TRAINING REPORT

ON
CONSTRUCTION OF CEMENT CONCRETE ROAD
At
PUBLIC WORKS DEPARTMENT

Project Report Submitted in Partial Fulfilment of the Requirements for the

Degree of

Bachelor of Engineering
In
Civil Engineering

Submitted by
Anurag Jangir: 16CIV32015

Department of Civil Engineering

M.B.M Engineering College
Faculty of Engineering & Architecture
Jai Narain Vyas University, Jodhpur
 ACKNOWLEDGEMENT

I would like to express my deepest appreciation to all those who provided me the possibility to
complete this report. A special gratitude I give to my mentor Mr. J.C. PATHAK, whose
contribution in stimulating suggestions and encouragement, helped me to coordinate my training
especially in writing this report. I would also like to thank my parents for their inexhaustible
source of inspiration.

I have to appreciate the guidance given by other supervisor as well as the panels especially in
my training that has improved my learning skills thanks to their comment and advices.
CERTIFICATE
CONTENTS

1. PWD Introduction

2. About Cement Road

3. Material

4. Tests

5. Cement Road Construction

6. Preparation of Subgrade
7. Preparation of Base
8. Form Work
9. Watering of Base

10.Joints

11.Material Mix & Placing

12.Compaction

13.Finishing of Surface
14.Curing
15.Filling joint

16.Edging

17.Open to Traffic

References……………………………………………………………………..
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 Yojna and pre-fabricated construction of rural roads linking the
work of other district roads broad the scale bases are edited.

Successful operation of various schemes for the Public Works Department

engineers and 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 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

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, cementum, 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.
Portland fly ash cement
It 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

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

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 non- tropical 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 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, soil- cement, 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 weight 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 Collect a sample.

3 Stand firmly on the foot pieces 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.

4 Now fill to 2/3 and again rod 25 times, just

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

6 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
foot pieces.

7 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 off-site. The only work done on-site is to make a
concrete cylinder for the compression test.
The strength is measured in Mega-pascals (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

1 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.

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

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.

6 Cap, clearly tag the cylinder

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

7 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 road

1. 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.

2. Preparation of base

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 used for better drainage facilities

• Stabilization soil
3. Form work
Material for form work-

Wooden sheets, battens, plywood, fiber 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 mixer-
• Batch mixer- at site, used for small road construction
• Continuous mixer- 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- 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- 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.
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 method of curing are-
1. Shading concrete works
2. Covering with hessian & gunny bags
3. Sprinkling of water
4. 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