• Survey & Marking: Establish the road alignment and levels as per drawings
• Subgrade Preparation:
  • - Excavate and compact the soil
  • - Perform plate load test as per IS 1888 to check soil strength
  • - Achieve minimum 97% compaction of MDD as per IS 2720
• Sub-base Layer (if required):
  • - Place a granular sub-base (GSB) layer as per IS 2720
  • - Compact using rollers to achieve required density
  • - Check levels and crossfall (2-2.5%)
• Material Preparation:
  • - Test cement, aggregates, and water as per IS standards
  • - Store materials safely at designated locations
  • - Prepare reinforcement if required by design

• Subgrade Preparation:
  • - Excavate to the desired depth (typically 450-600mm below finished road level)
  • - Remove all organic material, debris, and unsuitable soil
  • - Proof-roll the subgrade to identify soft spots; remove and replace with suitable material
  • - Compact the subgrade to minimum 97% of Modified Proctor Density (MDD) as per IS 2720
  • - Conduct field density tests every 500 sq.m to verify compaction
  • - Check levels at 10m intervals to ensure proper gradient (transverse slope 2-2.5%)
• Sub-base Layer:
  • - Place granular sub-base (GSB) material in layers not exceeding 150mm thickness
  • - Ensure proper moisture content (OMC ±2%) for optimum compaction
  • - Compact each layer using vibratory rollers (minimum 8-10 ton capacity)
  • - Ensure minimum compaction of 98% MDD as per IS 2720
  • - Verify levels and camber (2-2.5%) using appropriate instruments
  • - Conduct plate load tests to check the bearing capacity (min. CBR value as per design)
• Drainage Provisions:
  • - Install side drains as per design specifications
  • - Create proper outlets for water discharge
  • - Ensure longitudinal slope of at least 1 in 500 for effective drainage
  • - Install culverts at required locations as per drainage plan
  • - Check functionality of drainage system before proceeding with concrete work

• Formwork Placement:
  • - Install formwork along road edges ensuring proper alignment
  • - Set forms to correct levels using surveying instruments
  • - Secure forms firmly using steel pins/stakes at 1m intervals
  • - Apply releasing agent to prevent concrete adhesion
  • - Verify formwork stability and dimension accuracy
• Reinforcement (if required):
  • - Place reinforcement bars/mesh as per structural drawings
  • - Use 8mm-10mm diameter bars with spacing as per design (typically 150-200mm c/c)
  • - Ensure proper cover using spacer blocks (minimum 50mm from bottom)
  • - Check for proper binding and overlaps (minimum 50D or as specified)
  • - Install dowel bars at expansion joints if required by design
• Concrete Mix Preparation:
  • - Use minimum M30 grade concrete as per IS 456:2000
  • - Follow approved mix design with proper proportioning
  • - Maximum water-cement ratio: 0.45
  • - Use mechanical mixers or ready-mix concrete from approved plants
  • - Test slump at batching point and placement location (target: 75-100mm)
• Concrete Pouring:
  • - Pour concrete evenly, ensuring no segregation
  • - Maximum pouring height: 1.5m to prevent segregation
  • - Pour in panels as per planned construction joints
  • - Complete each panel in one continuous operation
  • - Maintain consistent supply of concrete to avoid cold joints
• Vibration & Compaction:
  • - Use vibratory screeds for surface compaction
  • - Use needle vibrators at 500mm intervals for internal compaction
  • - Insert vibrator vertically at close intervals (300-600mm)
  • - Maintain vibration duration of 15-30 seconds per point
  • - Ensure a dense, uniform surface without honeycombing
• Finishing:
  • - Use a bull float immediately after screeding
  • - Wait for bleed water to evaporate before further finishing
  • - Use wood floats followed by steel trowels for smoother finish
  • - Create required texture (broom finish for skid resistance)
  • - Check surface regularity with 3m straight edge (max deviation 3mm)

• Initial Curing:
  • - Apply curing compound or cover with wet burlap immediately after finishing
  • - Protect concrete from rain, wind, and direct sunlight
  • - Avoid any traffic for first 24 hours
• Main Curing Process:
  • - Cover with hessian cloth and sprinkle water for at least 14 days
  • - Maintain moisture consistently (never let concrete dry)
  • - Use curing compounds if water curing is not feasible
  • - Minimum curing period: 14 days for OPC, 21 days for PPC/PSC
• Contraction Joints:
  • - Create joints within 24 hours using concrete saw (1/4 depth of slab)
  • - Typical spacing: 4.5m to 5m as per IRC:58
  • - Follow specified joint pattern from drawings
• Expansion Joints:
  • - Provide expansion joints at regular intervals as per IS 6509
  • - Install dowel bars coated with bond-breaker if required
  • - Maintain 20-25mm gap filled with bitumen/filler board
• Joint Sealing:
  • - Clean joints thoroughly before applying sealant
  • - Fill joints with appropriate sealant material (polysulphide/polyurethane)
  • - Ensure sealant is flush with surface or slightly recessed

• Surface Inspection:
  • - Check for cracks, honeycombing, or surface defects
  • - Verify surface regularity using 3m straight edge (max 3mm deviation)
  • - Ensure proper camber and cross slopes for drainage
• Strength Testing:
  • - Test concrete cubes at 7 and 28 days
  • - Conduct core tests if required
  • - Verify achievement of design strength (min. M30 grade)
• Joint Inspection:
  • - Check all joints for proper execution and sealing
  • - Verify joint width and depth as per specifications
  • - Ensure no unsealed joints remain
• Drainage Check:
  • - Conduct water test to verify proper drainage
  • - Ensure no water ponding on finished surface
  • - Verify side drains functionality
• Road Opening:
  • - Allow vehicle traffic only after achieving 80% of design strength
  • - Typically after 14-21 days depending on cement type
  • - Install any required signage or road markings

Problem: Fine cracks appearing on surface during setting.

Solution: Apply fog spray/evaporation retarder, use windbreaks, schedule pours during cooler times, and begin curing immediately after finishing. Consider adding polypropylene fibers to the mix.

Problem: Flaking or peeling of surface.

Solution: Ensure proper air entrainment, avoid excess water in the mix, use proper finishing techniques (no finishing while bleed water is present), and provide adequate curing period with consistent moisture.

Problem: Test cubes failing to meet target strength.

Solution: Check cement quality, verify W/C ratio, ensure proper gradation of aggregates, improve mixing time/technique, and verify curing conditions. If detected early, consider longer curing; if structural, conduct core tests for further evaluation.

Problem: Edge damage along joints.

Solution: Create joints at proper timing, ensure joint sawing depth is correct (1/4 of slab depth), use proper joint filler materials, avoid heavy loads on new pavement, and ensure proper concrete consolidation at joints.