pavement quality concrete (pqc)

7/24/2019 Pavement Quality Concrete (Pqc)

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BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITYCONCRETE (PQC)

PURPOSE:-

The purpose of this Quality Plan for Construction of Pavement

Quality Concrete (PQC) is to provide detailed Construction

Methodology, Materials used, Resources deployed.

SCOPE:-

The Scope of this Segmental Quality Plan/ Methodology shall covers

the construction of pavement quality concrete insertion of dowel

bars, tie bars in accordance with the requirement of Technical

Specifications and in conformity with the line, grades and cross

sections shown in drawings.

It covers the following activities:

Selection, Testing and Acceptance of all incorporated Materials forPQC.

Design of Mixes for PQC and Trials, Acceptance etc.

Details of Plant, Equipment / Machinery as required in execution of

PQC.

Batching, Mixing, Transporting, Placing, Finishing and Curing ofConcrete for PQC.

Mechanized Texturing and Curing operation for PQC.
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Joint Cutting and application of Joint Sealing compound as approved.

Quality Assurance and Control Checks during operation and post

concreting

DEFINITIONS:-

The words like contract, Contractors, Engineer (Synonymous to

Engineer's representative), Drawing, Employer, Government, Works,

Worksite used in this Quality Plan shall be considered to have themeaning as understood from the definitions pertaining Quality

Management System Developed for the Particular Project.

The following abbreviation shall have the meaning as set forth below:

MORT & H: Ministry of Roads Transport & Highways

NHAI: National Highways Authority of India

BIS: Bureau of Indian standards

QA: Quality Assurance

PQC: Pavement Quality Concrete

MTC: Manufacture's Test Certificate

ITP: Inspection Test Plan

CROSS REFERENCE:-
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This Segment Quality Plan should be read in conjunction with the

following documents:

ISO 9001 2000 Quality management system

Contractor Document / Technical Specifications

MoRTH/IS/ASTM /ACI Codes, where applicable

IRC: SP: 57-2000, Guideline on Quality system for roads.

RESPONSIBILITY:-

S.

NO

Activity Description

Performing

Checking/

Verifying

Approving

01 Preparation Quality Plan Section-incharge &

QC

Engineer

Works

Manager &

QC

Manager

Project

manager

02 Selection and Testing of

various materials for PQC,Mix Design & Trials etc

prior to start of activity

Section-in-

charge &QC

Engineer

Works

Manager &QC

Manager

Project

manger

03 Survey, setting out fixing

of string lines prior to startof PQC

Surveyor Section-in-

charge /Site

Engineer
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Engineer

04 PQC Paver deployment atvarious locations and

other logistics

management etc.

Section-in-charge /

Site

Engineer

WorksManager

Project

Manager

05 Batching & Mixing of

concrete as per approvedDesign mix

Batching

Plantin-charge

QC

Engineer /Lab

technician

06 Control of movement of

Paver and maintenance0checks / control during

operation

Paver

engineer/

Supervisor

Paver- in

charge

Project

MechanicalEngineer

for effective

control ofPaving

operation07 Transportation,

Placing, Compaction andfinishing of PQC layers,

Section-in-

charge /Site

Engineer

QC

Engineer /Lab

technician

Engineer

08 Texturing, curing JointCutting and Sealing

operations for PQC

Section-in-charge /

Site

Engineer

QCEngineer

/ Lab

technician

Engineer

09 Inspection & Testing ofPQC as per approved ITP

and maintaining allformats.

QCEngineer /

LabTechnician

QCManager /

QCEngineer

Engineer

PROCEDURE:-

The detailed Construction Methodology involved in execution of PQC

including Quality Assurance & Control etc. has been described in the

following sub-chapters.


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Survey and Setting out for PQC:

The following steps are involved in Setting out of string wire before lying

PQC:

Center line of Carriageway will be marked at every 50M intervals on

DLC surface by using Total station.

Approval of survey and setting will be ensured and survey check sheet

CGGC 34 17 01 is filled prior to commencement of the laying activity.

Material Required:

Cement:

Any of the following types of cement may be used with prior approval

of the Engineer:

(i) Ordinary Portland Cement IS: 269

(ii)

Portland Slag Cement IS: 455

(iii)

Portland Pozzolana Cement IS:1489

Cement to be used may preferably be obtained in bulk form. It shall be

stored in accordance with stipulations contained in Clause 1014 and shall
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be subjected to acceptance test prior to its immediate use.

.

Coarse Aggregate:

Aggregates to be used in the construction of PQCwill be Crushedaggregates .

The aggregate complying IS: 383 will be used.

Max Size of coarse aggregate 25mm as per MoRTH 601.2.3.2(Fourth Revision : August 2001).

Fine Aggregate:

Clean, natural sand from River Banas form location Triveni 20km

form Ladpura will be used. The material conforming IS: 383 is

ensured.

The fine aggregate shall consist of clean, natural sand or crushed

stone sand or a combination of the two and shall conform to IS: 383.

Fine aggregate shall be free from soft particles, clay, shale, loam,cemented particles, mica, organic and other foreign matter. The fine

aggregate shall comply with MoRTH 602.2.4.3.(Fourth Revision :
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August 2001).

(The grading limits for all in aggregates shall be per IS:383 for 20mm

nominal size Aggregate for Pavement Quality Concrete )

Sieve Designation

Percentage passing the Sieveby Weight

40 mm 100

20 mm 95100

4.75 mm 3050

600 micron 1035

150 micron 06

Water:

Water used for mixing and curing concrete conforming to IS:

456: 2000.

In case of PQC During hot weather, water for preparation of

concrete will be taken form water chilling plant.
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Admixtures:

Admixture conforming to IS: 6925 and IS: 9103 to improve

workability of concrete or extension of setting time to be done.

Storage of materials :

Aggregates:

Aggregate will be stock piled separately and sufficient distance will

be maintained from each fraction to avoid intermingling.

Storage space must be easy to inspection, removal and restorage

of materials.

Regular testing of aggregate stock pile will be exercised to ensure

required gradation control.

Cement

Bulk cement will be stored in bulk storage containers having

200MT capacity and the number of such bulkers will be sufficient

to cater to the requirement at site.

Water

Water will be tanks covered at top and cleaned at regular

intervals. The intake of pipe will be enclosed to exclude silt and
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other solid materials and there shall be a minimum depth of 0.60

m of water below the intake at all times.

Proportioning of concrete

Concrete Strength

The pavement concrete should be a class M-40 concrete with a

minimum 28 days compressive characteristic strength of 40 MPa

1. Characteristic flexural strength at 28 days = 4.5 MPa

2.

Target mean strength at 28 days = 5.80MPa

3.

Water cement ratio =0.45 Maximum

4.

Slump as per IS: 1199 =31+/-15 mm

Minimum flexural characteristic strength of 4.5 MPa.

The ration between the 7 & 28 days strengths of 4.5 Mpa.

For each batch

7days (avg.)

The average flexural strengths ( R7) =

28 days (avg.)

R7 to be determined for three decimal levels.
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(Flexural strength of any Six consecutive 7day test result) >4.50+1.65*s

S: Standard deviation of the group.

Workability:

The control of workability will be done by the slump test

Slump will be controlled so that mix is compacted and finished

without undue flow.

The exact slump required at plant and site will be exercised duringtrail patch.

Separation Membrane :

Two applications of approved wax-based white pigmentedcuring compound will be applied on DLC.

First coat will be applied immediately after DLC laying and

compaction and the other before start of PQC.

The process of application will be done using mechanical sprayer.

The other parameters will be meeting the additional specificationClause- A-12.

Preparation of base :

Any visible defects / cracks more than 10mm size to be required

by fine cement concrete mix.

Surface will be made clean of dirt or extraneous material and free

from damage before application compound.


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Joints:

The exact location and type of joint to be transferred at site as

mentioned in drawing.

Concrete Penetrometer and testing as per ASTM C 403 will be

used in monitoring setting of concrete / Maturity of concrete and

saw cutting period.

Initial saw cut of 3mm wide , 100mm depth in transverse and

longitudinal direction will be provided after initialset(approximately 6~8hrs).

Final saw cutting 10~12mm wide ,20~25mm depth will de

provided after 14days of curing at accommodate joint sealant.

The staggering of transverse joints with reference to the base will

be minimum 0.3m.

Transverse joints:

Contraction joints will be provided at every 4.5m interval except

where expansion joints are provided.

Transverse joints to be provided at the junction of the approach

slabs of bridged and the rigid pavement and special location e.g.

transition sections i.e. transition of flexible vs. rigid pavement.

Transverse joints will be straight within specified tolerances.

Expansion joints will be provided at the junction of the approach

slabs of Bridges and the rigid pavement.


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Contraction Joint:

Contraction joints will be as per the drawing given by NHAI

Expansion Joints:

Joint filler board for Expansion joint will be premoulded joint

filler as per MoRTH spec. 602.2.7

Premoulded joint filler conforming As per IS: 1838 or BS: 2630

Thickness of the joint = 20-25 mm

Tolerance limit will be within +/-1.5mm

It shall be 25 mm less in depth than the thickness of the slab

The filler for each joint shall be furnished in a single piece for the

full depth and width required for the joint.

Holes to accommodate dowel bars will be as accurately board or

punched to give a sliding till on the dowel bars.

Dowel bars for expansion joint will as per

Joints will be provided at the junctions of rigid and flexible

pavement with transition slab as per the drawings.

Where due to unavoidable conditions (for example:- joints at two

contract package) joint are to be provided, dowel bars are fixed

into the rigid pavement.

The adjacent slabs shall be completely separated from each other
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by filling joint filler board.

Transverse construction joint

Transverse construction joint shall be placed when concreting is

done after a day's work.

It will be provided at the regular location of contraction joints using

dowel bars.

The joint will be made butt type.

Longitudinal joints

Tie bars shall be provided at the longitudinal joints as per the

drawing given by NHAI.

Dowel bars

These shall confirm to the requirements of IS: 432, IS: 1139 and

IS: 1786 as relevant. The dowel bars shall confirm to Grade S 240

and tie bars to Grade S 415 of I.S.

It should be mild steel round, free from dirt, loose rust, scale

straight and burring restricting slippage in the concrete.

The dowel bars will be supported on cradles / dowel chairs in

prefabricated joint.

Dowel bars will be positioned at the mid depth of the slab with in a

tolerance of + 20mm.
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Dowel bars shall be covered by a thin plastic sheath for at least

2/3 of length from one end for dowel bars in Contraction joint or

half the length plus 50mm for expansion joints.

The sheath shall se tough, durable and of an average thickness

not less 1.25mm

The dowel bars will be inserted by vibration method in the plastic

concrete.

For Expansion joints, a closely fitting cap 100mm long cotton

waste placed over sheathened end of each dowel bar.

Tie bars

Free form oil, dirt, loose rust and scale.

In longitudinal joints shall be deformed steel bars of strength 415

MPa complying with IS: 1786.

It should protect from corrosion for 75mm on each side of the joint

by applying bituminous paint.

The coating shall be dry when the Tie Bars are used.

It should be perpendicular to the line of the joint, with the center of

each bar on the intended line of the joint within a tolerance

of +50mm and with a minimum cover of 30 mm below joint

groove.

Weather and Seasonal Limitations:

Concreting during monsoon months:


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Sufficient supply of tarpaulin or other waterproof cloth will be

provided along the line of work.

Any concrete damaged by rain will be removed and replaced.

If the damage is limited to texture it will be retextured.

Concreting in Hot Weather:

Care will be taken in reducing temperature of concrete such as

use of

Chilled water, sprinkling of chilled water over aggregates.

Guide wires

Use of guidewires

Each guidewire shall be at a constant height above and parallel to

the required edges of the slab as described in the contract /

drawing within a vertical tolerance of + 3 mm.

The guidewires shall be supported and stakes preferably not more

then 8 m apart by connectors capable of fine horizontal and

vertical adjustment.

The stack shall be positioned and the connectors maintained at

their correct height and alignment before commencement of work.

The guidewire shall be erected and tensioned for at least 2 hours

before concreting that section.
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Care will be taken to avoid any disturbance to the guidewire

during paving by any construction equipment or any other means.

CONSTRUCTION:-

10.1 Concrete production, transportation, Paving, Texturingand Curing:-

A batching plant of 120cum per Hr. capacity has to use for

Production of Concrete

Dumpers having hydraulic jack system to unload having capacity

35 Mt (Approx. 9 cum) concrete will be deploy for transportation of

concrete.

Paving will be carried out in full carriageway width of 8.5 m length.

The Paver used will be slip from Paver.

The slip from-paving machine shall compact the concrete by

internal vibration and shape it between the side forms with a

conforming plate and oscillating finishing beams.

The final finish of the surface will be done by super smoother

attached to the rear portion of the Paver.

Manson Trolley will be placed in between Paver and Texturing

and Curing Mechine (TCM) for rectification of any surface defects.

The alignment of the Paver shall be controlled automatically from

the guide wire by 4 set of level sensors and 2 set of steering


17/28

sensors attached to the Paver.

Planning and preparation will be done to pave at least at an

average uniform speed of one m / min.

The surface of concrete slab will Tine-textured in a direction

parallel to the longitudinal axis of the carriageway.

Texturing / Tining will be done with a specified machine specially

designed for the purpose for providing grooves at a uniform

spacing of 18 mm to 21mm.

Depth = 3mm to 4mm

Width = 3mm

Curing of PQC using curing compound will be followed by

texturing by the same TCM.

Curing will be taken care at the edges also.

The curing compound will be resin based aluminized reflective

curing compound.

After providing initial cut entire PQC will be covered with Hessian

cloth and water turned for 14 days.

Trail length:

The Trial length will be constructed at least one month advance

before starting of concrete paving work.

Trial length of 60mm with same width, Depth etc as per

permanent work will be done at nearer to site.

Transverse joints and longitudinal joint of each type that are to be

included in the pavement work will be constructed and assessed
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18/28

in the Trial length.

Density:

At least 3 cores drilled when the concrete is not less than 7 days

old.

11.2 Strength:

Minimum of thirty (30) beams for flexural strength and thirty cubes

for compressive strength will be prepared form the concrete

delivered to the paving plant.

Each pair of beams and cubes will be representing a different

batce of concrete.

Compressive and flexural strength will be after 28 days curing.

At the age of 28 days thirty cores with diameter 150 mmshould be

saw cut from the slab.

The cores will be saw cut in both ends to provide a specimen

height of 300 mm +/-15mm.

The mix will be designed to achieve

The average flexural strength >4.5

+1.65*s(Mpa)

[s=standard

deviation]

Strength of any sample >fck1.65 s

The average compressive strength of the

cores0.8/ (Average compressive strength


19/28

of the thirty cubes.)

Temperature Measurement:

The temperature development in the concrete slab should be

recorded after every 3 hours during hardening after installment of

the thermometer & temperature-age relationship should be

determined.

It should be measured in the middle of the slab (vertically) at a

horizontal distance of at least 1000 mm from any free end.

The temperature should not exceed 70 degree C.

Inspection Dowel Bars:

Alignment of dowel bars and construction joint shall be checked

by measurement relative to guide wires.

The position of dowel bars, filler board will be measured after

carefully exposing plastic concrete across the whole width of

concrete.

Preparation of joint and sealing of joint grooves:

Transverse Joint shall not be sealed before 14 days after

construction

Joint grooves will be constructed to an additional depth / width as

mentioned in drawing.

The groove shall be cleaned and dried at the time of priming and

sealing
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20/28

All grooves shall be cleaned of any dirt or loose material by air

blasting with filtered, oil-free compressed air.

Before sealing the temporary seal provide for blocking the ingress

of dirt, soil etc., shall be removed.

A height compressible heat resistant paper-backed debonding

strip as per drawing shall be inserted in the groove.

In the case of longitudinal joints, heat resistant tapes may be

inserted to block the leakage though bottom of the joint.

Sealing with sealants:-

The primer recommended by the manufacturer should be applied

for sealants.

Priming and sealing with applied sealants should not be carried

out when temperature in the joint groove to be sealed is below 7deg C.

If hot applied elastomeric type sealant complying AASHTO M282

is used it shall be heated and applied from a thermostatically

controlled, indirectly heated preferably with oil jacketed melter and

pourer having recirculation pump and extruder (This is applied at

junction of Asphalt and concrete pavements.

Cold applied polyeurethrene / Polysulphide type complying BS:

5212-1990Sealan will be mixed and applied according to the time

limit specified the Manufacture to the concrete pavements.

Primer will be applied with an appropriate brush.

Care such as temperature and time of sealing will be emphasized

to avoid any bulge of sealant during contraction of joint.

Sealant shall be applied slightly to a lower level than the slab with
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21/28

a tolerance of 5+ 2mm.

The type and details of different joints treatment are tabulated

below:-

TYPE OF

JOINT

JOINT

DETAILS & TREATMENT

Polysulphide

Sealant(cold)

Debonding

Strip

3~4

Mm

Groove

Soft

Rope

Butt

Joint

Compressible

Filler Board

Longitudinal

Expansion

Construction

Contraction

Testing of applied Sealant:-

Joint sealant compound and primer should be tested in:


22/28

Cold applied Polysulphide sealant (according to BS: 5212 Part 2)

In case if deliveries are made more frequent than testing may be

reduced to every three months.

Measurement of texture depthSand Patch Method

The apparatus as mentioned in MoRTH601.12.1 will be used to

measure the texture depth.

The surface texture will be measured as per the method laid down

in MoRTH601.12.1 and the same is recorded in lab format.

Opening to Traffic:-

No vehicular traffic including contractor's vehicles will be allowed

on the finished surface until a field flexural strength of minimum

4.50 MPa has been achieved where average flexural strength of

minimum 3 specimens should exceed 4.50+1.65 s(s=standard

deviation).

Each series of test specimens for measurement of flexural

strength should consists of minimum 3 test specimens.

Prior to opening to traffic the joints should be sealed and areas

adjacent to the pavement should be completed to a degree that

will ensure traffic safety.

Quality Assurance and Control Checks


23/28

As part of Quality Assurance this Segment Quality Plan for PQC

has been prepared in line with the specification provided in

relevant MoRTH clauses, Contract Supplementary Technical

Specification and other Codes/ Standard / Specifications etc. else

where mentioned in this Plan.

As a part of Quality Control all the Inspection and Testing

requirements for various activities involved in laying of PQC will

be carried out as per relevant MoRTH Specifications & Contract

Technical Specification atc. As described in Inspection and Test

Plans attached to this Segment Quality Plan for PQC.

These Inspection and Test Plans shall consist of type of

Inspection and name of the Test to be conducted for Product

Realization, frequency of testing acceptance criteria and category

of Inspection.

Inspection and Test Plans should be revised whenever there any

change in methodology and specifications etc.

Nonconformities in PQC:-

Any Non-Conformity observed during field Inspection and also

during Testing of Materials / mixes / laying system etc. the sameshould be recorded in the specified Nonconformance Report and

necessary Corrective / Preventive actions should be initiated to

prevent such things in future.

QA/QC Engineers are responsible to control the Nonconforming

products as described in Procedure, and relevant section-in-

charge site engineers are to take appropriate corrective

/preventive actions.


24/28

All Product Non-Conformities shall be observed, recorded,

corrective/preventive actions and closing of NCR's should be as

per the established documented procedure described in Project

Quality Plan.

Safety & Environmental Requirements:

Hazard Identification, Risk assessment and Risk control measures

for each activities and sub-activities involved in the present

Segment shall be identified and necessary action plan shall be

initiated.

Environmental Aspects and Impacts associated with various

activities and sub-activities involved in the present segment and

their mitigation/control measures shall be identified and necessary

measures shall be initiated.

SEQUENTIAL OPERATION OF PQC LAYING

DLC layer Approval

Site cleaning, Application of 2ndcoat of curing

compound as a separation membrane

Survey, Setting out ,fixing of String line
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25/28

Transportation of Mix to Site

Placing Paver and TCM

Clearance to B/Plant for Production ofconcrete after checking string line &

Equipment.

Production of concrete as per the Mix design

and adjust as per the requirement

YES
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26/28

Dumping concrete at regular spacing in front of

r and start paving


NO

YES

Monitoring levels through level sensors.

Check the mix as per therequirement i.e. Slump,Temperature, Air content

etc and meets as per design ?

Reject the Mix and find out Root Cause
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27/28

Fixing of Dowel bars and tie bars by DBI & TBI

as per Drawing

Rectification of surface defects (if any) manuallyby Mesons.

Texturing & curing by TCM and Test rate of

spraying.

Fixing of Stopper after End of day's Work.

Initial Joint cutting after setting of concrete

Cleaning of joint and fixing backup rod.


Covering PQC with hesian cloth and water

curing for min.14 days.

Removal of hesian cloth and final joint cutting

Cleaning of joint and providing soft rope,debonding strip, polysulphide sealant,

compressible filler board , butt joint asmentioned in Table-2 in PQC methodology

Test texture depth by Sand Patch Method
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28/28

Proceed for the next activity
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pavement quality concrete (pqc)

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