REPORT SUMMARY

OBJECTIVES:
For students to learn highway and railway construction materials and design, the specifications and
tests of pavement materials, pavement design factors and pavements design as per IRC.
A. 1. HIGHWAY PAVEMENT MATERIALS
Highway pavement is a system of processed materials overlaid on in-situ soil, providing a uniform,
skid-resistant running surface. Its primary structural purpose is to support vehicle wheel loads, either in cut
or fill construction, and distribute them to the subgrade underneath.
HIGHWAY PAVEMENT COMPONENTS
1. FOUNDATION- consists of native subgrade soil and graded stone
2. BASE- is the primary structural layer responsible for absorbing and distributing wheel stresses and strains
3. SURFACING- Pavement surface
- should provide good riding quality, skidding resistance, and minimize water infiltration.
2 types of pavement
 FLEXIBLE PAVEMENTS -bituminous pavement or black top pavement
 RIGID PAVEMENTS - cement concrete pavement or white surface pavement
I. FLEXIBLE PAVEMENT MATERIALS
1. BITUMEN
There are two basic types of bituminous binder:
a)TAR - obtained from the production of coal gas or the manufacture of coke
b)BITUMEN - obtained from the oil refining process
2. ASPHALT CONCRETE (COATED MACADAMS)- a mixture of graded aggregate and bituminous
binder
3. HOT ROLLED ASPHALT(HRA)- is a dense, low-air content material with a mixture of aggregate,
fines, binder, and filler.
HRA surface courses have 0-55% coarse aggregate content, with binder courses at 50-60% and bases
at 60%.
4. AGGREGATES- Aggregates for Bituminous or Portland Cement Concrete Pavement(PCCP) must
meet AASHTO standards or Department of Public Works and Highways specifications, and undergo various
tests for quality
5. SURFACE DRESSING AND MODIFIED BINDERS
Surface dressing involves applying a thin bituminous binder
followed by spreading and rolling of stone chippings.
Modifications binders like cutback bitumen and bitumen emulsion are used for effective application.
6. CHIPPINGS - provide skidding resistance.
II. RIGID PAVEMENT MATERIALS
A rigid pavement is a subgrade and subbase foundation covered by a concrete slab. Rigid pavement is
designed with hard materials like Reinforced Cement Concrete(RCC) and Portland Cement Concrete(PCC).
A. CONCRETE
A.1. PORTLAND CEMENT CONCRETE (PCC)
Portland Cement- developed by Joseph Aspdin in the 19th century,
- is the most common cement used globally for concrete, mortar, stucco, and grout.
-Made from limestone
 Types of portland cement
There exist many different types of Portland cements in the world to meet the needs for specific purposes.

Type I. General-purpose cement

Type II. used in areas with moderate sulfate attack due to its limited C3A content.
Type III. Offers higher strength at early age and long-term strength
Type IV. This cement is used to minimize heat generation from hydration, with a lower strength rate
development, and is specially ordered and not readily available.
Type V. cements are used to prevent severe sulfate exposure, with high resistance due to limited C3A
content.
A.2. AGGREGATES
Aggregates are crucial for the performance of hardened concrete pavements subject to cycles of
freezing and thawing. Fine aggregate is natural sand or crushed rock with smaller particle sizes than the No.
4 sieve.
A.3. WATER
WATER USED FOR PAVEMENT MATERIALS IS Potable water without any pronounced taste or odor is
suitable for making PCC. If the water is not potable, it can also be used if the 7 day compressive strength of
mortar cubes with this water is at least 90% of the 7 day compressive strength of mortar cubes made with
distilled water (ASTM C-109 and AASHTO T106).
A.4. ADMIXTURES
Admixtures are used in concrete to enhance the desirable characteristics in the fresh and hardened
concrete. This includes reducing the W/CM, entraining air, retarding or accelerating the set time, increasing
the slump without increasing the W/CM, inhibiting corrosion, and self-leveling
B. REINFORCEMENT
B.1 PRESETTING REINFORCEMENTS SUCH AS DOWEL BARS, TIEBARS, AND CONTINUOUS
REINFORCEMENT STEEL
SOIL EXLORATION/SURVEY
Soil is also a part of pavement materials. In construction of pavements and design we need to consider the
soil conditions and quality .
A. 2. RAILWAY CONSTRUCTION MATERIALS AND DESIGN
RAILWAY TRACK
The structure is separated into two main structure elements:
 substructure: subgrade and protection layer,
 superstructure: ballast, sleepers, baseplates, fastenings and rails.
 PROTECTION LAYERS
1. FINE MATERIALS ABOVE V>120 KM/H VELOCITY
coarse-grained mixture 1=CGM1
2. FINE MATERIALS BELOW V<120 KM/H VELOCITY
coarse-grained mixture 2=CGM2
3. ASPHALT PROTECTION LAYER
 RAILS
Railway rails generally contains the following three structural parts
rail head,
rail web,
rail foot.
Material of rails
There are the following types of rail related to manufacturing technology [Lichtberger, 2005]:
naturally" hard rails, thermally treated rails, high-alloy rails,bainitic rails.
Strap rail, T rail, Plate rail, Bridge rail, Barlow rail, Flat bottomed rail, Flanged T rail, Vignoles rail, Double-
headed rail, Bullhead rail, Grooved rail, Girder guard rail, Block rail.
5.RAIL FASTENINGS
Normal fishplate joints
Types of fishplates
The following types/forms of fishplates can be mentioned: common flat fishplate (in Fig. 5.53 the left
picture), angled fishplate (in Fig. 5.53 the middle picture), bone shape fishplate (in Fig. 5.53 the right
picture).

Types of rail connections

The following types of fishplate joints can be differentiated in case of non- contiuous welded track:
 stiff connection (joint),
suspended joints (Figures 5.55-5.56),
supported joints (Figures 5.57-5.61).

6.SLEEPERS
Wooden sleepers

Concrete sleepers

Ballast materials
Basalt, porphyr, sand stone, lime stone

1.2 STONE
Stone which is obtained from natural rock is most durable and least expensive of all the materials of
construction so far as upkeep maintenance is concerned and when properly chosen to suit climate condition.
1.2.1 Classification of stones:
(a) Igneous, eruptive or unstratified- - Formed by the solidification of molten material which
was in a state of perfusion and is of volcanic origin.
(b) Sedimentary, aqueous or stratified- - it is gradually deposited in layers and formed by the
action of air or water, such as limestone, sandstone and slate.
(c) Metamorphic, altered or foliated- it is either of the above classes with alteration in form
caused by great heat, pressure or both; such as clay, slate, marble, dolomite and gneiss.
1.3 BRICKS
There are many different forms, such as (i) bricks, (ii) tiles, (iii) earthen wares and stone wares, (iv)terra
cotta and other clay wares, in which clay after it is burnt or baked is used by engineers and architects.
1.4 LIME
In engineering works, stones, bricks, and sometimes tiles are set in mortar resting on beds of concrete and
finished with plaster or pointing with or without white or colour washing. Lime or cement is the binding
material in the mixture of mortar, concrete etc.
1.5 CEMENT
Cement is a calcareous substance similar in many respects to eminently hydraulic lime but possesses
hydraulic properties to a far greater extent. Cement is divided into two classes: (1) Natural cement; and (2)
Artificial cement.
1.6 MORTAR
Mortar is a paste generally made by mixing cement, sand and water, or lime, sand or surkhi and
water, or cement, lime, sands and water.
1.7 CONCRETE
Concrete is an artificial compound generally made by mixing lime surkhi or cement mortar with some hard
material, such as broken stone, gravel, broken brick, slag, breeze, burnt clay etc.
1.9 TIMBER
Wood has been used as an important engineering material from the inception of civilization.
1.10 CONCRETE PUMPS
A concrete pump is a tool to transfer green (liquid) concrete, by pumping it to the location, which otherwise
is not easily accessible either due to its height or otherwise.
1.11 TRANSIT MIXER
A transit mixer is a revolving drum mounted on a truck.
1.12 PILING RIGS
There two types of piling rigs:
1.12.1 Bored cast-in-situ piling rigs:
Also known as Cast-in-drilled-hole piles (CIDH piles). Rotary boring technique offers larger dia. piles than
any other piling method and permits pile construction through particularly dense or hard strata.
1.12.2 Driven cast-in-situ piling rigs:
A pipe casing is first driven into the earth and thereafter concreting is done.
1.13 BATCHING PLANT
A plant where RMC (Ready Mix Concrete) is prepared is called a Batching Plant.