Quality Management System

For Flexible Pavement

February 20-21,2019
Training Programme for PWD Engineers on QMS for Rigid, Flexible
and Semi-Rigid Pavements
Jaipur
By
BL Rawat
BE(Honours), M.E.(Transportation), MBA
Chief General Manager, CEG Ltd, Jaipur

Consulting Engineers Group Ltd. ISO 9001:2015 Company

 Relevant IS and ICR Specifications

 IS:73:2013(2006, 1992)
 IS:8887:2018(2004)
 IRC:37-2012 (2001)
 MS-2-2014 7th edition
 MoRTH 5th Edition 2013
 IRC:111-2009

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 IRC:37-2012 Design of Flexible Pavements
Clause 5.2 Effective CBR

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 Job Mix Formula_MoRTH Specification

 Types of Bituminous Mixes

 Dense graded
 Open graded
 Desirable Properties
 Stability: resistance to deformation
 Density: degree of compaction
 Durability: resistance against weathering
 Flexibility: extent of deformation before failure
 Resistance to skidding
 Workability during construction
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 Bituminous Mix Design (Job Mix Formula)

 Marshall Stability Test

Marshall Stability Test adopted by US Corps of Engineers is a
semi-confined compression test which is comparable to a
triaxial test with a cell pressure of about 0.7 kg/cm2
MS-2
 Hveem Stabilometer and Cohesiometer Tests
Hveem Stabilometer embodies main characteristics of triaxial
test. It requires kneading compactor.

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 Bituminous Mix Design (Job Mix Formula)

• MoRTH Specifications 5th Edition 2013

• IRC:111-2009 (DBM, SDBC, BC) SMA

• MS-2 : 2014
Asphalt Mix Design Method
7th Edition (Asphalt Institute, USA)

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 Job Mix Formula

 The proportion in which the different aggregates,

filler and bitumen are to be mixed are specified by
weight or by volume for implementation during the
construction, is called Job Mix Formula.

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 Marshall Stability Test
 The Marshall Test is made to obtain optimum binder
content (OBC) for the type of aggregate mix and traffic
intensity.
 This stability test is applicable to hot-mix design using
bitumen and aggregates with maximum size of 25mm.
 Stability: The Marshall Stability of the mix is defined as a
maximum load carried by a compacted specimen at a
standard test temperature at 60°C and at the rate of 5 cm
per minute.
 Flow value: The flow value is the deformation the Marshall
test specimen undergoes during the loading, upto the
maximum load, in 0.25 mm units.

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 Design Steps of Job Mix Design

 Design Steps
 Select Type and grading of mix to be used.
 Select aggregates to be employed in the mix.
 Determine the proportion of each aggregate required to
produce the design grading.
 Determine the specific gravity
 Make up the trial specimens with varying bitumen contents.
 Determine the specific gravity of each compacted specimen.
 Make stability tests on the specimen.
 Calculate the percentage of voids, VMA and the percent VFB in
each specimen.
 Select the optimum bitumen content.
 Check the values of Marshall Stability, Flow, Voids in total mix,
VFB with optimum bitumen content and Gmm .
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 Apparatus
 Marshall Mould: Cylindrical moulds of 10 cm diameter, 7.5 cm
height with interchangeable base plate and collar.
 Sample Extractor: a jack or compression machine
 Hammer: 8.8 cm diameter, 4.5 kg weight, free fall 45.7 cm.
 Breaking Head
 Loading Machine: movement at the rate of 5 cm per minute,
proving ring of 5 tonne capacity.
 Flow Meter: least count of 0.025 mm.
 Oven, Hot Plate, Mixing Apparatus, Water Bath, Thermometer

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 Preparation of Test Specimen
 Aggregate: 1200 gm, heated to temperature of 175° to 190°C.
 Mould Assembly and Rammer: pre-heated: 100° to 145°C.
 Bitumen: heated 121° to 138°C.
 Mixing temperature
 VG-10/20 grade: 154°C.
 VG-30/40 grade: 160°C.
 Compaction
 50 blows on either side, for medium traffic roads
 75 blows on either side, for heavy traffic roads
 Compaction temperature
 VG-10/20 grade: 138°C.
 VG-30/40 grade: 149°C.
 Compacted thickness: 63.5 ± 3.0 mm.
 Bitumen content: 3% to 7.5% with increment of 0.5%

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 Representation of Volumes in a
compacted Specimen-MS-2 7th Edition 2014

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 Calculations
 Specific gravity of Compacted Specimens:
Gt = 100 / (W1/G1 + W2/G2 + W3/G3 + W4/G4 )
2

Where, W1 = percent by weight of coarse aggregates

W2 = percent by weight of fine aggregate
W3 = percent by weight of filler
W4 = percent by weight of bitumen in total mix
G1, G2 and G3 are apparent specific gravity
values of coarse aggregates, fine aggregates and
filler and G4 is the specific gravity of bitumen.

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 Density and Void Analysis
Vv, % = 100(Gt – Gb)/ Gt
Vb, % = Gb * W4/ G4
VMA, % = Vv + Vb
VFB, % = 100 * Vb/ VMA
Where, Gb = bulk density of a specimen
Gt = theoretical specific gravity mixture
Vv = air voids in the mix, %
Vb = volume of bitumen
VMA = voids in mineral aggregate, %
VFB = voids filled with bitumen, %

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 Marshall Stability and Flow Values

 The specimen is kept immersed under water at 60°C ±

1°C for 30 to 40 mins.
 Placed in test head and maximum load before failure is
noted.
 Flow value at failure is noted.
 Correction in thickness if specimen not exactly 63.5 mm.
 Correction factor is applied.

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 Correction Factors

Volume of Specimen in Approximate Thickness of Correction Factors

cubcm Specimen (mm)
457 – 470 57.1 1.1.9
471 – 482 58.7 1.14
483 – 495 60.3 1.09
496 – 508 61.9 1.04
509 – 522 63.5 1.00
523 – 535 65.1 0.96
536 – 546 66.7 0.93
547 – 549 68.3 0.89
560 – 573 69.9 0.86

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 Determination of Optimum Bitumen Content
Five graphs are plotted with values of bitumen content against the
values of:
 Density Gb, g/cubcm
 Marshall stability S, kg
 Voids in total mix Vv, %
 Flow value F, 0.25 mm units
 Voids filled with bitumen VFB, %
 Theoretical maximum Specific Gravity of the loose mix (Gmm)
Bulk density, Stability and Flow are measured whereas
percentage air voids, Vv, VFB, VMA and Gmm are
computed from formula.
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 Optimum Bitumen Content

Optimum Bitumen Content

B0 = (B1 + B2 + B3)/ 3
where,
B1 = bitumen content corresponding to maximum density.
B2 = bitumen content corresponding to maximum stability
B3 = bitumen content corresponding to specified voids content, Vv
 Value of flow and VFB are found from graphs, corresponding to B0. All the
design values of Marshall Stability, Flow, Voids and VFB are checked at the
B0 with the specific design requirement of the mix.
 If mix designed does not fulfill any one or more of the design requirements,
the gradation of aggregates or filler content or bitumen content or
combination of these are altered and the design tests are repeated till all the
requirements are simultaneously fulfilled.
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 Requirement of the Dense Graded Bituminous
Mix using Viscosity-Graded (VG) Paving/ Modified Bitumen
Properties Viscosity Grade Modified Bitumen Test Method
Paving Bitumen Hot climate Cold climate

Compaction level 75 blows on each face of the specimen

(Number of blows)
Minimum stability 9.0 12 10 AASHTO T245
(kN at 60°C)
Marshall flow (mm) 2–4 2.5 – 4 3.5 – 5 AASHTO T245

Marshall Quotient 2–5 2.5 – 5

(stability/ flow)
% Air Voids 3–5 MS-2, ASTM D2041

% Voids filled with 65 – 75 MS – 2

bitumen (VFB)
Tensile Strength Ratio 80% (Minimum) AASHTO T283

Coating of Aggregate 95% (Minimum) IS: 6241

Particles with bitumen Stripping not more
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 % Voids in Mineral Aggregate, VMA

Nominal Maximum Min. % VMA related to designed % air voids

Particle Size (mm)
3 4 5

9.5 14 15 16
13.2 13 14 15
19.0 12 13 14
26.5 11 12 13
37.5 10 11 12

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 Modified Marshall Test

 Asphalt Institute Manual MS-2 and ASTM D5581.

 Used where maximum size of aggregate is more
than 26.5 mm.
 Mould diameter: 150 mm.
 When the modified Marshall test is used, the
specified minimum stability values and the specified
flow values shall be multiplied by 2.25 and 1.5
respectively.

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 IRC:111-2009 Field Compaction
Clause 5.6.4

 The Density of the finished paving layer should be

determined by taking 150mm dia cores. The Density
of finished paving layer should not be less than 92%
of the Theoretical maximum Specific Gravity of
the loose mix (Gmm). Gmm should be determined
in lab at Optimum Binder Content B0.
 Gmm should be specified in the Job Mix Formula itself
by the lab.

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 Permissible Variation from the Job Mix
Formula
Description Permissible Variation
DBM BC/ SDBC
Aggregate passing
19 mm or larger ± 8% ± 7%
13.2 mm/ 9.5 mm ± 7% ± 6%
4.75 mm ± 6% ± 5%
2.36 mm, 1.18 mm, 0.6 mm ± 5% ± 4%
0.3 mm, 0.15 mm ± 4% ± 3%
0.075 mm ± 2% ± 1.5%
Binder Course ± 0.3% ± 0.3%
Mixing Temperature ± 10°C ± 10°C

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 IRC:111-2009, Viscosity Graded (VG) Bitumen
General Applications
Viscosity Grade General Applications
VG-40 Use in highly stressed areas such as those
(40-60 penetration) in intersections, near toll booths, and
truck parking lots in lieu of old 30/ 40
penetration grade
VG- 30 Use for paving in most of India in lieu of
(50-70 penetration) old 60/ 70 penetration grade
VG- 20 Use for paving in cold climate, high
(60-80 penetration) altitude regions of North India
VG-10 Use in spraying applications and for paving
(80-100 penetration) in very cold climate in lieu of old 80/ 100
penetration grade

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 Selection Criteria for Viscosity-Graded (VG)
Paving Bitumen Based on Climatic Conditions
(IRC:111:2009)

Lowest Daily Mean Highest Daily Mean Air Temperature, °C

Air Temperature, °C

Less than 20°C 20 to 30°C More than 30°C

More than -10° VG-10 VG- 20 VG- 30

-10°C or lower VG- 10 VG- 10 VG- 20

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 IS:73-2013 Paving Bitumen-Specification
(fourth Revision)

 Grade Viscosity at 60°C Suitable for 7 days Average

(Absolute) Max Air Temp. °C
 VG- 10 800-1200 poises <30
 VG- 20 1600 -2400poises 30-38
 VG-30 2400-3600 poises 38-45
 VG-40 3200-4800 poises >45

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 IRC:37-2012 Design of Flexible Pavements
Clause 7.4.2 and Annex-VII

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 Paving Bitumen-Specifications
IS:73:2013 (2006,1992)

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 IS:73-2013 Paving Bitumen-
Criteria for Conformity Cl7.4
Type of samples:-
• Individual sample
• Composite sample
Number of Tests:-
1) All Individual Samples:-
• Absolute Viscosity at 60ºC,
• Penetration at 25ºC and
• Softening Point Tests
2) Composite sample:-
• Kinematic Viscosity.
• Flash Point,
• Solubility,
• Test on Residue from rolling thin film oven test
a)Viscosity and
b)Ductility
Criteria for Conformity:- From Test results of Absolute Viscosity at 60ºC, Penetration
at 25ºC and Softening Point Tests, the mean X and the range (R) shall be as follows

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 Chemical Composition of Bitumen

CHEMICAL
COMPOSITION BITUMEN

n-heptane precipitation ASPHALTENES

(5 – 25 %) black or
MELTENES brown solids
Silica gel / Alumina
Chromatography (hardness)

Elution with n-heptane, SATURATES AROMATICS RESINS

toluene, methanol (5 – 20 %) non- (40 – 65 %) (15 – 35 %)
polar viscous oil viscous liquid adhesive

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 Grading Requirement of Mineral Filler

• Filler should be finally mineral such as Rock Dust or Hydrated lime or cement
• Hydrated lime is prefer because of its anti stripping and antioxidant properties

IS Sieve Cumulative % passing

(mm) by weight of total
aggregate
0.6 100
0.3 95 – 100
0.075 85 – 100

Ageing Index & Change in Bitumen Composition after adding Aggregates

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 Mixing, Laying and Rolling Temperatures for Dense
Mixtures (°C)
Bitumen Bitumen Aggregate Mixed Laying Rolling
Viscosity Aggregate Temperature Material Temperature Temperature
Grade Temperature

VG – 40 160 – 170 160 – 175 160 – 170 150 Min. 100 Min.

VG – 30 150 – 165 150 – 170 150 – 165 140 Min. 90 Min.

VG – 20 145 – 165 145 – 170 145 – 165 135 Min. 85 Min.

VG – 10 140 – 160 140 – 165 140 – 160 130 Min. 80 Min.

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 Selection Criteria for Grade of
Modified Bitumen
Lowest Daily Mean Highest Daily Mean Air Temperature, °C
Air Temperature, °C
Less than 20°C 20 to 30°C More than 30°C

More than -10°C PMB/ NRMB 120 PMB/ NRMB 70 PMB/ NRMB 40
CRMB 50 CRMB 55 CRMB 60

-10°C or lower PMB/ NRMB 120 PMB/ NRMB 120 PMB/ NRMB 70
CBMB 50 CRMB 50 CRMB 55

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 IS:8887:2018 (2004) BITUMEN EMULSION FOR
ROADS (CATIONIC TYPE)-SPECIFICATION

Grades:-
Rapid Setting-1 Grade RS-1
Rapid Setting-2 Grade RS-2
Medium Setting Grade MS
Slow Setting-1 Grade SS-1
Slow Setting-2 Grade SS-2

Requirements:- Bitumen Emulsion shall be Homogenous.

Within one year after manufacture date, it shall show no
un-dispersed bitumen after through mixing

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 IS:8887:2018 (2004) BITUMEN EMULSION FOR
ROADS (CATIONIC TYPE)-SPECIFICATION

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 IS:8887:2018 (2004) BITUMEN EMULSION FOR
ROADS (CATIONIC TYPE)-RECOMMENDED USE

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 Physical Properties of Coarse Aggregate
MoRTH Specification
Property Test Requirement Test method
Cleanliness Grain size analysis Max. 5% passing 0.075mm IS: 2386 Part I

Particle Shape Flakiness and Elongation Index Max. 35% IS: 2386 Part I

Strength Los Angeles Abrasion Value BC- Max. 30% IS: 2386 Part IV
Others- Max. 35%
Aggregate Impact Value BC- Max. 24% IS: 2386 Part IV
Others- Max. 27%
Polishing Polished Stone Value Min. 55 IS: 2386 Part IV
Soundness (Either Sodium or Magnesium Sulphate) – 5 cycles
Sodium Sulphate Max. 12% IS: 2386 Part V
Magnesium Sulphate Max. 18% IS: 2386 Part V
Water Absorption Water Absorption Max. 2% IS: 2386 Part III

Stripping Coating and Stripping of Bitumen Min. Retained Coating 95% IS: 6241
Aggregate Mixtures
Water Sensitivity Retained Tensile strength
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Min 80% ASHTO 283
 Aggregate Grading and Bitumen Content
Specification DBM SDBC BC
Grading 1 2 1 2 1 2
Normal maximum 37.5 mm 26.5 mm 13.2 mm 9.5 mm 19 mm 13.2 mm
aggregate size
Layer thickness 75–100 mm 50 – 75 mm 40 mm 25 mm 50 mm 25/ 40 mm
IS Sieve size (mm) Cumulative percent by weight of total aggregate passing
45 100
37.5 95 – 100 100
26.5 63 – 93 90 – 100 100
19 - 71 – 95 100 90 – 100 100
13.2 55 – 75 56 – 80 90 – 100 100 59 – 79 90 – 100
9.5 - - 70 – 90 90 – 100 52 – 72 70 – 88
4.75 38 – 54 38 – 54 35 – 51 35 – 51 35 – 55 53 – 71
2.36 28 – 42 28 – 42 24 – 39 24 – 39 28 – 44 42 – 58
1.18 - - 15 – 30 20 – 34 34 – 48
0.6 - - 15 – 27 26 – 38
0.3 7 – 21 7 – 21 9 – 19 10 – 20 18 – 28
0.15 - - 5 – 13 12 – 20
0.075 2–8 2–8 3–8 3–8 2–8 4 – 10
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Bitumen content (Min) 4% 4.5% 4.5% 5% 5.2% 5.4%
 Types of Dense Graded Bituminous Mixes,
their Mixes, their Use, Number of Layers and Layer Thickness

Specification Purpose Number of Thickness of

Layers each Layer
Dense Bituminous Base/ Binder Single or Multiple 50 mm – 100 mm
Macadam (DBM) Course/ Overlay for
Strengthening

Semi- Dense Wearing Course Single 25 mm – 40 mm

Bituminous
Concrete (SDBC)

Bituminous Wearing Course Single 25 mm/ 40 mm/

Concrete (BC) 50 mm

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 Maximum permissible frequency of unevenness

Type of surface Unevenness, Max. no. of Surface

mm Unevenness
NH/ SH MDR and
others
Semi-Dense 4–6 20 40
Bituminous Concrete
(SDBC)
Bituminous Concrete 3–5 15 30
(BC)

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 Maximum permissible values of roughness
(mm/ km) for surface with Dense Graded Bituminous Mixes

MoRTH Section 900

S. No. Type of surface Condition of Road Surface ( mm/ km)

Good Average Poor

1. SDBC < 2500 2500 – 3500 > 3500

2. BC < 2500 2000 – 3000 > 3000

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 Control tests for Dense Graded Bituminous
Mixes and their Minimum Frequency
S. Test Frequency
No.
1. Quality of binder Number of samples per lot and tests as per
IS:73 or IRC:SP: 53
2. Aggregate impact One test per 350 mtr cube of aggregate for each
value/ Los Angeles source and whenever there is change in the
Abrasion value quality of aggregate.
3. Flakiness Index One test per 350 mtr cube of aggregate for each
source and whenever there is change in the
quality of aggregate.
4. Soundness test 1 test for each source and whenever there is
(Sodium and change in the quality of aggregate.
Magnesium Sulphate
test)
5. Water absorption of 1 test for each source and whenever there is
aggregate change in the quality of aggregate.
6. Sand equivalent test 1 test for each source and whenever there is
change in the quality of aggregate.
7. Plasticity Index 1 test for each source and whenever there is
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change in the quality of aggregate.
 S.No. Test Frequency
8. Polished stone value 1 test for each source and whenever there is
change in the quality of aggregate.
9. Percent of fractured faces 1 test per 350 mtrcube of aggregate when
crushed gravel is used.
10. Mix grading 1 test for individual constituent and mixed
aggregate from dryer for each 400 tonnes of mix
subject to minimum of 2 tests per day per plant.
11. Stability and voids analysis of 3 tests for stability, flow value, density and void
mix including theoretical content for each 400 tonnes of mix subject to
maximum specific gravity of minimum of 2 tests per day per plant.
loose mix
12. Moisture susceptibility of mix 1 test for each mix type whenever there is
(AASHTO T283) change in the quality or source of coarse or fine
aggregate.
13. Temperature of binder in At regular intervals
boiler, aggregate in dryer and
mix at the time of laying and
compaction
14.Engineers
Consulting Binder content
Group Ltd. One set for each 400 tonnes of mix subject to
 Thank you

SK Singhvi (Director Design)

BL Rawat, CGM
Contact : CEG Ltd. Jaipur
E-mail : pmcpwd@ cegindia.com
Tel: +91-141-2751805

ISO 9001:2015 Company

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