b.6.9 - Std. Specification Asphalt Road

Page 1 of 21
HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI REFINERY
DHT PROJECT – OSBL FACILITIES
TITLE : SPECIFICATIONS FOR ASPHALT ROAD
DOCUMENT NO. : 44LK-5100-00/C.02/1118/A4
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
A 25/10/2008 21 ISSUED FOR TENDER DK SSP MBR
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Pages 2 of 21 Specification for Asphalt Road HPCL, Mumbai
Standard Specification 44LK5100
Doc.no.44LK-5100-00/C.02/1118/A4
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE OF WORK
3.0 TECHNICAL REQUIREMENTS
3.1 SETTING OUT & LEVELLING

3.2 CLEARING & STRIPPING
3.3 PREPARATION OF SUBGRADE
3.4 EMBANKMENT & GRADING BACKFILLING MATERIAL
3.5 FILLING & COMPACTION
3.6 PREPARATION OF GRANULAR SUB BASE & BASE USING WATER BOUND MACADAM
3.6.1 GRANULAR SUB BASE
3.6.2 GRANULAR BASE
3.7 PRIME COAT & TACK COAT
3.8.a BITUMINIOUS MACADAM
3.8.b DENSE BITUMINOUS MACADAM
3.9 PREMIX CARPET
3.10 TOP WEARING /SEAL COAT
3.11 SEMI DENSE BITUMINOUS CONCRETE
3.12 BITUMINOUS CONCRETE
3.13 POINTS TO BE NOTED BY THE CONTRACTOR WHILE CARRYING OUT WBM &
BITUMINOUS LAYERS
APPENDIX - A
APPENDIX - B
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HPCL, Mumbai Specification for Asphalt Road Pages 3 of 21
44LK5100 Standard Specification
Doc.no.44LK-5100-00/C.02/1118/A4
1.0 PURPOSE
The purpose of this document is to state the requirements of materials, workmanship,

plant & equipments, test & construction procedure to be followed carried out during the
asphalt road/ paving works.
2.0 SCOPE OF WORK
This specification covers the supply, preparation of sub base, base & top bituminous
courses, requirements of materials, necessary equipments, testing, transportation, etc., for
asphalt / paving works.
3.0 TECHNICAL REQUIREMENTS
All the materials & construction procedures adopted for asphalt road/paving works shall
conform to MORT & H specifications & IRC 37.
3.1 SETTING OUT & LEVELLING
The Contractor shall be responsible for accurate and proper setting out of the work with
respect to dimensions, alignments and levels of the work in conformity with the drawings.
The Contractor at his own cost shall be provide all necessary instruments, equipment,
labours for this purpose. Any error discovered, at any time, during the progress of work or
thereafter, in the dimensions, alignment or level of part or all of work, the Contractor shall
at his own expense rectify the errors to the satisfaction of the Owner/Consultant. Any
checking of line or level by the Owner/Consultant shall in no way relieve the Contractor of
his responsibilities.
3.2 CLEARING & STRIPPING
The Contractor shall clear the site of all shrubs, roots and grass or any vegetation and any
other organic/non-organic impurities. At least minimum 150 mm thick top soil to be
removed. The exposed surface (subgrade) shall be consolidated properly to obtain 90 %
of maximum laboratory dry density of soil.
Any kind of under ground construction, which is existing in place & is an obstruction to
the future construction activities shall be removed.
3.3 PREPARATION OF SUBGRADE
The preparation of subgrade includes all operations before the pavement structure to be
laid over it and compacted. Thus the preparation of subgrade would include site clearance,
grading (embankment or cut section) and compaction to desired density at optimum
moisture. The subgrade may be situated on embankment, excavation or at the existing
ground surface. In all cases the Contractor shall clear the site of all shrubs, roots and
grass or any vegetation and any other organic/non-organic impurities, minimum 150mm
thick topsoil to be removed. The exposed surface (subgrade) shall be consolidated
properly to obtain 90% of maximum laboratory dry density of soil. Any kind of underground
construction, which is existing in place & is an obstruction to the future construction
activities, shall be removed.
The grading operations shall be started thereafter so as to bring the profile of the subgrade to
designed grade and compaction where necessary. The original ground shall be leveled to
facilitate placement of first layer of embankment, scarified, mixed with water and then
compacted by rolling so as to achieve minimum specified dry density.
If the difference between the subgrade level (top of the subgrade on which pavement rests)
and ground level is less than 0.5m and the ground does not have 95% relative compaction

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with respect to the dry density as given in Table below, the ground shall be loosened upto a
SUBGRADE level 0.5m below the subgrade level, watered and compacted in layers in
accordance with MoRT&H Clause 3.4 to not less than 90% of dry density as given in Table
below.
Any unsuitable material occurring in the embankment foundation shall be removed and
shall be replaced by approved materials laid in layers to the required degree of
compaction, as directed by engineer.
Embankment or subgrade work shall proceed after the inspection by the Engineer for
satisfactory condition and approved.
COMPACTION REQUIREMENTS FOR EMBANKMENT AND
Type of work / material Relative compaction as percentage

of max. laboratory dry density as per
IS:2720 ( Part 8 )
1) Subgrade and earthen shoulders Not less than 97
2) Embankment Not less than 95
3) Expansive clays
a) Subgrade and 500mm portion just Not allowed
below the subgrade
b) Remaining portion of Not less than 90
embankment
3.3.1 Gradation Requirement for Soil in Embankment
The size of the coarse material in the mixture of earth shall ordinarily not exceed 75mm when
being placed in the embankment at his discretion permit the use of material coarses than
this also if he is satisfied that the same will not present any difficulty as regards the placement
of fill material and its compaction to the requirements of these specifications. The maximum
particle size shall not be more than two-third of the compacted layer thickness.
The following type of material will be considered unsuitable for filling.

1. Material with vegetation and shrubs
2. Material in frozen condition or susceptible to combustion
3. Safety material resulting in leaching of embankment.
4. Any material which classifies as CH, OH, OI, LI as per IS:1498
5. Material with swelling index more than 50 as per IS: 2720 part-40
3.4 EMBANKMENT AND GRADING BACK FILLING MATERIAL
3.4.1 The fill material shall be granular, well graded compactable and possess good drainage
characteristics, and no swelling properties. It shall be free of vegetation, any organic matters
and other impurities. In extra ordinary circumstances expansive soil of acceptable free swell
index, generally less than 50 % may be used, however approval shall be sought from the
central engineering office on case to case basis. Use of expansive soil, as a fill material shall
be limited to a depth of at least 500 mm below the sub grade level. All relevant test, such as
optimum moisture content, maximum dry density, liquid limit , plastic index shall be carried
out as per IS 2720 to determine the suitability of the fill material.
3.4.2 The suitability of proposed fill material shall be tested to determine optimum moisture
content, However filling material shall have Liquid limit between 20-35 and Plasticity
index shall not be more than 12 & dry density shall be minimum 1.70gm/cc. The
material finer than 75 microns shall be limited to a max. of 35 % & clay percent within
fines shall be limited to 15 %. All these testing cost shall included in contractors scope.

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3.4.3 If top soil encountered is of clay or swelling in nature. The top soil removal guidance shall
be referred in site grading drawing and removed area shall be back filled with cohesive-
non-swelling soil. The properties of such soil shall be as per Appendix-A attached here
with
3.4.4 Expansive clay exhibiting marked swell and shrinkage properties (‘free swelling index’
exceeding 50 per cent when tested as per IS: 272 – Part40) shall not be used as fill
material.
3.4.5 For non expansive sub-grade compaction shall be carried out to 95 % of lab dry density of
Optimum moisture content.
3.5 FILLING AND COMPACTION
3.5.1 The fill shall be constructed in layers, each layer being compacted to the required density
before the next layer is laid. The compacted thickness shall be 200mm for each layer.
3.5.2 Compaction shall be carried out using 10 Mt static road roller. The Contractor shall
determine the number of passes of the roller required to achieve the required density by
first conducting trials over a test stretch. Vibrating roller of 80-100 KN static weight shall
be used if faster compaction is required. Precaution to be taken about adjacent property.
The compaction can be done using mechanical rammers or manual ramming in places
where road roller access is not possible as per directions of engineer.
The number of passes shall be reviewed and adjusted in consultation with the site
in-charge as required during the course of the work.
3.5.3 All lumps and clods in the fill material shall be broken before rolling. The top surface of
each layer shall be roughened before placing the subsequent layer to ensure proper
keying in between layers.
3.5.4 Prior to rolling, the moisture content of the material shall be brought to within +1 / -2% of
the optimum moisture content.
3.5.5 Each layer shall be compacted at least 95% of modified proctor density for embankment &
for subgrade and shall posses minimum dry density 1.70 gm/cc for subgrade &
embankment.
If the layer fails to meet required density, the failed part shall be reworked to achieve
the specified density. In future any settlement occurs due to improper compaction,
Contractor shall rectify at his own cost. Minimum one test for every 500 sq.m. filling area
shall be conducted.
3.6 PREPARATION OF GRANULAR SUB-BASE & BASE USING WATER BOUND

MACADAM
3.6.1 Granular sub-base

Sub-base to be prepared by filling supersaturated river sand/stone grit/murrum/granular
soil or mixture of all, in case of murrum & soil the liquid limit & plasticity index shall be less
than 20 & 6 respectively, complete as per drawing. The compaction shall be in layers to
get 98 % relative density after sprinkling required quantity of water. The consolidation shall
be done using 8-10 ton roller as per the camber required. Suitable thickness of Sub-base
shall be selected as per SOAK CBR VALUE available at site. The gradation and CBR
value of the material to be used for sub-base shall be as per Table 1A / 1B.

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Table 1A
Grading for Close Graded Granular Sub-base materials
IS Sieve Designation Per cent by weight passing the IS sieve
Grading I Grading II Grading III

75.0 mm 100 -- --
53.0 mm 80-100 100 --
26.5 mm 55-90 70-100 65-95
9.50 mm 35-65 50-80 50-80
4.75 mm 25-55 40-65 40-65
2.36 mm 20-40 30-50 20-35
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
CBR Value (Min) 30 25 20
Table 1B
Grading for Coarse Graded Granular Sub-base materials
IS Sieve Designation Per cent by weight passing the IS sieve
Grading I Grading II Grading III

75.0 mm 100 -- --
53.0 mm 100
26.5 mm 55-75 50-80 100
9.50 mm
4.75 mm 10-30 15-35 25-45
2.36 mm
0.425 mm
0.075 mm < 10 < 10 < 10
CBR Value (Min) 30 25 20
Note : The material passing 425 micron (0.425 mm) sieve for all the three gradings when tested
according to IS : 2720 (Part 5) shall have liquid limit and plasticity index not more than 25
and 6 per cent respectively.
3.6.2 Granular base

Granular base shall be made out of coarse aggregate crushed from hard rock or broken stone
metal and shall meet physical & chemical properties as per table-2 & table-3 respectively. The type
and sizes range of aggregates shall be as per grade listed in table-4.The interstice shall be filled
completely with murrum, liquid limit less than 20,plasticity index less than 6 and fraction passing
75 micron sieve shall not exceed 10%. In absence of murrum of the above characteristics
aggregate grit shall be used. The grading of screenings shall be Type A for grading 1 & 2, Type B
for grading 3 as per table 5, the layer to be compacted with 3 wheeled power rollers of 10 tonne.
Suitable thickness of Granular-base shall be selected as per SOAKED CBR VALUE available at
site. The work shall be carried out as specified in clause 404 of MORTH specification.
3.6.2.a Screenings :-
Screening to fill voids in the coarse aggregate shall generally consist of the same
material as the coarse aggregate. However, where permitted, predominantly non-plastic
material such as moorum or gravel (other than rounded river borne material) may be
used for this purpose provided liquid limit and plasticity index of such material are below
20 and 6 respectively and fraction passing 75 micron sieve does not exceed 10 per cent.
Screening shall conform to the grading set forth in Table below.
The use of screening shall be omitted in the case of soft aggregates such as brick
metal, kankar, laterites, etc. as they are likely to get crushed to a certain extent under
rollers.

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Table 5
GRADING FOR SCREENINGS
Grading Size of IS Sieve Per cent by weight passing

Classification Screening Designation the IS Sieve
A 13.2 mm 13.2 mm 100
11.2 mm 95-100
5.6 mm 15-35
180 micron 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180 micron 15-35
TABLE 2 PHYSICAL REQUIREMENTS OF COARSE AGGREGATES
Test Test method Requirements
Los-angeles abrasion value IS-2386 Part-4 40 % max
Aggregate impact value IS-2386/ IS-5640 30% max
Flakiness index IS-2386 15% max
Elongation index IS-2386 30%max
TABLE 3 CHEMICAL REQUIREMENTS OF COARSE AGGREGATES
Chemical stability To comply with requirements of appendix of BS : 1047
Sulphur content Max 2% (Not applicable for crushed stone aggregate)
Water absorption Max 2%
TABLE- 4 GRADING REQUIREMENTS OF COARSE AGGREGATES.
Grading no. Size Range IS Sieve Designation Per cent by weight passing
1 90 mm to 45 mm 125 mm 100
90 mm 90-100
63 mm 25-60
45 mm 0-15
22.4 mm 0-5
2 63 mm to 45 mm 90 mm 100
63 mm 90-100
53 mm 25-75
45 mm 0-15
22.4 mm 0-5
3 53 mm to 22.4 mm 63 mm 100
53 mm 95-100
45 mm 65-90
22.4 mm 0-10
11.2 mm 0-5
Note : Use of grading I shall be restricted to construction of sub-base course only. The
compacted thickness for a layer with Grading 1 shall be 100 mm while for layer
with other Gradings i.e. 2 and 3, it shall be 75 mm.

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3.7 PRIME COAT & TACK COAT
The spraying of single prime coat of low viscosity liquid bituminous material on well graded
granular base(WBM coarse). The prime coat is bitumen emulsion complying to IS-8887
grade 60/70 bitumen and shall be sprayed at the rate of 0.9 Kg/sq.m. Tack coat shall be of
bitumen emulsion conforming to IS-8887 and shall be sprayed at 0.3 Kg/sq.m.
Bituminous material shall not be applied during a dust storm or when weather is foggy,
rainy/windy or when temperature in the shade is less than 10 degree centigrade.
3.8.a BITUMINOUS MACADAM

The bituminous macadam should be laid in 50 mm thickness.
The base on which the bituminous macadam is to be placed shall be prepared, shaped &
compacted to required profile over which the prime coat & tack coat to be applied as described
in clause no. 3.6.
The bitumen to be used for bituminous macadam shall conform to IS 73 and shall be of 60/70
grade. The coarse aggregates to be used shall be clean, hard, durable & cubical shaped.
The fine aggregate shall be consist of crushed or naturally occurring material or combination
of two passing through 2.36 mm sieve & retained on 75 micron sieve. They shall be clean,
hard & durable.
The mix shall be as per table given below:-
COMPOSITION OF BITUMINOUS MACADAM
Mix designation nominal Grading 2
19 mm
Aggregate size layer
Thickness IS Sieve(mm) Cumulative % by weight of total aggregate
passing
26.5 100
19 90-100
13.2 56- 88
4.75 16-36
2.36 4-19
0.3 2-10
0.075 0-8
Bitumen content % by wt. 3.3-3.5

Of total mixture
Anti-stripping agent As per Appendix B
PHYSICAL REQUIREMENTS FOR COARSE AGGREGATES FOR BITUMINOUS

MACADAM
Property Test Specification
Cleanliness Grain size analysis max 5 % passing 0.075 mm sieve
Particle shape Flakiness & elongation index max. 30 %
(combined)
Strength Los angeles abrasion value max. 40 %
Aggregate impact value max. 30%
Durability Soundness
Sodium sulphate max. 12 %
Magnesium sulphate max. 18 %
Water absorption water absorption max. 2 %
Stripping Coating & stripping of bitumen minimum retained coating
95%
Aggregate mixtures
Water sensitivity Retained tensile strength min. 80 %

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The aggregates shall be proportioned & blended to produce a uniform mixture complying with
the requirement of the above table.
Mixing of aggregate & bitumen shall be in accordance with 3.8.1 Compaction shall be
continued till the density achieved is 95% of Marshal density and should be completed before
the temperature of mix falls below 90°C.
3.8.b DENSE BITUMINOUS MACADAM
Scope
This work shall consist of construction in single layer of DBM on previously prepared basel
sub-base. The thickness of layer shall be 50mm to 100mm. The work shall be carried out as
specified in clause 505 of MORT&H.
Materials
Bitumen :-
Bitumen shall be paving bitumen of 60/70 grade as per IS : 73.

Coarse Aggregate :-
Coarse aggregate shall be crushed rock/crushed gravel retained on 2.36mm sieve. They
shall be clean, hard, durable and cubical shape free from dust or other organic material.
Where the aggregate have poor affinity with bitumen, the bitumen shall be treated with anti
stripping agent without extra payment. The aggregate shall satisfy the physical requirement
given in Table – 6.
Where crushed gravel is used not less than 90% by weight of crushed material retained on
4.75 mm sieve shall have at least two fractured faces.
Fine Aggregate :-
Fine aggregate shall be crushed or naturally occurring material passing 2.36mm and retained
on 75 micron sieve. They should be clean, hard, durable and free from dust, organic material.
The fine aggregate shall have sand equivalent value of not less than 50 as per IS:2720
Part37.
PI of material passing 425 micron sieve shall not exceed 4
Physical requirement of Aggregate
Table – 6
Property Test Specifications
Cleanliness Grain size analysis Max 5% passing 75 micron
Particle shape EI & FI (combined) Max 30%
Strength Aggregate Impact value Max 27%
Water absorption As per IS:2386 (Part 3) Max 2%
Stripping IS : 6241 – Stripping Minimum retained coating 95%
Durability Soundness Sodium
sulphate Magnesium Max 12%
sulphate Max 18%
Water sensitivity test Retained tensile strength Min 80%
Abrasion value Los Angeles Test Max 35%
Filler

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Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement
as approved by engineer. Grading requirement for filler
IS Sieve Cumulative % by wt. of total

(mm) aggregate passing
0.6 100
0.3 95-100
0.075 85-100
The filler shall be free from organic impurities and have a Plasticity Index not greater than 4.
The Plasticity Index requirement shall not apply if filler if cement or lime. W hen the coarse
aggregate is gravel, 2 percent of weight total aggregate, shall be Portland cement or hydrated
lime and the percentage of fine aggregate reduced accordingly. Cement or hydrated lime is
not required when the limestone aggregate is used. Where the aggregates fail to meet the
requirements of water sensitivity test (water absorption not more than 2%), then 2% by total
weight of aggregate, hydrated lime shall be added without additional cost.
Grading and Binder Content
When tested as per IS:2386, Part-I, combined grading should fall within in the limits given
below.
IS Sieve (mm) Cumulative % by wt. of total

aggregate passing
37.5 100
26.5 90-100
19 71-95
13.2 56-80
4.75 38-54
2.36 28-42
0.3 2-8
Bitumen Grade (Pen) 65
Anti stripping agent As per Appendix – B
Bitumen Content % Min. 4.5
Work of DBM shall not be done rainy, foggy or when the temperature is shed is less than 10°
C.
Mixture Design
Requirement for the mixture

Apart from conformity with the grading and quality requirements for individual ingredients, the
mixture shall meet the requirements set out in Table 7.
Table – 7
Requirements for Dense graded Bituminous Macadam
Minimum stability (kN at 60° 9.0

C)
Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (no. of 75 blows on each of the two
blows) faces of the specimen
Percent air voids 3–6
Percent voids in mineral See Table 8 below
aggregates (VMA)
Percent voids filled with 65-75
Bitumen (VFB)

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The requirements for minimum per cent voids in mineral aggregate ( VMA ) are set out in
Table 8
Table – 8
Minimum Percent voids in Mineral aggregate ( VMA )
Nominal max. Min. VMA Percent Related to Design Air Voids Percent
Particle size (mm) 3.0 4.0 5.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
37.5 10.0 11.0 12.0
Notes : 1. The nominal maximum particle size is one size larger than the first sieve to retain
more than 10 per cent.
2. Interpolate minimum voids in the mineral aggregate ( VMA ) for design air voids
values between those listed.
Binder Content
The binder content shall be optimised to achieve the requirements of the mixture set out in
table 7 and the traffic volume specified in the contract. The Marshall method for determining
the optimum binder content shall be adopted as described in the Asphalt Institute Manual
MS-2, replacing the aggregates retained on the 26.5 mm sieve by the aggregates passing the
26.5 mm sieve and retained on the 22.4 mm sieve, where approved by the engineer.
Where 40mm dense bituminous macadam mixture is specified, the modified Marshall
method described in MS-2 shall be used. This method requires modified equipment and
procedure; particularly the minimum stability values in Table 7 shall be multiplied by 2.25 and
the minimum flow shall be 3mm.
Job mix formula

The contractor shall inform the Engineer in writing, at least 20 days before the start of the
work, of the job mix formula proposed for use in the works, and shall give the following
details:
i) Source and location of all materials
ii) Proportions of all materials expressed as follows where each is applicable
a) Binder type, and percentage by weight of total mixture
b) Coarse aggregate / fine aggregate / mineral filler as percentage by weight of
total aggregate including mineral filler
iii) A single definite percentage passing each sieve for the mixed aggregate
iv) The individual gradings of the individual aggregate fractions, and the proportion of each
in the combined grading.
v) The results of tests enumerated in Table 7 as obtained by the Contractor
vi) W here the mixer is a batch mixer, the individual weights of each type of aggregate and
binder per batch.
vii) Test results of physical characteristics of aggregates to be used
viii) Mixing temperature and compacting temperature
While establishing the job mix formula, the contractor shall ensure that it is based on a
correct and truly representative sample of the materials that will actually be used in the work
and that the mixture and its different ingredients satisfy the physical and strength
requirements of these specifications.
Approval of the job mix formula shall be based on independent testing by the Engineer for
which samples of all ingredients of the mix shall be furnished by the contractor as required by
the Engineer.

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The approved job mix formula shall remain effective unless and until a revised Job Mix
Formula is approved. Should a change in the source of minerals be proposed, a
new job mix formula shall be forwarded to the Engineer for approval before the placing of the
material .
Plant trials – permissible variation in job mix formula

Once the laboratory job mix formula is approved, the contractor shall carryout plant trials at
the mixer to establish that the plant can be set up to produce a uniform mix conforming to the
approved job mix formula. The permissible variations of the individual percentages of the
various ingredients in the actual mix from the job mix formula to be used shall be within the
limits as specified in Table 9.
Table 9
Permissible Variations from the Job mix Formula
Description Permissible Variation
Base / Binder course W earing course
Aggregate passing 19mm sieve or larger ± 8% ± 7%
Aggregate passing 13.2mm, 9.5mm ± 7% ± 6%
Aggregate passing 4.75mm ± 6% ± 5%
Aggregate passing 2.36mm, 1.18mm, 0.6mm ± 5% ± 4%
Aggregate passing 0.3mm, 0.15mm ± 4% ± 3%
Aggregate passing 0.075mm ± 2% ± 1.5%
Binder Content ± 0.3% ± 0.3%
Mixing temperature ± 10°C ± 10°C
Once the plant trials have demonstrated the capability of the plant, and the trials are
approved, the laying operation may commence.
Mixing and transportation of mix clause 3.8.1 shall apply.
Spreading of mix shall be by self propelled paver capable of laying in uniform thickness and
maintaining required levels. The temperature of mix at the time of laying shall not be less
than 120°C.
Rolling shall continue till the density achieved is 98% of marshal density and shall be
completed before temperature of mix falls below 100°C.
MANUFACTURING AND ROLLING TEMPERATURE
Bitumen Bitumen Aggregate Mixed Material Rolling ( °C ) Laying ( °C )

Penetration Mixing ( °C ) Mixing ( °C ) ( °C )
35 160 – 170 160 – 175 170 Max 100 Min 130 Min
65 150 – 165 150 – 170 165 Max 90 Min 125 Min
90 140 - 160 140 – 165 155 Max 80 Min 115 Min
3.9 Premix Carpet

Tack coat as previous shall be applied of 0.3 Kg/sq.m. Over prepared (shaped) bituminous
macadam base as required by engineer in charge.
Binder for premix wearing course shall be straight run bitumen complying with IS:73The
Premix carpet of 20 mm compacted thickness shall comprise of bitumen of 60/70 grade &
small sized aggregate which shall be premixed & laid . The aggregates used shall have water
absorption limited to max. of 1 percent. The qty of materials required shall be as in table
given below:-

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QTY OF MATERIAL REQUIRED FOR 10 SQ.M OF ROAD SURFACE FOR 20 MM THICK

PREMIX SURFACING
Aggregate
a) Coarse aggregate of Nominal stone size 13.2 mm
Passing IS 22.4 mm sieve & retained on 11.2
mm sieve) 0.18 cu.m.
b) Coarse aggregate of Nominal stone size 11.2 mm
Passing IS 13.2 mm sieve & retained on 5.6
mm sieve) 0.09 cu.m.
Total 0.27 cu.m. per 10 sq.m.
Binder qty in terms of straight run bitumen

a) For 0.18 cu.m of 13.2 mm nominal size stone at 52 kg bitumen per cu.m- 9.5 Kg
b) For 0.09 cu.m of 11.2 mm nominal size stone at 56 kg bitumen per cu.m- 5.1 Kg
Total 14.6 Kg
3.9.1 Hot mix plant of appropriate capacity shall be used for preparation of mix material. The hot mix
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plant shall have a separate arrangement for heating aggregate. The temperature of 150 C to
o O O
160 C & that of aggregate in range of 155 C to 163 C provided the difference in
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temperature between the binder & aggregate at no time exceeds 14 C. Mixing shall be
through to ensure that a homogenous mixture is obtained in which all particles of the
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aggregates are coated uniformly & discharge temperature of mix shall be between 130 C &
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160 C. The mix shall be immediately transported from mixer to the point of use in suitable
vehicles or hand barrows. The vehicles employed for transport shall be clean & the mix being
transported covered in transit if so directed by engineer.
Rolling of layers shall be carried out using 10 T capacity smooth wheeled road roller before the
O
temperature of the mix falls below 100 C. The roller wheels shall be kept damp to prevent the
premix from adhering to the wheels. In no case fuel/lubricating oil be used for this purpose.
Excess use of water also shall be avoided. Joints along & transverse to the surfacing laid &
compacted earlier shall be cut vertically to their full depth so as to expose fresh surface which
shall be painted with a thin coat of appropriate binder before the new mix is placed against it.
Excessive rolling should be avoided.

3.10 Top wearing /Seal coat
The top wearing/Seal coat of 10 mm thickness shall be laid immediately over the premix
carpet .
In premixed seal coat the quantity of bitumen shall be 10 kg per 10 sq.m. of area. The bitumen
in seal coat shall be of grade 60/70 and comply with IS: 73.
Aggregates for seal coat:- The aggregates shall be stone chips which shall consist of angular
fragments of clean, hard, durable rock of uniform quality. The aggregate shall pass 11.2 mm
sieve & be retained on 2.36 mm sieve. The qty. used for premixing shall be 0.092 cu.m. per 10
sq.m area.
Wearing course mix shall be hot mixed, yielding uniform quality with thoroughly bitumen
coated aggregates. Seal coat- A mixer of appropriate capacity & type approved by the
engineer shall be used for preparation of the mixed material .The plant shall have separate
dryer arrangements for heating aggregates.
The binder shall be heated in boilers of suitable design approved by engineer to the
temperature appropriate to the grade of bitumen or as directed by engineer in charge. The
O O
aggregates shall be dry & suitably heated to temperature between 150 C & 165 C or as
directed by engineer in charge before these components are placed in the mixer. Mixing of
binder with aggregates to the specified proportions shall be continued until the latter are
thoroughly coated with the former.

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The mix shall be immediately transported from mixing plant to the point of use & spread
uniformly on the premix surface. Rolling shall be done using 10 T capacity smooth wheeled
road roller until the premix material is sealed completely. Excessive rolling should be avoided
Opening to traffic - The finished road surface shall be opened to traffic after minimum 24
hours period.
3.11 SEMI DENSE BITUMINOUS CONCRETE
Scope
Work shall consist of construction of a single layer of 25mm thickness on previously laid
DBM. The work shall be carried out as specified in clause 508.1 of MORTH specification.
Material
Bitumen shall be paving bitumen of 60/70 grade as per IS : 73
Coarse Aggregate
Coarse aggregate shall be as specified for Dense bituminous concrete except as given in
Table – 9
Fine Aggregate
Fine aggregate shall be as specified for DBM
Filler
Filler shall be as specified for DBM
Aggregate grading and binder content
When tested as per IS:2386 (Part-I) combined grading shall fall within limits shown below.
IS Sieve (mm) Cumulative % by wt. Of

total aggregate passing
13.2 100
9.5 90 – 100
4.75 35 – 51
2.36 24 – 39
1.18 15 – 30
0.3 9 – 19
0.75 3–8
Binder content (By wt. Of Min. 5.0
total mix)
Bitumen Grade (Pen) 65
TABLE – 9
Property Test Specifications

Polishing Polished stone value Min. 55
Water sensitivity Retained Tensile strength Min. 80%

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Requirement for Semi Dense Bituminous Pavement layers
Minimum stability ( kN at 60 deg. C ) 8.2

Minimum flow ( mm ) 2
Max. flow ( mm ) 4
Compaction level ( no. of blows ) 75 blows on each of the two faces of the
specimen
Percent voids in mineral aggregates ( VMA ) See table 8 above
Percent voids filled with Bitumen ( VFB ) 65 – 78
W ater and seasonal limitation
As specified for Dense Bituminous Macadam.
Tack coat
Tack coat shall be applied @ 0.3 kg/sq.m. over dense bituminous macadam
Mixing, Transportation, Spreading and Compaction
As specified in Dense Bituminous Macadam.
3.12 BITUMINOUS CONCRETE
Scope
This clause specifies the construction of Bituminous Concrete, for use in wearing and profile
corrective courses. This work shall consist of construction in a single or multiple layers of
bituminous concrete on a previously prepared bituminous bound surface. A single layers shall
be 25mm to 100mm in thickness. Bituminous concrete shall be done as per clause 509 of
MORTH specification.
Materials
Bitumen
The bitumen shall be paving bitumen of penetration grade complying to IS:73 and of the
penetration indicated in Table 11.
Coarse Aggregates
The coarse aggregates shall be generally as specified in Clause for DBM, except that the
aggregates shall specify the physical requirements of Table 10.
Fine Aggregates
The fine aggregates shall be all as specified in Clause for DBM.
Filler
Filler shall be generally as specified in clause for DBM, where the aggregates fail to meet the
requirements of the water sensitivity test in Table 10 then 2 per cent by total weight of
aggregate, of hydrated limit shall be added without additional cost.
Aggregate grading and binder content

When tested in accordance with IS:2386 Part 1 ( wet grading method ), the combined grading
of the coarse and fine aggregates and added filler shall fall within the limits shown in Table 11
for grading 1 or 2 as specified in the contract.

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Mixture Design
Requirements for the mixture
Apart from conformity with the grading and quality requirements for individual ingredients, the
mixture shall meet the requirements set out in Table 12.
The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in
Table 8.
Binder Content
The binder content shall be optimised to achieve the requirements of the mixture set out in
Table 12 and the traffic volume as specified in the contract. The Marshall method for
determining the optimum binder content shall be adopted as described in the Asphalt Institute
Manual MS-2, replacing the aggregates retained on the 26.5mm sieve and retained on the
22.4mm sieve, where approved by the Engineer.
Job mix formula

The procedure for formulating the job mix formula shall be generally as specified in clause
for DBM and the results of tests enumerated in Table 12 as obtained by the Contractors.
Preparation of base
The surface on which the bituminous concrete is to be laid shall be prepared in accordance
with clause 501 and 902 of MORTH specs. as appropriate, or as directed by the Engineer.
The surface shall be thoroughly swept clean by mechanical broom and dust removed by
compressed air. In locations where a mechanical broom cannot access, other approved
methods shall be used as directed by the Engineer.
Table 10 Physical requirements for Coarse aggregate for

Bituminous Concrete pavement layers
Property Test Specification

Cleanliness (dust) Grain size analysis (1) Max 5% passing
0.075mm sieve
Particle shape Flakiness and Elongation Index Max 30% (Combined) (2)
Strength* Los Angeles Abrasion Value (3) Max 30%
Aggregate Impact Value (4) Max 24%
Polishing Polished Stone Value (5) Min 55
Durability Soundness (6)
Sodium Sulphate Max 12%
Magnesium sulphate Max 18%
Water absorption Water absorption (7) Max 2%
Stripping Coating and stripping of Bitumen Minimum retained
Aggregate Mixtures (9) Coating 95%
Water Sensitivity** Retained Tensile strength (8) Min 80%
Notes
1) IS:2386 Part 1 6) IS:2386 Part 5
2) IS:2386 Part 1 7) IS:2386 Part 3
( the elongation test to be done only on non-flaky aggregates in the sample )
3) IS:2386 Part 4* 8) AASHTO T283**
4) IS:2386 Part 4* IS : 6241
5) BS:812 Part 114
* Aggregate may satisfy requirements of either of those two tests

** The water sensitivity test is only required if the minimum retained coating in the stripping
test is less than 95%.

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Table 11 Composition of Bituminous Concrete Pavement Layers
Grading 1 2
Nominal aggregate size 19mm 13mm
Layer Thickness 50 – 65mm 30 – 45mm
IS Sieve (mm) (1) Cumulative % by weight of total aggregate passing
45
37.5
26.5 100
19 79 – 100 100
13.2 59 – 79 79 – 100
9.5 52 – 72 70 – 88
4.75 35 – 55 53 – 71
2.36 28 – 44 42 – 58
1.18 20 – 34 34 – 48
0.6 15 – 27 26 – 38
0.3 10 – 20 18 – 28
0.15 5 – 13 12 – 20
0.075 2–8 4 – 10
Bitumen content % by mass 5.0 – 6.0 5.0 – 7.0
of total mix (2)
Bitumen grade (Pen) 65 65
Notes 1. The combines aggregate grading shall not vary from the low limit on one sieve to
the high limit on the adjacent sieve.
2. Determined by the Marshall method.
Table 12 Requirement for Bituminous Pavement Layers
Minimum stability ( kN at 60 deg. C ) 9.0

Minimum flow ( mm ) 2
Max. flow ( mm ) 4
Compaction level ( no. of blows ) 75 blows on each of the two faces of the
specimen
Percent voids in mineral aggregates (VMA) See table 8
Percent voids filled with Bitumen (VFB) 65 – 75
Loss of stability on immersion in water at 60 Minimum 75 percent Retained strength
deg. C ( ASTM D 1075 )
3.13 POINTS TO BE NOTED BY THE CONTRACTOR W HILE CARRYING OUT WBM &
BITUMINUOUS LAYERS :-
1.0 Check for W BM Surface undulations :-
Compacted coarse aggregate are checked for desired profile using 3 m Straight edge &
Corrected where the irregularities exceed 12 mm. The unevenness indicator instrument
developed by CRRI (Central Road Research Institute) Shall be used to check excessive
undulations & correcting patches during construction. After final compaction of each layer

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Doc.no.44LK-5100-00/C.02/1118/A4
the surface shall be allowed to cure overnight. Any unevenness noticed on the surface
shall be filled with screenings or binding material shall be lightly sprinkled with water &
rolled. No traffic shall be allowed till the WBM sets & dries out & then the bituminous
surfacing layers are laid. Levels shall be taken before & after laying layers.
2.0 Rolling :-
Rolling in case of road should commence from the edges/sides & proceeds to the center,
parallel to the centerline of the road, the overlap recommended being 1/3 of width of
drum. But in case of paving will depend on the camber needed.
3.0 Plants & Equipments:-
Required Plant & Equipment like bitumen distributor, bitumen heating device
(mechanical sprayer or mechanical blower) , aggregate spreader( whirl spreader/vane
spreader/hopper spreader/self propelled spreader),roller for compaction, Template for
checking desired profile. Mixing of aggregate & bitumen shall be done in a central plant
or travelling plant taking care that the aggregate & bitumen for premix & seal coat has
been properly mixed prior to laying.
4.0 W eather precaution:-
The laying of layers shall be done in dry & clear weather. The laying of bitumen layers
shall be avoided in very hot climate.
5.0 Prime and Tack Coat:-
Prime coat shall be spray applied on all granular layers as per the details given in the
document before laying of any bituminous layers. Thereafter a tack coat as detailed shall
be applied before laying of subsequent bituminous layer.
Tack coat shall be spray applied to all bituminous surfaces, whenever the time taken to
lay the subsequent bituminous layer is more than 24 hours.

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APPENDIX- A
VERY BROAD SPECIFICATION FOR SOIL TO BE CONSIDERED AS CNS

MATERAIL
Sr. Property Very Broad

No. Specification Range
1 Grain Size analysis
(i) Clay 15-25%
(ii) Silt 35-50%
(iii) Sand 30-40%
(iv) Gravel 10%
2 Consistency limits
(i) Liquid limit 30-50%
(ii) Plastic limit 20-25%
(iii) Plasticity index 10-25%
(iv) Shrinkage limit 15% and above
3 a) Swelling pressure when compacted to maximum dry Less than 0.1 Kg/cm²
density corresponding to standard Proctor (10 KN/m²)
compaction with zero initial compaction moisture
constant, for no volume change condition. Less than 0.05
b) Swelling pressure when compacted to maximum dry Kg/cm² (5
density corresponding to standard Proctor KN/m²)
compaction and initial compaction moisture
corresponding to optimum moisture content for no
volume change condition.
4 Clay minerals Preferable Kaolinite
and illite.
5 Shear strength of compacted sample compacted to Cu = 0.15-0.35 kg/cm²
maximum dry density correspond to standard Proctor (15 to35 kN/m²)
compaction and initial moisture content corresponding
to optimum moisture content, but sample tested on
saturation.
(a) From unconfined compression.
Ccu = 0.1-0.3 kg/cm²
(10 to30 kN/m²) φcu
(b) From consolidated undrained direct shear test. 8°-15°

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APPENDIX – B
ANTI-STRIPPING AGENTS USED FOR BITUMINOUS

MATERIAL AND MIXES
1.0 Scope
1.1 Anti-stripping agents are used for bituminous materials and mixes to ensure adhesion
between aggregates (hydrophilic in nature) and bitumen, even under submergence in
water. Prior approval of the Engineer shall be taken in respect of both qualitative and
quantitative use of a particular product.
2.0 Materials
2.1 The anti-stripping agents shall be fatty acid amines having a long hydrocarbon chain.
2.2 Physical and chemical Requirement : The anti-stripping agents shall conform to the
physical and chemical requirements as detailed in Table below.
SPECIFICATION FOR ANTI-STRIPPING COMPOUND
Sr. Test Method Limit

No.
1 Appearance Visual Liquid / Solid
2 Odor Smelling Agreeable
3 Specific gravity 27°C IS : 1202 – 1978 0.860 – 1.03
4 Pour point °C Maximum IS : 1448 42
5 Flash point (COC) Minimum IS : 1448 150
6 Water Content per cent Vol. IS : 1448 1.0
Maximum
7 Solubility in diesel oil (HDO or LDO) in As given at the end Complete
the ratio of 2.98 at 50°C of Appendix
8 Total base value mg KOH/g minimum ASTM D 664 200
9 Nitrogen content per cent Wt. Elemental Analyser 7.0
minimum
10 Stripping value with bitumen IS : 6241 As given No stripping
containing 1 per cent Wt. anti- at the end of
stripping compound at 40°C 24 hours Appendix
11 Under water coating test - do - Complete coating
12 Thermal stability at 163°C 5 hours - do - Should not lose its
efficacy
13 Boiling water test per cent minimum ASTM D 3625 95
coating
14 Retained Marshall Stability per cent As given at the end 75
minimum of Appendix
2.3 Storage and Handling : Anti-stripping agents shall be properly stored in closed
containers made of steel or aluminum. Containers made of zinc, copper, polythene PVC
and most type of rubber are not suitable for use. As most of the anti-stripping agents
cause irritation when in contact with human skin and are also irritating to the eyes,
protective gloves for hands, goggles for the eyes shall be used while handling them,
specially in case of liquid anti-stripping agents.
3.0 Use in Sprayed Work
3.1 Additive Dosage : The dosage shall be determined depending on the nature (stripping
value) of the aggregate and the size of aggregate. W hile the recommended minimum

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dose of anti-stripping agent for sprayed work is given in Table below, the actual dosage
shall be determined in the laboratory as directed by the Engineer.
TENTATIVE RECOMMENDED MINIMUM DOSE OF ANTI-STRIPPING AGENT

FOR SPRAYED WORK
Aggregate Dose of anti-stripping agent in per cent by weight of bitumen

stripping Surface Penetration Surface Liquid seal
value dressing with Macadam / dressing with coat
pre-coated Built up spray uncoated
aggregate grout aggregate
0 - 25 0.5 0.6 0.7 0.8
25 – 50 0.6 0.7 0.8 1.0
50 - 100 0.75 1.0 1.0 1.0
3.2 Mixing Procedure During Construction : The anti-stripping agent supplied in liquid,
solid or concentrate form shall be thoroughly mixed with liquid bituminous material or
with straight run bitumen. When used with straight run bitumen, the correct dose of anti-
stripping agent shall be mixed in a hot bitumen tank boiler.
The two constituents shall be agitated till the anti-stripping agent is thoroughly mixed.
The dose of anti-stripping agent shall suitable increased if the binder is to remain in
bitumen boiler for a longer period.
4.0 Use of Premix Work
4.1 Additive Dosage : The dosage shall be determined depending on the nature ( stripping
value ) of the aggregate and the percent voids in the mix. While the recommended
minimum doses for different types of bituminous premix materials in terms of voids
content given in Table below, the actual dosage shall be determined in the laboratory as
directed by the Engineer.
TENTATIVE RECOMMENDED MINIMUM DOSE OF ANTI-STRIPPING

COMPOUND IN BITUMEN PREMIX WORKS
Stripping value of Dose of anti-stripping agent in per cent by weight of bitumen

aggregate Voids content 3-5 Voids content 5-10 Voids content 10-15
per cent per cent per cent
0 – 25 0.3 0.4 0.5
25 – 50 0.4 0.5 0.6
50 – 100 0.6 0.8 1.0
4.2 Mixing Procedure During Construction : The required dose of the anti-stripping agent
shall be poured into the hot bitumen tank and allowed 15 to 30 minutes of circulation or
stirred to ensure a homogeneous mix. It is necessary to use a stable anti-stripping agent
or increase the dose according to expected degradation. Alternatively, the correct dose
shall be injected into the bitumen line by means of pump. The agent is fed into the
bitumen first before it is sprayed on the aggregate in the mix; thus, no separate mixing
time for mixing the agent with bitumen is required. In rolled asphalt and bitumen mastic
surfacing works, precoated chippings are pressed into the hard surface while the mix is
still hot to make the newly laid surface skid resistant. These chippings shall be precoated
with bitumen treated with anti-stripping compound.

b.6.9 - Std. Specification Asphalt Road

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Page 1 of 21

HINDUSTAN PETROLEUM CORPORATION LIMITED

DHT PROJECT – OSBL FACILITIES

TITLE : SPECIFICATIONS FOR ASPHALT ROAD

DOCUMENT NO. : 44LK-5100-00/C.02/1118/A4

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2.0 SCOPE OF WORK

3.0 TECHNICAL REQUIREMENTS

3.1 SETTING OUT & LEVELLING

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The purpose of this document is to state the requirements of materials, workmanship,

2.0 SCOPE OF WORK

3.0 TECHNICAL REQUIREMENTS

3.1 SETTING OUT & LEVELLING

3.2 CLEARING & STRIPPING

3.3 PREPARATION OF SUBGRADE

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COMPACTION REQUIREMENTS FOR EMBANKMENT AND

Type of work / material Relative compaction as percentage

2) Embankment Not less than 95

3.3.1 Gradation Requirement for Soil in Embankment

The following type of material will be considered unsuitable for filling.

3.4 EMBANKMENT AND GRADING BACK FILLING MATERIAL

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3.5 FILLING AND COMPACTION

3.6 PREPARATION OF GRANULAR SUB-BASE & BASE USING WATER BOUND

3.6.1 Granular sub-base

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Grading I Grading II Grading III

Grading I Grading II Grading III

3.6.2 Granular base

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Grading Size of IS Sieve Per cent by weight passing

TABLE 2 PHYSICAL REQUIREMENTS OF COARSE AGGREGATES

Test Test method Requirements

Los-angeles abrasion value IS-2386 Part-4 40 % max

Aggregate impact value IS-2386/ IS-5640 30% max

Flakiness index IS-2386 15% max

Elongation index IS-2386 30%max

TABLE 3 CHEMICAL REQUIREMENTS OF COARSE AGGREGATES

Chemical stability To comply with requirements of appendix of BS : 1047

Sulphur content Max 2% (Not applicable for crushed stone aggregate)

Water absorption Max 2%

TABLE- 4 GRADING REQUIREMENTS OF COARSE AGGREGATES.

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3.7 PRIME COAT & TACK COAT

3.8.a BITUMINOUS MACADAM

Bitumen content % by wt. 3.3-3.5

Anti-stripping agent As per Appendix B

PHYSICAL REQUIREMENTS FOR COARSE AGGREGATES FOR BITUMINOUS

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3.8.b DENSE BITUMINOUS MACADAM

Bitumen shall be paving bitumen of 60/70 grade as per IS : 73.

PI of material passing 425 micron sieve shall not exceed 4

Physical requirement of Aggregate

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