AN INTERNSHIP REPORT AT

GHANA HIGHWAYS MATERIAL

SECTION.

ABSTRACT

This report is a compilation of the education I received and the tasks I was engaged in
during my internship at the Ghana Highway Authority Materials Division. This training
period lasted for a total of six weeks, beginning on from 31st October to 16th December
2022. Over the course of the training period, a numerous amount of lab tests were
conducted on soil and concrete samples alike. Some of these tests included but are not
limited to, Grading, Atterberg Limits Determination, Elongation tests on coarse material,
Flakiness Tests, Compressive strength tests, Concrete Mix design, Compaction and CBR
Testing, Apparent and Bulk Density determination, Free soil tests and many others.
Running these tests has broadened my perspective on the geotechnical difficulties
encountered during the progression of many engineering projects and how they can
possibly be tackled in the future.

ACKNOWLEDGEMENT

I want to sincerely thank my lab manager and my lab mates for their passion and
commitment to teaching me about this geotechnical field of work. Their collaboration and
desire to share knowledge and assist me have been a huge help to me during this learning
phase and have helped to make my time at work productive and enjoyable.

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 TABLE OF CONTENTS

ABSTRACT………………………………………………………………..1
ACKNOWLEDGEMENT……………………………………………….1
INTRODUCTION……………………………………………………….3
LAB TEST…………………………………………………………………3
SOIL GRADING TEST………………………………………………….4
COMPACTION………………………………………………………….5
CBR TESTING……………………………………………………………9
IMPACT VALUE TEST…………………………………………………..15
LOS ANGELES ABRASION TEST…………………………………….19
ATTERBERG LIMIT TEST………………………………………………..21
CONCLUSION……………………………………………………………..24
REFERENCES………………………………………………………………..24

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 Introduction

All public highways and associated facilities in Ghana are managed, controlled, developed,
and maintained by the Ghana Highway Authority, a national corporate agency. The
following tasks have been assigned to the authority in order to carry out this duty:

• To plan, develop, maintain, and administer the truck road network, ferries traffic devices
and any related works;

• To control traffic on truck roads with the aim of providing safe and adequate
infrastructure for road transportation commensurate with the economic development of
Ghana;

• To undertake research or collaborate with any research organization with the view to
facilitating its planning, development, maintenance and administrative activities;

• To collect and preserve data relating to its functions as it considers expedient;

• To collect toll and other revenue on behalf of the Government on the truck road network;

• To negotiate concession agreements with private sector entities;

• To carry on any other activity as appear to the Authority to be conducive or accidental to

the attainment of its responsibility;

• To develop human capital adequate to achieve the mission of GHA.

The Ghana Highway Authority is divided into three main departments which include
Development, administration, and maintenance. Under the development department is the
Materials section where most lab tests are performed on prospective materials to be used
in various projects.

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 SOIL GRADING TEST
According to the various sizes of the soil particles present, coarse-grained soils can be
categorized using soil gradation, also known as particle size distribution. Geotechnical
engineering places a lot of importance on soil gradation tests since the outcomes serve as
indicators of things like soil compressibility, drainage, and shear strength as they relate to
specific engineering projects.

Typically, the findings of a sieve analysis or a hydrometer study are used to grade the soil. A
washed sieve analysis is the primary test typically conducted at the Ghana Highway
Authority Central Materials Lab for the majority of projects.

Procedure

● To get a representative sample for the test, the soil sample is first cut in half and run
through the riffle boxes.
● Starting with the pan and working up to the 19.0mm sieves in order of increasing size, the
sieves are positioned from the bottom up.
● A quartered soil sample is weighed and then run through a set of sieves, weighing about
3200 g.
● The quantity of soil retained on each sieve is collected into a bowl, its weight is recorded,
and it is then preserved in an oven to subsequently determine its moisture content.
● Both samples are weighed separately, and one is put in the oven to measure the moisture
content.
● Once practically all of the clay material has been removed, the remaining sample is filtered
using a 0.075mm sieve.
● The cleaned sample is then allowed to dry in the oven for 24 hours before being sieved once
more, this time with sieves positioned in ascending order from 0.075 up to the 9.5 mm
sieve.
● Each sieve's retained material is once more weighed and recorded.
● The acquired results are utilized to fill out the grade sheet below, which is then used to
produce a PSD curve.

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COMPACTION

It is the act of applying mechanical compactive effort or stress to soil in order to densify it
by reducing the spore spaces between the soil particles. A well compacted soil reduces
both water infiltration and drainage.

Apparatus

4.5kg rammer / compaction hammer

Cylindrical mold made of metal with specified dimensions according to ASSHTO standards.

Sample extruder for removing compacted specimens

Steel straightedge used for trimming compacted sample

Mixing tools - Mixing pan, scoop, trowel

Lid to cover already mixed soil from losing moisture

An electric scale

Sample Preparation

If the sample is damp, dry it until it becomes friable under a trowel. Drying may be in air or

by use of a drying apparatus maintained at a temperature not exceeding 60°C (140°F).

Thoroughly break up aggregations in a manner that avoids reducing the natural size of

individual particles.

Obtain a representative test sample of the mass required by the agency by passing the

material through the sieve required by the agency.

In instances where the material is prone to degradation, i.e., granular material, compaction

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samples with differing moisture contents should be prepared for each point.

If the sample is plastic (clay types), it should stand for a minimum of 12 hours after the

addition of water to allow the moisture to be absorbed. In this case, several samples at

different moisture contents should be prepared, put in sealed containers and tested the
next

day.

Procedure

During compaction, rest the mold firmly on a dense, uniform, rigid, and stable foundation
or

base. This base shall remain stationary during the compaction process.

1. Determine the mass of the clean, dry mold. Include the base plate, but exclude the

extension collar. Record the mass to the nearest 1 g.

2. Thoroughly mix the selected representative sample with sufficient water to dampen it to

approximately 4 to 8 percentage points below optimum moisture content. For many

materials, this condition can be identified by forming a cast by hand.

a. Prepare individual samples of plastic or degradable material, increasing moisture

contents 1 to 2 percent for each point.

b. Allow samples of plastic soil to stand for 12 hrs.

3. Form a specimen by compacting the prepared soil in the mold assembly in

approximately

equal layers. For each layer:

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a. Spread the loose material uniformly in the mold.

Note 2: It is recommended to cover the remaining material with a non-absorbent sheet or

damp cloth to

minimize loss of moisture.

b. Lightly tamp the loose material with the manual rammer or other similar device, this

establishes a firm surface.

Compact each layer with uniformly distributed blows from the rammer. See Table 1

for mold size, number of layers, number of blows, and rammer specification for the

various test methods. Use the method specified by the agency.

d. Trim down material that has not been compacted and remains adjacent to the walls of

the mold and extends above the compacted surface.

4. Remove the extension collar. Avoid shearing off the sample below the top of the mold.

The material compacted in the mold should not be over 6 mm

(¼ in.) above the top of the mold once the collar has been removed.

5. Trim the compacted soil even with the top of the mold with the beveled side of the

straightedge.

6. Clean soil from exterior of the mold and base plate.

7. Determine and record the mass of the mold, base plate, and wet soil to the nearest 1g or
better.

8. Determine and record the wet mass (Mw) of the sample by subtracting the mass in Step
1

from the mass in Step 6.

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9. Calculate the wet density, in kg/m3 by dividing the wet mass by the measured

volume (Vm).

10. Extrude the material from the mold.

Determine and record the moisture content of the sample in accordance with the FOP for

AASHTO T 255 / T 265.

12. Prepare another individual soil sample to repeat the test.

14. Add sufficient water to increase the moisture content of the soil by 1 to 2

percentage points and carry through with the test again.

15. Continue determinations until there is either a decrease or no change in the wet mass.

There will be a minimum of three points on the dry side of the curve and two points on

the wet side.

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CBR TESTING

CBR testing (California Bearing Ratio) is a strength test generally performed to provide data
on prospective soil samples to be used for road pavement design. It is a penetrative test
used to evaluate the strength of the subgrade soil of roads, pavements and foundations. In
road design, it enables an appropriate selection of suitable pavement thickness for the
calculated traffic density. In foundation design, it is indicative of the stability of the
underlying ground and settlement.

A CBR Test is done by testing the pressure required to penetrate a soil sample with a
plunger of the standard area and measuring this.

This measurement is divided by the pressure needed to achieve an equal penetration on a

standard, high quality crushed rock material. The harder the surface, the higher the CBR
value.

The CBR test can be carried out on soils with a maximum particle size of 20mm.

Sample Preparation

The CBR test is carried out on material passing a 20mm test sieve. If soil contains particles
larger than this the fraction retained on 20mm shall be removed before preparing the test
sample. If this fraction is greater than 25% of the original sample the test is not applicable.
The moisture content of the specimen orspecimens can be adjusted if necessary.

The moisture content used is normally to the Optimum Moisture Content (OMC), This value
can be obtained from a dry density against moisture content curve constructed from the
data of a compaction test carried out beforehand.

3 prepared soil samples are compacted with the 4.5 kg hammer for compactive blows of 56
blows, 25 blows, and 10 blows respectively.

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After removing the cutting shoe from the mold, the ends of the sample are cut and
trimmed so that they are flushed with the ends of the mold body. Any cavities observed are
filled in with fine soil and well pressed in.

After weighing the mass of the compacted sample and the mold after each compaction the
soil is not extruded from the mold but rather allowed to soak in water for 4 days. Before
soaking, a base plate is attached to the mold and a plate placed on top of the face to seal it.

Soaking

The test sample prepared normally represents the material shortly

after compaction in road works. However, if the material is likely to be

subjected to an increase in moisture content, either from rainfall, ground-water or

seepage through the surfacing it is possible that its strength and hence, CBR, will

drop as the moisture content increases. In an attempt to estimate these effects

CBR samples are usually soaked in water for 4 days prior to penetration testing.

PENETRATION TEST PROCEDURE;

APPARATUS

a) A cylindrical metal plunger, the lower end of which shall be of hardened steel

and have a nominal cross-sectional area of 1935 mm2, corresponding to a

specified diameter of 49.65±0.10 mm.

b) A machine for applying the test force through the plunger, having a means for

applying the force at a controlled rate. The machine shall be capable of

applying at least 45 KN at a rate of penetration of the plunger of 1 mm/min to

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within ±0.2 mm/min.

c) A calibrated force-measuring device, usually a load ring or proving ring. The

device will be supported by the cross-head of the compression machine to prevent its own
weight from being transferred to the test specimen.

d) A means of measuring the penetration of the plunger into the specimen, to

within 0.01 mm. A dial gauge with 25 mm travel, reading to 0.01 mm and

fitted to a bracket attached to the plunger is suitable

e) The CBR mold.

f) Surcharge discs

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PROCEDURE

a) Place the mold with base-plate containing the sample, with the top face of

the sample exposed, centrally on the lower platen of the testing machine.

b) Place the appropriate annular surcharge discs on top of the sample.

c) Fit into place the cylindrical plunger and force-measuring device assembly

with the face of the plunger resting on the surface of the sample. Make sure

that the proving ring dial gauge is properly adjusted, i.e. that there is no

daylight between the bottom of the stem and the proving ring anvil.

Note. It may be necessary to move the crosshead up to allow the plunger to

be inserted through the surcharge discs and the stabilizer bar (if

fitted). Be careful to lower the cross-head again in order to make sure

that the lower platen and penetration dial gauge have enough travel

left before starting the test. This must be level before starting the

penetration test.

e) Record the reading of the force-measuring device as the initial zero reading

(because the seating force is not taken into account during the test) or reset

the force measuring to read zero.

f) Secure the penetration dial gauge in position. Record its initial zero reading,

or reset it to read zero. Make sure that all connections between plunger,

crosshead, proving ring and penetration dial gauge assembly are tight.

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g) Start the test so that the plunger penetrates the sample at the uniform rate of

1±0.2 mm/min, and at the same instant start the timer.

h) Record readings of the force gauge at intervals of penetration of 0.25 mm to a

total penetration not exceeding 7.5 mm

The CBR percentages for each mold are calculated for intervals of 0.100 and 0.200 inches
each. This percentage can be found using the formula:

CBR =

Hench, The CBR percentage at 0.001inches is given by:

CBR =

and that at 0.200 inches:

CBR =

The relative compaction percentages for each mold can be obtained from the data
obtained during compaction of the prepared sample.

The highest CBR percentages recorded for each mold tested are plotted against the relative
compaction percentages to produce a graph which can be used to evaluate whether the
soil brought for testing passes the standards tailored by the Ghana Highway Authority for a
specific project.

Interpretation of results

The management of moisture during the construction and operational phases of a

pavement affects its eventual performance, especially when unbound, unprocessed, often
relatively plastic, materials, are used. The table below shows the variation of strength, as
measured by the laboratory CBR test, with moisture content expressed as the ratio of the
in situ (Field) Moisture Content (FMC) and the Optimum Moisture Content (OMC) for
compaction. The Table illustrates the effect of drying out of materials of varying quality in
terms of an increase in their strength (CBR) and, conversely, a loss in strength in their

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wetting up from a dry state. As indicated, if such materials can be maintained in a relatively
dry state in service, then they can be expected to perform satisfactorily at this “elevated”
strength provided appropriate precautions are taken to avoid their wetting up.

• The G in the material class stands for granular or gravel natural material. The term
“natural material” includes, but is not limited to, lateritic gravel, quarzitic gravel, calcareous
gravel, soft stone, conglomerate, sand or clayey sand or a combination of any of these
materials. A natural material that can be processed using bulldozers and shovels without
the need for blasting or crushing plant is also referred to as gravel.

• The number that follows after the “G” indicates the CBR laboratory value of the soaked
material.

• A material that is classified as G80 is suitable to be used as a base.

• A material classified as G60 is also suitable to be used as a base, although for areas of
lower traffic density.

• A material classified as G40 or G30 is suitable to be used as a sub-base

• A material classified as G15 is suitable for subgrade improvement.

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IMPACT VALUE TEST

Aggregates which are used in road construction projects are constantly subjected to forces
on impact due to the movement of vehicles on the road. These impacts cause the material
to break down into smaller pieces which result in the failure of roads and pavements. The
aggregates to be used must therefore be sufficiently tough enough to resist their
disintegration upon impact. A measure of this toughness is determined through an impact
value test. Thus, an aggregate impact value is a measure of the resistance of aggregates to
sudden impact or shock load on it as compared to their resistance to gradually applied
compressive loads.

The impact value test is primarily used to assess the sustainability of the rock aggregates in
road layers construction on the basis of the impact value. It is carried out to know the
response of aggregates to different kinds of loads that the aggregates will be subjected to
during their service life.

APPARATUS

1. A testing machine weighing 45 to 60 kg and having a metal base with a plane lower
surface of not less than 30 cm in diameter. Level and plane concrete floor of minimum 45
cm thickness are used to support it. The base of the machine should also have provisions
for fixing its base.

2. A cylindrical steel cup of internal diameter 102 mm, depth 50 mm and minimum
thickness 6.3 mm.

3. A metal hammer or tup weighting 13.5 to 14.0 kg the lower end is cylindrical in shape, is
50 mm long, 100.0 mm in diameter, with a 2 mm chamfer at the lower edge and case
hardened. The hammer is arranged in such a way that it should slide freely between
vertical guides and be concentric with the cup. It is arranged that the free fall of the
hammer should be within 380±5 mm.

4. A cylindrical metal measure having an internal diameter of 75 mm and depth 50 mm for

measuring aggregates.

5. One end rounded tamping rod 10 mm in diameter and 230 mm long.

15
6. A balance of capacity not less than 500 g, and readable and accurate up to 0.1 g.

Impact Value Testing Machine

Procedure

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

2. Then, just 1/ 3rd depth of measuring cylinder is filled by aggregate by pouring.

3. Compact the material by giving 25 gentle blows with the rounded end of the tamping rod
in the cylinder.

4. Two more layers are added in a similar manner, to make cylinder full.

5. Strike off the surplus aggregates.

6. Determine the net weight of the aggregates to the nearest gram (W1).

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

8. 25 gentle strokes with tamping rod are used to compact the test sample by fixing the cup
firmly in position on the base of the machine with placing the whole of the test sample in it.

16
9. After that raise the hammer until its lower face is 380 mm above the surface of the
aggregate in the cup and allow it to fall freely on the aggregate sample. 15 such blows at an
interval of not less than one second between successive falls are acted on it.

10. Remove the crushed aggregate from the cup and sieve it through 2.36 mm IS sieves
until no further significant amount passes in one minute. Weight the fraction passing the
sieve to an accuracy of 1 gm (W2). The fraction retained in the sieve is weighted.

11. Note down the observations and compute the aggregate impact value. The aggregate
impact value is the mean of two observations, rounded to a nearest whole number.

Aggregate impact value = ) x 100

Interpretation of Results

RecommendedAggregate Impact Test Values

Aggregate Impact Value Nature

<20% Exceptionally strong

10-20% Strong

20-30% Satisfy for surface course

>35% Weak for surface Course

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Precautions

1. Place the plunger centrally so that it falls directly on the aggregate sample and does not
touch the wall of the cylinder in order to ensure that the entire load is transmitted on the
aggregates.

2. In the operation of sieving the aggregates through 2.36 mm sieve, the sum of weights of
fractions retained and passing the sieve should not differ from the original weight of the
specimen by more than 1 gm.

3. The tamping is to be done properly by gently dropping the tamping rod and not by
hammering action. Also, the tamping should be uniform over the surface of the aggregate
taking care taking care that the tamping rod does not frequently strike against the wall of
the mold.

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 LOS ANGELES ABRASION TEST

The abrasion test measures aggregate toughness and abrasion resistance against crushing,
degradation and disintegration. This test is suggested by AASHTO T 96 or ASTM C 131:
Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in Los
Angeles Machine.

The aggregates used for the surface course (last layer of road construction which is in
direct contact with traffic) of highway pavements are subjected to wearing due to the
movement of traffic. When vehicles travel on the road, the soil particles present between
the tires of the vehicles and the road surface creates an abrasion effect on the aggregates.
Therefore, the aggregates used in road construction must be hard enough to resist
abrasion. The resistance offered by aggregate to abrasion is determined in the laboratory
by the Los Angeles Test machine.

The working principle of the Los Angeles abrasion test is to produce abrasive action by use
of standard steel balls which when mixed with aggregates and rotated in a drum for some
specified time for a specific number of revolutions also causes an impact on aggregates.
This impact on the aggregates is synonymous to the wear that they experience from
moving traffic.

The percentage wear of the sample aggregates due to rubbing with steel balls is
determined and is known as Los Angeles Abrasion Value.

Apparatus

● Los Angeles abrasion machine

● Abrasive charge balls: Cast iron or steel balls, approximately 48mm in diameter and each
weighing between 390 to 445 gm; six to twelve balls are required

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● Sieves: 1.70mm , 2.36mm, 4.75mm, 6.3mm, 10mm, 12.5mm, 20mm, 25mm, 40mm, 50mm,
63mm, 80mm IS Sieves.
● Balance of capacity of 5 kg or 10 kg is used.
● Oven Drying.
● Tray.

Procedure

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

2. Take exactly 5 kg of the sample for grades A, B, C & D, and 10 kg for grading E, F & G.

3. Choose the abrasive charge balls as per the table above depending on the grading of
aggregates.

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

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

revolutions should be 500 for grades A, B, C & D and 1000 for grading E, F & G.

6. The machine is stopped after the specified number of revolutions and the aggregate
sample is discharged to a tray.

7. The entire stone dust made from a machine is sieved on a 1.70 mm IS sieve.

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

Interpretation of results

original weight of the aggregate sample = W1 g

The weight of the aggregate sample retained = W2 g

Weight sample passing 1.7mm IS sieve = W1 – W2 g

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Abrasion Value = x 100

ATTERBERG LIMIT TESTS

The Atterberg limits test is a classification test used to determine the moisture content at
which fine-grained clay and silt soils transition between the different phases. The test for
Atterberg limits is performed on the fraction of soil that will pass through a No. 40 or
425µm or 0.425mm sieve as per ASTM D 4318-00. The test aids in the classification of soil
and its plasticity characteristics and evaluates the shrink/swell potential of near-surface
soil. It can be used to distinguish between silt and clay in its different types and determines
the shrinkage limit (SL), plastic limit (PL), and liquid limit (LL) of the soil sample.

Clay soil changes consistency and behavior depending on its moisture content. The
boundary at which the change in behavior takes place is defined based on the behavior of
the soil sample. The Atterberg limits test is crucial in the early stages of structural design to
ensure that the soil performs as expected. The test is performed only on soil fraction that
passes through sieve No. 40 as per ASTM D 4318.

Test Apparatus

Evaporating dishes – to mix specimen to desired moisture content.

Spatula – to mix, form and smooth the soil specimen.

Aluminum containers – for soil moisture samples.

Mortar and pestle – to reduce particle size.

Digital scale with 0.01g readability.

Drying oven – for moisture content test.

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Casagrande grooving tool for liquid limit test

Glass plate.

Test Procedures

Liquid Limit (LL) Test - The soil sample is mixed with a minimal amount of water and made
into a paste. A portion of the soil sample is then spread in the brass cup of the liquid limit
machine. It is then divided at the center using the Casagrande grooving tool. The liquid limit
is reached when the opposing walls of soil created by the groove close along the bottom
after 25 blows. The moisture content is noted. The test is conducted at varying moisture
content for the same soil with the number of blows varying between 15 and 35.

Plastic Limit (PL) Test - A small ball of moist plastic soil is repeatedly remolded and rolled
out into a 3.18 mm thread. The moisture content at which the thread crumbles before it is
completely rolled out is the plastic limit. Alternatively, the ball of moist plastic soil can be
repeatedly rolled until cracks develop in it. Gather the portions of the crumbled soil
together, place in the moisture content container and cover. Repeat the steps until 10 g of
sample have been tested and placed in the container. Alternatively, if the test was done by
rolling the soil into a ball until cracks were developed, the ball is then divided equally into 4
pieces with 2 pieces each placed in a separate container. Determine the moisture content
of the sample in accordance with the FOP for AASHTO T 255/T 265 (Soil) and record the
results.

The moisture content determined is the plastic limit

22
Plasticity Index

The Plasticity Index (PI) of the soil is equal to the difference between the Liquid Limit (LL)

and the Plastic Limit (PL). If either the liquid limit or plastic limit cannot be determined,

report the plasticity index as NP (non-plastic). If the plastic limit is equal to, or greater than

the liquid limit, report the plasticity index as NP.

PI = LL – PL

23
 CONCLUSION

The running of lab tests day in and day out has provided a well rounded understanding of the
behavior of the materials used for road construction works and the importance of testing them
thoroughly before any engineering project can be completed safely and successfully.My internship
at Ghana Highways materials section has been one of the most learning experience of my life.
All public highways and associated facilities in Ghana are managed, controlled, developed,
and maintained by the Ghana Highway Authority, a national corporate agency

There are also some challenges this organization faces and one is;

● Inadequate infrastructure.

The Ghana highway does not have sufficient equipments to undergo some test ,thus delaying most
tests.

REFERENCES

The information gathered in this report was taken from:

Ghana Highway Authority website

Notes from personal notebook

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