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1. 1
A Summer Training Report
On
Construction of Cement Concrete Road Pavement
At
UTTAR PRADESH PUBLIC WORKS DEPARTMENT
CONSTRUCTION DIVISION-1,BASTI
Submitted for Partial fulfillment for the award of degree
Bachelor of Technology
In
CIVIL ENGINEERING
Submitted to: - Submitted By:
Mr. Sandeep Tripathi Ajay Kumar Upadhyay
Assistant Professor BTech 4th Yr
Roll No:-1303200013
ABES Engineering College, Ghaziabad
Affiliated to
Dr. A.P.J. Abdul Kalam Technical University, Uttar Pradesh,
Lucknow

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AKNOWLWDGEMENT
I express my satisfaction on the completion of this summer training program
and project report submission as a part of the curriculum for the degree of
Bachelor of Technology, Civil Engineering. I express my deepest gratitude to
my Assistant Engineer and
Junior Engineer Mr. RAJESH KUMAR and Mr. P.S. PATEL for his kind
guidance during the entire period of training. His consistent support and advices
has helped me to complete this research project successfully. Also I thank all
the members of Building block-1 P.W.D. Basti (U.P.) Department for their kind
support. They have always been a source of inspiration to me.
DATE: - 20/07/2016 AJAY KUMAR UPADHYAY

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CONTENT
1. PWD Introduction
2. About Cement road
4. Material
5. Tests
6. Cement road construction
6.1 Preparation of subgrade
6.2 Preparation of base
6.3 Form work
6.4 Watering of base
6.5 joints
6.6 Material mix & placing
6.7 Compaction
6.8 Finishing of surface
6.9 Curing
6.10 Filling joint
6.11 Edging
6.12 open to traffic
7 Reference

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INTRODUCTION
Point of view geographic and population of the state is the nation's largest state.
State Industrial, economic and social development of the state and the
population of each village is absolutely necessary to re-connect to the main
roads. In addition to state important national roads, state roads and district roads
and their proper broad be made to improve the quality of traffic point of view is
of particular importance. Public Works Department to build roads and improve
connectivity in rural zones, Other District Road and State broad and
improvement of rural roads and main routes narrow construction of zones and
depleted bridges brides reconstruction of the bases are transacted on a priority
basis . Also under Pradhan Mantri Gram Sadak Yojana and pre-fabricated
construction of rural roads linking the work of other district roads broad
Suddikrn the scale bases are edited.
For the purpose of management and administration, roads in India are divided
into the following five categories:
 National Highways (NH)
 State Highways (SH)
 Major District Roads (MDR)
 Other District Roads (ODR)
 Village Roads (VR)

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.

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Materials
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 used in construction that sets and hardens and
can bind other materials together. The most important types of cement are used
as a component in the production of mortar in masonry, and of concrete, which
is a combination of cement and an aggregate to form a strong building material.
Cements used in construction can be characterized as being
either hydraulic or non-hydraulic:
Hydraulic cements (e.g., Portland cement) set and become adhesive due to a
chemical reaction between the dry ingredients and water. The chemical reaction
results in mineral hydrates that are not very water-soluble and so are quite
durable in water and safe from chemical attack. This allows setting in wet
condition or underwater and further protects the hardened material from
chemical attack.
Non-hydraulic cement will not set in wet conditions or underwater; rather, it
sets as it dries and reacts with carbon dioxide in the air. It is resistant to attack
by chemicals after setting.

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Types of Cement
 Portland Cement
Portland cement is by far the most common type of cement in general use
around the world. This cement is made by heating limestone (calcium
carbonate) with small quantities of other materials (such as clay) to 1450 °C in
a kiln, in a process known as calcination, whereby a molecule of carbon
dioxide is liberated from the calcium carbonate to form calcium oxide, or
quicklime, which is then blended with the other materials that have been
included in the mix. The resulting hard substance, called 'clinker', is then ground
with a small amount of gypsum into a powder to make 'Ordinary Portland
Cement', the most commonly used type of cement (often referred to as OPC).
Portland cement is a basic ingredient of concrete, mortar and most non-
specialty grout. The most common use for Portland cement is in the production
of concrete. Concrete is a composite material consisting
of aggregate (gravel and sand), cement, and water. As a construction material,
concrete can be cast in almost any shape desired, and once hardened, can
become a structural (load bearing) element. Portland cement may be grey or
white.
 Portland fly ashcement
Its contains up to 35% fly ash. The fly ash is pozzolanic, so that ultimate
strength is maintained. Because fly ash addition allows a lower concrete water
content, early strength can also be maintained. Where good quality cheap fly
ash is available, this can be an economic alternative to ordinary Portland
cement.
 Portland pozzolan cement
It includes fly ash cement, since fly ash is a pozzolana , but also includes
cements made from other natural or artificial pozzolans. In countries
where volcanic ashes are available.

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 Portland silica fume cement
Addition of silica fume can yield exceptionally high strengths, and cements
containing 5–20% silica fume are occasionally produced. However, silica fume
is more usually added to Portland cement at the concrete mixer
Sand
Sand is a naturally occurring granular material composed of finely
divided rock and mineral particles. The composition of sand is highly variable,
depending on the local rock sources and conditions, but the most common
constituent of sand in inland continental settings and 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.
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.

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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 sub-bases, 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 weights and voids
 absorption and surface moisture
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

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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.

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Standard slump cone (100 mm top diameter x 200 mm bottom diameter x 300 mm high)
Small scoop
Bullet-nosed rod
mm long x 16 mm diameter(600 )
Rule
Slump plate (500 mm x 500 mm)
Method
1 Dampen with water and place on the slump plate.Clean the cone.
The slump plate should be clean, firm, level and non-absorbent.
2 Collect a sample.
3 Stand firmly on the footpieces and fill 1/3 the volume of the cone with
the sample.Compact the concrete by 'rodding' 25 times.
RoddingRodding 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
Top up the cone till it overflows.of the second layer.
6 Level off the surface with the steel rod using a rolling
Clean any concrete from aroundaction.
the base and top of the cone, push down on the
handles and step off the footpieces.
7 Carefully lift the cone straight up making sure
not to move the sample.
8 T
u
rnthe cone upside down and place the rod across the
up-turned cone.

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THE COMPRESSION TEST
The compressiontest shows the compressive strength of hardened concrete. The
testing is done in a laboratory off-site. The only work done on-site is to make a
concrete cylinder for the compression test.
The strength is measured in Megapascals (MPa) and is commonly specified as a
characteristic strength of concrete measured at 28 days after mixing. The
compressive strength is a measure of the concrete’s ability to resist loads which
tend to crush it.
Tools
Cylinders (100 mm diameter x 200 mm high or 150 mm diameter x 300 mm
high)
( The small cylinders are normally used for most testing due to their lighter
weight )
Small scoop
Bullet-nosed rod (600 mm x 16
mm) Steel float Steel plate
Method
1 Clean the cylinder mould
and coat the inside lightly
with form oil, then place on a clean, level and firm surface, ie
the steel plate.
2 Collect a sample.
3 Fill 1/2 the volume of the mould with concrete then
compactby 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.

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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.
5 Level off the top with the steel float and
clean anyconcrete from around the
mould.
6 Cap, clearly
tag cylinder
and put it in a cooldry 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.

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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
Compressiontesting machine
PREPARATION OF CUBE SPECIMENS
The proportionand 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

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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.

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Using mix Concrete , there some Point to constructthe 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
A. Floating
B. Belting
C. Brooming
9. Curing
10.Joint filling
11.Edging
12.Open to traffic
1. Preparation of subgrade
i. Rolling on sub grade by roller
ii. Filling the granular soil in the weak part and pot holes
iii. Correct the soil coat , Camber , longitudinal slop
iv. When concrete direct laid on subgrade, For preventing the water-
seepaging into the soil , used water proof paper on entire length.
v. Rolling on sub grade by roller
vi. Filling the granular soil in the weak part and pot holes
vii. Correct the soil coat , Camber , longitudinal slop

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viii. 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
Chooseany one type of base
1.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.
2. Concrete base
On the road used 10cm Cement concrete(1:2:4) or lime concrete(16:32:64)
3. Granular medium material layer
10-15cm composite layer of sand , moorum , bajri are used for better drainage
facilities
1. Stabilization soil

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3. Form work
Material for form work-
Wooden sheets, battens, plywood, fibre hard board, steel plates, angles, rope,
minerals.
a) before using form work, it should free from all type material like as dust
,cement.
b) To placing the concrete in appropriate depth used 2.5-5cm thick and
3mtr long wooden sheeting.
c) The depth of wooden block must be same as level of slab thick.
d) After 24hrs form work displaced next length of road.
4. Watering of base
If base is dry, then 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-
1. Batch mixer-
at site, used for small road construction
2. Continuous mixer-

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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 .
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.

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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
A.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.
B.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.
C. 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.

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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:-
a) Shading concrete works
b) Covering with hessian & gunny bags
c) Sprinkling of water
d) By ponding
e) Membrane curing
f) Steam curing
10. Filling joint
After drying road, clean the joints and fill the shelling compound or hot
bitumen . Also bitumen fill road bank.

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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.

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Reference
www.Google.com
www.concrete.net.au
www.res.gov.in
www.upjl.com
www.concrete.com
www.sand.uk