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CONCRETE(PQC)
PURPOSE:
ThepurposeofthisQualityPlanforConstructionofPavement
QualityConcrete(PQC)istoprovidedetailedConstruction
Methodology,Materialsused,Resourcesdeployed.
SCOPE:
TheScopeofthisSegmentalQualityPlan/Methodologyshallcovers
theconstructionofpavementqualityconcreteinsertionofdowel
bars,tiebarsinaccordancewiththerequirementofTechnical
Specificationsandinconformitywiththeline,gradesandcross
sectionsshownindrawings.
Itcoversthefollowingactivities:
Selection,TestingandAcceptanceofallincorporatedMaterialsfor
PQC.
DesignofMixesforPQCandTrials,Acceptanceetc.
DetailsofPlant,Equipment/Machineryasrequiredinexecutionof
PQC.
Batching,Mixing,Transporting,Placing,FinishingandCuringof
ConcreteforPQC.
MechanizedTexturingandCuringoperationforPQC.
JointCuttingandapplicationofJointSealingcompoundasapproved.
QualityAssuranceandControlChecksduringoperationandpost
concreting
DEFINITIONS:
Thewordslikecontract,Contractors,Engineer(Synonymousto
Engineer'srepresentative),Drawing,Employer,Government,Works,
WorksiteusedinthisQualityPlanshallbeconsideredtohavethe
meaningasunderstoodfromthedefinitionspertainingQuality
ManagementSystemDevelopedfortheParticularProject.
Thefollowingabbreviationshallhavethemeaningassetforthbelow:
MORT&H:MinistryofRoadsTransport&Highways
NHAI:NationalHighwaysAuthorityofIndia
BIS:BureauofIndianstandards
QA:QualityAssurance
PQC:PavementQualityConcrete
MTC:Manufacture'sTestCertificate
ITP:InspectionTestPlan
CROSSREFERENCE:
ThisSegmentQualityPlanshouldbereadinconjunctionwiththe
followingdocuments:
ISO90012000Qualitymanagementsystem
ContractorDocument/TechnicalSpecifications
MoRTH/IS/ASTM/ACICodes,whereapplicable
IRC:SP:572000,GuidelineonQualitysystemforroads.
RESPONSIBILITY:
ActivityDescription
S.
NO
01
02
03
PreparationQualityPlan
Performing
Checking/
Approving
Verifying
Sectionin Works
charge&
Manager&
QC
QC
Engineer
Manager
SelectionandTestingof
Sectionin
Works
variousmaterialsforPQC, charge&
Manager&
MixDesign&Trialsetc
QC
QC
priortostartofactivity
Engineer
Manager
Survey,settingoutfixing
Surveyor
Sectionin
ofstringlinespriortostart
charge/
ofPQC
Site
Project
manager
Project
manger
Engineer
04
PQCPaverdeploymentat
variouslocationsand
otherlogistics
managementetc.
Batching&Mixingof
concreteasperapproved
Designmix
Sectionin
charge/
Site
Engineer
Batching
Plantin
charge
06
Controlofmovementof
Paverandmaintenance
0checks/controlduring
operation
Paver
engineer
/
Supervisor
07
Transportation, Sectionin
Placing,Compactionand
charge/
finishingofPQClayers,
Site
Engineer
Texturing,curingJoint
Sectionin
CuttingandSealing
charge/
operationsforPQC
Site
Engineer
Inspection&Testingof
QC
PQCasperapprovedITP Engineer/
andmaintainingall
Lab
formats.
Technician
05
08
09
Engineer
Works
Manager
QC
Engineer/
Lab
technician
Paverin
charge
QC
Engineer/
Lab
technician
QC
Engineer
/Lab
technician
QC
Manager/
QC
Engineer
Project
Manager
Project
Mechanical
Engineer
foreffective
controlof
Paving
operation
Engineer
Engineer
Engineer
PROCEDURE:
ThedetailedConstructionMethodologyinvolvedinexecutionofPQC
includingQualityAssurance&Controletc.hasbeendescribedinthe
followingsubchapters.
SurveyandSettingoutforPQC:
ThefollowingstepsareinvolvedinSettingoutofstringwirebeforelying
PQC:
CenterlineofCarriagewaywillbemarkedatevery50Mintervalson
DLCsurfacebyusingTotalstation.
Approvalofsurveyandsettingwillbeensuredandsurveychecksheet
CGGC341701isfilledpriortocommencementofthelayingactivity.
MaterialRequired:
Cement:
Anyofthefollowingtypesofcementmaybeusedwithpriorapproval
oftheEngineer:
(i)OrdinaryPortlandCementIS:269
(ii)PortlandSlagCementIS:455
(iii)PortlandPozzolanaCementIS:1489
Cementtobeusedmaypreferablybeobtainedinbulkform.Itshallbe
storedinaccordancewithstipulationscontainedinClause1014andshall
besubjectedtoacceptancetestpriortoitsimmediateuse.
.
CoarseAggregate:
AggregatestobeusedintheconstructionofPQCwillbeCrushed
aggregates.
TheaggregatecomplyingIS:383willbeused.
MaxSizeofcoarseaggregate25mmasperMoRTH601.2.3.2
(FourthRevision:August2001).
FineAggregate:
Clean,naturalsandfromRiverBanasformlocationTriveni20km
formLadpurawillbeused.ThematerialconformingIS:383is
ensured.
Thefineaggregateshallconsistofclean,naturalsandorcrushed
stonesandoracombinationofthetwoandshallconformtoIS:383.
Fineaggregateshallbefreefromsoftparticles,clay,shale,loam,
cementedparticles,mica,organicandotherforeignmatter.Thefine
aggregateshallcomplywithMoRTH602.2.4.3.(FourthRevision:
August2001).
(ThegradinglimitsforallinaggregatesshallbeperIS:383for20mm
nominalsizeAggregateforPavementQualityConcrete)
SieveDesignation
40mm
20mm
4.75mm
600micron
150micron
PercentagepassingtheSieve
byWeight
100
95100
3050
1035
06
Water:
WaterusedformixingandcuringconcreteconformingtoIS:
456:2000.
IncaseofPQCDuringhotweather,waterforpreparationof
concretewillbetakenformwaterchillingplant.
Admixtures:
AdmixtureconformingtoIS:6925andIS:9103toimprove
workabilityofconcreteorextensionofsettingtimetobedone.
Storageofmaterials:
Aggregates:
Aggregatewillbestockpiledseparatelyandsufficientdistancewill
bemaintainedfromeachfractiontoavoidintermingling.
Storagespacemustbeeasytoinspection,removalandrestorage
ofmaterials.
Regulartestingofaggregatestockpilewillbeexercisedtoensure
requiredgradationcontrol.
Cement
Bulkcementwillbestoredinbulkstoragecontainershaving
200MTcapacityandthenumberofsuchbulkerswillbesufficient
tocatertotherequirementatsite.
Water
Waterwillbetankscoveredattopandcleanedatregular
intervals.Theintakeofpipewillbeenclosedtoexcludesiltand
othersolidmaterialsandthereshallbeaminimumdepthof0.60
mofwaterbelowtheintakeatalltimes.
Proportioningofconcrete
ConcreteStrength
ThepavementconcreteshouldbeaclassM40concretewitha
minimum28dayscompressivecharacteristicstrengthof40MPa
1.Characteristicflexuralstrengthat28days=4.5MPa
2.Targetmeanstrengthat28days=5.80MPa
3.Watercementratio=0.45Maximum
4.SlumpasperIS:1199=31+/15mm
Minimumflexuralcharacteristicstrengthof4.5MPa.
Therationbetweenthe7&28daysstrengthsof4.5Mpa.
Foreachbatch
7days(avg.)
Theaverageflexuralstrengths(R7)=
28days(avg.)
R7tobedeterminedforthreedecimallevels.
(FlexuralstrengthofanySixconsecutive7daytestresult)>4.50+1.65*s
S:Standarddeviationofthegroup.
Workability:
Thecontrolofworkabilitywillbedonebytheslumptest
Slumpwillbecontrolledsothatmixiscompactedandfinished
withoutundueflow.
Theexactslumprequiredatplantandsitewillbeexercisedduring
trailpatch.
SeparationMembrane:
Twoapplicationsofapprovedwaxbasedwhitepigmented
curingcompoundwillbeappliedonDLC.
FirstcoatwillbeappliedimmediatelyafterDLClayingand
compactionandtheotherbeforestartofPQC.
Theprocessofapplicationwillbedoneusingmechanicalsprayer.
Theotherparameterswillbemeetingtheadditionalspecification
ClauseA12.
Preparationofbase:
Anyvisibledefects/cracksmorethan10mmsizetoberequired
byfinecementconcretemix.
Surfacewillbemadecleanofdirtorextraneousmaterialandfree
fromdamagebeforeapplicationcompound.
Joints:
Theexactlocationandtypeofjointtobetransferredatsiteas
mentionedindrawing.
ConcretePenetrometerandtestingasperASTMC403willbe
usedinmonitoringsettingofconcrete/Maturityofconcreteand
sawcuttingperiod.
Initialsawcutof3mmwide,100mmdepthintransverseand
longitudinaldirectionwillbeprovidedafterinitial
set(approximately6~8hrs).
Finalsawcutting10~12mmwide,20~25mmdepthwillde
providedafter14daysofcuringataccommodatejointsealant.
Thestaggeringoftransversejointswithreferencetothebasewill
beminimum0.3m.
Transversejoints:
Contractionjointswillbeprovidedatevery4.5mintervalexcept
whereexpansionjointsareprovided.
Transversejointstobeprovidedatthejunctionoftheapproach
slabsofbridgedandtherigidpavementandspeciallocatione.g.
transitionsectionsi.e.transitionofflexiblevs.rigidpavement.
Transversejointswillbestraightwithinspecifiedtolerances.
Expansionjointswillbeprovidedatthejunctionoftheapproach
slabsofBridgesandtherigidpavement.
ContractionJoint:
ContractionjointswillbeasperthedrawinggivenbyNHAI
ExpansionJoints:
JointfillerboardforExpansionjointwillbepremouldedjoint
fillerasperMoRTHspec.602.2.7
PremouldedjointfillerconformingAsperIS:1838orBS:2630
Thicknessofthejoint=2025mm
Tolerancelimitwillbewithin+/1.5mm
Itshallbe25mmlessindepththanthethicknessoftheslab
Thefillerforeachjointshallbefurnishedinasinglepieceforthe
fulldepthandwidthrequiredforthejoint.
Holestoaccommodatedowelbarswillbeasaccuratelyboardor
punchedtogiveaslidingtillonthedowelbars.
Dowelbarsforexpansionjointwillasper
Jointswillbeprovidedatthejunctionsofrigidandflexible
pavementwithtransitionslabasperthedrawings.
Whereduetounavoidableconditions(forexample:jointsattwo
contractpackage)jointaretobeprovided,dowelbarsarefixed
intotherigidpavement.
Theadjacentslabsshallbecompletelyseparatedfromeachother
byfillingjointfillerboard.
Transverseconstructionjoint
Transverseconstructionjointshallbeplacedwhenconcretingis
doneafteraday'swork.
Itwillbeprovidedattheregularlocationofcontractionjointsusing
dowelbars.
Thejointwillbemadebutttype.
Longitudinaljoints
Tiebarsshallbeprovidedatthelongitudinaljointsasperthe
drawinggivenbyNHAI.
Dowelbars
TheseshallconfirmtotherequirementsofIS:432,IS:1139and
IS:1786asrelevant.ThedowelbarsshallconfirmtoGradeS240
andtiebarstoGradeS415ofI.S.
Itshouldbemildsteelround,freefromdirt,looserust,scale
straightandburringrestrictingslippageintheconcrete.
Thedowelbarswillbesupportedoncradles/dowelchairsin
prefabricatedjoint.
Dowelbarswillbepositionedatthemiddepthoftheslabwithina
toleranceof+20mm.
Dowelbarsshallbecoveredbyathinplasticsheathforatleast
2/3oflengthfromoneendfordowelbarsinContractionjointor
halfthelengthplus50mmforexpansionjoints.
Thesheathshallsetough,durableandofanaveragethickness
notless1.25mm
Thedowelbarswillbeinsertedbyvibrationmethodintheplastic
concrete.
ForExpansionjoints,acloselyfittingcap100mmlongcotton
wasteplacedoversheathenedendofeachdowelbar.
Tiebars
Freeformoil,dirt,looserustandscale.
Inlongitudinaljointsshallbedeformedsteelbarsofstrength415
MPacomplyingwithIS:1786.
Itshouldprotectfromcorrosionfor75mmoneachsideofthejoint
byapplyingbituminouspaint.
ThecoatingshallbedrywhentheTieBarsareused.
Itshouldbeperpendiculartothelineofthejoint,withthecenterof
eachbarontheintendedlineofthejointwithinatolerance
of+50mmandwithaminimumcoverof30mmbelowjoint
groove.
WeatherandSeasonalLimitations:
Concretingduringmonsoonmonths:
Sufficientsupplyoftarpaulinorotherwaterproofclothwillbe
providedalongthelineofwork.
Anyconcretedamagedbyrainwillberemovedandreplaced.
Ifthedamageislimitedtotextureitwillberetextured.
ConcretinginHotWeather:
Carewillbetakeninreducingtemperatureofconcretesuchas
useof
Chilledwater,sprinklingofchilledwateroveraggregates.
Guidewires
Useofguidewires
Eachguidewireshallbeataconstantheightaboveandparallelto
therequirededgesoftheslabasdescribedinthecontract/
drawingwithinaverticaltoleranceof+3mm.
Theguidewiresshallbesupportedandstakespreferablynotmore
then8mapartbyconnectorscapableoffinehorizontaland
verticaladjustment.
Thestackshallbepositionedandtheconnectorsmaintainedat
theircorrectheightandalignmentbeforecommencementofwork.
Theguidewireshallbeerectedandtensionedforatleast2hours
beforeconcretingthatsection.
Carewillbetakentoavoidanydisturbancetotheguidewire
duringpavingbyanyconstructionequipmentoranyothermeans.
CONSTRUCTION:
10.1Concreteproduction,transportation,Paving,Texturing
andCuring:
Abatchingplantof120cumperHr.capacityhastousefor
ProductionofConcrete
Dumpershavinghydraulicjacksystemtounloadhavingcapacity
35Mt(Approx.9cum)concretewillbedeployfortransportationof
concrete.
Pavingwillbecarriedoutinfullcarriagewaywidthof8.5mlength.
ThePaverusedwillbeslipfromPaver.
Theslipfrompavingmachineshallcompacttheconcreteby
internalvibrationandshapeitbetweenthesideformswitha
conformingplateandoscillatingfinishingbeams.
Thefinalfinishofthesurfacewillbedonebysupersmoother
attachedtotherearportionofthePaver.
MansonTrolleywillbeplacedinbetweenPaverandTexturing
andCuringMechine(TCM)forrectificationofanysurfacedefects.
ThealignmentofthePavershallbecontrolledautomaticallyfrom
theguidewireby4setoflevelsensorsand2setofsteering
sensorsattachedtothePaver.
Planningandpreparationwillbedonetopaveatleastatan
averageuniformspeedofonem/min.
ThesurfaceofconcreteslabwillTinetexturedinadirection
paralleltothelongitudinalaxisofthecarriageway.
Texturing/Tiningwillbedonewithaspecifiedmachinespecially
designedforthepurposeforprovidinggroovesatauniform
spacingof18mmto21mm.
Depth=3mmto4mm
Width=3mm
CuringofPQCusingcuringcompoundwillbefollowedby
texturingbythesameTCM.
Curingwillbetakencareattheedgesalso.
Thecuringcompoundwillberesinbasedaluminizedreflective
curingcompound.
AfterprovidinginitialcutentirePQCwillbecoveredwithHessian
clothandwaterturnedfor14days.
Traillength:
TheTriallengthwillbeconstructedatleastonemonthadvance
beforestartingofconcretepavingwork.
Triallengthof60mmwithsamewidth,Depthetcasper
permanentworkwillbedoneatnearertosite.
Transversejointsandlongitudinaljointofeachtypethataretobe
includedinthepavementworkwillbeconstructedandassessed
intheTriallength.
Density:
Atleast3coresdrilledwhentheconcreteisnotlessthan7days
old.
11.2Strength:
Minimumofthirty(30)beamsforflexuralstrengthandthirtycubes
forcompressivestrengthwillbepreparedformtheconcrete
deliveredtothepavingplant.
Eachpairofbeamsandcubeswillberepresentingadifferent
batceofconcrete.
Compressiveandflexuralstrengthwillbeafter28dayscuring.
Attheageof28daysthirtycoreswithdiameter150mmshouldbe
sawcutfromtheslab.
Thecoreswillbesawcutinbothendstoprovideaspecimen
heightof300mm+/15mm.
Themixwillbedesignedtoachieve
Theaverageflexuralstrength>4.5
+1.65*s(Mpa)
[s=standard
deviation]
Strengthofanysample>fck1.65s
Theaveragecompressivestrengthofthe
cores0.8/(Averagecompressivestrength
ofthethirtycubes.)
TemperatureMeasurement:
Thetemperaturedevelopmentintheconcreteslabshouldbe
recordedafterevery3hoursduringhardeningafterinstallmentof
thethermometer&temperatureagerelationshipshouldbe
determined.
Itshouldbemeasuredinthemiddleoftheslab(vertically)ata
horizontaldistanceofatleast1000mmfromanyfreeend.
Thetemperatureshouldnotexceed70degreeC.
InspectionDowelBars:
Alignmentofdowelbarsandconstructionjointshallbechecked
bymeasurementrelativetoguidewires.
Thepositionofdowelbars,fillerboardwillbemeasuredafter
carefullyexposingplasticconcreteacrossthewholewidthof
concrete.
Preparationofjointandsealingofjointgrooves:
TransverseJointshallnotbesealedbefore14daysafter
construction
Jointgrooveswillbeconstructedtoanadditionaldepth/widthas
mentionedindrawing.
Thegrooveshallbecleanedanddriedatthetimeofprimingand
sealing
Allgroovesshallbecleanedofanydirtorloosematerialbyair
blastingwithfiltered,oilfreecompressedair.
Beforesealingthetemporarysealprovideforblockingtheingress
ofdirt,soiletc.,shallberemoved.
Aheightcompressibleheatresistantpaperbackeddebonding
stripasperdrawingshallbeinsertedinthegroove.
Inthecaseoflongitudinaljoints,heatresistanttapesmaybe
insertedtoblocktheleakagethoughbottomofthejoint.
Sealingwithsealants:
Theprimerrecommendedbythemanufacturershouldbeapplied
forsealants.
Primingandsealingwithappliedsealantsshouldnotbecarried
outwhentemperatureinthejointgroovetobesealedisbelow7
degC.
IfhotappliedelastomerictypesealantcomplyingAASHTOM282
isuseditshallbeheatedandappliedfromathermostatically
controlled,indirectlyheatedpreferablywithoiljacketedmelterand
pourerhavingrecirculationpumpandextruder(Thisisappliedat
junctionofAsphaltandconcretepavements.
Coldappliedpolyeurethrene/PolysulphidetypecomplyingBS:
52121990Sealanwillbemixedandappliedaccordingtothetime
limitspecifiedtheManufacturetotheconcretepavements.
Primerwillbeappliedwithanappropriatebrush.
Caresuchastemperatureandtimeofsealingwillbeemphasized
toavoidanybulgeofsealantduringcontractionofjoint.
Sealantshallbeappliedslightlytoalowerlevelthantheslabwith
atoleranceof5+2mm.
Thetypeanddetailsofdifferentjointstreatmentaretabulated
below:
TYPEOF
JOINT
JOINT
DETAILS&TREATMENT
Polysulphide
Debonding 3~4
Soft
Butt
Compressible
Sealant(cold) Strip
Mm
Longitudinal
Groove
Expansion
Construction
Contraction
TestingofappliedSealant:
Jointsealantcompoundandprimershouldbetestedin:
ColdappliedPolysulphidesealant(accordingtoBS:5212Part2)
Incaseifdeliveriesaremademorefrequentthantestingmaybe
reducedtoeverythreemonths.
MeasurementoftexturedepthSandPatchMethod
TheapparatusasmentionedinMoRTH601.12.1willbeusedto
measurethetexturedepth.
Thesurfacetexturewillbemeasuredasperthemethodlaiddown
inMoRTH601.12.1andthesameisrecordedinlabformat.
OpeningtoTraffic:
Novehiculartrafficincludingcontractor'svehicleswillbeallowed
onthefinishedsurfaceuntilafieldflexuralstrengthofminimum
4.50MPahasbeenachievedwhereaverageflexuralstrengthof
minimum3specimensshouldexceed4.50+1.65s(s=standard
deviation).
Eachseriesoftestspecimensformeasurementofflexural
strengthshouldconsistsofminimum3testspecimens.
Priortoopeningtotrafficthejointsshouldbesealedandareas
adjacenttothepavementshouldbecompletedtoadegreethat
willensuretrafficsafety.
QualityAssuranceandControlChecks
AspartofQualityAssurancethisSegmentQualityPlanforPQC
hasbeenpreparedinlinewiththespecificationprovidedin
relevantMoRTHclauses,ContractSupplementaryTechnical
SpecificationandotherCodes/Standard/Specificationsetc.else
wherementionedinthisPlan.
AsapartofQualityControlalltheInspectionandTesting
requirementsforvariousactivitiesinvolvedinlayingofPQCwill
becarriedoutasperrelevantMoRTHSpecifications&Contract
TechnicalSpecificationatc.AsdescribedinInspectionandTest
PlansattachedtothisSegmentQualityPlanforPQC.
TheseInspectionandTestPlansshallconsistoftypeof
InspectionandnameoftheTesttobeconductedforProduct
Realization,frequencyoftestingacceptancecriteriaandcategory
ofInspection.
InspectionandTestPlansshouldberevisedwheneverthereany
changeinmethodologyandspecificationsetc.
NonconformitiesinPQC:
AnyNonConformityobservedduringfieldInspectionandalso
duringTestingofMaterials/mixes/layingsystemetc.thesame
shouldberecordedinthespecifiedNonconformanceReportand
necessaryCorrective/Preventiveactionsshouldbeinitiatedto
preventsuchthingsinfuture.
QA/QCEngineersareresponsibletocontroltheNonconforming
productsasdescribedinProcedure,andrelevantsectionin
chargesiteengineersaretotakeappropriatecorrective
/preventiveactions.
AllProductNonConformitiesshallbeobserved,recorded,
corrective/preventiveactionsandclosingofNCR'sshouldbeas
pertheestablisheddocumentedproceduredescribedinProject
QualityPlan.
Safety&EnvironmentalRequirements:
HazardIdentification,RiskassessmentandRiskcontrolmeasures
foreachactivitiesandsubactivitiesinvolvedinthepresent
Segmentshallbeidentifiedandnecessaryactionplanshallbe
initiated.
EnvironmentalAspectsandImpactsassociatedwithvarious
activitiesandsubactivitiesinvolvedinthepresentsegmentand
theirmitigation/controlmeasuresshallbeidentifiedandnecessary
measuresshallbeinitiated.
SEQUENTIALOPERATIONOFPQCLAYING
DLClayerApproval
Sitecleaning,Applicationof2ndcoatofcuring
compoundasaseparationmembrane
Survey,Settingout,fixingofStringline
PlacingPaverandTCM
ClearancetoB/PlantforProductionof
concreteaftercheckingstringline&
Equipment.
ProductionofconcreteaspertheMixdesign
andadjustaspertherequirement
TransportationofMixtoSite
YES
SEQUENTIALOPERATIONOFPQCLAYING
RejecttheMixandfindoutRootCause
NO
Checkthemixasperthe
requirementi.e.Slump,
Temperature,Aircontent
etcandmeetsasperdesign?
YES
DDumpingconcreteatregularspacinginfrontof
Paverandstartpaving
Monitoringlevelsthroughlevelsensors.
FixingofDowelbarsandtiebarsbyDBI&TBI
asperDrawing
Rectificationofsurfacedefects(ifany)manually
byMesons.
Texturing&curingbyTCMandTestrateof
spraying.
FixingofStopperafterEndofday'sWork.
InitialJointcuttingaftersettingofconcrete
Cleaningofjointandfixingbackuprod.
SEQUENTIALOPERATIONOFPQCLAYING
CoveringPQCwithhesianclothandwater
curingformin.14days.
Removalofhesianclothandfinaljointcutting
Cleaningofjointandprovidingsoftrope,
debondingstrip,polysulphidesealant,
compressiblefillerboard,buttjointas
mentionedinTable2inPQCmethodology
TesttexturedepthbySandPatchMethod
Proceedforthenextactivity