INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-1

INTRODUCTION

1.1 GENERAL 4-5

CHAPTER-2

LITERATURE REVIEW 6-9

CHAPTER-3

OBJECTIVES 10

CHAPTER-4

REQUIREMENT 11

CHAPTER-5

METHADOLOGY 12

CHAPTER-6

PRECAST PAVEMENT REPAIRS

PRECAST CONCRETE PAVEMENT REPAIRS 13

INTERMEDIATE REPAIRS 13

CONTINIOUS APPLICATION 14

CHAPTER-7

COMPARISION

7.1 COMPARISION OF PRECAST PANEL PAVEMENT WITH OTHER 16

7.3 PRECAST PANEL INSTALLATION TIME 17

CHAPTER-8 PG NO

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

BENEFITS OF PRECASTE CONCRETE PAVEMENT SYSTEMS

BETTER QUALITY CONCRETE AND CURING CONDITIONS 18

SPEED OF CONSTRUCTION 18

DURABILITY OR LONGTERM SOLUTION 18

SAFETY 18

SUSTAINABILITY 19

CHAPTER -9

BARRIERS TO PRECAST CONSTRUCTION IN INDIA 20

INVESTMENT 20

SPACE AVAILABILITY 20

TAXATION 20

TRANSPORTION 20

INFRASTRUCTURE 21

STANDARDIZATION 21

JOINTS & CONNECTIONS 21

CHAPTER-10

CASE STUDY 22-23

CHAPTER-11

CONCLUSION 24

REFERENCES 25

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

LIST OF FIGURES

FIGURE
TITLE OF FIGURE PG NO
NO

1.1 INSTALLATION OF PRESTRESS CONCRETE 4

LENGTH WISE DIFFERENT TYPES OF ROADS IN

1.2 5
INDIA

PERCENTAGE OF CONCRETE ROADS IN MAJOR

1.3 5
CITIES

2.1 PREPARING PRECASTE PAVEMENT 6

2.2 REECTION OF PRECASTE PAVEMENT 7

2.3 JOINTS OF PRECASTE PAVEMENT 8

2.4 PRECASTE SLABS 9

6.1 INTERMEDIATE REPAIR 13

6.2 CONTINIOUS APPLICATION 15

6.3 SCHEMATIC REPRESENTATION OF JOINT 15

10.1 PRECASTE PAVEMENT 22

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-1

INTRODUCTION

1.1 GENERAL

After 2014, the speed of the construction of cement concrete road for national highways and
expressways, in cities and even at village level has significantly increased due to the policy
adopted by the Government of India. India has a road network of more than 5.6 million
kilometre, comprising of a mix of modern and narrow national highways, besides expressways,
state highways, project roads, urban roads, rural roads, including unpaved roads.

Figure 1 shows the length-wise percentage of different type of roads in India as on March 2016.
About 2 percent of the total road length in our country is made up of cement concrete. The
share of cement concrete road in total road length in India will be increasing at a faster rate as
the construction of cement concrete road is being encouraged by the GOI due to numerous
technical added advantages such as a longer service life with a little to no maintenance cost for
the first 10 years or so, etc. As per a report, in 2018-19, about 5000 km of cement concrete road
has to be constructed for national highways alone. Figure presents a comparative share of
concrete pavement in total motor- able roads in India with respect to a few most developed
countries in the world.

FIG 1.1 INSTALLATION OF PRESTRESS CONCRETE

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

The Durability of road structures depends on the quality of its maintenance & minor
renovations. Maintenance keeps the roadway safe, provides good driving conditions &
prolongs the life of the pavement, thus protecting the road investment. Currently in India more
than 2000 km of concrete road is in the operation since last few years. Most of the projects
completed by NHAI, MSRDC and other state government authorities. Though the quality &
procedural aspects, specifications / guidelines clearly mentions in IRC, MORTH, but still we
observes that various minor cracks, potholes and joints edge spalling in the PQC due to various
factors which requires maintenance. Maintenance includes the prompt sealing of cracks &
filling of potholes to prevent water entering through the surface.

FIG 1.2 LENGTH WISE DIFFERENT TYPE OF ROADS IN INDIA

FIG 1.3 PERCENTAGE OF CONCRETE ROADS IN MAJOR COUNTRIES

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-2

LITERATURE REVIEW

Prof. Komal D. Dagwal “Review on use of precast panels for the important
of pavements” By international research of journal of engineering and technology,
volume 07issue 04, April 2022

ABSTRACT

• This report reviewed published literature on application of precast element in various

forms and systems and found that precast concrete elements have had limited
application in flexible pavements, specially to the layered pavement system.

• The review of application of precast concrete element and past experiences of an

analytical study of precast slab system concluded that available analysis and design
methodologies can be adopted for the improvement of various other types of pavements

CONCLUSION

• On basis of evaluation of different types of pavements, Pre-cast concrete panels were

determined to be the most practical type of pavement to apply for pavement
construction.

• Precast panel effectively reduces thickness of the pavement and improves the durability
of the pavement, which is particularly important for handling operations.

FIG 2.1 PREPARING PRECAST PAVEMENT

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

Shiraz Tayabji, Dan Ye, and Neeraj Buch “Precast concrete pavements:
Technology overview and technical considerations” Article in Pci international
journal December 2013.

ABSTRACT

• This paper summarizes the results of a study aimed at developing the necessary
information and guidelines to encourage the successful adoption of this new
technology.

• This paper presents a summary of the work performed under the study and reports on
potential refinements to the precast concrete technology.

CONCLUSION

• This paper addresses some technical considerations related to the design of precast
concrete pavements. The load transfer provision at transverse joints and the support
condition under the precast concrete panels are two critical design features and must be
properly addressed for any precast concrete pavement.

• The precast concrete pavement technology for durable, rapid repair and rehabilitation
of existing pavements and will help reduce the cost of panel fabrication and installation.
FIG 2.2 ERECTION OF PRECAST PAVEMENT

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

Ashutosh Signh, D S Roy “Study and evaluation of precast concrete

pavement” Research article international journal BBDU Lucknow, India, volume 09
issue 03, 2019

ABSTRACT

• This Paper aims at the study on evaluation of precast concrete pavement system. This
paper presents the new system of development in the highway and road construction.
• This time we faces the many problem during the road construction like Long-term
traffic restrictions which is belongs due to conventional cast-in-plane concrete
pavements which have been used this pavement system also have short construction
time, low production costs, long-term durability, low maintenance requirements etc.
COCLUSION

• This paper has examined evolution of precast pavement technology application in

particular in the Soviet Union and more recently in Russia.
• The many aforementioned benefits show why concrete pavement is a sustainable
choice. It can get an even more consistency rating if optimizing materials, design, and
construction.

FIG 2.3 JOINTS OF PRECASTE PAVEMENT

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

Radan Tomek, Msc. Et Msc “Advantages of precaste concrete in highway

infrastructure construction” Creative construction conference 2017, CCC 2017, 19-22
June 2017, Primosten,Croatia.2017

ABSTRACT

• Prefabrication of any structure component off-site during highway construction offers

major time and user cost savings in comparison with the traditional cast-in-place
methods of construction. Precast prestressed road pavements’ technology offers
dramatic increase in durability, It also decreases the construction time and costs.

• Precasting bridge parts and elements offsite is also very beneficial as bridges are
generally among the most expensive objects constructed and also serve as a natural
bottleneck for the traffic flows and so speeding up the construction process is beneficial
again.
CONCLUSIONS

• Higher pace of construction works to answer the need to cut the time of traffic flow
limitation.
• Higher and stable quality due to better controlled production process in the dedicated
facility and the benefits of pre- and post-tensioning.
• Long-term durability thanks to the higher quality material used.
• Less frequent maintenance of the critical parts of the network – highways’ pavements
and bridges.

FIG 2.4 PRECASTE SLABS

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-
10
OBJECTIVES

The main objectives of instant concrete road construction and repair using precast
technology are,

▶ To identify potential preventative maintenance projects along in-service concrete

pavements, and install precast concrete patches.

▶ To investigate the effectiveness and efficiency of precast patches through the

development of maintenance performance guidelines.

▶ To recommend strategies for monitoring the “newly” installed precast patches.

▶ To Produce step-by-step guidelines for the construction of precast concrete patches.

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-
11
REQUIREMENTS

Requirements of the product for repairs of concrete surface,

These are all the main requirements of the product for repairs of concrete surface,
1) Resistant to abrasion and weather conditions.

2) Skid resistance, non-reflective finish with colour matching with concrete.

3) Fast setting so that repaired patch can accept traffic in as little as one hour.

4) Resistance to deicing chemicals & various industrial chemicals.

5) Jet fuel and other fuel resistance like petrol, diesel, oil and grease.

6) Good bond between concrete and steel, Impermeable.

7) Flexible enough to accommodate anticipated expansion and contraction.

8) Ultra-violet Resistance, User friendly and pain table.

9) Manufacturer of the material should have the good track record & experience in such kind
of repair products.

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-
12
METHODOLOGY

The below flow chart shows the methodology of instant concrete road construction and
repair using precast technology.

Methodology

Research stages Activities

Internet and
Mapping of Literatuerereview
available repair
Interviews with
experts

Selection of
Based on short work
repair technique
window, avoid traffic
congestion and long
lasting pavement

Evaluation of Three
case studies of Focussing on
precast technology speed, performance
and cost

Recommendations
for future work

FIG 5.1 METHODOLOGY OF INSTANT CONCRETE ROAD CONSTRUCTION AND

REPAIR USING PRECAST TECHNOLOGY.

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-6
PRECAST PAVEMENT REPAIRS

PRECAST CONCRETE PAVEMENT REPAIRS

The precast concrete pavement repairs can be divided into two categories.

1. Intermittent repair of concrete pavement

2. Continuous applications

Intermittent repair of concrete pavement

Isolated pavement repairs are conducted using precast concrete panels under this approach. The
intermittent repairs can be divided into two possible approaches
• Full-depth repairs (FDRs) are used to repair deteriorated joints or cracking. This repair
technique can also be used to repair punch-outs and deteriorated cracks in continuously
reinforced concrete pavements (CRCP) full- panel replacement.
• Full-panel replacement are used to replace cracked slab panels.
Key features required for intermittent repair applications to ensure that the adequate load
transfer between panels, proper installation of panels and base support under the panels must
be achieved are listed below. The variation of intermittent repair techniques is illustrated in
Figure.

FIG 6.1 INTERMEDIATE REPAIR

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• Provide uniform support condition under the precast panels

• Ensure a load transfer at transverse joints
• Level the elevation differences between the panel and the existing pavement • Ensure
long-term performance of the repair

a) With slots of dowel bars cut in existing b) Dowel bars positioned in

pavement existing pavement

Continuous application
This approach includes full-scale project-level rehabilitation (reconstruction or overlay
application) of asphalt and concrete pavements using precast concrete panels. For continuous
applications two types of system have been used in the United States

1. Jointed precast concrete pavement (JPCP) systems:

a. Reinforced concrete panels.
b. Prestressed (pre-tensioned) concrete panels.
2. Precast post-tensioned concrete pavement systems (PPCP)
Jointed precast concrete pavement (JPCP) system
JPCP is designed so that the precast panel expands or contracts at joints. In JPCP, the transverse
joint load transfer between the precast panels or the precast panels and the existing pavement
is achieved by providing standard load transfer dowels. The width of the JPCP panel is one
lane wide (typically 3.6 m) and the length is 4.8 m or less dependent on the type of application.

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FIG 6.2 CONTINIOUS APPLICATION

`The structural design of JPCP (design of panel size, load transfer system, transverse joint
spacing) is the same that of jointed cast in place concrete pavements; therefore, the designs can
be performed confidently across the world. The key design and construction element in jointed
precast concrete pavement is presented in Figure. The four basic requirements of jointed
precast concrete pavement are:

• Adjust the panels to the grade

• Install bedding material to support panels uniformly.
• Establish effective load transfer between panels
• Provide a geometrically correct pavement surface (by grinding, using non planar panels
or other means).

FIG 6.3 SCHEMATIC REPRESENTATION OF JOINT

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CHAPTER-7

COMPARISION

COMPARISION OF PRECAST PANEL PAVEMENT WITH OTHER

MATERIALS

As opposed to precast, site cast, sometimes known as in-situ concrete, is poured, moulded and
cured on site. Like precast concrete, on site concrete is formed in a mould and then lifted in
place. However, one of its advantages over precast slabs is that it does not need to be moved
far to be lifted into place

TABLE 7.1 COMPARISION OF PRECASTE PANEL CONCRETE WITH OTHER

POPULAR METHODS

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PRECASTE PANEL INSTALLATION TIME

For a partially precast slab construction, 10 workers are required for 10 days for placing precast
slab panels, which include lifting, and fixing of slab joints in 14 hrs working time

TABLE 7.2 PRECASTE PANEL INSTALLATION TIME

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CHAPTER-8

BENEFITS OF PRECAST CONCRETE PAVEMENT SYSTEMS

Better-quality concrete and curing conditions

The problem related to concrete delivery on construction sites and flooring equipment
operations, including poor concrete quality, concrete consolidation and concrete surface
finishing, are eliminated. One main advantage of precast technology is that curing of the precast
panels takes place under controlled environmental conditions at the plant. Another one is that
they are installed on the construction site during night time and ready to be opened to the traffic
the next morning, which help to reduce the delay before opening to traffic.

Speed of construction
Precast concrete pavement has the potential of rapid construction or, more importantly, the fast
opening of the pavement to traffic. The rapid-setting concrete paving mixtures require 2 to 4
hours for curing. The short closure time reduces the construction activities on-site and prevents
the congestion of traffic.

Durability or long term solution

The primary consideration of choosing PCPS is the longevity or durability of precast concrete
pavement. Precast pavement panels require little, if any, additional on-site curing time since
they are cast off-site, fully cured and ready for use upon arrival. The precast concrete pavement
also helps to ensure the uniformity of the concrete mixture because the mixtures are transported
only for a short distance between batch plant and forms. The precast concrete panels can be
reinforced or prestressed. Prestressed concrete pavement systems are the attractive solution of
long-term service life performance, i.e., 30 to 40 years service life. But for short term
performance, other solutions are more cost-effective.

Safety
The essential advantage in the work zone of precast concrete pavement is safety. The
constructions can be completed during short time closures if the construction is restricted to
non-peak travel times. The safety of pavement users and construction workers is improved by
reducing the frequency and duration of the work.

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Sustainability
Precast concrete pavement systems are acknowledged to be a sustainable solution. They are
helpful to reduce associated pollution and traffic congestion during construction. PCPS is fast
to install, and these products are designed for long-term performance, reducing annual energy
consumptions. Precast fabrication plants produce quality concrete mixtures with low water-to
cementitious materials ratio and a high level of uniformity.

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CHAPTER-9

BARRIERS TO PRECAST CONSTRUCTION IN INDIA

There are various barriers for using precast technology in India based on literature study
which are as follows
Investment
The initial investments are very high for setting up a precast construction plant near or at site.
This method of construction requires big players of construction industry to participate and
encourage the application of precast construction technology. As this construction technology
requires a high initial investment therefore it’s difficult to apply this method to smaller scale
project. The government should provide additional benefits for setting up a precast construction
yard.

Space Availability
The initial investments are very high for setting up a precast construction plant near or at site.
This method of construction requires big players of construction industry to participate and
encourage the application of precast construction technology. As this construction technology
requires a high initial investment therefore it’s difficult to apply this method to smaller scale
project. The government should provide additional benefits for setting up a precast construction
yard.

Taxation
The taxation system in Indian applies 18% GST to the rate which further increases the overall
cost of construction. The transportation of precast components from other state requires to pay
an additional tax, which increase the overall cost of project. The government can provide an
additional subsidy to encourage the application of this method
Transportation
The sizes of individual precast components depends on availability of transportation vehicles.
The components must reach on its scheduled time and also without getting any damage. The
damage may affect the strength of structure or the process of assembling.

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Infrastructure
Maximum load-carrying capacity of bridges and pavements also affects the module size of the
precast components. The vertical and horizontal clearance of roads, bridges and underpass are
also required to be checked before finalization of the components.

Standardization
There is a lack of standardization, codes, and certification by BIS to check the quality of
manufacturing. The erection of precast elements also needs to be verified with some standards
to ensure the quality of construction.

Joints & Connections

The issues with joints and connections lead to the problem of leakage, seepage. This is because
the IS codes and standards on precast concrete does not have sufficient guidelines to improve
the water tightness of structure at the junctions.

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-10

CASE STUDY

BENGALURU: BBMP Deploys Prefabricated Concrete Slabs To Reduce Time For White
Topping Roads To Just 5 Days Per Km

FIG 10.1 PRECASTE PAVEMENT

• The Bruhat Bengaluru Mahanagara Palike (BBMP) launched what it termed as 'rapid
road technology' utilizing precast concrete slabs to a white-top a 500-metre stretch at
Binnamangala junction, where 100 Feet Road and Old Madras Road meet.

• Some of the key roads that are planned to be white-topped include the Outer Ring Road
(ORR) from Silk Board to KR Puram, Kammanahalli Main Road, Ulsoor Lake Road,
Indiranagar Double Road, and Inner Ring Road at Yeshwanthpur, among others.

• Under the first two phases of the project, around 143 km of roads in the city have been
white-topped(or almost nearing completion).

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• In the current scheme of things, the BBMP takes around 26 to 28 days to white-top a
road. This includes milling, levelling, providing bituminous concrete in the addition to
the 21 days of curing period. Under the new experimental technology it is deploying,
the concrete slabs are brought to the site and placed on the road using cranes.

• According to BBMP officials, the new method helps in white-topping half a kilometer
of road in a day. The entire project can be completed in five days including one or two
days for preparatory work like milling and levelling, before placing the concrete slabs.

• While the conventional white topping of 1 km of road typically costs Rs 7.5 crore, under
the new method, it is higher at Rs 9.3 crore. The higher cost is because of transportation
of the precast from the plant to the construction site

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INSTANT CONCRETE ROAD CONSTRUCTION USING PRECAST CONCRET TECHNOLOGY

CHAPTER-11

CONCLUSION

The following are the conclusions of instant concrete road construction and repair using
precast concrete technology,

 The application of Precast Construction technology is very effective and efficient in

terms of executing large scale construction projects like housing, commercial,
institutional buildings etc.
 It is also very efficient with respect to saving time, requirement of manpower, providing
better construction quality, less wastage of materials, flexible in executing all sets of
design requirements like façade, repetitive module blocks.
 The initial investment for establishing a precast yard in very high but it also provides
the benefit of speedy construction which can contributes towards mitigating delays in
large scale construction projects.
 All these advantages can only be achieved with the help of adequate planning and
designing.

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REFERENCES

1. Prof. Komal D. Dagwal “Review on use of precast panels for the important of
pavements” By international research of journal of engineering and technology,
volume 07 issue 04, April 202
2. Shiraz Tayabji, Dan Ye, and Neeraj Buch “Precast concrete pavements: Technology
overview and technical considerations” Article in Pci international journal December
2013.
3. Ashutosh Signh, D S Roy “Study and evaluation of precast concrete pavement”
Research article international journal BBDU Lucknow, India, volume 09 issue 03,
2019
4. Radan Tomek, Msc. Et Msc “Advantages of precaste concrete in highway
infrastructure construction” Creative construction conference 2017, CCC 2017, 19-22
June 2017, Primosten, Croatia.2017

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