A

Summer Training Report

On
Construction of Cement Concrete Road
At
U.P. P.W.D, MUZAFFARNAGAR
Submitted for Partial fulfillment of

Bachelor of Technology
CIVIL ENGG.
Submitted to: -

Submitted By:-

Dept. of

Virendra kumar
B.Tech 4th Yr.

(CIVIL ENGINEERING)

Roll No:-1209700123

GALGOTIA COLLEGE OF ENGG. & TECH.,

GR. NOIDA, UP
Batch: 2012-16

ACKNOWLEDGEMENT

I express my satisfaction on the completion of this summer training

program and project report submission as a part of the curriculum for the
degree of Bachelor of Technology, Civil Engineering. I express my deepest
gratitude to my supervisor and mentor Mr. A.K.VERMA for his kind
guidance during the entire period of training. His consistent support and
advices has helped me to complete this research project successfully. Also I
thank all the members of P.W.D., MUZAFFARNAGAR, U.P. Department
for their kind support. They have always been a source of inspiration to me.

DATE: - 08/07/2015

VIRENDRA KUMAR

Content
1.
PWD Introduction
2.

About Cement road

4.

Material

5.

Tests

6.

Cement road construction

6.1

Preparation of subgrade

6.2

Preparation of base

6.3

Form work

6.4

Watering of base

6.5

Joints

6.6

Material mix & placing

6.7

Compaction

6.8

Finishing of surface

6.9

Curing

6.10

Filling joint

6.11

Edging

6.12

open to traffic

Reference

Introduction
Point of view geographic and population of the state is the
nation's largest state. State Industrial, economic and social
development of the state and the population of each village
is absolutely necessary to re-connect to the main roads. In
addition to state important national roads, state roads and
district roads and their proper broad be made to improve
the quality of traffic point of view is of particular
importance. Public Works Department to build roads and
improve connectivity in rural zones, Other District Road and
State broad and improvement of rural roads and main
routes narrow construction of zones and depleted bridges
brides reconstruction of the bases are transacted on a
priority basis . Also under Pradhan Mantri Gram Sadak
Yojana and pre-fabricated construction of rural roads linking
the work of other district roads broad Suddikrn the scale
bases are edited.

Successful operation of various schemes for the Public

Works Department engineers and supervisory boards in
different districts of the engineers office has been settled.
Activities by planning, execution, and quality control etc.
remove impediments find joy in relation to the supervision
over the activities are focused. Various schemes operated
by the Department of the Office of the Regional Chief
Engineers and Chief Engineers office.

About Road
A road is a thoroughfare, route, or way on land between two places, which
has been paved or otherwise improved to allow travel by some conveyance,
including a horse, cart, or motor vehicle. Roads consist of one, or
sometimes two, roadways (carriageways) each with one or more lanes and
also any associated sidewalks (British English: pavement) and road verges.
Roads that are available for use by the public may be referred to as public
roads or highways.

MATERIAL
Concrete is widely used in domestic, commercial, recreational, rural and
educational construction.
Communities around the world rely on concrete as a safe, strong and
simple building material. It is used in all types of construction; from
domestic work to multi-storey office blocks and shopping complexes.
Despite the common usage of concrete, few people are aware of the
considerations involved in designing strong, durable, high quality concrete.

There are mainly three types1-Cement

2-Sand
3-Aggregate

Cement
A cement is a binder, a substance that sets and hardens independently, and
can bind other materials together. The word "cement" traces to the Romans,
who used the term caementicium to describe masonry resembling
modern concrete that was made from crushed rock with burnt lime as
binder. The volcanic ash and pulverized brick additives that were added to
the burnt lime to obtain a hydraulic binder were later referred to
as cementum, cimentum, cement, and cement.
Cements used in construction can be characterized as being
either hydraulic or non-hydraulic. Hydraulic cements (e.g., Portland
cement) harden because of hydration, a chemical reaction between
the anhydrous cement powder and water. Thus, they can harden underwater
or when constantly exposed to wet weather. The chemical reaction results
in hydrates that are not very water-soluble and so are quite durable in water.
Non-hydraulic cements do not harden underwater; for example, slaked
limes harden by reaction with atmospheric carbon dioxide.
The most important uses of cement are as an ingredient in the production
of mortar in masonry, and of concrete, a combination of cement and an
aggregate to form a strong building material.

Types of Cement:-

Portland cement
Portland cement is by far the most common type of cement in general use
around the world. This cement is made by heating limestone (calcium
carbonate) with small quantities of other materials (such as clay) to
1450 C in a kiln, in a process known as calcination, whereby a molecule
of carbon dioxide is liberated from the calcium carbonate to form calcium
oxide, or quicklime, which is then blended with the other materials that
have been included in the mix. The resulting hard substance, called
'clinker', is then ground with a small amount of gypsum into a powder to
make 'Ordinary Portland Cement', the most commonly used type of cement
(often referred to as OPC). Portland cement is a basic ingredient
of concrete, mortar and most non-specialty grout. The most common use

for Portland cement is in the production of concrete. Concrete is a

composite material consisting of aggregate (gravel and sand), cement,
and water. As a construction material, concrete can be cast in almost any
shape desired, and once hardened, can become a structural (load bearing)
element. Portland cement may be grey or white.

Portland fly ash cement

Its contains up to 35% fly ash. The fly ash is pozzolanic, so that ultimate
strength is maintained. Because fly ash addition allows a lower concrete
water content, early strength can also be maintained. Where good quality
cheap fly ash is available, this can be an economic alternative to ordinary
Portland cement.

Portland pozzolan cement

Its includes fly ash cement, since fly ash is a pozzolan , but also includes
cements made from other natural or artificial pozzolans. In countries
where volcanic ashes are available.

Portland silica fume cement

Addition of silica fume can yield exceptionally high strengths, and cements
containing 520% silica fume are occasionally produced. However, silica
fume is more usually added to Portland cement at the concrete mixer

Sand
Sand is a naturally occurring granular material composed of finely
divided rock and mineral particles. The composition of sand is highly
variable, depending on the local rock sources and conditions, but the most
common constituent of sand in inland continental settings and nontropical coastal settings is silica (silicon dioxide, or SiO2), usually in the
form of quartz.

The second most common type of sand is calcium carbonate, for

example aragonite, which has mostly been created, over the past half
billion years, by various forms of life, like coral and shellfish. It is, for
example, the primary form of sand apparent in areas where reefs have
dominated the ecosystem for millions of years like the Caribbean.

Composition
In terms of particle size as used by geologists, sand particles range in
diameter from 0.0625 mm (or 116 mm) to 2 mm. An individual particle in
this range size is termed a sand grain. Sand grains are between gravel (with
particles ranging from 2 mm up to 64 mm) and silt (particles smaller than
0.0625 mm down to 0.004 mm). The size specification between sand and
gravel has remained constant for more than a century, but particle diameters
as small as 0.02 mm were considered sand under the Alter berg standard in
use during the early 20th century. A 1953 engineering standard published
by the American Association of State Highway and Transportation
Officials set the minimum sand size at 0.074 mm.

Aggregate
Aggregates are inert granular materials such as sand, gravel, or crushed
stone that, along with water and Portland cement, are an essential
ingredient in concrete. For a good concrete mix, aggregates need to be
clean, hard, strong particles free of absorbed chemicals or coatings of clay
and other fine materials that could cause the deterioration of concrete.
Aggregates, which account for 60 to 75 percent of the total volume of
concrete, are divided into two distinct categories-fine and coarse. Fine
aggregates generally consist of natural sand or crushed stone with most
particles passing through a 3/8-inch (9.5-mm) sieve. Coarse aggregates are
any particles greater than 0.19 inch (4.75 mm), but generally range between
3/8 and 1.5 inches (9.5 mm to 37.5 mm) in diameter. Gravels constitute the
majority of coarse aggregate used in concrete with crushed stone making
up most of the remainder.

Natural gravel and sand are usually dug or dredged from a pit, river, lake,
or seabed. Crushed aggregate is produced by crushing quarry rock,
boulders, cobbles, or large-size gravel. Recycled concrete is a viable source
of aggregate and has been satisfactorily used in granular subbases, soilcement, and in new concrete. Aggregate processing consists of crushing,
screening, and washing the aggregate to obtain proper cleanliness and
gradation. If necessary, a benefaction process such as jigging or heavy
media separation can be used to upgrade the quality.
Once processed, the aggregates are handled and stored in a way that
minimizes segregation and degradation and prevents contamination.
Aggregates strongly influence concrete's freshly mixed and hardened
properties, mixture proportions, and economy. Consequently, selection of
aggregates is an important process. Although some variation in aggregate
properties is expected, characteristics that are considered when selecting
aggregate include:
grading
durability
particle shape and surface texture
abrasion and skid resistance
unit weights and voids
absorption and surface moisture

Grading refers to the determination of the particle-size distribution for

aggregate. Grading limits and maximum aggregate size are specified
because grading and size affect the amount of aggregate used as well as
cement and water requirements, workability

Shape and size

Particle shape and surface texture influence the properties of freshly mixed
concrete more than the properties of hardened concrete. Rough-textured,
angular, and elongated particles require more water to produce workable
concrete than smooth, rounded compact aggregate. Consequently, the
cement content must also be increased to maintain the water-cement ratio.
Generally, flat and elongated particles are avoided or are limited to about
15 percent by weight of the total aggregate. Unit-weight measures the
volume that graded aggregate and the voids between them will occupy in
concrete. The void content between particles affects the amount of cement
paste required for the mix. Angular aggregate increase the void content.
Larger sizes of well-graded aggregate and improved grading decrease the
void content. Absorption and surface moisture of aggregate are measured
when selecting aggregate because the internal structure of aggregate is
made up of solid material and voids that may or may not contain water. The
amount of water in the concrete mixture must be adjusted to include the
moisture conditions of the aggregate. Abrasion and skid resistance of an
aggregate are essential when the aggregate is to be used in concrete
constantly subject to abrasion as in heavy-duty floors or pavements.
Different minerals in the aggregate wear and polish at different rates.
Harder aggregate can be selected in highly abrasive conditions to minimize
wear.

Test
There are four main tests to be done on concrete:
1-The Slump Test.

2-Compression Test
3-Impact Test
4-Cube Test

THE SLUMP TEST

The slump test is done to make sure a concrete mix is
workable.
Workability measures how easy the concrete is to place,
handle and compact

Standard slump cone (100 mm top diameter x 200 mm bottom diameter x 300 mm high
Small scoop
Bullet-nosed rod
(600 mm long x 16 mm diameter
)
Rule
Slump plate (500 mm x 500 mm)

Method
1

Clean the cone.Dampen with water and place on the slump plate.
The slump plate should be clean, firm, level and non-absorbent.

2
3

Collect a sample.
Stand firmly on the footpieces1/and
fill volume of the cone with
3 the
the sample.Compact the concrete by 'rodding' 25 times.
Rodding

Rodding means to push a steel rod in and out of the

concrete to compact it into the cylinder, or slump cone.

Always rod in a definite pattern, working from outside into the middle.
2/3
4 Now fill to

and again rod 25 times, just into the top

of the first layer.

Fill to overflowing, rodding again this time just into the top
of the second layer.
Top up the cone till it overflows.

Level off the surface with the steel rod using a rolling
action. Clean any concrete from around
the base and top of the cone, push down on the
handles and step off the footpieces.

Carefully lift the cone straight up making sure

not to move the sample.

8 Turn

the cone upside down and place the rod across the

up-turned cone.

THE COMPRESSION TEST

The compression test shows the compressive strength of
hardened concrete. The testing is done in a laboratory offsite. The only work done on-site is to make a concrete
cylinder for the compression test.
The strength is measured in Megapascals (MPa) and is
commonly specified as a characteristic strength of concrete
measured at 28 days after mixing. The compressive
strength is a measure of the concretes ability to resist
loads which tend to crush it.
Tools
Cylinders (100 mm diameter x 200 mm high or 150 mm
diameter x 300 mm high)
( The small cylinders
are normally used for
most testing due to
their lighter weight )
Small scoop
Bullet-nosed rod (600
mm x 16 mm)
Steel float
Steel plate

Method
1 Clean the cylinder mould and coat the inside
lightly with form oil, then place on a clean, level
and firm surface, ie the steel plate.
2 Collect a sample.

3 Fill 1/2 the volume of the mould with

concrete then compact by rodding 25 times.
Cylinders may also be compacted by
vibrating using a vibrating table.

The Compression Test continues on the next page

13

4 Fill the cone to overflowing and rod

25 times into the top of the first

layer, then top up the mould till overflowing.

5

Level off the top with the steel float and clean any
concrete from around the mould.

Cap, clearly tag the cylinder

and put it in a cool dry place
to set for at least 24 hours.

After the mould is removed the cylinder is sent to the laboratory

where it is cured and crushed to test compressive strength.

Impact Testing
An impact test is a dynamic test conducted on a selected specimen which
is usually notched. The specimen is struck and broken by a single blow in
a specially designed machine.
This demo illustrates the experiment setup, procedure and the energy
absorbed in an impact test.

Cube Test
Test applied to the concrete, this is the utmost important which gives an idea
about all the characteristics of concrete. By this single test one judge that whether
Concreting has been done properly or not. For cube test two types of specimens
either cubes of 15 cm X 15 cm X 15 cm or 10cm X 10 cm x 10 cm depending
upon the size of aggregate are used. For most of the works cubical moulds of
size 15 cm x 15cm x 15 cm are
commonly used.
This concrete is poured in the
mould and tempered properly so as
not to have any voids. After 24
hours these moulds are removed
and test specimens are put in water for curing. The top surface of these
specimen should be made even and smooth. This is done by putting
cement paste and spreading smoothly on whole area of specimen.
These specimens are tested by compression testing machine after 7 days
curing or 28 days curing. Load should be applied gradually at the rate of
140 kg/cm2 per minute till the Specimens fails. Load at the failure
divided by area of specimen gives the compressive strength of concrete.

APPARATUS
Compression testing machine

PREPARATION OF CUBE SPECIMENS

The proportion and material for making these test specimens are from the
same concrete used in the field.

SPECIMEN
6 cubes of 15 cm size Mix. M15 or above

MIXING
Mix the concrete either by hand or in a laboratory batch mixer

HAND MIXING
(i)Mix the cement and fine aggregate on a water tight none-absorbent
platform until the mixture is thoroughly blended and is of uniform color
(ii)Add the coarse aggregate and mix with cement and fine aggregate
until the coarse aggregate is uniformly distributed throughout the batch
(iii)Add water and mix it until the concrete appears to be homogeneous
and of the desired consistency.

PRECAUTIONS
The water for curing should be tested every 7days and the temperature of water must
be at 27+-2oC.

PROCEDURE
(I) Remove the specimen from water after specified curing time and wipe out excess
water from the surface.
(II) Take the dimension of the specimen to the nearest 0.2m
(III) Clean the bearing surface of the testing machine
(IV) Place the specimen in the machine in such a manner that the load shall be applied
to the opposite sides of the cube cast.
(V) Align the specimen centrally on the base plate of the machine.
(VI) Rotate the movable portion gently by hand so that it touches the top surface of
the specimen.
(VII) Apply the load gradually without shock and continuously at the rate of
140kg/cm2/minute till the specimen fails
(VIII) Record the maximum load and note any unusual features in the type of failure.

Using mix Concrete ,

there some Point to
construct the road1. Preparation of base
2. Form working
3. Preparation of subgrade
4. Watering of base
5. Joints
6. Material mix & placing
7. Compaction
8. Finishing of surface
8A.

Floating

8B.

Belting

8C.

Brooming

9. Curing
10.

Joint filling

11.

Edging

12.

Open to traffic

1. Preparation of subgrade
1. Rolling on sub grade by roller
2. Filling the granular soil in the weak part and pot holes
3. Correct the soil coat , Camber , longitudinal slop
When concrete direct laid on subgrade, For preventing the
water-seepaging into the soil , used water proof paper on
entire length.
1. Rolling on sub grade by roller
2. Filling the granular soil in the weak part and pot holes
3. Correct the soil coat , Camber , longitudinal slop
When concrete direct laid on subgrade, For preventing the
water-seepaging into the soil , used water proof paper on
entire length.

2. Preparation of base
Choose any one type of base
1. W.B.M. base
As base material of W.B.M. Road; stone ballast, concrete
10-15cm layer are used. For bonding between concrete
slab & W.B.M. used 1:2 cement wash on W.B.M.
2. Concrete base
On the road used 10cm Cement concrete(1:2:4) or lime
concrete(16:32:64)
3. Granular medium material layer

10-15cm composite layer of sand , moorum , bajri are

used for better drainage facilities
4. Stabilization soil

3. Form work
Material for form workWooden sheets, battens, plywood, fibre hard board, steel
plates, angles, rope, minerals.
1. before using form work, it should free from all type
material like as dust ,cement.
2. To placing the concrete in appropriate depth used
2.5-5cm thick and 3mtr long wooden sheeting.

3. The depth of wooden block must be same as level of

slab thick.
4. After 24hrs form work displaced next length of road.

4. Watering of base
If base is dry
Than using the sprinkling process on it properly after that
placing the concrete.
5.Joints
Where is necessary to provide transverse, Longitudinal
joints; there wedge of woods, metals fix on level of
concrete.
After setting of concrete it should be pull out.
If provided the dowel bar in joints, bars should be fit
at right position.

6.Material mix & placing

Mixer is equipment that mix the concrete using
distinct amount of cement , concrete, sand and
water. Concrete slab should have more than 5-10cm
thick cause of drying.
Used two type mixer1. Batch mixerat site, used for small road construction
2. Continuous mixerContinuous mixer used for large construction .
if distance is more from site , mix concrete
transported at site within setting time.
Two methods generally used in placing of concrete1. Alternate bay methodPlaced the concrete on both side of road
alternatively like as1,3,5 part at one side and
2,4,6 part other side .

1st side
2nd side
This method have slow process due to road traffic
problems.
2. Continuous bay methodconstruct one side of road regularly, if
completed some part of first side than construct
other side.
this method have fast process without no
obstruction of traffic

7. Compaction
Purpose of compaction is that to pull out air from
void and make concrete harden.
Compaction done by1. mechanically surface vibrator
2. manually hand tempers

8. Finishing of surface
1.FloatingFor levelling the surface use floating, screeding , power trowel. So that there is no acceptable
more than 3mm variation in concrete level surface.

2.Belting-

For making surface clean used belting process.

Belt is nothing but a 15-30cm thick sheets of canvass
which have more length than road.

3. BroomingBrooming is the process in which we made rough

surface parallel to road by brush.
It useful in avoiding slip & comfortable travelling on
road .
The depth of line on road no more than 1.5mm.

9.Curing
Curing is the name of increasing the hydration
process of cement.
after setting the concrete , curing process done till
14-28days.
Some method of curing are1.Shading concrete works
2. Covering with hessian & gunny bags
3. Sprinkling of water
4.By ponding
5. Membrane curing
6. Steam curing

10. Filling joint

After drying road, clean the joints and fill the shelling
compound or hot bitumen .
also bitumen fill road bank.

11. Edging
To protect damaging the sides of concrete
pavements used over burnt brick work.
in place of brick, provided kerb of pre mix concrete.

12.open to traffic
Generally after a month, road should be open to
traffic.
If used rapid hardening cement it take 7 days to
open traffic.

Reference

www.Google.com
www.concrete.net.au
www.res.gov.in
www.upjl.com
www.concrete.com
www.sand.uk