Construction of Concrete Pavings and Roadways

1. SCOPE………………………………………………2. REFERENCES
2. GENERAL
3. SUBGRADE ……………………………………….4.1 Material

4.2

Construction

1. GRANULAR SUB-BASE ………………………5.1 Materials

5.2

Construction

5.3

Tolerances……………………………………..

1. CONCRETE PAVING AND ROADWAYS

6.1 Materials

6.2

Construction …………………………………..

6.3

Testing

6.4

Inspection

1. CONCRETE CURBS AND SIDEWALKS

1. Scope

This specification is for construction of concrete pavings and roadways.

1. References

Reference is made in this specification to the following documents. The latest issues, amendments, and

supplements to these documents shall apply unless otherwise indicated.

SABIC Engineering Standards (SES)

B51-S01 Cast-in-Place Reinforced Concrete

C02-S01 Site Preparation Specification

C02-S02 Excavation and Backfill Specification

C04-E01 Design Criteria for Surfacing, Paving and Roadways

American Concrete Institute (ACI)

325.9R Construction of Concrete Pavements and Concrete Bases

504R Guide to Joint Sealants for Concrete Structures

American Society for Testing and Materials (ASTM)

C 78 Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)

D 994 Specification for Preformed Expansion Joint Filler for Concrete (Bituminous Type)

D 1196 Test Methods for Non-repetitive Static Plate Load Tests of Soils and Flexible Pavement

Components, for Use in Evaluation and Design of Airport and Highway Pavements

D 1557 Test Methods for Moisture-Density Relations of Soils and Soil-Aggregate Mixture

Using 4.54 kg (10 lb) Rammer and 457 mm (18 Inch) Drop

D 1751 Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural

Construction (Non-extruding and Resilient Bituminous Types)

D 1752 Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for

Concrete Paving and Structural Construction

D 1854 Specification for Jet-Fuel-Resistant Concrete Joint Sealer, Hot-Poured Elastic Type

D 2103 Specification for Polyethylene Film and Sheeting

Federal Specification of U.S.A.

SS-S-200d Sealing Compounds, Two-Component, Elastomeric, Polymer-Type, Jet Fuel Resistant,

Cold Applied

Portland Cement Association (PCA)

IS061P Design and Construction of Joints for Concrete Streets

1. General

3.1 The construction of concrete pavings and roadways shall be in accordance with this specification,

design drawings and ACI 325.9R.

3.2 Any conflict(s) between this specification and other specifications, design drawings, and contract

documents shall be resolved at the discretion of SABIC.

3.3 If pavement slope is not shown in design drawings, then the pavement slope shall be a maximum of

1 percent and the maximum elevation change between high point of paving (HPP) and low point of paving

(LPP) shall be 150 mm.

3.4 Foundations, underground piping and cables, and other underground objects that are below

pavements, shall be completed before pavement is installed.

1. Subgrade

4.1 Material

The fill material used for graded and excavated areas shall be as specified on design drawing or shall be

in conformance with SES C02-S01 and C02-S02 respectively.

4.2 Construction

4.2.1 Graded and excavated areas which shall receive fill material, shall be compacted in accordance with

SES C02-S01 and C02-S02 respectively.

4.2.2 Unless otherwise shown on the design drawings or in the project geotechnical report, for pavements

subject to zero or occasional vehicular traffic, fill material shall be compacted to at least 95 percent of the

maximum dry density at the optimum moisture content, as determined by ASTM D 1557.

4.2.3 For pavements subject to normal plant vehicular traffic, all fill material, to a depth of 150 mm below

the subgrade surface, shall be compacted to at least 95 percent of the maximum dry density at the

optimum moisture content, as determined by ASTM D 1557. In cut areas, it shall be scarified and

compacted to a depth of 150 mm, achieving the same density requirements. Fill areas, below a depth of

150 mm from subgrade surface, shall be compacted to at least 90 percent of the maximum dry density at

the optimum moisture content, as determined by ASTM D 1557. Compacted fill material shall have a

modulus of the subgrade reaction equal to or greater than that specified on the design drawings or in the

project geotechnical report. The compacted subgrade shall undergo non-repetitive static plate load tests

conforming to ASTM D 1196, to determine whether it has attained the specified modulus of subgrade

reaction.

4.2.4 Before the subsequent layer of fill material is deposited, the subgrade will be inspected by SABIC,

and any soft material shall be replaced. The replaced material shall be compacted to the density specified

in 4.2.3.

1. Granular Sub-base

5.1 Materials

The granular sub-base materials used for pavings and roadways subject to normal plant vehicular traffic,

shall be as specified on design drawing or in SES C04-E01. It shall also conform to the modulus of

subgrade reaction specified in the project geotechnical report.

5.2 Construction

5.2.1 Granular sub-base materials shall be placed and spread in uniform layers, without segregation, to a

loose depth that will compact to a maximum thickness of 150 mm.

5.2.2 Each layer shall be adequately moistened and compacted by a 10-ton vibratory roller (for granular

soils) until substantially smooth, even, and uniformly compacted. Hand tampers or small vibrating plate

compactors shall be used for compacting sub-base materials in areas that are inaccessible to a vibratory

roller.

5.2.3 The compacted sub-base for paving subject to normal plant vehicular traffic shall undergo

nonrepetitive static plate load tests conforming to ASTM D 1196, to determine whether it has attained the

specified modulus of subgrade reaction.

5.2.4 The surface of each layer shall be maintained in a finished condition until the succeeding layer is

placed.

5.3 Tolerances

The finished sub-base surface shall be within +10 mm and -15 mm of the elevations shown on the design

drawings.

1. Concrete Paving and Roadways

6.1 Materials

6.1.1 Concrete

Concrete materials testing, proportioning, furnishing, and construction shall be in accordance with

SES B51-S01.

6.1.2 Reinforcement
The reinforcing steel and welded steel wire fabric shall be in accordance with SES B51-S01.
6.1.2.1 Reinforcement for Pavements
The minimum clear cover from the top of the pavement shall be 40 mm for 100 mm thick pavement, and
50 mm for pavement thicker than 100 mm.
6.1.2.2 Reinforcement for Roadways
The minimum clear cover from the top of the road slab shall be 50 mm.
6.1.3 Expansion Joint Filler
Expansion joint filler shall conform to the requirements of ASTM D 1751 for bituminous filler and
ASTM D 1752 or D 994 for non-bituminous filler. Bent, twisted, or broken materials shall not be used. The
minimum thickness shall be 10 mm. For heavy duty expansion joints, dowel reinforcing bars with sleeves
shall be used.
6.1.4 Joint Sealer
Cold-poured, oil-resistant joint sealer conforming to Federal Specification SS-S-200d, or hot poured oil
resistant joint sealer conforming to ASTM D 1854, shall be used where the pavement is exposed to oil
spillage. Other joint sealers conforming to ASTM standards are acceptable where oil spillage does not
occur. See ACI 504R for more information on other joint sealers.
6.1.5 Membrane Vapor Barrier
Polyethylene sheeting for covering the subgrade shall conform to ASTM D 2103, and shall be capable of
withstanding impact during the placing and consolidation of the concrete, without tearing. Polyethylene
sheeting shall have a minimum thickness of 250 µm (0.25 mm).
6.1.6 Curing Materials
The curing materials shall be of salt-free moist earth or sand, wet burlap, polyethylene sheeting,
waterproof paper, or a SABIC approved liquid membrane-forming compound. Burlap that has contained
sugar shall not be used, since sugar attacks concrete surfaces.
6.2 Construction
6.2.1 Forms
6.2.1.1 The subgrade or granular sub-base under the forms shall be compacted and graded so that the
forms, when set, are uniformly supported for their entire length and are at the correct elevation.
6.2.1.2 The forms shall be of wood or steel, and shall be cleaned and oiled before use. Bent, twisted or
broken forms shall not be used.
6.2.1.3 The forms shall be aligned and securely positioned in a way that movement is minimized when the
concrete is placed and finished. Each form shall be within 6 mm of true alignment.
6.2.1.4 The forms shall remain in place for a minimum for 24 hours if the ambient temperature after
placing the concrete is more than 10 °C. If the ambient temperature is below 10 °C, after placing the
concrete, then the forms shall remain in position until the pavement edges have hardened sufficiently for
the forms to be removed without damage to the pavement.
6.2.2 Joints
6.2.2.1 The joint details shall conform to PCA IS061P and this section.
6.2.2.2 Unless otherwise specified on the drawings or in the project specifications, only expansion joints
shall be provided in concrete pavements. However, construction joints shall be installed where concreting
operations are concluded for the day. Expansion joints shall be provided at 10 m maximum intervals. The
location and the details of the joints shall be shown on the design drawings or in the project specification.
6.2.2.3 Isolation joints shall be installed around all structures and features, for example foundations,
manholes, and ditches, that occur in the concrete pavement.

6.2.2.4 The joint filler shall be straight and perpendicular to the pavement.
6.2.2.5 Load transfer devices required by the design drawings or the project specifications shall be
installed in accordance with ACI 325.9R.
6.2.2.6 The tops of the expansion joints shall be sealed with sealing materials, which shall be in
accordance with the project specifications. Before the sealing material is installed, the joint opening shall
be thoroughly cleaned of foreign matter, and bond breaker shall be provided, if required. Any excess
material spillage on concrete surface shall be removed immediately after the pouring.
6.2.3 Placing Concrete
6.2.3.1 Concrete shall be mixed and transported in accordance with SES B51-S01.
6.2.3.2 Before the concrete is placed, the subgrade or the granular sub-base shall be moistened, and the
polyethylene sheeting shall be laid on top. At joints, the edges of the polyethylene sheeting shall be
overlapped a minimum of 10 cm.
6.2.3.3 Concrete shall be placed carefully to prevent segregation of the aggregate and displacement of the
reinforcement or formwork. After spreading, the concrete shall be thoroughly consolidated with immersion
vibrators, or as specified in project specification.
6.2.3.4 Wooden or steel grade stakes shall be driven into the subgrade or granular sub-base at required
intervals and at critical elevations, as determined by the contractor. The concrete shall be leveled to the top
of the grade stakes, which shall be the finished paving grade. Grade stakes shall be removed before the
concrete starts to set, and any cavities shall be filled with concrete.
6.2.4 Finishing Concrete
Either the machine method or hand method may be used; however, only the hand method is described in
this specification. Machine methods shall be as approved by SABIC.
6.2.4.1 General
Sequence of operations shall be:
a. Strike-off and consolidation
b. Longitudinal floating and removal of laitance
c. Straight edging
d. Final finishing
6.2.4.2 Strike-Off and Consolidation
a. Concrete shall be struck-off and screeded to the cross-section shown on the design drawings,
and to an elevation at which, when consolidated and finished, the surface of the pavement shall be to
the required grade.
b. The strike-off screed shall always be moved in the direction the work is progressing, with a
combined longitudinal and transverse shearing motion, maintaining the template in contact with the
forms, and keeping a slight excess of material in front of the cutting edge.
c. The concrete shall be tamped with an approved tamping template to compact the concrete
thoroughly and eliminate surface voids. The surface shall be screeded to the required section.
6.2.4.3 Longitudinal Floating
a. The hand-operated float shall not be less than 3.5 m in length and 150 mm in width. It shall be
properly stiffened to prevent flexing and warping.
b. The float shall be worked with a sawing motion while held in a floating position, parallel to the
centerline of road for road work, and moving gradually from one side of the pavement to the other.
c. Movement ahead shall be in successive advances of not more than one-half the length of the
float. Excess water or soupy material shall be wasted over the side forms.

6.2.4.4 Straight Edging
a. After the longitudinal floating has been completed and excess water has been removed, but
while the concrete is still plastic, the slab surface shall be tested for trueness with a straight edge.
b. Any depressions shall be immediately filled with freshly mixed concrete, struck-off, consolidated,
and refinished. High areas shall be cut down and refinished.
6.2.4.5 Final Finishing
Process area pavement and tank truck loading areas shall be given a woodfloat finish, which permits
sweeping clean. Other areas shall be finished by brooming as follows:
a. The pavement shall be given a broom finish after floating, and as soon as any surplus water has
risen to surface
b. Brooming shall produce corrugations in the surface, of uniform appearance and not less than
1.5 mm in depth
c. Surface, when finished, shall be free from rough and porous areas, irregularities and
depressions
6.2.4.6 Edging
After final finishing is completed, but before concrete has its initial set, the edges of the slab shall be
carefully finished with an edger, to the radius required by the design drawings. The pavement edge shall
be smooth and true to line.
6.2.4.7 Surface Test
Plane surfaces shall be checked with SABIC approved 3 m straight edge. Deviation from a true plane shall
be a maximum of 5 mm in 3 m. Repairs shall be as directed by SABIC.
6.2.5 Curing
6.2.5.1 Curing shall commence immediately after the concrete has hardened sufficiently to withstand
surface damage. Concrete surfaces, including the vertical sides, shall be completely covered with curing
material.
6.2.5.2 The curing material shall be wet burlap, salt-free moist earth or sand, polyethylene sheeting,
waterproof paper, SABIC approved curing compound, or other project specified materials. Burlap, earth, or
sand shall be continually moistened during the curing period. Burlap that has contained sugar shall not be
used, since sugar attacks concrete surfaces. The moist concrete shall be covered with polyethylene
sheeting or waterproof paper, the edges of which shall be overlapped and sealed to prevent excessive
moisture loss. SABIC approved curing compound shall be applied according to the manufacturer’s
instructions while the concrete surface is still damp but free from water. However, curing compound shall
not be applied to pavement on which concrete will be placed later. White curing materials are preferred.
6.2.5.3 Curing shall continue for at least 7 days at a temperature of 21 °C or higher.
6.2.5.4 The finished pavement shall be closed to pedestrian traffic for a minimum of 3 days, and to
vehicular traffic for a minimum of 14 days.
6.3 Testing
Concrete tests shall be carried out in accordance with SES B51-S01 except that samples shall be taken at
least once a day or for each 500 m2
of pavement. Flexural strength tests conforming to ASTM C 78 may
be substituted for compressive strength tests.
6.4 Inspection
Pavement finish elevations will be inspected by SABIC, and shall not vary by more than 5 mm from the
cross-section elevations specified on the design drawings, nor more than 5 mm in 3 m. Where surface
drainage is required, water shall be poured on the finished pavement to verify that the surface drains off
correctly.

7. Concrete Curbs and Sidewalks
7.1 For curbs, the expansion joints shall be 10 mm wide and shall be constructed at 10 m intervals. They
shall be at right angles to the curbs.
7.2 The surface of sidewalks shall be marked into rectangles of not more than 1.5 m
with a scoring tool,
which will leave the edges rounded.
2
7.3 For sidewalks, the expansion joints shall be 10 mm wide and shall be constructed opposite to the
expansion joints in an adjacent curb. If the curb is not adjacent, expansion joints shall be at intervals of 6 m
and control joints shall be provided midway between expansion joints.
7.4 Sidewalks shall be broom-finished, with the brooming transverse to the direction of traffic.