The document discusses the construction of cement concrete roads. It begins by describing the various materials used, including cement, sand, aggregates, and admixtures. It then outlines the steps for constructing the supporting layers beneath the cement concrete pavement slab such as the subgrade, drainage layer, and dry lean concrete sub-base course. Finally, it describes the process for constructing the cement concrete pavement slab itself along with the joints, curing, and opening the road to traffic.

1. An Internship Report on
CONSTRUCTION OF CEMENT CONCRETE
ROAD
Submitted in the partial fulfillment of the Requirements for the award of degree of
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING
Submitted by:
Hemant Kumar (2000540000027)
Submitted to
Mr. Navneet Singh Yadav(Assistant Professor)
AT
Department of Civil Engineering
BABU BANARASI DAS INSTITUTEOF TECHNOLOGY AND
MANAGEMENT
2023 - 24

2. ACKNOWLEDGEMENT
I express my satisfaction with 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
supervisor and mentor Mr. MANEESH VERMA EXECUTIVE ENGINEER for
his kind guidance during the entire period of training. His consistent support and
advice have helped me to complete this research project successfully. Also, I
thank all the members of P.W.D. LUCKNOW U.P. Department for their kind
support. They have always been a source of inspiration to me.
Submitted to: Mr. Navneet Singh Yadav HEMANT KUMAR
Assistant Professor, BBDITM 20005400000027
DATE:- 21/11/2023 B.Tech , Final Year, CE-41

3. INDEX
S.NO CONTENT PAGE
NO.
1 INTRODUCTION 5
2 ABOUT ROAD 6
3 MATERIAL 7
4 CEMENT 9
5 SAND 11
6 AGGREGATE 12
7 CONSTRUCTION OF CEMENT CONCRETE PAVEMENT 14
8 CONSTRUCTION OF SUPPORTING LAYER 15
9 CONSTRUCTION OF CEMENTCONCRETE PAVEMENT SLAB 19
10 CONSTUCTION OF JOINTS IN CEMENT CONCRETE
PAVEMENT
21
11 OPENING OF TRAFFIC 24
12 CONCLUSION 25
13 REFERENCE 26

4. LIST OF FIGURE
S.No. FIGURE NAME PAGE
NO.
1. COMPONENT OF CEMENT CONCRETE PAVEMENT 16
2. SUBGRADE 16
3. LABOUR ORIENTED METHOD OF PAVING 20
4. CONSTRUCTION JOINTS 21
5. EXTENSION JOINTS 23
6. DOWEL BARS 23
7. TIE BARS 23

5. Introduction
Point of view geographic and population of the state is the nation's largest state.
State Industrial, economic and social development of the state and the
population of each village is absolutely necessary to re-connect to the main
roads. In addition to state important national roads, state roads and district
roads and their proper broad be made to improve the quality of traffic point of
view is of particular importance. Public Works Department to build roads and
improve connectivity in rural zones, Other District Road and State broad and
improvement of rural roads and main routes narrow construction of zones and
depleted bridges brides reconstruction of the bases are transacted on a priority
basis . Also under Pradhan Mantri Gram Sadak Yojana and pre- fabricated
construction of rural roads linking the work of other district roads broad
Suddikrn the scale bases are edited.
Successful operation of various schemes for the Public Works Department
engineers and supervisory boards in different districts of the engineer’s office
has been settled. Activities by planning, execution, and quality control etc.
remove impediments find joy in relation to the supervision over the activities
are focused. Various schemes operated by the Department of the Office of the
Regional Chief Engineers and Chief Engineers office.

6. 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.
A road is a linear way for the conveyance of traffic that mostly has an improved
surface for use by vehicles (motorized and non-motorized) andpedestrians. Unlike
streets, the main function of roads is transportation .There are many types of roads,
including parkways, avenues, controlled-accesshighways (freeways, motorways,
and expressways), tollways, interstates, highways, thoroughfares, and local roads.
The primary features of roads include lanes, sidewalks (pavement), roadways
(carriageways), medians, shoulders, verges, bike paths (cycle paths), and shared-
use paths.

7. MATERIALS
COMPONENTS OF BASIC MATERIALS:
The basic component materials for the construction of CC pavement consist of
Portland cement, coarse aggregates, fine aggregates, water and admixtures; also steel
is used at the joints, in the form of dowel bars and tie bars.
Portland cement:
The types of cement that may be used for the preparation of PQC and construction of
CC pavements are, (1) Ordinary Portland cement of 43 Grade (ii) Ordinary Portland
cement of 53 Grade (iii) Portland - Pozzolana cement with fly ash content up to 20
percent by weight and (iv) Portland Slag cement. However the most commonly
preferred cement for cement concrete pavement construction is ordinary Portland
cement of 43 Grade.
Coarse aggregates :
The coarse aggregates that are used for the preparation of PQC shall fulfil the
following requirements:
Los Angeles abrasion value :less than 35%
Combined flakiness and elongation index :less than 35%
Water absorption :less than 3%
Soundness test after 5 :less than 12%

8. Fine Aggregates:
Fine aggregates consist of clean natural sand or crushed stone sand or a combination
of both; the fine aggregates shall be free from clay, coal and lignite. The fine
aggregates shall be well graded, with 100 percent passing 10 mm sieve. The IRC has
suggested four gradations of fine aggregates for the preparation of the PQC mix. Water
used for mixing of the cement concrete and also that used for curing of the concrete
pavement shall be clean and potable. The water should be free from salt ,acid, oil and
other organic matter.
Admixtures:
Commonly used chemical admixtures workability with cement concrete are: (i) to
improve the of the concrete, a suitable air-entraining agent may be used provide
adequate extension of setting time of the concrete mix without adversely affecting the
other desirable properties of the concrete; super-plasticizers which retard the setting
time may be used. The total quantity of chemical admixtures used is limited to a
maximum of 2.0 percent by weight of the cement or (cement + fly ash, etc.) used.

9. CEMENT
A cement is a binder, a substance that sets and hardens independently, and can
bind other materials together. The word "cement" traces to the Romans, who
used the term caementicium to describe masonry resembling modern concrete
that was made from crushed rock with burnt lime as binder.The volcanic ash
and pulverized brick additives that were added to the burnt lime to obtain a
hydraulic binder were later referred to as cementum, cimentum, cement, and
cement.
Cements used in construction can be characterized as being either hydraulic or
non-hydraulic. Hydraulic cements (e.g., Portland cement) harden because of
hydration, a chemical reaction between the anhydrous cementpowder and water.
Thus, they can harden underwater or when constantly exposed to wet weather. The
chemical reaction results in hydrates that are not very water-soluble and so are
quite durable in water. Non-hydraulic cements do not harden underwater; for
example, slaked limes harden by reaction with atmospheric carbon dioxide. The
most important uses of cement are as an ingredient in the productionof mortar in
masonry, and of concrete, a combination of cement and an aggregate to form a
strong building material.

10. 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 groundwith a small
amount of gypsum into a powder to make 'Ordinary Portland Cement'.
 Portland fly ash cement
Its contains up to 35% fly ash. The fly ash is pozzolanic, so that ultimate strength
is maintained. Because fly ash addition allows a lower concrete watercontent,
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
Its includes fly ash cement, since fly ash is a pozzolan , but also includes
cements made from other natural or artificial pozzolans. In countries
where volcanic ashes are available.
 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

11. 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, theprimary form
of sand apparent in areas where reefs have dominated the ecosystem for millions
of years like the Caribbean.
Composition:
In terms of particle size as used by geologists, sand particles range in diameter
from 0.0625 mm (or 1⁄16 mm) to 2 mm. An individual particle in this range size
is termed a sand grain. Sand grains are between gravel (with particles ranging
from 2 mm up to 64 mm) and silt (particles smaller than 0.0625 mm down to
0.004 mm). The size specification between sand and gravel has remained
constant for more than a century, but particle diameters as small as 0.02 mm were
considered sand under the Alter berg standard in use during the early 20thcentury.
A 1953 engineering standard published by the American Association of State
Highway and Transportation Officials set the minimum sand size a 0.074 mm.

12. 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 60to 75 percent of the total
volume of concrete, are divided into two distinct categories-fine and coarse. Fine
aggregates generally consist of natural sand or crushed stone with most particles
passing through a 3/8-inch (9.5-mm) sieve.
Coarse aggregates are any particles greater than 0.19 inch (4.75 mm), but generally
range between 3/8 and 1.5 inches (9.5 mm to 37.5 mm) in diameter.Gravels constitute
the majority of coarse aggregate used in concrete with crushed stone making up most
of the remainder. Natural gravel and sand are usually dug or dredged from a pit, river,
lake, or seabed. Crushed aggregate is produced by crushing quarry rock, boulders,
cobbles, or large-size gravel. Recycled concrete is a viable source of aggregate and
has been satisfactorily used in granular subbases, soil-cement, and in new concrete.
Aggregate processing consists of crushing, screening, and washing theaggregate to
obtain proper cleanliness and gradation. If necessary, a benefactionprocess 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.

13. 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 cementcontent 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 contentbetween particles affects
the amount of cement paste required for the mix Angular aggregate increase the
void content. Larger sizes of well-graded aggregate and improved grading
decrease the void content. Absorption and surface moisture of aggregate are
measured when selecting aggregate because the internal structure of aggregate is
made up of solid material and voids that may or may not contain water. The
amount of water in the concrete mixture must be adjusted to include the moisture
conditions of the aggregates

14. CONSTRUCTION OF CEMENT CONCRETE PAVEMENT
1. Construction of supporting layers
● Construction of subgrade
● Construction of drainage layer
● Construction of dry lean concrete sub base course
2. Construction of cement concrete pavement slab
3. Construction of joints in cc pavement
● Contraction joints
● Expansion joints
● Joint filling
4. Curing
5. Opening to traffic

15. Construction of supporting layers
1. Construction of subgrade:
(a) 1The selected soil in loose condition is spread to the required grade and cross slope
in layer of desired thickness over the prepared surface. The thickness of the loose soil
layer is decided so as to obtain the desired compacted thickness,
(b) Additional water as required is sprayed so as to obtain the OMC of the soil
determined from the laboratory compaction test
(c) The soil with the added water is mixed thoroughly so that the water gets distributed
in the soil layer uniformly, the mixed soil is spread again to uniform layer thickness,
grade and cross slope
(d) The soil layer is compacted by rolling using the selected equipment so as to obtain
the specified density
(e) After ensuring that the layer has been compacted to the desired density, the next
layer of soil is spread over this, water added, mixed and compacted as mentioned in
steps (a) to (d) above. The process is repeated until the desired compacted thickness
of subgrade is achieve

16. COMPONENT OF CEMENT CONCRETE PAVEMENT
Figure : 1
SUBGRADE
(Figure : 2)

17. 2. Construction of drainage layer:
(i) The sub-base material is spread to uniform thickness and specified cross slope
using a motor grader by adjusting the blade of the grader
(ii) The moisture content of the material is checked and the additional quantity of
water required to bring up to the optimum moisture content is sprinkled at an uniform
rate
(iii) The watered material is mixed properly using machinery such as dise harrows and
rotavators
(iv) The mixed material is spread to the desired thickness, grade and camber using a
motor grader with hydraulic controls of the blade
(v) The loose GSB layer is compacted by rolling
(vi) Rolling is done starting from the lower edge and proceeded towards the centre of
the undivided carriageway or towards the upper edge of the divided carriageway, with
a minimum one third overlap between each run of the roller; the rolling speed is
limited to less than 5 kmph
(vii) Rolling is continued till at least 98 percent of maximum density of the material
is achieve

18. 3.Construction of dry lean concrete sub-base course:
Provision of a lean cement concrete sub-base layer below the CC pavement slab has
been found to have several advantages such as providing a firm and uniform structural
support, high resistance to deformation and prevention of failures due to pumping.
"Dry lean concrete' (DLC) is the most common type of cement treated sub-base course
laid over the drainage layer. The recommended thickness of DLC sub-base course on
important highways is 150 mm; a minimum thickness of 100 mm may be adopted in
the case of less important roads with less traffic. The IRC recommends that the DLC
sub-base shall extend 500 mm beyond the edges of the CC pavement in order to
facilitate further construction operations and to provide good support to the CC
pavement slab.
Proportioning the components of the DLC and mixing are done in a central batching
and mixing plant of adequate capacity. The mix is discharged and transported to the
construction site in covered tipping trucks. The DLC is laid to the desired grade and
cross slope with a paver. Compaction shall be carried out immediately after concrete
mix is laid and is levelled by the paver. Double drum type smooth wheeled vibratory
rollers of static weight 8 to 10 t are used for compaction of the DLC layer, the
compaction is carried out to obtain 97 percent of the maximum density achieved
during trial rolling.
Curing of the DLC layer is done by spraying liquid curing compound immediately
after final rolling. Further curing is continued by covering the surface with gunny bags
spread in three layers and kept moist continuously for a minimum of seven days.

19. Construction of cement concrete pavement slab
The different operations involved in the construction of CC pavement slab are listed
below:
(a) Spreading the prepared concrete mix to desired thickness, grade and cross profile
(b) Compacting
(c) Finishing the surface to desired surface profile
(d) Texturing
(e) Curing
(f) Cutting of contraction joints and longitudinal joints
 The cement concrete mix prepared in RMC plant or in small mixing units is
brought to the site and placed in position, taking care to minimize segregation.
The concrete is placed between the side forms, with appropriate surcharge
over the final slab thickness. The concrete is compacted using needle vibrators
and plate vibrators
 The surface profile is checked with templates and the irregularities are
corrected by adding or removing concrete, followed by further compaction

20. and finishing. The surface is smoothened by longitudinal float operated from
movable foot bridge. surface is textured manually using steel brush with long
handle. Curing compound is sprayed by hand using a pressure sprayer.
 After the cement concrete is set, the side forms are removed and shifted
forward curing compound is applied on the sides of the slab. The location of
the transverse contraction joints and longitudinal joints are marked and
grooves are cut by diamond saw machine cutters up to the desired depth.
Further curing is done by covering the pavement surface and the sides by two
to three layers of moist hessian, and keeping it for a minimum curing period of
14 days as mentioned before.
LABOUR ORIENTED METHOD OF PAVING
(Figure : 3)

21. Construction of joints in cement concrete pavement
1)Contraction joints:
Markings are made to indicate the exact locations where the grooves of the contraction
joints are to be cut, as per the design. Transverse groove cutting work is carried out
during the specified period after the concreting was done, using diamond saw cutting
machines at the marked locations. Soon after each groove is cut, it is cleaned and a
temporary seal is inserted to block the ingress of grit and soil.
After the CC pavement is cured for a minimum period of 14 days, the hessian cloth
covers are removed and the pavement surface is cleaned. The temporary seal is
removed and the grit and dust are thoroughly removed from the dummy grooves by
blowing air, before application of appropriate sealant. If specified, the groove may be
widened depending on the type of permanent sealant selected. Cold sealant such as
polysulphide or silicone formulation may be used as sealant, alternatively a hot sealant
such as rubberized bitumen may be applied after application of the primer
CONTRACTION JOINT
(Figure : 4)

22. 2)Expansion joint:
 A steel bulk head of appropriate size is made use of to provide support at the
end of the slab adjoining the expansion joint during concreting. Holes are drilled
through the bulk head at the desired intervals such that the dowel bars can be
inserted through them and central portion of dowel bars are held in proper
position.
 The steel bulkhead is firmly fixed in position at the location of the expansion
joint and oil or grease is applied on the inner side of the bulkhead to prevent
bonding with the concrete. The dowel bars are inserted through these holes of
the bulkhead up to the mid-length and the ends of these rods are held in correct
position and alignment with the help of supporting cradles.
 The concrete is laid and compaction is carried out up to the bulkhead as done
in other stretches. Special care is taken not to disturb the dowel bars during
laying and compaction. After the concrete is set, the bulkhead is carefully
removed.
 The filler board is inserted through the gap of the expansion joint so that the
dowel bars are accommodated in the slots. When properly placed in position,
the top edge of the filler board will be 25 mm below the surface of the slab.
Wooden strips of 20 or 25 mm width and 25 mm depth are placed on the top of
the filler board to temporarily fill up this gap during concreting of the slab
adjoining the expansion joint.
 After the concrete is cured for a minimum period of 14 days, the wooden strips
on the top of the filler board are removed and the gap is thoroughly cleaned to
remove grit and dust. Primer is applied in the area to be filled up by sealant, if
specified. The sealant is heated and poured through a dispenser in the gap of the
expansion joint, above the filler board. The top of the sealant shall be at the
same level as the adjoining pavement surface.

23. EXPENSION JOINT
(Figure : 5)
DOWEL BAR
(Figure : 6)
TIE BAR
(Figure : 7)

24. Opening to Traffic
Before opening the road to traffic, the pavement surface shall be thoroughly cleaned.
The joints shall be checked and the locations where the joint sealing is not
satisfactory shall be properly sealed. The entire surface of the newly laid pavement is
carefully examined to find whether: (i) fine cracks have developed on the surface
and (ii) non-uniform settlement of CC slabs has taken place near bridge abutments or
along high embankments. If any such defect is noticed, appropriate corrective
measures may be taken up.
A constructed CC pavement stretch shall be opened to traffic only after a minimum
curing period of 28 days.
CURING
(Figure : 8)

25. CONCLUSION
From this report on pavement it is observed that cement concrete pavement
are the most economical for greater volume of traffic .The life of cement concrete
pavement is near about 30 years whose initial cost may is more but routine and
periodic maintenance cost is very low as maintenance of joints only is required.The
life cycle cost of Cement Concrete pavements are much lower than that of flexible
pavements.
Cement Concrete pavements do not get deteriorated under wet weather conditions and
when exposed to stagnant water. The total thickness of cement concrete pavement and
the quantity of hard aggregates required are lower than flexible pavements ,
particularly for the construction of highways passing though weak soils and carrying
heavy traffic loads. Good night visibility even under wet weather conditions.

26. References
 www.Google.com
 Highway Engineering by S.K.KHANNA
 www.civil.iitb.ac.in
 www.aalimec.ac.in