CODE OF PRACTICE FOR CONSTRUCTION OF JOINTED PLAIN CONCRETE PAVEMENTS -
This Code of Practice is intended to indicate what is considered to be good practice for the construction of jointed plain concrete pavements, including preparation of the subgrade and sub-base underneath these pavements.
The Code deals with various aspects of jointed plain concrete pavement construction, like, materials, equipment, proportioning, measurement, handling of materials, and mixing subgrade and sub-base preparation, formwork, joints, reinforcement of concrete,placing, llnishing, curing, evaluation for acceptance criteria etc.
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3. CODE OF PRACTICE
FOR
CONSTRUCTION OF JOINTED PLAIN
CONCRETE PAVEMENTS
(Fifth Revision)
Published by:
INDIAN ROADS CONGRESS
Kama Koti Marg,
Sector-6, R.K. Puram,
New Delhi-'110 022
NOVEMBER,2O17
IRC:'15-2017
Price : t 10001
(Plus Packing & Postage)
Ajit Pratap Singh, NH-56
ajit42chat1@rediffmail.com
4. IRC:'15-2017
rst Published
First Revision
Second Revision
Third Revision
Reprinted
Reprinted
Fourth Revision
Reprinted
Fifth Revision
July, '1965
December, 1970
December, 1981
February,2002
September,2003
October.2005
May, 20'11
Aptil, 2014
November. 2017
Printed by lndia Offset Press, Dethi -'l1O 064
500 Copies
(All Rights Reserved. No part of this publication shalt be reproduced,
translated or transmitted in any form or by any means without the
permission of the lndian Roads Congress)
5. CONTENTS
S.No. Description
Personnel of the Highways Specifications and Standards Committee
'1. lntroduction
2. Scope
3. Materials
4. Proportioning of Concrete
5. Tools, Equipment, Machines and Appliances (lRC:43)
6. Preparation of Subgrade, Sub-base and Laying of Separation Membrane
7 Weather Limitations
8. Joints
9. Storage of Materials and Preparation for Construction
10. Construction
11. Trial Length
12. Quality Control
'13. Opening to Traffic
Appendix - A
IRC:15-2017
Page No.
FI
I
2
3
10
12
21
43
45
67
71
89
90
l
=
7. :-
:-
:-
!'
=
-
IRC:15-2017
Direclor General (Road Development) & Special Secrelary to Govt of
lndia, Ministry of Road Transporl and Highways. New Delhi
Addl Director General (lncharge), .[,4inistry of Road Transport and
Highways, New Delhi
Chief Engineer (R) S,R & I [.iinistry of Road Transport & Highways,
New Delhi
Members
R&D. lndian lnstitute of Mass Communlcation, New Delhi
Chief Engineer, PWD, Arunachal Pradesh
Chairman, TED, Bureau of lndian Standards, New Delhi
Secreiary (Retd.), PWD Maharashtra
DG(RD) & AS (Retd.), Ministry of Road Transport and Highways,
New Delhi
Professor, lndian lnstitute of Technology, Roorkee
Chief Engineer (Retd.), PWD Haryana
Chief Execulive, L.R. Kadiyali &Associates
Expted on 18.02.2016), New Delhi
Chairman. Environment Pollution Control Authority. Delhi
Engineer in-Chief, Gurugram Melropolitan Development Aulhority.
Haryana
DG. Centre for Science and Environment, New Delhi
JI,4D, Maharashtra Slate Road Development Corporation Ltd , i/umbai
Member (Projects), National Highways Authorily ol lndia New Delhi
Dean, SRIC, lndian lnstitute ofTechnology, Roorkee
Director (Tech), National Rural Roads Development Agency, New Delhi
Secretary (Retd.), PWD Maharashlra
ADG {Retd.), Border Roads organisation, New Delhi
Engineer-in-Chief (Retd.), Roads & Building, Andhra Pradesh
Executive Director, AECOM lndia Pvi. Ltd
CG[,1, National Highways Authority of India, New Delhi
Chief Engineer, Irinistry of Road Transport and Highlvays New Oelhi
DGiRD) & SS (Reld.), Minislry of Road Transport and Hrghways
New Delhi
2
3
Kumar, Manoi
(Conveno4
Singh, B.N
(Co-convenor)
Verma, Dr. S K.
(Member Secrelary)
4 Bamezai, Prof. (Dr.) Gita
5 Basar, Toli
6 Bhanol, Bahaj
7 Bongirwar, PL.
8 Gupta, D.P
9 Jain, Prof. (Dr.) S.S.
10 Jain. R.K.
11 Kadiyali, Dr L.R.
12 Lal, Bhure
13 Lal, Chaman
14 Narain, Sunita
15 Nashikkar, J.l
16 Pandey, R.K.
17 Parida, Prof. (Dr.) M.
18 Pateriya, Dr. l.K.
19 Pawar, Ajit
20 Porwal, Dr. S.S. (VSM)
21 Raju, Dr. G.VS.
22 Rawat, M.S.
23 Sarangi, D.
24 Sharma, M.P
25 Sharma, S.C.
PERSONNEL OF THE HIGHWAYS SPECIFICATIONS
ANO STANDARDS COMMITTEE
(As on 23.06.2017)
1
8. IRC:1 5-2017
26 Sheokand, Balbir Singh
27 Singh, Nirmaliil
28 Singh, Pawan Kumar
29 Sinha, A V
30
31
32
33
34
35
Executive Engineet PWD Haryana
DG(RD) & SS (Retd.), Minislry of Road Transporl and Highways,
New Delhi
GM. 3M lndia Ltd
DG(RD) & SS (Retd.), Ministry of Road Transport and Highways,
New Delhi
Member (T), National Highways Aulhority of tndia, New Dethi
Cenlral Road Research lnsl tule. New Dethl
Border Roads Organisation, New Delhi
Society of lndian Automobile Manufactures. New Delhi
Military Engineer Services, New Delhi
Secretary (T), PWD Jammu
Professor, lndian lnstitute ofTechnology, New Delhi
Superintending Engineer, Ministry of Road Transport and Highways,
New Delhi
MD, Engg and Planning Consultants Ltd., New Delhi
Conesponding Members
President, lnslitute of Road Traffic Educalion, New Delhi
Engineer-in-Chief (Retd.), Tripura
DG(RD) & SS (Retd.), Ministry of Road Transport and Highways
New Oelhi
Central lnstilute of Road Transport, pune
Ex-Otficio Memberc
(Pradhan, N K.), EngineeFtn-Chief cum Secretary, Works Department,
Odisha
(Kumar, ftranoi), Ministry of Road Transport and Highways, New Delhi
Nirmal, Sanjay Kumar
Tawade. D.O
The Directot
(Chandra, Dr Salish)
The Direclor ceneral,
(Shrivaslava, Lt. Gen. S K.)
The Director ceneral,
(Mathur, Vishnu)
The Engineer in-Chief,
(Sharma, Lt. Gen Suresh)
Tickoo, Bimal
Tiwari, Prof. (Dr.) Geetam
37 Varshney, Sharad
38 Verma. c.L
1 Baluja, 0.. Rohit
2 Bhowmik. Sunil
3 Kandasarny, C
The Drrector
(Patil, Capl. (Dr.)Rajendra B
Saner)
2
3
I
President.
lndian Roads Congress
Director General(Road
Developnent) & Special
Secrelary to Govt of lndia
Secrelary ceneral,
lndian Roads Congress
1
9. -
CODE OF PRACTICE FOR
CONSTRUCTION OF JOINTED PLAIN CONCRETE PAVEMENTS
Jain, R.K.
Ganju, Col. (Retd.) V.K.
IRC:1 5-2017
Convenor
Co-Convenor
Member-Secretary
Ramachandra, Dr. V. (1 8.08.201 6
onwards)
l INTRODUCTION
The Standard Specification and Code of Practice for Construction of Concrete Road was Iirst
published in July 1965. The second edition was brought out in December 1970, and the third
edition was brought out in the year of2002. The fourth edition ofthe document was published
in 201'l under the Convenorship of Late Sh. V. K. Sinha and Sh. R. K. Jain as Co-Convenor
of the Rigid Pavement Committee. Since then the technology for road construction has
undergone considerable changes and MOSRTH Specification for Road and Bridge Works
has been revised. Some special requirements like widening of existing four lane concrete
road to six lane and construction of four lane concrete pavement in place of existing two
lane bituminous road have arisen. Some problems relating to the construction of transition
slab between rigid and flexible pavement, corrosion of dowel bars and damage done to the
slabs by vibratory trails have been observed in concrete pavements constructed in the last
few years. The use of Ground Granulated Blast Furnace Slag (GGBFS) and Metakaolin as
mineral admixture, Poly-Carboxylate Ether based High Range Water Reducing Admixtures,
string-less paving system for paving concrete, lvlagnetic Pulse lnduction technique for
checking alignment of dowel bars have emerged and being practiced for better construction
of concrete roads.
Therefore a need was felt to update the standard to include the latest development in the area
of construction of concrete roads. The revised draft was prepared by the subgroup comprising
of Sh Binod Kumar, Sh. R. K Jain, Sh. Raman Kumar, and Sh. Rajesh Madan, members of
the Rigid Pavement Committee. The Rigid Pavement Committee (H-3) deliberated on the
document in a series of meetings and finalised it in its meeting held on 27rh May,2017
The revised draft was placed before the Highways Specillcations and Standards Committee
(HSS) in its meeting held on 23d June, 2U7 . fhe HSS committee approved the draft with
some suggestions including the change in the title of the code. The draft revised as per the
suggestions of HSS and with changed title of "Code of Practice for Conskuction of Jointed
Plain Concrete Pavement" was approved by the Council of IRC after taking on board the
comments of the members in its 2121h Mid-Term Council meeting held on 14'h July,2017 at
Udaipu r.
Members
1
Avtar. Ram
10. IRC:15-2017
BongiMar, PL. Ramana, Dr. G.V
Gajria, Maj. Gen. K.T. Reddy, S.S.
Gupta, Prof. (Dr.) PK. Sengupta, J.B.
lndoria, R.P Sharma, M.P
Jain, A.K. fuplo 17.08.2016) Sheokand, B.S.
Jain, L.K. Srivastava, R.K.
Joshi, Brig. Girish Tare, Dr. Vandana
Kumar, Binod Thaka( Vikas
Kumar, Raman Thombare, Vishal
Madaan, Rajesh Tipnis, Col. (Retd.) Manoj
Maiti, Dr S.C. Trivedi, Anil
Nayak, Sanjay Venkatesha, M.C.
Corresponding Members
Justo, Prof. (Dr.) C.E.G. Ramchandani, S.M.
Pandey, Prof. (Dr.) B.B. Veeraragavan, Prof. (Dr.)A.
Ex-Oflicio Memberc
President, (Pradhan, N.K.), Engineer-in Chief
lndian Roads Congress cum Secretary, Works Department,
Odisha
Director General (Kumar, Manoj), Ministry of Road
(Road Development) & Special Transport & Highways
Secretary to Govt. of lndia
Secretary General, Nirmal, Sanjay Kumar
lndian Roads Congress
2 SCOPE
2.1 This Code of Practice is intended to indicate what is considered to be good
practice for the construction of jointed plain concrete pavements, including preparation of the
subgrade and sub-base underneath these pavements.
2.2 The Code deals with various aspects of jointed plain concrete pavement
construction, like, materials, equipment, proportioning, measurement, handling of materials,
and mixing subgrade and sub-base preparation, formwork, joints, reinforcement of concrete,
placing, llnishing, curing, evaluation for acceptance criteria etc.
2
11. IRC:1 5-20i 7
,2, ? The present code incorporates relevant provisions of the latest version of codeslisted below. For further details wherever required, these codes may be referred
i) Guidelines for Cement Concrete Mix Design for pavements (tRC:44)
ii) Recommended practice for Sealing of Joints in Concrete pavements
(tRC:57)
iij) Guidelines for Maintenance, Repairs and Rehabilitation ot Cement Concretepavements (tRC:Sp-83).
Guidelines for Conventionat and Thin Whitetopping (lRC:Sp:76)
Guidelines for Design and Construction of Fjbre Reinforced Concrete
Pavement (lRC:Sp:46)
Recommendations about Overlays on Cement Concrete pavements
(lRC:SP;17)
G!idelines for the Use of Dry Lean Concrete as Sub_Base for Rigjd pavement
(lRC:SP:49)
IRC:'117-20'15 Guidelines for the Structural Evaluation of Rigid pavements
with Falling Weight Deflectometer.
IRC:85-20'15 Recommended practice for Accelerated Strength Testing &
Evaluation of Concrete (First Revision).
IRC:43-2015 : Recommended practice for Tools, Equipment and Appliances
for Concrete Pavement Construction (First Revisio;)
IRC 114-2013 Guidelines for Use of Silica-Fume in Rigjd pavement.
IRC;118-20'15 Guidelines for Design and Construction of Continuousty
Reinforced Concrete pavement (CRbp)
iv)
v)
vi)
vii)
viii)
xi)
xii)
2:4
. . S,9T9
".pects
ofjointed plain concrete pavements are dealt in detail in separate
standards of lRC. Reference to these standards is drawn in the text where relevant.
3 MATERIALS
3.1 Cement
Any of the following types of cement capable of achieving the design strength may be used
with prior approval of the Engineer, but the minimum 28 days corn'pressive strength of lhe
cement should not be less than 43 Mpa.
Ordinary Portland Cement 15:269 (33 Grade,43 crade and 53 crade)
including 5% performance lmprover ( Mineral admixture etc as per tS: ZiSy
Potlland-Pozzolana Cement lS:1489 (part .l) (33 crade)
Portland Slag Cement, tS:45S (33 crade)
Composite Cement (btended wjth granutated stag & fly ash), tS: 16415 (33
Grade)
i)
ii)
iii)
iv)
3
ix)
x)
12. I RC: '1
5-2 0'1 7
Note
3.2
tests prior to its use
Admixtures
lf the soil around concrete pavement has soluble salts' like sulphates in excess of 0 5 per
""",,
,-f,l" *r"" used shali be Sulphate Resisting Portland Cement' IS:12330 lf chlorides
"l." "f".
pt"""", Srfphate Resisting Cement shatl not be used and in such case PSC should
be used.
Cement to be used may preferably be obtained in bulk form' ll cement in paper bags is
o'.p.".ii" U. ,t"a tnere stralt ue bag-splitlers with the facility to separale pieces of paper
["-J"
"nJ
aepo"" tn"m off suitably No iaper pieces shall enler the concrete mix' Bulk cement
ffi;;;:; in vertical or horizontal silos The cement shall be subjected to acceptance
3.2.1 ChemicalAdmixtures
Admixtures conforming to lS; 9103 may be used to improve workability of the concrete or
exiension ot setting tirie' on satisfactory evidence that they will not have any adverse effect
on-in" prop"rti"" oi concrete with respe;t to strength' volume change' durability and have no
J"teterious
"fre"t
on embedded steel. Satisfactory performance of the admixtures should be
proved both on the taboratory concrete trial mixes and in trial paving works. lf air entraining
;d;xture is used for improving the workability of the mix and to reduce bleeding' the total
quantity ot a,r in air-entrained concrete as a plrcentage of the volume of the concrete shall
i"u" +srl.s p",
""nt
entrained air for 31.5 mm maximum size of aggregate and 5.0i1.5 per
centfor ZO mm maximum size of aggregate ln freezing weather' use of air entraining agent
i" re"omr"nO"O to counter the lreeirni and thawing effect with 5'5t'1'5 per cent entrained
u-ii io, gf S mm maximum size of aggiegate and 6 Ol1'5 per cent for 20 mm maximum
size of aggregate. The maximum quJitity or chemical admixture-shall be 2% by weight of
"u."ntiti"o"ra
i,rt"rials (cement + fly ash/ground granulated blast furnace slag/silica fume)'
3.2.2 Compatibility and optimum dose of the particular admixture (from a speciflc
manufacturer) with thJ specific cement type (tr(nn a particular manufacturing plant) to be
,""0,
"n"ft
be established by Marsh Cone Test as per ASTM C939' Concrete mix should be
Oe",gneO fo,
"
corUination of a particular cement and admixture' and admixture supply and
typeiannot be substituted without test confirming the required results'
3.2-3 MineralAdmixtures
Mineral admixtures can improve the workability' long term strength and durability of concrete'
l;;p;;;r; by the Engineer, the following materials may be added as mineral admixtures as
per their availability:
3.2.3.1 Fly ash (as per lS:3812 (Paft 1)
Fly ash upto 25 per cent by weight of Cementitious Material (CM) may be mixed at site with
oloi*.v Fortr"no cementioPC) 53/43 Grade' The fly ash shall conform to ls:3812 (Part l)'
Fly ash of no other Grade shall be used
4
13. -
'1
-
I
IRC;15-20'17
Site mixing of fly ash shall be permitted only after ensuring availability of the equipments
at site for uniform brending through a specific mechanized facirity with automated process
control like batch mix prants conforming to rs:4925 and rs:4926. sire mixing wi not be
allowed otherwise.
3.2.3.2 Ground Granutated Blast Fumace Slag (GGBFS)
Factory manufactured cround cranulated Blast Furnace SIag (as per lS:1OgZ5) upto 50 per
cent by weight of cementitious material may be mixed at site with Ordinary poruand Cement
of 43153 Grade. Regurar tests shal be conducted on GGBFS at a testing frequency of 1 test
pe|I00 l.4T of slag lo ensure the quality.
3.2.3.3 Silica fume
Silica fume up to '10% by weight of OpC (as per tS:1S388, tRC:Sp:.114 and tRC:44, if specified
by the engineer may be used.
3.2.3.4 Metakaolin
Metakaolin is obtained by calcinations of pure and refined kaolinitic clay at a temperature
between 650 and 850 'c forrowed by grinding to a lineness of 7oo to goo mrlkg. Metakaorin
conforming to lS:16354 may be used upto 20 per cent of the cementitious material.
3.3 Aggregates
3.3,'l Aggregates for pavement concrete shall be natural material complying with lS:
383. The rimits of dereterious materiars shaI not exceed the requirements set out in rs:3g3.
3.3.2 The aggregates shall be free from chert, flint, chalcedony or sitica in a form that
can react with the alkalies in the cement. ln addition, the total chlorides content expressed as
chroride ion content shafi not exceed o.06 per cent by weight and the totar surphate content
expressed as sulphuric anhydride (SO3) shall not exceed 0.25 per cent by weight. ln case the
Engineer considers that the aggregatea are not free from dirt, ihe same may Oe washed and
drained for at least 72 hours before batching, as directed by the Engineer.
3.3.3 Coarse aggregate
Coarse aggregate shall consist of clean, hard, strong, dense, non_porous and durable pieces
of crushed stone or crushed gravel and shall be dev;id of pieces of disintegrated stone, soft,
flaky' elongated, very angurar or sprintery pieces. The combined flakiness and erongation
index-shatl not be more than 35 per cent. Aggregate lmpact Value (AlV) shall not be more
than 30 per cent. Limestone aggregate may be used conforming to lS:383. The maximum
size of coarse aggregate shal not exceed 3'r.s mm in pec and zl.s mm in case of DLc.
Continuously graded aggregates may be used, depending on the combined grading of the
coarse and fine aggregate. No aggregate which has watei absorption more than 2 per cent
5
14. shall be used in concrete mix. Wherever aggregates of 2 per cent water absorption are not
available, higher value of water absorption subjected to the maximum of 3 per cent may
be allowed if other engineering properties are satislied as per lS:383. All aggregates shall
be tested for soundness in accordance with lS; 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, irrespective of their water absorption'
lron slag aggregate, steel slag aggregate upto 30 per cent, Recycled Concrete Aggregate
(RCA) upto 30 per cent of total coarse aggregate can be used in Dry Lean Concrete (DLC)
onlY.
3.3.4 Fine aggregate
The fine aggregate shall consist of clean natural sand or crushed stone sand or a combination
of the two and shall conform to lS: 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. All 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 pet cent if sodium sulphate solution is used or 1 I per cent if
magnesium sulphate solution is used, irrespective of their water absorption. Aggregates with
water absorption more than 3% shall, however, be rejected irrespective of soundness test
results. The fine aggregate shall not contain substances more than the following;
Clay lumps : 1.0 Per cent
Coal and lignite : 1.0 Per cent
Material passing lS sieve No 75 micron :
i) Natural sand : 3 per cent by weight of natural sand
ii) Crushed Stone sand" : 12 per cent by weight of crushed stone
iii) Blend of natural sand and crushed stone sand shall not exceed 8 % by total
weight oi fine aggregates (1S 383)
* Cautionary Note
Although lS:383 permits in the case of stone crushed sand' the fines passing 75 microns upto
15 per cent, this provision should be used with caution when crushed stone sand is used
as ine aggregate and when the mix produced in the Laboratory and the field is satisfactory
in all res[ectJ and complies with the requirement ol Speciflcalion The grading zone of fine
aggregates as per lS: 383 shall be within the limits as given in Table I
Table't Fine Aggrggates Requirements of Different Grading zone
Percentage Passing for
Grading Zone lllGrading Zone llGrading Zone I
lS Sieve Designation
10010010 mm
90 -'10090 - 1004.75 mm
85 - 10075 - '100
60-952.36 mm
6
IRC;15-20'17
100
90 - 100
15. 1
Note:
l. Where concrete of high strength and good durability is required, fine aggregates conforming
to any one of the three grading zones may be used. From grading zones I to lll, the line
aggregate grading becomes progressively finer and therefore the ratio of fine aggregate
to coarse aggregate shourd be progressivery reduced. ln a[ cases concrete mix shourd be
properly desagned as per IRC:44 recommendations. Mix design shall be guided by the actual
grading, particle shape and surface texture ot both fine and coarse aggregate.
ll. Where the grading in all Grading Zones falls outside the limits of any particular grading zone of
sieves olher than 600 micron lS: Sieve by an amount not exceeding 5 per cent for a particular
sieve size, (subject to cumurative amount of 1o per cent), il shal be regarded as faling within
that grading zone. This tolerance shall not be applled to percentage p;ssing the 600 micron
lS: Sieve or to percentage passing any other sieve size on the coa;se limit of grading zone l_
lll For crushed stone sands, the permissibre rimit on 150 micron rs sieve rs increased to 20
percentage an Table I above, all other parameters shall remain same. The use of cnrshed
slone sand is permitted in peo. However, its percentage of fines passing 75 micron lS Sieve
shall not exceed 12 per cent.
3.3.5 Combined Grading
Table 2 and 3 is recommended forcombined gradation offine and coarse aggregate) in case
of DLC (Dry Lean Concrete) and peC (paving euality Concrete) respectively.
Table 2 Aggregato Gradalion for Dry Lean Concrete
IRC:15-201 7
1.18 mm 30-70 55-90 75 - 100
600 micron 15 - 34 35-59
300 micron 5-20 8-30 12-40
150 micron 0 - 10 0 - 10 0 -'10
The above gra
fraction passin
ding is appllcable both for natural sand and crushed stone sand_ For finding the
g 75 micron, wet sieving ofwhole aggregate sample shall be performed. "
7
Sl No. Sieve Designation Percentage by weight passing the Sieve
26.50 mm 100
2 19.0 mm
9.50 mm 50-70
4 4.75 mm 30-55
5 2.36 mm 17-42
6 600 micron 8-22
7 300 micron 7-17
150 micron 2-12
9 75 micron (Wet Sieving) 0-5
Note
60-79
1
75-95
3
8
16. IRC:'15-20'17
Table 3 Aggregate Gradation for Pavement Quality Concrete
* Crushed sand
** Natural sand
3.4 Water
Water used for mixing and curing of concrete shall be clean and free from injurious amount
ofalkalies,sulphates,chlorides,oil,salt,acid,vegetablematterorothersubstancesharmful
to the finished concrete. lt shall meet the requirements stipulated in ls: 456. Portable water
is generally considered satisfactory for mixing and curing'
3.5 Steel Dowel Bars and Tie Bars
These shall conform to the requirements of ls: 432 and lS: l TS6 as relevant The dowel bars
shall conform to ls: 432 of Grade l. Tie bars shall be either High Yield strength Deformed
barsconformingtols:lT36andgradeofFe500lfsteelmeshiSUsed.itShallconformto
lS: 1566. The steel shall be coated with epoxy/anti-corrosive paint for protectron against
corrosion as per lS: '13620 in coastal region and high rain fall areas'
3.6 Temperature Reinforcement
Whenever the steel bars are used as temperature, reinforcement bars' those shall be
deformed TMT (Thermo Mechanically Treated) bars as per lS: 1786 and shall preferably be
welded. Where spot welding is not possible these bars can be tied with binding wire to form
the mesh. The size and spacing of bars depends on the design considerations' material
prop"rt,"" ,nO climatic condition of the region, but in any case the weight of the mesh shall
noi'0" t".. than 3.14 kgimr. The steet mesh may be placed in the upper hall of the slab
U"i*""n
"uV
50-75 mmlelow the top surface and to be sufficiently at'ove the dowel bars
"u"n
u. notio
""u"e
any interference to their movement Welded wire mesh (spot welded in
manufacturing ptant) can also be used as temperature reinforcement'
8
Percentage weight pass ing the Sieve
19 mm Nominal Size31.5 mm Nominal Size
sl.
No.
Sieve Desiqnation
1001001 37.5 mm
10090-100
'
2 31.50 mm
10085-953 26.50 mm
90-10068-8819.0 mm4
48-7845-655 9.50 mm
30-5830-556 4.75 mm
8-358-307 600 micron
0-120-10'1
50 micron
0-5-
0-2'.
0-5.
0-2"
75 micron (Wet Sieving)I
8
17. IRC:15-2017
r
3.7 Materials for Joint Construction
3.7-1 Pre-moulded joint fi er
Synthetic joint flller board for expansion joints which are proposed for use only at some
abutting structures, like, bridges and culverts shall be of2o-2s mm thickness within a tolerance
of t 1.5 mm and of a firm compressible material and having compressibility of more than 25
per cent as per ls; 1838. lt shafl be 25 mm less in depth than the thickness of the slab within
a tolerance of 1 3 mm and provided to the full width between the side forms. lt shall be in
suitable length which shall not be less than one lane width. lf two pieces are joined to make
up full width, the joint shall be taped such that no slurry escapes through the joint. Holes to
accommodale dowel bars shall be accurately bored or punched out to give a sliding fit on the
dowel bars. lS: 1838 (Part 1) and lS: 1 0566 may be referred for more details.
3.7.2 Joint Sealing
The joint sealing compound shall be of hot poured, elastomeric type or cold polysulphide/
polyurethane/silicon type having flexibility, durability and resistance to age hardening.
Iy'anufacturer's certificate shall be produced by the contractor for establishing that the
sealant is nol more than six months old and stating that the sealant complies with the relevant
standard mentioned below.
lf the sealant is of hot poured type, it shall conform to lS;1834 oTASTM: D 3406, as applicable.
Hot poured joint sealing compound should not be heated above jgOoC and also over long
duration; both are not permitted as it will lose its properties due to overheating. Material once
heated cannot be reheated agajn for use. Hence, the quantity of material to be heated should
be such that it is used fully. The overheated or reheated maierial will be rejected. Therefore,
quantily of sealing cornpound required for one operation of joint sealing work shall only be
heated. Cold poured sealant shall conform to any one of theiollowing:
Polysulphide
Polyurethene
Silicon
Preformed Seals3.7.3
3.8 Fibers
The prejormed joint sealing material shall be a vulcanized elastomeric compound using
polychloroprene (Neoprene) as the base polymer. The joint seal shall conform to requirementl
of ASTN.4 D 2628.
Fibers may be used subject to the provisjon in the design/approval by the Engineer to reduce
the shrinkage cracking and improve post_cracking residual skength. The fibers may be steel
Iiber as per IRC:SP:46 or polymeric synthefic fibers. The polymiric synthetic fibers will be
I
ASTM D 5329, ASTM C792, tS: 11433 (part t),
BS:52'12 (Part ll)
BS:5212
ASTM D5893.04
18. IRC:'15-2017
within the following range of specifications:
Effective Diameter 8 - 3OO micron for micro fibers
O.20 mm - '1.2 mm for macro flbers/steel flbres
. Length 6-18 mm (micro)' 40-65 mm (Macro)
. Specific gravity 0 90 to 1 36
. Suggested dosage 0 6 - 2 5 kg/m3 for micro fibers
2.0 - 8.0 kg/m3 for macro fibers
Actual dosaqe may be taken from Table 3 of lRc:SP:46-2013
Techno-economical consideration should also be kept in view'
. Usage will be regulated/designed as stipulated in IRC:44' IRC:SP:46 and
lS:456.
. Water absorption less than 0.45 per cent
' Melting point shall not be less than 160"C'
. The aspect ratio shall vary from 200 to 2000'
' Synthetic fibers shall have good alkali and UV light resistance'
Use of fibers reduces the slump of concrete mix, hence, when flbers are used' the mix shall
be so designed that the slump of concrete at paving site shall be appropriate' which should
be in the rlnge of 20 to 30 mm for concrete taid with slip form paver and 40 to 60 mm for
concrete laid with flxed-form paver or manually.
4 PROPORTIONING OF CONCRETE
4.1 Proportioning on the Basis of Strength
4.1.1 ln case ol dry lean concrete, mix design shall be done as per IRC:SP:4g and in
case of PQC, guidance ior mix design, may be taken from IRC:44 for ascertaining the flexural/
compressive itrength of cement concrete required to match with the prescribed design
streng th of concrete. As the stresses induced in concrete pavements are mainly flexural' it is
requi;ed that their design is based on the flexural strength of concrete in all major projects'
The rnix shall be so deligned in the laboratory as to ensure the minimum flexural strength
in the field with the desired tolerance level as per IRC:44 To achieve the desired minimum
strenglh in the lield, the mix in the laboratory shall be designed for somewhat higher strength,
makin g due allowance for the type and extent of quality control likely to obtained in the field
as to e;sure the minimum strength is achieved in the Jleld for this purpose'
4.1,2 For concrete roads, flexural Strength of concrete is the design criteria. For all major
projects, flexural strength of the mix shall be determined by third point loading of flexural
'b""-=lriO mm X 150-mm X 7oO mm) as per lS:5l6 Determination of flexural strength by
correlating with cube strength (compressive strength) shall not be allowed for maior pojects'
as the correlation is not well established'
10
19. --l
..:-
IRC:15-2017
Where it is proposed to estimate the flexural strength by correlating with cube compressive
strength, the correration shourd first be estabrished with raboratory t-ests by testing minimum
30 specimens of cubes as well as beams prepared from the same mix which is to be used
in the field.
41..3. .ln case of small size projects, where facilities for testjng beams with three
point loading are not available, in such cases, the mix design may be"caried out by using
compressive strength values and there after flexural strength will be determined as pe-r
correlation between flexural strength with compressive strenglh given below.
f", = 0.7 i(f"k) ........ ........ ... eq. 1
Where f., is the Flexural strength in Mpa or N/mm, and f"k is the characteristic compressive
strength in MPa or N/mm, as per lS: 456. For design oicement concrete mixes, guidance
may be taken from IRC:44.
4.2 Cement Content
, The minimum cement content for the mix corresponding to achieve flexural strength of 4.5ri MPa in the field at 28 days is given as under;
Y 4.2.'l Minimum cement content shall be 360 kg/m3 for afl type of cements i.e OpC,
+ PPC, pSC and composite cement. rn case fly ash (aJper rs:3812- part 1) js brended aisite,
' rhe quantity of fly ash sha, be.restricted to 2s per cent by weight of cM and the quantity oi
i OPC in such a blend shall not be less than 310 kg/m3. ln;ase of GGBFS, minimum cement
-
content sha, be 250 kg rf this minimum opc conlent is not sufficient to piodr""
"on"r"t"
oi
. rne specrlred strength, it shall be increased as necessary. The OpC content, howeve( shall
- not exceed 450 kg/m3 of concrete.
: 4.3 Approximate proportions
- The approximate proportions by weight necessary to produce concrete satisfying the above
documents, for guldance only- lt should be expresslliunderstood that this intorration is oniifor the convenience of the bidder and does not rerieve the bidder from ttre requiremenl o't
proper mix design for the specified characterisuc strength.
4.4 Fietd Mix
After the award of the contract. the propo(ions, i.e., the field mix or job mix determined bythe laboratory for the particular aggregates approved by the Engineer strall govern. Theseproportions wil be corrected and ad.iusted by the Engineer tJcompensate for moisture
content in the aggregates or fluctuations in the grading Jf coarse ,nd tin" aggr"gates at thetime of use. Any change in the source of materiJs or mix proportrna iouro n"""ssary duringthe work shal be assessed by making raboratory triar ,j,,"" contru"toi ,ust make effortsto get the mix proportion approved at least one and a nalf montn jn advance of commencingpaving operation in trial length.
11
20. IRC:'15-2017
For very small projects, if fine aggregate is permitted to be measured volumetrically' due
allowance should be made for its bulking.
4.5 Water Content and Workability
4.5.1 The maximum free water-cement or water-cementitious material ratio of the
concrete mix shall be O.4O At such a low water cement ratio and on account of long distances
over which concrete needs to be transported in road projects, use of superplasticizers is
inevitable for achieving the desired workability The superplasticizers conforming to lS: 9103-
1999 are generally deiirable for road works. The quantity of admixtures shall be determined
by trials.
The requirement of workability depends upon the equipment used for the compaction and
the meihod of placement of concrete The slump in the range of 20 to 30 mm for concrete
Lio witn stip foim paver and 40 to 60 mm for concrete laid with fixed-form paver or manually
is reasonable. However, it may be modilled depending upon the site requirement and got
approved by the Engineer'
While specifying the workability requirement, the probable time for lransporting concrete
from mixing itait to paving site should be specifled Dudng this time delay slump loss takes
place, and concrete mix design should account for the slump loss'
4.5,2ThecontrolofworkabilityinthefieldshallbeexercisedbytheSlumptestasper
ls:1.199. These tests shall be carried out on every tipper or dumper at batching and mixing
piant site ano paring site initially when the work commences but subsequently the frequency
can be reduced to jlternate tipper or as per the instructions of the Engineer'
5 TOoLS, EQUIPMENT, MACHINEs AND APPLIANcES (lRC:43)
5.1 General
AII tools, equipment and appliances necessary for proper preparation of subgrade' laying
of sub base and batching, mixing, placing' finishing and curing of concrete shall be at the
p.i""t
"i,"
i" g""O *ortiig conOiiion, and shall have been inspected by the Engineer before
if',"'p"rrg op"t"tions are permitted to start Throughout the construction of the project' the
"onltru"tLn
,g"n"y shall maintain all necessary tools' equipment and appliances in flrst
class working condition to ensure proper execution of the work Arrangements shall also be
,ua" ioi t"q"ui.it" number of stand-by units in the event of break-downs during construction'
5.2 List ofTools' Equipment and Appliances (Also refer IRC 43)
5.2.1 List of Tools, Plants and
Construction:
Equipment for Fully Mechanised Concrete Road
12
21. (a)
(b)
(c)
(d)
IRC:'15-2017
Subgrade
(i) Compaction equipments (three_wheeled steel static roller or tandem
roller, pneumatic roller, vibratory roller (.lO to lZ tonnesl. oi ofate
compactor, baby roller, monkey (impact) compactor or'any other
suitable device).
(ii) Watering devices (water tankers/lorries, bhisties/water carriers or
watering cans, water sprinkler or browser fitted with pump)
(iii) Motor grader
(jv) Rotavator/disc harrow/tillers
Lower Sub-base (cSB/wBM/wMM)
(i) Pug-mill type mixing plant for granular sub_baseAiVBMMMly'
(ii) Dumpers
(iii) Paver finisher with electronic sensor
(iv) Motor grader
(v) Vibratory rolers of 1O-12 tonnes weight
(vi) Levelling instrument
Dry Lean Concrete Sub-base
(i) Batching plant with 4 or more bin_hoppers
(ii) Dumpers or tippers
(iii) Paver finisher with electronic sensor
(iv) Vibratory ro er
(v) Pneumatic roller
(vi) Plate compactor
(vii) Liquid curing compound sprayer
(viii) Gunny bags/Hessian/coir fett
(ix) Scabbler for correcting surface regularity
(x) Levellinginstrument
Paving Quality Concrete
(i) Batch mix plant with 4 or more bin hoppers including chilling plant wjth
suitable matching capacjty, cement bag stitter
""; ";;";t'prr;;;;arrangement
Dumpers/tipping trucks/transjt mixers
JCB/Back Hoe
Crawler mounted excavator operated on rubber belts for spreading
concrete in front of paver
Tractor compressor for cleaning the surface before paving peC
Slip-Form Paver (for large pro.,ects) or Fixed_Form paver (for smallprojects ).
(iD
(iii)
(iv)
(v)
(vi)
13
I
:
22. IRC:15-2017
(vii) Side forms/side rails for fixed form pavers
(viii) Devices for measuring concrete temperature, wind velocity and air
humidity at site
Slump cone for measuring workability at site
Joint cutting machine (concrete saw), early entry saw
Dowel Bar lnserter (DBl), if automatic dowel insertion system is adopted
as in slip lorm Paving
(ix)
(x)
(xi)
(xii) Dowel cradles/chairs' for manual dowel placement or automatic Dowel
Bar lnserter (DBl) facility
(xiii) Steel bulk-heads for construction joints
(xiv) Tie bar supporting assembly or automatic tie bar inserter
(xv) Guide-wires for slip-form pavers and stakes
(xvi) Texturing and curing machine
(xvii) Hand held trowel for localised surface finishing
(xvii) Liquid curing compound sprayer, Equipment for fog or mist spray
(xix) Steel mobile bridges (for manuallinishing of surface wherever required)
(xx) Portable pavement proteclion tents (preferably 150 m length) for hot
season operation
(xxi) Vacuum controlled extruder for silicon sealants and Gun for placing
PolYSulPhide
(xxii) Scabbler
(xxiii)Total Station/Auto-levelling instrument
(xxiv) Digital Vernier CalliPers
(xxv) Hessian/burlaP drag
5.2.2 List of Tools, Plants and Equipment for Semi-Mechanised Concrete Road
Construction including Fixed Form Paving'
(a) Subgrade
(i) Compaction equipment (three-wheeled
:!e^el
sgtic roller or tandem
roller, pneumaiic roller' vibratory roller (10 to '12 tonnes)' or plate
compactor, baby roller or any other suitable device)
(ii) Watering devices (water tankers/lorries' bhisties/water carriers or
watering cans, water sprinkler or browser fltted with pump)
(iii) Motor grader/rotavator/tiller
(b) Lower Sub-base
(i) DumPers
(ii) Motor grader
(iii) Vibratory rollers of 1O-12 tonnes weight
14
23. .:
=
IRC:15-2017
(iv) Levellinginstrument
(v) Rotavator, plougher, tiller
(vi) Scratch templates or strike boards
(vii) Pick axes, shovels and spades
(c) ConcreteProduction
(i) Shovels and spades
(ii) Sieving screens
(iii) Weigh batcher
(iv) Aggregate measuring boxes (onlywhere volume batching ofaggregates
is permitted as a special case)
(v) Water pump
(vi) Water measures
(vii) Concrete mixer
(d) Transportation, Laying and Compaction of Concrete
(i) Wheel barrows/iron pans
(ii) Rail, form-work and wooden bridges
(iii) Spades
(iv) Concrete vibrators (pocker, surface and vibrating screed)
(v) Wooden hand tampers
(vi) Tipping trucks/dumpers
(e) Finishing Op€ration: Surface and Joinls
(i) Wooden bidges
(ii) Floats (longitudinal and long handled wooden floats)
(iii) Templates
(iv) Three-metre long straighl edges including one master straight edge
(v) craduated wedge
(vi) Edging toots including doubte_edging toots
(vii) Canvas belts
(viii) Long handled brooms
(ix) Saw-cuttingmachines
(x) Scabbter (for grinding tocal hjgh spots)
(xi) LevellinginstrumenvTotalstation
(0 Curing
(i) Hessian cloth/burlap or polyethylene sheeting
(ii) Watering devices (for ponding operation)
(iii) Liquid curing compound spraying machine.
15
24. IRC:15-2017
6 PREPARATION OF SUBGRADE, SUB'BASE AND
LAYING OF SEPARATION MEMBRANE
6.1 General
The Pavement Ouality Concrete (PQC) shall be laid on two layers ofsub-base Granular Sub-
gu." icse) raing ai a tower sub-base and Dry Lean concrete (DLC) acting as upper sub-
[".". osg,'th" ro*"r sub-base shall be laid ovei a subgrade of minimum 500 mm compacted
;i;k^;". subgrade shall be of selected earth comptying the folowing requirements:
(i) No sott spots are present in the subgrade
16
(g) cleaning and Sealing of Joints
(i) lron raker/Scraper
(ii) Wire/Coir brush
(iii) Pneumatic air blower/air compressor
(iv) Tool for mixing two component sealants
(v) Vacuum controlled extruder for silicon sealants
(vi) Primer brush
(vii) Gun for placing polysulphide
. Semi-mechanised construction should be used only for small size projects' For major
projects fully mechanised construction is recommended'
5.2.3 Specifications for different toots, equipment and appliances are given in IRC;
43 "Recommended Practice for Tools, Equipment and Appliances for Concrete Pavement
construction,,. This document also gives a list of other small tools, equipment and appliances;
minimum balanced set of tools, equipment and appliances; their routine maintenance and
upkeep; and details of fleld laboratory equipment'
5.2.4 Specifications for tools, equ ipments and appliances required for special applications
are given in ihe following codes/standards. These may be referred as required'
i. lS: 4926:2003 - Ready Mixed Concrete- Code of Practice
ii. lS: 5892: 2OO4 - Concrete Transit Mixer- Specifications
iii. lS: 5500 (part 1 ): 2OO4 Vibratory Roller General Requirements Part 1: Self
Propelled Tandem Drum
iv. lS: 4925:2004 Concrete Batching and Mixing Plant - Specifications
v. lS: 5500 (patl 2: 2OO4 Vibratory Roller General requirements Part 1: Self
Propelled Single Drum
vi.|RC:57-2OO6"RecommendedPiacticeforsealingofJoinsinConcrete
Pavements"
25. IRC:1S-2017
(ii) The subgrade shall be ofcoarse grained material and have a minimum CBRof 8%.
(iii) The camber and super-erevation of subgrade shal be same as that of theconcrete slabs.
6.2 Capi[ary Cut-off
9.2.1 .. As a result of migration of water by capilladty from the high water table, the soil
llT:919",,
berow rhe pavemenr geG more and more wet and t;is i;;ds to graduat toss in(s bearing capacity besides non-uniform support. Sever;i ,"rarr",
"*n as, depressing
s^"^y,?^:?,i*."1:.|. "bte
by drainage measures, raising of the embankment and provision ofa captflary cut_off are available for mitigating this Oefriiency
"nA "norfO
be investigated forariving at the optimum sorution However, where der"t"riori
""rL
in
"r""ss
of the safe rimitsare present in the subgrade soil. a capillary cut_off should o" pioriJui'rn addition to othermeasures.
6.2-2 The capillary cut-off may be a layer of coarse or fine sand, graded gravel,bituminised material, geo-composite, or an impermeable m"mOrare.
--'
6.2.3 Capillary cut-ofi/blanket layer, of required thickness may be placed over compactedsubsrade layer cut-off with bituminised
". "ih";;;;"];;"7 * [r1"r,.* in any of thefollowing ways:
(i) Coarse or fine sand or graded gravel
The minimum thickness of these materials shall be 150 mm. Whenever sand/gravel is usedas cut-off layer, the layer shall not be provided ,t tn" .Jj""'Ori
"nlulo
be replaced withsuitabte fitter of graded granutar materiar *itt o,. *iti,ort noi--iJ'l'rl"?t"^tire ,"teriat.
(iD Geo-composite/ceo-filter layer
Geo-composite fabrics recommended to function as capillary cut-off.
6.2.4 For more detairs about mitigatrng the adverse effects of high water tabre, referencemay be made to tRc:34 ,.Recommenortions
rol. no"Jco;;;;;;'i;,fi:"r"ssed Areas,,.
6-3 The Sub-base
6.3.1 The Sub-base provided under the concrete slabs comprises Granular Sub_base(GSBI as tower sub-base and Drv Lean concrete 6r",-ffi; [;:vrded over cSB asupper sub-base. permeabitity coefiicienr ot csi sn1ir-o-""j,]"".i aior#ory
6,3.2 The material to be used for the work shall be natural sand, crushed gravel, crushedslone. or combination lhereor 0""":oll9
119"" I" silai"; ."qriila". iie mrteriar
"r,"tr
oe
f :j::ffi:TililJ :[Tfff :"j::,.
*nsrituenrs anid sha,-co-n-ri,i1o'*,e quarity srandards
17
l
i
26. IRC:15-2017
site as per lS: 383.
6.3.5 StrengthofSub-8ase
75.0 mm
It shall be ensured prior to actual execution oI sub-base that the material used in the sub-grade
""ti"n""it "
,"quir"ments of minimum CBR of 8% along with other physical requirements like
O"".i,V fga V" of the modified Proctor lab MDD) when compacted and finished'
6.3'6WhendirectedbytheEngineer,thisshallbevertfiedbyperformingCBRtestsin
iii'Loor"tory
".
r."quired on specimens remoulded at field dry density and moisture content'
Table 4 Grading for Granular Sub-Base Material (MORTH)
The matenal passinq 425 mrcron (O'425 mm) sieve for all lhe grading
,. is,ii)o ip"n sl .ii all have liqurd limil and plasticity rndex not more
1UU
when tested according
than 25 and 6 Per cent
the lS sievePer cent ht passin
Grading VlG radinGrading lllGrading llGrading I
lS Sieve
Designation
100
100
80-100
B0-10053.0 mm
75-10055-9050-80
100
100100
70-10055-9026.5 mm
55-7535-6550-8035-659.5 mm
30-5525-5015-3510-3040-6525-554.75 mm
10-2510-2030-5020-402.36 mm
2-10
0.85 mm
0-80-510-1510-150.425 mm
0-3<5<5<5<50.075 mm
30%30%300/"30%CBR,
N.4inimum
Note
respectivelY
18
6.3.3 Table 4 prescribes six grading for Granular Sub-Base (GSB )- Lower sub-base layer
iiurr
"o.pri""
or t*o layers. For lower llyer called as filter/separation layer Grading l' ll' V or
Vl shall be used. Alternativety, geo-complsite Iayer may alsobe used' For upper layer called
;;;;;i";;; l;;"t, Cr"oins lll it Gradins lv sh;ll be used Minimum compacted thickness
.nriL u" ioo ,. tor. each Lyer. However] if Geo-composite layer is used as separation layer
in"^ ,,"irr. 150 mm thic'k csB, Grading lll or Grading lv shall be provided as drainage
taver on top of geo-composite layer' Howlver' the use of geo-composite layer should be
resorted to only il rl is economicatly vtable
6.3.4 Physical Requiremenls of Aggregates used in GSB
The material shall have a 10 per cent fines value of sOkN or more (for sample in soaked
i"roiii""J *n"" tested in compliance with lS: 2386 (Part lV) 1963' The water absorption
""ir" "t
tfr" coarse aggregate shall be determined as per lS: 2386 (Part lll)' lf this value is
gr""Lt ,hr" ip"i
"eii
tn-" sounoness test shall be carried out on the material delivered to
Grading V
55-75
27. -
IRC:15-201 7
Table 5 Approximate 'k'- Value Corresponding to CBR Values for
Homogeneous Soil Subgrade
CBR Value
(%)
2 3 4 5 10 20 50 100
'k -Value
(MPa/m)
21 28 35 42 62 69 140 220
6.5 DLC Sub-base, Modified "k" Value
6.5.1 A Dry Lean Concrete (DLC) conforming to tRC:Sp:4g is genera y recommended
as upper sub-base for modern concrete pavements, particularly those with high intensity of
traffic. The use of granular sub-base or sub-base constructed out of semi rigid material is
also being suggested for use at some locations. The equivalency of ,.k,.value
for different
type of upper sub-bases (like DLC/semi rigid materials/cement treated or stabilized sub_
base/granular sub-base) corresponding to "k" value of the subgrade is required to be known
for construction of rigid pavement.
6,5.2 Table 6 gives the'k'values of granular and cement treated sub_bases for three
types of subgrade soils.
6.4 Modulus of Subgrade Reaction ,,k"
Rigid pavement is designed by using the corresponding "k,, value of subgrade/sub_base, as
the case may be. "k" value is normally determined from plate load test as per details given in
IRC:58. For the convenience of field engineers, correlation between CBR and ,k,
value (the
modulus of subgrade reaction) is given in Table 5.
6.5.3 Table 7 gives'k'values for Dry Lean Concrete (DLC)constructed as per IRC: Sp:
49 of 100 mm and 't50 mm thickness. The thickness and the type of sub_base shoutd be
selected depending upon the 'k' - value of the subgrade as given in Tables 5 and 6 and be
constructed in accordance with the respective Specifications.
'k'-value of
subgrade
(MPa/m)
Effective 'k' (MPa/m) over
untreated granular layer sub-base
of lhickness in mm
Effective 'k' (MPa/m) over cement
treated sub-base of thickness in
mm
'150 225 300 '100 150 200
39 53 76 108 141
56 63 75 88 127 ttJ 225
84 92 102 119
19
7 15
4B
Table 6 'K'.Values Over Granular and Cement T.eated Sub-Base
44
28. IRC:15-20'17
' Maximum k value shall be 3oo MPa/m. ln calculating other values as per proportion, the value
of 300 NrtPa/m shall be taken instead o[ 417 MPa/m,
6.5.4 Thickness of DLC sub-base should be minimum 150 mm in case of State Highways'
National highways and for others it can be '1OO mm, the surface flnish of the sub-base shall
be smooth. The average compressive strength of each consecutive group of 5 cubes shall
not be less than 7 l.4Pa at 7 days. For PQC bonded to DLC, the 7-day strength of DLC should
not be less than 1O l.4Pa. lf it is desired to have POC bonded to DLC, the surface of DLC is
to be roughened with wire brush within 3-6 hours of laying.
6.5.5 Where the embankment consists of heavy clay (1.1.>50 %), such as, black cotton
soil, the subgrade soil should be stabilised with lime and cement or any other approved
stabilizer (achieving minimum cBR '15olo) with a minimum thickness of 500 mm. Alternatively,
black cotton soil should be replaced with good soil of minimum CBR of 8%
6.5.6lnwater-loggedareasandWherethesub-gradeSoilisimpregnatedwithdeleterious
salts,suchas,sodiumsulphate,etc.ininjuriousamounts,acapillarycut-offshouldbe
provided before constructing the sub-base. lnjurious amount of sulphate concentration (as
sulphur trioxide) is that limit where either it is more than 0.2 per cent in subgrade soil or more
than 0.3 per cent in ground water. Cement used in both DLC and pavement quality concrete
in such situations should be sulphate-resistant.
6.5.7 The granular sub-base shall be in a moist condition at the time the DLC is placed
as per IRC:SP:i9. There shall, however, be no pools of water or soft patches formed on the
sub-base surface.
Table 7 'K'Values Over Dry Lean Concrete Sub-Base
'k'-value of Subgrade MPa/m
Effective 'k' over 100 mm DLC lvlPa/m
4A
208 278 389
Effective 'k' over '150 mm DLC MPa/m 277 417.
6.5 Separation Membrane
A separation membrane shall be used between the concrete slab and the DLC sub-base
uniess pOC is designed as bonded to DLC sub-base' Separation membrane shall be
imp".rmeaOfe Polyeth-ylene sheet 2OO micron thick as per lS: 2508' transparent or white in
coiour laid flat with minimum creases' lt shall be made of Low Density Polyethylene (LDPE)
and not manufactured from recycled polyethylene or plastic or flller materials like carbon
Uta"X erc. fn" minimum width of the separation membrane shall be 4 0 m Before placing
tn" separation membrane, the sub-base shall be swept clean of all the extraneous materials
using air compressor. Wherever overlap of plastic sheets is necessary' the same shall be at
L".i aoO ,, and any damaged sheaihing shall be replaced at the Contractor's cost. The
a"prr"tion membrans may be nailed to the lower layer with concrete nails'
62
20
29. , IRC:15-201 7
ln summer (when ambient temperature is more than 25'C), before placing polythene
membrane, the existing DLC surface shall be wetted with water.
Alternatively, non-woven geo-textile,4 mm thick, may also be used as separation layer
between PQC and DLC.
7 WEATHER LIMITATIONS
7.1 Concreting in Hot Weather
No concreting shall be done when the concrete temperature is above 30'C. As placing
of concrete in ambient temperatures above 35"C, is associated with defects, like, loss
of workability through accelerated setting, formation of plastic shrinkage cracks etc., it is
recommended that unless adequate precautions are taken, no concreting shall be done in
conditions more severe than the above.
7.1.1 The air temperature above 35'C, relative humidity below 25% and/or wind velocity
of more than 15 km/h constitute conditions necessitating precautions to be taken for concreting
to avoid plastic shrinkage cracking. The associated problem involved in concreting in hot
weather affect the production, placement and curing of concrete.
7.1.2 A higher temperature of the fresh concrete results in rapid hydration and leads
to accelerated setting of concrete. The slump of concrete decreases and hence the water
demand increases in hot weather. Plastic shrinkage cracks may develop in concrete due to
evaporation of water from the surface of the concrete. No concreting should be done when
the concrete temperature is above 30'C. To bring down the temperature o, concrete, chilled
water or ice flakes should be used. ln addition to chilled mixing water, cooling of aggregates
is also desirable. lt is advisable to install a chilling plant, so that the temperature of the
concrete mix can be controlled in hot weather. A ready to use chart to calculate the rate of
evaporation of water from the concrete for the construction of cemenl concrete pavement is
given in Fig. 1. lf the rate of evaporation is expected to be above 1 kg/m'? per hour near the
top of the surface, precautions against plastic shrinkage cracking are necessary. The surface
shall be continuously kept wet by slight fogging/misting and by the use of tents/covers to
minimize wind speed or providing wet hessian cloth before continuous curing i.e. after 24
hours of laying.
7 ,1.3 Plastic s hrin kage crack of width 0.2 mm in case of norma I weather cond ition a nd
0.3 mm in case of moderate/severe weather condition may be the nucleus for other types
of damage due to water penetrating through them. Due to increased tensile stresses.
these cracks may develop into structural cracks with passage of time. Plastic shrinkage
cracks reduce abrasion resistance of surface and wearing of surface due to traffic will be
faster.
21
30. IRC:'15-2017
7 .1.4 Agood quality concrete, which is strong, impermeable and du rable against abrasion,
chemical attack and adverse effects of weather can only be achieved with suitable choice
of materials, proper mix proportioning and satisfactory controls at all stages of producing,
placing and curing of concrete.
7.1.6 Due to high temperature, the hydration of concrete is faster and rapid stiffening
of concrete results in increased water demand. Use of rapid hardening cement or 53 grades
OPC shall be avoided in case of hot weather concreting. The aggregates may be kept shaded
to protect from direct sun rays. They may also be sprinkled with cold water.
7,1.7 To off-set the accelerating setting of concrete in hot weather and to reduce
increased demand, set retarding and water-reducing admixture should be used. However,
as some of the admixture can cause undesirable secondary effects such as reduction in
ultimate strength of concrete or increase of bleeding of concrete, it is recommended that prior
experience or test data should be available, before their use. The temperature of aggregates,
water and cement should be maintained at the lowest practical levels, so that the temperature
of concrete is below 30'C, at the time of placement.
7.1.8 The concrete mixer or transit mixer could be painted white on the outer side and
cover with wet hessian cloth to inhibit absorption of heat from sun and air. The location of
batching and mixing units should be as close as possible to the site of placement. The sub-
base shall be sprinkled with cold water, just prior to placement of concrete to keep the sub-
base cool but it should be surface dry at the time of placement.
7.1,9 Weather has profound impact on curing. The process of hydration of cement is
faster in summer then in winter. lmmediately after consolidation and surface finish, concrete
shall be protected from evaporation of moisture. Fogging or misting of the concrete surface
before and after final finishing and texturing is very effective way to minimize evaporation
and reduce plastic shrinkage cracking. It cools and raises the relative humidity of the air just
above the concrete surface to lessen rapid evaporation. lnitial curing shall be done using
curing compound which will be sprayed on the cement concrete surface when no free water
is visible on the surface and texturing has been completed. Wet hessian cloth should be
gently placed after the curing compound has lost its sheen. ln place of wet hessian cloth,
concrete surface may also be covered with plastic sheet from all sides. Wet curing shall
continue thereafter at least for 14 days in case of OPC and 16 days where blended cement
or fly ash admixed PQC has been used. There shall be sufficient supply of wet hessian cloth
for initial curing.
22
7.1.5 Mixing water has the greatest effect on lowering the temperature of concrete.
The temperature of water is easier to control than that of another ingredient. The use of cold
mixing waterwill reduce the temperature of placing ofconcrete to some extent. The reduction
of water temperature can be most economically accomplished by adding ice flakes to it. The
ice should be manufactured from non-chlorinated water.
31. IRC;15-2017
'xaa./JtJ, g /
e/. U" v I
7r, v
/t/l t/ 7 , I .r
z.2 2
sar.z .../
2 rl_ > -)R
=
I
A
I //
I
I
I
I
I I A.
I
I /
I
I )
'/-,
4'2
.'b2, 30 40
Atr talm?1"a,r/r-,.c
,aa uataarr|a arlx,fa -3
ffi-€/l., r.iFYlrrF -ar.c F4.4li.. HLil4g.UL _-
c.^cret trr;-rai .i
Bril v...ert ' 4rr+, !
S'",,^ U. a -,t, taa. .J .r.LhlLi >
- .t"ritnt^,. *
Jd
1.o
2.
i.o
o
Fig. 1 Cha.t for calculation of rate of evaporation of surtace moisture of concrete from air
temperature and relalive humidity, concrete temperature and wind velocity. (enter the chart
on the temperature scale and proceed as shown by dotted line, till the rate of evaporation
is reached,
23
v",
/1
/^c
I Z /-a
au
7.2 Concreting in Cold Weather
7-2.1 Except by speciflc written authorization from the Engineer-in_Charge, concreting
shall not be continued when a descending airtemperature in the shade and away from artificial
heat drops below 5"c, nor shal concreting be resumed untir an ascending air temperature in
the shade and away from artificial heat reaches 5.C.
7.2-2 When concrete is likely to be subjected to freezing and thawing the use of air
entraining agent is mandatory. The air content in the concrete shall be 5.511.5 per cent for
3'1.5 mm maximum slze of aggregate and 6.0t1.5 per cent for 20 mm maximum size of
aggregate.
Ajit Pratap Singh
32. IRC:15-2017
7.2.3 When specific written authorization is granted to permit concreting at temperatures
below those specified above, equipment to heat the aggregates and water shall have to
be provided. ln addition accelerating admixture can be used. The use of calcium chloride
as an accelerator, or an accelerating admixture containing chloride can be permitted, if
concrete does not have un-coated reinforcing steel. When concrete contains uncoated steel
reinforcement, chlorides free accelerators e.g. calcium nitrite or calcium formate may be
used.
7.2.4 Concrete heating equipment capable of producing concrete that will have
temperature of at least 15"C and not exceeding 30'C at the time of placing it between the
forms shall be provided. The aggregates shall be heated prior to being loaded into the
concrete mixer. The equipment used shall mix the mass uniformly and shall preclude the
possible occurrence of overheated zones which might affect the concrete properties. Water
used for mixing shall not be heated beyond 66'C. N,laterial containing frost, ice, snow or
lumps of hardened mass shall not be used. Heating methods which alter or prevent the
entrainment of the required amount of air in the concrete shall not be adopted.
7,2.5 During placement of concrete, tarpaulin covers or other readily removable
coverings should closely follow the placing of concrete, so that only a few meters of the
flnished slab are exposed to the outside air at any point of time. The coverings may be so
arranged that heated air, when provided, could be freely circulated on top of the pavement
The coverings may be further covered by layers of straw or other insulating materials; no
sooner the wet concrete is strong enough to take their load.
When concrete is being placed in cold weather and the air temperature is expected to fall
below 20"C, the air surrounding the concrete shall be maintained at a temperature of 15"C
for at least 3 days and not less than 4'C for a period of not less than 7 days.
7,2.6 Any concrete damaged by frost action shall be removed and replaced.
7.2,7 Under no circumstances shall the concreting operations continue when the air
temperature is less than 5"C.
7.2.8 When the fresh concrete is likely to be subiected to freezing temperature in the
nights, adequate measures are to be taken to protect the concrete from freezing by providing
thick mat of hay, two to three layers of Hessian, etc. The efficacy of this method should be
checked by constructing trial sections.
7.3 Frost Affected Areas
For protection against frost, the balance between the frost depth (450 mm) and total pavement
thiciness should be made up with non-frost susceptible material. ln frost affected areas, the
sub-base may consist of any of the specifications having the compressive strength of the
stabilised or;emi-rigid material cured in wet condition shall be at least 1 7 MPa at 7 days in
24
33. :-
:-
IRC:15-2017
the laboratory For moderate conditjons, such as, those prevailing in areas al an altitude of
3,000 m and below, the thickness of frost affected depth will be about 450 mm.
7.3.1 For exlreme conditions, such as, those prevailing in areas above an altitude of
3,000 m, the foundation may be designed individually ror every location after determining the
depth of frost.
7.3.2
follows
The suggested criteria for the selection of non-frost susceptible materials are as
(i) Graded gravel: Not more than I per cent passing 75 micron lS sieve
Plasticity index not more than 6. Liquid limit not more than 25.
(ii) Poorly graded sands; Generally, 100 per cent passing 4.75 mm sieve Max
10 per cent passing 75 mrcron sieve.
(iii) Fine uniform sand: Generally, '100 per cent passing 425 micron lS sieve
ly'ax. 18 per cent passing 75 micron lS sieve.
8 JOINTS
8.1 General
The location and type of joints shall be as shown in the drawings. Where semi-mechanised
method of construction is used, the concrete along the face of all joints and around all tie
bars and dowels shall be compacted with an internal vibrator inserted in the concrete and
worked along the joint and around all tie bars and dowels to ensure a concrete free from
honeycombing. lt shall be ensured that vibrator should not contact the dowel bar, and the
vibration operation does not misalign the dowels. ln case of mechanised construction,
working and their vibration/RPM of all the fixed vibrators shall be checked. There shall be
two additional needle vibrators to compact the concrele near bulk head. Wherever, tie bars
or dowel bars are inserted in the PQC, proper marking on the projecting surface of DLC will
help to cut the joint at proper location.
lnitial cut or a slot of 2.5 to 5 mm wide and having a depth equal to one-third to onejourth the
depth of the PQC slab at transverse and longitudinal joint is made as soon as the concrete
hardens. Normally, in summer when ambient temperature is more than 3O.C initial cutting
may be carried after 4-8 hours of laying and in winter when ambient temperature is less than
30'C, initial cut may be done at 8-'12 hours of laying. ln any case initiat cut of all the transverse
and longitudinal joints shall be completed within 24 hours to avoid the random cracking.
Subsequent widening of joint groove will be done aftet 14-16 days of casting concrete
pavements. No sealing ofjoints shall be undertaken before 2.1 days of construction. Alljoints
in surface slabs shall be sealed using sealants and joints shall be sealed when grooves are
dry and clean and free from foreign object or loose material. Alternatively, compression seals
or solid seals can also be used to seal the joints after initial cut without widening with the
permission of Engineer.
25
34. IRC:'15-2017
Joint cutting equipment which can be used to cut joint at the early age of concrete is called
as early-entry saw. This is light weight equipment and has a plate on both sides of saw to
keep concrete pressed at the location of saw cutting to basically control raveling. With use of
eariy-entry joint cutting equipment, joints can be cut even earlier than that mentioned above
using early-entry saw with the permission of the Engineer. The depth of cut shall be minimum
10 % subject to 30 mm minimum.
8-2 Types of Joints
There are four general types of joints (lRC:57). These are:
(i) Expansion Joint: Expansion joint provides the space into which pavement
can expand thus relieving compressive stresses due to expansion and
inhibiting any tendency towards buckling of concrete slabs.
(ii) Contraction Joint; Contraction joint relieves tensile stresses in the concrete
and prevents formation of irregular cracks due to restraint in free contraction
of concrete. Contraction joints also relieve stresses due lo warping
(iii) Longitudinal Joint: Longitudinal joint relieves stresses due to warping.
These are commonly used for longitudinaljoints dividing the pavement into
lanes when width of the slab becomes more than 4.5 m.
(iv) Construction Joint: Construction joints are provided whenever day's
construction operations start and stops. These are full depth joints
Construction should be so planned that days construction activity may end
at the location of regular contraction joint.
(v) Eady Entry Saw Cut Joints: Early-entry saw cutting are dry-cuts so their
blades are designed for use without water for cooling.
Figs.2to 5 showsthe location ofcontraction and longitudinaljoints. Allioints shall be carefully
installed in accordance with the location and details given in the plans. The details ofdifferent
types ofjoints, sealing groove, their plan, cross section etc, are shown in Figs. 6lo 10. For
details IRC:57 may be referred.
26
35. !-
IRC:15-2017
Fig. 2 Joints Configuration of Two Lane Road withoul Tied Shoulder
0 2tn FOR OTHER ROAoS
Fig. 3 Joints Configuration tor each Carriageway of Four Lane Oivided Road
9
&
Jq NT
27
,t9l
5t
ul
36. IRC:'15-2017
0 25 r rOR OTHER RoADs
Fig. 4 Alternate Joints Configuration for each Carriageway of Four Lane Divided Road
0 25 n FOe OThER ROAOS
Fig. 5 Joints Configuration for each Carriageway of Six Lane Divided Road
28
,t
5l
3l
,l
t
EI
5t
EI
37. :
:-
:-
8.3 Transverse Joints
8.3,2 Transverse Expansion Joints
These shall extend over the entire width of the pavement. They shall be of the dimensions
and spacing as shown on the drawing. These shall be provided only at bridge, under passes
and culvert abutments.
INITIAL CONDITION OF SLAB WHEN SLAB CONTRACTS WHEN SLAB EXPANDS
Fig, 6 Shape of Joint Sealing Groove
(Shape Factor = 1.O-1.25 fot Hot Poured Sealant and Cold Poured Polysulphide sealant in
contraction/construction joinVlongitudinal joint
= 0.75 for Cold Poured Silicon Sealant in contraction/construction
joinvlongitudinal joint
= 0.50 for Expansion Joint)
29
IRC:15-201 7
8.3.1 General
Transverse joints can be expansion, contraction or construction joints and shall be placed
across the trafflc direction as indicated on the drawing. These shall make a right angle with the
centre Iine of the pavement and surface of the sub-base/subgrade. Contraction, construction
and expansion joints shall be continuous from edge to edge of the pavement through all
lanes constructed at the same or different times. The maximum joint spacing shall be 4.5 m.
38. PLASTIC SHEAI1lIIIG
IRC:15-2017
TOP OF THE GROOVE IS
"i/IOEIIEO
Lls RqJ o oot?EL BAR
CONTRACTION JOINT WITH DOWEL BAR
(a)
TOP OF TNE GROOVE IS
PORPC6E lIE BAR
LONGITUDINAL JOINI WITH THE,ROD BETWEEN TWO LANES
(b)
ov/rTH
EXPANSION JOINT WITH DOWEL
(c)
150MM LEIJGTH PAII{TED IVITH
BITUT,IINOUS PAINT
IIS ROUND DOI','EL
COI"IPRESS 8LE
!
PLASTIC SIlEATI] I]G
Fig.7 Typical Cross - Section ofJoints
Note: Construction joint shall be same as contraction joint at (a) above with a butt type-
30
39. l
T-
-r-
IRC:'15-2017
!
F_ji___-t
E
T_
!1.!r a^ara c' cox.tsl A't :!to:5 5-rr 5 o'
ac!3r^tr ,'-E 31. s c^.!rot!Ei rvrl
.o _s a aa 3tA-:: Et
^:cf
3 ca o. '-! 'nc c.- 3 cF
:!ac: i 3'rr r !1:r!r-ra:rs 3-a r
:a.a: t -rc a!a. - ,^-r^a--rIt3
t!ccta.!:^'c --: s:as c! _-! itc?,! !.,^l -^).'l _a !!
s^:!-45'!:SA: 'rrrll!: :rr !a:
--! itoarr A: sEAr- :r,!a 0s l-or lr! a-.r .ot
to-t3 3a{.A_ rc A,c: $
a--: r. !3 cs it --
Fig. 8 Sealing Details of Joinls
(Grooves Suitable for Hot Poured Rubberized Bitumen Sealant)
Iffi
I
31
aa,i T.aa Tra'i -a r"T
LC'r6lluatr{aL .JotNT
EXFAn$C JO rr{r
,.J OtES
40. LOHOITTTOINA! -arir
2a-;a
T_
:
Fig. 9 Sealing Details of Joints (Grooves Suitable for Cold Poly-Sulphide Sealant)
IRC'15-2017
T-
:
=
IME
32
aanrPAatia..,alI
EXPANSTON JCrit
llaTEs
t^t!r aA:<3 c. car':t!5! R! :!!a:a s'i; s .,c-
!:!33^tY r'-! 3-t r 3aa!3a.!!-1.:
,a -s aA ?l sE -:: !i l:a.. : cl:
:laaa 3 s-r: !4:i:r.t:: a3 3-a . ..
:!.i1: : .:r --a s!a^.,- t1.-.a:-.r!t,r
r!:ar.,i:a-: -_: r:!3 "^r
-_:3-rai,! rrr _^ r -: !a
3^:!-AS_a: s.r:.i::r!:A,::tr !,a:
'-! :i-: : 4: s!A.^. :.,:.,! :!
!raet r:: !a: {--: .,.: s-^.. !!:,!.1:!::.:3!:.:!..
l:s a. _-: s!A-A_ ir::.! 3-A-. !r :--:i.!: !1t:r:.i-i 1i 3EA-a_'a r,3: !. .-^5!.a-arr!,t
^.-
: r'!s a9 Ar! - -
t
ilt
41. :
:
IRC:15-2017
El!--{
- a|r T
i:-i!
T-
ri c TEs
:?.ll='il j-'. f i; l:,'i*l-.T, ]-14''''t, - . .' -,' .'
ii::ii:t:,r-:-i;.1,:i::.-:i"'r"..ii)-ri;.:v;;_-!-^it:c.! A: s!^-^j:;;:ri:ii s-:, r ata :.r r:i
1i;i-'-"ii;l{i::' t:: !-^'- !! :':i:!: .-.s!:r!..
:l:i l;lt1*ii..;s.-r .!-^.-{ !: ..-i;!: !:.c,!
Fig. l0 Sealing Detaits ot Joints (crooves Suitabte for Cotd Silicon Sealant)
W#Yrgrl,bt
ffi t
33
LCIIGITUCINAL J'NI'
42. IRC;15-2017
Lg.2.1 Experience the world over has shown that there is no need to provide expansion
toints at reqular intervals but they are essential where cement concrete pavement is designed
1.
"i*'*,,]n-"ljrliri".
r,r." oriog"". It may sometime be necessary to provide more number
oJ
"*p"naarrlointa
in successi;n in suchiocations to release the pressure' Expansion joints
;g;;;.i;;i";a, underpasses etc having RCC box structure should. normallv be avoided
uilrri"g th" pOc ou"i the deck of suc-h culverts' To deal with the lack of compaction in
the vicinity of RCC box structures and subsequent settlement' RCC approach slabs must
l" p.",O"O on both sides abutting with DLC layer' Wherever PQC is taken over the deck
of culverts, underpasses etc., saw cut transverie construction joints must be provided just
u0""" in" o*i and approach slabs on both sides to avoid full depth transverse cracks in
POC.
8.3,2,2 Dowel bars aS per dimensions' location and Spacing Shown on the drawing are
Iiiuir"O
"t "rpun"ion
joints to transfer wheel loads to the ad1acent slab For slabs ofthickness
less than 200 mm dowel bars may not be provided (lS: 6509) The pre-moulded synthetic
"rprn.ion
joint llller board, a compressible material shall be used to fill the gap between
"l["""i
Slu" .,
"xpansion
joint. ih" r'"igt't of th" filler board sh,all be such that its top is
i5 mm oetow the surface of the pavement' The accurate placing of dowels at the end of the
;;y ;;;l;
";;"""d
bv means of sufficientlv strong bulkheads made of steel sections with
noL. Oiiff"O along the centre line to accommodate the dowel bars in a mild steel section
;;;;;;p,"g arrJngement not allowing displacement of bars while placing and compacting
""""i"t".'f1,""
bulkh-ead shall be oiled Jr greased belore placing in position to avoid bonding
with concrete. The top and oottom edgei of the bulkheads and mild steel section shall be
"n"p"O "
correspond to camber of tlie pavements at the joint' lf considered convenient'
t*oipl"""
"piit
uritneads may also be used When dowel bars are provided' bulkheads shall
;;;;;;J such that thev can hold the projecting ends of the dowel bars to maintain their
,ilg;";i;; k;"p all bars parallel to each other' A box section normallv is adopted for such
designs.
8.3,2,3 The bulkheads Shall be Securely f]xed in place at right angles to the centre |ine and
Ir?""" of ,t
"
pru".ent with sutficient sta'kes to hold them in the specified position' This may
inroir" ariffinq ot i,oles in sub-base to anchor the bulkhead with stakes'
8.3.2.4 Sealing grooves can be formed by placing wooden or PVC strips of 20-25 mm
x25mmsectionsabovethelillerboard.Thiscanbepulledoutwhenconcretesufflciently
hardens. For easy removal of tne wooden strip without damaging the edqes' the sides of the
strips may be shaped (tapered) suitably'
8.3.2.5 Under no circumstances shall any concrete be left above the expansion ioint filler
or across the joint at any point' nny concrete spanning the ends of the joint next to the forms
at rff U"
"rr"fuffy "rt
away after the forms are removed'
34
43. IRC:15-2017
8.3.3 TransverseContractionJoints
These shall be placed as shown on the drawing and shall be of the weakened plane of
"dummy" groove type. They shall be constructed by forming in the surface of the slab, a slot 2.5
to 5 mm wide and havlng a depth equal to one-fourth to one{hird the depth of the pavement.
The groove is formed preferably by a joint cutting saw. This groove is subsequenfly widened
and sealed with sealant as shown in Figs.6 to 10. Alternatively, in manual construction
and minor works, the slot may be formed in a manner approved by the Engineer_in-Charge,
such as, by pushing into the concrete a flat bar or plastic strip or the web of a
,.T,'
bar using a
suitable vibratory device. removing the bar subsequen y, and keeping the slot open. lt shall
be ensured that no spalling of concrete occurs while removing the bar Such manually formed
grooves are found to affect the riding quality of the pavement.
8.3.4 TransverseConstructionJoints
These shall be formed whenever placjng of concrete is suspended for more than 30 minutes.
Excepting in the case of emergency, construction shall always be suspended at the regular
site of expansion or contraction joint. lf the construction joint is located at the site of an
expansion ioint, regular expansion joint shall be provided; if at the site of a contraction joint
or otherwise, the construction joint shall be of butt type with dowels. ln case of emergency
the joints should be placed only in the middle third of the specified contraction joint interval
or slab length.
At all construction joints, bulkhead shall be used to retain the concrete and care shall be taken
in striking off and finishing the concrete surface to the top face of the bulkhead. when work
is resumed, the surface of concrete laid subsequenty, shall conform to the grade and cross_
section of previously laid pavemenl, and a straight edge 3 m in length shall be used parallel
to the centre line of pavement, to check any deviation in the surface of the two sections. Any
deviation from the general surface in excess of 3 mm shall be corrected.
8.3.5 General Requirements of Transverse Joints
Transverse ioints shall be straight within the following tolerances along the intended line
of joints which is the straight-rine transverse to the rongitudinar axis ofihe carriageway at
the position proposed by the Engineer, except at road junctions or roundabouts where the
position shall be as described in the drawings:
(i) Deviations of the filler board in the case of expansion joints from the intended
line of the joint shall not be greater than i 1O mm.
(ii) The best fit straight line through the joint grooves as constructed shafi not be
more than 25 mm from the intended line of the joint.
(iii) Deviations of the joint groove from the best fit straight line of the joint shalt
not be greater than 10 mm.
35
44. IRC:15-2017
(iv) Transverse ioints on each side of the longitudinal ioint shall be in line with
each other and of the same type and width. Transverse ioints shall have a
sealing groove which shall be sealed as per Clause 8.6 and 8.7.
(v) The transverse joints at curves shall be radial in the direction of the radius.
8.3.6 Dowel Bars
Dowel bars shall be mild steelrounds conforming to lS:432, ofGrade S:240 and in accordance
with details/dimensions as indicated in the drawing and free from oil, dirt, loose rust or scale
These shall be coated with epoxy or any other anti-corrosive paint as per lS:13620 Coated
bars should be protected from scratching during handling, and should be manually recoated
by epoxy or anti-corrosive paint wherever scratches are observed. For uniformity in thickness
of coating, the coating done in factory environment is preferable. Coating shall be done within
4 hours of cleaning of bars from all rust. Cleaning is done by sand/shot blasting. They shall
be straight, free of irregularities and burring restricting free movement in the concrete. The
sliding ends shall be sawn or cropped cleanly with no protrusions outside the normal diameter
of the bar. The dowel bar shall be supported on cradles/dowel chairs in pre-fabricated joint
assemblies positioned prior to the construction of the slabs or mechanically inserted by a
Dowel Bar lnserter (DBl) with vibration into the plastic concrete by a method which ensures
correct placement of the bars besides full re-compaction of the concrete around the dowel
bars.
8.3.7 Design of dowel bars is discussed in IRC:58. The minimum length of dowel bar
shall be 5OO mm keeping in view the requirement of load transfer and placement errors. The
dia and spacing of dowels shall be designed as per IRC:58. Dowel bars are not necessary
for slabs of small thickness and shall not be provided for slab of less than 200 mm thickness.
8.3.8 Unless shown otheMise on the drawings, dowel bars shall be positioned at mid
depth of the slab within a tolerance ! 25 mm, and centred equally about intended line of the
joint within a tolerance of I 50 mm. They shall be atigned parallel to the finished surface of
the slab and to the centre line ofthe carriageway and to each otherwithin tolerances as given
hereunder;
For bars placed by dowel bar inserter during laying of the slab:
(a) Horizontal or vertical rotational alignment I 10 mm
(b) Longitudinal shift < 50 mm
(c) Depth of dowel bar : mid-depth ! 25 mm
8.3.9 Dowel bars shall be covered by a thin plastic sheath for at least 60 per cent of
the length from one end for dowel bars in contraction joints or half the length plus 50 mm for
erpansion joints. The sheath shall be tough, durable, smooth' slide lit' and of an average
thickness not greater than 0.5 mm and shall have closed end The sheathed bar shall comply
with the following PUll out test.
36
45. I
1:
r-
]-
:-
I
:-
:
IRC:15-20'17
8.3.10 Four bars shall be taken at random from stock or without any special preparation
shall be covered by sheaths as required in this Clause. The ends of the dowel bars which
have been sheathed shall be cast centrally into concrete specimens 150 x 150 x 600 mm,
made of the same mix proportions to be used in the pavement, but ,Yith a maximum nominal
aggregate size of 31 .5 mm and cured in accordance with lS:516. At 7 days a tensile load
shall be applied to achieve a movement of the bar of at least 0.25 mm. The average bond
stress to achieve this movement shall not be qreater than 0.14 MPa.
8.3.11 For expansion Joints, a closely fitting cap 100 mm long with closed end consisting
of G1 pipe or stiff plastic of 2 mm thickness shall be placed over the sheathed end of each
dowel bar. An expansion space at least equal in length to the thickness of the joint flller
board shall be formed between the end of the cap and the end of the dowel bar by using
compressible sponge. To block the entry of cement slurry between dowel and cap it may be
taped all round.
8.4.1 General
These joints known as warping joints can be formed by two different methods: (i) These can
be of construction butt type formed by placing the concrete against the face of the slab cast
earlier The face of the slab cast earlier, shall be painted with bitumen before placing of fresh
concrete. (ii) When a pavement of width of more than one lane is laid, the longitudinal joint
may be cut by a joint cutting machine (generally within 6-'14 hours). ln case of four lane divided
road, when a two-lane cariageway (7.2517.5 m wide) with tied shoulder (2.5 m wide) is laid
using full width paver, then, two longitudinal saw cut joints shall be provided-one between the
inner and outer lane and the other between outer lane and tied concrete shoulder (Fig.3).
ln place of two longitudinal joints, one longitudinal joint may also be provided in the centre
of carriageway dividing the carriageway into two equal parts of 4.875/5.0 m width as per
the design recommended by the designer (Fig. 4). Longitudinal joint becomes necessary to
relieve warping stresses when the pavement width exceeds 4.5 m.
8.4.2 Tie bars
Tie bars in longitudinal joints shall be tor steel bars complying with lS: 1786 and in accordance
with the requirements glven below. The bars shall be free from oil, dirt, loose rust and scale.
8.4.3 Tie bars are used across the longitudinal loints of concrete pavements wherever
it is necessary or desirable to ensure firm contact between slab faces or to prevent abutting
slabs from separating. Tie bars are not required for structural reasons, but their only function
is to prevent separation of the slabs, especially at fills or curves. Tie bars are not designed
to act as load transfer devices. Tie bars are designed to with stand tensile stresses only and
provided at mid-depth.
37
8-4 Longitudinal Joints
46. IRC:15-20'17
8,4.4 Tie bars projecting across the longitudinaljoint shall be protected from corrosion
for 75 mm on each side of the joint by a protective coating of bituminous paint with the
approval of the Engineer. The coating shall be dry when the tie bars are used.
8.4.5 Tie bars shall be laid automatically in a fully mechanised construction using slip
form paving as being followed these days for most rigid pavement construction. For semi
mechanised construction tie bars in longitud inal joints shall be made up into rigid assemblies
with adequate supports and fixings to remain firmly in position during the construction of the
slab. Alternatively, tie bars at long itudinal joints may be mechanically or manually inserted into
the plastic concrete from above by vibration using a method which ensures correct placement
of the bars and re-compaction of the concrete around the tie bars (tie bar inserter). When
the pavement is constructed in single lane width, tie rods are also inserted mechanically or
manually from sides. During side insertion in fixed form paving these may be bent so that
half length remains along the form. After removal of forms, bars shall be straightened using
hollow Gl pipe so that they extend into the concrete placed on the other half of the concrete
sla b.
8.4.6 Tie bars shall be positioned to remain within the middte third of the slab depth but
well below the proposed sawing depth as indicated in the Fig. 7 (b), approximately parallel
to the surface and approximately perpendicular to the line of the joint, with the centre of each
bar on the intended line of the joints within a tolerance of 50 mm, and with a minimum cover
of 30 mm below the joint groove. Typical tie bar details for use at central longitudinaljoint in
double-lane rigid pavement with a lane width of 3.5 m are given in Table 8. To be designed
as per IRC:58.
8.5 Arrangement of Different Types of Joints
8.5.1 For more details about arrangement of the different types of joints, IRC:57 may
be refened. The joint spacing at curve portion may be reduced by 20-3Oo/..1n general, slab
configuration is corrsidered as 3.5 rll x 4.5 rn. The lenglh of the slab shail be either more or
equal to its width.
8.5.2 Anchor Eeam and Terminal Slab Adjoining Bridge Structures
Cement concrete slab will expand during hot season and this will result rn the building up
of horizontal thrust on adjoining bridge structure. To contain this thrust RCC anchor beams
are to be provided in the terminal slab. The grade of concrete for anchor beam shall be the
same as for terminal slab. The terminal slab also needs to be provided with reinforcement
to strengthen it. A typical arrangement of anchor beam and the terminal slab are shown in
Fig.l1. ln case of culverts, etc. where the PQC slabs are provided above the superstructure,
there is no need to construct anchor beam, approach slab and terminal slab. ln case the PQC
slab abuts with culvert structure, the construction of approach slab and terminal slab with
anchor beam will be necessary.
38
47. -
j
l
:-
:'
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!
Note
1)
IRC:15-2017
Table 8 Details of Tie Bars for Longitudinal Joints of
Two.Lane Rigid Pavements (Same as IRC:5E)
Slab
Thickness
(mm)
Tie Bar Details
Diameter
(d) (mm)
Max. Spacing (mm) Minimum Length (mm)
Plain Bars Deformed
Bars
Plain Bars Deformed
Bars
't50 8 330 530 440 480
10 520 830 510 560
200 10 390 620 510 560
12 560 900 580 640
12 450 720 580 640
300 12 370 600 580 640
'16 660 1060 720 800
350 12 320 510 580 640
16 570 910 720 800
S = 125 MPa for plain bars, 200 l,4Pa for deformed bars, Bond stress for plain bars = 1.75 MPa,
for deformed bars = 2.46 MPa, W = 24 kg/sqm/cm of slab.
Where, S is minimum tensile strength of steel, g is minimum bond strenglh of concrete with
steel bar, W is the weight of concrete/sq cm/cm.
*E
8E:
Eg
-;I
fl
^.r
oxarsdl},rit & m
o.TY IYA'TL R€TrciCET€NT
o€.rrs }(vE *!ir $€rr ot n€
Fig. 1'l Details ofAnchor Beam and Terminatslab
39
250
48. IRC:15-2017
8.6 Preparation of Joint Grooves for Sealing
8.6.1 Joint grooves are not constructed to provide the maximum width specilied in the
drawings when initial saw cut is made upto one-fourth to one-third of the slab depth. They
shall be widened subsequently by sawing before sealing. Depth and width gauges shall be
used to control the dimensions of the groove during widening process.
8.6.2 lf spalling occurs or the angle of the former is greater than '10 degrees, the joint
sealing groove shall be sawn wider and perpendicular to the surface to encompass the
defects upto a maximum width including any chamfer, of 12 mm for transverse joints and
10 mm for longitudinal joints. lf the spalling cannot be so eliminated then the arises shall be
repaired by an approved thin bonded arises repair using cementitious materials, like, epoxy
or Polymer concrete.
8.6.5 Before sealing, the temporary seal inserted before subsequent widening for
blocking the ingress of dirt, soil etc. shall be removed. A highly compressible heat resistant
paper-backed debonding strip as per drawing/lRC:57 shall be inserted in the groove to serve
the purpose of breaking the bond between sealant and the bottom of the groove and to plug
the joint groove so that the sealant may not leak into the crack below. The width of debonding
strip shall be slightly more than the joint groove width so that it is held tightly in the groove.
ln the case of hot sealant, heat resistant tapes may be ioserted to block the leakage through
bottom of the joint.
8,7,1 When sealants are applied an appropriate primer shallalso be used if recommended
by the manufacturer and it shall be applied in accordance with the recommendation of the
manufacturer. The sealant shall be applied within the minimum and maximum drying times
of the primer recommended by the manufacturer. Priming and sealing with applied sealants
shall not be carried out when the temperature of the pavement is below 7'C.
8.7.2 lf hot applied sealant is used, it shall be heated and applied (after using raker)
from melter and pourer as shown in Figs. 12,'13 and '14. Hot sealants shall be rubberized
bitumen type. For large road projects, sealant shall be applied with extruder having flexible
hose and nozzle. The sealant shall not be heated to a temperature higher than the safe
heating temperature, as specified by the manufacturer. The dispenser shall be cleaned out at
the end of each day in accordance with the manufacturer's recommendations and reheated
material shall not be used.
8.6.3 All grooves shall be clea ned of any dirt or loose material by air blasting with filtered,
oil-free compressed air. lf need arises, the Engineer may instruct cleaning by pressurized
water jets. Depending upon the requirement of the sealant manufacturer, the sides of the
grooves may have to be sand blasted to increase the bondage between sealant and concrete.
8.6.4 The groove shall be cleaned and dried at the time of priming and sealing.
8.7 Sealing with sealants
40
49. I
IRC:15-2017
SIOEVEW
!
3R
Fig. 12 Oetaits of Raker
8.7.3 Cold applied sealants with chemical formulations, like, poly-sulphide/silicone/
polyurethane or other similar formulation may be used as per IRC:57. These shall be maxed
and.applied within the time rimit specified by the manufacturer. rf primer is recommended it
shall be applied neatry with an appropriate brush after creaning the grooves/cut portion with
compressed air. The Movement Accommodation Factor (MAF) shjtt be t lO per cent for
bituminous sealant i 25 per cent for poly sulphide sealant and for silicon sealant it shall be
in the range of - 50 per cent to + .1OO
per cent. Silicon sealant can be compressed to its 50
per cent size whereas it can be stretched to l0O per cent without any change in the volume
of sealant.
4.7.4 Movement Accommodation Factor (MAF) is defined as:
Originat Width
9:].5 The groove configuration is different for poly_sulphide, sjlicone and potyurethane.
silicone, a singre chemicar formura, hardens by absoibing moisiure from the air and hence
il
"!9y19 -b."
placed in a thinner tayer vis-d-vis primer based poty_sutphide. Accordingty, the
depth/width ratio of grooves shourd be modified. Besides the cuiing time of siricone is rnore
than that of poly-sulphide.
8.7.6 The sealants applied during contraction phase of the slabs woutd resull in bulging
of the sealant over and above the slab. The righi temperature and time for applytng th6
sealant shall be as per manufacturer instructions.
= G) (Compressed Width - Originat Width )x 100
Original Width
= (+) (Expanded Widlh - Originat Width) X 1OO
(
41
50. IRC:15-2017
Sealant shall be filled, slightly to a lower level than the slab top with a tolerance of
8.7.8 During sealing operation, it shall be ensured that no air bubbtes are introduced in
the sealant either as vapours or voids by the sealing process
8.7.9 Preformed/premoulded neoprene seals shalt not be used for sealing the joints
as these can be very easily removed/stolen from the joint Where there are no chances of
theft like internal ro;ds in premises, these seals can be permitted Fig l2 to 14 show the
appliances used for ioint sealing as per IRC:57 and IRC:43'
lloll oll /r.J
Fig. 13 Schematic View ot a Sealant Melter
::
:;
42
8.7 .7
3t1mm.
51. :
-
]-
!-
IRC:15-2017
50
1 mm THICK
ISHEET HANDLE WOUND
WITH ROPE
Fig. 14 A Pouring Kettle for Hot poured Seatant
9 STORAGE OF MATERIALS AND PREPARATION FOR CONSTRUCTION
9.1 General
A systems approach may be adopted for construction of the pavement, and the method
statement for carrying out the work, detairing alr the activities incruding indication of time-
cycle equipment, personnel, etc. These shall be got approved from the Engineer before
the commencement of the work The above shall include the type, capacity and make of
the batching and mixing plant besides the hauling
"rrang"reni
and paving can progress
withoul any stoppage. During planning stage, it should be noted that constructing multilane
pavement is better than constructing singre rane at a time from the point of viJw of riding
quality. Therefore, the capacity of plants should be planned accordingiy.
9.2 Storage and Handling of Cement
9.2.1 The requirement of cement being of a very high, cement is normally stored in large
capacity vertical silos. cement is carted in bulk to feed the storage silos. ln the case of small
projects involving manual or semi-mechanised paving cement in bags may be used.
9.2.2 Supply of cement should be co-ordinated such that its long period of storage is
avoided. rts procurement and consumption shourd be pranned so ttra'i it is not storeoiigni
through lhe rainy season. Cement having lumps which have been caused due to improier
storage or by pressure due to over-loading of bags shall not be considered for use unless
43
52. IRC:'15-20'17
these lumps can be easily powdered with pressure between fingers' Before such cement is
used, rep;esentatiye sample containing the lumps in fair proportion also shall be taken and
tested to fulfil the minimum requirements. Any cement stored more than 3 months' or more
than6weeksduringmonsoon,shallbetestedforitsacceptanceandalsoforrevalidationof
mix design.
9.2.3 Owing to the slightly deliquescent nature of rapid hardening cement and 53 Grade
cement, special;are should be taken in its storage and in any case, it should not be stored
for longer than three months.
9.3 Storage and Handling ofAggregates
9.3.1 The location and preparation of sites, minimum size of stack and the methods
adopted for dumping and stacking to prevent segregation of coarse and flne material shall be
subjected to the approval of the Engineer. Aggregates stock piles may be made on ground if
it is denuded ofvegetation, levelled, compacted with good quality soil sub-base material and
well drained. Aggregates near the bottom of the heap may get mixed with soil and shall not
be used withoui washing. Aggregates from different sources and/or of different grading shall
not be stacked together. Each separate size oI coarse aggregate shall be stacked separately
and separate wo;den or steel partition shall be provided to avoid intermixing' The storing of
aggregates upon the carriageway or shoulders shall not be permitted'
9.3.2 lf aggregates are stored in conical stacks, segregation will be increased by the
roling ol the coirser particles down the sides of the stacks. To avoid this, stacks should be
built up in approximately horizontal layers. Dry fine aggregate get blown away easily, it may
be helpful to moisten the aggregates stacked in heaps on the ground'
9.3.3 Sufficient quantity of aggregates should be crushed in advance so that there is
adequate supply of matching aggregates available in the site' Stock piling aggregates for use
beyond 2-3 months should be done cautiously as it is likely to be contamrnated with dust and
foreign matter.
9.3.4 The aggregates shall be handled form the stacks and fed into the mixer in such
a manner as to ;ure the stipulated grading of the material Aggregates that have become
mixed with earth or other foreign material shall not be used They shall be washed clean
before use. The aggregates contaminated with fine dust, etc are normally screened with a
mobile screening plant before use.
9.4 Batching of Materials
9.4.1 All batching of materials shall be by weight. After determining the proportion of
ingredients for the fiell mix, the fine aggregate and each separated size of coarse aggregate
.tiff U" propottionud by weight in a caiibrated and approved weigh-batching plant and placed
into the ;opper of the mixer along with the necessary quantity of cement
44
53. l
:-
10.1 .1
IRC:15-2017
10.1
1O CONSTRUCTION
Fully Mechanised Construction
General
The batching plant shall include minimum four bins, weighing hoppers, and scales for the
fine aggregaie and for each size of coarse aggregate. More bins may be required to handle
mineraiadmixtures like fly ash, GGBFS and also different types of sand like fine, coarse and
crushed etc. lf 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'
npfroreiO sjfety Oevices shall be provided and maintained for the protection of all personnel
engaged in pla;t operation, inspection and testing. The batch plant shall be equipped with
a s]uiiaOte non-res"ttabl" batch counter which will correctly indicate the number of batches
proportioned. The batch mixing plant and concrete production shall be confirming to the
requirements of lS:4929 and IRC:SP:96
10.1.2 Bins and HoPPers
Bins with minimum four numbers of adequate separate compartments shall be provided in
the batching plant.
10.'1.3 AutomaticWeighing Devices
Batching plant shall be equipped to proportion aggregates and bulk cement by means of
automatic weighing devices using load cells.
The batching plant shall have facility for adding at least two admixtures in the mixing pan'
The discharging mechanism shall have appropriate chutes, down pipes, etc' so that the
discharged mix will not get segregated.
'10.1.4 Control Cabin
An air-conditioned centralised control cabin shall be provided for automatic operation of the
equipment.
10.1.5 Batching by weight only is recommended However, if batching by volume is
permitted, as a special case, separate measuring boxes shall be provided for the different
aggregates. The boxes shall be of strong construction provided with handles for convenient
lifting and loading into the mixer. They shall be of such size that it should be possible to
measure out the requisite quantity and capable of being lifted by two men. Each box shall
be provided with a straight edge of required length for striking off after lilling lf so directed
by the Engineer, improved facilities, such as, tipping boxes of accurate capacity working
on run-out rails arranged for direct delivery into the hopper of the mixer shall be provided
by the construction agency. ln volume batching, suitable allowance shall be made for the
bulking of fine aggregate due to the presence of water. For this purpose, the bulking shall be
determined as per relevant lndian Standard Specification.
45
54. IRC:15-2017
10,1.6 The location of the batching plant is an important issue to be looked into while
planning the project. As there is a limitation on using the concrete mix after adding the water
within a stipulated time, the mix shall not normally be carried beyond 15 km of lead on a
maintained road not requiring more than 40 minutes of travel time. Therefore, the location
of the batching plant in a road project has to be decided carefully. The travel time from plant
to construction site should be considered while designing the concrete mix for loss of siump
during travel.
Mixers shall be pan type, reversible type with single or twin shaft or any other mixer capable
of efficiently mixing the aggregates, cement, water and admixtures into a thoroughly mixed
and uniform concrete withln the specific mixing period, and of discharging the mixture,
without segregation. ln twin shaft mixer, mixing time is normally very low (about 6 cubic
materials may be mixed in 20-30 seconds). Hydrometers for the measurement of the density
of the admixtures shal be avairabre at site. Each stationary mixer shafl be equipped with an
approved timing device which will automatically rock the discharge rever when the drum has
been charged and release it at the end of the mixing period. ThL device shall be equjpped
with a bell or other suitabre warning device adjusted t; give a crearry audibre signar each time
the lock is released. ln case of failure of the timing device, the ,ir", ,"y be used for the
balance of the day while it is being repaired, providid that each batch is mixed 60 seconds
or as per the manufacturer's recommendation. The mixer shall be equipped with a suitable
non-resettable batch counter which shall correcfly indicate the number of batches mixed.
The mixers shall be cleaned at suitable intervals or whenever mixing is suspended for about
an hour or more. The pickup and throw-over blades in the drum or diums shall be repaired or
replaced when they are worn down 20 mm or more. The Contractor shall (1) have at the job
site a copy of the manufacturer's design, showing dimensions and arrangements of blades
in reference to original height and depth, or (2) provide permanent marks on btade to show
points of 20 mm wear from new condjtions. Drilled holes of 5 mm diameter near each end
and at midpoint of each brade are recommended. Batching prant shafl be caribrated for the
each ingredient up to its maximum quantity being used in the mix at site in the beginning and
thereafter at suitable interval not exceeding 1 month.
'10.'1.8 Mixing
10.1-7 Mixers
10.1.8.1 General
The mixing of concrete sharr be done in a prant which wifi ensure a uniform distribution of
materials throughout the mass so that the mix is uniform in colour and homogeneous. All
concrete shall be mixed in quantities for immediate use.
10.1.8.2 fhe mixer shall be equipped with an approved water measuring device capable of
accurate measurement of water required per batch. The mixer shall preferably be equipped
with a mechanically operated pump for filling the mixer tank.
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