Rigid Pavement Repair Methodology PDF

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25.04.2013 B Issued for Approval GJR SR MJT

15.03.2013 A Issued for Approval GJR SR MJT
DATE REV. NO. DESCRIPTION Designed Checked Approved
REVISIONS
CONTRACTOR :
LARSEN & TOUBRO LIMITED

(Infrastructure IC of Construction Division)
such person or firm without our prior permission writing
CLIENT : INDEPENDENT CONSULTANT :

NATIONAL HIGHWAYS AUTHORITY OF URS SCOTT WILSON INDIA
DE
INDIA PRIVATE LIMITED
VE
CONCESSIONAIRE : DESIGN CONSULTANT :
L& T Construction
D.A.TOLL ROAD PRIVATE LIMITED Infrastructure - EDRC&T
PROJECT : DELHI-AGRA ROAD PROJECT (DARP )
JOB No. O12217-C-RP

TOTAL NO. OF PAGES 14 TITLE :
NAME SIGN DATE
DSGN GJR 15.03.2013
CHKD SR 15.03.2013
Concrete Pavement Repair Methodology
APPD MJT 15.03.2013

CODE REV.
DOC. No. O 12 2 1 7 - C - R P - C M - S P - 0 0 0 1
IRC B
RELEASED FOR PRELIMINARY TENDER INFORMATION P APPROVAL CONSTRUCTION

LARSEN & TOUBRO LTD DOCUMENT NO: O12217-C-RP-CM-SP-0001
Infrastructure IC of Construction Division SHEET 1 of 14
Table of Contents
1. Introduction ............................................................................................................................ 2
2. Scope ..................................................................................................................................... 2
3. Major Distress Types .............................................................................................................. 2
3.1 Transverse Cracking ......................................................................................................... 3

3.2 Longitudinal Cracking ....................................................................................................... 4
3.3 Corner Breaks................................................................................................................... 4
3.4 Edge Spalling .................................................................................................................... 5
3.5 Shattered slab................................................................................................................... 5
3.6 Blow-ups ........................................................................................................................... 6
3.8 Asphalt Shoving at Concrete/Asphalt Pavement Interface ................................................ 6
3.9 Shallow depth Pot Holes ................................................................................................... 7
3.10 Joint Seal damage .......................................................................................................... 7
4. Repair Methods for Concrete Pavements ............................................................................... 8
4.1 Corner Breaks (Structural Distress, Refer Annexure I) / Edge Spalling ............................. 8
4.2 Transverse cracking near slab joint with or without multiple breaks towards the Joint ....... 9
4.3 Blow-ups ........................................................................................................................... 9
4.4 Multiple Transverse cracks / Shattered Slabs (Structural Distresses, Refer ................... 10
Annexure I) ........................................................................................................................... 10
4.5 Asphalt Shoving at Concrete/Asphalt Pavement Interface .............................................. 11
4.6 Shallow depth Pot holes.................................................................................................. 12
4.7 Single Transverse Crack / Diagonal / Longitudinal cracks / Corner Breaks / ................... 12
Multiple cracks (Functional Distresses, Refer Annexure I) .................................................... 12
4.8 Single Transverse Cracks / Diagonal / Longitudinal Cracking (Structural distresses, ..... 13
Refer Annexure I) ................................................................................................................. 13
4.9 Joint seal Damage .......................................................................................................... 13
5. Summary .............................................................................................................................. 14
Delhi Agra Road Project L&T Construction

Section of NH 2 Infrastructure EDRC&T
1. Introduction
The existing Delhi-Agra Road has a four lane carriageway, which is to be widened to six
lanes as part of the present project. The existing road was widened from two to four lanes in
an earlier project. The widened carriageway of two lanes on alternating one side of the
existing flexible road was paved as Rigid Pavement. The rigid pavement stretch in either
directions totals to approximately 54 Km.
A detailed site condition survey was conducted to identify the distress type and their mapping
over the extent of rigid pavement. The data was used to classify the distress types (functional/
structural) and further to detail the repair methodology based on the guidelines of IRC: SP-83,
2008, for each of these observed defect types. In general, it is observed that the major portion
of existing rigid pavement is in good condition and amenable to repairs, which would allow
for satisfactory pavement performance.
2. Scope
The scope of this report includes,
Identification of major distress types in the existing rigid pavements

Propose Repair Methodology for each identified distress types
3. Major Distress Types

The major distress types observed in the existing Rigid Pavement slabs are as under.
1. Single Transverse Crack near slab joint with or without multiple slab breaks towards the
joint
2. Single Transverse Crack away from slab joint
3. Multiple Transverse Cracks
4. Longitudinal Cracking
5. Corner Breaks
6. Edge Spalling
7. Shallow depth Pot holes
8. Shattered slabs
9. Blow-ups
10. Asphalt Shoving at Concrete/Asphalt Pavement Interface
11. Joint seal Damage
The distresses as classified above have been photographed and are appended to their descriptions
in the following paragraphs. The chainages mentioned on the photographs identify the location
of typical distress class observed over the rigid pavement extent, so as to allow proposals for
repair methodology in respect of each of the typical distress types, to be applied at all locations
where similar distresses are observed / mapped.

3.1 Transverse Cracking

These are full depth cracks perpendicularly aligned to the Road Centreline. The distresses
are classified for rectification measures as per distance from slab joint; Transverse cracks
near Pavement Joint, i.e. within one third (1/3) of the slab length including those
accompanied with multiple longitudinal cracks towards the slab joint and transverse
cracks away from the Slab joints i.e. more than one third (1/3) slab length away from the
joint.
Ch: 67+900 (LHS) Ch: 67+900 (LHS)

Photograph 1: Single Transverse Crack Photograph 2: Single Transverse Crack
away from Joint Near the Joint
Ch: 67+900 (LHS)
Photograph 3: Transverse crack near joint with multiple slab breaks towards Joint

Ch: 67+900 (LHS)

Photograph 4: Multiple Transverse cracks
3.2 Longitudinal Cracking

These are full depth cracks observed, aligned parallel to the direction of the road
centerline.
Ch: 50+700 (LHS)

Ch: 44+500 (LHS)
Photograph 5: Longitudinal cracking
3.3 Corner Breaks

Corner breaks are developed near the corner of a concrete slab, forming a triangle with
the adjoining slab joints. The cracks are either limited on one of the corner slab or across
the joints onto, multiple slabs.

Ch: 86+000 (RHS) Ch: 51+300 (LHS)

Photograph 6: Corner Breaks
3.4 Edge Spalling

The distress type is manifested as cracking, breaking, chipping, or fraying of slab along
the edges of cracks and joints.
Ch: 67+900 (LHS)
Photograph 7: Edge spalling
3.5 Shattered slab

Shattered slabs are identified by intersecting longitudinal and transverse or diagonal
cracks that break up the slab into four or more pieces.

Ch: 50+700 (LHS) Ch: 52+100 (LHS)

Photograph 8: Shattered Slabs
3.6 Blow-ups
Concrete slabs are pushed up or be crushed at a joints.
Ch: 121+200 (LHS)

Photograph 9: Blow-up
3.8 Asphalt Shoving at Concrete/Asphalt Pavement Interface
The flexible pavement surfacing is shoved up causing a heaved hump on the Asphalt
surface.

Ch: 81+000 (RHS)

Photograph 10: Aspahalt shoving Near Concrete /Asphalt Pavement Interface
3.9 Shallow depth Pot Holes
Bowl-shaped holes of various sizes in the pavement surface, with loss of pavement
material from within.
Ch: 47+200 (LHS)

Photograph 11: Shallow depth Pot Holes
3.10 Joint Seal damage
Loss of sealant in the joints

4. Repair Methods for Concrete Pavements

The observed distresses in the existing concrete pavement have been largely classified in
according to IRC: SP: 83-2008 and further classified them as functional or structural
distresses. Strategy for repair of each distress type has been included in this report and the
same is given in Annexure I.
Repairing methodology for the above discussed distresses shall be done as per the
techniques enumerated below.
4.1 Corner Breaks (Structural Distress, Refer Annexure I) / Edge Spalling
Corner breakss shall be repaired where the length the break is observed to be less
than 1.5 m
The repair boundaries shall be clearly marked, keeping minimum repair dimension
requirements of 250 mm length and 100 mm width. Repair boundaries shall also be
at least 75 mm away from the unsound areas
Saw cut shall be made in the concrete slab along the breaks so that repair area should
be triangular or rectangular
The deteriorated concrete may be removed by using one of the following four
methods:
I. Saw cutting (Using Diamond-bladed saw)
II. Chipping (Using lightweight jackhammer with a maximum weight of 7 kg)
III. Milling (Using Carbide-tipped milling machines)
IV. Clean-and-patch(Using Hand tools or a light jack hammer)
Following removal of the concrete, the surface of the repair area shall be prepared to
provide a clean, regular surface for the development of a good bond between the
repair material and the existing slab. Dry sweeping or sandblasting or compressed air
blasting shall be used for cleaning the surface
After the surface of the existing concrete has been cleaned, and just prior to
placement of the repair material, the surface shall be coated with a bonding agent to
ensure complete bonding of the repair material to the surrounding concrete
Cut portion shall be filled with a repair material like elastomeric concrete / epoxy
concrete / free flow, high strength, non-shrink, cementitious mix / grouts as per
strategy given in Annexure I. After placing the filling material, compaction,
finishing and curing (if required) shall be followed
Joint shall be prepared and resealed with sealant material
Figure 1 in Appendix A (Drawing No: O12217-C-RP-RD-SK-0001) demonstrates
the repairs

4.2 Transverse cracking near slab joint with or without multiple breaks towards the
Joint
This repair methodology shall be implemented at distress locations where the length
of deteriorated slab is less than one third (1/3) of the slab length and adjoining the
slab Joints
Saw cut shall be made in the concrete slab to full depth in a straight line parallel to
the adjoining slab joint over the entire width of the slab. The entire slab panel
towards the joint is to be removed
methods:
IV. Clean-and-patch(Using Hand tools or a light jackhammer)
Care is to be exercised while saw cutting and removal of concrete to retain the
existing dowels in place.
Following removal of the concrete, the surface of the Dry Lean Concrete base in the
repair area shall be prepared to provide a clean, regular surface
After the surface of the existing base layer has been cleaned, a polythene sheet bond
breaking membrane shall be laid over the entire exposed base layer
Top steel of diameter 10 mm and spacing 200 mm c/c on both sides and 75 mm
cover to reinforcement shall be placed in the cut-out before PQC pouring
Tie bars of 500 mm length shall be provided to tie existing and new slabs in
transverse direction. The existing dowel bars of the adjoining slab shall be retained.
The existing dowel bars shall be straightened. Fresh Bituminous paint shall be
applied to the exposed dowel bar surface.
PQC with Flexural strength of minimum 4.5 MPa at 28 days shall be poured in the
slab cut-out
The PQC shall be properly compacted, finished and cured.
Joints shall be prepared at the new slab edges and resealed with sealant material
Figure 2 in Appendix A (Dwg No: O12217-C-RP-RD-SK-0001) demonstrates the
repairs
4.3 Blow-ups
Slab Blow-up was observed only at one location (Chainage: 121+200 (RHS)).
Both of the blown up slabs adjoining the joint at which the Blow-up has occurred
shall be replaced with new slabs
The existing slabs shall be fully removed first.
Either of the following two methods may be used to remove the deteriorated concrete
slabs.

a. Breakup and Cleanout Method: Alongside the slab joints the affected concrete to
be removed is broken up using a jackhammer, drop hammer, or hydraulic ram,
and then removed using a backhoe and hand tools. Breakup should begin at the
center of the repair area and not at the sawcuts
b. Lift-Out Method: Drill holes in the existing affected concrete slabs. Lift pins are
placed in drilled holes in the distressed slab and hooked with chains to a front-end
loader or other equipment capable of vertically lifting the distressed slab. The
concrete is then lifted out in one or more pieces (FHWA 1985; ACPA 1995).
existing Dowels and Tie bars, in place.
Following removal of the concrete, the surface of the Dry Lean concrete base in the
repair area shall be prepared to provide a clean, regular surface.
breaking membrane shall be laid over the entire exposed base layer.
The existing Dowel bars and Tie bars shall be straightened. Fresh Bituminous paint
shall be applied to the exposed dowel bar surface.
PQC with Flexural strength of minimum 4.5 MPa at 28 days shall be pour placed in
the slab cut-out. The PQC shall be properly compacted, finished and cured
An isolation joint shall be provided between the two new slabs and sealed.
Transverse dowelled expansion joints shall be provided alongside edges of the new
slabs and existing slabs
The newly formed Transverse and longitudinal repair joints alongside edges of the
new slabs shall be filled and resealed
Figure 3 in Appendix A (Dwg No: O12217-C-RP-RD-SK-0001) demonstrates the
repairs
4.4 Multiple Transverse cracks / Shattered Slabs (Structural Distresses, Refer

Annexure I)
The distressed slabs shall be replaced with new slabs.

The existing affected slabs shall be fully removed first.
slabs
a. Breakup and Cleanout Method: Alongside the slab joints the affected concrete to
center of the repair area and not at the sawcuts.
b. Lift-Out Method: Drill holes in the existing affected concrete slabs. Lift pins are

New Dowel bars shall be provided at the new joint to be formed between the two
new slabs to be installed with proper dowel embedment methods
shall be applied to the exposed dowel bar surface.
the slab cut-out.
The newly formed Transverse and longitudinal repair joints alongside edges of the
new slabs shall be filled and resealed
Figures 4(ii) and 5 in Appendix A (Dwg No: O12217-C-RP-RD-SK-0001),
demonstrates the repairs of slabs with multiple transverse cracks and shattered slab
respectively.
4.5 Asphalt Shoving at Concrete/Asphalt Pavement Interface
The existing concrete slab overlaid with asphalt at, adjoining the rigid pavement slab
shall be replaced with new full depth concrete slab and a proper Asphalt- Concrete
interface joint shall be formed.
The existing affected slabs shall be fully removed first.
slabs.
c. Breakup and Cleanout Method: Alongside the slab joints the affected concrete to
center of the repair area and not at the sawcuts.
d. Lift-Out Method: Drill holes in the existing affected concrete slabs. Lift pins are

New Dowel bars shall be provided at the new joint to be formed between the two
new slabs to be installed with proper dowel embedment methods
shall be applied to the exposed dowel bar surface
the slab cut-out.
The PQC shall be properly compacted, finished and cured
The adjoining existing 3 m length of flexible pavement shall be reduced by a depth
of minimum 200mm. The Asphalt layers may be removed by milling or by scrapping
from above the base course layer. The existing base layer shall be repaired,
compacted and made up to correct grade and camber. In case of existing bituminous
layer underneath (found after milling of the top 200mm), the surface shall be cleaned
and tack coated. Over the prepared base course, 3 layers of DBM (each 50 mm) and
one layer of BC (50 mm) shall be constructed
A proper Asphalt Concrete interface joint shall be provided. And also transverse
expansion joint shall be provided alongside edges of the new slab and existing slab
Figure 7 in Appendix A (Dwg No: O12217-C-RP-RD-SK-0001), demonstrates the
repairs.
4.6 Shallow depth Pot holes
The pothole shall be cleaned with compressed air.

Vertical, straight saw cuts shall be made along the pot hole so that the repair area
should be in rectangular shape, with minimum 75mm margin inside sound concrete.
Cut portion shall be filled with epoxy mix / Free flow, high strength, non-shrink,
cementitious mix / grouts material as per strategy given in Annexure I.
Figure 8 in Appendix A (Dwg No: O12217-C-RP-RD-SK-0001), demonstrates the
repairs
4.7 Single Transverse Crack / Diagonal / Longitudinal cracks / Corner Breaks /

Multiple cracks (Functional Distresses, Refer Annexure I)
Slab with cracks of functional type shall be repaired with crack repair method using
epoxy mix material
A groove shall be made along the crack to a width of 12 to 20 mm up to the affected
depth. The width needs to be sufficient to allow the material to stretch and contract
with movement in the pavement.

The groove shall be cleaned dry and free of dirt, dust, and other material that might
prevent bonding of the filling material
Cut portion shall be filled with epoxy mix / Free flow, high strength, non-shrink,
cementitious mix / grouts material as per strategy given in Annexure I.
Figures 1.A(i), 4(i), 5(i), 6(i) and 9(i) in Appendix A (Dwg No: O12217-C-RP-RD-
SK-0001), demonstrate the repairs
4.8 Single Transverse Cracks / Diagonal / Longitudinal Cracking (Structural distresses,

Refer Annexure I)
Saw cut shall be made in the concrete slab to full depth along the crack
methods:
IV. Clean-and-patch(Using Hand tools or a light jackhammer)
Care is to be exercised while saw cutting and removal of concrete.
Following removal of the concrete, the surface of the Dry Lean Concrete base in the
breaking membrane shall be laid over the entire exposed base layer
Top steel of diameter 10 mm and spacing 200 mm c/c on both sides and 75 mm
cover to reinforcement shall be placed in the cut-out before PQC pouring
Tie bars of 500 mm length shall be provided to tie existing and new slabs.
PQC with Flexural strength of minimum 4.5 MPa at 28 days shall be poured in the
slab cut-out
Figures 6(ii) and 9(ii) in Appendix A (Dwg No: O12217-C-RP-RD-SK-0001)
demonstrates the repairs
4.9 Joint seal Damage
Old sealant in the joint shall be removed by using Rectangular Plough/ rakes or
diamond - bladed sawing or High Pressure waterblasting
Reface the joint to provide a clean surface for bonding with the new sealant to
establish a reservoir of the proper size to produce the desired shape factor (Ratio of
sealant or Joint width (W) and sealant depth (D))
Following refacing of joint, the joint shall be cleaned with high-pressure air or water.
The backer rod shall be installed as soon as possible after the joints are airblasted. The
backer rod must be a flexible, non-absorptive material that is compatible with the
sealant material in use. The backer rod should be about 25 percent larger in diameter
than the joint width.

As soon as possible after backer rod placement, the sealant material shall be installed.
5. Summary
The table given below summarizes the repair methodology for major distresses in the
concrete pavement.
Table 6.1: Summary of Concrete pavement repair methodology
S.No Distress Type Repair Methodology
1. Corner Breaks Crack repair using epoxy mix / Partial / Full
depth repair using Elastomeric/Epoxy concrete
(As per Annexure I)
2. Edge Spalling Partial depth repair using Epoxy concrete as per
Annexure I.
3. Transverse Cracking near slab Cracks and multiple breaks within 1/3rd of the
joint with or without multiple slab slab length from joint, slab replacement is made
breaks towards the joint from saw cut line (75 mm from crack line) with
new slab and top steel over base layer and new
tie bars to connect old and new slab
4. Blow ups Full depth replacement of both of the blown up
slabs with new concrete slabs and New isolation
joint in between new slabs. Dowelled expansion
joint in between existing and new slabs
5. Shattered slab Full depth slab replacement with new slab
6. Multiple transverse cracking Crack repair using epoxy mix /Full depth slab
replacement with new slab as per Annexure I
7. Asphalt shoving at concrete / Full depth replacement of concrete slab overlaid
Asphalt Pavement Interface with Asphalt, adjoining to rigid pavement, with
new slab and new asphalt-concrete interface
joint. Three layers of DBM (Each 50 mm) and
one layer of BC (50 mm) over base layer of the
existing flexible pavement of 3 m length
8. Pot holes Partial depth repair using Epoxy concrete as per
Annexure I
9. Single Transverse Crack / Crack repair using epoxy mix / Full depth repair
Diagonal crack/ Longitudinal of the affected portion of minimum 1m width
cracking with mesh reinforcement and new tie bars to
connect old and new slab (As per Annexure I)
10 Joint Seal Damage Clean and Reseal the affected joint location

Infrastructure IC of Construction Division
Annexure I
Repair Methodology of Various Distresses in Concrete

Pavements (As per IRC: SP: 83, 2008)

LARSEN & TOUBRO LIMITED
Infrasture IC of Construction Division Doc. No: O12217-C-RP-CM-SP-0001
Annexure I: Repair Methodology of Various distresses in Concrete Pavements (As Per IRC: SP: 83 - 2008)
Distress Classification
Repair Action
S.No Type of Distress Severity (Functional / Structural)
d < D/2 d > D/2 d < D/2 d > D/2
w < 1.5 mm Functional Functional Seal with Epoxy mix Seal with Epoxy mix by widening crack to a width of 12 to 20 mm
Single Discrete cracks (Not
1
Intersecting any Joint) Full Depth Repair of affected Portion of minimum 1 m width with
Seal with Epoxy mix by widening crack to a width of 12 to 20 mesh reinforcement (10 mm diameter and 200 mm C/C Spacing,
w > 1.5 mm Functional Structural
mm and depth of 35 mm 75 mm cover to reinforcement) and newTie bars to connect old
and New slab
Seal with Epoxy mix by widening crack to a width of 12 to 20
w < 3 mm Functional Functional Seal with Epoxy mix by widening crack to a width of 12 to 20 mm
mm and depth of 35 mm
Single Transverse crack (or
2 Diagonal Crack) intersecting with
one or more joint Full Depth Repair of affected Portion of minimum 1 m width with mesh reinforcement (10 mm diameter and 200 mm C/C Spacing,
w > 3 mm Structural
75 mm cover to reinforcement) and newTie bars to connect old and New slab
Transverse crack Near Joint with Full Depth Repair of affected Portion of minimum 1.5 m width with mesh reinforcement (10 mm diameter, 200 mm C/C Spacing and
3 P < 1.5 m Structural
Multiple breaks towards joint 75 mm cover to reinforcement) and new tie bars to connect old and new slab
Seal with Epoxy mix by widening crack to a width of 12 to 20

w < 3mm Functional
mm and depth of 35 mm
Full Depth Repair of affected Portion of minimum 1 m width with
Seal with Epoxy mix with minimum depth of D/2 and width of 12
Single Longitudinal Crack w= 3-6 mm Functional mesh reinforcement (10 mm diameter and 200 mm C/C Spacing,
4 Structural to 20 mm
intersecting one or more Joints 75 mm cover to reinforcement) and newTie bars to connect old
w = 6-12 mm - - and New slab
w > 12 mm - -
w < 0.5 mm Functional Seal with Epoxy mix

5 Multiple Tranverse Cracks Structural Dismantle and Reconstruct whole slab
w > 0.5 mm (Slab broken into more
Structural Dismantle and Reconstruct whole slab
than two pieces)
w < 1.5 mm, L < 0.6 m (One broken Seal with Epoxy mix by widening crack to a width of 12 to 20
Functional Functional Seal with Epoxy mix by widening crack to a width of 12 to 20 mm
Corner) mm and depth of 35 mm
6 Corner Breaks
w > 1.5 mm, 0.6 < L < =1.5 (More
Structural Structural Partial Depth Repair of the affected portion with Epoxy mix Full Depth Repair of the affected portion with Epoxy mix
than one broken corner)
a= 50- 100 mm, h < 50 mm Functional - Partial Depth repair 65 mm deep with Epoxy mix
a= 100- 300 mm, h =50-100 mm Functional - Partial Depth repair 110 mm deep with Epoxy mix
7 Shallow depth Pot Holes -
a > 300 mm, h > 100 mm - Structural
Full Depth Repair of Affected Potion with Epoxy mix
8 Joint seal Damage Loss or damage Functional - Clean Joint and Reseal -
b < 20 mm , m < 25 % - Fill with Epoxy mix
9 Spalling of Joints b = 20 - 80 mm, m> 25 % Functional - Partial Depth Repair 20- 50 mm deep with Epoxy mix -
b > 80 mm, m> 25 % - 50 - 100 mm Deep Repair with Epoxy mix
10 Blow Up k > 25 mm Structural - Replace blown Slabs -
11 Shattered Slab Structural Dismantle and Reconstruct whole slab
Full depth replacement of concrete slab overlaid with Asphalt, adjoining to rigid pavement, with new slab and new asphalt-concrete
Asphalt Shoving At concrete/
12 Structural interface joint. Three layers of DBM (Each 50 mm) and one layer of BC (50 mm) over base layer of the existing flexible pavement
asphalt concrete Interface
of 3 m length
Measurement Parameters:
d = Depth of Crack
D = Depth of Slab
w = Width of Crack
L = Length of Crack
a = Diameter of the Pot hole
h = Maximum Depth of Pot Hole
b = Width of Spalling
m = Length of the spalled Portion (% of Joint Length)
k = Vertical Displacement from Normal Profile
P = Distance from the transverse Joint
Delhi Agra Road Project, Section of NH 2

Infrastructure IC of Construction Division
Appendix A
Concrete pavement Repair Methodology (Typical Details)

NOTES:-
* EXISTING DOWELS TO BE RETAINED
** NEW TIE BARS ARE NOT APLICABLE FOR MEDIAN FACE
APPENDIX - A *** BACKING ROD DIA FOR JOINTS SHALL BE 1.5 X JOINT WIDTH.
DISTRESS TYPE REPAIR METHOD DISTRESS TYPE REPAIR METHOD
1. A) CORNER BREAKS 3. BLOW UPS
(i) Functional Distress (Refer Annexure I) *EXISTING DOWEL BARS

A B ROAD MEDIAN FACE *EXISTING DOWEL BARS
A A
ISOLATION JOINT
SIDE VIEW
EPOXY MIX 12 - 20 mm
E E
Varies JOINT JOINT
(Refer Annexure I) A B
SECTION A-A
PLAN PLAN
EXPANSION JOINT EXISTING TIE BARS
PLAN
PLAN
20 mm
5 mm
20 mm JOINT SEALANT
***BACKING ROD
(ii) Structural Distress (Refer Annexure I) NEW DOWELLED EXPANSION JOINT
B B NEW ISOLATION JOINT
75 mm
50 mm
À' À' À'
SAW CUT EPOXY MIX NEW JOINT
Varies (Refer
Annexure I) RECOMPACTING 20 mm CLOSED CELL
ELASTOMERIC / 125 microns POLYETHYLENE JOINT
EPOXY CONCRETE LOOSE DLC MATERIAL
THICK POLYMER SHEET FILLER TO FULL DEPTH
SECTION E-E DETAIL À' OF SLAB
PLAN PLAN SECTION B-B
1.B) EDGE SPALLING 4. MULTIPLE TRANSVERSE CRACKS
(i) Functional Distress (Refer Annexure I)
C C F
SAW CUT Varies
SAW CUT (Refer Annexure I)
75 mm NEW JOINT F
Varies (Refer
EPOXY MIX Annexure I)
EPOXY MIX SECTION F-F
JOINT
PLAN PLAN
SECTION C-C
PLAN PLAN
(ii) Structural Distress (Refer Annexure I)

**NEW TIE BARS
*EXISTING DOWEL BARS *EXISTING DOWEL BARS EXISTING CONTRACTION JOINT
RETAIN EXISTING DOWELS
2. TRANSVERSE CRACK NEAR SLAB JOINT WITH OR WITHOUT MULTIPLE SLAB BREAKS TOWARDS JOINT
G NEW SLAB G
NEW TIE BARS
L1 < L3 1.5m 75 mm COVER TO REINFORCEMENT
75 mm
500 mm LONG
(BOTH DIRECTIONS) RECOMPACTING 125 microns
TIE BAR RETAINED DOWEL
RETAIN EXISTING DOWELS LOOSE DLC MATERIAL THICK POLYMER SHEET
JOINT PLAN EXISTING TIE BARS
D D PLAN SECTION G-G
SAW CUT
5. SHATTERED SLABS
RECOMPACTING
125 microns
L LOOSE DLC MATERIAL
NEW SLAB THICK POLYMER SHEET
PLAN
PLAN
**NEW TIE BARS
SECTION D-D EXISTING CONTRACTION JOINT
*EXISTING DOWEL BARS *EXISTING DOWEL BARS RETAIN EXISTING DOWELS
SHATTERED SLABS H NEW SLAB H
RECOMPACTING 125 microns

LOOSE DLC MATERIAL THICK POLYMER SHEET
PLAN EXISTING TIE BARS PLAN SECTION H-H
JOB No. : O12217-C-RP

D.A.TOLL ROAD PRIVATE CONCRETE PAVEMENT - REPAIR METHODOLOGY
LIMITED (APPENDIX - A)
(Infrastructure IC of
Construction Division) - - - - -
DELHI - AGRA ROAD PROJECT (DARP) URS SCOTT WILSON INDIA
PRIVATE LIMITED
Cad File No: R:\Project Documents\DARP\Package I\Pavement Design\Working Documents\Reports\Rigid Pavement Repair Methodology\Rev B\ Concrete Pavement Repair Methods.dwg Plot Date: 25 April, 2013 - 4:16 PM
APPENDIX - A
DISTRESS TYPE REPAIR METHOD
6. LONGITUDINAL CRACKS
12 - 20 mm
I I Varies
(Refer Annexure I )
SECTION I-I
PLAN PLAN
75 mm COVER TO REINFORCEMENT
1m
(ii) Structural Distress (Refer Annexure I)
TOP STEEL NEW 500 mm LONG
TIE BARS
(BOTH DIRECTIONS)
J J
NEW SLAB RECOMPACTING

125 microns
LOOSE DLC MATERIAL
THICK POLYMER SHEET
PLAN SECTION J-J
PLAN
7. ASPHALT SHOVING AT CONCRETE ASPHALT INTERFACE
1 mm
3 mm
EXISTING CONTRACTION JOINT CONCRETE ASPHALT 50mm BC JOINT SEALANT 10
6-9
HUMP INTERFACE JOINT 50mm DBM
DOWELLED
5
50mm DBM
ASPHALT EXPANSION À' `B' 50mm DBM CONCRETE
CONCRETE SLAB JOINT
29-32
NEW SLAB
AC
ELEVATION 3.0m
DOUBLE CAPPED
DOWEL BAR ASPHALT
125 microns
(FOAM INSERT) THICK POLYMER SHEET ***BACKING ROD
RECOMPACTING
LOOSE DLC MATERIAL
ELEVATION DETAIL `B'
8. POT HOLES
SAW CUT EPOXY MIX

JOINT K K JOINT
75 mm
Varies
(Refer
Annexure 1)
PLAN PLAN SECTION K-K
9. SINGLE TRANSVERSE CRACKS

L
L
Varies
(Refer Annexure I)
PLAN SECTION L-L

PLAN
TOP STEEL 75 mm COVER TO REINFORCEMENT
(ii) Structural Distress (Refer Annexure I) NEW 500 mm LONG
(BOTH DIRECTIONS) TIE BARS
M
1m
NEW SLAB
M RECOMPACTING
125 MICRONS
LOOSE DLC MATERIAL
THICK POLYMER SHEET
PLAN PLAN SECTION M-M
NOTES:-
* EXISTING DOWELS TO BE RETAINED
** NEW TIE BARS ARE NOT APLICABLE FOR MEDIAN FACE
*** BACKING ROD DIA FOR JOINTS SHALL BE 1.5 X JOINT WIDTH.
JOB No. : O12217-C-RP

D.A.TOLL ROAD PRIVATE CONCRETE PAVEMENT - REPAIR METHODOLOGY
LIMITED (APPENDIX - A)
(Infrastructure IC of
Construction Division) - - - - -
DELHI - AGRA ROAD PROJECT (DARP) URS SCOTT WILSON INDIA
PRIVATE LIMITED
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This document is the property of Larsen & Toubro Limited, INFRA IC, EDRC&T must not be passed on to any

25.04.2013 B Issued for Approval GJR SR MJT

LARSEN & TOUBRO LIMITED

CLIENT : INDEPENDENT CONSULTANT :

PROJECT : DELHI-AGRA ROAD PROJECT (DARP )

JOB No. O12217-C-RP

APPD MJT 15.03.2013

RELEASED FOR PRELIMINARY TENDER INFORMATION P APPROVAL CONSTRUCTION

3. Major Distress Types .............................................................................................................. 2

3.1 Transverse Cracking ......................................................................................................... 3

Delhi Agra Road Project L&T Construction

Identification of major distress types in the existing rigid pavements

3. Major Distress Types

Delhi Agra Road Project L&T Construction

3.1 Transverse Cracking

Ch: 67+900 (LHS) Ch: 67+900 (LHS)

Ch: 67+900 (LHS)

Delhi Agra Road Project L&T Construction

Ch: 67+900 (LHS)

3.2 Longitudinal Cracking

Ch: 50+700 (LHS)

3.3 Corner Breaks

Delhi Agra Road Project L&T Construction

Ch: 86+000 (RHS) Ch: 51+300 (LHS)

3.4 Edge Spalling

Ch: 67+900 (LHS)

Photograph 7: Edge spalling

3.5 Shattered slab

Delhi Agra Road Project L&T Construction

Ch: 50+700 (LHS) Ch: 52+100 (LHS)

Ch: 121+200 (LHS)

Delhi Agra Road Project L&T Construction

Ch: 81+000 (RHS)

Ch: 47+200 (LHS)

Delhi Agra Road Project L&T Construction

4. Repair Methods for Concrete Pavements

Delhi Agra Road Project L&T Construction

Delhi Agra Road Project L&T Construction

4.4 Multiple Transverse cracks / Shattered Slabs (Structural Distresses, Refer

The distressed slabs shall be replaced with new slabs.

Delhi Agra Road Project L&T Construction

4.5 Asphalt Shoving at Concrete/Asphalt Pavement Interface

Delhi Agra Road Project L&T Construction

4.6 Shallow depth Pot holes

The pothole shall be cleaned with compressed air.

4.7 Single Transverse Crack / Diagonal / Longitudinal cracks / Corner Breaks /

Delhi Agra Road Project L&T Construction

4.8 Single Transverse Cracks / Diagonal / Longitudinal Cracking (Structural distresses,

4.9 Joint seal Damage

Delhi Agra Road Project L&T Construction

Delhi Agra Road Project L&T Construction

Repair Methodology of Various Distresses in Concrete

Delhi Agra Road Project L&T Construction

d < D/2 d > D/2 d < D/2 d > D/2

Seal with Epoxy mix by widening crack to a width of 12 to 20

w < 0.5 mm Functional Seal with Epoxy mix

10 Blow Up k > 25 mm Structural - Replace blown Slabs -

11 Shattered Slab Structural Dismantle and Reconstruct whole slab

Delhi Agra Road Project, Section of NH 2

Concrete pavement Repair Methodology (Typical Details)

Delhi Agra Road Project L&T Construction

(i) Functional Distress (Refer Annexure I) *EXISTING DOWEL BARS

SAW CUT EPOXY MIX NEW JOINT