This document describes an internship report on the construction of a cement concrete road by Deepak Athwal at the Public Works Department in Mainpuri, Uttar Pradesh, India from June 26 to July 24, 2014. It provides details on the materials, design, and process used to construct an 800 meter long, 7 meter wide cement concrete road with a cost of 4.5 crore rupees. Key steps in the construction included preparation of the subgrade and base, formwork, mixing and placing concrete, compaction, curing, and allowing the road to be opened for traffic. Standard tests were performed on the concrete including slump, compression, and cube tests to ensure quality.

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A
INTERNSHIP REPORT
ON
CONSTRUCTION OF
CEMENT CONCRETE ROAD
AT
U.P P.W.D, PROVINCIAL DIVISION
MAINPURI, UTTAR PRADESH
TRAINING PERIOD ( 26 JUNE 2014 TO 24 JULY 2014)
SUBMITED BY : DEEPAK ATHWAL

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CIVIL : 3RD YEAR
ROLL .NO : 111940015
H. R. INSTITUTE OF TECHNOLOGY, GHAZIABAD

3. ACKNOWLEDGEMENT
It is indeed a great pleasure and privilege to present this report on training at
PWD.
I am extremely greatfull to my training and placement officer for issuing a
training letter, which made my training possible at PWD, U.P .
I would like to express my gratitude to Er. SATYAPRAKASH for his invaluable
suggestion , motivation , guidance and support through out the training
period . his methodology to start from simple and then deepen the concept
made me to bring out this project report without anxiety.
Thanks to all other PWD officials , operators and all other members of PWD
,especially. Er AZAD SINGHWAL accounted for their help in completing the
project and see light of success.
Dated DEEPAK ATHWAL
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ABSTRACT.
This project is about the construction of the CC road at the KUSHMARA situated at mainpuri
district u.p. This project is under the pwd, pd, mainpuri of having construction length of 800
mm of cc road, having widt h of 7 m .
With having cost of 4.5 crore

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INDEX
1. PWD Introduction ………………………………
2. About Cement road ………………………….
3. Material ……………………………………………
4. Design of concrete mix used………………
5. Tests …………………………………………………..
6. Cement road construction ………………
 Preparation of subgrade …………
 Preparation of base …………………
 Form work …………………………………..
 Watering of base ………………………

6.  Joints ……………………………………........
 REINFORCEMENT……………………………..
 Material mix & placing ……………
 Compaction …………………………………
 Finishing of surface…………………..
 Curing …………………………………………
 Filling joint………………………………
 Edging ………………………………………..
7.Open to traffic…………………………
8. Reference……………………………………….
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PWD INTRODUCTION
Introduction Point of view geographic and population of the state is the nation's largest
state. State Industrial, economic and social development of the state and the population
of each village is absolutely necessary to re-connect to the main roads. In addition to
state important national roads, state roads and district roads and their proper broad be
made to improve the quality of traffic point of view is of particular importance. Public
Works Department to build roads and improve connectivity in rural zones, Other District
Road and State broad and improvement of rural roads and main routes narrow
construction of zones and depleted bridges brides reconstruction of the bases are
transacted on a priority basis .
Also under Pradhan Mantri Gram Sadak Yojana and pre-fabricated construction of rural
roads linking the work of other district roads broad Suddikrn the scale bases are edited.
Successful operation of various schemes for the Public Works Department engineers and

7. supervisory boards in different districts of the engineer’s office has been settled. Activities
by planning, execution, and quality control etc. remove impediments find joy in relation
to the supervision over the activities are focused. Various schemes operated by the
Department of the Office of the Regional Chief Engineers and Chief Engineers office.
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ABOUT CEMENT ROAD
A road is a thoroughfare, route, or way on land between two places, which has been
paved or otherwise improved to allow travel by some conveyance, including a horse, cart,
or motor vehicle. Roads consist of one, or sometimes two, roadways (carriageways) each
with one or more lanes and also any associated sidewalks (British English: pavement) and
road verges. Roads that are available for use by the public may be referred to as public
roads or highways.
MATERIAL
Concrete is widely used in domestic, commercial, recreational, rural and educational
construction. Communities around the world rely on concrete as a safe, strong and
simple building material. It is used in all types of construction; from domestic work to
multi-storey office blocks and shopping complexes. Despite the common usage of
concrete, few people are aware of the considerations involved in designing strong,
durable, high quality concrete. There are mainly three types
1-Cement

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2-Sand
3-Aggregate.
CEMENT.
A cement is a binder, a substance that sets and hardens independently, and can bind
other materials together. The word "cement" traces to the Romans, who used the term
caementiciumto describe masonry resembling modern concrete that was made from
crushed rock with burnt lime as binder. The volcanic ash and pulverized brick additives
that were added to the burnt lime to obtain a hydraulic binder were later referred to as
cementum, cimentum, cement, and cement.
Cements used in construction can be characterized as being either hydraulic or non-hydraulic.
Hydraulic cements (e.g., Portland cement) harden because of hydration, a
chemical reaction between the anhydrous cement powder and water. Thus, they can
harden underwater or when constantly exposed to wet weather. The chemical reaction
results in hydrates that are not very water-soluble and so are quite durable in water.
Non-hydraulic cements do not harden underwater; for example, slaked limes harden by
reaction with atmospheric carbon dioxide. The most important uses of cement are as an
ingredient in the production of mortar in masonry, and of concrete, a combination of
cement and an aggregate to form a strong building material.

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Types of Cement:
 Portland cement:
Portland cement is by far the most common type of cement in general use around the
world. This cement is made by heating limestone (calcium carbonate) with small
quantities of other materials (such as clay) to 1450 °C in a kiln, in a process known as
calcination, whereby a molecule of carbon dioxide is liberated from the calcium carbonate
to form calcium oxide, or quicklime, which is then blended with the other materials that
have been included in the mix. The resulting hard substance, called 'clinker', is then
ground with a small amount of gypsum into a powder to make 'Ordinary Portland
Cement', the most commonly used type of cement (often referred to as OPC). Portland
cement is a basic ingredient of concrete, mortar and most non-specialty grout. The most
common use for Portland cement is in the production of concrete. Concrete is a
composite material consisting of aggregate (gravel and sand), cement, and water. As a
construction material, concrete can be cast in almost anyshape desired, and once
hardened, can become a structural (load bearing) element. Portland cement may be grey
or white.

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 Portland fly ash cement:
Its contains up to 35% fly ash. The fly ash is pozzolanic, so that ultimate strength is
maintained. Because fly ash addition allows a lower concrete water content, early strength
can also be maintained. Where good quality cheap fly ash is available, this can be an
economic alternative to ordinary Portland cement.
 Portland pozzolana cement :
Its includes fly ash cement, since fly ash is a pozzolan , but also includes cements made
from other natural or artificial pozzolans. In countries where volcanic ashes are available.

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 Portland silica fume cement:
Addition of silica fume can yield exceptionally high strengths, and cements containing 5–
20% silica fume are occasionally produced. However, silica fume is more usually added to
Portland cement at the concrete mixer.
SAND:
Sand is a naturally occurring granular material composed of finely divided rock and
mineral particles. The composition of sand is highly variable, depending on the local rock
sources and conditions, but the most common constituent of sand in inland continental
settings and nontropical coastal settings is silica (silicon dioxide, or SiO2), usually in the
form of quartz.
The second most common type of sand is calcium carbonate, for example aragonite,
which has mostly been created, over the past half billion years, by various forms of life,
like coral and shellfish. It is, for example, the primary form of sand apparent in areas
where reefs have dominated the ecosystem for millions of years like the Caribbean.
 Composition:
In terms of particle size as used by geologists, sand particles range in diameter
from 0.0625 mm (or 1⁄16 mm) to 2 mm. An individual particle in this range size
is termed a sand grain. Sand grains are between gravel (with particles ranging
from 2 mm up to 64 mm) and silt (particles smaller than 0.0625 mm down to

12. 0.004 mm). The size specification between sand and gravel has remained constant
for more than a century, but particle diameters as small as 0.02 mm were
considered sand under the Alter berg standard in use during the early 20th
century. A 1953 engineering standard published by the American Association of
State Highway and Transportation Officials set the minimum sand size at 0.074
mm.
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Aggregate
Aggregates are inert granular materials such as sand, gravel, or crushed stone that, along
with water and Portland cement, are an essential ingredient in concrete. For a good
concrete mix, aggregates need to be clean, hard, strong particles free of absorbed
chemicals or coatings of clay and other fine materials that could cause the deterioration
of concrete. Aggregates, which account for 60 to 75 percent of the total volume of
concrete, are divided into two distinct
categories-fine and coarse. Fine aggregates generally consist of natural sand or crushed
stone with most particles passing through a 3/8-inch (9.5-mm) sieve. Coarse aggregates
are any particles greater than 0.19 inch (4.75 mm), but generally range between 3/8 and
1.5 inchs(9.5 mm to 37.5 mm) in diameter. Gravels constitute the majority of coarse
aggregate used in concrete with crushed stone making up most of the remainder.
Natural gravel and sand are usually dug or dredged from a pit, river, lake, or seabed.
Crushed aggregate is produced by crushing quarry rock, boulders, cobbles, or large-size

13. gravel. Recycled concrete is a viable source of aggregate and has been satisfactorily used
in granular subbases, soilcement, and in new concrete. Aggregate processing consists of
crushing, screening, and washing the aggregate to obtain proper cleanliness and
gradation. If necessary, a benefaction process such as jigging or heavy media separation
can be used to upgrade the quality.
Once processed, the aggregates are handled and stored in a way that minimizes
segregation and degradation and prevents contamination.
Aggregates strongly influence concrete's freshly mixed and hardened properties, mixture
proportions, and economy. Consequently, selection of aggregates is an important process.
Although some variation in aggregate properties is expected, characteristics that are
considered when selecting aggregate include:
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 grading
 durability
 particle shape and surface texture
 abrasion and skid resistance
 unit weights and voids
 absorption and surface moisture
Grading refers to the determination of the particle-size distribution for aggregate.
Grading limits and maximum aggregate size are specified because grading and size affect
the amount of aggregate used as well as cement and water requirements, workability .
Shape and size
Particle shape and surface texture influence the properties of freshly mixed concrete
more than the properties of hardened concrete. Rough-textured, angular, and elongated
particles require more water to produce workable concrete than smooth, rounded
compact aggregate. Consequently, the cement content must also be increased to maintain
the water-cement ratio. Generally, flat and elongated particles are avoided or are limited

14. to about 15 percent by weight of the total aggregate. Unit-weight measures the volume
that graded aggregate and the voids between them will occupy in concrete. The void
content between particles affects the amount of cement paste required for the mix.
Angular aggregate increase the void content. Larger sizes of well-graded aggregate and
improved grading decrease the void content. Absorption and surface moisture of
aggregate are measured when selecting aggregate because the internal structure of
aggregate is made up of solid material and voids that may or may not contain water. The
amount of water in the concrete mixture must be adjusted to include the moisture
conditions of the aggregate. Abrasion and skid resistance of an aggregate are essential
when the aggregate is to be used in concrete constantly subject to abrasion as in heavy-duty
floors or pavements. Different minerals in the aggregate wear and polish at different
rates. Harder aggregate can be selected in highly abrasive conditions to minimize wear.
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Design of concrete mix used
IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15,
M20, M25, M30, M35 and M40. In this designation the letter M refers to the mix and the
number to the specified 28 day cube strength of mix in N/mm2. The mixes of grades M10,
M15, M20 and M25 correspond approximately to the mix proportions (1:3:6), (1:2:4),
(1:1.5:3) and (1:1:2) respectively.
The design of concrete mix used in this project has been approved by the a well known
institute H.B.T.I. Kanpur . In this project we have used the M20 concrete.
Test
There are four main tests to be done on concrete:
1. The Slump Test.
2. Compression Test
3. Impact Test
4. Cube Test

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THE SLUMP TEST
The slump test is done to make sure a concrete mix is workable. Workability measures
how easy the concrete is to place, handle and compact
 Standard slump cone (100 mm top diameter x 200 mm bottom diameter x 300
mm high)
 Small scoop Bullet-nosed rod (600 mm long x 16 mm diameter )
 Rule Slump plate (500 mm x 500 mm)
Method
 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.
 Stand firmly on the footpieces and fill 1/3 the volume of the cone with the sample.
Compact the concrete by 'rodding' 25 times. Rodding 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.
 Now fill to 2 /3 and again rod 25 times, just into the top of the first layer.

16.  Fill to overflowing, rodding again this time just into the top of the second layer.
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Top up the cone till it overflows.
 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 footpieces.
 Carefully lift the cone straight up making sure not to move the sample.
 Turn the cone upside down and place the rod across the up-turned cone.
THE COMPRESSION TEST
The compression test shows the compressive strength of hardened concrete. 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 Megapascals(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. Tools 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 ) Small scoop Bullet-nosed rod (600 mm x 16 mm) Steel float Steel
plate.
Method

17.  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
 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. . Fill the cone to overflowing and rod 25 times into the top of the first 4
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layer
 then top up the mould till overflowing.
 Level off the top with the steel float and clean any concrete from around the
mould.
 Cap, clearly tag the cylinder and put it in a cool dry place to set for at least 24
hours.
 After the mould is removed the cylinder is sent to the laboratory where it is
cured and crushed to test compressive strength.
Impact Testing

18. An impact test is a dynamic test conducted on a selected specimen which is usually
notched. The specimen is struck and broken by a single blow in a specially designed
machine. This demo illustrates the experiment setup, procedure and the energy absorbed
in an impact test.
18
Cube Test
Test applied to the concrete, this is the utmost important which gives an idea about all
the characteristics of concrete. By this single test one judge that whether Concreting has
been done properly or not.

19. For cube test two types of specimens either cubes of 15 cm X 15 cm X 15 cm or 10cm X 10
cm x 10 cm depending upon the size of aggregate are used. For most of the works cubical
moulds of size 15 cm x 15cm x 15 cm are commonly used.
This concrete is poured in the mould and tempered properly so as not to have any voids.
After 24 hours these moulds are removed and test specimens are put in water for curing.
The top surface of these specimen should be made even and smooth. This is done by
putting cement paste and spreading smoothly on whole area of specimen.
These specimens are tested by compression testing machine after 7 days curing or 28
days curing. Load should be applied gradually at the rate of 140 kg/cm2 per minute till
the Specimens fails. Load at the failure divided by area of specimen gives the compressive
strength of concrete.
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APPARATUS
Compression testing machine.
PREPARATION OF CUBE SPECIMENS
The proportion and material for making these test specimens are from the same
concrete used in the field.
SPECIMEN
6 cubes of 15 cm size Mix. M15 or above

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MIXING
Mix the concrete either by hand or in a laboratory batch mixer.
HAND MIXING
 Mix the cement and fine aggregate on a water tight none-absorbent platform until
the mixture is thoroughly blended and is of uniform color
 Add the coarse aggregate and mix with cement and fine aggregate until the coarse
aggregate is uniformly distributed throughout the batch
 Add water and mix it until the concrete appears to be homogeneous and of the
desired consistency.
PRECAUTIONS
The water for curing should be tested every 7days and the temperature of water must be
at 27+-2oC.
PROCEDURE
 Remove the specimen from water after specified curing time and wipe out excess
water from the surface.
 Take the dimension of the specimen to the nearest 0.2m
 Clean the bearing surface of the testing machine
 Place the specimen in the machine in such a manner that the load shall be applied
to the opposite sides of the cube cast.
 Align the specimen centrally on the base plate of the machine.
 Rotate the movable portion gently by hand so that it touches the top surface of
the specimen.

21.  Apply the load gradually without shock and continuously at the rate of
140kg/cm2/minute till the specimen fails
 Record the maximum load and note any unusual features in the type of failure.
21
Using mix Concrete
There some Point to construct the road
1. Preparation of subgrade
2. Preparation of base
3. Form working
4. Watering of base
5. Joints
6. Material mix & placing
7. Compaction
8. Finishing of surface
 Floating
 Belting
 Brooming
9. Curing
10. Joint filling
11. Edging
12. Open to traffic

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1. Preparation of subgrade
1. Rolling on sub grade by roller
2. Filling the granular soil in the weak part and pot holes
3. Correct the soil coat , Camber , longitudinal slop.
When concrete direct laid on sub grade, For preventing the water seepaging into the soil
, used water proof paper on entire length.
2. Preparation of base
( Actual site scene of construction )

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Choose any one type of base
 W.B.M. base As base material of W.B.M. Road; stone ballast, concrete 10-15cm layer
are used. For bonding between concrete slab & W.B.M. used 1:2 cement wash on
W.B.M.
 Concrete base On the road used 10cm Cement concrete(1:2:4) or lime
concrete(16:32:64)
 Granular medium material layer 10-15cm composite layer of sand , moorum,
bajriare usedfor better drainage facilities
 Stabilization soil
3. Form work
Material for form work Wooden sheets, battens, plywood, fibre hard board, steel plates,
angles, rope, minerals.
 before using form work, it should free from all type material like as dust cement.
 To placing the concrete in appropriate depth used 2.5-5cm thick and 3mtr long
wooden sheeting.
 The depth of wooden block must be same as level of slab thick.
 After 24hrs form work displaced next length of road.
4. Watering of base
If base is dry Than using the sprinkling process on it properly after that placing the
concrete.
5. Joints
Where is necessary to provide transverse, Longitudinal joints; there wedge of woods,
metals fix on level of concrete. After setting of concrete it should be pull out. If provided
the dowel bar in joints, bars should be fit at right position.

24. REINFORCEMENT
Reinforcement is provided at depth between 3cm to 10 cm from the top of the
CC road. This is provided for the tensile strength of the CC road. Also to maintain the
friction between the vehicle and the surface.
But the main advantage of providing the reinforcement is to avoid the expansion of the
surface due to the increase of the surface temperature.
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(actual site scene of providing the reiforcement )
6.Material mix & placing
Mixer is equipment that mix the concrete using distinct amount of cement , concrete,
sand and water. Concrete slab should have more than 5-10cm thick cause of drying.

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Used two type mixer
1. Batch mixer
a. At site, used for small road construction
2. Continuous mixer
a. Continuous mixer used for large construction . if distance is more from site
, mix concrete transported at site within setting time.
Two methods generally used in placing of concrete
1. Alternate bay method
a. Placed the concrete on both side of road alternatively like as1,3,5… part at
one side and 2,4,6… part other side
1st side
2nd side
This method have slow process due to road traffic problems.
2. Continuous bay method

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(Actual site scene of continous bay )
construct one side of road regularly, if completed some part of first side than
construct other side. this method have fast process without no obstruction of
traffic
7. Compaction
Purpose of compaction is that to pull out air from void and make concrete harden.

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Compaction done by
1.Mechanically surface vibrator
2. Manually hand tempers
8. Finishing of surface
1.Floating
For levelling the surface use floating, scree-ding , power trowel. So that there is no
acceptable more than 3mm variation in concrete level surface.
2.Belting
For making surface clean used belting process. Belt is nothing but a 15-30cm
thick sheets of canvass which have more length than road.
3. Brooming
Brooming is the process in which we made rough surface parallel to road by brush. It
useful in avoiding slip & comfortable travelling on road . The depth of line on road no
more than 1.5mm.
9. Curing
Curing is the name of increasing the hydration process of cement. after setting the
concrete , curing process done till 14-28days.
Some methods of curing are
 Shading concrete works
 Covering with hessian & gunny bags
 Sprinkling of water

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 By ponding
 Membrane curing
 Steam curing
10. FILLING JOINT
After drying road, clean the joints and fill the shelling compound or hot bitumen . also
bitumen fill road bank.
11. EDEGING
To protect damaging the sides of concrete pavements used over burnt brick work. in
place of brick, provided kerb of pre mix concrete.
12.open to traffic
Generally after a month, road should be open to traffic. If used rapid hardening cement it
take 7 days to open traffic.
Reference

31. www.Google.com
www.concrete.net.au
www.res.gov.in
www.upjl.com
www.concrete.com
www.sand.uk
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