VRC-SPIDL (JV)

(A joint venture of VRC Constructions(I)Pvt.Ltd.&

S&P Infrastructure Developers (P) Ltd. (JV) )
Project name:
Four laning of rohtak-jind section from
K.M. 307+000 to K.M. 347+800 of NH –71 and
connecting link from KM 347+800 of
NH-71 to K.M. 9+400 of NH-71
A on EPC mode in the state of
Haryana Corrigendum IV REG.

Under the supervision of:

Mr. Sandeep Kumar
(Chief Project Manager)
Office address: Flat no. D-158, Sector-35,
Rohtak, Haryana,
Pin code: 124001
Contact no.: +91-94673-51094
 CONTENTS
1. ROAD CONSTRUCTION
2. EXCAVATION FOR BRIDGE
3. BORING
4. REINFORCEMENT
5. PILING
6. PILE CAP
7. PIER
8. PIER CAP
9. REINFORCED EARTHWALL
10. MINOR BRIDGE
11. RMC PLANT
ROAD CONSTRUCTION

Earthwork including grading and sloping of

subgrade
A subgrade is the lowest layer of a road. It
is the foundation for the road. The soil is a
subgrade material.
The process of preparing the subgrade is as
follows:

• Clean the ground of plants, bushes, organic

matter etc.
• Mark the road dimensions like alignment,
pavement width and the footpath on the
ground.
• Excavate the ground if the road level is lower
than the ground. For the road level higher
than the ground level, the embankment is
prepared for the road. The subgrade level
equals road elevation minus the total
thickness of the overlying layers.
 • If the soil is loose at the desired elevation,
compact it with a mechanical roller. If the soil
has swelling property on water absorption,
replace it with non-expansive soil.
• Grade the subgrade to replicate the top
profiles of the road to the subgrade. The
elevation and camber are maintained at the
subgrade level to drain off the water.
Sub-Base Course
A sub-base layer lays over the subgrade. The
material quality and the traffic load over it
determines the sub-base layer thickness. The
lower the sub-base material quality, the thicker is
the layer. A sub-base layer distributes the load
evenly to the subgrade. It prevents the capillary
action from subgrade to the base course by
providing free drainage.
The sub-base material is a mixture of course
and fine aggregates. The traffic load on the layer
and the materials’ properties determine the ratio
of course to fine aggregate. Several iterations
determine the most economical and feasible
sub-base material mix.
 The sub-base provides stable support to the
road. The method of sub-base preparation is
detailed below.
Lay the sub-base material over subgrade,
maintaining the thickness of the layer. The
maximum allowable variation for material
thickness is 6mm for a 4.5 m stretch of road.
Water the layer before compaction, if needed.
Compact the layer with a tandem roller or a
vibratory roller. The thickness of the sub-base
layer and the roller weight determines the
required roller repetitions. The number of
repetitions is inversely proportional to the roller
weight.
If anywhere the sub-base settles more than the
average settlement of the layer, dig down the
spot. Remove the failed subgrade portion and
replace it with the sub-base material and
compact it.
Check the field dry density (FDD) of the sub-base
layer for every 100 sqm area. It should be at least
95% of the maximum dry density (MDD).
Base Course
A base course lies over the subgrade and acts as
a foundation for the surface course. The base
course thickness enables it to take the traffic
load. Therefore, it has stiffness and strength.
The base course is thinner than the sub base.
However, the material quality of the base course
is higher than the sub-base material. The base
course has good quality crushed aggregates
only.
Apply a low viscous cutback bitumen over the
sub base course. It is called a prime coat. A
prime coat penetrates the sub-base layer and
clogs the pores.
Spread the base course material over the prime
coat. Maintain the base course material
thickness across the lateral and longitudinal
directions. A road paver machine lays the base
course.
Compact the base course with a tandem roller
or a pneumatic roller. The roller speed is not more
than 5-10 km per hour.
Surface Course
A surface course is the top layer of the road. It
bears all the wear and tear due to traffic on the
road. Therefore, it is also known as wearing
course. A surface course is made of a rich
bituminous mix.
Apply a tack coat over the base course. A
tack coat is a thin layer of bitumen emulsion with
water. It provides bonding between the base
course and surface course.
A road paver machine lays the surface course
over tack coat. The machine is equipped with a
material thickness control mechanism. The dump
trucks dump the bituminous mix in the paver
machine’s hopper.
A tandem roller compacts the surface course by
multiple passes.
Check the surface with a straight edge. The
undulations in longitudinal direction should not
exceed 8mm in 300 m length of road. Also, for
the lateral direction, the undulations should not
exceed 4mm.
Need of Drainage in Roads
 A drainage system in highways ensures
road survival throughout the service life. Water
causes pavement failures. Running water may
cause erosion of the subgrade. Therefore, a road
should always be dry, i.e., water should not
accumulate on or below the pavement.
A highway should have a proper cross profile to
drain off the water. The pavement has drains on
either side. A drain carries the water and
disposes of it suitably. It also prevents subgrade
erosion.
Road Construction Materials
The road construction materials are soil,
aggregates (coarse and fine), bitumen, binders,
and admixtures. The use of each material is
exclusive for each layer.
The application of road construction materials is
in the following forms-
• Soil as naturally occurring or processed
material finds its’ use as subgrade material.
• The coarse and fine aggregate mixture forms
the sub-base coarse.
 • The aggregate of size 0-10 mm mixed with
bitumen forms the base coarse and wearing
coarse.
• Bitumen as cutback bitumen, emulsion,
asphalt finds application in bitumen mix, tack
coat, and prime coat.
• Cement concrete is the core material for
rigid pavement.
Conclusion on Roads Construction Procedure
Road construction involves multiple
considerations. The finance, public
convenience, technical aspects, social impact,
environmental impact etc. However, the core
construction procedure includes the survey and
layout, geometric design, material selection,
drainage design, and construction execution.
To continue the core construction activities, a
road construction procedure is more or less
similar for both rigid and flexible pavement. The
article describes the flexible road construction
procedure step by step. Furthermore, road
construction materials play an important role in
road stability and serviceability throughout the
service life.
Nowadays, specialized additives and
geotextiles find their extensive use in highway
construction. Such materials improve the load-
carrying capability of the road. Retaining walls
also find extensive usage in road construction.
EXCAVATION FOR BRIDGE
Work procedure for excavation at
construction site involves
understanding of center line and
excavation drawings, setting out of
plan on ground, excavation of soil
and removal of excess soil. Quality
checks such as recording ground
level and marking of reference points
should be done. Excavation is the
process of moving earth, rock or
other materials with tools, equipment
or explosives. It also includes
trenching, wall shafts, tunnelling and
underground. It is the preliminary
activity of the construction project.
The major works done before,
while and after excavation are as
follows,
1. Setting out of corner
benchmarks.
2. Survey for ground levels.
3. Survey for top levels
4. Excavation to approved depth.
5. Dressing of loose soil.
6. Making up to cut off level
7. Constructing dewatering wells
and interconnecting trenches.
8. Marking boundaries of the
building.
9. Constructing protection bunds
and drains.
 BORING/PILING

In the context of the construction

industry, boring involves the drilling of
holes into the ground for various
purposes, such as determining
whether or not the ground at a
project site is safe to build on. Boring
is typically the first task to be
completed on a project site
because the foundation must be
established before any significant
work can take place. Piling is
defined as being foundations that
are driven or bored through the
ground along a certain length of
area to carry and transfer loads to
soil considered to be weak in
structure due to the soil conditions.
Essentially this means that piles are
generally used when the bearing
capacity of the soil is considered to
be inadequate for the structural
load of heavy construction. The piles
transfer the load to the solid ground
located at a depth.
 REINFORCEMENT

Most concrete used for construction

is a combination of concrete and
reinforcement that is called
reinforced concrete. Reinforcement
for concrete is provided by
embedding deformed steel bars or
welded wire fabric within freshly
made concrete at the time of
casting. The purpose of
reinforcement is to provide additional
strength for concrete where it is
needed. The steel provides all the
tensile strength where concrete is in
tension, as in beams and slabs; it
supplements the compressive
strength of concrete in columns and
walls; and it provides extra shear
strength over and above that of
concrete in beams.
 PILE CAP

A pile cap is a thick concrete mat

that rests on concrete or timber piles
that have been driven into soft or
unstable ground to provide a suitable
stable foundation. It usually forms
part of the deep foundation of a
building, typically a multi-story
building, structure or support base for
heavy equipment, or of a bridge. The
cast concrete pile cap distributes the
load of the building into the piles.
 PIER

Pier, in building construction, vertical

loadbearing member, such as an
intermediate support for adjacent ends
of two bridge spans. In foundations for
large buildings, piers are usually
cylindrical concrete shafts, cast in
prepared holes, but in bridges they take
the form of caissons, which are sunk into
position. Piers serve the same purpose as
piles but are not installed by hammers
and, if based on a stable substrate, will
support a greater load than a pile.
 PIER CAP

Pier caps transfer the loads from the

superstructure to the piers. They hold the
bridge girders on bearing pads and
disperse the loads from the bearings to the
piers. Bridges with piers will all have pier
caps to transfer the load from the
superstructure.
REINFORCED EARTH WALL

A reinforced earth wall is designed

and constructed to resist the lateral
pressure of the soil and supports the
soil laterally so that it can be
maintained at different levels on both
sides. The lateral pressure could be
also due to earth filling, liquid
pressure, sand, and granular
materials. The walls are used to
bound soils between two different
elevations often in areas of terrain
possessing undesirable slopes. These
walls are an economical way to meet
every-day earth retention needs for
highway and bridge grade
separations, railroads and mass
transit systems. They are also used in
response to difficult design conditions
such as very high structures, restricted
space, where obstructions within the
soil mass are present.
 MINOR BRIDGE (MNB)

A bridge structure carrying a road,

path, railway, etc. across a river, road
or obstacle with span ranging from
6m - 60 m are minor bridges.
Bridges with span less than 6
meters with a purpose of conveying
water through a pipe or channel is
culvert.
Span exceeding 60m are major
bridges.
 RMC PLANT
A concrete plant, also known as a
batch plant or batching plant or a
concrete batching plan, is equipment
that combines various ingredients to
form concrete. Some of these inputs
include water, air, admixtures, sand,
aggregate (rocks, gravel, etc.), fly
ash, silica fume, slag, and cement. A
concrete plant can have a variety of
parts andaccessories,including:
mixers (either tilt drum or horizontal, or
in some cases both), cement
batchers, aggregate batchers,
conveyors, radial stackers,
aggregate bins, cement bins,
heaters, chillers, cement silos, batch
plant controls, and dust collectors.
The heart of the concrete batching
plant is the mixer, and there are
many types of mixers, such as tilt
drum, pan, planetary, single shaft
and twin shaft. The twin shaft mixer
can ensure an even mixture of
concrete through the use of high
horsepower motors, while the tilt
mixer offers a comparatively large
batch of concrete mix. In North
America, the predominant central
mixer type is a tilt drum style, while in
Europe and other parts of the world,
a twin shaft mixer is more prevalent. A
pan or planetary mixer is more
common at a precast plant.
Aggregate bins have 2 to 6
compartments for storage of various
sand and aggregate (rocks, gravel,
etc.) sizes, while cement silos are
typically one or two compartments,
but at times up to 4 compartments in
a single silo. Conveyors are typically
between 24-48 inches wide and carry
aggregate from the ground hopper
to the aggregate bin, as well as from
the aggregate batcher to the
charge chute.

A twin shaft concrete mixer, which is

common in concrete plants
The aggregate batcher, also named
aggregate bins, is used for storage
and to batch the sand, gravel and
crushed stone of the concrete plant.
There are also many types of
aggregate batchers, but most of
them measure aggregate by
weighing. Some use a weighing
hopper, some use a weighing belt.
The cement silos are indispensable
devices in the production of
concrete. They mainly store bulk
cement, fly ash, mineral powder and
others. There are three types of
cement silos: bolted cement silos,
horizontal cement silos and
integrated cement silos. Integrated
cement silos are made in factories,
and can be used directly. Bolted
cement silos are bolted for easy
installation and removal. Horizontal
cement silos have lower requirements
on foundations and can be
transported by truck or flatbed
without disassembly.

Cement silo
The screw conveyor is a machine to
transfer the materials from the
cement silos to the powder weighing
hopper.
Screw conveyor
Concrete plants use the control
system to control the working of the
machine. Concrete batch plants
employ computer aided control to
assist in fast and accurate
measurement of input constituents or
ingredients. With concrete
performance so dependent on
accurate water measurement,
systems often use digital scales for
cementitious materials and
aggregates, and moisture probes to
measure aggregate water content
as it enters the aggregate batcher to
automatically compensate for the
mix design water/cement ratio
target. Many producers find moisture
probes work well only in sand, and
with marginal results on larger sized
aggregate.