CONSTRUCTION OF CONCRETE PAVEMENTS

PRIMARY STEPS
Preliminary steps prior to paving by machineries

Surface preparation Concrete mixing plant operations Transport to paver

Surface Preparation
Prepare subgrade for new pavement
Soil type Moisture content Density

Preparing an existing pavement surface for overlay by removing top layer through milling, demolition Remove pockets of unsuitable materials Stabilize unsuitable soils

Surface Preparation
Prepare granular subbase or base course
Similar to subgrade preparation Usually higher density requirement

Cement-stabilized materials
Placed using slipform or asphalt equipment

Plant Operations
Almost all PCC intended for pavement use is ready mixed concrete Mixing cement, aggregate, water and admixtures

Transport
Transportation to paving machinery from batching facility via truck mixer or non-agitating truck Unload quickly upon arrival Unload as close as possible to final placement spot Quality control Synchronisation rates of batching plant production, truck transport and paver
NEXT STEP PAVING but reinforcement placement also common to both

TWO KINDS OF PAVING TECHNIQUES

FIXED FORM PAVING SLIP FORM PAVING manual

ALL functions to place reinforcement, strikeoff, spread, compact/consolidate, finishing, texturing, cure

Fixed Form Paving

Different activities done by separate independent machine traveling on fixed forms (rails)

Slip Form Paving

Different activities done by a single or not more than 3 machines traveling on crawlers

Manual method - for small jobs

Fixed Form Paving Operations

Paving form is the mould
Holds concrete in place Establishes grade and alignment Serves as tracks for paving equipment

Forms
Mould that determines
Pavement depth Pavement width Pavement smoothness Made of steel (large job) or timber (small job with less machineries) and has small side holes for insertion of tie bars

Typical Steel Form

Form Lock

Reinforcement
Dowel bars Tie bars fixed by hand (FF) or tie bar inserter (SP) Mesh reinforcement, if required

Dowel Bars Placed on a Lean Concrete Base in Advance of PCC Placement

End Dump Truck Discharging PCC in Front of a Paver

End Dump Truck Discharging PCC onto a Spreader/Placer

Initial Leveling by Vibrating Truss Screed

Traveling Carriage Screed

Roller Screed
Roller screed consists of a steel tube that rotates up to 250 rpm in the opposite direction of movement. The tube strikes off PCC and pushes excess PCC forward by the rolling action

Small Hand-Operated Vibrator

Compaction 1. Hand-operated vibrators. 2. Screed vibration.

Compacted Concrete in Steel Forms

Finishing and Texturing

Finishing using hand floats to eliminate high/low spots Texture types: Longitudinal Transverse 20 mm or less spacing Random Spacing

Mechanised dragging artificial turf

Manual dragging texturing

Manual Texturing

Curing

Curing carried out to prevent moisture loss. Ponding water or cover slab with water retaining material.

Manually insert dowel bars into the construction joint at the end of the work day

Forms Removal

Tie Bars Along a Longitudinal Joint

When one lane at a time is paved, tie bars are inserted at mid-slab depth and bent back until adjacent slab is ready to be paved

Critical Factors in Fixed Form Paving - Ride Quality

Uniform grade - properly compacted Uniform subbase eliminate if subgrade CBR above 15% Forms meet specifications Consistent mix, slump Placement of reinforcing, dowel baskets Timely delivery of concrete Proper placement mix on grade

Critical Factors Fixed Form Paving - Ride Quality

Adequate vibration - compaction Care in placement and vibration of reinforcements, dowels Proper machine adjustments Steady machine progress Avoid excessive finishing Avoid excessive water on surface Straightedge check of slab Adequate cure

SLIPFORM PAVING

SLIPFORM PAVING
Uses low-slump PCC. Low-slump PCC is necessary so that the fresh PCC is able to hold its shape once the slipform paver has passed. High productivity. Large jobs generally require high production rates in order to be profitable. Smooth riding surface. Automation and computer control allow slipform pavers to produce very smooth riding surfaces

GENERAL SLIPFORM PAVING PROCESS

EITHER a single OR accomplished by 3 separate machineries: spreader/placer; concrete paver; texturing and curing machine

Slipform Paving Philosophy

To shape a material by forcing it through a mould.

Extrusion Envelope
Movement 1-2.5 m/min Strike Off remove excess portion of auger-placed PCC Vibrator (group) Tamper (150 strokes/min) pushes large aggregate below surface Profile Pan levels concrete to right elevat

Excess Concrete Concrete Head

Fluidized Side Form Resistance Batter Concrete Spread by auger

Dowel bar inserter

Profile Pan Batter Compression-Paver Uplift

Slipform
Compaction/consolidation Steel placement Form into a Shape Finish the Surface

SUBGRADE
Proper Compaction Built to Specified Tolerances Uniform Support May be Stabilized

Place SUBBASE to Specified Tolerances

Enhance UNIFORM support for concrete layer Working platform for concrete paving Enhance smoothness Reduce occurrence of mud pumping

Track Line
Extend base one meter beyond outside edge of pavement Durable for paving train Keep it clean

Pavement Steel
Dowel bars Tie bars Reinforcing mesh Continuous reinforcement

Placing Dowel Bars

Automatic Manual

Mechanical method

Hand placing or manual method

Discharging
Place PCC in front of paver using a series of conveyor belts, augers and strikeoff devices

Leveling and Vibration

Initial leveling by strike off screed Compacting Concrete Mass Series of vibrators at 7000-9000 VPM

Vibration
Positioned so that their influence zone overlap by 50-75 mm

Finishing and Curing

As in fixed form paving

Dragging Artificial Turf behind SP

Groove texture

Curing
Uniform Timely

Spraying Curing Membrane

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