BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITYCONCRETE (PQC) PURPOSE: ・ The purpose of this Quality Plan for Construction of Pavement Quality Concrete (PQC) is to provide detailed Construction Methodology, Materials used, Resources deployed. SCOPE: ・ The Scope of this Segmental Quality Plan/ Methodology shall covers the construction of pavement quality concrete insertion of dowel bars, tie bars in accordance with the requirement of Technical Specifications and in conformity with the line, grades and cross sections shown in drawings. It covers the following activities: Selection, Testing and Acceptance of all incorporated Materials for PQC. Design of Mixes for PQC and Trials, Acceptance etc. Details of Plant, Equipment / Machinery as required in execution of PQC. Batching, Mixing, Transporting, Placing, Finishing and Curing of Concrete for PQC. Mechanized Texturing and Curing operation for PQC. Joint Cutting and application of Joint Sealing compound as approved. Quality Assurance and Control Checks during operation and post concreting DEFINITIONS: The words like contract, Contractors, Engineer (Synonymous to Engineer's representative), Drawing, Employer, Government, Works, Worksite used in this Quality Plan shall be considered to have the meaning as understood from the definitions pertaining Quality Management System Developed for the Particular Project. The following abbreviation shall have the meaning as set forth below: MORT & H: Ministry of Roads Transport & Highways NHAI: National Highways Authority of India BIS: Bureau of Indian standards QA: Quality Assurance PQC: Pavement Quality Concrete MTC: Manufacture's Test Certificate ITP: Inspection Test Plan CROSS REFERENCE: where applicable IRC: SP: 572000. RESPONSIBILITY: Activity Description S. NO 01 02 03 Preparation Quality Plan Performing Checking/ Approving Verifying Sectionin� Works charge & Manager & QC QC Engineer Manager Selection and Testing of Sectionin Works various materials for PQC. charge & Manager & Mix Design & Trials etc QC QC prior to start of activity Engineer Manager Survey. Guideline on Quality system for roads. setting out fixing Surveyor Sectionin of string lines prior to start charge / of PQC Site Project manager Project manger Engineer .This Segment Quality Plan should be read in conjunction with the following documents: ISO 9001 2000 Quality management system Contractor Document / Technical Specifications MoRTH/IS/ASTM /ACI Codes. 04 PQC Paver deployment at various locations and other logistics management etc. Technician 05 08 09 Engineer Works Manager QC Engineer / Lab technician Paver in � charge QC Engineer / Lab technician QC Engineer / Lab technician QC Manager / QC Engineer Project Manager Project Mechanical Engineer for effective control of Paving operation Engineer Engineer Engineer PROCEDURE: The detailed Construction Methodology involved in execution of PQC including Quality Assurance & Control etc. Site Engineer Texturing. Sectionin Placing. Compaction and charge / finishing of PQC layers. . Batching & Mixing of concrete as per approved Design mix Sectionin charge / Site Engineer Batching Plant �in charge 06 Control of movement of Paver and maintenance 0checks / control during operation Paver engineer / Supervisor 07 Transportation. curing Joint Sectionin Cutting and Sealing charge / operations for PQC Site Engineer Inspection & Testing of QC PQC as per approved ITP Engineer / and maintaining all Lab formats. has been described in the following subchapters. It shall be stored in accordance with stipulations contained in Clause 1014 and shall . Material Required: Cement: Any of the following types of cement may be used with prior approval of the Engineer: (i) Ordinary Portland Cement IS: 269 (ii) Portland Slag Cement IS: 455 (iii) Portland Pozzolana Cement IS:1489 Cement to be used may preferably be obtained in bulk form. Approval of survey and setting will be ensured and survey check sheet CGGC 34 17 01 is filled prior to commencement of the laying activity. Survey and Setting out for PQC: The following steps are involved in Setting out of string wire before lying PQC: Center line of Carriageway will be marked at every 50M intervals on DLC surface by using Total station. shale. clay.be subjected to acceptance test prior to its immediate use. The material conforming IS: 383 is ensured. Max Size of coarse aggregate 25mm as per MoRTH 601.2.4. Coarse Aggregate: Aggregates to be used in the construction of PQC will be Crushed aggregates .(Fourth Revision : . natural sand from River Banas form location Triveni 20km form Ladpura will be used. Fine Aggregate: Clean. The fine aggregate shall consist of clean.3. natural sand or crushed stone sand or a combination of the two and shall conform to IS: 383. loam.3. cemented particles. Fine aggregate shall be free from soft particles.2. organic and other foreign matter. mica. . The aggregate complying IS: 383 will be used.2 (Fourth Revision : August 2001). The fine aggregate shall comply with MoRTH 602. 75 mm 600 micron 150 micron Percentage passing the Sieve by Weight 100 95 � 100 30 � 50 10 � 35 0 � 6 Water: Water used for mixing and curing concrete conforming to IS: 456: 2000. (The grading limits for all in aggregates shall be per IS:383 for 20mm nominal size Aggregate for Pavement Quality Concrete ) Sieve Designation 40 mm 20 mm 4. . In case of PQC During hot weather.August 2001). water for preparation of concrete will be taken form water chilling plant. Storage space must be easy to inspection. removal and restorage of materials. Regular testing of aggregate stock pile will be exercised to ensure required gradation control. The intake of pipe will be enclosed to exclude silt and . Storage of materials : Aggregates: Aggregate will be stock piled separately and sufficient distance will be maintained from each fraction to avoid intermingling. Water Water will be tanks covered at top and cleaned at regular intervals. Admixtures: Admixture conforming to IS: 6925 and IS: 9103 to improve workability of concrete or extension of setting time to be done. Cement Bulk cement will be stored in bulk storage containers having 200MT capacity and the number of such bulkers will be sufficient to cater to the requirement at site. ) R7 to be determined for three decimal levels.80MPa 3.) The average flexural strengths ( R7) = 28 days (avg.45 Maximum 4. Water cement ratio =0.5 Mpa. Slump as per IS: 1199 =31+/15 mm Minimum flexural characteristic strength of 4. Proportioning of concrete Concrete Strength The pavement concrete should be a class M40 concrete with a minimum 28 days compressive characteristic strength of 40 MPa 1.other solid materials and there shall be a minimum depth of 0. The ration between the 7 & 28 days strengths of 4.60 m of water below the intake at all times. For each batch 7days (avg.5 MPa 2. Target mean strength at 28 days = 5. Characteristic flexural strength at 28 days = 4.5 MPa. . The process of application will be done using mechanical sprayer. Surface will be made clean of dirt or extraneous material and free from damage before application compound.(Flexural strength of any Six consecutive 7day test result) >4. . The other parameters will be meeting the additional specification Clause A12. First coat will be applied immediately after DLC laying and compaction and the other before start of PQC.50+1. Separation Membrane : Two applications of approved waxbased white �pigmented curing compound will be applied on DLC.65*s S: Standard deviation of the group. Preparation of base : Any visible defects / cracks more than 10mm size to be required by fine cement concrete mix. The exact slump required at plant and site will be exercised during trail patch. Workability: The control of workability will be done by the slump test Slump will be controlled so that mix is compacted and finished without undue flow. . The staggering of transverse joints with reference to the base will be minimum 0. Transverse joints: Contraction joints will be provided at every 4.5m interval except where expansion joints are provided. Joints: The exact location and type of joint to be transferred at site as mentioned in drawing. 100mm depth in transverse and longitudinal direction will be provided after initial set(approximately 6~8hrs).20~25mm depth will de provided after 14days of curing at accommodate joint sealant. transition sections i. Initial saw cut of 3mm wide . Transverse joints to be provided at the junction of the approach slabs of bridged and the rigid pavement and special location e.g. Final saw cutting 10~12mm wide .e. Expansion joints will be provided at the junction of the approach slabs of Bridges and the rigid pavement. transition of flexible vs. Transverse joints will be straight within specified tolerances. Concrete Penetrometer and testing as per ASTM C 403 will be used in monitoring setting of concrete / Maturity of concrete and saw cutting period. rigid pavement.3m. Contraction Joint: Contraction joints will be as per the drawing given by NHAI Expansion Joints: Joint filler board for Expansion joint will be premoulded joint filler as per MoRTH spec. The adjacent slabs shall be completely separated from each other .7 Premoulded joint filler conforming As per IS: 1838 or BS: 2630 Thickness of the joint = 2025 mm Tolerance limit will be within +/1.2. 602. Dowel bars for expansion joint will as per Joints will be provided at the junctions of rigid and flexible pavement with transition slab as per the drawings.5mm It shall be 25 mm less in depth than the thickness of the slab The filler for each joint shall be furnished in a single piece for the full depth and width required for the joint. Holes to accommodate dowel bars will be as accurately board or punched to give a sliding till on the dowel bars. Where due to unavoidable conditions (for example: joints at two contract package) joint are to be provided. dowel bars are fixed into the rigid pavement. The dowel bars will be supported on cradles / dowel chairs in prefabricated joint. Longitudinal joints Tie bars shall be provided at the longitudinal joints as per the drawing given by NHAI.by filling joint filler board. IS: 1139 and IS: 1786 as relevant. Dowel bars will be positioned at the mid depth of the slab with in a tolerance of + 20mm.S. It should be mild steel round. loose rust. Dowel bars These shall confirm to the requirements of IS: 432. The dowel bars shall confirm to Grade S 240 and tie bars to Grade S 415 of I. scale straight and burring restricting slippage in the concrete. Transverse construction joint Transverse construction joint shall be placed when concreting is done after a day's work. . The joint will be made butt type. It will be provided at the regular location of contraction joints using dowel bars. free from dirt. It should protect from corrosion for 75mm on each side of the joint by applying bituminous paint. Weather and Seasonal Limitations: Concreting during monsoon months: . For Expansion joints. dirt. It should be perpendicular to the line of the joint.25mm The dowel bars will be inserted by vibration method in the plastic concrete. loose rust and scale. Tie bars Free form oil. The sheath shall se tough. In longitudinal joints shall be deformed steel bars of strength 415 MPa complying with IS: 1786. with the center of each bar on the intended line of the joint within a tolerance of +50mm and with a minimum cover of 30 mm below joint groove. durable and of an average thickness not less 1. a closely fitting cap 100mm long cotton waste placed over sheathened end of each dowel bar.Dowel bars shall be covered by a thin plastic sheath for at least 2/3 of length from one end for dowel bars in Contraction joint or half the length plus 50mm for expansion joints. The coating shall be dry when the Tie Bars are used. Sufficient supply of tarpaulin or other waterproof cloth will be provided along the line of work. Any concrete damaged by rain will be removed and replaced. Guide wires Use of guidewires Each guidewire shall be at a constant height above and parallel to the required edges of the slab as described in the contract / drawing within a vertical tolerance of + 3 mm. Concreting in Hot Weather: Care will be taken in reducing temperature of concrete such as use of Chilled water. If the damage is limited to texture it will be retextured. . The guidewires shall be supported and stakes preferably not more then 8 m apart by connectors capable of fine horizontal and vertical adjustment. sprinkling of chilled water over aggregates. The stack shall be positioned and the connectors maintained at their correct height and alignment before commencement of work. The guidewire shall be erected and tensioned for at least 2 hours before concreting that section. The final finish of the surface will be done by super smoother attached to the rear portion of the Paver.1 Concrete production.5 m length. Paving. The alignment of the Paver shall be controlled automatically from the guide wire by 4 set of level sensors and 2 set of steering . The Paver used will be slip from Paver. transportation. Texturing and Curing: A batching plant of 120cum per Hr. 9 cum) concrete will be deploy for transportation of concrete.Care will be taken to avoid any disturbance to the guidewire during paving by any construction equipment or any other means. CONSTRUCTION: 10. Paving will be carried out in full carriageway width of 8. Manson Trolley will be placed in between Paver and Texturing and Curing Mechine (TCM) for rectification of any surface defects. capacity has to use for Production of Concrete Dumpers having hydraulic jack system to unload having capacity 35 Mt (Approx. The slip frompaving machine shall compact the concrete by internal vibration and shape it between the side forms with a conforming plate and oscillating finishing beams. Curing will be taken care at the edges also. Transverse joints and longitudinal joint of each type that are to be included in the pavement work will be constructed and assessed . After providing initial cut entire PQC will be covered with Hessian cloth and water turned for 14 days. ・ Depth = 3mm to 4mm ・ Width = 3mm Curing of PQC using curing compound will be followed by texturing by the same TCM. Planning and preparation will be done to pave at least at an average uniform speed of one m / min.sensors attached to the Paver. Depth etc as per permanent work will be done at nearer to site. The curing compound will be resin based aluminized reflective curing compound. Texturing / Tining will be done with a specified machine specially designed for the purpose for providing grooves at a uniform spacing of 18 mm to 21mm. Trail length: The Trial length will be constructed at least one month advance before starting of concrete paving work. Trial length of 60mm with same width. The surface of concrete slab will Tinetextured in a direction parallel to the longitudinal axis of the carriageway. Compressive and flexural strength will be after 28 days curing.65*s(Mpa) [s=standard deviation] Strength of any sample >fck � 1. Density: At least 3 cores drilled when the concrete is not less than 7 days old.2 Strength: Minimum of thirty (30) beams for flexural strength and thirty cubes for compressive strength will be prepared form the concrete delivered to the paving plant.8/ (Average compressive strength . 11.in the Trial length. At the age of 28 days thirty cores with diameter 150 mmshould be saw cut from the slab. Each pair of beams and cubes will be representing a different batce of concrete.5 +1.65 s The average compressive strength of the cores ≥ 0. The mix will be designed to achieve The average flexural strength >4. The cores will be saw cut in both ends to provide a specimen height of 300 mm +/15mm. The groove shall be cleaned and dried at the time of priming and sealing . Preparation of joint and sealing of joint grooves: Transverse Joint shall not be sealed before 14 days after construction Joint grooves will be constructed to an additional depth / width as mentioned in drawing. filler board will be measured after carefully exposing plastic concrete across the whole width of concrete. It should be measured in the middle of the slab (vertically) at a horizontal distance of at least 1000 mm from any free end.of the thirty cubes.) Temperature Measurement: The temperature development in the concrete slab should be recorded after every 3 hours during hardening after installment of the thermometer & temperatureage relationship should be determined. Inspection Dowel Bars: Alignment of dowel bars and construction joint shall be checked by measurement relative to guide wires. The temperature should not exceed 70 degree C. The position of dowel bars. Priming and sealing with applied sealants should not be carried out when temperature in the joint groove to be sealed is below 7 deg C. Primer will be applied with an appropriate brush. In the case of longitudinal joints. Sealant shall be applied slightly to a lower level than the slab with . Sealing with sealants: The primer recommended by the manufacturer should be applied for sealants. indirectly heated preferably with oil jacketed melter and pourer having recirculation pump and extruder (This is applied at junction of Asphalt and concrete pavements.All grooves shall be cleaned of any dirt or loose material by air blasting with filtered. heat resistant tapes may be inserted to block the leakage though bottom of the joint. If hot applied elastomeric type sealant complying AASHTO M282 is used it shall be heated and applied from a thermostatically controlled. Care such as temperature and time of sealing will be emphasized to avoid any bulge of sealant during contraction of joint. A height compressible heat resistant paperbacked debonding strip as per drawing shall be inserted in the groove. Cold applied polyeurethrene / Polysulphide type complying BS: 52121990Sealan will be mixed and applied according to the time limit specified the Manufacture to the concrete pavements. Before sealing the temporary seal provide for blocking the ingress of dirt. soil etc. shall be removed.. oilfree compressed air. The type and details of different joints treatment are tabulated below: TYPE OF JOINT JOINT DETAILS & TREATMENT Polysulphide Debonding 3~4 Soft Butt Compressible Sealant(cold) Strip Mm Longitudinal Groove Expansion Construction Contraction Rope Joint Filler Board Testing of applied Sealant: Joint sealant compound and primer should be tested in: .a tolerance of 5+ 2mm. 65 s(s=standard deviation).1 will be used to measure the texture depth. The surface texture will be measured as per the method laid down in MoRTH601.50 MPa has been achieved where average flexural strength of minimum 3 specimens should exceed 4. Cold applied Polysulphide sealant (according to BS: 5212 Part 2) In case if deliveries are made more frequent than testing may be reduced to every three months.1 and the same is recorded in lab format.50+1. Each series of test specimens for measurement of flexural strength should consists of minimum 3 test specimens. Prior to opening to traffic the joints should be sealed and areas adjacent to the pavement should be completed to a degree that will ensure traffic safety.12. Measurement of texture depth � Sand Patch Method The apparatus as mentioned in MoRTH601.12. Opening to Traffic: No vehicular traffic including contractor's vehicles will be allowed on the finished surface until a field flexural strength of minimum 4. Quality Assurance and Control Checks . Inspection and Test Plans should be revised whenever there any change in methodology and specifications etc. These Inspection and Test Plans shall consist of type of Inspection and name of the Test to be conducted for Product Realization. QA/QC Engineers are responsible to control the Nonconforming products as described in Procedure. and relevant sectionin charge site engineers are to take appropriate corrective /preventive actions.As part of Quality Assurance this Segment Quality Plan for PQC has been prepared in line with the specification provided in relevant MoRTH clauses. Contract Supplementary Technical Specification and other Codes/ Standard / Specifications etc. the same should be recorded in the specified Nonconformance Report and necessary Corrective / Preventive actions should be initiated to prevent such things in future. frequency of testing acceptance criteria and category of Inspection. As described in Inspection and Test Plans attached to this Segment Quality Plan for PQC. . As a part of Quality Control all the Inspection and Testing requirements for various activities involved in laying of PQC will be carried out as per relevant MoRTH Specifications & Contract Technical Specification atc. Nonconformities in PQC: Any NonConformity observed during field Inspection and also during Testing of Materials / mixes / laying system etc. else where mentioned in this Plan. recorded. Setting out . Application of 2nd coat of curing compound as a separation membrane Survey. SEQUENTIAL OPERATION OF PQC LAYING DLC layer Approval Site cleaning. corrective/preventive actions and closing of NCR's should be as per the established documented procedure described in Project Quality Plan. Environmental Aspects and Impacts associated with various activities and subactivities involved in the present segment and their mitigation/control measures shall be identified and necessary measures shall be initiated.fixing of String line . Risk assessment and Risk control measures for each activities and subactivities involved in the present Segment shall be identified and necessary action plan shall be initiated. Safety & Environmental Requirements: Hazard Identification.All Product NonConformities shall be observed. Placing Paver and TCM Clearance to B/Plant for Production of concrete after checking string line & Equipment. Production of concrete as per the Mix design and adjust as per the requirement Transportation of Mix to Site YES . Air content etc and meets as per design ? YES D Dumping concrete at regular spacing in front of Paver and start paving Monitoring levels through level sensors. . Slump. SEQUENTIAL OPERATION OF PQC LAYING Reject the Mix and find out Root Cause NO Check the mix as per the requirement i.e. Temperature. polysulphide sealant. Texturing & curing by TCM and Test rate of spraying. Fixing of Stopper after End of day's Work. Initial Joint cutting after setting of concrete Cleaning of joint and fixing backup rod. Fixing of Dowel bars and tie bars by DBI & TBI as per Drawing Rectification of surface defects (if any) manually by Mesons. butt joint as mentioned in Table2 in PQC methodology Test texture depth by Sand Patch Method . debonding strip. Removal of hesian cloth and final joint cutting Cleaning of joint and providing soft rope. compressible filler board .14 days. SEQUENTIAL OPERATION OF PQC LAYING Covering PQC with hesian cloth and water curing for min. Proceed for the next activity .