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WORK METHOD STATEMENT

WORK ACTIVITY: Providing and laying of Cement Concrete Pavement as per

BOQ Item No.4.05 .

DATE OF SUBMITTAL: 27th August 2001.

DATE OF PROPOSED START:

Tentative start date is January, 2002. However this work will start stretch wise after at
least 1000 M continuos stretch of DLC is laid , cured & approved by the Engineer .

LOCATION / EXTENT / DESCRIPTION OF THE WORK: -

This Work Method Statement is for the entire contract stretch (i.e. Km 0+000 to
Km 53+410.) along the proposed alignment. The area involved will be within inner
edges of Gravel shoulders on either side of the proposed carriageways.
The work involve , the construction of unreinforced , Dowel jointed , Plain Cement
Concrete Pavement in accordance with the requirements of the MOST specification
clause 602 and in the conformity with the lines , grades & cross fall as per the
contract drawing .

For entire section the approximate quantity of Cement Concrete Pavement is

290489 cum.

APPROXIMATE PRODUCTION RATE AND WORKING DAYS REQUIRED:

One team with Wirtgen SP 500M Paver will be deployed for complete job.
Effective paving rate per hour = 70 M 3/Hr.
Considering effective paving hour = 10 Hr.
There fore per day paving quantity = 70X10 = 700 M 3
Hence total working days required =290489/700 = 415 Days
Considering 25 days paving/month,Total days required=498 days
Add for monsoon =180 days
Total duration of paving =678 days say 23months.

POSSIBLE PROBLEMS:

1. The road side slope of embankment of carriageway to be paved first will encroach
upon the existing road by 4 to 5 mts as shown in the enclosed Annexure-I.In view
of the above encrochment,the available pavement width will be insufficient to
accommodate the existing traffic. For uninterrupted traffic ,an additional pavement
of width of atleast 4.0M has to be constructed on the other side with sufficient
crust thickness to withstand the axle loads under clause 51.1(e) of GCC.
2. Adverse climatic condition such as high ambient temperature, high velocity of
wind, unexpected/ intermittent rain may hamper the paving work.
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3. External unforseen disturbances as local festival / local problems causing stoppage

of works.
4. Non completion of bridges of more than 30M length by other agency will affect the
continuity of paving operations and movement of pavers.

CONCLUDED/PARALLEL/PRECEEDING ACTIVITIES:-

a) Activities to be concluded before starting of Pavement Concrete Paving work for a

particular stretch are
1. Establishment of road center line at the mid of carriage way on DLC
surface by nailing or by paint marking with the help of Total station.
2. Levels & Density of DLC shall be checked & got approved by the Engineer.
3. DLC surface shall be cured by wet hessian cloth for 7 days.

b) Activities that can continue parallel to the concrete paving work are
1. Construction of gravel shoulder by the side of previously laid pavement.
2.Paving of DLC over approved GSB layer at other locations.
3.Initial joint cutting of pavement laid on the previous day.
4.Preparation for next days paving work.

c) The succeeding activity to follow Pavment Concrete Paving work.

1. Construction of Gravel shoulder
2. Fixing of Metal crash barrier and guard posts.
3.Pavement marking

RESOURCES:

KEY PERSONNELS

For entire section from Km. 0+000 to 53.410

1. Construction Engineer K. M. Dixit

2. QA/QC Engineer S. K. Das
3. Survey Engineer B. Anthwal
4. Plant & machinery Engineer K. Bhaskaran

Other personnel like Paving supervisors, grade & level checker , QC helpers and
operators will be available at site on shift basis as per actual requirement.
MAJOR EQUIPMENTS :

1. Crushing plant with primary & secondary Crushers - Capacity 200 TPH
2. Automatic Concrete Batching Plant of 90cum - 2Nos
3. Wirtgen SP 500M Concrete Slip Form Paver - 01 No.
4. Wirtgen SP 850 Texturing & Curing Machine - 01No.
5. Excavator - 01No.
6. Concrete cutting Saw (Target 65 HP 4 Stroke M/C) - 02 Nos.
7. Water tankers with side sprinkling bar - 03 Nos
8. Tipper Trucks (TATRA 25 MT capacity ) - 09 to 14 Nos
(As per lead from
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Batching Plant to site )

MATERIALS :

1. Cement - Slag/OPC 43 Grade cement

2. Coarse Aggregate - Crushed Aggregate as per IS 2386
3. Fine aggregate -Natural/Crushed sand as per IS 383
4. Water - locally available water meeting the requirement of clause 1010
of MOST specification.
5. Admixture – It will be as per the approved brand, meeting the requirements
of IS 6925 & IS 9103.
6. Dowel bars - 32 mm  & 600 mm long covered by plastic sheathing over 2/3 rd of
its length .Dowel bars will be of mild steel grade S240 conforming to IS
7. Tie Bars - 12mm dia & 560 mm long deformed steel bars of grade S415
conforming to IS 1786. Tie bars will be painted with bitumen paint over a length of
150 mm in the middle of the bar for protection from corrosion.
8. Separation Membrane – It shall be white/transparent impermeable plastic sheet of
125 micron thickness.
9. Premoulded Joint Filler – For expansion joints , it will be a 20 mm thick firm
compressible material complying with the requriments of IS 1838 or BS
specification clause No. 2630.
10. Curing Compound - The brand will be as approved by the Engineer and will
be in accordance with BS specification No. 7542.
10 . Joint sealing compound – The brand will be as approved by the Engineer. It will be
cold applied Polyurethane / Polysulphide type complying with BS 5212 –1990.

QUALITY CONTROL:

Quality Control tests for Concrete Pavement construction will be done as per MOST
specification clause 903.5.2 and will be followed by routine tests . Frequency of the
quality control tests will be as per the table No. 900.6 of MOST specification.
In addition to that , temperature of water before mixing at batching plant will be
ensured to bring concrete temperature within 30 0C at site . If required necessary
quantity of Chilled water / Ice will be added .
Before starting the paving work , wind velocity will be measured with the help of
Anemometer and will be ensured to be within the specified limit.

QUALITY ASSURANCE :

QA team will be responsible for documentation of all tests, QC records, Jointly with the
Engineer. QA team will ensure that QC tests are being conducted at site as per the
MOST norms and Engineers requirements.
In addition to the above , a paving register will be maintained at paving site in which
following details will be recorded for each dump truck / TATRA jointly with the
Engineer
1. Dump truck / TATRA No.
2. Quantity in M3
3. Time of despatch from Batching Plant .
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4. Batching Plant No. / Location .

5. Temperature of concrete at Batching Plant .
6. Slump of concrete at Batching Plant.
7. Unloading time of concrete at site.
8. Slump of concrete at site.
9. Temperature of concrete at site.
10. Remarks if any.

Level Pads will be given at 5M interval at the both sides of paving lane at 1.5M or
suitable distance from the paving edge. Levels of these level pads will be jointly
checked by the Engineer before commencement of the days paving work. During
paving , level dips will be checked with the help of a measuring tape & string behind
the paver at every level stack (ie. @ 5M interval ).

QUANTITY SURVEY :

For the assessment of Quantity , a joint record of paved locations during the month
with lane details & levels/thickness details will be maintained at site and will be
produced before raising the monthly invoice.

SAFETY CONTROLS :
1. One safety plan will be prepared before commencement of Paving work activities.
2. Paving area will be marked/ barricated.
3. Necessary sign-boards and precautionary boards will be placed near working
locations.
4. Flag man and signal man will ensure regulation of traffic and dump trucks/TATRA at
paving site.
5. Dump trucks/TATRA will travel with minimum speed limit and will be provided with
reverse horns or signal man near unloading / paving area .
6. Safety stewards will conduct daily checking to ensure the working areas as safe.
7. Workmen and operators will be provided with necessary safety appliances.
8. Pep-talks will be given to all workmen at site to provide awareness and follow safe
working practice at site.

ENVIORNMENTAL CONTROL :

1. Dust pollution at Batching Plant area & paving area will be kept under control by
sprinkling of water from water tankers on earthen road / service road.
2. Sound pollution due to heavy machineries will be ensured to be minimum by way
of proper maintenance and tuning of engines.
3. Smoke pollution from all machines like Paver unit , Poclain , DG sets, Dump trucks/
TATRAs , Water tankers etc. will be ensured to be minimum by proper maintenance
and tuning of engines .
4. Cement leakage from Silos at Batching Plant will be ensured to be minimum by
proper maintenance and by introduction of cement filter unit so that the wastage
and escape of cement particles to the atmosphere will be controlled . In addition
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to that proper care will be taken at the time of cement loading in Silos by using
proper pipe connection.

HOW THE WORKS WILL BE CARRIED OUT :

The Cement Concrete Pavement will be laid over Dry Lean Concrete, which will
be laid by sensor Paver to the required level , grade and compaction. PQC will be
laid over DLC after a curing period of seven days.Slipform Paving operation will be
in the following steps :-

I) Establishment the string line

1. The string line will be of 2 to 4 mm dia. steel wire rope / Piano wire.
2. The stakes used will be of mild steel and of adequate length for necessary
adjustment of string line
3. The stakes will be placed in vertical position outside the hub line given by the
suveyor prior to commencement of paving operations.
4. Stakes will be placed on DLC by drilling holes of 16mm dia. in DLC by electric
hammer drill machine and fixed properly without any lateral movement.
5. When the string line is placed into the holder cum slot, it is adjusted to a point
directly over the hub lock point.
6. The string line support (stakes) will be placed at 5-m intervals both in straight and
curve alignment.
7. String line will be fixed on both sides of the paver for sufficient length to cover the
days paving work.
8. Hand winches will be used to tighten the string line to proper tension so as to avoid
any sagging. These winches will be placed at approximately 500 m interval.
9. The completed line installation will be visually checked. Any mistake in setting the
line will be informed to the surveyor, who will resurvey the area in question.
10. Prior to the beginning of paving, the string line will be checked again by the
survey team for ensuring proper level.
11. As the excavator will be travelling close to the string line, the same will be
checked for its level periodically during paving operation.

II) Preparation for Paving :

1. The top surface of DLC will be cleaned using suitable means.

2. Polythene sheet of 125-micron thickness will be spread over the approved DLC
layer.
3. This sheet will be fixed to the DLC by nailing concrete nails at every 1-m interval on
both the edges of the paving width. Nails will be fixed in such a way that the nail
head is flush with DLC top.
4. If required, the sheet will be cleaned using compressed air prior to spreading
concrete .
5. The polythene sheet fixing team will be just in front of the paving team to lay 10 m
long sheets before dumping of each load of concrete.
6. The dimension of sheet and its overlapping will be as per Specification.
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III). Paving Process :

1. Paving will be done in two phases of 5.0m & 3.5m.

2. Traffic plan will be as per Annexture -1
3. The fresh concrete of required workability will be supplied by dump trucks /TATRA
to the paving site.
4. The concrete will be unloaded from the dump trucks directly in front of Paver and
spread over entire paving width with the help of a excavator placed just outside
the string line.
5. The loose thickness of concrete in front of the paver will be maintained at 600
mm approximately .
6. The spreading auger in the paver helps to maintain the concrete level in front of
the paver.
7. The side forms, vibrators, mould extrude the pavement to the required thickness .
Consolidation of the concrete will be done by electrically operated immersion
vibrators with a frequency of 7000 to 9000 vibrations per minute. These vibrators
are placed 300 mm apart to get the overlap of zone of influence and are
permanently fixed to the paver.
8. The approved quality of Dowel bars with specified length of plastic sleeves will be
fed into the Dowel bar distribution tray manually.These Dowel bars will be
automatically distributed into proper slots of the Dowel Bar Inserter (DBI) unit of
paver.
9. Dowel bar will be dropped at every 4.5 M interval at the pre marked locations along
the length of paving .
10. Once the dowel bars are dropped on the top of concrete the same will be
inserted to the required depth by the hydraulically operated dowel bars inserter
forks .Each dowel is inserted by two vibratory forks .
11. The surface irregularities caused by DBI forks will be made good by oscillating
beam.
12. The approved quality of tie bars will be inserted on the side of the paved
concrete by using a hydraulically operated tie bar inserter,while paving 3.5m
width. Side bar inserter needs to be activated every time a bar to be inserted and
hence manned by a person .
13. The tie bars across the longitudinal joint between the carriageway and the
paved shoulder will be inserted into the concrete by a central tie bar inserter unit
fixed with the paver while paving 5m width.The spacing of the tie bars will be as
per the specification.
14. After the insertion of side bar the final finisher (Super smoother ) attached with
the paver unit gives the final finish to the top surface of the extruded concrete
pavement.
15. In case any localised minor spots remain unfinished, the same will be made
good by masons working from a platform spanning across the paving width which
will travel behind the paver.
16. Edges of paved concrete also will be made good , if required , by a mason using
a tool called “Edger”.
17. Final road level will be checked at every stake with the help of measuring tape
and string behind the paver . If any discrepancy is found ,same will be rectified by
adjusting the elevation sensor of paver.
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18. Expansion joints will be provided at the end of the days work only to minimize
the number of joints for better riding quality.
19. At the expansion joint filler board will be provided as per the specification.

IV). Texturing and Curing

1. Texturing and Curing machine will follow the paver and the working platform.
2. The distance between paver and curing machine will be as per the climatic
condition , initial hardening of concrete and finally texturing grove depth and this
distance will be decided by the paving engineer at site.
3. The movement of the brush will be in the transverse direction and it will be
automatically controlled by the texturing machine .The depth of the Texturing will
be as per the specification.
4. Soon after the texturing , the approved quality of curing compound will be sprayed
on the paved surface by the texturing/curing machine. The process of texturing
and curing will go on simultaneously for complete paving operation.
5. Curing compound will be sprayed using pressure nozzles on top and on both sides
of the paved surface @ 4 to 5 sqm/lit.

V). Covering

1. After the application of curing compound the concrete will be covered by the
plastic sheet to prevent loss of moisture from concrete due to evaporation.
2. The concrete will be kept covered till curing compound is set.

VI). Joints Cutting

1. The location of dowel bars marked on the side of concrete will be once again
confirmed by the cutting team and marked on both sides of paved surface. These
points on either side of paved surface will be joined and marked on concrete
surface with the help of a string & paint brush in the transverse direction.
2. The transverse joints cutting will be taken up after confirming the hardening and
setting of the concrete – to take the load of the sawing machine and no impression
formed on laid concrete.
3. This joint cutting will be done by using diamond edge saw blades of required
thickness (3mm) . The width and depth of cut will be maintained as per the
specification. After the initial cut ,the joints will be observed everyday. If any crack
does not develop at this location the cut is taken again to slightly more depth.
4. Soon after initial cut a compressible backup rod is inserted to avoid accumulation
of dirt in the joints.

VII). Curing

1. After the initial cut of transverse joints are completed, the paved surface will be
covered with wet hessian cloth.
2. Paved surface will be kept moist by sprinkling water with the help of water tankers
fitted with sprinkler arm for a period of 14 days after laying of concrete.
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VIII). Joint Sealing

1. Joint sealing work will be carried out after the completion of curing period of
concrete (ie. After the 14 days of construction)
2. The transverse and longitudinal joints will be widened subsequently by sawing
before sealing. Depth/width gauges shall be used to control the dimension of the
groove.
3. The widened grooves will be cleaned to remove the loose dirt and dust particles by
using air compressor.
4. For joint sealing, an approved quality material will be used.
5. Joint sealing will be done by specialised applicators.

IX). Communication

1. The communication in between paving team, Batching Plant, P & M workshop, QC

lab and other related set ups will be effectively organized by using wireless sets.