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

Principal

Guided By

Er.S.K.Gupta

Dr.J.S. Parihar

Er.S.K.GUPTA

(Civil Engg)

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.

(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
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 CONSTRUCTIONSin partial
fulfillment of the requirement of the degree of
Bachelor

of

Engineering
4

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
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

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

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

if

any,

shall

13

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.
On construction reaching the formation level stage,
the centre line again be set out by the contractor and
14

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
and cross section at intervals as required by the
Engineer.

15

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 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
18

sub grade material and the performance such as

susceptibility
pavement
bearing

to

frost

etc.also

capacity

approximately

and

action,

pumping

permeability
some

estimated

other

based

of

rigid

characteristics,
properties,
on

grain

are
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

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

19

out using sieves the principle of sedimentation in

water.
The sieves analysis is a simple test consisting of
sieving

measured

quantity

successively smaller sieves.

each

sieves.

The

weight

of

material

through

The weight retain on

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:
Various apparatus set of standard sieves of different
sieves

size,

balance,

and

rubber

mortar, oven, riffle, sieves shaker.

Procedure
20

covered

pestle

 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.

CALCULATION:
The weight of dry soil fraction retained on each sieve
is calculated as a percentage of the total dry weight of

21

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

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
moisture

or

may

content.

be

very

stiff

Plasticity

23

depending
is

on

the

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.
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

identification and classification of soil

24

used

in

the

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
specified

for

height,

raising

and

grooving

dropping

tool.

Other

through

apparatus

include spatula, moisture containers, and balance of

capacity 200g sensitive to0.01 g oven to maintain 105
to110c.

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

uniform thick paste. The liquid limit device is adjusted

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

25

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
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.

26

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 1W 2
W 10W 100
log n2Logn1 = log10 100/10

=w

W 10W 100

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.

27

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.

PROCEDURE:

28

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

kneaded together to a ball

is

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.

CALCULATION:
29

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

(III)
COMPACTION TEST
30

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 a detachable base plate and
removable collar extension of about 6 cm hight.
31

(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

diameter circular face, but havin g

has

cm

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 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
32

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.
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.

33

(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.

CALCULATION:
Let weight of mould copacted soil be = W1 g
Weight of empty mould =W2 g

34

Volume of mould = W

Wet density =

W 1W 2
W

Then dry density =

g/cc

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
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

36

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
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
37

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

NUMBER

WEIGHT

FALL,

NUMBER

COMPACTION

OF

OF

cm

OF

LAYERS

HAMMER,

Light

Kg
2.6

31

56

compaction
Heavy

4.89

45

56

BLOWS

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 the specimen, both at the time of soaking and
testing the sample, as surcharge.

38

Beside

above

equipment,

coarse

sieves, oven, balance, etc. Required

39

filte

paper,

TEST ON
CEMENT

(1) FINENESS TEST:

INTRODUCTION:

40

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
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.

41

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
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:

42

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

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
44

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
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,
45

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.

Then the percentage of water or standard

consistency is
P = (m2/m1)x100

Usually standard consistency P lies between 26 to

33 percent.

46

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
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.
48

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
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

49

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
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.

50

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:

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
51

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
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
52

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 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
53

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.

Tamping rod: A straight metal tamping rod of

circular cross section, 1.0 cm in diameter and 23 m
long, rounded at one end.

54

 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
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
55

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
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
56

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:
Ordinary part land cement 43 grade confirming IS:
8112.

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

57

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.

58

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

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.
60

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.
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.

61

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
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
62

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
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
63

the specified temperature for 30 minutes, after which

cut off the excess bitumen by means of a hot, straightedged 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.

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
64

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

penetration of bitumen is
i) Penetrometer
ii) Water bath

65

to

determine

the

iii) Bath thermometer Range 0 to 44 oC, 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 30 oC

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
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
69

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
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
76

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.

2. Highway material testing book by
3. S.K. Khanna, C.E.G Justo.
4. Organizations Laboratory.
5. Organizations Engineers.
78

79