Training File
Short Description
DMRC training File...
Description
DECLARATION I hereby declare that the project work entitled “Noida Metro Project” is an authentic record of my own work carried out at Sector 147-149 , Noida as requirements of project semester training (One semester Industrial Training) for the award of degree of B.Tech. (Civil Engineering), Department of Civil Engineering, Punjabi University, Patiala, under the guidance of Mr. Mudit (SAM INDIA) and Dr. Maninder Singh (Department of Civil Engineering) from February 1 ,2017 to May 31 , 2017.
(Signature of student) Damandeep Singh (11304180) Date: ___________________
Certified that the above statement made by the student is correct to the best of my knowledge and belief.
Dr. Maninder Singh Head of Department Department of Civil Engineering
NOIDA METRO PROJECT REPORT 1
ACKNOWLEDGEMENT First of all I would like to thank almighty God for the successful completion of this project. The successful completion of this project is the result of concerted efforts, guidance and inspiration from many people. I express my sincere gratitude to the Punjabi University, Patiala for giving me the opportunity to undergo industrial training and to work on the project during my final year of B.Tech.
I am grateful SAM INDIA, for providing me with an opportunity to work with them and undertake a project of such high importance. This training and experience has not only enriched me with technical knowledge but has also imparted the maturity of thought and vision. Sincere thanks to all my colleagues at Noida Metro Project for their support and assistance throughout the project.
I would like to thank the following persons for their kind suggestions and guidance throughout the project:
Mr. Madhur Goel (Resident Engineer DMRC)
Mr. Mudit (Project Manager)
09912020000
Mr. Ravi (Laboratory In charge)
09536543454
Mr. Shankar (Site Engineer, Station 147)
09313611061
Mr. Mahesh (Assisting Engineer, Station 147)
07065106194
Mr. Sandeep (Safety Supervisor, Station 147)
09205018771
All petty contractors and labourers.
I also owe my sincerest gratitude towards Dr. Maninder Singh whose constant encouragement helped me to complete this project in the most efficient way I could. I would also like to thank my family and friends for being with me at every hours of need and for directly and indirectly helping me in completion of this project.
NOIDA METRO PROJECT REPORT 2
TECHNICAL SUMMARY This report has been written based on the work experience gathered at Noida - Greater Metro Rail Corporation work site at Noida. It includes all the important work stages in the execution of the project. In present day world, metro rail network alone is a solution for smooth, cheap and efficient means of transport. Noida & Greater Noida are fastest growing towns in National Capital region. Noida & Greater Noida Authorities have decided to provide a world class metro with sustainable development in the name of Noida Metro Rail Corporation (NMRC) to facilitate mass transit & other urban transport in Noida & Greater Noida. The project is working to Provide Safe, Reliable & Eco-Friendly Transportation Services for people.
NOIDA METRO PROJECT REPORT 3
CONTENTS 1. Candidate’s declaration 2. Acknowledgment 3. Technical Summary 4. Contents 5. Abstract 6. Introduction to Noida Metro Rail Corporation 7. Introduction to Sam India Introduction Salient Features Activities 8. Literature Survey Of Project 9. Materials Used in Project 10. Project Monitoring Station Monitoring Lab and Field Testing 11. Planning The Project – Casting Yard 12. Project Execution (Problem Statement) 13. Risk Assessment and Environmental Management 14. Problems Encountered During Training and Remedial Steps 15. Overall Benefits Of Training 16. Conclusion 17. References
NOIDA METRO PROJECT REPORT 4
ABSTRACT Metro rail transportation occupies a unique and world class mass rapid transit system amongst the modern transportation means Presently, the Delhi Metro network consists of about 218.17 Km with 164 stations along with six more stations of the Airport Express Link. The network has now crossed the boundaries of Delhi to reach NOIDA and Ghaziabad in Uttar Pradesh, Gurgaon and Faridabad in Haryana. Having seen the utility and efficacy of metro rail transportation, other states have also adopted the same model eg. Metro rail in Noida and Greater Noida, Metro Rail in Lucknow, Metro Rail in Jaipur, Metro Rail in Kochi and Metro Rail in Mumbai etc. I am fortunate as I have been granted permission to understand Metro rail execution in DMRC/NMRC work sites and DMRC/NMRC authorities have been kind enough to allow me to learn and gain experience in Metro rail execution in Noida - Greater Noida stretch. I will remain ever indebted to DMRC/NMRC for the kind permission. The execution of metro rail network is to be done between Noida Sector-71 in Noida to Delta Depot Station in Greater Noida but I was allowed to understand the work from sector 147-149 of Noida city. The stretch is totally elevated and consists of about 29.707 km track and 21 metro stations. The metro network will be catering to approximately 65000 passengers per day.
NOIDA METRO PROJECT REPORT 5
Introduction to Noida Metro Rail Corporation “Everyone who has travelled by Delhi Metro wants one in his or her city. Today there is a national resurgence in public interest in public urban transport”:- Dr. Manmohan Singh Prime Minister of India in 2006. Delhi metro was meant to solve the Delhi’s traffic problems which had become almost unmanageable. The first step to build a metro system in the city was taken in early 1990. In 1995 Government of India (GOI) and the government of national capital territory of Delhi (GNCTD) formed the Delhi Metro Rail Corporation Ltd (DMRC) under the companies act to construct the Delhi Metro. Conceived as a social sector project, a significant portion of the project cost was funded through a soft loan provided by the Japanese government through Japan Bank International Corporation (JBIC). The rest was contributed by Government India & GNCTD through equity. DMRC faced any number of technical and systematic challenges during the construction of the Metro. However due to thorough planning, an effective project design and a “we mean business culture” it was able to overcome all these hurdles. In the process of implementing the project, DMRC has gained a lot of technical expertise, which would be used by other cities in India and abroad to builds metro system similar to Delhi Metro. A new metro rail network will shortly be developed between Noida and Greater Noida, measuring 29.707 KM. It will be developed at an estimated cost of Rs 5064 Crores. The detailed Project Report (DPR) has already been prepared by Delhi Metro Rail Construction and Noida Metro Rail Construction has been formed under the chairmen ship of the chief Secretary of Uttar Pradesh.
NOIDA METRO PROJECT REPORT 6
Introduction to SAM INDIA
The construction sector has many players big & small. But when it comes to excellence and leadership there is not much room at the top and only a few companies make the cut. One such company is Sam INDIA the company has a strong lineage of around two decades in the construction arena. With its experienced professionals including engineers, architects and technocrats the company has moved from the strength to strength. A depth of management expertise has been the company’s greatest asset, which has helped it to effectively address customer requirements. Use of cutting edge construction technology remains the pillar of the company’s growth and rising consumer popularity.
Salient Features
VISION Our vision is to contribute to the construction of a modern India by offering state-of-the art solutions that are both technologically superior and environmentally friendly.
MISSION To become the preferred Construction Partner, who sustainably delivers best-in-class solutions to meet and exceed customer needs. We aim to accomplish this by using cutting edge construction technology and responding to dynamic consumer requirements with passion and pro activity. We recognize the need to be flexible and aggressive, both as individuals and as a company. Teamwork, transparency and long-term decision-making remain the corner stones of our operations towards maximizing value for consumers and building a strong reputation for ourselves.
NOIDA METRO PROJECT REPORT 7
Activities Completed Projects
LUCKNOW METRO - LUCKNOW (U.P.)
CENTRAL JAIL AMRITSAR – PUNJAB
SHAHEED SUKHDEV COLLEGE - ROHINI - NEW DELHI
MUKUNDPUR DEPOT AND STAFF QUARTERS- DELHI
TIRUPATI AIRPORT - TIRUPATI (ANDHRA PRADESH)
CHOUDHARY BHRAM PRAKASH AYURVEDIC CHARAK HOSPITAL - NEW DELHI
HEADQUARTERS OF NWR AT JAIPUR – RAJASTHAN
NIT HOSTEL (NATIONAL INSTITUTE OF TECHNOLOGY) - HIMACHAL PRADESH
ILBS-INSTITUTE OF LIVER AND BILIARY SCIENCES - NEW DELHI
CHANDIGARH JUDICIAL ACADEMY - PUNJAB
MILITARY HOSPITAL - DEHRADUN (UTTARAKHAND)
Ongoing Projects
NOIDA - GREATER NOIDA METRO
PALM OLYMPIA- GREATER NOIDA (WEST)
MINI SECRETARIAT - ALWAR - RAJASTHAN
NATIONAL AGRICULTURE BIOTECH INSTITUTE - MOHALI - PUNJAB
NOIDA METRO PROJECT REPORT 8
Literature Survey of Project Starting from Noida city center in sector 32, the proposed metro corridor will lead towards Greater Noida via stations in sector 50, 51, 78,101, 81 on Dadri Road, 83, 85, 137, 142,143 147, and 153 and sector 149 in Noida. It will enter Greater Noida through knowledge park II and transverse Pari Chowk, sector alpha I and II before terminating at depot station proposed near recreational green, knowledge park IV in Greater Noida. The metro alignment is proposed to be elevated. The metro rail link is expected to be commissioned by December 2017. Geometrical design norms are based on international practices adopted for similar metro system with standard gauge on the assumption that permissible speed on the section is limited to 85 KMPH. Planning for any higher speed is not desirable as the inter-station distance is about is about 1 to 1.5 km and trains will not be able to achieve higher speed. The tracks will be carried on box – shaped elevated decking supported by single circular piers generally spaced at 25 meters center and located on the median or one side of the road.
NOIDA METRO PROJECT REPORT 9
Noida Metro: Proposed route
Noida Metro: Proposed route. The entire work has been awarded to M/S CEC-SAM India JV Noida. The scope of work included design, construct and complete the whole of the work and commission and remedying any defect within 24 months. During the period of training I was involved in works in Casting Yard, casting of main structural elements and lab testing. All these activities are covered in succeeding paragraphs.
NOIDA METRO PROJECT REPORT 10
MATERIALS USED IN PROJECT
Cement: OPC 53 Grade make JK LAXMI/ ACC/Ultratech.
Steel : TMT bars Fe 500 D and make TATA/TISCON confirming to IS :1786 : 2008.SAIL Plants, Rashtriya Ispat Nigam Ltd, Tata Steel (JH), Ispat Industries(MH), JSW Steels, JSP, Essar Steel Gujarat, Shyam Steel Durgapur and any other integrated steel plant as per Ministry of Steel definition.
Coarse Aggregate: 20 mm and 40 mm
Fine Aggregate: River coarse sand grade II/III sand as per IS 383.
Concrete Grades: Pile- M35, M45 and M60 Pile Cap- M35, M45, and M60 Pier - M55 and M60 Pier Cap- M 45 Pedestal- M 45 I-Girder- M 45 C-Girder-M60
Admixture: Fosroc, MBT, Sika, APEX, Polygon, Choksy, Durabuild, Conproof, CAC, HR Johnson, Araldite, BASF, Kunal Conchem, SWC, STP, CICO.
Water: Potable water with PH >7.
Structural Steel: TATA, SAIL Plants,JSW Steels, JSP, Essar, Maharashtra Pipe.
Stainless Steel: Jindal, SAIL or equilavent.
Pre Stressing Strand: TATA SSL Ltd, Usha Martin.
Welding Electrodes: ESAB, Advani, Modi, Arc/Weld Excel India, GEE, Honavar, KM Crown Welding Consumables, Supercon, L&T Eutectic, Victor.
Horizontal Toe Bars/ Shear Bars: BB Bars System, BBV Systems or equivalent.
Formwork Release Agent: FOSROC, MBT, MC Baucheme, Ado Conmat, CICO, SWC, Choksey, BASF, Adoadditives, STP. NOIDA METRO PROJECT REPORT 11
Prestressing System: Freyssinet, BBR, VSL, Dyanamic, Killick Nixon, Tensaccial, JK Prestressing, Usha Martin, Posten, CSIL.
Reinforcement Couplers: Dextra, Moment.
Hollow Sections, Pipes: Surya Pipes, HI-Tech Pipes, JSW, JSPL, Bihar, Ravindra Tubes.
Drainage Pipes: Tirupati Plasomatics, Duraline, REX, STIPL.
Bonding Coat: Sika, FOSROC, Sunanda Speciality coating Pvt Ltd, SWC, TAM, BASF, CICO.
Paints: Berger, APEX, Asian, Johnson & Nicolson, Akzo Noble, PPG, Jotun.
Micro Silica: Sika, Elkem, FOSROC, MAPEI, Comiche, Star Silica, TAM, Calipar, CICO.
Fire Resistant Paints: Akzo Noble, PPG or equivalent, Jotun.
External Acrylic Emulsion: Berger, APEX, Asian, Johnson & Nicolson.
Water Stopper Bars: Kanta Rubber, Greenstreak, Maruti, Duron.
Curing Compound: Clean Tech concur, SANAK, FOSROC, Adoadditives, TAM, STP, SWC, CICO.
Polycarbonate sheet: M/S Gallina Acroplus, Coxwell, Poly U.
Fly Ash: Therml plants, Ashcrete, Ultra Pozz, Star Pozz.
NOIDA METRO PROJECT REPORT 12
PROJECT MONITORING
STATION MONITORING Staircase Supervision Staircase’s Full process shown with the help of photographs clicked by me which was fully supervised by me and drawings are also shown.
Reinforcement Tying
Shuttering
NOIDA METRO PROJECT REPORT 13
Outer Stairs Of Station
Casted Stairs Along with Flooring
NOIDA METRO PROJECT REPORT 14
Structural Drawings Of Staircase
NOIDA METRO PROJECT REPORT 15
Deck Slab Supervision
Deck slab Reinforcement Caging
NOIDA METRO PROJECT REPORT 16
Completed Structural Part of our Station
Company Officials addressing Labour
NOIDA METRO PROJECT REPORT 17
Deshuttering of Mumty Part of Station
Station site Panaroma
NOIDA METRO PROJECT REPORT 18
LAB AND FIELD TESTING During the course of training, I was entrusted the laboratory duties. A brief detail about field testing carried out by me is illustrated in succeeding paragraphs.
DETERMINATION OF SILT CONTENT IN FINE AGGREGATES OBJECT:
This method of test deals with the procedure for determining the silt content of sand by sedimentation method.
APPARATUS:
A 250ml capacity- measuring capacity, Water, Sand & Tray
TEST SAMPLES:
Materials sampled for the test should be thoroughly mixed before sampling and it should contain sufficient moisture to prevent segregation.
PROCEDURE:
1. Fill the cylinder to 50ml mark with 1% salt solution of water. 2. Pour in the sample of sand to be tested until the level of sand is 100ml mark. 3. Add more water until 150ml mark is reached. 4. Shake the cylinder well, talking a particular care to spill any of the content. 5. Keep the cylinder filled with sand for 3 hours. 6. Note the silt height (above sand layer) and sand height (below silt layer)
NOIDA METRO PROJECT REPORT 19
REPORTING OF RESULTS:
S.no.
Description
Result obtained
1
Take 50ml of salty water
2
Add sand and make the volume up to 100ml
3
Add water make the volume up to 150ml and wait 3 hours
4
Silt layer(W1)ml
4
5
Sand layer(W2)ml
110
6
Silt content (W1/W2)*100
3.63
ACCEPTANCE CRITERIA: 8% maximum (by volume) as per CPWD specification.
NOIDA METRO PROJECT REPORT 20
DETERMINATION OF SILT CONTENT IN FINE AGGREGATES (BY WEIGHT)
OBJECT: This method of test deals with the procedure for determining the total quantity of material finer than 75micron IS sieve in aggregates by washing.
APPARATUS: Balance or scale shall be sufficient capacity and sensitivity and shall have an accuracy of 0.1, Sieves – a nest of two sieves, the lower being 75-micron IS sieve and the upper approximately 1.18mm IS sieve, Container- A pan or vessel of a size sufficient to contain the sample covered with water and to permit of vigorous agitation without loss of any part of the sample of water and Oven- an oven of sufficient size capable of maintaining a uniform temperature 110°C ± 5°C.
PROCEDURE:
1. The test sample shall be dried to constant weight at a temperature of 110°C ± 5°C and weighed to the nearest 0.1 percent. 2. The dried and weighed sample shall be placed in the container and sufficient water is added to cover it. 3. Then the contents of the container are agitated vigorously. 4. The agitation shall be sufficient vigorous such that the coarse particles are separated and the fine particles are brought into the suspension. 5. The water (mixed with fine particles) shall be poured over the nested sieves arranged with the coarser sieve at the top. 6. All materials retained on the both the sieves shall be container containing coarser particles. Steps 3, 4 and 5 above are repeated till the wash water looks clear. Care should be taken such that no materials retained on the sieve get lost. NOIDA METRO PROJECT REPORT 21
7. The retained materials should be dried to a constant weight at a temperature not exceeding 110°C and weighed to the nearest 0.1 percent.
REPORTING OF RESULTS:
S.no
description
results observed
1
Total weight of sample taken(gms)
500
2
Weight of sample after drying (gms)W1
466
3
Weight of sample after sieving 75microns 471 and drying (gms)W2
4
Difference in weight W3=W1-W2
5.0
5
Silt in % weight (W3*100)/W1
1.07%
ACCEPTANCE CRITERIA: 3% maximum for uncrushed and 5% maximum for crushed sand (by weight).
FINE
AND
COARSE
AGGREGATES
–
PARTICLE
SIZE
DISTRIBUTION:
OBJECT:
This method of test covers the procedure for the determination of particle size distribution of fine and coarse aggregates by sieving.
APPARATUS:
Sieves-sieves
(confirming
to
IS:460-1962)
of
size
40mm,20mm,12.5mm,
10mm,4.75mm,2.36mm,1.18mm,600micron, 300micron and 150 micron.
NOIDA METRO PROJECT REPORT 22
PROCEDURE:
1. Bring the sample to an air dry condition before weighing and sieving. 2. Weigh the air dry sample and sieve successfully on the appropriate sieves starting with the largest. 3. Each sieve shall be taken separately over a clean tray until not more than a trace passes, but in any case for a period of not less than 2 minutes. 4. Shake with a varied motion so that the materials is kept moving over sieve surface in frequently changing directions. 5. Light brushing of the underside of sieve with a soft brush may be used to clear the sieve openings. 6. On the completion of sieving the material retained on each sieve together with any materials cleaned from the mesh, shall be weighed.
NOIDA METRO PROJECT REPORT 23
REPORTING OF RESULTS:
IS sieve
Weight
%of
Cumulative
% passing
IS
retained
weight
%of weight
(gm)
retained
retained
12.5
0
0
0
100
100
10
166
4.33
4.33
95.07
85-100
4.75
3244
84.63
88.96
11.04
0-20
2.36
275
7.17
96.14
3.86
0-5
Pan
148
3.86
Total
3833
%
IS
requirements
Sieve analysis of 10mm aggregates
IS Sive
Weight
% of weight Cumulative
retained
retained(gms) % of weight passing
(gm)
requirements
retained
40
0
0
0
100
100
20
412
10.90
10.90
89.10
85-100
10
3142
83.12
94.02
5.98
0-20
4.75
175
4.63
98.65
1.35
0-5
Pan
51
1.35
Total
3780
Sieve analysis of 20mm aggregates
NOIDA METRO PROJECT REPORT 24
IS sieve
Weight
%
of Cumulative
Passing
IS
retained
weight
% retained
%
requirements
(gm)
retained
10
0
0
0
100
100
4.75
56
9.0
9.0
91.00
90-100
2.36
66
10.61
19.61
80.39
75-100
1.18
78
12.54
32.15
67.85
55-90
600micron
75
12.06
44.21
55.79
35-59
300micron
173
27.81
72.03
22.97
8-30
150micron
132
21.22
93.25
6.75
0-10
Pan
42
6.76
Total
622
Sieve analysis of sand
FINE AND COARSE AGGREGRATES -SPECIFIC GRAVITY AND WATER ABSORPTION:
OBJECT:
This method of test covers the procedures for determining the specific gravity of aggregates as per IS 2386 (part III).
APPARATUS:
A balance of capacity 3kg or more, readable and accurate to 0.5g, An oven to maintain a temperature of 100°C to 110°C, A Pycnometer of about one litre capacity, A tray of area not less than 325cm2 and Filter paper and funnel.
NOIDA METRO PROJECT REPORT 25
TEST SAMPLE:
The sample taken for test shall be approximately 500g for fine and 1000g for coarse aggregates.
PROCEDURE:
1. A sample of about 1000g for coarse and 500g for fine aggregates shall be placed in separate trays and water is poured in the tray such that the sample gets completely immersed in water. 2. The temperature of water shall be maintained between 22°C to 32°C. The immersed aggregates shall be agitated with rod so the entrapped bubbles get completely removed from the aggregates. 3. Then the sample is left immersed in water for 24 hours, the water shall then be carefully drained from the sample such that no particles get lost. 4. The sample is kept in exposed air or below fan so that the surface moisture gets evaporated (i.e. the sample shall be stirred at frequent interval to ensure uniform drying until no free surface moisture is seen and the material just attains a “free running condition”. 5. The weight (W1) of the sample is taken which is SSD (Saturated Surface Dry Condition) weight. 6. The SSD aggregates shall then be placed in the Pycnometer, which shall then be filled with distilled water. 7. The hole at the top of brass cone of Pycnometer shall be closed with finger and the trapped air shall be removed by rotating the Pycnometer on its side. 8. The Pycnometer shall be completely filled with water, wiped/dried from outside and weighed (W2). 9. The aggregates along with water are taken out carefully on a tray. 10. The Pycnometer shall be completely filled with water, wiped/dried from outside and weighted (W3). 11. The water present in the tray along with aggregates shall be completely drained such that no aggregate particle get lost. NOIDA METRO PROJECT REPORT 26
12. The sample with tray shall then be kept in the oven at a temperature 100°C to 110°C for 24hours.It shall be cooled and weighed (W4). W1= Weight in g of SSD sample. W2= Weight in g of Pycnometer containing sample and filled with water. W3= Weight in g of Pycnometer filled with water only. W4= Weight in g of oven dried sample.
REPORTING OF RESULTS:
S.No.
Description
Result observed
1
Weight of sample (W1)
500 g
2
Weight
of
Pycnometer
+
water
+ 1832g
aggregates(W2) 3
Weight of Pycnometer + water (W3)
1510g
4
Weight of oven dried aggregates (W4)
497g
5
S.G= W4/(W1-(W2-W3)
2.78
Specific gravity of coarse aggregates (10mm)
S.No.
Description
Result observed
1
Weight of sample (W1)
500g
2
Weight
of
Pycnometer
+
water
+ 1831g
aggregates(W2) 3
Weight of Pycnometer + water (W3)
1510g
4
Weight of oven dried aggregates (W4)
498g
5
S.G= W4/(W1-(W2-W3)
2.78
Specific gravity of coarse aggregates (20mm)
NOIDA METRO PROJECT REPORT 27
S.No
Description
Results observed Test1
Test 2
1
Weight of the sample at SSD condition(W1)
500g
498
2
Weight of the sample after drying (W4)
492g
491
3
Difference in weight A=(W1- W4)
8g
7
4
Absorption in%=A*100/W4
1.63
1.43
5
Average
1.53%
Fine aggregate water absorption test
FINE AND COARSE AGGREGATES – MOISTURE CONTENT:
OBJECT:
This method of test cover the procedures for determining the moisture content of aggregates as per IS 2386 part III.
APPARATUS:
A balance of capacity 3kg or more, readable and accurate to 0.5g. An oven to maintain a temperature of 100°C to 110°C
TEST SAMPLE:
The test sample taken shall be approximately 500g for fine aggregate and 1000g for coarse aggregates.
NOIDA METRO PROJECT REPORT 28
PROCEDURE:
1. Take the sample in container and weigh it accurately.(W1) 2. Dry sample in oven and weight it. (W2) 3. Weight of water can be calculated as follows: 4. Weight of water (W3) =W1-W2 5. Moisture content can be calculated as follows: 6. Moisture content %=(W3/W2)*100
REPORTING OF RESULTS:
S.No.
Description
Result observed
1
Weight of sample (W1)
500g
2
Weight of dry sample (W2)
465g
3
Weight of water(W3)=(W1-W2)
35g
4
Moisture content%=(W3/W2)*100
7.52%
Moisture content of fine aggregates
BULKING OF SAND:
OBJECT:
This method of test covers the procedures for determining the necessary adjustment for bulking of sand (fine aggregate)
APPARATUS:
A container of capacity 3 litre, A steel ruler, A steel rod 6mm in diameter, and A 250 ml capacity measuring cylinder.
NOIDA METRO PROJECT REPORT 29
TEST SAMPLE:
The sample taken for test shall be approximately 5kg.
PROCEDURE:
1. In a 250 ml- measuring cylinder, pour the damp sand and consolidate it by staking until it reaches 200ml mark(X). 2. Fill the cylinder with water and stir the sand well (the water shall be sufficient to submerge the sand completely). 3. It will be seen that the sand surface is now below its original level. 4. Suppose the surface is at the mark of (Y) level, therefore the %of bulking of sand due to moisture shall be calculated as: 5. Percent bulking =(X/Y-1)*100
REPORTING RESULTS:
S.no.
Description
Results observed Test 1
1
Reading
of
measuring
Test 2
cylinder(sand 200
200
Reading of measuring cylinder (after 190
186
consolidated)-X 2
pouring water till sand is completely submerged)-Y 3
Bulking of sand (X/Y-1)*100
5.26
7.53
COARSE AGGREGATE FLAKINESS INDEX OBJECT: This method of test covers the procedures for determining the Flakiness Index of coarse aggregates (As per IS: 2386 part I).
NOIDA METRO PROJECT REPORT 30
APPARATUS
Balance or scale shall be sufficient capacity and sensitivity and shall have an accuracy of 0.1 % of the weight of sample, IS Sieves of sizes 50 mm, 40 mm, 20 mm, 12.5mm, 10mm, & 6.3 mm and a Metal gauge of the pattern specified in IS 2386(Part I)-1963.
PROCEDURE
1. Sample shall be sieved in accordance with the method described as par IS 2386(Part I)-1963 with the sieves specified in table I. 2. Separation of flaky material: Each fraction shall be gauged in turn for thickness on a metal gauge of the pattern specified in IS 2386(Part I)-1963 or in bulk on sieves having elongated slots. The width of the slot used in the gauge or sieve shall be of dimensions specified for appropriate size of material. 3. Weighing of flaky material: The total amount passing the gauge shall be weighed to an accuracy of at least 0.1 % of the weight of sample.
REPORTING RESULTS SIZE OF AGGREGATE 20 mm, source - Kotputli.
LENGTH GAUGE
Total
wt
Passing through IS Retained on IS Sieve
sample gm
of Total
sample retained Gm
Sieve 50
40
-
-
40
25
-
-
25
20
2605
322
20
16
1887
215
16
12.5
941
121
12.5
10
461
81
10
6.3
189
32
6133
771
Total
NOIDA METRO PROJECT REPORT 31
wt
of
The calculation & report shall be maintained in the format specified.
ACCEPTANCE CRITERIA: Minimum 35%.
COARSE AGGREGATE – ELONGATION INDEX TEST
OBJECT
This method of test covers the procedures for determining the Elongation Index of coarse aggregates (As per IS:2386 part I).
APPARATUS
Balance or scale shall be sufficient capacity and sensitivity and shall have an accuracy of 0.1 % of the weight of sample, IS Sieves of sizes 50 mm, 40 mm, 20 mm, 12.5mm, 10mm, & 6.3 mm and a Metal gauge of the pattern specified in IS 2386(Part I)-1963.
PROCEDURE
1. Sample shall be sieved in accordance with the method described as par IS 2386(Part I)-1963 with the sieves specified in table I. 2. Separation of elongated material: Each fraction shall be gauged in turn for thickness on a metal gauge of the pattern specified in IS 2386(Part I)-1963 or in bulk on sieves having elongated slots. 3. The gauge length used shall be that specified for appropriate size of material. 4. Weighing of flaky material: The total amount passing the gauge shall be weighed to an accuracy of at least 0.1 % of the weight of sample.
NOIDA METRO PROJECT REPORT 32
SIZE OF AGGREGATE 20 mm, source - Kotputli. LENGTH GAUGE
Total
wt
Passing through IS Retained on IS Sieve
sample gm
of Total
wt
of
sample retained Gm
Sieve 50
40
-
-
40
25
-
-
25
20
2605
322
20
16
1887
215
16
12.5
941
121
12.5
10
461
81
10
6.3
189
32
6133
771
Total
Elongation Index = 771/6133x100= 12.5 %.
SIZE OF AGGREGATE 10 mm, source - Kotputli.
LENGTH GAUGE
Total
wt
Passing through IS Retained on IS Sieve
sample gm
of Total
sample retained Gm
Sieve 50
40
-
-
40
25
-
-
25
20
-
-
20
16
-
-
16
12.5
-
-
12.5
10
481
91
10
6.3
204
32
685
123
Total
Elongation Index = 123/685X100=17.5% ACCEPTANCE CRITERIA: Minimum 35%. NOIDA METRO PROJECT REPORT 33
wt
of
FINENESS OF CEMENT
OBJECT
This method of test covers the procedures for determining the fineness of cement by sieving as represented by the weight of the residue left on a standard 90 micron IS Sieve conforming to IS: 460-1962( As per IS 4031-1968).
APPARATUS
IS Sieves No 9 and sieve shaker.
PROCEDURE
1. Break down any air set lumps in the cement sample if any with fingers. Place 100 gram of the cement accurately weighed on a standard IS Sieve no 9-90 micron (Wt A). 2. Continuously sieve the sample giving circular and vertical motion for a period of 15 minutes. Mechanical sieving device may be used. 3. Weigh the residue left on the sieve (Wt B). This weight shall not exceed 10 % for ordinary cement. Percentage of fineness of cement shall be calculated as follows & the average shall be reported.
4. % of fineness = BxA / A
REPORTING OF RESULTS
The result & report of fineness of cement should be maintained in the format specified.
NOIDA METRO PROJECT REPORT 34
Description of test
Sample 1
Sample 2
Sample 3
1
Wt of cement in grams (A)
100
100
100
2
Wt of cement retained on 90 1.5
1.6
1.7
1.6%
1.7 %
Sl No
micron sieve in grams (B) 3
% fineness
1.5 % Avg. Fineness = 1.6 %
CONSISTENCY OF STANDARD CEMENT
STANDARD: IS: 4031(Part4) 1988
DEFINITION The standard consistency of cement paste is defined as that consistency which will permit the Vicat plunger to penetrate to a point 5 to 7 mm from the bottom of the Vicat’s mould.
APPRATUS
Vicat apparatus conforming to IS: 5513-1976, Balance of capacity 1 Kg and sensitivity to 1 gram and Gauging trowel conforming to IS: 10086-1982.
NOIDA METRO PROJECT REPORT 35
PROCEDURE
1. Unless otherwise specified the test shall be conducted at a temperature 27+/- 2 Deg C and relative humidity of laboratory should be 65+/-5%. 2. Prepare a paste of weighed quantity of cement (300 gms) with weighed quantity of potable or distilled water, taking care that the time of gauging is not less than 3 minutes nor mare than 5 minutes and the gauging is completed before any sign of setting occurs. 3. The gauging is counted from the time of adding water to the dry cement until commencing to fill the mould. 4. Fill the Vicat mould with this paste resting upon a non porous plate. 5. Smoothen the surface of the paste making it level with the top of the mould. 6. Slightly shake the mould to expel the air. 7. In filling the mould operator’s hands and the blade of the gauging trowel shall only be used.
NOIDA METRO PROJECT REPORT 36
8. Immediately place the test block with the non porous resting plate, under the rod bearing the plunger. 9. Lower the plunger gently to touch the surface of the test block and quickly release, allowing it sink into the paste. Record the depth penetration. 10. Prepare trial pastes with varying %ages of water and test as described above until the plunger is 5mm to 7mm from the bottom of the Vicat mould.
CALCULATIONS
Standard Consistency (%) = Weight of water added / weight of cement X 100
REPORT
Express the amount of water as a percentage by mass of dry cement to the first place of decimal.
SETTING TIME CEMENT
OBJECT
This method of test covers the procedures for determining the initial and final setting time of cement (As per IS 4031-1968).
APPARATUS
Vicat apparatus conforming to IS: 5513-1976.
NOIDA METRO PROJECT REPORT 37
PROCEDURE
1. The temperature of water and that of test room at the time of gauging shall be within 27+/- 2 Deg C. 2. Take 500 gram of cement sample & gauge it with 0.85 times the water required to produce cement paste of standard consistency (0.85 P). 3. Fill the paste into the Vicat mould in specified manner within 3-5 minutes. 4. Start the stopwatch the moment water is added to the cement.
DETERMINATION OF INITIAL SETTING TIME: 1. Place the test block confined in the mould & resting on non porous plate under the rod bearing the needle. 2. Lower the needle gently in contact with the surface of the test block & quickly release allowing it to penetrate into test block. 3. In the beginning the needle will completely pierce the test block. Repeat this procedure until the needle when brought in contact with the test block & release as described above, fails to pierce the block for 5 =/- 0.5 mm measured from the bottom of the mould. 4. The period elapsing between the time when water is added to the cement & the time at which the needle fails to pierce the test block shall be the initial setting time.
DETERMINATION OF FINAL SETTING TIME: 1. Replace the needle of Vicat apparatus by a circular attachment. 2. The cement shall be considered as finally set when upon, lowering the attachment gently over the surface of the test block; the center needle makes an impression, while the circular cutting edge of the attachment fails to do so. NOIDA METRO PROJECT REPORT 38
3. The period elapsing between the time when water is added to the cement & the time at which the needle makes an impression on the surface of test block while the attachment fails to do so shall the final setting time.
ACCEPTANCE CRITERIA
Physical characteristics of various type of O.P. Cement Grade
of Setting time
Cement
Slag Cement (IS
Fineness
Initial
Final
(Min)
(Min)
Max
Compressive Strength 3 days MPA
7 days
28 days
MPA
MPA
30
600
10 %
16
22
33
30
600
10%
23
33
43
30
600
10%
27
37
53
269-
1989/IS455) 43 OPC (IS 8112-1989) 53 OPC (IS
12269-
1987)
COMPRESSIVE STRENGTH OF CEMENT
OBJECT
This method of test covers the procedures for determining the compressive strength of cement as represented by compressive strength tests on mortar cubes compacted by means of a standard vibration machine (As per IS 4031-1968).
APPARATUS: Enamel tray and trowel.
NOIDA METRO PROJECT REPORT 39
PROCEDURE
1. The standard sand to be used in the test shall confirm to IS 650-1991. 2. Take 555 grams of standard sand, 185 grams of cement (ratio 1:3) in a non porous enamel tray & mix them with a trowel for 1 minute. 3. Add water of quantity (P/4) + 3% of combined weight of cement & sand and mix the three ingredients thoroughly until the mixture is of uniform color. The time of mixing should not be less than 3 minutes or more than 4 minutes. 4. Immediately after mixing the mortar is filled into a cube mould of size 7.06 cm. 5. The area of face of the cube will be equal to 50 sq.cm. 6. Compact the mortar either by hand compaction in a standard specified manner or on vibrating equipment for 2 minutes. 7. Keep the compacted cube in the mould at a temperature of 27’ deg C +/- 2 ‘C & at least 90 % relative humidity for 24 hours. 8. Where the facility of temperature & humidity room is not available, the cube may be kept under wet gunny bag to stimulate 90% relative humidity. 9. After 24 hours, remove the cubes from the mould & immerse in clean fresh water until taken out for testing. 10. Three cubes are tested for compressive strength at the interval of 3,7 & 28 days. 11. The compressive strength shall be average of the strength of 3 cubes for each period respectively.
NOIDA METRO PROJECT REPORT 40
ACCEPTANCE CRITERIA
Physical characteristics of various type of O.P.Cement
Grade
of
Cement
Slag Cement (IS
Setting time Initial
Final
(Min)
(Min)
Fineness
Compressive Strength
Max
3 days MPA
7 days
28 days
MPA
MPA
30
600
10 %
16
22
33
30
600
10%
23
33
43
30
600
10%
27
37
53
269-
1989/IS455) 43 OPC (IS 8112-1989) 53 OPC (IS
12269-
1987)
REPORTING RESULTS
Field observations of various measurements.
Grade
of
Cement
Compressive Strength 3 days
7 days
MPA
MPA
28 days MPA
OPC
34.11, 35.31,& 36.11
47.5, 46.5, & 45.5.
70.22, 69.62 & 69.64
JK Laxmi
Avg= 35.17
Avg= 46.2
Avg = 69.76
53 Grade OPC UltrTech
36.82, 36.12, & 34.15 50.61, 49.36 & 48.5 70.22, 69.22 & 70.12
53 Grade
Avg = 35.71
Avg = 49.47
NOIDA METRO PROJECT REPORT 41
Avg = 69.88
COMPRESSIVE STRENGTH OF CONCRETE
OBJECT
This method of test covers the procedures for determining the compressive strength of concrete in compression testing machine (As per IS:516).
PROCEDURE
1. Cube specimens will be manufactured and cured as per IS:516-1951. Take sample of concrete for test specimen at the mixer or in the case of ready mixed concrete from the transportation vehcle discharge. 2. Lightly oil the interior surface of the mould before placing concrete. 3. Place fresh concrete in the mould in three layers and rod each layer 35 times with 16 mm rod, 60 cm in length, bullet pointed at lower end. In the case of vibration care is to taken that there is no mortar loss. 4. After the top layer has been rodded, the surface of the concrete shall be struck of with a trowel and covered with glass plate. If needed the concrete can be compacted by vibration. 5. Cover the moulds with wet straw or gunny bags to ensure uniform temperature and moisture conditions during the first 24 hours. The tests shall be generally at the end of 7 days and at the end of 28 days and immediately after the removal of test specimen from curing room. 6. Place the test specimen in the machine in such a manner that the load is applied to the side of specimen as cast. The load shall be applied axially without shock at the rate of approximately 140 kg per sq cm per minute. 7. Record the total load indicated by the testing machine at failure of test specimen. Calculate the unit compressive strength in kg per sq cm using the area computed from the measured dimensions of the test specimen. The type of failure and the appearance of concrete shall be recorded.
NOIDA METRO PROJECT REPORT 42
ACCEPTANCE CRITERIA: As per IS: 516-1951
REPORTING RESULTS
Grade ConcreteM35
of Setting time
Fineness
Initial
Final
and (Min)
(Min)
Max
Compressive Strength 3 days MPA
7 days
28 days
MPA
MPA
location 30
600
10 %
16
22
33
30
600
10%
23
33
43
30
600
10%
27
37
53
NOIDA METRO PROJECT REPORT 43
PLANNING THE PROJECT-CASTING YARD: The casting yard is a place where all the concrete structures like girders and pier caps are casted/ manufactured, shifted to the stack yard and shifting to the worksite / Viaduct after they gain their required strength.
Requirements of Casting Yard:
Accessible approach to sites. Good environmental conditions Medical and canteen facilities. Proper water drinking places at different points in site. Lab for testing.
Casting Yard
NOIDA METRO PROJECT REPORT 44
Batching Plant
Helmet Color Codes NOIDA METRO PROJECT REPORT 45
Color Code for Lifting Tools and Tackles
UCOE classmates at DMRC/NMRC Canteen (Casting Yard)
NOIDA METRO PROJECT REPORT 46
PROJECT EXECUTION (PROBLEM STATEMENT) The main scope of work where I was deployed consisted of execution of work in casting yard, constructing I/C girders and plate-forms ,stations etc. To facilitate above, there was a system of furnishing method statement for construction of all important activities in metro rail construction. For example during the process of my training, I came across with following method statements;
Method statement for construction of I Girder/C Girder.
Method statement for repair of concrete structures.
Method statement of Construction of various elements of Stations.
Out of above method statements, I observed execution of girder more closely and I had the opportunity to understand the NMRC work culture. To my surprise I found the method statement to be a comprehensive document which provided an in-depth knowledge of execution stage and quality norms. The same is elaborated in detail in succeeding paragraph;
METHOD STATEMENT FOR CASTING OF PRE-TENSIONED U- GIRDER SPANS
The method statement submitted by contractor M/s CEC-SAM INDIA to Noida Metro Rail Corporation consisted of details such as purpose, scope, reference documents, definitions, responsibilities, machinery/tools/equipment& materials, methodology, inspection & test plan, risk assessment, environment management, and enclosures. Method statement in detail is elaborated as below;
1. PURPOSE The purpose of the document is to describe the work procedure to be adopted for construction of the Pre-Tensioned U - Girder as per the design drawings in planned and systematic manner. Furthermore this document provides sufficient information on the construction methods including site installations, the personnel to execute the job, major machinery and materials required, inspection and the safety and health matters considered necessary to successfully carry out the construction.
NOIDA METRO PROJECT REPORT 47
2. SCOPE To set out the requirement for Pre-Tensioned U - Girder construction works for the project to meet all the contract requirements and contractor standards for work operation, safety, quality and environmental compliance.
3.
REFERENCE DOCUMENTS
Contract document
Good for construction drawing of Pre-Tensioned U - Girder
IS 456 for reinforced cement concrete
IS 1786 for reinforcement
IS 1343 for pre-stressing works
Bar bending schedules as prepared by Contractor and approved by DMRC.
Health, Safety and Environment plan.
Project Quality management plan.
4. DEFINITIONS For the purpose of this document the term:
DMRC :Delhi Metro Rail Corporation
CEC-SAM JV : Contractor
GFC
: Good for Construction
IS
: Indian Standard
ITP
: Inspection and Test Plan
OCS
: Outline Construction Specifications
QA
: Quality Assurance( applies essentially to process)
QC
: Quality Control( applies essentially to works and products)
SHEVC
: SHE Verification checklist.
5. RESPONSIBILITIES
The proposed organization charts associated with this work are enclosed in succeeding paragraphs. NOIDA METRO PROJECT REPORT 48
Project Leader Site In charge
U Girder/I Girder
EXECUTION
SHE
DAY Engineer (1NO) Superviso r (1 N0)
Night Engineer (1NO) Supervisor (1 N0
DAY Engineer (2NO) Foreman (01 No) Supervisor (2 N0)
NOIDA METRO PROJECT REPORT 49
Night Engineer (2NO) Foreman (01 No) Supervisor ( 2 No)
Project Manager
Review of the proposed method statement and its approval. Overall scope of the work Coordination of the personnel and equipment to ensure continuous program of work during the execution. Receiving the daily progress reports and distributing the same to the clients approved representative and to ensure the appropriate action based on the client comment.
Site Manager
Implementation of this method statement. Safety to personnel, incident reporting and implementation of safety management plan and safety management system. Ensuring that the works are carried out in accordance with approved permits.
Site Engineer
Ensuring that the construction is as per the method statement. Ensuring that all required as per the built data is recorded. To calculate the relevant field calculations as required during execution and recording the same.
QA/ QC Engineer
Responsible for verification/inspection of all the activities in accordance with the ITP. Ensuring that all required tests are carried out and respective records are maintained. Reporting the result to QA/QC head.
Safety Supervisor
Responsible for verification/inspection of all the activities in accordance with the safety manual/ risk assessment.
6. MACHINERY, TOOLS, EQUIPMENTS AND MATERIALS Following major equipment/tools shall be required in the construction of a PreTensioned U- Girder.
NOIDA METRO PROJECT REPORT 50
S NO
DESCRIPTION
Qty
1 2
Batching Plant 60 Cum/hr cap Transit Mixers 6 cum cap
03 No + 1 standby 20 No + 1 standby
3 4 5 6 7 8 9 10 11
Shutter vibrators Needle vibrators 20/40/60 mm dia Concrete Placer/pump Jet/ Sprayer/ Sprinkler system for curing Curing Pump Total Stations Auto level Air Compressors with accessories 155cfm Mono strand pre-stressing jacks with power packs with additional master grip
40 No + 5 standby 20 No + 8 standby 2 set + 1 standby 7 sets 2 sets 1 sets 1 sets 1 sets 2 sets
12
Central hole pre-stressing jacks with power packs ( 1 1 set (additional set consisting of 6 no hollow jack, 1 no EOHP,1 no standby 02 no hollow manifols, 6 set of macalloy bar with 18 no nuts & jacks) plates)
13 14 15
Reinforcement cutting machine Reinforcement bending machine Gantry crane for shifting of rebar cage/ c-girder
7 sets 7 sets 2 no for one bay
Any other equipment, machinery, tools and plants etc wherever required to complete the erection successfully shall be deployed. MATERIALS Major materials to be used in the construction of Pre-Tensioned C- Girder are as follows:
Approved grade of concrete as per drawing for Pre-Tensioned C- Girder.
TMT reinforcement bars confirming to IS 1786-2008.
Approved prestressing strands
Approved prestressing hardware
Concrete cover blocks
Approved curing compound
Approved shuttering oil demolding agent. NOIDA METRO PROJECT REPORT 51
Batching Plant
Boom Placer
Bar Straighter Machine
Transit Mixer
NOIDA METRO PROJECT REPORT 52
METHODOLOGY CASTING YARD Casting yard as proposed consisted of following major items: Long line precasting beds- total 2 nos for pre cast spans. Formwork sets for pre- casting straight spans. 1. Bottom forms- 2 sets for all long line beds. 2. Outer forms- 2 sets for all long line beds. 3. Inner forms- 1 sets of 6 for 12 long line beds. 4. End forms- 6 sets for 12 long line beds. Rebar cage tying beds/jigs for pre cast spans. 27 m-6 Nos( 3 Nos/bay) 2 Nos of batching plants, each 60 cum / hr cap Stacking yard for pre-tensioned spans Fine and coarse aggregate bins Silos for cement Facility to feed micro silica Stores for prestressing materials, general civil & mechanical items Water tank with required capacity and pumps Q C laboratory Project Manager Office Survey tower for survey work Sheds for generators and miscellaneous activities Access and internal service roads Gantry crane 100 MT – 4 Nos( two per bay with sync operation) Curing arrangement with GI pipe lines & PVC jet/sprinklers/showers Curing compound with spraying system
LABORATORY Laboratory set at casting yard equipped with all kinds of testing apparatus for testing of aggregates, cement, and concrete & for concrete mix design. Equipment like digital balance, cube testing machine, thermometer will be calibrated at a specified standard frequency. SHUTTERING FOR U GIRDERS Each shuttering set comprises 4 major components; 1. Bottom shuttering supported on long line RCC beds. 2. Outer shuttering supported against bottom shutters & pre-cast yard bed. 3. Inner shuttering supported against independent supports & outer shutters so that these could be shifted to other beds as and when required. 4. End shutters are supported against bottom, outer & inner forms. NOIDA METRO PROJECT REPORT 53
U - GIRDER PRODUCTION SEQUENCE 1. Clear and clean bottom shutters. 2. Clean bring back and align outer shutters to required positions. 3. Fix in position end shutters. 4. Apply demoulding agent to bottom and outer shutters 5. Shift and feed pre-fabricated reinforcement cages along with debonding tubes. 6. Align reinforcement cages and place clear cover blocks in position. 7. Thread HT strands through pre-fabricated reinforcement cages and debonding tube. 8. Align HT strands and debonding tubes in position. 9. Remove initial slack of HT strands ay appling load with monojack. Check the cable/ strand for twist. If there is twist, the same shall be removed. 10. Stress HT strand from the anchor end for design loads. 11. Record details like design loads applied v/s extensions of the strands observed. 12. Fix in position clear cover blocks. 13. Realign debonding tubes and seal tube ends going to be embedded in concrete. 14. Fix in position inner shutters/ inserts as per drawing. 15. Place, consolidate and finish concrete. 16. Attend curing with hessian cloth after presetting of concrete. 17. Release end shutters. 18. Release, clean and shift inner shutters to adjacent beds. 19. Release outer shutter. 20. Allow concrete to gain further strength of M-35. 21. Release pre-stress, design load from stressing end and record movement of strand holding structural beam and all U- girders spans at their both ends. 22. Cut HT strands by wheel cutting machine flush with concrete face. 23. Sift C-girders to stacking beds. 24. Attend HT strand both end finishing. 25. Continue curing till 14 days after placing concrete by wet/ membrane curing.
NOIDA METRO PROJECT REPORT 54
CURING OF U-GIRDERS
Girders shall be cured by either two procedures below:
Wet curing:
Curing shall be continuous over a minimum of 14 days period after concreting. Curing by either ponding/ spraying/jetting water shall be attended un-interruptedly. Clean hessian cloth shall be wrapped on exposed concrete surfaces shall be used for moist curing. Water shall be sprayed to keep hessian cloth un-interruptedly moist. Frequency of wall shuttering shall be such that, hessian cloth will not be allowed to get dried. Top of bottom shall be ponded with water.
Curing in stacking yard:
Slab bottom will be attended for curing over the balance period either by water sprinkling or with approved curing compound. Or Membrane curing followed by wet curing:
Curing shall be continuous over a minimum of 4 days period after concreting/ concrete attains strength of 35MPa as per the procedure mentioned above. Curing compound shall be then sprayed over the girder surface as per manufacture’s recommendation and shifted to the stacking yard.
Suitable arrangements of recycling the water during curing of all the castings at casting yard shall be made to save water.
DESHUTTERING
Internal shuttering shall be retracted and removed using turn buckles provided after 24 hours of concreting. Only trained personals shall be deployed in retracting of turn bukles activity. Gantry crane positioned and third party certified lifting gears shall be used for lifting NOIDA METRO PROJECT REPORT 55
of inner shutters. Inner shutter all turn buckles shall be made free and before lifting guide rope to be provided at both ends to control the swing. Lifting will be done under lifting supervisor. Then internal shuttering shall be cleaned and kept ready to feed in adjoining precast bed. Before shifting it to adjoining bed, it will be applied with de-moulding agent. A set of beams supporting inner shutter sets shall be shifted to adjoining pre-cast bed using goliath gantry crane. Required PPE’s shall be provided to all workmen.
Outer shuttering shall be retracted using turn buckles and moved outward after 3-4 days of concreting. Outer shuttering shall remain in retracted place till C-girder is shifted to stacking yard. Then it shall be cleaned, realigned and applied with de-moulding agent to receive pretied reinforcement cage along with debonding tubes.
Bottom shuttering shall be exposed only after shifting of pre-tensioned C-girders. Then it shall be cleaned, realigned and applied with demoulding agent to receive pre-tied reinforcement cage along with debonding tubes.
RELEASING PRE-TENSIONED STRANDS
Pre-tensioned strands shall be released after only when concrete gains a minimum strength of M35 grade. Releasing shall be done from stressing end only by using central hole stressing jacks meant for stressing as well as for releasing. Movement of strand holding structural beam and all C-girder shall be recorded “Stress v/s Movement”. For all C-girders movement at their both ends shall be recorded. All strands shall be cut by using wheel/s as far as possible flush with C-girder concrete faces. Trained personal shall be deployed with safety gears (Face guard, leather hand gloves, safety shoes) for strand cutting activity. Electrical certified portable tools to be used. Gas cutting set shall not be used for cutting the strands. Lifting arrangement shall be proper reading to be taken before activities if required. Strand cutting sequence shall be from stressing end towards anchor end and from outer to inner strands symmetrically.
NOIDA METRO PROJECT REPORT 56
INSPECTION AND TEST PLAN “Request for inspection (RFI)” shall be raised for inspection to the DMRC representative. Casting shall be done after getting clearance from the client. Inspection Test Plan shall be followed.
1. Formwork inspection checklist. 2. Reinforcement and HT strand inspection checklist. 3. Concrete inspection format. 4. Concrete pour card. 5. Bar bending schedule (BBS) 6. Concrete test report for span. 7. Embedment checklist 8. Pre-tensioned items checklist and pre-tensioning record. 9. Request for inspection format
RISK ASSESSMENT Risk assessment and control measures to reduce the risk level shall be followed. All site personal shall be provided with helmet, boots, and other personal safety devices. All safety precautions for safe working at height shall be taken. Precautions to eliminate electrical hazards, safety devices shall be used for all the electrical equipment used for fabrication, erection, concreting and electrically operated hand tools etc. All site personal shall follow the DMRC approval health, safety and environment policy/ plan.
ENVIRONMENTAL MANAGEMENT
Safety, Health and Environment plan will be followed throughout the construction programme.
NOIDA METRO PROJECT REPORT 57
PROBLEMS ENCOUNTERED DURING THE TRAINING: 1. Verticality of shuttering in piers. 2. Offset in joints. 3. Honeycombing and Spalling of concrete.
REMEDIAL STEPS 1. For assuring the verticality of column, proper arrangement of plumb bob should be done so that accuracy is maintained within limits. If there is still some error, then the shuttering should be held tightly in position using steel bars and welding.
2. Sometimes, in spite of best efforts in matching the mould panels and covering the minor gap between the panels, offsets in concrete cannot be eliminated. Though it does not affect strength, it is a strain to eye and therefore calls for removal of it. This can be chipped out by small chisel and area should be smoothened by grinding.
3. Inspite of careful handling of formwork at the time of demoulding some concrete comes out. This part of the segment requires to be rebuilt in its proper shape and profile. Concrete of same mix should be used for making this area. Before the placement of concrete, the parent concrete area should be cleaned thoroughly and all loosely bonded materials shall be removed.
Overall Benefits of Training Industrial Training is a class healed at site to provide an enhanced understanding of the outside working environment before the student graduate. Student like civil and urban engineering and other fields also take this practice. The main aim of this practice (industrial training) is that to teach students communication with different workers or employees, to improve practical skill what they learned at class, up grading the theoretical knowledge in addition to the class, improve their leadership skill, team playing skill and etc. I have acquired much knowledge in different tasks as explained below in different section. That different knowledge gets me a good performance in the training period and I gain an experience that helps me after the graduation in the upcoming working era of mine.
NOIDA METRO PROJECT REPORT 58
Improving practical skill
The aim of the internship is to address more practical knowledge for student. So, I found a practical knowledge at the site as much possible within the four months. The knowledge we have learn in the class is helpful to get those practical or real work in the site and totally different from the actual knowledge gained from the class. Thus I found some knowledge in the site which helps me to work with the site environment or site peoples. Some of the practical knowledge I gain from the training class was:
Construction of formwork and false work for some reinforced concrete structure.
In any construction work the first stage before casting of concrete is designing and constructing of form work. As I explained in the work procedure the formwork and false work must be stiff and must resist the fresh concrete till the concrete gain its strength. Thus the construction stage of form work was new to me since I‘m new for the practical world now I gain practical knowledge about how it is worked and erected.
Bar bending, positioning, splicing and tying, according the specified drawing.
After the formwork and false work is ready the bar bending, positioning and tying work goes next. This work is done based on the working drawing provided in the working drawings (structural drawing) by the design team of that specified structure. In most case it was new for me to see such work since it is a practical work only performed at the site. Surveying on building construction. We conduct the surveying class in the field for its lab session of the course in the normal class. But we don‘t know about how it is going to be in building construction in particular and in which particular stage of the construction work it used either the super structure or sub structure. Concrete is a vital material in any construction of reinforced concrete Concrete is a vital material in any construction of reinforced concrete and is the main constituent or ingredient of any reinforced concrete structure. Thus it is mandatory to know this material in practice including how it is treated, placed (poured), mixed and the equipment used for those work. I got the practical knowledge in terms of those listed aspects of concrete.
Different construction equipment (machines) and their use in construction site. Many of great structures before are a product of numerous human power and countless days inspired by great powers. Machines are capable of handling tough work which may be beyond the scope of human labor to be performed. They can be expected to work with fair degree of effectiveness even under adverse weather, climate or topographical conditions. I generally know how equipment‘s are used in the site including their specific purpose.
NOIDA METRO PROJECT REPORT 59
Upgrading the theoretical knowledge
The training is not only depending on the practical aspect but it also help students to upgrade or increase knowledge on already that they have. I try to integrate the practical knowledge with that of the theory learned in the class in different place in order to get more knowledge than the theory we learned on the class. I got the internship class very interesting in terms of upgrading a theoretical knowledge and I learned from the site some theories that we haven‘t learn in the class room by searching different related literature. Some of this is: Quantity surveying Structural design of shear wall and its advantage Construction equipment Report writing I learned those things in exclusive cause it is hard to read and understand everything from books and asking some peoples at site to those things ashamed me. Generally I change myself alit bit after the internship period in my knowledge than before I took it.
Upgrading interpersonal communication skill
Communication is sharing or exchanging information or ideas with others in order to get some messages and knowledge. The communications systems within the building design and construction enterprise has taken on a large role in the achievement of profitability and efficiency. A basic understanding of communication systems is beneficial to all building professionals and trades, as they all play a part in the success of the construction. Construction is one of the places that ask a good communication skill either managing every trade of work or asking what is gowning on over there. So, communication is an important way of learning, which can be defined formally as the act, process, or experience of gaining knowledge or skills and sharing what we know. Cool communication is important in the real constructions world and it can appear in different forms as speaking, writing, and listening. In the site the most things I gain is due to communication with other workers like engineers, skilled and non-skilled workers, Forman etc. in some place/case it is very difficult to talk workers and ask them what we want because of that they underestimate us and sometimes they are not eager to tell.
Improving team playing skill
Team playing skill for construction work Team works, especially for engineers, involve in every piece of task and achieving good team playing skill is essential for Effective completion of tasks and Increasing productivity. This skill already exists in my personality in the campus due to different assignment and project works that I work together with student. But this skill is more than this in the construction site. In the construction site the work is already a team work and it needs more closeness of workers to solve problems arise in different aspects, misunderstanding in the drawing or working methodology and consult every work. We the student at the site also works together as a team to get more understanding and share ideas. More or less I improve my team work status by working together with different professionals, student and workers as a whole in the civil engineering works and consulting. NOIDA METRO PROJECT REPORT 60
Improving leadership skill
Leadership is the process of influencing individuals or groups to accomplish an organizational goal or mission. I have seen how each worker is controlled and organized to perform its day to day activities. Among all other managements I have seen that human resource management is the most important one. I have actually observed the method of controlling the working time and amount of work done by each worker so that the work proceeds according to the work plan (schedule).Leadership is a skill to guide, control and monitor peoples. For effective leadership i understood that personal values like confidence, effective communication and devotion are very important.
In order to be good Leadership the following criteria should be fulfilled. Those are:Be technically proficient (skilled with different knowledge‘s). Seek responsibility and take responsibility for your actions. Make sound and timely decisions. Know your people and look out for their well-being. Keep your workers informed. Develop a sense of responsibility in your workers. Ensure that tasks are understood, supervised, and accomplished. Use the full capabilities of your organization. Listening to others. Being organized. Able to communicate clearly and efficiently. In the site it was impossible to us to lead anything because we go to the site tolearn about the site work and we don‘t have enough ability to handle such works in such short time but we have learned how to become a good leader and the main signal of a good leader. Finally what I take hold of is Becoming a leader isn‘t easy because it takes a conscious commitment and consistent effort to develop one‘s leadership skills
Work ethics and related issues
The concept of work ethics may be summarized as the overall quality in one‘s behavior towards appreciating the process of work flow and performing rather well on the job so that this work flow will not be jeopardized in the long run. During my internship program, I could say that I have managed to do my side of the job description with a high spirit and enthusiasm so that there was a smooth flow of activities both in the office and on construction site. Work ethics involve such characteristics as honesty, responsibility, reliability, accountability and etc. NOIDA METRO PROJECT REPORT 61
Punctuality
Punctuality is one of the major issues that could be raised when talking about work ethics and on my side I tried meet this criteria by attending to my working station in time so that there will not be any delay on the activities planned for that day. The behaviour that one shows towards his peers and colleagues is also one manifestation of the concept of work ethics. Personally, I always respected and gave priority the employers of the company. Elements of work ethics that worth mentioning are:-punctuality, honesty, reliability, office discipline, corporation and responsibility. We as a student should follow the rules and regulations set by the company and avoid complaining any work load, activity or assignment that may arise on the site or office. It is a pleasure of supervisors if we have a good work ethics and we are responsible for any given tasks. Since the aim of internship is to let students know the outside environment pertinent to their field, which includes of such the above dealt qualities, I was with the great interest that I tried to meet my responsibilities and work ethics that I suppose to be fulfil by my side.
Conclusion The entire period of Industrial Training has given me good & important practical exposure of construction work. At the end of the Industrial Training under SAM INDIA, I feel myself better equipped and ready to face the field problems related to Civil Engineering works. In these four& half months, I have learnt how to deal with Authorities and workers under supervision and I have become familiar with the fact that the field work is much difficult from theoretical knowledge. But until you don’t have the theoretical knowledge, the practical work is very difficult to carry-out and understand. Working with experienced engineers has enhanced my technical skills to a great extent for which I am grateful to them. Their professional approach towards work is appreciable. The training has provided me with much needed field exposure to shape up my thinking in a better way as a professional making me a lot more capable to face the challenges of life.
NOIDA METRO PROJECT REPORT 62
REFERENCES
DMRC Contract Documents & Drawing
Reinforced Concrete By Limit State Design By Dr A K Jain
Images shown in the report are self-clicked images at various locations
Text include the details carried out through the Site engineers, Supervisors, labourers.
DMRC Website www.delhimetrorail.com
NMRC Website www.nmrcnoida.com
SAM INDIA Website www.samindia.com
NOIDA METRO PROJECT REPORT 63
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