orissa state road project - osrposrp.gov.in/sites/default/files/pdf/material report.pdf · orissa...

AUGUST - 2006

GOVERNMENT OF ORISSA

WORKS DEPARTMENT ORISSA STATE ROAD PROJECT

MATERIAL REPORT( Part –III )

( PHASE-I , FIRST YEAR ROADS )

C O N S U L T I N G Engineers Group Ltd. Jaipur E-12, Moji Colony, Malviya Nagar , Jaipur, Raj.

+ 91-141-2520899, Telefax +91-141-2521348 E-mail : [email protected] URL : www.cegindia.com

Consulting Engineers Group Ltd., Bhubaneswar Material Report–III

__________________________________________________________________________________________ Consultancy Service for Feasibility Study and Detailed Project Preparation for Proposed Orissa State Road Project

MATERIAL INVESTIGATION REPORT

BHAWANIPATNA- KHARIAR (SH-16)

(KM 0.0/0.0 to KM 70.0/0.0)

C O N T E N T S

CHAPTER NO.

DESCRIPTION PAGE NO.

1. Introduction 1-1 to 1-14

2. Earthwork For Embankment & Sub grade 2-1 to 2-90

3. Fly Ash For Embankment 3-1 to 3-5

4. Granular Sub Base material 4-1 to 4-21

5. Coarse Aggregate 5-1 to 5-18

6. Sand / Fine Aggregate 6-1 to 6-8

7. Cement / Cement concrete 7-1 to 7-10

8. Water 8-1 to 8-2



List of Annexures (Figures And Tables)

NO. DESCRIPTION PAGE NO.

1.1 Road Location Map 1-5

1.2 Borrow area chart for Bhawani Patna to Kheriar.( Km 0/0 to Km70/0.0)

1-6 to 1-10

1.3 Photos for in-situ Sub-grade / Quarry sample collection 1.11 to 1-14

2.1 Soil Investigation Data of Existing Subgrade 2-7 to 2-14

2.2 Record of Quarry / Borrow area details 2-15 to 2-19

2.3 Soil Investigation Data of Borrow area Soil 2-20

2.4 Grain size Analysis curves for Sub grade Soil 2-21 to 2-90

3.1 Fly ash test results 3-3 to 3-4

4.1 Test Results of Granular sub Base Material from Borrow area

4-10 to 4-12

4.2 Test Results of Granular sub Base Material from Borrow area (After Blending)

4-13 to 4-15

5.1 Test results of Stone Metal / Aggregates from Quarry 5-13 to 5-18

6.1 Test results of River Sand / Fine Aggregates 6-5 to 6-7

6.2 Test results of River Sand / Fine Aggregates ( For Construction Purpose.)

6-8



SOIL INVESTIGATION REPORT BHAWANI PATNA TO KHERIAR (SH-16)

KM 0.0/0.0 TO 70/0.0

RELEVANT IS :CODES USED FOR REFERENCE OF LABORATORY/INSITU TESTING AND ANALYSIS OF TEST RESULT

S. No. Name of Test Relevant IS Code

1. Natural Moisture content

determination

IS : 2720 Part II

2. Dry unit weight B.S 1377

3. Specific gravity IS : 2720 Part III

4. Liquid Limit IS : 2720 Part V

5. Plastic Limit IS : 2720 Part V

6. Grain Size Analysis IS : 2720 Part IV

7 CBR IS : 2720 Part XVI

8. Soil Classification IS : 1498

9. Standard/Modified Proctor IS : 2720 Part VIII

10. DFS IS : 2720 Part XXXX

11. Chemical analysis of soil IS : 2720 Part XXVII

12. Chemical analysis of water IS : 3025,456

13. Coarse / Fine Aggregate Testing 2386 pt I to v, & 383

14. Stripping Value IS : 6241

15 Cement IS : 1489, 8112,12269



CHAPTER – 1 INTRODUCTION



MATERIAL INVESTIGATION REPORT

CHAPTER 1

INTRODUCTION

1. GENERAL

1.1 This Package consists of the roads of corridor -III which has been Strated namely from Bhawani Patna to Khariar on SH-16 (km 0.0/0.0 to 70.0/0) . This section of SH-16 is mainly single lane undivided carriageway with varying width. This length has been covered under the project with the approval of Orissa works Department. The location of these road sections are shown in Fig 1.1

1.2 In order to widening and strengthening of the roads and bridges, various kind of materials shall be required. To identify potential sources of material for construction, the survey of following materials have been carried out in the months of Jan,06– Feb,06 in respect of their likely sources and the availability and suitability of various materials. This report includes detailed investigation of materials and their potential sources with the relevant laboratory tests conducted on representative samples as per IRC: SP -19.

1.3 This report is intended to summarize the test results and to serve as a source of information to all concern. But during the construction phase, Certain frequency of tests will have to be conducted again at the time of execution as per the relevant codel provisions. The report is presented under the following headings:

(1) General

(2) Earthwork for Embankment

(3) Fly Ash for Embankment

(4) Granular Sub Base material

(5) Coarse Aggregate

(6) Sand / Fine Aggregate

(7) Cement / Cement Concrete

(8) Water



2.0 SURVEY METHODOLOGY

In particular soil and materials surveys are required

• To determine the quantity and physical characteristics of soil for design of embankment and subgrade for pavement.

• To locate sources for aggregates required for pavement and structures and to ascertain their availability and suitability for use.

The field investigations at each road section included broadly:

• Study of available information

• Demarcate the possible borrow areas

• Site inspection and assessment of quantity of potential materials

• Sampling of representative materials and preparation of Lead chard with the name and location of borrow area /Quarry

• Estimation of approximate potential reserves and other necessary details.

The investigations of the materials were mainly concentrated on the above guidelines and was initially restricted along the respective road alignments and nearby sources adjoining to road section. When suitable information were not available, the reconnaissance extended towards further more kilometers where potential sources were found and where access was not a major constraint. Sub surface drilling or trenching was not carried out, however at most of sites there were sufficient existing workings and /or exposed faces to enable a reasonable and conservative estimation of quality and quantity.

3.0 LABORATORY TESTING

Laboratory Testing is done so that the design of proposed structure can be made within the existing conditions. The testing program ranges from visual examination to sophisticated elaborated tests. The visual test in the laboratory indicates colour, texture and consistency of the samples. The representative samples of various types of materials were collected from their potential sources and the following necessary laboratory tests were conducted to assess their possible uses in design:

A. Soil (Borrow Area)

- Gradation (IS: 2720, Pt IV)

- Atterberg’s Limits (IS : 2720, Pt V)

- Modified Proctor Test (IS : 2720, Pt VIII)

- California Bearing Ratio (CBR, Soaked) (IS: 2720, Pt XVI)



B. Soil (Existing Subgrade)

- Gradation (IS : 2720, Pt IV)



- California Bearing Ratio ( CBR, Soaked) (IS : 2720, Pt XVI)

- Field density and Insitu moisture content (IS : 2720, Pt XXIX & Pt II)

- Free swell Index (IS : 2720, Pt XXXX)

C. Fly ash

- Gradation ( IS : 2720, Pt IV)



- Shear Strength parameters (IS : 2720, Pt XI)

- Specific Gravity (IS : 2720, Pt III)

D. Granular Sub Base (Borrow Area)

- Gradation (MORT&H)



- California Bearing Ratio (CBR, Soaked) (IS: 2720, Pt XVI)

E. Sand / Fine Aggregate (Quarry)

- Gradation (IS: 383)

- Silt content and Fineness Modulus (IS: 383)

- Specific Gravity (IS: 2720, Pt III)

- Deleterious content (IS: 2386, Pt-I & IS : 383)

F. Coarse Aggregate (Quarry)

- Gradation (IS: 2386, Pt I& MORT&H)

- Aggregate Impact Value (IS: 2386, Pt IV)

- Specific Gravity& Water Absorption (IS: 2386, Pt III)



- Combined Flakiness & Elongation Index (IS: 2386, Pt I)

- Stripping Value (IS : 6241)

G. Water.

The location and availability of water and their suitability for the construction purpose should be checked.

H. Manufactured Items Like Cement, Bricks, Steel, and Bitumen etc.

No laboratory tests for the manufactured items are required for the investigation purpose at this level. Only their source and availability are to be assessed.(As Per SP: 19 Clause )

4.0 LEAD CHART OF BORROW AREA / QUARRY AND THEIR TEST RESULTS

The borrow area chart/ Lead chart showing the major location of quarries and the average lead of materials like Soil, Morrum, Coarse Aggregate & Fine aggregate are given in Fig 1.2. In addition there are some smaller alternative quarries (Probable quarries if acquired from revenue / Forest Department) and some of the quarries that are lying in forest reserve area have also not been considered in detail.

Most of the sites are currently being operated manually with very limited scales of production. The material volume estimates are largely based upon geological judgment such as appropriate covered area, average depth of materials, nature of underlying materials, weathering characteristics and consequent effects on material properties etc. The approximate estimated reserves are indicated in the concerned Tables. The quantities of various materials are sufficiently available.

The results of the laboratory investigations are summarized in tabular form in the following concerned chapters. The results are discussed in details and their suitability is assessed in accordance to MORT&H provisions.

5.0 SPECIFICATIONS

This report besides analyzing and discussing the tests results of different materials in their respective chapters keeping in view the suitability of material for the construction purpose, also discussed the various general requirements for different materials, which the relevant materials must satisfy before putting into use for the construction purposes like physical requirements of the materials / type and frequency of quality control tests mentioned as per relevant standard specifications i.e. MORT& H.

__________________________________

ORISSA STATE ROADS PROJECT

Photo No .01-( Km 0/0 ) Insitu Density test of Existing Sub grade

Photo No .02 (Km 02/ 0) Insitu Density test of Existing Sub grade

RECORD OF QUARRY / MATERIALS SITE INVESTIGATION

Road No : S.H.-16

Section : Bhawanipatna to Khariar


, Photo No .03 (Km 05/ 0 ) Insitu Density test of Existing Sub grade

Photo No .04 (Km 64/ 0 ) Insitu Density test of Existing Sub grade


Road No : S.H.-16



Photo No .05 ( Km 4 / 0, Road side L.H.S ) Karla soda GSB Quarry.

Photo No .06 (Km 53 / 0, 5.0 km L.H.S ) Dabujhar GSB Quarry.


Road No : S.H.-16



Photo No .07 (Km 28 / 0, Both side) River sand Quarry.

Photo No .8 (Km 59 / 0, Both side ) Sunder river sand Quarry.


Road No : S.H.-16

Section : Bhawanipatna to khariar



CHAPTER – 2 EARTHWORK FOR EMBANKMENT



CHAPTER – 2

EARTHWORK FOR EMBANKMENT

2.0 GENERAL

The soils were collected from each km of the existing subgrade and also from borrow areas located at some leads by the sides of project Roads (SH-16). The borrow area locations with sufficient quantity of material is given in the borrow area lead chart in Fig 1.2 It will be ensured that the quality of borrow area soil should conform the MORT&H specifications. To assess their suitability as subgrade materials the following laboratory tests were conducted on the representative samples. The test results of existing subgrade soil samples, borrow area soil and borrow area moorum samples are tabulated in Table 2.1 ,6.1,2.2 respectively.

A. Soil (Borrow Area)

- Gradation (IS: 2720, Pt IV)



- California Bearing Ratio (CBR , Soaked) (IS: 2720, Pt XVI)


a. Gradation (IS : 2720, Pt IV)

b. Atterberg’s Limits (IS : 2720, Pt V)

c. Modified Proctor Test (IS : 2720, Pt VIII)

d. California Bearing Ratio ( CBR, Soaked) (IS : 2720, Pt XVI)

e. Field density and Insitu moisture content (IS : 2720, Pt XXIX & Pt II)

f. Free swell Index (IS : 2720, Pt XXXX)

2.1 Materials and General Requirements

The following are the general requirements; only the materials satisfying these requirements shall be employed for the constructions.

It will be ensured that the borrow area soil transported/brought for construction of embankment and sub grade should meet the following requirements.

The following type of material shall be considered unsuitable for the embankment or subgrade:

• Materials from swamps, marshes;

• Peat, log stump and perishable material: any soil classifies as OL, OI, OH or Pt;



• Clay having Liquid limit exceeding 70 and plasticity index exceeding 45:

• Expansive Clay having free swell index exceeding 50%;

The top 500mm portion of the embankment just below subgrade shall be non – expansive soil in nature.

Table - 2.4: Density Requirement of Embankment And Subgrade Materials

Sl. No.

Type of work Maximum laboratory dry unit weight when test as per IS: 2720 (Part 8)

1. Embankments upto 3 meters height not subject to extensive flooding

Not less than 15.2 KN / cu.m

2.

Embankments exceeding 3 meters height or embankments of any height subject to long periods of inundation.


3. Sub-grade and earthen shoulders / verges / back fill


The material to be used in subgrade should also satisfy design CBR at the dry unit weight applicable as per Table 2.5

Table - 2.5: Compaction Requirement for Embankment and Sub grade

S. No. Type of work / material

Relative compaction as percentages of max laboratory dry density as per IS: 2720 (part

8) 1. Sub grade and earthen shoulders Not less than 97

2. Embankment Not less than 95

3. Expansive clays

a) Sub grade and 500 mm portion just below the sub grade Not allowed

b) Remaining portion of embankment Not less than 90



2.2 CONTROL TESTS AND ITS FREQUENCY ON BORROW MATERIAL

2.2.1 The particular type of tests required to be conducted on the borrow material and their frequency would depend on interplay of several factors such as the nature of plant or machinery employed on the project, the quantum of manual labour involved, and the nature of specifications to be followed. The recommended frequencies indicated only to be taken as applicable to routine cases. These tests are meant to verify during execution of the work that the material coming to site conforms to specification for borrow material and should be regarded as distinct from the test referred to in report which relate to the initial selection of soils for embankment construction. All the tests would not be applicable on all projects. Depending upon site conditions, etc, only particular tests may be found necessary for a particular project. The frequency of testing relates generally to the minimum number of tests to be conducted. The rate of testing would have to be stepped up much more than indicated depending upon the heterogeneity of the material and the compaction technique adopted in any particular project.

2.2.2 Gradation (IS: 2720 Part IV): At least one test for each kind of soil. Usual rate of testing is 1-2 tests per 8000 m3 Clear of soil. The test would be necessary only if specifications call for checks using gradation of grain size distribution as a criterion for selecting the soil. However, sand content determinations should be carried out invariably at the rate of 1-2 tests per 8000 m3.

2.2.3 Plasticity index (IS: 2720 Part V) : At least one test for each kind of soil. Usual rate of testing 1-2 tests per 8000 m3 of soil.

2.2.4 Proctor test (IS: 2720 Part VII) 1980/ (IS: 2720 Part VIII): This test is performed to ensure that soil of requisite quality is coming out of borrow areas as also to provide information on optimum moisture content and maximum laboratory dry density. Usual rate of testing 1-2 tests per 8000 m3 of soil.

2.2.5 Deleterious constituents (IS: 2720 Part XXVII): The soil shall be free of harmful salts like sodium sulphate and organic matter (permissible limits) of 0.2 and 1 per cent respectively. The tests will be done when required.

2.2.6 Natural moisture content (IS: 2720 Part II): One test for every 250 m3 of soil. The natural moisture content of the soil coming out of the borrow pits will have to be determined in order to evaluate how far the natural moisture content tallies with the optimum value and whether further addition or reduction of water content would be necessary.

2.3 COMPACTION CONTROL

Compaction control mainly involves two operations, namely, control of moisture content just before compaction and density of compacted layer

2.3.1 Moisture content determination: Moisture content determinations for compaction control shall be in addition to those on borrow material spelt out in Clause 2.6.6. This test is necessary for ensuring proper moisture content at the time of compaction, which significantly influences the density results. Usual rate of testing should be 2-3 tests per 250 m3 of soil.



2.3.2 Density measurements:

Except when otherwise directed, at least one measurement of density shall be made for each 1000 m2 of compacted area. Test locations shall be chosen only through predetermined random sampling techniques. Control shall not be based on the result of anyone test but on the mean value of 5-10 density determinations. The number of tests in one set of measurements shall be 6 as long as it is felt that sufficient control over borrow material and the method of compaction was being exercised. But if there be any doubt about this control, or considerable variations are observed between individual density results, the number of tests in one set of measurement shall forth with be increased to 10. The acceptance of results shall be subject to the condition that the mean dry density not less than the specified density plus [1.65 – 1.65/(No. of samples) 0.5] Times the standard deviation In general, the control at top sub-grade layers of the formation shall be strict than stated above with density measurements being carried out at the rate of 1 per 500 m2 of compacted area. Further, for the determination of mean density and standard deviation the number of tests in one set of measurements shall not be less than 10. Acceptance of the work shall be subject to the same conditions as stipulated above. Table 2.6 Sets out the minimum desirable frequency of tests for compaction control.

Table - 2.6: Quality Control Tests & Frequency

S. No. Test Test Method Minimum desirable frequency

1. Gradation * / Sand- content IS: 2720 Part IV-1985 2 tests per 3000 m3 of soil

2. Plasticity Index IS: 2720 Part V-1985 -do-

3. Standard Proctor Test IS: 2720 Part VII-1980/ Part VIII-1983 -do-

4. CBR on a set of 3 specimens ** IS: 2720 Part XVI-1987 One test per 3000 cum at least

5. Deleterious constituents IS: 2720 Part XXVII-1977 As & when required

6. Natural moisture content IS: 2720 Part II-1973 (Second Revision)

One test per 250 cum of soil

7. Density Test IS 2720 Part VIII-1983 2 test for 3000 Cum

8. Sand content IS 2720 Part IV-1985 2 test per 3000 Cum

* If specifications call for such tests ** For purposes of design only unless otherwise specified.



Table - 2.7: Tests for Compaction Control

Sl. No. Test Test Method Minimum desirable frequency

1. Moisture content just before compaction

IS: 2720 Part II-1973 (Second Revision) 2-3 tests per 250 of m2

loose soil

2. Dry density of compacted layer

IS: 2720 Part XXVIII-1974

Generally, one test per 1000 m2 of compacted area for the body of the embankment to be increased to one test per 500-1000 m2

of compacted area for top sub-grade layers, i.e. top 500 mm portion of the embankment.

2.5 DISCUSSION OF RESULTS

A. Soil (Borrow area-River Sand)

The soil in this stretch mainly found in Kms 28/0(Tel River) , and 59/0(Sunder River) which classified in the group of SM described as Silty Sand. The Silty Sand ( SM) soil is non plastic and cohesion less .The maximum dry density at O.M.C. of the existing subgrade soil of SM group varies between 1.84 gm/cm3 to 2.07 gm/cm3. The various test results of soil samples collected from the road (Borrow area ) are given in Table 2.2,6.1.The sand from River borrow area is available in much quantity, also another alternative is either to use Moorrum as subgrade material, which is abundantly available in this stretch . The test results of Moorrum available in different borrow areas are tabulated in Table 2.3


The soil in this stretch mainly classify in the group of CL /SC/CI/CH and it is described as Silty Clay with Sand respectively. The Silty clay with Sand,Silty clay ( CL),CI/CH soil is low to high plastic and cohesive having CBR values( Soaked) ranging from 2.2% to 5.0% . While the soil Clayey Sand with Silt (SC) is little plastic. In these sections PI value ranges from 5.0 to 20.0. The CBR value (Soaked) of the soil ranges from 6.2% to 10.6%. The maximum dry density at O.M.C. of the existing subgrade soil of CL/CI group varies between 1.86 gm/cm3 to 1.97 gm/cm3. In maximum kilometers (from 0.0/0.0 to 35/0.0), there are Expansive soils found with low to high degree of expansion. The treatments for such soils are discussed in the following Paragraph.



C. Expansive Soils and their Treatment

Low to high expansive soils of CL-CI-CH group are found in various Sections of SH 16 i.e.km0.0/0, 6/0, 8/0, 9/0, 10/0, 11/0, 18/0,21/0, 22/0, 23/0, 24/0, 25/0, 26/0, 27/0, 29/0, 31/0, 32/0, 42/0, 54/0, Though, there are very Large kilometers (from 0/0 to 35) in such a long stretch of road section, it is always preferable either to replace the soil of high expansive properties or to treat the soil of low to medium expansive soils as below.

Thus to reduce the expansive properties of soil, firstly the expansive soil should be compacted slightly 1-2 % wet of the O.M.C and provide a buffer layer of non-expansive cohesive soil cushion of 0.6 – 1.0m thickness. It prevents the ingress of water in the underlying expansive soil layer, counteracts swelling and secondly even if the underlying expansive soil heaves, the movement will be more uniform and consequently more tolerable or it is recommended to either replace the soil by importing good soil from borrow area in the case of highly expansive soils. However where provision of non-expansive buffer layer is not economically feasible, a blanket course of suitable material and thickness as discussed below must be provided.

A blanket course of at least 225 mm thickness and composed of coarse/ medium sand or non-plastic moorum having PI less than five should be provided on expansive soil subgrade as a sub-base to serve as an effective intrusion barrier. The blanket course should extend over the entire formation width together with measures for efficient drainage of the pavement section. Improvement of drainage can significantly reduce the magnitude of seasonal heaves. The various test results of soil samples collected from the road (Existing subgrade SH-16) are given in Table 2.1.

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index (PI)

Max. dry

density gm/cc.

OMC %

1 2 4 5 6 7 8 9 10 11 12 13 16 18 19

Approximate Area /

Quantity Avaliable

Name of Road :

CBR Soaked %

Group of soil

TABLE - 2.1 : SOIL INVESTIGATION DATA OF BORROW AREA SOIL

Sl. No.

Name of the Location

Gradation: Percent by weight retained the Sieve (IS:2720-IV)

Clay and silt

content %

Atterberg Limits Modified Proctor Test

(IS:2720-Pt-VIII)Lead in K.M

L.H.S /R.H.S

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 4 5 6 7 8 9 10 11 12 13 16 17 18 19

1 Karlasoda ( Km 4/0 )

Road side L.H.S 34.1 8.1 13.5 18.2 26.1 24 NP NIL 2.17 7.09 33.5 8.57 SM <30,000

cum

2 Karlaguda ( Km 13/0 )

Road side L.H.S 15.7 5.4 10.15 24.05 44.71 33 21 12 1.98 9.05 22.5 14.6 SC < 50,000

cum

3 Adhamunda ( Km 18/5 ) 4.5 R.H.S 24.5 9.9 27.1 9.35 29.15 26 NP NIL 2.11 8.1 28.8 9.8 SM <70,000

cum

4 Donguriguda ( Km 23/0 )

Road side R.H.S 12.7 6.8 8.68 24.06 47.76 34 20 14 1.93 10.9 21.1 18.3 SC <100,000

cum

5 Dabujhar ( Km 53 / 0 ) 5.0 L.H.S 15.1 11.5 25.05 27.9 20.45 24 NP NIL 2.09 7.05 25.1 10.2 SM < 50,000

cum

TABLE - 2.2 : SOIL INVESTIGATION DATA OF BORROW AREA MOORUM

Sl. No.


Gradation: Percent by weight retained the Sieve (IS:2720-IV)

Clay and silt

content %

Atterberg Limits [IS 2720-Pt-V]

Modified Proctor Test

(IS:2720-Pt-VIII)Lead in K.M

L.H.S /R.H.S

Area/ Quantity Avaliable

Bhawanipatna to khariar (S.H-16)Name of Road :

CBR Soaked %

DFS %

Group of soil

Name of Road: BHAWANIPATNA to KHARIER (SH-16)

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 0/0 Silty Clay with sand 3.52 3.04 14.29 25.37 53.78 30 18 12 1.91 13.52 1.76 8.2 5.2 37 CL

2 1/0Silty sand

with clay and gravel

7.58 15.76 36.97 9.57 30.12 29 24 5 - - 1.775 10.0 - 21.87 SM-SC

3 2/0Clayey sand with silt and

gravel3.35 15.83 32.77 14.77 33.28 28 20 8 2.04 9.5 1.829 8.0 8.0 8.3 SC

4 3/0 Silty sand with clay 8.88 16.85 35.82 14.05 24.4 27 22 5 - - 1.772 9.0 - 20.83 SM-SC

5 4/0 Silty sand with clay 0.87 2.1 18.05 31.37 47.61 27 21 6 1.97 13.4 1.782 4.5 9.5 18.2 SM-SC

6 5/0 Silty sand with clay 2.32 4.23 26.41 29.82 37.22 25 20 5 - - 1.775 6.0 - - SM-SC

7 6/0 Silty sand with clay 0.5 0.5 16.17 34.1 48.73 37 25 12 1.98 11.05 1.789 7.0 8 22.61 SC

8 7/0 Silty sand with gravel 14.84 3.94 27.21 25.98 28.03 27 NP NIL 1.89 12.9 1.89 8.5 13.6 - SM

9 8/0 Silty Clay with sand 1.87 5.16 15.7 20.76 56.51 27 20 7 1.86 13.05 1.766 11.0 6.2 22.27 ML-CL

CBR Soaked

%DFS

Group of soil

[IS:1498]

TABLE - 2.1 : SOIL INVESTIGATION DATA OF EXISTING SUBGRADE

Sl. No.

Location (Km.)

Description of soil

Gradation: Percent by weight retained the Sieve (IS:2720-IV) Clay

and silt content

%

Atterberg Limits [ IS :2720-Pt-V]

Modified Proctor Test (IS:2720-Pt-

VIII)Field dry density at subgrade

level gm/cc

In-situ Moisture content

%

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CBR Soaked

%DFS

Group of soil

[IS:1498]

Sl. No.

Location (Km.)

Description of soil


and silt content

%




level gm/cc


%

10 9/0 Silty Clay with sand 0.42 1.89 11.94 17.47 68.28 36 21 15 1.78 14.9 1.76 12.5 4.5 56 CI

11 10/0 Silty clay 4.29 1.26 7.2 23.56 63.69 38 18 20 1.79 17.02 1.769 12.0 2.7 78 CI

12 11/0 Clayey sand with gravel 15.61 3.86 11.27 19.49 49.77 32 18 14 2.08 11.4 1.72 10.5 6.2 25 SC


14 13/0Silty sand

with clay and gravel

16.4 4.06 15.16 18.9 45.48 28 22 6 1.92 12.8 1.776 10.2 12.0 - SM-SC

15 14/0 Sandy gravel with silt&clay 39.04 8.8 15.2 13.1 23.86 27 20 7 - - 1.79 9.0 - - SM-SC

16 15/0Sandy gravel

with silt& clay

31.14 8.92 15.77 12.45 31.72 46 35 11 - - 1.81 9.5 - - SC

17 16/0 Sandy gravel with silt&clay 23.08 11.57 16.63 14.89 33.83 39 28 11 - - 1.79 10.5 - 25 SC

18 17/0 Sandy gravel with silt&clay 25.73 9.78 18.17 15.08 31.24 42 31 11 1.85 14.5 1.81 12.0 8.6 24 SC

19 18/0 Silty clay 1.77 0.7 4.57 20.97 71.99 37 20 17 1.78 16.82 1.764 12.0 2.5 55 CI

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CBR Soaked

%DFS

Group of soil

[IS:1498]

Sl. No.

Location (Km.)

Description of soil


and silt content

%




level gm/cc


%

20 19/0 Silty sand with clay 5.64 12.5 19.68 28.5 33.68 23 19 4 1.94 10.65 1.773 12.5 12.5 - SM-SC

21 20/0 Clayey sand with silt 0.32 1.21 15.33 37.86 45.28 35 25 10 - - 1.771 10.0 - 23.92 SC

22 21/0 Silty clay 0.65 0.63 5.66 22.58 70.48 42 22 20 1.91 12.85 1.771 12.0 3 58 CI

23 22/0 Silty clay 3.85 0.87 4.58 21.47 69.23 39 20 19 1.81 15.9 1.774 11.3 3.5 49 CI

24 23/0 Clayey sand 18.42 5.35 12.73 29.76 33.74 24 12 12 2.13 10.4 1.703 7.0 7.00 22 SC

25 24/0 Silty clay 1.98 1.21 4.2 14.56 78.05 50 23 27 1.81 12.9 1.738 18.5 2.9 62.7 CI-CH

26 25/0 Silty clay 0.89 0.61 0.43 13.32 84.75 47 24 23 1.77 17.05 1.75 16.5 2.2 50.8 CI

27 26/0Silty clay

(Inorganic/ fat clay)

3.0 0.98 3.35 13.34 79.33 53 26 27 1.77 16.65 1.758 17.0 2.4 67 CH

28 27/0 Silty clay 5.37 2.76 5.7 14.18 71.99 50 22 28 1.88 16 1.674 10.0 2.8 57 CI - CH

29 28/0 TEL RIVER

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CBR Soaked

%DFS

Group of soil

[IS:1498]

Sl. No.

Location (Km.)

Description of soil


and silt content

%




level gm/cc


%

30 29/0 Silty clay 6.96 3.34 9.69 29.94 50.07 30 20 10 1.79 15.05 1.736 10.5 5 38 CL

31 30/0 Silty sand with gravel 6.17 4.42 11.87 40.49 37.05 25 NP NIL - - 1.731 12.0 - - SM

32 31/0 Silty clay with gravel 6.34 2.22 8.13 30.11 53.2 41 20 21 1.79 15.05 1.779 12.5 3.5 52 CI

33 32/0Silty sand with clay &

gravel6.38 2.03 7.92 31.6 52.07 39 18 21 1.84 16.8 1.704 11.0 4.5 47.4 CI


gravel9.86 3.22 9.57 36.86 40.49 24 20 4 - - 1.731 9.5 - - SM-SC

35 34/0 Silty sand with clay 5.57 2.41 9.53 36.13 46.36 26 21 5 1.94 11.87 1.697 11.0 14.1 15.0 SM-SC

36 35/0 Sandy gravel with silt 24.48 5.93 16.44 27.3 25.85 26 NP NIL - - 1.738 12.5 - - SM

37 36/0 Sandy gravel with silt 25.3 7.24 15.3 23.61 28.55 27 NP NIL - - 1.725 10.0 - 21.59 SM


gravel7.88 3.94 20.13 39.46 28.59 25 21 4 - - 1.747 10.5 - - SM-SC

39 38/0 Silty Sand 8.91 5.84 19.79 34.09 31.37 28 NP NIL 2.06 13.9 1.774 11.0 15.5 6.06 SM

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CBR Soaked

%DFS

Group of soil

[IS:1498]

Sl. No.

Location (Km.)

Description of soil


and silt content

%




level gm/cc


%

40 39/0 Silty sand with gravel 11.47 5.95 22.26 36.57 23.75 25 20 5 1.92 11.5 1.75 12.0 9.8 - SM-SC

41 40/0 Silty gravel with sand 42.03 7.55 10.52 15.49 24.41 25 21 4 - - 1.782 10.8 - - SM-SC

42 41/0 Silty sand 1.2 1.25 14.51 47.18 35.86 19 NP NIL 1.97 11.35 1.949 10.0 12.8 - SM

43 42/0 Silty clay with sand 3.64 3.01 11.55 24.97 56.83 27 14 13 2.01 10.2 1.659 12.0 5.5 31.76 CL

44 43/0 Clayey sand with gravel 8.55 5.08 15.43 27.02 43.92 28 22 6 - - 1.647 10.0 - - SM-SC

45 44/0 Clayey sand with gravel 13.73 7.89 15.43 25.96 36.99 31 24 7 1.90 12.0 1.648 11.5 11.5 - SM-SC

46 45/0 Silty clay with gravel 11.98 9.34 18.24 29.63 30.81 30 20 10 2.06 11.3 1.631 13.0 - 17.65 SC

47 46/0 Clayey sand 4.02 5.3 15.5 28.5 46.68 28 20 8 1.98 12.05 1.635 15.00 10.6 22.0 SC

48 47/0 Silty sand 0.7 2.15 15.41 38.72 43.02 22 NP NIL - - 1.747 6.8 - - SM


4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CBR Soaked

%DFS

Group of soil

[IS:1498]

Sl. No.

Location (Km.)

Description of soil


and silt content

%




level gm/cc


%

50 49/0 Silty sand 22.71 7.25 27.54 22.35 20.15 25 NP NIL 2.09 8.85 1.708 7.0 15.8 6.67 SM

51 50/0 Clayey sand with gravel 7.77 4.52 19.95 38.12 29.64 30 25 5 - - 1.719 9.0 - - SM-SC


53 52/0 Silty sand 15.35 3.87 14.98 41.57 24.23 21 NP NIL - - 1.76 10.50 12.20 - SM


55 54/0 Silty Clay 1.82 1.11 10.37 29.3 57.4 26 18 8 2.04 10.05 1.771 13.00 6.5 36.25 CL

56 55/0 Silty sand 1.06 1 9.22 55.83 32.89 21 NP NIL - - 1.746 9.00 - - SM

57 56/0 Silty sand 0 0.2 4.58 62.62 32.6 22 NP NIL 1.96 12.8 1.748 11.00 12.5 - SM

58 57/0 Silty sand 0 0.4 4.6 63.65 31.35 23 NP NIL - - 1.751 10.50 - - SM


4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CBR Soaked

%DFS

Group of soil

[IS:1498]

Sl. No.

Location (Km.)

Description of soil


and silt content

%




level gm/cc


%



62 61/0 Silty sand with gravel 6.54 9.7 22.53 31.55 29.68 22 NP NIL 2.12 11.5 1.781 10.00 - 7.8 SM



65 64/0 Silty sand 3.2 1.87 12.22 32.95 49.76 32 20 12 1.98 12.05 1.721 9.00 8.5 SC

66 65/0 Clayey Sand with gravel 13.94 2.43 12.57 26.18 44.88 29 14 15 2.03 11.25 1.702 12.00 6.2 26.47 SC

67 66/0 Silty sand 5.96 2.9 13.64 31.84 45.66 27 20 7 1.87 13.9 1.76 9.50 10.7 SM-SC

68 67/0 Silty sand 6.34 3.75 25.53 36.17 28.21 22 NP NIL 2.16 8.0 1.741 8.00 28.2 13.3 SM

69 68/0 Silty sand 0 0.26 12.35 54.35 33.04 18 NP NIL - - 1.742 9.00 - - SM

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CBR Soaked

%DFS

Group of soil

[IS:1498]

Sl. No.

Location (Km.)

Description of soil


and silt content

%




level gm/cc


%





CURVES FOR GRADATION OF GRANULAR SUB BASE MATERIAL

Consulting Engineers group Ltd., Jaipur Material Report

Consulting Engineers Group Ltd.

Sample Location - Km 0 / 000 S.H.-16Source of Material - SubgradeName of the Road - Bhawanipatna to Khariar

GRAINSIZE ANALYSIS FOR EXISTING SUBGRADE MATERIAL

Consultancy services for Feasibility Study and Detailed Project Report Preparation of Phase-1 Roads for Orissa State Road Project Under World Bank Assistance.

0.000

10.000

20.000

30.000

40.000

50.000

60.000

70.000

80.000

90.000

100.000

0.01 0.1 1 10IS Sieve size (mm)

% P

ASS

ING

Silt & ClaySand

Fine Medium Coarse Gravel






0.000

10.000

20.000

30.000

40.000

50.000

60.000

70.000

80.000

90.000

100.000


% P

ASS

ING

Silt & ClaySand

Fine Medium CoarseGravel






0.000

10.000

20.000

30.000

40.000

50.000

60.000

70.000

80.000

90.000

100.000


% P

ASS

ING

Silt & ClaySand




CURVES FOR GRAINSIZE ANALYSIS FOR

SUBGRADE SOIL



CHAPTER – 3 FLY ASH FOR EMBANKMENT



CHAPTER 3

FLY ASH FOR EMBANKMENT

3 GENERAL

Fly ash is causing environmental pollution and requires large area of precious land for disposal. Due to increasing awareness of the ill effects of the pollution, utilization and safe disposal of ash generated at thermal power plants has become an urgent and challenging task. Fly ash can be utilized in many ways but bulk utilization can be done mainly in the field of civil engineering applications, especially construction of roads and embankments. In developed urban areas natural borrow sources for soil or earth is scare and expansive. The environmental degradation caused due to using topsoil for construction of embankment is also very high. Fly ash can provide an economical and environmentally preferable alternative to natural borrow soil.

The design and construction of road embankments using fly ash should be done as per IRC: SP: 58-2001 and MORT&H specification. The density of fly ash is considerable lower than density of many types of soils. So unlike soils, fly ash with low maximum dry density value should not be rejected for using it as a fill material. However, in general fly ash of density lower than 0.9 gm/cc may not be suitable for embankment construction.

3.1 Fly Ash Embankments

The fly ash embankment should be covered on the sides and top by soil to prevent erosion of ash. The top soil must have max dry density more than 1.52 gm/cc for embankment upto 3 m height and in the area not subjected to extensive flooding, other wise the maximum dry density of cover soil should not be less than 1.6 m/cc.

The design of embankment is an iterative process. It involves developing conceptual plans, which satisfy site needs, design requirements pertaining to slope stability, bearing capacity, settlement and drainage. The compacted fly ash attains sufficient shear strength so that the embankment can be constructed with 2:1 (Horizontal: vertical) side slope. This is confirmed through stability analysis for each specific application. It is recommended that factor of safety for embankments constructed using fly ash should not be less than 1.25 under normal serviceability condition and when checked for worst combination under seismic and saturated conditions, it should not be less than 1.0. Fly ash embankments cab be constructed using reinforced earth technique to avoid necessity of providing retaining walls.

The depth of top soil should be at least 50 mm to 100 mm minimum. The thickness of side cover (measured horizontally) would be typically in the range of 1m to 3m. Height and side slope of the embankment governs the thickness of earth cover. The embankment would therefore, be designed as a composite structure with fly ash in the core and earth cover on the sides as shown in Fig.3.1 Sometimes intermediate soil layers are also provided in the fly ash embankment if the height of embankment is more than 3 m and for ease of construction, to facilitate compaction of ash and to provide adequate confinement. Such layers minimize liquefaction potential also. The compacted thickness of intermediate soil layers shall not be less than 200 mm. One or



more layers shall be constructed depending upon the design requirements. The vertical distance between such layers may vary from 1.5 m to 3.0 m

The sulphate content in fly ash should be within the specified limits of 1.9 gm/lit.

3.2 Utilization of fly ash in road works

Fly ash can be used for constructing different layers of road pavements. Utilization of fly ash for stabilization of sub-grade depends on the interaction between fly ash and sub-grade soil. If the type of soil available in the area is found to be amenable to pozzolanic action with fly ash, strength parameter of the soil would improve when fly ash is added. This characteristic of fly ash is important in formulation of pavement specifications, which are economical, and permits utilization of Fly ash in bulk quantities for road construction. Generally clayey soil reacts with pozzolanic compounds present in fly ash to cause an effect similar to that of cement. No such reaction is observed in case of sandy soils or gravels. Silty soils also react with fly ash to a limited extent; this reaction can be improved by using an additive such as lime. On the other hand, when fly ash is used along with lime for soil stabilization, leaching can be considerably inhibited. Sub-base/base layers can be constructed using compacted pond ash or bottom ash, alone which are coarser fraction of Fly ash.

3.3 Discussion of Test results

The samples of Fly Ash and bottom Ash were collected from JK Paper Ltd,Unit-JK Paper Mills,Jaykaypur-765017 Distt-Raygada, Orissa located at 42 km left side from SH-4.Lead from Bhawani Patna to Kheriar section is around 120km.The following tests are conducted on the samples of fly ash & bottom ash (Cinder) collected.

Laboratory Tests:

- Gradation (IS : 2720, Pt IV)


- Modified Proctor Test (IS: 2720, Pt VIII)

- Shear Strength parameters (IS: 2720, Pt XI)

- Specific Gravity (IS : 2720, Pt III)

The test results are tabulated in table 3.1 and 3.2



Table - 3.1: Physical Test Results of Bottom Ash (Cinder)

Name of Source : JK Paper Ltd,Unit-JK Paper Mills,Jaykaypur-765017 Distt-Raygada, Orissa

Gradation:

IS.Sieve Designation % Finer

10.0mm 100

4.75mm 100

2.0mm 94.290

0.425mm 79.450

0.075mm 53.115

Index Properties:

Sl. No. Test Description Test Result

1. Liquid Limit 29.0

2. Plastic Limit NIL

3. Plasticity Index Non Plastic

4. Optimum moisture content % 24.08

5. Maximum dry density g/cc 1.11 g/cc

6. Specific gravity 1.60

6. Coefficient of Uniformity ( Cu) 5.75

7. Cohesion ( kg /cm2) 0.02

8. Angle of internal Friction (φ) 220



Table - 3.2: Physical Test Results of Fly ash

Name of Source : JK Paper Ltd, Unit-JK Paper Mills,Jaykaypur-765017 Distt-Raygada, Orissa

Gradation:

IS.Sieve Designation % Finer

10.0mm 100

4.75mm 100

2.0mm 100

0.425mm 91.125

0.075mm 93.245

Index Properties:

S. No. Test Description Test Result

1. Liquid Limit 32.0

2. Plastic Limit NIL

3. Plasticity Index Non Plastic

4. Optimum moisture content % 18.65

5. Maximum dry density g/cc 1.09 g/cc

6. Specific gravity 1.96

6. Coefficient of uniformity

(Cu)

22.70

7. Cohesion kg /cm2 0.03

8. Angle of internal Friction 240



Table - 3.3: Typical Properties of Fly Ash According to IRC: SP: 58-2001

S.No. Parameter Range

1 Specific Gravity 1.90-2.55

2 Plasticity Non-Plastic

3 Maximum dry density (gm/cc) 0.9-1.6

4 Optimum moisture content (%) 38.0-18.0

5 Cohesion Negligible

6 Angle of internal friction 300-400

7 Coefficient of cohesion Cv (cm2/sec) 1.75 X 10-5 – 2.01X 10-3

8 Compression Index (Cc) 0.05-0.4

9 Permeability 8 X 10-6 – 7 X 10-4

Particle Size Distribution (% of materials)

Clay Size Friction 1-10

Silt Size Fraction 8-85

Sand Size Fraction 7-90

10

Gravel Size Fraction 0-10

11 Coefficient of Uniformity 3.1-10.7

The bottom ash as well as fly ash are available in sufficient quantities on the above site and on comparing the test results from the Table 3.3 as per IRC: SP: 58-2001, it is evident that some of the physical properties of Fly ash / Bottom ash do not lie exactly as per the requirement but can be made suitable for the construction of subgrade by mixing it in certain percentage with the locally available soil thus improving its physical properties.



CHAPTER – 4 GRANULAR SUB BASE



CHAPTER 4

GRANULAR SUB-BASE

4.0 GENERAL

This work shall consist of laying and compacting well-graded material on prepared sub-grade in accordance with the requirements of these specifications. The material shall be laid on one or more layers as sub-base or lower sub-base and upper sub-base (termed as sub-base hereinafter) as necessary according to lines, grades and cross-sections shown on the drawings or as directed by the Engineer.

In the road section of SH-16, Bhawani Patna to Kheriar, Six quarries were found., The representative materials were collected from these quarries and the following tests were conducted.

Laboratory Tests:

- Gradation (MORT&H)

- Atterberg’s Limits (IS: 2720, Pt V)

- Modified Proctor Test (IS: 2720, Pt VIII)

- California Bearing Ratio (CBR, Soaked) (IS : 2720, Pt XVI)

The Tests results are tabulated in Table. 4.1 to 4.2 and their suitability for different type of works is found out on the basis of these results.

4.1 Materials and General Requirements

The material to be used for the work shall be natural sand, moorum, and gravel, depending upon the grading required. The material shall be free from organic or other deleterious constituents and conform to one of the three grading given in Table 4.3 & Table 4.4

For Grading II and III materials, the CBR shall be determined at the density and moisture content likely to be developed in equilibrium conditions, which shall be taken as being the density relating to a uniform air, voids content of 5 per cent. In General After blending with sand of Grade (I) shall be followed on project.



Table - 4.3: Grading for Close Graded Granular Sub-base Materials

IS Sieve Per cent by weight passing the IS Sieve

Designation Grading I Grading II Grading III

75.0 mm 100 - -

53.0 mm 80-100 100 -

26.5 mm 55-90 70-100 100

9.50 35-65 50-80 65-95

4.75 mm 25-55 40-65 50-80

2.36 mm 20-40 30-50 40-65

0.425 mm 10-25 15-25 20-35

0.075 mm 3-10 3-10 3-10

CBR Value (Minimum) 30 25 20

Table - 4.4: Grading for Coarse Graded Granular Sub-base Materials

IS Sieve Per cent by weight passing the IS Sieve

Designation Grading I Grading II Grading III

75.0 mm 100 - -

53.0 mm 100

26.5 mm 55-75 50-80 100

9.50

4.75 mm 10-30 15-35 25-45

2.36 mm

0.425 mm

0.075 mm <10 <10 <10

CBR Value (Minimum) 30 25 20



Note: The material passing 425 micron (0.425 mm) sieve for all the three gradings when tested according to IS: 2720 (Part 5) shall have liquid limit and plasticity index not more than 25 and 6 per cent respectively.

4.1.1 Strength of sub-base

It shall be ensured prior to actual execution that the material to be used in the sub-base satisfies the requirements of CBR and other physical requirements when compacted and finished.

Table - 4.5: Control tests & their frequency for Sub Base & Bases

S. No. Type of Construction

Test Frequency (Min)

(i) Granular Gradation One test per 200 m3

(ii) Atterberg limit -do-

(iii) Moisture content One test per 250 m2

(iv) Density of compacted layer One test for 500 m2

(v) Deleterious constituents As required

(vi) CBR As required

4.1.2 The evaluation of density result and acceptance criteria for compaction shall be as per

MORT&H specification para 903.2.2 Density measurement shall be taken for every 500 square meters. If considerable variation are observed between individual densities the minimum number of test in one set of measurement shall be increased to 10.

The acceptance criteria shall be subject to the conditions that mean density is not less than specified density plus [1.65 – 1.65/(No. of samples) 0.5] Times the standard deviation

These requirements and the specified grain size distribution of the sub-base material should be strictly enforced in order to meet stability and drainage requirements of the granular sub base layer.

4.2 DISCUSSION OF TEST RESULTS

The sub base material should have minimum CBR of 30 percent for traffic exceeding 2 msa and 20 percent for traffic upto 2 msa. The samples of granular sub base materials were collected from various quarries along the Bhawani Patna to Kheriar road . From the tests results it is clearly evident that in Bhawani Patna to Kheriar road section, Six number of quarries named Karlasoda (Km 4/0), Karlaguda (Km 13/0), Pastipada ( Km 15/0), Adhamunda (Km 18/500),Dongiriguda (km 23/0),Debujhar (Km 53/0), in which two GSB quarry are suitable having liquid limit and P.I. value within the prescribe limit of MORT&H . For rest of quarries in which liquid limit and Plasticity Index is more than 25 and 6.0 respectively, blending of coarse grained sandy soil is suggested to lower down their Liquid limit & P.I. within the prescribed



limit. Quarries having CBR values less than 30% also need blending. and for rest of quarries blending of sand in required proportion is to be done and their revised tests results have been tabulated in Table 4.2

Therefore it shall be ensured prior to actual execution that the material to be used in the sub-base satisfies the requirements of CBR and other physical requirements.

Name of Road : Bhawanipatna to Khariar ( km 0/0 to 70/0 ) S.H - 16

75 mm

53 mm

26.5 mm

9.5 mm

4.75 mm

2.36 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index

(PI)

Density gm/cc

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1.A Karlasoda ( Km 4/0 )

Road side L.H.S _ _ 100 38.1 _ _ 31.50 34 20 14.0 2.11 8.4 21.5 _ _

B _ _ 100 41.05 _ _ 39.60 35 18 17.0 2.09 9.65 19.6 _ _

C _ _ 100 39.6 _ _ 24.05 33 20 13.0 2.1 9.4 20.5 Grade -III _

Average _ _ 100 _ 39.583 _ _ 31.72 34 19 15 2.1 9.13 20.53 Blending Required

(200 X 100 X 1.5)m (>30,000

cum)

2.A Karlaguda ( Km 13/0 )

Road side L.H.S _ 100 66.5 _ 34.27 _ _ 32.00 30 20 10 2.14 8.05 28.5 _ _

B _ 100 64.8 _ 36.42 _ _ 29.60 29 20 9 2.15 9.14 27.35 _ _

C _ 100 69.3 _ 37.48 _ _ 33.80 31 21 10 2.13 9.05 27.4 Grade -II _

TABLE : 4.1 : TEST RESULT OF GRANULAR SUB-BASE MATERIAL FOR BORROW AREA

Sl. No.

Aprox. Area / QuantityLocation Lead in

KM

Gradation: Percent by weight passing the Sieve (Close graded) (MORT&H)

Atterbeing limits (IS:2720-Part V)

Moditied Proctor Test (IS:2720-

Part VIII) Confirm to Grade /

Suitability

CBR value

(Soaked)%

L.H.S / R.H.S

75 mm

53 mm

26.5 mm

9.5 mm

4.75 mm

2.36 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index

(PI)

Density gm/cc

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Sl. No.


KM





Suitability

CBR value

(Soaked)%

L.H.S / R.H.S

Average _ 100 66.9 36.057 _ _ 31.8 30 20 10 2.14 8.75 27.8 Blending Required

(250 X 150 X 1.5)m (>50,000

cum)

3.A Pastipada Quarry ( Km 15/0 ) 4.0 L.H.S _ 100 55.1 _ 13.27 _ _ 12.17 28 18 10 2.14 8.05 26.5 _ _

B _ 100 51.8 _ 12.75 _ _ 11.01 29 20 9 2.15 9.45 27.0 _ _

C _ 100 56.05 _ 14.01 _ _ 12.42 30 19 11 2.13 8.3 26 Grade-II _

Average _ 100 54.3 _ 13.3 _ _ 11.87 29 19 10 2.14 8.6 26.5 Blending Required

(150 X 50 X 1.0)m (<10,000

cum)

4.AAdhamunda

Quarry ( Km 18/5 )

4.5 R.H.S 100 _ 66.5 17.05 _ _ 6.55 25 20 5 2.19 6.95 35.1 _ _

B 100 _ 59.1 21.3 _ _ 7.80 24 20 4 2.14 8.8 36.0 _ _

75 mm

53 mm

26.5 mm

9.5 mm

4.75 mm

2.36 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index

(PI)

Density gm/cc

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Sl. No.


KM





Suitability

CBR value

(Soaked)%

L.H.S / R.H.S

C 100 _ 57.5 19.3 _ _ 5.40 23 18 5 2.15 7.8 34 Grade-I _

Average 100 _ 61.0 19.2 _ _ 6.58 24 19 5 2.16 7.85 35.0 Suitable

(350 X 200 X 1.5)m

(>100,000 cum)

5.ADonguriguda

Quarry ( Km 23/0 )

Road side R.H.S 100 _ 67.5 _ 18.9 _ _ 5.90 24 20 4 2.17 7.4 34.5 _ _

B 100 _ 55.5 _ 17.5 _ _ 6.80 25 20 5 2.15 7.6 36.0 _ _

C 100 _ 59.1 _ 19.05 _ _ 4.70 24 20 4 2.14 8.05 35 Grade-I _

Average 100 _ 60.7 _ 18.5 _ _ 5.8 24 20 4 2.15 7.7 35.2 Suitable(300 X 200 X

1.5)m (>90,000 cum)

6.A Debujhar Quarry ( Km 53/0 ) 5.0 L.H.S _ _ 100 _ 20.14 _ _ 15.24 28 20 8 2.07 8.55 24.1 _ _

75 mm

53 mm

26.5 mm

9.5 mm

4.75 mm

2.36 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index

(PI)

Density gm/cc

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Sl. No.


KM





Suitability

CBR value

(Soaked)%

L.H.S / R.H.S

B _ _ 100 _ 19.27 _ _ 14.42 27 17 10 2.06 9.05 22.6 _ _

C _ _ 100 _ 18.12 _ _ 15.07 26 18 8 2.07 9.4 25.8 Grade-III _

Average _ _ 100 _ 19.177 _ _ 14.91 27 18 9 2.07 9 24.2 Blending Required

(250 X 150 X 1.0)m (<50,000

cum)

Name of Road : Bhawanipatna to Khariar ( km 0/0 to 70/0 ) S.H - 16

75 mm

53 mm

26.5 mm

9.5 mm

4.75 mm

2.36 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index

(PI)

Density gm/cc

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1.A Karlasoda ( Km 4/0 )

Road side L.H.S _ _ 100 37.24 _ _ 5.27 24 19 5.0 2.21 7.8 30.5 _

B _ _ 100 42.50 _ _ 4.71 23 19 4.0 2.20 8.4 32.1 _

C _ _ 100 40.27 _ _ 3.38 25 21 4.0 2.18 9 31.5 Grade -III

Average _ _ 100 _ 40.0 _ _ 4.45 24 20 4 2.2 8.4 31.38 After Blending 18% sand of Tel river

2.A Karlaguda ( Km 13/0 )

Road side L.H.S _ 100 63.2 _ 32.17 _ _ 7.15 24 20 4.0 2.23 8.0 33.2 _

B _ 100 62.4 _ 30.3 _ _ 6.40 25 20 5.0 2.20 7.8 30.7 _

C _ 100 60.17 _ 29.4 _ _ 5.30 23 19 4.0 2.19 8.2 33.8 Grade -II

Average _ 100 61.92 30.6 _ _ 6.28 24 20 4 2.21 8.00 32.6 After Blending 15% sand of Tel river

L.H.S / R.H.S

TABLE : 4.2 : TEST RESULT OF GRANULAR SUB-BASE MATERIAL FOR BORROW AREA (After Blending )

Sl. No. Location Lead in

KM




Part VIII)Confirm to Grade /

Suitability

CBR value

(Soaked)%

75 mm

53 mm

26.5 mm

9.5 mm

4.75 mm

2.36 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index

(PI)

Density gm/cc

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

L.H.S / R.H.S


KM





Suitability

CBR value

(Soaked)%

3.A Pastipada Quarry ( Km 15/0 ) 4.0 L.H.S _ 100 62.5 _ 18.4 _ _ 8.20 20 NP NIL 2.28 7.9 34.2 _

B _ 100 60.4 _ 20.4 _ _ 7.10 23 19 4 2.26 8.3 32.4 _

C _ 100 63.7 _ 23.6 _ _ 5.60 25 20 5 2.2 9.2 33.7 Grade-II

Average _ 100 62.2 _ 20.8 _ _ 6.97 22.7 19.5 4.5 2.25 8.47 33.4 After Blending 20% sand of Tel river

4.AAdhamunda

Quarry ( Km 18/5 )

4.5 R.H.S 100 _ 66.5 17.05 _ _ 6.55 25 20 5 2.19 6.95 35.1 _

B 100 _ 59.1 21.3 _ _ 7.80 24 20 4 2.14 8.8 36.0 _

C 100 _ 57.5 19.3 _ _ 5.40 23 18 5 2.15 7.8 34 Grade-I

Average 100 _ 61.0 19.2 _ _ 6.58 24 19 5 2.16 7.85 35.0 Suitable

5.ADonguriguda

Quarry ( Km 23/0 )

Road side R.H.S 100 _ 67.5 _ 18.9 _ _ 5.90 24 20 4 2.17 7.4 34.5 _

B 100 _ 55.5 _ 17.5 _ _ 6.80 25 20 5 2.15 7.6 36.0 _

75 mm

53 mm

26.5 mm

9.5 mm

4.75 mm

2.36 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %

Plasticity Index

(PI)

Density gm/cc

OMC %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

L.H.S / R.H.S


KM





Suitability

CBR value

(Soaked)%

C 100 _ 59.1 _ 19.05 _ _ 4.70 24 20 4 2.14 8.05 35 Grade-I

Average 100 _ 60.7 _ 18.5 _ _ 5.8 24 20 4 2.15 7.7 35.2 Suitable

6.A Debujhar Quarry ( Km 53/0 ) 5.0 L.H.S _ _ 100 _ 27.85 _ _ 6.40 19 NP NIL 2.2 7.6 30.5 _

B _ _ 100 _ 30.7 _ _ 5.20 23 18 5 2.19 8.5 29.4 _

C _ _ 100 _ 31.4 _ _ 4.30 24 19 5 2.17 8.9 27.8 Grade-III

Average _ _ 100 _ 30.0 _ _ 5.3 22 18.5 5 2.19 8.33 29.2 After Blending 20% sand of sunder river



GRADATION CURVES FOR GRANULAR SUB

BASE MATERIAL



Sample Location -

Source of Material - G.S.B. Quarry

Name of the Road - Bhawanipatna to Khariar ( S.H.-16)

LegendConfirming to Grade III ( After Blending 18% sand of Tel river)

Grading after blendinglower limit

GRADING FOR COARSE-GRADED GRANULAR SUB-BASE MATERIAL AS PER MORTH TABLE 400 - 2

Consultancy services for Feasibility Study and Detailed Project Report Preparation of Phase-1 Roads for Orissa State Road Project Under World Bank Assistance

KarlasodaKm 4 / 0 ( 25.0 km L.H.S )

Upper limit

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10 100IS Sieve size (mm)

% P

ASS

ING



Sample Location - Km 13 / 0 ( Road side L.H.S)


Name of the Road - Bhawanipatna to Khariar ( S.H-16 )

LegendConfirming to Grade II ( After Blending 15% sand of Tel river)

Grading after blendingLower limit



Karlaguda

Upper limit

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10 100IS Sieve size (mm)

% P

ASS

ING



Sample Location - Km 15 / 0 ( 4.0 km L.H.S)


Name of the Road - Bhawanipatna to Khariar ( S.H-16 )

Confirming to Grade II ( After Blending 20 % sand of Tel river)

Lower limit

Legend



Pastipada

Upper LimitGrading after blending

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10 100IS Sieve size (mm)

% P

ASS

ING



Sample Location -


Name of the Road - Bhawanipatna to Kharior ( S.H -16)

Legend

Confirming to Grade IActual Grading



Km 18 / 5 ( Km 4.5 R.H.S) Adhamunda

Upper Limit

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10 100IS Sieve size (mm)

% P

ASS

ING



Sample Location -


Name of the Road - Bhawanipatna to Khariar ( S.H.-16)

Confirming to Grade III ( After Blending 20% sand of Sunder river) Upper limit

Grading after blending

Lower Limit

Legend



DebujharKm 53 / 0 ( km 5.0 L.H.S )

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10 100IS Sieve size (mm)

% P

ASS

ING


Lower limit



Sample Location -


Name of the Road - Bhawanipatna to Kharior ( S.H -16)

LegendConfirming to Grade I

Actual GradingLower limit



Km 23 / 0 (Road side R.H.S) Donguriguda

Upper limit

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10 100IS Sieve size (mm)

% P

ASS

ING



CHAPTER – 5 COARSE AGGREGATE



CHAPTER – 5

COARSE AGGREGATE

5.0 GENERAL

Coarse aggregates are extensively used in the construction of Wet Mix Macadam as base course material and in various types of bituminous and other construction works. Therefore its suitability is to be checked as per the requirements of different works. In this chapter, the general requirements to be fulfilled by the aggregate during the construction of WMM only is discussed. For other type of construction like Bituminous work its requirements will be discussed in the relevant chapters. In the road section of SH-16, Bhawani to Kheriar, Seventeen quarries were found and in the other road section of SH-16. The representative materials were collected from these quarries and the following tests were conducted.

Laboratory Tests:

- Gradation (IS: 2386, Pt I& MORT&H)

- Aggregate Impact Value (IS: 2386, Pt IV)

- Specific Gravity& Water Absorption (IS: 2386, Pt III)

- Combined Flakiness & Elongation Index (IS: 2386, Pt I)

- Stripping Value (IS : 6241)

The Tests results are tabulated in Table 5.1 and their suitability for different type of works is found out on the basis of these results.

Wet mix macadam is a pavement layer where in crushed graded aggregate and granular material like graded Coarse and granular material are mixed with water in mixing plant and rolled in a dense mass on a prepared surface. The thickness of an individual layer shall not be less than 75 mm and can be up to 200 mm.

5.1 Materials and General Requirements Crushed or broken stone shall be hard, durable and free from excess flat, elongated,

soft and disintegrated particles and other deleterious material. The aggregate shall conform to the physical requirement set forth in Table 5.2 as follows:



Table - 5.2: Physical Requirements of Coarse Aggregate for Wet Mix Macadam for Sub-base/ Base Courses

S. No. Test Test Method Requirements

1. *Los Angeles Abrasion value or IS: 2386 (Part IV) 40 per cent (Maximum)

2. *Aggregate Impact Value IS: 2386 (Part IV) 30 per cent (Maximum)

3. Combined Flakiness and Elongation indices (Total)

IS: 2386 (Part I) 30 per cent (Maximum)**

z* Aggregate may satisfy requirement of either of the two tests.

** To determine this combined proportion, the flaky stone from a representative sample should first be separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles are separated out from the remaining (non-flaky) stone metal. Elongation index is weight of elongated particles divided by total non-flaky particles. The value of flakiness index and elongation index so found are added up.

If the water absorption value of the coarse aggregate is greater than 2 percent, the soundness test shall be carried out on the material delivered to site as per IS: 2386 (Part V).

Table - 5.3: Grading requirement of Coarse Aggregates for Wet Mix Macadam

IS Sieve Designation Per cent by weight passing the IS sieve

53.0 mm 100

45.00 mm 95-100

26.50 mm --

22.40 mm 60-80

11.20 mm 40-60

4.75 mm 25-40

2.36 15-30

600.00 micron 8-22

75.00 micron 0-8

Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.The final gradation approved within these limits shall be well graded from coarse to fine



and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice verse. The work shall be carried as per MORT&H specification for Road & Bridges and IRC Paper 109 - 1997.

5.2 Quality Control of work.

The frequency of the Quality Control tests shall be as under:

Table - 5.4: Frequency of the Quality Control Tests

1. Gradation One Test per 100 m3

2. Plasticity index One Test per 100 m3

3. Moisture Content prior to compaction One Test per 100 m2

4. Density of compacted layer One Test per 500 m3

5. Aggregate impact value or Los Angles Abrasion Value One Test per 200 m3

6. Flakiness and Elongation Index One Test per 200 m3

For testing the compaction requirements, test locations shall be chosen only through random sampling techniques. Control shall not be based on the result of any one test but on the mean value of 5-10 density determinations. The number of tests in one set of measurements shall be 6 (if non-destructive tests are carried out, the number of tests shall be doubled) as long as it is felt that sufficient control over the constituent materials forming the mix is being exercised. If considerable variations i.e. 15 % and above are observed between individual density results, the minimum number of tests in one set of measurement shall be increased to 10. The acceptance criteria shall be subject to the condition that the mean density of a set of measurement shall not be less than the specified density plus: [1.65 – 1.65 / (No. of samples) 0.5 ] x standard deviation

The degree of compaction should not be less than 98 % of the maximum laboratory density in any case.

5.3 Discussion of Tests Results

The samples collected from various queries were tested in the laboratory. All the samples comply with the physical requirement of MORT&H specifications.

Their water absorption value ranges from 0.30 % to 0.77% and the combined flakiness and elongation indices also comply with the physical requirements as per MORT&H specifications. The Impact values are in the range from 15% to 24% which is also well within the prescribed limits as per MORTH. The aggregates from quarries do not conform exactly to the grading specified in the specification of MORT&H. Therefore; the blending as per the requirement should be done prior to mixing at plant. The stripping value of most of aggregate do not fulfill the requirements except



some of the quarries like Kamathana (6/0), Adhamunda (18/0), For the aggregates whose stripping value do not fulfill the requirement then anti stripping agent should be used during execution as per the requirement. the Morth’s (Appendix 1000-1) The tests results are given in Table 3.1. In most of the quarries the aggregate is available in large quantities except in some of quarries named Singh Badi (70/0), Risipeti (km 61/0),(km 31/0), Kamathana ( 6.0/0) where material is available in small quantities. Materials from quarries / crusher (aggregate) given in test results Table 5.1 are suitable for W.M.M., Bituminous work and other construction works in accordance to MORT&H specifications.

Name Of the Work : Consultancy Services for Feasibility Study and Detailed Project Report Preparation of Phase-1 roads for Orissa State Road Project Under world Bank Assistance

Name Of the Road : Bhawanipatna to kharior ( S.H-16 ) Km 0/0 to 70/0

40 mm 20 mm1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1.ABhawanipatna

to Khariar ( S.H-16)

Singh Bhadi Km 70/0 4 km R.H.S 10 100 100 100 73.89 33.56 0.1 24.6 2.71 0.58 _ _ 86 _

B 100 100 100 71.24 32.1 1.4 24.1 2.69 0.54 _ _ 88 _

C 100 100 100 69.92 33.08 1.8 23.4 2.7 0.8 _ _ 83 _

Average 100 100 100 71.68 32.91 1.10 24.0 2.7 0.64 _ _ 85.7 >40,000 cum

2.A " Singh Bhadi Km 70/0 4 km R.H.S 20 100 100 98.24 _ 28.13 2.10 18.42 2.71 0.23 _ 23.47 89 _

B 100 100 96.27 _ 29.73 1.90 17.87 2.69 0.57 _ 27.15 86 _

C 100 100 96.82 _ 30.15 2.83 18.04 2.68 0.48 _ 23.41 90 _

Average 100 100 97.11 _ 29.3 2.28 18.11 2.69 0.43 _ 24.7 88.3 >40,000 cum

3.A " Singh Bhadi Km 70/0 4 km R.H.S 40 100 100 38.40 _ 16.27 2.4 18.86 2.68 0.52 28.3 _ 88 _

B 100 100 36.47 _ 14.28 1.8 18.24 2.7 0.67 26.42 _ 90 _

C 100 100 35.68 _ 14.9 2 17.45 2.67 0.72 25.76 _ 86 _

Average 100 100 36.85 _ 15.15 2.07 18.2 2.68 0.64 26.8 _ 88.0 >40,000 cum

Aggregate Impact Value % (IS:2386

Part IV)

Water Absorptions (IS:2386 Part III) %

Combine Flakiness &

Elongation Index Retained coating

in %Nominal size Aproximate

Area / Quantity Avaliable

Location and Name of quarry

Gradation: Percent by weight passing the Sieve IS:383 & MORTH

12.5 mm

63 mm

L.H.S / R.H.S

TABLE NO :- 5.1 TEST RESULT SHEET OF AGGREGATES.

40 mm

20 mm

Name of Road / Chainage

Lead From road

chainage

Size Of Agg in

mm

Specific Gravity4.75

mm10

mm

Sl. No.

40 mm 20 mm


Part IV)


Combine Flakiness &






12.5 mm

63 mm

L.H.S / R.H.S 40

mm20

mm


Lead From road

chainage

Size Of Agg in

mm


mm10

mm

Sl. No.

4.A " Risigaon Quarry Km 64/0 1 km R.H.S 10 _ _ 100 92.99 72.52 0.22 22.8 2.77 0.46 _ _ 89 _

B _ _ 100 89.27 68.43 1.2 23.2 2.72 0.52 _ _ 92 _

C _ _ 100 90.43 70.85 1.9 22.1 2.74 0.5 _ _ 87 _

Average _ _ 100 90.9 70.6 1.11 22.7 2.74 0.49 _ _ 89.3 Large Qunatity

5.A " Risigaon Quarry Km 64/0 1 km R.H.S 20 _ 100 64.6 _ 18.2 1.7 15.4 2.79 0.52 _ 43.5 89 _

B _ 100 62.13 _ 16.52 1.2 14.5 2.73 0.8 _ 37.8 85 _

C _ 100 60.7 _ 14.2 0.8 15.2 2.72 1.0 _ 32.4 80 _

Average _ 100 62.5 _ 16.307 1.23 15.03 2.75 0.77 _ 37.9 84.7 Large Qunatity

6.A " Risigaon Quarry Km 64/0 1 km R.H.S 40 100 82.4 26.7 _ 6.7 0.8 24.73 2.78 0.25 41.9 _ 90 _

B 100 80.5 24.6 _ 5.8 0.6 23.5 2.7 0.51 35.2 _ 82 _

C 100 76 20.6 _ 4.8 1.3 22.4 2.69 0.9 32.7 _ 80 _

Average 100 79.63 24.0 _ 5.77 0.9 23.5 2.72 0.55 36.6 _ 84 Large Qunatity

40 mm 20 mm


Part IV)


Combine Flakiness &






12.5 mm

63 mm

L.H.S / R.H.S 40

mm20

mm


Lead From road

chainage

Size Of Agg in

mm


mm10

mm

Sl. No.

7.A " Risipeti Quary Km 61/0 3 km R.H.S 10 _ _ 100 66.7 37.2 2.7 23.5 2.68 0.6 _ _ 86 _

B _ _ 100 62.7 36.4 1.8 22.4 2.7 0.4 _ _ 90 _

C _ _ 100 64.6 35.8 1.2 20.7 2.69 0.7 _ _ 83 _

Average _ _ 100 64.67 36.47 1.91 22.2 2.69 0.57 _ _ 86.3 >30,000 Cum

8.A " Risipeti Quary Km 61/0 3 km R.H.S 20 _ 100 70.24 12.4 _ 0.8 21.68 2.67 0.4 _ 26.0 90 _

B _ 100 66.4 14.7 _ 0.9 20.3 2.69 0.6 _ 30.70 84 _

C _ 100 67.9 15.7 _ 1.2 20.8 2.7 0.5 _ 27.40 83 _

Average _ 100 68.18 14.3 _ 1.0 20.9 2.69 0.5 _ 28.03 85.7 >30,000 Cum

9.A " Risipeti Quary Km 61/0 3 km R.H.S 40 100 81.27 3.4 _ 0.9 _ 20.8 2.64 0.46 40.6 _ 84 _

B 100 76.5 2.5 _ 0.6 _ 19.5 2.68 0.8 32.5 _ 85 _

C 100 78.7 3.8 _ 0.4 _ 20.6 2.7 0.6 30.4 _ 87 _

Average 100 78.8 3.2 _ 0.6 _ 20.3 2.7 0.6 34.5 _ 85.3 >30,000 Cum

40 mm 20 mm


Part IV)


Combine Flakiness &






12.5 mm

63 mm

L.H.S / R.H.S 40

mm20

mm


Lead From road

chainage

Size Of Agg in

mm


mm10

mm

Sl. No.

10.A " Dabujhar Quarry Km 53/0 5 km L.H.S 40 100 80.8 10.7 _ 1.2 _ 26.4 2.65 0.5 22.6 _ 90 _

B 100 78.6 11.7 _ 0.9 _ 24.8 2.7 0.6 24.7 _ 85 _

C 100 77.4 9.4 _ 0.6 _ 23.7 2.69 0.8 20.6 _ 87 _

Average 100 78.9 10.6 _ 0.9 _ 25.0 2.7 0.6 22.6 _ 87.3 Large Qunatity

11.A " Sindhigela Km 47/0 5 km R.H.S 20 _ 100 86.5 _ 22.4 1.2 22.7 2.67 0.41 _ 27.5 84 _

B _ 100 82.4 _ 20.7 0.8 23.1 2.7 0.54 _ 32.4 80 _

C _ 100 83.7 _ 21.3 0.7 23.4 2.72 0.81 _ 30.8 87 _

Average _ 100 84.2 _ 21.5 0.9 23 2.7 0.6 _ 30.2 83.7 Large Qunatity

12.A " Km 31/0 8 km R.H.S 40 100 79.5 15.2 _ 4.2 2.4 25.4 2.69 0.42 25.7 _ 89 _

B 100 75.4 14.5 _ 3.5 1.8 24.5 2.67 0.6 24.5 _ 83 _

C 100 73.8 13.4 _ 2.1 0.9 23.4 2.70 0.7 22.4 _ 86 _

Average 100 76.2 14.4 _ 3.3 1.7 24.4 2.7 0.6 24.2 _ 86.0 <50,000 Cum

40 mm 20 mm


Part IV)


Combine Flakiness &






12.5 mm

63 mm

L.H.S / R.H.S 40

mm20

mm


Lead From road

chainage

Size Of Agg in

mm


mm10

mm

Sl. No.

13.A "Kamathana

Crusher Quarry ( Km 6/0 )

3.0 km R.H.S 10 100 100 100 82.14 60.55 0.8 19.98 2.78 0.34 _ _ Satisfactory _

B 100 100 100 80.4 55.24 0.7 20.4 2.76 0.26 _ _ Satisfactory _

C 100 100 100 78.5 54.3 1.1 18.7 2.7 0.4 _ _ Satisfactory _

Average 100 100 100 80.3 56.7 0.9 19.7 2.7 0.3 _ _ Satisfactory >50,000 Cum

14.A "Kamathana


3.0 km R.H.S 20 100 100 56.5 _ 3.25 1.2 15.2 2.73 0.7 _ 42.7 Satisfactory _

B 100 100 54.8 _ 2.18 0.9 16.1 2.71 0.5 _ 35.4 Satisfactory _

C 100 100 52.4 _ 4.5 2.1 17.4 2.69 0.6 _ 32.7 Satisfactory _

Average 100 100 54.6 _ 3.3 1.4 16.2 2.7 0.6 _ 36.9 Satisfactory >50,000 Cum

15.A "Kamathana


3.0 km R.H.S 40 100 81.4 22.8 _ 1.8 0.8 18.5 2.71 0.7 27.80 _ Satisfactory _

B 100 79.4 20.6 _ 1.2 0.5 19.4 2.73 0.5 34.70 _ Satisfactory _

C 100 78.2 19.2 _ 0.9 0.4 18.2 2.70 0.8 30.60 _ Satisfactory _

Average 100 79.7 20.9 _ 1.3 0.6 18.7 2.7 0.7 31.0 _ Satisfactory >50,000 Cum

40 mm 20 mm


Part IV)


Combine Flakiness &






12.5 mm

63 mm

L.H.S / R.H.S 40

mm20

mm


Lead From road

chainage

Size Of Agg in

mm


mm10

mm

Sl. No.

16.A " Adhamunda Quarry Km 0/0 18.0 R.H.S 10 _ _ 100 99.25 79.53 2.42 19.4 2.72 0.9 _ _ Satisfactory _

B _ _ 100 97.5 76.78 1.82 18.2 2.74 0.7 _ _ Satisfactory _

C _ _ 100 96.83 75.76 1.4 18.7 2.74 0.6 _ _ Satisfactory _

Average _ _ 100 97.9 77.4 1.9 18.8 2.7 0.7 _ _ Satisfactory Large Qunatity

17.A " Adhamunda Quarry Km 0/0 18.0 R.H.S 20 _ 100 95.9 _ 27.5 1.8 19.4 2.78 0.4 _ 27.1 Satisfactory _

B _ 100 96.8 _ 29.4 1.2 18.4 2.75 0.7 _ 24.8 Satisfactory _

C _ 100 98.2 _ 28.4 0.8 18.7 2.72 0.3 _ 23.5 Satisfactory _

Average _ 100 97.0 _ 28.4 1.3 18.8 2.8 0.5 _ 25.1 Satisfactory Large Qunatity

1



CHAPTER – 6 SAND/FINE AGGREGATE



CHAPTER –6

SAND / FINE AGGREGATES

6.0 GENERAL

Sand will be required for concrete work and for blending with marginal quality sub base materials. It is also used for the improvement of subgrade, drainage layers and for bedding and can be used in the bituminous mix design.

The only source for good quality sand is rivers flowing in the nearby regions. In this section of road, there are many large sand deposits close to the project roads, which can be used either in subgrade or for construction purpose.

The following tests are conducted to assess their suitability - Gradation (IS: 383) - Silt content and Fineness Modulus (IS: 383) - Specific Gravity (IS: 2720, Pt III) - Deleterious content (IS: 2386, Pt-I & IS : 383)

6.1 MATERIALS AND GENERAL REQUIREMENTS 6.1.1 For masonry work, sand shall conform to the requirements of IS: 2116.

6.1.2 For plain and reinforced cement concrete (PCC and RCC) or prestressed concrete (PSC) works, fine aggregate shall consists of clean, hard, strong and durable pieces of crushed stone, crushed gravel, or a suitable combination of natural sand, crushed stone or gravel. They shall not contain dust, lumps, soft or flaky, materials, mica or other deleterious materials in such quantities as to reduce the strength and durability of the concrete, or to attach the embedded steel. Motorized sand washing machines should be used to remove impurities from sand. Fine aggregate having positive alkali-silica reaction shall not be used. All fine aggregates shall conform to IS: 383 and tests for conformity shall be carried out as per IS: 2386 (Parts I to VIII). The fineness modulus of fine aggregate shall neither be less than 2.0 nor greater than 3.5.

Sand/fine aggregate for structural concrete shall conform to the following grading requirements:

Table - 6.3: Gradation Of Sand / Fine aggregates

Percent by Weight Passing the Sieve IS Sieve

Size Zone I Zone II Zone III

10 mm 100 100 100

4.75 mm 90-100 90-100 90-100

236 mm 60-95 75-100 85-100

1.18 mm 30-70 55-90 75-100

600 micron 15-34 35-59 60-79

300 micron 5-20 8-30 12.40



150 micron 0-10 0-10 0-10

Table - 6.4: Frequency of tests at site during execution

S. No. Test IS Code Frequency

(i) Gradation IS: 2386 (Part I) One test per 15 m3 of each fraction of fine aggregate

(ii) Deleterious constituents IS: 2386 (Part-I) -do-

(iii) Moisture content IS: 2386 (Part III) Two test / day for fine aggregates


The representative Sand samples were collected from Two numbers of quarries (Tel River ,Sunder River) and their test results for both as subgrade material and for construction purpose are tabulated in Table 6.1 and Table 6.2 .

Sand sources are generally suitable for fine aggregate materials in Bituminous works and Concrete works but would require the removal of deleterious materials and Clay / Silt contents. From the Table 6.1 and Table 6.2, it is evident that the Sand of Tel River and Sunder rivers are laying in zone III (at selected bed) it may vary at different bed levels. Though there are certain frequency of tests &type of test may be conducted during construction test results shows that sand samples from both sources are also suitable for subgrade material as well as RCC / Masonry work.

4.75 mm

2.0 mm

425 micron

75 micron

Liquid Limit

(LL) %

Plastic Limit

(PL) %


Max. dry

density gm/cc.

OMC %

1 2 4 5 6 7 8 9 10 11 12 13 16 19

1.A Tel River K.M 28/0 Road side Both side 0.0 0.0 25.27 44.26 30.47 20 N.P NIL 1.90 5.5 22.46 650x400x2.0m

B 0.0 0.0 23.44 48.62 27.94 23 N.P NIL 1.91 6.8 20.7 -

C 0.0 0.0 23.5 47.13 29.37 18 N.P NIL 1.93 7.01 21.3 -

Average 0.0 0.0 24.1 46.7 29.3 20.3 N.P NIL 1.91 6.4 21.5 -

2.A Sunder River K.m 59/0

Road side Both side 0 0 26.86 48.6 24.54 20 N.P NIL 1.87 6.7 20.4 500x300x2.0m

B 0 0 25.7 50.7 23.6 19 N.P NIL 1.82 5.8 19.4 -

C 0 0 24.62 46.8 28.58 22 N.P NIL 1.84 6.2 20.2 -

Average 0.0 0.0 25.7 48.7 25.6 20 N.P NIL 1.84 6.2 20.0 -

Lead in K.M

L.H.S /R.H.S

CBR Soaked %

Bhawanipatna to Khariar

TABLE - 6.1 : TEST RESULT OF RIVER SAND / FINE AGGREGATE ( FOR FILLING WORK )

Name of Road : Bhawanipatna to Khariar (S.H-16)

approx Area / Quantity Avaliable

Sl. No.


Gradation: Percent by weight retained the Sieve (IS:2720-IV) Clay and

silt content

%

Atterberg Limits [IS:2720 Pt-V]

Modified Proctor Test

(IS:2720-Pt-VIII)

Name of Road :

10 mm

4.75 mm 2.36 mm 1.18 mm 600

micron300

micron150

micron

Silt content

%1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 Bhawanipatna to Kherior Tel River (Km 28/0) 0 Both

side 100 100 99.92 99.19 71.24 16.48 5.70 1.8 2.07 2.61 III Large Quantity

2 Bhawanipatna to Kherior Sunder River (Km 59/0) 0 Both

side 100 100 96.21 95.84 66.73 20.17 4.09 1.2 2.17 2.63 III Large Quantity

TABLE - 6.2 : TEST RESULT OF RIVER SAND / FINE AGGREGATE ( FOR CONCRETE WORKS )

Specific gravity

Sand laying in zone as

per IS:383

Bhawanipatna to Kherior (km 0/000 to 70/000) S.H-16

Finess modules

L.H.S / R.H.S

Lead in Km from Road

Name & Location of

river & Source

Aprox. avliable Quantity

Sl. No. Name of Road

Gradation: Percent by weight passing the Sieve (IS:383)



GRADATION CURVES FOR SAND/FINE AGGREGATE


Sample Location -

Source of Material - Tel River

Name Of The Road Bhawanipatna to Khariar ( S.H-16 )

LegendIII

Actual GradingLower limit

GRADING ANALYSIS FOR SAND AS PER IS : 383


Km 28 / 0 (0.0 km) Both side

Confirming the Zone as per IS 383 : Upper limit

0

10

20

30

40

50

60

70

80

90

100

0.1 1 10IS Sieve size (mm)

% P

ASS

ING


Sample Location -

Source of Material - Sunder River


III




Confirming the Zone as per IS 383 :

0

10

20

30

40

50

60

70

80

90

100


% P

ASS

ING

Lower limit

Actual Grading

Uper Limit


Sample Location -

Source of Material - Tel River


III




Confirming the Zone as per IS 383 :

0

10

20

30

40

50

60

70

80

90

100


% P

ASS

ING

Lower limit

Actual Grading

Uper Limit



CHAPTER – 7 CEMENT /CEMENT CONCERETE



CHAPTER- 7

Cement / Cement Concrete

7.0 GENERAL

As cement is made by branded manufacturers in the regions. In this region, Konark Slag Cement and Lafarge Cement are mainly in use for construction purpose. As cement is manufactured by branded companies and its testing is done on lot to lot basis regularly. Therefore, samples of these two types of cement were tested for the physical properties. The test results are tabulated in Table 7.1 and 7.2

Table - 7.1: Physical Test Results

Brand of cement : Konark slag cement

S. No. Physical requirement IS: 12269 54 Grade Normal Ranges

1. Consistency

(in %) 33% 28%-32%

Setting time (Minutes)

Initial

56 min

Minimum 30 minute 2.

Final 260 min 600 minute, Maximum

Compressive Strength -- --

3 days 200 kg/cm2 ---

7 days 360 kg/cm2 ----

3.

28 days 542 kg/cm2 ----



Table - 7.2: Physical Test Results

Brand of Cement: Lafarge 43 grade cement

S. No. Physical requirement IS: 12269 54 Grade

Mostly Indian cement with compaction with

IS: 1489 IS: 8112

IS: 12269

1. Consistency

(in %) 32% 28%-32%

2.

Setting time (Minutes)

Initial

48 min Minimum 30 minute

Final 245 min 600 minute, Maximum

3. Compressive Strength -- --

3 days 100 kg/cm2 ---

7 days 300 kg/cm2 ----

28 days 446 kg/cm2 ----

7.1 CONCRETE

The concrete work shall consist of furnishing and placing structural concrete and incidental construction with these specifications and in conformity with the lines, grades and dimensions, as shown on the drawings or as directed by the Engineer. A mix design of grade M-25 is conducted and results are reported in this chapter. Though ,it is recommended that as the gradation and other physical properties of materials used in mix design varies site to site. Therefore fresh mix designs of the required grade should always be conducted before the construction starts.

7.2 MATERIALS AND GENERAL REQUIREMENTS

All materials shall conform to specification of MORT&H Section 1000



Grades of Concrete

The grades of concrete shall be designated by the characteristic strength as given in Table 7.3 where the characteristic strength is defined as the strength of concrete below which not more than 5 percent of the test results are expected to fall.

Table- 7.3: Grades of Concrete

Grade designation Specified characteristic compressive strength of 150 mm cubes at 28 days, in Mpa

M 15 15

M 20 20

M 25 25

M 30 30

M 35 35

M 40 40

M 45 45

M 50 50

M 55 55

7.3 The lowest grades of concrete in bridges and corresponding minimum cement contents and water cement ratios shall be maintained as indicated in Tables 7.4 and 7.5

Table - 7.4: For Bridges with Prestressed Concrete or Those with Individual Span Length more Than 30 M OR Those That are Built with Innovative Design /

Construction.

(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO

Maximum water cement ratio

Exposure conditions

Structural Member

Minimum Cement content for all exposure

condition (kg /cum) Normal Severe

a) PCC members 360 0.45 0.45

b) RCC members 400 0.45 0.40

c) PSC members 400 0.40 0.40



(B) MINIMUM STRENGTH OF CONCRETE

Conditions of Exposure

Member Moderate Severe

a) PCC members M 25 M 30

b) RCC members M 35 M 40

c) PSC members M 35 M 40

Table - 7.5: For Bridges Other Than Those Mentioned in Table 7.4 and for Culverts and Other Incidental Construction.

(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO.

Minimum cement content (kg/cum)

Maximum water cement ratio

Exposure conditions Exposure conditions Structural Member

Normal Severe Normal Severe

a) PCC members 250 310 0.50 0.45

b) RCC members 310 400 0.45 0.40

(B) MINIMUM STRENGTH OF CONCRETE

Conditions of Exposure Member

Moderate Severe

a) PCC members M 15 M 20

b) RCC members M 20 M 25

Notes Applicable to Tables (7.4) and (7.5)

i. The minimum cement content is based on 20 mm aggregate (nominal max. size). For 40 mm and larger size aggregates, it may be reduced suitably but the reduction shall not be more than 10 percent.

ii. For underwater concreting, the cement content shall be increased by 10 percent.



iii. Severe conditions of exposure shall mean alternate wetting and dying due to sea spray, alternate wetting and dying combined with freezing and buried in soil having corrosive effect.

iv. Moderate conditions of exposure shall mean other than those mentioned in (iii) above.

The cement content shall be as low as possible but not less than the quantities specified above. In no case shall it exceed 540/cu.m of concrete.

Concrete used in any component or structure shall be specified by designation along with prescribed method of design of mix i.e. “Design Mix” or “Nominal Mix”. For all items of concrete, only “Design Mix” shall be used, except where “Nominal Mix” concrete is permitted as per drawing or suggested by the Engineer. “Nominal Mix” may be permitted only for minor bridges and culverts or other incidental construction where strength requirements are upto M 20 only. “Nominal Mix” may also be permitted for non-structural or for screed below open foundations.

7.4 PROPORTIONING OF CONCRETE

Prior to the start of constructions, the Contractor shall design the mix in case of “Nominal Mix Concrete” and submit to the Engineer for approval, the proportions of materials, including admixtures to be used. Water reducing admixtures (including plasticisers or super-plasticisers) may be used at the Contractor’s option, subject to the approval of the Engineer. Other types of admixtures shall be prohibited, unless specifically permitted by the Engineer.

7.5 REQURIMENTS OF CONSISTENCY

The mix shall have the consistency, which will allow proper placement and consolidation in the required position. Every attempt shall be made to obtain uniform consistency.

The slump of concrete shall be checked as Per IS: 516.

Table - 7.6: Slump Requirement of Concrete

TYPE SLUMP (mm)

1. (a) Structures with exposed inclined surface requiring low Slum concrete to allow proper compaction 25

(b) Plain cement concrete 25

2. RCC structures with widely spaced reinforcement, e.g. solid Columns, piers, abutments, footings, well staining

40 – 50

3.

RCC structures with fair degree of congestion of Reinforcement, e.g. pier and abutment caps, box culverts well Curb well, cap, walls with thickness greater than 300 mm

50 – 75



4. RCC and PSC structures with highly congested Reinforcement e.g. deck slab girders, box girders, Walls with thickness less than 300 mm

75 – 125

5. Underwater concreting through tremie e.g. bottom plug, cast-in-situ piling 100 - 200

Table - 7.7: Frequency of Quality Control Tests

Concrete (i) Strength of Concrete

IS: 516 2 cubes and 2 beams per 150 m2 or part thereof (one for 7 day and other for 28day strength) or minimum 6 cubes and 6 beams per day’s work whichever is more

(ii) Core strength on hardened concrete

IS: 516 As per the requirement of the Engineer, only in case of doubt.

(iii) Workability of fresh concrete Slump Test

IS: 1199 One test per each dumper load at both Batching plant site and paving site initially when work starts. Subsequently sampling may be done from alternate dumper

(iv) Thickness determination

From the level date of concrete pavement surface and sub base at grid points of 5/6.25 m x 3.5 m`

(v) Thickness measurement for trial strength

3 cores per trail length

(vi) Verification of level of string line in the case of slip from paving and steel forms in the case of fixed form paving.

String line or steel forms shall be checked for level at an interval of 5.0 m or 6.25 m. The level tolerance allowed shall be +/- 2mm. These shall be got approved 1-2 hours before the commencement of the concreting activity.



7.6 CONCRETE ADMIXTURES

Admixtures are materials added to the concrete before or during mixing with a view to modify one or more of the properties of concrete in the plastic or hardened state.

Concrete admixtures are proprietary items of manufacture and shall be obtained only from established manufacturers with proven track record, quality assurance and full-fledged laboratory facilities for the manufacture and testing of concrete.



CHAPTER –8 WATER



CHAPTER - 8

WATER

8.0 GENERAL

Water used for mixing and curing shall be clean and free from injurious amounts of oils, acids alkalis, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. Potable water is generally considered satisfactory for mixing concrete. Mixing and curing with seawater shall not permit. As a guide, the following concentrations represent the maximum permissible values:

a) To neutralize 200 ml sample of water, using phenolphthalein as an indicator, it should not require more than 2 ml of 0.1 normal NaOH.

b) To neutralize 200 ml sample of water, using methyl orange as an indicator, it should not require more than 10 ml of 0.1 normal HCL.

c) To permissible limits as per IS: 456 shall be as follows when tested in accordance with IS: 3025:

Permissible Limits (max) as per IS: 456 Organic 200 mg/lit Inorganic 3000 mg/lit Sulphates (SO4) 400 mg/lit Chlorides (CI) 2000 mg/lit * Suspended matter 2000 mg/lit

* In case of concrete not containing embedded steel and 500 mg/lit. for R.C.C work All samples of water shall be tested and suitable measures taken where necessary to ensure conformity of the water to the requirements stated herein. d) The pH value shall not be less than 6 as per I.S 456 – 2000 e) The Acidity and Alkalinity should not be more than 5.0 ml and 25 ml.

Respectively.

8.1 TEST RESULTS

Water found satisfactory shall be used for concreting, R.C.C work & prestressed concrete for mixing & curing. The presence of toxic acid or iron compounds is objectionable.

During actual execution of work chemical tests for each source of ground water shall be carried out and approval shall be in according IS.456 –2000-5.4.2. The results are tabulated in Table 8.1 &8.2



Table - 8.1: Chemical Test Result of Water of Bhawanipatna to Khariar ( SH-16) Source: Tel River

Name of Tests Value

pH Value Organic

Inorganic Sulphates (SO4) Chlorides (CI)

Suspended matter Acidity

Alkalinity

8.12 52.4 mg/l 70.6 mg/l 89.5 mg/l 57.3 mg/l 114.1 mg/l

Nil 3.0 ml

Table - 8.2: Chemical Test Result of Water of Bhawani Patna to Kheriar ( SH-16) Source: Sunder River

Name of Tests Value

pH Value Organic

Inorganic Sulphates (SO4) Chlorides (CI)

Suspended matter Acidity

Alkalinity

7.02 40.4 mg/l 81.2 mg/l 42.7 mg/l 86.1 mg/l 94.3 mg/l

Nil 3.5 ml


Two samples of water from each road sections of Bhawani Patna to Kheriar ( SH-16) were collected and tested for the required parameters. From the given test results it is evident that these water samples are suitable for the construction purpose.

________________________



CHAPTER–9

STONE FOR BRIDGE WORK

9.1 Stone used for Bridges & Pitching shall be hard sound; free cracks decay & weathering stones are obtained from rock occurring in nature. Stone shall be freshly quarried from an approved quarry.

9.2 The various stones derived from these types of rocks are as follows:

(a) Principal stones from igneous rock: Granite, Basalt and trap

(b) Principal stones from sedimentary rocks: sand stone, shale, lime stone & laterite

(c) Principal stones from metamorphic rock: quartzite, schist, slate, marble and gneiss.

9.3 Require of a good stone for bridges & other structures:

(i) High strength-crushing strength >1000 kg/cm2

(ii) High durability, sufficient hardness- coefficient of hardness > 14

(iii) High resistance to wear, good file resistance

(iv) Specific gravity- More than 2.7

(v) Crystalline structure

(vi) High impact value- toughness index > 13

(vii) Low water absorption- 0.6% to 2% after 24 hours.

Generally stones from Igneous & Metamorphic rocks are heavier & more durable than stones from sedimentary rocks.

9.4 Suitable size of stones (i) The length of stone shall not exceed 3 times in height nor shall be less than

twice its height plus one joint (ii) No stone shall be less in width than the height (iii) Width of the base shall not be greater three-fourth of the thickness of the wall

nor less than 150 mm (iv) Pitching stone shall not be less than 40 k

9.5 Test results of stone quarries given in table 8.10 which are suitable for pitching /

masonry work.



TABLE 9.10

PHYSICAL REQUIREMENT FOR COARSE AGGREGATE

Name of Test Test Result

Water Absorption 0.35% -0.97%

Stripping 87 %--88% Coating and stripping of Bitumen

Specific gravity 2.68-2.71



CHAPTER- 10

BITUMINOUS WORK



CHAPTER – 10

BITUMINOUS WORK

10 BITUMINOUS WORKS MATERIAL USED ARE:

(i) Bitumen (iii) Filler

(ii) Aggregate (iv) Cutback / Emulsion

10.1 It consists of application of a single coat of low viscosity liquid bituminous material to an existing bituminous road surface. This is bituminous road surface preparatory to the superimposition of a bituminous mix.

Table 10.1

Material The binder used for tack coat shall be a bituminous emulsion or cut back as specified.

Temperature of application Bituminous emulsion – 20 degree to 70 degree C

Cut back – 50 degree to 80 degree C

For RC-70 / MC 70 grade is used

Rate of application i) 2.0 to 2.5 kg per 10 sqm for normal bituminous surface.

ii) 2.5 to 3.0 kg per 10 sqm dry and hungry bituminous surface

iii) Non-bituminous surface (not primer) 3.5 to 4.00 kg per 10 sqm.

Note: There is no need to tack coat on a freshly laid bituminous course if the sub-sequence bituminous course is overlaid the same day without opening it to traffic.

The cut back shall be free from water and shall not show any sign of separation prior to use. Material shall be as IS: 8887 and sampling testing of bituminous primer shall be as per IS: 217, IS: 454 and IS: 8887.

The emulsion of M.S. and S.S. type supplied by Indian Oil Corporation met the specification requirement. The results are computed as follows.

10.2 Bituminous Primer Coat

10.2.1 On W.M.M. surface a cost of bituminous primer of medium curing cut back (MC) shall be applied with pressure sprayed distributor at rate specified in contract.

10.2.2 Cut back bituminous is defined as the bitumen, the viscosity of which has been reduced by volatile diluents. The viscosity of the cut back and rate of which it hardens on the road depends on the characteristics and quantity of both bitumen and volatile oil used as the diluents. Cut back bitumen are available in three types, namely.



(i) Rapid curing (RC)

(ii) Medium curing (MC) and

(iii) Slow curing (SC)

This classification is based on the rate of curing or hardening after application. The grade of cut back or its fluidity is depends on viscosity, which is tabulated below.

10.2.3 Viscosity of Cutbacks

The lower grade cutback the RCO-RCI etc. would contain higher proportion of solvent whereas higher grade like RC4-MC4 may contain approx. 45 percent solvent and 55 percent bitumen, RC-5 and HC-5 may contain approximately 15 per cent solvent and 85 percent bitumen.

• Rapid curing cutbacks

• Medium curing cutbacks

• Slow curing cutbacks

• Tests for cut back bitumen

1. Viscosity tests

2. Penetration test

3. Flash point test

10.2.4 The choice of a bituminous primer shall depends upon the porosity characteristics of the surface to be primed as classified in IRC 16, these are:

i) Surface of low porosity, such as wet mix macadam and water bound,

ii) Surface of medium porosity, such as cement stabilized soil base

iii) Surface of high porosity, such as a gravel base

TABLE 10.2

Viscosity requirement and quantity of bituminous primer

Type of surface Kinematic viscosity of primer at 60 degree C (Centi

stokes)

Quantity per 10 sqm

(Kg)

Low porosity 30-60 6-9

Medium porosity 70-140 9-12



High porosity 250-500 12-15

The bituminous primer shall be medium curing cut back (MC) produced by fluxing, in an approved manner.

10.3 DENSE BITUMINOUS MACADAM

10.3.1 Material used for DBM

i) Bitumen – 60/70 grade (Table 10.3) as per MORT&H specification

ii) Coarse aggregate – As per MOST specification (Table 10.4)

iii) Fine aggregate

iv) Filler (Table 10.5) – as per MORT & H

10.3.2 Bitumen:

The Bitumen shall be paving bitumen of penetration grade 60/70 as per Indian Standard specification of “Paving Bitumen” IS:73. 60/70 Bitumen Grade has been recommended as per Annexure (6) of IRC: 37

Bitumen shall be transferred from refinery. 60/70 bitumen is manufactured on special advance requisition. Average cost per km at per Ton.

Requirements as per IS: 73-1992 are as follows: (Table 10.3)

TABLE- 10.3

i) Penetration value 60 to 70 mm

ii) Ductility Minimum 75 cm

iii) Softening point 40 degree C-55 degree C

iv) Flush point Minimum 175 degree C

TABLE 8.4

PHYSICAL REQUIREMENT FOR COARSE AGGREGATE FOR DENSE GRADED BITUMINOUS MACADAM

Property Test Specification

Cleanliness (dust) Grain size analysis 1 Max 5 % passing 0.075 mm sieve

Particle shape Flakiness and Elongation Index (Combined) 2

Max 30 %

Strength* Loss Angeles Emersion Value 3

Max 35 %

Aggregate Impact Value 4 Max 27 % Durability Soundess:5



Sodium sulphate Max 12 % Magnesium Sulphate Max 18 % Water Absorption Water absorption 6 Max 2 % Stripping Coating and stripping of

Bitumen Minimum retained

Aggregate Mixtures7 Coating 95 % Water Sensitivity** Retained Tensile Strength8 Min 80% Notes: 1. IS: 2386 Part 1 5. IS: 2386 Part 5 2. IS: 2386 Part 1 6. IS: 2386 Part 3 (The elongation test to be done only on non-flaky Aggregates in the sample) 3. IS: 2386 Part 4* 7. IS: 6241 4. IS: 2386 Part 4* 8. AASHTO T283**

* Aggregate may satisfy requirements of either of these two tests.

** The water sensitivity test is only required if the minimum retained coating in the stripping test is less than 95 %.

10.3.5 Filler:

Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement approved by the Engineer.

The filler shall be graded within the limits indicated in Table 10.5

TABLE 10.5

GRADING REQUIREMENTS FOR MINERAL FILLER

IS Sieve (mm) Cumulative per cent passing by weight of total aggregate

0.6 100

0.3 95 – 100

0.075 85 - 100

The filler shall be free from organic impurities and have a Plasticity Index not greater than 4. The Plasticity Index requirement shall not apply if filler is cement or lime. When the coarse aggregate is gravel, 2 per cent by Weight of total aggregate, shall be Portland cement or hydrated like and the percentage of fine aggregate reduced accordingly. Cement or hydrated lime is not required when the limestone aggregate is used. Where the aggregates fail to meet the requirements of the water sensitivity test,



then 2 per cent by total weight of aggregate, of hydrated lime shall be added without additional cost.

10.3.6 Aggregate grading and binder content:

When tested in accordance with IS: 2386 Part 1 (wet sieving method), the combined grading of the coarse and fine aggregates and added filler for the particular mixture shall fall within the limits shown in Table 10.6 for dense bituminous macadam grading 1 or 2 as specified in the Contract. The type and quantity of bitumen, and appropriate thickness, are also indicated for each mixture type.

Table 10.6

COMPOSITION OF DENSE GRADED BITUMINOUS MACADAM PAVEMENT LAYERS

Grading 1 2

Nominal aggregate size 40 mm 25 mm

Layer Thickness 80-100 mm 50-75 mm

IS Sieve Thickness Cumulative % by weight of total aggregate passing

45 100

37.5 95-100 100

26.5 63-93 90-100

19 - 71-95

13.2 55-75 56-80

9.5 - -

4.75 38-58 38-54

2.36 28-42 28-42

1.18 - -

0.6 - -

0.3 7-21 7-21

0.15 - -

0.075 2-8 2-8

Bitumen content % by mass of total mix 2

Min 4.0 Min 4.5

Bitumen grade (pen) 65 65

Notes: 1. The combined aggregate grading shall not vary from the low limit

on one sieve to the high limit on the adjacent sieve.

2. Determined by the Marshall method.

3.



10.4 BITUMINOUS CONCRETE

10.4.1 Scope:

The construction of Bituminous concrete used in wearing and profile corrective courses. This work shall consist of construction in a single or multiple layers of bituminous concrete on a previously prepared bituminous bound surface. A single layer shall be 25 mm to 100 mm in thickness.

10.4.2 Materials

10.5 Bitumen:

The bitumen shall be paving bitumen of Penetration grade complying with Indian Standard Specification for Paving Bitumen, IS: 73 and of the penetration indicated in Table 3.8 for bituminous concrete, or this bitumen as modified by one of the methods specified in Clause 521 of MORT & H or as otherwise specified in the Contract. Guidance on the selection of an appropriate grade of bitumen is given in The Manual for Construction and Supervision of Bituminous Works. Bitumen Grade 60/70 shall be used as per Annexure (6) IRC paper 37.

10.5.1 Coarse aggregates:

The coarse aggregates shall be generally as specified in Clause 507.2.2 of MORT & H except that the aggregates shall satisfy the physical requirements of Table 8.7

10.5.2 Fine aggregates:

The fine aggregates shall be all as specified in Clause 507.2.3.

10.5.3 Filler:

Filler shall be generally as specified in Clause 507.2.4 of MORT & H where the aggregates fail to meet the requirements of the water sensitivity test in Table 4.7 then 2 per cent by total weight of aggregate of hydrated lime shall be added without additional cost.

10.5.4 Aggregate grading and binder content:

When tested in accordance with IS: 2386 Part 1 (Wet grading method), the combined grading of the coarse and fine aggregates and added filler shall fall within the limits shown in Table 8.8 for grading 1 or 2 as specified in the Contract.

10.5.5 Mixture Design.

10.5.6 Requirements for the mixture.

Apart from conformity with the grading and quality requirements for individual ingredients, the mixture shall meet the requirements set out in Table 10.9.



The requirements for minimum percent voids in mineral aggregate (VMA) are set out in Table 10.9

10.5.7 Binder Content:

The binder content shall be optimized to achieve the requirements of the mixture set out in Table 8.9 and the traffic volume as specified in the Contract. The Marshall method for determining the optimum binder content shall be adopted as described in the Asphalt Institute Manual MS-2, replacing the aggregates retained on the 26.5 mm sieve and retained on the 22.4 mm sieve, where approved by the Engineer.

10.5.7.1 Job mix formula:

The procedure for formulating the job mix shall generally as specified in MORT&H specification and tests specified in Table 10.9.

TABLE 8.7: PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE FOR BITUMINOUS CONCRETE PAVEMENT LAYERS.

Property Test Specification

Cleanliness (dust) Grain size analysis 1 Max 5 % passing 0.075 mm sieve

Particle shape Flakiness and Elongation index

Max 30 % (combined) 2

Strength* Los Angeles Abrasion Value 3

Max 30 %

Polishing Polished Stone Value 5 Max 254 %

Durability Soundness: 6

Sodium Sulphate Max 12 %

Magnesium Sulphate Max 18 %

Water absorption Water absorption 7 Max 2 %

Stripping Coating and Stripping of Bitumen Aggregate Mixtures 9

Minimum retained coating 95 %

Water sensitivity ** Retained Tensile Strength 8 Min 80 %

Notes: 1. IS: 2386 Part 1 6. IS: 2386 Part 5

2. IS: 2386 Part 1 7. IS: 2386 Part 3

(The elongation test to be done only on non-flaky aggregates



in the sample)

3. IS: 2386 Part 4* 8. AASHTO T283**

4. IS: 2386 Part 4* 9. IS: 6241

5. BS: 812 Part 114

* Aggregate may satisfy requirements of either of these two tests.

** The water sensitivity test is only required if the minimum

Retained coating in the stripping test is less than 95 %.

Mix formula shall be generally as specified in Clause 507.3.3 and the results of tests enumerated in Table 500-19 as obtained by the Contractors.

Table 8.8

COMPOSITION OF DENSE GRADED BITUMINOUS CONCRETE PAVEMENT LAYERS

Grading 1 2 Nominal aggregate size 19 mm 13 mm Layer Thickness 50-65 mm 30-45 mm IS Sieve Thickness Cumulative % by weight of total aggregate passing

45 37.5 26.5 100 19 79-100 100

13.2 59-79 79-100 9.5 52-72 70-88 4.75 35-55 53-71 2.36 28-44 42-58 1.18 20-34 34-48 0.6 15-27 26-38 0.3 10-20 18-28 0.15 5-13 12-20 0.075 2-8 4-10

Bitumen content % by mass of total mix 2

5.0 – 6.0 5.0-7.0

Bitumen grade (pen) 65 65 Notes: 1. The combined aggregate grading shall not vary from the low limit on one sieve to the high limit on the adjacent sieve.

2. Determined by the Marshall method.

TABLE: 8.9 REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS

Minimum stability (KN at 60 Degree C) 9.0

Minimum flow (mm) 2

Maximum flow (mm) 4



Compaction level (Number of blows) 75 blows on each of the two faces of the specimen

Per Cent air voids 3-6

Per cent voids in mineral aggregate (VMA) See Table 500-12

Per cent voids filed with bitumen (VFB) 65-75

Loss of stability on immersion in water at 60 Degree C (ASTM D 1075)

Min. 75 per cent retained strength

10.6 Test for Bitumen Construction

As per I.R.C. (MORT & H) specification clause 903.4

10.6.1Test & frequency:

The test and their minimum frequencies for the different types of bituminous work shall be as given Table 900-4 (MORT & H specification). The engineer may direct additional testing as required.

10.6.2Acceptance Criteria:

The acceptance criteria for tests on density and Marshall stability shall be subject to the condition that the mean value is not less than the specified value plus.

[1.65 - 1.65 / (No. of samples) 0.5] times the standard deviation

10.6.3 For Dense Bituminous Macadam / Bituminous Concrete

S.No. Test Test Method Minimum 1. Quality of binder IS:73-1961

215-1961 217-1961

As required

2. Los Angeles / Abrasion value / Aggregate impact value

IS: 2386 Part IV-1963

One test per 50 cum

3. Stripping value of aggregate IS: 6241-1971 -do- 4. Flakiness index of Aggregate IS: 2386 (Part I) –

1963 -do-

5. Water absorption of aggregate IS: 2386 (Part II) – 1963

-do-

6. Grading of Aggregate IS: 2386 (Part I) – 1963

One test per 25 cum

7. Temperature of binder at application

- Regularly

8. Rate of spread of binder Tray test One test per 500 sqm

9. Rate of spread of aggregate Tray test -do- 10. Density of compacted layer As per IS One test per 250



sqm Area 11. (i) Mix grading

(ii) Stability of Mix (iii)Control of binder content & grading of Mix

As per IS One test for each 400 Tones of Mix – Minimum 100 test

per day 12. Plasticity index As per IS As required

10.6.4Test results of Aggregates from quarries / crusher.

Total 24 Nos. of Aggregate sources are selected in km 0/0 to km 150/0 on SH-17 reach & their testing was carried out as per IS specification and all physical requirement specified in MORT & H specification are satisfied except stripping value for which anti stripping Agent shall be used @ 0.60% as per MORT & H specification Appendix-5. Anti-stripping Agent used for bituminous materials and mixes.

Test results are given of aggregate given in Table 8.10 having sample from different quarries.



CHAPTER–9

STONE FOR BRIDGE WORK

9.1 Stone used for Bridges & Pitching shall be hard sound; free cracks decay & weathering stones are obtained from rock occurring in nature. Stone shall be freshly quarried from an approved quarry.

9.2 The various stones derived from these types of rocks are as follows:

(d) Principal stones from igneous rock: Granite, Basalt and trap

(e) Principal stones from sedimentary rocks: sand stone, shale, lime stone & laterite

(f) Principal stones from metamorphic rock: quartzite, schist, slate, marble and gneiss.

9.3 Require of a good stone for bridges & other structures:

(viii) High strength-crushing strength >1000 kg/cm2

(ix) High durability, sufficient hardness- coefficient of hardness > 14

(x) High resistance to wear, good file resistance

(xi) Specific gravity- More than 2.7

(xii) Crystalline structure

(xiii) High impact value- toughness index > 13

(xiv) Low water absorption- 0.6% to 2% after 24 hours.

Generally stones from Igneous & Metamorphic rocks are heavier & more durable than stones from sedimentary rocks.

9.4 Suitable size of stones (v) The length of stone shall not exceed 3 times in height nor shall be less than

twice its height plus one joint (vi) No stone shall be less in width than the height (vii) Width of the base shall not be greater three-fourth of the thickness of the wall

nor less than 150 mm (viii) Pitching stone shall not be less than 40 k

9.5 Test results of stone quarries given in table 8.10 which are suitable for pitching /

masonry work.



TABLE 8.10

PHYSICAL REQUIREMENT FOR COARSE AGGREGATE

Name of Test Test Result

Water Absorption 0.35% -0.97%

Stripping 87 %--88% Coating and stripping of Bitumen

Specific gravity 2.68-2.71



CHAPTER-10

Design of High Embankment

10.0 (As per IRC: 75 – 1979)

10.1 Case I: Stability analysis of the Cohesionless soil

In the case of cohesionless soil, the stability of slope depends upon a) The angle of Internal friction (φ) of fill material b) The Slope angle c) The unit wt. of fill d) The pore pressure

The pore pressure due to seepage through the fill reduces the stability of the slopes, but static water pressure, with the same water level inside and outside the slopes, has no effect on stability. Hence, the factor of Safety,

F = Tan φ / Tan β Where, φ = angle of internal friction; and β = angle of slope with horizontal.

It is important to note that the angle of stable slope of cohesionless materials is independent of height, which may be indefinite. In Berhampur – Bangi JN Section, where C= 0 then,

φ = 6 0, β = 26.56 0 (As the side slope is 2:1)

F = Tan 6 0 / Tan 26.56 0

= 0.105 / 0.5 = 0.210. > 1.0

Hence safe.

Slopes in fine sands, silty sands, and silts are susceptible to failure by erosion due to surface runoff. Therefore protection of slopes by pitching etc should be done.

10.2 Case II: Stability analysis of the Cohesive Soil Slopes For Ht. (H) =5.0 m, Soil Properties, c = 6.5 t/m2 φ = 6 0 ϒ = 1.89 t/m3 β = 33.80 (Side slope with the horizontal is 1.5:1)

N= Taylor’s stability number from graph corresponding to β and φ values = 0.018 From the Taylor’s Stability Number method



F = c / N . γ. H

= 0.65/ 0.018 x 1.89 x 5.0 = 3.821 hence, safe

In all the cases of high embankment at Berhampur – Raygada section this must of factor of safety is achieved if side slope of 1.5: 1 is considered for the design. Other than above methods Analysis for embankment design 259-has been done by using MoRT&H software and results are coming safe for both high and low embankment.

orissa state road project - osrposrp.gov.in/sites/default/files/pdf/material report.pdf · orissa...

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