SPECIFICATIONS

FOR
CONCRETE PAVEMENT
(MoRTH & MoRD)

Presented By
Deva Ram Vishnoi
Executive Engineer
PWD QC Dn Jodhpur
 Refer Latest version of Codes for the Concrete
Pavement
❖For Expressway/NH/SH/MDR (MoRTH Specification )

❖Specification for Road and Bridge Works.(Vth Revision)

❖IRC: 15-2017:- Standard Specifications and Code of Practice for
Construction of Concrete Roads. (Vth Revision)
❖IRC: 58-2015:- Guidelines for the Design of Plain Jointed Rigid Pavement for
Highway. (IVth Revision)
❖IRC:SP:49-2008:- Guidelines for Use of Dry Lean Concrete as Sub-Base for
Rigid Pavement
❖IRC: 44-2017:- Guidelines for Cement Concrete Mix Design for Pavements.
(IIIrd Revision)

❖For ODR/VR Roads (MoRD Specification )

❖Specification for Rural Roads-2014 .(Ist Revision)

❖IRC: SP:62-2014:- Guidelines for Design and Construction of Cement
Concrete Pavements for Low Volume Roads. (Ist Revision)
❖MoRTH specifications and Design Guidelines of IRC:58-2015
are applicable for Major Roads like NH/SH/MDR Carrying an
Average Daily Traffic >450 CVD with laden weight exceeding
30 KN.

❖MoRD specifications and Design Guidelines of IRC:SP:62-2014

are applicable only for Low Volume rural roads like ODR/VR
Carrying an Average Daily Traffic <450 CVD with laden weight
exceeding 30 KN.

❖Here we will discuss provisions in both MoRTH & MoRD

Specification :-
 Why we require Concrete Pavement

1. Tyre pressure is predominant in upper layers.

2. Greater depth, effect of tyre pressure diminishes
3. Tyre pressure of high magnitude : demand high quality In
Upper Layer.
 Road Composition

Vehicle

Cement Concrete

SUB Base DLC Road

Crust
Sub Base GSB

500mm Sub Grade

Embankment

450 Ground Level

 Comparison of Flexible and Rigid Pavements
Flexible Pavements
1. Deformation in subgrade is transferred
to upper layers
2. Have low flexural strength
3. Load is transferred by grain to grain
contact.
4. Low life span (High Maintenance Cost)
5. No thermal stresses are induced as the
pavement have the ability to contract
and expand freely
6. Force of friction is less
7. Thats why joints are not needed
8. Strength of the road is highly
dependent on the strength of the sub
grade
9. Road can be used for traffic within 24
hours
10.Damaged by Oils and Certain Chemicals
Rigid Pavements
1. Deformation in the subgrade is not
transferred
2. Have high flexural strength
3. No such grain to grain load
4. Long life (Low Maintenance Cost)
5. Thermal stresses are more vulnerable
to be induced as the ability to contract
and expand is very less in concrete
6. Force of friction is high
7. Thats why joints are needed
8. Strength of road is dependent on
flexural strength
9. Road cannot be until 14 days of
curing
10.No Damage by Oils and Greases
 As per MoRD Specification

Cement Concrete Pavements on different type of sub Base

As per MoRD Specification
Sub Base should be provided under PQC depending
upon the volume and type of traffic.

S.No. Traffic Sub-Base min composition

1 <50 CVPD 75 mm WBM Gr.-III/WMM over 100 mm GSB

2 50-150 CVPD 75mm WBM Gr.-III/WMM over 100 mm GSB

3 150-450 CVPD 150 mm WBM Gr.-III/WMM over 100 mm GSB

❖As per MoRTH Specification , in cement concrete
Pavement mainly following crust component are
suggested.

Cement Concrete
Pavements

Dry Lean Concrete (DLC) Pavement Quality Concrete

as such Base Course (PQC) as Base & Wearing Course
 FACTOR GOVERNING DESIGN

❖Wheel Load : -
▪ Maximum legal load limit on single axle with dual
wheels in India = 100 kN.
▪The recommended design load on dual wheel
= 50 kN.
❖ Tyre Pressure may be taken as 0.8 MPa.
❖ Design period shall be taken as min. 20 Years in MoRD
Specifications & min. 30 Years in MoRTH Specification
 ➢ Materials
• Cement
• Admixture
• Aggregate
• Water

➢ Cement
• Ordinary Portland Cement (OPC) IS 269 : 2015
(IS 8112 & IS 12269 amalgamated)
• Portland Pozzolana Cement (Fly ash based) - IS 1489 :
1991– Part I
• Sulphate resisting Portland Cement – IS 12330 : 1988
(When Sulphate Content in soil > 0.5%)
• Testing of Cement has been made compulsory, when it
to be used after “ Best before Date”
➢ Admixture
▪ Chemical Admixture
▪ Mineral Admixture
➢Chemical Admixture (IS : 9103)
▪ Improve Workability
▪ Extension of Setting

Desirable Properties of Chemical Admixture

should have
- No adverse effect to strength
- Volume Change
- Durability
- No Steel Deterioration

Max. Dosages of Chemical Admixture - 2 % by

weight of cementitious materials
➢ Cementitious Materials
- Combination of Cement + Fly ash/Silica fume
/ alumina slag

➢ Mineral Admixture
Improve workability , Long term strength , Durability

▪ Fly Ash(IS : 3812 , Part – I )

Max. dosage – 25 % of Cementitious Material
It should be permitted only after proper mechanical
facility is available
▪ Silica Fume
Max. dosage – 10 % of OPC
▪ Ground Granulated Blast furnance slag(GGBFS)
Max. dosage – 50 % of Cementitious Material
▪ Metakaolin
Max. dosage – 20 % of Cementitious Material
➢ Aggregate ( IS : 383 – 2016 )
▪ Water absorption – Max. 2.00 %
▪ Sulphate Content – Max. 0.50 %
▪ Chloride Content – Max. 0.06 %
➢ Coarse Aggregate
▪ FI & EE – 35 %
▪ AIV – 30 %
▪ Max. N/Size – 31.5 mm (PQC)
– 26.5 mm (DLC)
➢ Fine Aggregate
▪ It should free from soft particles, Clay etc.
▪ % passing 75 µ
Natural Sand - Max. 3 %
Crushed Stone Sand - Max. 15 %
Blended Sand - Max. 8 %
 Requirements of fine Aggregate as per IS: 383

IS Sieve Percentage Passing for Grading

Zone-I Zone-II Zone-III Zone-IV

10mm 100 100 100

4.75mm 90-100 90-100 90-100
2.36mm 60-95 75-100 85-100 Not
1.18mm 30-70 55-90 75-100 Recommended
600µ 15-34 35-59 60-79
300µ 5-20 8-30 12-40
150µ 0-10* 0-10* 0-10*

I II III
When crushed stone sand is used, permissible limit on 150 µ may be
➢ Combined Grading
For Dry Lean Concrete ( Table – 2 of IRC : 15 – 2017)

Earlier Revised
Sieve % Passing Sieve % Passing

26.5 mm 100 26.5 mm 100

19.0 mm 75-95 19.0 mm 75-95

9.50 mm 50-70 9.50 mm 50-70

4.75 mm 30-55 4.75 mm 30-55

2.36 mm 17-42 2.36 mm 17-42

600 µ 8-22 600 µ 8-22

300 µ 7-17 300 µ 7-17
150 µ 2-12 150 µ 2-12
75 µ 0-10 75 µ 0-5
➢ Combined Grading
For Pavement Quality Concrete ( Table – 3 of IRC : 15 – 2017)

Earlier Revised

Sieve % Passing Sieve % Passing

31.5 mm 100 37.5 mm 100

26.5 mm 85-95 31.5 mm 90-100
19.00 mm 68-88 26.5 mm 85-95
9.50 mm 45-65 19.00 mm 68-88
4.75 mm 30-55 9.50 mm 45-65
600 µ 8-30 4.75 mm 30-55
150 µ 5-15 600 µ 8-30
75 µ 0-5 150 µ 0-10
* Natural Sand 75 µ 0-5**
** Crushed Sand 0-2*
 ➢ Water
▪ It shall meet requirement as per IS 456
▪ Permissible limit for solids in water shall be as per
Table – 1 of IS 456 : 2000
▪ pH Value > 6

S.No. Properties Permissible Limit

1 Ph value >=6
2 Solids in water
a Organic Max 200 mg/l
b Inorganic Max 3000 Mg/l
c Sulphates as S03 Max 400 Mg/l
d Chlorides as Cl- Max 2000 Mg/l (PCC)
Max 500 Mg/l (RCC)
e Suspended Matter 2000 Mg/l
 ➢ Steel Bars - Dowels and Tie Bars
❖Dowel bars:-
• Plain steel bars (IS: 432 -Part-I) having min yield
strength 240 N/mm2 shall be used as Dowel Bars.
These shall be treated by epoxy coating or anti
corrosion paint. The dowel bar shall be supported on
cradle/dowel chairs.
• Dowel bar shall be positioned at mid depth of slab
and shall be aligned parallel to the finished surface of
the slab and to the centerline of the carriage-way.
❖ Tie Bars:-
• Tie bars shall be of TMT Steel (IS: 1786) with min
yield stress of 500 N/mm2. Tie bar shall be positioned
to remain within the upper middle third of the slab
approximately parallel to the surface and
perpendicular to the line of the joint.
❖Pre moulded joint filler board IS: 1838 (for Expansion
joint )

• 20/25 mm pre moulded synthetic joint filler board.

• It shall be 25mm less in depth and should be
provided in entire width of pavement.
• Compressibility > 25%
❖Joint sealing compound IS: 1834
• Joint sealing compound shall have following properties -
• Flexibility
• Resistance to age hardening
• Durability
• Type of sealant are –
a)-Hot Pouring Type – Elastomeric (IS : 1834 or ASIM : D-
3406)

b) Cold Pouring Type - Polysulphide IS : 11433

- Polyurethene BS : 5212
- Silicon ASTM D – 5893-04
➢ Fibres
▪ to reduce Shrinkage Cracking
▪ Improve Post Cracking Residual Strength
▪ Steel Fibres or Polymerie synthetic fibres

Properties Micro Fibre Micro Fibre

Effective Dia 8-300 µ 0.20 – 1.2 mm

Length 6-18 mm 40 – 45 mm

Dosages 0.6 – 2.50 Kg/m3 2.0 – 8.0 Kg/m3

➢ Desirable Properties of Dry Lean Concrete
▪ Proportioning of Material (Design Mix)
- Max. Aggregate : Cementitious material Ratio =
15 : 1
- For Different moisture content (5.0 % , 5.50 %,
6 % etc.) to meet strength and density
requirement
▪ Cement Content
- Min. Cement 150 Kg/Cum
- If any ash is blended as part replacement
- Fly ash 20 % ≤ of Cementitious Materials
- Min. OPC Content = 120 Kg/Cum

▪ Concrete Strength
- Average. Compressive Strength = Min.10 MPa
at 7 days
- Individual Compressive Strength = Min.7.5 MPa
at 7 days
▪ Construction
• Dry Lean Concrete (Upper Sub Base)
• Granular Sub Base (Lower Sub Base)
• Sub Grade 500 mm (minimum) with min CBR 8
%
▪ Batching & Mixing
• Check grading of CA & FA
• Batching by mass for all ingredients
• Maintain WC ratio constant , To this end, determine
moisture content in CA & FA frequently and adjust
water dosages accordingly.
• Calibration of measuring equipment and Batching
plant frequently.
Accuracy/ Tolerance -Cement ±1%
- Aggregates ± 2 %
- Water ± 2%
- Admixture ± 2 %

• Mixing time shall be of about 60 Sec.

• Transportation , Placing, Compaction
• Concrete shall be transported as rapidly as possible, so that
desired workability at placing is maintained.
• Minimum Loss of water by evaporation in hot weather shall be
ensured.
• Placing should be at least 75mm wider on each side than
proposed width.
• All activities like transporting , spreading, compacting
finishing shall be with in
90 min. – when temp of concrete 250 C - 300C
120 min. – when temp of concrete < 250
• Core test 3 core(100 mm dia) /km. to check strength.
• Workability
• In DLC Concrete should be of Zero Slump
• Curing
• Moist curing
by gunny bags/hessian - 7 days
• Membrane curing
Resin based aluminized reflective curing compound ASTM – C – 309-81
Wax based white pigment curing compound (WRI 790 %)
24
Separation membrane
A impermeable 125 µ thick PVC transparent or white in colour should
be provided in between PQC and Sub-Base. Sheet should be nailed with
minimum creases to lower layer with concrete nails. PVC sheet should not
be manufactured out of recycled plastic. Minimum over lap should be 300
mm. Concept of membrane can be understood in fig.
➢ Desirable Properties of Pavement Quality Concrete
▪ Proportioning of Material
- Proportion of all approved ingredients shall be as per
design
mix approved by the Engineer in-charge
-Concrete Mix Design shall be done as per IRC 44 or IS:10262

▪ Cement Content

As per MoRTH Specification

Min. OPC Cement 360 Kg/Cum
-If Fly ash is blended as part replacement
-Fly ash 20 % ≤ of Cementitious Materials
-Min. OPC Content = 310 Kg/Cum

As per MoRD Specification

Min. OPC Cement 350 Kg/Cum
➢ Concrete Strength
• As per MoRTH Specification
Concrete Strength is governed by the characteristics
Flexural strength not less than 4.5 MPa.
• As per MoRD Specification
Concrete strength governed by the characteristic
Compressive Strength not less than 30 MPa.

• Establish Ratio between 7 and 28 days strength in

advance to monitor concrete strength
Ratio R(upto three decimal)
= 7 days Strength/ 28 days Strength

• Flexural Strength ,fcr = 0.7*(fck) ^0.50

➢ Water Cement Ratio
• As per MoRTH Specification
Max. free Water Cementitious Material Ratios = 0.40
At such a low water cement ratio and long
transportation , use of High range water reducing
like Poly Carboxylate Ether (PCE) base admixture
inevitable for achieving the desired workability.
• As per MoRD Specification
Max. Water Cement Ratio is = 0.50
• Workability
Workability depend on equipment used for method of
placement of concrete.
• As per MoRTH Specification,
Slump = 20-30 Slipform paver, 40-60 fixed form paver
As per MoRD Specification
Slump = 30 ± 10 mm
➢ JOINTS
• The location and type of joints shall be decided and
be shown in the drawings.
• Proper marking of joint location at site should be
done prior to laying PQC.

TYPE OF JOINT

LONGITUDINAL
TRANSVERSE

CONTRACTION
CONSTRUCTION EXPANSION
GENERAL LAYOUT OF JOINT OF C.C. PAVEMENT
 RIGID PAVEMENT

PQC Pavement Quality Concrete

DLC Dry Lean Concrete

Contraction Joints
These are purposely made weakened planes
They are also provided to
• Relieve stresses due to warping.
• To permit the contraction of the slab
• Spacing of contraction joints -3.50m to 4.5 m.
Construction joints
Construction joint shall be placed when concreting is
completed after a day’s work or is suspended for more than
30 minute.
Expansion joints
There are full-depth joints provided transversely to
expand, thus relieving compressive stresses. The current
practice is to provide these joints only when concrete slab
abuts with bridge or culvert.
• They allow expansion of slabs due to temperature
• prevent tendency towards distortion, buckling
• They permit contraction of slabs
LONGITUDINAL JOINTS
Lanes are jointed together by joint known as
Longitudinal joint. Longitudinal joints are provided
when the pavement is more than 4.5 m wide.
▪ To Relieve stresses due to warping.
▪ To allow differential shrinkage & swelling due to
changes of Sub Grade Moisture
▪ To prevent longitudinal cracking
Typical Cross Sections of JOINTS
Sealing Details of JOINTS
 Main activities regarding Joint preparation
shall be as under –
Activities Detail Time after laying
Initial cut (i) Slot width 3-5 mm wide In summer (Temp >30o C) 4-8 hr.
(ii) Depth 1/3 to ¼ of total In winter (temp > 30oC) – 8 -12
depth hr.
Widening of Width – 8-10mm After 21-28 days
joint groove Depth – 20-25mm
Sealing of joint Groove should be dry and After 28 days
by sealent clean
GENERAL VIEW OF DOWEL BAR AT CONSTRUCTION
JOINTS
Cleaning of Joint by Air Compressor
• Weather Limitations

• Concreting in Hot Weather

• Ambient temperature > 35°C
• Relative Humidity < 25 °C
• Wind velocity > 15 Km/hr.
• No Concreting shall be done unless adequate precautions are
taken
• Adverse effects
- Loss of workability
- Formation of plastic shrinkage
- IF Rate of evaporation is about 1 Kg/m²/hrs.
- Plastic shrinkage is nucleus for type of damages which lead to
structural cracks
Concreting in Cold Weather
Ambient temperature < 5°C (No Concreting)
➢ Curing

Curing can be done by one of the following two

methods immediately after the finishing operations to
counter weather limitations.
Moist Curing – Min. 14 Days (OPC)
- Min. 16 Days (Blended Cement)

Membrane Curing – resin based aluminized reflective

type curing compound is used
for the PQC work
 ➢Acceptance Criteria
• Fresh Concrete
• Concrete used in the member represented by a core
test shall be considered acceptable if,
• Flexural Strength

• Mean flexural strength (04 consecutive test results)

exceeds fcr + 0.3 N/mm²
• The strength determined from any test result is not
less than fcr - 0.1 N/mm²
• Compressive Strength
• Mean Compressive strength ( 04 consecutive test
results exceeds fck + 3 N/mm²
• The strength determined from any test result is not
less than fck - 1 N/mm²
• Hardened Concrete
❖ Core Test

• Concrete used in the member represented by a core

test shall be considered acceptable if,

Average Eq. Cube Compressive Strength of Cores

sample
= 85% of Grade of Concrete
Individual Eq. Cube Compressive Strength of Core
specimen
= 75% of Grade of Concrete
• Cracked Concrete Slab
• Crakes of minor to serious nature unless appropriate
precaution are taken either during construction as post
construction period
- Drying Shrinkage
- Plastic Shrinkage
- High wind velocity with low humidity
- Delayed sawing joints
- Rough and uneven surface of the base or which concrete
slab are construction
- Combination of the above.
• Acceptance Criteria
• Under the following condition concrete slab should be
rejected.
- Full depth cracks as structural crack
- Plastic shrinkage crack (> 3000mm) in a panel
- Any type of crack > half depth.
Well Finished PQC Surface after sealing of Joint
Ready to Open traffic
 ➢ Conclusion
• A Good quality concrete, which is strong, impermeable
and durable against abrasion chemical attack and
adverse effects of weather CAN only be achieved with
suitable choices of materials proper mix proportioning
and satisfactory at all stage of producing, placing and
curing of concrete.

➢ Message with Humble Request

The Principle to “Think globally and Act locally” is to be
ensured for rigid pavement construction at all cost.
“ To do things right first time and every time” in the rigid
pavement construction otherwise one gets a little or no
chance to correct the mistakes and those mistakes will be
corrected at great expense.