PQC laying guidelines as per MoRTH section 602 and IRC guidelines

Rigid Pavement Construction Flowchart with IRC & MoRTH References

flowchart TD A1([Start
Ref: IRC:15 Intro]) A2["Subgrade Preparation
• Achieve 97% MDD
• Remove soft pockets
Ref: MoRTH 305, IRC:15 Cl. 5.1"] A3["DLC Placement
• 10–20 MPa
• Min 100 mm thick
• Compacted with roller
Ref: MoRTH 601, IRC:SP:62"] A4["DLC Curing
• 7 days minimum
Ref: IRC:SP:62 Cl. 7"] A5["Surface Cleaning
• Remove dust & laitance
Ref: MoRTH 602.4.1"] A6["Polyethylene Sheet Laying
• 125 micron
• Joints overlapped 300 mm
Ref: MoRTH 602.4.2"] A7["Dowels & Tie Bars Placement
• Epoxy-coated
• Dowel tolerance: ±5 mm
• Tie bars as per IRC:58 Table 10
Ref: IRC:58 Cl. 10"] A8["Side Forms / Slipform Setup
• Level tolerance ±3 mm
Ref: MoRTH 602.5"] A9["Concrete Batching & Mixing
• w/c ratio per IS 10262
• Use IS 383 aggregates
Ref: MoRTH 602.6, IS 9103"] A10["Concrete Transport
• No segregation
• Place within 30 min
Ref: MoRTH 602.7"] A11["Concrete Placement
• No vibration on dowels
• Spread uniformly
Ref: MoRTH 602.8"] A12["Compaction with Vibrators
• Internal & surface vibrator
• Avoid over-vibration
Ref: IRC:15 Cl. 8.3"] A13["Surface Finishing
• Texturing with burlap or broom
Ref: MoRTH 602.9"] A14["Alignment & Level Checks
• Straightedge check 3 m
• Max 3 mm deviation
Ref: IRC:15 Cl. 10"] A15["Joint Cutting (Grooving)
• 1/3 slab depth
• Saw-cut within 6–24 hrs
Ref: IRC:58 Cl. 11.3"] A16["Joint Sealing
• Sealant Type: Polysulphide
• Reservoir cleaning required
Ref: IRC:57 & MoRTH 602.13"] A17["Curing of PQC
• 14 Days minimum
• White curing compound allowed
Ref: IRC:15 Cl. 11"] A18["Opening to Traffic
• Strength >= 30 MPa
• Min 28 days unless permitted
Ref: IRC:15 Cl. 12"] A19([End]) A1 --> A2 --> A3 --> A4 --> A5 --> A6 --> A7 --> A8 --> A9 --> A10 A10 --> A11 --> A12 --> A13 --> A14 --> A15 --> A16 --> A17 --> A18 --> A19

IRC References for Pavement QC Tests

Quality Control Tests in Pavement Construction – IRC References

Test Category	Specific Test	Primary IRC Reference	Notes / Related Standards
1. Soil / Subgrade Tests	Field Density Test (Sand Cone / Nuclear Gauge)	IRC:SP:20-2002, IRC:37-2018	IS:2720 (Part 28); 95–100% Proctor density
	CBR Test (California Bearing Ratio)	IRC:37-2018, IRC:SP:72-2015	IS:2720 (Part 16); soaked CBR for design
	Atterberg Limits	IRC:SP:20-2002, IRC:37-2018	IS:2720 (Part 5); plasticity index control
	Proctor Test (OMC & MDD)	IRC:37-2018, IRC:SP:72-2015	IS:2720 (Part 8); Modified Proctor
2. Base & Sub-Base Layer Tests	Gradation Test (Sieve Analysis)	IRC:SP:11-1984, IRC:109-2015	IS:2386 (Part 1)
	Aggregate Crushing Value (ACV)	IRC:SP:11-1984, IRC:37-2018	Max 30%; IS:2386 (Part 4)
	Los Angeles Abrasion (LAA)	IRC:SP:11-1984, IRC:109-2015	Max 40%; IS:2386 (Part 4)
	Field Density Test	IRC:SP:11-1984	IS:2720 (Part 28)
	Plate Load Test	IRC:SP:11-1984	Bearing capacity & modulus
3. Asphalt (Flexible Pavement) QC Tests	Asphalt Content (Extraction Test)	IRC:SP:11-1984	IS:2720 (Part 19)
	Marshall Stability & Flow Test	IRC:SP:11-1984, IRC:111-2009	Min 9 kN stability
	Core Cutting & Thickness Check	IRC:SP:11-1984, IRC:29-2009	Tolerance ±5 mm
	Density / Compaction Test	IRC:SP:11-1984	95–98% of lab density
	Temperature Monitoring	IRC:SP:11-1984, IRC:111-2009	Mix 150–165°C, laying >100°C
	Air Voids & VMA / VFA Analysis	IRC:SP:11-1984, IRC:37-2018	Air voids 3–6%, VMA >14%
4. Concrete (Rigid Pavement) QC Tests	Slump Test	IRC:15-2011, IRC:SP:62-2004	25–50 mm; IS:1199
	Compressive Strength (7-day & 28-day)	IRC:15-2011, IRC:44-2017	Min 30 MPa (M40); IS:516
	Flexural Strength (Modulus of Rupture)	IRC:15-2011, IRC:58-2015	Min 4.5 MPa; IS:516
	Air Content Test	IRC:15-2011	4–6%; IS:1196
	Concrete Temperature Test	IRC:15-2011	Max 32°C at placement
	Core Thickness & Strength Check	IRC:15-2011, IRC:SP:83-2008	Tolerance ±5 mm
5. Surface Quality Tests	Benkelman Beam Deflection (BBD)	IRC:81-1997	Structural evaluation
	IRI (International Roughness Index)	IRC:SP:16-2004	<2.5 m/km acceptable
	Skid Resistance Test	IRC:SP:11-1984	British Pendulum Number ≥45
	Texture Depth (Sand Patch Method)	IRC:SP:11-1984	Min 0.6–1.0 mm