DRY LEAN CONCRETE

KSTP-II Package-III-Rehabilitation and Up gradation of Kakkadassery -

Kaliyar Road (Length -20.176 KM)in Ernakulam District

METHODOLOGY OF DRY LEAN CONCRETE – ( DLC )

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 DRY LEAN CONCRETE

KSTP-II Package-III-Rehabilitation and Up gradation of Kakkadassery -

Kaliyar Road (Length -20.176 KM)in Ernakulam District

CONTANTS

 OBJECTIVE
 SCOPE
 PLANT / EQUIPMENT & MANCHINERY
 CONSTRUCTION PROCEDURE
 SERVEY & SETTING OUT
 TRAIL WORK OF DLC
 CONSTRUCTION OF DLC
 QULALITY ASSURANCE & CONTROL CHECKS FOR DLC
 SAFETY & EMVIRONMENTAL DETAILS

Objective:

To construct and supervise the Construction of Dry Lean Concrete (DLC).

Scope:

Selection, Testing and Acceptance of all incorporated Materials for DLC.

Design Mixes for DLC and Trials, Acceptance etc.

Plant, Equipment / Machinery:

 Batching, Mixing, Transporting, placing, Finishing and Curing of Concrete for DLC.
 Control Checks during operation and post Concreting.

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 DRY LEAN CONCRETE

KSTP-II Package-III-Rehabilitation and Up gradation of Kakkadassery -

Kaliyar Road (Length -20.176 KM)in Ernakulam District

Construction Procedure:

Selections, Testing and Acceptance of Construction Materials for DLC.

Cement :
As per the Technical Specification – IRC: SP: 49- 2014, CI 3.1, Ordinary Portland Cement of
53 Grade Conforming to IS 8112 Shall be used.

Coarse Aggregate:
Aggregate’s to be used in the Construction of DLC Shall be Crushed Aggregate complying
with IS: 383-2016, Aggregate Shall not be Alkali reactive Coarse Aggregate Shall comply
with Clause : 3.2.1 of IRC:SP:49-2014 Table-1 Maximum size of Aggregate used Shall be
26.5mm for DLC .

Fine Aggregate:
The Fine Aggregate Conforming to Clause 601.2.4.3 Shall consist of clean Natural Sand or
Crushed stone sand or a combination of the two and shall conform to IS : 383-2016 &
IRC:15-2017, Fine Aggregate shall be free soft particles, clay, shale, loam, cemented
particles, mica, and organic and other foreign matter.

The Coarse & Fine Aggregate may be obtained in either way mentioned as per IRC:SP:49-
2014, Clause 3.2.1 but after blending it shall to the grading as indicated in Table -1 of
IRC:SP:49-2014.

Water:
Water used for mixing and curing of concrete will be clean and free from injurious amounts
of oil, salt, acid, substance or other harmful to the finished concrete, It will meet the
requirements stipulated in IS: 456.

Mix Proportions for Dry Lean Concrete ( DLC )

The mix design shall be carried out for concrete for DLC as per IRC: SP: 49-2014.The
Aggregates used for the construction of Dry Lean Concrete shall conform to the grading the
mix shall be proportioned with a maximum aggregate cement ratio of 1:14.

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 DRY LEAN CONCRETE

KSTP-II Package-III-Rehabilitation and Up gradation of Kakkadassery -

Kaliyar Road (Length -20.176 KM)in Ernakulam District

The water content shall be adjusted to the optimum for facilitating compaction by rolling. The
optimum water content shall be determined and demonstrated by rolling trail work and the
optimum moisture content and degree of compaction shall have to be approved by the CSC’S
Engineer.
The Cement Content in the Dry Lean Concrete shall not be less than 140 kg/cum In the event
of this minimum cement content is not sufficient to produce concrete of specified strength,
Clasue: 4.2 – IRC: SP: 49-2014 shall be fulfilled.
The average compressive strength of each consecutive group of 5 cubes made in accordance
with Clause 4.1 for IRC: SP: 49-2014, Shall not be less than 7 MPa at 7 days. With individual
cube strength not loss than 5.5 MPa. Trial stretch for DLC shall be conducted as per CI: 601.8
of MoRT&H and results submitted to the CSC’S Engineer for approval.

Plant / Equipment and Machinery:

 Batching Plant
 DLC Paver
 Concrete Transporting tippers
 Tandem Vibratory Roller
 Total Station, Level instruments, string wires & pegs, hand winches etc. as required
 Water tanker with sprinkling bars, gunny bags etc. as required
 QC Machinery/tools Cube Moulds, Core cutting machine etc.

Survey and Setting out for DLC:

Survey and setting out of string line is a very important and crucial activity to be completed
and thoroughly checked prior to start of DLC Layer. The following steps are involved in
setting out of string wire before laying DLC.

Reference line of carriageway shall be marked at suitable intervals on the surface by using
Total station. String line of 3mm dia. Wire rope shall be fixed on both sides of proposed DLC
edges approximately 1.0 – 1.5m away from edge of the DLC. The string line shall be
supported anchored by stakes at 10 mts intervals on both sides.
The string wire shall be tensioned on the stakes so that a 500 gms. Weight shall produce a
deflection of not more than 20mm when suspended at the midpoint between any pair of
stakes to ensure the required tension of string wire, hand winches shall be used to tighten the
string line to avoid any sagging These winches shall be placed at maximum 300m intervals.

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 DRY LEAN CONCRETE

KSTP-II Package-III-Rehabilitation and Up gradation of Kakkadassery -

Kaliyar Road (Length -20.176 KM)in Ernakulam District

The stakes shall be positioned and the string wire maintained / tensioned at their correct
level/height and alignment as per relevant section drawings on the day before concreting
takes place. It shall ensured that the stakes and guide wires are not affected by the
construction equipment when concreting is in progress, the DLC edge shall be marked with
lime. Detailed survey check sheet shall be maintained incorporating all survey and setting out
details relevant to DLC being executed.

Construction of Dry Lean Concrete (DLC):

Laying of DLC on main Carriageway shall be carried out as per the following steps :
Surface Preparation shall start a day before of DLC sub-base. The approved DL surface shall
be given a fine spray of water and rolling with one or two passes of smooth wheeled roller
after a lapse of 2-3 hours in order to stabilize loose surface. Concrete production shall be with
silo(s) of adequate capacity shall be provided to store the cement and a suitable arrangement
shall be made to feed the cement. Concrete shall be transported by tippers, Tipper carrying
concrete shall be protected adequately by covering them with tarpaulins, and DLC shall be
laid/placed by DLC Paver capable of laying the concrete in full width in one pass without any
segregation.
Compaction with Double drum smooth-wheeled vibratory rollers of 8 to 10 Tones static
weight shall be carried out immediately after the DLC is laid by paver. Area inaccessible for
the roller shall be compacted by plate vibration. The optimum rolling shall be broadly
determined during trial patch exercise, The rolling shall be continued until the minimum
density obtained is 97 percent of the density achieved during the trial patch/stretch, surface
undulation shall be checked with 3m straight edge and deficiency should ne made concrete
with aggregate of size 10mm and below.
As soon as the lean DLC surface is compacted, curing shall commence. Initial curing shall be
done by spraying liquid curing compound by suitable means and later when curing compound
lost its tackiness curing shall be done by covering the surface by gunny bags/Hessian. Which
shall be kept continuously moist for 3 days by sprinkling water as per the Specification.

Quality Assurance & Control checks for DLC:

Inspection and test plans shall be revised whenever there I any change in methodology and
specifications etc. various field and Laboratory test formats shall be maintained as per the
required frequency.

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 DRY LEAN CONCRETE

KSTP-II Package-III-Rehabilitation and Up gradation of Kakkadassery -

Kaliyar Road (Length -20.176 KM)in Ernakulam District

Non-Conformance in DLC:
Any nonconformity observed during field inspection and also during testing of
Materials/mixes/laying system etc. the same shall be recorded in the specified
nonconformance report and necessary corrective/preventive actions approved by the CSC’S
Engineer shall be initiated to prevent such things in future. All product nonconformities shall
be observed, recorded corrective/preventive actions and closing of NCR’s shall be as per the
established documented procedure.

Documentation:
 Construction Schedules for the Segment.
 MoRT&H and other Technical Specifications including relevant IS/BS/ASTM Codes.
 Clients / CSC Field memos/notes/complaints etc including action taken status.
 Product Non-conformance reports etc.
 Compressive strength of concrete cubes.
 Aggregate testing Reports.
All the above document/records shall be maintained at appropriate location with proper and
defined filing system, which can be easily, identified 7 traceable.

Segment safety & Environmental Details :

Hazard identification, risk assessment and Risk control measures for each and every activities
and sub – activities involved in the present segment shall be identified and necessary action
plan shall be initiated. Environmental Aspects and impacts associated with various activities
and sub activities involved in the present segment and their mitigation/control measures shall
be identified and necessary measures shall be initiated

References :
 MoRT&H Specification ( Fifth Revision ) Clause 601
 Contract Document
 IRC:SP:49 – 2014
 IS : 10262 -2019

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