BRIEF AND DETAILED SPECIFICATIONS OF

PAVEMENT QUALITY CONCRETE (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 for PQC.
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 of
Concrete for PQC.
Mechanized Texturing and Curing operation for PQC.
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 the meaning as understood from
the definitions pertaining Quality Management System Developed for the
Particular Project.

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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: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.

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

RESPONSIBILITY:-

Activity Description

Performing

Checking/

S.

Verifying

Approvi
ng

N
O

01

Preparation Quality Plan

Section-in charge &

Works

Project

QC Engineer

Manager &

manager

QC Manager
02

Selection and Testing of various Section-in- charge & QC Works

Project
materials for PQC, Mix Design Engineer
Manager & manger
& Trials etc prior to start of
QC Manager
activity

03

Survey, setting out fixing of Surveyor

string lines prior to start of PQC

04

PQC Paver deployment at Section-in-charge / Site Works

various locations and other Engineer
Manager
logistics management etc.

05

Batching & Mixing of concrete Batching

as per approved Design mix
charge

Section-inEngineer
charge / Site
Engineer

Plant

in- QC Engineer /
Lab
technician

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

Project
Manager

Paver- in Project
Mechani
charge
cal
Engineer
for
effective
control
of
Paving
operation

06

Control of movement of Paver Paver engineer

and maintenance 0checks / Supervisor
control during operation

07

Transportation,
Placing,
Compaction
finishing of PQC layers,

08

Texturing, curing Joint Cutting Section-in-charge / Site QC Engineer

and Sealing operations for PQC Engineer
/
Lab Engineer
technician

09

Inspection & Testing of PQC as QC Engineer

per
approved
ITP
and Technician
maintaining all formats.

Section-in- charge / Site QC Engineer /

and Engineer
Lab
Engineer
technician

Lab QC Manager /
QC Engineer Engineer

PROCEDURE:The detailed Construction Methodology involved in execution of PQC

including Quality Assurance & Control etc. has been described in the
following sub-chapters.
Survey and Setting out for PQC:
The following steps are involved in Setting out of string wire before lying
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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 be
subjected to acceptance test prior to its immediate use.
Coarse Aggregate:
Aggregates to be used in the construction of PQC will be Crushed
aggregates .
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
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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 : 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 Sieve by

Weight

40 mm

100

20 mm

95 100

4.75 mm

30 50

600 micron

10 35

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.
Admixtures:

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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 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
2. Target mean strength at 28 days

= 4.5 MPa
= 5.80MPa

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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.

(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 during
trail patch.
Separation Membrane :
Two applications of approved wax-based white pigmented curing
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.

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

The other parameters will be meeting the additional specification

Clause- 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.
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 initial set(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.

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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 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.
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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.
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.
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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:
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.
Care will be taken to avoid any disturbance to the guidewire during
paving by any construction equipment or any other means.
CONSTRUCTION:-

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

10.1 Concrete production, transportation, Paving, Texturing and

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 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

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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 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 batch of
concrete.
Compressive and flexural strength will be after 28 days curing.
At the age of 28 days thirty cores with diameter 150 mm should 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
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

 The average flexural strength >4.5 +1.65*s(Mpa)

[s=standard
deviation]

Strength of any sample >fck +1.65 s

The average compressive strength of the
cores 0.8/ (Average compressive strength 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
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.
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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 7 deg 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: 52121990Sealan 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 a
tolerance of 5+ 2mm.

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

The type and details of different joints treatment are tabulated below:-

TYPE
JOINT

OF JOINT
DETAILS & TREATMENT

Polysulphide Debondin
g
Sealant(cold
)
Strip

3~4

Soft

Butt Compressible

Mm

Rop
e

Join
t

Groove

Filler Board

Longitudinal
Expansion
Construction
Contraction

Testing of applied Sealant:Joint sealant compound and primer should be tested in:
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 depth & Sand Patch Method
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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:
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.
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

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 same should be
recorded in the specified Non-conformance 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.
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 2nd coat of curing

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

compound as a separation membrane

Survey, Setting out ,fixing of String line

Placing Paver and TCM

Clearance to B/Plant for Production of concrete

after checking string line & Equipment.

Production of concrete as per the Mix design and

adjust as per the requirement

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

Transportation of Mix to Site

YES

SEQUENTIAL OPERATION OF PQC LAYING

Reject the Mix and

find out Root Cause

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

Check the mix as per the requirement

i.e. Slump,
Temperature, Air
content
etc and meets as per design ?

NO

YES

Dumping concrete at regular spacing in front of

Paver and start paving

Monitoring levels through level sensors.

Fixing of Dowel bars and tie bars by DBI & TBI

as per Drawing

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

Rectification of surface defects (if any) manually by

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.

SEQUENTIAL OPERATION OF PQC LAYING

Covering PQC with hesian cloth and water curing

for min.14 days.
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)

Removal of hesian cloth and final joint cutting

Cleaning of joint and providing soft rope,

debonding
strip,
polysulphide
sealant,
compressible filler board , butt joint as mentioned
in Table-2 in PQC methodology

Test texture depth by Sand Patch Method

Proceed for the next activity

BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (PQC)