METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

Project:-Four/Six Laning of Karodi (KM 320.640) To Telwadi (KM 37

Road Section of NH-211(New NH No.52):(Existing Length 54.896 km:
Length 55.610 km) in the state of Maharashtra under NHDP Phase IV-B
Mode.

CONTENTS

1 PURPOSE

2 SCOPE

3 REFERENCE

4 PLANT & EQUIPMENT

5 TOOLS

6 MATERIALS

7 PROPORTION OF MATERIAL & MIX DESIGN TRIALS

8 METHOD of OPERATION

9 LAYING & COMPACTION

10 TEXTURING

11 CURING

12 JOINTS

13 SAND PATCH METHOD(for Measuring the Texture Depth)

METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
14 QUALITY

15 MATERIALS TESTING

16 TRAFFIC

17 SAFETY PRECAUTIONS
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
1● PURPOSE:

This submittal pertains to methodology to be adopted by Dilip Buildcon Limited for “M

Laying of Pavement Quality Concrete”. This statement describes the construction meth
and covers production patterns to be adopted, Personnel to be involved, Plants and Equ
be used, Testing frequencies and Quality assurance and control methods planned to be e
for this work. This statement subject to the Client’s/Authority Engineer approval shall b
guide by the Field staff, Engineers etc. for the construction of the Pavement Quality Co
to the satisfaction of the Supervision Consultant (LION).

2● SCOPE:
The scope of this methodology covers the following activities:
Survey and Setting out works,
Selection of materials for PQC and other materials, storage, handling and testing of the
Laying, Compaction and Finishing of Pavement Quality Concrete
Recording of all results / Inspection test data etc. in relevant Inspection and Test format
controlling of all Inspection / Test records / Files as per existing internal document cont
for identification and traceability.

3● REFERENCE:
MORT&H (Ministry of Road Transport & Highways ,Fifth Revision)

IS (Indian Standards)
ASTM (American Society for Testing Materials)
IRC (Indian Road Congress )
BS : British Standard Contract Technical Specification
Contract Technical Specification
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

4● PLANT & EQUIPMENT:

i) Batching Plant

a) Batching Plant @ km 369+000 LHS (Kannad)

Fully Automatic 30 cum/hr, Make- Stetter, India.

ii) Needle vibrator (5 nos.) and Screed board vibrator (3 nos.)

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
Transit Mixers – Capacity of 6.0 cum, the numbers of vehicles should vary between 8 t
depending upon the lead and plant capacity

iii) Wheel Loader

iv) Tractor broomer / Tractor air compressor.

v) Texturing and Curing compound machine

vi) Water tanker with sprinkling arrangement (Minimum 1 tanker of 10 KL dedicat

PQC work & supported by tankers from other operations) & Gunny bags.
vii) Drilling Machine (2 nos.) & Saw cutting machine (Minimum 2 nos., however m

shall be deployed as & when required).

viii) DG sets / Light mast (2 nos.)

ix) Survey Equipment (Total station-1 no. as and when required, leveling instrumen

x) Laboratory Equipment (Slump Cone, Cube moulds, Beam moulds Needle vibra
trowel,thermometer, anemometer, Steel Scale, Core cutting machine.)

xi) Work Platform/ mason Trolley

xii) Cement Storage capacity – Min. 100 MT

xiii) Capacity of Cement Feeding Pump – 18/25 MT/hr (each location)

xiv) Joint sealing Equipments.

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

5● TOOLS:

Floor Form, Wire brush, supporting tools, Steel pegs, string wire, Straight edge, Trowe
finisher, edge finisher, Spode, Plough, mortar pan, pick axe, thread point, joint seating t
texture measuring tools. Winch and measuring tape, steel scale, hammer, texturing broo
METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

6● MATERIALS:

Material to be used in PQC will be as per approved drawing & mix design.

Conforming to IS: 383 and as per clause 602.2.6.2 of MO

a) Coarse Aggregate
specification and shall be arranged from Approved crushe

Conforming to IS: 383 as per Clause 602.2.6.3 of MORT&

b) Fine Aggregate
specification.

c) Cement OPC 53 grade as per IS-12269

d) Fly ash Conform to IS :3812 (part-1)

The water shall be conforming to IS:456 & Clause 602.2.

e) Water
MORT&H specification.

The Admixture shall be Conforming to IS:6925, IS:9103

Admixture
602.2.3 of MORT&H specification.

Mild Steel Dowels bars with

g) Confirming to Clause 602.2.8 for dowels and tie bars of I
sleeve

h) Tie bars with grouting material Confirming to Clause 602.2.8, IS: 1786 Grade Fe 500

Joint Sealant Compound with

i) Confirming to Clause 602.2.10 of MORT&H specificatio
primer

j) Premoulded Joint Filler Confirming to Clause 602.2.9 and as per drawing

k) Debonding strip & Backup rod As per drawing

METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

l) Separation Membrane Confirming to Clause 602.5 of MORT&H specification

m) Dowel bar sleeves Confirming to IRC 15 & drawing.

n) Curing compound Confirming to clause 602.9.12

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

7● PROPORTION OF MATERIAL & MIX DESIGN TRIALS

The minimum cement content in PQC is 310 kg/m3 when use upto 20% Flyash by weig
Cementitious Material and maximum Cementitious Material is 450 Kg/m3 of concrete.
proportioning of the material and the design shall be carried out as per IS: 10262 and M
IRC guidelines. Mix design is as per following table –

Mix proportion
Ingredient Rema
(kg/m3)

Cementitious Material

Cement 328 Ultratech OPC 53

Thermal Power P
Fly ash 72
Vaijnath

31.5 mm coarse aggregate 754 Source –Kannad

10 mm coarse aggregate 495 Source –Kannad

C.Sand 794 Source –Kannad

Water 136 Borw water

Admixture 4 BASF Master Po

8● METHOD of OPERATION:

A. PREPARATION OF SURFACE
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
Prior to laying separation membrane thorough cleaning shall be done on DLC by mecha
means. Making up of DLC levels if required, shall be with M-10 grade concrete with 1
aggregate.

B. LAYING OF SEPARATION MEMBRANE

Separation membrane shall be laid for the first hour before start of paving works and sh
continuous process thereafter ensuring sufficient membrane in place at all time of pavin
ever overlap of membrane is necessary, the same shall be maintained at least 300mm. S
membrane shall be 125 micron thick and laid flat without crease and fixed by nails to th
layer. Separation membrane shall be prevented from damage by aggregates falling from
carrying concrete by manual brooming ensured by close supervision .
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
C. MIXING OF CONCRETE

a) An automatic Batching and Mixing plant installed at respective camp locations.

The coarse and fine aggregate, cement shall be weighed in a scale separately as
b) mix design and placed in to the mixers. The quantity of water shall be pumped
mixer as per the water cement ratio in the design mix.

Mixing time shall be maintained as per manufacturer recommendation (30 sec)

c)
established to the satisfaction of the engineer’s representative.

The quantity of admixture shall be pumped into the mixer by weight of cement
d)
design, based on lead of the transportation of mix and ambient temperature.

Concrete will not be produced when ambient temperature falls below 50C or ex
e)
C and wind speed exceeds 15 km/hr.

f) Following measures to control temperature of concrete within 300C will be ado

i) Chilled water shall be used for preparation of Concrete.

Water to be sprinkled on aggregate stock piles and necessary correction to be ap

ii) change weight of all ingredients due to addition of moisture and workability to
constant.

A print out of each Batch mix produced giving details of all ingredients consum
g)
percentage error shall be provided.
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
The temperature and slump of each mix shall be taken at batching plant & recor
h)
dispatch of each Transit Mixers.

A copy of approved format for recording temperature, slump, wind velocity, hu

i)
be attached with dispatch slip.

j) Each Transit Mixers shall be washed and cleaned before 1st loading.

k) Slump should be checked for every Transit Mixers after reaching at paving site
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

9● Laying and Compaction:

Steel side shutters shall be fixed on the both edges of the lane. Side shutters shall be fix
proper alignment as per the drawing. Top levels of side shutters shall be the finished ro
and shall got checked. Shutters shall be secured firmly to avoid any bulging. Shutters sh
cleaned and shuttering oil shall be applied on the surface. Any gaps between side shutte
DLC surface shall be filled with cement mortar. Ends of lane shall be made by fixing of
head, accommodating the Dowel bars on the specified position. Contraction joints shall
as per the approved drawing. Specified Dowel bars shall be placed and tied with bindin
chairs as per the drawing (It shall be ensured that the Dowel bars are positioned at speci
position). Tie bars shall also be kept in position.
Concrete for PQC as per the approved Mix Design shall be transported by Transit Mixt
shall be poured directly in the lane. Temperature and slump shall be recorded for every
Mixture. Compaction of full thickness of laid concrete shall be achieved by using imme
vibrator having dia 60 mm. Dowel bars and Tie bars shall be kept in specified position
drawing during vibration and it shall be ensured that specified position is maintained af
vibration as well. Top finish shall be achieved by Electric Screed Vibrator (Dynapac M
segregated patch in laid concrete surface shall be repaired by masons immediately . Top
PQC shall be maintained as per the approved FRL.

10● TEXTURING:

Texturing shall be done with a Brush texturing in transverse direction to appropriate siz
described in Clause: 602.9.11.2 of Contract Technical Specification, immediately after
finishing of the concrete surface and before the application of curing compound . The te
shall be measured by suitable means to see that it satisfies the specification requirement
initial setting of concrete side shutters shall be removed and Contraction joints shall be
with the help of line thread and paint. Joint cutting shall be done as explained below.

11● CURING:
METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
Curing shall commence as soon as the completion of texturing operation of con
a)
surface.

Curing shall be carried out by spraying approved curing compound at the spray
b)
recommended by the manufacturer.

After 3 hours of spraying of curing compound, moist gunny bags shall cover on
c)
surface without causing damage to curing compound film and texturing groove
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
Gunny bags shall be used and will be kept moist for 14 days by regular sprinkli
from flexible pipe attached with a water tanker. Water tanker shall be deployed
d)
clock for providing water for curing. Water will be available from the bore wel
length of the project road.

In adverse weather condition, the freshly textured and Cured surface shall be pr
e)
at least 3 hrs by covering with tents as per clause 602.7.2.

12● JOINTS:

A● Contraction Joints:

Transverse joints shall be contraction and expansion joints, cut with mechanical saw, co
early as 4-8 hours, i.e. initial hardening of concrete, after paving. The contraction joints
consist of mechanical sawn joint groove, 3 to 5mm wide and 1/4 to 1/3, ±5 depth of the
expansion joints shall consist of a joint filler board positioned vertically with the prefab
assemblies along the line of joint.The dowel bars shall mild steel with details and dimen
indicated in the drawings. Unless otherwise shown in the drawings the dowel bars shall
positioned at the mid depths of the slab with suitable tools/means within +/-20mm toler
dowel bars shall be covered with plastic sheath for at least 2/3rd from one end for contr
joint, and ½ length +50mm for expansion joint. For expansion joints, a closely fitting c
100mm long shall be provided at the sheath end. To block the entry of cement slurry be
dowels and cap a compressible sponge may be used.The dowel bars shall be supported
chairs in pre-fabricated joint assemblies positioned prior to the construction of slab or
mechanically inserted with vibration into the plastic concrete by a method which ensure
placement of the bars besides full re-compaction of the concrete around the dowel bars

B● Longitudinal Joints:
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
The longitudinal joints shall be saw cut as shown in the drawings. A groove of 1/3rd ±5
of the slab may be cut after the final set of the concrete. The tie bars shall be deformed
of 500 Mpa complying to IS 1786. Tie bars shall be painted with bituminous paint for 7
both ends and positioned with suitable tools/means. Tie bars shall be placed within the
third of the slab depth.Tie bars in the longitudinal joints shall be made up into rigid asse
with adequate supports to remain firmly in position during the construction of slab.

c● Tranverse Construction Joints:

Transverse construction joints shall be place whenever concreting is completed for the d
on is suspended for more than 30 minutes. These shall be provided at regular location o
contraction joints using dowel bars as stated above.Using sealants, not before 14 days a
construction of slab shall seal all transverse and longitudinal joints, but prior to allowin
ply on the new construction.
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
13● Sand Patch Test (for measuring the texture depth):

The surface to be tested shall be dried; any extraneous mortar and loose material shall b
and swept clean, using a wire brush at right angles and parallel to the carriageway. A cy
container of 25ml capacity shall be filled with sand passing 300microns sieve and retain
150microns sieve, compacted by tapping the base and excess sand stroked off to level w
of cylinder. Then the sand shall be poured on the surface to be tested into a heap and sp
the help of flat wooden disc of 64mm diameter of Rubber disc 1.5mm thick, with its fac
in a circular motion, so that the sand is spread into a circular patch, with the surface dep
filled with sand to the level of peaks.The diameter of the patch shall be measured to the
5mm. The texture depth of concrete shall be calculated as follows:

Texture depth in mm = 31000/ D2

Where D is the mean diameter of the patch.

Five such texture depth tests shall be taken along the diagonal line across the lane width
2m apart, between 50m points along the road. No measurement shall be taken within th
of longitudinal edges of the slab constructed in one pass.

The requirements of texture depth as per MORT&H table 600-2 are as follows:

Required texture d
Time of test No. of measurements Specified
value

Between 24hrs. and 7days after

Average of 5 measurements 1.00
the construction of the slab
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

Not later than 6 weeks, before the

Average of 5 measurements 1.00
road is opened to traffic

14● QUALITY:

Testing of Main Carriageway and Trial Section quality of materials shall be carried out
section 900 & table 900-6 as follows.
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
15● Material Tests:

S.No. Test Frequency Referenc

1 Cement One test for each lot IS 122

2 Aggregate One test per day’s work IS 38

3 Impact value One test per day’s work IS 2386 P

4 Soundness Once for source approval IS 2386 P

5 Alkali aggregate Reactivity Once for source approval IS 2386 P

6 Water Once for source approval IS 45

Workability of fresh Concrete One test at batching plant and one test
7 by slump at site for alternate TM.
IS 11

2 cubes & 2 beams per 150 cum or

part thereof (1 for 7 day & other for 28
8 Strength of concrete by cube
day strength)/minimum 6 beams per
IS 51
day’s work whichever is more

16● TRAFFIC:

No vehicular traffic shall be allowed to ply on the finished surface within a period of 28
before joints are sealed and cured.

17● SAFETY PRECAUTIONS:

1. All concrete transit mixers shall be provided with reverse horns.

2. Flagman shall be provided at all exit points of the trucks / tippers.

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
3. The speed of vehicles plying in the work area shall be restricted to 40kmph maximum

4. If night work is to be carried out the area shall be sufficiently provided with lighting.

5. Check for the working condition of safety valves of air compressors, if compressed a
used for cleaning.
6. The 1000 mm work area on the both sides of the paving area shall be kept clear of an
unauthorized person / workmen.

7. All the exposed moving parts of the joint saw cutters shall be provided with guards.

8. Hand gloves shall be used while application of joint sealants.

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
elwadi (KM 376.113)
th 54.896 km: Design
DP Phase IV-B on EPC

TRIALS

re Depth)
METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

n Limited for “Manual

onstruction methodology
, Plants and Equipments to
s planned to be executed
approval shall be used as a
ment Quality Concrete layer

nd testing of the materials

and Test formats and

al document control system
METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
vary between 8 to 13

of 10 KL dedicated for
unny bags.
nos., however more nos.

veling instrument -2 nos.)

lds Needle vibrator ,

chine.)

on)
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

ght edge, Trowel,

nt, joint seating tools,
r, texturing broom.
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

ix design.

e 602.2.6.2 of MORT&H
m Approved crusher plant .

02.2.6.3 of MORT&H

6 & Clause 602.2.7 of

IS:6925, IS:9103 & Clause

ls and tie bars of IS: 432.

6 Grade Fe 500

RT&H specification.

er drawing
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

&H specification
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

% Flyash by weight of
/m3 of concrete. The
IS: 10262 and MORT&H /

Remarks

Ultratech OPC 53 grade

Thermal Power Plant at Parli

Vaijnath

Source –Kannad Quarry

Source –Kannad Quarry

Source –Kannad Quarry

Borw water

BASF Master Polyheed 8158

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
n DLC by mechanical
concrete with 10 mm down

ng works and shall be

all time of paving . Where
least 300mm. Separation
xed by nails to the DLC
ates falling from tippers
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

camp locations.

ale separately as per the

hall be pumped in to the

ndation (30 sec) or shall be

eight of cement as per mix

temperature.

below 50C or exceeds 350

300C will be adopted

orrection to be applied to
d workability to be kept

gredients consumed and

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
ng plant & recorded before

wind velocity, humidity etc

ading.

ng at paving site.
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

tters shall be fixed in the

e the finished road level
ging. Shutters shall be
ween side shutters and
made by fixing of steel bulk
ction joints shall be marked
tied with binding wire on
ositioned at specified

by Transit Mixture and

corded for every Transit
d by using immersion
ecified position as per the
is maintained after
tor (Dynapac Make). Any
mmediately . Top level of

o appropriate size as
mmediately after the
ompound . The texture depth
tion requirements. After
n joints shall be marked
plained below.
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
operation of concrete

und at the spray rate

gs shall cover on concrete

exturing groove .
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
y regular sprinkling of water
hall be deployed round the
om the bore wells along the

urface shall be protected for

echanical saw, could start as

ontraction joints shall
, ±5 depth of the slab. The
y with the prefabricated
details and dimensions as
dowel bars shall be
n +/-20mm tolerances. The
one end for contraction
closely fitting cap of
cement slurry between
all be supported on cradles /
ction of slab or
od which ensures correct
d the dowel bars.
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
oove of 1/3rd ±5 the depth
all be deformed steel bars
inous paint for 75mm at the
laced within the middle
up into rigid assemblies
tion of slab.

mpleted for the day ’s work

egular location of
before 14 days after
prior to allowing the traffic
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

e material shall be removed

arriageway. A cylindrical
s sieve and retained on
ked off to level with the top
to a heap and spread with
hick, with its face kept flat,
h the surface depressions
measured to the nearest

ss the lane width at least

e taken within the 300mm

quired texture depth (mm)

Tolerances

±0.25
 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
0.25
&
-0.35

ll be carried out as per

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE

Reference Code

IS 12269

IS 383

IS 2386 PART 4

IS 2386 PART 5

IS 2386 PART 7

IS 456

IS 1199

IS 516

in a period of 28 days and

 METHODE STATEMENT OF PAVEMENT QUALITY CONCRETE
0kmph maximum.

ed with lighting.

if compressed air is being

e kept clear of any

ed with guards.