Ceigall India Limited

Construction Methodology
PROJECT : 4/6 Laning of Kharar to Ludhiana Section of NH95 (New NH-05) from
Kharar km. 10+185 (Design Chainage) to Samrala Chowk, Ludhiana km.
86+199 (Design Chainage) in the State of Punjab

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Contents
 TRAFFIC CONTROL...............................................................................................3

 SITE CLEARANCE.................................................................................................4

 DISMANTLING STRUCTURES..............................................................................5

 EARTH WORKS......................................................................................................6

 SUB-BASE, SHOULDERS etc................................................................................8

 PRIMER COAT.......................................................................................................8

 HOT MIX DENSE BITUMINOUS MACADAM BITUMINOUS CONCRETE...........9

 WET MIX MACADAM BASE COURSE................................................................10

 PIPE CULVERTS..................................................................................................11

 BOX CULVERTS...................................................................................................12

 BRIDGES..............................................................................................................13

 DRAINAGE AND PROTECTIVE WORKS............................................................16

 MAINTENANCE....................................................................................................18

 DRY LEAN CONCRETE.......................................................................................20

 PAVEMENT QUALITY CONCRETE.....................................................................21

 CEMENT CONCRETE KERB...............................................................................43

 STRUCTURAL CONCRETE.................................................................................45

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TRAFFIC CONTROL
OPERATIONAL PROCEDURE:

In order to ensure safety of traffic and to ensure smooth traffic flow during construction,
all necessary measures such as providing, erecting and maintaining signboards
barricades, speed breakers wherever required. The letters and signs on the signboards
and other markings will be painted in fluorescent paint so as to be clearly visible during
the night. Lights and flags will also be provided at all important junctions. Flagmen will
be employed wherever it is considered to be essential.

The barricades to be erected will be sufficiently strong to resist any untoward violation
and painted with alternate black and white stripes. Wherever required warning lights will
be mounted on the barricades all through the night and kept lit throughout from sunset
to sunrise.

Wherever existing traffic needs to take a diversion the channel for traffic will be marked
distinctly using pavement marking or painted drums. At night, these passages will be
delineated with lanterns or other suitable lighting. On both sides a minimum of 2 signs,
(in reflective paint) one close t the point where the diversion begins and the other abut
120 m. away will be put up. At all crucial junctions, flagmen equipped with red and green
flags and lanterns/lights will be employed for regulating the traffic.

Supervisors acting as traffic enforcers will be employed to ensure all the necessary
traffic safety guidelines required for National Highway construction works to be strictly
carried out and followed.

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SITE CLEARANCE
OPERATIONAL PROCEDURE:

Clearing and grubbing shall be done using both mechanical means and manual
operations to suit the site conditions. For removal of tree stumps and roots machines
equipped with ripper attachments shall be deployed. All the trees, stumps, roots etc. will
be cut to sufficient depth below ground level so that they do not fall within 500 mm of the
sub-grade. Also, all vegetation such as roots, under-growth, grass and other deleterious
matter unsuitable for incorporation in the embankment/subgrade shall be removed.

All excavations subsequent to removal of trees stumps and roots etc. will be filled with
approved material and compacted thoroughly so as to make the surface at these points
conform to the surrounding area.

The material/vegetation removed as part of site clearance will be stacked in designated

dumping areas. The dismantling and breaking of cross-drainage structures, wherever
required will be done manually and mechanically taking sufficient care to see that no
damage whatsoever is caused to the receivable materials to be salvaged and the part of
the structures to be retained at the adjacent structures/other properties. The debris will
be removed by tippers from the respective site of works.

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DISMANTLING STRUCTURES
OPERATIONAL PROCEDURE:

1.0 Dismantling:
Dismantling and removal operations shall be carried out with such equipment and
such a manner as to leave undisturbed, adjacent structures, pavement and any
other work to be left in place.
All operations necessary for the removal of any existing structure, which might
endanger new construction, shall be completed prior to the start of new work.

1.1 Dismantling culverts and Bridges:

The structures shall be dismantled carefully and the resulting materials so
removed as not to cause any damage to the serviceable materials to be
salvaged, the part of structure to be retained any other properties or structures
nearby.
Where existing culverts/bridges are to be extended or otherwise incorporated in
new work, only such part or parts of the existing structure shall be removed as
are necessary to provide a proper connection to the new work. Due care should
be taken to ensure that reinforcing bars which are to be left in place so as to
project into the new work as dowels or ties are not injured during removal of
concrete.
While dismantling Brick masonry and stone masonry care shall be taken to
remove stones and bricks in such a manner as to avoid damage to bricks and
stones which can be salvaged.

1.2 Dismantling pavements and other structures:

In removing pavements, kerbs, gutters and other structures like guard rails,
fences, manholes, catch basins inlets etc., where portions of the existing
construction are to be left in the finished work.

1.3 Back filling:

Holes and depressions caused by dismantling operations shall be back-filled with
excavated or other approved materials and compacted to required density.

1.4 Disposal of materials:

All materials obtained by dismantling and having any salvage value shall be
placed in neat stacks of like materials within the sight of way as per instructions
of Engineer-in-charge.

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EARTH WORKS

OPERATIONAL PROCEDURE:

1.0 Excavation:

1.1 Earth-cut:

All earth work excavation in general will be done by means of excavators and the
excavated earth will be loaded on tippers and deposited in areas requiring
embankment. Wherever the excavated earth is found unsuitable for use in
embankment it will be filled in designated dumping areas.

All debris and loose material occurring on the slopes and cutting will also be
removed where after the sides of the excavated area will be trimmed and the
area contoured to minimise erosion and ponding, allowing natural drainage to
take place.

Batter rails with the required slopes as per the drawings will be set out to assist
proper slopes in excavation. Additionally, excavation works will proceed in such a
manner that drainage gradients are maintained at all times. Access roads from
cut to fill areas will be continuously maintained. Water bowsers may be required
frequently over dry periods to keep the dust down to a minimum.

1.2 Embankment:

The top soil in embankment area will be removed up to a depth of 150 mm

levelled and suitably compacted to facilitate placement of first layer of
embankment which will be scarified, mixed with water as necessary and then
compacted using rollers so as to achieve the necessary compaction.

The envisaged deficit in earthfill to be used for embankment will be brought in

from suitable borrow areas in tippers and dumped in heaps which will be spread
in layers by using dozers. It will then be levelled with graders before being
watered suitably by means of water tankers, finally rolling will be done using
vibratory rollers.

The subgrade material will also be brought in by tippers and dumped on the
embankment. They will be spread in layer of uniform thickness using dozers and
levelled by graders and compacted. These layers will be watered using tankers
and rolled by vibratory rollers. The subgrade material will be tested to ensure the
necessary CBR values as per contract, to be attained.

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The blade of the grader will be adjusted initially with hydraulic control so as to
maintain the same to achieve the specific slope and grade. Each layer will be
compacted thoroughly to be specified requirement and finished approximately
parallel to the final cross section of the embankment before the succeeding layer
is spread and only after the field density test results have been obtained
successfully.

While watering the layers, the tanker will be fitted with a sprinkler capable of
applying water uniformly with a controlled rate of flow to variable widths of
surface but without flooding until a uniform moisture content is obtained
throughout the depth of the layer.

1.3 Subgrade Trimming:

Survey level peges will be put at suitable intervals (say 25 m) to allow the
“Dipping-level system” to be implemented. The subgrade levels will be properly
graded and then compacted to within the subgrade tolerances as per the
contract.

1.4 All compaction shall be done layer by layer using vibratory and tandem vibratory
rollers following a pre-determined way of compaction with required number of
passers in particular direction under approval of customer.

Sufficient number of testing for compaction shall be done at regular intervals for
various layers as per approval of customer.

Final grading shall be executed by a motor grader. Slope levelling is carried out
by motor grader. Earthen Sub-grade geometry shall be checked at elevation
marks, set out position by surveyor.

Sub-grade quality and compaction shall be controlled by Field laboratory.

1.5 In case of construction of sub grade with cement treated soil (2 % cement mixed
by weight of dry soil), the mixture of soil and cement shall be done in pug mill or
in situ using road harrow as shall be approved by engineer. Cement grade shall
be of 33 grade or 43 grade. Compaction shall be done as described above in
Sub-grade compaction. A recommended method statement shall be submitted to
customer for approval sufficiently prior to starting of the job.

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SUB-BASE, SHOULDERS etc.

OPERATIONAL PROCEDURE:

Just before laying of sub-base, already finished sub grade will be prepared by removing
any extraneous matter, lightly sprinkled with water and rolled with roller. The sub-grade
material brought from quarries will be spread on this prepared subgrade by means of
shovels and dozers and levelled by a motor grader of adequate capacity, its blades
having hydraulic controls enabling adjustment whereby required slope and grade will be
maintained during the operation.

After doing dry rolling initially, water will be sprinkled through a trailer mounted water
tank, uniformly and at controlled speed in order to achieve the required moisture
content. Rolling will then be done using a vibratory roller of required capacity to achieve
the required compaction. The required camber will be maintained using a Dipping-
system as for subgrade trimming.

This shoulder construction is envisaged to be carried out in layers each matching the
thickness of adjoining pavement layers.

PRIMER COAT
OPERATIONAL PROCEDURE:

After the surface to be primed is swept clean, free from dust and wetness, the
bituminous primer will be sprayed uniformly over the dry surface using self-propelled
sprayers, suitable pump, compressor of adequate capacity and spraying bar with
nozzles having constant volume of pressure system capable o supplying primer at
specified rate and temperature so as to provide a uniformly unbroken spread of primer.

The surface thus primed will be allowed to cure for at least 24 hours to allow penetration
into the base course and aeration of volatiles from the primer material during which
period no traffic of any kind will be permitted on the surface. This can be achieved by
suitably cordoning off the affected area with stringers and/or used oil drums.

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HOT MIX DENSE BITUMINOUS MACADAM BITUMINOUS

CONCRETE
OPERATIONAL PROCEDURE:

A HMP (Hot Mix Plant) yard will be located at suitable places with respect to travel time
and other relevant parameters in an area of 10-15 acres approximately will have the HM
Plant, WMM plant, Concrete Mixing and Batching Plant, workshop, garage, store,
offices, laboratory. A backup power supply unit of suitable capacity to meet the
eventuality in the event of power failure will also be available. The aggregate, bitumen
and the materials will be stocked/stored in the yard.

The HMP (Batch type) will produce the desired mix which will be carried to the required
location by means of tipper trucks. Job mix formula proposed to be used for desired mix
shall be intimated to the Engineer-in-charge well in advance before regular production
from Hot Mix Plant is planned. The surface will be coated in advance by bitumen
sprayer. The hot mix will be discharged in the paver which will spread the mix on the
surface. The paver will be set for desired camber and profile.

The rolling will follow the paver by means of static roller, vibratory roller or pneumatic
tyre roller and tandem roller as the case may be. The levels and profile will be
continuously monitored by level instruments. The road will not be opened to traffic until
12 hours after rolling. Water tankers will be kept available to spray water in the
surrounding areas to avoid dust caused by movement of vehicles. The edges will be
restrained by steel channels pegged in the ground. The edges of the previous day’s
work will be cut by means of mechanical cutter and work will be continued.

Appropriate trial mixers for each mix design will be carried out to the approval of the
Engineer. Once the right mix is approved, trial lays will be carried out to ensure the
reproducibility of the laboratory design criteria to be achieved in the field. Field couings
will be done and appropriate laboratory tests carried out to ensure compliance with
specifications.

All Asphaltic concrete works will be carried out in compliance with the specifications.
In case of cold milling and recycling, suitable equipment as per tender specification shall
be installed in site. Aggregate from milling of existing surface shall be collected and
analysed in site laboratory. A suitable job mix formula shall be designed for recycling
process. Additional materials required shall be properly designed to achieve desired
results.

The design mix shall be submitted to the Engineer-in-charge for his approval and also
the operation shall be physically demonstrated at site for a small stretch for Engineer’s
approval.

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WET MIX MACADAM BASE COURSE

OPERATIONAL PROCEDURE:

The wet mix macadam will be prepared in a centrally located batch plant yard. Wet mix
macadam will be used for this purpose. The wet-mix macadam will be batched to the
predetermined and approved laboratory mix’s optimum moisture content + 1% or more
(to be suitably adjusted) to take into consideration the hot weather during transit. The
material will be transported by tippers with canvas covers to the site of work and
discharged into a paver to enable the aggregate to be spread uniformly and evenly upon
the prepared base (in this case GSB).

Stringline level control system suitable to the paver will be established and implemented
to ensure the WMM design levels to be achieved.

The screen of the paver will be adjusted suitably so as to achieve the specified layer
thickness and slope. The surface of the aggregate will be checked with templates and
corrections done, if needed by removing or adding aggregate as may be required. After
the mix is laid to the required thickness, grade and camber it will be uniformly
compacted, to the full depth with a vibratory roller of suitable capacity.

Rolling will be continued till the density achieved is at least 98% of the maximum dry
density of the material. After this final compaction, the road will be allowed to dry for not
less than 24 hours, keeping it well closed, far from movement under any compaction
equipment.

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PIPE CULVERTS
PIPE CULVERTS PROCEDURE:

The foundation bed for pipe culverts will be excavated by mechanical means, true to the
lines and grades as shown in the drawings or as directed by the Engineer. The RCC
Hume pipes of the required diameter and length will be laid on a concrete bed before
the concrete has set and after the foundation has been approved by the Engineer.

Where two or more pipes need to be laid adjacent to each other they will be placed,
maintaining a gap as shall be mentioned in the drawing or approved by the Engineer-in-
charge. The entire operation of lifting, loading and unloading the pipes from the yard at
site will be such that the pipes do not suffer any amount of undue structural strain and
damage due to fall of impact.

The pipes will be lowered in the bed manually or by means of a crane in a manner that
they are placed in the proper position, without damage. The pipe laying work will start
from the outlet and proceed towards the inlet and completed to the specified lines and
grades. They will be so fitted and matched that after laid in work they form a culvert with
a smooth uniform invert.

Flush joint may be internal flush joint or external flush joint. In either case, the ends of
the pipes shall be specially shaped to form a self-centering joint with a jointing space.
The jointing space shall be filled with cement mortar 1cement to 2 sand, mixed
sufficiently dry to remain in position when forced with a trowel or rammer.

The back filling will be started after the pipes are laid ad the jointing material has
hardened. The backfill will be clear, free from boulders, large roots, vegetable matter
and lumps. The soil above the top of the pipes will be thoroughly rammed, tamped or
vibrated in layers, taking particular care to ensure thorough consolidation of materials
under the haunches of the pipes. Approved light mechanical equipment/vibratory
hammers will be used for compaction. Filling will be done simultaneously on both sides
of the pipe to prevent development of unequal pressure.

In case of high embankment, after the trench is filled up to the top of the pipe, as
enumerated above, a loose fill of a depth equal to the external diameter of the pipe will
be placed over the pipe before placing further layers and doing compaction.

Head walls, wing walls and other ancillary works will be done in accordance with the
details shown on the drawings. No traffic will be permitted to cross the pipeline until and
unless the height of filling above the top of the pipeline is at least 600 mm.

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BOX CULVERTS

BOX CULVERTS PROCEDURE:

Depending on the location of box culvert and the height of embankment on the
concealed box culverts, different methods shall be applied for box culverts construction
to suit the site condition requirement.

Embankment will be supported by palisading during lay on new lane and will be
compacted properly. Then after excavation of compacted embankment in trenches, bed
preparation, shuttering, bar fixing , concreting and completion of inlets and outlets shall
proceed on in the 1st phase. After completion of this phase, embankment will be done
and pavement on new lane will be laid to the layers that could pass the traffic. Then
excavation and construction of box culvert in the 2 nd stage would accomplish the work.

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BRIDGES
OPERATIONAL PROCEDURE:

The method of construction will be as follows in respect of major structures. Simple

structures will be constructed using conventional methods.

Pile Foundation:

Required no. of pile rigs shall be mobilised for pile boring. Boring shall be done through
specialised agency. The method of boring shall be as per tender specification.

Well Foundation:

Specialised agency shall be engaged for well foundation work. The following
methodology for construction in principal shall be applied :

In general the following equipment’s shall be deployed for well foundation construction.

1. Crane with grab buckets.

2. Submersible pumps.
3. Air compressor, air locks and allied accessories in case pneumatic sinking of well is
anticipated.
4. Chisel of appropriate sizes.
5. Aqua-header for cutting of rocky strata.
6. Equipment for concrete production, transportation and compaction.

CUTTING EDGE:

The mild steel cutting edge shall be made from structural steel section. The parts of
cutting edge shall be erected on level firm ground. Temporary supports shall be
provided to facilitate erection and maintaining the assembly in true shape. The cutting
edge shall be laid about 300 mm above prevalent water level

WELL CURB:

The well curb in general shall be cast-in-situ. Steel formwork for well curb shall be
fabricated in conformity with the drawing. The outer face of the curb shall be vertical.
Steel reinforcements shall be assembled as shown on the drawings. The bottom ends of
vertical bond rods of steining shall be fixed securely to the cutting edge with check nuts
or by wields. The formwork on outer face of curb shall be removed within 24 hours after
concreting. The formwork on inner face shall be removed after 72 hours. All concreting
in the well curb shall be done in one continuous operation.

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WELL STEINING:

Steining built in the first lift above the well curb shall be restricted to 2 meters.
Subsequent lift shall be decided base on the depth of well sunk below the adjoining bed
level. The first lift of the steining shall be cast only after sinking the curb at least partially,
to ensure stability. Concreting of steining in subsequent lifts shall be 2 to 2.5 meters.

The steining of the well shall be built in one straight line from bottom to top such that if
the well is tilted, the next lift of steining will be aligned in the direction of the tilt.

The height of steining shall be calibrated by making at least 4 gauges in traffic direction
and in a direction normal to the traffic.

WELL SINKING:

The well shall be sunk true and vertical through all types of strata as far as possible. The
well shall be sunk by excavating material uniformly from inside the dredge hole. In case
it is required permission from the engineer shall be taken for use of explosive.

Kentledge shall be place in an orderly and safe manner on the loading platform in a way
that it does not interfere with the excavation of the material inside the dredge hole and it
does not in anyway damage steining of the well. Where tilts are present or there is a
danger of well developing a tilt, the position of the load shall be regulated in a manner to
provide greater sinking effort on higher side of the well.

In view of site condition mild explosive charges shall be used as an aid for sinking of the
well. For this purpose necessary permission from the engineer-in-charge shall be
obtained.

Piers:

The concrete piers will be cast in lifts using conventional steel form work and false work.
The concrete will be placed using a crane and skip or manually as appropriate. The
concrete will be vibrated using poker and surface vibrators.

Deck:

Deck construction for short spans will be carried out using scaffolding and conventional
soffit forms.

For larger spans which incorporate prestressed beams, the beams will be manufactured
off site by a specialist agency, transported to a site and lifted into position using heavy
duty cranes. The actual comprehensive procedure with regard to complex bridge
construction will be detailed and submitted to the Engineer for approval before start of

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construction as each bridge site will pose its own constraints and peculiarities which
must be seriously thought over and properly planned.

General Approach:

By arranging an appropriate area in the site, construction of prestressed girders shall be

carried out individually. In these circumstances, girders can be shifted to the location
without loosing time for shuttering for cast-in-situ method. Other steps of bridge work
would comprise of.

1. Precise setting-out and grading of centre line and other alignments.

2. In case of pile foundation.

a) Construction of pilot piler and load test.

b) Boring of pile as per tender conditions.
c) Fixing the re-bars and placement in boreholes.
d) Concreting the cast-in-situ piles.
e) Stripping of pile caps and shuttering for pile and abutment caps.
f) Concreting of caps.

3. In case of well foundation.

a) Installation of cutting edge.

b) Installation and concreting of well curb.
c) Construction of well steining and well sinking.
d) Construction of bottom plug.
e) Sand filling in well.
f) Construction of top plug.
g) Concreting of well cap.

4. Installation of prestressed girders, bar fixing, formworks for cast-in-situ concrete and
concreting according to the drawings.

5. Fixing of the bearings

6. Installation of pre-fabricated girders on exact location, formworks and casting in-situ

concrete of diaphragm.

7. Isolation, laying mortar and finishing.

8. Fixing of hand rails.

Batching plant is proposed to be erected at site for concrete production. Transit mixers
will carry out the produced concrete to the required places.

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DRAINAGE AND PROTECTIVE WORKS

OPERATIONAL PROCEDURE:

Drainage:

The drains along the roads will be excavated by using a mechanical excavator. The
concrete shall be placed using a mobile mixer. The masonry work shall be done
manually. In case where the section of the drains are of precast elements the same
shall be produced in a central precast yard, transported to site and lowered in position
by a mobile crane or manually.

Protective works:

Protective works like aprons, stone pitching etc., will be executed manually as follows.

Aprons:

The work mainly consists of laying boulders on the bed of the river for protection against
scour. The size of the stone will be seen to be as large as possible.

To ensure regular and orderly disposition of the total required quantity of stone in the
apron, template cross walls in dry masonry will be built about a metre thick and to the
full height of the specified thickness of the apron at about 30 M. intervals all along the
length and width of the apron. Within these walls, the stones will then be hand packed.

Before laying the apron, the surface will be levelled and prepared for the entire apron
area as shown on the drawings. If the surface happens to be below the low water level
the ground level will be raised up to low water level by dumping earth and the apron will
be laid thereon.

Pitching/Revetment of slopes:

The work consists of covering the slopes of guide bunds/roads embankments, with
stone over a layer of granular material called filter. Before doing pitching, the sides of
the banks/embankment will be trimmed to required slope and profiles put up by means
of line and pegs at 3 M. intervals to ensure regular straight work and a uniform slope
throughout.

The granular material (sand, gravel or coarse sand) which acts as a filter media to
prevent escape of the embankment material through the voids of the stone pitching and

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to allow free movement of water without creating any uplift head on the pitching, will be
laid over the prepared base and suitably compacted to the required thickness.

The lowest course of pitching will be started from the toe wall and built up in courses
upwards. The toe wall will be built in dry rubble masonry (VCRS) in case of dry rubble
pitching and in CC M-15 grade in case of CC block pitching.

The stone pitching will start in a trench below the toe of the slope and the stone will be
placed in the required lengths, thickness and depth conforming to the drawings. Stones
will be set normal to the slope keeping its longest dimensions perpendicular to the face
of the slope. Normally the longest stones will be placed in the bottom courses and for
use as headers for subsequent courses.

The pattern of laying will be such that the joints are broken and voids are minimum by
packing with spalls, wherever necessary, and the top surface is as smooth as possible.
When full depth of pitching can be formed with a single stone, the stones will be laid
breaking joints and all the interstices between adjacent stones will be filled in with spalls
of proper size and wedged in with hammers to ensure tight packing.

In case the design thickness of pitching is such that 2 or more layers of stones are
required to be laid dry masonry will be used ensuring that stones are well bonded.

To ensure regular and orderly disposition of the full intended quality of stone, template
cross walls in dry masonry will be built about a meter wide and to the full height of the
specified thickness at suitable intervals and all along the length and width of the
pitching. Within these walls the stones will be hand packed.

Toe Wall:

A toe wall will be built in dry uncoursed rubble masonry in case of dry rubble pitching
and in CC-M-15 grade in case CC bricks are used in pitching in order to protect the
slope pitching from falling even when the apron is not laid at low water level. For
protection of toes of bank slopes terminating either in short aprons at bed levels or
anchored in flooring/rocky bed the relevant guidelines of IRC 89 will be strictly complied
with.

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MAINTENANCE

It is understood that the existing carriageway maintenance shall be under the scope of
contractor. It is also understood that till the activities of strengthening of existing
carriageway for a particular stretch of work is taken up, maintenance of the existing
carriageway shall be undertaken by the contractor as per the B.O.Q. items of work for
maintenance.
The responsibility of maintenance work shall be under manager (maintenance).

Maintenance of Existing Roadway

Routine maintenance of highway:

This work shall consist of earthwork for restoration of rain cuts in the embankment and
shoulders, using suitable material (soil) and compacting the same.

Construction Operation:

The area affected by rain cuts shall be cleaned of all loose soil and benched. The width
of the benches shall not be less than 300 mm and they shall extend continuously for a
sufficient length. The height of the benches shall be in between 150-300 mm.

Fresh material (soil) shall be deposited in layers not exceeding 250 mm loose thickness
and compacted so as to match with the benching at a moisture content close to the
optimum. Compaction shall be carried out using rammers and plate compactors or by
manual ramming. The finished work shall confirm to alignment, levels and slopes as
existing profile.

Filling pot-holes and patch repair:

This work shall include repair of pot-holes and patching of all types of bituminous
surfaces with a bituminous mix.

Preparation of surface

Each pot-hole and patch repair area shall be inspected and all loose material shall be
removed. The area shall be cut/ trimmed either with jack hammer or hand tools like
chisel, pickaxe, etc, in such a manner that the area is in the shape of rectangle or
square. The edges shall cut vertically upto the level where the lower layer is stable
without any loose material. The area shall be thoroughly cleared with compressed air or

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with a suitable method to remove all the dust particles. The area shall be tacked or
primed with cut-back or emulsion depending upon whether the lower layer is bituminous
or granular in nature. The sides shall be painted with hot tack coat material using a
brush.

Material:

The material to be used for the pot-holes repair shall be the same dense bituminous
macadam or a suitable mix as shall be approved by the Engineer. The grading of
aggregates and bitumen content of the mix to be used shall be approved by the
customer. For sealing small cracks finer then 3mm, a fog seal shall be applied, while
larger cracks wider than 3mm shall be treated with emulsion slurry seal.

Providing renewal coat:

Preparation of surface

Same method as described above in pot-hole and patch repairs shall be followed.

Material

Material to be used for renewal coat shall be the same material of bituminous concrete
mix. The customer shall approve the grading of aggregates and bitumen content of the
mix to be used.

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DRY LEAN CONCRETE

OPERATIONAL PROCEDURE:
Preparatory to sub-base concreting, the sub-base surface will be given a fine spray of
water a day in advance, and rolled with one or two passes of smooth wheeled roller
after lapse of 2 to 3 hours in order to stabilise loose surface. The concrete of the
required mix will be produced in a centrally located batching and mixing plant of required
capacity having all the necessary automatic controls to ensure accurate proportioning
and mixing.
The plant mix lean concrete will be discharged from the mixer into tipping trucks and
transported directly to the point where it is to be laid. Sufficient number of tipping trucks
will be employed to ensure a continuous supply of material to feed the laying equipment
to work at a uniform speed and in an uninterrupted manner.
The cement concrete will be unloaded from the tipping trucks into the site for laying the
material manually in one layer in an even manner without segregation to ensure the
specified thickness, after compaction. In order to ensure thorough compaction, the
rolling which will be started immediately after the material is laid and levelled, will be
continued on the full width till there is no further visible movement under the roller and
the surface is closed. In general, the spreading, compacting and finishing of the lean
concrete will be carried out as rapidly as possible.
Double drum smooth-wheeled/vibratory rollers of 6 to 10 Ton capacity will be used for
compacting the concrete. In addition to the normally required number of passes for
compacting there will be a preliminary pass without vibration to bed the lean concrete
down and a final pass without vibration to remove the roller marks and to smoothen the
surface. Special care will be taken during compaction near joints, kerbs, channels,
manholes etc. using a plate vibrator in case the compaction achieved by the roller there
is not adequate.
The final concrete surface will be inspected immediately after compaction and all loose,
segregated or defective areas will be concreted by using fresh lean concrete material
laid and compacted as per specification. Honeycombs, if found, will be repaired by
spreading concrete with aggregates of size 10 mm and below and compacting it.
Any level deficiency with reference to the level of the road surface will be made good
after applying concrete with aggregates of size 10 mm and below after roughening the
surface. Contraction and longitudinal joints will be provided as per the drawing. As soon
as the concrete surface is compacted, curing will be commenced, by covering the
surface by gunny bags which will be kept continuously moist for 7 days by sprinkling
water. No traffic will be allowed on the surface during the curing period.
Sufficiently ahead of the proposed date of commencement of the work on a regular
stretch, work will be done initially on a trail length using the mix design as approved by
the engineer. Actual work will proceed only after the work done on the trail length
satisfies the technical criteria laid down by the Engineer.

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PAVEMENT QUALITY CONCRETE

NOTE :

This construction methodology is based on cement concrete pavement work executed

by Centrodorstroy in Russia and in consultation with Indian Standards. Detailed proper
methodology shall be prepared on award of contract and shall be submitted to client for
approval.

1.0 SCOPE

This work consists of construction of un-reinforced, dowel jointed plain cement

concrete pavement in conformity with the lines, grades and cross sections.

2.0 MATERIALS:

2.1 Source of materials:

At least 45 days before the commencement of the work the engineer should get
the source of all the materials with relevant test data from the contractor.

2.2 Cement:

a) The cement used should be Ordinary Portland Cement of grade 43 or

Portland Slag Cement or Portland Pozzolona Cement. We may propose using
Blended Cement for approval.

b) If the sub-grade is of soluble sulphates in a concentration more than 0.5 %

cement used shall be sulphate resistant.

c) Refer IS:SP-23, handbook for ascertaining the minimum 7 days strength of

cement.

2.3 Admixtures:

a) Admixtures conforming to IS 6925 & IS 9103 shall be used after approval by

the Engineer.

b) Satisfactory performance of the admixtures should be proved both on the

laboratory concrete trial mixes & in trial paving works.

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2.4 Aggregates:

a) Aggregates for pavement concrete shall be natural material complying with IS

383 with a Los Angles Abrasion Test result not more than 35%.

b) The total chlorides content expressed as chloride ion content shall not exceed
0.06% by weight & the total sulphate content expressed as sulphuric
anhydride (SO3) shall not exceed 0.25% by weight.

c) Coarse aggregate shall consists of clean, hard, strong, dense, non-porous

and durable pieces of crushed stone or crushed gravel. The maximum size of
aggregate shall not exceed 25mm.

d) No aggregate which has water absorption more than 2% shall be used. The
aggregate shall be tested for soundness. After 5 cycles of testing the loss
shall not be more than 12% if sodium sulphate solution is used or 18% if
magnesium sulphate solution is used.

e) The fine aggregate shall consist of clean natural sand or crushed stone or a
combination of the two. The fine aggregate shall not contain clay lumps more
than 4%, coal & lignite more than 1% & material passing through IS Sieve
No.-75 micron more than 4%.

2.5 Water:

Water used for mixing & curing of concrete shall be clean & free from injurious
amount of oil, salt, acid, vegetable matter or other substances harmful to the
finished concrete.

2.6 Mild Steel Bars or Dowels and Tie Bars:

These shall conform to the requirements of IS:432, IS:1139, IS:1786. The dowel
bars shall conform to grade S240 and tie bars to grade S425 of IS.

2.7 Pre-moulded joint filler:

a) Joint filler board for expansion joints shall be of 20-25mm thickness within a
tolerance of +/- 1.5mm & of a firm compressible material.

b) It shall be 25mm less in depth than the thickness of the slab within a tolerance
of +/- 3mm & provided to the full width between the side forms. Its length shall
not be less than one lane width.

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c) Holes to accommodate dowel bars shall be accurately bored or punched out
to give a sliding fit on the dowel bars.
2.8 Joint sealing compound:

The joint sealing compound shall be hot poured, Elastomeric type or cold Poly-
Sulphide type having flexibility, resistance to age hardening and durability.

3.0 STORAGE OF MATERIALS:

3.1 Cement shall be stored above ground level in perfectly dry & watertight sheds. It
shall be stacked not more than 8 days high. When bulk storage containers are
used their capacity should be as per the requirement at site. The container
should be cleaned at least once every 3 to 4 months.

3.2 The platform where aggregates are stocked piled shall be leveled with 15 cm of
watered, mixed and compacted granular sub-base material.

3.3 Area shall have slope and drain. Space must permit easy inspection, removal
and storage.

4.0 PROPORTIONING OF CONCRETE

4.1 The mix design shall be submitted at least 30 days prior to the paving of trial
length and the design shall be based on laboratory trial mixes using the approved
material or on the basis of any other rational method agreed by the Engineer.

5.0 CEMENT CONTENT

5.1 The cement content shall not be less than 350 kg/cum of concrete.

5.2 If this minimum cement content is not sufficient, it shall be increased as

necessary without additional compensation under the contract.

5.3 The cement content shall not exceed 425 kg/cum of concrete.

6.0 CONCRETE STRENGTH

6.1 While designing the mix in the laboratory, correlation between flexural and
compressive strengths of concrete shall be established on the basis of at least
thirty tests on samples.

6.2 The water content shall be minimum required to provide the agreed workability
for full compaction of the concrete to the required density as determined by the

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trial mixes or other means approved by the Engineer and the maximum free
water cement ratio shall be 0.5.

6.3 The ratio between 7 & 28 day strengths shall be established for the mix to be
used in the slab in advance, by testing pairs of beams & cubes at each stage on
at least six batches of trial mix. The above ratio `R’ shall be expressed to three
decimal places.

6.4 If the average value of any four consecutive 7 day test results falls below the
required 7 day strength as derived from the value of `R’, then the cement content
of the concrete shall, without extra payment, be increased by 5% by weight.

6.5 The increased cement content shall be maintained at least until the four
corresponding 28day strengths have been assessed for its conformity with the
requirements.

7.0 WORKABILITY

7.1 The control of workability in the field shall be exercised by the slump test as per
IS:1199.

7.2 A slump value should be in the range of 30 +/- 15mm for paving works but this
may be modified depending upon size requirements & get approved by the
Engineer.

7.3 These tests shall be carried out on every truck / dumper initially but can be
reduced to alternate trucks as per the instructions of the Engineer.

8.0 DESIGN MIX

8.1 Laboratory trials of design mixes with the materials from approved sources
should be carried out.

8.2 Trial mixes shall be repeated if necessary until the proportions that will produce
concrete which conforms to the requirement of the design.

8.3 Any change in the source of materials or mix proportions during the course of
work shall be assessed by making laboratory trial mixes.

9.0 SUB-BASE

9.1 If the sub-base is found damaged at some places or it has cracks wider than
10mm, it shall be repaired with fine cement concrete or bituminous concrete
before laying separation layer.

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9.2 Before laying the concrete, separation membrane should be placed in position
and the same should be free from dirt or other extraneous materials and free
from any damage.
10.0 SEPARATION MEMBRANE

10.1 A separation membrane shall be used between the concrete slab & the sub-base.

10.2 Separation membrane shall be impermeable plastic sheeting 125 micron thick
laid flat without creases.

10.3 Before placing the separation membrane, the sub-base shall be swept clean of all
the extraneous materials using air compression.

10.4 Wherever overlap of plastic sheets is necessary, the same shall be at least
300mm.

10.5 The separation membrane may be nailed to the lower layer with concrete nails.

11.0 DOWEL BARS

11.1 Dowel bars shall be mild steel rounds and free from oil, dirt, loose rust or scale.
They shall be straight, free from irregularities.

11.2 The dowel bars shall be mechanically inserted with vibration into the plastic
concrete. Dowel bars shall be positioned at mid depth of the slab within a
tolerance of +/- 20mm and centred equally about the intended lines of the joint
within a tolerance of +/- 25mm.

11.3 They shall be aligned parallel to the finished surface of the slab and to the centre
line of the carriageway and to each other within tolerances.

12.0 TIE BARS

12.1 Tie bars in longitudinal joints shall be deformed steel bars of strength 415 MPa
complying with IS 1786 and should be free from oil, dirt, loose rust and scale.

12.2 Tie bars projecting across the longitudinal joint shall be protected from corrosion
for 75mm on each side of the joint by a protective coating. The coating should be
dry when the tie bars are used.

12.3 Tie bars at longitudinal joints may be mechanically or manually inserted into the
plastic concrete by a method which ensures correct placement of the bars and re-
compaction of the concrete around the tie bars.

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12.4 Tie bars shall be positioned to remain within the middle third of the slab depth,
with the centre of each bar on the intended line of the joints within a tolerance of
+/- 50mm, and with a minimum cover of 30mm below the joint groove.

13.0 WEATHER ANS SEASONAL LIMITATIONS

13.1 Concreting during monsoon months

When concrete is being placed during monsoon months, sufficient supply of

tarpaulin or other waterproof cloth shall be provided. All freshly laid concrete
which had not been covered for curing purposes shall be protected. Any concrete
damaged by rain shall be removed and replaced. If the damage is limited to
texture, it shall be re-textured.

13.2 Concreting in hot weather

No concreting shall be done when the temperature is above 30ºC to bring down
the temperature, if necessary, chilled water or ice flakes should be made use of.
No concreting shall be done when the concrete temperature is below 5ºC.

14.0 CONSTRUCTION

14.1 A systems approach for construction of the pavement & method statement for
carrying out the work should be adopted and got approved from the Engineer
before the commencement of the work.

14.2 Batching and mixing plant should be located at a suitable place and at an
approved distance, duly considering the properties of the mix & the transporting
arrangements available.

15.0 EASE OF LAYING

15.1 Fluidity (hardness) of concrete mixture taking into account its compaction
properties.

a) Sedimentation stability, adhesiveness (non-lamination) during technological

processing including during the process of vibratory compacting.

b) Volume of air entrapment in the concrete mix after compaction.

c) Longevity- i.e. long term and stable working of the concrete in the road cover
in the conditions during environmental extremity.

d) Strength for maintaining carrying capacity of the pavement.

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e) Processing ease, enough for formation of quality pavement surface and high
air-retaining capacity.

f) Stability of edges and sides of freshly laid pavement after passing of the
Rolling Machine having sliding form / shape.

15.2 The index of measuring ease of laying, defined by flow ability (setting of cone)
should be in the range of 2.5 – 5 cm at places of laying of pavement by
`GOMACO’ type equipment.

15.3 Volume of entrapped air in the concrete mix should be in line with equivalent
Indian Standard of GOST 26633-85. For preparing concrete for pavement as per
the required cold proofness, it is recommended that as mentioned in GOST
26633-85, volume of the entrapped air, should be attained not before 30 min.
after the concrete mix is prepared. At the place of usage the same should be in
the range of7-9% keeping in mind that after technological processing of the
mixture it will be constituting 5-7%.

15.4 Working composition of the cement concrete mixture is defined by introducing

supply of the nominal composition, which had been determined using dried
additives(dried to permanent mass), after taking into account factual humidity of
the additives.

If the actual humidity content of sand and large grain aggregate is equal to
Wp(%) and Wk2(%), respectively, then the working content of water Vr(kg), sand
Pr(kg) and large grain aggregate KZr(kg) in the cement concrete mixture will be.

(℘−P) (Wk 2 × KZ)

Vr=V −
100 100

(℘−P)
Pr=P−
100

(Wk 2−KZ)
KZr=KZ+
100

Where V, P, KZ are contents of water, sand and of large grain aggregate

respectively in 1m3 of concrete of nominal composition.

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15.5 Working composition of concrete (water content) if necessary needs to be
compensated after taking into account concentration of the water solution
containing plasticizing and air entrapping additives.

15.6 During correction/compensation of the cement concrete composition, it is

necessary to follow the following stipulations.

a) Processability (ease of furnishing) of the concrete mix improves with increase

in the comparative content of the solution in a unit volume of concrete.

b) Sedimentation stability, adhesiveness (non lamination) of the concrete mix

during its technological processing and vibratory compacting (at optimal
content of cement and minimum quantity of water) increases with increase in
the volume of entrapped air and relative content of sand in the mix of
aggregates i.e. co-efficient of splitting of high grain aggregates in the solution.

c) Air-retaining property of concrete mixture i.e. property of the mixture to

preserve, during the technological processing, the air content trapped during
mixing with air, increases with the increase in relative content of sand in the
mix of aggregates(co-efficient of splitting) and its specific surface.

d) Stability of the edges and sides of freshly laid pavement after passing of
sliding shaped concrete laying machine, increases, if there is decrease in the
fluidity of the concrete mix, size of the aggregates and if the relative ratio of
the sand in the aggregate mix is increased (splitting co-efficient).

e) Requirement of water for concrete mix i.e. quantity of water necessary for
preparing the concrete mixture of a given fluidity(rigidity), practically does not
change for cement content from 350 to 380-390 kg/m 3.

f) Fluidity (Rigidity) of the concrete mix is defined by the water content, volume
of the entrapped air, quantity of the plasticizing, air entrapping chemical
additives, and also to a great extent, by the relative sand content in the
aggregate mix (co-efficient of splitting of large grain aggregate in the solution).
Concrete mixtures with air volume of about 50-60 L/m3 and co-efficient of
splitting of 1.6-2.2 (depending on the size of sand grains) have the lowest
requirement of water (at standard conditions).

g) Volume of the air entrapped by the concrete mix is defined by the quantity of
the air entrapping additives, grain size, and natural mineral aggregates,
cement content, and its properties, fluidity of the mixture, ratio of the large
size and small size aggregates, the temperature of the mix and the method
and duration of mixing and compaction.

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h) The air content increases with increase in the fluidity of the concrete mixture,
increase in the ratio of sand in the mixture of aggregates intensiveness and
duration of the mixing. With increases in temperature of the content mix and
duration of vibration (specially with deep vibrator) the air content decreases.

i) Longevity (life) of the concrete to a large extent depends on the initial ratio of
water and cement, water content in the concrete mix, air bubbles in dried
concrete and the concrete working process (technology). In order to ensure
long life of the concrete at minimum cement content, it is necessary to
prepare the concrete mix along with a range of additives (PAV0 – plasticizing
and air entrtapping agents. At the same time, the volume of air entrapped
should be as per norms given in p 15.3.

j) Strength of the concrete on input materials depends on the water cement

ratio, volume of air bubbles after compaction of the concrete mixture and the
technology of concrete work (specially quality of mixing, vibratory compaction,
method of maintenance of freshly laid concrete).

16.0 Dosage of constituent components of working mix of cement concrete in the

mixing chamber is done at following time interval:

Crushed stone ballast & sand : 2 sec.

Cement : 2 sec.
Water & Chemical additives : 5 sec.

16.1 Chemical additions are put into the mixture simultaneously with water. Additions
of chemical ingredients should be completed 3-5 seconds before the addition of
water is completed.

16.2 Mixing of the concrete after adding chemical additions for 30 seconds.

16.3 If during the process of preparation of concrete mixture, insufficient quantity of air
is entrapped, then the amount of air entrapping agent required to be added as
per the factual requirement should be indicated in the work sheet prepared by
Civil Laboratory. This should not be based on the theoretical (nominal) selection
and should ensure the necessary amount of air entrapment at the place of
pavement concrete laying.

The required degree of air entrapment can be attained by increasing the time of
mixing of the concrete, after the addition of chemical additives, upto 40-50 secs.

17.0 TRANSPORTATION OF CEMENT CONCRETE MIXTURE

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17.1 Construction process of preparation and transportation of cement concrete mix
should ensure un-interrupted process of concrete laying Manually.

17.2 The properties of concrete mix in the pavement depend on the process of
technological preparation of concrete mix with sufficient ait intake. Periodic
completion and loosening of the mixture in case of increased duration of
transportation and time difference between preparation and compaction of
mixture in the pavement may lead to decreased cold resistance of the concrete
mix with chloride salts, due to losses and changes in the structure of air phase.

17.3 The conditions mentioned in 17.1, 17.2 demand an organized movement of

automobile transport on constructed base and previously laid concrete pavement
track. At places of entry into concrete pavements or tracks, metallic or modern
ramps should be installed.

17.4 Quantity of the automobiles (vehicles) required for maintaining the shift wise
tempo of work, is calculated as follows:

N = Q x p x (2L/V + ti + tr) / q x Kv x Kt x T

Where Q = Volume of mix, m3 – Additional quantity.

P = Density of mixture, T / M3.
L = Distance of transportation, KM.
Ti,tr = Time of loading & unloading , respectively.
Q = Load capacity of vehicle, T.
Kv = Coefficient of utilization of time between shifts.
Kt = Coefficient of changeover from technical efficiency to
execution efficiency.
T = Duration of shift, hour.

18.0 PREPARATORY WORKS

19.0 MOBILISATION OF THE MACHINES FOR WORKS

20.0 REGUALTION OF “OUT-FLOAT”

21.0 WORKING ON EXISTING PAVEMENT

22.0 FORMATION OF ROUGH SURFACE, CARVING OF FRESHLY LAID

CONCRETE WITH THE HELP OF FILON FORMING MATERIAL T/S-600

23.0 UNIT FOR TEXTURING OF THE SURFACE

24.0 SPREADING OF FILM FORMIMG MATERIAL.

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25.0 UNIT FOR DEFORMATION JOINTS

26.0 UNIT FOR JOINTING

26.1 During long periods of intervals in the work or at the end of a working shift, it is
required to make joints, which are recommended to be mixed with the joints of
the next row in the following manner:

a) Spread the concrete mixture with some excess material beyond the line of the
next joint.

b) Remove the concrete mixture from the area of the joint and secure at the
base of the side form, so that the next joint is in line with the upper surface of
the pavement.

c) Remove the concrete mixture, which is pushed out from beneath the sliding
forms on the sides of plates. Fix the forms on the bases. Spread the mixture
with some allowance in steps of 40 cm.

d) The vibrator should be lowered on to the concrete vertical to the plane of the
concrete and it should be lifted uniformly, taking due care that holes / cavities
are not formed in the concrete, the surface of the pavement should be
finished using a press and dress the edge of the joints using G-type trowel, in
such a way that a rounded edge of 1 cm radium is formed.

26.2 While continuing to work on concreting of pavement it is necessary to remove the

side and edge moulds, cover the sides with film forming material, spread the
concrete mixture, compact it using deep vibrators, around the joints and dress the
surface of the concrete (smoothness is checked using a 3 M long leveling rod).
Thereafter the other edge of the joint should be rounded using a G type
smoothening fixture. Subsequently, in the dry concrete, slot is cut and filled with
sealed material.

27.0 SEALING OF JOINTS

27.1 The filing of deformation joints should be done at an air temperature of +5C.

27.2 The preparation and filing of the above joints with sealing material should be
carried out in the following sequence:

a) The joint should be washed immediately after cutting until all slurry / slime is
removed.

b) The slots should be treated with compressed hot air (temp. +50 to 60C) under
pressure.

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c) A 12 mm dia rubber string should be laid at the bottom of the slot using manual
means, taking due care that the string is not stretched. This is essential to
prevent entry of mastic under slot of the joint.

d) The walls of the slots should be applied with primer coat.

e) Not later than 30 minutes after priming, the joints should be filed with mastic.

f) Excess of mastic, which comes out of the slots of the joint, should be cut off using
a sharp scraper after initial preheating.

28.0 QUALITY CONTROL.

28.1 The control of quality of work during construction of cement concrete pavement
should be carried out by specialized experts. The operational control of quality
should include.

a) Inward inspection of incoming materials for preparation of cement concrete

mix and various tools / machinery for executing the work.

b) Operational control of individual processes during preparation of concrete

mixture and hardware used for such processes.

c) Acceptance inspection for concrete pavement construction work.

28.2 During inward inspection of incoming materials, visual checks should be carried
out as per catalogues / documents and establishing of the conformity of the
materials to the standards and norms. If necessary in certain cases, it may be
required to verify the quality of the materials by actual testing of specimens as
per the applicable norms for that material. Based on the results of the inward
inspection, permission may be given for usage of these materials for construction
of pavement.

28.3 Operational quality checks should be done during execution of individual

technological processes for construction of the concrete pavement. It should
ensure timely detection of defects and steps taken for their prevention and
rectification. The results of such operational quality checks should be recorded in
the respective logbooks.

The extent of the operational and inward inspection and its content is governed
by SN & P 3.06.03-85 and SN & p 3.06.06-86 and also as per the process sheets
for the given work.

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28.4 During all stages of construction work, selective inspection should also be done
to ensure effectiveness of the earlier checks carried out. Such selective
inspection should be done by specialized experts or special purpose inspection
committees set up for this purpose.

28.5 All laboratory tests for the purpose of process and inspection control is done by
specialized laboratories including site laboratory established by Centrodorstroy.

28.6 Quality check of concrete mixture should be carried out at the concrete
manufacturer’s place and at the site of concreting work. This should include
inspection of the raw materials for making of concrete and control of the
properties of the concrete mix.

28.7 During the period of storage of the raw materials at the stores and also in the
plant, it is essential to monitor the properties of the materials. The frequency of
such checks is decided by visual inspection of the state of such materials and
also by any change in the properties of the same. When incases where cement is
stored for more than 30 days from the day it is supplied by the plant, inspection of
the same should be carried out. For high quality cement, same should be done
after 60 days of supply. After expiry of this duration and thereafter for not less
than every 3 months. It is essential to undertake periodic testing of cement for its
density, time for setting, uniformity of volume, fineness of the grains and
activeness.

During periodic inspections, the quality of the finer component i.e. sand, is
determined by the humidity content, grain structure, grain size and presence of
dust and clay particles.

28.8 In case of doubts during inspection of chemical additives, it is necessary that they
are subjected to special tests. The concentration of the working mixture of
chemical additives should be checked in the flow reservoir during dosing and also
whenever a new solution is prepared.

28.9 Ease of laying and volume of entrapped air should form a part of the compulsory
checking of cement mix technical parameters. However, the same should be
checked in the plant in case of obvious change in the quality of the mix. It is also
recommended to assess the cohesive properties (non-lamination) of the concrete
mix and also separation of water and breakdown in the homogeneity if any of the
solution as per GOST 10181.4.81.

28.10 Parameters like ease of laying and air entrapment at the manufacturing plant
should be determined after a gap of about 30-40 min after selection of the test
specimen. This is required for proper stabilization of the properties. During this
time the specimen should be well protected from all environmental precipitations
and evaporation of humidity.

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28.11 In addition to above it is also advised to verify the composition of the concrete
mix by wet screening method in case of obvious worsening of “ease-of-laying”
properties presence of non-cohesiveness, water separation and so on i.e. break
down in the properties of the mixture.

28.12 For determining the compositions of the concrete mix by wet screening method it
is recommended to select an average specimen (about 10-15 kg) thoroughly mix
it and separate in two parts and then weigh each portion. The first part should be
dried, while continuously stirring it, cooled and then weighed again. The second
part, should be laid on a sieve with mesh size 0.16 mm and washed in flowing
water till the water coming out of the sieve becomes clean. The specimen left
over on the sieve should be dried, cooled and weighed after passing through
another sieve of mesh size 5 mm. The dries residue on the 0.16 mm mesh sieve
gives the summation of mass of sand and stone.

The humidity content of the mix is determined by the following formula:

Rv−Rs
V= × 100
Rs
Where Rv = Mass of mix before drying
Rs = Mass of dried mix.
For increasing the accuracy of determining the above, along with the selection of
specimen of concrete mix, another specimen is taken from the running conveyor
of sand and stone (5-10 kg of each). They are likewise dried, weighed, washed
using a 0-16 mm mesh sieve and subsequently once again dried, cooled and
weighed. The quality of particles of size < 0-16 mm is deducted.

28.13 Similarly it is also advised to periodically check the quality of mixing of concrete
mixture by comparing the content of coarse grain content in the specimen,
selected at the start, during the process and at the end of unloading of the
mixture. The quantity of the coarse grain content in the specimen should be
determined by wet screening method on a sieve of 5 mm mesh, for this the
difference between the content of the coarse grain in 3 different specimens
should not exceed 5%.

28.14 Based on the results of inspection of the quality of concrete at the concrete
supplying plant, conformity of the concrete to the designed characteristics is
verified. Based on the results of inspection at the site, actual strength of the
concrete in site conditions is determined.

Specimens of the concrete prepared at the site should be subjected to, if

necessary, strength testing at various ages, for example, during opening up of
transport, determination of effect of hardening conditions of strength, lowering of
ambient temperature and similar situations.

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28.15 For determining the quality of concrete, it is recommended to additionally monitor
the parameter of its porosity.

28.16 During inspection the volume of the concrete mixture should be determined as
per 2.10 GOST 7473. It should be noted that volume of the entrapped air at the
manufacturing plants after 30 minute after mixing should be 5- 6% in conformity
to the composition of the mix.

Non-conformity of the volume of concrete mix produced at the plant and that
received at site may be observed due to change in the volume of entrapped air
and as a consequence, change in density of the mix at the produced at the plant
should take into consideration the actual density.

For this, the actual requirement of materials for 1 m 3 of concrete mix should be
determined as per the nominal composition and actual density of the mixture. The
total actual requirement of the materials will depend on the actual volume of
concrete pavement. During inspection of geometric dimensions of the edge of the
pavement slab after the concrete layer has passed, it is necessary to check the
following:

a) Deviation from cross incline at the edge of the slab.

b) Deviation from the vertical position of the side face of slabs

c) Roughness of the slab edges along the height in the longitudinal direction

d) Extent of flow of the edges.

e) Deviation from straightness in the longitudinal direction

f) Edges of the slabs.

Inspection is carried out 3-5 minutes after the passing of concrete laying
equipment. For inspection, it is recommended to use the following.

i) 3 meter long leveling road

ii) Triangle, side of which should be equal to or more than thickness of
the slab.
iii) 2 Scales for measuring not less than 50 cm.

28.17 Change in the cross incline and deviation from vertical position of side face of the
slabs should be determined at the beginning of the shift, after long period of
stoppage of work and also in cases where there are obvious change in the same.
Deviation along the height in the longitudinal direction should be monitored

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constantly throughout the shift. The extent of flow of the edges is determined
selectively.
28.18 Deviation from the cross incline at the edge of the slabs can be found out with the
help of a 3 meter leveling rod. The end of the rod should project out by 10 – 15
cm. From the edge of the pavement and the height of the surface roughness, not
more than ± 3 mm.

28.19 Deviation from the verticality of slab side face can be measured with the help of
triangle and scale. The triangle is put on a surface, which is free from concrete
etc. and with the help of the scale; depending on the thickness of pavement h the
value of L is determined. The later should not exceed 0.18 h.

28.20 For arriving at the value of the roughness on the edges of the slab, along the
height in the longitudinal direction, a 3 m. leveling rod and wedge should be used.
The rod is put on the edge of the slab. Gap in the longitudinal direction should not
exceed 3 mm.

28.21 The extent of flow of the pavement edges is determined with the help of two
scales. The allowable extent of the flow for pavement strips adjacent to each
other should be 6 mm and the edge strips – 12 mm.

28.22 Deviation from linearity (straightness) in the longitudinal direction of the slab
edges is measured with the help of 3 m. leveling rod, which is put along the upper
part of the side face. Deviation from straightness is allowed depending upon the
condition of subsequent cutting of slot for longitudinal joint in the dried concrete.

28.23 The accuracy of installation of the rails form should be checked by control
leveling of each joint. The areas of settling or slumping are rectified. It is
recommended that currature of the rails form does not exceed 2 mm in the
vertical plant and 5 mm in the horizontal plane. For ease of installation and
speeding up of the work of rails form, they are numbered.

28.24 The accuracy of installation of the master wire should be checked constantly at
all stages as follows :

a) Accuracy of installation is checked with pegs for their collinearity by using

theodolite, distance between pegs in the longitudinal direction and the
distance from axis or edges of the pavement to the installed leveling pegs
is measured by using measuring taps.

b) Control inspection of leveling is carried out.

c) The strength of fixing of supports and their stability is checked, giving

special attention to the fixing of cramps and the accurate matching of slabs
of cross beam with the top of leveling pegs.

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d) The height level of wire above the leveling pegs is checked using a
template and scale. The extent of tension in the wire is also ascertained.

28.25 During cutting of slots in the hardened concrete, it is necessary to monitor and
control the time of cutting and geometrical parameters of the joint. The
geometrical parameters of the joint are recommended to check with the help of
nylon string and a metallic scale. The slots of the joints should be straight and
any deviation from straightness should not exceed 3 mm for 1 m.

28.26 Before filing of the deformation joints, it is necessary to visually check the
following:

Thorough cleaning of the slots, proper washing and the extent of drying,
formation of proper depth of filling and the quality of priming of slots of joints.
During the heating of mastic in the vessel, visual control should be ensured for
presence of any foreign matter in the mastic (paper, stone, gravel, etc.) and same
should be removed timely, temperature of heating of the mastic, time of soaking
and its homogeneity, After filling of the slots is complete, the quality of filling
should be checked visually.

28.27 After expiry of the guarantee period of storage of mastic, which should meet the
technical requirement of 6 months, from the date of supply to the user, mastic
should be used only after checking of the same for conformity to the technical
conditions.

28.28 During maintenance of freshly laid concrete it is necessary to check the quality of
film forming materials; its viscosity, inclusion of the film forming substance (dry
residue) for “PM” type materials or content of bitumen in the bitumen emulsion,
filtration properties of the film forming material and also the quality of its
application on the fresh concrete. The indicated checks should be carried out not
less than 2 – 3 times for each batch of materials. The specimen for inspection
should be selected from the transportation vessel (drums, cisterns) and at he exit
of the sprayer during the working of the equipment.

28.29 In case of detection of unsatisfactory results during inspection of application of

film forming material, an additional layer of the same should be applied. The
quantum of such checks should be not less than 3 time throughout the period of
drying. Quality (uniformity and continuity) of application on the concrete surface
of emulsion of humidity evaporator type “DSSL” is checked visually.

28.30 In the process of construction, it is recommended to also verify the planarity of

each strip of pavement in the longitudinal direction by either:

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a) At 5 control points recording of clearances below 3 m metallic leveling rod,
suing wedges (measuring type). These control points should be located at
0.5 m from the edge of rod, and from each other.

b) Or by the reading of indicators of the mobile twin stand leveling bar, type
PKR-1 or PKR-5, moving them along the pavement across equal
distances.

c) Or by analyzing the graphic printouts from the multi-stand leveling bar,

type PKR-4M.

With the usage of the above mentioned apparatus, roughness of upto 3.0 m
length can be inspected. The place of measurements should be selected in such
a way that it reflects the overall quality of the surface and takes into account the
technological specifics of the equipment or the pavement.

Measurement of roughness, inspection of conformity to actual longitudinal profile

to the designed values, determination of the differences in the levels or projection
of edges of adjacent slabs – all these are recommended to be done at distance of
0.75 – 1.0 m from upper (with reference to the pavement axis) edge of each strip.

28.31 The texture of the surface also needs to be inspected in the process of
construction of the pavement suing the “sand-spot” method (instrument type KP-
138). Average depth of “Valleys” of macro roughness is determined as per
formula:

V 4V
H avg =10× =10 × 2
F nD

Where, V = Volume of sand, distributed on the surface upto the “perks” of the
projections, cm3

F = Area on which sand is spread, cm2

D = Diameter of the sand spot, cm.

The instrument “sand spot” consists of 2 measurement glasses of volumes 10

and 25cm3 of sand.

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Measurement of textured roughness (mean depth of “valleys” ….?) is done in the
following manner:

On the pavement surface using the measurement glasses, a portion of fine dry
sand is spread. The size of grains of sand should be 0.14 to 0.31 mm. The
volume of sand depends on the type of texture: for slightly textured surface – 10
cm3, for average texture – 25 cm 3 and for highly textured – 50 cm 3. Thereafter,
using the disc, sand is spread by moving it in a rotating manner until all the
“Valleys” are filled up. After this process is over, sand should be in the form of a
uniform circle and on the surface only the peaks of the highest projection should
be visible. Then, the monogram is laid on to the sand with the respective scale
conforming to the volume of sand. The end of the scale is marked on to the san
spot using a triangle and the marking on the scale is counted upto the end of the
spot. If, during spreading of the sand on the pavement surface, a non uniform
circle of sand (ellipse) is formed, then the measurements are carried out on the
major and minor diameters of the ellipse and mean values are taken.

Such measurements should be carried out in dry season. On each strip of the
pavement lane, 5 measurements for 1000 m should be taken. An arithmetic
mean of the results is taken from all the readings for a given stretch.

28.32 Keeping in mind the specific technological requirements of construction of the

base from hard concrete mix, the construction laboratory should also monitor the
following:

The degree of compacting of the laid concrete on the full thickness by the method
of indentation based on 3 measurements on a 1000 sq.m. base (similar to the
testing of bases from large grain soil).

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WORK INSTRUCTION TABLE
[Note: The indices in the following tables are as per standards of Centrodorstroy for
working at Russia. The parameters shall be modified to suit Indian Standard]
OPERATIONAL QUALITY CONTROL FOR PREPARATION OF CONCRETE MIX AT
THE CONCRETE MANUFACTURING PLANT
Sr. Control parameters Allowable deviations as Volume of test Responsible
No. per SN&P 3.06.03-85 (Specimen) Authority

1. Cement PTs 500-DO-N As per requirement of At lest 1 test for Laboratory

GOST 10178-85 each batch
- Fitness of grain Residue on sieve No.008
- Normal density of not more than 15%  1%
cement mass as per technical
- Duration of setting documents
Start not before 2 hrs.
End not later than 10 hrs.

2. Sand
As per requirement of At least once in a Laboratory
- Granulometric GOST 8736-93, GOST shift
composition 26633-91
- Content of dust and
clay particles MKT = 1.5 – 3.25
- Humidity Not more than 2%

3. Crush Stone 5 – 20 mm As per GOST 8267 and At least once in a Laboratory

GOST 26633 shift
- Granulometric Complete residue on
composition sieve
- Content of dust and Not less than 1%
clay particles
- Humidity
- Type of stones per > 1200 Not less than 1
size testing from each
- Content of grains of < 25% batch
needle and laminar
forms
- Cold resistance > F150

4. Additions As per GOST 24211 As per tech. Laboratory

Documents
- Content of dry 45 – 95%
components
- Concentration of the LST - 10% Not less than
working solution SNV - 3% twice in a shift and
on preparation of
a new batch

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OPERATIONAL QUALITY CONTROL FOR PREPARATION OF CONCRETE MIX AT THE CONCRETE
MANUFACTURING PLANT
Page 2

Sr. Control parameters Allowable deviations as Volume of test Responsible

No. per SN&P 3.06.03-85 (Specimen) Authority

5. Concrete Mix As per GOST 26633-19 & Not less than once Laboratory
GOST 7473-94 on a shift and
- Correction of the mix every time during
as per the grain atmospheric
composition of sand precipitation and
and stone and change in the
depending on their supplier
humidity content

- Entrapment of air As per removal of air for Not less than 4

mass compaction of 6-8% at times in a shift
the site of laying, 5-7% in
hardened concrete

- Shrinkage of cone 4-5 cm at site Not less than

twice in a shift

- Wet screening As per the approval Once in a shift

Composition of concrete

- Volumar mass of mix As per design specs. Once in a shift

6. Concrete As per design spec. & Laboratory

GOST 18105-86
- Compression  10% of the design value 6m3 10x10x10 cm
strength 7 & days in a shift

- Tension strength  10% of the design value 3 points 10x10x40

against banding in cm in a shift
28 days
12m3 10x10x10cm
- Resistance to cold > F150 for 3 points, not
less than once in a
quarter

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WORK INSTRUCTION TABLE
FOR OPERATIONAL QUALITY CONTROL OF CONCRETE LAYING UNIT

Sr. Control parameters Allowable Volume of test Responsible

No. deviations as (Specimen) Authority
per SN&P
3.06.03-85
1. Correctness of the + 5 cm from Not less than after 100 Geologist
location of the axis line designed m at 3 points across
and at places where
working division –
signs are located

2. Height levels 5% + 2 cm Not less than after 100 Geologist

95% + 1 cm m at 3 points across
and at places where
working division –
signs are located

3. Cross incline 5% of the results Not less than after 100 Geologist
of measurement m at 3 points across Supervisior
may have a and at places where Foreman
deviation of –0.01 working division –
to 0.015 Rest + signs are located
0.05
4. Planarity (clearances) 2% of the After 50 m. at 3 place Geologist
below 3 m levelling rod readings may across Supervisor
have the value Foreman
upto 6 mm, Rest Laboratory
upto 3 mm.
5. Thickness of layer + 1.5 cm At 2 points across Geologist
taken after 50 m. Supervisor
Foreman

6. Width of layer + 5 cm Across after 50 m. Geologist

Supervisor
Foreman

7. Shrinkage of cone of 5-6 times in a shift Laboratory

concrete mix at the site

8. Amount of entrapped air 5-7% 5-6 times in a shift Laboratory

in the concrete mix at
the site

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WORK INSTRUCTION TABLE
FOR OPERATIONAL QUALITY CONTROL OF CONCRETE LAYING UNIT

Page 2

Sr. Control parameters Allowable Volume of test Responsible

No. deviations as per (Specimen) Authority
SN&P 3.06.03-85
9. Spreading of the Checked along the Supervisor
concrete mix, vertical face of the Foreman
thickness and width of scale, with feeler Laboratory
layer gauges with
allowance for
coefficient of
compaction
10. Cutting of joints Supervisor
Foreman
11. Cutting of slots for Overall depth not
joints less than ¼” of the
thickness of
pavement, reduction
of depth not allowed
Depth of the upper
Widened part of the 3 cm + 5 mm
joint

Width of joint:

- Longitudinal 10 – 12 mm ± 1 mm
- Transverse
12. Cleaning of the slots Visual inspection Foreman
of the joint, laying of Supervisor
rubber strap, priming
of the slot, filling of the
slot with mastic
13 Uniformity of Foaming due to Visually and by Foreman
spreading of the film hydrochloric acid not hydrochloric acid Supervisor
forming material and more than 2 spots in after 50 m, at 3 Laboratory
the quality of film 1 dm2 places across
14 Viscosity of the film 15 Sec. as per Twice in a shift Laboratory
forming material viscosity meter VZ-4
15 Difference in the 10% upto 6 mm, Every joint Foreman
levels of surface at the rest upto 2 mm. Supervisor
joints on the pavement Laboratory
16. Roughness in texture Depth of roughness By “sand-spot” Laboratory
of the pavement 0.5 – 1.5 mm Method, 5 readings
At 1000 m. on one
Stretch of laying

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CEMENT CONCRETE KERB

OPERATIONAL PROCEDURE:

Kerbs will be constructed cast-in-situ with suitable kerb casting machine in all situations
except at locations where continuous casting with equipment is not practicable. In such
situations, precast blocks will be used.

The machine which has adequate capacity and controls and is capable of laying the
kerb in required cross sections and producing a well compacted mass of concrete free
of voids and honeycombs will be used.

Kerb will be laid on firm foundation as per the drawing and specifications. Before laying
the foundation, the base will be levelled and slightly watered to make it damp.

In the median portions in the straight reaches, the kerb will be cast in continuous lengths
whereas in the portions where the slope of the carriageway is towards median sufficient
gap will be left in the kerb to facilitate drainage openings.

After laying the kerb and just before hardening of the concrete saw cut grooves will be
provided in 5 M intervals or as specified by the Engineer. On the drainage ends such as
along the footpath or the median in super-elevated portions, kerbs will be cast with
monolithic concrete channels as indicated in the drawings.

The slope of the channel towards drainage pipes will be strictly ensured for efficient
drainage of the road surface.

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STRUCTURAL CONCRETE
Proportioning of concrete:

Prior to start of construction of concrete, we shall design the mix for particular
grade and submit for approval of the customer, for construction of all structural
concrete mix design of concrete.

For local smaller quantity of concrete, concrete mixer with weigh batching
arrangement shall be deployed.

For substantial volume of concrete work concrete shall be produced in centrally

located concrete mixing and batching plant. Transportation of concrete shall be
done with transit mixers and or by dumper under approval of engineer. For
transportation of concrete at longer distance, suitable plastisier shall be used.
Pouring of concrete shall be done with concrete pump or manually.

Conventional formwork shall be used in general.

For retaining wall type structure special formwork shall be designed which can be
removed and replaced for further construction at a faster speed.

Compaction of concrete shall be done generally with needle vibrator.

Special care shall be taken so that concrete does not segregate while pouring
and also concrete is compacted properly to form a dense mass and also
produces smooth surface finish.

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