23-10-2024
Dr. Punith B Kotagi
Dr. Punith B Kotagi, NIE Mysuru 1
Module - I
Highway construction
materials
Dr. Punith B Kotagi, NIE Mysuru 2
Dr. Punith B Kotagi 1
23-10-2024
Dr. Punith B Kotagi, NIE Mysuru 3
Rigid Pavement Layers
Dr. Punith B Kotagi, NIE Mysuru 4
Dr. Punith B Kotagi 2
23-10-2024
Road Aggregates
Requirements of road aggregates:
• They must be crushed aggregate.
• They shall be clean, hard, durable and cubical in shape.
• They must be free from the dust, organic matter and other
deleterious matter.
• They not be flakey or elongated.
• They must not consist of injurious or harmful materials such
that they reduce the strength of structure.
• They should resist wear due to abrasive action of traffic on
the surface course.
Dr. Punith B Kotagi, NIE Mysuru 5
Properties of aggregates:
The aggregate have three properties
1. Physical properties.
2. Mechanical properties.
3. Chemical properties.
Dr. Punith B Kotagi, NIE Mysuru 6
Dr. Punith B Kotagi 3
23-10-2024
Road Aggregates
Desirable properties of road aggregates:
1. Strength (Crushing value test)
2. Hardness (Abrasion test)
3. Toughness (Impact test)
4. Durability (Soundness test)
5. Shape of aggregates (Shape test)
6. Adhesion with bitumen (Stripping test)
Dr. Punith B Kotagi, NIE Mysuru 7
Crushing value test
Crushing Value = B/A * 100
B = wt. of fraction passing 2.36 mm IS Sieve
A = wt. of aggregate sample
Dr. Punith B Kotagi, NIE Mysuru 8
Dr. Punith B Kotagi 4
23-10-2024
Abrasion test
Abrasion Value = W1-W2/W1 * 100
W1 = original mass of test sample
W2 = wt. of fraction retained on 1.7 mm IS Sieve
Dr. Punith B Kotagi, NIE Mysuru 9
Dr. Punith B Kotagi, NIE Mysuru 10
Dr. Punith B Kotagi 5
23-10-2024
Impact test
Impact Value = B/A * 100
B = wt. of fraction passing 2.36 mm IS Sieve
A = wt. of aggregate sample
Dr. Punith B Kotagi, NIE Mysuru 11
Soundness test
Avg. loss for 10 cycles should
not exceed 12 % - 18 %
Dr. Punith B Kotagi, NIE Mysuru 12
Dr. Punith B Kotagi 6
23-10-2024
• In order, to quicken the effects of weathering due to alternate
wet-dry or freeze-thaw cycles in the laboratory, the
resistance to disintegration of aggregate is determined by
using saturated solution of sodium sulphate or magnesium
sulphate.
• Clean, dry aggregates of specified size is weighed and
counted. Then immersed in the saturated solution of sodium
sulphate or magnesium sulphate for 16 to 18 hours.
• Then the aggregates are dried in an oven at 105-110°C to a
constant weight, thus making one cycle of immersion and
drying.
Dr. Punith B Kotagi, NIE Mysuru 13
Shape test
Dr. Punith B Kotagi, NIE Mysuru 14
Dr. Punith B Kotagi 7
23-10-2024
Dr. Punith B Kotagi, NIE Mysuru 15
Angularity Number
Dr. Punith B Kotagi, NIE Mysuru 16
Dr. Punith B Kotagi 8
23-10-2024
Stripping value test
Stripping value should not exceed 25%
Dr. Punith B Kotagi, NIE Mysuru 17
• IRC has specified that stripping value of aggregates
should not exceed 25percent for use in bituminous
surface dressing, penetration macadam,
bituminous macadam and carpet constructions,
when aggregate coated with bitumen is immersed
in water bath at 40°C for 24 hours.
Dr. Punith B Kotagi, NIE Mysuru 18
Dr. Punith B Kotagi 9
23-10-2024
Concept of Size and Gradation
• The gradation analysis or sieve analysis of weight the coarse
and the fine aggregates available is carried out by sieving
through the standard IS sieves.
• Design Gradation
• It is the gradation or distribution of particles or aggregates
specified by the designer.
• The design gradation is obtained using a number of trials by
mixing different size aggregate to satisfy the requirement of
density and CBR value.
Dr. Punith B Kotagi, NIE Mysuru 19
Maximum Aggregate Size
• Maximum aggregate size is the sieve size or mean
size of the smallest sieve through which 100% of
material will pass.
• The maximum size and the grading of the aggregate
are controlled by the specification which describes
the distribution of particle sizes to be used of a
particular work.
Dr. Punith B Kotagi, NIE Mysuru 20
Dr. Punith B Kotagi 10
23-10-2024
Aggregate Blending
• Aggregate blending is a method of mixing the aggregates of
different sizes to obtain or to satisfy the design gradation.
• There are several techniques used to blend the aggregates.
• The trial method is the one in which the aggregates are
blended by several trials to get the design gradation and to
meet the required specification.
• Two graphical methods in common use for
proportioning/blending are:
• Triangular Chart
• Rothfutch’s Method
Dr. Punith B Kotagi, NIE Mysuru 21
Dr. Punith B Kotagi, NIE Mysuru 22
Dr. Punith B Kotagi 11
23-10-2024
The proportions of coarse aggregate, sand and
fines are given by:
Dr. Punith B Kotagi, NIE Mysuru 23
Rothfuch’s Method
Dr. Punith B Kotagi, NIE Mysuru 24
Dr. Punith B Kotagi 12
23-10-2024
Binders….
Dr. Punith B Kotagi, NIE Mysuru 25
Bituminous Binders:
1. Paving grade bitumen
2. Modified bituminous binders
3. Cut back bitumen
4. Bitumen emulsions
5. Tar
Dr. Punith B Kotagi, NIE Mysuru 26
Dr. Punith B Kotagi 13
23-10-2024
Requirements of Bitumen
• Attainment of desired stability of the mix
• To maintain the stability under adverse weather conditions
• To maintain sufficient flexibility
• Avoid cracking of bituminous surface
• To have sufficient adhesion with the aggregates in the mix in
presence of water
Dr. Punith B Kotagi, NIE Mysuru 27
Desirable properties of bitumen material
• Adequate viscosity
• Low temperature susceptible
• Good amount of volatiles
• Capable of being heated
• Good affinity towards aggregates
Dr. Punith B Kotagi, NIE Mysuru 28
Dr. Punith B Kotagi 14
23-10-2024
Tests on Bitumen Material
• Penetration test • Solubility test
• Ductility test • Spot test
• Viscosity test • Float test
• Specific gravity test • Loss on heating test
• Softening point test • Water content test
• Flash and Fire point
test
Dr. Punith B Kotagi, NIE Mysuru 29
Penetration test (measure of hardness or consistency)
Dr. Punith B Kotagi, NIE Mysuru 30
Dr. Punith B Kotagi 15
23-10-2024
Ductility test (measure of adhesive property)
Dr. Punith B Kotagi, NIE Mysuru 31
Viscosity test (resistance to flow)
Orifice size = 4 mm or 10 mm
Test Temperature = 25 or 50 °C
Dr. Punith B Kotagi, NIE Mysuru 32
Dr. Punith B Kotagi 16
23-10-2024
Specific gravity test (to measure quality)
S.G of bitumen = 0.97 – 1.02, tested at 27 ±0.1 °C
Dr. Punith B Kotagi, NIE Mysuru 33
Softening point test (to know temperature upto which
bitumen should be heated for road works)
S.P = 35 – 70 °C
Heated at rate of 5 ± 0.5°C /min
Dr. Punith B Kotagi, NIE Mysuru 34
Dr. Punith B Kotagi 17
23-10-2024
Flash and Fire point test (measure of safety)
Should not be less
than 175 °C for any
grade of bitumen
Dr. Punith B Kotagi, NIE Mysuru 35
Paving grade bitumen
• BITUMEN is a petroleum product obtained by the distillation of
petroleum crude.
• TAR is a thermoplastic material obtained from the destructive
distillation of coal/wood.
• The grade of bitumen used for pavement construction work of
roads and airfields are called paving grades and used for water
proofing of structures and industrial floors etc. are called
industrial grades.
• The paving bitumen available in India is classified into two
categories
• 1) Paving bitumen from Assam petroleum denoted as A-type and
designated as grades A35, A [Link].
• 2) Paving bitumen from other sources denoted as S-type and
designated as grades S35, S90 etc.
Dr. Punith B Kotagi, NIE Mysuru 36
Dr. Punith B Kotagi 18
23-10-2024
Modified Bitumen
• Certain additives or blend of additives called as bitumen
modifiers can improve properties of Bitumen and
bituminous mixes.
• Bitumen treated with these modifiers is known as modified
bitumen.
• Polymer modified bitumen(PMB)/crumb rubber modified
Bitumen (CRMB) should be used only in wearing course
depending upon the requirements of extreme climatic
variations.
• The detailed specifications for modified bitumen have been
issued by IRC: SP: 53-1999.
Dr. Punith B Kotagi, NIE Mysuru 37
Advantages of modified bitumen
• Lower susceptibility to daily and seasonal temperature
variations
• Higher resistance to deformation at high pavement
temperature
• Better age resistance properties
• Higher fatigue life for mixes
• Better adhesion between aggregates and binder
• Prevention of cracking and reflective cracking
• Relatively economical
Dr. Punith B Kotagi, NIE Mysuru 38
Dr. Punith B Kotagi 19
23-10-2024
TYPE OF BITUMEN MODIFIER
• There are 3 type of bitumen modifier, namely
1. Physical modification
2. Chemical modification
3. Other type modification
Dr. Punith B Kotagi, NIE Mysuru 39
Dr. Punith B Kotagi, NIE Mysuru 40
Dr. Punith B Kotagi 20
23-10-2024
Dr. Punith B Kotagi, NIE Mysuru 41
Dr. Punith B Kotagi, NIE Mysuru 42
Dr. Punith B Kotagi 21
23-10-2024
Dr. Punith B Kotagi, NIE Mysuru 43
Cutback Bitumen
Dr. Punith B Kotagi, NIE Mysuru 44
Dr. Punith B Kotagi 22
23-10-2024
• Cutback bitumen is defined as the bitumen, the
viscosity of which has been reduced by a volatile
diluents.
• For use in surface dressings, some type of bitumen
macadam and soil bitumen stabilization, it is necessary
to have a fluid binder which can be mixed relatively at
low temperatures.
• Hence to increase the fluidity of the bituminous binder
at low temperatures the binder is blended with volatile
solvent.
• After the cutback mix is used in construction work, the
volatile gets evaporated and the cutback develops the
binding properties.
• The viscosity of cutback and rate of which it hardens on
the road depend on the characteristics and quantity of
both bitumen and volatile oil used as the diluents.
Dr. Punith B Kotagi, NIE Mysuru 45
Types of Cutback Bitumen
• This classification is based on the rate of curing or hardening
after the application.
• Rapid Curing (RC)
• Medium Curing (MC)
• Slow Curing (SC)
Dr. Punith B Kotagi, NIE Mysuru 46
Dr. Punith B Kotagi 23
23-10-2024
Emulsions
Dr. Punith B Kotagi, NIE Mysuru 47
• An emulsion is a two-phase system consisting of
two immiscible liquids (un mixable or un blend
able).
• The dispersed or internal phase is the liquid that is
broken up into globules and
• The surrounding liquid is known as the continuous
or external phase.
• Oil-in-water emulsions have the oil as the dispersed
phase and water as the continuous phase.
• Oil phase consisting of bitumen or tar.
Dr. Punith B Kotagi, NIE Mysuru 48
Dr. Punith B Kotagi 24
23-10-2024
Types of Emulsion
Based on setting time
• 1. Rapid setting: If the bitumen emulsion is intended to
break rapidly, the emulsion is said to possess rapid-set
quality and this type is used in surface dressing &
penetration macadam.
• 2. Medium setting: Emulsion which does not break
spontaneously on contact with stone but break during
mixing or by fine mineral dust are MC. Used in premixing
with coarse aggregate.
• 3. Slow setting: When specified type of emulsifying agent is
used to make the emulsion relatively stable, they are called
slow setting grade. Used in surface course along with the
coarse aggregate.
Dr. Punith B Kotagi, NIE Mysuru 49
Properties of Emulsion
• Residue on sieving
• Stability to mixing with coarse-graded aggregate
• Stability to mixing with cement
• Water content
• Viscosity
• Coagulation at low temperature
• Sedimentation
• Stability on long-period storage
Dr. Punith B Kotagi, NIE Mysuru 50
Dr. Punith B Kotagi 25
23-10-2024
Tar
• Tar is the viscous liquid obtained when natural organic
materials such as wood and coal carbonized or destructively
distilled in the absence of air.
• Based on the materials from which tar is derived, it is
referred to as wood tar or coal tar
Dr. Punith B Kotagi, NIE Mysuru 51
Types of Tar
• There are five grades of roads tar based on their viscosity
and other properties.
• RT-1 has the lowest viscosity and is used for surface painting
under exceptionally cold weather as this has very low
viscosity.
• RT-2 is recommended for standard surface painting under
normal Indian climatic conditions.
• RT-3 may be used for surface painting, renewal coats and
premixing chips for top course and light carpets.
• RT-4 is generally used for premixing tar macadam in base
course.
• RT-5 is adopted for grouting purposes, which has highest
viscosity among the road tars.
Dr. Punith B Kotagi, NIE Mysuru 52
Dr. Punith B Kotagi 26