Industrial Internship Project Report-Odu Paul-14115

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INDUSTRIAL INTERNSHIP PROJECT REPORT

OCTOBER 2012 – APRIL 2013

AT

I.Z.A CONSTRUCTION COMPANY SDN BHD

ODU PAUL DUKU ERIKOLE

14115

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INDUSTRIAL INTERNSHIP PROJECT REPORT

01

ST

OCTOBER 2012 – 12

TH

APRIL 2013

SOIL CEMENT STABILIZATION OF PAVEMENT

SUBGRADE FOR A NEW 2.5KM ROAD IN ANAK KURAU

SUBMITTED TO

CENTER FOR STUDENT INTERNSHIP, MOBILITY

AND ADJUNCT LECTURESHIP (CSIMAL)

UNIVERSITI TEKNOLOGI PETRONAS

BY

ODU PAUL DUKU ERIKOLE - 14115

DEPARTMENT OF CIVIL ENGINEERING

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EXECUTIVE SUMMARY

The construction of new roads often results in the necessity to cope up with problematic subgrade materials such as expansive soils, collapsible soils, erodible soils, very soft soils and wet areas. These problems associated with subgrade materials are common in many parts of the world, although they tend to be localized in certain areas of which Kampung Anak Kurau is not an exception.

Most of the soil at the project site is unsuitable (consists of mud/clay) which undergo a huge amount of volume change due to changes in temperature and moisture. This shrinking and swelling of the soil can lead to cracking of overlying pavement layers. According to (Karin, Sven-Erik & Ronny, 2002), a conventional solution in this situation is soil substitution, which involves excavating the loose soil layers and replacing them with frictional/granular material of higher bearing capacity. This layer is then followed by sub-base and base courses which are normally constructed of aggregates. But fill materials can deteriorate due to intrusion of stone base, pumping of subgrade soil and infiltration of water from subgrade, leading to a substantial damage of pavement[5].

Soil substitution is also not cost effective (aggregates are costly) and frequently also problematic, as the replaced material must be disposed of and new filling material hauled to the site. Furthermore, soil substitution takes longer time (several layers to be constructed) and it is not environmentally friendly method due to the greenhouse emissions during raw material mining, processing, and transportation of raw materials to the construction site.

This project entitled as “Soil Cement Stabilization of Pavement Subgrade for a new 2.5km road in Anak Kurau” therefore, aims at improving the strength of subgrade materials and reducing road construction cost in terms of material, time and maintenance.

The improvement of the strength of the subgrade materials is through the use of geotextile to separate the soft subgrade materials from the granular fill materials prevent

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migration and mingling of the soft subgrade soil and granular fill material under the action of the construction equipment or subsequent traffic but yet allow free movement of water. This unsuitable subgrade material replacement is then followed by stabilizing the fill materials with cement.

During the unsuitable soil replacement by using geotextile separator, the unsuitable material was excavation to a sufficient depth, a type „A‟ non-woven geotextiles was then placed as a separator with a minimum overlap of about 500mm (figure 2.3.4-3), followed by river sand filling in layers and then compaction.

The untreated fill material was then subjected to in-situ CBR test, Field Density Test, sieve analysis, Atterberg limits tests and compaction test to determine its properties. Samples of the granular fill materials were also dosed with different Portland cement content (2.5%, 3.5% and 5%) at the optimum moisture content and subjected to unconfined compressive strength (UCS) test so as to determine the optimum cement content to be used for the stabilization. The UCS test result shows that the strength of the subgrade material increases with an increase in the cement content and based on this result, a cement content of 4% was used in the Mix Design for the soil cement stabilization.

The area to be stabilized is then demarcated and 4% of cement by proportion is added to the subgrade soil and mixed into it until a uniform color is obtained, and the mixture is then thoroughly compacted.

Comparison of the CBR values before and after soil cement stabilization shows a significant increase in the value of CBR after soil cement stabilization. The CBR of the subgrade before stabilizing with cement is between 19% and 42% while the CBR value increases to between 78 and 82 at the age of three days and as high as 103% at the age of seven days after soil cement stabilization. This CBR value is higher than the recommended CBR value (80%) for road base constructed of crusher run or aggregate material. For this reason, it is not advisable to have sub-base and base courses, surface course can be constructed directly on the stabilized subgrade because it (the subgrade) is strong enough to withstand the subsequent traffic loading from the vehicle that will be

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using the road. Soil cement stabilization of the subgrade therefore reduces the design and construction thickness of flexible pavement.

Based on the cost analysis, it can be concluded that soil cement stabilization is more cost effective than conventional method of constructing flexible pavement because construction cost when using soil cement stabilization of the subgrade material is RM 245,000.00 (table 2.4.2-1) but the cost would have beenRM 516,390.26 (table 2.4.2-2) if conventional method were used.

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ACKNOWLEDGEMENTS

I would like to express my sincere gratitude to all those people whose immeasurable contributions made it possible for me to complete my industrial internship training. I would like to thank especially the Center for Student Internship, Mobility and Adjunct Lectureship (CSIMAL) and the Department of Civil Engineering of Universiti Teknologi PETRONAS (UTP) for giving the students such a golden opportunity to do industrial internship training and for their well-organized Internship Guidelines which made work easier for us during our training period. I would also like to thank my UTP supervisors Dr. Tee Hee Min of UTP for his encouragement and advice during the first visit and Dr. Mohd Faris Khamidi during the second visit for his support and guidance about what I need to add to the Internship Report.

I am also thankful to the management of I.Z.A Construction Company for offering me the opportunity to do my industrial training with the company and for every assistance that they rendered to me from October 2012 up to date. Special thanks also go to my host company supervisor, Mr. Mior for assigning me several tasks and always being available to guide me in executing the tasks. I appreciate the project manager Mr. Firdaus, site manager Mr. Ravi and the project engineer Mr. Zulhelmy so much for helping me at site supervision work, in understanding construction drawings and taking off. I am thanking Mr. Rama of Jabatan Kerja Raya Malaysia (JKR) for his advance and for always asking me to join him for any laboratory tests and for providing an explanation for both laboratory and in-situ test results.

Last but not least, I am thankful to all the staff of I.Z.A Construction Company and my fellow interns in the company for their support especially for providing me with relevant information that helped me during my training.

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APPENDIX 1 – TRAINING SCHEDULE ... II APPENDIX 2 – PROJECT GANTT CHART ... III APPENDIX 2- LABORATORY REPORT ... IV APPENDIX 3 – UNSUITABLE SOIL REPLACEMENT WITH GEOTEXTILE SEPARATOR ... XI APPENDIX 4 – CULVERT INSTALLATION ... XII APPENDIX 5 – SOIL CEMENT STABILIZATION APPLICATION PROCESS ... XIV

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LIST OF FIGURES

FIGURE 2.1-1 PROJECT LOCATION PLAN ... 7

FIGURE 2.3.1-1 SPECIALIZED MACHINE ... 16

FIGURE 2.3.1-2 SUPPORTING MACHINES ... 17

FIGURE 2.3.3-1 ROAD CROSS SECTION IN CUT AND FILL AREAS ... 19

FIGURE 2.3.4-1 REASONS FOR DETERIORATION OF FILL MATERIALS ... 20

FIGURE 2.3.4-2 IMPORTANCE OF GEOTEXTILE SEPARATOR. ... 20

FIGURE 2.3.4-3 JOINING OF GEOTEXTILE SEPARATOR BY OVERLAP ... 21

FIGURE 2.3.4-4 TYPICAL DETAILS FOR STANDARD FILL SECTION TREATMENT TYPE 1(SAND REPLACEMENT WITH GEOTEXTILE SEPARATOR ... 21

FIGURE 2.3.5-1 SUB-SOIL DRAIN CROSS SECTION (CH900–CH1150) ... 22

FIGURE 2.3.5-2 BEDDING TYPE B1,SOFT FOUNDATION ... 23

FIGURE 2.4.1-1 PARTICLE SIZE DISTRIBUTION CURVE ... 28

FIGURE 2.4.1.2-1 DRY DENSITY /MOISTURE CONTENT RELATIONSHIP SITE SOIL ... 29

FIGURE 2.4.1.2-2 DRY DENSITY /MOISTURE CONTENT RELATIONSHIP RIVER SAND FILL ... 30

FIGURE 2.4.1.2-3 DRY DENSITY /MOISTURE CONTENT RELATIONSHIP FOR IMPORTED EARTH FILL ... 31

FIGURE 2.4.1.3-1 LIQUID LIMIT GRAPH ... 32

FIGURE 2.4.1.4-1 ULTIMATE STRENGTH DESIGN MIX FOR SOIL AND SAND MIX ... 33

FIGURE 2.4.1.4-2 ULTIMATE STRENGTH DESIGN MIX FOR SOIL ... 34

FIGURE 2.4.1.4-3 ULTIMATE STRENGTH DESIGN MIX FOR SAND ... 35

FIGURE 2.4.2-1 THICKNESS OF FLEXIBLE PAVEMENT BY USING SOIL CEMENT STABILIZATION ... 42

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LIST OF TABLES

TABLE 2.2.4-1 CEMENT REQUIREMENTS (QUANTITIES) FOR VARIOUS SOILS (HICKS,2002) ... 12

TABLE 2.2.4-2 MINIMUM UNCONFINED COMPRESSIVE STRENGTH AT 7 DAYS FOR CEMENT AND 28 DAYS FOR LIME, LIME -CEMENT, AND LIME-CEMENT-FLY ASH STABILIZED SOILS (GUYER,2011). ... 12

TABLE 2.2.4-3 DURABILITY REQUIREMENTS FOR STABILIZED SOIL (GUYER,2011) ... 13

TABLE 2.4.1-1 SIEVE ANALYSIS RESULTS ... 28

TABLE 2.4.1.2-1 DRY DENSITY/MOISTURE CONTENT RELATIONSHIP FOR SITE SOIL ... 29

TABLE 2.4.1.2-2 DRY DENSITY/MOISTURE CONTENT RELATIONSHIP FOR RIVER SAND FILL ... 30

TABLE 2.4.1.2-3 DRY DENSITY/MOISTURE CONTENT RELATIONSHIP FOR IMPORTED EARTH FILL ... 31

TABLE 2.4.1.3-1 PLASTIC LIMIT TEST RESULTS... 32

TABLE 2.4.1.3-2 LIQUID LIMIT TEST RESULTS ... 32

TABLE 2.4.1.4-1 DESIGN MIX (TRIAL MIX) FOR SOIL-SAND MIXTURE ... 33

TABLE 2.4.1.4-2 DESIGN MIX (TRIAL MIX) FOR SOIL ... 34

TABLE 2.4.1.4-3 DESIGN MIX (TRIAL MIX) FOR SAND ... 35

TABLE 2.4.1.5-1 CBRVALUES BEFORE SOIL CEMENT STABILIZATION ... 36

TABLE 2.4.1.5-2 CBRVALUES AFTER SOIL CEMENT STABILIZATION ... 38

TABLE 2.4.2-1 SOIL CEMENT STABILIZATION OF SUBGRADE MATERIALS ... 43

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1.0. INTRODUCTION

1.1. BRIEF DESCRIPTION OF THE HOST COMPANY

I.Z.A Construction Co. Sdn. Bhd was formed on 15th September 1982 and was incorporated under the Company Act 1965 on the 21st September 1991. The Board of Directors are Dato' Baharuddin Bin Hj. Mahyuddin, a Civil Engineer and Mr. Farouk Bin Anwar a Chemical Engineer. Since its formation in 1982, the company due to the expertise and technical experiences of the directors has secured and completed contracts well exceeding Ringgit Malaysia 560 million. The company has progressed tremendously from a small time Class 'D' contractor to a fully-fledged Class 'A' Bumiputera contractor registered with Contractor Service Centre since 1994. Since then it has well established itself and received high recognition by the Ministry of Finance and the Prime Minister's Department with the status COMPETENT CONTRACTOR. The award of MS ISO 9001:2000 certification by SIRIM QAS International Sdn. Bhd. is a proven testament of the company systematic management being recognized internationally.

1.2. OBJECTIVES OF THE INDUSTRIAL INTERNSHIP

 To apply theoretical knowledge in industrial application and implement Health Safety and Environment (HSE) practices at workplace.

 To expose the students to ethical and professional work culture, industrial practices and potential employers

 To develop students skills in work ethics, communication, leadership and management

 To engage students in real research-based assignments, research-based activities and team-work activities

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1.3. SCOPE OF WORK, TASKS OR PROJECTS UNDERTAKEN DURING INTERNSHIP

During my training period, I was tasked with the following tasks which can be divided into project management, supervision, material testing, health safety and environment, and reporting.

1. Project management

a. Help the QS in tendering work especially in taking off and in pricing the tender document.

b. Attend a two days course about Microsoft Project 2010 and then come up with work programs for assigned task and thereafter do weekly project tracking

c. Report project progress based on project tracking to the supervisor.

2. Supervision

a. Inspect daily site activities

b. Ensure effective flow of traffic flow is not interrupted by using adequate temporary traffic signs where necessary.

c. Determine the area for closed turfing and ensure that closed turfing is done for slope protection in both cut and fill slopes.

4. Material testing

a. Check the results for slump test before any concreting is done

b. Ensure that concrete cubes are cast during concreting and follow the JKR technician to the concrete supplier‟s laboratory for cube test on the seventh and 28th day after concreting

c. Carry out speedy test for imported earth to ensure that the moisture content is not less than 10% and does not exceed 27%

e. Help the technician recommended by JKR during Field Density Test (FDT) f. Coordinate with JKR to inspect California Bearing Ration (CBR) test and

ensure that the CBR value is ≥5% for soil, ≥30% for sand and ≥80% after soil cement stabilization

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5. Health Safety and Environment (HSE)

a. Involved in a BOMBA inspection to ensure the safety of occupants of completed building projects for a period of one week

b. Always wear safety boots and ensure that all the general workers wear safety boots when carrying out any site activity

c. Ensure that each and every worker at the construction site wears face musk especially during spreading of the stabilizing agent which can be airborne when it is windy.

d. Ensure that traffic barriers are in place especially when working at road intersection to prevent accidents.

e. Ensure that water samples are collected every month for environmental water quality monitoring.

6. Reporting

a. Prepare daily site diary including the daily site activities, workforce at site, machinery and equipment used, materials delivered to the site, visitors at the site, and daily weather conditions.

b. Prepare weekly progress report consisting of the site activities for the week and overall progress, workforce present and those on leave for the week, materials delivered to the site, machinery and equipment at the site, visitors at the site and weather conditions for the whole week

c. Take site photos every Friday and make progress photo report

d. Do weekly project tracking and tracking on the 4th, 20th and 30th of every month

e. Help the project manager in preparing monthly report

The projects that I undertook during my training consists ofunsuitable soil replacement by using non-woven geotextile as a separator, drainage work and soil cement

stabilization. My responsibilities as stated below are all under the direct supervision of the site manager Mr. Ravi. I performed most of the tasks in his presence and whether he is around or absent, he double check my work, make changes where necessary and then ask me to include those changes in my work.

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During unsuitable soil replacement by using non-woven geotextile as a separator, my responsibility is to:

1. Determine the volume of cut materials and granular fill materials based on the existing ground level and finished road level by using Microsoft office excel. 2. Measure the volume of fill materials from each truck upon arrival at the site and

then compute the total daily volume hauled to the site and report it to the site manager Mr. Ravi

3. Ensure that unsuitable materials such as roots of trees are removed from the fill materials during off hauling and leveling by motor grader.

4. Ensure that, the overlap of geotextiles is as shown in the drawing (figure 3.6) before the geotextile is covered with fill materials.

My responsibility during drainage work is to:

1. Check with the project engineer and site manager the culverts upon arrival at the site to ensure that the dimensions of each and the total quantities confirm to the one in the order sheet before unloading.

2. Check the culverts to ensure that the culverts have not been damaged during delivery and set aside any damaged culvert during delivery and unloading. 3. Ensure that the unloaded culverts are stockpiled near to where they will be

installed so as to avoid re-handling and unnecessary equipment movement. 4. Ensure that the culverts are installed in the right location and beddings were

properly graded to avoid the culverts from settling after being installed 5. Ensure proper alignment and jointing especially for box culverts in order to

reduce the migration of soil fines and water between sections of the box culverts and their surroundings.

6. Determine the volume of materials to be used for bedding preparation and for backfill of culverts as shown in.

7. Ensure that backfill materials are free from debris, organic matter, wood, frozen material or large stones.

8. Determine the quantity of reinforcement bars required for culvert wingwalls from construction drawings and the volume of concrete to be ordered after the

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steelwork and formwork for the wingwalls as well as the quantities of bricks, cement and sand for sumps.

9. Inspect the steelwork and formwork for culvert wingwalls to ensure that the spacing for the steel bars confirms to that in the drawing, the number of steel bars is as I determined and the formwork is strong enough to withstand the weight of the fresh concrete.

10. Ensure the safety of the works during unloading and installation of culverts and during the construction as well as concreting of culvert wingwalls.

Last but not least, my scope of work during soil cement stabilization is to:

1. Check and verify that the proportion of the stabilizing agent is as indicated in the mix design

2. Check and verify that mixing or depth of soil cement stabilization is as shown in the construction drawing

3. Ensure that all the workers wear face mask during spreading of stabilizing agent 4. Ensure that soil cubes are cast and FDT conducted for use in the laboratory to

determine the optimum moisture content and maximum dry density

5. Ensure that CBR test is conducted at the age of three days and seven days to determine the mechanical strength of the subgrade after stabilization with cement.

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2.0. INTERNSHIP PROJECT REPORT

2.1.0. PROJECT BACKGROUND

2.1.1. BACKGROUND

This project involves the construction of a new road from Kamunting to Anak Kurau, Taiping-Perak Darul Ridzuan (figure 2.1-1) and it consists of two phases: - phase 1 involves the construction of a 2.5 Km road starting at state route A137 at Kampung Anak Kurau while phase 2 involves the construction of an 11Km road connecting the 2.5 Km road to state road A7 at Sungai Relong. Phase 1 uses soil cement stabilization method for the road embankment construction while phase 2 uses the conventional method of road construction which composes of layers of crushed rock for the road sub-base and road sub-base courses. This report is entirely about phase 1 of the construction in which unsuitable soil replacement with geotextile separator precedes the soil cement stabilization process.

In this project, non-woven geotextiles type „A‟ are placed between the soft subgrade and the granular fill materials so as to filter and hence prevent migration and mingling of the soft subgrade soil and granular fill material under the action of the construction equipment or subsequent traffic but yet allow free movement of water. After the unsuitable soil replacement, a cement content of 4% is added to the soil and mixed into it until a uniform color is obtained, and the mixture is then thoroughly compacted. This process called soil cement stabilization is used to increase the strength of the subgrade materials, thereby elimination the need for sub-base and base courses which is normally constructed of crusher run, thus resulting into a great cost saving.

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Funding for the project is by Kementerian Kemajuan Luar Bandar & Wilayah (KKLW) and all the project work is done according to the JKR standards & specifications. The total value of the contract at award to I.Z.A Construction Sdn. Bhd was RM 7,228,925.40. I.Z.A Construction Sdn. Bhd received the contract document on 27th December 2011 and it started the project work on 09th January 2012 with total project duration of 53 weeks. Contractually, the project is to be completed on 07th January 2013.

Figure 2.1-1 Project Location Plan

2.1.2. PROBLEM STATEMENT

An efficient road network is a key factor in the development of a region or an area because it helps in the mobility of people and goods from one place to another. The construction of this new road by the Malaysia Government will help connect the residents of Kampung Anak Kurau to Kamunting, Taiping and other parts of the country. Site condition however poses a serious challenge to the construction work.

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Most of the soil at the project site is unsuitable (consists of mud/clay) which undergo a huge amount of volume change due to temperature and moisture. This shrinking and swelling of the soil can lead to cracking of overlying pavement layers. According to (Karin, Sven-Erik & Ronny, 2002), a conventional solution in this situation is soil substitution, which involves excavating the loose soil layers and replacing them with frictional material of higher bearing capacity normally well-graded aggregates so as to obtain a stable sub-grade, sub-base or base layers. Soil substitution is however not cost effective and frequently also problematic, as the replaced material must be disposed of and new filling material hauled to the site. Soil substitution also takes longer time and it is not environmentally friendly method due to the greenhouse emissions during raw material mining, processing, and transportation of raw materials to the construction site.

2.1.3. SIGNIFICANCE OF THE PROJECT

A well-constructed road must be durable, cost effective, easy to maintain and most of all it must be able to serve its intended function. This can only be achieved if the road is constructed on a solid, stable foundation. Mixing cement and or lime into the soil will help stabilize the soil thus making it denser, waterproof and more stable. Soil stabilization improves the soil strength and it will be used as a substitute to well graded aggregates in this project because it takes shorter time to stabilize the soil than using layers of well-graded aggregates to obtain stable sub-grade, sub-base or base layers. For this 2.5km road, the soil stabilization process has taken only two weeks. Soil cement stabilization improves the engineering properties of soil thus making the stabilized base strong enough to withstand vehicle loading like crusher run base and it is cost effective, easy to maintain and more environmentally friendly than the conventional method of road construction. Cost effectiveness here is realized by the fact that soil cement stabilization eliminates the need to import large volume of aggregates and the associated production and hauling cost whereas it is more environmentally friendly because it reduces greenhouse emissions during raw material mining, processing, and transportation to the site in the conventional method.

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2.1.4. PROJECT OBJECTIVE

The objective of this project is to improve the strength of subgrade materials and to reduce cost of road construction in terms of material, time and maintenance.

2.1.5. SCOPE OF WORK FOR THE PROJECT

The scope of work for this project can be divided into work prior to soil cement stabilization and soil cement stabilization work.

 The work to be done prior to soil cement stabilization include: 1. Mobilization of machinery

2. Site clearing and demolition of existing structures in the entire area of the road reserves

3. Earthwork and unsuitable material replacement with geotextile separator 4. Drainage work

5. Sampling, testing and mix design

 Soil cement stabilization work on the other hand consists of: 1. Spreading the stabilizing agent

2. Weighing to verify proportion of stabilizing agent 3. Pulverization and mixing

4. Digging to verify the depth of mixing or depth of stabilization 5. Preliminary compaction

6. Grading to chamber 7. Final rolling 8. Curing

9. Cube Casting and Testing, Field Density Test, CBR test 10. Site cleaning and demobilization

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2.2.0. LITERATURE REVIEW

2.2.1. BRIEF DESCRIPTION OF SOIL CEMENT STABILIZATION

Soil stabilization and can be defined as the treatment of natural soil to improve its engineering properties (Garber & Hoel, 2002). Soil cement stabilization is a process to improve the strength and durability of soil by mixing an appropriate amount of cement with the soil. This can be achieved by pulverizing the natural soil or borrow material, adding the appropriate amount of cement to the pulverized soil and mixing it properly and then thoroughly compacting the mixture. When cement comes in contact with soil water, it forms calcium silicate hydrate and calcium hydroxide (Ca(OH)2). The calcium silicate hydrate formed has a strong cementing effect hence binding the soil together and increasing its strength. The Ca(OH)2 formed results in pozzolanic reactions which provides a further increment of strength in the longer term (Karin, Sven-Erik & Ronny, 2002).

Both subgrade and road base can be stabilized with cement. The thickness of a cement-stabilized road base depends upon the traffic loads, traffic volumes and the stability of the subgrade. The thickness of sub-base or subgrade cement stabilization on the other hand, depends up-on the nature of the soils and the conditions of the job. The effectiveness of soil cement stabilization depends on the type of soil being stabilized, the quantity of cement added, the degree of mixing, the time of curing, the dry density of the compacted mixture,

2.2.2. TYPES OF CEMENT USED TO STABILIZE SOIL

Normal (Type I) and Air Entraining (Type IA) Cements are most commonly used types of cement for soil stabilization. Sulfate Resistant Cement (Type II) and High Early Strength Cement (Type III) have also been successfully used for cement stabilization of soils. Each type of cement used for soil stabilization depends on the type of soil and its contents (Guyer, 2011).

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2.2.3. SOILS SUITABLE FOR CEMENT STABILIZATION

Most types of soil can be stabilized with cement ranging from gravelly and sandy soils to fine-grained silts and clays. It is generally more effective and economical to use it with granular soils due to the ease of pulverization and mixing and the smaller quantities of cement required (Hicks, 2002).

Fine-grained soils of low to medium plasticity can also be stabilized, but not as effectively as coarse-grained soils. It is difficult to mix cement with the soil of PI more than 30 so in such cases, lime needs to be added first to reduce the PI and improve workability before adding the cement. For soils that contain sulfates, it is advisable to use sulfate resistant cement for stabilization of the soils. If the pH of the soil is lower than 12.1, it is not advisable to use cement to stabilize the soil (Hicks, 2002).

2.2.4. DESIGN CEMENT CONTENT FOR CEMENT-STABILIZED SOILS

Determining the design cement content for cement-stabilized soils involves the classificationof the untreated soil (table 2.2.4-1) and the determination of the gradation of the soil to be stabilized and using it to select estimated cement content for moisture-density tests to determine the maximum dry moisture-density and optimum water content of the soil-cement mixture. Triplicate samples of the soil-cement mixture are then prepared for unconfined compression and durability tests at the cement content selected. The results of the unconfined compressive strength and durability tests are compared with the requirements shown in (table 2.2.4-2 and table 2.2.4-3).

The lowest cement content which meets the required unconfined compressive strength requirement and demonstrates the required durability is the design cement content.

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Table 2.2.4-1 Cement requirements (quantities) for various soils (Hicks, 2002)

Table 2.2.4-2 Minimum unconfined compressive strength at 7 days for cement and 28 days for lime, lime-cement, and lime-cement-fly ash stabilized soils (Guyer, 2011).

Usual Range in Estimated Cement Cement Contents

AASHTO Cement Requirement Content and That for Wet-Dry and

Soil Unified Soil

Percent by

Used in

Moisture-Density Test Freeze-Thaw Tests Classification Classification* Volume Weight Percent by Weight Percent by Weight

A-1-a GW, GP, GM, 5–7 3–5 5 3–5–7 SW, SP, SM A-1-b GM, GP, SM, SP 7–9 5–8 6 4–6–8 A-2 GM, GC, SM, SC 7–10 5–9 7 5–7–9 A-3 SP 8–12 7–11 9 7–9–11 A-4 CL, ML 8–12 7–12 10 8–10–12 A-5 ML, MH, CH 8–12 8–13 10 8–10–12 A-6 CL, CH 10–14 9–15 12 10–12–14 A-7 OH, MH, CH 10–14 10–16 13 11–13–15

Stabilized soil layer Minimum Unconfined Compressive strength, MN/m2

Flexible Pavement Rigid Pavement

Base course 5.171 3.447

Sub-base course, select material or subgrade

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Table 2.2.4-3 Durability requirements for stabilized soil (Guyer, 2011)

2.2.5. SOIL CEMENT STABILIZATION PROCESS

The basic soil cement stabilization processes include:  Assessment and testing

 Site Preparation  Introduction of cement  Mixing

 Compaction and shaping or trimming  Curing

2.2.6. OTHER STABILIZING AGENTS

Other soil stabilizing agents that have been used successfully include lime, bitumen/asphalt, fly ash, granulated blast furnace slag, filler materials.

Lime is used to stabilize medium, moderately fine, and fine-grained clay soils. When mixed in soil, lime reduces the soil moisture content thus reducing the plasticity of the soil, making it more rigid. Lime also increases strength and workability of the soil and reduces the ability of the soil to swell (Caterpillar, 2006).

Bitumen is used in soil stabilization because it makes the soil stronger and resistant to water and frost. Soil bitumen stabilization benefits from fewer-weather related delays Type of soil Stabilized Maximum Allowable Weight Loss After 12 Wet-Dry or

Freeze-Thaw Cycles percent of Initial Specimen Weight

Granular, PI < 10 11

Granular, PI > 210 8

Silt 8

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during construction and makes compaction easier and more consistent (Caterpillar, 2006).

Fly ash is normally mixed with lime and water to stabilize granular materials with few fines to produce a hard, cement-like mass. It acts as a pozzolan and as a filler to reduce air voids.

Filler, such as fine sand is added in soil stabilization to increase the number of solid particles and to fill any voids formed during stabilization. The filler itself does not react but increases the strength of the soil by acting as a stiffener. Filler material is normally used in the stabilization of peat and mud, as these soils often require large quantities of stabilizers thus, replacing part of the stabilizer with inexpensive filler can save costs. Therefore, there are many stabilizers used in soil stabilization, the effectiveness of each stabilizer depends on the quantity of the stabilizer, the soil type, storage temperature, degree of compaction, weather condition and availability of the stabilizer.

2.2.7. BENEFITS OF SOIL STABILIZATION (CATERPILLAR, 2006)

There are several advantages of soil stabilization:

 Improved soil strength, improved soil workability and improved durability  Cost reduction, dust reduction in work environment and reduction of soil volume

change due to temperature and moisture

 Conservation of energy and aggregates materials  Waterproofing the soil and improving runoff

 Functioning as a working platform for the project especially in wet weather  Control shrinkage and swell

 Improve load carrying and stress distribution characteristics  Improve substandard materials

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2.2.8. APPLICATION OF SOIL STABILIZATION

 Soil stabilization is used in Yards, parking places, sports grounds, road, and street, railway, and cable/pipe channel and storage construction sites

 It is used as foundations for buildings pools, landfill areas and bridges

 It is also use in the protection of adjacent structures, slopes of the rivers, lakes, roads and earth pressure

 Noise embankments and Erosion control and for frost and ground water protection layers

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2.3.0. METHODOLOGY

2.3.1. MOBILIZATION OF MACHINERY

Two categories of machinery are used for the execution of the soil cement stabilization works, these include:

a) Specialized Machine (figure 2.3.1-1)

The specialized machines used in this project are the Stabilizer Spreader and Reclaimer or Mixer Machine. The reclaimer is a 4-wheel base CATERPILAR machine Model SS-250 which is equipped with a 300 horse power engine that has a self-propelled hydraulic rotor drum with mixing chamber that could mix and cut up to depth of 650mm. it is used for the mixing of soil stabilizer agent with the existing earth/material.

Stabilizer Spreader Reclaimer

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b) Supporting Machines

Supporting machines are provided by I.Z.A Construction Company Sdn Bhd except those supporting machines that I.Z.A Construction does not have, such machines are rented from local supplier when the soil cement stabilization work started. The supporting machinery used for this project includes: Motor Grader, Vibratory Rollers and Water Trucks as shown in (figure 2.3.1-2).

Excavator

Excavator has been used in this project to excavate unsuitable materials, excavate for culvert installation, excavate interceptor and toe drains, and to cut and trim slopes

Motor Grader

The Motor Grader is used for site preparation to remove unwanted vegetation and all the undergrowth during the site preparation. It is also used to trim and level area in the road reserve before the compaction of the stabilized materials.

Vibratory Rollers

Vibratory Rollers are used for the compaction of the mixed stabilized materials.

Water Trucks

The Water Trucks are used to supply water to the Reclaimer machine during the mixing process if the site condition requires and to supply water for curing.

Excavator Motor Grader Vibratory Roller Water Truck

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2.3.2. SITE CLEARANCE AND DEMOLITION WORKS

The Right of Way (R.O.W) was surveyed and Right of Way Limits were indicated by wooden pegs. Photographs of structures, landscaping trees and shrubs, fences, telephone, electrical poles and anything that are payable were then taken before site clearing and demolition of existing structures commenced. Site clearing of trees, vegetation, undergrowth, bushes and demolition of existing structures in the entire area of the road reserve are then carried out by hydraulic excavators from CH O towards increasing Chainage. Demolished structures consists of two storey brickwork building, one storey masonry building, two storey masonry building, one storey timber building, two storey timber building, fences and gates, pipe culverts, box culverts, and inlet/outlet structures for culvert No.1 which is to be extended.

2.3.3. EARTHWORKS

Before the earthwork commenced, surveying and setting out of center line was carried out using a theodolite and a tripod for Original Ground Level (OGL) and pegged at 10 meters interval lengthwise. Survey pegs were also placed at the toe limits located at 5 meter away from the center line.

Where the OGL was higher than the finished road level, the road centerline and slope batters were set out and topsoil stripped, the area is then cut by hydraulic excavators. The cut materials were then hauled using Dump trucks to the filling area. Slopes trimming and slope or erosion protection (closed turf) was then immediately carried out for the slopes formed.

Whereas in areas where the OGL was lower than the finished road level, topsoil was stripped off up to the filling limits and suitable cut materials hauled by Dump trucks from the cut area are placed and spread out using back pusher. The filling with suitable materials was carried out in layers and each layer compaction by vibratory roller until relative compaction of at least 90% of maximum dry density is obtained.

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Figure 2.3.3-1 Road Cross Section in Cut and Fill Areas

2.3.4. UNSUITABLE SOIL REPLACEMENT WITH GEOTEXTILE SEPARATOR

Problem with soft subgrade

The stability and the durability of any structure depend on how stable and durable its foundation is. For this Anak Kurau road project however, the subgrade material is very weak. It therefore needs to be replaced with granular fill materials which will then be compacted adequately to obtain a more stable subgrade. But fill materials can deteriorate, leading to a substantial damage of pavement. Such fill materials deteriorate due to intrusion of stone base, pumping of subgrade soil and infiltration of water from subgrade as illustrated (figure 2.3.4-1) [5].

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Figure 2.3.4-1 Reasons for deterioration of fill materials

Problem Solution

This problem can be solved by using geotextiles. In road constructions, Geotextiles have been widely used for filtration and in order to prevent migration and mingling of materials, yet allowing free movement of water. In this project, a geotextile is used as a separator by placing it between the soft subgrade and the granular fill material. It acts as a filter to allow water but not fine material to pass through it, preventing any mixing of the soft subgrade soil and granular material under the action of the construction equipment or subsequent traffic [5].

Figure 2.3.4-2 Importance of geotextile separator.

Unsuitable soil replacement by using non-woven geotextile as a separator consists of excavation of unsuitable material to a sufficient depth, laying a type „A‟ non-woven

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geotextiles as a separator with a minimum overlap of about 500mm (figure 2.3.4-3), followed by placement of river sand and then compaction. Filling with suitable fill materials continues to the specified embankment height as shown in (figure 2.3.4-4) and the unsuitable soil excavated is then leveled at the sides of roadway.

Figure 2.3.4-3 Joining of Geotextile separator by Overlap

Figure 2.3.4-4 Typical details for standard fill section treatment type 1 (sand replacement with geotextile separator

2.3.5. DRAINAGE WORK

It is important to ensure that there is an adequate drainage in any road construction in order to avoid road damage due to both surface water and underground water.

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The drainage works for this project involved the construction of surface and subsoil drains, installation of new precast box and pipe culvert, extension of existing precast box culvert at CH 0, construction of sumps and wing walls both as inlet and outlet structures, not forgetting the excavation and backfilling for such works listed above.

The surface drains for this project involved the excavation of interceptor drains and toe drains and the installation of precast concrete U-drains.

Sub-Soil Drainage

For sub-soil drains, concrete porous pipes were installed with the details as shown in (figure 2.3.5-1). The trench to receive the concrete porous pipe is first excavated followed by placing of geotextile with 300 mm overlap. The porous concrete pipe is then placed on a less thick aggregate layer and its sides and top also fill with aggregates. This aggregate layer is again covered with geotextile before filling granular materials until the finished road level is obtained.

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Culvert works

Trench Method is used to install both precast reinforced concrete pipe and box culverts based on the following procedures:

 After the Surveyor provides alignment of the Pipe Culvert, Invert Level, R.O.W. and all necessary point, Temporary diversion of water flow is constructed

 The trench to receive the culvert is then excavated, followed by Laying and compaction of bedding materials.

 Pipe or box culvert is then laid and checked for alignment before inserting subsequent pipe or box culverts. Both sides of culvert are temporary secured using timber wedges to prevent sideways movement.

 Upon completion of installation, both sides of the culvert are backfilled simultaneously with suitable granular backfill in layer of 150mm thick and compact to 90% Maximum Dry Density.

 Wingwalls and headwalls are then constructed at upstream and downstream of the culvert with concrete G 20/20 and structural steel fabric B 705 placed as bedding The bedding type and installation locations for all the culvert except the giant culvert is as shown in (figure 2.3.5-2).

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2.3.6. MATERIAL SAMPLING, TESTING AND MIX DESIGN

Tests are conducted, both before and during the progress of soil cement stabilization to ensure compliance with the requirements of the Standard Specification for Road Works (JKR/SPJ/1988), Guidelines for inspection &Testing of Road Works. The tests are conducted by MMTS-IETS JOINT VENTURE Building & Construction Materials Testing Laboratory and by Tasek Soil & Materials Lab Sdn. Bhs (TSML) which is specialized in soil, concrete and asphaltic concrete testing.

The Laboratory testing carried out on the Untreated Soil samples consisting of Imported soil fill, river sand fill, and imported soil-river sand mixture includes: Sieve Analysis (Gradation), Atterberg Limits, Soil Classification, Maximum Dry Density (MDD), Optimum Moisture Content (OMC), Unconfined Compressive Strength (UCS) and Californian Bearing Ration (CBR).

It is important that those tests are carried out both before and during soil cement stabilization. Gradation or particle size distribution is particularly important in determining the stabilizer content; more fines require higher cement content or even addition of lime before adding the cement. Uniform gradation results in uniform mixing, uniform compaction and hence uniform strength development. The test method used in sieve analysis is MS 30 Part 4: 1995. Atterberg Limits (Plastic Limit, PL and Liquid Limit, LL) are used to determine active clay content which helps in deciding if there is need to increase the cement content. The PL and LL test were conducted by following the test procedure of BS: 1377: Part 2: 1990, Clause 4.5. Moisture-density relationship is used to determine the degree of compaction of the material, high densities obtained is an indication that the shear strength and elastic modules improved and the ingress of water is reduced. Finally, CBR and UCS tests are used to determine the strength of the soil attained.

Determination of the Mix Design is by trial and error. To determine the mix design (required cement content) for the soil cement stabilization, different dosage of cement (2.5%, 3.5% and 5% cement) is admixed with the untreated material thoroughly until a uniform color is obtained, the optimum moisture content is then added. Specimens were

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then prepared for UCS test which was conducted at the age of 3 days and 7 days, the results obtained are shown in (table 2.4.1.4-1, table 2.4.1.4-2 & table 2.4.1-4) and for soil, sand and soil mixed with sand respectively.

2.3.7. GRADING TO PROFILE

Before the commencement of the soil cement stabilization work, the exposed platform is checked for reduced level to ensure that the reduced level of the working platform is within ±12mm of the design level for the base of next layer. Where the reduced level of the working platform is not within ±12mm, motor Grader was used to level and grade the existing material to the required new profile.

2.3.8. SPREADING THE STABILIZING AGENT

After the surface was leveled and graded with motor grader, the determined stabilization area was marked and the required quantity of cement was spread over the areas to be stabilized. Spreading of the stabilizing agent was done using a purpose built additive spreader to the design percentage at a spreading rate of +/-5 % absolute value.

2.3.9. PULVERIZING AND MIXING

Pulverizing and dry (primary) mixing by use of a purpose built Reclaimer- Stabilizer CMI RS500 to the design depth starts after spreading of the stabilizing agent on the prepared platform has reached a length of +/-60 meters and a minimum width of 3.0 meters. Where necessary, water is added during mixing through the mixing chamber of the Reclaimer- Stabilizer CMI RS500 to ensure that the moisture content of the mix materials does not fall below 2% of Optimum Moisture Content (OMC). The secondary mixing (called wet run) is to ensure the chemical reaction between the stabilizing agent

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and existing material and to ensure the highest density of the mixture after compaction since maximum Dry Density (MDD) is achieved at OMC.

2.3.10. PRELIMINARY COMPACTION

A Vibratory Roller was used for preliminary compaction to enable the Motor Grader to work on the loose stabilize material. Vibratory roller with 10 metric tons static mass ideal was used with rolling pattern of two (2) static passes and six (6) vibration passes. The critical variable in achieving densification with minimum effort is moisture content of the material being compacted. Compaction by vibratory roller is continued until a maximum Dry Density (MDD) of 95% or more is achieved as confirmed by laboratory test results. Final Rolling is then done using pneumatic tire roller after grading to chamber to ensure a better compaction and surface.

2.3.11. GRADING TO CAMBER

A Motor Grader was used to grade and form the desired camber; undulations were also eliminated by the motor grader. The grading and shaping of the stabilized treated layer is done to ensure that the finished levels are within +/- 6mm of the required reduced levels. During the process of grading and shaping, the vibratory roller is used for the compaction.

2.3.12. FINAL ROLLING

Final rolling is done after grading or trimming and shaping. Pneumatic tire roller is used for the final rolling so as to ensure a better compaction and surface.

2.3.13. CURING

Curing was done for seven days after soil cement stabilization. Curing is to increase the rate of hydration of the cement used as stabilizing agent and to prevent rapid setting. The main purpose of curing is so as to obtain the intended/required/design strength after

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cement stabilization and to maintain a uniform temperature of the stabilized subgrade to prevent thermal shrinkage cracking.

2.3.14. QUALITY CONTROL

Testing was carried out accordingly during the soil cement stabilization work. The tests that have been carried out during the stabilization process include:

 Field Density Test to determine the degree of compaction of the stabilized layer,

 Moisture Content test is done both before and after mixing to ensure the relativity of moisture to the mix. This is because the best mixing when using cement is at the Optimum Moisture Content and so is the Maximum Dry Density,

 Cube test, UCS test to give an indication of the tensile strength of the material after stabilization and

 CBR test to evaluate the mechanical strength of the subgrade materials after stabilization.

2.3.15. RECOMMENDATION

1. It is not advisable to proceed with the stabilization under the following climatic conditions:

2. The ambient temperature is below 50C or above 380C 3. It is raining or likely to rain

4. The wind is sufficiently strong to cause the additive to become airborne

5. During conditions that may cause danger to people, property or the environment

2.3.16. SITE CLEANING AND DEMOBILIZATION

Upon completion of the soil cement stabilization work, all waste materials which resulted from the work is disposed to a dump site approved by JKR, construction machinery demobilized from the site before and the project handed over for the pavement works.

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28 0 20 40 60 80 100 120 0 5 10 % Passing Sieve Size

Particle Size Distribution Curve 2.4.0. RESULTS AND DISCUSSION

2.4.1. RESULTS

2.4.1.1. Sieve Analysis

Test Conditions; Temperature: 28.6 0C Relative Humidity: 53%

Table 2.4.1-1 Sieve Analysis Results

Figure 2.4.1-1 Particle Size Distribution Curve

Sieve Size Weight Retain ed % Retained % Passing 50.0 mm 37.5 mm 28.0 mm 25.0 mm 20.0 mm 14.0 mm 12.5 mm 0.0 0.0 100 10.0 mm 44.6 3.7 96.3 6.30 mm 47.8 4.0 92.3 5.00 mm 42.2 3.5 88.8 3.35 mm 51.3 4.3 84.5 2.36 mm 57.6 4.8 79.7 1.18 mm 43.3 3.6 76.1 0.600 10.1 0.8 75.3 0.425 1.9 0.2 75.1 0.300 3.3 0.3 74.8 0.150 3.6 0.3 74.5 0.075 4.0 0.3 74.2 Pan 0.0

Weight Before Wash: 1200.5 grams Weight After Wash: 309.7 grams

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2.4.1.2. Dry Density/Moisture Content Relationship for site soil

Test Condition: Temperature = 29.4 0C, Relative Humidity = 57% & Volume 998.4 cm3

Table 2.4.1.2-1 Dry Density/Moisture Content Relationship for site soil

Figure 2.4.1.2-1 Dry Density / Moisture Content Relationship site soil

Test No. 1 2 3 4 5

Mass of Soil + Mould (g) 7533 7632 7701 7745 7688 Mass of Mould (g) 5395 5395 5395 5395 5395 Mass of Compacted Soil (g) 2138 2237 2306 2350 2293 Bulk Density of Soil (Mg/m3) 2.141 2.241 2.31 2.354 2.297 Container No. B17 B5 B13 B3 B10 Mass of Container + Wet Soil (g) 139.4 125.3 140.6 148.8 164.2 Mass of Container + Dry Soil (g) 123.8 110.2 122.8 126.8 137.9 Mass of Container (g) 36.3 35.5 38.3 38.1 37.6 Mass of Dry Soil (g) 87.5 74.7 84.5 88.7 100.3 Mass of Moisture (g) 15.6 15.1 17.8 22 26.3 Moisture Content (%) 17.8 20.2 21.1 24.8 26.2 Measurement uncertainty for Moisture content (%) 0.33 0.39 0.34 0.33 0.29 Dry Density (Mg/m3) 1.817 1.864 1.908 1.886 1.82 Measurement uncertainty for Dry Density (Mg/m3) 0.005 0.005 0.005 0.004 0.004

1.8 1.82 1.84 1.86 1.88 1.9 1.92 1.94 0 5 10 15 20 25 30 Dry Density (Mg/m3) Moisture Content (%)

Dry Density/Moisture Content Relationship for Site Soil

MDD = 1.839 Mg/m3 ρs= 1.316 Mg/m3 OMC = 22.7 % OMC = Optimum Moisture Content MDD = Maximum Dry Density ρs = Bulk density of calibrating sand

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Table 2.4.1.2-2 Dry Density/Moisture Content Relationship for River Sand fill

Test Condition: Temperature = 29.9 0C, Relative Humidity = 62% and Volume 949 cm3

Figure 2.4.1.2-2 Dry Density / Moisture Content Relationship River Sand fill

Test No. 1 2 3 4 5

Mass of Soil + Mould (g) 7245 7455 7698 7602 7450 Mass of Mould (g) 5478 5478 5478 5478 5478 Mass of Compacted Soil (g) 1767 1977 2220 2124 1972 Bulk Density of Soil (Mg/m3) 1.862 2.083 2.339 2.238 2.078 Container No. C2 C8 C13 C18 C19 Mass of Container + Wet Soil (g) 209.0 223.0 198.0 221.0 205.0 Mass of Container + Dry Soil (g) 204.0 215.9 190.4 210.0 193.6 Mass of Container (g) 101.2 101.2 101.3 101.4 101.3 Mass of Dry Soil (g) 102.8 114.7 89.1 108.6 92.3 Mass of Moisture (g) 5.00 7.10 7.60 11.00 11.40 Moisture Content (%) 4.9 6.2 8.5 10.1 12.4 Measurement uncertainty for Moisture content (%) 0.28 0.25 0.32 0.26 0.31 Dry Density (Mg/m3) 1.776 1.962 2.155 2.032 1.850 Measurement uncertainty for Dry Density (Mg/m3) 0.005 0.005 0.006 0.005 0.005

1.7 1.8 1.9 2 2.1 2.2 0 2 4 6 8 10 12 14 Dry Density (Mg/m3₎ Moisture Content (%)

Dry Density/Moisture Content Relationship for River Sand

MDD = 2.156 Mg/m3

ρs=1.186 Mg/m3

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Table 2.4.1.2-3 Dry Density/Moisture Content Relationship for imported earth fill

Test Condition: Temperature = 29.9 0C, Relative Humidity = 63% and Volume 949 cm3

Figure 2.4.1.2-3 Dry Density / Moisture Content Relationship for imported earth fill

2.4.1.3. Atterberg Limits

Test No. 1 2 3 4 5

Mass of Soil + Mould (g) 7188 7310 7468 7422 7314 Mass of Mould (g) 5395 5395 5395 5395 5395 Mass of Compacted Soil (g) 1793 1915 2073 2027 1919 Bulk Density of Soil (Mg/m3) 1.889 2.018 2.184 2.136 2.022 Container No. 17 24 28 32 34 Mass of Container + Wet Soil (g) 85.2 76.3 92.4 78.1 79.4 Mass of Container + Dry Soil (g) 80.0 71.5 84.2 71.4 71.8 Mass of Container (g) 41.2 _42.2 _41.1 _41.0 _41.3 Mass of Dry Soil (g) 38.8 29.3 43.1 30.4 30.5 Mass of Moisture (g) 5.2 4.8 8.2 6.7 7.6 Moisture Content (%) 13.4 16.4 19.0 22.0 24.9 Measurement uncertainty for Moisture content (%) 0.74 0.98 0.67 0.95 0.96 Dry Density (Mg/m3) 1.666 1.734 1.836 1.750 1.619 Measurement uncertainty for Dry Density (Mg/m3) 0.010 0.013 0.009 0.011 0.010

1.6 1.65 1.7 1.75 1.8 1.85 0 5 10 15 20 25 30 Dry Density (Mg/m3₎ Moisture Content (%)

Dry Density/Moisture Content Relationship for Dark Brown Sandy Clayed Silt

MDD = 1.839 Mg/m3

ρs=2.80 Mg/m3

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32 0 10 20 30 40 50 60 70 0 10 20 30 40 50 Moisture Content (%) Number of Blows

Liquid Limit Graph

Test Condition: Temperature = 29.4 0C, Relative Humidity = 57 & Test Date:16/10/2012

Table 2.4.1.3-1 Plastic Limit Test Results

Plastic Limit Test No. 1 2

Container No. A2 A4

Mass of Container + Wet Soil (g) 26.4 25.1

Mass of Container + Dry Soil (g) 24.1 23.1

Mass of Container (g) 15.0 15.4

Mass of Moisture, M1 (g) 2.3 2.0

Mass of Dry Soil, M2 (g) 9.1 7.7

Moisture Content (M1 / M2) X 100 (%) 25.3 26.0

Measurement uncertainty for Moisture content (%) 3.2 308.0

Average Moisture Content (%) 25.6

Table 2.4.1.3-2 Liquid Limit Test Results

Liquid Limit Test No. 1 2 3 4 5

Number of Blows 11.00 17.00 30.00 37.00 47.00

Container No. A1 A3 A7 A5 A9

Mass of Container + Wet Soil (g) 29.20 30.50 27.30 29.80 28.40

Mass of Container + Dry Soil (g) 23.70 25.00 22.90 24.80 24.10

Mass of Container (g) 14.60 15.50 14.60 14.90 14.70

Mass of Moisture, M1 (g) 5.50 5.50 4.40 5.00 4.30

Mass of Dry Soil, M2 (g) 9.10 9.50 8.30 9.90 9.40

Moisture Content (M1 / M2) X 100 (%) 60.40 57.90 53.00 50.50 45.70

Measurement uncertainty for Moisture content (%)

3.63 3.44 3.86 3.20 3.31

Figure 2.4.1.3-1 Liquid Limit Graph

Proportion Retained on 425 um Sieve:

Liquid Limit (LL): 55% Plastic Limit (PL): 26% Plastic Index (PI): 29%

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2.4.1.4. Unconfined Compressive Strength (UCS) Test Result

Table 2.4.1.4-1 Design Mix (Trial Mix) for Soil-Sand Mixture

Water-Cement Ratio Weight (Kg) Nominal Size L x W x H (mm) Condition of Spacemen Max. Load (KN) Type of Failure Density (Kg/m3) Ultimate Strength (MN/m2) at 3 days 7 days 5% Cement 6.910 150x150x150 Dry 128.6 Normal 2047 0.6 5.7 3.5% Cement 7.125 150x150x150 Dry 102.4 Normal 2111 0.8 4.6 2.5% Cement 7.140 150x150x150 Dry 62.3 Normal 2116 1.3 2.8

Figure 2.4.1.4-1 Ultimate Strength Design Mix for Soil and Sand Mix

0 1 2 3 4 5 6 0 2 4 6 8 Ultimate Strength (MN/m2₎ Age (days) 2.5% Cement 3.5% Cement 5% Cement

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Table 2.4.1.4-2 Design Mix (Trial Mix) for Soil

Water-Cement Ratio Weight (Kg) Nominal Size L x W x H (mm) Condition of Spacemen Max. Load (KN) Type of Failure Density (Kg/m3) Ultimate Strength (MN/m2) at 3 days 7 days 5% Cement 5.710 150x150x150 Dry 80.4 Normal 1692 0.3 3.6 3.5% Cement 5.705 150x150x150 Dry 48.6 Normal 1690 0.6 2.2 2.5% Cement 5.260 150x150x150 Dry 20.5 Normal 1559 1.2 0.9

Figure 2.4.1.4-2 Ultimate Strength Design Mix for Soil

0 0.5 1 1.5 2 2.5 3 3.5 0 2 4 6 8 Ultimate Strength (MN/m2₎ Age (days) 2.5% Cement 3.5% Cement 5% Cement

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Table 2.4.1.4-3 Design Mix (Trial Mix) for Sand

Water-Cement Ratio Weight (Kg) Nominal Size L x W x H (mm) Condition of Spacemen Max. Load (KN) Type of Failure Density (Kg/m3) Ultimate Strength (MN/m2) at 3days 7days 5% Cement 6.610 150x150x150 Dry 75.2 Normal 1959 0.4 3.3 3.5% Cement 6.490 150x150x150 Dry 47.5 Normal 1923 0.8 2.1 2.5% Cement 6.310 150x150x150 Dry 40.2 Normal 1870 1.1 1.8

Figure 2.4.1.4-3 Ultimate Strength Design Mix for Sand

2.4.1.5. CBR Values before Soil Cement Stabilization

Jack/Load rig no. 0.0318 KN/div

Mass of Surcharge: 4.5 kg Test date: 5/3/2013

0 0.5 1 1.5 2 2.5 3 3.5 4 0 2 4 6 8 Ultimate Strength (MN/m2₎ Age (days) 2.5% Cement 3.5% Cement 5% Cement

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Table 2.4.1.5-1 CBR Values before Soil Cement Stabilization

CH 10, Before Soil Cement Stabilization Jack/Load rig no. 0.0318 KN/div

Mass of Surcharge: 4.5 kg Test date: 5/3/2013 Penetration of Force on Plunger Standard CBR Value Plunger (mm) Load Guage KN Force (KN) (%)

0 0 -0.5 35 1.11 1 80 2.54 1.5 120 3.82 2 150 4.77 2.5 175 5.57 13.24 42.03

CH 260, Before Soil Cement Stabilization Jack/Load rig no. 0.0318 KN/div

0 0 -0.5 30 0.95 1 60 1.91 1.5 100 3.18 2 130 4.13 2.5 160 5.09 13.24 38.43 CH 510, Before Soil Cement Stabilization

0 0 -0.5 40 1.27 1 56 1.78 1.5 70 2.23 2 87 2.77 2.5 100 3.18 13.24 24.02 CH 760, Before Soil Cement Stabilization

0 0 -0.5 30 0.95 1 55 1.75 1.5 80 2.54 2 110 3.50 2.5 130 4.13 13.24 31.22

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CH 1010, Before Soil Cement Stabilization

0 0 -0.5 10 0.32 1 20 0.64 1.5 31 0.99 2 43 1.37 2.5 52 1.65 13.24 12.49

CH 1260, Before Soil Cement Stabilization (same for CH1510)

0 0 -0.5 20 0.64 1 30 0.95 1.5 40 1.27 2 50 1.59 2.5 55 1.75 13.24 13.21

0 0 -0.5 30 0.95 1 60 1.91 1.5 75 2.39 2 85 2.70 2.5 95 3.02 13.24 22.82

0 0 -0.5 30 0.95 1 52 1.65 1.5 65 2.07 2 83 2.64 2.5 90 2.86 13.24 21.62

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2.4.1.6. CBR Values after Soil Cement Stabilization

Mass of Surcharge: 4.5 kg Test date: 21/3/2013

Table 2.4.1.5-2 CBR Values after Soil Cement Stabilization

CBR at CH 115, three days after soil cement stabilization

Jack/Load rig no. 0.02577 KN/div Mass of Surcharge: 4.5 kg

Penetration of Force on Plunger Standard

Plunger (mm) Load Guage KN Force (KN) CBR Value 0 0 -0.5 165 4.25 1 274 7.06 1.5 340 8.76 2 420 10.82 2.5 430 11.08 13.2 83.95 3 475 12.24 3.5 490 12.63 4 501 12.91 4.5 510 13.14 5 515 13.27 20 66.36 Ave. 75.15

CBR at CH 125 three days after soil stabilization

Penetration of Force on Plunger Standard CBR Value Plunger (mm) Load Guage KN Force (KN) (%)

0 0 -0.5 81 2.09 1 160 4.12 1.5 250 6.44 2 330 8.50 2.5 410 10.57 13.20 80.04 3 460 11.85 3.5 495 12.76 4 520 13.40 4.5 530 13.66 5 555 14.30 20.00 71.51 Average 75.78

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CH 150, Age: 3days after Soil Cement Stabilization

0 0 -0.5 139 3.58 1 220 5.67 1.5 290 7.47 2 361 9.30 2.5 429 11.06 13.2 83.75 3 475 12.24 3.5 520 13.40 4 594 15.31 4.5 615 15.85 5 625 16.11 20 80.53 Average 82.14

CH 110, Age: 7days after Soil Cement Stabilization Jack/Load rig no. 0.02577 KN/div

0 0 -0.5 185 4.77 1 283 7.29 1.5 420 10.82 2 517 13.32 2.5 580 14.95 13.2 113.23 3 623 16.05 3.5 654 16.85 4 680 17.52 4.5 710 18.30 5 725 18.68 20 93.42 Average 103.32

Industrial Internship Project Report-Odu Paul-14115

INDUSTRIAL INTERNSHIP PROJECT REPORT

OCTOBER 2012 – APRIL 2013

AT

I.Z.A CONSTRUCTION COMPANY SDN BHD

ODU PAUL DUKU ERIKOLE

14115

INDUSTRIAL INTERNSHIP PROJECT REPORT

01

OCTOBER 2012 – 12

APRIL 2013

SOIL CEMENT STABILIZATION OF PAVEMENT

SUBGRADE FOR A NEW 2.5KM ROAD IN ANAK KURAU

SUBMITTED TO

CENTER FOR STUDENT INTERNSHIP, MOBILITY

AND ADJUNCT LECTURESHIP (CSIMAL)

UNIVERSITI TEKNOLOGI PETRONAS

BY

ODU PAUL DUKU ERIKOLE - 14115

DEPARTMENT OF CIVIL ENGINEERING

EXECUTIVE SUMMARY

ACKNOWLEDGEMENTS

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES

1.0. INTRODUCTION

2.0. INTERNSHIP PROJECT REPORT

Liquid Limit Graph