TURAPAN LENTUR

Civil Engineering Department | DCC3113 : Highway & Traffic Engineering



DCC3113 :







e-
Course Notes






| Unit 1 : Introduction to Highway and Traffic

| Unit 2 : Pavement Materials

| Unit 3 : Construction Of Flexible Pavement

| Unit 4 : Construction Of Rigid Pavement

| Unit 5: Flexible Pavement Design


| Unit 6 : Highway Maintenance

| Unit 7 : Transportation Planning

| Unit 8 : Traffic Control Equipment And Road Furniture

| Unit 9 : Junction Design

| Unit 10 : Traffic Management


Prepared By :
SITI ZURAIFA BINTI MD SAH |Lecturer in Civil Engineering Department, Politeknik Mukah, Sarawak
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| Introduction


| Video


| Concept


| Assessment


| Summary






Prepared By :
SITI ZURAIFA BINTI MD SAH |Lecturer in Civil Engineering Department, Politeknik Mukah, Sarawak
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Introduction Introduction




COURSE LEARNING OUTCOMES (CLO)

Upon completion of this course, students will be able to:-
CLO 1 : Comprehends and applies the fundamentals engineering concepts of highway and traffic engineering and related act in
Malaysia.(C3, PLO1) (C3,PO1)


CONTENT




3.1
Understand
the UNIT 3:
construction
of flexible CONSTRUCTION OF
pavement FLEXIBLE
PAVEMENT















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Introduction Introduction




COURSE LEARNING OUTCOMES (CLO)

Upon completion of this course, students will be able to:-
CLO 1 : Comprehends and applies the fundamentals engineering concepts of highway and traffic engineering and related act in
Malaysia.(C3, PLO1) (C3,PO1)


CONTENT




3.1
Understand
the UNIT 3:
3.1.1 Describe about the flexible pavement construction
of flexible
3.1.2 Explain preparation of materials used in the pavement CONSTRUCTION OF
a. sub base FLEXIBLE
b. sub road PAVEMENT
c. road surface
3.1.3 Discuss the construction of road:
a. Sub base
b. Base
c. Surface
d. Shoulders
3.1.4 Identify priming work in flexible pavement



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Video Video













































Source : How to Pave a Road with Asphalt - https://www.youtube.com/watch?v=T0Y3RtY7tNo



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Concept Concept


















































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Concept Pavements




 Pavement is the structure which separates the tyres of vehicles from the underlying
foundation material.
 Pavement grants friction for the vehicles thus providing comfort to the driver and transfers
the traffic load from the upper surface to the natural soil.
 In earlier times before the vehicular traffic became most regular, cobblestone paths were
much familiar for animal carts and on foot traffic load.

 Storm water drainage and environmental conditions are a major concern in the
designing of a pavement.
 The roads of the earlier times depended solely on stone, gravel and sand for construction
and water was used as a binding agent to level and give a finished look to the surface.
 All hard road pavements usually fall into two broad categories namely
 Flexible Pavement
 Rigid Pavement

















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Concept Flexible Pavement




Flexible Pavements are constructed from bituminous or unbound material and the stress is
transmitted to the sub-grade through the lateral distribution of the applied load with depth.

The FOUR (4) layers of flexible pavement structure
 Sub-grade soil or simply sub-grade

 Sub-base
 Road Base
 Surface layer


Tack Coat

Prime Coat





















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Concept Function of Flexible Pavement















To provide level,
comfortable and safe
surface.











To receive and
To protect lower
distribute load
layers from effects from vehicle to the
of water.
lower layers.










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The different between flexible pavement and rigid pavement






Flexible pavement Rigid pavement


In flexible pavement, load distribution is based on Rigid pavement most of the load carries by slabs
layered system. itself.
Due to layered system in flexible pavement,
structural capacity depends on the characteristics Rigid pavement, most of the structural capacity

of all layers. depends on the characteristics of slab only, because
of low bearing capacity of underlying layers.

In flexible pavements, intensity of load decreases as A rigid pavement, due to minor capacity of
the depth increases or as the load moves to the underlying layers maximum load intensity reduces in
further underlying layers. the top most layers and that is slab.

Flexible pavement has very low modulus of Modulus of elasticity of rigid pavement is very high,
elasticity (less strength). because of high strength and more loads bearing
capacity than as compared to flexible pavements.


In flexible pavements, underlying layers play very Rigid pavements, little function of underlying layers.
important role. Therefore, more roles are playing Maximum role is playing by the top layer (that is slab)
only underlying layers. by itself. Therefore, little influence on sub layers.






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Concept Pavement Design Overview




Original Design
• Guideline - ATJ 5/85 (Pindaan 1993)

• Expected Design Life – 10 Years
• Traffic Loading – 25 million standard axle (MSA)

• Subgrade CBR – 5% Soaked CBR ( Top 1000mm thick)

































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Concept Pavement Works


















































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Concept Asphalt Concrete Pavement Sequence




i. Subgrade is a layer of natural soil or filled soil, ready to receive the pavement material
over it.
ii. Subgrade is the lowest layer below the road formation level.
iii. It acts as foundation underneath the pavement structural layer.
iv. Must possess enough soil bearing capacity.



















WATER TANK
Subgrade












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Concept Formation/Subgrade













































WATER TANK

Subgrade
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Concept Preparation Subgrade Layer




• Prepare the subgrade layer, it is done after placing the drainage system, piping and
electric cable.
• The subgrade surface will be compacted levelled and be cut to make camber as in
plan.
• If the material of the soil did not have a good quality, it will be changed with suitable
material.

• Base formation covers with 50-75mm sand layer or quarry dust and will be compacted
with 8-10 tone compactors.
• This job must be done to prevent the clay from absorbing into the stone layer of sub-base
and reduce the shear strength of the pavement.




















WATER TANK

Subgrade
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Concept Preparation Subgrade Layer













































WATER TANK

Subgrade
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Concept Asphalt Concrete Pavement Sequence




Sub-base is one course that is constructed with quality materials. This is the lowest layer of
pavement that is constructed onto the sub-grade. The functions of sub-grade:
• Support the road base and spreads the load to the sub-grade.
• Prepares the drainage using rough materials.
• Prepares a cover at any layer that is constructed.
• Bears the pressure from heavy vehicles so the sub-grade will not crack.

• Prevent the sub-grade from traffic flow.














Subbase
Subgrade












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Concept The construction of sub-base




• After the sub-base has been prepared with list materials, it will be placed and
constructed into two layers if the thickness is more than 150mm.

• Every layer will be compacted according to the plan. Sub-base layer must be
compacted carefully with compactor machine.
• Compactors with rubber roller can compact 120mm layer in 12 times.

• Compacting should start from the side of the road hen slowly towards the middle of the
road in horizontal way.
• In super-elevated bends compaction machine will start at the lowest part and slowly
towards the higher level.

• The finished part is not more than 20mm from the plan.













Vibratory Roller (Penggelek Bergetar)



Subbase
Subgrade

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Concept Testing




• The most suitable materials used for the sub-base
are:

– The liquid limit shall be not more than 25%.
– Plasticity Index (PI) shall be not more than 6%.

– The Aggregate Crushing Value shall be not
more than 35%.

– The material shall have a CBR value of 30 or
more when compacted to 95% of the MDD.

– Laterite Sand – which have CBR value > 20%
– Crushed Agg.-with the size ranging from
75mm to dust & the CBR value > 30%

– Sub-base material should fulfill the test CBR,
Liquid Limits, Plastic Limits, Aggregate Impact
Value (AIV), Los Angeles Abrasion (LAA) and
Sieving.







Subbase
Subgrade

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Concept The gradation limits for sub-base material













































Subbase
Subgrade

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Concept Asphalt Concrete Pavement Sequence




• Base or road base is the main course to absorb force from surface directly and spread
the force to the thickest layer. This layer is normally made from broken stones which may
be bounded or unbounded. It is used to help spread traffic load on large area of sub-
grade so that the stress intensity remains within the capabilities of the sub-grade. Thus
undue deformation caused by the consolidation of the sub-grade is prevented.
















Road Base/ Base

Subbase
Subgrade












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Concept Preparation of materials used in flexible pavement




The FOUR (4) methods for the construction of road base course in flexible pavement
 Macadam Crusher-Run Road Base (Batu Hancur)
 Dry Bound Macadam Road Base (Macadam Ikatan Kering)
 Wet-Mix Macadam Road Base (Macadam Ikatan Basah)
 Bituminous Bound Macadam Road Base

 Cement-Treated Road Base
































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Concept Macadam Crusher-Run Road Base




• Materials: natural or artificial aggregates
• Graded aggregate mixture: Maximum size of 75 mm
• Moistened and compacted aggregate: Layer thickness (100 mm - 150 mm)
• Advantages:
 Construction costs is low because of using only one type of aggregate

 Easily cut and trim
 Fast compaction achieved
 Less human energy usage
• Disadvantages:
 Isolation of aggregates during carried from crushing plant to the construction site
 The fine aggregate will be at the bottom, the surface becomes loose and difficult to
compact




















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Concept Dry Bound Macadam Road Base




• Graded aggregate mixture: coarse aggregate size of 37.5 mm or 50 mm and fine
aggregate size of 5 mm to filler size
• Separated into two layers with 75 mm to 100 mm thickness and compact
• Spread the 25 mm - 50 mm thickness of fine aggregate (sand) to fill the void and
compacted
• Advantage:

 Avoid aggregate isolation occurs during trip
 Low of cost
• Disadvantages:
 When it rainy, fine aggregates will wet and cannot fill the void
























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Concept Wet-Mix Macadam Road Base




• Spreader dry coarse aggregate and compact
• Spreader fine aggregate, vibrated / rolled
• Flush 2.5% of water to the surface that compacted and rolled the coating
• Water acts as a lubricating agent for aggregates and as an adhesive to filler
• Advantage:
 Not applicable isolation, tractable and easily compacted

• Disadvantages:
 For the compacted layer should have time to dry




























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Concept Bituminous Bound Macadam Road Base




• Graded aggregates + bitumen 3-4%
• 38% of aggregate passing 3.18 mm, 65% of is coarse aggregate
• Bitumen has a high viscosity, penetration grade 80/100
• Advantages:
 Good load distribution
 Reducing base course thickness

 The use of bitumen can adding stability
 Have a degree of elasticity that avoid crack
 Plasticity properties, allowing some sediment
 Give protection to the subbase and subgrade if rainy
 Can be used for traffic during construction
• Disadvantages:
 High cost


















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Concept Cement-Treated Road Base




• Aggregate + 3-6% cement
• Advantages:

 Good load distribution, stable and moderate cost
• Disadvantages:

 Need curing time

































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Concept The construction of road base




• Before road base is constructed, sub-grade surface and sub-base must be formed
perfectly and compacted enough.
• The lowest layer and sub-base must be prepared at least distance of 200m from the base
construction.
• The road base in Malaysia is commonly constructed with a material known as crusher
run.

• This material is place and compacted to on the surface of the road.
• The road base must be constructed in two layers of same thickness. Each layer should not
exceed 150mm.



















Road Base/ Base
Subbase
Subgrade

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Concept The construction of road base











































Road Base/ Base
Subbase
Subgrade

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Tests that should be carried out to ensure the quality
Concept
of the sub-base and road base layers



Following are some of the standard tests, used to evaluate the strength properties of the soil.
• C.B.R test
• Plate bearing test
• Triaxial compression test
• LOI, LL and PL
• ACV

• FI
• Soundness
• Grading

The sub-base spec: CBR soaked ≥ 30% (if ≥ 10% retained on 20mm, can be assumed passed),
PI ≤ 12, TFV ≥ 30kN, Sand equivalent ≥ 45

The roadbase spec: PI ≤ 6, ACV ≤ 25, FI ≤ 30, Soundness ≤ 18, CBR ≥ 80%, Sand equivalent ≥ 45









Road Base/ Base
Subbase
Subgrade

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Concept Coating












Tack Coat Wearing Course
Surface Course
Prime Coat
Binder Course


Base Course



Sub Base Course


Subgrade


Figure 4-3: Cross – section of a Flexible Pavement










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Concept Asphalt Concrete Pavement Sequence




TYPE OF
DEFINITION PRIME COAT TOOLS CURING COMMON ISSUE
MATERIAL
1. An application of a low viscosity Slow-setting 1. Power broom 24 hours 1. Not uniformly sprayed
asphalt to a granular base in grades of 2. Air compressor 2. Spray nozzle stuck
preparation for an asphalt asphalt 3. Tray for spraying 3. Area not ready
surface course 1. Cut back test 4. Rain after spraying
2. to protect the underlying layer bitumen 4. or pre weighted 5. Spraying area is
from wet weather by providing (MC 70) board disturbed
a temporary waterproofing 2. Emulsion (SS 6. Material is not
layer 1K) uniformly mixed
3. promoting bond to the Hot
Mixed Asphalt layer






Prime
Road Base/ Base
Coat
Subbase
Subgrade












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Concept Asphalt Concrete Pavement Sequence




DEFINITION TACK TYPE OF TOOLS CURING COMMON ISSUE
COAT MATERIAL

To ensure a bond Rapid-setting 1. Power broom time must be allowed for emulsion 1. Impurities
between the grades of 2. Air compressor to break (turn from brown to 2. Immediate asphalt
succeeding asphalt 3. Tray for spraying black) depend on the weather. In laying after
layers of a emulsions test good paving weather, it will take spraying
pavement. RS 1 K 4. or pre weighted only a few minutes. In marginal 3. Rain after spraying
board ditto weather it may take several 4. Over spray,
minutes. bleeding







Tack
Coat
ACBC 28 / Binder Course
Prime
Road Base/ Base
Coat
Subbase
Subgrade












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MODIFIED Bitumen Emulsion Sprayer



















































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Concept Prime and Tack Coat


















































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Concept


















































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Concept Coating




Two types of coating:

Prime Coat (Salut Perdana)
• liquid bitumen, sprayed onto clean unbound roadbase using pressure distributor at the
rate of 0.5 – 1 liter/m
2
• The temperature must be according to the specifications stipulated.

• MC-70 (50°C -70°C), SS-1K (25°C - 45°C) cured for 24 hours to achieve maximum
penetration
















Tack Coat
ACBC 28 / Binder Course
Prime Coat
Road Base/ Base
Subbase
Subgrade

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Concept Coating




Two types of coating:

Tack Coat (Salut Jelujur)
• shall be sprayed about 50 to 100 yards forward from paver machine for a reasonable
time
2
• bitumen emulsion, sprayed onto bituminous layer, rate 0.25 – 0.55 liter/m
• RS-1K, 25°C - 45°C
• Carried out in dry, warm weather and dry surface, prevent spattering adjacent trees,
furniture etc, not to be discharged into drains, gutter, keep traffic off
• Equipment – power broom, compressed air blower, pressure distributor











Tack Coat
ACBC 28 / Binder Course
Prime Coat
Road Base/ Base
Subbase
Subgrade

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Concept Asphalt Concrete Pavement Sequence




i. Takes up wear and tear due to traffic.
ii. Provides water tight surface against filtration of surface water.
iii. Provides hard surface which can withstand the pressure exerted by tyres of vehicles.











A B C




ACBC 28 / Binder Course
Prime
Road Base/ Base
Coat
Subbase
Subgrade












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Important of Coating Layer



















































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Concept Asphalt Concrete Pavement Sequence




• The wearing course is the top most layers in a pavement. Provides smooth and dense
ridding surface











C B A





Tack ACWC 20 / Wearing Course
Coat
ACBC 28 / Binder Course
Prime
Road Base/ Base
Coat
Subbase
Subgrade












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Concept Different between ACB and ACW





Binder Course Wearing Course

 Second layer before the wearing course  Provides smooth and dense ridding
 Spread the force from the surface surface
 ACB28, BMB20  Takes up wear and tear due traffic
 Provides water tight surface against
filtration of surface water
 Provides hard surface which can

withstand the pressure exerted by tyres of
vehicles
 ACW20, BMW14























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Concept Functions of Binder Course













Binder Course is the second
layer before the wearing
course.





is used to distribute load to
road base.






Provide the flat surface to
construct wearing course.












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Concept Functions of Wearing Course















Wearing course As a top course, it
provides smooth and receives the traffic
dense riding surface. forces directly.













Provide a safe &
comfortable riding As a drainage system.
surface.











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Concept The construction of road surface




• The road surface is constructed with bitumen materials, such as concrete asphalt,
macadam bitumen and so on. The constructed should be free from dust and waterproof.
• To construct the surface layer, the base course must be prepared first.
• Prime coat is poured onto the road base surface to be a binder between the road bases
and the base course. To pour the prime coat, the temperature must be according to the
specifications stipulated.

• Base course is built on one layer only with a paver machine and after this layer is
constructed, it is placed before it is compacted.
• Like always, base course should be cleaned before prime coat is poured.






C B A





ACWC 20 / Wearing Course

ACBC 28 / Binder Course

Road Base/ Base
Subbase
Subgrade

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Concept The construction of road surface




• The compacting must be done immediately. It should be compacted from the side
towards the middle of the road.
• It there is a super elevated bend, then it should be compacted from lower part to higher
part. The type of compactors must be according to the specifications.
• Finally wearing course is prepared.















C B A





ACWC 20 / Wearing Course

ACBC 28 / Binder Course

Road Base/ Base
Subbase
Subgrade

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Concept The construction of road surface


















































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Concept Pavement Works - Surfacing




• Asphaltic Concrete
– Binder course will be laid on the broomed, clean and prime coated road-base.

– Laying & compacting job shall be carried out in dry weather.
– After binder course has been properly compacted, sprayed with tack coat, wearing
course will then be laid & compacted.

– Bituminous mix for surfacing shall pass all test specified for aggregate, bitumen &
bituminous mixture.

– Aggregate: LAAV ≤ 25, soundness ≤ 18%, FI ≤ 25, PSV ≥ 40, Coating ≥ 95% & Grading.







C B A





ACWC 20 / Wearing Course

ACBC 28 / Binder Course

Road Base/ Base
Subbase
Subgrade

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Concept Premix




Premix is the process of surface layer after finishing spraying the prime coat. Usually the
process of paving of the road will use the paving machine. The pavement construction is as
follows:

• Firstly, the trunk will pour the premix (the call to a mixture of aggregate and bituminous oil
in the paver).
• Paver machine will move forward while premix will pass from the machines slowly.

• Elevation will be controlled automatically follow the design
• The temperature must be approximately 150 degrees Celsius.

• Make sure the condition method follow the standard



C B A





ACWC 20 / Wearing Course

ACBC 28 / Binder Course

Road Base/ Base
Subbase
Subgrade

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The preparation and varieties of materials used in flexible
Concept
pavement road surface



Premix - ADT >1000pcu
• Asphaltic concrete - graded aggregate and bitumen

• Bituminous Macadam - continuously graded aggregate, filler (Portland cement,
hydrated lime, fly ash, quarry dust)


Non premix - ADT <1000pcu

• Cold Fine asphalt - lime aggregate, medium to high penetrated cutback bitumen
• Dry sand mix - mixture of sand, clay, gravel < 1”

• Wet sand mix - mixture of sand, binder (SRO @ low viscosity cut back), filler Portland
cement @ hydrated lime)





















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