Current Design, Construction, Quality Control and

Maintenance Specifications of Rigid Pavements for:

i) National Highways,
ii) Air Field Pavements,
iii) Rural Roads, and
iv) City Roads.

Satander Kumar Scientist (ex, CRRI),

satander50@gmail.com

1
Rigid Pavement Flexible pavement
750 mm 300 mm

Deflection ~ 0.2 mm ~1 mm
or 200 micron
For For
5 t load 5 ton load
K value/modulus of CBR %
subgrade reaction = (Load on 50mm)*100
1370kg
2

= Load on 750mm
Plate area*1.25 mm Unit - kg/cm2/cm or MPa/m
 Age of Concrete

1. In 1756, British
engineer John
Smeaton made first
modern concrete
(hydraulic)

2. by adding pebbles as
a coarse aggregate
and mixing powered
brick into cement.
Dr. R K Ghosh, CRRI
3. Joseph Aspdin Sh Y.R Full, CRRI
First Portland Cement Dr L.R. Kadiyali & CMA
1824 Prof BB Pandey
Prof C E G Justo
BMC Bombay/MSRDC/MORTH
PWD Haryana /MORTH
Wayne County Road Commission introduced the

world to a new kind of road: Concrete. Detroit .

First Mechanized Concrete Road Danish,

1939 Bombay Poona ,

5
106 ft/hour (0.5 m/min)
First Mechanized Road = 8” (4”+4”) 1948
6
Mumbai- Pune 1939
1
9
5
1
7
FRERE ROAD =
MUMBAI

8” (4”+4”) 1960

1: 2: 4 M 20
Matunga Bombay 1960 200 mm

8
First Published in 1951-Airfield

9
 IRC Codes Published First on CC Roads
National Highways and Rural Roads:

Cement Corporation of India 1948: A manual of Concrete Roads

IRC: 15-1965: Design & Construction

IRC: 58-1974 Guidelines for Design of Plain Jointed Rigid Pavement

IRC: 77- 1979: Repair of Concrete Pavements Using Synthetic Resins

IRC: 43- 1972 Equipment's
Specification

MORTH 1973 : Specification

Rural Roads after PMGSY

IRC: SP:62-2004 Design and Construction of Cement Concrete Pavements for Low Volume Roads
First IRC Code
Rural Roads

IRC SP: 20-97

PMGSY Started
25th December
2000,

NRRDA January
2002
11
IS Codes Published First on Cement/Concrete
1. IS: 269: Cement Code 1951
2. IS: 1199: Fresh Concrete 1959
3. IS: 516: Hardened Concrete 1959
4. IS: 456: Specification 1951

12
 Current Codes IRC
Activities National Air Field Rural Roads and

Highways/Expressways Pavements city Roads

Design IRC: 58-2015 International Civil IRC:SP:20

IRC:SP:111-2017 Aviation Manual IRC:SP:62-2014

Construction IRC:15-2017, IRC:43-2015

Repair and IRC:SP:83 -2008 MORD

Revised up to
Maintenance IRC:57 -2006 Specification
2018 Addendum
Specification MORTH 2013 2014

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 Current Codes IS
National Highways Air Field Rural Roads City

Pavements Roads

Design, Construction , Repair & Maintenance:

IS: 269-2015 Cement
IS:383- 2016 Aggregates
IS: 516- Amendment upto 2017 Concrete Hardened
IS: 1199- -do- Concrete Fresh
Specification IS: 456-2000 Code of Practice for Plain and
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Reinforced Concrete
First Mechanised Road NH -2, h= 300 mm 1993

Manual 1948

Price Rs 1Jabalpur MP,

Yamuna Expressway,
2018
h= 320 mm 2011
Damage due to shoulder above FRL

16
Damage due to MUMBAI PUNE EXPRESSWAY _ OUR
Settlement sub base slow moving lane FIRST
Dowel bars and tie bars Nether together nor at joints

Dowel Bars
 Quality CONTROL/ ASSURANCE
• IRC:SP:112 Clause 2.2.3
• Quality Assurance= QC + Quality Acceptance

• Page 8 clause 2.2.3 IRC:SP:112

• Quality Ensure (Personally checking)

• Quality Insure ( Penalty/reward)

Q1 and Q2 RR, Q 3 NH/SH

Q-4 Tunnels and elevated Highways

 DURABILITY –
Adequate Strength, Minimum Air Voids
Consolidation Compaction Densification

Clayey soil Clayey/non-plastic Non plastic

Clayey-silty Concrete Filter media

Static load Mechanical Mechanical

Removal of Water Removal of air Addition of water

Flooding water
AVOID HONEY-COMBING (Honey bee house)
1% air Void reduces about 6% Compressive strength

1. Crack: Irregular shape partial depth

2. fracture mean crack in harder material,
3. fissure- crack in softer material
 Composite Cement- IS: 16415-2015
• Cement 35-65% - 35 kg cement
• Fly ash 15-35% - 35 kg fly ash
• Slag 20-50% - 30 kg slag

28 days For M 30 Rural road

Use 33 Grade Composite Cement.
Reasons of 33 Grade means to arrive Concrete
strength Fck+3 = 33
For NH and Airfield 43 or 53 Grade OPC
 Manufactured Aggregate
• Sand or fine aggregate means- Passing 4.75 mm

Why Natural sand is better

i) Less surface area less binder, more workable

ii) Washed sand, good bond
iii) No wear and tear of sharp edges like of stone dust
iv) No sticking of fines on the surface

Natural sand Crusher dust

Size < 4.75 mm Size < 4.75 mm

CONSTRUCTION Low Volume Roads
CONSTRUCTION Urban/city Roads
Low Volume City Roads

24
 25
Fixed Form Pavers- Laying Slip Form Paver Laying
Expressway laying
 NH

Automatic Tie Bars Inserter Automatic Dowel Bars Inserter

Tining Mechanical Broomer

 Floating, Finishing
Mechanical Floating, Finishing

Texturing – Tinning App. Texturing by Tinning

Low Volume Roads

There is R&D need on

Low Volume Roads Texturing ?
City Roads
Texturing by Brooming Transvers crack -tinning
 Joints Cutting, Filling - sealing

All Types
 Riding Quality – Bump Integrator
Integrate (add) no. of bumps
• Maximum irregularity after initial curing < 3 mm
100mm 100 mm
• FRL
•IRC:SP 16 2004 BI= 630 (IRI)1.12

Vibro meter through Mobile

BI less than 2200 mm/km in CC

(Table 4.2 page 29) IRCSP:83

Av. < 2000mm 902.6 + 3000 mm /km Poor

 Logics of checking Quality of M 40 or M 30
Grade Concrete

• Add 1 kg cement /cum to get CS 1kg/cm2

• Scratch concrete surface of pointed nail –

depth 0.2 -0.3 mm

• Sprinkle a glass water- Evaporate in 4 hrs

• Sound meter- 60-70 dB sound

• Compare with M 30 or M40 Conc. cubes
31
 Plastic Crow Foot or Y Scaling
Shrinkage Junction Cracks
Cracks Drying Shrinkage cracks

Excessive excessive water Early traffic

Evaporation
of water

After 4-6 hr After 28 days With in 2-3 days

More fine Early opening to
Sprinkle 200 No admixture traffic
ml/sqm
Low viscosity Microcrete/Epoxy/
Cement slurry Epoxy rich cement mortar
Reasons of transverse cracks Full width:

 Too late initial joint cutting

 Cold Joints

 Depth of cutting less than specified

 Dis similar material in lower layers near cracks

 Dowel bars may be misaligned

 Pushing tinning at Improper time & poor quality 33

tine
Reasons - longitudinal crack & crack at adjoining joints, :

• Heavy Vibration of machine during

joint during cutting
• Bits /blades may not be too sharp,
• Movement machinery on unmatured slab,
• Deficiency in curing
• Black cotton soil

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 IRC:SP:83-2008 Maintenance of CC Roads

• Maximum crack width = at least 50% of length.

• Shallow cracks donot need repair p-31).

• Table 4.4 Max servicibility 2,

• Clause 4.6.4. FDR when: severity 5, crack 12
mm in 50% area, rocking (Page 33)
 Bangalore Expressway

Cracks sealing

Cracks sealing

Eastern Periphery
37
 TYRE BURSTING on High Speed Corridors

Flattening of tyres

DOES DONOTS
• Old tyre /Bald Tyre/ OLD
• Speed max 100 km/h
TUBE
• Good Tyre/tube quality
• Very High or low tyre
• Specified tyre pressure
pressure
• Nitrogen
• Do not have sharp edges
NEW TECHNOLOGIES

39
Cell Filled Concrete Pavement

40
Fibre Geo Textile
.. ......................................
PVC Backing

CONCRETE CLOTH

(6-14 mm thickness )
IRC: SP: 83 EOT /M 200
Two Lift Paving

42
 DO’s Do nots

• HFL 600 mm below • Have shoulder highly

subgrade, above or below FRL
• Camber in subgrade
• Have density less
• Minimum fines in GSB,
than 97.5 % in DLC,
• PQC M 43 not M 40
• Let PQC dry before/
• Joints cutting after 4
till joint cutting-
hr in summer,
progress
 Major points for discussion
• W/C ratio is inversely proportion to stregth

• Dry cube gives more (20%) strength, but test wet

• Good quality sand

• Rebound hammer

• Slump 25 + 15 mm

46
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