D.V.Bhavanna Rao. M.Tech., F.I.E.

,
Retired R&B Chief Engineer
PM, TPQA, NCRMP&AF
Ph:9494440202

6/14/2018 d v bhavanna rao

 Important IRC Publications and IS codes
IRC:SP:42-2014 Road Drainage
IRC:SP;50-2013 Urban Drainage
IRC:35-2015 road markings
IRC:67-2012 Code of practice for road signs
IRC:82-2015 Maintenance of BT roads
IRC:116-2014 Ready made pot hole mix
IRC:119-2015 Guidelines for traffic safety barriers
IRC:58-2105 Guidelines for design of Rigid Pavements for
Highways
IRC:37-2012 design of flexible pavements
IRC:15-2017 Construction of CC roads
IRC:SP-73-2015 Two laning with paved shoulders
IRC-75-2015 Guidelines for design of High Embankments
IRC:SP-84-2014 manual fo 4 laning under PPP
IRC:SP-87-2013 Manual for Six Laning
IRC:SP-89-2010 Guidelines for Soil and Granular Material
Stabilisation
6/14/2018
using Cement, dLime & Fly Ash
v bhavanna rao
 Important IRC Publications and IS codes continued

IRC-SP-76-2015 Conventional and Thin White Topping

IRC-SP-72-2015 Flexible pavement design for rural roads
IRC-SP-62-2014 (CC pavement for low volume roads)
IS 2911 Design and Construction of piles
IRC -78 - 2014 Standard Specifications and Code of Practice for
Road Bridges
IRC-112-2011 Code of practice for Concrete bridges
IS 269-2015 Ordinary Portland Cement Specification
IS;456-2000 Plain and reinforced concrete code Of practice
IS 9000 2005 Project Management
!S; 516: Methods of tests of Concrete strength
IRC-SP-108-2015 Environment Management Plan
IS:34 Handbook on Concrete Reinforcement And Detailing
IS 1786:2008 Standard Code for steel reinforcement including
Amendment issued in 2012
6/14/2018 d v bhavanna rao
 Ministry of Road Transport & Highways
Standard Specifications
for Road and Bridge Works
MORTH – 5th Revision - 2013

6/14/2018 d v bhavanna rao

MORTH(5th revision)300 Earthwork, Erosion control and Drainage
301 Excavation for roadway and drains
302 Blasting operations
303 presplitting rock excavation slopes
304 Excavation for structures
305 Embankment construction(including sub Grade and
shoulders)
306 Soil erosion and sedimentation control
307 Turfing with sods
308 Seeding and mulching
309 Surface/ sub surface drains
310 Preparation and surface treatment of formation
311 works to be kept free of water
312 water course at culverts
313 Rockfill embankment
314 Ground improvement for weak embankment foundation using
geosynthetics
6/14/2018 and stone columns
d v bhavanna rao
 400 Sub-bases, Bases (non bituminous)
and Shoulders (5th Revision)

401 Granular Sub Base

402 Lime treated soil for improved sub grade/ sub base
403 Cement treated soil and cement fly ash treated soil
for sub-base/ base
404 Water Bound macadam sub-base/ base
405 Crushed cement Concrete sub-base/ base
406 Wet Mix Macadam sub-base/ base
407 Crusher Run Macadam base
408 Shoulders, Islands and median
409 Cement concrete kerb and kerb with channel
410 Footpaths and Separators
6/14/2018 d v bhavanna rao
 500 Bases and Surface courses (Bituminous)
(5th Revision)
501 General requirements for Bituminous pavement
layers.
502 Prime coat over Granular Base
503 Tack coat
504 Bituminous Macadam
505 Dense Bituminous Macadam
506 Sand Asphalt base course
507 Bituminous Concrete
508 Close-Graded premix surfacing/ Mixed seal
surfacing
509 Surface Dressing
510 Open-Graded premix surfacing
6/14/2018 d v bhavanna rao
 500 Bases and Surface courses (Bituminous)
continued (5th Revision)

511 Seal coat

512 Slurry seal
513 Fog spray
514 Micro Surfacing
515 Stone Mastic Asphault
516 Mastic Asphalt
517 Crack prevention Courses
517 Recycling of Bituminous pavement
518 Bituminous Cold Mix (Including Gravel Emulsion)
519 Recycling of Bituminous Pavement
520 Supply of stone Aggregates for pavement courses
6/14/2018 d v bhavanna rao
 Other Important Sections (5th Revision)
100 General
200 Site Clearance
600 Concrete Pavement
601 Dry Lean Concrete sub Base
602 Cement Concrete Oavement
700 Geosynthetics
800 Traffic signs, markings & other road appurtenances
900 Quality control for road works
1000 Materials for structures
1100 Pile foundations
1200 Well foundations
1600 Steel Reinforcement
1700 Structural concrete
2000 Bearings
2100 Open foundations
2500 River Training and Protective Works
2600 Expansion joints
2700 Wearing coat and appurtenances
3100 Reinforced Earth
3200 Soil nailing
6/14/2018 d v bhavanna rao
 Shoulders Shoulders
Granular Base
Granular sub Base
Granular Sub base
Sub-Grade

Embankment

typical cross section of road (with 2 layer GSB) showing

the required pavement composition as per IRC
guidelines.
Minimum thickness of each GSB layer is 100mm.
6/14/2018 Grading III and IV dare suitable
v bhavanna rao for drainage layer
Important Quality Control Tests in Selecting soil or earth
for embankment, sub-grade and shoulders

Liquid Limit in% (water absorbing nature)

Plasticity Index in% = L.L - P.L (Softening Nature)
Free Swell Index in% (expansive nature)

Maximum Dry Density (indirect strength indicator)

Optimum Moisture Content in% (enables effective
compaction at site)
Standard Procter’s Compaction for low traffic roads
Modified Procter’s Compaction for high traffic roads

California Bearing Ratio (CBR in%) indicates bearing

6/14/2018
capacity
d v bhavanna rao
 MORTH - Important Soil Requirements as per Clause
305 for Embankment, Sub-Grade and Shoulders
Sub Grade
S No Soil Characterstics Embankment and
Shoulders
1 Liquid Limit Max.50% Max.50%
2 Plasticity Index Max.25% Max.25%
3 Free swell Index Max.50% Max.50%
Min. 1.52kN/cuM
MDD (modified up to 3m height Min.1.75kN/cu
4
Procter’s test) Min1.60kN/cuM M
above 3m height
5 CBR - As specified

Expansive soils are not allowed in the embankment

6/14/2018 layers below sub
d v bhavanna rao grade for 500mm thick
MORT&H Table 300-1, Density Requirements of Embankment
and subgrade materials
Maximum laboratory dry unit
S.No Type of work weight when tested as per
IS:2720 (part 8)
Embankment up to 3m
1 height, not subject to Not less than 15.2kN/cu.m
extensive flooding
Embankments exceeding
3M height or embankments
2 Not less than 16.0kN/cu.m
of any height subject to
long periods of inundation
Subgrade and earthen
3 Not less than 17.5kN/cu.m
shoulders/ verges/ backfill

Notes: 1) This table is not applicable for lightweight fill material e.g. for
cinder, fly ash etc. 2) The engineer may relax these requirements at his
discretion taking into account the availability of materials for construction
and other relevant factors. 3) The material to be used shall satisfy design
6/14/2018 d v bhavanna rao
at CBR at the dry unit weight as applicable in table 300-2
 Procter’s Compaction test
IS: 2720 part 7 & 8

7 Standard Procter’s test:

light hammer: 2.6 Kg
310mm drop - 3 layers
8 Modified Procter’s test:
heavy hammer: 4.89 Kg
drop: 450mm - 5 layers
1000 cc mould: 25 blows
2250 cc mould: 56 blows
larger mould for coarser
materials is to be used
if more than 20% is
retained on 4.75mm sieve
test be conducted on
material passing 20mm IS
6/14/2018 d v bhavanna rao
sieve
 Note : 1 g/cm3 = 9.81 kN/m3
Proctor Test Curve (Dry Density vs Moisture Content)
6/14/2018 d v bhavanna rao
Loading of embankment material at approved borrow source.

6/14/2018 d v bhavanna rao

Dumping of embankment material. Quantity required for a single
layer(maximum compacted thickness is 250mm) in a measured
and marked area.

6/14/2018 d v bhavanna rao

 Construction aspects of earthwork

• Max.250mm (vibratory) and

Layer thickness
200mm (ordinary)

Moisture content • +1 to - 2% on OMC

• Clods larger than 75mm shall be

Breaking clods broken.

Trimming: additional width of 0.6m on either side

to ensure proper edge compaction

6/14/2018 d v bhavanna rao

Sectioning the soil uniformly. Existing moisture content is to be
measured.

6/14/2018 d v bhavanna rao

Watering of embankment material. OMC - existing water in% of
the soil spread shall be sprinkled uniformly.

6/14/2018 d v bhavanna rao

Field density test for embankment layers after rolling. Relative
compaction = Field Dry Density/Lab MDD in%.

6/14/2018 d v bhavanna rao

MORT&H Table 300-2, Compaction requirements for subgrade
and shoulders

Relative compaction as % of
S.No Type of work/ material laboratory MDD as per IS:2720
(part 8)
Subgrade and
1 Not less than 97%
shoulders

2 Embankments Not less than 95%

Expansive clays
a) Subgrade and
Not allowed
500mm portion just
below the subgrade
3
Expansive clays
b) Remaining portion 90% to 95%
of embankment
6/14/2018 d v bhavanna rao
 Step by step road construction
as per MORT&H specifications
along with requirements

BT. Surfacing

Base Course (RC ≥ 98%)

GSB (RC ≥ 98%) CBR: 30%(min). Permeability: 20m/day(min)

SUB – GRADE (FSI ≤ 50%, LL ≤ 50% & PI ≤ 25%)

500MM
M.D.D≥1.75 kN/cuM RELATIVE COMPACTION (R.C) ≥ 97%

EMBANKMENT (FSI ≤ 50%, LL ≤ 50% & PI ≤ 25%)

RELATIVE COMPACTION ≥ 95%
M.D.D≥1. 52 kN/cuM up to 3M Height M.D.D≥1.60 kN/cuM above 3M Height

6/14/2018 GL d v bhavanna rao

 MORT&H(5th revision) TABLE 400-1, GSB grading requirements

Percent by weight passing through the IS sieve

IS Sieve
size Grading Grading Grading Grading
Grading I Grading V
II III IV VI
75.0mm 100 -- -- - 100 -

53.0mm 80-100 100 100 100 80-100 100

26.5mm 55-90 70-100 55-75 50-80 55-90 75-100

9.50mm 35-65 50-80 - - 35-65 55-75

4.75mm 25-55 40-65 10-30 15-35 25-50 30-55

2.36mm 20-40 30-50 - - 10-20 10-25

0.85mm - - - - 2-10 -

0.425mm 10-15 10-15 - - 0-5 0-8

0.075 mm
6/14/2018 <5 <5 <5
d v bhavanna rao <5 - 0-3
 MORT&H (5th revision) TABLE 400-2, Physical Requirements of GSB
materials
Aggregate Impact Value IS:2386-part 4 or
40 Maximum
(AIV) IS;5640
Liquid Limit IS:2720-part 5 25 Maximum
Plasticity Index IS:2720-part 5 6 maximum
CBR at 98% dry density Minimum 30 unless
IS:2720-part 16
(IS:2720-part 8) otherwise specified
If water absorption is greater than 2%, Wet Aggregate Impact test shall
be done.
As per MORTH, Grading III and IV are preferable for LSB and
separation or filter layer. Gradings V and VI are for USB and drainage layer.

As per IRC:15-2017, Grading I, II, V or VI is suitable for LSB-filter/

separation layer. For drainage layer and USB, Grading III or IV is suitable.
Minimum thickness of each layer is 100mm.

If granular layers are not required because of high strength sub grade,
synthetic Geo-composite can be used as a separation layer over a thin granular
layer6/14/2018
as levelling course. d v bhavanna rao
Table 400-13. Grading Requirements of
Aggregates for the Wet Mix Macadam WET MIX MACADAM
IS Sieve Per cent by weight
Designation passing the IS Sieve
53.00 mm 100
45.00 mm 95-100
22.4 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600 micron 8-22
75 micron 0-5

Materials : 40mm, 20mm, 12mm, 6mm &Stone Dust, Mixing at Pug

Mill with Water, Conveyed to Site, Spreading by Paver and Rolling.
Relative Compaction = 98 %
Aggregate Impact Value (IS:2386: part-4) :30% (max). Combined
flakiness and elongation dindex
6/14/2018 (IS:2386:
v bhavanna rao part-1) : 35% (max)
 Recommended use of Cationic Emulsions
as per IS 8887

Type Recommended uses

Rapid Setting RS 1 Quick setting for Tack Coat

Surface treatment, Surface Dressing,
Rapid Setting RS 2
Penetration macadam, Grouting

Medium Setting MS Pre mixes and plant mixes

Slow Setting SS 1 Fog seal, Crack Seal, Prime Coat

Slurry Seal and mixes with higher fine
Slow Setting SS 2
aggregate %
Modified Emulsion Micro Surfacing
6/14/2018 d v bhavanna rao
Table 500-2, Mixing, laying and rolling temperatures
for VG grade paving bitumen
Bitumen Aggregate Mix Laying Rolling
Bitumen
Temp. Temp. Temp. Temp. Temp.
grade
⁰C ⁰C ⁰C ⁰C ⁰C

VG - 40 160 - 170 160 - 170 160 – 170 150 min. 100 min.

VG - 30 150 - 165 150 – 165 150 – 165 140 min. 90 min.

VG - 20 145 – 165 145 – 165 145 – 165 135 min. 85 min.

VG - 10 140 – 160 140 – 160 140 – 160 130 min. 80 min.

6/14/2018 d v bhavanna rao
 502 of MORTH Prime Coat over granular base
Application of single coat of low viscosity liquid bituminous
material (SS 1 Emulsion) to an absorbent granular surface for
any superimposed bituminous treatment

Table 500-3, Quantity of bituminous primer for various

granular surfaces

Quantity /Sq.m
Type of surface
(Kgs)

WMM or WBM 0.7 to 1,0

Stabilised soil bases/ Crusher Run

0.9 to 1.2
Macadam

6/14/2018 d v bhavanna rao

 Prime Coat with Cutback Bitumen

Table 500-4, Type and Quantity of Cutback Bitumen over

Granular Surfaces

Quantity
Type of surface Type of cutback per Sq.m
(Kgs)

WMM/WBM MC 30 0.7 to 1,0

Stabilised soil bases/

MC 70 0.9 to 1.2
Crusher Run Macadam
6/14/2018 d v bhavanna rao
 503 Tack Coat ( MORT & H )
503.4.3: The application of tack coat shall be at the rate
specified in the contract and shall be applied uniformly. If rate
of application of tack coat is not specified in the contract then it
shall be at the rate specified in table 500-2

Table 500-5, rate of application of tack coat

Bituminous material
Type of Surface Emulsion or cutback in
Kg/10 Sq.M
Normal bituminous surfaces 2.0 to 2.5
Dry and hungry bituminous surfaces 2.5 to 3.0
Granular surfaces treated with primer 2.5 to 3.0
Non- bituminous surfaces:
Granular base (not primed) 3.5 to 4.0
6/14/2018 d v bhavanna rao
Cement concrete pavement 3.0 to 3.5
 Physical Requirements of Coarse Aggregates for
BM/DBM/SDBC/BC
Table 500-6 for BM, table 500-8 for DBM & 500-17 for BC of 5th
Revision. Table 500-14(4th revision) for SDBC
Code
Property Test Specification
Reference
Grain size Max. 5% passing IS: 2386 part
Cleanliness
analysis 0.075mm sieve 1
Flakiness and
Particle IS: 2386 part
Elongation Max. 35%
shape 1
Index
Los Angeles Max. 40% for BM, 35%
Abrasion Value IS: 2386 part
Strength for DBM & SDBC
4
or &30% for BC
Max 30%for BM,
Aggregate IS: 2386 part
27%for DBM & SDBC,
6/14/2018 Impact Value d v bhavanna rao 4
24%for BC
 Physical requirements continued
Soundness:
Durability Sodium Sulphate 12% IS: 2386 part 5
Magnesium Sulphate 18%

Absorption Water Absorption 2% IS: 2386 part 3

Coating and Stripping

Stripping of Aggregate bitumen 95% IS: 6241

Water Retained Tensile to be done if

Strength Min. 80%
Sensitivity stripping fails
Polishing Polished Stone Value Min. 55 Bs: 812 part
for SDBC and BC 114

6/14/2018 d v bhavanna rao

 Table 500-7, COMPOSITION OF BITUMINOUS MACADAM (5th Revision) 504
Mix Designation Grading I Grading II
Nominal Aggregate Size 40 mm 19 mm
Layer Thickness 80 – 100 mm 50 – 75 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing

45 100 -----
37.5 90 – 100 ------
26.5 75 – 100 100
19 --- 90 – 100
13.2 35 – 61 56 – 88
4.75 13 – 22 16 – 36
2.36 4 – 19 4 – 19
0.30 2 -10 2 -10
0.075 0 -8 0 -8
Bitumen content, % 3.3 3.4
Bitumen Grade 35 to 90 35 to 90
6/14/2018 Bitumen content shall be a tolerance of ± 0.3% for
withinrao
d v bhavanna
individual specimens for quality control tests
 Mix Design of DBM and BC

1 Proportioning of Coarse aggregate and Fine

aggregate to satisfy the specified gradation.

2 Optimum Bitumen Content to satisfy the

specified values of:
a) Marshal Stability Value
b) Flow Value
c) Voids in Mineral Aggregate (VMA)
d) Voids Filled by Bitumen (VFB)
e) Air Voids in Mix
6/14/2018 d v bhavanna rao
6/14/2018 d v bhavanna rao
 Marshal Stability Test ASTM: D 1559

If material contains
fraction retained on 26.5
mm sieve, it be replaced
specimen by material passing 26.5
and retained on 22.4 mm
sieve.
specimen: 64mm
height and 102 mm dia.
compaction: 50
blows on each side for
low traffic roads 75 blows
for high traffic roads
Specimen
6/14/2018 Compaction d v bhavanna rao
102mm

6/14/2018 d v bhavanna rao

 MORTH 505 Table 500-10 Composition of Dense Bituminous Macadam
Grading 1 2
Nominal aggregate size 40 mm 25 mm
Layer Thickness 80-100mm 50-75 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
4.75 38-54 38-54
2.36 28-42 28-42
0.3 7-21 7-21
0.075 2-8 2-8
Bitumen content % by
Min 4.0 in 4.5
mass of total mix
6/14/2018 d v bhavanna rao
Table 500-9, Grading Requirements of mineral filler
IS Sieve Cumulative per cent passing
(mm) by weight of total aggregate
0.6 100
0.3 95 - 100
0.075 85 - 100

The filler shall be free from organic impurities and have a Plasticity
Index not greater than 4. The Plasticity Index requirement shall not apply if
filler is cement or lime. When the coarse aggregate is gravel, 2 per cent by
weight of total aggregate, shall be Portland cement or hydrated lime and
the percentage of fine aggregate reduced accordingly. Cement or hydrated
lime is not required when the limestone aggregate is used. Where the
aggregates fail to meet the requirements of the water sensitivity test in
Table 500-8, then 2 per cent by total weight of aggregate, of hydrated lime
6/14/2018 d v bhavanna rao
shall be added without additional cost.
 Table 500-11, Requirements of DBM and BC
Description Requirements
Minimum stability (KN at 600C) 9.0

Minimum flow (mm) 2

Maximum flow (mm) 4
Compaction level (Number of blows) 75 blows on each face of the
specimen
Percent air voids 3-5

Marshal Qutient (Stablity/flow) 2-5

Percent voids in mineral aggregate

See table 500-12
(VMA)
Percent voids filled with bitumen
65-75
(VFB)
6/14/2018 d v bhavanna rao
Table 500-12, Minimum per cent voids in mineral
aggregate (VMA)

Nominal Minimum VMA, per cent related to

Maximum design air voids, per cent
particle
size 3.0 4.0 5.0

26.5 11.0 12.0 13.0

37.5 10.0 11.0 12.0

Note: Interpolate minimum voids in the mineral (VMA)

for design air voids values between those listed
6/14/2018 d v bhavanna rao
 Table 500-13, Permissible variations from job mix
formula for DBM

Permissible variation
Description
Base/binder course
Aggregate passing 19mm sieve or larger ± 8%
Aggregate passing 13.2mm, 9.5mm ± 7%
Aggregate passing 4.75mm ± 6%
Aggregate passing 2.36mm, 1.18mm,
± 5%
0.6mm
Aggregate passing 0.3mm, 0.15mm ± 4%
Aggregate passing 0.075mm ± 2%
Binder content ± 0.3%
6/14/2018 Mixing temperatured v bhavanna rao ± 10ºC
For Dense bituminous layers, compaction is to be done
to achieve 92% of theoretical maximum specific gravity
of loose bituminous mix used on that day. Density is to
be obtained by cutting 150mm diameter cores.

6/14/2018 d v bhavanna rao

 MORTH 507
Table 500-17 Composition of Bituminous Concrete
Grading 1 2

Nominal aggregate size 19 mm 13.2 mm

Layer Thickness 50mm 30-40 mm

IS Sieve (mm) Cumulative % by weight of total aggregate passing
26.5 100
19 79-100 100
13.2 59-79 90-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content % by
6/14/2018 d v bhavanna rao
5.2 5.4
mass of total mix²
Table 500-18, Permissible variations from job mix formula
for Bituminous Concrete
Permissible variation
Description
Wearing course

Aggregate passing 19mm sieve or larger

± 7%
Aggregate passing 13.2mm, 9.5mm ± 6%
Aggregate passing 4.75mm ± 5%
Aggregate passing 2.36mm, 1.18mm,
± 4%
0.6mm
Aggregate passing 0.3mm, 0.15mm ± 3%
Aggregate passing 0.075mm ± 1.5%
Binder content ± 0.3%

6/14/2018
Mixing temperature
d v bhavanna rao
±10ºC
 508 Mix Seal surfacing
Table 500-19, aggregate gradation
IS sieve Cumulative per cent by weight of total
designation aggregate passing
(mm) Type A Type B
13.2 mm - 100
11.2 mm 100 88 - 100
5.6 mm 52 - 88 31 - 52
2.8 mm 14 - 38 5 - 25
0.090 mm 0-5 0-5
Bitumen 22 kg / 10 sqm 19 kg / 10 sqm

As per Manual for construction and supervision of bituminous

works Type A grading may be used for 25mm thick MSS also,
6/14/2018 by proportionately dincreasing
v bhavanna rao bitumen content
 Bump integrator towed by a jeep

6/14/2018 d v bhavanna rao

 Recommended Roughness Values for roads
In India in mm/km as per IRC:SP:30-2009
Surface type good average poor Very poor

Bituminous
< 2000 2000 to 3000 3000 to 6000 Over 6000
Concrete

Surface Dressing <3500 3500 to 4500 4500 to 7000 Over 7000

Premix Bituminous
carpet/(Open <3000 3000 to 4000 4000 to 6000 Over 6000
Graded)
Water Bound Over
<8000 8000 to 9000 9000 to 10000
Macadam/Gravel 10000

Cement Concrete <2200 2200-3000 3000-4000 Over 4000

6/14/2018 d v bhavanna rao
 Extra width of pavement and roadway

Radius of curve extra width

Up to 40m 1.5m

41 to 60m 1.2m

61 to 100m 0.9m

101 to 300m 0.6m

Super elevation shall be provided in curves as per IRC: 73

and shall be limited to 7%. It shall not be less than the
6/14/2018
minimum specified cross fall/ camber
d v bhavanna rao
 Minimum radii of horizontal curves

Desirable
Nature of terrain Absolute minimum
minimum

plain 360m 230m

Rolling 230m 155m

Mountainous 90m 60m

Steep 60m 30m

6/14/2018 d v bhavanna rao
 Recommended Vertical Gradients

Nature of terrain Ruling gradient Limiting gradient

Plain and rolling 3.3% 5.0%

Mountainous 5.0% 6.0%
Steep 6.0% 7.0%

The vertical alignment should provide for a smooth

longitudinal profile.
Gradients up to ruling gradients shall be adopted as
far as possible.
Limiting gradients shall be adopted only in very
difficult
6/14/2018
situations and for dshort lengths
v bhavanna rao
Design service volume of two-lane highway in PCUs per day

Design Service volume in PCUs per day

Nature of terrain
Without paved With 1.5m paved
shoulder shoulder

Plain 15,000 18,000

Rolling 11,000 13,000

Mountainous and
7,000 9,000
Steep
6/14/2018 d v bhavanna rao
 MORT&H Table 900–1, Tolerances in Surface Levels

1.Sub-grade ±20mm
2.Sub-base
a) Flexible pavement ±10mm

b) Concrete pavement ±6mm

3.Base course for flexible pavement

a) Bituminous course +6mm to -6mm
b) Granular
i) Machine laid ±10mm
ii) Manually laid ±15mm
4. Wearing Course for flexible pavement
a) Machine laid ±6mm
b) Machine laid ±10mm
5. Cement concrete pavement ±5mm
6/14/2018 d v bhavanna rao
 MORT&H Table 900–2,Maximum permitted number of
irregularities
Surfaces of Surfaces of laybys,
carriageways and service roads and all
paved shoulders bituminous courses

Irregularity 4mm 7mm 4mm 7mm

Length(m) 300 75 300 75 300 75 300 75

National highways/
15 9 2 1 40 18 4 2
Expressways
Roads of lower
40 18 4 2 60 27 6 3
category
𝑻𝒉𝒆 𝒍𝒐𝒏𝒈𝒊𝒕𝒖𝒅𝒊𝒏𝒂𝒍 𝒑𝒓𝒐𝒇𝒊𝒍𝒆 𝒔𝒉𝒂𝒍𝒍 𝒃𝒆 𝒄𝒉𝒆𝒄𝒌𝒆𝒅 𝒘𝒊𝒕𝒉 𝒂 𝟑𝒎 𝒍𝒐𝒏𝒈
𝒔𝒕𝒓𝒂𝒊𝒈𝒉𝒕 ed𝒈𝒆 𝒐𝒓 𝒎𝒐𝒗𝒊𝒏𝒈 𝒔𝒕𝒓𝒂𝒈𝒉𝒕 𝒆𝒅𝒈𝒆 𝒂𝒔 𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝒃𝒚
𝒆𝒏𝒈𝒊𝒏𝒆𝒆𝒓 at the middle of each traffic lane parallel to the
6/14/2018 d v bhavanna rao
center line of the road
 MORT&H 902.4 : The maximum allowable difference
between the road surface and underside of a 3m straight
edge when placed parallel with, or at right angles to the
center line of the road at points decided by the Engineer

For pavement surface (bituminous

3mm
and cement concrete)
For bituminous courses 6mm
For granular sub-base or base
8mm
courses
For sub-base under concrete
10mm
pavements

For sub-grade 15mm

6/14/2018 d v bhavanna rao
MORT&H 903.2 Tests on Earthwork for embankment, sub-grade
construction and cut formation for each source

Test type As per code Frequency of testing

2 per 3000 cubic

Sand Content IS:2720 – part 4
meters
2 per 3000 cubic
Plasticity IS:2720 – part 5
meters
2 per 3000 cubic
Density IS:2720 – part 8
meters
As and when
Deleterious Content IS:2720 – part 27 required by
engineer
2 per 3000 cubic
Moisture Content IS:2720 – part 2
meter
Soaked/ un-soaked 1 per 3000 cubic
6/14/2018 IS:2720 – part
d v bhavanna rao 16
CBR meters
MORT&H 900.3 control tests and their minimum frequency
for sub-bases and bases

Type of
Test Frequency (min)
Construction
One test per
gradation
400cum
One test per
Atterberg Limits
400cum
Moisture content prior to One test per
Granular compaction 400cum
Density of compacted One test per
layer 1000sq.m
Deleterious content As required

6/14/2018
CBR
d v bhavanna rao
As required
MORT&H 900.3 control tests and their minimum frequency
for sub-bases and bases
Type of
Test Frequency (min)
Construction
One test per each consignment
Quality of lime or cement subject to a minimum of 1 test
per 5 tonnes
Regularly, through procedural
Lime or cement content
checks
Periodically as considered
Degree of pulverisation
Lime/Cement necessary
stabilised soil CBR or UCS on a set of 3
sub-base As required
specimens
Moisture content prior to
1 set of 2 tests per 500sq.m
compaction
Density of compacted layer 1 set of 2 tests per 500sq.m
6/14/2018 d v bhavanna rao
Deleterious constituents As required
MORT&H 900.3 control tests and their minimum frequency
for sub-bases and bases
Type of
Test Frequency (min)
Construction
One test per
Aggregate Impact Value
1000cum
One test per
Grading of Aggregate
250cum
One test per
Water Bound Combined FIV & EIV
500cum
macadam
Atterberg limits for binding One test per 50cu.m
material of binding material
One test per
Atterberg limits for
100cu.m of
screenings
screenings
6/14/2018 d v bhavanna rao
MORT&H 900.3 control tests and their minimum frequency
for sub-bases and bases

Type of
Test Frequency (min)
Construction
One test per
Aggregate Impact Value
1000cum
One test per
Grading of Aggregate
200cum
One test per
Wet Mix Combined FIV & EIV
500cum
Macadam
One test per
Atterberg limits for material
200cu.m of
passing 425 microns
aggregate
Density of compacted One set of 3 tests
layer per 1000 sq.m
6/14/2018 d v bhavanna rao
MORT&H 900.4 control tests for bituminous works and their
minimum frequency

Type of
Test Frequency (min)
Construction
Number of samples per
lot and tests as per
Quality of binder
IS:73, IS:217and
Prime coat/ IS:8887 as applicable
tack coat/fog
At regular close
spray Binder temperature
intervals
Rate of spread of
3 tests per day
binder

6/14/2018 d v bhavanna rao

MORT&H 900.4 control tests for bituminous works and their minimum frequency
Type of
Test Frequency (min)
Construction
Number of samples per lot and tests as
Quality of binder per IS:73, IS:217and IS:8887 as
applicable
AIV or LAV One test per 200cum per source
Combined FIV & EIV One test per 100cum per source
Stripping value of
One test for each source
aggregate
Water absorption of
One test for each source
Seal Coat/ aggregate
surface Water sensitivity of mix One test for each source
dressing
Grading of aggregate 2 tests per day

Soundness One test for each source

Temperatures At regular intervals

Rate of spread Same as for item1
% fractured faces One test per 100cu.m
6/14/2018 d v bhavanna rao
Stone polishing value One test of each source
MORT&H 900.4 control tests for bituminous works and their
minimum frequency
Type of
Test Frequency (min)
Construction
Number of samples per lot and
Quality of binder tests as per IS:73, IS:217and
IS:8887 as applicable
AIV or LAV One test per 200cum per source
Combined FIV & EIV One test per 100cum per source
Stripping value One test for each source
Open grade Water absorption One test for each source
pre-mix Water sensitivity of mix One test for each source
surfacing/ MSS
Grading of aggregates 2 tests per day
Soundness One test per 200cum per source
Polished stone value One test per 200cum per source
temperatures regularly
Binder content 2 tests per day
6/14/2018 d v bhavanna rao
% fractured faces One test per 100cum of aggregate
MORT&H 900.4 control tests for bituminous works and their minimum frequency

Type of
Test Frequency (min)
Construction
Number of samples per lot and tests as
Quality of binder
per IS:73, IS:217and IS:8887 as applicable
AIV or LAV One test per 350cum per source
Combined FIV & EIV One test per 350cum per source
Stripping value of
One test for each source
aggregate
Water absorption of
One test for each source
aggregate
Bituminous Water sensitivity of mix One test for each source
Macadam Grading of aggregate 2 tests per day
Soundness One test for each source
Temperatures At regular intervals
Rate of spread Same as for item1
% fractured faces One test per 100cu.m
Stone polishing value One test of each source
Density of compacted layer 1 test per 100sq.m
6/14/2018 Rate of spread of mixd v bhavanna rao Regular intervals
 MORT&H 900.4 control tests for bituminous works
Additional tests over the tests for BM

Type of
Test Frequency (min)
Construction
One test for individual constituent and
mixed aggregate from dryer for each
Mix Grading
400t of mix subject to minimum of 2
tests per day per plant
Stability, voids
Dense analysis and 3 tests for stability, flow value, void
Bituminous theoretical max. content, density for each 400t of mix
Macadam/ sp.gravity of subject to 2 tests per day per plant.
Bituminous loose mix
Concrete Moisture
One test for each mix type whenever
Susceptibility of
there is change in quality or source of
Mix (AASHTO
coarse or fine aggregate
T283)
Density of
1 test per 700 sq.m area
compacted layer
6/14/2018 d v bhavanna rao
305.4.4: Embankment and Sub Grade Requirements
around structures

The filling around culverts, bridges and other

structures upto a distance of twice the height of the
road from the back of the abutment shall be carried
out independent of the work on the main
embankment.
Material with LL more than 40% and PI more than
20% shall not be allowed as backfill for all earth
retaining structures. Backfill material shall conform to
the general requirements given in appendix 6 of IRC:
78 (Standard Specifications and Code of practice for
6/14/2018 road bridges-section VII)
d v bhavanna rao
6/14/2018 d v bhavanna rao
Filling behind abutments, retaining walls and return walls General
guide to the selection of soils on basis of anticipated embankment
performance – appendix - 6, IRC: 78-2000
Soil group to Anticipate
IS: 1498-1970 Visual MDD OMC % d
Most description Kg/ m3 range performan
possible ce
probable
GW,GP, Good to
Granular 1850 to
GM, SW, - 7 - 15
materials 2280 Excellent
HP
SB, SM, Granular
materials 1760 to Fair to
GM, GC, - 9 - 18
2160 excellent
SM, SC With soils
1760 to Fair to
SP - sand 19 - 25
1850 good
CL,
MI, MH, Sandy soils & 1760 to Fair to
SM,SB, 10 - 20
DL6/14/2018 silts d v bhavanna rao
2080 good
SC
 Weep holes with 100 mm dia AC/PVC/HDPE pipes at 1 M
spacing in either direction. They extend through full width of
concrete with slope of 1V : 20 H. Lowest shall be 150mm above
low water level (2706) or ground level whichever is higher.

6/14/2018 d v bhavanna rao

 MORTH (5th Revision) 2702: Bituminous Wearing Coat over
Bridges

1 Bituminous Concrete 50mm thick laid in one layer

2 Bituminous Concrete 40mm overlaid with 25mm thick
Mastic Asphalt layer
3 Stone Matrix Asphalt 50mm thick laid in one layer
4 Mastic Asphalt 50mm thick laid in one layer
Before laying wearing coat deck surface shall be
thoroughly cleaned and tack coat applied.
Profile making course of the same material shall be
provided before laying the wearing coat. Thickness of wearing
coat shall not be less than the thickness specified above at
any point. Cross slope of deck shall be kept as 2.5%

Bituminous Wearing Coat as per MORTH(4th Revision)

6mm thick Mastic Asphault+50mm thick BC in 2 layers
6/14/2018 d v bhavanna rao
 MORTH 2702 : Cement Concrete Wearing Coat over
Bridges
75m thick CC minimum M30 grade Wearing Coat
shall be laid separately over the bridge deck. Cross slope
of deck shall be kept as 2.5%.
Steel reinforcement of 8mm dia at 150mm C/C shall
be provided in both directions at mid depth of wearing coat.
In a length of 1m near the expansion joint, additional
reinforcement shall be provided to make the spacing as
75mm. Curing of wearing coat shall start as early as
possible.
Profile corrective course along with wearing coat
shall be laid in a single layer.
Overlay on the existing wearing coat shall not be
permitted. Dismantling of damaged wearing coat shall be
done as per MORTH 2800.
6/14/2018 d v bhavanna rao
 MORTH Table 1000-1: Grading Requirements of Coarse Aggregate

Percentage passing for graded aggregate of

nominal size
IS Sieve Size
40mm 20mm 12.5mm

40mm 95 - 100 100 -

20mm 30 - 70 95 - 100 100
12.5mm - - 90 - 100
10mm 10 - 35 25 - 55 40 – 85
4.75mm 0-5 0 - 10 0 - 10

Note: In IS;383-2016, 95-100 range is modified as 90-100 for 40mm and

20mm nominal sizes.
AIV shall not be more than 30% for wearing surfaces, roads, pavements,
runways, spillways, carrying water and stilling basins.
AIV shall not be more than 45% for concrete other than wearing surfaces.
Flakiness Index shall not be more
6/14/2018 than 35%
d v bhavanna rao
 MORTH Table 1000-2: Grading Requirements of Fine Aggregate

Percentage passing for

IS Sieve
Size Grading Zone Grading Zone Grading Zone
I II III
10mm 100 100 100
4.75mm 90 - 100 90 - 100 90 – 100
2.36mm 60 - 95 75 – 100 85 – 100
1.18mm 30 – 70 55 – 90 75 – 100
600 micron 15 – 34 35 – 59 60 – 79
300 micron 5 – 20 8 – 30 12 – 40
150 micron 0 - 10 0 - 10 0 - 10
Note: Fineness Modulus shall be between 2.0 to 3.5. Total deleterious content
shall not exceed 5%.
When the grading falls outside the limits of grading zone of sieves other than 600
Micron IS sieve by a total amount not exceeding 5%, it shall be regarded as falling
within the grading zone. However for crushed stone sand, the permissible limit on
150-micron
6/14/2018 IS sieve is increased to d20%
v bhavanna rao
 MORTH Table 1000-3: Grades of Reinforced bars

IS Elastic
Grade Bar type conforming to
Characteristic Modulus
designation governing specifications
Strength fy MPa GP
Fe 240 IS: 432 part I Mild steel 240 200

Fe 415 415 200

Fe 500 or
500 200
Fe 500D IS:1786 High Strength
Fe 550 or Deformed Steel Bars(HSD)
550 200
Fe 550D
Fe 600 600 200

Note: If any grade of steel mentioned in the above table is not available steel
of next higher grade may be used.
6/14/2018 d v bhavanna rao
 Mechanical properties of HYSD bars and wires as per IS:1786-2008
including Amendment issued in 2012
Grade of Steel
Property
Fe Fe Fe Fe Fe
Fe 415 Fe 550 Fe 550 D Fe 600
415D 415S 500 500D 500S
0.2% proof
stress/yield
stress, 415 415 415 500 500 500 550 550 600
min.MPa
0.2% proof
stress/yield
stress, - - 540 - - 625 - - -
max..MPa
Elongation, %
minimum on a
gauge length of
5.65A, where 14.5 18 20 12 16 18 10 14.5 10
A is cross
section area of
test piece
Total elongation
at max force - 5 10 - 5 8 - 5 -
–do-

TS/YS ratio
Minimum 1.1 1.12 1.25 1.08 1.10 1.25 1.06 1.08 1.06
6/14/2018 d v bhavanna rao
 MORTH Table 1700-1: Different grades of concrete
Type of concrete/Grade Description
Characteristic
Nominal Mix High Performance strength in MPa
Standard Concrete
Concrete Concrete
M15 M15 15
M20 M20 20
M25 25
M30 M30 30
M35 M35 35
M40 M40 40
M45 M45 45
M50 M50 50
M55 55
M60 60
M65 65
M70 70
M75 75
M80 80
M85 85
6/14/2018 d v bhavanna rao M90 90
 MORTH Table 1700-2: Requirement of concrete for different
Exposure using 20mm aggregate
Exposure Maximum Water Minimum Cement Minimum Grade of
condition Cement Ratio Content, Kg/m3 Concrete
Moderate 0.45 340 M25
Severe 0.45 360 M30
Very Severe 0.40 380 M40

The term cement content for maximum water Cement ratio

and minimum cement content shown in table includes all
cementations mentioned in MORTH clause 1715.2. The maximum
limit of fly ash and ground granulated blast furnace slag in the
blended cement shall be as specified in IS:1489(part 1) and IS:455.
For plain cement concrete with or without surface
reinforcement, the minimum grade of concrete can be lowered by
5MPa and maximum water cement ratio exceeded by 0.05.
Cement content shown in the above table can be increased
by 40Kg/m3 for use of 12.5mm nominal size aggregate and
decreased by 30Kg/m3 for use of 40mm size nominal size
6/14/2018 d v bhavanna rao
aggergate.
 MORTH Table 1700-4: Requirement of consistency

Slump in mm
S No Type at the time of
placement
a) Structure with exposed inclined surface
1 requiring low slump to allow proper compaction 25mm
b) Plain Cement Concrete
RCC structure with widely spaced reinforcement;
2 e.g Solid columns, piers, abutments, footings and 40-50mm
steining
RCC structure with fair degree of congestion of
reinforcement; e.g pier and abutment caps, box
3 50-75mm
culverts, well curb, well cap, walls with thickness
greater than 300mm
RCC and PSC structure with highly congested
4 reinforcements; e.g deck slab girders, box girders, 75-125mm
walls with thickness less than 300mm
Underwater concreting through Tremie; e.g bottom
5 150-200mm
plug, cast in-situ piling

6/14/2018 d v bhavanna rao

 MORTH Table 1700-7: Maximum nominal size of Coarse Aggregates

Maximum Nominal size

Component
of Coarse Aggregate
a) RCC Well Curb 20mm
b) RCC/PCC well steining 40mm

c) Well cap or pile cap, solid type piers and abutments 40mm

d) RCC work in girder, slab wearing coat, kerb,

approach slab, hollow pier and abutments, pier/abutment 20mm
caps, piles
e) PSC work 20mm
As specified by the
f) Any other item
engineer

Maximum nominal size of aggregates shall be restricted to the smaller of

the following values
i) 10mm less than the minimum lateral distance between individual
reinforcements
ii) 10mm less than the clear cover to the reinforcement
iii) One quarter of the minimum thickness
6/14/2018 d v bhavannaof
raothe member
 MORTH Table 1700-9: Minimum frequency of Sampling

Quantity of Concrete in Work, m3 No. of samples

1-5 1
6 – 15 2
16 – 30 3
31 – 50 4
4 plus one additional sample for every
51 and above
additional 50 m3 or part thereof
At least one sample shall be taken from each shift of work

MORTH 1717.17:Acceptance Criteria:

Cubes: the mean strength determined from any group of 4 consecutive non-
overlapping samples exceeds the specified characteristic compressive
strength by 3MPa
Strength of any sample is not less the the specified characteristic
compressive strength minus 3 MPa.

Cores:(Minimum=3) Acceptable if the equivalent cube strength of the cores is

equal to at least 85% of cube strength of the grade of concrete specified for
the corresponding age and no individual core has strength less than 75% of
6/14/2018 d v bhavanna rao
the specified strength.
 D.V .Bhavanna Rao M.Tech., F.I.E.,
Retired R&B Chief Engineer
E-mail: bhavannarao@yahoo.co.in
Phone: +919494440202

6/14/2018 d v bhavanna rao

 IRC: 58-2015, Guidelines for the design of Plain
Jointed Rigid Pavements for Highways
IRC: 15-2017, Code of practice for Construction of
Cement Concrete Roads
IRC: 44-2008, Guidelines for cement concrete mix
design for pavements

IRC: 57-2006: Sealing Joints in CC roads

IRC:SP 62 – 2014, Guidelines for design of CC
roads for Rural Roads
IRC:SP:83-2008, guidelines for maintenance and
rehabilitation of CC pavements
6/14/2018 d v bhavanna rao
 Design Guidelines of IRC:58 are
applicable for roads having a daily
commercial traffic (vehicles with laden
weight more than 3t) over 450

For low traffic volume roads,

IRC:SP:62-2014 shall be followed.

6/14/2018 d v bhavanna rao

 Curling and warping of slabs

The solution to cracking is not

necessarily to focus on increasing
concrete strength. Design strength
must be balanced with other factors
that affect cracking, such as volume
changes, curling and warping, loading,
6/14/2018 weather
d v bhavanna rao and level of support
 Axle load placed in the
6/14/2018
middle of the slab during mid day
d v bhavanna rao
Placement of two axles of a commercial vehicle curled during
night hours
6/14/2018 d v bhavanna rao
 Concrete Strength
Since concrete pavements fail due to bending stresses, design is
based on flexural strength of concrete.
ff = 0.7√fc

Approximate Flexural strength for M30 = 3.83MPa

Approximate Flexural strength for M35 = 4.14MPa
Approximate Flexural strength for M40 = 4.43MPa

Where fc = characteristic compressive strength

ff= characteristic flexural strength
In IRC:SP:62, 90 day flexural strength of concrete is taken for
design.
90 day ff = 1.2×28 day ff
Minimum 28 day flexural strength is 3.8MPa for low volume roads
and minimum grade is M30 (less than 450 CVPD)
Minimum 28 day flexural strength is 4.5MPa for high volume
6/14/2018 roads and minimumd vgrade is M40 (≥ 450 CVPD)
bhavanna rao
Minimum sub grade CBR required is 8% as per IRC:15-2017

CBR of 500mm thick sub Grade

6/14/2018 d v bhavanna rao
 150

Debonding layer of 30 to 40mm

Debonding layer of 150mm
BC over cement treated
polythene sheet over DLC.
aggregate sub base layer
(4mm thick non-woven geo textile
may be also used) as separation
membrane.
Typical cross section of concrete pavement
for high volume traffic roads
6/14/2018 d v bhavanna rao
 Pavement Thickness for traffic up to 50 CVPD as per
IRC:SP:62-2014

WBM or WMM 75mm thick over GSB(min.CBR=30, LL<25%

and PI<6%) 100mm is considered. Alternately 150mm thick
Cementitious granular layer using marginal aggregates with
minimum UCS of 3MPa at 7days with cement or at 28days
with lime or lime-fly ash

Sub-Grade CBR is 4%. Effective k is 35+7=42MPa(35+20%of

35).
Thickness for dual wheel load of 60KN is 160mm for all the
joint spacing of 2.5m, 3.25m and 4m.

Temperature stresses not considered.

For other k values, excel sheet can be used to get thickness.
A minimum thickness of 150mm is recommended for even
6/14/2018 d v bhavanna rao
higher values of effective k.
M30(minimum flexural strength of 3.8MPa at 28days) Concrete
Pavement thickness for traffic between 50 to 150 CVPD
and sub-grade CBR 4% as per IRC: SP:62-2014

Pavement Thickness(mm)
Joint
Wheel load – 50 kN
spacing in
m Zone- Zone- Zone-
Zone-iv Zone-v Zone-vi
i ii iii
4.00 180 180 190 180 180 180
3.25 170 170 170 170 170 170
2.50 160 160 160 160 160 160

GSB 100mm + WBM or WMM 75mm. Alternately 100mm thick Cementitious

granular layer with minimum UCS of 3MPa at 7days with cement or at
28days with lime or lime-fly ash+100mm thick cementitious layer with natural
material having minimum UCS of 1.5MPa at 7days with cement or at 28 days
with lime or lime-fly ash
6/14/2018 d v bhavanna rao
M30(minimum flexural strength of 3.8MPa at 28days)
Concrete Pavement thickness for traffic of 250 CVPD
and sub-grade CBR 8% as per IRC: SP:62-2014

Pavement Thickness (mm)

Joint
spacing Wheel load – 50 kN
in m Zone-
Zone-i Zone-iii Zone-iv Zone-v Zone-vi
ii
4.00 180 180 190 180 180 180

3.25 170 170 170 170 170 170

2.50 160 160 160 160 160 160

GSB 100mm+WBM/WMM150mm
6/14/2018 d v bhavanna rao
or Cementitious base 200mm (100+100)
 Cements that can be used as per IRC: 15-2017
Any of the following types of cements capable of
achieving the design strength and durability may be
used with the prior approval of the Engineer.
1. Ordinary Portland Cement, 43 grade and 53 Grade
as per IS:269
2. Portland Pozzalona Cement as per IS: 1489, part1
3. Portland Slag Cement as per IS:455
4. Composite cement (blended with granulated slag and
fly ash)
5. Sulphate Resistant Portland cement as per IS:12330
in sulphate infested areas
6/14/2018 d v bhavanna rao
 Minimum Cement content as per IRC:15-2017
Design Flexural strength = 4.5MPa at 28 days
1) For OPC, PPC, PSC and composite cement the
minimum cement content is 360Kg/Cum.
2) For fly ash as per IS:3812-Part-I (25% max by weight
of cementitious material) blending at site, the quantity of
OPC in the blend shall not be less than 310Kg/Cum.
3) In case of GGBFS blended cement, minimum OPC
content is 250Kg/cum

Maximum limit of OPC content = 450Kg/Cum

6/14/2018 d v bhavanna rao
 Concrete Mix Design with GGBS
HI TECH CITY, Hyderabad

 Construction Company : L & T, ECC
PARTICULARS Grade M 50 Grade M 50
OPC 53 Grade 250 Kgs/M3 350 Kgs/M3
Duncan GGBS 250 Kgs/M3 150 Kgs/M3
Sand 757 Kgs/M3 757 Kgs/M3
Aggregates 10 mm 421 Kgs/M3 421 Kgs/M3
20 mm 505 Kgs/M3 505 Kgs/M3
Water/Binder Ratio 0.33 0.33
Slump 80 mm 95 mm
Compressive Strength (N/mm2)
7 Days 38.90 47.30
21 Days 51.90 59.0
6/14/2018 28 Days d v bhavanna rao
58.40 60.0
 Table 1of IRC:15-2017 for fine aggregates

Percent passing
IS Sieve
Designation Grading Grading Grading
Zone-I Zone-II Zone-III
10mm 100 100 100
4.75mm 90 – 100 90 – 100 90 – 100
2.36mm 60 – 95 75 – 100 85 – 100
1.18mm 30 – 70 55 – 90 75 – 100
600microns 15 – 34 35 – 59 60 – 79
300microns 5 – 20 8 – 30 12 – 40
150microns
6/14/2018 0 – 10
d v bhavanna rao 0 – 10 0 – 10
 Zone-I sand Zone-II sand
FM=3.32 F M =3.08

Zone-III sand.
F.M =2.75

Physical Requirements shall be as per IS:383. FM = 2.0 to 3.5.

6/14/2018 All deleterious content shall
d v bhavanna rao not exceed 5%
6/14/2018 d v bhavanna rao
Table 2 of IRC:15-2017: Combined Gradation of Coarse and
fine aggregates for Dry Lean Concrete
Percent by Weight Passing the
IS Sieve Size
Sieve
26.5mm 100
19 mm 75-95
9.5 mm 50-70
4.75 mm 30-55
2.36mm 17-42
0.600mm 8-22
0.300mm 7-17
0.150 2-12
0.075mm (wet sieving) 0-5
The above grading is applicable for natural sand and crushed stone sand.
7 day average compressive strength of each consecutive group of 5 cubes
shall not be less than 7MPa. It shall not be less than 10MPa for PQC
bonded DLC. In case of PQC bonded
6/14/2018 d v bhavannaDLC,
rao its surface shall be roghened
with wire brush 3 to 6 hours after laying.
Table 3 of IRC:15-2017: Combined Gradation of Coarse and fine
aggregates for Pavement Quality Concrete
Percent by Weight Passing the Sieve
Sieve
Designation 31.5 nominal 26.5mm nominal
19mm nominal size
size size
37.5mm 100 100 100
31.5mm 100 100 100
26.5mm 85-95 90-100 100
19 mm 68-88 75-95 90-100
9.5 mm 45-65 50-70 48-78
4.75 mm 30-55 30-55 30-58
600 micron 8-30 8-30 8-35
150 micron 0-10 0-10 0-12
75 micron (wet 0-5* 0-5* 0-5*
sieving) 0-2** 0-2** 0-2**

*Crushed
6/14/2018 sand ** Natural sandd v bhavanna rao
MORD Table 1500.1: Combined Gradation of Coarse and fine
aggregates for low volume CC roads (As per IRC:SP:62-2014)

Percent by
IS Sieve
Weight Passing
Size
the Sieve

26.5mm 100
19 mm 80-100
9.5 mm 55-80
4.75 mm 35-60
0.600mm 10-35
0.075mm 0-8
6/14/2018 d v bhavanna rao
 Mineral Admixtures as per IRC:15-2017
Mix design shall be done as per IRC:44-2008

 Fly Ash as per IS:3812 (Part-I). Maximum dosage 25 percent

by mass of cementitious materials. May be mixed with OPC
53/43 grade at site.
 Ground Granulated blast furnace slag(as per IS:10875) up to
50% by weight of cementitious materials. May be mixed with
OPC 53/43 grade at site. Good in coastal region.
 Silica Fume up to 10% by weight (as per IS:15388, IRC:SP-
114 and IRC:44), if specified in design may be used.
 Metakaolin conforming to IS:16354 may be used up to 20% of
the cementitious material
6/14/2018 d v bhavanna rao
 Fibers
Fibers may be used subject to the provision
in the design/approval by the engineer to reduce
shrinkage cracking and post cracking. The fibers
may be steel fibers as per IRC:SP:46 or
polymeric synthetic fibers.
When fibers are used the mix shall be so
designed that the slump of concrete at paving
shall be in the range of 25±10mm and that in
manual construction the slump shall be in the
range of 40±10mm
6/14/2018 d v bhavanna rao
 Water for mixing and curing as per
IS:456
Potable water is generally considered
satisfactory for both mixing and curing.
In case of doubt, 28 days average
compressive strength of at least three 150mm
cubes prepared with water proposed to be used
shall not be less than 90% of the average strength
of 3 similar cubes prepared with distilled water.
Initial setting time of test block made with
water proposed to be used shall not be less than 30
minutes and shall not differ by ± 30 minutes from the
initial setting time of test block prepared with
distilled water.
6/14/2018 d v bhavanna rao
 Permissible limits for solids in Water
Cl. 5.4 of IS: 456-2000
Permissible limt
Tested as per
maximum
Organic IS 3025 part 18 200 mg/l
Inorganic IS 3025 part 18 3000 mg/l
Sulphate as SO3 IS 3025 part 24 400 mg/l

2000 mg/l for PCC

Chloride as cl IS 3025 part 32
500 mg/l for RCC

Suspended matter IS 3025 part 18 2000 mg/l

6/14/2018 pH value of water shall

d v bhavanna rao not be less than 6.
 Concreting in Hot weather

No concreting shall be done when the

concrete temperature is above 30ºC. It is desirable
to install a chilling plant to control the concrete
temperature.
As placing of concrete in air ambient
temperature above 35ºC, relative humidity less than
25% or wind velocity more than 15kmph requires
adequate protective measures. Otherwise defects
like loss of workability through accelerated setting,
rapid hydration, loss of workability, increase in water
requirement and formation of shrinkage cracks are
likely.
6/14/2018 d v bhavanna rao
 Concrete Batching Plant - 120 m3 / hr.

Concrete Batching Plant - 120 m3 / hr.

21/10/2003
6/14/2018 Road Construction Tech.
d v bhavanna rao& Mngt., 45
Kochi, 20-21 OCT, 2003
 Concrete Batching Plant - 120 m3 / hr.
21/10/2003
6/14/2018 Road Construction Tech.
d v bhavanna rao& Mngt., 45
Kochi, 20-21 OCT, 2003
 21/10/2003
6/14/2018 Cement Debagging
Road Construction rao&Unit
Tech.
d v bhavanna Mngt., 600–900 bags / hr.
46
Kochi, 20-21 OCT, 2003
 Chilling Plant with 450 KL
Water Storage

21/10/2003
6/14/2018 Road Construction Tech.
d v bhavanna rao& Mngt., 46
Kochi, 20-21 OCT, 2003
 Rear side of DLC Paver
Sensor of DLC Paver
21/10/2003
6/14/2018
for Tech.
Road Construction
Grade
d v bhavanna
Control
rao& Mngt., 39
Kochi, 20-21 OCT, 2003
6/14/2018
21/10/2003 d v bhavanna
Road Construction rao& Mngt.,
Tech. 40
Sensor of DLC Paver
Kochi, 20-21 OCT, 2003 for Grade Control
 Sensor of DLC Paver for Grade Control

21/10/2003
6/14/2018 Road Construction Tech.
d v bhavanna rao& Mngt., 40
Kochi, 20-21 OCT, 2003
6/14/2018
21/10/2003 d v bhavanna
Road Construction rao
Tech. & Mngt., 39
Paving and Compaction with DLC Paver
Kochi, 20-21 OCT, 2003
 CURING OF DLC – Wax Based Curing
Compound
Curing of DLC – Wax Based Curing Compound

21/10/2003
6/14/2018 Road Construction Tech.
d v bhavanna rao& Mngt., 42
Kochi, 20-21 OCT, 2003
 Compaction of Concrete
Compaction is necessary to remove entrapped air present
in concrete after it is mixed, transported and placed. Compaction
also eliminates stone pockets and remove all types of voids.
Consolidation is the process of making the freshly placed PCC
into a more uniform and compact mass by eliminating undesirable
air voids and causing it to move around potential obstructions
(such as reinforcing steel).

Vibrators work by rotating an eccentric weight which

causes the entire vibrator to move back and forth. This movement
excites particles within the PCC mass, causing them to move
closer together and better flow around obstructions. On vibration,
concrete mix gets fluidized resulting in entrapped air raising to the
surface and concrete becoming
6/14/2018 denser
d v bhavanna rao
 Plate Compactor

6/14/2018 d v bhavanna rao

 CC road under finishing with trowel.

6/14/2018 d v bhavanna rao

 Verification of thickness during laying.

6/14/2018 d v bhavanna rao

 Cube casting.

6/14/2018 d v bhavanna rao

 Slump checking.

6/14/2018 d v bhavanna rao

 Slump checking.

6/14/2018 d v bhavanna rao

 Material gradation checking.

6/14/2018 d v bhavanna rao

 Temperature checking.

6/14/2018 d v bhavanna rao

 Concrete Curing
Curing is the process of maintaining a
satisfactory moisture content and favorable
temperature in the concrete during hydration of
cementitious material so that the desired properties of
the concrete are developed. Its objective is specifically
to keep the concrete saturated until the water filled
spaces in the fresh cement paste are filled to the
desired extent by products of the hydration.
Water evaporation from concrete
surface
Continuous
water supply

6/14/2018 d v bhavanna rao

 Methods of Curing

Ponding with water

Covering concrete with wet burlaps which are
maintained close to the concrete surface
Intermittent spraying with water and continuous
sprinkling of water
Covering concrete with wet sand, saw dust etc.,
Covering with polyethylene sheets or water
proof paper and holding it in position
Curing with liquid membrane forming curing
compounds

6/14/2018 d v bhavanna rao

 Effects of Improper Curing

Lowering of compressive and flexural strengths

Sanding and dusting of surface and lower
abrasion resistance
Higher permeability and lower durability
Cracks due to plastic shrinkage, drying shrinkage
and thermal cracking
Increased rate of Carbonation and chloride
ingress
Lower weathering and frost resistance

6/14/2018 d v bhavanna rao

Observe the freshly laid concrete in dried up condition.

6/14/2018 d v bhavanna rao

 MORD 1501.18: Curing
After finishing, the pavement surface shall be
entirely covered with wet hessian cloth (minimum of 2
layers), burlap or jute mats. The coverings used shall be
of such size that when laid, will extend by 500mm
beyond the slabs. They shall be placed as soon as the
concrete has set sufficiently to prevent marring of the
surface. They shall be maintained fully wetted for 24
hours. The concrete slab shall not be exposed for more
than 30 minutes for saw cutting of joints. After saw
cutting of joints, it shall be covered and kept wet. Upon
the removal of wet covers after 24 hours, the slabs shall
be thoroughly wetted and then cured by ponding.
Exposed edges shall be banked with substantial amount
of earth.
6/14/2018 d v bhavanna rao
 C.C Road Curing by ponding.

6/14/2018 d v bhavanna rao

Gunny rolls used for primary curing and or secondary curing.

6/14/2018 d v bhavanna rao

 Fresh CC covered with wet gunny rolls.

6/14/2018 d v bhavanna rao

 CC covered with wet gunny rolls. Side earth pushed to protect edges.

6/14/2018 d v bhavanna rao

 Curing with coconut coir

6/14/2018 d v bhavanna rao

 Coconut coir for both primary and secondary curing

6/14/2018 d v bhavanna rao

 Secondary curing with coconut coir and soil.

6/14/2018 d v bhavanna rao

Surface due to ineffective curing before ponding or high W/C ratio

6/14/2018 d v bhavanna rao

 Joints in Rigid pavements

Joints are provided in cement concrete roads for

expansion, contraction and warping of slabs due
to the variation in the temperature of slab.
Initial cut or slot not less than 3mm and a depth of
1/3rd to 1/4th of PQC slab at transverse or
longitudinal joint as soon as concrete hardens.
During summer (ambient temperature is more than
30ºC), cutting may be carried after 4-8 hours of
laying.
When the temperature is less than 30ºC, joint
cutting may be done 8-12 hours of laying.
6/14/2018 d v bhavanna rao
 Types of joints

a)Contraction joints

b) longitudinal joints

c) Expansion joints

d) Construction joints
6/14/2018 d v bhavanna rao
6/14/2018 d v bhavanna rao
 Joints Configuration of 2 lane road
6/14/2018 d v bhavanna rao
Contraction joints:
These are purposely made weakened planes
which relieve the tensile stresses in the concrete
caused due to changes in the moisture content
(Drying shrinkage) and/or temperature and
prevent the formation of irregular cracks due to
restraint in free contraction of concrete.

They are also provided to

1) Relieve stresses due to warping. 2) To permit
the contraction of the slab.
The spacing of Contraction joints should be limited
to 4.5m
6/14/2018
for high volume roads
d v bhavanna rao
 Why are Controlled Cracks at contraction Joints
Preferable to Random Cracks?

1) Properly constructed contraction joints have many

benefits.
2) Joints can be sealed more efficiently to limit
infiltration of harmful materials.
3) Joints prevent the slab from randomly
cracking into small, weak pieces.
4) Joints can be constructed with dowel bars and
tie bars to prevent slab deflection at the joints and to
allow proper transfer of vehicle loads between
pavement sections (panels).
5)Joints help designate lanes.
6) 6/14/2018
Joints generally provide a smoother ride than random
d v bhavanna rao
cracks
A saw cut that
has cracked
through as
planned

6/14/2018 d v bhavanna rao

 Details of the contraction joints are given in
IRC:15. They are formed initially by sawing a
groove of 3-5 mm with up to about one-fourth to
one-third the slab thickness.This facilitates the
formation of a natural crack at this location
extending to the full depth. In order to seal the
joint, the top 10-20 mm of this groove is widened
to 6-10 mm.
For heavy traffic, greater than 450CVPD,
these joints are provided with steel dowel bars to
improve the continuity of slab and improved
performance of joints, including load transfer.
6/14/2018 d v bhavanna rao
 Contraction Joint with dowel at 4.5m C/C

Joints 3 to 5mm wide are to be cut to 1/3 to ¼ depth

Dowel bars (MS Rounds) are to be placed at mid depth
and covered with thin plastic sheathing for 2/3 length
Dowel bars at contraction joints shall be provided for heavy
trafficroads (>450CVPD) to increase service life.
 Contraction joints as per IRC:SP:62-2014:

Contraction joints may be spaced at 2.5m to 4m.

They may be formed by sawing the pavement
slabs within 24 hours of concrete casting. Practice
abroad indicates the narrow contraction joints 3 to
5mm wide perform well with better riding quality.
HDPE strips 3mm to 5mm thick with suitable
tensioning and intermediate support for keeping
the strip in position can be also used for creating
joints. The strps are kept in place. Metal strips and
T section are the other options. Joint depth can be
extended from 1/4th to 1/3rd depth of slab.
6/14/2018 d v bhavanna rao
Longitudinal joints:

Lanes are jointed together by joint known as

Longitudinal joint

Longitudinal joints are provided in multilane

pavements and also when the pavement is more
than 4.5 m wide.

They are provided normally at 3.5m c/c in two lane

road to:
1) Relieve stresses due to warping.
2) To allow differential shrinkage & swelling due to
changes of sub grade moisture
3) To prevent longitudinal
6/14/2018 cracking
d v bhavanna rao
 Longitudinal Joint

Longitudinal Joints are to be provided when width is

more than 4.5m. Joints are to be saw cut to 1/3rd slab
thick ± 5mm. Bars are to be placed middle third of slab
thickness. Tie bars are to be coated with bitumen paint
for 75mm on either side
 Expansion joints

These are full-depth joints provided

transversely into which pavement can expand,
thus relieving compressive stresses due to
expansion of concrete slabs, and preventing
any tendency towards distortion, buckling, blow-
up and spalling.
These joints are very difficult to maintain
and they get filled up with dirt etc. causing
locking of joints. They are therefore not in use.
The current practice is to provide these joints
only when concrete slab abuts with bridge or
culvert.
6/14/2018 d v bhavanna rao
 Anchor Beam and terminal slab adjoinig
Bridge and Culvert structures.

Cement Concrete slab will expand during

hot season and this will aid in the building up of
horizontal thrust on adjoining bridge structure.
To contain this thrust RCC anchor beam and
terminal slab are to be provided with
reinforcement. In case of culverts etc., where
the concrete slabs are provided above the
superstructure, there is no need to construct
anchor beam or approach slab in the terminal
slab.
6/14/2018 d v bhavanna rao
6/14/2018 Anchor beam and terminal
d v bhavanna rao slab abutting bridge
 Transit slab between rigid and flexible
pavement
6/14/2018 d v bhavanna rao
 Pre-moulded joint filler

Joint filler board for expansion joints which

are proposed for use only at bridges and
culverts shall be of a synthetic
compressible material having
compressibility more than 25% as per
IS:1838
Holes to accommodate dowel bars shall be
accurately bored or punched out to give
6/14/2018
sliding fit on the dowel
d v bhavanna rao
bars.
6/14/2018 d v bhavanna rao
 Expansion Joint

Filler board: compressible Joint filler 20 to 25mm ± 1.5mm

Filler depth 25mm ± 3mm lower than slab thickness
Dowel bars (MS rounds) to be covered with plastic sheathing for
½ length +50mm
 Construction joints

Construction joints are provided whenever day’s

construction operation starts and stop/ends.These are
full depth joints. Construction operation should be so
planned so that the construction activity ends at the
location of the regular contraction joint. It may also be
provided when placing of concrete stops for more than
half an hour due to stoppage of work. At all
construction joints bulkheads shall be used to retain
the concrete and care shall be taken to strike off and
finishing the concrete to the top face of the bulkhead.

6/14/2018 d v bhavanna rao

 Bulkhead is just removed. MS dowels just removed at construction
joint/ contraction joint. Removed bulkhead is also seen.

6/14/2018 d v bhavanna rao

 Dowel bars
a) Load transfer to relieve part of load stresses in edge
and corner regions at transverse joints is provided by mild
steel Dowel bars. Coated Dowel bars are often to prevent
corrosion. Dowel bars are assumed to transfer about 40% of
wheel load.
b) Dowel bars embedded and fixed in concrete at one end
and kept free to expand / contract at the other end
c) Spacing between dowel bars normally 30 cm
d) The size varies from 25 - 38 mm & length 36-50 cm
e) Dowel bars are required at contraction joints also if
traffic intensity is more than 450 CVPD
f) Dowel bars shall be coated with anti corrosive coating
as per IS:13620
6/14/2018 d v bhavanna rao
 Necessity of providing dowel bars

6/14/2018 d v bhavanna rao

 Table 5 of IRC:58-2015 Recommended
Dimensions of Dowel bars
Slab thickness Dowel bar details
mm Diameter Length mm Spacing
mm mm
200 25 360 300
230 30 400 300
250 32 450 300
280 36 450 300
300 38 500 300
350 38 500 300

Note: Dowel bars shall not be provided for slabs of less than
200mm thick. For heavy traffic, more than 450 CVPD, dowel bars
6/14/2018
shall be providedd at
v bhavanna rao
contraction joints also,
 Mild steel dowel rods with sheathing and caps. Groove
cutting in progress at expansion joint

6/14/2018 d v bhavanna rao

 Low cost Groove cutting machine

6/14/2018 d v bhavanna rao

 Joint cutting

6/14/2018 d v bhavanna rao

 Freshly cut contraction joints

6/14/2018 d v bhavanna rao

 Contraction joint 3 to 5 mm wide
1/3rd to 1/4th in depth

6/14/2018 d v bhavanna rao

 Tie rods at
longitudinal joint

6/14/2018 d v bhavanna rao

 Table6 of IRC:58-2015,Details of tie bars for longitudinal
joint
Slab Max. spacing mm Max. length mm
Dia
thickness
mm Plain bars deformed Plain bars deformed
mm
8 330 530 440 480
150
10 520 830 510 560
10 390 620 510 560
200
12 560 900 580 640
250 12 450 720 580 640
12 370 600 580 640
300
16 660 1060 720 800
12 320 510 580 640
350
6/14/2018 d v bhavanna rao
16 570 910 720 800
 Types of sealants

 Hot poured rubberised asphalts

(Thermoplastic type)
 Cold applied poly sulphide
sealants
 Cold silicone Sealants

6/14/2018 d v bhavanna rao

 Stress Generated in Field-Moulded Sealants due to Temperature Changes
As per IRC:57-2006

6/14/2018 d v bhavanna rao

 Notes:
1.Paper backing of compressible de-bonding
strip is not necessary if the strip is non-
absorbent type.
2.Joins can be sealed by adopting one of the
two options of de-bonding strip/Backer-rod as
shown.
3. Depending upon the sealant manufacturer’s
recommendation, the sides of the groove may
have to be sand blasted/sand papered and
primed.
4. The groove and sealant dimensions shown
are only for guidance.
5. Backer rod/Back-up rod shall be expanded
Sealing Details of Joints closed-cell polyethylene foam.
(Grooves Suitable for Hot Poured Rubberised 6. Ends of the sealing groove shall be plugged.
Bitumen Sealant 7.All dimensions are in mm.
6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 PQC Paver

d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Polythene
6/14/2018 Sheet on Cleaned DLC Surface
d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Starter Beam with

d v bhavanna rao Dowel Bars
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Unloading of Concrete

d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Unloading of Concrete

d v bhavannain
rao front of Paver
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Placing of
d v Concrete
bhavanna rao with Loader
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Fixing of String line

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Band Saw for Dowel Bar Cutting & Stock of Dowel Bars
6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Automatic Dowel Bar Inserter

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Checking depth of Dowel Bar after Insertion

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Checking spacing of Dowel Bar

d v bhavanna rao after Insertion
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Tie Bar Inserter

d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Tie Bar Inserters

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Oscillating Beam behind Tie Bar Inserter

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Super Smoother – Behind Paver

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Working Bridge for Masons

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

PQC Surface immediately behind Super Smoother

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Spraying of Resin Based Aluminum Curing Compound

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Spraying of Resin Based Aluminum Curing Compound

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 View of freshly laid

d v bhavanna rao PQC
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Weather Protection

d v bhavanna rao Shed
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018
Executed PQC Layer
d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Hessian Cloth on PQC

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Moist Curing of PQC –raoWet Hessian

d v bhavanna
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Wet Hessian surface covered

d v bhavanna rao with Polythene
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Contraction Joint – Initial

d v bhavanna rao Cut
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Cleaning of Longitudinal

d v bhavanna rao Joint
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Fixing of Back upd vRod after

bhavanna rao Initial Cut
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Widened Groove afterrao14 days

d v bhavanna
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Cleaning of Groove with Compressed Air

6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Primer Application after fixing Masking Tape & before Sealant filling
6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

Finishing of Sealant
6/14/2018 d v bhavanna rao
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Removal of Masking Tape after rao

d v bhavanna Sealant Filling
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Finished PQC surface

d v bhavannawith
rao Sealed Joints
 EXECUTION METHODOLOGY
Pavement Quality Concrete (PQC)

6/14/2018 Finished PQC Surface showing

d v bhavanna rao Texturing
Joints sealed with hot-pour liquid sealants. Normally
these joints should coincide with lane divisions

6/14/2018 d v bhavanna rao

 Preparation for slump test, casting cubes (150 mm)
and beams (70 х 15 х 15 cm)

6/14/2018 d v bhavanna rao

 12.8 of IRC:15-2017 Accepting Criteria of
Strength
Flexural Strength:

i)The mean strength determined from any

group of 4 consecutive samples (each sample
containing 3 beam specimens) at 28 days should
exceed the specified characteristic flexural
strength (4.5MPa) by at least 0.3MPa
ii) The strength of any specimen is not less
than the specified characteristic flexural strength
(4.5MPa) minus 0.1MPa

6/14/2018 d v bhavanna rao

 12.8 of IRC:15-2017 Accepting Criteria of
Strength
Compressive Strength:

i)The mean strength determined from any

group of 4 consecutive samples (each sample
containing 3 cube specimens) at 28 days should
exceed the specified characteristic compressive
strength by at least 3MPa
ii) The strength of any specimen is not less
than the specified characteristic compressive
strength minus 1MPa

6/14/2018 d v bhavanna rao

 12.21 of IRC:15-2017 Quality Control Chart-Cores
A quality control chart indicating the strength
values of individual specimens shall be maintained for
continuous quality assurance. Where the
requirements are not met with, or the quality of
concrete or compaction is suspect, the actual
strength of concrete in slab shall be ascertained by
carrying out tests on cores at the rate of 2 cores
/150cu.m of concrete. The average crushing strength
of these cores shall not be less than 0.8×0.85 times
the corresponding characteristic compressive
strength of cubes, where the height to diameter ratio
is 2.0.
6/14/2018
Dia. of core shall not be less than 150mm.
d v bhavanna rao
 The crushing strengths of cylinders with
height to diameter ratios between 1 and 2 may be
corrected to correspond to standard cylinder of
height to diameter ratio of 2 by multiplying with the
following correction factor.
f= 0.11 n+0.78
where f = correction factor and
n = height to diameter ratio
The corrected test results shall be analysed
for conformity with specification requirement for
cube samples.
`Minimum core diameter is 150mm. 2 cores
per 150 Cum is necessary when doubt arises about
the strength.
6/14/2018 d v bhavanna rao
 Physical and Chemical Tests on Cement
Once for each source
of supply and
occasionally when
As per requirements called for
of IS Codes: long/improper
455, 1489, 8112, storage. Besides, the
12269 and 12330 contractor will submit
daily test data on
cement released by
the contractor.
6/14/2018 d v bhavanna rao
 Physical tests on Coarse and Fine Aggregates 1

One test for every day’s work

Gradation as per
of each fraction of coarse
IS:2386 part 1 and
aggregate and fine aggregate,
deleterious constituents
initially; may be relaxed at the
as per IS:2386 part 2
discretion of engineer

Regularly as required subject

to a minimum of one test a day
for coarse aggregate and 2
Water Absorption as
tests a day on fine aggregate.
per IS: 2386 part 3
This data shall be used for
correcting the water demand of
d v bhavanna rao
the mix on daily basis
6/14/2018
 Physical tests on Coarse and Fine Aggregates 2

Los Angeles Abrasion

Value or Aggregate Once for each source of supply
Impact Value and on monthly basis
As per IS:2386 part 4

Before approving the

Soundness as per
aggregates and monthly
IS:2386 part 5
subsequently

Alkali aggregate Before approving the

reactivity as per aggregates and monthly
d v bhavanna rao
IS:2386 part 7 subsequently 6/14/2018
 Tests on Water and Mineral Admixtures

One from each source as per

Mineral Admixtures IS:3812, IS:12089 and IS:
15388

Water Once for approval of source of

Chemical tests supply, subsequently only in
As per IS:456 case of doubt
d v bhavanna rao
6/14/2018
 Tests on concrete 1

3 cubes and 3 beams per 200

Strength of Concrete cu.m or minimum 6 cubes and 6
as per IS: 516 beams per day’s work whichever
is more

Core Strength on
As per the requirement of
hardened Concrete as
Engineer or 2 cores/km
per IS:516
1 test per dumper load at both
Workability of fresh batching plant site and paving
concrete as per site initially when work starts.
IS:1199 Subsequently sampling may be
d v bhavanna rao
6/14/2018
done from alternate dumper
 Tests on concrete 2
From the level data of concrete
pavement surface and sub base
Thickness
at grid points of 5m×3.5m or
Determination
6.25m×3.5m. Cores may be cut
in case the Engineer desires.
Thickness measured
3 cores per trial length
for trial length
String line or steel forms shall be
Verification of level of checked for level at an interval of
string line in the case 5m or 6.25m. The level tolerance
of slip form paving allowed shall be ± 2mm. These
and steel form in case shall be got approved 1-2 hours
of fixed form paving before the commencement of
d v bhavanna rao
6/14/2018

concrete activity.