ANNEXURE A

PQC DESIGN AND DRAWING GUIDELINES

As per MORTH specifications, the following parameters for PQC are to be adopted:

1. Design & Drawings

 Contractor shall design the rigid pavement conforming to the specifications mentioned
in Schedule D of the Contract Agreement or as per the addendums to the contract.
 Specifications mentioned in MORTH guidelines i.e IRC 015-2017: Standard
Specifications and Code of Practice for Construction of Concrete Roads (Fourth Revision)
and IRC-58-2015: Guideline for the Design of Plain Jointed Rigid Pavement Design for
Highways shall be followed for the Design of PQC.
 The main factors governing design of Rigid pavements are: design period, design speed,
design commercial traffic volume, composition of commercial traffic in terms of single,
tandem, tridem and multi-axles, axle load spectrum, tyre pressures of commercial
vehicles, lateral placements characteristics of commercial vehicles, composition and
strength of subgrade and climatic considerations.
 Rigid pavement shall be designed for a design period of 30 years or operation period
whichever is more.
 Grade of PQC shall M40.
 The thickness and cross section of the pavement shall be designed in accordance with
the drawings and specifications mentioned in the Contract Agreement.
 The (PQC) Pavement Quality Concrete shall rest on a de-bonding interlayer of
polythene sheet (Separation Membrane) having a minimum thickness of 150 micron.
Below the same Dry Lean Concrete (DLC) of 150 mm and sub-base of at least 150 mm
thickness shall be provided.
 The DLC shall meet the minimum cement content and compressive strength as
mentioned in IRC 44 – 2017 and IRC SP 49 - 2014.
 The DLC shall extend beyond the PQC by 1 meter on either side.
 Below the DLC, a properly designed drainage layer of gradation zone-6 as per clause
6.3.3 of IRC 15 – 2017 of minimum thickness 150mm or as per the codal requirement
shall be provided throughout the road width. It shall be designed to obtain drainage
coefficient of not less than 30m per day. Required field test should be conducted and
conformation to be obtained.
 Temperature differential factor shall be considered for the design of the pavement.
 PQC Slab design procedure shall be done in pursuant to Cl. 6.9 ‘Recommended
Procedure for Slab Design’ of IRC-58-2015.
 Surface texturing of the pavement shall be achieved using Tining method as per clause
10.1.14.1 of IRC 15 – 2017.
 As per clause 11.3 of IRC 15 - 2017, core 150 mm thickness of the laid PQC, thorough
care should be taken.
 Concrete at the time of laying should be with maximum temperature 220C.
 Ensure the ice made from same water (Potable) is used and proper care of water
cement ratio is taken to have consistent quality of the concrete.
 PQC to be cut as per the codal frequency.

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 ANNEXURE A
PQC DESIGN AND DRAWING GUIDELINES
 All the packages will have similar panel width to have uniformity as well as will adopt
same traverse joint as well as joint sealing material.
 The curing compound to be adopted for all the packages should be of a similar nature.
 The transportation facility for PQC should be such as that there is no grout loss in turn
reflect on cement contain per cubic meter and workability and covered with the
tarpaulin to avoid the loss of the moisture and contamination due to dust.
 The maximum travel distance to be restricted to 10 km to avoid bleeding of concrete.
 The service road should be properly maintained, intermittently watered/sprinkled
with water and should not have potholes which results in segregation of the concrete.

2. PQC Mix Design

 The Mix Design shall be submitted at least 30 days prior to the paving of trial length.
 The design mix shall be based on laboratory trial mixes using the approved materials
and methods as per IS: 10262. Guidance for preparing the mix design can be obtained
from IS: SP: 23 ‘handbook on concrete mixes’ and IRC: 44 - 2017: ‘Guidelines for Cement
Concrete Mix Design for Pavements’.
 As stresses induced in concrete pavements are mainly flexural, the Mix design shall be
based on flexural strength of the Concrete.
 All the materials to be used shall be in conformity to MORTH specifications and the
specifications mentioned in Schedule D.
 The cement content (OPC) shall not be less than 350 kg per cum of concrete and shall
not exceed 425 kg per cum of concrete.
 In case fly ash blended at site, the quantity of fly ash shall be restricted to 20 percent by
weight of cementitious material and the OPC in such a blend shall not be less than 340
kg/cum.
 Suitable admixture conforming to IS: 9103 and IS: 6925 for ensuring good workability
and durability shall be used. The particulars of the admixtures and the quantity to be
used must be furnished to the AE and the same needs to be approved by AE and the
Authority before the use.
 The aggregates for PQC mix shall be natural material complying with IS: 383 but with a
Los Angeles abrasion test result not more than 35%. The limits of deleterious material
shall not exceed the requirements set forth in IS: 383.
 The maximum size of coarse aggregates shall not exceed 31.5 mm for pavement
concrete.
 No aggregate which has water absorption more than 2 percent shall be used.
 The Contractor shall indicate to the AE the source of all materials to be used in the
concrete work with relevant test data sufficiency in advance, and the approval of the AE
for the same shall be obtained at least 45 days before the scheduled commencement of
the work.
 PQC Mix must be workable with sufficient slump which allows it to be paved smoothly
with slip form paver.

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 ANNEXURE A
PQC DESIGN AND DRAWING GUIDELINES
3. Design of PQC Panel (Transverse and longitudinal joints) and Spacing of
Joints/Grooves.
 PQC Panels shall be designed for transverse joints which shall be either Contraction or
Expansion Joints. The spacing shall be as per drawings and design prepared in pursuant
to MORTH specifications, IRC 015-2017: Standard Specifications and Code of Practice
for Construction of Concrete Roads (Fourth Revision) and IRC-58-2015: Guideline for
the Design of Plain Jointed Rigid Pavement Design for Highways.
 Type of coarse aggregates and the average temperature fluctuation in different seasons
shall be considered for designing the joints.
 Longitudinal joints are required in pavements of width greater than 4.5m to allow for
transverse contraction and warping.
 Contraction joints shall be of mechanical sawn joint groove, 3 to 5mm wide and 1/3
depth of the slab ± 5mm or as stipulated in the drawings and dowel bars complying
with clause 602.6.5 of MORTH and as detailed in the design drawings.
 The Expansion joint shall consist of a filler material as specified by the Authority and
dowel bars complying with relevant clauses of MORTH specifications.
 Load transfer to relieve part of the load stresses in edge and corner regions of
pavement slab at transverse joints is provided by means of mild steel round dowel
bars.
 Transverse construction joints shall be provided at the regular location of construction
joints using dowel bars. All the specifications mentioned in the aforementioned
relevant codes shall be adhered for providing the transverse construction joints.
 Tie bars shall be provided at the location of longitudinal joints and the design of tie bars
shall conform to IRC: 15 and IRC: 58. To permit the warping at the joint, the maximum
diameter of the tie bars shall not be more than 16mm and the spacing between the tie
bars shall not be more than 750mm.
 The longitudinal joints shall be saw cut after the final set of the concrete. The sawing of
the joints has to be done on the right time.
 Construction joints should, as far as possible, be placed at the location of contraction
joints except in case of emergency when a key joint may be used.
 All the details adopted in the design shall be described by the Contractor in the
submission for perusal and approval from AE and the Authority.
 Illustrative indicative figure of slab layout is attached at the end of this document.

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 ANNEXURE A
PQC DESIGN AND DRAWING GUIDELINES

4. Joint Filler Board, Joint Sealant and Separation Membrane.

 Materials used for Joint filler boards, joint sealant and separation membrane shall be in
accordance to MORTH Specifications, IRC: 15 – 2017 and best industry practice.
 Joint filler board for expansion joints which are proposed for use only at some abutting
structures like bridges and culverts shall be of 20-25mm thickness within a tolerance of
± 1.5mm and of a firm compressible synthetic material and complying with the
requirements of IS 1838.
 The joint sealing compound shall be PU-based as per MSRDC Letter No.
MSRDC/NMSCEW/5320/2019 dated August 21 2019, Section 6 Guideline:
Material Procurement, Annexure 7
 Standard material specification shall be followed across all the Construction Packages.
 All the material specifications to be used shall be detailed along with design and
drawing submission for perusal and approval from AE and the Authority.

5. Dia. of MS Dowel bars and flaps.

 Dowel bars shall be mild steel and all the other specifications shall be in accordance to
Cl. 602.2.6 of MORTH specifications.
 Dimensions of dowel bars shall be as indicated in design drawings.
 Dowel bar shall be free from oil, dirt, loose rust or scale and they shall be straight free
from irregularities and burring restricting slippage in the concrete.
 The cutting of the dowel bars should not be shear cut but should be done using
electrical saw or grinder and the edges should be free of burr.
 Unless specifically shown in the drawing dowel bar shall be positioned at the mid depth
of the slab within a tolerance of ±20mm and centered equally about intended lines of
joint within a tolerance of ±25mm.
 Dowel bars shall be covered by a plastic sheath for at least two third of the length from
one end for dowel bars in contraction joints or half the length plus 50mm for expansion
joints. Proper grip must be provided in the sheathing to avoid slippage of the sheathing.

6. Methodology for laying of PQC layer

 PQC laying methodology shall comply all the specifications mentioned in MORTH
specifications and IRC 015-2017: Standard Specifications and Code of Practice for
Construction of Concrete Roads (Fourth Revision) and IRC-58-2015: Guideline for the
Design of Plain Jointed Rigid Pavement Design for Highways.
 Detailed stepwise methodology of laying PQC needs to be described in the submission
for approval. Time cycle details shall be mentioned.
 Equipment to be used along with their specifications and make/model details needs to
be mentioned. The paver must be capable of paving the entire width of the carriageway.
 Quality tests to be performed and safety precautions to be taken needs to be mentioned
in the methodology.

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 ANNEXURE A
PQC DESIGN AND DRAWING GUIDELINES
7. Joint Treatment methodology
 Joints shall be treated in accordance to the specifications mentioned in MORTH
specifications.
 Stepwise methodology along with the resources to be used and time cycle shall be
mentioned in detail in the submission by the Contractor and the same shall be reviewed
and approved by the Authority.

8. Curing Compound.
 Immediately after the surface texturing, the surface & sides of the slab shall be cured by
the application of approved resin- based aluminized reflective curing compound which
hardens into an impervious film or membrane with the help of mechanical sprayer.
 Curing compound shall contain sufficient flake aluminum in finely divided dispersion to
produce a complete coverage of the sprayed surface with metallic finish.
 The compound shall become stable & impervious to evaporation of water from the
surface of the concrete within 60 minutes of application & shall be of approved type.
 The curing compound shall have water retention efficiency index of 90 % in accordance
with BS Specification No. 7542.
 In addition to spraying of curing compound, the fresh concrete surface shall be
concrete surface shall be protected for at least 3 hours by covering the finished
concrete pavement with tents as described in clause 602.7.2, during adverse weather
conditions as directed by the Engineer.

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 ANNEXURE A
PQC DESIGN AND DRAWING GUIDELINES

9. Concrete Durability chemical compound

 Admixtures conforming to IS: 6925 and IS: 9103 shall be used to improve durability of
Concrete.
 Best quality admixtures and good industry practice shall be adopted for ensuring the
durability of the concrete shall be used.
 The admixtures to be used in the concrete shall be tested in trial mixes and all the
details such as specifications, properties and brand details shall be submitted by the
Contractor for perusal and approval from AE and the Authority.

10. Test for Joint Material

 Details of tests to be performed on the Joint material shall be described in QAP.
 Test methodology along with relevant details needs to be submitted and same shall be
reviewed and approved by AE.
 Frequency of tests to be performed needs to be mentioned and Authority’s Engineer
shall witness the tests.

11. Construction Materials

All materials shall follow:
 Guidelines issued by MSRDC Letter No. MSRDC/NMSCEW/5320/2019 dated August 21
2019, Section 6 Guideline: Material Procurement, Annexure 7, and
 Guidelines issued by MSRDC Letter No. MSRDC/NMSCEW/7133/2019 dated November
19 2019
 Guidelines issued by MSRDC Letter No. MSRDC/NMSCEW/Guidelines/2019/7453
dated December 05 2019

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 MUMBAI NAGPUR EXPRESSWAY PROJECT
SLAB LAYOUT
DEPRESSED MEDIAN

4500

DEPRESSED MEDIAN

750
Eff. Lane Width
4375

3750
3625

25
200 mm LANE
Eff. Lane Width
LINE MARKING

3750
3750

3525
15000

25
Eff. Lane Width

3750
3750

3525

25

200 mm EDGE
LINE MARKING
3125

3000

MBCB AND EARTHEN SHOULDER

DIRECTION OF TRAVEL
 ANNEXURE B
GUIDELINES FOR TRIAL PATCH

1. General Instructions:

 The trial patch shall be constructed at least one month prior of the proposed start of concrete
paving work.
 Prior to the construction of the trial length, a detailed method statement shall be submitted
giving description of the proposed materials, plant, equipment’s like paving train, batching
plant, tippers, texturing and curing machines etc., proposed in the construction and get it
approved from Engineer before their procurement.
 No trials of new materials, plant equipment or construction methods, or any development of
them shall be permitted either during the construction of trial length or in any subsequent
paving work, unless they form part of approved trials.
 These trial lengths shall be constructed away from the carriageway but with at least a sub-base
layer stipulated below it. The trial patch should be independent from the corridor, within the
ROW without disturbing the main carriageway cross section.

2. Execution Instructions:

 The trial patch shall be constructed in two parts over a period comprising at least two patches
constructed on two separate working days, with minimum of 50 m constructed each day for
mechanized construction.
 The trial length shall be constructed at a similar rate at which the main work is supposed to
progress.
 Minimum of 30 beams for flexural strength and 30 cubes for compressive strength or
additional as required by the Engineer for the purpose of co-relation shall be casted.
 At the age of 28 days, 30 cores with diameter 150mm shall be saw cut from the slab. The cores
shall be saw cut in both ends to provide a specimen height of 300mm ± 5mm and core shall be
tested for compressive strength at the age of 28 days.
 The test results of beam, cube and core shall conform to Clauses 12.8.1, 12.8.2 and 12.21 of IRC
15 2017.

Note:
 Consolidation of concrete around the dowel should also be checked by taking few random
cores above the dowel bars. If lack of proper compaction is detected due to honey-combing in
the cores then the paver setting should be checked and problem should be resolved.
 Transverse joints and longitudinal joints of each type (i.e. contraction, construction and
expansion) that are proposed for dowel-jointed unreinforced concrete slabs in the main work
shall be constructed and assessed in the trial length.

3. Acceptance Criteria of Trial Length and Normal Construction

The trial length shall comply with the specification in all respects, with the following additions
and exceptions including strength criteria as per Clauses 12.8.1, 12.8.2 and 12.21of IRC 15
2017. A detailed report shall be prepared and should be approved from the Engineer.
 ANNEXURE B
GUIDELINES FOR TRIAL PATCH

4. Surface levels and regularity

 While checking for compliance, the levels shall be taken at intervals at the locations as
specified in clause 12.14 of IRC 15 2017 along any line or lines parallel to the
longitudinal centre line of the trial length.
 The maximum number of permitted irregularities of pavement surface shall comply with
the specified requirements.

5. Alignment of Dowels

 Alignment of dowel bars shall be inspected at all of the transverse joints in a trial length
construction by using magnetic pulse induction (MPI) device as per ASTM
E3013/E3013-15. The acceptance criteria for dowel placement shall be the following:
a. Horizontal or Vertical rotational alignment : ≤10mm over 500mm
b. Longitudinal side shift : ≤ 50mm over 500mm
c. Depth : Mid-depth ±25mm

 Alignment of dowel bars may also be inspected in any two consecutive transverse joints
in a trial length construction by removing the fresh concrete in a width of 0.5m on either
side of the joint. The joint pit shall be refilled with freshly prepared concrete, after
inspection.

 If the position or alignment of the dowel bars at one of these joints does not comply with
the requirements and if that joint remains the only one that does not comply after the
next 3 consecutive joints of the same type have been inspected, then the method of
placing dowels shall be deemed to be satisfactory. In order to check sufficient joints for
dowel bar alignment without extending the trial length unduly, joints may be
constructed at more frequent joint intervals then the normal spacing required in trial
slabs.

 If there are deficiencies in the first expansion joint that is constructed as a trial, the next
expansion joint shall be a trial joint. Should this also be deficient, further trial of
expansion joint shall be made as part of the trial length which shall not form part of the
permanent works.

6. Density
Density shall be assessed from at least 3 cores drilled from each part of the trial length.
Voids in the cores shall not be more than 3 per cent.

7. Position of Tie Bars

Compliance for the position and alignment of tie bars shall be checked by using Magnetic
Pulse Induction (MPI) device as per ASTM E3013/3013M-15.

8. Position of Dowel Bars

Compliance for the position and alignment of dowel bars at transverse joints in normal
construction work shall be checked randomly at 25 per cent of the joints by using
Magnetic Pulse Induction (MPI) device as per ASTM E3013/E3013-15.
 ANNEXURE B
GUIDELINES FOR TRIAL PATCH

9. Rejection Criteria
The alignment of dowel bars should be checked using Magnetic Pulse Induction (MPI)
device as per ASTM E3013/E3013M-15. The engineer shall check the MPI report of the
joints to locate the joints of possible failure due to locking of joints in advance and
correct them at the earliest. If more than half of the dowel bars at a joint do not meet
any of the acceptance criteria mentioned in Clause 11.5.2 IRC 15 2017, then the joint
shall be reconstructed using Full Depth Repair (FDR) method as per IRC:SP:83. The
joint having any bar misaligned by more than 38mm shall be rejected.

However, if MPI device is not available then the position and alignment of dowel bars
and any filler board shall be measured after carefully exposing them in one meter
width in plastic concrete across the whole width of the slab. When the joint is an
Expansion joint, the top of the the filler board shall first be exposed sufficiently in the
plastic concrete to permit measurement of any lateral or vertical displacement of the
board. During the course of normal working, these measurements shall be carried out
in the pavement section at the end of day’s work by extending slab shall be removed
carefully soon after concrete has set in order to expose dowel over half the length
These dowels can be tested for tolerance.

If the position and alignment of the bars in a single joint in the slab is unsatisfactory
then the next two joints shall be inspected. If only one joint of the three is defective, the
rate of checking shall be one joint per day until the Engineer is satisfied that
compliance is being achieved. In the event of non-compliance in two or more
successive joints, fresh trial lengths shall be constructed adopting any necessary
alteration to concrete mix, paving plant or methods until the dowel bars position and
alignment are satisfactory.

10. Approval
Approval of the material, plant, equipment and construction methods shall be given
after the trial length complies with these specification. Normal working shall not be
taken up until the trial length has been approved.

When approval has been given, the material, plant, equipment and construction
method shall not thereafter be changed, except for normal adjustments and
maintenance of plant, without the approval of the Engineer. Any changes in material,
plant, equipment and construction methods shall require the laying of further trial
length to demonstrate that the changes will not adversely affect the permanent works.

Trial lengths which do not comply with the requirements, with the exception of
areas which are deficient only in surface texture and which can be remedied
shall be removed immediately upon notification of deficiencies by the Engineer
and further trial length shall be constructed.

Construction trial sections is considered obligatory on the part of the Contractor

and the entire cost of construction, dismantling and transportation of debris is to
be borne by the Contractor.
 ANNEXURE C
DOCUMENTS AND INFORMATION REQUIRED FROM THE
AUTHORITY’s ENGINEER (AE) and to be submitted to
PROJECT DIRECTOR
Source approval of Course Aggregates and Fine
1 Aggregate - As per IRC:15:2017 and clause 600 of PROVIDE PROOF OF DOCUMENTATION
MORT&H Specification
2 Test Reports of Construction Material (Conducted on
PROVIDE PROOF OF DOCUMENTATION
site and third party labs – FOR BELOW)
NOTE - All materials shall mandatorily follow:
1. Guidelines issued by MSRDC Letter No. MSRDC/NMSCEW/5320/2019 dated August
21 2019, Section 6 Guideline: Material Procurement, Annexure 7, and
2. Guidelines issued by MSRDC Letter No. MSRDC/NMSCEW/7133/2019 dated
November 19 2019
3. Guidelines issued by MSRDC Letter No. MSRDC/NMSCEW/Guidelines/2019/7453
dated December 05 2019
As per clause 601.2.2 of MORT&H Provide List of Vendors:
I Cement Specification and clause 3.1 of
IRC:15:2017 and as above
As per clause 602.2.6 of MORT&H Provide List of Vendors:
Coarse
II Specification and clause 3.3 of
Aggregate
IRC:15:2017 and as above
As per clause 602.2.6. of MORT&H Provide List of Vendors:
Fine
III Specification and clause 3.3 of
Aggregate
IRC:15:2017 and as above
Materials Silica As per clause 602.2.6. of MORT&H Provide List of Vendors:
& IV Fumes/ Specification and clause 3.3 of
Inspection MicroSilica IRC:15:2018 and as above
As per clause 601.2.3 of MORT&H Provide List of Vendors:
V Fly Ash Specification and clause 3.2.3 of
IRC:15:2017 and as above
As per clause 602.2.7 of MORT&H ---
VI Water Specification and clause 3.4 of
IRC:15:2017 and as above
As per clause 602.2.3 of MORT&H Provide List of Vendors:
VII Admixtures Specification and clause 3.2 of
IRC:15:2017 and As per above note
Crystalline Provide List of Vendors:
VIII Durability As per above note
Admixture
Curing As per clause 10.8 of IRC:15:2017 and Provide List of Vendors:
IX
Compound As per above note
As per clause 602.2.5 of MORT&H Provide List of Vendors:
PP Micro
X Specification and clause 3.8 of
Fibers
IRC:15:2017 and As per above note
As per clause 602.2.11 of MORT&H Provide List of Vendors:
Joint
XI Specification and clause 3.7 of
sealant
IRC:15:2017 and As per above note
Dowel and As per clause 602.2.8 of MORT&H Provide List of Vendors:
XII
Tie Bars Specification
 ANNEXURE C
DOCUMENTS AND INFORMATION REQUIRED FROM THE
AUTHORITY’s ENGINEER (AE) and to be submitted to
PROJECT DIRECTOR
Frequency and Acceptance Criteria for Quality Control tests as per clause PROVIDE PROOF OF
3 DOCUMENTATION
12.34 of IRC:15:2017.
Source details for Procurement of Cement and Peak Requirement of PROVIDE PROOF OF
4 DOCUMENTATION
Cement during the project with guaranteed continuous supply.
Mix Design details of DLC carried out by the QA/QC Engineers as per IRC PROVIDE PROOF OF
1 DOCUMENTATION
:SP:49:2014.
Methodology for Placing and Compaction of DLC as per clause 601.6 of PROVIDE PROOF OF
Dry Lean 2 MORT&H Specification and IRC:15:2017. DOCUMENTATION
Concrete
(DLC) Placing of separation membrane between DLC & PQC as per MSRDC
3
Guidelines PROVIDE PROOF OF
Quality and Thickness of Separation in microns as per clause 602.5 of DOCUMENTATION
4
MORT&H Specification.
Mix Design details for Pavement Quality Concrete along with % of all PROVIDE
1
materials as per IRC:44:2017. DOCUMENTATION
Design and Drawings of PQC (Showing all the details) including Surface PROVIDE
2 DOCUMENTATION
Texture and Storm water Drain arrangement.
Details of PQC panels (Sizes and Shapes).Detail design with Dowel and Tie PROVIDE
3 DOCUMENTATION
Bar details.
Details of PQC Paver ( slip form along with the productivity) and paving PROVIDE
4 DOCUMENTATION
equipment's to be used (Automatic).
Methodology for placing Dowel bar, tie bar and concreting followed with PROVIDE
5 Expansion, contraction joints, construction joint making and Tining depth DOCUMENTATION
/with and method of tining. Design of dowel bars and spacing.
Pavement 6 Methodology for curing on PQC as per clause 601.6.7 of MORT&H PROVIDE
Quality Specification and IRC:15:2017. DOCUMENTATION
Concrete Design details of Transverse and Longitudinal Joints in the PQC as per PROVIDE
(PQC) 7 clause 8 of IRC:15:2017. DOCUMENTATION
Identification of the areas where pavers cannot be used and the laying PROVIDE
8 DOCUMENTATION
method of PQC for the same.
Transition slab details between flexible and rigid pavements as per clause PROVIDE
9 DOCUMENTATION
10.7 of IRC:15:2017.
PROVIDE
10 Trial length / mock up area as per MoRTH requirements Cl.602.11 DOCUMENTATION
Surface Levels and Regularity check methods and acceptance criteria as PROVIDE
11 DOCUMENTATION
per clause 12.16 and 12.17 of IRC:15:2017.
Approach and Terminal slab to all structures (Detail Design & Drawings) as PROVIDE
12 DOCUMENTATION
per clause 8.5.2 of IRC:15:2017.