Construction of Concrete Pavement in Packages II-A, II-B and II-C (World Bank Project) at Kanpur - A Case Study

Construction of Concrete Pavement in Packages II-A, II-B & II-C of NHAI (World Bank Project) at Kanpur
Construction of Concrete Pavement in Packages II-A, II-B and II-C (World Bank Project) at Kanpur - A Case Study
NH-2, Highway Section from Km.393 (Sikandra) to Km.115 (Khaga) Totaling a length of 190 Kms
SRINAGAR DELHI
NH-2, Package IIA, IIB & IIC
SILCHAR PORBANDAR
1. The length of Golden Quadrilateral > Delhi-KolkataChennai-MumbaiDelhi = Km. 5,846 The length of Eastwest-North-South Corridor = Km. 7,300
KOLKATTA
MUMBAI CHENNAI KOCHIN KANYAKUMARI
2.
INTRODUCTION
NATIONAL HIGHWAYS DEVELOPMENT PROJECT (NHDP), the largest infrastructure development project undertaken in independent India, envisages development of 14,000 Km of world class 4/6 lane highways connecting all corners of the country. It includes:
The Golden Quadrilateral: Comprising the metros DelhiKolkata-Chennai-Mumbai-Delhi circuit of 5,846 Km length. Project Cost: over Rs. 25,050 crore. North-South & East-West Corridors : Involving a distance of 7,300 km and costing over Rs. 30,000 crore, connecting Kashmir with Kanyakumari and Silchar with Porbandar.
The project Road is part of NH-2 (Delhi Calcutta), which forms part of the Golden quadrilateral
The present daily Traffic varies between 10000 20000 PCUs.

The Projected Traffic by year 2025 is 75000 170000 PCUs with the growth of industry and economy The existing Road is proposed to widen to 4/6 lane under World Bank assistance under Grand Trunk Road Improvement Project (GTRIP).
The designer has designed the rigid pavement for a design life of 30 years. The PCA method (The Portland Cement Association) has been used for thickness design of new rigid pavement.
SALIENT FEATURES OF RIGID PAVEMENTS

Item
Specification Total Length Width Thickness Joint Spacing (Transverse Joint) Dowels (Length, Diameter, Spacing) Tie Bars (Length, Diameter, Spacing) Separator Expansion Joint
Package II-A
MORT&H and Addendum 79.80 Km. 8.75 m 320-330 mm 4.5m C/C 450 mm, 36 mm dia (MS bar), 300 mm C/C 450 mm, 12 mm deformed, 350 mm C/C 125 Micron Thick Polythene Sheet 300 m C/C or at end of days work (Now eliminated) Flexural Strength of beam - 4 Mpa (min), Target Mean strength 5MPa
Package II-B
MORT&H and Addendum 19.86 Km. 8.75 m 330 mm 4.5m C/C 450 mm, 36 mm dia (MS bar), 300 mm C/C 600mm, 12mm deformed, 500 mm C/C 125 Micron Thick Polythene Sheet 300 m C/C or at end of days work Flexural Strength of beam - 4 Mpa (min), Target Mean strength 5MPa
Package IIC
MORT&H and Addendum 93.87 Km. 8.75 m 330 mm 4.5m C/C 450 mm, 36 mm dia (MS bar), 300 mm C/C 450mm, 12mm deformed, 350 mm C/C 125 Micron Thick Polythene Sheet 300 m C/C or at end of days work (Now eliminated) Flexural Strength of beam - 4 Mpa (min), Target Mean strength 5MPa
Specified Strength
Item Slip Form Paver with Automatic Dowel bar & Tie Bar inserter Kerbs Batch Plant
Package II-A Wirtgen SP 850 (2 Nos.) Slip Form - Separate Steelfield 250 m3 / hr
Package II-B Wirtgen SP 850 (1 Nos.) Slip Form Separate Stetter (2 Nos.) each of 120 m3 / hr
Package IIC
Gomaco GHP 2800 Slip Form Separate Stetter each of 120 m3 /hr
Tippers
Average Production Rate
Volvo 25 ton X 20 Nos.

2.9 Km. per month
Volvo 25 Ton X 16 Nos.

3.0 Km. per month (Max. 5.5 Km. in a month)
TATA 25 Ton X 25 Nos.

1.5 Km. per Month
Mix Design for Contract Package II A

Ingredients Cement Content Water Content Water Cement Ratio Coarse Aggregate (20 mm) Coarse Aggregate (10 mm) Quantity 370 Kg 148 Lit 0.40 791 Kg 264 Kg
Coarse Aggregate Ratio (20/12.5) Fine Aggregate

CA / FA Ratio Admixture : Plasticizer SP 430 A1 (PQC) Air Entrainer : AEA
75 : 25 828 Kg
56 : 44
2300 ml
185 ml
Mix Design for Contract Package II B

Ingredients Quantity
Cement Content Water Content Water Cement Ratio Coarse Aggregate (20 mm) Coarse Aggregate (10 mm) Coarse Aggregate Ratio (20/12.5) Fine Aggregate CA / FA Ratio Admixture : Plasticizer SP 430 A1 (PQC) Air Entrainer: AEA
370 Kg 148 Lit 0.40 773 Kg 342 Kg 69 : 31 683 Kg 62 : 38 2590 ml 185 ml
Mix Design for Contract Package II C

Ingredients Cement Content Water Content Water Cement Ratio Coarse Aggregate (20 mm) Coarse Aggregate (12.5 mm) Coarse Aggregate Ratio (20/12.5) Fine Aggregate CA / FA Ratio Admixture : Plasticizer T101S Air Entrainer Quantity 380 Kg 152 Lit 0.40 597 Kg 597 Kg 50 : 50 663 Kg 64 : 36 2280 ml NIL
Key Points
1. During initial trials excessive bleeding, resulted in development of shrinkage cracks. It was controlled by introduction of Air Entraining Agent. Fresh concrete deposited over the filler board due to incorrect installation at construction joints and got in touch with old concrete face. This resulted in spalling of concrete at joints. Correct depth of joint filler board is to be maintained. Exposure of construction joints to local traffic before filling of joint sealant, got partially damaged at transverse edges. Any type of traffic should not be allowed before filling of sealant in all type of joints.
2.
3.
4.
Brush finish done in some reach reflected low durability after opening to traffic. Tine finish is substituted for better durability of roughness.
TYPICAL X-SECTION OF PQC
Plan of Joints in PQC

1500 8750 3625 3625
CC Shoulder
4500
4500
Longitudinal Joint
3 mm wide
Transverse Joint
8-10 mm wide
4500
Median Side
Typical Distribution Plan for Dowel Bars / Tie Bars

8750 1500 3625 3625
4500
Dowel Bars (450 mm long), MS 36mm
(@300 mm C/C)
Tie Bar (600 mm long), Tor Steel
4500
12mm (@ 500 mm C/C)
4500
A.
Inflow of Material 1. 2. 3. 4. 5.
Material
Selection of Quarry / Beds / Physical Properties Production Pattern of Stone Crushing Plants - Jaws; Cone; Impact; Roller. Feed to Crusher/Production/Storage Production Pattern Inflow to Construction Camps/Sites
B.
Processing of Material Ingredients

1. 2. 3. Stack Yards/Stacking of Materials Lab Control Field Control
C.
Finished Product / Services 1. 2. Method of Delivery from Stack Yards to Plant & Site Execution Activities related to Concrete Mix
CONCRETE BATCHING PLANT
capacity 120 Cum/Hr

1. 3. 5. Pollution Control / Safety Measures Handling of Material Lab Control Gradation, Slump, Cubes, Beams, 2. 4. 6. Calibration / Operation Temperature Control Chilling Plant & Night working Cleaning / Maintenance
SLIP FORM CONCRETE PAVER
Paving screed 9M wide by 0.35M thick. Paving speed 0.5 to 1.5M per min.
Net output @ 110cum/Hr to 325 cum/Hr.
Transport trucks are Backbone of paving operation
An uninterrupted communication between concrete plant and unloading site to be ensured.
Transport trucks are Backbone of paving operation

The loaded dumpers to have the priority of movement. Good maintenance of Service Roads and Sprinkling of water
Bucket door to be properly locked during transportation to avoid leakage of slurry. Mirrors to be installed on left & right of the vehicle. Proper lights during night operation.
Acoustic warning signal to operate during reverse.

Dumpers to be covered by using a removable sheet covering and protecting the entire bucket so that there is : no sun access to the concrete
no wind access during transportation

no rain access no dust access
The cover need to protect the bucket from sun and dust on the way back to the batching plant.
DLC: TRANSPORTATION & UNLOADING
The Surface of Drainage Layer (Sub-base for rigid pavement) to remain moist before laying of DLC (the base-course layer of rigid pavement).
DLC LAYING BY PAVER
Moisture loss to be minimized during haulage and laying of Dry Lean Concrete.
Uninterrupted running of DLC Paver minimize cold joints and surface cracks. Minimum 7days curing by gunny bags / Hessian cloth and sprinkling of water.
SEQUENCE OF COMPACTION FOR DLC
752
DLC DL
DLC
Open Vibration Close Vibration
(B) 1 Completed Zone (5) (4) (3) (2) (A) 2 (1)
Vibration starts from lower end, covering entire width in each pass with offsets
DLC COMPACTION
Starting from lower edge towards upper edge Vibration in forward direction with plain pass in reverse. Controlled speed in forward and reverse movements. No stoppage of roller on the green Bed
FINISHED DLC SURFACE BEING CURED BY SPRINKLING OF WATER
Adequate barricading to avoid movement of villagers and animals
Preparation of Surface for PQC Paver

Compacting Shoulder for PQC Paver Track Care taken not to damage the DLC edge
Alignment for PQC Paver

Steel Pegs of sensor wire to be fixed in obstruction free area and secured for safety In case of night working, sensor wire to be fixed during day light and protected
Laying Polythene Sheet ( 125 ) over DLC
Any foreign material / loose aggregates to be cleaned before spreading the sheet. Wrinkles are avoided during placing Longitudinal overlaps to start from higher end of DLC towards lower end Sheet to be secured by umbrella cap GI Pins
OPERATION OF SLIP FORM PAVER
Paving unit to be cleaned free of any remaining concrete of previous day operation. All Grade and Steering sensors to be installed correctly All inbuilt vibrator needles to be checked for their function All reservoirs for water, fuel, hydraulic oils etc. to be sufficient for days work.
PQC Laying
Unloading Concrete
Use of higher capacity dumpers to
minimize movement on Ploythene Sheets. Dumpers equipped with acoustic warning signals. Caution on Super elevated portions to avoid overturning. Dumping in two rows by Dumpers to facilitate even distribution by bucket spreader. Care taken not to damage the Polythene Sheet during movement of equipments
Spreading Concrete by Backhoe in front of PQC Paver
Laying of Concrete Mix

Uniform distribution of Concrete by
bucket spreader
Inbuilt Concrete Vibrators in PQC Paver are regularly checked for vibration
Placing of Dowel Bars and Tie Bars

Sufficient stock of Tie Bars for days work Tie Bars to be straight & correct in dimension. It helps in regular Placing of Tie Bars.
Dowel Bar Magazine & conveyor Dowel Bars to be cut correct in length and alignment and properly fitted in PVC Caps. All slots of trolley conveyor to be
checked for proper functioning Sufficient stock of Dowel Bars for days work
VIEW OF DOWEL BARS
End of Stopper /PVC capped end exposed
Quality Control Behind the PQC Paver

Leveling of Top Surface by Finishing Beam Correct workability of concrete is very important for smooth finish.
Troweling by Super Smoothener
FINISHING AND TEXURING Finishing by Sack, assisted by masons on lateral platform
Making Texture on finished surface by TCM Texturing brush to be kept clean. Increased slump results in slurry deposition. Time gap is required before doing texturing which should be avoided Textures to be created normal to the edges of slab
CURING OPERATION BY TCM

Uniform spray of curing compound by spray bar over entire surface i/c vertical edges by hand sprayer to minimize moisture loss Adequate windshield cover helps in homogeneous spray of curing compound
View of Finished Pavement
View of Vertical Edge of Slab
Correct vibration by inbuilt vibrators and smooth finish by masons behind Paver avoid the collapse of vertical edges.
Protection from animals / Public is to be ensured
Control of Moisture loss

Complete Cover to Slab by Jute Bags / Hessian Cloth Continuous Wetting of Hessian Cloth is required
The shape and size of tent is so designed to avoid damage to the pavement It is preferable to have a length of tent protection for a three hours production length of slab by paver.
Initial Joint Cutting
Initial cut upto 1/3rd depth to start just when the concrete has hardened, preferably after 6 to 8 hours of concrete laying. The generated dust during cutting is to be removed / washed away immediately by pressure jets.
Widening of Joints
Widening of transverse Joints up to 8 mm The generated dust during widening is to be removed / washed away immediately by pressure jets.
Joint Preparation
Cleaning of Joints with Air pressure if needed, thin brush is required to clean the vertical faces
Filling of Backer Rod after cleaning of Joint.

Uniform depth for placing of backer rod to be maintained .
Joint Preparation
Top surface to be cleaned before application of Protection Tape for adequate adhesion. Sealant Primer not to spill out on protection tape and to be applied uniformly.
Joint Filling
The Concavity in the sealant material is accurately maintained by use of grooving tools.
TYPICAL SECTION OF TRANSVERSE / LONGITUDINAL JOINTS

8-10 mm. Recess 3 to 5 mm. Sealant + Recess 3 _ 1 Expanded closed cell Polyethylene Foam Backer Rod 3-4 mm. Sealant
20-30 mm.
Expanded closed cell 25-30 mm. d/3 Polyethylene Foam Backer Rod 3-4 mm. saw cut in green concrete
d/3
TRANSVERSE JOINT
PQC PQC
LONGITUDINAL JOINT
Riding Quality in Highway :

Working within the Design Parameters, geometric of Highway (i.e. ruling gradient, Grade Separators, Horizontal Curves, super elevations and design speed), the riding quality of a Highway mainly depends on :
1.
2.
3.
4. 5. 6.
Use of Homogeneous Materials as specified for various layers. e.g. Sub Grade, Drainage Layer, Sub Base, Base Course and Bituminous layers for flexible pavement. Use of Well graded and Homogeneous Concrete Mixes for Rigid Pavements. Control in Compaction and thickness of individual layers. Control of levels and surface regularities. Proper Roads Signage with design speed. Plying within the specified design speed.
CONTROL OF ALIGNMENT, LEVEL AND SURFACE REGULARITY

Horizontal Alignment : 10mm w.r. to C/Line of C/Way. Surface Levels : +5 mm, -6mm Surface Regularity :
Longitudinal 4mm : maximum 20Nos. in 300M
Longitudinal Length and Maximum 9 Nos. in 75M Longitudinal Length. 7mm : Maximum 2Nos. in 300M length and Maximum 1 No. in 75M length.
Transverse
Max. 3mm underside of 3M Straight-Edge
Construction Joint in PQC
PVC Caps
SITE TESTING DURING NIGHT
Slump Testing
Slump Cone to be removed correctly to maintain accuracy
Beam and Cube Samples

Beam and Cube moulds to be kept on a leveled horizontal bed Correct application of shuttering oil to avoid damage of edges / corners
Kerb Casting in Stages
First stage of kerb casting in progress. Second stage of kerb laying to be done after initial hardening of first stage.
Kerb casting in one stage
JOINTS IN KERB
Joint cutting in kerb is done when the concrete has just hardened
VIEW OF KERB WITH RIGID PAVEMENT
Specific observations and suggestions

1. 2.
At present, maximum size of aggregate used is 20mm. The 40mm size aggregate, if introduced in the design of PQC mix, will provide better concrete properties. The width of DLC layer (Base course for PQC) has to be sufficient enough for smooth movement of paver tracks. The movement of paver on in-sufficient width breaks the edges of DLC and creates problem for the movement of Paver, which may further affect the riding quality. The width of contraction joint should be kept to a minimum, i.e. between 3.0 mm to 6.0 mm to minimize the breaking of edges etc. However in some of the contracts, the width of the contraction joints is kept more than 10 mm, which is not really required. The texture depth as specified in MORT&H specifications is 1.0 mm + 0.25 mm - 0.35 mm which is difficult to achieve at site. The depth of texture should be specified as 2.0 mm to 4.0 mm with + 0.5 mm. Brush finish done for texturing on PQC surface reflects low durability on the stretches after the opening to traffic. With the passage of time, it will further reduce, rendering a smooth skidding surface. Methodology for roughening the surface at later stage, should be included in future specifications. Guidelines for repair of cracks and broken joints should be elaborated & included in specifications.
3.
4. 5.
6.

Construction of Concrete Pavement in Packages II-A, II-B and II-C (World Bank Project) at Kanpur - A Case Study

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Construction of Concrete Pavement in Packages II-A, II-B and II-C (World Bank Project) at Kanpur - A Case Study

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Construction of Concrete Pavement in Packages II-A, II-B & II-C of NHAI (World Bank Project) at Kanpur

NH-2, Package IIA, IIB & IIC

MUMBAI CHENNAI KOCHIN KANYAKUMARI

The present daily Traffic varies between 10000 20000 PCUs.

SALIENT FEATURES OF RIGID PAVEMENTS

Volvo 25 ton X 20 Nos.

Volvo 25 Ton X 16 Nos.

TATA 25 Ton X 25 Nos.

Mix Design for Contract Package II A

Coarse Aggregate Ratio (20/12.5) Fine Aggregate

Mix Design for Contract Package II B

370 Kg 148 Lit 0.40 773 Kg 342 Kg 69 : 31 683 Kg 62 : 38 2590 ml 185 ml

Mix Design for Contract Package II C

TYPICAL X-SECTION OF PQC

Plan of Joints in PQC

Typical Distribution Plan for Dowel Bars / Tie Bars

Dowel Bars (450 mm long), MS 36mm

12mm (@ 500 mm C/C)

Processing of Material Ingredients

CONCRETE BATCHING PLANT

capacity 120 Cum/Hr

SLIP FORM CONCRETE PAVER

Net output @ 110cum/Hr to 325 cum/Hr.

Transport trucks are Backbone of paving operation

An uninterrupted communication between concrete plant and unloading site to be ensured.

Transport trucks are Backbone of paving operation

Acoustic warning signal to operate during reverse.

no wind access during transportation

DLC: TRANSPORTATION & UNLOADING

DLC LAYING BY PAVER

SEQUENCE OF COMPACTION FOR DLC

(B) 1 Completed Zone (5) (4) (3) (2) (A) 2 (1)

FINISHED DLC SURFACE BEING CURED BY SPRINKLING OF WATER

Adequate barricading to avoid movement of villagers and animals

Preparation of Surface for PQC Paver

Alignment for PQC Paver

Laying Polythene Sheet ( 125 ) over DLC

OPERATION OF SLIP FORM PAVER

Spreading Concrete by Backhoe in front of PQC Paver

Laying of Concrete Mix

Placing of Dowel Bars and Tie Bars

VIEW OF DOWEL BARS

End of Stopper /PVC capped end exposed

Quality Control Behind the PQC Paver

Troweling by Super Smoothener

FINISHING AND TEXURING Finishing by Sack, assisted by masons on lateral platform

CURING OPERATION BY TCM

View of Finished Pavement

View of Vertical Edge of Slab

Protection from animals / Public is to be ensured

Control of Moisture loss

Initial Joint Cutting

Filling of Backer Rod after cleaning of Joint.

TYPICAL SECTION OF TRANSVERSE / LONGITUDINAL JOINTS

Riding Quality in Highway :

CONTROL OF ALIGNMENT, LEVEL AND SURFACE REGULARITY

Longitudinal 4mm : maximum 20Nos. in 300M

Max. 3mm underside of 3M Straight-Edge

Construction Joint in PQC

SITE TESTING DURING NIGHT

Beam and Cube Samples

Kerb Casting in Stages