Recommended Practice for Bituminous Penetration Macadam (Full Grout)

The IRC 20 Introduction and related clauses provide key specifications and tables for bituminous penetration macadam construction:

• Coarse Aggregate Spreading Quantities (Table 2): | Compacted thickness | Quantity (m³/10 m²) | |--------------------|--------------------| | 50 mm | 0.60 | | 75 mm | 0.90 |

• Key Aggregate Grading (Table 3): Percent passing for various sieve sizes varies with compacted thickness 50 mm or 75 mm.

• Key Aggregate Spreading Quantities (Table 4): | Compacted thickness | Quantity (m³/10 m²) | |--------------------|--------------------| | 50 mm | 0.15 | | 75 mm | 0.18 |

• Seal Coat Materials (Table 5): | Material | Size | Quantity per 10 m² | |----------|------|-------------------| | Chipping | 9 mm passing 12 mm and retained on 6 mm sieve | 0.09 to 0.11 m³ | | Binder | - | 9.8 to 12 kg |

• Binder Application Rates (Table 6): | Compacted thickness | Binder Type | Quantity (kg/10 m²) | |--------------------|----------------------|---------------------| | 50 mm | Straight-run bitumen | 50 | | | Road tar RT-4/RT-5 | 60-65 | | 75 mm | Straight-run bitumen | 68 | | | Road tar RT-4/RT-5 | 82-88 |

• Construction Notes:

  • No construction below 16°C or in damp/foggy/rainy weather.
  • Proper preparation and compaction of base and aggregates.
  • Rolling sequence and surface tolerance limits (max 12 mm deviation).
  • Opening to traffic after 24 hours or earlier with speed restrictions.

These details are from IRC 20 clauses 1, 2.36, 3.2.3 to 3.2.6, 4.1 to 4.6, and 5.

Sources: Clause 2.36, Clause 3.2.3, Clause 3.2.5, Clause 3.2.6, Clause 4.1, Clause 4.4, Clause 4.5, Clause 4.6, Clause 5

The general requirements per IRC 20 for aggregates and seal coat are as follows:

• Coarse Aggregate Spreading Quantities (Table 2):

  Compacted thickness	Quantity (m³/10 m²)
  50 mm	0.60
  75 mm	0.90

• Key Aggregate Grading (Table 3):

  Sieve No.	% Passing for 50 mm	% Passing for 75 mm
  38 mm	-	-
  25 mm	--	100
  19 mm	100	35-70
  12 mm	35-70	-
  9 mm	-	0-15
  4.75 mm	0-15	-
  2.36 mm	0-5	0-5

• Key Aggregate Spreading Quantities (Table 4):

  Compacted thickness	Quantity (m³/10 m²)
  50 mm	0.15
  75 mm	0.18

• Seal Coat Materials (Table 5):

  Material	Size Description	Quantity per 10 m²
  Chipping	9 mm passing 12 mm and retained on 6 mm sieve	0.09 to 0.11 m³
  Binder	Straight-run bitumen or road tar of suitable grade	9.8 to 12 kg

These specifications ensure proper layering and material quality for road construction as per IRC 20 Clause 3.2.1 to 3.2.6. Physical requirements for aggregates are also mandated but details are not provided in the context.

Sources: Clause 3.2.1, Clause 2.36, Table 3.2.3, Table 3, Table 4, Table 5, Clause 3.2.5, Clause 3.2.6

Key materials specifications for bituminous penetration macadam as per IRC 20 include:

• Coarse Aggregate Quantity (Table 2):

  • 50 mm compacted thickness requires 0.60 m³ per 10 m²
  • 75 mm compacted thickness requires 0.90 m³ per 10 m²

• Key Aggregate Grading (Table 3): Percent passing by sieve size varies with compacted thickness (50 mm or 75 mm). For example, for 50 mm thickness, 19 mm sieve passes 100%, 12 mm sieve 35-70%, 4.75 mm sieve 0-15%, and 2.36 mm sieve 0-5%. For 75 mm thickness, 25 mm sieve passes 100%, 19 mm sieve 35-70%, 9 mm sieve 0-15%, and 2.36 mm sieve 0-5%.

• Key Aggregate Quantity (Table 4):

  • 50 mm thickness: 0.15 m³ per 10 m²
  • 75 mm thickness: 0.18 m³ per 10 m²

• Seal Coat Materials (Table 5):

  • Chipping: 9 mm passing 12 mm and retained on 6 mm sieve, quantity 0.09 to 0.11 m³ per 10 m²
  • Binder (Straight-run bitumen or road tar): 9.8 to 12 kg per 10 m²

These specifications ensure proper gradation and quantities for durable bituminous layers.

Tables reproduced below for clarity.

Sources: Clause 2.36, Clause 3.2.5, Clause 3.2.6

Key specifications and tables for Bituminous Materials per IRC 20 include:

• Bituminous binders: Straight-run bitumen grades 80/100, 60/70, 30/40; road tar grades RT-4/RT-5; cutbacks as per climatic conditions (Clause 3.1).

• Coarse aggregate spreading quantities: | Compacted thickness | Quantity (m³/10 m²) | |---------------------|--------------------| | 50 mm | 0.60 | | 75 mm | 0.90 |

• Key aggregate grading and quantities: | Sieve No. | % Passing (50 mm) | % Passing (75 mm) | |-----------|------------------|------------------| | 38 mm | - | - | | 25 mm | - | 100 | | 19 mm | 100 | 35-70 | | 12 mm | 35-70 | - | | 9 mm | - | 0-15 | | 4.75 mm | 0-15 | - | | 2.36 mm | 0-5 | 0-5 |

Quantities:

• Seal coat materials and quantities: | Material | Size Description | Quantity (per 10 m²) | |----------|------------------|---------------------| | Chipping | 9 mm passing 12 mm and retained on 6 mm sieve | 0.09 to 0.11 m³ | | Binder | Straight-run bitumen or Road tar of suitable grade | 9.8 to 12 kg |

• Binder application rates: | Compacted thickness | Straight-run bitumen (kg/10 m²) | Road tar RT-4/RT-5 (kg/10 m²) | |---------------------|---------------------------------|------------------------------| | 50 mm | 50 | 60-65 | | 75 mm | 68 | 82-88 |

• Construction notes:

  • No bituminous penetration macadam below 16℃ or in damp/foggy/rainy conditions.
  • Aggregate must be dry before binder application.
  • Rolling sequence and surface tolerances specified (max 12 mm deviation).
  • Opening to traffic after 24 hours rolling or earlier with speed restriction (15 km/h).

These details are from IRC 20 clauses 3.1, 3.2.3, 3.2.5, 3.2.6, 4.1, 4.4, 4.5, and 5.

Sources: Clause 3.1, Clause 2.36, Clause 3.2.3, Clause 3.2.5, Clause 3.2.6, Clause 4.1, Clause 4.4, Clause 4.5, Clause 5

Key specifications and tables for aggregates in IRC 20 are as follows:

• Coarse Aggregate Quantity (Table 2):

  Compacted thickness	Quantity (m³/10 m²)
  50 mm	0.60
  75 mm	0.90

• Key Aggregate Grading (Table 3): Percentage passing for different sieve sizes varies with compacted thickness:

  Sieve No.	50 mm Thickness (%)	75 mm Thickness (%)
  38 mm	-	-
  25 mm	-	100
  19 mm	100	35-70
  12 mm	35-70	-
  9 mm	-	0-15
  4.75 mm	0-15	-
  2.36 mm	0-5	0-5

• Key Aggregate Quantity (Table 4):

  Compacted thickness	Quantity (m³/10 m²)
  50 mm	0.15
  75 mm	0.18

• Seal Coat Materials (Table 5):

  Material	Size Description	Quantity per 10 m²
  Chipping	9 mm passing 12 mm and retained on 6 mm sieve	0.09 to 0.11 m³
  Binder	Straight-run bitumen or road tar of suitable grade	9.8 to 12 kg

• Aggregates must be clean, strong, durable, cubical, and free from deleterious materials.

These tables and specifications govern the selection, grading, and quantities of aggregates for bituminous penetration macadam layers as per IRC 20.

Sources: Clause 2.36, Table 2, Table 3, Table 4, Table 5, Clause 3.2.4, Clause 3.2.5, Clause 3.2.6

Key construction methods for Bituminous Penetration Macadam (BPM) per IRC 20 include:

• Weather Limitations: No BPM construction below 16℃ or in damp, foggy, rainy, or dusty conditions (Clause 4.1).

• Base Preparation: Uniform grade and section; potholes filled and compacted; priming as per IRC tentative specs (Clause 4.3).

• Coarse Aggregate Spreading & Compaction: Spread uniformly with edge protection; compact with 10-ton roller starting at edges, overlapping shoulders by 30 cm; surface tolerance ±12 mm checked by template and straight edge; rolling stops before voids close to allow bitumen penetration (Clause 4.4).

• Bituminous Binder Application: Applied at specified rates and temperatures; aggregate must be surface dry; use pressure distributor or nozzle; pouring pots only if permitted (Clause 4.5).

• Key Aggregate Application: Spread immediately after bitumen penetration; rolled and broomed until locked; maintain grade and cross-section (Clause 4.6).

• Seal Coat: Applied before opening to traffic; binder heated and spread, followed by chippings and rolling (Clause 3.2.6).

• Opening to Traffic: Preferably after 24 hours; if earlier, speed limited to 15 km/h (Clause 5).

Tables for quantities and sizes:

These specifications ensure uniformity, durability, and quality control in BPM construction.

Sources: Clause 2.36, Clause 3.2.5, Clause 3.2.6, Clause 4.1, Clause 4.3, Clause 4.4, Clause 4.5, Clause 4.6, Clause 5

As per IRC 20 Clause 4.1, bituminous penetration macadam shall NOT be constructed when atmospheric temperature is below 16℃, or when the pavement is damp, foggy, rainy, or during dust storms. This ensures proper binder application and compaction. For cold regions, Grade 175/225 bitumen is suggested, and for warm climates, Grade 80/100 is recommended. Road tar grades RT-2 and RT-3 are suggested for hilly and plain areas respectively. Equipment must be in good condition and ready at the site. The aggregate must be dry before binder application, which should be done at specified rates (see Table below). The surface must be checked for uniformity and compacted properly before opening to traffic, preferably after 24 hours, with speed restrictions if opened earlier.

Binder Application Rates (Kg per 10 m²):

These weather and seasonal limitations ensure quality and durability of bituminous macadam pavements.

Sources: Clause 4.1, Clause 4.5, Table 6 in Clause 4.5

For preparation of base in bituminous penetration macadam as per IRC 20, Clause 4.3: The underlying course must be prepared, shaped, and conditioned to a uniform grade and section. Depressions or potholes should be properly filled and compacted well in advance. Priming may be applied if needed following IRC tentative specifications.

Key tables and specifications include:

• Coarse Aggregate Spreading Quantity (Table 2): | Compacted thickness | Quantity (m³/10 m²) | |--------------------|---------------------| | 50 mm | 0.60 | | 75 mm | 0.90 |

• Key Aggregate Grading (Table 3): | Sieve No. | 50 mm (%) | 75 mm (%) | |-----------|-----------|-----------| | 38 mm | - | - | | 25 mm | - | 100 | | 19 mm | 100 | 35-70 | | 12 mm | 35-70 | - | | 9 mm | - | 0-15 | | 4.75 mm | 0-15 | - | | 2.36 mm | 0-5 | 0-5 |

• Key Aggregate Spreading Quantity (Table 4): | Compacted thickness | Quantity (m³/10 m²) | |--------------------|---------------------| | 50 mm | 0.15 | | 75 mm | 0.18 |

• Seal Coat Materials (Table 5): | Material | Size Description | Quantity per 10 m² | |----------|------------------|-------------------| | Chipping | 9 mm passing 12 mm and retained on 6 mm sieve | 0.09 to 0.11 m³ | | Binder | Straight-run bitumen or Road tar | 9.8 to 12 kg |

• Binder Application Rates (Table 6): | Compacted thickness | Binder Type | Quantity (kg/10 m²) | |--------------------|-------------|---------------------| | 50 mm | Bitumen | 50 | | | Road tar RT-4/RT-5 | 60-65 | | 75 mm | Bitumen | 68 | | | Road tar RT-4/RT-5 | 82-88 |

Construction notes:

• Spreading and compacting must ensure uniform depth and grade (Clause 4.4).
• Rolling starts at edges overlapping shoulders and proceeds to center.
• Surface irregularities must not exceed 12 mm.
• Bituminous material applied at specified temperature and rate (Clause 4.5).
• Key aggregate spread immediately after bitumen application and compacted (Clause 4.6).
• Seal coat applied before opening to traffic.

Weather restrictions: No construction below 16°C or in damp/foggy/rainy conditions (Clause 4.1).

This ensures a well-prepared base for durable bituminous penetration macadam pavement.

Sources: Clause 2.36, Clause 3.2.5, Clause 3.2.6, Clause 4.1, Clause 4.3, Clause 4.4, Clause 4.5, Clause 4.6

For spreading and compacting coarse aggregate in bituminous penetration macadam as per IRC 20:

• Spreading quantity (Table 2):

  • For 50 mm compacted thickness: 0.60 m³ per 10 m²
  • For 75 mm compacted thickness: 0.90 m³ per 10 m²

• Key aggregate grading (Table 3): Percentage passing sieve sizes varies with compacted thickness (50 mm or 75 mm). For example, for 50 mm thickness, 25 mm sieve passing is 35-70%, 19 mm is 100%, 12 mm is 35-70%, 4.75 mm is 0-15%, and 2.36 mm is 0-5%.

• Key aggregate spreading quantity (Table 4):

  • 50 mm thickness: 0.15 m³ per 10 m²
  • 75 mm thickness: 0.18 m³ per 10 m²

• Seal coat materials (Table 5):

  • Chipping (9 mm passing 12 mm retained on 6 mm sieve): 0.09 to 0.11 m³ per 10 m²
  • Binder (straight-run bitumen or road tar): 9.8 to 12 kg per 10 m²

These specifications ensure proper layer thickness and grading for effective compaction and durability (Clause 2.36, 3.2.3 to 3.2.6).

Sources: Clause 2.36, Table 2, Table 3, Table 4, Table 5

The application of bituminous material as per IRC 20 includes key specifications and tables as follows:

• Coarse Aggregate Spreading Quantity: | Compacted thickness | Quantity (m³/10 m²) | |--------------------|--------------------| | 50 mm | 0.60 | | 75 mm | 0.90 |

• Key Aggregate Grading (Percent Passing): | Sieve No. | 50 mm Thickness | 75 mm Thickness | |-----------|-----------------|-----------------| | 38 mm | - | - | | 25 mm | - | 100 | | 19 mm | 100 | 35-70 | | 12 mm | 35-70 | - | | 9 mm | - | 0-15 | | 4.75 mm | 0-15 | - | | 2.36 mm | 0-5 | 0-5 |

• Key Aggregate Quantity: | Compacted thickness | Quantity (m³/10 m²) | |--------------------|---------------------| | 50 mm | 0.15 | | 75 mm | 0.18 |

• Seal Coat Materials and Quantities: | Material | Size Description | Quantity (per 10 m²) | |----------|-----------------------------------------|---------------------| | Chipping | 9 mm passing 12 mm retained on 6 mm sieve | 0.09 to 0.11 m³ | | Binder | Straight-run bitumen or Road tar | 9.8 to 12 kg |

• Bituminous Binder Application Rates: | Compacted thickness | Binder Type | Quantity (kg/10 m²) | |--------------------|-----------------------|---------------------| | 50 mm | Straight-run bitumen | 50 | | | Road tar RT-4/RT-5 | 60-65 | | 75 mm | Straight-run bitumen | 68 | | | Road tar RT-4/RT-5 | 82-88 |

• Construction Notes:

  • Binder applied at suitable temperature.
  • Aggregate must be surface dry before binder application.
  • Use pressure distributor for uniform application.
  • Key aggregate spread immediately after binder penetration, rolled and broomed until locked.
  • Seal coat applied before opening to traffic.
  • Weather restrictions: No application below 16°C or in damp/foggy/rainy conditions.

These details are from IRC 20 clauses 3.1, 3.2.5, 3.2.6, 4.5, and 4.6.

Sources: Clause 3.1, Clause 3.2.5, Clause 3.2.6, Clause 4.5, Clause 4.6

For the application of key aggregate in bituminous penetration macadam as per IRC 20, the following key specifications and tables apply:

• The size of coarse and key aggregates depends on the compacted thickness of the layer (50 mm or 75 mm) as per Tables 1 and 3.

• Quantity of coarse aggregate spread:

  Compacted thickness	Quantity (m³/10 m²)
  50 mm	0.60
  75 mm	0.90

• Key aggregate grading (percent passing sieve):

  Sieve No.	50 mm thickness	75 mm thickness
  38 mm	-	-
  25 mm	--	100
  19 mm	100	35-70
  12 mm	35-70	-
  9 mm	-	0-15
  4.75 mm	0-15	-
  2.36 mm	0-5	0-5

• Quantity of key aggregate spread:

  Compacted thickness	Quantity (m³/10 m²)
  50 mm	0.15
  75 mm	0.18

These values ensure proper gradation and quantity for effective interlocking and stability of the bituminous layer. The aggregates must be spread using approved methods as per Clause 2.36.

This summary is based on IRC 20 clauses 2.36, 3.2.3, 3.2.5, and related tables.

Sources: Clause 2.36, Clause 3.2.3, Clause 3.2.5

As per IRC 20 Clause 5, the finished bituminous penetration macadam surface shall preferably be opened to traffic 24 hours after rolling. If earlier opening is necessary, vehicle speed must be restricted to 15 km/h. Key specifications related to opening to traffic include:

• Seal coat application before opening, with binder heated to the requisite temperature and chippings spread and rolled uniformly (Clause 4.6).
• Maximum permissible undulation on longitudinal profile: 12 mm; number of undulations ≥10 mm should not exceed 30 in 300 m length.
• Maximum permissible cross-profile variation: 8 mm.

These ensure the surface is stable and uniform before traffic load (Clause 4.6 and 5).

Key tables relevant to construction and quality control before opening include:

These ensure proper surface preparation and durability before opening to traffic.

Sources: Clause 5, Clause 4.6, Clause 2.36, Clause 3.2.5, Clause 3.2.6