Summer traning report

BIHAR RAJYA PUL NIRMAN NIGAM LIMITED

TRAINING REPORT

Mithapur to chiraiyatad flyover

By-AMIT RAJ

201610MAY-10JUNE

1Bihar State Bridge Construction Limited, Patna

ABOUT THE AUTHORAmit Raj

I was Born In Patna , 1996. I am doing Bachelor of technology in Civil engineering at IIT Kharagpur. Currently I am in 3rd year.

Contact Information: -

Amit Raj email :- [email protected]

Institute Id Roll no :- 14CE10005

Department of civil engineering, IIT Kharagpur

Nehru Hall of Residence, IIT Kharagpur

AMIT RAJ

mailto:[email protected]


AMIT RAJ


Contents……………………………………………………………………………………………………….2

Acknowledgement………………………………………………………………………………………….4

Abstract …………….…………………………………………………………………………………………..5

SECTION-AComponents of a bridge

Foundation……………………………………………………………………………………………….6 Substructure …………………………………………………………………………………………….7 Superstructure………………………………………………………………………………………….8

SECTION-B

Construction Procedure & Dimensions

Pile……………………………………………………………………………………………………….….9 Pile-Cap………………………………………………………………………………………………….10 Pier…………………………………………………………………………………………………………11 Pier-Cap………………………………………………………………………………………………….12 I-Girder…………………………………………………………………………………………………..13 Deck……………………………………………………………………………………………………….14 Bearing……………………………………………………………………………………………………15 Crash Barrier…………………………………………………………………………………………..16 Installation of Light…………………………………………………………………………………17

AMIT RAJ


SECTION-C Quality control

Test on Aggregates…………………………………………………………………….18 Crushing Test……………………………………………………………………………………….18 Impact test…………………………………………………………………………………………..19 Shape test…………………………………………………………………………………………….19 Bitumen adhesion Test…………………………………………………………………………19

Test on cement ………………………………………………………………………….20 Date of packing Color Rubbing Hand insertion Float test Shape test Strength test

Performance test……………………………………………………………………..21 Load teat………………………………………………………………………………………….21 Capacity test…………………………………………………………………………………….22 Stress ………………………………………………………………………………………………22

AMIT RAJ


Acknowledgement

First of all I would like to thank every families and friends that participate on my life and get me in this intensity and individuals who support and share idea and also helping me to be like this.

I am very thankful to BIHAR RAJYA PULL NIRMAN NIGAM LIMITED (BRPNNL) and its managing director RANJAN KUMAR. For having given me the opportunity to undertake my one-month summer training in their working area. It was a very good learning experience for me to have worked at this area. I would like to convey my heartiest thanks to chief engineer ARVIND KUMAR and CDC of IIT Kharagpur, who made it all possible.

I would also thank VIJAY SIR for his endless support at site and in his office by consulting me how do things in the site, all teachers of civil engineering who brought me to my present performance and shape me like this during the last two successive years, Special thanks to my prof SUSHANT CHAKRABORTY for guiding me to do training at BRPNNL.

Before I finish I would like to give my deepest thanks to all workers from the contractor, SP Singla construction private limited and the consultant side starting from engineers to daily laborers. Also for those who do not listed in the above but support me in different areas I would like thank all.

AMIT RAJ


Abstract

The Training report in broad spectrum contains three sections in which I try to explain my one month learning experience in the running project, construction of MITHPUR TO CHIRAIYATAND FLYOVER. The content of all sections id broadly explained and it’s made from the practical basis of the site work of weekly basis.

In section A, I give all the details of the different components of the bridge including its type and the type I preferred, in this section I put all the specification of each and every component, its advantage and disadvantage.

The section B is most important chapter which explains all the dimensions and construction procedure of each and every component with some practical images whatever I clicked during the whole training period.

In the last section C, I explain different tests of aggregate, cement, soil and the model testing of pile, on the basis of which we decide the size of different part of the bridge, which type of material is suitable for construction process, how we can minimize the cost that particular project, also the load capacity of the pile.

After reading all the three section, one can easily understand basics of bridge construction procedure dimension and minimization of the cost of the project.

AMIT RAJ


SECTION-A COMPONENTS OF BRIDGE FOUNDATION

Piles and Pile-Cap comes under the foundation part.

Piles: - function of pile is to transfer the load to soil

Three types of pile occur

1. End Bearing Pile 2. Friction Pile 3. End bearing and Friction Pile

In this project we used End bearing pile, some part of load transfers by the pile by end of the pile and remaining load is by the friction between pile and the surface of soil around the pile.

Arrow in the above image denotes how load transferred to ground

Pile cap reinforcement: - piles usually exists as a group which are all integrated by means of a pile cap as shown in figure.

Piles carrying very heavy point loads tend to produce high tensile stress at the pile cap.

Reinforcement is thus designed to provide: -

1. Resistance to tensile bending forces in the bottom of the cap2. Resistance to the vertical shear.

AMIT RAJ


SUBSTRUCTURE

Pier and Pier-cap: Support of superstructure, transfer dean and live load to pile

It also carries its own considerable weight.

It is only a model dimension

Pier – Is a raised structure typically supported by well-spaced piles or the pile cap. It can be made by wooden concrete, steel, mixed, but in this project we use concrete pier with well-maintained iron rod.

Pier cap - The upper or bearing part of the pier, usually made of concrete or hard stone; designed to distribute concentrated loads evenly over the area of pier.

The width of pier cap depends upon the width of carriageway, its size depends upon the dive load and dead load bridge capacity.

Ex: - for middle carriageway (5.5 meters). We use pier cap of width 4.5 meters.

SUPERSTRUCTUREAMIT RAJ

Pier CAP

Pier

9Bihar State Bridge Construction Limited, PatnaWearing surface: - consists of the deck structure itself, which support the direct leads due to traffic and all the other permanent and variable leads to which the structure is subjected. Also known as carriageway.

Width of carriageway depends upon number of lane of flyover. For middle lane-5.5 m and for two lane-7.5 m.

Bearing: - bridge bearings are used to transfer forces from the superstructure to substructure, allowing the following types of movements of the superstructure.

Translational movements; are displacements in vertical and horizontal directions due to in-place or out-of-place forces like wind and self-weight.

Rotational movements; cause due to moments. Until the middle of this century, the bearings used considered of following types: - pin, roller, rocker, metal sliding etc.

Girder: - is support of carriageway between two piers, it is of many types like box shape, Z shape, I-shape and many other forms.

In this flyover, I-shape pre-stressed beam used.

Crash barrier: - a strong fence at the side of carriageway, intended to reduce the risk of serious accidents.

It is of various types ex: - wooden, tin, steel, cable, wire, concrete.

Concrete barrier is strongest one and chip as well.

Now these days for using in flyover we prefer concrete crash barrier.

AMIT RAJ


SECTION-B Construction procedure & dimensions Pile –

In this particular project, we use rotary hammer machine for drilling purpose.

After that the whole is filled by suitable concrete mix and steel rod of diameter 32 mm.

Its dimension is 28 m depth and 1 m diameter.

AMIT RAJ

11Bihar State Bridge Construction Limited, Patna Constructed pile top view Rotary hammer machine and cylindrical pipe for concrete filling

Number of piles: number of piles required for a particular pier is depends upon the spam, length number of lane of carriage way, capacity of a particular pile and type of bridge it is.

Capacity of each pile in this project is 230 tones.

AMIT RAJ


PILE CAP –

A pile cap is a thick concrete mat that rests on concrete piles that have been driven into soft or unstable ground to provide a stable foundation.

Dimension of pile cap varies as number of piles and type of soil at that particular place, Carry a height in the rage of 10-15 feet.

AMIT RAJ


PIER –

A part of substructure which transfers the load to pile followed by pile cap, its construction is a normal process of filling concrete mixture with steel rod arranged in particular manner as shown in picture.

its dimension varies depends upon number of lanes, height of pier.

AMIT RAJ


PIER CAP –

Main function is to distribute concentrated loads evenly over the area of pier.

Pier cap carry a standard shape of inverse triangle shape, which behave like a truss of compression and tension member. I tried to show it in the picture below, tension member by dotted line and compression member by bold line. P1, P2, P3, P4, P5 shows the vehicle load of the carriageway.

Its dimension varies as number of lane required for that particular carriageway. Also calculation of length and width can be done by using the length of tension and compression member.

AMIT RAJ


I-GIRDER –

It is a pre-stressed beam of having a shape of I. that’s why also called as I-girder. There are so many factor are considering for its construction.

Its dimension varies as the dead and live load of carriageway. It is only for low spam Length Bridge. Its length varies 20- 40 m.

Here are some pictures which explain how to assemble it in bridge.

AMIT RAJ

Lower part of I girder is of 600 mm, upper part is of 700 mm and middle part is 500 mm


DECK –

The part of superstructure which carry the load of vehicle, also known as wearing surface.

Also support the crash barrier and light installation.

Its construction is of simple molding of concrete and steel bar (in well-arranged manner).

Takes 28 days in fully settings of concrete. Daily and enough water is required for setting.

A worker is distributing (spraying) water on the constructed deck for settings purpose

AMIT RAJ


BEARINGS –

Bearing in bridge is used to transfer forces from the superstructure to substructure, allowing the translational and rotational movements.

There is various type of bearing, in this project we choose rod bearing followed by concrete.

Here the gap is 70 mm width for compression expansion and other safety purposes.

gap of 70 mm can be seen in the following picture.

Red line arrows shows the gap of bearing & whole picture is the space for bearing

AMIT RAJ


CRASH BARRIER –

Main purpose is to prevent the vehicle by ride of from the road, prevent the accident and also used as holder of light installation.

It is of size lower part 500 mm and upper part is of 200 mm in parabolic shape w.r.t vertical

line.

AMIT RAJ


LIGHT INSTALLATION –

Installation of light is different aspects of bridge construction, but we have to leave space according to its decoration. But in some project it comes in under it.

I haven’t seen the process of installation of light in this one-month training period so don’t have too much idea about the process of installation of light.

Installed light over a flyover

AMIT RAJ


SECTION-CQUALITY CONTROL

Test on aggregates: - Aggregate plays an important role in pavement construction, pile construction, pile construction. Aggregates influence, to a great extent, the load transfer capability of pavements. Hence it is essential that they should be thoroughly tested before using for construction. Not only that aggregates should be strong and durable, they should also possess proper shape and size to make the pavement act monolithically. Aggregates are tested for strength, toughness, hardness, and shape and water absorption.

1. Crushing test: - used to determine the strength of aggregates.

The test consists of subjecting the specimen of aggregate in standard mould to a compression test under standard load conditions. Dry aggregates passing through 12.5mm sieves and retained 10 mm sieves are filled in a cylindrical measure of 11.5 mm diameter and a8 cm height in three layers. Each layer is tamped 25 times with at standard rod. The test sample is weighted and placed in the test cylinder in three layers each layer being tamped again. The specimen is subjected to a compressive load of 40 tones gradually applied at the rate of 4 tones per minute. Then crushed aggregates are then sieved through 2.36 m sieve and weight of passing material is expressed as percentages of the total sample which is aggregate crushing value.

A value less than 10 signifies an exceptionally strong aggregate.

AMIT RAJ

21Bihar State Bridge Construction Limited, Patna2. Impact test: - the aggregate impact test is carried out to evaluate the resistance to impact of aggregates. Aggregate passing 12.5 mm sieve and retained 10 mm sieve is filled in a cylinder steel cup of internal diameter 10.2 mm and depth of 5 cm which is attached to a metal base of impact testing machine.

3. Shape test: - flakiness and elongation test

Flakiness index is defined as the percentage by weight of aggregate particles whose least dimension less than .6 times their size. Flakiness gauge is used for this test.

The elongation index of an aggregate is defined as the percentage by weight of particles whose great dimension is 1.8 times their mean dimension. This test is applicable to aggregate larger than 6.3 mm. elongation gauge is used for this test.

Flakiness index test

Elongation index test

4. Bitumen adhesion test: - Bitumen adheres well to all normal types of road aggregates provided they are dry and free from dust. In the absence of water there is practically no adhesion problem of bituminous construction.

Adhesion problems occur when the aggregate is wet and cold. This problem can be dealt with by removing moisture from the aggregates by drying and increasing and mixing temperature.

AMIT RAJ


TEST ON CEMENT

A. Date of packing: - Date of manufacturing should be seen on the bag, it is important because the strength of cement reduces with age.

B. Color: - The cement should be uniform in color. In general, the color of cement is grey with a light greenish shade. The color of cement gives an indication of excess lime or clay and the degree of burning.

C. Rubbing: -we take a pinch of cement between fingers and rub it. It should feel smooth while rubbing. If it is rough, that means adulteration with sand.

D. Hand insertion: - Thrust hand into the cement bag and it should give cool feeling. It indicates that no hydration reaction is taking place in the bag.

E. Float test: - throw a small quantity of cement in a bucket of water. It should sink and should not float on the surface.

F. Shape test: - Take 100g of cement and make a stiff paste prepare a cake with sharp edges and put on the glass plate. Immerse this plate in water. Observe that the shape shouldn’t get disturb while setting. It should be able to set and attain strength. Cement is capable of setting under water also and that is why it is also called “hydraulic cement”.

G. Strength test: - A block of cement 25 mm* 25 mm and 200 mm long is prepared and it is immersed for 7 days in water. It is then placed on supports 15000 mm apart and it is loaded with a weight of 340 N. The block should not show any sign of failure.

AMIT RAJ


PERFORMANCE TEST

Load test: load tests on piles are conducted on completion of 28 days after casting of piles. Two types of tests namely initial and routine test, for each type of loading ex: - vertical, horizontal are performed

Initial test on pile: The test is performed to confirm the design load calculation and to provide guidelines for setting up the limits of acceptance for routine tests. It also gives an idea of the suitability of the pilling system. Test on pile are to be carried out at one or more locations depending on the number of piles required. Load test for the initial load test is 2.5 times (safety factor) the safe carrying capacity of the pile.

Routine test: selection of piles for the routine test is done based on the number of piles required subjected to maximum of ½ of total number of piles required. The number of test may be increased to 2% depending on the nature/type of structure. The test load applied 3/2 times the safe carrying capacity of pile.

This test will be performed for the following purpose:

a) To ensure the safe load capacity of the piles b) Defection of any unusual performance contrary to the finding of the initial test.

Vertical load test:

Pile head- the pile head shall be chipped of till sound concrete is met wherever applicable. The reinforcement shall be cut and head leveled with plaster of Paris. A bearings plate with a hole shall be placed on the head for the jack to rest.

Initial tests: it can be done in two steps;

I. 2/3 of the final load at which the total displacement attains value of 12 mm unless otherwise requires on the basis of nature and type of structure in which case, the safe load should be corresponding to the stated total displacement permissible.

II. 50 % of the final load at which the total displacement equals 10 % of the pile diameter in case of uniform diameter piles or 7.5 % of the bulb diameter in case of under reamed piles.

AMIT RAJ


Horizontal load test:

The jack should be placed horizontally, between two piles. The load on the jack shall be the same on both the piles. The load will be applied in increments of 20 % of the estimated safe load and cut off level. The load will be increased after the rate of displacement is nearest to .1 mm per minutes. If the cut of level is approachable, 2 dial gauges 30 cm apart vertically, shall be set up and the lateral displacement of the cut-off level calculated by similar triangles.

The safe load on the pile shall be the least of the following:

I. 50 %of the final load at which the total displacement increases to 12 mm.II. Final load at which the total displacement corresponds to 5 mm.

Pull out tests on pile:

A suitable set up shall be designed to provide an uplift force to the piles. The load increments and the consequent displacements shall be as per the case of a vertical load test.

The safe load shall be the least of following:

I. 2/3rd of the load at which the total displacement is 12 mm or the load corresponding to a specified permissible lit.

II. Half of the load at which the load displacement curve shows a clear break.

AMIT RAJ

Engineering

Summer traning report