Materials

DUTIES OF A MATERIAL ENGINEER DUTIES OF A MATERIAL ENGINEER

y

y Ensures that all materials comply with the schedule of miEnsures that all materials comply with the schedule of mi nimum testing requirement.nimum testing requirement. y

y AAdvises the project engineer on the acceptance/ rejection of construction materials.dvises the project engineer on the acceptance/ rejection of construction materials. y

y RRecommends remedial measures to correct unsatisfactory condition of materials.ecommends remedial measures to correct unsatisfactory condition of materials. y

y PPrepare design mixes for concrete and bituminous materials.repare design mixes for concrete and bituminous materials. y

y Ensures the samples are properly cured by standard procedures.Ensures the samples are properly cured by standard procedures. y

y FFully acquainted with standard procedures of sampling, testing and quality control of materials.ully acquainted with standard procedures of sampling, testing and quality control of materials. y

y TTo see if the laboratory is adequately equipped.o see if the laboratory is adequately equipped. y

y KKeep record of daily his activities.eep record of daily his activities. y

y SSubmit test reports & pertinent papers.ubmit test reports & pertinent papers. y

y TTo see to it that quality of completed projects are attained as per Do see to it that quality of completed projects are attained as per DPWHPWHstandard.standard.

TERMINOLOGIES TERMINOLOGIES

QUALITY CONTROL PROGRAM

QUALITY CONTROL PROGRAM- prepared by Materials Quality Control Division of the- prepared by Materials Quality Control Division of theRR_{egional Office and MQCegional Office and MQC} S

S_{ection of the District Office to be ection of the District Office to be complied by the contractor.complied by the contractor.} FIELD DENSITY REPORT

FIELD DENSITY REPORT- if pavement is being constructed- if pavement is being constructed CONCRETE POURING PERMIT/ POURING SLIP

CONCRETE POURING PERMIT/ POURING SLIP- - to ensure that all coto ensure that all concreting works are done in accordance ncreting works are done in accordance withwith the approved plans and specifications (Dept Order NO. 211 ser 2000).

the approved plans and specifications (Dept Order NO. 211 ser 2000). MONTHLY MATERIALS REPORT

MONTHLY MATERIALS REPORT- every 25- every 25ththof the month.of the month.

POLICIES AND ADMINISTRATIVE ISSUANCES POLICIES AND ADMINISTRATIVE ISSUANCES

DO No. 206

DO No. 206- - re-guidelines on re-guidelines on accreditation accreditation of Contractors of Contractors & Consultan& Consultants Mts Materials Engineersaterials Engineers

DO No. 14

DO No. 14- adoption of D- adoption of DPWHPWH SS_{tandardtandard}SS_{pecification 1995 Edition Volume 2 in the implementation of allpecification 1995 Edition Volume 2 in the implementation of all} Infrastructure

InfrastructurePP_{rojects.rojects.}

DO No. 184

DO No. 184- guidelines on accreditation of Contractors & Consultants Materials Engineers- guidelines on accreditation of Contractors & Consultants Materials Engineers

DMC No. 03

DMC No. 03  SS_{tandardtandard}SS_{pec for Chemicalpec for Chemical}AA_{dmixturesdmixtures}

Quality Control

Quality Control - checking for conformance to requirements to ensure the highest quality of work. Check and- checking for conformance to requirements to ensure the highest quality of work. Check and regulate the use of construction material to e

regulate the use of construction material to e conomize the cost of construction.conomize the cost of construction.

Quality Assurance

Quality Assurance- acceptance inspection- acceptance inspection

STD SPEC FOR AGGREGATES AND SOIL AGGREGATES SUBBASE, BASE AND SURFACE COURSES STD SPEC FOR AGGREGATES AND SOIL AGGREGATES SUBBASE, BASE AND SURFACE COURSES

COARSE AGGREGATE

COARSE AGGREGATE   retain retain on on # # 10 10 sieves.sieves. % wear < 50

% wear < 50 FINE AGGREGATE

FINE AGGREGATE - - passing passing # # 10.10. P

P_{assing # 200 sieve ( 0.075 mm) < 2/3 of passing at # 40 sieve (0.425)assing # 200 sieve ( 0.075 mm) < 2/3 of passing at # 40 sieve (0.425)} SURFACE COURSE MATERIAL

SURFACE COURSE MATERIAL- minimum 8 % passing # 200 sieve. Maximum liquid limit of 35.- minimum 8 % passing # 200 sieve. Maximum liquid limit of 35. PP_{lasticity Indexlasticity Index} range of 2 to 9.

range of 2 to 9.

SOIL CLASSIFICATION (AASHTO 145) SOIL CLASSIFICATION (AASHTO 145)

GRANULAR MATERIALS

GRANULAR MATERIALS- - 35 35 % or % or less less 0.075 mm 0.075 mm sievesieve

SILT CLAY MATERIALS

SILT CLAY MATERIALS- more than 35 % passing- more than 35 % passing BINDER

STONE-STONE-angular particles of rock, passes 75 mm (3) sieve and retained on 2 mm (#10) sieve.angular particles of rock, passes 75 mm (3) sieve and retained on 2 mm (#10) sieve. GRAVEL

GRAVEL-rounded particles of rock w/c passes75 mm (3) sieve, retained 25.0 mm (1) sieve.-rounded particles of rock w/c passes75 mm (3) sieve, retained 25.0 mm (1) sieve. SAND

SAND- granular materials , passes 2 mm (#10) sieve retained on 0.075 (#200) sieve.- granular materials , passes 2 mm (#10) sieve retained on 0.075 (#200) sieve. SILT FRACTION

SILT FRACTION-passes #200 but larger than 0.002 mm-passes #200 but larger than 0.002 mm CLAY FRACTION

CLAY FRACTION-smaller than 0.002 mm-smaller than 0.002 mm

COLLOID-COLLOID-smaller than 0.001 mmsmaller than 0.001 mm

GROUP INDEX

--GROUP INDEX --measure of the relative supporting power of the subgrade soil. Greater depth is required formeasure of the relative supporting power of the subgrade soil. Greater depth is required for higher GI value.Empirical value from 0 to 20, Zero (0) GI indicates good material and GI of 20 indicates a very higher GI value.Empirical value from 0 to 20, Zero (0) GI indicates good material and GI of 20 indicates a very poor material.

poor material.

GI= (F  35) 0.2 + 0.005(LL-40) + 0

GI= (F  35) 0.2 + 0.005(LL-40) + 0.01 (F  15) (PI  10).01 (F  15) (PI  10) F=

F=_{percentage passing 0.075 sieve expressed in positive whole number.percentage passing 0.075 sieve expressed in positive whole number.} LL

LL==_{numerical Liquid Limit, pos whole numbernumerical Liquid Limit, pos whole number} P

P_II==_{numericalnumerical}PP_{lasticity Index,pos whole numberlasticity Index,pos whole number}

Granular material to control pumping

Granular material to control pumping under concrete pavement:under concrete pavement: -max size not more than 1/3 the

-max size not more than 1/3 the thickness of the subbase.thickness of the subbase.

-passing # 200 -15% max -passing # 200 -15% max P P_II==_{6 max6 max} LL LL==_{25 max25 max}

LIME FOR ROAD STABILIZATON

LIME FOR ROAD STABILIZATON- causes finely divided clay particles to agglomerate into coarser particles to- causes finely divided clay particles to agglomerate into coarser particles to improve load bearing properties

improve load bearing properties

H

H_{ydrated lime- ydrated lime- retained on retained on #30 <3%, #30 <3%, retained on retained on #200<25%#200<25%}

Quicklime- shall all pass 1 sieve Quicklime- shall all pass 1 sieve

DRY PREPARATION OF DISTURBED SOIL AND SOIL AGGREGATE SAMPLES FOR TEST DRY PREPARATION OF DISTURBED SOIL AND SOIL AGGREGATE SAMPLES FOR TEST

1.

1. PP_{article size analysis of soil.article size analysis of soil.}

H

H_{ydrometerydrometer}AA_{nalysis- determines the particle size nalysis- determines the particle size distribution of soil passing No. 200.distribution of soil passing No. 200.}

%

%_{of of Hygroscopic Hygroscopic Moisture= Moisture= ( ( W-W1 W-W1 x100 x100 ) ) / / W1W1} W

W_{- wt of air dried sample- wt of air dried sample} W

W_{1-wt of oven dried sample1-wt of oven dried sample}

Con Mass of air

Con Mass of air dried sample for dried sample for hygroscopic moisture= hygroscopic moisture= (air dried mass) (air dried mass) x x (100/100+(100/100+%%_{hyg moisture)hyg moisture)}

%

%_{of originally of originally dispersed dispersed soil remsoil remaining in saining in suspension, Puspension, P= = (Ra/w) (Ra/w) x 100x 100} R

R_{- Corrected hydrometer reading.- Corrected hydrometer reading.} a- constant depending on density of

a- constant depending on density of suspensionsuspension

w- mass in grams of soil originally dispersed minus the hygroscopic moisture w- mass in grams of soil originally dispersed minus the hygroscopic moisture aa

2.

2. SS_{pecific Gravity.pecific Gravity.} 3.

EXCAVATION EXCAVATION

1.

1. RR_OOAA_DDWAYWAY_EXCEXCAA_VVATAT_{ION-unclassified excavation, rock exc., common exc., muck exc.(with organic matter)ION-unclassified excavation, rock exc., common exc., muck exc.(with organic matter)} 2.

2. BOBORRRR_OOWW_EXCEXCAA_VVATAT_{ION approved materials for const embankment.ION approved materials for const embankment.} Borrow Case 1- designated in plans and specs Borrow Case 1- designated in plans and specs Borrow Case 2- provided by contractors. Borrow Case 2- provided by contractors.

ITEM 200, AGGREGATE SUBBASE COURSE ITEM 200, AGGREGATE SUBBASE COURSE

% passing No. 200 shall not be greater than

% passing No. 200 shall not be greater than 2/3 of the fraction passing No. 40 (0. 425 2/3 of the fraction passing No. 40 (0. 425 mm)mm)

F

F_{raction passing No. 40 shall haveraction passing No. 40 shall have LL< LL< 35, 35, PI< PI< 12.12.}

ITEM 201, AGGREGATE BASE COURSE ITEM 201, AGGREGATE BASE COURSE

% passing No. 200 shall not be greater than

% passing No. 200 shall not be greater than 2/3 of the fraction passing No. 40 (0. 425 2/3 of the fraction passing No. 40 (0. 425 mm)mm)

FILLER

FILLER- shall not contain more than 15% materi- shall not contain more than 15% materi als retained on the No. 4.als retained on the No. 4.

F

F_{raction passing No. 40 shallraction passing No. 40 shallhave LL< have LL< 25, 25, PI< PI< 6.6.}

F

F_{raction passing No. 10 shall have massraction passing No. 10 shall have mass}%%_{wear<50.wear<50.}

F

F_{raction passing No. 10 shall have soakedraction passing No. 10 shall have soaked CBR<80CBR<80}%%

ABRATION

ABRATION TEST TEST -- evaluates structural strength of coarse aggregates, resistance to impact and wear.evaluates structural strength of coarse aggregates, resistance to impact and wear.

A

A_{pparatus: Lospparatus: Los}AA_{ngeles Machine,ngeles Machine,}SS_ieve,ieve,AA_{brasive Charges,brasive Charges,}PP_{ans and Balance /ans and Balance /}WW_eightseights A

A_{brasive Charges--- cast-iron spheres on steel spheres, approx. 48 mm diameter each weighing 390 & 455brasive Charges--- cast-iron spheres on steel spheres, approx. 48 mm diameter each weighing 390 & 455} grams. Charge depends on grading of test sample.

grams. Charge depends on grading of test sample.

R

R_{otated at speed of otated at speed of 30-33 rpm.30-33 rpm.}

%

%_{wear= oriwear= orig mass g mass of sample of sample  sample  sample retained on retained on 1.7 mm 1.7 mm sieve sieve / orig m/ orig mass of ass of sample sample x 100x 100}

LIQUID LIMIT

LIQUID LIMIT-- lowest moisture content at which lowest moisture content at which the soil will flow upon the application of a very small the soil will flow upon the application of a very small shearing force.shearing force. -- MC at 25 blows at CMC at 25 blows at CASAASA_GGRARA_NDENDE

-- water content at which a soil changes from plastic to liquid behaviorwater content at which a soil changes from plastic to liquid behavior

PLASTIC LIMIT

PLASTIC LIMIT   minimum moisture content at which the soil can be readily molded w/o breaking.   minimum moisture content at which the soil can be readily molded w/o breaking.PP_{lasticity Indexlasticity Index} indicates compressibility.

indicates compressibility.

Crumbled soil at 1/8 diameter Crumbled soil at 1/8 diameter

Compressibility-- ability of a soil or rock to reduce in volume with applied pressure Compressibility-- ability of a soil or rock to reduce in volume with applied pressure P

P_{ermeability-- ability of a porous material to allow fluids to pass through itermeability-- ability of a porous material to allow fluids to pass through it}

PI = LL - PL PI = LL - PL 

SHRINKAGE LIMIT

SHRINKAGE LIMIT-- water content where water content where further loss of moisture will not result in further loss of moisture will not result in any more volume reduction.any more volume reduction.

Proctor Moulds

Proctor Moulds- use to determine re- use to determine re lationship b/w moisture content& density of compacted soil.lationship b/w moisture content& density of compacted soil. Proctor Rammers

Proctor Rammers- use to compact the - use to compact the soil in proctor moulds.soil in proctor moulds. Pavement Coring Machine

Pavement Coring Machine- use to cut concrete samples, asphalt or similar materials.- use to cut concrete samples, asphalt or similar materials.

BASIC CONCRETE TECHNOLOGY

BASIC CONCRETE TECHNOLOGY

2

2 main main parts parts --- --- paste, paste, and and aggregatesaggregates

If air content of fresh concrete. If air content of fresh concrete.

Increases 1%, compressive strength decreases 5% Increases 1%, compressive strength decreases 5%

Decreases 1%, yield (volume) decreases about 0.93 (1/4 cu.

Decreases 1%, yield (volume) decreases about 0.93 (1/4 cu.FF_{t/ cu yd)t/ cu yd)} Decreases 1%, slump decreases about ½ inch

Decreases 1%, slump decreases about ½ inch Decreases 1%, durability decreases about 10% Decreases 1%, durability decreases about 10%

CEMENT CEMENT

1.

1. Pozzolan Pozzolan cement- cement- ww/ volcanic earths./ volcanic earths. 2.

2. Portland cementPortland cement  calcium, alumina, iron and silica calcium, alumina, iron and silica

Note:

Note: 30 k30 kg of water g of water are required are required to hydrate to hydrate 100 k100 kg of cement.g of cement.

Chemical Compounds in

Chemical Compounds inPP_{ortland cementortland cement} 1.

1. Tricalcium SilicateTricalcium Silicate- C3- C3SS_{hydrates and hardens rapidly.hydrates and hardens rapidly.}RR_{esponsible for initial set.esponsible for initial set.} 2.

2. Dicalcium SilicateDicalcium Silicate-C2-C2SS_{contributes to strength increase at ages.contributes to strength increase at ages.}HH_{ydrates andydrates and}HH_{ardens slowly.ardens slowly.} 3.

3. Tricalcium AluminateTricalcium Aluminate- C3- C3AA_{liberates large amount of heat.liberates large amount of heat.} 4.

4. Tetracalcium AluminoferriteTetracalcium Aluminoferrite-C4-C4AFAF_{reduces clinkering temperature.reduces clinkering temperature.}

P

P_{roperties of roperties of} PP_{ortland cement:ortland cement:} 1.

1. Fineness of cementFineness of cement- affects heat released and rate - affects heat released and rate of hydration. Greater cement fineness increase of hydration. Greater cement fineness increase hydrationhydration thus, accelerates strength development.

thus, accelerates strength development. (Blaine Permeability Test)(Blaine Permeability Test) 2.

2. Soundness-Soundness- ability to return to retain its volume after ability to return to retain its volume after setting.setting. 3.

3. Consistency-Consistency- mobility/ ability to growmobility/ ability to grow 4.

4. Setting Time-Setting Time- (Vicat(VicatAA_{pparatus or Gilmore Needle)pparatus or Gilmore Needle)} 5.

5. False Set-False Set-6.

6. CompressiveCompressiveSS_{trengthtrength} 7.

7. Heat of HydrationHeat of Hydration- generated when cement and water react- generated when cement and water react 8.

8. Loss of IgnitionLoss of Ignition 9.

9. Specific GravitySpecific Gravity--PP_{ortland Cement-ortland Cement- 3.153.15,,}PP_{ortland blast furnace slag andortland blast furnace slag and}PP_{ortland pozzolan-ortland pozzolan- 2.92.9} 10.

10. Weight of CementWeight of Cement--WW_{ater of Convenience, 10 to 50 exater of Convenience, 10 to 50 ex tra kg of water for workabilitra kg of water for workability.( add to 30kg )ty.( add to 30kg )}

AIR VOIDS AIR VOIDS

1.

1. AA_{ir entrapped  readily visibleir entrapped  readily visible} 2.

2. AA_{ir entrained- barely visible, beneficial.ir entrained- barely visible, beneficial.}TT_{hese tiny bubbles absorb pressure built up w/in concrete.hese tiny bubbles absorb pressure built up w/in concrete.}

ADMIXTURES ADMIXTURES

1.

2.

2. ChemicalChemicalAA_{dmixturedmixture} a.

a. TT_ypeypeAA_{,, Water reducing AdmixtureWater reducing Admixture- reduce amount of water required to produce concrete of a given slump- reduce amount of water required to produce concrete of a given slump} or consistency.

or consistency. b.

b. TT_{ype B,ype B,Retarding MixtureRetarding Mixture- slows down the early hardening of concrete.- slows down the early hardening of concrete.}SS_{low hydration produces denserlow hydration produces denser} structure.

structure. c.

c. TT_{ype C,ype C,Accelerating AdmixtureAccelerating Admixture-speeds up initial and final set, faster development of strength.-speeds up initial and final set, faster development of strength.} d.

d. TT_{ype D,ype D,Water Reducing and Retarding MixtureWater Reducing and Retarding Mixture} e.

e. TT_{ype E,ype E,Water Reducing and Accelerating MixtureWater Reducing and Accelerating Mixture} f.

f. TT_ypeypeFF_{,,Water Reducing, High Range Admixture-Water Reducing, High Range Admixture- super plasticizers or fluidizerssuper plasticizers or fluidizers: : Do not Do not have undesirablehave undesirable} effect at high dosage.

effect at high dosage.

3.

3. MineralMineralAA_{dmixture- modifies the properties of concrete, or as a dmixture- modifies the properties of concrete, or as a partial cement replacement to lower the partial cement replacement to lower the cost.cost.} a.

a. Fly AshFly Ash- from stack emission of coal combustion, fineness similar to cement. Use at a rate of 30-150 kg / m3.- from stack emission of coal combustion, fineness similar to cement. Use at a rate of 30-150 kg / m3. Class

ClassFF_{- pozzolanic; reacts chemically with cement hydration.- pozzolanic; reacts chemically with cement hydration.}

Class C- cementitious; can give strength by itself when mixed w/ water. Class C- cementitious; can give strength by itself when mixed w/ water. b.

b. Ground Granulated Blast Furnace Slag (GGBF Slag)Ground Granulated Blast Furnace Slag (GGBF Slag) mineral admixture. But it is in reality a hydraulicmineral admixture. But it is in reality a hydraulic cement; it gains considerable strength when mixed with water.

cement; it gains considerable strength when mixed with water. RR_{eplaces cement at a rate of 15 to 70 %.eplaces cement at a rate of 15 to 70 %.} Derived from a by-product of the manufactured iron.

Derived from a by-product of the manufactured iron. c.

c. Micro Silica/ Silica FumeMicro Silica/ Silica Fume- by-product of the production of silicon metals.- by-product of the production of silicon metals. AA_{n extremely fine powder, finern extremely fine powder, finer} than cigarette smoke.it is handled as slurry mixed with water or as densified powder. (20 to 70 kg per cu m). than cigarette smoke.it is handled as slurry mixed with water or as densified powder. (20 to 70 kg per cu m). Low permeability & high strength but is more susceptible to cracking (plastic shrinkage).

Low permeability & high strength but is more susceptible to cracking (plastic shrinkage).

AlkaliSilica Reactivity (ASR)

-Alkali-Silica Reactivity (ASR) - a gel is produced w/c increases in volume by taking up water and so exerts expansivea gel is produced w/c increases in volume by taking up water and so exerts expansive pressure resulting to serious expansion & cracking in concrete.

pressure resulting to serious expansion & cracking in concrete.

Sulfate Attack on Sulfate Attack on

Concrete-Ettringite Formation

Ettringite Formation- occurs in high temperature curing, above 70 deg- occurs in high temperature curing, above 70 deg rees Celsius.rees Celsius.

-- HH_{ydrous calcium aluminum sulfate mineral, crystallizes in voids/ ydrous calcium aluminum sulfate mineral, crystallizes in voids/ cracks.cracks.}

Soundness

Soundness- volume stability of a cementitious paste- volume stability of a cementitious paste

T 

T _{he lower the water cement ratio, the higher the strength.he lower the water cement ratio, the higher the strength.}

Concrete Curing

Concrete Curing- maintaining sufficient moisture and a favorable temperature. (7 -14 days)- maintaining sufficient moisture and a favorable temperature. (7 -14 days) 1.

1. By maintaining a moist environment: spraying, steam, saturated cover materials such as earthBy maintaining a moist environment: spraying, steam, saturated cover materials such as earth , sawdust, hay or, sawdust, hay or burlap.

burlap. 2.

2. By preventing loss of mixing water: sealing with impervious sheets or application of member forming curingBy preventing loss of mixing water: sealing with impervious sheets or application of member forming curing compound to freshly placed concrete.

compound to freshly placed concrete.

DESIGN OF CONCRETE MIX DESIGN OF CONCRETE MIX

1.

1. Choice of slump (for consistency of mixture)Choice of slump (for consistency of mixture) 2.

2. Choice of maximum size of aggregateChoice of maximum size of aggregate 3.

3. Estimate amount of mixing water and water contentEstimate amount of mixing water and water content 4.

4. SS_{elect water cement ratioelect water cement ratio} 5.

5. Calculate cement contentCalculate cement content 6.

6. Estimate quantity Estimate quantity of fine and of fine and coarse aggregatescoarse aggregates 7.

7. AA_{djust moisture content of aggregatesdjust moisture content of aggregates} 8.

8. Check mixture proportion by testing trial batchesCheck mixture proportion by testing trial batches

Usual Initial Mixing time: 1 minute for ¾ cubic meters. Usual Initial Mixing time: 1 minute for ¾ cubic meters.

S

S_{pecifiedpecified}SS_{trengthtrength} M

MPP_aa

W

W_{ater cement ratioater cement ratio} By weight By weight 27.6 0.44 27.6 0.44 25.8 0.48 25.8 0.48 24.1 0.51 24.1 0.51 20.7 0.58 20.7 0.58 17.2 0.65 17.2 0.65

PLACIN

PLACING OF G OF CONCRETECONCRETE-It should be placed in horizontal layers not exceeding 60 cm in depth, avoiding inclined layers-It should be placed in horizontal layers not exceeding 60 cm in depth, avoiding inclined layers and cold joint.

and cold joint. Cold Joint

Cold Joint- when fresh concrete is poured on top - when fresh concrete is poured on top or adjacent to a concrete or adjacent to a concrete that has already begun to setthat has already begun to set up.(that is why vibration is needed).

up.(that is why vibration is needed). Internal Vibration

Internal Vibration- most effective method of consolidating concrete. (8300 to 960 impulses per minute under a- most effective method of consolidating concrete. (8300 to 960 impulses per minute under a load at a maximum spacing of 60 cm)

load at a maximum spacing of 60 cm)

PORTLAND CEMENT CONCRETE PAVEMENT PORTLAND CEMENT CONCRETE PAVEMENT

F

F_ineineAA_{ggregateggregate}

-- SS_{hall not contain morehall not contain morethan 3than 3}%%_{of materials passing # 200,of materials passing # 200,} -- 11%%_{of clay lumps or shaleof clay lumps or shale}

-- WW_{hen subjected to 5 cycles of sodium sulfate soundness test, hen subjected to 5 cycles of sodium sulfate soundness test, the weighted loss shall not exceedthe weighted loss shall not exceed} 10

10%%_.. Coarse

CoarseAA_{ggregateggregate}

-- SS_{hall not contain more thanhall not contain more than 11}%%_{of materials passing # 200,of materials passing # 200,} -- 0.250.25%%_{of clay lumps or shaleof clay lumps or shale}

-- WW_{hen subjected to 5 cycles of sodium sulfate soundness test, hen subjected to 5 cycles of sodium sulfate soundness test, the weighted loss shall not exceedthe weighted loss shall not exceed} 12

12%%_.. R

R_{einforcingeinforcing}SS_teelteel

-- TT_{ie bars shall be deformed bars.ie bars shall be deformed bars.} -- Dowels shall be plain round bars.Dowels shall be plain round bars.

-- ½ of the length of the dowel shall be ½ of the length of the dowel shall be painted with 1 coat of approved lead or painted with 1 coat of approved lead or tar paint.tar paint. -- SS_{leeves shall be metal.leeves shall be metal.}

Joint

JointFF_{iller- asphalt and mineral or rubber filler.iller- asphalt and mineral or rubber filler.}

Proportioning, Consistency and Strength of Concrete Proportioning, Consistency and Strength of Concrete --SS_{lump betweenlump between40-75,40-75, if vibrated.if vibrated.}

--FF_{lexurallexural}SS_{trength of not less than trength of not less than 3.8 Mpa (midpoint),4.5 Mpa (third point)3.8 Mpa (midpoint),4.5 Mpa (third point)} -Compressive

-CompressiveSS_{trength of 24.1 Mtrength of 24.1 M}PP_{a when tested at 14 days.a when tested at 14 days.}

Mixing Concrete Mixing Concrete

y

y In central MixingIn central MixingPPlant: Mixinglant: Mixing TTime shall not less be thanime shall not less be than50 seconds nor more than 90 seconds50 seconds nor more than 90 seconds.. y

y TThe time elapsed the water is added to the mix until the concrete is deposited in place shall not exceedhe time elapsed the water is added to the mix until the concrete is deposited in place shall not exceed

45 minutes 45 minutes..

y

y RetemperingRetempering of concrete is only permitted in concrete delivered in truck mixers, provided that theseof concrete is only permitted in concrete delivered in truck mixers, provided that these

shall be performed within

shall be performed within45 minutes after the initial mixing operation45 minutes after the initial mixing operation and theand thewater cement ratio iswater cement ratio is not exceeded.

not exceeded.

y

y Concrete not in place withinConcrete not in place within 90 minutes90 minutes from the time the ingredients were charged to mixing drum orfrom the time the ingredients were charged to mixing drum or

that has developed initial set shall not be use. that has developed initial set shall not be use.

Placing Concrete Placing Concrete

y

y Vibrators shall not be operated longer thanVibrators shall not be operated longer than15 seconds15 seconds in one location.in one location.

Joints Joints

y

y TTie bars shall not be painted or coated ie bars shall not be painted or coated with asphalt or other material or enclosed in slwith asphalt or other material or enclosed in sl eeve.eeve. y

y TTransverse expansion joint.ransverse expansion joint.FFinished joint shall not deviate more than 6 mm from a straight line.inished joint shall not deviate more than 6 mm from a straight line. y

y TTransverse Contraction Joint shall consist of plane of weakness by cutting grooves in the surface of theransverse Contraction Joint shall consist of plane of weakness by cutting grooves in the surface of the

pavement.

pavement. SS_{awing shall commence as soon as the concrete hardened sufficiently usually within 24awing shall commence as soon as the concrete hardened sufficiently usually within 24} hours.

y

y No transverse joint shall be constructed within 1.5 m of the expansion joint, contraction joint or plane of No transverse joint shall be constructed within 1.5 m of the expansion joint, contraction joint or plane of 

weakness. weakness.

Load Transfer Device Load Transfer Device

y

y TThe sleeve for the dowel shall be metal designed to cover 50 mm plus or minus 5 mm of the dowel.he sleeve for the dowel shall be metal designed to cover 50 mm plus or minus 5 mm of the dowel.

Finishing Finishing

y

y Concrete shall be screeded as soon as placed.Concrete shall be screeded as soon as placed.ScreedScreed shall beshall be 2 ft. longer2 ft. longer than the maximum width of than the maximum width of 

the slab. the slab.

Surface Test Surface Test

y

y AAs soon as the concrete has hardened, thes soon as the concrete has hardened, thepavement surfacepavement surfaceshall be tested using theshall be tested using the3 meter straight3 meter straight

edge.

edge.AA_{reas showing high spot of reas showing high spot of more than 3 mm but not more than 3 mm but not exceeding 12 mmexceeding 12 mm shall be ground down withshall be ground down with} and approved grinding tool. If it

and approved grinding tool. If it exceeds 12 mm, the pavement shall be removed and replaceexceeds 12 mm, the pavement shall be removed and replace..

y

y AAny areas so removed shall be not less ny areas so removed shall be not less than 1.5 m in length and not less than the full wthan 1.5 m in length and not less than the full w idth of the laneidth of the lane

involved. involved.

Removal of Forms Removal of Forms

y

y FForms shall be in place undisturbed for not less thanorms shall be in place undisturbed for not less than 24 hours24 hours after concrete pouring.after concrete pouring.

Acceptance of concrete Acceptance of concrete

y

y SStrength will be considered satisfactory if the average of all sets of trength will be considered satisfactory if the average of all sets of three consecutive test resultsthree consecutive test results equalequal

or exceed the specified strength, and no individual test result is

or exceed the specified strength, and no individual test result is deficient by more than 15deficient by more than 15 of theof the specified strength.

specified strength.

y

y Concrete represented by cores may be considered adequate if theConcrete represented by cores may be considered adequate if theaverage strengthaverage strength is equal to at leastis equal to at least

85

85%%_{of, if of, if no single core is less than 75no single core is less than 75} %%_{of the specified strength.of the specified strength.}

Pavement thickness and tolerance Pavement thickness and tolerance

y

y Completed pavement shall be accepted by lot.Completed pavement shall be accepted by lot.AAlot is equal to 1000 lm lot is equal to 1000 lm (single lane) or 500 lm (two(single lane) or 500 lm (two

lanes) .

lanes) .TT_{he last units in each slab can be considered as he last units in each slab can be considered as lot when its length is at least ½ of lot when its length is at least ½ of the normal lotthe normal lot}

length.---Concrete Pipe Concrete Pipe

1.

1. Non reinforced concrete sewer, storm drain and Non reinforced concrete sewer, storm drain and culvert pipe.culvert pipe. 2.

3.

3. PP_{erforatederforated}PP_ipe.ipe. 4.

4. PP_{orous concrete pipe.orous concrete pipe.}

Sampling and Testing:

Sampling and Testing: 0.5% of the number of pipes each size but not less than two and not to exceed five.0.5% of the number of pipes each size but not less than two and not to exceed five.

Hollow Blocks Hollow Blocks

1.

1. Load Bearing Block-capable of carrying superimposed load, may be exposed to weather.Load Bearing Block-capable of carrying superimposed load, may be exposed to weather.

S

S_{trengthtrength}RR_{equirement:equirement:} Individual: 500 psi (5.45 M

Individual: 500 psi (5.45 MPP_{a) mina) min} A

A_{verage: 600 psi (4.14 Mpa) minverage: 600 psi (4.14 Mpa) min}

2.

2. Non-Load Bearing- not exposed to weather.Non-Load Bearing- not exposed to weather.

S

S_{trengthtrength}RR_{equirement:equirement:} Individual: 800 psi (5.5 M

Individual: 800 psi (5.5 MPP_{a) mina) min} A

A_{verage: 1000 psi (6.9 Mpa) minverage: 1000 psi (6.9 Mpa) min} A

A_{bsorption: 240 kg/m maxbsorption: 240 kg/m max} Moisture Content: 25% max Moisture Content: 25% max

Sampling and Testing

Sampling and Testing: to be submitted for testing: 6 units for each lot of 10,000. 12 units for more than 10,000: to be submitted for testing: 6 units for each lot of 10,000. 12 units for more than 10,000 units. 6 units from 50,000.

units. 6 units from 50,000.

REINFORCIN

REINFORCING G STEELSTEEL- used primarily to control cracking.- used primarily to control cracking. S

S_{ampling: ampling: one one meter meter long long specimen specimen to to present present 10,000 10,000 kg kg of of steel steel bars bars of of each each size.size.} T

T_{esting: esting: maximum maximum phosphorous phosphorous content content of of only only 0.10%.0.10%.}

Tension Test

Tension Test is done by subjecting the specimen with an effective gage length of200 mm tensile stress andis done by subjecting the specimen with an effective gage length of200 mm tensile stress and determining the maximum load that the bar can resist before breaking.

determining the maximum load that the bar can resist before breaking. 60,000 psi (414 Mpa) - Grade 60

60,000 psi (414 Mpa) - Grade 60 40,000 psi (276 Mpa) - Grade 40 40,000 psi (276 Mpa) - Grade 40

Bar Diameter Bar Diameter mm mm Nominal weight Nominal weight K K_g/mg/m 10 0.560 10 0.560 12 0.994 12 0.994 16 1.552 16 1.552 20 2.535 20 2.535 22 3.042 22 3.042 25 3.973 25 3.973 28 4.96 28 4.96 32 6.403 32 6.403 36 7.906 36 7.906 GALVANIZE

GALVANIZED IRON D IRON SHEETS, STEEL SHEETS SHEETS, STEEL SHEETS AND COILSAND COILS

T

T_{est shall be made from one sheet in each 2500 sheets.est shall be made from one sheet in each 2500 sheets.} Coating of Zinc-

1.

1. TT_ripleripleSS_potpotTT_estest 2.

2. SS_ingleingleSS_potpotTT_estest 3.

3. Coating BendCoating BendTT_{est- shall stand bending through 180 at room temperature wiest- shall stand bending through 180 at room temperature wi thout bending.thout bending.}

PAINTS PAINTS

Prime Pigment

Prime Pigment  low refractive index, classified as extenders. low refractive index, classified as extenders. Aluminum Paint

Aluminum Paint- primer for woods- primer for woods Zinc Oxide

Zinc Oxide- readily wetted by oil, tends to thicken t- readily wetted by oil, tends to thicken t he paint and retards the setting of he paint and retards the setting of the pigment.the pigment. White Lead

White Lead- - ability to impart to the paint all the properties necessary to a successful paint pability to impart to the paint all the properties necessary to a successful paint performance.erformance. Colored Pigments

Colored Pigments- iron oxide and red lead.- iron oxide and red lead. Linseed oi

Linseed oil- drying oil.l- drying oil.

Sampling

Sampling- 4 L or 20 L cans for every lot of 100cans of paint- 4 L or 20 L cans for every lot of 100cans of paint

ASPHALT TECHNOLOGY

ASPHALT TECHNOLOGY

Cracks 13 mm (1/2 in) is usually sealed with asphalt mix. If the slab is broken to the point where sealed with asphalt mix. If the slab is broken to the point where it cannot beit cannot be undersealed, it should be further broken into pieces less than 0. 3 m (12 in) in diameter, rolled and sealed. undersealed, it should be further broken into pieces less than 0. 3 m (12 in) in diameter, rolled and sealed.

1.

1. Pavement Condition SurveyPavement Condition Survey- 10 to 20 slabs. Identify type, extent and severity of pavement distress.- 10 to 20 slabs. Identify type, extent and severity of pavement distress. 2.

2. Nondestructive TestingNondestructive Testing- Deflection measurement shall be taken at joints and cracks to determine loss of - Deflection measurement shall be taken at joints and cracks to determine loss of  support exist.

support exist.PP_{erformed usingerformed using NDT deviseNDT devise that deliversthat delivers 8000 to 10000 lb (356 to 445 kN)8000 to 10000 lb (356 to 445 kN) load to theload to the} pavement.

pavement.

R

R_{eflection Cracking- fractures in an overlay or surface that reflects the crack or joint pattern.eflection Cracking- fractures in an overlay or surface that reflects the crack or joint pattern.}

Methods to minimize cracking: Methods to minimize cracking:

1.

1. Design a thicker asphalt overlayDesign a thicker asphalt overlay.- may be used if cracking is less than 9 inches (229 mm)..- may be used if cracking is less than 9 inches (229 mm). 2.

2. Crack and Seal.Crack and Seal.- break and seal. Cracking- break and seal. Cracking PP_{CC into small segments with heavy rollers to eliminateCC into small segments with heavy rollers to eliminate} underlying voids and overlaying with asphalt.

underlying voids and overlaying with asphalt. TT_{he segment is usually 4 to 6 ft2 (0.37-0.56 m2).he segment is usually 4 to 6 ft2 (0.37-0.56 m2).} 3.

3. Crack Relief Layer in OverlaysCrack Relief Layer in Overlays.- It is placed as the first course of an overlay system,.- It is placed as the first course of an overlay system,3.5 in (90 mm)3.5 in (90 mm) layer of layer of  course open graded asphalt containing 25 to 35 interc

course open graded asphalt containing 25 to 35 interc onnecting voids and is made up of 100% crushedonnecting voids and is made up of 100% crushed material.

material. 4.

4. INLAYINGINLAYING- for extensive cracking.- for extensive cracking.TT_{he work consists of removing the damaged pavement and replacing of he work consists of removing the damaged pavement and replacing of}  sub base courses and subgrade if necessary.

sub base courses and subgrade if necessary.

TYP

TYP_ICICAA_{L CL C}RR_OOSSSS SS_ECECTT_{ION OION O}FF_OVEOVERR_LLAYAY WW_IITHTH_CCRARA_CCK RKR_ELIEELIEFF_LLAYAY_EERR 1.

1. ExistingExistingPP_{avementavement} 2.

2. TT_{ack Coat- to ensure sufficient bond.ack Coat- to ensure sufficient bond.} 3.

3. Open GradedOpen GradedHH_{ot Mixot Mix}AA_{sphalt- 3.5 in (88.9 mm)sphalt- 3.5 in (88.9 mm)} 4.

4. Dense graded intermediate Binder or leveling course  for smooth foundation,2 to 4 in (51 -102 mm) thick.Dense graded intermediate Binder or leveling course  for smooth foundation,2 to 4 in (51 -102 mm) thick. 5.

5. Dense GradedDense GradedSS_{urface /urface /}WW_{earing Course - 1.5 in (38 mm)earing Course - 1.5 in (38 mm)}

Open graded aggregate

Open graded aggregate- aggregate with no mineral filler, compacted with relatively large voids.- aggregate with no mineral filler, compacted with relatively large voids.

Materials used for producing

Materials used for producingAA_{sphalt:sphalt:} a.

b.

b. Bituminous Binder.Bituminous Binder.

F

F_ines/ines/FF_{illers- minerals from sound rock, may cillers- minerals from sound rock, may contain cement or lime. It increases stability and quality of ontain cement or lime. It increases stability and quality of}  mixture.

mixture. Mineral

MineralPP_{owder- filler for hot asphalt mixture. It is produced owder- filler for hot asphalt mixture. It is produced by crushing limestone or igneous rock and shallby crushing limestone or igneous rock and shall} contain 1% water and free of agglomerators.

contain 1% water and free of agglomerators.

A

A_{gglomerates are coarse accumulations of large blocks of volcanic material with mass of molten rock(no grain,gglomerates are coarse accumulations of large blocks of volcanic material with mass of molten rock(no grain,} w/c make it extrusive).

w/c make it extrusive).

Different

DifferentTT_{ypes of ypes of} PP_{lant Mixeslant Mixes}

1.

1. Bitumenous Mortars.- fillers, sand, bindersBitumenous Mortars.- fillers, sand, binders 2.

2. Bitumenous Macadams-comprise in addition, one or more sizes of chippings.Bitumenous Macadams-comprise in addition, one or more sizes of chippings. 3.

3. Bitumenous Concrete.-excellent quality.Bitumenous Concrete.-excellent quality.

Binder Content Binder Content Mortar- 6-10% Mortar- 6-10%

Bitumen Macadam- 4-7% (dense), 4-5% (open) Bitumen Macadam- 4-7% (dense), 4-5% (open) Bituminous Concrete-5-8%

Bituminous Concrete-5-8%

P=

P=₍₍WW_{eight of Bitumen/eight of Bitumen/}TT_otalotalWW_{eight of Mix)x 100eight of Mix)x 100}

A.

A. SUBBASE COURSESUBBASE COURSE

y

y CBCBRRnot less than 25%not less than 25% y

y PPI (passing 0.425 ) < 12 , max size under 50 mmI (passing 0.425 ) < 12 , max size under 50 mm

B.

B. BASE COURSEBASE COURSE

y

y Max size of aggregate for GradeMax size of aggregate for GradeAAand B are 50 mm and 37.5 mm respectively.and B are 50 mm and 37.5 mm respectively. y

y PPI<6I<6

PLACING

PLACING- 150mm thickness or less (one layer).- 150mm thickness or less (one layer).WW_{here the required thickness is more than 150 mm, the subhere the required thickness is more than 150 mm, the sub} base/base course shall be spread and compacted in two or more layers of approximately equal layers and the base/base course shall be spread and compacted in two or more layers of approximately equal layers and the compacted thickness of any one layer shall not exceed 150 mm

compacted thickness of any one layer shall not exceed 150 mm..

y

y MARSHALL MIX DESIGNMARSHALL MIX DESIGN--TThe main idea of the Marshall Mix Design method involves the selection of thehe main idea of the Marshall Mix Design method involves the selection of the

asphalt binder content with a suitable density which satisfies minimum stability and range of flow asphalt binder content with a suitable density which satisfies minimum stability and range of flow values.

values.

y

y Optimum Binder ContentOptimum Binder Content- aggregates are fully coated with bitumen and the voids are - aggregates are fully coated with bitumen and the voids are sealed up.sealed up.

y

y Marshall StabilityMarshall Stability is the resistance to plastic flow of cyis the resistance to plastic flow of cy lindrical specimens of a bituminous mixturelindrical specimens of a bituminous mixture

loaded on the lateral surface. loaded on the lateral surface.

y

y Blue smokeBlue smoke indicates overheated asphalt.indicates overheated asphalt. y

y Hard Blown AsphaltHard Blown Asphalt is also known asis also known asOxidized BitumenOxidized Bitumen produced by passing air through soft bitumenproduced by passing air through soft bitumen

under controlled temperature conditions which gives the bitumen more rubbery properties. under controlled temperature conditions which gives the bitumen more rubbery properties.

ITEM 301- BITUMENOUS PRIME COAT

ITEM 301- BITUMENOUS PRIME COAT- (initial treatment on base before surfacing with granular material)- (initial treatment on base before surfacing with granular material) treatment of an aggregate base course in preparation for bituminous surface course.

treatment of an aggregate base course in preparation for bituminous surface course.

1.

1. RAPRAP_{ID CUID CU}RR_{ING (ING (}RR_{C) CUC) CU}TT_BBAA_CCKK ASPHAASPHA_LLTT_{- asphalt cement with low boiling point petroleum distillate such as- asphalt cement with low boiling point petroleum distillate such as} gasoline and naphtha.

2.

2. MEDIUM CUMEDIUM CURR_{ING (MC) CUING (MC) CU}TT_BBAA_CCKK ASPHAASPHA_LLTT_{-with light petroleum distillate such as kerosene.-with light petroleum distillate such as kerosene.}

y

y Do not apply on foggy or rainy weather.Do not apply on foggy or rainy weather. y

y SSprayed by pressure distributor of not less than 1000 liprayed by pressure distributor of not less than 1000 li ters capacity mounted on pneumatic tires w/cters capacity mounted on pneumatic tires w/c

produces load of not more than 1N (100kgf) per

produces load of not more than 1N (100kgf) per cm width of tire.cm width of tire.

y

y RRate of application shallate of application shallbe 1-2 liters / square meterbe 1-2 liters / square meter.. y

y PPrime coat should not be disturbed for at least 24 hours.rime coat should not be disturbed for at least 24 hours. y

y AAreas not accessible shall be sprayed manually.reas not accessible shall be sprayed manually. y

y RRate of application shall beate of application shall be 0.2 to 0.7 liters per square meters0.2 to 0.7 liters per square meters (for manual application)(for manual application)

ITEM 302-BITUMENOUS TACK COAT

ITEM 302-BITUMENOUS TACK COAT-preparation and treatment of bituminous or concrete surface with-preparation and treatment of bituminous or concrete surface with bituminous material in preparation for the construction of bituminous surface course.

bituminous material in preparation for the construction of bituminous surface course.

1.

1. RAPRAP_{ID CUID CU}RR_{ING (ING (}RR_{C) CUC) CU}TT_BBAA_CCKK ASPHAASPHA_LLTT 2.

2. EMULEMULSS_IIFF_IEDIEDASPHAASPHA_LLTT_{-asphalt cement and water with a small quantity of an emulsifying age-asphalt cement and water with a small quantity of an emulsifying age nt.nt.}

y

y (same above)(same above) y

y PPressure distributor should have heating device.ressure distributor should have heating device.

ITEM 310-BITUMENOUS CONCRETE SURFACE COURSE, HOT

ITEM 310-BITUMENOUS CONCRETE SURFACE COURSE, HOT LAIDLAID- laid on a prepared base.- laid on a prepared base.

T

T_{olerances for the job mix formula:olerances for the job mix formula:}

y

y PPassing assing No. No. 4 4 and and large large sieves sieves +-7%+-7% y

y PPassing Noassing No. 8 . 8 to to No. 100 No. 100 sieves sieves +-4%+-4% y

y PPassing assing No. No. 200 200 sieve sieve +-2%+-2% y

y Bituminous Bituminous Material Material +-0.4%+-0.4% y

y TTemperature emperature of of mixture mixture +-10 +-10 degrees degrees CelsiusCelsius

New job mix formula shall comply with the ff. requirements New job mix formula shall comply with the ff. requirements

y

y Minimum dry compressive strength -1.4 MMinimum dry compressive strength -1.4 MPPa (200 psi)a (200 psi) y

y Mass % Voids  5-7%Mass % Voids  5-7% y

y Index of Index of RRetainedetainedSStrength- not less than 70.trength- not less than 70.

Accepting, Sampling and Testing Accepting, Sampling and Testing

y

y Core drill,Core drill,150 x150 100 mm150 x150 100 mm diameter full depth.diameter full depth.AAt least one but not more than 3 samplest least one but not more than 3 samples

taken each day or operation. taken each day or operation.

y

y 9090%%or greater of the Laboratoryor greater of the LaboratorySSpecimen --pecimen --DensityDensity of the compacted pavement.of the compacted pavement. y

y Variation of the pavement surface (from the contract) Variation of the pavement surface (from the contract) shall not exceedshall not exceed6 mm6 mm. (measured using 3. (measured using 3

m straight edge after the initial compaction). m straight edge after the initial compaction).

y

y PPlacing temperature for the mixture should not be less thanlacing temperature for the mixture should not be less than 107 degrees Celsius107 degrees Celsius (225 deg(225 degFF))

PHASES OF ROLLING PHASES OF ROLLING 1.

1. BreakdownBreakdownRR_{olling- carried out by steel wheeled rollers and mix should be 200-225olling- carried out by steel wheeled rollers and mix should be 200-225}FF_.. 2.

2. IntermediateIntermediateRR_{olling- Carried out byolling- Carried out by}PP_{neumaticneumatic}RR_oller.oller. 3.