DETAILED PROJECT REPORT MHOW MANDLESHWER

GHAT SECTION (SH-1)

&

A Observational Training Report Submitted to

Rajiv Gandhi Proudyogiki Vishwavidyalaya, Bhopal
In partial fulfillment of degree of

BACHELOR OF ENGINEERING
IN
CIVIL ENGINEERING

By- SHUBHAM GEETE (0827CE121094)

DEPERTMENT OF CIVIL ENGINEERING

Acropolis Institute Of Technology And

Research, Indore

Content
1. Project Description
2. Flexible Pavement
3. Embankment & Tests of preparation for Embankment
4. Sub grade & Tests of preparation for sub grade
5. G.S.B. (Granular sub base) & Tests for preparation of
G.S.B.
6. W.M.M. (Wet mix Macadum) & Tests for preparation of
W.M.M.
7. D.B.M. (Dense Bitumen Macudum) & Tests for preparation
of D.B.M.
8. B.C. (Bitumen Carpet)

Project
Description
Rau - Mhow - Jamghat - Mandleshwar road is a segment of Old NH-3 and SH-1
situated at western part of Madhya Pradesh State having Project length of 74.40
Kms. But the actual length of the project is reduced to 67.559 Kms. due to the
introduction of Gawli Palasia bypass and Medh bypass.

LOCATION OF THE PROJECT ROAD

The starting point of the project is at existing km. 14.780 of old NH-3 near Rau with
new NH-3 junction. The project road passes through two district of Madhya Pradesh
namely Indore and Khargone. The end point of project road is at existing km. 0.000
at Mandleshwar town with three arm junction on SH-38. The existing length of project
road is 74.40 km as per agreement which is reduced to 67.559 km. as stated above.

TERRAIN CLASSIFICATION
The Project highway road alignment traverses through Plain Terrain, Hilly Terrain
approximate 11 kms. & Reserve Forest Ch. 25+670 to 41+670 in Indore District 16
kms. & from Ch. 41+670 to 50+670 in Khargone District 9 Kms.

TOWN AND VILLAGES

The alignment passes through village Harniya Khedi, Rasalpura, Kishanganj, Mhow
Cantonment , Dongargaon, Gawli Palasia, Badgonda, Mendh, Badhtalai, Choti Jam, Lalpura,
Choli, Dhapla, Vangaon and Mandleshwar.
The strip plan enclosed showing the scope of work i.e. selected stretches passing through
builtup area shall be widened to two lane with paved shoulder carriageway in length 5.3 kms.
, 4 laning carriageway 1 km., Toll Plaza , Bus Shelter ,Truck Lay Bay , Major/Minor
Intersection , location of Major Bridges , Minor Bridges , Widening of Minor Bridges/Slab

Culvert , Reconstruction / New Construction / Widening of Hume Pipe Culvert.

SALIENT FEATURES
1.

Name of Work

Development of Rau Mhow Mandleshwar Road on

B.O.T. + Grant Basis from Ch. 0+00 to 74+400
Rs. 176.06 Crores
As per agreement 74.40 km, Revised 67.56 km

2.
3.

Estimated Cost
Length of the Project

4.

Number of Lane / Carriageway Existing Carriageway from Ch. Start to End is proposed to
be widen to two lane undivided carriageway width with
2.5m granular shoulder in rural and 1.5m wide paved
shoulder in Built-up area.

5.

Major Bridge

01 No.

6.
7.

Minor Bridge (Retained)

Minor Bridge (Widening)

12 Nos.
04 Nos.

8.

Minor Bridge (New /

Reconstruction)

18 Nos.

9.

New Construction / Widening

of Pipe Culverts

108

10
.

New Construction / Widening

of Slab/Box Culverts

14

11
.
12
.
13
.
14
.
15
.
16
.
17
.
18
.
19
.

Toll Plaza

02 Nos.

Bus Shelter

10 Nos.

Truck Lay Bye

1 No. Both Side

Major Intersection

08 Nos.

Minor Intersection

57 Nos.

Paved Shoulder

5.30 Kms.

4-Lane

1 Km.

No. Of Districts

Two, (1) Indore (2) Khargone

Villages In The Corridor

Haarniya Khedi, Rasalpura, Kishanganj, Dongargaon,

Gawli Palasia, Mhow Cantonment, Badgonda, Mendh,
Badhatalai, Choti-jam, Bagdara, Choli, Dhapla, Vangaon &

Mandleshwar.

PROJECT FACILITIES
1.

Toll Plaza

S.No.
1

Location of Toll Plaza

(Design Chainage)
Km 3.000 to Km 4.000

Km 63.000 to Km 64.000

2.
S.No.
1

3.
S.No.

Homogeneous Section
(Design Chainage)
Rau Mhow
(Km 0.00 to Km 20.50)
Mhow - Mandleshwar
(Km 20.50 to Km 74.40)

Length
(Km)
20.50
53.90

Truck Lay-Bye
Locations (Km)
61.50

Side
Both

Remarks
Near Toll Plaza

Bus Shelter
Proposed
Chainage (Km)
2.73
3.26
3.42
9.80

Side

Village Name

1
2
3
4

Existing Chainage
(Km)
17.50
18.05
18.05
24.60

RHS
RHS
LHS
RHS

5
6
7
8
9
10

25.60
26.45
26.45
26.70
7.10
14.15

10.72
11.65
11.65
11.80
27.55
60.55

RHS
RHS
LHS
LHS
RHS
RHS

Harniya Khedi
Vikrant Inst. Of Tech.
Vikrant Inst. Of Tech.
Near Army Commando
Area
Dongargaon Village
Balasia Village
Balasia Village
Balasia Village
Badgonda Village
Somkheda Village

Flexible Pavement

Pavement -

Pavement is the actual travel surface especially made durable and

serviceable to withstand the traffic load commuting upon it. Pavement grants friction
for the vehicles thus providing comfort to the driver and transfers the traffic load from
the upper surface to the natural soil.

Flexible Pavement -

Those pavements which reflect the deformation of

subgrade and the subsequent layers to the surface. Flexible, usually asphalt, is laid
with no reinforcement or with a specialized fabric reinforcement that permits limited
flow or repositioning of the roadbed underground changes.
The design of flexible pavement is based on load distributing characteristic of the
component layers. The black top pavement including water & gravel bound macadam
fall in this category.
Flexible pavement on the whole has low or negligible flexible strength flexible in their
structural action). The flexible pavement layers transmit the vertical or compressive
stresses to the lower layers by grain transfer through contact points of granular
structure.
The vertical compressive stress is maximum on the pavement surface directly under
the wheel load and is equal to contact pressure under the wheels. Due to the ability
to distribute the stress to large area in the shape of truncated cone the stresses get
decreased in the lower layer.
As such the flexible pavement may be constructed in a number of layers and the top
layer has to be strongest as the highest compressive stresses.
To be sustained by this layer, in addition to wear and tear, the lower layer have
to take up only lesser magnitude of stress as there is no direct wearing action die to
traffic loads, therefore inferior material with lower cast can be used in the lower
layers.

Flexible Pavement

Advantages Of Flexible Pavement

Adaptability to stage construction
Availability of low-cost types that can be easily built
Ability to be easily opened and patched
Easy to repair frost heave and settlement
Resistance to the formation of ice glaze

Hand Made tyipical pavement Design used at

Mhow Mandleshwer

Embankment and Subgrade

1. Top of embankment should be 0.6m to 1.0m above HFL.
2. Before construction of embankment clearing and grubbing of soil surface is done.
3. Limits are marked by fixing pegs on both sides and drawing lime line. Then earth
collection starts.
4. It should be checked prior to C and G that 500 mm below the top of embankment
there should not be any expensive soil. It is to be removed by digging before
construction of embankment (Soil FSI < 50).
5. The soil will be spread in layers not exceeding 200 mm thickness and with
precaution to maintain the camber from start of work by motor grader.
6. The water is spread evenly with a tanker over it calculating the amount of water
required to maintain the OMC (1% above or 2 % below) .Than soil is mixed
thoroughly by blading, discing or harrowing for uniformity of moisture. The
moisture is checked by moisture meter.
7. After this stage compaction starts. It should be done by 80 KN to 100 KN
vibratory roller from sides to centre so as to maintain the required camber. Layer
is thoroughly compacted until the required density is achived. Density is checked
by sand replacement method (IS-2720 Part-28).
8. Each layer (200mm) of Embankment is Compacted to the desired density (95% of
MDD for embankment & 97% for sub-grade) and only than the next layer over it is
laid.
9. The side slope of embankement should be maintained as below.
S.No.

Description

H:V

1.
2.
3.
4.
5.
6.

Embankment is silty/sand gravelly soil

2:1
Embankment in dry or clayey silt
2.5:1 to3:1
Cutting in silty / sandy / gravelly soil
1:1 to .5:1
Cutting in disintergrated rock
.5:1 to .25 :1
Cutting in soft rock
.25:1 to 1/8 :1
Cutting in hard rock
Near vertical
10.
Material used in embankment construction shall be soil, moorum,
gravel, mixture of these or other materials approved by engineer in-charge
with not more than 75mm bigger particles for embankment and 50mm for subgrade in the material.
11.
The density requirement for embankment

Height upto 3m
Height above 3m
Sub-grade and shoulder

12.

Not less than 15.2

KN/cum
Not less than 16.0
KN/cum
Not less than 17.2
KN/cum

FDD greater than 95%

FDD greater than 95%
FDD greater than 97%

Tests for approving the soil material for embankment and sub-grade.

Grain size analysis

Liquid / plastic limits / PI
Proctor density
CBR value
Free swell index

Size not greater than 75mm

LL < 70, PI < 45
As per specified above
> 7% for subgrade material
< 50

As per IS-2720
As per IS-2720
As per IS-2720
As per IS-2720
As per IS-2720

part-4
part-5
part-8
part-16
part-40

Granular Sub base

1. The thickness of subbase can range from 75-100 mm for garden paths
through 100-150 mm for driveways and public footpaths, to 150-225 mm for
heavy used roads, and more for highways.
2. The laying and compacting well-graded material on prepared sub grade. The
material shall be laid in one or more layers termed as sub-base as necessary
according to lines, grades and cross-sections shown on the drawings and as
directed by the Engineer.
3. The material to be used for the work shall be natural sand, moorum, gravel,
crushed stone, or combination thereof depending upon the grading required.
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
53.0 mm
26.5 mm
9.50 mm
4.75 mm
2.36 mm
0.425 mm
.075 mm
CBR Value

100
55-75

100
50-80

100

10-30

15-35

25-45

<10
30

<10
25

<10
20

5. Physical requirements:
The material shall have a 10 per cent fines value of 50 kN or more (for sample in
soaked condition).
The water absorption value of the coarse aggregate shall be determined as per IS:
2386 (Part 3); if this value is should not be greater than 2 percent
6. 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. When directed by the Engineer, this shall be verified by
performing CBR tests in the laboratory as required on specimens remolded at field
dry density and moisture content and any other tests for the quality of materials, as
may be necessary.
Values for above test should lie between:CBR tests Dry density Moisture content 7. Construction Operations
Spreading: The sub-base material of grading specified in the Contract shall be spread
on the prepared sub grade with the help of a motor grader of adequate capacity, its
blade having hydraulic controls suitable for initial adjustment and for maintaining the
required slope and grade during the operation.
Mixing shall be done mechanically by the mix-in-place method.
Compacting:
For a compacted single layer upto 225 mm the compaction shall be done with
the help of a vibratory roller of minimum 80 to 100 kN static weight with plain
drum or pad foot-drum or heavy pneumatic tyred roller of minimum 200 to 300
kN weight having a minimum tyre pressure of 0.7 MN/m2 or equivalent
capacity roller capable of achieving the required compaction.
If the thickness of the compacted layer does not exceed 100 mm, a smooth
wheeled roller of 80 to 100 kN weight may be used.
The speed of the roller shall not exceed 5 km per hour.
Rolling shall be continued till the density achieved is at least 98 percent of the
maximum dry density for the material determined as per IS : 2720 (Part 8).
Moisture content of the loose material shall be checked it should be from 1
percent above to 2 percent suitably by sprinkling additional water. While
adding water, due allowance shall be made for evaporation losses.

Wet Mix Macadum

1. The thickness of WMM varies from 75-200 mm.
2. This work shall consist of laying and compacting clean, crushed, graded
aggregate and granular material, premixed with water, to a dense mass on a
prepared subgrade/sub-base/base or existing pavement. The material shall be
laid in one or more layers as necessary to lines, grades and cross-sections
shown on the approved drawings.
3. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WET MIX
MACADAM FOR SUB-BASE/BASE COURSES
Test
Test Method
Requirements
Los Angeles abrasion value
IS : 2386 (Part-4)
40 per cent (Max.)
or
Aggregate Impact value
IS : 2386 (Part-4) or IS :
30 per cent (Max.)
5640
Combined Flakiness and
IS: 2386 (Part-1)
30 per cent (Max.)
Elongation indices (Total)
Water adsorption value of the coarse aggregate should not be greater than 2 percent.
4. GRADING REQUIREMENTS OF AGGREGATES FOR WET MIX MACADAM
IS Sieve Designation
Per cent by weight passing the IS sieve
53.00 mm
100
45.00 mm
95-100
26.50 mm
60-80
22.40 mm
11.20 mm
40-60
4.75 mm
25-40
2.36 mm
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.
5. Construction Operations
Preparation of mix:
Wet Mix Macadam shall be prepared in an approved mixing plant of suitable
capacity having provision for controlled addition of water and forced/positive
mixing arrangement like pugmill.
Optimum moisture for mixing shall be determined in accordance with IS : 2720
(Part-8) after replacing the aggregate fraction retained on 22.4 mm sieve with
material of 4.75 mm to 22.4 mm size.
While adding water, due allowance should be made for evaporation losses.
However, at the time of compaction, water in the wet mix should not vary from
the optimum value by more than agreed limits.
The mixed material should be uniformly wet and no segregation should be
permitted.

Spreading of mix:
Immediately after mixing, the aggregates shall be spread uniformly and evenly
upon the prepared subgrade/sub-base/base in required quantities.
The mix may be spread by a motor grader which shall be capable of spreading
the material uniformly all over the surface. Its blade shall have hydraulic
control suitable for initial adjustments and maintaining the same so as to
achieve the specified slope and grade.
Compaction:
After the mix has been laid to the required thickness, grade and
crossfall/camber the same shall be uniformly compacted, to the full depth
with suitable roller.
If the thickness of single compacted layer does not exceed 100 mm, smooth
wheel roller of 80 to 100 kN weight may be used.
For a compacted single layer upto 200 mm, the compaction shall be done with
the help of vibratory roller of minimum static weight of 80 to 100 kN or
equivalent capacity roller.
The speed of the roller shall not exceed 5 km/h.
In portions having unidirectional cross fall/superelevation, rolling shall
commence from the lower edge and progress gradually towards the upper
edge. Thereafter, roller should progress parallel to the centre line of the road,
uniformly over-lapping each preceding track by at least one third width until the
entire surface has been rolled.
If irregularities develop during rolling which exceed 12 mm when tested with a
3 metre straight edge, the surface should be loosene and premixed material
added or removed as required before rolling again so as to achieve a uniform
surface conforming to the desired grade and crossfall.
Rolling shall be continued till the density achieved is at least 98 per cent of
the maximum dry density for the material as determined by the method
outlined in IS : 2720 (Part-8).
6. Setting and drying: After final compaction of wet mix macadam course, the
road shall be allowed to dry for 24 hours.
7. Rectification of Surface Irregularity: Where the surface irregularity of the wet
mix macadam course exceeds the permissible tolerances or where the course
is otherwise defective due to subgrade soil getting mixed with the aggregates,
the full thickness of the layer shall be scarified over the affected area,
reshaped with added premixed material or removed and replaced with fresh
premixed material as applicable and recompacted.

Dense Bitumen macadam

1. Dense Bituminous Macadam consists of construction of a single course of 50
to 100 mm thick base/binder course on a previously prepared base.
2. Materials
Bitumen: The bitumen shall be paving bitumen of Penetration Grade S 65 or A 65
(60/70) as per Indian Standard Specifications for Paving Bitumen IS: 73.
Coarse aggregates: The coarse aggregates shall consist of crushed stone, crushed
gravel/shingle or other stones.
They shall be clean, strong, durable, of fairly cubical shape and free from
disintegrated pieces, organic or other deleterious matter and adherent coating.
The portion of the total aggregate passing 4.75mm sieve shall have a sand
equivalent value of not less than 50 when tested in accordance with the requirement
of IS : 2720 (Part-37).
The plasticity index of the fraction passing the 425 micron sieve shall not exceed 4.
PHYSICAL REQUIREMENTS OF AGGREGATES FOR DENSE BITUMINOUS MACADAM
S.No.
Test
Test Method
Requirement
1.
Los Angles Abrasion Value
IS: 2386 (Part-4)
40 per cent Maximum
2.
Aggregate Impact value
IS : 2386 (Part-4) 30 per cent Maximum
3.
Flakiness and Elongation Indices IS : 2386 (Part-1) 30 per cent Maximum
(Total)
4.
Coating and Stripping of
AASHTO T 182
95 per cent
Bitumen Aggregate Mixtures
Minimum retained
coating
5.
Soundness
IS : 2386 (Part-5)
(i) Loss with Sodium Sulphate
5 cycles
12 per cent Maximum
(ii) Loss of Magnesium Sulphate 5 cycles
18 per cent Maximum
6.

Water absorption

IS : 2386 (Part-3)

2 per cent Maximum

Fine aggregates: Fine aggregates shall be the fraction passing 2.36 mm sieve and
retained on 75 micron sieve, consisting of crusher-run screening , gravel , sand or a
mixture of both. These shall be clean, hard, durable, uncoated, dry and free from any
injurious, soft or flaky pieces and organic or other deleterious substances.
Filler: Filler shall consist of finely divided mineral matter such as rock dust, cement.

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 filter is cement or lime.
When the coarse aggregate is gravel, 2 per cent by mass of total aggregate of
portland cement or hydrated lime shall be added and the percentage of fine
aggregate reduced accordingly.
3. Aggregate gradation:
AGGREGATE GRADATION FOR DENSE BITUMINOUS MACADAM
Sieve Designation
Percentage passing the sieve by weight
37.5 mm
26.5 mm
13.2 mm
4.75 mm
2.36 mm
300 micron
75 micron

S.
1.

2.
3.
4.
5.
6.

100
90-100
56-80
29-59
19-45
5-17
1-7

4. REQUIREMENTS OF DENSE BITUMINOUS MACADAM MIX

No.
Description
Requirements
Marshall stability (ASTM Designation-D-1559)
820 kg (1800 lb)
determined on Marshall specimens compacted
minimum by 75 compaction blows on each end
Marshall flow (mm)
2-4
Per cent Air voids
3-5
Minimum voids in mineral aggregates (VMA)
10 per cent-12 per cent
Per cent voids in mineral aggregates filled
65-75
by bitumen (VFB)
Binder content per cent by weight of total mix
Not less than 4.0 per cent

5. Construction Operations
Preparation of base: The base on which Dense Bituminous Macadam is to be laid
shall be prepared, shaped and conditioned to the specified lines, grades and cross
sections.
The surface shall be thoroughly swept clean free from dust and foreign matter using
mechanical broom and dust removed or blown off by compressed air
Tack coat: A tack coat over the base shall be applied as per IRC.
Spreading: The mix transported from the hot mix plant to the site shall be spread by
means of a self-propelled paver with suitable screeds capable of spreading, tamping
and finishing the mix to specified grade, lines and cross-section.
The temperature of mix at the time of laying shall be in the range of 1200-160 0 C.
Mixes with a temperature of less than 120 0 C shall not be put into paver spreader.
Rolling: After spreading the mix by paver, it shall be thoroughly compacted by rolling
with a set of rollers moving at a speed not more than 5 km/h, immediately following
close to the paver.
Generally the initial or breakdown rolling shall be done with 80-100 kN static weight
smoothwheeled roller. The intermediate rolling shall be done with 80-100 kN static

weight vibratory roller or with a pneumatic tyred roller of 150-250 kN weight having a
tyre pressure of at least 0.7 MPa.
The finish rolling shall be done with 60-80 kN weight smooth wheeled tandem roller.
Rolling shall be continued till the density achieved is at least 98 per cent of that of
laboratory Marshall specimen (compacted as defined in Table 500-10) and all roller
marks are eliminated.
Rolling operations shall be completed in all respects before the temperature of the
mix falls below 1000C.
Skin patching of an area that has been rolled will not be permitted.
6. Opening to Traffic: Traffic may be allowed after completion of the final rolling
when the mix has cooled down to the surrounding temperature. The Dense
Bituminous Macadam shall be provided with an appropriate wearing course as
early as possible prior to regular opening to normal traffic and/or impending
rain.
7. Measurements for Payment: Dense Bituminous Macadam shall be measured
as finished work in cubic metres or tonnes .

Bitumen Concrete

1. This work shall consist of construction in a single layer, bituminous concrete

(asphaltic concrete) of thickness 25-100 mm on previously prepared
bituminous course.
2. Materials
Bitumen: Same as that of DBM is applied
Coarse aggregates: Same as that of DBM is applied
The Stone Polishing Value as measured by BS: 812 (Part 114) shall not be less than
55.
The maximum value for the water absorption should be 1 per cent.
Fine aggregates: Same as that of DBM is applied
Filler: Same as that of DBM is applied
3. AGGREGATES GRADATION FOR BITUMINOUS CONCRETE
IS Sieve Designation
Per cent passing the sieve by weight
26.5 mm
100
19 mm
90-100
9.5 mm
56-80
4.75 mm
35-65
2.36 mm
23-49
300 micron
5-19
75 micron
2-8
4. REQUIREMENTS OF BITUMINOUS CONCRETE MIX
S. No.
Description
Requirements
1.
Marshall stability (ASTM Designation: D-1559)
820 kg (1800 lb) Minimum
determined on Marshall specimens compacted
by 75 compaction blows on each end
2.
Marshall flow (mm)
2-4
3.
Per cent voids in mix
3-5
4.
Per cent voids in mineral aggregates (VMA)
Minimum 11-13 per cent
5.
Per cent voids in mineral aggregates filled by
65-75
bitumen(VFB)
6.
Binder content, per cent by weight of total mix
Minimum 4.5
7.
Water Sensitivity (ASTM D1075) Loss of stability 75 per cent retained
on Min immersion in water at 60o C strength
8.
Swell Test (Asphalt Instt. MS-2, No. 2)
1.5 per cent Max

5. Construction Operations
Preparation of base: The base on which bituminous concrete is to be laid shall be
prepared, shaped and conditioned to the specified levels, grade and crossfall
(camber) as directed by the Engineer.
The surface shall be thoroughly swept clean free from dust and foreign matter using
mechanical broom and dust removed by mechanical means or blown off by
compressed air. In portions where mechanical means cannot reach, other approved
method shall be used.
All other processes like spreading, rolling, Etc are done same as that of DBM.

6. Opening to Traffic: Traffic may be allowed immediately after completion of the

final rolling when the mix has cooled down to the surrounding temperature.
7. Measurements for Payment: Bituminous concrete shall be measured as
finished work in cubic metres or tonnes as provided in the Contract.