Jan 20224

JANUARY 2024
Volume: 52 Number: 01 Total Pages: 68
A view of Cable Stayed Bridge Across Waingangna River at Ambhora in

Nagpur District (Maharashtra)
INDIAN HIGHWAYS
Volume: 52 Number: 01 JANUARY 2024 ISSN 0376-7256
Indian Roads Congress
Founded : On 10th December, 1934
CONTENTS
¾ )URPWKH(GLWRU¶V'HVN
¾ $GYHUWLVHPHQWV
¾ IRC Technical Committees Meeting Schedule for the Month of January, 2024 65
Technical Papers
¾ Development of Correlation Between Indirect Tensile Strength and Resilient Modulus for
VG-40 Bituminous Concrete 17
By Dr. Aakash Gupta, Prajwal M G, Sachin Gowda & Jaya R S
¾ 3UDFWLFDO$SSURDFKIRU3UH6WUHVVLQJLQ%ULGJHV±$FWLYLWLHVDQG,VVXHV 28
By N N Bandhu
¾ 3HUIRUPDQFHRI7KLQ:KLWH7RSSLQJ 7:7 2YHUOD\IRU1+1DVKLN3HWK6HFWLRQLQ0DKDUDVKWUD6WDWH 45

By Vikas Thakar, Anshumali Srivastava & Prashant Auti
¾ $&RPSUHKHQVLYH6WXG\RQ$SSOLFDWLRQVDQG'HVLJQ3DUDPHWHUVRI&HPHQW*URXWHG%LWXPLQRXV0L[ 55
By Dr. Lokesh Gupta & Dr. Rakesh Kumar
¾ 1HZ0DWHULDOV7HFKQLTXHV(TXLSPHQW3URGXFWV$FFUHGLWHG 64-65
¾ MoRTH Circular 66
FEEDBACK
Suggestion/Observation on editorial and Technical Papers are welcome and may be sent to IRC Secretariat on
Email-indhighways@gmail.com/dd.irc-morth@gov.in
Publisher & Editor: Sanjay Kumar Nirmal, Secretary General, IRC

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Headquarter: IRC Bhawan, Kama Koti Marg, Sector-6, R.K. Puram, New Delhi-110 022.
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DISASTER RESILIENT GREEN HIGHWAYS

Disaster resilience is our ability to prevent, withstand and recover from the harmful impacts of natural
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years to control the damage.
In an era where climate change poses an increasing threat, the imperative to create disaster-resilient green
highways has never been more crucial. These corridors serve as lifelines for transportation, fostering
economic growth while embracing sustainable practices to mitigate environmental impacts. The foundation
of disaster resilience lies in thoughtful planning and cutting-edge engineering. Green highways integrate
environment friendly features, such as eco-sensitive landscaping, ensuring that they not only withstand
disasters but also contribute to ecological balance.
The need for improvement of Disaster resilient highways by learning from the experience and innovative
technology-driven engineering interventions in the planning, design, construction, and maintenance is
increasingly being felt across the globe.
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in the areas of fragile ecology, is made disaster resilient.
The aim of achieving sustainable highways continued to capture the imagination of highway engineers
with the urge to transform planning, design, and construction practices in highway sectors. Experience
of building roads and highways in terrains of extreme diversity and environmental fragility repeatedly
indicates that highways and the associated infrastructure could not be sustainable unless they are also
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GLVDVWHUUHVLOLHQWJUHHQKLJKZD\VDJDLQVWPXOWLSOHKD]DUGVDVWKH\DUHOLNHO\WRIDFHGXULQJWKHLUVHUYLFH
lives.
The new challenge before the highway engineers is to anticipate plausible multi-hazard scenarios associated
with the highway routes and ensure that highways always remain safe and resilient to multiple hazards.
Nature-friendly engineering interventions are superior and most essential for disaster resilient green
highways. Nature-friendly interventions for slope protection are preferred because they, by design, aim at
internally strengthening the potentially unstable slope masses in hazardous areas.
Both the short and long-range adverse impacts of highway construction on the ecosystem shall be mitigated
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&23 'XEDLDORQJZLWKWKHWDUJHWVRI6XVWDLQDEOH'HYHORSPHQW*RDOV 6'*V DQG6HQGDL)UDPHZRUN
4 INDIAN HIGHWAYS JANUARY 2024

FROM
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THE EDITOR’S
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proper planning and good construction techniques.
By utilizing resilient materials and innovative construction methods, these highways act as a shield
against the unpredictable forces of nature. Beyond their structural fortitude, green highways symbolize a
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not only reduces the carbon footprint but also provides a glimpse into a future where transportation and
environmental responsibility coexist harmoniously. The deployment of smart technologies adds another
layer of resilience, enabling real-time monitoring and rapid response during emergencies. Public awareness
and engagement play pivotal roles in the success of disaster-resilient green highways. Communities must
be informed and involved throughout the planning and implementation phases to ensure that these projects
DGGUHVVORFDOQHHGVDQGFRQFHUQV$GGLWLRQDOO\HGXFDWLRQDOFDPSDLJQVFDQIRVWHUDVHQVHRIRZQHUVKLS
encouraging responsible use and preservation of these eco-friendly corridors.
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Job creation, increased property values, and a boost to local businesses are by products of such projects.
Moreover, the long-term cost savings resulting from reduced environmental impact and lower maintenance
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sustainability and infrastructure development, prioritizing disaster-resilient green highways is a clear
pathway forward. These corridors not only safeguard against the growing threats of natural disasters but
also pave the way for a greener, more sustainable future. It's time to steer our transportation infrastructure
towards resilience, sustainability, and a brighter tomorrow.
We should have rigorous climate change assessments scaled down to the state district and panchayat levels
VRWKDWZHFDQWDNHXSFOLPDWHDGDSWDWLRQDWDORFDOOHYHO7KHFOLPDWHGLVDVWHUVWKDW,QGLDKDGDOUHDG\PHW
with, under a 10C global warming, underscore this need. Recently concluded COP28 points to a 20C global
warming by 2050 where India will be facing extreme weather events that are more intense, frequent and
cover larger areas. Hence, India needs to disaster-proof each and every village with an adaptation plan
based on these future weather events that will emerge as we move towards an inevitable 20C arise.
Recently IRC has published "Guidelines for Highway Engineers on Disaster resilient green highways in
PXOWLKD]DUGHFRV\VWHP ,5& 7KLVJXLGHOLQHLQWHJUDWHVWKHJUHHQKLJKZD\FRQFHSWLQGLVDVWHU
resilient roads in planning, design, construction and maintenance of highways incorporating the lessons
learnt from the past. This should help in our aim of providing sustainable highway infrastructure for the
country.
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INDIAN HIGHWAYS JANUARY 2024 5

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DEVELOPMENT OF CORRELATION BETWEEN INDIRECT

TENSILE STRENGTH AND RESILIENT MODULUS FOR
VG-40 BITUMINOUS CONCRETE
'U$DNDVK*XSWD1 Prajwal M G 2 Sachin Gowda Jaya R S4
ABSTRACT
This study focuses on establishing a correlation between Indirect Tensile Strength (ITS) and Resilient Modulus (MR). The
motivation behind this research arises from the limited availability of advanced equipment and the high costs associated
with precise Resilient Modulus measurements, prompting an exploration of their correlation with ITS. Additionally, there
LV D SDXFLW\ RI UHVHDUFK DQG WKH DEVHQFH RI FRUUHODWLRQV IRU GL൵HUHQW ELWXPLQRXV PL[WXUHV 7R WDFNOH WKHVH FKDOOHQJHV D
comprehensive investigation was conducted using virgin aggregates and Viscosity Grade-40 (VG-40) bitumen. The Marshall
Mix design method was employed to ascertain the optimal binder content for mixtures featuring varying aggregate gradations
in Bituminous Concrete-1 (BC-1) and Bituminous Concrete-2 (BC-2) grades. Tests were conducted to assess the performance of
asphalt blends in terms of Resilient Modulus and Indirect Tensile Strength, thereby enabling the establishment of correlations
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at test temperatures of 25°C and 35°C were as follows: 0.54, 0.72, 0.62, and 0.58 for ITS and (MR), respectively. This research
forms a foundational basis for future investigations into the relationship between ITS and (MR), enhancing the understanding
of bituminous concrete behaviour and facilitating the development of more robust and resilient road surfaces.
1. INTRODUCTION measure of asphalt concrete's tensile strength, serves as

a basic mechanical attribute for assessing a pavement
The correlation between various engineering attributes of PDWHULDO V UHVLOLHQFH DJDLQVW FUDFNLQJ DQG IUDFWXULQJ ,Q
PDWHULDOVKROGVVXEVWDQWLDOUHOHYDQFHLQWKH¿HOGVRIFLYLO the test procedure, an axial load is applied to a cylindrical
engineering and pavement design. Notably, Indirect Tensile VDPSOHZKLFKLVGLDPHWULFDOO\UHVWUDLQHG7KHSHDNWHQVLOH
Strength (ITS) and Resilient Modulus (MR DUHLGHQWL¿HGDV stress generated upon failure is subsequently measured to
NH\IDFWRUVLQHYDOXDWLQJWKHIXQFWLRQDOLW\DQGORQJHYLW\RI ascertain the sample's tensile strength. Various elements,
ÀH[LEOHSDYHPHQWVZKLFKDUHOLPLWHGWRWKHVWXGLHVFDUULHG such as the type of binder, characteristics of the aggregate,
RXWLQWKLVUHVHDUFK7KHVLJQL¿FDQFHRIFRPSUHKHQGLQJWKH air void composition, and ambient temperature, are
interplay between these two parameters is accentuated when DFNQRZOHGJHGWRLQÀXHQFH,76
considering the construction of durable and economically
H൶FLHQW URDGZD\V 7KH REMHFWLYH RI WKLV LQYHVWLJDWLRQ LV Resilient Modulus (MR) serves as an essential mechanical
to delve into the relationship between Indirect Tensile FKDUDFWHULVWLF HPSOR\HG WR FKDUDFWHUL]H WKH VWL൵QHVV RU
Strength and Resilient Modulus, and to elucidate its impact elastic response of asphalt concrete and unbound granular
on the engineering of pavements. PDWHULDOVZKHQVXEMHFWHGWRUHSHDWHGORDGLQJ/DERUDWRU\
WHVWV OLNH WKH UHSHDWHG ORDG WULD[LDO WHVW DUH XWLOL]HG WR
Indirect Tensile Strength (ITS), often considered the
1 Scientist, Pavement Evaluation Division, CSIR-Central Road Research Institute, New Delhi, E-mail: ag.csircrri@gmail.com
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PHDVXUH WKLV SURSHUW\ ZKLFK LV GH¿QHG DV WKH VWUHVVWR content, shape and gradation of the aggregate, frequency of
strain ratio across multiple loading cycles. Sensitivity of the load, and bitumen content. These factors collectively
Resilient Modulus (MR) to variables such as temperature, LQÀXHQFH WKH PDWHULDO V VWL൵QHVV DQG LWV DELOLW\ WR UHFRYHU
rate of loading, and moisture content is well-recognized. The from deformation in the context of road construction. The
relationship between Resilient Modulus and Indirect Tensile MRYDOXHVIRUELWXPLQRXVPL[HVWKDWLQFRUSRUDWHPRGL¿HG
6WUHQJWK KROGV FRQVLGHUDEOH VLJQL¿FDQFH IRU SDYHPHQW ELQGHUV FDQ H[KLELW D ZLGH UDQJH LQÀXHQFHG E\ YDULDEOHV
engineers and researchers for a variety of reasons. OLNHWKHW\SHRIPRGL¿HUGXUDWLRQRIEOHQGLQJTXDQWLW\RI
admixture, and the extent of air blowing applied to the base
Comprehending the relationship between Indirect Tensile ELWXPHQ $OWKRXJK WKHVH PRGL¿HG PL[HV PD\ VRPHWLPHV
Strength (ITS) and Resilient Modulus (MR) aids in the display lower MRYDOXHVFRPSDUHGWRWKRVHZLWKXQPRGL¿HG
optimization of pavement designs by ensuring compatibility binders, it should not be construed as indicative of subpar
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Establishing a correlation between ITS and (MR) furnishes binders are generally anticipated to outperform in aspects
valuable data on how the material performs under diverse such as fatigue resistance, resistance to rutting, and overall
loading conditions, thereby facilitating more informed durability. These performance advantages are attributed
FKRLFHVIRUVSHFL¿FOD\HUVRISDYHPHQW,IWKHFRQQHFWLRQ WR WKH XQLTXH FKDUDFWHULVWLFV LPSDUWHG E\ WKH PRGL¿HUV
between ITS and MR is well-understood, engineers have rendering them a favourable option for road construction and
the capability to estimate one property based on the maintenance, even if their modulus values appear lower.
other, even when one of the parameters is challenging to
measure or not readily accessible. This correlation proves 1.1 Materials
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in rehabilitated pavements where the existing material In this investigation, the primary materials employed
properties diverge from those of the original construction. ZHUH$JJUHJDWHVDQG%LWXPHQ6SHFL¿FDOO\9*JUDGH
Bitumen was utilized for the study. The aggregates were
$V SHU WKH JXLGHOLQHV VHW IRUWK LQ ,5&>@, the procured from the crusher located closest to CSIR-CRRI.
Resilient Modulus (MR RIELWXPLQRXVPL[HVLVD൵HFWHGE\D 7KHEDVLFSURSHUWLHVRI%LWXPHQDQG$JJUHJDWHVDUHJLYHQ
multitude of factors such as the grade of the binder, air void in Table 1.
Table 1 Results for the Basic Properties of Bitumen & Aggregates
Obtained Code Obtained

Test Name Code Referred Std Limits Test Name Std Limits
Result Referred Result
Softening
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2. GRADATION OF AGGREGATES combinations of BC-1 and BC-2 are commonly employed

The focus of the study was on the gradation of wearing in India. In the context of this investigation, gradations
course bituminous concrete-1 & 2 (BC-1 & 2), in alignment corresponding to BC grades 1 and 2 were selected, with the
with the guidelines provided by the Ministry of Road H[FOXVLRQRIDQ\¿OOHUPDWHULDO7KHJUDGDWLRQSDWWHUQIRU
Transport and Highways (MoRT&H). The wearing course the mixed products is illustrated in the subsequent Table 2.

TECHNICAL PAPER
Table 2 Middle Gradation of Aggregates used for Bituminous Concrete-1

Cumulative % Passing Cumulative % Weight
Sieve Size, mm Gradation Limits Weight Retained, gm
(MID) % Retained Retained
19 100 100 0 0 0
79-100 89.5 10.5 10.5 126
9.5 70-88 79 21 10.5 126
4.75 62 17 204
42-58 50 50 12 144
1.18 41 59 9 108
0.6 68 9 108
18-28 77 9 108
0.15 12-20 16 84 7 84
0.075 4-10 7 9 108
pan 0 0 100 7 84
Total Wt., gm 1200
3. BITUMINOUS MIX DESIGN )XUWKHUPRUH LW ZDV DFNQRZOHGJHG WKDW WKH YROXPHWULF
characteristics of a bituminous mix serve as reliable
In this section, an experimental investigation was conducted
indicators of its performance. Key factors such as
to establish a correlation between Indirect Tensile
Strength (ITS) and Marshall Stability (MR) in Bituminous PD[LPXP WKHRUHWLFDO VSHFL¿F JUDYLW\ Gmm VSHFL¿F
Concrete mixes. The methodology for mix design is mass of the asphalt mix (Gmb), percentage of air voids
delineated, along with an estimation of the optimal (Vv), volume percentage of bitumen (Vb), voids in mineral
binder content. The study encompasses the evaluation DJJUHJDWH 90$ DQG YRLGV ¿OOHG ZLWK ELWXPHQ 9)%
of strength characteristics for a variety of asphalt mixes, ZHUH LGHQWL¿HG DV FULWLFDO LQ IRUHFDVWLQJ WKH GXUDELOLW\
utilizing Marshall samples to establish a strong correlation and strength of asphalt mixes. The accurate assessment
EHWZHHQWKHWZRWHVWVDVVSHFL¿HGLQ,5&)RUWKH of these volumetric properties was considered crucial, as
achievement of the research objectives, careful selection LQDFFXUDFLHV LQ WKLV HYDOXDWLRQ FRXOG VLJQL¿FDQWO\ D൵HFW
of aggregates and binder concentrations was deemed WKH IXQFWLRQDOLW\ DQG RYHUDOO H൵HFWLYHQHVV RI WKH DVSKDOW
essential for the formulation of well-crafted bituminous mixes used in the study. Table-3, Shows the Volumetrics
mixes. The implementation of the Marshall mix design of Marshall Mix Design for the OBC of BC-1 & BC-2 and
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their various gradations.
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Table 3 Shows the Volumetrics of Marshall Mix Design for the OBC of BC-1 & BC-2 and their Various Gradations
S.
Mix Gradation OBC, % G_mb G_mm VMA, % Air Voids, % VFB, % 6WDELOLW\NJ Flow, mm
No.
1 Middle 5.25 2.721 2.706 14.54 59.98 1781.21 4.11
2 BC-1 8SSHU 5.15 2.644 2.807 12.65 4.55 47.58 4.75
/RZHU 5.2 2.602 2.716 4.11 62.07 1977.27 4.12
4 Middle 5.45 2.688 2.817 11.99 4.14 42.74 4.04
5 BC-2 8SSHU 5.55 2.609 2.705 14.25 4.09 68.26 2142.09
6 /RZHU 5.4 2.604 2.71 11.07 64.87 4.48

TECHNICAL PAPER
Fig. 1 Binder Content vs Unit Weight Fig. 5 Binder Content vs Air Voids
The above graphs (Figs. 1-5 VKRZWKH&RPSDUDWLYH$QDO\VLV
of various Marshall Stability Parameters vs Binder Content.
4. INDIRECT TENSILE STRENGTH (ITS) AND

RESILIENT MODULUS (MR)
The evaluation of moisture sensitivity in asphalt mixes

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Fig. 2 Binder Content vs Stability
with a vertical diameter is subjected to loading via two curved
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this applied force, a uniform tensile stress is generated in the
vertical plane perpendicular to the direction of the load, leading
to the specimen splitting along its vertical diameter. The test is
performed at a consistent strain rate of 5.1 cm per minute until
failure occurs, with the total vertical tension at failure being
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can no longer be sustained, failure is deemed to have occurred.
The test mandates the maintenance of two parallel stress strips,
and the ITS test>@ is executed on a load strip with a width of
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Fig. 3 Binder Content vs Flow Value
vulnerability to moisture, thereby informing the design and
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%&DQG%&ZLWKVL[JUDGDWLRQV¿IWHHQ0DUVKDOOVDPSOHV
were prepared for the ITS test. These samples were formulated
using optimal binder content and were subjected to 75 blows
on each face. The application of ITS provides valuable
insights into the tensile properties of asphalt mixtures, which
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higher ITS value is indicative of enhanced resistance to low-
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failure suggests the mix's capability to endure higher tensile
Fig. 4 Binder Content vs VFA stresses before fracturing (Fig. 6).

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$670' >@DQGWKH,3&*OREDO8QLYHUVDO7HVWLQJ
0DFKLQH 870 Fig.9). Three specimens were evaluated
for each replacement percentage. The test employed a have
sine loading waveform with a 0.1-second loading duration
followed by a 0.9-second rest period, and a Poisson's ratio of
ZDVDVVXPHG'XULQJWKHMR test, one hundred specimens
were subjected to conditioning cycles with a load equal to 10
percent of the mix's Indirect Tensile Strength (ITS). The MR
test was conducted at two distinct temperatures, 25°C and
&HQDEOLQJWKHHYDOXDWLRQRIWKHDVSKDOWPL[ VVWL൵QHVV
performance at elevated temperatures. This comprehensive
Fig. 6 ITS Testing approach provided insights into how the mix responded to
)RU WKH Resilient Modulus (MR WHVW ¿IWHHQ 0DUVKDOO varying temperature conditions concerning its resilience
samples were prepared in each of the six gradations characteristics. The results of ITS and resilient modulus for
found in BC-1 and BC-2. Most materials utilized in road both BC-1 and BC-2 are given in Table 4 to Table 9.
construction display varying degrees of deformability when
exposed to external stresses, as evidenced by the MR. Such
deformation is generally reversible and directly correlates
with the stress applied, demonstrating elastic behaviour
if the stress is relatively low in relation to the material's
LQKHUHQW VWUHQJWK 7KH )HGHUDO +LJKZD\ $GPLQLVWUDWLRQ
underscores the importance of the MR test as a technique for
characterizing a wide array of pavement materials, including
+RW 0L[$VSKDOW +0$ PDWHULDOV XVHG LQ VXUIDFH EDVH
and subgrade layers. This characterization encompasses a
YDULHW\RIWHPSHUDWXUHVDQGORDGLQJFRQGLWLRQVPLPLFNLQJ
the real-world conditions of pavements under wheel loads
(Fig.7 & 8 +HUHORDGLVXVHGDVORDGIRUWHVWLQJMR and
ORDGLVWKHLQSXWJLYHQDV&RQWDFW/RDd.
The MR holds considerable importance in understanding

the elasticity of pavement materials and in predicting their
SHUIRUPDQFH XQGHU WUD൶FLQGXFHG loads, based on the
practical strain encountered during repeated loading cycles. Fig. 7 MR Testing
Fig. 8 Interface of MR Testing Software

TECHNICAL PAPER
Fig. 9 Test Sample of MR (Graph and values)

Table 4 Indirect Tensile Strength Test (ITS) Results & Resilient Modulus (MR) test Inputs for all the Three
Gradations of BC-1
Sample Height Load, 10% Load 4% Load
Sample Dia. (mm) Load (KGf) ITS (KPa)
No. (mm) 3 1PPð (KPa) (KPa)
Middle 1 61 100 1289
2 61 100 1404.97
61.5 100 1445 14161 1416.1 56.64
4 61 100 54.45
5 61.5 100
Average 13455.4 1345.54 53.82
/RZHU 1 62.5 100 1421 1419.19 55.70
2 61 100 1281 50.22
62 100 1282 1290.69 50.25
4 62.5 100 1454 14249.2 1452.15 1424.92 57.00
5 62.5 100
Average 13331.92 1333.192 53.33
8SSHU 1 61.5 100 1404.71 54.25
2 62 100 52.84
62 100 1448 14190.4 1457.82 1419.04 56.76
4 61.5 100 52.92
5 62 100 1287 12612.6 1261.26 50.45
Average 13361.32 1336.132 53.45

TECHNICAL PAPER
Table 5 Indirect Tensile Strength Test (ITS) Results & Resilient Modulus (MR) test inputs for all the three
Gradations of BC-2
Sample Height Load Load, 10% Load 4% Load
Sample Dia. (mm) ITS (KPa)
No. (mm) (KGf) P (N/mm2) (KPa) (KPa)
Middle 1 62 101 899 8810.2 881.02
2 61.5 102 944 9251.2 925.12
60.5 101 969 9496.2 989.86 949.62
4 62 101.5 1009 9888.2 988.82
5 62.5 101 954
Average 9359 935.9 37.44
/RZHU 1 62 101 8212.4 821.24
2 62 101.5 762 7467.6 746.76 29.87
60.5 102 855 864.84
4 62 101 8555.4 870.22 855.54
5 101.5 797 7810.6 778.00 781.06
Average 8085 808.5 32.34
8SSHU 1 101 1019 9986.2 998.62
2 61 101.5 985
62.5 101.5 956 940.67
4 101
5 101.5 1058 41.47
Average 9801.96 980.196 39.21
Table 6 & 7 Resilient Modulus (MR) Test Results for BC-1 @250C & 350C
Sample (Gradation) Sample no. MR (MPa) Sample (Gradation) Sample no. MR (MPa)
1 2890 1
2 2
Mid. Mid.
4 4
5 5
1 1
2 2995 2
8SSHU 8SSHU 2991
4 4
5 5
1 1
2 2
/RZHU /RZHU
4 4
5 2881 5 2918
5. RESULTS AND DISCUSSIONS construction. While the ITS test focuses on assessing the
tensile strength and resistance of the asphalt mixture, the
The correlation between Indirect Tensile Strength (ITS) MR test examines the material's elastic behavior and its
and Resilient Modulus (MR KROGV VLJQL¿FDQW LPSRUWDQFH ability to recover its original shape after repeated cycles
in evaluating both the mechanical properties and the of loading and unloading. The relationship between ITS
performance of bituminous mixes utilized in road and MR provides valuable insights to pavement's ability
INDIAN HIGHWAYS JANUARY 2024

TECHNICAL PAPER
WR UHVLVW FUDFNLQJ DQG GHIRUPDWLRQV ,PSDFWLQJ VWUXFWXUDO SUHGLFWHG $GGLWLRQDOO\ WKLV XQGHUVWDQGLQJ DLGV LQ WKH
LQWHJULW\ DQG ORQJHYLW\ RI WKH SDYHPHQW $ VWURQJ optimization of bituminous mix design by ensuring a
positive correlation between these two indices suggests EDODQFHG FRPELQDWLRQ RI WHQVLOH VWUHQJWK DQG VWL൵QHVV
that an asphalt mix with higher tensile strength will also leading to the development of asphalt pavements capable of
H[KLELW HQKDQFHG VWL൵QHVV DQG ORDGEHDULQJ FDSDFLW\ DV ZLWKVWDQGLQJWKHFKDOOHQJHVSRVHGE\WUD൶FZHDWKHUDQG
LQGLFDWHG E\ D KLJKHU UHVLOLHQW PRGXOXV 8QGHUVWDQGLQJ environmental conditions. By establishing the relationship
WKLV FRUUHODWLRQ R൵HUV PXOWLSOH DGYDQWDJHV WR SDYHPHQW between ITS and MR HQJLQHHUV DUH HPSRZHUHG WR PDNH
designers and engineers. Based on the ITS values obtained informed decisions regarding material selection, pavement
during mix design or quality control tests, the robust design, and maintenance strategies, ultimately contributing
SHUIRUPDQFH RI WKH SDYHPHQW XQGHU WUD൶F ORDGV FDQ EH to the construction of safe, and durable roads.
Table 8 & 9 Resilient Modulus (MR) Test Results for BC-2 @250C & 350C
Sample (Gradation) Sample no. MR (MPa) Sample (Gradation) Sample no. MR (Mpa)
1 1
2 2
Middle Middle
4 4 4191
5 5
1 2798 1
2 2 2722
8SSHU 8SSHU
4 4 2781
5 2997 5
1 4019 1
2 4169 2
/RZHU /RZHU 2971
4 2945 4
5 5 4081
Fig. 10 Shows the Linear graph plotted against ITS vs Fig. 11 Shows the Linear graph plotted against ITS vs
MR values for BC-1 @250C MR values for BC-1 @350C
Therefore, the developed Correlation gives out the Therefore, the developed Correlation gives out the
following Correlation Equation of BC-1 @250C IROORZLQJ &RUUHODWLRQ (TXDWLRQ RI %& #0C
MR ,76 (eq 1) MR ,76 (eq 2)

TECHNICAL PAPER
Therefore, the developed Correlation gives out the

following Correlation Equation of BC-2 @250C
MR ,76 (eq 3)
Therefore, the developed Correlation gives out the

IROORZLQJ &RUUHODWLRQ (TXDWLRQ RI %& #0C
MR ,76 (eq 4)
5.1 Statistical Data Analysis
$129$ analysis was performed to assess the impact of

independent variables (ITS) on the variance in the dependent
Fig. 12 Shows the Linear graph plotted against ITS vs variable (MR 7KHUHVXOWVGHPRQVWUDWHGVLJQL¿FDQW¿QGLQJV
MR values for BC-2 @250C LQFOXGLQJTXDQWL¿FDWLRQRIYDULDELOLW\WKURXJK5HJUHVVLRQ
SS and Residual SS, calculation of degrees of freedom (df)
for statistical precision, determination of Mean Square
(MS) values encompassing MSR (Mean Square for
Regression) and MSE (Mean Square for Residual),
FRPSXWDWLRQ RI WKH )6WDWLVWLF WR LQGLFDWH WKH UDWLR RI
explained variance to unexplained variance, and a low
SYDOXH W\SLFDOO\OHVVWKDQ FRQ¿UPLQJWKHVWDWLVWLFDO
VLJQL¿FDQFH RI WKH UHJUHVVLRQ PRGHO 7KLV VLJQL¿FDQFH
was particularly evident in the correlation between
ITS and MR ,Q HVVHQFH WKH $129$ UHVXOWV HPSKDVL]H
WKH VWDWLVWLFDO VLJQL¿FDQFH RI WKH UHJUHVVLRQ PRGHO LWV
explanatory capacity, and the extent to which independent
Fig. 13 Shows the Linear graph plotted against ITS vs variables (ITS) contribute to the variance in the dependent
MR values for BC-2 @350C variable (MR).
Fig. 14 Statistical Analysis for the obtained MR and ITS values using ANOVA for BC-1 @250C
6. CONCLUSION WHPSHUDWXUHVRI&DQG&ZHUHDQG
0.58 for ITS and MR, UHVSHFWLYHO\7KHVLJQL¿FDQFHRIWKH
Through an in-depth investigation into the correlation
5VTXDUHG FRH൶FLHQWRIGHWHUPLQDWLRQ YDOXHLQUHJUHVVLRQ
between Indirect Tensile Strength (ITS) and Resilient
analysis lies in its ability to quantify how well a regression
Modulus (MR VHYHUDOVLJQL¿FDQWREVHUYDWLRQVZHUHPDGH
PRGHO¿WVWKH,TS & MR data. It serves as a measure of the
7KH FRUUHODWLRQ FRH൶FLHQWV RU 5ð YDOXHV REWDLQHG IRU
proportion of variance in the dependent variable (MR) that
Bituminous Concrete-1 and Bituminous Concrete-2 at test

TECHNICAL PAPER
LVH[SODLQHGE\WKHLQGHSHQGHQWYDULDEOHV ,76 R൵HULQJD larger portion of the variability in the MR is accounted for
FOHDULQGLFDWLRQRIWKHPRGHO VH[SODQDWRU\SRZHU$KLJKHU E\ WKH PRGHO 7KLV PDNHV 5VTXDUHG D YDOXDEOH WRRO IRU
5VTXDUHGYDOXHLQGLFDWHVDVWURQJHU¿WDQGVXJJHVWVWKDWD model assessment and comparison.
SUMMARY OUTPUT
ZĞŐƌĞƐƐŝŽŶ^ƚĂƚŝƐƚŝĐƐ
Multiple R 0.850650034
R Square 0.723605481
Adjusted R Square 0.702344364
Standard Error 163.3163663
Observations 15
ANOVA
ĚĨ ^^ D^ & ^ŝŐŶŝĨŝĐĂŶĐĞ&
Regression 1 907768.672 907768.672 34.03421781 5.8386E-05
Residual 13 346739.0613 26672.23549
Total 14 1254507.733
ŽĞĨĨŝĐŝĞŶƚƐ ^ƚĂŶĚĂƌĚƌƌŽƌ ƚ^ƚĂƚ WͲǀĂůƵĞ >ŽǁĞƌϵϱй hƉƉĞƌϵϱй >ŽǁĞƌϵϱ͘Ϭй hƉƉĞƌϵϱ͘Ϭй

Intercept -2768.516028 1067.42649 -2.593636241 0.022273256 -5074.550759 -462.481297 -5074.550759 -462.481297
X Variable 1 4.509929421 0.773057608 5.83388531 5.8386E-05 2.839839996 6.180018846 2.839839996 6.180018846
Fig.15 Statistical Analysis for the Obtained MR and ITS values using ANOVA for BC-1 @350C
Fig. 16 Statistical Analysis for the Obtained MR and ITS Values using ANOVA for BC-2 @250C
Fig. 17 Statistical Analysis for the obtained MR and ITS values using ANOVA for BC-2 @350C

TECHNICAL PAPER
The research aiming to establish a correlation between DPRQJ YDULRXV W\SHV RI 5HFODLPHG $VSKDOW 3DYHPHQW
indirect tensile strength (ITS) and resilient modulus for 5$3 PL[HV )XUWKHU UHVHDUFK LV DOVR HQFRXUDJHG WR
ELWXPLQRXV FRQFUHWH DV SUHVFULEHG E\ ,5& VWDQGDUGV establish relationships between additional parameters such
is of paramount importance for pavement engineers. as fatigue and rutting properties of bituminous mixes,
5HVLOLHQWPRGXOXVLVDNH\SDUDPHWHULQSDYHPHQWGHVLJQ with the ultimate goal of enhancing road construction for
UHÀHFWLQJDPDWHULDO VDbility to withstand repeated loading improved quality and durability.
and deformation. However, direct resilient modulus
REFERENCES
testing can be resource-intensive and time-consuming. By
developing a correlation with the widely conducted ITS 1. $670 ' QG 6WDQGDUG 0HWKRG IRU 6RIWHQLQJ
test, engineers gain a practical tool for estimating resilient Point of Bitumen.
PRGXOXV PRUH FRQYHQLHQWO\ DQG FRVWH൵HFWLYHO\ 7KLV $670 ' QG 6WDQGDUG 7HVW 0HWKRG IRU
VLPSOL¿HVSDYHPHQWGHVLJQUHGXFHVWHVWLQJH[SHQVHVDQG Penetration of Bituminous Materials
HQKDQFHVTXDOLW\FRQWURODVHQJLQHHUVFDQTXLFNO\DVVHVV ,5& *XLGHOLQHV IRU WKH 'HVLJQ RI )OH[LEOH
material performance and suitability during construction Pavements, Indian Road Congress
DQG PDLQWHQDQFH )XUWKHUPRUH WKH FRUUHODWLRQ DLGV LQ $670' ± 6WDQGDUG 7HVW 0HWKRG IRU 6SHFL¿F
optimizing mix designs and material selection, ultimately *UDYLW\DQG'HQVLW\RI6HPL6ROLG$VSKDOW%LQGHU
resulting in safer, longer-lasting roadways and more $670'±6WDQGDUG7HVW0HWKRGIRU9LVFRVLW\
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for both engineers and the communities they serve.
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(CRMB), needs to be developed to understand their $670'±6WDQGDUGWHVWIRU5HVLOLHQW0RGXOXV
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being made to improve road quality and safety, the $670'±6WDQGDUG7HVW0HWKRGIRU,QGLUHFW
immediate focus should be on developing correlations Tensile (IDT) Strength of Bituminous Mixtures

TECHNICAL PAPER
PRACTICAL APPROACH FOR PRE-STRESSING IN

BRIDGES – ACTIVITIES AND ISSUES
N N Bandhu1
ABSTRACT
Roads and Bridges are the two parts of KLJKZD\VLQIUDVWUXFWXUHVXSSOHPHQWDU\WRHDFKRWKHU%ULGJHVFRPSULVHVRIGL൵HUHQW

W\SHRIVXSHUVWUXFWXUHVD\5&&36&RU&RPSRVLWHW\SH,Q5&&VWUXFWXUHVFRPSUHVVLYHVWUHVVHVDUHWDNHQXSE\FRQFUHWH
and tensile stresses by steel. The load carrying capacity of concrete sections can be increased if concrete is stressed before the
applications of external loads. This is the concept of prestressed concrete. Now a days, PSC super structures became more
popular due to long span requirements. Prestressing in bridges is one of the most important activities. Time and accuracy
DUHWKHHVVHQFHRISUHVWUHVVLQJ$FWLYLWLHVLQSUHVWUHVVLQJDUHPRUHVHQVLWLYHDFFRUGLQJO\HYHU\FDUHVKDOOEHWDNHQWRPDLQWDLQ
accuracy. This paper explains all activities involved and issues before, during and after stressing (Post tensioned, internal
ERQGHGWHQGRQ &DOFXODWLRQRIPRGL¿HGHORQJDWLRQDQGSUHVVXUHGHYLDWLRQDQJOHDQGVOLSRIZHGJHVKDVEHHQH[SODLQHGIURP
practical point of view.
1. INTRODUCTION WHQVLRQHG $V QDPH LPSOLHV LQ SUHWHQVLRQHG IRUFH LQ

strands is applied before concreting whereas, in post
Journey of Bridges starts accidently by fallen tree across tensioned force in strands is applied after casting of
the river. Subsequently bridges were constructed by concrete and it hardened. In case of post tensioned
ZRRGHQ ORJV VWRQHV EULFNV 3&& 5&& 36& VWHHO RU structures, stressing can be one end or both ends depending
its combinations. Several activities are involved in the upon span length and site constraint.
construction of bridges, prestressing is one of them.
Prestressing itself has no use unless until it supplements to 2.2$VSHUVWURNHVWUHVVLQJPD\EHVLQJOHVWURNHRUPXOWL
concrete. Time and accuracy are the essence of prestressing. VWURNH*HQHUDOO\VWUHVVLQJMDFNKDVOLPLWDWLRQVRIVWURNH
In case of post tensioning, grouting is a supplementary length. If elongation is less than 200 mm, stressing can
activity without which stressing is incomplete. EH GRQH LQ VLQJOH VWURNH ,Q FDVH RI ORQJHU VSDQ KDYLQJ
elongation more than 200 mm, stressing can be completed
Stressing is an activity which is deployed permanently in ZLWKWZRVWURNHRUPRUH0D[LPXPHORQJDWLRQLVFRQVLGHUHG
concrete. It boosts up the tensile capacity of the structures. PPOHVVWKDQWKHPD[LPXPVWURNHOHQJWKRIMDFN,QFDVH
In prestressed concrete, a force is applied which induces an RIPXOWLVWURNHRQFHHMHFWLRQRIUDPLVDFKLHYHGVWUHVVLQJ
axial compression that counteracts with the tensile stresses LVVWRSSHGDQGZHGJHLVORFNHGWHPSRUDULO\5DPLVWDNHQ
set up in the member due to dead load and live load during EDFNDQGVWUHVVLQJLVGRQHDVQRUPDOSURFHGXUH
service conditions.
6RPHWLPHVVWUHVVLQJLVGRQHLQVHYHUDOVWURNHWKRXJKMDFN
2. CLASSIFICATIONS LV FDSDEOH WR VWUHVV LQ VLQJOH VWURNH ,Q FDVH RI ,JLUGHU
2.1 $V SHU FDVWLQJ VHTXHQFH RI FRQFUHWH SUHVWUHVVLQJ where two cables are eccentric to the vertical centre line,
LV FODVVL¿HG LQWR WZR W\SHV VD\ SUH WHQVLRQHG DQG SRVW FDEOHV DUH VWUHVVHG LQ VXFK D ZD\ GL൵HUHQFH LQ IRUFHV LQ
ERWKFDEOHVVKRXOGQRWPRUHEHWKDQ
([&KLHI5HVLGHQW(QJLQHHU$KPHGDEDG0HWUR5DLO(PDLOQQEDQGKX#JPDLOFRP

TECHNICAL PAPER
2.3 $V SHU VWDJH RI VWUHVVLQJ LW FDQ EH VLQJOH RU PXOWL vi. PSC Guide beam for Monorail
stages. Two or more stages stressing are required when vii. PSC Pier cap
dead load is applied in stages. Multi stage stressing is done viii. PSC Portal
to avoid excessive hogging and tensile & compressive ix. PSC Cantilever Pier cap
IRUFHLQFRQFUHWH)RUH[DPSOHLQFDVHRI,JLUGHUKDYLQJ x. PSC Extended Pier cap
PVSDQJHQHUDOO\FDEOHVRI7DUHUHTXLUHG,IDOO xi. Cable Stayed Bridge
FDEOHVDUHVWUHVVHGLQRQHVWDJHFUDFNVRQWRSRIWKHJLUGHUV
will develop due to excessive hogging and tension. 5 ACCESSORIES AND EQUIPMENT FOR
STRESSING AND GROUTING.
3. ADVANTAGES AND DISADVANTAGES OF 5.1. Anchorage System
PSC STRUCTURES
$QFKRUDJHLVDFRPELQDWLRQRIDFFHVVRULHVZKLFKLVXVHG
3.1 Advantages of PSC Structures: to hold the tendons (strands) in stressed condition without
any slip for post tensioned system of pre-stressing. Main
L /RQJHU VSDQ LV SRVVLEOH ZLWK VPDOOHU VHFWLRQ RI function of anchorage is to transfer the stressing force
structures. permanently to the concrete, once the stressing process
LL 6HFWLRQ UHPDLQV XQFUDFNHG GXULQJ VHUYLFH is completed. It is a combination of anchor cone, bearing
condition for more durability. plate and wedges. (Refer Photo-1)
iii. Suitable for pre-cast construction.
iv. Very fast construction due to repetition possibility.
Y %HWWHU4&GXHWRIDFWRU\OLNHZRUNLQJHQYLURQPHQW
YL $OODFWLYLWLHVGRQHE\VNLOOHGZRUNHUV
3.2 Disadvantages/Limitations of PSC structures:

L +LJKO\VNLOOHGWHFKQLFDOPDQSRZHULVUHTXLUHG
ii. Relatively higher cost for normal structures due to
casting yard set up and requirement of auxiliary
equipment.
iii. Design is more complex.
iv. Chances of slip of anchorages. Photo-1 Anchorage system- Anchor cone, Bearing
Y %UHDNLQJRIVWUDQGV Plate and Wedges
vi. Punching of guide cone and/or bursting of concrete 5.1.1 Anchor Cone
near anchorage.
YLL /HDNDJHLQVKHDWKLQJGXULQJJURXWLQJ This is specially formed component made of cast iron,
YLLL 9HU\SUHFLVHZRUNXWPRVWFDUHQHHGHG which is embedded in the concrete and used to distribute/
transfer the prestressing forces to the concrete. Its internal
4. STRUCTURES FOR WHICH VKDSHLVDWUXQFDWHGFRQH,WVRXWHUÀDWVKDSHÀXVKHGZLWK
PRESTRESSING CAN BE USED: concrete stands the prestressing force and inner circular
4.1 Example of Pre-Tensioned structures portion is connected with sheathing. In nut cell, anchor
FRQH LV XVHG WR FRQQHFW WKH GXFWV DQG SURYLGHV D ÀDW
i. PSC I- girder
VXUIDFH IRU WKH SODFHPHQW RI EHDULQJ SODWH RQ LW$QFKRU
LL 36&8JLUGHU
FRQHLV¿[HGZLWKHQGVKXWWHUDVSHUGHYLDWLRQDQJOHJLYHQ
iii. PSC Sleeper (None Bridge structures)
in the drawing. Provision for grouting is made in anchor
iv. PSC Electric Pole (None Bridge structures)
cone. Size of the anchor cone depends upon number
4.2 Example of Post-Tensioned structures RI VWUDQGV WR EH XVHG DQG GHQRWHG DV 7 7 HWF
i. PSC I-girder (full length and segmental) +HUH ¿UVW QXPEHU LQGLFDWHV QXPEHU RI VWUDQGV ZKHUHDV
ii. PSC Box girder (full length and segmental) VHFRQGQXPEHULQGLFDWHVGLDRIVWUDQGV6HFRQGQXPEHU
LLL 36&8JLUGHU IXOOOHQJWKDQGVHJPHQWDO indicates strands of 12.7 mm diameter whereas 15 denotes
iv. PSC Balanced Cantilever Box girder. PPGLDPHWHURIVWUDQGV$QFKRUFRQHLV¿[HGLQVXFK
v. PSC Voided Slab (full length and segmental) a manner, grouting hole is at top corner.

TECHNICAL PAPER
5.1.2 Bearing Plate GXFWV VKRXOG EH IXOO\ OHDNWLJKW DJDLQVW ZDWHU SUHVVXUH
Bearing plate is a cylindrical round shaped component equivalent to 1.1 x (maximum expected gravity head of
made by forging of graded alloy steel. It contains a number JURXWLQJPDWHULDOJURXWLQJSUHVVXUH $VIDUDVSRVVLEOH
RIWUXQFDWHGFRQHVKDSHGKROHVIRUORFNLQJRISUHVWUHVVLQJ single length shall be used to avoid joint and subsequent
strands with the help of wedge grips. Its diameter and OHDNDJHLVVXH:KHUHVKHDWKLQJGXFWMRLQWVDUHXQDYRLGDEOH
WKLFNQHVVGHSHQGXSRQQXPEHURIVWUDQGVWREHDQFKRUHG such joints shall be made cement slurry tight by the use of
corrugated threaded sleeve couplers which can be tightly
5.1.3 Wedges VFUHZHG RQ WR WKH RXWHU VLGH RI WKH VKHDWKLQJ GXFWV $
Wedge is a truncated cone shaped components made from KHDWVKULQN FRXSOHU FRXOG DOVR EH XVHG LI VXLWDEOH 5HIHU
alloy carbon steel and subsequently hardened. Inner portion Photo-3 5HIFODXVHDQG,5&
of wedge is threaded for better grip to hold the strands
XQGHU SUHVWUHVVLQJ IRUFH $IWHU ¿QLVKLQJ WKH ZHGJH RQH
grove is made for a ring to hold the three parts of wedge
WRJHWKHU$IWHU JLYLQJ WKH ¿QDO VKDSH LW LV FXW LQWR WKUHH
HTXDOSDUWVWRZRUNOLNHDVSOLWMDZ
5.1.4 Bursting Reinforcement

Tensile stresses are induced during prestressing operation
and the maximum bursting stress occurs at right angle
WR WKH SUHVWUHVVLQJ IRUFH ,W LV SURYLGHG LQ WKH HQG EORFN
portion of girders to counter the bursting force developed
Photo-3 Sheathing made of HDPE and Bright Metal
GXHWRVWUHVVLQJIRUFH,W¶VDFRPELQDWLRQRIVSLUDOVKDSHG
and Grid/Mesh type reinforcement. Spiral reinforcement
5.1.6 HT Strands
LV SODFHG MXVW EHKLQG ÀDW SRUWLRQ RI DQFKRU FRQH DURXQG
the tube. Grid/Mesh reinforcement is placed after spiral Strands plays a vital role for pre stressing in bridges.While
at a location mentioned in the drawing in both directions pulling it and transferring the load, girder is compressed.
perpendicular to the prestressing axis.(Refer Photo-2) Quantum of pulling force in strand is applied such that the
compression created at bottom of girder (simply supported)
is more than the expected tension due to dead load and live
ORDG$W WKH VDPH WLPH WHQVLRQ VKRXOG QRW EH FUHDWHG DW
top of the simply supported girder/beam. Now a days, low
relaxation 7 ply type 2 strands of diameter 12.7 mm and
15.2 mm are used. (Refer Photo-4 5HI±,6
Photo-2 Bursting Reinforcement – Spiral and Mesh
5.1.5 Sheathing Duct

,W¶V D NLQG RI WXEH WR SURYLGH KROH LQ FRQFUHWH VWUXFWXUHV
to thread the strands through and through of the girder. Photo-4 7 Ply HT Strands Photo - 5 Dummy Pipe
Sheathing may be of bright metal or HDPE. Now a days,
5.1.7 Dummy pipe
HDPE (High Density Poly-Ethylene) sheathing is more
SRSXODUGXHWRLWVÀH[LELOLW\DYDLODELOLW\LQUHTXLUHGOHQJWK It is a single piece PVC or HDPE pipe with smooth
DQGOHDNSURRISURSHUW\2XWVLGHFRUUXJDWLRQRIVKHDWKLQJ surface having diameter smaller than the inner diameter of
improves bond between concrete and inside corrugation sheathing. It is inserted in sheathing for its full length of
improves bond between grout and strands. The sheathing the girder. During concreting of girders/segments, dummy

TECHNICAL PAPER
SLSHLVVKDNHQWRDQGIURWRDYRLGDQ\DFFLGHQWDOFKRFNLQJ
RIVKHDWKLQJGXHWRVOXUU\OHDNDJH 5HIHUPhoto -5)
3KRWR±3RZHU3DFN
5.1.12 Linear Scale
Photo-6 Multi-pull Jac) FPORQJVWHHOVFDOHLVXVHGWRPHDVXUHWKHHORQJDWLRQ

in strands.
0XOWL3XOO-DFN6HW
,WFRQVLVWVRIMDFNWRSXOODWDWLPHDOOVWUDQGVLQDSDUWLFXODU
FDEOHFROODUSODWHORFNLQJSODWHHWF 5HIHU Photo-6) Photo-9 Linear Scale
5.1.13 Grout Mixing Agitator
,WLVXVHGWRPL[FHPHQWJURXWWR¿OOWKHVKHDWKLQJGXFWDIWHU
stressing. It consists of drum, motor and mixing blades.
(Refer Photo-10)
3KRWR6LQJOH3XOO-DFN
6LQJOH3XOO-DFN
7KLVMDFNFDQSXOOVLQJOHVWUDQGVDWDWLPH*HQHUDOO\LWLV
XVHGIRUVODFNUHPRYDORIVWUDQGVDQGGHVWUHVVWKHVWUDQGV Photo – 10 Grout Agitator
in the case of emergency. (Refer Photo-7)
5.1.14 Grout Pump
3RZHU3DFN The Grout pump is a positive displacement dual piston
,WLVDNLQGRISXPSWRIHHGK\GUDXOLFRLOLQMDFNWRFUHDWH SXPSGHYHORSLQJDSUHVVXUHXSWRNJFP2 and generally
a delivery of 20 litres grout/minute. (Refer Photo-11)
pressure and withdraw pressure for the movement of ram
RIWKH-DFN,WFRQVLVWVRIPRWRURLOWDQNSUHVVXUHJDXJH
and connecting pipes. (Refer Photo-8)
5.1.11 Pressure Gauge

Pressure gauge is an equipment to measure pressure
DSSOLHG LQ WKH MDFN 0LQLPXP VL]H RI PP GLDPHWHU
with concentric scale type gauge is used. Capacity of
pressure gauge shall be such that when strands is stressed
WRRIEUHDNLQJORDGWKHSUHVVXUHJDXJHUHDGLQJVKDOO
EHEHWZHHQDQGRILWVIXOOFDSDFLW\ Photo-11 Grout Pump

TECHNICAL PAPER
'L൵HUHQFH LQ GLVWDQFH RI KLJKHU HGJH DQG ORZHU HGJH RI
inner recess plate is calculated with a method mentioned
EHORZ VD\PP 7ZRVWUDLJKWVTXDUHEDURIOHQJWK
PP JHQHUDOO\ DQGWZREDURI PP
is cut accurately.
&/RIDQFKRUFRQHRQLQQHUVLGHRIHQGVKXWWHULVPDUNHG
Concentric rectangle of 270 mm X 267.6 mm (270 mm
became 267.6 mm in plan after rotation as per deviation)
with reference to centre line of cable is drawn.
3KRWR*URXWFDS 1LSSOHZLWKORFNLQJGHYLFH $OO IRXU SUHYLRXVO\ FXW EDUV DUH HUHFWHG RQ FRUQHUV RI
5.1.15 Grout cap square drawn such that smaller bar shall be at lower edge
and bigger bar at higher edge. Plate of size 170 X 170 mm
It is used for grouting of cable duct after stressingto safe on top of erected bars is welded accurately. Position of this
guard the strands from corrosion. (Refer Photo – 12) inner recess plate will provide deviation angle. Side plates
RIUHFHVVZHOGHGDVPHQWLRQHGLQ*)&GUDZLQJZLWKPDWFK
6 IMPORTANT PRE ACTIVITIES
¿QLVKLQJ$IWHUZHOGLQJFRQFHQWULFFLUFXODURUUHFWDQJXODU
)ROORZLQJDUHWKHLPSRUWDQWDFWLYLWLHVZKLFKUHTXLUHGWR hole w.r.t. centre line of cable is made in end shutter. Hole
EHWDNHQXSIRUWKHVXFFHVVIXOSUHVWUHVVLQJ IRU EROWV LV PDGH LQ LQQHU UHFHVV SODWH WR ¿[ WKH DQFKRU
FRQH6L]HRIUHFHVVLVWDNHQLQVXFKDZD\PRXWKRIMDFN
3URYLVLRQDQG&KHFNLQJRI'HYLDWLRQ$QJOH can be inserted and after cutting of strands, grout covers
the strands end by 25 mm.
This is one of the most important design parameters for
PSC bridges. Deviation angle is a deviation of cable from
KRUL]RQWDO SODQH DW ERWK HQGV RI JLUGHU $QFKRU FRQH LV
¿[HGZLWKJLYHQDQJOHWRVDWLVI\WKHGHVLJQUHTXLUHPHQW7R
achieve this angle, arrangement is made in end shutter and
DQFKRUFRQHLV¿[HGZLWKLW7KLVLVWKHSULPHUHVSRQVLELOLW\
of site engineers to achieve the given deviation angle.
6.1.1 Fabrication of end shutter with aprovision of

design deviation angle
Here it is described, how to fabricate end shutter with a
SURYLVLRQ RI FRUUHFW GHYLDWLRQ DQJOH ,I FDUH LV QRW WDNHQ
GXULQJ IDEULFDWLRQ LW LV +HUFXOHV WDVN IRU LWV UHFWL¿FDWLRQ &KHFNLQJ RI HQG VKXWWHU WR FRQ¿UP GHVLJQ
(Refer Photo-13 )XUWKHU LI FDUH LV QRW WDNHQ E\ WKH deviation angle.
HQJLQHHUFRQVXOWDQW GXULQJ FKHFNLQJ SXUSRVH RI GHVLJQ
It is noticed several times that the site engineers are very
will be forfeited.
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DQGRU LJQRUDQFH $Q HDV\ PHWKRG LV H[SODLQHG EHORZ
WRFKHFNWKHGHYLDWLRQDQJOHRIHQGVKXWWHUWRVDWLVI\WKH
design
2QHWRROOLNHJDUGHQVZLQJIUDPHLVIDEULFDWHGZLWKKHLJKW
25 cm and length 40 cm with angle or square bar as shown
below. This will help to measure vertical and horizontal
imaginary lines.
(QGVKXWWHULVNHSWLQWUXHKRUL]RQWDOSRVLWLRQ)DEULFDWHG
tool is placed on shutter and height between higher and
lower edge of inner plate of recess is measured with the
3KRWR5HFWL¿FDWLRQRIGHYLDWLRQDQJOH

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help of set sTXDUHDQGPHDVXULQJVFDOH'L൵HUHQFH³S´LV 6.3 Tests on Equipment and Materials

IRXQGRXW SVD\PP 3ODQOHQJWKRIUHFHVVHVSODWH
6.3.1 System acceptance test
LV PDUNHG RQ KRUL]RQWDO EDU RI WRRO 3ODQ OHQJWK RI LQQHU
plate is measured (b say 267.6 mm). Before approval of system and stressing starts, following
tests on system is required to be conducted. Value given in
Deviation angle is calculated with trigonometrical formula
WKLVWHFKQLFDOSDSHUVKDOOEHYHUL¿HGIURPODWHVWVWDQGDUG
as mentioned:-
VSHFL¿FDWLRQVEXOOHWLQHWF
D $QFKRUDJHH൶FLHQF\WHVW
,WLVUHTXLUHGWRNQRZWKHH൶FLHQF\RIDQFKRUDJHV\VWHP
ZKLFKVKDOOQRWEHOHVVWKDQRIWKHDFWXDOPHDQWHQVLOH
ultimate strength of the tendons. It is conducted by the
system supplier on a permanent test set up. This test is
similar to regular prestressing. (Refer Photo- 15) Ref- Cl
,5&
'XULQJ FKHFNLQJ LI GHYLDWLRQ DQJOH LV IRXQG ZURQJ

re-fabrication is required to be done (Refer Photo-13)
3UR¿OLQJRIFDEOH
'HVLJQHU SURYLGHV WKH FDEOH SUR¿OH RUGLQDWHV LQ WKHLU
GUDZLQJ ,W¶V D SULPH UHVSRQVLELOLW\ RI VLWH HQJLQHHUV WR
PDLQWDLQWKHDFFXUDF\RISUR¿OHZLWKRXWDQ\NLQN6KHDWKLQJ 3KRWR$QFKRUDJHH൶FLHQF\WHVW
LV VXSSRUWHG DQG ¿[HG DW D UHJXODU LQWHUYDO DV VKRZQ LQ (b) Load transfer test
SKRWR VXFK WKDW SUR¿OH PXVW QRW FKDQJH GXULQJ YLEUDWLRQ
of concrete and due to buoyancy (Refer Photo-14). If ,W LV UHTXLUHG WR NQRZ WKH EHKDYLRXU RI DQFKRU FRQH DQG
FDEOHSUR¿OHLVQRWPDLQWDLQHGDVSHUGUDZLQJWKHUHLVD surrounding concrete. It is conducted by the system supplier
possibility of reduction or excess of friction force which on a permanent test set up. Behaviour of concrete of test beam
H൵HFWWKHHORQJDWLRQRIVWUDQGV+RJJLQJRIJLUGHUPD\DOVR is compared with concrete cubes without any loading with the
EH D൵HFWHG LI FDEOH SUR¿OH LV QRW PDLQWDLQHG DFFXUDWHO\ KHOSRIVWUDLQJDXJH 5HVLVWDQFH ZKLFKVKRZH൵HFWRQPRQLWRU
,I FDEOH SUR¿OH LV QRW FRQFHQWULF HVSHFLDOO\ IRU , JLUGHUV IRUHYHQ QRQYLVLEOH PLQRU FUDFNV 7KH FRQFUHWH DQG WKH
KRUL]RQWDOGHÀHFWLRQPD\RFFXUZKLFKOHDGVWRUHMHFWLRQLI reinforcement in this region are designed to transfer load not
goes beyond limit. OHVVWKDQSHUFHQWRIQRPLQDO876RIWHQGRQVLWLVH[SHFWHG
WRKROG7KHFUDFNZLGWKVKDOOQRWH[FHHGPPDWSHUFHQW
RI876 5HIHUPhoto – 16 5HI&O,5&20
Photo – 14 Fixing of Sheathing Photo – 16 Load transfer test set up

TECHNICAL PAPER
F -DFNH൶FLHQF\WHVW Note- Out of above tests, site Engineers need the actual
YDOXHRIDUHDDQG02(RIVWUDQGVIRUWKHPRGL¿FDWLRQRI
,W LV UHTXLUHG WR NQRZ WKH H൶FLHQF\ RI VWUHVVLQJ MDFN elongation before stressing.
(൶FLHQF\ RI MDFN VKDOO QRW EH OHVV WKDQ -DFN
H൶FLHQF\LVFRQGXFWHGEHIRUH¿UVWVWUHVVLQJLQDQ\EULGJH 6.4 Calibration of Pressure Gauge
DQGDWWKHLQWHUYDORIPRQWKVRULQFDVHZKHQHORQJDWLRQ Pressure gauge is an equipment to measure the applied
and pressure is not proportionately. To conduct this test, force on strands. Since, success of prestressing process
WZRMDFNVDUHXVHGIRUVWUHVVLQJWRDFWDVDFWLYHDQGSDVVLYH depends upon accuracy of pressure gauge, it is mandatary
UHVSHFWLYHO\%RWKMDFNVDUHSRVLWLRQHGLQRQHOLQHWRXFKLQJ to calibrate pressure gauge regularly at the interval of
PRXWK WR PRXWK DQG FRQQHFWHG ZLWK SRZHU SDFN ,QLWLDO PRQWKV &DOLEUDWLRQ FHUWL¿FDWH DORQJ ZLWK WUDFHDELOLW\
SUHVVXUHRINJLVDSSOLHGRQRQHDFWLYHMDFNDQGSDVVLYH VKDOOEHYHUL¿HGEHIRUHWKHVWUHVVLQJSURFHVVLVVWDUWHG
SUHVVXUHRQDQRWKHUMDFNLVQRWHG3URFHVVLVUHSHDWHGDWWKH
LQWHUYDORINJXSWRGHVLJQSUHVVXUH3HUFHQWDJHSUHVVXUH 6.5 Tests on HDPE Sheathing
in passive with respect to active is calculated. Now process )ROORZLQJ7HVWVRQVKHDWKLQJDUHUHTXLUHGWREHFRQGXFWHG
LVUHYHUVHGSDVVLYHEHFDPHDFWLYHDQGYLFHYHUVD$YHUDJH EHIRUHVKHDWKLQJLVVXSSOLHGDWVLWH$WOHDVWVDPSOHVIRU
SHUFHQWDJHLQERWKWKHFDVHVZLOOEHWKHH൶FLHQF\RIERWK one lot of supply (not exceeding 7000 metre length) shall
MDFNV(൶FLHQF\ RI MDFNVLV FRQVLGHUHGZKLOHFDOFXODWLQJ be tested.
PRGL¿HGSUHVVXUH 5HIHUPhoto -17)
6.5.1 Tests on Raw materials of sheathing:
5HI,5&¿E%XOOHWLQ
L 'HQVLW\ ±JPFFDW0C) as declared by

manufacturer.
ii. Tensile Strength Test (20-26 N/mm2)as declared
by manufacturer.
LLL (ORQJDWLRQ DW <LHOG 0LQ DV GHFODUHG E\
manufacturer.
LY 0HOW)ORZ,QGH[ WRJPSHUPLQXWH DV
declared by manufacturer.
3KRWR-DFN(൶FLHQF\7HVW Y &KDUS\,PSDFW7HVW N-P2 at 40&N-P2
DW0& DVSHU,62,,H$
6.3.2 Tests on HT strand (15.2 mm dia) YL &RH൵RI7KHUPDO([SQ [-4 N-P2 for 200 to
5HI,6,6)ROORZLQJ3K\VLFDO 800C) as declared by manufacturer.
Mechanical tests are required to be conducted on HT
strands before stressing. 6.5.2 Tests on HDPE Sheathing Duct: -Ref- IRC:112,
¿E%XOOHWLQ
i. Measurement of diameter of all 7 ply of strand.
LL 3HUFHQWDJHGL൵HUHQFHLQGLDPHWHURIFRUHSO\DQG L &DUERQ%ODFNFRQWHQW7HVW 0LQ 5HI&O
RXWHUSO\± 0LQ RI¿E%XOOHWLQ
LLL 'LDPHWHURIVWUDQGV± PPPP LL :DOO 7KLFNQHVV WROHUDQFH PP
LY /D\OHQJWK 'WR' 5HI$QQH[$RI¿E%XOOHWLQ
Y 6WUDLJKWQHVV± P ORQJ SLHFH RI VWUDQG VKDOO EH LLL 'LDPHWHURI6KHDWKLQJ RUPPZKLFKHYHU
straight) LVJUHDWHU $QQH[$RI¿E%XOOHWLQ
YL $UHDRIVWUDQG± 1RPLQDOPP2) LY 6WL൵QHVVRI'XFW5HI$QQH[$RI¿E%XOOHWLQ
YLL 0RGXOXVRIHODVWLFLW\N1PP2 75 (Photo-17a)
YLLL 3URRIORDG 0LQN1 Y /RQJLWXGLQDO /RDG UHVLVWDQFH RI GXFW V\VWHP
L[ %UHDNLQJVWUHQJWK± 0LQN1 5HI$QQH[$RI¿E%XOOHWLQ
[ (ORQJDWLRQDWEUHDNLQJORDG YL 7UDQVYHUVH /RDG 5DWLQJ 7HVW 1R GHIRUPDWLRQ
xi. Relaxation test (Max 1.8 percent after 100 h and H[FHHGLQJRIGXFWLQWHUQDOGLDPHWHURUPP
2.5 percent after 1000 h) whichever is smaller two minutes after release of

TECHNICAL PAPER
ORDG ) Photo-17b 5HI$QQH[$ RI ILE %XOOHW ix :HDU5HVLVWDQFH7HVW5HGXFWLRQLQ:DOO7KLFNQHVV

in 75 7HVW 0LQUHVLGXDOWKLFNQHVVPP 5HI$QQH[
YLL :RUNDELOLW\7HVW 1R GHIRUPDWLRQ H[FHHGLQJ $RI¿E%XOOHWLQ
RI GXFW ,' ZKLOH WHVW VSHFLPHQ LV LQ ¿QDO EHQW
[ %RQG /HQJWK 7HVW PDLQWDLQ ERQG ZLWK RI
position with bending radius of R mm on 1100 mm
WKH WHQGRQ 87 IRUFH DW ERQG OHQJWK RI GLD RI
ORQJWHVWVSHFLPHQ 5HI$QQH[$RI¿E%XOOHWLQ
VKHDWKLQJ 5HI$QQH[$RI¿E%XOOHWLQ
75 (Photo- 17c)
viii. Water loss test (Shall with stand internal pressure 6.5.3 Tests on mild steel sheathing duct:
of 0.05 MPa for 5 minutes with maximum water -Ref- IRC:112 ANNEXURE A-5
ORVVRI 5HI$QQH[$RI¿E%XOOHWLQ
i. WDOO7KLFNQHVVPPPPDQGPPIRU
sheathing ducts having internal diameter up to 50
mm, 75 mm and 90 mm and above respectively.
LL 'LDPHWHURI6KHDWKLQJ RUPPZKLFKHYHU
is greater)
LLL :RUNDELOLW\7HVW 1RIDLOXUHDWEHQGLQJUDGLXVRI
1800 mm on test sample 1100 mm long)
iv. Transverse Load Rating Test: The test ensures the
VWL൵QHVVRIWKHVKHDWKLQJZZWRSUHYHQWSHUPDQHQW
distortion during handling and concreting. The
Photo -17(a) sample is placed on a horizontal support 500 mm
long so that the sample is supported at all points
RI RXWZDUG FRUUXJDWLRQV$ ORDG WDEXODWHG EHORZ
is applied gradually at the centre of the supported
portion through a circular contact surface of 12
mm dia and load is applied approximately at the
centre of two corrugations.
v. Tension Load Test:- The test specimen is subjected
WRDWHQVLOHORDG7KHKROORZFRUHLV¿OOHGZLWKD
ZRRGHQFLUFXODUSLHFHKDYLQJDGLDPHWHURI
of the inner dia of the sample to ensure circular
Photo- 17(b) SUR¿OHGXULQJWHVWORDGLQJ$FRXSOHULVVFUHZHGRQ
DQGWKHVDPSOHORDGHGLQLQFUHPHQWVWLOOVSHFL¿HG
load. If no deformation of the joints nor slippage
of couplers is noticed, the test shall be considered
satisfactory:
Load Chart for Tension Load Test
Dia (mm) Test Load (N) Dia in mm Test Load
XSWR >65 up to 75 1400
!XSWR 500 >75 up to 85 1600
>45 up to 55 800 >85 up to 90 1800
Photo – 17(c) >55 up to 65 1100
Load Chart for Transverse Load Rating Test

Dia (mm) WR !WR > 45 to 55 > 55 to 65 > 65 to 75 > 75 to 85 > 85 to 90
/RDG 1 250 400 500 600 700 800 900

TECHNICAL PAPER
vi. Water Loss Test: The sample is sealed at one L[ :DWHUDEVRUSWLRQ7HVW± /HVVWKDQ
HQG 7KH VDPSOH LV ¿OOHG ZLWK ZDWHU DQG DIWHU [ 6ROYDELOLW\LQZDWHU± /HVVWKDQ
sealing, the end is connected to a system capable [L +HDW5HVLVWDQFH± 7KHVKHDUVWUHVVIDLOXUHVKRXOG
RI DSSO\LQJ D SUHVVXUH RI 03D DQG NHSW 1PP2 at 50oC)
constant for 5 minutes. The sample is acceptable if [LL &RORXU± &RORXU RI WKH PL[HG DQG FXUH ERQGLQJ
WKHZDWHUORVVGRHVQRWH[FHHGRIWKHYROXPH agent shall be similar to the adjoining concrete).
(Ref Photo 17(d)) [LLL &RPSUHVVLYH VWUHQJWK ± 03D DW KRXUV DQG
75 MPa at 168 hours on 50 x 50 x 50 mm cube (at
lower temperature limit)
7. ACTIVITIES INVOLVED FOR STRESSING
7.1 Review the Drawing notes to Clarify the

Elongation and Force
Several considerations/assumptions are written in the
drawing notes must be read carefully. Elongation, design
force and its unit and slip are very important information
IRUH൵HFWLYHVWUHVVLQJ6RPHGHVLJQHUVXVHWRZULWHDERXW
inclusion or exclusion of slip clearly in design elongation.
Photo- 17(d) Water Loss Test However, some designers are not writing clearly about
6.6 Tests on Glue (In case of Dry VOLSZKLFKPD\D൵HFWEDGO\WKHDFFXUDF\RISUHVWUHVVLQJ
Matching segmental construction):- Generally, slip is mentioned as 6 mm however, it may vary
system to system and it plays a vital role so neither it shall
5HI ,5&63± ),3
be ignored nor manipulated. In addition to slip, one more
)ROORZLQJ WHVWV DUH UHTXLUHG WR EH FRQGXFWHG RQ
measurement is required to be considered is elongation due
Glue before execution-
to grip length extension which comes around 4 mm.
L 3RWOLIHRI0L[HGERQGLQJDJHQW±0LQPLQXWH
&KHFNLQJRI&XEH6WUHQJWK
(at upper temperature limit)
ii. Open time - Min 60 minute (at upper temperature 6WUHQJWKRIFRQFUHWHFXEHLVFKHFNHGZUWGHVLJQUHTXLUHPHQW
limit) EHIRUHVWDUWWKHVWUHVVLQJ&RQFUHWHFXEHVVKDOOEHNHSWDWJLUGHU
LLL 7KL[RWURSK\± 6KRXOGQRWEHPRUHWKDQPPLQ top for curing to adopt true representation of cube strength for
10 minute) safe stressing without any cone punching or bursting.
LY 6TXHH]DELOLW\ ± $UHD RI 6SUHDG 0LQ PPð
7.3 Conversion of force to pressure
)RU/RDGRI.JZLWKPPGlue)
Y %RQGLQJEHWZHHQ&RQFUHWHDQG*OXH± $IWHU+UV )RUFHVPHQWLRQHGLQWKHGUDZLQJPD\EHLQ07RULQN1
total fracture of concrete paste and aggregate should which cannot be measured directly with Pressure Gauge.
occur with no evidence of bonding agent failure) Therefore, force is required to be converted to pressure
YL &XULQJ 5DWH± &RPSUHVVLYH VWUHQJWK RQ before stressing as per following method.
50 x 50 x 50 mm cube shall be 20 MPa at 12 hours,
40 MPa at 24 hours and 75 MPa at 168 hours (at
lower temperature limit)
YLL 6KULQNDJH7HVW± 1RWPRUHWKDQDIWHUGD\V
YLLL &UHHS 7HVW D 3XUH &RPSUHVVLRQ )RU DQ
instantaneous MOE of 8000N/mm2, the deferred
modulus at one hour should not be less than 6000
N/mm2 E 3XUH6KHDU± )RUDQLQVWDQWDQHRXV &DOFXODWLRQIRUPRGL¿HGHORQJDWLRQ
Modulus of Shear of 1500N/mm2, the deferred
Modulus at 28 days should not be less than 1000 During design stage, elongation in strands due to stressing
N/mm2) is calculated based on standard value of area and MOE of
VWUDQGV7KHUHIRUHPRGL¿HGHORQJDWLRQLVFDOFXODWHGEDVHG

TECHNICAL PAPER
on actual area and MOE of strands. Design elongation is

PRGL¿HGDVSHUIROORZLQJPHWKRG
In the given example, elongation mentioned in the drawing

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-DFN JULS OHQJWK HORQJDWLRQ LV HODVWLF DQG LW ZLOO UHFRYHU
after release of force so it shall be added in gross elongation. Photo – 18 Collar Plate
$QGLQFDVHRIRQHHQGVWUHVVLQJPPZHGJHVLWWLQJVKDOO
be added to gross elongation before stressing.
/LPLWLV PPPPPP
PP
[ PPPP
PP PP
[ PPPP
PP PP
6OLS PP-DFNJULSOHQJWKH[WQ PPORFNLQJHQG
wedge sitting = 2 mm)
While calculating net elongation, actual slip (it is a 3KRWR±/RFNLQJ3ODWH
FRPELQDWLRQ RI VOLS DQG MDFN JULS OHQJWK HORQJDWLRQ DQG
ZHGJHVLWWLQJDWORFNLQJHQGVKDOOEHGHGXFWHGIURPJURVV 3ODFHPHQWRI0XOWL3XOO-DFN
elongation after stressing. 0XOWLSXOO MDFN LV OLIWHG DQG SRVLWLRQHG ZLWK WKH KHOS RI
Note - In case, slip is added in the design elongation, slip is hydra, small crane or specially fabricated frame with chain
GHGXFWHGDQGHORQJDWLRQLVPRGL¿HGDVPHQWLRQHGDERYH SXOOH\ 2QFH SUHVVXUH LV JLYHQ LQ WKH MDFN LW EHFRPHV
7.5 Cutting of HT Strands as per Required Length self-supporting, hanging arrangement is loosened. Once
SUHVVXUH LV UHOHDVHG DIWHU VWUHVVLQJ DQG ORFNLQJ VDPH
6WUDQGV LV FXW DV SHU SUR¿OH OHQJWK PHQWLRQHG LQ WKH hanging arrangement is tightened.
GUDZLQJ SOXV MDFN JULS OHQJWK DURXQG PP MDFN HQG
DQGPPIRUORFNLQJHQGDVWKHFDVHPD\EH $SSOLFDWLRQRI9D[DQG¿[LQJRI0DVWHU:HGJHV
7.6 Threading of HT Strands Vax is applied on outer surface of master wedges. Master
wedges are placed and tightened with especially procured
$IWHUFXWWLQJRIVWUDQGVLWLVLQVHUWHGLQWRGXFWSURYLGHG a piece of MS heavy duty pipe to avoid any slip during
with the help of sheathing at the time of concreting. stressing.(Refer Photo -20)
3RVLWLRQLQJRI%HDULQJ3ODWH :RUNLQJ:HGJH
at Both end of the Girder
Portion of extra strands outside the girder are properly
cleaned of dustand any traces of oil then bearing plate &
ZRUNLQJZHGJHVDUHSRVLWLRQHG
3ODFHPHQWRI&ROODU3ODWH /RFNLQJ3ODWH
$IWHUSODFHPHQWRI EHDULQJSODWHDQGZHGJHFROODUSODWH
DQG ORFNLQJ SODWH LV SODFHG -DFN UHVWV KRUL]RQWDOO\ RQ
&ROODU3ODWHZLWKRXWDQ\SUHVVXUHRQEHDULQJSODWH/RFNLQJ
SODWHLVSXVKLQJEDFNWKHZHGJHVGXULQJORFNLQJRIZRUNLQJ
wedge. (Refer Photo-18&19) Photo-20 Fixing and Tightening of Master Wedges

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7LJKWHQLQJRI:RUNLQJ:HGJHDWORFNLQJHQGLQ HORQJDWLRQ LV OHVV WKDQ KRZHYHU RWKHU SDUDPHWHU
case of one end stressing UHDFKHG XS WR IXUWKHU VWUHVVLQJ LV VWRSSHG VWUDQG
,Q FDVH RI RQH HQG VWUHVVLQJ ZRUNLQJ ZHGJHV DW ORFNLQJ is destressed and designer is informed. It may be due to
end are tightened in a method used for master wedge. GHVLJQ SUREOHPV EDG IXQFWLRQLQJ RI MDFN DQG SUHVVXUH
gauge. Once problem is resolved, stressing is started.
&RQQHFWLRQ RI 3UHVVXUH *DXJH DQG -DFN ZLWK
3RZHU3DFN 7.14 Entry of pressure and measured Elongation in
approved format and zero correction
/HDNSURRIFRQQHFWLRQRISRZHUSDFNK\GUDXOLFMDFNDQG
pressure gauge is insured. $SSURYHGIRUPDWLQFOXGHVQDPHRIVWUXFWXUHWREHVWUHVVHG
7.13 Application of force, measurement of elongation casting date & grade of concrete, cube strength, coil number
DQGORFNLQJ of strands, actual area and MOE of strands and calculated
HORQJDWLRQ DQG SUHVVXUH $OO UHDGLQJV RI SUHVVXUH DQG LWV
7KLV LV WKH ¿QDO DFWLYLty for which above-mentioned sub-
FRUUHVSRQGLQJHORQJDWLRQ H[FHSW¿UVWHORQJDWLRQUHDGLQJ LV
activitieV KDYH EHHQ SHUIRUPHG $ IRUFH RI NJFPð LV
HQWHUHGLQDQDSSURYHGIRUPDW$IWHUIRXUWKUHDGLQJVDYHUDJH
applied and elongation is measured with the help of ram
of three (2ndrd & 4th) readings is considered as elongation
RIMDFNHMHFWHGRXW3UHVVXUHLVDSSOLHGLQDXQLIRUPVSHHG
IRU¿UVWNJFPðSUHVVXUH7KLVLVNQRZQDV]HURFRUUHFWLRQ
ZLWKRXWDQ\MHUN6RPHWLPHVVODFNQHVVRIVWUDQGVLVUHPRYHG
Example of one end stressing, data entry for calculated
E\ SXOOLQJ LW DW ]HUR SUHVVXUH )RU EHWWHU DQG XQLIRUP
HORQJDWLRQRIPPDQGSUHVVXUHRINJFPð
HORQJDWLRQLWLVH[SHULHQFHGWRJLYHSUHVVXUHRINJFPð
DQGORDGLVUHOHDVHGWR]HUR$FWXDOVWUHVVLQJZLWKSUHVVXUHDW /RFNLQJRI:RUNLQJ:HGJH
WKHLQWHUYDORINJFPðLVJLYHQDQGUHDFKHGXSWRUHTXLUH $IWHUVXFFHVVIXOFRPSOHWLRQRIVWUHVVLQJZRUNLQJZHGJH
pressure and at the end of every stressing elongation is LVORFNHGZLWKRIDSSOLHGSUHVVXUH/RFNLQJSUHVVXUH
PHDVXUHGDFFXUDWHO\2QFHVWUHVVLQJLVFRPSOHWHGZRUNLQJ is given uniformly.
ZHGJHLVORFNHGZLWKRIVWUHVVHGSUHVVXUH
7.16 Release of Pressure
In case of both end stressing, simultaneous pressure with same
$IWHU ORFNLQJ RI ZHGJHV SUHVVXUH LV UHOHDVHG VORZO\ DQG
speed is given to maintain equal elongation for both ends.
uniformly. This activity is very critical as load is transferred
6LWHHQJLQHHUVDUHSHUPLWWHGWRPDLQWDLQWKH¿QDOSUHVVXUH through wedges, bearing plate and anchor cone. It is noticed, most
DQG HORQJDWLRQ EHWZHHQ DQG RI PRGL¿HG RIWKHV\VWHPVXSSOLHUXVHWRVWRSUHOHDVHRISUHVVXUHDWNJFPð
SUHVVXUH DQG HORQJDWLRQ ,I SUHVVXUH LV UHDFKHG DW DQGVOLSLVPHDVXUHGLVQRWFRUUHFW7RNQRZWKHDFWXDOVOLSWKHUH
DQGHORQJDWLRQDFKLHYHGLVOHVVWKDQIXUWKHUSUHVVXUH VKRXOGQRWEHDQ\SUHVVXUHLQMDFNEXWDW]HURSUHVVXUHMDFNZLOO
is given to achieve elongation up to calculated elongation be out of its position and measurement of slip is not possible.
VXEMHFW WR SUHVVXUH GRHV QRW H[FHHG RI PRGL¿HG %DVHGRQH[SHULHQFHNJFPðSUHVVXUHLQMDFNLVVX൶FLHQWWR
pressure. Same activity is applicable when elongation KROGWKHMDFNLQSRVLWLRQ7KRXJKDWNJFPðVOLSZLOOQRW
reached early also. In any case, if either pressure or occur however, it is very near to accuracy.
3UHVVXUH NJ Ram extension Reading /RFNLQJHQG5HDGLQJ

2
Reading (mm) Gross Elongation
cm ) (mm) (mm)
50 46 =& 100
100 66 20
150 86 20
200 107 21
250 126 19
148 22
168 20
5 98
$FWXDOH[WHQVLRQFRQVLGHULQJORFNLQJHQGVLWWLQJ
10 164 -9 Net elongation

TECHNICAL PAPER
0HDVXUHPHQWRI6OLSDW-DFNLQJ(QGDQG6LWWLQJ Note for Last Incremental Pressure: During stressing,

RI:HGJHDW/RFNLQJ(QG incremental pressure is applied and corresponding
$IWHUUHOHDVHRISUHVVXUHXSWRNJFPðVOLSLVPHDVXUHG elongation is noted down. If elongation is about to reach
7KLVVOLSLVWKHFRPELQHGH൵HFWRIZHGJHVLWWLQJDQGHODVWLF WKHOLPLW¿UVW,QWKHODVWLQFUHPHQWDOSUHVVXUHWKHUHLVD
VKRUWHQLQJ RI VWUDQG¶V JULS OHQJWK *HQHUDOO\ JULS OHQJWK chance of excessive elongation and it can go beyond the
is approx. 600 mm so @ 7 mm/M, it comes around 4 mm limit. To avoid this situation, it is required to know, how
ZKLFKLVFRQVLGHUHGLQPRGL¿HGHORQJDWLRQVKHHW,IVOLSLV much permissible elongation is balance. Scale is put on
coming in the tune of 10 mm (6 mm for sitting of wedge jack ram and technician is asked to increase the pressure
and 4 mm for elastic shortening of grip length extension), slowly. Once elongation limit is reached on scale, pressure
site engineer should not worry. LQFUHPHQWLVVWRSSHGDQG¿QDOSUHVVXUHLVQRWHG
This 6 mm slip value has entered so deeply in the mind of 8. GROUTING
technicians, they use to tell 6 mm only irrespective of actual
slip value of 9-10 if site engineer is dependent on them. (Ref- Clause 1 RI ,5& 0257+$SSHQGL[
1800/III) Whenever post tensioned prestressing is
5HPRYDORI-DFN
considered, automatically grouting comes in picture. The
%HIRUHUHOHDVHRIWRWDOSUHVVXUHVXSSRUWRIMDFNLVWLJKWHQHG purpose of grouting is to provide permanent protection to
WRDYRLGIDOOLQJGRZQRIMDFNDFFLGHQWO\-DFNLVWDNHQRXWRI the strands against corrosion and to develop bond between
VWUDQGVDQGORZHUHGGRZQDQGNHSWDWDSSURSULDWHORFDWLRQ prestressing cables and the surrounding structural concrete
7.19 Calculation of Pressure and net Elongation in % WRPDNHWKHFRQFUHWHDQGVWUDQGVDVPRQROLWKLF*URXWLQJ
is carried out as early as possible, but not later than two
Total pressure applied and net elongation achieved is to
ZHHNVDIWHUWKHVWUHVVLQJ:KHQHYHUWKLVVWLSXODWLRQFDQQRW
EHFRQYHUWHGLQWRZLWKUHVSHFWWRPRGL¿HGSUHVVXUHDQG
be complied due to any unavoidable reasons, adequate
elongation. In the above example, net elongation achieved is
temporary protection of the strands against corrosion
PPZKHUHDVWRWDOSUHVVXUHDFKLHYHGLVNJFPð
is ensured. Special precautions are required for joints in
L 3HUFHQWDJH HORQJDWLRQ [
SUHFDVW VHJPHQWDO FRQVWUXFWLRQ WR DYRLG DQ\ OHDNDJHV DW
LL 3HUFHQWDJH SUHVVXUH DSSOLHG [ joints of segments. Joints of precast segmental construction
are treated with epoxy resin. The epoxy resin seals the
MRLQW DQG SUHYHQWV JURXW OHDNLQJ WKURXJK DQG RXW RI WKH
7.20 Preparation of summary sheet for the use of segment joint. However, there is a possibility that epoxy
Dummy Cable
may be squeezed into adjacent ducts, when the segments
$IWHUVXFFHVVIXOFRPSOHWLRQRIVWUHVVLQJIRUDOOFDEOHVH[FHSW DUH SUHVVHG WRJHWKHU FDXVLQJ EORFNDJHV 7R SUHYHQW WKLV
GXPP\LWLVUHTXLUHGWRNQRZWKHVKRUWIDOOLQFXPXODWLYH dummy pipe with slightly lesser dia than the internal dia
stressing force. Once, summary of force is prepared, dummy of sheathing is inserted and it is given to and fro motion
FDEOH LV VWUHVVHG FRQVLGHULQJ WKH VKRUW IDOO LI DQ\$V SHU GXULQJWHPSRUDU\VWUHVVLQJ,QDGGLWLRQOHDNWLJKWQHVVFDQ
following example, summary sheet is prepared. be improved by the use of rubber rings around the ducts
Cable Design No of Actual Shortfall/ at the joints between segments which is placed in recess
No pressure Strands Pressure Access prepared at the time of casting of segments.
1 NJFPð 19 +5
8.1 Equipment and Materials required for Grouting.
2 NJFPð 19 0
NJFPð 19 -10 i Wheel Cutter
4 NJFPð 19 -15 LL *URXW&DSZLWK$LU9HQW
LLL 1LSSOHDQG/RFNLQJYDOYH
7RWDO VKRUWIDOO LV NJFPð 6WUHVVLQJ FDSDFLW\ RI RQH LY *URXW$JLWDWRU
VWUDQGRIPPGLDLV NJFPð7KHUHIRUH v Grout Sieve
DGGLWLRQDO VWUDQG UHTXLUHG WR PDNH WKH SUHVVXUH vi Grout Pump
20/19.21 = 1.04 Nos. Means one strand is required to vii Ice
be provided/added in dummy cable in consultation with YLLL /LPH
designer.

TECHNICAL PAPER
L[ 3ODVWLFL]HU 1RQVKULQN&RPSRXQG FDS,WLV¿[HGWLJKWO\ZLWKEROWWRPDNHLWZDWHUWLJKW:KLOH

x Thermometer ¿[LQJJURXWFDSFDUHLVWDNHQWRNHHSWKHDLUYHQWDWXSSHU
xi Cube Moulds SRUWLRQ RI JURXW FDS 1LSSOH ZLWK ORFNLQJ YDOYH LV ¿[HG
with threaded hole in anchor cone for the supply of grout.
8.2 Activities Involved for Grouting
8.2.4 Washing of cable duct
)ROORZLQJ DFtivities are carried out for successful In the process of manufacturing of strands, strands-
completion of Grouting: coil is dipped in cut oil to protect strands from rusting. It
8.2.1 Observation of slip at both end of girder LV QHFHVVDU\ WR ZDVK WKH FXW RLO VWLFNV RQ VWUDQGV VXUIDFH
IRU SURSHU ERQGLQJ RI VWUDQGV ZLWK JURXW $IWHU ¿[LQJ
$IWHUKRXUVRIVWUHVVLQJDQFKRUDJHV\VWHPLVREVHUYHG
RI JURXW FDS ZDVKLQJ RI FDEOH LV VWDUWHG ZLWK FOHDQ
DJDLQVWDQ\DEQRUPDOVOLSRUEUHDNDJHRIZHGJHSXQFKLQJ
lime water. Same grout pump is used to feed lime water.
of cone, EUDNLQJ RI VWUDQGV HWF ,I HYHU\WKLQJ LV RN LW LV
'XULQJZDVKLQJLWLVREVHUYHGFDUHIXOO\IRUOHDNDJHDOVR
allowed to cut the extended portion of strands.
IURPFDEOHGXFW,IDQ\OHDNDJHLVQRWLFHGSURSHUWUHDWPHQW
8.2.2 Cutting of extra length of strands ZLWK DSSURYHG PHWKRGRORJ\ LV GRQH WR VWRS OHDNDJH ,Q
Once nothing is noticed abnormal, extended strands are FDVH RI QR OHDNDJH IXUWKHU FOHDQLQJ LV FRQWLQXHG WLOO WKH
cut carefully with cutting wheel. The cutting line is about lime water coming out from other end is found to be
PPDZD\IURPEHDULQJSODWHVXFKWKDWDIWHUFXWWLQJ without dust, oil etc. Then duct is cleaned with fresh water.
external portion of strands shall not touch the grout Compressor is used to clean duct for span 50 m and more.
cap and strands shall fully covered with grout.(Refer (Refer Photo -23)
Photo -21)
8.2.5 Mixing of grout as per design with plasticizer
Grout is a homogenous mixture of cement and water.
$SSURYHGFKHPLFDODGPL[WXUHVLVDGGHGLQJURXWWRPRGLI\
WKH SURSHUWLHV DQG PDNH WKH JURXW QRQVKULQN *URXW LV
prepared as per approved mix designby mixing Cement,
Water and Plasticizer. W/C ratio of grout depends upon
weather condition but should not exceed 0.4. Required
quantity of water is poured in mixing drum followed by
DGPL[WXUHGRVH$IWHUPL[LQJRIDGPL[WXUHDQGZDWHUFHPHQW
is fed gently in the running condition of agitator to avoid any
Photo – 21 Cutting of Strands lumps formation. It is required to maintain homogeneous and
consistent mix throughout the grouting operation. To maintain
the temperature below 250C, chilled water is used instead of
normal water. Once mixing is completed, it is discharged to a
drum passing through sieve mesh.
&XEH¿OOLQJDQGLWVWHVWLQJ
$IWHUPL[LQJJURXWFXEHPRXOGVRIVL]H[[
DUH¿OOHGFXEHVWHVWHVDWGD\VDQGEDODQFHDWGD\V
Strength requirement of 7 days is 27 MPa and 28 days is
03D
Photo – 22 Washing of cable duct 8.2.7 Filling of duct with grout
8.2.3 Fixing of grout cap and nipple $IWHUPL[LQJJURXWSXPSVWDUWHGWRIHHGJURXWLQFDEOHGXFW
$IWHUFXWWLQJRIH[WUDOHQJWKRIVWUDQGVJURXWFDSZLWKDLU from one end at a continuous and steady rate of 6 to 8 m /
YHQWLV¿[HG*UHDVH is applied on inner surface of grout minute. Once feeding of grout VWDUWHG HDUOLHU ¿OOHG ZDWHU

TECHNICAL PAPER
LQGXFWZLOOFRPHRXW¿UVW6XEVHTXHQWO\ZDWHUPL[HGZLWK
grout will come then pure grout will come. Consistency of
JURXWLVFKHFNHGZLWKK\GURPHWHU'XULQJWKHHQWLUHJURXWLQJ
process temperature of grout is maintained below 25°C.
8.2.8 Same consistency of grout-in and grout-out is

assured
,IJURXWFRPLQJRXWYLVXDOO\IRXQGWREHSXUHLWLVFRQ¿UPHG
ZLWKK\GURPHWHUDQGYDOYHLVORFNHG
8.2.9 Air vent of remote end is opened Photo- 25, 25(a) Recess Finishing and Painting
(QWU\DQGH[LWSRLQWRIJURXWLVDWDERXWPPLQVLGHIURP
grout cap outer surface, therefore, grout cap and some portion 9 ISSUES AND ITS REMEDIAL MEASURES
of anchor cone is having air and water trapped. One air vent During stressing, following are the general problems Site
is provided at top of outer surface of grout cap. Once, air vent Engineers used to face.
is opened, grout in pressure pushed out water and air through
YHQW,IWKHUHDUHQRDLUEXEEOHVFRPLQJRXWYHQWLVORFNHG 9.1 Hiding Facts by the Site Engineers
Same process is adopted to remove air from pumping end. This is the major issue in bridge construction. Each and
8.2.10 End of grouting process every problem of civil engineering can be sorted out if
LW LV DGGUHVVHG LQ WLPH$WPRVSKHUH DW VLWH VKDOO EH VXFK
$IWHU UHPRYDO RI DLU IURP ERWK HQG SXPSLQJ FRQWLQXHG friendly, the Site Engineers should not afraid of telling fact
to achieve a minimum pressure of 0.5 MPa. If no loss of WRWKHLUUHSRUWLQJR൶FHULQFDVHRIDQ\PLVWDNH
SUHVVXUHIRURQHPLQXWHZLWKRXWSXPSLQJYDOYHLVORFNHG
,QIULQJLQJRI5HEDULQ&DEOH3UR¿OH
8.2.11 Removal of Grout cap
It is noticed, while detailing the reinforcement, infringing
Grout cap is removed gently after 24 hours, once the grout with cable is not considered in the drawing. Once it
KDUGHQHG &DUH LV WDNHQ WR DYRLG DQ\ EUHDNDJH RI JURXW happens, site engineer is requiring to consult designer to
portion covering projected strands. PRGLI\WKHUHEDUWRPDLQWDLQFDEOHSUR¿OHDVSHUGUDZLQJ
No rebar shall be cut at site engineer level.
9.3 Data Given in the Drawings for Elongation
It is seen in the drawings that the data given is not
clear with respect to slip. Some designers use to write
³([WHQVLRQ%HIRUH6OLS´DQRWKHUXVHWRZULWH³(ORQJDWLRQ
DW -DFNLQJ (QG XS WR DQFKRU SRLQW ´ DQRWKHU ZULWHV
³(VWLPDWHG(ORQJDWLRQ PP ZLWKRXW6OLS´,WLVQRWRXWRI
ZD\WRPHQWLRQPP VOLS KDVYLWDOH൵HFWLQVWUHVVLQJ
If it assumed wrongly by the site engineers, girder may be
XQGHU VWUHVVHG RU RYHU VWUHVVHG DQG GH¿QLWHO\ SXUSRVH Rf
Photo-24 Recess Filling
design is for feited.
8.2.12 Filling of Recess
This is the last activity of prestressing & grouting
SURFHVV 5HFHVV LV UHTXLUHG WR EH ¿OOHG ZLWK VDPH JUDGH
of concrete, that is of girders. Concreting in recess is
YHU\ GL൶FXOW WKHUHIRUH D VSHFLDO SLHFH RI VKXWWHULQJ
OLNH OHWWHU ER[ LV SUHSDUHG DV VKRZQ LQ WKH SKRWR EHORZ
(Refer Photo-24 & 25 $SSOLFDWLRQ RI FRDO WDU HSR[\
SDLQW RQ UHFHVV SRUWLRQ LV YHU\ H൵HFWLYH IURP GXUDELOLW\
point of view as it stops water ingress. (Refer Photo-25(a))

TECHNICAL PAPER
In this connection I request all designers to write the similar

notes on national basis as suggested below in their issued
GUDZLQJVIRUSHUIHFWLRQLQVWUHVVLQJZRUN
³([WHQVLRQPHQWLRQHGLQWKHWDEOHLVGXHWRDSSOLFDWLRQRI
force on strands only, please add 6 mm or as advised by the
system supplier for slip and grip length extension as per
MDFNVSHFL¿FDWLRQVEHIRUHVWUHVVLQJ´
6L]HRI5HFHVVLV6PDOOHUWKDQWKH-DFN0RXWK
6RPHWLPHVDWWKHWLPHRISODFHPHQWRIMDFNLWLVQRWLFHG
WKDWVL]HRIWKHUHFHVVLVVPDOOHUWKDQWKHPRXWKRIMDFN$W Photo-26 Equidistant wedge parts
WKHWLPHRIVWUHVVLQJVLWHWHDPKDVWRFKLSR൵VRPHSRUWLRQ
RIFRQFUHWHWRDFFRPPRGDWHMDFN'HVLJQHUVKDOOFRQVLGHU
WKH VL]H RI MDFN WR EH XVHG 6LWH (QJLQHHU PXVW FDVW WKH
JLUGHUVRQFHVL]HRIMDFNLVHQVXUHG
9.5 Variation in Elongation and Force During
Stressing
There are several reasons for this occurrence. It may be due
WRODFNRIIUHHPRYHPHQWRIVWUDQGVEHFDXVHRIFKRFNLQJRU
GHVKDSH RI VKHDWKLQJ QRQSURSHU IXQFWLRQLQJ RI MDFN
SRZHU SDFN DQG SUHVVXUH JDXJH ,W PD\ DOVR KDSSHQ LI
UHDGLQJRIHORQJDWLRQLVQRWWDNHQFRUUHFWO\7RDYRLGVXFK Photo-27 Punching of anchor cone
SUREOHPVHORQJDWLRQDQGSUHVVXUHVLVUHFRQ¿UPHGE\WKH
GHVLJQHUV3UHVVXUHJDXJHLVFDOLEUDWHGSURSHUO\DQGMDFN 9.8 Punching of anchor cone
H൶FLHQF\LVFKHFNHG It is a very common problem, occurs mainly due to
6OLSSDJHDQG%UHDNLQJRI:HGJH KRQH\FRPE LQ FRQFUHWH 'XH WR FRQJHVWLRQ DW HQG EORFN
portion, sometimes compaction of concrete is not done
It may happen if inner portion of wedge is not threaded SURSHUO\)LUVWGLVFKDUJHRIFRQFUHWH ±EXFNHWVFRQWDLQ
properly and/or not hardened. Improper hole in bearing mostly aggregates) shall be thrown out. Concrete pouring
SODWH PD\ EH RQH RI WKH UHDVRQV ,I ORFNLQJ LV QRW GRQH shall start at one meter away from end of the girder. In
SURSHUO\ GXH DEVHQFH RI SURSHU ORFNLQJ SODWH LW PD\ addition to vibrator, tamping helps to reduce chances of
happen. During system approval, hardness and threading KRQH\ FRPE )RU IRRO SURRI FRQVWUXFWLRQ HQG EORFN RI
V\VWHPLVWREHFRQ¿UPHG size approximately 650 mm is cast separately and erected
%UHDNLQJRIZLUH DW HQGV DQG EDODQFH SRUWLRQ RI JLUGHU LV FDVW WR PDNH
itmonolithic. (Refer Photo-28)
It may occur due to over stressing, pitting corrosion
RQ VWUDQGV EORFNDJH RI VWUDQGV ZHGJHELWH RU ZURQJ
IXQFWLRQLQJ RI MDFN VHW 2YHU VWUHVVLQJ VKDOO DOZD\V EH
avoided. Before threading, pitting (if any) in strands shall
EHFKHFNHG7RDYRLGWKUHDGELWHDOOWKUHHSDUWVRIZHGJH
LV NHSW DW HTXLGLVWDQW VR WKDW QR FURVVUDGLDO PRYHPHQW
occur of any part of wedge. While wedges are going inside
the bearing plate its combined diameter get reduces and
subsequently gap between three parts of the wedge also
UHGXFHV,IJDSEHWZHHQDQ\WZRSDUWVLVQRWVX൶FLHQWRULWV
touching to each other, there will be a radial movement is the
main cause of bite anGEUHDNLQJRIVWUDQGV Refer Photo-26
PDNLQJZHGJHSDUWVHTXLGLVWDQWZLWKVFUHZGULYHU 3KRWR$UUDQJHPHQWIRUSUHFDVWHQGEORFN

TECHNICAL PAPER
9.9 Bursting of Concrete behind and Around the

Anchor Cone
Bursting is the severe condition of cone punching. It may
EHGXHWRODFNRIEXUVWLQJUHLQIRUFHPHQWRUZHDNFRQFUHWH
around and behind anchor cone due to honeycomb or what
so ever may be the reason.In case of segmental box girder, ill
end segment can be cut at 150 mm away from joint with rope
cutter and replaced with new end segment. Gap of 150 mm
is wet matching. (Refer Photo-29 and 30)
Photo-31 Anchor Cone Bursting
Photo – 29 Bursting of concrete Photo -32 Anchor Cone Repaired

9.10 Excessive hogging of girder
Sometimes excessive hogging is noticed in I-girder after
VWUHVVLQJ ,W PD\ EH GXH WR SUR¿OH SUREOHP RU ZURQJ
sequence of stressing of cables. Designer shall provide
the limit of hogging in the drawing. During stressing
KRJJLQJ VKDOO EH FKHFNHG DIWHU VWUHVVLQJ RI HYHU\ FDEOH
$Q\H[FHVVLYHKRJJLQJVKDOOEHLQIRUPHGWRWKHGHVLJQHUV
WR YHULI\ WKH FDEOH SUR¿OH DQG VHTXHQFH *LUGHU PD\ EH
DFFHSWHG LI VDWLV¿HV WKH FODXVH RI ,6
'XH WR KRJJLQJ )5/ KDV WR EH UDLVHG IRU ZKLFK URDG
on either side of bridge has to be raised and match with
Photo-30 End segment replaced smooth gradient will increase the cost of the project.
,WFDQDOVREHUHSDLUHGZLWKH[SHUWDGYLFH$OOORRVHFRQFUHWH 9.11 Bending of Girders in Plan

LVUHPRYHGDQGVRXQGQHVVRIEDODQFHFRQFUHWHLVFRQ¿UPHG
,WKDSSHQVLQ,±JLUGHUVGXHWRVHYHUDOUHDVRQV*HQHUDOO\LW
with non-destructive test. If concrete is found to be sound, PD\EHGXHWRHFFHQWULFFDEOHSUR¿OH)RUVSDQPRUDERYH
damaged portion of sheathing is replaced and new anchor 2 cables are provided at bottom layer and both are eccentric.
FRQH LV ¿[HG LQ WUXH SRVLWLRQ ,Q VRPH FDVHV DGGLWLRQDO Due to space constraint in I-girder, both eccentric cables
reinforcement is provided (Refer Photo-31&32).Here, cannot be stressed simultaneously. During stressing, if any
epoxy concrete is better option for early strength. While cable is stressed fully, it may result in temporary eccentric
repairing, we have to judge, can it sustain the load as loading, will bend the girder. In case of two eccentric cable,
RULJLQDO VWUXFWXUH DQG GXUDELOLW\ ZLOO QRW H൵HFW" :LWKRXW ¿UVWFDEOHVKDOOEHVWUHVVHGWRRIGHVLJQSUHVVXUHVHFRQG
WKLVFRQVLGHUDWLRQVWUXFWXUHVPD\QRWEHUHMHFWHGDVLW¶VD WRWKHQ¿UVWWRDQGVHFRQGDQG¿UVWWR'XH
QDWLRQDOORVVDQGQRWHQYLURQPHQWIULHQGO\WRR$VVWUHVVLQJ to bending of girder in plan, there is a torsional moment for
itself is a test, if stressing and grouting is done successfully which, diaphragm/cross girder needs to be strengthened to
after repairing, there will not be any problem in its stability counteract the tortional moment. Girder may be accepted if
and durability. VDWLV¿HVWKHFODXVHRI,5&

TECHNICAL PAPER
,QDGHTXDWH+\GUDXOLF2LOLQ3RZHU3DFN LLL -DFNVQHYHUEHKDQGOHGE\FRQQHFWHGKRVHV

Sometimes site people face this type of problem. On the iv. The permissible pressure never be exceeded.
midway of stressing neither wHORFNWKHMDFNQRUFRQWLQXH v. During stressing, no one be allowed to stand behind
the stressing. Before start of stressing, hydraulic oil shall RUEHORZWKHMDFN2QHKHDY\GXW\SO\ERDUGVKDOO
EHFKHFNHGIRULWVDGHTXDWHTXDQWLW\ EH HUHFWHG YHUWLFDOO\ EHKLQG MDFN WR VWRS EURNHQ
wedge or strand.
0DVWHU:HGJH6WXFNZLWK-DFN YL &DUH VKDOO EH WDNHQ GXULQJ KDQGOLQJ RI VWUDQG¶V
'XULQJUHPRYDORI-DFNVRPHWLPHVPDVWHUZHGJHVWXFNZLWK FDEOHDVLWPD\ZKLSEDFNZLWKIRUFH
MDFN,WPD\EHGXHQRQDSSOLFDWLRQRULQDGHTXDWHDSSOLFDWLRQ vii. Hand gloves and protective goggles shall be used
RIYD[RQZHGJHRXWHUVXUIDFH&DUHVKDOOEHWDNHQWRFOHDQ while cutting the strands.
and apply vax properly on outer portion of wedge. 10.2 Safety During Grouting
%UHDNLQJRI&RUQHUHGJHRI*LUGHUV L $OO SHUVRQDOV ZRUNLQJ QHDU JURXW PXVW XVH
$IWHUVWUHVVLQJLWLVQRWLFHGWKDWHGJHRIWKHJLUGHUDWHQGV protective goggles.
FUDFNVRUEUHDNVLQ,JLUGHUV$IWHUKRJJLQJLQJLUGHUGXH ii. Pump shall not be started when its valve is closed
to stressing, weight of girder transferred through both end as it can damage pressure gauge.
edge only. Due to concentrated load at end-edge of the iii. Grouting process for any individual cable shall be
JLUGHUV VWUHVV LQ FRQFUHWH H[FHHGV DQG FUDFN GHYHORSHG FRQWLQXRXVXSWR¿QLVK,IJURXWLQJLVVWRSSHGGXH
600 mm bottom shutter at both ends shall be removable so WRDQ\UHDVRQHQVXUHWRÀXVKRXWWKHJURXWIURP
WKDWLWFDQEHUHPRYHGEHIRUHVWUHVVLQJVWDUWV$OWHUQDWLYHO\ cable before it sets.
PPWKLFNUXEEHUSDGIRUPPOHQJWKDWERWKHQGV
shall be provided in the level of bottom shutter. This way, 11 CONCLUSION
FUDFNVDWHQGRIWKHJLUGHUVFDQEHDYRLGHG Prestressing and grouting are the essence of PSC bridges.
9.15 Unequal extension of strands in both end stressing In addition to concrete strength, proper prestressing and
grouting plays a vital role for the safety and durability of
Sometimes it is noticed that, extension in strands is not bridges. Both prime activities are supplementary to each
equal for both sides though equal force is applied. It may other in post tensioned prestressing system. Being very
happen if stressing not starts at the same time and same speed VHQVLWLYHDFWLYLWLHVHYHU\FDUHVKDOOEHWDNHQIRUSURSHUDQG
IRUERWKHQGVDVERWKMDFNVDUHRSHUDWHGE\GL൵HUHQWSHUVRQV perfect prestressing and grouting. Several sub activities
PDQXDOO\'XHWRFKRFNLQJRIFDEOHVLWFDQKDSSHQ7RDYRLG are involved for the successful completion of prestressing
such situation, pressure on both sides shall be given up to and grouting. Each and every sub - activity has its own
100 Kg/cm2 and released to zero then normal stressing shall LPSRUWDQFHOLNHFKDLQOLQNKHQFHQRQHRIWKHVXEDFWLYLWLHV
EH FRQWLQXHG %RWK VLGH MDFN V\VWHP FDQ EH V\QFKURQL]HG VKDOO EH LJQRUHG RU WDNHQ OLJKWO\ 6WUHVVLQJ DQG JURXWLQJ
to avoid such variation in elongation. Stressing shall be activities shall be done in presence of experienced engineer
started with the help of whistle. Due to any reason, if one ZKR FDQ WDNH GHFLVLRQ UHJDUGLQJ ORFNLQJ RI ZHGJHV RU
VLGH HORQJDWLRQ LV PRUH E\ ³/´ PP LQ QH[W LQFUHPHQWDO destressing of strands if required.
stressing, cable having less elongation shall be pulled the
GL൵HUHQFH³/´PP¿UVWWKHQWKH\VKRXOGSXOOSDUDOOHOO\ STANDARDS AND REFERENCES
1. IRC:112-2020. Code of Practice for Concrete Road Bridges. (1st Revision)
10 SAFETY PRECAUTIONS 2. IRC: SP: 65-2005. Guidlines for Design and Constructions of Segmental Bridges.
6DIHW\ RI ZRUNHUV DQG SXEOLF SDVVLQJ WKURXJK QHDUE\ 0257+6SHFL¿FDWLRQVIRU5RDGDQG%ULGJHZRUNV th Revision) Section 1800.
,63UHVWUHVVHG&RQFUHWH&RGHRI3UDFWLFH
stressing and grouting site are our prime responsibility and
,66SHFL¿FDWLRQIRU+LJK7HQVLOH6WHHO%DUVXVHGLQ3UHVWUHVVHG
DOZD\VDGHTXDWHFDUHVKDOOEHWDNHQ Concrete
10.1 Safety during stressing ,6 6SHFL¿FDWLRQ IRU 8QFRDWHG 6WUHVV 5HOLHYHG 6WUDQG IRU
Prestressed Concrete
Very huge amount of forces are applied to the tendons ,6*URXW$GPL[WXUHV
during stressing and the equipment is under high hydraulic ,6±6SHFL¿FDWLRQIRU8QFRDWHG6WUHVV5HOLHYHG/RZ5HOD[DWLRQ
SUHVVXUH)ROORZLQJSUHFDXWLRQVFDQKHOSWRDYRLGDFFLGHQWV Deven Ply Strand for Prestressed Concrete.
),% %XOOHWLQ ± 3RO\PHU'XFW 6\VWHP IRU ,QWHUQDO %RQGHG 3RVW
i. Only experienced and trained personal shall Tensioning.
SHUIRUPWKHVWUHVVLQJZRUN %6(1*URXWLQJZRUNV
ii. The equipment especially high-pressure hose pipe ),35HFRPPHQGDWLRQVIRUWKH$FFHSWDQFHRI3RVW7HQVLRQLQJ6\VWHPV
DQGDGDSWHUVVKDOOEHLQZRUNLQJFRQGLWLRQZLWKRXW 7HFKQLFDO6SHFL¿FDWLRQVRI6HYHUDO3URMHFWVIRU3UHVWUHVVLQJ:RUNV
³3XQFKLQJRI$QFKRU&RQH´E\11%DQGKXLQ-(6$5DQFKL6RXYHQLU
any sign of damage.

TECHNICAL PAPER
PERFORMANCE OF THIN WHITE TOPPING (TWT) OVERLAY FOR

NH-848 NASHIK PETH SECTION IN MAHARASHTRA STATE
9LNDV7KDNDU1 $QVKXPDOL6ULYDVWDYD2 3UDVKDQW$XWL
ABSTRACT
Thin White Topping (TWT) overlay is Cement Concrete layer laid on top of existing bituminous pavement surface which is
LQVWUXFWXUDOO\VRXQGFRQGLWLRQ,WLVDFRPSRVLWHSDYHPHQWZKLFKWDNHVDGYDQWDJHRIH[LVWLQJÀH[LEOHSDYHPHQWFUXVWDVEDVH
for providing a maintenance free and durable concrete overlay. TWT is used to strengthen the existing bituminous pavement
to increase the life, durability and reduce maintenance. The existing bituminous surface acts as a base layer over which the
WKLQFRQFUHWHOD\HULVODLGE\VHHNLQJSURSHUERQGEHWZHHQELWXPLQRXVVXUIDFHDQGRYHUOD\VODE7:7RYHUOD\VKDYHEHHQ
FRQVWUXFWHGLQQXPHURXVXUEDQURDGVLWHVKDYLQJORZWUD൶FYROXPHLQFLWLHVOLNH7KDQH3XQH$XUDQJDEDG0XPEDL1DJSXU
-DLSXUDQG%DQJDORUHLQWKHODVWIHZ\HDUV7:7RYHUOD\WHFKQLTXHIRUKLJKYROXPHURDGWUD൶FURDGDVHODERUDWHGLQWKLV
SDSHUZDVXVHGIRUWKH¿UVWWLPHE\3XEOLF 1DWLRQDO+LJKZD\ 0DKDUDVKWUDIRUWKHSURMHFWRIUHKDELOLWDWLRQRIWZRODQHZLWK
SDYHGVKRXOGHUVIRU1DWLRQDO+LJKZD\1RVWUHWFKHVEHWZHHQ1DVKLNDQG3HWK *XMDUDW%RUGHU LQ0DKDUDVKWUDVWDWH
7KHSURMHFWZDVIXQGHGE\WKH0LQLVWU\RI5RDG7UDQVSRUWDQGKLJKZD\V 0R57+ 7RWDONPOHQJWKRI7:7RYHUOD\ZDV
FRPSOHWHGLQ0DUFKIRUWKHSURMHFWKLJKZD\EHWZHHQWKHVHFWLRQVLQNPWRNPNPWR NP
WR7KH7:7RYHUOD\SHUIRUPDQFHXQGHUKHDY\FRPPHUFLDOWUD൶FLVPRQLWRUHGIRUWKHSDVW\HDUVLVIRXQG
WREHVDWLVIDFWRU\DQGHQFRXUDJLQJ7KLVSDSHUPDLQO\FRYHUVWKHLPSOHPHQWDWLRQRI7:7RYHUOD\SURMHFWIRUKLJKYROXPH
WUD൶FRQ1DWLRQDO+LJKZD\DQGLWVSHUIRUPDQFHREVHUYHGRYHUWKHSDVW\HDUVDORQJZLWKOHDUQLQJVIURPWKLVSURMHFW:LWK
WKHH[SHULHQFHJDLQHGLQWKHFRQVWUXFWLRQRIWKH7:7RYHUOD\IRUKLJKYROXPHWUD൶FDQGWKHHQFRXUDJLQJSHUIRUPDQFHLWLV
FRQFOXGHGWKDW7:7FDQEHXVHGDVDFRVWH൵HFWLYHPDLQWHQDQFHDQGUHKDELOLWDWLRQDOWHUQDWLYHIRUELWXPLQRXVSDYHPHQWVHYHQ
XQGHUKLJKWUD൶FYROXPHVXFKDV1+6+
1. INTRODUCTION WR NP WR LQ WKH VWDWH RI
0DKDUDVKWUD´ 7KH SURMHFW ZDV H[HFXWHG RQ (QJLQHHULQJ
,5&63 GH¿QHV 7KLQ :KLWH 7RSSLQJ 7:7 DV procurement contract basis by P.W. (NH) Maharashtra
FRQFUHWHRYHUOD\ZLWKWKLFNQHVVEHWZHHQWRPP with funding through Ministry of Road Transport and
The Thin white topping treatment for the current project site Highways (MoRTH).
of NH 848 is carried out on existing bituminous pavement
ZLWKFRQFUHWHRYHUOD\WKLFNQHVVRIPPDIWHUPLOOLQJRI The existing carriageway of the Project Highway is two
existing bituminous surface for creation of bond. Proper /DQHZLWKSDYHGVKRXOGHUIURPNPWRNP
Pre overlay treatment is carried out for the isolated failed NP WR NP WR 7KH WZR
SDWFKHV EHIRUH XQGHUWDNLQJ WKH FRQFUHWH RYHUOD\ ZRUN ODQHG SDYHG VKRXOGHU FRQ¿JXUDWLRQ LV PDLQWDLQHG LQ WKH
7KHSURMHFWZDVWLWOHGDV³&RQFUHWHRYHUOD\IRU1DVKLNWR TWT concrete overlay project and concrete carriageway
6WDWH %RUGHU RI 7KDQH1DVKLN3HWK.DSDUGD3DUGL 5RDG of 10 m width (7 m + 1.5 m wide paved shoulders on each
1+&RPPHQFLQJIURPNPWRNPNP side) are constructed. The existing carriage way in these
0DQDJLQJ'LUHFWRU3DYHWHFK&RQVXOWDQWV0DKDUDVKWUD(PDLOWKDNDUYLNDV#JPDLOFRP
&KLHI*HQHUDO0DQDJHU1+$,0DKDUDVKWUD(PDLODQVKXPDOLVULY#JPDLOFRP
&KLHI(QJLQHHU3:'1DVKLN0DKDUDVKWUD(PDLOSVDXWL#JPDLOFRP

TECHNICAL PAPER
VHFWLRQV ZDV ÀH[LEOH SDYHPHQW ZLWK IDLU FUXVW WKLFNQHVV to a new rigid pavement. TWT is also an eco-friendly
WR PP ELWXPLQRXV OD\HU DQG WR PP WHFKQLTXHZKLFKPDNHVXVHRIWKHH[LVWLQJDYDLODEOH
JUDQXODU EDVH $IWHU FRPSOHWLRQ RI WKH GHIHFW OLDELOLW\ material and eliminates the requirement of additional costly
SHULRG '/3 IRUWKHVDLGVWUHWFKHVZLWKÀH[LEOHSDYHPHQW material for new crust layers thus drastically reducing need
RYHUOD\ LW ZDV GHFLGHG WR FRQFUHWL]H WKH NP OHQJWK for quarrying and crushing operations.
LQ YDULRXV VWUHWFKHV RI WKH SURMHFW KLJKZD\ $V WKH
H[LVWLQJ ÀH[LEOH SDYHPHQW ZDV LQ IDLU FRQGLWLRQ LW ZDV 1.2 Types of White Topping
decided to use the technology of Thin white topping White Topping (Concrete Overlay) is categorized into
7:7 IRU FRQYHUVLRQ RI ÀH[LEOH SDYHPHQW WR FRQFUHWH WKUHHW\SHVEDVHGRQWKLFNQHVVRIFRQFUHWHOD\HU
SDYHPHQW ZLWK D GHVLJQ OLIH RI \HDUV7KLV ZDV WDNHQ
up as a pilot project by MoRTH for implementation of this L 7KLFNQHVVDERYHPPLVWHUPHGDV&RQYHQWLRQDO
FRVWH൵HFWLYHWHFKQRORJ\IRUKLJKYROXPHWUD൶FURDGV White Topping
LL 7KLFNQHVVRYHUPPDQGOHVVWKDQPPLV
$FFRUGLQJO\WKHGHVLJQZDVSUHSDUHGIRUWKHVDLGSURMHFW
called Thin White Topping (TWT)
E\XVLQJJXLGHOLQHVRI,5&63'HVLJQWKLFNQHVV
of 200 mm with M40 grade concrete was implemented for LLL 7KLFNQHVVEHWZHHQPPWROHVVWKDQPPDUH
WKHZKLWHWRSSLQJZRUNZLWKVPDOOVL]HSDQHOV7KHSUR¿OH WHUPHG8OWUD7KLQ:KLWH7RSSLQJ 87:7
FRUUHFWLRQZDVXQGHUWDNHQZLWKELWXPLQRXVPDFDGDPOD\HU :KLWH7RSSLQJ%HQH¿WV
IRUFURVVSUR¿OHFRUUHFWLRQDQGUHPRYDORIORFDOL]HGVDJVLQ
7KHREYLRXVEHQH¿WVRIZKLWHWRSSLQJLQFOXGH
WKHH[LVWLQJELWXPLQRXVSDYHPHQWEHIRUHWKHRYHUOD\ZRUN
7KHSUHRYHUOD\WUHDWPHQWVXFKDVUHFWL¿FDWLRQRIWKHIDLOHG i. Superior riding experience with designed Service
VWUHWFKHVDQGSUR¿OHFRUUHFWLRQZHUHXQGHUWDNHQEHIRUHWKH life of above 25 years
white topping overlay treatment. The design for the TWT LL &RVWH൵HFWLYHLQPDLQWHQDQFHFRVWDQG2SHUDWLQJ
was reviewed and approved by CRRI New Delhi in 2020. cost.
1.1 Reasons for White Topping iii. Resistance to weather, oil spills etc.
LY %HWWHUUHÀHFWLYLW\VSHFLDOO\GXULQJQLJKWV
The white topping technology overcome some the problems
Y 8VH RI LQGLJHQRXV PDWHULDOV OLNH FHPHQW
in bituminous/asphalt roads which include
aggregates as against imported bitumen
L )UHTXHQW IDLOXUHV RI URDGV UHVXOWLQJ LQ SRWKROHV YL 8VHRIHFRIULHQGO\SURGXFWVOLNH)O\DVK**%6
and high recurring maintenance cost 6LOLFDIXPH&RQFUHWHDIWHULWVVHUYLFHOLIHLV
LL )RUPDWLRQ RI SRWKROHV DQG XQVDIH GULYLQJ recyclable.
conditions in monsoon
1.4 Construction Stages–White Topping Road
iii. Need for resurfacing very frequently
LY $PHQDEOHWRGDPDJHGXHWRGUDLQDJHLVVXHV The construction steps for white topping project are
broadly summarized below.
These disadvantages are mitigated in White Topping by
providing a durable and maintenance free concrete riding i. Milling of existing bituminous surface
VXUIDFH XVLQJ 7:7 WHFKQRORJ\ 8VLQJ WKH EHQH¿W RI LL &OHDQLQJRIWKHH[LWLQJVXUIDFH SUR¿OHFRUUHFWLRQ
composite action and lower warping stresses due to small iii. Conduit laying (if required)
SDQHOVL]HDVLJQL¿FDQWUHGXFWLRQLQWKHFRQFUHWHOD\HULV iv. Concrete laying by Paving machines
possible in TWT as compared to conventional concrete
Y 6XUIDFH¿QLVKE\%XOOÀRDW7H[WXULQJ
pavement. The TWT layer is also useful in strengthening
YL &XULQJ&RPSRXQGVSUD\LQJ*URRYHFXWWLQJ/DQH
RI WKH H[LVWLQJ ÀH[LEOH SDYHPHQW FRQVLGHULQJ WKH IXWXUH
0DUNLQJ
WUD൶F JURZWK 7KH DGYDQWDJHV RI D ULJLG ULGLQJ VXUIDFH
ZLWKOLIHDERYH\HDUVLVR൵HUHGE\PDNLQJFRPSHWHXVH 2. WHITE TOPPING PROJECTS
of the existing available bituminous road crust. In addition
WR WKHVH DGYDQWDJHV 7:7 LV FRVW H൵HFWLYH WHFKQRORJ\ White Topping in its various forms has been used in the
ZLWKVDYLQJVRIDSSUR[LPDWHO\WRDVFRPSDUHG 86$DQG(XURSHRQ$LUSRUWV,QWHUVWDWHURDGV3ULPDU\

TECHNICAL PAPER
6HFRQGDU\ +LJKZD\V /RFDO 5RDGV 6WUHHWV DQG 3DUNLQJ 3DYHPHQW 'LVWUHVV ,QGH[ 3', .(16/$% ZDV
lots to improve the performance, durability and riding used to determine pavement response for fatigue
quality of deteriorated bituminous pavement surfaces. analysis.
Conventional White topping, and Thin White topping
7:7 ZLWK\HDUVRIGHVLJQOLIHR൵HULPPHQVHSRWHQWLDO 3. CASE STUDY ON TWT FOR NH-848
as a rehabilitation strategy for Indian roads and Highways. PROJECT
6HYHUDO VXFFHVVIXO ORZPHGLXP YROXPH WUD൶F SURMHFWV The white topping treatment for urban roads with low/
KDYHEHHQH[HFXWHGDW7KDQH$XUDQJDEDG3XQH0XPEDL PHGLXP YROXPH WUD൶F LV VXFFHVVIXOO\ LPSOHPHQWHG RQ
Nagpur, Jaipur and Bangalore in the last decade or more. YDULRXVURDGVLQ,QGLD7KHZKLWHWRSSLQJZRUNRQ1DWLRQDO
7KHUHKDELOLWDWLRQDQGVWUHQJWKHQLQJRIÀH[LEOHSDYHPHQW +LJKZD\KDYLQJKLJKYROXPHFRPPHUFLDOWUD൶FKDVEHHQ
using TWT has shown satisfactory performance over the XQGHUWDNHQDQGVXFFHVVIXOO\FRPSOHWHGIRUWKH¿UVWWLPHRQ
past decade in these cities. However, all TWT projects in 1+1DVKLNWR3HWK6HFWLRQLQWKHVWDWHRI0DKDUDVKWUD
,QGLDKDYHEHHQXQGHUWDNHQIRUORFDOURDGVLQWHUQDOURDGV The project highway consists of existing two-lane
KDYLQJORZWRPHGLXPYROXPHWUD൶F SDYHG VKRXOGHU ÀH[LEOH SDYHPHQW P ZLGH 7KH
2.1 Literature Survey width of the white topping overlay (with paved shoulders)
is maintained as 10.00 m. The TWT overlay is constructed
White topping is a type of concrete pavement overlay E\XVLQJ0JUDGHFRQFUHWHZLWK¿EHUVDQGWKHWKLFNQHVV
that is used to resurface old or deteriorated pavements. design is done as per guidelines of the IRC:SP:76-2015.
Some of the important and literature on white topping is 7KHWRWDOOHQJWKRIWKHSURMHFWLVNPZKLFKFRQVLVWV
summarized in this section. RI WKUHH VHFWLRQV EHWZHHQ NP WR NP
WR NPWR
L 7KLQ :KLWH 7RSSLQJ 6WDWHRIWKH$UW 5HYLHZ E\
%99HQNDWDUDPDHWDOVWDWHGLQWKLVSDSHUDVWKHZKLWH 'DWD&ROOHFWLRQIRU7KLQ:KLWH7RSSLQJ:RUN
topping technique with construction methodology
and the construction process are explained in this )RU WKH GHVLJQLQJ RI WKH 7:7 RYHUOD\ WKH GHWDLOHG ¿HOG
paper along with pre overlay treatment. data collection and extensive investigation study are
required. The investigation and data collection activities
LL $FULWLFDOUHYLHZRIWKH3&$DQG,5&PHWKRGVRI
included the detailed pavement condition survey, existing
WKLQ ZKLWH WRSSLQJ SDYHPHQW GHVLJQ E\ 9HQNDWD
FUXVWDQGVRLOLQYHVWLJDWLRQVWUXFWXUDOHYDOXDWLRQRIÀH[LEOH
Jogarao Bulusu et al., stated that TWT is the most
SDYHPHQWGUDLQDJHVWXG\DQGWUD൶FGDWDFROOHFWLRQIRUWKH
HFRQRPLFDOVROXWLRQIRUEODFNWRSURDGVWUHQJWKHQLQJ
design purpose.
7KH SDSHU VWXGLHG WKH GL൵HUHQFHV EHWZHHQ ,5&
DQG3&$GHVLJQPHWKRGVIRU7:7E\FRQVLGHULQJ 3.1.1 Pavement Condition Survey
various parameters. In this study, both methods
considered 8-ton single axle load and 16-ton 3DYHPHQW &RQGLWLRQ VXUYH\ ZDV XQGHUWDNHQ WR DVVHVV
tandem axle load for estimating the stresses in WKH H[LVWLQJ ÀH[LEOH SDYHPHQW DQG LGHQWL¿FDWLRQ RI
cement concrete layer. The stresses estimated with distresses in the existing pavement crust. Overall, the
,5&HTXDWLRQVDUHWRKLJKHUFRPSDUHGWR H[LVWLQJ ÀH[LEOH SDYHPHQW IRU WKH VDLG SURMHFW VWUHWFKHV
3&$HTXDWLRQVIRUWRQVLQJOHD[OHORDGDQGWR ZDVREVHUYHGWREHVWUXFWXUDOO\VRXQGZLWKRXWVLJQL¿FDQW
KLJKHUIRUWRQWDQGHPD[OHORDG GLVWUHVVHVVXFKDVIDWLJXHFUDFNLQJUXWWLQJHWF+RZHYHU
iii. Performance evaluation of thin white topping some localized failures were observed such as settlement,
pavements under accelerated loading conditions FUDFNVHWFVSHFL¿FDOO\DWWKHORFDWLRQVZLWKSRRUGUDLQDJH
E\19DLVKDNKHWDOVWDWHGWKDWWKHSHUIRUPDQFH DQG ZKHUH WKH KHLJKW HPEDQNPHQW ZDV LQDGHTXDWH
of in-service white topping pavements as a resulting in inundation conditions. The distresses such as
rehabilitation technology, by means of pavement UDYHOLQJ SRWKROHV LVRODWHG VHWWOHPHQWDQG FUDFNLQJZHUH
GLVWUHVV VXUYH\ DQG IDOOLQJ ZHLJKW GHÀHFWRPHWHU also observed at few locations. The detailed distress survey
):' WHVW LV UHSUHVHQWHG 7KH SHUIRUPDQFH RI was carried out for the existing pavement to assess the
white topping pavements was characterized by condition of existing pavement and to device a treatment
both the Pavement Condition Index (PCI) and the schedule. The photograph showing distresses on existing
pavement are shown in Photo 1 and 2.

TECHNICAL PAPER
Photo 1 Depression and Pothole with Poor Drainage Photo 2 Heaving and Settlement Observations at
Arrangement Isolated Locations
Table 1 Details of Crust for Existing Road
7UD൶FGDWD The details of the axle load survey and percentage distribution
The seven (07) day KRXU &ODVVL¿HG 7UD൶F 9ROXPH of loads in various categories (Rear single axle, Rear
&RXQWZDVFRQGXFWHGDW&KDQGWKHWUD൶FYROXPH tandem axle) is shown in Table 3.This data was used
data is summarized given in Table 1. The axle load survey for the design of TWT overlay as per the guidelines of
was also conducted near Karnjale Village. The axle load IRC:SP: 76-2015.
VXUYH\IRUGHWHUPLQDWLRQRI$[OHORDGFKDUDFWHULVWLFVDQG Table 3 Percentage Distribution of Axles
loading pattern are required as inputs for the design of the Rear Single Axle Rear Tandem Axle
FRQFUHWHRYHUOD\)ROORZLQJTable 1 gives the details of the Load Group % of Axle Load Group % of Axle
crust for existing road and Table 2 provides the details of (KN) Loads (KN) Loads
$YHUDJH'DLO\7UD൶F $'7 for the project highway.
15-17 0.0 0.0
7DEOH$YHUDJHGDLO\7UD൶FGDWD 0.0 0.0
Sr. No. Types of Vehicles Ave. Daily 0.0 22-26 8.02
7UD൶F 9-11 1.9 18-22 10.48
1 Mini Bus, Bus 281 8-9 65.4 14-18 14.20
2 Mini Bus, Bus 919 <8 0.0 <14 0.0
$[OH7UXFNV 1020 Total 67.3 Total 32.7
4 $[OH7UXFNV
5 0XOWL$[OH7UXFNV 764
3.1.3 Evaluation of existing bituminous layer for K
value estimation
6 Tractor with Trailer & Without trailer 69
Comm. Veh. Per Day (CVPD) 4112
The subgrade support for design of the concrete overlay
is assessed in terms of Modulus of subgrade reaction

TECHNICAL PAPER
N YDOXH 7KH PRGXOXV RI VXEJUDGH UHDFWLRQ RQ WRS

RI WKH ÀH[LEOH SDYHPHQW FDQ EH GHWHUPLQHG XVLQJ WKH
JUDSK SURYLGHG LQ $SSHQGL[ ,,, RI ,5&63
The K value is estimated based on correlation
DYDLODEOH EHWZHHQ WKH FKDUDFWHULVWLF GHÀHFWLRQV RQ
WKH ELWXPLQRXV VXUIDFH PHDVXUHG ZLWK D %HQNHOPDQ
%HDP GHYLFH DV SHU $SSHQGL[ ,,, RI ,5&63
'HÀHFWLRQ VWXG\ XVLQJ D %HQNHOPDQ %HDP GHÀHFWLRQ
device was carried out and the K value on top of the
ÀH[LEOH SDYHPHQW ZDV GHULYHG EDVHG RQ WKH FRUUHODWLRQ 3KRWR7ULDO&RUHIRU&RQ¿UPDWLRQRI%LWXPLQRXV
FKDUWSURYLGHGLQ,5&637KHFKDUDFWHULVWLFGHÀHFWLRQ /D\HU7KLFNQHVV
IURP %HQNHOPDQ EHDP %%' VWXG\ ZDV IRXQG WR EH DV
3.2 Pre-overlay Treatment for the Thin White
PPDQGEDVHGRQWKHGHÀHFWLRQDQGFRUUHODWLRQ¿JXUH
Topping Design
LQ ,5&63 WKH . YDOXH ZDV HVWLPDWHG DV NJFP.
BBD survey can be seen in Photo 3. The pre overlay treatment is vital for correction of all the
GDPDJHGIDLOXUH ORFDWLRQV EHIRUH XQGHUWDNLQJ WKH 7:7
treatment and ensuring a uniform support to the TWT
RYHUOD\$W DOO VXFK GDPDJHG ORFDWLRQV LGHQWL¿HG GXULQJ
the distress survey were excavated upto subgrade level
IRU IXOO UROOHU ZLGWK RI P 7KH EDFN¿OOLQJ ZDV GRQH
with 200 mm GSB and 250 mm Wet mix macadam and
75 mm bituminous macadam layer to match level with the
existing road level. The typical cross section for correction
of distressed portions is shown in Table 4.
7DEOH7\SLFDO&URVV6HFWLRQIRU5HFWL¿FDWLRQRI
Distressed Flexible Pavement Sections
3KRWR%HQNHOPDQ%HDP'HÀHFWLRQ6WXG\ 7:72YHUOD\PPWKLFN
Bituminous macadam layer 75 mm
7ULDOSLWVIRUH[LVWLQJFUXVWWKLFNQHVV
Wet mix macadam layer 250 mm
7KHWULDOSLWVDQGWULDOFRUHVZHUHWDNHQDORQJWKHSURMHFW
Granual subbase 200 mm
highway to assess the availability of the existing pavement
Existing subgrade after compaction
FUXVWOD\HUWKLFNQHVV,WZDVIRXQGWKDWWKHDYHUDJHWKLFNQHVV
of the bituminous layers was between 100 to 120 mm and 3UR¿OHFRUUHFWLRQFRXUVH
WKHWKLFNQHVVRIWKHJUDQXODUEDVHDQGVXEEDVHOD\HUVZDV 7KH SUR¿OH FRUUHFWLRn course as required on site was
EHWZHHQ WR PP 'HWDLOV RI H[LWLQJ FUXVW FDQ EH provided for some stretches for provision of cross fall and
seen in Photo 4 & 5. FRUUHFWLRQ RI WKH ORFDOL]HG VDJV 7KH SUR¿OH FRUUHFWLRQ
ZDV GRQH XVLQJ ELWXPLQRXV PDFDGDP OD\HU DIWHU WDNLQJ
proper road levels for the existing road cross sections and
LGHQWL¿FDWLRQ RI WKH SUR¿OH FRUUHFWLRQ VHFWLRQV FDUHIXOO\
7KHDYHUDJHWKLFNQHVVRISUR¿OHFRUUHFWLRQFRXUVHZDV
PP3UR¿OHFRUUHFWLRQZRUNFDQEHVHHQLQPhoto 6.
3KRWR3UR¿OH&RUUection Course for Selected

Photo 4 Trial Pits for Existing Pavement Layer Stretches with Bituminous Macadam

TECHNICAL PAPER
3.3 Thin White Topping Design based on IRC:SP:76

Guidelines
The thin white topping overlay was designed as a bonded

RYHUOD\ ZLWK VPDOO VTXDUH SDQHOV WR WDNH DGYDQWDJH RI
the composite action of the overlay concrete and existing
ELWXPLQRXV SDYHPHQW )RU WKH GHVLJQ WKH JXLGHOLQHV RI
,5&63ZHUHXVHGDQGWKHGHVLJQWKLFNQHVVZDV
derived as 200 mm using M 40 grade concrete and square
panel size of 1.25 m X 1.25 m. The typical section of the
TWT overlay treatment is shown in Table 5. Photo 8 TWT Overlay Laying with Slip form Paver
Table 5 Typical Cross Section of TWT Overlay

7:72YHUOD\PPWKLFNZLWKVTXDUHSDQHOV
1.25 m X 1.25 m
Existing bituminous layer after milling
(avg 80 to 90 mm)
Existing Wet mix macadam layer 200 mm
Existing Granual subbase 150 to 200 mm
Existing subgrade layer
3.4 Construction of the TWT Overlay
7KH7KLQZKLWHWRSSLQJRYHUOD\ZDVXQGHUWDNHQE\XVLQJ Photo 9 Timely Groove Cutting using Multiple

slip form paver for a paving width of 5.0 m. The pre overlay Machines for Square Panels and Continuous curing
for 14 days
treatment for the failed/settled and damaged portions was
FRPSOHWHGLQDGYDQFHDQGWKHWUD൶FZDVDOORZHGWRSDVVRQ Grade concrete and slab size of 1.25 m X 1.25 m was
WKHUHFWL¿HGSRUWLRQVIRUDEULHISHULRGRIWRZHHNVEHIRUH provided by cutting of the concrete slab within 10-12 hours
FRQFUHWH RYHUOD\ ZRUN 7KH ELWXPLQRXV PDFDGDP SUR¿OH ZLQGRZZLWKWRPPLQLWLDOJURRYHFXW&RPSOHWHFXULQJ
FRUUHFWLRQ ZDV SURYLGHG XVLQJ SDYHU ¿QLVKHU ZLWK VHQVRU of surface and sides with wet hessian cloths was provided
GHYLFHVDIWHUSURSHULGHQWL¿FDWLRQDQGPDUNLQJRIWKHSUR¿OH for a period of 14 days after which the cleaning and sealing
correction stretches on site. The milling of the existing RI MRLQWV ZLWK SRO\VXOSKLGH VHDODQWV ZDV XQGHUWDNHQ 7LH
ELWXPLQRXVOD\HUZDVXQGHUWDNHQIRUWRPPWRFUHDWH bars were provided at the center of the carriageway with 12
DERQGEHWZHHQWKHH[LVWLQJÀH[LEOHSDYHPHQWDQGWKHQHZ mm tor steel diameter bars, 500 mm long and 450 mm c/c
concrete overlay. Subsequently, the Thin White topping provided at the mid depth of the concrete overlay. Dowel
overlay treatment with M 40 concrete. Milling operation can EDUVPPGLDPHWHUPPORQJDWPPFFSURYLGHG
EHVHHQLQ,PDJHDQGFRQFUHWLQJZRUNZLWKVOLSIRUPSDYHU at mid depth at the construction joints only.
can be seen in Photo 8. Construction operation for groove
cutting and curing can be seen in Photo 9 &10 respectively. $SSUR[LPDWHO\ WR P FRQFUHWH RYHUOD\ LQ OHQJWK
with 5 m width was carried out daily with adequate quality
FRQWURO DQG VXSHUYLVLRQ IRU WKH FRQFUHWLQJ ZRUN 7KH
Wirtgen SP 64 Slip form paver with automated tie bar
inserter was used for the paving operations with laying,
FRPSDFWLRQ ¿QLVKLQJ QG WH[WXULQJ GRQH ZLWK WKH SDYHU
¿QLVKHUPDFKLQH*URXQG*UDQXODWHG%ODVW)XUQDFH6ODJ
**%6 DW WKH UDWH RI NJ ZDV XVHG LQ WKH FRQFUHWH
mix in accordance to the provisions of IRC:17-2018. The
FHPHQWFRQWHQWZDV.JSHUFXPDQGZFUDWLRRI
Photo 7 Milling of Existing Bituminous Layer for in controlled environment. The target mean strength of 52
Bond Creation with TWT Overlay MPa was intended in the concrete mix. Design slump was

TECHNICAL PAPER
PDLQWDLQHG DW PP RQ VLWH $GHTXDWH PHDVXUHV ¾ $EVROXWH9LVFRVLW\DW0C --4000 Poise
were enforced for concreting to maintain the temperature ¾ .LQHPDWLF9LVFRVLW\DW0&F6W
of the concrete below 27 deg cel during the concreting
operations. The plant placement was such as to complete iv. GSB/WMM Test:- The samples collected from various
WKH ¿QLVKLQJ RSHUDWLRQV ZLWKLQ PLQV RI FRQFUHWH chainages along the road for WMM and GSB material and
PL[LQJ DW WKH 50& SODQW VLWH )LEULOODWHG SRO\SURS\OHQH tested under control condition for following test
¿EHUVDWWKHUDWHRI RQH .JSHUFXPZHUHLQWURGXFHGLQ
¾ Sieve analysis
WKHPL[WRDUUHVWVKULQNDJHFUDFNV$GHTXDWHDUUDQJHPHQWV
¾ /LTXLGOLPLW
in the form of plastic sheets were provided to cover the
¾ Plastic limit
fresh concrete to avoid rapid evaporation and subsequent
¾ Impact value
VKULQNDJHFUDFNV
¾ &RPELQHGÀDNLQHVVDQGHORQJDWLRQLQGH[
4. QUALITY TESTING & MONITORING
Test result were found acceptable.
7KH7:7RYHUOD\ZRUNZDVPRQLWRUHGDQGVXSHUYLVHGZLWK v. Concrete Test:- Concrete cube and concrete beam
WKH EHVW TXDOLW\ VWDQGDUGV DV SHU 0R57+ VSHFL¿FDWLRQV ZHUHFDVWHGGDLO\IRUWHVWLQJWRFKHFNWKHFRPSUHVVLYHDQG
DQGJXLGHOLQHVRI,5&$FRPSUHKHQVLYH4XDOLW\ ÀH[XUDO WHVW FXEHV DQG EHDPV RI VSHFL¿F VL]H ZHUH
$VVXUDQFH 3ODQ 4$3 ZDV GHYLVHG DQG LPSOHPHQWHG WR IRU0JUDGHFRQFUHWHEDWFKZLVH$YHUDJHFRPSUHVVLYH
ensure the highest quality of the concrete pavement used VWUHQJWK DERYH 03D DQG ÀH[XUDO VWUHQJWK DERYH
IRU 7:7 RYHUOD\ WUHDWPHQW )XOOÀHGJHG ODERUDWRU\ ZDV 5.5 Mpa was achieved for the concrete in the laboratory
established by contractor at site for conducting all routine tests with continuous monitoring and implementation of
tests for material such as aggregates, sand, cement, GGBS, the approved concrete mix at the RMC plant.
FRQFUHWHFXEHDQGÀH[XUDOEHDPWHVWVVWHHOHWF
vi. Water Test:- The water used in the concrete was tested
i. Cement: -7KHFHPHQWXVHGLQFRQVWUXFWLRQLVRI23& RQDVSHU,6 3DUW
JUDGHZKLFKZDVWHVWHGDVSHU,6Table-3 and and the value of all test were found to be within permissible
the test result were found to be within permissible limit. limit.
The test on cement included
vii. Steel Material:- 25 mm dia dowel bars and 12 mm tie bar
¾ )LQHQHVVRI&HPHQW used at construction joint and were tested as per IS 2062-2011
¾ 6WDQGDUG&RQVLVWHQF\ for its chemical composition. The steel bars were tested
¾ Soundness of Cement---1.8 mm for weight per meter, tensile strength test, elongation test,
¾ Initial setting time---100 min EHQGDQGUHEHQGWHVWDVSHU,6DQGWKHYDOXHVRI
¾ )LQDOVHWWLQJWLPHPLQ test result were found to be in permissible limit.
¾ GD\FRPSUHVVLYHVWUHQJWK²1PP2
viii. Slump testing: The slump for the concrete mix was
ii. Aggregate:- The routine aggregate use for the concrete carried out for each dumper and maintained at 25+/-15
were 20 mm , 12 mm, 6 mm coarse aggregate (Ramshej, mm. The material from vehicles with higher slump were
*DZDOZDGL DQGWHVWHGDVSHU,63DUW9,,, UHMHFWHGDQGXVHGIRUPLQRUVLWHZRUNV
iii. Bitumen Testing: Bitumen use in this project for 5. PERFORMANCE MONITORING FOR TWT
various purposes was VG-40 and viscosity test Penetration WORK OF NH 848 PROJECT HIGHWAY
WHVW'XFWLOLW\WHVW6RIWHQLQJSRLQWWHVWDQGÀDVKDQG¿UH
SRLQW WHVW GRQH WR FKHFN WKH TXDOLW\ RI ELWXPHQ DV SHU 7KH7:7RYHUOD\ZRUNZDVFRPSOHWHGE\WKHFRQWUDFWRU
,67KHWHVWUHVXOWVIRUELWXPHQVDPSOHVZHUHDV LQ $SULO 7KH SHUIRUPDQFH RI WKH 7:7 RYHUOD\ LV
follows. being monitored for the past two (02) years by conducting
routine inspections after every six (06) months for
¾ 3HQHWUDWLRQWHVWPP FKHFNLQJ DQ\ REVHUYHG GLVWUHVVHV LQ WKH7:7 ZRUN7KH
¾ Ductility Test-----84cm ODVWVLWHLQVSHFWLRQZDVFRQGXFWHGLQ0DUFKIRUYLVXDO
¾ 6S*UDYLW\7HVW² inspection of the concrete pavement and assessment of the
¾ )ODVK3RLQW0 GLVWUHVVHVLQWKH7:7ZRUNRQWKLVSLORWVWUHWFK

TECHNICAL PAPER
6RPHRIWKHGLVWUHVVHVREVHUYHGRQWKH7:7RYHUOD\ZRUN iv. Ravelling and low severity scaling at some

LQFOXGHPXOWLSOHVWUXFWXUDOFUDFNLQJLQVWUHWFKHVDWVRPH locations
ORFDWLRQVZKLFKLVFRQ¿QHGWRDGD\¶VZRUNWKXVSRLQWLQJ
WRZDUGVWKHGH¿FLHQF\RUSUREOHPVZLWKWKHPL[IRUWKDW
GD\$GGLWLRQDOO\ VKULQNDJH FUDFNV DUH DOVR REVHUYHG RQ
WKH34&DWVRPHORFDWLRQVDQGIXOOGHSWKWUDQVYHUVHFUDFNV
are observed at some locations. The complete stretch
ZDV YLVXDOO\ LQVSHFWHG DQG FRUHV ZHUH WDNHQ DW VHYHUDO
locations in the concrete slab to ascertain the concrete
VWUHQJWKDWWKHORFDWLRQVRIFUDFNHGFRQFUHWHSDQHOV7KH
FRUHV ZHUH DOVR WDNHQ DW WKH FRQWUDFWLRQ MRLQW ORFDWLRQ WR
ascertain the depth of the saw cut and the propagation of
WKHFUDFNXQGHUWKHVDZFXW7KHFRUHVZHUHDOVRWHVWHGLQ 3KRWR0XOWLSOH6WUXFWXUDO&UDFNV$FURVV+DOI
the laboratory to cross verify the concrete strength as per Width of Carriageway and Multiple Panels (1/2 days
the design requirement. The core strength of the concrete FRQFUHWHZRUN
is found to be within the acceptance limit.
7KH WRWDO FUDFNHG SDQHOV REVHUYHG RQ WKH SURMHFW KLJKZD\

after 2.5 years are shown in Table 3. Out of total 96000 panels
FDVWHGIRUWKH7:7ZRUNFUDFNVDQGGLVWUHVVHVDUHREVHUYHG
RQSDQHOVZKLFKLVDSSUR[LPDWHO\RIWKHWRWDO
panels casted under the project. These include panels with
IXOO GHSWK DV ZHOO DV SDUWLDO GHSWK DQG VKULQNDJH FUDFNLQJ
5HSODFHPHQWRIWKHIXOOGHSWKFUDFNHGSDQHOV DSSUR[
RIWRWDOFUDFNHGSDQHOV LVVXJJHVWHGDQGKDVEHHQXQGHUWDNHQ 3KRWR)XOO'HSWK7UDQVYHUVH&UDFNV$FURVVP
by the contractor in his defect liability period. Due to small width of Carriageway
size panels without tie or dowel bars the replacement activity
is comparatively easier as compared to conventional PQC
SDQHOV7KHUHSODFHPHQWRIWKHFUDFNHGSDQHOVLVFRQGXFWHG
during the defect liability period. Details of distressed panels
is shown in Table 6. The observed distresses on white topping
ZRUNFDQEHVHHQLQPhoto 10, 11 and 12DQG¿HOGFRUHVRI
concrete can be seen in Photo 13.
7DEOH2EVHUYHG&UDFNHG'LVWUHVVHG3DQHORQ
Photo 12 Sealed Transverse and other Diagonal
1+3URMHFW &UDFNVZKLFKDUH,QWDFWDW6RPH/RFDWLRQVDQG
Number of panels with Widened/Propagated at Few Locations
Sr. Stretch
distress
1 Stretch 1
2 Stretch 2 561
6WUHWFK 942
Total distressed

panels
A. Primary Distresses observed in TWT Pavement

L 3ODVWLF6KULQNDJH&UDFNV
3KRWR&RUHVWDNHQDWWKH&RQWUDFWLRQ-RLQW
LL 7UDQVYHUVH&UDFNV DFURVVPZLGWK±SDQHOV Indicating Lower Saw cut Depth (55 mm) in Some
LLL 0XOWLSOH 6WUXFWXUDO &UDFNV LQWHUFRQQHFWHG DFURVV Cores. But Bond between BT and TWT Concrete
multiple panels Formed well Indicated by Cores

TECHNICAL PAPER
B. 7KHFDXVHVRIWKHFUDFNVDQGGLVWUHVVHVREVHUYHGLQ ¾ Excessive water at surface (bleeding)

the TWT iGHQWL¿HGRQVLWHDUHDVIROORZV
L 0XOWLSOH6WUXFWXUDOFUDFNLQJLVRIWHQFDXVHGGXHWR
L 3ODVWLF 6KULQNDJH &UDFNV GXH WR FRQFUHWLQJ LQ KRW excessive loading, long joint spacing, and shallow
weather and due to high wind velocity as mostly or late sawing of joints, restraint at base or edge,
FRQFUHWHLVGRQHEHWZHHQ)HEUXDU\DQG0DUFKPRQWKV GXHWRMRLQWORFNXSLQDGHTXDWHWKLFNQHVVPDWHULDO
LL 7UDQVYHUVH&UDFNV DFURVVPZLGWK±SDQHOV UHODWHG SUREOHPV HWF 8VH RI SURSHU FRQVWUXFWLRQ
±'XHWRQRQIRUPDWLRQRIWKHSDQHOVRIVL]H WHFKQLTXHVDQGWUD൶FORDGFRQWUROVFDQUHGXFHDYRLG
m X 1.25 m (as per design) due to inadequate VXFKVWUXFWXUDOFUDFNV2IWHQUHDVRQVIRUVWUXFWXUDO
MRLQW FXW GHSWK DQG QRQSURSDJDWLRQ RI WKH FUDFN FUDFNLQJFRXOGEHSXPSLQJRI¿QHVIURPWKHVXE
underneath the saw cut thus resulting is slab size grade or the sub base, excessive warping of the slab,
higher than the design size. subsidence of utility trench, excessive temperature
LLL 0XOWLSOH 6WUXFWXUDO &UDFNV LQWHUFRQQHFWHG DFURVV VWUHVVHV DQG PRLVWXUH FRQWHQW 6WUXFWXUDO FUDFNV
multiple panels- XQOHVVUHSDLUHGH൵HFWLYHO\UHGXFHWKHORDGFDUU\LQJ
¾ Due to non-formation of the panels of size 1.25 capacity of the pavement and adversely impact the
m X 1.25 m due to inadequate joint cut depth and designed service life of the pavement.
QRQFUDFNLQJXQGHUQHDWKWKHVDZFXW LL 7UDQVYHUVH DQG ORQJLWXGLQDO FUDFNV DUH DOVR
¾ Suspect material quality during the days paving/ observed in the concrete pavement as seen in
KLJKHUZFUDWLRH[FHVV¿QHVHWF Photo 14 which occur due to the following reasons.
¾ :HDNFUDFNHG%7VXUIDFHQRWWUHDWHGDGHTXDWHO\
before the TWT (WMM+BM layer) ¾ ([FHVVLYHGU\LQJVKULQNDJHVWUHVVHV
¾ Internal drainage issues for the existing pavement. ¾ Inadequate depth of joint or late joint sawing
7KH FUDFNV DUH REVHUYHG JHQHUDOO\ ZKHUH WKH ¾ Excessive joint spacing
¾ Sudden/abrupt thermal & moisture gradient changes
H[LVWLQJ HPEDQNPHQW LV QRW YHU\ KLJK DQG SRRU
¾ 'RZQKLOO SDYLQJ FUDFNV SHUSHQGLFXODU WR WKH
drainage conditions exist in the pavement. direction of super elevation
iv. Raveling/ scaling (low/ medium severity) at some ¾ 6HWWOHPHQW RI HPEDQNPHQW ZKLFK OHDGV WR
locations- Due to segregation during paving, mix subsequent settlement of slabs
issues etc. ¾ "Vibrator trails" caused by malfunctioning or
improper adjustment of vibrators on the paving
C. Brief Technical Information Concerning Distresses machine
Observed on the Project is presented in this section. ¾ Tensile stresses in concrete are more than tensile
L 3ODVWLF 6KULQNDJH &UDFNLQJ± 3ODVWLF VKULQNDJH strength of concrete
FUDFNVDUHWLJKWDERXWPWRPORQJIRUPHG ¾ 0LVDOLJQHGFRUURGHGORFNHGEXUUHGHQGVGRZHO
LQSDUDOOHOJURXS¶VSHUSHQGLFXODUWRWKHGLUHFWLRQRI bars
¾ &UDFNDWWKHHQGRIWKHGRZHOEDUVRUORFNLQJRI
WKH ZLQG DW WKH WLPH RI SDYLQJ 3ODVWLF VKULQNDJH
dowel bars
FUDFNLQJLVDUHVXOWRIUDSLGGU\LQJDWWKHSDYHPHQW ¾ Delays or interruption of concrete placing for
VXUIDFH 7KH FUDFNV QRUPDOO\ H[WHQG GRZQ WR D more thaQPLQXWHV
GHSWK RI DERXW PP PP $GHTXDWH FXULQJ
E. 'LDJRQDO FUDFNLQJ LV DOVR REVHUYHG LQ FRQFUHWH
measures are necessary to prevent their occurrence.
pavement due to some of the above stated reasons
([SHULHQFH KDV VKRZQ WKDW WKHVH FUDFNV UDUHO\
LQÀXHQFHWKHRYHUDOOSHUIRUPDQFHRIWKHSDYHPHQW DQGLQVRPHLQVWDQFHVWKHFRUQHUEUHDNVDUHREVHUYHG
WKHUHIRUHDVXSHU¿FLDOUHSDLUPD\EHUHTXLUHG due to poor load transfer, dowel restraint etc.
LL 'U\LQJ6KULQNDJHFUDFNLQJ:LGHUGHHSHUFUDFNLQJ 6. CONCLUSIONS

LV XVXDOO\ DWWULEXWDEOH WR WKH GU\LQJ VKULQNDJH
and restraint developed in the concrete due to Based on the construction of TWT overlay for high volume
inadequate joints pacing, improper saw cutting or WUD൶F FRUULGRU DV D SLORW SURMHFW PDQ\ LQVLJKWV DUH JDLQHG LQ
misalignment of dowel bars. WKH WHFKQRORJ\ 7:7 SUHVHQWV LWVHOI DV D FRVWH൵HFWLYH DQG
sustainable solution for rehabilitating and strengthening of
D. 5HDVRQVIRUSODVWLFVKULQNDJHFUDFNVWKHIROORZLQJ ÀH[LEOHSDYHPHQWV7KHH[SHULHQFHJDLQHGIURPWKHFRQVWUXFWLRQ
¾ 'U\LQJVKULQNDJHVWUHVVHVLQVXUIDFH RI7:7 RYHUOD\ IRU KLJK WUD൶F YROXPH 1+ VHFWLRQ FDQ
¾ Poor curing be used to further encourage this technology to other NH/SH
¾ Hot windy conditions projects with improvements suggested as stated under.

TECHNICAL PAPER
7. ACKNOWLEDGEMENTS
The thin white topping project for National Highway

No 848 could not have been implemented without the
encouragement and active support from the Ministry of
Road Transport and Highways (MoRTH) Mumbai, NH
3:' 0DKDUDVKWUD DORQJZLWK 3: 1+ WHDP 1DVKLN
6SHFLDOWKDQNVWRWKH&RQWUDFWRUDQG&55,5LJLG3DYHPHQW
3KRWR7UDQVYHUVHDQG/RQJLWXGLQDO&UDFNVLQWKH Section for providing valuable inputs for the white topping
ZKLWH7RSSLQJZRUN project implementation.
:KLOH WKH 7:7 ZRUN KDV VRPH OLPLWDWLRQV WKHVH FDQ
be mitigated by proper design, construction and close REFERENCES
supervision and quality monitoring practices. Research on 1. Bulusu, V. J., KXVDP65 0XSSLUHGG\$5 $&ULWLFDO
improving the performance and durability of TWT, which 5HYLHZ RI WKH 3&$ DQG ,5& 0HWKRGV RI 7KLQ :KLWH 7RSSLQJ
ZLOOIXUWKHUHQKDQFHLWVDSSOLFDWLRQDQGEHQH¿WV 3DYHPHQW'HVLJQ7UDQVSRUWDWLRQ5HVHDUFK3URFHGLD
6NDQGD.XPDU%16XKDV5 %KDYDQ9 3HUIRUPDQFH
A. 6RPH RI WKH LPSRUWDQW ¿QGLQJV DQG VXJJHVWHG
Evaluation of Thin White Topping. Int J Res Eng Technol. https://
improvement in thin white topping projects for high GRLRUJLMUHW
YROXPHWUD൶FFRUULGRUVLQFOXGHWKHIROORZLQJSRLQWV 1DLGX * 5DPHVK % 'HVLJQDQG ([HFXWLRQ RI 7KLQ
White Topping Roads.
L 8VHRIKLJKHUJUDGHFRQFUHWHIRURYHUOD\PLQ0
,5&63 ³*XLGHOLQHV IRU &RQYHQWLRQDO 7KLQ :KLWH
JUDGHFRQFUHWHZLWK¿EHUVVKRXOGEHSUHIHUUHGIRU 7RSSLQJ´ )LUVW5HYLVLRQ ,QGLDQ5RDGV&RQJUHVV1HZ'HOKL
durable pavement with service life above 25 years ,5& ³*XLGHOLQHV IRU WKH 'HVLJQ RI 3ODLQ -RLQWHG 5LJLG
ii. Improvement in drainage measures for the project 3DYHPHQWV IRU +LJKZD\V´ )RXUWK 5HYLVLRQ ,QGLDQ 5RDGV
to avoid drainage related failures is critical and Congress, New Delhi
9LQD\ + 1 6XQLO 6 5HKDELOLWDWLRQ RI /RZ 9ROXPH
essential in the form of cross band drains, open
)OH[LEOH 3DYHPHQWV E\ :KLWH 7RSSLQJ$ &DVH 6WXG\ ,-5(7
drain augmentation etc International Journal of Research in Engineering and Technology.
iii. Dense bituminous macadam should be preferred 0LVKUD% $6WXG\RQ7KLQ:KLWH7RSSLQJ$Q$OWHUQDWHIRU
IRU SUR¿OH FRUUHFWLRQ LQVWHDG RI RSHQ JUDGHG Pavement Treatment. IJES) E-Issn, 07-117.
bituminous macadam layer. %XUQKDP 7 5HWWQHU ' :KLWH WRSSLQJ DQG +RW0L[
$VSKDOW 2YHUOD\ 7UHDWPHQWV IRU )OH[LEOH 3DYHPHQW 0LQQHVRWD
B. The following good construction practices are &DVH+LVWRU\7UDQVSRUWDWLRQ5HVHDUFK5HFRUG
recommended to be followed to achieve good quality and %DOER - 7 $SSOLFDWLRQV RI +LJK3HUIRUPDQFH &RQFUHWH
longer lasting white topping overlay pavements. IRU 8OWUD7KLQ 3DYHPHQW 2YHUOD\V :KLWHWRSSLQJ $&, 6SHFLDO
L $OO FUDFNHG SRUWLRQV LQ WKH H[LVWLQJ ÀH[LEOH 3XEOLFDWLRQV
3DWLO5< 5DQDGLYH06 'HVLJQDQG'HYHORSPHQW
pavement should be completely removed and of Methodology for Construction of Thin White Topping for Rural
reinstated before the TWT treatment Roads in India. Innovative Infrastructure Solutions, 7(4), 245.
LL $GHTXDWH SURYLVLRQV IRU SUH RYHUOD\ WUHDWPHQW 'DGKLFK * 3DWHO + 3DWHO 0 $ 7UHDWPHQW RI 'LVWUHVVHG
DQG WKRURXJK LGHQWL¿FDWLRQ DQG UHFWL¿FDWLRQ 8UEDQ 5RDGV XVLQJ 8OWUDWKLQ :KLWH7RSSLQJ $ &DVH 6WXG\ RI
of damaged portions before concrete overlay 'DPDQ&LW\ 8W ,QGLD
-XQGKDUH'5.KDUH.& -DLQ5. /LIH&\FOH&RVW
treatment is to be followed to ensure proper base $QDO\VLVRI&RQYHQWLRQDO:KLWH7RSSLQJYV5LJLG3DYHPHQWDQG
support for concrete overlay. )OH[LEOH3DYHPHQW,QWHUQDWLRQDO-RXUQDORI/LIHF\FOH3HUIRUPDQFH
iii. Provision of multiple concrete initial groove cutting (QJLQHHULQJ
HTXLSPHQWZLWKEDFNXSWRDYRLGGHOD\HGFXWWLQJDV 3DVHWWR0 %RUWROLQL* 8VHRI8OWUD7KLQ:KLWHWRSSLQJ
LQ 7KH 5HKDELOLWDWLRQ RI 'HJUDGHG )OH[LEOH 3DYHPHQWV LQ WK
WKHFXWWLQJOHQJWKRIVPDOOSDQHOVLVVLJQL¿FDQW
International Symposium on Concrete Roads.
iv. Slightly higher depth of groove cut appox 1DJDNXPDU 0 6 $MD\ 1 -RKQ 6 ( $Q $QDO\WLFDO
WRPPPRUHWKDQUGVODEGHSWKWRHQVXUH $SSURDFKWR$QDO\VLVRI&RQFUHWH2YHUOD\ :KLWH7RSSLQJ 2YHU)OH[LEOH
proper square panel is essential. 3DYHPHQW +RW0L[$VSKDOW 8VLQJ$16<66RIWZDUH,Q6XVWDLQDELOLW\
Trends and Challenges in Civil Engineering: Select Proceedings of
Y &RQWLQXRXV FKHFNLQJ RI LQLWLDO JURRYH FXW GHSWK
&7&6 SS 6LQJDSRUH6SULQJHU6LQJDSRUH
is critical to avoid formation of large size panels 5DVKPL 6 0 .XPDU . 5 $NNL % 5HGG\ , 5
UHVXOWLQJLQUDQGRPFUDFNLQJLQWKHVODEV 'HFHPEHU 3HUIRUPDQFH 6WXGLHV RQ :KLWH 7RSSLQJ /D\HUV 2YHU
vi. Enforcement of strict quality control and )OH[LEOH 3DYHPHQW LQ ,23 &RQIHUHQFH 6HULHV 0DWHULDOV 6FLHQFH
VXSHUYLVLRQIRUFRQFUHWHRYHUOD\ZRUNV DQG(QJLQHHULQJ 9RO1RS ,233XEOLVKLQJ

TECHNICAL PAPER
A COMPREHENSIVE STUDY ON APPLICATIONS AND DESIGN

PARAMETERS OF CEMENT GROUTED BITUMINOUS MIX
'U/RNHVK*XSWD1 'U5DNHVK.XPDU2
ABSTRACT
Cement Grouted Bituminous Mix (CGBM) is a composite mixture prepared by allowing the grout slurry to penetrate within
the air voids of Open Graded Bituminous Mix (OGBM) under the action of gravity. Therefore, the open graded bituminous
PL[HQVXULQJWKHKLJKHUSHUFHQWDJHDLUYRLGVDQGWKHSUHSDUHGJURXWVOXUU\KDYLQJVDWLVIDFWRU\ÀXLGLW\WRJHW¿OOHGLQWKHDLU
YRLGVRI2*%0DUHWKHWZRHVVHQWLDOGHVLJQDVSHFWVRI&*%07KLVSDSHULVPDLQO\HPSKDVL]HGWRPDNHFRPSUHKHQVLYH
UHYLHZRQWKHGHVLJQSDUDPHWHUVRI&*%0YL]DLUYRLGVLQ2*%0ELQGHURSWLPL]DWLRQFRPSDFWLRQH൵RUWVÀXLGLW\RIJURXW
and its compressive strength and the durability aspects of the CGBM. This study also summarizes the advantages and the
application of the CGBM.
1. INTRODUCTION v. Requirement of joints in case of non-continuous

type reinforced concrete pavements (Oliveira et
Cement Grouted Bituminous Mix (CGBM) is a composite DO$QGHUWRQ
mixture where cementitious grout slurry is penetrated
vi. Post construction, the time required to open the
within the air voids of an Open-Graded Bituminous
IDFLOLW\ FRQFUHWHSDYHPHQW IRUWUD൶FXVH +DVVDQ
Mix (OGBM). Therefore, the CGBM surface has both
HW DO 7R DYRLG WUD൶F PRYHPHQW RQ WKH
ÀH[LEOH DQG ULJLG SDYHPHQW PHULWV DQG LV FRQVLGHUHG D
XUEDQ URDG HVSHFLDOO\ GXULQJ SHDN KRXUV LV D
VHPLÀH[LEOHSDYHPHQWW\SH)XUWKHUWKHFKRLFHRIFROGPL[
WRXJKWDVNWLOOWKHRSHQLQJRIWKHIDFLOLW\
layer of CGBM may minimize and or control the following
challenges associated with conventional mix types. The presence of such defects and challenges has an
impact on the service life of pavement and riding
L +HDY\ WUD൶F FDXVLQJ WKH UXWWLQJ LQ FDVH RI KRW
quality. In addition, the cost of annual rehabilitation
bituminous mix.
DQG RU PDLQWHQDQFH LV LQFUHDVHG GUDVWLFDOO\$V D UHVXOW
ii. Ingress of water resulting in the moisture induced comprehensive studies are needed on new pavement
damages. materials with enough durability and resistance to
LLL )UHTXHQW VWDUW DQG VWRSSLQJ EUDNLQJ RI WKH mentioned failures, which simultaneously can function
vehicle causing the pavement distresses and as concrete and asphalt pavements. The CGBM mix as
damages nearly at intersections, bus rapid transit VHPLÀH[LEOHSDYHPHQWKDVWKHSRWHQWLDOWRRYHUFRPHWKH
stops (BRTS stops) etc. concerns associated with the conventional pavements.
iv. Damages caused due to oil spillage noticed in the
YLFLQLW\RISDUNLQJDUHDVIXHOVWDWLRQVEXVVWRSVWUD൶F In the past two decades, researchers have conducted
VLJQDOVHWF 'KDQGDSDQLDQG0XOODSXGL VHYHUDOVWXGLHVRQVHPLÀH[LEOHSDYHPHQWVDVDSRWHQWLDO
to resist the heavy loads as well as with its high load
$VVLVWDQW3URIHVVRU'HSDUWPHQWRI&LYLO(QJLQHHULQJ6LU3DGDPSDW6LQJKDQLD8QLYHUVLW\8GDLSXU(PDLOORNHVKJXSWD#JPDLOFRP
3URIHVVRU'HSDUWPHQWRI&LYLO(QJLQHHULQJ691,76XUDW(PDLONUDNHVK#FHGVYQLWDFLQ

TECHNICAL PAPER
bearing capacity and resistance to the distresses such as may be noted that a bituminous mix having such a higher
UXWWLQJ DQG VKRYLQJ &RUUDGLQL HW DO $Q HW DO void content may be responsible for other consequences and
$IRQVRHWDO*RQJHWDO<DQJHWDO GLVWUHVVVXFKDVUXWWLQJIDWLJXHFUDFNLQJPRLVWXUHLQGXFHG
&DLHWDO.KDQHWDO'XHWDO damages etc. But in case of CGBM, these high volume of
The distresses such as rutting or shoving which appear in DLUSRFNHWV DLUYRLGV PDNHVWKHRSHQJUDGHGELWXPLQRXV
ÀH[LEOHSDYHPHQWVGHSHQGRQWUD൶FFRQGLWLRQV LHWUD൶F mix a pervious mix layer. Which is the prerequisite for the
GHQVLWLHVKHDY\ORDGVVORZWUD൶F DQGFDQEHFDXVHGE\ SHQHWUDWLRQ DQG ÀRZ RI WKH JURXW ZLWKLQ WKHVH DLU YRLGV
extremely high temperatures (Dhandapani and Mullapudi, .HHSLQJ WKH DLU YRLGV ORZHU WKDQ PD\ FDXVH ORZ
'XHWDO SHUPHDELOLW\ DQG LPSURSHU SHQHWUDWLRQ RI JURXW ¿OOLQJ
the voids. Thus, may cause not to obtain a homogeneous
The presence of such defects and challenges has an impact CGBM mix resulting the adequate strength.
on the service life of pavement and riding quality. In
addition, the cost of annual rehabilitation/maintenance also 'L൵HUHQW GHVLJQ SURFHGXUH KDV EHHQ DGRSWHG E\ WKH
LQFUHDVHVGUDVWLFDOO\$VDUHVXOWFRPSUHKHQVLYHVWXGLHVDUH researchers to prepare the open graded bituminous mix for
needed on new pavement materials with enough durability the CGBM that is discuss subsequently in this article.
and resistance to mentioned failures, which simultaneously
can function as concrete and bituminous pavements. 2.1 Binder Optimization through Drain down Test
&HPHQW JURXWHG ELWXPLQRXV PL[ OD\HU 6HPL ÀH[LEOH $V IDU DV 2*%0 LV FRQFHUQHG ELWXPHQ FRQWHQW VKDOO
pavement or Semi-rigid pavements) are a solution to resist be optimised to develop and ensure the adequate binder
against the rutting and shoving distresses considering their coating around the aggregates without leaving traces of
UHPDUNDEOHVWL൵QHVVGXUDELOLW\DQGWKHVLJQL¿FDQWIDWLJXH ELQGHU GUDLQ GRZQ 6LQFH 2*%0 ODFNV LQ WHUPV RI ¿QH
OLIHLQFRPSDULVRQZLWKELWXPLQRXVSDYHPHQWV $IRQVRHW DJJUHJDWHVWKHUHLVKLJKSRVVLELOLWLHVWKDWELWXPHQPD\JHW
DO6DERRHWDO/XRHWDO 7KHPDNLQJ drain while transporting the mix from hot mix plant to the
of cement grouted bituminous mix layer deviates than construction site as well as during the compaction of the
the conventional procedure of the hot bituminous mix. It PL[ .KDQHWDO +RZHYHUWKHDGGLQJRI¿EUHVLQWKH
primly emphasizes on two aspects: PL[PD\FRQWUROWKHELQGHUGUDLQGRZQ 6HW\DZDQ
Oliveira et al. 2007). Woodside and Woodward (1998) and
i. Open graded bituminous mix (OGBM) possessing /\RQVDQG3XWPDQ KDVVXJJHVWHGDUDQJHRI
WKHKLJKHUYROXPHRIDLUSRFNHW DLUYRLGV WRRIWKH¿EHUE\WKHWRWDOZHLJKWRIWKHELWXPLQRXV
LL $ SUHSDUHG VOXUU\ QDPHG DV JURXW SUHIHUDEOH mix may be added.
penetrable under the action of gravity. )LEHUVPD\EHPL[HGHLWKHUE\IROORZLQJWKHGU\DSSURDFK
2. AIR VOIDS IN OGBM or the wet approach. The dry approach is the mixing of
¿EHUV ZLWK WKH KRW DJJUHJDWHV EHIRUH DGGLQJ WKH ELWXPHQ
9DULRXVUHVHDUFKHUVKDYHGLVFXVVHGWKHH൵HFWRIDJJUHJDWH ZKHUHDVWKHZHWDSSURDFKLQYROYHVWKHPL[LQJRI¿EHUVZLWK
gradation on the properties of the open-graded bituminous WKHELQGHULWVHOI.QRZLQJWKHIDFWWKDWDGGLQJ¿EHUFRQWUROV
PL[ 6HW\DZDQ 2OLYHLUD HW DO +XVDLQ HW DO WKHGUDLQGRZQLWPD\D൵HFWWKHJURXWSHQHWUDWLRQZLWKLQWKH
2010). These studies have summarised that incorporation air voids of the porous mix as far as CGBM is concerned.
of uniformly graded aggregates results in high percentage
air voids. However, a uniformly graded mix may even The optimum binder content of the OGBM may be
depict a better strength than the continuous graded mix due optimized by performing the drain down test as per the
to a pore structure change (Ding et al. 2011). $670 ' DQG $$6+72 7 'UDLQ GRZQ LV WKH
essential criteria to determine the Optimum Binder Content
$OPRVWVLQJOHJUDGHGELWXPLQRXVPL[KDYLQJYRLGFRQWHQW (OBC) of the Open-Graded Bituminous Mix (OGBM).
DURXQG LQ VRPH SUDFWLFDO FDVHV PD\ EH XS WR The OBC is the minimum bitumen content that limits the
ZKLFKLVPRUHWKDQWKHYRLGLQWUDGLWLRQDOGHQVH GUDLQGRZQORVVRIWKH2*%0WR 6HW\DZDQ
graded bituminous mixes is suitable for preparing the
FHPHQW JURXWHG ELWXPLQRXV PL[ &LKDFNRYD HW DO The parameters of the OGBM with respect to OBC and
3HLHWDO$IRQVRHWDO+RXHWDO ,W aggregate types described in the previous studies are
summarized in Table 1.

TECHNICAL PAPER
Table 1 Properties of the Open Graded Bituminous Mix OLNHFHPHQWFRQWHQWPRLVWXUHFRQWHQW¿OOHUPDWHULDOVLH

S. Aggregate OBC LWVW\SHDQGSHUFHQWDJH 1DXGWVHWDO 7KHJURXWHG
Authors (s) % Air Voids
N Types (%) material's main suitability criterion for the CGBM is the:
1 Saboo et al., 2019 2.5
L )ORZDELOLW\ ÀXLGLW\ SURYLGLQJIXOOGHSWKSHQHWUDWLRQDQG
2 Zhang et al., 2019 20
ii. Compressive strength
Gong et al., 2019 22-25
<DQJDQG:HQJ /LPHVWRQH Table 2 Compactions Approaches of the OGBM Specimen.
4
2015
Compaction
&LKDFNRYDHWDO No of faces Researchers
5 4.5 Type
2015
$QGHUWRQ/LQJHWDO
6 Hong et al., 2020 27 2009, Khan 2010, Husain
7 /XRHWDO 17-19, 24-26 2QH)DFH HWDO+RXHWDO
Basalt
8 Pei et al., 2016 18,21 Marshal Blows Bharath et al., 2019, Gupta
DQG.XPDUDE
9 Sun et al., 2018 2.5
$O4DGLHWDO+XVDLQ
10 Bharath et al., 2019 2.41 %RWK)DFHV
Granite et al., 2014
11 Wang et al., 2018 15, 20-25
Gyratory Hassan et al. (2002) and
12 Hou et al., 2015 Gabbros 25 --
Compaction *DZHG]LQVNL
&RPSDFWLRQ(൵RUWV
7KHUHLVQRVSHFL¿FPHWKRGDYDLODEOHWRGHWHUPLQHWKHQXPEHU
of blows required to compact the OGBM specimen. Table 2
presents the various compaction approaches studied by the
researchers. In past, investigators (Cited in Table 2) have
LPSOHPHQWHGGL൵HUHQWDSSURDFKHVWRGHWHUPLQHWKHFRPSDFWLRQ
H൵RUWVLQWHUPVRIWKHQXPEHURI0DUVKDOOEORZVRUWKHJ\UDWLRQ
to preparing the mix specimen. Some studies (Cited in Table 2)
have reported the compaction of the specimen on the one face
only whereas few have compacted on both the faces by varying Fig. 2 Percentage Air Voids Vs Marshall Blows of the
WKHQXPEHURIEORZVRUJ\UDWLRQXQWLOWKHUHLVQRVLJQL¿FDQW OGBM (Source Bharath et al., 2019)
variation in the percentage air voids is observed.
$ SUHSDUHG JURXW RI LQDGHTXDWH ÀXLGLW\ ZRXOG QRW EH
The number of Marshall blows beyond which there is capable enough to penHWUDWHDQGJHW¿OOHGZLWKLQWKHYRLGV
QR VLJQL¿FDQW YDULDWLRQ LQ SHUFHQWDJH DLU YRLGV PD\ EH of open graded bituminous mix under the action of gravity
considered as minimum blows required to prepare the mixed DQGRURWKHUPHDQV$VDUHVXOWWKHSUHSDUHGWKH&*%0
specimen (Bharath et al., 2019). Fig.2 is a plot (Bharath et al., mix exhibits the non-uniform behavior i.e., the variation in
2019) of the variation of percentage air voids versus number the results of strength and durability of the mix.
of Marshall hammer blows for the CGBM mix prepared with
the application of the Marshall hammer on only one face. ,5&63 SUHVHQWV FHPHQW VDQG À\ DVK VLOLFD
The plot indicates that a minimum of 40 blows are adequate fumes and super plasticizer and or the chemical additives as
to achieve the desired degree of compaction, as there is no WKH FRQVWLWXHQWV IRU PDNLQJ WKH JURXW VOXUU\ 7R DFKLHYH WKH
VLJQL¿FDQWFKDQJHLQDLUYRLGVEH\RQGWKDWFRPSDFWLRQ better quality of grout, IRC:SP:125-2019 has recommended
WKH 23& RU 23& JUDGH FHPHQW FRPSO\LQJ ZLWK
3. CEMENTITIOUS GROUT ,6VDQGSDVVLQJPPVLHYHVL]HRUHYHQPLQLPL]HG
À\DVKDQGVLOLFDIXPHFRQ¿UPLQJ,6ZLWKPLQLPXP
*URXWFDQEHGH¿QHGDVDPL[WXUHRIFHPHQWLWLRXVPDWHULDO SDVVLQJPLFURQVLHYHVXSHUSODVWLFL]HU ,6 DQGRWKHU
and water (with or without aggregates) proportioned to chemical additives to reduce the water content and improve the
produce a slurry of pourable consistency not causing
ÀRZDELOLW\RIWKHJURXWZLWKRXWUHGXFWLRQLQWKHVWUHQJWK
segregation of the constituents." Grout is neither a mortar
nor concrete. It is a cementitious slurry material that )ORZDELOLW\ ÀXLGLW\ 3URYLGLQJ )XOO 'HSWK
penetrates within the air voids of the porous bituminous Penetration
PL[6HYHUDOIDFWRUVLQÀXHQFHJURXWPDWHULDO VSHUIRUPDQFH 7ZR GHFLVLYH FULWHULRQV RI WKH JURXW LH ÀXLGLW\ DQG WKH

TECHNICAL PAPER
FRPSUHVVLYH VWUHQJWK DUH PDLQO\ D൵HFWHG E\ WKH ZDWHU WRJHWWKHUHTXLUHGÀXLGLW\DWWKHORZHUZDWHUFRQWHQWVIRU

FHPHQWUDWLR7KHÀXLGLW\RIWKHJURXWLPSURYHVZLWKWKH cement grout without loss of strength.
increase in the water cement ratio whereas, declines with 3.1.1 Flow time of grout
the increase in the water sand ratio. The consequences of
increasing in water cement ration may be the- 7RHQKDQFHWKHÀRZtime some of the researchers (Koting
HWDO+DVVDQHWDO KDYHDWWHPSWHGWKHKLJKHU
L ,QFUHDVHLQGU\VKULQNDJH +XHWDO GRVDJH RI VXSHU SODVWLFL]HU YDU\LQJ IURP WR
LL :DWHUEOHHGLQJDQGVOXUU\OHDNDJH *XRHWDO Studies revealed that a higher dosage of super plasticizer
causes an increase in setting time, water bleeding, and even
Guo et al. (2017) suggested a maximum water cement sometimes samples does not set after 24 hours. Therefore, the
ration as 0.55 whereas Saboo et al. (2019) recommended optimum dosage of chemical admixture and the proportion
it to be in the range of 0.4 to 0.6. The variation in these of constituents of the grout need to critically analyze.
parameters of the grout demonstrates the inconsistency
$FFRUGLQJ WR $670 ' WKH 0DUVK FRQH WHVW LV
LQ WKH ÀXLGLW\ RI WKH JURXW 7KHUH LV ZLGH YDULDWLRQ DQG
SHUIRUPHG WR HYDOXDWH WKH ÀRZDELOLW\ RI JURXWV DQG WKH
contradiction among the results presented by the various admixture's saturation dosage (Jayasree and Gettu, 2008).
researchers (Cited in Table 3). The various results of Saturation dosage is the maximum content of chemical
the grout study obtained and or suggested by numerous DGPL[WXUHEH\RQGZKLFKWKHUHLVQRVLJQL¿FDQWFKDQJHLQWKH
researchers are summarized in Table 3. ÀXLGLW\ ÀRZWLPH RIPRUWDULVREVHUYHG$VWDQGDUGÀRZ
7R LPSURYH WKH JURXW SURSHUWLHV DQG PDNH LW PRUH FRQHLVSUHVHQWHGLQWKH$QQH[XUH'RI,5&63WR
HFRQRPLFDOPDQ\UHVHDUFKHUV +DVVDQHWDO.RWLQJ GHWHUPLQHWKHH൷X[RIDVSHFL¿HGYROXPHRIDJURXW
HWDO=KDQJHWDO SDUWO\UHSODFHG23&ZLWK 3.2 Compressive strength
À\DVKVDQGUHVLQVDQGVLOLFDIXPHHWF7KHSURSRUWLRQRI
7KHYDULDWLRQLQWKHUHVXOWVRIWKHÀXLGLW\DOVRLQÀXHQFHVWKH
VDQG DQG À\ DVK PD\ EH YDULHd to optimize strength and
compressive strength of the grout. Therefore, constituents
ÀRZDELOLW\RIJURXW)O\DVKDQGVLOLFDIXPHVDOVRNQRZQ adopted and its proportion to prepare the grout need to
as micro silica, are used to improve strength, durability, FDUHIXOO\DQDO\VHGZLWKUHVSHFWWRÀXLGLW\DQGFRPSUHVVLYH
DQG SHUIRUPDQFH ,5&63 .XPDU DQG 6XPDQ strength that ensures the full depth penetration of grout
2022). Super plasticizer and or chemical additive is used with in the air voids of the open graded bituminous mix.
Table 3 Test Particulars and Parameters of the Grout
Water 28 Days Strength

S. Water Sand Super Fluidity,
Researchers Cement Compressive Flexural Strength,
N. Ratio plasticizer type seconds
Ratio strength, MPa MPa
1 Gong et al., 2019 -- -- -- --
2 0.40-0.50 Polycarboxylic 21-25 -- 10-14
Saboo et al., 2019
0.57-0.60 20-25 --
4 Zhang et al., 2019 0.6 0.5 -- 12
5 Sun et al., 2018 0.45-0.55 0.15-0.25 Polycarboxylic 1.6-19 0.27-1.28 5-16
6 $QHWDO -- 'D\V 'D\V --
7 0.5 -- 12-17 09-15 12-17
Zhang et al., 2016
8 0.56-0.58 -- -- 11-14 15-20 11-14
9 Pei et al., 2016 0.56 -- Polycarboxylic 25 06 11
10 <DQJDQG:HQJ 0.7, 0.75 0.2 24, 26 (7 Days) 'D\V
11 Koting et al., 2014 -- -- 58 6 14
12 Huang et al., 2012 0.6 0.5 Naphthalene powder 49 7.5 12
0.2 -- -- 6 11.1
/LQJHWDO
14 0.14 -- -- 17 4.5 11.4
15 Hu et al., 2012 0.45 0.25 Polycarboxylic 20 5
.DXVKLNDQG6LGGD-
16 0.6 -- - 19.6 (28 Days) -- 27
JDQJDLDK

TECHNICAL PAPER
4. DURABILITY OF THE CGBM 5. CONSTRUCTIONS OF CGBM LAYER
CantabURWHVWLVSHUIRUPHGDVSHUWKH$670' The conclusion of the construction procedure explain in

XVLQJ WKH /RV $QJHOHV DEUDVLRQ DSSDUDWXV :LWKRXW the various studies such as Bharath et al., 2019, Gupta
charge) to assess the durability of the mix type in terms of DQG.XPDU$QHWDO,5&63LVWKH
percentage weight loss. CGBM layer is paved in two VWDJHV ZKHUH ¿UVW VWDJH LV
similar to construction of conventional bituminous layer.
It determines the abrasion loss of a compact bituminous
mix. Prior to testing the mix specimen were conditioned 7KH¿UVWVWHSLVWKHFOHDQLQJRIWKHH[LVWLQJVXUIDFHDQGWKH
at a test temperature of 25°C for 6 hours. The conditioned DSSOLFDWLRQRIWDFNFRDWRYHULW$IWHUZRUGVDQRSHQJUDGHG
VSHFLPHQ DUH NHSW LQ WKH /RV DQJHOHV DEUDVLRQ PDFKLQH bituminous mix is laid and then lightly compact with smooth
without charge and the cylinder is rotated at a speed of wheel Static Roller to achieve the target air void. Once the laid
USPIRUURXQGV surface layer (porous open graded bituminous mix) is cooled
$VDUHVXOWRIWKHWHVWSHUFHQWDJHZHLJKWORVV DEUDVLRQORVV down to ambient temperature, prepared grouting material as
is determined, which is an indirect measure of durability. per the design is spread uniformly over the existing surface.
3HUFHQWDJHZHLJKWORVVLQGLFDWHVWKHZHDNHQLQJRIERQGLQJ $SSOLFDWLRQ RI FHPHQWLWLRXV JURXW FDQ EH GRQH PDQXDOO\
between the particles, cohesion, and resistance against wear or by mechanical means over the high voids bituminous
DQGWHDUGXHWRWUD൶FDEUDVLRQ,WPD\EHGHWHUPLQLQJDV surface. Sweeping and or squeezing or any other such simple
techniques can be adopted for this purpose. The applied
P = 100 (W1-W2)/ W1 (1) JURXWVKRXOGEHDEOHWRDXWRPDWLFDOO\ÀRZLQWRWKHYRLGVRI
Where,
WKHELWXPLQRXVVXUIDFHXQGHUWKHH൵HFWRIJUDYLW\DORQH7KH
3 3HUFHQWDJHZHLJKWORVV $EUDVLRQ
edges of the bituminous layer should necessarily be covered
W1= Initial weight of the sample
ZLWKDQ\VXLWDEOHPDWHULDOOLNHÀ\DVKLQRUGHUWRUHVWULFWWKH
W2 )LQDOZHLJKWRIWKHVDPSOHDIWHUWKHWHVW
RXWÀRZRIWKHJURXWVOXUU\*URXWDSSOLFDWLRQZRUNVKRXOGQRW
$670''0DQG$QHWDOKDVVXJJHVWHG be executed in rainy or snowy environments.
the maximum abrasion loss (Percentage weight loss) of
$Q\H[FHVVLYHJURXWPDWHULDORYHUWKHVXUIDFHLVUHPRYHG
&*%0DVWREHXVHGDVZHDULQJFRXUVH
To improve the surface roughness, the grouted surface
Hong et al., (2019) used a beam sample of 200 mm in length can be mechanically and or manually broomed to create
and 50 mm of width and height to assess the durability of texture on the surface. Moist curing can be done by
the CGBM in terms of freeze and thaw study. The study VSULQNOLQJZDWHUIRUGD\VHYHQZLWKWUD൶FLQRSHUDWLRQ
revealed that after the freeze thaw cycles, air voids and Fig. 4 explains the construction procedure of the CGBM as
pores connectivity of the specimen increases as presented in presented in the IRC:SP:125-2019.
Fig 3. This tarnishes the adhesion between the bituminous
%KDUDWKHWDOSUHVHQWHG¿HOGSHUIRUPDQFHRIWKH&*%0
mix and grout. Subsequently the cement pastes segregates
VXUIDFH$VSHUWKHVWXG\QRUXWWLQJZDVREVHUYHGLQWKH¿HOG
and therefore the weigKWRIWKHVSHFLPHQGHFUHDVHVPDNHV
VHFWLRQ WLOO PRQWKV PVD RI SRVW FRQVWUXFWLRQ 7KH
it less durable. Whereas other studies reported the CGBM
&*%0VXUIDFHZDVDOVRFKHFNHGIRULWVVNLGUHVLVWDQFHXVLQJ
durable in terms of moisture susceptibility.
%ULWLVK 3HQGXOXP 7HVWHU %31 LQVWUXPHQW DV SHU $670
(7KHREVHUYHGYDOXHRIVNLGUHVLVWDQFHDVPHDVXUHGLQ
terms of BPN were 60 for wet condition and 70 for the dry
FRQGLWLRQ7KHVNLGUHVLVWDQFHRIWKH&*%0VXUIDFHLVIRXQG
to be adequate for the dry as well as wet conditions.
5.1 Cost Economics
)RU WKH EHWWHU XQGHUVWDQGLQJ RI &*%0 .DXVKLN DQG
6LGGDJDQJDLDK DQDO\]HG WR HYDOXDWH KRZ PXFK
Fig. 3 The Macroscopic Morphology of CGBM reduction in material cost could be obtained in comparison
6DPSOHV6XEMHFWHGWR)UHH]HWKDZ&\FOHV D %HIRUH to a conventional composition when CGBM is used as a
&RQGXFWLQJWKHWHVW E $IWHU&RQGXFWLQJWKHWHVW surface layer. TwoGL൵HUHQWPRGHOV &DVHDQG&DVH DV
(Source: Hong et al., 2020) presented in Fig. 5ZHUHDQDO\]HGXVLQJ.(1/<(5

TECHNICAL PAPER
Fig. 4 Stages of CGBM Construction at Site (Source: IRC: SP:125-2019)

)RU WKH SDYHPHQW FRPSRVLWLRQ &DVH DQG &DVH
presented in the Fig 5, The cost analysis is carried out as
SHUWKHUDWHVRIWKHODWHVW&HQWUDO3XEOLF:RUNV'HSDUWPHQW
India (CPWD) schedule of rates (SOR) for a unit length
of road inclusive of materials, labour, machinery and
WKH FRQWUDFWRU SUR¿WV DQG RYHUKHDGV 7KH SDYHPHQW
width adopted in meters to surface layer, granular layer
and subgrade & earthen shoulder are 7, 8.2 and 10.4 m
respectively. 10.4 m (subgrade).
$VSHUWKHDQDO\VLVWKHLQLWLDOFRVWRIFRQVWUXFWLRQZDVDURXQG
OHVV WKDQ WKH FRQYHQWLRQDO SDYHPHQW FRPSRVLWLRQ
Fig. 5 (a) Composition used for case 1 (b) Composition It could be noticed from Fig.5 that for comparable
XVHGIRUFDVH 6RXUFH.DXVKLNDQG6LGGDJDQJDLDK performance, the overall material requirement for the
2023) SDYHPHQWZLWK&*%0UHGXFHVVXEVWDQWLDOO\)XUWKHUWKH

TECHNICAL PAPER
variation in the initial construction cost may substantially slurry using pozzolanic materials other than OPC results
increase in the case of conventional composition due to in lower carbon dioxide emissions and lesser consumption
the cost associated with the procurement of good quality RIUDZPDWHULDOVDVFRPSDUHGWR23&7KLVZLOOPDNHWKH
aggregates from long distances. Therefore a life cycle cost SDYHPHQW PRUH VXVWDLQDEOH DV ZHOO DV XVH RI À\ DVK DQG
analysis as well as consideration of marginal aggregates GGBS results in the increase of the strength at later stage
may give a better insight to explore the CGBM as a feasible DQG UHGXFWLRQ LQ WKH VKULQNDJH GXH WR WKH UH¿QHG SRUH
option to create sustainable road assets. VWUXFWXUHRIWKHKDUGHQHGJURXW 0XNKHUMHHHWDO
6. APPLICATION OF CGBM 8. CHALLENGES INVOLVED IN THE CGBM
The presence of the cementitious slurry in CGBM provides CGBM is prepared by means of allowing the grout slurry
a rut resistant, impermeable surface with protection against to penetrate within the air voids of open graded bituminous
RLO DQG IXHO VSLOODJH$W WKH VDPH WLPH LW HOLPLQDWHV WKH mix (OGBM) under the action of gravity. Hence OGBM
necessity of joint construction. In addition to these it and prepared grout slurry are the two essential aspects
requires much less curing period as compared to rigid of the CGBM. Therefore, the OGBM containing high
SDYHPHQWV 7KHUHIRUH VXFK SDYHPHQWV DOORZ TXLFN percentage air voids and the prepared grout slurry having
FRPPLVVLRQLQJ RI URDG IRU RSHQLQJ WR WUD൶F )XUWKHU LWV DGHTXDWH ÀRZDELOLW\ LV UHTXLUHG WR H൵HFWLYHO\ ¿OO WKH DLU
LQFUHDVHGVWL൵QHVVFRPSDUHGWRÀH[LEOHSDYHPHQWVPDNHV voids and avoid premature pavement failure.
it an ideal choice for areas subjected to high tyre pressure 7KH &RQVWUXFWLRQ RI VHPL ÀH[LEOH SDYHPHQW &*%0
DQG KHDY\ VWDWLF ORDG OLNH SDUNLQJ DSURQV DLUSRUWV EXV could be the susceptible to the situations where the air
terminals and similar heavily stressed areas. CGBM, YRLGVDUHQRWWKRURXJKO\¿OOHGZLWKJURXWVOXUU\PD\FDXVH
being a rut resistant mix may be used in toll plazas, airport the premature failures.
aprons and container yards including urban roads, which
are subjected to heavy static loading. In this regard, exercising the mixing of various possible
FRQVWLWXHQWVRIVOXUU\VXFKDVFHPHQWÀ\DVKVLOLFDIXPH
7. ADVANTAGES OF CGBM VDQG ZDWHU DGPL[WXUHV VXSHU SODVWLFL]HUV LQ GL൵HUHQW
Considering the widespread application of CGBM around proportions is a real challenge ensuring the most decisive
the world, it may prove to be an emerging sustainable criterion i.e., full depth penetration. To determine the
technology in road infrastructure development. The optimum proportion of all the constituents resulting in a
advantages of using CGBM surface in comparison to VXLWDEOHJURXWUHTXLUHVH[WHQVLYHDQGULJRURXVH൵RUWVLQWKH
conventional pavement are as follows: laboratory prior to its execution. This exercise possesses
LWVRZQVLJQL¿FDQFHEHIRUH¿QDOL]LQJWKHMREPL[IRUPXOD
i. Resistance to oil induced damages caused due to (mix design) as all the trial mixes of grout may not meet
fuel spillage the performance requirement.
ii. Resistance to permanent deformation
iii. Resistance to abrasion/wearing 9. SUMMARY OF THE PREVIOUS CGBM
iv. Resistance against moisture induced damages STUDIES
Y /RZHU WKHUPDO VXVFHSWLELOLW\ LQ FRPSDULVRQ WR
ÀH[LEOHSDYHPHQWV Past researchers have conducted laboratory studies on
YL ,PSHUPHDELOLW\DQGJRRGVNLGUHVLVWDQFHSURSHUW\ VWL൵QHVV WHQVLOH DQG FRPSUHVVLYH VWUHQJWK 0DUVKDOO
6WDELOLW\ WKHUPDO H[SDQVLRQ FRH൶FLHQW ORZ WHPSHUDWXUH
7KHVH DGYDQWDJHV HQDEOH &*%0 VXUIDFH WR WDNH FDUH fracture, fatigue properties of CGBM and found to show
RI VRPH RI WKH LQGLYLGXDO OLPLWDWLRQV OLQNHG WR FHPHQW satisfactory performance. Previous studies reveal properties
concrete and bituminous mixes. of the CGBM enhances as compared to the bituminous
mixes. However, the performance of the CGBM is not
)XUWKHUWRPDNHWKH&*%0PL[PRUHHFRQRPLFDOPDQ\ much clear in the comparison of dense graded bituminous
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REFERENCES Special Cement Grout. The Baltic Journal of Road and
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'KDQGDSDQL%3 0XOODSXGL56 'HVLJQ Introduction, design, and performance. Construction
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Bituminous Mixtures-a Review. Construction and 27. Hong, J., Wang, K., Xiong, Z., Gong, M., Deng, C.,
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JANUARY 2024

Volume: 52  Number: 01  Total Pages: 68

A view of Cable Stayed Bridge Across Waingangna River at Ambhora in

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DEVELOPMENT OF CORRELATION BETWEEN INDIRECT

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Obtained Code Obtained

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2. GRADATION OF AGGREGATES combinations of BC-1 and BC-2 are commonly employed

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Table 2 Middle Gradation of Aggregates used for Bituminous Concrete-1

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4. INDIRECT TENSILE STRENGTH (ITS) AND

The evaluation of moisture sensitivity in asphalt mixes

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The MR GHWHUPLQDWLRQ XWLOL]HG ERWK WKH $670 WHFKQLTXH

The MR holds considerable importance in understanding

Fig. 8 Interface of MR Testing Software

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Fig. 9 Test Sample of MR (Graph and values)

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Therefore, the developed Correlation gives out the

Therefore, the developed Correlation gives out the

5.1 Statistical Data Analysis

$129$ analysis was performed to assess the impact of

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PRACTICAL APPROACH FOR PRE-STRESSING IN

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3.2 Disadvantages/Limitations of PSC structures:

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help of set sTXDUHDQGPHDVXULQJVFDOH'L൵HUHQFH³S´LV 6.3 Tests on Equipment and Materials

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3UHVVXUH NJ Ram extension Reading /RFNLQJHQG5HDGLQJ

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0HDVXUHPHQWRI6OLSDW-DFNLQJ(QGDQG6LWWLQJ Note for Last Incremental Pressure: During stressing,

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LL 'U\LQJ6KULQNDJHFUDFNLQJ:LGHUGHHSHUFUDFNLQJ 6. CONCLUSIONS

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Table 1 Properties of the Open Graded Bituminous Mix OLNHFHPHQWFRQWHQWPRLVWXUHFRQWHQW¿OOHUPDWHULDOVLH