Abriefaccount on

InPlant Training

By-
Abhishek Bharti
A Road Project was going on under
R.C.D. , Giridih
Widening and
Strengthening of
Kowar Kodarma
Length Of Road= 79 km Road
The Road Passes
No. Of Culverts = 44 through many thickly
populated villages.
Width of the existing
No. Of Bridges = 2 crust is 3 m.
Which is to be
widened up to 7 m.
The improvement of
this road will uplift the
social and economic
condition of the area.
A typical road section consists of
four layers-
Granular Sub Base
(GSB)
Wet Mix Macadam
(WMM)
Bituminous macadam
(BM)
The
Semi dense bituminous concrete
materials
(SDBC)
used in the above
layers has to go
through various
quality control
checks
 Some of the tests that are
done to ensure good quality
of the road are-
Water Absorption test
Aggregate Impact test
Flakiness Index
Sieve analysis
Bitumen content test
 Designing of Pavement
A traffic census had been conducted previously at three
points on the road continuously for 7 days to get average
daily traffic. Number of CV/day is obtained from it, denoted
by P
N = {365*(1+r)^n -1}
*D*F*P(1+r)^x
r
Cumulative Traffic
is found out as
given in IRC 37
-2001.
From the
Cumulative Traffic,
and known CBR
value ; we use the
Pavement design
Catalogue and
obtain thickness of
all the layers
The portion to be widened beyond the
existing crust was excavated using the
excavator.
 The GSB was brought from the mixing plant in Dumpers
and Dumped at the Site. It was then spread uniformly
ThewithGSB
the Motor
was Grader
then
compacted in layers
such that each layer did
not exceed 100 mm
compacted thickness.
Next the layer of
WMM was spread over
the GSB and was
compacted in layers.
To fill the voids
remaining, stone dust
was used, rolling was
continued until no more
dust could be forced
into the voids.
Sprinkling of water
is done with continued
rolling to obtain well
Compacted WMM is allowed to completely dry and
set before the next pavement is laid.
 Surface of
WMM is swept
clean and
dust is blown
of using
compressed
air. Once the
surface is
clean, the
Prime coat is
sprayed over
the surface
using sprayer.
The surface is
allowed to
cure24for
After 24the Tack coat or binder is uniformly
hours
hours. over the surface. Emulsion is used as binder shall
sprayed
have temperature 20 c to 50 c.
Immediately after spraying the tack coat, the layer of
BM is laid over it. The BM is brought at site by a
Dumper, at that time the temperature of BM should be
120 c.

The Dumper is slowly tilted over the Rack of the

Paving machine while both paver and dumper slowly
moves forward.
The conveyor Belt arrangement in the Paver and
leveling plate spreads the BM neatly behind as both
Dumper and paver moves forward. The Camber is
provided by adjusting the leveling plate.
Paving is accompanied with rolling. Any high spots or
depressions noticed are corrected by removing or adding
material and rolling done over it again. Water is sprinkled
over roller wheels to prevent sticking of materials to it.

Rolling must be complete before the temperature of BM

falls below 90 c
A tack coat is again applied over the BM course. The
top wearing course of SDBC is also applied with the
same process as BM.

Tolerance level for BM = 6mm

Tolerance level for SDBC = 4 mm
The rolling is done as
such each pass
overlaps with at least
one third of the track
made in preceding
pass.

The layer of SDBC is

immediately sprinkled
with Stone Dust to
prevent the sticking of
materials to shoes or
wheels.
Traffic is allowed 24
Hot Thermoplastic compound is used for marking,
which is laid with the help of a Road Marking
Machinery.
Thermoplastic material is homogenously composed of
pigments, reflecting glass beads and resins.
Binder -
18%
Glass beads -
40 %
Titanium dioxide -
10%
Calcium carbonate -
42%
Aculvertis a structure that allows water
to flow under a road
Mostly two types of culverts were
constructed along the road. RCC Culvert and
Stone Masonry Culvert.
First excavation pit for the Foundation slab was dug.
Foundation slab for both the abutments were casted as
one unit.

Series of parallel bars 8

mm dia @ 200 mm c/c are
laid on the slab
First 400 mm of the bar is
made to rest on the slab and
rest part is folded above at
right angles.
These bars are called Skin
Reinforcement.
Formwork for further
casting of substructure is
fixed.
Casting is done in two
layers of 200 mm, hence
casting of 400 mm was done
in one day.
According to the shape of the abutment, the skin
reinforcements were bent at the desired angle where
ever necessary , fixing of formwork and casting was
done as usual.
At 0.5 m above the ground level, weep holes are
provided.
Weep holes drain the water that accumulates on
either side of the abutment. Diameter of weep holes
= 75 mm @ 1m c/c

The construction till Dirt wall is completed in

following the usual procedure.
Lets see how Stone masonry Culvert was completed
till here.

Stone Masonry Culverts are built where good quality

stones are readily available. Stones of standard size
are joined using mortar one by one.
 A string is stretched along
the length of the culvert
which is used to keep the
alignment of the stones
correct while placing them.
The stones are placed at the
edges first, the flat surface
of the stone is kept facing
outward to get a good
finished surface.

Weep Holes are

provided in the same way
as in RCC Culvert.
Dirl wall is also made up
of stones, smaller size of
stones are used in it.
After construction till dirt wall is complete, the process for
further construction in both types of Culvert is same.
o The reinforcement for
the abutment cap is tied
and form work is fixed.
o Then casting of
abutment cap is done.
o Abutment cap is cured for
at least 1 week then the
formwork for slab is fixed.
o The reinforcement for slab
is tied while keeping the
necessary camber.
o Concreting of slab is done
as usual.
o The slab is now cured for
28 days
 A new bridge was proposed at
16th km of the road over the Irga
river
The old bridge was
narrow, damaged and
insufficient to carry
present traffic load.
It was a five span
bridge with total length
123 m.
Hard strata was found
at a depth of 20 m
The construction was
just started and the
location of first pile
was well marked.
A metal sheet was
folded with the help of a
machine into a desired
diameter of 1.2 m.
 A large tripod is
centered over the
point of piling
The cylinder is driven
at that point and
water is filled to make
the strata loose.
Next a pile hammer
is mounted over the
tripod with a system
of pulley and
cables.
The diameter of the
hammer is just
enough to fit in the
casing.
The hammer is then
constantly made to
drop from a height
of 5 m inside the
casing.
 When enough
strata is broken
down, the mud
collected inside
the pile gutter, is
taken out with the
help of one way
valve.
This process is
continued and it
takes near about 5
days to complete
the excavation of 20
m.
 The reinforcement bars
are then tied
30 bars of 25 mm dia
were provided as main
steel
Helical Stirrups are
provided of dia 10 mm
with a spacing of 150
mm c/c.
This reinforcement is
then placed inside the
pile casing with the help
of a crane.
Concrete is then placed
inside the pile with
Tremie method.
The tremie pipes are
coupled together and
inserted inside the pile.
It is fitted with a
The concrete is placed
on the top of the Hopper.
whole length of pipe is
filled with concrete.
The tremie pipe is lifted
up and a slight jerk is
given by pulley and
cable arrangement.
The concrete gets
discharged in the pile,
the end of the tremie
pipe remains dipped in
the concrete so no mud
enters the tremie pipe.
This method is
continued until
concreting for whole of
the pile is complete.
The concrete does not
get affected due to mud
except the top layer.
Thank
You