Pune City experience

with Thin White Topping

for Urban streets
INTERNATIONAL SEMINAR ON CONSTRUCTION AND
REHABILITATION OF RIGID PAVEMENT –
CURRENT PRACTICE AND WAY FORWARD
JAN 2019, NEW DELHI
 Thin White Topping Technology

 Thin White Topping is Concrete layer

constructed on top of existing
Bituminous pavement which is in sound
condition
 Bonded type overlay is used in TWT with
design life of 20 years
 Concretization without excavation of
the existing Road crust
 M40 Grade concrete is used with
thickness between 100 to 200 mm
 Concrete Panel size is 1.0 m X 1.0 m
 IRC SP 76 2015 used for design and
construction guidelines
 3
THIN WHITE TOPPING (TWT) ON
EXISTING BITUMINOUS PAVEMENT – TYPICAL SECTION

THIN WHITE TOPPING (TWT) 100 - 200 mm

EXISTING Black Top road

EXISTING BASE/SUBBASE (WBM /WMM/GSB)

SUBGRADE SOIL
Pune city experience with Thin White
Topping for urban roads

 Pune city started TWT road works in 2006

 Till date successfully constructed over 180 Km urban roads with
TWT technology
 TWT streets offer excellent ride quality and are pothole and
maintenance free
 TWT done for streets with width between 3 m to 24 m
 Urban utilities can be catered in these projects if thoughtfully
planned
 Condition of roads in Pune is much better that other cities due
to concretization
 Over the past decade, Pune has saved over Rs. 500 Crore on
recurring road maintenance work due to concrete & TWT roads
 5

Typical TWT treatment on residential street

and busy Market area in Pune city (5 to 6 m wide)
 Selection of locations/ roads for TWT
treatment

 Selection of road for TWT treatment is to be done cautiously

 Internal residential streets with negligible truck traffic (6-8 m wide
roads) – TWT thickness upto 125 mm
 Roads with medium traffic i.e. bus, truck traffic (12-18 m wide
roads) – TWT thickness 125 to 175 mm
 Roads on hill slope can be treated with TWT
 Existing bituminous road should be well consolidated
 Roads where existing BT has surface distresses & no structural
failure or subgrade related problems are observed.
TYPICAL CANDIDATE
ROADS FOR
TWT TREATMENT
re

TYPICAL LOCATIONS
WHERE TWT SHOULD
BE AVOIDED

• ROAD WITH
DEFICIENT BASE/
SUBBASE

• ROAD WITH
EXTENSIVE
CRACKING/
SETTLEMENT
 Technical considerations in TWT
road work

 Thickness of existing BT layer not less than 75 mm (after

milling)
 Existing road free of excessive cracking and settlement
 Evaluation of existing BT Road is done using Benkelman
Beam Deflection study
 Design of TWT thickness as per IRC SP 76-2015
 Profile correction is done in overlay concrete layer or
DBM layer
 Correction of minor settled portions – removal and crust
development with GSB, WMM, DBM
EVALUATION OF
BITUMINOUS PAVEMENT
USING BENKELMEN
BEAM DEFLECTION TEST

BT CORING FOR
CONFIRMTION OF
THICKNESS
 Construction Steps for TWT work

 Existing bituminous surface roughened & thoroughly cleaned

 Pre overlay correction and utility line shifting
 Laying of concrete manually or mechanically
 Spreading, compaction and finishing of concrete
 Texturing of concrete
 Groove cutting (1m x 1m) in 12 to 16 hours
 Concrete Curing for 14 days
 Joints filled with sealant (after 14 weeks)
 Opening to traffic after 14 days
Construction steps

1. Milling/ Roughening

2. Cleaning of surface
Construction steps

3. Channel Fixing

4. Concrete Laying,
spreading, compaction
5. Concrete finishing 6. Texturing
7. Groove cutting 8. Curing for 14 days
 Dowel Bar at
construction joint only
Tie Bars at Centre of
TWT pavement

Dowel bars at Construction Joint only

Tie bars at Longitudinal Joint

Dowel Bars at
1mX 1 Construction
m panels Joint Sealed joints with
Polysulphide sealant
Quality of TWT overlay Concrete

 Monitoring of concrete quality is utmost important for

success of TWT overlay projects in urban area
 M 40 Grade concrete is used with polypropylene
fibres to minimize shrinkage cracking
 Concrete is procured from SCADA controlled RMC
Batch plants and transit mixers
 Requisite concrete testing like slump testing, cube
and flexural beam testing, core testing is done at site
laboratory
 Continuous monitoring of the concrete mix as per
the approved mix design is done
Testing at field lab for
urban road projects
Challenge
Problemsof tackling existing
with utilities &utilities
Trafficin Urban road projects
Existing Electrical cables, Water Supply Line, OFC Cables, Sewer
 Common problems in Urban area

 Level of surrounding houses is affected due to

concrete overlay – avg 75 mm increase in road level
 Storm Water drainage/ stagnation issue arise at some
locations
 Some utilities may be buried under the concrete
overlay – maintenance issues at later stage
 Existing utilities are damaged during the work
 Laying of new utilities after concrete overlay is difficult
 Limited time period for concretization
 Heavy traffic plying on existing roads affects the
concretization
Concrete Roads in Urban area –
Provision for Utilities/ Crossings

 Laying new utilities at edge and making existing

utility defunct
 Utility crossings at 75 to 100 m & junctions with RCC
pipes & chambers
 Edge strip of 1.0 to 1.5 m with 80 mm removable
concrete blocks
 RCC / DWC pipes provided along the edge
 Storm water management of individual property
 Utility provisions in TWT work for urban area
Cross pipes provided at every 50 to 75 Providing 80/ 100 mm paver block
m interval (300 mm and 450 mm pipes) crossings at every 50 m interval to
for utility crossings cross any unforeseen utility
 Improvisation in TWT work in urban area
2 Nos RCC pipes 300 mm dia on 1.50 m wide 80/ 100 mm
each side underneath footpath for (removable) section of paver blocks
OFC cables to house utilities like water supply,
sewer lines
Relaying of new utility after some years

REMOVAL OF PAVER BLOCKS FOR LAYING

WATER SUPPLY LINE (after 6 years)
AND TWT ROAD AFTER REINSTATEMENT OF BLOCKS
 Improvisation in TWT work
No cutting of central longitudinal joint
(left as it is and filled after it opens up
by traffic)
Provision of RCC mesh around sewer
chamber frame to prevent damage in
future (mesh is embedded in the TWT
concrete)
Steel mesh
around
utility chambers
Storm water management of
individual properties

 Storm water drainage & management is an

important aspect of the overlay project
 L Section of the road needs to be properly
designed to ensure proper surface drainage as
well as storm water drainage (RCC pipe)
arrangement
 Each property along the project needs to be
mapped and connected to the Storm Water line
to discharge into nallah/ stream
 28

STORM WATER
CHAMBERS
OUTLET FROM PROPERTY
CONNECTED TO
MAIN STORM LINE
REVERSE SLOPE AWAY FROM PROPERTY
Model Colony
Lakaki Road
30
Completed
In 2012

Busy market area

in Old city 2012
Taljai Hill
side 12 m
2014
& Smart city
Street 24 m
TWT 2017
 32

Shantishilla Society
Law College Road

5 m ,9 m 12 m wide
internal street-2011
 33

Shivajinagar
State Transport Depot
18 m wide Road
(5000 Buses daily) -
2013
 34

Aundh 18 m wide Streets

2014
Abhimanshree
Society 18 m wide
Street 2014
Koregaon Park
12 m wide Streets
2014
 37

9, 12 m wide Streets
2007-2008
Latest equipment and
Capacity Building

 Pune has encouraged contractors

to procure latest equipment like
Fixed Form pavers, Bull Float,
Mechanical Float, Tine texture
equipment, Walk behind rollers etc

 Equipment is mandated as part of

the contract agreement

 Continuous training and capacity

building workshops are conducted
for the Municipal Engineers,
Contractors and Consultant
Engineers for TWT work
 Use of modern construction equipment

 LATEST EQUIPMENT USED

 BULL FLOAT, TINING EQUIPMENT
 WALK BEHIND ROLLER
 SCREED PAVERS
 FIXED FORM PAVER
 Costing for BT and Concrete Overlay
(only pavement course considered as per Pune DSR Rates)

Costing
Life
Sr Road Type Treatment (Rs per
(years)
sqm)
60 DBM, 25 BC 570 /- 3 to 4
Bituminous
1
Overlay
75 DBM, 40 BC 820 /- 3 to 4

125 mm 720 /- Min 20

2 TWT Overlay
150 mm 870 /- Min 20
 Observed distresses in TWT roads

OBSERVED DISTRESSES: CORNER BREAKS, UTILITY CHAMBER DAMAGE

Way forward for road
concretization in Pune

 Currently Pune city already has 250 Km new

concrete roads (full crust) and 180 Km TWT roads
and many roads are identified for concretization
 Considering the successful implementation of
TWT for city streets Pune city is overlaying most
city streets in a phased manner
 Some wider streets (24 to 30 m) with higher
traffic volume are also being undertaken for TWT
treatment
Thank You