METHODOLOGY FOR DRY LEAN CONCRETE

A. S co pe:

A1. The work shall consist of construction of Dry Lean Concrete (DLC) Sub-base for Cement
Concrete Pavement in accordance with the requirement of technical specifications and in
conformity with approved lines, grades and cross-sections.

A2 . The w or k shal l be e xe c ute d in ac c or danc e wi th f ol l owi ng Code s /

Spe ci fi c ati on:

A2 .1 Te c hni c al Spe ci fi c ati ons f or Road and Br i dge w ork s publi she d by Indi an Road
Congr e ss (III Re vi si on).

A2 .2 G ui de li ne s f or use of D LC as Sub- Base f or Ri gi d Pave m e nt (IRC- SP- 5 9- 1 9 9 8 ).

A2 .3 Standar d Spe ci fi c ati on and Code of Pr ac ti ce for Constr uc ti on of Conc re te

Roads (IRC: IS- 20 0 2 ).

A2 .4 Code of Pr ac ti c e f or Curi ng of Cem e nt Concr e te Pave m e nt (IRC: 8 4 - 1 98 3 ).

B. M at er ials :

B1 . C em ent : It i s pr opose d to use Or di nar y Por tl and Ce m e nt of 4 3 Gr ade as pe r

IS: 8 11 2 . Ce m e nt shal l be pr oc ure d fr om r e pute d m anuf ac tur e s i n c em e nt
bags of 5 0 k g e ac h. The Ce me nt shall initi al l y be stor e d i n c ove r e d ce m e nt
G odow n and the n tr ansf e rr e d to ce m e nt si l os thr ough Ce me nt Bag Spli tti ng
U ni t or m anual f ee di ng i n Sil os.

B1 .1 OP C 43 Gr ade Ce m e nt shal l nor m all y be pr oc ure d f r om Appr ove d

M anuf ac tur e r s.

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B1 .2 To ensur e re gul ar uni nte rr upte d suppl y of c e me nt, w e have e nte re d i nto
M em or andum of Unde r standi ng w i th the se m anuf ac tur e r s f or c onti nuous and
r e gul ar suppl y of ce me nt.

B2 . A g gr egat es : Aggr e ga te s to be use d f or D LC shal l be natur al m ate ri al

c om pl yi ng w i th IS: 38 3 and shal l not be al k ali re ac ti ve .

B2 .1 C o ar s e A ggr egat es : Coar se aggr e g ate shall c onsi st of Cr ushe d stone . Stone
aggr e g ate s shal l be pr oduc e d at PLL’s i nte gr ate d Stone Cr us hi ng and
Sc r ee ni ng Pl ants e stabli she d on the pr oje c t. The c r ushe d aggr e ga te s hall be
c he ck e d for physi c al pr ope r ti e s suc h as Aggr e gate Im pac t Val ue , W ate r
absor pti on e tc ., be f ore ac ce pti ng f or inc or por ati on i n w ork s. The m axi m um
s i ze of c oar se aggr e g ate shal l be 20 m m .

B2 .2 Fine A ggr egat e : The fi ne aggr e g ate shal l c onsi st of cl e an, natur al s and or
c r ushe d stone sand or a c om bi nati on of tw o and shal l c onf or m to IS: 3 83 .
Fi ne aggr e ga te shall be f r ee f r om soft par ti c le s, c l ay, shale , l oam , ce me nte d
par ti c le s, m i c a, or gani c and othe r f or e i gn m att e r . It i s pr opos e d to use
c r ushe d sand pr oduce d at i nte gr ate d Stone Cr ushi ng and Sc r ee ni ng P l ant
s e tup on pr oje c t.

B.2.3 Design Mix has been conducted with both Crushed Sand alone and also Crushed Sand blended
with natural sand as fine aggregate. This has been done to continue with work in case of
shortage of stone dust from stone crusher installed at site.

The material after blending shall conform to the grading as indicated in table given below:

TABLE: 1.1 AGGREGATE GRADATION FOR DRY LEAN CONCRETE

Per cent age pas s ing t he s iev e

IS S iev e Designation
by weight
26 .5 0 mm 10 0
19 .0 0 mm 8 0 - 10 0
9 .5 0 mm 5 5 - 75
4 .7 5 mm 3 5 - 60
60 0 .0 0 mi c r on 1 0 - 35

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 75 .0 0 mi c r on 0- 8

B3 . W at er : W ate r use d f or m ixi ng and cur i ng of c onc r e te shal l be cl e an and f re e

f r om i nj ur i ous am ounts of oil s, sal t, aci d, ve ge tabl e m att er or othe r
s ubstanc e s har mf ul to the fi ni she d c oncr e te . It is pr opose d to use
unde r gr ound w ate r and thr ough de e p bor e we ll s. The w ate r shal l be tes te d
to c he c k i ts sui tabi li ty f or use in c onc r e te w ork be f ore ac tual star t of w ork .
Lar ge unde r gr ound w ate r stor age tank s have be e n c onstr uc te d at loc ati ons of
al l Batc hi ng Pl ants w i th stor age c apac i ty suffi c i e nt to pr oduc e Si ngl e day’ s
c onc r e te re qui re m e nts.

C. S to r ag e of m at er ials :

C1 . Fi ne and Coar se Aggr e ga te s shall be stor e d at pl ant ar e a in Stac k yar ds

s e par ate l y ide nti fi e d f or di ff e r e nt si ze s of aggr e gate s in suc h a m anne r s o as
to pre ve nt thei r de te ri or ati on and c ontam i nati on by f or ei gn m att e r and to
e nsur e thei r sati sf ac tor y qual i ty and fi tne ss f or use i n the w ork . The s tac k
yar ds f or the se m ate ri al s shal l have ac c e ssi bi li ty f or wi thdr aw al and
i ns pec ti on.

C2 . Ce me nt shal l be stor e d ei ther i n 5 0 Kg bags i n Ce m e nt Godow n or i n bul k

f or m i n Ce m e nt Sil os at Batc hi ng Pl ant si te s.

D. M ix D es ign and Qual it y Co ntr o l:

D1. The m i x shal l be pr opor ti one d wi th m axi m um Aggr e g ate – Cem e nt r ati o of
1 5 :1 . The w ate r c onte nt shal l be adj uste d to the opti m um f or f ac il i tati ng
c om pac ti on by r oll i ng. The opti m um m oi stur e c onte nt and de gr e e of
c om pac ti on shall be got appr ove d f r om the E ngi ne e r . The le an c oncr e te s hal l
have m oi stur e c onte nt be twe e n the opti m um and opti m um + 2% , ke e pi ng in
vi ew the eff e c ti ve ne ss of c om pac ti on ac hi e ve d and to c om pe ns ate f or
e vapor ati on losse s.

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D2. C em ent co nt ent : The ce m e nt c onte nt as pe r the appr ove d desi gn m i x has
be e n ke pt at 1 5 5 k g/c u.m . of c onc re te , w hi c h m e e ts the re qui r em e nt of
m i ni m um c em e nt c onte nt of 15 0 Kg / c u.m .

D3. C o ncr et e St r engt h: As pe r Cl ause No. 6 0 1 .3 .4 of M OST Spec ifi c ati ons , the
de si gn mi x is to be pr e par e d in suc h a w ay that ave r age c om pre ssi ve s tr e ngth
of e ac h c onse c uti ve gr oup of 5 c ube s m ade as pe r spe ci fi c ati ons i s not le s s
than 10 M pa at 7 days. Al so m ini m um str e ngth of any cube shall not be
l es s than 7 .5 MPa.

D4. The Qualit y C o nt ro l of D LC ac ti vi ty shal l be done as pe r Cl ause No. 90 3 .5 of

M OST Spe ci fi c ati ons.

D 4 .1 I n- s it u D ens it y (C laus e No . 90 3 .5 .1 .2 and 6 0 1 .5 .5 .1 o f MOS T S pecifi cati o n ):

The dr y de nsi ty of the l ai d m ate ri al shal l be de te r mi ne d fr om thr ee de nsi ty
hol e s at loc ati ons e qual l y spac e d al ong a di agon al that bise c ts e ac h 2 0 0 0m 2
or par t the r e of l ai d e ac h day. In- si tu de nsi ty shal l be c om par e d w i th
de nsi ty ac hi e ve d in tri al str e tc h. The de nsi ty ac hie ve d at si te shall not be
l es s than 9 7 % of the M DD establ i she d in tri al str e tc h l ai d at si te . The
de nsiti e s ac hi e ve d at e dge s i.e . 0 .5 m fr om edge shal l not be l ess than 9 5 % of
the M D D establ i she d dur i ng tr i al str e tc h. The MD D ac hi e ve d in tri al s tr e tc h
l ai d at si te on 08 /0 1 /2 0 0 3 w as 2 .44 T/m 3 .

D 4 .3 Thick n es s : The ave r age thi ck ne ss of D LC l aye r i s r e qui r e d to be as pe r the

thi ck ne ss spe c ifi e d i n the c ontr ac t te r m s. It shal l be e nsur e d that thi c k ne s s
at any si ngle l oc ati on is not 1 0 mm l ess than the spec ifi e d thi c k ness . In c as e
any ar e a has a thi ck ne ss m ore than 1 0 m m l e ss than the spe ci fi e d thi ck ne s s .
Suc h ar e a shal l be c orr e c te d by c onc r e te w i th aggr e gate s of si ze 10 m m and
be l ow aft e r r oughni ng thi s surf ac e . Aft e r c onc re ti ng the surf ac e r e gul ar i ty
s hal l be c he c ke d wi th 3 m m str ai ght e dge .

The ac ti vi ty of c or r e c ti on of l aye r thi c k ne ss w he r e ve r w ar r ante d s hal l be

done i mm e di ate l y w he n Concr e te is gr ee n. Thi s shal l be done by m aki ng
l oose the c om pac te d sur f ac e , addi ng D LC m ate r i al and r aki ng off aggr e g ate s

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 of si ze l ar ge r than 1 0m m , m atc hi ng the sur f ac e pr ofi le and c om pac ti ng to
ac hi e ve the re qui r e d thic k ne ss and pr ofi le .

D 4 .4 The sur f ac e pr ofi l e of fi ni she d D LC Laye r shal l be che ck e d j oi ntl y w i th

Consul tant i mm e di atel y aft e r c om pac ti on of D LC Laye r is fi nishe d. Any
de vi ati on shall be sim il ar l y c orr e c te d by addi ng or re m ovi ng m ate ri al as
s pe ci fi e d.

D 4 .5 C om pr es s iv e S tr engt h: The cube s shall be c ast as pe r Cl ause No. 90 3 .5 .1 of

M OST Spec ifi c ati ons. The y shal l be te ste d f or c om pr e ssi ve stre ngth aft e r 7
days’ and ne xt l aye r of PQ C shal l be l ai d on D LC onl y if ave r age c om pre s s i ve
s tr e ngth e qual to 1 0 M pa i s ac hi e ve d.

E. P ro ducti o n and Tr ans po r t ati o n:

E1. Bat ching and Mixing : The c onc r e te f or D LC shall be pr oduc e d in f ul l y

autom ati c “STE TTE R” m ak e Conc re te Batc hi ng Pl ants of 12 0 m 3 /hr . c apac i ty.
The pl ants ar e c apabl e of pr opor ti oni ng the m ate r i al s by we i ght and
pr ovi di ng a unif or m hom oge ne ous m i x. Ce me nt, Admi xtur e and W ate r f r om
Sil os shal l be we i ghe d se par ate l y fr om the aggr e g ate s. The batc hi ng and
m i xi ng is c ar r i e d out i n f or ce d ac ti on c e ntr al Mi xer of the Pl ant.
E 1 .1 To ke e p the te m pe r atur e of c onc r e te pr oduc e d wi thi n 30 0 C, e ac h Conc r e te
Batc hi ng Pl ant has se par ate uni t of Chi ll i ng Pl ant so as to pr ovi de c hil le d
w ate r to e nsure that the fi nal te m pe r atur e of c onc re te is wi thi n 30 0 C. Si nc e
the m axi m um te m per atur e i n the pr oj ec t ar e a i s ge ne r al l y le ss than 3 5 0 C,
m ai ntai ni ng tem pe r atur e of c onc r e te shall not be a c onstr ai nt.

E2. Tr ans po r t ati o n : Mi xe d Le an Conc re te f r om the pl ant shal l be tr ans por te d

f r om pl ant to si te i n D um pe rs of 15 T c apac i ty. The m i x shall be unl oade d i n
hoppe r of pave r at si te by re ar ti ppi ng.

F. S pr eadi ng and C om pacti o n:

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F1 . P laci ng: The Le an c oncr e te shal l be pl ac e d on D r ai nage l aye r pr e par e d
e ar li e r . A day bef or e pl ac i ng of the D LC, the dr ai nage l aye r shall be gi ve n a
fi ne spr ay of w ate r and r oll e d w i th one or tw o passe s of sm ooth w hee l r ol le r .
The Le an Concr e te shal l be l ai d / pl ace d by a H ydr aul ic Pave r e qui ppe d w i th
e le c tr onic se nsor s to c ontr ol both l ongi tudi nal and l ate r al gr ade s of pave d
s ur f ac e . The Conc re te Pave r c apabl e of pavi ng up to 9 .4 0 m wi dth has be e n
de pl oye d on the pr oj e c t. Pavi ng shal l be done i n si ngl e wi dth of 9 .3 5 m
r e qui r e d f or 2 l ane c ar ri age w ay. Pavi ng of D LC f or 3 l ane c ar ri age w ay s hal l
be done i n 2 l ane s as the total D LC w i dth re qui re d i s 1 2 .8 5 m f or 3 l ane
c ar r i age w ay.

F1 .1 The H ydr auli c Pave r is c apabl e of l ayi ng Le an Conc re te i n one l aye r i n an

e ve n m anne r w i thout se gr e gati on, so that aft e r c om pac ti on the total
thi ck ne ss ac hi e ve d is as spec ifi e d i .e . 1 5 0 mm . The pave r has sc re e d wi th
tam pi ng ar r ange m e nt f or ini ti al c om pac ti on of D LC l aye r .

F2 . C om pacti o n : The c om pac ti on shal l be c ar ri e d out im m e di ate l y aft e r the

m ate r i al is l ai d w i th Pave r .

F2 .1 Com pac ti on and fi ni shi ng of the l e an c onc r e te shall be c ar r ie d out

i mm e di ate l y be hi nd pavi ng.

F2 .2 Si ngl e D r um Vi br ator y Rol le r s of 1 0 T Capac i ty or D ouble dr um Tande m

Vi br ator y Rol l er s of 10 T c apac i ty of D YNAPAC / ING E RSOL L / G RE AVE S m ak e
s hal l be use d f or c om pac ti on of D LC.

F2 .3 Ini ti all y one pass of Roll e r w i thout vi br ati on shall be appl i e d on Gr ee n

c onc r e te . The r e aft e r the vi br ati on shal l be star te d ti ll r e quir e d c om pac ti on is
ac hi e ve d. One fi nal pass wi thout vi br ati on shal l be appl ie d at the e nd to
r e m ove Roll e r m ar k s.

F2 .4 The fi nal sur f ac e shall be inspe c te d im me di ate l y on c om pl e ti on and al l l oose ,

s e gr e gate d or de fe c ti ve ar e as shal l be c or re c te d by usi ng fr e sh l e an c onc re te
m ate r i al l ai d and c om pac te d as pe r te c hni c al spe ci fi c ati on.

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F2 .5 Sur f ac e re gul ar i ty dur i ng the c our se of l ayi ng shal l be c he c ke d w ith a 3 m
s tr ai ght e dge . Hi gh poi nts of the surf ac e w il l be c orr e c te d by sc ar i f yi ng and
r e - r ol li ng and the l ow ar e as shal l be c or r e c te d by fi l li ng w i th fr e sh m ate r i als
and r oll i ng.

F3 . C ur ing (C laus e No . 6 0 1 .5 .7 ): The M OST Spe c ifi c ati ons pr ovi de that Cur i ng
s hal l be done by any of the f ol l owi ng me thods:

F3 .1 The i ni ti al c ur i ng shal l be done by spr ayi ng w ith l iqui d cur i ng c om pound.

Cur i ng c om pound shal l be whi te pi gm e nte d or tr anspar e nt type wi th w ate r
r e te nti on inde x of 9 0% Cur i ng Com pound shal l be spr aye d im m e di ate l y aft e r
r oll i ng is c om ple te d. As soon as the cur i ng c om pound has lost its tac k i ne s s,
the sur f ac e shall be c ove r e d w ith we t H e ssi an f or thr ee days.

F3 .2 Cur i ng shall be done by c ove r i ng the sur f ac e by G unny bags/H e ss i an, whi c h
s hal l be ke pt c onti nuousl y m oi st f or 7days by spri nkl i ng w ate r .

F3 .3 It is pr opose d that ini ti al c uri ng shall be done wi th W ax Bas e d c ur i ng

c om pounds. Any of the f oll ow i ng tw o cur i ng c om pounds shal l be use d for
c uri ng:

i) Anti sol – E (W P) of Sik a m ake

ii) Conc ur e (W B) of Fosr oc m ak e

F3 .4 For 3 days’ fur the r c uri ng He ssi an c l oth shal l be spre ad on c oncr e te s urf ac e
and i t shall be ke pt m oi s t f or thr ee days by spr ayi ng w ate r at inte r val s .

G. E xecuti o n S eque nce:

G1. Nor m al l y it shall be the e ff or t to pave l onge r str e tc he s of D LC f or be tt er

qual i ty and be tt e r ri di ng quali ty of w ork and r e duce d num be r of tr ans ve r s e
j oi nts.

G2. A day bef or e D LC pavi ng i s pr opose d, the pr e par e d and appr ove d GSB s hal l
be w ate r e d and r ol l e d.

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G3. The boundar y of pavi ng w idth shal l be m ar ke d w i th l im e pow de r aft e r
c he ck i ng and m ar ki ng of pr opose d ce nte rl i ne wi th Total Stati on.

G4. Se nsor pe gs at the spaci ng of 1 0 m c e nter to c e nter shal l be fi xe d on both

s i de s of pavi ng wi dth f or 2 0 0m stre tc h on pre vi ous eve ni ng.

G5. Str i ng l ine shall be fi xe d on the Se nsor pe gs at fi xe d he i ght 2 0c m above

pr opose d top l e ve l of D LC wi th the he l p of Auto le vel s. The he i ght of s tri ng
l ine above D LC c an be var i e d, if so r e qui r e d, at si te .

G6. Ve r ti c al cut shall be m ade at the star t of pavi ng f or ne xt day f or ve r ti c al j oi nt

f or m ati on be tw e e n new and ol d D LC.

G7. Conc r e te shall be pr oduc e d f r om 1 2 0m 3 Batc hi ng Pl ant and tr ans por te d i n

1 5 M T D um pe rs fi tt e d w i th tail boar ds. The y shall be c ove r e d w ith Tar paul i n
w he n the am bi e nt te m per atur e shall star t r isi ng above 35 0 C.

G8. D um pe r s shal l appr oac h Pave r hoppe r by re ve r si ng and i ts m ove m e nt s hal l be

c ontr ol le d by a per son standi ng in fr ont of Pave r hoppe r , i n suc h a w ay that
r e ar tyr e s of dum pe r s do not hi t the Push Rol l er s of Pave r . The dum pe r s
s hal l unl oad m ate ri al i nto Pave r hoppe r i n suc h a w ay that m ate r i al unl oade d
i s l ess than the c apac i ty of hoppe r and i t doe s not spi ll on the gr ound i n
f r ont of Pave r .
G9. The Pave r ope r ator shal l dr aw the c onc re te mi x on the r e ar si de and s hall
s tar t pavi ng onl y aft e r e nti r e 9 .3 5m wi dth has suffi ci e nt quanti ty of c onc r e te
m i x f or star t of pavi ng. The dum per s shall be ke pt in ne utr al pos i ti on and
s hal l be pushe d f orw ar d by the Pave r . The j oi nt be twe e n ol d and the ne w
D LC Laye r shall be c ar e f ul l y pre par e d m anual l y by r em ovi ng c oar se par ti c le s
f r om the top i n a wi dth of about 3 0 cm and tr ansve r se r ol li ng shall be done
be f ore star ti ng r ol li ng of m ai n D LC l aye r . The r e gul ar i ty of j oi nt s ur f ac e
s hal l be c he c ke d wi th 3 m str ai ght e dge .

H. Tr ial M ixes :

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H1. The M ix De si gn of Dr y Le an Conc re te shall be c onduc te d wi th m oi s ture
c onte nts li ke 5 .0 , 5 .5 , 6 .0 , 6 .5 and 7 .0 pe r ce nt usi ng c em e nt c onte nt and
aggr e g ate as spec ifi e d above .

H 1 .2 . Aft e r e stabl i shi ng the opti m um m oi sture , a se t of si x cube s shal l be c as t at

that m oi stur e f or the de te r mi nati on of c om pr e ssi ve str e ngth on 3 r d and the
7 t h day. Aft e r the mi x is appr ove d, a tr i al stre tc h shall be c onstr uc te d in the
pr e se nc e of Consul tant.

H2. If duri ng the c onstr uc ti on of the tri al l ength, the opti m um m oi stur e c onte nt
de te r mi ne d as above is f ound to be unsati sf ac tor y, sui tabl e c hange s in the
m oi stur e c onte nt to ac hi e ve a sati sf ac tor y mi x shall be m ade . The c ube
s pe ci m e ns pr e par e d wi th the change d m oi stur e c onte nt shall s ati s f y the
s tr e ngth re qui r em e nt. Bef or e pr oduc ti on of the mi x, natur al m ois tur e
c onte nt of the aggr e gate shall be de te r mi ne d so that the m oi stur e c onte nt
c an be adj uste d. The mi x fi nall y shall be de si gne d that i t nei the r sti ck s to the
r oll e r s nor be c om e too dr y re sul ti ng in Rave l i ng of sur f ac e .

I. Tr ial L engt h:

I1 . Tr i al le ngth shal l be e xe c ute d at l e ast 14 days i n advanc e i n c ons ul tati on

w i th Consul tant / Cl i e nt. The tr i al le ngth shal l be of m i ni m um 60 m le ngth
and f or f ul l wi dth of pave me nt.

I2 . Aft e r c onstr ucti on of the tri al le ngth, the in- si tu de nsi ty of the f re s hl y l ad
m ate r i al shall be de te r mi ne d by Sand Re pl ac e m e nt M e thod w i th 20 c m di a
de nsi ty c one . Thr e e de nsi ty hole s shal l be m ade at loc ati ons e qual l y s pac e d
al ong a di agonal that bi se c ts the tr i al l ength and ave r age of the se de ns i ti e s
s hal l be de te r m i ne d. Cor e s, if re qui r e d, shall be c ut as pe r instr uc ti ons of
Consul tant to c he c k f or se gr e gati on or othe r defi ci e nc y.
I3 . The har de ne d c onc re te shall be c ut ove r 3m wi dth and r e ve r se d to i ns pe c t
the bott om f or any se gr e gati on or hone y c om bi ng. In c as e of any
s e gr e gati on, ne ce ssar y c hange s shall be m ade i n M ix D e si gn.

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Tr affi c:

J.1 H e avy c om me r ci al ve hi cl e s shall not be al l owe d on D LC, l i ght ve hic l e s, if

r e qui r e d, shal l be all ow e d aft e r 7 days of i ts c onstr uc ti on.

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 J. Tr affi c:

J.1 H e avy c om me r ci al ve hi cl e s shall not be al l owe d on D LC, l i ght ve hic l e s, if

r e qui r e d, s hal l be all ow e d aft e r 7 days of i ts c onstr uc ti on.

J. Tr affi c:

J.1 H e avy c om m e rc i al ve hi cl e s shal l not be al l owe d on D LC, li ght ve hic l e s, i f

r e qui r e d, shal l be all ow e d aft e r 7 days of i ts c onstr uc ti on.

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