METHOD STATEMENT

PQC ROAD CONCRETE

METHODOLOGY FOR P.Q.C CONCRETE ROAD PAVEMENTS

1. Layout
As per approved drawings, layout of road will be marked including curves.
As derived from finalized formation levels, grading of the existing of
ground will be done.

2. UCR Masonry
Grading of road will be followed up with construction UCR Masonry for
confining the earth filling. Masonry of width 600 mm will follow the
longitudinal profile of the road length. Masonry will not be constructed at
locations of Road Crossing. Once the hume pipe laying and jointing is
finished, masonry will be done at crossing. Proper curing will be done for
required period.

3. Earth Filling
After sufficient length of UCR masonry is completed, filling within UCR
masonry will be started in layers. Simultaneously watering and rolling with
power roller will be carried out to ensure the required degree of
compaction is achieved. Compaction will be checked by taking cores and
determining the field dry density.

4. Soling
Soling activity will be started for a particular stretch after compaction test
for filling is passed for that stretch. Soling stones will be of sizes between
150-200mm. Stones having more than 200 mm will be broken at site &
will be used. Voids between stones will be filled with smaller one and the
surface shall be dry rolled.

After the dry rolling, the surface shall be spread with a combination of 6
mm and 10 mm downgraded crushed stone materials and the surface will
be rolled again.
5. P. C. C.

Over a prepared surface of soling, PCC 1:4:8 grade of 50mm thk. will be
laid and compacted carefully. Utmost care will be taken to maintain the
camber and gradient as per drawing. PCC at location of kerb stones will be
lowered by minimum 30mm to receive mortar and kerb stone over RR
Masonry.
5. Laying & Fixing of R.C.C. Kerb Stones.
In order to avoid unevenness between joints of kerb stones and PQC
pavement, we propose to fix the RCC Kerb Stones to the required gradient
and camber before casting concrete pavement. It also serves as
shuttering on one side for pavement. Kerb Stones will be laid in position
over CM 1:6 after PCC laid. Proper attention will be taken to ensure the
fixing of Kerb Stones as per requirement.

6. P.Q . C.
PQC activity will be started after curing for 3 days of pre laid PCC. PQC will
be planned by alternate panel method from expansion joint to expansion
joint spaced at 36 M.

Prior to start, construction joint and expansion joints will be decided.

Sequence of concreting in alternate panels will be preplanned.
Guide channels of 125 mm will be fixed to the required level over a
bed of
Mortar. Guide channels will be properly cleaned and applied with
suitable

Releasing agents.

Channels will not be grouted from in side for the alignment.

Reinforcement as per drg for total panel size will be tied with cover as
15mm from side and 60 mm from top.
 Top transverse R/F will pass through the holes drilled in guide channels
And protruded into other side of vertex with minimum lap of 50 dia.

Bottom R/F as stipulated in drg shall be placed at all construction joints

both laterally and longitudinally.

At expansion joints, R/F will be terminated. Expansion dowel bars will

be
embedded as per drawing, which will pass through the holes, drilled
in

end channels.

Special walkway stand will be used, so that labour may not walk on
reinforcement cage.

PCC will be watered before starting PQC.

Concrete will be produced from Batching plant and supplied through
transit mixers. Mix will be designed for flexural strength of 40
kg/sq.cm.

To avoid distortion/dislocation of R/F during concreting by manually or

by pouring directly by transit mixer, concreting will be done by
pumping. Concrete will be placed and distributed evenly and as near
the final level as possible.
Concrete will be vibrated with an immersion vibrator before screed
vibrator. Heaping of concrete of screed vibrator will be avoided except
sufficient quantity of concrete to maintain uniform level of top surface.
Area close to channel will be carefully vibrated.
After immersed vibration, surface vibration will start with screed
vibrator, which will be pulled from both ends.
Scrapping of concrete will be carried out to collect any excess amount
concrete over surface & to use the same to fill any depressions.
 Finishing operation will be done by floating with skim floater attached
with a disc and again attached with trowelling blades.
As finishing of concrete for a panel is completed, grooves will be cut
transversely as well as longitudinally as per finalised layout of joints
after 24 hours.
Casting date will be marked an each panel.
Curing will be done by ponding for period of minimum 7 days.

7. Treatment of joints.
Grove will be cut at all construction as well as expansion joints. Sizes of
groove

will be maintained as per drawings / tender specifications.

Cutting will be started as early as possible but not later than 48 hrs of
casting.

Cutting will be followed by drying, cleaning by blowing air and filling it

with

elastomatic polysulphide sealings of approved make, after completion of

curing period.

Joints between kerb stones and pavement:-

Because of dissimilarity of materials, a thin crack may appear between

kerb stones and pavement. At this joint a groove will be cut and treated
as per 7 above.

8. Quality assurance during casting concrete pavement.

MAGUS will exert sufficient efforts to assure quality at all phases of Road
Work. Separate team consisting of efficient engineers and supervisors will
 be deployed. Check list will be maintained during casting of pavement
and will be followed strictly.

Quality Control Engineer will closely monitor the execution to avoid any
non -conforming out put.

WORK INSTRUCTION FOR PQC ROAD

Initial suitable layout of construction joints and isolation joints shall be

decided prior to start of concrete flooring.
The surface of the guide channels (on which the surface vibrator is
supported), shall be cleaned from concrete. Align the guide channels to
true required level. Panel casting layout shall be strictly followed as per
step 1.
No channel shall be grouted from inside, because the mortar used for
fixing the channels is of inferior quality than the parent concrete and
leaves loose pockets in the uniform concrete.
Difference between the channel size and the required thickness of the
slab should not be more than 25 mm. i.e. For 175 mm thick slab, channel
should not be of lesser dimension than 150 mm.
Reinforcement should have maximum 25 mm cover from side faces.
Special walk-way stand should be used so that labours should not walk on
reinforcement cage.
PCC shall be well watered before starting PQC.
An exclusively allotted charge hand shall monitor weigh batcher.
 Concrete shall be placed and distributed evenly and as near the final level
as possible.
Concrete shall be vibrated with an immersion vibrator before screed
vibrator. Heaping of concrete in front of screed vibrator will be avoided,
however, sufficient quantity of concrete should be maintain in front of the
screed vibrator to maintain uniform level of top surface.
Ensure that the areas close to channels and stop ends are carefully
vibrated. Ensure not to distribute the concrete with the poker vibrator as it
would create a risk of over vibration and segregation. Tamping with
wooden mallet to the channel can be opted for better finish on the side.
Surface vibration should start as soon as there is enough concrete in front
of the screed vibrator. Screed Vibrator is to be pulled from both ends.
The filter pads should be placed as soon as the sufficient concrete surface
is vibrated. Vacuum dewatering process must start within 30 minutes from
the time of start of concrete pouring.
Finishing should be proper and brooming should be light and uniform in all
the panels. Brooming should be in the direction perpendicular to the
direction of travel Sketch of a broom.
The filter pads are placed in such a way that there is at least 100 mm
(4) fresh concrete visible around the filter pads on all four sides. Filter
pads should be overlapped with each other by at least 250 mm (10).
Suction pad must be rolled open over the filter pads and dewatering must
then start. Extent of dewatering is related to thickness of floor concrete
i.e. Average 4 minutes per inch thickness OR physical check of dewatered
surface which should not give foot print while walking on it. Excess/less
dewatering is not advisable.
While repeating dewatering process subsequently, suction pad must be
rolled out atleast 300 mm over the vacuum dewatered area. Before
spreading the suction pad on dewatered area, it is essential to give one
 pass of skimfloater (with the disc) along the edge of the dewatered
concrete.
The central pipe of the suction pad shall be attached to the suction hose,
which in turn shall be connected to the vacuum pump. When the pump is
started, vacuum will be created between the top cover and filter pads.
Excess water from the concrete will be taken into the vacuum pump tank
and discharged through a pipe away from fresh panel.
After Vacuum Dewatering, scrapping operation shall be made diagonally
in two directions over the concrete surface.
The concrete, which is collected during scrapping, shall be used for
adjusting small surface irregularities of the vacuum treated surface.
The first finishing operation shall be done by floating with the skimfloater
attached with a disc.
The second finishing operation shall be trowelling with skimfloater
attached with the trowelling blades. Normally, trowelling is to be
continued till the smooth surface finish is achieved without floater marks.
Casting date shall be marked on each panel.
Curing can be done by ponding, covering with plastic sheets or gunny
bags. Curing must be done for at least 14 days.
Groove cutting for construction joints or isolation joints shall follow the
sequence of flooring within 48 hrs. Alternatively teak wood batten can be
inserted in the fresh concrete to make a groove during finishing the
surface. This batten should be removed while the concrete is still green
without damaging the edges.
Groove filling can be done with any elastomeric material or as specified in
the tender subsequently. Proper groove cleaning and drying should be
ensured.
 DONTS FOR ROAD CONCRETE

PCC work should not be started without checking line, level, width and
alignment of the soling.
Channel laying should not be started without checking line, level, width
and alignment of PCC.
No channel shall be grouted from inside, because the mortar used for
fixing the channels is of inferior quality than the parent concrete and
leaves loose pockets in the uniform concrete.
Difference between the channel size and the required thickness of the
slab should not be more than 25 mm. i.e. For 175 mm thick slab, channel
should not be of lesser dimension than 150 mm
No labours / person should be allowed to walk on the reinforcement cage.
PQC should not be started without ensuring that the surface of PCC is
cleaned properly.
Fresh PQC placed in the panel should not be over-vibrated near the edges
& corners to avoid loss of slurry.
Side channel should not be removed while concrete is still green.
Heaping of concrete in front of screed vibrator shall be avoided, however,
sufficient quantity of concrete should be maintain in front of the screed
vibrator to maintain uniform level of top surface.
Do not use poker vibrator to spread or distribute the laid concrete.
Do not mix mortar or concrete on the finished surface of the road.
Do not keep cut grooves open for longer period to avoid damage to the
edges.