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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

1.0 OBJECTIVE

The purpose of this method statement is to describe the activities and methods, which
will be used to carry out FLEXIBLE PAVEMENT (Rehabilitation and Resurfacing).

2.0 CONSTRUCTION METHOD

The sequence of the work to be carried out shall be as follows:-

2.1 General Requirements
2.2 Resurfacing Works
2.3 Partial Reconstruction Works
2.4 Total Reconstruction Works
2.5 Cold In-Place Recycle (CIPR) – Cement Treated Base
2.6 Cold In-Place Recycling (CIPR) – Foamed Bitumen
2.7 Hot In-Place Recycling (HIPR)

2.1 General Requirements

2.1.1 Before starting full-scale work, a trial lay is required to ensure that
the asphaltic mixture will be produced according to the design mix
specification and familiar with the actual operations on site.

2.1.2 An electronic sensor paver shall be used for laying of asphaltic

pavement. Laying temperature shall be in the range of 125o C and
170o C.

2.1.3 Compaction shall be carried out using the specified equivalent type
of rollers and compacted in accordance with the specification.

2.1.4 Rolling shall be commenced from the lower to the higher side. The
final rolling temperature shall not less than 110o C.

2.1.5 The surface of asphaltic pavement shall be finished to the grade

and line as required and a joint survey shall be carried out to
confirm these.

2.1.6 Coring shall be carried out to determine the compaction 24 hours

after laying.

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Revision No. : 1.0 Revision Date : 1/11/2002
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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.2 RESURFACING WORKS

2.2.1 Demarcation on site shall be carried out to determine the extend of
repair area.

2.2.2 Joint survey on existing pavement shall be carried out prior to the
commencement of milling works.

2.2.3 Milling out of the existing to a depth of not exceeding 110mm or as

shown in the accompanying drawings.

2.2.4 The surface to receive the premix shall be cleaned, free from dirt,
loose materials and standing water.

2.2.5 Supply and apply bituminous Tack Coat prior to the laying of
ACBC. The spray rate of the Tack Coat shall be between 0.15 to
0.30 liters/sq.m.

2.2.6 The approved premix shall be delivered to site by tipper trucks. To

prevent loss of heat, the mixture shall be covered by tarpaulin.

2.2.7 Supply, lay and compact ACBC as specified thickness including

necessary regulating works. Materials and workmanship shall be as
per specification. The ACWC shall be laid the next day after
completion of ACBC.

2.2.8 Supply and apply bituminous tack coat prior to the laying of ACWC.

2.2.9 Supply, lay and compact ACWC as specified thickness including

the necessary regulating works. Materials and workmanship shall
be as per specification.

2.2.10 Asphaltic concrete shall not be opened to traffic until compaction

has been completed and the materials has thoroughly cooled and
set in the opinion of the Engineer’s representative. This is usually
not less than 4 hours from the initial of rolling.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.3 Partial Reconstruction Works
2.3.1 Demarcation on site shall be carried out to determine the extend of
repair area.

2.3.2 Joint survey on existing pavement shall be carried out prior to the
commencement of milling and excavation works.

2.3.3 Milling and excavate out of the existing asphalt and road-base
layers to a required depth or as shown in the accompanying
drawings.

2.3.4 In the event of inclement weather a “drainage channel” cut through

the shoulder to prevent water ponding on the milled/excavated
surface.

2.3.5 Preparing the existing unbound base course for the application of
the DBM. This preparation consists of (a) proof rolling to identify
weak areas in the unbound base, (b) repairing the unbound base in
weak areas using crushed stone, (c) further rolling to meet density
requirements.

2.3.6 The surface to receive the premix shall be cleaned, free from dirt,
loose materials and standing water.

2.3.7 Supply and laying of prime coat/tack coat on the prepared unbound
base, and allowance for a curing period.

2.3.8 Supply, lay and compact DBM layer with a nominal maximum stone
size of 40 mm to required thickness.

2.3.9 Supply and apply bituminous Tack Coat prior to the laying of
ACBC. The spray rate of the Tack Coat shall be between 0.15 to
0.30 liters/sq.m.

2.3.10 The approved premix shall be delivered to site by tipper trucks. To

prevent loss of heat, the mixture shall be covered by tarpaulin.

2.3.11 Supply, lay and compact ACBC as specified thickness including

necessary regulating works. Materials and workmanship shall be as
per specification. The ACWC shall be laid the next day after
completion of ACBC.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.3.12 Supply and apply bituminous tack coat prior to the laying of ACWC.

2.3.13 Supply, lay and compact ACWC as specified thickness including

the necessary regulating works. Materials and workmanship shall
be as per specification.

2.3.14 Asphaltic concrete shall not be opened to traffic until compaction

has been completed and the materials has thoroughly cooled and
set in the opinion of the Engineer’s representative. This is usually
not less than 4 hours from the initial of rolling.

2.4 TOTAL RECONSTRUCTION

2.4.1 Demarcation on site shall be carried out to determine the extend of
repair areas.

2.4.2 Joint survey on existing pavement shall be carried out prior to the
commencement of milling and excavation works.

2.4.3 Milling and excavate out of the existing asphalt, road-base and
unsuitable sub-grade layers to a required depth or as shown in the
accompanying drawings.

2.4.4 All formation and Sub-base/upper-base preparation shall be

followed specification.

2.4.5 In the event of inclement weather a “drainage channel” cut through

the shoulder to prevent water ponding on the milled/excavated
surface.

2.4.6 The surface to receive the premix shall be cleaned, free from dirt,
loose materials and standing water.

2.4.7 Supply and laying of prime coat/tack coat on the prepared unbound
base, and allowance for a curing period.

2.4.8 Supply, lay and compact DBM layer with a nominal maximum stone
size of 40 mm to required thickness.

2.4.9 Supply and apply bituminous Tack Coat prior to the laying of
ACBC. The spray rate of the Tack Coat shall be between 0.15 to
0.30 liters/sq.m.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.4.10 The approved premix shall be delivered to site by tipper trucks. To
prevent loss of heat, the mixture shall be covered by tarpaulin.

2.4.11 Supply, lay and compact ACBC as specified thickness including

necessary regulating works. Materials and workmanship shall be as
per specification. The ACWC shall be laid the next day after
completion of ACBC.

2.4.12 Supply and apply bituminous tack coat prior to the laying of ACWC.

2.4.13 Supply, lay and compact ACWC as specified thickness including

the necessary regulating works. Materials and workmanship shall
be as per specification.

2.4.14 Asphaltic concrete shall not be opened to traffic until compaction

has been completed and the materials has thoroughly cooled and
set in the opinion of the Engineer’s representative. This is usually
not less than 4 hours from the initial of rolling.

2.5 COLD IN-PLACE RECYCLING (CIPR) - CEMENT TREATED BASE

2.5.1 Description
This Work shall include the breaking, mixing compacting and shaping the
cement stabilized base course in accordance with this specification and
the lines, levels, grades, dimensions and cross-sections shown on the
drawings and/or as required by the Engineer.

2.5.2 Setting up the Recycling Train

Recycling should only commence once all preliminary requirements have
been met. These include, in order of sequence:

• A thorough check on all machines and equipment to be used in the

recycling operation, including rollers and water tanker.
• The bags of cement based on calculation, shall be placed at regular
internal along stretch of works.
• Check that the recycling operator has all the data concerning the rate
of application of stabilizing agents for keying into the computer, that
there is a clear guideline for the full length of cut and that all start-up
procedures are clearly understood.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.5.3 Preparatory Works
Prior to the commencement of works, the areas should be thoroughly
investigated and checked. Presence of any underground utilities
especially cabling work shall be detected and marked in order to avoid
damaged during the mixing operation. Any utilities that could not be
avoided during the stabilization operation, relocation works need to be
done.

2.5.4 Coring and Investigation

Coring need to be done to identify the thickness of the existing pavement.
Upon identify the thickness of each of the pavement layer, the thickness of
the asphalt and the existing crusher run base in the vicinity of the
determined recycle stabilization areas should be taken for sieve analysis
and laboratory compaction. The dosage of stabilizing agent such as
Ordinary Portland Cement (OPC) to be applied in respect to the required
strength shall be pre-determined in the Laboratory by Unconfined
Compression Strength Test.

2.5.5 Pre-Treatment
If the base is wet and above the Optimum moisture content, the base
material need to be pre-treated. The process of pre-treatment using the
stabilizer machine or any other mechanical mean approved by the
Engineer is by pulverized the base material to dry-out the material until
below the Optimum moisture Content before the process of spreading the
cement for stabilization.

2.5.6 Spreading of Stabilization Agent

The determined recycle stabilization areas shall be marked and the
required quantity of cement shall be spread over the areas. If case of the
stabilization area is small, spreading could be done manually, in order to
reduce the spreading cost. To have a uniform spreading, the cement
bags shall be placed in areas that already been marked off, opened and
spread with a rake or other mechanical mean alike.

The Ordinary Portland Cement (OPC) or any other stabilizing agent in

powder form shall be spread with the mechanical spreader in order to get
a better production of the works.

The quantity of the cement for recycle stabilization area shall be spread
manually to the required design.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

The rotor of stabilizer shall be so adjusted that the required thickness of
breaking and mixing is achieved after compaction. The area near edge of
the pavement shall be worked by shifting the rotor of the stabilizer
sideways, the maximum offset outward from machine wheel is 35cm on
either side.

2.5.7 Breakdown Compaction

When necessary to have a break-down compaction after mixing,
pneumatic tired roller shall be used for break-down compaction.
Sprinkling of water from pneumatic tired roller shall be permitted to obtain
the Optimum Moisture Content (OMC) during the break-down compaction.

Vibrating roller with 20 t static mass ideal is use with rolling pattern of 2
passes static and 6 passes vibration. Moisture content is the most critical
variable in achieving densification with minimum effort. Due to the time
delay between recycling and finishing off, a light application of water
should always be applied to the surface before final rolling.

2.5.8 Trimming and Compaction

• Immediately after break-down compaction (if require), undulations shall
be eliminated by a motor grader. Further compaction by a pneumatic
tired roller or a viabratory roller shall be used for full pavement
compaction. To achieve best suitable compaction the moisture content
of the mixture should be controlled to an about of Optimum Moisture
Content (OMC). Fine trimming by motor grader to obtain the required
level after final compaction. Final smooth rolling by pneumatic tired
roller to knead down any loose material left over on the surface.

2.5.9 Prime Coating

After compaction of the above operations, prime coat of cationic
Bituminous Emulsion with Bitumen content not less than 58% shall be
sprayed at the rate 0.5L/m2 – 1.0L/m2.

2.5.10 Trial Area

Prior to the commencement of site works, it is recommended a trial area
shall be carried out to establish the rolling method, required to produce the
specified field density. The established method thereafter shall be used
be used as a standard for site control.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.6 COLD IN-PLACE RECYCLING (CIPR) – FOAM BITUMEN

2.6.1 Description
This Work shall include the breaking, mixing compacting and shaping the
foamed bitumen stabilized in accordance with this specification and the
lines, levels, grades, dimensions and cross-sections shown on the
drawings and/or as required by the Engineer.

2.6.2 Setting up the Recycling Train

Recycling should only commence once all preliminary requirements have
been met. These include, in order of sequence:

• A thorough check on all machines and equipment to be used in the

recycling operation, including rollers and water tanker.
• The bags of cement based on calculation, shall be placed at regular
internal along stretch of works.
• Check that the recycling operator has all the data concerning the rate
of application of stabilizing agents for keying into the computer, that
there is a clear guideline for the full length of cut and that all start-up
procedures are clearly understood.

2.6.3 Preparatory Works

Prior to the commencement of works, the areas should be thoroughly
investigated and checked. Presence of any underground utilities
especially cabling work shall be detected and marked in order to avoid
damaged during the mixing operation. Any utilities that could not be
avoided during the stabilization operation, relocation works need to be
done.

2.6.4 Coring and Investigation

Coring need to be done to identify the thickness of the existing pavement.
Upon identify the thickness of each of the pavement layer, the thickness of
the asphalt and the existing crusher run base in the vicinity of the
determined recycle stabilization areas should be taken for sieve analysis
and laboratory compaction. The dosage of stabilizing agent such as
Ordinary Portland Cement (OPC) and foamed bitumen to be applied in
respect to the required strength shall be pre-determined in the Laboratory
by Indirect Tensile Test.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.6.5 Pre-Treatment
If the base is wet and above the Optimum moisture content, the base
material need to be pre-treated. The process of pre-treatment using the
stabilizer machine or any other mechanical mean approved by the
Engineer is by pulverized the base material to dry-out the material until
below the Optimum moisture Content before the process of spreading the
cement for stabilization.

2.6.6 Spreading of Stabilization Agent

The determined recycle stabilization areas shall be marked and the

required quantity of cement shall be spread over the areas. If case of the
stabilization area is small, spreading could be done manually, in order to
reduce the spreading cost. To have a uniform spreading, the cement
bags shall be placed in areas that already been marked off, opened and
spread with a rake or other mechanical mean alike.

The Ordinary Portland Cement (OPC) or any other stabilizing agent in

powder form shall be spread with the mechanical spreader in order to get
a better production of the works.

The quantity of the cement for recycle stabilization area shall be spread
manually to the required design.

The binder properties for foamed asphalt material shall be bitumen grade
80/100 penetration and temperature during foaming is between 160oC –
180oC.

The bitumen tanker shall consist of heating system capable to raise the
temperature of the bitumen by at least 20oC per hour.

The actual bitumen and water content to produce foam asphalt shall be
determined at laboratory prior mixing in-situ will be carried out.

The rotor of stabilizer shall be so adjusted that the required thickness of

breaking and mixing is achieved after compaction. The area near edge of
the pavement shall be worked by shifting the rotor of the stabilizer
sideways, the maximum offset outward from machine wheel is 35cm on
either side.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

2.7 HOT IN-PLACE RECYCLING (HIPR)
2.7.1 Description of works

HIPR or Hot In-Place Recycling is a method of road rehabilitation where

existing pavement is recycle and laid back in one single pass. The
process is most suitable to rehabilitate pavement experiencing functional
distress i.e. surface cracking, minor rutting and shoving etc.

2.7.2 HIPR Process and Construction Method

The existing pavement is heated between 90oC – 100oC to soften the

bituminous surface layer. Clusters of infrared heaters fed with propane
gas which radiate thermal energy onto the wearing course surface shall do
the pre-heating process.

Additional heater banks on the Remixer heat the asphalt wearing course
to the working temperature of about 120oC – 140oC.

The surface temperature can be effectively controlled via the variable gas
pressure, heater bank height and forward speed.

The rotating scarifier fitted with spirally shaped carbide-tipped scarify the
surface to the required depth.

New virgin material and rejuvenator will be added into the pug-mill where
thorough mixing is done. The amount of this two materials is controlled
electronically and shall be followed the approved mix design.

The final remixed materials is discharge from the pug-mill in the windrow
and evenly spread over the heated surface with a vibrating and temping
screed.

The Remix asphalt shall not be opened to traffic until compaction has
been completed and the materials has thoroughly cooled and set in the
opinion of the Engineer’s representative. This is usually not less than 4
hours from the initial of rolling.

2.7.3 Trial Area

Prior to the commencement of site works, it is recommended a trial area
shall be carried out to establish the rolling method, required to produce the
specified field density. The established method thereafter shall be used
be used as a standard for site control.

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METHOD STATEMENT

FLEXIBLE PAVEMENT (REHABILITATION)

3.0 PLANT AND EQUIPMENT

Type of machineries required,

i. Back pusher with power broom

ii. Diamond Cutter and jack hammer
iii. Milling Machine
iv. Water tanker
v. Air compressor
vi. Bituminous Tack Coat distributor
vii. Tipper lorries
viii. Asphalt paver
ix. Tandem roller & Pneumatic tyre roller
x. Recycler
xi. Bitumen Tanker
xii. Motor Grader
xiii. Pre-heater
xiv. Remixer

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