MID SEM REPORT

UPGRADATION OF FLEXIBLE PAVEMENT AND

RECONSTRUCTION OF SINGLE SPAN STEEL BRIDGE
Submitted by

NAVROOP SINGH

101602087

SUBMITTED TO - DR. GURBIR KAUR

DEPARTMENT OF CIVIL ENGINEERING

THAPAR UNIVERSITY, PATIALA

(Declared as Deemed-to-be-University u/s 3 of UGC Act, 1956)

1
 DECLARATION

I Navroop Singh a student of B.E. Civil 4th year want to declare that I have started my training
semester here at PWD from 10 June 2019. I want to state that all the information here in this report
is correct and original to the best of my knowledge.

TIET, Patiala

2
 ACKNOWLEDGEMENT

The internship opportunity I have with PWD is a great chance for learning and professional
development. Therefore, I consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful
people and professionals who led me though this internship period.

I am using this opportunity to express my deepest gratitude and special thanks to who in spite of
being extraordinarily busy with his duties, took time out to hear, and allowing me to carry out my
project at their esteemed organization and extending during the training..

I would also thank Civil Engineering Department, Thapar University who has given me this
opportunity to explore, learn and enhance my practical knowledge and gave me industrial
exposure so as to see future career aspects.

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 TABLE CONTENT
1. INTRODUCTION 1

2. GOALS AND OBJECTIVES TO BE ACHIEVED 2

3. JOB MIX FORMULA FOR DBM (50mm) 4

4. JOB MIX FORMLA FOR BC (Bituminous Concrete) 5

5. MIX DESIGN OF M-35 (PILE) 12

5.1 DESIGN STIPULATIONS 12

5.2 TEST DATA OF MATERIALS 12
5.3 GRADING 13
5.4 TARGET STRENGTH FOR MIX PROPORTIONING 14
5.5 SELECTION OF WATER CONTENT 14
14
5.6 CALCULATION OF CEMENT CONCRETE
15
5.7 PROPORTIONING OF VOLUME OF COARSE AND FINE
AGGREGATE
15
5.8 MIX CALCULATION 16
5.9 MIX PROPORTION TRIALS
6. WORKING AND COMPONENT OF BITUMEN BATCHING 18
PLANT
7. DESIGN OF FLEXIBLE PAVEMENT AND 20
CONSTRUCTION
8. CONSTRUCTION OF BORED PILE 24
8.1 INTRODUCTION 24
25
8.2 PROCEDURE
9. CONSTRUCTION OF PIER CAP 29
9.1 INTRODUCTION 29
30
9.2 METHODOLOGY
31
9.3 PROCEDURE
10. SAFETY MEASURES 34

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LIST OF TABLE
Table 1 Material available for dense bituminous macadam
Table 2 Sieve analysis of DBM aggregate
Table 3 Physical properties of DBM material
Table 4 % passing of mixed aggregates for DBM
Table 5 Different design parameters with 4.50% Bitumen
Table 6 Composition of one tonne DBM
Table 7 Material available for Bituminous Concrete
Table 8 Sieve analysis of BC Aggregate
Table 9 Physical properties of BC material
Table 10 Percentage passing of mixed aggregate for BC
Table 11 Different design parameters with 5.40% Bitumen
Table 12 Composition of one tonne BC
Table 13 Sieve analysis of aggregate for M-35 cement
Table 14 Grading of aggregate according to IS 383 1970
Table 15 Grading of fine aggregate
Table 16 Mix proportion trial 1
Table 17 Mix proportion trial 2
Table 18 Mix proportion trial 13
Table 19 28 days Compressive strength test( Mpa)

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1. INTRODUCTION

Upgradation of Road Retgarh to Shuttrana road , Section of this road is from 7.00 Km to 10.00
Km and 12.50 Km to 24.20 Km. It is an ODR road (Other District Road ).This project was
started in 2019 and will be completed in 2020.The project road falls in plain terrain.

The Asphalt mix batching plant is in village Pahadgarh in Samana which includes
Laboratory for material testing, asphalt batching plant, concrete batching plant, retaining
wall side panel casting and storing yard, storage of aggregate, sand is also done in datawas,
living arrangement for labours.

Reconstruction of Single Span Steel Bridge on BML Canal across Patiala Samana Patra
BOT road Corridor at Samana (RD 96.7000 including approaches and dismantiling of
existing unsafe bridge etc. job work by M-35

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2. GOALS AND OBJECTIVES TO BE ACHIEVED:-

1. Construction of the various elements of the structure, roads and their assembling is carried
out.

 Pile cap
 Pile foundation
 Pier cap formation
 Pre formed steel bridge material
 Dismantling of already formed bridge
 Study of designing of flexible road

2. To learn, how to read and interpret the various drawings and plans.
 Understand and interpreting the drawings will be one of the most important
objectives as all the work is carried out with the help of drawings
 Each and every details of structures and roads are given in drawings. Hence it is
important to be able to read the drawings efficiently.

3. To learn, how to make a Bar Bending Schedule (BBS).

 Bar bending schedule is a list of reinforcement’s bars for a given reinforced
concrete work items, and is represented in tabular form for easy visual reference.
 It is usually used for calculating the total cost of reinforcements to be provided in
concrete

4. Quality control
 Mix proportioning - concrete mix and bitumen mix plants type, components.

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  Cement tests :-Initial and final setting time of cement, Fineness of cement,
Soundness of cement, Normal consistency of cement, Compressive strength of
cement (3 days, 7 days, 28 days )
 Bitumen tests :-Penetration test of bitumen, Determination of softening point of
bitumen, Absolute viscosity test of bitumen, Marshal stability determination of
bituminous mix, Quantitative extraction and sieve analysis of bituminous mixes,
Gradation test for DBM, Modified proctor compaction test, California bearing ratio
(CBR) test soaked, Liquid limit and plastic limit
 Concrete tests :-Fresh concrete- workability (slump test), Concrete cube
compression test in Mix design, To study mix design of concrete
 Aggregate tests :-Aggregate gradation, Aggregate impact test for toughness,
Aggregate impact test for strength

5. To enhance my practical knowledge as well as theoretical knowledge regarding the

concepts of Civil Engineering
 The achievement of the above mentioned goals would enhance my both practical
and theoretical knowledge regarding the subject
 I will try to study the IS codes being used in this project i.e. IS10262:2009,IS 383-
1970, IRC81, IRC37, IRC58, IRC73, IRC 64

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3. JOB MIX FORMULA FOR DBM 50mm (GRADE II)

Paving of the DBM layer is done according to the instruction given by the laboratory of the
department.Hence a job mix formula is given by the research lab of PWD department given
whose calculation and procedures are given as under,which is to be followed strictly on site
,for laying of the DBM layer .

The following materials were received –

1. 25mm Aggregate

2. 13.2mm Silt

3. 11.2mm Silt

4. Coarse Sand

5. Filler (lime)

6. Bitumen VG-30

Table 1:Material available for DBM

The material were checked for their individual grading and results are given as under –

Sieve %age passing of materials

size
(mm) 25mm 13.2mm 11.2mm Coarse Filler(lime)
Sand
37.5 100 100 100 100 100

26.5 60 100 100 100 100

19.00 04 100 100 100 100

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 13.2 NIL 52 100 100 100

4.75 - 01 25 100 100

2.36 - NIL 08 97 100

0.300 - - - 44 100

.075 - - - 06 99

Table 2:Sieve Analysis of DBM Aggregate

The different materials were tested for their specific gravity and other physical properties and
results are given below –

Materials Specific gravity AIV % Water Absorption

(Aggregate Impact
Value)

25mm 2.63 20.00 0.48

13.2mm 2.63 20.00 0.55

11.2mm 2.63 20.00 0.61

Sand 2.58 - 1.96

Lime 2.32 - -

Bitumen VG-30 1.00 - -

Table 3:Physical Properties of DBM material

Blending of materials – A number of trials were made for achieving the gradation as per MORTH
and finally the blending in the following proportions was found to be the most suitable from
gradation point of view –

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 25mm Aggregate : 16%
13.2mm Silt : 31%
11.2mm Silt : 18%
Coarse Sand : 33%
Filler (lime) : 02%

With the above proportions by weight , the actual grading achieved is as under –
Sieve Size (mm) % passing of mixed aggregates

Observed Value
37.5 100
26.5 94
19.0 85
13.2 69
4.75 40
2.36 36
0.300 16
.075 04
Table4: Percentage passing of mixed aggregates

The permissible variations of the individual percentage of the various ingredients in the actual mix
from the job mix formula shall be with in the limits as specified in table 500-13 of MORTH
specification (4th revision)
With above graded materials Marshall moulds were filled with 4.0%,4.5%,5.0%and 5.50%,6.0%
Bitumen by weight of the total mix by giving the 75 no of blows on each face of the specimen.
The Specimen so obtained were tested for the
 Marshal stability
 Bulk density
 Flow value
Percent air voids and voids filled with bitumen were also worked out . It is observed that the
optimum binder content comes out to be 4.50% Bitumen VG-30 by weight of the total mix.

11
The value of different design parameters with 4.50% Bitumen VG-30 by weight are given as under
:-
Maximum Specific Gravity of loose mix 2.401
Bulk Specific Gravity 2.305
Marshal Stability 10.70KN
Air void in the mix 4.00%
Void filled with Bitumen 74.27%
Flow Value 3.53mm
Table 5 Different design parameters with 4.50% Bitumen
The mix with 4.50% Bitumen VG-30 by weight of the total mix gives the basic requirement of
strength , flow value and other parameter of design . Hence recommendation were given

As per mix design worked out as above one tone of DBM 50 mm mix shall be prepared from the
following ingredients :-

25mm Aggregate 152.8 Kg

13.2 Silt 296.05 Kg
11.2mm Silt 171.90 Kg
Coarse Sand 315.15Kg
Filler (lime) 19.10 Kg
Bitumen VG-30 45.00 Kg
Table 6:Composition of one tonne DBM

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4. JOB MIX FORMULA FOR BITUMINOUS CONCRETE

Before laying of bituminous concrete the instruction are followed given by the laboratory of
the department.Hence a job mix formula is given whose calculation and procedures are given
as under.
The following material were used:

1 13.2mm Silt

2. 11.2mm Silt

3. Sand

4. Filler (lime)

5. Bitumen VG -30

Table 7:Material available for Bituminous Concrete

The material were checked for their individual grading and the results are given as under

Sieve size %age passing of materials

(mm) 13.2mm 11.2mm Coarse Sand Filler(lime)

19.0 100 100 100 100

13.2 52 100 100 100

9.5 10 80 100 100

4.75 01 25 100 100

2.36 NIL 08 97 100

1.18 - 01 78 100

13
 0.600 - NIL 67 100

0.300 - - 44 100

0.150 - - 29 100

0.075 - - 06 99

Table 8 Sieve Analysis of BC Aggregate

The Different materials were tested for their specific gravity and other physical properties and
results are given as below:-

Materials Specific gravity AIV % Water Absorption

(Aggregate Impact
Value)

13.2mm 2.63 20.00 0.55

11.2mm 2.63 20.00 0.61

Sand 2.58 - 1.96

Lime 2.32 - -

Bitumen VG-30 1.00 - -

Table 9 Physical properties of BC material

A number of trials were made for achieving the gradation as per MORTH and finally the blending
in the following proportions was found to be the most suitable from gradation point of view –

13.2 mm Aggregate 12%

11.2mm Aggregate 40%

Sand 46%

Filler (Sand) 02%

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 With the above proportions by weight , the actual grading achieved as under:-

Sieve Size (mm) % passing of mixed aggregates

Observed Value

19.0 100

13.2 94

9.5 81

4.75 58

2.36 50

1.18 38

0.600 33

0.300 22

0.150 16

0.075 05

Table 10:percentage passing of mixed aggregate for BC

The permissible variations of the individual percentage of the various ingredients in the actual mix
from the job mix formula shall be with in the limits as specified in table 500-13 of MORTH
specification (4th revision)

With above graded materials Marshall moulds were filled with 4.0%,4.5%,5.0%and 5.50%,6.0%

Bitumen by weight of the total mix by giving the 75 no of blows on each face of the specimen.
The Specimen so obtained were tested for the,Marshal stability,Bulk density ,Flow value.

15
Percent air voids and voids filled with bitumen were also worked out . It is observed that the
optimum binder content comes out to be 5.40% Bitumen VG-30 by weight of the total mix.

Maximum Specific Gravity of loose mix 2.462

Bulk Specific Gravity 2.363

Marshal Stability 11.70 KN

Air void in the mix 4.00%

Void filled with Bitumen 71.32%

Flow Value 3.30 mm

Table 11:Different design parameters with 5.40% Bitumen

The mix with 5.40% Bitumen VG-30 by weight of the total mix gives the basic requirement of
strength , flow value and other parameter of design. Hence ,it is recommended to adopt 5.40%
Bitumen VG-30 by weight of the total mix for bituminous concrete .

As per mix design worked out as above one tone of DBM 50 mm mix shall be prepared from the
following ingredients :-

13.2 Aggregate 113.52 Kg

11.2mm Aggrgate 378.40 Kg

Coarse Sand 435.16 Kg

Filler (lime) 18.92 Kg

Bitumen VG-30 54.00 Kg

Table 12: Composition of one tonne BC

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5. MIX DESIGN OF M-35 CONCRETE (PILE)
Pile , in building construction , a postlike foundation member used from prehistoric times .
In modern civil engineering ,poles of steel are driven into ground to support a structure,
bridge etc .
Hence before actual construction of pile mix design is formulated in the lab which is a step
wise step to construct a pile . hence mix design od M-35 concrete pile is given under:-

5.1 DESIGN STIPULATIONS:-

i) Characteristic compressive : 35 N/mm2

strength required in the field at 28
days
ii) Max size of aggregate : 20mm
iii) Type of coarse aggregate : Crushed
iv) Type of fine aggregate : Uncrushed
v) Workability(slump) : 150-200mm
vi) Degree of quality control : Good
vii) Type of exposure : Moderate
viii) Type or brand of cement : Ultra tech (OPC 43 GRADE)
ix) Type of admixture : BASF
( Badische Anilin und
Soda Fabrik)

5.2 TEST DATA OF MATERIALS

1. Specific Gravity

Cement : 3.15
Coarse aggregate : 2.64
Fine aggregate : 2.60
Admixture : 1.10
2. Water absorption
Coarse aggregate
20mm : 0.48%
10mm : 0.56%
Fine aggregate : 1.84%

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5.3 GRADING
i) Coarse aggregate

Sieve size %age passing of materials

(mm) 20mm 10mm

Fraction -1 Fraction-2

40 100 100

20 91 100

10 3.40 70.60

4.75 NIL 12.60

Table 13:Sieve analysis of aggregate for M-35

To satisfy the required grading of combined aggregate , the 20 mm size and 10 mm

size coarse aggregate are mixed in the following properties

Fraction 1 (20mm) : 46%

Fraction 2 (10mm) : 54%

The grading achieved of the blended aggregate is given under

Sieve size % passing Required as per IS 383 1970

observed
40mm 100 100

20mm 95.9 95-100

10mm 39.7 25-55

4.75mm 6.8 0-10

Table14:Grading of aggregate according to IS 383 1970

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 ii) Fine aggregate

Sieve size % passing Limit for zone – II

10.0mm 100 100
4.75mm 95.6 90-100
2.36mm 90.0 75-100
1.18mm 77.6 55-90
0.60mm 51.8 35-59
0.30mm 21.4 8-30
0.15mm 9.6 0-10
Table 15:Grading of fine aggregate
Fine aggregate belongs to Zone-II as per Table-4 of IS383-1970

5.4TARGET STRENTH FOR MIX PROPORTIONING

From current margin as per clause 1700-5 pf MORTH Specification , the target mean
strength of M-35 is 47 Mpa
A-1 SELECTION OF WATER CEMENT RATIO
As per clause 1700-2 of MORTH specification ,Maximum water cement ratio=0.45
Water cement ratio taken for the target mean strength and required
workability=0.40

5.5 SELECTION OF WATER CONTENT

As per Table 2 of IS 10262:2009 maximum water content per cubic metre of concrete
for 20mm sized aggregate is 186 litres .

As per clause 4.2 of IS 10262:2009 as Admixture is used, the water content can be
reduced

As per required workability , water content taken =170 litre

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5.6CALCULATION OF CEMENT CONTENT
Water-cement ration = 0.40
Cement content = 425Kg/m3

5.7 PROPORTIONS OF VOLUME OF COARSE AGGREGATE AND FINE

AGGREGATE CONTENT
From Table 3 of IS 10262:2009 , volume of coarse aggreagate per unit volume of total
aggregate corresponding to 20 mm size aggregate and fine aggregate for cement ratio
of 0.40 is taken as 0.640
Therefore the volume of fine aggregate is = 1-0.642=0.360

5.8MIX CALCULATION
The mix calculation per unit volume of concrete shall be as follows:

a) Volume of concrete =1m3

b) Volume of cement = Mass of cement ÷ (Specific gravity of cement × 100 )
= 0.1349m3
c) Volume of water = Mass of water ÷ (Specific gravity of cement × 100 )
=0.170 m3
d) Volume of Chemical = Mass of Chemical admixture ÷ (Specific gravity of
Admixture (Super Admixture × 100 )
Plasticizer @ 0.90% =0.0035m3
by mass of
cementious material )
e) Volume of all in =[a-(b+c+d)]
aggregate =0.6916m3
f) Mass of coarse =1168.5 Kg
aggregate
g) Mass of fine =647.3Kg
aggregate

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5.9 1) MIX PROPORTION FOR TRIAL NUMBER 1

Water-Cement ratio =0.40

Quantity of cement =425 Kg/m3
Quantity of Water taken =170 Kg/m3
Quantity of Fine aggregate =647.3Kg/m3
Quantity of Coarse aggregate =1168.5 Kg/m3
Quantity of Admixture @0.90% =3.825 Kg/m3
Table16:Mix proportion trial 1

2) MIX PROPORTION FOR TRIAL NUMBER 2

Water-Cement ratio =0.40

Quantity of cement =430 Kg/m3
Quantity of Water taken =172 Kg/m3
Quantity of Fine aggregate =643.9Kg/m3
Quantity of Coarse aggregate =1162.4 Kg/m3
Quantity of Admixture @0.90% =3.870 Kg/m3
Table 17: Mix proportion trial 2

3) MIX PROPORTION FOR TRIAL NUMBER 3

Water-Cement ratio =0.40

Quantity of cement =435 Kg/m3
Quantity of Water taken =174 Kg/m3
Quantity of Fine aggregate =640.5Kg/m3
Quantity of Coarse aggregate =1156.3 Kg/m3
Quantity of Admixture @0.90% =3.915 Kg/m3
Table18: Mix proportion trial 3

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The concrete cubes (150mm x 150mm) were casted with these mixes and the following results
were obtained

Mix no Water Cement W/C Ratio Slump (mm) 28 days

Compressive
Strength Mpa
1 170 425 0.40 155 44.9
2 172 430 0.40 170 47.6
3 174 435 0.40 185 50.2
Table19: 28 days Compressive strength( Mpa)

The 28 days compressive strength of trial mix no @ fulfills the design criteria as per MORTH
specification and IS10262:2009. Hence M-35 grade Cement concrete to be adopted
Quantites of Material for one cubic metre of concrete –

Water =172Kg
Cement =430Kg
Sand =643.9Kg
Coarse Aggregate =1162.4Kg

Fraction 1 20 mm =534.7Kg
Faction 2 10mm =627.7Kg
Admixture @0.90% by wt of cement =3.870Kg

22
6. BITUMEN BATCHING PLANT

Bitumen mixing plant is a key equipment for any road construction . Any asphalt batch
mix plant has many functions. We can categorize the mixing plants as batch mix plant
and drum mix plant. The mixing plant on site we have is batch mix plant. Having a
production capacity of 20 TPH and 1000 kg storing capacity. We have 1 tanks of bitumen
in bitumen supply system having capacity of 34 tonnes each right near about 4% by
weight of bitumen is added with respect to aggregate.

i. Aggregate Storage
Different aggregate sizes are stored out in open .

ii. Cold aggregate bin feeder

The desired aggregate are supplied to the bin feeder with the help of cranes

iii. Conveyor to take the cold aggregates from the feeder and supply the same to the
dryer drum.
It simply helps to transport the aggregate from the bin feeder to the burner via a
conveyor belt and in the process it also removes the unwanted dust

iv. Burner
The burner is used to heat up the aggregate to desired temperature level. It is also
where the ashaplt is mixed to the aggregate once they have reached the required
temperature level

v. Conveyor to take hot aggregate to the truck

After the completion of asphalt mix the aggregate are transferred via conveyor
belt to the truck .In this process the temperature of the aggregates are kept in
check , and kept under desired level .

vi. Control system

Fully computerized air conditioned control cabin with on board electrical power
control console, distribution switch board, fully automatic process & sequence
control are a standard on all Drum Mix Plants

23
 vii. Asphalt content tester
After the completion of process sample is taken from the mix plant and is put into
asphalt machine to check the bitumen content of the batch . it is done on batch
plant itself before taking it on site .

(1) (2)

(3) (4)

Tile1. Cold aggregate bin feeder

Tile 2. Conveyor belt taking cold aggregate to the burner
Tile3. Asphalt content Tester
Tile 4. Temperature checking by IR thermometer

24
7. Design of flexible pavement and its construction

Laying of flexible pavement : In construction of flexible pavement various operations are

involved such as
● Preparation of subgrade,
● Laying of subbase,
● Laying of base course,
● Laying of wearing course.

The preparation of subgrade involves clearing the site surface after deforestation which
was done on site with the help of bulldozers. once the ground is levelled it is either
excavated or its embankment is raised depending upon whether the road comes in filing or
cutting. this stage also involves transportation of soil from the borrow pit and uniformly
spreading it in layers which was done on our site with the help of motor graders. Required
quantity of water is added on selected pavement width according to the OMC and each
layer is compacted with power rollers to bring it to the desired degree of compaction. After
preparation of subgrade Laying of subbase is done. Subbase can be described as layer
between base course and subgrade which is then compressed to desired density. on site we
32 have added aggregates of 60mm, 50mm, 40mm, 20mm, 10mm, stone dust according to
the mix proportions in mix design required. GSB layer on site is 200mm thick. After this
Laying of WMM layer is done. On site WMM was laid which consists of 40mm, 20mm,
10mm, stone dust particles and water. all of these were laid in proportions according to the
WMM mix design. Addition of water in WMM layer also depends upon Weather condition
of site if moisture content on site is sufficient the water addition is less and vice versa.
WMM layer on site is 250mm thick. After this laying WMM layer Prime coat is applied
on the road and it should be applied on track before 24 hours. it is applied between WMM
and DBM layer to bond loose material particles on the surface of the WMM layer, to plug
capillary voids in the base course surface to prevent migration of moisture by giving a
watertight surface, and to provide adhesion between the WMM and DBM layer. after the
application of prime coat, tack coat is applied just 1 hour before laying of DBM layer. no
vehicular movement is allowed on carriage way after tack coat is applied except vehicles
used for construction, the main purpose of tack coat is to maintain a proper bond with DBM
layer. so that particles of DBM stick properly after this a layer of DBM (g-1) and BC were
Laid on site thickness of these layers are 85mm and 40mm respectively. At the end the
total thickness of all the road comes out to be layer excluding subgrade is 575mm with
subgrade layer of 500mm.

25
 Tile5 Mixing plant loading Tile6 Compaction of DBM Layer

Tile7 Paving Machine Tile8 Laying of BC layer

26
For design of flexible pavement we have referred IRC 37 guidelines for the design of
flexible pavement. According to the feasible report of the project we got some data of the
road. it gave us the value of Avg. vehicle damage factor of 1.67 which was calculated by
converting all the commercial vehicles of different configuration into standard million
axles. Initial traffic when construction started was calculated with the help of traffic survey
which come out to be 482 CVPD. The lane distribution factor used was taken from clause
4.5.1 from IRC 37-2012 of 50%. Construction time given for this project is 1.5 years with
a design life of pavement to be 15 years. According to the geometrical design the camber
of the road is 2.5%. A=p*((1+R/100) ^x) N= (365*A*((1+R/100) ^ (n-1))*D*F)/(R/100)

As in most of the reaches CBR ranges between 5 to 6 so for design porpose assume
CBR=5.50

CBR=5.50%

Cumulative Traffic = 2.5msa

Average CBR 5 and 6

msa=2.00 Crust=490+450/2 =470

msa=3.00 Crust=530+490/2 =510

470+510/2=490 mm

According to the Calculation we get the crust value to be 490mm

BC layer of 20 mm, DBM layer of 50 mm, GSB layer of 202.5 mm and having a subgrade
thickness of 500 mm.

Layers of Thickness required Exisiting Proposed for

pavement as per IRC 37 Thickness Strengthing
GSB 215+230+175+190/4 - -
=202.5mm
WBM 225+250/2 225mm 150mm
=237.5mm
DBM 50mm 50mm 50mm
BC 20mm 20mm 20mm
Table 20

27
Tile 9 Checking temperature of DBM on site Tile 10 Tackcoat VG-30

Tile 11 Tendom vibrator roller

28
8. CONSTRUCTION OF BORED PILE
8.1 INTRODUCTION
Bored pile is a reinforced-concrete foundation that supports structures with heavy
vertical loads.
 Depth
18375 mm

 Width
1000mm diameter

 CONCRETE
M-35

A Bore is dug into the ground via DMC method (Direct mud circulation method) so that
reinforcement cage could be fitted into the bore and later concreteing is done

Tile12
Direct Mud Circulation method of pile foundation installation is used for bored cast
in-situ piles. Direct Mud Circulation method is best suited when working-space is a
huge constraint. The method is termed as Direct Mud Circulation because it
involves the circulation of mud from the pile bore directly to the bentonite pit where
the pump reuses the bentonite slurry leaving alone the settled mud.

29
8.2 Procedure

The Tripod is made to stand around the target pile (two legs around the pile and one into
the slot provided in winch machine) and a plumb bob is then hung down the pulley
(mounted on the tripod) aiming the center of the target pile so as to obtain the center for
the chisel.

1. Once the position of winch machine and the tripod is fixed, casing is installed into
the earth keeping the center point intact. A wall made up of sacks filled with rubble
or soil is created around the pile-area so as to channel an artificial conduit directed
towards the bentonite pit. This channel directs the mixture of mud and bentonite
slurry coming out from the bore to the bentonite pit.

2. The topmost drill pipe is connected with a hose emerging from the vertical pump
(installed in the bentonite) pit sending fresh bentonite slurry to the borehole through
a fine opening in chisel and when the bore hole is filled to the brink, it flows back
to the bentonite pit along with the mud through the artificial conduit. In this way the
mud from the bore keeps on moving up the borehole and is directed to the bentonite
tank.

Tile 13: Bentonite pit

3. The specific gravity of the bentonite suspension should be between 1.05 to 1.10

4. Chisel is then driven inside the casing and the earth is bored until the chisel has fully
gone down inside the earth. Drill pipes are attached to the chisel in tandem and the

30
 boring progresses by maneuvering the winch machine until the requisite depth is
bored. Flushing is done all the while during the pile boring. After the completion of
bore, chisel is brought outside and the second flushing of the bore hole is done to
remove all the mud and impurities.

Tile 14 Chisel Tile15 Reinforcement cage brought down

5. Chisel is then driven inside the casing and the earth is bored until the chisel has
fully gone down inside the earth. Drill pipes are attached to the chisel in tandem
and the boring progresses by maneuvering the winch machine until the requisite
depth is bored. Flushing is done all the while during the pile boring. After the
completion of bore, chisel is brought outside and the second flushing of the bore
hole is done to remove all the mud and impurities.

6. A reinforced cage is prepared before according to the map issued by the engineer as
shown in tile 9 and tile 10

7. The reinforced cage prepeared is then brought into the bore hole via cranes and
then is ready for concreteing as shown in tile 8

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 Tile16 reinforcement cage Tile 17 Architectural drawing of R/F cage

8. Tremie are finally inserted into the bore hole attached to a hopper at the top hung
by the wire rope. The joint between the hopper and tremie pipe is closed with a steel
plug before the first charge of concrete. The hopper is then filled with concrete to
its full capacity. Once filled, the steel plug is removed to allow the concrete to flow
down the tremie pipes thereby replacing the bentonite solution.Concreting is done
up to at least 1m above the cut-off levels to ensure good concrete for proper
embedment into pile cap.

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 Tile 18 & 19 Concreting of the pile

9. Slump Test
The slump test of concrete is performed on site to check the workability of concrete .
according to the design for M-35 concrete workability of concrete reflected by the slump
whose value should be between 150-220 mm

Tile 20 Slump Test Tile 21 Concrete cube compression test

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9. CONSTRUCTION OF PIER CAPS

9.1 INTRODUCTION

Pier caps are the component of bridge which transfer load from superstructure to the piers.

Pier caps provide sufficient seating for the girders and disperse loads from the bearing to the
piers.

The design of our pier cap is designed and the details of the measurement are as follows

 Length of pier cap is 4300 mm

 Breadth of pier cap 3250 mm

 Height 700mm

 Concrete M-30

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9.2 METHODOLOGY

Making of reinforcement cage

Shifting of cage to the bed

Insertion of spirals and couplers

Inserting tin pipes

Strands insertion

Shuttering

Concreting

Opening of shuttering after 24 hours

Curing

Stacking

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 9.3 PROCEDURE

1. Reinforcement cage preparation:- Bar bending schedule will be prepared and then get approved.
In the reinforcement yard the bending and cutting of reinforcement is done. Reinforcement cage
is prepared by tying of the reinforcements. The cage preparation is done according to the
architectural drawing provided to them as shown in Tile 15.

Tile22 &23 Reinforcement cage preparation for pier cap

Tile 24 Architectural Drawing for pier cap

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2. Insertion of spirals and couplers:- Spirals of 105mm and 85mm while the couplers are of 20mm
dia. Inserting tin pipes through the cage so that later ply can be inserted through them for post
tensioning.

3. Cleaning:- Cleaning along with oiling is done. Thermocol is placed so as to prevent entering of
concrete to the points from where it had to be joined. Shutters are cleaned and properly oiled.

4. Shuttering:- After completion and checking of the reinforcement cage according to the drawings,
shuttering is done as per the schedule and is fixed. Required support is given to the shutters.As
shown in Tile 15

Tile 25 Shuttering

5. Concreting:- After proper fixing of shutters it is the time for the concreting. The grade of
concrete is used according to the specified design and it is prepared in the batching plant in the
casting yard. And then it is sent to the location in the transit mixer. From which the concrete is
poured in using the boom placer which is at a certain distance from the pier cap.

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 Tile 26 Reinforcement cage Tile 27 Concreting

6. Opening of shuttering and curing:- Shutters are opened after a duration of 24 hours
systematically. And then later on curing is done regularly.

Tile 28 After removal of shuttering

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10.Safety Measures

Environment health and safety (EHS) manager ensures that all his team members are given
brief on the design and the scheme of operation so that everything works efficiently and
meets EHS plan.

Some of the EHS measures are given as follows:-

 Personal protective equipment (PPE) must be worn by all workmen and staff which
includes protective clothing, helmets, goggles, or other equipment designed to protect the
wearer’s body from injury.

 Workmen shall be screened and trained before deploying.

 Proper lighting shall be maintained during the night work.

 Safety equipment shall also be provided to the visitors, supervisors and workers.

 All the machines should be inspected before deployment and proper guarding of the
moving parts should be in place before starting work.

 First aid facilities should be available at the site.

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