PWD (WB), Schedule of Rates : 2018 Volume III : Road & Bridge Works
(cl. 505 of MORT&H)
The specification describes the design and construction procedure for Dense Bituminous Macadam, (DBM), for use mainly,
but not exclusively, in base/binder and profile corrective courses. The work shall consist of construction in a single or
multiple layers of DBM on a previously prepared base or sub-base. The thickness of a single layer shall be 50 mm to 100
mm.
The bitumen shall be viscosity grade paving bitumen complying with the Indian Standard Specification IS:73, modified
bitumen complying with Clause 501.2.1 or as otherwise specified in the Contract.
The type and grade of bitumen to be used shall be specified in the Contract.
The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material retained on 2.36 mm sieve. They
shall be clean, hard, durable, of cubical shape, free from dust and soft or friable matter, organic or other deleterious
substances. Where the Contractor's selected source of aggregates has poor affinity for bitumen, the Contractor shsil produce
test result that with the use of anti-stripping agents, the stripping value is improved to satisfy the specflcation requirements.
The Engineer may approve such a source and as a condition for the approval of that source, the bitumen shall be treated with
an approved anti-stripping agent, as per the manufacturer's recommendations, at the cost of the Contractor. The aggregates
shall satisfy the requirements specified in Table 500-8.
Where crushed gravel is proposed for use as aggregate, not less than 90 percent by weight of the crushed material retained on
the 4.75 mm sieve shall have at least two fractured faces.
Fine aggregates shall consist of crushed or naturally occurring mineral material, or a combination of the two, passing the
2.36 mm sieve and retained on the 75 micron sieve. These shall be clean, hard, durable, dry and free from dust, and soft or
friable matter, organic or other deleterious matter. Natural sand shall not be allowed in binder courses. However, natural
sand upto 50 percent of the fine aggregate may be allowed in base courses. The fine aggregate shall have a sand equivalent
value of not less than 50 when tested in accordance with the requirement of IS:2720 (Part 37). The plasticity index of the
fraction passing the 0.425 mm sieve shall not exceed 4, when tested in accordance with IS:2720 (Part 5).
Filter shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement approved by the Engineer.
The filler shall be graded within the limits indicated in Table 500-9.
The filler shall be free from organic impurities and have a plasticity Index not greater than 4. The Plasticity Index
requirement shall not apply if filler is cement or lime. Where the aggregates fail to meet the requirements of the water
sensitivity test in Table 500-8, then 2 percent by total weight of aggregate, of hydrated lime shall be used and percentage of
fine aggregate reduced accordingly.
When tested in accordance with IS:2386 Part 1 (wet sieving method), the combined grading of the coarse
and fine aggregates and filler for the particular mixture shall fall within the limits given in Table 500-10 for grading 1 or 2 as
specified in the Contract. To avoid gap grading, the combined aggregate gradation shall not vary from the lower limit one
sieve to higher limit on the adjacent sieve.
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Volume III : Road & Bridge Works PWD (WB), Schedule of Rates : 2018
(Table 500-8 of MORT&H)
Cleanliness (dust) Grain size analysis Max 5% passing IS:2386Partl
0.075 mm sieve
Particle shape Combined Flakiness and Elongation Max 35% IS:2386 Parti
Indices*
Strength Los Angeles Abrasion Value Max 35% IS:2386 Part IV
or
Aggregate Impact Value Max 27%
Durability Soundness either : IS:2386PartV
Sodium Sulphate or Max 12%
Magnesium Sulphate Max 18%
Water Absorption Water Absorption Max 2% IS:2386 Part III
Stripping Coating and Stripping of Bitumen Minimum retained coating IS:6241
Aggregate Mix 95%
Water Sensitivity Retained Tensile Strength** Min. 80% AASHTO 283
To determine this combined proportion, the flaky stone from a representative sample should first be separated out.
Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles be
separated out from the remaining (non-flaky) stone metal. Elongation index is weight of elongated particles divided by
total non-flaky particles. The values of flakiness index and elongation index so found are added up.
** If the minimum retained tensile test strength falls below 80 percent, use of anti-stripping agent is recommended to
meet the requirement.
(Table 500-9 of MORT&H)
0.6 100
0.3 9 5 - 10 0
0.075 8 5 - 10 0
(Table 500-10 of MORT&H)
45 100
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
9.5 - -
4.75 38-54 38-54
2.36 28-42 28-42
1.18 - -
0.6 - -
0.3 7-21 7-21
0.15 - -
0.075 2-8 2-8
Bitumen content % by mass of total mix Min 4.0** Min 4.5**
* The nominal maximum particle size is the largest specified sieve size upon which any of the aggregate is retained.
** Corresponds to specific gravity of aggregates being 2.7. In case aggregate have specific gravity more than 2.7, the
minimum bitumen content can be reduced proportionately. Further the region where highest daily mean air temperature is
30°C or lower and lowest daily air temperature is - 10°C or lower, the bitumen content may be increased by 0.5 percent,
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PWD (WB), Schedule of Rates : 2018 Volume III : Road & Bridge Works
Bitumen content indicated in Table 500-10 is the minimum quantity. The quantity shall be determined in
accordance with Clause 505.3.
The bitumen content required shall be determined following the Marshall mix design procedure contained in Asphalt
Institute Manual MS-2.
The Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.
Apart from conformity with the grading and quality requirements for individual ingredients, the mixture shall meet the
requirements set out in Table 500-11.
(Table 500-11 of MORT&H)
Compaction level 75 blows on each face of the specimen
Minimum stability (kN at 600C) 9.0 12.0 10.0 AASHTO T 245
Marshall flow (mm) 2-4 2.5-4 3.5-5 AASHTO T 245
Marshall Quotient 2-5 2.5-5 MS-2 and
ASTM D 2041
% air voids 3-5
% Voids Filled with Bitumen (VFB) 65-75
Coating of aggregate particle 95% minimum IS:6241
Tensile Strength ratio 80% Minimum AASHTO T 283
% Voids in Mineral Aggregate (VMA) Minimum percent voids in mineral aggregate (VMA) are set out in Table 500-13
The binder content shall be optimized to achieve the requirements of the mix set out in Table 500-11. The binder content
shall be selected to obtain 4 percent air voids in the mix design. The Marshall method for determining the optimum binder
content shall be adopted as described in the Asphalt Institute Manual MS-2.
Where maximum size of the aggregate is more than 26.5 mm, the modified Marshall method using 150 mm diametre
specimen described in MS-2 and ASTM D 5581 shall be used. This method requires modified equipment and procedures.
When the modified Marshall test is used, the specified minimum stability values in Table 500-12 shall be multiplied by
2.25, and the minimum flow shall be 3 mm.
(Table 500-12 of MORT&H)
3.0 4.0 5.0
26.5 11.0 12.0 13.0
37.5 10.0 11.0 12.0
Interpolate minimum voids in the mineral aggregate (VMA) for designed percentage air voids values between those listed.
The Contractor shall submit to the Engineer for approval at least 21 days before the start the work, the job mix formula
proposed for use in the works, together with the following details:
i) Source and location of all materials;
ii) Proportions of all materials expressed as follows:
(a) Binder type, and percentage by weight of total mix;
(b) Coarse aggregate/Fine aggregate/Mineral filler as percentage by weight of total aggregate
including mineral filler;
iii) A single definite percentage passing each sieve for the mixed aggregate;
iv) The individual gradings of the individual aggregate fraction, and the proportion of each in the
combined grading;
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Volume III : Road & Bridge Works PWD (WB), Schedule of Rates : 2018
v) The results of mix design such as maximum specific gravity of loose mix (Gmm), compacted specimen
densities, Marshall stability,flow, air voids, VMA, VFB and related graphs and test results of AASHTO T
283 Moisture susceptibility test;
vi) Where the mixer is a batch mixer, the individual weights of each type of aggregate, and binder per
batch;
vii) Test results of physical characteristics of aggregates to be used;
viii) Mixing temperature and compacting temperature
While establishing the job mix formula, the Contractor shall ensure that it is based on a correct and truly representative
sample of the materials that will actually be used in the work and that the mix and its different ingredients satisfy the
physical and strength requirements of these Specifications.
Approval of the job mix formula shall be based on independent testing by the Engineer for which samples of all ingredients
of the mix shall be furnished by the Contractor as required by the Engineer.
The approved job mix formula shall remain effective unless and until a revised Job Mix Formula is approved. Should a
change in the source of materials be proposed, a new job mix formula shall be forwarded by the Contractor to the Engineer for
approval before the placing of the material.
Once the laboratory job mix formula is approved, the Contractor shall carry out plant trials to establish that the plant can
produce a uniform mix conforming to the approved job mix formula. The permissible variations of the individual
percentages of the various ngredients in the actual mix from the job mix formula to be used shall be within the limits as
specified in Table 500-13 and shall remain within the gradation band. These variations are intended to apply to individual
specimens taken for quality control tests in accordance with Section 900.
(Table 500-13 of MORT&H)
Aggregate passing 19 mm sieve or larger ±8%
Aggregate passing 13.2 mm, 9.5 mm ±7%
Aggregate passing 4.75 mm ±6%
Aggregate passing 2.36 mm, 1.18 mm, 0.6 mm ±5%
Aggregate passing 0.3 mm, 0.15 mm ±4%
Aggregate passing 0.075 mm ±2%
Binder content ± 0.3%
Mixing temperature ±10°C
Once the plant trials have been successfully completed and approved, the Contractor shall carry out laying trials, to
demonstrate that the proposed mix can be successfully laid and compacted all in accordance with Clause 501. The laying
trial shall be carried out on a suitable area which is not to form part of the works. The area of the laying trials shall be a
minimum of 100 sq.m of construction similar to that of the project road, and it shall be in all respects, particularly
compaction, the same as the project construction, on which the bituminous material is to be laid.
The Contractor shall previously inform the Engineer of the proposed method for laying and compacting the material. The
plant trials shall then establish if the proposed laying plant, compaction plant, and methodology is capable of producing
satisfactory results. The density of the finished paving layer shall be determined by taking cores, no sooner than 24 hours
after laying, or by other approved method. The compacted layers of Dense Graded Bituminous Macadam (DBM) shall have
a minimum field density equal to or more than 92% of the density based on theoretical maximum specific gravity (G mm)
obtained on the day of compaction in accordance with ASTM D 2041.
Once the laying trials have been approved, the same plant and methodology shall be applied to the laying of the material
on the project, and no variation of either shall be acceptable, unless approved in writing by the Engineer, who may at his
discretion require further laying trials.
The provisions of Clause 501.5.1 shall apply.
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PWD (WB), Schedule of Rates : 2018 Volume III : Road & Bridge Works
The base on which Dense Graded Bituminous Material is to be laid shall be prepared in accordance with Clauses 501 and
902 as appropriate, or as directed by the Engineer.
Where Geosynthetics are specified in the Contract, this shall be in accordance with the requirements stated in Clause 703.
Where a stress absorbing layer is specified in the Contract, this shall be applied in accordance with the requirements of
Clause 517.
Where the material on which the dense bituminous macadam is to be laid is other than a bitumen bound layer, a prime
coat shall be applied, as specified, in accordance with the provisions of Clause 502, or as directed by the Engineer.
Where the material on which the dense bituminous macadam is to be laid is either bitumen bound layer or primed granular
layer, tack coat shall be applied, as specified, in accordance with the provisions of Clause 503, or as directed by the
Engineer.
The provisions as specified in Clauses 501.3 and 501.4 shall apply. Table 500-2 gives the mixing, laying and rolling
temperature for dense mixes using viscosity grade bitumen. In case of modified bitumen, the temperature of mixing and
compaction shall be higher than the mix with viscosity grade bitumen. The exact temperature depends upon the type and
amount of modifier used and shall be adopted as per the recommendations of the manufacturer. In order to have uniform
quality, the plant shall be calibrated from time to time.
The provisions of Clauses 501.5.3 and 501.5.4 shall apply.
The general provisions of Clauses 501.6 and 501.7 shall apply, as modified by the approved laying trials. The compaction
process shall be carried out by the same plant, and using the same method, as approved in the laying trials, which may be
varied only with the express approval of the Engineer in writing
It shall be ensured that the traffic is not allowed without the approval of the Engineer in writing, on the surface until the
dense bituminous layer has cooled to the ambient temperature.
(cl. 506 of MORT&H)
This work shall consist of a base course composed of a mixture of sand, mineral filler where required and bituminous binder,
placed and compacted upon a prepared and accepted sub-base in accordance with these Specifications and the lines, levels,
grades, dimensions and cross sections shown on the Drawings or as directed by the Engineer.
Sand Asphalt Base course is used in special situations like quality coarse aggregates not being available within
economical leads and/or water needed for conventional base course not being readily available, as in desert areas.
The bitumen shall be paving bitumen of viscosity grade VG 30 or VG 20, as specified in the Contract, conforming to IS: 73.
The sand shall be clean, naturally occurring or blended material free from any deleterious substances, dry and well graded
within the limits given in Table 500-14 and with other physical properties conforming to the requirements of this Table.
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