MoRT&H section for quality assurance Section 900.pptx

Dry Lean Concrete (DLC) is a Zero Slump concrete Sub-Base for wearing concrete course in conformity with the lines, grades and cross-sections shown on the drawings.

The design parameters of dry lean concrete sub-base say, width, thickness, grade of concrete, details of joints, etc. shall be as stipulated in the drawings.
CEMENT:-
Ultratech OPC 53 Grade conforming to IS 269 : 2015

AGGREGATES:-
Coarse Aggregate:-
Source:- Chikhli
Aggregates complying with IS 383.
Maximum size of the coarse aggregate is 26.5 mm.
The Aggregate Impact Value shall not exceed 35%.
The combined flakiness and elongation index of aggregate shall not be more than 35%.

1. SKILL ENHANCEMENT PROGRAMME GEO DESIGNS & RESEARCH PVT.LTD. VADODARA Geo Designs & Research (P) Ltd. 1

2. SECTION 600 : CONCRETE PAVEMENT SECTION 900 : QUALITY CONTROL FOR ROAD WORKS PREPARED BY : MR. NIRBHAY BAROT ( Technical Assistant ) MR. KARAN TEKWANI ( Material Engineer ) GUIDED BY: MR. BHAVESH PANCHAL ( Assistant Resident Engineer ) MR. C.B. LAKUM ( Resident Engineer ) MR. VIKRAMSINGH PARMAR ( Team Leader ) TOPIC Geo Designs & Research (P) Ltd. 2

3. PROJECT DETAILS Name of Work : Construction of rigid and flexible pavement on either side of existing canal along with other allied works on road from BRTS near Panas via Breadliner circle to Soham circle in south- west ( Athwa ) zone Package-18. Project Cost : 20,41,15,623.66 Rs. Project Duration : 19 Months ( including 3 months monsoon ) Client : Surat Municipal Corporation ( Road Development Department ) Design Consultant: SVNIT, Surat Consultant : Geo Designs & Research Pvt. Ltd. Contractor : J.P. Structures Pvt. Ltd. Geo Designs & Research (P) Ltd. 3

4. Latest Cross section picture Geo Designs & Research (P) Ltd. 4

5. SECTION 600 CONCRETE PAVEMENT Geo Designs & Research (P) Ltd. 5

6. DRY LEAN CONCRETE Geo Designs & Research (P) Ltd. 6

7. Dry Lean Concrete (DLC) is a Zero Slump concrete Sub-Base for wearing concrete course in conformity with the lines, grades and cross-sections shown on the drawings. The design parameters of dry lean concrete sub-base say, width, thickness, grade of concrete, details of joints, etc . shall be as stipulated in the drawings. SCOPE Geo Designs & Research (P) Ltd. 7 cl.601.1

8. As per mix design CEMENT:- Ultratech OPC 53 Grade conforming to IS 269 : 2015 AGGREGATES:- Coarse Aggregate:- Source:- Chikhli Aggregates complying with IS 383. Maximum size of the coarse aggregate is 26.5 mm. The Aggregate Impact Value shall not exceed 35%. The combined flakiness and elongation index of aggregate shall not be more than 35%. MATERIALS Geo Designs & Research (P) Ltd. 8 cl.601.2

9. Fine Aggregate:- Source:- Finer Sand: Nareshwar Aggregates complying with IS 383 WATER:- It shall meet the requirements stipulated in IS 456 – 2005 clause 5.4. The pH value of water shall be not less than 6. Geo Designs & Research (P) Ltd. 9

10. All in Aggregate Gradation for Dry Lean Concrete Table 600-1 Sieve Designation Percentage by Weight Passing the Sieve 26.50 mm 100 19.0 mm 75-95 9.50 mm 50-70 4.75 mm 30-55 2.36 mm 17-42 600 micron 8-22 300 micron 7-17 150 micron 2-12 75 micron 0-10 Geo Designs & Research (P) Ltd. 10

11. As per mix design Cement Content:- The cement content in the dry lean concrete is 150 kg/cum. Concrete Strength:- The average compressive strength of each consecutive group of 5 cubes shall not be less than, 10 Mpa at 7 days. In addition, the minimum compressive strength of any individual cube shall not be less than 7.5 Mpa at 7 days. PROPORTIONING OF MATERIALS FOR THE MIX Geo Designs & Research (P) Ltd. 11 cl.601.3

12. As per site condition Sub-Grade:- 1 st layer is of Lime Flyash Stabilised Subgrade of thickness 300 mm 2 nd layer is of Treated Existing Material with Murrum of 200 mm thickness Sub-Base:- GSB layer of thickness 150 mm above sub-grade layer Geo Designs & Research (P) Ltd. 12

13. DLC is laid on GSB layer It is cured for atleast 7 days before laying of PQC layer Placing:- DLC is laid with help of Paver having Electronic Sensors. It is done in full width of pavement. It is laid 150 mm extra from each edge for support . CONSTRUCTION Geo Designs & Research (P) Ltd. 13 cl.601.6

14. Compaction:- It is done by using Vibratory roller having 8-10 ton capacity. First and last pass without vibration and Six passes with vibration. Strength tests shall be carried out, and if deficiency in strength is noticed, at least three (evenly spread) cores of minimum 100 mm dia per km shall be cut to check deficiency in strength. The holes resulting from cores shall be restored by filling with concrete of the specified strength and compacted by adequate rodding . Rolling on DLC Geo Designs & Research (P) Ltd. 14 cl.601.6.5

15. Joints:- Transverse joint is provided at the end of the construction in a day. Longitudinal construction joint shall be provided only when full width paving is not possible. Geo Designs & Research (P) Ltd. 15 Curing:- Curing is done by covering the surface by hessian cloths, which is kept wet continuously for 7 days by sprinkling water . Curing on DLC cl.601.6.6 cl.601.6.7

16. Trial length was constructed in main work of 50 metre length in full width of 6.5 metre due to non availability of extra space and time as directed by client. TRIAL LENGTH Geo Designs & Research (P) Ltd. 16 cl.601.8

17. CEMENT CONCRETE PAVEMENT Geo Designs & Research (P) Ltd. 17

18. The work consist of construction of un-reinforced, dowel jointed, plain cement concrete pavement in accordance with the requirements of MORTH Specifications and in conformity with the lines, grades and cross sections shown on the drawings. The design parameters say, thickness of pavement slab, grade of concrete, joint details etc. shall be as stipulated in the drawings. SCOPE Geo Designs & Research (P) Ltd. 18 cl.602.1

19. As per mix design CEMENT:- Ultratech PPC (Fly Ash based) conforming to IS 1489 : 2015 Part 1 CHEMICAL ADMIXTURE:- BASF Master Polyheed 8155:- Super Plasticizer with Retarder POLYESTER FIBRE:- Recron 3S Recron 3S acts as “secondary reinforcement” in concrete which arrests cracks, increases resistance to impact & improves quality of construction Due to inclusion of fibre , design is done in such a way that slump will be 25±15 mm MATERIALS Geo Designs & Research (P) Ltd. 19 cl.602.2

20. AGGREGATES:- Coarse Aggregate:- Source:- Chikhli Aggregates complying with IS 383. Maximum size of the coarse aggregate is 31.5 mm. The Aggregate Impact Value shall not exceed 35%. The combined flakiness and elongation index of aggregate shall not be more than 35%. Water Absorption shall be less than 2%. Fine Aggregate:- Source:- Finer Sand: Nareshwar Coarser Sand: Bodeli Aggregates complying with IS 383. Geo Designs & Research (P) Ltd. 20

21. WATER:- It shall meet the requirements stipulated in IS 456 – 2005 clause 5.4. The pH value of water shall be not less than 6. All in Aggregate Gradation for Pavement Quality Concrete Table 600-3 Sieve Designation Percentage by Weight Passing the Sieve 31.5 mm 100 26.5 mm 85-95 19.0 mm 68-88 9.5 mm 45-65 4.75 mm 30-55 600 micron 8-30 150 micron 5-15 75 micron 0-5 Geo Designs & Research (P) Ltd. 21

22. Steel for Dowels:- Steel shall conform to the requirements of IS 432 and IS 1786 as relevant. The dowel bars shall conforming to lS 432 of Grade l are of Mild steel plain bars of 32 mm dia spaced at 300 mm c/c, 450 mm long covered by PVC sheath of 275 mm long. Craddle is provided to support Dowel Bars made up of 4 longitudinal MS bars of 8 mm dia welded on chairs of size 145mm*250mm*145mm spaced at 300 mm c/c. Craddles of dowel bars Geo Designs & Research (P) Ltd. 22 cl.602.2.8

23. Steel for Tie Bars:- Tie bars are TMT bars conforming to IS1786 and grade of Fe 500 of 12 mm dia spaced at 800 mm c/c, 640 mm long having central 150 mm length coated with bituminous paint. 2 Longitudinal bars of TMT 8 mm dia to support projected end of tie bar. Tie Bars in PQC layer Geo Designs & Research (P) Ltd. 23 cl.602.2.8

24. Joint Sealing Compound:- The joint sealing compound is of cold poured polysulphide type Choksey Techseal having flexibility, resistance to age hardening and durability as per IRC:57. From MTC it is confirmed that the sealant is not older than 6 months as per MORTH requirement. For polysulphide sealant referance codes are IS:11433 (Part I) and BS 5212:1990 (Part II) Geo Designs & Research (P) Ltd. 24 cl.602.2.10

25. As per mix design Cement Content:- The cement content in the Pavement Quality Concrete is 410 kg/cum Concrete Strength:- The characteristic flexural strength of concrete shall not be less than 4.42 Mpa unless specified otherwise. Target mean flexural strength for mix design shall be more than 0.7*√(Target mean compressive strength), for M-40 grade. Quality control in the field is exercised on the basis of flexural strength. Water –Cement Ratio is 0.37 PROPORTIONING OF MATERIALS FOR THE MIX Geo Designs & Research (P) Ltd. 25 cl.602.3

26. Workability is checked by Slump test as per IS 1199 at plant and observed slump value is 25±15 mm conforming to MORTH requirements. These tests shall be carried out on every tipping truck/dumper at batching and mixing plant site and paving site initially when the work commences but subsequently the frequency can be reduced to alternate tipping trucks or as per the instructions of the Engineer . WORKABILITY Geo Designs & Research (P) Ltd. 26 Slump Test cl.602.3.4

27. The cement concrete pavement is laid over the sub-base constructed in accordance with the relevant drawings and Specifications. It is ensured that the sub-base is not damaged before laying the concrete pavement. If the dry lean concrete sub-base is found damaged at some places or it has cracks wider than 10 mm, it shall be repaired with fine cement concrete (aggregate size 10 mm and down) or bituminous concrete before laying separation membrane layer. SUB BASE Geo Designs & Research (P) Ltd. 27 cl.602.4

28. A separation membrane is used between the concrete slab and the sub-base. Separation membrane is impermeable PVC sheet 125 micron thick black colour laid flat with minimum creases. Before placing the separation membrane, the sub-base is swept clean of all the extraneous materials manually. Wherever overlap of plastic sheets is necessary, the same is kept 300 mm. SEPARATION MEMBRANE Geo Designs & Research (P) Ltd. 28 Separation Membrane cl.602.5

29. The locations and type of joints are as shown in the drawing. Joints are constructed depending upon their functional requirements. The location of the joints are transferred accurately at the site and mechanical saw cutting of joints done as per stipulated dimensions. It is ensured that the required depth of cut is made from edge-to-edge of the pavement. Joints in the Pavement and Dry Lean Concrete sub-base are staggered so that they do not coincide vertically and Transverse joints are at least 800 to 1000 mm and Longitudinal joints are 300 to 400 mm apart respectively. JOINTS Geo Designs & Research (P) Ltd. 29 cl.602.6

30. Transverse Joints:- Transverse joints are of contraction and construction types constructed at the spacing described in the drawings. Transverse joints are straight within the following tolerances along the intended line of joints i ) The best fit straight line through the joint grooves as constructed shall be not more than 25 mm from the intended line of the joint. ii) Deviations of the joint groove from the best fit straight line of the joint shall not be greater than 10 mm. iii) Transverse joints on each side of the longitudinal joint shall be in line with each other and of the same type and width. Transverse joints shall have a sealing groove which shall be sealed. Geo Designs & Research (P) Ltd. 30 cl.602.6.2

31. Contraction Joints:- The contraction joints are placed transversely at pre-specified locations as per drawings/design using dowel bars. These joints are cut as soon as the concrete has undergone initial hardening and is hard enough to take the load of joint sawing machine without causing damage to the slab. Contraction joints consist of a mechanical sawn joint groove, 3 to 5 mm wide and one-third depth of the slab ±5 mm. Contraction joint are widened subsequently to accommodate the sealant as per dimensions shown on drawings. Geo Designs & Research (P) Ltd. 31 cl.602.6.2.2

32. Transverse Construction Joints:- Transverse construction joint is placed at completion of a day's work by inserting stopper and dowel bars After minimum 14 days of curing, in case OPC cement is used and 16 days of curing when flyash or blended cement is used, the construction joint shall be widened to accommodate the sealant to dimensions shown on drawing. Geo Designs & Research (P) Ltd. 32 cl.602.6.3

33. Longitudinal Joint:- The longitudinal joints shall be constructed by sawing as per details of the joints shown in the drawing. Sawed longitudinal joints shall be constructed when the concrete pavement placement width exceeds 4.5 m. The groove may be cut after the final set of the concrete. Joints should be sawn to at least one-third the depth of the slab ±5 mm as indicated in the drawing. The joint shall be widened subsequently to dimensions shown on the drawings. Where adjacent lanes of pavement are constructed separately using slip form pavers or side forms, the tie bars may be bent at right angles against the vertical face/ side of the first lane constructed and straightened before placing concrete in the adjacent lane. Geo Designs & Research (P) Ltd. 33 cl.602.6.4

34. Concreting during Monsoon Months:- Concreting should be avoided during rainy season. However, when concrete is being placed during monsoon months and when it may be expected to rain, sufficient supply of tarpaulin or other waterproof cloth shall be provided along the line of the work. Any time when it rains, all freshly laid concrete which had not been covered for curing purposes shall be adequately protected. Any concrete damaged by rain shall be removed and replaced. If the damage is limited to texture, it shall be retextured in accordance with the directions of the Engineer. WEATHER AND SEASONAL LIMITATIONS Geo Designs & Research (P) Ltd. 34 cl.602.7

35. Temperature limitation:- No concreting shall be done when the temperature of the concrete reaching the paving site is above 30°C. Besides, in adverse conditions like high temperature, low relative humidity, excessive wind velocity, imminence of rains etc., tents on mobile trusses may be provided over the freshly laid concrete for a minimum period of 3 hours as directed by the Engineer. To bring down the temperature, if necessary chilled water or ice flakes should be made use of. When the ambient temperature is more than 35°C, no concreting shall be permitted. No concreting shall be done when the concrete temperature is below 5°C and the temperature is further falling. Geo Designs & Research (P) Ltd. 35

36. Use of guidewires : - For slip form paving, guidewires are provided along both sides of the pavement. Each guidewire should be at a constant height above and parallel to the required edges of the slab. Both the wires are kept at a constant horizontal distance from the required edge of the pavement. The guidewires are supported on stakes 5-6 m apart by connectors capable of fine horizontal and vertical adjustment. The ends of the guidewires are anchored to fixing point and winch. On the curves, the stakes shall be fixed at not more than 3 m centre-to-centre. The stakes are positioned and hammered into the ground and the connectors will be maintained at their correct height and alignment It is ensured that the stakes and guidewires are not affected by the construction equipment when concreting is in progress. SLIP FORM PAVING Geo Designs & Research (P) Ltd. 36 cl.602.8.3

37. Equipment for Proportioning of Materials and Paving:- Proportioning of materials was done in the batching plant by weight, each type of material being weighed separately. Batching Plant and Equipment:- General Automatic weighing devices Mixer Control Cabin Paving Equipment:- Slip form paver Concrete Saw:- CONSTRUCTION Geo Designs & Research (P) Ltd. 37 cl.602.9

38. Hauling and placing of concrete: - Construction by Slip form paver:- The slip form paver consists of a power machine which spreads, compacts and finishes the concrete in a continuous operation. The level of the conforming plate and finishing beams is controlled automatically from the guide wires installed by sensors attached at the four corners of the slip form paving machine. The alignment of the paver is controlled automatically from the guide wire by at least one set of sensors attached to the paver. Tube Floating:- Geo Designs & Research (P) Ltd. 38

39. Brush Texturing:- The surface texture shall be applied evenly across the slab in one direction by the use of a wire brush not less than 450 mm wide but wider brushes normally of 3 m length are preferred. The brush shall be made of 32 gauge tape wires grouped together in tufts placed at 10 mm centers. The tufts shall contain an average of 14 wires and initially be 100 mm long. The brush shall have two rows of tufts. The rows shall be 20 mm apart and the tufts in one row shall be opposite the centre of the gap between tufts in the other row. The brush shall be replaced when the shortest tuft wears down to 90 mm long. SURFACE TEXTURE Geo Designs & Research (P) Ltd. 39 cl.602.9.11 Texturing

40. After the surface texturing, the surface and sides of the slab are cured by the application of curing compound Shalicure STP. The curing compound is sprayed in two applications to ensure uniform spread. The compound shall become stable and impervious to evaporation of water from the surface of the concrete within 60 minutes of application and shall be of approved type. The pavement is covered by moist hessian laid in two layers and the same were then kept damp for a minimum period of 14 days after which the hessians are removed. CURING Geo Designs & Research (P) Ltd. 40 cl.602.9.12

41. Geo Designs & Research (P) Ltd. 41 Application of Curing Compound Curing on PQC

42. Preparation of Joint Grooves for Sealing:- Grooves are saw cut in the first instance just to provide minimum width(3-5 mm) to facilitate development of crack at joint locations. Subsequently before sealing, grooves are widened by sawing as per the dimensions in the drawing. All grooves are cleaned of any dirt or loose material by air blasting with filtered, oil-free compressed air. Sealing with Sealant:- Priming and sealing with applied sealants shall not be carried out when the naturally occurring temperature in the joint groove to be sealed, is below 7°C. Cold applied sealants with chemical formulation like polysulphide / polyurethene / silicone as per IRC:57 shall be used. PREPARATION AND SEALING OF JOINT GROOVES Geo Designs & Research (P) Ltd. 42 cl.602.10

43. Geo Designs & Research (P) Ltd. 43

44. Trial length was constructed in main work of 50 metre length in full width of 6.5 metre due to non availability of extra space and time as directed by client Joints Density Strength For cylindrical specimen of dia 100 mm, the variation in dia shall be ± 0.3 mm, and a tolerance on height shall be ±1 mm for a specimen height of 200 mm. Concrete in the member represented by a core test shall be considered acceptable, if the average equivalent strength of the cores is equal to at least 85 percent of the cube strength (characteristic strength) of the grade of the concrete specified for the corresponding age of 28 days and no individual core has a strength less than 75 percent. TRIAL LENGTH Geo Designs & Research (P) Ltd. 44 cl.602.11

45. SECTION 900 QUALITY CONTROL FOR ROAD WORKS 45 Geo Designs & Research (P) Ltd.

46. A process of implementation and maintenance of standard specifications to confirm that the work meets the expected quality as per requirements of project. Expected quality can be ensured through performance of necessary tests, site checking and satisfactory results as per requirements of specifications . Quality in construction can be said to have been achieved if it is completed without time and cost overruns, ensuring the required serviceability, durability and safety, without undue maintenance. What is Quality Control ? 46 Geo Designs & Research (P) Ltd.

47. The materials to be used, methods to be adopted and works to be executed should be strictly in accordance with the requirements of specification. Field Laboratory should be located & set up with adequate equipments in order to carry out all the required tests as directed by Engineer in-charge . (see cl.120) Essential facilities such as water supply, electric supply, sanitary facilities, space for storage of material, curing tank etc. should be provided and got approved from the Engineer in-charge in advance. Fundamental requirements for Q.C. 47 Geo Designs & Research (P) Ltd. cl.901.1,2 & 8

48. The method of sampling and testing of materials should be in accordance with the requirements of the relevant Standards and specifications. For every lot of incoming materials like cement, steel, admixture etc. Manufacturer’s test certificate and invoice/delivery challan shall be furnished. In addition, modifications in the procedure of work can be done, if found necessary, as directed by the engineer. The list of test equipments available in field laboratory are mentioned in following table: 48 Geo Designs & Research (P) Ltd. cl.901.10 & 11

49. Sr. No. Name of Equipment Method of test confirming IS 1 Compression Testing Machine IS: 516 2 Flexural Testing Machine IS: 516 3 Sieves set IS: 2386 Part-1 4 Flakiness & Elongation Apparatus IS: 2386 Part-1 5 Impact Testing Machine IS: 2386 Part-4 6 Casagranda Apparatus IS: 2720 Part-5 7 Slump cone & Tamping rod IS: 1199 8 C.B.R. Testing Machine ( Third party lab) IS: 2720 Part-16 9 Sand pouring cylinder IS: 2720 Part-28 10 Cube & Beam moulds IS: 10086 List of Field laboratory test equipments 49 Geo Designs & Research (P) Ltd.

50. Sr. No. Name of Equipment 11 Electronic weighing balance 12 Electrically operated Oven 13 Thermometer 14 Vibratory table & Vibratory Hammer 15 Gas stove 16 Water Bath 50 Geo Designs & Research (P) Ltd.

51. The testing is also done at laboratories other than field lab for which samples of materials are collected, sealed and sent for testing to the Government approved third party laboratory and GERI/Government engineering college laboratory. Frequency of test to be performed in different Laboratory as per requirement of client:- 51 Geo Designs & Research (P) Ltd.

52. Sr. No. Name of Material & Manufacturer Source 1 Cement – Ultratech OPC 53 Grade & PPC Magdalla, Surat 2 Fine Aggregate/Sand Nareshwar & Bodeli 3 Coarse Aggregate Chikhli 4 Steel – National Anjar , Kutchh 5 Murrum Areth-Mandvi , Surat 6 Flyash Reliance- Hazira , Surat 7 Curing compound STP Ltd, Mumbai 8 Admixture – BASF 8155 Master polyheed Turbhe , New Mumbai 9 Polyester Fiber Recron 3S – Reliance Hoshiyarpur , Punjab 10 Water Bore well at Plant 11 Paver Block – Kismat tiles Pipodara 12 Kerb Stone – Kismat tiles Pipodara 13 Hydrated Lime – Maruti lime chem. Ltd Vadodara 14 NP3 Pipe – Shreeji Krupa Bodeli 15 Sealent – Techseal Choksey Chemicals, Mumbai List of Materials & their sources 52 Geo Designs & Research (P) Ltd.

53. Sample of the materials 53 Geo Designs & Research (P) Ltd.

54. Defective Material : Materials found not conforming to the requirements of the contract shall be rejected and immediately removed from site as per instruction of the engineer. If non compliance of the instruction, then the engineer have authority to cause the removal of rejected material from site and cost for removal of such material shall be deducted from contractor’s bill. Materials which have been subsequently corrected, shall not be used in the work unless writing approval of the engineer. 54 Geo Designs & Research (P) Ltd. cl.901.13

55. Imported Material: The Contractor should provide a list of materials or finished products which are manufactured & imported from outside India. The certificate of compliance of the tests carried out for such materials required which shall conform to the relevant specifications of the contract. Time limit shall not be extended for acts or events occurring outside India causing delay in delivery of material. 55 Geo Designs & Research (P) Ltd. cl.901.14

56. Sr. No. Particulars Reference of IS Frequency 1 Cement -Physical test -Chemical test IS:269 IS:8112 lS:12269 lS:1489(Part-I) IS:455 Once for each source of supply and in case of long or improper storage. 2 Aggregates -Gradation IS:2386(Part-1) 1 test for every day's work of each fraction of coarse aggregate and fine aggregate. -Deleterious constituents IS:2386(Part-2) 1 test for every day's work of each fraction of coarse aggregate and fine aggregate. - Aggregate impact test or L.A. abrasion value IS:2386(Part-4) Once for each source of supply and subsequently on monthly basis. Frequency of quality control tests as per MORT&H 56 Geo Designs & Research (P) Ltd. cl.903.5.2.5, Table 900-6

57. Sr. No. Particulars Reference of IS Frequency - Water absorption IS:2386(Part-3) Regularly as required subject to a minimum of one test a day for coarse aggregate and two tests a day for fine aggregate. This data shall be used for correcting the water demand of the mix on a daily basis - Soundness IS:2386(Part-5) Before approving the aggregates and every month subsequently. -Alkali aggregate reactivity IS:2386(Part-7) Before approving the aggregates and every month subsequently. 3 Water -Chemical Tests IS:456 Once for approval of source of supply, subsequently only in case of doubt. 4 Concrete -Strength of concrete IS:516 Minimum 6 cubes and 6 beams per day's work, 3 cubes & 3 beams for both 7 & 28 day’s strength. - Core strength on hardened concrete IS:516 Min. 2 cores per 150 cu.mt. or As per the requirement of the Engineer, only in case of doubt. 57 Geo Designs & Research (P) Ltd.

58. Sr. No. Particulars Reference of IS Frequency - Workability of fresh concrete IS:1199 1 test per each dumper load at both Batching plant site and paving site initially when work starts. Subsequently sampling may be done from alternate dumper. - Thickness determination From the level data of concrete pavement surface and sub-base at grid points of 5m or 6.25m x 3.5m - Verification of level of string line in the case of slip form paving and steel forms in the case of fixed form paving String line or steel forms shall be checked for level at an interval of 5.0 m or 6.25 m. The level tolerance allowed shall be ± 2mm. These shall be got approved 1-2 hours before the commencement of the concreting activity. 58 Geo Designs & Research (P) Ltd.

59. The material used and the work carried out by the agency should conform to the specifications for the relevant items of work. For ensuring the requisite quality of construction, the materials and works shall be subjected to quality control tests like: Quality Control tests during construction Sieve Analysis Aggregate Impact Value 59 Geo Designs & Research (P) Ltd. cl.903

60. Compressive strength test Slump test Flexural strength test FI&EI test 60 Geo Designs & Research (P) Ltd.

61. Sr. No. Particulars Test Req. Frequency (min.) 1 Lime/Fly ash stabilized soil Subgrade 1) Quality of Lime One test for each consignment subjected to a minimum of 1 test per 5 tones 2) Lime/Cement content Regularly, through procedural checks 3) CBR Test on a set of 3 specimens As required 4) Moisture content prior to compaction One set of 2 tests per 500 sq.mt 5) Density of compacted layer One set of 2 tests per 500 sq.mt 6) Deleterious constituents As required Frequency of quality control tests for concrete pavement 61 Geo Designs & Research (P) Ltd.

62. Sr. No. Particulars Test Frequency (min.) 2 Granular Sub base Gradation 1 test per 400 cum 2) Moisture content prior to compaction 1 test per 400 cum 3) Density of compacted layer 1 test per 1000 cum 4) Deleterious constituents As required 5) CBR As required 3 Dry Lean Concrete (Base Course) Gradation 1 Test per day’s work 2) Aggregate Impact Value 1 Test for each source of supply & on monthly basis. 3) FI-EI Value 1 Test per day’s work 4) FDD 1 Test per 1000 sq.mt. 5) Workability For each dumper load per day’s work 6) Compressive strength (Cubes) Min. 5 Cubes for 7 days strength test 62 Geo Designs & Research (P) Ltd.

63. Sr. No. Particulars Test Frequency (Min.) 4 Pavement Quality Concrete (Wearing Course) Gradation 1 Test per day’s work 2) Aggregate Impact Value 1 Test for each source of supply & on monthly basis. 3) FI-EI Value 1 Test per day’s work 4) Workability For each dumper per day’s work at Plant & Site 5) Temperature For each dumper per day’s work at Plant & Site 6) Texture depth Once in a week & when required by engineer 7) Compressive strength (Cubes) Min. 6 Cubes, 3 for each 7 & 28 days strength test 8) Flexural strength (Beams) Min. 6 Beams, 3 for each 7 & 28 days strength test 9) Core strength on hardened concrete Min. 2 cores per 150 cum 63 Geo Designs & Research (P) Ltd.

64. The testing frequencies set forth are the desirable minimum and the Engineer have the full authority to carry out additional tests frequently if necessary, to satisfy himself that the materials and works comply with the appropriate specifications. The number of tests recommended may be reduced at the discretion of the Engineer if it is felt that consistency in the quality of materials can still be maintained with the reduced number of tests. 64 Geo Designs & Research (P) Ltd. cl.903.1

65. Dry Lean Concrete (Sub-base course): Laying of Dry lean concrete of grade M-10 on granular sub base. 65 Geo Designs & Research (P) Ltd. cl.903.5.1

66. Sampling and Testing of Cubes: Samples for making cubes shall be taken from the loose material before compaction from different locations at the rate of 5 samples per day’s work for surface area of each 1000 sq.mt. or part thereof laid for 7 days strength test. Cubes shall be made in accordance with the methods described in relevant standard except that the cubes shall be compacted by means of a vibratory hammer with the moulds placed on a level and rigid base. The vibrating hammer shall be electric or pneumatic type fitted with a square or rectangular foot having an area of between 7500 to 14000 sq.mm. 66 Geo Designs & Research (P) Ltd. cl.903.5.1.1

67. The compaction shall be uniformly applied for 60 ± 5 seconds with a downward force of between 300 N and 400 N on to each of the three layers of the lean concrete material placed into the mould. The surface of each compacted layer shall be scarified before the next layer is added. The final layer shall be finished flush with the top of the cube mould. The average compressive strength of each consecutive group of 5 cubes shall not be less than 10 MPa at 7 days & compressive strength of any individual cube shall not be less than 7.5 MPa at 7 days. 67 Geo Designs & Research (P) Ltd. cl.903.5.1.1

68. Pavement Concrete : Pavement quality concrete is a wearing course having M-40 grade of concrete laid on dry lean concrete. 68 Geo Designs & Research (P) Ltd. cl.903.5.2

69. Sampling and Testing of Beam and Cube Specimens: Minimum 6 pair of beam and cube specimens are casted, three pair for each 7 days and 28 days strength tests for every 150 cu.mt. or part thereof of concrete placed during construction. On each day's work, not less than 3 pairs of beams and cubes shall be made for each type of mix from the concrete delivered to the paving site. 69 Geo Designs & Research (P) Ltd. cl.903.5.2.1

70. Each pair shall be from a different delivery of concrete and tested at a place to be designated by the Engineer in accordance with the testing procedure. Groups of four consecutive results from single specimens tested at 28 days shall be used for assessing the strength for compliance with the strength requirements. Quality control reports indicating the strength values of individual specimens should be maintain for continuous quality assurance. 70 Geo Designs & Research (P) Ltd. cl.903.5.2.1

71. Where the quality of the concrete or its compaction is in suspect, the actual strength of the concrete in the slab shall be ascertained by carrying out tests on cores cut at the rate of 2 cores for every 150 cu.mt. of concrete. The average of the results of crushing strength tests on these cores shall not be less than 0.8x0.85 times the corresponding characteristic compressive strength of cubes. If the tests on cores confirm that the concrete is not satisfying the strength requirements, then the concrete corresponding to the area from which the cores were cut should be replaced, at least over an area extending between two transverse joints. 71 Geo Designs & Research (P) Ltd. cl.903.5.2.1

72. Control of Alignment and Level Horizontal alignment: - It is checked with respect to the centre line of the carriageway. - The edges of the carriageway as constructed shall be correct within a tolerance of ± 10mm. - The edges of the road way and lower layers of pavement shall be correct within a tolerance of ± 25mm. 72 Geo Designs & Research (P) Ltd. cl.902.2

73. Surface Levels The levels of sub grade and different pavement courses should not vary with reference to the longitudinal and cross-profile of road shown on the drawings beyond the tolerances mentioned in following table: Tolerances in Surface Levels 1 Sub grade ± 20 mm 2 Sub-base Flexible Pavement Concrete Pavement ± 10mm ± 6mm 3 Base-course for flexible pavement - Bituminous Base/Binder course -Granular: i ) Machine laid ii) Manually laid ± 6mm ± 10mm ± 15mm 4 Wearing courses for flexible pavement i ) Machine laid ii) Manually laid ± 6mm ± 10mm 5 Cement concrete Pavement ± 5mm 73 Geo Designs & Research (P) Ltd. cl.902.3, Table 900-1

74. - The negative tolerance for wearing course is not permitted in conjunction with the positive tolerance for base course. Level checking for Sub-grade, Sub-base & Base course - For checking compliance, levels shall be taken on a grid of points placed at 6.25 m longitudinally and 3.5 m transversely. - For any 10 consecutive measurements taken longitudinally or transversely, not more than one measurement shall be permitted to exceed the tolerance as above, this one measurement being not in excess of 5 mm above the permitted tolerance. 74 Geo Designs & Research (P) Ltd.

75. Level checking for Wearing course: - Measurements of the surface levels shall be taken on a grid of points spaced at 6.25 m along the length and at 0.5 m from the edges and at the centre of the pavement. - In any length of pavement, compliance shall be deemed to be met for the final road surface, only if the tolerance given above is satisfied for any point on the surface. 75 Geo Designs & Research (P) Ltd.

76. THANK YOU Geo Designs & Research (P) Ltd. 76