TPL-SUCG Consortium

Standard Procedure for Pathway PCC, Paver block and

other related work

Table of Contents
S.NO. DESCRIPTION PAGE NO.
1 Preamble 2
2 Scope 2
3 References Documents 2
4 Materials 2
5 Equipment 3
6 PROCEDURE for Pathway PCC and Paver 3
Block fixing
9 Health, safety & Hazard Analysis 8
10 Organization 8
11 Do’s & Do not’s 9
12 Image with Caption 10

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1. PREAMBLE
The manual has been developed as guiding tools for the site team to introduce Pathway PCC,
Paver Block fixing, and other related works. This manual is intended to serve as an educational
tool for the concerned and also to practice for all the construction activities in a safe and efficient
manner with all safety aspects, improve the quality of works, reduce the reworks and deviations.

2. SCOPE
This procedure covers general requirements to execute activities of pathway PCC .i.e. site
clearance, excavation, filling, Paver block fixing, kerb stone fixing, sand bedding, sand for
spacing in blocks etc in LBL (LHS and RHS) as shown in drawing, transportation and disposal of
surplus soil or stacking all those properly.

3. REFERENCE DOCUMENTS
a. Approved Drawings (Good For Construction)
b. Customer’s Specification ( Technical Specification )
c. IS : 3764: Code of Safety for Excavation Work
d. IS : 15658: Precast concrete blocks for paving
e. IS : 5758: 1984 Precast Concrete Kerb, Channels, Edgings, Quadrants and Gutter Aprons
f. IRC SP 063: Guidelines for the Use of Interlocking Concrete Block Pavement
g. IS-456 – For concreting works

4. MATERIALS

 Cement- OPC cement shall be used for all concrete work related to pathway
PCC and in fillings in between paver block as per technical specification or as
describe in drawing. It should be at least OPC 33/43/53 grade and governed to
IS 269 latest revision.

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 Water- The water used shall be clean free from impurities, oil, floating materials and
injurious amount of deleterious material. It should be at least suitability of construction
purpose as specified in IS-456: 2000.
 Fine Aggregate (River Sand) – The used sand in concrete shall confirm to IS 383 and
for paver block IRC SP:63 , The used sand shall be free from organic materials,
vegetation etc.
 Stone- The used sand in concrete shall confirm to IS 383. The used stone should be
hard, free from loose spot and any external cracks. One vertical surface is mandatory at
outer side of wall.
 Concrete- The grade of concrete shall be governed with IS-456:2000 or as per
drawing

5. EQUIPMENTS
The following equipment’s will be deployed / used, depending upon site conditions:
 Excavators or manual excavating tools.
 Lifting tools and tackle, stone grinders
 Working tools for mortar works and finishing
 Electrical or Mechanical Operator mortar mixing machine
 Measuring box for mortar preparation
 Ramming tools
 Curing arrangement

6. PROCEDURE for Pathway PCC and Paver Block fixing

a) Surveying:-
 Before starting the excavation work, the site shall be surveyed first. All those utility lines will
be checked out and necessary precaution shall be taken, if any line found up to the excavation
level.
 At least two temporary bench mark shall be established nearby the site, so that, the level can
be checked out time to time and can be verified at the end of the day of work.

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 The lay out plan shall be given by surveyor as per drawing and that shall be confirmed by
concern engineer and that should be marked by wooden peg as well as lime powder.
 Before start excavation, the formation level (TBL top ) must be completed on that stretch.

b) Excavation:-
 After getting proper lay out plan, the excavation/ filling can be started, according the quantum
and site situation, equipment should be deployed for the work either manual hand tools is
sufficient.
 The foundation level shall be checked out time to time during the excavation/filling work.
Anyhow, the final level shall not differ from the required level of PCC (Plain Cement
Concrete) bottom.
 The final level shall be trimmed out by spade in manual method and the loose surface shall be
watered and rammed thoroughly as per drawing.
 The excavated material shall be stacked in proper way by maintaining a distance at least 1 .5
meter from the edge of cutting.

c) Plain Cement Concrete :-

Preliminary preparation –
i) Soil should be cut or filled (compacted in layers, if filled) up to required level.
ii) Soil should be dressed and water should be sprinkled on soil.
iii) For dressing of top layer manually or mechanical vibrators may be used.
iv) Top layer should be marked for levels by means of line-dori marking and pags in between.
v) Shuttering channel should be checked for level, alignment, shuttering oil and support.
vi) Lining edge should be clean from dust.
vii) If any manhole is in between the PCC reach it should be marked and PCC will not be done
over it.

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During and After PCC-
i) Concrete should not fall from more than from .9m to 1.5 m.
ii) Concrete should be compacted by suitable method, (if thickness is limited to 100mm skid vibrator
is used, if thickness is more needle vibrators can be used.)
iii) Final finishing should be done so that smooth surface with correct level can be found on the
surface.
iv) To avoid shrinkage cracks proper curing or shading arrangement should be available at site.
v) In case of rainy seasons, Plastic sheets or other suitable sheets should be used.
vi) No vehicle movement is permissible until concrete get herded.
vii) At least 7 days of curing should be done.

Fig01- Width Checking of LBL PCC. Fig02- Prepared surface.

Fig03- Use of skid vibrator and finishing of PCC. Fig04- Compaction Test at PCC
subgrade.

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Fig05- Level Checking for PCC. Fig06- PCC in Progress.

d) Paver Block Fixing:-

Paver block fixing, if required should be done over PCC with laying sand bedding. The
thickness of sand after compaction should be in range of 20 to 40 mm, where in the loose form
it can be 25 to 50 mm. Compaction thickness is restricted to 20-25 mm level. Bedding sand
should not be used to fill up local depression on the surface of base or sub-base. The
depression should be repaired in advance before placing, Sand should have uniform moisture
of 8 to 6 %, it should not be too wet or too dry, the sand is subsequently compacted with plate
vibrators weighing 0.6 tones or more. Level checks shall be carried out on a grid pattern to
establish that the desired level is achieved. Local correction can be done either by removing or
adding extra sand followed by levelling and compacting the layer. There will be some
settlement of sand after the blocks are placed and compacted, which must be allowed for,
while fixing the level of sand bed. Laying should commence from the edge strip and proceed
towards the inner side. When dentate blocks are used, the laying done at two fronts will create
problem for matching joints in the middle. Hence, as far as possible, laying should proceed in
one direction only, along the entire width of the area to be paved. While locating the starting
line, the following should be considered:
 On a sloping site, start from the lowest point and proceed uphill on a continuous basis, to
avoid down hill creep in incomplete areas.
 In case of irregular shaped edge restraints or strip, it is better to start from straight.
 Influence of alignment of edge restraints on achieving and maintaining laying bond.

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Fig07 Effect of thickness variations in paving blocks

Fig08 Effect of base-course surface shape on bedding sand and block surface shape

Joint filling : The importance of complete joint filling cannot be over-emphasised. Unfilled or
partially filled joints allow blocks to deflect, leading to loose blocks, possibly spalling the edges and a
locally disturbing bedding sand layer. After the compaction of the bedding sand has been completed
(and some bedding sand has been forced up in the joints between blocks), the joints should be
completely filled with sand meeting the desired specifications, as given in Section 6. The joint filing

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sand should be stockpiled at suitable locations for convenience. There should be minimum delay in
joint filling; the process should in any case, be completed by the end of the day's work.

Fig09 UNFILLED JOINT ALLOWS BLOCK TO DEFLECT LEADING

TO LOOSE BLOCKS WITH POSSIBLE CREAKS

7. HEALTH, SAFETY & HAZARD ANALYSIS

Environment, Health and Safety (EHS) plan will be followed throughout the construction
duration. All precautions and warning/sign boards shall be indicated sufficiently distance
from exact work place and soft or hard barricading shall be provide where as necessary. The
project HIRAC shall be prepared and maintained as per general norms. A dynamic HIRA
shall be classed before each and every activity as per safety rules and norms and the same
shall be implemented at site.

8. ORGANISATION
Organization for PCC and Paver block, role-responsibility will be as per site organization
Chart. The chart shall be prepared by site planning concerning with Project- RCM to regulate
the work and that should be approved by Project Director.

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9. Do’s and Do not’s

 - Do’s-
1. Moist subgrade before placing of concrete.
2. Level should be checked before placing of concrete.
3. For PCC thickness greater then 100mm needle vibrator may be used otherwise
skid vibrator may be used.
4. Curing should be done for at least 7 days.
5. For paver block, sand should be checked before starting of work.
6. Sand should be moist and compacted.
7. Use line dory and water pipe level at site.
8. Paver joints should be filled with sand.
9. Any gap from edge to paver should be filled with concrete.

Χ -Do not’s-
1. PCC finishing is rough,
2. Sand having more silt as specified.
3. Paver depth is variable more than specified limit.
4. Uneven level of PCC.
5. Uneven Level in laid pavers/kerb stone.
6. Large gaps in between pavers.
7. Un-approved design pattern.
8. Gaps are not filled with sand.
9. Use of damaged paver blocks/kerb stone.

Image-1

Image-2

Image-3

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Image-4

Image-5

Using bore water for mixing, moistening and curing.

Image-6 (Completed part)

Stone laid on PCC

Innerdirectly-
side of wall
No is full of cavity.
Moistening, No soil
removing/Cleaning,
mortar not placed at
bottom and thick
mortar used in
joints etc.

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Cladding should be
Rail fixing under
last activity at
progress…
Compound wall.

Thanks….
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