Introduction

Access Engineering Ltd 080861K
Earth Resources Engineering Page 43
CHAPTER 1
1.1Introduction of the Access
Access Engineering is one of the most dynamic and progressive business entities in Sri
Lanka. Established in this year 1990, the Access Group ventured into the construction sector
in 1994 to secure itself a niche market for providing turnkey engineering services for Gabion
related structures. Having optimized the available business opportunities in this sector, we
gradually expanded our engineering services to cater to the demands of the civil engineering
industry, which resulted in the formation of Access Engineering Ltd., in 2001.
Logo of Access :-
We stand today in the forefront of the civil engineering sector in Sri Lanka rendering our
expertise in diversify fields providing turnkey engineering solution including design,
procurement, construction, and commissioning of many multi disciplinary engineering
projects for our customers both in the state and private sector.
Our head office is located at our own promises at Access Towers, 278 Union Place,
Colombo 2 the flagship of the access group. As a results of our ongoing expansion, most of
the management and support staff involved in project implementation moved into a purpose
built project office in 2007.
While we still continue to design and construct gabion structures, our extension and
stable growth has resulted in the expansion of our business in providing value engineering
services to many challenging civil engineering projects, earning the distinction of being the
pioneer in the industry to use certain technologies and construction methods.
Having some of the best available human resources in the industry which presently
stands at 1400 employees including over 100 engineering professionals, an in-house design
office and a modern fleet of specialized machinery and equipment, we look forward to more
challenging projects in the civil engineering industry.
 Water and waste water
 Roads and Highways

 Bridges and Flyovers
 Irrigation and Land Drainage
 Harbours and Marine works
 Dredging and Reclamation
 Environment and Waste Management
 Telecommunication
 Piling and Building
 Engineering designs
1.2Vision
To be the foremost Sri Lankan business enterprise in value engineering
1.3Mission
To meet the challenges in the development of multi sector civil engineering projects,
providing innovative solutions whilst developing long term progressive relationships with all
our stakeholders.
1.4Quality Policy
Access engineering limited is a term committed to satisfy our customer needs by providing
high quality civil construction services with effective and efficient and innovative solutions.
Our almost considerations have been the responsibilities to our customers, our
dedicated & committed staff, our principals, our subcontractors, suppliers and our society at
large.
To meet with the above commitment we continually improve our quality management
system whilst adhering to the ISO 9001:2008
and other applicable regulatory requirements
through cost effective, profitable, safe and
sound environmental friendly operation.
1.5Health & Safety Policy
Access engineering ltd., operating in
infrastructure development field, shall provide
and maintain high standard of health & safety for all its employees and general public who

may be affected by the operation, according to applicable health & safety regulations and
safety manual of the company.
Creating awareness by training, sharing information & supervision and maintaining
preparedness to meet health & safety emergencies to ensure a safety & health working
environment at all offices and sites.
1.6Environmental Policy
Access engineering ltd recognizes that in carrying out its activities it has a responsibility
to customers, employees and the general public to minimize environmental impacts. The
environment policy of Access engineering is to:
 Ensure compliance with all applicable legal and other requirements, which relate to
its environmental aspects.
 Promote environmental awareness and commitment to the policy amongst all
employees and Stakeholders through training and communications to encourage
suppliers and subcontractors to apply sound environmental principles.
 Avoid the wastage of materials, water and energy by paying careful attention to their
use.
 Prevent pollution and minimize environmental disturbance from our activities.
 Apply continual improvement by reviewing the environmental aspects related to our
activities by setting appropriate targets and objectives for improving performance.
1.7Awards
 National Business Excellence Awards 2008
 International Star Award for quality 2008
 The Platinum Technology Award for Quality & best trade name – Switzerland
2010
 Institute for Construction training and Development National Awards 2010
 The Golden Award for Quality & Business Prestige - 2011

1.8Organization Structure
1.1Project Brief
1.9. A Project Details
 Name of Project : Sarvodaya – Vavuniya Quarry
 Project Manager : Mr. Melvin
 Foreman : Mr. Vijeyathunka
 Project location : Vavuniya
 Period : 5 Years
1.9. A.1 Hierarchical Structure
Managing Director and Chairman
Chief Executive Officer

1.8. B Project Details
 Name of Project : Rehabitation of Roads in North Project
 Employer : Road Development Authority
 Consultant : Central Engineering Consultancy Bureau
 Contractor : China Railway No- 05 Engineering Group – Ltd
 Sub- Contractor : Access Engineering Ltd
 Project Manager : Mr. P.N.I. Pathirana
 Construction Manager : Mr. DHNCK. Wijesinghe
 Planning Engineer : Mr. Nadeeja
: Mr. N. Amila
 Site Engineer : Mr. Ubeksha
: Mr. Mahesh
 Project location : Jaffna - Kankesanthurai Road AB 16
: Jaffna - Palali Road AB 18
: Puttur – Meesalai Road AB 32
 Time for completion : 2 Years
 Project sum : 917 658 896 .72
Director
Project Manager
Plant Manager
Mining Engineer Mechanical Engineer
Drilling Operators
Foremen
Crusher Plant Operators Electrician Mechanic WeldersOperator
s
Admin OfficerAccountant Store
Keeper

1.8. B.1 Hierarchical Structure
Director
Project
Manager
Construction
Manager
Planning
Engineer
Site
Engineers
Quantity
surveyor
Accountants
Staff &
others

CHAPTER 2
2. A.1 Introduction and General Information
This method statement provides the details of the materials, the equipment, the
procedure and relevant documents related to the Quarry Blasting activity, including the
quality control verifications, the measurement verifications, and also the safety precaution to
be implemented for this work.
The use of explosives within the quarry site and other permitted area is extensive and,
when large or even small quantities have to be handled properly, the responsibilities fall
heavily upon the supervisory staff. Those responsible must consider the acquisition, storage,
transporting, handling, and use of explosives as well as the procedures to be adopted in case
of misfire, accident or fire.
2. A.1.1 Location of Works
The location of the Quarry blasting works will be limited to selected areas bound within the
land acquired, by the Access Engineering Ltd. Alternatively, as required; these works may be
applicable to locations outside the Quarry site (i.e. borrowed areas).
2. A.2 Responsibilities
All necessary licenses, all fees and charges in respect to the purpose of importing and
moving explosives, as well as approvals from relevant authorities of the Government of Sri
Lanka , shall be obtained prior to commencing blasting at any specific location.
Only experienced and skilled personnel in this type of work may take part in blasting
operations. They should be acquainted with the requirements of the Government Authorities
as they are applied to their particular task. All employees who take part in blasting operations
should be in good health, over 18 years of age, and should be properly trained to operate the
equipment provided for both their personal protection and the protection of property. They
should comply with the standards and procedures and strictly follow the instructions of the
Mining Engineer.
The Blasting Foreman will lead the blasting works, according to the instructions of
the Mining Engineer, and must be responsible for the safe handling and storage of explosives,
fuses, and other blasting equipment (on site ) which are to be used by himself or other
workers.

The Mining Engineer must ensure that no unauthorized person is allowed access to the
blasting site and all explosives are carefully guarded in a safe location.
2. A.2.1 Responsibilities of Mining Engineer
The Mining Engineer shall be responsible for the:
a) Accept overall responsibility for safety of the blasting site.
b) Ensure that safe working procedure, safety methods and practices are adopted and are
carried out as planned.
c) Control and monitor the safety of the blasting / quarry site.
d) See that all explosives handling, blasting regulations and other legal requirements are
in order.
e) Ensure that all personnel employed are suitable for the job and possess valid licences
to carry out the job.
f) Ensure that all conditions imposed by authorities are being followed.
g) Ensure that correct procedures (SOP’s) and systems of blasting work are being
maintained.
h) Ensure all workers are wearing appropriate Personal Protective Equipment (PPE)
i) Ensure that the temporary evacuation of residents (if required) is done in accordance
with the conditions of the Mining Licence issued by the Geological Survey and Mines
Bureau prior to blasting operation.
j) Ensure that the following documents/check lists are being maintained.
 Daily Blasting Schedule, Daily Blasting Detail sheets
 Daily Drilling Log Sheets
 Daily Consumption Record – Explosive Sheets
 Explosive Stock Status sheets
 Degraded Explosive Stock status sheets
 Stores Explosives Issuing / Returning Record Sheets
 Safety Check List
k) Check all the environmental requirements are being done on locations concerned.
2. A.3 Definitions
a) Approved Storage Facility

Storages area for explosive materials conforming to the requirements of this part and covered
by a permit issued under the Explosive ordinance.
b) Blasting Area
The area where explosives charging and blasting operations are been conducted.
c) Blaster
Persons authorized to use explosives for blasting purposes and qualified for the same.
d) Blasting agent
A blasting agent is any material or mixture consisting of a fuel and oxidizer used for blasting.
A common blasting agent presently in use is a mixture of Ammonium Nitrate ( NH4 NO3 )
and carbonaceous combustibles such as fuel, oil or coal, premixed and packaged from
explosives manufactures or mixed.
e) Blasting Caps
A metallic tube closed at one end, containing a charge of one or more detonating compounds,
and designed to be capable of detonation from the sparks or flame from a safety fuse inserted
and crimped in to the open end.
f) Conveyance
Any unit for transporting explosives or blasting agents, including but not limited to trucks,
trailer, rail car, barges, and vessels.
g) Detonators
Blasting caps, Electric Blasting caps, delay Electric blasting caps, and non-electric Delay
blasting caps.
h) Electric blasting caps
A blasting cap designed to capable of detonation by means of an electric current.
i) Explosives

Any chemical compound, mixture or device, the primary or common purpose of which is a
function by explosion, that is with substantially instantaneous release of gas and heat unless
such compound, mixture or device is otherwise specifically classified by the Authorities.
j) Fuse Lighters
Special devices for the purpose of igniting safety fuse.
k) Magazine
A building or structure used for the storage of explosives.
l) Misfire
Explosive charges which are failed to detonate.
m) Mud capping
A blasting of boulders by placing a quality of explosives is against a rock, boulder without
confining the explosive in a drill hole.
n) Primary Blasting
The blasting operation by the original rock formation is dislodged from its natural location.
o) Primer
The cartridge or container of explosives which detonator or detonating cord is inserted or
attached.
p) Safety Fuse
A flexible cord containing an internal burning medium by which fire is conveyed at a
Continuous and uniform rate for the purpose of firing of blasting caps.
q) Secondary Blasting
The reduction of oversize material by the use of explosives to the dimension required for
handling, including mud capping.
r) Stemming

A suitable inert incombustible material or device used to confine or separate explosives in a
drill hole, or to cover explosives in mud- capping.
2. A.4 Rock Excavation Schedule
While rock excavation is being progressed, the rock excavation schedule may be
changed to accommodate other works which are planned to be done concurrently with the
excavation operation.
The charging and blasting operation shall be scheduled during weekdays so that
enough time is available for drilling & removing of loose rocks.
Drilling, charging, & rock removal shall be carried out on a cyclical basis as a part of
the overall excavation program. (Flow Chart – Quarry Blasting Activities)
Charging & Blasting shall be done at any time (9:00~16:00 Hours) on the days when
blasting operations are scheduled.
2. A.4.1 Rock Excavation Method
Rock excavation method should be decided depending on the location, properties and
geological formation of the rock. It is proposed to carryout test blasts to study the vibration,
condition & behavior of the rock before the actual method of rock excavation is
implemented. After the test blast has completed and rock conditions studied, the factors given
Below shall be adjusted as necessary to achieve an acceptable blasting method.
a. Blast hole parameters of the rock.
b. Charge concentration per delay
c. Number of delay detonators use and pattern of detonation.
Number of hole must be decided dependent upon the location and according to Geological
Survey and Mines Bureau ( GSMB )’s recommendations.
Drilling should be done using air compressors and hand drill machines; the diameter
and depth of the hole will be decided by the GSMB mining engineer’s recommendation.
(After Test Blast)
The following authorities’ representatives will inspect the test blast:
I. Mining Engineer of Geological Survey and Mines Bureau,
II. Mining Engineer Access Engineering Ltd.,
III. Assistant Explosives Controllers,
IV. Representative from Central Environmental Authority,

V. Representative from relevant Divisional Secretary’s Division,
VI. Representative from relevant “Pradeeshiya sabha” ,
VII. Representative of general public (where required by GSMB).
2. A.4.2 Blasting Pattern & Drilling
The rock area should be inspected by the Engineer with blasting in-charge before preparation
of blasting pattern.
A blasting pattern must be prepared by blasting in-charge and should be approved by
the engineer at each particular location requires for blasting.
The blasting holes must be bored using pneumatic rock drill in accordance with the
depth and configuration of the approved blasting pattern. The approved quantities and set to
go off in accordance with the approved blasting pattern.
2. A.4.3 Boulder Drilling
Before the commencement of the work, the Engineer shall be notified of the areas where rock
boulders will be blasted. Accordingly, the Engineer must inspect the area for taking
additional safety measures before commencement of the works. Boulders, Which cannot be
broken by rock barker, shall be drilled using Hand drill machines.
Parameters of drilling holes will be given by the IML after the test blast but as usual,
the following dimensions can be used.
 Hole depth <=1m, 1 hole per one boulder if boulder volume <2 m3
 Hole diameter 32mm to 40mm
2. A.4.4 Charging method of bore Holes
1. The borehole must be cleaned out with compressed air just before commence of
charging.
2. The cartridges of explosives must then be inserted in to the bore hole one at a time
and pressed with a wooden rod or PVC pipe.
3. The primer cartridge must then be pushed until it rest against main charge.
4. When ANFO is permitted to use by the IML, the required quantity of the same must
be inserted to the hole.
5. If bore holes will be wet, packet ANFO shall be used.
6. Metal rod should never be used to charge boreholes.

7. No drill or metal equipment of any kind should be introduced in to the hole once
explosives have been inserted.
8. After loading the explosives, stemming must be quarry fines or sand which must be
gently tamped for the first few inches from the bottom.
9. Pressure must be gradually increased for tamping so that the stemming is firmly
packed in the hole.
10. During the tamping, the leading wire of the detonators or detonating cord must be
held on to one side of the borehole to prevent damages.
2. A.4.5 Electric Blasting Circuitry
1. Bus wire, an expendable wire, used in parallel or series, in parallel circuits to which
is connected the leg wires of electric blasting caps.
2. Connecting wire, an insulated expendable wire used between electric blasting caps
and the leading wires or between the bus wire and the leading wires.
3. Leading wire, an insulated wire used between the electric power source and the
electric blasting cap circuit.
4. Permanent blasting wire, a permanently mounted wire used between the electric
power source and the electric blasting cap circuit.
5. Electric delay blasting caps, Electric Blasting Caps designed to detonate at a
predetermined period of time after energy is applied to the ignition system.
2. A.5 Security and Safety for Storage ( Ref. Method statement for
Explosive storage )
It is required to provide adequate security and protective facilities to safety store and
to prevent the loss or theft of explosive and detonators. It is required to maintain an inventory
record of storage and withdrawal of all explosives and detonators.
Care shall be taken, when handling and transporting explosives, to ensure that they do
not come in contact with any source of ignition. Smoking during charging or within 100ft of
explosives is forbidden. Detonators and blasting agents should never be transported together.
(The possibility of electric blasting caps accidental firing)
There are four criteria for the storage of explosives:
1. Security
2. Safety

3. Prevention of fumes, which could be hazardous to health
4. Maintain Explosive record book
2. A.5.1 Security and Safety Transportation
It is required to make arrangement to transport, store and handle explosives in a safe manner
for protecting the public in accordance with the laws and security regulations in Sri Lanka
I. Explosive magazines should be built according to explosive controller’s specification
to stock caps and blasting agent separately.
II. Barbwire fence must be installed around the magazine for additional security of the
explosives.
III. Explosive log book should be maintained daily by the authorized personnel and
should be kept under lock & key (materials controller).
IV. Flood lights have must be installed at corners of the magazine for the security at night.
V. Transport of explosives should be under Police guard and in the day-time.
VI. Transport of explosives should be handled by the responsible person, nominated by
the license holder and who should be over 21 years of age.
VII. It should be followed all the procedure laid down by the explosive controller (all
details should be submitted to the Engineer)
VIII. The personnel should be evacuated to safe distances as per the requirements of the
environmental plan, licenses and permits.
All unused Explosive which are remaining in the site should be kept away from blasting
location prior to blasting operation.
2. A.6 Licenses and Permission
The permission and licenses should be obtain from the following Government Departments
and licensing authorities before commence of rock blasting operation.
I. Geological Survey & Mine Bureau (Mining License)
II. Central Environmental Authority (Environmental Clearance)
III. Archaeological Department (clearance if necessary)
IV. Assistant Explosive Controller at the region (Explosive Permit)
V. Divisional Secretary

2. A.7 Personal Protective Equipment
The following personal protective equipment (PPE’s) should be provided for all workers at
the quarry site.
a) Hard Hats
b) Safety Boots
c) Dust Masks
d) Ear Plugs
e) Plain Goggles
f) Gloves
g) Safety Belts (for drilling and blasting teams)
h) Safety vest
2. A.7.1 controlling of Flying Rocks
In the areas where the fly rock needs to be controlled, the charged rock area should be
covered with covering materials such as
a) Wire mesh
b) Used tyres and Sand bags
Alternatively, used conveyer belts or heavy geo-textiles with sand bags can be used for
covering the charged area. A sand bag should have a weight of 25kg.
Drilling direction will be selected in accordance to avoid Fly Rock flying on to
residences.
2. A.7.2 Method of Informing Surrounded Area Residents
1. Surrounded area residents should be informed the date, time and location through the
loudspeaker announcement prior to blasting (if the quarry site is located in a residential area).
2. Resident should be evacuated in accordance with blasting license condition prior to
blasting operation (if such condition is stipulated by the IML)
2. A.7.3 Safety Precautionary Actions for the Quarry Sites
The following safety precautions must be implemented in order to minimize accidents.
I. Warning sign boards such as “NO ENTRY”, “DANGER MEN AT WORK”, “NO
SMOKING” and Red/Green flags must be available at the site.

II. Safety requirements and other environment protection condition stipulated in the
Mining license issued by the GSMB should be implemented.
III. Stand-by vehicle for an emergency must be available at the site.
IV. Mining Engineer should make sure there are no persons unauthorized in the site.
V. Nearby roads and footpaths must be temporarily closed (if required) during the time
of the blasting with proper permission from the authorities.
VI. When blasting face exceeds 40 feet it should follow a bench system for the safety of
the drillers as instructed by the Engineer.
VII. Charged holes must be fully covered with covering material (accepted) and sand bags
to avoid flying rocks.
VIII. Special attention should be taken for loose boulders before commencing the blasting
works.
IX. Loose boulders shall be removed before drilling the holes after each blasting
operation.
X. All cellular phones should be retained 50m away from charge area.
XI. All Radio Transmitters / Walkie Talkies should be retained 50m away from charge
area.
XII. Electric Detonators should only be used at locations a minimum 50m away from live
power lines.
2. A.7.4 Siren signal Alarm
I. A code of blasting signals equivalent to section 7.5 bellow shall be posted in one or
more conspicuous place at the operation and all employees shall be required to
familiarize themselves with the code and conform to it.
II. The Mining Engineer should ensure that a loud warning signal is given before the
blast is fired, also he must take the responsibility and ascertain that all surplus
explosives are in a safe place and all employees, vehicle and equipment are at a safe
distance or under sufficient cover.
III. Flagman shall be safety stationed on around the perimeter of the danger zone, so as to
stop traffic and persons entering during the rock blasting operation.
IV. Ensure all members of the public in danger zone are evacuated to a safe distance
depending on the site location. (If required by the IML)
2. A.7.5 Announcement and siren Alarm System

Three times of siren alarms should be made after five minutes of loudspeakers announcement
as follows. (Flow Chart – Warning Procedure)
I. First signal – A one minute long alarm, starts 9 minutes prior to blast.
II. Second signal – 3 Short alarms, starts 3 minutes prior to the blast. (90 seconds in
duration)
III. Third signal – A prolonged alarm, starts 30 seconds prior to the blast.
Firing order should be given by loudspeaker and completion of blast also announced by the
same after checking any misfires. The “ALL CLEAR” siren alarm of fifteen second duration
must be made subsequent to the blast completion announcement.
2. A.7.6 Safety regulations (technical)
Rock excavation operations should be carried out under the following safety regulations.
1. Before adopting any system of electrical firing, the Mining Engineer or authorized
Blaster must conduct a thorough survey for extraneous electric line, and all dangerous
Electric wires should be eliminated before any holes will charged.
2. All detonators use in “a blast” should be supplied by a same manufacture and same
model.
3. The use of blasting circuits or power circuits should be in accordance with the Electric
Blasting detonators producer’s recommendations and should be checked by the
Mining Engineer or authorized Blaster.
4. When firing a circuit of Electric Blasting caps, care must be exercised to ensure that
an adequate quantity of current is available in accordance with the explosive
producer’s recommendation.
5. Connecting wires and lead wires should be insulated and single solid wires should
have capacity for carrying sufficient current and be good in condition.
6. All power circuits used for firing electric blasting caps should not be grounded.
7. When firing from power circuit, the firing switch should be locked in the “OFF”
position at all times.
8. The Exploder should be in good condition and the efficiency of the exploder should
be tested periodically to make certain, that it can deliver power at its rated capacity.

9. When firing with blasting machines (Exploders), the connection should be as
recommended by the producer of the Electric Blasting caps.
10. The number of electric blasting caps connected to a blasting machine (Exploder)
should not be exceeded of its rated capacity.
11. The authorized Blaster should be in-charge of the blasting machine (Exploder), and
no other person will connect the leading wires to the machine.
12. When testing circuits to charged holes, only blasting galvanometers or other
instruments that are specifically designed for the purpose should be used.
13. In electric firing, only the authorized blaster making leading wire connections shall
fire the shot. All connections shall be made from the drill hole back to the source of
firing current, and the leading wires shall remained shorted and not be connected to
the blasting machine (Exploder) or other source of current until the charge is to be
fired.
14. After each firing an electric blast using the blasting machine (Exploder), the leading
wires shall be immediately disconnected from the machine (Exploder) and short –
circuited.
15. Electric blasting Caps shall not be used where source of extraneous electricity make
the use of Electric Blasting Caps dangerous. Blasting Caps leg wires shall be kept
short circuited (Shunted) until they are connected into the circuit for firing.
16. The authorized blaster (Blasting in-charge) shall request a safe signal from all signal
mans carrying flags (one by one) immediately prior to giving the Firing Order.
2. A.7.7 Site Inspection after Blasting Operation
I. Immediately after the blast has been fired, the firing line shall be disconnected from
the blasting machine (Exploder) or where power switches are used, they shall be in
the “OFF” position
II. Sufficient time shall be allowed, not less than 5 minutes for the smoke and fumes to
leave the blasted area before returning to the shot. An inspection of the area and the
surrounding rubble shall be made by the mining Engineer to determine if all charges
have been exploded before anyone is allowed to return to the site.
2. A.7.8 In Case of Misfire

I. If a misfire is found, the Mining Engineer or safety Manager shall provide proper
safety for the persons present and keep them out of the danger zone.
II. No other work shall be done except that necessary to remove the hazard of the misfire
and only those employees necessary to do the work shall remain in the danger zone.
III. If there is any misfire while using cap & fuse, all employees should have to remain
away from the charge for at least one hour. The misfire shall be handled under the
direction of the Mining Engineer or Safety Manager.
IV. No drilling, digging or picking shall be permitted until all misfired holes have been
reset for blasting or blower out.
2. A.7.9 handling of safety Fuse
I. Safety fuse shall only be used where sources of extraneous electricity make the use
of Electric Blasting caps dangerous or as stated by the IML condition. The use of a
fuse that has been hammered or injured in any way shall be forbidden.
II. The hanging of a fuse on nails or their projections, which will cause a sharp bend to
be formed in the fuse, is prohibited.
III. Before attaching the safety fuse to the cap a short length of insulation shall be cut
from the end of the supply fuse and shall be used so in a manner so as to assure a
fresh cut end in each blasting cap.
IV. Only a cap crimper of approved design shall be used for attaching blasting caps to
safety fuses. Crimpers shall be kept in good condition and accessible for use.
V. No unused cap or short- capped fuse shall be placed in any hole to be blasted; such
unused detonators shall be removed from the working place and destroyed.
VI. No fuse shall be capped or primer made up, in any magazine or near any possible
source of ignition.
VII. No one shall be permitted to carry detonators or primers of any kind on his person.
VIII. The minimum length of safety fuse to be used in blasting shall not be less than 1m.
IX. Minimum two persons shall be present when multiple cap and fuse blasting is done
by hand lighting methods.
X. Not more than 12 fuses shall be lit by each Blaster when hand lighting devices are
used. However, when two or more safety fuses in a group are to be lit as one by
means of ignite cord, or other similar fuse lighting devices, they may be considered
as one fuse.

XI. The so- called “drop fuse” method of dropping or pushing a primer or any
explosive with a lighted fuse attached is forbidden.
XII. Cap and fuse shall not be used for firing mud cap charges unless charges are
separated sufficiently to prevent charges for dislodging other shots in the blast.
XIII. When blasting with safety fuses, consideration shall be given to the length and
burning fate of the fuse. Sufficient time, with a margin of safety shall always be
provided for the Blaster to reach a place of safety.
2. A.8 Crusher Plant
1. Primary unit
(a) Jaw crusher
(b) Grizzly feeder
(c) Horizontal vibrating screen
2. Secondary unit
(a) Spring cone crusher
(b) Hi performance cone crusher
3. Vibrating screen
4. Vertical shaft impactor
5. Vibrating screen

2. A.8.1 Lay Out of the Crusher Plant
2. A.8.2 Hopper
Hoper is the stating part of the crusher plant. The transported material from the quarry with
the help of Drum Truck is put to the hopper. We can store quarry product at limited time in
the hopper for continuous crushing operation. Because of that we can increase efficiency of
the crusher plant production rate. The walls of the hopper should have suitable inclination to
collect all the material from the Drum Truck.
Physical dimensions
-5m*5.25m
-capacity 38m3
2. A.8.3 Vibrating Grizzly Feeder
Main hopper
Grizzly feeder
Jaw crusher
Cone crusher
cone crusher
VS
Vibrating Screen
Production Screen
0-5mm
5-10mm 10-15mm
15-20mm
ABC
Mixture
Quarry
mug
Horizontal screen
B
Here, BC-Belt
Conveyer

Electro Magnetic Field
special motor
Grizzly feeder is most important part of the crusher pant. It is used feeding a
quarry product from hopper to jaw crusher. Quarry mud (sand, clay) was filtered by Grizzly
feeder before crushing. Vibrating process is created by unbalance mass. The motion helps to
gradual flow of rock mix to the forward. Special motor was used for grizzly feeder. That
motors always rotate. But we can rotate a pulley and unbalance mass according to our needs.
Electromagnetic field is used for the process. That EM field can ON/OFF according to our
requirement.
The technical data of the Grizzly feeder and its motor follows.
 Model-VG 1350
 Motor-18.5kw
 No of belt-3pc
 Motor pulley diameter-300mm
2. A.8.4 Jaw Crusher
Jaw crusher is primary unit of the crusher plant. The product after passing through the jaw
crusher is known as ‘Rock Fill’ and it is suitable to feed the secondary cone crusher.
2. A.8.4.1Crushing Mechanism
 Power come from motor and then transfer through V-Belt to machine pulley.
 Machine pulley rotated and swing jaw would do a eccentric rotation by eccentric shaft
rotation. Also there have toggle plate and tension rod behind swing jaw to support it.
 Due to this eccentric rotation, movable jaw plate which is fixed with swing jaw will
make a kind of relatively eccentric rotating.
 Fixed jaw plate fixed with frame.
 Gap between fixed jaw plate and movable jaw plate will change accompany with
movable jaw plate rotating. So as to crushed row material.

2. A.8.4.2 Caution before Operation for Jaw Crusher
 Every bolt was tightened
 Uncrusharble materials’ were cleaned in crusher chamber
 Feed material size should be 0.7 time small than feed opening size.
 Lubrication level was checked
 Tightness of tension rod was adjusted.
 Remaining materials’ were cleaned before start to avoid overload.
2. A.8.4.3 Trouble Shooting for Jaw Crusher
 Can’t start
 Incorrect wiring
 Damage of bearing
 V-Belt is loosed
 Unusual vibrating when operation
 Frame bolts are un tightened
 Loosen jaw plates, bolts
 Feed hopper is unfixed
 Collar damage
2. A.8.4.4 Adjusting the Discharge Gap Of The Jaw Crusher
The discharge gap of the jaw crusher will increase due to the wear of the operation. It
will increase the size of the primary crushing product. Then the gap should be adjusted at the
jaw stock side. The plates called ‘shims’ are used for this purpose. Two shim plates were
fixed at the start of the jaw crusher, and then we fixed another two plates to reduce the
discharge gap.

2. A.8.5 Cone Crusher
Mantle Core Assembly Top Cell Assembly
Eccentric Sleeve Assembly Main Frame Assembly
Main Assembly of Cone Crusher
2. A.8.5.1 The Technical Data of the Cone Crushers and Its Motor
The Technical Data of the Cone Crushers
Parameter Spring cone crusher Hi performance cone
crusher
Model SCC1300 MLF300
Feed opening -open side
-closed side
40mm 35mm
75mm 70mm
Capacity 220tons/hour 200tons/hour
Feed material max 75 mm 40 mm
Oil pump 5Hp 7.5Hp
Motor power 200kw 240kw
Belt type 8V192 8V182
No of belt 9pc 6pc

In correct method of feed. correct method of feed.
Pulley diameter 430mm 600mm
2. A.8.5.2 Adjusting the Discharge Width
The discharge width of the mechanical cone crusher should be adjusted according to
the product we required. As an example when producing ABC we have to adjust the
discharge gap of the secondary cone crusher. Also due to the long term operation mantle and
concave subjected to wear and gap will increase. In that instant also we have to adjust the
discharge gap. This process can be carried out by means of the hydraulic jack which is fitted
to the mechanical crusher when it producing. Housing of the cone is fitted with a thread and
if can be raised or lowered rotating the housing with the help of the jack.
*Clockwise rotation decreases the opening
*Counter-clockwise rotation increases the opening
2. A.8.5.3 Feeding Control of Cone Crusher
Feeding material should be distributed around the circumference of crushing chamber inlet.
Because of feed material is obliquely concentrated in the same position of crushing
chamber.
2. A.8.6 Vertical shaft impactor
Vertical shaft impactor crusher is the most important crusher for Asphalt production. Because
dust content of aggregate and smoothness increase by give impact force to aggregate by the
crusher. It is used only Asphalt production.

2. A.8.6.1 The Rotor and Wear Parts
Rotor is the very important part in the VSI crusher there are so many wear parts attach
this rotor wear parts are designed to protect the by it. They are not involved in the crushing
action of the machine. To ensure trouble free operation of the vertical crusher it is necessary
to inspect the condition of the rotor wear parts and the rock build-up within the machine on a
regular basis.
2. A.8.6.2 Feed Control of the VSI Crusher
20mm Sieve passing and 15mm retaining of aggregate feed in to the crusher. Feed control is
very important for VSI crushing operator. Feed control is to govern the ratio of feed to the
rotor and cascade. Reason for controlling this feed distribution is very dependent on the
product requirement of the operator.
Uses of control as follows
 To protect the motor from overload
 To achieve the absolute highest efficiency of crushing
 To maximize the production of a particular size fraction
2. A.8.6.3 Pre Requirement of VSI Crusher
Start-up procedure and shut down procedure are the special for vertical shaft
Impactor crusher. Start-up procedure should be used after a major repair such as bearing
cartridge replacement or crushing chamber refurbishment has taken place.
 Before start-up
 Check pulley alignment and drive belt tensions
 Check rotor rotation

Vibrating Direction Rotation Direction
450
 Remove all tools from on or within the crusher
 Ensure that all guards, doors, hatches and safety pins are in place.
 Initial start-up
 Confirm ammeter is operating accurately
 Run without load for 30min
 Inspect rotor and cascade assembly ensure that all rotor parts are in place
 After 3 hours
 Check build-up in rotor, crushing chamber and base
 Check bearing temperature
 Check belt tensions
 Grease at the end of the shift and perform daily inspection as listed
 Shut-down procedure
Extended period of running out the circuit and weather condition permits, step all
conveyer belts before VSI fully loaded
 Stop conveyer(feed) before VSI
 Observe ammeter unload prior to disconnecting power from the VSI
2. A.8.7 Vibrating Screen
2. A.8.7.1 Principles of Vibrating Mechanism
Powers comes from motor and transfers to driving shaft by pulleys, V-Belt and also
through gear set. The unbalance counter weight rotate and give eccentric force is produced to
make machine to from reciprocation motion in a 45 degree straight line. Because of that
material would be send forward in a motion.

2. A.8.8 Conveyer Belt
The conveyor belts are used to transport materials. The gradient of the conveyor belt is very
important, because high gradient will require more power and slip of the materials can be
happened. So, proper gradient of the belts should be decided when arranging conveyor belts.
Conveyor belts are driven by a motor and to adjust the speed of the belt gear box is utilized.
Those are mainly divided in to two groups.
(1) Production belt
(2) Others belts
Ending of asphalt aggregate is going through the production belt. All conveyers are
named my numbers (BC 1, 2, 3…).Output of production screens (VT720-2) aggregate go
through this four belts. Conveyer belt width and thickness are smaller than other belt.600mm,
10mm width and thickness used for production belt. Those are indicated by 9,10,11,12
numbers. Nylon matrix layer and rubber layers were consisted in the conveyers.
2. A.8.8.1 Maintains of the Conveyer Belt
Two separate section of belt fixed with some special clips. It can be rotated
Around the drum without any disturbers.
Material
Rubber layer
Nylon matrix layer
Rubber layer
Cross section of conveyers
Special clip
Special clipBelt
Fixed systemof the conveyer belt

2. A.8.8.2 Conveyer Belt Details
Details of Conveyer belt
Belt
no
Length
(m)
Width
(mm)
Thickness
(mm)
No
of
idler
No of
drum
Di’a
of
drum
No of
roller
Power
01 25 600 10 13 2 400 108 7.5Hp,1450rpm
02 7 900 12 4 2 400 39 10Hp,1450rpm
03 21 900 12 10 2 400 87 25Hp,1450rpm
04 7 900 12 4 2 400 39 7.5Hp,1450rpm
05 32 900 12 15 2 400 135 7.5Hp,1450rpm
06 31 900 12 14 2 400 135 25Hp,1450rpm
07 7 900 12 5 2 400 45 7.5Hp,1450rpm
08 35.5 900 12 8 2 400 150 7.5Hp,1450rpm
09 25 600 10 13 2 400 108 7.5Hp,1450rpm
10 25 600 10 13 2 400 108 7.5Hp,1450rpm
11 25 600 10 10 2 400 94 7.5Hp,1450rpm
12 26 600 10 10 2 400 108 7.5Hp,1450rpm
13 24 900 12 11 2 400 90 15Hp,1450rpm
14 19 900 12 9 2 400 84 15Hp,1450rpm
15 18 900 12 10 2 400 111 15Hp,1450rpm
When we talk about conveyor belts, the important accessories to driven belts we have
to use rollers, idlers and drum. All are manufactured by metal and drum; roller can rotate
around the horizontal axis. The upper and lower side of the belt is driven on these rollers.
Advantages- To minimize the wear of the belt
For smooth operation of the belt
Disadvantages-The slip can be occurred in rainy days between the belt and rollers
Conveyor Belt Rollers

2. A.8.9 Generator
There are three generator used in crusher operation. Such as
(1) 725kva generator
2. A.8.9.1 Properties of the Generator
Technical Data of Generator
2. A.8.10 Control Room of the Crusher Plant
The operating instructions of the crusher plant are carried out in the control room. In here
there is a panel board with switches. There is a separate switch for all crushers, conveyers and
screens. The control room operator does appropriate actions to operate the plant. Normally
the ending side of the plant operated earlier then the starting side of the plant to avoid
overflow of the materials. The safety of the control room is very important, because high
voltage and current is maintained with fuses.imdicate all operationin the plant by different
color bulb.
 Red light-Stop
 Yellow light-Trip
 Green light-Run time
2*725kva generator 500kva generator
Model 800F 550
Serial number CAT 00000CTGC00359,
CAT00000CTGC00360
CAT00000AC6C00354
Year of manufacture 2005 2005
Rated power standby 800kva,640kw ,0.8cosΦ 500KVA,400KW, 0.8 cosΦ
Rated Voltage 400/230V 400/230V
Phase 3 3
Rated Frequency 50HZ 50HZ
Rated Current 1154.7A 722A
Rated R.P.M 1500 1500
Generator Connection S’Star S’Star
Engine 1Ez08160, IEz08073 STH03389

2. B.1 Structure of the Project Team
For this project, a project team which was separated from the head office staff had been
established to run the project while the head office limited it’s involvement with the project
only to the financial aspects of the project through the control exercised on fund allocation. In
dealing with the organizational structure adopted all the professionals required for the project
had been appointed on contract basis for the duration of the project, except the Project
Manager, Construction Manager and Planning Engineer who provide their services
permanently for the Access Engineering Limited.
Entire management of the site was under the authority of the Project Manager and the
Construction Manager assisted him. Planning Engineer was directly under the Construction
Manager. According to the type of the work Site Engineers had been appointed separately
and they were under the authority of Assistant Project Engineers. Quantity surveying division
was also under the Assistant Project Engineers. The Administration Manager and his
assistants managed all the administration aspects of the project.
2. B.2 Embankment Construction
Normally embankment is called the earth fill from the natural ground up to formation
level, this is consists of backfills with approved type II materials.
Where the existing embankment are to be widened, adequate bonding between the
old and new filling should be established by removing the top soil and scarifying the
sloping faces of the embankment.
Barrow soil is used for embankment construction. Because of non plastic action of
the excavated material. Naturally soils, that should not include highly plastic clay, silts, peat
or any other organic Mater. The material used for the embankment construction is type II.
Type II material should have maximum dry density under stranded condition of
compaction not less than 1500 kg/m3 .
2. B.2.1 Step by step construction procedure
 Excavate the trench by using excavator. (appropriate dimension)
 Manually cut straight edge and ensure the alignment.
 Properly compact the bottom of the trench.
 Getting approvals from the consultant by an inspection.

 Wet the bottom of the trench for improve the proper bonding of soil layers.
 Fill the type II material for a thickness not more than 300mm.
 Ensure the optimum moisture contain by any field techniques.
 Compact the 1st layer by using roller (firstly compact without vibrating after that with
vibrating)
 Field compaction test was carried out with material technician & keep the records for
billing purposes. (It should more than 98 %) .
 Same procedure repeated for 2 nd Layer and ensure the slope of embankment
2. B.3 Shoulder Construction
Shoulders are one of important part in road
construction, because traffics are passing on the
shoulders incase of emergency. Normally shoulders are
construct by using type II Barrow material.
Material Spreading for Shoulder
2. B.3.1 Step by step construction procedure
 Excavate the trench by using excavator.
 Manually cut straight edge and ensure the
alignment.
 Properly compact the bottom of the trench.
 Getting approvals from the consultant by an
inspection.
 Wet the bottom of the trench for improve the
proper bonding of soil layers. Shoulder Compaction
 Fill the type II material for a thickness (Compactor of soil=1.4).
 Ensure the optimum moisture contain by any field techniques
 Compact the soil layer roller
 Field compaction test was carried out with material technician & keep the records (It
should more than 95 %).
 Grade the shoulder by using a motor grader to get the good finishing and gradient of
the shoulder.

2. B.3.2 Shoulder construction in soft ground areas and existing pavement areas
In the soft ground areas, the soft ground layer should removed up to good soil. If the
water table become over the formation level, the excavated area should fill with the
pours material such as sand. In the existing pavement areas, the pavement should
scarify before start the work.
In the construction, there are several tests should be carried out for materials and
work. Standard compaction test, sieve analysis, liquid limit test, plastic limit test and CBR
test should carried out for materials. Each soil type should test at least once. Layer
thickness, field moisture content and degree of compaction test was carried out.
2. B.4 Base Construction
Base construction was carried out at the site specially for badly damaged (Bomb blasted)
areas and widening areas (Edge correction). According to the BOQ Single Size Aggregate
Base (SSAB) was the item. But getting approval for Aggregate Base Course (ABC) laying,
because of less time consumption easy construction procedure.
The aggregate base course is a graded metal mix consists of different sizes of metal
particles. The gradation of the mix is very important and when dealing with the ABC,
segregation of the particles should be minimized as much as possible. Normally aggregate is
mixed at the crusher and transported to the required place at the site. At the transporting
stage, there may be a segregation of material. This can be avoided by adding some amount of
water to the mix while mixing. At the same time this moisture helped to get the maximum
density at the compaction stage.
2. B.4.1 Material
The aggregate used for mixing of ABC should graded crushed rock with
nominal size of 37.5mm (112”), 19mm (3/4”), 12.5mm (1/2”) and Quarry dust according to
the proportion of 40:30:15:15, from an approved quarry. Aggregate shall consist of clean
hard sound durable particle of angular shape and rough surface texture. That should free from
weathered, soft, laminated or elongated pieces, deleterious matter and free from clay. The
aggregate should have aggregate impact value not greater than 30% and the flakiness
index not greater than 35%.
2. B.4.2 Construction Procedure

In the base construction the first step was preparing the sub base or an existing
pavement of the carriageway. In this case minimum thickness of the base layer should be
considered.
As first step of the construction, road finish level at the center and the 4.2m from the
center were marked on the pegs. String was stretched to the transverse direction and depth
was measured using steel tape. Then depth at the center and the 1.5m,3m and 4.2m away
from the center were measured and noted down on a sheet. This sheet is called “Dip Sheet”.
At the same time distance to the edge of the existing pavement from the center of the road
was measured. Then considering the minimum thickness of the base layer, places where there
is no sufficient depth was highlighted. With the aid of this data sheet, motor grader was
applied on the soil sub base. If the depth over the existing surface was not sufficient, scarify
the existing surface and remove that by using motor grader.
Then surface was cleaned and depth was checked again. If there were sufficient depth
at all places, actions were taken to unload the ABC. Motor grader was applied for spread the
ABC and leveled the surface. This was the ideal machine to handle the ABC. The plate of the
grader can be used to spread and lever the ABC surface exactly and used to scarify the
compacted ABC surface.
After spreading the ABC to the level little higher than the required level, water was
applied to it using water bowser. There may be a possibility of segregation of material,
because due to application of water, quarry dust may go inside. So application of water was
done when the level of the ABC was little higher than the required. In this case water should
not be added excessively. The ideal amount of water is just sufficient enough to bound the
dust of the ABC to the large metal particles of it.
Afterwards ABC was spread and level of the surface was decreased as suite. The base
thickness was constructed as two layers. In the first layer it was constructed to a thickness
and at the thickness of the final layer was 125mm. The thickness of the final layer was kept
little more than the first layer to avoid the failure of the base by shear off the top layer.
When spreading the final layer it was important to level the surface exactly. In this
case ABC was spread and leveled to a level about 20mm more than the base finish level. In
this case level mark pegs at the centre and the edge of the carriageway was not sufficient to
operate the motor grader. So 50mm x 50mm wooden pegs were placed at the edge of the
carriageway and it was embedded in the base to a level about 25mm more than the base finish
level. Then surface was cut using blade of the grader until the peg was found. Then roller was
applied once on the ABC surface and level was checked. Whenever level is higher or lower

the surface should be scarified and all the material should be removed. Then if the level was
high some amount of material should be removed and in the case of insufficient level some
amount of material should be added. Then material should be placed at the scarified place and
should be compacted.
To compact the ABC surface 8-10 tone smooth wheel vibrating roller was used. When
applying the roller it was applied from the edge of the road to the centre with a three quarter
of the drum width over lap. The number of passes to get sufficient compaction depended on
the site observations. Compaction was done until there was no wheel marks on the surface. In
the proper compacted surface, it was hard to see the metal particles and whole surface was
covered with quarry dust.
ABC Compaction
2. B.4.3 Improve efficiency of the sub base or ABC filling works.
The filling works in the foot walk such as soil sub base filling and the
aggregate base course filling may be categorized in to three parts as follows.
i. Transporting and placing material at the required place.
ii. Spreading and levelling of loose material.
iii. Compaction work.
For the above three purposes three different types of machinery and workers were
involved. So if the compaction work was done at a single place only one group has the work
and other two do not have any work to do until present work is finished. So ideal method to
improve efficiency of this work is performing the filling work at three or more nearby places
at once and appointing these three groups in different places.
Another thing is officer who supervised the work had some rough idea of the capacity
of the loader. So he could unload the required amount of soil of ABC exactly. If not, further
effort is required to re-transport material or to remove excess material. Compare to very short
length soil filling area long length filling is efficient wise, labors wise and equipment wise.

2. B.5 Testing
2. B.5.1 Sieve Analysis (Coarse Analysis)
“The separation of the coarser fractions by sieving on a series of standard
sieves“. The finest sieve has an opening of about 0.075 mm. Therefore the sieve analysis could be
used for particles larger than fine sand size. For coarse analysis either dry or wet sieving may be
used.
2. B.5.1.1 Testing procedure
 The air-dried soil is washed and placed on the oven for 24 hours. After drying, the dry
sample is weighed.
 The set of sieves are cleaned and arranged such that, largest mesh on the top and smallest
mesh sieve at the bottom followed by pan.
 The specimen is shaken through a set of sieves with progressively smaller openings. The
amount retained on a particular sieve represents the fraction that is larger than the sieve size
on which it is retained but smaller than that of the preceding sieve.
 Retaining weight of soil sample on the each mesh sieve is weighed.
 Calculate the percentage of passing of soil that is compare with specific passing limit. It
should be within the specific limit of passing percentage.
Percentage of retained = Weight of soil retained x 100 %
Total weight of soil
The result is plotted,( the cumulative percentage against the particle size ) in a semi-logarithmic
graph.
Particle Size (mm)
Diagram 3.1 Particle Size Distribution Curve
2. B.5.2 In-situ density test
In-situ density test could done by the following methods. They are,

I. Core Cutter Method
II. Sand Cone Method
Here, Core cutter method is suitable only for cohesive soils. So, in our road project we use
the Sand cone method to determine the in-situ dry density.
In the field, the in-situ dry density test is carried out for check the compaction of
layers. Compaction, in general is considered most useful in the preparation of sub grade and
other pavement layers and in construction of embankment in order to increase the stability
and to decrease settlement. In field compaction, the compacting moisture content is first
controlled at optimum moisture content and the adequacy of rolling or compaction is
controlled by checking the dry density achieved and comparing with the maximum dry
density.
2. B.5.2.1 Testing procedure ( Sand Cone Method )
 The weight of empty sand cone is measured and then filled with dry sand and
weighed.
 The soil excavated from the test hole is collected and weighed.
 After weighing, a specimen of soil is taken to determine its water content.
 The apparatus is inverted over the test hole with the help of the base plate.
 Sand is allowed to run by opening the control valve.
 When the sand stops running, the valve is closed and the apparatus is weighed with
the remaining sand.
Then, the dry density of soil can be calculated and the percent of compaction of soil is
determined by using the maximum dry density. It should be greater than the specific value of
compaction otherwise the compaction is failure. Then, the compacted place is re-compacted
and re-tested.
Volume of hole = Mass of sand in hole
Density of used sand
Wet density = Mass of wet excavated soil
Volume of hole
Dry density = Wet density x 100 %
(Moisture content of soil + 100)

Degree of compaction = Dry density x 100 %
Maximum dry density
2. B.5.3 Proctor Compaction Test
“ Compaction is the packing together of soil particles with the expulsion of air. “
It is accomplished by rolling, ramming, or vibration, and results in a decrease in the volume
of air voids and an increase in the density of soil. The object of compaction is to improve the
desirable qualities of the soil. The soil particles are brought into a closer state of packing due
to compaction.
This results in a reduction of the voids ratio and porosity of the soil. A well compacted soil is
more stable than a loose soil. It has a high compressive strength and a high resistance to
deformation.
When placing any fill material, it is generally desirable to achieve the smallest possible voids
ratio, for three reasons.
I. The maximum shear strength occurs approximately at the minimum voids ratio.
II. Large air voids may lead to subsequent compaction under working loads, causing
settlement of the structure during service.
III. If large air voids are left in the soil, they may be subsequently filled with water,
which may reduce the shear strength of the soil. This increase in water content
may also be accompanied by swelling.
Factors affecting compaction are,
I. Water content
II. Compactive effort
III. Nature of soil
The degree of compaction of a soil is measured by its dry density. From the compaction test,
the maximum dry density (MDD) and optimum moisture content (OMC) of the soil is found
for the selected type and amount of compaction. The OMC of the soil indicates the particular
moisture content at which the soil should be compacted to achieve MDD. The MDD in the
proctor compaction test lower value indicating weaker soils.

2. B.5.3.1 Testing procedure
The apparatus consists of a cylindrical metal mould having a volume of 1000 cm3. A
detachable collar fits on the top of the mould, and the base is also detachable. This test is
named as BS heavy hammer test.
 The soil to be used in the test is first air dried and passed through a 20 mm BS sieve.
 It is then mixed thoroughly with a small amount of water and compacted into the
mould in 5 equal layers.
 Each layer being compacted by 27 blows of the 4.5 kg rammer dropped through a
height of 450 mm above the soil surface.
 The soil is trimmed to the top of the mould and weighed to determine its dry density.
 The test is repeated five times with gradually increasing water contents until the
whole of the relevant range of water content has been covered.
Then, the moisture content and the dry density are determined and plot the Dry density vs
Moisture content graph. From this graph, the maximum dry density and optimum moisture
content are read out.
Wet density = Mass of wet soil
Volume of mould
Mass of water = Mass of (wet soil + can) – Mass of (dry soil + can)
Moisture content = Mass of water x 100%
Mass of dry soil
Dry density = Wet density x 100 %
(Moisture content + 100)

W %
optimum w%
d
max d
d dry density
water contentW %
Dry density Vs Water content Curve
2. B.5.3.2 The Effect of Water Content on Compaction
The shearing resistance to relative movement of the soil particles is large, at low
water contents. As the water content increase, it becomes progressively easier to disturb the
soil structure, and the dry density achieved with a given compactive effort increases.
However, if the dry density is plotted against the water content for a given
compactive effort, it is seen that the dry density reaches a peak, after which any further
increase in water content results in a smaller density.
Initially there are large voids in the sample, which are mostly filled with air.
Compaction with increase in water helps to pack the soil particles closer. The voids become
smaller during this process, and air gets squeezed out. Thus more soil particles are packed in
the volume of the mould, and the dry density increase.
Once most of the air is squeezed out, further addition of water will displace some soil
particles in the volume of the mould, and this results in a decrease of dry density.
2. B.5.3.3 Compaction in the Field
The compacted dry density to be achieved for a given fill is specified on the basis of
laboratory compaction tests. The standard compaction tests are also useful as a guide to the
water content at which compaction should be carried out in the field. As controlled in the
field cannot be as rigid as in the laboratory, usually about 95% of the dry density attained in
the laboratory is specified to be achieved in the field. But in the road construction, the
shoulder should compact to 100% of maximum dry density, and the ABC layer is compact to
98% of maximum dry density.

The fill is made up of successive horizontal or nearly horizontal layers. Each layer is
compacted before placing the next layer on it. It is necessary to control carefully the water
content of the soil which is to be compacted, and to adjust it to the optimum value as nearly
as possible.
If the soil from the barrow pit is too dry, water is sprinkled to increase the water
content. It is usually convenient to do so during excavation or transport to site rather than
after spreading in the fill area.
If the soil in the barrow pit is too wet, it may be dug out in advance and left to dry, if
the weather is clear. This is likely to cause delay in the work and therefore as far as possible
barrow areas with water content above the optimum should be avoided.
2. B.6 Tact coat
This work shall consist of an application of a tack coat to an existing pavement prior to
construction of a surfacing, so as to provide a bond between layers.
2. B.6.1 Application
Where CSS-1 emulsion used for tack coat it shall normally be applied at ambient
temperature. The rate application of tack coat shall be as specified or as directed by engineer
and shall generally range between 0.25 and 0.55 litter per square meter depending on the
surface condition. Normally tack coat shall not be left applied for more than about 6 hours
with out the placement of the surface course.
2. B.7 Road Surveying
The road survey is a most important work in the road construction.
Before designed the road, the existing road is surveyed for length, width, level and cross
section. These readings are taken and then designed for constructing a new road. When the
initial surveying, the centerline of the design road is located on the ground using driving pegs
at 20 m intervals and also the temporary benchmarks are fixed for length of road. The cross
section levels are taken up to the desired width at intervals of 10 m or at closer intervals.
During the road excavation or filling, the level survey is carried out. For design
road width, the survey is done during the construction such as embankment, edge treatment,
preparing each layer and culvert, bridge, drain and retaining wall construction. After
constructed, width, level and cross section are checked again.

Levelling
2. B.8 Machinery and Equipments used in Highways
2. B.8.1 Backhoe Loader
This is a popular machine in construction sites in Sri Lanka. The machine comprises of rigid
frame, a loader bucket at the front and the backhoe at the back. The 52.5hp diesel engine
powers the rare wheels only.
The backhoe of 430mm wide and capacity of 0.16m3 is mounted on a
horizontal bar at the backside of the machine. It can turn through 90’ in plan. This can be
used for excavations approximately 3.5m below the ground and it has a maximum discharge
height of 4.9m. The maximum out stretch of the bucket from the centre line of the stabilizer
is 5.3m. In this mode, machine must be stabilized using the jacks.
The 2m wide 0.7m3 capacity front bucket was used as a loader and it has a
maximum discharge height of 3m.
2. B.8.2 Motor Grader
This is an ideal machine for finish the surface smoothly without any undulations and
ridges. This consists of two major parts, the mould board and a riper. Mould board is similar
to the bulldozer blade. It is hung between the axels and position of the mould board can be
adjusted to suit the work. When levelling and trimming on the horizontal, mould board can be
set central or swung out either left or right. If the mould board set at an angle on plan,
material will roll off the blade to form a window. The ripper of the machine can be used for
scarify the hard surfaces such as soil sub grade and aggregate base course.

Motor Grader
2. B.8.3 Bitumen Spreader
This machine was used for applying the tack coat and the prime coat prior to the
application of the aggregate cover in the seal coat treatment. This was a pedestrian control
machine two persons required to operate. One skilled person required for spread the tar and
other person required for drive the vehicle.
In this machine tar mix is heated using a kerosene flame and at the same time
recirculation the mix using a pump. The machine has a horse with a nozzle at the end and tar
spread by that. The bitumen at the bowser is heated up to about minimum 160’c.
2. B.8.4 Aggregate spreader
This is used to apply a uniform aggregate cover at a specified rate. Here the
spreader is attached with the tipper. The spreader has two separate attachments, which is use
to lock the spreader with the back side wheels of the tipper. The width of the spreader could
change according to the road width, and the speed of movement of the spreader is controlled
by the tipper, which is controlled the spreading rate of aggregate.
2. B.8.5 Rammer
This is small-scale compacting equipment that can be transport and handle easily.
Mainly this was applied at the compaction work at the trenchers backfilling. In this machine
raising a heavy weight and allowing it to fall on the surface utilize kinetic energy. Due to that
effective depth is much higher compare to the 1T-vibrating roller. The effective depth of this
machine is about 500mm. But at the same time there are several disadvantages of this. This
cannot be used for clay soil and it is difficult to get exactly level surface. The detail of the
rammer machine used is given below.

Rammer
2. B.8.6 The Single Drum Vibratory Roller (weight of 400 kg)
This is used to compact cold mix, gravel, sand and soil for repair works and
maintenance of roads. It is pedestrian operated and easy to handle. The Fig 4.2 shows a sketch of
Single Drum Vibratory Roller.
Single Drum Vibratory Roller
2. B.8.7 Seven Ton Twin Drum Vibrating Roller
This was the most suitable roller for the compaction work at the foot walk because
of its weight and the width. This has an ability to turn both front and the rare wheel and due
to that reason this may handle easily at the foot walk area.
2. B.8.8 Air Compressor
Air compressor is a very useful machine in road projects. In this machine there is a power
unit and several tools can be attached to this unit for various purposes. In this machine
compress air is generate by means of an air pump driven by diesel engine. The normal
operating pressure of the machine is 7kg/cm2. At this pressure 1.5-2.0m3/min of compressed
air is required to operate one breaker.

The compressed air blow generate by the compressor can be used for several works such as
cleaning shutters after fixing reinforcement, drying the wetted road surface and cleaning the
road surface for seal coat treatment. In addition to that this can be used to power the breaker.
The breaker has several tools to fix and by changing these, it can be used for various
purposes.
Air Compressor
2. B.8.9 Water Bowser
There were two types bowsers used in the road projects. They are
I. Truck Bowser
II. Tractor Bowser
The normal capacity of the truck bowser was 2000 gallons and capacity of the tractor bowser
was 800 gallons. These were used to transport water for the construction works such as
masonry works, construction of aggregate base course and soil fillings. In addition to that
these were used to apply water to the road surface to avoid arising of dust. Normally, one 800
gallon capacity tractor bowser is sufficient for apply water to 2km.
2. B.9 Arrangements of traffic during construction
In road construction work, traffic controlling was done in a manner consistence with
satisfactory execution of work involving improvement to existing road. A part of the existing
pavement of the road carriageway under improvement or along temporary diversion
constructed close to the road.
The importance of the road and the points connected by the
road making arrangement for the traffic diversion was done in a good manner. Arrangements
made to close sections of road where necessary subjected to satisfactory alternative routs
being provided.

2. B.9.1 Using part of the road
Part of the carriageway kept open to traffic while improvement work such as
widening of the road, strengthening of the existing pavement was being carried out in the
other part, provided the part kept open to the traffic was adequate for the purpose. Keeping
part of the carriageway to traffic practicable adopted in respect of reconstruction culvert and
walls. Most of the construction was done using part of the road open to the traffic.
2. B.9.2 Temporary Diversion
It is not possible to pass the traffic a part width of the carriageway, by any other
route a temporary diversion close to the road constructed as directed. Such a diversion
constructed using locally available material as far as practicable. The diversion maintained in
good condition till the original road is opened to traffic.
2. B.9.3 Traffic safety and control
All necessary safety to traffic during construction was taking by providing
barricades, markings, flags, lights, etc. The barricades were arranging firmly fixing steel rods
to the ground, arrow-marking boards painted by using yellow and black background color.
All construction areas two flagmen’s kept, in road paving areas two security men’s kept with
phones and red light torch.
2. B.10 Safety
Unaccepted accident causes pain, permanent disabilities, human suffering or death. This
affects the victim and other working resulting in loss of morale and even a fear of performing
certain tasks. Therefore accident in construction competent, safety-conscious, supervision,
education, discipline, job safety organization, safety device and equipment.
2. B.10.1 Safety procedures
 All persons must wear safety helmets before enter the site works.
 Do not though any heavy thing on high level that may case injures.
 Ensure that there is no danger from live electrical cables or equipment near to
work is carried out.
 Goggles and screens must be used when doing the work that might cause damage
eyes.

 Always wear a suit when doing work that creates dust.
 As the nature of the work boots and gallowses must be use.
 Keep work area clean.
 Consider area environment.
 Power tools were not exposes to rain. They were not used in damp or wet
location.
 Machineries were not use if there is risk to cause fire of explosion.
 Do not let visitors touch the tools or extension chord.
 Do not force tools
 Use right tools.
 Use safety glasses, also use face or dusk mask if cutting operating is dusty.
2. B.10.2 Red flag and Green flag / Stop and Go board
When we doing some work on the road (demarcation works the center line) we want to stop
the vehicles. Then we can use this apparatus for it. If we want to stop the vehicles, we can lift
the red flag or stop board. After our work, we lift the green or go board.

CHAPTER 3
3.1 CONCLUSION
As I mentioned under the preface out of 22 weeks industrial training gained
experience and knowledge in practice and able to realize what we learned in past academic
carrier. At the end of level 3 academic stage I earned industry experience with sufficient
theoretical knowledge with lot of imagination without knowing how those theories are
applied in to the real life. So this period is merely suitable to exposing the undergraduates to
working environment.
Considering the training organization, Access Engineering Ltd. is one of
the reputed organization in Sri Lanka and which operates construction work that includes
highway, bridges and flood control. In our Project Manager, Construction Manager, Planning
Engineer, Site Engineers and staff also had good interest on trainees to give adequate training
from their organization.
I had freedom to refer all their documents, drawings etc. and clarify any
doubts at any time and they encourage to gained experience in not only construction site but
also management site.
First two month of my industrial training program, I worked in Sarvodaya-Vavuniya
Quarry(A). During this period I got excellent experience in quarrying & crusher plant. The
safety was considered most important thing at Access Engineering Ltd. I improved my
English and Sinhala spoken knowledges because I worked with Tamil and Sinhalese. One of
the most valuable things which I gained ability to work with different kinds of people. I learnt
to work with people of different age limits, different knowledge and different mentalities. So,
I think this would be very useful for my future career. I understood that how to call every
people such as Staffs, Labours, Senior Engineers and Project Manager.
Mining engineer explained all of the managing level how to keep our level. When
considering about the training establishment, Access Engineering Ltd is the one of good
places for engineering trainees because all of them can acquire good training from them. The
local staffs are well qualified and they are very skillful workers. That makes the speed of the
project accomplishment faster with good quality. And also it causes to do some works in
more economical manner. ACCESS management always thinks about their safety and
welfare. They had good interest on trainees to give adequate training from their
establishment. I got all freedom to refer all their documents, reports and manual. All of the
Engineers taught me and explained everything. I clarified my doubts at any time. All

Engineers encouraged me to get good experience in all site. I got blasting experience, quarry
management, handling of machineries and vehicles and labour huddling, maintenance of
machineries and vehicles, mine development, explosive handling and quarry license
procedure. I involved in drilling works and identified the difficulties in drilling. I observed
about blasting within my training period. I operated rock breaker, excavator and familiarized
with wheel loader driving, crew cape driving.
I learnt the mechanism of crushers, main parts of every crushers and important things.
I understood the flow chart of crusher plant and crusher maintenance. When talking about the
field of Mining Engineering, as I think the undergraduate should have to participate training
in both open cast and underground operations and sometimes undergraduate may have to
train in two different establishments to get that opportunity. This may not possible in some
situations where the undergraduate has to go for such places where he can get required kind
of training and getting approvals for that etc. If department engage in this, the process will be
much easier and all undergraduates get overall training experience related to the field.
Next four month of my industrial training program I had shared certain tasks
with our technical officers. During this period we have done excavation, scarifying, ABC
laying, priming work, and road marking. Not like other road construction here I got a good
opportunity the different highway construction sequence at the mean time.
In my view as a trainee one must take responsibilities during this industrial
training other than just looking the constructions and other process. He has no any fear to
take responsibilities of any duty. If a trainee takes such responsibilities at this stage, he will
have good confidence about himself after passing out and he will gain knowledge, experience
and proficiency in the following field.
Training division should consider about level of the training that is given
from that particular organization. Some of our colleagues are faced this problem due to
inappropriate selection of the training organization and worksite. In addition to that certain
Site engineers and Managers are not much bothered about the trainees like us. If that kind of
situation arises we haven’t proper guiding. Due to that there is possibility of loss to achieve
our purpose of the industrial training objectives. In addition to that our monthly assessment is
not standard. That is varying according to the training organization and official person.
Sometimes we have certain level difference between our colleagues if we did our work
properly.
I would like to do the following suggestion to improve the quality of the in
plant training.

a) Appointed the trainees at short-term projects as possible or
b) Prepare a training schedule by each training organization and placed the trainees at
different work sites to get the experienced of different works.
In addition to these, if there is an opportunity to select the work projects
rather than the training organization, it will give the good results.
Access Engineering Ltd. has trained a large number of trainees successfully
throughout its history. They allow the trainees not only the chance to learn but to take their
own responsibilities in the assigned tasks for the successful completion of the organizational
objectives. In this way they give the trainee a much better chance of developing capabilities
as well as the capacity of facing various challenges that can possibly occur in the dynamic
engineering environment.

Introduction

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Introduction