Detailed Report on Summer Internship Project at KMC constructions Ltd.

During 6th of June, 2011 to 24th of June, 2011

Submitted By-

Name of the project: Widening & Strengthening of Existing National Highway from 2 Lane to 4 Lane from km 183.000 t0 205.000 Sonapur-Dharampur section of NH-37 in Assam State EastWest Corridor Under Phase II, programme of NHDP Contract Package No. EW-II (AS-20) Client: National Highway Authority of India Engineer: RITES Ltd. Contractor: KMC Constructions Ltd.

Laboratory at KMC

The aggregates used in the Batching Plant are generally collected from the KMC crushing Plant and in case of sand directly from the Digaru river. A few samples from the tests we observed are tried to put in tabular forms. The tests are respectively AGGREGATE IMPACT VALUE (AIV) TEST, GRADING OF COARSE AGGREGATES FOR CONCRETE WORKS, FLAKINESS INDEX (FI) TEST METHOD, GRADING OF FINE AGGREGATES FOR CONCRETE WORKS.

AGGREGATE IMPACT VALUE TEST (AIV) TEST METHOD Location: Batching plant Description of material: Aggregate Source of material: KMC crusher plant OBSERVATIONS

Sl no 1

Desigtation

Remarks

Total weight of aggregate

358.

356.

taken for test, W1 2 Weight of aggregate retained on 2.36 mm IS sieve after impact, W2 3 Weight of aggregate passing 2.36 mm IS Sieve, W3 4 Aggregate impact value(AIV)=100*W3/W1 % 5 Average impact value %

360.2

295. 299.1 4

296. 2

Repeat the test if W1-(W2+W3) is greater than 1 g.

60.5

62.3

60.3

16.8

17.4

16.8

17.0%

GRADING OF COARSE AGGREGATE FOR CONCRETE WORKS

OBSERVATIONS Total wt:- 21600g

IS sieve

Mass of

Cumulative mass

Cumulative % %

Specification remarks

designation Agg gm 63 mm 40 mm 20 mm 12.5 mm 10 mm 0 1900 17455

passing of limits

retained, retained,gm retained

0 1900 19355

0 8.8 896

100 19.2 10.4

100 85-100 0-20

4.75 mm 2.36 mm

1855

21210

98.2

1.8

0-5

FLAKINESS INDEX (FI) TEST METHOD Location: batching plant Description of material: aggregate Source of material: KMC crusher plant

Sieve Sl no designation Passing through IS sieve, mm Retaining sieve, mm determination Weight of

Flakiness index

Weight of aggregate in each fraction passing Thickness Gauge, mm

aggregate taken in each fraction, mm

A 1 2 3 4 5 6 7 8 63 50 40 25 20 16

C 50 40 25 20 16 12.5 10 6.3 W= 2146 1930 1610 1213 1048

264 249 181 142 112

12.5 10 Summation : INDICES

7965

w=

948

F.I. :- (w/W) *100 = 11.9 %

Flakiness F.I. = 11.9 %

GRADING OF FINE AGGREGATE FOR CONCRETE WORKS TEST

Location : batching plant Description of material: sand Source of material: Digaru river OBSERVATION Total weight: 1400 g Mass of material IS sieve desigtation g 10.0 mm 4.75 mm 2.36 mm 1.18 mm 600 mic 300 mic 0 62 60 150 156 702 Cumulative Cumulative mass g 0 62 122 272 428 1130 0 4.4 8.7 19.4 30.6 80.7 100 95.6 91.3 80.6 69.4 19.3 100 90-100 85-100 75-100 60-79 12-40 % retained % passing Specification limit of zone 1/2/3 s Remark

retained, retained,

150 mic

239

1369

97.8

2.2

0-10

Material conforms to zone : 3 Fineness modulus: 2.416 (acceptable range is 2.0 to 3.5)

Crusher at KMC
The rocks are obtained from the blasting site. At the blasting site using dynamites we got the big sized boulders and then those boulders are disintegrated using semi manual machines. Then these pebbles are carried to the crusher in dumpers and in the crusher they are crushed to relatively small aggregates of different sizes. Then sieves of various sizes such as 10 mm, 20 mm, 40mm etc sieve the aggregates and conveyor belts carry them and deposit separately with respect to their sizes. These help the batching plant fellows to get it conveniently. The whole crushing plant runs on two power transmission supplies. At the gate of the crushing plant the dumpers carrying the aggregates are weighed carefully. The section for making the dowel bars is in front of the plant only, where the dowels are cut at the required lengths with some sharp cutting machine.

Rigid pavement
As the name implies, rigid pavements are rigid i.e. they do not flex much under loading like flexible pavements. They are constructed using cement concrete. In this case, the load carrying capacity is mainly due to the rigidity ad high modulus of elasticity of the slab. Rigid slabs are casted with the help of a very big as well as expensive machine called PQC Paver. The word PQC stands for Pavement Quality Concrete.

Flexible pavement
Flexible pavements are so named because the total pavement structure deflects, or exes, under loading. A flexible pavement structure is typically composed of several layers of materials. Each layer receives loads from the above layer, spreads them out, and passes on these loads to the next layer below. Thus the stresses will be reduced, which are maximum at the top layer and minimum on the top of sub-grade. In order to take maximum advantage of this property, layers are usually arranged in the order of descending load bearing capacity with the highest load bearing capacity material (and most expensive) on the top and the lowest load bearing capacity material (and least expensive) on the bottom.

Pavement designing :-

1. Rigid Pavement. GSB (ground sub base)- 200mm, DLC (Dry Lane Concrete)- 150mm , PQC (pavement quality concrete)- 300mm 1. Flexible Pavement.

Sub-grade- 500mm CBR:-7%

Drainage Layer for Drainage -125mm GSB (Ground Sub Base) 125mm WMM (Water Mix Macadam)- 125mm each- 2 layers,

Prime Coat- 6-9 kg/10 m2 , Tack Coat- 2.5 kg/10 m2 , BM (bituminous mecadam)- 75mm DBM (Dense Bituminous Mecadam) 125mm (Layer I- 65mm & Layer II- 60mm)

Tack Coat 2.5kg/10m2 (Necessary only if time duration is more than 24hours) ,

BC (Bituminous Course)- 50mm Service Road.

Sub-grade- 500mm,

Drainage Layer for Drainage -125mm , GSB (Ground Sub Base) 125mm WMM (Water Mix Macadam)- 100mm each - 2 layers

BM (bituminous macadam)- 75mm,

 SDBC (Semi Dense Bituminous Coarse) 25mm,

Batching Plant
The Batching plant is near to the KMC office. Here, mainly concrete and bitumen are batched and prepared in some huge computer aided mixers. Required quantities of different ingredients to be mixed are fixed in the computer then machines will automatically mix all the ingredients and the product is poured into the dumpers.

Total Station Survey

A total station is an electronic/optical instrument used in modern surveying. The total station is an electronic theodolite (transit) integrated with an electronic distance meter (EDM) to read slope distances from the instrument to a particular point. Coordinates of an unknown point relative to a known coordinate can be determined using the total station as long as a direct line of sight can be established between the two points. Angles and

distances are measured from the total station to points under survey, and the coordinates (X, Y, and Z or northing, easting and elevation) of surveyed points relative to the total station position are calculated using trigonometry and triangulation. To determine an absolute location a Total Station requires line of sight observations and must be set up over a known point or with line of sight to 2 or more points with known location.

Some Points to be remembered at the site

Divisional Island: Provided in order to differentiate service roads form main carriage way.

Camber is provided to drain the water in the surface in the transverse direction.

Deck Slab is placed above the culvert

In Case of compaction

Roller should move from side having Lesser RL. Roller should overlap 1/3 of the previously compacted Layer.

Broomer: For Cleaning the dust in order to obtain proper binding

Approach slab: The approach slab provides a transition between roadway pavement and the bridge.

Expansion Joint: It is provided for the purpose of allowing expansion due to rise in temperature.

Dowel bars: It is used to transfer the load from one slab to the other. Diameter-35mm, Length- 500mm,

Tie bars: It just holds two slabs firmly together. Diameter12mm, Length- 600 mm,

Weep holes: Weep holes or "weeper holes" are small openings left in the outer wall of masonry construction as an outlet for water inside a building to move outside the wall and evaporate.

Shuttering plates Used as a confining wall for the purpose of concreting.

2:1 ratio is maintained at the outer side of a flexible pavement

Separator

(median)-

(1.5m-4.5m)

These

highly

visible

separators provide a temporary barrier system for an effective separation of traffic. Also for provisional

roundabouts and road works marking.

Carriage Way 8.75m (7.50m + 1.25m) in each two lane system.

PQC paver- lays the PQC layer. Bitumen paver- lays the bituminous layer.

Kerb setting machine: with the help of sensor it can construct very long kerb in a short period of time.

Retaining wall is used to resist the lateral earth pressure of the soil itself within the underpass.

Reinforcement: 12mm & 20mm. 20 mm at the side where Active earth pressure is acting and 12 mm diameter bars at the opposite side.

Aggregate 10mm, 20mm, 40mm are generally preferred.