Concrete Paving Work Procedure

This concrete paving work procedure is intended to provide general application guidance and to establish controls during preparation and construction. Likewise to ensure that the work is conducted and carried out safely and with good working practice as per project specifications. 

This procedure is applicable to all concrete paving activities at site and shall be realized upon the commencement of site preparation and concrete casting. Inclusive to this scope are site preparation such as levelling, grading and compaction, installation of formworks, survey works, rebar works, concrete casting and inspection procedures.

RESPONSIBILITIES

1. Civil Superintendent / Supervisor

Ensure compliance by all subordinates, equipment operators and associated craftsmen during the construction and execution of the work. The parameter of the work procedure includes project quality control, test plan, relevant drawings, safety procedures and specifications. Make sure that all necessary work permits are obtained prior to commencement of any activity.

2. Quality Control Inspector

Conduct inspection as per relevant procedure and QC inspection test plan. Coordinate with responsible personnel to ensure their punctual attendance to perform inspection whenever required. Prepare daily QC records and final acceptance documentation whenever required.

3. Safety Supervisor

Check the work areas for any unsafe condition and shall furnish a hazard identification plan prior to commencement of the work. Ensure all safety requirements have been adequately addressed and the work is carried out with project safety procedure and specifications.

4. Engineering Department

Provide technical support to site operation group. Provide latest revision of IFC drawings, procedures, material specifications, standard, and technical specifications.

PROCEDURE

1. The construction of concrete paving and roadways shall be in accordance with [] project specification, design drawings and ACI 325 -9R. Pavement slope shall be a minimum of 1 percent and maximum elevation change between high point of paving (HPP) and low point of paving (LPP) shall be 150mm. in case where pavement slope is not shown in the construction drawing. Concrete paving and roadways shall commence after all the works on foundations, underground piping and cables, and other underground objects have been completed.

2. All materials for concrete paving and roadways shall conform with [] project specification.

3. Site Preparation:

3.1 Sub-grades shall receive fill material and shall be compacted to its required compaction (FDT) as per relevant drawing details for concrete paving. Before the backfilling works commences, competent surveyor should check and verify the required elevation and grade of the sub-base and shall establish elevation references and controls for formworks installation and pouring guides. All fills material shall be compacted to at least 95% of the maximum dry density as per standard.

  

3.2 Granular sub-base shall be placed and spread in uniform layers of 150mm. and shall be compacted using a 10 ton vibratory roller. However, areas which are inaccessible to the equipment, a small plate compactor or manual tamping may be used. The surface of each layer shall be maintained in a smooth finish condition until the succeeding layer is placed and shall be tested by FDT (Compaction Test). 

3.3 When the final layer is completed and all elevations given on the design is obtained and has been inspected and tested (FDT), a membrane vapour barrier shall be installed and laid on the surface top of sub-base.

3.4 The finished sub-base surface shall be within +10mm and -15mm of the elevation shown on the design drawings.      

4. Formworks:

4.1 Forms shall either be made of steel or wood and shall rest directly on top of the sub-base and correctly set for the entire length and correct elevations, allowing the surveyor to establish reference points and elevations prior to the installation of forms. Moreover, forms shall be in good condition, cleaned and oiled before use. Forms shall be aligned and securely positioned in such a way that movement is minimized when the concrete is placed and finished. Formworks materials shall meet the requirements of [] project specification.

4.2 After the completion of the installation of the forms, measure the dimension and level and the top of the concrete to be casted shall be marked on the forms  by marking or wire with nail.

5. Placement of Reinforcements

5.1 Reinforcements shall be accurately placed in accordance with the placement drawing and shall be adequately secured and held in position.

5.2 Lap splices shall be in accordance with the placement drawings. Welded wire fabric (WWF) shall be lapped 1 ½ mesh plus the extension of the wires unless shown otherwise on the drawings. WWF shall be in accordance with [] project specification.

5.3 Placement of welded wire fabric (WWF) and other embedded items shall commence after the completion of the forms. The minimum concrete cover for pavements and roadways shall conform with [] project specifications.

5.4 When everything is intact, the polyethylene sheets, the (WWF) re-bars, the forms and all other accessories required prior to concrete casting has been completed, Request for Inspection (RFI) shall be raised at least 24 hours prior to commencement of concrete casting.

5.5 Inspection can be carried out with the approved Inspection Test Plan (ITP), after approval, schedule of concrete shall commence.  

6. Concrete Joints

6.1 All joints for concrete paving and roadways shall be in accordance with [] project specification.

6.2 Unless otherwise specified in the construction drawings or project specifications, expansion joints shall be provided in concrete pavements.  Expansion joints shall be provided at 6.0, 10.0, and 25.0 meters maximum interval for 100, 150 and 200/250 mm thickness paving respectively.

 

6.3 Joint filler for expansion joints shall conform to ASTM D1751 for bituminous filler & ASTM D1752 for non-bituminous filler. Joint sealer shall be cold poured, oil resistant conforming to federal specification SS-S-200d, or hot poured oil resistant joint sealer conforming to ASTMD1854.

7. Placement of Concrete

7.1 Prior to casting, the temperature , slump, unit weight and air content of fresh concrete shall be measured prior to placement in the forms. Concrete not conforming to the requirements shall be rejected.

7.2 Placing of concrete to its final deposit shall be carefully done  to avoid segregation. A vibratory screed is recommended to this type of casting, however, in the absence of the the said equipment a aluminium bar with size 2”x4”x L is acceptable. Avoid using rakes in spreading or moving freshly poured concrete, thus, hand spading is acceptable.

7.3 Samples of concrete for compression test shall be taken each day concrete is poured. Concrete shall be sampled, cured and tested for compressive strength in accordance with ASTM C172, C31, and C39. There shall be seven (7) test cylinders per sample, wherein 1 cylinder shall be kept and cured at site in the same manner as the concrete paving. In case of small pours, there shall be one (1) sample as minimum. For large pours, one (1) sample shall be taken for each 38 cu.meter or portion of 38 cu.meter of concrete placed. 

7.4 Concrete shall not be dropped into place from a height that exceeds one (1) meter nor it shall be dropped through dense welded wire fabric (WWF) reinforcements  which could cause segregation of aggregates.

7.5 Finishing concrete shall be in accordance with SES-C04-S01, para.6.2.4.

8. Concrete Curing:

8.1 Curing shall commence immediately after finishing (flatwork) or within two (2) hours after consolidation and shall continue for a minimum of 14 days. Project can consider using 7 days during winter months and for concrete attaining 7day compressive strength in accordance with [] project specification. The finished pavement shall be closed to pedestrian traffic for three (3) days and vehicular traffic for a minimum of fourteen (14) days after curing.

8.2 An approved curing compound can be used and shall only be applied on surface not receiving subsequent finishes.

8.3 Regular, frequent inspection shall be made to the concrete being cured to establish whether or not curing is being performed in accordance with standard curing practice and this procedure.

8.4 Concrete surface shall be covered with polyethylene sheets which shall be in contact with concrete surface with the edges lapped or tied down to exclude air circulation.

8.5 Polyethylene sheets shall be placed over the wetted burlaps to avoid evaporation and shall be continuously water cured.

9. Removal of Forms and Shoring

9.1 When the required number of curing days is achieved, stripping of forms commences and immediately after the forms are removed, exposed surfaces shall be inspected, and small holes and minor honeycombing, which do not impair strength shall be filled with approved mortar  likewise, surfaces shall be draped with wet burlap and covered with polyethylene sheet.

QUALITY INSPECTION

Inspect the pavement finish elevations and shall consider tolerances in elevations. With relevance to the above work procedures, QC Inspector shall check in accordance with the Inspection Test  Plan (ITP) for Concrete Paving Works.

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