INTERNSHIP REPORT

Submitted By:
Shahzaib Rehmani
Session 2014-17
DHA CITYAT A GLANCE..
The upcoming city is planned on an area spanning 11,640 acres,
comprising residential, commercial and mixed-use elements. It is going
to be a sustainable Green City. Engineers have started the topographical
survey and town planning of the Defence Housing Authority,
Karachi society called DHA II, which will become a satellite town. This
is the authority’s next project after DHA I adjacent
to Clifton and Korangi. DHA II is located near the Super Highway.
DHA City, Karachi is divided in into 16 sectors. After a year-long
evaluation, the Institute of Sustainable Infrastructure in Washington DC,
USA, has given the “International Award” to Defence Housing
Authority City Karachi (DCK).
DHA City is located accessible from the city of Karachi as well as
Hyderabad by M-9 Super Highway. The project is situated at a distance
of 56 km from the city core area of Karachi. As per the DCK
Transportation Plan there will be a myriad of road networks, major
intersections, collector roads, service roads, roundabouts, one way
regimes and the concept of using maximum public transport.
CULVERT
DEFINITION
An opening through an embankment for the conveyance of water by mean of pipe
or an enclosed channel.

OR

It is a transverse and totally enclosed drain under a road or railway.

TYPE OF
CULVERTS
1. Pipe Single or Multiple
2. Pipe Arch Single or
Multiple
3. Box Culvert Single or
Multiple
4. Bridge Culvert
5. Arch Culvert
Pipe culverts are made of smooth steel, corrugated metal, or concrete material.
Their primary purpose is to convey water under roads, although a variety of
wildlife uses them as passageways. Pipe culverts typically range from 1- 6 feet in
diameter and are the least expensive type of culvert. Round culverts are best suited
to medium and high stream banks.

Pipe Arch Single or Multiple

Pipe-arch culverts provide low clearance, openings suitable for large waterways,
and are more aesthetic. They may also provide a greater hydraulic advantage to
fishes at low flows and require less road fill.

Box Culvert Single or Multiple

Box culverts are used to transmit water during brief runoff periods. These are
usually used by wildlife because they remain dry most of the year. They can have
an artificial floor such as concrete. Box culverts generally provide more room for
wildlife passage than large pipe culverts. Box culverts are usually made up of
Reinforced Concrete (RCC)
Arch Culvert

A pipe arch culvert is a round culvert

reshaped to allow a lower profile while maintaining flow characteristics. It is good
for installations with shallow cover.

Materials used for arch culverts are RCC, Corrugated Metal or Stone Masonry.

DESIGN OF REINFORCED CONCRETE

CULVERTS
Location
Ideally, the axis of a culvert should coincide with that of the natural streamed and
the structure should be straight and short. This may require modification of the
culvert alignment and grade. Often it is more practical to construct the culvert at
right angles to the roadway. However, the cost of any change in stream channel
location required to accomplish this should be balanced against the cost of a
skewed alignment of the culvert, and changes in channel hydraulics should be
considered.

Grade and camber

The culvert invert gradient should be the same as the natural streambed to
minimize erosion and silting problems. Foundation settlement should be countered
by cambering the culvert to ensure positive drainage.

Entrance and outlet conditions

It is often necessary to enlarge the natural channel a considerable distance
downstream of the culvert to prevent backwater from entering the culvert. Also,
enlargement of the culvert entrance may be required to prevent pending above the
culvert entrance. The entrance and outlet conditions of the culvert structure directly
impact its hydraulic capacity. Rounding or beveling the entrance corners increases
the hydraulic capacity, especially for short culverts of small cross section. Scour
problems can occur when abrupt changes are made to the streamed flow line at the
entrance or outlet of the culvert.

MATERIALS USED

Foundation material
Materials to be used for the culvert pipe foundation should be indicated on the
drawings. Refer to the geotechnical foundation report for the project.

Bedding materials
Bedding class and materials for culverts should be indicated on the drawings.
When designing the bedding for a box culvert, assume the bedding material to be
slightly yielding, and that a uniform support pressure develops under the box
section.

PURPOSE AND USE

1. Culverts are used in roads, bridges, and berm construction to prevent
flooding and washing out of roads.
2. They also minimize erosion, build-up of standing water, and provide
pathways for run-off.
 TYPES OF CONCRETE WALLS
Many different types of concrete walls are available today. You have the option of
a concrete wall that looks like stone or brick. The wall can be made right on the
premises or shipped in already made. The traditional color of concrete, although
still available, is becoming a thing of the past. These new concrete walls no longer
need shrubbery to camouflage their existence. They can be the vocal point of your
property.

Precast Walls
 Precast concrete walls come in many forms. Some are reinforced with steel ribs,
and others are solid panels. The controlled environment of a factory allows the
precast walls to set and cure no matter what the weather. As a building foundation,
these panels can be installed in any climate zone. A completed foundation using
these panels takes one-sixth the time to complete, compared to pouring a concrete
foundation on site, and the panels cost less than the traditional poured concrete.

Poured Walls
 Poured concrete walls can be used for a foundation, retaining wall or decorative
wall. First the forms need to be put up and reinforced for the liquefied concrete to
be poured into. For smaller jobs, concrete can be mixed in a small portable mixer
or even in tubs or pails. For larger walls and foundations, the concrete is usually
trucked in for pouring. You need to do this in weather that is conducive to the
curing and setting of concrete. This type of wall is expensive and time consuming
to construct.

Block Walls
 Concrete block walls can be used for foundations and retaining and decorative
walls also. They come in different shapes and sizes for different jobs and designs.
These blocks are pre-made in a factory and shipped to the site where the wall will
be built. The wall is constructed in a brick-laying fashion, with mortar put between
blocks. This type of concrete wall is one of the more inexpensive and less time
consuming ways to build a wall.
 Stucco Walls
 A stucco concrete wall is a thin layer of concrete that goes over an existing wall.
This not only allows for coverage of cracks and chips, but it also adds texture to
the wall. This is an inexpensive way of giving a wall the look of concrete. The
stucco material can be put on in patterns that swirl, crisscross or go straight up and
down. This type of material is easy to work with and can withstand the coldest and
hottest of weather.

Stamped Walls
 Stamped concrete walls are becoming popular. The stamping is done using the
poured concrete technique, with the forms molding the concrete in the shapes of
stones or masonry patterns instead of as smooth panels. The resultant wall can look
remarkably like stone or brick, which adds a natural rustic look to the wall you are
constructing. This technique is less expensive and takes less time than building a
stone or masonry wall.

Colored Walls
 Colored concrete walls are available in all the poured concrete techniques and
some of the pre-made panels. This works especially well with the stamped concrete
in the shapes of stones, giving them a more realistic coloring. Many colors are
available in addition to the options for the natural colors of stone and brick. This
coloring technique allows you to deviate from the plain chalky look of traditional
concrete.
PLUM CONCRETE
In this concrete mix used with plums (large stones) mixed with concrete. It is used
in gravity dams, embankments and below the structures.

Plum concrete is usually done where the surface is uneven and to minimize the
costing of concrete for eg. below footings of residential buildings where in a small
portion where the slope of ground below single footing is 1:10 to 1:50 in that case
to save the cost of concrete plum is usually preferred this finally leads to minimize
the construction cost of building in all.
CURING
Curing is the process in which the concrete is protected from loss of moisture and
kept within a reasonable temperature range. The result of this process is increased
strength and decreased permeability. Curing is also a key player in mitigating
cracks in the concrete which severely impacts durability.

METHODS USED FOR CURING OF CONCRETE

There are various methods of curing. The adoption of a particular method will
depend upon the nature of work and the climatic conditions. The following
methods of curing of concrete are generally adopted.
1. SHADING OF CONCRETE WORK
The object of shading concrete work is to prevent the evaporation of water from
the surface even before setting. This is adopted mainly in case of large concrete
surfaces such as road slabs. This is essential in dry weather to protect the concrete
from heat, direct sun rays and wind. It also protects the surface from rain. In cold
weather shading helps in preserving the heat of hydration of cement thereby
preventing freezing of concrete under mild frost conditions. Shading may be
achieved by using canvas stretched on frames. This method has a limited
application only.

2. COVERING CONCRETE SURFACES WITH HESSIAN OR GUNNY

BAGS
This is a widely used method of curing, particularly for structural concrete. Thus
exposed surface of concrete is prevented from drying out by covering it with
hessian, canvas or empty cement bags. The covering over vertical and sloping
surfaces should be secured properly. These are periodically wetted. The interval of
wetting will depend upon the rate of evaporation of water. It should be ensured that
the surface of concrete is not allowed to dry even for a short time during the curing
period. Special arrangements for keeping the surface wet must be made at nights
and on holidays.

3. SPRINKLING OF WATER
Sprinkling of water continuously on the concrete surface provides an efficient
curing. It is mostly used for curing floor slabs. The concrete should be allowed to
set sufficiently before sprinkling is started. The spray can be obtained from a
perforated plastic box. On small jobs sprinkling of water may be done by hand.
Vertical and sloping surfaces can be kept continuously wet by sprinkling water on
top surfaces and allowing it to run down between the forms and the concrete. For
this method of curing the water requirement is higher.

4. PONDING METHOD
This is the best method of curing. It is suitable for curing horizontal surfaces such
as floors, roof slabs, road and air field pavements. The horizontal top surfaces of
beams can also be ponded. After placing the concrete, its exposed surface is first
covered with moist hessian or canvas. After 24 hours, these covers are removed
and small ponds of clay or sand are built across and along the pavements. The area
is thus divided into a number of rectangles. The water is filled between the ponds.
The filling of water in these ponds is done twice or thrice a day, depending upon
the atmospheric conditions. Though this method is very efficient, the water
requirement is very heavy. Ponds easily break and water flows out. After curing it
is difficult to clean the clay.

5. MEMBRANE CURING
The method of curing described above come under the category of moist curing.
Another method of curing is to cover the wetted concrete surface by a layer of
water proof material, which is kept in contact with the concrete surface of seven
days. This method of curing is termed as membrane curing. A membrane will
prevent the evaporation of water from the concrete. The membrane can be either in
solid or liquid form. They are also known as sealing compounds. Bituminised
water proof papers, wax emulsions, bitumen emulsions and plastic films are the
common types of membrane used.

Whenever bitumen is applied over the surface for curing, it should be done only
after 24 hours curing with gunny bags. The surface is allowed to dry out so that
loose water is not visible and then the liquid asphalt sprayed throughout. The
moisture in the concrete is thus preserved. It is quite enough for curing.

6. STEAM CURING
Steam curing and hot water curing is sometimes adopted. With these methods of
curing, the strength development of concrete is very rapid.

These methods can best be used in pre cast concrete work. In steam curing the
temperature of steam should be restricted to a maximum of 750C as in the absence
of proper humidity (about 90%) the concrete may dry too soon. In case of hot
water curing, temperature may be raised to any limit, ay 1000C.
At this temperature, the development of strength is about 70% of 28 days strength
after 4 to 5 hours. In both cases, the temperature should be fully controlled to avoid
non-uniformity. The concrete should be prevented from rapid drying and cooling
which would form cracks.
SPACER

Spacer may refer to:

 An unthreaded piece of rigid tubing used as

a separator. See Standoff (separator).
 Spacer (Asimov), in Isaac Asimov's Robot
Series
 Spacer, one of several cheela that was
stranded in space in Robert L. Forward's
novel Star quake
 Rebar spacer, in concrete construction
 Spacer, alias for flesh tunnel, a type of body piercing

A Rebar Spacer is a device that secures the reinforcing steel or "rebar"

in reinforced concrete structures as the rebar is assembled in place prior to the final
concrete pour. The spacers are left in
place for the pour to keep the
reinforcing in place, and become a
permanent part of the structure.

The main categories of rebar spacers

are:

 Linear Spacers (Π-section profiles,

H-section profiles, or other 3
dimensional shapes),
 Point Spacers (wheel spacers,
various tower or chair-like shapes)
Rebar spacers can be divided in two raw
materials categories:

1. Concrete spacers
2. Plastic spacers
SILT
Silt is granular material of a size somewhere between sand and clay whose mineral
origin is quartz and feldspar. Silt may occur as a soil or as sediment mixed
in suspension with water (also known as a suspended load) in a body of water such
as a river. It may also exist as soil deposited at the bottom of a water body. Silt has
a moderate specific area with a typically non-sticky, plastic feel. Silt usually has a
floury feel when dry, and a slippery feel when wet. Silt can be visually observed
with a hand lens.
 CONCRETE ADMIXTURES

1. Concrete Admixtures: Set-Retarding

Set retarding concrete admixtures are used to delay the chemical reaction that takes
place when the concrete starts the setting process. These types of concrete
admixtures are commonly used to reduce the effect of high temperatures that could
produce a faster initial setting of concrete. Set retarding admixtures are used in
concrete pavement construction, allowing more time for finishing concrete
pavements, reducing additional costs to place a new concrete batch plant on
the and helps eliminate cold joints in concrete. Retarders can also be used to resist
cracking due to form deflection that can occur when horizontal slabs are placed in
sections. Most retarders also function as water reducers and may entrain some air
in concrete.

2. Concrete Admixtures: Air-Entrainment

Air entrained concrete can increase the freeze-thaw durability of concrete. This
type of admixture produces a more workable concrete than non-entrained
concrete while reducing bleeding and segregation of fresh concrete. Improved
resistance of concrete to severe frost action or freeze/thaw cycles. Other benefits
from this admixture are:
 High resistance to cycles of wetting and drying

 High degree of workability

 High degree of durability
The entrained air bubbles act as a physical buffer against the cracking caused by
the stresses due to water volume augmentation in freezing temperatures. Air
entrains are compatible with almost all the concrete admixtures. Typically for
every 1% of entrained air, compressive strength will be reduced by about 5%.
3. Concrete Admixtures: Water-Reducing
Water-reducing admixtures are chemical products that when added to concrete can
create a desired slump at a lower water cement ration than what is normally
designed. Water-reducing admixtures are used to obtain specific concrete strength
using lower cement content. Lower cement contents result in lower CO2 emissions
and energy usage per volume of concrete produced. With this type of
admixture, concrete properties are improved and help place concrete under difficult
conditions. Water reducers have been used primarily in bridge decks, low-slump
concrete overlays, and patching concrete. Recent advancements in admixture
technology have led to the development of mid-range water reducers.

4. Concrete Admixtures: Accelerating

Accelerating concrete admixtures are used to increase the rate of concrete strength
development, or to reduce concrete setting time. Calcium chloride could be names
as the most common accelerator component; however, it could promote corrosion
activity of steel reinforcement. Nonetheless, concrete best practices such as
proper consolidation, adequate cover and proper concrete mix design could prevent
these corrosion issues. Accelerating admixtures are especially useful for modifying
the properties of concrete in cold weather.

5. Concrete Admixtures: Shrinkage Reducing

Shrinkage reducing concrete admixtures are added to concrete during initial
mixing. This type of admixture could reduce early and long term drying shrinkage.
Shrinkage reducing admixtures can be used in situations where shrinkage
cracking could lead to durability problems or where large numbers of shrinkage
joints are undesirable for economic or technical reasons. Shrinkage reducing
admixtures can, in some cases, reduce strength development both at early and later
ages.
6. Concrete Admixtures: Super plasticizers
The main purpose of using super plasticizers is to produce flowing concrete with
very high slump in the range of 7-9 inches to be used in heavily reinforced
structures and in placements where adequate consolidation by vibration cannot be
readily achieved. The other major application is the production of high-strength
concrete at w/c's ranging from 0.3 to 0.4. It has been found that for most types of
cement, super plasticizer improves the workability of concrete. One problem
associated with using a high range water reducer in concrete is slump loss. High
workability concrete containing super plasticizer can be made with a high freeze-
thaw resistance, but air content must be increased relative to concrete without
super plasticizer.

7. Concrete Admixtures: Corrosion-Inhibiting

Corrosion-inhibiting admixtures fall into the specialty admixture category and are
used to slow corrosion of reinforcing steel in concrete. Corrosion inhibitors can
significantly reduce maintenance costs of reinforced concrete structures throughout
a typical service life of 30 – 40 years. Other specialty admixtures include
shrinkage-reducing admixtures and alkali-silica reactivity inhibitors. Corrosion
inhibiting admixtures have little effect on strength at later ages but may accelerate
early strength development. Calcium nitrite based corrosion inhibitors do
accelerate the setting times of concretes over a range of curing temperatures unless
they are formulated with a set retarder to offset the accelerating effect.
TESTS ON CONCRETE
SAMPLING The first step is to take a test sample from the large batch of
concrete. This should be done as soon as discharge of the concrete commences.
The sample should be representative of the concrete supplied. The sample is taken
in one of two ways:

For purposes of accepting or rejecting the load: Sampling

after 0.2 m3 of the load has been poured.

For routine quality checks: Sampling from three places in

the load.

A) CONCRETE SLUMP TEST

This test is performed to check the consistency of freshly
made concrete. The slump test is done to make sure a
concrete mix is workable. The measured slump must be
within a set range, or tolerance, from the target slump.

Workability of concrete is mainly affected by consistency i.e. wetter mixes will be

more workable than drier mixes, but concrete of the same consistency may vary in
workability. It can also be defined as the relative plasticity of freshly mixed
concrete as indicative of its workability.

Tools and apparatus used for slump test (equipment):

1. Standard slump cone (100 mm top diameter x 200 mm bottom
diameter x 300 mm high)
2. Small scoop
1. Bullet-nosed rod (600 mm long x 16 mm diameter)
3. Rule
1. Slump plate (500 mm x 500 mm)
Procedure of slump test for concrete:
1. Clean the cone. Dampen with water and place on the slump plate. The slump
plate should be clean, firm, level and non-absorbent. Collect a sample of
concrete to perform the slum test.
2. Stand firmly on the foot pieces and fill 1/3 the volume of the cone with the
sample. Compact the concrete by 'rodding' 25 times. Rodding 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.
3. Now fill to 2/3 and again rod 25 times, just into the top of the first layer.
4. Fill to overflowing, rodding again this time just into the top of the second
layer. Top up the cone till it overflows.
5. Level off the surface with the steel rod using a rolling action. Clean any
concrete from around the base and top of the cone, push down on the
handles and step off the foot pieces.
6. Carefully lift the cone straight up making sure not to move the sample.
7. Turn the cone upside down and place the rod across the up-turned cone.
8. Take several measurements and report the average distance to the top of the
sample. If the sample fails by being outside the tolerance (i.e. the slump is
too high or too low), another must be taken. If this also fails the remainder of
the batch should be rejected.

B) THE COMPRESSION TEST

The compression test shows the compressive strength of hardened concrete. The
compression test shows the best possible strength concrete can reach in perfect
conditions. The compression test measures concrete strength in the hardened state.
Testing should always be done carefully. Wrong test results can be costly.

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 Mega
Pascal (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.
Apparatus for compression test
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)

1. Small scoop
2. Bullet-nosed rod (600 mm x 16 mm)
3. Steel float
4. Steel plate

Procedure for compression test of concrete

1. Clean the cylinder mould and coat the inside lightly with form oil, then place
on a clean, level and firm surface, i.e. the steel plate. Collect a sample.
2. Fill 1/2 the volume of the mould with concrete then compact by rodding 25
times. Cylinders may also be compacted by vibrating using a vibrating table.
3. Fill the cone to overflowing and rod 25 times into the top of the first layer,
then top up the mould till overflowing.
4. Level off the top with the steel float and clean any concrete from around the
mould.
5. Cap, clearly tag the cylinder and put it in a cool dry place to set for at least
24 hours.
6. After the mould is removed the cylinder is sent to the laboratory where it is
cured and crushed to test compressive strength
ROAD CONSTRUCTION

CONSTRUCTION STAKING
Prior to the construction activity the design information has to be moved from the
plan to the ground. This is accomplished by staking. Slope stakes are an effective
way to insure compliance with the design standards and to keep soil disturbance to
an absolute minimum.

Stakes, marking various road design points, are typically obliterated during the
clearing and grubbing phase. In order to relocate the stakes (centerline, slope
stakes) it is helpful to establish reference points outside the clearing limits.
Reference points should be set at least 3 to 5 meters behind the uphill clearing
limits. On the average, reference points (or RP's) should be set at least every 70 to
100 meters. Typically, reference points are placed at points where the center line
alignment can be easily re-established, such as points of curvature.
CLEARING AND GRUBBING
Preparing the road right-of-way or construction area is referred to as clearing and
grubbing. During the clearing phase, trees are felled. Grubbing refers to the
clearing and removal of stumps and organic debris.

BULL DOZER IN ROAD CONSTRUCTION

Probably the most common piece of equipment in forest road construction is the
bulldozer equipped with straight or U-type blades. These are probably the most
economical pieces of equipment when material has to be moved a short distance.
The economic haul or push distance for a bulldozer with a straight blade is from 17
to 90 meters depending on grade. The road design should attempt to keep the mass
balance points within these constraints.

The road design should consider the following points when bulldozers are to be
used for road construction.

1. Roads should be full benched. Earth is side cast and then wasted rather than used
to build up side cast fills.

2. Earth is moved down-grade with the aid of gravity, not up-grade.

3. Fill material is borrowed rather than pushed or hauled farther than the economic
limit of the bulldozer.

4. Rock outcrops should be bypassed. Unless substantial rock blasting is specified

requiring drilling and blasting equipment, solid rock faces should be avoided

SUBGRADE EXCAVATION
Proper construction equipment and techniques are critically important for
minimizing erosion from roads during and after the construction. There are clear
indications that approximately 80 percent of the total accumulated erosion over the
life of the road occurs within the first year after construction. Of that, most of it is
directly linked to the construction phase.

In order to keep erosion during the construction phase to an absolute minimum,

four elements must be considered.

1. Keep construction time (exposure of unprotected surfaces) as short as possible.

2. Plan construction activities for the dry season. Construction activities during
heavy or extended rainfall should be halted.

3. Install drainage facilities right away. Once started, drainage installation should
continue until completed.

4. Construct filter strips or windrows at the toe of fill slopes to catch earth stumps
and sheet erosion

FILL CONSTRUCTION
Fill construction is required to cross draws, creeks, flats or swampy areas and when
excess excavation has taken place. Road fills support traffic and therefore must
withstand considerable abuse. Only mineral soil, free of organic debris such as
stumps, tree tops and humus should be used. Fills should be constructed and built
up in layers Each layer, or lift, should be spread and then compacted. Lift height
before compaction depends on the compaction equipment being used. Typically lift
height should be about 30 cm and should not exceed 50 cm. A bulldozer is not a
good machine for compacting fills because of their low ground pressure
characteristics. Fills across draws or creeks are especially critical since they may
act as dams if the culvert should plug up. It is considered poor practice to build fills
by end dumping instead of layering and compacting

COMPACTION
Proper compaction techniques result in significant cost reduction and reductions in
erosion. Erosion potential is directly proportional to the excavation volume
especially if it is side cast in unconsolidated and loose fills. Conventional side cast
techniques where most of the road surface is excavated into a stable hill side
results in approximately 25 to 35 percent more excavated material when compared
to "balanced" road design and construction where the excavation is incorporated
into the road prism. In the former case, most if not all of the excavated Material is
wasted as loose side cast material readily available for erosion. In the latter case, it
has been incorporated into the fill, properly compacted, and presumably
unavailable for erosion.

SUBGRADE CONSTRUCTION WITH

EXCAVATOR
Excavators are becoming more and more common in road construction. Because of
their excellent placement control of excavated material, they are ideal machines for
construction under difficult conditions. The backhoe or excavator should be the
preferred machine on steep side slopes. The construction sequence differs from the
bulldozer approach and is explained below.

The excavator works from a platform or pioneer road at the lower end of the
finished road.

1st pass: Pioneering of log and stump removal accomplished in the fist pass. Just
enough overburden is moved to provide a stable working platform.

2nd pass: After completion of the first pass the operator begins retracing its path.
During this pass unsuitable material is stripped and placed below the toe of the fill.

3rd pass: During the third pass, now working forward again, the exposed mineral
soil is dug up for the embankment construction. At the same time a ditch is
prepared and the cut slope smoothed and rounded. The portion of pioneer road or
platform which consist of organic debris is outside the load bearing road surface
fill.
PROCESSES IN BITUMINOUS ROAD
CONSTRUCTION

Bituminous road constructions steps:

1. Preparation of the existing base course layer

The existing surface is prepared by removing the pot holes or rust if any. The
irregularities are filled in with premix chippings at least a week before laying
surface course. If the existing pavement is extremely way, a bituminous leveling
course of adequate thickness is provided to lay a bituminous concrete surface
course on a binder course instead of directly laying it on a WBM.

2. Application of Tuck Coat

It is desirable to lay AC layer over a bituminous base or binder course. A tack coat
of bitumen is applied at 6.0 to 7.5 kg per 10 sq.m area, this quantity may be
increased to 7.5 to 10 kg for non-bituminous base.

3. Preparation and placing of Premix

The premix is prepared in a hot mix plant of a required capacity with the desired
quality control. The bitumen may be heated up to 150 – 177 degree C and the
aggregate temperature should not differ by over 14 degree C from the binder
temperature. The hot mixed material is collected from the mixture by the
transporters, carried to the location is spread by a mechanical paver at a
temperature of 121 to 163 degree C. the camber and the thickness of the layer are
accurately verified. The control of the temperatures during the mixing and the
compaction are of great significance in the strength of the resulting pavement
structure.
4. Rolling

A mix after it is placed on the base course is thoroughly compacted by rolling at a

speed not more than 5km per hour.

The initial or break down rolling is done by 8 to 12 tones roller and the
intermediate rolling is done with a fixed wheel pneumatic roller of 15 to 30 tones
having a tyre pressure of 7kg per sq.cm. the wheels of the roller are kept damp
with water.

The number of passes required depends on the thickness of the layer. In warm
weather rolling on the next day, helps to increase the density if the initial rolling
was not adequate. The final rolling or finishing is done by 8 to 10 tonne tandem
roller.

5. Quality control of bituminous concrete construction

The routine checks are carried out at site to ensure the quality of the resulting
pavement mixture and the pavement surface.

Periodical checks are made for

a) Aggregate grading

b) Grade of bitumen

c) Temperature of aggregate

d) Temperature of paving mix during mixing and compaction.

At least one sample for every 100 tones of the mix discharged by the hot mix plant
is collected and tested for above requirements. Marshall tests are also conducted.
For every 100 sq.m of the compacted surface, one test of the field density is
conducted to check whether it is at least 95% of the density obtained in the
laboratory. The variation in the thickness allowed is 6mm per 4.5m length of
construction.

6. Finished surface:

The AC surface should be checked by a 3.0 m straight edge. The longitudinal

undulations should not exceed 8.0 mm and the number of undulations higher than
6.0 mm should not exceed 10 in a length of 300 m. The cross-traffic profile should
not have undulations exceeding 4.0mm.
CONCLUSION

The whole experience of working with NLC was great.

This organization has a superb work culture, great minds
and very high quality of work. The work I could complete
here was very satisfactory. These few weeks have helped
me in many ways. The construction work going on here is
par excellence. I wish to work with NLC again not just as
an internee but to continue my career as a Professional
Engineer too. Insha Allah.