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IRC:19-2005

STANDARD SPECIFICATIONS

AND
CODE OF PRACTICE
FOR
WATER BOUND MACADAM
(Third Revision)

THE INDIAN ROADS CONGRESS


2005

IRC: 19-2005

STANDARD SPECIFICATIONS

AND
CODE OF PRACTICE
FOR
WATER BOUND MACADAM
(Third Revision)

Published by

THE INDIAN ROADS CONGRESS


Sector 6,

Kama Koti Marg,


R.K. Puram, New Delhi -

10 022

2005
Price Rs. 100/-

(Packing

& Postage Extra)

IRC: 19-2005
First

Published

April,

1966

Reprinted

February, 1970

Reprinted

Reprinted

May, 1972
November, 1972
May, 1977
September, 1982
March, 1 987 (incorporates amendment No.
May, 1988
March, 1999
October, 2000
April, 2002
May, 2005
September, 2006
February, 2008

Reprinted

October, 2009

First

Revision

Second Revision
Reprinted
RepriiK.

Reprinted
Reprinted
Reprinted

Reprinted
Third Revision

Reprinted

Reprinted

July,

& Corrected Sieve sizes)

20 11

(The Rights of Publication and Translation are reserved)


The official amendments to this code would be published by the
in its periodical, ^Indian

effective

Highways

',

which shall be considered as

and as part of the Code/Guidelines/Manual,


from the date specified therein

Printed at Aravali Printers

IRC

& Publishers (P.) Ltd. New Delhi


(500 copies)

etc.

10020

IRC: 19-2005

CONTENTS
Personnel of the Highways Specifications and Standards Committee

(i)

& (ii)

1.

Introduction

2.

Scope

3.

Materials

4.

Construction Procedure

5.

Surface Evenness of

6.

Rectification of Defective Construction

7.

Construction of

WBM over Narrow Widths

10

8.

Maintenance of

WBM Wearing Courses

10

WBM Course

10

Digitized by the Internet Archive


in

2014

https ://arch ve org/detai Is/govlawi rcy 2005sp 1 9_0


i

IRC: 19-2005

PERSONNEL OF THE HIGHWAYS SPECIFICATIONS AND


STANDARDS COMMITTEE
(As on 10-12-2004)

2.

V. Velayutham
(Convenor)
G. Sharan (Co-Convenor)

3.

Chief Engineer

1.

(R&B) S&R

Addl. Director General, Ministry of Shipping,

Road Transport

& Highways, New Delhi


Member

(Tech),

NHAI, New Delhi

Ministry of Shipping,

Road Transport & Highways, New Delhi

Member-Secretary )

Members
Bahadur

A.P.

Chief Engineer, Ministry of Shipping, Road Transport

Highways,
5.

P.K. Chakarabarty

P.K. Dutta

Desai

J.P.

&

New Delhi

Executive Director, Consulting Engg. Services

New
7.

Delhi

Chief Engineer Ministry of Shipping, Road Transport

Highways,
6.

New

&

(I)

Pvt. Ltd.,

Delhi

Vice-President (Tech. Ser.), Gujarat Ambuja Cements Ltd.,

Sr.

Ahmedabad
Dhingra

Professor, Indian Institute of Technology,

Mumbai

8.

Dr. S.L.

9.

A.N. Dhodapkar

10.

D.P.

11.

S.K.Gupta

Chief Engineer, Uttaranchal

12.

R.K. Jain

Chief Engineer (Retd.), Sonepat

13.

Dr. S.S. Jain

Coordinator (COTE), Indian Institute of


Technology, Roorkee

14.

Dr. L.R. Kadiyali

Chief Executive, L.R. Kadiyali

15.

Prabha Kant Katare

Joint Director (PI.), National Rural

Gupta

NITHE,

Director,

DG (RD) & AS, MOST (Retd.), New Delhi

Professor

Mathur

J.B.

17.

H.L.

Meena

Momin

S.S.

19.

A.B. Pawar

20.

Dr.

21.

S.S. Rathore

Gopal Ranjan

New

& Associates, New Delhi


Roads Dev. Agency (Min

Delhi

Chief Engineer (Retd.),

NOIDA

Chief Engineer-cum-Addl. Secy, to the Govt, of Rajasthan,

PWD,
18.

PWD, Almora

&

of Rural Dev.),
16.

NOIDA

Jaipur

Secretary (Works), Maharastra

PWD, Mumbai

Secretary (Works) (Retd.), Pune


Director, College of Engg.

Roorkee

Secretary to the Govt, of Gujarat,

R&B

Department,

Gandhinagar
22.

Arghya Pradip Saha

23.

S.C.

24.

Dr. P.K.

25.

Dr. C.K. Singh

Sharma

Nanda

Sr.

Consultant,

DG

&

(RD)

New Delhi

AS,

Director, Central

Engineer

in

Ranchi

(i)

MORT& H (Retd.), New Delhi


Road Research

Chief-cum Addl.

Institute,

Comm cum

New

Delhi

Spl Secy. (Retd.)

IRC: 19-2005
26.

Nirmal

Jit

Member

Singh

New
27.

Highways Authority of

(Tech.), National

India,

Delhi

Chief General Manager, National Highways Authority of India,

A.V. Sinha

New

Delhi

28.

N.K. Sinha

DG

29

V.K. Sinha

Chief Engineer, Ministry of Shipping, Road Transport

(RD)&SS,

Highways,
30.

K.K. Sarin

31.

T.P.

32.

Maj. V.C. Verma

DG

Velayudhan

(RD)

MOSRT& H

New

&

(Retd.),

New

MOST

AS,

(Retd.),

New

Delhi

New

Delhi

Executive Director, Marketing, Oriental Structural Engrs.

New

Delhi

R&B

33.

The Chief Engineer (NH)

(B. Prabhakar Rao),

34.

The Chief Engineer

(S.B. Basu), Ministry of Shipping,

(Pig

Highways,

The Chief Engineer (Mech)

New

Department, Hyderabad

New

Road Transport

&

Road Transport

&

Delhi

(V.K. Sachdev), Ministry of Shipping,

Highways,

Delhi

36.

The Chief Engineer (Mech)

PWD,

37.

The Chief Engineer (NH)

(Ratnakar Dash), Sachivalaya Marg, Bhubaneshwar

38.

The Engineer-in-Chief

(Tribhuvan

39.

The Chief Engineer

Kolkata

vlational

President

(S.S.

Ram)

PWD, Lucknow
PWD, Bangalore

U.P.

Highways,

Ex-Officio
40.

&

Delhi

Addl. D.G., Directorate General Border Roads,

Pvt. Ltd,

35.

Delhi

Members

Momin), Secretary (Works), Mumbai

Indian Roads Congress

41

Director General

(Indu Prakash), Ministry of Shipping,

(Road Development)

Highways,

&
42.

New

Road Transport &

Delhi

Special Secretary

Secretary

(R.S. Sharma), Indian

Roads Congress,

New

Delhi

Indian Roads Congress

Corresponding Members

PWD (Retd.), Panchkula

1.

M.K. Agarwal

Engineer-in-Chief, Haryana

2.

Dr. C.E.G. Justo

Emeritus Fellow, Bangalore University, Bangalore

3.

M.D. Khattar

Executive Director, Hindustan Construction Co. Ltd.,

4.

Sunny C. Madhathil

Director (Project), Bhagheeratha Engg. Ltd., Cochin

5.

N.V. Merani

Principal Secretary, Maharashtra

(ii)

PWD

(Retd.),

Mumbai

Mumbai

IRC: 19-2005

STANDARD SPECIFICATIONS AND CODE OF PRACTICE FOR

WATER BOUND MACADAM


1.

INTRODUCTION

Sitaramanjaneyulu, Scientists of Central Road


Institute. The draft of the revised code
was presented and discussed in the meeting of
Flexible Pavement Committee held on 1 th May,
2002 and it was decided that the draft document
may be modified in the light of the comments of
the members and sent to Convenor, Flexible
Pavement Committee for forwarding to Highways
Specifications & Standards (HSS) Committee. Dr.

Research

was originally published in 1 966.


The first revision of the standard was approved
by the Specifications and Standards Committee in
their meeting held on the 29 th & 30 th September,
1972, by the Executive Committee in their meeting
held at Gandhinagar on the 25 th November, 972
and by the Council in their 79 th meeting held at
Gandhinagar on the 25 th November, 1972 for
1 . 1 This standard

at its

the

th

meeting held on the 28 August, 1 976,

the tolerance of surface evenness

the basis of

document and forwarded to Convenor, Flexible


Pavement Committee. The draft standard was

IRC

publication. Following the decision of the

Council

P.K. Jain, and Shri K. Sitaramanjaneyulu modified

IRC

reviewed by the Flexible Pavement Committee

were revised on

(constituted in January, 2003) in

Special Publication 16 "Surface

Evenness of Highway Pavements" and the second

on

was published in May, 1 977


amended in March, 1987.

st

its

meeting held

August, 2003 and authorized a Group

revision of standard

consisting of Shri S.C. Sharma, Shri K.K. Singal

which was further

document
members and
forward the same to HSS Committee. The draft
standard was finalised by the Group in its meeting
held on 7 th May, 2004 and then sent for
and Dr. P.K. Jain

to finalise the

incorporating the suggestions of the

The decision to review and revise the code of


practice was taken during meeting of Flexible
Pavement Committee on 10 th February, 2001 The
task was assigned to Dr. P.K. Jain and K.
.

Members

consideration of HSS Committee.

of Flexible Pavement Committee

S.C.

Sharma

Secretary

up

to

December 2002

Convenor
Co-Convenor

R&B, Gujarat.

(S.S. Rathore)

Member-Secretary

Dr. S.S.Jain

Members
D. Basu

Prof. C.G. Swaminathan


C.E (R) S&R, T&T (Jai Prakash)

A.K. Bhatnagar
S.K. Bhatnagar
Dr.

Dr. Animesh Das


Dr.M.PDhir
D.P. Gupta

Rep. of DG(W), E-in-C Br.

Rep. of DGBR (Hargun Das)

FP Dn., CRRI

Dr. L.R. Kadiyali

Head,

Dr.CE.G.Justo

(Dr. Sunil

H.L.

AHQ

(Col. R.N. Malhotra)

Meena

Director,

Bose)

HRS, Chennai

Prof. B.B. Pandey


R.K. Pandey

Corresponding Members

Sukomal Chakrabarti

S.KNirmal

Dr. P.K. Jain

Smt. A.P. Joshi


R.S. Shukla

IRC: 19-2005

Members

of Flexible Pavement Committee reconstituted w.e.f. January 2003


S.C.

Sharma

Chief Engineer (Roads),

PWD,

Convenor
Co-Convenor

....

Guwahati

Member-Secretary

Dr. S.S. Jain

Members
(R&B) S&R

Aran Bajaj
Sukomal Chakraborty
Dr. Animesh Das
D.P. Gupta

Chief Engineer

Dr. L.R. Kadiyali

A Rep.

D. Mukhopadhyay

(Col. V.K.P. Singh)

Dr. B.B.

MORT&H
A Rep.

of IOC, Faridabad

(B.R. Tyagi)

A Rep.

Pandey

of E-in-C's Branch
of

DGBR

R.K. Pandey

(P.K.

R.S. Shukla

Area Co-ordinator (FP Dn.), CRRI

Mahajan)

K.K. Singal

(Dr. Sunil

Dr. A. Veeraragavan

Director,

Bose)

HRS, Chennai

Corresponding Members
Dr. P.K. Jain

S.K. Nirmal

Dr. C.E.G. Justo

The Manager (Bitumen), HPC,

J.T.

Mumbai

Nashikkar

m
mm

The draft document finalised by the Flexible


Pavement Committee was considered by the
Highways Specifications and Standards Committee
th
in its meeting held on 10 December, 2004 and

(Vijay Kr. Bhatnagar)

metre
millimetre

1.2.1.2 Abbreviations

approved with certain modifications.

The Council

in its 173

rd

meeting held on 8 th

January, 2005 at Bangalore approved the

BS

British Standards

IRC

Indian Roads Congress

IS

Indian Standard by Bureau of

document

for publication subject to modification in light of

Indian Standards

comments/suggestions given by the


participants. The document was modified suitably
by Shri S.C. Sharma, Convenor, Flexible
Pavement Committee and printed by IRC as Third
the

LL

Liquid Limit

PI

Plasticity

WBM

Water Bound Macadam

Index

Revision of IRC: 19.

1.2.

1.3.

References

1.3.1

The following IRC, IS and BS

Symbols and Abbreviations

For the purpose of this Standard, the


following symbols for SI units and abbreviations
1.2.1

standards

contain provisions, which, through reference in the


text, constitute

shall apply.

provisions of this standard. At the

time of publication, the editions indicated were


valid. All standards are subject to revision

1.2.1.1 Symbols for SI Units

kN

parties to agreements based

on

and

this standard are

encouraged to investigate the possibility of applying


kilo-newton

IRC: 19-2005
most recent editions of the standard indicated below

the

No.

Title

IRC:SP: 16-2004

Guidelines for Surface Evenness of

Highway Pavements

(First Revision)

IS460:Part

1985

Specification for test sieves: Part

cloth test sieves (Third

Revision)
IS 460:Part 2

Specification for test sieves: Part 2 Perforated plate test

1985

sieves (Third Revision)

IS460:Part3: 1985

Specification for test sieves: Part 3

of apertures of

test sieves

Method of Test

IS 2386:Part 1-1963

(Third Revision)

for Aggregates for Concrete

Part

and Shape (Reaffirmed 2002 Amds. 3)

Particle Size

Method of Test

IS 2386:Part 3-1963

Methods of exami nation

for Aggregates for Concrete

- Part

3:

Specific gravity, density, voids, absorption and bulking

(Reaffirmed 2002)

Method of Test for Aggregates

IS 2386:Part 4-19

Methods

IS 2430: 1986

for

for Concrete

- Part 4:

Sampling of Aggregates for Concrete

(First

Revision) (Reaffirmed 2000)

Method of test

IS 5640: 1970

for determining aggregate impact value of

soft coarse aggregates

(Reaffirmed 1998 Amds. 1

IS 14685-1999

BS

1047:1983

Specification for air-cooled blast furnace slag aggregate


for use in construction (Replaced by

2.

SCOPE

EN

2620)

subgrade, sub-base, base or existing pavement as


the case

may

be.

WBM

may

be used as a sub-

base, base course or surfacing course depending

This Standard covers the specification for

Bound Macadam as SubBase Course and Surfacing Course of a road


pavement.
construction of Water

upon category of road.

In

each case,

it

shall

be

constructed in accordance with the specifications

base,

given in this Code and

in

conformity with the

lines,

grades and cross-sections shown on the drawings


2.1.

Description

2.1.1

Water Bound Macadam

or as directed.

(WBM)

2.1.2

shall

The

WBM shall not be laid on an existing

consist of clean, crushed coarse aggregates

bituminous top surface without scarifying or

mechanically interlocked by rolling, and voids

providing adequate measures for proper bond and

thereof filled with screening and binding material

drainage at the interface of existing bituminous

with the assistance of water, laid on a prepared

surface and

WBM layer.

IRC: 19-2005

WBM should not be laid directly over a

2.1.3
silty

or clayey subgrade.

It is

from

advisable to lay a

elongated, soft and disintegrated

flat,

particles, dirt or other deleterious materials.

suitable intervening granular layer.

Crushed

3.1.3
3.

MATERIALS

Coarse
Requirements

Aggregates

General

shall

be angular

shall

in shape,

be

slag.

reasonably uniform

in

quality and density, and generally free from soft,

elongated and
material.

Coarse aggregates

3.1.1

Crushed slag

manufactured from air-cooled blast furnace


It

3.1.

slag

shall consist of clean

1 1

.2

kN

flat

pieces, dirt or other deleterious

Crushed slag

per

shall not

weigh

and the glassy material

crushed or broken stone, crushed slag, over burnt

not be in excess of 20 per cent.

brick (Jhama) metal or naturally occurring

comply with

It

less than
in

it

shall

should also

the following requirements.

aggregates such as kankar and laterite of requisite


quality as stated hereinafter.

Use of crushable

(i)

Chemical

To comply with

stability

type aggregates should generally be restricted to

requirement of

lower layers of the pavement. The aggregates shall

Appendix of BS

conform
Table

1047

to the physical requirements set forth in

1.

(ii)

Sulphur content

(iii)

Water absorption

(IS

Crushed or broken stone

3.1.2.

Crushed

or broken stone shall be hard, durable and free

Table
SI.

1:

2.

Maximum

10 per cent

(IS 2386, Part 3)

Test +

Test

WBM

Method

equirements

IS

(Part 4)

Max. 50%

Aggregate Impact Value*

2386 (Part 4)
or IS 5640**

Max. 40%

Base course with

Los Angeles Abrasion Value* or

IS

(Part 4)

Max. 40%

bituminous surfacing

Aggregate Impact Value*

2386 (Part 4)
orlS 5640**

Max. 30%

Flakiness Index***

IS

(Part 1)

Max. 20%

Los Angeles Abrasion Value* or

IS 2386 (Part 4)

Max. 40%

Aggregate Impact Value*

IS 2386 (Part 4)

Max. 30%

Surfacing course

3.

2 per cent

Los Angeles Abrasion Value* or

Sub-base

1.

14685-1999

Maximum

Physical Requirements of Coarse Aggregates for

No. Type of Construction

2386

IS

2386

IS

2386

or IS 5640**
IS 2386 (Part 1)

Flakiness Index***

Notes

Max. 15%

may

Aggregates

**

Aggregates like brick metal, kankar,

satisfy the

requirements of either the Los Angeles

tested for impact value under

laterite, etc.,

wet conditions

*** The requirement of Flakiness Index

shall

in

which get softened

test

in

or Aggregate Impact Value Test.

presence of water should invariably be

accordance with IS 5640.

be enforced only

in the case

of crushed/ broken stone and crushed

slag.

Samples for
procedure

tests shall

set forth in IS

be representative of the materials to be used and collected


2430.

in

accordance with the

IRC: 19-2005

O verburnt

3.1.4

metal shall be

Jhama) brick metal B rick

made

out of overburnt bricks or

3.2.3

The crushable type aggregates

like brick

metal, kankar and laterite shall also generally

brick bats and be free from dust and other

satisfy the grading requirements of Table 2.

deleterious materials.

Relaxation in grading

may be

permitted for such

materials with the permission of the Engineer.


3.1.5

Kankar

Kankar

shall

be tough having a

blue almost opalescent fracture.

any clay

in the cavities

It

shall not contain

3.3 Screenings

between nodules.
3.3.1

3.1.6 Laterite

Laterite shall be hard, compact,

shall not

be used.

material such as kankar,

and Grading

and

one of the grading given


shall

in

moorum or gravel (other


may also be

than river-borne rounded aggregate)

used for

The coarse aggregates

However, from

economic considerations, predominantly non-plastic

Requirement
3.2.1

voids in the coarse

as the coarse aggregates.

those containing ochreous clay

3.2 Coarse Aggregates-Size

fill

aggregates shall generally be of the same material

heavy and of dark colour. Light coloured sandy


laterities, as also

Screenings to

this

purpose provided that the liquid limit

plasticity

index of such material are below 20

and 6 respectively and the fraction passing 75 micron

conform to
Table 2. Grading 1
shall

sieve does not exceed 10 per cent.

be used only for sub-base courses, with a

compacted layer thickness of 100

The

3.2.2

size of aggregates to

As Tar as possible, screenings shall


conform to the grading shown in Table 3.

mm.

3.3.2

be used would

Screenings of type

depend on the type of aggregates available and


compacted thickness of the layer.

Table 2

Grading
No.

Size

90

Size

with coarse aggregates of grading

1,

and of type

3.

With coarse

with coarse aggregates of grading

and Grading Requirement of Coarse Aggregate for

Range and compacted

Sieve Designation

thickness for layer

(IS 460)

mm to 45 mm (100 mm)

mm
90 mm
63 mm
45 mm
22.4 mm
125

53

WBM

Per cent by Weight


Passing the Sieve
100

90-100
25-60
0-15
0-5

mm to 45 mm (75 mm)

90 mm

100

90-100

mm to 22.4 mm (75 mm)

mm
53 mm
45 mm
22.4 mm
63 mm
53 mm
45 mm
22.4 mm
11.2 mm

63

63

A shall be used in conjunction

25-75
0-15
0-5

100

90-100
65-90
0-10
0-5

IRC: 19-2005
Table 3

Grading Requirements of Screenings for

Grading

Size of Screenings

Sieve Designation

Classification

(IS 460)

Passing the Sieve

13.2

mm

11.2

mm

or type

95-100

80 micron

0-10

mm
5.6 mm

100

90-100

80 micron

15-35

100

<

available nearby, limestone dust or kankar nodules

may be used as

may be used. For crushable screenings


moo rum and gravel, the grading given in Table

screenings
like

mm
11.2 mm
5.6 mm
11.2

aggregates of grading 2, either type

Percent by Weight

13.2

WBM

3.4.2

3 shall not be binding.

binding material.

Application of binding material

may

not

be necessary, where the screenings consist of

The use of screenings may be dispensed


with when crushable type soft aggregates such

moorum

3.3.3

crushable type material like

as brick metal, kankar, laterite, etc., are used as

However, for
used as a surfacing course,
where the PI of crushable type screenings is less

coarse aggregates, as these are likely to get

than 4, application of a small quantity of binding

crushed to a certain extent during rolling.

material having PI of 4-6


top.

3.4 Binding Material


3.4.1

WBM as

consist of a fine grained material passing

possessing PI value of 4-8


as a surfacing course,

3.5.1

when

and

the

WBM

less than

is

bituminous surfacing.

Table 4

If

Approximate quantities of coarse

aggregates and screenings required for 100

used

compacted thickness of

6 when the

limestone formations are

materials for

Classification

sub-base/base or surfacing

Screenings

Size

Loose

Range

Quantity

Stone Screenings

Grading

Loose

classification

quantity

and

WBM

WBM

Coarse Aggregates

Grading

sub-base course

Approximate Quantities of Coarse Aggregates and Screenings Required for


mm compacted thickness of
Sub-base Course per 10 m 2

100

WBM

(mm)

(m 3 )

90 to

1.21 to

45

1.43

mm

are given in Table 4. Likewise, quantities of

adopted as a sub-base/base course with

is

The quantity of screenings could be reduced

3.5 Quantities of Material

100 per cent through 425 micron sieve and

WBM

would be required at the

correspondingly.

Binding material to be used for

filler shall

or gravel.

WBM

Crushable Type Such


as

Moorum

Properties

and

size

or Gravel

size

(m 3 )

(m 3 )
5

0.27 to

mm

LL<20,
PI<6

0.30 to

0.30

Type
13.2

Per cent
passing 75

micron < 10

Loose
quantity

0.32

IRC: 19-2005

Approximate Quantities of Coarse Aggregates and Screenings Required for


compacted thickness of
Sub-base/Base Course/Surfacing Course per 10 m 2

Table 5

mm

75

WBM

Coarse Aggregates
Classification

Crushable Type Such


as Moorum or Gravel

Stone Screenings

Size

Loose

Range

Quantity

Loose quantity or

Grading
classification

WBM sub-

WBM

Properties

Loose

and size

base/ base

surfacing

and size

quantity

course

course*

(m3)

(m3)

(m3)

(m3)

(nun)

(m3)

0.91 to

Type A,

0.12 to

0.10 to

LL<20,

0.22 to

0.15

0.12

PI<6

0.24

63

Grading 2

Screenings

to 45

1.07

13.2

mm

Percent
passing 75

micron

<10

TypeB,

63 to 45

Grading 2

11.2

Grading 3

0.20 to

0.16 to

022

0.18

0.18 to

0.14 to

021

0.17

mm

53 to 22.4

Quantities in Col. 6 are 80 per cent of those in Col. 5 as larger quantity of binding material will need to be used where
the

WBM

is

to act as a surfacing course (see Clause 3.5.2.).

course for a compacted thickness of 75

given in Table

mm are

grade and camber and cleaned of all dust,


other extraneous matter.

5.

dirt

and

Any ruts or soft yielding

places that have appeared due to improper


3.5.2
is

to

The

quantity of binding material where

be used (see Clause

3.4.), will

type of screenings and function of

WBM. Generally,

mm

m /10 m
3

shall

depend on the

the quantity required for 75


thickness will be 0.06-0.09

drainage, service under traffic or other reasons

it

4.1.2

compacted

in the case

depressions and potholes

removed and

made good with suitable

material before spreading the coarse aggregates

WBM.

The above mentioned quantities should be

taken as a guide only, for estimation of quantities

4.1.3

for construction, etc.

avoided since it will cause problems of proper bond

CONSTRUCTION PROCEDURE

WBM

As far as possible, laying of WBM course

over an existing bituminous surface should be

and internal drainage of the pavement at the


interface of two courses. It is desirable to
completely remove the existing thin surfacing of
is proposed to be
bituminous layer, where
laid over it. Where the intensity of rain is low and

4.1 Preparation of Foundation for Receiving

the

be laid on an

for

4.1.1

is to

strengthened, corrugations

mm thickness, the quantity needed


will be 0.08-0.10 m /10 m for sub-base course.

course. For 100

WBM

and re-shaped to the required grade and


camber as necessary. Weak places shall be

is

3.5.3

the

scarified

Where

until firm.

existing un-surfaced road, the surface shall be

of

WBM sub-base/base course and 0.10-0.15 m /10


m when the WBM to function as a surfacing
2

be corrected and rolled

WBM

Layer

The subgrade, sub-base or base to receive

interface drainage facility

WBM course shall be prepared to the required

is efficient,

WBM can

be laid over existing thin bituminous surfacing by

IRC: 19-2005
cutting

50

mm x 50 mm (minimum) furrows at

metre intervals

at

45 degrees to the centre

4.3.3

The coarse aggregates

be spread

line of

in lengths

the carriageway before proceeding with the laying

work ahead of

ofWBM.

preceding section.

The

direction

and depth of furrows

shall

shall

normally not

exceeding three days average

the rolling and bonding of the

4.4 Rolling

be

such that they provide adequate bondage and also


serve to drain water to the existing granular base

4.4.1

course beneath the existing bituminous surface.

these shall be

4.1.4

kN capacity or an equivalent vibratory roller.

After the laying of coarse aggregates,

compacted to full width by rolling


three wheel-power roller of 80 to 100

with either
In

all

cases, the foundation shall be kept

well drained during the construction operations.

4.2

The

from edges with


roller running forward and backward until the edges

4.4.2

Provision of Lateral Confinement of


Aggregates

rolling shall begin

have been firmly compacted. The

roller shall then

progress gradually from edges to the centre, parallel

For construction of WBM, arrangement should

be made for the

to the centre line of the road

and overlapping

confinement of aggregates.

uniformly each preceding rear wheel track by one

This shall be done by building adjoining shoulders

half width and shall continue until the entire area

alongwith
constructing

lateral

WBM layers. The practice of


WBM in a trench section excavated

in the finished

of the course has been rolled by the rear wheel.

Rolling shall continue until the road metal

formation must be completely

is

thoroughly keyed and the creeping of stone ahead


of the roller is no longer visible. Slight sprinkling of

avoided.

water

may be

4.4.3

On

done,

if

required.

4.3 Spreading of Coarse Aggregates


4.3.1

The coarse aggregates

shall be spread

uniformly and evenly upon the prepared base

super elevated portions of the road,

rolling shall

commence from

the lower edge and

progress gradually towards the upper edge of the

in

required quantities from stockpiles along the side

pavement.

of the road or directly from vehicles. In no case


shall these

be dumped

where these are

to

in

heaps directly on the area

be laid nor shall

4.4.4

Rolling shall not be done when the

subgrade

their hauling

is

soft or yielding or

when

it

causes a

over a partly completed base be permitted. The

wave-like motion in the base course or subgrade.

aggregates shall be spread to proper profile by using

If irregularities

templates placed across the road about 6

m apart.

exceed 12

Where possible, approved mechanical devices shall

mm

develop during rolling, which

when

tested with a 3

straight

edge, the surface shall be loosened and aggregates

be used to spread the aggregates uniformly so as

added or removed as required before rolling

minimize the need for their manipulation by hand.

WBM Course shall be constructed in

again so as to achieve all uniform surface


conforming to the desired cross section and grade.
The surface shall also be checked transversely by

compacted layer

template for camber, and any irregularities corrected

to

4.3.2

The

layers such that thickness of each

is not more than 100 mm for grading 1 (Table 2).


The compacted thickness of layer shall be 75 mm
for grading 2 and grading 3. Each layer shall be

tested

by depth blocks.

in the

manner described above. In no case shall


make up depressions be

the use of screenings to

permitted.

No segregation of large or

fine particles shall be allowed.

The coarse

which gets crushed excessively


during compaction or become segregated shall be
removed and replaced with suitable aggregates.
4.4.5

aggregates as spread shall be of uniform gradation

with no pockets of fine material.

Material,

IRC: 19-2005
4.5 Application of Screenings

sub-base before
After coarse aggregates have been rolled

4.5.1

as per Clause 4.4, screenings to

(is still

rolling shall

it

shall

be done when the screenings are being

to the lime treated

has picked up enough strength

"green") and thus cause

base layer. The laying of

interstices

fill

be applied gradually over the surface. Dry

shall

down

excessive water to flow

damage to the sub-

WBM layer in such cases

be done after the sub-base attains adequate

strength, as directed

by the Engineer.

spread so that the jarring effect of roller causes

them

to settle into the voids

The screenings

shall not

4.7 Application of Binding Material

of the coarse aggregate.

be dumped

in piles but

After the application of screenings as per

applied uniformly in successive thin layers either

4.7.1

by the spreading motion of hand shovels,


mechanical spreaders, or directly from trucks.

Clauses 4.5 and 4.6, binding material where

Trucks plying over the base course to spread

at

screenings shall be equipped with pneumatic tyres

successive thin layers. After each application of

and operated such as not to disturb the coarse

binding material, the surface shall be copiously

aggregates.

sprinkled with water and the resulting slurry swept


in

The screenings shall be applied at a slow


more applications as necessary.

4.5.2

an uniform and slow rate in two or more

with hand brooms/mechanical brooms or both

so as to

rate in three or

by

This shall be accompanied by rolling and brooming.

shall

Either mechanical brooms/hand

may

brooms or both

the voids properly. This shall be followed

rolling with 80-

100 kN

which water

roller during

be applied to the wheels to wash down the

may

get stuck to them.

The

spreading of binding material, sprinkling of water,

sweeping with brooms and rolling

applied so fast and thick as to form cakes or ridges


filling

fill

binding material that

be used. In no case shall the screenings be

on the surface making the

it is

required to be used (see Clause 3.4), shall be applied

of voids difficult

until the slurry

or preventing the direct bearing of roller on the

shall continue

of binding material and water forms

wave ahead of the wheels of moving

roller.

coarse aggregates. The spreading, rolling and

brooming of screenings shall be taken up on


sections, which can be completed within one day's
operation.

used

in

Damp

and wet screenings

shall not

4.8 Setting and Drying

be

4.8.1

After final compaction of the course, the

layer shall be allowed to dry overnight. Next

any circumstances.

morning, hungry spots shall be filled with screenings

4.6 Sprinkling of Water and Grouting

or binding material, lightly sprinkled with water if


necessary, and rolled.

4.6.1

After application of screenings, the

till

the

macadam

No

traffic shall

be allowed

sets.

surface shall be copiously sprinkled with water,

swept and

sweep

rolled.

Hand brooms

shall

be used to

the wet screenings into the voids,

distribute

them evenly. The

and rolling operations

and to

be

and

laid

only after the

base course to be

WBM course

dry and before allowing any

bonded and firmly set


and a grout of screenings and water forms ahead
roller.

WBM

traffic

is

on

latter shall

completely

it.

where necessary until

the coarse aggregates are

of the wheels of the

In the case of

provided with bituminous surfacing, the

sprinkling, sweeping

shall be continued

additional screenings applied,

4.8.2

Care

shall

the base or subgrade does not get

5.

SURFACE EVENNESS OF
COURSE

WBM

be taken that

damaged due

5.1

to

The surface unevenness of completed

addition of excessive quantities of water during the

WBM course in longitudinal and transverse directions

construction.

shall

4.6.2

In case of lime treated soil sub-base,

construction of

WBM

on top of

it

5.2

be within the limits specified in Table

The

6.

longitudinal profile shall be checked

with a 3-metre long straight edge at the middle of

can cause

IRC: 19-2005
Table 6
SI

Permissible Surface Unevenness for

Range of

Longitudinal Profile measured

x^UdlbC /AgglCgalCS

with a 3-Metre Straight Edge

Size

mm
63-45 mm or
53-22.4 mm
90-45

1.

2.

each

line of the road.

checked with a
at intervals

The

Max

permissible

of undulations

variation

Surface

permitted in any

specified profile

unevenness

300-metre length,

under camber

exceeding

template

mm

12

15

30

mm

10

camber templates

construction of

8.

sub-grade

is

WBM shall be carried out as

MAINTENANCE OF
COURSES

WBM WEARING

The successful performance of

WBM as

timely maintenance. Maintenance measures for

can be considered under three heads: periodic

WBM

patching of potholes along with removal of ruts

Table 6

and depressions, blinding of the surface, and

the surface irregularity of the

soil

level.

a surfacing course depends to a large extent on

this

in

this

RECTIFICATION OF DEFECTIVE
CONSTRUCTION

or where the course

mm

per the procedure prescribed in Clause 4.

8. 1

courses exceeds the tolerances given

from

12

The

transverse profile shall be

of 10 m. For detailed guidance in

nprmissihlp

should be removed only up to the sub-base

may be made to IRC:SP:162004 "Guidelines for Surface Evenness of


Highway Pavements (First Revision)".

Where

mm

30

respect, reference

6.

Transverse Profile

Maximum number

12

series of three

Courses

Max.

along a line parallel to the centre

traffic lane

WBM

otherwise defective due to

surface renewals.

mixing with the aggregates, the layer

affected area, reshaped with added material, or

Patching of pot-holes along with


removal of ruts and depressions Potholes,

removed and replaced with

ruts

to

thickness shall be scarified over the

its full

8.1.1

fresh material as

and other depressions should be drained of

applicable, and recompacted in accordance with

water and cut to regular shape with vertical sides.

manner

All the loose and disintegrated material shall be

be less than 10 nr. In no case shall

removed and the exposed surfaces swept clean.


The holes/depressions shall then be filled with
salvaged coarse aggregates mixed with sufficient

Clause

4.

shall not

The area treated

in the aforesaid

depressions be filled up with screenings or binding


material.

quantity of fresh aggregates and recompacted as


7.

CONSTRUCTION OF

WBM OVER

normal

NARROW WIDTHS

WBM to operations described in Clause 4

so that the patched area merges with the adjoining

Where the area so treated is small, hand


rammers may be used for compaction instead of
surface.

Where

the

WBM course

is

to

be constructed

narrow widths for widening of an existing


pavement, the existing shoulders should be
in

excavated to their

full

rollers.

depth and width up to the

8.1.2

Blinding of surface

Blinding of the

subgrade level except where the widening

surface shall be resorted to periodically as soon

specifications envisage laying of a stabilised-soil sub-

as the blinding material applied earlier has been

base using in-situ operations in which case the same

eroded away due to a

10

traffic

or weather action

IRC: 19-2005
and the surface has started showing signs of

For renewal, the existing surface shall


be scarified to a depth of 50-75 mm and the
resulting material removed to berms for screening
to salvage the usable coarse aggregates. The
exposed pavement shall be scarified again at high

ravelling. Blinding operations shall consist of

application of binding material in thin layers and

grouting in accordance with the procedure given


in

Clause 4.7.

spots so as to ensure proper grade and camber.

8.1.3

WBM

Surface Renewal
wearing
when the surface is worn
:

The salvaged coarse aggregates mixed with

course shall be renewed

sufficient quantity of fresh aggregates (usually

and badly ravelled or has a


profusion of potholes and depressions which can
not be treated economically with patching or

between one half to one

blinding operations.

Clause

out, is corrugated

third

of the quantity of

salvaged aggregates) shall then be used to


construct a

11

4.

new WBM course in accordance with

The official amendments to this code would be published by the IRC


in its periodical, 'Indian

effective

Highways', which shall be considered as

and as part of the Code/Guidelines/Manual,


the date specified therein

etc.

from

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