satander50@yahoo.co.

in 9971974477
 IRC SP:83-Structural Distress
• 3.2.1 Structural distresses –
• Cracks/defects D> half the depth
• Uncontrolled/random crack like
• longitudinal, transverse, diagonal,
• intersecting cracks that extends
• through depth of slab
• > D/2, where ‘D’ is depth of PQC
• Slab-Structural crack.
 3.2.2 Functional distressIRC 134.pdf, 10, 11, 18, 32-34, 45
• 3.2.2 Functional distress
➢ These distresses do not reduce load carrying capacity of
pavements
➢ But affect riding quality,
➢ Affect road Safety.
➢ Roughness > 2000 mm/km- rectify,
loss of surface texture, Faulting, Scaling, Raveling ,Pop outs
Raveling Scaling, Faulting and smooth
• NSV - Guidelines - letter - 31.07.20.pdf

• FWD Maintenance Cell_RAMS_MoRT&H_08-

07-2021.pdf

• Final sent to Members

• MoRT&H Specifications - Bridge Part 3 Oct
2022
1. Routine Maintenance or reactive Maintenance:

i) To keep Functionally proper

ii) Start immediately or approval from higher authority
may not be necessary being very very small budget
iii) Not applicable for severely distressed otherwise
wasted effort.
 a. Routine Maintenance

i. Vegetation Control,
ii. Line Marking,
iii. Road marking,
iv. Sign post
v. Drain Cleaning
vi. Monitoring condition of pavement,
vii. Pavement/ joints clean
viii.Restoring damaged / eroded shoulders
b. Programmed Maintenance: IRC:SP:83 cl 2.1 IRC
SP 83-2018.pdf page 11
➢ To arrest deterioration
➢ To restore to its original condition
➢ Work is programmed, methodology is
approved
Repairing Defective joints:
➢ Cross –stitching
➢ Partial depth, full depth repair
➢ Remove faults with diamond grinding
 , x stitching single slide.mp4,cleaning
hole and cracks.mp4
Chase 10mm groove along the
For d < D /2 , as confirmed by Core Cutting. See Note 1

line of the crack and seal with Preliminary Vertical Hole

low viscosity epoxy resin
150

Plastic Shrinkage Crack

0 - Surface

36o
Governed by length of Drill Bit

d
110 mm

12 dia
High Yield Deformed Reinforcing bar
Epoxy Resin

350
PQC 400

Notes: '(All dimensions in mm)

1. This method of repair shall only be accepted where
discrete cracks are demonstrated by core cutting to be less
than 50% of thickness PQC and written approval is provided
by the Engineer.
20 12
2. Maximum spacing 500mm

3. EPOXY as per IRC:77 only. Polyester resins shall not be

330 - Bottom of PQC used

DLC
CROSS STICHING
 Programmed
Maintenance

2. Restoration-

i. Slab Replacement,

ii. Partial depth repairs,

iii) Diamond grinding locally

11.3 Restoration of Evenness
and Skid Resistance (Diamond
Grinding)

➢ 11.3.1 Removing of bumps

and re-profiling of surface
of concrete pavement
➢ By means of diamond
grinding improves surface
evenness
➢ Decreases severity of
impact from dynamic load
of vehicles.
➢ Presence of bumps and
unevenness in pavement
causes increased tensile
stress
➢ Reduces its life.
 c. Rehabilitation and Strengthening:
➢Structurally restore the condition
➢To impart further design
➢ Diamond grinding for retexturing
➢ Reconstruction
➢ Overlay
➢ Dowel bar retrofitting
d. Emergency repair- oiled/fired/speed break/localized earth quake
Bonded/unbonded OverlayIRC SP 17-
2019 Last Proofs.pdf 36
Crack Width Wrong 5 mm Crack Width Right 0.5 mm
0.5 mm 5 mm 0.5 mm 5 mm

Shrinkage Crack or shallow cracks < 0.5 mm wide cumulative length > 3m IRC 15
Plastic shrinkage after 4 hours, width 0.5 mm depth 50 mm

Reasons of plastic shrinkage cracks: LOW RH, HIGH TEMP., HIGH

WIND SPEED, POOR/MORE SAND, NO ADMIXTURE, MORE FINES

Reasons of Drying shrinkage: crack after 14 days width 0.5 mm depth 50 mm

MORE WATER, NO PLASTICIZER, NO PROPER CURING, NO TIMELY COVERING
 Plastic Cracks Y -Cracks Corner Cracks
Evaporation of High Shrinkage Excessive load
water > 1kg/m2/h cracks- high water
i.

Wind Y
ii.
iii.

Spalling faulting Scaling

Agg in joints: unstable base, no Loss of wearing
No sealant, weak dowel or mis- Too early traffic
concrete at edges alignment open, more slump
over vibration
 Edge Longitudinal and Diagonal Cracks
Cracks Transverse Cracks Punchout
Under design, mis align D. Poor sub base/base Poor filter media, weak lower layers
More camber, more slump,
D cracking, joint cutting BC soil, late joint cut Low strength
machine not oiled

Construction Cold J.
Differential settlement

Crazing Reflection Blowup/ mud

sympathetic crack pumping
rich mixes, Cracks in lower layer, Locked joints, no dowel
Inadequate No APP, No Debonding No sealant, agg in joint
curing layer
 Practical Reasons of longitudinal cracks
Tie Bar - Dowel Bar Alignment for Concrete Pavements - MIT-DOWEL-SCAN.mp4
IRC:SP:83-2018 Table 3.1 page 19, Reasons of Longitudinal cracks

• Black Cotton soil, lower side poor, less E value

• Widening- over different densities - TRF.
• L/B > 1.5 and wrong alignment
• Slippage , More camber/ slump
• Channelized movement
• Late joint cutting
• Wt of panel = 10.6 ton
• Too low/high slump

25 per cent of the joints by using Magnetic Pulse Induction (MPI) device as per
ASTM E3013/E3013M – IRC 15.
11.5.5.2 Rejection Criteria
If more than half of the dowel bars at a joint do not meet any of acceptance
criteria mentioned in Clause 11.5.2, then the joint shall be treated as a locked joint
and rejected.
Practical Reasons of transverse cracks:

i) Too late final joint cutting

ii) Joints not cleaned timely

iii) Cold joints or old joint cutting machine

iv) Deficiency curing,

v) Dis similar like on Box Culverts

vi) Dowel bars misaligned,

vii) Shoulder drop off in BC soil

22
Cross
Stitching in
Process

23
 MORTH Clause 3004 Page 791IRC 82-2015 excel sheet.xls,
• BITUMINOUS WORK - MAINTENANCE AND REPAIR:

1. Pothole and patch repair, Cold mix/Hot mix

2. Crack-sealing / filling cracks/ Fog spray,

1. Routing and Crack Seal Process
(1).mp4 Crack sealing.mp4

3. Dusting, Slurry sealing,

(IRC:SP:81)

Slurry Seal Kuihelani Hwy, Maui HI.mp4

4. Surface dressing, IRC:110-2005

• IRC:SP:17- Bonded Overlay
• Bonded milling 10 mm or extra PQC
• Minimum Thickness 100-150 mm up to 15 msa
• Fr = 1.305 Fte
• IRC:SP:17- un-Bonded Overlay
• Seperation layer 40 mm BC geogrid in PCC, No in RCC
• Minimum Thickness 150-200 mm up to 15 msa
• Fr = 1.305 Fte
In partially bonded system, the
overlay is designed similar to
un-bonded.
Provision of separation layer
(for bond breaking) is not
required, or the interlayer layer
if provided may not function as
separation layer
6.4 As separation layer is omitted,
the slurry from PQC can fill the
cracks in the layer below, and hence
it need not be repaired for small
cracks and minor distress.
IRC SP 17-2019 Last Proofs.pdf 20, 36
 IRC:SP:17 REHABILITATION
Unbonded Overlay
ho= ( hm2 - C he2 )1/2
Partially bonded Overlay
ho= ( hm1.4 - C he1.4 )1/1.4

Category Length of crack m/sq m

Value of C
Slightly Cracked 1.0- 2.5 C = 1.0
Fairly Cracked 2.5- 5.5 C = 0.75
Moderately Cracked 5.5- 8.5 C = 0.55
Badly Cracked 8.5- 12 C = 0.35
 IRC:SP:83-2018 Maintenance of CC Roads

• BI less than 2200 mm/km in CC (Table 4.2 page 28)

• BI less than 2000 mm/km in BC (Table 4.2 page 9)
• Shallow cracks/shrinkage cracks donot need repair p-29.
• Table rating 4.4 page 33: Max 2, but up to 3-DLP acceptable, more
than 3 ? Page 31 IRC:SP:83
• Clause 4.6.4. FDR when: severity 5, crack/faulting more
than 12 mm in 50% area, rocking (Page 31)
• Maximum crack width - recorded as at least 50% of length.
Clause 4.5.1.b page 29IRC-SP-83-2018.pdfP37-39
• irc.gov.in.082.2015.pdf P 50
• IRC 82-2015 excel sheet.xls
As per IRC:15-2017: Plastic shrinkage
cracks with cumulative length of 3000 mm
in a slab can be accepted after repair as

per IRC:SP:83. clause 12.33 page 82.

MORTH 2013.PDF P 312, 313

IRC 15 2017.pdf, page 84
3D
902.4, 902.5 and 902.6 MORTH clauses
IRC SP 99 2021.pdf 214-218
IRC SP 84 2019.pdf 30,51,55
IRC SP 87-2019.pdf 48
IRCSP:99-2021
 Table 4.5 Severity
Distress Degree Assessment Depth of crack Depth of crack
of S. less than half more than half
the PQC Depth the PQC Depth

Discrete 1 Width < 0.2 mm No action Not applicable

Cracking
2 0.2 -0.5 mm Seal without Seal and stich
delay L > 1m

3 0.5-1.5 mm Seal without Seal and stich

delay L > 1m

4 1.5 -3 mm Seal and stich Staple/retrofit

L > 1m dowel. FDR
affected

5 > 3mm upto 12 mm Seal and stich Staple/retrofit

L > 1m dowel. FDR
affected
Table 4.5 Page 32, IRC:SP:83-2018Repair of Longitudinal cracks

38
 IRC 15 2017.pdf, 38, 65
page 28,
•FIELD PROBLEM
IRC:SP:83 Page 11-12
• Ravelling: low in depth
• Loss of fine aggregates and
hardened cement paste < 5mm.
• Scalling: More in depth
• Peeling off upper part of slab
surface (5-15 mm)
Causes:
• more fine,
• early traffic
• Plasticizer?,
• low lying areas
• dusty aggregates

Remedial Low viscosity Epoxy/Microcrete/GP2

 Repairs – Ravelling--aggregates are
exposed and Re-surfacing of Pavements
With Epoxy:
➢ Chiselling and Cleaning with compressed air,
➢ surface dry and apply epoxy resin of low viscosity
epoxy
➢ epoxy sand mortar about 1:3 to 1:6 ( Epoxy+
Hardener: cleaned Sand ) 10-15 mm depth
 Repairs – Ravelling—widening/jacketing
With Conventional Mortar/microcrete:
➢ Exposed surface > 15 mm in depth but no cracking
➢ Flooded water for 48 hours or keep wet for 48 hours,
➢ Apply cement slurry
➢ After 2-3 hours apply 1: 3 Cement sand mortar
1:1:2 ( cement :sand: 6.3 mm
aggregate) when depth more

➢ Use pre cast block, steel bars

as stitch segment..
 Spalling Layout
Distress < 0,6 m
width

A B C D
Crack Joint
Joint
Transv. Transv. Transv.
Joint Joint Joint

Low Sev.:
1,8 m Low Sev.: C D
2m Moder. Sev.:
2,5 m
High Sev.:
1,5 m Traffic
A B

Shoulder
 Faulting Layout
A
faulting B

Longitudinal Joint
C
L
Transv.
Transv. Joint
Joint

A B
Traffic
Slab
IRC 57 2018.pdf 10 page (Hot sealant )
 Clause 903.5.2.3 PQC-
Insitu density
• Air voids not more than 3% as compared to
theoretical density 150 mm dia cores
100
Gt =
Pca Pfa Pmf Pb
+ + +
• From trial and next 2 km new work Gca G fa Gmf Gb
• air meter hardened conc.mp4 ( SP-1(02); ASTM C457,
• Page
• Determination air content fresh IS 1199
• 434 MORTH, then 1:2:2 re-laid
MAINTENANCE IRCSP:83-2018 Page 28

52
 Mr Radhey Shyam 09971591132
• Full depth cutter cum grinder.mp4
• ACPA Pavement.docx
• FHWA-NJ-1974-001-7713.pdf page 8 and 15

• Diamond Grinding : IRCSP:83 page 9

• A specialized technique used to extend serviceability,

improve ride and skid resistance

• Pavement preservation technique that corrects variety of surface

imperfections.
• It uses a series of diamond tipped saw blades gang-mounted on a
shaft for correcting irregular surfaces in concrete pavement
• Faulting, curling and warping of slabs.
• To restore skid resistance.
 Preventative Treatment
DOWEL BARS RETROFIT

Edge of Slab

32 dia Dowel Bars

x 450 long

3-4 per wheel path

@ 300-375 mm cts
TYPICAL

Slot 500 long x 50 wide

Longitudinal Joint

Edge of Slab

(a) Plan (b) Side View

MUMBAI PUNE EXPRESSWAY _ OUR FIRST
58
EXPRESSWAY OF RIGID PAVEMENT 100 KM
59
Page 70

60
PARTIAL DEPTH REPAIR

EP 75
Hard Texturing in Process/ Micro milling
63
Table 900-2 Max. Irregularity allowed -3 m st. edge
Once a day
• Longitudinally----

• Irregularity 4mm 7mm

• Length 300m 75 m 300m 75m

• NH 15 9 2 1
• RR 40 18 4 2

• Longitudinal/Transversally: allowable difference –

• Cement Concrete 3 mm
• Bituminous base 6 mm
• GSB 8 mm
• DLC/WBM 10 mm
 100 mm

100 mm

- 9mm - 6 mm
12mm
- 3 mm 0 mm
+ 3 mm + 6 mm + 9 mm
21 mm 18 mm 15mm 12mm 9 mm 6 mm 3 mm

12.5 mm
12.5 mm

3 meter straight

100 mm 100 mm
 902.6 bituminous concrete wearing surface-
Riding Quality of New Pavement
• Maximum irregularity soon after initial curing < 3 mm

• Bumpintegrator (BI) values < 2000 mm/km (~3 IRI)

IRC 134.pdf, skid reisitance,
•IRC SP 135.pdf,
•IRC SP 17-2019 Last Proofs.pdf
• IRC:SP 16 2004 BI= 630 (IRI)1.12

Av. < 2000mm 902.6 + 3000 mm /km

Good Poor
 IRC: 134-2022 skid resistanceIRC
134.pdf 12, 27, 38

Coeff of Friction): f = F/L

F = Frictional resistance to
motion in plane of interface
L = Load perpendicular to
interface Skid Number:
SN = 100 ( f )
• Bush hammering retexturing Hand
techniques
held Bush hammer

• Shot blasting

• Grooving/grinding

• Orthogonal grooving shot blsting

• Carbonising

• Water jetting

• Fine milling

• High Friction Surface treatment (HFST)

• High-Friction Surface Treatments (Long Version) 2014.mp4

• MIND BLOWING LATEST ROAD TECHNOLOGIES.mp4

 Air Voids AVOID
Air Voids %= ((Sp gr – density)/Sp gr)*100

In PQC air voids maximum 3%

1% air Voids reduces 6% Compressive strength, (

Inter contacted Voids)
Maximum plasticizer 2%
No honey Combing means more strength
deflection Evaluation Process IRC 117 FWD

Distance
71
Ground Penetrating Radar
The pavement-maintenance management
system (PMMS)

• It is a systematic method of
examination and classification of the
condition of roads in the studied area.
 Expansion Joint
Diamond Grinding of
Welds
MORTH 2800. REPAIR OF STRUCTURES clause 2802
 MORTH 2800. REPAIR OF STRUCTURES clause 2803

03.6. Testing

Viscosity test for resin and hardener and the mix: three specimens each.
Pot life test: three specimens each.
Bond test: three specimens each.
Shear test: six specimens each, 3 after 24 hours and the other three after 72 hours of
curing.

Pot Life Test- 500 gm of resin , when becomes just difficult to spread the resin properly
with the brush, the time is noted.
 MORTH 2800. REPAIR OF STRUCTURES clause 2803

shotcrete.wmv3DMiniii.wmv
2807. GUNITING/SHOTCRETING

2807.1. The gunite shall comprise 100 parts by weight of cement, 300 parts by weight
quartz sand, 35-50 parts by weight water and 2 parts by weight approved
quick setting compound.

TABLE 2800-2: PROPERTIES OF ACRYLIC ELASTOMERIC COATING

Sl.no. Parameter Requirement Reference

1 Specific Gravity 1.4±0.05 IS:345
2 Solid contents 70+ 3% IS:345
3 UV resistance No colour change ASTM-G-53/DIN-EN-150-105
4 IR-Spectrum As per Acrylic IR-Spectrometer standards
Polymer
5 Adhesion with concrete 1.5 N/m2 ASTM-D-4541-
02/DIN500014
6 Dry film thickness 200-225 Microns (for
minimum 2 coats)
7 Coverage 400-450 gm /m2 (2
Coats)
8 Physical properties Diffusion Equivalent air layer DIN 53122 Part –I
resistance against carbon thickness SDCO2
dioxide shall be >50 m
9 Diffusion resistance against Equivalent air DIN 52615
water vapour thickness SDH20 <4 m
10 Water proofing Percentage reduction
characteristics in flux should
be>50%
 MORTH Clause 3004 Page 791
• BITUMINOUS WORK - MAINTENANCE AND REPAIR:
5. IRC:SP:34-1989 Equipment -Bituminous Surface Dressing

6. Overlays and Special repairs. (IRC 115 FWD)

7. Materials (patching and overlay materials)

used in maintenance operations shall be of a
standard not less than those specified for the
original construction. 3004.1 Page 791 MORTH,

8. IRC:129-2019 Open-Graded Friction Course (OGFC)

IRC:112-/IS 456 page 37/38, IRC 112-
108/118 deflection

456.PDF 68-71, crack width,

FOS, 32-33, 37deflection,
17 relation
IRC:112-2020 page IRC 112.2020.pdf
108,118, 32 Fe 500 S
 Video Rolling .

• IRC:SP-86-2010 Guidelines for Selection, Operation and

Maintenance of Paver Finishers
IRC:90-2010 Selection, Operation and Maintenance of Bituminous Hot Mix Plant
SN D8efects
1 Crack W < 3, 3-6 mm
2 Pot Hole
3 Scaling/raveling/stripp
ing
4 Alligator cracking
5 Rutting/ Settlement/
shoving
6 Fatty surface, MORTH
3004.4.1 Dusting
page 796
7 MORTH 708.3.6 page
321,, Renewal
/strengthening
Causes Treatment
Over heating, dusty Fog Seal SS1 MORTH
3004.3.2,Compressed
agg, more moisture air, Scrubber, 0.7 l/sqm
Pressure tank/spraying
loss of adhesion Trimming Vertical faces IRC 116, IRC 100, IRCSP:82
Removal of failed
ingress of water material
higher voids, loss of Tack coat - all faces
Placing, compaction
cohesion, less Finishing with
Emulsified/ modified
binder bitumen, Sealed
Occurrence of rain/dust, Liquid seal, slurry seal,
hydrophilic aggregates micro surfacing
Insufficient rolling, IRC:SP-100-2014 Cold Mix
Technology Using
rolling of tender mix, Bitumen Emulsion
less void IRC:SP-101-2019 Warm
Mix Asphalt
Over loading, weak IRC : 116 Ready
layers, BC soil made mix /Pot hole
Lower voids , Use of Hot sand, coated
softer grade binder , chips, RAP, silt < 10%,
heavy tack coat 2.5 kg/sq m
After 6-8 years of Minimum Thickness
heavy distress of Overlay 40 mm
• IRC 82-2015 excel sheet.xls
 Slurry seal clause 4.2
Water (pH 6-7), 6-12%
Additive as per Manufacturer 0.5-2%
mix time minimum 180 sec
permit traffic with in 4 hours
Tack coat RS1+ 3 parts water cl 4.4.3
Type 1 Type 2 Type 3
Thickness 2-3 mm 4-6mm 6-8 mm
agg 4.75 mm 6.3 mm 9.5mm
Quantity slurry 4.3 to 6.5 8.4 to 9.8 10.1 -12
kg/sq m
Binder residual by 10-16 7.5-13.5 6.5-12
wt dry agg
Filler by wt dry agg 0.5-2% 0.5-2% 0.5-2%
IRC 82 Clause 5.3 Circular NSV - Guidelines -
letter - 31.07.20.pdf

Circular Integration of NSV_FWD Survey Data

with RAMS for all NHs_OM dt 040221.pdf

➢Condition surveys from a vehicle travelling

5 km/hour

➢ Supplemented by inspection of critical

locations by walking.
Ancient Silk Route
 Fresher can take care of him/her only, but
Senior shall take care him/her and self

Yes, it is my Job
Don't
walk in front of me,
I may not follow.
Don't walk behind me,
I may not lead.
Walk beside me and
It is not my Job
•EXTRA SLIDES
Steel may be coated, or galvanised to improve its resistance to
corrosion. Use of stainless steelIS:16651:2017. is permitted subject to
requirements stipulated in Clause , IS:13620
 CT Scan on X-Rays Scan on normal
core sample
sample

12 cored samples

Fiber QTY = 158kg/m3 (2% vol.)

34 mil fibers; Total Length = 643 km/m3
 The National Highway Precast Concrete Policy Circular
and Policy on use of UHPFRCNational Highway Pre-cast
Concrete Policy 08-04-2022 (1).pdf
Project Details
• Kundli- Ghaziabad – Palwal Section of NE-II in Delhi-NCT
• Project Length – 135km
• Lane Configuration – 6 laned access controlled expressway
• Pavement – Rigid pavement
• Operation start date – June 2018
• Construction completed in 6 packages -
➢ km 01.0 – km 22.0 – Sadbhav Engineering
➢ km 22.0 – km 46.5 - Sadbhav Engineering
➢ km 46.5 – km 71.0 - Jaiprakash Associates
➢ km 71.0 – km 93.0 - Ashoka Buildcon
➢ km 93.0 – km 114.0 - Oriental Structural Engineers
➢ km 114.0 – km 136.0 - Gayatri Projects

98
Observations on Rigid Pavement
• Most of the Section has higher Roughness
Roughness LHS RHS
Condition Range Inner Lane Middle Outer Lane Inner Lane Middle Outer
(mm/km) (%) Lane (%) (%) (%) Lane (%) Lane (%)
Good <2000 5.9% 9.7% 11.2% 9.6% 17.0% 13.4%
Fair 2000-2400 22.9% 24.4% 19.2% 19.2% 16.4% 20.7%
Poor >2400 71.2% 65.9% 69.6% 71.2% 66.6% 65.9%

• Longitudinal and transverse cracking within 3 years of construction

• Revelling from concrete surface
• Embankment slope is steep and not as per specification (V:H – 1:2) at many locations
• Approach slabs are settled for more than 70% of structures.
• Flexural strength of concrete panels is lower than 4.0MPA for more than 95% of the sections as per FWD.

99
 Roughness
Km-wise Roughness LHS (Sonepat to Palwal)
6000

4000
BI (mm/Km)

2000

0
17

72
12

22
27
32
37
42
47
52
57
62
67

77
82
87
92
97
2
7

127
102
107
112
117
122

132
Inner Middle Outer
6000
Km-wise Roughness RHS (Palwal to Sonepat)

4000
BI (mm/Km)

2000

0
1…
1…
1…
1…
1…
1…
1…
1…

90

25
95

85
80
75
70
65
60
55
50
45
40
35
30

20
15
10
5
Inner Middle
*NSV Survey – Sep 2021 100
FWD Assessment & Findings
Percentage of Project Road (%)
Pavement Layer Range Pre-tendering (Sep'2021)
LHS RHS
Greater than 30000 4 0
30000 - 25000 11 1
Elastic Modulus of PQC Layer 25000 - 20000 27 4
(MPa)
20000 - 10000 55 49
Less than 10000 3 46
Greater than 4.0 4 0
Flexural Strength of PQC Layer 4.0 – 3.5 11 0
(MPa) 3.5-3.0 17 2
Less than 3.0 68 97
Greater than 55 (equivalent CBR >
100 99
10%)
Modulus of Subgrade Reaction
48 – 55 (equivalent CBR 7% -10%) 0 1
(MPa/m)
Less than 48 (equivalent CBR < 7% 0 0

*FWD Survey – Sep 101

2021
Photographs

102
Photographs

103
IRC
52.2019.pdf
26-28

104
 Classification of damages
Minor damage amage

• spalls up to 30 mm

• structural capacity is not reduced.

• Restore concrete cover

• Moderate damage
• cracks and wide spalls 30-100 mm, exposed reinforcing steel and
prestressing strand.
• No immediate effect on the structural capacity. Can reduce structure’s life on.

• SEVERE

• Exposed prestressing strands and reinforcing steel

lateral mis-alignment due to girder distortion
 Major rehabilitation techniques

Impregnating additional Provision of External

low viscosity reinforcement additional prestressing
epoxy resin with a cast-in- beams (post–tensioning)
under high situ or gunited
pressure cover

FRP wrapping Bolting steel Externally Externally

stirrups bonded plates embedded
weak in shear
or flexure bolting/epoxy (FRP/steel
adhesive reinforcement
Shotcrete IS: 9012 MORTH 2803 page 765
• Pneumatically applied concrete or mortar placed directly on
surface, could be wet or dry mix process

• Used where area is larger ,depth of repair is greater and

about 25 mm below or behind the reinforcement

RCC jacketing MORTH Clause: 2804, 2805 page 766

• increases member size significantly and stiffness

• Shear keys and the bond coat in the form of epoxy coat shall
be applied for load transfer
 Concrete jacketing
(b) RCC Jacketing Of Existing Slab And Beam Connection
Shotcrete

Bolting of plates for shear

Fig: (a) Steel Plate Bonding On Side Faces Using Bolts
deficiency
J A C K E T I N G - Defective Piers
 Failure of
patch works
km 51.8
• Reasons:
• No time allowed
after prime
• No roughening
• Remedial Either
Epoxy or Cement
paste of rich mix
with smaller agg.
• Retexturing
after
diamond
grinding
 After Geo Grid
Minimum 40 mm BC
with PG Grade
bitumen
IS 15462 2019 PMB
NO CRMB al All
Reason settlement
No Epoxy
No PQC
also at km 40.3 LHS
full width BC
Partial Depth Repair after levelling
 After the soil has been stabilized, it is common to
reinforce retaining walls with the aforementioned
earth retention methods.
Perforated steel plates & Bamboo mats
Reinforcement at the founding level by bamboo pinning
 Concrete removal Rust Remover Chemical

Anti-Corrosive on reinforcement Provision of supplemental

reinforcement in RCC
Dye penetration test
Ultrasonic Inspection for flaw detector test
Paint coating thickness
 Before and after Lifting

b) Steel
a) Concrete
Bracket
Bracket
Extension of Seat
Length
 MORTH 2800. REPAIR OF STRUCTURES clause 2803

Vedio Pressure Grouting satander

maintenance.mp4
Satander X.mp4
128
 INNOVATIVE TECHNOLOGIES FOR GREEN
HIGHWAYS USING INDUSTRIAL WASTES

Total 424 Million Ton per Annum in India IRC:SP:132-2022 satander50@gmail.com

 Green Highways - INDUSTRIAL WASTE.pdf
One of the objectives of green highways is to reduce the impact of air pollution and dust by

planting trees and shrubs along the National Highways and making them sustainable. use

of industrial-wastes or by-products as one of the option to compliment it.

➢ fly ash, Processed C&D waste

➢ slag,
➢ recycled aggregate & concrete, (RA or RCA) not used
➢ construction and demolition
wastes
➢ Iron, Steel, chrom and Copper ➢ reinforced soil walls
Slag
➢ Jarofix ➢ concrete in structural/
➢ Phospho- Gypsun,
➢ Marble Slurry dust
➢ Foundry sand load bearing elements,
➢ Municipal wastes,
➢ Red Mud ➢ pre-stressed concrete
irc.gov.in.121.2017.pdf, 15 not used, 24-30 ,
irc.gov.in.sp.121.2018.pdf 22 as agg. New Code waste
Waste materials Source Production in MT/Year Main Use
--------------------------------------------------------------------------------------------------------------------------------------------------------------

➢ Fly Ash- Thermal Power Plant, coal burning, 190 concrete/soil/agg

➢ Copper Slag – manufacture of copper 6.3 Agg/soil/conc.

➢ Jarofix- extraction of zinc, 0.34 soil

➢ Phosphogypsum from fertilizer industry 12.5 Soil

➢ Marble Dust during processing and slabbing of marble stones, 8 Soil

➢ Foundry Sand from the foundry industries 3 Soil

➢ Blast Furnace Slag steel plants - extraction of iron from ores 11 Soil/agg/concrete

➢ Chrome slag extraction of chrome from its concentrate ore. 0.2 Soil/agg/concrete

➢ Red mud refining of bauxite, to produce alumina 4 soil

➢ recycled agg. /concrete Highway, building and structures 124 agg/ concrete
➢ Municipal soil waste generation of from Municipal Solid Wastes 65 Fillup/soil
After processing
-----------------------------Total= 424 MT/year

IS:1 7 2 7 : 1 9 6 7 TEST FOR POZZOLANIC MATERIALS

 Broad Content of the Policy Circular dtd 8th April ‘22
1. Ministry encourages the use of factory-produced precast
concrete elements in infrastructure projects
2. Minimum 25% of concrete shall be from a factory within
100 Km radius of the project other than the foundations
&:sub-structures of Bridges/Viaduct/RoB. – A move
which will encourage the establishment of factories
producing such elements
3. Standardisation of span lengths is promoted to facilitate
mass scale pre-casting of elements.
4. Minimum requirements for factory set-up spelt out. QCI is
entrusted to certify the factory.
1. Raessons flattening of tyres
2. Fill air and petro early morning
3. Proper removal of welds
4. Round edges of expansion joints to

Weld properly grind Sharp edges to be rounded

 IRCSP:83 page 104 Improve Riding quality:
Reasons of Diamond Grinding/Sealing
• Settlement, Heave, Distortion, Faulting - Correction of
surface irregularities scheduled when surface deviation
reaches 38 mm in a length of 2.5 m or when riding quality
is objectionable (> 4000 mm/km).
• Otherwise results in poor riding quality /extra loading on
slabs which accelerates pavement deterioration.

• Diamond grinding -level difference between two slabs

across a joint or cut becomes more than 4 mm.

• 11.3.3. Grinding followed by applying a layer of siloxane

• Cracks - Individual cracks 3 mm wide /areas with extensive

finer cracking repaired before rainy season to prevent
infiltration of water into the foundation layers.
 Continue to improve riding quality
• Settlement of approach slab is otherwise likely to
occur. Early detection and filling of voids can often
prevent slab settlement

• Spalling - Transverse spalling exceeding 100 mm in

direction of travel and more than 6 mm deep
• Joint separation - separation between the concrete
slabs exceeding 3 mm shall be filled to prevent
infiltration of water into the foundation layers.
• Interface of concrete pavement and paved/ unpaved
shoulder

• Before commencing grinding operations all forms of

loose concrete in corners, potholes, pop outs etc
should be patched
Reasons

1. Stone etc damage the pavement surface causes skidding /uneven ness
2. chute drains in median protection
3. prevents free drainage of water
4. Avoid increasing the risk of damage under traffic.
 11.3.4 Numerous forms of
machines are manufactured to
carry out diamond grinding as
per requirement of the client.

A typical machine generally

grinds from 3 mm up to 5 mm.
Localized bumps or damage
surface is to be measured with
straight edge & the area to be
ground is marked.
Machine is operated in end to
end pass on pavement (parallel
to transverse joint).
Grinded surface resembles
typical Indian mosaic flooring
with micro texture serrations
exposing fresh layer of
concrete.
11..3.6 IRCSP83 Although diamond grinding does reduce thickness of the pavement,
by making the surface even and by reducing tensile stress in slab it adds to the overall
life of the pavement.
 IRCSP17 2.3.2 over lay neededIRC SP
17-2019 Last Proofs.pdf page 30
• Modulus of resilience (MR) of a layer
estimated by test < 50% of standard MR for
fresh layer condition, -damaged.
• Vertical compressive stress in each layer of
subbase and subgrade -not allow cumulative
deflection > 0.5 mm at top of pavement
under design wheel load.
IRC:SP:87-2019
IRC:SP:87-2019/IRCSP:99-2021
 IRC:SP:87-2019
• During the operation and maintenance period, the pavement
strength shall be evaluated periodically through deflection
measurements (Refer to Para 5.8 (ii) of this Section)

• Stretches exhibiting any structural deficiency shall be suitably

strengthened with overlays.

• 5.4.4 The performance of the rigid pavement shall meet the

requirements as specified in IRC:SP:16 and IRC:SP:83.

• 1.13 Safety of Design All designs shall be safe to ensure that the
Project Highway or any part thereof (for example embankment,
pavement, retaining structures, bridges, culverts, etc.) does not
collapse (global stability) nor its serviceability/performance (for
example settlement, roughness, undulations, deflections, etc.)
deteriorates below acceptable level as prescribed in Schedule ‘K’
of the Concession Agreement.
 IRC:SP:87-2019
5.8 Performance Evaluation
i) Roughness in each lane for full length shall be measured
twice a year using appropriate approved method and
equipment.

ii) The structural evaluation of the pavement shall be made

by taking deflection measurements every 5 years unless
needed earlier, for stretches exhibiting severe distress
during the operation and maintenance period.

5.9.3 Necessary corrective measures to treat the identified

deficiency shall be taken along with strengthening of the
pavement.
5.9.4 In stretches pavement is damaged/deteriorated to such an
extent that use of Falling Weight Deflectometer (FWD) may
not result in a realistic assessment of the strengthening
treatment, pavement shall be designed as new pavement.
 IRC:SP:16-2019
• An increase in road roughness results in higher
road user costs and uncomfortable ride
inviting criticism from the traveling public.
• Response Type Road Roughness Measuring
System (RTRRMS).
 No black colour
epoxy,
Yellow honey like
Sikadur 52, EP 10, or
any equivalent

RS ~ Rs 1000,
for water proofing
and very thin surface
repair Fixit Piddilite
MUMBAI PUNE EXPRESSWAY _ OUR F
147
EXPRESSWAY OF RIGID PAVEMENT 1
 Eucalyptus-यूकेलिप्टस
(Safeda Tree) का पेड़ जमीन से प्रतिदिन
20 िीटर से िेकर 90 िीटर िक पानी िेिा
है ! वैसे िो इसके जड़े ज्यािा गहरी जािीहै.
Absorb water ` 20 litre /day
Application in Single Project NH VID_20160930_155331.mp4
NH 45C

NH 45C

NH 45C

Tests149
Protection and Control of Hill Slopes and Drainage/catchment areas IRC:SP:48
clause11.7IRC SP 4 8.1998.pdf 169-177- Erosion Control
• IS 14457 2000 Protection of Slopes
by Retaining walls
Part 1 Selection of type of wall,
Part 2 Design of Retailing/Front wall
Part 3 Construction of dry stone walls,
Part 4 Construction of banded dry stone walls,
Part 5 Construction~of cement stone walls,
Part 6 Construction of gabion walls,
Part 7 Construction of RCC crib walls,
Part 8 Construction of timber crib walls
Part 9 Design of RCC cantilever wall/buttressed walls/L-type walls,
Part 10 Design and construction of reinforced earth retaining walls.

➢ Drainage at best location: reduces weight,

increase strength, control erosion
➢ Vegetative cover on loose soil
➢ Re-shapping slopes, paved ditches
➢ Paving/bituminous treatment slopes
➢ Horizontal drainage
➢ Asphalt mulch slopes- Heat/moisture
➢ Jute Geo IRC SP .126.2019.pdf
textiles-Natural/
Synthetic
➢ Bally Benching

150
 IRC 102 irc.gov.in.sp.102.2014.pdf 39 causes of failure , MORTH 700
Difference in Dimension + 5 mm
Repair
of
Buldging
Out Panel
Strip seal joints

•Better than compression

seal joints
•Strip seal is
mechanically locked into
a pair of rolled steel
•Strip seal can function
in compression and
tension
•Protects the joint edge
from live load
•Seals can accommodate
125 mm, preferred for
100 mm
 Specification MORTH 2800. REPAIR OF STRUCTURES clause 2803

Penetration- Visual examination of core show epoxy adhesive filling a minimum of 90

percent of the crack.

b) Bond Strength- When tested for bond, concrete failure should occur before adhesive failure.
Also, minimum bond strength of 40 MPa should be developed with no failure of either
concrete or adhesive.

2804. REPLACEMENT OF SPALLED CONCRETE - EPOXY MORTAR / POLYMER MORTAR

2804.1. Epoxy Mortar 2804.1.1. Material:

Pot Life 60 minutes at 30ºC
Bond Strength 12 MPa
Tensile Strength 16 Mpa
2804.1.2. Proportioning and Mixing:

For a total weight of 1kg or less, the components shall be mixed for 3 minutes in
a slow speed (400-600 rpm) mixer. If no power is available, a flat putty knife may be used to
reach into the corners of the can and hand mixing done for at least 5 minutes.

2804.1.3. Surface Preparation:

Seal coat shall be applied 24 hours after curing and mild roughening of the surface of the
mortar.
 MORTH 2800. REPAIR OF STRUCTURES clause 2803 page 884 MORTH

2804.2 Polymer Mortar

latex acrylic polymer for use in the polymer modified cementitious mortar (PMC)

Pot Life 60 minutes at 300 C

Compressive strength at 28 days 18.20 N/mm2
Flexural strength at 28 days 3.0 N/mm2 to 5.0 N/mm2
Addition to concrete (slant shear) 3.0 N/mm2 to 5.0 N/mm2

2805. EPOXY BONDING OF NEW CONCRETE TO OLD CONCRETE

2805.3.2. Two concrete cubes of 150 mm size cast as per approved

design mix shall be placed at a distance of 150 mm from each
other. Fresh cement concrete cube of grade as per approved design
mix shall be cast with water cement ratio of 0.4 or less . The cube
assembly shall be subjected to compression load after 28 days of
curing, thereby subjecting the bond to shearing load. Failure must not
occur at this joint.
 ULTRA HIGH PERFORMANCE CONCRETE2- Dr. satish Jain.pdf
UHPFRC in Design & Construction_0001(1).pdf
Nominated List of IRC Members_Officials (1).pdf
UHPFR workshop.pdf
• Has cement matrix
• compressive strength = 150 to 250 MPa
• Steel fibers- ductile, impact resistance- IRC:SP:46
• Tensile strengths >7 MPa
 Broad Content of the Policy Circular dtd 8th April ‘22
1. Ministry encourages the use of factory-produced precast
concrete elements in infrastructure projects
2. Minimum 25% of concrete shall be from a factory within
100 Km radius of the project – A move which will
encourage the establishment of factories producing such
elements
3. Standardisation of span lengths is promoted to facilitate
mass scale pre-casting of elements.
4. Minimum requirements for factory set-up spelt out. QCI is
entrusted to certify the factory.
 MORTH 2013 Pavement Quality Concrete Clause 602.6.2.2 page 273
602.11.5.2 page 291 MORTH 2013.PDF 290-291

• Contraction Joints
• Tie Bar - Dowel Bar Alignment for Concrete
Pavements - MIT-DOWEL-SCAN.mp4
Magnetic Imaging Tomography technique (MIT),
• Contraction joints shall consist of a mechanical
sawn joint groove, 3 to 5 mm wide and one-fourth
to one-third depth of the slab ± 5 mm

• Contraction joint widened subsequently after 14

d. to accommodate the sealant as per IRC:57
 MORTH Paving clause 602.8 Page 289
• All grooves cleaned of dirt or loose
material by air blasting

• Temporary seal provided for

blocking ingress of dirt, soil.

• A highly compressible heat resistant

paper-backed debonding strip
inserted:
i. To serve purpose of breaking bond
between sealant and bottom of
groove
ii. To plug joint groove so that sealant
may not leak. 163
 IRC: 51 Load Testing of Bridges, Clause 5.2
Type of Bridge Live Load Duration Minimum
of Test Per Cent
load age of
Recovery
of
Deflection
at 24 hrs
RCC, Live Load 24 75
Reinforced + Impact hours
Cement IRC
Concrete Code

Pre-stressed “ 24 85
Concrete hours

Steel “ 24 85
hours
Composite “ 24 75
Concrete hours

Shall not show visible evidence of failure crack >0.3mm

under test load, spalling, deflection excessive
 Characteristics of foamed bitumen

• Expansion ratio is
defined as the ratio
between the maximum
volume achieved in the
foam state and the final
volume of the binder
once the foam has
dissipated.
• Half-life is the time, in
seconds, taken by the
foam to reduce to half
of its volume from the
point at which it
achieves the maximum
value. 166
 Cold in-place recycling - Case studies in
IndiaStehr_Roorkee 1 min.mpg
Equip 2 Wirtgen.MPG
• Rehabilitation of NH-5 between Chennai to Tada was
carried out -South African mix design procedure

6.1 Milling is control removal of an existing pavement to a desired

depth, using specially designed equipment having replaceable
tungsten carbide cutting teeth mounted on a rotor drum driven by
power supplied by milling machine.
It is most common way of reclaiming bituminous pavement material.
 IRC Codes on Road Safety
• IRC:35-2015 Code of Practice for Road Markings
• IRC:67-2012 Code of Practice for Road Signs
• IRC:99-2018 Traffic Calming Measures in Urban and Rural Areas
IRC:119-2015 Guidelines for Traffic Safety Barriers
• IRC:SP:55-2014 Guidelines on Traffic Management
• IRC:2-1968 Route Marker Signs for National Highways
• IRC:8-1980 Type Designs for Highway Kilometre Stones
• IRC:25-1967 Type Designs for Boundary Stones
• IRC:26-1967 Type Design for 200-Metre Stones
• IRC:30-1968 Standard Letters and Numerals of Different Heights
for Use on Highway Signs
• irc.gov.in.035.2015.pdf (page 32, 150)
• ( IRC 99 page 18) Speed breaker
• irc.gov.in.025.1967.pdf page 7 Km stone
• irc.gov.in.119.2015.pdf page 28-32 W beam
MORTH POCKET BOOK 2019 page, 121 road
safety, signs
IRC:99-2018 Guidelines for Traffic Calming Measures
in Urban and Rural Areas (Speed breaker)
IRC 35-2015
 IRC:35-2015 Code of Practice for Road Markings
Warranty majorly means repair of product to be done free of cost,
Guarantee means that product will be replaced if it cannot be
rectified after servicing. MORTH Page 333 801.3.11
IRC:35-2015 Code of Practice for Road Markings
IRC 35 page 140
 Preventive maintenance
• Leading better pavement quality- lower costs.
• Retard progressive failures,
• Reduce - routine maintenance
activities.
• Extend functional life before pavement
deteriorates
• to a condition do not requires
• structural
• overlay.
IRC:SP:81 Micro-surfacing
 Pressure Grouting Aircraft landing

Automation in Steel Girder Rain water Harvesting

 INNOVATIVE BRIDGES IN INDIA
Jadukata Bridge
longest span cantilever bridge
Meghalaya
Most beautiful bridges
in the world
Jadukata Bridge
 INNOVATIVE BRIDGES IN INDIA

Mahatma Gandhi Setu:

longest river bridge

5.575KM long in the world,

Patna
Kathipara Interchange
Khardung Pass
auto testing cut.mp4
Automark_Cold plastic.mp4
Automark_i-lite.mp4
Automark_Preformed marking.mp4
Routing and Crack Seal Process

(1).mp4 Crack sealing.mp4

Slurry Seal Kuihelani Hwy, Maui HI.mp4 Jadukata Bridge Meghalya
Most beutiful in the World

192
 Fresher can take care of him/her only, but
Senior shall take care him/her and self

Yes, it is my Job
Don't
walk in front of me,
I may not follow.
Don't walk behind me,
I may not lead.
Walk beside me and
It is not my Job