Rajiv Gandhi Proudyogiki Vishwavidyalaya, Bhopal(M.P) Aditya College of Technology & Science

Satna (M.P)

CERTIFICATE

This is to certify that the project entitled as “ national HIGHWAY CONSTRUCTIONS” which has been completed & submitted by CHANDRADEEP SHUKLA , ABHINAV JAISWAL, AMAR DEEP GAUTAM ,

PRAKASH NARAYAN MISHRA , PAWAN GAUTAM in partial fulfillment of the requirement for the award of the degree of Bachelor of Engineering in “CIVIL ENGINEERING for the session 2009-2013 is a bonafied work by them and has been completed under my guidance and supervision. It has not been submitted elsewhere for any other degree.

H.O.D Principal Guided By

Er.S.K.Gupta Dr.J.S. Parihar Er.S.K.GUPTA

1

(Civil Engg)

RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA, BHOPAL(M.P)

Aditya College of Technology & ScienceSatna (M.P)

CERTIFICATE

This is to certify that the Project entitled as “

national HIGHWAY CONSTRUCTIONS” which has

been completed & submitted by CHANDRADEEP

SHUKLA , ABHINAV JAISWAL, AMAR DEEP GAUTAM ,

PRAKASH NARAYAN MISHRA , PAWAN GAUTAM in

partial fulfillment of the requirement for the

award of the degree of Bachelor of Engineering

in “CIVIL ENGINEERING” for the session 2009-

2013.

2

(External Examiner) (Internal Examiner)

ACKNOWLEDGEMENT

A Project report like this one involves many

people and would be incomplete without the

mention of all those people whose guidance and

encouragement helped in the successful

completion of this report.

Our heartily thanks to all faculty members of

Department of “CIVIL ENGINEERING” ,Aditya

College of Technology & Science, Satna for

their effort towards our report.

I would like to thanks our H.O.D ER. S.K.

GUPTA who has been a great source of inspiration

for us and without whose humble guidance the

report was never to shape.

I am also thankful to many people whose

timely help but paucity of space is restricting us

from mentioning their name. And finally we also

3

thank to all my colleagues who were constant

support during the whole report.

CHANDRADEEP SHUKLA (0307CE091017)ABHINAV JAISWAL (0307CE091001)AMAR DEEP GAUTAM (0307CE091006)PRAKASH NARAYAN MISHRA(0307CE091030)PAWAN GAUTAM(0307CE091029)

DECLARATION

We hereby declare that the work which is

being presented in the Training report entitled

“national HIGHWAY CONSTRUCTIONS”in partial

fulfillment of the requirement of the degree of

“Bachelor of Engineering in “CIVIL

ENGINEERING” branch is an authentic record of

our work carried out under the guidance of “ER.

4

S.K.GUPTA ”. The work has been carried out at

Aditya College of Technology & Science,

Satna.

CHANDRADEEP SHUKLA (0307CE091017)ABHINAV JAISWAL (0307CE091001)AMAR DEEP GAUTAM (0307CE091006)PRAKASH NARAYAN MISHRA(0307CE091030)PAWAN GAUTAM(0307CE091029)

5

INTRODUCTION

In a National Highway project, the engineer has

to plan, design and construct either a network of

new roads or road link.

Once a highway is constructed, development takes along the

adjoining land and subsequent changes in alignment in

6

geometric standards become very difficult. A badly aligned

highway is not only a source of potential traffic hazard, but

also causes a considerable increase in transportation cost and

strain on the drivers and the passengers. Therefore, proper

investigation and planning are most important in a road

project, keeping in view the present day needs as well as the

future development of the region

7

NATIONAL HIGHWAY

PROJECT

DEFINITIONS

In the contract the following words and expressions

shall have the meanings here by assigned to them,

except where the context otherwise requires:

(i) A BOLLARD is a short vertical post typically found

where large ships docks. While originally it only meant

a post used on a quick for mooring, the word now also

8

describes a variety of structure to control or direct

road traffic. The term may be related to bole, meaning

the lower trunk of a tree.

(ii) A BYEPASS is a road or highway that avoids or

“bypasses” a built up area, town, or village, to let

through traffic flow without interference from local

traffic, to reduce congestion in the built up area, and

to improve road safety.

If there are no strong land use controls, buildings are

built a bypass, converting it into an ordinary town

road, and the bypass may eventually become as

congested as the local streets it was intended to avoid.

(iii) A CURB or KERB is the edge where a raised

pavement/footpath, road median, or road shoulder

meets an unraised street or other roadway. Typically

made from concrete, asphalt, or long stones, the

purpose is twofold: first as a gutter for proper drainage

of the roadway, and second for safety, to kee p

9

motorist from driving into the shoulder, median,

sidewalk, or pavement.

(iv) “EMPLOYERS” means the person named as such

in part II of these conditions and the legal successors

in title to such person. But not any assignee of such

person.

(V) “CONTRACTOR” means the person whose tender

has been accepted by the employer and the legal

successors in title to such person. But not any

assignee of such person.

“Contract” means the conditions, the

specification, the drawings, the bill of quantity,

the tender, the letter of acceptance; the contract

agreement and such further documents as may be

expressly incorporated in Letter of Acceptance or

Contract Agreement.

“Specifications” means the specification of the

work included in the contract and any modification

therefore or addition.

10

“Drawings” means all drawings, calculations and

technical information of a like nature provided by

the Engineer to the contractor under the contract

and all drawings, Calculations, Samples, Pattern,

Models, Operations and maintenance, manuals

and other technical information of a like nature

submitted by the contractor and approved by the

Engineer.

“Bill of Quantities” means the priced and

completed bill of quantities forming part of tender.

“Section” means a part of the works specifically

identified in the Contract as a section.

“Site” means the places provided by the

Employer where the works are to be executed and

any other places as may be specifically

designated in the Contract as forming part of the

site.

11

SETTING OUT

12

The contractor shall establish working Bench marks

tied with the reference Bench Mark in the soon after

taking possession of the site. The reference Bench

Mark for the area shall be as indicated in the contract

document of the values of the same shall be obtained

by the Contractor from the Engineer. The working

bench mark shall be at rate of 4 per km and also at or

near all drainage structures, over bridges and under

passes. The working Bench Mark/levels should be got

approved from the Engineer. Check must be based on

this Bench Mark once every month and adjustments, if

any, got agreed with the Engineer and recorded. An

13

up-to-date record of all Bench Mark including approved

adjustments, if any, shall be maintained by the

contractor and also a copy supplied to the Engineer for

his record.

The lines and levels of formation, side slopes, drainage

works, carriageways and shoulders shall be carefully

set out and frequently checked, care being taken to

ensure that correct gradients and cross sections are

obtained everywhere.

In order to facilitate the setting out of the works, the

centreline of the highway must be accurately

established by the contractor and approved by the

engineer. It must then be accurately referenced in a

manner satisfactory to the engineer, every 50m

intervals in plain and rolling terrains and 20m intervals

in highly terrain and in all curve point as directed by

the engineer, with marker pegs and chainage boards

sets in or near the fence line, and schedule of

reference dimensions shall be prepared and supplied

by the Contractor to the Engineer. These markers shall

be maintained until the works reach finished formation

levels are accepted by the Engineer.

14

On construction reaching the formation level stage,

the centre line again be set out by the contractor and

when approved by the Engineer, shall be accurately

referenced in a manner satisfactory to the Engineer by

markers pegs set at the outer limits of the formation.

No marker pegs or markers shall be moved without

the approval of the Engineer and and no earth work

shall be commenced until the centre line has been

referenced.

The contractor will be the sole responsible party for

safeguarding all survey monuments, bench marks, etc.

The Engineer will provide the Contractor necessary for

setting out of the centre line. All dimensions and levels

shown on the drawing or mentioned in documents

forming part of the or issued under the contract shall

be verified by the Contractor on the site and he shall

immediately inform the engineer of any apparent error

in such dimensions. The Contractor shall in connection

with the staking out of the canter line, survey the

terrain along the road and shall submit the engineer

for his approval, a profile along the road centre line

15

and cross section at intervals as required by the

Engineer.

After obtaining approval of the engineer, work on

earthwork can commence and the profile and cross

section shall from the basis for measurements and

payments.

The work of setting out shall be deemed to be a part of

general works preparatory to the execution of work

and no separate payments shall be made for the

same..

16

TEST DONE IN PROJECT

LABORATORY

17

TEST ON SUB GRADE SOIL

(I) GRAIN SIZE ANALYSIS

INTRODUCTION:

Most of the method for the soil identification and

classification are based on certain physical properties

of the soil. The commonly used properties for the

classification are the grain size distribution liquid limit

and plasticity index. These properties have also been

used in empirical design method for flexible

pavement; and in deciding the suitable of sub grad

soil.

Grain size analysis also known as mechanical analysis

of soil is the determination of the percent of individual

grain size present in the sample. The results of the

test are of great value in soil classification. In

18

mechanical stabilization of soil and for designing soil

aggregates mixture the result of gradation test are

used .correlation have also made between the grain

size distribution of soil and the general soil behavior as

the sub grade material and the performance such as

susceptibility to frost action, pumping of rigid

pavement etc.also permeability characteristics,

‘bearing capacity and some other properties, are

approximately estimated based on grain size

distribution of the soil. The soil is generally divided

into four parts on the particle size. The fraction of the

soil which is larger than 2.00 mm size is called gravel,

between 2.00 mm and 0.06 mm is sand 0.002mm silt

and that is smaller than 0.002 mm size is clay. Two

type of sieves are available, one type with square

perforation on plate to sieves course aggregate and

gravel, the other type being mesh sieves made of

woven wire mesh to sieves finer particle such fine

aggregate and soil fraction consisting of sand silt and

clay. However the sieves opening of the smallest mesh

sieves commonly available is about 0.075 mm, which

is commonly known as 200 mesh sieves therefore all

soil particle consisting of silt and clay which are

19

smaller than 0.06 mm size will pass through the fine

mesh sieves with 0.075 mm opening. Therefore the

grain size analysis of course fraction of soil is carried

out using sieves the principle of sedimentation in

water.

The sieves analysis is a simple test consisting of

sieving a measured quantity of material through

successively smaller sieves. The weight retain on

each sieves. The weight retain on each sieve is

expressed as a percentage of the total sample. The

sediment principle has been used for finding the grain

size distribution of fine fraction; two methods are

commonly used pipette method and the hydrometer

method.

The grain size distribution of soil particle of size

greater than 63 micron is determine by sieving the

soil on set of sieves of decreasing sieve opening

placed one below the other and separating out the

different size ranges.

APPARATUS:

20

Various apparatus set of standard sieves of different

sieves size, balance, and rubber covered pestle

mortar, oven, riffle, sieves shaker.

Procedure

For the fraction retained on 2.0 mm sieves.

Sufficient quantity of dry soil retained on 2.0 mm

sieves is weighed out. The quantity of sample

taken may be increased when the maximum size

of particle is higher. The sample separated into

various fraction by sieving through the set of

sieves of size100, 63, 20, 6, 4.75, and 2 mm is

sieves. After initial sieves, material retained on

each sieves carefully collected and weighed.

For fraction passing 2.0 mm sieves and retained

on 0.63 mm size.

The required quantity of soil sample is taken by

riffling or quartering method, dried in oven at 105

to 110 c and is subjected to dry sieves analysis

using a set of sieves with sieves opening 2.0, 0.6,

0.425, 0.15, and 0.075 mm, pan lid. The material

collected on the each sieves and on the pan are

separately collected and weighed.

21

CALCULATION:

The weight of dry soil fraction retained on each sieve

is calculated as a percentage of the total dry weight of

the sample taken. The gravel, sand , silt ,and clay

contain in percentage.

RESULT:

The gravel, silt sand clay contents are marked as

result.

22

(II) CONSISTENCY LIMITS &

INDICES

23

The physical properties of fine grained soil, especially

of clay differ much at different water content. Clay

may be almost in liquid state, or it may snow plastic

behavior or may be very stiff depending on the

moisture content. Plasticity is a property of

outstanding importance for clayey soil, which may be

explained as the ability to undergo changes in shape

without rupture.

Liquid limit it may be defined as the minimum content

at which soil will flow under the application of a very

small shearing force. The liquid limit is usually

determined in the laboratory using mechanical device.

Plastic limit may define in general term, as minimum

terms, as minimum moisture content at which the soil

remain in a plastic state. The lower limit is arbitrarily

defined and determined in the laboratory by

prescribed test procedure.

Plastic index is defined as the numerical difference

between the liquid and plastic limit.

24

p.i thus indicates the range of moisture content over

which the soil in plastic condition.

Consistency limit and plasticity index vary for different

type. Hence properties are generally used in the

identification and classification of soil

LIQUID LIMIT TEST:

Liquid limit is the moisture content at which 25 blow in

standard liquid limit apparatus will just close a groove

of standardized dimension cut in the sample by

grooving tool by a specified amount.

APPARATUS:

Mechanical liquid limit device consists of a cup and

arrangement for raising and dropping through a

specified height, grooving tool. Other apparatus

include spatula, moisture containers, and balance of

capacity 200g sensitive to0.01 g oven to maintain 105

to110c.

PROCEDURE:

25

About 120 g of dry pulverized soil sample passing 425

micron sieve is weighted, and mixed thoroughly with

distilled water in the evaporating dish to from a

uniform thick paste. The liquid limit device is adjusted

to have a free fall of cup through 10mm.a portion of

the paste is placed above the lowest spot, and

squeezed down with the spatula to have a horizontal

surface . the specimen is trimmed by firm strokes of

spatula in a such a way that the maximum depth of

soil sample in the cup is 10 mm. the soil in the cup is

divided along the diameter through the center line pf

the cam followed by firm strokes of the grooving tool.

So as to get a clean and sharp groove. The crank is

rotated at the rated at the rate of two revolutions per

second by hand so that the cup is lifted and dropped.

This continued till the two halves of the soil cake come

in to contact at the bottom of the groove along a

distance of 10 mm, and the number of blows given is

recorded . a representative soil is taken, placed in

moisture container, lid placed over it and weighed. The

container in dried in oven and the dry weight

determined the next day for finding the moisture

content of the soil. The operations are repeated for at

26

least three more trial with slightly increased moisture

content each time, nothing the number of blows so

that there at least four uniformly distribute reading of

number of blows between 10 and 40 blows.

CALCULATION:

the flow index The flow cure is plotted by taking the

number of blows in the log scale on the x-axis, and the

water content in arithmetic scale on the y-axis, of

format sheet .the flow curve is straight line drawn on

semi-logrithmetic plot. The moisture content

corresponding to 25 blow is read from this curve

rounding off the nearest whole number and is reported

as the liquid w1 of the soil. The slope of the straight

line flow cure is flow index. It may be calculated from

the following formula;

For index, If= W 1−W 2

log n2−Logn1=W 10−W 100log 10100 /10

=wW 10−W 100

Hence if the flow curve is extrapolated and moisture

w10 and w100 corresponding to 10and 100 blows

27

respectively are found, then the difference in these

water content would give of the soil.

PLASTIC LIMIT TEST

Plastic limit is the moisture content at which a soil

when rolled in to thread of smallest diameter possible,

start crumbling and has diameter of 3 mm.

APPARATUS:

Evaporating dish, spatula, glass plate, moisture

containers, rod of 3 mm diameter , balance sensitive

to 0.01 g, drying oven controlled at temperature 105

to110c.

28

PROCEDURE:

About 20 g of dry, pulverized soil passing 425 micron

IS sieve is weighed out. The soil is mixed thoroughly

with distilled water in the evaporating dish till the soil

paste is plastic enough to be easily molded with

fingers. A small ball is formed glass plate to a thread.

The pressure just sufficient to roll into a thread of

uniform diameter should be used. The rate of rolling

should be between 80 and 90 strokes per minute

counting a stroke as one complete motion of hand

forward and back to starting position again. The rolling

is done till the diameterof thread is 3 mm . then the soil is

kneaded together to a ball and roller again to from

therad this process of alternate rolling and kneading is

continude untill the thread. This process of alternate

rolling and kneading is continude until th ethread

crumbles under prassure required for rolling and the

soil can no longer to roll into a thread.

If the crumbling start at diameter less than 3 mm, then

moisture content is more than the plastic limit and if

the diameter is greater while crumbling starts, the

moisture content is lower.

29

CALCULATION:

The plastic limit (w0) is expressed as a whole number

by obtaining the mean of the moisture content of the

plastic limit.

Plastic index is calculated as the diffrence between

liquid limit and plastic limit.

Plastic index = liquid limit – plastic limit

W1-wp

30

(III)

COMPACTION TEST

Compaction of soil is a mechanical process by which

by which the soil partical are constrained to be packed

more closley together by reducing the air void. Soil

compaction causes decreases ia air void and

consequently an increase in dry density. This may

result in increase in shearing strength., the possible of

future settelment or compressibility decrease. Degree

of compaction is usually measured quantitativily nby

dry density.

31

APPARATUS:

(a) Cylindrical mould of capacity 1000 cc. with an

internal diameter of 10 cm and height 12.73 cm. the

mould is fitted with a detachable base plate and

removable collar extension of about 6 cm hight.

(b) For the light compaction, a metal rammer having

5 cmdiameter circular face, and weight 2.6 kg is

used which has drop oif 31 cm.

For heavy compaction, the rammer has 5 cm

diameter circular face, but havin g weight 4.89

kh free drop of 45 cm.

(c)Steel straight edge having behaving beveled edge

for trimming top of the specimen.

(d) Other accessories include moisture container,

balance of capacity 10kg and 200kg, oven, sieves,

mixing tools.

PROCEDURE:

In case of soil sample has particle bigger than 4075

mm sieve, about 20 kg of the representstive soil is air

dried, mixed pulerized and sieved through 20 mm and

32

4.75 m sieve is not use in the test the percentage

passing 20 mm sieve and retained on 4075 mm sieve

is noted and if this is less than 20 percen this sample

is used as such. It is more than this phenomenon is

repeated. In case the sample passes 4075 sieves, than

the bdry pulverized sample is sieved through 4.75 mm

sieve and the portion passing this sievesis only used

for the test. About 16 kg of dry soil in total may be

neccessery for the compaction test in the 1000 cc

mould. For compaction the soil in the mould every

time the required quantity quantity will depend on the

soil type, size of mould, moisture content and amount

of compaction. As arough guidance, for each test 2.5

kg of soil may taken for light compaction. As arough

guidance, for each test 2.8 kg for heavy compaction,

and than the required water ia added. The estimated

weight to be added to the soil every time may be

measured in in a jet graduated in cc. enough water is

added to to the specimen to bearing the moisture

content to about 7% less than the estimated o.m.c. for

sandy soil and 10% less for clay soils. The processed

soil stored in an air tight container for about 10 to 20

enable moisture to spread uniform in the soil mass.

33

The mould with base fitted in is weighed. The process

soil water mixture throughly and divided into eight

equal part.

(1) For light compaction the wet soil is compacted

into the mould in three equal layers, each layer

being 25 blow of the 2.6kg rammer.

(2) For heavy compaction the wet soil mix is

compacted in the mould in five equal layer being

25 bloq of 4.89 kg hammer.

The blow should be uniform ly disributed over the

surface of each layer. Each layer of the compacted soil

is scored with a spatula before placing the soil for the

succeeding. The amount of the soil used should be just

sufficient to fill the mould leaving about 5 mm to strike

off on the top after compacting the final layer.

The coller is removed and the compacted soil is

leveled to th top of the mould by mean of straight

edge. The mould and the soil are then weighed. The

soil is then ejected out of the mould and cut in the

middle and a representative specimen is determine

by finding the wet weight, keeping in the oven at 105c

to 110c and finding the dry weight the next day.

34

CALCULATION:

Let weight of mould copacted soil be = W1 g

Weight of empty mould =W2 g

Volume of mould = W

Wet density = W 1−W 2W

g/cc

Then dry density = Wet Density

(100+M .C )∗100

RESULT:

The result are dry density and wet density.

35

CALIFORNIA BEARING RATIO

TEST

INTRODUCTION:

The California bearing ratio (CBR) test was developed

by the California division of highway as a method of

classification and evaluating soil-subgrade and base

course material for flexible pavements. Just after world

war-2, the U.S.Crops of engineers adopted the C.B.R.

test for use in designing base course for air field

pavement. The test is empirical and result can not be

related accurately with any fundamental property of

36

the material. The CBR is a measure of resistance of a

material to penetration of a standard plunger under

controlled density and moisture conditions. The test

procedure should be strictly adhered if high degree of

reproducibility is desired. The CBR test may be

conducted in remould or undisturbed specimen in the

laboratory. U.S. crops of engineers have also

recommended a test procedure for in-situ test. Many

methods exist today which utilize mainly CBR test

value for designing pavement structures. The test is

simple and has been extensive investigated for field

correlation of flexible pavement thickness requirement

briefly, the test consist of causing a cylindrical plunger

of diameter 50 mm to penetrate component material

at 1.25 mm/minute. The loads, for 2.5 mm and 5.0 mm

are recorded. This load is expressed as a percentage

of standard load value at a respective deformation

level to obtain CBR value.

APPARATUS:

Loading machine: Any compression machine which

can operate at a constant rate of 1.25 mm/minute can

be used for this purpose. If such machine is not

37

available then a calibrate hydraulic press with proving

ring to measure load can be used. A metal penetration

piston or plunger of a diameter 50 mm is attached to

the loading machine.

Cylindrical moulds: Mould of 150 mm diameter and

175 mm height provided with a collar of about 50

mm length and detachable perforated and base are

used for this purpose. A spacer disc of 148 mm

diameter and 47.7 mm thickness is used to obtain a

exactly 127.3 mm height

Compaction rammer: The material is usually

compacted as specified for the work, either by

dynamic compaction or ISI are given in table

bellow:-

TYPE OF

COMPACTION

NUMBER

OF

LAYERS

WEIGHT

OF

HAMMER,

Kg

FALL,

cm

NUMBER

OF

BLOWS

Light

compaction

3 2.6 31 56

Heavy

compaction

5 4.89 45 56

38

Adjustable stem, perforated plate, tripod and dial

gauge: the standard procedure require that the soil

sample before testing should be soaked in water to

measure swelling.

Annular weight: in order to stimulate the effect of

the overlying pavement weight, annular weight each

of 2.5 kg and 147 mm diameter are placed on the

top of the specimen, both at the time of soaking and

testing the sample, as surcharge.

Beside above equipment, coarse filte r paper,

sieves, oven, balance, etc. Required

39

TEST ON

CEMENT

40

(1) FINENESS TEST:

INTRODUCTION:

The object of this is to check the proper grinding of

cement. The rate of hydration depends on the fineness

of cement. The finer is the cement, the earlier the

hydration and the faster and greater is the gaining of

strength. This because of hydration starts at the

surface. Larger the surface area (i.e. finer the cement),

faster will be hydration. However, very fine cement is

susceptible to air set and deteriorates earlier. The

grinding of cement shall be as fine as to conform to

the standard specification and also shall be uniformly

fine .If the cement is not uniformly fine, the concrete

made out of it will have poor workability and will

require a large quantity of water while mixing. Also

bleeding of concrete can occur i.e. even before the

concrete is set , water will come out of the surface due

41

to the settlement of concrete particle. To check the

fineness of the cement IS: 4031-1998 gives three

methods:

By drying sieving.

1. Blaine air permeability method.

2. By wet sieving.

First method is used to find the fineness of cement in

the project laboratory.

DRY SIEVING METHOD:

The fineness of the cement depends on the particle

size distribution. A small mass of fine cement may

have surface area have large surface area than a large

mass of coarser particle of cement. It is therefore

necessary to reduce the percentage of coarse particles

to get require fineness of cement .In this test mass of

coarser cement particle is found out which is limited to

specified percentage for various cements as per

respective Indian standard. Take 100g of various

42

cements from samples and breakdown any air set

lumps with finger. Place it on a standard IS sieve no.9.

Continuously sieve the sample with a gentle wrist

motion for 15 minutes. The mass of residue shall not

exceed 10g in case of ordinary Portland cement and

5g in case of rapid hardening cement.

CALCULATION AND RESULT:

The weight of cement retained is divided by weight

taken and is multiplied by 100 so the percentage

retained cement on 90 micron sieve is calculated.

Three trials are done and the average of percentage.

Cement retained is calculated. The average

percentage of cement retained should not be more

than the specified limit.

43

(II) TEST FOR

CONSISTENCY, INITIAL &

FINAL SETTING TIME OF

CEMENT

44

CONSISTENCY OF CEMENT PASTE:

INTRODUCTION:

This test determines the quantity of water required to

produce a cement paste of standard consistency for

the use of other test. The vicat apparatus is used for

this purpose. The consistency of standard cement

paste is defined as that consistency which will permit

the vicat plunger 50mm long and having 10mm

diameter to penetrate to a point 5mm to 7mm from

the bottom of the vicat mould. The unit of the

consistency is percentage of water by mass of dry

cement and denoted by P.

PROCEDURE:

45

Take 400g cement and add to it 30% water on a glass

plate or any non porous surface. Mix thoroughly and

fill the mould of vicat apparatus. The interval from the

time of adding water to the dry cement until

commencing to fill the mould is known as the time of

gauging and must be not less than 3 minutes and not

more than 5 minutes. Lower plunger gently to touch

the surface of test block and quickly release it,

allowing it to sink into the paste. Note the settlement

of the plunger. The settlement of the plunger should

be 5mm to 7 mm from the bottom of the mould. If not,

repeat the procedure using fresh cement and other

percentage of water until the described penetration of

the plunger is obtained.

The consistency of standard cement paste is

expressed as the amount of water as percentage by

mass of dry cement.

Let, m1= mass of cement taken

m2= mass of water added when the plunger

has a penetration of 5mm to

. 7mm from the bottom of the mould.

46

Then the percentage of water or standard

consistency is

P = (m2/m1)x100

Usually standard consistency P lies between 26 to

33 percent.

47

TEST FOR SETTING

TIMES

INTRODUCTION:

The change of the cement paste from fluid to rigid

state may be referred to as setting. The gaining of

48

strength of a cement of a set cement paste is known

as hardening. During the setting, cement acquires

some strength, however it is not considered in

definition to distinguished setting from hardening,

where hardening is gain of strength of a set cement

paste.

Objects of these tests are:-

1. To find initial and final setting times of cement.

2. To distinguished between quick setting and normal

setting types of cement

3. To detect deterioration due to storage.

When water is added to cement and mixed properly.

The chemical reaction soon starts and the paste of

cement remains plastic for a short period. During this

period, it is possible to remix the paste for a short

period. During this period, it is possible to remix the

paste. This period is called initial setting time. It is

assumed that no hardening will starts in this period .As

time lapses, the reaction is continued and cement

begins to harden. At some stages it gardens also

49

called ‘finally set’ and the time elapsed since the

water was added is called final setting time. It is not

possible to express the exact state of hardening and

hence empirical measurements are taken.

This is purely a conventional one and does not relate

to the setting and hardening of actual concrete.

PROCEDURE:

Mix 400g of cement with 0.85 P percentage of water

where P is the consistency of standard cement paste.

Start the stop watch at the instant when water is

added to cement. Fill the vicat mould with this paste

and smooth of the surface of the paste making it level

with the top of the mould attach 1mm* 1mm square

cross section needle to the vicat rod. Lower the needle

gently near the surface of the block. Note whether the

needle pierces completely .If so, wait for a while drop

the needle at a fresh place. Repeat the procedure till

the needle fails to pierce the block for 5 + 0.5mm

measured from the bottom of the mould. The interval

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between the time when water was added to cement

and the time at which the needle fails to pierce the

block by 5 + 0.5mm is known as initial setting time.

Replace the needle by the needle which has a sharp

pointing, projecting in the centre with a annular

attachment and release it on the same test block as

before. Note the time when needle makes an

impression, but the attachment fails to do so. The

interval between these time and the time when water

was added is known as the final setting time.

The initial setting time for a ordinary Portland cement

should not be less than 30 minutes and the final

setting time should not more than 10 hours. For quick

setting cement, the initial setting time should not be

less than 5 minutes and the final setting not more than

30 minutes.

The minimum limits on initial setting are specified

because:

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Concrete once placed should not be distributed after

the initial setting has taken place.

There must be sufficient time for placing of second

batch which may be distribute the first batch of the

concrete.

The transportation of concrete from the place where

concrete is prepared to the placing of concrete

requires some finite time.

The maximum limits of the final setting time are

specified because the concrete should achieve the

desired strength as early as possible so that the

shuttering can be remove and reused.

(I) AGGREGATES IMPACT TEST

INTRODUCTION:

Toughness is the property of the materials to resist

impact. Due to traffic loads, the load stones are

52

subjected to the pounding action or impacts and there

possibility of stones breaking into smaller pieces. The

road stones should therefore be tough enough to resist

fracture under impact. A test designed to evaluate the

toughness of the stones therefore the resistance of the

two fractures under repeated impacts may be called

an impact test for road stones. Impact test may either

carry out cylindrical stone specimens as in page

impact test or stone aggregates as in a aggregate

impact test. The aggregate test has been standardized

by the British Standard Institution and the Indian

Standard Institution. The aggregate impact value

indicates the a relative measure of the resistant of

aggregate to sudden shock or an impact, which in

some aggregate differ from its resistant to slow

compressive load. The method of test covers the

procedure for determine the aggregate impact value

of coarse aggregates.

APPARATUS:

The apparatus consists of an impact testing machine,

53

a cylindrical measure temping rod, IS sieve, balance

and oven.

Impact Testing Machine : The machine consist

of a matter base with a plane lower surface

supported well on a firm flour, without rocking

detachable cylindrical steel cup of internal diameter

10.2cm and depth 5.0cm is rigidly fastened

centrally to the base plate. A matter hammer of

weight between 13.5 and 14 kg having the lower

and cylindrical in shape, 10cm in diameter and 5.0

cm long, with 2.0 mm chamber at the lower edge is

capable of sliding freely between vertical guides,

and fall concentric over the cup. There is an

arrangement for raising the hammer and allowing

it to fall freely between vertical guides from a

height of 38 cm on the test sample in the cup, the

height fall being adjustable up to 0.5 cm a key is

provided for supporting the hammer while

fastening.

Measure: A cylindrical metal measure having

internal diameter 7.5 cm and depth 5.0 cm for

measuring aggregates.

54

Tamping rod: A straight metal tamping rod of

circular cross section, 1.0 cm in diameter and 23 m

long, rounded at one end.

Sieve: IS sieve of size 12.5mm, 10mm and

2.36mm for sieving the aggregates.

Balance : A balance of capacity not less than 500g

to weight accurate up to 0.1g.

Oven: A thermostatically controlled drying oven

capable of maintaining constant temperature

between 100oC and 110oC.

PROCEDURE:

The test sample consist of aggregates passing

12.5mm sieves and retained on 10mm sieve and dried

in an oven 4 hours at a temperature 100oC to 110oC

and cooled. The aggregates are filled up to about one

–third full in the cylindrical measure and tamped 25

times with rounded and of the tampering rod. Further

55

quantity of aggregates is then added up to about two –

third full in the cylinder and 25 strokes of the tamping

rod are given. The measure is now filled with the

aggregates to over flow, tamped 25 times. The surplus

aggregates are stuck off using the tamping rod as

straight edge. The net weight of the aggregates in the

measures determined to the nearest gram this weight

of the aggregates is used for carrying out duplicate

test on the same materials. The impact machine is

placed with its bottom plate on the flour so that the

hammer guide columns are vertical. The cup is mixed

firmly in position on the base of the test sample from

the cylindrical measure is transferred to the cup and

compacted by tamping with 25 strokes.

The hammer is raised until its lower face is 38 cm

above the upper surface of the aggregates in the

cup ,and allowed to fall freely on the aggregates. The

test sample is subjected to a total 15 such blows, each

being delivered at an interval of not less than one

second. The crushed aggregates is then removed from

the cup and whole of it sieve on the 2.36mm sieve

until no further significant amount passes. The fraction

56

passing the sieve is also weighed accurate to

0.1gm.The fraction retained on the sieve is also

weighed and if the total weight of the fraction passing

and retained on the sieve is added, it should not be

less than the original by 1g, the result should be

discarded and a fresh test made

METHODOLOGY OF PQC.

SCOPE:

The work shall consist of construction of un-reinforced,

dowel jointed plain cement concrete pavements in

accordance with the requirements of MOST

specification and in conformity with the lines grades

and cross sections as shown on the approved

drawings. The work shall include furnishing of all plant

and equipment, materials and labour as directed by

the Engineer.

MATERIALS:

CEMENT:

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Ordinary part land cement 43 grade confirming IS:

8112.

ADMIXTURES:

Admixtures used conforming to IS: 9625 and IS: 9103.

COARSE AGGREGATE :

The maximum size of aggregate is 20 mm. the coarse

aggregate complying with IS: 383

FINE AGGREGATE:

As approved in mix design confirm to IS: 383.

WATER:

It shall meet the requirement as stipulated in IS: 456.

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Bitumen testing

59

Bitumen is a mixture of organic liquids that is black,

highly viscous, sticky product used for paving roads,

waterproofing products (used in sealing roofs). There

are many tests which are conducted to check the

quality of bitumen. Bitumen is very important

component of many construction sites like roads,

highways. Many tests are done to ensure the quality of

bitumen. Some of these are given below :-

1. Bitumen Content 

2. Ductility Of Bitumen

3. Penetration of Bitumen

4. Specific Gravity of Bitumen

5. Softening Point Of Bitumen

6. Flash And Fire Point Of Bitumen

7. The Marshall Stability of Bituminous Mixture

60

This test is done to determine the bitumen content as

per ASTM 2172. The apparatus needed to determine

bitumen content are -

i) Centrifuge extractor

ii) Miscellaneous – bowl, filter paper, balance and

commercial benzene.

A sample of 500g is taken.

Procedure to determine bitumen content

i) If the mixture is not soft enough to separate with a

trowel,place 1000g of it in a large pan and warm upto

100oC to separate the particles of the mixture

uniformly.

ii) Place the sample (Weight ‘A’) in the centrifuge

extractor. Cover the sample with benzene, put the filter

paper on it with the cover plate tightly fitted on the

bowl.

61

iii) Start the centrifuge extractor, revolving slowly and

gradually increase the speed until the solvent ceases to

flow from the outlet.

iv) Allow the centrifuge extractor to stop. Add 200ml

benzene and repeat the procedure.

v) Repeat the procedure at least thrice, so that the

extract is clear and not darker than the light straw

colour and record the volume of total extract in the

graduated vessel.

vi) Remove the filter paper from the bowl and dry in the

oven at 110 + 5oC. After 24hours, take the weight of

the extracted sample (Weight ‘B’).

REPORTING OF RESULTS

Bitumen content = [(A-B)/B]×100 %

Repeat the test thrice and average the results.

Determining the Ductility Of Bitumen

This test is done to determine the ductility of distillation

residue of cutback bitumen, blown type bitumen and

other bituminous products as per IS: 1208 – 1978. The

principle is : The ductility of a bituminous material is

measured by the distance in cm to which it will

62

elongate before breaking when a standard briquette

specimen of the material is pulled apart at a specified

speed and a specified temperature.

The apparatus required for this test:

i) Standard mould

ii) Water bath

iii) Testing machine

iv) Thermometer – Range 0 to 44oC, Graduation 0.2oC

Procedure to determine the Ductility Of Bitumen

i) Completely melt the bituminous material to be tested

by heating it to a temperature of 75 to 100oC above the

approximate softening point until it becomes

thoroughly fluid. Assemble the mould on a brass plate

and in order to prevent the material under test from

sticking, thoroughly coat the surface of the plate and

63

the interior surfaces of the sides of the mould with a

mixture of equal parts of glycerine and dextrin. While

filling, pour the material in a thin stream back and forth

from end to end of the mould until it is more than level

full. Leave it to cool at room temperature for 30 to 40

minutes and then place it in a water bath maintained at

the specified temperature for 30 minutes, after which

cut off the excess bitumen by means of a hot, straight-

edged putty knife or spatula, so that the mould is just

level full. ii) Place the brass plate and mould with

briquette specimen in the water bath and keep it at the

specified temperature for about 85 to 95 minutes.

Remove the briquette from the plate, detach the side

pieces and the briquette immediately.

iii) Attach the rings at each end of the two clips to the

pins or hooks in the testing machine and pull the two

clips apart horizontally at a uniform speed, as specified,

until the briquette ruptures. Measure the distance in cm

through which the clips have been pulled to produce

rupture. While the test is being done, make sure that

the water in the tank of the testing machine covers the

specimen both above and below by at least 25mm and

the temperature is maintained continuously within ±

0.5oC of the specified temperature.

64

REPORTING OF RESULTS

A normal test is one in which the material between the

two clips pulls out to a point or to a thread and rupture

occurs where the cross-sectional area is minimum.

Report the average of three normal tests as the

ductility of the sample, provided the three

determinations be within ± 0.5 percent of their mean

value.

If the values of the three determinations do not lie

within ± 0.5 percent of their mean, but the two higher

values are within ± 0.5 percent of their mean, then

record the mean of the two higher values as the test

result.

Determining Penetration of Bitumen

This test is done to determine the penetration of

bitumen as per IS: 1203 – 1978. The principle is that

the penetration of a bituminous material is the distance

in tenths of a mm, that a standard needle would

penetrate vertically, into a sample of the material

under standard conditions of temperature, load and

time. The apparatus needed to determine the

penetration of bitumen is

65

i) Penetrometer

ii) Water bath

iii) Bath thermometer – Range 0 to 44oC, Graduation

0.2oC

SAMPLE

Bitumen should be just sufficient to fill the container to

a depth of at least 15mm in excess of the expected

penetration.

Procedure to determine the penetration of

bitumen 

i) Soften the bitumen above the softening point

(between 75 and 100oC). Stir it thoroughly to remove

air bubbles and water.

ii) Pour it into a container to a depth of at least 15mm

in excess of the expected penetration.

66

iii) Cool it at an atmospheric temperature of 15 to 30oC

for 11/2 hours. Then place it in a transfer dish in the

water bath at 25.0 + 0.1oC for 11/2 hrs.

iv) Keep the container on the stand of the penetration

apparatus.

v) Adjust the needle to make contact with the surface

of the sample.

vi) Adjust the dial reading to zero.

vii) With the help of the timer, release the needle for

exactly 5 seconds.

viii) Record the dial reading.

ix) Repeat the above procedure thrice.

REPORTING OF RESULTS

The value of penetration reported should be the mean

of not less than three determinations expressed in

tenths of a mm.

67

MACHINERY USED IN

CONSTRUCTION

68

LIST OF PLANT & MACHINERY

DEVELOPED AT SITE:

WMM Mixing plant

Tailor

Stone Crusher unit 100TPH

Tipper (6/8)

GSB Crusher unit 100 TPH

Tipper (14cum)

Weight Bridge

Tractor

Concrete Batching Plant

Plate Compactor

Transit Mixer

Concrete Mixer

Motor Grader

Generator set 250KVA

Front end loader

Generator set 180KVA

Generator set 125KVA

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Generator set 100KVA

Generator set 22KVA

Generator set 17.5KVA

Generator set 5KVA

Excavator

J.C.B

Soil Compactor

Sensor Pavers

WMM Pavers

Vibratory Tandem Roller

Static Roller

Hydra

Air Compressor

Needle Vibrator

Water Pump

Bitumen Spryer

Welding set with Generator 8KVA

Mechanical Boomer

Vehicles

Water Tanks

70

71

72

73

74

75

SUGGESTION AND

CONCLUSION

1. Civil engineer should perform the work at their

level best so that it will give better result and

improve the production of the company.

2. Infrastructure of Civil Contractor Cell should be

more developed for giving the contract to the

best contractor.

3. Welfare facilities should be increase in for civil

engineers of Construction Company.

4. For the safety of civil engineers at the

construction, company should give the best

equipments of safety to the civil engineers.

5. The hostel facility and amenities should be

improved so that the civil engineers could work

with more efficiency.

6. The civil engineers are advised to do their work

in slot as they do it bulk which create adverse

problems for example the road was dug during

76

the rainy season in one flow which resulted in

heavy loss of material, money and machinery of

the company. The work should have been done

in small phases and according to the

circumstances. The clipping can be seen on the

next page as to how destruction was made

during the time when I was undergoing my

training.

77

BIBLIOGRAPHY

1. I.S. specification book on highway.

78

2.Highway material testing book by

3.S.K. Khanna, C.E.G Justo.

4.Organization’s Laboratory.

5.Organization’s Engineers.

79