Concrete pavement construction

In consideration of the construction methods, the overall arrange of works and

the interaction of activities, the critical activities of this project is concrete
pavement construction.

We propose to use the slip-form paver to complete the concrete pavement, this
slip-form paver is capable of spreading, consolidating, and finishing a concrete
slab without the use of conventional forms, and the concrete develops sufficient
strength to be self-supporting by the time it leaves the paver. The slip-form
paver is capable of placing slabs up to 45 cm thick and 6 m wide at speeds up
to 3 m/min.

As specified in the tender drawings, the Concrete Aprons will be divided into
four worksites namely A1, A3 and A4. We intend to adopt the continuous flow
process technology, in the sequence of Apron A3, A4, and A1, and shows in the
drawing (construction sequence schematic of concrete aprons).

1. Temporary Traffic Management

Temporary traffic management schemes will be carefully planned in advance
and properly implemented to minimize the impact of construction on the existing
traffic. The Engineering Manager will prepare temporary traffic management
schemes for various stages of the Works. At all times, measures will be in
place to minimize the impact to local traffic, while meeting the Contract
requirements and the Works Programme. The proposal plan shows in the
drawing (general view showing haulage routes).

2 Steps in the construction process

Chart 3-2-6 Construction sequences of apron concrete

 Prepare cement treated base
Maintain and check course surface
mixing plant

Survey and layout

Adjust design mixture

Prepare reinforcement where the
L:W is over 1.25

Fix dowels, tie bar and expansion

Trail mixing joint falsework

Multifunctional
Construct trial section or Apron
paver

Dump truck Finishing of concrete

Texturing of running surfaces

Approved by Engineer

Design Concrete mixing formula Covering&Curing by water truck

Cut the joint by cutting machine

Fill the joint with filling machine

Flatness, flexural strength, concrete

Approved by engineer
thickness checking

Open to Traffic

3 Preparing the base

 When the base has been thoroughly compacted it will need to be shaped to
conform to the specified profile and cross-section. Sometimes, good base have
soft spots from which the soft material has to be ripped, removed and replaced
with material of the same quality as specified by the design, and compacted.

The base will need to be laid to a regular and accurate level, and maintained in
a clean condition until the concrete is laid; in the interim, its use by construction
traffic should be strictly limited. Good control of the base surface level improves
the uniformity and quality of performance of a concrete pavement, as any
unevenness in the finished base will be reflected in variations in the thickness of
the poured slab.

4 Joint assemblies and reinforcement

At this stage various joint
assemblies will be placed in
position, depending upon the
design drawing.

Type A expansion joint

assemblies with dowel bars
and filler boards are
prefabricated and securely
supported on cradles and fixed
to the base so that they will
not shift when the concrete is
being spread and compacted.

Type B expansion joint only

filler boards are prefabricated
and securely supported and
fixed to the base.

Contraction joint dowels are

placed on prefabricated metal
cradles and fastened to the
base ahead of the paving
machine; cradles supporting
dowel bars should not extend
across the joint line.

To work effectively the dowels

in each assembly must be aligned parallel to both the surface of the slab and
the centreline of the pavement. Filler boards, which are normally 25 mm thick,
must be set vertically to ensure that adjacent slab ends are also vertical and
that there is no likelihood of one riding up over the other.

Concrete saws are used to cut contraction

joints in concrete slabs to control
shrinkage cracking. The depth of control
joints should be depended on design
drawings, but not less than the maximum
size of the aggregate used. Sawing should
be done when the concrete is still green
but has hardened sufficiently to produce a
clean cut. This is usually 6 to 30 h after the
concrete has been placed.
 Tie bars in wet-formed longitudinal joints assemblies are made up into rigid
assemblies with adequate supports, and securely attached to the base in
advance of the paving machine. The tie
bars at longitudinal joints will be vibrated
into position, using a method that ensures
compaction of the concrete about the tie
bars.

5 Preparing the concrete

For the concrete of a consistent quality
must be provided at the site at a steady
rate. Steady progress requires the careful
and matching of the paving machine’s
productive capacity with the mixing
plant’s output capability and the availability of enough suitable vehicles to
transport the fresh concrete, to keep the paving machine in continuous
operation.

We propose to use HZS75 concrete mixing plant which the theory productivity
would be 75m3 per hour, and located nearby the construction site which shows
in the drawing (general view showing haulage routes).

We have more storage facilities and equipment that can control the flow of
materials from the stockpiles, through the batching and mixing plant, to the
mixed concrete into waiting vehicles for transport to the site.

When the construction of ApronA4 sections, the haul-road is through urban

areas, and it is long and bumpy, the risk of vehicles bunching in traffic
congestion increases, with the consequent risk of an irregular supply to the
paving machine. And the concrete may begin to stiffen and its consistency and
workability at the site will be detrimentally affected, so concrete mixer truck will
be used, to ensure the quality and workability of the concrete at the placement
point on-site should be such as to enable it to be fully compacted and finished.

When the construction of Apron A1，A3 sections, trucks will be used.

Unless otherwise specified, use air entrainment in all slip-form concrete.

6 Placing and finishing the concrete

The placing of the fresh concrete upon the base should be carried out so as to
obtain an even depth, of uniform density.

The slip-form paver is self-propelled and mounted on caterpillar tracks. The

correct alignment and the true surface level of the concrete slab are achieved
with the aid of an electronic sensing system that is attached at the paving
machine; this continuously picks up guidance signals from tensioned guide-
wires on stakes on side of the pavement, and automatically adjusts the
machine’s operation as necessary. The accuracy to which the vertical and
horizontal alignments of the guide-wires are established is absolutely critical to
the success of the slip-form paving operation.

With a conforming plate slip-form paver the concrete is deposited in a hopper at

the front of the moving paver. A hydraulically-adjustable plate attached to the
hopper maintains a constant surcharge of concrete above the level of the
conforming plate. As the paver moves forward the slab edges are formed by the
moving slip-forms as the concrete is forced under the conforming plate.
 Immersed vibrators between the strike-off and conforming plates keep the con-
crete in a fluid state, and help compact it as it is forced into the space between
the base and the conforming plate. The hopper will be fitted with a spreader to
help distribute the concrete across its full width.

Slip-form pavers have the ability to insert transverse contraction-joint dowels, at

predetermined positions, into the concrete as it flows from the front of the
machine.

If transverse and longitudinal joints have not been wet-formed a vibrating blade
is used to saw them as soon as the concrete has hardened sufficiently to allow
a sharp-edged groove to be produced without spalling, and before random
cracks appear in the slab.

sawing is carried out between 10 and 20 h after slab construction. Typically, the
grooves are between 1/4 and 1/3 of the slab depth and not less than 3 mm
wide. Preformed compressed formers that can accommodate the normal
expansion and contraction changes in the joint, without allowing the entry of
water or grit, are then vibrated into the joints.

7 Texturing of running surfaces

 If the slab surface is to have good skid resistance it must have an adequate
microtexture and macrotexture.

The macrotexture of the running surface is obtained by wire-brushing the

surface, at right-angles to the centreline, upon completion of the final regulation
of the slab surface and before the application of the curing membrane.

Wire brushing is carried out manually, from a travelling bridge, at right angles to
the longitudinal axis of t the slab.

8 Curing the concrete

Curing aims to ensure that a satisfactory moisture content and temperature are
maintained in the newly-placed concrete slab, so that hydration of the cement
continues until the design strength is achieved.

Curing involves keeping the surface of the concrete damp for at least 7 days
using curing compound. The method used will be to mechanically spray the
surface and exposed edges of the concrete slabs with the curing compound
immediately after the finishing/texturing processes.

The curing compound which is sprayed that completely covers the surface with
a membrane, and, the membrane will be then worn away by tyre traffic when
vehicles or planes are allowed on the slab surface.

Rain damage to the freshly-textured concrete is minimized with the aid of about
60 m of polythene sheeting; this is towed behind the curing compound sprayer.