It contains the construction sequence and process of a road construction and test track construction.

1. PROJECT REPORT ON HIGH SPEED TEST TRACK
DEPARTMENT OFCIVIL ENGINEERING (B.TECH)
SRM INSTITUTE OF SCIENCE AND TECHNOLOGY
NCR CAMPUS, GHAZIABAD
SUBMITTED BY,
Nikhil Kumar

2. ABOUT PROJECT
Name of Work: Construction of Balance Works of in High Speed Track (HST) for National
Automotive Test Track (NATRAX) at Pithampur, near Indore
Type of Contract: Item Rate Contract
Employer: NATRiP Implementation Society
Contractor: M/s Larsen & Toubro Ltd.
Original Contract Value: Rs. 578,89,00,000/-
Special Feature of track
 Oval in shape.
 Straight Portion- 4035.864 m.
 Transition Portion- 1926.32 m.
 Parabolic Portion- 5320.024 m.
 16m wide road.
 Total area is equal to 230000 m2.
 250 km/h neutral speed, maximum testing speed up to 350 km/h.

3. 1. CONSTRUCTION SEQUNCE OF A ROAD OR TEST TRACK
 TBM Fixing
 Center line marking
 Toe marking
 Tree marking & cutting
 Cleaning & Grubbing (C&G)
 Soil sampling
 Execution of work according to the soil report.
 Prepration of bed according to given plan.

4. CONSTRUCTION METHDOLOGY OF ROAD
• LAYERS OF ROAD
• EMBANKMENT
• SUBGRADE
• GRANULAR SUB BASE/ DRAINAGE
LAYER
• WATER MIX MECADEM
• DENSE GRADED BITUMINOUS
MECADEM
• BITUMINOUS CONCRETE

5. EMBANKMENT CONSTRUCTION
TECHNICAL SPECIFATION (AS PER MORTH)
(i) Free swell index is not more than 50%.
(ii) Size of coarse aggregate should not more than 75mm.
(iii) liquid limit should not be more than 50%.
(iv) Plasticity index should not be more than 25%.
(v) Layer thickness should not be more than 250mm.
(vi)Organic soil is not allowed.
(vii)Compaction of embankment is more than 95%.
(viii)Optimum moisture content (OMC), it depends on MDD of material.
(ix)Tolerance of OMC is +1 to -2
(x) California Bearing Ratio more than 10%.
(xi) Maximum Dry Density (MDD)
In case of height of embankment is more than 3m then
its MDD is >1.62 gm/cc.
If height is less than 3m then MDD is >1.52 gm/cc.

6. COMPACTION TEST
by Sand Replacement Method.
 Calibration of Sand Pouring Cylinder
 Clean and dry, sand passing 1mm sieve and retained on 600 microns sieve approximately 28 kg of sample taken.(W1).
 Weight sand in cone were given by quality lab.(W2)
 Prepare a flat area approximately 450mm square by trimming preferably with the aid of a scraper tool.
 Place the metal tray with central hole on the prepared surface of the soil to be tested.
 Excavate the hole in the soil with a dibber using the hole in the tray as a pattern to the depth of the layer to be tested.
 Carefully collect the excavated soil from the hole and weight.
 Weight of wet material from the hole. (Ww).
 Place the cylinder above the hole and open the shutter and after sometime when flow stopped then we close the shutter.
 Final weight of sand and cylinder after pouring.(W3)

7. SAND REPLACMENT METHOD (SRM)

8. RESULT OF FIELD DRY DENSITY(EMBANKMENT)

9. GRANULAR SUB-BASE CONSTRUCTION
 TECHNICAL SPECIFICATION (AS PER MORTH)
 Liquid limit not more than 25%.
 Plastic index not more than 6%.
 Aggregate impact value should not be greater than 40%.
 Field density should be more than 98%.
 Maximum size of aggregate should not be more than 53mm.
 California Bearing Ratio should be more than 30%.
 Maximum dry density should be greater than 2.305 gm/cc.
 Optimum moisture content tolerance in between +1 to -2.
 Leveling tolerance (survey) +10 to -10mm.
 Minimum layer thickness should not be less than 125mm.
 It provide strength and support to the overlying pavement.

10.  COMPACTION TEST
 The Compaction test shall be carried out by Nuclear Density Gauge.
 The minimum compaction requirement shall be 98 % .
NUCLEAR DENSITY GAUGE

11. RESULT OF NDG

12. 4. HIGHWAY MATERIAL
The materials used for roadway construction have progressed with time, dating back to the early days of the Roman
Empire. Advancements in methods with which these materials are characterized and applied to pavement structural
design has accompanied this advancement in materials
There are two major types of pavement surfaces - Portland cement concrete (PCC) and hot-mix asphalt (HMA).
Underneath this wearing coarse are material layers that give structural support for the pavement system. These
underlying surfaces may include either the aggregate base and subbase layers, or treated base and subbase layers,
and additionally the underlying natural or treated subgrade. These treated layers may be cement-treated, asphalt-
treated, or lime-treated for additional support.
 Some of major highway materials are;
 Soil
 Aggregate (of different shape and size)
 Cement
 Sand
 Bitumen
 Concrete

13.  To ensure the quality of material, we do some test on highway material i.e.
 For soil, tests are;
 FREE SWELLING INDEX
 GRAIN SIZE ANALYSIS
 LIQUID LIMIT
 PLASTICITY INDEX
 MAXIMUM DRY DENSITY
 CALIFORNIRY BEARING RATIO
 For aggregate;
 AGGREGATE IMPACT VALUE
• ELONGATION AND FLAKINESS

14.  For cement;
 FINE PARTICAL
 INITIAL & FINAL SETTING TIME
 CONSISTENCY TEST
 SOUNDNESS TEST
 COMPRESSIVE TEST
 For concrete;
 CUBE TEST
 SLUMP TEST
 PERMIABLITY TEST
 For Bitumen;
 SOFTENING POINT
 PENETRATION TEST
 FLASH POINT TEST

15.  TO DETERMINE FREE SWELLING INDEX OF SOIL
FSI TEST

16.  Take two specimens of 20gm each of pulvarised soil passing through 425micron IS sieve and oven dry.
 Pour distilled water in one and kerosene oil in the other cylinder up to 100ml mark
 Allow the suspension to attain the state of equilibrium for not less then 24 hours.

17. DETERMINATION OF LIQUID LIMIT OF SOIL
• About 150 gm. of air dried soil from thoroughly mixed portion of material passing 425
micron IS sieve is obtained.
• Distilled water is mixed to the soil thus obtained in a mixing disc to form a uniform paste.
• Then the wet soil paste is transferred to the cylindrical cup of cone penetrometer apparatus,
ensuring that no air is trapped in this process.
• Finally the wet soil is leveled up to the top of the cup and placed on the base of the cone
penetrometer apparatus.
• The penetrometer is so adjusted that the cone point just touches the surface of the soil paste
in the cup and the initial ready is to be taken.
• The vertical clamp is then released allowing the cone to penetrate into soil paste under its
own weight for 5 seconds. After 5 seconds the penetration of the cone is noted to the nearest
millimeter.
• The test is repeated at least to have four sets of values of penetration in the range of 14 to 28
mm

18. CONE PENETRO METHOD

19. DETERMINATION OF PLASTIC LIMIT OF SOIL
 Mix about 20 gm of soil passing IS: 425 micron sieve, with distilled water.
 Take approximately 8 gm of soil from the mix. Make a ball and roll it on a glass plate, with
hand to make a thread.
 When the diameter of 3 mm is reached re-mould the soil again to a ball.
 Repeat the process of rolling and re-molding until the thread of soil just starts crumbing at a
diameter of 3 mm.
 Determine the moisture content of the crumbled threads.
 Repeat the test twice more, with fresh portion of the soil mix.
 The average of moisture contents determined in the three trials, gives the plastic limit of the
soil

20. RESULT OF LL & PL

21. DETERMINATION OF MAXIMUM DRY DENSITY
 Take 3 Kg of air dried soil passing 19 mm IS: Test Sieves.
• Add a known percentage of water (% moisture content well below the assumed optimum moisture
content) by weight of dry soil depending on the expected optimum moisture content.
 Fill the mould by compacting the specimen in five layers with 4.89 kg rammer for heavy compaction and in
three layers with 2.6 kg hammer for light compaction by giving 25 blows to each layer in any method.
 Remove the extension and level off carefully to the top of the mould by means of a straight edge.
 Take the weight of the mould and the soil (m2).
 Repeat the same procedure for various percentages of water until the weight of the mould + soil attains a
peak and starts reducing with increase in water content so that a minimum of 5 point are available to plot
the graph between dry density and moisture content.
• Find out the water content as per IS-2720 II by using the graph between dry density and moisture content;
find the maximum dry density and the corresponding moisture content and report as MDD and OMC
respectively

22. MDD MOULD
RAMER OF MDD

23. RESULT OF MDD (OMC)

24. LABORATORY DETERMINATION OF CALIFORNIA BEARING RATIO
 The material used in the above methods shall pass 19 mm sieve for fine grained soils and 37.50mm sieve for coarse materials
up to 37.50 mm.
 Replace the material retained on 37.50mm sieve by an equal amount of material passing 37.50mm sieve and retained on
4.75mm sieve.
Dynamic Compaction
 Take representative sample of soil weighing approximately 6kg and mix thoroughly at OMC.
 Record the empty weight of the mould with base plate, with extension collar removed (m1).
 Place the mould on a solid base such as a concrete floor or plinth and compact the wet soil in to the mould in five layers of
approximately equal mass each layer being given 56 blows with 4.90kg hammer equally distributed and dropped from a height
of 450 mm above the soil.
 Remove the extension collar and carefully level the compacted soil to the top of the mould by means of a straight edge.
 Place the weights to produce a surcharge equal to the weight of base material and pavement to the nearest 2.5kg on the
perforated plate.
 Immerse the whole mould and weights in a tank of water allowing free access of water to the top and bottom of specimen for

25. CBR MACHINECBR MOULD AND SURCHARGE

26. Penetration Test
 After 96 hours of soaking take out the specimen from the water and remove the extension collar, perforated disc,
surcharge weights and filter paper.
 Drain off the excess water by placing the mould inclined for about 15 minutes and weigh the mould.
 Place the mould on the lower plate of the testing machine with top face exposed
 To prevent upheaval of soil in to the hole of surcharge weights, place 2.5kg annular weights on the soil surface prior to
seating the penetration plunger after which place the reminder of the surcharge weights.
 Set the plunger under a load of 4kg so that full contact is established between the surface of the specimen and the plunger
 Consider the initial load applied to the plunger as the zero load.
 Apply the load at the rate of 1.25 mm / min.
 Take the readings of the load at penetration of 0, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 4, 5, 7.5, 10 and 12.5.
 Raise the plunger and detach the mould from the loading equipment.
 Collect the sample of about 20 to 50gms of soil from the top 30mm layer of specimen and determine the water content in
accordance with IS: 2720 (Part 4) 1973.
Examine the specimen carefully after the test is completed for the presence of any oversize soil particles, which are likely to
affect the results if they happen to be located directly below the penetration plunger

27. RESULT OF CBR

28. GRAPH OF CBR

29. DETERMINATION OF FLAKINESS INDEX AND ELONGATIO INDEX
 Sieve the sample through IS sieves 63, 50, 40, 31.5, 25, 20, 16, 12.5, 10 and 6.3 mm.
 Take the weight of minimum 200 pieces of each fraction to be tested (W1 gm).
 Separate the flaky material by using the standard flakiness gauge.
 Take weight of flaky material which passes through standard gauge.
 The Flakiness Index = (Weight of Material Passing the Gauge / Total Weight of Sample) x 100
 Take the non-flaky portion of the sample tested and take weight (W2 gm.).
 Separate elongated material by using standard elongation gauge and take weight.
 The Elongation Index = (Weight of Elongated Particles/Weight of Sample Tested (W2))
x100
 Combined Flakiness and Elongation Index = FI + EI values as above

30. RESULT OF ELONGATION & FLAKINESS

31. DETERMINATION OF AGGREGATE IMPACT VALUE
 Take representative sample of aggregates passing 12.5mm IS sieve and retained on 10mm IS sieve.
 Keep the sample in the oven for a period of four hours till the time the weight becomes constant at a temperature of 105
to 110 oC and cool to room temperature.
 Fill the cup in three equal layers, each layer being subjected to 25 strokes.
 Determine the net weight (A) of the aggregate.
 Compact the material in the cup by a single tamping of 25 strokes with the tamping rod.
 Subject the test sample to a total of 15 blows by the hammer (weighing 13.50 Kg to 14Kg) of the Impact machine each
being delivered at an interval of not less than one second and from a height of 380 + 5 mm above the upper face of the
aggregate as shown in Fig: 1
 Remove the crushed aggregates from the cup and sieve the whole sample on the 2.36 mm IS sieve till no further
significant amount passes through the sieve in one minute and weigh (B)
 Weigh the material that has passed through the sieve (C).

32. AIV MACHINE

33. RESULT OF AIV

34. FINENESS TEST OF CEMENT
 Take representative sample of 10grams (R1) of cement from the specified lot
 Agitate the sample of cement to be tested by shaking for 2 minutes in a stoppered jar to disperse
agglomerates wait 2 minutes and stir the resulting powder gently using a clean dry rod in order to
distribute the fines throughout the cement.
 Fit the tray under the sieve and place the sample on the sieve.
 Fit the lid over the sieve, agitate the sieve by swirling, planetary and linear movement until no more fine
material passes through it.
 Remove and weigh the residue (R2).
 Express its mass as a percentage of the total quantity.
 Gently brush all the fine material of the base of sieve in to the tray.
 Make at least two determinations for each test.

35. RESULT OF FINENESS

36. CONSISTENCY OF STANDARD CEMENT
 Unless otherwise specified this test shall be conducted at a temperature 27 + 20C.and the relative
humidity of laboratory should be 65 + 5%.
 Prepare a paste of weighed quantity of cement (400gms) with weighed quantity of potable or distilled
water, taking care that the time of gauging is not less than 3minutes nor more than 5minutes and the
gauging is completed before any sign of setting occurs.
 The gauging is counted from the time of adding water to the dry cement until commencing fill mould.
 Smoothen the surface of the paste, making it level with the top of the mould.
 Slightly shake the mould to expel the air.
 In filling the mould operator’s hands and the blade of the gauging trowel shall only be used.
 Lower the plunger gently to touch the surface of the test block and quickly release, allowing it sink
into the paste.
 Prepare trial pastes with varying percentages of water and test as described above until the plunger is
5mm to 7mm from the bottom of the vicat mould.

37. INITIAL & FINAL SETTING TIME
 Unless otherwise specified this test shall be conducted at a temperature of 27 + 20C and 65 + 5% of
relative humidity of the Laboratory.
 Prepare a paste of 300 grams of cement with 0.85 times the water required to a give a paste of standard
consistency IS: 4031 (Part 4) 1988.
 The time of gauging in any case shall not be less than 3 minutes not more than 5 minutes and the gauging
shall be completed before any sign of setting occurs.
 Count the time of gauging from the time of adding water to the dry cement until commencing to fill the
mould
 Fill the vicat mould with this paste making it level with the top of the mould.
 Slightly shake the mould to expel the air.
In filling the mould the operator hands and the blade the gauging trowel shall only be used

38. Initial Setting Time
 Immediately place the test block with the non-porous resting plate, under the rod bearing the initial setting
needle.
 Lower the needle and quickly release allowing it to penetrate in to the mould.
 In the beginning the needle will completely pierce the mould
 Repeat this procedure until the needle fails to pierce the mould for 5 + 0.5mm.
 Record the period elapsed between the time of adding water to the cement to the time when needle fails to
pierce the mould by 5 + 0.5mm as the initial setting time.
Final Setting Time
 Replace the needle of the vicat apparatus by the needle with an annular ring
 Lower the needle and quickly release.
 Repeat the process until the annular ring makes an impression on the mould.
 Record the period elapsed between the time of adding water to the cement to the time when the annular ring
fails to make the impression on the mould as the final setting time.

39. VICAT APPRATUS WITH NEEDLE

40. RESULT OF CONSISTENCY, INITIALAND FINAL SETTING TIME

41. DETERMINATION OF SOUNDNESS (LE- CHATLIER METHOD)
IS 4031 (Part 3) 1988
 Take representative sample of cement and mix with 0.78 times the water required to give a paste of standard
consistency as per IS: 4031 (Part 4) 1988.
 Place a lightly oiled mould on a lightly oiled glass and fill it with this cement paste.
 Immediately submerge the whole assembly in water bath maintained at a temperature of
27 + 20C and keep there for 24 hours.
 After 24 hours remove the mould from the water bath and measure the distance separating the indicator points
(E1).
 Again submerge the whole assembly in water bath at a temperature of 27 + 20C and bring the water to boiling
in 27 + 3 minutes and keep it for 3 hours.
 Remove the mould from the water bath, allow it to cool and measure the distance between the indicator points
(E2).
The distance between the two measurements indicates the expansion of the cement.

42. RESULT OF SOUNDNESS OF CEMENT

43. DETERMINATION OF COMPRESSIVE STRENGTH
(IS 4031 (Part 6) 1988)
• Weigh the material required for each cube separately.
• The quantity of cement, standard sand and water required for each cube are as follows
Cement = 200gms
2mm to 1mm - 200gm
Standard Sand = 600gms 1mm to 500mic - 200g
500mic to 90mic - 200gm
Water = (P/ 4+ 3) Percentage of combined mass of cement and sand.
P is the consistency of cement.
• Mix it dry with a trowel for one minute and then with water until the mixture is of uniform colour.
• The time of mixing shall in any event be not less than 3 minutes and should be the time taken to obtain
uniform colour exceeds 4 min.
• Place the assembled mould on the table of the vibration machine and hold it firmly in position by means of suitable
clamp, attach a hopper of suitable size and shape securely at the top of the mould to facilitate filling and hopper
shall not be removed until the completion of vibration period.
• Immediately after fixing the mould in the vibrating machine, place the mortar in the cube mould and prod with the rod.
• Prod the mortar 20 times in about 8 seconds to ensure elimination of entrapped air and honey combing.
• Place the remaining mortar in the cube mould and prod again as specified for the first layer and then compact the mortar
by vibration.
• The period of vibration shall be two minutes at the specified speed of 12000 + 400 vibrations per minute

44. RESULT OF MORTAR CUBE