IRC Code 82: Smart Material Selection for High-Quality Bituminous Road Repairs

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In India’s vast and ever-expanding road network, timely maintenance is not just a requirement—it's a necessity. Bituminous roads, though durable, are prone to wear and tear due to weather conditions, water infiltration, and heavy traffic. This is where IRC Code 82 comes into play, offering a robust framework for maintaining bituminous road surfaces with a focus on smart material selection and efficient repair techniques.

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In this blog, we dive deep into IRC Code 82:2015, titled “Code of Practice for Maintenance of Bituminous Road Surfaces,” and understand how it enables engineers to make the right decisions for long-lasting road repairs.

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What is IRC Code 82?

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First published in 1982 and revised in 2015, IRC Code 82 provides comprehensive guidelines for the maintenance of bituminous road surfaces. The code aims to prevent road deterioration by guiding maintenance activities based on the type, extent, and cause of distress in bituminous pavements. It emphasizes the importance of early detection and prompt repair using suitable materials and technologies.

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The code covers three primary types of maintenance:

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• Routine Maintenance

• Preventive Maintenance

• Periodic Maintenance

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Why Material Selection Matters in Bituminous Road Maintenance

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Choosing the right materials isn't just a technical decision—it directly impacts road durability, user safety, and cost-effectiveness. Improper or mismatched material can lead to recurring failures, increased lifecycle costs, and dangerous driving conditions.

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Smart material selection, as advised by IRC Code 82, ensures:

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• Better bonding and cohesion in repairs

• Improved resistance to moisture, traffic loads, and temperature changes

• Enhanced skid resistance and surface texture

• Longer intervals between maintenance cycles

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Types of Road Maintenance Explained

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1. Routine Maintenance

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Routine maintenance includes regular, small-scale repairs such as pothole patching, crack filling, and surface cleaning. These activities are carried out throughout the year to maintain road usability.

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2. Preventive Maintenance

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This is carried out when the pavement is still in good condition. Its purpose is to extend the pavement’s life and delay the need for major repairs. Common preventive treatments include fog seals, slurry seals, and microsurfacing.

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3. Periodic Maintenance

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Performed at predetermined intervals, periodic maintenance includes resurfacing treatments like bituminous overlays or surface dressing. These are more substantial operations aimed at restoring the structural integrity and surface quality of the road.

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Common Pavement Distresses and Treatment Materials

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IRC Code 82 categorizes pavement distress into four groups:

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Surface Defects

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Includes conditions like bleeding (excess binder), smooth or slippery surfaces, streaking, and hungry surfaces. These are usually caused by improper binder content or poor material application.

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Recommended Materials: Coarse sand, pre-coated chips, open-graded mixes.

Treatment Techniques: Sand blotting, premix carpeting, or microsurfacing.

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Cracks

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Cracking can appear in different forms—hairline, alligator, longitudinal, transverse, edge, and reflection cracks.

Recommended Materials: Bitumen emulsion, rubberized bitumen, fog seals.

Treatment Techniques: Crack sealing, microsurfacing, slurry seals, or overlays depending on severity.

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Deformation

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Includes rutting, shoving, corrugation, slippage, and shallow depressions. These often result from poor compaction, material instability, or sub-base failures.

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Recommended Materials: Dense or open-graded premix, RAP (Reclaimed Asphalt Pavement), and polymer-modified bitumen.

Treatment Techniques: Milling and filling, resurfacing, and strengthening with better compaction.

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Disintegration

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Stripping, ravelling, potholes, and edge failures fall into this category. These are serious issues that lead to road failure if not addressed promptly.

Recommended Materials: Emulsions, rejuvenators, anti-stripping agents, fresh bituminous mix.

Treatment Techniques: Surface recycling, patching, fog seals, and complete resurfacing where needed.

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Tools and Technologies Recommended in IRC Code 82

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To support high-quality and efficient repairs, the code recommends the use of modern, mechanized tools such as:

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• Mobile pothole repair units

• Crack sealing machines

• Emulsion sprayers

• Infrared heaters

• Mechanized patchers

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These tools ensure consistency, reduce human error, and increase productivity, especially over large maintenance zones.

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Traffic Safety and Work Zone Management

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During any road maintenance activity, managing traffic flow and ensuring public safety is crucial. IRC Code 82 recommends:

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• Proper road signs, barricades, and reflective markers

• Safety gear for workers

• Clear visibility during night works

• Traffic diversion where necessary

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Ensuring these measures helps reduce accidents and provides a safe working environment.

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Best Practices for Maintenance Planning

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IRC Code 82 emphasizes a systematic approach to road maintenance. This includes:

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• Conducting pavement condition surveys before and after monsoon seasons.

• Assessing both visual and structural conditions using automated or manual methods.

• Prioritizing repairs based on severity levels and traffic volumes.

• Organizing resources—materials, equipment, and skilled personnel—for maximum efficiency.

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The code also recommends adopting Pavement Maintenance Management Systems (PMMS) to automate decision-making and optimize maintenance cycles.

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Conclusion

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IRC Code 82 is more than a maintenance manual—it's a roadmap for building longer-lasting, safer, and more cost-efficient bituminous roads. The key takeaway is clear: smart material selection based on the type of distress ensures better repair quality, less frequent maintenance, and improved road user experience. For engineers, contractors, and infrastructure planners, adhering to this code is essential to achieving durable and high-performance roads.

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RoadVision AI is revolutionizing the way we build and maintain infrastructure by leveraging the power of AI in roads to enhance road safety and optimize road management. By utilizing cutting-edge roads AI technology, the platform enables the early detection of potholes, cracks, and other road surface issues, ensuring timely maintenance and improved road conditions. With a mission to create smarter, safer, and more sustainable roads, RoadVision AI ensures full compliance with IRC Codes, empowering engineers and stakeholders to make data-driven decisions that reduce costs, minimize risks, and improve the overall transportation experience.