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A

INTERNSHIP REPORT

ON

CONSTRUCTION OF

CEMENT CONCRETE ROAD

AT

U.P P.W.D, PROVINCIAL DIVISION

MAINPURI, UTTAR PRADESH

TRAINING PERIOD ( 26 JUNE 2014 TO 24 JULY 2014)

SUBMITED BY : DEEPAK ATHWAL

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CI VIL : 3RD YEAR

R OLL .NO : 111940015

H. R. INSTITUTE OF TECHNOLOGY, GHAZIABAD

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ACKNOWLEDGEMENT

It is indeed a great pleasure and privilege to present this report on training at

PWD.

I am extremely greatfull to my training and placement officer for issuing a

training letter, which made my training possible at PWD, U.P .

I would like to express my gratitude to Er. SATYAPRAKASH for his invaluable

suggestion , motivation , guidance and support through out the training

period . his methodology to start from simple and then deepen the concept

made me to bring out this project report without anxiety.

Thanks to all other PWD officials , operators and all other members of PWD

,especially. Er AZAD SINGHWAL accounted for their help in completing the

project and see light of success .

Dated DEEPAK ATHWAL

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ABSTRACT.

This project is about the construction of the CC road at the KUSHMARA s ituated at mainpuri

district u.p. This project is under the pwd, pd, mainpuri of having construction length of 800

mm of cc road, having widt h of 7 m .

With having cost of 4 .5 crore

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INDEX

1. PWD Introduction ………………………………

2. About Cement road ………………………….

3. Material ……………………………………………

4. Design of concrete mix used………………

5. Tests …………………………………………………..

6. Cement road construction ………………

Preparation of subgrade …………

Preparation of base …………………

Form work …………………………………..

Watering of base ………………………

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Joints ……………………………………........

REINFORCEMENT……………………………..

Material mix & placing ……………

Compaction …………………………………

Finishing of surface…………………..

Curing …………………………………………

Filling joint………………………………

Edging ………………………………………..

7.Open to traffic…………………………

8. Reference……………………………………….

PWD INTRODUCTION

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

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supervisory boards in different districts of the engineer’s 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 CEMENT 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 types

1-Cement

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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

caementiciumto 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.

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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 anyshape desired, and once

hardened, can become a structural (load bearing) element. Portland cement may be grey

or white.

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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 pozzolana 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.

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Portland silica fume cement:

Addition of silica fume can yield exceptionally high strengths, and cements containing 5–

20% 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 1⁄16 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

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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 inchs(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

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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

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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.

Design of concrete mix used

IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15,

M20, M25, M30, M35 and M40. In this designation the letter M refers to the mix and the

number to the specified 28 day cube strength of mix in N/mm2. The mixes of grades M10,

M15, M20 and M25 correspond approximately to the mix proportions (1:3:6), (1:2:4),

(1:1.5:3) and (1:1:2) respectively.

The design of concrete mix used in this project has been approved by the a well known

institute H.B.T.I. Kanpur . In this project we have used the M20 concrete.

Test

There are four main tests to be done on concrete:

1. The Slump Test.

2. Compression Test

3. Impact Test

4. Cube Test

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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

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

Collect a sample.

Stand firmly on the footpieces and fill 1/3 the volume of the cone with 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.

Now fill to 2 /3 and again rod 25 times, just into the top of the first layer.

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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.

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 off-site. 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 concrete’s 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

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Clean the cylinder mould and coat the inside lightly with form oil, then place on a

clean, level and firm surface, i.e the steel plate.

Collect a sample

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. . Fill the cone to overflowing and rod 25 times into the top of the first 4

layer

then top up the mould till overflowing.

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

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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.

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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

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MIXING

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

HAND MIXING

Mix the cement and fine aggregate on a water tight none-absorbent platform until

the mixture is thoroughly blended and is of uniform color

Add the coarse aggregate and mix with cement and fine aggregate until the coarse

aggregate is uniformly distributed throughout the batch

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

Remove the specimen from water after specified curing time and wipe out excess

water from the surface.

Take the dimension of the specimen to the nearest 0.2m

Clean the bearing surface of the testing machine

Place the specimen in the machine in such a manner that the load shall be applied

to the opposite sides of the cube cast.

Align the specimen centrally on the base plate of the machine.

Rotate the movable portion gently by hand so that it touches the top surface of

the specimen.

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Apply the load gradually without shock and continuously at the rate of

140kg/cm2/minute till the specimen fails

Record the maximum load and note any unusual features in the type of failure.

Using mix Concrete

There some Point to construct the road

1. Preparation of subgrade 2. Preparation of base 3. Form working 4. Watering of base 5. Joints 6. Material mix & placing 7. Compaction 8. Finishing of surface

Floating

Belting

Brooming 9. Curing 10. Joint filling 11. Edging 12. Open to traffic

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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 sub grade, For preventing the water seepaging into the soil , used water proof paper on entire length.

2. Preparation of base

( Actual site scene of construction )

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Choose any one type of base

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.

Concrete base On the road used 10cm Cement concrete(1:2:4) or lime concrete(16:32:64)

Granular medium material layer 10-15cm composite layer of sand , moorum, bajriare usedfor better drainage facilities

Stabilization soil

3. Form work

Material for form work Wooden sheets, battens, plywood, fibre hard board, steel plates, angles, rope, minerals.

before using form work, it should free from all type material like as dust cement.

To placing the concrete in appropriate depth used 2.5-5cm thick and 3mtr long wooden sheeting.

The depth of wooden block must be same as level of slab thick.

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.

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REINFORCEMENT Reinforcement is provided at depth between 3cm to 10 cm from the top of the CC road. This is provided for the tensile strength of the CC road. Also to maintain the friction between the vehicle and the surface. But the main advantage of providing the reinforcement is to avoid the expansion of the surface due to the increase of the surface temperature.

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(actual site scene of providing the reiforcement )

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.

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Used two type mixer

1. Batch mixer

a. At site, used for small road construction

2. Continuous mixer a. Continuous 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 concrete

1. Alternate bay method

a. Placed 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 method

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(Actual site scene of continous bay ) construct 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.

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Compaction done by 1.Mechanically surface vibrator 2. Manually hand tempers

8. Finishing of surface

1.Floating For levelling the surface use floating, scree-ding , 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. Brooming Brooming 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 methods of curing are

Shading concrete works

Covering with hessian & gunny bags

Sprinkling of water

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By ponding

Membrane curing

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. EDEGING

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

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www.Google.com

www.concrete.net.au

www.res.gov.in

www.upjl.com

www.concrete.com

www.sand.uk

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