COURT PREPARATION - NEW BASE

  1. Whenever the original sub-soil is of weak nature, the original soil should be watered and rolled with 10-ton roller. Before rolling call the shrubs, and vegetable growth should be removed. Anti weeding chemicals should be spread over the entire area. Over this the stabilized layer of 3" compacted thickness of soil stabilized materials by mixing 1/3 soil, 1/3 murum with lime (lime should be 20Kg per 1000 ft.) 1/3 stone dust, should be provided. The entire area should be watered and compacted to uniform level.

  2. The hard core layer of 4 ½ “compacted thickness, of hand broken stone should be provided. This surface consists of hand broken metal, plus metal No.3 (1/2") plus metal No.1 in small quantities to fill in all the small voids. Over this add stone dust and roll the entire area with roller, after rolling spread murum and dry roll the complete area. After the dry rolling, water should be spread and again rolled, filling the visible cavities with metal No.1, stone dust & murum.

  3. Over this hard-core layer two layers of water bound macadam, of 4 ½ “ thick rolled down to 3" thick should be provided. The second anti weeding treatment should be provided over the final layer of W.B.M, before laying the asphalt.

  4. The existing ground should be cleaned and all the cow-dung/sand should be removed. If the existing surface has no slope (I" per 10’ feet, from east to west) then the existing surface should be excavated, and whenever filling is required the slop should be maintained by filling murum khadi, and stone. It should be then watered and compacted to uniform level, with desired slope. Anti weeding treatment should be given to this base and also to the final base before Asphalt.

  5. Two layers of water bound macadam, of 4 ½ ' -thick rolled down to 3" thick should be provided. The aggregate of specified sizes as given below, should be first mixed, with appropriate binding material, at separate mixing area, and after the whole thing is mixed properly, then should be sprayed on the court. The specified aggregates should be stacked size wise, layer by layer, one on top of the other, with binding material sand witched between the layers. This will ensure mixing up of graded metal and mixing up with the binder. This whole thing, when cut, mixed and laid on court will produce a dense, uniform surface, which should then be rolled dry and then with sufficient water, till the slurry rolls in front of the roller wheels.

  6. The second compaction is to be done after a gap of 10 to 12 hours, while the binder is still in the semi plastic state, after which it is allowed to cure.

  7. The second compaction is to be done after a gap of 10 to 12 hours, while the binder is still in the semi plastic state, after which it is allowed to cure.

    WBM - Layer No.1
    Aggregates: 2½’ thick - 70% 1 ½’ thick - 20% ¾ ‘thick - 20%
    Adequate quantity of binding material of murum and stone dust should be laid over each aggrega
    WBM - Layer No.2
    Aggregates: 1 ½’ thick - 70% ¾ ‘thick - 20 % ½ ‘thick - 20% 6 mm – 10%
    Adequate quantity of binding material of murum and stone dust should be laid over each aggregate layer.

  8. Fully compacted and laid at correct slope is allowed to set and cure. First layer for 3 to 4 days and second layer from 6 to 8 days. It is essential to get rid of the excess binder material from the surface by wire brushing and fanning, so as to expose up to 90% of the ‘face' of the aggregate on which tack coat is to be applied before hot mix is laid.

  9. Recommended gradation for hot mix. First layer of 2 ½ " thick (65mm) bituman macadam using graded metal as given below should be laid and compacted with power roller.

  10. Recommended gradation for hot mix. First layer of 2 ½ " thick (65mm) bituman macadam using graded metal as given below should be laid and compacted with power roller.

    First layer of 2 ½ " thick (65mm) bituman macadam using graded metal as given below should be laid and compacted with power roller.
    Gradation: ¾ “ thick aggregates = 20% ½ “thick aggregates = 50% ¼ “thick aggregates = 20% 1/8” thick aggregates = 10%
    Stone dust around 10% should be mixed.
    Second layer of 1" thick (25mm) Bituman Concrete using graded metal should be laid and compacted with power roller .
    Gradation: ½ “thick aggregates = 20% ¼ “thick aggregates = 50% 1/8” thick aggregates = 20% Stone dust = 10%
    Lime by 10% by WT as an individual should be added.

  11. Bituman grade 80/100 by WT 6% should be used. All materials should be of best quality and correct size. Use sieve for elimination over size mental especially for second layer. Seal coat of 6 mm premix material should be provided over the asphalt concrete, so as to protect the asphalt concrete surface from damage while in use during monsoon, and before the final deco turf is laid after the monsoon.