03 Construction Practices in India .ppt

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1. CONCRETE PAVEMENT
CONSTRUCTION PRACTICES IN
INDIA AND DEFICIENCIES
NOTICED
ByBy
DR. L.R.KADIYALIDR. L.R.KADIYALI

2. CONSTRUCTION PRACTICES
IN INDIA
•MANUAL METHOD OF CONSTRUCTION
(BEFORE 1990)
–Entire construction activities were by
manual method using wooden float etc.
–Spreading operation is done by manual
means but compaction is done by needle
vibrators and vibratory screeds
•MECHANIZED PAVEMENT
CONSTRUCTION (AFTER 1990)
–Entire operation is done by mechanical
means

3. CONSTRUCTION PRACTICES
BEFORE 1990’s
•BY AND LARGE CONSTRUCTIONS WERE
DONE MANUALLY.
•USING SIDE SHUTTERING OF WOODEN
PLANKS/PLYWOOD OR STEEL
CHANNELS.
•CONCRETE MIX PRODUCED BY HAND
MIXING OR USING 7/10 OR 10/14 cft
DRUM MIXERS ON VOLUMETRIC BASIS.
•CONCRETE MIX OF 1:2:4 OR 1:1.5:3 OR
RICHER RATIO.

4. CONSTRUCTION PRACTICES
BEFORE 1990’s (Contd.)
•COMPACTION DONE WITH STEEL RODS,
TAMPER BEAMS, NEEDLE VIBRATOR, PLATE
COMPACTOR.
• WOODEN SCREED, SCREED VIBRATORS Etc.
WERE USED FOR LEVELING AND FINISHING
•ALTERNATE PANELS WERE CAST, SO NO
JOINTS WERE REQUIRED
•WHEN REQUIRED, JOINTS WERE FORMED
BY INSERTING STEEL T-SECTIONS OR
WOODEN PLANKS OR PLY-WOOD
SECTIONS.
•SURFACES WERE NOT TEXTURED.

5. L.R. Kadiyali & AssociatesL.R. Kadiyali & Associates

10. JOINT FORMED BY INSERTING
WOODEN PLANK

13. A MINI MOBILE CONCRETE
BATCHING PLANT

14. A MINI BATCHING PLANT

15. A SCREED VIBRATOR

16. A SCREED VIBRATOR

17. MANUAL CONSTRUCTION

18. MARINE DRIVE IN MUMBAI

19. CONSTRUCTION PRACTICES
OF NHs AFTER 1990’S
•GENERALLY MECHANIZED CONSTRUCTION
•INTRODUCTION OF DLC AS A SUBBASE
•FIXED-FORM OR SLIP-FORM PAVING WAS
ADOPTED
•USE OF LARGE BATCHING PLANTS TO FEED THE
PAVERS CONTINUOUSLY. NORM IS TO
CONSTRUCT 1m PER min.
•APPLICATION OF TEXTURE
•CURING WITH LIQUID CURING COMPOUND AS
WELL AS WATER CURING
•JOINT FORMING WITH CONCRETE SAW
•USE OF IMPROVED JOINT SEALANTS

20. VISITS TO VARIOUS HIGHWAY PROJECTS WITH
CONCRETE PAVEMENTS
MANY PROJECTS
FINISHED OR IN THE
COURSE OF
CONSTRUCTION WERE
VISITED.
FOR EACH PROJECT, THE
CONSULTANT’S TEAM
MET PROJECT
DIRECTORS,
SUPERVISION
CONSULTANTS AND
CONTRACTORS WHERE
POSSIBLE.
FOR EACH PROJECT, A
REPORT WAS DRAWN UP,
DELIVERING IN
PARTICULAR THE
ASSESSMENT OF THE
CONSULTANT'S TEAM .

21. SOME ONCRETE ROAD PROJECTS
VISITED
PROJECTS
•LUCKNOW – MUZAFFARPUR ON NH-28,
3 PACKAGES FROM LUCKNOW TO
AYODHYA/BASTI
•DELHI – MATHURA ON NH-2
•AMBUJA CEMENT FACTORY AT ROPAR
(PUNJAB)
•MUMBAI CITY ROADS
•MUMBAI – PUNE EXPRESSWAY
•PUNE CITY ROADS
•SATARA – KOLHAPUR – KAGAL ON NH-4

22. SOME PROJECTS VISITED
(CONTD.)
•KAGAL – BELGAUM – DHARWAD ON NH-4
•SUNAKHALA - GANJAM ON NH-5
•V-A & V-B PACKAGES IN JHARKHAND & BIHAR ON
NH-2
•IV-B & IV-D PACKAGES : MOHANIA TO SASARAM
AND DEHRI-ON-SONE TO AURANGABAD IN BIHAR
ON NH-2
•VARANASI – FATEHPUR : III-C & III-A PACKAGES IN
UTTAR PRADESH ON NH-2
•ALLAHABAD BYPASS : ABP-II & ABP-III IN UTTAR
PRADESH ON NH-2
•FATEPUR-KANPUR-ETAWAH : II-C, II-B & II-A IN
UTTAR PRADESH ON NH-2

23. TYPICAL CROSS-SECTION
Median
E
d
g
e

S
h
y
n
e
s
sCarriageway
Paved
Shoulder
Shoulder
1000 1500 7000 250
2.5%
Kerb
Base
Subbase
Drainage Layer
GSB cum Drainage Layer, 150 Thk.
Dry Lean Concrete, 150 Thk.
125 Micron Polythene Sheet
Subgrade, 500 Thk.
L
C
Pavement Quality Concrete, 300 Thk.

24. USE OF ANTIFRICTION
LAYER/SEPARATION LAYER
–NORMALLY 125 MICRON THICK PLASTIC SHEET
–DOUBLE LAYER OF WAX BASED CURING
COMPOUND WAS SPRAYED IN LIEU OF
PLASTIC SHEET IN ONE PROJECT IN
RAJASTHAN
–TO USE A GEOSYNTHETIC LAYER OVER 5 TO 10
CM THICK BITUMINOUS LAYER – AN
EUROPEAN PRACTICE

25. DESIGNS FOLLOWED IN DIFFERENT PROJECTS

26. DLC CONSTRUCTION
•MIXING PLANTS: ABOUT 100 cum/hr
•PAVERS: ASPHALT PAVERS CAN BE
USED FOR THIS WORK. PAVERS WITH
ELECTRONIC SENSORS ARE NECESSARY
FOR CONTROLLING THICKNESS, LEVEL,
GRADE AND ALIGNMENT.
•ROLLERS: VIBRATORY ROLLERS ARE
NECESSARY. USE OF PNEUMATIC
TYRED ROLLERS HAVE ALSO BEEN
ABROAD TO GET SMOOTHER SURFACE.

27. MIX DESIGN
5.0 5.5 6.0 6.5 7.0
2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26
2.27
D
R
Y

D
E
N
S
I
T
Y

(
g
m
/

c
c
)
MOISTURE CONTENT (%)
MDD: 2.237 gm/ cc
OMC: 6.05 %

28. MATERIALS REQUIRED
•COARSE AGGREGATES, 25MM AND DOWN
SIZE AGG.
•FINE AGGREGATES ( SAND OR CRUSHED
STONE DUST)
•CEMENT
•WATER: SHALL CONFORM TO IS:456
•LIQUID CURING COMPOUND
(OPTIONAL)/ WATER CURING

29. CEMENT
•ORDINARY PORTLAND CEMENT:
GR. 33,43
•PORTLAND SLAG CEMENT
•PORTLAND POZZOLANA CEMENT (PPC)

30. QUALITY OF AGGREGATES
•AGG IMPACT VALUE/ LOS ANGELES
ABRASION VALUE
•FLAKINESS AND ELONGATION
•SOUNDNESS
•SP. GR. AND WATER ABSORPTION
•GRADATION-COMBINED

31. SIDE SHUTTERING
•SIDE SHUTTERING IS OPTIONAL
•WITHOUT SIDE SHUTTERING, SIDES
REMAIN LOOSE REQUIRING TRIMMING
OF EDGES
•WITH SIDE SHUTTERING, THE SIDES
ARE LIKELY TO BE HONEYCOMBED

32. A VIEW OF PAVING OPERATION

36. CURING
–APPLICATION OF LIQUID CURING
COMPOUND –NORMALLY WHITE
PIGMENTED AND WAX BASED
FOLLOWED BY WATER CURING
–PLACING OF WET HESSIAN
–PONDING
–APPLICATION OF DOUBLE LAYER OF
CURING COMPOUND
–OTHER METHODS

40. PRODUCTION OF
CONCRETE MIX

41. TYPES OF CRUSHERS

42. JAW CRUSHER

43. CONE CRUSHER

44. VERTICAL SHAFT IMPACT
CRUSHER

45. AGGREGATES
•Max. Size of 25 mm
•Los Angeles Abration : Max 35%
•Water Absorption: Max 2%
•Soundness:Not more than 12/18% Sod.
Sul/Mag. Sul respectively

46. CEMENT
•OPC : 33,43 or 53
•Sulphate resisting cement if soil around
has soluble salt like sulphate in excess of
0.5%

47. CONCRETE BATCHING
PLANT

49. LAYOUT PLAN OF A BATCHING PLANT
SITE
WORKSHOP
MAIN AGGREGATE STACKYARD
D
A
Y

B
I
N
S

F
O
R

M
A
T
E
R
I
A
L
S
PARTITION WALLS
RAMP
BINS FOR AGGREGATES OF VARIOUS SIZES
WASHING BAY
MIXING
PLANT
DUMPER
CONVEYOR
CEMENT
CONTROL CABIN
PLAT FORM
FOR
COVERING
TARPAULIN
S
I
D
E

L
A
B
CEMENT
FLY ASH
WATER
TANK

50. A VIEW OF A MODERN BATCHING PLANT

52. MOBILE SILOS

53. SEQUENCE OF MIXING
INGREDIENTS
IN A MIXER

ELAPSED TIME
FIG. 11.2. SEQUENCE OF ADDING MATERIALS IN A STATIONARY
MIX PLANT
CEMENTITIOUS
MATERIALS
AGGREGATE
WATER REDUCER
AIR (ADMIXTURE)
WATER

54. QUALITY CONTOL

56. TESTING LABORATORY

57. CONSTRUCTION WITH
FIXED FORM PAVER
FIXED FORMS AND MACHINERIES REQUIRED
•SIDE FORMS
•TRANSIT MIXER/VEHICLES TO TRANSPORT MIX
•SPREADER
•PAVER
•DOWEL BAR INSERTER( OPTIONAL)
•FINISHER
•TEXTURING MACHINE/CURING COMPOUND SPRAYING
M/C
•JOINT CUTTING SAW

58. A FIXED FORM PAVER

59. FIXED-FORM WITH PAVERFIXED-FORM WITH PAVER

60. CRACK INDUCER IN PLACE

61. A VIEW OF ANOTHER FIXED-FORM A VIEW OF ANOTHER FIXED-FORM
PAVERPAVER

65. TYPICAL LAYOUT PLAN OF A
CONCRETE PAVEMENT
CARRIAGEWAY
CONTRACTION JOINTS
LONGITUDINAL JOINTS
WITH TIE BARS
TIE RODS
M
E
D
I
A
N
EARTHEN SHOULDER TIED SHOULDER
DOWEL BARS

66. TYPES OF JOINTS
•TRANSVERSE JOINTS
•LONGITUDINAL JOINTS
•EXPANSION JOINTS
•CONSTRUCTION JOINTS
•ISOLATION JOINTS

67. SAWING WINDOW
SAWING WINDOW
TOO LATE
(CRACKING)
RESTRAINT STRESS EQUALS
CONCRETE STRENGTH
MINIMUM STRENGTH TO AVERT
EXCESSIVE SAW CUT / RAVELING
TIME
C
O
N
C
R
E
T
E

S
T
R
E
N
G
T
H
TOO EARLY
(RAVELING)

68. CONTRACTION JOINT WITH DOWEL
BAR

69. LONGITUDINAL JOINT WITH TIE-ROD
BETWEEN TWO LANES

70. EXPANSION JOINT WITH DOWEL

71. SEALANTS
•RUBBERIZED BITUMEN ( HOT POURED )
•POLYSULPHIDE( COLD)
•POLYURETHENE (COLD)
•SILICONE ( COLD)( PAVEMENT QUALITY)
•PREMOULDED NEOPRENE STRIPS

72. STRESSES GENERATED IN FIELD-
MOULDED SEALANTS DUE TO
TEMPERATURE CHANGES

73. SEALING DETAILS OF JOINTS
(GROOVES SUITABLE FOR HOT POURED
RUBBRISED BITUMEN SEALANT)

74. SEALING DETAILS OF JOINTS
(GROOVES SUITABLE FOR COLD SILICONE SEALANT)

75. SEALING DETAILS OF JOINTS
(GROOVES SUITABLE FOR COLD
POLYSULPHIDE SEALANT)

77. SEALED JOINT WITH BOTH POLYSULPHIDE
AND PRE-MOULDED STRIP
NEOPRENE SEAL WITH NEOPRENE SEAL WITH
POLYSULPHIDE SEALANTPOLYSULPHIDE SEALANT

78. CONDITION OF NEOPRENE CONDITION OF NEOPRENE
PREMOLDED STRIPS IN MUMBAI – PREMOLDED STRIPS IN MUMBAI –
PUNE EXPRESSWAYPUNE EXPRESSWAY

79. CONSTRUCTION WITH SLIP
FORM PAVER
MACHINES USED IN SLIP-FORM
CONSTRUCTION
I) PAVER
II) FINISHER
III) DOWEL BAR INSERTER
IV) TIE BAR INSERTER
V) TEXTURING M/C
VI) LIQUID CURING COMPOUND SPRAYING
M/C
VII) JOINT CUTTING M/C
VIII) MOBILE TENT

81. DOWEL PLACEMENT
•MANUAL PLACEMENT- DOWEL BAR
BASKET
•WITH DOWEL BAR INSERTER

82. TIE BAR PLACEMENT
–MANUAL PLACEMENT–PLACED ON
STEEL OR PLASTIC CHAIRS
–AUTOMATICALLY WITH MACHINE
CAPABLE OF INSERTING FROM
SIDE OR FROM THE TOP

83. MANUAL METHOD OF PLACEMENT
DOWELS AND TIE RODS
Specified spacing
d/2
d
10mm dia bars
d/2
d
Longitudinal joints
Concrete nail
Tie
TYPICAL ARRANGEMENT FOR PLACING TIE RODS
TYPICAL ARRANGEMENT OF STEEL CHAIR
ASSEMBLY FOR PLACING DOWELS

84. AUTOMATIC DOWEL BAR INSERTER

85. AUTOMATIC TIE ROD INSERTER

87. SIDE SHUTTERING REQUIRED TO
REPAIR EDGE COLLAPSE OF CONCRETE
SLAB
WOODEN OR
STEEL SHUTTERING
BRACING
CONCRETE
NAIL
COLLAPSED
EDGE

92. A BULL FLOAT OR TUBE FLOAT

93. STOP END

94. TEXTURING
TYPES
–BRISTLE
–TYNE
DIRECTION OF TEXTURING
–TRANSVERSE
–LONGITUDINAL

98. CURING PQC SLABS
•INITIAL APPLICATION OF SYNTHETIC
LIQUID CURING COMPOUND-
NORMALLY ALUMINIZED RESIN BASED
CURING COMPOUND
•PROTECTING FRESH CONCRETE
SURFACE FROM SUN RAYS WITH
MOBILE TENT FOR A SHORT TIME
•FOLLOWED BY PLACING WET HESSIAN
ON THE SURFACE AND SUBSEQUENTLY
TO KEEP IT WET CONTINUOUSLY AS
PER SPECIFICATION

101. WATER CURING

102. JOINT FORMING
TYPES OF JOINTS
I)CONTRACTION JOINT
II)LONGITUDINAL JOINT
III) EXPANSION JOINT
1V) CONSTRUCTION JOINT
v) ISOLATION JOINT

103. SAW CUTTING WINDOW

104. MATURITY METER

105. A CLOSE-UP OF CONCRETE SAW

107. INSERTION OF TEMPORARY SEAL

108. FORMING JOINT GROOVES
I) RELATED TO FIRST CUT
II) SECOND CUT
III) SOME ISSUES RELATED TO JOINTS
–MANUAL METHOD OF FORMING JOINTS IS NOT
PERMITTED IN MODERN CONCRETE ROADS
–JOINTS ARE SAWN WITH DIAMOND STUDDED
BLADES AND ARE TEMPORARY SEALED
–JONTS WIDENED TO FORM A SEALING GROOVE
ON THE TOP
–SAND BLASTING SIDES OF GROOVES
–PRIMING SIDES OF GROOVES
–SEALING JOINTS – ADOPT TECHNIQUES TO
AVOID INTRUSION OF AIR POCKET

109. SEALANTS
RUBBERIZED BITUMEN SEALANT
•THIS IS A LEAST EXPENSIVE
MATERIAL.
POLYSULPHIDE
•THE MOST WIDELY USED SEALANT
IN INDIA. THIS IS A TWO
CHEMICAL COMPOUND
SILICONE
•ONE CHEMICAL COMPOUND

110. SEALANTS (Contd.)
POLYURETHENE
•NOT USED IN INDIA BUT TRIALS
HAVE BEEN MADE IN SOME
PLACES.
PREMOULDED NEOPRENE SEALING STRIPS
•HAS BEEN USED IN A COUPLE OF
PROJECTS INCLUDING MUMBAI-
PUNE EXPRESSWAY, ALLAHABAD
BYPASS, NH-4 Etc.

112. INSERTION OF 5MM THK DEBONDING INSERTION OF 5MM THK DEBONDING
STRIP IN PROGRESSSTRIP IN PROGRESS

114. SHOULDERS
•NORMALLY THE SHOULDER WIDTH
ADOPTED IN INDIA IS 2.5 m IN
NATIONAL HIGHWAYS. BUT LATELY
SHOULDERS OF 3.5 m ALSO HAVE BEEN
ADOPTED IN SOME PROJECTS.
–HARD SHOULDER + EARTHEN
•THE LATEST TREND IN INDIAN DESIGNS
IS TO CONSTRUCT 1.5 m OF FULL DEPTH
PAVEMENT AND TO CONSTRUCT
BALANCE AS EARTHEN SHOULDER.

115. BRIEF REVIEW CONSTRUCTION PRACTICES
ADOPTED PRESENTLY IN ADVANCED
COUNTRIES
•Two-lift constructions are popular
where top layer is constructed with
high-quality aggregates are used. Low
quality or recycled agg. Are used in
lower layers
•Their foundations are deeper and
made of better quality material. In
one European country DLC
recommended is 200mm and min.
CBR recommended is 10%.

116. •Great care is given quality of concrete.
In Western Europe the flexural strength
of concrete was 7 MPa much higher than
USA and India.
•As a separation layer in Germany
geotextile layer is used in lieu of plastic
sheet over cement treated bases. In
some countries a bit layer overlaid with
geotextile layer is used instead of DLC
layer

117. •Exposed aggregate surfacing produced
with high-quality aggregates is used in
Europe to reduce noise pollution.
•In Austria Los Angeles test value
specified is 20
•The advanced countries mostly depend
Design Catalouges for designing their
roads. Now there is more empasis on
Mechanistic- Empirical Pavement Design.
•Their design life is generally 30 years
but the pavement lasts for more than 40-
50 years

118. SOME OF THE DEFICIENCIES
NOTED IN OUR CONSTRUCTIONS
–EARLY CRACKS IN NEWLY CONSTRUCTED
SLABS
–DELAY IN FORMING JOINTS
–DEFICIENT JOINT GROOVE DEPTH
–VARIATION IN STRENGTH PROPERTY OF
FOUNDATION LIKE IN CUT AND FILL
SECTIONS; ROCKY BED Etc.
–INEFFECTIVE DRAINAGE LAYER
–INADEQUACY OF SURFACE AND
SUBSURFACE DRAINAGE
–HIGH AMBIENT TEMPERATURE AND
HIGH WIND VELOCITY DURING
CONCRETING

119. SOME OF THE DEFICIENCIES NOTED IN
OUR CONSTRUCTIONS (CONTD.)
-MISPLACED DOWELS
-NON- UNIFORM SUPPORT CONDITION IN CUT AND FILL
SECTIONS
-EMBANKMENT OF BLACK COTTON SOIL
SEALANTS
-EARLY FAILURE OF LIQUID SEALANTS
-EXTRUTION OF PREMOULDED SEALING STRIPS FROM
THE JOINTS
LOWER CONCRETE STRENGTH
-RAVELED/ERODED SURFACE
-EARLY CRACKS

120. SOME OF THE DEFICIENCIES NOTED IN
OUR CONSTRUCTION (CONTD.)
•TEXTURE
-BRISTLE TEXTURE FOUND TO BE NOT VERY
DURABLE
•PAVEMENT DESIGN
-GENERALLY SATISFACTORY

121. THANK YOU