An

Industrial Training Report On

NHAI BHARATMALA PARIYOJNA PNC Inf. Ltd.
Under the supervision Of
Er. Amit Chaursiya
(Quality Engineer)
National Highway Authority of India
Requirement for the award of the degree of
Bachelor of Technology
In
Civil Engineering

AXIS INSTITUTE OF TECHNOLOGY AND

MANAGEMENT, KANPUR

SUBMITTED BY SUBMITTED TO
Prashant Gautam Er. Jyoti Swaroop Pandey
2107190009007 Assistant Professor, AITM-CE

1
 DECLARATRION

It is to declare that the internship report work published in this report entitled “NHAI
Bharatmala Pariyojna” is performed by Prashant Gautam under the guidance of
Er. Amit Chaursiya, Acchalganj, Unnao, Uttar Pradesh, the project work is original
and does not contain any material previously published or written by another
candidate. I further declare that to the best of my knowledge, the thesis does not
contain any part of the work which has been submitted for the award of any other
degree or diploma at Axis Institute of Technology and Management or any other
institution without due acknowledgment.

Prashant Gautam
2107190009007

2
 ACKNOWLEDGEMENTS

I am extremely grateful and remain indebted to my guide Er. Amit Chaursiya for source of
inspiration and for his constant support in the formulation, implementation and evaluation of this
report. I am thankful to him for his constant constructive suggestions, which benefited me a lot in
developing this report. He had been a constant source of inspiration and motivation for hard work.
Through this column, it would be my utmost pleasure to express warm thanks to him for his
encouragement, cooperation and constant support without which I might have not been able to
accomplish this report.

I would also like to express my gratitude to PNC Inf. Ltd. for providing me the infrastructure to
carry out the Internship and to all staff-members who were directly or indirectly instrumented in
enabling me to stay committed for this project.

Prashant Gautam
2107190009007

3
 CONTENTS

 Certificate ........................................................................... 1

 Declaration ......................................................................... 2

 Acknowledgement ............................................................. 3

 Contents ........................................................................... 4-5

 List of Figures ..................................................................... 6

 Indian Standard Code ......................................................... 7

1. Introduction ........................................................................ 8
2. Safety Induction .................................................................. 9
3. Soil Tests .......................................................................... 11
 Grain Size Analysis .................................................. 11
 Liquid Limit .............................................................. 13
 Plastic Limit and Plasticity Index ............................. 16
 Modified Proctor Test ............................................... 18
 Free Swell Index ....................................................... 21
4. Cement Test ...................................................................... 23
 Consistency Test ....................................................... 23
 Fineness Test ............................................................ 26
4
  Initial & Final Setting Time ...................................... 27
5. Test on Bituminous Concrete ........................................... 29
 GMM & Density of Asphalt Mixture........................ 29
 Marshall Stability Test .............................................. 31
6. Learning Outcomes ........................................................... 34

5
 LIST OF FIGURES

 Fig. 2.1 Safety Helmet ........................................................ 9

 Fig. 2.2 Safety Jacket ........................................................ 10
 Fig. 2.3 Eye Protection ..................................................... 10
 Fig. 2.4 Safety Shoes ....................................................... 10
 Fig. 3.1 Divided Soil Before Cut ...................................... 14
 Fig. 3.2 Soil Cake after Cut .............................................. 14
 Fig. 3.3 Modified Proctor Test .......................................... 19
 Fig. 3.4 Free Swell Index .................................................. 21
 Fig. 4.1 Consistency Test .................................................. 24
 Fig. 5.1 Density Test ......................................................... 30
 Fig. 5.2 Marshall Stability Test......................................... 32

6
INDIAN STANDARD CODE USED:

IS:2720 (Part 4 Section 3&4):1985 Grain Size Analysis

IS:2720 (Part 5):1985 Liquid Limit

IS:2720 (Part 5):1985 Plastic Limit and Plasticity Index

IS:2720 (Part 8): Modified Proctor Test

1983 (Reaffirmed-May 2015)

IS:2720 (Part 40): Free Swell Index

1977 (Reaffirmed 2021)

IS:4031 (Part 4):1988 Consistency Test

IS:4031 (Part 3):1988 Fineness Test

IS:4031 (Part 5):1988 Initial & Final Setting Time

AASHTO T 209 GMM & Density of Asphalt

Mixture

AASHTO T 209 Marshall Stability Test

7
 CHAPTER 1
INTRODUCTION:

National Highway Authority of India (NHAI) was constituted by an Act of Parliament in 1988
under the administrative control of the Ministry of Road Transport and Highways. NHAI has been
set up as a Central Authority to develop, maintain and manage the National Highways entrusted
to it by the Government of India.

PNC INFRATECH LIMITED is in the industry of Highway, Street, and Bridge Construction.

The project which is Lab Department “Rehabilitation and Up-gradation from 2 lanes to 4 lanes of
NH stretch under Bharatmala Pariyojna for Unnao-Lalganj section of New-31 (old NH-232A). I
have mainly done my internship training under the guidance of Quality engineer of PNC in the lab
department.

In Lab department, there are several important test has been done by the technician and quality
engineer. These lab work is much important because without testing, the amount of risk is more.

Firstly, there is some soil testing, these soil is use as the embankment and filling for the pavement.
In soil testing, check all the soil properties which can be affect to the pavement base.

After that, there is some aggregate testing for the right amount of aggregate which is suitable for
the pavement. Since the pavement is rigid pavement so there are several test for the cements which
is important for the good quality of cement which is use for the rigid pavement.

8
 CHAPTER 2
SAFETY INDUCTION:

 On the jobsite, security is essential. The essential items for safety are a helmet, a jacket,
shoes, and gloves. These things improve the workers' health, safety, and working
conditions on the site. To avoid accidents and fatalities, safety procedures must be
implemented. Depending on whether you need to wear personal protective equipment or
not, the site is separated into a PPE zone and a non-PPE zone. There are various PPE and
safety items here.

HELMET

 Helmet is the most important safety equipment. On the site it is compulsoryto all to wear
helmet, it protect our head which is very essential for us. There are some different types
of helmets are used on site.

Figure2.1
(Safety Helmets)

9
SAFETY JACKET

 The main function is to make the wearer visible in environments and circumstances where
there may be risks to their health and safety. Construction workers and those doing
maintenance on motorways, roads, or frequently wear reflective apparel.

Figure2.2
(Safety Jacket)
EYE PROTECTION

 For the workers trained in welding (Face Shield), grinding, gas cutting, pouring concrete,
chipping, etc. work on a site, appropriate goggles must be ensured.

Figure 2.3
(Eye Protection)

SHOES

 All participants in site operations are required to wear shoes with additional
traction soles and bonded seams.

Figure2.4
(Safety Shoes)
10
 CHAPTER 3

3.1 SOIL TESTS:

3.1.1 GRAIN SIZE ANALYSIS:

STANDARD

 IS: 2720 (Part 4 Section 3&4) 1985

OBJECTIVE

 To determine the Grain size analysis of soils.

APPARATUS

 Balance of capacity 15 Kg and sensitivity 1 gram.

 Sieves 75 mm, 19 mm, 4.75 mm, 2 mm, 425 microns and 75 micron conforming to IS: 460
(Part -1)1978.
 Non-corrodible trays.
 Bucket no.

PROCEDURE

Sieve analysis of soil fraction passing 4.75 mm and retained on 75 microns IS sieve
Wet Analysis

 Oven dry the portion of material passing 4.75 mm IS sieve at the temperature of 105 to
110°C.
 Riffle the oven dried material so that a fraction of convenient mass of about 200 gm is
obtained.
 Spread out the riffled and weighed fraction in a large tray or bucket and fill with water.
 Add 2 gm of Sodium Hexametaphosphate gram of Sodium hydroxide and 1 gram of
Sodium carbonate per liter of water.
 Thoroughly stir the sample and leave it for 24 hours soaking.
 After the specified period of soaking, wash the sample thoroughly over 75 microns IS
sieves.
 Continue washing until the water passing sieve is substantially clear.
 Care shall be taken to see that the sieves are not over loaded in the process.
 Oven dry at 105 to 110°C the sample and entry the fraction retained on each sieve which
is 4.75 mm, 2 mm, 425 microns, 75 microns.

11
REPORT

 Report the percentage of passing to the nearest second decimal.

PRECAUTION

 Any particle may be tested to see if they will fall though but they shall not be pushed
though.

12
3.1.2 LIQUID LIMIT:

STANDARD

 IS: 2720 (Part 5) 1985.

OBJECTIVE

 Determination of Liquid limit by Casagrande Apparatus.

DEFINITION

 Liquid Limit is defined as the water content at which the soil changes from liquid state to
plastic state.

APPARATUS

 Casagrande apparatus confirming to IS: 9259-1979.

 Grooving tool.
 Balance of capacity 500 grams and sensitivity 0.01gram.
 Thermostatically controlled oven with capacity up to 2500 C.
 Porcelain evaporating dish about 12 to 15cm in diameter.
 Spatula flexible with blade about 8cm long and 2cm wide.
 Palette knives with the blade about 20cm long and 3cm wide.
 Wash bottle or beaker containing distilled water.
 Containers airtight and non- corrodible for determination of moisture content.

PROCEDURE

 Take representative soil sample of approximately 120gms passing through 425 microns IS
sieve and mix thoroughly with distilled water in the evaporating dish to a uniform paste.
 The paste shall have a consistency that will require 30 to 35 drops of the cup to cause the
required closure of the standard groove.
 Leave the soil paste to stand for 24 hours to ensure uniform distribution of moisture
throughout the soil mass.
 Remix the soil thoroughly before the test.
 Place a portion of the paste in the cup above the spot where the cup rests on the base,
squeeze down and spread in to position with a few strokes of the spatula as possible and at
the same time trim to a depth of 1cm at the point of maximum thickness.
 Make a clean, sharp groove by a grooving tool along the diameter through the centerline
of the cam follower.

13
  Drop the cup from a height of 10 + 0.25 mm by turning the crank at the rate of two-revolutions/
sec, until the two halves of the soil cake come in contact with the bottom of the groove along the
distance of about 12mm.
 Record the number of drops required to cause the groove close for the length of 12mm.
 Collect a representative slice of sample of soil approximately the width of spatula, extending from
about edge to edge of the soil cake at right angle to the groove in to an air tight container and keep
in the oven for 24hrs, maintained at a temperature of 1050 to 1100 C and express its moisture
content as the percentage of the oven dried weight.
 Transfer the remaining soil in the cup to the evaporating dish and clean the cup and the grooving
tool thoroughly.
 Repeat the operation specified above for at least three more additional trials (minimum of four in
all) with soil collected in evaporating dish to which sufficient water has been added to bring the
soil to more fluid condition.

Figure3.1
(Divided Soil Before Cut)

 In each case record the number of blows and determine the moisture content as before.
 The specimens shall be of such consistency that the number of drops required to close the
groove shall not be less than 15 or more than 35.

Figure3.2
(Soil Cake After Cut)

REPORT

 Plot a flow curve with the points obtained from each determination on a semi logarithmic
graph representing water content on the arithmetical scale and the no of drops on the
logarithmic scale.
 The flow curve is a straight line drawn as nearly as possible through the four or more
plotted points.
 The moisture content corresponding to 25 drops as read from the curve shall be rounded
off to the nearest second decimal and is reported as liquid limit of the soil.

14
PRECAUTIONS

 This test should proceed from the drier (more drops) to the wetter (less drops) condition of
the soil.
 This test may also be conducted from wetter to drier condition provided drying is achieved
by kneading the wet soil and not by adding dry soil.

15
3.1.3 PLASTIC LIMIT AND PLASTICITY INDEX:

STANDARD

 IS: 2720 (Part-5) 1985.

OBJECTIVE

 Determination of Plastic Limit and Plasticity Index

DEFINITION

 Plastic limit is defined as minimum water content at which soil remains in plastic state.

APPARATUS

 Porcelain evaporating dish about 12cm in diameter.

 Flat glass plate 10mm thick and about 45cm square or longer.
 Spatula flexible with the blade about 8cm long and 2cm in wide.
 Ground glass plate 20 x 15 cm.
 Airtight containers.
 Balance of capacity 500grams and sensitivity 0. 01gram.
 Thermostatically controlled oven with capacity up to 250°C.
 Rod 3mm in diameter and about 10cm long.

PROCEDURE

 Take representative soil sample of approximately 20g from the portion of the material
passing 425 microns IS sieve and mix thoroughly with distilled water in an evaporating
dish till the soil mass becomes plastic enough to be easily molded with fingers.
 In the case of clayey soils, leave the soil mass to stand for 24 hours to ensure uniform
distribution of moisture throughout the soil.

 Form a ball with about 8 grams of this soil mass and roll between the fingers and the glass
plate as shown in Fig: 2.7.1 with just sufficient pressure to roll the mass into a thread of
uniform diameter throughout its length.

 The rate of rolling shall be between 80 and 90 strokes/minute counting the stroke as one
complete motion of the hand forward and back to the starting position again.
 Continue the rolling till the thread crumbles exactly at 3mm diameter.
 If the soil thread doesn’t crumble exactly at 3mm knead the soil together to a uniform mass
and roll it again.
 Continue this process of alternate rolling and kneading until the thread crumbles under the
16
 pressure exactly at 3mm diameter.
 Collect the pieces of crumbled soil thread in an airtight container and determine its
moisture content.
 Determine the plastic limit for at least two points of the soil passing 425 microns IS sieve.
REPORT

 Report the individual and the mean of the results as the plastic limit of the soil to the nearest
second decimal.

PRECAUTIONS

 At no time shall an attempt be made to produce failure at exactly 3mm diameter by allowing
the thread to reach 3mm then reducing the rate of rolling or pressure or both and continuing
the rolling without further deformation until the thread falls apart.

PLASTICITY INDEX

DEFINITION
 The plasticity Index is defined as the numerical difference between its Liquid Limit and
Plastic Limit

REPORT

 Plasticity Index = Liquid Limit - Plastic Limit

PRECAUTIONS

 In the case of sandy soils plastic limit should be determined first.

 When plastic limit cannot be determined the Plasticity Index should be reported as NP
(Non-Plastic).
 When the plastic limit is equal to or greater than liquid limit, the plasticity index shall be
reported as zero.

17
3.1.4 MODIFIED PROCTOR TEST:
STANDARD
 IS-2720 (Part-8):1983 (Reaffirmed- May 2015)
OBJECTIVE

 To obtain the graphical relationship of the “dry density’ to “moisture content” in the form
of “compaction curve”, for determining the values of Optimum Moisture Content (OMC)
and Maximum Dry Density (MDD).
DEFINITION

 Optimum Moisture Content (OMC) is the water content at which the soil attains maximum
dry density.
 Maximum Dry Density (MDD) is the dry density of soil corresponding to Optimum
Moisture Content.
APPARATUS

 Proctor Mould (volume = 1000 cm3 for 100 mm diameter mould and volume= 2250 cm3
for 150 mm diameter mould (as per IS:10074-1982)
 Metal rammer conforming to IS: 9189-1979. (weight = 4.9 kg)
 Balance
 Sieve 4.75mm, 19 mm and 37.5 mm I.S. Sieves
 Oven
 Steel Straight Edge
 Airtight Container
PROCEDURE

 Take a representative portion of air-dried soil large enough to provide about 5 kg of

material passing 19mm IS sieve (for soils not susceptible to crushing during compaction)
or about 15 kg of material passing 19mm IS sieve (for soils susceptible to crushing during
compaction. Sieve this on a 19mm IS sieve and the reject the coarse fraction after its
proportion of the total sample has been recorded.
 Add suitable amount of water with the soil and mix it thoroughly. For sandy and gravelly
soil add 3% to 5% of water. For cohesive soil the amount of water to be added should be
12% to 16% below the plastic limit.

18
  Weigh the mould with base plate attached, to the nearest 1g and record the weight as W1.
Attach the extension collar with the mould. Compact the moist soil into the mould in five
layers of approximately equal mass, each layer being given 25 blows, with the help of 4.9
kg rammer, dropped from a height of 450mm above the soil. The blows must be distributed
uniformly over the surface of each layer. The operator shall ensure that the tube of the
rammer is kept clear of soil so that the rammer always falls freely.

Figure3.3
(Modified Proctor Test)

 After completion of the compaction operation, remove the extension collar and level
carefully the top of the mould by means of straightedge. Weigh the mould with the
compacted soil to the nearest 1 g and record this weight as W2.

 Remove the compacted soil from the mould and place it on the mixing tray. Determine the
water content of a representative sample of the specimen. Record the moisture content as
‘M’.

 The remainder of the soil shall be broken up and repeat Steps (iii) to (v) above, by adding
suitable increment of water to the soil. For sandy and gravelly soils, the increment is
generally 1% to 2% and for cohesive soils the increment is generally 2% to 4%. The total
number of determinations made shall be at least five, and the moisture contents should be
such that the optimum moisture content, at which the maximum dry density occurs, is
within that range.

 For compacting soil containing coarse material up to 37.5 mm size, the 2250 cm3 mould
should be used. A sample weighing about 30 kg and passing the 37.5 mm IS sieve is used
for the test. Soil is compacted in five layers; each layer being given 55 blows of the 4.9 kg
rammer.
REPORT
 The dry densities, γd, obtained in a series of determinations is plotted against the
corresponding moisture content ‘M’. A smooth curve is then drawn through the resulting
points and the position of the maximum on this curve is determined, which is called
19
 maximum dry density (M.D.D). And the corresponding moisture content is called optimum
moisture content (O.M.C.).

PRECAUTIONS

 Soil should not contain excess moisture during the compaction process.

 Mould used for compaction should be cleaned well before using.

20
3.1.5 FREE SWELL INDEX:

STANDARD
 IS 2720 (Part-40): 1977 (Reaffirmed 2021)
OBJECTIVE

 Determination of Free Swell Index of Soil.

DEFINITION

 Free swell is the increase in volume of a soil, without any external constraints, on
submergence in water.
APPARATUS

 425 microns IS Sieve.

 Glass Graduated Cylinders l00-ml capacity 2 Numbers. (IS: 878 -1956).
 Glass rod for stirring.
 Balance of capacity 500 grams and sensitivity 0.01 gram.

PROCEDURE

 Take two representative oven dried soil samples each of 10 grams passing through 425-
micron sieve.
 Pour each soil sample in to each of the two glass graduated cylinders of 100ml capacity.
 Fill one cylinder with kerosene and the other with the distilled water up to the100ml
mark.

Figure3.4
(Free Swell Index)

21
  Remove the entrapped air in the cylinder by gentle shaking and stirring with a glass
rod.
 Allow the samples to settle in both the cylinders.
 Sufficient time, not less than 24 hours shall be allowed for soil sample to attain
equilibrium state of volume without any further change in the volume of the soils.
 Record the final volume of the soils in each of the cylinders.

REPORT

 Read the level of the soil in the kerosene graduated cylinder as the original volume of the
soil samples, kerosene being non polar liquid does not cause swelling of the soil.
 Read the level of the soil in the distilled water cylinders as free swell level.
 Record the individual and the mean results to the nearest second decimal.

PRECAUTION

 In the case of highly expansive soils such as Sodium Betonites. the sample size may be 5
grams or alternatively a cylinder of 250ml capacity for 10 grams of sample may be used.

22
 CHAPTER 4

4.1 CEMENT TEST:

4.1.1 CONSISTENCY TEST:
STANDARD
 IS: 4031 (Part 4) 1988
OBJECTIVE

 Determination of Consistency of Standard Cement Paste.

DEFINITION

 The standard consistency of a cement paste is defined as that consistency which will permit
the vicat plunger to penetrate to a point 5 to 7mm from the bottom of the vicat mould.
APPARATUS

 Vicat Apparatus Conforming to IS: 5513-1976.

 Balance of capacity 1Kg and sensitivity to 1gram.

 Gauging trowel conforming to IS: 10086-1982.

PROCEDURE

 Unless otherwise specified this test shall be conducted at a temperature 27 + 20 C and the
relative humidity of laboratory should be 65 + 5%.

 Prepare a paste of weighed quantity of cement (300gms) with weighed quantity of potable
or distilled water, taking care that the time of gauging is not less than 3minutes nor more
than 5minutes and the gauging is completed before any sign of setting occurs.

 The gauging is counted from the time of adding water to the dry cement until commencing
to fill the mould.

 Fill the vicat mould with this paste resting upon a non-porous plate.

 Smoothen the surface of the paste, making it level with the top of the mould.

23
  Slightly shake the mould to expel the air.

 In filling the mould operators’ hands and the blade of the gauging trowel shall only be used.

 Immediately place the test block with the non-porous resting plate, under the rod bearing
the plunger.

 Lower the plunger gently to touch the surface of the test block and quickly release, allowing
it sink into the paste.

 Record the depth of penetration.

 Prepare trial pastes with varying percentages of water and test as described above until the
plunger is 5mm to 7mm from the bottom of the vicat mould.

Figure4.1
(Consistency Test)

REPORT
 Express the amount of water as a percentage by mass of dry cement to the first place of
decimal.

24
PRECAUTION
 Care shall be taken to maintain the specified temperature, humidity and the time of mixing
so as to avoid setting of cement paste.

25
4.1.2 FINENESS TEST:
STANDARD
 IS: 4031 (Part 3) 1988
OBJECTIVE

 To determine the fineness of cement by dry sieving.

APPARATUS

 Standard balance with 100 gm weighing capacity.

 IS: 90-micron sieve confirming to IS: 460 – 1962 and a Brush.

PROCEDURE
 Break down any air-set lumps in the cement sample with fingers.
 Weigh accurately 100 gms of the cement and place it on a standard 90 microns IS Sieve.
 Continuously sieve the sample for 15 minutes.
 Weigh the residue left after 15 minutes of sieving. This completes the test.
REPORT
 The percentage weight of residue over the total sample is reported.
PRECAUTIONS
 Sieving shall be done holding the sieve in both hands and gentle wrist motion, this will
involve no danger of spilling the cement, which shall be kept well spread out on the screen.
More or less continuous rotation of the sieve shall be carried out throughout sieving.
 Washers, shots and slugs shall not be used on the sieve. The underside of the sieve shall be
lightly brushed with 25 or 40 mm bristle brush after every five minutes of sieving.
 Mechanical sieving devices may be used may be used, but the cement shall not be rejected
if it meets the fineness requirements when tested by the hand method.

26
4.1.3 INITIAL & FINAL SETTING TIME:
STANDARD
 IS: 4031 (Part 5) 1988
OBJECTIVE

 To determine the initial and final setting times of cement.

APPARATUS
• Vicat apparatus conforming to IS: 5513-1976.
• Balance of capacity 1kg and sensitivity 1 gram.
•Gauging trowel conforming to IS: 10086-1982.
PROCEDURE
• Unless otherwise specified this test shall be conducted at a temperature of 27 + 20C and 65
+ 5% of relative humidity of the Laboratory.
• Prepare a paste of 300 grams of cement with 0.85 times the water required to a give a paste
of standard consistency IS: 4031 (Part 4) 1988.
• The time of gauging in any case shall not be less than 3 minutes not more than 5 minutes
and the gauging shall be completed before any sign of setting occurs.
• Count the time of gauging from the time of adding water to the dry cement until
commencing to fill the mould
• Fill the vicat mould with this paste making it level with the top of the mould.
• Slightly shake the mould to expel the air.
• In filling the mould the operator hands and the blade the gauging trowel shall only be used.

Initial Setting Time

• Immediately place the test block with the non-porous resting plate, under the rod bearing
the initial setting needle.
• Lower the needle and quickly release allowing it to penetrate in to the mould.
• In the beginning the needle will completely pierce the mould
• Repeat this procedure until the needle fails to pierce the mould for 5 + 0.5mm.
• Record the period elapsed between the time of adding water to the cement to the time when
needle fails to pierce the mould by 5 + 0.5mm as the initial setting time.

27
 Final Setting Time
• Replace the needle of the vicat apparatus by the needle with an annular ring Lower the
needle and quickly release.
• Repeat the process until the annular ring makes an impression on the mould.
• Record the period elapsed between the time of adding water to the cement to the time when
the annular ring fails to make the impression on the mould as the final setting time.

REPORT
• Report the initial setting time and final setting time in minutes.

PRECAUTIONS
• The time of gauging in any case shall not be less than 3 minutes not more than 5 minutes.

28
 CHAPTER 5

5.1 TEST ON BITUMINOUS CONCRETE:

5.1.1 MAXIMUM SPECIFIC GRAVITY (GMM) & DENSITY OF ASPHALT
MIXTURE:

STANDARD
 AASHTO T 209
OBJECTIVE
 To determine the specific gravity and density of asphalt mixture (bituminous & aggregate)
APPARATUS
 Balance or scale: 10,000 g capacity, readable to 0.1 g, meeting AASHTO M 231, Class G2
 Container: A glass, metal, or plastic bowl, pycnometer or volumetric flask between 2000
and 10,000 mL as required by the minimum sample size requirements in Table 1 sample
and capable of withstanding full vacuum applied
 Pycnometer / volumetric flask covers: A glass plate or a metal or plastic cover with a vented
opening
 Vacuum lid: A transparent lid with a suitable vacuum connection, with a vacuum opening
to be covered with a fine wire mesh
 Vacuum pump or water aspirator: Capable of evacuating air from the container to a residual
pressure of 3.4 kPa (25 mm Hg)
 Vacuum measurement device: Residual pressure manometer or vacuum gauge, capable of
measuring residual pressure down to 3.4 kPa (25 mm Hg) or less and accurate to 0.1 kPa
(1 mm Hg)
 Manometer or vacuum gauge: Capable of measuring the vacuum being applied at the
source of the vacuum
 Water bath: A constant-temperature water bath (optional for Pycnometer or Volumetric
Flask Method)
 Thermometers: Thermometric devices accurate to 0.25°C (0.5°F) and with a temperature
range of at least 20 to 45°C (68 to 113°F).
 Bleeder valve to adjust vacuum
 Automatic vacuum control unit (optional).
 Timer
 Towel

29
PROCEDURE
 Separate the particles of the sample, taking care not to fracture the mineral particles, so that
the particles of the fine aggregate portion are not larger than 6.3 mm (1/4 in.). If the mixture
is not sufficiently soft to be separated manually, place it in a large flat pan and warm in an
oven only until it is pliable enough for separation.
 Cool the sample to room temperature.
 Determine and record the mass of the dry container to the nearest 0.1 g.
 Place the sample in the container.
 Determine and record the mass of the dry container and sample to the nearest 0.1 g.
 Determine and record the mass of the sample by subtracting the mass determined in Step
3 from the mass determined in Step 5. Designate this mass as “A.”
 Add sufficient water at approximately 25 C (77 F) to cover the sample by about 25 mm (1
in.).

Figure5.1
(Density Test)
 Place the lid on the container and attach the vacuum line. To ensure a proper seal between
the container and the lid, wet the O-ring or use a petroleum gel.
 Remove entrapped air by subjecting the sample to a partial vacuum of 3.7 ±0.3 kPa (27.5
±2.5 mm Hg) residual pressure for 15 ±1 minutes.
 Agitate the container and sample, either continuously by mechanical device or manually
by vigorous shaking at 2-minute intervals. This agitation facilitates the removal of air.
 Release the vacuum. Increase the pressure to atmospheric pressure in 10 to 15 seconds if
the vacuum release is not automated. Turn off the vacuum pump and remove the lid. When
performing the pycnometer / volumetric flask method, complete steps 12B through 16B
within 10 ±1 minute.

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5.1.2 MARSHALL STABILITY TEST:
STANDARD
 AASHTO T 209
OBJECTIVE
 To determine the stability, flow, voids, voids in mineral aggregates, voids filled with
asphalt and density of the asphalt mixture by Marshall stability test.

APPARATUS

 Specimen mould assembly

 Specimen extractor
 Compaction hammer
 Compaction pedestal
 Breaking head
 Loading machine
 Oven
 Mixing apparatus
 Thermostatically control eater bath
PREPARATION OF TEST SPECIMEN

 1200 grams of aggregates blended in the desired proportions is measured and

heated in the oven to the mixing temperature
 Bitumen is added at the mixing temperature to produce viscosity of 170 ±
centi-stokes at various percentages.
 The materials are mixed in a heated pan with heated mixing tools.
 The mixture is returned to the oven and reheated to the compacting
temperature (to produce viscosity of 280±30 centi-stokes).
 The mixture is then placed in a heated Marshall mould with a collar and base
and the mixture is spaded around the sides of the mould. A filter paper is
placed under the sample and on top of the sample.
 The mould is placed in the Marshall compaction pedestal.

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  The material is compacted with 50 blows of the hammer (or as specified),
and the sample is inverted and compacted in the the other face with same
number of blows.
 After compaction, the mould is inverted. With collar on the bottom, the base
is removed and the sample is extracted by pushing it out the extractor.
 The sample is allowed to stand for the few hours to cool.
 The mass of the sample in air and when submerged is used to measure the
density of specimen, so as to allow, calculation of the void properties.

PROCEDURE
 Specimens are heated to 60 ±1oC either in a water bath for 30-40 minutes or in an oven for
minimum of 2 hours.
 The specimens are removed from the water bath or oven and place in lower segment of the
breaking head. The upper segment of the breaking head of the specimen is placed in
position and the complete assembly is placed in position on the testing machine.
 The flow meter is placed over one of the post and is adjusted to read zero.

Figure5.2
(Marshall Stability Test)

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 Load is applied at a rate of 50 mm per minute until the maximum load reading is obtained.
 The maximum load reading in Newton is observed. At the same instant the flow as recorded
on the flow meter in units of mm was also noted. Specimens are heated to 60 ±1oC either
in a water bath for 30-40 minutes or in an oven for minimum of 2 hours.
 The specimens are removed from the water bath or oven and place in lower segment of the
breaking head. The upper segment of the breaking head of the specimen is placed in
position and the complete assembly is placed in position on the testing machine.
 The flow meter is placed over one of the post and is adjusted to read zero.
 Load is applied at a rate of 50 mm per minute until the maximum load reading is obtained.
 The maximum load reading in Newton is observed. At the same instant the flow as recorded
on the flow meter in units of mm was also noted.

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 LEARNING OUTCOMES

 In this industrial training period, I have mainly studied

about the lab experiments which are very necessary and
important for the highway pavement construction.

 Learn about the test of soil which is base of the highway

pavement which is very necessary for the test of the
stability of test of soil and also check all the properties and
all the lab procedure has done under the Indian Standard
Code which is basic for all the laboratory test.

 Learn about the test of aggregates where I learnt about the

aggregates which is good and suitable for the highway
construction.

 Learn about the test of cement, this is one of the important

for the rigid pavement highway construction.

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