Table of Contents. Chapter 1 : Introduction 1. Chapter 2 : Structure and design 15

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1 Table of Contents Chapter 1 : Introduction Overview of Japan Topography Climate Population Economy History and current status of roads in Japan Road developments in Japan Road classification and administration Traffic volume Expenditures for road works Road pavement History of road pavement General issue 13 References 14 Chapter 2 : Structure and design Structural design Overview Structure of pavement Overview Subgrade Base course Binder course Surface course Design methods Overview Structural design conditions Frost blanket Design of pavement thickness Selecting a pavement structure Examples of structural design Design of drainage facilities Overview Surface drainage Subsurface drainage 32

2 Slope drainage Drainage during construction Structural design of asphalt pavement for light traffic Overview The structure of pavement Overview Subgrade Base course Surface course Design method Overview Design CBR Frost penetration depth Design of each pavement thickness Thickness of each pavement course Drainage 37 Chapter 3 : Materials Overview Bituminous materials Overview Pavement petroleum asphalt Petroleum asphalt emulsion Cut-back asphalt Modified asphalt Aggregates Overview Crushed stone Crushed gravel Gravel Sand Fillers Steel slag Special aggregates Recycled aggregates Stabilization additives Overview Cement Lime Bituminous materials 56

3 3-5 Resin-based binding materials Petroleum-resin-based binding materials Epoxy resin Acrylic resin Urethane resin Base course materials Overview Granular base course materials Stabilized base course materials Other materials Antistripping agents Reinforced fiber materials Medium temperature admixtures Other additives Waterproofing materials Other base course materials 62 Chapter 4 : Construction equipment Overview Construction equipment Overview Mixed-in-place equipment Excavating and loading equipment and forming equipment Spraying equipment Spreading equipment Compacting equipment Construction equipment for asphalt pavement Overview Spraying equipment Spreading equipment Compacting equipment 67 Chapter 5 : Construction Overview Construction plan Drafting a construction plan Plan items Ensuring safety and environmental preservation Considerations for the construction base Construction of subgrade 75

4 5-3-1 Overview General subgrades Soft Subgrade Overview Embankment with good quality soil Soil replacement method Stabilization method Sandwich method Filter course Anti-frost layer Construction of sub-base course Overview Materials Characteristics of each construction method Construction with granular materials Construction of cement and lime stabilized base courses Mix design Construction Construction of base course Overview Materials Characteristics of each construction method Construction of mechanical stabilization Mixing and spreading Compaction Construction of hot mix bituminous stabilized base course Materials Mix design Construction Construction of cold mix bituminous stabilized base course Materials Mix design Construction Construction of cement and lime stabilized base course Materials Mix design Construction Penetration method Materials Design example 99

5 Construction Macadam method Materials and quantity to be used Construction Crusher-run method Material Construction Construction of cement-bituminous stabilized base course Mix design Construction Prime coat Purpose of prime coat Used material and standard amount Key points of consideration during construction Construction of surface and binder courses Overview Bituminous mixtures by the hot mixing method Overview Types of asphalt mixtures Mix design Mixing and transportation Paving Bituminous mixture by the cold mixing method Overview Materials Mix design Mixing Paving Penetration macadam method Overview Selection of material Standard proportions of materials (Example of design) Construction Surface dressing Overview Selection of materials Standard proportions of material (Example of design) Construction 133

6 Chapter 6 : Construction management and inspection Overview Concepts of management Overview How to perform management Trial batch test Purposes of trial batch test Trial batch test on materials Checking pavement equipment, etc Trial construction Checking the results of a trial batch test Establishing work standards Control of finished work quality Overview Control items of finished work quality Quality control Overview Means of quality control Quality control in very small-scale construction Considerations for quality control in each type of construction Safety management and environmental measures Overview Safety management Environmental measures Inspection Overview How to inspect finished work quality and construction quality Implementation items and methods of inspection on finished work quality Implementation items and methods of quality inspection Using control data 157 Chapter 7 : Pavement for specific locations Overview Pavement for pedestrian walkways Overview Selection of pavement Pavement structure for general portions Subgrade Base course Surface layer 161

7 7-2-4 Pavement structure Asphalt mixture pavement Concrete plate pavement Interlocking block pavement Decorative materials such as tiles Resin spray pavement Sidewalk pavement of bridges and footbridge Pavement for sidewalk on bridge Pavement of footbridge Others Bridge deck pavement Overview Pavement structure Drainage Surface treatment of bridge deck Adhesive layer Waterproof layer Tack coat Joint Pavement in tunnel Overview Selection of pavement Pavement structure Pavement on rock bed Overview Pavement structure 170 Chapter 8 : Pavement with special functions and structure Overview Semi-flexible pavement Overview Materials and proportions Construction Guss asphalt Overview Materials Proportions Construction Porous asphalt pavement Overview 178

8 8-4-2 Pavement structure Materials Proportions Construction 181 APPENDIX : Pavement recycling methods Overview Plant Recycling method Overview Materials used in plant recycling Overview Reclaimed asphalt pavement (RAP) Cement concrete recycled aggregate Recycled base course aggregate New asphalt Rejuvenator Stabilizer Recycled pavement materials Overview Recycled base course materials Recycled hot mix asphalt Recycled asphalt Quality based application Mixing design of recycled pavement material Overview Mixing design for recycled base materials Mixing design for recycled hot mix asphalt Production of recycled aggregate and recycled pavement materials Construction In-place base course recycling methods Overview Types of methods Making use of the pre-existing pavement Methods involving preparatory stabilization Methods involving stabilization of the existing base course alone Preparatory investigation Areas of application Structure design Raw materials Overview 216

9 3-6-2 Stabilizers In-place recycled base course aggregate Mixing design Overview Preparation of test samples for mixing design Mixing design for recycled treated asphalt Mixing design for in-place recycled cement-bituminous stabilization Construction equipment Overview In place pavement milling machine Construction Overview The construction process without preliminary preparation The procedures with preliminary preparation Construction Management Overview Standard tests Product management Quality management 231