Standard Operating Procedure for Bituminous (BT) road construction, ensuring stability, durability, and compliance with industry standards and IS Codes for road construction projects.
To establish a structured procedure for Bituminous (BT) road construction, ensuring stability, durability, and compliance with industry standards and IS Codes. Bituminous roads provide flexible pavement options that are suitable for varying load conditions and climate factors experienced in road construction projects.
This SOP applies to all BT road construction projects, covering material selection, preparation, laying, compaction, quality control, and testing procedures as per relevant IS codes. It includes main access roads, peripheral roads, and service pathways.
Ensures compliance with specifications, IS codes, and project timelines
Monitors execution & ensures compliance with drawings
Ensures availability of materials, tools & workforce coordination
Perform material spreading, grading & compaction
Checks material quality, layer thickness & compaction density
Ensures all safety measures are followed at the site
Ensures timely availability of quality-tested bitumen and aggregates
Establishes proper alignment, levels, and gradients for road construction
VG-10, VG-30, VG-40 as per IS 73:2013 specifications
Coarse and fine aggregates as per IS 2386 standards
Stone dust, cement, or lime for bituminous mix
Prime coat and tack coat as per IS 8887:2004
For preparing bituminous mix at controlled temperature
Dumpers/trucks with insulated beds for material transportation
For uniform laying of bituminous mix with thickness control
Vibratory, tandem, pneumatic-tired for effective compaction
Penetration (IS 1203), Softening Point (IS 1205), Viscosity tests
Gradation, Impact Value, Abrasion, Flakiness/Elongation Index as per IS 2386
Marshall Stability (min 9kN), Flow (2-4mm), Air Voids (3-5%)
Core cutting tests to verify specified thickness (±5mm tolerance)
Field density 97-98% of lab density, void content 3-6%
During mixing (150-165°C), laying (130-150°C), compaction (>120°C)
Maximum 4mm deviation under 3m straight edge
AASHTO T283: min 80% retained stability after water conditioning
Safety boots, gloves, helmets, and high-visibility vests for all personnel
Barricading, signage, and traffic management at construction site
Heat-resistant gloves, face shields when handling hot bitumen
Only certified operators to handle hot mix plant, pavers, and rollers
First aid kits, burn treatment supplies, eye wash stations on site
Proper ventilation, respiratory protection when necessary
Clear communication protocols between vehicle operators and ground crew
Regular hydration, shade provisions, work-rest cycles during hot weather
Problem: Excess bitumen rises to surface creating shiny, slick patches.
Solution: Reduce bitumen content in mix design, ensure proper mix temperature, apply sand blotter in severe cases, check compatibility between bitumen grade and traffic load.
Problem: Surface aggregates dislodge from pavement.
Solution: Ensure proper bitumen content, check aggregate quality and cleanliness, improve compaction techniques, verify mix is not being laid at too low temperature.
Problem: Longitudinal depression in wheel paths.
Solution: Improve subgrade/base layer stability, use stiffer bitumen grade, adjust aggregate gradation, increase field compaction, review mix design for proper voids in mineral aggregate (VMA).
Problem: Separation of coarse and fine materials during placement.
Solution: Improve handling during loading/unloading, maintain proper paver hopper level, reduce drop heights, avoid stopping paver during operations, check for proper mix temperature.
Avoid laying BT mix during rainy conditions or when surface is wet; ideal temperature range: 15-40°C
Use infrared thermometers to continuously monitor mix temperature during all phases
Create neat, well-compacted edges using edge restraints or proper rolling techniques
Ensure proper cross-slope (2-2.5%) and longitudinal drainage (min 0.5%)
Coordinate truck delivery timing with paving operations to maintain continuous laying
Develop systematic rolling pattern diagrams for operators to ensure uniform compaction
Use level controls and frequent checking to maintain uniform layer thickness
Minimize manual raking and placement to prevent segregation and texture issues
By following this Standard Operating Procedure, Bituminous (BT) road construction can be executed efficiently, ensuring stability, durability, and compliance with IS standards. Proper execution and strict adherence to safety measures will result in strong, durable, and smooth road surfaces. Regular quality checks and documentation will help maintain high standards throughout the construction process, resulting in roads that provide reliable service while requiring minimal maintenance.