Satander Kumar QC Rigid Pavement

Quality Control in Construction of Rigid Pavements
Satander Kumar, Scientist (retd) CRRI, New Delhi
satander50@yahoo.co.in
Embankment and Subgrade Material
· (Clay having LL exceeding 50 and PI exceeding 25 )
Granular Sub-base (GSB)
(The plasticity index of material passing 425  sieve shall be less

than 6 Liquid limit less than 25 per cent. )
Dry Lean Concrete (DLC) as Base/sub base Course
(M-10 Grade concrete and distinctly superior load dispersion

Specifications are given in IRC: SP 49-2013.)
MUMBAI PUNE EXPRESSWAY _ OUR FIRST
EXPRESSWAY OF RIGID PAVEMENT 100 KM
First Mechanised Road NH -2, h= 300 mm
Manual 1948
IInd Mechanised RoadPrice

Yamuna
Rs 1 Expressway,
h= 320 mm
Slip Form Pavers of
width 15-16 m
Two layer construction

Double ply paper
In Airfield 500 micron thick
Two coat wax based curing compound
NEED OF POLYTHENE SHEET
1. Crack arresting layer as

no joints in DLC
2. Water Proof layer
3, Insulating layer
4. To reduce friction
10
16 MTRS PAVING IN A SINGLE PASS AT TAJ EXPRESSWAY
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
12
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
14
Compaction - embankment and subgrade
S.No. Type of work/material Relative compaction as

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
subgrade
Not less than 90
(b) Remaining
portion of
embankment
Quality control tests and their frequencies
Sl.No Test Relevant Frequency of

code test
1. Deleterious content IS:2720 : Min 2 tests per
Part - 27 borrow area
2. Natural Moisture IS:2720 : 1 test / 250 m3
content Part - 2
3. Gradation IS:2720 : 2 tests / 3000 m3
Part - 4
4 Plasticity Index IS:2720 : 2 tests / 3000 m3
Part - 5
5. Compaction tests IS:2720 : 2 tests / 3000 m3
Part - 8
6. C.B.R IS:2720 : 1 test / 3000 m3
Part - 16
7. FField density IS:2720 :
(a) Embankment Part – 28 1 test / 1000 m2
(b) Subgrade/shoulde 1 test / 500 m2
rs IS:2720:
Part - 29
Field Test By: DCP & Geoguage
17
Clause 601- DLC PQC
• Sieve mm % Passing %
Passing
31.5 100 100
26.6 100 85-95
19 80-100 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

• Strength 10 Mpa at 7 days
Transportation
 Every truck is numbered
 It is washed with jet of water before loading NGT
 It is moved back and forth while loading
 It is covered with Tarpaulin on journey.
 If transit mixer, covered with wet jute cover
QUALITY CONTROL
• IS : 1199 Fresh Concrete
• IS 516 Hardened Concrete
• One Sample from 200 cu m
• Honey Combed Repair 1: 4 W/C = 0.4
• Core 85% Av and Individual 75%

Principal Controlling Factors-strength
“W/C ratio is inversely proportion to

strength” for more than 0.27 W/C ratio
Logic 1 kg cement needed for 1 kg/cm2 CS

W/C 0.36 to 0.38 for M 44 averge
1
strength = k -----
W/C ratio
Loose 100 cum = Compacted 87% in CC
In Bitumen 100 loose = 80 % compacted
Materials other than agg
• OPC (IS 8112/IS:12269) 360 - 425 kg/cum
• PPC (Flyash; IS 3812 upto 20%) OPC > 340, PPC > 425
• PSC ( Slag IS 12089, upto 50%) OPC > 255, PSC < 255
• Admixture ( IS 9103, upto 2%)
• Silica Fume (IS 15388 upto 10%)
• Any strength of cement more than 15 Mpa is rejected

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%
• Avoid Zone IV sand

• BATCHING PLANT
• Variation allowed
• Cement +/- 2%
• Aggregate +/- 3%
• Water +/- 3%
• Admixture +/- 3%
• Flexural vs Compessive
fcr = 0.7 √(fck)

REQUIREMENTS OF PURCHASER
• Variation +/- 10 mm for slump upto 75 mm
• Variation +/- 25 mm for > 75 mm
• Cement 95%,
• Agg = 95%
• Ratio of Coarse/fine agg < 10%

• Slump of concrete mix for pavements
compacted by vibration using paving trains
• 25 ± 10 mm
• Manual construction using needle vibrators

for compaction, the slump -
• 40±10 mm.
DESIGN OF TIE AND DOWEL BARS
Design of Tie bars (deformed) (in cm) When W > 5m)
Slab Thickness, dia Max spacing, Mini. Length

20 10 62 56
25 12 72 64
30 12 60 64
Bond Stress 17.5kg/sq cm- plain , 24.6 kg/sq cm-deformed
Design of Dowel bars (deformed)

Slab Thickness, dia Length Spacing
20 25 45 30
25 32 45 30
30 38 50 30
Construction Photos on NHDP
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%
Max. Irregularity allowed -3 m st. edge
Once a day
• Longitudinally----
• Irregularity 4mm 7mm

• Length 300m 75 m 300m 75m
• NH 20 9 2 1
• RR 40 18 4 2
• Transversally----
• Cement Concrete 3 mm
• Bituminous 6 mm
• GSB 8 mm
• DLC/WBM 10 mm
Riding Quality of New Pavement
• Maximum irregularity soon after initial curing < 3

mm
• Bumpintegrator (BI) values < 2250 mm/km (3 IRI)
• No difference in level is permitted across the joints
• IRC:SP 16 2004 BI= 630 (IRI)1.12

Av. < 2000mm
902.6 + 3000 mm
/km Poor
Un-evenness TEST
REQUIREMENTS
• Horizontal Alignment = +/- 10 mm
• Subgrade +20 to –25 mm
• Sub-base (DLC) +6 to –10 mm
• Cement Concrete + 5 mm to – 6* mm
* this may not exceed –8 mm at 0-30 cm from
edges.
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
• Transversally----
• Cement Concrete 3 mm
• Bituminous 6 mm
• GSB 8 mm
• DLC/WBM 10 mm
HOW TO RECTIFY
• 902.5 MORTH,DLC:-
• Defective area minimum 3 m X1m,

replaced with new or repaired with
concrete with agg 10 mm
• PQC (Pavement Quality Concrete)-
• + 3-6mm Cutting, retexturing- 5 mm

deep
903.2 MORTH
Frequency
• Borrow soil
Sand con., PI, Density- 2 test /3000 cu.m
Moisture 1test/ 250 cum
CBR 1test / 3000cum
• GSB
• Gradation, PI, LL,PI, moisture content ---- 1
test/250 cum
Density 1 test/ 500 cum
CBR as required
903.2/0.4 MORTH, Frequency
• Granular
– AIV- 1 test /3000 cum, Gradation 1test/ 100 cum
– FI/EI 1test / 200cum
• PQC 903.5.2.4 MORTH
• Joints 1test/400m
• Surface unevenness Once a day IRC:SP 16 , 1 test /km
• Texture Depth Once a day ---- 2.5 mm- 4.5 mm Tines, broom 0.65 mm
• Cement – Once for each source
• Agg- Gradation once a day
• Water absorption 2 tests / day
• LAA/AIV/soundness- once / source
• CS/FS 3 cube, 3 beam / 150 cum or 6 cube/6 beams/day
• Core – 2 core/150 cum
• Workabiliy 1 test / dumper
DLC – Density 3/ 2km Void < 3%,, not more than -5 mm, +10 mm 903.5.2.3
CS = 3 sample /1000 sq m, 2 cores / 150 cum
Clause 601- DLC Gradation
• Sieve mm % Passing
26.6 100
19 80-100
9.5 55-75
4.75 35-60
600 micron 10-35
75 micron 0-8
• Water Absorption < 2%

• Cement > 150 kg/cum
• Strength 10 MPa
Joints in PQC
• Contraction Joints/ transverse joint
3 –5 m 3- 5 mm wide
1/3 to ¼ th depth PQC
Construction - At end of days
Joints work – Butt
Expansion Joint – Full Depth 20mm
wide dowelled
Warping Joints- Corner/ edge
Textute Depth 1mm +/- 0.25
Construction Joint Cutting NHDP Water leakage
Through Joint.
Crack must come below cut in 28-60 days
TYRE BURSTING on High Speed Corridors
DOES DONOTS
• Speed max 100 km/h • Do not have old tyre /Bald
Tyre/ OLD TUBE
• When road surface • Do not have -High tyre

temperature < 350C pressure
• Hardness of top surafce • Do not have sharp

edges/spots in PQC/Wearing
course
• Good Tyre/tube quality
/toughness because of • Do not have poor repaired
flattening of tyres surface

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Quality Control in Construction of Rigid Pavements

Satander Kumar, Scientist (retd) CRRI, New Delhi

· (Clay having LL exceeding 50 and PI exceeding 25 )

Granular Sub-base (GSB)

(The plasticity index of material passing 425  sieve shall be less

Dry Lean Concrete (DLC) as Base/sub base Course

(M-10 Grade concrete and distinctly superior load dispersion

First Mechanised Road NH -2, h= 300 mm

IInd Mechanised RoadPrice

Two layer construction

NEED OF POLYTHENE SHEET

1. Crack arresting layer as

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

S.N Type of work Maximum laboratory dry

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

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

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

S.No. Type of work/material Relative compaction as

1. Subgrade and earthen Not less than 97

2. Embankment Not less than 95

(a) Subgrade and Not allowed

Sl.No Test Relevant Frequency of

• Cement > 150 kg/cum

• IS 516 Hardened Concrete

• One Sample from 200 cu m

• Honey Combed Repair 1: 4 W/C = 0.4

• Core 85% Av and Individual 75%

“W/C ratio is inversely proportion to

Logic 1 kg cement needed for 1 kg/cm2 CS

• Admixture ( IS 9103, upto 2%)

• Silica Fume (IS 15388 upto 10%)

• Any strength of cement more than 15 Mpa is rejected

• 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)

• LAA < 35%

• Sulphate < 0.25

• MSA 31.5 mm for PQC

• Water absorption < 3%

• Soundness < 12% with sodium sulphate

• Silt Content in sand Sand < 3%

• Avoid Zone IV sand

fcr = 0.7 √(fck)

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

• Variation +/- 25 mm for > 75 mm

• Ratio of Coarse/fine agg < 10%

• Manual construction using needle vibrators

Design of Tie bars (deformed) (in cm) When W > 5m)

Slab Thickness, dia Max spacing, Mini. Length

Bond Stress 17.5kg/sq cm- plain , 24.6 kg/sq cm-deformed

Design of Dowel bars (deformed)

• Tining (Texture depth ) 3mm Width

• No undulation in form work

• Irregularity 4mm 7mm

• Maximum irregularity soon after initial curing < 3

• Bumpintegrator (BI) values < 2250 mm/km (3 IRI)

• No difference in level is permitted across the joints

• IRC:SP 16 2004 BI= 630 (IRI)1.12