Subgrade is the foundation layer supporting all highway pavement layers. MoRTH Clauses 301–303: preparation, compaction ≥97% MDD, drainage, QC: density, moisture, CBR, thickness 150–250mm, stabilization with lime/cement/flyash, ensuring long-term performance.

Granular Sub-base (GSB) – 10 FAQs

GSB distributes load, provides drainage, supports WMM/bituminous layers. MoRTH Clause 400: well-graded aggregates, compaction ≥98% MDD, thickness ≥150mm, QC: density, CBR, LL, PI, AIV, surface tolerance ±15–20mm, optional recycled aggregates with approval.

CTGSB is cement-treated GSB for strength. MoRTH Clause 504: cement 3–6%, OPC 43/53, layer thickness 150–250mm, compaction with rollers, curing ≥7 days, QC: dry density, UCS, CBR, proper cement dispersion, foundation for DBM/BC.

WMM is water-bound granular base per MoRTH Clause 405. Layer thickness 150–250mm per lift, compaction ≥98% MDD, QC: dry density, moisture, gradation, CBR. Provides uniform load distribution, base for DBM, surface tolerance ±15–20mm.

DBM Profile Corrective Course – 10 FAQs

DBM corrects pavement irregularities. MoRTH Clause 505: thickness 25–50mm, mix: aggregates, bitumen, mineral filler, compacted with rollers. QC: Marshall stability, flow, density, thickness, smoothness. Provides load distribution and base for BC.

BC with Plastic Waste – 10 FAQs

BC with plastic waste improves durability & skid resistance. MoRTH Clause 507: plastics 5–10% of bitumen, hot mix plant, compacted with rollers. QC: Marshall, density, bitumen content. Environmental benefit: reduces landfill, suitable for all traffic.

Prime Coat & Tack Coat – 10 FAQs

Prime coat: prepares GSB/WMM for overlay. Tack coat: bonds old/new layers. MoRTH Clauses 508 & 509: VG-30 bitumen/emulsion, prime 0.7–1.2 l/m², tack 0.3–0.5 l/m², surface clean/dry, QC: uniform coverage, allow curing, ensures adhesion.

Table of Contents

Highway Construction Methodology – Step-by-Step Process (MoRTH 5th Revision)

By: Kishor Kumar | Category: Highway Methodology | Updated: November 2025

Introduction

The construction of a highway pavement involves several layers placed one over another to achieve desired strength, durability, and serviceability. As per MoRTH 5th Revision, each layer has specific material, compaction, and testing requirements to ensure quality and long-term performance.

This section covers the complete step-by-step methodology for all pavement layers — starting from Subgrade to Bituminous Concrete (BC).

Layer-wise Construction Methodology

Click on each layer to read its full methodology and testing process 👇

🟤 Earthwork Methodology – Summary

Earthwork is the foundation of highway construction and includes excavation, embankment formation, filling, and compaction of soil to the required lines, levels, and cross-sections. The methodology focuses on proper soil selection, moisture control, layer-wise compaction, and field density testing in accordance with MoRTH specifications. Accurate execution of earthwork ensures long-term stability of pavement layers and prevents settlement, deformation, and premature failures.

🟡 Granular Work Methodology (GSB / WMM) – Summary

Granular works such as Granular Sub-Base (GSB) and Wet Mix Macadam (WMM) form the primary load-distributing layers of flexible pavement. The methodology includes material grading, spreading, moisture conditioning, compaction, and surface tolerance checks as per MoRTH requirements. Proper control of gradation, thickness, and compaction is essential to achieve required strength, drainage characteristics, and durability of the pavement structure.

⚫ Bituminous Work Methodology (DBM / BC) – Summary

Bituminous works involve construction of Dense Bituminous Macadam (DBM) and Bituminous Concrete (BC) layers, which provide pavement strength, waterproofing, and riding comfort. The methodology covers mix design approval, plant mixing, temperature control, laying, compaction, and joint treatment in compliance with MoRTH specifications. Strict quality control of bitumen content, temperature, and compaction is critical for long-term pavement performance.

⚪ Concrete Work Methodology – Summary

Concrete works in highway projects include rigid pavement, drainage structures, and other ancillary concrete components. The methodology emphasizes mix design, batching, placement, vibration, curing, and strength testing in accordance with MoRTH and IS standards. Proper workmanship, curing practices, and testing ensure durability, load-carrying capacity, and effective crack control in concrete highway works.

🏗️ Highway Construction Methodology Hub

Standard construction methodologies for highway works as per MoRTH 5th Revision and IRC Specifications.

Objective of Adopting Standard Methodology

The purpose of adopting the prescribed standard methodology is to ensure systematic execution of works in accordance with the Ministry of Road Transport & Highways (MoRTH) Specifications. Compliance with the approved methodology ensures the required quality, strength, and performance of pavement layers.

The standard methodology aims to:

Achieve uniform compaction and consistent structural strength throughout the pavement layers.
Ensure durability and satisfactory in-service performance of the pavement.
Minimize the risk of settlement, deformation, and premature distress.
Enable effective quality control and quality assurance in conformity with MoRTH requirements.

Reference Documents

The construction and quality control activities shall be carried out in accordance with the latest applicable provisions of the following documents, unless otherwise specified in the Contract Agreement:

Ministry of Road Transport & Highways (MoRTH), Specifications for Road and Bridge Works, 5th Revision, 2013.
IRC:37 – Guidelines for the Design of Flexible Pavements.
IS 2720 (Part 8 and Part 28) – Methods of Test for Soils: Determination of Water Content–Dry Density Relation and Field Density Tests.

Highway Pavement Methodologies – FAQs & Step-by-Step Guides

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