INTERNSHIP REPORT

VARANASI AURANGABAD ROAD PROJECT

Varanasi Aurangabad road project is a project of Ministry of road transport and
highways (MORTH). It is joint venture of NHAI and Sphiro Infratech Pvt. Ltd and
others.

Submitted By:
Om Prakash Kumar
7th Semester;
Civil Engineering
Govt. Engg. College Aurangabad Bihar
Regn No- 19101147005
Submitted To:
P.V. Srinivas
Senior Project Manager
Sphiro Infratech (P) Ltd.
VARANASI AURANGABAD ROAD PROJECT

Project Details Six laning of Varanasi to Aurangabad section from Km.

786.00 to Km.978.400 of NH-2 under NHDP Phase-V on
BOT (Toll) basis in the state of UP & Bihar

Name National Highways Authority of India

of Authority

Concessionaire- 1 Soma-Roadis and Welspun Enterprises.

Concessionaire- 2 Sphiro Infratech Pvt Ltd.

Independent ICT Pvt Ltd

Engineer

Project Cost Rs. 2848 Crore

The 192 km six-lane project is situated in Uttar Pradesh and Bihar.

The contract value for the company is estimated at Rs 2,366 crore.
Under the contract, the WEL will undertake the procurement and
construction, while engineering will be undertaken by the SPV. The
project construction has been started in April 2021 and is likely to be
completed in 24 to 27 months.
Table of Contents
• Compressive Strength of Concrete - Cube Test.
• Sieve Analysis of Fine Aggregate for Concrete.
• Sieve analysis of coarse aggregate for concrete (Gradation of
10mm aggregates)
• Workability of fresh concrete by Slump cone test.
• Flexural Strength test.
• California bearing ratio (CBR) test.
• Marshall Stability test of Bituminous mixture.
• Modified Proctor Compaction test.
• Casting of Mortar Cubes & its Compressive strength test.
• Concrete design mix.
• Testing of MDD of dust (Flyash & Stonedust).
• Cement Treated Base (CTB) preparation in WMM Plant.
• Granular Sub Base (GSB) Construction.
• A texture curing machine & Automatic concrete paver.
Compressive Strength of Concrete - Cube Test
For cube test specimens of 15cm X 15cm X 15cm or 10cm X 10cm x 10cm
depending upon the size of aggregate are used. Here 6 cubes of 15 cm size & Mix
M45 have been used. Concrete is poured in the mold and appropriately tempered so
as not to have any voids. After 24 hours, molds are removed, and test specimens
are put in water for curing. These specimens are tested in compression testing
machine after 7 days curing or 28 days curing. Load is applied gradually. The
compressive strength of concrete is calculated as the load at the failure divided by
area of specimen. Minimum three specimens should be tested at each selected age.
If the strength of any specimen varies by more than 15 percent of average
strength, the results of such specimens should be rejected. The average of three
specimens gives the crushing strength of concrete, The strength requirements of
concrete.
Sieve Analysis of Fine Aggregate for Concrete.
Gradation of sand is done in this test. A natural sand sample is taken from a
source (sand sample of Sone river in our case). Then the sample is dried and
initial weight of sample is measured (950 gm in our case). This sample is further
passed through various sieves as specified by IS Code. Retained weight of each
sieve is noted. Cumulative retained weight and % of passing is then calculated.
Fineness modulus is obtained by adding the total percentage of the sample of an
aggregate retained on each of a specified series of sieves, dividing the sum by
100. Fineness modulus is 2.516 as calculated in above format.
Cement Treated Base (CTB) preparation in WMM Plant
Cement Treated Base is a mixture of Base/Sub-Base material (aggregate material) with
some amount of Portland cement. In this plant three types of aggregates of nominal
diameter 10mm, 20mm, 40mm & dust and some amount of cement with 6.4% water is
mixed thoroughly in Wet Mixed Macadam (WMM) plant. Plant calibration and and
gradation in limits are also taken into account. Its mix design should be in accordance
with MORTH guidelines. In this way CTB is prepared and it is then loaded into
containers and transported to road site. CTB acts as a support between the dirt and
slab, and ultimately, reduces cracking of the slab. CTB is a strong, frost-resistant base
for a concrete or asphalt pavement wearing surface. CTB is well known for providing a
weather resistant base which actually gains strength with age. It can distribute loads
over a wider area, reducing the stresses on the subgrade. Pictured above, a WMM
plant located in Mohania Kaimur Bihar, uses the rapidmix capabilities to produce high
quality CTB using the aggregate/granular material, cement, dust and water on projects
like 6 laning of NH2.
Sieve analysis of coarse aggregate for concrete
(Gradation of 10mm aggregates):

The aggregates are graded as fine and coarse aggregate based on the grain size.
When the aggregate size is greater than 4.75mm is called coarse aggregate, and
less than 4.75mm is called fine aggregate. The sieve analysis test will do
the grading of aggregates. In this method collected sample aggregates are
thoroughly sieved through appropriate IS Sieve to determine the particle size.

Test Procedure:

1. Take initial weight of dried and clean sample (8000 gm in our case) of the
coarse aggregate test sample.
2. Arrange the IS sieve in descending order as 12.5mm,10mm, 4.75mm, 2.36mm.
3. Now fill the sample to the highest sieve and sieve well for up to 10 minutes.
4. After completion of sieving, then weigh the aggregates retained in each sieve &
note it down. Gradation results have been shown in above picture.
Flexural Strength test:
Flexural strength is defined as the stress in a material just before it fails in a
flexure test. It plays a vital role when a road slab with bad sub-grade
support is subjected to wheel loads and/or there are volume modifications
because of temperature/shrinking. Prepare a Beam mould of size 150 x
150 x 700 mm. Tamping bar & Flexural test machine is also required in it.
Make ready the test sample by loading the concrete into the mould in 3
layers of roughly equal thickness. Tamp each layer 35 times with the help
of the tamping bar. Clean the bearing surfaces of the supporting and
loading rollers, and clear any loose sand or other material. Circular rollers
manufactured out of steel having cross-sections with a diameter of 38 mm
will be utilized for offering support and loading points to the samples. The
load shall be applied at a rate of loading of 400 kg/min for the 15.0 cm
specimens and at a rate of 180 kg/min for the 10.0 cm specimens. Measure
the load at which it gets broken into two parts.
Testing of MDD of dust (Flyash & Stonedust)
Stone dust is a waste material obtained from stone crushing units. Stone
dust is used in W.B.M road for proper bonding of coarse aggregate. Flyash
is a by- product obtained from thermal power plant in large amount. When
fly ash is mixed with cement, fly ash gain the property same as cement.
Addition of Stone dust modifies the gradation of fly ash and also there will
be an increase in unit weight of the composite material. Due to addition of
stone dust, a significant increase in California Bearing Ratio (CBR) value is
observed. The composite material consists of 60% fly ash +40% of stone
dust and 40% of fly ash + 60% of stone dust were further tested by adding
lime. With addition of lime, there is a decrease in MDD and increase in the
CBR value. The composite consisting of 40% fly ash + 60% stone dust with
2% lime resulted in a soaked CBR value of 9.0 at Maximum Dry Density
(MDD) of 1.55 g/cm3. This composite material may be used for the
construction of subgrade for rural roads.
Granular Sub Base (GSB) Construction:
GSB is a designed construction material used as a sub-base layer for road construction.
It is a layer in the road foundation just above the compacted sub-grade layer.
Equipment and Machinery for GSB required are Vibratory Rollers, Water Tanker,
Dumpers & Grader/Loader. GSB material should conform to MORTH guidelines.
Granular Sub Base Construction Method:
➢ Spreading of GSB Layer: Mark the outside lines of the GSB layer with lime
powder or pegs on the completed subgrade. The required material shall be
dumped between the limiting lines previously marked with the help of lime
powder. It shall be spread in layers of uniform thickness.
➢ Compaction of GSB Layer: Compaction of Granular Sub Base shall start
immediately after achieving the required moisture content. The compaction shall
be done with a vibratory compactor. The compaction behind the structure shall
be accomplished with a vibratory roller or plate compactors to achieve 98% of
MDD.
A texture curing machine & Automatic concrete paver:
PCC slab casting of width 12m is being done. Dowel bars of 32mm dia & 600mm
length is used here.
The WPS 62(i) placer spreader is normally used in combination with a slipform
paver and a texture curing machine. While trucks and semitrailers successively
dump concrete into the conveyor belt unit’s large receiving hopper, the conveyor
belt guides the conveyed material to the center of the road.
Modern texture/cure machine features a new walking end car with a cure tank.
The innovative system for extending the working width enables fast and
convenient on-site reconfiguration of the paving mould. The result is shorter
reconfiguration times and maximum machine utilisation rates while maintaining
the usual high quality.
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California bearing ratio (CBR) test

The California Bearing Ratio(CBR) test is a measure of resistance of a material to
penetration of standard plunger under controlled density and moisture conditions.
Apparatus for CBR Test: Loading machine, Cylindrical moulds- moulds of 150mm
diameter and 175mm height, Compaction rammer, surcharge weight. The CBR test is
penetration test meant for the evaluation of subgrade strength of roads and pavements.
The results obtained by these tests are used with the empirical curves to determine the
thickness of pavement and its component layers.
Specification:Cylindrical diameter:150mm, Height: 175mm, Penetration Plunger Dia:
50mm-5cm, Rate of Penetration: 1.25mm/Min
Test Procedure:
The Specimen may be compacted to max dry density at the optimum moisture content.
(heavy compaction is required for high trafficked road like Express Highway). The
specimen is subjected to 4 days (96hr) of soaking and swelling and the water
absorption values are noted. The surcharge weight is placed on the top of specimen in
the mould and the assembly is placed under the plunger of loading frame. The load
values corresponding to various penetration values are noted as given in table.

Load-Penetration graph (CBR Curve) is plotted. If CBR curve is convex throughout then
Load Corresponding to 2.5mm and 5.0mm penetrations are notes from CBR curve.
CBR = (Corrected unit load/Standard unit load) X100

In this way CBR value is calculated and corresponding thickness is found by referring to
Code.
 1 2 3

Casting of mortar cubes & its Compressive strength test:

Apparatus required are Vibration Machine, Poking Rod, Cube Mould of size of 70.6 mm x 70.6
mm x 70.6 conforming to IS : 10080-1982, Trowel, Balance. Standard sand & cement are
weighted and mixed in definite proportions.
The temperature of water & test room at the time of mixing operations shall be maintained at 27
± 2°C. Use Potable water for preparing the cubes. Cement, standard sand & water for each
cube shall be taken as per below mentioned standard:

• Cement 200 g
• Standard Sand 600 g (200 gm of each grading)
• Water ( P/4+ 3.0) percent of combined mass of cement and sand, where P is the normal
consistency of cement.

In assembling the moulds ready for use, the sides of the mould shall be made from
ferrous metal.
Place the assembled mould on the vibrating table machine vibration by proper holding
in position by suitable clamp & shall not be removed until the completion of the vibration
period.
Immediately after mixing the mortar properly, place the mortar in the cube mould and
rodded with the rod specified rod. The mortar shall be rodded 20 times in about 8
second to eliminate entrained air.
Keep the period of vibration 2 minutes at the speed of 12000 ± 400 vibration per minute.
After the end of vibration, remove the mould with base plate from the machine and
make proper smooth finish top surface of the cube mould with the blade of a trowel.
The representative sample of the cement selected as above shall be thoroughly mixed
before testing requirements of different equipment used for testing of cement.
The temperature of the testing room, dry material ingredient and water should be
maintained at 27 ± 2°C & relative humidity of the chamber or room should be
maintained at 65 ± 5 percent.
Place on a nonporous plate, a mixture of cement and standard sand, Mix it dry with a
trowel for one minute and then with water until’ the mixture is of uniform colour. The
mixing time shall be in between 3 to 4 minutes.
In assembling the moulds ready for use, the sides of the mould shall be made free from
ferrous metal and base plate shall be coated with oil or grease to prevent leakage of
water from mould .
Place the assembled mould on the vibrating table machine vibration by proper holding
in position by suitable clamp & shall not be removed until the completion of the
vibration period.
Immediately after mixing the mortar properly , place the mortar in the cube mould and
rodded with the rod specified rod. The mortar shall be rodded 20 times in about 8
second to eliminate entrained air . Pour the remaining quantity of cement mortar into
the hopper of the cube mould and rodded again as done previously for the first layer
and then compact the mortar by vibration.
After the end of vibration, remove the mould with base plate from the machine and
make proper smooth finish top surface of the cube mould with the blade of a trowel.
Keep the prepared cube mould in curing tank for 24 hours.
Take out the three test cubes each for 3 , 7 & 28 days respectively for testing of
compressive strength.
Place the test cube in center of cube testing machine without any packing and apply the
load steadily and uniformly , starting from zero at a rate of 35 N/mm²/min.
Calculate compressive strength of cement by dividing the maximum load applied to the
cubes during the test by the cross-sectional area, calculated from the mean dimensions
of the section.
Concrete design mix:
MIX DESIGN CALCULATION FOR M45 GRADE CONCRETE:
Mix provision for ingredients of concrete
Grade of Concrete : M45
Type of Cement : OPC 43 grade confirming to IS 269
Workability : 150 ± 25 mm (slump)
Procedure for Concrete Mix Design of M 45 Concrete
ftarget = fck + 1.65 x s
‘ftarget‘ is the Target Average Compressive Strength at 28 days,
‘fck’ is the Characteristic Compressive Strength at 28 days, and
‘s’ is the Standard Deviation
as per the table I of IS: 10262-2009 , the standard deviation, s is 5.0 N/mm2
Therefore, target strength = 45 + 1.65 x 5.0 = 53.25 N/mm2
water-cement ratio = 0.40
Calculation of Cement Content
Water-cement ratio =0.40
Cement content = 147/0.40 = 370 kg/m3
From Table 5 of IS 456:2000, minimum cement content for ‘EXTREME’ exposure
condition = 370 kg/m3
370 kg/m3 > 360 kg/m3, hence, O.K.
Mix Calculations
a) Volume of concrete = 1m3
b) Volume of cement = (Mass of Cement/Specific Gravity of Cement) X (1/1000)
= (370/3.15) X (1/1000)
= 0.117 m3
c) Volume of water = (Mass of Water/Specific Gravity of Water) X (1/1000)
= (147/1) X (1/1000)
= 0.147 m3
d) Volume of superplasticizer = (Mass of Superplasticizer / Specific Gravity of
Admixture) X (1/1000)
= (8.2/1.145) X (1/1000)
= 0.007 m3
e) Volume of all aggregate = (a-(b+c+d))
= 1 – (0.117 + 0.147+0.007)
= 0.729 m3
f) Mass of coarse aggregate = Volume of all Aggregate X Volume of coarse Aggregate
X Specific Gravity of Coarse Aggregate X 1000
= 0.729 x 0.56 x 2.74 x 1000
= 1118.57 kg
g) Mass of fine aggregate = Volume of all Aggregate X Volume of Fine Aggregate X
Specific Gravity of Fine Aggregate X 1000
= 0.729 x 0.44 x 2.65 x 1000
= 850.01 kg
Modified Proctor compaction test:
Modified Proctor Test is performed to know the characteristics of soil through compaction with change in
water content ultimately giving us the relation between soil moisture content and dry density of soil. It is a
modified version of the Standard Proctor Test. IS-2720-PART-8 is used for Modified Proctor Compaction
Test and Heavy Compaction Test. Apparatus required are Cylindrical shaped mould, Oven, Sample
Extruder Tool, Sieve of standard size – 19 mm, 75 mm, Capacity balance, Rammer.

• Modified Proctor Test Procedure:

• Take about 4 kg of air-dried soil passing No. 4 sieve and mix it with an optimum quantity of water.
• Weigh the empty mold without a collar, with base plate attached.
• Place the mold With the collar attached on a solid base and compact the soil mass into the mold
using standard compaction in five layers with 25 blows per layer; and with a 4.5 kg rammer
dropping from a height of 45 cm.
• Take care to distribute the blows uniformly over the surface of each layer, and to let the rammer
fall freely.
• Remove the collar carefully strike off the projected part of the compacted soil by steel straight
edge. Then weigh the mold + soil.
• Extrude the compacted soil specimen from the mold and split it on a large tray.
• Take a sample for moisture content determination.
• Break-up the specimen to No.4 sieve size, and mix it with the remainder of the original sample.
Add suitable increments of water, and mix thoroughly for at least six trials.Then repeat 3 to 5
steps for each trial.
• Draw compaction curve on a graph with dry density on ordinate and moisture contents on the x-
axis.
• Maximum dry density shall be at the apex of the curve and optimum moisture content (OMC) at
which maximum dry density is obtained.
 •
Workability of fresh concrete by Slump cone test:
Slump cone and temping rod are the apparatus required for it.
PROCEDURE-
• The internal surface of the mould is thoroughly cleaned and applied with a light
coat of oil/water.
• The mould is then filled in four layers with freshly mixed concrete, each
approximately to one-fourth of the height of the mould.
• Each layer is tamped 25 times by the rounded end of the tamping rod.
• After the top layer is rodded, the concrete is struck off the level with a trowel.
• The mould is removed from the concrete immediately by raising it slowly in the
vertical direction.
• The difference in level between the height of the mould and that of the highest
point of the subsided concrete is measured.
• This difference in height in mm is the slump of the concrete.
Marshall Stability test of Bituminous mixture :
Marshall stability is the resistance to plastic flow of cylindrical specimens of a
bituminous mixture loaded on the lateral surface. It is the load carrying capacity of the
mix at 60oC and is measured in kg.
Marshall stability apparatus: Marshall stability apparatus, Balance and water bath
SAMPLE: From Marshall stability graph, select proportions of coarse aggregates, fine
aggregates and filler in such a way, so as to fulfill the required specification.
S. No Weight in air (gm) Weight in water Weight in SSD Volume Bulk density
1 1231 716 1234.5 518 2.376
2 1221 714.5 1222.5 508 2.403
3 1219 715 1220 505 2.414
PROCEDURE
i)Heat the weighed aggregates and the bitumen separately upto 170oC and 163oC respectively.
ii) Mix them thoroughly, transfer the mixed material to the mould arranged on the compaction pedestal.
iii) Give 75 blows on the top side of the specimen mix with a standard hammer (45cm, 4.86kg). Reverse
the specimen and give 75 blows again. Take the mould with the specimen and cool it for a few minutes.
iv) Remove the specimen from the mould by gentle pushing. Mark the specimen and cure it at room
temperature, overnight.
v) A series of specimens are prepared by a similar method with varying quantities of bitumen content, with
an increment of 0.5% (3 specimens) or 1 bitumen content.
vi) Before testing of the mould, keep the mould in the water bath having a temperature of 60 oC for 30 min.
vii) Check the stability of the mould on the Marshall stability apparatus.
REPORTING OF RESULTS
Plot % of bitumen content on the X-axis and stability in kg on the Y-axis to get maximum Marshall stability
of the bitumen mix.