Construction & Quality Control Aspects of Rigid Pavements’

1. Introduction to various layers & their function in a Rigid Pavement

2. Material for construction – Cement, Sand, Aggregates, Admixtures etc.
(Storage, Batching..)
3. DLC – Mix Design, Construction Operations, Acceptance Criteria
4. PQC – Mix Design, Plant & Equipment
5. PQC – Construction Operations
6. PQC - Quality Control aspects, Acceptance Criteria, Troubleshooting

satander50@yahoo.co.in

1
 L–Section of Rigid Pavement
Joint Spacing
3 - 6 m

Dowels PQC M40

Sub base, DLC

Granular Sub Base (GSB) OR Drainage Layer

Sub-grade, Compacted Natural Formation camber 3-4%

• Jointed Plain with dowels

 Jointed Reinforced

In steep terrain, Fill up area, super elevation

L/B>1.5
10 - 20 m

Slab
Dowels

Base

Welded Wire Fabric

(0,1 - 0,2 %)
 Road Composition

Vehicle

PQC M 40

DLC M 10 at 7 days Road Crust

Sub Base GSB/DL 27% CBR

300mm Sub Grade 9% CBR /Permeability 30 m/day

450
Embankment 3% CBR
Ground Level
Expansion Joints Construction Joint Longitudinal Joint

6
Contraction Joints Placement of dowel bars Crack below
Longitudinal Joints Transverse Joints Contraction Jt.

-Plan Load transverse device

Contraction Joints
Dowel bars Placement
7

If no dowel bars. Dummy Contraction Joi

Expansion Joint/

Contraction Joint Without Gap

Dowel Bars ( ~25 – 38 mm) Plain

IS: 432

Longitudinal/ Construction Joint

Tie Bars ~ 12-16 mm deformed

IS: 1786

8
 CCI Established in 1927, Manual 1948

Matunga Bombay 1960 200 mm

9
First Mechanised Road NH -2, h= 300 mm NHDP G Q

Manual 1948

IInd Mechanised RoadPrice

Yamuna
Rs 1 Expressway,
h= 320 mm
 MIX DESIGN-
CEMENT

 Ordinary Portland Cement, 43 Grade, IS: 269 - Durability consideration

 Ordinary Portland Cement, 53 Grade, IS 269 - Durability consideration


 Portland Pozzolana Cement (flyash), IS:1489, (I)

 Portland Blast Furnace Slag Cement, IS:455, slag 50%, sulphate < 1%

 Sulphate Resistant Portland Cement IS:12330, sulphate in soil > 0.2%

11
 CHEMISTRY OF CEMENT

C3S (3CaO.SiO2) Gives strength at 3 day

C2S (2CaO.SiO2) , Gives strength at 7 day

Tricalcium silicate + Dicalcium silicate=

C3S (3CaO.SiO2)+C2S (2CaO.SiO2) + H2O

CxSyH gel (Tobermorite gel) + Ca(OH)2

Hydrated/
Reactive Lime (25%)
Composite Cement- IS: 16415-2015
• Cement 35-65% - 35 kg cement
• Fly ash 15-35% - 35 kg fly ash
• Slag 20-50% - 30 kg slag

• 3 day compressive strength 16 MPa,

• 7 days “ 22 MPa
• 28 days “ 33 MPa
 Specifications of all Grade of Grade Cement

33 GRADE 43 GRADE 53 GRADE LOW

ORDINARY MEDIUM HIGH HEAT
(IS : 269) (IS: 269) (IS : 269)

C 3S 45 % 50 % 55 % 30 %

C 2S 27 % 22 % 17 % 46 %
Or fck + o.825* Standard
Deviation which ever is greater

30.1 Fail
Performance improver Mineral admixtures, lime
stone powder, slag etc 5%
Properties 33 Grade 43 Grade 43 Grade, 53 Grade 53 Grade,
OPC OPC S, Sleeper OPC sleeper S
FINENESS 225 225 370 225 370
m2/kg
Setting IS 30 30 60 30 60
Time FS 600 600 600 600 600
Min CS 3 D 16 23 23 27 27
Min 7D 22 33 37.5 37 37.5
Min 28 D 33 43 43 53 53
Max 28 D 48 58 - - --
 IS: 4031 – 1988
DETERMINATION OF SOUNDNESS

CONSISTENCY OF STANDARD CEMENT PASTE

500 gm cement+ about 25-40% water = penetration 5-7 mm from
bottom

Soundness Test: Take 500 gm Cement add +

0.78 times Standard Consistency or normal consistency.
Soundness not more than 10 mm expansion

INITIAL AND FINAL SETTING TIMES

0.85 times normal consistency = penetration 5 mm +/-

0.5 mm from bottom
IS: 4031 –PART 6 DETERMINATION OF COMPRESSIVE
STRENGTH OF HYDRAULIC CEMENT8/26

Water = (P/4+ 3) % by weight of total 800 gm

1:3 Cement :sand mortar, vibrate 2 minutes,

( 200 gm cement + 600 gm standard sand) 24 hours moist

curing + remaining wet curing , 3 d, 7 d and 28
days.
IS: 4031 – PART 11 DETERMINATION OF
DENSITY (FIRST REVISION
9/26

60 gm cement placement
in flask having kerosene oil.

Mass/ Vol
CHARACTERISTICS GRADE OF CEMENT Pozolana or Slag cement
PPC-I PPC-II
FLY ASH CALCINED CLAY
SETTING TIME
INITIAL, NOT LESS 30 30
THAN, min.
FINAL, NOT MORE 600 600
THAN, min.
FOR FALSE SET: REMIX
AND BREAK THE FALSE
SET, RE-TEST.

COMPRESSIVE STRENGTH,
PROGRESSIVE INCREASE
IN STRENGTH, NOT LESS THAN
72+1 HR. 16 MPA 16 MPA
168+2 HR. 22 MPA 22 MPA
672+4 HR. 33 MPA 33 MPA
 IS: 4031 –PART 6 DETERMINATION OF COMPRESSIVE
STRENGTH OF HYDRAULIC CEMENT8/26

Water = (P/4+ 3) % by weight of total 800 gm

1 part cement :3 part sand mortar, vibrate 2 minutes,

P = Standard Consistency or Normal Consistency

( 200 gm cement + 600 gm standard sand) 24 hours moist)

Standard Sand 2 mm -1mm 200 gm

CHEPAK 1mm -500 micron 200 gm

500 micron -90 micron 200 gm

 IS: 383-2016
Coarse and Fine Aggregates for
concrete
 Manufactured Aggregate
• Agg manufactured from other than natural resources by
processing materials, using thermal or other process such
as separation, washing, crushing & scrubbing like
Recycled Concrete Aggregates (RCA) coarse agg.
• Sand or fine aggregate means- Passing 4.75 mm
% passing 75 µ silt
Ö Crush Ö
Natural
er
sand
dust

Size 4. 0 mm Size 4. 0 mm
Silt 3% Natural, 15% Crushed
Texture Smooth Rough
Area Less with no fine More with more fine
 Coarse aggregates
WEARING OTHER
COURSE WORKS
CRUSHING VALUE Max. 30 % 30%
If Max>30
10% fine
minimum
load 5 t

IMPACT VALUE Max. 30 % Max.45 %

M 65 Max. 22%

ABRASION VALUE Max. 30 % Max. 50 %

Soundness Fine Agg. 10% Na2SO4, Mg SO4 15%

Coarse agg 12% Na2SO4, Mg SO4 18%

Water absorption 5 % Max IS: 383

 Sieve Grading Zone 1 Grading Zone II Grading Zone III Grading Zone IV
FM 3.0 -3.5 2.5 – 3.0 FM 2- 2.5
size FM Less than 2

10 mm
100 100 100 100
4.75
mm 90-100 90-100 90-100 95-100

2.36
mm 60-95 75-100 85-100 95-100

30

15-34 35-59 60-79 80-100

5 50

0 15

out side limit except 600 micron upto 5% Permissible

26
Fineness Modulus of sand 2-3.5 MORD clause 2009 page 574
No change in blue values, 150 micron value 0-20% crushed stone sand
 Maximum Utilization
Coarse Type Plain Cement Reinforced Lean Concrete
agg Concrete Concrete Less than M 15
Iron Slag 50 25 100
Steel Slag 25 nil 100
RCA 25 20 upto M 25 100

Copper slag 40 35 50
RCA 25 20 upto M 25 100

Chlorides = 0.5%
Sulphates = 0.04 %
Water absorption = 5% upto 10% With precaution
MORTH- DLC

28
MORTH Specification for Roads and BridgesCl. 601 /602
DLC (Dry Lean Concrete) QC (Pavement Quality Concrete)
Sieve mm ------% Passing-----
31.5 100 100 (Max Size)
26.5 100 (MSA) 85-95 (Nominal)
19 80-100 (Nominal) 68-88
9.5 55-75 45-65
4.75 35-60 30-55
600 micron 10-35 8-30
150 micron ---- 5-15
75 micron 0-5 0-5

Cement > 150 kg/cum > 340kg/cum

Strength 10 MPa at 7 days M 40 at 28 days

 6 Cubes shall give 90% strength
with Sample as compared to pur water

pH value shall be 6-8

Drinkable V Good

IS: 456-2000:
Code of Practice for Plain and Reinforced Concrete
 Curing Compound and With water - ASTM C -309

• Waxes, Resins, Chlorinated rubber

• Do not apply on surfaces are to be bonded

• Do not apply on dry surface

Slump in mm
 Chemical Admixture
• Cl = 0.2%by weight of admixtures

• pH = 7-8

• Water reduction minimum 20%

• 3/7 days strength 25% more

• 28days same strength

IS: 9103 Chemical admixture Max 2% by weight of Cementitious material/cement

33
 CHEMICAL ADMIXTURE -- IS 9103

• CHEMICAL ADMIXTURE, liquid < 2%

• Mineral admixture -powder

• Fly ash IS: 3812 (Coal) upto 35%

• Slag IS: 12089 (Hematite) 50 %

• Silica fume (Qrz) IS:456/ IS:15388 5-10%

 DESIGN STRNGTH
f ’ck = fck + t xs
Target Strength = Characteristic + Tolerance X Standard Deviation
Strength Value

= 40 MPa + 1.65 X 5 MPa

= 48 MPa or 48 N/mm2 or 480 kg/cm2

f ’ck = target mean compressive strength at 28 days, N/mm2

fck = characteristic compressive strength at 28 days, and, N/mm2

s = standard deviation, N/mm2

t = standard normal variate which is taken as 1.65 as per IS:456-2000

35
for accepted proportion of low results 1 in 20.
 CHARACTERISTIC
STRENGTH
The term characteristic strength indicates that value of the strength below
which not more than 5 % of the test results are expected to fall.

Target Strength
 ASSUMED STANDARD DEVIATION

Grade of concrete Assumed Standard Deviation N/mm2

M25 4.0
M30
M35
M40
5.0 (Roads and building)
M45
6 Mpa for structures
M50
M55
M60

TARGET STRENGTH = 40+ 1.65 * 5 MPa as Standard Deviation =

40+ 8.25 Mpa = 48.25 MPa

37
PRELIMINARY SELECTION OF WATER – CEMENT RATIO

Sl No. Target mean strength/ Approximate Water

Grade of Concrete Cement Ratio
1 M 25 0.50
2 M 30 0.45
3 M 35 0.42
4 M 40 0.38
5 M50 0.34
6 M60 0.28

W/C = Let us take 0.36 for M 48

38
 APPROXIMATE WATER CONTENT PER CUBIC METRE OF
CONCRETE FOR NOMINAL MAXIMUM SIZE OF AGGREGATE
(WITH OUT PLASTICISER /SUPERPLASTICISER)

Nominal Maximum Approximate Water

Size of Aggregate Content
mm kg
10 208
20 186
40 165

• 1) Water content for angular coarse aggregate and for

20-50 mm slump say 35 mm

For each increase of 25 mm slump, 3% water is

increased in case of mixes without chemical
admixtures. 39
 Water Content (Contd.)

• with Super-plasticizing, water reduction up to 30%

Water content is 186 kg/m3 for 20 mm MSA without admixture,

148.8 kg/m3 assuming 20 % reduction

186 litre – 20 % 0f 186 = 186 – 37.2 = 148.8 litre or

(186 X 0.80 ) = 148.8 litre water for 1 cubic m concrete

WE ARE DESIGING FOR:

(2400 kg = 24 kN/cum = 2.4 tonnes, one cu m of concrete

40
 EXAMPLE FOR EACH CUBIC M OF CONCRETE
• Water 186 l /cubic m.

• Let us take 80% after adding admixture

•
=0.80*186 =148.8 litre/cubic m.

• W/C = 0.36 148.8 = 0.36

C 1
• 0.36 * C = 148.8 donot add admixtures then cement content =
W/C= 0.36
186 /C= 0.36
Cement content = 186/0.36
• C= 148.8 = 516.7 kg/ cu
0.36 Extra Cement required = 516.7- 413.3 = 103.4 kg

= 413.3 kg < 450 kg/cu m -- IS: 456 41

 EXAMPLE

• Absolute volume of water 148.8/1000 = 0.1488 cum

• Absolute volume of cement = 413.3/3150 =0.1312 cum

• Absolute volume of admixture sp gr 1.2 = 1% of 413.3 kg

• 4.133 kg/1200 cum = 0.0034 cum (1% by wt of cement)

Absolute volume of all agg =1- 0.1488- 0.1312-0.0034

= 0.7166 m3

42
 ESTIMATION OF COARSE AGGREGATE CONTENT
Nominal Volume of Coarse Aggregate Per Unit
Maximum Volume of Concrete for Different Zones
Size of of Fine Aggregate
Aggregate Zone Zone III Zone II Zone I
mm IV
10 0 .50 0. 48 0 .46 0. 44
20 0 .66 0. 64 0 .62 0. 60
40 0 .75 0. 73 0 .71 0. 69
For pumpable mixes 10% coarse aggregate is decreased and Fine
aggregate content is increased.
Proportion is for W/C ratio 0.5.
For each decrease in 0.05 W/C ratio, there shall be increase of 1% coarse aggregate
0.50 – 0.36 = 0.14. For Change in - 0.05 there is + 1%
1 +1/0.05
for 0.14 + (1/0.05)*0.14= + 2.8 %
2.8 + 62% = 64.8 % Coarse agg
 Absolute volume of agg = 0.7166 cum

coarse aggregate 64.8% of 0.7166 cum =

0.648* 0.7166 = 0.4644 cum

Coarse aggregate down 20 mm = 0.2522 cum

Fine agg = 35.2% of 0.7166 cum

= 0.352*0.7166 cum = 0.2522 cum

Total volume of all agg = 0.7166 cum

44
 ABSOLUTE VOLUME in CUM

• Absolute volume of water 1 = 0.1488 cum

• Absolute volume of cement = 0.1312 cum

• Absolute volume of admixture = = 0.0034 cum

• coarse agg = 0.4644 cum

• fine agg = 0.2522 cum

• Total Volume = 1.000 cu m 45

 SSD Weight
• Weight of water = 0.1488 cum *1000 = 148.8 litre

• Weight of cement = 0.1312 cum *3150 = 413.3 kg

• Weight of admixture = 0.0034 * 1200 = 4.1 kg

• coarse aggregate = 0.4644 cum *2600 = 1207 kg

• fine aggregate = 0.2522 cum * 2600 = 656 kg

• Total weight =2429 kg in one cubic meter of concrete

46
46
 DRY Weight Basis
Say absorption 1%
• Absolute volume of water = 148.8 +12.1 + 6.6 =

= 167.5 Litre or kg

• coarse agg = 1207– 12.1 = 1195 kg

• fine agg = 656 – 6.6 = 649.4 kg

If Water absorption, is high 3-10% as per IS: 383,

Either wet the aggregates or take water absorption of two hours

47
47
 MIX PROPORTION mixing time 2 minutes
• Weight of water = 167.5 L

• Weight of cement = 413.3 kg

• Weight of admixture = 4.1 kg

• Dry coarse aggregate = 1195 kg
• Dry fine aggregate = 649 kg

• Total weight =2429 kg

• Cement : sand : Coarse agg : Water Admixture

• 413.3/413.3 : 649/413.3 : 1195/ 413.3 : 167.5 /413.3 (By weight)

1: : 1.571 : 2.891 : 0.41 free water/binder ratio

To convert by volume, we take bulk density = Mass/ Bullk Density= Volume

1 * 1440 : 1.571*1440 : 2.891*1440 = 1 cu m: 1.41 cum :2.60 cum

1440 1600 1600 48
Target Mean Strength of Cocrete :

As per Clause 601.3.4 of "MORTH" Specification Mix Design of DLC

1) Average of Compressive
Strength < 10Mpa at 7 Days Dry Lean Concrete
2) Minimum compressive Strength
< 7.5 Mpa at 7 Days (of Any
Cube)
TRIAL
MIXES:
Cement Content (Minimum cement as per
Clause 601.3.3 of T.S 150
Free Water 5.5 %
OMC 129
Absolute Volume of Fine and
Coarse Agg
49
Free Water 5.5 %
OMC 129
AbsoluteVolume
Absolute Volume of aggregates
of Fine and = 1 -150/3000 - 129/1000
Coarse Agg
= 1 cum - 0.05 cum (cement) - 0.129 cum (W)
150 129 0.821
= 1-( + )=
= 0.821 cu m
3000 1000
Volume of Stone Dust (45 % of total Volume of
Coarse & Fine Agg.) 0.821 x 0.45 = 0.3695
Volume of 20 mm (35 % of total volume of
Coarse & fine Agg.) 0.821 x 0.35 = 0.2874
Volume of 10 mm ( 20% of total volume of
Coarse & Fine Agg.) 0.821 x 0.2 = 0.1642

Weight abstract from Volume

Weight of Crusher Dust 0.3695 x 2.67 X1000

= = 986.43
Weight of
20 mm 0.2874 x 2.69 X1000
= = 773.83
Weight of
10mm 0.164 x 2.69 X1000
= = 441.86

50
Quantitiies for 1 Cum. Batch (Based on
SSD Condition)

1 Cement 150 KG

2 Water 129.00 KG
Stone 45
3 Dust 986.43 KG %
773.83 35
4 20mm 4 KG %
441.86 20
5 10mm 22 KG %
51
 IS 456-2000

Grade of Aggregate Water

concrete Per bag of cement
M5 800 60
M 7.5 625 45
M 10 480 34
M 15 330 32
M 20 250 30
330 : 680 : 1360 Plus water 32 litre
1 : 2 : 4 M 15
7/9/2018 . 52
 CPWD and IS= Specification Nominal
Mixes By Volume
Mix 7 day Comp. Strength 28 day Comp.

1: 1: 2 210 kg/cm2 ( 21 MPa) 315 kg/cm2 ( 31.5 MPa)

1: 1.5: 3 175 kg/cm2 (17.5MPa) 265 kg/cm2 ( 26.5 MPa)

1: 2: 4 140 kg/cm2 (14 MPa) 216 kg/cm2 ( 21.6 MPa)

IS: Code= 1:2:4 means 15 Mpa at 28 days Charasteruistics

CPWD Code = 15 + 1.65*4 by Target strength = M 20

7/9/2018 Concrete Pavement -Design & 53
Applications.
Tests for strength in tension
2. Flexural Strength Test
 P
P

A B X
y= d/2 d d y= d/2 d d
C ? /3 ? /3 ? /3 D
Y ?/2 ?/2
ℓ/2 Z
ℓ/3 ℓ/3 ℓ/3 ℓ/2
P/2 ? P/2
ℓ = 20*3= 60 cm P/2 ? P/2
ℓ

BM = P/2x ℓ/3 = Pℓ/6

BM = P/2x ℓ/3 = Pℓ/6 BM = BM
P/2x= ℓ/2
P/2x ℓ/2 = Pℓ/4
= Pℓ/4
M = f
MI = f y M =M f = f
I y I I y y
f = M*y
F= I F= f = M*y
I
= =(Pℓ/6
(Pℓ/6x xd/2)/
d/2)bd3/12 = (Pℓ/4= x(Pℓ/4
d/2)/xbd3/12
d/2)/
= Pℓ/bd2bd3/12 = 3/2Pℓ/bd2 bd3/12
= Pℓ/bd2 = 3/2[Pℓ/bd2]
Case 1 Fb = (Pℓ)/ (bd2) if a> 20cm for 15cm

25kn i.e 2.5 ton = 2500*60/15*15*15 = 4.44 MPa

= 10,000*450/350*30*30 = 1.5 MPa
Case 2:
Fb = (3PXa)/ (bd2) 17cm 20cm P
(For if a< 20cm ---17cm17cm-- ---20 cm---- ----------------

but > 17 cm ------------------- ℓ ------------------

for 15cm) --a---I I 20cm 20 cm
( a= 17-20cm)

Case 3: For if a< 17 cm for 15cm DISCARD

a= distance between line of fracture and nearest support,
on centre line of the tensile side of specimens
 Case 1 = Stress -10,000*450/350*30*30 = 14 kg/cm2
Case 2 = Stress - 10,000*350/450*30*30 = 9 kg/cm2
----------------------------------------------------------------------------

----------------------------------------------------------------------------

Wrong Right -----MORD 1501 p412

Direction of traffic
Length of panel in direction of traffic) shall not be
less than width of panel

57
 SLOPE COMPACTOR - Earth Work- Embankment
Embankments ( 95%)

Unsuitable Soil : OI, OL,OH, Pt, > 75 mm

LL >50%
PI >25
FSI > 50%

Density:
1.52gm/cc upto 3 m

58
 California Bearing Ratio Test
CBR - % of actual load causing penetrations
of 2.5 mm or 5.0 mm to standard loads.
– Load values on standard crushed stones:
– 1370 kg at 2.5 mm, 2055 kg at 5.0 mm
– Water Bound Macadam CBR 100 % - deflection
2.5 mm load of 1370 kg or 1.37 ton
– 5 mm for load of 2.055 ton on WBM
 Density

S.N Type of work Maximum laboratory dry

o. unit weight when tested
as per IS: 2720 (Part 8)

1. Embankments up to 3 Not less than 15.2 kN/cu.m

metres height, not subjected
to extensive flooding

2. Embankments exceeding 3 Not less than 16.0 kN/cu.m

metres height or
embankments of any height
subject to long periods of
inundation

3. Subgrade and earthen Not less than 17.5 kN/cu.m

shoulders/verges/backfill
 Sand Replacement

Rapid Moisture meter

Density Gauge Nuclear

ASTM =
ASTM 6938, 7759

Surface depth shall depth

61
Compaction - embankment and subgrade

S.No Type of Relative compaction as

. work/material percentage of max. laboratory
dry densiy as per IS: 2720
(Part 8)

1. Subgrade and earthen Not less than 97

shoulders

2. Embankment Not less than 95

3. Expansive clays

(a) Subgrade and Not allowed

500 mm
portion just
below the
Not less than 90
subgrade

(b) Remaining
portion of
embankment
 DURABILITY –
Adequate Strength, Minimum Corrosion, Minimum Air Voids

Consolidation Compaction Densification

Clayey soil Clayey/non-plastic Non plastic

Clayey-silty Concrete Filter media

Static load Mechanical Mechanical

Removal of Water Removal of air Addition of water

AVOID HONEY-COMBING (Honey bee house) 63

64
65
Lower sub base Upper sub base
Filter layer Drainage layer
Common

III - VI
100
100
75
60
30
20
6
4
2

66
67
68
 Construction of CC roads- IRC: 15

• IS : 1199 Fresh Concrete

• IS 516 Hardened Concrete

• IRC:SP:57; Quality Systems

• One Sample from 200 cu m

• Honey Combed Repair 1: 4 W/C = 0.4

 Materials other than agg
• Water (IS 456 ) Drinkable, pH 6-8

• Steel - IS:1786; Fe 500 Tie bars /

• Steel IS: 432; S 240, dowel bars

• Expansion board (IS 1838) at abutting Structure

• Fibre 0.2 -0.6% (IRC:SP:46)

 Aggregates IS: 383-2016
• Chloride content < 0.6%

• LAA < 35%

• Sulphate < 0.25

• MSA 31.5 mm for PQC

• 26.5 mm for DLC

• Water absorption < 3%

• Soundness < 12% with sodium

sulphate

• Silt Content in sand Sand < 3%

• Crusher dust < 15 %
• Blend < 8%
 Disadvantages hot weather
IS: 7861- Hot Weather, IS: 4926 RMC

• Accelerated Setting/Rapid evaporation

• Air content increased

• Reduction in strength ( 6% per 1 % void)

• Cracking
EFFECT OF CURING TEMPERATURE ON STRENGTH, IS: 7861
 REQUIREMENTS OF PURCHASER

• Variation +/- 10 mm for slump upto 75 mm

• Variation +/- 25 mm for > 75 mm

• Slump of concrete mix for pavements
compacted by vibration using paving trains

• 25 ± 10 mm

Flexural MPa vs Compressive in MPa =

fcr = 0.7 √(fck)

77
78
Finished
Road

• Tining (Texture depth ) 3mm Width

4 mm Depth
• Brooming (Texture depth ) 1.0+0.25 mm

• No undulation in form work

• Widening/transition Step/tied
• Density 97% in PQC
• Air < 3%
TWIN SHAFT MIXERS
PAN MIXERS MIXERS
WHY DLC M10:

1. Levelling Course/levelled platform

2. To move paver smoothly @ 1m/min
3. Sub base to take some load
4. To modify subgrade CBR indirectly

CROSS-SECTION
DEBONDING/SEPARATION MEMBRANE

LONGITIDINAL JOINT
TIE BAR
BASE (PQC)

tied shoulder
SUB-BASE (DLC)
DRAINAGE LAYER
Camber not Shown

SUB-GRADE

EMBANKMENT

FIGURE 1.4 - RIGID PAVEMENT TYPICAL CROSS-SECTION

Dowel bars across transverse Joints not shown for

clarity
 Slip Form Paver Wrtgen/
Meckstar/

Gomaco LAYING

CONMET BARODA/BRDC/Walia 84
AB Mumbai/Walia Delhi
Thank you
WHERE RCC ?:

1.Steep Terrain
2.L/B>1.5
3.Fill up Areas/ Marshy areas
4.Tool Plazas,
5.Acute angled/ Curved/super elevated
6.Better riding quality
7.High Temperature/Low RH/
8.High wind speed
 IS 1786-2008- Fe 500, 16 mm/ clause 1001.6.2.2 page 239
MORD
• Carbon Max 0.3%
• Sulpher Max 0.055
• Phosphorous Max 0.055
• Sulphur +Phorphorous Max 0.105

• Carbon Equivalent, C + Mn + Cr+ Mg+ V + Ni + Cu

(Morth 530p) IRC: 112 6 5 15
Guaranteed weldability, Carbon Equivalent, <
0.4% (For special grade Fe 415) page 239
MORD--- 2 times bar dia, away from bends
• Tensile Strength (8% More YS) > 545 Mpa
• Yield Strength > 500 Mpa
• % elongation 5.65 ( Area)1/2 12% minimum
• Mass / meter 1.580+/- 5%
89
90
91
92
• Construction Methodology- Mumbai 1988-
2004
CONSTRUCTION
DLC Construction
 Acceptance Criteria DLC MORTH
• Longitudinal joint staged by 350 mm

• Construction joint by about 900 mm

• Curing compound gets tackiness spread

hessian.

• 0.2 Litre /sq m

• Six cubes Minimum /day

• 100 m length trial in 2 days

97
• Insitu density 98% -601.6.5.1
 MORTH- DLC
• 3 samples /1000 sqm cubes -903.5.1.1

• Square plate 7500-14000 sq. mm compaction

• For 1 min 30-40 kg load. -903.5.1.1

• Thickness not less than 8 mm- 903.5.1.3

• Repaired with lean concrete 10 mm down

98
MORTH- DLC

99
PQC- Pavement Quality Concrete M 40
• 2 Cores /150 cum

• If core fails - panel is replaced.

• Age factor at 60 days 1.14 (Core st. /1.14)

• At 90 days 1.21

• Density 97% ( 3% air Voids) 903.5.2.3

100
Laying polythene sheet double at crack

Double
layer as
crack
arresting
layer
WHY POLYTHENE SHEET ? Slip Form Pavers of
width 15-16 m

1. Crack arresting layer as
no joints in DLC
Two layer
construction
Double ply paper
In Airfield 500 micron thick
Two coat wax based curing compou

2. Water Proof layer

3. Insulating layer

4. Reduce friction 103

104
 Take care- tipper shall not fall on paver
Take
care-
Slump
15-40
mm,
M 40
PQC
M 10 DLC
at 7 d

Take care- Alignment, location of Do-well bars/Tie

105 bar
Dowel bars insertion

106
Do not Stop Paver more than 30 minute to avoid cold joint/crack
PQC PAVING
PQC IN PROGRESS
Automatic Tie Bars Inserter Automatic Dowel Bars Inserter

Mechanical Broomer
 IS: 8142 Setting Time of Concrete
• Initial Setting Time - Elapsed time, after
initial contact of cement and water, required
for mortar (sieved from concrete ) to reach a
penetration resistance of
3.43 N/mm2 ( 35 kgf/cm2 ).
• = Load in kg/area of plunger
• Final Setting Time - Elapsed time, after
initial contact of cement and water, required
for mortar ( sieved from concrete ) to reach
a penetration resistance of
26.97 N/mm2 ( 275 kgf/cm2).
 Floating, Finishing
Mechanical Floating, Finishing

Texturing – Tinning App. Texturing by Tinning

Texturing by Brooming
WHY- Contraction Joint - 4.5 m

Drying Shrinkage = 0.06%

So for 100 mm = 0.06 mm

For 1 mm = 0.06/100 mm

= 0.0006 mm

so in 4.5 m or 4500 mm: = 0.0006mm*4500

= 2.7 mm

Required Contraction Joint width = ~3 mm

 Expansion Joint say 140 m?

Coefficient of Thermal Expansion, α

= 10*10-6 mm/mm/oC

in 1mm increase in length = 10*10-6 mm/oC

in 140000mm increase =140 000*10*10-6 mm/oC

for Temp gradient /oC = 1.4 mm /oC

So for ∆ t = 15oC change in India

Required Expansion Joint width 1.4 mm *15oC= ~ 20 mm
Joints Cutting, Filling - sealing
How to minimise cracks Over Dowel bars ?

• Tamping device should be attached to finishing

mould to achieve proper consolidation of
concrete around bars.

• In case of high slump when tamper device is

used, there is chance of moving dowel out of
position.

• Appropriate concrete slump,

• homogeneity of mix,
• Speed of the paver 1 m /min,
• Temperature 25-30 oC 117
 In continue
• Deposited concrete shall be struck off by means of the
strike off plate /metering gate or a screw auger.

• Spreading Plough extend across whole width of slab.

• Electrical vibrators operate at variable speed from 9000

to 12000 vpm.

• Suitable for paving concrete slump of 20-30 mm.

• Variable vibration setting across paving width shall be

provided in the machine
118
Single Paver- two lift paving

119
Two pavers- two lift paving

120
Tent Protection for Paved
surface

121
Or fck + o.825* Standard
Deviation which ever is greater

30.1 Fail
REBOUND HAMMER, IS:
13311, IRC: 112

TYPICAL CORELATION FOR N TYPE REBOUND HAMMER

123
Crack Depth Measurement using SURFER
In case of doubt -Concrete cores are cut :

Core 85% Av and Individual 75%

Rate of Loading 140 kg/sq cm/ minute

h/d ratio, n 1 1.4 1.8 2

Correction factor, f 0.89 0.93 0.98 1

f= 0.11 n +0.78, n=h/d

Equivalent cube strength = f X crushing strengthX1.25

Acceptable Minimum

Core strength = 85% of Charasteristic

Individual Core = 75% of Charasteristic

7/9/2018 Concrete Pavement -Design & 126

Applications.
As per IS 456

1. Load = full dead load +1.25 times the imposed load -24 hours

2. If in 24 hours of removal of load, structure does not recover

atleast 75% of the deflection under the imposed load

4. Repeated after a lapse of 72 hours, if recovery is <80%-

unacceptable

5. Deflection , mm < 40 ℓ2/D , ℓ - effective span m, D –overall depth in

mm, then it is not necessary to for recovery to be measured and
recovery provision shall not apply

6. Members other than flexural member – analysis

40*20 m*20 m/1000 mm = 16 mm

20 m length 1000 mm depth girder

 IRC:SP:83-2008 Maintenance of CC Roads

• BI less than 2200 mm/km in CC (Table 4.2 page 29)

• The maximum crack width shall be recorded as at
least 50% of length.
• Shallow cracks/shrinkage cracks donot need repair
p-31).
• Table rating 4.4 page 33: Max 2, but up to 3-DLP
acceptable, more than 3 ?
• Clause 4.6.4. FDR when: severity 5, crack 12
mm in 50% area, rocking (Page 33)
 Table 4.5 Severity
Distress Degree Assessment Depth of Depth of
of S. crack less crack more
than half the than half the
PQC Depth PQC Depth

Cracking 1 Width < 0.2 mm No action Not

applicable
2 0.2 -0.5 mm Seal without Seal and
delay stich
L > 1m
3 0.5-1.5 mm Seal without Seal and
delay stich
L > 1m
4 1.5 -3 mm Seal and Staple/retrofi
stich t dowel. FDR
L > 1m affected

5 > 3mm upto 12 Seal and Staple/retrofi

mm stich t dowel. FDR
 Table 4.5 Severity
Distress Degree Assessment Depth of Depth of
of S. crack less crack more
than half the than half the
PQC Depth PQC Depth

Transverse/d 1 Width < 0.2 mm Route & Seal Staple/retrofi

iagonal with epoxy t dowel.
Cracking 2 0.2 -0.5 mm Route & Seal Staple/retrofi
with epoxy t dowel.
3 0.5- 3 mm Route, seal ?
and stich
L > 1m

4 3-6 mm Dowel bar FDR

retrofit

5 > 3mm upto 12 ? FDR affected

mm
 Table 4.5 Severity
Distress Degree Assessment Depth of Depth of
of S. crack less crack more
than half the than half the
PQC Depth PQC Depth

Longitudinal 1 Width < 0.5 mm Seal with Staple/retrofi

Cracking epoxy L>1 m t dowel.
2 0.5 - 3 mm Route, Seal Staple/retrofi
& stich L>1 t dowel.
m
3 3-6 mm Staple L>1 m Partial depth
repair with
stapling
4 6-12 mm - Partial depth
repair with
stapling
5 > 12 mm - FDR affected
PLASTIC SHRINKAGE CRACKS
EP 10

Sika Dur 52

Y Shape Crack
Transverse Crack
Corner Crack
Crack less then 0.5 mm wide cumulative length < 1m
Crack less then 0.5 mm wide cumulative length more then 1m (Repaired)
Inadequate Joint Sealing
Drainage
Spacing
 Faulting of Edge- No load transfer
Mud pumping
Remedy- Diamond grinding

Pumping-expulsion water caused by action of repetitive-load.

Transverse Crack (with edge spall)

NEW
PARTIAL DEPTH REPAIR

EP 75
 Pot Hole Repair
i. with
Epoxy Mortar 1:
2

i.
i.
 For d < D /2 , as confirmed by Core Cutting. See Note 1
Chase 10mm groove along the
line of the crack and seal with Preliminary Vertical Hole
low viscosity epoxy resin
150

Plastic Shrinkage Crack

0 - Surface

36o
Governed by length of Drill Bit

d
110 mm

12 dia
High Yield Deformed Reinforcing bar
Epoxy Resin

350
PQC 400

Notes: '(All dimensions in mm)

1. This method of repair shall only be accepted where
discrete cracks are demonstrated by core cutting to be less

20 12
than 50% of thickness PQC and written approval is provided
by the Engineer.
WIDE CRACK REPA
2. Maximum spacing 500mm

3. EPOXY as per IRC:77 only. Polyester resins shall not be

330 - Bottom of PQC used

DLC

CROSS STICHING
Jabalapur L&T

141
142
143
144
145
 Load-Transfer
Restoration
• Placement of load
transfer devices
across joints or cracks
in an existing
pavement

 Provide reliable load transfer

 Reduce or eliminate pumping, faulting,
and corner breaks
OPERATION AND
MAINTENANCE

REPAIR OF JOINT AND ROUNDING EDGES

 TYRE BURSTING on High Speed Corridors

DOES DONOTS
• Do not have old tyre /Bald
• Speed max 100 km/h Tyre/ OLD TUBE

• Hardness of top surfac • Do not have – Very High or

low tyre pressure
• Good Tyre/tube quality
• Do not have sharp
• Specified tyre pressure edges/spots in
PQC/Wearing course
• Nitrogen
• Do not have poor repaired
• Never apply break quickly surface
 TYRE BURSTING
1. Flattening of tyres
2. Fill air and petrol early morning
3. Proper removal of welds
4. Round edges of expansion joints

Weld properly grind Sharp edges to be rounde

 Riding Quality of New Pavement

• IRC:SP 16 2004 BI= 630 (IRI)1.12

Roughness-

Function of faulting, spalling and cracking

> 2000 Av. <

2000 mm /km 3000 + 3000 mm
good /km Poor
 100 mm

100 mm

- 9mm - 6 mm 12mm
- 3 mm 0 mm + 3 mm + 6 mm + 9 mm
21 mm 18 mm 15mm 12mm 9 mm 6 mm 3 mm

12 mm
12 mm

3 meter straight Bump I.

100 mm 100 mm
Max. Irregularity allowed -3 m st. edge
• Longitudinally----

• Irregularity 4mm 7mm

• Length 300m 75 m 300m 75m

• NH 20 9 2 1

• RR 40 18 4 2
Texture Depth = M/D
Area FWD Evaluation
HARD TEXTURING IN PROCESS 3 mm TEXTURING/- Micro Milling
 Plastic Cracks Crow Foot or Y Corner Cracks
Junction
Cracks
Excessive excessive water Excessive load
Evaporation of unsupported
water corner

Spalling faulting Scaling

Locking Joints unstable base Loss –wearing C.
or undowelled

A
faulting B

Longitudinal Joint
C
L
Transv.
Transv. Joint
Joint

A B
Edge Cracks Longitudinal and Diagonal Cracks
Transverse Cracks
Over load cold joint, late joint Near abutment, poor
Settlement cutting compaction filter med
shoulder

Crazing Patching/pot holes Blowup

rich mixes, voids excessive expansion,
High moisture
FULL DEPTH REPAIR AWAITING CONCRETE
MUMBAI PUNE EXPRESSWAY _ OUR158
FIRST
EXPRESSWAY OF RIGID PAVEMENT 100 KM
 Choice and Economics
 Built up areas

 Poor Drainage

 Heavy rain fall & Flood Prone Area

 Water logging

 Aggregates are costly

 Poor soil condition

 Cost of flexible pavement - 25% less than RP

160
 Modulus of Subgrade Reaction ‘k’ value
k value =
Load, kg on 750 mm plate
(area cm2*0.125 cm)

kg/cm2/cm or MPa/m

Soaked
2 3 4 5 7 10 15 20 50
CBR
k Value
21 28 35 42 48 50 62 69 140
MPa/m
Radius of Contact area - wheel
P (Wheel Load) = 4.5 ton

p, tyre pressure, = 8 kg/sq cm = 4500/  a2

 a = √ (P/p ᴫ) = √ (4500/8 ᴫ) = √ [(4500*7/8 *22)]
a : radius of Single wheel load= 13.38 cm

Equivalent radius for dual wheel = 17.5 cm ( excel sheet )

 Radius of Relative Stiffness

P = Single wheel load = 45 kN or 4.5 tonne

h = Thickness of Pavement Quality Concrete (PQC)

 = Poisson’s ratio = Transverse strain/ Axial strain = 0.15

ℓ = Radius of relative stiffness in cm

¼
[ E xh3]
________________
12xk (1- 2)]
 Calculation of Radius of relative
¼
ℓ = Radius of relativeness , in cm [ E xh3]
[12xk (1- 2)]

3.75- 4.5 m

[3x105 x203] ¼
[12x4.2 (1- 0.152)] 3.75 m

ℓ= 83 cm
83.5 cm = or 0.835m = or 835 mm
 Conditions of Contract (40)
Load flexural = +

2 linear
 = (E x  x dt x C) Eq 22
tc

2
4( 1- µ )
Temp Stress non linear

Adjust Thickness sothat Load Stress + Temp Stress <FLEXURAL STRENGTH

< 4.2 MPa

 Determination of Bradbury coefficient

ℓ = 0.835 m L = 3.75 m, L/ ℓ = 3.75 m/0.835 = 4.5 and C =0.56

Charts for Determining C

L/ℓ or W /ℓ C value L/ℓ or W /ℓ C
value
1 0.0 6 0.92
4 0.44 7 1.03
6 0.92 8 1.07

If 4.5 m then 4.5/0.835, 5.4 , C = 0.776 166

 Edge Temperature linear Stress Punjab .UP

tc = (E x  x ∆tX C ) …. linear behaviour

= 3x100000x10-5x(13.1) x 0.56
2 1.1 MPa or 11 kg/sq

Residual 41.8 – 11 = 30.8 kg/cm2

167
 IRC:SP-62
 Axle loads be multiplied by LSF is 1.0.
 Computation of load stresses
1 - through charts
2 - user friendly computer
3 - empirical relation =

Edge Wheel Load Stress =

(0.803P/h2 )*[4 log10(ℓ/a)+ 0.666 (a/ℓ)-0.034]

Calculation of Edge Wheel Load Stress

Flexural St at 90 d = 3.8*1.1 = 4.18 MPa,  0.15

 te = (0.803P/h2 )*[4 log10(ℓ/a)+ 0.666 (a/ℓ)-0.034]

 = [0.803*4500/(20*20)]*[ 4*log (83.5/13.38) + 0.666 *( 13.38/83.5)-0.034]

 = [ 9.0337]*[ 4* log 6.2406 + 0.666*0.1602 - 0.034]

 = [ 9.0337] * [ 3.181 +0.1067 - 0.034] = 29.39 kg/cm2.

 =Load stresses =29.39 kg/cm2 at 9 t axle load

 Edge Wheel Load Stress + Temperature Stresses

29.39+ 11 = 40.39 kg/sq cm < 41.8 kg/cm2

So, 200 mm PQC is safe for - 9 ton axle load - case 2 (144 CVPD)
For case 3: Analysis through fatigue /no of repetition
Stress Ratio =

Flexural Stresses Due to load

Flexural Strength

= 29.39/42 = 0.70
Allowable Repetition From Stress Ratio
SR= 29.39/42 = 0.7 Nf = allowable
repetition
2.222
SR
log10 N f 
0.523
Log 10 Nf = 0.7 -2.222
0.523

Stress Ratio 0.5 0.6 0.7 0.8

Allowable 83,26,33,865 8,89,264 16,736 1,378
Repetition
 Stress ratio and allowable
repetition

• Stress Ratio 0.8 Allowable = 13 78

• Stress Ratio 0.7 = 16737
• Stress ratio 0.6 = 8 89 000
• Stress ratio 0.5 = 8326 lakhs

172
 Culverts
• Transverse, totally enclosed drain
under a road or railway.
• OR

• A water course enclosed

of size through which a man can pass
 IRC: SP 13 -
i) Culvert- slab length 1-6 m

ii) Small bridge -

- overall length between

inner faces of dirt walls 30 m ,

individual span < 10 m

iii) Minor bridge-length upto 60 m.

 IRC:SP:13-2014.
• Catchment area <1 sq km, a culvert
• Catchment a. > 1 km sq, small bridge

• Length of span =

1.5 times height

of abutment
or piers from the bottom of its
foundation to its

top in metre.
Vertical Clearance Table 12.1
Discharge in Cubic Minimum Vertical
meter / second (m3/s) clearance in mm
Upto 0.30 150
0.3 - 3.0 450
3.0 -30 600
30-300 900
300-3000 1200
> 3000 1500
 Application in India
• Chandikhole- Jagatpur Bhubneshwar Cuttack Orissa
-
NP 1 Un reinforced Drainage/irrigation

NP 2 Reinforced , Light duty Drainage/irrigation/CD/

Culverts

(0.07 Mpa 7 m head)

NP 3 UnRein./Reinforced, medium duty Drainage/irrigation/CD/Culverts

NP 4 UnRein./Reinforced, heavy duty Drainage/irrigation/CD/Culverts

PRESSURE and Non Pressure Pipe- Very Severe IS: 458

 LIFTING SYSTEM
Causeway:
Paved submersible structure which allows
flood to pass through and /or over it.
Atleast for two lanes

ASTM C-1504
Cleaning soil around Piles
One Pile can take load of about 200 Ton
9 Piles *200 Tonnes= 1800 Tonnes
One Segment max 60 Tonne
5 *2 segment 5*2* 80= 800 Tonnes
 1. Geotextiles in India – An Introduction
 Geosynthetics are planar products manufactured from polymeric or natural materials used with
soil, rock, or other geotechnical-related material as part of a project or system.

Product Categories

Geocomposit
Geotextiles Geogrids Geonets Geomembranes Geocells Others
es

Continuous Plastic Extruded Continuous Products Relatively • Geomats

sheets of filaments and polymer ribs sheets of manufacture thick, three- • Geo-clayliners
woven, tapes etc. set in net impermeable d using a dimensional • Geofoam
nonwoven, formed into a like fashion plastic and are combination networks • Geobags
knitted or very open, with small not textiles. of two or made of • Geotubes
stitch-bonded grid like apertures. Impermeable more strips of • Geopipes
fibres or yarns. configuration fabric acts as a geosynthetic polymeric • Erosion
The sheets are having larger barrier. s sheet. The Control
flexible and apertures. strips are Blankets(ECB)
permeable and joined • Turf
generally have together to Reinforcement
the appearance form Mats(TRM)
of a fabric. conjoint
cells.