Material for rigid pavement

Concrete base
1. Cement and Fly ash
Cement shall be Type GP Portland cement complying with AS 3972. When submitting details of
the nominated mix in accordance with Clause 5.03.3 the Contractor shall nominate the brand and
source of the cement. On approval of a nominated mix by the Superintendent, the Contractor
shall use only the nominated cement in the work.
Documentary evidence of the quality and source of the cement shall be furnished by the
Contractor to the Superintendent upon request at any stage of the work.
If the Contractor proposes to use cement which has been stored for a period in excess of three
months from the time of manufacture, a re-test shall be required to ensure the cement still
complies with AS 3972, before the cement is used in the work. The cost of re-testing the cement
shall be borne by the Contractor and results of the testing forwarded to the Superintendent.
Cement shall be transported in watertight containers and shall be protected from moisture until
used. Caked or lumpy cement shall not be used. The use and quality of flyash shall comply with
AS 3582.1. When submitting details of the nominated mix in accordance with Clause 5.03.3, the
Contractor shall nominate the powerhouse source of the flyash. The
Contractor shall use only flyash from the nominated powerhouse. Documentary evidence of the
quality and source of the flyash shall be furnished by the Contractor to the
Superintendent.
2. Aggregates
(i) General
In addition to properties specified in AS 2758.1, the maximum soluble sulphate salt content of
aggregates, expressed as percentage SO3 by mass, shall not exceed 0.1 %. Aggregates containing
more than the maximum permissible amount of sulphates or with visible encrustations of
salts shall be washed and drained before being used in concrete. The Superintendent may direct
washing or rewashing of the aggregates until he is satisfied that harmful quantities of salts are
not present. At least 40 per cent by mass of the total aggregates in the concrete mix shall be
quartz sand. Quartz sand is aggregate having a nominal size of less than 5mm and shall contain

at least 70 per cent quartz, by mass. Where present, chert fragments will be regarded as `quartz'
for the purpose of this specification, but the ratio of chert to quartz shall not exceed unity.
Coarse and fine aggregates shall be washed as necessary or directed to facilitate achievement of
the specified drying shrinkage.
(ii) Fine Aggregates
Fine aggregate shall consist of clean, hard, tough, durable, uncoated grains uniform in quality.
Fine aggregate shall comply with AS 2758.1 in respect of bulk density (1200 kg/m3 minimum),
water absorption (maximum 5 per cent), material finer than 2 micrometres, and impurities and
reactive materials. The sodium sulphate soundness, determined by AS 1141.24.
The grading of the fine aggregate, determined by AS 1141.11. When submitting details of the
nominated mix the Contractor shall submit to the Superintendent a NATA Certified Laboratory
Test Report on the quality and grading of the fine aggregate proposed to be used. The grading
shall be known as the "proposed fine aggregate grading".
(iii) Course Aggregates
Coarse aggregate shall consist of clean, crushed, hard durable rock, metallurgical furnace slag or
gravel. Coarse aggregate shall comply with AS 2758.1 in respect of particle density, bulk density,
water absorption (maximum 2.5 per cent), material finer than 75 micrometres, weak particles,
light particles, impurities and reactive materials, iron unsoundness and falling or dusting
unsoundness. In all other respects, the coarse aggregate shall comply with this Specification. If
required, coarse aggregate shall be washed to satisfy these requirements. The grading of the
coarse aggregate, determined by AS 1141.11. When submitting details of the nominated mix the
Contractor shall submit to the Superintendent a NATA Certified Laboratory Test Report on the
quality and grading of the coarse aggregate proposed to be used. The grading shall be known as
the proposed coarse aggregate grading.
The coarse aggregate shall also conform to the requirements of AS 1141.22 Wet Strength Shall
not be less than 80 kN for any fraction and/or constituent AS 1141.22. Wet/Dry Strength
Variation (10 per cent Fines) Shall not exceed 35 per cent for any fraction and/or constituent
AS 1141.24 Soundness The loss in mass when tested with sodium sulphate shall not exceed 9 per
cent for any constituent. AS 1141.14 Particle Shape The proportion of misshapen particles

(2:1ratio) shall not exceed 35 per cent. AS 1141.18 Fractured Faces At least 80 per cent by mass
of the particles shall have two or more fractured faces
3. Admixtures
Chemical admixtures and their use shall comply with AS 1478. Admixtures shall not contain
calcium chloride, calcium formate, or triethanolamine or any other accelerator. Admixtures or
combinations of admixtures other than specified below, shall not be used. An air-entraining agent
shall be included in the mix and the air content of the concrete shall comply with Clause 5.03.4.
During the warm season a lignin or lignin-based (`ligpol') set-retarding admixture (Type Re or
Type WR Re) approved by the Superintendent may be used to control slump within the limits
stated in Clause 5.03.4. The dosage shall be varied to account for air temperature and haul time
in accordance with the manufacturer's recommendations. A copy of the NATA endorsed
Certificate of Compliance with AS 1478 for Type Re or Type WR Re shall be submitted to the
Superintendent, together with the proposed `dosage chart' in accordance with Clause 5.03.4
During the cool season a lignin or lignin based set-retarding admixture containing not more than
6 per cent reducing sugars (Type WR Re complying with AS 1478) may be used in the mix.
When submitting details of the nominated mix in accordance with Clause 5.03.4, the Contractor
shall nominate the proprietary source, type and name for each admixture to be used.
Documentary evidence of the quality shall be furnished by the Contractor to the Superintendent
upon request at any stage of the work.
4. Concrete
Mix design, manufacture, placing, compaction and finishing of concrete for concrete base shall
be the responsibility of the Contractor. Concrete shall have properties within the limits below :
Characteristic flexural strength at 90 days - 4.0MPa
Compressive Strength - 36 MPa at twenty eight (28) days
Air Content - 4.7%
Slump on delivery - 30-40mm
mechanically placed - 55- 65mm hand placed
Drying Shrinkage at 56 days (max.) - 450 microstrain (after 3 weeks air drying)

Where concrete is to be cast between fixed forms the nominal maximum size of the mix shall be
40mm. Where the Superintendent has approved of the placement of concrete by means of a selfpropelled slip-form paving machine, the mix design, slump and workability shall suit the
machine proposed for use.
5. Reinforcement, Tie Bars and Dowels
Reinforcing steel for concrete pavements shall comply with the requirements of AS 1302, AS
1303, AS 1304 as appropriate. All steel shall be clean and free from mill scale, loose rust or oil.
Tie bars shall be Grade 230S and dowels shall be Grade 230R steel, both complying with AS
1302. Dowels shall be straight, one-piece and cut accurately to length. Ends of dowels shall be
square and free from burrs. Plastic bar chairs or plastic tipped wire chairs shall be capable of
withstanding a load of 200kg mass on the chair for one hour at 23 5oC without malfunction.
The Contractor shall demonstrate that the proposed chairs conform with these requirements.
6. Joint Sealers
Types of Sealer
Joint sealers shall be of one of the following types as detailed:
preformed elastomeric strips;
preformed self-expanding cork strips; or
silicone sealants
The use of hot or cold poured joint sealants will not be approved unless the Contractor can
demonstrate satisfactory installation techniques and adequate performance of the completed seal.
Prior to use of the nominated sealer the Contractor shall submit to the Superintendent a
Certificate of Compliance, from a NATA registered laboratory, showing that the sealant meets all
the requirements of this clause.
Materials for Concrete Subbase
Materials for concrete subbase shall conform to the requirements of Clause 5.03 except that:
(a) Cement shall be Type GP Portland cement or Type GB blended cement complying with AS
3972

(b) The combined grading of aggregate used in the work shall not deviate from the proposed
grading bymore than the amounts.

EQUIPMENT USED
1. Spreaders
Concrete spreaders are required when the width of pavement being placed in one operation is 3.6
meters (12 feet) or more and the area of any given width exceeds 8,300 square meters
(10,000square yards). They must be adjusted to leave the proper amount of concrete to build the
slab. The amount left is determined by the elevation of a strike off plate which is located behind
the screw, paddle or hopper which distributes the concrete. The elevation of the bottom of the
strike off in relation to the top of the forms is shown on an indicator that is visible to the
operator. The equipment should be checked to make sure that the indicator shows zero when the
bottom of the strike off is exactly even with the top of the forms.
2. Vibrators
When vibrators are used for full width vibration of concrete paving slabs, they shall be internal
type either with immersed tube or multiple spuds. They may be attached to the spreader or the
finishing machine, or may be mounted on a separate carriage. They should not come in contact
with the joint, load transfer devices, subgrade, or side forms. Multiple spuds should not be
spaced further apart than 0.76 m (2 1/2 feet). Therefore, a minimum of 10 are required for a full
7.2 meter (24 feet) width paving. Internal vibrators shall operate at 7,000 to 11,000 impulses per
minute. The Contractor is required to provide the Engineer a method to verify
vibrator frequency. Vibration is required for all concrete pavement. Small irregular areas require
vibration by hand held or machine mounted equipment to assure that adequate consolidation for
the full depth and width is achieved without segregation 5. Vibrators shall be turned off when the
machine on which they are mounted is stopped.

3. Transverse Finishing Machines

A. Operating Condition
The transverse finishing machine first should be checked for its operating condition. The
bearings, especially those of the cranks actuating the oscillating screeds, should fit snugly so that
the screed will reverse direction without slap which would rack the forms.
B. End Plates and Screeds
The end plates which slide on the forms should be inspected for wear and reversed or replaced if
necessary. The screed should be checked for straightness or crown if one is required. This is done
by placing a block on the forms under each end of the screeds and stretching wires at both front
and back across from form to form. The crown then is checked by measuring the offsets from the
wire to the screed as outlined in 17.3. Adjusting bolts can be loosened or tightened to secure
proper adjustment. The exact tilt required in each screed cannot be determined until construction
begins. However, at the start of paving operations the front edge of the
forward screed should be titled about 5mm (3/16 inch) and the rear screed set level. Adjustments
can be made readily by end bolts provided for this purpose.
C. Stroke
Springs are used as shock absorbers to prevent slap at the end of the stroke. These should be
checked to insure that they are in compression at all times. The screed lift chains must be long
enough that they are not tight at the end of the stroke or the screed will be lifted off of the forms
at every oscillation. Finally, the wheel scrapers should be tightened so that they will be sure to
keep the wheels clean.
4. Mesh Installer
A. General
Pavement mesh may be installed by placing it on top of the full depth of concrete, then vibrating
it into position using an approved mesh installer. This method eliminates the need for placing

two courses of concrete and thereby eliminates the possibility of a plane of weakness between
two separately placed courses. Control of the placement of the mesh within
the slab has been found to be more accurate than when placed between courses, based on
measurements of cores removed for checking thickness requirements. Another advantage of this
method is that a bulkhead can be placed readily and quickly in the event of breakdown since the
concrete is placed full depth, and not in two separate courses.
B. Types
Two types of machines have been approved for use in vibrating the mesh into position. One type
consists of a grid of steel plates approximately 4.6 m (15 feet) in length and extending the full
width of pavement being placed. The machine which is selfpropelled is positioned over the
mesh, stopped, the mesh depressed into the freshly placed concrete and
moved ahead to repeat the operation. The other type also is self-propelled and consists of long
tapered longitudinal runners across the width being placed. This machine gradually depresses the
mesh into position within the fresh concrete using an oscillating tamping motion while
continuously moving forward.
C. Tolerances
Since there is a forward movement during placing, the latter type of machine may cause
movement of the mesh across transverse contraction joints when not properly adjusted. When
using a machine of this type, periodic checks shall be made by uncovering the mesh at joint
assemblies to assure that the specified clearance of 305 51 mm (12 2 inches) is being
maintained on each side of the center of the joint. If the position of the mesh is found to be
outside of tolerance, it should be corrected and the machine adjusted at once, or its use
immediately discontinued. Production may be continued without the mesh installer by changing
to the two-course method. Both types of machines can be adjusted to control the depth of the
mesh. Therefore, depth checks shall be made daily to assure control of the depth of mesh.
Specifications require the mesh to be placed between 64 mm (2 1/2 inches) and T/3 plus 25 mm
(1 inch), T being the thickness of the slab, below the surface of the pavement. When mesh is
found to be outside of tolerance, immediate adjustment shall be made. It may be necessary to use

the two-course method at expansion joints and at abutting pavements, if the machine with the
long tapered runners cannot position the mesh properly. The two-course method should be
employed any time satisfactory performance of the machine is not being obtained.
5. Combination Float Finisher
A. Types
The combination float finisher commonly is used to provide the final mechanical finish on a
pavement. The machine which consists of two screeds and a float is designed for use on a 7.2m
(24 foot) pavement.
B. Adjustment
The front screed of the machine is a conventional reciprocating screed which rides the forms.
The rear screed and float, however, are suspended from an approximately 4.9m (16 foot) beam
platform and do not receive any support from the forms. The elevation of both the rear screed
and the float is determined by adjustment of the hangers which connect them to the platform. As
a result, variations in forms do not significantly affect the plane of operation of either the rear
screed or float. The key to smooth finishing with this machine is the rear screed since it is the
final screeding tool and operates from a 4.9m (16 foot) straightedge essentially free from
influence of deviations in the forms. Spring loaded shoes are fastened to both ends of the rear
screed to keep the screed in contact with the forms. The springs are sufficiently strong so that the
rails will be kept clean, but not so strong that they will cause the screed to raise when an
undetected highpoint in the forms is being traversed. The float does not oscillate but moves
forward with the machine providing a smooth trowelled surface. It is approximately 0.7m (30
inches) in length and rides on the slab between the forms. Both of the screeds and the float are
provided with devices which permit rapid changes in crown. These devices make it possible to
change crown at super-elevated sections without delay. Crown is checked as described in 4.5.2
and 17.3.

6. Transit Mix and

Central Mix Equipment
Before beginning paving operations and at regular intervals during paving, concrete plants and
hauling units shall be checked for proper condition. Water metering devices and admixture
metering devices should be checked to assure proper calibration within specified tolerances.
A. Transit Mixers
Transit mixers should be checked to determine if the counters are functioning properly. After
having been mixed for not less than 70 revolutions at mixing speed, the mixer should contain
concrete of uniform consistency and be able to discharge the batch without segregation. Since
this determines acceptablility, mixers that do not perform in this manner should not be approved,
and, if encountered, their use should be discontinued. Sources of trouble are badly worn blades
and leaky valves which prevent mixers from producing uniform concrete. They should not be
used until corrected.
B. Central Mixers
Central mixers should be checked to see that the mixer is capable of mixing and discharging the
large volume of conrete with uniformity. During paving, the Contractor or ready mix supplier
must keep mixer blades free from concrete build up and excessive wear.
C. Hauling Units
When the concrete is to be transported to the paving site in dumptrucks or other non-agitating
units, these bodies should be checked to see that they are water tight and free of objectionable
corners or internal ribs where concrete may accumulate. Canvass covers to shield concrete from
sun and wind shall be provided when required by the Engineer.

7. Slip Form Pavers

Slip form pavers are generally of two basic types. One has an extrusion meter which shapes and
extrudes the concrete pavement, while the other type has the same features as the combination
float finisher which shapes, consolidates and then finishes the pavement in a manner similar to
conventional methods.
A. Adjustment
The extrusion meters or screeds and the float should be checked for proper crown setting before
using. They should be adjusted if necessary to conform to the typical section.
B. Tampers and Vibrators
Slip form machines usually are equipped with both tampers and vibrators. Both should be
checked to assure they are in working order before paving starts. Vibrator frequency shall be
monitored periodically to assure the specified impulses per minute are being obtained.

EQUIPMENT USE IN RIGID PAVEMENT