Rigid Pavement

Rigid Pavement
Ankita Bhadane 2018H1300053H

Jay Gandhi 2018H1300060H
Kshitija Ghogare 2018H1300056H
1
Contents
 Introduction
 Advantages of rigid pavement
 Materials
 Types of rigid pavement
 Types of joints
 Sealing of joints
 Construction procedure
 Distresses in rigid pavement
2 BITS Pilani, Hyderabad Campus

Introduction
 Concrete pavements have been used for highways, airports, streets, local
roads, parking lots, industrial facilities, and other types of infrastructure.
 When properly designed and built out of durable materials, concrete

pavements can provide many decades of service with little or no
maintenance.
 “Concrete generally has a higher initial cost than asphalt but lasts longer
and has lower maintenance costs” (Hoel and Short 2006: 26).
BITS Pilani, Hyderabad Campus

Advantages of rigid pavement
 Long life
 Maintenance free performance
 Good riding quality
 Good abrasion resistance
 Ability to withstand extremes of weather
 Exclusion of water
 Effect of oil spillage
 Skid resistant

Advantages of rigid pavement
 Useful in areas where soils have poor engineering properties

 Availability of binder
 Reflectivity characteristics
 Pollution free
 Conservation of material
 Economy in life cycle cost
 Good foundation for strengthening

Materials
Cement
 Ordinary Portland Cement (33 grade, 43 grade , 53 grade )
 Portland Pozzolana Cement (33 grade)
 Portland slag cement (33 grade)
 Composite cement (blended with slag and fly ash)( 33 grade)
Admixtures
 Fly ash : 25% by weight of CM with OPC
 Ground granulated blast furnace slag : 50% by weight of CM with OPC
 Silica fumes : 10% by weight of CM
 Metakaoline : 20% by weight of CM

Materials
Aggregates
Coarse aggregate
Physical Characteristics :
 Maximum size : 31.5 mm in PQC & 26.5 mm in DLC (25 mm as per IRC:SP:62-
2014).
 Combined Flakiness and Elongation index ≤ 35 %
 Water absorption Max 3 % (However if water absorption is more than 3 %,
aggregates shall be tested for Soundness)
 Soundness : After 5 cycles of testing, the loss shall not be more than 12 % of
Sodium Sulphate solution is used or 18 % if Magnesium Sulphate solution is used.
 Abrasion Value (Los Angeles) – Max 35 %
 Aggregate Impact Value < 30 % (IRC:SP:62-2014).
Materials
Fine aggregate
PHYSICAL CHARACTERISTICS :
 Clay lumps ≤ 1 %
 Coal and Lignite ≤ 1%
 Material passing : Natural sand - ≤ 3 %
 IS Sieve 75 Micron : Crushed stone sand - ≤ 15 %
: Blend of natural sand and crushed stone and ≤ 8 %
 Soundness / Water absorption : Same as for Coarse Aggregates

Materials
Steel dowel bars and tie bars

 High yield strength deformed bars and grade of Fe 500
Temperature reinforcement
 TMT bars
Fibres
 Reduce shrinkage cracking
 Improve post cracking residual strength
 Steel fiber or polymeric synthetic fiber

Materials for joint reinforcement
Premoulded joint filler

 Synthetic joint filler board for expansion joint shall be 20 to 25 mm thickness
with tolerance of 1.5 mm with firm compressible material and having
compressibility greater than 25%
 It shall be 25 mm less in depth than thickness of slab within tolerance of 3
mm
Preformed seals
 Valcanized elastomeric compound using polychloroprene (Neoprene) as the
base polymer

Materials for joint reinforcement
Joint sealing
 Hot sealants or cold sealants with chemical formulation like
polysulphide / silicone / polyurethane or other similar formulation may
be used for sealing.
 Overheated and reheated material should be avoided
 Quantity of sealing compound required for one operation of joint sealing work
shall only be heated.

Cross section of rigid pavement

Types of Rigid Pavement
 Jointed Plain Concrete Pavement (JPCP)
 Jointed Reinforced Concrete Pavement (JRCP)
 Continuously Reinforced Concrete Pavement (CRCP)

Jointed Plain Concrete Pavement (JPCP)
 It consists of unreinforced concrete slabs

3.6–6.0 m (12–20 ft) in length with
transverse contraction joints between the
slabs.
 The joints are spaced closely
 The pavement expansions and
contractions are
addressed through joints.
 Performance issue with JPCP - load
transfer across the joints
 Two methods are used to provide load
transfer across JPCP joints – aggregate
interlock and dowels.

Jointed Reinforced Concrete Pavement
(JRCP)
 Longer slabs and light reinforcement in the
slabs.(temperature steel )
 Slab length : 7.5 to 9 m (25–30 ft), although
slab lengths up to 30 m (100 ft) have been
used.
 The slab steel content : 0.10–0.25 percent
of the cross-sectional area, in the
longitudinal direction, with less steel in the
transverse direction.
 Either individual reinforcing bars or wire
fabrics and meshes may be used.

Continuously Reinforced Concrete
Pavement (CRCP)
 Heavy steel reinforcement and an absence of
joints.
 steel is used for CRCP typically on the order of
0.4–0.8 percent by volume in the longitudinal
direction. Steel in the transverse direction is
provided in a lower percentage as temperature
steel.
 Cracks form in CRCP approximately 0.6–2 m (2–
6 ft) apart.
 The reinforcement holds the cracks tightly
together and provides for aggregate interlock and
shear transfer.
 CRC pavements require anchors at the beginning
and end of the pavement to keep the ends from
contracting due to shrinkage, and to help the
desired crack pattern develop.
Concrete pavement types
PQC PQC PQC

125 MICRON THICK PVL BC DBM-1
SHEET
CEMENT TREATED GRANULAR SUBBASE
DLC/ CEMENT TREATED GRANULAR SUBBASE
SUBBASE LAYER GSB AS DRAINAGE LAYER
GSB AS DRAINAGE LAYER
GSB AS DRAINAGE LAYER
FILTER/ SEPARATION LAYER
FILTER/ SEPARATION LAYER FILTER/ SEPARATION LAYER
SUBGRADE SUBGRADE
SUBGRADE
500mm 500mm
500mm
Debonding layer of polythene Debonding layer of 40 mm BC PQC over 100mm of DBM-1

sheet over cement treated over cement treated subbase and granular subabase
subbase layer layer

Joints
 Initial cut or slot : 2.5mm to 5mm wide

 Depth : 1Τ3 to 1Τ4 th depth of PQC slab
 During summer : initial cutting (after 4 to 8 hr of laying)
 During winter : initial cutting (after 8 to 12 hr of laying)
 initial cut for all joints shall be completed within 12 hrs to avoid cracking
 Widening after 12 to 16 days
 No sealing before 21 days of construction
 All joints in surface slab shall be sealed using sealant when grooves are
clean

Types of joints
 Transverse joint
• Expansion joint
• Contraction joint
• Construction joint
 Longitudinal joint
 Early entry saw cut joint

Expansion joint
 Provides the space into which pavement can
expand
 Such a joint relieve compressive stresses due
to expansion
 Provided where concrete slabs abut with
bridges and slab culverts.
 The joints width may be 20mm, dowel bars
25mm diameter, 500mm long and spaced at
250mm centre to centre
 Joint shall consist of bitumen impregnated
joint/ premoulded synthetic joint filler board
about 20 mm thick complying IS: 1838 and
dowel bars passing
through the holes in the board.

Contraction joint
 Such a joint relieves tensile stresses in the concrete.
 Prevents formation of irregular cracks due to restraint in free contraction of

concrete.
 Also relive stresses due to warping.
 Maximum joint spacing shall be 5 m. In general, slab configuration is

considered as 3.5 m x 5.0 m (IRC:15-2011).
 Joints spacing at curve portion may be reduced by 20 to 30 percent.

Contraction joint
 Joints shall be formed by mechanically sawing a joints groove, 3-5 mm wide

and 1Τ3 to 1Τ4 depth of slab, as soon as the concrete has undergone initial
hardening and is hard enough to take the load of the joint sawing machine
without causing damage to the slab.
 Temporary seal (jute rope) shall be provided for blocking ingress or dirt,
stone pieces etc.
 After the concrete slabs have been cured, before allowing for traffic, joints
shall be widened to 10 mm width and depth of 20 mm for sealing.
 Joints can also be formed by pressing a mild steel T section into the fresh
concrete.

Construction joints
 Shall be placed whenever day’s construction operations starts and stops.
 Whenever work is suspended for more than 30 minutes.
 For accurate placing of dowels at the end of the day, strong bulkheads made of
steel with holes drilled along the centre line shall be used. If considered
convenient, two piece bulkheads may be used.

Initial groove cutting Insertion of jute rope

Initial groove cutting at edge

Longitudinal joints
 Longitudinal joints relieve stresses due to warping.

 Provided in multilane pavements and when pavement is more than 5 m wide.
 Initially joint is cut to a depth 1/3 to 1/2 of the slab.
 Top 15-20 mm of the joint is sawn to a width of 6-8 mm for sealing.
 Longitudinal joints are not provided for rural roads as they generally of single
lane, and the full lane width (3.0m-3.75m) is concreted in one operation.
 In rural roads where width of concrete slab exceeds 4.5m in the case of
causeways, etc. Longitudinal joints shall be provided.

Early entry saw cut joint
 Dry cutting operation with specially designed blade , do not require water for
cooling
 Up cutting rotation blade : to keep debris out of joint
 Light weight device is used

Sealing of joints
 Widen the first saw cut joint to required width / depth.

 Rough arises develop when grooves are made they shall be ground to
provide a chamfer approximately 5 mm wide.
 Clean the groove of any dirt or loose material by air blasting / pressurized
water jets / sand blasting.
 Dry the groove at the time of priming and sealing.
 Remove the temporary seal inserted.

Sealing of joints
 A highly compressible heat resistant paper backed depending strip shall be

inserted in the groove to serve purpose of breaking the bond between sealant
and the bottom of the groove. The sealant shall be applied within the minimum
and maximum drying times of the primer recommended by the manufacture.
 Hot sealants or cold sealants with chemical formulation like polysulphide /

silicone / polyurethane or other similar formulation may be used for sealing.
 Sealant shall be applied slightly to a lower level than slab with a tolerance of 3 ±
1 mm

Sealing materials Mixing of sealants

Baker Rod Baker Rod with Applying sealant
debonding strip

Joints after sealing
Construction procedure of rigid pavement
Stages involved in construction of concrete pavements
 Preparation of sub-grade
 Preparation of sub-base
 Fixing of forms
 Batching of materials and mixing
 Carrying and placing of concrete
 Compaction and finishing
 Floating and edging
 Curing

Preparation of Sub-grade:
A rigid pavement’s subgrade has to be prepared carefully, in order to realize
adequate and uniform thickness throughout the pavement structure
Subgrade shall be selected of earth complying the following requirements-
 No soft spots present in the pavements
 The sub grade shall be of coarse grained material and have a minimum CBR
of 8%
 The camber and super elevation shall be same as that of the concrete slab.

Sub-Bases for Rigid Pavements
 Sub-bases should be provided as they provide a uniform and a
reasonably uniform support.
 Prevents mud-pumping on sub-grades of clays and silts.
 Acts as a capillary cut-off.
 Supports the construction of traffic even if the sub grade is wet.
 When subbase is provided, the effective k value may be taken as
20 percent more thank value of the subgrade.
 Sub base shall be constructed on a subgrade of selected coarse
grained soil of 300 mm thickness
Recommended GSB types

 Grade I&II is used at locations where drainage
requirements are not predominant.
 Grade IV&III used as Gap graded, at locations

experiencing heavy rainfall.

Formwork
 Side forms shall be of mild steel sections of depth equal to the thickness of
the pavement with provision for insertion of tie bars wherever essential.
 Side forms shall have a length of at least 3.0 mtr.
 At least three stake pickets for each 3m of form shall be provided with ample bracing
and support to prevent springing of the forms under the pressure of concrete.

Formwork
 Wooden forms shall be held by stakes set at intervals not exceeding 2m.
 Wooden forms shall be capped along the inside upper edge with 30-50mm
angle iron, well recessed and kept flush with the face of the wooden forms.
 All forms shall be cleaned and oiled each time they are used.
 Bulkheads of suitable dimensions shall be used at constructions joints with
facility to provide dowel bars.

Formwork
 Forms shall be removed only after the concrete has set for at least 12
hours.
 After removal of forms, the ends shall be cleaned and any honey combed
areas pointed with 1:2 cement sand mortar.

Separation Membrane
• A polythene membrane of 125 microns thickness shall be provided over the
sub-base to act as a separation layer between the subbase and concrete slab.
• Separation member shall be transparent or white in colour and laid flat with
minimum creases (IRC:15-2011 clause 6.6).

Separation Membrane
• Wherever overlap of Polythene membrane is necessary, the same shall be
atleast 300 mm
• In summer(When ambient temperature is more than250C)before
• placing polythene membrane, the existing subbase shall be wetted with water.

Dry Lean Concrete Sub-bases for rigid
pavements
• Recommended as a sub-base layer where the traffic intensity is high
• A minimum of 150mm for NH and 100mm for other roads needs to be ensured.
• The DLC shall be extended beyond the pavement edges by 50cm to facilitate the further
construction operations and provide an adequate support for the concrete slab.
• The cement content shall be at least 150kg/cum.
• The average compressive strength of 5 concrete cubes shall not be less than 7Mpa in 7
days and not than 5.5 Mpa for an individual cube.
• Maximum aggregate cement ratio should be 15:1
• Optimum moisture content should be determined by rolling during trial length
construction and can be allowed to be 1% higher moisture while laying.
• The number of passes to obtain maximum compaction shall be determined during trial
run as well.

• Concrete shall have 0 Slump value.
• DLC shall be laid by hydrostatic power.
• Double drum smooth wheeled vibratory roller min. 80-100kN static weight
should be used for smooth and thorough compaction.
• Laying of two lane sub-bases should be down in full width.
• Spreading, Laying and Finishing of DLC should be finished within 90 minutes
when the concrete temperature is between 25-30and 120 if less than 25.
• Work should not be carried if the temperature is greater than 35 degrees.

Storage of materials and Preparation for construction
Storage and Handling of cement:

• High vertical silos
• Supply should be co-ordinated such that its long storage should be avoided.
• Owing to the deliquescent nature of cement it should not be stored for longer than three
months.
Storage and handling of aggregates:
• Aggregate stock piling may be done on the ground if it is, without vegetation, levelled,
compacted with good quality sub-base material and is well drained.
• Each separate size of coarse aggregate should be stacked separately and separated by
wooden or steel partition to avoid inter-mixing
• Moisten the fine grained aggregate aggregates to avoid them getting blown away.

• Sufficientt quantity of aggregates should be crushed in advance.
• The aggregates shall be handled from the stacks and fed into the mixers
without affecting the grade of the aggregates.
Batching of Materials:
• All batching materials should be by weight.
• After determining the proportion of each ingredient the fine aggregate and
each proportioned coarse aggregate shall be weighed and approved and
placed into the hopper of the mixer along with the necessary quantity of
cement.

Bins and hoppers

Location of the Batch Mix plant
• Important issue to be considered.
• Limitation on using the concrete mix after adding the water within a
stipulated time the mix shall not be carried beyond 15km of lead on a
maintained road having travel time less than 40mins.
• Travel time from the batch mix plant to the construction site shall be
considered for loss of slump during travel time

Objectives of mixing
 Mixing shall be done to ensure uniform distribution of materials throughout the
mass so that the mix is uniform and homogenous.
 All quantities shall be mixed for immediate use.
 Mixers shall be equipped with suitable device to measure the accurate
quantity of water per batch.
 Also equipped with a timing device.(60 seconds)
 Type size and number should be chosen so as to avoid overloading.
 Mixing speed not less than 15rpm and not more than 60 rpm.
 Hauling of concrete:

Placing of concrete
 The total time taken from the addition of water until the completion of
surfacing and texturing shall not exceed 120 minutes for concrete 25 degrees
and 90 minutes for concrete having temp between 25-30

Compaction of concrete

• Compaction shall be done by screed compactors resting on side forms and being drawn
ahead by sawing action assisted by needle vibrators
• Inadequate compaction induces presence of excess voids. Presence of 5% voids reduce the
strength from that of fully completed concrete by about 30% and presence of 10% voids will
reduce the strength by 60 percent.

• As soon as practicable after the concrete has been compacted its surface shall be smoothened by
means of a longitudinal float operated from a footbridge or using mechanical floater.
• Work on gradients: The progress on gradient of placing, compacting and finishing of concrete should
proceed from the lower to the higher reaches. The concrete mix shall be stiffer than that used on level
reaches. In case of very steep gradient, or where fill up areas/ very weak subgrade is there,
reinforcement in single layer or in two layers in the PQC may be provided. Slump of concrete mix in
such situations should be adjusted from field trials.

Floating and Straight edging
 As soon as concrete has compacted, its surface shall be smoothened by

means of longitudinal float.
 The longitudinal float working with sawing motion while held in position
parallel to carriageway.
 Straight edge shall be held in successive position parallel to road center line
in contact with surface
 High areas shall be cut down and refinished. The departure should not be
more than 3mm.

surface floating

SURFACE TEXTURING
 After final floating and finishing and before application of the liquid curing
membrane, the surface shall be textured by TINING or BRUSH TEXTURING
 The pavement shall be given a broom finish with an approved clean steel or
fibre broom not less than 450mm wide.
 Texturing (Brooming) shall be perpendicular to the centre line of the
pavement, and the texture shall be uniform in character and width, and not
more than 1.5 mm deep (This value is 1 ± 0.25mm as per IRCL15-2011)
 Measurement of texture by using an sand patch method.

Tinning / transverse tinning
 A texturing can be done by using rectangular steel tines. A bridge mounted

with steel tines shall be equipped and operated with automated sensing
 The grooves produced shall be at random spacing but uniform depth and
width.
 The random spacing
10 14 16 11 10 13 15 16 11 10 21 10
 It follows above pattern.

Sand patch method-

Finished
surface Textured
surface
texturing brush

Brooming
Texturing brush

Curing
 Initial curing shall be done by the applications of curing compound followed

by covering the pavement surface entirely with wetted burlap or jute mat.
 The covering shall be maintained fully wetted and in position for 24 hours
after the concrete has been place.
 Final curing shall be done by ponding or continuing with wetted burlap for at
least 14 days

Curing
 Curing compound has water retention efficiency of not less than 90%.
 Covering shall be done 2 to 3 hrs of spraying curing compound.
 Worn coverings and coverings with holes shall not be permitted
 Coverings shall be provided from suitable wooden bridge.

Before After
curing spraying of
compound curing

Curing by
wetting
rice husk Water
ponding

Failures in rigid pavement
The distress and defects in rigid pavement categorized in various types –

 Cracking
 Surface defects
 Joint deficiencies
 Other missallenous defects

Longitudinal and Transverse Cracking
 The cracks which are parallel to pavement Centerline or likely occur at

crowned pavement
 Longitudinal cracks are also likely to occur at the crowns of crowned
pavements if longitudinal joints are not provided
 It occurs perpendicular longitudinal direction. It forms due to heavy load
repetition and temperature gradient
 transverse cracks are usually caused by a combination of heavy load
repetitions and stresses due to temperature gradient, moisture gradient, and
drying shrinkage.
 It is one of key performance measure for jointed plain concrete pavement, as
transverse crack happens its faulting and deterioration leads to severe
roughness.

Surface defects
 Map cracking
• Series of cracks that extends only on surface of slab.
• These type of cracks caused by excessive bleeding and plastic shrinkage
 Polished aggregates
• In this surface mortar and texturing warn away
• To expose aggregates
 scaling
the deterioration of the upper concrete slab surface, normally 3–13 mm (1/8-
1/2 inch), and may occur anywhere over the pavement.

Map cracking scaling Aggregate polishing
Blowups and pop out-
Blowups-
 It is an upward movement of pavement at transverse joint and cracks.
 It is buckling failure due to compressive stress in concrete pavement
Pop out/punch out-

 A localized area of concrete slab that is broken into pieces will be named as
punch out distress.
 The main reason behind punch outs is heavy repeated loads, the slab
thickness inadequacy, the foundation support loss or the construction
deficiency like honeycombing.

blowups Punch outs
Joint deficiencies-
Corner breaks-
 Triangular pieces at corner about (30cm)
Causes of corner breaks -

 Because as slab curl up or slab warp, The slab
corners may be Unsupported and break
 Poor load transfer across the joint Thermal and

moisture warping

Joint deficiencies-
Joint seal damage-

 Joint seals are used to keep incompressible materials and water from
penetrating joints.
 Typical types of joint seal damage include extrusion (seal coming up out),
hardening, adhesive failure (loss of bond), cohesive failure
(splitting),complete loss of sealant.
 Transverse joint seal damage is only an issue with JPCP or JRCP.
Longitudinal joint seal damage may occur with any type of conventional
concrete pavement.

Joint deficiencies-
Joint spalling-
 Breaking, cripping fraying of slab
 Spalls are surface phenomenon and Caused due

to stress concentration at Joints
 Joint that is accumulated with water that results in

rapid freezing and thawing.

Joint deficiencies-
Faulting
 Faulting is defined as “difference in elevation across a joint or crack ”.
Faulting is most likely for pavements with aggregate interlock joints, or at
mid-slab cracks in JPCP.
 As traffic moves across the joint it imposes impact loads on the leave slab,
forcing loose materials from under the leave slab to under the approach
slab. This phenomenon is termed pumping

Thank You!

Rigid Pavement

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Rigid Pavement

Ankita Bhadane 2018H1300053H

2 BITS Pilani, Hyderabad Campus

 When properly designed and built out of durable materials, concrete

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

 Useful in areas where soils have poor engineering properties

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

Steel dowel bars and tie bars

BITS Pilani, Hyderabad Campus

Premoulded joint filler

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

 Jointed Plain Concrete Pavement (JPCP)

 Jointed Reinforced Concrete Pavement (JRCP)

 Continuously Reinforced Concrete Pavement (CRCP)

BITS Pilani, Hyderabad Campus

 It consists of unreinforced concrete slabs

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

PQC PQC PQC

Debonding layer of polythene Debonding layer of 40 mm BC PQC over 100mm of DBM-1

BITS Pilani, Hyderabad Campus

 Initial cut or slot : 2.5mm to 5mm wide

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

 Prevents formation of irregular cracks due to restraint in free contraction of

 Also relive stresses due to warping.

 Maximum joint spacing shall be 5 m. In general, slab configuration is

 Joints spacing at curve portion may be reduced by 20 to 30 percent.

BITS Pilani, Hyderabad Campus

 Joints shall be formed by mechanically sawing a joints groove, 3-5 mm wide

BITS Pilani, Hyderabad Campus

 Shall be placed whenever day’s construction operations starts and stops.

 Whenever work is suspended for more than 30 minutes.

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

 Longitudinal joints relieve stresses due to warping.

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

 Widen the first saw cut joint to required width / depth.

BITS Pilani, Hyderabad Campus

 A highly compressible heat resistant paper backed depending strip shall be

 Hot sealants or cold sealants with chemical formulation like polysulphide /

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

Subgrade shall be selected of earth complying the following requirements-

 No soft spots present in the pavements

BITS Pilani, Hyderabad Campus

BITS Pilani, Hyderabad Campus

 Grade IV&III used as Gap graded, at locations

BITS Pilani, Hyderabad Campus

 Side forms shall have a length of at least 3.0 mtr.

BITS Pilani, Hyderabad Campus

 Bulkheads of suitable dimensions shall be used at constructions joints with

facility to provide dowel bars.