CHINA ROAD AND BRIDGE CORPORATION

PCCP Construction Method

PORTLAND CEMENT CONCRETE PAVEMENT

1.0 Introduction

The pavement is the portion of the road that vehicles come in direct contact with. A
rough riding pot-holed pavement is hard on vehicles and uncomfortable to the
motorist. For these and many other reasons, a structurally sound, smooth riding, and
long lasting pavement is very important. A quality pavement requires materials and
construction practices in accordance with the design and specifications for the
pavement. Those responsible for this quality are required to know how the
pavement is built, the design and specifications requirements, and how to check for
compliance of the design and specifications.

2.0 Description

Portland Cement Concrete Pavement (PCCP), or rigid pavement as it is sometimes

called, refers to the rigid concrete layer of the pavement structure that is in direct
contact with the traffic. Typical concrete is composed of coarse aggregate (crushed
stone and gravel), fine aggregate such as sand, portland cement and water. The
concrete can be modified in a number of ways, including the addition of
cementitious materials other than portland cement, or through the use of
admixtures, which are materials that are added to the mixture to enhance the
properties of the fresh or hardened concrete. Once the concrete has been mixed, it
is placed on a prepared base coarse and consolidated and shaped, typically using
slip-form paving equipment. PCCP are subject to challenging environments and loads
over their lifetimes, so the concrete must be strong and durable, yet cost effective
and workable.

3.0 Scope of Work

 This method statement outlines the procedures to be followed in construction

of the PCCP.

 Remove the existing PCCP in STA 0+013.980 to STA 0+028.480 and STA
-0+014.005 to STA. -0+029.205 and replace with 280mm thickness.

 This procedure is applicable to the following works associated with the project.

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4.0 Materials Requirements

4.1 Proportioning, Consistency and Strength of Concrete

 Submit design mixes obtained from samples made in accordance with

Standard Method of Making and Curing Concrete Compression and Flexure
Test Specimen in the Laboratory for each strength required, stating the
proposed slump and the proportioning weight of cement, saturated surface
aggregates and water.

 Mixes shall be proven by preliminary tests 30 days before concreting and

shall show 28-day strength of 15% higher than the ultimate strength
required.

 The combined aggregates shall be such compositions of sizes that when

separated on the No. 4 sieve, the weight passing the sieve shall not be less
than 30% or greater than 50% of the total, except that these proportions do
not necessarily apply to lightweight aggregates.

 The water shall in no case, exceed 23 liters per bag (40kg) of cement for all
concrete with specified minimum flexural strength of 550 psi when tested
by the third-point method or 650 psi by the mid-point method and a
compressive strength of 3500 psi.

4.2 Material Properties and Testing Methods

Concrete Aggregate

Since aggregates used in concrete mixtures comprise approximately 80 to 85

percent of the concrete mixture by mass (60 to 75 percent of the concrete
mixture by volume), the aggregate materials used have a profound influence on
the properties and performance of the mixture in both the plastic and hardened
states. The following is a listing and brief comment on some of the more
important properties for aggregates that are used in concrete paving mixtures:

 Gradation – the size distribution of the aggregate particles affects the relative
proportions, cementing materials and water requirements, workability, pump
ability, economy, porosity, shrinkage, and durability. The size distribution of
the aggregate particles should be a combination of sizes that results in a
minimum of void spaces.

 Absorption – the absorption and surface moisture condition of aggregates

must be determined so that the net water content of the concrete can be
controlled.

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 Particle Shape and Surface Texture – the particle shape and surface texture
of both coarse and fine aggregates have a significant influence on the
properties of the plastic concrete. Rough textured, angular, or elongated
particles require more water to produce workable concrete than smooth,
rounded, compact aggregates, and as a result, these aggregates require more
cementing materials to maintain the same water-cement ratio. Angular or
poorly graded aggregates may result in the production of concrete that is
more difficult to pump and also may be more difficult to finish. The hardened
concrete strength will generally increase with increasing coarse aggregate
angularity, and flat or elongated coarse aggregate particles should be
avoided. Rounded fine aggregate particles are more desirable because of
their positive effect on plastic concrete workability.

 Abrasion Resistance – the abrasion resistance of an aggregate is often used

as a general index of its quality.

 Durability – resistance to freezing and thawing is necessary for concrete

aggregates, and is related to the aggregate porosity, absorption,
permeability, and pore structure.

 Deleterious Materials – aggregates should be free of potentially deleterious

materials such as clay lumps, shale, or other friable particles, and other
materials that could affect its chemical stability, weathering resistance, or
volumetric stability.

 Particle Strength – for normal concrete pavements, aggregate strength is

rarely tested. It is usually much greater than and therefore not as critical a
parameter as the paste strength or the paste-aggregate bond. Particle
strength is an important factor in high-strength concrete mixtures.

4.3 Concrete Paving Material

The mix proportions for concrete paving mixtures are determined in the
laboratory during mix design testing. This involves determination of the
optimum characteristics of the mix in both the plastic and hardened states to
ensure that the mix can be properly placed and consolidated, finished to the
required texture and smoothness, and will have the desired properties necessary
for pavement performance. Properly designed, placed, and cured concrete
paving mixtures should be evaluated for the following properties:

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Freshly Mixed (Plastic) Concrete

 Slump – slump is an indication of the relative consistency of the plastic

concrete. Concrete of plastic consistency does not crumble but flows
sluggishly without segregation.

 Workability – workability is a measure of the ease of placing, consolidating,

and finishing freshly mixed concrete. Concrete should be workable but not
segregate or bleed excessively.

 Setting Time – knowledge of the rate of reaction between cementing

materials and water (hydration) is important to determine setting time and
hardening. The setting times of concrete mixtures do not correlate directly
with the setting times of the cement paste because of water loss and
temperature differences.

 Air Content – the amount of entrapped or entrained air in the plastic

concrete can influence the workability of the concrete mixture and reduce its
propensity for bleeding.

Hardened Concrete

 Strength – concrete pavements must have adequate flexural strength to

support the design traffic loads (repetitions of loaded axles) that will be
applied over the service life of the facility. While compressive strength can
also be measured, flexural strength is more relevant to the design and
performance of concrete pavements.

 Density – the density of concrete paving mixes varies depending on the

amount and relative density of the aggregate, the amount of air that is
entrained or entrapped, and the water and cementing materials content of
the concrete.

 Durability – the hardened concrete pavement must be able to resist damage

from freezing and thawing, wetting and drying, and chemical attack (e.g.,
from chlorides or sulfates in deicing salts).

 Air Content – the finished and cured concrete should have adequate
entrained air in the hardened cement paste to be able to withstand cycles of
freezing and thawing.

 Frictional Resistance – for user safety, the surface of an exposed concrete

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pavement must provide adequate frictional resistance and resist polishing

under traffic. Frictional resistance is a function of the aggregates used and
the compressive strength of the concrete.

 Volume Stability – concrete paving mixtures must be volumetrically stable

and must not expand due to alkali aggregate reactivity. Concrete paving
mixtures should not shrink excessively upon drying

5.0 Construction Equipment

1. Batching Plant and Mixers

2. Hauling Equipment
3. Finishing Equipment
4. Finishing Machine
5. Concrete Saw
6. Forms

6.0 Safety Measures

The project team will be experienced in their designated areas of responsibility.

The integrated project team will ensure the work is competently supervised with
respect to environment as well as health and safety and quality.

All personnel will have to attend the mandatory (CRBC) site inductions and will
have been briefed on the contents of the Risk Assessments, Method Statement
and JHA (Job Hazardous Analysis) assessments relevant to their operations.

All personnel accessing the site will be subject to CRBC site rules and will wear
PPE as required.

In addition to the above, all operatives will wear appropriate PPE relevant to the
tasks being carried out. These include the mandatory long sleeves, long trousers,
safety boots, task-specific gloves, safety helmet, and safety glasses. Other task-
specific PPE may include disposable overalls, face protection, hearing protection,
boots (for concreting) or full body safety harness where there is a risk of falls
from height.

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a. Health, Safety, Security and Environment (HSSE)

Safety of the personnel and properties is to be given prime importance and all
the works to be carried out without causing any accidents or property damages.
Materials involve the following activities.

 Storage
 Transportation of materials
 Fabrication and fixing
 Lifting of material at site
 Removal

Adequate access and egress should be provided to the site for work. All
personnel should wear the proper PPE (Personnel Protective Equipment). All
equipment, tools and tackles being used for the work should be in good working
condition and maintained. All Personnel shall be provided with tool box meeting
on the procedures to execute the work safety and must follow the safety rules
listed below:

 Approved safety plan procedures shall be strictly followed.

 Where possible hazards may arise from filling activities, the necessary safety
measures will be taken to prevent accident or injury at all times. This may
include barriers, warning tape/ net, signage, watchman, and proper lighting.

 Where work upon existing services may be required, the necessary work permits
and safety equipment should be obtained prior to the activity commencement.

 HSSE will enforce that Personal Protective Equipment be worn by site personnel
at all times during construction activities.

 Provisions of adequate cool drinking water, shade, and salt water tablets will be
in place.

 Plant & Equipment will be provided back-up alarms, lights, and all other
applicable safety devices.

 Prior to the commencement of any activities, the workforce will receive an

induction Talk on the Project Site Safety Requirements. This Induction Talk Will
Include Both activity safety issues, as well as general safety requirements.

 Safety engineer will ensure that Personal Protective Equipment is worn by site
personnel at all times during construction activities

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7.0 Construction Method

7.1 Preparation of Grade - After grading and compacting the roadbed, trim the
grade to the approximate correct elevation, extending the work at least two feet
beyond each edge of the proposed concrete pavement. Grade and maintain the
track path in a smooth compacted condition until after constructing the pavement.

7.2 Setting Forms

a. Base Support -The foundation under the forms shall be hard and true to
grade so that the form, when set, shall be firmly in contact for its whole
length and at the specified grade. Fill the grades found below established
grade with granular material in lifts of 0.5 inch or less for a distance of 18
inches on each side of the base of the form, and thoroughly compacted.
Correct the above grade imperfections or variations by tamping or trimming
as necessary.

b. Form Setting - Set the forms sufficiently ahead of concrete placement to

provide time to check the line and grade and provide a continuous concrete
placement operation. After setting the forms to the correct grade, tamp the
grade thoroughly, mechanically or by hand, at both the inside and outside
edges of the base of the forms. Stake the forms into place with not less than
three pins for each 10-foot section. Place a pin at each side of every joint.
Lock the form sections tightly from play or movements. The forms shall not
deviate from true line by more than 1/4 inch. Set the forms so that the
forms will withstand, without visible spring or settlement, the impact and
vibration of the consolidating and finishing equipment. Clean and coat the
forms with a form release agent or oiled before placing the concrete.

c. Grade and Alignment - Check and correct the alignment and grade
elevations of the forms immediately before placing the concrete. When the
forms are disturbed or grades become unstable, reset and recheck the
forms.

7.3 Conditioning of Subgrade or Base Course - Bring the subgrade or base course to
proper cross section. Trim the high areas to proper elevation. The low areas may be
filled and compacted to a condition similar to that of surrounding grade, or fill the
low areas with concrete integral with the pavement. Maintain the finished grade in a
smooth and compacted condition until placing the pavement.

7.5 Mixing Concrete - No hand mixing shall be allowed during concreting operation.
In emergency cases such as batching plant breakdown during paving operation a
badger mixer may be allowed and shall stop at the first allowed construction joint.

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Concrete shall be machine mixed for at least 1½ minutes after all materials including
water are in the mixing drum.

7.6 Limitations of Mixing - Do not mix, place, or finish the concrete when the natural
light is insufficient, unless an adequate and acceptable artificial lighting system is
operated.

Before placing concrete pavement, have a good and sufficient supply of water
available throughout the work. An inadequate water supply will be cause for
delaying or shutting down the concrete mixer. In case of a deficiency of water, use
the water available for curing the concrete already placed.

Make advance arrangements to prevent delay in delivery and placing of the

concrete. An interval of more than 30 minutes between placing of two consecutive
batches or loads of concrete shall constitute cause for stopping paving operations.

7.7 Placing Concrete - Place the concrete while fresh. Do not use water for re-
tempering concrete. Deposit the concrete on grade so as to require as little re-
handling as possible. Unless truck mixers, truck agitators, or non-agitating hauling
equipment are equipped with means for discharge of concrete without segregation
of the materials, unload the concrete into an accepted spreading device and
mechanically spread on the grade so as to prevent segregation of the materials.
Placing shall be continuous between transverse joints without use of intermediate
bulkheads. Use shovels for hand spreading, not rakes. Do not allow the workers to
walk in the freshly mixed concrete with boots or shoes coated with earth or foreign
substances.

Forms and shoring shall not be removed until the concrete has adequately set and
stable enough to withstand the anticipated loadings, and in no chase less than 2 days
after concreting. Removal of forms may be allowed earlier provided that test
samples of concrete are taken and are shown to withstand safely dead and
construction loads.

7.8 Joints - Construct the joints normal to the pavement surface of the type,
dimensions, and at locations required by the contract.

a. Longitudinal Joints - The width of the joint shall be as required with a depth
of d = t/4 where:

d = minimum depth rounded up to the nearest 0.01-foot

t = thickness of pavement in each lane

When paving lanes are poured separately and a sawed longitudinal joint is

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required, the longitudinal joints shall be as required by the contract.

Place the deformed steel tie bars of the specified length, size, spacing and
material perpendicular to the longitudinal joint at a target depth of d = t/2.
Place the deformed steel tie bars by mechanical equipment or secure the
deformed steel tie bars rigidly by chairs or other supports to prevent
displacement. Use 30 inches long No. 5 rebars and space 30 inches center to
center. Tie bars which are to be bent and later straightened shall be grade 40.
The Engineer may require other sizes, grades, lengths, and spacing base on slab
width, thickness and the type of underlying base. Do not paint or coat the tie
bars with asphalt or other material not enclosed in tubes or sleeves.

b. Transverse Expansion Joints - The expansion joint filler shall be continuous

from form to form. Shape the expansion joint to the subgrade and to the
keyway, if any, along the form. Furnish the preformed joint filler in lengths
equal to the pavement width or equal to the width of one lane. Do not use
damaged or repaired joint filler.

Hold the expansion joint filler in a vertical position to secure the preformed
expansion joint filler at the proper grade and alignment during placing and
finishing of the concrete. Finished joints shall not deviate more than 0.25 inch
in the horizontal alignment from a straight line. When assembling joint fillers in
sections, do not use the offsets between units. The Engineer will not permit
plugs of concrete anywhere within the expansion space.

c. Transverse Contraction Joints - Transverse contraction joints include planes

of weakness created by forming or cutting grooves in the surface of the
pavement and, when shown on the plans, shall include load transfer
assemblies.

7.9 Curing - When completing the finishing operations and when marring of the
concrete does not occur, cover and cure the entire surface of the newly placed
concrete according to one of the following methods shown below. When curing
requires the use of water, the curing shall have priority to water supplies. Failure to
provide sufficient cover material or lack of water to take care of both curing and
other requirements shall be cause for immediate suspension of the concrete
operations. Do not leave the concrete exposed for more than 1/2 hour between
stages of curing or during the curing period. Maintain the covering in place for 72
hours after pouring the concrete.

7.10 Protection of Pavement - Protect the pavement and its appurtenances against
both public traffic and traffic caused by its own employees and agents. This shall

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include flaggers to direct traffic and the erection and maintenance of warning signs,
lights, pavement bridges, or crossover.

When by the Engineer, construct pavement crossings for the convenience of public
traffic according to Subsection 104.04 - Maintenance of Traffic. The Engineer will not
make additional compensation for the work involved.

Repair or replace damages to the pavement before final acceptance.

7.11 Opening to Traffic - before opening to traffic, the pavement shall be cleansed
thoroughly and all joint shall be seal completely. The Engineer will not allow
construction traffic, equipment, or materials on the pavement while the pavement is
attaining the strength.

8.0 References:

 Federal Highway Administration > Publications > Research Publications >

97148 > User Guidelines for Waste and Byproduct Materials in Pavement
Construct

 Industrial Resources Council/ Applications/ Portland Cement Concrete

Pavement

 DPWH - Standard Specifications for Highways Bridges and Airports (2013)

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