6.

1 General

The product quality of block pavements is immensely necessary for satisfactory performance during
service. Thus the manufacturing process quality of individual materials has to be emphasized.

Table 1 Design Catalogue for Pavement Thickness

6.2 Mix Design Aspects

A dry and low slump concrete is envisaged in the manufacturing precast units. Other characteristics are
of the mix are as under:

W/c ratio 0.34 to 0.38

Water content of the mix
Quantity of cement in mix
Pfa
Aggregate/cement ratio
Aggregate
Aggregate size
Coarse & fine Agg. proportion
Strength
Abrasion Resistance
Addition of Pigments
Other additives
5 to 7 % by weight of total mix
380 to 450 kg/m3
Fly ash can be used to the extent of 35% by weight of cement
3:1 to 6:1
Aggregate should conform to IS : 383
6mm to 12mm max. size
Coarse aggregate- 60% and fine aggregate – 40%
30 MPa min. compressive strength for single block
40 MPa min. for commercial traffic less than 20 msa
50 MPa min. for commercial traffic more than 20 msa
When tested with the rolling machine according to ASTM C779:
1.5 mm max. for depth of wear after 60 minute in case of M-30
grade block
1.25mm max. in case of M-40 Grade block
1mm max. in case of M-50 Grade block
Inorganic type, fineness value between 2 and 15 m 2/gm, and of
volume 5 to 9 percent of cement of content
Superplasticizers (around 0.4 %), water repellent admixtures, blast
furnace slag (50%), pozzolans like fly ash (35%), and air entraining
admixture can be used

6.3 Manufacture of Paving Blocks

Ultimate performance of a block pavement depends on method of manufacture of blocks and hence
hand cast blocks is not accepted. A manufacturing process essentially involves compacting well designed
concrete in a steel mould clamped to a vibrating table and compressing the concrete by hydraulic
pressure.

6.4 Dimensional and other Requirements of Paving Blocks

Normally the length of a paving block is not greater than the mean width. Minimum thickness is 60 mm
the maximum length is 280 mm. The width is within the range 75 to 140 mm with chamfer in the range
3-5 mm and the sides are perpendicular.

Blocks have dimensional tolerance is ± 2 mm in all sides.

Water absorption should not exceed 5 %.

Weight loss in freeze-thaw durability test should not exceed 1 %.

A block should be purpose cut at site.

A multi-layer method of manufacture should be used to reduce block thicknesses.

6.5 Bedding and Joint Filling Sand

6.5.1 Bedding sand

The thickness of bedding sand should be uniform. Otherwise serious irregularities in surface profile can
result. Excessive differential deformation and rutting can also take place in service life.

Particle size and shape should be carefully selected. A graded sand with sharp shape is preferred for
ease of achieving density which can resist traffic. The sand should be free of deleterious materials.

6.5.2 Joint filling sand

The gap between two paving block should be filled with sand relatively finer than bedding sand.

Gradation of filling sand is as under:

Sieve size, mm Percent Passing

2.36 100

1.18 90 - 100

0.600 60 - 90

0.300 30 - 60

0.150 15 - 30

0.075 0 - 10

A sand should be clean, washed and dry. it should not be mixed with cement.

6.6 Base Layer

Base courses are unbound crushed rock, water bound macadam, wet mix macadam, cement bound
crushed rock/granular materials and lean cement concrete.

Wherever the subgrade is weak (having CBR value below 5), bound granular materials is used to reduce
the stress on subgrade provided that climatic and environmental conditions permit the usage of such
base.

6.7 Sub-base Layer

A subbase course is introduced where commercial traffic is expected. It is inferior to base and includes
natural gravels, cement treated gravels and sands and stabilized subgrade materials.

7 DRAINAGE

At the construction stage, water is seeping through the joint filled with sand. The water finds its way to
sand bed below base, subbase and subgrade layers. If these layers are not free draining, appropriate
drainage arrangement has to be provided. Generally, a subsurface drainage is provided which is
surrounded by a filter material or geotextile.

Following diagram illustrates the function and use of subsurface drainage for block pavement.

8 CONSTRUCTION

8.1 General

The construction of block pavement involves preparation of subgrade, subbase, base course layers ,
bedding sand and finally laying of blocks. The laying can be made either manually or by mechanical
means. Technical specification is provided for such operation.

8.2 Preparation of Subgrade

It is the foundation layer for the block pavement. Conventionally the depth of water table should be
600mm minimum.

8.3 Base and Subbase Courses

Base and Subbase courses are constructed in accordance with standard procedures as per MoRTH
Specifications.
When cement bound base is proposed it may be constructed using dry lean concrete as per IRC:SP:49.
The QC specified in IRC:SP:112 shall apply. In case of repair work where compaction is not possible CLSM
may be used as under:

i. For footpaths and cycle tracks 2 MPa

ii. For cars and light vehicles 4 MPa
iii. For heavy vehicles 6 MPa

Maintaining level and grade are very important for block pavements. In small widths where compaction
of GSB, WBM, WMM may not be done adequately it is recommended that 75 mm to 100 mm thick DLC
be provided over these granular layers to maintain the level and surface regularity.

8.4 Placing and Screeding of Bedding Sand

The thickness of compacted sand bedding should be 30 ± mm. Localized depressions should be
corrected before filling.

Sand should be placed when it is slightly moist having M/C of 6 to 8%. Prepared bed should be protected
tarpaulin or polythene sheets.

8.5 Laying of Blocks

Laying of blocks can be made by made manually or by mechanical means to speed up construction.
Laying should start from the edge strip towards the inner side and in one direction only.

8.6 Bonds or Patterns of Laying Block

Blocks can be placed to different bonds or patterns depending upon choice. Some popular bonds
commonly adopted for block paving are:

i) Stretcher or running bond

ii) Herring bone bond
iii) Basket weave or parquet bond

A typical layout of these bonds are given in Fig. 14

8.7 Establishing the Laying Pattern

In relation to the starting line, the blocks should be placed at correct angle to achieve the final
orientation as required by the laying pattern. If the edge restraint is straight and suitably oriented, the
first row of blocks can abate it. For irregular shaped and unfavourably oriented edge restraints, a string
line should be established a few rows away to position the first row.

The control over alignment, laying pattern and joint widths can be maintained by the use of chalked
string lines, at about 5 m intervals.

8.8 Methods of Construction of Block Pavement

8.8.1 Manual Methods

In the traditional manual method, a pavior along with an assistant can lay 50 to 75 m 2 of paving per day.
The output of finished pavement varies widely with training of workmen, over a wide range from a low
of 20 to a high of 120 m2/man-day.

8.8.2 Mechanised Methods

Mechanised laying requires the use of specialized equipment for transporting and placing cluster of
paving blocks. The size of paving block cluster suitable for paving, is usually 0.3 to 0.5 m 2 in area for hand
operated equipment. For fully mechanized equipment, the cluster surface area can be upto about 1.2m 2.

8.8.3 Compaction

Plate vibratory compactor is used. A minimum of 2 passes are need to achieve required compaction.
Compaction should not proceed closer to 1 m from laying face, except after completion of pavement.

8.8.4 Joint Filling

Operation of joint filling comprises of spreading a thin layer of the joint filling sand on the block surface
and working the same sand into each joint by brooming. Following this, a few passes of heavy plate
compactor are applied to facilitate fine sand to fill joints. The sand should be broomed or spread over
the surface with a small surcharge.

Unfilled or partly filled joints allow blocks to deflect, leading to loose blocks, possibly spalling the edges
and a locally disturbing bedding sand layer.

8.8.5 Opening to Traffic

Lime or cement treated layers in the pavement require 14 and 7 days respectively to cure, before traffic
is permitted. Frequent inspection is required to ensure quality.

8.8.6 Laying and Surface Tolerances

While laying the surface tolerances, given below may be observed:

Layer/Item Tolerance, mm
Subgrade +0, -25mm of nominated
level
Select subgrade/Subbase -0, -20 mm of nominated
level
Base course -0, +10 mm of nominated
level
10 mm deviation from a 3m
straight edge
Plan deviation
10mm max
20mm max
Vertical deviation from 3 m line at kerbs intrusions, +3mm, -0mm
Channels, edge restraints elsewhere
Maximum difference in surface level between adjacent paving units +5mm, -5mm
Deviation of finished surface level from designated level +10mm, -15mm
Joint width range 2mm to 3mm
Percentage of joints outside range 10% max. along 10m line
Nominal joint width 3mm
Final finished surface with 3m straight edge +3mm, -3mm