DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institute affiliated to VTU, Belagavi – 590018, Approved by AICTE & ISO 9001:2015 Certified)
Accredited by National Assessment & Accreditation Council (NAAC) with ‘A’ grade

An Internship Report on
HIGHWAY CONSTRUCTION TRAINING
Submitted in partial fulfillment for the award of degree of

Bachelor of Engineering
in
Civil Engineering
Submitted by
SHWETANK
1DS18CV136
Internship carried out
at
BSC-C&C “JV”
M.No: 8-2-502/1/A, JIVI Towers,Road No.7, Banjara Hills, Hyderabad

DEPARTMENT OF CIVIL ENGINEERING

(Accredited by NBA)
DAYANANDA SAGAR COLLEGE OF ENGINEERING
Shavige Malleshwara Hills, Kumaraswamy Layout
Bengaluru-560078
2021-22
 DAYANANDA SAGAR COLLEGE OF ENGINEERING
(An Autonomous Institute affiliated to VTU, Belagavi – 590018, Approved by AICTE & ISO 9001:2015 Certified)
Accredited by National Assessment & Accreditation Council (NAAC) with ‘A’ grade
Shavige Malleshwara Hills, Kumaraswamy Layout
Bengaluru-560078
2021-2022
DEPARTMENT OF CIVIL ENGINEERING

(Accredited by NBA)

CERTIFICATE
Certified that an internship report of the internship work carried out by SHWETANK bearing a USN:

1DS18CV136 a bonafide student of DAYANANDA SAGAR COLLEGE OF ENGINEERING, an

autonomous institute affiliated to VTU, Belagavi in partial fulfilment for the award of Bachelor of Engineering

in Civil Engineering during the year 2021-2022. It is certified that all corrections/suggestions indicated for

Internal Assessment have been incorporated in the Report deposited in the departmental library. The Internship

report has been approved as it satisfies the academic requirements in respect of Internship work prescribed for the

said Degree.

Signature of the Project Guide Signature of the Internship coordinator

Mohammed Ismail Shahaji Patil / Prashant N Nilugal

Signature of the HOD

Dr. H K Ramaraju
Professor & HOD

Name of the Examiners Signature with date

1........................................... ..........................................

2........................................... ..........................................

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COMPANY CERTIFICATE

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 Declaration by the Student

I, Shwetank, hereby declare that the Internship entitled, “Highway Construction Training”, which has been
submitted by me as partial fulfilment for the 8th semester internship examination of Bachelor of Engineering degree
from Visvesvaraya Technological University, Belgaum, is an authentic record of my own work carried out by me
during B.E 8th semester in Civil Engineering at BSC-C&C “JV”, under the supervision of my Prof. Mohammed
Ismail, DSCE, Bangalore and external supervisor Mr. Ravi Shekhar, BSC-C&C “JV”.

I further undertake that the matter embodied in the internship has not been submitted previously for the award of any
degree or diploma by me to any institution.

SHWETANK
(1DS18CV136)
VIII SEM, B.E
Civil Engineering

Place: Bangalore.

Date:17.06.2022

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 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompanies the successful completion of any task would be incomplete
without mentioning the people who made it possible, whose constant guidance and encouragement crowned my
efforts with success.

I thank our Principal, Dr. C P S PRAKASH, I thank Head of the Department, Dr. H K Ramaraju and Internship
Coordinator Shahaji Patil and Prashant N Nilugal, Department of Civil Engineering who has given us
confidence to believe in ourselves and complete the Internship.

Guidance and deadlines play a very important role in successful completion of the internship report on time. I
convey my gratitude to my project guide, Mr. Mohammed Ismail, and external supervisor Mr. Ravi Shekhar,
BSC-C&C “JV” who helped me carry out my internship work.

SHWETANK
(1DS18CV136)

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 EXECUTIVE SUMMARY

Roads have been existing in India for the last 5000 years. In early stages of Indian history, Ashoka and
Chandragupta made efforts to construct roads. But the real progress was made during the Mughal period. One
such road was constructed by Sher Shah Suri which connected Peshawar to Kolkata. It was named as Grand Trunk
(G.T.) Road and joined Amritsar with Kolkata after partition of India in 1947. Presently, it is known as ‘Sher
Shah Suri Marg’.

Roads play a very important role in the transportation of goods and passengers for short and medium distances.
It is comparatively easy and cheap to construct and maintain roads. Road transport system establishes easy contact
between farms, fields, factories and markets and provides door to door service. Roads can negotiate high gradients
and sharp turns which railways cannot do. As such, roads can be constructed in hilly areas also. Roads act as great
feeders to railways. Without good and sufficient roads, railways cannot collect sufficient produce to make their
operation possible. Road transport is more flexible than the railway transport. Buses and trucks may be stopped
anywhere and at any time on the road for loading and unloading passengers and goods whereas trains stop only
at particular stations. Perishable commodities like vegetables, fruits and milk are transported more easily and
quickly by roads than by railways.

Due to above-mentioned advantages, the road transport has become very popular and its share is constantly
increasing.

The National Highways Authority of India or NHAI is an autonomous agency of the Government of India, set
up in 1995 (Act 1988) and is responsible for management of a network of over 50,000 km of National
Highways out of 1,32,499 km in India. It is a nodal agency of the Ministry of Road Transport and Highways.

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 TABLE OF CONTENTS

Serial Number Title Page Number

1 Company Profile 8

2 Introduction to the Project 9

3 Bitumen 10

4 Flexible Pavements 11

5 Road Layers 12

6 Tasks Performed 14

Reflection Notes and

7 18
Learning from Internship

8 References 19

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 COMPANY PROFILE

BSC-C&C “JV” is a joint venture between BSCPL Infrastructure Ltd. (Formerly known as B. Seenaiah &
Company Projects Ltd.) and C&C Construction Ltd.

BSCPL Infrastructure Limited introduce themselves as an ISO 9001:2015, 14001:2015 & 45001:2018 accredited
infrastructure development company pioneers in execution of Highways, Irrigation, Airport Runway, Railway
and Urban Infrastructure Projects in India. We have executed several prestigious projects across India and abroad
including Construction of Afghan Parliament Complex and Indian Chancery Complex at Kabul, Afghanistan.

C & C Constructions Limited, incorporated in July 1996 by a group of professionals, is now one of India's fastest
growing ISO 9001:2008 construction conglomerates focused on creating nationally important infrastructure
assets. C & C Constructions' activity areas include turnkey responsibility for Roads, Highways and Urban
Infrastructure (water, sanitation and sewerage, power/telecom transmission, towers and commercial buildings).

Vision:
BSCPL envisages being a partner of the emergent world in the field of infrastructural development through
enduring structures with an elegant face.
To deliver to the client the best solutions and broaden activity base by diversifying into other infrastructure
disciplines to sustain a healthy growth rate.

Mission:
Maintain the quality of construction through the synergizing of experience, vision, resource and professional
values.
To achieve our objectives in an environment of fairness and courtesy to our clients, employees, vendors, investors
and the society.

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 INTRODUCTION TO THE PROJECT

NH 77 is a National Highway of India entirely within the state of Bihar that links Hajipur to Sonbarsa near India-
Nepal border, and is 142 km long. National Highway Authority of India was the client which gave the task of
two-laning of national Highway number 77 which is currently now called NH 22. The task was to be completed
on a section of the national Highway 77 starting from Muzaffarpur to Sonbarsa with a total stretch of 86 km.

During the training period of highway construction, the instructor started by giving a fresh idea on the aspects
that have to be kept in mind during the planning of a national highway. Since the highway was already in place,
we were taught from scratch about how a highway is laid on the ground. After that, during regular visits to the
site, we were taught about the machines and the materials which were required to construct that particular section
of the highway. The instructor should as a detailed view of cross-section of a highway song with all its layers. At
few locations where the road was heavily destroyed by weather conditions, we could witness complete procedure
and the heavy machinery that is required for the construction of highway.

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 BITUMEN

Bituminous materials or asphalts are extensively used for roadway construction, primarily because of their
excellent binding characteristics and waterproofing properties and relatively low-cost Bituminous materials
consists of bitumen which is a black or dark coloured solid or viscous cementitious substances consists chiefly
high molecular weight hydrocarbons derived from distillation of petroleum or natural asphalt, has adhesive
properties, and is soluble in carbon disulphide. Tars are residues from the destructive distillation of organic
substances such as coal, wood, or petroleum and are temperature sensitive than bitumen. Bitumen will be
dissolved in petroleum oils where unlike tar.

It is obtained by partial distillation of crude petroleum. It is chemically a hydro-carbon. Bitumen is insoluble in

water, but it completely dissolves in carbon bi-sulphide, chloroform, benzol, coal tar, naphtha, alkalis, alkaline
carbonates, petroleum spirit ad oil of turpentine. It is found on analysis to compose of 87 percent carbon, 11
percent hydrogen and 2 percent oxygen by weight. The bitumen is black or brown in colour and it is obtained in
solid or semi-solid state.

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 FLEXIBLE PAVEMENTS

Flexible Pavements are constructed from bituminous or unbound material and the stress is transmitted to the
sub-grade through the lateral distribution of the applied load with depth.

Flexible pavement is composed of a bituminous material surface course and underlying base and subbase
courses. The bituminous material is more often asphalt whose viscous nature allows significant plastic
deformation. Most asphalt surfaces are built on a gravel base, although some 'full depth' asphalt surfaces are
built directly on the subgrade. Depending on the temperature at which it is applied, asphalt is categorized as hot
mix asphalt (HMA), warm mix asphalt, or cold mix asphalt. Flexible Pavement is so named as the pavement
surface reflects the total deflection of all subsequent layers due to the traffic load acting upon it. The flexible
pavement design is based on the load distributing characteristics of a layered system.

It transmits load to the subgrade through a combination of layers. Flexible pavement distributes load over a
relatively smaller area of the subgrade beneath. The initial installation cost of a flexible pavement is quite low
which is why this type of pavement is more commonly seen universally. However, the flexible pavement
requires maintenance and routine repairs every few years. In addition flexible pavement deteriorates rapidly;
cracks and potholes are likely to appear due to poor drainage and heavy vehicular traffic.

Fig: Cross-section of a flexible pavement

(Source: https://civiconcepts.com/blog/what-is-pavement-types-of-pavement-road-construction-layers)

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 ROAD LAYERS

1. Compacted Sub-grade (150 – 300 mm)

The compacted subgrade is a base of all pavement layers. All the above pavement layers transfer the stress to this
layer. So, it is essential to ensure that soil sub–grade is not overstressed. Therefore, it should be properly
compacted to the desired density, near the optimum moisture content.

2. Sub-base Course (100 – 300 mm)

It is a layer of material below the base course. It is a major role to provide structural support, improve drainage,
and reduce the intrusion of fines from the sub-grade in the pavement structure. In the case of the base,
the course is open graded then the sub-base course with more fine material can be utilized as filler between sub–
grade and the base course.

A sub–base is not strictly needed or used. For example, road pavement made on high quality, hard sub-grade may
not need the additional features offered by a sub-base course. In such situations, the sub-base course can
be avoided.

3. Base Course (100 – 300 mm)

It is a layer of materials just below the surface of the binder course and it provides additional load distribution
and contributes to the sub-surface drainage. The different materials are used for base courses such as crushed
stone, crushed slag, and other untreated or stabilized materials.

4. Prime Coat

A prime coat is applied by spreading low viscous cutback bitumen to an absorbent surface like granular bases on
which the binder layer is placed. It is primly used to provide a bond between two layers. A prime coat is able
to penetrate into the below layers, plug the voids, and form a watertight surface.

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5. Binder Coat (50 -100 mm)

The Binder coat has the bulk of the asphalt concrete structure. Its main function is to distribute the load to the base
course. The binder course primly consists of aggregate mixed with low asphalt and doesn’t require quality as high
as the surface course. Replacement of some part of the surface course by the binder course results in a
more economical design.

6. Tack Coat:

In tack coat, a little amount of asphalt is applied to the surface. It is generally asphalt emulsion diluted with water.
Its main function is to provide proper bonding between two layers of binder course and must be
thin, uniformly cover the entire surface, and set very fast.

7. Surface Course (25 – 50 mm)

It is the main layer that bears the direct traffic load and generally contains superior quality materials. The surface
course is generally constructed with graded asphalt concrete (AC). The functions and requirements of
this layer are:

• This course offers major characteristics like friction, smoothness, drainage, etc. Also, it prevents
the entry of excess water into the underlying base, sub–base, and sub–grade,
• It should be provided with a hard surface to resist the distortion under traffic and provide a
smooth and skid–resistant riding surface,
8. Seal Coat

The seal coat is a thin layer with water–proof the surface and provides skid resistance.

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 TASKS PERFORMED: BITUMINIOUS ROAD CONSTRUCTION

1. Preparation of Sub-Grade

Sub-grade preparation works involve Earthwork is one of the major works involved in road construction. It
involves the removal of top layer of soil, vegetation. Road area is prepared for the finished formation level. This
is usually done using a manually and mechanically like tractor shovel, grader etc. Below the formation level,
the soil is known as the sub - grade.

The required thickness of the pavement layer is determined by the strength of sub-grade, so it is must important
to make the strong subgrade as far as possible.
The can make strength of the subgrade by doing these works:
- Remove vegetation and poor material.
- Remove the bad and loose soil by cuttings and replacing with selected fill.
- Providing adequate subsoil drainage system.
- Maintain camber on sub-sub grade for sub soil drainage.

Fig: Preparation of soil sub-grade

2. Preparation of Sub-Base Course

Generally before base course we prepare sub-base course with the crushed aggregate 63mm down. We place these
materials on road and with the help of grader on such a way that it provide uniform camber. We should compact

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the sub base material with the help of Roller and water browser by draining water on the surface. Provide roller
0.022 hr/cum with vibration to obtain dry (95-98) % dry density.

Fig: Construction of aggregate sub-base course

3. Preparation of Base Course

After preparing of layer of sub base course we provide base material which is 43mm down aggregate. Process are
same as sub base course but material and time of rolling should change i.e 0.033 hr/cum, to make Water Bond
Macadam WBM road. The irregularities are filled in with premix chippings at least a week before laying surface
course. If the existing pavement is extremely way, a bituminous leveling course of adequate thickness is provided
to lay a bituminous concrete surface course on a binder course instead of directly laying it on a WBM.

Fig: Construction of aggregate base course

4. Bituminous Coat
a. Prime coat
This coast is applied after base course for this reasons :
· To coat and bond loose material on the surface
· To harden or toughen the surface.

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 · To provide adhesion between bituminous and granular material.
We must provide (6-9) kg per 10sqm prime coat on WBM road.

b. Tack coat
A tack coat is applied after the prime coat, to form an adhesive bond between the tack coat and the next
layer of coating. The tack coat prevents slippage and may sometimes function as a more long-term sealer to
protect the substrate from moisture and bacteria.

Fig: Construction of prime coat

5. Paving of bituminous mix

Bituminous mix paving with equal thickness and making camber on the road surface. At first 10mm down silicon
aggregate and 80/100 bitumen material used for premix or it is prepared in a hot mixture plant of a required
capacity with the desired quality control. The bitumen may be heated up to 150 – 177 degree Ceelcius and the
aggregate temperature should not differ by over 14 degree Celsius from the binder temperature. Both are mixed
up.

The hot mixed material is collected from the bitumen mixture by the transporters, carried to the location is spread
by a manually of mechanical paver at a temperature of 121 to 163 deg. Celsius the camber and the thickness of
the layer are accurately verified.

The control of the temperatures during the mixing and the compaction are of great significance in the strength of
the resulting pavement structure. The temperature of mixed material during laying is not less than 105 degree
Celsius.

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6. Rolling

When after placing bitumen mixture on the base course is than it is equally and thoroughly compacted by static
rolling at a speed not more than 5km per hour or use vibration. In rolling a graded area with a side slope, as a
crowned or banked road, you should work from the edge to the center of the of the road which is known as camber

The static rolling is done by (8 – 12) tonnes roller and the intermediate rolling is done with a fixed wheel
pneumatic roller of (15 – 30) tonnes having a tyre pressure of 7kg per sq.cm. The wheels of the roller are kept
damp with water. The number of passes required depends on the thickness of the layer. The final rolling or
finishing is done by 8 to 10 tonne tandem roller.

7. Seal coat

Final coat of bituminous material applied during construction to a bituminous macadam or concrete for sealing
the surface of the pavement. In this coat sand mix up with bitumen and spread on road to plug the void and
final rolling is done with 8-10 tonne roller.

Fig: Highway can be open to public use

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 REFLECTION NOTES AND LEARNING FROM INTERNSHIP

My internship as a student at BSC-C&C “JV” to train in Highway Construction was one of the most fulfilling and
motivating experiences I have had during my time at the Dayananda Sagar College of Engineering. I made
connections with my teacher and other members of the institution's staff, all of whom directly and indirectly aided
my development as a trainee. This experience has aided me in finishing my internship programme necessary for
bachelor's programme for my degree in education, thanks to such sensitive, kind, and helpful mentors. Not simply
because of the things I gained from my mentors. I am confident in my ability to continue to grow and develop
both professionally and personally.

With the help and mentoring of my cooperating teacher, I was able to create and maintain a very happy and
compassionate learning environment during my internship. My classroom management skills improved
significantly as a result of the use of time management, organisation, discipline, and constant practise.
The internship programme aided me in the following ways. The internship programme assisted me in connecting
academic knowledge with real civil engineering aspects. It made me realise how broad civil engineering is. I can
have a high level of confidence in dealing with challenges that develop during the design of a structure. Overall,
the internship programme has provided me with a solid platform on which to begin my career.

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 REFERENCES

• IRC 37-2001 : Guidelines for design of flexible pavement.

• Oad, Pardeep & Kajewski, Stephen & Kumar, Arun. (2020). Innovation in Road Construction Industry:
An Analysis of Different Case Studies. 537-546. 10.29117/cic.2020.0067.

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