Construction of Road

Presented by engr Haris

Contents:
 Definition
 Roadway construction.
 Layers of Road/Carriageway
 Basic Pavement Types
 Flexible Pavements
 Advantages of Flexible Pavement
 Disadvantages of Flexible Pavement
 Surface Course Distress
 Foundation Distresses
 Fatigue Cracking
 Rigid Pavements
Contents
 Typical Applications – Rigid Pavement.
 Advantages of Rigid Pavement.
 Disadvantages of Rigid Pavements.
 Composite Pavement.
 Typical layers of a flexible pavement
What is road?
 A road is a thoroughfare for the conveyance of traffic that mostly has an
improved surface for use by vehicles and pedestrians.

Roadway Construction:
 Carriageway
 Pavement
 Kerb
 Shoulder
 Sidewalks/footpath
Road/Carriageway
 The part of a road used by vehicular traffic is called carriageway

Layers of Road/Carriageway
 Earth work(Sub Grade).
 Granular sub base (GSB).
 Wet Mix Macadam (WMM) or Water
Bound Macadam (WBM).
 Prime Coat or MC Spray.
 Bituminous Macadam (BM) or Asphalt Base Course.
 Tack Coat.
 Asphalt Wearing Course
Basic Pavement Types
• Flexible
• Rigid
• Composite
 Typical Pavement Layers
• Wearing course or surface
• Base course
• Subbase
• Subgrade

– Compacted or Stabilized
– Natural
Flexible Pavements:
Flexible pavement can be defined as the one consisting of a mixture of asphaltic or bituminous material
and aggregates placed on a bed of compacted granular material of appropriate quality in layers over the
subgrade. Water bound macadam roads and stabilized soil roads with or without asphaltic toppings are
examples of flexible pavements.

• Made up of multiple, fairly thin layers

• Each layer distributes load over larger area of layer below
• Pavement deflects under load
• Typically asphalt
• Easily and commonly recycled
• Typical lives 15-20 years (to first rehab)
Flexible Pavement
• Pavement layers bend
• Each layer spreads load to next layer
• Loads over a smaller area of subgrade

Typical Applications - Flexible Pavement

• Traffic lanes (wide range of traffic levels)
• Auxiliary lanes
• Ramps
• Parking areas
• Frontage roads
• Shoulders
Advantages of Flexible Pavement

• Adjusts to limited differential settlement

• Easily, quickly constructed and repaired
• Additional thickness can be added
• Quieter and smoother (generally)
Disadvantages of Flexible Pavement

• Properties may change over time as pavement

ages
• Generally shorter service life before first
rehabilitation
• May experience moisture problems
Surface Course Distress
• Rutting mainly controlled by choice of materials
and design of surface mixes
• Surfaces also must be resistant to cracking

original
profile

weak asphalt layer

shear plane
Foundation Distresses
• Poor subgrade support can cause rutting.
– Drainage
– Frost penetration?
– Stabilization
original
profile

asphalt layer

weak subgrade or underlying layer

Fatigue Cracking

Repeate Leads to
d Fatigue Cracking
Bending
 Rigid Pavements:
A rigid pavement is constructed from cement concrete or
reinforced concrete slabs.

• Generally stiffer – may have reinforcing steel.

• Little bending
• Distributes loads over relatively large area of subgrade
• Portland cement concrete
• Can be recycled, but less common
• Service lives 20-40 years (to first major rehab)
Typical Applications – Rigid Pavement
• High volume traffic lanes
• Freeway to freeway connections
• Exit ramps with heavy traffic

PCC Slab

Base (optional)

Subgrade
Advantages of Rigid Pavement
• Good durability
• Long service life
• Minor variations in subgrade strength have little effect
• Withstand repeated flooding and subsurface water without
deterioration (as long as base and/or subgrade are
resistant to moisture damage)
Disadvantages of Rigid Pavements

• Distresses may be harder/more expensive to repair

• May polish (lose frictional properties) over time
• Needs even subgrade support
• Generally (but not always) considered more expensive to
construct
 Composite Pavement
 HMA/PCC composite pavement is a type of pavement structure with rigid-
flexible combination. The cement concrete layer is below. Asphalt concrete
layer on top can buffer the impact of traffic load and climatic factors on the
cement concrete slab. Because of the protection from asphalt concrete layer,
diseases on cement concrete layer, such as erosion, creeping mud, emptying,
broken slab and staggered platform can be greatly reduced.
 In HMA/PCC composite pavement structure, cement concrete slab is the main
bearing structure, which requires the layer to resist fatigue cracking and
durability.
 The asphalt pavement layer is the functional layer, and at the same time
protect the cement concrete slab, which requires better road surface
performance and safety
Composite Pavement.

The typical structure of HMA/PCC composite pavement

Typical layers of a flexible pavement:
 Typical layers of a conventional flexible pavement includes seal coat,
surface course, tack coat, binder course, prime coat, base course, sub-
base course, compacted sub-grade, and natural sub-grade.

1. Sub-grade:
The top soil or sub-grade is a layer of natural soil prepared to receive the stresses from
the layers above. It is essential that at no time soil sub-grade is overstressed. It should be
compacted to the desirable density, near the optimum moisture content.

a) Civil inspector should check IR with approved shop Drawing.

b) Check Loose Compacted Areas,
c) Check Pumping/Moisture 2% to 7.5%
d) Compacted Layer should be 20cm to 25cm.
e) Compaction 95% min.
f) CBR 30% min.
g) Suitability test (Gradation, Proctor, CBR & Plasticity Index etc..)
Typical layers of a flexible pavement:
1. Sub-base Course:
The sub-base course is the layer of material beneath the base course and the
primary functions are to provide structural support, improve drainage, and reduce
the intrusion of fines from the sub-grade in the pavement structure

a) Civil inspector should check IR with approved shop Drawing.

b) Check Loose Compacted Areas and Segregation etc,
c) Check Pumping/Moisture 2% to 7.5%
d) Compacted Layer should be 15cm to 20cm.
e) Compaction 98% min.
f) CBR 30% min.
g) Suitability test (Gradation, Proctor, CBR & Plasticity Index etc..)
Typical layers of a flexible pavement:
1. Base Course:
The base course is the layer of material immediately beneath the surface of binder
course and it provides additional load distribution and contributes to the sub-surface
drainage It may be composed of crushed stone, crushed slag, and other untreated
or stabilized materials

a) Civil inspector should check IR with approved shop Drawing.

b) Check Loose Compacted Areas and Segregation etc,
c) Check Pumping/Moisture 2% to 7.5%
d) Compacted Layer should be 15cm to 20cm.
e) Compaction 100% min.
f) CBR 80% min.
g) Proper Gradation (Coarse Aggregate & Fine Aggregate)
Typical layers of a flexible pavement:
1. Prime Coat:
Prime coat is an application of low viscous cutback bitumen to an absorbent surface
like granular bases on which binder layer is placed. It provides bonding between two
layers. prime coat penetrates into the layer below, plugs the voids, and forms a
water tight surface.

a) MC Spray 0.7 to 1.5 l/m²

b) Temperature 50°C to 80°C.
c) Bitumen 60%, kerosine oil 40%.
d) Curing Time 48Hr min.
e) Purposes:
a) To seal moisture contents.
b) Binding loose particles.
c) It promotes adhesion between the base layer and the first layer of asphalt.
Typical layers of a flexible pavement:
1. Asphalt Base Course:
This layer provides the bulk of the asphalt concrete structure. It's chief purpose is to
distribute load to the base course The binder course generally consists of aggregates having
less asphalt, so replacing a part of the surface wearing course by the binder course results
in more economical design.

a) Civil inspector should check IR with approved shop Drawing.

b) Civil Inspector should check at site:
a) Surface cleaning,
b) Chainage on every 10m RHS, Center line and LHS with string line.
c) Machinery checking.
d) While asphalt laying check temp (135°C to 163°C)

c) Bitumen Ratio 3.2% to 4.2%.

d) Asphalt laying temperature 135°C to 163°C.
e) Compacted Layer should be 6cm to 10cm.
f) Compaction 101.25% min.
g) Rolling with:
a) Break down rolling with steel roller.
b) Intermediate rolling with PTR.
c) Final Rolling with STR.
Typical layers of a flexible pavement:
1. Tack Coat:
A tack coat in road construction is a thin layer of asphalt emulsion that is applied to an
existing asphalt or concrete surface before a new layer of asphalt is laid. This coat serves to
create a strong adhesive bond between the old and new pavement layers.

a) Spray Rate 0.3 to 0.6 l/m²

b) Temperature 10°C to 60°C.
c) Bitumen 50%, Water 49.5% & other ingredient 0.5%.
d) Curing Time 1 to 2Hr.
e) Purposes:
a) This helps to prevent slippage and delamination between the layers.
b) To create a strong adhesive bond.
Typical layers of a flexible pavement:
1. Asphalt Wearing Course:
The wearing course is the top layer of the road and is typically made of asphalt. It is the layer
that is in direct contact with vehicles and provides the road's smooth, durable surface.

a) Civil inspector should check IR with approved shop Drawing.

b) Civil Inspector should check at site:
a) Surface cleaning,
b) Chainage on every 10m RHS, Center line and LHS with string line.
c) Machinery checking.
d) While asphalt laying check temp (135°C to 163°C)

c) Bitumen Ratio 3.4% to 4.2%.

d) Asphalt laying temperature 135°C to 163°C.
e) Compacted Layer should be 6cm to 10cm.
f) Compaction 101.25% min.
g) Rolling with:
a) Break down rolling with steel roller.
b) Intermediate rolling with PTR.
c) Final Rolling with STR.