
Coarse
(i)
aggregate
Los Argeles
Abrasion Value/
Aggregate Impact
IS:2386
(Pt.
IV)-1963
Test
(iit
(iii)
Soundness
Alkali-
aggregate
IS:
(Pt.
2386
(Pt.
V) -1963
2386
VII)-1963
IS:
456-1964
IS:
bulking
nship
Once for each source

of supply and subsequently when warranted by changes in the
quality of aggregate
As required
do-
'
reactivity
4.
Water
Chemical
tests
Once for approval of

supply,
source
of
subsequently only in
case of doubt
67
Concrete Pavements
Processing and Construction
6.3.
Weather and
6.3.1.
precautions
as
specified
seasonal
are
limitations
taken,
Unless
concreting
special
shall
not
be
done during extreme weather conditions, e.g., during monsoon

months, and when atmospheric temperature in shade is above
40"C or below 4''C. For guidelines for construction of cement
concrete pavements in hot weather, reference may be made
to
IRC
61-1976.
Preparation of base
6.3.2.
The base to receive the cement concrete shall be

grade and cross-section as spelt out in Chapter 7.
All irregularities beyond the permitted tolerances shall be rectified
6.3.2.1.
checked for
line,
as specified.
Where concrete
6.3.2.2.
is
to
be laid over an absorbent
surface, the latter shall be kept moist in saturated surface dry condition or
as
covered over by a water-proof kraft/polyethylenc sheeting
specified so as to prevent absorption of water
from the concrete
mortar.
Where
6.3.2.3.
checked for
'k*
6.3.3.
required, the
strength
of the base shall be
value by carrying out plate bearing
test.
Fixing of formwork
6.3.3.1.
The formwork shall be of correct shape, free from
bends and kinks and sufficiently rigid to maintain its shape and
position under the weight and working conditions of the laying and
compacting equipment.. It shall be set to true lines and levels and
securely fixed in position to prevent any subsequent disturbance
during compaction. Trueness of the formwork from the specified
in 3 m
profile shall be checked and any deviation greater than 3
No deviation shall, however, be permitted at the joints.
rectified.
mm
6.3.4.
Manufacture and placement of concrete
6.3.4.1.
Unless otherwise
permitted, the
proportioned by weight
aggregates shall
be
batching plant.
The weighing mechanism
in
coarse
and
fine
an approved weigh
shall be regularly chec-
ked for accuracy, once daily before the work starts, over the fuP
working range by means of a standard set of weights.
68
Concrete Pavements
Cement may be measured either by weight or by
Where cement is used in full bags, frequent checks shall be
6.3.4.2.
bags.
made to see that the bags contain the full specified weight of cement
and any shortage of weight made good. Alternatively, 10 per cent
of the bags in a consignment shall be weighed in advance and
batch-weight of materials adjusted on the basis of average weight
for the consignment.
Water may be measured by volume using
standard measures. The designated water-cement ratio shall be
strictly adhered to and due adjustments made in the water to be
added on account of free moisture content in the aggregates. Suitable adjustment in the weights of aggregates, due to moisture in
them, shall also be made.
Where volume batching
made to minimise variations
6.3.4.3.
should
be
standard
filling
is
in
permitted,
Also the volume of
procedure.
every effort
batching by following a
fine
aggregates
in a
batch shall be duly corrected for bulking.
Mixing of concrete shall be done in a power driven

mixer of approved type that will ensure a uniform distribuThe minimum mixing time
tion of materials throughout the mass.
shall be fixed in relation to the mixer type and capacity and adhe6.3.4.4.
batch
red to strictly.
Workability of concrete shall be checked as specified

6.3.4.5.
by performing "slump test" or "compacting factor test" in accordance with IS 1199. Frequency of testing shall be as indicated
The permissible tolerances from the specified value
in Table 6.2.
:
for workability shall be
Slump
...
'
Compacting
factor
Necessary adjustment
cement
ratio, shall be
in
...
12
mm
0.03
water content, keeping the same watervariations beyond the permitted
made where
tolerances are observed so as to
brihg workability within the speci-
fied limits.
6.3.4.6.
transported
Immediately
placement
for
loss of constituent materials
after
in
is
mixing, the
concrete shall be
manner
that segregation or
such
avoided in transit.
69
Concrete Pavements
Concrete
6.3.4.7.
between the formwork
and uneven compaction.
height greater than 90
from
the
shall
in
be
Concrete
cm
to
shall not be
base
avoid segregation
dropped from
and shall be deposited within 20 minutes
time of discharge
from the mixer.
It
a horizontal layer as near to the final position as
avoiding
prepared
placed on the
such a manner as
shall be laid in
possible
thereby
unnecessary rehandling.
all
Adequate surcharges of concrete shall be given over

level.
The amount of surcharge shall be
determined in the field by actual trial. The surcharge shall be
uniform over the entire area and the concrete as spread shall be
to the same camber and slope as the required finished surface.
6.3.4.8.
desired
the
finished
6.3.4.9.
The concrete
shall
be compacted fully using vibrat-
The vibrating
and internal vibrators shall conform to IS 2506 and
IS
2505 respectively. Compaction shall be so controlled as to
prevent excess mortar and water working on to the top due to overscreeds and/or internal vibrators as specified.
ing
screeds
vibration.
During compaction, any low or high spots

made up by adding or removing concrete.
6.3.4.10.
6.3.4.11.
while
shall
After longitudinal floating has been completed
concrete
is
still
plastic,
be
but
the slab surface shall be tested for
accordance with the procedure

high spots showing
departure from the true surface shall be immediately rectified.
High spots shall be cut down and refinished. Depressions shall
be enlarged to about 8-10 cm and filled up with fresh concrete,
compacted and finished. All the above operations shall be completed within 75 minutes (60 minutes in hot weather) of mixing.
trueness with a
set forth in
Chapter
6.3.4.12.
before the
finished
7.
Any
depressions or
After correcting the
concrete
by belting,
6.3.4.13.
straight edge in
surface
becomes non-plastic,
brooming and edging as
Where
the
slab
second layer shall be placed

of the lower layer.
is
to
within
be
30
for
the
profile
surface
but just
shall
be
specified.
laid
in
two
layers, the
minutes of compaction
70
Concrete Pavements
Control of concrete strength
6.3.5.
The
6.3.5.1
strength of concrete shall be
ascertained
either
For this purpose,

from cube or beam specimens as specified
during the progress of work, cube/beam samples shall be cast for
Sampling and testing shall be in accordtesting at 7 and 28 days.
ance with IS: 1199 and 516 respectively. Frequency of testing
shall be as indicated in Table 6.2.
Table
S.
No.
6,2.
Minimum
Test method
Test
desirable
frequency
1.
Workability of fresh
concrete
IS
2.
Concrete strength
IS
11991950
One
516-1959
test per 10
m*
cube/beam samples
as
specified for each

age of 7 days and 28
days for every 30 m"
of concrete
3.
18:5161959
Core strength on hardened concrete (see clause
2 cores
for
every 30
m' of concrete
6.4.2.)
6.3.5.2.
progress
chart
indicating
the strength values of
The statistical
and upper and lower control limits
be calculated per set of 15 test specimens and indicated
shall
These parameters and proappropriately on the progress chart.
individual
sets
parameters,
of specimens shall be maintained.
viz.,
mean
strength
cedure for statistical analysis are explained in Chapter 8. Where

average strength of concrete shows a consistent increase or
tb.e
decrease from the field design strength, the mix shall be redesigned.
6.3.5.3.
Acceptance of the work shall nut be based on a

on statistical basis, such that the lower control
single test result but
limit calculated for a tolerance level

results, shall
not
be
lower
of
in 15, for sets
than the specified
of 15
mmimum
test
strength.
The lower control limit is given by the mean value of the set of
minus 1.61 times the standard deviation. The work shall be
taken to meet the specification requirements when the lower conWhere the above requiretrol limit is above the specified strength.
tests
Concrete Pavements
compaction
concrete
Clause
met with or where
not
are
merits
suspected,
is
the quality of concrete or
shall
of the
strength
actual
the
pavement
the
in
71
checked as
be
set
its
hardened
forth
in
6.4..
Joints
6.3.6.
All materials required
6.3.6.1.
for
the joints,
bars,
viz., tie
dowel bars, expansion joint filler boards and joint sealing compound shall be checked for specification requirements before their
incorporation in the work. The sealing compound shall conform
to IS: 1834.
Dowel
6.3.6.2.
and
bars shall be
parallel to the surface
permissible tolerances
mm
in
100
placed parallel to each other

line of the pavement.
The
and centre
in this
regard shall be
mm for
mm
dowels of 20
and smaller
diameters;
mm
0.5
20
in
100
mm
for
dowels of diameter greater than
mm.
The dowel assembly
shall be
vent dislocation during concreting.

holes for dowels
fitting
may be
secured in place to pre-
Bulkheads
used for
this
in pairs with tight
purpose.
and grooves
All joint spaces
6.3.6.3.
specified lines
firmly
shall
conform
to the
and dimensions.
During concreting special care shall be exercised at

of joints. Care shall also be taken to
ensure that joints do not cause any discontinuity in the riding
6.3.6.4.
dowels and
in the vicinity
surface.
At the end of the curing period before opening to

cleaned thoroughly and sealed as
Care shall be taken to see that the
specified in IRC: 57-1974.
sealing compound is not heated beyond the specified temperature.
6.3.6.5.
traflBc,
the joint grooves shall be
6.3.7.
6.3.7.1.
Curing of concrete
Curing
shall
commence soon
after
the
finished
pavement surface can take the weight of the wet burlap, cotton or
jute mats normally employed for initial curing, without leaving
11
Concrete Pavements
any marks thereon. The mats shall extend beyond the pavement
edges at least by 0.5 m and be constantly wetted.
Initial curing
shall be for 24 hours or till the concrete is hard enough to permit
labour operations without damage.
6.3.7.2.
Final curing, after the
shall be carried
means
out
by wet earth,
Where water
specified.
ensured that the entire
is
removal of the mats, etc.,

ponding of water or other
used for curing, it shall be
is kept well saturated
pavement surface
throughout the specified curing period.

shall
Where water
is
scarce or
on a steep gradient, impervious membrane curing

be adopted as per details specified.
pavement
is
6.4.
Checking the Quality of Hardened Concrete
Soon after the initial curing period (see Clause 6.3.7.),

hardened concrete shall be checked for surface
regularity in accordance with the procedure set forth in Chapter 7.
Surface irregularities beyond the permissible tolerences shall be
6.4.1.
the surface of the
rectified as indicated in
IRC
15-1981.
Where the strength of

6.4.2.
concrete
tested
vide
Clause 6.3.5. falls below the specified limits or where the quality
of concrete or its compaction is suspected, the actual strength of
the hardened concrete shall be ascertained by carrying out tests
on cores cut from the hardened concrete. Frequency of testing
Crushing strength tests on
in Table 6.2.
cores shall be corrected for height diameter ratio and age for
obtaining the corresponding cube strength at 28-days in accordance
The corrected test
with the procedure given in IRC: 15-1981.
results shall then be analysed for conformity with the specification
requirements on the lines of Clause 6.3.5.
shall be as indicated
6.5.
Reinforcement
where
required to be provided,
before incorporarequirements
shall be checked
as specified.
be
placed
shall
Reinforcement
tion in the pavement.
reinforcement
that
the
is not
Due care shall be taken to ensure
6.5.1.
Reinforcing
.steel,
for specification
displaced during concreting operations.
Control of Alignment,
73
and Surface
Evenness
Profile
Control of
Alignment Profile
and Surface
Evenness
CHAPTER
CONTROL OF ALIGNMENT, PROFILE AND

SURFACE EVENNESS
General
7.1.
All works shall be constructed to the specified lines,

and dimensions. The objective is to achieve
7.1.1.
grades, cross-sections
a well built
pavement conforming
to the
required
vertical profile, design thickness of different
horizontal and
pavement courses, and
stipulated standards of riding quality.
Given
7.1.2.
here
are
the
procedures
checking and
for
permissible tolerances in different cases.
Honzootal Alignment
7.2.
The checking of horizontal alignment shall be done

to the centre line of the road as shown on the plans.
It involves checking the geometry of the roadway
as well as edges
of the various pavement layers vis-a-vis the design centre line.
7.2.1.
with' respect
Horizontal alignment can be controlled 'properly only

line.of the road has
been marked
if
the centre
by means of reference
pillars on both sides of the centre line located at frequent
intervals
along the straights and at all changes of horizontal curvature.
Manner of doing so is explained in IRC: 36-1970. To ensure compliance with plans, edges of each pavement layer should be delineain the field
ted with respect to the centre line before placement, with

the help
of pegs, strings or other tools.
7.2.2.
respect
follows
of
Except
for
horizontal
hill
roads the
alignment are
allowable tolerances in
to be a
recommended
(i)
(ii)
For
Carriageway edges
25
mm
Edges of the roadway and

lower layers of pavement
40
mm
hill
roads, the
Engineer-in-charge.
tolerances shall
be as specified
by the
76 Control
7.3.
of Alignf lent. Profile

i
and Surface Evenness
Surface Levels of Pavement C ourses
Surface levels of pavement courses
7.3.1.
calculated
vvith
the drawings
shown on
tlie longitudinal and

checked through grid levelling/spot levelling, etc., from the
subgrade upwards for each successive layer. Actual levels of the
the
different courses shall not vary from the design levels beyond
cross profiles
respect to
shall be
tolerances indicated below
Subgrade
Sub-base
Base course
Bituminous wearing
course (of premix type)
and cement concrete
25
15
mm
mm
mm
10
"i""'
20
be taken that the negative tolerance for

wearing course indicated in Clause 7.3.1. is not permitted in
conjunction with the positive tolerance for base course if the thickness of the former is reduced by more than 6 mm.
Care
7.3.2.
shall
Control on Layer Thickness
7.4.
Even though checks on surface
7.4.1.
levels
of pavement
courses provide an indirect control on the layer thickness, additof

ional measures may be necessary to establish that the thickness
constructed course is in accordance with specification. These
measures could be in the form of thickness blocks, or cores as may
provides
be applicable. Control on the spread of materials also
deviations
small
Whereas
thickness.
an indirect check on the layer
in
thickness
vitiate the
may
be unavoidable, larger deviations
pavement
would unduly
designs.
In general, the average thickness should not be less

In addition, the spot reduction in
than the specified thickness.
in the case of bituminous
thickness should not exceed 15
7.4.2.
mm
macadam and
mm
in the case
of asphaltic concrete and cement
concrete.
7.5.
Standards of Surface Evenness
both for longituand the latest

reviewed
dinal and transverse profile, have been
Congress in
Roads
recommendations approved by the Indian
"Surface
1977
16:
August 1976 (Published in IRC: Special Publication
7.5.1.
The
criteria
for surface evenness,
ContrdI of Alignment, Profile and Surface

Evenness 77
WITH A STRING
Fig.
SURFACE
Fig. 2.
1.
One
design of template adjustable profile
PROFILE BOARD
Another design of template with adjustable
profile
78 Control of Alignment.
Profile
o
c
.SP
*S3
Control of Alignment, Profile and Surface Evenness 79

Evenness of Highway Pavements") are indicated
in
Table
The
7.1.
various existing standards of the Indian Roads Congress are being
on the basis of these recommendations. During construcsurface evenness should be controlled as explained in
paras 7.6. and 7.7.
revised
tion,
the
Table
Recommendfd Standards for Surface Evenness of

Pavement Constructions
7.1.
Type of Construction
SI.
No.
Cross
Longitudinal Profile with 3
metre
Maximum
permissible
undula-
mm
tion,
straight-edge
Profile
Maximum number
of undulations
permitted in any
300 metre length,
exceeding
Maximum
permissible
variation
from
mm
speci-
fied profile
under camber temp-
1.
2.
Earthen subgrade
Stone soling Brick soling
24
20
3.
Stabilised soil
15
4.
Water Bound Macadam with
15
mm size)
oversize metal (40-90

5..
Water liound Macadam with
mm
12
mm
12
10
30 _
30
30
-30

12
12
18
16
late,
15
12
30
normal size metal (20-50

and 40-63 mm size). Penetration
macadam
6.
7.
9.
10.
BUSG
Surface dressing (two coat) over

12
(20-50
or 40-63
size metal), Penetration macadam
or BUSG
WBM
mm
mm
Open graded premix

20-25
8.
or
mm thick
carpet
Bituminous macadam
Asphaltic Concrete
Cement Concrete
Notes:
1.
10
10
8
20
30
20@@
10@@
4
4
in all other cases, the standard of surface

be the same as for the surface receiving the surface
**For surface dressing

evenness
will
dressing.
2.
@@lhese
If laid manually due to

are for machine laid surfaces.
unavoidable reasons, tolerance upto 50 per cent above the values
in this column may be permitted at the discretion of the Engineerin-Charge. However, this relaxation does not apply to the values
of maximum undulation for longitudinal profile mentioned in
column
3.
of the table.
Surface evenness requirements in respect of both longitudinal and

cross profiles should be simultaneously satisfied.
80 Control of Alignment,
7.6.
Profile
Control of Transverse Profile
The checking of transverse profile should commence

subgrade level and continued for each successive
layer upto the top.
Checking is done with the help of camber
boards/templates, a few typical designs of which are shown in
Figs. 1,2 and 3.
7.6.1.
from
right
the
The template
7.6.2.
in Fig. 1,
has adjustable reference pods
so that the template can be pre-set for any desired profile.
shows
Fig. 2,
which the bottom piece for checking is replaceable to correspond to the specified profile. These designs are meant
usually for checking the profile over a single-lane width.
For twolane or multi-lane roads, generally the checking operations will
require to be carried out individually for each lane.
Fig. 3, depicts
a design of the scratch template used for checking the regularity of
a
template
in
the base for concrete pavements.
For obtaining correct transverse
7.6.3.
surface
of a
layer,
it is
profile
on the finished
necessary that the spread material (before
should conform to the desired profile as far

Therefore, the profile of the spread material should be
compacting/finishing)
as possible.
continuously
regulated
with template/camber boards (placed per-
Normally, a set of three teman interval of about 10 metres.

Checking of the finished surface subsequently should be on the
same lines. Additional checks may be made where visual appearance suggests an excessive variation.
pendicular to the road centre
should
plates
7.7.1.
maximum
are
used
line).
in series at
Control of Longitudinal Profile
7.7.
Typical
be
The longitudinal evenness

permissible
designs
given
commence
7.7.2.
is
under
a 3
metre straight-edge.
and measuring wedge

The checking of surface evenness must also
from the subgrade
The procedure
to be
level.
followed for making surface un-
evenness measurements with a straight-edge
is
given at Appendix 6.
Straight-edge measurements are slow and rather tediTravelling and rolling type of straight-edges as well as other
7.7.3.
ous.
specified in terms of the
for a metallic straight-edge
in, Fig. 4.
right
irregularity
Control of Alignment. Profile and Surface Evenness 81
1
H K30
HANOtC
OIA
12
ELEVATION
HAAKtNC
WELOE D
5R
300
300
ftOO
PLAN
GRADUATED WEDGE
see note 2)
elevation
^yWElDED
ôl*
<
section- aa
IT-
3000
^50f^
PLAN
STRAIGHT EDGE
<
Note
AIL
DIMENSIONS ARE
IN
mm
In this design of the wedge, graduations are marked upto 15 mm.

For
measurements on subgrade and sub-bases, where variations are larger, a
modified wedge with graduations upto 25 mm should be employed.
Fig. 4.
Typical design of straight ed" and wedge
82 Control of Alignment, Profile and Surface Evenness

improved devices have been developed in some other countries for
facilitating the work on control of surface evenness.
A device available in India for this purpose is the Unevenness Indicator developed at the Central Road Research Institute. This is a travelling
straightedge
type
specification
for
of device
surface
the
functions on being run by two
ment
at a
(!)
Instantaneously
indicates
Sounds a buzzer
of the
(iii)
maximum
Automatically
irregularity
The
unit
the market.
7.7.4.
meant
workmen
walking speed of about

moving on a graduated
(ii)
which, when pre-set according to the

under check, performs the following
is
is
km
size of irregularity
the
dial, to
along the lines of measure-
per hour
an enlarged
through a pointer
scale.
locations where the irregularity
at
is
in
excess
permissible (as pre-set).
marks,
through
colour spray, locations where the
in excess of the premissible
simple to operate and
is
maximum
now
(as pre-set).
readily
available
in
This should be used wherever possible.
The
criteria in
columns 4
to 8
of Table
7.1.
are
many irregularities of a size

maximum. This check is exercised
to ensure that there are not too
one lower than the permissible

by counting the related irregularities as they occur and then seeing
whether there is excessive occurrence over any 300 m length. Each
depression/hump is to be counted only once. Both straight-edge
and Unevenness Indicator methods are amenable to exercising of
this control.
Statistical
Approach to 83
Quality Control
Statistical
Approach
to
Quality Control
CHAPTER
STATISTICAL APPROACH TO QUALITY CONTROL
8.
Statistical Quality Control
be appreciated that the road and runway construction, like most other construction process, has certain amount
of variability inherent in the materials and methods involved. It
8.1.1.
It is
to
will thus be prohibitively expensive and rather impracticable to

have acceptance criteria for quality in such absolute terms as
would imply the rejection of a piece of construction or a material
on the basis of single sub-standard sample. Because of the in-
aim of
herent variability, the

as
variability
much
quality
is
to
The acceptance
practicable.
as
control
limit
this
criteria are
thus required to be based on statistical evaluations so that they
not only
realistic,
and
but restrictive
as
required by
are
the design
and performance requirements of the structure.

8.1.2.
The
statistical
evaluations of the quality
data provide
a scientific analysis of the entire production process with respect to

quality.
They not only point out
variations
but also
many
the general trends in the
time
quality
go to expose the unsuspected
causes of variation and thus lead to a striking improvement in constructional quality.
8.2.
8.2.1.
Definition of
Arithmetic
Common
mean
Statistical
Terms
(also referred to as
ttie
average)
is
the
sum
of observations (strength results, say) divided by their number:
the
observations
8.2.2.
average of the deviations of

is an
mean. This is defined as the square
the mean square deviation from the tme
Standard deyfation
from
root of variance which
is
their
86
Statistical
mean
Approach to Quality Control
Standard deviation
value.
is
given by
A more
convenient formula, as given
generally used
below
however,
is,
...
of
Co-efBcient
8.2.3.
variation
expressed as a percentage of the
mean
is
standard
the
Range
deviation
...
difference
the
is
between the
smallest values of the observations in the set
R =
Notations
(3)
.--'^
8.2.4.
(2)
largest
(4)
and the
XmaK Xmin
A:=any value
n number
in the set
of values of observations in the set
Sarithmetic mean
y=standard deviation
/^coefficient of variation
R T&ngc
Normal Distribution Curve and Control Limits
8.3.
8.3.1.
number
It
has been established that
when values from
of tests are considered for any of the tests on
large
concrete in
general, and its strength in particular, they conform to the Normal

Gaussion Distribution Curve, Fig. 5, the spread of which, for all
practical purposes,
on either
may be taken
mean value.
The value which

or percentage
have only a specified number (1 in N)

as tolerance level of test data falling
given by Xmin=(xrj), where r is a factor dependent
The values of
8.1.
deviation
will
(p%) termed
below it, is
upon the specified tolerance
Table
as 3 times the standard
side of the
for
level.
various tolerance
levels
are given in
Statistical
IX
IX
IX
CM
87
IX
IX
IX
/ \
1
1
/
/
'
'
ID
'
'
'
'
'
NORMAL
1
DISTRIBUTION
CURVE
Ul
1
,
'
'ill'
Ul
'
ft
o
Ul
1
X
3
;/:
STRENGTH
STANDARD DEVIATION
FACTOR FOR TOLERANCE LEVEL
Xr MEAN VALUE,
r
Fig. 5.
Normal
Conversely, for a specified
distribution curve
minimum
.strength requirement
hence r), the average value
X for mix design strength has to be at least x=Xmrn-f-r/. The
magnitude of standard deviation j is a function of the extent of
uniformity achieved in quality of the product.
x.nin
with a given tolerance level (and
While the desired quality of the product is defined by Xmin

the level of quality achieved is assessed from a knowledge
of X, 7 and r. (X r/) and (x -f- rj) are termed as the lower control
limit (L.C.L.) and the upper control limit (U.C.L.) respectively.
When the stipulated specification requirements are satisfied
and
r,
L.C.L.>Xm<n.
Qoality Control Progress Charts
8.4.
8.4.1.
specimen)
is
quality
control
the progressive
progress chart (see Fig. 6 for a

of the desired test values, e.g.,
plot
as
Statistical
Approach
Smpt
No.
Progress chart for strength
Fig. 6.
test
number of sample
strength, against the serial

a general idea
to Quality Control
of the average
variation
in
vl
-x
To obtain
tested.
quality,
the
moving
which for any sample is the average of the

five consecutive tests (including the sample under reference and
four immediately preceding it) is also plotted on the chart.
The
number
of samples as well as
X, U.C.L. and L.C.L. for stipulated
t he specified Xmin are also drawn. The progress chart enables seeing
at a glance whether the desired quality is being achieved or not.
average of
five tests
Table
8.1.
Value of
for Different Levels of Confidence
Confidence level in terms of extent of test

values that can be tolerated below the
specified minimum value
(31%)
(16%)
10.00(10%)
in 3.20
in 6.25
1.0
in
1.28
in 15.40
in 40.00
1
1
(6.5%)
(2.5%)
in 100.00(1.0%)
in 666.00 (0.15%)
0.5
1.5
2.0
2.33
3.00
to infinite number of samples and appropriate for applicamajor concreting jobs. For small number of samples r value
could be found in standard reference books, for example IRC: 44-1972.
Corresponds
tion to
8.5.
Illustrative
Example Strength Test Data
8.5.1.
The data for the 28 day compressive strength of
concrete cubes from a construction project are given in Table 8.2.
Statistical
89
and 2). The minimum specified concrete strength Xmtn

(columns
on the project was 280 kg/sq. cm, with a tolerance level of 1 in 10
1
(r=1.28).
Table 8,2. Cube Compressive Strength Test Data prom A
Project and Computations for Their Statistical Analysis
No.
S.
Compressive
strength
kg/sq. cm
Moving average
tive strength
results kg/sq. cm
-
Deviation
of 5 consecu-
L.
J
J.
cm
kg/sq.
90
400
10
too
909 <
50
45
10
9500
9095
100
ÔJ
A
<
O.
9Qn
90 S
7
Q
în
JJKJ
^90
O.
Q
y.
9R0
1 1
Z.
J.
14
1
10.
17
1 K
1
10
9QS
9on
^9S
975
J jyj
jjyj
inn
JlVJ
IS).
98n
DC
lÔO
RO
O'tUU
10
JOUU
1 no
45
50
1
A5
10
oU
oo
lUU
iouy
1
j*tj
ZD
^ J.
90S
95
45
<9<
9n9<
9^
9A
97
Li
4nn
ISO
45
Ô
OU
90T
Knrt
JoUU
28
360
4 on
315
340
345
370
360
350
340
360
370
370
370
380
360
340
330
340
330
340
20
29!
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
25
625
"71
440
420
340
310
385
330
350
280
330
370
385
25
100
80
10000
-30
900
2025
100
100
3600
100
900
2025
45
10
10
-60
-10
30
45
6400
90
Statistical
300
350
350
385
330
330
340
370
360
315
345
295
320
295
295
330
340
340
330
340
330
330
310
310
df\
47
48
4Q
25
40
fiC\
UV/
in
100
2025
1600
1 \JM\J
45
40
50.
51.
52.
53.
54.
55.
56.
57.
Ja:
~25
= 19220
Check whether
being met
900
400
625
30
20
5
25
45
-20
45
-45
2025
400
2025
2025
X(x-x)=87505
the stipulated specification
requirements
Tabulation of data for the calculation of various

parameters is shown in Table 8.2.
Sx= 19220 kg/sq. cm
5c
Ex~
340 kg/sq.
are
statistical
cm
S(x-x)ii= 87505
40 kg/sq.
7X100.
40
340
5c
L.C.L.
x-rj
As L.C.L.>x,n,n
Xniin
Taking Xmin
288.8 kg/sq.
RXmin
L.C.L.
_
~
actually
level
340280
11.7%
cm
achieved
for
rj
40
Therefore the tolerance level

(3)
the specification requirements are met.
(2) Calculate the tolerance

specified concrete
340-1.28x40
X 100
cm
is
60
40
1
_
~
^'^
in 15.40
(Table
8.1.).
CoDStnict a quality control progress chart with this data
The Progress Chart
is
shown
in Fig. 6.
the
Statistical
91
Aggregate Graaation Data
8.6.
Table 8.3. shows the aggregate gradation data for the project.
Both the stipulated aggregate gradation required to be achieved
with a confidence
level
corresponding to
= 2,
and the
gradation tests run on aggregate samples are shown in

(1)
Check whether
the stipulated
specification requirements are being
Step
I.
results of
this table.
For each sieve
met
size, calculate x,
j,
L.C.L. and U.C.L.
individually.
L.C.L.
C/.C.L.
This data
= X r/
= x + ry
also tabulated in Table 8.3.
is
too
MEAN
CONTROL LIMITS
SPECIFICATION LIMITS
80
/////
/////'
3?
O 60
/////
in
t
v.-
40
<
a
/^y
/
/
20
//
/
//
150 300
m'lcrtn
600
4*
M8
2-36
475
mm
10
20
SIEV5 IZE
Fig. 7^
C ontrol chart for aggregate
grading
40
80
92
Statistical

On
s
o
ON
VO
o\
ri
oo
ts
00
00
O
o
84.2
57.5
83.7
00
OS
CM
c-
q
od
vd
VO
od
<s
<N
d
m
42.0
33.8
32.0
30.7
29.0
21.2
60.7
46.9
35.4
30.8
28.0
26.4
19.5
ri
NO
od
od
rsi
<
cn
oo
ON
in
OO
VO
00
00
OO
On
Q
w
^
.J
S <
H
2
^
<
<
>
52
vd
rv
00
oo
o
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o
00
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00
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VO
o\
oo
VO
ON
od
VO
n
f*^
m
r>
ri
ro
VO
od
ON
tT
ri
*r\
VO
ro
<s
<N
ON
ri
vd
ON
vd
rN
r-
<N
On'
wi
"J
m
d
ON
m*
d
m
VO
od
CN
rr\
d
m
od
<s
f*^
(N
ro
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<N
vq
rON
oo
od
ro
ri
m
r*%
rn
q
ON
m
q
r-*
00
<N
rf"
00
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v-i
oo
vd
00
00
^*
VO
oo
o
VO
o
Ov
VO
vd
q
^
od
<N
N
ON
od
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od
CI
e
s
m
^.
&
a
a
E
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00
IS
VO
od
On
rj
r-
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ao
d
s
i5
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>/->
On
O P W
a
q
ON
ts
Tf
ON
<M
VO
On
Statistical
93
81.2
58.4
38.5
29.8
27.4
25.3
15.8
33.8
31.8
30.5
23.8
ro
87.6
Dm
= s
VO
58.9
40.3
o
rj
ri
ri
84.4
65.4
48.7
35.7
31.8
29.6
27.9
19.8
87.8
65.0
43.2
32.4
30.6
28.8
27.0
17.2
83.8
68.2
50.2
35.3
31.5
29.8
28.6
16.1
84.0
61.2
43.9
33.6
30.5
27.2
24.7
18.2
82.6
68.9
39.2
32.6
30.4
28.2
26.6
21.4
83.1
68.8
52.8
36.2
31.9
30.2
29.1
17.7
84.3
65.9
42.0
32.0
30.3
28.8
27.4
18.9
85.6
64.2
42.9
33.7
31.0
29.1
27.6
18.6
87.1
67.2
50.7
31.3
28.8
27.3
17.2
86.2
64.1
47.8
34.6
31.7
30.0
82.2
70.2
60.0
40.5
32.6
28.6
37.1
28.7
27.1
19.4
8
I
s
B
o
vn
a
a
a
a
a
a
94
Statistical
Step
II.
On
a plot of the
stipulated
In case x lies within the zone, plot
both L.C.L. and U.C.L.

cation
is
being met.
lie
The
gradation zone, plot
L.C.L. and U.C.L., as well.
within the
actual plot
is
x.
If
stipulated zone, the specifi-
shown
in. Fig. 7.
It is
seen
are being met, except for sieve

Nos. 300 and 600 micron for which U.L.C. does not lie within the
that the specification requirements
stipulated zone.
Appendices
Appendices
95
Appendix
OF STANDARD SPICCIFICATIONS OF INDIAN ROADS

CONGRESS REFERRED TO IN THE TEXT
LIST
Number of Standard
IRC 14 1977
:
Title
Recommended,
practice
for
cm
thick
bitumen and
tar carpets (First Revision)
IRC
IRC
151981
Standard specifications and code of practice for construction of concrete roads (First Revision)
171965
Tentative specification for single coat bituminous surface
Standard specifications and code of practice for water
dressing
IRC
iv 1977
IRC
201966
Recommended practice for bituminous

macadam (full grout) (First Revisitm)
IRC
23 1966
Tentative specification for two coat bituminous surface
IRC
27
bound macadam
(First Revision)
penetration
dressing
1967
Tentative
specification
for
macadam
bituminous
(base and binder course)
JRC
29
1968
Tentative specification for 4
cm
asphaltic concrete
sur-
face course
IRC
361970
Recommended
embankments
IRC
43
1972
Recommended
practice
for road
for
the
construction of earth
works
practice for tools, equipments
and applia-
nces for concrete pavement construction
IRC
44
1976
Tentative guidelines for cement concrete mix design for
road pavements (For non air entrained and continuously graded concrete) (First Revision)
IRC
IRC
471972
Tentative specification for built-up spray grout
481972
Tentative specification for bituminous surface dressing

us''ng
IRC
571974
precoated aggregates
Recommended
practice for sealing of joints
in
concrete
pavements
IRC
1976
59
611976
Tentative guidelines tor design of gap graded cement
concrete mixes for road pavements
IRC
Tentative
guidelines
for the construction
.oncrete pavements in hot-weather
IRC SP
161977
Surface evenness of highway pavements
of cement
Appendix 2
STANDARDS OF BUREAU OF INDIAN

STANDARDS AND OTHER BODIES REFERRED TO
IN THE TEXT
LIST OF TEST
Number of Standard
Title
IS
2151961
Road Tar (Revised)
IS
217-1961
Cutback Bitumen (Revised)
IS
2691967
Ordinary,
Rapid-hardening
and
Low Heat
Portland
Cement (Second Revision)

IS
454-1961
Digboi Type Cutback Bitumen (Revised)
IS
455-1967
Portland Blast Furnace Slag Cement (Second Revision)
456-1964
Code of
IS
for
Practice
Plain and Reinforced Concrete
(Second Revison)
IS
4601962
Test Seives (Revised)
IS
5161959
Methods of Test for Strength of Concrete
1199-195S
Methods of Sampling and Analysis of Concrete
IS
IS
1203-1958
Determination of Penetration (Procedure for testing

tar and bitumen products)
IS
14891967
Portland-pozzolana Cement (First Revision)
IS
1514-1959
Methods of Sampling and Test

Hyderated Lime
IS
18341961
Sealing
IS
2386
Methods of Test
II) 1963
Lime and
for Joints in Concrete
for Aggregates for Concrete
Particle Size
and Shape
Estimation
of
(Part I)-1963
(Part
Compounds, Hot applied
for Quick
deleterious
materials
and
Organic
impurities
(Part III)-1963
Specific
Gravity,
Density,
Voids,
Bulking
(k'art
IV) 1963
Mechanical Properties
(Part
V)-1963
Soundness
(Part
VII)-1963
25051968
Alkali-aggregate Reactivity'
Concrete Vibrators, Immersion Type
IS
IS
IS
25141963
Concrete Vibrating Tables
IS
2720
Methods of Test
2506
964
Screed Board Concrete Vibrators
for Soils
Absorption and
99
Appendices
(Part II) 1973
Determination of Water Content (Second Revision)
(Part
IV) 1975
Grain Size Analysis
(Part
V) 1970
Determination
of
Liquid
and
Plastic
Limits (First
Revision)
(Part
VII)-1974
Determination of Water Content-Dry Density Relation

using Light Compaction
(Part
VIII)-1974
Determination of Water Content-Dry Density Relation

using
(Part
X)-
1973
Heavy Compaction
Determination
of
Unconfined
Compressive Strength
(First Revision)
(Part
XVI)- 1965
(Part
XXVII) 1968
Determination of Total Soluble Sulphates
(Part
XXVin)-1974
Determination of Dry Density of Soils, in-place of

Sand Replacement Method (First Revision)
IS
IS
IS
Laboratory Determination of C.B.R.
3495-1973
Method of test
4098-1967
Lime pozzolana Mixture
62411971
for Clay Building Bricks (First Revision)
Method of Test for Determination of

Road Aggregate
Stripping Value
of
ASTM.D-1138-1952
Test for Resistance to Plastic Flow of Fine Aggregate
Bituminous Mixtures by means of the Hubbard-Field

Apparatus
ASTM
D- 1559- 1965
Resistance to Plastic Flow of Bituminous

for
Mixtures using Marshall Apparatus
Test
Appendix 3
CONSOLIDATED LIST OF EQUIPMENT TO BE PROVIDED

IN THE STATE CENTRAL LABORATORIES
S.
No.
Number
Equipments
required
A.
General Equipment
(i)
High
sensitivity
proving ring
(iii)
(iv)
(V)
2.
3.
100 kg Capacity
Capacity
Capacity
Capacity
Capacity
200
500
1000
2000
(ii)
kg
kg
kg
kg
2
1
1
Dial Guages
(i)
12
(ii)
25
mm Travel
mm Travel
.6
Balances
7 kg capacity accuracy
(i)
(ii)
(iii)
(iv)
gm
capacity accuracy 0.001 gm

Chemical Balance 100 gm. Accuracy 0.0001
Pan balance 5 kg capacity
500
gm
gm
1
1
balance 0.001 gm accuracy

Platform scale 5 cwt. capacity
(v) Physical
(vi)
4.
Ovens
(i)
(ii)
(iii)
Upto
Electrically operated, thermostatically controlled
110C-Sensitivity 1C
x 16" x 14"
Size 24"
Upto 400F
rotating
type Determination of
loss
on
heating bitumen
5.
Sieves
(i)
(ii)
6.
B.S. Sieves size 18" dia. 3", 2", H", l\ 2"

B.S. Sieves- 8" dia. 7. 14, 25, 36, 52, 72, 100, 170
set
set
operated wiih time switch assembly
Proving Rings
(i)
(ii)
(iii)
Note:
& 200
Sieve shaker capable of taking 8" and 12" dia. sieves

electrically
7.
400 lbs. capacity

6000 lbs. capacity
1
1
5 ton capacity
All
Indian testing equipment, instruments and materials shall conform
to ISI specifications
and
shall bear, IS
Markings, as
far as possible.
Appendices
101
Dial Guages
8.
(i)
1"
(ii)
2"
travel 0.001" division

travel 0.001 division
Load frame
9.
6
6
'
5 ton capacity electrically operated with
speed control
10.
200 ton compression testing machine
11.
Stop watches
12.
Glass ware
1/5 sec. accuracy
13.
Miscellaneous
14.
Hot
B.
plates 1" dia.
Sub-surface Investigations
Truck
1.
*2.
1^
Drilling Rig. upto 60
& rock
3.
Soil
4.
Vane shear
*5.
*6.
7.
*8.
m depth
drilling kit
kit
Portable equipment for seismic survey
Stratometer for electrical
resistivity
(TERRASOOUT)
survey
Binocular type micro scope
*9.
Borehole deformation meter

Static penetrometer
Hydraulic Jacks (30, 50, 100 and 200 tonnes)
12.
Borehole Camera
10.
1
Undisturbed
soil
equipment (10 tonnea^
samplers (Dension
13.
Plate load test equipment
14
Thin
vvall
&
1
1
Piston Sampler)
sampling tubes
(100
& 50 mm
15.
SPT
Test equipment and static cone penetrometers
C.
Soils
dia.
and
0.75
100 each
long)
type
1.
WatterSiill
2.
Liquid Limit device and tools
3.
Sampling pipette
fitted
with
pressure and
10 ml. capacity
4.
compaction appratus (Proctor)
Ôptional items deoending on the requirements.
suction
inlets,
Appendices
102
AASHO compaction apparatus
5.
Modi6ed
6.
Sand pouring cylinder with conical funnel and tap
7.
Capillary water absorption test equipment
8.
Sampling tins with lids 03" dia. x 21" ht. 1

and miscellaneous items like moisture tins,
9.
PH
lb.
size 100 nos.
etc.
meter
&
variable head permometer-
10.
Constant head
11.
Unconfined compression
4 springs and masks
12.
Lab.
13.
Field
apparatus
test
CBR test equipment with

CBR test equipment
12
with a set of
moulds
14.
Plate bearing test equipment with 12" dia. plate
15.
Shear box
16.
Triaxial compression test equipment
test
equipment
equipment
17.
Consolidation
18.
19.
Post hole auger 4" dia. with extensions and Shelby tube
test
ton capacity mechanical jack
for undisturbed sampling

20.
Truck chassis capable of loading, upto 8
21.
Sample extractor frame with hydraulic jack hand operated
22.
Motorised unconfined compression testing machine
23.
Motorised direct shear operators with 12 rate of strain
24.
Triaxial testing
toiis
equipment (Motorised) with 8 rates of
feed and assembly for lateral-pressure and pore pressure

25.
Tor Vans Appratus
26.
Universal Automatic Compactor
27.
Core
28.
Soil lathe
29.
Vaccum pump
30.
*31.
D.
1.
cutter
Proctor needle (spring type)
Consolidation
test
equipment
Bitumen
Constant temperature bath
2.
Petrol gas generator (laboratory model)
3.
Ring
4.
(BRTA) Viscometer
5.
Fngler viscometer for emulsions
&
Ball softening point apparatus
with 4
mm and
10
mm cups
103
Appendices
6.
Red wood No.
7.
Penetrometer automatic type, adjustable weight arrange-
8.
Soxhlet extraction appratus type SJB 50
and 2 viscomeiers
ment and needles
9.
Moisture determination apparatus with
still
(copper) and
othjcr accessories
10.
Extraction thimbles 43 x 123
11.
Laboratory mixer 1/2

fitted
12.
mm size
30
capacity, electrically operated
eft.
with heating jacket
Ductibility testing apparatus with variable speed

complete with moulds
13.
Moulds for Hubbard -Field
14.
Equipment
15.
Hveem
16.
Marshall compaction apparatus
E.
Rock
for distillation
stability test 6'
gears
x 2' dia.
of tars, cut-backs, etc.
stabilometer
testing equipment
1.
Rock sample
2.
Rock
3.
Portable rock tester
*4.
Field direct shear kit
F.
Concrete and Structures
height guage
hammer
classifaction
1.
Water
2.
Vicat needle appratus for setting time
3.
Moulds
(i) r X
(ii)
still
4"
test
with plungers
X 20'
Cubical 6". 4
12
2.78'
each
size
4.
Lechatelier soundness testing apparatus
5.
Air permeability apparatus
6.
High frequency mortar cube vibrator
7.
Concrete mixer power driven 1

Concrete mixer power driven 5
8.
capacity
eft.
capacity
Variable frequency and amplitude vibrating Table size

2"
9.
eft.
X 3 load 200
'
lbs.
Aggregate crushing
test
apparatus
apparatus
10.
Aggregate impact
11.
Los- Angles abrasion apparatus
12.
D-val attribution apparatus
test
104
Appendices
2
13.
Flexural attachement to compression testing machine
14.
Concrete laboratory
15.
In-siiu concrete strength testing
16.
UTM
17.
Strain measuring equipment set
G.
Equipment for Hydraulic Studies
set
up
equipment,
test
hammer &
pachometer
for tension,
compression and other
tests
1
1
1.
Current meter
2.
Echo sounding equipment
H.
Road Testing Equipment
Beam
1.
lienkelman
Profile meter
(hand towed)
*3.
British portable skid tester
*4.
Accelerated polishing machine
I.
Traffic Engineering
*1.
Radar speed meter

Enoscope
2.
3.
4.
*5.
6.
J.
trafiSc counter
Multi-bank event recorder
Multi-pen event recorder
Time lapse photography camera and projector unit
Electronic
6
1
1
Terrain Evaluation and Photography
*2.
Pocket stereoscope
Stereoscope with Parallex Bar
K.
Mobile Laboratory
*1.
2
1
*1.
Laboratory Truck
*2.
Equipment
L.
Special Research Equipment
*l,
Equipment, (individual items should be

depending on actual needs)
M.
Quality Control Equipment
*1.
Equipment' (individual items to be identified depending
on
N.
1
actual needs)
identified
1
in Field
Miscellaneous
Electronic
Desk Calculator
*2.
Slide Projector
*3.
Camera
*4.
Photostat Machine
Appendices
105.
STATEMFNT SHOWING THE RANGE OF ADDITIONAL

EQUIPMENT PROPOSED BY SOME OF THE STATES FOR
AUGMENTING THEIR CENTRAL LABORATORIES
S.
No.
1.
Additional Equipment
Discipline
Soils
Dynamic cone penetrometer; soil lathe Flash shaker;

Grimilaboratory blender; Winkworth laboratory mixer;
Dieter's
compaction apparatus; speedy
moisture
tester;
'conductivity bridge; electrical earth pressure apparatus;
sand equivalent test apparatus; soil density probe with

utility seater; automatic compaction machine; platform
kit; rotary high vaccum
presso-vac pump; mechanical stirrer;
mechanical mixer; shrinkage factor apparatus; Proctor
vibrator with relative density
pump;
Genco
Abbot's cylinder;
needle;
apparatus; sand equivalent

apparatus;
Biiunnen
PVC
Distillation
compactor;
tus;
soil
centrifuge
apparatus; vane shear
meter.
apparatus:
float test
new model
calcimeter;
test
electro-hydraulic
kneading
appra-
apparatus; settlement ratio
versa tester;
Higler speaker absorption
meter; barometer; Gilson testing screen and accessories;

Kipp's apparatus; hydro vapourising unit.
Concrete and
Prestressing bed;
Bridges
coring equipment;
twisting
plant;
machine;
jack and other equipments, concrete

beam breaker concrete test hammer;
Universal
supersonic tester;
testing machine;
Acrow weighmore
meter; drying shrinkage apparatus B.T.L.

furnace;
internal
vibrator;
shutter
boring
consisto-
oven;
vibrator;
muflBe
masonry
saw: briquette testing machine;
K.C.P. tensile testing
machine;
bend
fatigue tester;
cold
test;
Askamia
vibrator;
4.
Aggregates
Dorry's attrition test; Stewart's impact

jaw crusher slitting, grinding
Page impact
and polishing
test;
test;
machine.
5.
Traffic
Electronic traffic counter; electric speed meter;

vehicle counter;
tion
decelcro-meter;
width of curves; hand

6.
Road
Testing
Skyke's
enoscope wheel weigher; brake inspecinstrument
for
tracing
track
tally counter.
Bcnkelraan beam; bump integrator; immersion tracking

machine; skid resistance tester electronic roughness
tester.
Appendices
106
ment
Photometer; lux meter; recording camera; super cameras;

movie camera; sound projector; slide proamplifiers; photostat machine.
jector; epidiascope
Electric/
Polarising microscope; electronic weighing machine; gen-
Photographic/
sound equip-
enlarger;
Electronic
erator; oscilloscope; vibration pick up; excitation ampli-
and other
fier;
miscellane-
Varistant;
ous equip-
pallet
ment
measuring
strain
bridge;
oscolo
mobile van; gas generator;
trucks;
G.K.
script;
electronic calculator; duplicating
machine;
electric tube,
furnace, cassette tape recorder; refrigerator, analytical
and other preicsion balances.
TESTING EQUIPMENT REQUIRED FOR SETTING OF
REGIONAL LABORATORY
S.
No.
Particulars of
1.
Equipment
Nos. required
GENERAL
Balances:
(i)
7 kg to 10 kg capacity-semi-self indicating
(lii)
Accuracy 1 gm
type
500 gm capacity-semi-self indicating typeAccuracy 0.001 gm
Chemical Balance-100 gm capacity-Accuracy 0.0001
(iv)
Pan Balance
(ii)
(v) Physical
(vi)
(i)
gm
kg capacity
0.001 gm accuracy
300 kg capacity
Balance
Platform scale
Ovens
(ii)
Electrically Operated, Thermostatically Controlled
Upto 110C
Upto 200C
Sensitivity
LC.
for determination on loss on
heating bitumen
Sieves
(i)
LS.
80
10
(ii)
Sieves 450 mm internal dia.
mm,
mm,
I.S.
as per I.S. 460-1962
Sieves
mm.
mm,
of sizes 100
mm, 40 mm, 25 mm, 20 mm,

6.3 mm, 4.75 mm complete with
63
12.5
lid
and pan
set
set
200 mm internal dia (brass frame)
consisting of 2.36
mm,
1.18
mm,
600 microns, 425
microns, 300 microns, 212 microns, 150 microns,

90 microns and 75 microns with lid and pan
107
Appendices
Sieve shaker capable of taking 200
4.
mm and 300 mm
dia, sieves-electrically operated with time switch assembly
Proving rings
5.
charts
(iii)
Dial
(i)
7.
complete with dia guage and calibration
250 kg capacity
2000 kg capacity
5 tonnes capacity
(i)
(ii)
6.
2
2
Guage
25
mm travel-O.Ol
mm/division
Load frame-5 tonnes capacity
2 Nos.
electrically
operated
with speed control
8.
200 tonnes compression
9.
Stop watches 1/5
10.
No.
sec.
testing
machine
accuracy
Glassware comprising Brakers, Pipettes, dishes,

measuring cylinders (100 to 1000 cc capacity) rods
&
1 dOk..
each
funnels
11.
Hot
12.
Enamel
(i)
(ii)
(iii)
(iv)
plates 200
mm oia. (1
no 1500 watt)
2 Nos.
trays
mm
600
x 450
450 inm x 300
300
x 250
mm
mm
mm
mm
mm
mm
x 50
x 40
x 40
Circular plates of 250
dia
mm
6
6
mm
SOILS
1.
2.
Water
still
Liquid limh device with Casagrande and A.S.T.M

grooving tools and as per l.S. 2720-Part V-1970
3.
Sampling pipette
10 ml. caoachy
4.
Compaction apparatus (Proctor;
5.
Modified
fitted with pressure
and suction
inlets,
as per l.S.
1
Sand pouring cylinder with conical funnel and tap and

complete as per LS. 2720 Part
8.
AASHO compaction apparatus
2720-Part VlIi-1974
7.
as per l.S. 2720 Part
Vll-1974
6.
No.
XXVIIM974
Sampling tins with lids 100 mm dia x 50 mm ht. ^ kg

capacity and miscellaneous items like moisture tins, etc.
Unconfined compression test apparatus with a set of 4
springs and masks and complete as per l.S. 2720
Part X-1974
doz.
2 doz.
Lab C.B.R.
per
I.S.
(i)
equipment for conducing
test
CBR
test as
2720-Part XVI-1965 and consisting of following
CBR
mm
moulds 150
dia. 175
mm
complete with
ht,
collar, base plate, etc

(ii)
Tripod stands-for holding
(iii)
C.B.R. plunger with settlement dial guage holder
(iv)
Surcharge weight 147
mm
dial
guage holder
dia. 2.5
kg wt. with central
hole.
(V)
(vi)
(vii)
Spacer discs 148
mm dia., 47.7 mm
ht.
with handle
Perforated plate (Brass)
Soaking tank for accommodating 6
CBR
moulds each
Field C.B.R. test equipment consisting of hand
operated
mechanical jack of 5 tonnes capacity,
capable for sliding

on I section fixable to truck chassis, proving ring of 2000
kg capacity, extension pieces (of adjustable length upto
1 metre
length), CBR Plunger, settlement dial guage
holder,
datum
central
hole (47.7
9.07 kg
mm (10 in) dia. surcharge wt. with

mm dia) and 4.53 kg (10 lb)-2 nos. and
bar, 254
(20 lb)-2 nos.
and one
I-section
of 1.25 metre
length having arrangement of clamping to truck chassis

Plate bearing test equipment consisting of following
items
(i)
plates 25.4 mm
in thick and dia 762 mm (30 in.)
mm (26 in.) 558 mm (22 in.) 457 mm (18 in.)
305 mm (12 in.) 228 mm (9 in.) and 154 mm (6 in.)
M.S
(1
660
(ii)
Hydraulic jack 20 tonnes capacity with remote control

through flexible tubing of 2-3 metre length
iii)
Proving ring 25 tonnes capaciiy with dial guage and

calibration chart
(iv) Ball
bearing plates 25
mm thick
and 100
mm dia. with
centre groove
(v)
Datum Bar
clamps
metre long with stand and dial guage

attaching arrangements
(2 nos.) with suitable
Standard Penetration
test
equipment
3.
BITUMEN
Constant temperature bath for accommodating bitumen

specimen, electrically operated and thermostatically
test
controlled.
Appendices
2.
Petrol
109
gas
alternative
generator (Laboratory model or any other

arrangement for heating of specimens in
laboratory)
3.
Penetrometer automatic type, adjustable weight arrangement, and needles as per I.S. 1203-1958.
4.
Soxhiet extraction apparatus
complete
with
extraction
thimbles, etc.
5.
Laboratory mixer about 0.02 cu. metre capacity

operated
electrically
with heating jacket
fitted
apparatus complete
6.
Hubbard-field stability
7.
Marshall compaction apparatus as per
test
AST M
1559-62
and complete with electrically operated loading unit,

compaction pedestal hearing head assembly, dial micrometre and bracket for flow measurement, load transfer
bar, specimen mould (4 in. dia) with base plate, collars,
specimen extractor, compaction hammer 4.53 kg. (10 lb)x
457
mm (18
in.) fall
8.
Distant reading thermometers
1.
Water
2.
CONCRETE AND iMATERIALS
still
Vicat needle apparatus for setting time test with plungers,

as per LS. 269-1967
3.
Moulds
(i)
(ii)
100
mm
mm
x 100
Cubicais 150
mm,
mm
mm (each
x 500
100
size)
4.
Air permeability apparatus
5.
High frequency mortar cube vibrator
6.
Concrete mixer power driven,
7.
Variable frequency
1
metre
<
Flakiness index
9.
Aggregate Impact
test
cu.
ft.
capacity
and amplitude vibrating
metre, as per
8.
I.S.
table
size
2514-1963
apparatus
test
apparatus as per
I.S.
2386 Part
IV-1963
10.
No
Los-Angeles abrasion
apparatus
as
per
I.S.
2386 Part
IV 1963
11.
Flow
12.
Equipment for slump
13.
Equipment for the determination of specific gravity of

fine and coarse aggregate as per I.S. 2386 Part III 1963
table as per I.S. 712-1973

test
4
4
Nc
No
No
Appendices
110
2
14.
Flexural attachment to compression testing machine
15.
Core cutting machine
CONTROL OF PROFILE AND SURFACE EVENNESS
5.
2.
Survey level and

3
staff
metre straight-edge and measuring edge
set
set
3.
Unevenness indicator (optional)
4.
Camber templates
5.
Profilograph for checking pavement unevenness
6.
Automatic road unevenness recorder
Single lane
Double lane 2
OF TESTING EQUIPMENTS REQUIRED TO BE

MAINTAINED AT DIVISION/SUB DIVISION /FIELD, LEVEL
LIST
Requirement
S.
No.
Particulars
(1)
For testing
Set of I.S. Sieves
1.2
1.3
Sand replacement equipment

Core cutter
1.4
Field oven
1.5
Electric
oven
1.6
Proctor
Mould
1.7
Proctor needle
1.8
Balance
(ii)
1.9
1.10
1.12
1.13
~
_
& hammer
kg
gramms
CBR
(5
tonnes
CBR
Moulds
Equipment for testing LL
Speedy moisture motors
& PL
2 (Optional)
2
11
12
11
11
Pan balance (15 kg)

Load frame for testiqg
(2)
selection)
capacity)
1.11
Field (each
level
5 to 7
500
Sub DnI
soil
1.1
(1)
Dnl
level
9
1
For Testing Aggregate
2.1
Impact
equipment
2.2
Flakiness index testing equipment
test
Appendices
(3)
3.1
3.2
For Testing Concrete Mortar
& tamping rod
Slump cone
Moulds
(i)
12
70.7
12
12
mm
Proving ring for 1 ton

Proving ring for 5 tons
(i)
(ii)
(4)
mm
IQJ X
50 X 50 X 50
(ill)
moulds
150 X 150 X 150
70 X 7
(ii)
3.3
111
Bitumen
4.1
Test trays
4.2
Thermometers
12
4.3
Spring balance
FUNCTIONS OF THE DIRFXTOR QUALITY CONTROL

(1)
To
carry out the instructions of the Engineer-in-Chief/Chief Engineer
work audit, arrange seminars and training

nomination of the staff for outside training and
regarding policy matter,
programmes, help
in
as directed.
(ii)
(iii)
To
guidelines to
issue
regional
the
Quality
Control
Executive
Engineers and other staff from time to time.

To keep in touch with the latest developments on use of new mateQuality Control
rials
methods and
K & D
activities in the State
and
elsewhere.
(iv)
To frame and
organise the
training
programmes
for
the
new
entrants and in-service staff

(v)
To
analyse the reports received from the regional Quality Control
Officers
and
issue
necessary instructions to the officers concerned
with the works.

(iv)
To
arrange closer association with Quality Control aspects in case of
major projects for roads and bridges.
FUNCTIONS OF QUALITY CONTROL DIVISIONS

(i)
To
provide
all
assistance
to the field officers for
compliance of the
instructions contained in the Circular connected with quality control.

(ii)
(iii)
Inspection of works identified by Chief Engineer or
Superintending
Engineer concerned to ensure quality control.
To carry out tests on construction and road materials locally available and to suggest use of alternative materials.
(iv)
fv)
To
To
give suggestions for
mproving the quality at the site of work.

and road construction mate-
identify ihe various types of building
rials
available in a specified area or for the execution of a particular
While doing so the desired properties of the material and

economic viability of their use, should be kept in view.
To provide testing and investigation facilities to the field officers,
To educate and train the technical personnel engaged at construction
project.
also the
(vi)
(vii)
sites for
carrying out the field
tests.
Appendix 4
SAMPLE FORMS FOR QUALITY TESTS
for the
The samples of the suggested proformae lor recording the

undermentioned items of the work.
lest results
Road Works
(1)
Q/R/1
(2)
Q/R,2
Characterstics of
Borrow Materials
Compaction Characterstics of Earth Work/Gravel/Stabilized

layers
(3)
Q/R/3
Characterstics of Aggregate/Binding Material/Screening for
WBM (Surface, Base, and Sub-base)

(4)
Q/R/4
Characterstics of Bricks for Sub-base/Base Courses
(5)
Q/R/5
Aggregate Characterstics for Bituminous Courses
(6)
Q/R/6
(7)
Q/R/7
(8)
Q/R/8
(9)
QR
Coarse Aggregate for Concrete
Rate of spread of Binder, Aggregate and Bitumen content for

Bituminous work
Temperature Record
for Bituminous
Surface Evenness Record
(10)
Q/R/10
Fine Aggregates for Concrete
(11)
Q/R
Water
(12)
Q/R/12
Cement Concrete
Note
11
Work
for Bridge Construction
Frequency of the
test to
Works
be carried out shall be as per the requirement
prescribed in the handbook.
The
quality control records in the prescribed
proformae should be main-
numbered registers, issued to personnel in charge of quality

control tests on works in the same way as measurement books are issued.
These registers should be presented with every third running bill. The pay-
tained
in
ments of
serially
bills
should thus be linked with assured quality of work.
Appendices
113
U
u
do
Recorded
c/)
by
^<
con-
soil
ON
tent
Moist-
ure
comp1
acted
Lab
sity
Den-
)a3)no3 djn)
JOd^QOO
VO
1
snonsppG
<
OC
Ed
Ref
CBR
8
Ref
O
o
2
ctor
Disity
o
cc
OC
o
OQ
b
O
5"
T3
Ref
P.L
value
c/2
ill
H
E
H
(J
<
OC
<
X
OS
a 9
00
2e
through
g I ii
o
5
1
GRADING
passing
0.
Sl
s|
.2 f
û BM
U D Z
oC
OQ
o/
/O
J03JO0D pUBS
1
p3sn
SI
jBuajBui
qoiq/w ui
B3JB MOJJOq
|0
UOUBDOl
OM
-S
8"
ui^
Appendices
114
00
I
CO
U
H
OS
o
Z
S
12"
Z
o
.2
<
' I
ill
a>
60
o
u
So
II
a
.2
> ?
^ 3
i;
<u
W3 -
:3q
O O
2.
cs
CO <*5
JO
^
S s
Q
J?
*^ ^ JO
Appendices
115
8.
T3
00
^-
o
a
E
E
4>
CO
CO
Ou
Is
o
&0
*c
ro
0)
k<
u
C/3
00
.S
CO
5iE
O = C
o
00
00
BJ
00
>
Appendices
o
2
o
s
>
o
00
p
o
o
-
S
e
E
CM
'75
118
Appendices
Ref
.6
Be
VO
<N
*r%
to
<
X)
>
o
U
0^
Appendices
119
ed
.9
- 3
I
00
00
.n:
js ja
o o o ^ ^
*>
S S
b
i
2 = 5 3 5
eS
Ui
4)
5 u
eS
rt
>
a>
a a a
E E s e S
o O V V
HH H H H
!l
!l
II
^ ^
H H H
120
Appendices
121
Appendices
T -
3
O
00
00
Si
(J
X)
o
4>
5^1
îi
S S c
i o 3
>^
c
u
3
aa
Ui
X)
i/)
&8 3
O
Appendices
122
o
u
e00
a
V.C
11
^
At
oi
<
<
QW5
4>
<
C/5Z
<N
Appendices
III
e
*<=>
<^ is
ea
CM w
S JS
<=5
1)
a o
111
z
Soil
6
coZ
124
Appendices
.c
09
l-l
E
o
a
O
(tf
g >
a
is
^1
Appendix 5
PROCEDURE FOR CERTAIN FIELD CONTROL TESTS

NOT COVERED BY PUBLISHED STANDARADS
A.
TRAY TEST FOR CONTROL OF RATE OF SPREAD OF BINDER
Light metal trays of about 20 cm x 20 cm arid 3 cm deep previously

weighed and numbered are placed at intervals along the road in the path 6f
After the distributor has
.he binder distributor bet\\een the wheel tracks
passed, the trays are removed one wrapped in weighed sheets of paper so that
they can be handled, stocked and weighed as soon as convenient. The spacing
and the number of trays can be varied to suit the circumstances of the particular site, but at least five trays shall normally be used. The tray test gives a
measure of the variation in rate of spread along the road and a good approximation to the average rate of spread.
The trays shall be weighed correct

The maximum Kingitudinal distribution error
to first place of decimal in
be within
shall
gram.
10 per cent of
the specification.
Similarly,
transverse
number of
by the machine can be checked by
distribution
cm of the
width of the spray bar. The variation in transverse distribution shall not be
more than 20 per cent from the mean (not counting the extreme 15 cm at
either side of the sprayed area).
placing a
iravs to collect the binder sprayed over each 5
TRAY TEST FOR CHECK OF RATE OF SPRtlAD OF GRIT

SURFACE DRESSING
B.
he rate of spread of
grit
area covered by each lorry load of
by
gritters
known
IN
can be checked by measuring the
capacity.
This can also be checked by removing the chippings from small areas
road and weighing them. A sm til square metal frame is laid on the
new dressing and all the chippings within trie enclosed area which is 10 cm
square are collected and washed in solvent to remove the binder, weighed and
of
the
t f spread is measured
metre to 4 metre.
the rate
1
The
transverse
at points
variation
shall
along the road at intervals of between
be
less
than
20 per cent of the
mean.
C.
METHOD Of TEST FOR BINDER CONTENT FOR PAVING

MIXTURES BY CENTRIFUGE
The
intended for determination of binder content m the mix by

The mineral matter recovered from the test can be
used, for checking the gradation of the aggregates in the mix.
cold
test
solvent
is
extraction.
126
Appendices
A representative sample about 500 gm is exactly weighed aod placed

tbt bowl of the extraction apparatus and covered with commercial grade
of benzene. Sufficient time (not more than 1 hour) is allowed for the solvent
in
to disintegrate the
The
the edge
is
sample before running the centrifuge.
ring of the extractor
filter
and theî fitted around

clamped tightly. A beaker
dried, weighed
is
The cover of the bowl
of the bowl.
is
placed under to collect the extract.
The
machine
is
maximum
increased to a
revolved slowly and then gradually, the speed is

The speed is maintained till the
of 3600 r.p.m.
The machine is allowed to stop and

added and the above procedure is repeated.
solvent ceases to flow from the drain.
200 ml. of the benezene
A number
till
the extract
The
is
is
of 200 ml. solvent additions (not less than three) are used
and not darker than a light straw colour.
clear
from the bowl is removed, dried in air and then in oven

The fine materials that might
115^C, and weighed.
have passed through the filter paper are collected back from the extract
preferably by centrifuging.
The material is washed and dried to constant
weight as before. The percentage of binder in the sample is calculated as
filter
ring
to constant weight
follows
at
Percentage binder on the total mix
W\
weight of sample
where
f|^x=: weight of the sample after extraction
FF,=weight
of
fine
material,
recovered
from
the
extract
>f4= increase
in weight of the filter ring
In the case of road tar which is not completely soluble in benzene,

is made on the basis of the per cent insoluble of the neat
necessary correction
road tar
D.
in the solvent.
DETERMINATION OF IN-SITU DENSITY

CARPET BY ÂND POURING DEVICE
OF ASPHALTIC
The metallic tray of the field density unit is kept on a level spot of the
and a hole, 10 cm in dia, is cut to the entire thickness of the
All materials removed from the hole are carefully collected and
carpet.
surface
weighed.
A known
52
B.S.
Steve,
directly over
is
weight of dry standard sand, passing 25 and retained on

taken in the sand pouring cylinder. The cylinder is kept
the hole and the shutter of the cylinder
is
released without any
127
Appendices
jerk and closed
when
the hole
is
filled
with the sand.
sand in the cylinder as well as the quantity

cylinder are weighed.
residual
The
in-situ density
where
of the carpet
^
Density
A =
is
The qauntity of the
filling
the cone of the
calculated as follows
gm
per cc.
weight of the materials removed from the carpet hole
W = initial weight of sand taken in the cylinder

Wx = weight of the sand filling the cone of the cylinder
d = bulk density, gm per cc of the sand
Wt ^
weight or sand remaining in the cylinder
Appendix 6
PROCEDURE FOR CHECKING SURFACE

REGULATING USING A STRAIGHT-EDGE
The procedure
straight-edge
(i)
is
be followed for checking the surface regularity with a
The 3-metre straight-edge may be made of steel or seasoned hard

wood When made of wood, it may be 75 mm wide and 125 mm
deep and its test face should preferably be shod with a metallic
plate.
The edge should be perfectly straight and free from warps,
defects of any kind.
rots or
(ii)
to
as follows
be checked for its truentss

master straight-edge. The straightedge should be rectified/replaced as soon as the same has lost its
Periodically, the straight-edge should
a string or a metallic
with
trueness.
(iii)
The depressions under the straight-edge are to be measured with a

graduated wedge. The wedge should preferably be metallic but
may alternatively be of seasoned hard wood. These should be
graduated to read undulations upto 25
with a least count of
mm
at
least
mm.
Typical designs for a
measuring edge are given

(iv)
For recording undulations

edge
is
to be placed
metallic staight- edge
and
in Fig. 4.
in the
longitudinal
longitudinally
parallel
to
the straight-
profile
the centre
line
of
Measurements along two parallel lines may normally

be sufficient for a siggle-lane pavement and along three lines for
the two-lane pavement. One additional line may be covered for
the road.
each additional lane.

(v)
The straight-edge has

of undulations at
made
(vi)
The
limitations
vertical curves.
for this purpose especially
straight-edge
inserted between
it
may
if
as regards the measurement
Additional templates
be placed at the starting point,
and the
test
may be
the curves are sharp.
surface where the gap
is
wedge
maximum
The edge may then be slided forward by

about J length, i.e., 1.5 m, and the wedge reading repeated. This
process should be continued. The straight-edge need not always
be moved forward but may be moved backward and forward to
record the maximum undulation existing at a location. Locations
with undulations in excess of the specified magnitude should be
and reading taken.
marked on
the surface.
129
Appendices
(vii)
team of three persons consisting of two
workmen
supervisor and equipped with one straight edge and
wedges would be required.
The two workmen
and a
two graduated
will
operate
straight-edge while the supervisor will take measurements
wedges and do the marking on the surface.
the
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HANDBOOK OF QUALITY

CONTROL FOR CONSTRUCTION

c)igitized by the Internet Archive

INDIAN ROADS CONGRESS

and Translation are reserved)

India Offset Press,

Bituminous Surface Courses

Control of Alignment, Profile and

List of Standards/Specifications of Indian

referred to in the text

Range of equipment required for a testing

Procedure for certain field control tests

standards of Bureau of Indian

Standards and other bodies referred to

for quality tests

Procedure for checking surface regularity

materials and product is an

Quality control of construction

essential requirements for obtaining

(1) that quality control

of materials and the end product together with

involved should form an integral

of road and runway projects, and that materials

wherever necessary, the existing specifications be reviewed so

be provided in the form of either a

a Committee of experts be set up to prepare a

the details of quality control code

reviewed periodically based on experience gained;

term training programmes be organised to provide the

requisite trained personnel for quality control.

pursuance of Resolution No.

constituted for drafting the

(1) Shri S.N. Sinha

(3) Shri J. Datt

Dr. M.P. Dhir

tees to prepare drafts of various Sections.

that, before finalising the Handbook, its

with responsibility of preparing the

tion to the delegates attending the National Seminar.

discussed by the Committee and

National Seminar were

Shri T.K. Natarajan and Dr.

The draft prepared by the Subcommittee was discussed by

The Manual was

revised in 1977 (First

rate the new standards on surface evenness approved by the I.R.C.

observation/test results by the field officers.

for Quality Control

part of any production

ensuring a more economical

cost of exercising quality

cent of the construction cost.

fraction of the resulting

the other hand, the

of materials, also affords a

significant reduction in user costs, in

that quality control, besides

economic return from

quality control could be of the order of 5 to 10 per cent of the total

construction cost and even more.

prc-requisites for effective

control of highway construc-

effective quality control.