ROAD

CONSTRUCTION
METHODS
 OUTLINE OF PRESENTATION

PART I : OVERVIEW
PART II : PREPARATORY WORK
PART III : EARTHWORK
PART IV : SUBBASE AND BASE COURSES
PART V : SURFACE COURSES
PART VI : DRAINAGE AND SLOPE PROTECTION
STRUCTURE
PART VII : MISCELLANEOUS STRUCTURES
 PART I:
OVERVIEW
 TYPICAL CROSS SECTION

Item 102: Surplus Excavation

Existing ground

Item 300: Gravel Surface

Item 311: PCCP

Item 200: Aggregate

Subbase

Item 104:
Embankment

Item 505: Line canal

Item 505:
Slope
protection
 Main Road Components

 Earthworks (Item 100, Item 102, Item 103,

Item 104 and Item 105)
 Subbase Course (Item 200)
 Surface Courses (Item 310 and Item 311)
 Drainage and Slope Protection Structures
(Item 500, Item 505 and Item 506)
 Miscellaneous Structures (Item 603)
 Subgrade Aggregate Base Course
Aggregate Subbase Course Surface Course
• Subgrade - It is the upper layer of natural soil which may be the
undisturbed local materials, or soil excavated elsewhere placed as fill.
• In either case, it is compacted during construction for road stability.
• Aggregate Subbase Course - They are individual stabilizing layers of
selected material and designed thickness placed on top of the
subgrade to distribute the load transmitted from the surface course.
• Surface Course - It is the uppermost structural component of the
roadway, which provides resistance to wear and shearing stress due
to traffic load.
• It also provides an even skid resistance surface with comfortable
durability and is appropriately crowned to prevent rain water from
penetrating into the subgrade.
• Shoulders - They are located beside the carriage way which is the
total width available for passing vehicles, and is used to receive
lateral clearance to protect major structures on the roadside, to
secure safety and comfort of both motorists and pedestrians and for
emergency stopping purposes.
 Drainage Structures
Slope Protection/Retaining Structures
Miscellaneous Structures

• Drainage Structures - They are located beneath or alongside

the roadway used in collecting, transporting and disposing of
surface water originating in or near the road right-of-way.
• Types of Drainage - It can be lateral drainage such as a U-
shaped, V-shaped lined canal (side ditch) or perforated drain
canal.
• It can also be transverse or cross drainage such as a box culvert
or a pipe culvert.
• Slope Protection Structures - They are constructed along the
side of the roadway to stabilize the slopes.
• Retaining Walls - They are constructed along the side of the
roadway if there are space constrictions.
 PART II:
PREPARATORY WORK
 PREPARATORY WORK

 Pre-construction Conference /Preliminary

Preparations
 As-Staked Survey
 Access and Detour Roads (Traffic
Management)
 Pre-construction Conference

• Pre-construction conference between the

Contractor’s representative on the project and
the Project Engineer and his staff is required.
• A discussion of the project, on the
specifications, unusual conditions,
Contractor’s plan and schedule of operation,
and other pertinent items is helpful to a better
job understanding in the implementation of
the project.
• The site for the project field office should be
determined, as well as the sites for storage of
material and equipment.
 Preliminary Preparations
Before the start of work, the Project Engineer should make sure
that all of the following items applicable to the project are always
on site:

– Complete contract drawings, including any revisions that have

been done
– Cross-sections
– Blue Book and Standard Specifications
– Right-of-Way plans, Entry Agreements
– Plans for adjustments or relocations of any utilities that may be
affected
– Contract Agreement
– Notice to Proceed
– Material Test Equipment
– Material Test Reports
– Project Logbooks (Construction Logbook and Materials Logbook)
– Surveying Equipment and Surveying Notes
– Pertinent Correspondence
 As - Stake Survey

Its Importance :
 It determines the actual position of the road
structure based on the plans.
 It helps in determining what necessary
deviation should be undertaken.
What Plans That Govern an Infra Project

Original Plans
As-Staked Plans
As-Built Plans
 Access and Detour Roads

• In planning the construction work, care

must be taken to see that alternative routes
or temporary deviations are provided for
traffic using the route.

• Access to properties along the road, must

be maintained at all times and the works
must be barricaded where necessary to
protect any passing traffic from accident.
 Detour Roads

• It is necessary to divert traffic from any existing

roadway, whenever the construction operations
block the flow of traffic.

• They are to be maintained, so that they will

have sufficient durability to remain in good
condition and carry the required traffic at any
weather condition for the entire duration that
the detour is required.
 Access Roads

• It a road by which a job is connected to

the highway system and is generally
used in connection with borrow pits.

• They are also built for each isolated

piece of job it services.
Road Construction are classified
into five (5) parts, namely:

PART III Earthworks

PART IV Subbase and Base Courses

PART V Aggregate Surface Course

PART VI Surface Courses
Drainage and Slope Protection
PART VII
Structures
PART VIII Miscellaneous Structures
 PART III:
EARTHWORK
 EARTHWORK
Item 100 Clearing and Grubbing

Item 101 Removal of Structures and Obstructions

Item 102 Excavation

Item 102(1) Unsuitable Excavation

Item 102(2) Surplus Common Excavation

Item 102(3) Surplus Rock Excavation

Item 102(4) Surplus Unclassified Excavation

Item 103 Structure Excavation

Item 104 Embankment

Item 105 Subgrade Preparation

 EARTHWORK
Before the start of work on the different items
of work, a joint survey must be
undertaken/conducted with the contractor to
locate the center line of the proposed road, to
check the existing elevations, cross-sections and
other existing structures as shown on the
Original Plan, and to prepare/submit an “As-
Staked Plan” if there are deviations from the
Original Plan, for approval of the higher
authorities.
Item 100 - Clearing and Grubbing
 General

• Clearing and Grubbing - It is the removal and

disposal of all surface objects including
vegetation, grass, stumps, trees and other
protruding obstructions not designated to
remain along the roadway prior to
commencing of any earth-moving activity.
 Types of Clearing and Grubbing
1. Individual Removal of Trees - Removal of Trees is
classified depending on the size (Diameter at height
of 1.40 m.) :
a. Item 100(3) - Individual Removal of Trees (over
150 mm to 900 mm), Small
b. Item 100(4) - Individual Removal of Trees (over
900 mm), Large

[Link] of Debris - The Contractor should coordinate

with the Project Engineer regarding the
identification of sites for the disposal area, in
compliance with the provisions stated in the
Environmental Clearance Certificate issued by the
Department of Environment and Natural Resources
(DENR).
 Equipment Requirements

• Bulldozer (D6H Series II PSDS/DD)

• Backhoe
• Payloader (1.50 cu.m.)
• Dump Truck (10 cu.m. capacity)
• Road Grader
 Construction Procedures

1. Plans, special provisions and right-of-way

limits must be provided with stakes, as
reference in determining the
vertical/horizontal control.

2. Trees that are selected for preservation

must be protected while trees that are
needed to be cut/ball shall be
identified.
 Construction Procedures
3. After the construction limits are established,
scarify up to a depth of 6 inches (150 mm.)
the existing roadway and segregate the roots,
stumps and other unsuitable materials for
proper disposal.
4. Hauled the excavated materials to the
designated approved disposal area or to the
stockpile of the contractor.
5. Clearing shall extend one (1) meter beyond
the toe of the fill slopes or beyond rounding
of cut slopes for the entire length of the
project.
To be filled up in Const. Logbook
• Item 100 - Clearing & Grubbing, & Individual
Removal of Trees:
(choose any of the following)

Removal and disposal of vegetations/grass,

roots, and other protruding obstructions at
Sta.____ to Sta. ____.
Cutting of Trees at Sta. ____ to Sta. ____.
Stockpiling of Trees
Hauling of Trees (to DENR Depot)
Item 101 - Removal of Structures and
Obstructions
 General

Removal of structures and obstructions - It

consist of the taking away, wholly or in part,
and the satisfactory disposal off the site of all
structures within the construction site and
right-of-way which have not been designated
to remain.
It is important that removal operations are
carefully studied and carried out under the
careful supervision of the Project Engineer
with adequate consideration of safety.
 Types of Obstruction

1. Existing Pavements
2. Existing Drainage Structures
3. Underground Waterline
4. Electrical Post and Lines
5. Cable and Telephone Lines
6. Residential Houses & Buildings
 Equipment Requirements

- Backhoe with Pavement Breaker(0.80 cu.m.)

- Dump Truck (10 cu.m. capacity)
- Chain Saw
- Minor Tools
 Construction Procedures

Simultaneously with the clearing and grubbing

works, removal of obstructions both
overhead and underground utilities in
particular waterlines and telephone lines
shall be undertaken.
 Construction Procedures

This picture shows the removal of obstruction. Prior to

actual construction work, obstructions are removed in
order not to hamper the work.
To be filled up in Const. Logbook
• Item 101 – Removal of Structures &
Obstructions
(choose any of the following)

Removal (specify what structure) at Sta. ____

Item 102 - Excavation
 General

Excavation - consists of all the excavation for

grading and draining the roadway. It also
includes loading, hauling and placing the
excavated materials from roadway cuts to
construct embankments or its disposal to a
designated location.
 Types of Excavation

1. Common Excavation
2. Surplus Unsuitable Excavation
3. Surplus Rock Excavation
4. Surplus Unclassified Excavation
5. Surplus Excavation
 Equipment Requirements

- Bulldozer (D6H Series II PSDS/DD)

- Backhoe (0.80 cu.m.)
- Dump Truck (10.00 cu.m. capacity)
- Payloader (1.50 cu.m.)
- Drilling Machine
- Air Compressor (161-185 cfm)
- Blasting Equipment and Accessories
 Construction Procedures

1. Right-of-way limits must be provided with

stakes.
2. Survey works must be conducted on the
existing ground.
3. Excavate the roadway to the required
elevation per approved plans.
4. If unsuitable materials are encountered,
excavate the roadway up to the stable soil.
5. If surplus materials are encountered, haul
the said materials to the designated
approved disposal area.
The above picture shows that before starting excavating for any part
of the structure, it must be ascertained that sufficient ground levels
have been taken for computing excavation quantities, and the proper
alignment points are provided for laying out the work.
Item 102(1) - Unsuitable Excavation
 General

Unsuitable Excavation - It is the removal and

disposal of saturated mixture of soils and
organic matter such as peat and muck which
are not suitable for road foundation materials
which can cause instability in embankments.
 General

As a rough guide in recognizing and

identifying unsuitable materials, said
materials is composed of thoroughly
decomposed organic material with
considerable mineral material, usually black
with a few fibrous remains, odorous when
dried or burnt, some sand and silt and those
materials excavated from swamps and
stagnant water. In order to determine the
exact property of the unsuitable materials,
subject a representative sample to laboratory
test.
 Equipment Requirements

• Payloader (1.50 cu.m.)

• Backhoe (0.80 cu.m.)
• Dump Truck (10.00 cu.m. capacity)
• Minor Tool
 Construction Procedures

[Link] survey works on the existing

ground to compare the data as reflected in
the approved plans.

[Link] the roadway having unsuitable

materials up to the stable soil condition.

[Link]/haul the said unsuitable materials to

the designated/approved disposal area.
Item 102(2) – Surplus Common
Excavation
 General

Surplus Common Excavation – It refers to the

excavation of common materials along the
road traverse that may be placed as fill or
disposed as surplus.
 Equipment Requirements

• Payloader (1.50 cu.m.)

• Backhoe (0.80 cu.m.)
• Dump Truck (10.00 cu.m. capacity)
• Minor Tool
Item 102(3) – Surplus Rock Excavation
 General

Surplus Rock Excavation - It is the digging on

the ground along the road way traverse to
remove encountered rock to its designed
elevation either for use as an embankment or
for hauling to a waste disposal/approved area.

Means of Excavating Rock :

1. Thru Mechanical Ripping - if the rock is soft.
2. Thru Controlled Blasting - if the rock is too
hard.
 Equipment Requirements

- Backhoe (0.80 cu.m.)

- Dump Truck (10.00 cu.m. capacity)
- Payloader (1.50 cu.m.)
- Drilling Machine
- Air Compressor (161-185 cfm)
- Blasting Equipment and Accessories
This is one of the types of Excavation called the Surplus Rock
Excavation. This consists of igneous, sedimentary and
metamorphic rocks which cannot be excavated without
blasting or the use of rippers.
Item 102(4) – Surplus Unclassified
Excavation
 General
Surplus Unclassified Excavation - are suitable
materials excavated along the road traverse
which are disposed as excess in the formation
of embankment sub-grade.

Types of Surplus Excavation :

1. Surplus from Common Excavation
2. Surplus from Rock Excavation
3. Surplus from Unclassified Excavation
 Equipment Requirements

- Bulldozer (D6H Series II PSDS/DD)

- Backhoe (0.80 cu.m.)
- Dump Truck (10.00 cu.m. capacity)
- Payloader (1.50 cu.m.)
To be filled up in Const. Logbook
• Item 102 – Surplus Excavation (Common soil,
Soft Rock, Hard Rock, Unsuitable)
(choose any of the following)

Excavation at Sta. ____ to Sta. ____.

Hauling & disposal of Surplus excavated
materials.
Item 103 - Structure Excavation
 General

Structure Excavation - It consists of the

necessary excavation, removal and
satisfactory disposal of all materials within the
stipulated limits.

Types of Structure Excavation

1. Culvert Excavation
2. Dry Excavation
3. Wet Excavation
4. Rock Excavation
5. Bridge Excavation (Unclassified)
 Equipment Requirements

• Dump Truck (10 cu.m. capacity)

• Backhoe with Breaker (0.80 cu.m.)
• Minor Tools
 Construction Procedures
[Link] to structure excavation, all necessary
clearing and grubbing shall have been
performed.

[Link] and review the plans.

[Link] shall be excavated to the lines and

grades or elevations shown on the Plans.

[Link] foundation surface shall provide a firm

throughout the length of the culvert.
To be filled up in Const. Logbook
• Item 103(1) – Structure excavation
(choose any of the following)

Excavation for (specify what structure) at Sta.

____ to Sta. ____.
Item 104 - Embankment
 General

Embankment - is describe as the work or

volume of earthen material necessary in the
formation of embankment roadway thru the
use of suitable materials which may be
sourced along the road traverse or borrow
from an outside source. These materials are
brought and compacted together to a
specified degree to form a stable
embankment to bring the road to a desired
grade or to elevate it above flood level.
 Types of Embankment

1. Embankment from Excavation

2. Embankment from Borrow
 Equipment Requirements
(A) For Excavation Work :
- Bulldozer (D6H Series II PSDS/DD)
- Payloader (1.50 cu.m.)
- Dump Truck (10.00 cu.m. capacity)

(B) For Spreading and Compaction :

- Motorized Road Grader (140 hp), G710A
- Vibratory Roller (10 m.t.), SD100DC
- Water Truck/Pump (16000 L)
 Construction Procedures
A. Construction of embankment on a relatively
flat terrain:
[Link] sub grade if already completed in
accordance with the plans and specifications
for clearing and grubbing and sub grade
preparation prior to filling of embankment
materials.
[Link] material is spread in relatively thin layer
of 200 mm with appropriate crown/cross
slope to ensure proper draining of surface
water when it rains.
 Construction Procedures
[Link] should be done by rolling with
a minimum weight of 10 tons.
Rolling/compaction operation shall progress
gradually from the sides to the center, parallel
to the center of the road and shall continue
until the whole surface has been rolled up to
the number of passes required based on the
trial section result where a minimum density
of 95% is attained. During the progress of
rolling, a minimum overlapped width of 300
mm. shall be observed for each succeeding
parallel passes to ensure level compacted
surface.
 Construction Procedures
[Link] one group of three in-situ density
tests for each five hundred (500) square meter
or fraction thereof of compacted layer. If it fails
to meet the minimum 95% density, additional
rolling shall be undertaken until such time that
the required compaction is obtained.
For a saturated material wherein the
minimum density could not be attained,
windrowing should be undertaken and allow it to
dry, and proceed with rolling up to the desired
compaction.
If the material is too dry,
watering/sprinkling with water shall be
undertaken uniformly.
Spreading of embankment materials
 What is an FDT ?

FDT is Field Density Test which is

conducted on site in order to determine
if the required compaction specification
has been attained to a specific layer.
 What Do We Mean by Blue Tops?

Blue Tops are painted sticks placed along

the side of the road traverse as guide and
reference in the elevation of the different
layering requirements of the road project
To be filled up in Const. Logbook
• Item 104 – Embankment from Roadway
/Borrow
(choose any of the following)

Hauling & Stockpiling of embankment

materials at Sta. ___ to Sta. ___.
Spreading & compaction of embankment
materials at Sta. ___ to Sta. ___.
Item 105 - Subgrade Preparation
 General
Subgrade - is that portion of the earth
roadbed which after having been constructed
to reasonably close conformance with the
lines, grades and cross-sections indicated on
the plans, receives and supports the sub base
or base course materials.
In a fill section, the sub grade is the top of
the embankment or the fill.
In a cut section, the sub grade is the
bottom of the cut.
 Equipment Requirements

• Motorized Road Grader (140 hp), G710A

• Vibratory Roller (10 m.t.), SD100DC
• Water Truck/Pump (16000 L)
 Construction Procedures
1. Subgrade in Common Excavation :
a. Roadbed shall be cleared of unstable materials.
[Link] shall be done by rolling using vibratory
road roller or tandem roller.
[Link] one group of three in-situ density test for
each 500 square meter or fraction thereof of
compacted layer.
-if it fails to meet the minimum 95 percent density,
additional rolling is needed to obtained the required
density.
[Link] succeeding structural layers should proceed
immediately after preparation of the subgrade.
To be filled up in Const. Logbook
• Item 105 – Subgrade Preparation
(choose any of the following)

Grading & compaction of subgrade at Sta. ___

to Sta. ___.
 PART IV :
SUBBASE AND BASE
COURSES
 SUBBASE AND BASE COURSE

Item 200 Aggregate Subbase Course

Item 201 Aggregate Base Course
Item 200 - Aggregate Subbase Course
 General

Aggregate Subbase Course - refers to the

structural sub-layer material of a roadway
placed directly on top of the sub-grade.
 Equipment Requirements

• Motorized Road Grader (140 hp), G710A

• Vibratory Roller (10 m.t.), SD100DC
• Water Truck/Pump (16000 L)
 Construction Procedures
1. Check the subgrade, if already completed in
accordance with the plans specifications
before proceeding with the laying of sub base
course materials.

2. Provide blue-top of every 20 meters

interval (marked staked) for vertical control
reference, to be placed along the side of the
roadway.
 Construction Procedures

[Link] and spreading of aggregate sub base

materials shall be done using road grader on a
prepared subgrade in a quantity which will
provide the required compacted thickness.

Appropriate crown/cross slope should be

maintained during laying/spreading operation
to ensure proper draining when rains occur.
No laying/spreading operation should be done
when it is rain; or when base is too saturated.
 Construction Procedures
4. Compaction should be done using a vibratory road
roller or tandem roller with a minimum weight of 10
tons. A maximum compacted thickness for any layer
shall not exceed 150 mm. No rolling / compaction
operation should be done when it is raining or when
the laid sub base course is fully saturated with rain.

Rolling/compaction shall progress gradually from

the sides to the center, parallel to the center of the
road and shall continue until the whole surface has
been rolled up to the number of passes required
based on the trial section result where 100%
compaction is attained. Progress rolling should
provide 300 mm. overlap of the width of the wheel
for each succeeding parallel passes to ensure level
compacted surface.
 Construction Procedures
5. Conduct Field Density Test (FDT) for each
compacted layer. If failed to satisfy the Field
Density requirements of at least 100% of the
maximum dry density, additional rolling shall
be undertaken until such time that the
required compaction is attained.

Check the allowable tolerance prior to the

start of the succeeding layer. Allowable
tolerance is plus or minus 20 mm.
This presents that the subbase/base materials
should be spread to the required thickness for
compaction
 Spreading

The subbase/base materials shall be spread to the

required thickness for compaction.
If the required thickness is 200 mm or less, the
material may be spread and compacted in one layer.
 Compaction

Each layer shall be compacted to the full width.

Required degree of compaction is 100%
To be filled up in Const. Logbook
• Item 200 – Aggregate Subbase Course
(choose any of the following)

Hauling & Stockpiling of aggregate subbase

materials at Sta. ___ to Sta. ___.
Spreading & compaction of aggregate subbase
materials at Sta. ___ to Sta. ___.
 PART V :
SURFACE COURSES
 SURFACE COURSES

Item 300 Aggregate Surface Course

Item 301 Bituminous Prime Coat

Item 302 Bituminous Tack Coat

Bituminous Concrete Surface
Item 310
Course, Hot Laid
 Item 300 -
Aggregate Surface Course
 General

Aggregate Surface Course - is one of the

predominantly granular materials that are
placed on the natural soil to serve as a
wearing course or a abase for a relatively thin
flexible surface. This type of pavement
sometime referred to as the low cost road.

It is made of granular base materials that is

dense-graded but has strict limits on the
amount of fine sand to increase strength and
allow drainage.
 Equipment Requirements

• Pneumatic Tire Roller (10 m.t.)

• Tandem Steel Roller (10.1 m.t.), CC421
• Tamping Roller
• Vibratory Roller (10 m.t.), SD100DC
• Water Truck/Pump (16000 L)
• Motorized Road Grader (140 hp), G710A
 Construction Procedures

1. Check the delivery of the material to the

project site if it conforms to the required
specifications prior to its stockpiling and
depositing at the road bed.
2. Identify a trial section in order to attain
data regarding the efficiency of the
tamping/tandem and vibratory roller and road
grader.
3. Stockpile the aggregate materials beside
the proposed roadway.
 Construction Procedures
4. Push the aggregate materials stockpiled on
the sides of the proposed roadway using
motorized road grader.
5. Immediately conduct survey works to check
compliance to the required elevation and
alignment.
6. Conduct FDT (Field Density Test) on the
finished surface course to determine
compliance to the required denseness and
thickness prior to placing subsequent courses
or surface construction.
To be filled up in Const. Logbook
• Item 200 – Aggregate Subbase Course
(choose any of the following)
Hauling & Stockpiling of aggregate subbase
materials at Sta. ___ to Sta. ___.
Spreading & compaction of aggregate subbase
materials at Sta. ___ to Sta. ___.
 Item 311 -
Portland Cement Concrete Pavement
 General

Portland Cement Concrete Pavement

(PCCP) - is constructed by casting in place,
on a prepared foundation, a concrete slab
with the top finished to provide a smooth
and durable wearing surface for traffic.

Portland Cement Concrete Pavement

is one of the two basic types of pavement
which is also called “rigid pavement”.
Material Requirements

1. Portland Cement
2. Fine Aggregate
3. Coarse Aggregate
4. Water
 Equipment Requirements

• Concrete Vibrator (2”, 50mm)

• Concrete Saw (7.5 hp), 14 “ Blade Dia.
• Concrete Paver
• Concrete Screeder
• Water Truck/Pump (16000 L)
• Transit Mixer (5 cu.m.)
• Payloader (1.50 cu.m.), LX80-2C
• Concrete Batch Plant (30 cu.m.)
• Bar Cutter, Single Phase
 Construction Procedures
1. Before concreting operation start
considering that the road foundation are
properly prepared, check over the job to
determine the adequacy of the following
details:
a. Condition of sub-base or base
b. Working condition of major
equipment
c. Number of types of hand tools and
finishing tools.
d. Provision of curing.
e. Number of crews to place, finish
and cure the concrete.
 Construction Procedures

2. Check the Setting of Forms:

a. It should be of steel, of an approved
section
b. Check the base of the form
c. Steel forms should be installed firmly
d. Steel forms shall be rigidly supported
on bed
e. Steel forms shall be provided with
adequate devices for secure setting
 Construction Procedures

3. Placing of Steel Reinforcement:

a. Deformed Tie Bars shall not be painted
or coated
b. Provide Dowel Bars as required at all
contraction joints
 Construction Procedures

4. Handling, Measuring and Batching

Materials:
a. Check the batching plant site,
equipment, and provisions for
transporting materials.
 Construction Procedures

5. Placing of Concrete:

a. Concrete shall be unloaded into an

approved spreading device.

b. Workers are not allowed to walk on

the freshly concrete.

c. Placing should be continuous.

 Construction Procedures

d. Test Specimen - at least one (1) set

consisting of three (3) concrete beam
test specimens, 150 mm x 525 mm or
900 mm shall be taken from each 330 sq.
m. of pavement, 230 mm depth, fraction
thereof each day.
 Construction Procedures

e. Using of Concrete Vibrator - Concrete

should be thoroughly consolidated along
faces of all steel forms
 Construction Procedures

Concrete Vibrators shall not be

operated longer than fifteen (15) seconds in
any single location.
 Construction Procedures

6. Screeding :
a. Screeder is used to grade concrete in
such manner as to prevent
segregation.
 Construction Procedures

7. Concrete Finishing :
a. Longitudinal Float is used after the
concrete has been consolidated
 Construction Procedures

8. Brooming :
• Brooming of concrete shall be in a
uniform appearance of corrugations

9. Concrete Curing :
• Curing is necessary for the hydration to
take place
 Construction Procedures
10. Curing Method :
a. Earth or straw:
 Construction Procedures

b. Burlap or cotton mats:

• Spread over the surface
• Mats are sprinkled and kept constantly wet
c. Waterproof paper or polytelene sheets:
• May be placed over the surface to retain
moisture
d. Curing Compound:
• Popular method
• Involves the spray application of light –
colored fluid to the entire area of the wet
concrete
 Construction Procedures

11. Removal of Forms:

a. Crowbars are used in the removal
of steel forms

b. Forms for concrete shall remain in

place undistributed within 24 hours
after pouring.
 Construction Procedures
12. Concrete Cutting :
a. Cutting at weakened plane joint
/contraction joint is done within 24
hours after concrete pouring .
 Construction Procedures
13. Sealing of Joints :
a. Joints shall be sealed with asphalt
sealant
 Construction Procedures

14. Pavement Protection :

a. Against Rain – To protect the newly

poured concrete pavement.

b. Against Traffic - To protect the newly

poured concrete pavement at its
early age.
 Construction Procedures

“To have a good workmanship, a well

trained mason should be hired to have a
smooth pavement surface.”
 Types of PCCP Joints

1. Construction Joint :
• Construction Joint is also called “cold
joint”.

2. Contraction Joint :
• Contraction Joint is also called as
Weakened Plane Joint.
• If Contraction Joint or Weakened
Plane Joint (WPJ) is not installed,
random cracking will occur.
 Types of PCCP Joints

3. Longitudinal Joint :
• If the lanes are concreted separately,
a longitudinal construction joint in
the form of a key and keyway is used.

• Deformed Tie Bars are placed

perpendicular to this joint.
 Types of PCCP Joints

4. Expansion Joint :
• Expansion Joint is usually from 19 to
25 mm wide and extend the full depth
of the slab.
• Dowel Bars is used in expansion joint
 Types of Re-bars used in PCCP

1. Dowels :
• Dowels are “plain round steel bars”
generally coated with a thin file of
bitumen to protect them against
corrosion and to facilitate sliding in
concrete.
 Types of Re-bars used in PCCP

2. Tie Bars :
• Tie Bars are deformed bars used in
construction joints and longitudinal
joints together with keys to tie two
slabs together.

• Its installation must be midway in

the slab.
Being the uppermost component of the roadway, it should provide
long lasting, smooth, clean surface and should spread the load
sufficiently so that the base material can support them
It protects the base against damage by traffic and weather.
 General

TYPES OF PAVEMENT :

1. Portland Cement Concrete Pavement

(PCCP) – Rigid Pavement

2. Asphalt Concrete Pavement (ACP) –

Flexible Pavement
 General
RIGID PAVEMENT:

Rigid Pavement (PCCP) consists of three (3)

layers:
1. Concrete Slab – Made of reinforced on
plain concrete;
2. Subbase – Portion of the pavement
structure between the subgrade and
the slab; and
3. Subgrade – Bottom portion of the
pavement structure.
 I. Quality Control (PCCP)

The contactor shall perform all sampling,

testing, and inspection necessary to assure
quality control of the component materials
of the concrete.
 II. Design Mix And Trial Paving (PCCP)

The contractor is required to formulate the

design mix, conduct trial mix and trial
paving for approval of the Project Engineer
before commencement of pavement
construction.

Flowchart for Preparatory Work for Concrete Paving

 III. Admixture/Additive (PCCP)

Admixture/Additive shall be added only to

the concrete mix to produce some desired
modifications to the properties of concrete
whenever necessary, but not as partial
replacement of cement.

Requirements for Admixture

IV. Concrete Paving Activities (PCCP)

Preparation and Cleaning

IV. Concrete Paving Activities (PCCP)

Moistening prior to placing

IV. Concrete Paving Activities (PCCP)

Transport of concrete
(from slip form paver)
IV. Concrete Paving Activities (PCCP)

Placing of Concrete
IV. Concrete Paving Activities (PCCP)

Conduct of slump test

IV. Concrete Paving Activities (PCCP)

Checking of temperature of the mix

IV. Concrete Paving Activities (PCCP)

Checking of the thickness

IV. Concrete Paving Activities (PCCP)

Finishing by means of a floater

IV. Concrete Paving Activities (PCCP)

Finishing by means of a screeder

IV. Concrete Paving Activities (PCCP)

Checking of the texturing Tool

IV. Concrete Paving Activities (PCCP)

Texturing of the surface

IV. Concrete Paving Activities (PCCP)

Spraying of curing compound

IV. Concrete Paving Activities (PCCP)

Provision of protective cover sheets

IV. Concrete Paving Activities (PCCP)

Sawing of weakened plane joint

IV. Concrete Paving Activities (PCCP)

Checking the depth and width of the joint

V. Types of Formworks (PCCP)
1. FIXED-FORM

Using Fixed Form

V. Types of Formworks (PCCP)
2. SLIP-FORM

Using Slip Form Paver

 VI. Weakened Plane Joints (PCCP)

• All joints shall be protected from the

intrusion of injurious foreign material
until sealed;
• All joints shall be cut within 4 to 24 hours
after pouring and sealed with asphalt
sealant;
• Depth of the weakened plane joint shall
not be less than 50mm while the width
not more than 6mm.
[Link] and Functions of PCCP Joints
[Link] Joints and Load Transfer Device
 IX. Size and Length of Dowel/Tie Bars

• Tie bars are installed across longitudinal joints to hold the

2 slabs in close contact or to prevent them for separating;
• Tie bars are located at mid-depth of the pavement;
• Dowel bars are placed in contraction joints and in some
construction joints when it falls at full block (4.5m) to
transfer a portion of the load across the joint and to hold
the 2 slab ends at the same location;
• Dowel bars must be parallel to the surface and to the
centerline of the pavement.
X. Replacement of Deteriorated PCCP Slabs

1. The Engineer and the Contractor conduct

joint inspections prior to the commencement
of work to confirm the current conditions
and identify the PCC slabs to be replaced.
2. The Contractor removes broken/deteriorated
PCCP slabs in accordance with the Plans,
Specifications or as directed by the Engineer.
3. The subgrade and sub base course are
prepared in accordance with the
specifications or as directed by the Engineer.
X. Replacement of Deteriorated PCCP Slabs

4. Existing tie bars on longitudinal joints are to

be retained if these are still in good condition.
Where necessary, new tie bars shall be
installed on drilled holes and bonded with
high viscosity epoxy resin.
5. Install forms; side surfaces of the existing
PCCP shall be cleaned.
6. Pour concrete; perform the required surface
texturing, cutting and curing.
7. Thoroughly clean the joints and apply
sealants adequately.
X. Replacement of Deteriorated PCCP Slabs

Deteriorated PCCP
XI. Portland Cement Concrete Pavement Widening

PCCP Widening

Drilling of holes Placing Concrete

for Tie Bars
XI. Portland Cement Concrete Pavement Widening

• The provision for widening blocks at

curves shall be poured simultaneously
with the adjoining lane.

• Weakened plane joints at curves shall be

perpendicular to the centerline.
 [Link] Control (PCCP)

• The Engineer shall require that measures be taken into

consideration to prevent the temperature of concrete mix
from exceeding 32oC;
• Shrinkage cracks occur when the concrete is placed at a high
temperature, which may include any or all of the following:
a) Addition of ice blocks in the water.
b) Shading and water sprinkling of aggregates,
formworks and steel bars.
c) Shading of working area.
d) In transporting concrete using trucks, provide
necessary cover sheets.
e) Placing of concrete at a time when the humidity is low.
[Link] Control (PCCP)

Thermometer
 [Link] Texturing (PCCP)

Surface texturing is necessary to keep a

skid resistant surface and is done after the
surface has hardened enough.
XIV. Spreading Of Subbase Materials (PCCP)

Laying of Base Materials by means of Road

Grader and Paver
To be filled up in Const. Logbook
• Item 311 – Portland Concrete Cement Pavement:
(choose any of the following)

 Installation of Steel forms at Sta. ___ to Sta. ___

(L/S)
 Concrete pouring at Sta. ___ to Sta. ___ (L/S)
 Sawing of weakened plane joints at Sta. ___ to
Sta. ___ (L/S)
 Sealing of weakened plane joints at Sta. ___ to
Sta. ___
 PART VI :
DRAINAGE AND SLOPE
PROTECTION STRUCTURES
DRAINAGE AND SLOPE PROTECTION
STRUCTURES

Item 500 Pipe Culverts and Storm Drains

Item 505 Riprap and Grouted Riprap
Item 506 Stone Masonry
Item 500 - Pipe Culverts and Storm
Drains
 General

The primary purpose of a drainage system is

to provide adequate means of channeling
run-off and surface water so as to prevent
damage by water which, either directly or
indirectly, is the cause of many roadway
failures.
Main Functions of Pipe Culverts and Storm Drains

[Link], collect and direct runoff which is

draining naturally towards the roadway from
adjacent catchments areas.
[Link] runoff from the road formation and
adjacent cutting and embankment slopes.
[Link] the means for containing and
draining these waters to points of disposal.
[Link] Culverts and Storm Drains may also
intercept and drain subsoil moisture.
Main Functions of Pipe Culverts and Storm Drains

Pipe Culverts and Storm Drains can be

constructed before the commencement of
earthworks, during earthworks or when the
formation has reached sub grade level.

The key to successful culvert installation is

achieving the correct standard of bedding and
backfill for the type of conduit being laid.
 Types of Pipe Culverts and Storm Drains

1. Pre-cast Reinforced Concrete Pipes (RCP)

2. Pre-cast or Cast-in-Place Reinforced Concrete
Box Culverts (RCBC)

“The type of pipe culverts used depends

upon site conditions,waterway requirements,
depth of cover and bedding available”.
Equipment Requirements

• Backhoe (0.80 cu.m.)

• Plate Compactor (5 HP)
• Minor Tools
 Construction Procedures

[Link] Project Inspector should verify if the inlet

and outlet channel are adjusted to ensure a
smooth flow of water and avoid scour.

[Link] is important that the base of the excavation

is smooth and conforms to the design culvert
grade line.
 Construction Procedures

[Link] the excavation is being carried out in wet

conditions then, it should be started at the
lowest point and progressively dug to the
higher end. The trench or streambed must be
shaped to fit the bottom of the culvert. Flat if
it is flat bottom and circular if RCPC is used.

[Link] are installed in the original streambed

with their grades and flow line conforming to
the natural channel or canal. Pipe is usually
laid with the bell or female ends upstream.
 Construction Procedures

[Link] must be taken in the jointing process

that the pushing together of the pipes to
complete the joint does not disturb the
bedding.
Pipes are installed in the original streambed with their grades and flow line
conforming to the natural channel or canal.
Laying begins at downstream end of the culvert line to use gravity in
properly installing the pipes.
Groove ends are placed such that the pipe ends fit at its nearest ends.
Lower segment of each pipe should be in contact with the shape of the
bedding throughout its full length.
 Collaring of RC Pipes

Mortar proportion is 1:2 with enough water to obtain

the desired consistency.
The collar is to form a continuous bead around the
outside of the pipe.
The inside of pipe is finished smooth.
 Backfilling

Backfill are placed and compacted in layers not exceeding

15 cm. on both sides up to an elevation of 30 cm above
the top of the culvert.
Spreading maybe done manually using rakes and shovels
at a thin layer which is most ideal to produce easy
compaction of material done using hand tampers to insure a thoroughly
tamped backfill.
After backfilling, pipe culverts are protected by providing
extra fill as cover before any heavy equipment is
permitted to cross during the construction of the roadway to protect the job
from possible damage by excessive loads.
Item 505 - Riprap and Grouted Riprap
 General

Riprap and Grouted Riprap - is a type of slope

protection using boulders of specified size
and character which may be done with or
without grout and which holds in place
embankment slopes, cut slopes and other
earth surfaces that may either be eroded or
washed away by water.

All work must be constructed on firm ground

so that there is no chance of settlement or
failure by cracking.
 General

A. Dry Riprap:
1. Dry Riprap is more economical without
considering the grout to bring together the
boulders however; it is only applicable to a
limited height and slope.
2. Dry Riprap is stone laid carefully by hand
following a definite pattern with the voids
between the larger stones filled with smaller
stones and the surface kept relatively even. It
requires that the stone be relatively uniform in
size and shape (square or rectangular).
 General

Advantages associated with the use of Dry

Riprap include:
1. The even interlocking surface produces a neat
appearance.
2. It is more flexible that it can accommodate
movements due to foundation failures
without breaking.
 General

Disadvantages associated with Dry Riprap

include:

1. Installation is very labor-intensive resulting in

high costs.
 General

B. Grouted Riprap:
1. Grouted Riprap requires the use of grout to
fill up the interstices of the boulders both of
which are put together to form a monolithic
armor and obtain a strong but rigid slope
protection structure.
 General

2. Grouted Riprap can reduce the quantity of

boulders required as grouting anchors the
boulders.
 Equipment Requirements

• One Bagger Mixer

• Backhoe (Wheel Type), 0.28 cu.m.
• Water Truck (16000 L)
• Minor Tools
 Construction Procedures

1. Excavated the trench to the required depth,

per approved plan. Shape the side slopes and
compact same before placing the
stones/boulders.
2. Pour concrete mortar on the trench before
laying the first layer of stones/boulders for
the foundation.
3. Moisten the surface of the stones before the
stone is bedded.
 Construction Procedures

4. Lay the stones/boulders wherein the longer

axis of the stones/boulders is perpendicular
to the slopes.
5. Alternately lay the stones/boulders and fill
all voids with concrete mortar for the
succeeding layers.
6. Install the weep holes (usually, PVC – 2
inches in diameter, staggered 1.0 m. on
center) provided with filter cloth and
granular materials.
 Construction Procedures

7. Seat the stones/boulders to the required

thickness and that all boulders are placed on
firm and compacted ground.
8. Wet by spraying with water the face of the
grouted riprap structure prior to the
application of the grouts and fill the voids to
the specified depth.
9. Check that the faces of stones are relatively
free of grout.
Grouted Riprap Methodology

 Excavation of Foundation
 Use of Batterboards As Guide
 Laying of Boulders and Grout
 Finishing Work
 Importance of Weep Holes
 Excavation of Foundation

A backhoe is an ideal equipment to use in

the excavation of foundation for grouted
riprap.
 Use of Batterboards as Guide

 Good workmanship requires a reliable reference to guide the

work up to completion.
 The unevenness of the embankment slopes is then trimmed
using shovels and rakes.
 The high areas are removed and patched and compacted to
low areas until a flat surface is attained.
 Laying of Boulders and Grout

Boulders and grout are placed layer by layer alternately.

Each stone is laid with its longest axis perpendicular to the
slope in close contact with the adjacent stone.
 Laying of Boulders and Grout

The riprap is thoroughly rammed into place and the finished

stone are laid to an even tight surface.
Spaces between stones are filed with cement mortar sufficient
enough to fill completely all the voids.
 Finishing Work

Cement grout is placed starting from the bottom to the top of

the surface and then swept with a stiff broom.
After grouting, the surface is cured for a period of at least 3
days from the date of installation.
 What is the importance of weep holes in slope
protection/retaining structure?

Weep holes are opening provided to permit draining of water

in filter layer or soil layer from behind the structure.
If no or insufficient weep holes are installed, this will cause
oversaturation of the embankment and the subsequent failure
of the road structure.
Item 506 - Stone Masonry
 General

Retaining Wall - are structures that support

soils at slopes steeper in their angle of repose
and because of their resistance to earth
pressure derived from their own weight they
are also known as “gravity walls”.
 Types of Stone Masonry

1. Sizes and Shapes :

Stones should have a thickness of not less
than 150 mm.
 Types of Stone Masonry

2. Dressing :
Stones should be dressed to remove any thin
or weak portions.
 Types of Stone Masonry

3. Finish for Expose Faces :

Face stones should be pitched to the line
along the beds and joints. The maximum
projection of rock faces beyond the pitch lines
should not be more than 50 mm.
Equipment Requirements

• One Bagger Mixer

• Water Truck/Pump (16000 L)
• Backhoe (Wheel Type), 0.28 cu.m.
• Minor Tools
 Construction Procedures

1. Excavate the trench to the required depth

and/or at the stable foundation of the stone
masonry structure.
2. Pour concrete mortar on the trench before
laying the first layer of stones/boulders for
the foundation.
3. Moisten the surface of the stones before the
stone is bedded to prevent the stone from
absorbing moisture from the mortar and
thereby causing the mortar to shrink and
become non-plastic.
 Construction Procedures

4. Place the larger stones in the foundation to

give the greatest strength and lessen the
danger of unequal settlement.
5. Alternately lay the stones/boulders and fill
all voids and interstices of the
stones/boulders with concrete mortar for the
succeeding layers.
6. Lay the stones/boulders upon its broadest
face, so that the spaces between the stones
may be filled most easily.
 Construction Procedures
7. Install the weep holes (usually, PVC – 2
inches in diameter, staggered 1.0 m. on
center) provided with filter cloth and
granular materials.
8. Seat the stones/boulders to the required
thickness and that all stones/boulders are
placed firmly;
 Construction Procedures

9. Flush with mortar all joints between

stones/boulders so that the individual stones
laid are parallel to the faces of the wall in
which the stones are set.
[Link] the stone masonry when the mortar
has gained sufficient strength.
 Stone Masonry Specifications
 Boulders - thickness of not less than 150
mm, and widths of not less than one and
one-half times their respective thickness,
and lengths of not less than one and one-
half times their respective widths.

 Mortar - composed of one part of Portland

Cement and two parts of fine aggregate by
volume and sufficient water to make the
mortar such consistency that it can be
handled easily and spread with a trowel.
Excavating Stone Masonry Foundation

The foundation bed where the masonry is to be

placed should be firm and normal to the face of the
wall.

The bed that will receive the stone should be clean

and moistened before the mortar is spread.
Use of Batter boards Essential to Produce
Good Workmanship

As in grouted riprap, batter boards are necessary

to keep the lines and grades of the finished stone
masonry structure in accordance to the lines and
grades of the plans.
 Laying of Boulders and Grout

 Large stones are used in the corners.

 Bunching of small stones of the same size is not allowed.
 Stones are laid with their longest face horizontal in full beds of
mortar.
 Joints are flushed with mortar.
 The exposed face of the individual stone should be parallel to the
face of the wall in which stones are set.
 The stones are handled carefully so as not to jar or displace the
stones already set.
 Finishing Works

Immediately after laying and while the mortar

is still fresh, all face should be thoroughly
cleaned of mortar stains and should be kept
clean until the work is completed.
 TYPICAL CROSS SECTION

Item 102: Surplus Excavation

Existing ground

Item 300: Gravel Surface

Item 311: PCCP

Item 200: Aggregate

Subbase

Item 104:
Embankment

Item 505: Line canal

Item 505:
Slope
protection
THANK YOU!!!