A major PROJECT REPORT

ON
national HIGHWAY CONSTRUCTIONS
Session 2009-13

Under guidance of
Er. S.K.Gupta
H.O.D (CIVIL ENGINEERING)
SUBMITTED BY
CHANDRADEEP SHUKLA

(0307CE091017)

ABHINAV JAISWAL

(0307CE091001)

AMAR DEEP GAUTAM

(0307CE091006)

PRAKASH NARAYAN MISHRA

(0307CE091030)

PAWAN GAUTAM

(0307CE091029)

SUBMITTED TO

Er. S.K.Gupta
H.O.D (CIVIL ENGINEERING)
ADITYA COLLEGE OF TECHNOLOGY AND SCIENCE
SATNA (M.P.)
1

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 20092013 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
Er.S.K.Gupta

Principal

Guided By

Dr.J.S. Parihar

Er.S.K.GUPTA

(Civil Engg)
2

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 20092013.

(External Examiner)

(Internal Examiner)
3

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
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

national

entitled

HIGHWAY

CONSTRUCTIONSin 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. 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)

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 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
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
bypasses
through

is a road or highway that avoids or

built

traffic

up

flow

area,

town,

without

or

village,

interference

to

from

let
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)

CURB

or

KERB

is

the

edge

where

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

10

second for safety, to keep 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
such

of

acceptance;

further

the

documents

11

contract
as

may

agreement
be

and

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.

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,

Models,
other

Calculations,

Operations
technical

and

Samples,

maintenance,

information

of

Pattern,

manuals
like

and

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.
12

 Section

means

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

Contract as forming part of the site.

13

in

the

SETTING OUT

14

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

15

with the Engineer and recorded. An 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

16

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.

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
17

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 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..

18

19

TEST DONE IN
PROJECT
LABORATORY

TEST ON SUB GRADE SOIL

(I) GRAIN SIZE ANALYSIS
INTRODUCTION:

20

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

stabilization

value
of

in

soil

soil

and

classification.

for

designing

In

mechanical

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

21

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

perforation

on

are

available,

plate

to

sieves

one

type

course

with

square

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 smaller than 0.06 mm size will
22

pass

through

opening.

the

Therefore

fine
the

mesh
grain

sieves

with

0.075

size

analysis

of

mm

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

smaller sieves.

of

material

through

successively

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.

23

APPARATUS:
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,

sieves,

4.75,
material

and

mm

retained

is

on

sieves.
each

After

sieves

initial

carefully

collected and weighed.

For fraction passing 2.0 mm sieves and retained on
0.63 mm size.
24

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.

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:
25

The gravel, silt sand clay contents are marked as result.

26

(II) CONSISTENCY LIMITS &

INDICES

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

undergo changes in shape without rupture.

27

the

ability

to

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.

p.i

thus indicates the range of moisture content over

which the soil in plastic condition.

28

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

cup

and

arrangement for raising and dropping through a specified

height, grooving tool. Other apparatus include spatula,
moisture

containers,

and

balance

of

capacity

sensitive to0.01 g oven to maintain 105 to110c.

29

200g

PROCEDURE:
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

30

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

weighed.

moisture
The

container,

container

in

lid

dried

placed

in

oven

over
and

it

and

the

dry

weight determined the next day for finding the moisture

content of the soil. The operations are repeated for at
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

31

semi-logrithmetic
corresponding

to

plot.
25

The

blow

is

moisture
read

from

content
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

Hence if the flow curve is extrapolated and moisture

w10

and

w100

corresponding

to

10and

100

blows

respectively are found, then the difference in these

water content would give of the soil.

32

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

to110c.

33

at

temperature

105

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

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

roller

again

to

is kneaded together to a ball

from

therad

this

process

of

and

alternate

rolling and kneading is continude untill the thread. This

process of alternate rolling and kneading is continude until

34

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.

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

35

(III)
COMPACTION TEST

36

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.

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

detachable

base

plate

removable collar extension of about 6 cm hight.

37

and

(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 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
38

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

39

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.

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
40

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.

CALCULATION:
Let weight of mould copacted soil be = W1 g

Weight of empty mould =W2 g

Volume of mould = W
Wet density =

g/cc
41

Then dry density =

RESULT:
The result are dry density and wet density.

42

CALIFORNIA BEARING
RATIO TEST
INTRODUCTION:
The California bearing ratio (CBR) test was developed by
the

California

division

of

highway

as

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 the material. The CBR
43

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

percentage

of

standard load value at a respective deformation level to

obtain CBR value.
44

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 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

45

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

NUMBER

WEIGHT

COMPACTION

OF

OF

LAYERS

HAMMER,

FALL, NUMBER
cm

OF
BLOWS

Kg
Light

2.6

31

56

4.89

45

56

compaction
Heavy
compaction
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
46

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

47

TEST ON
CEMENT

48

(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
49

can occur i.e. even before the concrete is set , water will
come out of the surface due 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

50

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 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

51

done and the average of percentage.

Cement retained is calculated. The average

percentage of cement retained should not be more than
the specified limit.

52

(II) TEST FOR

CONSISTENCY, INITIAL &
FINAL SETTING TIME OF
CEMENT

CONSISTENCY OF CEMENT
PASTE:

INTRODUCTION:

This test determines the quantity of water required to

53

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:

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

plate or any non porous surface. Mix thoroughly and fill
54

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.

55

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.

Then the percentage of water or standard

consistency is

P = (m2/m1)x100

Usually standard consistency P lies between 26 to

33 percent.

56

TEST FOR SETTING

TIMES

57

INTRODUCTION:

The change of the cement paste from fluid to rigid state

may be referred to as setting. The gaining of 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:-

58

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 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
59

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

60

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
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.

61

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:

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.
62

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
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
63

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, a

64

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

65

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.

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.

66

 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 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
67

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 passing the sieve is also
68

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:
69

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.

70

71

Bitumen testing

Bitumen is a mixture of organic liquids that is black,

highly viscous, sticky product used for paving roads,
72

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

This test is done to determine the bitumen content as

per ASTM 2172. The apparatus needed to determine
bitumen content are 73

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

74

paper on it with the cover plate tightly fitted on the

bowl.
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
75

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 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

76

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 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

77

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
78

temperature is maintained continuously within 0.5oC of

the

specified

temperature.

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.

79

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
i) Penetrometer
ii) Water bath
iii) Bath thermometer Range 0 to 44oC, Graduation
0.2oC

80

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.

81

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

82

not less than three determinations expressed in tenths of

a mm.

MACHINERY USED IN
CONSTRUCTION
83

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
84

 Plate Compactor
Transit Mixer
Concrete Mixer
Motor Grader
Generator set 250KVA
Front end loader
Generator set 180KVA
Generator set 125KVA
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
85

 Water Pump
Bitumen Spryer
Welding set with Generator 8KVA
Mechanical Boomer
Vehicles
Water Tanks

86

87

88

89

90

91

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.

92

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 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.

93

BIBLIOGRAPHY

94

1. I.S. specification book on highway.

2.

Highway material testing book by

3.

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

4.

Organizations Laboratory.

5.

Organizations Engineers.

95

96