DESIGN, CONSTRUCTION AND

MAINTENANCE OF CC ROADS -

PMGSY

satander50@yahoo.co.in
1
 Road Composition

Vehicle

PQC M 30

WMM 75-150 mm at 7 daysCBR Road Crust

Sub Base100-150mm GSB/DL 27% CBR

300mm Sub Grade 9% CBR /Permeability 30 m/day

450
Embankment 3% CBR
Ground Level
Road Composition
Contraction Joints Placement of dowel bars Crack below
Longitudinal Joints Transverse Joints Contraction Jt.

-Plan Load transverse device

Contraction Joints
Dowel bars Placement
5

If no dowel bars. Dummy Contraction Joi

Properties and Specification of Concrete
Constituents- Cement, Water, aggregates,
admixtures as per IS: 456, IS:269 and
IS:383. Cement Concrete Mix Design of PQC
& DLC with examples

IS 1199 Tests of Fresh Concrete

IS: 516: Tests of Hardened Concrete
Specifications of Fresh and Hardened
concrete IS:456
satander50@yahoo.co.in
 What is Portland Cement
PORTLAND CEMENT CLINKER : IS PRODUCED BY BURNING

1450 O C A MIX OF -

CALCIUM CARBONATE (LIMESTONE OR CHALK)- 70%

+

ALUMINOSILICATE(CLAY OR SHALE- 30%

Lime Saturation Factor (LSF) =

LSF = CaO
2.80 Si O2 + 1.18 Al2O3 + 0.65 Fe2O3
 CHEMISTRY OF CEMENT

C3S (3CaO.SiO2) Gives strength at 3 day

C2S (2CaO.SiO2) , Gives strength at 7 day

Tricalcium silicate + dicalcium silicate=

C3S (3CaO.SiO2)+C2S (2CaO.SiO2) + H2O =
CxSyH gel (Tobermorite gel)+ Ca(OH)2
Hydrated/
Reactive Lime (25%)
 Specifications of all Grade of Grade Cement

33 GRADE 43 GRADE 53 GRADE LOW

ORDINARY MEDIUM HIGH HEAT
(IS : 269) (IS: 269) (IS : 269)

C 3S 45 % 50 % 55 % 30 %

C 2S 27 % 22 % 17 % 46 %
IS: 4031 – PART 1 DETERMINATION OF FINENESS BY DRY SIEVING , 90 micron

7/26

PART 2 DETERMINATION OF FINENESS BY SPECIFIC

SURFACE BY AIR PERMEABILITY METHOD
(FIRST REVISION) FIRST REPRINT MARCH 1992
Comparison the fineness with Standard Cement from
NCCBM
 IS: 4031 – 1988
DETERMINATION OF SOUNDNESS

PART 3 Take 500 gm Cement add + 0.78 times Standard Consistency or

normal consistency. Soundness not more than 10 mm
expansion

PART 4 DETERMINATION OF CONSISTENCY OF STANDARD CEMENT

PASTE (FIRST REVISION) FIRST REPRINT AUGUST 1993
500 gm cement+ about 25-40% water = penetration 5-7 mm
from bottom

PART 5 DETERMINATION OF INITIAL AND FINAL SETTING TIMES

(FIRST REVISION) FIRST REPRINT NOVEMBER 1991

0.85 times normal consistency = penetration 5 mm +/-

0.5 mm from bottom
IS: 4031 –PART 6 DETERMINATION OF COMPRESSIVE
STRENGTH OF HYDRAULIC CEMENT8/26

Water = (P/4+ 3) % by weight of total 800 gm

1:3 Cement :sand mortar, vibrate 2 minutes,

( 200 gm cement + 600 gm standard sand) 24 hours moist

curing + remaining wet curing , 3 d, 7 d and 28
days.
IS: 4031 – PART 11 DETERMINATION OF
DENSITY (FIRST REVISION
9/26

60 gm cement placement
in flask having kerosene oil.

Mass/ Vol
CHARACTERISTICS GRADE OF CEMENT Pozolana or Slag cement
PPC-I PPC-II
FLY ASH CALCINED CLAY
SETTING TIME
INITIAL, NOT LESS 30 30
THAN, min.
FINAL, NOT MORE 600 600
THAN, min.
FOR FALSE SET: REMIX
AND BREAK THE FALSE
SET, RE-TEST.

COMPRESSIVE STRENGTH,
PROGRESSIVE INCREASE
IN STRENGTH, NOT LESS THAN
72+1 HR. 16 MPA 16 MPA
168+2 HR. 22 MPA 22 MPA
672+4 HR. 33 MPA 33 MPA
 IS: 8142 Setting Time of Concrete
• Initial Setting Time - Elapsed time, after
initial contact of cement and water, required
for mortar (sieved from concrete ) to reach a
penetration resistance of
3.43 N/mm2 ( 35 kgf/cm2 ).
• = Load in kg/area of plunger
• Final Setting Time - Elapsed time, after
initial contact of cement and water, required
for mortar ( sieved from concrete ) to reach
a penetration resistance of
26.97 N/mm2 ( 275 kgf/cm2).
Expansion Joints near bridge
Longitudinal16
Joint
CONTRACTION JOINT after 28 days
17
 CEMENT (Clause 2006.1 Page 570 MORD)

 Ordinary Portland Cement, 33 Grade, IS:269, C< 450 kg/m3

 Ordinary Portland Cement, 43 Grade, IS: 269 - Durability

 Ordinary Portland Cement, 53 Grade, IS 269 - Durability

Portland Pozzolana Cement (PPC) (flyash), IS:1489, (I)

 Portland Slag (PSC) Cement, IS:455, slag 50%,

 Sulphate Resistant Portland Cement IS:12330,

18
Composite Cement- IS: 16415-
2015
• Cement 35-65% - 35 kg cement
• Fly ash 15-35% - 35 kg fly ash
• Slag 20-50% - 30 kg
slag
• 3 day compressive strength 16 MPa,
• 7 days “ 22 MPa
• 28 days “ 33 MPa
 Manufactured Aggregate
• Agg manufactured from other than natural resources by
processing materials, using thermal or other process such
as separation, washing, crushing & scrubbing like
Recycled Concrete Aggregates (RCA) coarse agg.
• Sand or fine aggregate means- Passing 4.75 mm
% passing 75 µ silt
Ö Crush Ö
Natural
er
sand
dust

Size 4. 0 mm Size 4. 0 mm
Silt 3% Natural, 15% Crushed
Texture Smooth Rough
Area Less with no fine More with more fine
 Sieve size Grading Zone 1 Grading Zone II Grading Zone III Grading Zone IV

Fineness modulus 5.1 FM= 4.6 FM 2.5

FM 1.8

10 mm
100 100 100 100
4.75 mm
90- 100 90- 100 90- 100 95- 100

2.36 mm
60- 95 75- 100 85- 100 95- 100

30

15- 34 35- 59 60- 79 80- 100

5 50

0 15

NOTE out side the limit except 600 micron upto 5% Permissible 21
No change in blue values, 150 micron value 0-20% crushed
• Tie bars

22
Cube
Testing
M 30

30 MPa Fail
 oCORE TESTING
h/d ratio, n 1 1.4 1.8 2

Correction factor, f 0.89 0.93 0.98 1

f, correction factor= 0.11 n +0.78, n=h/d

Equivalent cube strength

= f* Core Strength * 1.25

i) Average eq cube strength > 0.85 X M 30

ii) Individual sample > 0.75 X M 30

As per IS 456

1. Load = full dead load +1.25 times imposed load

-24 hours

1. If in 24 hours of removal of load, structure recover

atleast 75% of deflection

5. Deflection , mm < 40 ℓ2/D , ℓ - effective span m, D –

overall depth in mm
 Maximum Utilization
Coarse Type Plain Cement Reinforced Lean Concrete
agg Concrete Concrete Less than M 15
Iron Slag 50 25 100
Steel Slag 25 nil 100
RCA 25 20 upto M 25 100

Copper slag 40 35 50
RCA 25 20 upto M 25 100

Chlorides = 0.5%
Sulphates = 0.04 %
Water absorption = 5% upto 10% With precaution
Performance improver Mineral admixtures, lime stone powder, slag etc 5%
Properties 33 Grade 43 Grade 43 Grade S 53 Grade 53 Grade S
OPC OPC OPC
FINENESS 225 225 370 225 370
m2/kg
Setting IS 30 30 60 30 60
Time FS 600 600 600 600 600
Min CS 3 D 16 23 23 27 27
Min 7D 22 33 37.5 37 37.5
Min 28 D 33 43 43 53 53
Max 28 D 48 58 - - --
 DURABILITY –
Adequate Strength, Minimum Corrosion, Minimum Air Voids

Consolidation Compaction Densification

Clayey soil Clayey/non-plastic Non plastic

Clayey-silty Concrete Filter media

Static load Mechanical Mechanical

Removal of Water Removal of air Addition of water

AVOID HONEY-COMBING (Honey bee house) 28

Flexural strength in tension or modulus of rupture
 P
P

A B X
y= d/2 d d y= d/2 d d

C ? /3 ? /3 ? /3 D
Y ?/2 ?/2
ℓ/3 Z
ℓ/3 ℓ/3 ℓ/3 ℓ/3
P/2 ? P/2
ℓ = 20*3= 60 cm P/2 ? P/2

BM = P/2x ℓ/3 = Pℓ/6

BM = P/2x ℓ/3 = Pℓ/6 BM = BM
P/2x= ℓ/2
P/2x ℓ/2 = Pℓ/4
= Pℓ/4
M = f
MI = f y M =M f = f
I y I I y y
f = M*y
F= I F= f = M*y
I
= =(Pℓ/6
(Pℓ/6x xd/2)/
d/2)bd3/12 = (Pℓ/4= x(Pℓ/4
d/2)/xbd3/12
d/2)/
= Pℓ/bd2bd3/12 = 3/2Pℓ/bd2 bd3/12
= Pℓ/bd2 = 3/2[Pℓ/bd2]
Case 1 Fb = (Pℓ)/ (bd2) if a> 20cm for 15cm

25kn i.e 2.5 ton = 2500*60/15*15*15 = 4.44 MPa

= 10,000*450/350*30*30 =
1.5 MPa
Case 2:
Fb = (3PXa)/ (bd2) P
(For if a< 20cm ---17cm-- ---20 cm---- ----------------

but > 17 cm ------------------- ℓ ------------------

for 15cm) --a---
( a= 17-20cm) 400 kg/min 150 mm or 7 kg/sq cm/ min

180 kg /min 100 mm

Case 3: For if a< 17 cm for 15cm DISCARD
a= distance between line of fracture and nearest
support,
 Design of Rigid Pavements

Single lane road- 3.75 m in plain

Maximum wheel load on dual wheel is 50 kN

Maximum Traffic per day =

450 CVPD/2 million commercial vehicle

 IRC:SP:62-2014
 Choice and Economics
 Built up areas

 Poor Drainage

 Heavy rain fall & Flood Prone Area

 Water logging

 Aggregates are costly

 Poor soil condition

 Cost of flexible pavement - 25% less than RP

33
Road Composition
 Modulus of Subgrade Reaction ‘k’ value
k value =
Load, kg on 750 mm plate
(area cm2*0.125 cm)

kg/cm2/cm or MPa/m

Soaked
2 3 4 5 7 10 15 20 50
CBR
k Value
21 28 35 42 48 50 62 69 140
MPa/m
Thickness mm Granular base /subbase
Traffic CVPD< 50, CVPD 50-150 CVPD> 150
Sub base/base Case 1 Case 2 Case 3

Granular Sub 100 100 100

Base GSB
WBM Base 75 75 150
Thickness mm Cement Treated base /subbase
Traffic CVPD< 50, CVPD 50-150 CVPD> 150
Sub base/base Case 1 Case 2 Case 3
Cement 175 100 100
Treated Sub
base
Cement treated - 100 100
Base
 EFFECTIVE - k Value
Soaked CBR 2 3 4 5 7 10 15 20 50

k Value over
granular sub
25 34 42 50 58 60 74 83 170
base(150-250
mm) MPa/m
k Value over
Cementitious
subbase(150- 42 56 70 84 96 100 124 138 280
200 mm)
MPa/m
  Traffic Maximum = 144 CVPD Case 2
 Life = 20 years
 Rate of traffic growth = 6 %

Weight Wheel Load

 Wheel Load on either side = 32.5 kN (3.25 ton)
 Dual wheels load on either side = 50 kN ( 5 ton)

 Case 1- Traffic upto 50 CVPD

 Case 2- Traffic ,, 50-150 CVPD
 Case 3 – Traffic .. 150-450 CVPD
 Concrete Properties
Flexural strength (Minimum) = 38 kg/cm2

or Minimum Flexural strength = 3.8 MPa at 28 days

or Minimum Flexural strength = 4.2 MPa at 90 days

Minimum Cement 310 kg/cum

Maximum Cement 425 kg/cum

Minimum Compressive strength = M30 MPa

= 300 kg/cm2 at 28 days.
ACCEPTANCE of 4 Cube Samples = 33 MPa
Resilient modulus, µ and Coeff. of Thermal Expansion

 E, Modulus of elasticity = 3 X 105 kg/cm2

= 30 000MPa

 µ Poisson ratio = 0.15

 Drying Shrinkage Concrete = 0.06%

 α Coefficient of Thermal linear expansion

= 10 X10-6 /cm/cm/oC
Temperature Differential, oC - Thickness
Zone STATES 150 mm 200mm 250 mm
I Punjab, Haryana 12.5 13.1 14.3
Mizoram, Gujarat, N MP

II Bihar, Jharkhand, West 15.6 16.4 16.6

Bengal
III Maharashtra, 17.3 19 20.3
Karnataka, N TN
IV Kerala, South Tamil 16 16.4 17.6
Nadu
V Coastal Bounded 14.6 15.8 16.2
Hill
V I Coastal Unbounded 15.5 17 19
 Design Procedure

 Design wheel load = Take 4500 kg ( 9 ton axle)

 Traffic Intensity = 144 CVPD (Max) Case 2
 Tyre pressure = 0.8 MPa or 8 kg/cm2
 CBR value of soil = 4 %
 k value = 3.5 kg/cm2/cm or 35 Mpa/m
 Flexural strength = 38 kg/sq cm at 28 d. (3.8MPa)
= 41.8 kg/sq cm at 90 d. (4.2MPa)
Tentative Design
Grade Concrete = M-30 PQC thickness 200 mm
WBM 75 mm
GSB as drainage layer 100 mm
Thick subgrade 300 mm
Radius of Contact area - wheel
P (Wheel Load) = 4.5 ton

p, tyre pressure, = 8 kg/sq cm = 4500/  a2

 a = √ (P/p ᴫ) = √ (4500/8 ᴫ) = √ [(4500*7/8 *22)]
a : radius of Single wheel load= 13.38 cm

Equivalent radius for dual wheel = 17.5 cm ( excel sheet )

 Radius of Relative Stiffness

P = Single wheel load = 45 kN or 4.5 tonne

h = Thickness of Pavement Quality Concrete (PQC)

 = Poisson’s ratio = Transverse strain/ Axial strain = 0.15

ℓ = Radius of relative stiffness in cm

¼
[ E xh3]
________________
12xk (1- 2)]
 Calculation of Radius of relative
¼
ℓ = Radius of relativeness , in cm [ E xh3]
[12xk (1- 2)]

3.75- 4.5 m

[3x105 x203] ¼
[12x4.2 (1- 0.152)] 3.75 m

ℓ= 83 cm
83.5 cm = or 0.835m = or 835 mm
 Conditions of Contract (40)
Load flexural = +

2 linear
 = (E x  x dt x C) Eq 22
tc

2
4( 1- µ )
Temp Stress non linear

Adjust Thickness sothat Load Stress + Temp Stress <FLEXURAL STRENGTH

< 4.2 MPa

 Determination of Bradbury coefficient

ℓ = 0.835 m L = 3.75 m, L/ ℓ = 3.75 m/0.835 = 4.5 and C =0.56

Charts for Determining C

L/ℓ or W /ℓ C value L/ℓ or W /ℓ C
value
1 0.0 6 0.92
4 0.44 7 1.03
6 0.92 8 1.07

If 4.5 m then 4.5/0.835, 5.4 , C = 0.776 48

 Edge Temperature linear Stress Punjab .UP

tc = (E x  x ∆tX C ) …. linear behaviour

= 3x100000x10-5x(13.1) x 0.56
2 1.1 MPa or 11 kg/sq

Residual 41.8 – 11 = 30.8 kg/cm2

49
 IRC:SP-62
 Axle loads be multiplied by LSF is 1.0.
 Computation of load stresses
1 - through charts
2 - user friendly computer
3 - empirical relation =

Edge Wheel Load Stress =

(0.803P/h2 )*[4 log10(ℓ/a)+ 0.666 (a/ℓ)-0.034]

Calculation of Edge Wheel Load Stress

Flexural St at 90 d = 3.8*1.1 = 4.18 MPa,  0.15

 te = (0.803P/h2 )*[4 log10(ℓ/a)+ 0.666 (a/ℓ)-0.034]

 = [0.803*4500/(20*20)]*[ 4*log (83.5/13.38) + 0.666 *( 13.38/83.5)-0.034]

 = [ 9.0337]*[ 4* log 6.2406 + 0.666*0.1602 - 0.034]

 = [ 9.0337] * [ 3.181 +0.1067 - 0.034] = 29.39 kg/cm2.

 =Load stresses =29.39 kg/cm2 at 9 t axle load

 Edge Wheel Load Stress + Temperature Stresses

29.39+ 11 = 40.39 kg/sq cm < 41.8 kg/cm2

So, 200 mm PQC is safe for - 9 ton axle load - case 2 (144 CVPD)
For case 3: Analysis through fatigue /no of repetition
Stress Ratio =

Flexural Stresses Due to load

Flexural Strength

= 29.39/42 = 0.70
Allowable Repetition From Stress Ratio
SR= 29.39/42 = 0.7 Nf = allowable
repetition
2.222
SR
log10 N f 
0.523
Log 10 Nf = 0.7 -2.222
0.523

Stress Ratio 0.5 0.6 0.7 0.8

Allowable 83,26,33,865 8,89,264 16,736 1,378
Repetition
 Stress ratio and allowable
repetition

• Stress Ratio 0.8 Allowable = 13 78

• Stress Ratio 0.7 = 16737
• Stress ratio 0.6 = 8 89 000
• Stress ratio 0.5 = 8326 lakhs

54
 Design- Roller Compacted Concrete Pavement

 MORD specifications and MORD Hand Book Quality

Assurance 2016.

 Assuming spacing of the cracks/joints to be 6 m,

 An initial of traffic of 100 CVPD,

 k value of 100 MPa/m ,
 Zone I,
 90 day modulus of rupture =4.20 MPa,
 Total of wheel load and curling stress from axle sheet
computed for a 200 mm slab =3.60 MPa<4.20 MPa.

 The thickness of 200 mm is appropriate.

 Trial Length of Roller Compacted
Concrete Pavement
Ensure a trial length of 30 m is laid for
demonstrating the procedure and equipment
for laying the main pavement.

It will be re-laid if found deficient in any

respect.
 pwd

ROLLER COMPACTED CONCRETE PAVEMENT Karnal

 Inter Locking Pre-Cast Concrete Block Pavement

 IRC : SP : 63 and as per MORD Quality Assurance Hand

Book on Rural Roads clause 1504, page 314.

 Minimum thickness of paving blocks shall be 60 mm for

projected traffic upto 100 vehicles per day.

 80 mm for projected traffic from 100 to 250 vehicles/day.

 The dimensions and tolerances for paving blocks shall meet

the requirements of Table 1504.1 of MORD Quality
Assurance Hand Book on Rural Roads.
 C S: 63

Paver Block pavement Specification

Salient Features of White Topping/ Short
panelled Rigid Pavement
• Joints spacing 8-10 times Thickness

• More transfer of load to the underlying

• Uses potential value of lower layers

• Due to bond between the top and the existing bituminous layer

• Close joint spacing to make flexible behaviour

• Durability and compatibility due to Fibres in white topping

• Needs minimum 75 mm HMA or BBD 1 mm or stabilised layer or

lean concrete or WBM minimum 75 mm
 Pavement evaluation DATA CORRELATION

• IRC:SP:62 for ‘k’

25

value from CBR 22.08

'k'-Value on Top Existing AC PAvement (Kg/cm3)

20

• ACPA chart to 15 15.18

determine modified
‘k’ value 10
11.73

9.8

8
6.76
5.52
5

• Benkelman Beam 0
Deflection - modified 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

modulus of Characterstic Benkelman Beam Deflection (mm)

subgrade reaction -
IRC 81 (Source Corporation of Engineers and Portland Cement Association (PCA) USA

Figure 1: Relation Between Benkelman Beam Deflection and modulus of Subgra

Reaction on the Top of Asphalt Pavement (Applicable for Conventional Whiteto
UTWT and TWT)
 Granular
base
Source
ACPA

Modulus

of

Subgrade

Reaction
 X sctn
X section -Paver Block pavement Specification
 Transverse joints not
matching the edges of
Cellunderlying
Fill Pavementculvert –
cracks
Cells Spread over sub-base

Cells Filled with

Concrete and Compacted
with Plate Vibrator
Cell Filled Concrete Pavement

65
SELF COMPACTING CONCRETE_ Flow
Test.
30 sec, Largest Dia at two places
 Check Workability Properties of SCC
EFNARC-2002
TYPICAL RANGE OF VALUES
S.NO METHOD PROPERTY UNIT
MINIMUM MAXIMUM
1 SLUMP FLOW FILLING ABILITY mm 650 800
2 V-FUNNEL FILLING ABILITY sec 6 12
3 L-BOX PASSING ABILITY mm 0.8 1
4 U-BOX PASSING ABILITY % 0 30
5 FILL-BOX PASSING ABILITY % 90 100
6 V-FUNNEL AT T5 sec SEGREGATION RESISTANCE sec 0 +3
Don't
walk in front of me,
I may not follow.
Don't walk behind me,
I may not lead.
Walk beside me and
be my friend.
 Standard Proctor Test Modified Proctor Test

Soil passing 20 mm / Soil passing 20 mm /

37.5 mm IS sieve 37.5 mm IS sieve

25 blows 100 mm dia / 25 blows 100 mm dia /

55 blows foe 150 mm dia 55 blows for 150 mm dia

Soil compaction by 2.6 kg Soil compaction by 4.9 kg

hammer, 31 cm- height of fall hammer, 45 cm-height of fall

Soil compacted in 3 layers, Soil compacted in 5 layers,

urban areas and village roads NH, SH, MDR

 California Bearing Ratio Test

CBR - % of actual load causing penetrations

of 2.5 mm or 5.0 mm to standard loads.

– Load values on standard crushed stones:

– 1370 kg at 2.5 mm, 2055 kg at 5.0 mm

If ratio at 5 mm greater than 2.5 mm

May be adopted after repetition.
1. Introduction to various layers & their function in a Rigid Pavement

2. Material for construction – Cement, Sand, Aggregates, Admixtures etc.

. PQC – Pavement and Mix Design, Plant & Equipment

5. PQC – Construction Operations

6. PQC - Quality Control aspects, Acceptance Criteria, Troubleshooting

7. Distresses in Rigid pavements - Causes, Prevention & Repair Strategies

satander50@yahoo.co.in
71
 Coefficient of uniformity Cu - shape

Cu = D60/D10
 well graded soils Cu = 15 or more

 Coefficient of curvature, Cc

 Cc=(D30)2/D10XD60
Embankment MORD(301.2.3 page 29)
Unsuitable soil-
• Ol, OI, OH or Pt IS: 1489

• LL> 70%, PI > 45%

• Free swelling index > 50%

• pH > 8.5 sodic soil

• coarse material > 75 mm

 Embankment -Density
Clause 300.1

 Embankment subject to flooding,

 Max dry density min = 1.44 gm/cm3

 Embankment not subject to flooding,

Max dry density min = 1.52 gm/cm3
 EMBANKMENT COMPACTION:
Conventional Soil

 not less than 98% 2720 Part 7

 > 90-95% in case of expansive soil

SUBGRADE: Density & Compaction

 top 300 mm top .

 < 50 mm.

 MDD >1.65 gm/cm3, Standard Part 7, compaction 100%

 Gradation for Granular Sub-base (GSB)
SIEVE Percent by weight passing IS Sieve
Grade I Grade II Grade III
% Pass. % Passing % Passing
75mm 100 - -
53 mm - 100 -
26.5mm 55-75 50-80 100
9.5 mm - - -
4.75 mm 10-30 15-35 25-45
2.36 mm - - -
425 µ - - -
75 µ* on clayey <15%
< 15% <15%
subgrade value <5%
 Water Bound Macadam
Sl N Size IS sieve % passing
1) 90 mm-45 mm 125 mm 100
90 mm 90-100
63 mm 25-60
45 mm 0-15
22.4 mm 0-5
2) 63 mm-45 mm 75 mm 100
63 mm 90-100
53 mm 25-75
45 mm 0-15
22.4 mm 0-5
3) 53 mm -22.4 63 mm 100
mm 53 mm 95-100
45 mm 65-90
22.4 mm 0-10
CONSTRUCTION OF FLY ASH ADMIXED CONCRETE
81
82
Finishing, Floating and Texturing Manual
Methods
3-5 mm wide 1/3 to ¼ of depth

After 6 hours in summer

10 hours in winter
Avoid transverse crack by
timely joint cutting
Cube
Testing
M 30

30 MPa Fail
 oCORE TESTING
h/d ratio, n 1 1.4 1.8 2

Correction factor, f 0.89 0.93 0.98 1

f, correction factor= 0.11 n +0.78, n=h/d

Equivalent cube strength

= f* Core Strength * 1.25

i) Average eq cube strength > 0.85 X M 30

ii) Individual sample > 0.75 X M 30

As per IS 456

1. Load = full dead load +1.25 times imposed load

-24 hours

1. If in 24 hours of removal of load, structure recover

atleast 75% of deflection

5. Deflection , mm < 40 ℓ2/D , ℓ - effective span m, D –

overall depth in mm
 TARGET DESIGN STRNGTH
f’ck= fck+ t x s= 30 + 1.65*5 = 38.25 MPa = Target strength

f ’ck =38 MPa target compressive strength at 28 days,

fck = 30 MPa, characteristic compressive strength at 28 days

s = standard deviation, 5 Mpa or N/mm2

t = standard normal variate which is taken as 1.65

89
PRELIMINARY SELECTION OF
WATER – CEMENT RATIO
Sl No. Grade of Approximate Water
Concrete/ Cement Ratio
Target strength
1 M 25 0.50
2 M 30 0.45
3 M 35 0.42
4 M 40 0.38
5 M50 0.34
6 M60 0.28

Design W/C ratio = 0.40 90

Example For Each Cubic M of Concrete
 Water 186 l /cubic m.

 80% after adding admixture

 0.80*186 =148.8 litre/cubic m.

 W/C = 0.4 148.8 = 0.4

 C
 0.4 * C = 148.8

 C= 148.8
0.4 = 372 kg per cubic m of concrete 91
 Total Volume - Mix Design 1 cubic Meter

 Absolute volume of water 148.8/1000= 0.1488 cum

 Absolute volume of cement = 372/3150 =0.1181 cum

 Absolute volume of admixture ( Sp gr 1.2 of admixture) =

 3.72/1200 cum = 0.0031 cum (1% of 372 = 3.72 kg admixture)

 Absolute volume of agg = 1- 0.1488-0.1181-.0031 = 0.73 cum

Absolute Volume of all aggregates = 0.73 cu m

92
 ESTIMATION OF COARSE AGGREGATE CONTENT
Nominal Volume of Coarse Aggregate Per Unit
Maximum Volume of Concrete for Different Zones of
Size of Fine Aggregate
Aggregate mm
Zone Zone III Zone II Zone I
IV

10 0 .50 0. 48 0 .46 0. 44
20 0 .66 0. 64 0 .62 0. 60
40 0 .75 0. 73 0 .71 0. 69
This is for W/C ratio 0.50. For each decrease of 0.05,
93
there is increase of 1% Coarse agg. Increase agg % by 2%
 SSD Weight
Weight of water in litre/kg = 0.1488 cum *1000 kg/cum = 148.8 kg

Weight of cement = 0.1181 cum *3150 kg/cum = 372 kg

Weight of admixture = 0.0031 cum*1200 kg/cum =

3.72 kg

Wet Coarse aggregate = 0.4672 cum* 2600 kg/cum = 1215 kg

Wet Fine agg = 0.2628 cum*2600 kg/cum = 683 kg

Total Volume = 1.000 cu m

Quantity = 2422 kg94
 SSD Weight
Weight of water in litre/kg = 0.1488 cum *1000 kg/cum = 148.8 kg

Weight of cement = 0.1181 cum * 3150 = 372 kg

Absolute volume of admixture = 0.0031 cum*1200 kg/cum = 3.72 kg

Wet Coarse aggregate = 0.4672 cum* 2600 kg/cum = 1215 kg

Wet Fine agg = 0.2628 cum*2600 kg/cum = 683 kg

1 : 1.8 : 3.2 by weight W/C free = 0.45

Total Volume = 1.000 cu m
Quantity = 2422 kg

95
 Functional Evaluation MORD
Specification
 Surface regularity:

 +/- 6 mm in transverse & +/- 7 mm in longitudinal

direction -measured with 3 m st edge.

 PQC: +/- 10 mm -1501.26 page 424 of MORD

 Deficiency 5 mm thickness <3 panels 1501.27

 Functional Evaluation MORD Specification

 Acceptance criteria for distress/cracked slabs:

i) Length of single crack < 1500 mm even though

depth of crack is less than half of slab depth
ii) Sum of cracks < 2000 mm in a standard slab of
size 3.75 mx 4.5 m.

 Structural crack (more than half depth full depth

repair) -removed and replaced
 Riding Quality evaluation
IRC:SP:16
 Texture in transvers direction. 1.25 mm;
brooming- sand patch
 3-4 mm in case of tinning at 20 mm interval. -
 5th wheel bump integrator: roughness index
 < 2200 mm/km for very good riding
 2200-3000mm for average riding quality
 > 3000 mm/km; poor in riding quality
 Max. Irregularity allowed -3 m st. edge

 Longitudinally- IRC:SP:16 for Rural Roads---

 Irregularity 4mm 7mm

 Length 300m 75 m 300m 75m

 Rural Road 40 18 4 15
 Av. Comp. Strength of 4 cube samples > fck + 3 MPa
Structural Evaluation
 Variation in cube results < 15%.

 Dull and hollow sound emitted from unsound concrete

 Metallic sound emitted from sound concrete-impact

steel hammer

 Visual Survey- after rains /washing PQC surface

 width of cracks - gauges or optical micro scope

 NDT: UPV/ rebound hammer (IS:13311).

A. NDT /rebound hammer test for determining compressive strength IS: 13311 (II)

• Rebound No at 90 deg angle Quality

• 20 15 Mpa
• 30 32 Mpa
• 40 48 Mpa
• 50 70 Mpa
• 55 80 Mpa

Wet Results 20% lower than dry and Variation allowed 25%
 Core Testing - Acceptance
Core Drilling: variation < 15%

Specimens - tested immediately on removal from water

after 24 hour wetting

Rate of Loading 140 kg/sq cm/ minute

h/d ratio, n 1 1.4 1.8 2

Correction factor, f 0.89 0.93 0.98 1

F= 0.11n+0.78, F = Correction factor

N= height to dia ratio
 Core Testing - Acceptance

Equivalent cube strength =

f (Correction factor) X crushing strength of core X1.25

acceptable when equivalent concrete cube strength of core

is at least 85% of the characteristic.

no individual core has a strength less than 75% of the

characteristic.
 Plastic Cracks Y -Cracks Corner Cracks
Evaporation of High Shrinkage Excessive load
water > 1kg/m2/h cracks- high water
i.

Wind Y
ii.
iii.

Spalling faulting Scaling

material in joints unstable base Loss of wearing
 Edge Longitudinal and Diagonal Cracks
Cracks Transverse Cracks
Under Poor sub base/base Poor filter media
design, BC soil, late joint cut

Construction Cold J.
Crazing Patching Blowup
rich mixes, Soft clots Locked joints
Inadequate Joint Sealing/Super elevation
Drainage pipe below crack
More Spacing L/B > 1.5
Transverse Cracking
 Transverse Cracking
Distress Distress
width width

A B C D

Longitudinal Joint
C
L
C D
Transv. Transv.
Joint Joint

A B Traffic
Slab

Shoulder
 Material
Clause 1905.1.2 of MORD specification

 Very Low Viscosity Epoxy Material

 Sika Dur 52, Monopol, Araldite, EP 10
 Epoxy Modified Mortar
 Polyurethane based coating over Epoxy
Mortar
 Elastomeric Concrete
 Specification – Epoxy
 Viscosity of 2-4 poise at ambient temperature.

 Compressive strength 60-70 Mpa at 28 days

 1½ times the Compressive strength of concrete

used for PQC.

 100 % epoxy mortar is brittle-not rigid.

 Modified by 5 % Poly-sulphide polymer

 Repair- Low Viscosity Epoxy Resins:
clause 1905 (page 551) of MORD Specification for Rural Roads
published by Indian Roads Congress in 2014.

 Cracked area cleaned –blasting-with air.

 A low viscosity, cracks 0.5 mm – 6 mm

 viscosity 300 centipoise @ 20°C.

 Temperature < 600C.

Partial Depth Repair/Pothole Repair

EP 75
 Partial Depth Repair/Pothole Repair

i.Pot Hole Repair with Epoxy Mortar 1: 2 Cutting

ii.
iii.
Pouring Epoxy Pot Hole Repair
 Faulting Layout

A
faulting B

Longitudinal Joint
C
L
Transv.
Transv. Joint
Joint

A B
Traffic
Slab
 Faulting of Edge- settlement
Reasons:
i) No load transfer
ii) Mud pumping
iii) Not providing proper sub base
iv) No tie bars at butt type joints
v) Weak sub bases.

Evaluation: FWD/ Core cutting

Remedy: -Timely Diamond grinding/

Filling Void below PQC by making hole
 Spalling Layout
Distress < 0,6 m
width

A B C D
Crack Joint
Joint
Transv. Transv. Transv.
Joint Joint Joint

Low Sev.:
1,8 m Low Sev.: C D
2m Moder. Sev.:
2,5 m
High Sev.:
1,5 m Traffic
A B

Shoulder
 NEW

Spalling: Transverse Crack (with edge spall)

Repair as Pot Hole in two
separate parts by placing board at joint
 No acute angle
 Try to have obtuse angle
 Use Square, pentagon, or hexagon
Repair Cracks- MORD Hand Book on Quality
Assurance Manual 2016.

crack <1.5 mm wide, 10 mm dia holes driven to a

depth slightly more than depth of crack, at 300
mm interval on alignment of crack.

 Low viscosity flowing epoxy resin is injected.

 After 10-15 minutes holes are again topped up as

earlier epoxy resin flows into the cracks (IRC: SP:
83).
122
123
 Pressure grouting technique:
1. On both sides of crack, side edges chiselled, V-
shape, if required
2. Remove loose material
3. compressor or air blower.
4. Drill holes ; depth 100-150mm
& 10 mm diameter @ 400 mm c/c.
1. Fix Injection ports (Nipples), 6-8 mm ; 30-50mm- L
2. Apply primer till tacky,
3. Fill the top of V-grove portion by appropriate Epoxy
modified mortar or place M seal/cello-tape on top
and apply by pressure grouting technique.
 Partial Depth Repair Cracks- MORD Hand Book
on Quality Assurance Manual 2016.
Partial depth repair, if width of the crack >1.5 mm
< 6 mm V shape.

washed with jet of water. It is allowed to dry.

Low viscosity epoxy poured

Sand passing through 2.36 mm sieve

on epoxy and same is lightly tamped.

The traffic is allowed after 4 hours (IRC: SP: 83).

 Blowups

 Gradual or sudden
 full-depth and full-width
 Compressive joint failure
 Causes:
 Elevated temperature & moisture
 Restricted joint movement
 More pronounced in longer slabs
 Joint-less
 Very Weak or very strong base
 Remidial : Full Depth Repair
Side view- Blowup of Concrete Pavement,
CRRI Campus
Top view- Blowup of Concrete Pavement,
CRRI Campus
Rehabilitation by Full depth of Blowup - CRRI Campus
 Full depth repair methodology:
panel broken into 4 or 5 pieces
parts are tending to move or blow-up
M 30-40 Grade concrete (Preferably RCC)

Full Depth Repair Awaiting Concrete

 For d < D /2 , as confirmed by Core Cutting. See Note 1
Chase 10mm groove along the
line of the crack and seal with Preliminary Vertical Hole
low viscosity epoxy resin
150

Plastic Shrinkage Crack

0 - Surface

36o
Governed by length of Drill Bit

d
110 mm

12 dia
High Yield Deformed Reinforcing bar
Epoxy Resin

350
PQC 400

Notes: '(All dimensions in mm)

1. This method of repair shall only be accepted where
discrete cracks are demonstrated by core cutting to be less

20 12
than 50% of thickness PQC and written approval is provided
by the Engineer. for wide
2. Maximum spacing 500mm

3. EPOXY as per IRC:77 only. Polyester resins shall not be

crack
used
330 - Bottom of PQC

DLC
repair-
longitudinal
Cross Stitching
 Repair of Damaged Joints:
 cleaned with compressed
 repaired the spalls
 sealing of joins with poly sulphide or poly
urethane

Repair of Joint and Rounding Edges

Hard Texturing in Process/ Micro milling
134
 Acceptance criteria for
distress/cracked slabs:

 Length of single crack < 1500 mm even

though depth of crack is less than half of
slab depth

 Sum of cracks < 2000 mm in a standard

slab of size 3.75 mx 4.5 m
 5th wheel bump integrator:
roughness index

2200-3000mm for average

riding quality
 12mm + 5 mm 12 mm 15 mm
+7 mm - 7 mm

+12 +9 +6 +3 0.0 mm -3 -6 -9 -12

 IRC:SP:16

 Irregularity 4mm 7mm

Length 300m 75 m 300m 75m

 Rural Road 40 18 4 2
PARTIAL DEPTH REPAIR

EP 75
With Epoxy:

 Chiselling and Cleaning with compressed air,

 surface dry , apply - low viscosity epoxy
 epoxy sand mortar about 1:6 --10-15 mm depth
 With Conventional Mortar:
 Exposed surface > 15 mm in depth but no cracking
 Flooded water for 48 hours or keep wet for 48 hours,
 Apply cement slurry
 After 2-3 hours apply 1: 3 Cement sand mortar
1:1:2
 Use pre cast block, steel bars
as stitch segment..
Performance improver Mineral admixtures, lime stone powder, slag etc 5%
Properties 33 Grade 43 Grade 43 Grade S 53 Grade 53 Grade S
OPC OPC OPC
FINENESS 225 225 370 225 370
m2/kg
Setting IS 30 30 60 30 60
Time FS 600 600 600 600 600
Min CS 3 D 16 23 23 27 27
Min 7D 22 33 37.5 37 37.5
Min 28 D 33 43 43 53 53
Max 28 D 48 58 - - --
 IS: 383-2016
Coarse and Fine Aggregates for
concrete
 Maximum Utilization
Coarse Type Plain Cement Reinforced Lean Concrete
agg Concrete Concrete Less than M 15
Iron Slag 50 25 100
Steel Slag 25 nil 100
RCA 25 20 upto M 25 100

Copper slag 40 35 50
RCA 25 20 upto M 25 100

Chlorides = 0.5%
Sulphates = 0.04 %
Water absorption = 5% upto 10% With precaution
 DESIGN STRNGTH
f ’ck = fck + t x s = 30 + 1.65*5 = 38.25 MPa = Target
strength
where

f ’ck =

38 Mpa target mean compressive strength at 28 days,

146
 PRELIMINARY SELECTION OF WATER – CEMENT RATIO

Sl No. Grade of Concrete Approximate Water

Cement Ratio
1 M 25 0.50
2 M 30 0.45
3 M 35 0.42
4 M 40 0.38
5 M50 0.34
6 M60 0.28

f’ck= fck + t x s = 30 + 1.65*5 = 38.25 MPa = Target strength

• Let us take W/C = 0.40

147
 ASSUMED STANDARD DEVIATION

Grade of concrete Assumed Standard

Deviation N/mm2
M25 4.0
M30
M35
M40
M45 5.0
M50
M55
M60 148
 APPROXIMATE WATER CONTENT PER
CUBIC METRE OF CONCRETE FOR
NOMINAL MAXIMUM SIZE OF AGGREGATE
(WITH OUT PLASTICISER
/SUPERPLASTICISER)
Nominal Maximum Approximate Water
Size of Aggregate, mm Content, kg
10 208
20 186
40 165
149
 Water Content (Contd.)

• Plasticising admixtures decrease water - 5 – 10%

•Superplasticising 20 – 30%

Water content is 186 kg/m3 for 20 mm MSA without

admixture,

(186 X 0.80 ) = 148.8 litre or kg, considering 20%

reduction in water due to admixture
150
 PRELIMINARY SELECTION OF WATER – CEMENT RATIO

Sl No. Grade of Approximate Water

Concrete Cement Ratio
1 M 25 0.50
2 M 30 0.45
3 M 35 0.42
4 M 40 0.38
5 M50 0.34
6 M60 0.28

151
EXAMPLE FOR EACH CUBIC M OF CONCRETE

• Water 186 l /cubic m. No admixtures

• 80% after adding admixture 186 = 0.4

C
=0.80*186 =148.8 litre/cubic m.
C = 465 kg/ cu
• W/C = 0.4 m.
148.8 = 0.4
C
• 0.4 * C = 148.8
Extra Cement
• C= 148.8 465 – 372 =93 kg
0.4 = 372 kg per cubic m of 152
concrete
 EXAMPLE
• Absolute volume of water 148.8/1000= 0.1488 cum

• Absolute volume of cement = 372/3150 =0.1181 cum

• Absolute volume of admixture ( Sp gr 1.2 of admixture) =

• 3.72/1200 cum = 0.0031 cum (1% of 372 = 3.72 kg admixture)

• Absolute volume of agg = 1- 0.1488-0.1181-.0031 = 0.73 cum

Absolute Volume of all aggregates = 1 – 0.27 = 0.73 cu m

153
 ESTIMATION OF COARSE AGGREGATE CONTENT

Nominal Volume of Coarse Aggregate Per

Maximum Unit Volume of Concrete for
Size of Different Zones of Fine Aggregate
Aggregate Zone Zone III Zone II Zone I
mm IV
10 0 .50 0. 48 0 .46 0. 44
20 0 .66 0. 64 0 .62 0. 60
40 0 .75 0. 73 0 .71 0. 69
Fine aggregate content is obtained by subtraction

For 0.5 + W/C ratio. For 0.4 W/C ratio correction foe each decrease
154
of W/C ratio 0.05 increase coarse agg g by 1%. So 2% increase
Absolute volume of total agg =0.73 cum
Coarse agg : fine agg = 64% : 36%

• 0.73 cum → coarse aggregate 64% =

0.73*0.64 = 0.4672 cu
m

Coarse aggregate down 20 mm = 0.4672cum

Fine agg = 36% of 0.73 = 0.2628 cum
155
DESIGN OF NATIONAL HIGHWAYS
 Jointed Reinforced

10 - 20 m

Slab
Dowels

Base

Welded Wire Fabric

(0,1 - 0,2 %)
 Continuously Reinforced

IRC: 101
IRC: 118
Cracks separation
Slab

Base
Reinforcement Steel
0,6 - 0,8 % Area

Jointless Rigid Pavement--- Donot avoid

proper compaction
De-bonding layer

PQC PQC PQC

DBM-2 DBM-2
DLC/ CEMENT
TREATED
CEMENT TREATED GRANULAR SUBBASE
SUBBASE GRANULAR SUBBASE
DRAINAGELAYER
LAYER
DRAINAGE LAYER
FILTER/SEPARATION DRAINAGE LAYER
LAYER FILTER/SEPARATION
FILTER/SEPARATION LAYER
LAYER
SUBGRADE
SUBGRADE
SUBGRADE

(a) (b) (c)

Figure 7- Concrete Pavements over different types of subbase

 Aggregates
• Chloride content < 0.6%

• LAA < 35%

• Sulphate < 0.25

• MSA 31.5 mm for above 200 mm

• 26.5 mm for DLC 100-200mm

• Water absorption < 3%

• Soundness < 12% with sodium sulphate

• Silt Content in sand Sand < 3%

• Crusher dust < 15 % /M sand
• Blend < 8%

• Avoid Zone IV sand

 Materials other than agg
• OPC ( IS 8112/IS:12269) 360 - 450 kg/cum

• PPC (Flyash; IS 3812 upto 20%) OPC > 340, PPC >
425

• PSC ( Slag IS 12089, upto 50%) OPC > 255, PSC <
255

• Admixture ( IS 9103, upto 2%)

• Silica Fume (IS 15388 upto 10%)

 Materials other than agg
• Water (IS 456 ) Drinkable, pH 6-8

• Steel (IS:1786; Fe 500/IS: 432; S 240)

• Expansion board (IS 1838) at abutting

Structure

• Fibre 0.2 -0.6% (IRCSP46)

 Concrete Properties
• Target strength = Characteristic St + 1.65*SD
•
• where SD= 0.32 Mpa

• Maximum W/C ratio 0.5 (PPC/PSC); 0.45 (OPC)

• Slump 25+/- 10 mm
• 40 +/- 10 mm ( SM)

• Workability One test per dumper

• Laying tme 100 minute when temp < 25oC

120 minute When temp 25-30 oC

• Flexural Strength 0.7 ( fck) 1/2

 CBR %
Effective or Design CBR % Subgrade

EMBANKMENT
Insitu soil

Select Soil CBR % Subgrade

 Clause 601- DLC
PQC
• Sieve mm % Passing % Passing
31.5 100 100
26.6 100 85-95
19 75-95 68-88
9.5 50-70 45-65
4.75 30-55 30-55
2.36 17-42 ---
600 micron 8-22 8-30
300 micron 7-17 ---
150 micron 2-12 5-15
75 micron 0-10 0- 5

310 PPC
• Cement > 150 kg/cum 360 OPC
• Strength 10 MPa M 40
 First 25% of (Total Traffic * 2.35 on
Maximum tensile stress at top single lane one direction)
(top-down cracking)
6 hours traffic 60% *0.5 = 0.3
( out of 100 CVPD 60 night ( 12 hr) and
40 day ( 2 hr)
Figure 4 Two Axles of a commercial vehicle
acting on warped pavement in night hours
(TDC Night Time 60% Loading)*0.55

Figure 5 Different types of trucks causing tensile stress at the top fibre
of pavement Slab with tied concrete shoulder
First 25% of (Total Traffic * 2.35 on single lane one direction)
BUC Day Time 40% Loading ( 12 hours). For 6 hr CVPDX 0.2
 LANE DISTRIBUTION FACTOR

1. Single-lane roads: 100% CVPD in both directions.

2. Two-lane single carriageway roads-
50% of the CVPD in both directions.

3. Four-lane single carriageway roads-

40 per cent of the total number CVPD.
4. Dual carriageway roads-
75 % of CVPD in each direction.
5. Three-lane/dual four-lane carriageway-
60 /45% .
 Steps of Design
• Select trial thickness say 32 mm for

• W = 7500*1.2 = 9000 kg
• 15 tonnes Axle load

• Calculate temperature stresses at edge

• Calculate available residual strength

• Determine edge load stresses

• Check for Stress ratio < 0.5

 TABLE 4. k-VALUES OVER DRY LEAN CONCRETE SUB-BASE

k-value of 21 28 42 48 55 62
Subgrade (MPa/m)
Effective k over 100 56 97 166 208 278 389*
mm DLC, (MP/m)
Effective k over 150 97 138 208 277 412* -
mm DLC, (MPa/m)
3
Note: 100pci=2.77kg/cm = 27.2MPa/m
k-value of Effective k (MPa/m) over untreated Effective k (MPa/m) over cement
subgrade granular layer sub-base of thickness treated sub-base of thickness in
(MPa/m) in mm mm
150 225 300 100 150 200
28 39 44 53 76 108 141
56 63 75 88 127 173 225
84 92 102 119 - - -
Cement concrete slabs laid during morning hours remain
flat

Intense solar radiation, high air temperature and chemical

reaction are responsible for high temperature difference.

Permanent curl equivalent to negative temperature

differential of 50C

During the night hours, if temperature differential is 100C,

effective differential can be 150 C.

If there is mist spray of water, the built-in permanent curl

will be less.
•

• Design Parameters

• Flexural strength of concrete = 45 kg/cm2(4.5 MPa)

• CBR value of the soil (%) =10 (K 5.5 kg/cm3 )

• Modified k for 150 DLC = 300 MPa/m or 30 kg/cm3

• Elastic Modulus =3x105 kg/cm2

• Poison’s ratio =0.15

• Coefficient of expansion =10x10-6 /0C

• Tyre Pressure =7.2 kg/cm2

• Rate of traffic increase (%) =7.5

 Design Joint Width and Joint Spacing- Expansion Joint

Coefficient of Thermal Expansion, α

= 10*10-6 mm/mm/oC

Spacing of Expansion Joint = 140 m

in 1mm = 10*10-6 mm/oC

in 140000mm = 140 000* 10*10-6 mm/oC

for Temp gradient /oC = 1.4 mm

So for φt = 15oC change

Required Expansion Joint width 1.4 mm *15oC= ~ 20 mm
Design Joint Width and Joint Spacing- Contraction Joint
Contraction Joint 4.5 m

Drying Shrinkage = 0.06%

So for 100 mm = 0.06 mm

For 1 mm = 0.06/100 mm = 0.0006 mm

so in 4.5 m or 4500 mm:

For 4500 mm = 0.0006mm * 4500 = 2.7 mm

Required Contraction Joint width = ~3 mm

 DESIGN ASPECTS

# Cement concrete is weak in bending (1/10th of CS)

# Design has been traditionally based on the classic

formulae of Westergaard, (1926) /FEM

# Temperature stresses are calculated by Bradbury’s

coefficient.

+ 3.8 MPa

- 3.8
MPa
 Westergaard’s (1926) Formulae

Corner
Load Stresses
a
Max- corner
Lesser/medium Interior
Edge
- edge
Least- Interior

Critical Loading Positions for Westergaard Analysis, 1926

 Curling stresses due Restraining Stresses
to Temperature max in interior

Gradients Lesser/medium at edge

Day time Curling
Convex upward Least in corner

C
Corner
T

a
Night time Curling Concave upward
Edge Interior
T
C
40
80
150
300

300
150
80
40
 Jointed Reinforced

10 - 20 m

Slab
Dowels

Base

Welded Wire Fabric

(0,1 - 0,2 %)
 Continuously Reinforced

IRC: 101
IRC: 118
Cracks separation
Slab

Base
Reinforcement Steel
0,6 - 0,8 % Area

Jointless Rigid Pavement--- Donot avoid

proper compaction
De-bonding layer

PQC PQC PQC

DBM-2 DBM-2
DLC/ CEMENT
TREATED
CEMENT TREATED GRANULAR SUBBASE
SUBBASE GRANULAR SUBBASE
DRAINAGELAYER
LAYER
DRAINAGE LAYER
FILTER/SEPARATION DRAINAGE LAYER
LAYER FILTER/SEPARATION
FILTER/SEPARATION LAYER
LAYER
SUBGRADE
SUBGRADE
SUBGRADE

(a) (b) (c)

Figure 7- Concrete Pavements over different types of subbase

 CBR %
Effective or Design CBR % Subgrade

EMBANKMENT
Insitu soil

Select Soil CBR % Subgrade

 Clause 601- DLC
PQC
• Sieve mm % Passing % Passing
31.5 100 100
26.6 100 85-95
19 75-95 68-88
9.5 50-70 45-65
4.75 30-55 30-55
2.36 17-42 ---
600 micron 8-22 8-30
300 micron 7-17 ---
150 micron 2-12 5-15
75 micron 0-10 0- 5

310 PPC
• Cement > 150 kg/cum 360 OPC
• Strength 10 MPa M 40
 First 25% of (Total Traffic * 2.35 on
Maximum tensile stress at top single lane one direction)
(top-down cracking)
6 hours traffic 60% *0.5 = 0.3
( out of 100 CVPD 60 night ( 12 hr) and
40 day ( 2 hr)
Figure 4 Two Axles of a commercial vehicle
acting on warped pavement in night hours
(TDC Night Time 60% Loading)*0.55

Figure 5 Different types of trucks causing tensile stress at the top fibre
of pavement Slab with tied concrete shoulder
First 25% of (Total Traffic * 2.35 on single lane one direction)
BUC Day Time 40% Loading ( 12 hours). For 6 hr CVPDX 0.2
 LANE DISTRIBUTION FACTOR

1. Single-lane roads: 100% CVPD in both directions.

2. Two-lane single carriageway roads-
50% of the CVPD in both directions.

3. Four-lane single carriageway roads-

40 per cent of the total number CVPD.
4. Dual carriageway roads-
75 % of CVPD in each direction.
5. Three-lane/dual four-lane carriageway-
60 /45% .
 Steps of Design
• Select trial thickness say 32 mm for

• W = 7500*1.2 = 9000 kg
• 15 tonnes Axle load

• Calculate temperature stresses at edge

• Calculate available residual strength

• Determine edge load stresses

• Check for Stress ratio < 0.5

 TABLE 4. k-VALUES OVER DRY LEAN CONCRETE SUB-BASE

k-value of 21 28 42 48 55 62
Subgrade (MPa/m)
Effective k over 100 56 97 166 208 278 389*
mm DLC, (MP/m)
Effective k over 150 97 138 208 277 412* -
mm DLC, (MPa/m)
3
Note: 100pci=2.77kg/cm = 27.2MPa/m
k-value of Effective k (MPa/m) over untreated Effective k (MPa/m) over cement
subgrade granular layer sub-base of thickness treated sub-base of thickness in
(MPa/m) in mm mm
150 225 300 100 150 200
28 39 44 53 76 108 141
56 63 75 88 127 173 225
84 92 102 119 - - -
•

• Design Parameters

• Flexural strength of concrete = 45 kg/cm2(4.5 MPa)

• CBR value of the soil (%) =10 (K 5.5 kg/cm3 )

• Modified k for 150 DLC = 300 MPa/m or 30 kg/cm3

• Elastic Modulus =3x105 kg/cm2

• Poison’s ratio =0.15

• Coefficient of expansion =10x10-6 /0C

• Tyre Pressure =7.2 kg/cm2

• Rate of traffic increase (%) =7.5

•

• DESIGN OF RIGID PAVEMENT (i) Design Parameters

•Design traffic intensity =2500 cvpd

•Cumulative in 36 years, cvpd = 2500x365 ( 1.05 36 - 1)/0.05

= 87 450 644

•Design Traffic (Total number of axles) =87 450 644*2.35

= 205 509 015 ( 205 msa)

Design Traffic = 0.5*25% = 0.5*0.25*205 509 015= 25 688 627

•

• DESIGN OF RIGID PAVEMENT (i) Design Parameters

day 10 am – 4pm night 0 am – 6 am Constant

Design Traffic = 0.5*25% = 0.5*0.25*205 509 015= 25 688 627

= 25 688 627 for 12 hour day 40% traffic + 12 hours Night 60% traffic

= 25 688 627 * 0.4 + 25 688 627* 0.6 = for 12 hours - so for 6 hr

= 25 688 627 * 0.4 + 25 688 627* 0.6 = 25 688 627 for 6 hours hr
2 2 2

= 5137725 + 7706588 = 12 844 313 Commercial vehicles

day (TDC) + Night ( BUC) *0.55 = for 6 hours day and night
CFD <1 + <1 IRC: 58, 2011

Revised CFD of TDC + BUC < 1

k-value of Effective k (MPa/m) over untreated Effective k (MPa/m) over cement
subgrade granular layer sub-base of thickness treated sub-base of thickness in
(MPa/m) in mm mm
150 225 300 100 150 200
28 39 44 53 76 108 141
56 63 75 88 127 173 225
84 92 102 119 - - -
 TABLE 4. k-VALUES OVER DRY LEAN CONCRETE SUB-BASE

k-value of 21 28 42 48 55 62
Subgrade (MPa/m)
Effective k over 100 56 97 166 208 278 389*
mm DLC, (MP/m)
Effective k over 150 97 138 208 277 412* -
mm DLC, (MPa/m)
3
Note: 100pci=2.77kg/cm = 27.2MPa/m The maximum recommended value may
be taken as 300 MPa/m
•

• DESIGN OF RIGID PAVEMENT (i) Design Parameters

•Design traffic intensity =2500 cvpd

•Cumulative in 36 years, cvpd = 2500x365 ( 1.05 36 - 1)/0.05

= 87 450 644

•Design Traffic (Total number of axles) =87 450 644*2.35

= 205 509 015 ( 205 msa)

Design Traffic = 0.5*25% = 0.5*0.25*205 509 015= 25 688 627

•

• DESIGN OF RIGID PAVEMENT (i) Design Parameters

day 10 am – 4pm night 0 am – 6 am Constant

Design Traffic = 0.5*25% = 0.5*0.25*205 509 015= 25 688 627

= 25 688 627 for 12 hour day 40% traffic + 12 hours Night 60% traffic

= 25 688 627 * 0.4 + 25 688 627* 0.6 = for 12 hours - so for 6 hr

= 25 688 627 * 0.4 + 25 688 627* 0.6 = 25 688 627 for 6 hours hr
2 2 2

= 5137725 + 7706588 = 12 844 313 Commercial vehicles

day (TDC) + Night ( BUC) *0.55 = for 6 hours day and night
CFD <1 + <1 IRC: 58, 2011

Revised CFD of TDC + BUC < 1

N = unlimited for SR < 0.45
Cumulative repetitions, = 113222346

Design traffic =25% of repetitions of total traffic, B = 28305586

Bottom-up cracking (BUC)
For the analysis of BUC, 6 hours of day traffic is considered
12 hr day time traffic (40% of B), D = 11322235
12 hr night time traffic (60% of B), E = 16983352
6 hr day time traffic for BUC (50% of D), F = 5661117
6 hr night time traffic for BUC, (50% of E), G = 8491676
Single axle load(SAL) 50% of F for BUC = 2830559
Tandem axle load(TAL) 50% of F for BUC = 2830559
Top-down cracking (TDC)
For analysis of TDC 6h night traffic with wheel base less than 4.5m is considered
6hr night traffic with wheel base less than 4.5m (50% of G), H = 4245838
Here the traffic for top-down cracking consists of single axle with single tyre touching the
approaching transverse joint and the following axles of the tandem/tridem axle groups
close to the following transverse joint 4.5m behind the approaching joint(Figure-5) .
Single axle load (50% of H) for TDC = 2122919
Tandem axle load (50% of H) for TDC = 2122919
Bottom-up cracking:
1. Single axle with tied concrete shoulders with temperature differential(TD)

(a) k<=80 MPa/m

S = 0.008 - 6.12 (γh2/kl2) + 2.36 Ph/(kl4) + 0.0266 ΔT ………….(7)

(b) k>80, k<=150 MPa/m

S = 0.08 – 9.69 (γh2/kl2) + 2.09 Ph/(kl4) + 0.0409 ΔT ………….(8)

(c) k>150 MPa/m

S= 0.042 + 3.26 (γh2/kl2) + 1.62 Ph/(kl4) + 0.0522 ΔT ………….(9)

2. Single axle with TD having no concrete shoulder

(a)k<= 80 MPa/m
S= 0.042 + 3.26 (γh /kl ) + 1.62 Ph/(kl ) + 0.0522 ΔT ………….(9)

2. Single axle with TD having no concrete shoulder

(a)k<= 80 MPa/m

S= - 0.149 - 2.60 (γh2/kl2) + 3.13 Ph/(kl4) + 0.0297 ΔT ………….(10)

(b) k>80, k<=150 MPa/m

S = - 0.119 - 2.99 (γh2/kl2) + 2.78 Ph/(kl4) + 0.0456 ΔT ………….(11)

(c) k>150 MPa/m

S = - 0.238 + 7.02 (γh2/kl2) + 2.41 Ph/(kl4) + 0.0585 ΔT ……….....(12)

3. Tandem axle with tied concrete shoulders with TD

(a) k <= 80 MPa/m

S= -0.188 + 0.93 (γh2/kl2) + 1.025Ph/(kl4) + 0.0207 ΔT …………..(13)

(b) k>80, k<=150 MPa/m

S = -0.174 + 1.21 (γh2/kl2) + 0.87Ph/(kl4) + 0.0364 ΔT …………..(14)

(c) k>150 MPa/m

S = -0.210 + 3.88 (γh2/kl2) + 0.73Ph/(kl4) + 0.0506 ΔT …………(15)

5. Tandem axle with TD having no concrete shoulder

(a) k<= 80 MPa/m

S = -0.223 + 2.73 (γh2/kl2) + 1.335Ph/(kl4) + 0.0229 ΔT …………(16)

(b) k>80, k<=150 MPa/m

S = -0.276 + 5.78 (γh2/kl2) + 1.14Ph/(kl4) + 0.0404 ΔT …………(17)

(c) k>150 MPa/m

S = -0.3 + 9.88 (γh2/kl2) + 0.965Ph/(kl4) + 0.0543 ΔT …………(18)

1. Top-down cracking

For the analysis of top-down cracking, only rear axle load is the input. Front axle load is
taken as 50% of the rear axle load (first rear axle for tandem and tridem).
4 2 2
S = -0.219 + 1.686βPh/kl + 168.48h /kl + 0.1089 ΔT ………….(19)
2
R values for all equations are over 98%
In case of doubt -Concrete cores are cut :

Rate of Loading 140 kg/sq cm/ minute

h/d ratio, n 1 1.4 1.8 2

Correction factor, f 0.89 0.93 0.98 1

f= 0.11 n +0.78, n=h/d

Equivalent cube strength = f X crushing strengthX1.25

Average of Four Cores > 0.85 times Characteristic

Individual core not less than 75% of Characteristic

 ABSOLUTE VOLUME in CUM

• Absolute volume of water 1 = 0.1488 cum

• Absolute volume of cement = 0.1181 cum

• Absolute volume of admixture = = 0.0031 cum

• Wet Coarse aggregate down 20 mm = 0.4672cum

• Wet Fine agg = 38% of 0.73 = 0.2628 cum

• Total Volume = 1.000 cu m

209
 Mass of each ingredients in kg for 1
CUM
• Mass of water 1 = 0.1488 cumX 1000= 148.8

litre/kg

• Mass of cement = 0.1181 cum X 3150= 372 kg

• Mass –Chemical admixture = 0.0031 cumX 1200= 3.72 kg

• Mass of Wet Coarse aggregate = 0.4672cum X 2600= 1215

kg
210
 CPWD and IS= Specification Nominal
Mixes By Volume
Mix 7 day Comp. Strength 28 day Comp.

1: 1: 2 210 kg/cm2 ( 21 MPa) 315 kg/cm2 ( 31.5 MPa)

1: 1.5: 3 175 kg/cm2 (17.5MPa) 265 kg/cm2 ( 26.5 MPa)

1: 2: 4 140 kg/cm2 (14 MPa) 216 kg/cm2 ( 21.6 MPa)

IS: Code= 1:2:4 means 15 Mpa at 28 days Charasteruistics

CPWD Code = 15 + 1.65*4 by Traget strength

7/9/2018 Concrete Pavement -Design & 211
Applications.
Fck +4 for less than 4 samples

30.8 Fail
ed
TYPICAL CORELATION FOR N TYPE REBOUND HAMMER
 IS: 13311 (Part 2)
NDT –REBOUND HAMMER
• Rebound No Quality
• 20 15 Mpa
• 30 32 Mpa
• 40 48 Mpa
• 50 70 Mpa
• 55 80 Mpa

• Wet Results 20% lower than dry

• Variation allowed 25%
As per IS 456

1. Load = full dead load +1.25 times the imposed load for a period of 24 h

2. Then imposed load is removed

3. If within 24 hours of removal of the load, the structure does not recove
75% of the deflection under the imposed load

4. Test is repeated after a lapse of 72 hours, if recovery is less than 80%-

5. Deflection in mm < 40 ℓ2/D , ℓ - effective span in m, D –overall depth in

then it is not necessary to for the recovery to be measured and recov
provision shall not apply
6. Members other than flexural member – analysis

7. NDT IS 13311 Part 1 and Part 2 (RHM)

8. IRCSP 71 Pretensioned Girder _ Load test to destruction of precast g

be carried our, if specifically given in contract