A Training Report

on
Construction of Expressway
Carried out at
Agra-Lucknow Expressway Under UPEIDA and L&T
at Lucknow Region.

Submitted by:-Divyanshu Shukla

Roll No.-30625503414

Under the guidance of

Mr. J.B Singh
{Assistant Engineer(UPEIDA)}

JIMS Engineering Management Technical Campus

48/4 Knowledge Park III, Greater Noida 201306 U.P
 ACKNOWLEDGEMENT

I express my satisfaction on the completion of this summer training program

and project report submission as a part of the curriculum for the degree of
Bachelor of Technology, Civil Engineering. I express my deepest gratitude to
my supervisor and mentor Mr. J.B Singh for his kind guidance during the
entire period of training. His consistent support and advices has helped me to
complete this research project successfully. Also I thank all the members of
UPEIDA and L. Department for their kind support. They have always been a
source of inspiration to me.

DATE: - 5/08/2016 Divyanshu Shukla

TRAINING CERTIFICATE:-
Content
1.
UPEIDA Introduction

2. Larsen &Toubro Introduction

4. About Agra-Lucknow Expressway

5. Materials and Tests

6. Cement road construction

6.1 Preparation of subgrade

6.2 Preparation of base

6.3 Form work

6.4 Watering of base

6.5 Joints

6.6 Material mix & placing

6.7 Compaction

6.8 Finishing of surface

6.9 Curing

6.10 Filling joint

6.11 Edging

6.12 Open to traffic

7 Reference
UPEIDA(Uttar pradesh Expressway Industrial
Development authority)

The Government of Uttar Pradesh has set up an Authority named "Uttar

Pradesh Expressways Industrial Development Authority" (UPEIDA), under UP
Industrial Area Development Act 1976, vide Notification Number 4246/77-4-
07-94 Bha/07TC, dated December 27, 2007 issued by Industrial Area
Development Department-4, Uttar Pradesh Government.
The Uttar Pradesh Expressways Industrial Development Authority, popularly
known by its acronym UPEIDA was set up under U.P Industrial Area
Development Act, 1976. UPEIDA act as a Nodal Agency for implementation of
Expressway projects in the State entrusted by GoUP. Presently, GoUP has
entrusted UPEIDA to implement two Greenfield Access Controlled Expressway
projects on Engineering Procurement & Construction (EPC) mode.

LARSEN&TOUBRO

Larsen & Toubro is a major technology, engineering, construction, manufacturing and

financial services conglomerate, with global operations. L&T addresses critical needs in key
sectors - Hydrocarbon, Infrastructure, Power, Process Industries and Defence - for customers
in over 30 countries around the world.
L&T is engaged in core, high impact sectors of the economy and our integrated capabilities
span the entire spectrum of design to deliver. With over 7 decades of a strong, customer
focused approach and a continuous quest for world-class quality, we have unmatched
expertise across Technology, Engineering, Construction, Infrastructure Projects and
Manufacturing, and maintain a leadership in all our major lines of business.
Every aspect of L&T's businesses is characterised by professionalism and high standards of
corporate governance. Sustainability is embedded into our long-term strategy for growth.
The Companys manufacturing footprint extends across eight countries in addition to India.
L&T has several international offices and a supply chain that extends around the globe.

AGRA-LUCKNOW EXPRESSWAY

The Agra Lucknow Expressway is a 302 km controlled-access highway or expressway,

constructed by the Uttar Pradesh Expressways Industrial Development Authority to reduce
traffic in already congested roads and to reduce pollution and carbon footprint. It is the longest
expressway in India. The expressway reduced the distance between the cities of Agra and
Lucknow in the Indian state of Uttar Pradesh. It is a 6-lane expressway which is expandable to
8-lanes in future and was inaugurated on 21st November 2016 by the then Chief Minister of
Uttar Pradesh Akhilesh Yadav.

The cost of project was expected to be 15,000 crore (US$2.3 billion) but was completed in
13,200 crore (US$2.1 billion) and in record time of 22 months. It would cut travel time
between Lucknow and Agra from 6 hours to 3:30 hours. The expressway is 6-lane wide
(expandable to 8-lane in future) although the structures (major, minor bridges and
underpasses) on the expressway are already being constructed as 8-laned to be in tune with
the expanded width of the expressway in future.It is proposed on minimum distance and
minimal agricultural land formula and will be financed by the Government of Uttar Pradesh.
The Expressway will carry all public amenities viz. underpasses, service roads, provision for
green belt, rest houses, petrol pumps, service centers, restaurants and four agricultural
mandis for milk, potatoes, grains, fruits and vegetable
About Road
A road is a thoroughfare, route, or way on land between two places, which
has been paved or otherwise improved to allow travel by some conveyance,
including a horse, cart, or motor vehicle. Roads consist of one, or sometimes
two, roadways (carriageways) each with one or more lanes and also any
associated sidewalks (British English: pavement) and road verges. Roads that
are available for use by the public may be referred to as public roads or
highways.

MATERIAL

Concrete is widely used in domestic, commercial, recreational, rural and

educational construction.

Communities around the world rely on concrete as a safe, strong and

simple building material. It is used in all types of construction; from
domestic work to multi-storey office blocks and shopping complexes.

Despite the common usage of concrete, few people are aware of the
considerations involved in designing strong, durable, high quality concrete.

There are mainly three types-

1-Cement
2-Sand
3-Aggregate
Cement
A cement is a binder, a substance that sets and hardens independently, and
can bind other materials together. The word "cement" traces to the Romans,
who used the term caementiciumto describe masonry resembling
modern concrete that was made from crushed rock with burnt lime as
binder. The volcanic ash and pulverized brick additives that were added to
the burnt lime to obtain a hydraulic binder were later referred to as
cementum, cimentum, cement, and cement.
Cements used in construction can be characterized as being
either hydraulic or non-hydraulic. Hydraulic cements (e.g., Portland
cement) harden because of hydration, a chemical reaction between
the anhydrous cement powder and water. Thus, they can harden underwater
or when constantly exposed to wet weather. The chemical reaction results
in hydrates that are not very water-soluble and so are quite durable in
water. Non-hydraulic cements do not harden underwater; for example,
slaked limes harden by reaction with atmospheric carbon dioxide.
The most important uses of cement are as an ingredient in the production
of mortar in masonry, and of concrete, a combination of cement and an
aggregate to form a strong building material.

Types of Cement:-

Portland cement
Portland cement is by far the most common type of cement in general use
around the world. This cement is made by heating limestone (calcium
carbonate) with small quantities of other materials (such as clay) to
1450 C in a kiln, in a process known as calcination, whereby a molecule
of carbon dioxide is liberated from the calcium carbonate to form calcium
oxide, or quicklime, which is then blended with the other materials that
have been included in the mix. The resulting hard substance, called
'clinker', is then ground with a small amount of gypsum into a powder to
make 'Ordinary Portland Cement', the most commonly used type of
cement (often referred to as OPC). Portland cement is a basic ingredient
of concrete, mortar and most non-specialty grout. The most common use
for Portland cement is in the production of concrete. Concrete is a
composite material consisting of aggregate (gravel and sand), cement,
and water. As a construction material, concrete can be cast in almost any
shape desired, and once hardened, can become a structural (load bearing)
element. Portland cement may be grey or white.

Portland fly ash cement

Its contains up to 35% flyash. The fly ash is pozzolanic, so that ultimate
strength is maintained. Because fly ash addition allows a lower concrete
water content, early strength can also be maintained. Where good quality
cheap fly ash is available, this can be an economic alternative to ordinary
Portland cement.

Portland pozzolan cement

Its includes fly ash cement, since fly ash is a pozzolan , but also includes
cements made from other natural or artificial pozzolans. In countries
where volcanic ashes are available.

Portland silica fume cement

Addition of silica fume can yield exceptionally high strengths, and cements
containing 520% silica fume are occasionally produced. However, silica
fume is more usually added to Portland cement at the concrete mixer

Sand
Sand is a naturally occurring granular material composed of finely
divided rock and mineral particles. The composition of sand is highly
variable, depending on the local rock sources and conditions, but the most
common constituent of sand in inland continental settings and non-
tropical coastal settings is silica (silicon dioxide, or SiO2), usually in the
form of quartz.
The second most common type of sand is calcium carbonate, for
example aragonite, which has mostly been created, over the past half
billion years, by various forms of life, like coral and shellfish. It is, for
example, the primary form of sand apparent in areas where reefs have
dominated the ecosystem for millions of years like the Caribbean.

Composition
In terms of particle size as used by geologists, sand particles range in
diameter from 0.0625 mm (or 116 mm) to 2 mm. An individual particle in
this range size is termed a sand grain. Sand grains are between gravel (with
particles ranging from 2 mm up to 64 mm) and silt (particles smaller than
0.0625 mm down to 0.004 mm). The size specification between sand and
gravel has remained constant for more than a century, but particle
diameters as small as 0.02 mm were considered sand under the Alter berg
standard in use during the early 20th century. A 1953 engineering standard
published by the American Association of State Highway and
Transportation Officials set the minimum sand size at 0.074 mm.

Aggregate
Aggregates are inert granular materials such as sand, gravel, or crushed
stone that, along with water and Portland cement, are an essential
ingredient in concrete. For a good concrete mix, aggregates need to be
clean, hard, strong particles free of absorbed chemicals or coatings of clay
and other fine materials that could cause the deterioration of concrete.
Aggregates, which account for 60 to 75 percent of the total volume of
concrete, are divided into two distinct categories-fine and coarse. Fine
aggregates generally consist of natural sand or crushed stone with most
particles passing through a 3/8-inch (9.5-mm) sieve. Coarse aggregates are
any particles greater than 0.19 inch (4.75 mm), but generally range
between 3/8 and 1.5 inches (9.5 mm to 37.5 mm) in diameter. Gravels
constitute the majority of coarse aggregate used in concrete with crushed
stone making up most of the remainder.

Natural gravel and sand are usually dug or dredged from a pit, river, lake,
or seabed. Crushed aggregate is produced by crushing quarry rock,
boulders, cobbles, or large-size gravel. Recycled concrete is a viable source
of aggregate and has been satisfactorily used in granular subbases, soil-
cement, and in new concrete. Aggregate processing consists of crushing,
screening, and washing the aggregate to obtain proper cleanliness and
gradation. If necessary, a benefaction process such as jigging or heavy
media separation can be used to upgrade the quality.

Once processed, the aggregates are handled and stored in a way that
minimizes segregation and degradation and prevents contamination.
 Aggregates strongly influence concrete's freshly mixed and hardened
properties, mixture proportions, and economy. Consequently, selection of
aggregates is an important process. Although some variation in aggregate
properties is expected, characteristics that are considered when selecting
aggregate include:

grading
durability
particle shape and surface texture
abrasion and skid resistance
unit weights and voids
absorption and surface moisture

Grading refers to the determination of the particle-size distribution for

aggregate. Grading limits and maximum aggregate size are specified
because grading and size affect the amount of aggregate used as well as
cement and water requirements, workability

Shape and size

Particle shape and surface texture influence the properties of freshly mixed
concrete more than the properties of hardened concrete. Rough-textured,
angular, and elongated particles require more water to produce workable
concrete than smooth, rounded compact aggregate. Consequently, the
cement content must also be increased to maintain the water-cement ratio.
Generally, flat and elongated particles are avoided or are limited to about
15 percent by weight of the total aggregate. Unit-weight measures the
volume that graded aggregate and the voids between them will occupy in
concrete. The void content between particles affects the amount of cement
paste required for the mix. Angular aggregate increase the void content.
Larger sizes of well-graded aggregate and improved grading decrease the
void content. Absorption and surface moisture of aggregate are measured
when selecting aggregate because the internal structure of aggregate is
made up of solid material and voids that may or may not contain water. The
amount of water in the concrete mixture must be adjusted to include the
moisture conditions of the aggregate. Abrasion and skid resistance of an
aggregate are essential when the aggregate is to be used in concrete
constantly subject to abrasion as in heavy-duty floors or pavements. Different
minerals in the aggregate wear and polish at different rates. Harder aggregate
can be selected in highly abrasive conditions to minimize wear.

Test
There are four main tests to be done on concrete:

1-The Slump Test.

2-Compression Test

3-Impact Test

4-Cube Test
THE SLUMP TEST
The slump test is done to make sure a concrete mix is workable.
Workability measures how easy the concrete is to place, handle and
compact
 Standard slump cone (100 mm top diameter x 200 mm bottom diameter x 300 mm high)

Small scoop

Bullet-nosed rod

(600 mm long x 16 mm diameter )

Rule

Slump plate (500 mm x 500 mm)

Method

1.Clean the cone. Dampen with water and place on the slump
plate. The slump plate should be clean, firm, level and non-
absorbent.

2.Collect a sample.

3. Stand firmly on the footpieces and fill 1 / the volume of the cone with
3
the sample. Compact the concrete by 'rodding' 25 times.

Rodding Rodding means to push a steel rod in and out of the

concrete to compact it into the cylinder, or slump cone.

4.Now fill to 2 /3 and again rod 25 times, just into the

top of the first layer.

5.Fill to overflowing, rodding again this time just into the

top of the second layer. Top up the cone till it overflows.

6.Level off the surface with the steel rod using a

rolling action. Clean any concrete from around

the base and top of the cone, push down on the

handles and step off the footpieces.

7.Carefully lift the cone straight up making

sure not to move the sample.
8.Turn the cone upside down and place the rod across
the up-turned cone.
THE COMPRESSION TEST
The compression test shows the compressive strength of hardened
concrete. The testing is done in a laboratory off-site. The only work done
on-site is to make a concrete cylinder for the compression test.

The strength is measured in Megapascals(MPa) and is commonly specified

as a characteristic strength of concrete measured at 28 days after mixing.
The compressive strength is a measure of the concretes ability to resist
loads which tend to crush it.

Tools
Cylinders (100 mm diameter x 200 mm high or 150 mm diameter x
300 mm high)
( The small cylinders are
normally used for most
testing due to their lighter
weight )

Small scoop

Bullet-nosed rod (600 mm x

16 mm)

Steel float

Steel plate

Method

1 Clean the cylinder mould and coat the inside lightly with
form oil, then place on a clean, level and firm surface, ie
the steel plate.

2 Collect a sample.
3 Fill 1/2 the volume of the mould with concrete then
compact by rodding 25 times. Cylinders may also be
compacted by vibrating using a vibrating table.

The Compression Test continues on the next page

4 Fill the cone to overflowing and rod 25 times

into the top of the first
layer, then top up the mould till overflowing.

5 Level off the top with the steel float and clean any
concrete from around the mould.

6 Cap, clearly tag the

cylinder and put it in a
cool dry place to set for at
least 24 hours.

7 After the mould is removed the cylinder is sent to the laboratory

where it is cured and crushed to test compressive strength.
Impact Testing

An impact test is a dynamic test conducted on a selected specimen which

is usually notched. The specimen is struck and broken by a single blow in
a specially designed machine.

This demo illustrates the experiment setup, procedure and the

energy absorbed in an impact test.
 Cube Test
Test applied to the concrete, this is the
utmost important which gives an idea
about all the characteristics of concrete.
By this single test one judge that
whether Concreting has been done
properly or not. For cube test two types
of specimens either cubes of 15 cm X
15 cm X 15 cm or 10cm X 10 cm x 10 cm depending upon the size of
aggregate are used. For most of the works cubical moulds of size 15 cm
x 15cm x 15 cm are commonly used.

This concrete is poured in the mould and tempered properly so as not to

have any voids. After 24 hours these moulds are removed and test
specimens are put in water for curing. The top surface of these
specimen should be made even and smooth. This is done by putting
cement paste and spreading smoothly on whole area of specimen.

These specimens are tested by compression testing machine after 7 days

curing or 28 days curing. Load should be applied gradually at the rate
of 140 kg/cm2 per minute till the Specimens fails. Load at the failure
divided by area of specimen gives the compressive strength of concrete.

APPARATUS
Compression testing machine

PREPARATION OF CUBE SPECIMENS

The proportion and material for making these test specimens are from the same
concrete used in the field.

SPECIMEN
6 cubes of 15 cm size Mix. M15 or above

MIXING
Mix the concrete either by hand or in a laboratory batch mixer
HAND MIXING
(i)Mix the cement and fine aggregate on a water tight none-absorbent platform
until the mixture is thoroughly blended and is of uniform color

(ii)Add the coarse aggregate and mix with cement and fine aggregate until the
coarse aggregate is uniformly distributed throughout the batch

(iii)Add water and mix it until the concrete appears to be homogeneous and
of the desired consistency.

PRECAUTIONS
The water for curing should be tested every 7days and the temperature of water must be at
27+-2oC.

PROCEDURE
(I) Remove the specimen from water after specified curing time and wipe out excess
water from the surface.

(II) Take the dimension of the specimen to the nearest 0.2m

(III) Clean the bearing surface of the testing machine

(IV) Place the specimen in the machine in such a manner that the load shall be
applied to the opposite sides of the cube cast.

(V) Align the specimen centrally on the base plate of the machine.

(VI) Rotate the movable portion gently by hand so that it touches the top surface
of the specimen.

(VII) Apply the load gradually without shock and continuously at the rate of
140kg/cm2/minute till the specimen fails

(VIII) Record the maximum load and note any unusual features in the type of failure.
Using mix Concrete, there some
Point to construct the road.
1. Preparation of base

2. Form working

3. Preparation of subgrade

4. Watering of base

5. Joints

6. Material mix & placing

7. Compaction

8.Finishing of surface
9.Curing

10.Joint filling

11.Edging

12.Open to traffic
1.Preparation of subgrade
1. Rolling on sub grade by roller

2. Filling the granular soil in the weak part and pot holes

3. Correct the soil coat , Camber , longitudinal slop

When concrete direct laid on subgrade, For preventing the water-

seepaging into the soil , used water proof paper on entire length.

1. Rolling on sub grade by roller

2. Filling the granular soil in the weak part and pot holes

3. Correct the soil coat , Camber , longitudinal slop

When concrete direct laid on subgrade, For preventing the water-

seepaging into the soil , used water proof paper on entire length.

2. Preparation of base
Choose any one type of base

1. W.B.M. base
As base material of W.B.M. Road; stone ballast, concrete 10-15cm layer are
used. For bonding between concrete slab & W.B.M. used 1:2 cement wash
on W.B.M.

2. Concrete base
On the road used 10cm Cement concrete(1:2:4) or lime
concrete(16:32:64)

3. Granular medium material layer

10-15cm composite layer of sand , moorum, bajriare usedfor better
drainage facilities
 4. Stabilization soil

3. Form work
Material for form work-

Wooden sheets, battens, plywood, fibre hard board, steel plates,

angles, rope, minerals.

1.Before using form work, it should free from all type material like as dust
,cement.
2.To placing the concrete in appropriate depth used 2.5-5cm thick and
3mtr long wooden sheeting.
3.The depth of wooden block must be same as level of slab thick.
4.After 24hrs form work displaced next length of road.
4. Watering of base
If base is dryThan using the sprinkling process on it properly after that placing
the concrete.

5.Joints
Where is necessary to provide transverse, Longitudinal joints; there wedge of
woods, metals fix on level of concrete.
After setting of concrete it should be pull out.
If provided the dowel bar in joints, bars should be fit at right position.

6.Material mix & placing

Mixer is equipment that mix the concrete using distinct amount of cement ,
concrete, sand and water. Concrete slab should have more than 5-10cm thick
cause of drying. Used two type mixer-

1.Batch mixer-at site, used for small road construction

2.Continuous mixer-
Continuous mixer used for large construction .
if distance is more from site , mix concrete transported at site within
setting time.
Two methods generally used in placing of concrete-
1. Alternate bay method-
Placed the concrete on both side of road alternatively like
as1,3,5 part at one side and 2,4,6 part other side .
1st side
2nd side
This method have slow process due to road traffic problems.
2. Continuous bay method-
construct one side of road regularly, if completed some part of first side
than construct other side.
this method have fast process without no obstruction of traffic

7. Compaction
Purpose of compaction is that to pull out air from void and make concrete
harden.

Compaction done by-

1.Mechanically surface vibrator
2.Manually hand tempers

8.Finishing of surface
1.Floating-
For levelling the surface use floating, scree-ding , power trowel. So that
there is no acceptable more than 3mm variation in concrete level surface.
2.Belting-
For making surface clean used belting process. Belt is nothing but a 15-30cm
thick sheets of canvass which have more length than road.
3. Brooming-
Brooming is the process in which we made rough surface parallel to road by
brush.
It useful in avoiding slip & comfortable travelling on road .
The depth of line on road no more than 1.5mm.

9.Curing
Curing is the name of increasing the hydration process of cement.
after setting the concrete , curing process done till 14-28days.
Some method of curing are-
1.Shading concrete works
2.Covering with hessian & gunny bags
3.Sprinkling of water
4.By ponding
5.Membrane curing
6.Steam curing

10. Filling joint

After drying road, clean the joints and fill the shelling compound or hot
bitumen .
Also bitumen fill road bank.
11. Edging
To protect damaging the sides of concrete pavements used over burnt brick
work.
In place of brick, provided kerb of pre mix concrete.

12.Open to traffic
Generally after a month, road should be open to traffic.
If used rapid hardening cement it take 7 days to open traffic.

Reference
1.www.res.gov.in
2.www.upjl.com
3.www.sand.uk
4.www.upeida.in
5.ww.google.com
G 1.