BRIEFANDDETAILEDSPECIFICATIONSOFPAVEMENTQUALITY

CONCRETE(PQC)

PURPOSE:

ThepurposeofthisQualityPlanforConstructionofPavement
QualityConcrete(PQC)istoprovidedetailedConstruction
Methodology,Materialsused,Resourcesdeployed.

SCOPE:

TheScopeofthisSegmentalQualityPlan/Methodologyshallcovers
theconstructionofpavementqualityconcreteinsertionofdowel
bars,tiebarsinaccordancewiththerequirementofTechnical
Specificationsandinconformitywiththeline,gradesandcross
sectionsshownindrawings.

Itcoversthefollowingactivities:

Selection,TestingandAcceptanceofallincorporatedMaterialsfor

PQC.
DesignofMixesforPQCandTrials,Acceptanceetc.

DetailsofPlant,Equipment/Machineryasrequiredinexecutionof

PQC.
Batching,Mixing,Transporting,Placing,FinishingandCuringof

ConcreteforPQC.
MechanizedTexturingandCuringoperationforPQC.

JointCuttingandapplicationofJointSealingcompoundasapproved.

QualityAssuranceandControlChecksduringoperationandpost

concreting

DEFINITIONS:

Thewordslikecontract,Contractors,Engineer(Synonymousto
Engineer'srepresentative),Drawing,Employer,Government,Works,
WorksiteusedinthisQualityPlanshallbeconsideredtohavethe
meaningasunderstoodfromthedefinitionspertainingQuality
ManagementSystemDevelopedfortheParticularProject.

Thefollowingabbreviationshallhavethemeaningassetforthbelow:

MORT&H:MinistryofRoadsTransport&Highways

NHAI:NationalHighwaysAuthorityofIndia

BIS:BureauofIndianstandards

QA:QualityAssurance

PQC:PavementQualityConcrete

MTC:Manufacture'sTestCertificate

ITP:InspectionTestPlan

CROSSREFERENCE:

ThisSegmentQualityPlanshouldbereadinconjunctionwiththe
followingdocuments:
ISO90012000Qualitymanagementsystem

ContractorDocument/TechnicalSpecifications

MoRTH/IS/ASTM/ACICodes,whereapplicable

IRC:SP:572000,GuidelineonQualitysystemforroads.

RESPONSIBILITY:

ActivityDescription
S.

NO

01

02

03

PreparationQualityPlan

Performing

Checking/

Approving

Verifying

Sectionin Works
charge&
Manager&
QC
QC
Engineer
Manager
SelectionandTestingof
Sectionin
Works
variousmaterialsforPQC, charge&
Manager&
MixDesign&Trialsetc
QC
QC
priortostartofactivity
Engineer
Manager
Survey,settingoutfixing
Surveyor
Sectionin
ofstringlinespriortostart
charge/
ofPQC
Site

Project
manager

Project
manger
Engineer

04

PQCPaverdeploymentat
variouslocationsand
otherlogistics
managementetc.
Batching&Mixingof
concreteasperapproved
Designmix

Sectionin
charge/
Site
Engineer
Batching
Plantin
charge

06

Controlofmovementof
Paverandmaintenance
0checks/controlduring
operation

Paver
engineer
/
Supervisor

07

Transportation, Sectionin
Placing,Compactionand
charge/
finishingofPQClayers,
Site
Engineer
Texturing,curingJoint
Sectionin
CuttingandSealing
charge/
operationsforPQC
Site
Engineer
Inspection&Testingof
QC
PQCasperapprovedITP Engineer/
andmaintainingall
Lab
formats.
Technician

05

08

09

Engineer
Works
Manager
QC
Engineer/
Lab
technician
Paverin
charge

QC
Engineer/
Lab
technician
QC
Engineer
/Lab
technician
QC
Manager/
QC
Engineer

Project
Manager

Project
Mechanical
Engineer
foreffective
controlof
Paving
operation
Engineer

Engineer

Engineer

PROCEDURE:

ThedetailedConstructionMethodologyinvolvedinexecutionofPQC
includingQualityAssurance&Controletc.hasbeendescribedinthe
followingsubchapters.


SurveyandSettingoutforPQC:
ThefollowingstepsareinvolvedinSettingoutofstringwirebeforelying
PQC:

CenterlineofCarriagewaywillbemarkedatevery50Mintervalson
DLCsurfacebyusingTotalstation.

Approvalofsurveyandsettingwillbeensuredandsurveychecksheet
CGGC341701isfilledpriortocommencementofthelayingactivity.

MaterialRequired:

Cement:

Anyofthefollowingtypesofcementmaybeusedwithpriorapproval
oftheEngineer:

(i)OrdinaryPortlandCementIS:269
(ii)PortlandSlagCementIS:455
(iii)PortlandPozzolanaCementIS:1489

Cementtobeusedmaypreferablybeobtainedinbulkform.Itshallbe
storedinaccordancewithstipulationscontainedinClause1014andshall

besubjectedtoacceptancetestpriortoitsimmediateuse.
.

CoarseAggregate:

AggregatestobeusedintheconstructionofPQCwillbeCrushed
aggregates.

TheaggregatecomplyingIS:383willbeused.

MaxSizeofcoarseaggregate25mmasperMoRTH601.2.3.2
(FourthRevision:August2001).

FineAggregate:

Clean,naturalsandfromRiverBanasformlocationTriveni20km
formLadpurawillbeused.ThematerialconformingIS:383is
ensured.

Thefineaggregateshallconsistofclean,naturalsandorcrushed
stonesandoracombinationofthetwoandshallconformtoIS:383.
Fineaggregateshallbefreefromsoftparticles,clay,shale,loam,
cementedparticles,mica,organicandotherforeignmatter.Thefine
aggregateshallcomplywithMoRTH602.2.4.3.(FourthRevision:

August2001).

(ThegradinglimitsforallinaggregatesshallbeperIS:383for20mm
nominalsizeAggregateforPavementQualityConcrete)

SieveDesignation

40mm
20mm
4.75mm
600micron
150micron

PercentagepassingtheSieve
byWeight

100
95100
3050
1035
06

Water:

WaterusedformixingandcuringconcreteconformingtoIS:

456:2000.
IncaseofPQCDuringhotweather,waterforpreparationof
concretewillbetakenformwaterchillingplant.

Admixtures:

AdmixtureconformingtoIS:6925andIS:9103toimprove
workabilityofconcreteorextensionofsettingtimetobedone.

Storageofmaterials:

Aggregates:

Aggregatewillbestockpiledseparatelyandsufficientdistancewill
bemaintainedfromeachfractiontoavoidintermingling.

Storagespacemustbeeasytoinspection,removalandrestorage
ofmaterials.

Regulartestingofaggregatestockpilewillbeexercisedtoensure
requiredgradationcontrol.

Cement
Bulkcementwillbestoredinbulkstoragecontainershaving
200MTcapacityandthenumberofsuchbulkerswillbesufficient
tocatertotherequirementatsite.

Water

Waterwillbetankscoveredattopandcleanedatregular
intervals.Theintakeofpipewillbeenclosedtoexcludesiltand

othersolidmaterialsandthereshallbeaminimumdepthof0.60
mofwaterbelowtheintakeatalltimes.

Proportioningofconcrete

ConcreteStrength

ThepavementconcreteshouldbeaclassM40concretewitha
minimum28dayscompressivecharacteristicstrengthof40MPa

1.Characteristicflexuralstrengthat28days=4.5MPa
2.Targetmeanstrengthat28days=5.80MPa
3.Watercementratio=0.45Maximum
4.SlumpasperIS:1199=31+/15mm
Minimumflexuralcharacteristicstrengthof4.5MPa.

Therationbetweenthe7&28daysstrengthsof4.5Mpa.

Foreachbatch

7days(avg.)
Theaverageflexuralstrengths(R7)=

28days(avg.)

R7tobedeterminedforthreedecimallevels.

(FlexuralstrengthofanySixconsecutive7daytestresult)>4.50+1.65*s
S:Standarddeviationofthegroup.

Workability:

Thecontrolofworkabilitywillbedonebytheslumptest

Slumpwillbecontrolledsothatmixiscompactedandfinished

withoutundueflow.
Theexactslumprequiredatplantandsitewillbeexercisedduring

trailpatch.

SeparationMembrane:

Twoapplicationsofapprovedwaxbasedwhitepigmented

curingcompoundwillbeappliedonDLC.
FirstcoatwillbeappliedimmediatelyafterDLClayingand

compactionandtheotherbeforestartofPQC.
Theprocessofapplicationwillbedoneusingmechanicalsprayer.

Theotherparameterswillbemeetingtheadditionalspecification

ClauseA12.
Preparationofbase:

Anyvisibledefects/cracksmorethan10mmsizetoberequired

byfinecementconcretemix.
Surfacewillbemadecleanofdirtorextraneousmaterialandfree

fromdamagebeforeapplicationcompound.


Joints:

Theexactlocationandtypeofjointtobetransferredatsiteas

mentionedindrawing.
ConcretePenetrometerandtestingasperASTMC403willbe

usedinmonitoringsettingofconcrete/Maturityofconcreteand
sawcuttingperiod.
Initialsawcutof3mmwide,100mmdepthintransverseand

longitudinaldirectionwillbeprovidedafterinitial
set(approximately6~8hrs).
Finalsawcutting10~12mmwide,20~25mmdepthwillde

providedafter14daysofcuringataccommodatejointsealant.
Thestaggeringoftransversejointswithreferencetothebasewill

beminimum0.3m.

Transversejoints:

Contractionjointswillbeprovidedatevery4.5mintervalexcept

whereexpansionjointsareprovided.
Transversejointstobeprovidedatthejunctionoftheapproach

slabsofbridgedandtherigidpavementandspeciallocatione.g.
transitionsectionsi.e.transitionofflexiblevs.rigidpavement.
Transversejointswillbestraightwithinspecifiedtolerances.

Expansionjointswillbeprovidedatthejunctionoftheapproach

slabsofBridgesandtherigidpavement.

ContractionJoint:

ContractionjointswillbeasperthedrawinggivenbyNHAI

ExpansionJoints:

JointfillerboardforExpansionjointwillbepremouldedjoint
fillerasperMoRTHspec.602.2.7
PremouldedjointfillerconformingAsperIS:1838orBS:2630

Thicknessofthejoint=2025mm

Tolerancelimitwillbewithin+/1.5mm

Itshallbe25mmlessindepththanthethicknessoftheslab

Thefillerforeachjointshallbefurnishedinasinglepieceforthe

fulldepthandwidthrequiredforthejoint.
Holestoaccommodatedowelbarswillbeasaccuratelyboardor

punchedtogiveaslidingtillonthedowelbars.
Dowelbarsforexpansionjointwillasper

Jointswillbeprovidedatthejunctionsofrigidandflexible

pavementwithtransitionslabasperthedrawings.
Whereduetounavoidableconditions(forexample:jointsattwo

contractpackage)jointaretobeprovided,dowelbarsarefixed
intotherigidpavement.

Theadjacentslabsshallbecompletelyseparatedfromeachother

byfillingjointfillerboard.

Transverseconstructionjoint

Transverseconstructionjointshallbeplacedwhenconcretingis

doneafteraday'swork.
Itwillbeprovidedattheregularlocationofcontractionjointsusing

dowelbars.
Thejointwillbemadebutttype.

Longitudinaljoints

Tiebarsshallbeprovidedatthelongitudinaljointsasperthe
drawinggivenbyNHAI.

Dowelbars

TheseshallconfirmtotherequirementsofIS:432,IS:1139and

IS:1786asrelevant.ThedowelbarsshallconfirmtoGradeS240
andtiebarstoGradeS415ofI.S.
Itshouldbemildsteelround,freefromdirt,looserust,scale

straightandburringrestrictingslippageintheconcrete.
Thedowelbarswillbesupportedoncradles/dowelchairsin

prefabricatedjoint.
Dowelbarswillbepositionedatthemiddepthoftheslabwithina

toleranceof+20mm.

Dowelbarsshallbecoveredbyathinplasticsheathforatleast

2/3oflengthfromoneendfordowelbarsinContractionjointor
halfthelengthplus50mmforexpansionjoints.
Thesheathshallsetough,durableandofanaveragethickness

notless1.25mm
Thedowelbarswillbeinsertedbyvibrationmethodintheplastic

concrete.
ForExpansionjoints,acloselyfittingcap100mmlongcotton

wasteplacedoversheathenedendofeachdowelbar.

Tiebars

Freeformoil,dirt,looserustandscale.

Inlongitudinaljointsshallbedeformedsteelbarsofstrength415

MPacomplyingwithIS:1786.
Itshouldprotectfromcorrosionfor75mmoneachsideofthejoint

byapplyingbituminouspaint.
ThecoatingshallbedrywhentheTieBarsareused.

Itshouldbeperpendiculartothelineofthejoint,withthecenterof

eachbarontheintendedlineofthejointwithinatolerance
of+50mmandwithaminimumcoverof30mmbelowjoint
groove.

WeatherandSeasonalLimitations:

Concretingduringmonsoonmonths:

Sufficientsupplyoftarpaulinorotherwaterproofclothwillbe

providedalongthelineofwork.
Anyconcretedamagedbyrainwillberemovedandreplaced.

Ifthedamageislimitedtotextureitwillberetextured.

ConcretinginHotWeather:

Carewillbetakeninreducingtemperatureofconcretesuchas
useof
Chilledwater,sprinklingofchilledwateroveraggregates.

Guidewires

Useofguidewires

Eachguidewireshallbeataconstantheightaboveandparallelto

therequirededgesoftheslabasdescribedinthecontract/
drawingwithinaverticaltoleranceof+3mm.
Theguidewiresshallbesupportedandstakespreferablynotmore

then8mapartbyconnectorscapableoffinehorizontaland
verticaladjustment.
Thestackshallbepositionedandtheconnectorsmaintainedat

theircorrectheightandalignmentbeforecommencementofwork.
Theguidewireshallbeerectedandtensionedforatleast2hours

beforeconcretingthatsection.

Carewillbetakentoavoidanydisturbancetotheguidewire

duringpavingbyanyconstructionequipmentoranyothermeans.

CONSTRUCTION:

10.1Concreteproduction,transportation,Paving,Texturing
andCuring:

Abatchingplantof120cumperHr.capacityhastousefor

ProductionofConcrete
Dumpershavinghydraulicjacksystemtounloadhavingcapacity

35Mt(Approx.9cum)concretewillbedeployfortransportationof
concrete.
Pavingwillbecarriedoutinfullcarriagewaywidthof8.5mlength.

ThePaverusedwillbeslipfromPaver.

Theslipfrompavingmachineshallcompacttheconcreteby

internalvibrationandshapeitbetweenthesideformswitha
conformingplateandoscillatingfinishingbeams.
Thefinalfinishofthesurfacewillbedonebysupersmoother

attachedtotherearportionofthePaver.
MansonTrolleywillbeplacedinbetweenPaverandTexturing

andCuringMechine(TCM)forrectificationofanysurfacedefects.
ThealignmentofthePavershallbecontrolledautomaticallyfrom

theguidewireby4setoflevelsensorsand2setofsteering

sensorsattachedtothePaver.
Planningandpreparationwillbedonetopaveatleastatan

averageuniformspeedofonem/min.
ThesurfaceofconcreteslabwillTinetexturedinadirection

paralleltothelongitudinalaxisofthecarriageway.
Texturing/Tiningwillbedonewithaspecifiedmachinespecially

designedforthepurposeforprovidinggroovesatauniform
spacingof18mmto21mm.
Depth=3mmto4mm
Width=3mm

CuringofPQCusingcuringcompoundwillbefollowedby

texturingbythesameTCM.
Curingwillbetakencareattheedgesalso.

Thecuringcompoundwillberesinbasedaluminizedreflective

curingcompound.
AfterprovidinginitialcutentirePQCwillbecoveredwithHessian

clothandwaterturnedfor14days.

Traillength:

TheTriallengthwillbeconstructedatleastonemonthadvance

beforestartingofconcretepavingwork.
Triallengthof60mmwithsamewidth,Depthetcasper

permanentworkwillbedoneatnearertosite.
Transversejointsandlongitudinaljointofeachtypethataretobe

includedinthepavementworkwillbeconstructedandassessed

intheTriallength.

Density:

Atleast3coresdrilledwhentheconcreteisnotlessthan7days
old.

11.2Strength:

Minimumofthirty(30)beamsforflexuralstrengthandthirtycubes

forcompressivestrengthwillbepreparedformtheconcrete
deliveredtothepavingplant.
Eachpairofbeamsandcubeswillberepresentingadifferent

batceofconcrete.
Compressiveandflexuralstrengthwillbeafter28dayscuring.

Attheageof28daysthirtycoreswithdiameter150mmshouldbe

sawcutfromtheslab.
Thecoreswillbesawcutinbothendstoprovideaspecimen

heightof300mm+/15mm.
Themixwillbedesignedtoachieve
Theaverageflexuralstrength>4.5
+1.65*s(Mpa)
[s=standard
deviation]

Strengthofanysample>fck1.65s
Theaveragecompressivestrengthofthe
cores0.8/(Averagecompressivestrength

ofthethirtycubes.)
TemperatureMeasurement:

Thetemperaturedevelopmentintheconcreteslabshouldbe

recordedafterevery3hoursduringhardeningafterinstallmentof
thethermometer&temperatureagerelationshipshouldbe
determined.
Itshouldbemeasuredinthemiddleoftheslab(vertically)ata

horizontaldistanceofatleast1000mmfromanyfreeend.
Thetemperatureshouldnotexceed70degreeC.

InspectionDowelBars:

Alignmentofdowelbarsandconstructionjointshallbechecked

bymeasurementrelativetoguidewires.
Thepositionofdowelbars,fillerboardwillbemeasuredafter

carefullyexposingplasticconcreteacrossthewholewidthof
concrete.

Preparationofjointandsealingofjointgrooves:

TransverseJointshallnotbesealedbefore14daysafter

construction
Jointgrooveswillbeconstructedtoanadditionaldepth/widthas

mentionedindrawing.
Thegrooveshallbecleanedanddriedatthetimeofprimingand

sealing

Allgroovesshallbecleanedofanydirtorloosematerialbyair

blastingwithfiltered,oilfreecompressedair.
Beforesealingthetemporarysealprovideforblockingtheingress

ofdirt,soiletc.,shallberemoved.
Aheightcompressibleheatresistantpaperbackeddebonding

stripasperdrawingshallbeinsertedinthegroove.
Inthecaseoflongitudinaljoints,heatresistanttapesmaybe

insertedtoblocktheleakagethoughbottomofthejoint.

Sealingwithsealants:

Theprimerrecommendedbythemanufacturershouldbeapplied

forsealants.
Primingandsealingwithappliedsealantsshouldnotbecarried

outwhentemperatureinthejointgroovetobesealedisbelow7
degC.
IfhotappliedelastomerictypesealantcomplyingAASHTOM282

isuseditshallbeheatedandappliedfromathermostatically
controlled,indirectlyheatedpreferablywithoiljacketedmelterand
pourerhavingrecirculationpumpandextruder(Thisisappliedat
junctionofAsphaltandconcretepavements.
Coldappliedpolyeurethrene/PolysulphidetypecomplyingBS:

52121990Sealanwillbemixedandappliedaccordingtothetime
limitspecifiedtheManufacturetotheconcretepavements.
Primerwillbeappliedwithanappropriatebrush.

Caresuchastemperatureandtimeofsealingwillbeemphasized

toavoidanybulgeofsealantduringcontractionofjoint.
Sealantshallbeappliedslightlytoalowerlevelthantheslabwith

atoleranceof5+2mm.
Thetypeanddetailsofdifferentjointstreatmentaretabulated
below:

TYPEOF
JOINT

JOINT
DETAILS&TREATMENT

Polysulphide

Debonding 3~4

Soft

Butt

Compressible

Sealant(cold) Strip

Mm

Longitudinal

Groove

Expansion

Construction

Contraction

Rope Joint FillerBoard

TestingofappliedSealant:

Jointsealantcompoundandprimershouldbetestedin:

ColdappliedPolysulphidesealant(accordingtoBS:5212Part2)

Incaseifdeliveriesaremademorefrequentthantestingmaybe
reducedtoeverythreemonths.

MeasurementoftexturedepthSandPatchMethod

TheapparatusasmentionedinMoRTH601.12.1willbeusedto
measurethetexturedepth.

Thesurfacetexturewillbemeasuredasperthemethodlaiddown
inMoRTH601.12.1andthesameisrecordedinlabformat.

OpeningtoTraffic:

Novehiculartrafficincludingcontractor'svehicleswillbeallowed
onthefinishedsurfaceuntilafieldflexuralstrengthofminimum
4.50MPahasbeenachievedwhereaverageflexuralstrengthof
minimum3specimensshouldexceed4.50+1.65s(s=standard
deviation).

Eachseriesoftestspecimensformeasurementofflexural
strengthshouldconsistsofminimum3testspecimens.

Priortoopeningtotrafficthejointsshouldbesealedandareas
adjacenttothepavementshouldbecompletedtoadegreethat
willensuretrafficsafety.

QualityAssuranceandControlChecks

AspartofQualityAssurancethisSegmentQualityPlanforPQC
hasbeenpreparedinlinewiththespecificationprovidedin
relevantMoRTHclauses,ContractSupplementaryTechnical
SpecificationandotherCodes/Standard/Specificationsetc.else
wherementionedinthisPlan.

AsapartofQualityControlalltheInspectionandTesting
requirementsforvariousactivitiesinvolvedinlayingofPQCwill
becarriedoutasperrelevantMoRTHSpecifications&Contract
TechnicalSpecificationatc.AsdescribedinInspectionandTest
PlansattachedtothisSegmentQualityPlanforPQC.

TheseInspectionandTestPlansshallconsistoftypeof
InspectionandnameoftheTesttobeconductedforProduct
Realization,frequencyoftestingacceptancecriteriaandcategory
ofInspection.

InspectionandTestPlansshouldberevisedwheneverthereany
changeinmethodologyandspecificationsetc.

NonconformitiesinPQC:

AnyNonConformityobservedduringfieldInspectionandalso
duringTestingofMaterials/mixes/layingsystemetc.thesame
shouldberecordedinthespecifiedNonconformanceReportand
necessaryCorrective/Preventiveactionsshouldbeinitiatedto
preventsuchthingsinfuture.

QA/QCEngineersareresponsibletocontroltheNonconforming
productsasdescribedinProcedure,andrelevantsectionin
chargesiteengineersaretotakeappropriatecorrective
/preventiveactions.

AllProductNonConformitiesshallbeobserved,recorded,
corrective/preventiveactionsandclosingofNCR'sshouldbeas
pertheestablisheddocumentedproceduredescribedinProject
QualityPlan.

Safety&EnvironmentalRequirements:

HazardIdentification,RiskassessmentandRiskcontrolmeasures

foreachactivitiesandsubactivitiesinvolvedinthepresent
Segmentshallbeidentifiedandnecessaryactionplanshallbe
initiated.
EnvironmentalAspectsandImpactsassociatedwithvarious

activitiesandsubactivitiesinvolvedinthepresentsegmentand
theirmitigation/controlmeasuresshallbeidentifiedandnecessary
measuresshallbeinitiated.

SEQUENTIALOPERATIONOFPQCLAYING

DLClayerApproval

Sitecleaning,Applicationof2ndcoatofcuring
compoundasaseparationmembrane

Survey,Settingout,fixingofStringline

PlacingPaverandTCM

ClearancetoB/PlantforProductionof
concreteaftercheckingstringline&
Equipment.
ProductionofconcreteaspertheMixdesign
andadjustaspertherequirement

TransportationofMixtoSite

YES

SEQUENTIALOPERATIONOFPQCLAYING

RejecttheMixandfindoutRootCause

NO

Checkthemixasperthe
requirementi.e.Slump,

Temperature,Aircontent

etcandmeetsasperdesign?

YES
DDumpingconcreteatregularspacinginfrontof
Paverandstartpaving

Monitoringlevelsthroughlevelsensors.


FixingofDowelbarsandtiebarsbyDBI&TBI
asperDrawing

Rectificationofsurfacedefects(ifany)manually
byMesons.
Texturing&curingbyTCMandTestrateof
spraying.
FixingofStopperafterEndofday'sWork.
InitialJointcuttingaftersettingofconcrete
Cleaningofjointandfixingbackuprod.

SEQUENTIALOPERATIONOFPQCLAYING

CoveringPQCwithhesianclothandwater
curingformin.14days.
Removalofhesianclothandfinaljointcutting
Cleaningofjointandprovidingsoftrope,
debondingstrip,polysulphidesealant,
compressiblefillerboard,buttjointas
mentionedinTable2inPQCmethodology
TesttexturedepthbySandPatchMethod

Proceedforthenextactivity