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INTERNSHIP AT TARUN DRAWING AND CONSTRUCTION

AN INTERNSHIP REPORT ON ROAD CONSTRUCTION

In partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY
in

CIVIL ENGINEERING

SUBMITTED BY:

SUNIL KUMAR SAINI

AMITY SCHOOL OF ENGINEERINGAND TECHNOLOGY

AMITY UNIVERSITY JAIPUR RAJASTHAN

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I hereby declare that this submission is my own work and to the best of my
knowledge and belief, it contains no material previously or written by another
person nor materialwhich to a substantial extent has been accepted for the award
of any other degree or diploma of the university or other institute of higher
learning, except where due acknowledgment has been made in the text.

NAME SUNIL KUMAR SAINI

ROLL NO. A20415822006 DATE

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ACKNOWLEGMENT

I express my satisfaction on 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 Teachers
and mentor for his kind guidance during the entire period of training, His
consistent support and advices has helped me to complete this research project
successfully. Also I thank all the members of Sun Rise Infra Pvt Ltd Rajasthan.
for their kind support. They have always been a source of inspiration to me.

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Table of Contents
• Introduction
.About the company

. Project feature
• Introduction of Road construction
• Introduction of Bitumen Road
• Bitumen Road Layer
• Materials
• Step of Bitumen Road Construction
• Equipment Uses in the Road Construction
• My roles and responsibilities
• Merit and Demerit of Bitumen Road Pavement
• Conclusion
• My overall Experience

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Introduction
It is planned based on the benefit which it gives for both the students and their
hosting company This report has been written because it is curtailing to senior
students like me to real exposure for the practical application of what we
learned in the class.
As mention in the first paragraph students and the company can benefit from
this program; for instance;

For the Students:-

-Have the opportunity to develop interpersonal skills with workers
-Have an opportunity to gain practical skill

For the Company;

-They have an opportunity to obtain well-skilled persons
-The gate opportunity to advert

About The Company

• Name: SUNRISE Infra Engineering pvt ltd
• Location: Plot No.80,Second Floor ,Rathore Nagar, Vaishali nagar ,Jaipur
Rajasthan- 302021
• Nature of work: various services in civil construction business such as road,
bridge, irrigation, building

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Project Features

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Introdution to Road construction

HISTORY OF ROAD DEVELOPMENT OF INDIA
The history of road development in India is not very long. The first construction
in National Highway road was started in the UP 2022. In the 1950s.the road length
of the country was only 376 km .Currently 18,828 km including District and
Urban Roads. The Government of Indi has been giving high priority to the
development of roads since the beginning of planned development programmes
in 1956.Linking of Delhi with the southern border was taken up in 1953 with
Indian assistance and was opened for traffic in 1956.The Government of
India constructed the Delhi- Lucknow road in 1966.The same time, the
Government of India initiated to construct the east–west highway (1,028Km)
with the support of bilateral and multilateral agencies. At present, the
Strategic Road Network consists of 15 national highways and 51 feeder roads
totaling 7,917 km. The government plans to extend Delhi to 9,900 km by 2022.
Development of country depends on the connectivity of various place with
adequate road network. Road are the major channel of transportation for carrying
goods and passenger. They play in significant role of the socio-economic
standards of a region .Road constitute the most important mode of
communication in area where Railways have not developed much and form the
basic infra-structure for the development and economic growth of country
.The benefits From the investment in road sector are indirect, long term and not
immediately visible. Road are import assets for any nation . India are large
country having huge resource of materials. If these local material are used
properly, the cost of construction can be reduces .There are various type of
pavement which differ in their suitability in different environment .Each type
of pavement has its own merits and demerits . India has one of largest road
networks in the world (over 3 million km at present).We are going to the
vocational training on the 16.602km length of flexible pavement

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TYPE OF PAVEMENT

PAVEMENT
➢Pavement or Road I an open , generally public way for passage of vehicles ,
people and animals .
➢Pavement is finished with a hard smooth surface . It helped make them durable
and able to withstand traffic and the environment . They have a life span of
between 20-30 years.
PURPOSE
Many people rely on paved roads to move themselves and their products

TYPE OF PAVEMENT
There are mainly two types of pavement depending upon the material used .
1. RIGID PAVEMENT
2. FLEXIBLE PAVEMENT
1) RIGID PAVEMENT Rigid pavements , through costly in initial investment ,
are cheap in long run because of low maintenance cost. There are various merits
in the use of rigid or summarized below:-
➢ The demand for bitumen in coming year is likely to grow steeply,far
outstripping the availability.hence it will be in India’s interest to explore
alternative binder.Cement is available in sufficient quantity in India,and its
availability in the future is also assured.
➢ Beside the easy available of cement,concrete road have a long life and are
practically maintencefree

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➢ Another major advantage of concrete roads in the saving in fuel by

commercial vehicles to an extent of 14-20%.The fuel saving themselves
support a large programme of concreting.
➢ Cement concrete road save a substantial quantity of stone aggregate and
this factor must be consider when a choice pavement is made.
➢ Though cement concrete road may cost slightly more then a flexible
pavement initially,they are economical when whole life costing is considered

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INTRODUCTION TO BUTIMEN

2) FLEXIBLE PAVEMENT
Bitumen has widely used in the construction of flexible pavement for a long
time.This is most convenient and simple type of construction.the cost of
construction of single lane bituminous pavement varies from 20 to 30 lacks per
km in plain area.
Bitumen is a black or dark colored or viscous cementitious substance having an
adhesive properties.
1) It consist chiefly high molecular weight hydrocarbons derived from
distillation of petroleum or natural asphalt.
2) It is semi-solid hydrocarbons product produced by removing the lighter
friction such as liquid petroleum gas , petrol and diesel from heavy crude oil
during the refining process.
3) Bitumen is often confused with tar.Although bitumen and coal tar similarly
black and sticky,they are distinctly different substance in origin,chemical
composition and in their properties.

ORIGIN :-Asphalt material have been utilized since 3500 B.C .In building
and road construction.Their main uses have been as adhes uses have been as
adhesive and water proof agents.

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INTRODUCTION TO BITUMINOUS ROAD

➢ Bituminous road is road constructed by using bitumen.It is also called flexible
pavement because it change it shape according to nature of load and sub base.
➢ A road or pavement is a structure consisting of superimposed layer of proceed
materials above the natural soil sub-grade, whose primary function is to
distribute the applied vehicle loads to the sub grads.

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CONSTITUENTS OF BITUMEN MIX

. Coarse aggregate ( retained on 4.75mm sieve )

. Fine aggregate(passing 4.75mm sieve but retained on 75micro)
• Finer(passing 75 micro)may be cement • Binder: bitumen
BITUMEN ROAD LAYER
Mainly four types of layer has present in flexible pavement they are:-
1) Sub-grade course
2) Sub-base course
3) Base course
4) Surface course
Sub-grade course:-
Top of the ground on which the foundation of road rest is called sub
grade.The sub grade material is cleaned and free from organic matter and
should be compacted by roller, to from stable sub base.Its thickness is 20-
30cm.

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SUB-BASE COURSE:-
It is layer of granular material provided above sub grade generally natural
gravel. It is usually not provided on sub grade of good quality. Its thickness is
10-15mm

BASE COURSE:-
It is the layer immediately under the wearing surface (Applied
whether the wearing surface is bituminous or cements concrete and
whether it’s a thick or thin bituminous layer).its thickness is 10-15cm

SURFACE COURSE:-
The top layers of pavement which is in direct contact with the wheel
of the vehicle. Usually constructed of material in which bitumen is
used as binder materials.
Its thickness is 25-50mm

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MATERIAL

Pavement Material Asphalt and concrete are the most common paving materials
found in the developed landscape. However, there are other strong,
durable pavements that can add variety to the built landscape and help reduce
pavement's imperviousness. The following is a review of selected paving
materials:

1 Asphalt :-
Bituminous concrete or asphalt is composed of aggregates bound together
with asphalt cement. The aggregate is heated and mixed with hot (275º f)
asphalt then taken to the construction site where it is placed, as a wearing
surface, over a base course. The asphalt is laid by hand and paving machine,
then rolled to force the mixture to firmly set. It is then allowed to cool, typical
asphalt pavement has a life expectancy of 20 years before it needs resurfacing.
Asphalt pavement is composed of the following two layers, the wearing course
and the base course The Wearing Course transfers and distributes traffic
loads to the base course. The Wearing course is actually composed of two
layers, a 1-1/4" to 1-1/2" surface layer nd a 3" bonding layer. The bonding
course penetrates voids in the sub base and binds the wearing course to the sub
base aggregate.

2. Stone: Stone is a durable paving surface that is available in either

natural or synthetic form. Natural paving stone is graded based on its' hardness,
porosity and abrasion resistance. It is available either in cut or uncut form in
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various degrees of smoothness. Examples of uncut or rubble stone, are broken

quarry rock and river stone available in Varying degrees of smoothness. Crushed
stone of various sizes and hardness is used as sub-base for other surface materials,
surface pavement or ground cover. When mixed with asphalt or concrete, crushed
stone or aggregate is used in the wearing and base coarse of roads, drives, parking
lots and sidewalks. Larger stones are mixed with asphalt or concrete when a
rougher or more porous surface is desired.

3. Earth Materials: Earth materials used for paving include gravel, soil,
granular products, and turf. The volume of earth materials is determined by its
state in the earth moving process. For example a cubic yard of gravel as it lies in
its natural, undisturbed state usually swells to 1.25 cubic yards after it has been
disturbed by excavation. The same quantity of gravel decreases in volume to
about .90 cubic yards after it has been compacted by machinery on site.

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Step of Bitumen Road Construction

Bitumen road construction consists of various steps such as preparation of base
course, application of bituminous coat, placement of bituminous mix, rolling and
check for quality etc. which are discussed.

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 deg C and
the aggregate temperature should not differ by over 14 deg 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 deg 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.

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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 tonnes roller and the intermediate rolling is done with a fixed wheel
pneumatic roller of 15 to 30 tonnes having a tyre pressure of 7kg per sq.cm. 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 tonnes 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 atleast 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
Equipment uses in road construction:-
1.) Motor Grader commonly referred to as road grader or a maintainer,
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motor grader is equipment used to create flat surfaces for asphalt to

be placed on.

2.) Asphalt Mixing Plant

An asphalt plant is used for the manufacture of asphalt concrete and other forms
of coated road-stone used in road construction projects. It combines mineral
aggregates, sand and a filler – in correct proportions, heats the mixture and then
coats it with a binder.
The plant then keeps the final product heated to avoid setting before the product
is laid down in layers.

3) Crawler Excavator
Also referred to as diggers, excavators are heavy construction

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equipment used for excavating earth and rocks and loading

them onto a dump trucks.

4) Rollers:-
Rollers are heavy road construction machines used for compacting hot and
therefore flexible asphalt pavements.

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5) Paver
Use to lay BC DBM and WMM in level on roads bridge and other such places
with small compaction

6) Crusher plant
Designed to reduce the large stone into the smaller size and output gravel dust
different size of the material.

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COMPACTION TEST
Field Density Tests

1.Core Cutter method

Equipment for Core Cutter Method

1.Cylindrical core cutter, 100mm internal diameter and 130mm long

2.Steel rammer, mass 9 kg, overall length with the foot and staff about
900mm.
3.Steel dolley, 25mm high and 100 mm internal diameter
4.Weighing balance, accuracy 1g.
5.Palette knife
6.Straight edge, steel rule etc

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Procedure of Core Cutter Method

1.Determine the internal diameter and height of the core cutter to the
nearest 0.25mm
2.Determine the mass (M1) of the cutter to the nearest gram.
3.Expose a small area of the soil to be tested. Level the surface, about
300mm square in area.
4.Place the dolley over the top of the core cutter and press the core cutter
into the soil mass using the rammer. Stop the pressing when about 15mm
of the dolley protrudes above the soil surface.

5.Remove the soil surrounding the core cutter, and take out the core cutter.
Soil soil would project from the lower end of the cutter.
6.Remove the dolley. Trim the tip and bottom surface of the core cutter
carefully using a straight edge.
7.Weigh the core cutter filled with the soil to the nearest gram (M2).
8.Remove the core of the soil from the cutter. Take a representative sample
for the water content determination.
9. Determine the water content

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CURING
Curing is the process of increasing hydration in cement; after setting the
concrete, curing process is done till 20 to 25 days. There are some method of
curing-
•Shading concrete works
•Covering with hessian & gunny bags
•Sprinkling of water
•By ponding
•Membrane curing

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My Roles and Responsibilities

• Record the temperature of bitumen before mixing, after mixing and at the
time of spraying on site.
• Visit construction sites at which our brand represents are being used, from
time to time and offer technical assistance.
• Look into any matter of dispute that may occur regarding quality of the
Bitumen.
• Help site engineers with mix design.
• Guide engineer less projects about good construction practices.
• Give feedback to operation department regarding genuine issues with
Bitumen.

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MERIT AND DEMERIT OF BITUMINOUS PAVEMENT

MERIT OF BITUMINOUS PAVEMENT,

1.It does not make use of any joints; Hence provide a smooth surface to ride. It
also gives less sound emission when compared with concrete pavements. The
wear and tear are less in the bituminous pavement, thus maintaining the
smoothness.
2.The deformation and the failure in the bituminous pavement is a gradual
process. The concrete pavement shows brittle failures.
3.They have an option to be repaired to be quick. They don't consume
time in reverting the path for traffic; as they set fast.
4.This helps in carrying out staged construction in a situation when problems of
fund constraint or traffic estimation problems are faced.
5.The initial cost and overall maintenance cost of bituminous pavement are less
compared to concrete pavement.
6.They act resistant against high temperature from melting and are not affected
by de-icing materials

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DEMERIT OF BITUMINOUS PAVEMENT

1.Bituminous pavements are less durable

2.Low tensile strength compared to concrete pavement
3.Extreme weather and improper weather conditions tend to make bituminous
pavement slick and soft.
4.Bitumen with impurities can cause pollution to soil, hence ground water by
their melting. These may have hydrocarbons in small amounts.
5.Clogging of pores and drainage path during construction and service life
6.More salting- to prevent snow during winter season
7.Cost of construction high during extreme conditions of temperature

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Conclusion:
During internship period a lot of experience, knowledge and exposure that I
have handled .Practical is a complement to the science or theory learned.
There are many changes from the point of learning environment. It can directly
increase the dedication and rational attitude towards myself. However, there
areas till some weakness that can be improved in the future. Therefore, I
conclude that the industrial training program has provided many benefits
to students even if the rare minor flaws that are some what disfiguring
condition ,so that this weakness
can be rectified in the future.
I would like to thank my training Assistant Rupesh Gauniyal to help in my
training.

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My Overall Experience:
My experience of working with. J&J Buildcon Pvt Ltd, was an amazing one.
I found many engineers there who were willing to help me every time.
The contractors and the labour was also supportive. We faced many problems
which we solved them ourselves. Sometimes we had to take help of the Project
Incharge , Rupesh Gauniyal who helped us everywhere in every conditions.
The team of the company was very supportive. The HR, lab head, company head,
and all the engineers were supportive. I thank all of them for making my
internship a great

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