PUNJ LLOYD LIMITED

Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

A. Sc ope :

A1. T h e w o r k s ha l l c o ns is t o f co n s t r uc t i o n o f u n r e i n f o r c e d, d o w e l
j oi n t e d , p l ai n ce m e n t c on c r e t e p a v e me n t in ac co r d a n c e w i t h t h e
r e q u i r e m e n ts o f t h e t ec h n ic a l s p ec i fi c a ti o ns a n d i n co n f o r m i ty
w i t h t he l in e s , g r a d es a n d c r os s s ec t i o ns s ho w n o n t h e d r a w i ng s .

A2. Th e w o rk sh al l b e e xe cu te d in a cco rda n ce w i th fo ll o wi n g

C od e s / Sp e ci fi ca ti o n :

A 2 .1 Te ch n i ca l Spe ci fi ca tio n s fo r Ro a d an d Bri d g e wo rks pu b li sh e d

b y In d i an Ro a d Co n g re ss (III R e vi si o n ).

A 2 .2 Gu i d el i ne s fo r u se o f D LC a s Sub -Ba se fo r Ri gi d Pa ve men t

(IR C -SP-49 -1 9 98 ).

A 2 .3 Sta n d a rd Sp e ci fi ca ti o n a n d Co de o f Pra cti ce fo r C o n stru ctio n

o f Co n cre te R oa d s (IR C :IS- 20 0 2 ).

A 2 .4 C od e o f Pra cti ce fo r C u ri n g o f Ce men t Co n cre te Pa ve men t

(IR C :8 4 -19 8 3 ).

B. Ma te r ia ls :

B1. B as ic Ma te r ia ls :

B 1 .1 C em e nt : It is pro p o se d to u se Ordi n a ry Po rtl a nd Ce me n t o f

4 3 Gra d e a s p e r IS: 26 9 . Ce me n t sh a ll be p ro cu re d fro m
re p u ted ma nu fa ctu re s i n ce me n t ba g s o f 50 kg ea ch . Th e
C e me n t sha l l i ni ti a ll y be sto re d i n co ve re d ce me n t Go d o wn
a n d th e n tra n sfe rre d to ce me n t si lo s th ro u gh C e me n t B a g
Sp li tti n g Un i t o r ma n ua l fe e d in g i n Si lo s.

B 1 .2 OPC 4 3 Gra d e C e me n t sha l l no rma l l y be pro cu red fro m a n y o f

th e fo ll o wi n g Ma n u fa ctu re rs:
a) AC C b) C o ro ma n da l

B 1 .3 To e n su re re gu l a r un in te rru p te d su p p l y o f ce me n t, w e h a ve
e n te red in to Me mo ra nd u m of Un d e rsta nd i ng wi th the se
ma n u fa ctu re rs fo r co n tin u o u s a nd re g u la r su p p l y o f ce me n t.
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

B 1 .4 A ggr e ga te s : Agg re g a te s to b e use d fo r PQC sh a ll b e na tu ra l

ma te ri al co mp l yi n g w i th IS: 38 3 an d sh al l n o t b e a l ka l i re a cti ve .

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B 1 .5 C oa rs e A ggr e ga tes : C oa rse a gg re g a te sh a ll co n si st of

C ru sh e d sto ne . Ston e ag g re ga te s sh a ll b e p ro du ce d a t PL L ’ s
i n te g ra te d Sto n e C ru shi n g a nd Scre e n in g Pl a n ts e sta bl i sh ed
o n th e p roj e ct. Th e cru sh ed ag g reg a te sh a ll be ch e cke d fo r
p h ysi ca l p rop e rti e s su ch a s Ag g re g a te Imp a ct Val u e , Wa te r
a b so rp ti o n e tc., b e fo re a cce p ti n g fo r i n co rp o ra ti on in w o rks.
Th e ma xi mu m si ze o f co a rse ag g reg a te sh a ll be 25 mm.

B 1 .6 Fine A ggr e ga te : Th e fi n e a g g re g a te sh al l co n si st o f cl e a n ,
n a tu ral sa nd o r cru sh e d ston e sa nd o r a co mbi n a ti on o f tw o
a n d sh a ll co n fo rm to IS: 38 3 . Fi n e ag g reg a te sh al l be fre e
fro m so ft p a rti cle s, cl a y, sh al e , l oa m, ce me n te d p a rti cle s,
mi ca , o rg a n i c a n d o th e r fo rei g n ma tte r. It is p rop o se d to u se
cru sh ed sa n d p rod u ce d a t i n te g ra te d ston e cru sh in g an d
scre e ni n g p la n t se tu p on p ro je ct.

B 1 .7 D e si g n Mi x h a s be e n co n du cte d w i th b o th Cru sh ed S a nd
a lo n e an d al so C ru sh e d Sa n d b l en d e d w i th na tu ra l sa n d as
fi n e ag g reg a te . Th i s ha s b ee n do n e to co n ti n ue w i th wo rk in
ca se o f sh o rta g e o f sto n e d u st fro m sto ne cru sh e r i n sta ll e d a t
si te .

B1.8 A d m i x t u r e s : A d mi x t u r es c o n fo r m i n g t o IS : 69 2 5 a n d IS : 9 1 0 3
w i ll be us e d t o im p r o v e w o r k a bi l it y o f th e co n c r e t e o r ex t e ns i o n
o f s et t i n g ti m e , o n s a ti s f ac t o r y ev i d e nc e t h a t t h e y wi ll n o t h av e
a n y a dv e r s e e f f e c t o n t h e p r o p e r t i e s o f c o nc r e t e wi t h r es p e c t t o
s t r e n g t h , v ol u m e c ha n g e , d u r a b il i ty a n d h av e n o de l e t e r i o us
e f f ec t o n s te e l b a rs . S a ti s f ac t o r y p e r f o r m a nc e o f t h e ad m ix t u r e
s h al l b e p r o v e d b o t h o n t h e la b o r a t o r y c on c r e t e t r i al m ix es a n d
i n t r ia l p av i n g w o rk .

B1.9 W a t e r : Wa t e r us e d fo r m ix i ng a n d c u ri n g of co n c r e t e s h al l b e
c le a n and free from in j u r io u s a mo u n t s of o il s , sa l t , ac id ,
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

v e g et a b l e ma t t e r o r ot h e r su bs t a n c es h a r m f ul t o t h e fi n is h e d
c o nc r e t e . It is p r o p o s e d t o u s e u n d e r g r o u n d w a t e r a n d t h r o u g h
d e e p b o r e w el l s. T h e w a t e r s h al l b e te s t e d to c h ec k it s su it a b il i ty
f o r us e in co nc r e t e w o r k b e f o r e a c t u al st a r t of w o r k . Large
u n d e r g r o u n d w a te r s t o r a g e t a nk s h a ve b e e n co n s t r uc t e d at
l oc a t i o ns o f al l B a tc h i n g Pl a n ts w it h st o r a g e ca p ac i ty su f f ic i e nt
t o p r o d u ce S i ng l e d ay ’s c o nc r e t e r e q u i r e m e n ts .

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B2. Othe r Ma te r ia ls :

B 2 .1 Se pa r a tion Mem br a ne : Imp e rme ab l e Pl a sti c She e t o f12 5

Mi cron th i ckn e ss sh a ll be l ai d on D LC su rfa ce a fte r cl ea n i ng
o f DL C su rfa ce . Pol yth e n e sh ee ts o f a b ou t 5 m w id th sh a l l
b e u sed in tw o la ne s wi th ove rla p o f 30 0 mm. The Se p a ra tio n
Me mb ran e sha l l be na i le d to DL C la ye r wi th co n cre te n ai l a t
su i ta bl e i n te rval so as to e n su re th a t i t re mai n s in p o si ti o n
d u ri n g p a vi n g .

B2.2 Pre-moulded Filler Board: 2 0 m m t hi ck co m p r e ss i bl e Fi l l e r

B o a r d s a r e to b e u se d a t t h e lo c at i o n o f ex p a ns i o n jo i nt s . We
propose to use sy nt h e t ic c om p r e s si b l e Fi l le r Bo a r d of
“ S U P R E ME ” ma k e . T h e s e a r e n o n - d e g r a d a bl e a n d h av e lo n g
l if e . T h e s e sh a ll b e t es t e d fo r c om p r e s si o n a s p e r IS - 1 8 38 .
T h e h e i g ht o f t h es e b o a r d s sh a ll b e 2 5m m l es s th a n t h ic k ne ss
o f sl ab w it h i n a to l e r a n c e + 3 m m . H o l es t o h ou s e d o w e l b a r s
s h al l b e a cc u r a t e ly b a r e d o r p u n c h ed o u t t o gi v e a s li d i ng f i t o n
the bars.

B2.3 M i l d s t e e l b a r s f o r d o we l s a n d t i e b a r s : T h e s e sh a ll c on f o r m
t o t h e r e q ui r e m e n t s of I S : 4 3 2, I S : 1 1 39 a n d I S : 1 7 8 6 a s
r e l e va n t . T h e d o w e l b a r s s ha l l c o n f o r m t o Gr a d e S 4 1 5 .

B 2 .3 .1 D owe l Ba r : 3 2 mm Di a MS Do we l Ba rs o f 5 0 0 mm l e ng th a re
to be use d a t eve ry co n tra cti on jo i n t sp a ced a t 4 .5 m a nd a t
Exp a n si o n Joi n t. The Do w el Ba rs sh a ll be cu t smo o th wi th
Po we r Sa w / Be n d Saw i nsta l l ed a t th e Ce n tra l Re in fo rce me n t
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

Ya rd . Th e se sh al l b e cu t fro m fu ll le n g th MS R od s in
a d van ce a n d sto cke d in Re in fo rce me n t Ya rd .

B2.3.2 Tie Rods: T i e Ba r s o f 1 2m m / 8 m m di a H YS D S t e el a r e t o b e

p r o v id e d a t lo n g i t u di n a l j oi n ts a t d i ff e r e n t sp a ci n g s a s sp e ci f i e d
i n a p p r o v e d d r a w i n gs . T h e s e s h al l b e cu t t o th e r e q ui r e d le n g t h
o f 64 0 m m / 4 80 m m an d st a ck e d i n R e i n f o rc e m e n t Y a r d . M i d dl e
1 5 0 m m le n g t h o f D o w e l B a r sh a ll b e p ai n t e d w i th b i t u mi n o us
p a i n t f o r p r o t ec t io n f r o m c o r r o si o n . T h e bi t u m i no u s p ai n t sh a ll
b e d o n e w el l in a dv a n c e so t h a t th e p a i nt g e t s d ri e d b e f o r e us e
i n t he w o r k s .

B2.4 P V C S l e ev e s f o r C o n t r a c t i o n J o i n t : PV C S l e ev es o f m in i m u m
3 3 4 m m le n g t h a r e r e q ui r e d to b e p r o vi d e d o n D o w el B a r . T h es e
s h al l b e p r o c u r e d f r o m e st a b li s h e d v en d o r s a n d st oc k e d i n
C e n t r a l St o r e in a dv a n c e.

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B2.4.1 P u l l o u t T e s t : T h e Pu l l o u t T e s t a s sp e ci f i e d u n d e r Cl a u se N o .
6 0 2 . 6 . 5 of M O S T S p ec i f ic a ti o n s sh a ll b e d o n e t o c h ec k t h e
a v e r a g e b o n d s t r es s b e t w e e n P V C S le e v es an d D o w el Ba rs.
Th e te st h a s b ee n co n du cte d in th e Fi e l d La b o ra to ry a nd i t
h a s b ee n fo u n d th a t the bo n d stre ss be tw e en PVC Sl e e ve
a n d Do w el Ba r fo r a mo ve men t o f 0 .2 5 mm i s l e ss th a n
0 .1 4 Mpa as spe ci fi ed in Te ch n i cal Sp e ci fi ca ti o n s.

B2.5 PVC S l e ev e s for Expansion Joint: PVC Sl e e ve s for

E xp a n si o n J oi n t sh a ll b e 3 0 0 mm . F o r Ex p a ns i on J oi n t a cl os e ly
f i t ti n g ca p o f 1 0 0 mm l o n g PV C sh a ll b e p la c e d ov e r s h e at h e d
e n d o f D o w el Ba r . T h e e x p an s io n sp a c e o f 2 0 m m s ha l l b e
f o r m e d b e t w e e n en d o f ca p a n d a t th e e n d o f D o w el B a r b y
u si n g co m p r es s ib l e s p o n ge . T o b l oc k t h e e n t r y o f c e m e nt
s lu r r y b e t w e e n D o w el B a r a n d ca p , i t s h al l b e ta p e d .

B2.6 B a c k - u p R o d : S yn t h e t ic Ba ck - u p R o d o f 6 m m / 8m m Di a sh a ll
b e u se d i n C o nt r a c t i o n / E xp a n si o n / L o n gi t u di n a l Jo i n ts .

B2.7 De-bonding Strip: D e b o n di n g s t ri p s o f fo l lo w i n g si ze s a r e t o

b e u se d f o r v a r i ou s ty p e s of j oi n t s :
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

B2.7.1 C o n t r a c t i o n J o i n t – C o mp r e s si b l e de b o n d i n g s t r i p wi t h p a p e r
h o o k o f s iz e 10 m m x 5 m m .

B2.7.2 E x p a n s i o n J o i n t – C o mp r e s si b l e d e b o n di n g s t r i p w i t h p a p e r
b a ck o f si ze 2 0 m m x 1 – 2 mm s iz e

B2.7.3 L o n g i t u d i n a l J o i n t – C o m p r e ss i bl e d e b o n di n g st r i p w i t h pa p e r
b a ck o f si ze 8 m m x 1 – 2 m m.

B2.8 S e a l a n t : T h e j oi n t s ea l i ng c o m po u n d s ha l l be C o l d Po ly s ul p h i d e
t y p e c o n f o r mi n g t o BS : 5 2 1 2 h av i ng f l ex i bi l it y , r e si s ta n c e t o a g e
hardening an d d u r a b il i ty . P ol ys u l p hi d e S e al a n t sh a ll be
p r o c u r e d f r o m r e p u t e d ma n u f a ct u r e r s a n d s to r e d i n C e n t r a l
S t o r e s. T h i s is g e n e r a l ly a v ai l a bl e in 2 p a r t s a n d s ha l l b e
m ix e d b e f o r e a p pl ic a t i on .

C. Stor a ge of m a te r ia ls :

C1. F i n e a n d C oa r s e Ag g r e g a t e s sh a ll b e s to r e d a t p l a n t a r e a i n
S t ac k ya r d s se p a r a t e ly i d en t i fi e d for different si ze s of
a g g r e g a t es in su c h a manner so as to p r ev e n t their
d e t e r i o r a t io n and co n t a m in a t i o n by f o r e i gn m a tt e r and to
e n s u r e t he i r s a ti s f ac t o r y qu a l it y a n d fi t n es s f o r us e i n t h e
work. The st a ck y a r ds for these m a t e r i al s sh a ll have
a cc e ss i bi li t y f o r wi t h d r a w a l a n d in s pe c ti o n .

Page 4
C2. Ma te ri al s su ch a s PVC Sl e e ve s, de b on d in g stri p , sea l a n t e tc.
sh al l b e p ro cu re d i n b ul k an d sto re d i n Ce n tra l Sto re so a s to
p re ven t th e m fro m an y d a mag e d u e to h a rsh w ea th e r e tc.

D. Mix De s ign a nd Qua lity C ontr ol:

D1. M 4 0 G r a d e o f C on c r e t e i s sp e ci f i e d t o b e us e d f o r R ig i d
P av e m e n t o n th e P r o j ec t . T h e t r ia l mi x es s h al l be c o n d uc t e d
i n t he F i e l d La b o r a t o r y t o es t a b li s h D e s ig n M ix f o r M 4 0 Gr a d e
o f C o nc r e t e f o r th is w o r k . T h e im p o r t a n t p a r a m e t e r s th a t s ha l l
g u i d e t h e d es i g n mi x a r e :

i) C o n si s t e nc y o f M ix
ii) L o w S lu m p o f 3 0m m
i ii ) F l e xu r a l S t r e n g t h
iv) C o m p r e ss iv e S t r e n g t h
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

D1.1 W hi l e it i s p r o p o s e d t o u s e C r u s h e d sa n d a s F i n e A g g r e g a te ,
D e si g n M ix sh a ll a ls o b e co n d u c te d w i t h C r u sh e d S a n d bl e n d e d
w i t h R iv e r S a nd t o e ns u r e c on t i n ui t y o f w o r k in ca se o f
shortage of Crushed Sand. T h e p r o p o s e d D e si g n M ix sh a ll b e
s u bm i t t e d to C o n s ul t a n t f o r a p p r ov a l b e f o r e us e in w o r k s .

D2. Quality Control - T h e Qu a l i ty C o n t r o l of P QC P av e m e n t i s

v e r y c ri t ic a l a n d i m p o r t a n t f o r t he lo n g la s ti n g R i g id Pa v e m e nt .
T h e Q u a li t y C o n t r o l s ha l l b e e x e rc i se d as pe r C l a us e N o.
9 0 3 . 5 . 2 of M O S T S p ec i f ic a ti o n s .

D2.1 S a m p l i n g & T e s t i n g o f B e a m a n d C u b e s p e c i m e n : A tl e a s t t w o
b e a ms a n d t w o cu b e sp e ci m e n s, o n e e ac h f o r 7 a n d 2 8 da y
s t r e n g t h te s ti n g s ha l l be c as t f o r e ve r y 1 5 0 m 3 o f c o nc r e t e
p l ac e d a t si t e . At l e as t 3 p ai r s of b e am s a n d cu b es sh a ll be
m a d e f o r e ac h d ay ’s w o r k . Ea c h p ai r s h al l b e di f f e r e n t f r o m a
B a tc h of co n c r e t e . T h e r a t i o be t w e e n 7 a n d 2 8 d a y s t r e n gt h s
s h al l b e e s t a bl is h e d f o r t h e mi x to b e u se d i n sl a b i n a dv a n ce
b y t es t i n g b e a ms a nd cu b e s o n a t l e as t s ix b a t c he s o f t ri a l m ix .
T h e av e r a g e st r e n g t h o f 7 d ay sp e ci m e ns sh a ll be di vi d e d by
a v e r a g e s t r e n g th o f 2 8 d a y s pe c im e n s f o r e ac h b a t c h a n d r a t i o
“ R ” sh a ll b e d e t e r m in e d .

Page 5

D 2 . 2 I f d u r i n g co ns t r u c t io n o f t r i al l e n g th o r du r i n g n o r m a l w o r k i n g , th e
a v e r a g e v al u e o f an y f o u r co n s ec u t iv e 7 d ay s’ r es u l ts fa l ls be l o w
t h e r e q u i r e d 7 d ay s’ s t r e n g t h a s d e r iv e d f r o m va l u e o f “ R ” , t h e n
c e me n t co n t e n t of c o nc r e t e sh a ll be in c r e a se d by 5% in
c o ns u l ta t i o n w i t h E n gi n e e r a nd w o r k s ha l l b e e x ec u t e d w i t h
i nc r e a s e d ce m e n t co n t e n t u n t il four c o r r e s p o nd i n g 28 da y
s t r e n g t hs a r e i n co n f o r m a nc e w i t h T a r g e t Me a n S t r e n g t h .

D2.3 Workability: T h e w o r k a bi li t y o f co nc r e t e s h al l b e ch ec k e d bo t h
a t po i n t o f p r o d u c ti o n a nd le n g t h . T h e sl u mp t es t sh al l b e
c o n du c t e d as p e r I S - 1 1 9 9 an d i ts v al u e sh a ll b e m ai n t a i n ed i n t h e
range of 30 + 15mm. H o w e v e r , t h e sl um p a t B a tc h in g P la n t
l oc a t i o n s h al l b e co n t r o ll e d d e p e n di n g u p o n d is t a n c e be t w e e n
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

p a vi n g s it e a n d B at c hi n g pl a n t . I n it i a ll y S lu m p T e s t s h al l b e
c a r r i e d o u t o n ev e r y d u m p e r . H o w e v e r , t h e f r e q u e n cy sh a ll be
r e d u c e d on c e t h e c o ns is t e n cy o f sl u m p v al u e i s e s ta b l is h e d .

D 2 .4 In- Situ D e ns ity : Th e de n si ty o f the co n cre te l a id a t si te sh a ll

b e ch e cke d b y ta ki ng co re s a t si te an d th e sa me sh al l be
co mp a re d w i th th e o re ti ca l Ma xi mu m Dry De n si ty.

D 2 .5 Thic k ne s s : Th i ckn e ss sha l l b e con tro l l ed by ta ki n g l e ve l s o f

th e p a ved con cre te . Th i ckne ss o f th e sl ab a t a n y p oi n t sh a ll be
ma in ta i n ed wi th i n a to l e ra n ce of –5 mm to +25 mm of th e
sp e ci fi e d th i ckn e ss.

D 13 . Pos ition of Tie Ba r s : Th e po si ti on a n d a li g n men t o f Tie B a rs

sh al l b e ch e cked by dri ll i n g co re s. Th e po si ti on o f Ti e B a rs
sh al l be ch e cke d fo r th e ce n te r o f ea ch b a r w i thi n 5 0 mm o f th e
i n te nd e d p o si ti o n a nd mi n i mu m co ve r o f 3 0 mm be l o w jo i n t
g ro o ve .

E. Production and Transportation:

E1. B a t c h i n g a n d M i x i n g : T h e co n c r e t e f o r P QC s h al l b e p r o d u c e d i n
f u ll y a u t o m a ti c “ S T E T T E R ” m ak e C on c r e t e B a tc h i n g P la n t s o f
1 2 0 m 3 / h r . c a p ac i ty , t h at h av e be e n ha v e b e e n i ns t a ll e d at al l t h e
f o u r c a mp l oc a t i o ns . T h e m ax im u m B a tc h si ze t h e s e p l a n ts i s
3m3. H o w e ve r , s ma l le r B a tc h si ze s in t h e m ul t i pl e s o f 0 . 5 m 3 c a n
a ls o b e p r o d uc e d f r o m t h es e p l an t s . T h e pl a n ts a r e c a p ab l e o f
p r o p o r t i o n in g t h e m a t e ri a ls by w ei g h t a n d p r ov i di n g a u ni f o r m
h o m o g e n eo u s mi x . C em e n t f r o m Si l os s ha l l be w e i g h e d s e p a r a t el y
f r o m t he a g g r e g a t es . T h e b a tc h i ng a n d m ix in g is c a r r i e d o u t i n
f o r c e d ac t i on c e n t r al M ix e r o f t h e Pl a n t .

Page 6

E 1 . 1 T o ke e p th e t em p e r a t u r e o f c o nc r e t e p r o d uc e d w i t hi n 3 0 0 C , e ac h
C o n c r e t e B a tc h i n g Pl a n t h a s s ep a r a t e u ni t of C hi l li n g P l a nt so as
t o p r o vi d e c hi ll e d w a t e r t o e ns u r e t h a t t h e f i n al t e m p e r a t u r e o f
c o nc r e t e is w i t hi n 30 0 C . Si nc e th e ma x im u m te m p e r a t u r e in t he
p r o j ec t a r e i s g e n e r a ll y le ss t h a n 3 5 0 C , ma i n t ai n i n g te m p e r a t u r e
o f c on c r e t e sh a ll n o t b e a co ns t r a i n t .
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

E2. T r a n s p o r t a t i o n : P la n t m ix e d le a n c on c r e t e sh a ll b e t r a n s p o r t e d
f r o m p l a nt t o s it e in D u m p e r s co v e r e d wi t h t a r p a u li n . T h e mi x
s h al l b e u n l o a d ed i n f ron t o f PQC Pa ve r a t si te b y r e a r t i pp i n g .

F. Spr e a ding a nd C om pa c tion:

F1 . Fre sh l y mi xed co n cre te sh al l b e b ro ug h t in d u mpe rs in re ve rse

a n d th e d u mp e r d ri ve r sha l l be ca re fu l l y gu i de d to un l oa d
co n cre te in fro n t of Pa ve r in su ch a ma nn e r th a t it is
a p p ro xi ma tel y eq u al to q ua n ti ty req u i red fo r p a vi n g i .e . l a rge
h e ap s o f co n cre te are no t fo rmed . In i ti al l y co n cre te sh al l b e
d u mpe d a t tw o lo ca ti o n s in fron t o f Pa ve r. L a te r o n co n cre te
ma y b e d u mp e d i n mid d l e o f p a vin g w id th an d co n cre te sh al l b e
sp re ad in to fu l l w id th wi th sp re ad e r pro vid e d i n fro n t o f Co n cre te
Pa ve r. In ca se Sp rea d e r o f PQC Pa ve r ne e d s ma te ri al to b e
p u she d i n fro n t o f p a ve r sa me sh a ll be d o ne wi th Ru bb e r pa d de d
e xca va to r o r l oa d e r. Fo r sta rti n g PQC Pa vi ng fo r th e fi rst ti me ,
a sta rte r be a m sha l l be po si ti o ne d in fro n t o f PQC Pa ve r. Th i s
sta rte r be a m sh a ll ha ve fa ci li ty to h ol d Do we l Ba r a t spe ci fi e d
sp a ci n g o f 30 0 mm. Th e sta rte r be a m sh a ll be po si tio n e d i n
g ro un d b y sp i kin g .

F1 .1 “ W I R T G E N ” m a k e P QC C on c r e t e P a ve r c a pa b l e o f pa vi n g in
u n i f o r m t h ic kn e ss a n d w i dt h u p to 9 m s ha l l b e u s ed o n p r o j ec t .
T h i s P av e r h as b o t h Ve r t ic a l Gr a d e C o n t r o l a n d H o ri z o n t al
A li g n m e n t C o n t r o l . T h e r e f o r e , th e st r i n g l in e sh a ll be fi x e d a t a
s p ec i fi c d is t a nc e a nd p a r a ll e l t o C e n t e r l in e o f t h e p r o p o s e d
a li g n m e n t . O n c e t h e se n s o r wi r e is fi x ed a n d c he ck e d f o r l ev e ls
a n d h o r i z o nt a l a li g n m e n t , t h e P av e r s ha l l a u t o ma t ic a l ly c o n t r o l
p a vi n g as p e r g e o m e t r ic d es i g n . T h e se ns o r pe g s sh a ll b e
p r o v id e d o n b o t h s id es o f p av e m e n t . H o w ev e r , ho r i z o n t al
a li g n m e n t i s r e q ui r e d t o b e p r o v i d ed o nl y o n o n e si d e w h il e l ev e ls
a r e t o b e p r o v i de d o n b o t h t h e s e ns o r wi r e s . T h e Pa v e r ha s
o sc il l a ti n g be a m be h i n d s c re e d . T h e os ci l l at i n g b e a m c o mp a c ts
t h e c o nc r e t e a n d sm o o t h e ns t op su r f a c e o f P QC . The Super
s m oo t h e r b e hi n d os ci ll a t i ng b e am gi v es fi n a l f in i sh i n g t o u ch e s t o
P Q C s u r f ac e .

Page 7
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

F1 .2 Th e sl u mp o f co n cre te sh al l b e ke p t a s cl o se to 3 0 mm a s
p o ssi b l e so a s to en su re th a t si d e s o f p a ved co n cre te d o no t
co ll a p se . In ca se , th e sl u mp ob ta i ne d a t si te is h ig h an d i t is
fe l t th a t si de s ma y no t re ma i n ve rti cal , i n su ch a ca se , th e
si de s sha l l be sup p o rte d te mp o ra ri l y wi th ste el sh u tte ri n g to
a ll o w i ni ti a l se tti n g .

F1.3 I n s e r t i o n o f D o we l B a r : T h e P QC P av e r h as th e f ac il i ty o f
i ns e r t i n g D o w e l B a r at p r e - d e t e r m i n e d sp a ci n g i. e . 3 0 0 m m a n d
a t p r e - d e t e r mi n e d de p t h be l o w t o p su r f a c e . T h is c o m p on e n t of
m a ch i n e i s ca ll e d D o w el Ba r I ns e r t e r ( D B I ) . T h e l oc a t i o n o f
c o n t r ac t i o n j oi n ts a t e ve r y 4 .5 m ce n t e r to ce n t e r sh a ll b e
m a r k e d m a n u al ly o n t h e g r o u n d a s t h e p a vi n g p r oc e e d s. The
D o w e l Ba r s s ha l l be a u t o m a ti c al ly i ns e r t e d b y P QC Pa v e r o nc e
t h e D B I ha s r e ac h e d m a r k e d l oc a t i o n an d t h e o p e r a t o r p r e ss e s
a bu t t o n p r ov i d e d o n s id e of t h e p av e r . T h e D o w el Ba r s w i t h
P V C S le e v e s ha l l b e l o a de d in D o w el Ba r t r o ll e y i n a dv a n c e .
T h e D o w el Ba r I ns e r t e r w i ll au t o m a ti c al l y ke e p in po si t i o n t h e
r e q u i r e d n u m b e r o f D o w el B a rs i . e . 30 N o s . in t h is ca s e f o r n ex t
i ns e r t i o n a f te r ev e r y in s e r t io n o f D o w e l Ba r s is co m p l et e d .

F1.4 T i e B a r s : T h e T i e Ba r s s h al l be p r o v i de d i n t he T i e B a r
m a g az i n e p r o vi d e d at sp e ci f i e d l oc a ti o n s a l o ng t h e w i d th o f
p a vi n g behind DBI. The Ti e Ba r I ns e r t e r g e ts ac t iv a t e d
a u t o m a ti c al ly o n t h e a ct i o n o f D o w el Ba r I ns e r t e r a n d i ns e r t s
t h e T i e Ba r s a t p r e - d e t e r m i ne d s p ac i n g a l r e a d y f e d i n to t h e
C o m p u t e r i ns t al l e d al o n g w i th T i e B a r I ns e r t e r s .

F1.5 T h e d e p r es si o n s i n t h e C o n c r e t e p av i n g c a us e d d u e to D o w el
B a r an d T i e B a r I n s e r ti o n sh a ll be le v el l e d b y os ci l l at i n g b e a m
a n d su p e r s m o o th e r , w hi c h f o ll o w D o w e l Ba r a nd T i e B a r
I n s e r t e r s.

F1.6 Speed of machine: T h e P QC Pa v e r i s d es i g n ed t o p av e

@ 0 . 3 m a n d 1 . 2 m pe r mi n u t e . T h e C o n c r e t e p r o d uc t i o n sh al l
b e r e g u l a te d i n su c h a w a y t ha t p a vi n g is d o n e @ 1 m per
m i n ut e . H o w e v e r , ac t u al s p e e d s h al l b e r e g ul a t e d t o ma t c h th e
s p e ed o f c on c r e t e su p p ly .
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

Page 8

F1 .7 Te x tur ing a nd C ur ing: Te xtu rin g a n d cu ri n g sh al l b e d o ne

w i th TC M ma ch in e p ro vid e d b eh i n d th e PQC Pa ve r. Th i s i s a
se p a ra te un i t an d sh al l fo l lo w th e Pa ve r a t a spe ci fi e d
d i sta n ce . A 2 m wi de te xtu ri n g b ru sh h a s be e n pro vi de d ,
w hi ch sha l l au to ma ti cal l y te xtu re 2m w id th o f p a ve me n t. Fo r
th i s, TC M mo ve s i n in cre men ts o f 2 m a t a ti me an d te xtu ri ng
a n d cu ri ng b o th are do n e in in cre me n ts o f 2m a t a ti me . Fo r
cu rin g a sp ra y b a r o f 2m le n g th a nd 3 sp ra y no zzl e s i s
p ro vi d e d be hi n d th e te xtu ri n g bru sh . Th e a p p ro ve d Re si n
Ba se d C u ri n g Co mp ou n d sha l l b e fe d i n th e ta n k p ro vi d ed a t
to p o f TC M Ma ch i ne . Th e TC M al so ha s fa cil i ty fo r sp ra yi n g
cu rin g co mpo u n d a t tw o sid e s fo r wh i ch se p a ra te n o zzle s
h a ve b e en p ro vi d e d o n TC M. The cu rin g co mpo u n d sh a ll b e
ke p t i n a gi ta te d co n d i tio n w i th a gi ta to r p ro vi de d in cu rin g
co mp ou n d ta n k. The sp re a di n g ra te s sh a ll be as pe r
Ma n u fa ctu re rs’ Sp e ci fi ca ti o n , wh i ch is 0 .1 to 0 .2 l tr / m 2 .
Fu rth e r cu ri n g o f PQC pa ve men t sh a ll b e d o ne b y kee p i ng th e
su rfa ce mo i st w i th He ssia n clo th a n d w a te r. Fre sh co n cre te
su rfa ce sh al l b e p ro te cte d fo r a tl e a st 3 h o u rs b y co ve ri n g
w i th te n t in ca se o f ad ve rse we a th e r co nd i ti o n s.

G. Te m pe r a ture of C onc r e ting:

G1 . In ord e r to re d u ce sh ri n ka ge , cra cks e tc. in co n cre te , P QC

sh al l b e p ro du ce d a t Ba tch i n g Pla n t by u si n g chi l l ed wa te r.
As su ch , Ch i ll i ng Pl an ts ha ve be e n i n sta ll e d a t lo ca tio n o f
e a ch 12 0 m 3 Ba tch in g p l an t. Sin ce the te mpe ra tu re o n th e
p roj e ct si te ge n e ral l y d o e s no t e xcee d 3 5 0 C , ma in ta i ni n g
te mp e ra tu re o f co n cre te w i thi n 3 0 0 C sha l l n o t b e a p rob l e m.
In ca se , i t i s fe l t tha t i t i s a d vi sa b l e to a voi d di re ct su n li g h t,
co n cre te pa vi n g sha l l be sta rte d in th e e ven i n g s an d
co n ti nu e d th ro u g h ou t n ig h t fo r ma in ta i n in g be tte r qu a li ty o f
p a ve me n t. Fo r su ch a si tu a tio n su ffi cie n t l ig h ti n g
a rra ng e me n t sh al l b e ma de a t si te fo r ni g h t w o rki n g .
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

H. Se pa r a tion Mem br a ne :

H1. Imp e rme ab l e p la sti c sh e e ti ng , 1 25 mi cro n s th i ck sh al l b e l ai d

fl a t w i tho u t cre a se s o n to p o f p re vi o u sl y l a id D LC . Be fo re
p la ci n g th e se pa ra ti o n me mb ra n e , th e DL C Su rfa ce sha l l b e
sw ep t cl e a n of a ll th e e xtran e o u s ma te ri al s u sin g a ir
co mp re sso r. Th e o ve rl a p o f pl a sti c sh ee t sha l l b e kep t a t
l ea st 3 00 mm. Th e se pa ra ti o n me mb ra n e sh al l b e n ai l ed to
D LC la ye r w i th con cre te na il s.
Page 9

J. J oints :

J1 . In i ti al cu tti n g o f the j oi n ts, wh i ch sh al l be 3 mm wi d e an d 10 0 mm

d e ep (co n tra ctio n j oi n ts) sh al l be d on e a s so o n as i t i s p o ssib l e
to do so wi th o u t d a ma g i ng co n cre te su rfa ce a fte r pa vi ng .
N o rma l l y in i tia l cu tin g o f th e jo in ts sh a ll b e sta rte d a b ou t 10
h o u rs a fte r p a vin g o f con cre te . Th e con cre te slu rry fo rme d a fte r
j oi n t cu tti ng sh a l l be re mo ve d b y w a sh i ng th e jo i n t w i th se pa ra te
w a te r. Th e fi n al cu t o f jo in t a s sh ow n i n th e d ra wi n g sh al l b e
d o ne a t a bo u t 15 da ys a fte r th e d a te o f p a vin g . Th e fin a l cu t
sh al l be 8 – 1 0 mm wi d e a n d 20 -2 2 mm d e ep . Th e w id e ni n g o f
i ni ti a l 3 mm j oi n t to 8 – 1 0 mm w id th sh a ll be ma d e b y ma kin g on e
/ tw o p a sse s o f cu tti n g bl a d e on ei th e r si d e o f th e i n i tia l cu t.
Jo in t cu tti n g sh al l b e d on e w i th p e trol dri ve n Joi n t Cu tti n g
ma chi n e w i th d ia mo nd po i n te d cu tti ng di scs.

J2 . Th e j o in t sha l l b e cle a n ed wi th w a te r a n d ba ck up ro d sh a ll be
p ro vi d e d in th e g ro o ve so a s to p re ven t in g re ss o f a n y du st
p a rti cl e s. Su b se q u en tl y d e -bo n di n g stri p sh a ll b e p ro vid e d a fte r
fi n al cu t. Th e b a ck u p ro d , th e n sha l l b e pu sh e d b e lo w th e
w id e n ed cu t. Po l ysu l p hi d e Se a l an t, wh i ch i s a va i l ab l e in tw o
p a rts sha l l be mi xe d in a mi xe r a t si te an d sh a ll b e fil l ed i n
g ro o ve w i th a Sea l a n t Gu n . The to p su rfa ce o f th e Sea l a n t sha l l
b e sh ap e d w i th a sh ap i ng to ol . The sa me pro ce ss sh al l b e
fo l lo w e d fo r Exp a n si o n a nd Lo n gi tu d i na l Jo i n ts.

K. C o n s t r u c t i o n Se q u e n c e o f P QC :
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

K1. C l e a n th e D L C S u r f a ce w i t h C o m p r es s o r / M ec h a ni c al B r o o m o r
m a n u al ly .

K2. M a r k t h e b o u n d a r i es o f p av i n g wi d t h .

K3. S p r e a d Se p a r a t i o n M em b r a n e w i t h ov e r l a p o f 3 0 0 m m .

K4. F i x pe g s @ 1 0 m m ce n t e r t o ce n t e r o n b o t h si d es a t a fi x ed
d is t a n ce f r o m p a v em e n t e d g e .

K5. F i x st r i n g li n e at a f ix e d h ei g h t a b ov e p r o p o se d p a v em e n t s u r f ac e .

K6. S t a r t C h i ll i n g P la n t w e l l i n a dv a n c e t o h a ve ch il l e d w a t e r av a il a b l e
f o r c o nc r e t e p r o d u c ti o n .

K7. C h e ck t h e Ba t c hi n g P la n t f o r a ll i ts f u nc t i o ns .

Page 10

K8. K e e p r e q ui si t e n u m b e r o f 15 M T d u m p e r s r e a dy a f t e r c le a n in g a t
B a tc h i n g Pl a n t.

K9. C h e ck t h e P Q C Pa v e r f o r a ll f u nc t i o ns .

K 1 0 . C h e ck w a t e r t a nk o n P av e r a n d C u r i n g C o mp o u n d T a n k on T C M
f o r t h e i r co n t e n ts .

K 1 1 . C h e ck T C M s p r ay n o zz l es f o r p r o p e r s p r a y.

K 1 2 . P os i ti o n P Q C p a v e r a t St a r t i n g Po i n t . F i x po si t i o n o f T i e B a r
I n s e r t e r s o n P Q C P av e r . A ls o f e e d ne c es s a r y de t a il s in C o m p u t e r
r e g a r d i n g sp a ci n g o f T i e Ba r s .

K 1 3 . P os i ti o n W o r ki n g b r i d ge a n d T C M b e hi n d P av e r .

K 1 4 . P os i ti o n S t a r t e r b e a m fi t t e d wi t h D o w e l Ba r s a t St a r t p o i n t . I t
s h o ul d m a tc h w i th t h e f r o n t sh u t t e r o f P av e r .

K 1 5 . M a r k p os i ti o n o f C o n t r ac t i o n Jo in t s @ 4 . 5 m ce n t e r t o c en t e r f r o m
s t a r ti n g p o i nt o n D L C w i t h pa i n t .

K 1 6 . C h e ck Ma s o n , S ki ll e d W o r ke r s f o r t h e i r t o o ls in cl u d i ng 3 m s t r ai g h t
edge.

K 1 7 . P os i ti o n a t r a i n e d p e r s on in f r o n t o f P a ve r t o g u i d e D u m p e r d ri v e r
d u r i n g r e ve r s i n g .
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

K 1 8 . Ke e p Q u a li t y C o n t r ol t o o ls s uc h as S lu m p T e s t a p p a r a t u s , C ub e
m o u ld s , Be a m m o ul d s r e a dy a t si t e a nd B a tc h i n g Pl a n t .

K 1 9 . F i ll t h e D o w el B a r T r a y w i t h D o w el B a rs a n d T i e Ba r In s e r t e r w i t h
T i e B a rs .

K 2 0 . S t a r t p r o d uc t i o n o f C o n c r e t e , t r a ns p o r t i n d um p e r an d o n r e a c hi n g
s it e r e v e r s e t h e d u m p e r u p t o f r o n t o f P av e r .

K 2 1 . U n l o a d co nc r e t e i n f r o n t o f P a ve r a t t w o l oc a t i o ns .

K 2 2 . P us h c o nc r e t e w i t h W h e el L o a d e r / Ex c av a t o r u p t o Pa v e r sc r e e d .

K 2 3 . U s e Sp r e a d e r to s p r e a d co n c r e t e in f ul l w id t h .

K 2 4 . S t a r t P av e r m ov e m e n t .

K 2 5 . A f t e r p a vi n g of fi r s t 2 - 3 m P av e d C o n c r e t e s h al l b e c o m pa c t e d
e x t e r n al ly wi t h n ee d l e v ib r a t o r a n d s u r f ac e fi n is h e d m a n u al l y.
T h e r e a f t e r ma n u a l fi n is h in g i s n o t r e q u i r e d .

Page 11

K 2 6 . C o n t i n ue p a vi n g .

K 2 7 . I n s e r t D o w el B a r s at m a r k e d po s it i o n o f C on t r a c t i on J oi n t .

K 2 8 . T i e B a r sh a ll b e a u t om a t ic a ll y in s e r t e d a t sp ec i fi e d s p ac i ng a n d
l oc a t i o n.

K 2 9 . C h e ck t h e p av e d la y e r b e hi n d P av e r f o r a n y fi n is h i n g r e q u i r e d a n d
v e r t ic a li t y o f s id e ed g e s . I n ca s e o f e x t r a s lu m p , s u p po r t e d g es
w i t h si d e sh u t t e rs o f 3 0 0 m m h e i g h t .

K 3 0 . F i n is h t h e to p s u r f ac e w h e r e v e r r e q u i r e d by u si n g Wo r k i n g B ri d g e .

K 3 1 . S t a r t T e x tu r i n g o f C o nc r e t e s u r f ac e w h e n it i s f i t t o a p p ly b r u s h .

K 3 2 . C u r i n g sh a ll f o ll o w i m me d i a t el y a ft e r te x t u r i n g b y sp r a y in g c u r i ng
c o mp o u n d .

K 3 3 . M o n it o r te m p e r a t u r e , s lu m p o f C o nc r e t e r e c ei v e d at s it e .

K 3 4 . C o v e r t h e Pa v e d P Q C wi t h w e a t h e r p r o t ec t i o n sh e d .

K 3 5 . S t a r t in i t ia l cu t t i n g of J oi n t s ab o u t 8 – 1 0 h r s . a f t e r p av i n g .
 PUNJ LLOYD LIMITED
Belgaum–Maharashtra Border Road Project (Km. 515 to Km. 592 of NH-4)

WORKING METHODOLOGY-CEMENT CONCRETE PAVEMENT

K 3 6 . Fi n is h p av i ng by p ut t i n g E n d S t o pp e r a t t h e en d a nd fi n is h i n g l as t
1 - 2m s t r e tc h m a n u al ly u si n g n e e dl e v ib r a t o r s .

K 3 7 . K e e p th e s u r f ac e m o is t w it h w e t H e ss i a n c lo t h .

K 3 8 . D o f i n al c ut t i n g of j oi n t s a ft e r 15 d a ys a n d fi ll t h e j oi n ts w i t h
s e al a n ts .

K 3 9 . O p e n to t r a f f ic a f t e r J oi n t s a r e co m pl e t e d .

L. Trial Length:

L1. T h e t r a i l st r e t c h o f P QC s h al l b e l a id o v e r t h e t ri a l st r e t c h o f D L C
i n t he p r e s e nc e o f C o ns u l t a n ts a n d Cl i e n ts . Al l ne c es s a r y t e s ts
s h al l b e c o n d uc t e d a t ti m e o f t h e t r i al s t r e tc h .

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