A REPORT ON

Qualitative Aspects and Preventive Methods involved in the Construction of the CWPH Project by IVRCL at the NTECL site

BY GATTAMNENI SAI KOUSHIK 2008A2PS300H

IVRCL Infra, Chennai

AT

A PRACTICE SCHOOL - II STATION OF

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI December, 2011 1

A REPORT ON Qualitative Aspects and Preventive Methods involved in the Construction of the CWPH Project by IVRCL at the NTECL site
BY

Gattamneni Sai Koushik

2008A2PS300H

B.E Civil

Prepared in partial fulfillment of the Practice School II Course No: BITS C412/ BITS C413 AT IVRCL Infra, Chennai A PRACTICE SCHOOL-II STATION OF

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI December, 2011 2

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI HYDERABAD CAMPUS Practice School Division Station: IVRCL Infra Duration: From: 6th July, 2011 Date of Submission: 14th Dec, 2011 Title of the Project: Qualitative and Preventive Aspects involved in the Construction of the CWPH Project by IVRCL Infra at the NTECL site. Center: Chennai To: 14th Dec, 2011

ID No. 2008A2PS300H

Name of the Student Gattamneni Sai Koushik

Discipline B.E Civil

Name of Expert Designation: Mr. V. Rajesh Kumar, Senior Project Manager Name of the PS Faculty: Mr. V. R. Rajan Project Area: Infrastructure and Civil Works Abstract: This report titled, Qualitative Aspects and Preventive Methods involved in the Construction of the CWPH Project by IVRCL Infra at the NTECL site, discusses the various Qualitative aspects involved and Preventive methods taken by IVRCL to ensure good quality in the construction of the CWPH Project. In this report all the qualitative aspects that need to be taken care of like Proper Compaction of the concrete, Curing methods, Joints in concrete as well as the various defects and cracks that are the result of not proper care taken and how these defects can be repaired to ensure good quality of construction are discussed. Some of the tests involved in determining the properties of the concrete like the slump test, the cube test or the compression test are also discussed. Other than these the Preventive Methods like the protective coatings, joint sealants, etc that are taken to ensure no defects or failures that result in the construction are also discussed. Signature of the Student Date: 3 Signature of PS Faculty Date:

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI HYDERBAD CAMPUS, Practice School Division Response Option Sheet Station: IVRCL Infra ID No. & Name: 2008A2PS300H, Gattamneni Sai Koushik Title of the Project: Qualitative Aspects involved in the Construction of a Sea Water Channel Centre: Chennai

Code No. 1. 2. 3.

Response options A new course can be designed out of this project The project can help modification of the course content of some of the existing courses The project can be used in some of the existing Compulsory disciplinary courses/ Discipline courses other than Compulsory (DCOC) /Emerging Area etc. courses The project can be used in preparatory courses like Analysis and Application Oriented Courses (AAOC) / Engineering Science (ES)/ Technical Art (TA) and Core Courses This project cannot come under any of the above mentioned options as relates to the professional work of the host organization

Course No. & Name

4.

5.

Signature of Student

Signature of Faculty

Acknowledgements
I whole-heartedly thank Mr.V.R.Rajan for guiding us through and motivating us till the very end. I would like to thank Mr. V. Rajesh Kumar, PS II - Coordinator and Senior Planning Manager, for allotting me this project. I thank Mr. Habeeb, Assistant Planning Manager (IVRCL Infra) for guiding me and helping me gather information. I thank all my co-employees who were with me whenever I need them to help and motivate me. I thank my co-trainee Uday Kovur who has helped me whenever I needed any help. Thanks to all those who may have helped me indirectly. Thank u all.

Table of Contents
1. Introduction 1.1. Project Plan and Description 2. Excavation and Filling 2.1. Purpose of Compaction 2.2. Factors affecting Compaction 2.3. Standard Proctor Density Test 3. Sheet Pilling 4. Cast in-situ Concrete and Concrete Testing 4.1. Concrete Testing 4.1.1. The Slump test 4.1.2. The Compression test 5. Curing Concrete 6. Joints in Concrete 6.1. Control Joints 6.2. Isolation Joints 6.3. Construction Joints 6.4. Cold Joint 6.5. Joint Sealants 6.5.1. Bitumen impregnated fiber board joint filler 6.5.2. EPS board non-self-extinguishing type 6.5.3. PVC Water Stops 6.5.4. Hydro Swelling joint sealing flexible strip 6.5.5. Cement Slurry modified with Acrylic Polymer 6 10 10 12 12 12 13 15 17 17 17 18 20 21 21 21 22 22 23 23 23 25 25 26

6.5.6. Hot applied bitumen sealing compound 7. Defects in Concrete 7.1. Rain Damage 7.2. Spalling 7.3. Honeycombing 8. Cracking in Concrete 8.1. Presetting Cracks 8.2. Cracks after hardening 9. Damp proofing and Protective layer 9.1. In Dry Conditions 9.2. In Wet Conditions 10. Grouting 11. Protective Coating on Structural steel 11.1. Inorganic Zinc Silicate primer 11.2. Epoxy based Titanium dioxide/Micaceous iron oxide 11.3. Epoxy based Poly Amide cured paint 11.4. Polyurethane finish paint 11.5. Heavy duty polyurethane coating 12. Masonry and allied works 13. Wall or Ceiling Finishes 13.1. Oil Bound distemper 13.2. Acrylic emulsion paint 13.3. Oil paint vs. Acrylic emulsion 14. Water Proofing 7

26 27 27 27 28 30 30 31 32 32 32 34 35 35 35 35 36 36 37 37 37 38 38 39

14.1. Non-Woven Geotextiles or Poly Scrim Cloth 14.2. Urethane Elastomer 15. Pressure Release Valves Conclusion References

39 40 41 42 43

List of figures
Figure 2.1 Zero Air Void Curve Figure 2.2 Figure depicting the specifications for the standard proctor density test Figure 3.1 Sheet piling done at the NTECL site to retain the soil below the water table Figure 4.1 Measuring the slump Figure 4.2 Cube being filled with concrete for cube test at the site Figure 6.1 Control Joints Figure 6.2 Isolation Joints Figure 6.3 Construction Joints Figure 6.4 Cold Joint Figure 7.1 Spalling due to heavy loads or impact with hard objects Figure 7.2 Honeycombing concrete structures at the site Figure 10.1 Grouting of Underside of base plate Figure 15.1 Pressure Release Valve Figure 15.2 Pressure release valves in the channel 13 14 15 18 19 21 22 22 23 27 28 34 41 41

1. Introduction [5]
NTECL (NTPC Tamilnadu Energy Company Limited) is a joint venture company between NTPC Limited (formerly National Thermal Power Corporation) and The Tamil Nadu Electricity Board (TNEB), and is currently setting up Vallur Thermal Power Project (VTPP) near Chennai with 2 x 500 MW under Phase-I and another 500 MW in Phase-II, in 1184 acres of land. In the NTECL site, IVRCL has taken up contract for constructing the Civil Works Pump House (CWPH) which includes a Pump House, Control Room, Forebay, CW Channel and Basin, CW duct and discharge pipes from the Pump House and a Pump House for Miscellaneous Pumps. Power is an essential requirement for all facets of our life and has been recognized as a basic human need. It is the critical infrastructure on which the socio-economic development of the country depends. The growth of the economy and its global competitiveness hinges on the availability of reliable and quality power at competitive rates. The demand of power in India is enormous and is growing steadily. India requires immediate electricity from whatever source possible. So, Defects or failures in constructed facilities can result in very large costs. Even with minor defects, re-construction may be required and facility operations impaired. Increased costs and delays are the result. In the worst case, failures may cause personal injuries or fatalities. Adding to this the Project is being constructed on a clayey soil with a high water table due to which there is a lot of seepage problems and many other problems combined with necessity of the proper functioning of the project for the socio-economic development of the country calls for maintaining high standards in quality. Owing to the importance of the qualitative aspects involved in this project, this technical report is aimed at analyzing the Qualitative Aspects involved from a civil engineering point of view and to gain an understanding as to the operations and the Preventive methods adopted by IVRCL in the construction of Civil Works Pump House Project. 1.1. Project Plan and Description I attempted to do two projects. One is a documentation project on the qualitative aspects and preventive methods used in the construction of CWPH project by IVRCL as detailed in this report and the other is a Project Scheduling & Management project. The second one is about scheduling the CWPH Project undertaken by IVRCL Infrastructures, Ltd. in the NTECL Power Plant site and this was a mutual project done by me and Uday Kovur (Fellow Trainee), estimating the expected project completion time and efficient allocation of the resources using CPM (Critical Path Method) and PERT (Program Evaluation Review Technique). The planning division guided us through the second project other than the individual project. The projects were interrelated and were aimed at helping in the application of the observation from one 10

into the other. The duration of my stay at the organization allowed us to take up other small tasks and projects up that I have not been able to mention in this presentation of my work. The Project on planning has not found mention in my project except in the conclusion for it is an improvement on the work that the company has already performed and we just arrived at conclusions from an analysis of this work. Essentially speaking we updated the project plan and developed the new criterion of comparison that needs to be set in to achieve near optimum results and completion of project. Plan of Action: July, 2011 - September, 2011 October, 2011 November, 2011 Qualitative aspects and Preventive Methods Quantitative aspects and Preventive Methods and Planning

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2. Excavation and Filling [7]

Backfilling is done from selected excavated material in layers not exceeding 300 mm compact thickness so as to ensure proper compaction. In case of compaction using special type of equipment, such as vibratory roller etc. backfilling is done in layers not exceeding thickness up to 500 mm. Higher the thickness of the layer lesser the compaction. As the soil is clayey which is cohesive, its particles stick together. Therefore, a machine with a high impact force is required to ram the soil and force the air out, arranging the particles. A rammer is the best choice (used by IVRCL) or a pad-foot vibratory roller if higher production is needed. Compaction is the application of mechanical energy to a soil to rearrange the particles and reduce the void ratio. 2.1. Purpose of Compaction [8] The principal reason for compacting soil is to reduce subsequent settlement under working loads. 1. Compaction increases the shear strength of the soil. 2. Compaction reduces the voids ratio making it more difficult for water to flow through soil. This is important if the soil is being used to retain water as in the case of channel, forebay, etc. 3. Compaction can prevent the buildup of large water pressures that cause soil to liquefy during earthquakes. 2.2. Factors affecting Compaction [8] 1. Water content of the soil: As water is added to a soil (at low moisture content) it becomes easier for the particles to move past one another during the application of the compacting forces. As the soil compacts the voids are reduced and this causes the dry unit weight (or dry density) to increase. Initially then, as the moisture content increases so does the dry unit weight. However, the increase cannot occur indefinitely because the soil state approaches the zero air voids line as shown in the figure 2.1 below which gives the maximum dry unit weight for given moisture content. Thus as the state approaches the no air voids line further moisture content increases must result in a reduction in dry unit weight. As the state approaches the no air voids line a maximum dry unit weight is reached and the moisture content at this maximum is called the optimum moisture content.

12

Figure 2.1. Zero Air Void Curve

[8]

2. The amount of compactive energy being used used: Increased compactive effort enables greater dry unit weights to be achieved which because of the shape of the no air voids line must occur at lower optimum moisture contents. It should be noted that for moisture contents greater than the optimum the use of heavier compaction machinery will have only a small effect on increasing dry uni unit t weights. For this reason it is important to have good control over moisture content during compaction of soil layers in the field. 3. The type of soil being compacted. 2.3. Standard Proctor Density Test [8] There are several types of test which can be used to study the compactive properties of soils. Because of the importance of compaction in most earth works standard procedures have been developed. These generally involve compacting soil into a mould at various moisture contents. The Standard Proctor Density ity Test is a laboratory method of experimentally determining the optimal moisture content at which a given soil type will become most dense and achieve its maximum dry density. Soil is compacted into a mould in 3 equal layers, each layer receiving 25 blows of a hammer of standard weight. The apparatus is shown in Figure 2.2 below. The energy supplied in this test is 595 kJ/m3. 13

Figure 2.2. Figure depicting the specifications for the standard proctor density test [1] Because of the benefits from compaction, contractors have built larger and heavier machines to increase the amount of compaction of the soil. It was found that the Standard Comp Compaction test could not reproduce the densities measured in the field and this led to the development of the Modified Compaction test. The procedure and equipment is essentially the same as that used for the Standard test except that 5 layers of soil must be e used. To provide the increased compactive effort (energy supplied = 2072 3 kJ/m ) a heavier hammer and a greater drop height for the hammer are used. To control the soil properties of earth constructions (e.g. dams, roads) it is usual to specify that the soil must be compacted to some pre pre-determined determined dry unit weight. This specification is usually that a certain percentage of the maximum dry density, as found from a laboratory test (Standard or Modified) must be achieved. Compaction at the CWPH Site is done to a minimum of 85% Standard Proctor Density at optimum moisture content in case of soil and 85% of original volume in case of boulders and filling the openings/interstices with selected excavated materials materials.

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3. Sheet Pilling [6]

Sheet pile is a hot or cold rolled structural shape with interlocks on the flange tips. The interlocks permit individual sections to be connected in order to form a continuous steel wall which is earth tight and virtually water resistant. Steel sheet piling is shown in the figure 3.1. It is a top choice in water retention systems. It is also excellent for retaining soils that are below the water table as in case of the water channel or the forebay being constructed where sheet pilling is done to retain the soil below the water table by dewatering the site while sheet piles prevent the entry of water into the site due to which IVRCL is using them at the channel and the forebay.

Figure 3.1. Sheet piling done at the NTECL site to retain the soil below the water table Sheet piling will maintain its shape during installation. Driven sheet piles displace soil rather than remove it. Therefore the support of adjacent structures is not compromised due to soil movement. 15

Steel sheet piling is environmentally friendly. In addition to being produced with recycled steel the sheet piles are installed in manner that produces no spoils. Therefore there is no risk of exposure and disposal of potentially hazardous or contaminated materials. Sheet piling is also useful in very soft clay soils that have little or no strength as at the site where the soil is soft clayey soil. So, sheet piles are the best option. With proper engineering and maintenance you can expect steel sheet piling walls to give you a very long service life. There are examples of sheet piling structures installed prior to 1920 that are still in service and performing well.

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4. Cast in-situ Concrete and Concrete Testing

In case of plain concrete 40mm nominal mix aggregate is used except for M20 for which 20mm nominal mix aggregate is used. As the nominal size of the aggregate should never be more than one fourth the thickness of the steel member for proper adhesion to take place 20mm nominal aggregate is used mostly in case of reinforced concrete. Super plasticizer cum retarder cum water proofing agent is used as an admixture. 4.1. Concrete Testing [4] There are two main tests that are done on concrete to ensure the quality of the construction work: 1. The Slump test: The Slump test is done to make sure a concrete mix is workable. Workability measures how easy the concrete is to place, handle and compact. 2. The Compression test: The Compression test shows the best possible strength concrete can reach in perfect conditions. The compression test measures concrete strength in the hardened state. Testing should always be done carefully. Wrong test results can be costly. Sampling: The first step is to take a test sample from the large batch of concrete. This should be done as soon as discharge of the concrete commences. The sample should be representative of the concrete supplied. The sample is taken in one of the two ways: For purposes of accepting or rejecting the load: Sampling after 0.2 m3 of the load has been poured. For routine quality checks: Sampling from three places in the load. 4.1.1. The Slump test: The measured slump must be within a set range, or tolerance, from the target slump. The testing is done on site. Equipment: Standard slump cone (100 mm top diameter x 200 mm bottom diameter x 300 mm high) Small scoop, Bullet-nosed rod (600 mm long x 16 mm diameter), Rule, Slump plate (500 mm x 500 mm).

17

Figure 4.1. Measuring the slump Method: 1. Clean the cone. Dampen with water and place on the slump plate. The slump plate should be clean, firm, level and non-absorbent. 2. Collect a sample. 3. Stand firmly on the foot pieces and fill 1/3 the volume of the cone with the sample. Compact the concrete by 'rodding' 25 times. 4. Now fill to 2/3 and again rod 25 times, just into the top the first layer. 5. Fill to overflowing, rodding again this time just into the top of the second layer. Top up the cone till it overflows. 6. Level off the surface with the steel rod using a rolling action. Clean any concrete from around the base and top of the cone, push down on handles and step off the foot pieces. 7. Carefully lift the cone straight up making sure not to move the sample. 8. Turn the cone upside down and place the rod across the up-turned cone as shown in figure 3.1. 9. Take several measurements and report the average distance to the top of the sample. 10. If the sample fails by being outside the tolerance (i.e. the slump is too high or too low) another must be taken. If this also fails the remainder of the batch should be rejected. 4.1.2. The Compression test: The testing is normally done in a laboratory off-site. But, at the NTECL site it is done in the site itself as all the equipment are readily available on the site. Normally the only work done on-site is to make a concrete cube for the compression test. The strength is measured in Megapascals (MPa) and is commonly specified as a characteristic strength of concrete measured at 28 days after 18

mixing. The compressive strength is a measure of the concretes ability to resist loads which tend to crush it.

Figure 4.2 Cube being filled with concrete for cube test at the site Equipment: Cubes, Small scoop, Bullet-nosed rod (600 mm x 16 mm) Steel float, Steel plate. Method: 1. Clean the cube mould and coat the inside lightly with form oil, then place on a clean, level and firm surface, i.e. the steel plate. 2. Collect a sample. 3. Fill 1/2 the volume of the mould with concrete then compact by rodding 25 times. Cubes may also be compacted by vibrating using a vibrating table. 4. Fill the cube to overflowing and rod 25 times into the top of the first layer, then top up the mould till overflowing. 5. Level off the top with the steel float and clean a concrete from around the mould. 6. Cap, clearly tag the cube and put it in a cool dry place to set for at least 24 hours. 7. After the mould is removed the cube is sent to the laboratory where it is cured and crushed to test compressive strength.

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5. Curing Concrete [4]

Curing means to cover the concrete so it stays moist. By keeping concrete moist the bond between the paste and the aggregates gets strong. Concrete doesnt harden properly if it is left to dry out. Curing is done just after finishing the concrete surface, as soon as it will not be damaged. Concrete that is cured is less likely to crack and more durable. The concrete can carry more weight without breaking. Cured concrete has a surface that wears better, lasts longer and better protects the steel reinforcement which is very important to prevent the corrosion of steel reinforcement in the channel due to the sea water, hence ensuring the quality of the water channel. Precautions: When curing formwork has to be left in place to help reduce water loss. In hot weather (above 30C), or during high winds and low humidity, concrete can dry out easily. In these conditions take extra care while curing. Methods: Concrete is cured by covering it with plastic sheets to slow down water loss. This method is very easy and cheap. The only problem is that the sheets may cause concrete to become darker in places. To avoid this concrete must be kept evenly moist. The sheets must be held down to stop them from blowing away and the concrete surface drying out. The sheets are held down with sand, timber or bricks. Always the concrete under the plastic sheet should be checked from time to time to make sure the concrete is evenly moist. If it feels dry, some water must be sprinkled and again covered with the plastic sheets. Condensation on the underside of the plastic is a good sign. Concrete keeps getting harder and stronger over time. The longer concrete is cured, the closer it will be to its best possible strength and durability.

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6. Joints in Concrete [3] [5]

Joints are used to control cracking in concrete. Joints are planned breaks in the concrete which allow it to move and prevent random cracking. Random cr cracking acking can weaken the concrete. Joints are made at two different times: Before any concrete is poured as for Construction joints or Isolation joints. After concrete has been placed and compacted, as for Control joints to control cracking in concrete.

6.1. Control Joints: Wet formed joints are inserted with the use of a grooving tool to create a plane of weakness which conceals where the shrinkage crack will occur. To be effective the joint is tooled to a minimum depth of 1/4 the depth of the concrete. Control joints may be made while concrete is hardening by slicing it with a thin piece of metal. The edges of the joints should be finished with a grooving or edging tool.

Figure 6.1. Control Joints A joint is filled with a flexible filler to minimize w water ater entry and to prevent stones etc. entering which may later cause spalling of the concrete. Control joints in unreinforced concrete should be located at a spacing of a width to depth ratio of about 20 (to 25). In steel reinforced slabs the joint spacin spacing g is controlled by the area of steel. The more steel there is, the further apart the joints can be. 6.2. Isolation joints: An isolation joint totally separates a concrete element from another concrete element, or a fixed object such as a wall or column, so that each can move and not affect the other. The joint filling should be full depth and soft. It can be made of cork, foam rubber, or some other flexible material.

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Figure 6.2. Isolation Joints 6.3. Construction Joints: A construction joint is a place wh where ere work finishes temporarily. Formwork is used to support the edge of the concrete already in place so that it doesnt just collapse. Concrete is finished square and the reinforcement normally runs through the joint. When placing begins again the formwork is removed and any loose material is brushed from the old surface. The old surface is roughened up to expose the coarse aggregate, so as to help the new concrete bond properly. The new concrete is poured against the old surface.

Figure 6.3. Construction Joints 6.4. Cold Joints: In hot and/or windy weather a concrete mix may stiffen rapidly and not be workable. A 'set retarding' admixture may be added to the concrete during mixing to give a longer working time. In hot and/or windy weather, if concrete stiffens quickly, a cold un-bonded bonded joint may form between concrete already in place and the new concrete. If there is a chance of this happening you need to make a construction joint. 22

Figure 6.4. Cold Joint 6.5. Joint sealants [9] s are used to seal joints and openings (gaps) between two or more substrates, and are Joint sealants a critical component to building design and construction. The main purpose of sealants is to prevent air, water, and other environmental elements from entering or exiting a structure while permitting limited movement of the substrates. 6.5.1. Bitumen itumen impregnated fiber board joint filler [10], conforming to IS: : 1838, is provided at joints in the concrete, at all levels (12.5mm and 25mm) Bitumen itumen impregnated fibreboard expan expansion joint filler is suitable for forming joints in in-situ in or precast concrete components, and to protect waterproof membranes against physical or mechanical damage. Forming structural expansion and separation joints in: 1. 2. 3. 4. 5. Concrete pavements and floors Roads, s, ramps and runways Pedestrian areas Concrete retaining walls and bridges Concrete basement structures and subways

Advantages 1. 2. 3. 4. 5. 6. Easy to handle, cut and tamp Resilient Will not extrude under compression High recovery Low distortion Standards compliance

6.5.2. Expanded xpanded polystyrene board non non-self-extinguishing type [11] (Type-1) 1) conforming to IS: 4671, is provided and installed all around the concrete foundations. (100 100 mm thick with nominal density of 20 Kg/ Cum um and nominal panel size of 1.0 M x 1.0M 1.0M) It is used due to its high compression strength which is not affected by wetting. 23

Expanded polystyrene (EPS) is primarily used as an effective thermal insulation material for walls, roofs and floors in all kinds of buildings. The low weight of EPS also makes it easy to handle on the site. EPS boards can be laid quickly and in any weather conditions, since it is unaffected by moisture. The combination of light weight with considerable and durable compressive strength is used in load bearing applications of EPS. The unique structure of EPS brings the benefits of exceptional compressive strength. Wetting of the material will not result in settlement of the material or other performance characteristics. This means it is ideal for use in many construction and civil engineering applications, particularly as a structural base infill, for example in road, railway and bridge infrastructures. Strength tests performed on EPS, after almost 30 years underground, showed that it routinely exceeded the original minimum design strength of 100kPa. EPS bridge foundations, which had been subject to many years of sustained loading, showed creep deformation of less that 1.3%: only half as much as had been theoretically predicted. Most importantly, EPS stability does not deteriorate with age. EPS has excellent mechanical properties making it good choice for the repetitive loading of roof insulation (walkability), sub-pavement flooring, road building and as a general load bearing insulation. With its flexible production process, the mechanical properties of EPS can be adjusted to suit every specified application. Resistance to moisture EPS does not absorb moisture and resists degradation of the mechanical and insulation properties due to water, damp, humidity or moisture. After almost 30 years in the ground, samples of EPS retrieved from locations as little as 200 mm above the groundwater level all showed less than 1% water content by volume, whilst blocks which are periodically entirely submerged show less than 4% water content - performance notably superior to other foamed plastic materials. Handling and installation EPS is a light weight, rigid material without being brittle. It is practical and safe to handle and install. Shape moulding allows the factory production of complex shapes to match the most demanding architectural and design requirements. Flexible processing machinery enables delivery of products with the correct specified density, insulation and mechanical properties, dimensions and shape which will minimise waste on the building site. On-site customising is possible without the need for specialist cutting tools. It is possible to cut to size using simple 24

means such as a knife or a handsaw. Handling of the material presents no dangers to health during transport, installation, use and demolition as no radiation, fibres or other substances are released. EPS can be handled and processed comfortably without causing irritation, eczema or inflammation of skin, lung or eyes. This means breathing masks, goggles and protective clothing and gloves are not required for working with EPS. Cement, lime, gypsum, anhydrite and mortar modified by plastics dispersions have no effect on EPS, so it can confidently be used in conjunction with all conventional types of mortar, plaster and concrete encountered in building construction. All of this makes it entirely safe and practical in use across all of its construction applications including subterranean and marine environments. 6.5.3. PVC Water Stops [12] For expansion joint, PVC water stops of minimum size 225 mm x 6 mm ribbed with central bulb are used. A Water stop is usually a section of flexible waterproof material placed at any joint in concrete to prevent the passage of water. Buried in the concrete, water stops can bear the tensile stress caused by the contraction of the concrete & shearing stress formed by the changes at the joints of the concrete due to sinking of the floor pan, it can produce marked effect of water leakage protection. Currently EM BEE Rubber & PVC water stops are widely used in large and small civil engineering water conservation. PVC water stops are for use in concrete joints subjected to hydrostatic pressures. After being embedded in concrete, PVC water stops fill up the joints to form a continuous watertight diaphragm that prevents the passage of fluid. The water stop must be designed and installed properly to accommodate joint expansions, contraction and lateral & transverse movements. In addition to these considerations the water stop must be compatible with the concrete system and the liquids and chemicals to be contained or controlled. 6.5.4. Hydro Swelling joint sealing flexible strip [13]: For construction joint, hydro swelling joint sealing flexible strip of nominal size 20 mm x 5 mm made of hydrophilic expanding rubber combined with chloroprene rubber is provided. Hydro swelling joint sealant for construction joints, cold joints, etc. It is a flexible strip made of a Hydrophilic expanding rubber combined with Chloroprene Rubber. It is used primarily for foundation walls slabs, slabs-on-grade, precast wall panels, manholes, pipe connections, box culverts, utility and wet wells, and portable water tanks. Expansion of the water stop creates a positive seal against the face of the concrete joint and prevents the water entry into the structure through the protected joint. 25

6.5.5. Cement Slurry modified with Acrylic Polymer [13]: For construction joints, cement slurry modified with acrylic polymer @ minimum 1.0 liter with every 3 kg. of cement and 1.0 liter of water and applying this slurry on the concrete surface @ 2.0kg./sq.m. 1. 2. 3. 4. 5. 6. Offers an impermeable coating; quite good as waterproof coating. Excellent adhesion to cementitious substrates. Works as an effective bonding agent by facilitating more open time. Can modify mortar / concrete for specifiers' requirements in repair. Reduces cracking in mortar and screeds. Suitable for internal and external applications.

6.5.6. Hot applied bitumen sealing compound [13], conforming to Grade A of IS: 1834 It has high adhesive and cohesive strength and is not affected by oxidation (that causes evaporation) and any chemical attack. Used to fill joint space where pipes are laid, the Sealing Compound is applicable in cross-sections in extruded rope form. Features 1. A hot -applied sealant for the joint to handle expansion, contraction and dynamic loads and absorbing bridge deck movement. 2. Suitable for all horizontal joints in pavement and buildings. 3. A bitumen-based filling compound subjected to electrical stress. It is used in cable joint boxes and also used by bat. 4. Resilient and adhesive barrier in concrete joints 5. Resists water infiltration 6. Resists solid particle ingress Advantages 1. 2. 3. 4. 5. Easy to apply No effect due to temperature variation Provides strong concrete adhesion No danger of outflow in hot weather conditions No danger of becoming brittle or resiliency loss in cold weather

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7. Defects in Concrete [1] [2]

Some defects are obvious only to a trained eye, others, such as cracking, are obvious to anyone. Some common defects, their causes and how to prevent and repair them are explained below. 7.1. Rain damage: The surface has bits washed away or many small dents. Causes: Heavy rain while concrete is setting or rainwater being allowed to run across the concrete surface. Prevention: The concrete should be covered if it is raining or if it is likely to rain. Concrete should not be laid if it looks like it might rain. Repair: If the concrete has not hardened and damage is minimal the surface can be refloated and re-trowelled taking care not to overwork excess water into the surface. If the concrete has hardened it may be possible to grind or scrape the minimal amount of the surface layer and apply a topping layer of new concrete or a repair compound. This may not always be possible. 7.2. Spalling:

Figure 7.1. Spalling due to heavy loads or impact with hard objects When the slab edges and joints chip or break leaving an elongated cavity. 27

Causes: Edges of joints break because of heavy loads or impact with hard objects as shown in the figure 7.1. As concrete expands and contracts the weak edges may crack and break. Entry of hard objects, such as stones, into joints may cause spalling when the concrete expands. Poor compaction of concrete at joints is also a reason. Prevention: The joints should be designed carefully. Joints must be kept free from rubbish and heavy loads. Proper compaction should be done. Repair: For small spalled areas: the weak areas must be scraped, chipped or grinded away until sound concrete is reached, old concrete must be brushed clean of any loose material. Then the area must be refilled with new concrete. The new patch must be compacted, finished and cured carefully. Care should be taken that all joints be maintained and not filled. 7.3. Honeycombing: When too much coarse aggregate appears on the surface it is called honeycombing as shown in figure 7.2. Causes: Poor compaction, segregation during placing or paste leakage from forms, a poor concrete mix with not enough fine aggregate causing a rocky mix.

Figure 7.2. Honeycombing concrete structure at the site Prevention: Use a better mix design. Take care during placing concrete to avoid segregation. Compact concrete properly. Good watertight formwork.

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Repair: If honeycombing happens only on the surface it can be rendered. If honeycombing happens throughout the concrete it may need to be removed and replaced. The surface may require rendering. Rendering means to cover the surface with a layer of mortar.

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8. Cracking in Concrete [1] [3]

Random cracking in concrete is not desirable; it can lead to structural weakness of the concrete. Reinforcement and joints are used to control cracking. Bad cracking leaves the reinforcement exposed to air and moisture, which may cause it to rust and weaken concrete. Two types of cracks happen in reinforced concrete: 1. Presetting cracks: Cracks that happen before concrete hardens, while it is still workable. 2. Hardened cracking: Cracks which happen after concrete hardens. 8.1. Presetting cracks: Pre-setting cracks are cracks which form during placing, compaction and finishing caused by movement of concrete before it is dry. There are three types of pre-setting cracks: Pre-setting cracks: They can be prevented by looking for them as they happen, while the concrete is still setting. If they are detected early on they can be easily fixed by re-compacting, retrowelling or re-floating the concrete surface. Plastic Settlement Cracks: They form soon after concrete is placed, while it is still plastic. They get bigger as concrete dries and shrinks and tend to follow the lines of reinforcement. Re-vibrate the concrete. Re-trowel the surface. Cracks must be looked as the concrete is setting. At this stage they can easily be fixed. Plastic Shrinkage Cracks: On very hot days or in low humidity and moderate winds. Cracking is more common in summer but may occur during winter. Dampen the subgrade and forms and protect the concrete from the wind. All the materials must be kept cool on hot days. Place, compact and cure as quickly as possible on hot days so concrete wont dry out. Once the concrete has been compacted, screeded and floated apply a uniform spray film of evaporant retardant (Aliphatic Alcohol) to prevent rapid loss of surface moisture, then continue with finishing. Placing should better be done at the cooler times of the day. Formwork Movement: If formwork is not strong enough it may bend or bulge. Formwork movement may happen at any time during placement and compaction. It should be made sure that the formwork is strong. If the concrete collapses, strengthen the formwork and re-vibrate the concrete. Plywood or Steel Formwork is provided. Thermal Shock: Applying cold water, as curing, over concrete on a hot day can result in cracks from the sudden contraction. It is better to use warm water.

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8.2. Cracks after hardening: Cracks after hardening may be caused by drying shrinkage, movement or settling of the ground, or placing higher loads on the concrete than it was designed to carry. Little can be done with cracks after hardening. Careful and correct placement helps prevent serious cracking after hardening. Only uncontrolled cracks are a possible problem. Cracks at control joints or controlled by steel reinforcing is expected and acceptable.

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9. Damp proofing and Protective layer

Damp proofing is a treatment of a surface or structure to resist the passage of water in the absence of hydrostatic pressure. A damp proofing barrier system is used to perform the same functions as a waterproofing system but cannot be used to protect against water pressure. A protective layer is applied for damp proofing and water proofing to concrete structures, at all levels. 9.1. In Dry Conditions [14] Minimum two coats of hot bitumen of Industrial grade 85 / 25, conforming to IS: 702, mixed with 1% anti-stripping (additive that assists the asphalt to adhere to wet surfaces) compound, on the plastered / un-plastered concrete surface, @ 1.70 Kg. / Sq. M. (for all coats). Bitumen is a dark black, thick, petroleum residue. The source of bitumen is from oil Refineries. Bitumen procured from refineries are highly viscous which by oxidation, becomes industrial bitumen. Bitumen of Industrial grade 85 / 25 85 refers to the softening point of bitumen and 25 refers to the penetration value 1. Precise chemical composition 2. Highly physical stability 3. Resistant to corrosion Softening point or Vicat hardness is used for materials that have no definite melting point, such as plastics. It is taken as the temperature at which the specimen is penetrated to a depth of 1 mm by a flat-ended needle with a 1 square mm circular or square cross-section. Penetration gradings basic assumption is that the less viscous the asphalt, the deeper the needle will penetrate. This penetration depth is empirically (albeit only roughly) correlated with asphalt binder performance. Therefore, asphalt binders with high penetration numbers (called "soft") are used for cold climates while asphalt binders with low penetration numbers (called "hard") are used for warm climates. 9.2. In Wet Conditions [15] Tar extended two component coating system based on synthesized epoxy resin and amine adduct of minimum thickness 300 micron (dry film thickness), compatible to water, application in wet conditions and tolerant to under prepared surfaces. Coal Tar Epoxy Coating Resin System is a two component coal tar epoxy coating, black in color, used to protect steel, concrete structures, timber, and other construction materials in corrosive environments. 32

The cured coating is flexible and affords excellent resistance to impact, thermal shock and abrasion. It cures to a hard, smooth surface, possesses exceptional resistance to immersion in salt water, or in water where an altered pH condition is present. So, it is perfectly suitable for the site conditions. Caution: Contain Xylene. Keep away from heat, sparks and flame. Avoid breathing vapor. Use with forced air ventilation in confined areas. Avoid contact of resin or hardener with the skin or eyes.

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10. Grouting
Grout is a construction material used to embed rebars in masonry walls, connect sections of precast concrete, fill voids, and seal joints (like those between tiles). Grout is generally composed of a mixture of water, cement, sand, often color tint, and sometimes fine gravel (if it is being used to fill the cores of cement blocks). It is applied as a thick liquid and hardens over time, much like mortar. Grout (fluid mix and /or plastic mix) for grouting of foundation bolt holes, underside of base plates, etc. Grout consisting of 2 parts by weight of sand, 1 part by weight of cement, blended with non-metallic anti-shrinkage admixtures is used. Cement aggregate grout (stiff mix) for dry pack application for grouting of underside of base plates where grout thickness is more than 40 mm with anti-shrinkage admixtures in required proportions. 40mm is used because for higher thicknesses stiff mix grout can be applied which cannot be applied in case of <40mm as it will be very difficult to apply in case of lesser thickness.

Figure 10.1. Grouting of Underside of base plate

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11. Protective Coating on Structural steel (for all pipes, steel beams, etc)
High performance epoxy based Poly Amide cured painting system of approved color and shade consisting of Zinc silicate primer (under) coat including blast cleaning of steel surfaces to near white metal surface (Sa 2), is provided and applied to steel surfaces of all types, shapes and sizes, at all levels, to achieve an even shade. 11.1. Inorganic Zinc Silicate primer [16]: minimum 75 micron Dry film thickness (DFT) of zinc silicate primer including touch up painting for the damaged surfaces of primer is applied to provide tough abrasion resistance and to immensely upgrade anticorrosive performance of Epoxy based over coating system. Zinc silicate primer is used in marine, coastal and heavy industrial environments. Advantages: 1. 2. 3. 4. They are made with zero VOC and are very environmental friendly. It provides a tough abrasion resistant coating It renders outstanding galvanic protection to steel by eliminating sub-film corrosion. It immensely upgrades anticorrosive performance of over coating systems like Epoxy, chlorinated rubber, vinyl and polyurethane paints.

Disadvantages: Being Zinc based, the coating is not resistant to acid and alkali solutions. So, it is not recommended for exposure to acids or alkalis without suitable top coats. As this is the case here, it is top coated with high performance epoxy based Poly Amide cured painting system. Ensure surface is clean, dry and free from zinc salts before over coating. A mist coat should first be applied to avoid bubbling problem which appears due to air entrapment. 11.2. Epoxy based Titanium dioxide/Micaceous iron oxide: minimum 75 micron DFT epoxy based Titanium dioxide/Micaceous iron oxide (pigmented) intermediate coat is applied over inorganic Zinc Silicate primer to act as a tough barrier coat with excellent impermeability to moisture. It is designed for application on structural steel as an intermediate or finish coat exposed to aggressive coastal and industrial environment. The product acts as a tough barrier coat with excellent impermeability to moisture. 11.3. Epoxy based Poly Amide cured paint [15]: minimum 75 micron DFT Epoxy based color pigmented finish Poly Amide cured paint is applied as the final finish coat for their superior adherence to epoxy based primer surface.

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These epoxies generally have superior adherence to any type of galvanized surface. Because they are not resistant to sunlight, they are typically used as a primer or for corrosive interior applications. A galvanized steel/polyamide epoxy primer /aliphatic urethane as in this case top coat system is considered to be a superior high performance duplex system. 11.4. Polyurethane finish paint: minimum 25 micron DFT Polyurethane color pigmented finish paint, including final touch up painting for the damaged surfaces of Finish and Final Finish Paint. Advantages: 1. 2. 3. 4. 5. 6. Excellent Abrasion Resistance Excellent Chemical Resistance UV Resistant - means a long life even in direct sunlight Excellent Color Stability - Pigmented Version Exterior and Interior Uses May be used on both Horizontal and Vertical Applications

11.5. Heavy duty polyurethane coating: 2mm thick high build heavy duty polyurethane coating having formulation of 100% solvent free solids is applied on the inside surface of CW liner, all pipes and fittings in contact with the sea water. Heavy duty polyurethane coating is a three-coat system with a zinc-rich primer, an epoxy intermediate coat and two-pack polyurethane topcoat can be considered as a point of reference for heavy duty coatings applied to metals. Three coat system to minimize the penetration of any contaminants to the substrate, provide resistance to abrasion, impact, severe weather conditions, corrosive atmospheres or liquids.

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12. Masonry and allied works

Class A bricks of minimum crushing strength of 75 Kg/ cm2, are used at all levels, for all kinds of works, to give good bearing capacity and strength. Galvanized hexagonal wire netting of 0.9 mm wire diameter and 19 mm mesh size is provided and fixed, for all types of members and all types of surfaces, for plastering on masonry / concrete/ steel sections, in all kinds of works for better integrity of the plaster and for tensile strength.

13. Wall or Ceiling Finishes [1]

Minimum of 2 mm thick Plaster of Paris is provided to give even and smooth surface for all walls. Minimum of three coats of finish paint of approved color and shade and a coat of compatible primer, for all types of plastered and / or exposed concrete surface, in all kinds of works, at all levels, including preparation of surfaces by providing minimum 2 mm thick Plaster of Paris, to give even and smooth surface is provided. 13.1. Oil Bound distemper It is used for interiors. Its high quality, decorative and economical paint with quality of colors. The paint is suitable for interior surfaces only as the paint is alkali resistant, and maintains excellent porosity in new and old buildings. 1. 2. 3. 4. 5. 6. 7. Easy in application. Provides a range of colors. Durable and economical paints. Dry quickly, touch dry in 4 hours. Non-flammable. Environment-friendly paint Has no harmful ingredients and lead free

Before applying oil bound distemper a coat of alkali resistant primer paint should be applied and allow drying for at least 48 hours if oil bound distemper is done on newly plastered surface. Distemper Primer and the Oil bound distemper should be of the same brand to ensure top quality. If any drop of distemper falls down on any object it should be cleaned quickly as once it dries it cannot be washed off. For ceiling, Oil bound distemper is without a coat of plaster of paris. 37

13.2. Acrylic emulsion paint: It is used for both interior and for exteriors. Resin and polymer bonded granular textured coating finish plastered and / or exposed concrete surface is applied. 2.5 mm natural stone chips are used for rough external finish. 13.3. Oil paint vs. Acrylic emulsion 1. Oil paint is said to be "oil-based", while acrylic paint is "water-based" 2. Oil paint has a higher pigment load than acrylic paint. As linseed oil has a smaller molecule than does acrylic, oil paint is able to absorb substantially more pigment. Oil provides a unique "look and feel" to the resultant paint film. 3. Not all pigments in oil are available in acrylic. Prussian blue has been recently added to the acrylic colors. Acrylic paints, unlike oil, may also be fluorescent. 4. The rapid drying of the paint tends to discourage the blending of color and use of wet-inwet technique as in oil painting. While acrylic retarders can slow drying time to several hours, it remains a relatively fast-drying medium, and the addition of too much acrylic retarder can prevent the paint from ever drying properly. 5. Acrylics appear more stable than oil paints. Oil paints fade in color and develop a yellow tint over time; they also begin to crack with age 6. As temperatures rise and fall, this oil film cracks. Meanwhile, acrylic paint is very elastic, which prevents cracking from occurring. Acrylic paint's binder is acrylic polymer emulsion; as this binder dries the paint remains flexible. 7. The addition of oil with an emulsifier such as borax creates a more durable and often washable distemper depending on its formulation, which can be considered a predecessor of modern resin based emulsions. 8. It became popular as an interior paint in the early 19th century when a number of manufacturers began to produce it commercially, and it remained in common use until after the Second World War when it was finally superseded by vinyl and acrylic emulsion paints. It is now popular once again for its visual qualities.

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14. Water Proofing

Waterproofing is a treatment of a surface or structure to prevent the passage of water under hydrostatic pressure. Waterproofing barrier system may be placed on the positive or negative side. Water proofing treatment is provided for roof, for water retaining structure, basement type of underground structure. Primer coat of polymerized mastic is provided to achieve smooth surface, reinforcing layer of poly scrim cloth or non-woven geo-textile is laid over the primer, High Solid content liquid applied urethane based elastomeric membrane is used for finishing, joints at junction of horizontal surfaces with vertical surfaces and at panel junctions are sealed by wearing a course non-bituminous sealant / elastomeric compound, etc. at all levels and for all type of work. 14.1. Non-Woven Geotextiles or Poly Scrim Cloth [17] Non-Woven Geotextiles are manufactured from virgin Polypropylene/ Polyester fibers-needle punched to provide a dimensionally stable fabric. It provides optimum strength and permeability. Characteristics: 1. 2. 3. 4. Can withstand construction installation stresses UV (Ultra Violet) Stabilized High Chemical Resistance Optimum Elongation Or Poly Scrim 6 [17]: It is a 3ply, 6 mil extrusion laminate combining two layers of linear, low density polyethylene a highstrength cord grid. It is specifically engineered to provide high strength and durability in a lightweight material. Characteristics: 1. Multiple layers and cord reinforcement resists tears. 2. Flexibility and light weight allow for easy handling and quick installation 3. UV stabilization protects the material from degradation during extended exposure to sunlight. 4. Coldcrack resistance eliminates failures in extremely cold temperatures. 5. Low permeability greatly inhibits moisture transmission 6. High durability allows for significant savings through reuse and fewer replacements. Polyester String Reinforced Polyethylene sheeting is the industry standard for use as a vapor retarder or vapor barrier when one is trying to waterproof, or reduce moisture, radon, methane, or VOC levels entering a home or any other structure from a crawlspace or basement.

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The reinforced products come in a variety of types, and one should make sure that any product used in this application has been extrusion laminated. This is a method of joining together the layers of polyethylene (or other types of plastic) with the scrim reinforcement layer(s), where molten polyethylene is used, along with a lot of pressure. The resulting product is very strong, and has amazing tear resistance compared to most types of polyethylene films. The scrim reinforced films are quite appropriate for this application, and serve the purpose very well. Because of breakthroughs in polymer technology, it is now possible to make a polyethylene film that blocks virtually all of the extremely small particle gasses, like Radon, Methane, and many VOC's, along with water vapor molecules. Poly Scrim Cloth is a better choice compared to non-woven geotextiles in this case. 14.2. Urethane Elastomer waterproofing applications.
[15]

is a two component, high solids, elastomeric urethane used in

Urethane Elastomer exhibits excellent elongation properties along with high tensile strength and tear resistance to make it an ideal crack resistant membrane. Advantages: 1. 2. 3. 4. 5. 6. Bridges Hairline Cracks Resistant to Automotive fluids Quick Cure Time One Coat Application Low Odor Available in 100% Solids

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15. Pressure Release Valves [1] [5]

To resist pressures of very high magnitude caused due to the water in the channel, the channel would need to be constructed from a very strong material.

Figure 15.1. Pressure Release Valve This problem can be overcome by the use of a "controlled pressure" system, known as Breather Valves or Pressure Relief Valves as shown in the figure 15.1 and 15.2. These low-pressure, highflow valves automatically adjust the pressure with respect to the amount of water over the channel. The rate of pressure change, multiplied by the net volume of water in the channel will determine how much water, in cubic feet per minute, the valve must flow to relieve pressure or vacuum as rapidly as it might build up.

Figure 15.2. Pressure release valves in the channel

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Conclusion
Analysis of the qualitative processes associated with the construction of the CWPH and the preventive measures taken are discussed in my project report. Based on the understanding obtained from this analysis, I have attempted to conclude few points regarding the situation and operations in the site. This conclusion is based both on the project that I have performed individually and another planning project that I have worked on with Mr. Uday Kovur at IVRCL Infrastructures. The main conclusion that we have arrived upon is that the Project site is at the mercy of the weather conditions and is highly prone to rain and water logged most of the times. Continuous dewatering of the site is done, yet it is unmanageable to remove the water and retain the soil. This is due to the high water table which is way above the foundation level and due to the type of soil. This soil type is not suitable for major excavation and foundation laying activities such as this one. In the case of heavy rainfall the sub-soil being clay causes disturbances mostly to the underground structures. So, locations like these should be avoided. It is very difficult to Plan a project in this type of location due to many unpredictable factors that influences the progress of the project. Due to this reason IVRCL has failed in completing the milestones in the specified time. From the construction point of view, records of the work performed, both quantitative as well as qualitative must be kept at all times and this data must be verified for consistency in at least one form or the other to ensure constant measurability of the project progress through the activities that have been completed. This project allowed me to get a good experience in the field and gave me a perspective on the Infrastructure and Construction Industry. It was an enlightening experience being allowed to take part in this huge thermal power project, even though for just a short period of time. I was able to practically get experience and a better idea of the aspects that were discussed in the classroom.

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References
1. www.en.wikepedia.org 2. www.concretenetwork.com/ 3. www.askthebuilder.com/ 4. www.concrete.net.au/publications/pdf/concretebasics.pdf 5. NTECL 6. http://sheetpilespiling.com/ 7. www.concrete-catalog.com/soil_compaction.htm 8. www.intelligentcompaction.com/downloads/ 9. www.wbdg.org Design Guidance Products & Systems 10. www.scribd.com/doc/52331094/bitucell 11. www.eumeps.org/show.php?ID=4716&psid=xwctaave 12. www.catalogs.indiamart.com 13. www.alibaba.com 14. www.vinoragroup.com/industrial_grade_bitumen.html 15. www.epoxysystems.com 16. www.tambourpaints.com/home/HeavyDuty.aspx 17. www.globalplasticsheeting.com/

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