SUMMER

INTERNSHIP REPORT (7/5/2012 - 24/6/2012)

Submitted by:- Umed Paliwal Second Undergraduate Student, Department of Civil Engineering, Indian Institute of Technology Kanpur

INDEX ______________________________________________________________________ Sno. Contents Page no. 1 Aknowldgement 3 2 Introduction 4 3 EHS Department 15 4 QA/QC Department 21 5 Project Execution 47 6 Planning 57 7 Conclusion 59 ______________________________________________________________________
2

 Aknowldgement

I am very thankful to LARSEN & TOUBRO CONSTRUCTIONS BUILDINGS & FACTORIES INDIPENDENT COMPANY (L&T CONSTRUCTION, B&F IC) for having given me the opportunity to undertake my summer training at their prestigious FORD INDIA PVT LTD, # 2 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. Ashutosh Tripathi, L&T Construction. Ahmadabad Cluster Project Manager Factory Division, who heartily welcomed me for the internship. I would also like to give my heart-felt thanks to Mr. S. K. Basu, Project Co- Ordinator, Mr. Sudeep Ghosh ,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. G. M. Mir, Planning Head, who assisted and guided me whenever I needed help. I would like to thank all the department heads of L&T Construction, B&F IC, 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 L&T Construction , B&F IC, for being so helpful during this summer training. Name: Umed Paliwal Date: 16th June 2012

INTRODUCTION
ABOUT THE ORGANIZATION:
Larsen & Toubro Limited is the biggest legacy of two Danish Engineers, who built a world-class organization that is professionally managed and a leader in India's engineering and construction industry. It was the business of cement that brought the young Henning Holck-Larsen and S.K. Toubro into India. They arrived on Indian shores as representatives of the Danish engineering firm F L Smidth & Co in connection with the merger of cement companies that later grouped into the Associated Cement Companies. Together, Holck-Larsen and Toubro, founded the partnership firm of L&T in 1938, which was converted into a limited company on February 7, 1946. Today, this has metamorphosed into one of India's biggest success stories. The company has grown from humble origins to a large conglomerate spanning engineering and construction. Larsen & Toubro Construction is Indias largest construction organisation. Many of the country's prized landmarks - its exquisite buildings, tallest structures, largest industrial projects, longest flyover, and highest viaducts - have been built by it. Leading-edge capabilities cover every discipline of construction: civil, mechanical, electrical and instrumentation. L&T Construction has the resources to execute projects of large magnitude and technological complexity in any part of the world. The business of L&T Construction is organized in six business sectors which will primarily be responsible for Technology Development, Business Development, International Tendering and work as Investment Centres. Head quarters in Chennai, India. In India, 7 Regional Offices and over 250 project sites. In overseas it has offices in Gulf and other overseas locations. L&T Constructions cutting edge capabilities cover every discipline of construction civil, mechanical, electrical and instrumentation engineering and services extend to large industrial and infrastructure projects from concept to commissioning.

L&T Construction has played a prominent role in Indias industrial and infrastructure development by executing several projects across length and breadth of the country and abroad. For ease of operations and better project management, in-depth technology and business development as well as to focus attention on domestic and international project execution, entire operation of L&T Construction is structured into four Independent Companies. Hydrocarbon IC Buildings & Factories IC Infrastructure IC Metallurgical & Material Handling IC Power Transmission & Distribution Heavy Engineering Shipbuilding Power Electrical & Automation Machinery & Industrial Product

BUILDING & FACTORIES The Buildings & Factories Independent Company is equipped with the domain knowledge, structures. Commercial Buildings & Airports Residential Buildings & Factories requisite expertise and wide-ranging experience to undertake Engineering, Procurement and Construction (EPC) of all types of building and factory

RESIDENTIAL BUILDINGS & FACTORIES L&T undertakes turnkey construction of a wide range of residential buildings and factory structures. Projects are executed using the cutting edge technology, sophisticated construction equipment and project management tools for quality, safety and speed. Residential Building Factories 5

FACTORIES L&T offers design and turnkey construction of heavy and light factories, cement & plants including Defence Projects using the latest construction technology, with a focus on Quality, Safety and Speed. The spectrum covers Heavy & Light Factories (HLF) Automobile & Ancillary Factories, Glass plants, Food processing Factories, Pharmaceutical plants, Warehouses & Logistics Parks, Workshop Complexes, Solar thin film manufacturing units, etc. Cement & Plants (C&P) Cement Plants, Sugar Plants, Distillery Plants, Food Grain storage structures, Pulp & Paper Mills, Textile Mills etc. Defence Construction of Manufacturing Facilities and Warehouse Facilities for Defence.

SERVICE SPECTRUM L&T Constructions range of services includes: Pre-engineering, feasibility studies and detailed project reports. Complete civil and structural construction services for all types of buildings, industrial and infrastructure projects. Complete mechanical system engineering including fabrication and erection of structural steel works; manufacture, supply, erection, testing and commissioning of plant and equipment; heavy lift erection; high-pressure piping; fire-fighting; HVAC and LP/ utility piping networks. Electrical system design, project electrification, automation and control system including instrumentation for all type of industrial and telecom projects. Design, manufacture, supply and installation of EHV switchyards, transmission lines.

QUALITY POLICY
At L&T, Environment, Health & Safety (EHS) is given the highest priority. The EHS policy enunciated by the Corporate Management lays emphasis on Environment, Health and Safety through a structured approach and well defined practices. Systems and procedures have been established for implementing the requisites at all stages of construction and they are accredited to the International standards of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007.

1.1

HEALTH SAFTEY AND ENVIRONMENTAL POLICY

HR POLICY

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

TRAINING
Human Resources Department believes that Quality is the hallmark of any successful venture. Quality Training and Development of Human Resources is realized through: Identifying training needs within the Organization and designing and implementing those need based training programs to bring about continuous up-gradation of knowledge, skills and employee attitudes.

VISION & MISSION

VISION L&T shall be professionally managed Indian multinational committed to total customer satisfaction and enhancing shareholder value. L&T shall be an innovative entrepreneurial and empowered team constantly creating value and attaining global benchmarks. L&T shall foster a culture of caring trust and continuous learning while meeting expectations of employees, stakeholders and society.

10

MISSION To achieve excellence in the field of Engineering, Procurement and Construction through world class practice and standards in quality, Safety and Project Management.

11

PROPOSED PROJECT CAR MANUFATURING FACILITY FOR FORD INDIA PVT LTD, AHMEDABAD, INDIA.

12

THE PROJECT DETAILS PROJECT - CAR MANUFATURING FACILITY CLIENT - M/S. FORD INDIA PVT LTD. CONSULTANT - KAJIMA INDIA PVT LTD CONTRACTOR - L&T CONSTRUCTION BUILDING & FACTORIES TYPE OF CONTRACT LUMPSUM CONTRACT CONSTRUCTION PERIOD DEFECT NOTIFICATION PEROD - 365 DAYS PROJECT COMPONENT ENGINE SHOP PAINT SHOP TCF SHOP BODY SHOP STAMPING ROAD AND ADMIN BUILDING PACKAGE UNDER L&T ENGINE PLANT PAINT SHOP PILING WORK TCF SHOP PROJECT LOCATION AND AREA SANAND AHMEDABAD, NEAR TATA NANO PLANT AREA UNDER SCOPE 460 ACRES CONSULTANT KAJIMA INDIA PVT LTD

13

BRIEF INTRODUCTION OF PROJECT

Ford India has laid the foundation for its new US $1 billion state-of-the-art, integrated manufacturing facility in Sanand and its future growth on the subcontinent. The total area of the plant is 406-acre. Ford India Sanand facility will deploy global best practices and technology including a state-of-the-art Paint Shop Ford Indias Sanand facility attracts 19 world-class supplier manufacturers to date Ford India is laying the foundation for its new US $1 billion state-of-the-art, integrated manufacturing facility in Sanand and its future growth on the subcontinent. It will be complete in 2014; the integrated manufacturing facility will have the capacity to produce an additional 240,000 new Ford vehicles and 270,000 engines per year for Indian customers and for export market. The new state-of-the-art assembly plant will be fully integrated to support stamping, body assembly, paint, trim and final assembly. The paint shop will utilize Fords environmentally friendly rotational dip technology and 3-Wet technology paint processes, which will improve paint quality, depth and durability, as well as significantly reducing Volatile Organic Compounds, CO2 emissions and waste. The idea behind selecting Sanand as project site is, the way the Chennai Port served the companys markets in the East and South East Asia, the Gujarat terminal, or a roll-on roll-off (RoRo) facility, could be used for exports to the western markets like Mexico, South Africa and the Middle East as and when necessary. Plus, the State Government has also prioritized land adjacent to the site for supplier operations. It will be protected by the local government in order to attract and locate automotive suppliers within close proximity of both the plants.
The project has divided into various packages; L&T has received three packages: first package is Paint shop(Piling work) , second package Engine and third package is TCF. The location of project makes it more important due to TATA NANO PLANT by side and upcoming MARUTI PLANT.

14

EHS DEPARTMENT

GENERAL EHS RULES &REGULATIONS

1. No workmen below 18 years and above 58 years of age shall be engaged for a job. 2. All workmen shall be screened before engaging them on the job. Physical fitness of the person to certain critical jobs like working at height or other dangerous locations to be ensured before engaging the person on work. The final decision rests with the site management to reject any person on the ground of physical fitness. 3. Visitors can enter the site after EHS induction with the visitor pass. He should be provided Safety helmet & safety Shoes, also he should be accompanied with the responsible person of that area. 4. Smoking is strictly prohibited at workplace. 5. Sub-contractors shall ensure adequate supervision at workplaces. They shall ensure that all persons working under them shall not create any hazard to self or to the co-workers. 6. Nobody is allowed to enter the site without wearing safety helmet. Chinstrap of safety helmet shall be always on. 7. No one is allowed to work at or more than two-meter height without wearing full body harness and anchoring the lanyard of full body harness to firm support preferably at shoulder level. 8. No one is allowed to enter into workplace and work at site without adequate foot protection (including female worker). 9. Usage of eye protection equipment shall be ensured when workmen are engaged for grinding, chipping, welding and gas cutting. For other jobs, as and when site safety co-ordinator insists eye protection has to be provided. 10. All PPEs like shoes, helmet, full body harness etc. shall be arranged before starting the job as per recommendation of the EHSO. 11. Rigid barrication must be provided around the excavated pits, and barrication shall be maintained till the backfilling is done. Safe approach is to be ensured into every excavation.

15

12. Adequate illumination at workplace shall be ensured before starting the job at night. 13. All the dangerous moving parts of the portable/fixed machinery being used shall be adequately guarded. 14. Ladders being used at site shall be adequately secured at bottom and top. Ladder shall not be used as work platforms. 15. Erection zone and dismantling zone shall be barricaded and nobody will be allowed to stand under the suspended loads. 16. Horseplay is completely prohibited at workplace. Running at site is completely prohibited except in case of emergency. 17. Material shall not be thrown from the height. Proper arrangement of Debris Chute can be installed. 18. Other than the electrician possessing B licence with red helmet, no one is allowed to carryout electrical connection, repairs on electrical equipment or other job related thereto. 19. Inserting of bare wires for tapping the power from electrical socket is completely prohibited. 20. All major, minor accidents near misses and unhygienic conditions must be reported. 21. All scaffoldings/ work platform shall meet the requirement. The width of the working platform and fall protection arrangement shall be maintained as per the Standard. All tools and tackles shall be inspected before use. Defects to be reported immediately. No lifting tool&tackle to be used unless it is certified by the concerned Engineer Incharge / P&M engineer. 22. Good house keeping to be maintained. Passage shall not be blocked with materials. Material like bricks shall not be stacked to the dangerous height at workplace. 23. Debris, scrap and other material to be cleared then and there from the work place and at the time of closing of work every day. 24. Contractors shall ensure that all their workmen are following safe practices while travelling in the companys transport and staying at companys accommodations. 25. Adequate fire fighting equipment shall be made available a workplace and persons to be trained in fire fighting techniques with the co-ordination of EHSO. 26. All the unsafe conditions, unsafe act identified by the contractors, reported by site supervisor and / or safety personnel to be corrected on priority basis.

16

27. No children shall be allowed to enter the workplace. 28. Workwomen are not allowed to work at high-risk areas. 29. Other than the Driver/operator, no one shall travel in a tractor / tough rider etc. 30. Wherever the vehicle/equipment has to work near or pass through the overhead electrical lines, the goal post shall be installed. 31. Identity card should always be displayed and shown when demanded. 32. Any person found to be interfering with or misusing fixtures, fittings or equipment provided in the interest of health, safety and welfare would be excluded from site.( like using helmet and fire bucket for carrying the material, removing the handrails, etc.) 33. Visitors must use safety helmet before entering the Site. 34. Safety signs and notices must be displayed and followed. 35. Transistor radios or personal stereos / Walkman must not be used. 36. All site personnel, for their own safety and for the safety of others, are required to fully comply with the agreed safety systems/ procedures and working method. 37. Consumption of alcohol and drugs is prohibited. 38. No person is to operate any mechanical / Electrical equipment unless they have been authorized and have been certified as competent. 39. Take Food only at the designated area (like dinning, Rest Room etc). The Waste food, PVC/Paper covers need to be dumped in the Dustbin. The House keeping gang on regular intervals will clear this. Also hand / vessels should be washed in the same area with proper drainage. 40. No workers should enter the site with lunghies and dhotis. 41. No body should sit / sleep on the floor edges. 42. Dont enter inside the room where there is no light. 43. Dont take shelter under the vehicle or in an electrical installation rooms. 44. Look for warnings signs, caution boards and other notices. 45. Must be aware about the locations of the first aid canter, fire extinguisher, emergency assembly point and emergency siren. 46. No floor opening, floor edges should be left unguarded 47. Training is must for all scaffolders and only trained scaffolders should make platforms. 48. Dont keep loose materials at height. 49. Permission should be taken for all earthworks from P&M Department.

17

50. Those who are violating the safety norms will be penalized. 51. Female workers should not be engaged on work between 7.P.M. To 8 A.M. 52. Physical fitness check shall be carried out for crane operators & Drivers. 53. PPE Shall is provided to visitors at gate. 54. No smoking sign boards shall be kept at flammable and combustible material Storage places. 55. Debris, scrap and other materials shall be disposed daily at closing hours of the day by the same crew. 56. Environment poster shall be displayed at site as and when required Depending upon the activities in progress. 57. Fire points should be placed at all required areas

Use of Personal Protective Equipment and safety devices relevant to site activities.

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: 2925- 1984 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

18

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: 5983-1980.

EAR PROTECTION Ear Muff / Earplug should be provided to those working at places with high sound levels (confirm to IS: 9167-1979).

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: 6994-1973 2) RUBEER Gloves-18 (380/450mm long) electrical grade, tested

to 15000 Volts conforming to IS: 4770-1991

3) LEATHER Gloves hot work / handling of sharp edges

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: 3521-1999(Third Revision).

19

1) Lanyard should be of 12mm Polypropylene rope and of length not more than 2m. 2) Double lanyard, based on the requirement.

20

QUALITY ASSURANCE & QUALITY CONTROL DEPARTMENT

Quality is the key component which propels performance and defines leadership traits. At L&T Construction, Quality Standards have been internalised and documented in Quality Assurance manuals. L&T Construction recognizes the crucial significance of the human element in ensuring quality. Structured training programmes ensure that every L&T employee is conscious of his/her role and responsibility in extending L&T Constructions 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. L&T, Buildings & Factories IC 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 L&T, Buildings & Factories IC 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 stages of construction and they are accredited to the International standards of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007. L&T continues to maintain the trail blazing tradition of meeting the stringent quality standards and adherence to time schedules in all the projects. PROJECT QUALITY PLAN (PQP): The Project Quality Plan is prepared and formulated as a Management Summary of Quality related activities required to meet the terms of contract. This Quality plan sets out the Management practices and describes the Quality Management System based 21

on PDCA (Plan, Check, Do and Act) Principle. The Project Quality Plan comprises of two sections: A. VOLUME I SCOPE: The contents of this document are applicable to SHOP CONSTRUCTION FOR M/s. FORD INDIA Pvt. Ltd. and Construction of Civil and Structural works for M/s. FORD INDIA Pvt. Ltd. At Sanand, Gujarat that will be carried out by Larsen & Toubro Limited, Buildings & Factories IC for FIPL. In preparation of this document, due regard has been paid to the requirements of ISO 9001: 2008 series of System Standards. PURPOSE: This Project Quality Plan is prepared and formulated as a Management Summary of Quality related activities required to meet the terms of contract. This Quality plan sets out the Management practices and describes the Quality Management System. 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

22

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 23

ii) Start a stop-watch, 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 non-porous 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.

REPORTING OF RESULTS The results of the initial and the final setting time should be reported to the nearest five minutes.

24

TESTS ON AGGREGATES SIEVE ANALYSIS AIM To determine the particle size distribution of fine and coarse aggregates by sieving as per IS: 2386 (Part I) - 1963.

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 of sizes - 80mm, 63mm, 50mm, 40mm, 31.5mm, 25mm, 20mm, 16mm, 12.5mm, 10mm, 6.3mm, 4.75mm, 3.35mm, 2.36mm, 1.18mm, 600m, 300m, 150m and 75m ii)Balance or scale with an accuracy to measure 0.1 percent of the weight of the test sample PROCEDURE i) The test sample is dried to a constant weight at a temperature of 110 + 5oC 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.

25

REPORTING OF RESULTS 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.

WATER ABSORPTION

AIM To determine the water absorption of coarse aggregates as per IS: 2386 (Part III) 1963. APPARATUS i) Wire basket - perforated, electroplated or plastic coated with wire hangers for suspending it from the balance ii) Water-tight container for suspending the basket iii)Dry soft absorbent cloth - 75cm x 45cm (2 nos.) iv) Shallow tray of minimum 650 sq.cm area v) Air-tight container of a capacity similar to the basket vi) Oven SAMPLE A sample not less than 2000g should be used.

PROCEDURE i) The sample should be thoroughly washed to remove finer particles and dust, drained and then placed in the wire basket and immersed in distilled water at a temperature between 22 and 32oC. ii) After immersion, the entrapped air should be removed by lifting the basket and allowing it to drop 25 times in 25 seconds. The basket and sample should remain immersed for a period of 24 + 12 hrs. afterwards.

26

iii) The basket and aggregates should then be removed from the water, allowed to drain for a few minutes, after which the aggregates should be gently emptied from the basket on to one of the dry clothes and gently surface-dried with the cloth, transferring it to a second dry cloth when the first would remove no further moisture. The aggregates should be spread on the second cloth and exposed to the atmosphere away from direct sunlight till it appears to be completely surface-dry. The aggregates should be weighed (Weight 'A'). iv) The aggregates should then be placed in an oven at a temperature of 100 to 110oC for 24hrs. It should then be removed from the oven, cooled and weighed (Weight 'B'). REPORTING OF RESULTS Water absorption = [(A-B)/B] x 100%

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 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 one-fourth of the height of the mould.

27

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.

REPORTING OF RESULTS 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.

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

28

PREPARATION OF SAMPLE A representative portion of air-dried 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 air-dried 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 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.

29

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 air-dried 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 being given 55 blows of the 4.9kg rammer. The rest of the procedure is same as above. REPORTING OF RESULTS 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 optimum 30

moisture 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. WATER CONTENT OVEN DRYING METHOD AIM To determine the water content in soil by oven drying method as per IS: 2720 (Part II) - 1973. PRINCIPLE The water content (w) of a soil sample is equal to the mass of water divided by the mass of solids. APPARATUS i) Thermostatically controlled oven maintained at a temperature of 110 5oC ii) Weighing balance, with an accuracy of 0.04% of the weight of the soil taken iii) Air-tight container made of non-corrodible material with lid iv) Tongs SAMPLE The soil specimen should be representative of the soil mass. The quantity of the specimen taken would depend upon the gradation and the maximum size of particles as under: PROCEDURE i) Clean the container, dry it and weigh it with the lid (Weight 'W1'). ii) Take the required quantity of the wet soil specimen in the container and weigh it with the lid (Weight 'W2'). iii) Place the container, with its lid removed, in the oven till its weight becomes constant (Normally for 24hrs.). iv) When the soil has dried, remove the container from the oven, using tongs. v) Find the weight 'W3' of the container with the lid and the dry soil sample.

31

REPORTING OF RESULTS The water content w = [(W2 W3) 100%] /(W3 W1)

CALCIUM CARBIDE METHOD(RAPID MOISTURE METER TEST) AIM To determine the water content in soil by calcium carbide method as per IS: 2720 (Part II) - 1973. PRINCIPLE It is a method for rapid determination of water content from the gas pressure developed by the reaction of calcium carbide with the free water of the soil. From the calibrated scale of the pressure gauge the percentage of water on total mass of wet soil is obtained and the same is converted to water content on dry mass of soil. APPARATUS i) Metallic pressure vessel, with a clamp for sealing the cup, alongwith a gauge calibrated in percentage water content ii) Counterpoised balance, for weighing the sample iii) Scoop, for measuring the absorbent (Calcium Carbide) iv) Steel balls - 3 steel balls of about 12.5mm dia. and 1 steel ball of 25mm dia. v) One bottle of the absorbent (Calcium Carbide) PREPARATION OF SAMPLE Sand - No special preparation. Coarse powders may be ground and pulverized. Cohesive and plastic soil - Soil is tested with addition of steel ball in the pressure vessels. The test requires about 6g of sample. PROCEDURE i) Set up the balance, place the sample in the pan till the mark on the balance arm matches with the index mark. ii) Check that the cup and the body are clean. iii) Hold the body horizontally and gently deposit the levelled, scoop-full of the 32

absorbent (Calcium Carbide) inside the chamber. iv) Transfer the weighed soil from the pan to the cup. v) Hold cup and chamber horizontally, bringing them together without disturbing the sample and the absorbent. vi) Clamp the cup tightly into place. If the sample is bulky, reverse the above placement, that is, put the sample in the chamber and the absorbent in the cup. vii) In case of clayey soils, place all the 4 steel balls (3 smaller and 1 bigger) in the body alongwith the absorbent. viii) Shake the unit up and down vigorously in this position for about 15 seconds. ix) Hold the unit horizontally, rotating it for 10 seconds, so that the balls roll around the inner circumference of the body. x) Rest for 20 seconds. xi) Repeat the above cycle until the pressure gauge reading is constant and note the reading. Usually it takes 4 to 8 minutes to achieve constant reading. This is the water content (m) obtained on wet mass basis. xii) Finally, release the pressure slowly by opening the clamp screw and taking the cup out, empty the contents and clean the instrument with a brush. REPORTING OF RESULTS The water content on dry mass basis, W = (m/100 m)*100%

IN-SITU DRY DENSITY CORE CUTTER METHOD AIM To determine the in-situ dry density of soil by core cutter method as per IS: 2720 (Part XXIX) - 1975. APPARATUS i) Cylindrical core cutter ii) Steel dolley iii) Steel rammer 33

iv) Balance, with an accuracy of 1g v) Straightedge vi) Square metal tray - 300mm x 300mm x 40mm vii) Trowel PROCEDURE i) The internal volume (V) of the core cutter in cc should be calculated from its dimensions which should be measured to the nearest 0.25mm. ii) The core cutter should be weighed to the nearest gram (W1). iii) A small area, approximately 30cm square of the soil layer to be tested should be exposed and levelled. The steel dolly should be placed on top of the cutter and the latter should be rammed down vertically into the soil layer until only about 15mm of the dolly protrudes above the surface, care being taken not to rock the cutter. The cutter should then be dug out of the surrounding soil, care being taken to allow some soil to project from the lower end of the cutter. The ends of the soil core should then be trimmed flat in level with the ends of the cutter by means of the straightedge. iv) The cutter containing the soil core should be weighed to the nearest gram (W2). v) The soil core should be removed from the cutter and a representative sample should be placed in an air-tight container and its water content (w) determined as in Para 5.1. REPORTING OF RESULTS Bulk density of the soil = (W2 W1)/V g /cc Dry density of the soil d = [100/100+w] g cc MIX DESIGN Concrete is the basic engineering material used in most of the civil engineering structures. Its popularity as basic building material in construction is because of, its economy of use, good durability and ease with which it can be manufactured at site. The ability to mould it into any shape and size, because of its plasticity in green stage and its subsequent hardening to achieve strength, is particularly useful. Concrete like other engineering materials needs to be designed for properties like strength, durability, workability and cohesion. Concrete mix design is the science of deciding relative proportions of ingredients of concrete, to achieve the desired 34

properties in the most economical way. With advent of high-rise buildings and pre-stressed concrete, use of higher grades of concrete is becoming more common. Even the revised IS 456-2000 advocates use of higher grade of concrete for more severe conditions of exposure, for durability considerations. With advent of new generation admixtures, it is possible to achieve higher grades of concrete with high workability levels economically. Use of mineral admixtures like fly ash, slag, meta kaolin and silica fume have revolutionised the concrete technology by increasing strength and durability of concrete by many folds. Mix design of concrete is becoming more relevant in the above-mentioned scenario. However, it should be borne in mind that mix design when adopted at site should be implemented with proper understanding and with necessary precautions. Durocrete mix design manual is an attempt to increase the awareness among the users, about concrete mix design. It is made with intention of serving as ready reckoner for personnel, implementing mix design at site. Advantages of mix design Mix design aims to achieve good quality concrete at site economically. I. Quality concrete means Better strength Better imperviousness and durability Dense and homogeneous concrete II. Economy a) Economy in cement consumption It is possible to save up to 15% of cement for M20 grade of concrete with the help of concrete mix design. In fact higher the grade of concrete more are the savings. Lower cement content also results in lower heat of hydration and hence reduces shrinkage cracks. b) Best use of available materials: Site conditions often restrict the quality and quantity of ingredient materials. Concrete mix design offers a lot of flexibility on type of aggregates to be used in mix design. Mix design can give an economical solution based on the available materials if they meet the basic IS requirements. This can lead to saving in transportation costs from longer distances. c) Other properties: Mix design can help us to achieve form finishes, high early strengths for early deshuttering, concrete with better flexural strengths, concrete with pumpability and 35

concrete with lower densities. What is mix design? Concrete is an extremely versatile building material because, it can be designed for strength ranging from M10 (10Mpa) to M100 (100 Mpa) and workability ranging from 0 mm slump to 150 mm slump. In all these cases the basic ingredients of concrete are the same, but it is their relative proportioning that makes the difference. Basic Ingredients of Concrete: 1. Cement It is the basic binding material in concrete. 2. Water It hydrates cement and also makes concrete workable. 3. Coarse Aggregate It is the in the coarse aggregates. 5. Admixtures They enhance certain properties of concrete e.g. gain of strength, workability, setting properties, imperviousness etc Concrete needs to be designed for certain properties in the plastic stage as well as in the hardened stage. Properties desired from concrete in plastic stage: Workability Cohesiveness Initial set retardation Properties desired from concrete in hardened stage: Strength Imperviousness Durability Concrete mix design is the method of correct proportioning of ingredients of concrete, in order to optimise the above properties of concrete as per site requirements. In other words, we determine the relative proportions of ingredients of concrete to achieve desired strength & workability in a most economical way. Information required for concrete mix design The site engineer should give following information while giving material for mix 36 basic building component of concrete. 4. Fine Aggregate Along with cement paste it forms mortar grout and fills the voids

design to the mix design laboratory: Grade of concrete (the characteristic strength) Workability requirement in terms of slump Other properties (if required): i. Retardation of initial set (to avoid cold joints in case of longer leads or for ready mix concrete) ii. Slump retention (in case of ready mix concrete) iii. Pumpability (In case of ready mix concrete) iv.Acceleration of strength (for precast members or where early deshuttering is desired) v. Flexural strength (normally required for concrete pavements) Ascertain whether condition of exposure to concrete is mild, moderate severe or very severe. Proper investigation of soil should be done to ascertain presence of sulphates & chlorides, in case of doubt. Following factors indicate degree of control at site: Batching weigh batching / volume batching. Type of aggregates whether mixed graded aggregate will be used or 20mm, 10mm aggregates will be used separately. Testing of concrete whether casting & testing of concrete cubes will be done regularly at site. Source of aggregate whether sources of sand and aggregate will be standardised or likely to change frequently. Supervision whether qualified staff will be present to supervise concreting work and make necessary corrections e.g. correction for moisture in sand and changes in material properties. Site laboratory whether the site will have necessary laboratory equipment like sieves, weighing balance etc. to check material properties. Material properties and how they affect mix design Cement a) Strength/grade of cement: Grade of cement e.g. 43 grade or 53 grade can influence the mix design. Grade of cement indicates minimum strength of cement in N/mm2 tested as per standard conditions laid down by IS codes (OPC 43 grade IS 8112-1989, OPC 53 grade IS 12269 1987 e.g. a 43 grade cement should give minimum strength of 43 N/mm2 at 28 days). Higher the strength of cement, higher is 37

the strength of concrete for the same water/cement ratio. In other words a higher strength of cement permits use of higher water/cement ratio to achieve the same strength of concrete. The IS 10262 - 1982 for mix design gives the different curves of cement based on the actual strength of cement on 28th day. These cement curves give water/cement ratio required to achieve a given target strength. Information on grade of cement may not be as useful as the actual 28days strength of cement. This is because some of the 43 grade cements practically give strengths more than 53 N/mm2. When a 53-grade cement is stored for a long time, its strength may deteriorate and become equivalent to 33 grade or 43 grade cement. Thus 28 days strength of cement is required to select the cement curve before starting the mix design. Finding the 28 days strengths of cement consumes time. It is not practical in many cases to wait for 28 days strength of cement to start the mix design. In such cases 28 days strength reports of the manufacturers may be used and can be supplemented by accelerated strength of cement found by reference mix method given in IS 10262 Apart from strength of cement, the type of cement e.g. Ordinary Portland Cement, pozzolona cement (blended cement) etc, is also important factor affecting the gain of strength. Blended cements achieve strengths later than Ordinary Portland Cements and require extended curing period. However, use of these cements result in more durable concrete by offering greater resistance to sulphate and chloride attacks. b) Initial & Final setting time of cement: The initial setting time of cement indicates the time after which the cement paste looses its plasticity. Operations like mixing, placing and compaction should be completed well before the initial setting time of cement .The minimum initial setting time specified by IS 456 2000 (Clause 5.4.1.3 page no 14 and IS 8112-1989 page 2) is 30 minute. Most of the cements produced today give an initial set of more than 60 minutes. Beginning of hardening of cement paste indicates the final setting of cement. The maximum limit for final setting permitted by IS 8112: 1989 (Clause 6.3. page 2) is 600 minute. Most of the cements produced today give a final setting of between 3 to 5 hours. Curing can be started after final setting of cement. The initial setting and the final setting can be extended by use of retarders in order to avoid cold joints when lead-time for placing concrete is longer. Fine Aggregates a) Gradation of fine aggregates: The gradation of sand is given by sieve analysis. 38

The sieve analysis is done by passing sand through a set of standard sieves and finding out cumulative passing percentage through each sieve. The IS 383 1970 classifies fine aggregates in 4 zones starting from zone I representing coarse sand, to zone IV representing the finest sand. The limits of cumulative percentage passing for each sieve for above zones are given in table 4 of IS 383 The fineness of sand found by sieve analysis governs the proportion of sand in concrete .The overall fineness of sand is given by factor called fineness modulus. Fineness Modulus is given by division of the summation of cumulative retained fractions for standard sieves up to 150-micron sieve size by 100. c) Silt Content by weight: This is found by wet-sieving of sand and material passing 75 micron sieve is classified as silt. This silt affects the workability of concrete, results in higher water/cement ratio and lower strength. The upper limit for 75-micron sieve in case of sand is 3% by weight. This limit has however been extended to 15% in case of crushed sand in IS 383 1970 Table 1 Coarse Aggregate a) Maximum size of coarse aggregate: Maximum size of aggregate is the standard sieve size (40mm, 25mm, 20mm, 12.5mm, 10mm) through which at least 90% of coarse aggregate will pass. Maximum size of aggregate affects the workability and strength of concrete. It also influences the water demand for getting a certain workability and fine aggregate content required for achieving a cohesive mix. For a given weight, higher the maximum size of aggregate, lower is the surface area of coarse aggregates and vice versa. As maximum size of coarse aggregate reduces, surface area of coarse aggregate increases. Higher the surface area, greater is the water demand to coat the particles and generate workability. Smaller maximum size of coarse aggregate will require greater fine aggregate content to coat particles and maintain cohesiveness of concrete mix. Hence 40 mm down coarse aggregate will require much less water than 20 mm down aggregate. In other words for the same workability, 40mm down aggregate will have lower water/cement ratio, thus higher strength when compared to 20mm down aggregate. Because of its lower water demand, advantage of higher maximum size of coarse aggregate can be taken to lower the cement consumption. Maximum size of aggregate is often restricted by clear cover and minimum distance between the 39

reinforcement bars. Maximum size of coarse aggregate should be 5 mm less than clear cover or minimum distance between the reinforcement bars, so that the aggregates can pass through the reinforcement in congested areas, to produce dense and homogenous concrete. It is advantageous to use greater maximum size of coarse aggregate for concrete grades up to M 35 where mortar failure is predominant. Lower water/cement ratio will mean higher strength of mortar (which is the weakest link) and will result in higher strength of concrete. However, for concrete grades above M40, bond failure becomes predominant. Higher maximum size of aggregate, which will have lower area of contact with cement mortar paste, will fail earlier because of bond failure. Hence for higher grades of concrete (M40 and higher) it is advantageous to use lower maximum size of aggregate to prevent bond failure. The fineness modulus of sand varies from 2.0 to 4.0; higher the FM coarser is the sand. Type of Sand Fine Medium Coarse FM 2.0 to 2.8 - 2.8 to 3.2 - 3.2 and above

b) Specific gravity of fine aggregates: This is the ratio of solid density particles to the density of water. Higher the specific gravity, heavier is the sand particles and higher is the density of concrete. Conversely a lower specific gravity of sand will result in lower density of concrete. Specific gravity of sand is found with help of pycnometer bottles. The specific gravity of fine aggregates found in Pune region varies from 2.6 to 2.8. b) Grading of coarse aggregate: The coarse aggregate grading limits are given in IS 383 1970 - table 2, Clause 4.1 and 4.2 for single size aggregate as well as graded aggregate. The grading of coarse aggregate is important to get cohesive & dense concrete. The voids left by larger coarse aggregate particles are filled by smaller coarse aggregate particles and so on. This way, the volume of mortar (cement-sandwater paste) required to fill the final voids is minimum. However, in some cases gap graded aggregate can be used where some intermediate size is not used. Use of gapgraded aggregate may not have adverse effect on strength. By proper grading of coarse aggregate, the possibility of segregation is minimised, especially for higher workability. Proper grading of coarse aggregates also improves 40

the compactability of concrete. c) Shape of coarse aggregate: Coarse aggregates can have round, angular, or irregular shape. Rounded aggregates because of lower surface area will have lowest water demand and also have lowest mortar paste requirement. Hence they will result in most economical mixes for concrete grades up to M35. However, for concrete grades of M40 and above (as in case of max size of aggregate) the possibility of bond failure will tilt the balance in favour of angular aggregate with more surface area. Flaky and elongated coarse aggregate particles not only increase the water demand but also increase the tendency of segregation. Flakiness and elongation also reduce the flexural strength of concrete. Specifications by Ministry of Surface Transport restrict the combined flakiness and elongation to 30% by weight of coarse aggregates. d) Strength of coarse aggregate: Material strength of coarse aggregate is indicated by crushing strength of rock, aggregate crushing value, aggregate impact value, aggregate abrasion value. In Maharashtra the coarse aggregates are made of basalt rock, which has strengths in excess of 100 N/mm2. Hence aggregates rarely fail in strength. e) Aggregate Absorption: Aggregate can absorb water up to 2 % by weight when in bone dry state, however, in some cases the aggregate absorption can be as high as 5%. Aggregate absorption is used for applying a correction factor for aggregates in dry condition and determining water demand of concrete in saturated surface dry condition. Decision Variables in Mix Design A. Water/cement ratio B. Cement content C. Relative proportion of fine & coarse aggregates D. Use of admixtures A. Water/cement ratio Water to cement ratio (W/C ratio) is the single most important factor governing the strength and durability of concrete. Strength of concrete depends upon W/C ratio rather than the cement content. Abrams law states that higher the water/cement ratio, lower is the strength of concrete. As a thumb rule every 1% increase in quantity of water added, reduces the strength of concrete by 5%. A water/cement ratio of only 0.38 is required for complete hydration of cement. (Although this is the theoretical limit, water cement ratio lower than 0.38 will also increase the strength, since all the cement that is added, does not hydrate) Water added for workability over and above 41

this water/cement ratio of 0.38, evaporates leaving cavities in the concrete. These cavities are in the form of thin capillaries. They reduce the strength and durability of concrete. Hence, it is very important to control the water/cement ratio on site. Every extra lit of water will approx. reduce the strength of concrete by 2 to 3 N/mm2 and increase the workability by 25 mm. As stated earlier, the water/cement ratio strongly influences the permeability of concrete and durability of concrete. B. Cement content Cement is the core material in concrete, which acts as a binding agent and imparts strength to the concrete. From durability considerations cement content should not be reduced below 300Kg/m3 for RCC. IS 456 2000 recommends higher cement contents for more severe conditions of exposure of weathering agents to the concrete. It is not necessary that higher cement content would result in higher strength. In fact latest findings show that for the same water/cement ratio, a leaner mix will give better strength. However, this does not mean that we can achieve higher grades of concrete by just lowering the water/cement ratio. This is because lower water/cement ratios will mean lower water contents and result in lower workability. In fact for achieving a given workability, a certain quantity of water will be required. If lower water/cement ratio is to be achieved without disturbing the workability, cement content will have to be increased. Higher cement content helps us in getting the desired workability at a lower water/cement ratio. In most of the mix design methods, the water contents to achieve different workability levels are given in form of empirical relations. Water/cement ratios required to achieve target mean strengths are interpolated from graphs given in IS 10262 Clause 3.1 and 3.2 . The cement content is found as follows: Cement content (Kg/m3) = Water required achieving required workability (Lit/m3) Water/cement ratio Thus, we see that higher the workability of concrete, greater is cement content required and vice versa. Also, greater the water/cement ratio, lower is the cement content required and vice versa. C. Relative proportion of fine, coarse aggregates gradation of aggregates Aggregates are of two types as below: a. Coarseaggregate(Metal): Theseareparticlesretainedonstandard IS 4.75mm sieve. b. Fine aggregate(Sand): These are particles passing standard IS 4.75mm sieve. 42

Proportion of fine aggregates to coarse aggregate depends on following: i. Fineness of sand: Generally, when the sand is fine, smaller proportion of it is enough to get a cohesive mix; while coarser the sand, greater has to be its proportion with respect to coarse aggregate. ii. Size & shape of coarse aggregates: Greater the size of coarse aggregate lesser is the surface area and lesser is the proportion of fine aggregate required and vice versa. Flaky aggregates have more surface area and require greater proportion of fine aggregates to get cohesive mix. Similarly, rounded aggregate have lesser surface area and require lesser proportion of fine aggregate to get a cohesive mix. iii. Cement content: Leaner mixes require more proportion of fine aggregates than richer mixes. This is because cement particles also contribute to the fines in concrete. D. Use of admixtures Now days, admixtures are rightly considered as the fifth ingredient of concrete. The admixtures can change the properties of concrete. Commonly used admixtures are as follows: i. ii. iii. iv. v. vi. i. Plasticisers & superplasticisers Retarders Accelerators Air entraining agents Shrinkage compensating admixtures Water proofing admixtures Plasticisers & super plasticisers

Plasticisers help us in increasing the workability of concrete without addition of water. It means that we can achieve lower water/cement ratio without reducing the workability at the same cement content. Cement particles tend to form flocs trapping a part of mixing water in them. Hence not all the water added is useful for generating workability. Plasticisers work as dispersion agents (de flocculent) releasing the water trapped in the flocs resulting in workability. Use of plasticisers is economical as the cost incurred on them is less than the cost of cement saved; this is more so in concrete designed for higher workability. Compatibility of plasticisers with the cement brand should be checked before use. Also plasticiser should not be added in dry concrete mix. 43

Plasticizers are used for moderate increase of workability whereas super plasticizers are used where very large increase in workability is required. Plasticizers are normally lignosulphonated formaldehydes and are normally added in small dosages. This is because large dosage can cause permanent retardation in concrete and adversely affect its strength. Super plasticizers are naphthalene or melamine based formaldehyde. They can be used in large dosages without any adverse effect on concrete. This is contrary to popular perception that term super plasticizers means more potent, hence lower dosage is required when compared to normal plasticizers. In practice super plasticizers are used in large dosages for generating higher workability and better slump retention. Compatibility of plasticizers with cement should be ascertained before use in concrete. Since action of plasticizers is based on ionic dispersion certain plasticizers are more effective with certain cements, thus requiring lower dosages. Non-compatible plasticizers if used, will not adversely affect the concrete, but its high dosage will make it uneconomical for use. ii. Retarders: They are used for retarding (delaying) the initial setting time of concrete. This is particularly required when longer placing times are desired as in case of ready mixed concrete. Retarders are commonly used to prevent formation of cold joints when casting large concrete. Retarders are normally added in lower dosages as large dosages can cause permanent retardation in concrete. Retarders are recommended in case of hot weather concreting to prevent early loss of slump. It is important to note that retarders reduce early strength of concrete e.g. 1-day and 3-day strength. However, 28 days strength is not affected. iii. Accelerators They are used for accelerating the initial strength of concrete. Typical accelerators increase the 1-day (up to 50 %) and 3-days (up to 30 %) strength of concrete. Most of the accelerators show little increase for 7 days strength. For this reason, accelerators are commonly used in precast concrete elements for early removal of moulds. Accelerators may not be much useful for early deshuttering where early strengths are required in range of 5 to 7 days. This is because accelerators are expensive and their ability to increase strengths decreases after 3-5 days. A better option for early deshuttering would be the use of plasticizers, reducing the water/cement ratio and achieving a higher grade of concrete. It is believed that accelerators may cause retrogression of strength after 28 days when compared with normal concrete. 44

Concrete Mix Design Methods The basic objective of concrete mix design is to find the most economical proportions (Optimisation) to achieve the desired end results (strength, cohesion, workability, durability, As mentioned earlier the proportioning of concrete is based on certain material properties of cement, sand and aggregates. Concrete mix design is basically a process of taking trials with certain proportions. Methods have been developed to arrive at these proportions in a scientific manner. No mix design method directly gives the exact proportions that will most economically achieve end results. These methods only serve as a base to start and achieve the end results in the fewest possible trials. The code of practice for mix design-IS 10262 clearly states following: - The basic assumption made in mix design is that the compressive strength of workable concretes, by and large, governed by the water/cement ratio. Another most convenient relationship applicable to normal concrete is that for a given type, shape, size and grading of aggregates, the amount of water determines its workability. However, there are various other factors which affect the properties of concrete, for example the quality & quantity of cement, water and aggregates; batching; transportation; placing; compaction; curing; etc. Therefore, the specific relationships that are used in proportioning concrete mixes should be considered only as the basis for trial, subject to modifications in the light of experience as well as for the particular materials used at the site in each case. Different mix design methods help us to arrive at the trial mix that will give us required strength, workability, cohesion etc. These mix design methods have same common threads in arriving at proportions but their method of calculation is different. Basic steps in mix design are as follows: Find the target mean strength. Determine the curve of cement based on its strength. Determine water/cement ratio. Determine cement content. Determine fine and coarse aggregate proportions

45

BATCHING PLANT

46

PROJECT EXECUTION
METHOD STATEMENT FOR CIVIL AND MECHANICAL 1. METHOD STATEMENT FOR CIVIL METHOD STATEMENT FOR SURVEY WORKS OBJECTIVE: To formulate guidelines for Setting out and routine survey works REFERENCE: 1. Drawing 2. Technical Specifications for Civil works 3. Inspection and test plan 4. Survey Layout showing control stations MAJOR EQUIPMENTS: Calibrated Auto - level, Theodolite (LC-1"), Total Station and necessary measuring tools METHOD STATEMENT FOR BUILDING UP OF PILES UPTO CUTOFF LEVEL OBJECTIVE: Building up of Plies up-to cut-off levels REFERENCE: 1. Drawing 2. Technical Specifications for Civil works 3. Technical Data sheet of Nitobond EP METHOD STATEMENT FOR REINFORCEMENT WORK 1. OBJECTIVE: This procedure covers method for cutting, bending and tying of reinforcement and inspection of works. 2. REFERENCE: Reinforcement placing and handling shall be as per IS-456 MAJOR EQUIPMENTS: Bar cutting & bending machines, rebar tying tool. METHOD STATEMENT FOR FORMWORK 1. OBJECTIVE: This Procedure covers fixing and removal of formwork and checking of formwork. 2. REFERENCE: 1. Approved Drawings

47

2. IS 456 & IS 6461(Part 5) 3. Tender Document METHOD STATEMENT FOR BOLTS PROCUREMENT & FIXATION 1. OBJECTIVE: This Procedure covers procuring and fixing of bolts. 2. REFERENCE: 1. Tender Specification 2. Approved Drawings METHOD STATEMENT FOR CONCRETING WORKS 1. OBJECTIVE: This Procedure covers fixing and removal of formwork and checking of formwork. 2. REFERENCE: 1. Tender Specification 2. Approved Drawings 3. IS 10262, IS 3370 & IS 456 4. IS 383 METHOD STATEMENT FOR BACKFILLING 1.OBJECTIVE: The scope of back-filling covers the filling in plinths, pits, trends, depressions in layers 200mm thick including watering and compaction by Roller / plate compactor. 2. REFERENCE: 1. Drawing 2. Bill of Quantities

METHOD FOR REINFORCEMENT WORK 1.All reinforcement shall be placed above the ground by using wooden sleepers or concrete blocks. 2.For reinforcement, care shall be taken to protect the reinforcement from exposure to saline atmosphere during storage, fabrication and use. 3.Against requirement from site, bars shall be cut and bent to shape and dimension as shown in bar bending schedule based on Good For Construction (GFC) drawings.

48

4.Reinforcement shall be tied as per the latest GFC drawing and any extra bars provided at site shall be recorded in the pour card/ lap register. 5.Unusable cut rods and scrap reinforcement shall be properly placed at yard. Bar Bending Schedule: 1.Prepare bar bending schedule based on the latest GFC drawings and to be submitted to Engineer for review 2.Bar bending schedule shall clearly specify the following: a) Bar dia. b) Numbers. c) Cut-lengths. d) Shapes. 3.Bar bending schedule shall take into account the following field/ design requirement. a) Desirable lap locations and staggering of laps. b) Lap lengths. c) Development length/ Anchorage length. Cutting, Bending and Placing: 1.All reinforcement shall be free from loose mill scales, loose rust and coats of paints, oil, mud or any other substances which may destroy or reduce bond. Use wire brush to clean the reinforcement. 2.Cutting and bending shall conform to the details given in the approved bar bending schedule. a) Cutting of Rebar by heat is not permitted, only cutting by grinding or shearing is permitted. b) No heating is allowed to facilitate bending of Rebar. 3.Place the reinforcement as per GFC drawings ensuring the following aspects properly. a) Type & size of bar. b) Number of bars. c) Location and lengths of laps, splices. d) Curtailment of bars. e) In two way reinforcement, check the direction of reinforcement in various layers. f) Adequate number of chairs, spacer bars and cover blocks.

49

g) Size of cover blocks. h) All the bars shall be tied with double fold 18g soft GI annealed binding wire. 4.Reinforcement may be placed with in the following tolerance whenever required: a) for effective depth 200mm or less 10mm. b) for effective depth more than 200mm 15mm. c) The cover shall in no case be reduced by more than one third of the specified cover or 0 /+ 10mm. d) The cover should suit various cover requirement as per Drawing Notes. 5.The sequence of reinforcement shall be correlated with fixing of inserts, sleeves, conduits, anchors and formworks. 6.In walls, place accurately bent spacer bars wired to vertical or horizontal bars between successive rows. 7.No steel parts of spacers sure allowed inside the concrete cover. Spacer blocks made from cement, sand and small aggregate shall match the mix proportion of the surrounding concrete. Alternatively PVC cover blocks of approved make can be used. 8.Spacers, cover blocks should be of concrete of same strength or PVC 9.Spacers, chairs and other supports detailed on drawings, together with such other supports as may be necessaray, should be used to maintain the specified nominal cover to the steel reinforcement. 10.Spacers or chairs should be placed at a maximum spacing of 1.0 mtr and closer spacing may sometimes be necessary. 11.All reinforcement shall be placed and maintained in the positions shown in the drawing by providing proper cover blocks, spacers, Supporting bars. 12.Rough handling, shock loading (Prior to embedment) and the dropping of reinforcement from a height should be avoided. Reinforcement should be secured against displacement.

METHOD FOR FORMWORK

Pre Check 1.Check if the shutters are properly cleaned by removing the concrete/ mortar and protruding nails. 50

2.Formwork shall be made to the exact dimensions within the permissible tolerances as mentioned below. 3.Required thickness and quality of plywood conforming to IS 6461 shall be used to meet the requirements of design and surface finish. 4.For beam bottom & sides, proper size of timber at required spacing shall be provided to take the design loads/ pressure considering sleeves, conduit anchors & inserts. Erection of formwork 5.Sufficiently rigid and tight to prevent the loss of grout or mortar from the concrete. 6.Capable of providing concrete of the correct shape and surface finish within the specified tolerance limits. 7.Soffits forms capable of imparting a camber if required. 8.The formwork may be of timber, plywood,steel,plastic or concrete depending upon the type of finish specified. 9.Erect staging/shuttering as per drawing/sketches in such a way that deshuttering can be done easily including provision for repropping, if planned. 10.Check the location, line,level,plumb and dimensions of the formwork to ensure that the deviations are within the permissible limits. 11.Provide bracing at proper places & intervals as specified by the manufacturer or as per formwork scheme to take care of lateral loads. 12.Apply mould oil/other coatings as release agents before reinforcement steel is placed. 13.Wire ties passing through beams,columns and walls shall not be allowed .In their place bolts passing through sleeves shall be used.For liquid retaining structures ,sleeves shall not be provided for through bolts. 14.Check all the shutters are properly aligned and fixed firmly with required lateral supports and ties. 15.Check all the spanning members have proper bearing at the supports. 16.Wedges or jacks shall be secured in position after the final check of alignment. 17.Forms shall be thoroughly cleaned of all dirt, mortar and other matters such as metals, blocks, saw dust and foreign materials before concreting if required through clean-out openings. 18.Check all the gaps/openings are properly closed to avoid leakages.

51

19.Check all the inserts/embedments and openings are exactly placed as per the drawings. 20.In case of leakages, bulging and sagging immediate actions shall be taken by tightening wedges or adjusting by jacks which must be done before the concrete takes its initial set. Removal of Forms 21.Formwork components shall not be dropped but shall be lowered without damage to the components and structures. All the removed formwork materials shall be thoroughly scarped, cleaned immediately and stacked properly for reuse. 22.'All forms shall be removed after the minimum period stipulated mentioned below without damage to the concrete including removal without shock as per IS 456

METHOD FOR BACKFILLING

1. Backfilling area shall be free from foreign matters (ie. wooden scraps , plywood pieces rebar bits etc) and tie rods recesses shall be rendered with polymer based non shrink compound with a subsequent application of curing compound on them. 2.Filling around foundation or other places indicated shall be done with approved material obtained from excavation or approved materials brought from out side. 3.The material shall be good quality soft or hard murrum or Panna sand or other approved back filling material.Back filling soil shall be free from black cotton soil. 4.Filling shall be done in layers not exceeding 20 cms thick and each layer shall be watered adequately and consolidated properly by rollers or pneumatic rammers 8 to 10 tonnes wherever conditions permit. If it is not possible, the consolidation shall be done by hand rollers/ heavy pneumatic/ hand rammers/ plate compactor. 5.The surface of the filling shall be finished to lines and levels as required. 6.The approved materials shall be plced in layers, not exceeding 200mm in depth before compaction and shall be compacted to minimum 95% dry density. Layers placed in the top 300mm of the fill shall be compacted to 98% of maximum dry density. No of Samples: (i)For foundation filling - one for every 10 foundation for each compacted layer. (ii)For area filling one for every 1000 sqm area for each compacted layer.

52

METHOD FOR PILING

1.Excavate till the COL of pile 2.Predict the level of concrete in side the pile by driving rebar to touch the hard strata of concrete. 3.Excavate till the predicted level of pile till visibility of concrete 4.Chip off loose concrete/ laitance from the top level of exposed concrete and ensure the quality of concrete after chipping. 5.Straighten the distorted vertical bars & tie the lateral ties/ helical to COL 6.Fix the formwork of the required size up to the pile COL. 7.Apply the bonding agent(Nitobond EP) before pouring the concrete with the help of an extended brush. 8.Pour concrete of the same grade(M30) 9.Strip the form work after 24 hrs 10.Back fill around the piles in layers not exceeding 200mm up to COL and allow for PCC 11.FDT to be carried out as per relevent IS Code and Technical specification. 12.Curing of concrete with approved water shall start after completion of Initial setting time of concrete and in hot weather after 4 hours. Concrete will be cured for a minimum period of seven days when OPC with high water cement ratio is used, curing for minimum 10 days in hot weather or low water cement ratio is used. Curing shall be done by continous sprays or ponded water or continously saturated coverings of sacking canvas,hessain or other absorbent material for the period of complete hydration with a minimum of 7 days.Curing shall also be done by covering the surface with an impermeable material such as Polyethlene ,which shall be well sealed and fastened.

METHOD FOR CONCRETING

53

1.Concrete mix design for Different Structure should be as per Notes in the specific approved drawing 2.For Design Mix Concrete,the mix shall be designed to provide the grade of concrete having the required strength, workability & durability requirements given in IS: 456 for each grade of concrete taking into account the type of cement, minimum cement content and maximum W/C ratio conforming to exposure conditions as per tender specifications. 3.Mix design and preliminary tests are not necessary for Nominal Mixconcrete (M5, M7.5, M10, M15, M20 as Specified in IS 456 - Table 9) .However works tests shall be carried out as per IS:456 4.No concreting shall be done without the approval of engineer. Prior notice shall be given before start of concreting. 5. Cement shall be measured by weight in weigh batching machines of an approved type, aggregate shall be measured by volume / weight. The machines shall be kept clean and in good condition and shall be checked adjusted for accuracy at regular intervals when required by the engineer. Material shall be weighed within 2.5% tolerances, inclusive of scale and operating errors. The weigh batching machines / Measuring Boes shall discharge efficiently so that no materials are retained. 6.Concrete shall be mixed in mechanical mixers of an approved type. In no case shall the mixing of each batch of concrete continue for less than 2 minutes.The water to be added in concrete 3.6 shall be adjusted based on moisture contents in fine and coarse aggregates. During hot and cold weather, suitable methods to reduce the loss of water by evaporation in hot weather and heat loss in cold weather will be adopted as per procedure set out in IS: 7861. 7.The compaction of concrete will be done by immersion type needle vibrator which shall be inserted into concrete in vertical position not more than 450 mm apart. Vibration will be 3.7 applied systematically to cover all areas immediately after placing concrete and will be stopped when the concrete flattens and takes up a glistening appearance or rise of entrapped air ceases or coarse agregate blends into the surface but does not completely disappear. The vibrator shall be slowly withdrawn to ensure closing of the hole resulting from insertion. 8.Unless otherwise approved, continuous concreting shall be done to the full thickness of 3.8 foundation rafts, slabs, beams & similar members. For placing on slope, 54

concreting will be started at the bottom and moved upwards. Concrete shall not fall from a height of more than 1m to avoid segregation. 9.Special care shall be taken to guarantee the finish and Water-Tightness of concrete for liquid retaining structures,underghround structures and those if specifically mentioned.The minimum 3.9level of surface finish for liquid retaining structures shall be Type F-2 and it shall be Hydrotested to approved procedure.Any leakage during hydrotest or subsequently during difect liability period, if occurred shall be effectively stopped either by cement /epoxy presure grouting or any other approved method. 10.Curing of concrete with approved water shall start after completion of Initial setting time of concrete and in hot weather after 3 hours. Concrete will be cured for a minimum period of seven days when OPC with high water cement ratio is used, curing for minimum 10 days in hot weather or low water cement ratio is used and where mineral admixture used minimum curing period is 14 days. Freshly laid concrete shall be protected from rain by suitable covering. Curing shall be done by continous sprays or ponded water or continously saturated coverings of sacking canvas,hessain or other absorbent material for the period of complete hydration with a minimum of 7 days.Curing shall also be done by covering the surface with an impermeable material such as Polyethlene ,which shall be well sealed and fastened. Alternatively Curing compound of approved make can be applied immediately after stripping of formwork. 11.The workability of concrete shall be checked by the site engineer. 3.12 The prepared surface shall be inspected and certified in pour card. 12.Staining or discoloration shall be washed out. If surface is not upto the acceptable standard, as 3.13 per IS 456, cement wash is to be provided on exposed concrete surface of foundation, beam, column,wall etc. 13.All blemishes and defect if any, shall be rectified immediately after the removal of formwork. 14.For each sample of concrete pour 150mm cubes shall be prepared and cured.3 nos shall be crushed at 7days and other 3 nos at 28 days. Record shall be made for each test in enclosedormats as per ITP. 15.PVC water stoppers shall be provided in construction joints as per AFC drawing confirming to IS-12200. Prior approval shall be taken for location & material.

55

Alternatively G.I.sheet of 200mm wide and 18 guage thk shall also be used for the same with the approval of Engineer

56

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 job shop 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.

57

A parallel step in the planning process is to define the various work tasks that must be accomplished. These work tasks represent the necessary framework 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 L&T uses Microsoft Project as a powering tool for reducing risk. Microsoft Project 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. Microsoft Project 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, Microsoft project 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 Microsoft Project. 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.

58

CONCLUSION
It was a wonderful learning experience at L&T Construction B&F ICs site of L&T project for two months in Sanand. 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 L&T. I hope this experience will surely help me in my future and also in shaping my career.

59