SPECIFICATIONS FOR

CONCRETE AIRFIELD PAVEMENTS

10/2011

AIRFIELD

TECHNICAL INSTRUCTION

FOREWORD

Military Airfields are strategic assets of Nation which need to be maintained and kept operational all the time. Aviation sector in the country has grown very rapidly in the 20th Century. With the introduction of lethal fighter aircrafts and very heavy transport aircrafts, we need to upgrade and modernize the airfields by adopting latest technologies, construction materials and mechanized construction methods to keep pace with growing requirement of security of the Nation.

MES is responsible for management of about 48 % of the air assets of the Nation and is one of our core competencies. I am certain that Technical

Instruction No 10/2011 on“SPECIFICATIONS FOR CONCRETE

AIRFIELD PAVEMENTS” will go a long way in providing necessary guidance to all stake holders viz Users, MES Executives, Planners, Designers, and Construction Agencies to plan, construct, upgrade and maintain our air assets.

Station: New Delhi (MC Badhani)

Lt Gen Dated: 03Oct 11 Engineer-in-Chief

PREFACE

1. Creation of aviation infrastructure for the AF, Navy, Coast Guard and the Army has been a challenging task, keeping in view the rapid progress in the technology offighters/bombers and transport aircrafts being inducted into the Services. Advancements in concrete paving technologies and joint sealants coupled with use of state of the art equipments can ensure quality construction with speed.

2. All the stakeholders, which include the ground executives, design, planning and survey officers involved with pavement works, need to continuously enhance the threshold of skills and competencies in this field. The Technical Instruction (TI No 10/2011) on “SPECIFICATIONS FOR CONCRETE AIRFIELD PAVEMENTS” aims at achieving this objective.

3. The TI was last issued in 1987. I am sanguine that the revised TI will enable all personnel, dealing with planning, designing and execution of pavement construction, in delivery of world class concrete pavements for military air bases in the country and abroad.

Station: New Delhi (RK Mattu) Maj Gen Dated :03 Oct 11 Director General Works

INDEX

Ser No Description Page No

1. Section-1: Materials 1-4 2. Section-2: Concrete Mix Design and Placing of Concrete 5-13 3. Section-3: Joints in Concrete Pavement 14-16 4. Section 4: Plants and Machinery 17-20 5. Section 5: Tests and Quality Control 21-25 6. Appendices: A to H 26-51 7. Annexure: I to V 52-66 .

1

TECHNICAL INSTRUCTION NO 10/2011

SPECIFICATIONS FOR CONCRETE AIRFIELD PAVEMENTS

SECTION-1: MATERIALS

1. Introduction.

1.1 TI 10/87 was introduced in 1987. The construction technology, plant and machinery have gone through a revolution phase in last 23 years. IS codes and IRC codes have also been amended. The ICAO manual on which the designs of pavement are based has also been amended. Although necessary amendments and policy letters have been issued from time to time, the amendments in the TI had become essential. This TI covers the materials and construction techniques involved in providing concrete pavements for runway, taxi tracks, aprons, hard standings, operational readiness platforms and floors for hangars/aircraft shelters. This TI does not include the structural design aspects of pavements, which depends on the local factors and condition of the sub-grade. The specification and techniques are to be followed strictly to improve quality of work. 2. Materials.

2.1 Cement: Cement used in the work should conform to one of the following standards:-

(a) IS: 8112 - Ordinary Portland Cement 43 Grade.

(b) IS: 12269 - Specification for High Strength Ordinary Portland Cement 53 Grade.

(c) IS: 12330 Sulphate Resisting Portland Cement. (If soluble salt like sulphate in soil is more than 0.5 per cent)

(d) IS: 1489 Pt-I Portland Pozzolona Cement(Fly ash content not more than 25 per cent by weight of OPC)

(e) Portland Pozzolona cement, IS:1489 (Flyash content not more than 25 per cent by weight of PC)

2.2 In case different type of cement is to be used, prior approval from Design Sub Dte, E-in-C’s Branch should be obtained after the design mix is finalized and record should be kept showing type of cement to be used for each slab. Two types of cement should never be mixed together or used in any one slab. Proper storage facilities to prevent deterioration of cement during storage due to climatic and other causes should be provided. Cement remaining in stores for more than three months from the date of manufacture must be retested before use and to be rejected, if it fails to conform to any of the requirements of the specifications. High strength cement shall be used for Rigid Overlays. Its 7 days compressible strength shall not be less than 330 Kg/ sq-cm i.e. it should conform to IS: 8112 (latest revision). However it is desirable to use HSC with 7 days compressive strength not less than 370 Kg/ sq-cm.

2

2.3 Fly Ash. Fly ash as per specification given in IS: 3812(latest revision) may be used as admixture. Decision to use fly ash should be taken at planning stage after identifying the source and carrying out necessary tests. Design mix using fly ash as per IS: 456(latest revision) should be approved by competent authority and recommendation for compaction and curing should be obtained from the agency preparing design mix. Extensive trials should be conducted at trial bay/length stage before incorporating fly ash as admixture to concrete.

2.4 Water.

2.4.1 Water for mixing concrete will ordinarily be obtained from a source which is used for drinking. Where water from such a source is not available, it will be ensured that it is clean and free from injurious quantities of acid, alcohol, salts, oil, organic matter or other impurities. Sample of water should be sent to laboratory for testing. The provisions laid down in clause 5.4 of IS: 456 (latest revision)be adhered to.

2.4.2 Arrangement should be made for the storage of water to ensure adequate supply at all times during execution of the work so that concreting and curing operations are not interrupted. Water stored for concreting should not be used for any other purpose. Storage tank should be cleaned on regular basis every fortnightly and sample should be tested in Govt approved Lab on quarterly basis.

2.5 Aggregates. Aggregates shall be natural materials conforming to IS: 383(latest revision) but with Loss Angels Abrasion value not more than 35 per cent. Aggregates shall be non-Porous, Hard, Strong, Durable, Clean and free from various impurities and adherent coating and shall not contain any deleterious materials exceeding the limits specified in the above IS and tested as per IS: 2386(latest revision). Grading of aggregate will be as shown in Appendix ‘F’.

2.5.1 Coarse Aggregates. Where coarse aggregates of a maximum size more than 20 mm are used, a separate bin shall be used e.g one bin to contain 20 mm maximum aggregates size and the other to contain aggregates of the higher maximum size. The proportion in which they are to be mixed to contain the desired grading has to be worked out in the field. Coarse aggregate should be obtained from integrated cone crushing plant having appropriate primary crusher, secondary crusher and vibratory screen. It is desirable that for wearing course, aggregates obtained from igneous rocks only be used.

2.5.2 Fine Aggregates. It shall consist of river sand, pit sand or crushed stone sand. Tests for slit, clay and loam shall be carried out as per Appendix ‘A’.

2.6 Grading and Handling of Aggregates.

2.6.1 Grading of Aggregates. Grading of coarse and fine aggregates shall be as per IS: 383(latest revision). Coarse aggregates and fine aggregates shall be mixed in suitable proportions to get the final mix, which shall be within the specified limits. A sieve analysis test of the mixed aggregates will be carried out at-least once a day at random and result recorded.

3

2.6.2 Handling of Aggregates. Stock piles shall be made immediately on receipt of aggregates. Aggregates from different sources and different grading shall not be stacked together. Separate size of coarse aggregates shall be stacked separately. In case the concrete is to be mixed in a central batch plant, site of such plant will be decided keeping in mind the interruptions to air and road traffic due to movement of tippers and the length of the circuit route. In that case all materials shall be stockpiled around mixing plant.

2.6.2.1 Aggregates shall be staked on a hard surface so as to exclude the possibility of soil or grass getting mixed. When stacked in close proximity, the stock piles shall be separated by bulk heads to prevent the aggregates mixing together. Special care will be taken to clean and wash the last layer of aggregates in contact with ground surface before use.

2.6.2.2 Before batching, the aggregates shall have been stockpiled for at least 48 hours to allow for draining of water, if wet. Adequate provision should be made for stock- piling aggregates to an extent sufficient to meet the needs of the work taking into account the availability of supplies and rate of delivery. Aggregate should be covered suitably after sample is taken for moisture content test to prevent ingress/escape of moisture.

2.7 Load Transfer Device. Dowel bars and tie bars are not being provided since single slab design is being followed. However same will be provided if specified in design.

2.8 Pre-molded Joint Filler. The joint filler shall be pre-moulded, compressive filler board, with high performance closed-cell material available in board form (HD 100)and shall comply with the requirements of ASTM –D3575 /IS Standards(latest revision), Pre-moulded joint filler shall be of the thickness as stated within a tolerance of ± 1.5 mm. It shall provided for the full width of slab between form-work.

2.9 Joint Sealing Compound. Poly-urethane/poly-sulphide cold joint sealant to be used conforming to BS 5212 (Part 2)/IRC SP-57 2010 having movement accommodation factor ±30%, flexible, resistance to age hardening, fuel resistance, heat resistance and durable with 10 years warranty. The hot applied sealing compound shall comply with the requirements of IS: 1834(latest revision). Fuel and heat resisting joint sealing compound complying with grade ‘B’ of the IS Code should be used. Before filling the sealant, polyethylene backup rod of suitable size shall be placed mechanically. Masking tape should be fixed on the sides to avoid spillage.

2.10 Polyethylene Back Up Rod. Alkali resistant and non staining polythene Back Up Rod shall be used in the joints. The diameter of rod should be ¼ times more than the joint width. It should be placed mechanically so that the depth is uniform. The bar should conform to ASTM C 1016-1994A, ASTM D 3575-1993 and ASTM D 5249-1992. Before placing the backup rod it should be free from moisture, dampness, oil stains paint and any type of loose aggregate.

4

2.11 Synthetic Fibre. Non circular synthetic fibre of length 12 mm, specific gravity 1.31 to 1.41, UV stable and alkali resistant ( as per ASTM C 1116-02 and ICAO AC 32) to be used up to 0.25% by wt of cement as per manufacturers specification, if specified in the design. Design mix to be prepared after incorporating fibres.

2.12 Curing Compound. Curing compounds shall contain sufficient flake aluminium in finely divided dispersion to produce the complete coverage of the sprayed surface with a metallic finish. The compound should become stable and impervious to evaporation of water from surface of the concrete within 60 min of application and shall be of approved type. The curing compound should have a water retention efficiency index of 90% in accordance with BS specification No 7542 and conformation with ASTM c 309-74. The curing compound shall not react with the concrete and the film or membrane shall not crack, peel or disintegrate within three weeks after application. Immediately prior to application, the curing compound shall be stirred thoroughly in its containers. The rate of spread should be as per manufacturer’s instructions (approx. 3-5

m2 / litr depending on the concrete surface)and shall be checked during the construction of trial length and subsequently whenever required by the engineer. Mechanical sprayer should be used for continuous agitation and mixing of compound during spraying.

5

SECTION-2: CONCRETE MIX DESIGN AND PLACING OF CONCRETE

3.0 Mix Proportions.

3.1 Mix Design. A mix will be designed based on flexural strength as given in design after taking into account the type of aggregates, plant and method of laying to give the desired workability, which will enable the concrete to be properly compacted to its full depth and finished to the surface tolerance specified. Details of concrete mix design, for rigid pavements are given in TI 12/87 and should be as per SP 23. Design mix shall be different for different type of cement and for use of admixtures in hot climate.

3.2 Water/Cement Ratio. The term water /cement ratio means the ratio by weight of water to cement in the mix expressed in decimal terms. The water to be taken into account for this purpose is that which is free to combine with the cement in the mix, including free water in the aggregates. This is over and above the water, which may be absorbed by the aggregates. The actual quantity of water to be added in the mix at any time will depend on the water cement ratio adopted as well as the difference between the actual and the saturation moisture content of the aggregates used. Site document shall be maintained for use of different w/c ratio on daily basis.

3.3 Cement Content. The minimum cement content for the mix corresponding to 4.5 MPa flexural strength in the field at 28 days is given as under:-

(a) When Ordinary Portland Cement (OPC) is used the quantity of OPC shall not be less than 400Kg/cum. In case fly ash (as per IS:3812-Part I) is blended at site, the quantity of fly ash shall be up to 20 per cent by total weight of cementitious materials and the quantity of OPC in such a blend shall not be less than 360 kg/cum. If this minimum OPC content is not sufficient to produce concrete of the specified strength, it shall be increased as necessary by the Contractor at his own cost. The OPC content shall, not exceed 425 Kg/cum of concrete.

(b) In the case of factory produced PPC, (with fly ash content restricted to 25 per cent), the total quantity of cementitious material (OPC+ fly ash) shall not be less than 425 kg/cum. In case the specified strengths are not achieved, the quantity of PPC shall be increased as necessary by the Contractor at his own cost.

3.4 Trial Mix. Trail mixes should be made and beams tested for their flexural strength. For each trial mix, nine preliminary test beams should be made and tested in accordance with IS: 516. For compaction in the moulds of beams, Appendix ‘B’ will be followed. Three of these beams shall be tested for seven days and three 28 days flexural strength. If the differences between the highest and lowest values at 28 days strength from any trial mix is more than 15% of the average strength of three beams, the test is to be discarded and a further trial mixes shall be prepared. The mix giving the design flexural strength will be approved. Nine preliminary test cubes will also be made of the same approved mix used for casting beam. Three cubes will be tested to find the corresponding crushing strength of the concrete at seven days and three others at 28 days. The remaining three beams and three cubes, if the mix is finally approved, will be

6

preserved carefully for one year from the completion of work for test or any subsequent check. Crushing strength of concrete arrived at thereafter be specified for testing and acceptance of concrete in field. For testing and acceptance of quality concrete for airfield pavements, refer TI 16/87.

4.0 Preparation of Base.

4.1 Before fixing the form works for laying concrete, the base shall be checked for proper compaction density and levels and record of the same shall be kept. Base shall be laid using paver with sensor. Whenever specified, approved standard water proof, wrinkle free craft/polyethylene sheeting (minimum 400 micron thick) without puncture shall be laid to prevent absorption of water for the concrete mortar. Before placing the membrane, the surface shall be cleaned of all the extraneous material using air compressor. Where-ever overlap is required, minimum overlap shall be 300mm. The damaged/punctured sheet should be replaced. In case of overlays, the existing surface shall be kept moist in saturated condition. Important aspects about sub-grade, sub-base and base have been discussed at Appendix ‘G’ attached.

5.0 Trial Bays/Trial Lengths.

5.1 Trial Bays. Before commencement of the work, where paver cannot be used a trial bay of 3.5X3.5 meter square, of the approved concrete mix shall be laid at suitable place as soon as possible before the actual concrete pavement work is to start. The method of mixing, spreading, curing and compacting shall be the same as laid down in the specification for work. At-least three cores shall be cut when the concrete is seven days old, in order to determine the degree of compaction achieved. Alternately the concrete shall be broken and cut by pneumatic hammer or a pick-axe and a saw. Should any of cores or the cut portion show honey-combing in the concreting, a further trial bay shall be laid after improving the techniques of spreading and compaction and shall be tested as before. Needle vibrator, screed type of vibrator and paver to compact the pavement concrete shall be used as planned for the actual execution. On no account should the cut portion of the sample concrete exhibit honey–combing. When the water cement ratio for the mix has been worked out for achieving the definite strength, it will result in reduced aggregate/ cement ratios and reduce the unit yield of the concrete. However extreme care shall be exercised not to exceed the specified Water Cement Ratio. This will be done by forbidding use of under-graduated receptacles and preventing spillage. The frequency of the vibrator plays an important role in the efficiency of compaction and it shall be checked at frequent intervals. Further trial bays shall be laid and degree of compaction tested as before until the method of spreading and compaction has been so improved that the cores or cut portions do not show honey-combing. The trial bays should also be given the described surface finish as described in Para 10.

5.2 Trial Length. The trial length shall be constructed at least 14 days in advance of the proposed date of commencement of work. At-least 30 days prior to the construction of the trial length, the contractor shall submit for the Engineer’s approval a detailed Method Statement giving description of the proposed material, plant, equipment and construction methods. All the major equipment like paving train, batching plant, tippers, etc., proposed in the construction are to be approved by the engineer before

7

their procurement. The trial length should be constructed away from carriage way. The Engineer-in-charge shall also approve the location and length of trial construction which shall be a minimum of 60 m length and for full paver width of the paver. The trial length shall contain the construction of at least one transverse construction joint involving hardened concrete and freshly laid subbase. The construction of trial length will be repeated till the contractor proves his ability to satisfactory construct the pavement in subsequent trials. The hardened concrete shall be cut over 3 m width and reversed to inspect the bottom surface for any segregation taking place. The length shall be constructed after making necessary change in the gradation of the mix to eliminate segregation of the mix. The lower surface shall not have honey-combing and the aggregate shall not be held loosely at the edges.

6.0 Form Work.

6.1 Steel Forms.

6.1.1 All side forms shall be of mild steel except for curves having a radius of less than 45 meters, which may be of wood. The steel forms shall be of M.S. Channel section. Depth of side form shall be equal to the thickness of the pavement.

6.1.2 A side form shall have a length of at-least 3 meters in case of longitudinal joints except on curve of less than 45 meters radius where short length may be used. In case of transverse joint, a full length of bulkhead shall act as form work. When set to grade and stacked in place, no deviation of the top surface from the specified level shall be allowed.

6.1.3 The method of connection between the two lengths of forms shall be such that the joints formed are free from play or movement in any direction. Use of bent, twisted or worn out forms shall not be permitted. At least three stake pickets for bracing pins or stakes shall be provided for each 3 meters of the forms. The bracing and support must be adequate to prevent springing of the forms under the pressure of the concrete or weight or thrust of light machinery (like vibrator screed) operating on the forms. Separate rails are to be provided with adequate fixing arrangements if mechanical paver is used for laying the pavement slab. While removing the steel forms, care should be taken to withdraw them gradually so that edges of the slabs are not damaged. In no case, the form will be nailed to existing/adjacent concrete surface

6.2 Wooden Forms.

6.2.1 Wooden forms may be used only for curves having a radius of less than 45 meters. Wooden forms shall have smooth surface on inner side and shall have a minimum base width of 10 cm thick for slabs upto 20 cm thick and a minimum base width of 15cm for slabs over20 cm thick and their depth shall be equal to thickness of the pavement at the corresponding edges.

6.2.2 Forms shall be held by stakes set at intervals not exceeding 2 meters and by placing two stakes, at each joint. The forms shall be firmly nailed or secured to the side stakes. And shall be securely braced as necessary to ensure that no movement results from the pressure of the impact of the vibrator or temper during finishing of the surface. The forms shall be caped along the inside upper edge with 5 cm angle iron. The edge

8

shall be suitability recessed so that the outer face of the angle iron is flush with the upper and inner face of the wooded forms. It is recommended to prepare angle iron and MS steel form specific to curve rather than using wooden forms.

6.3 Setting of Forms.

6.3.1 Setting of forms shall be done according to the slab plan and concreting shall not commence until the setting of the forms is approved.

6.3.2 Forms shall be set in advance to a length sufficient for at least one day’s concreting and shall not be removed until at least 12 hours after the laying of the concrete. Care must be taken in setting out the side forms to ensure that the bar width shown in the drawing are strictly adhered to. The trueness of the formation shall be checked by the means of 3m straight edge and precision level equipment and any deviation greater than 1.5mm shall be rectified. No deviation from straight edge shall, however, be permitted at the joints. Proper shuttering oil shall be applied to the form to get good finish. For more details refer IS: 14687.

7.0 Batching and Mixing.

7.1 All the ingredients of concrete shall be batched by weight by combined batching and mixing plants. Power driven mechanical concrete mixers of adequate capacity with water measuring devices as per IS: 1791 and IS: 12119 in conjunction with weigh batchers shall be used. Standby plant will be catered for to avoid disruption of the works.

7.2 A small quantity of water will be added before loading of aggregate and cement. The remaining water shall be added during the mixing operation. The mixing will be done for atleast two minutes and until a uniform colour and consistency is achieved. The method of batching should be made fool proof. Batching of water by buckets, drums or tins shall be strictly prohibited.

7.3 Quantity of concrete mixed in any one batch shall not exceed the rated capacity of the mixer. The drum of the mixer should be completely emptied before ingredients for the next mix are charged into it. Concrete mix as above shall not be modified by addition of water or otherwise in order to facilitate handling or for any other purpose.

7.4 On cessation of work and during other stoppages exceeding 20 minutes, the mixer and the other equipment/accessories used for handling wet mix shall be thoroughly washed with clean water. Blades in the drum of the mixer which are worn down 20 mm or more in depth shall be replaced with new blades.

8.0 Hauling Placing and Compaction of Concrete.

8.1 Hauling/Transportation of concrete

8.1.1 Freshly mixed concrete from central batching plant shall be transported to the paver site by means of tippers or transit mixers of sufficient capacities of approved design in sufficient numbers to ensure a constant supply of concrete. Tarpaulin covers shall be used for protection of concrete against weather. The tippers shall be capable of maintaining mix concrete in a homogeneous state and discharging the same without

9

segregation and loss of cement slurry. The feeding to the paver is to be regulated in such a way that paving is done in an uninterrupted manner with uniform speed throughout the day’s work.

8.2 Placing of Concrete.

8.2.1 Concrete shall be transported without delay and incorporated in the works before initial setting time as per clause 13.2 of IS: 456- 2000 from the time of discharge from the mixer unless special transportation devices are employed. Temperature of concrete must

be below 35⁰C. Concrete shall be placed and spread to such a depth that when compacted and finished, it shall conform to the grade and cross section specified in the plan to ensure the minimum slab thickness shown on the drawing to be obtained at all points.

8.2.2 In order to obtain adequate compaction, the concrete shall be spread so as to stand proud of the finished level and produce a surcharge of 20% of the required slab thickness.

8.2.3 Concrete shall be placed in such a manner as to require as little handling as possible. Spreading, compacting and finishing (except final boom/belt finishing) operations shall be completed within a period not exceeding initial setting time from the time the mixing starts. In case of dry and hot weather, this time will not exceed 35 minutes. Concrete shall be placed around manholes and other structures after these have been brought to the correct alignment.

8.3 Compaction of Concrete.

8.3.1 Compaction shall be carried out by electrically operated needle and screed vibrators as stipulated hereafter. Needle vibrators should be used all over the area for obtaining initial compaction of the concrete. These should be of diameter not less than 4.5cm. If the vibrators are pneumatic, the pressure must not be below 4kg/cm2. If electrically operated, they should have minimum frequency of 3500 impulses per minute. Minimum number of petrol driven vibrators as specified by the Engineer-in-Charge with minimum frequency of 3500 impulses per minutes shall be provided at each work site as a standby arrangement. The vibrator shall conform to IS: 2505/1968, 2506/1968 and IS: 4656.

8.3.2 There should be at least three needle vibrators working in one day. Vibrating screed consisting of a steel section or timber section of not less than 7 cm width and with a vibrator mounted thereon shall follow needle vibrators to obtain full compaction. The face of wooden tampering edge of the screed shall be lined with an M.S plate rigidly fixed by means of counter sunk screws. Where screed vibrator are used for compaction, a stand by unit shall always be maintained ready for use, should the other one go out of order. Where electrically driven vibrators are employed, a standby pneumatic unit shall be kept ready for use in case of power failures. Under no circumstances, honeycombing of concrete at joints or elsewhere shall be permitted.

8.3.3 When using vibrating screed for compaction, it should not be dragged over the concrete. During the initial passes, it shall be lifted to the adjacent forward position in short steps. Subsequently, it shall be slowly slide over the surface with its axis slightly

10

tilted away from the direction of sliding and the operation repeated until a close, dense surface is obtained. Concreting shall be carried out in one operation between the expansion joints and construction joints without any break at the dummy joints.

8.3.4 Use of slip form pavers with independent units designed to spread, consolidate, screed, float finish and texture the freshly placed concrete in one complete pass of the machine is mandatory for large works. Paver shall be equipped with electronic sensors and controls to grade from either side of machine. Slip form/fixed form paver to be used as per the guidelines given in MORTH(Road Wing) Specifications clause no 602.9.5 and 602.9.6. 9.0 Finishing of Concrete. 9.1 Surface Finish.

9.1.1 Immediately after the compaction of concrete but before the concrete has hardened (within 90 min of placing concrete) and while the concrete is still in a plastic state, the pavement surface shall be inspected for irregularities with a profile checking template and any needed correction made by adding or removing concrete by means of long handled floats and scraping straight edge followed by further compaction and finishing. The long-handled floats may be used to smoothen and fill in open-textured areas in the pavement surface but the final finishing is to be made with scraping straight edges.

9.1.2 The scraping straight edges are to be 3 meters long with flexible handles long enough to reach the other side of slab when operated from inside of pavement. They are to be placed parallel to the form at the side of the pavements and worked backwards and forward uniformly across the width of the slab. After this operation has been completed and the surface has been brought up to the required finish, the straight edges are to be moved forward by not more than half their length and this process repeated. The straight edge testing and re-floating is to continue until entire surface:-

(a) Is free from observable departure from the straight-edge. (b) Conforms to the required levels and cross section. (c) When the concrete has hardened, it shall conform to the specified surface levels.

9.1.3 The foregoing work is to be carried out while the concrete is still plastic and workable and in such time sequence as to ensure the removal of water of laitance from the surface. After the concrete has sufficiently hardened to about 12 hours and not later than 24 hours, the surface shall be tested again for high spots. All high spots shall be marked and those exceeding 3 mm shall be ground down immediately. Care shall be taken to ensure that the grinding does not in any way damage the concrete surface. 9.1.4 The final surface finish is to be such that when tested with 3 meters long straight edge placed anywhere within the same or adjoining slab in any direction on the surface, there is no gap greater than 3 mm between the bottom of the straight edge and the surface of the pavement. This will not be required if slip form paver with guide wires is used at appropriate paving speed and sensors.

11

9.2 Belting. Just before the concrete becomes non plastic, the surface shall be belted with a two –ply canvas belt not less than 20 cm wide and at least 1 meter longer than the width of the slab. Hand belts shall have suitable handles to permit controlled uniform manipulation. The belt shall be operated with short strokes transverse to entire line of pavement and with a rapid advance parallel to the centre line. This will smoothen the marks of straight edge.

9.3 Brooming.

9.3.1 After belting and as soon as surplus water, if any has arisen to the surface, the pavement shall be given a broom finished with an approved steel or fiber broom not less than 45 cm wide. The broom shall be pulled gently transversely and in straight strokes over the surface of pavement from edge to edge. Adjacent strokes shall be slightly over-lapped. Brooming shall be perpendicular to the centre line of the pavement and so executed that the corrugation thus produced will be uniform in character and width and not more than 1.5 mm deep. No pressure will be applied to the broom and scoring will be done under the weight of the broom head without tearing the surface.

9.3.2 Brooming shall be completed before the concrete reaches such a state that the surface is likely to be torn of or unduly roughened by the operation. The broom surface shall be free from porous or rough spots, irregularities, depressions, and pot-holes which may be caused by accidental disturbing of particles of course aggregate embedded near the surface.

9.4 Edging. Immediately after belting/brooming has been completed, the end edges of the slab and edges of expansion joints should be carefully finished with an edging tool of 6 mm radius and the pavement edges shall be left smooth and true to line.

9.5 Honey-Combing. As soon as the side form are removed, any minor honey-combed areas shall be filled with mortar composed of one part of cement to two parts of fine aggregates. Major honey-combed areas or segregated concrete or other defective work or areas damaged by removal of the forms of concrete, damaged by rain or any other reasons whatsoever will be considered as defective work and shall be removed and replaced. The total areas of honey-combed surface more than 2.5 sq cm each shall not exceed 4%area of the slab side. Honey-combing exceeding 300 sq cm in area at any one location shall be considered as major honey-combing.

9.6 Marking on Slabs. Every slab shall bear an impression not exceeding 3mm in depth with text size of min 40mm in height comprising the number allotted to the slab and the date on which it was laid. This impression shall be formed when concrete is green so as to leave permanent mark of setting. In case paver is used one or all these action are done by a separate attachments. However checks as specified must be carried out and reasons for defects be found before the work is progressed further.

10. Curing and Protection of Concrete.

10.1 Initial Curing.

10.1.1 Immediately after the surface texturing, the surface and sides of the slab shall be cured by the application of approved resin-based aluminized reflective curing compound

12

which hardens into impervious film or membrane with the help of a mechanical sprayer. Curing compound shall contain sufficient flake aluminum in finely divided dispersion to produce a complete coverage of the sprayed surface with a metallic finish. The compound shall become stable and impervious to evaporation of water from the surface of the concrete within 60 minutes of application and shall be approved type. The curing compounds shall have a water retention efficiency index of 90 percent in accordance with BS Specification No. 7542 or ASTM-C-309-81, Type II/ relevant IS/IRC code.

10.1.2 The curing compound shall not react chemically with the concrete and the film or membrane shall not crack, peel or disintegrate within three weeks after application. Immediately prior to use the curing compound shall be thoroughly agitated in its containers. The rate of spread shall be in accordance with the manufacturer’s instructions and should be checked during the construction of the trial length and subsequently whenever required by the Engineer-in-charge. The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation and mixing of the compound during spraying. To give continuous covering curing compound may be spread in two layers.

10.1.3 In addition to spraying of curing compound, the fresh concrete surface shall be protected for at least three hours by covering the finished concrete pavement with tents as described in Clause 602.7.2 of MORTH (Road Wing) during adverse weather conditions as described by the Engineer-in-charge. After three hours, the edges of pavement shall be covered by moist hessian cloth in two layers and the same then be kept moist for entire period of curing. All damaged/torn hessian shall be removed and replaced by new hessian cloth on regular basis. The hessian shall be so placed that the entire surface of the edge of the slab are completely covered. It shall be placed and weighed down as to cause them to remain in intimate contact with the surface covered. If it becomes necessary to remove hessian for any reason, the concrete slab shall not be exposed for a period more than half an hour. If hessian is obtained in strip, the strip shall be laid to overlap at least 150 mm.

10.2. Final Curing

shall be After Initial curing and joint cutting a system of transverse and longitudinal dykes of clay about 50 mm high shall be laid and shall be immediately covered with blanket of sandy soil free from stones to prevent the drying up and cracking of clay. The rest of slab shall then be covered with sufficient sandy soil so as to produce a blanket of earth not less than 37 mm deep, after wetting. The earth covering shall be thoroughly wetted while it is being placed on the surface and against the side of the slab and kept thoroughly saturated with water for 28 days and then covering shall be removed and the pavement shall be cleaned and swept. If the earth covering becomes displaced during the curing period, it shall be replaced to the original depth and restarted.

10.2.2. Concrete shall not be subjected to any load or weight of any plant until at-least 14 days after laying. Concentrated loads or sharp objects like iron wheels of concrete mixer and any vehicular traffic including construction traffic will not be allowed on the concrete surface for 28 days. Contractor will appoint chaukidars at his own expenses to prevent workmen, cattle etc straying on the pavement concrete for a minimum of three

13

days from the date of laying. For extreme weather conditions IS: 7861 Part I and Part II should be referred.

10.3 Concreting During Monsoon. When concrete is being placed during monsoon and when it may be expected to rain, sufficient supply of tarpaulin or other water proof cloth shall be provided along the line of the work. Any time when it rains, all freshly laid concrete which had not been covered for curing purpose shall be adequately protected. Any concrete damaged by rain shall be removed and replaced. If the damage is limited to texture, it shall be retextured in accordance with directives of the engineer.

10.4 Concerting in Hot Weather. No concerting shall be done when the concrete temperature is above 350 C. Besides, in adverse conditions like high temperature, low relative humidity, excessive wind velocity, imminence of rains etc., if so desired by the Engineer, tents on mobile trusses may be provided over the freshly laid concrete for a minimum period of three hours as directed by the Engineer-in-charge. The temperature of the concrete mix on reaching the paving site shall not be more than 300 C. To bring down the temperature, if necessary chilled water or ice flakes should be made use of.

10.5 Concreting in Extreme Cold Climate. No concreting shall be done when the concrete temperature is below 50C and the temperature is descending. However, where concrete is to be deposited at or near freezing temperature, precautions shall be taken to ensure that at the time of placing, it has a temperature not less than 5 0C and that the temperature of the concrete shall be maintained above 40C until it has thoroughly hardened. When necessary, concrete ingredient shall be heated before mixing but cement shall not be heated artificially other than by the heat transmitted to it from other ingredients of the concrete. Stock piled aggregate may be heated by the use of dry heat or steam. Aggregate shall not be heated directly by gas or on sheet metal over fire. In general the temperature of aggregate or water shall not exceed 650C. Salt or other chemicals shall not be used for the prevention of freezing. No frozen material or material containing ice shall be used. All concrete damaged by froth shall be removed. It is recommended that concrete exposed to freezing weather shall have entrained air and the water content of the mix shall not exceed 30 liters per 50 kg of cement.

14

SECTION-3: JOINTS IN CONCRETE PAVEMENT

11.0 Joints in Concrete Pavement.

11.1 Joints shall be of the types and dimensions specified and shall be located in all cases as indicated on the drawings. Location of joint should be transferred accurately on site as per stipulated dimension. The sawing of joints shall be carried out with diamond studded blades soon after the concrete has hardened to take load and vibration of the sawing machine and working personal without damaging texture of the pavement and without disturbing edges. Sawing operation may commence as early as 12 hours from the placing of concrete but after the concrete is suitably hardened. The various types of joints in concrete pavement are described in the following paragraphs.

11.2 Dummy joints. The dummy joints shall be 6-8 mm wide and shall extend vertically from the surface of the slab to a depth equal to 1/3 to 1/4 of the thickness of the slab. The initial slot of 3mm to be formed by sawing the concrete with a diamond bit, high rotation frequency joint cutting machine of approved design as early as 12 hours of placing under moderate climatic conditions and when the concrete has sufficiently hardened. Under extreme cold condition, this period may be suitably increased based on experience. Joint to be widened to specified width, in increments of 2mm. In all cases, except where cutting is done with saw, the joint edges shall be bull nosed. Care shall be taken that the edges of the joints are not damaged. The edge will not stand proud of the concrete slab. In case of rain or sudden storm, the work can be concluded at the location of the dummy joint but the joint then will be formed as a construction joint.

11.3 Construction Joints. The construction joints shall be straight and vertical through full thickness of the slab. The vertical edge of the concrete on the side of the joint shall be treated with a coat of lime wash or bituminous paint before the adjacent bay is laid. Joints should be cut to its width of 8-10mm and up-to depth of 25 mm to receive the sealing compound and backup rod. The groove will be formed in the same manner as that for a dummy joint. The edges of the groove shall be bull-nosed and will not stand proud of the concrete surface.

11.4 Expansion Joint.

11.4.1 The expansion joints shall be straight, extend through the full thickness of the slab and shall be of the shape and dimensions shown on the drawings. The slab edges adjacent to the joint shall be formed truly vertical. The joint shall be filled with 20-25mm thick approved joint filler board as specified, shall be placed in position and properly supported.

11.4.2 The groove to receive the sealing compound may be formed by placing suitable wooden or metal strip of specified width and required depth coated with soft soap or other suitable lubricant over the joint filler board and shall be kept in position when concreting the adjoining slab. The top of this strip is to be flush with the finished concrete surface. The edge of the groove shall be bull-nosed when it is withdrawn after approximately half an hour. Care shall be taken that the edges of the grooves are not damaged and that no bridging or plugging of the joint with concrete occurs; also that the

15

joint is of uniform width from top of slab to top of the joint filler. Alternatively, in place of metal/wooden strip, joint filler board of full depth with pre cut at specified depth be placed while concreting adjacent slab and top pre cut portion -+be subsequently removed to form groove for receiving joint sealing compound and backup rod.

12. Sealing of Joints.

12.1 All joints shall be sealed as soon as practicable after 28 days of placing of the slabs. The joints shall be finished flush with finished concrete surface, if the sealing of the joints is done in winter. Level of sealant should be 3-5 mm below the concrete surface if filling is done during summers. After the sealing compound has hardened the excess sealing compound, if any adhering to the slab outside the joints shall removed by scraping or otherwise and the surface left clean. The pavement shall be opened to the traffic only after completion of joints sealing over the entire pavement.

12.2 Joint Sealing Compound.

12.2.1 Either of the Polysulphide or Polyurethane joint sealant from approved source shall be used in new rigid pavement. The criteria for selection of the joint sealant will depend on the minimum performance guarantee of ten years offered by the firm. The technical specification of the cold applied joint sealants (irrespective of whether polysulphide or polyurethane) should meet the requirement mentioned in BS-5215, BS 4254 and EN-141875-2003 (for hydrolysis/water resistance test). In addition, the movement accommodation factor (MAF) of the sealant should be minimum ± 30 %.

12.2.2 In old pavements with residual life more than 5 years, the existing sealant compound should be raked out of the existing joints by special tools like cutting blades / machines (use of hammers is prohibited as it damages the edges) and joint cleaned thoroughly with application of compressed air. Any polysulphide/polyurethane joint sealant, which offers minimum ten years performance guarantee and conforming to specifications, shall be incorporated in works.

12.2.3 Where the edges of the joint are not damaged, the dummy and construction joints should be widened by 2 mm (from present 6 mm to 8 mm in case of dummy joints and from 10 mm to 12 mm in case of construction joints) by using joint cutting blades of appropriate size in order to have straight, clean and smooth edges to achieve proper bond between sealant and the concrete surface. If width of the dummy and construction joints is more than 6 mm and 8 mm respectively, widening is still required by at least 2 mm to achieve proper bond.

12.2.4 When the quantity of application is more than three thousand (three thousand) running meter of joint sealants (either polysulphide or polyurethane), the same will be done only by mechanical means. No manual application will be permitted and the same shall be incorporated in the tender documents.

12.2.5 The selection and application of joint sealant should be on a ‘Supply and Apply’ basis. i.e. the firm shall supply the material and employ their trained applicators to apply it. Quality tests as specified will be done for every five MT/for each lot from a reputed testing laboratory who has the NABL accreditations.

16

12.2.6 The joint shall be made dry, free of dirt and vacuum cleaned by a mechanical device, as well as free of oil, vegetation and other debris. Two coats of primer should be applied with a thin brush by the forward and backward movement at an interval of 30 minutes before pouring the sealant. (i.e. one side will be brushed twice, forward and backward) with adequate quantity of primer.

12.2.7 The application temperature of the sealant should be strictly adhered to as per manufacturer’s instruction. The pneumatic pressure, while application should not be too high which causes a high speed flow and results in over filling of joints. Too low pressures forms small bubbles, which can be starting point for cohesive failures. Every air bubbles that appear on the surface should be immediately popped with a leveling tool.

12.2.8 In case of old pavements with residual life less than 5 years, hot applied Joint sealing compound may be used. Hot applied joint sealing compound shall conform to grade ‘B’ of IS: 1834-1984 ‘Specification for Hot Applied Sealing Compound for Joints in Concrete’. Recommended brand of the primer shall be obtained from the firm supplying the joint sealing compound so that sealing adheres properly to the concrete surface. Before commencing joint sealing operations, the following shall be ensured:-

(a) The groove extends fully across the bay between consecutive longitudinal joints in the case of transverse joints, and continuous in case of longitudinal joints. (b) No concrete or foreign matter is left in the groove.

(c) In case of expansion joints, the filler board is exposed to the full depth of the joints. All joints shall be thoroughly cleaned out of dust and pebbles by compressed air or hand tools.

(d) Cutting saw of suitable size should be used to clean the side of the joints.

(e) Backup rod/bond breaker has been inserted to the even and appropriate depth.

(f) Masking tape has been fixed on the sides.

12.2.9 The cleaned and prepared joints shall be primed with primer conforming to IS: 6509-1972 at the rate 6 liters per 10 sqm and filled with approved sealing compound in accordance with the manufacturer instructions. Great care will be taken to ensure that sealing compound is not over heated beyond specified temperature, and there is no spilling on the slab outside the joints while filling them. Any deteriorated sealing compound observed after pouring due to over heating or any cause attributable to negligence or bad workmanship, shall be removed and refilled. Before applying hot or cold applied joint sealant, masking tapes should be fixed on the sides to avoid spillage on concrete surface.

17

SECTION-4: PLANTS AND MACHINERY

13.0 Plants and Machinery.

13.1 Batch mixing Plant. The batch plant shall include minimum four bins, with automatic weighing hoppers, and scales for the fine aggregate and for each size of coarse aggregate. If cement is used in bulk, a separate scale for cement shall be included. The weighing hoppers shall be properly sealed and vented to preclude dust during operation. Approved safety devices shall be provided and maintained for the protection of all personal engaged in plant operation, inspection and testing. The batch plant shall be equipped with a suitable non resettable batch counter which will correctly indicate the number of batches proportioned.

13.2 Mixers.

13.2.1 Mixers shall be pan type, reversible type or any other mixer capable of combining the aggregate, cement and water into a thoroughly mixed and uniform mass within the specific mixing period and discharging the mixer, without segregation. Each stationary mixer shall be equipped with approved timing devices which will automatically lock the discharge lever when the drum has been charged and release it at the end of the mixing period. The device shall be equipped with a bell or other suitable warning device, adjusted to give a clearly audible signal each time the lock is released. The mixer shall be equipped with a suitable non-resettable batch counter which shall correctly indicate the number of batches mixed.

13.2.2 The mixers shall be cleaned at suitable intervals. The pickup and throw over blades in the drum shall be repaired or replaced when they are worn down 20 mm or more. The Contractor shall have available at the job site, a copy of the manufacturer design showing dimensions and arrangements of blades in reference to original height and depth and provide permanent marks on blades to show points of 20 mm wear from new conditions. Drilled holes of 5 mm diameter near each end and at midpoint of each blade are recommended. A water tank with suitable control should be fitted with the mixer to strictly ensure W/C ratio. Batching Plant shall be calibrated in the beginning and thereafter at suitable interval not exceeding one month. An air conditioned centralized control cabin shall be provided for automatic operation of the equipment.

13.3 Transportation. Freshly mixed concrete from the central batching and mixing plant shall be transported to the paver site by means of transit mixers of suitable capacity and approved design in sufficient number to ensure a constant supply of concrete. The feeding of the paver is to be regulated in such a way that the paving is done in an uninterrupted manner with a uniform speed throughout the day’s work.

13.4 Paving Equipment. The concrete shall be placed with an approved fixed form or slip form paver with independent units designed to spread, consolidate, screed, float finish, texture and cure the freshly placed concrete in one complete pass of the machine in such a manner that a minimum of hand finishing will be necessary and so as to

18

provide a dense and homogenous pavement in conformity with the plans and specification. The paver shall be equipped with electronic controls to control/sensor line and grade from either or both side the machine.

13.4.1 Construction by Fixed Form Paver. The fixed form paving train shall consist of separate powered machines which spread, compact and finish the concrete in a continuous operation. The concrete shall be discharged without segregation into a hopper spreader which is equipped with means for controlling its rate of deposition on to the base. The spreader shall be operated to strike off concrete up to a level requiring a small amount of cutting down by the distributor of the spreader. The distributor of spreader shall strike off the concrete to the surcharge, adequate to ensure that the vibratory compactor thoroughly compacts the layer. If necessary, poker vibrators shall be used adjacent to the side forms and edges of the previously constructed slabs. The vibratory compactor shall be set to strike off the surface slightly high so that it is cut down to the required level by the oscillating beam. The machine shall be capable of being rapidly adjusted for changes in average and differential surcharge necessitated by change in slab thickness or cross fall. The final finisher shall be able to finish the surface to the required level and smoothness as specified. Care shall be taken to avoid bringing up of excessive mortar to the surface by over working.

13.4.4 Construction by Slip Form Paver.

13.4.4.1 The slip form paving train shall consist of power machine which spreads, compacts and finishes the concrete in a continuous operation. The slip form paving machine shall compact the concrete by internal vibration and shape it between the side forms with either a conforming plate by vibrating and oscillating finishing beams. The concrete shall be deposited without segregation in front of slip form paver across the whole width and to a height at all times in excess of the required surcharge. The deposited concrete shall be struck off to the necessary average and differential surcharge by means of the strike off plate or a screw auger device extending across the whole width of the slab. The equipment for striking-off the concrete shall be capable of being rapidly adjusted for change of the average and differential surcharge necessitated by change in slab thickness or cross fall.

13.4.4.2 The level of the conforming plate and finishing beams shall be controlled automatically for the guide wires installed by sensors attached at the four corners of the slip form paving machine. The alignment of the paver shall be controlled automatically from the guide wire by at least one set of sensor attached to the paver. The alignment and level of ancillary machines for finishing, texturing and curing of the concrete shall be automatically controlled relative to the guide wire or to the surface and edge of the slab.

13.4.4.3 Slip-form paving machines shall have vibrator of variable output with a maximum energy output of not less than 2.5 KW per meter width of slab per 300 mm depth of slab for a laying speed up to 1.5 m per minutes or pro data for higher speeds. The machines shall be of sufficient mass to provide adequate reaction during spreading and paving operations on the traction units to maintain forward movement during the placing of concrete in all situations.

19

13.4.4.4 If the edges of the slip formed slab slump to the extent that the surface of the top edge does not comply with the requirements of clause 602.14 of MORTH orange book, then special measures approved by the Engineer-in-charge shall be taken to support the edges to the required levels and work shall be stopped until such time as the contractor can demonstrate his ability to slip from the edges to the required level.

13.5 Construction by Hand Guide Method. Area in which hand-guided method of construction becomes indispensable shall be got approved by the Engineer-in-charge in writing in advance. Such work may be permitted only in restricted areas in small lengths. Work shall be carried out by skilled personnel as per methods approved by the Engineer. The acceptance criteria regarding level thickness, surface regularity, texture finish, strength of concrete and all other quality control measures shall be the same as in the case of machine laid work.

13.6 Use of guide wires. Where slip form paving is proposed, a guide wire shall be provided along both sides of the slab. Each guide wire shall be at a constant height above and parallel to the required edges of the slab as described in the contract/drawing within a vertical tolerance of ± 3 mm. Additionally one of the wires shall be kept at a constant horizontal distance from the required edge of the pavement as indicated in the contract/drawing within a lateral tolerance of ±10 mm. The guide wires shall be supported on stakes not more than 8 m apart by connectors capable of fine horizontal and vertical adjustment. The guide wire shall be tensioned on the stakes so that a 500 gram weight shall produce a deflection of not more than 20 mm when suspended at the midpoint between any pair of stakes. The ends of the guide-wire shall be anchored to fixing point and not on the stakes. The stakes shall be positioned and the connectors maintained at their correct height and alignment from 12 hours on the day before concreting takes place until 12 hours after finishing of the concrete. The guide wire shall be erected and tensioned on the connectors at any section for at-least 2 hours before concreting that section. The contractor shall submit to the Engineer for his approval of line and level of the stakes and connectors which are ready for use in the length of pavement to be constructed by 12 hours on the working day before the day of construction of the slab.

13.7 Surface Texture Equipment. After the final regulation of the slab and before the application of the curing membrane, the surface of concrete slab shall be brush textured in a direction at right angles to the longitudinal axis of the carriageway. The brushed surface texture shall be applied evenly across the slab in one direction by the use of wire brush not less than 450 mm wide but longer brushes are preferred. The brush shall be made of 32 gauge tape wires grouped together in tufts spaced at 10 mm centers. The tufts shall contain an average of 14 wires and initially be 100 mm long. The brush shall have two rows of tufts. The rows shall be 20 mm apart and the tufts in one row shall be opposite the centre of the gap between tufts in the other row. The brush shall be replaced when the shortest tuft wears down to 90 mm long. The texture depth shall be determined by the Sand Patch Test as described in Clause 602.12 of MORTH (Roads Wing) Specification for Roads and Bridges. This test shall be performed at least once for each days paving and wherever the Engineer considers it necessary. At times after constructions, five individual measurements of the texture depth shall be taken at least 2 m apart anywhere along a diagonal line across a lane width between points 50

20

mm apart along the pavement. No measurements shall be taken within 300 mm of the longitudinal edges of a concrete slab constructed in one pass. Texture depths shall not be less than the minimum required when measurements are taken as given in Table 600-2 of MORTH nor greater than a maximum average of 1.25 mm. After the application of the brushed texture, the surface of the slab should have a uniform appearance.

13.8 Concrete Saw. The Contractor shall provide adequate number of concrete saw with sufficient number of diamond edge saw blades. The saw machine shall be either electric or petrol/diesel driven type. A water tank with flexible hose and pump shall be made available for this activity on priority basis. The Contractor shall have at least one standby saw in good working condition. The concreting work shall not commence if the saws are not in working condition. Contractor shall have concrete saw capable of cutting full depth of slab.

21

SECTION-5: TESTS AND QUALITY CONTROL

14.0 Testing of Pavement concrete

14.1 Testing of pavement concrete shall be in accordance with relevant IS Codes as mentioned hereinafter. The following tests shall be carried out during the progress of works:-

14.1.1 Workability. Compacting factor tests and slump tests should be carried out as per IS: 1199(latest revision). In case concrete is being machine laid, then only compacting factor tests should be carried out other-wise either of the two can be carried out at the discretion of the Engineer-in-Charge. Compacting factor/slump test should be carried out for every 10 cum of concrete mixed. The concrete should not be laid unless the appropriate test has been carried out and the authority given for start of lay. Any batch of concrete giving a compacting factor or slump which does not comply with the laid down values + 0.02 (in case of compacting factor only) should be rejected and removed from the site.

14.1.2 7-day strength. Concrete will be accepted on 28 days strength. However, 7-day strength gives an early indication of the strength likely to be achieved. 7-day strength should be determined at least 8 to 10 days prior to laying of concrete. At least three beams should be casted and tested for flexure as per IS: 516 of 1959. The strength should be 70 to 75% of the 28 days strength. If it is less, then the concrete mix should be redesigned and retested.

14.1.3 28-day Strength. At least three beams for every slab (100 ft x 12.5 ft x 1ft) will be cast and tested for flexure as per IS: 516. After at least 30 sample have been cast for slab laid in similar conditions their results should be tabulated and LCL determined as follows:-

LCL = x̄ - t σ Where LCL = Local Control Limit (Minimum flexure strength) x̄ = Mean flexural strength from the sample tested ť = Tolerance level factor σ = Standard deviation of the sample tested

LCL so determined should not be less than flexural strength specified in the design. Along with the beams, cubes will also be cast and tested for compression as per IS: 516. The compressive strength will be tabulated alongwith the corresponding flexural strength to establish correlation between flexural and compressive strength. 14.1.4Honeycombing. For slabs where honeycombing is expected, at least two cores per slab each of 10 cm dia (D) and 20 cm height (L) should be cut from slab which are at least 28 days old for visual inspection. The position of the cores will be decided by the Engineer-in-Charge. If any core shows honey-combing then, at least two more cores should be cut as directed, to determine the extent of

22

unsatisfactory concrete. The entire unsatisfactory portion should be cut and replaced.

14.1.5 Size of mould for testing purpose should not be less than 3 to 4 times the maximum size of course aggregate. Standard mould sizes of 15x15x70 (cm) and 15x15x15 (cm) are used for beams and cubes respectively. If the maximum size of the aggregate bigger than 50 mm does not exceed 15%, the same standard moulds shall be used for testing. If the aggregate bigger than 50 mm exceed 15%, the mould size will be 20x20x90 (cm) and 20x20x20 (cm) for beams and cubes respectively. The results with this increased size of beams/cubes may show lower values and they are to be correlated with the values obtained with 15x15x70 (cm) beams /15x15x15(cm) cubes by actual tests at sites.

15.0 Acceptance of Concrete.

15.1 Concrete will only be accepted if it satisfies the following main conditions:-

(i) LCL of every lot (at least 30 samples) is not less than specified strength.

(ii) Co-efficient of variation is not greater than 10%.

(iii) Tolerance level factor is 1.5.

(iv) There is no honeycombing in the concrete.

15.2 Critical Examination of Test Data. In case the LCL of lot is less than specified strength, then the following procedure will be adopted before core tests are undertaken:-

(i) Omit the slab having lowest average strength and revaluate the remaining test data of the sample.

(ii) If the revaluated data confirms to the above acceptance criteria, accept the lot less the slab omitted.

(iii) In case of unsatisfactory result repeat the process by omitting the next lowest till all weak slabs are segregated for further testing by core cutting and the lot gets accepted.

15.3 Core Tests. In case the concrete fails in flexure test i.e. the LCL is less than specified for the particular lot, then concrete will not be rejected unless it also fails in core test. In core test, at least two cores of the dia not less than 150 mm shall be cut per slab. The crushing strength of this core is then determined. The crushing strength should not be less than 0.8 times the corresponding strength of 15 cm cube. The crushing strength determination will as per IS: 516. In case the L/D ratio of the core is between 1 and 2, then the crushing strength of the cube will be reduced. The correction will be carried as per the formulae given below:-

f = 0.11n + 0.78 Where f = Correction factor

n = L/D ratio

23

In case the concrete fails the flexure (LCL) test, but is found satisfactory in core test, it will be accepted as the core test takes the precedence over the flexure test. However in case the concrete fails both in flexure as well as core test, then it will be rejected and replaced. All holes from which core have been cut, will be filled with same concrete with which original slab was laid i.e. concrete of the same design mix. While filling the concrete, due care should be taken to ensure proper bond between old and new concrete. 15.4 Example. To clarify the mechanism of statistical quality control, procedure is explained below:-

15.4.1 Sample Mix. (a) W/C ratio : 0.43 (b) C/A ratio : 1:5.5 (c) Minimum flexural strength : 30 kg/cm2 At 28 days

15.4.2 Source of Materials

(a) Coarse aggregate : Chandigarh (b) Fine aggregate : Chandigarh (c) Water : bore water (d) Cement : ACC

15.4.3 Test Sample. (a) Size of beam : 15cm x 15cm x 70cm (b) No of sample from each slab : 5 (c) Sample size of the lot : 30 Nos (d) Tolerance level : 1 in 15 (e) Tolerance level factor : 1.5 15.4.4 Test Data.

Slab Date of Strength (Kg/cm2) No. Casting Testing 1 2 3 4 5 6

1. 9.9.74 7.10.74 29.3 29.5 28.8 28.5 28.9 29.0 2. 9.9.74 7.10.74 31.5 31.7 31.7 31.9 32.5 31.9 3. 9.9.74 7.10.74 32.7 32.3 32.5 32.7 33.3 32.7 4. 10.9.74 8.10.74 33.3 33.2 32.2 33.3 32.7 33.1 5. 10.9.74 9.10.74 32.7 32.5 32.7 33.3 33.5 32.9 6. 10.9.74 8.10.74 30.3 30.5 30.8 29.5 30.2 30.2

24

15.4.5 Statistical Quantities

(a) Mean Strength (x) = 1/6*(29.0+31.9+32.7+33.1+32.9+30.2)

=31.63 Kg/Sq Cm

(b) Standard Deviation (β) =1.5 Kg/Sq Cm

(c) Co-efficient of Variation =100X1.5/31.63

=4.74%

(d) Lower control limit =31.63-1.5X1.5

=29.38 Kg/Sq Cm

As the LCL is lower than minimum specified value of 30 kg/SQ cm. critical examination of the data will be done for further core tests.

15.4.6 Critical Examination of Data.

15.4.6.1As a first step, the beam test sample data of slab No.1 having lowest mean strength of 29.0 kg/cm is omitted and the sample characteristics are revaluated for the remaining sample of the lot. The result for sample of slabs 2 to 6 are as given below:-

(a) Mean Strength X = 32.3 Kg/Sq Cm (b) Standard Deviation = 1.3 Kg/Sq Cm (c) Co-efficient of variation = 100X1.3/32.2 =4.1% (d) Lower Control Limit = 32.2-1.5X1.3 = 30.25 Kg/Sq cm

As the acceptance criteria are now satisfied, all slabs except slab No.1 will be accepted. Core will be taken out from slab no.1 and the strength will be evaluated by testing the compressive strength of the cores.

15.4.6.2 Strength of Slab No.1 from Cores. Corresponding to minimum flexural strength of 30 kg/cm2, the minimum cube strength from correlation curves established through testing of specimens of other slab/specimens, of the two, strength is 300 kg/cm2 and minimum equivalent work cylinder strength will be 240 kg/cm2( 0.8x 300). The cores are to be taken immediately after 28 days test and if the average core strength is found to be greater than 240 kg/cm2, slab No. 1 is also acceptable and in case average core strength is less than 240 kg/cm2 then the slab No.1 gets finally rejected.

16.0 Field Laboratory Equipment and Establishment

16.1 Adequate sampling and testing at different stage during construction is well recognized. For proper implementation of such quality control measures, a field laboratory equipped well enough to cope with quality of testing is essential. The aim of this note is to indicate the minimum equipment considered essential for field laboratory. The number of tests for a project with an output of 20-30 cum per day work head (i.e. covering the construction of one slab between expansion joints) is as follows:-

25

(a) Aggregate Grading Analysis.

(i) Coarse aggregate (2 fractions)

(ii) Fine aggregate

(b) Aggregate Moisture Content.

(i) Coarse aggregate

(ii) Fine aggregate

(c) Silt content in Fine Aggregate

(d) Workability of concrete, Slump test, Compacting factor test.

(e) Strength test for concrete beams and/or cube samples.

16.2 Details of establishment of Field Laboratory functioning and lists of test to be carried out and equipment are given as per Appendix ‘G’ 16.0 Revision. This TI 10/2011 includes and supersedes TI Nos. 10/87 and TI 18/87 issued by this HQ

26

Appendix ‘A’

FIELD TEST FOR SILT, LOAM, CLAY ETC FOR FINE AGGREGATE

1. A sample of the aggregate to be tested shall be placed without drying in a 200 ml measuring cylinder. The size of the sample shall be such that it fills the cylinder up to 100 ml. Water should be added so as to bring the level to 150 ml. The mixture shall be shaken vigorously and the content should be allowed to settle for three hours.

2. The height of slit etc. visible as a layer above the aggregate shall be expressed as Percentage of height of the aggregate. Before the pavement work is undertaken, relationship between volumetric measures and weight of deleterious materials will be ascertained in a laboratory and the permissible limit of the deleterious material by volume worked out for approving the aggregate in the field. For limits of deleterious material Table 1 of IS 383 of 1970 should be followed.

27

Appendix ‘B’

TESTING FLEXURAL STRENGTH OF CONCRETE IN PAVEMENTS- COMPACTION IN MOULDS

Compaction in the Mould: - The test specimens shall be made as soon as practicable after mixing, and in such a way as to produce full compaction of the concrete with neither segregation nor excessive laitance. The concrete shall be filled in the mould in layers of 5 cm. While filling, the scoop shall be moved around the top edge of the mould to distribute the concrete uniformly. Each layer of the concrete shall be compacted fully by use of the tamping bar. The number of strokes per layer required to produce the specified condition will vary according to the type of the concrete but in no case shall the concrete be subjected to less than 175 strokes per layer for 15 cm specimen or 100 strokes per layers for 10cm specimens. The strokes shall penetrate into the underlying layer and the bottom shall be rodded throughout its depth. Vibrating table may also be used for compaction but the frequency and amplitude of the machine and method of compaction on site should be intimated to the agency responsible for mix design for recommendation on duration of compaction by vibrating table and at site.

28

29

Appendix ‘C’

LIST OF IS/IRC/OTHER PUBLICATIONS TO BE REFERRED

Sr No IRC No Description

1 IS : 383 Specifications for Course & Fine Aggregates for natural

Sources for Concrete.

2 IS: 432 Part I & Part II Specifications for MS Medium Tensile Steel Bars and Hard

Drawn Steel Wire for Concrete Reinforcement

3 IS: 455 Portland Slag Cement (Revised)

4 IS: 456 Code of Practice for Plain and Reinforced Cement.

5 IS: 460 Test Sieves

6 IS: 516 Method for Tests for Strength of Concrete Method of

Sampling & Analysis of Concrete.

7 IS:1199 Tests for Concrete

IS: 1834 Hot Applied Sealing Compound for Joints in Concrete

8 IS: 1838, Part I & Part II Specification for preformed Filler for Expansion Joints

9 IS: 2386, Part 1 to Part 8 Method of test for aggregate for concrete.

10 IS 2430 Method of sampling for Aggregate

11 IS : 2505 Concrete Vibrators – Immersion type.

12 IS :2506 Concreter Vibrators – Screed board Type.

13 IS: 2508 Low density polythene films

14 IS: 2720, Part 1 to Part 41 Method of Tests for Soil.

15 IS : 5892 Concrete Transit Mixes and Agitators.

16 IS : 6509 Concrete Joints in Pavements.

17 IS : 7245 Specifications for Concrete Pavers.

18 IS : 7320 Concrete Slump Test

29

19 IS: 7861 Part I and II Concreting in extreme weather conditions.

20 IS : 8142 Determining the Setting Time.

21 IS: 8112 Specification for High Strength Ordinary Portland

Cement.

22 IS :9103 Concrete Admixture.

23 IS : 9284 Abrasion Resistance of Concrete.

24 IS : 9399 Apparatus for Flexural testing of Concrete.

25 IS:1791 and IS :12119 Mixers (Bath type & Pen type)

26 IS 13311_2 Non Destructive Tests for Concrete

27 IS: 14687 Form work

28 IS: 12269 Specification for High Strength Ordinary Portland Cement

(53 Grade).

29 IS: 12330 Sulphate Resisting Portland Cement (If soluble salt like sulphate in soil is more than 0.5%).

30 IRC : 15 -2011 Standard Specifications and Code of Practice for Construction of Concrete Roads (Fourth Revision).

31 IRC: 19 - 1977 Standard specifications and code of practice for water bound macadam.

32 IRC: 29 of 1968 Tentative specification for 4 cms (1 asphaltic concrete surface course).

33 IRC : 43-1972 Recommended practice for Tools, Equipment Appliances F for Concreter Pavement Construction.

34 IRC : 44-208 Guidelines for Cement Concrete Mix Design for Pavements (Second Revision).

35 IRC : 57-2006 Recommended Practice for Sealing of joints in Concrete Pavements (First revision).

36 IRC : 58-2002 Guidelines for the Design of Plain Joints Rigid Pavements for Highways (Second Revision).

37 IRC : 60-1976 Tentative Guidelines for the Use of Lime –Fly Ash

Concrete as a Pavement Base or sub- Base.

38 IRC : 74-1979 Tentative Guidelines for lean – Cement Concrete and lean- Fly Ash Concrete as a Pavement Base or sub- Base.

30

39 IRC : 76-1979 Tentative Guidelines for Structural Strength Evaluation of rigid Airfield.

40 IRC : 84 -1983 Code of Practice for Curing of Cement Concrete

Pavement.

41 IRC : 85 -1983 Recommended Practice for Accelerated Strength Testing & Evaluation of Concrete for Road and Airfield Constructions.

42 IRC : 91 -1985 Tentative Guidelines for Construction of Cement Concrete Pavements in Cold Weather.

43 IRC : 101-1988 Guidelines for Design of Continuously Reinforced Concrete Pavement with Elastic Joints.

44 IRC : SP : 17 -1977 Recommendations about Overlays on Cement Concrete Pavements.

45 IRC : SP : 46 -1997 Steel Fibre Reinforced Concrete for Pavements.

46 IRC : SP : 49 -1998 Guidelines for the Use of Dry lean Concrete as Sub-Base for Rigid Pavement.

47 IRC : SP : 61 -1976 Tentative Guidelines for the Construction of Cement Concrete Pavements in Hot Weather.

48 IRC : SP : 68 -2005 Guidelines for Construction of Roller Compact Concrete Pavements.

49 IRC Seminar, 2004 Seminar on “ Design Construction and (Proceedings) Maintenance of Concrete Pavement”, New Delhi 8-10 October, 2004

50 IRC : SP : 83 -2008 Guidelines for Maintenance, Repairs & Rehabilitation of Cement Concrete Pavements.

51 IRC : SP : 89 -2010 Guidelines for soil and Granular Martial Stabilization using Cement Lime & Fly Ash.

52 MORTH Orange Book Specification for Road Transport & Highway.

31

Appendix ‘D’

USE OF ACCELERATED CURED CONCRETE TEST SPECIMENS IN CONTROLLED CONCRETE

1.0 Introduction.

1.1 As per IS: 456-2000 “Indian Standard Code of Practice for Plain and Reinforced concrete”, 28 days compressive strength shall alone be the criteria for acceptance or rejection of the concrete. Experiences have shown that if after 28 days, the quality of concrete is found to be dubious it would have considerably hardened by that time and also might have been buried by subsequent construction. Thus demolition and replacement of concrete of Questionable Attributes is often an impracticable preposition. Hence standard 28 days cube testing of concrete by itself is not adequate for proper quality control of controlled concrete. 2.0 Accelerated Curing Method.

2.1 To overcome the difficulty explained in Para 1 above, IS: 9013-2008“Method of

making, curing and determining compressive strength of accelerated cured concrete

test specimens” have been issued by BIS. This code describes two method of

accelerated curing i.e. warm water method and boiling water method. Warm water method can be easily adopted at site as it involves only the control of temperature in the curing regime. Since in the boiling water method besides temperature, relative humidity is also required to be controlled, this method is not recommended as it calls for more elaborate facilities at site.

2.2 Using accelerated curing techniques, it is possible to test the compressive strength of the concrete within 24 hours and thereby to estimate whether or not it is likely to reach the specified strength at 28 days. This timely information can be of immense value to an executive in applying corrective measures to concrete mix design and also to decide whether the concrete should be replaced while it is still accessible and sufficiently green, when its removal is practicable.

2.3 IS: 9013-2008 gives correlations between compressive strength of concrete specimens cured by accelerated methods and normally cured (for 28 days). However it is desirable to establish the actual correlation in each case for the given material and mix proportions. IS: 456-2000 provides for casting of additional cube required for testing cube by accelerated method. In order to reduce the number of cubes which are required to be tested the frequency of 7 and 28 days compressive strength tests may be suitably relaxed on the lines recommended in clause 15.3 of IS: 456-2000.

3.0 Rigid Pavement and Overlays.

3.1 In case of rigid pavement and overlay, the quality control of concrete is exercised by determining the flexural strength of test beams. The requirement as laid down by this HQ is to achieve minimum 28 days field flexural strength of 44 kg/cm2 in case of new pavements. The flexural strength of concrete can be converted into its compressive strength by the relation Y=7.63 x + 25.8, where Y is compressive strength in kg/cm2 and

32

x is flexural strength in kg/cm2. Having thus determined the required minimum 28 days compressive strength, correlations between compressive strength of concrete cube cured by accelerated method and normally cured for 28 days will have to be established in each case as described in Para 2.1 above.

3.2 The final acceptance criteria for pavement concrete will still remain its 28 days field flexural strength. The 24 hrs tests are only intended to serve as a tool for giving early warning in respect of concrete of dubious strength so that necessary and timely corrective measures can be implemented.

4.0 Conclusion.

4.1 It is recommended that suitable provisions as per IS: 9013-1978 may be made in the tender documents of all the large specialist work i.e. runways, overlays, marine works, multistoried buildings etc. where quality control of controlled concrete based on 24 hrs compressive flexural strength of cube/beam in additions to 28 days strength will be of great help in timely detection and replacement of sub –standard concrete.

33

Appendix ‘E’

WORKABILITY, SLUMP AND COMPACTION FACTOR OF CONCRETE

WITH 20 MM OR 40 MM MAXIMUM SIZE OF AGGREGATE AS PER SEC 7.1 OF IS:456 2000,IS:1199 AND IS:9103

Degree of Workability

Slump (mm)

Compacting factor Use for which concrete is suitable

Small Apparatus

Large Apparatus

Very low Up-to 25

0.75 0.80 Roads operated by power operated machines. At the more workable end of this group, concrete may be compacted in certain cases with hand operated machines.

Low 25-75 0.85 0.87 Roads vibrated by hand-operated machines. At the more workable end of this group, concrete may be manually compacted in roads using aggregates of rounded or irregular shape. Mass concrete foundations without vibrations or lightly reinforced sections with vibrations.

Medium 50-100 0.92 0.935 At the less workable end of this group, manually compacted flat slabs using crushed aggregate. Normal reinforced manually compacted and heavily reinforced section with vibration.

High 100-150

0.09 0.96 For sections with congested reinforcement. Not normally suitable for vibration.

*Not normally used unless aggregates size exceeds 40 mm.

34

Appendix ‘F’

COARSE AND FINE AGGREGATE

1.0 Aggregates 1.1 Aggregates for pavement concrete shall be natural material complying with IS: 383 but with a Los Angeles Abrasion Value not more than 35%. The limits of deleterious materials shall not exceed the requirements set out in IS: 383.

1.2 The aggregates shall be clean, hard, strong, dense, non porous and durable crushed stone free from dirt and shall not be alkali reactive. In addition, the total chlorides content expressed as chloride ion content shall not exceed 0.06 per cent by weight and the total sulphate content expressed as sulphuric anhydride (SO3) shall not exceed 0.25 per cent by weight. Table 1 and 2 may be referred for combined gradation of fine and coarse aggregate) in case of DLC (Dry Lean Concrete) and PQC (Paving Quality Concrete) respectively.

Table 1. Aggregate Gradation for Dry Lean Concrete

Sieve Designation Percentage by weight passing the Sieve

26.50 mm 100 19.0 mm 80-100

9.50 mm 55-75 4.75 mm 35-60

600.00 micron 10-35

75.00 micron 0-5

Table 2. Aggregate Gradation of Pavement Quality Concrete

Sl No

Sieve Designation Percentage by weight passing the Sieve

1 31.50 mm 100 2 26.50 mm 85-95

3 19.0 mm 68-88 4 9.50 mm 45-65

5 4.75 mm 30-55

6 600 micron 8-30 7 150 micron 5-15

8 75 micron 0-5

Note : The grading given in Table-1 and Table -2 above are applicable both for natural river sand and crushed stone sand aggregate.

35

1.3 Coarse aggregate:

1.3.1 Coarse aggregate shall consist of clean, hard, strong, dense, non-porous and durable pieces of crushed stone or crushed gravel and shall be devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery pieces. The combined flakiness and elongation index shall not be more than 35 per cent. The aggregate may be used conforming to IS: 383. The maximum size of coarse aggregateshallnotexceed31.5mminPQCand 26.5 mm in case of DLC.

1.3.2 Continuously graded aggregates may be used, depending on the combined grading of the coarse and fine aggregate. No Aggregate which has water absorption more than 3 per cent shall be used in concrete mix. The aggregates shall be tested for soundness in accordance with IS: 2386 (Part V). After 5 cycles of testing, the loss shall not be more than 12 per cent if sodium sulphate solution is used or 18 per cent if magnesium sulphate solution is used.

1.4 Fine aggregate: The fine aggregate shall consist of clean natural sand or crushed stone sand or a combination of the two shall conform to IS: 383. Fine aggregate shall be free from soft particles, clay, shale, loam, cemented particles, mica and organic and other foreign matter. Aggregates which have water absorption of more than 3 per cent shall not be used. The fine aggregate shall not contain substances more than the following:-

(a) Clay Lumps : 1.0 per cent

(b) Coal and lignite : 1.0 per cent

(c) Material passing IS sieve No. 75 micron:-

(i) Natural sand : shall not exceed 3 per cent by weight of natural sand.

(ii) Crushed Stone sand: shall not exceed 15 per cent by weight of crushed stone.

(iii) Blend of natural sand: shall not exceed 8 per cent by weight of and crushed stone dust natural sand and crushed stone dust.

Cautionary Note : Although IS:383 permits fines passing 75 microns up to 15 percent in the case of stone crushed sand, this provision should be used with caution when crushed stone dust is used as fine aggregate and when the mix produced in the Laboratory and the field is satisfactory in all respects and complies with the requirement of Specification. The grading of fine aggregates as per IS: 383 shall be within the limits given in Table 3.

36

Table 3. Fine Aggregate Requirements

lS Sieve Designation

Percentage passing for

Grading Zone I Grading Zone II Grading Zone III 10 100 100 100

4.75 mm 90-100 90-100 90-100 2.36 mm 60-95 75-100 85-100

1.18 mm 30-70 55-90 75-100

600 micron 15-34 35-59 60-79 300 micron 5-20 8-30 12-40

150 micron 0-10 0-10 0-10

Note :-

1. Where the grading falls outside the limits of any particular grading zone of sieves other than 600 micron IS: Sieve by a total amount not exceeding 5 per cent, it shall be regarding as falling within that grading zone. This tolerance shall not be applied to percentage passing the 600 micron IS: Sieve or to percentage passing any other sieve size on the coarse limit of grading zone I or the final limit of grading zone III.

2. For crushed stone sands, the permissible limit on 150 micron IS: Sieve is increased to 20 per cent.

37

Appendix ‘G’

PREPARATION OF BASE

1.0 The base of concrete consists of various layers. It is essential to prepare all the layers as per the specifications, grade and camber. The instruction has been divided in following parts as brought out in succeeding paragraph:-

(a) Soil/ Sub grade

(b) Sub Base

(c) Base

(d) Rigid pavement

(e) Material

2.0 Soil/Sub Grade.

2.1.0 In new works, the working strip i.e. the main runway, over run, soft ground arrester, apart from taxi track, hard standings, aprons and so on as required by the users, including the shoulders and drainage and working areas for the borrow pits generally beyond the limits of Air Field areas, shall be cleared of all trees bushes and other vegetation. However to preserve the ecological balance of the area, all trees and saplings shall be carefully preserved. In the safe areas beyond the restricted limits, large scale afforestation should be resorted to compensate for felled trees.

2.1.1 The trees/vegetation will be removed complete with roots and holes so formed shall be backfilled with material meeting the CBR requirements of sub grade material and compacted to 95% of the max lab density at OMC. Site clearance in bushy area will comprise the digging out and removal of all vegetation from the working strip.

2.1.2 Removal of Top Soil. The top soil shall be stripped from the areas within the limits of all cutting and embankments where the top soil contains hums or other harmful material. The depth of the stripping shall generally be 150 mm within the limits of the strip including shoulders on either side. In case, it is considered necessary, additional material shall be stripped and should be considered as cutting.

2.1.3 Sub-grade. The sub-grade level of the Air Field is defined as the interface between the formation level and the pavement whether it is the runway or over-run or Soft Ground Arrester or taxi track or hard standing or aprons. At no cost, the requirement of sub-grade be compromised as it is the foundation for the Air Field pavements to ease out laying of subsequent layers in correct profile. The requirements of the sub-grade material in 300 mm thick should meet the sub grade strength parameter specified in design.

2.2.1 Testing of sub-grade shall include the testing 300mm of material below the formation and should that material fail to meet the requirements as brought out above subsequent testing of lower layers as directed by laboratory staff be carried out. In case, it is considered, the replacement of reasonable thickness may be carried out with the material, meeting the requirements of sub-grade or with the slab base material whichever

38

is economical, technically sound and in the interest of the works as recommended during design stage. The replacement be carried out and controlled for quality in terms of IS: 2770 Pt XXVIII. If required, the stabilization as laid down in TI-5 of 84 be carried out wherever directed by lab staff. The tests required on the sub-grade should be as under:-

Ser Test IS Code Frequency

1. Gradation (a) Particles size wet sieve

analysis (including determination of the uniformity if required)

(b) Particles size analysis by hydrometer method

IS: 2770 Part IV 1975 -

4 Tests per 8000 m³ of soil To be carried out in case essential as per direction of Lab Staff.

2. Atterberg Limits (a) Liquid limit

(b) Plasticity index

IS: 2770 Part V -do-

As per S.No. 1(a) above As above

3. Natural Moisture Contents IS: 2770 Part II 1973

One test for 250 m³ of soil

4. Standard Proctor Test IS: 2770 Part VII & VIII 1974

As 1 (a) above

5. Modified Proctor Test IS: 2720 Pt VII & VIII-1974

As 1(a) above

6. CBR on a set of 3 specimens IS: 2720 Part XVI

One test for 3000 m³ or one test each in case of change in soil.

7. Deleterious constituents IS: 2720 Part XXVIII

As required

8. Moisture content just before compaction

IS: 2720 Part II 1973

Two to three tests for 250 m³ of loose soil.

9. Dry density of compacted layer IS: 2720 Part XXVIII

One test per 750 m² of compacted area

10. CBR at 95% compaction specification for the layer concerned

IS: 2720 Part XVI 1965(as revised)

As above

2.2.2 Tolerances in Sub-grade: - The final trimmed slopes shall be within ±1/8 to the specified slope and rate of change in slope shall not be greater than ±1/8 in 50 m. 2.2.4 The half width of cutting measured between Air Field centre line and toe of the cutting shall not be less than that specified but may be up to 200 to 300 mm greater than specified half width of the Air field.

39

2.2.5 The finished level of the sub-grade shall nowhere be higher than required. The grade and cross fall tolerances on the finished surface shall be ±0.1% 2.2.6 For compaction of sub grade, use of vibratory roller is recommended in case soil is sandy/silty. In case of clayey soils, sheep foot roller is recommended. Type of roller and number of passes to achieve required compaction should be included in the soil report at the time of soil testing. The pneumatic rollers should be as per IS: 5501-1969. 2.3.0 Drainage. This is one of the critical requirements of any airfield construction. All surface water in the specified zone and the water coming from other catchment area should be properly flushed out by designing efficient drainage system. While carrying out survey for the earth work, detailed survey for drainage should be carried out and plotted, specifying required slope which will itself become guidelines for finished level of runway and gradient. 2.3.1 For detailed planning and construction of drainage TI No 15 of 87 (revised) May be referred. 3.0Sub Base. 3.1.0 Sub Base material shall comprise of well graded natural sand/gravel/moorum or screened natural sand and gravel as specified in Para 401.2.2 of “Specifications for Roads and Bridges” of MORTH. The oversize particles which are screened out may be crushed and re-combined. Before sub base is laid, the sub-grade is checked for centre line, grade and cross section.

3.1.1 Minimum Requirements of Sub Base Material

(a) One day soaked CBR of material passing 20 mm sieve when compacted to 95 % heavy compaction must be less than 30%. (Lower value can be accepted considering the pavement thickness designed) (b) Plasticity index of fraction passing 425 micron test sieve must not be more than 15%. (c) The material shall pass a 75 mm test sieve except where the compacted layer thickness is less that 150 mm in which case the maximum size be half the thickness of the later. (d) The grading curve of the material shall have a co-efficient of uniformly greater than or equal to 10 where co-efficient of Uniformity = D60 ÷ D10 (D60 and D10 represent the sieve sizes through which 60% and 10% respectively by weight will pass.)

3.2.0 One complete analysis prior to opening of any borrow pit or the use of any stock-pile for every 1500 cum of material to be used subject to a minimum of five complete analysis per borrow pit or stock pile to be done.

40

3.2.1 Where sub-grade material is rock, no sub-base is required. However, regulating layer of sub base material will be done. The thickness of the regulating layer should be normally 10 to 15 cm. Sub base will be compacted at 95% heavy compaction at moisture content from 80% to 110% of optimum. 3.2.2 The surface shall be nowhere higher than the required levels and shall be checked with 4 m straight edge and there shall be no gaps between surface and straight edge exceeding 30 mm. The average thickness of the layer or each layer measured at five points over the span of 100 m shall not be less than specified. The grade and cross fall tolerance on the finished surface shall be ±0.1%. 3.3.0 Water Mixed Macadam Sub-base. For use as sub-base, WMM shall be constituted with over size aggregate up-to 75 mm size. The material to be used and the work shall conform to the requirements of the IRC: 19-1977 and the quality shall be controlled on the same line as outlined in base course (WMM) as per the IS referred therein. 3.4.0 Granular Sub Base 3.4.1 Granular Sub Base is the name usually given to naturally occurring material formed by disintegration of rock. Refer Para 401.2.2 of “Specifications for Roads and Bridges” of MORTH. 3.4.2 Control Tests and Their Frequency. Quality control tests on material and work with their minimum desirable frequency are as indicated below:- S.No. Test Test Method Minimum desirable

frequency 1. Gradation IS:2720(Part-VI) One test per 200m3

2. Plasticity IS:2720(Part-V) ----do---- 3. Natural moisture content IS:2720(Part-II) One test per 250m3

4. Deleterious Constituents IS:2720(Part-XXVII) As required

5. Moisture content prior to compaction

IS:2720(Part-II) One test per 250m2

6. Density of compacted layer IS:2720(Part-XXVIII)

One test per 500m2

7. Control of Grade, camber thickness and surface finish

---- Regularly

8. CBR test (on a set of 3 specimens)

IS :2720(Part-XVI) As required

Note: Wherever required, stabilization of soil on sub-grade prior to laying sub-base be done as per standard specification laid down in relevant IS Codes, IRC Special publication No.11 and Technical Instruction No.5 of 84 (revised).

41

4.0 Base Course.

4.1.0 One complete analysis prior to opening of the quarry or the use of any stock pile for every 1500 cum of material to be used shall be done subject to a minimum of five complete analysis from any quarry or stock pile and complete analysis shall include the following tests:-

(a) Bulk density IS: 2386. (Part-III)

(b) Particle analysis IS: 2386/1963, (Part-I)

(c) Aggregate crushing value IS: 2386. (Part-V)

(d) Specific gravity IS: 2386. (Part-III)

(e) Shape of particles IS: 2386. (Part-I)Only if considered necessary

(f) Los Angeles abrasion IS: 2386. (Part-V)

(g) Test for silt clay and IS: 2386. (Part-II)

Impurities of fine aggregate

4.1.1 The combine aggregate shall have a smooth grading curve within an approximately parallel to the grading envelope limits given below:-

IS Test Sieve % by Wt Passing

(a) 50 mm 100

(b) 37.5/40 mm 87-100

(c) 20 mm 67-93

(d) 5 mm 28-60

(e) 2.36 mm 20-45

(f) 0.425 mm 15-30

(g) 0.075 mm 5-10

This grading will meet the requirements of the fine as screenings and to be

followed when mechanical mixing and laying is done. In case of manual spreading and screenings used separately, the gradation of aggregate should conform to TI 7 of 84 revised and should conform to one of the grading of IRC: 19-2005 (Standard Specification and Code of Practice for Water Bound Macadam).

4.1.2 Base course shall be compacted to 97% of heavy compaction at the moisture content between 80% to 110% of optimum and the voids in the compacted layers not more than 20 %. The finished surface of base course shall nowhere be higher than required levels but be up to 15 to 20 mm lower. The surface shall be checked with 3 m straight edge and there shall be no gaps between the base course level and the straight

42

edge exceeding 6 mm. The average thickness of the layer measured at five points over a distance of 100 m shall not be less than that specified and nowhere may be the thickness be less than 90% of the specified thickness of each layer. The half width of the layer shall not be less than that specified and required by camber. The grade and cross fall tolerances on the finished surface shall be ± 0.1% 4.1.3 Base course shall be laid strictly in accordance with IRC: 19-2005 with references to relevant IS codes, IRC Special publication 11-1984 and TI 7 of 84. If it is possible, it is recommended that the materials in separate piles should be put in a pug mill of adequate capacity after adding sufficient quantity of water and thoroughly mixed and should be transported to the site immediately. Such mix shall be laid by approved mechanical paving machine or with a motor grader. 4.1.4 The base should be laid only after proper check of sub base for correct compaction grade and cross fall. Templates may be used for checking uniformity of spread. 4.1.5 Whether laid mechanically or manually, the quality control test on materials and the work and their minimum desirable frequency shall be as indicated below:- Ser No.

Tests Test Method Minimum Desirable Frequency

1. Los Angeles abrasion value/Aggregate Impact value

IS:2386 (Part IV) One test per 200m3

2. Grading of aggregate and screenings IS: 2386 (Part I) One test per 100m3

3. Flakiness index of aggregate IS: 2386 (Part I) One test per 200m3

4. Plasticity of binding materials IS: 2720 (Part V) One test per 200m3

5. Control of grade camber thickness and surface finish

- Regularly

6. Compaction (a) Density/Moisture content by

modified proctor

(b) Plate bearing test

One test per 750 m2 of compacted area ---do---

4.2.0 Following are the other types of base course used under the rigid and flexible pavement:

(a) Bituminous penetration macadam

(b) Built up spray grout

(c) Bituminous macadam

43

(d) Soil cement base

(e) Lean concrete

4.3.1 All base courses where asphalt or bitumen is used as binder are generally covered under flexible pavement. 4.4.0 Soil Cement Base. This is different than cement stabilized soil for sub-grade preparation. This is envisaged to be base course quality and proper mix design should be done for strength and durability. 4.4.1 Materials. Soil proposed for soil cement base course shall not have sulphate content of more than 0.2%. The cement used shall be checked for compliance with the requirements of IS: 269, 455 or 1489 as applicable. The quality of cement for incorporation shall be expressed as % by weight of dry soil. This shall be predetermined on the basis of strength and durability in lab. The material to be used should meet the requirements of sub base or sub-grade. The material shall be proportioned to the specified compressive strength. 4.4.2 Preparing and laying soil cement base should be in conformity with the IRC special publication No. 11. 4.4.3 The quality control tests and their frequencies are as under. However tests not specified may be carried out as desired by the lab staff. Ser No.

Test Test Method Minimum desirable frequency

1. Deleterious constituents of soil IS:2720(Part XXVII) As required

2. Quality of cement IS:269/455/1489 ----do--- 3. Cement content ---------- One test per 250 m2

4. Degree of pulverization ----------- -----do---- 5. Moisture content prior to

compaction IS:2720(Part II) -----do-----

6. Dry Density IS:2720 (part XXVIII)

One test per 500 m2

7. Control of grade camber thickness & surface finish

------------- Regularly

8. Cube strength of material mixed at site (a set of 2 specimens)

IS:516 One test per 50 m3 of mix

4.5.0 Lean Concrete Base Course. 4.5.1 This type of base course is suitable both for flexible and rigid pavement. 4.5.2 The material in general should meet the specified requirements. Cement, sand, course aggregate and water to be used should be approved by lab as per job mix. The

44

job mix/mix proportion shall be predetermined in the lab so as to obtain the specified compressive strength at 28 days. 4.5.3 Preparation sub-grade, mixing and laying should be in accordance with IRC-11 Special publication. 4.5.4 Quality control test on the materials and the work and minimum frequencies shall be as under:- S.No Test Test Method Minimum

desirable frequency

1. Quality of cement IS:269/455/1489 ----do---

2. Los Angeles Abrasion Value/Aggregate Impact Value

IS 2386 (Part IV) One test per 200m3

3. Aggregate gradation IS 2386 (Part I) One test per 100m3

4. Aggregate moisture content IS 2386 (Part III) As required 5. Wet analysis of mix IS:1119 As required

6. Control of grade, camber thickness and surface finish

- Regularly

7. Cube strength of material mixed at site (a set of 2 specimens)

IS:516 One test per 50 m3

of mix

5.5.1 Limiting Values for WBM Base Course are given below as a guide line:-

Ser No. Test WBM Base Course

1. Flakiness index Max 15% 2. Organic impurities Free

3. Bulk Density Artificial Agg Min 4. Crushing Value Max 45%

5. Impact Value Max 30%

6. Soundness (i) Sodium Sulphate (ii) Magnesium Sulphate

Max 20%

- 7. Los Angeles Abrasion Value Max 40%

8. Stripping Test NA 9. Water Absorption 1%

5.5.2 Screenings for WBM. Screenings to fill voids in the course aggregate shall generally be of the same material as the course aggregate. However from economic consideration, predominantly non-plastic material may also be utilized provided that the liquid limit and plasticity index of such material is below 20 and 6 respectively and the fraction passing 75 micron sieve does not exceed 10%.As far as possible, screening shall conform to the grading shown below:-

Grading Size Screening Sieve Designation % by weights

45

Classification IS-400 Passing sieve

A 13.2 mm 13.2 mm 11.2 mm 5.6 mm 180.00 micron

100 95-100 15-25 0-10

B 11.2 mm 11.2 mm 5.6 mm 180.00 micron

100 90-100 15-35

Note: -Screening of grading ‘A’ is generally suitable to the aggregate used for WBM conforming to grade 1 & 2 as shown in IRC: 19-2005 and the grading ‘B’ is suitable for grading 2 and3 aggregate of above mentioned IRC publication.

5.5.3 Binding Material. This is primarily used to avoid raveling of WBM. This should consist of fine grained material passing 100% through 457 micron sieve and should have PI value up-to 6. Lime stone dust is suitable for this purpose. Binder material should not be used where screening consists of crushable type material. When binder is used, then quantities of screening should be reduced accordingly. The quantity of screening and binder to be used is given in IRC: 19-2005.

46

Appendix ‘H’

INSTRUCTIONS ON ESTABLISHMENT AND FUNCTIONING OF LABORATORY FOR QUALITY CONTROL AT AIRFIELD PAVEMENT SITES

1.0 Introduction.

1.1 Runway resurfacing work carried out in the past has in certain cases invited adverse criticism from quality point of view, compromising the competence to execute quality work by the organization. There is thus a need to identify, critical activities of the construction which need to be highlighted and controlled through tests to achieve desired quality control. Following instructions are issued to amply clarify and provide guidance to executives, supervisory and coordinating staff. It is stipulated that guidelines are followed in letter and spirit to ensure quality control.

1.2 Establishment of laboratory under direct control of CE Zone is a step towards the said goal and is mandatory at each airfield pavement work services construction site before commencement of the work.

2.0 Aim.

2.1 To lay down the organization & functioning, equipment for tests and their frequency, documents to be maintained and the points required to be checked by visiting officers.

3.0 Organization and Functioning.

3.1 Organization. The suggested organization of the laboratory is given below:-

SO-2 (lab)-CE’s Rep AGE Lab (AEE/AE I/C lab)

Computer operator with computer and peripherals

Rigid & Flexible Material Pavement JE JE

Rigid Lab Flexible Lab Cement Aggregate Bitumen Attendant -1 Attendant-1 Mazdoor-1 Mazdoor-1 Lab Attendant-1 Mazdoor -2

47

3.2 Responsibility, Function and Qualitative Requirement.The lab shall function directly under the CE to whom SO-2 shall report directly. Delegation of powers for establishment of lab to CWE shall not be done and the staff will be provided by the CE Zones except lab assistants,mazdoorsand equipment. The interpretation of test result and remedial measure to overcome executive problems to maintain quality control will be undertaken by design staff available with the CE who would also be the accepting officer of the contract. The lab will be located at airfield pavement work services site. The lab and its staff will come under the concerned CWE for local administration. However, wherever the site of construction happens to be an out station of the concerned CWE, the local administrating will be responsibility of GE concerned under instruction of CWE. There functions and qualitative requirement of staff is given below:-

(a) SO-2 Lab. He will function directly under CE. He will be responsible for setting up, provisioning, coordination, checking of equipment from time to time and smooth function of the lab. He will conduct surprise checks to see that prescribed tests are being conducted regularly and correct reports rendered to all concerned. The officer so detailed could be the SO-2 (Design) or any other officer having experience of one or two airfield works,

(b) AGE Lab. He will function under direct technical control of SO-2 (Lab) and will be borne on the strength of CE Zone for the duration of the work. He will ensure that the tests are conducted as per instructions laid down in relevant standards or as ordered by CE, in case certain tests are not covered in standard. He will also be responsible for ensuring that equipment in the lab is fully functional at all times. He will maintain a proper record of all tests in duplicate; one copy at site and duplicate copy for CE office for his perusal. He should have sufficient executive experience and preferably a graduate. He should have successfully attended centralized training at CRRI New Delhi/SEMT wing CME Pune, for the purpose CE Zone will ensure that there is at least one trained officer in their Zone at all times before the commencement of works by taking up the case through CE Command with ADG (Pers) at E-in-C’s Branch. The officer will not be posted out till the completion of work and will be located at the site of work. (c) JE (B/R),Rigid and Flexible. He shall be in charge of rigid and flexible lab where all tests on concrete, asphaltic concrete and bitumen macadam will be carried out. He will be responsible for proper conduct of tests as per procedure laid down in standards on concrete asphaltic concrete and bitumen macadam and ensure maintenance of records of tests. He shall be assisted by lab attendant and mazdoors. He shall be borne on the strength of CE Zone. (d) JE (B/R) Material. He shall be in charge of test on cement, aggregate and bitumen and on any other material which may be required to be tested. He will be directly responsible for proper conduct of tests as per procedure laid down in the standard on cement, aggregate or bitumen or any other material and ensure maintenance of record of the tests. He shall be assisted by the Lab Attendant and Mazdoors. He shall be borne on the strength of the CE Zone.

48

(e) Computer Operator. A Computer operator with necessary computer peripherals will be provided by the CWE to maintain test records and will help in administrative cover to the field lab staff.

4.0 Tests and Frequency.

4.1 The details of the tests to be performed in the lab and site and their frequency is attached as Annexure-1.

4.2 The under mentioned tests will be performed at site:-

(a) Soil. Determination of moisture content, dry densities and achieved CBR/K value.

(b) Aggregates.

(i) Sieve analysis.

(ii) Examination of source.

(iii) Determination of moisture content.

(iv) Determination of silt content.

(c) Cement Concrete.

(i) Water Cement Ratio.

(ii) Slump and Compacting Factor Test.

(iii) Concrete Cube and Beams.

5.0 Equipment.

5.1 List of equipment which should be available in the lab for testing both in lab and the site are attached as Annexure II.

6.0 Documents.

6.1 Documents to be maintained in the lab for the under mentioned test are attached as Annexure IV. These are only suggested forms. They may be amended/improved upon at site. For minor test like moisture content and dry densities, form or document may be made at site.

(a) Aggregate crushing value/Impact value /Abrasion value.

(b) Concrete cube strength.

(d) Test result –cement.

(e) Test result – Flakiness/ elongation index, striping value and soundness.

(f) Test result –Sieve analysis.

(g) Test result - concrete flexural strength.

6.2 SO2(Lab) will keep duplicated/carbon copy of records of all test carried out by field lab in the CE’s office for regular perusal of CE and record.

49

7.0 Procedures for Testing.

7.1 Various test mentioned in Para 4 and 6 above shall be done in accordance with Indian Standards mentioned for each test in Annexure I above. The material/sample required to be tested shall be sent by GE to AE/AEE (Lab) along with the two copies of the work order. Specimen of the work order is given in Annexure V.

7.2 In case of testing of contractor’s work, where considered necessary by the GE, the signature of the Engineer-in-Charge and the contractor shall also be affixed on the work order and specific instruction as to whether tests to be carried out in the presence of the representative of contractor and the GE shall also be indicated by GE in the work order duly signed by him and shall retain the original copy for his record.

8.0 Storing of Sample.AE/AEE (Lab) shall not be responsible for storing the sample which have been tested/other sample. This should be done by the GE and engineer in charge for the project/work. Prior to testing of concrete beam for flexure, it should be ensured that lettering on the beam to indicate its date of casting and belonging to a particular slab is legible. Suggested system of numbering is given in Annexure VI. 9.0 Control. The lab for local administration which include transport accommodation ration etc will be under the CWE/GE. The technical control of the lab will be under the CE. 10.0 Checking by Visiting Officers.

10.1 During the visit of senior officer like CE, ACE and CWE, some random tests pertaining to the work being carried out at that time or of the work already completed should be ordered to be carried out in their presence. The test could be like compressive flexural strength of cement concrete cube and beams and grading of aggregate lying on site. The result of such test should be properly recorded and a report shall be sent immediately by AE/AEE I/C (Lab) to SO2(Lab) for his information. The results of various tests conducted in the lab will be regularly scrutinized at least once in fortnight by SO2(Lab). If considered necessary, he may order additional tests to satisfy himself about the quality of work being executed.

10.2 Deviation. Deviations from desired standard specifications found consequent upon random tests or other wise to maintain proper quality control shall be immediately brought to the notice of CE and GE, by SO2(Lab). Remedial measures suggested/decided by CE will be communicated and their incorporation ensured by SO-II (Lab) at site through GE.

10.3 Remedial Measures. GE will ensure that suggested remedial measures are incorporated in the further work to be executed and their efficiency evaluated and reported to CE at the earliest. Slabs incorporating remedial measure will be marked suitably to identify such work at later date. Proper record will be maintained in CE’s office of problems, suggested remedial measures and their efficiency.

50

11.0 Consultancy.

11.1 In case a problem is referred to any specialist i.e. SEMT, CRRI or any local Engineering Collage, Officer in charge of will be responsible for projecting the problem to the specialist institution with the assistance of GE. Remedial measure suggested by the specialist institution will be vetted by the CE and communicated to GE for adoption.

12.0 Pavement Section, Design Sub Dte, E-in-C’s Branch.

12.1 Pavement section of DDGW (Design) will be kept informed through DDGW (Air Force) and the projected problem and remedial measures received from specialist institution. A visit of rep of DDGW (Design) should be organized once construction of trial bay is completed.

13.0 Technical Examiner.

13.1 Inspection of Technical Examiner shall be conducted in the presence of SOII (Lab) and GE during the currency of work. Defects noticed shall be brought to the notice of CE for perusal and further action. Inspection program of TE shall be well formulated in advance to cover the execution for its critical activities in consultation with GE/SOII (Lab).

14.0 DDGW (AF).

14.1 DDGW (AF) shall oversee the work with a specialist of DDGW (Design) for quality of work being executed in the presence of CE. He will critically examine the functioning of independent field laboratory at construction site and assurance of quality control in lab. He will also check the specifications, suitability and functioning of the plant and machinery employed at the work site. He will take suitable action in consultation with the CE to overcome the problems in execution and quality control.

15.0 Records and Project Report.

15.1 Date of inspections, comments on quality of work being executed, problems noticed and methodology envisaged on all decisions shall be recorded on the site order book/work diary by the respective inspecting officers.

15.2 Project Report. A comprehensive project of the work executed shall be prepared under the responsibility and guidance of CWE with the assistance of SOII (Lab) and GE covering the following aspect:-

(a) Name of officers and JE’s who executed the work and manned the

Independent laboratory.

(b) Training courses attended by the personnel of serial 3.2

(c) Their previous experience on such works before taking up execution of the

present work.

(d) Plant and equipment used including their capacity, functional efficiency and

manufacturers of the same.

(e) Problem encountered and remedial measures adopted.

51

(f) Photographic record of each stage of construction.

(g) Lessons learnt and recommendations.

The project report will be duly vetted by CE (Zone) and submitted to DDGW (Air) and DDGW (Design) within 6 months of completion of project.

52

Annexure 1

Ser No.

Name of Tests Relevant IS Frequency

Aggregates

(i) Gradation test 2386 (Part I) of 1963 “Particles size and Shape”

One test for 15 cum of each fraction of coarse and fine aggregate

(ii) Deleterious constituents

2386 (Part II) of 1963 “Estimation of Materials & Organic Impurities”

One test for 15 cum of each fraction of coarse and fine aggregate

(iii) Moisture content test

2386 (III) of 1963 Regularly as required subject to minimum of one test per day for coarse aggregate and two tests per day for fine aggregate. Once for each source for deriving the moisture content relationship.

(iv) Bulking of the fine aggregate (for volume batching)

2386 (Part III) 1963 As required

(v) Los Angeles –Abrasion value /aggregate impact

IS: 2386 (Part IV of 1963) “Mechanical Properties”

Once for each source of supply and subsequently when warranted by change in the quality of aggregate

(vi) Soundness test for coarse aggregate

2386 (Part V) of 1963 “Soundness”

As required

(vii) Alkali aggregate reactively

2386 (Part VII) of 1963 As required

Cement

(i) Setting time 4031/1968 (Reaffirmed 1980)

1. Setting time test 2. Soundness test 3. Compressive strength 4. Specific gravity test: Once

each bulk supply and as and when required

(ii) Soundness -do- -do-

(iii) Compressive strength

-do- -do-

(iv) Specific gravity test 4031/1968 (reaffirmed 1980)

Once for each bulk supply as when required

(v) Chemical analysis 4032/1968 (reaffirmed 1980) “Chemical

Once for each bulk supply as and when required

53

analysis of hydraulic cement”

Ser No. Name of Tests Relevant IS Frequency

Cement Concrete

(i) Slump test IS: 1199/1959 “Method of sampling and analysis of concrete”

One test per 10 cum

(ii) Compacting factor One test per 10 cum

(iii) Compressive strength

516-1959 “Method of test as per strength of concrete (with amendment No.1)”

3 cube /beam sample as specified for each age of 7 days and 28 days for every 30 cubic meter

(iv) Flexural Strength 516/1959 “Method of test as per strength of concrete (with amendment No 1)”

3 cube /beam sample as specified for each age of 7 days and 28 days for every 30 cubic meter

(v) Core strength for hardened concrete

516/1959 2 cores/slab of concrete

54

55

Annexure II

AUTHORISATION OF LABORATORY EQUIPMENT

Ser No

Description Qty Authorized per site

SDO Lab

Break down authorization

GE (P) Total 1. Liquid limit device 1 1 - 1

2. Liquid limit penetrometer 1 1 - 1 3. Soil Densities

(a) Core cutter (b) Sand replacement

2 2

1 1

1 1

2 2

4. Proctor needle spring type 2 1 1 2

5. Proctor compaction apparatus 1 1 - 1 6. Rapid moisture meter 2 1 1 2

7. Hammer 4.89 kg for heavy compaction

1 1 - 1

8. Pycnometer flask 2 2 1 2 9. Aggregate impact tester 1 1 - 1

10. Aggregate crushing value apparatus

1 1 - 1

11. Los angeles abrasion testing machine

1 1 - 1

12. Sand bath apparatus 1 1 - 1

13. Anderson pipette 2 2 - 2 14. Sieve sets 2 1 1 2

15. Organic impurities testing set 1 1 - 1 16 Vicat needle apparatus 1 1 - 1

17. Tensile briquettes testing machine 1 1 - 1

18. Briquette moulds 2 2 4 2 19. Cube moulds 7.06x7.06x7.06 (cm) 18 6 12 18

20 Beam moulds 15x15x70x(cm) 18 6 12 18 21. Vibration machine for cube moulds 2 1 1 2

22. Le Chateliermoulds 3 2 - 1

23. Desicator 1 1 - 1 24 Bulk density apparatus 1 1 - 13

25 Water testing kit 1 1 - 2 26 Measurement cylinder 25 ml ,

100ml 3 1 1 1

27 (a) Electric oven (b) Field oven heated with oil stove

2 1

2 -

- 1

2 1

56

Ser No

Description Qty Authorized per site

SDO Lab

Break down authorization

GE (P)

Total

28 Weigh Balance (a) 250 gms (b) 10 kg

2 2

2 2

- -

2 2

29 Cylinder core cutting Machine 2 1 1 2

30 Thermometer (a) Normal (b) Bitumen (c) Max-min (d) Relative humidity (e) Rain gauge

2 4 1 1 1

1 2 1 1 1

1 2 - - -

2 4 1 1 1

31 Wind velocity 1 1 - 1 32 Weighing platform 1 1 - 1

33 Slump test apparatus 3 1 2 2 34 Compaction proctor apparatus 2 1 1 3

35 (a) Compression testing machine

(b) Flexural strength testing attachment

1 1

1 1

- -

1 1

36 Concrete testing machine 2 2 - 2

37 Stop watch 1 1 - 1 38 Variable frequency table vibrator 1 1 - 1

39 (a) Every balance 50 kg (b) Every balance spring 20 kg

1 2

1 2

- -

1 2

40 (a) Thickness gauge for elongation

(b) Length gauge for elongation

1 1

1 1

- -

1 1

41 Water tank for curing as required made locally of bricks (Water tank to be authorized for both lab & GE (P))

1

1

-

1

57

Ser No

Description Qty Authorized per site

SDO Lab

Break down authorization

GE (P) Total

42 Hand gloves of rubber 2 2 - 2

43 Wash bottles 500 ml 6 6 - 6 44 Specific gravity bottles

(a) 50 ml (b) 100 ml

2 2

2 2

- -

2 2

45 Volumetric flask 2 2 - 2 46 Bowls enameled

(a) 1 liter (b) 5 liter

8 4

8 4

- -

8 4

47 Enameled trays 12”x 15” x 12”

12 12 - 12

48 Aluminum trays 8 8 4 8

49 Crucible of porcelain 6 6 3 6 50 Hammers 14 lbs and 8 lbs 1 - 1 1

51 Tape measuring (a) 15 m (b) 5 m

1 2

1 2

- -

1 2

52 M.S. Round 0.6 m long 2 1 1 2

53 Steel scales 4 2 2 4 54 Set of wire brushes 2 2 - 2

55 IS Sieve 1.70 mm 2 2 - 2

56 Stove oil 2 2 - 2 57 Trimming blade 6” 3 1 2 3

58 Spatula 4” 5 5 - 5 59 Sample extractor 1 - 1 1

60 Vernier calipers 1 1 - 1 61 Adjustable spanners 1 1 - 1

62 Set of spanners 1 1 - 1

63 Set of screw drivers 1 1 - 1 64 Pliers 2 2 - 2

65 Moisture cans (a) 1 gallon (b) 4/5 gallon

4 4

2 2

2 2

2 2

66 Tongs 2 2 - 2

67 Chemical As required 68 Straight edge 3 m long 12 - 12 12

58

Annexure III (1)

TEST RESULT- FLAKINESS AND ELONGATION INDEX

Sample Identification

Size of age Total weight of aggregate in grams between gauge size

Total amount passing through thickness gauge in gms

Flakiness index%

Total amount retained on thickness gauge in gms

Elongation index Passing

IS sieve Retained on IS sieve

1 2 3 4 5 6 7 8

63 mm 50 mm w 1 w 1´ w1´ ---- x100 w1

w1-w1´ w1´ 1- -----x100 w1

50 mm 40 mm w 2 w 2´ w 2´ ---- x100 w 2

w 2-w2´ w 2´ 1- -----x100 w2

40 mm 25 mm w 3 w 3´ w 3´ ---- x100 w 3

w 3-w3´ w 3´ 1 - ---- x100 w 3

Work order no

(1) Internal job no (2) Max size of aggregate and other identification (3) Date of testing (4) Time of testing (5) Test conducted in presence of:

(a) GE’s rep ………………. Yes/No (b) Contractor’s rep ………………..Yes /No

Rep Name Signature Date GE _____ ________ _____ Contractor _____ ________ _____

(6) Test carried out as per Indian Standard IS 2386 (Part IV) – 1963 (7) Test Performed by*

(i) AE/AEE (ii) JE (B/R) (iii) JE (B/R) (8) Method and calculation checked by*

(i) AE/AEE (ii) JE (B/R) (iii) JE (B/R)

• Strike out which is not applicable

Sd/- AE/AEE (i/c)

59

Annexure III (2)

TEST RESULT – AGGREGATE CRUSHING VALUE/IMPACT VALUE/ABRATION VALUE

Aggregate Crushing Value

S No

Aggregate Used Retained on IS sieve

Dia of Cylinder used

Size of Sieve for Separating

Aggregate Crushing Value %

Mean Aggregate Crushing Value

Aggregate Impact Value

Sample No

Passing IS Sieve

Sample No

Impact Value %

1 2 3 4 5 6 7 8 9 10

LOS ANGELES ABRASION TEST

Sample No

Grading of Test Sample

No of Sphere Used

Weight of Charge gm

No of Revolutions

LA Abrasion Value

Remarks

11 12 13 14 15 16 17

(a) Crushing Value………………. (b) Impact Value…………………. (c) Abrasion Value……………….

Ref: (1) Work order no (2) Internal job no

(3) Date and time of casting (4) Test conducted in presence of

(a) GE’s rep…………..Yes/No (b) Contractor rep………………Yes/No

Rep Name Signature Date GE _____ ________ _____ Contractor _____ ________ _____

(5) Test Carried out as per Indian Standard IS 2386 (Part IV) – 1963 (6) Test Performed by*

(i) AE/AEE (ii) JE (B/R) (iii) JE (B/R) (7) Method and calculation checked by*

(i) AE/AEE (ii) JE (B/R) (iii) JE (B/R)

• Strike out which is not applicable � Sd/- � AE/AEE (I/C)

60

Annexure III (3) TEST RESULT – CONCRETE CUBE STRENGTH

Date of Casting Slab No. RESULT

I II III Mean Remarks 1. Identification Mark of Cube 2. Date and time casting 3. Mix Proportions 4. Method of mixing 5. Details of materials

(a) Type of Cement (b) Type of fine aggregate (c) Type of Coarse Aggregate (d) Admixtures (e) Remarks on Materials

6. Method of Compaction 7. Maximum and minimum Storage

Temperature 8. Curing Conditions 9. Weight of Specimens 10. Nominal Density 11. Date of test 12. Nominal Specimen Size 13. Age of Cube 14. Compressive Load at Failure 15. Type of Fracture 16. Remarks

SI No 1 to 8 Filled as per work order/laboratory record (1) Work order No………………… (2) Internal job No…………………. (3) Test conducted in presence of:

(a) GE’s rep…………..Yes/No (b) Contractor rep………………Yes/No Rep Name Signature Date GE _____ ________ _____ Contractor _____ ________ _____

(4)Test Carried out as per Indian Standard IS 2386 (Part IV) – 1963 (5)Test Performed by (6)Test Performed by*

(ii) AE/AEE (ii) JE (B/R) (iii) JE (B/R) (7)Method and calculation checked by*

(ii) AE/AEE (ii) JE (B/R) (iii) JE (B/R)

• Strike out which is not applicable

Sd/-

AE/AEE (i/c)

61

Annexure III (4)

TEST RESULT- CEMENT

Date of Testing:

Time of Testing:

SL No Sample No Compressive Strength Kg/Cm² Remarks

7 Days

Individual Cube Strength Mean Strength

(1) Work order No…………………

(2) Internal job No………………….

(3) Test conducted in presence of:

(a) GE’s rep…………..Yes/No (b) Contractor rep………………Yes/No

Rep Name Signature Date GE _____ ________ _____ Contractor _____ ________ _____

(4)Test carried out as per Indian Standard IS: 4031 of 1968

(5)Test Performed by*

(iii) AE/AEE (ii) JE (B/R) (iii) JE (B/R)

(6)Method and calculation checked by*

(iii) AE/AEE (ii) JE (B/R) (iii) JE (B/R)

Sd/-

AE/AEE (I/C)

62

Annexure III (5)

TEST RESULT- CONCRETE FLEXURAL AND EQUIPMENT CUBE STRENGTH

1. Work order No. Date of casting: 2. Internal job No. Slab No:

Ser No

Item Result Remarks

1. Identification mark of beam

2. Date and time of mixing 3. Mix proportions

4. Method of mixing

5. Details of materials (a) Type of cement (b) Type of fine aggregate (c) Type of Coarse Aggregate (d) Admixture (e) Remarks on Material

6. Method of Compaction 7. Maximum and minimum Storage Temperature

8. Curing Conditions 9. Weight of Specimens

10. Nominal Density 11. Date of test

12. Nominal Specimens Size

13. Age of beam 14. Load of Failure (Two point loading)

15. Modulus of rupture 16. Position of fracture (value ‘a’)

(a) Distance between the line of fracture and the nearer support measured on the centre line of the tensile side of the specimen

17. Curing condition

18. Appearance of concrete

19. Date of testing 20. Nominal specimens Size

21. Age of cube when cut 22. Compressive load at failure

23. Equivalent compressive strength 24 Weight of Specimens

25. Type of Fracture

Note: (a) Date of testing beam and cube should normally be same (b) SI No 1 to 8 Filled as per work order/laboratory record.

63

3. Test conducted in presence of: (a) GE’s rep…………..Yes/No (b) Contractor rep………………Yes/No

Rep Name Signature Date GE _____ ________ _____ Contractor _____ ________ _____

4. Test Carried out as per Indian Standard IS: 516/59

5. Test Performed by

(i) AE/AEE (ii) JE (B/R) (iii) JE (B/R) 6. Method and calculation checked by*

(i) AE/AEE (ii) JE (B/R) (iii) JE (B/R)

• Strike out which is not applicable

Sd/-

AE/AEE (i/c)

64

Annexure III (6)

TEST RESULT –SIEVE ANALYSIS COARSE AGGREGATE/FINE AGGREGATE

1. Work order No. 2. Internal job No. 3. Date and Time of Testing.

SL No

Sample No

Designation Sieve

PERCENTAGE PASSING Remarks 80 63 40 25 20 16 12.5 10 4.75 2.36 1.18 600 300 150 75 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

4 Test conducted in presence of (a) GE’s rep…………..Yes/No (b) Contractor Rep………………Yes/No Rep Name Signature Date GE _____ ________ _____ Contractor _____ ________ _____

5. Test Carried out as per Indian Standard IS 2386 (Part I) 1963 6. Test Performed by*

(i)AE/AEE (ii) JE (B/R) (iii) JE (B/R)

7. Method and calculation checked by* (iv) AE/AEE (ii) JE (B/R) (iii) JE (B/R)

• Strike out which is not applicable Sd/-

AE/AEE (I/C)

65

Annexure IV

SPECIMEN OF WORK ORDER

…………………..

………………….

To

AE/AEE Field Laboratory

PARTICULAR OF TEST

Please conduct the ……………..as per IS/CA………………… (as applicable) The particular of sample duly initiated by the representative of GE and contractor if applicable in respect of CA No………………………. tabulated below:-

S. No.

Samples particulars

Code (as per letter no …of… to be filled by GE

Desired date and time of testing

Weight of specimen

Dimensions Specimen marking

Signature of Rep. Test to be conducted Acceptance of job GE Contractor GE Rep. Yes/No

Contractor Rep. Yes/No Accepted/Not Accepted*

*Reason for not accepting job………………….. (to be given by AE/AEE) Special instructions are to be given on reverse (to be given by the concerned GE. If any) Job No…………………………….

Test result sent vide test report No………………………………

Sd/- Sd/-

AE/AEE (Lab) Name and appointment

Date: For GE

66

Annexure V

MARKING OF A CONCRETE CUBE AND BEAM SAMPLE

1. Each sample shall be marked as under

(39/3 of 13-3-74)

Where 39 indicates Slab No.

3 indicates beam/cube No.

13-3-74 indicates date of casting

2. Slabs will be marked serially.