Cement Concrete for Pavement Construction

Cement concrete is a widely used material for pavement construction due to its strength,
durability, and ability to distribute loads effectively. It is particularly suitable for high-traffic
areas and can be designed to meet specific requirements through variations in mix design and
construction techniques.

Types of Concrete Pavements

1. Jointed Plain Concrete Pavement (JPCP):

o Contains transverse joints to control cracking.
o Does not include steel reinforcement.
o Joints are spaced typically 3 to 15 meters apart.
2. Jointed Reinforced Concrete Pavement (JRCP):
o Contains both transverse joints and steel reinforcement.
o Reinforcement helps to control cracks between the joints.
o Joints are spaced at larger intervals (usually 10 to 30 meters).
3. Continuously Reinforced Concrete Pavement (CRCP):
o Contains continuous steel reinforcement without transverse joints.
o Designed to allow tightly spaced cracks that are held together by the
reinforcement.
4. Prestressed Concrete Pavement (PCP):
o Utilizes prestressed steel tendons to induce compressive stresses.
o Reduces or eliminates cracking, increases durability, and can use thinner
slabs.

Concrete Mix Design for Pavements

1. Materials:
o Cement: Typically, Ordinary Portland Cement (OPC) is used.
o Aggregates: Well-graded coarse and fine aggregates for strength and
durability.
o Water: Clean and free from harmful substances.
o Admixtures: Used to enhance workability, durability, and setting time (e.g.,
plasticizers, air-entraining agents).
2. Proportioning:
o The mix design aims to achieve a balance between workability, strength, and
durability.
o Typical concrete mix proportions by weight are:
▪ Cement: 1 part
▪ Sand: 2 parts
▪ Aggregates: 4 parts
▪ Water: 0.4 to 0.5 parts (water-cement ratio).
 3. Strength Requirements:
o Pavement concrete typically requires a compressive strength of 28-40 MPa.
o Flexural strength (modulus of rupture) is also crucial, typically 3.8-4.5 MPa.

Construction of Concrete Pavements

1. Subgrade Preparation:
o Proper preparation and compaction of the subgrade are crucial for load
distribution.
o Subgrade should be well-drained and compacted to the required density.
2. Formwork:
o Forms are set to define the edges of the pavement.
o Must be strong enough to hold the concrete and provide the desired shape
and finish.
3. Placing and Compaction:
o Concrete is placed using mixers and spread evenly.
o Compaction is performed using vibrators to remove air pockets and ensure
density.
4. Finishing:
o Surface is finished using screeds, floats, and trowels to achieve the desired
texture.
o Texturing provides skid resistance, typically achieved through brushing or
grooving.
5. Joint Construction:
o Joints are necessary to control cracking due to shrinkage and temperature
changes.
o Types of joints:
▪ Contraction Joints: Control cracking by creating weak points.
▪ Expansion Joints: Allow for thermal expansion and contraction.
▪ Construction Joints: Used where concrete placement stops and
starts.
6. Curing:
o Proper curing is essential to achieve the desired strength and durability.
o Methods include water curing, covering with wet burlap, or using curing
compounds.

Durability Considerations

1. Freeze-Thaw Resistance:
o Air-entraining admixtures create tiny air bubbles that provide space for water
to expand upon freezing, preventing damage.
2. Sulfate Resistance:
o Use sulfate-resistant cement in areas with high sulfate exposure to prevent
chemical attack.
 3. Alkali-Silica Reaction (ASR):
o Use low-alkali cement and non-reactive aggregates to mitigate ASR.
4. Abrasion Resistance:
o Use hard, durable aggregates and adequate cement content to resist surface
wear.

Testing and Quality Control

1. Compressive Strength Test:

o Determines the concrete's ability to withstand loads.
o Cylindrical samples are tested at 7 and 28 days.
2. Flexural Strength Test:
o Measures the concrete's ability to resist bending.
o Beam samples are subjected to third-point loading.
3. Slump Test:
o Assesses the workability of the concrete mix.
o A measure of the consistency and fluidity of the mix.
4. Air Content Test:
o Ensures proper air entrainment for freeze-thaw resistance.
o Typically conducted using a pressure meter.

Requirements for CC Pavement Mix Design

1. Strength:
o Compressive Strength: Typically specified as 28-day strength, ranging from
28 to 40 MPa, depending on traffic loads and environmental conditions.
o Flexural Strength: Modulus of rupture is critical for pavements, typically 3.8
to 4.5 MPa at 28 days.
2. Durability:
o Freeze-Thaw Resistance: Required in colder climates to prevent damage
from freeze-thaw cycles. Air-entraining admixtures are used to introduce
small air bubbles.
o Sulfate Resistance: Necessary in areas with sulfate-rich soils or water to
prevent chemical attack on the concrete.
o Abrasion Resistance: Essential for pavements subjected to heavy traffic to
prevent surface wear.
3. Workability:
o The mix should be workable enough to ensure proper placement,
compaction, and finishing without segregation or excessive bleeding.
o Slump value typically ranges from 25 to 75 mm, depending on the
construction method.
4. Shrinkage and Creep:
o The mix should have low shrinkage to minimize cracking.
 o Creep should be controlled to prevent excessive deformation under
sustained loads.

Materials for CC Pavement Mix

1. Cement:
o Ordinary Portland Cement (OPC) is commonly used.
o In specific conditions, Sulfate Resistant Cement (SRC) or blended cements
may be used.
2. Aggregates:
o Coarse Aggregates: Should be well-graded, hard, and durable, with a
maximum size typically ranging from 19 to 25 mm.
o Fine Aggregates: Should be clean, well-graded natural sand or
manufactured sand.
o Aggregate Properties: Should have a low alkali-silica reactivity, high
abrasion resistance, and appropriate shape and texture.
3. Water:
o Clean and free from harmful substances.
o The water-cement ratio (w/c) typically ranges from 0.40 to 0.50.
4. Admixtures:
o Air-Entraining Agents: Improve freeze-thaw resistance.
o Water-Reducing Admixtures: Improve workability without increasing water
content.
o Superplasticizers: Used for high-strength concrete to improve workability at
low w/c ratios.
o Set Retarders/Accelerators: Adjust setting times as needed based on
environmental conditions.

Steps in Mix Design for CC Pavement

1. Determine Design Parameters:

o Define the required compressive and flexural strength.
o Consider environmental conditions and traffic loads.
2. Select Water-Cement Ratio:
o Choose a w/c ratio that meets the strength and durability requirements.
o Use the lower value within the typical range (0.40 to 0.50) for high-strength
and durability.
3. Choose Slump Value:
o Select based on the workability needed for placement and compaction
methods (typically 25-75 mm).
4. Estimate Air Content:
o Determine the required air content for freeze-thaw resistance (typically 4-
7%).
5. Calculate Cement Content:
 o Based on the selected w/c ratio and water content, calculate the required
cement content.
o Ensure it meets minimum cement content requirements for strength and
durability.
6. Aggregate Proportioning:
o Choose coarse and fine aggregates that are well-graded and meet size and
shape requirements.
o Calculate the proportions to achieve the desired workability and strength.
7. Trial Mixes and Adjustments:
o Prepare trial mixes to verify workability, strength, and durability.
o Adjust the proportions as needed based on test results.

Example Mix Design Procedure (ACI Method)

1. Design Requirements:
o Compressive Strength: 35 MPa at 28 days
o Flexural Strength: 4.0 MPa at 28 days
o Slump: 50 mm
o Air Content: 5%
2. Select w/c Ratio:
o Based on strength requirements and exposure conditions, select w/c ratio =
0.42
3. Estimate Water Content:
o For a slump of 50 mm, approximate water content = 180 kg/m³
4. Calculate Cement Content:
o Cement content = Water content / w/c ratio
o Cement content = 180 kg/m³ / 0.42 ≈ 428.6 kg/m³
5. Determine Aggregate Proportions:
o Assume a combined aggregate weight of 2000 kg/m³.
o Fine aggregate = 35% of total aggregate weight = 0.35 * 2000 = 700 kg/m³
o Coarse aggregate = 65% of total aggregate weight = 0.65 * 2000 = 1300 kg/m³
6. Adjust for Air Content:
o Air content will replace part of the volume, so adjust the mix proportions
accordingly.
7. Trial Mix and Adjustments:
o Prepare trial mixes to verify the desired properties.
o Adjust water content, cement content, and aggregate proportions based on
test results to achieve the target slump, strength, and air content.

IRC and IS Specifications and Tests for Cement Concrete Pavement

In India, the design, construction, and quality control of cement concrete pavements are
governed by specifications and guidelines provided by the Indian Roads Congress (IRC) and the
Bureau of Indian Standards (BIS). Below are the key specifications and tests for cement concrete
pavement according to IRC and IS standards.

IRC Specifications

1. IRC:15-2017 – Standard Specifications and Code of Practice for Construction of

Concrete Roads:
o Provides guidelines for the construction of concrete pavements, including
materials, mix design, construction methods, and quality control.
2. IRC:44-2017 – Guidelines for Cement Concrete Mix Design for Pavements:
o Offers procedures for designing concrete mixes specifically for pavement
applications, focusing on achieving the required strength and durability.
3. IRC:58-2015 – Guidelines for Design of Plain Jointed Rigid Pavements for Highways:
o Covers the design aspects of plain jointed rigid pavements, including load
considerations, joint design, and reinforcement.
4. IRC:SP:49-2014 – Guidelines for the Use of Dry Lean Concrete as Subbase for Rigid
Pavements:
o Provides guidelines for the use of dry lean concrete (DLC) as a subbase
material under concrete pavements.

IS Specifications

1. IS 456:2000 – Code of Practice for Plain and Reinforced Concrete:

o General code for concrete design and construction, covering materials,
workmanship, structural design, and quality control.
2. IS 10262:2019 – Guidelines for Concrete Mix Design Proportioning:
o Provides guidelines for the proportioning of concrete mixes to achieve the
desired strength and durability.
3. IS 383:2016 – Specification for Coarse and Fine Aggregates from Natural Sources for
Concrete:
o Defines the quality requirements for aggregates used in concrete, including
grading, particle size, and impurities.
4. IS 2386 (Parts I to VIII):1963 – Methods of Test for Aggregates for Concrete:
o Series of standards providing methods for testing aggregates, including
mechanical properties, size distribution, and specific gravity.
5. IS 9103:1999 – Specification for Concrete Admixtures:
o Specifies requirements for admixtures used in concrete to improve
workability, strength, and durability.

Tests for Cement Concrete Pavement

1. Compressive Strength Test (IS 516:1959)

• Measures the compressive strength of concrete cubes.

 • Cubes are cured and tested at 7 and 28 days to ensure they meet the required
strength.

2. Flexural Strength Test (IS 516:1959)

• Measures the flexural strength or modulus of rupture of concrete beams.

• Beams are tested under third-point loading to assess their resistance to bending.

3. Slump Test (IS 1199:1959)

• Measures the workability and consistency of fresh concrete.

• A standard slump cone is used to determine the slump value, indicating the fluidity
of the mix.

4. Air Content Test (IS 1199:1959)

• Measures the air content in fresh concrete, which is crucial for freeze-thaw
resistance.
• Typically conducted using an air meter.

5. Aggregate Tests (IS 2386)

• Particle Size Distribution: Ensures aggregates are well-graded.

• Specific Gravity and Water Absorption: Determines the density and absorption
capacity of aggregates.
• Aggregate Impact Value: Measures the toughness of aggregates.
• Los Angeles Abrasion Test: Assesses the hardness and abrasion resistance of
aggregates.

6. Water Absorption Test (IS 516:1959)

• Measures the water absorption of concrete, indicating its porosity and durability.
• Concrete specimens are soaked and weighed to calculate absorption.

7. Rapid Chloride Penetration Test (RCPT) (ASTM C1202, adapted in Indian context)

• Measures the ability of concrete to resist chloride ion penetration.

• Important for assessing the durability of concrete in environments exposed to de-
icing salts or marine conditions.
8. Curing Tests

• Ensures that concrete is properly cured to achieve the desired strength and
durability.
• Methods include water curing, curing compounds, and moist curing.

Joint Filler Materials

Joint fillers are used to fill the space between concrete slabs, providing support and preventing
debris from entering the joints. They are typically used in expansion joints.

Types of Joint Fillers

1. Bituminous Joint Filler:

o Made from asphalt or bitumen.
o Flexible and can accommodate slight movements.
o Resistant to water infiltration.
2. Cork Joint Filler:
o Made from natural cork.
o Compressible and resilient.
o Good for accommodating large expansions and contractions.
3. Fibreboard Joint Filler:
o Made from wood fibers bound together.
o Inexpensive and readily available.
o Provides good compressibility and recovery.
4. Polyethylene Foam:
o Closed-cell foam material.
o Lightweight, flexible, and resistant to water and chemicals.
o Often used in combination with sealants.
5. Rubber Joint Filler:
o Made from natural or synthetic rubber.
o Highly flexible and durable.
o Good for high-movement joints.

Joint Sealer Materials

Joint sealers are applied over the joint filler to seal the joint and prevent water and debris from
entering. They are essential for maintaining the integrity and performance of the pavement.

Types of Joint Sealers

1. Hot-Poured Sealants:
o Made from asphalt or rubberized asphalt.
o Applied in a hot, molten state.
 o Provides excellent adhesion and flexibility.
o Ideal for climates with extreme temperature variations.
2. Cold-Poured Sealants:
o Typically made from silicone, polyurethane, or polysulfide.
o Applied at ambient temperature.
o Easy to apply and suitable for smaller projects.
o Good for moderate climates and less trafficked areas.
3. Silicone Sealants:
o Highly flexible and durable.
o Excellent adhesion and weather resistance.
o Suitable for a wide range of temperatures and environmental conditions.
o Expensive compared to other sealants.
4. Polyurethane Sealants:
o Good flexibility and abrasion resistance.
o Excellent adhesion to concrete surfaces.
o Suitable for moderate to high movement joints.
o Moderate cost.
5. Polysulfide Sealants:
o High chemical resistance and flexibility.
o Good adhesion to concrete and other materials.
o Suitable for joints subjected to movement and chemical exposure.
o Moderate to high cost.

Selection Criteria for Joint Filler and Sealer Materials

1. Movement Accommodation:
o The material should be able to accommodate the expected joint movements
due to thermal expansion, contraction, and load-induced stresses.
2. Durability:
o The material should have a long service life and be resistant to environmental
factors such as UV radiation, water, chemicals, and abrasion.
3. Adhesion:
o The sealer should have excellent adhesion to the concrete surface to prevent
water and debris infiltration.
4. Flexibility:
o The material should remain flexible over a wide range of temperatures to
accommodate joint movements without cracking or debonding.
5. Ease of Application:
o The material should be easy to apply, either in a hot or cold state, and should
set or cure within a reasonable time frame.
6. Cost:
o The cost of the material should be considered in relation to its performance
and the specific requirements of the pavement project.
Application Methods

1. Cleaning the Joint:

o Ensure that the joint is clean and free from debris, dust, and moisture.
o Use compressed air or a wire brush to clean the joint surfaces.
2. Installing Joint Filler:
o Cut the joint filler material to the required size and shape.
o Insert the joint filler into the joint, ensuring it fits snugly.
3. Applying Primer (if required):
o Some sealants require a primer to enhance adhesion.
o Apply the primer to the joint surfaces and allow it to dry.
4. Sealing the Joint:
o Apply the sealer over the joint filler using a caulking gun or a hot-pour
applicator.
o Ensure the sealer fills the joint completely and adheres to the sides.
o Tool the sealer to ensure a smooth, concave surface.
5. Curing:
o Allow the sealer to cure as per the manufacturer’s recommendations before
opening the pavement to traffic.

Maintenance and Inspection

1. Regular Inspection:
o Inspect joints regularly for signs of damage, such as cracking, debonding, or
loss of sealant.
o Check for water infiltration or debris accumulation.
2. Timely Repairs:
o Repair any damaged joints promptly to prevent further deterioration of the
pavement.
o Remove the old sealant, clean the joint, and apply a new sealant as needed.