Summer Intrenship at Gammon India Ltd

SUMMER TRAINING REPORT (9/6/2014 5/7/2014)

Submitted by: Mohtisham Ali Third year undergraduate student, Department of Civil Engineering, INTEGRAL UNIVERSITY, LUCKNOW

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SUMMER TRAINING REPORT 2014 (INTEGRAL UNIVERSITY, LUCKNOW)

MOHTISHAM ALI (1100111112)

Aknowledgement

I am very thankful to GAMMON INDIA LIMITED & NATIONAL

HIGHWAYS AUTHORITY OF INDIA for given me the opportunity to

undertake my summer training at their prestigious GANGA BRIDGE AND

FLYOVER PROJECT. It was a very good learning experience for me to

have worked at this site as this project involved many unique construction

practices and challenges. I would like to convey my heartiest thanks to

Mr. MANOJ BISWAS (Project Manager), who heartily welcomed me for the

internship. I would also like to give my heart-felt thanks to Mr. U.N. SINGH

(Execution Head), Mr. RAMESH PAL (QA/QC Head), who guided and

encouraged me all through the summer training and imparted in-depth

knowledge of the project. Also I would like to thank Mr. T.K. CHATTERJEE

(Planning Head), who assisted and guided me whenever I needed help.

We also thankful and pay our sincere gratitude to Mr. Somnath Bajpai

(Executive HR), We sincere thanks to all the department heads of Gammon

India Limited for giving their precious time and valuable guidance during

my internship programme.

Last but not the least; I would like to thank all the staff at Gammon India

Limited, for being so helpful during this summer training.

Name: Mohtisham Ali

Date: 5th July 2014

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ABSTRACT

GAMMON INDIA LIMITED have developed so many project which

are so large and whose costing alot. The project Rehabilitation and

Upgradation from 75 Km to 80.60 Km of NH-25. (GANGA BRIDGE &

FLYOVER PROJECT) is important to relief from a big jams in the town of

Kanpur.

The total length of the project is 5.06 KM and the estimating cost of

the project is Rs. 159.06 Cr. In this project I was Trainee. I work on Pre-

stressed Beam. Following are important department where I work :

PLANNING

QUALITY CONTROL

PLANT

EXECUTION

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INDEX

S.No. CONTENTS Page No.

1. Project Details 1

2. Objective 2

3. Brief Introduction of G.I.L 3

4. Organizational Chart 9

5. Product/Specification/Activities 11

6. Planning Department 12

7. System/Plan Layout 14

8. QA / QC Department 15

9. Plant Information 35

10. Project Execution 40

11. Chronological Training Dairy 47

12. Safety Requirement 49

13. Suggestions 51

14. Conclusion 52

15. References 53

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DETAIL OF THE PROJECT

A. PROJECT NAME Rehabilitation and Upgradation from 75 Km

to 80.60 Km of NH-25. (GANGA BRIDGE & FLYOVER PROJECT)

B. CLIENT NATIONAL HIGHWAYS AUTHORITY OF INDIA (N.H.A.I)

C. CONTRACTOR GAMMON INDIA LTD.

D. CONSULTANT Feedback Infra Pvt. Ltd. (F.I.P.L)

E. CONTRACT SECTION EW-II (UP-06)

F. CONTRACT LENGTH Km 75.00 to Km 80.60

G. AGREEMENT DATE 29.09.2005

H. TENDER AMOUNT INR 159.06 Cr.

I. TYPE OF CONTRACT BILLING OF QUANTITY

J. STARTING DATE 02.12.2005

K. CONTRACTUAL DATE OF COMPLETION

01.09.2008

L. EXTENDED DATE OF COMPLETION 18.09.2014

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OBJECTIVE

CONSTRUCTION OF PRE-STRESSED BEAM.

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INTRODUCTION

ABOUT THE ORGANIZATION:

HISTORY:

The beginning of such a formidable company is to be found in the

vision of an equally formidable man. Mr J. C. Gammon was the

driving force behind the introduction of prestressed concrete to India.

He designed the reinforced concrete piles of the Gateway of India.

The foundations of the arch reach deep into the bedrock. With time,

he came to be known as the Sculptor of Concrete.

His foresight was fundamental to the company reaching its present

stature. His pioneering spirit led to a number of innovations that were

the first of their kind.

His enduring values continue to build the Gammon legacy.

J. C. Gammon The Legacy

Bridges like the Bonum Bridge and the Patalganga Bridge.

The Colloidal Grouting Process at Mundali Weir.

The RCC Pile Foundations for the Gateway of India.

Thin Shell Prestressed Structures of Meerut Garages.

The Hyperbolic Cooling Towers at Sabarmati

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GAMMON GROUP : AN OVERVIEW

Gammon India is built on a legacy that has stood the test of time.

Technological and design excellence, and a discerning eye for quality and

safety are some of the characteristics that distinguish Gammons tradition

for perfection in its areas of operation.

Gammon India is amongst the largest physical infrastructure

construction companies in India. Its track record spans significant landmark

projects built over several decades, with a prominent presence across all

sectors of civil engineering, design and construction. It has a track record of

building landmark structures, some of which have become iconic. This

includes The Gateway of India, the piling and civil foundation work for

which was successfully executed by Gammon as its maiden project way

back in 1919.

Besides its large scale of operations

in the Construction and Infrastructure

domain, Gammon has a dominant

presence in energy business in which it

operates in the hydro, nuclear and

thermal power sectors. In fact,

Gammons association with the

construction of nuclear power projects dates back to 1959 when it

completed the Pre-Stresses Concrete (PSC) Ball Tank of Indias first

Atomic Reactor Plant in Trombay.

Gammons projects cover businesses

and projects involving highways, public

utilities, environmental engineering and

marine structures. Gammons expertise

also covers the design, financing,

construction and operation of modern

bridges, viaducts, and metro rail, both on a BuiltOperateTransfer (BOT)

basis as well as contract execution. An example is the upcoming Signature

Bridge project in Wazirabad in NorthWest Delhi. This project would

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significantly help in the efficient flow and management of traffic in the

region.

Gammon is also active in the Social Infrastructure sector through its

operations in the realty project segment. Examples include residential

complexes such as Pebble Bay and Godrej WoodsMan Estate in

Bangalore,Godrej Kalyan in Mumbai, RNA Exotica, Mumbai; Hotel

complexes such as Hotel Leela Palace, Chennai and G Staad, Bangalore

besides commercial complexes such as Galleria Mall(INXS) in Bangalore.

Gammon is also currently undertaking a major project for ISKON at Sri

Mayapur in West Bengal involving the construction of a temple complex

and a modern cultural centre.

Gammon international include a

majority holding in Franco Tosi

Meccanica, SAE Power lines, and

Sofinter group, Italy spanning the

sectors of power and industrial boilers as

well as waste and environment

management systems. Gammon has

received accolades and recognitions

from a variety of reputed institutions. Examples include the Indian Concrete

Institute Award for most outstanding concrete structure presented for the

segmental arch bridge across the River Beas (Himachal Pradesh) and the

first prize for Excellent Aesthetics for the Vidyasagar Sethu Project across

the River Hoogly in Kolkata.

Currently Gammon India has a

strong talent base of over 3350

employees on its own rolls apart from

5500 officers and staff working under its

aegis at various project sites. It further

engages more than 200,000 labour/staff on daily wage basis. Its standalone

turnover in financial year 201112 was close to US $ 1.1 billion with the

Groups turnover in excess of US $ 1.6 billion.

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QUALITY POLICY

Gammon India is the first Construction in India to have ISO9001

certification in design as well as execution for all Civil Engineering

structures.

Gammon is committed to form seamless partnership with its

customers, so that their requirements become our challenge. Gammons

quest for excellence is achieved by its innovative engineering and quality

execution of the projects, on time, within budget, by its high performance

team which is adaptable to each project..

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HEALTH SAFTEY AND ENVIRONMENTAL POLICY

At Gammon, extensive health and safety guidelines defined standards for every project. Regular safety training programmes are undertaken at the sites. Further, regular health and fitness checkup for every member of our staff is mandatory.

We maintain a high standard of safety through meticulous risk assessment. Gammon has a stellar record of twelve million hours of accidentfree work at Kalpakkam. This is a consistent track record, which is no mean achievement, since most of our initiatives take place under hazardous geographical conditions. These are challenges that our staff can face because of their training. They also have the assurance of a health & safety code that is considerate and transparent. To set standards, we must first set an example.

Gammon is an ISO 9001, ISO 14001 and OHSAS18001 certified company. We have a number of National Safety Awards to our credit. The concern inherent in our corporate culture inspires a sense of loyalty toward Gammon.

WORK CULTURE

Work Culture emphasises: Freedom to experiment Continuous learning and training Transparency Quality in all aspects of work Rewards based on performance and potential

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TRAINING

Human Resources Department believes that Quality is the hallmark

of any successful venture. Quality Training and Development ofHuman

Resourcesisrealized through: Identifying training needs within the

Organization and designing and implementing those need based training

programs to bring about continuous upgradation of knowledge, skills and

employee attitudes.

VISION&MISSION

VISION

To Consistently build the reputation of Gammon amongst all

stakeholders as a respected and influential leader in the Construction

and Infrastructure Domain with Global Presence and Local Expertise

backed with a sustained focus on attributes of Sustainability and

Profitability and Employee engagement and Pride

To be leaders in innovation engineering, with uncompromising integrity,

timely delivery, pride and ownership and highest standards of quality to

reinforce the positioning of the organisation as Builders to the Nation.

MISSION

"To design, build and service physical infrastructure for

improved living, enhanced work environment

and swift transportation."

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ORGANIZATIONAL CHART

CHIEF PROJECT MANAGER (C.P.M.)

PROJECT MANAGER (P.M.)

DEPUTY MANAGER (Dy. M.)

ASSISTANT MANAGER (A.M.)

ENGINEER (E.)

JUNIOR ENGINEER (J.E.)

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PROPOSEDPROJECT

Rehabilitation and Upgradation from 75 Km to

80.60 Km of NH-25. (GANGA BRIDGE & FLYOVER PROJECT)

KANPUR, INDIA

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PRODUCT (S) & SPECIFICATIONS / ACTIVITIES /

CODING

Product:- Rehabilitation and Upgradation from 75 Km to 80.60 Km of

NH25.

(GANGA BRIDGE & FLYOVER PROJECT).

Specifications:- All the works shall be carried out as per standard practice

of Engineering, IScodes, I.R.C specifications and M.O.R.T.H

specifications.

Activities:- All the work consists :

1. Planning ,

2. Quality Control ,

3. Plant Information ,

4. Execution ,

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PLANNING DEPARTMENT

Construction planning is a fundamental and challenging activity in the management

and execution of construction projects. It involves the choice of technology, the

definition of work tasks, the estimation of the required resources and durations for

individual tasks, and the identification of any interactions among the different work

tasks. A good construction plan is the basis for developing the budget and the

schedule for work. Developing the construction plan is a critical task in the

management of construction, even if the plan is not written or otherwise formally

recorded. In addition to these technical aspects of construction planning, it may also

be necessary to make organizational decisions about the relationships between project

participants and even which organizations to include in a project.

Essential aspects of construction planning include the generation of required

activities, analysis of the implications of these activities, and choice among the

various alternative means of performing activities.

In developing a construction plan, it is common to adopt a primary emphasis on either

cost control or on schedule control. Some projects are primarily divided into expense

categories with associated costs. In these cases, construction planning is cost or

expense oriented. Within the categories of expenditure, a distinction is made between

costs incurred directly in the performance of an activity and indirectly for the

accomplishment of the project. For example, borrowing expenses for project

financing and overhead items are commonly treated as indirect costs. For other

projects, scheduling of work activities over time is critical and is emphasized in the

planning process. In this case, the planner insures that the proper precedences among

activities are maintained and that efficient scheduling of the available resources

prevails. Traditional scheduling procedures emphasize the maintenance of task

precedences (resulting in critical path scheduling procedures) or efficient use of

resources over time (resulting in jobshop scheduling procedures). Finally, most

complex projects require consideration of cost and scheduling over time, so that

planning, monitoring and record keeping must consider both dimensions. In these

cases, the integration of schedule and budget information is a major concern.

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A parallel step in the planning process is to define the various work tasks that must be

accomplished. These work tasks represent the necessary frame work to permit

scheduling of construction activities, along with estimating the resources required by

the individual work tasks, and any necessary precedences or required sequence

among the tasks. The terms work "tasks" or "activities" are often used interchangeably

in construction plans to refer to specific, defined items of work. Planning department in Gammon India Limited uses Primavera as a powering tool for

reducing risk. Primavera gives efficiency to plan a project, identify the

resources required and identify the tasks required in a sequence, increasing probability

of delivery of the project to the time, cost and quality objectives. Primavera gives you

a powerful, visually enhanced way to effectively manage a wide range of projects and

programs. From meeting crucial deadlines, to selecting the right resources, Primavera

empowering your teams.

The initial schedule of major construction activities S0 is prepared according to the

Clients preference. S0 is the basis for all types of scheduling. Preliminary schedules

representing the monthly work estimates are prepared based on experience

considering local climate conditions, environment, learning curve, pace of work,

mobilization, etc in Primavera. Productivities of different activities are estimated and

validated during the course of execution. Man power requirement is calculated based

on these productivities. Drawings released by the Client. Revisions and change orders

are issued as and when there is a change and distributed to all the units. The planning

system is updated in the first week of every month. Two progress schedules are

maintained original schedule prepared in the starting of the project, planned schedule

which is modified according to the requirements and conditions. Actual progress is

compared with the planned schedule and in case any delay in progress is then a

Catch up schedule is prepared and executed accordingly to overcome the delay.

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System / Plan Layout

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QUALITY ASSURANCE & QUALITY CONTROL

DEPARTMENT

Quality is the key component which propels performance and defines leadership

traits. At GIL, Quality Standards have been internalised and documented in

Quality Assurance manuals. GIL recognizes the crucial significance of the human

element in ensuring quality. Structured training programmes ensure that every

GIL employee is conscious of his/her role and responsibility in extending

Companys tradition of leadership through quality. A commitment to safety springs

from a concern for the individual worker every one of the thousands braving the

rigours of construction at numerous project sites. Gammon India Limited has a well

established and documented Quality Management System (QMS) and is taking

appropriate steps to improve its effectiveness in accordance with the requirements of

ISO 9001:2008. Relevant procedures established clearly specify the criteria and

methods for effective operation, control and necessary resources and information to

support the operation and monitoring of these processes.

QUALITY IMPLEMENTATION AT SITE

GIL has established procedure for monitoring, measuring and analyzing of these

processes and to take necessary actions to achieve planned results and continual

improvement of these processes. It has also maintained relevant procedures to identify

and exercise required control over outsourced processes, if any Systems and

procedures have been established for implementing the requisites at all

stagesofconstructionandtheyareaccreditedtotheInternationalstandardsofISO

9001:2008, ISO 14001:2004 and OHSAS 18001:2007. GIL continues to maintain the

trail blazing tradition of meeting the stringent quality standards and adherence to time

schedules in all the projects.

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TESTS ON CEMENT

CONSISTENCY

AIM

To determine the quantity of water required to produce a cement paste of standard

consistency as per IS: 4031 (Part 4) 1988.

PRINCIPLE

The standard consistency of a cement paste is defined as that consistency which will

permit the Vicat plunger to penetrate to a point 5 to 7mm from the bottom of the Vicat

mould.

APPARATUS

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VICAT APPARATUS

Vicat apparatus conforming to IS: 5513 1976 Balance, whose permissible variation

at a load of 1000g should be +1.0g Gauging trowel conforming to IS: 10086 1982

PROCEDURE

i) Weigh approximately 400g of cement and mix it with a weighed quantity of water.

The time of gauging should be between 3 to 5 minutes.

ii) Fill the Vicat mould with paste and level it with a trowel.

iii) Lower the plunger gently till it touches the cement surface.

iv) Release the plunger allowing it to sink into the paste.

v) Note the reading on the gauge.

vi) Repeat the above procedure taking fresh samples of cement and different

quantities of water until the reading on the gauge is 5 to 7mm.

REPORTING OF RESULTS

Express the amount of water as a percentage of the weight of dry cement to the first

place of decimal.

INITIAL AND FINAL SETTING TIME

AIM

To determine the initial and the final setting time of cement as per IS: 4031 (Part 5)

1988.

APPARATUS

Vicat apparatus conforming to IS: 5513 1976 Balance, whose permissible variation

at a load of 1000g should be +1.0g Gauging trowel conforming to IS: 10086 1982

PROCEDURE

i) Prepare a cement paste by gauging the cement with 0.85 times the water required to

give a paste of standard consistency.

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ii) Start a stopwatch, the moment water is added to the cement.

iii) Fill the Vicat mould completely with the cement paste gauged as above, the mould

resting on a nonporous plate and smooth off the surface of the paste making it level

with the top of the mould. The cement block thus prepared in the mould is the test

block.

INITIAL SETTING TIME

Place the test block under the rod bearing the needle. Lower the needle gently in order

to make contact with the surface of the cement paste and release quickly, allowing it

to penetrate the test block. Repeat the procedure till the needle fails to pierce the test

block to a point 5.0 0.5mm measured from the bottom of the mould . The time

period elapsing between the time, water is added to the cement and the time, the

needle fails to pierce the test block by 5.0 0.5mm measured from the bottom of the

mould, is the initial setting time.

FINAL SETTING TIME

Replace the above needle by the one with an annular attachment.

The cement should be considered as finally set when, upon applying the needle gently

to the surface of the test block, the needle makes an impression therein, while the

attachment fails to do so. The period elapsing between the time, water is added to the

cement and the time, the needle makes an impression on the surface of the test block,

while the attachment fails to do so, is the final setting time.


The results of the initial and the final setting time should be reported to the nearest

five minutes.

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TESTS ON AGGREGATES

SIEVE ANALYSIS

AIM

To determine the Grain size analysis of coarseaggregates for Concrete Material by

sieving as per IS: 2386 (Part I) & Grain size analysis of Sand (As per Table 10002

MOST Specification).

PRINCIPLE

By passing the sample downward through a series of standard sieves, each of

decreasing size openings, the aggregates are separated into several groups, each of

which contains aggregates in a particular size range.

APPARATUS

A SET OF IS SIEVES

i) A set of IS Sieves a). Coarse Aggregate : 20mm (Nominal Singal Size) Sizes : 40mm, 20mm, 10mm, 4.75mm. b). Coarse Aggregate : 10mm (Nominal Singal Size) Sizes : 12.5mm, 10mm, 4.75mm, 2.36mm.

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c). Coarse Aggregate : 20mm : 10mm and Sand (36:24:40) Sizes : 40mm, 20mm, 4.75mm, 0.600mm, 0.150mm.

ii)Balance or scale with an accuracy to measure 0.1 percent of the weight of the test

sample.

iii) A set of IS Sieve for Sand : 10mm, 4.75mm, 2.36mm, 1.18mm, 0.600mm,

0.300mm, 0.150mm.

PROCEDURE

i) The test sample is dried to a constant weight at a temperature of 110 + 5 oC

and weighed.

ii) The sample is sieved by using a set of IS Sieves.

iii) On completion of sieving, the material on each sieve is weighed.

iv) Cumulative weight passing through each sieve is calculated as a percentage of the

total sample weight.

v) Fineness modulus is obtained by adding cumulative percentage of aggregates

retained on each sieve and dividing the sum by 100.


The results should be calculated and reported as:

i) the cumulative percentage by weight of the total sample

ii) the percentage by weight of the total sample passing through one sieve and

retained on the next smaller sieve, to the nearest 0.1 percent.

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AGGREGATE IMPACT

VALUE TEST

AIM

To determine the Aggregate Impact value of coarse aggregates as per IS: 2386 (Part IV).

APPARATUS

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PROCEDURE

i) The sample should be pass through 12.5mm and retained on 10mm IS sieve

weight as W1.

ii) The sample is filled in three layers and each layer is tampered with 25 blows of

tampering rod.

iii) Then the hammer of 14 kg is allowed to fall a height of 380mm.

iv) After 15 blows, sample is taken off and sieve on 2.36mm IS sieve and weight passing as W2.


Impact value = [W2 / W1] x 100%

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26



TESTS ON FRESH CONCRETE

SLUMP

AIM

To determine the workability of fresh concrete by slump test as per IS: 1199 1959.

APPARATUS

i) Slump cone

ii) Tamping rod

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PROCEDURE

i) The internal surface of the mould is thoroughly cleaned and applied with a light

coat of oil.

ii) The mould is placed on a smooth, horizontal, rigid and non absorbent surface.

iii) The mould is then filled in four layers with freshly mixed concrete, each

approximately to onefourth of the height of the mould.

iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are

distributed evenly over the cross section).

v) After the top layer is rodded, the concrete is struck off the level with a trowel.

vi) The mould is removed from the concrete immediately by raising it slowly in the

vertical direction.

vii)The difference in level between the height of the mould and that of the highest

point of the subsided concrete is measured.

viii) This difference in height in mm is the slump of the concrete.


The slump measured should be recorded in mm of subsidence of the specimen

during the test. Any slump specimen, which collapses or shears off laterally gives

incorrect result and if this occurs, the test should be repeated with another

sample. If, in the repeat test also, the specimen shears, the slump should be

measured and the fact that the specimen sheared, should be recorded.

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CUBE STRENGTH TEST

AIM

To determine the compressive strength of concrete cube by Compression Testing Machine (CTM).

APPARATUS

i) CTM

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PROCEDURE

i) The internal surface of the mould is thoroughly cleaned and applied with a light

coat of oil.

ii) The mould is placed on a smooth, horizontal, rigid and non absorbent surface.

iii) The mould is then filled in four layers with freshly mixed concrete, each

approximately to onefourth of the height of the mould.

iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are

distributed evenly over the cross section).

v) After the top layer is rodded, the concrete is struck off the level with a trowel.

vi) The mould is removed from the concrete immediately by raising it slowly in the

vertical direction.

vii)The difference in level between the height of the mould and that of the highest

point of the subsided concrete is measured.

viii) This difference in height in mm is the slump of the concrete.


The slump measured should be recorded in mm of subsidence of the specimen during

the test. Any slump specimen, which collapses or shears off laterally gives incorrect

result and if this occurs, the test should be repeated with another sample. If, in the

repeat test also, the specimen shears, the slump should be measured and the fact that

the specimen sheared, should be recorded.

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31



OMC & MDD TEST

This test is done to determine the maximum dry density and the optimum moisture

content of soil using heavy compaction as per IS: 2720 (Part 8 ) 1983.The apparatus

used is:

i) Cylindrical metal mould it should be either of 100mm dia. and 1000cc volume or

150mm dia. and 2250cc volume and should conform to IS: 10074 1982.

ii) Balances one of 10kg capacity, sensitive to 1g and the other of 200g capacity,

sensitive to 0.01g

iii) Oven thermostatically controlled with an interior of noncorroding material to

maintain temperature between 105 and 110oC

iv) Steel straightedge 30cm long

v) IS Sieves of sizes 4.75mm, 19mm and 37.5mm. PREPARATION OF SAMPLE

A representative portion of airdried soil material, large enough to provide about 6kg

of material passing through a 19mm IS Sieve (for soils not susceptible to crushing

during compaction) or about 15kg of material passing through a 19mm IS Sieve (for

soils susceptible to crushing during compaction), should be taken. This portion should

be sieved through a 19mm IS Sieve and the coarse fraction rejected after its

proportion of the total sample has been recorded. Aggregations of particles should be

broken down so that if the sample was sieved through a 4.75mm IS Sieve, only

separated individual particles would be retained.

Procedure To Determine The Maximum Dry Density And The Optimum

Moisture Content Of Soil

A) Soil not susceptible to crushing during compaction

i) A 5kg sample of airdried soil passing through the 19mm IS Sieve should be taken.

The sample should be mixed thoroughly with a suitable amount of water depending

on the soil type (for sandy and gravelly soil 3 to 5% and for cohesive soil 12 to

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16% below the plastic limit). The soil sample should be stored in a sealed container

for a minimum period of 16hrs.

ii) The mould of 1000cc capacity with base plate attached, should be weighed to the

nearest 1g (W1). The mould should be placed on a solid base, such as a concrete floor

or plinth and the moist soil should be compacted into the mould, with the extension

attached, in five layers of approximately equal mass, each layer being given 25 blows

from the 4.9kg rammer dropped from a height of 450mm above the soil. The blows

should be distributed uniformly over the surface of each layer. The amount of soil

used should be sufficient to fill the mould, leaving not more than about 6mm to be

struck off when the extension is removed. The extension should be removed and the

compacted soil should be levelled off carefully to the top of the mould by means of

the straight edge. The mould and soil should then be weighed to the nearest gram

(W2).

iii) The compacted soil specimen should be removed from the mould and placed onto

the mixing tray. The water content (w) of a representative sample of the specimen

should be determined.

iv) The remaining soil specimen should be broken up, rubbed through 19mm IS

Sieve and then mixed with the remaining original sample. Suitable increments of

water should be added successively and mixed into the sample, and the above

operations i.e. ii) to iv) should be repeated for each increment of water added. The

total number of determinations made should be at least five and the moisture

contents should be such that the optimum moisture content at which the maximum

dry density occurs,lies within that range.

B) Soil susceptible to crushing during compaction

Five or more 2.5kg samples of airdried soil passing through the 19mm IS Sieve,

should be taken. The samples should each be mixed thoroughly with different

amounts of water and stored in a sealed container as mentioned in Part A)

C) Compaction in large size mould

For compacting soil containing coarse material upto 37.5mm size, the 2250cc

mould should be used. A sample weighing about 30kg and passing through the

37.5mm IS Sieve is used for the test. Soil is compacted in five layers, each layer

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being given 55 blows of the 4.9kg rammer. The rest of the procedure is same as

above.


Bulk density Y(gamma) in g/cc of each compacted specimen should be calculated

from the equation,

Y(gamma) = (W2-W1)/ V

where, V = volume in cc of the mould. The dry density Yd in g/cc

Yd = 100Y/(100+w)

The dry densities, Yd obtained in a series of determinations should be plotted

against the corresponding moisture contents,w. A smooth curve should be drawn

through the resulting points and the position of the maximum on the curve should

be determined.

The dry density in g/cc corresponding to the maximum point on the moisture

content/dry density curve should be reported as the maximum dry density to the

nearest 0.01. The percentage moisture content corresponding to the maximum dry

density on the moisture content/dry density curve should be reported as the

optimummoisture content and quoted to the nearest 0.2 for values below 5

percent, to the nearest 0.5 for values from 5 to 10 percent and to the nearest whole

number for values exceeding 10 percent.

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35



PLANT INFORMATION

BATCHINGPLANT

36



EQUIPMENT USED IN CONSTRUCTION OF PRE-STRESSED

BEAM

Shutter handling Gantry 1 nos.

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Prestressing jack with Power pack 2 nos.

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Grouting Pump (fressy j600, 300kg/cm2, 2hp) 1 nos.

Grout mixer & Agitator 1 nos.

Compressor 300 CFM 1 nos.

Concrete pump 1 nos.

Poker Vibrators with needle 4 nos.

Shutter vibrators 4 nos.

Concrete production plant 1 nos.

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For Transportation of Concrete, steel bars, Aggregates, sand etc.

Transit Mixer (7m3)

Truck

40



PROJECTEXECUTION

METHOD STATEMENT FOR PRE STRESSED BEAM

I. SCOPE: This method of statement is applicable for casting of P40 to P41

(G1) super structure Beam of the project Rehabilitation and upgradation from

75.00 Km to 80.06 Km of NH25 in the town of Kanpur (including bridge across

river Ganga) to 4 lane divided carriageway configuration (contract package EW

II UP06).

II. REFERENCE:

1. Drawing nos. DCPL/KANPUR/SUP/3X26/004

DCPL/KANPUR/SUP/3X26/008

2. MoRT&H Specifications

3. Contract Document Technical specifications

III. MATERIAL AND RESOURCES :

For One Beam

1. Construction Material :

Cement (OPC 53 Grade) 140 Bags

Aggregate 20 mm 9 cum.

Aggregate 10 mm 6 cum.

Coarse Sand 9 cum.

Reinforcement Steel as per list

H T Steel (12.7mm) 1.20 ton

Sheathing Pipe 130 Rm

Anchorage 10 set

(Guide cone, Bearing Plate, Anchor Grips)

2. Plant and Equipments :

(Discussed in Plant Information)

3. Man Power :

Skilled worker for concrete breaking 4 nos.

Skilled / S.skilled workers for concreting & grouting 8 nos.

Reinforcement steel cutting and bending 6 nos.

Reinforcement steel and shuttering fixing 8 to 10 nos.

PreStressing 6 nos.

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IV. PROCEDURE :

Form Work :

Formwork for the beam will be fabricated at the site as per approved drawing of

Beam.

It is fabricated in panels for one beam of 2 sides. For the alignment of formwork,

adjustable struts & through bolts shall be used.

Rigid working platform shall be made at beam top level eith structural steel.

STEP 1: After completing of casting bed and pedestals, fabricated beam bottom shall be

erected and fixed as per our drawings. Uniform level of beam bottom shall be

made.

STEP 2: One side shuttering panel shall be erected and placed over beam bottom as per

drawing and true plumb of side shuttering to be made to start making of cable

profile. Flexi foams with adhesive shall be used at joints of each panel in order to

check the leakage of cement slurry during concreting.

STEP 3: Cable Profile

Cable profile shall be marked by paint over beam bottom and side shuttering as

per drawing.

STEP 4: Reinforcement

Steel shall be fabricated in advance as per approved bar bending scheduled at

centralized bending yard. Fabricated reinforcement shall be shifted to casting

yard.

Reinforcement cage shall be fabricated in advance outside the casting bed. The

prefabricated cage shall be shifted and placed at casting bed with the help of

spreader beam and lifting Gantry as soon as bed is ready to receive

reinforcement cage for next beam.

STEP 5: Laying of Sheathing Pipe

Sheathing pipe of 75mm (or shown in approved drawing) dia. of single length

shall be laid over marked profile (ref: STEP 3). Then the pipes shall be

accurately located and tied as per drawings in both direction of vertical and

horizontal.

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Ladders, spacers @ 2m C/C shall be provided to keep sheathing duct in position.

78mm dia. (or as suitable for sheathing pipe as per approved drawing) 150mm

long coupler shall be provided for joining sheathing ducts and at both junctions

of end Guide cone. Joints in between couplers and pipe shall be sealed with

adhesive celling tape to prevent ingress of cement slurry in to ducts during

concreting. In addition, couplers of adjacent ducts shall be staggered whenever

possible.

STEP 6: Closing of Shuttering

After checking of reinforcement and Profiling of sheathing, other side of beam

shuttering shall be shifted and erected by means of shutter handling gantry.

Shuttering shall be closed by side bolting as well as by fixing of tie angle and by

adjustable props.

STEP 7: Concreting of PSC Beam

Concrete of M50 grade shall be produced at batching plant and will be

transported by transit mixers to the casting yard.

Placing of concrete shall be done by concrete pump or concrete conveyor.

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Concreting shall be done up to a depth of 400 mm andthe same layer will be

continued until completion of the beam.

Compaction of concreting at bottom flange, web shall be done by using shutter

vibrator and with immersion vibrator simultaneously.

Proper care shall be taken to ensure all the cables are free from concrete.

During concreting and up to 3 to 4hrs after completion of concreting, the cable

duct shall be checked by movement of the dummy pipe through it for any ingress

of concrete slurry.

STEP 8: Threading of Cables

Cutting of HT Strands shall be done with angle grinder after uncoiling of HT

Strands. Proper care shall be taken to avoid damages, kinks or bents and stacking

shall be done properly preventing ground contact.

After 3 days of concrete, threading of cable shall be started from one end to the

other end. Bundle of 12nos. HT Strands be made and same to be inserted

manually inside the Sheathing duct. Proper care shall be taken to avoid damage

to sheathing duct while threading.

STEP 9: Curing & DeShuttering

Normal curing shall be commenced after final setting of concrete i.e. 6hrs

(approx.) depending on cement. Curing shall be continued until the concrete

reaches strength 35N/mm2

After attaining strength of 10Mpa, the vertical side shuttering of PSC girder shall

be removed and taken out of the bed with the help of gantry, to use in the second

bed.

STEP 10: PreStressing

Method of stressing: FPCC System (Proposed) or any other system

approved by Engineer

Important Points:

Stressing will be done after 10 days of concrete and achieves strength as

specified in Drawing. Number of cables to be stressed, will be as mentioned in

drawing.

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Future cable shall be stressed after completion of stressing and if required and as

advised by the Engineer.

It is to be seen whether the extensions specified in the table account for effect of

slip at each end or not. Accordingly, no extra allowance of slip should be made.

Extension at each end during stressing operation should be equal as far as

possible, max. Difference should not exceed 5% of the prescribe extensions at

each end. In case the required extensions are not obtained at the specified

pressure, stressing should be continued till the required extensions are obtained

subjected to jack pressures not exceeding the prescribe limits.

Difference between calculated and observed tension and elongations during the

prestressing operations shall be regulated as per MORTH sec. 1807 under post

tensioning head as point a, b, c, d.

Method of Stressing

During curing of PSC Beam, arrangements for prestressing shall be started

Erect a tripod or scaffolding tower on both end of PSC Beam.

HT Strands to be physically checked to ensure the strands are free from any

friction.

Keep all strands ends at particular point approx. 750mm from the anchorage

cone.

Clean all projected HT strands by petrol and afterward give a coating of wax for

smooth operation.

Place the bearing plate on the buter face of each of the anchorage cone of PSC

Beam.

Fix the anchorage grips in each hole of bearing plates by means of pipe.

Erect the pre stressing jack at both the end and place in first cable as per the

stressing sequence and then fix the barrel and master grips in prestressing jacks.

Initial force shall be applied for tightening of jacks till slackness of the strands is

removed. A mark shall be made at each strand at a suitable distance to measure

the extensions of cables at both ends.

Incremental load shall be applied to keep control over the extensions. A seesaw

action on loading may be applied to get equal extension at both the ends.

Stressing to continue till it reaches its final extensions as per table i.

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Afterward, all other cables shall be stressed as per sequence in above manner.

Slip of each cable shall be measured and recorded.

STEP 11: Grouting of cables in Prestressed girders

Grouting of cables shall be conducted at stacking bed as soon as it stacked there.

Materials: Water: clean, potable water free form impurities will be used.

Cement: OPC as mentioned above

Sand: sand conforming to IS: 383 will be used.

Admixture: admixture if required conforming to IS: 9102 will be used.

Equipment:

(Discussed in Plant Information)

Mixing of Grout:

Proportions of the required materials will be measured by weight before starting

of mixing operation.

Water shall be added to the mixer followed by cement, sand & admixture /

Readymade grout mixture.

Mixing shall be done for approximately 2 to 3 min until uniform and thoroughly

blended grout is achieved.

Adequate care shall be taken to prevent any addition of water to mixed grout to

increase fluidity.

Cubes of 100mm shall be taken for verification of compressive strength.

Grouting Operations:

Grouting shall be carried out within 2 weeks of stressing of cables.

Ducts shall be flushed with water for cleaning as well as for wetting the surfaces

of the ducts walls. Water used for flushing should of same quality as used for

grouting.

After cleaning, all the water shall be drained thoroughly by vent pipe or by

blowing compressed air through duct.

Sequence of grouting shall commence from bottom to top.

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During and after 3 to 4 hours of grouting other nonstressed cables shall be

checked manually for free movement.

All outlet points including vent openings should be kept open before to

commencement of grouting.

Injection of Grout:

After mixing grout should be kept in continuous movement and injection of

grout must be continuous without any interruptions.

Grouting shall be commenced initially with a low pressure of injection of up to

0.3Mpa increasing it until the grout come out through the other end with same

consistency as that of the grout @ injection end.

Full injection pressure (approx. 0.5Mpa) shall be maintained for a minimum of 1

min before closing the injection pipe.

TIME CYCLE:

Following is the time cycle of construction of 1 no. PSC Beam:

S.No Activity No of Days

1. Bottom plate cleaning, leveling 0.5 day

2. Erection of outer shutter 0.5 day

3. Lowering of Pre-fabricated cage 0.5 day

4. Sheathing laying and profiling 0.5 day

5. Shutter closing and checking 0.5 day

6. Concreting 1 day

7. Waiting and de-shuttering of side shutter 1 day

8. Cable threading and Pre-stressing after 10

days

11 days

9. Lifting of Beam and vacating bed 0.5 day

TOTAL 15 days

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CHRONOLOGICAL TRAINING DIARY

Date Description

06062014 Joining letter taken from G.I.L office.

07062014 Visit of office & site and meeting with Engineers.

08062014 Sunday holiday. 09062014 Visit the office & study the plan of project.

(Planning Department) 10062014 Discussion with the Planning Engineers.

11062014 Study different drawing, work and contract

documents. 12062014 Meeting with Plant Engineer and Discussion

about machines. 13062014 Meeting with QC Engineer and Discussion

about Quality Policy. 14062014 Performing Sieve analysis & Aggregate

impact value Test. 15062014 Sunday holiday. 16062014 Visit the site & Meeting with Execution

Engineer and Execution Team. 17062014 Visit full site and Discussion about Project

Execution with Engineers. 18062014 Construction of Prestressed Beam (G1)

start (Bottom Plate clearing and leveling). 19062014 Erection of outer shutter & Lowering of

Prefabricated cage. 20062014 Sheathing Laying and Profiling &

Shuttering Closing and Checking.

48



21062014 Visit plant and see making of Concrete and Concreting of Beam in casting yard.

22062014 Sunday holiday. 23062014 Deshuttering of side shutter & Curing of

Beam. 24062014 Curing of Beam &

Construction of Pier cap no. 43. 25062014 Curing of Beam &

Construction of Pier cap no. 43. 26062014 Curing of Beam &

Construction of Pile cap no. 45. 27062014 Curing of Beam &

Construction of Pile cap no. 45. 28062014 Curing of Beam & Laying of Reinforcement

on deck b/w P36 to P39. 29062014 Sunday holiday. 30062014 Curing of Beam & Laying of Reinforcement

on deck b/w P36 to P39. 01072014 Visit office (QC Department) and perform

Cube Test of Beam P39P40. 02072014 Cable Threading and PreStressing of Beam

after 10 days in Casting yard. 03072014 Lifting of Beam to Pier P40P41 with the

help of Gantry. 04072014 Collecting all Drawings & Preparation of

Project report. 05072014 Discussion with Project Manager about

Project Report. 06072014 Sunday holiday. 07072014 Submission of Project Report to Project

Manager at G.I.L office.

49



SAFETY REQUIREMENT

SAFETY APPLIANCES

The requirement of sufficient number of safety appliances are planned well in advance

and made available at stores.

HEAD PROTECTION

Every individual entering the site must wear safety helmet, confirming to IS: 29251984

with the chinstrap fixed to the chin.

FOOT AND LEG PROTECTION

Safety footwear with steel toe is essential on site to prevent crush injuries to our toes

and injury due to striking against the object.

HEARING PROTECTION

Excessive noise causes damage to the inner ear and permanent loss of hearing. To

protect ears use ear plugs / ear muff as suitable.

EYE PROTECTION

Person carrying out grinding works, operating pavement breakers, and those involved

in welding and cutting works should wear safety goggles & face shield suitably

Goggles, Safety Spectacles, face shield confirm to IS: 59831980.

EAR PROTECTION

Ear Muff / Earplug should be provided to those working at places with high sound levels

(confirm to IS: 91671979).

HAND AND ARM PROTECTION

While handling cement and concrete & while carrying out hot works like gas cutting,

grinding & welding usage of hand gloves is a must to protect the hand,

1) COTTON Gloves (for materials handling)IS: 69941973

2) RUBEER Gloves18 (380/450mm long) electrical grade, tested to 15000

Volts conforming to IS: 47701991

3) LEATHER Gloves hot work / handling of sharp edges .

50



RESPIRATORY PROTECTION

Required respiratory protection according to the exposure of hazards to be

provided.

SAFETY NET

Though it is mandatory to wear safety harness while working at height on the working

platforms, safety nets of suitable mesh size shall

be provided to arrest the falling of person and materials on need basis.

FALL PROTECTION

To prevent fall of person while working at height, personnel engaged more than 2m

wear standard Full Body harness should be conforming to IS: 35211999 (Third

Revision).

1) Lanyard should be of 12mm Polypropylene rope and of length not more than 2m.

2) Double lanyard, based on the requirement.

SAFETY DURING STRESSING

Use hydraulic equipments supplied with a relief valve.

Place safely valve in between jacks and connection highpressure hose.

Use hosepipes in good conditions and avoid using worn out hosepipes.

Check the concrete around bearing plate and anchorage to see whether there are any

voids / honeycombing.

Do not allow anybody behind stressing devices, in line with tendon, or near hydraulic

hoses.

When the stressing works are in progress no other work should continue in the vicinity.

Health of safety systems incorporated in the stressing equipment shall be ascertained

once a week.

Display a clearly visible sign DANGERPRESTRESSING WORKS IN

PROGRESS

51



SUGGESTION

Gammon India Limited (G.I.L) is playing a vital and very important role by giving the good and comfortable facilities of Bridges for the Roads users and also giving the better Structures which are giving beauty to our Country.

In this process of construction there is big jams occurs on Service Roads. So I requested to G.I.L. to provide good moving facilities for service lane users.

I have seen that several numbers of labour were working day &night as to complete the project in given estimated time. The Engineers Staff was also working very hard. Overall the Work of this Project is Satisfying its drawing& Specifications.

52



CONCLUSION

It was a wonderful learning experience at Gammon India Limited site

Rehabilitation and Upgradation from 75 Km to 80.60 Km of NH25

(GANGA BRIDGE & FLYOVER PROJECT) for one months in

KANPUR. I gained a lot of insight regarding almost every aspect of site. I

was given exposure in almost all the departments at the site. The friendly

welcome from all the employees is appreciating, sharing their experience

and giving their peace of wisdom which they have gained in long journey

of work. I am very much thankful for the wonderful accommodation

facility from G.I.L. I hope this experience will surely help me in my future

and also in shaping my career.

53



REFERENCES

In Preparing this Project Report the following references has been taken in accounts are :

SpecificationsofG.I.L.

SpecificationsofN.H.A.I.

Specificationsof MoRT&H.

Drawing nos. :

1. DCPL/KANPUR/SUP/3X26/004

2. DCPL/KANPUR/SUP/3X26/008

Contract Document Technical Specifications.

SUMMER TRAINING REPORT

Submitted in partial fulfillment for the award of Degree of Bachelor of Technology (B. Tech.)

Rehabilitation and Upgradation from 75 Km to 80.60 Km of NH-25. (GANGA BRIDGE & FLYOVER PROJECT)

KANPUR PROJECT, KANPUR

From 6th JUNE 2014 To 5th JULY 2014

Name of Officer :- Mr. MANOJ BISWAS

Designation PROJECT MANAGER, Company G.I.L

(Mohtisham Ali)

B.Tech (Civil) / IV Year

Roll No. :1100111112

Integral University, Lucknow

Faculty of Engineering Web : www.integraluniversity.ac.in

CENTER FOR CAREER GUIDANCE & DEVELOPMENT (CCG&D)

Phone : 0522-2890765, 09918246056 E-mail : [email protected] , [email protected]

2014


Documents

Summer Intrenship at Gammon India Ltd