GUIDE FOR

INSPECTORS

FORMAL BACHEO WITH

Hot asphalt mix
 GUIDE FOR INSPECTORS FOR FORMAL PATCHING
WITH HOT ASPHALT MIX

Solórzano-Murillo, Sandra1Salas-Chaves, Mauricio2,

Sequeira-Rojas, Wendy3Loria-Salazar, Luis Guillermo4
1Engineer of the Road Safety and Transport Unit PITRA LanammeUCR

Audit Engineer, Technical Audit Unit PITRA LanammeUCR (Reviewer)

2

3Coordinator of the Technical Audit Unit PITRA LanammeUCR (Reviewer)

4General Coordinator of the Transport Infrastructure Program (PITRA) LanammeUCR (Reviewer)

Palabras Clave:PITRA, bacheo, bacheo formal, riego de liga

Resumen:La presente publicación es el resultado de una investigación de literatura
both nationally and internationally related to the pothole repair activity. It has
with the aim of providing a tool to field inspectors to execute
the formal patching work with hot asphalt mixture. This document describes
the necessary attributes in an inspector, important concepts, necessary personnel
equipment, machinery, and materials required for the activity. It is also illustrated
and describe in simple language the detailed procedure for carrying out
of efficient work. Special recommendations for the inspector are outlined.
and a checklist is presented. Finally, examples of practices are presented.
adequate and inadequate and some typical problems of placing a folder of
hot asphalt mix and its possible causes. This guide represents an effort
from the Technical Audit Unit of the Infrastructure Program of
Transport of LanammeUCR that seeks to eliminate the recurrence of procedures
inadequate during the pothole repair work, in such a way as to guarantee works of
greater durability and an appropriate investment of resources.

References
1. Asphalt Institute (1982): Principles of Hot Mix Asphalt Pavement Construction, Series
from Manuals No. 22 (MS-22)
2. Federal Highway Administration Video VH-318, Part 1, 1996. Retrieved in October 2014 from https://
[Link]/watch?v=viAmYDTEigQ
3. Ministry of Public Works and Transport of the General Directorate of Traffic Engineering, Department
Road Signaling (2013): Technical Manual of Safety Devices and Temporary Control
Transit for the Execution of Work on the Roads.
4. Ministry of Public Works and Transportation, (2001); Volume of provisions for construction and
road conservation: Provision MN-02-2001.
5. Ministry of Public Works and Transport, (2010): General specifications manual for the
construction of roads, paths and bridges (CR-2010)
6. Ministry of Public Works and Transport, Public Works Division, (1980): Manual for
Training of Road Work Inspectors.
7. Ministry of Public Works and Transport, Division of Public Works, (1983): Construction Manual
for roads highways and bridges (MC-83)
8. PavementTools Consortium (PTC), Construction Section. Retrieved in September 2015 from www.
[Link]
9. Rodríguez, M., Castro,P., & Arce, M. (1998):Manual de procedimientos de bacheo con mezcla
hot asphalt. Costa Rica University. San José, Costa Rica: LanammeUCR. FUNDEVI.
National Learning Institute.

3
 CONTENT

CONCEPTS 7
PERSONAL 11
EQUIPMENT AND MACHINERY 11
MATERIALS 14
PROCEDURE 14

TONS REQUIRED FOR A POTHOLE 28

CHECKLIST 32

EXAMPLES 34

ANNEX 1. 42

ANNEX 2. 44

4
 INTRODUCTION

The content of the following guide aims to provide a

tool for field inspectors to carry out the tasks of
formal patching with hot asphalt mix.

This guide represents an effort by the Audit Unit

PITRA technique - LanammeUCR, which aims with this document
eliminate the recurrence of inadequate procedures during the
placement of hot asphalt mix for patching, in such a way
that ensures works of greater durability.

5
 NECESSARY ATTRIBUTES IN AN INSPECTOR

The personal attributes required in an inspector begin with

honesty. The inspector must be honest and must behave in a
fair and straight way.

In moments of pressure, you must keep your composure and take

good decisions. You must have common sense to execute
competent decisions.

You must be sincere in your relationships with people, possess skills.

diplomatic, to be polite and able to handle difficult situations without
generate hostility. Above all, you must be very observant and
to be able to keep good records. The inspector must work on
together with the engineer to determine the interventions and practices
most suitable constructive methods according to the work to be carried out.

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 [Link]

Asphalt: asphalt is a product obtained from the distillation of

oil, and it is used to strongly bind (stick) the particles of
added to the asphalt mixture. At ambient temperature it behaves
as a solid (like a hard paste), so the mixing with
the aggregates are carried out at temperatures between 150ºC and 160ºC,
depending on the type of asphalt. At these temperatures the material
It is more fluid and workable. There are several types of asphalts that have
different properties. Asphalt is the final residue that remains,
after extracting by distillation from crude oil: oils,
diesel, bunker, gasoline, etc.

Patching: it is a minor and localized repair of bituminous pavement.

with the aim of ensuring the uniformity of the surface of
bearings and repair the damages that occur at some points of
the road, which puts at risk both the integrity of the users,
the vehicles as well as the overall structure. The pothole can be
perform with hot mix asphalt.

Test patch and/or compaction strip: they are patches or strips of

tests that must be carried out to understand the behavior of the
hot asphalt mixture when placing and compacting it according to
the conditions of the site where the project is executed.

The compaction pattern defines the number of passes of the

compactor, its speed, vibration frequency, sequence of
route for a defined paving width and the optimal range
of compaction temperatures, in order to meet the density
required and a suitable quality on the surface, in accordance with the
required and available equipment on site, weather conditions,
the characteristics of the asphalt mix, among other factors.

Surface patching: Surface patching involves repairing with a mixture

asphaltic, disintegrations (potholes), deformations or crackings
severe on the rolling surface that consists exclusively of the
asphalt cover and in specific sites.

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asphalt cover Superficial scraping
Base

Subbase

Subgrade

Figure 1. Surface patching scheme on the wearing course only

Deep patching: Total or deep patching consists of repairing

disintegrations (gaps) that comprise the asphalt layer and layers
subgrades where the base, subbase, loan could be included
and up to the subgrade depending on the existing specific deterioration. These
repairs are usual for specific sites when a
severe deterioration condition, excessive moisture at the base or in the
underlying layers or where it is determined that the damage originates
due to deficiencies in the lower layers of the pavement.

Asphalt cover
Bacheo
Base
deep
Subbase

Subgrade

Figure 2. Diagram of deep patching that may include the replacement of

part of some internal layers of the pavement structure

Theoretical maximum density: corresponds to the weight ratio between

volume of the asphalt mix determined by
laboratory tests considering a maximum condition of
0% void compaction.

Loose density: weight relationship per volume

corresponding to an asphalt mix when it is found in the
staked cart

Asphalt emulsion: it consists of asphalt diluted with water (and a agent

emulsifier). In the patching process, it allows the patch to adhere to

8
the existing surface, whether it is a granular surface or a layer of
old asphalt paving, never to the ground, as it does not allow
adherence. When the surface is sprayed with emulsion, the water evaporates
leaving a layer of asphalt that acts as glue for the new one
asphalt mixture of the pothole. This asphalt film is known as
like a league cover.

When the emulsion loses water by evaporation, it is said that

"break." Depending on the time it takes to do it, they can be classified
emulsions into three categories:

•Rapid breaking: the emulsion breaks (loses water) quickly.

time.
•Of medium breakage: when the emulsion breaks (loses water) in a
greater time than rapid breakage.
Slow breakage: these are the emulsions that take longer to
to break.

At the workplace, it is easy to detect the moment when it breaks.

emulsion because a color change occurs, from brown to black that
it is the color of asphalt.

Figure 3. Breaking of asphalt emulsion.

In the patching technique, emulsions are usually used.

quick break to speed up the work procedure, with the
fin de reparar la carretera más rápido y minimizar así las interrupciones
to vehicle traffic. The breaking time for a quick emulsion

9
It takes minutes, and depends on the weather, the higher the ambient temperature.
the breaking of the emulsion is accelerated.

It should be considered that once the emulsion has broken, it should not be
wait to lay the asphalt mixture, as it loses its capacity
of adherence.

In Costa Rica, quick-breaking emulsions are usually available.

supplied by the Costa Rican Oil Refinery S.A. (RECOPE).

Exudation: it is the presence or rise of asphalt on the surface of the

pavement giving it a black and shiny appearance. They are caused by defects.
construction: contamination from excessive adhesion watering; or
they can be produced due to formulation defects: very low asphalt
viscosity or a higher dosage of asphalt than necessary in the
asphalt mixture.

Hydroplaning: effect in which adherence between the tires is lost

vehicle and the rolling surface due to the presence of a film
of water.

Priming: corresponds to a rate of irrigation of asphalt emulsion

by area of a surface of a granular or stabilized base with
cement with the aim of protecting it.

Asphalt mix: it is a heterogeneous material made up of a mixture

of aggregates of different sizes, mineral dust and asphalt, of shape
that once compacted shows sufficient properties to withstand
vehicular traffic.

League: corresponds to an asphalt emulsion spraying rate per area

on the surface of a new or existing pavement, with the aim
to provide adhesion between layers.

Profiling: cutting or roughing of one or more layers of the pavement, with

predetermined thickness, through a mechanical process carried out in
hot or cold, used as an intervention for restoration
of pavements.

Segregation: refers to the separation of coarse particles from

the fine particles in the asphalt mix. The mixture must have a

10
adequate granulometry (particle distribution), so that it
you must avoid their separation.

Thermal segregation: due to inadequate handling it occurs.

a lack of temperature homogeneity in the asphalt mix.

Maximum aggregate size: designated as a sieve larger than

the nominal maximum size of the aggregate. Typically, this is the sieve
smaller through which 100% of the aggregate particles pass.

Nominal maximum aggregate size: designated as a sieve larger than

greater than the first sieve that retains more than 10% of the particles
of aggregate, in a normal series of sieves.

2. PERSONAL

In charge
Machinery operators
Rastrillers
Peons

3. EQUIPMENT AND MACHINERY

The patching process requires the right equipment to achieve a

quality work and appropriate duration.

Camera: take a photographic record

georeferenced for the route database.

Wheelbarrows: used to transport the mix from

the cart to the potholes. The mixture does NOT
must launch with a shovel, to avoid segregation
of the particles. It must be manipulated according to
as little as possible.

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Broom and brush: it is used to clean and sweep the
surface of the pothole and the edges so that
remain free from dust or contaminating agents.

Template or gauge: piece of wood or aluminum

perfectly straight of at least 3 meters of
length, which is used to check the levels of
gap regarding the rest of the pavement.

Vibratory roller compactor: they are used for

to compact or densify soils, granular layers or
asphalt mixture. The appropriate weight must be chosen
of the compactor according to the thickness
from the pothole, in such a way that densification is achieved
adequately, without crushing the material.

Asphalt distributor with sprinklers or tank truck:

it must have a heating system and
thermometer to control the temperature, as well as
a spraying system. The asphalt sprayer
must be in good condition to obtain
homogeneous risks. Sprinklers can be used.
manuals as long as a distribution is achieved
adequate on the surface.

Air pressure equipment: the air compressor

allows sweeping the particles from the open pothole. It
complement it with manual sweeping, since this does not
it manages to eliminate the coarser particles.

Cutting or saw team: it consists of a motor that

it activates a diamond circular saw and can
cut stone materials and asphalt layers. Allows
perfectly delimit the edges of section a
repair without damaging the healthy pavement.

Backhoe: hydraulic equipment that

allows excavation and removal of material from the deteriorated area.
Itisadvisablefortheteamtohaveashortarmand
smallshovelandthattheworkeriscarefulwhileworking
toavoidaffectingbeyondwhatisnecessarytorepair.

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Shovels and picks: manual tools used
to refine the surface that will be intervened with
shoveling. It is advisable to have some shovels
squares for required flat surfaces in
the pothole.

Manual compactor: it is used for materials of

base and asphalt layers in hard-to-reach places
or for small potholes, where the compactor
The roller does not have enough space to work.
and perform its function.

Variable width profiler (optional): it is used

to remove a thickness from the asphalt layer. It
can profile the thickness of all or partially
the wear layer, eliminating only
the cracked depth. Generally with
this machinery guarantees better uniformity
in the repaired thickness. However, it is always
important the manual preparation of the edges
of the pothole. Its use must be approved by the
engineer in charge of the project.

Leveling rakes: hand tools

to accommodate the asphalt mix in the pothole
and look for well-built joints and surfaces
planes in the pre-compaction finishing.

Thermometerorthermocoupleforasphalt:theyareused
to measure the temperature of the asphalt mixture
when it arrives at the site and before being placed for
an adequate compaction.

Trolleys: they must have metal bottoms

hermetic, clean, and smooth, painted with material
that prevents the mixture from sticking to the bottom.
Provided with a waterproof tarp, to protect
the mixture against the elements.

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 4. MATERIALS

Hot asphalt mix

Asphalt emulsion
Base material
Subbase material

5. PROCEDURE

It is important to carry out the correct procedures in execution of

contracted works, so that the greatest durability is achieved and it
ensure the investment made. The specifications of the
cartel and the country's construction codes. In addition, it will not be started the
patching construction process in rainy conditions or other conditions
that prevents the correct application of the technique.

The detailed procedure for the following is presented

realization of efficient work.

a. Equipment inspection

Before the start of the work, it must be checked in advance that the
the equipment to be used is in perfect condition and that its
the operation is appropriate to ensure good results.

b. Placement of traffic prevention and control devices

The project engineer must give field staff instructions.

about the temporary signaling of work to control traffic.
It is essential for the inspector to consult the engineer about the
procedure to follow and communicate it to the teams as indicated. This
this aspect is of great importance, as it implies responsibilities
civil and criminal, where human lives are at stake.

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You must ensure that safety requirements are met.
specified in the contract. This may involve a control of
the operations of the equipment, and the use of elements such as
banderilleros, cones, barriers, warning lights and reflectors of
Agreement with the Technical Manual for Work Protection of the Directorate
General Transit Engineering of MOPT in its current version.

There must be properly identified flag bearers with the

road safety equipment and gear such as: vest
reflective, flags, intercom radio, among others.

Figure 4 shows the different types of gradual reductions.

of rail that can occur in a temporary control zone
in transit:

Space of
Damping
Longitudinal
Transition Transition Transition from
of Change of Change Convergence
1/2 L 1/2 L L

Length
1/2 L Damping
1/3 L
Transition Gradual decrease Transversal
Transition of Space of
of Change downstream track
Backrest Damping
Space of (30 meters minimum)
Longitudinal
Damping
Longitudinal

Figure 4. Gradual decrease of taper lanes and buffer space.

Source: General Directorate of Traffic Engineering, 2013

The following tables present distances as an example.

that depend on speed which could facilitate the work
field inspector to carry out traffic control of
in a safe manner:

15
 [Link].

Minimum first distance Minimum separation

Speed (km/h)
signal between signals "A" (m)
40 50 25
60 100 50
80 180 75
100 275 100

Note: the minimum distance from the first sign is measured from the first
closing cone.

[Link]
speed.

Speed (km/h) Maximum separation (m)

40 8
60 12
80 16
100 20

[Link]'L'accordingtothespeed.

Transition of Transition
Velocidad Longitud Transition from
convergence of change
(km/h) L(m) earthwork
(m) (m)
For one lane, W = 3.5 m
40 40 40 20 15
60 80 80 40 30
80 175 175 90 60
100 220 220 110 75
For two lanes, W=7.0 m
40 75 75 40 25
60 170 170 85 60
80 350 350 175 120
100 450 450 225 150

Note: the values of 'L' are approximate to the most practical values.
close.

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 [Link]
longitudinal damping.

Length Length
Speed Damping Speed Damping
(km/h) longitudinal (km/h) longitudinal
(m) (m)
30 10 70 65
40 15 80 85
50 25 90 100
60 50 100 150

The width of the lateral buffer space must be

determined by engineering criteria.

c. Personal protective devices and occupational safety

Safety is an aspect that concerns all staff

work. The inspector must be very attentive in order to guarantee
that safe conditions and practices are maintained in the project.
For the inspector, the safety of the project begins with himself.
Inspector must serve as an example in the use of safety equipment.
personal items, such as retroreflective vests, shoes, glasses,
protective clothing and helmet if necessary.

Check that the staff has the uniform and protective equipment
personal and other occupational safety elements in accordance
with the established national regulations regarding this.

d. Identify and mark the damaged area

It is the engineer's responsibility to indicate the points to the inspector.

where the patching will take place and the type of patching to be carried out. The
The area should be marked with paint, crayon, or chalk, in a way
rectangular or square. It is necessary for the marked area to cover
at least 30 cm more, separated from the deteriorated area in a way
that all weakened areas are ensured to be eliminated (Figure 5). It is not
It should mark a pothole in such a way that it is adjacent to an area.
leakage, as there is a possibility of water infiltration

17
towards the pothole and it cracks prematurely. The pothole
it must be regular, without sudden changes in its main dimensions
(Figure 6) (See Section 8: Examples).

asphalt folder Cutting area

rectangular or square Deteriorated area

0.30m

0.30m
0.30m

0.30m

Figure 5. Rectangular cut area for a pothole

Adequate
INAPPROPRIATE

Figure 6. Appropriate and inappropriate pothole shape

Source: Manual of procedures for patching with hot asphalt mix,
National Learning Institute, 1998.

e. Cut along the marked perimeter

The saw with a diamond tip is used (See Section 3: Equipment and
Machinery). It is of utmost importance that the cutting faces are
verticals, in order to ensure adhesion and union with the pavement
adjacent (Figure 7). It is not recommended to use the pneumatic hammer,
since they can cause damage to the adjacent asphalt layer.
straight cuts at their intersection must be carefully cut to
do not leave space for water to seep through them (Figure 7). In
in case cuts remain in the layer, outside the perimeter of the pothole, it
deben sellar para evitar filtración de agua o introducción de partículas
that affect the integrity of the edge. All cuts must remain
healthy and straight (See Section 8: Examples, best practices).

18
 Super straight

Figure 7. Straight finish of the cuts

Source: Manual of procedures for pothole repair with hot asphalt mix,
National Learning Institute, 1998.

f. Remove material

The material is removed with the help of the backhoe.

hydraulic (all present material must be completely removed,
including water). Shovels and picks can be used.
brooms and the pressure air equipment to leave the surface well
clean (Figures 8 and 9). The extraction of material must be done with
carefully, in order to ensure that a firm support base remains,
with healthy and well-cut edges (See Section 8: Examples, practices
suitable). Although the extraction of the material can be done with
Back Hoe, the final finish must be done with a shovel and brush to
maintain an appropriate surface. The bottom of the pothole must be
as much as possible, level, without undulations, gaps, or cracks,
in mounds of material (Figure 9).

Do not open the potholes without

news cut the
borders Tools for
cutting edge
Take care of the edges and not
weaken or alleviate the
base

Figure 8. Removal of the pothole material

Source: Procedures manual for pothole repairs with hot asphalt mixture,
National Learning Institute, 1998.

19
 Figure 9. Poorly prepared patch and suitable surface
Source: Hot asphalt mix patching procedures manual,
National Learning Institute, 1998.

In potholes where the pavement profiling is carried out (Figure 10 and

It will be carried out on areas previously approved by the engineer.
at room temperature and without the addition of solvents or other products
softeners that may affect the gradation of the aggregates or
the properties of the existing asphalt. The depth will be defined by
the responsible engineer.

Figure 10. Scarification of existing layer

Source: Federal Highway Administration Video VH-318, 1996.

It should be clear that the profiled material is the property of the State.
so it must be sent to the nearest MOPT facility or of
in accordance with the engineer in charge's criteria, use it in a way
efficient for purposes in favor of the State. In the vicinity of
sewer manholes, joints with the existing pavement
and in places inaccessible to profiling machinery, the pavement
It must be removed using methods that result in a surface.
suitable for the placement of the new layer.

20
 Figure 11. Scarified surface

g. Place filler material

In the case of a deep pothole, the base must be replaced.

and the subbase with a granular material of good quality to use it
up to the height where the asphalt mixing layer starts how
as shown in Figure 2. All this material must be compacted
with the help of a manual compactor prior to placement of the
mix. It is advisable to compact in layers no greater than 20 cm,
depending on the weight of the compactor.

h. Apply league irrigation

The league irrigation should be applied throughout the area, including the walls.
like the bottom of the cut. The irrigation should not pool at the bottom of the
the walls must be well covered. The distribution of
asphalt must be uniform (see Figure 12). The emulsion must be at the
suitable temperature (usually at 60ºC) to facilitate irrigation of
asphalt. The start of the placement of the mixture must be coordinated to
that the emulsion breaks with the ambient temperature, how can it be done
observe in Figure 3 of this guide. It should be dosed at a rate of
irrigation indicated by the project engineer, so that it is a
sufficient amount for full coverage if the application is deficient
or very little will not have adequate adherence, however it should not
be excessive, as it may affect the characteristics of the mixture
asphalt generating damages such as deformations or

21
exudation (See Annex 1. Typical problems of the mixing folder
hot asphalt and its possible causes). The inspector with the help of the
verification laboratory (or in its absence with quality control)
will carry out the tests to ensure that the irrigation rate used
in the field corresponding to the one indicated for the project each time
indicate the project engineer (See Annex 2. Types of league irrigation).

POOR ADHERENCE Adequate adherence

Figure 12. League irrigation at the bottom of the pothole

Fuente: Manual de procedimientos de bacheo con mezcla asfáltica en caliente,
National Learning Institute, 1998.

An easy way for the inspector to verify the irrigation rate.

daily, in addition to performing the visual auscultation of the irrigation,
consists of reviewing the initial content level of emulsion in the
tank that contains it (asphalt distributor or tank) and at the end of
the day to review the content level again to estimate in
liters the consumption of the day. Make a measurement and estimation of the area.
from the potholes and add the areas. The division of liters consumed by
the summation of the areas multiplied by that corresponds to the
contenido de asfalto requerido, le dará un estimado de la tasa de riego
of the league. The equivalent to that would correspond to the evaporated water
of the emulsion.

i. Placement of hot asphalt mix

Before placement, it is necessary to check that the cart carrying

the hot asphalt mix will arrive with a tarp or other material of
protection that prevents contamination during the journey and allows for
in addition to maintaining the temperature. You should visually check if the
mixture shows signs of being overheated, such as smoke
blue that rises from the truck mix or have an appearance
opaque (see Annex 1. Typical problems of the mixing folder
hot asphalt and its possible causes.) It is important to verify that
the gondola is not contaminated with other materials such as soil.
In addition, the seal must be verified by cart.

22
The inspector must ensure to complete the information on the ticket.
Delivery guide for asphalt mixture, which must be completed with
the following instructions:

Figure 13. Hot asphalt mix delivery guide.

Instructions for using the asphalt mix delivery guide

1. Delivery information: it refers to the data corresponding to

project, contractor, destination, route, area, date and time, that must
indicate in this delivery guide.

1.1. Project: name of the project where the mix is sent

asphaltic.

23
 1.2. Contractor: name of the contractor awarded the
project. If it is a natural person, the first name and two last names must be indicated.
1.3. Date: day, month, and year when this delivery is made. It must
indicate with two digits for the day, two for the month and four for the year
the year.
1.4. Time: indicate the time at which the dispatch is made.
asphalt mixture.
1.5. Destination: place where the mixture will be sent.
1.6. Route: designation established in the Ministry of Works
Public and Transport.
1.7. Zone: place where the project is being developed.

2. Asphalt mixing dispatch: information about the exit of the

asphalt mixture and the site where it is dispatched.

2.1. Carrier: name of the carrier responsible for

transport of the asphalt mixture.
2.2. Plate: license plate number of the vehicle in which it is transported
asphalt mixture.
2.3. Marchamo: vehicle security seal number that
transport the asphalt mix.
2.4. Outlet temperature: temperature in degrees Celsius of the
asphalt mixture at the moment it is delivered to the transporter
who is responsible for his/her transfer.
2.5. Time: hours and minutes when the exit temperature was taken.
2.6. Cantidad:cantidaddetoneladasdemezclaasfálticadespachada.
2.7. Sampled wagon: mark with an X in the space
corresponding if the wagonette was sampled or not.
2.8. Trip No.: corresponds to the trip number.
2.9. Sampler: name and two surnames of the responsible person
to sample this dispatch.
2.10. Observations: space to indicate any special situation
in this office.
2.11. Name and signature of the plant inspector: name and two
surnames of the Inspector in charge of the inspection at this plant.

3. Reception of the mixture on site: corresponding information

to the process of receiving the mixture on site at the construction site, arrival of the
material, installation section and use of the material.

24
 3.1. Arrival of the material: indicate the time when the asphalt mixture
he arrived at the site and the temperature in ºC at the time of his arrival.
[Link] placement section: indicate from where to where
he is going to place the asphalt mix, the time in hours and
minutes and the temperature of the asphalt mixture at the time of the
placement. Number and name of the control section.
3.3. Initial kilometer: indicate the initial kilometer established for the
repair of the respective route.
3.4. Final kilometer: indicate the established final kilometer for the
repair of the respective route.
3.5. Use of the material: mark with X in the corresponding space
to the use that will be given to the material indicated in this guide.
3.6. Observaciones:espacio para indicar alguna situación especial
related to the receipt of the material.
3.7. Name of the inspector on site: name and two surnames of
On-site inspector in charge of controlling the repair of the road.
3.8. Company: Signature of the inspector indicated in point 3.7.

THE USE OF THE 'TRABA' SHOULD NOT BE ACCEPTED,

activity that consists of spreading a thin layer
asphalt mix less than 4 cm in the area to be patched
once the league's irrigation has been applied and broken.

j. Compaction

When the asphalt mix layer that needs to be placed is greater

At 10 cm, compaction should be carried out in sub-layers less than the
10 cm and larger than 3 times the maximum nominal size of the aggregate,
for example: for a mixture of maximum nominal aggregate size
For 12.5 mm, the minimum thickness will be 4 cm compacted, see Figure.
14. The layers must be compacted on the same day, under the same
temperature conditions for placement and compaction and taking care
that the surfaces between layers do not get contaminated, which ensures
adhesion between layers, so work is not allowed on the day
next, it should also be avoided that an irregularity remains
important to the surface for more than 24 hours that affects the
safe transit of users. The last layer should extend over

25
above the road level (a height indicated by the engineer),
so that after compacting, the pothole remains the same
existing pavement level (Figure 15). In any case, it is necessary to
use roller compactors, except that the dimensions
Do not allow the pothole.

THE MATERIAL SHOULD NOT BE THROWN WITH A SHOVEL, IT

IT MUST BE PLACED IN SUCH A WAY THAT NOT
PRODUCE SEGREGATION, with care and less
90 cm in height.

During the compaction process, the hot asphalt mixture must

oscillate between 90ºC and 110ºC in temperature, but it is particular for
each project and the characteristics of the asphalt mix, the manual
road conservation recommends that the placement temperature and
compaction will not be less than 100°C.

The desired compaction will range between 92% and 97%, a range that
it must be verified in the bidding notice.

The inspector is responsible for checking the temperature of the

mix, in two or three points, for each download and will reject it if not
exceeds the specified minimum temperature for compaction, according to
the established terms in the bidding notice.

Raining code, the inspector must stop it

PLACEMENT OF HOT ASPHALT MIX.

In addition, the inspector is responsible for reviewing compliance.

with the compaction pattern established according to the test pit
or the control strip and decide if a new test pit is required

26
in case the thickness conditions change, change of
compactor, characteristics of the mixture or weather conditions. In
It is advisable to compact the edges first on the surface of the pothole.

4 cm minimum
10 cm maximum
in a single layer

Figure 14. Reference thicknesses for a nominal size of 12.5 cm

Source: Manual of procedures for pothole patching with hot asphalt mix,
National Learning Institute, 1998.

Excess asphalt mix

for compaction
Leveling rake

Acceptable level

Figure 15. Excess mixing for compaction

Source: Manual of procedures for patching with hot mix asphalt,
National Learning Institute, 1998.

k. Check pothole level

Using a ruler or template, the level and smoothness must be checked.

of the pothole along its perimeter. The surface finish of the pothole
it must be homogeneous and have an appropriate texture. If the edges do not
they are found to be regular, irregularity problems occur that
they translate into inconveniences for the user and operating overcosts
for the vehicles. In addition, it must be checked that it is maintained
pumping of the roadway (cross slope for drainage)
surface water).

27
1. Apply seal

It is advisable to apply a seal along the perimeter of the pothole.

The application consists of a liquid asphalt treatment, along with a
fine aggregate application. The above significantly increases
the lifespan of the pothole.

m. Remove waste, leftovers, remove equipment and safety signs

All debris and control devices must be removed.

transit for the reopening of the road, after verifying that the
the mixture has cooled and has the adequate support capacity for
resist the loads of traffic.

[Link] photographs

They should take some georeferenced photographs and with an indication of

the route and control section, of outstanding and/or representative cases,
in the final situation, which allows to show the work done.

[Link] REQUIRED FOR A POTHOLE

To calculate the required amount of tons, it is necessary to cube.

the pothole and multiply it by the density of the placed mixture.

Calculation of pothole volume

The volume of the pothole will be determined by measuring several

thicknesses distributed in a grid pattern across the width and length
from the pothole. It is recommended to take a thickness measurement using
a template or a cord to reference the upper surface
from the pothole several times, depending on the size of the pothole. Also
it can be measured using a thickness gauge like the one that
is shown in Figure 16c. The greater the number of measurements, the more accurate
it will be the measured volume.

28
 (a) (b)
tensed rope or
love template
(c)
h

Measurement points to obtain

the average height of the pothole Thickness gauge

Figure 16. Schematic for measuring pothole thickness

Source: Manual of procedures for patching with hot asphalt mix
National Learning Institute, 1998.

The volume of a rectangular pothole will be calculated using the formula:

Where:

V = Volume of pothole in m3(cubic meters)

A = Ancho en metros
L = Largo en metros
ep average thickness in meters

sum of all thicknesses measured in meters

n = number of measurements taken

Example:

If 6 thicknesses were measured in a pothole: 12 cm, 12 cm, 15 cm, 12 cm,

13 cm and 14 cm, and the width is 1.20 m and the length is 2.35 m, it
will have the following:

29
Conversion of centimeters to meters:

Volume of the pothole

Volume of irregular potholes

The cut potholes must have rectangular shapes with few

irregularities. To calculate the volume, the volumes of will be added.
cada parte rectangular usando la fórmula anterior.

Figure 17. Irregularly shaped pothole

Source: Manual of procedures for patching with hot asphalt mix,
National Learning Institute, 1998.

The total volume of that irregular pothole will be:

Density: relationships between volume and weight

The density of a material is the relationship between its mass (weight) and the
volume it occupies. That is to say, the heavier a material is in a
determined volume, the denser it is (example: a cube of iron
and a styrofoam cube can have the same volume as that of
iron weighs much more). Asphalt mixtures can have different
densities depending on the materials that compose it. On the other hand, a

30
the same asphalt mixture can have different densities depending on the
compaction that is applied and the arrangement of its particles.
In the same way, a granular material from the base, subbase or
Soil will be denser the more compacted it is.

For example, an asphalt mixture could have a density

approximately 2200 kg per cubic meter
(2,2 to 3), when it is in the cart or stacked, it is called density
release. This same properly compacted asphalt mixture could
to have an approximate density of about 2300 kg per meter
cubic (2.3 t/m)3), when it has been placed and compacted in the pothole.
The exact density value depends on the working formula and the
components that are being used on the day of production. In the design
The density of the mixture is obtained from the mixture, and this density varies.
considerably between one mixture and another.

Figure 18. Loose and compacted asphalt mix

Source: Manual of procedures for pothole filling with hot asphalt mix,
National Learning Institute, 1998.

Calculation of tons required for a pothole

Generally, patching is paid for by tons of mixture placed and

the following operation is performed:

Where:

T =Toneladas de mezcla asfáltica

V = Volume of the pothole in m3
D = Maximum theoretical density in
%C = Required compaction percentage

31
Example:

Yes, the volume of the pothole is 0.353 m3the maximum theoretical density
from the mixture to place is and the percentage of
desired compaction of 92% (0.92). The amount of mixture in
tons to search would be:

For the pothole of the example, 0.812 tons of are required.

asphalt mixture.

Unit of measurement:

Tonne[t]

Note: 1000 kg is equivalent to one ton

It is the responsibility of the project engineer to define the

guidelines for the interventions to be carried out in accordance
to the types of deterioration found and to an analysis
technical-economic justification for the intervention.

7. CHECKLIST

Below is an example of a checklist that is

You can use it in the field to verify, before starting the work, that
everything necessary is available to carry out the pothole repair properly
adequate.

32
Table 1. Checklist of equipment required by the inspector and
of materials and machinery required by the contractor.

OBJECT ✓
EQUIPMENT REQUIRED BY THE INSPECTOR
Field Notebook
Chalk or paint for marking pavement
Official forms of the institution
Pencil or pen
Measuring tape
Rope or strap / template
Thermocoupleandcase
Helmet and safety vest
Portable calculator
Copy of the pothole repair procedure manual
Communication device
MATERIALS
Asphalt mix
Asphalt emulsion
Base and sub-base material (if required)
EQUIPMENT AND MACHINERY
Shovels and picks
Brushes and Brooms
Air pressure equipment
Wheelbarrows
Leveling rakes
Codal / stencil
Asphalt distributor with sprayer (manual or truck)
Cutting or saw equipment
Backhoe
Profile cutter (optional)
Vibratory roller compactor
Manual compactor

33
 [Link]

Appropriate Practices

Location and demarcation of

edge to cut to carry out the
boy.

Saw team with disc of

diamond for making the cut
from the ditch.

Remove the cracked surface.

34
The tuning of is observed
corners and walls of the pothole
with a bar so that they are
totally vertical, it can
to be carried out through a peak.

Cleaning of the surface of the

suction through a compressor
of air.

Application of league irrigation.

The application is uniform and
homogeneous. Verify what
the walls of the cut of
girls remain impregnated
uniformly of the league irrigation.

35
 Temperature check
from the asphalt mixture before
compaction is carried out
in each download. Each
temperature check
of hot asphalt mixture
must be found within the
range established in the contract.

Tuning of the surface of the

rake the lawn,
which must be cleaned with
a solvent. To prevent that
the solvent affects the mixture
it is recommended that the asphalt
rake or another element such as
shovels, picks or bars are used
completely dry.

In case the pothole is of

large dimensions will be carried out
compaction through the
use of a compactor
roller vibrator. Continued
the compaction pattern and the
The process is carried out in strips.

36
Compaction of mix
new asphalt placed
through the use of a
compactor plate.

Example of formal patching

completed.

37
 Deficient Practices

Therepairmustincludeallthe
cracked area. In addition, they use
"hinder" when it is not necessary.

The walls of the pothole must

be straight and not irregular like
is shown in the photograph.

The surface of the pothole

it is irregular. Furthermore, the
cracks observed
they can be reflected in the
new asphalt mixture. By
on the other side, the walls of the
the bushes were not cut
adequately. It is necessary
check the minimum thickness.

Bar placed in 2 layers.

Pollution of the first
cover on which it will be placed
the second to complete
the total thickness of the pothole.
The adhesion between layers
of asphalt mix is seen
damaged and also the thickness
does not meet the appropriate minimum.

38
The "Back Hoe" circulates above
from the fresh asphalt mix
Installed. The tires pollute.
and harm the adherence between
the asphalt mix layers in
hot. The cracking is noticeable.
in the adjacent areas. Additionally
It should be emphasized that neither the backhoe
nor are the carts equipment for
the compaction of the mixture
asphalt.
The asphalt mixture should not be
launch, since this causes
thermal segregation and separation
the fine particles of the
thick affecting quality and the
durability of the applied layer.

The surface of the pothole is

irregular. The surface does not
is completely clean
of loose material. When there exists
considerable variations of
thickness, the compaction could
not be homogeneous.

The completed pothole is located

approximately 3 cm per
below the original level of the
road surface. The pothole
must maintain the conditions
originals of the surface of the
road, considering even
the necessary pumping.

39
 The mixture must be avoided
stand out from the surface
original from the ring. It must be
check the level by using
of a codal.

Bad conditions of
compaction of the different
bache layers could cause
significant sinkholes. The
water accumulation may
cause hydroplaning.

Irregular rolling surface

construction product
of different potholes with bad
finished.

Poorly finished could generate

differences in level in the
surface of the ring.

40
Mixture should never be placed
asphalt under conditions of
rain.

41
 9. ANNEX 1

Typical problems of the hot asphalt mix folder and its

possible causes

x x x x
x x x
x x x x x
x x x x x x x x x x
x x x x x x x x x x x
x x x x x x x x
x x x x x x x
x x x x x
x x x x x x x x x
x x x x
x
x x x x
x x x x x x x x
x x x x x x x x x

Source: Taken from principles of mixed pavement construction

hot asphalt (MS-22), Asphalt Institute.

42
Types of pavement imperfections that can occur when placing mixtures
of plant

Exudation
Opaque appearance
Points with excess asphalt or greasy
Poor surface texture
Uneven rough surface
Crumbling or rotten
Unequal lines
Tracks of the compactor
Waves or Displacement
Cracking (many fine cracks)
Cracking (long and large cracks)
Rocks fractured by the compactor
Surface displacement during placement
Displacement of the surface on the base

43
 10. ANNEX 2

Types of league irrigation

44
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 National Laboratory of Materials and Structural Models
C.P.11501-2060, San José, Costa Rica
Tel.: (506) 2511-2500 / Fax: (506) 2511-4440
Email: [Link]@[Link] / Web: [Link]