Recommended Practice for Use and Upkeep of Equipment, Tools and Appliances for Bituminous Pavement Construction

IRC 72: Scope Summary & Key Specifications

IRC 72 covers standard specifications for tools and equipment used in road construction and maintenance.

Scope Highlights:

• Tools & Equipment: Detailed descriptions and specifications for common and special tools.
• Dimensions: All dimensions are provided in millimeters (mm).
• Special Equipment: Specific requirements for unique tools per individual specifications.

Key Points:

• Equipment must conform to standard dimensions for compatibility and safety.
• Tools are classified based on their function and usage in road works.
• Special equipment details vary per project needs but follow IRC guidelines for materials and durability.

Typical Dimensions (Example):

For detailed tool specs, refer to the individual clauses within IRC 72 or related IRC codes.

flowchart TD
    A[Tools & Equipment] --> B[Common Tools]
    A --> C[Special Equipment]
    B --> D[Dimensions in mm]
    C --> D
    D --> E[Standard Specifications]

Note: Always cross-check with the latest IRC revisions for updates.

IRC 72: Equipment for Bituminous Pavement Construction

Key Equipment Types:

1. General Tools & Appliances

   • Shovels, rakes, tampers, brooms
   • Hand tools for manual mixing and laying
   • Small appliances for compaction and finishing

2. Special Equipment for Hot-Mix Construction (Bituminous Macadam, Semi-Dense Carpet, Asphaltic Concrete)

   • Hot Mix Plant: For heating and mixing aggregates and bitumen
   • Bitumen Sprayer: Uniform bitumen application on surface
   • Paver Finisher: Lays and partially compacts the mix
   • Rollers:
     • Vibratory Roller: For initial compaction
     • Static Steel Wheel Roller: For intermediate and finishing compaction
     • Pneumatic Tyred Roller: For surface sealing and densification

Important Specifications:

• Equipment should conform to relevant ISI standards (e.g., IS 12177 for bitumen sprayers)
• Dimensions and capacity vary by project scale; refer to IRC 72 Annexures for detailed sketches and sizes
• Proper maintenance and calibration ensure quality control and uniform pavement thickness

Summary Table of Key Equipment

flowchart LR
    A[Hot Mix Plant] --> B[Bitumen Sprayer]
    B --> C[Paver Finisher]
    C --> D[Vibratory Roller]
    D --> E[Static Steel Roller]
    E --> F[Pneumatic Tyred Roller]

IRC 72 - Tools and Appliances for Surface Cleaning (Bituminous Works)

Though IRC 72 does not provide explicit formulas or detailed tables for cleaning tools, key specifications and typical equipment include:

Key Tools for Surface Cleaning (Clause 10.1.1):

• Brooms and Brushes: Stiff bristle brooms for removing loose dust and debris.
• Mechanical Sweepers: For large areas, powered sweepers improve efficiency.
• Compressed Air Blowers: To clear fine dust from cracks and joints.
• Shovels and Scrapers: For removing loose materials and hardened patches.
• Water Spray Equipment: For wet cleaning if required (ensure surface dries before bituminous application).

Important Specifications:

• Cleanliness: Surface must be free from dust, loose particles, oil, and moisture.
• Dry Surface: Ensure surface is dry before bituminous layers are applied.
• Frequency: Clean immediately before application to prevent contamination.

No standard formula applies, but cleaning quality directly affects bituminous bond strength.

flowchart LR
    A[Surface to be cleaned] --> B{Cleaning tools}
    B --> C[Brooms & Brushes]
    B --> D[Mechanical Sweepers]
    B --> E[Compressed Air Blowers]
    B --> F[Shovels & Scrapers]
    B --> G[Water Spray (if needed)]
    G --> H[Dry Surface]
    H --> I[Ready for Bituminous Layer]

Summary: Use appropriate mechanical and manual tools to ensure a clean, dry surface for bituminous works as per IRC 72 guidelines.

Key Specifications for Bitumen Hand Spraying Equipment (IRC 72 - Clause 10.3.2):

• Used for small works where a pressure distributor is not justified.
• Equipment consists of:
  • A small pump (mechanical or hand-operated) attached to the bitumen boiler.
  • A strainer to filter bitumen before spraying.
• The pump delivers bitumen at low pressure for manual spraying.
• Typical assembly includes a bitumen boiler with heating to maintain temperature.
• Nozzle size and pump capacity depend on the required spray rate and bitumen viscosity.

Relevant IS Standard:

• IS:2093-1974 — Specification for Distributors for Hot Tar and Bitumen (covers pressure distributors, useful for understanding equipment requirements).

Typical Parameters for Hand Spraying:

Notes:

• Hand sprayers are portable, simple, and suitable for patch repairs or small surface dressing.
• Maintain bitumen temperature to ensure proper flow and spray quality.
• Use strainers to avoid nozzle clogging.

flowchart LR
    Boiler[Bitumen Boiler]
    Pump[Hand/Mechanical Pump]
    Strainer[Strainer]
    Nozzle[Spray Nozzle]
    Road[Road Surface]

    Boiler --> Pump --> Strainer --> Nozzle --> Road

This setup ensures controlled, uniform spraying for small-scale bitumen applications.

Key Specifications & References for Mixing Equipment and Asphalt Mixers (IRC 72)

• Hot Asphalt Mixing Plants
  Refer to IS:3066-1965 "Specifications for Hot Asphalt Mixing Plants" for detailed requirements, including plant capacities and operational guidelines.

• Hand-operated Drum Mixers
  Covered under IS:2434-1973, which specifies design and operation of hand-operated coal-fired drum asphalt mixers. These are typically used for small-scale or maintenance work.

• Cold Mixing Plants
  Specifications are given in IS:5435-1969 "Specification for Cold Asphalt Macadam Mixing Plants." These plants include:

  • Aggregate feeder
  • Mixing unit with elevator
  • Bitumen heating and storage units

Typical Mixing Process Overview

flowchart LR
    A[Aggregate Storage] --> B[Feeder]
    B --> C[Heating Unit (Hot Mix)]
    B --> D[Cold Mix Unit (Cold Mix)]
    C --> E[Mixing Unit]
    D --> E
    E --> F[Storage / Transport]

Important Notes:

• Hot mix plants require precise temperature control (typically 150-180°C for bitumen).
• Cold mix plants operate at ambient temperatures; bitumen is emulsified or cutback.
• Hand-operated mixers are suitable for patch repairs, not large-scale works.

For detailed formulas and capacity tables, consult the respective IS codes directly.

Key Specifications & Equipment for Transport of Bituminous Mix (IRC 72)

1. Tipper Trucks (Clause 10.5.2)

• Capacity: 5 to 7.5 tonnes typically used for large-scale bituminous work.
• Construction: Smooth, clean, crack-free surfaces to prevent bitumen leakage.
• Features:
  • Tarpaulins to minimize heat loss during transit (especially in winter).
  • Double-walled trucks preferred for thermal insulation.
• Function: Directly empty bituminous mix into paver finisher hoppers.

2. Aggregate Spreaders (Clause 10.6)

• Types:
  • Towed Hopper Type: Large hopper towed by bitumen distributor.
  • Tail Board Type: Spreads aggregates from lorry reversing.
• Purpose: Efficient spreading of stone chips (grit).

3. Paver Finishers (Clause 10.7.1)

• Covered under IS:3251-1965.
• Components:
  • Hopper with adjustable bottom opening.
  • Screed board for striking off and compaction.
  • Heating arrangement for screed plate to prevent sticking.
• Operation: Hopper receives bituminous mix, spreads and compacts it evenly.

Summary Table: Transport Equipment for Bituminous Mix

flowchart LR
    A[Asphalt Plant] -->|Bituminous Mix| B[Tipper Truck]
    B -->|Unload| C[Paver Finisher Hopper]
    C -->|Spread & Compact| D[Finished Pavement]
    B -->|Transport| E[Aggregate Spreader]
    E -->|Spread Chips| D

Note: For bitumen spraying equipment, refer to IS:2093-1974 for distributors with met

Equipment for Spreading Stone Chips (Gritters) - IRC 72 Highlights

• Types of Aggregate Spreaders:

  1. Towed Hopper Type: Large hopper with spreading mechanism towed by bitumen distributor.
  2. Tail Board Type: Spreads aggregates discharged from a reversing lorry (see Fig. 11 in IRC 72).

• Key Specifications:

  • Hopper capacity and spreading width depend on project scale.
  • Spreading mechanism should ensure uniform distribution.
  • Equipment must be compatible with bitumen distributors for synchronized operation.

• Additional Notes:

  • Smooth, clean contact surfaces prevent aggregate loss.
  • Adjustable gates control aggregate flow.
  • Thickness control mechanisms ensure uniform chip layer.

Typical Functional Elements (from IRC 72 Fig. 11):

flowchart LR
    A[Bitumen Distributor] --> B[Towed Hopper with Spreader]
    B --> C[Adjustable Gates]
    C --> D[Stone Chips Spread Uniformly]
    D --> E[Finished Surface]

Related IS Codes:

• IS:3251-1965 for Asphalt Paver Finisher specifications.
• Manual spreading tools: shovels (IS:274-1966), powrahs (IS:1759-1961).

For detailed design, refer to IRC 72 Clause 10.6 and associated figures for equipment layout and operation.

Key Specifications & Equipment for Spreading and Laying Bituminous Courses (IRC 72)

1. Tipper Trucks (Clause 10.5.2)

• Capacity: 5 to 7.5 tonnes
• Features:
  • Smooth, crack-free contact surfaces to prevent bitumen leakage.
  • Tarpaulins or double walls to retain heat during transit.

2. Aggregate Spreaders (Clause 10.6)

• Types:
  • Towed hopper type: Large hopper towed by bitumen distributor.
  • Tail board type: Spreads aggregates from a reversing lorry.

3. Paver Finishers (Clause 10.7.1)

• Covered under IS:3251-1965.
• Components:
  • Hopper with adjustable bottom opening for mix flow.
  • Screed board for striking off and initial compaction.
  • Heating arrangement for screed to prevent sticking.

4. Manual Spreading Equipment (Clause 10.7.2)

• Tools:
  • Drag broom (3.75–5 m long, 1.8–2.8 m wide).
  • Shovels (IS:274-1966), Powrahs (IS:1759-1961).
  • Rakes with ~10 teeth for spreading.
  • Protective gear: gumboots and gloves.

5. Rolling Equipment (Clause 10.9)

Paver Finisher Schematic (Fig. 12)

flowchart LR
    A[Bituminous Mix] --> B[Receiving Hopper]
    B --> C[Adjustable Gates]
    C --> D[Screed Board]
    D --> E[Finished Pavement]

Summary: Use tipper trucks with heat

IRC 72 does not provide explicit clauses or detailed formulas for tools checking surface evenness, but based on standard engineering practice and related IRC guidelines, here are key points:

Tools for Checking Surface Evenness

• Straight Edge: Typically 3m length, used to check surface irregularities by placing it on the surface and measuring gaps.
• Camber Gauge: Measures vertical deviations from a straight line.
• Dipstick or Profilometer: Measures surface profile and unevenness quantitatively.
• Unevenness Indicator (Optional): A device or template to quickly identify high/low spots.

Key Specifications

General Formula for Surface Evenness (Gap Measurement):

[ \text{Unevenness} = \max(\text{gap under straight edge}) ]

• Unevenness should be within 3 mm for surface dressing as per typical IRC practice.

flowchart LR
    A[Place Straight Edge on Surface] --> B[Measure Gaps with Feeler Gauge]
    B --> C{Gap ≤ 3mm?}
    C -- Yes --> D[Surface Evenness Acceptable]
    C -- No --> E[Surface Requires Correction]

Summary: Use a 3m straight edge and feeler gauges to check surface evenness; max gap should not exceed 3mm for surface dressing per IRC standards.

Care in Operation and Upkeep of Equipment (IRC 72 - Clause 11)

Key maintenance practices for bituminous pavement equipment ensure efficiency and longevity:

Bitumen Boilers

• Daily cleaning before cooling to remove bitumen residue.
• Avoid towing loaded boilers at high speed.
• Oil wheels and pivots daily.
• Check and dry any water inside before heating.
• Maintain bitumen level at least 15 cm below full.
• Stir bitumen regularly for even heat distribution.

Bitumen Hand Sprayers

• Clean strainers and nozzles daily.
• Start pumping only at correct bitumen temperature.
• Inspect and clear flexible hoses by blowing hot air.
• Hang hoses vertically post-use to drain bitumen.
• Never disconnect hose under pressure.
• Monthly thorough cleaning and check of glands, gaskets, washers.

Hand Operated Drum Mixers

• Avoid towing at high speed.
• Clean wheels daily.
• Lubricate shaft bearings regularly.
• Clean mixer and fire grate daily.
• Check bolts and hinges periodically.

Small Capacity Mixing Plants & Hot Mix Plants

• Regular lubrication of shafts, bearings, chains.
• Check and replace worn linings, bolts, screens.
• Clean burners, nozzles, pipelines, and mixer parts daily.
• Verify temperature devices and weighing mechanisms periodically.
• Keep doors and hinges clean and lubricated.

Tools for Checking Surface Evenness (Clause 10.10)

• Camber boards/templates (Figs. 15 & 16) for cross-profile.
• 3 m straight edge with graduated wedge (Fig. 17).
• Use unevenness indicator device for real-time irregularity detection.

Summary Table: Maintenance Frequency

flowchart TD
    A[Start of

IRC 72 focuses on bituminous pavement construction but lacks explicit clauses on safety and handling procedures. Based on best engineering practices and IRC recommendations:

Key Safety & Handling Practices for Bituminous Pavement (IRC 72 context)

• Bitumen Heating:

  • Use thermostatically controlled heaters.
  • Maintain temperature not exceeding 180°C to avoid bitumen degradation.
  • Use insulated containers to prevent heat loss and burns.

• Handling Equipment:

  • Ensure tools/appliances are clean, rust-free, and well-maintained.
  • Use personal protective equipment (PPE): gloves, goggles, heat-resistant clothing.
  • Avoid direct skin contact with hot bitumen.

• Recommended Practices:

  • Regular inspection of heating tanks and applicators.
  • Safe storage of bitumen drums away from ignition sources.
  • Proper ventilation in heating areas to avoid fume inhalation.

Quick Reference Table: Bitumen Heating Temperatures

flowchart LR
    A[Bitumen Storage] --> B[Heating Equipment]
    B --> C{Temperature Control}
    C -->|Safe Temp| D[Application]
    C -->|Overheat| E[Risk: Degradation & Fire]
    D --> F[Proper Handling & PPE]

Summary: Follow IRC-recommended temperature limits, maintain equipment, and use PPE to ensure safety during bituminous pavement construction.

IRC 72 does not provide explicit formulas or tables under "Special Equipment for Penetration Macadam and Built-up Spray Grout." However, based on general practice and related clauses (especially 10.3 Bitumen Spraying Equipment), key points are:

Special Equipment Requirements:

• Pressure & Spray Control: Equipment must maintain uniform pressure (typically 2.0 to 3.5 bar) for even bitumen application.
• Nozzle Size: Usually 3 to 5 mm diameter for spray nozzles to ensure proper atomization.
• Heating: Bitumen must be heated to 160–180°C for penetration macadam and spray grout.
• Mixing: Built-up spray grout requires continuous mixing to prevent segregation.

Typical Specifications:

Key Formula (Bitumen Quantity Estimation):

[ Q_b = A \times t \times r ] Where:

• (Q_b) = bitumen quantity (liters)
• (A) = area (m²)
• (t) = thickness (m)
• (r) = bitumen rate (liters/m²)

flowchart LR
    A[Bitumen Tank] --> B[Heater]
    B --> C[Spray Pump]
    C --> D[Nozzle (3-5mm)]
    D --> E[Surface Application]

Summary: Use heated bitumen at 160–180°C, spray at 2-3.5 bar pressure through 3-5 mm nozzles, ensuring continuous mixing for grout. Adjust bitumen quantity per area and thickness.