REPORT ON INTERNSHIP OF ROAD

CONSTRUCTION

Guided by:
 So. Divyesh R. Patel
 So. Tejal Patel

ROAD & BUILDING DPARTMENT SURAT

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Submitted by:
1. Nilesh Kumar (U16CE003)
2. Parimalkumar Patel (U16CE019)
3. Jayantilal Parihar (U16CE023)
4. Jainish Chaudhari (U16CE026)
5. Rakesh Singh Baghel (U16CE057)
6. Gunjan Kumari Jain (U16CE059)

Training Period: 15th May 2019 - 15th June 2019

PLACE : R & B department, kamrej Deputy Executive Engineer

Panchayat ( R & B) Sub Division,
DATE: Kamrej

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TABLE OF CONTENTS:

TOPIC PAGE NO.

1. Theoretical Documentation……………………………………………………… 4
2. Typical cross section of road ………………………….……………….………. 5
3. Key map ……….…………………………………………………………….…..…..…. 5
4. Estimation ……………………………….……………………………….……...…. . 6
A. Recapitulation sheet ……………………………………...….………….. 6
B. Abstract sheet ……………………………………….……………….….….. 7
C. Measurement sheet …………………………….………………………………… 8
D. Sample Rate Analysis ………………….…………………………………... 10
5. Tender process ….……………………………………………………………..…..…. 11
6. Construction Process………………………………………………………………… 13
7. Material Transportation …………………………………………. ……………….. 20
8. Asphalt batch mixing plant…………………………………………….……..…… 21
9. Intermediate structure………………………………………………………………. 22

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1. Theoretical Documentation

 Name of Project: Govt. letter no. VRR-2018-US1-8-D2 Dated.31/07/2018

 Name of Work: Constructing Chikhli Ishanpor road, Ta-Kamrej Dist-Surat

 Client : Road and building Department Surat.

 Contractor: Jay construction.

 Length of Road: 4.800 km.

 Estimated Cost: 150 lacs.

 Date of start: 10th Jan 2019.

 Date of completion: 10th June 2019.

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2. Typical cross section of road
Asphalt Painting
18 mm thick Seal coat
25 mm thick Carpet
37.5 mm thick B.B.C
150 mm thick WMM
100 mm thick 100 mm thick GSB-I
Hard Side Shoulder 100 mm thick GSB-II
Earth work

6m

0.6 m 3.75 m 0.6 m

SIDE SLOPE 1.5 : 1
Gutter

LAND WIDTH

4.35 m
7.3 m

8.5 m

3. Key map

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4.Estimation

A. Recapitulation sheet:

Sr no. Item Amount

1 Sub Estimation No-1 ₹ 88,49,275.64
GSB,WMM,Hard side shoulder
2 Sub Estimation No-2 ₹ 20,68,429.50
BBC-37.5mm thick
3 Sub Estimation No-3 ₹ 34,75,114.74
Carpet-25mm thick,0.0018 cum/sq m seal
coat, Asphalt painting
4 Sub Estimation No-4 ₹ 30,064.27
Furniture work
5 Sub Estimation No-5 ₹ 4,05,153.61
C.D. Work(single Row Pipe Drain)

Total Rs. ₹ 1,48,28,037.76

1 % for Quality Control charge ₹ 1,48,280.38
Lump Contingency ₹ 1,09,181.86
Total ₹ 1,50,85,500.00

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 B .Abstract sheet:
Sr.no. Item Quantity Rate Unit Amount
1 Cleaning & grubbing road including uprooting rank 14400.00 3.205639 m2 46161.2
vegetation, grass, bushes etc & trees girth up to
300mm
2 Constructing of granular sub base Ge-II by providing 3661.40 623.17 m3 2281675
course graded B.T. Machine crushed materials &
compacting with vibratory roller to achieve the
desired density.
3 Constructing of granular sub base Ge-I by providing 2245.40 639.33 m3 1435552
course graded B.T. Machine crushed materials &
compacting with vibratory roller to achieve the
desired density.
4 Wet Mix Macadam base course 150mm thick as 3152.10 692.86 m3 2183964
MORTH specification using machine crushed B.T.
Chips as per required gradation.
5 18000.00 26.87 m2 483660
Hincol made or Equivalent grade priming coat with
emulsion(SS-1) at rate of 7.5kg/Sq m
6 Hard side shoulder of GSB-I by providing course 576.00 639.33 m3 368254.1
graded B.T. Machine crushed materials
7 Earth work for embankment with selected soil 12928.10 191.9 m3 2480902
having CBR>5% including breaking clods, dressing
with all lead and lift including watering and rolling
8 1350.00 1532.17 MT 2068430
Bituminous grout 37.5 mm thick compacted in single
layer using B.T. Chips of required gradation &
asphalt VG-10 grade at 1.99% by weight of mix &
adding zycotherm @ 1kg/MT of bitumen mixing .
9 Bituminous carpet 25mm thick with B.T. Aggregate 945.00 2086.56 MT 1971799
as specified and using bitumen for tack coat at rate
of 2.5kg/10sq-m using VG 10 bitumen.
10 Seal coat with B.T. Agg. As specified using agg. At 486.00 2291.39 MT 1113616
rate of 0.18 cu.mt/10Sq mt. And bitumen for mixing
agg. At rate of 4.5%.
11 Asphalt painting of B.T. Surface with VG-10 at rate 18000.00 21.65 m2 389700
5kg/10Sq m adding zycotherm @ 0.1% of bitumen
and spreading stone dust for painting surface at rate
of 0.003 cu.m/sq.m
12 K.M. Stone precast C.C. 1:2:4 including necessary 6.00 490.86 no 2945.16
reinforcement.
13 19.00 281.79 no 5354.01
Hectometer. Stone precast C.C. 1:5:10 including
necessary reinforcement.
14 Village board name made out of 2mm aluminium 2.00 4163.22 no 8326.44
sheet; size 90x60 cms
15 Retro reflective High intensity Grade board using 2.16 6221.3 m2 13438.01
CR(MS) sheet 2mm , angle 75x75x6mm. Fixing with
C.C. 1:4:8.
Total 14853776
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 C .Measurement sheet:
Sr.no. Item No. Length Width Height Quantity Unit Description
1 Cleaning & grubbing road 2 4800 1.5 - 14400.00 m2 -
including uprooting rank
vegetation ,grass ,bushes etc
& trees girth up to 300mm

2 Constructing of granular sub 1 4800 7.3 0.1 3504.00 m3 -

base Ge-II by providing
course graded B.T. Machine
crushed materials &
compacting with vibratory
roller to achieve the desired
density.
Extra widening for 1 1574 0.1 157.40 m3 -
curvature, fanning &
junction as per statement
3661.40 m3

3 Constructing of granular sub 1 4800 4.35 0.1 2088.00 m3 -

base Ge-I by providing
course graded B.T. Machine
crushed materials &
compacting with vibratory
roller to achieve the desired
density.
Extra widening for 1 1574 0.1 157.40 m3 -
curvature, fanning &
junction as per statement
2245.40 m3

4 Wet Mix Macadam base 1 4800 4.05 0.15 2916.00 m3 -

course 150mm thick as
MORTH specification using
machine crushed B.T. Chips
as per required gradation.
Extra widening for 1 1574 0.15 236.10 m3 -
curvature, fanning &
junction as per statement
3152.10 m3

5 Hincol made or Equivalent 1 4800 3.75 - 18000.00 m2 -

grade priming coat with
emulsion(SS-1) at rate of
7.5kg/Sq m

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6 Hard side shoulder of GSB-I 2 4800 0.6 0.1 576.00 m3 -
by providing course graded
B.T. Machine crushed
materials
7 Earth work for embankment 1 4800 7.25 0.69 12928.10 m3 W=(6.0+8.5)/2
with selected soil having
CBR>5% including breaking
clods, dressing with all lead
and lift including watering
and rolling
8 Bituminous grout 37.5 mm 1 4800 3.75 - 18000.00 m2 Quantity required
thick compacted in single =1x18000x0.0375x2=1350M.
Tone
layer using B.T. Chips of
required gradation & asphalt
VG-10 grade at 1.99% by
weight of mix & adding
zycotherm @ 1kg/MT of
bitumen mixing.
9 Bituminous carpet 25mm 1 4800 3.75 - 18000.00 m2 Quantity required
thick with B.T. Aggregate as =1x18000x0.025x2.1=945
M.Tone
specified and using bitumen
for tack coat at rate of
2.5kg/10sq-m using VG 10
bitumen.
10 Seal coat with B.T. Agg. As 1 4800 3.75 - 18000.00 m2 Quantity required
specified using agg. At rate =1x18000x0.018x1.5=486
M.Tone
of 0.18 cu.mt/10Sq mt. And
bitumen for mixing agg. At
rate of 4.5%.
11 Asphalt painting of B.T. 1 4800 3.75 - 18000.00 m2 -
Surface with VG-10 at rate
5kg/10Sq m adding
zycotherm @ 0.1% of
bitumen and spreading
stone dust for painting
surface at rate of 0.003
cu.m/sq.m
12 K.M. Stone precast C.C. 1:2:4 6 - - - 6.00 no No= (4800/1000)+1=6
including necessary
reinforcement.
13 Hectometer. Stone precast 19 - - - 19.00 no No= (4800/200)+1=19

C.C. 1:5:10 including

necessary reinforcement.
14 Villege board name made 2 - - - 2.00 no -
oute of 2mm aluminium
sheet; size 90x60 cms
15 Retro reflective High 2 1.2 0.9 - 2.16 m2 -
intensity Grade board using
CR(MS) sheet 2mm , angle
75x75x6mm. Fixing with C.C.
1:4:8.

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Extra widening for curvature, fanning &junction
Sr.no. Item No. Area Quantity Unit Description
1 Fanning of approach roads for 14x2=28 0.215x10x10=21.5 602.00 sq m -
widening
2 Extra widening for curvature 18x0.5=9 120x0.9=108 972.00 sq m -
total 1574.00 sq m

D. Sample Rate Analysis:

Sr. No. item Qty. Unit Rate Amount
A Labor
1 Male 0.4 Day 286 114.4
2 Mazadoor skilled 2 Day 286 572
3 Mazdoor 8 Day 286 2288
2974.4

B Machinery
1 Motor grader 6 Hrs. 1545 9270
2 Vibratory Roller 6 Hrs. 994 5964
3 Water tank 3 Hrs. 200 600
15834

C Material
1 53mm to 26.5mm 134.4 cub m 484 65049.6
@35%
2 26.5mm to 4.75mm 172.8 cub m 480 82944
@45%
3 2.36mm below 76.8 cub m 259 19891.2
@20%
4 Coast of water 18 KL 20 360
168244.8

D Add 15% 2821.26

contractors profit
and over head
charges on A+B
total cost per 300 cub m 189874.46
total cost per 1 cub m 632.9148667

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5. Tender process
Tender Form type: B-1 type

MEMORANDUM
1 General Description of work (If it includes sub works, the details thereof :- As per Page No.1 Face-
will be given Separately) sheet

2 Estimated Cost :- 14825520.33

Rs.

3 Earnest Money 1% :- 148260.00

Rs.

4 Security Deposit 10% :- 1482560.00

Rs.

In the form of small savings or Narmada Bonds (of minimum one year 2.5% :- 370640.00
(i)
time limt) Rs.

To be deducted from bills @ 2.5 percent of value of work paycble 2.5% :- 370640.00
(ii)
under Running Bill Rs.

Performance bond of Shedule bank 5% :- 741280.00

(iii)
Rs.

Total 10% :- 1482560.00

Rs.

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Terms and Condition of Contract:
Important Clause :
 Security deposit:
 In respect of the tender up to Rs. Thirty Lacs, equal to 5 (Five) percent of the estimated
cost of the work put to tender.
 In respect of the work above thirty lacs, equal to 10 (Ten) percent of the estimated cost
of the work put to tender.
 Liquidated damages for delay:
 If the Contractor fails to complete the work under contract by the stipulated date, he
shall pay liquidated damages of Rs. 0.1* percentage of the contract value per day from
the date of delaying the said work up to the date of completion and handling over to the
Government
 Action & compensation in case of bad work:
 If, at any time before the expiry of Defects Liability period as detailed in Clause 17-A. It
shall appear to the Engineer-in-charge or his sub-ordinate in charge of the work
that/any work has been executed unsound, imperfect or unskilled workmanship or with
materials of inferior quality or that any materials or articles provided by him for the
execution of the work are unsound,

 Measures for Prevention of Fire :

 The contractor shall not set fire to any standing jungle, trees, bush wood or grass
without a written permit from the Engineer-in-charge.
 Compensation under the workmen's compensation Act :
 The contractor shall be responsible for and shall pay compensation to his workman
payable under the Workmen's Compensation Act. 1923

 Minimum age of person employed :

 No Contractor shall employ any person who is under the age of 15 years.
 Method of payment :
 Payment to contractor shall be made by cheque.
 Treasure-Trove :
 In the event of discovery by contractor or his employ during the progress of work it will
be submitted to government.
 Materials, Works Test Register and Core cutting Machine :
 A register in the prescribed proforma showing test results of materials & work tests will
be maintained and day-to day receipt, consumption and balance of cement on site of
work by the Department and every entry thereof shall invariably be signed by the
Contractor or his authorised representative in token of its correctness.
 FENCING AND LIGHTING :
 The contractor shall, unless otherwise specified, be responsible for the proper fencing,
lighting grading and taking of the necessary safety measures for all works comprised in
the contract

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6.Construction Process:
I. Cleaning & grubbing road land:
o Road land is cleaned by uprooting rank vegetation, grass bushes, shrubs, sapligs and
trees girth up to 300 mm.
o After that stumps of trees which are cut earlier are removed and disposed in area of light
jungle.

II. Cutting & Filling and preparation of Embankment.

o Cutting and filling is done as per requirement.

Embankment:
o Embankment is made with selected soil having California bearing ratio (>5%)
o After clearing the site, the alignment of the road is properly set out true to line, curves,
slopes grades and sections as shown on the plan or directed by the Engineer-in-charge.
o Embankment is constructed in uniform layers not exceeding 250 mm in loose thickness.
With watering and compaction.
o Moisture content of the materials is checked continuously if found less than that specified
for compaction, again compaction is done after spreading loose soil. Compaction is done
till the maximum dry density of soil is achieved.
o Watering shall be sprinkled water flooding is not permitted under any circumstances.

 Density requirement of embankment

Type of work
Embankment up to 3m height, not subjected to
extensive flooding
Embankment exceeding 3m height, not
subjected to extensive flooding
Sub-grade and earthen shoulder/verges/backfill
Max. Laboratory dry unit weight when
tested a per IS:2720(part-8)
Not less than 15.2 KN/cub m.
Not less than 16.0 KN/cub m.
Not less than 17.5 KN/cub m.

 Tests During Construction:

 Moisture content(IS:2720 Part 2)
 In-situ Density Measurements (IS:2720 Part 28)

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III. GSB II (Granular sub base)
 Preparation :
 GSB II is made from Natural sand, moorum, gravel, crushed-stone, or combination
depending upon the grading required .
 After the Earth Work the Sub-Base of the road is constructed with Granular material.
Granular sub-base (GSB) is constructed with well graded Granular stones etc.
 The sub-base material of grading specified in the Contract is spread on the prepared
sub-grade with the help of a motor grader of adequate capacity.
 After that water is sprinkled on material by maintaining OMC 1-2% with considering
evaporation losses.
 Immediately thereafter, rolling is started with smooth wheeled roller of 80 to 100 KN
weight. Compaction is done till required density is achieved as per the design.

 Grading for coarse graded GSB II

Is sieve Designation % by weight passing the IS sieve
75.0 mm --
53.0mm 100
26.5mm 50-80
9.5mm --
4.75mm 15.35
2.365mm --
0.425mm --
0.075mm <10
CBR Value(min.) 25

 Tests During Construction:

 Placement Moisture Content: (IS:2720 Part 2)
 In-situ Density measurements (IS:2720 Part 28)
 CBR test

IV. GSB I (Granular sub base)

o Preparation is same as GSB II.

 Grading for coarse graded GSB I

Is sieve Designation % by weight passing the IS sieve
75.0 mm 100
53.0mm --
26.5mm 55-75
9.5mm --
4.75mm 10-30
2.365mm --
0.425mm --
0.075mm <10
CBR Value(min.) 30
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V. Wet Mix Macadam (WMM)

 Preparation :
 Aggregate and binding materials are premixed in a batching plant or concrete mixing
machine and then brought to site for overlaying and rolling.
 Immediately upon mixing, the aggregate is spread uniformly and evenly upon the
prepared sub-base, in required quantities.
 Thickness of a single compacted WMM layer shall not be less than 75 mm.
 After the mix is laid to proper thickness, the same shall be uniformly compacted with a
suitable roller. Rolling is continued till the density achieved is at least 100% of the
maximum dry density as per IS: 2720 (Part 7).
 After final compaction of WMM, the road shall be allowed to dry for at least 24 hours.
 Preferably no vehicular traffic should be allowed on the finished WMM surface till it
has dried and the wearing course has been laid.

 Grading for WMM :

Is sieve Designation % by weight passing the IS sieve
53.00 mm 100
45.00mm 95-100
26.50mm --
22.40mm 60-80
11.20mm 40-60
4.75mm 25-40
2.36mm 15-30
600.00 micron 8-12
75.00 micron 0-8

 Requirements of aggregates for WMM:

Test Test Method Requirements
Los-Angeles Abrasion value IS:2386(part-4) 40% max.
Aggregate impact value IS:2386(part-4) 30% max.
Combined Flakiness and IS:2386(part-1) 30% max.
Elongation indices

 Tests for WMM:

 Grading Test (IS:2386 Part 1)
 Aggregate impact value (IS:2386-Part 4)
 Placement Moisture Content (IS:2720 Part 2
 Density of Compacted Layer (IS:2720 Part 28)

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VI. Bitumen Base Course(B.B.C.)
o It is mixture of specified coaurse aggregate and bitumen in our
construction site we used BBC layer of 37.5mm with tack coat.

Materials:
 Coarse aggregates.

Composition of Bituminous course

Nominal aggregate size 25 mm
layer thickness 37.5 mm
IS : Sieve [MM] Cumulative % by weight of total aggregate passing.
Coarse aggregate Key aggregate
40 mm 100 -
26.50 mm 40-75 -
22.4 mm - 100
13.20 mm 0-20 40-75
5.60 mm - 0-20
2.80 mm 0-5 0-5
Bitumen content % by 1.99
weight of total mixture
Bitumen Grade 80 /100 (VG-10)

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 Bitumen:
 bitumen shall be paving bitumen of penetration grade 80/100 (VG-10) complying with
Indian Standard specification for “Paving Bitumen” IS:73 .
o Bitumen (VG-10 grade) for mixing @ 1.99 % by weight of total mix in plant.
o Bitumen will be at the rate of 2.5 Kg./10Sqmt In tack coat.
 Preparation :
o stone aggregates of required gradation and bitumen (VG-10 grade) for mixing @
1.99 % by weight of total mix in plant.
o After this Spreading of material and rolling is done.

VII. Carpet layer

o It is mixture of specified coaurse aggregate and bitumen in our
construction site we used Carpet layer of 25mm with tack coat.
 Preparation :
o First material is mixed in mixing plant with zycotherm admixture.
o Mixed material is laid by paver machine with maintaining required slope of
embankment.
o After that rolling is done.

 Admixture:
o Zycotherm admixture shall be admixed in bitumen at the rate of 1.0kg / MT of bitumen.
o Zycotherm admixture is used for excellent bonding between aggregate and
bitumen.

 Material :
 Coarse aggregates shall consist of crushed stone only.
 No organic matter should present in material.
 The fine aggregates shall consist of crusher run screening, natural sand or mixture
of both.
 VG10 bitumen for mixing with aggregate at the rate of 3.36 % or 33.60
kg/M.Ton adding zycotherm @1Kg/MT of bitumen of total mix.

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 Table of aggregate gradation for Asphalt carpet
SIEVE SIZE % by weight passing the sieve for
20/25mm thickness
20mm 100
12.5mm 70-100
10.0mm 20-40
4.75mm 0-5

 Tests for carpet :

i ) Aggregate Impact value
ii ) Flakiness Index of aggregate
Iii ) Stripping value
Iv) Temperature of Binder

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VIII. Seal coat
o In our construction seal coat layer of 18mm is used.

 Material :
 Coarse aggregates shall consist of crushed stone only.
 Aggregate gradation for Seal coat:
IS Sieve Designation Cumulative per total weight of total
aggregate passing
13.2mm 100
11.2mm 88-100
5.6mm 31-52
2.8mm 5-25
0.09mm 0-5

 VG 10 bitumen for mixing agg. at the rate of 4.50% or 45.00 kg/M.T. adding
zycotherm @1Kg/MT of bitumen of total mix.

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IX. Asphalt Painting
 Materials: Bitumen as per IS:73
 Admixture: Zycothem bitumen shall be mixed in bitumen at rate of 0.1% of bitumen.
 The asphalt is heated in the tanker and the temperature of the asphalt at the time of
spraying shall be in the range of 1500C -1770C.

Stone dust:
o Applied to protect new construction from fresh mark of wheels.
o Soon after the spraying of asphalt, the stone dust is spread evenly with a twisting motion of
baskets at the rate of 0.03Cum/10 Sqm.

 After these all process Traffic may be allowed .

7. Material Transportation.
1. Stone aggregate : from Areth(28Km) and Chikhli
2. Aasphalt : from Hazira(68km)
3. Water :- Chikhli Ishanpur
4. Asphalt batch mixed material: Vadi, kamrej

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8. Asphalt batch mixing plant:

o It is automatically operated plant.

o In this plant aggregates of different size are feeded from feeders through conveyor belt.
o After that aggregates are hot mixed with bitumen at temperature 150-200 oC. and mixed
material is filled in truck.

BITUMEN EXTRACTION TEST

o This test is performed to know the % of bitumen present in mixed material.

o First weight of empty bowl is taken as W 1 than Sample is taken in bowl and it is weighted as
W2 after that material is washed by petrol to remove bitumen and after drying weight is taken
as W 3.
o % of bitumen = (W 2 – W3)/ (W 2 - W 1).

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9. Intermediate structure

Box Culvert:.
 Notation of box culvert:
No /ab-bc/H=no of box / clear height –clear width / earth cushion. Ex 1/22/0

 Procedure:
 Excavation in foundation.
 Laying of PCC.
 Preparation of steel net for Raft and walls.
 Concreting in raft and walls.
 Making of slab.
 Making of retaining walls.
 Coat of monastic Asphalt 12mm thick.
 50mm Concrete wearing coat

 Material used:
1) Ordinary Portland cement with 53 grade.
2) TMT and TMX bars of Fe500.
3) 1st class brick.
4) Mortar material Sand, aggregate etc.
5) Water.

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Plan:

Cross section:

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Rein forcemeat

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Bar bending Schedule.

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