CEMENT CONCRETE PAVEMENT

· DETAILS OF ROAD

Ø TECHNICAL AREA
1. MAIN ROAD

- Carriage way = 4.0m

- Shoulder = 1.0m

2. VILLAGE ROAD

- Carriage way = 3.6m

- Shoulder = 1.0m

Ø ADMIN AREA

1. MAIN ROAD

- Carriage way = 4.5m

- Footpath = 1.2m

· DESIGN OF CONCRETE PAVEMENT

Ø Concrete pavement will be designed as per IRC:SP:62-2014
Ø Following data is required for design of pavement
1. Soaked CBR test report at each location where road is on filling.

· MIX DESIGN FOR CONCRETE (CPWD Specification 2009,Vol 2 ,16.37.2.1)

Ø The mix shall be approved by Engineer-in-Charge so as to obtain the following mean strength
that exceeds the minimum specified flexural strength by 1.64 times the designed standard
deviation.
 Minimum works beam
Flexural strength at 28 days = 300 kg/sqm. for M-30 or specified in item
Designed standard deviation = 60 kg/sqm. for M-30 or for specified grade(s)
Design flexural strength
at 28 days = 300+60x1.64 = 398.4 kg/sqm. (f + 1.64 s )
= says 400 kg.
Water cement ratio by weight = 0.5

Minimum slump not more than 25 mm

Minimum Grade of Concrete – M-30

Ø For the purpose of tendering the contractor shall base his rate on the assumption that the
quantity of cement used for one cum. of finished concrete shall be 340 kg. or M - 30. If the actual
quantity of cement required to be used as a result of the laboratory test is different from that
assumed above, necessary adjustment in the cost due to short cement used shall be made on the
basis of issue rate of cement including storage charges plus 2.5% for handling charges. However,
under no circumstances the quantity of cement to be used shall either exceed 350 kg./cum or fall
below 330 kg. per cum of finished concrete

· Test on material

Sr Quantum / Frequency of Acceptance

Material Test to be carried out Ref Document
no Check Criteria

1 Cement i)Physical test

a) Fineness
b) Soundness
C) Setting One for each lot or as per
Timed)Compressive Directed by Engineer-in- IS: 8112 ,Table 3
Strength Charge

d) Transverse Strength
 Quantum /
Sr Ref
Material Test to be carried out Frequency of
no Document
Check
2 CPWD Specification
Coarse Aggregate
2009 16.37.19
Before the approval of Not more
a) Flakiness index quarry and at every IS 2386 (Part I) than 15%
subsequent change in the Not more
b) Impact Value source of supply and one than 30%
IS 2386 (Part IV)
test per 100 cum of Not more
C) Los Angles Abrasion aggregates than 40%
Before Approval of quarry
and at every subsequent
d)Deleterious material IS 2386 (Part II)
change in the sources of
IS 383
supply regular as required
subjected to min. one test
e)Moisture Content per day IS 2386 (Part III)

3 Fine Aggregates CPWD Specification

2009 16.37.19
a)Silt Content CPWD Specific.
One test Per 15 Cum
2009 Vol 1 App 'C'
b) Gradation of Sand IS 2386 (Part I)
c) Deleterious Material Before Approval of quarry IS 2386 (Part II) IS 383,Table
and at every subsequent 1
change in the sources of
d)Moisture Content IS 2386 (Part III)
supply regular as required
subjected to min. Two test
per day
Sr Quantum / Frequency of
Material Test to be carried out Ref Document
no Check

4 Water Water used for mixing and IRC Sp 62 0214

curing of concrete shall be
clean and free from
injurious amount of oil, salt,
acid, vegetable matter or
other substances harmful to
the finished concrete. It
shall meet the requirements
stipulated in IS:456.

5 Admixture Admixtures conforming to

IS:6925 and IS:9103 may be
used to improve workability
IRC Sp 62 0214
of concrete or extension of
the setting time
· TEST TO BE CARRIED ON CONCRETE USED IN PAVEMENT
Ø Refer CPWD Sp. Vol.2 - Cl No.16.37.3.1
Ø Frequency of sample – One Sample to be taken for 30Cum concrete
Ø One Sample – 8 Beams
Ø Beam size - 70cm x 15cm x 15cm ( Ref IS 1199 Cl. No. 4.3.2 )(CPWD Sp. Vol.1 - Cl No.16.37.3.1)
Ø 4 Specimen shall be tested after 7 days and 4 Specimen shall be tested after 28 days.

Sr Name of test Sampling/ Frequency of Check Ref Document

No

1 Strength of Concrete One test sample Consisting of eight CPWD Specification Vol
Specimen for every 30Cum of 2,16.37.3.5
Concrete IS 516-1959,5.1

2 Slump Test Each Mixer at least one in fifty CPWD Specification Vol
batches mixed or more frequently if 2,16.37.4
directed by the Engineer In charge IS 1199,5.1

3 Trial Length 3 Corse per trial length IRC sp 62 2014 Ch 7

4 Core Strength on hardened 2 Core for every 30Cum of Concrete IRC Sp 11-1984,Chap6,Table
Concrete 6.2
IS 516-1959

5 Surface Accuracy The surface shall be checked for CPWD Specification Vol 2
surface regularity with a straight ,16.37.13
edge of 3 m length. The tolerance in
this length shall not exceed 3 mm.
GUIDELINES FOR CONSTRUCTION OF CONCRETE PAVEMENT

BASE PREPARATION –

Ø The base to receive the cement concrete shall be checked for line, grade and cross-section as spelt
out in IRC Sp 11 1984 Chapter 7. All irregularities beyond the permitted tolerances shall be
rectified as specified.
Ø Where concrete is to be laid over an absorbent surface, the latter shall be kept moist in saturated
surface dry condition or covered over by a water-proof Kraft/polyethylene sheeting as specified so
as to prevent absorption of water from the concrete mortar.

FORM WORK – (CPWD Specification 2009 Vol 2 16.37.5)

Ø All side forms shall be of mild steel channel sections of depth equal to the thickness of the
Pavement.
Ø The supply of forms shall be sufficient to permit them to be taken out only after 12 hours after the
concrete has been placed. All forms shall be cleaned and oiled each time they are used.
Ø For setting of forms refer CPWD Speci 2009 Vol 2 16.37.5.6.

PLACING OF CONCRETE (Refer IRC:SP:62-2014)

Ø Concrete shall be placed on the prepared base in such manner as to avoid segregation and uneven
compaction between the form work.
Ø The concrete shall not be dropped from a height greater than 90cm and shall be deposited within
20min from the time of discharge from the mixer.
Ø The placing and spreading can be done by a paver, if available, or by manual means.
Ø While being placed, the concrete shall be rodded with suitable tools so that the formation of voids
or honeycomb pockets is avoided.

COMPACTION OF CONCRETE –

Ø As per CPWD Specification 2009 vol 2 16.37.8 and IRC :SP:62-2014,7.7

 FINISHING OF CONCRETE –

Ø As per CPWD Specification 2009 vol 2 16.37.9 and IRC :SP:62-2014 7.8

Ø After Correcting the surface for profile but just before the concrete becomes Non Plastic, the surface
shall be finished by belting , brooming and edging as specified in CPWD Specification 2009 Vol 2,
16.37.10,16.37.11,16.37.11.3

CURING OF CONCRETE (Reference CPWD Specification 2009 Vol 2, IRC:SP:62-2014 Ch 7,7.10)

Ø The initial curing shall be done by the application of curing compound followed by covering the
pavement surface entirely with wetted burlap or jute mats.
Ø The covering shall be maintained fully wetted and the mats used shall be of such length or width
that as laid they shall extend at least 45cm beyond the edges of the slab.
Ø During final curing all joints should be filled with filler to prevent the joint edges from getting
damaged and entry of clay material.
Ø After the initial curing, the final curing shall be done by pounding or continuing with wetted
burlap.
Ø Pounding shall consist of constructing earthen dykes of clay of about 50 mm height transversely
and longitudinally, spreading a blanket layer of sand over the exposed pavement and thoroughly
wetting the sand covering for 14 days. The wetted burlap also shall be placed for 14 days.
Ø JOINTS (Refer IRC:SP:62-2014)

Single lane Carriageway with lane width of 3.75m is constructed in one operation.

There is no need for longitudinal joints for single lane roads except when the pavement width is about
4.5m in case of causeways.

1. CONTRACTION JOINT

Ø The contraction joints 3 to 5 mm wide shall be cut as soon as the concrete has undergone initial
hardening and is hard enough to take the load of the joint sawing machine without causing damage to
the slab.

Ø The depth of sawing should be from 1/4 to 1/3 of the depth of the slab.
Ø The Contraction joints should be completed within 24 hours of casting of concrete. Metal Strips and
steel T sections can also be used for joint forming.
Ø High Density Polyethylene (HDPE) strips 3 mm to 5 mm thick with suitable tensioning and intermediate
support for keeping the strip in position can also be used for creating joints. HDPE strips are left in
place.

2. CONSTRUCTION JOINTS
Ø Transverse construction joints are provided wherever concreting is completed after days work or if
work is suspended for more than 90 minutes.
Ø At all construction joints, steel bulk head should be used to retain the concrete while surface is
finished.
Ø If bulk head /stop end positioning is not possible, concreting to an additional 1 or 2 m length
may be carried out to enable the movement of joint cutting machine so that joint grooves may be
formed and the extra 1 or 2 m length is cut out and removed subsequently after concrete has
hardened.

3. EXPANSION JOINTS

Ø Transverse expansion joints are necessary for the concrete slabs abutting the bridges and
culverts. The details of the joints are shown in Figs. 1(a), 1(b) and 1(c).
Ø Two expansion joints may be provided near a culvert or a minor bridge to take care of expansion
of the concrete slab as shown in Fig. 1(c).
Ø At expansion joints where width may be 20mm, dowel bars are required as shown in fig 2.
Ø Dowel bars shall be 25mm dia., 450mm long and spaced at 250mm c/c.

4. LONGITUDINAL JOINTS

Ø Longitudinal joints are provided where the width of concrete slab exceeds 4.5m in case of
causeways.etc.
Ø It is provided in the mid width of the slab.