Pavement Quality Concrete (Pqc)
Short Description
Pavement Quality Concrete - Construction process...
Description
BRIEF AND DETAILED SPECIFICATIONS OF PAVEMENT QUALITY CONCRETE (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:
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, where applicable
IRC: SP: 572000, Guideline on Quality system for roads.
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, setting out fixing Surveyor Sectionin of string lines prior to start charge / of PQC Site
Project manager
Project manger Engineer
04
PQC Paver deployment at various locations and other logistics management etc. 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, Sectionin Placing, Compaction and charge / finishing of PQC layers, Site Engineer Texturing, 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. 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. has been described in the following subchapters.
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.
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. 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. It shall be stored in accordance with stipulations contained in Clause 1014 and shall
be subjected to acceptance test prior to its immediate use. . Coarse Aggregate: Aggregates to be used in the construction of PQC will be Crushed aggregates .
The aggregate complying IS: 383 will be used.
Max Size of coarse aggregate 25mm as per MoRTH 601.2.3.2 (Fourth Revision : August 2001).
Fine Aggregate: Clean, natural sand from River Banas form location Triveni 20km form Ladpura will be used. The material conforming IS: 383 is ensured.
The fine aggregate shall consist of clean, natural sand or crushed stone sand or a combination of the two and shall conform to IS: 383. Fine aggregate shall be free from soft particles, clay, shale, loam, cemented particles, mica, organic and other foreign matter. The fine aggregate shall comply with MoRTH 602.2.4.3.(Fourth Revision :
August 2001). (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 4.75 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. In case of PQC During hot weather, water for preparation of concrete will be taken form water chilling plant.
Admixtures: Admixture conforming to IS: 6925 and IS: 9103 to improve workability of concrete or extension of setting time to be done.
Storage of materials : Aggregates: Aggregate will be stock piled separately and sufficient distance will be maintained from each fraction to avoid intermingling.
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.
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.
Water Water will be tanks covered at top and cleaned at regular intervals. The intake of pipe will be enclosed to exclude silt and
other solid materials and there shall be a minimum depth of 0.60 m of water below the intake at all times. 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. Characteristic flexural strength at 28 days = 4.5 MPa 2. Target mean strength at 28 days = 5.80MPa 3. Water cement ratio =0.45 Maximum 4. Slump as per IS: 1199 =31+/15 mm Minimum flexural characteristic strength of 4.5 MPa.
The ration between the 7 & 28 days strengths of 4.5 Mpa.
For each batch
7days (avg.) The average flexural strengths ( R7) =
28 days (avg.) R7 to be determined for three decimal levels.
(Flexural strength of any Six consecutive 7day test result) >4.50+1.65*s S: Standard deviation of the group. 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 exact slump required at plant and site will be exercised during
trail patch. Separation Membrane : Two applications of approved waxbased white �pigmented
curing compound will be applied on DLC. First coat will be applied immediately after DLC laying and
compaction and the other before start of PQC. The process of application will be done using mechanical sprayer.
The other parameters will be meeting the additional specification
Clause A12. Preparation of base : Any visible defects / cracks more than 10mm size to be required
by fine cement concrete mix. Surface will be made clean of dirt or extraneous material and free
from damage before application compound.
Joints: The exact location and type of joint to be transferred at site as
mentioned in drawing. Concrete Penetrometer and testing as per ASTM C 403 will be
used in monitoring setting of concrete / Maturity of concrete and saw cutting period. Initial saw cut of 3mm wide , 100mm depth in transverse and
longitudinal direction will be provided after initial set(approximately 6~8hrs). Final saw cutting 10~12mm wide ,20~25mm depth will de
provided after 14days of curing at accommodate joint sealant. The staggering of transverse joints with reference to the base will
be minimum 0.3m. Transverse joints: Contraction joints will be provided at every 4.5m interval except
where expansion joints are provided. Transverse joints to be provided at the junction of the approach
slabs of bridged and the rigid pavement and special location e.g. transition sections i.e. transition of flexible vs. rigid pavement. Transverse joints will be straight within specified tolerances.
Expansion joints will be provided at the junction of the approach
slabs of Bridges and the rigid pavement.
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. 602.2.7 Premoulded joint filler conforming As per IS: 1838 or BS: 2630 Thickness of the joint = 2025 mm
Tolerance limit will be within +/1.5mm
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. 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. 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 adjacent slabs shall be completely separated from each other
by filling joint filler board. Transverse construction joint Transverse construction joint shall be placed when concreting is
done after a day's work. It will be provided at the regular location of contraction joints using
dowel bars. The joint will be made butt type.
Longitudinal joints Tie bars shall be provided at the longitudinal joints as per the drawing given by NHAI.
Dowel bars These shall confirm to the requirements of IS: 432, IS: 1139 and
IS: 1786 as relevant. The dowel bars shall confirm to Grade S 240 and tie bars to Grade S 415 of I.S. It should be mild steel round, free from dirt, loose rust, scale
straight and burring restricting slippage in the concrete. The dowel bars will be supported on cradles / dowel chairs in
prefabricated joint. Dowel bars will be positioned at the mid depth of the slab with in a
tolerance of + 20mm.
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 sheath shall se tough, durable and of an average thickness
not less 1.25mm The dowel bars will be inserted by vibration method in the plastic
concrete. For Expansion joints, a closely fitting cap 100mm long cotton
waste placed over sheathened end of each dowel bar. Tie bars Free form oil, dirt, loose rust and scale.
In longitudinal joints shall be deformed steel bars of strength 415
MPa complying with IS: 1786. It should protect from corrosion for 75mm on each side of the joint
by applying bituminous paint. The coating shall be dry when the Tie Bars are used.
It should be perpendicular to the line of the joint, 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. Weather and Seasonal Limitations: Concreting during monsoon months:
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.
If the damage is limited to texture it will be retextured.
Concreting in Hot Weather: Care will be taken in reducing temperature of concrete such as use of Chilled water, sprinkling of chilled water over aggregates. 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. The guidewires shall be supported and stakes preferably not more
then 8 m apart by connectors capable of fine horizontal and vertical adjustment. 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.
Care will be taken to avoid any disturbance to the guidewire
during paving by any construction equipment or any other means. CONSTRUCTION: 10.1 Concrete production, transportation, Paving, Texturing and Curing: A batching plant of 120cum per Hr. capacity has to use for
Production of Concrete Dumpers having hydraulic jack system to unload having capacity
35 Mt (Approx. 9 cum) concrete will be deploy for transportation of concrete. Paving will be carried out in full carriageway width of 8.5 m length.
The Paver used will be slip from Paver.
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. The final finish of the surface will be done by super smoother
attached to the rear portion of the Paver. Manson Trolley will be placed in between Paver and Texturing
and Curing Mechine (TCM) for rectification of any surface defects. The alignment of the Paver shall be controlled automatically from
the guide wire by 4 set of level sensors and 2 set of steering
sensors attached to the Paver. Planning and preparation will be done to pave at least at an
average uniform speed of one m / min. The surface of concrete slab will Tinetextured in a direction
parallel to the longitudinal axis of the carriageway. 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. ・ Depth = 3mm to 4mm ・ Width = 3mm Curing of PQC using curing compound will be followed by
texturing by the same TCM. Curing will be taken care at the edges also.
The curing compound will be resin based aluminized reflective
curing compound. After providing initial cut entire PQC will be covered with Hessian
cloth and water turned for 14 days. 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, Depth etc as per
permanent work will be done at nearer to site. Transverse joints and longitudinal joint of each type that are to be
included in the pavement work will be constructed and assessed
in the Trial length. Density: At least 3 cores drilled when the concrete is not less than 7 days old.
11.2 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. Each pair of beams and cubes will be representing a different
batce of concrete. Compressive and flexural strength will be after 28 days curing.
At the age of 28 days thirty cores with diameter 150 mmshould be
saw cut from the slab. The cores will be saw cut in both ends to provide a specimen
height of 300 mm +/15mm. The mix will be designed to achieve The average flexural strength >4.5 +1.65*s(Mpa) [s=standard deviation]
Strength of any sample >fck � 1.65 s The average compressive strength of the cores ≥ 0.8/ (Average compressive strength
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. It should be measured in the middle of the slab (vertically) at a
horizontal distance of at least 1000 mm from any free end. The temperature should not exceed 70 degree C.
Inspection Dowel Bars: Alignment of dowel bars and construction joint shall be checked
by measurement relative to guide wires. The position of dowel bars, filler board will be measured after
carefully exposing plastic concrete across the whole width of concrete. 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. The groove shall be cleaned and dried at the time of priming and
sealing
All grooves shall be cleaned of any dirt or loose material by air
blasting with filtered, oilfree compressed air. Before sealing the temporary seal provide for blocking the ingress
of dirt, soil etc., shall be removed. A height compressible heat resistant paperbacked debonding
strip as per drawing shall be inserted in the groove. In the case of longitudinal joints, heat resistant tapes may be
inserted to block the leakage though bottom of the joint. Sealing with sealants: The primer recommended by the manufacturer should be applied
for sealants. 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. If hot applied elastomeric type sealant complying AASHTO M282
is used it shall be heated and applied from a thermostatically controlled, indirectly heated preferably with oil jacketed melter and pourer having recirculation pump and extruder (This is applied at junction of Asphalt and concrete pavements. 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. Primer will be applied with an appropriate brush.
Care such as temperature and time of sealing will be emphasized
to avoid any bulge of sealant during contraction of joint. Sealant shall be applied slightly to a lower level than the slab with
a tolerance of 5+ 2mm. 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:
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. Measurement of texture depth � Sand Patch Method The apparatus as mentioned in MoRTH601.12.1 will be used to measure the texture depth.
The surface texture will be measured as per the method laid down in MoRTH601.12.1 and the same is recorded in lab format.
Opening to Traffic: No vehicular traffic including contractor's vehicles will be allowed on the finished surface until a field flexural strength of minimum 4.50 MPa has been achieved where average flexural strength of minimum 3 specimens should exceed 4.50+1.65 s(s=standard deviation).
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.
Quality Assurance and Control Checks
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. else where mentioned in this Plan.
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. As described in Inspection and Test Plans attached to this Segment Quality Plan for PQC.
These Inspection and Test Plans shall consist of type of Inspection and name of the Test to be conducted for Product Realization, frequency of testing acceptance criteria and category of Inspection.
Inspection and Test Plans should be revised whenever there any change in methodology and specifications etc.
Nonconformities in PQC: Any NonConformity observed during field Inspection and also during Testing of Materials / mixes / laying system 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.
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.
All Product NonConformities shall be observed, recorded, corrective/preventive actions and closing of NCR's should be as per the established documented procedure described in Project Quality Plan.
Safety & Environmental Requirements: Hazard Identification, 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. 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. SEQUENTIAL OPERATION OF PQC LAYING DLC layer Approval Site cleaning, Application of 2nd coat of curing compound as a separation membrane Survey, Setting out ,fixing of String line
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
SEQUENTIAL OPERATION OF PQC LAYING
Reject the Mix and find out Root Cause NO
Check the mix as per the requirement i.e. Slump, Temperature, 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.
Fixing of Dowel bars and tie bars by DBI & TBI as per Drawing Rectification of surface defects (if any) manually by Mesons. 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. SEQUENTIAL OPERATION OF PQC LAYING Covering PQC with hesian cloth and water curing for min.14 days. Removal of hesian cloth and final joint cutting Cleaning of joint and providing soft rope, debonding strip, polysulphide sealant, compressible filler board , butt joint as mentioned in Table2 in PQC methodology Test texture depth by Sand Patch Method
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