Bituminous Road

Standard Operating Procedure for Bituminous (BT) road construction, ensuring stability, durability, and compliance with industry standards and IS Codes for road construction projects.

Duration: 10-15 days Team: 10-15 workers Risk Level: Medium

1. Purpose

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.

2. Scope

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.

3. Responsibilities

Project Manager

Ensures compliance with specifications, IS codes, and project timelines

Site Engineer

Monitors execution & ensures compliance with drawings

Supervisor

Ensures availability of materials, tools & workforce coordination

Operators & Workers

Perform material spreading, grading & compaction

Quality Inspector

Checks material quality, layer thickness & compaction density

Safety Officer

Ensures all safety measures are followed at the site

Material Manager

Ensures timely availability of quality-tested bitumen and aggregates

Survey Team

Establishes proper alignment, levels, and gradients for road construction

4. Materials and Tools Required

Bitumen

VG-10, VG-30, VG-40 as per IS 73:2013 specifications

Aggregates

Coarse and fine aggregates as per IS 2386 standards

Filler Materials

Stone dust, cement, or lime for bituminous mix

Coating Materials

Prime coat and tack coat as per IS 8887:2004

Hot Mix Plant

For preparing bituminous mix at controlled temperature

Transport Equipment

Dumpers/trucks with insulated beds for material transportation

Sensor Paver

For uniform laying of bituminous mix with thickness control

Rollers

Vibratory, tandem, pneumatic-tired for effective compaction

5. Procedure

1
Survey and Site Preparation
2
Prime Coat Application
3
Tack Coat Application
4
Bituminous Mix Preparation
5
Laying and Compaction

6. Quality Checks and Tests

Bitumen Tests

Penetration (IS 1203), Softening Point (IS 1205), Viscosity tests

Aggregate Testing

Gradation, Impact Value, Abrasion, Flakiness/Elongation Index as per IS 2386

Mix Design Tests

Marshall Stability (min 9kN), Flow (2-4mm), Air Voids (3-5%)

Layer Thickness

Core cutting tests to verify specified thickness (±5mm tolerance)

Compaction Tests

Field density 97-98% of lab density, void content 3-6%

Temperature Monitoring

During mixing (150-165°C), laying (130-150°C), compaction (>120°C)

Surface Regularity

Maximum 4mm deviation under 3m straight edge

Water Sensitivity Test

AASHTO T283: min 80% retained stability after water conditioning

7. Safety Measures

Personal Protective Equipment

Safety boots, gloves, helmets, and high-visibility vests for all personnel

Site Safety

Barricading, signage, and traffic management at construction site

Hot Material Handling

Heat-resistant gloves, face shields when handling hot bitumen

Equipment Safety

Only certified operators to handle hot mix plant, pavers, and rollers

Emergency Response

First aid kits, burn treatment supplies, eye wash stations on site

Fume Protection

Proper ventilation, respiratory protection when necessary

Team Coordination

Clear communication protocols between vehicle operators and ground crew

Heat Stress Prevention

Regular hydration, shade provisions, work-rest cycles during hot weather

8. Troubleshooting Common Issues

Bleeding/Flushing

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.

Raveling

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.

Rutting

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).

Segregation

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.

9. Documentation and Approval

Maintain records of material testing reports and approvals
Document compaction test results and layer thickness measurements
Keep records of temperature monitoring during mixing, transportation, and laying
Maintain daily progress reports and quality inspection results
Record photographic evidence at different construction stages
Obtain final approval from quality control team before opening for traffic
Prepare as-built drawings showing actual construction details

10. References and Standards

IS 73:2013 - Specification for Paving Bitumen
IS 2386 (Parts 1-8) - Methods of test for aggregates for concrete
IS 8887:2004 - Specification for bitumen emulsion for roads
IS 1203:1978 - Methods for testing tar and bituminous materials (Penetration test)
IS 1205:1978 - Methods for testing tar and bituminous materials (Softening point test)
IS 2720:1987 - Methods of test for soils (Field density)
IRC:SP:20 - Rural Roads Manual
MORTH 5th Revision - Specifications for Road and Bridge Works

11. Pro Tips

Weather Considerations

Avoid laying BT mix during rainy conditions or when surface is wet; ideal temperature range: 15-40°C

Temperature Control

Use infrared thermometers to continuously monitor mix temperature during all phases

Edge Treatment

Create neat, well-compacted edges using edge restraints or proper rolling techniques

Drainage Consideration

Ensure proper cross-slope (2-2.5%) and longitudinal drainage (min 0.5%)

Material Staging

Coordinate truck delivery timing with paving operations to maintain continuous laying

Rolling Pattern

Develop systematic rolling pattern diagrams for operators to ensure uniform compaction

Thickness Control

Use level controls and frequent checking to maintain uniform layer thickness

Hand Work Minimization

Minimize manual raking and placement to prevent segregation and texture issues

12. Conclusion

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.

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