Contents

List of Figures ............................................................................................................................................... 4

List of Tables ................................................................................................................................................ 5
List of Abbreviations..................................................................................................................................... 6
ABSTRACT .................................................................................................................................................. 7
About Company .................................................................................................................................... 8
CHAPTER 1.................................................................................................................................................. 8
INTRODUCTION ......................................................................................................................................... 8
Table 1: Detail about company project ......................................................................................................... 8
GENERAL .................................................................................................................................................... 9
RIGID PAVEMENTS .................................................................................................................................. 10
Advantages of Crush Sand .................................................................................................................. 12
Disadvantages of Crushed Sand .......................................................................................................... 12
Advantages of Natural sand ................................................................................................................ 12
Disadvantages of Natural Sand ........................................................................................................... 12
Properties of demolished aggregates ................................................................................................... 13
CHAPTER 2................................................................................................................................................ 14
LITERATURE SURVEY ............................................................................................................................... 14
CHAPTER 3................................................................................................................................................ 16
OBJECTIVES AND NEED JUSTIFICATION .................................................................................................. 16
Objective ............................................................................................................................................. 16
Needs for construction of rigid pavements.......................................................................................... 16
Needs of use of crushed sand .............................................................................................................. 16
Needs of use of demolished aggregate ................................................................................................ 17
CHAPTER 4................................................................................................................................................ 18
METHODOLOGY ....................................................................................................................................... 18
Proportioning of Materials for the Mix: .............................................................................................. 20
Construction: ....................................................................................................................................... 21
MIX DESIGN FOR PAVEMENT QUALITY CONCRETE(PQC) ...................................................................... 24
Test data for materials-........................................................................................................................ 24
PAVEMENT QUALITY CONCRETE (PQC) ................................................................................... 26
Methodology for Pavement Quality Concrete (PQC): ........................................................................ 27
Proportioning of Concrete: .................................................................................................................. 29
Surface Texture: .................................................................................................................................. 31
Methodology in Replacement of Sand and Aggregate ........................................................................ 32
1. Properties: ....................................................................................................................................... 33
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 2. Applications: ................................................................................................................................... 34
3. Quality: ........................................................................................................................................... 34
4. Grading Zone: ................................................................................................................................. 34
5. Bulk Density: .................................................................................................................................. 34
6. Specific Gravity: ............................................................................................................................. 35
TESTS PERFORMED FOR DIFFERENT TYPES OF MATERIAL ..................................................................... 35
B. Initial and Final Setting time of Cement (IS-4031 part5).................................................................... 36
C. Determination of Compressive Strength (IS 4031 (Part 6) 1988.): ..................................................... 37
D. Fineness test of cement (IS CODE: IS 4031:part 1-(1996))................................................................ 39
• Importance of Fineness of Cement: .................................................................................................... 39
• Procedure for finding Fineness test of cement: ................................................................................... 39
E. Compaction Factor for Concrete Mix (IS 1199 (1959))...................................................................... 40
F. Slump cone test (IS: 1199 – 1959) ...................................................................................................... 41
H. Liquid Limit (IS 2720 Part5) ............................................................................................................... 43
I. Plastic Limit test (IS 2720 Part5) ........................................................................................................ 44
Procedure: ................................................................................................................................................... 44
J. Moisture Content (IS 2720 part2) ....................................................................................................... 45
K. Free Swelling Test (IS: 2720 (Part 40) 1977) ..................................................................................... 45
M. California Bearing Ratio (IS 2720 Part16) .......................................................................................... 47
N. Sand Replacement Method (IS 2720 part28) ...................................................................................... 49
O. Flakiness and Elongation Index (IS 2386 part1) ................................................................................. 51
Procedure of Shape Tests on Coarse Aggregates: ....................................................................................... 52
P. Aggregate Impact Value (IS: 2386 (Part IV) – 1963) ......................................................................... 52
Procedure of Aggregate Impact Test:.......................................................................................................... 52
Q. Los Angeles Test (IS: 2386 (Part IV) – 1963) .................................................................................... 53
Materials and Physical Requirements: ................................................................................................ 55
Structural features and design of embankment: .................................................................................. 55
PAVEMENT DESIGN ....................................................................................................................... 55
Rigid Pavement–Design Period and Strategy ..................................................................................... 55
Pavement Performance Requirements: ............................................................................................... 56
CRUSHING PLANT .................................................................................................................................... 56
Components......................................................................................................................................... 57
Process of crushing plant..................................................................................................................... 57
READY MIX CONCRETE ............................................................................................................................ 58
CHILLING PLANT....................................................................................................................................... 60
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 EXPERIMENTAL WORK FOR REPLACEMENT OF SAND AND AGGREGATE.............................................. 61
Chapter 5 ..................................................................................................................................................... 64
RESULTS & DISCUSSIONS ......................................................................................................................... 64
Results Discussion: ............................................................................................................................. 63
Chapter 6 ..................................................................................................................................................... 67
CONCLUSION ............................................................................................................................................ 67
Future Scope........................................................................................................................................ 68
References ........................................................................................................................................... 69

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 List of Figures

Figure 1: Typical Cross section of Rigid pavement

Figure 2: Structure of Rigid Pavement
Figure 3: Pavement Quality Concrete
Figure 4: Vicat Apparatus
Figure 5: Vibrating machine for mortar cube casting
Figure 6: Compaction factor apparatus
Figure 7: Different Types of Slump
Figure 8: slump cone test.
Figure 9: Casagrande apparatus.
Figure 10: Plastic limit test.
Figure 11: Free swelling index test
Figure 12: Wire Basket Method
Figure 13: Pycnometer
Figure 14: CBR Apparatus
Figure 15: Sand Replacement Method
Figure 16: EI & FI Apparatus
Figure 17: Los Angeles Test Apparatus
Figure 18: Crusher Plant
Figure 19: RMC Plant
Figure 20: Chilling Plant
Figure 21: Crushed Sand Production
Figure 22: Concrete Cube Casting
Figure 23: Graphical Comparison For M-20 Concrete
Figure 24: Graphical Comparison For M-15

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 List of Tables

Table 1: Detail about company project

Table 2: Compressive strength of concrete cubes
Table 3 Fiber specification
Table 4: Rigid Pavement Test Results
Table 5: Composition of concrete
Table 6: Strength of concrete with Natural Sand
Table 7: Strength of Concrete with Crush Sand & Demolished Aggregate
Table 8: Strength of Concrete with Crush Sand and Natural Aggregate

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 List of Abbreviations

BIS Bureau of Indian Standards

CA Contract Agreement

CPWD Central Public Works Department

EPC Engineering Procurement Construction

GRIL G. R. Infra projects Ltd.

GSSHPL G R Solapur Sangli Highway Pvt. Ltd.

IE Independent Engineer

IRC Indian Roads Congress

IS Indian Standard

MORTH Ministry of Road Transport and Highways

NAC Natural Aggregate Concrete

NBC National Building Code

NCR Non-Conformance Report

NHAI National Highway NHAI Of India

OGL Original Ground Level

PM Project Manager (EPC Contractor)

QA Quality Assurance

QC Quality Control

PQC Pavement Quality Concrete

QMS Quality Management System

R.E. Resident Engineer

RFI Request for Inspection

RAC Recycled Aggregate Concrete

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 ABSTRACT
The construction of highway pavement is one of the most important parts of
civil engineering. The construction procedure includes a detail investigation of work
which starts with the appropriate selection of material till the entire life of the
pavement .This study highlighted the different layers of rigid pavement with their
design consideration from MORTH 5th revision & all the experiments were
conducted considering quality, control and management with the help of Indian
Standard codes like IRC SP-84, IS : 2720, IS : 456, IS : 516 etc.
Due to over excavation of sand from the river bed water heads are reduced
& have hazardous impact on environment. Natural sand contains high % of inorganic
materials, Chlorides, Sulphates, Silt & clay that Adversely affect the strength &
durability. In this report, we have studied the comparison between the properties
shown by the concrete when the Natural sand and aggregates are replaced by crushed
sand and aggregates obtained from demolished concrete material.
Although, most of the findings from this study support the existing
understanding of pavement performance, the methodology in the study provides a
systematic outline of interactions between the design and site factors as well as new
insights on various design options.

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 CHAPTER 1
INTRODUCTION

About Company

G R Infra Projects is an integrated road EPC company with experience in design and
construction of various road/highway projects across 14 states in India. Primary business
operations are broadly divided into three categories:

(i) Civil construction activities, under which we provide EPC services;

(ii) Development of roads and highways on a BOT basis.
(iii) Manufacturing activities, under which we process bitumen, manufacture
thermoplastic road-marking paint and road signage and fabricate and
galvanize metal crash barriers.

Table 1: Detail about company project

Sr Particulars Details
no
1 Project Four Laning of Akkalkot Solapur Section of NH-
150 E with design chainage Km 99 + 400 to Km 138
+352.
2 Client National Highway Authority of India (NHAI)
3 EPC Contractor GR Infra projects Ltd
4 Total length of project 38.952 Km
5 Bid Project Cost INR 807 Cr

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GENERAL

The construction of highway pavement is one of the most important parts of

civil engineering. The construction procedure includes a detail investigation of work
which starts with the appropriate selection of material till the entire life of the
pavement .This study highlighted the different layers of rigid pavement with their
design consideration from MORTH 5th revision & all the experiments were
conducted considering quality, control and management with the help of Indian
Standard codes like IRC SP-84, IS : 2720, IS : 456, IS : 516 etc. The report gives
brief detail of concrete mix design of M40 grade Pavement Quality Concrete (PQC)
in the “Four Laning Of Akkalkot-Solapur Highway Rigid Pavement Construction.”
Due to digging of the sand from river bed reduces the water head and have
an impact on environment. There is erosion of nearby land due to excess sand lifting
as well as it destroys the flora & fauna in surrounding areas. Natural sand contains
high % of inorganic materials, chlorides, sulphates, silt and clay that adversely affect
the strength & durability of concrete. Use of crushed sand has become a good
substitute for natural sand and it is essential in view of technical, commercial &
environmental requirements. Its chemical & physical properties such as color, size
& shape, surface texture up particles depend upon types of stone & its source. The
sand must be of proper gradation. When fine particle is in proper proportion, the
sand will have fewer void. For the purpose of experiment design concrete mixes of
M15 and M20 grades by 100% replacement of natural sand by artificial sand and
natural aggregate by demolished material as aggregate. Its mechanical properties
namely cube compressive strength is study in this experiment. There is an
experimental comparison of compressive strength of sand: aggregate ratio of
artificial sand: natural aggregate, artificial sand: demolished aggregate and natural
sand: natural aggregate. The use of demolished material as an aggregate in
experimental study is done by keeping the further use in future when there will be
scarcity of both crushed and artificial aggregate. By using demolished material, it
utilizes the waste material and is used in less importance structure like compound
walls and in roads.

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RIGID PAVEMENTS

Rigid pavements have sufficient flexural strength to transmit the wheel load stresses
to a wider area below. Compared to flexible pavement, rigid pavements are placed either
directly on the prepared sub-grade or on a single layer of granular or stabilized material.
Since there is only one layer of material between the concrete and the sub-grade, this layer
can be called as base or sub-base course.

Figure 1: Typical Cross section of Rigid pavement

In rigid pavement, load is distributed by the slab action constructed by Portland

cement concrete (PCC). Bending of the slab due to wheel load and temperature variation
and the resulting tensile and flexural stress.

Types of Rigid Pavements:

Rigid pavements can be classified into four types:

1. Jointed plain concrete pavement (JPCP)

2. Jointed reinforced concrete pavement (JRCP)
3. Continuous reinforced concrete pavement (CRCP)
4. Pre-stressed concrete pavement (PCP).

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Jointed Plain Concrete Pavement:
They are plain cement concrete pavements constructed with closely spaced
contraction joints. Dowel bars or aggregate interlocks are normally used for load transfer
across joints. They normally have a joint spacing of 5 to 10m.

Jointed Reinforced Concrete Pavement:

Although reinforcements do not improve the structural capacity significantly, they
can drastically increase the joint spacing to 10 to 30m. Dowel bars are required for load
transfer. Reinforcements help to keep the slab together even after cracks.

Continuous Reinforced Concrete Pavement:

Complete elimination of joints is achieved by reinforcement.

Number of layers and their detailed description:

Figure 2: Structure of Rigid Pavement

The structure of a rigid pavement consists following layers.

• Concrete slab or surface course

• Granular base or stabilized base course
• Frost protection layer
• Subgrade soil

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Advantages of Crush Sand

1. Crush sand is cheaper and easily available therefore the transportation cost is low.
2. Crush sand has a property same as that of Natural River sand.
3. The concrete with crushed sand performed better than concrete with natural sand
as the property of crush sand is better than that of natural sand.
4. Compressive strength and durability of concrete is increase by the use crush sand
because it cannot contain organic impurities.
5. Crush sand does not harm to the environment in any way.

Disadvantages of Crushed Sand

1. Crushed sand can be of course and angular texture. This can lead to more water and
cement requirement to achieve the expected workability.
2. Crushed sand contains a larger amount of micro- fine particles. This can affect the
strength of concrete.

Advantages of Natural sand

1. It is naturally available from river bed.

Disadvantages of Natural Sand

1. The presence of silt and clay in the sand reduces the setting time of cement and
make concrete and mortar weak and holds the dampness.
2. The requirement of cement is more.
3. Water table level get reduced due to dragging of the sand from the river and the
roots of the tree may not be able to get water.
4. In the absence of sand in river, water gets evaporated due to direct sun light.
5. The slump is more.
6. Water retentivity of mortar is more.
7. Bulkage correction is required during mix design.

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Properties of demolished aggregates

1. Less specific gravity.

2. High water absorption.
3. Relatively less compressive strength.
4. Less modules of elasticity 0f 15 % from natural aggregates.
5. Reduced workability

Closure: The topic was introduced in the above chapter; in the next chapter we will be
discussing about the literature survey. Literature Survey consist of the papers submitted
from all over the world in different journals about their prominent work which will guide
us throughout our work.

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 CHAPTER 2
LITERATURE SURVEY

The consumption of cement content, workability, compressive strength and cost of

concrete made with crush sand were studied by researchers BabuK. K. et.al, Nagaraj T. S.
et.al, and Narasimhan et.al. The mix design proposed by Nagaraj et.al shows the
possibilities of ensuring the workability by wise combination of rock dust and sand, use of
super plasticizer and optimum water content using high percentages of manufactured sands
in the aggregate blend may become a lot more common. It is seen from their studies there
a variation in strength enhancement of concrete made from artificial sand to encourage the
use of locally available artificial sand promotes to study to check it suitable replacement
percentage in the concrete.

Sakthivel et al. studied replacement of sand used in concrete as fine aggregates

made by the crush sand. This study made an attempt to partially replace artificial sand in
place of sand in M20 grade concrete. It was found that the partial replacement of sand with
10% of artificial sand has given the optimum results and concluded that if partial
replacement of sand with artificial sand up to 10% in M20 grade of concrete is done.
According to Sakthivel. al. study the replacement of natural sand with crush sand is
economical and use of crush sand is possible without affecting the strength of structure.

B Balapgol & SA Kulkarni According to B Balapgol & SA Kulkarni crush sand

gives more strength than natural sand because of properties of crush sand i.e. shape size,
strength etc. It gives higher strength than that of natural sand.

Sahu Kumar and Sachan investigated the suitability of crushed stone dust waste
as fine aggregate for concrete. Test results indicated that crushed stone dust waste can be
used effectively to replace natural sand in concrete. Concrete made with this replacement
can attain the same compressive strength, comparable tensile strength, modulus of rupture
and lower degree of shrinkage as the control concrete.

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 Dan Ravina He says that a combination of fly ash and crushed sand yield a far
superior concrete mix than crushed sand alone' and obviates the disadvantage of partial or
total replacement of natural sand with crushed sand. According to' Dan Ravina’ we can use
crush sand as a replacement in place of natural sand which is the cheapest way for
replacement and having no drawbacks.

Thaniya Kaosol (2010) has made study on the reuse of concrete waste as crushed
stone for concrete masonry units. The main objective was to increase the value of the
concrete waste, to make a sustainable and profitable disposal alternative for the concrete
waste. Attempts were made to utilize the concrete waste as crushed stones in the concrete
mix to make concrete blocks. Various percentages of crusted stones have been tried the
amount (i.e. 0%, 10%, 20%, 50% and 100%). From the results they found concrete waste
can used to produce concrete block masonry units. Suitability of Crushed sand to replace
river sand in concrete production was investigated Manaseeh Joel [2010]. Slump,
compressive and indirect tensile strength tests were performed on fresh and hardened
concrete. Twenty eight days peak compressive and indirect tensile strength values of 40.70
N/mm2 and 2.30 N/mm2 respectively were obtained with the partial replacement of river
sand with 20% crush sand, as against values of 35.00N/mm2 and 1.75N/mm2 obtained
with the use of river sand as fine aggregate.

Crentsil et al 2001 He states that at a high w/c ratio, Strength of recycled aggregate
is comparable to that of reference concrete even at a replacement level of 75%

Closure: The literature was carefully reviewed and important things were learned from
those papers. In the next chapter, the theory of the comparison of crushed sand, natural
aggregates, natural sand demolished aggregates and rigid pavement is discussed in details.

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 CHAPTER 3
OBJECTIVES AND NEED JUSTIFICATION

Objective

• To perform various laboratory tests to check suitability of materials for construction

of pavement.
• To examine the variation in the compressive strength of Concrete by using NAC
(Natural Aggregate Concrete) & RAC (Recycled Aggregate Concrete).
• To design the PQC mix for M40 grade of concrete as per IS: 10262: 2009

Needs for construction of rigid pavements

• Rigid Pavements deals with very heavy traffic flow and provide Excellent smooth
surface drains.
• As far as the life span maintenance cost of Rigid pavement is concerned, Rigid
pavement proves itself much superior than Flexible Pavement
• Even after their life span, they can be used as base course and surfacing can be
provided of the bituminous materials

Needs of use of crushed sand

• Compressive strength as well as flexural strength of concrete made from crush sand
is higher as compared to natural sand.
• It causes less damage to the environment.
• It has higher durability by overcoming the deficiencies like segregation, bleeding,
voids & capillary.
• It has less slump and better concrete/mortar quality.

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Needs of use of demolished aggregate

• If concrete aggregate is recycled via crushing machine this can be used for
construction which have less importance like Compound walls & village roads etc.
• This will reuse the waste material and reduce the environmental pollution.

Closure: The objective and the needs of rigid pavements, crushed sand and demolished
aggregate was introduced in the above chapter. In the next chapter, the theory and the
methodology of rigid pavement and the comparison in the compressive strength of rigid
pavements, crushed sand and demolished aggregate is discussed in detail.

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 CHAPTER 4
METHODOLOGY

NATURAL GROUND LEVEL

The level of ground before any excavation or filling has been carried out is referred
to as the natural ground level.

CLEARING AND GRUBBING

Removal of trees, shrubs, stumps and rubbish from the site.

ORIGINAL GROUND LEVEL

EMBANKMENT
The embankment refers to a volume of earthen material that is placed and
compacted for the purpose of raising the grade of a roadway above the level of the existing
surrounding ground surface. Its height is from 1.5 to 1.8m. It also holds the water.

SUBGRADE SOIL
The subgrade is nothing but the existing soil layer which is compacted using
equipment to provide stable platform for rigid pavement. The subgrade soils are subjected
to lower stresses than the top layers since the stresses will reduce with depth. The stresses
coming from the top layers is received by different soils in different manners. Some soils
may resist them and some may not. It is depending upon the interrelationship of texture,
density, moisture content and strength of subgrade. At the same time the pavement layers
above the subgrade should be capable of reducing stresses imposed on the subgrade soil to
prevent the displacement of subgrade soil layers.

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GRANULAR SUB-BASE
It is the third layer from the top and is in contact with the subgrade soil and base
course. It is constructed by using low quality aggregates than the base course but they
should be better quality than subgrade. Generally sub-base course is not required when the
traffic loading is light. When the loading exceeds 100000 pounds it should be constructed.

DRY LEAN CONCRETE (DLC)

It is an important part of modern rigid pavement. It is a plain concrete with a large
ratio of aggregate to cement than conventional concrete and generally used as a sub base
of rigid pavement. The compaction of DLC is done under 10 to 12T vibratory roller in
field.

Material:
The Contractor shall indicate to the IE the source of all materials with relevant test
data to be used in DLC work sufficiently in advance and the approval of the IE for the same
shall be obtained before the schedule commencement of the work in trial length.

1. Cement: Cement to be used may preferably be obtained in bulk form. Cement shall
be transported, handled and stored on the site in such a manner as to avoid
deterioration or contamination. Cement shall be stored above ground level in
perfectly dry and water tight sheds and shall be stacked to a height of not more than
eight bags. Wherever bulk storage containers are used, their capacity should be
sufficient to cater the requirement at site. M10 grade of cement is used. If subgrade
soil contains soluble sulphates in a concentration more than 0.5%, sulphate resistant
cement conforming to IS: 12330 or Portland slag cement with slag up to 50% shall
be used.

2. Fly-Ash: Fly-Ash up to 20 % by weight of cementitious material (Cement + Fly-

ash) may be used cement may be used to replace OPC cement and in such case the
cement content shall not be less than 100 kg/cum. Fly-ash shall conform to IS: 3812
Part I.

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 3. Aggregates: Aggregates for DLC shall be natural material complying with IS: 383.
The aggregates shall not be alkali reactive. The limits of deleterious materials shall
not exceed the requirements set forth in table 600-2 of MORTH specifications.

a. Coarse Aggregates: Coarse Aggregate shall comply with clause 602.2.6.2,

except that the maximum size of the coarse aggregate shall be 26.5 mm, and
aggregate gradation shall comply with Table 600-1.
b. Fine Aggregates: The fine aggregate shall comply with clause 602.2.6.3.

4. Curing Compound: The Curing compound shall be white pigmented or

transparent type with water retention index of 90 % when tested in accordance with
BS 7542.
5. Water: Water used for mixing and curing shall comply with Clause 602.2.7.

Proportioning of Materials for the Mix:

The mix shall be proportioned with a maximum aggregate cementitious material
ratio of 14:1 (as per IRC SP 49) where OPC is used and 12:1 where PPC or PSC is used.
The water content shall be adjusted to the optimum as per clause 601.3.2 for facilitating
compaction by rolling. The strength and density requirements of concrete shall be
determined in accordance with clause 601.7 and clause 601.8 by making trial mixes. Care
should be taken to prevent one size of aggregate falling into other size of the hopper of the
feeding bin while loading the individual size of the aggregates into the bins.

1. Moisture Content: The OMC shall be determined and demonstrated by rolling

during trial length construction and the OMC and degree of compaction shall be
got approved from IE. While laying in the main work, the DLC shall have a
moisture content between the optimum and optimum +2 percent, keeping in view
the effectiveness of the compaction achieved and to compensate for evaporation
losses.

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 2. Cement Content: The cement content in the DLC shall be such that the strength
specified in clause 4.1 of IRC SP: 49 is achieved. The minimum cementitious
content shall not be less than 140 kg/cum of concrete. In case fly-ash is blended at
site as part replacement of cement, the quantity of fly-ash shall be 15-30 percent by
weight of cementitious material and the content of OPC shall not be less than 100
kg/cu. m.

3. Concrete Strength: Clause 4.1 of IRC SP: 49 shall be applicable. The average
compressive strength of each consecutive group of 5 concrete cubes shall not be
less than 7 MPa at 7 days. In addition, the compressive strength of any individual
concrete cube shall not be less than 5.5 MPa at 7 days.

4. Sub-Grade: The subgrade shall conform to the grades and cross-sections on the
drawings and shall be uniformly compacted to the modified Proctor density not less
than 97%. The lean concrete sub-base shall not be laid on a subgrade softened by
rain after its final preparation, surface trenches and soft spots, if any, must be
properly back-filled and compacted to avoid any weak spot. A day before placing
of the sub-base, the subgrade surface shall be given a fine spray of water and rolled
with one or two passes of a smooth wheeled roller after a lapse of 2-3 hours in order
to stabilise loose surface. If found necessary, another fine spray of water may be
applied just before placing the sub-base.

5. Drainage Layer: A drainage layer conforming to Clause 401 shall be laid above
the subgrade before laying the DLC sub-base.

Construction:
1. General: The DLC shall be laid on the prepared granular drainage layer. The DLC
sub-base shall be overlaid with concrete pavement only after 7 days of sub-base
construction.

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 2. Batching and Mixing: The batching plant shall be capable of proportioning the
materials by weight, each type of material being weighed separately in accordance
with Clause 602.9.2, 602.9.3.1 and 602.9.3.2 of MORTH specifications.

3. Transporting: Plant mix DLC shall be discharged immediately from the mixer,
transported directly to the point where it is to be laid and protected from the weather
by covering the tipping trucks with tarpaulin during transit if necessary.

4. Placing: DLC shall be placed by a paver with electronic sensor on the drainage
layer. In roads with carriageway more than 2 Lanes a longitudinal joint shall be
provided. Transverse Butt type joints shall be provided at the end of the
construction in a day. The DLC shall extend beyond the PQC (including that in
shoulder, if any) by 0.75 m on either side.

5. Compaction: The compaction shall be carried out immediately after the material
is laid and levelled. In order to ensure thorough compaction, rolling shall be
continued on the full width till there is no further visible movement under the roller
and surface is well closed. The minimum dry density obtained shall not be less than
98 percent of that achieved during the trial length construction in accordance with
Clause 601.7. Double drum smooth-wheeled vibratory rollers of minimum 80 to
100 kN static weight are suitable for rolling DLC.The spreading, compacting and
finishing of the lean concrete shall be carried out as rapidly as possible and the
operation shall be so arranged as to ensure that the time between the mixing of the
first batch of concrete in any transverse section of the layer and the final finishing
of the same shall not exceed 90 minutes when the temperature of concrete is
between 25°C and 30°C, and 120 minutes if less than 25°C. This period may be
reviewed by the Engineer in the light of the results of the trial run but in no case
shall it exceed 120 minutes. Work shall not proceed when the temperature of the
concrete exceeds 30°C. If necessary, chilled water may be resorted to for bringing
down the temperature. It is desirable to stop concreting when the ambient
temperature is above 35°C. After compaction has been completed, roller shall not

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 stand on the compacted surface for the duration of the curing period except during
commencement of next day's work near the location where work was terminated
the previous day.

6. Joints: Construction and Longitudinal joints shall be provided as per drawings.

Transverse butt type joint shall be provided at the end of the construction in a day.
Longitudinal construction joint shall be provided only when full width paving is
not possible. Transverse joints in DLC shall be staggered from the construction butt
type joint in concrete pavement by 800-1000 mm. Longitudinal joint in DLC shall
be staggered by 300-400 mm from the longitudinal joint of concrete pavement.

7. Curing: The curing shall be done by either of the following ways:

a. Curing may be done by covering the surface by gunny bags / hessian, which
shall be kept wet continuously for 7 days by sprinkling water.
b. The curing shall be done by spraying with approved resin based aluminized
reflective curing compound in accordance with clause 602.9.12. As soon as
the curing compound has lost its tackiness, the surface shall be covered with
wet hessian for 3 days.
c. Wax-based white pigmented curing compound with water retention index
of less than 90% shall be used to cure the dry lean concrete. The compound
shall be applied uniformly with a mechanical sprayer and with a hood to
protect spray from the wind.

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 MIX DESIGN FOR PAVEMENT QUALITY CONCRETE(PQC)
Test data for materials-
• Cement-
1. Grade of cement - OPC 43 grade
2. Brand of cement - Birla shakti
3. Specific Gravity - 3.15
• Coarse Aggregate-
1. Specific Gravity - 26.5mm -2.942
20mm - 2.940
10mm - 2.924
2. Source - 115+800RHS Quarry GR 1.5km from road
3. Water absorption- 26.5mm - 0.66%
20mm - 0.82%
10mm - 1.45%
4. Aggregate impact value - 10%
5. Combined FI and EI - 27.79%
• Fine Aggregate-
1. Specific Gravity - 2.866
• Fly Ash-
1. Specific Gravity - 2.20
• Admixture (Kunaplast PC 50)-
1. Specific Gravity – 1.085
• Proportions-

26.5mm - 30%
20mm - 15%
10mm - 15%
Crusher sand - 40%
• Target Mean Strength of Concrete

By using (Fck=fck+1.65s) obtained target mean strength is 48.25 And as per IRC44-
2008,table 3,standard deviation value is 5MPa

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• Water cement ratio-

Max. W/c ratio is 0.5 but based on trials adopted W/C ratio is 0.34
• Selection of water content-

From Table no.5 of IRC 44 Water content is 186 lit and given correction factor is 0.731
hence arrived water content is 186*0.731=136 lit
• Cement Content-

1.W/C ratio-0.34
2. Weight of cementitious material content-136/0.34 = 400Kg/Cum
3. Fly ash @20% of total cementitious content = 80 kg/Cum
4. Cement (OPC) = 320 kg/Cum

• Mix calculation
1. Volume of concrete = 1 Cum
2. Volume of cement = (mass of cement / specific gravity of cement)*(1/1000) =0.1016 Cum
3. Volume of fly ash = (mass of fly ash / specific gravity of fly ash) *(1/1000) = 0.0364 Cum
4. Volume of water = (mass of water / specific gravity of water)*(1/1000) = 0.1360 Cum
5. Volume of admixture = (mass of admixture /specific gravity of admixture)*(1/1000) = 0.0337
Cum
6. Volume of all in aggregate = 1-(volume of cement +volume of fly ash + volume of water +volume
of admixture) = 0.7224 Cum
7. Mass of 26.5 mm coarse aggregate = 0.7224* volume of coarse aggregate * specific gravity of
26.5mm coarse aggregate*1000 = 638 kgs
8. Mass of 20 mm coarse aggregate = 0.7224* volume of coarse aggregate * specific gravity of
20mm coarse aggregate * 1000 = 319 kgs
9. Mass of 10 mm coarse aggregate = 0.7224* volume of coarse aggregate * specific gravity of
10mm coarse aggregate * 1000 = 317 kgs
10. Mass of fine aggregate (crush sand) = 0.7224*volume of fine aggregate *specific gravity of fine
aggregate *1000 =828 kgs
• Proposed mix proportion
1. Cement = 320 kg/Cum
25 Civil Department
2. Fly ash = 80 kg/Cum
3. 26.5 mm Agg. = 638 kg/Cum

Table No 2: Compressive strength of concrete cubes

Sr 7 days Avg. 28 Avg.

.No. days
1 44.28 43.06 51.84 52.41
41.84 52.98
2 43.58 42.70 50.93 53.18
41.81 55.42
3 41.58 42.32 55.17
43.05 54.43 54.80

42.69 53.46

PAVEMENT QUALITY CONCRETE (PQC)

Pavement Quality Concrete (PQC) is cement concrete made with large size
aggregates in accordance with IRC specifications and laid over a dry lean concrete sub-
base. This construction is used for highway concrete pavement as it can take heavy loads.
The design should be based on the flexural strength of concrete. The mix shall be designed
in the laboratory so as to ensure the minimum flexural strength on-field with the
permissible tolerance level. The concrete slab is the top most layer of rigid pavement which
is in direct contact with the vehicular loads. This is also called as surface course. It is water

26 Civil Department
resistant and prevents the water infiltration into the base course. It offers friction to the
vehicles to provide skid resistance. The thickness of concrete slab is kept between 150 mm
to 300 mm.

Figure3: Pavement Quality Concrete

Methodology for Pavement Quality Concrete (PQC):

Materials:

1. Cement: Any of the following types of cement capable of achieving the design
strength may be used. If the soil around concrete pavement has soluble salts like
sulphates in excess of 0.5 percent, the cement used shall be sulphate resistant and
shall conform to IS: 12330.Cement used is of OPC M40 grade.

2. Admixtures:
a. Chemical Admixtures: Admixtures conforming to IS: 9103 and IS: 6925 shall be
permitted to improve workability of concrete or extension of setting time, on
satisfactory evidence that they will not have any adverse effect on the properties of
concrete with respect to strength, volume change, durability and have no deleterious
effect on steel bars.

27 Civil Department
 b. Mineral Admixtures: Fly-ash up to 25% by weight of cementitious material may be
used in Ordinary Portland cement 43 or 53 grade as part replacement of cement
provided uniform blending with cement is ensured. The fly ash shall conform to IS:
3812 (Part I).

3. Silica Fumes: Silica fume conforming to a standard approved by the Engineer may
be used as an admixture up to 10% by weight of cement. Silica Fumes shall comply
with the requirements given in IS: 15388-2003, IRC SP: 114, and IRC: 44.

4. Fibres: Fibres may be used subject to the provision in the design / approval by the
IE to reduce the shrinkage cracking and improve the post-cracking residual strength.
Synthetic fibers will have good alkali and UV light resistance. Melting Point of fibre
shall not be less than 160ºC. The fibres may be steel fibre as per IRC SP: 46 or
polymeric Synthetic fibres within the following range of specifications:

Table2: Fiber specification

Effective Diameter 10 micron-100 microns

Length 6-48 mm
Specific Gravity More than 1.0
0.6-2.0 kg/cu. m (0.2-0.6% by weight of cement)
Suggested Dosage
Usage will be regulated as stipulated in IRC:44/IS:456
Water Absorption Less than 0.45 percent.
5. Aggregate: Aggregates for pavement concrete shall be natural material complying
with IS: 383 but with Los Angeles Abrasion Test value not exceeding 35 percent. The
limits of deleterious materials shall not exceed the requirements set out in Table 600-
2.
a. Coarse Aggregate:
• The maximum size of coarse aggregate shall not exceed 31.5 mm for
pavement concrete.
• The Los Angeles Abrasion Value shall not exceed 35. The combined flakiness
• elongation index of aggregate shall not be more than 35 percent.

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 b. Fine Aggregate:
• The Fine aggregate shall consist of clean natural sand or crushed stone sand
or a combination of the two and shall conform to IS: 383.
• The fine aggregates shall have a sand equivalent value of not less than 50
when tested in accordance with requirement of IS: 2720 (Part-37)

6. Water: Water used for mixing and curing of concrete shall be clean and free from
injurious amount of oil, salt, acid, vegetable matter and other substances harmful to
the finished concrete.

7. Steel for Dowels and Tie Bars:

i. Steel shall conform to the requirements of IS: 432 and IS: 1786 as relevant.
ii. The dowel bars shall conform to IS: 432 of Grade I.
iii. Tie bars shall be either High Yield Strength Deformed bars conforming to IS:
1786 and grade of Fe 500 or plain bars conforming to IS: 432 of Grade I.

Proportioning of Concrete:

1. Cement Content: The quantity of cement shall not be less than 360 kg/cu. m for
all types of cement. In case fly ash grade, I (as per IS:3812) is blended at site as part
replacement of cement, the quantity of fly ash shall be up to 20% by weight of
cementitious material and the quantity of OPC in such a blend shall not be less than
310 kg/cu. m. The OPC content in any case shall not be more than 250 kg/cum.

2. Concrete Strength: The characteristic flexural strength of concrete for 28 days

shall not be less than 4.5 MPa unless specified otherwise. Target mean flexural
strength for mix design shall be more than 4.5 MPa + 1.65s, where “s” is standard
deviation of flexural strength derived by conducting test on minimum 30 beams.
The water content shall be the minimum required to provide the agreed workability
for full compaction of the concrete to the required density as determined by the trial
mixes and the maximum free water cement ratio shall be 0.40 when only OPC is
used and 0.50 when blended cement (Portland Pozzolana Cement or Portland Slag

29 Civil Department
 Cement or OPC blended with fly ash ) is used IRC 44 shall also be referred
regarding the selection of w/c ratio. The ratio between the 7- and 28-day strength
shall be established for the mix to be used in the slab in advance, by testing pairs of
beams and cubes at each stage on at least six batches of trial mix. The average
strength of the 7 day cured specimens shall be divided by the average strength of
the 28-day specimens for each batch, and the ratio “R” shall be determined. The
ratio “R” shall be expressed to three decimal places.

3. Workability: The workability of the concrete at the point of placing shall be

adequate for the concrete to be fully compacted and finished without undue flow.
The optimum workability for the mix to suit the paving plant being used shall be
determined by the Contractor and approved by the IE. The workability shall be
established for the type of paving equipment available. A slump value in the range
of 25 ± 15 mm is reasonable for paving works but this may be modified depending
upon the site requirement and got reviewed by the IE.

4. Design Mix: The laboratory trials of design mix shall be carried out with the
materials from the approved sources to be used as per IRC: 44. Trial mixes shall be
made in presence of the IE and the design mix shall be subject to the review of IE.

5. Sub-Base: The cement concrete pavement shall be laid over the DLC sub-base
constructed in accordance with the relevant drawings and specifications. It shall be
ensured that the DLC sub-base is not damaged before laying the concrete pavement.
If the DLC is found damaged at some places or it has cracks wider than 10 mm, it
shall be repaired with fine cement concrete (aggregate size 10 mm and down)
before laying separation membrane layer.

6. Separation Membrane: A separation membrane shall be used between the PQC

and the DLC sub-base. Separation membrane shall be impermeable PVC sheet of
125-micron thickness, transparent or white in colour laid flat with minimum

30 Civil Department
 creases. Before placing the separation membrane, the DLC sub-base shall be swept
clean of all the extraneous materials using air compressor.

7. Tie Bars: Tie bars shall be provided at the longitudinal joints as per dimensions
and spacing shown in the drawing and in accordance with Clause 602.6.6. The
direction of the tie bars at curves shall be radial in the direction of the radius.

8. Dowel Bars: The work shall be done in accordance to the clause 602.6.5 of
MORTH specifications. Dowel Bars shall be mild steel rounds in accordance with
Clause 602.2.8, details / dimensions as indicated in the drawings and free from oil,
dirt, loose rust or scale. They shall be straight, free of irregularities and burring
restricting slippage in the concrete. The sliding ends shall be cropped cleanly with
no protrusions outside the normal diameter of the bar.

Surface Texture:

i. Tinning: After final floating and finishing of the slab and before application of the
liquid curing membrane, the surface of concrete slabs shall be textured either in the
transverse direction (i.e. at right angles to the longitudinal axis of the road) or in
longitudinal direction (i.e. parallel to the centre line of the roadway). The texturing
shall be done by tinning the finished concrete surface by using rectangular steel
tines. A beam or a bridge mounted with steel tines shall be equipped and operated
with automatic sensing and control devices from main paver or auxiliary unit.

ii. Brush Texturing: Alternatively, on the instructions of the IE, the brush texturing
shall be applied. The brushed surface texture shall be applied evenly across the slab
in one direction by the use of a wire brush not less than 450 mm wide but wider
brushes normally of 3 m length are preferred. The brush shall be made of 32-gauge
tape wires grouped together in tufts placed at 10mm centres. The tufts shall contain
an average of 14 wires and initially be 100 mm long. The brush shall have two rows
of tufts. The rows shall be 20 mm apart and the tufts in one row shall be opposite

31 Civil Department
 the Centre of the gap between tufts in the other row. The brush shall be replaced
when the shortest tuft wears down to 90 mm long.

Curing: Immediately after the surface texturing, the surface and sides of the slab shall be
cured by the application of approved resin-based aluminized reflective curing compound
which hardens into an impervious film or membrane with the help of mechanical sprayer.
The curing compound shall not react chemically with the concrete and the film or
membrane shall not crack, peel or disintegrate within three weeks of application.

Methodology in Replacement of Sand and Aggregate

The test was conducted to examine the variation in the compressive strength of concrete
having the sand to aggregate ratio as crushed sand: natural aggregate, crushed sand:
demolished aggregate and natural sand: natural sand in M15 and M20 grade of cement.
Methodology is the process of performing any work in proper manner i.e. step by step
procedure of work. This procedure of methodology is shown in following steps; a)
Procurement of material
b) Material testing
c) Arriving mix proportion
d) Cube Casting
e) Curing of specimens
f) Strength test 7 days

The specimen of standard cube of (150 mm x 150 mm x 150 mm) was used to determine
the compressive strength of concrete. Three specimens were tested for 7, 14 and 28 days
with varying proportion of manufactured sand replacement. The constituents were weighed
and the materials were mixed in a mixer. The mixes were compacted with the help of
tamping rod. The specimens were de moulded after 24 h, cured in water for 7, 14 and 28
days, and then tested for its compressive strength as per Indian Standards.

32 Civil Department
1. Properties:

(a) Shape
Crushed Sand: The shape of Crushed sand is cubical and angular and has a rough texture
and hence better for concrete.
Natural Sand: The shape of natural sand is rounded and has a smooth surface.

(b) Moisture Content

Crushed Sand: No moisture content.
Natural Sand: Moisture is generally present in between the particles. Hence, effects the
assumptions of concrete mix design and quality of concrete.

(c) Concrete Strength

Crushed Sand: The compressive strength as well as the flexural strength of concrete made
from Crushed sand are higher than natural sand.
Natural Sand: The compressive strength as well as the flexural strength of concrete made
from natural sand are lower than Crushed sand.

(d) Silt Content

Crushed Sand: It does not contain silt as it manufacturing by crushing aggregates.
However, if screen is not proper sometimes it may contain some dust.
Natural Sand: It contains silt as river water contains it due to erosion of soil in its catchment
area. Hence it needs washing on site.

(e) Over Sized Materials

Crushed Sand: It is artificially manufactured so there are no oversized materials.
Natural Sand: Oversized materials are expected in natural sand and hence needs screening
on site.

(f) Marine Products

Crushed Sand: It does not contain any marine products.

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Natural Sand: It may contain marine products such as grass, algae, clay lumps, bones,
shells, mica etc. which are harmful to properties of concrete.

(g) Eco Friendly

Crushed Sand: It causes less damage to the environment as compared to natural sand.
Natural Sand: It is harmful to the environment. It reduces the ground water level and rivers
water gets dried up.

(h) Adulteration
Crushed Sand: Less adulteration.
Natural Sand: It has high probability of adulteration because of acute shortage. River sand
adulteration with saline sea sand is common in coastal areas.

2. Applications:

Crushed Sand: It is highly recommended for RCC and brick/ block works.
Natural Sand: It is recommended for RCC, plastering and Brick/Block works.

3. Quality:

Crushed Sand: Better quality as compared to natural sand because it is manufactured in a

controlled environment.
Natural Sand: The quality of natural sand deferrers though they may be from the same river
bed.

4. Grading Zone:

Crushed Sand: Manufactured to conform to zone II.

Natural Sand: Mostly conforms to zone II and zone III.

5. Bulk Density:

Crushed Sand: 1.75 Kg/m3

Natural Sand: 1.44 Kg/m3

34 Civil Department
 6. Specific Gravity:

Crushed Sand: Approximate 2.73 (It will depend on parent rock.)

Natural Sand: Approximate 2.65 (It will depend on rocks in catchment area.)
.

TESTS PERFORMED FOR DIFFERENT TYPES OF MATERIAL

A. Consistency of Cement (IS 4031 part4)

When water is added to cement it starts hydration. When excessive amount of water is
added, then it increases the water cement ratio and ultimately there is a decrease in its strength,
when it hardens. Similarly, when less amount of water is added, cement isn't properly hydrated
and loses its strength. The consistency of cement is carried out to determine the amount of
water needed to be added to cement to reach the standard consistency. To determine the
standard consistency of cement we use vicat apparatus.

Figure 4: Vicat Apparatus

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Procedure:

1. Take a sample off cement 400g. Weigh it correctly.

2. Add water 25% by weight i.e., 75g (75ml) to the cement and mix it thoroughly, to
make a cement a cement paste.
3. Place the Vicat mould on a non-porous plate, fill the mould with cement paste,
smooth off the surface of the paste making it level with the top of the mould. To
expel air, shake the mould slightly. The care that the gauging time is between 3 to
5 minutes. While filling the mould use of operator’s hand and blade of trowel only
should be used.
4. Place the test block in the mould together with the non-porous plate, under the rod
bearing the 10mm diameter plunger gently to touch the surface of the test block and
quickly release, allowing it to sink into the cement paste. Carry this operation
immediately after filling the mould. Note the penetration of the needle from the
bottom of mould indicated on the scale.
5. Prepare trial pastes with varying percentages of water, increasing water percentage
by 1 % each time, until the amount of water necessary for making standard
consistency which permits plunger to penetrate to a point 5 to 7 mm from the bottom
of the mould) is determined.

B. Initial and Final Setting time of Cement (IS-4031 part5)

Initial setting time of concrete is the time when cement paste starts hardening while final
setting time is the time when cement paste has hardened sufficiently in such a way that 1
mm needle makes an impression on the paste in the mould but 5 mm needle does not make
any impression. Theoretically, Initial setting time of concrete is the time period between
addition of water to cement till the time at 1 mm square section needle fails to penetrate
the cement paste, placed in the Vicat’s mould 5mm to 7mm from the bottom of the mould.
Final setting time is that time period between the time water is added to cement and the time
at which 1 mm needle makes an impression on the paste in the mould but 5 mm attachment
does not make any impression.

36 Civil Department
 • Purpose: Initial setting time test is important for transportation, placing and
compaction of cement concrete.

C. Determination of Compressive Strength (IS 4031 (Part 6) 1988.):

Purpose: To find the compressive strength of cement.
Definition: Compressive strength is defined as the ratio of the load per unit area.

Figure 5: Vibrating machine for mortar cube casting

37 Civil Department
Procedure:
a. Take 200gm of cement and 600gm of standard sand in the mix ratio 1:3 by weight)
in a pan.
b. The standard sand shall be of quartz, of light, gray or whitish variety and shall be
free from silt.
c. The sand grains shall be angular, the shape of grains approximating to the spherical
form, elongated and flattened grains being present only in very small quantities.
d. Standard sand shall pass through 2 mm IS sieve and shall be retained on 90 microns
IS sieve with the following particle size distribution.
e. Mix the cement and sand in dry condition with a trowel for 1minitues and then add
water.
f. The quantity of water shall be (p/4+3) % of combined weight of cement and sand
where, p is the % of water required to produce a paste of standard consistency
determined earlier.
g. Add water and mix it until the mixture is of uniform color.
h. The time of mixing shall not be < 3 minutes & not > 4 minutes.
i. Immediately after mixing the mortar, place the mortar in the cube mould and prod
with the help of the rod. The mortar shall be prodded 20 times in about 8 sec to
ensure elimination of entrained air.
j. If vibrator is used, the period of vibration shall be 2 minutes at the specified speed
of 12000±400 vibrations /minutes. Then place the cube moulds in temperature of
27±2Oc and 90% relative humidity for 24 hours.
k. After 24 hours remove the cubes from the mould and immediately submerge in
clean water till testing. Take out the cubes from water just before testing.
l. Testing should be done on their sides without any packing. The rate of loading
should be 350 kg/cm2/minute and uniform. Test should be conducted for 3 cubes
and report the average value as the test result for both 7day and 28day compressive
strength.

38 Civil Department
 D. Fineness test of cement (IS CODE: IS 4031:part 1-(1996))
Fineness test of cement is done to determine the particle size of cement. As, the rule of
thumb, the finer the cement particle the best will be the cement and on the other hand the
coarser the particle it will not be that good. The fineness of cement is determined by two
methods.

1. Air Permeability Method (Blaine Method).

2. Fineness test of cement by sieving method.

• Importance of Fineness of Cement:

1. It can increase the final strength of cement.
2. Fineness can also affect workability.
3. Fineness test indirectly measures the surface area of the particles of cement per unit
mass.
4. Fineness increases the strength development in the cement principally during its
first seven days.
5. It can decrease bleeding.
6. It increases the rate of hydration. More is the fineness of cement particles more will
be the rate of hydration.

• Procedure for finding Fineness test of cement:

a) Take a sample of cement and rub the cement with your hands. The test sample
should be free of lumps.
b) Now Take 100g of cement and note it as W1.
c) Pour 100g of cement in 90 µm sieve and close it with the lid.
d) Now place the sieve in Sieve shaking machine. You can also shake the sieve with
your hands by Agitating the sieve in planetary and linear movements for 15
minutes.
e) Nextly, weight the residue retained on the 90 µm sieve as W2.
f) Then calculate the percentage of Wt. of cement-retained on Sieve.

39 Civil Department
 g) Repeat the above experiment with three different samples of cement and average
the values for accurate results.

E. Compaction Factor for Concrete Mix (IS 1199 (1959))

The compaction factor is defined as the ratio of the weight of partially compacted concrete
to the weight of fully compacted concrete.

Figure 6: Compaction factor apparatus.

Procedure of Compaction Factor Test on Concrete:

a) Place the concrete sample gently in the upper hopper to its brim using the hand
scoop and level it.

b) Cover the cylinder.

c) Open the trapdoor at the bottom of the upper hopper so that concrete fall into the
lower hopper. Push the concrete sticking on its sides gently with the road.

40 Civil Department
 d) Open the trapdoor of the lower hopper and allow the concrete to fall into the
cylinder below.

e) Cut of the excess of concrete above the top level of cylinder using trowels and level
it.

f) Clean the outside of the cylinder.

g) Weight the cylinder with concrete to the nearest 10 g. This weight is known as the
weight of partially compacted concrete (W1).
h) Empty the cylinder and then refill it with the same concrete mix in layers
approximately 5 cm deep, each layer being heavily rammed to obtain full
compaction.

i) Level the top surface.

j) Weigh the cylinder with fully compacted. This weight is known as the weight of
fully compacted concrete (W2).
k) Find the weight of empty cylinder (W).

F. Slump cone test (IS: 1199 – 1959)

The concrete slump test measures the consistency of fresh concrete before it sets. It is
performed to check the workability of freshly made concrete, and therefore the ease with
which concrete flows. It can also be used as an indicator of an improperly mixed batch.

The slump test is used to ensure uniformity for different loads of concrete under field
conditions.

Figure 7: Different Types of Slump

41 Civil Department
True Slump – True slump is the only slump that can be measured in the test. The
measurement is taken between the top of the cone and the top of the concrete after the cone
has been removed as shown in Figure.

Zero Slump – Zero slump is the indication of very low water-cement ratio, which results
in dry mixes. These types of concrete are generally used for road construction.

Collapsed Slump – This is an indication that the water-cement ratio is too high, i.e.
concrete mix is too wet or it is a high workability mix, for which a slump test is not
appropriate.
Shear Slump – The shear slump indicates that the result is incomplete, and concrete to be
retested. Concrete slump test is carried out from batch to batch to check the uniform quality
of concrete during construction.

Figure 8: slump cone test.

G. Gradation (IS 2386)

The grading or size distribution of aggregate is an important characteristic because it
determines the paste requirement for workable concrete.

42 Civil Department
 H. Liquid Limit (IS 2720 Part5)
The liquid limit of a soil is the water content at which the soil behaves practically like a
liquid, but has small shear strength. It flows to close the groove in just 25 blows in
Casagrande’s liquid limit device.

Figure 9: Casagrande apparatus.

Procedure of Liquid Limit Test on Soil:

a) Put 250 gm of air-dried soil, passed thorough 425 mm sieve, into an evaporating
dish. Add distilled water into the soil and mix it thoroughly to form uniform paste.
(The paste shall have a consistency that would require 30 to 35 drops of cup to
cause closer of standard groove for sufficient length.)
b) Place a portion of the paste in the cup of Liquid Limit device and spread it with a
few strokes of spatula.
c) Trim it to a depth of 1 cm at the point of maximum thickness and return excess of
soil to the dish.
d) Using the grooving tool, cut a groove along the center line of soil pat in the cup,
so that clean sharp groove of proper dimension (11 mm wide at top, 2 mm at
bottom, and 8 mm deep) is formed.
e) Lift and drop the cup by turning crank at the rate of two revolutions per second
until the two halves of soil cake come in contact with each other for a length of
about 13 mm by flow only, and record the number of blows, N.
f) Take a representative portion of soil from the cup for moisture content
determination.

43 Civil Department
 g) Repeat the test with different moisture contents at least four more times for blows
between 10 and 40.

I. Plastic Limit test (IS 2720 Part5)

The plastic limit of a soil is the moisture content at which soil begins to behave as a plastic
material. At this water content (plastic limit), the soil will crumble when rolled into threads
of 3.2mm(1/8in) in diameter.

Figure 10: Plastic limit test.

Procedure:

a) From the 20g sample select a 1.5 to 2 g specimen for testing.

b) Roll the test specimen between the palm or fingers on the ground glass plate to from
a thread of uniform diameter.
c) Continue rolling the thread until it reaches a uniform diameter of 3.2mm or 1/8 in.
d) When the thread becomes a diameter of 1/8 in. reform it into a ball.
e) Knead the soil for a few minutes to reduce its water content slightly.
f) Repeat steps 2 to 5 until the thread crumbles when it reaches a uniform diameter of
1/8 in.
g) When the soil reaches the point where it will crumble, and when the thread is a
uniform
h) diameter of 1/8", it is at its plastic limit. Determine the water content of the soil.

44 Civil Department
 J. Moisture Content (IS 2720 part2)
The soil moisture content of soil is the quantity of water it contains. water content is used
in a wide range of scientific and technical areas and is expressed as a ratio, which can range
from 0 (complete dry) to the value of the materials porosity at saturation.

K. Free Swelling Test (IS: 2720 (Part 40) 1977)

• Purpose:

There will be change in volume with the existence of the moisture. There will be increase
in volume of the soil during the wet or rainy season, and decrease in volume of the soil
during the dry season. This may lead to the settlement of soil and leads to failure of
foundation. Kerosene is a non-polar liquid which does not react with soil minerals present
in clay soils. Putting in kerosene ceases the soil to grab any moisture from atmosphere
which results in unaltered moisture content of the soil sample and now we can compare
this with the fully swell soil resting in the cylinder of water.

Figure 11: Free swelling index test.

L. Specific Gravity test and Water Absorption test (IS 4031 Part 11)
Specific gravity test of aggregates is done to measure the strength or quality of the material
while water absorption test determines the water holding capacity of the coarse and fine
aggregates. Specific Gravity is the ratio of the weight of a given volume of aggregate to
the weight of an equal volume of water. It is the measure of strength or quality of the

45 Civil Department
specific material. Aggregates having low specific gravity are generally weaker than those
with higher specific gravity values. We use wire basket method for 20 mm aggregates and
pycnometer method for aggregates having size of 10 mm and less than 10 mm.

Figure 12: Wire Basket Method Figure 13: Pycnometer

Procedure:
1. About 2 kg of aggregate sample is washed thoroughly to remove fines, drained and
placed in wire basket and immersed in distilled water at a temperature between 22-
32º C and a cover of at least 5cm of water above the top of basket.
2. Immediately after immersion the entrapped air is removed from the sample by
lifting the basket containing it 25 mm above the base of the tank and allowing it to
drop at the rate of about one drop per second. The basket and aggregate should
remain completely immersed in water for a period of 24 hour afterwards.
3. The basket and the sample are weighed while suspended in water at a temperature
of 22° – 32°C. The weight while suspended in water is noted = W1g.
4. The basket and aggregates are removed from water and allowed to drain for a few
minutes, after which the aggregates are transferred to the dry absorbent clothes. The
empty basket is then returned to the tank of water jolted 25 times and weighed in
water= W2 g.

46 Civil Department
 5. The aggregates placed on the absorbent clothes are surface dried till no further
moisture could be removed by this cloth. Then the aggregates are transferred to the
second dry cloth spread in single layer and allowed to dry for at least 10 minutes
until the aggregates are completely surface dry. The surface dried aggregate is then
weighed = W3 g
6. The aggregate is placed in a shallow tray and kept in an oven maintained at a
temperature of 110° C for 24 hrs. It is then removed from the oven, cooled in an air
tight container and weighted=W4 g.

• Recommended Values of Specific Gravity and Water Absorption for

Aggregates:
The specific gravity of aggregates normally used in road construction ranges from about
2.5 to 3.0 with an average of about 2.68. Water absorption shall not be more than 0.6 per
unit by weight.

M. California Bearing Ratio (IS 2720 Part16)

CBR test may be conducted in remoulded or undisturbed sample. Test consists of causing
a cylindrical plunger of 50mm diameter to penetrate a pavement component material at
1.25mm/minute. The loads for 2.5mm and 5mm are recorded. This load is expressed as a
percentage of standard load value at a respective deformation level to obtain CBR value.

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 Figure 14: CBR Apparatus

Procedure of California Bearing Ratio Test:

1. Sieve the sample through 20mm IS sieve. Take 5 kg of the sample of soil specimen.
Add water to the soil in the quantity such that optimum moisture Then soil and
water are mixed thoroughly. Spacer disc is placed over the base plate at the bottom
of mound and a coarse filter paper is placed over the spacer disc content or field
moisture content is reached.

2. The prepared soil water mix is divided into five. The mould is cleaned and oil is
applied. Then fill one fifth of the mould with the prepared soil. That layer is
compacted by giving 56 evenly distributed blows using a hammer of weight 4.89kg.

3. The top layer of the compacted soil is scratched. Again, second layer is filled and
process is repeated. After 3rd layer, collar is also attached to the mould and process
is continued.

4. After fifth layer collar is removed and excess soil is struck off. Remove base plate
and invert the mould. Then it is clamped to baseplate.

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 5. Surcharge weights of 2.5kg is placed on top surface of soil. Mould containing
specimen is placed in position on the testing machine.

6. The penetration plunger is brought in contact with the soil and a load of 4kg (seating
load) is applied so that contact between soil and plunger is established. Then dial
readings are adjusted to zero.

7. Load is applied such that penetration rate is 1.25mm per minute. Load at penetration
of 0.5, 1, 1.5, 2, 2.5, 3, 4, 5, 7.5, 10 and 12.5mm are noted.

N. Sand Replacement Method (IS 2720 part28)

The basic principle of sand replacement method is to measure the in-situ volume of hole
from which the material was excavated from the weight of sand with known density filling
in the hole Determine the in-situ density of natural or compacted soils using sand pouring
cylinders.

Figure 15: Sand Replacement Method

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Procedure:

Calibration of the Cylinder

a. Fill the sand pouring cylinder with clean sand so that the level of the sand in the cylinder
is within about 10 mm from the top. Find out the initial weight of the cylinder plus sand
(W1) and this weight should be maintained constant throughout the test for which the
calibration is used.

b. Allow the sand of volume equal to that of the calibrating container to run out of the
cylinder by opening the shutter, close the shutter and place the cylinder on the glass sand
takes place in the cylinder close the shutter and remove the cylinder carefully. Weigh the
sand collected on the glass plate. Its weight(W2) gives the weight of sand filling the cone
portion of the sand pouring cylinder.
Repeat this step at least three times and take the mean weight (W2) Put the sand back into
the sand pouring cylinder to have the same initial constant weight (W1).

Determination of Bulk Density of Soil

c. Determine the volume (V) of the container be filling it with water to the brim. Check
this volume by calculating from the measured internal dimensions of the container.

d. Place the sand poring cylinder centrally on the of the calibrating container making sure
that constant weight (W1) is maintained. Open the shutter and permit the sand to run into
the container. When no further movement of sand is seen close the shutter, remove the
pouring cylinder and find its weight (W3).

Determination of Dry Density of Soil In Place

e. Approximately 60 sq.cm of area of soil to be tested should be trimmed down to a level

surface, approximately of the size of the container. Keep the metal tray on the level surface
and excavate a circular hole of volume equal to that of the calibrating container. Collect all
the excavated soil in the tray and find out the weight of the excavated soil (Ww). Remove

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the tray, and place the sand pouring cylinder filled to constant weight so that the base of
the cylinder covers the hole concentrically. Open the shutter and permit the sand to run into
the hole. Close the shutter when no further movement of the sand is seen. Remove the
cylinder and determine its weight (W3).

f. Keep a representative sample of the excavated sample of the soil for water content
determination.

O. Flakiness and Elongation Index (IS 2386 part1)

• The Flakiness index of aggregates is the percentage by weight of particles whose
least dimension (thickness) is less than three- fifths (0.6times) of their mean
dimension. This test is not applicable to sizes smaller than 6.3mm.

• The Elongation index of an aggregate is the percentage by weight of particles whose

greatest dimension (length) is greater than nine-fifths (1.8times) their mean
dimension. This test is not applicable for sizes smaller than 6.3mm.

Figure 16: EI & FI Apparatus

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 Purpose:
The shape tests give only a rough idea of the relative shapes of aggregates. Flaky and
elongated particles should be avoided in pavement construction, particularly in surface
course. If such particles are present in appreciable proportions, the strength of pavement
layer would be adversely affected due to possibility of breaking under loads. Workability
is reduced for cement concrete.

Procedure of Shape Tests on Coarse Aggregates:

1. Sieve the sample through the IS sieves.

2. Take a minimum of 200 pieces of each fraction to be tested and weigh them.

3. To separate the flaky materials, gauge each fraction for thickness on a thickness gauge.

4. Weigh the flaky material passing the gauge to an accuracy of at least 0.1 per cent of the
test sample.

5. To separate the elongated materials, gauge each fraction for length on a length gauge.

6. Weigh the elongated material retained on the gauge to an accuracy of at least 0.1 per cent
of the test sample.

P. Aggregate Impact Value (IS: 2386 (Part IV) – 1963)

The property of a material to resist impact is known as toughness. Due to movement of
vehicles on the road the aggregates are subjected to impact resulting in their breaking down into
smaller pieces. The aggregates should therefore have sufficient toughness to resist their
disintegration due to impact. This characteristic is measured by impact value test.

Procedure of Aggregate Impact Test:

The test sample consists of aggregates sized 10.0 mm 12.5 mm. Aggregates may be dried
by heating at 100-110° C for a period of 4 hours and cooled.

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a. Sieve the material through 12.5 mm and 10.0mm IS sieves. The aggregates passing
through 12.5mm sieve and retained on 10.0mm sieve comprises the test material.

b. Pour the aggregates to fill about just 1/3 rd. depth of measuring cylinder.

c. Compact the material by giving 25 gentle blows with the rounded end of the tamping
rod.

d. Add two more layers in similar manner, so that cylinder is full.

e. Strike off the surplus aggregates.

f. Determine the net weight of the aggregates to the nearest gram(W).

g. Bring the impact machine to rest without wedging or packing up on the level plate,
block or floor, so that it is rigid and the hammer guide columns are vertical.

h. Fix the cup firmly in position on the base of machine and place whole of the test sample
in it and compact by giving 25 gentle strokes with tamping rod.

I. Raise the hammer until its lower face is 380 mm above the surface of aggregate sample
in the cup and allow it to fall freely on the aggregate sample. Give 15 such blows at an
interval of not less than one second between successive falls.

j. Remove the crushed aggregate from the cup and sieve it through 2.36 mm IS sieves until
no further significant amount passes in one minute. Weigh the fraction passing the sieve to
an accuracy of 1 gm. Also, weigh the fraction retained in the sieve.

Q. Los Angeles Test (IS: 2386 (Part IV) – 1963)

Abrasion test is carried out to test the hardness property of aggregates. The principle of Los
Angeles abrasion test is to find the percentage wear due to relative rubbing action between
the aggregate and steel balls used as abrasive charge. The percentage wear of the

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 aggregates due to rubbing with steel balls is determined and is known as Los Angeles
Abrasion Value.

Figure 17: Los Angeles Test Apparatus

Procedure for Los Angeles Test:

The test sample consists of clean aggregates dried in oven at 105° – 110°C. The sample
should conform to any of the gradings shown in table 1.

1. Select the grading to be used in the test such that it conforms to the grading to be used in
construction, to the maximum extent possible.

2. Take 5 kg of sample for gradings A, B, C & D and 10 kg for gradings E, F & G.

3. Choose the abrasive charge as per Table 2 depending on grading of aggregates.

4. Place the aggregates and abrasive charge on the cylinder and fix the cover.

5. Rotate the machine at a speed of 30 to 33 revolutions per minute. The number of

revolutions is 500 for gradings A, B, C & D and 1000 for gradings E, F & G. The machine
should be balanced and driven such that there is uniform peripheral speed.

6. The machine is stopped after the desired number of revolutions and material is discharged
to a tray.

7. The entire stone dust is sieved on 1.70 mm IS sieve.

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8. The material coarser than 1.7mm size is weighed correct to one gram.

Materials and Physical Requirements:

Sourcing of materials for embankment and subgrade construction, as well as
compliance with environmental requirements in respect of excavation and borrow areas
under the applicable laws shall be the sole responsibility of the Concessionaire. The
material to be used in subgrade shall satisfy the design California Bearing Ratio (CBR) at
the specified density and moisture content. The embankment and subgrade shall be
compacted to satisfy the minimum compaction requirements given in Clause 305 of
MORTH Specifications.

Structural features and design of embankment:

Embankment with height 6.0 m or above shall be designed in accordance with
IRC:75 taking into account slope stability, bearing capacity, consolidation, settlement and
safety considerations based on geotechnical and investigation data. Where the embankment
is to be supported on a weak stratum, appropriate remedial/ground improvement measures
shall be taken. Side slopes shall not be steeper than 2H:1V unless soil is retained by suitable
soil retaining structures. The side slopes shall be protected against erosion by providing a
suitable vegetative cover, kerb channel, chute, stone/cement concrete block pitching or any
other suitable protection measures depending on the height of the embankment and
susceptibility of soil to erosion. Drainage arrangement shall be provided.

PAVEMENT DESIGN

Rigid Pavement–Design Period and Strategy

(i) Rigid pavement shall be designed for a minimum design period of 30 years.
The stage construction shall not be permitted.
(ii) The Pavement Quality Concrete (PQC) of 280 mm shall rest over Dry Lean
Concrete (DLC) sub-base of 150 mm thickness.

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(iii) The DLC will meet the minimum cement and compressive strength
requirement as prescribed in IRC: SP :49. DLC will extend beyond the PQC
(including that in shoulder, if any) by 0.5 m on either side.
(iv) Below DLC layer, a properly designed drainage layer Granular Sub Base
(GSB) of 150 mm thickness shall be provided throughout the road width. It
shall be designed to obtain a drainage coefficient of not less than 20 m per day.

Pavement Performance Requirements:

(i) The pavement structure shall be capable of giving the specified performance over
the entire operation period.

(ii) The new pavement surface shall satisfy the following standards,

(a) Surface Finish. As per requirements of

Clauses 902 and 903 of
MORTH Specifications
(b) Roughness. Not more than 2000mm/km
For each lane in a km length

(c) Rutting In wheel path measured. Nil

by 3 m Straight Edge.

(d) Cracking or any other distress. Nil

CRUSHING PLANT

A Crushing plant is one-stop crushing installation, which can be used for rock
crushing, garbage crushing, building materials crushing and other similar operations.
Crushing plants may be either fixed or mobile. A crushing plant has different stations
(primary, secondary, tertiary.) where different crushing, selection and transport cycles are
done in order to obtain different stone sizes.

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Components

Crushing plants make use of large range of equipment such as a pre screener, loading
conveyor, intake hopper, magnetic separator, crushing unit such as jaw crusher and cone
crusher etc.

Vibration Feeder:

These machines feed the jaw and impact crusher with the rocks and stones to be crushed.
Crushers :

These are the machines where the rocks and stones are crushed. There are different types of crushers
for different types of rocks and stones and different sizes of the input and output material. Each
plant would incorporate one or several crushing machines depending on the required final material
(small stones or sand).

Vibrating Screen:

These machines are used to separate the different sizes of the material obtained by the
crushers.

Belt Conveyor:

These elements are the belts used for transportation of the material from one machine to
another during different phases of process.

Central electric Control system:

Control and monitor the operation of the entire system.

Process of crushing plant

1. Raw materials are evenly and gradually conveyed into jaw stone crushing
equipment for primary crushing via the hopper of vibrating feeder.
2. The crushed stone materials are conveyed to crushing plant by belt conveyor for
secondary crushing before they are sent to vibrating screen to be separated.

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 3. After separating, qualified materials will be taken away as final products, while
unqualified materials will be carried back to the stone crushing equipment for
refreshing. And customers can classify final products according to different size
ranges. All the final products are up to the related standards within and beyond
China. Of course, according to different requirements, customers can adjust the
size of their final products from this stone crushing plant. Process of Stone
Crushing Plant. Clients will get the satisfactory products after objects being
crushed for several times. Dust is generated during the working process while the
dust control un

Figure 18: Crusher Plant

READY MIX CONCRETE

Ready-mix concrete is often used over other materials due to the cost and wide
range of uses in building, particularly in large projects like high rise buildings and bridges.
It has a long-life span when compared to other products of a similar use, like road ways.

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It has an average life span of 30 years under high traffic areas compared to the 10 to 12
year life of asphalt concrete with the same traffic.

Ready-mix concrete, or RMC as it's also known, refers to concrete that is

specifically batched or manufactured for customers' construction projects, and supplied to
the customer on site as a single product. It is a mixture of Portland or other cements, water
and aggregates: sand, gravel, or crushed stone. All aggregates should be of a washed type
material with limited amounts of fines or dirt and clay.

Ready-mixed concrete is used in construction projects where the construction

site is not willing, or not able, to mix concrete on site. Using ready-mixed concrete means
product is delivered finished, on demand, in the specific quantity required, to the specific
mix design required. For a small to medium project, the cost and time of hiring mixing
equipment, labor, plus purchase and storage for the ingredients of concrete, added to
environmental concerns (cement dust is a particular airborne health hazard and nuisance )
may simply be not worth it when compared to the linear cost model of ready-mixed
concrete, where the customer pays for what they use, and lets someone else do the work
up to that point. For a large project, outsourcing concrete production to ready-mixed
concrete suppliers means delegating the quality control and testing, material logistics and
supply chain issues, and mix design, to specialists who are already set up for those tasks,
trading off against introducing another contracted external supplier who needs to make a
profit, and losing the control and immediacy of on-site mixing .

Advantages and disadvantages of ready-mix concrete

• Materials are combined in a batch plant, and the hydration process begins at the
moment water meets the cement, so the travel time from the plant to the site, and the
time before the concrete is placed on site, is critical over longer distances. Some sites
are just too far away; however, the use of admixtures, retarders and cements like
pulverized fly ash or ground granulated blast furnace slag (GGBS) can be used to slow
the hydration process, allowing for longer transit and waiting time.

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• Concrete is formable and pourable, but a steady supply is needed for large forms. If
there is a supply interruption, and the concrete cannot be poured all at once, a cold joint
may appear in the finished form.
• Cracking and shrinkage. Concrete shrinks as it cures. It can shrink 1/16 inch (1.59mm)
over a 10-foot-long area (3.05 meters). This causes stress internally on the concrete and
must be accounted for by the engineers and finishers placing the concrete, and may
require use of steel reinforcement or pre-stressed concrete elements where this is
critical.

Figure 19: RMC Plant

CHILLING PLANT
Chilling plant is considered as one of the essential parts of batching plant.
These plants are used to maintain the water temperature below 30degree. If
water temperature is maintained then this helps to get a proper mix of
concrete. These steps are considered in batching plant only when the water
temperature need to be controlled, if this is not required then this step is
skipped.

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 Figure 20: Chilling Plant

EXPERIMENTAL WORK FOR REPLACEMENT OF SAND AND

AGGREGATE

The experimental studies to examine the variation in the strength of concrete

having the replacement of sand to aggregate ratio as follows: crushed sand: natural
aggregate, crushed sand: demolished aggregate and natural sand: natural aggregate. In
this experimental work an attempt has been made to determine the effect of artificially
graded sand and demolished concrete structural aggregates on compressive strength and
workability of concrete. Crushed sand is manufactured from crushing of rocks, stone
chips and demolished concrete fines while the crushed aggregates are prepared from
demolished structures.

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 In the first phase of the study, the specimen of standard cube of (150 mm x 150
mm x 150 mm) was used to determine the compressive strength of concrete with natural
sand and stone aggregates. The specimens were tested for each nominal mix and definite
water cement ratio. Twelve cubes were prepared for obtaining average of 7- and 28-days
strength of concrete of M15 and M20 grade of concrete. Aggregate used are passing from
20 mm sieve and retained on 10 mm and also passing from 10 mm and retained on
4.75 mm.

In the second phase of the study, another specimen of standard cube of (150 mm
x 150 mm x 150 mm) was used to determine the compressive strength of concrete with
crushed sand with full replacement and demolished concrete structure aggregates. The
specimens were tested for each nominal mix and definite water cement ratio. Twelve
cubes were prepared for obtaining average of 7- and 28-days strength of concrete M15
and M20 grade of concrete.

Figure 21: Crushed Sand Production

In the third phase of the study, another specimen of standard cube of (150 mm x
150 mm x 150 mm) was used to determine the compressive strength of concrete with
artificial sand with full replacement and natural stone aggregates. The specimens were
tested for each nominal mix and definite water cement ratio. Twelve cubes were prepared

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for obtaining average of 7- and 28-days strength of concrete M15 and M20 grade of
concrete.

Figure 22: Concrete Cube Casting

Closure: In this chapter methodology working and operation of construction of rigid

pavement & variation in the compressive strength due to replacement of sand & aggregate
was discussed in detail. In the next chapter we will discuss about the various test results.

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 Chapter 5
RESULTS & DISCUSSIONS

TABLE 3: Rigid Pavement Test Results

Test IS Observed Acceptance

CODE Values Criteria
1. Consistency of IS- 4031 Consistenc Initial time –
cement & Part 4&5 y- 31% Min 30 min
initial &final Initial time Final time-
setting time -35min Not more
Final time- than 600min
210 min
2. Soundness test IS-4031 3.33mm 10mm
of cement Part 3
3. Compressive IS-4031 Grade 53 3day- 27MPa
strength of Part 6 3day- (Not less
cement mortar 30.12MPa than)
cube 7day- 7day-37MPa
39.63MPa 28day-
28day- 53MPa
49.53MPa
4 Fineness of IS-4031 4.5% 10%
cement Part 1
5 Aggregate IS-2386 GSB- GSB-<40%
impact value Part 4 11.14% DLC-<30%
PQC-<30%
6 Compaction IS- 0.86 0.7 to 0.95
factor of 1199:19
concrete mix 59
7 Field dry IS-2720 %compacti %compactio
density by Part 28 on-96.18% n-
sand Embankment
replacement - 95%
method
8 Flakiness & IS-2386 FI-15.50% FI-<30%
Elongation Part 1 EI-19.89% EI-<35%
index Combined-
35.39%

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9 Modified IS-2720 MDD- MDD-
proctor test Part 8 2.067g/cc <1.78g/cc
10 Free swelling IS-2720 27.5% <50%
index of soil Part 40
11 Specific IS- Bulk sp.gr. Bulk sp.gr. -
gravity & 2386:19 20mm-2.71 2.5 to 3
water 63 Part 3 10mm-2.88 Water
absorption of Dust-2.93 absorption<0
aggregate .6 per unit by
wt.
12 California IS-2720 CBR value- Not less than
bearing ratio Part 16 14.83% the design
CBR value of
7% at 97% of
MDD

A. With natural river sand only

B. With Crush Sand and Stone Aggregate
C. With Crush Sand and Natural stone aggregate

Table 4: Composition of concrete

Cate Mix Ratio Cement Sand Coarse Coarse Water Admixtu

gory Design Proportion used Used Aggregat Aggregate Used re
(In KG) (In e used used (KG) (In gm)
KG) (20mm) (10mm)
A M15 1:2:4 7.70 15.40 18.49 12.32 3.85 53.90
M20 1:1.5:3 9.80 14.70 17.64 11.76 4.90 68.60
B M15 1:2:4 7.70 15.40 18.49 12.32 3.85 53.90
M20 1:1.5:3 9.80 14.70 17.64 11.76 4.90 68.60
C M15 1:2:4 7.70 15.40 18.49 12.32 3.85 53.90
M20 1:1.5:3 9.80 14.70 17.64 11.76 4.90 68.60

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Results Discussion:

After the specimen of standard cube of (150 mm x 150 mm x 150 mm) was used to
determine the compressive strength of concrete. Three specimens were tested for 7 and 28
days with varying proportion of manufactured sand replacement. The constituents were
weighed and the materials were mixed in a mixer. The mixes were compacted with the help
of taping rod. The specimens were de moulded after 24 h, cured in water for 7 and 28 days,
and then tested for its compressive strength as per Indian Standards. Following results were
obtained and summarized below:

Case A: Concrete Cubes with Natural Sand

Table 5: Strength of concrete with Natural Sand

Sr. Mix W/C For Natural Sand: Average Compressive

No. Ratio strength in N/mm²
7 Days Avg 28 Days Avg

1. M 20 0.5 15.29 15.57 24.00 24.10

15.64 23.91

15.78 24.40
2. M 15 0.5 12.00 12.98 22.22 22.28
13.00 22.40
13.95 22.22

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Case B: With Crush Sand and Demolished Aggregate

Table 6: Strength of Concrete with Crush Sand & Demolished Aggregate

Sr. Mix W/C For artificial Sand: Average
No. Ratio Compressive strength in N/mm²
7 Days Avg 28 Days Avg

1. M 20 0.5 15.78 15.93 24.00 24.60

16.13 24.00

15.87 25.81
2. M 15 0.5 14.00 14.03 23.22 23.10
13.91 22.80
14.18 23.29

Case C: With Crush Sand and Natural aggregate

Table 7: Strength of Concrete With Crush Sand and Natural Aggregate

Sr. Mix W/C For artificial Sand & Stone aggregate:
No. Ratio Average Compressive strength in N/mm²
7 Days Avg 28 Days Avg

1. M 15 0.5 20.67 20.11 26.19 27.52

19.95 28.66

19.72 27.69
2. M 20 0.5 22.93 23.11 31.20 31.58
23.07 32.08
23.33 31.47

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 Graphical Comparison For M-20 Concrete

35 31.58

30
24.1 24.6
25 23.11

20
15.5715.93
15

10

0
7 days 28 days

Natural sand Recycled Aggregate Crushed Sand

Figure 23: Graphical Comparison For M-20 Concrete

Graphical Comparison for M-15

30 27.52

25 23.1
22.28
20.11
20

14.03
15 12.98

10

0
7 days 28 days

Natural sand Recycled Aggregate Crushed Sand

Figure 24: Graphical Comparison For M-15

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Closure : In this chapter all the test results were mentioned properly and the
bar diagrams gives the variation in the test results conducted in the laboratory.

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 Chapter 6
CONCLUSION

➢ Current trends shows that concrete pavement are prime choice compared to flexible pavement.

➢ Highway pavement play an important role in convenience warning and direction.

➢ The design of pavement is the upgraded form for the better and convenient traffic flow.

➢ From the test we conclude that the concrete containing crushed sand has more compressive

strength than natural sand.

➢ Concrete having demolished aggregate have low compressive strength than natural aggregate

but greater the concrete containing natural sand and natural aggregate.

➢ Replacement of 20% of natural aggregate by demolished material have nearly same strength

as that of natural aggregate concrete.

➢ For complete utilization of demolished materials, various polymers must be added into the

concrete.

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Future Scope

Rigid Pavement
1. It requires less maintenance compared to flexible pavement.
2. It can bear heavy static and dynamic load.
3. Rigid pavement is generally preferred for locations experiencing heavy rainfall,
waterlogged areas and areas having sub-grade soil with low CBR (California
Bearing Ratio) values.

Demolished Materials
1. The recycling and reuse of waste materials helps to keep environment balanced.
2. The cement concrete recycling from CDW leads to improvement of environmental
pollution parameters by preserving natural resources and generating free space in
landfills.
3. Demolished materials can be used directly in the place where the strength required is
minimum and with the help of chemicals and fibres Demolished materials can be break
down so that it can increase the strength.

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 References

➢ Mr. Navneet Purohit , Mr. Arpit chawda(2016), International journal of engineering science &
research tech on “Experimental study of effect of crushed sand and aggregate on compressive
strength and workability of concrete”.
➢ Dr. S. Elavenil, Prof. B. Vijaya “Manufactured sand, a solution & alternative to river sand and
in concrete manufacturing.”
➢ Prof. M.R. Chitlange, Dr. P.S. Pajgade, Dr.P. B. Nagarnaik, “Exprimental Study on Artificial
Sand and Concrete” First International Conference on Engineering Trends in Engineering and
Technology.
➢ Vinayak Supekar, Dr. Popat Kumbhar, “Properties of concrete by replacement of natural sand
with artificial sand.” Internation journal of engineering research and technology, volume 1,
issue 7, September 2012
➢ Nimitha Vijaya Raglavanand, A.S. Wayal,” Effects of manufactured sand on compressive
strength and workability of concrete” Internation journal of structural and civil
Engineering,155N 2319 -6009, Volume2, No4, November2013
➢ Rameshwar S. Ingalkar,Shrikant M. harle 2017 “Replacement of natural sand by crushed sand
in the concrete”
➢ IS:456 -2000(reaffirmed2005)” Plain and reinforced concrete code of practice”.
➢ B. Balgopal, S.A. Kulkarni, K.M. Bajoria,29 -30August 2002” Strength and Durability of
concrete with crushed sand”,27th conference on our world in concrete and structures.
➢ Ahmed, A.E. And EI. Kourd, A. A (1989)” Properties of concrete incorporating natural sand
and crushed sand”. American concrete journal, (4)86,417-424
➢ Ron Whik,W.Ronald Hudson ,Alvin H.Meyar,K.H.Stokar 2(September 1984)” Design and
construction of a rigid pavement research facility.”
➢ Arun Kumar (October 2017)” A study of design and method of rigid and flexible highway
pavements” journals of emerging technologies and innovative research.
➢ Sahu A. K., Kumar S. and Sachan A. K. ‘Crushed Stone waste as Fine Aggregates for
concrete’, Indian concrete Journal.

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➢ Ilangovana, R. Mahendrana, N. and Nagamanib, K. (2008), ‘Strength and durability properties
of concrete containing crush sand as fine aggregates’, ARPN Journal of Engineering and
Applied Science, Vol.3 (5), pp 2026.
➢ Shaikh, M. G., Daimi, S. A. (2011), Durability studies of concrete made by using artificial
sand with dust and natural sand, International Journal of Earth Sciences and Engineering (ISSN
0974-5904), Vol. 04, No. 06 SPL, pp 823-825.
➢ BIS Code IS: 383-1970. “Specification for Coarse and Fine Aggregates from Natural Sources
for Concrete, (Second Revision).

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