APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

METHODOLOGY OF DRY LEAN CONCRETE

(Rectification of Damaged Portion)

TABLE OF CONTENTS

S. No. Description of Title Page No.

1.0 Purpose 2
2.0 Scope 2
3.0 Definitions 2
4.0 Cross References 2
5.0 Responsibilities 3
6.0 Procedure 5-11
6.1 Construction Materials for DLC 4-5
6.2 Design of Mixes for DLC , Trials 5
6.3 Details of Plant, Equipment and Machinery 5-6
6.4 Survey and Setting out Works 6-7
6.5 Trial Patch for DLC 7-8
6.6 Paving of Dry Lean Concrete ( DLC ) 8-9
6.7 Quality Control Checks for DLC 9-10
6.8 Safety and Environmental requirements 11

1
 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

1.0 PURPOSE:
The purpose of this Methodology for Reconstruction of damaged or settled Dry Lean Concrete
(DLC) is to provide detailed Construction Methodology, Materials used, Resources deployed and
also Quality Assurance & Control System/Procedures to be followed by APCO. and its Sub-
contractor’s/Supplier’s etc. as approved by Engineer/rep. of Engineer in execution of DLC under
the said Contract.
2.0 SCOPE:
The Scope of this Segmental Quality Plan shall covers the following activities:
 Selection, Testing and Acceptance of all incorporated Materials for DLC.
 Design of Mixes for DLC and Trials, Acceptance etc.
 Details of Plant, Equipment/Machinery as required in execution of DLC.
 Batching, Mixing, Transporting, Placing, Finishing and Curing of Concrete for DLC.
 Quality Assurance and Control Checks during operation and post concreting.
3.0 DEFINITIONS:
The words like Contract, Contractor, Engineer (Synonymous to Engineer’s representative),
Drawing, Employer, Government, Works, Worksite used in this Quality Plan shall be
considered to have the meaning as understood from the definitions of these terms given in the
General conditions of the Contract.

4.0 CROSS REFERENCES:

This Segment Quality Plan shall be read in conjunction with the following documents:
i) Specifications for Road & Bridge works, Ministry of Road Transport &
Highways (MORTH) – 5TH Revision.
ii) Guidelines for Expressway (2010).
iii) Manual of Specifications and Standards for Expressways (IRC:SP:99- 2013)
published by IRC, Government of India

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 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

5.0 RESPONSIBILITIES:
Responsible personnel for execution and quality control activities in construction of DLC are as
per the Responsibility Matrix under mentioned:

Sl. Checking / Approving

Activity Description Execution
No. Quality Authority
Control
01 Preparation Quality Plan Section-in- Manager Project
for DLC. charge Pavement & Manager /
QC Manager Engineer
02 Selection and Testing of QC Engineer/ Project
various materials for DLC, Lab Technician QC Manager Manager /
Mix Design & Trials etc. Engineer
prior to start of DLC
activities.
03 Establishment of C/way Surveyor Survey in- Engineer
centerline with Total charge
station as per coordinate.
04 Survey, Setting out and Surveyor Section-in- Engineer
fixing of string lines prior charge/Site
to start of DLC Engineer
05 DLC Paver deployment at Section-in- Manager Project
various locations and other charge / Site Manager
logistics, management etc. Engineer
05 Batching and Mixing of Batching Plant Q.C. Engineer
Concrete as per approved In-charge Engineer/Lab
Design Mix. Technician
06 Control on movement of Paver Paver In- Manager
Paver and maintenance Engineer/ charge (P&M) for
checks/control during Supervisor effective
operation. control of
Paving
Operator
07 Transportation, Placing, Section-in- Q.C. Engineer
Compaction and finishing charge / Site Engineer/Site
of DLC Layer. Engineer Engineer

08 Inspection & Testing of DLC QC QC Manager / Engineer

as per approved ITP and Engineer/Lab QC Engineer
maintaining all formats. Technician

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 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

6.0 PROCEDURE:
The detailed Construction Methodology involved in execution of DLC including Quality
Assurance & Control etc. has been described in the following sub-chapters:
6.01 Removal of damaged DLC portion : First of all we shall remove damaged DLC
layer with mechanical tools i.e excavator, Concrete cutter without disturbing the GSb
Layer. Second we do correction in GSb layer if somewhere required followed by
compaction as per approved gradient & camber. Then we do relaying of DLC as
described below..
Selections, Testing and Acceptance of Construction Materials for DLC:

6.02 Cement: As per the Technical specifications – MoRT&H Cl. 601.2.2, Ordinary Portland
Cement of 43 grade conforming to IS: 8112 shall be used. MTC/Lab test report shall be
maintained for each and every batch of Cement received and Cement shall be stored as per
MoRT&H Clause no. 1014.4.

6.03 Coarse Aggregate: Aggregate’s to be used in the construction of DLC shall be of Crushed
aggregate complying with IS: 383. Aggregate shall not be Alkali reactive. Coarse aggregate
shall consist of clean, hard, strong, dense, & durable pieces of crushed stone & shall comply
with clause 601.2.4.2 of MoRT&H. Maximum size of Aggregate used shall be 26.5mm for DLC.
The coarse aggregate shall comply with clause 602.2.6.2 of MoRT&H.
6.04 Fine Aggregate: The Fine aggregate confirmed 601.2.4.3 shall consist of clean, natural
sand or crushed stone sand or a combination of the two and shall conform to IS: 383. Fine
Aggregates shall be free from soft particles, clay, shale, loam, cemented particles, mica, and
organic and other foreign matter. The fine aggregate may be obtained in either way
mentioned as per MoRT&H clause no. 602.2.6.3

After blending it shall conform to the grading as indicated in table 600.1 of MoRT&H.

Table – 01
( Aggregate Gradation for Dry Lean Concrete )

Sieve Designation Percentage passing the Sieve

by Weight
26.50 mm 100
19.00 mm 75-95
9.50 mm 50-70
4.75 mm 30-55
2.36 mm 17-42
600 micron 8-22
300 micron 7-17
150 micron 2-12

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 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

75 micron 0-10

6.05Water: Water to be used for mixing & curing of concrete shall meet the requirements
stipulated in Clause 1010 of Section 1000 of MoRT&H specifications. and approval
for the same shall be taken from the Engineer before use in mix. Water for preparation of
concrete during hot weather shall be from water chilling plant installed at site.

6.0.1 Curing Compound: The Curing compound shall be wax based white pigmented or
transparent type with water retention index of 90 % when tested in accordance with BS
7542. Curing shall be done as per cl.601.6.7 of MORT&H.

6.1 Design of Mixes for DLC and trials :

6.1.1 Mix proportions for Dry Lean Concrete (DLC) :

The mix design shall be carried out for Concrete for DLC as per MoRT&H Cl. 601.3. The
aggregates used for the construction of Dry lean concrete shall conform to the grading as
indicated in Table-01. The mix shall be proportioned with a maximum aggregate cement ratio of
15: 1.
The water content shall be adjusted to the optimum for facilitating compaction by rolling. The
Optimum water content shall be determined and demonstrated by rolling during trial length
construction and the optimum moisture content and degree of compaction shall be approved by
the Engineer.
The Cement content in the Dry Lean Concrete shall not be less than 150 kg /m3In the event of
this minimum cement content is not sufficient to produce concrete of specified strength the
clause 601.3.4 of MoRT&H shall be fulfilled.

The average compressive strength of each consecutive group of 5 cubes made in accordance
with Clause no. 903.5.1.1 of MORT&H, shall not be less than 10 Mpa at 7 days, with individual
cube strength not less than 7.5 Mpa. Trial stretch for DLC will be conducted as per Cl. 601.8 of
MoRT&H and results submitted to the Engineer for approval.
6.2 Details of Plant, Equipment and Machinery:
The following Plant, Equipment and Machinery shall be deployed for DLC execution and shall be
maintained as per manufacturers operations /maintenance guidelines:
Batching Plant:

Batching Plants of suitable capacity as per project requirement will be installed to cater the
needs of Concrete for DLC and PQC uninterruptedly and these Plants are fully automatic in
operation to produce Concrete of consistent proportions /quality & quantity at desired rate.

5
 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

DLC Paver:
Paver of VOGALE make shall be used for laying DLC. This Paver is capable to receive the
Concrete dumped at front end in hopper of the Paver from Concrete Dumpers, spread, impart
initial compaction laying and finishing. Level shall be controlled by Sensors fixed at two sides of
the Paver guided with pre-fixed gauge wire aligned as per level and alignment shown in the
drawing.

Paver shall be maintained as per manufacturer’s instructions and daily checks shall be carried
out to ensure proper and uninterrupted functioning of the machine.

In addition to the above Major Plant and Equipment the following Machinery shall also be used
for laying DLC:

 Concrete Transporting tippers – The concrete shall be transported by tipping trucks

(Capacity 22 MT), sufficient in numbers to ensure a continuous supply of material to feed the
laying equipment to work at a uniform speed and in an uninterrupted manner.
 Tandem Vibratory Roller – 02nos. Double drum smooth wheeled vibratory rollers of 80 to
100 KN capacities shall be used for compacting DLC.
 Curing Compound spraying pump/machine
 Total Station, Level instruments, string wires & pegs, hand winches etc – as required
 Water tanker with sprinkling bars, gunny bags etc. – as required
 Q.C. Machinery/tools Cube moulds etc. As required at field and a full-fledged Material
Testing Laboratory has already been established for performing various laboratory tests on
DLC as per relevant ITP’s.
 Lighting Towers /Illumination as per requirements.

6.3 Survey and Setting out for DLC:

Survey and setting out of String line is a very important and crucial activity to be completed and
thoroughly checked prior to start of DLC Layer. The following steps are involved in Setting out of
string wire before laying DLC:

1) Reference line of Carriageway will be marked at suitable intervals on DL surface by using

Total station.

2) String line of 3mm dia wire rope will be fixed on both sides of proposed DLC edges
approximately 1.0 – 1.5 M away from edge of the DLC. This string line will be supported /
anchored by stakes at 10 m intervals on both sides.

6
 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

3) The string wire shall be tensioned on the stakes so that a 500 gm. weight shall produce a
deflection of not more than 20mm when suspended at the midpoint between any pair of
stakes. To ensure the required tension of string wire, hand winches will be used to
tighten the string line to avoid any sagging. These winches will be placed at maximum
300 M intervals.

4) The stakes shall be positioned and the string wire maintained/tensioned at their correct
level/height and alignment as per relevant section drawings on the day before concreting
takes place.

5) It shall be ensured that the stakes and guide wires are not affected by the construction
equipment when concreting is in progress.

6) The DLC Edge shall be marked with Lime on Drainage Layer Surface with respect to
reference points marked in Step 1) above

7) Detailed Survey Check sheet, shall be maintained incorporating all survey and setting out
details relevant to DLC being executed.

6.4 Paving of Dry Lean Concrete (DLC):

Laying of DLC on main Carriageway will be carried out as per the followingsteps:

Surface Preparation:

 A day before start of DLC sub-base, the approved DL surface shall be given a fine spray of
water and rolled with one or two passes of a smooth wheeled roller after a lapse of 2-3
hours in order to stabilize loose surface.

 String line shall be fixed at both sides of proposed DLC pavement as per the procedure
described in previous clause and necessary setting out checks shall be performed by
Surveyor, survey check sheets recorded and approval from Engineer shall be obtained
before laying of DLC.

 DLC Paver positioned and checked in all respects for smooth and uninterrupted
functioning during DLC laying operation.

7
 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

Concrete Production:

 Silo(s) of adequate capacity will be provided to store the cement and a suitable
arrangement will be made to feed the cement.
 6 Nos. aggregate bins have been provided and wheel loaders/dumpers will be used to
load aggregate hopper. Aggregate bins shall be feed from stacks of approved materials
through feeder conveyor of Batching plant. Care shall be taken to feed the aggregates
into the designated bin.
 Water will be obtained from bore wells at the plant site or any other approved source
and shall be stored in adequate capacity water storage tanks.
 Batch size of up to 2.25 m3 will be produced from the plant and dispatched to the site.

Transportation:

 Concrete will be transported by tippers.

 Tipper carrying concrete shall be protected adequately by covering them with
tarpaulins
Paving:

 DLC shall be laid/placed by DLC Paver capable of laying the concrete in full width in one
pass without any segregation, to achieve so that after compaction the total thickness as
specified i.e., 150mm The Paver machine has high amplitude tamping bars to give good
initial compaction to the DLC.
 The laying of the two-lane road sub base 10.5m width shall be done by DLC Paver.
 The DLC paver shall move as per the string wire set at desired level guided by the
Sensors pegs at 10m interval.

Compaction:
 Compaction with Double drum smooth-wheeled vibratory rollers of 8 to10 T static
weight shall be carried out immediately after the DLC is laid by paver. Area inaccessible
for the roller will be compacted by plate vibrator.
 The optimum rolling shall be broadly determined during trial patch exercise.
 The rolling shall be continued until the minimum density obtained is 97 percent of the
density achieved during the trial patch/stretch.
 Surface undulations shall be checked with 3m straight edge and deficiency should be
made good with concrete with aggregate of size 10mm and below.

Curing:
 As soon as the lean DLC surface is compacted, curing shall commence. Initial curing
shall be done by spraying liquid curing compound by suitable means and later when
curing compound lost its tackiness curing shall be done by covering the surface by
gunny bags/Hessian, which shall be kept continuously moist for 3 days by sprinkling
water as per the specification.

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 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

1) Surface Tolerance: Surface Tolerance of finished DLC layer shall be within ± 05mm of
specified levels as per MoRT&H Table 900-1. The surface tolerance shall be checked at
every 6.25m longitudinally & 3.5m transversely grid point and recorded.

2) Various Quality Control checks during laying, compacting and after finishing of DLC shall
be performed and described in Quality Control sub-chapter of this Quality Plans.

6.5 Quality Assurance and Control Checks for DLC:

As part of Quality Assurance this methodology for DLC has been prepared in line with the
specifications provided in relevant MoRT&H clauses, Contract Supplementary Technical
Specifications and other Codes/Standards/Specifications etc. elsewhere mentioned in this Plan.
This Plan shall be distributed to all concerned personnel who are involved in overall execution
of DLC in order to ensure that work shall be performed as per the procedures furnished in this
Quality Plan and also to achieve consistency in execution at various locations.

As a part of Quality Control all the Inspection and Testing requirements for various activities
involved in laying of DLC shall be carried out as per relevant MoRT&H Specifications & Contract
Technical Specifications etc. as described in Inspection and Test Plans attached to this Segment
Quality Plan for DLC.

These Inspection and Test Plans shall consist of type of Inspection and name of the Test to be
conducted for Product Realization, frequency of testing, acceptance criteria and category of
Inspection as mentioned in the legend of ITP.

Inspection and Test Plans shall be revised whenever there is any change in methodology and
specifications etc. Various Field and Laboratory Test Formats referred in Inspection and Test
Plans shall be maintained as per the frequency mentioned in respective ITP’s for various
activities.

1) Surface Tolerance: Surface Tolerance of finished DLC layer shall be within ±5mm of
specified levels as per MoRT&H Table 900-1. The surface tolerance shall be checked at
every 6.25m longitudinally & 3.5m transversely grid point and recorded.

2) Various Quality Control checks during laying, compacting and after finishing of DLC shall
be performed and described in Quality Control sub-chapter of this Quality Plans.

9
 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

6.6 Segment Safety & Environmental Requirements:

Hazard Identification, Risk assessment and Risk control measures for each and every activities
and sub-activities involved in the present Segment shall be identified and necessary action plan
shall be initiated.

Environmental Aspects and Impacts associated with various activities and sub-activities
involved in the present segment and their mitigation/control measures shall be identified and
necessary measures shall be initiated.

The APCO Environmental Management Plan and APCO Safety Management Plan have been
incorporated with contract EMP as suggested.

EMP mentioned in contract specification in relation to all constituent materials activities/sub

activities forming DLC and its laying at site shall be strictly adhered to.

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