MIX DESIGN DENSE BITUMINOUS MACADAM (DBM-3) PREPARATION OF MOULDS

Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

Proportion 40mm 20mm 10mm Dust 30% 10% 18% 42%

Sieve size

JMF % Passing

Percentage retained 0 8 15 8 22 13.8 10.2 5.6 17.2

W.t retained , gm 0 332 655 355 950 593 437 241 738

Cum W.t retained, gm 0 94 860 1647 2657 3074 3834 4094 4832

Added bitumen % by Wt. Of aggregate 3 3.5 4 4.5 5 Wt. Taken 133 156 179 202.5 226

45 37.5 26.5 13.2 4.75 2.36 0.3 0.075 Pan Total

100 92 77 69 47 32.9 22.8 17.2

As per the above table for each specimen 4300gm of aggregates were taken & kept in the oven at 1050 C +/- 50C for overnight. Aggregates are heated to a temperature of 1600C after removing from the oven and mixed with required quantity of Binder 60/70 grade as given in the above table and temperature of binder was maintained at 1550C +/- 50C. Mould assembly and compaction hammer will be heated to 1000 C. Moulds are cast with 112 blows on both sides as mentioned in modified marshall method. for each different binder percentage, 3 nos of moulds are prepared & marked with Bitumen % on its face. After demoulding the over night cured moulds, weight in air, weight in water and weight of saturated surface dry (SSD) of each moulds are recorded and placed in waterbath at 600C +/- 10C for a period of 30 minutes, and Marshall stability & flow tests are performed for the same.

QC Mgr; HCC

ME; LASA

MIX DESIGN DENSE BITUMINOUS MACADAM (DBM-3) CONCLUSION

Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

Analysing the test results, it can be observed that, the binder content between 3.8% to 4.3% is satisfying all the marshall parameters (By modified marshall method) and also contract specification requirements. In order to maintain the air void always above 4% and close to 4.5% which is the mid value as specified in MoRTH, we have chosen optimum binder content as 4% instead of theoritycal optimum binder content 4.05%, which lies approximately in the centre of acceptable range. Marshall moulds are prepared with 4% bitumen content and results are given below. Moulds are also cast at 600 & 750 blows with 4% bitumen, which shows air void of 3.2% & 3.1% respectively. Calculated effective binder content ( Pbe ) is found to be 3.7 %.

Marshall parameters Maximum compacted density, g/cc Marshall stability, kg Air voids, % Voids in mineral aggregates, % Voids filled with bitumen, % Flow value, mm

Modified Marshall characteristics Bitumen: 4 % 2.613 2658 4.5 13.8 67.4 3.9 Sp. Limit NA 2025 3-6 Min 11 65 - 75 3-6

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MIX DESIGN DENSE BITUMINOUS MACADAM (DBM-3) PERMISSIBLE VARIATION FROM JMF FOR THE PLANT MIX
Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd. % Passing IS Sieve; mm

Specification as per MoRTH

(Table 500-10)

Proposed limit as per MoRTH

(Table 500-13)

JMF

Coarser Limit
45 37.5 26.5 13.2 4.75 2.36 0.3 0.075 100 95 63 55 38 28 7 2

Finer Limit
100 100 93 75 54 42 21 8

Coarser Limit
100 92 72 55 32 23.5 6.8 2.8

Finer Limit
100 100 88 69 44 33.5 14.8 6.8 92 77 69 47

100

32.9 22.8 17.2

Sp. Coarser Limit

Sp. Finer Limit

Proposed Finer Limit

Proposed Coarser Limit JMF

100 90 80

70
60 50 40 30 20

10
0 0.01

0.1

10

100

Proportion: 40mm 20mm 10mm Crusher dust

: 30% : 10% : 18% : 42%

* JMF: JOB MIX FORMULA (DESIGN GRADING)

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MIX DESIGN DENSE BITUMINOUS MACADAM (DBM-3) RANGE FOR ACCEPTABLE BITUMEN CONTENT & OBC
Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

SGMA VMA - CDMA - VIM

Satisfies all criteria 3.8 4.3

Voids in mineral aggregates (VMA)

Voids Filled with Bitumen (VFB) 4.3 5 Air Voids (VIM) 4.0 5.5 Stability 3.1 Flow 3.5

4.0

4.5

5.0

5.5

Binder Content of total mix

Satisfies Criteria

Does not satisfy criteria

Fig: 1 - Evaluation of test results, DBM-3

From Fig:1, it can be seen that, the marshall test criteria (Stability, VIM, VMA, VFB & Flow) are all satisfying binder content ranging from 3.8% to 4.3% . Therefore optimum binder content is choosen as 4.05, which lies approximately in the centre of acceptable range.

QC Mgr; HCC

ME; LASA

MIX DESIGN BITUMINOUS CONCRETE , BC-1 TEST PROPERTIES OF BITUMEN BY MODIFIED MARSHALL METHOD
Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

% Of Bitumen
CDM, g/cc Air Voids, % Stability, Kg VFB, % VMA, % Flow, mm
2.570 2.560 2.550 2.540 2.530 2.520 2.510 2.500 2.490 3 3.5 4

3.5
2.496 8.4 1761 47.8 16.1 2.6

4
2.516 6.9 1833 56.6 15.9 3

4.5
2.545 5.0 2108 67.2 15.4 3.3
9.0 8.5 8.0 7.5 7.0 6.5 6.0 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 3 3.5 4

5
2.559 3.7 1871 75.7 15.3 4.0

5.5
2.551 3.2 1778 79.8 16.0 5.3

4.5 % Bitumen

5.5

Air voids (%)

Density (g/cc)

4.5 % Bitumen

5.5

CDM (g/cc)
2200 2100 85 80 75

AIR VOIDS (%)

Stability (kg)

2000 70 1900 1800 1700 1600 45 1500 3 3.5 4 4.5 % Bitumen 5 5.5 6 40 3 3.5 4 4.5 5 5.5 6

VFB (%)

65 60 55 50

% Bitumen

STABILITY (Kg)
17.0 16.5 16.0 VMA (5) 15.5 15.0 14.5 14.0 3 3.5 4 4.5 5 5.5 6 5.5 5.0

VFB (%)

Flow (mm)

4.5 4.0 3.5 3.0 2.5 2.0 3 3.5 4 4.5 5 5.5 6

% Bitumen

% Bitumen

VMA (%)

FLOW (mm)

QC Mgr; HCC

ME; LASA

MIX DESIGN BITUMINOUS CONCRETE , BC DESIGN GRADING

Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd. % Passing 20 mm 100 72 18 1.2 0.3 0 0 0 0 0 0 40 mm 28% 28 20.3 5.0 0.3 0.1 0 0 0 0 0 0 20 mm 22% 22 22 22 18.5 0.5 0.4 0.3 0 0 0 0 10 mm 50% 50 50 50 50.0 46.1 32.6 22.4 17.2 12.4 8.3 5.1 100 92 77 69 47 32.9 22.8 17.2 12.4 8.3 5.1 10 mm 100 100 100 84 2.3 1.7 1.5 0 0 0 0 Grading Design Mid 100 90 69 62 45 36.0 27.0 21.0 15.0 9.0 5.0 Lower 100 79 59 52 35 28 20 15 10 5 2 5.6 mm 100 100 100 100 92.2 65.1 44.9 34.3 24.8 16.6 10.2 Limit Upper 100 100 79 72 55 44 34 27 20 13 8

IS Sieve in mm 26.5 19 13.2 9.5 4.75 2.36 1.18 0.6 0.3 0.15 0.075

IS Sieve; mm 26.5 19 13.2 9.5 4.75 2.36 1.18 0.6 0.3 0.15 0.075

100

90 80 70
60 50 40 30 Coarser Limit Mid Limit

Finer Limit

20 10 0 0.01 Design grading

0.1

10

100

QC Mgr; HCC

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MIX DESIGN DENSE BITUMINOUS MACADAM (DBM-3) PROPERETIES OF COLD BIN AGGREGATES
Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

IS Sieve, mm
45 37.5 26.5 13.2 4.75 2.36 0.3 0.075

% Passing 40 mm
100 72.4 18.03333333 1.2 0.333333333 0 0 0

20 mm
100 100 100 83.93333333 2.333333333 1.666666667 1.5 0

10 mm
100 100 100 100 92.2 65.1 44.86666667 34.33333333

Dust
0 0 0 0 0 0 0 0

Trial-1
IS Sieve; mm
45 37.5 26.5 13.2 4.75 2.36 0.3 0.075

40 mm 27%
27 19.5 4.9 0.3 0.09 0 0 0

20 mm 13%
13 13 13 10.9 0.3 0.2166667 0.195 0

10 mm 15%
15 15 15 15.0 13.8 9.8 6.73 5.15

Dust 45.0%
0 0 0 0 0 0.0 0.0 0.0

Achieved grading
55 48 33 26 14.2 10.0 6.9 5.2

Sp. Mid Grading

100 90 69 62 45 36 27 21

Trial-2
IS Sieve; mm
45 37.5 26.5 13.2 4.75 2.36 0.3 0.075

40 mm 30%
30 21.7 5.4 0.4 0.1 0 0 0

20 mm 10%
10 10 10 8.4 0.2 0 0.15 0

10 mm 20%
20 20 20 20.0 18.4 13.0 8.9733333 6.8666667

Dust 40.0%
0 0 0 0 0.0 0.0 0.0 0.0

Achieved grading
60 52 35 29 19 13.2 9.1 6.9

Sp. Mid Grading

100 90 69 62 45 36 27 21

Trial-3
IS Sieve; mm
45 37.5 26.5 13.2 4.75 2.36 0.3 0.075

40 mm 30%
30 21.7 5.4 0.4 0.1 0 0 0

20 mm 10%
10 10 10 8.4 0.2 0.1666667 0.15 0

10 mm 18%
18 18 18 18.0 16.6 11.7 8.076 6.18

Dust 42.0%
0 0 0 0 0.0 0.0 0.0 0.0

Achieved grading
58 50 33 27 17 11.9 8.2 6.2

Sp. Mid Grading

100 90 69 62 45 36 27 21

Note:

Trial -3 has been chosen as the design grading

QC Mgr; HCC

ME; LASA

MIX DESIGN DENSE BITUMINOUS MACADAM (DBM-3) MID GRADING OF AGGREGATE

Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

IS Sieve
26.5 19 13.2 9.5 4.75 2.36 1.18 0.6 0.3 0.15 0.075

Specification as per MoRTH

(Table 500-10)

Mid Limit
100 90 69 62 45 36 27 21 15 9 5

Coarser Limit
100 79 59 52 35 28 20 15 10 5 2

Finer Limit
100 100 79 72 55 44 34 27 20 13 8

100

90 80
70 60 % Passing 50 40 30 20

Finer Limit

Coarser Limit

Mid Limit
10

0 0.01

0.1

1 Sieve Size; mm

10

100

QC Mgr; HCC

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MIX DESIGN BITUMINOUS CONCRETE , BC INDIVIDUAL GRADING ANALYSIS

Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

IS Sieve
26.5 19 13.2 9.5 4.75 2.36 1.180 0.6

Agg.-A 20 mm
100 72 18 1 0.3 0 0 0 0 0 0

Agg.-B 10 mm
100 100 100 84 2.3 1.7 1.5 0 0 0 0

Agg.-C 5.6 mm
100 100 100 100 92.2 65.1 44.9 34.3 24.8 16.6 10.2

0.3 0.15 0.075

100 90 80 70 60
% Passing

20 mm

50 40 30 20 10 0 0.01 5.6mm

10 mm

0.1

1
Sieve size; mm

10

100

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4.8 3.6 4.5 3.8 0.56789 4.175

MIX DESIGN DENSE BITUMINOUS MACADAM (DBM-3) PROPERTIES OF MIX INGREDIENTS

Contract: Client: Engineer: Contractor: Material: Source of aggregate: Description of material: Property Gradation: Flakiness & Elongation index: Water absorption: Specific gravity: Aggregate Impact Value: Soundness: Sand equivalent of Fine aggregate: LA Abrasion value: Coating and Stripping of Bitumen Aggregate mixture Plasticity Index: Water sensitivity: Stone polishing value: Material: Type of Bitumen: Source of Bitumen: Property Specific gravity: Penetration: Ductility: Softening point: Water content: Flash point: Paraffin wax content: Loss on heating, TFOT: Matter soluble in trichloroethylene: Frass breaking point Penetration ratio: Absolute viscosity at 600C: Kinemativ viscosity at 1350C: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd. AGGREGATE (For data sheet see Annexure-1) DANKARI STONE QUARRY 40mm , 20mm ,10mm , 5.6mm and Crusher Dust Standard IS:2386 Part - 1 IS:2386 Part - 1 IS:2386 Part - 3 IS:2386 Part - 3 IS:2386 Part - 4 IS:2386 Part -5 IS: 2720 Part- 37 IS : 2386 Part - 4 IS :6241 IS: 2720 Part- V ASSTHO T-283 BS: 812 Part- 114

* Measured value
See Appendix - 1 24 0.227 to 0.617 Appendix 1 11.8 0.45 68.2 16 100 coating Np RA 61

Parameter Particle size and percentage combined ( % ) % Gs AIV Cummulative Loss(%) SE (%) % wear % % % -

Range Table 507 MORTH Max = 30 Max = 2 % NA Max = 27% Max = 12% Min = 50% max = 35 0.50% Antistipping agent Max = 4% Max = 80% Min = 55

BITUMEN (For data sheet see Annexure-2) 60 / 70 grade IOCL HALDIA Standard IS: 1202 IS: 1203 IS: 1208 IS: 1205 IS: 1211 IS: 1209 & IS: 1448 IS: 10512 IS: 1212 IS: 1216 IS: 9381 IS: 1203 IS: 1206 Part-2 IS: 1206 Part-3

* Measured value
1.036 61 >100 50 RA 360 RA 0.06 RA RA 35.6 RA RA

Parameter Ratio Pen cm

0

Range Min- 0.99 6 0 - 70 Min- 75 40 - 55 Max- 0.2 Min- 175 Max- 4.5 Max- 1 Min- 99 Min- 35

% by mass
0

% by mass % by mass % by mass

Poises Centistokes (cst)

1000 200 Mion- 150

The data sheets for Measured value of various tests attached in Annexure-1. External test report on Bitumen carried out at IIT; Kharagpur attached. RA = Results awaited from IIT; Kharagpur

QC Mgr; HCC

ME; LASA

MIX DESIGN DENSE BITUMINOUS MACADAM (BC) trial -1 DENSITY VOID ANALYSIS
Contract: Client: Engineer: Contractor: Four laning of Km.0.000 to Km.77.000 of Chandikol-Paradip section of NH-5A in the state of Orissa Paradip Port Road Company Limited Lea Associates South Asia Private Limited Hindustan Construction Co. Ltd.

Mix Type Bitumen Content Wt. Of Mix Bitumen Content by Wt. Of Agg Coarse aggregte (A) Fine aggregate (B) Passing 75 m (C) Total Volumetric Computation Bitumen/Gsa Vol of Agg - A (A/Gsb) Vol of Agg. -B (B/Gsb) Vol Agg.C (C/Gsa) Volume Specific Gravities Gsb or SGMA Gmm- measured Gse- based on measured Gmm Gmm at other bitumen content

Proportion of Total Aaggregate

Proportion of Ingredients by Weight of Mix (%) at Various Bitumen Contents 3.5 3.627 4 4.167 50.9 40.2 4.9 100 3.857 17.467 14.213 1.752 37.290 4.5 4.712 50.6 40.0 4.9 100 4.339 17.376 14.139 1.743 37.598 2.680 2.896 2.725 2.496 2.409 8.4 16.1 47.8 2.702 2.516 2.415 6.9 15.9 56.6 2.680 2.545 2.430 5.0 15.4 67.2 2.658 2.559 2.431 3.7 15.3 75.7 2.636 2.551 2.411 3.2 16.0 79.8 5 5.263 50.4 39.8 4.8 100 4.822 17.285 14.065 1.734 37.906 5.5 5.820 50.1 39.6 4.8 100 5.304 17.194 13.991 1.725 38.214 -

53 41.9 5.1 100

51.1 40.4 4.9 100 3.375

18.194 14.806 1.825 34.825 2.871

17.558 14.287 1.761 36.982 -

Compacted Density of Marshall specimen - CDM, (gm/cc) Measured Compacted Density of Mineral Aggregate-CDMA, (gm/cc) Calculated Voids in Mix-VIM (%) ,Calculated Voids in Mineral Aggregate-VMA (%),calculated Voids Filled with Bitumen-VFB (%),Calculated SPECIFIC GRAVITY & WATER ABSORPTION OF AGGREGATES MATERIAL Bitumen Coarse aggregate A Fine aggregate B Passing 75 m C Formulae: 2.913 2.830 Sp. Gravity Gsb Gsa 1.037 2.927 2.862 2.794 0.16 0.390

Water Absorption(%) Gsb:- Sp Gr Bulk Dry Gse:- Sp Gr Effective Gsa:- Sp Gr Apparent Gmm:- Maxm theoritical Sp. Gravity

CDM CDMA = --------------------Bit 1 + ----------100

SGMA - CDMA VMA = --------------------------- X 100 SGMA

Pmm - Pb Gse= ----------------------------------Pmm Pb ----------- ------Gmm Gb

Gmm - CDM VIM = ------------------Gmm

X 100

VMA - VIM VFB = ---------------------------- X100 VMA

100 Gmm= ----------------------------------Pa Pb ----------- + ------Gse Gb

Legends: Pb= Percentage Bitumen, Pa= Percentage Aggregate , Gb= Specific Gravity of Bitumen , Gmm= Specific Gravity of Mix, Gse= Effective Specific Gravity,Pmm=% of total mix , SGMA = Specific Gravity of Mineral Aggregates.

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ME; LASA