10/2011

TECHNICAL INSTRUCTION
AIRFIELD

SPECIFICATIONS FOR
CONCRETE AIRFIELD PAVEMENTS
 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

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 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.

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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.

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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.
[Link] 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.
[Link] 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.

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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.

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 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

5
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

6
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

7
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

8
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
9
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.

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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

11
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

12
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
0
temperature is above 35 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.

13
 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

14
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.

15
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.

16
 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

17
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.

[Link] 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.
[Link] 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.
[Link] 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.

18
[Link] 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

19
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.

20
 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

21
 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

22
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

23
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.

[Link] 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:-

24
 (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

25
 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.

26
 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.

27
 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

28
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.

29
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.

30
 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
31
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.

32
 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 Slump Compacting factor Use for which concrete is suitable

Workability (mm) Small Large
Apparatus Apparatus
Very low Up-to 0.75 0.80 Roads operated by power operated
25 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- 0.09 0.96 For sections with congested
150 reinforcement. Not normally suitable
for vibration.

*Not normally used unless aggregates size exceeds 40 mm.

33
 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 Sieve Designation Percentage by weight passing the

No 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.

34
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.

35
 Table 3. Fine Aggregate Requirements

lS Sieve Percentage passing for

Designation
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.

36
 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

37
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 IS: 2770 Part IV 4 Tests per 8000 m³
analysis (including 1975 of soil
determination of the
uniformity if required) - To be carried out in
(b) Particles size analysis by case essential as
hydrometer method per direction of Lab
Staff.
2. Atterberg Limits
(a) Liquid limit IS: 2770 Part V As per [Link]. 1(a)
above
(b) Plasticity index -do- As above
3. Natural Moisture Contents IS: 2770 Part II One test for 250 m³
1973 of soil
4. Standard Proctor Test IS: 2770 Part As 1 (a) above
VII & VIII 1974
5. Modified Proctor Test IS: 2720 Pt VII As 1(a) above
& VIII-1974
6. CBR on a set of 3 specimens IS: 2720 Part One test for 3000
XVI m³ or one test each
in case of change in
soil.
7. Deleterious constituents IS: 2720 Part As required
XXVIII
8. Moisture content just before IS: 2720 Part II Two to three tests
compaction 1973 for 250 m³ of loose
soil.
9. Dry density of compacted layer IS: 2720 Part One test per 750 m²
XXVIII of compacted area
10. CBR at 95% compaction IS: 2720 Part As above
specification for the layer concerned XVI 1965(as
revised)

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.

38
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.

39
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:-

[Link]. 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 IS:2720(Part-II) One test per 250m2
compaction
6. Density of compacted layer IS:2720(Part- One test per 500m2
XXVIII)
7. Control of Grade, camber ---- Regularly
thickness and surface finish
8. CBR test (on a set of 3 IS :2720(Part-XVI) As required
specimens)

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).

40
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

41
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 Tests Test Method Minimum

No. Desirable
Frequency
1. Los Angeles abrasion value/Aggregate IS:2386 (Part IV) One test per
3
Impact value 200m
2. Grading of aggregate and screenings IS: 2386 (Part I) One test per
3
100m
3. Flakiness index of aggregate IS: 2386 (Part I) One test per
3
200m
4. Plasticity of binding materials IS: 2720 (Part V) One test per
200m3
5. Control of grade camber thickness and - Regularly
surface finish
6. Compaction One test per 750
(a) Density/Moisture content by m2 of compacted
modified proctor area
---do---
(b) Plate bearing test

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

42
 (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 Test Test Method Minimum desirable

No. 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 IS:2720(Part II) -----do-----
compaction
6. Dry Density IS:2720 (part One test per 500 m2
XXVIII)
7. Control of grade camber thickness ------------- Regularly
& surface finish
8. Cube strength of material mixed at IS:516 One test per 50 m3 of
site (a set of 2 specimens) 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

43
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:-
[Link] Test Test Method Minimum
desirable
frequency
1. Quality of cement IS:269/455/1489 ----do---
2. Los Angeles Abrasion IS 2386 (Part IV) One test per 200m3
Value/Aggregate Impact Value
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 - Regularly
thickness and surface finish
7. Cube strength of material mixed IS:516 One test per 50 m3
at site (a set of 2 specimens) 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 Max 20%
(ii) Magnesium Sulphate -
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

44
Classification IS-400 Passing sieve
A 13.2 mm 13.2 mm 100
11.2 mm 95-100
5.6 mm 15-25
180.00 micron 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180.00 micron 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.

45
 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

46
3.2 Responsibility, Function and Qualitative [Link] 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.

47
 (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.

48
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 [Link]/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.

49
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.

50
 (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.

51
 Annexure 1

Ser Name of Tests Relevant IS Frequency

No.
Aggregates
(i) Gradation test 2386 (Part I) of 1963 One test for 15 cum of each
“Particles size and fraction of coarse and fine
Shape” aggregate
(ii) Deleterious 2386 (Part II) of 1963 One test for 15 cum of each
constituents “Estimation of Materials fraction of coarse and fine
& Organic Impurities” aggregate
(iii) Moisture content 2386 (III) of 1963 Regularly as required subject to
test 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 2386 (Part III) 1963 As required
aggregate (for
volume batching)
(v) Los Angeles – IS: 2386 (Part IV of Once for each source of supply
Abrasion value 1963) “Mechanical and subsequently when
/aggregate impact Properties” warranted by change in the
quality of aggregate
(vi) Soundness test 2386 (Part V) of 1963 As required
for coarse “Soundness”
aggregate
(vii) Alkali aggregate 2386 (Part VII) of 1963 As required
reactively
Cement
(i) Setting time 4031/1968 (Reaffirmed 1. Setting time test
1980) 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 -do- -do-
strength
(iv) Specific gravity test 4031/1968 (reaffirmed Once for each bulk supply as
1980) when required
(v) Chemical analysis 4032/1968 (reaffirmed Once for each bulk supply as
1980) “Chemical and when required

52
 analysis of hydraulic
cement”

Ser No. Name of Tests Relevant IS Frequency

Cement Concrete
(i) Slump test IS: 1199/1959 “Method One test per 10 cum
of sampling and
analysis of concrete”
(ii) Compacting factor One test per 10 cum
(iii) Compressive 516-1959 “Method of 3 cube /beam sample
strength test as per strength of as specified for each
concrete (with age of 7 days and 28
amendment No.1)” days for every 30 cubic
meter
(iv) Flexural Strength 516/1959 “Method of 3 cube /beam sample
test as per strength of as specified for each
concrete (with age of 7 days and 28
amendment No 1)” days for every 30 cubic
meter
(v) Core strength for 516/1959 2 cores/slab of
hardened concrete concrete

53
54
 Annexure II
AUTHORISATION OF LABORATORY EQUIPMENT

Ser Description Qty SDO Break down

No Authorized Lab authorization
per site
GE (P) Total
1. Liquid limit device 1 1 - 1
2. Liquid limit penetrometer 1 1 - 1
3. Soil Densities
(a) Core cutter 2 1 1 2
(b) Sand replacement 2 1 1 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 1 1 - 1
compaction
8. Pycnometer flask 2 2 1 2
9. Aggregate impact tester 1 1 - 1
10. Aggregate crushing value 1 1 - 1
apparatus
11. Los angeles abrasion testing 1 1 - 1
machine
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 , 3 1 1 1
100ml
27 (a) Electric oven 2 2 - 2
(b) Field oven heated with oil stove 1 - 1 1

55
Ser Description Qty SDO Break down
No Authorized Lab authorization
per site
GE Total
(P)
28 Weigh Balance
(a) 250 gms 2 2 - 2
(b) 10 kg 2 2 - 2
29 Cylinder core cutting Machine 2 1 1 2
30 Thermometer
(a) Normal 2 1 1 2
(b) Bitumen 4 2 2 4
(c) Max-min 1 1 - 1
(d) Relative humidity 1 1 - 1
(e) Rain gauge 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 1 1 - 1
machine
(b) Flexural strength testing 1 1 - 1
attachment
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 1 1 - 1
(b) Every balance spring 20 kg 2 2 - 2
40 (a) Thickness gauge for 1 1 - 1
elongation
(b) Length gauge for elongation 1 1 - 1
41 Water tank for curing as required 1 1 - 1
made locally of bricks (Water tank
to be authorized for both lab & GE
(P))

56
Ser Description Qty SDO Break down
No Authorized Lab authorization
per site
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 2 2 - 2
(b) 100 ml 2 2 - 2
45 Volumetric flask 2 2 - 2
46 Bowls enameled
(a) 1 liter 8 8 - 8
(b) 5 liter 4 4 - 4
47 Enameled trays 12 12 - 12
12”x 15” x 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 1 1 - 1
(b) 5 m 2 2 - 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 4 2 2 2
(b) 4/5 gallon 4 2 2 2
66 Tongs 2 2 - 2
67 Chemical As required
68 Straight edge 3 m long 12 - 12 12

57
 Annexure III (1)

TEST RESULT- FLAKINESS AND ELONGATION INDEX

Sample Size of age Total Total Flakiness Total Elongation

Identification Passing Retained weight of amount index% amount index
IS sieve on IS aggregate passing retained
sieve in grams through on
between thickness thickness
gauge gauge in gauge in
size gms gms
1 2 3 4 5 6 7 8
63 mm 50 mm w1 w 1´ w1´ w1-w1´ w1´
---- x100 1- -----x100
w1 w1
50 mm 40 mm w2 w 2´ w 2´ w 2-w2´ w 2´
---- x100 1- -----x100
w2 w2
40 mm 25 mm w3 w 3´ w 3´ w 3-w3´ w 3´
---- x100 1 - ---- x100
w3 w3
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)

58
 Annexure III (2)
TEST RESULT – AGGREGATE CRUSHING
VALUE/IMPACT VALUE/ABRATION VALUE

Aggregate Crushing Value

S Aggregate Used Retained Dia of Size of Aggregate Mean Aggregate
No on IS Cylinder Sieve for Crushing Aggregate Impact Value
Sample Passing sieve used Separating Value % Crushing Sample Impact
No IS Sieve Value No Value
%
1 2 3 4 5 6 7 8 9 10
LOS ANGELES ABRASION TEST

Sample Grading No of Weight No of LA Remarks

No of Test Sphere of Revolutions Abrasion
Sample Used Charge Value
gm
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)

59
 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)

60
 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)

61
 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 Item Result Remarks
No
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.

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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)

63
 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 Sample Designation PERCENTAGE PASSING Remarks
No No Sieve 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)

64
 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. Samples particulars
No.
Code (as per letter Desired date Weight of Dimensions Specimen
no …of… to be and time of specimen marking
filled by GE testing

Signature of Rep. Test to be conducted Acceptance of job

GE Contractor GE Rep. Yes/No Accepted/Not
Contractor Rep. Yes/No 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

65
 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.

66