Submitted by Guided by

Surbhi Sarawagi Mr. Hasibur Rahman

s
 Certificate from the Company

This is to certify that Surbhi Sarawagi, daughter of Mr. Suman Kumar Sarawagi
pursuing BE (civil engineering) from BIT Mesra, Ranchi has successfully
completed the Project Report in our organization on the topic titled “Planning
& execution of Nail Mill manufacturing unit at ISWP” from 14th of May to 8th
June 2018. During her project tenure in the company, we found her
hardworking, sincere and diligent person and her behaviour and conduct was
good. We wish her all the best for her future endeavours.

Mr. Neeraj Kant

(Managing Director)

1
 Certificate of Originality

This is to certify that the project report entitled “Planning & execution of Nail
Mill manufacturing unit at ISWP” submitted to BIT Mesra, Ranchi partial
fulfilment of the requirement for the award of the degree of BE (civil
engineering) is an original work carried out by Ms. Surbhi Sarawagi, under the
guidance of Mr. Hasibur Rahman (project guide) and Mr. Vijayant Kumar (Head
of Dept.). The matter embodied in this project is a genuine work done by Ms.
Surbhi Sarawagi to the best of my knowledge and belief and has not been
submitted before, neither to this university nor to any other university for the
fulfilment of the requirement of any course of study.

Surbhi Sarawagi
(Intern)

Mr. Hasibur Rahman Mr. Vijayant Kumar

(Project Guide) (Head of Dept.)

2
 Certificate

This is to certify that the project titled “Planning & execution of nail mill
manufacturing unit at ISWP” is an academic work done by “Surbhi Sarawagi”
submitted in the partial fulfilment of the requirement for the award of the
Degree of BE (Civil Engineering) from BIT Mesra, Ranchi. It has been completed
under the guidance of Mr. Hasibur Rahman (Faculty Guide) and Mr. Vijayant
Kumar (Head of Dept.). We are thankful to ISWP Ltd. for having allowed our
student to undergo project work training. The authenticity of the project work
will be examined by the viva examiner which include data verification, checking
duplicity of information etc. and it may be rejected due to non-fulfilment of
quality standards set by the Institute.

3
 ACKNOWLEDGMENT

The satisfaction and euphoria that accompany the successful completion of the
project would be incomplete without the mention of the people who made it
possible.

I would like to take the opportunity to thank and express my deep sense of
gratitude to Mr. Neeraj Kant (Managing Director) who provided me this
opportunity to work with ISWP and his valuable support and supervision have
certainly indispensable for my project work.

I would like to thank my corporate mentor Mr. Vijyant Kumar and Mr. Hasibur
Rahman my faculty guide. I am greatly indebted to both of them for providing
their valuable guidance at all stages of the study, their advice, constructive
suggestions, positive and supportive attitude and continuous encouragement.

I owe my wholehearted thanks and appreciation to the entire staff of the

company for their cooperation and assistance during course of my project.

I hope that I can build upon the experience and knowledge that I have gained and
make a valuable contribution towards this industry in coming future.

Surbhi Sarawagi,
BIT Mesra, Ranchi
Jharkhand th

4
 1.
aA

PREFACE

The objective of the project was “to understand the planning, designing, cost
estimation and execution of a civil work project based on machine foundation
of the nail mill at ISWP. This project consists of various details of the project like
drawing and design of foundation using AutoCAD, project costing, schedule
prepared using MS project, bar bending schedule for the requirements of
reinforcements, and cost estimation prepared in MS excel and description of the
processes carried for execution. Therefore, I got to learn about software like the
AutoCAD, draft sight, MS excel, MS project etc and understanding the structural
requirements for the foundation and its guidelines for construction from IS
codes. Then I learnt Mix Design and nominal mix for the required grade of
concrete. The objective of this study was to analyse the stages involved in
undertaking of a project in an industry.
I started with my project on 15th may after knowing all the relevant
information regarding the project, under the guidance of Mr. Hasibur Rahman
(project guide). I used Internet as a primary source of information for study, also
had an industrial tour at ISWP with Mr. Dutta who explained the manufacturing
process of rod mill and wire mill and then fasteners plant where the nail mill was
supposed to be setup, all the safety precaution and rules were explained on the
very first day and PPEs (personal protection equipment’s) were handed by safety
dept. Also, we had a tour to the already running nail plant at JEMCO. Hence, it
provided me a rough idea about the working process of the pant. The order for
construction was placed on 30th April and is scheduled to run by 14th June. Total
cost for civil work was approximately 3.7lakhs including flooring and
construction of an office made of aluminium partition walls. I got to witness each
and every step of construction and installation of ISWP nail plant and it has
greatly helped me gaining experience about the site work and its processes
involved in construction.

5
 Index

CHAPTER - 1: Company Profile

• About the company……………7-8
• Vision & mission…………………8
• Values…………………………………9
• Five major business
verticals……………………………..10
• Products……………………………..10-11
• Plant and project location…..11-12

CHAPTER – 2: Environment & safety

• Environmental
Considerations(aspects)…….12-13
• Waste management…………..13
• Safety measures………………...13
• Legal matrix………………………..14

CHAPTER – 3: Introduction to nail plant

• Wire nails…………………………….15
• Nail standards……………………..16
• Process description……………..17
• Forming……………………………….18
• Quality &future……………………19

CHAPTER – 4: Introduction to foundation

• Machine foundations………….20
• Drawing & designing…………..21-25
• Cost estimation…………………..26-27
• Planning……………………………….28
• Execution…………………………….29-44
• Conclusion & suggestion……..45
• Bibliography…………………………46

6
 Company Profile
About the Company

“The Tata philosophy of management has always been and is today more than ever, that
corporate enterprises must be managed not merely in the interests of their owners, but
equally in those of their employees, of the consumers of their products, of the local
community and finally of the country as a whole”.
J R D Tata.

The Indian Steel & Wire Products Ltd saw the light of the day in the year 1920.
In the year 1935 it was incorporated as a company under the Companies Act,
1913. A primary manufacturer of wire rods, TMT rebar’s, welding products,
fasteners, rolls and castings; ISWP strictly adheres to the highest standards of
quality and services.
There are many firsts with ISWPL! It established the first Wire Drawing Plant in
Asia & is a pioneer in the Rolls industry of India. Pre-independence it also
established the privately-owned fasteners plant and supported industrial
development. This is how ISWPL emerged as a major manufacturing centre
during the 20th Century thereby giving a boost to the nation building and
industrial growth.
With its wealth of experience and expertise in the welding consumable and
fastening industry, ISWP, markets its Welding and Fasteners products under the
brand name, “SPARK”. The Company has a state-of-the-art Welding Technology
Centre, efficient Fasteners manufacturing equipment imported from Germany
and an all-India distribution channel for all its facilities. Pioneer in the Rolls
industry, ISWPL’s Rolls and Casting products are sold under the brand “JEMCO”
across International market. JEMCO is manufacturer and supplier of cast Iron
and Cast Steel rolls and Engineering Castings. With continual improvement and
technological up-gradation, it has achieved the market leadership in domestic
market for Non-metallurgical (Hollow) Rolls in India. JEMCO also supplies rolls
for long and flat product segment of steel rolling and has also established itself
in the manufacturing and supply of engineering casting for Power sector and
Rolling Mills, binding wire and nail manufacturing sector.
ISWP continuously strives to attain leadership through business excellence,
while upholding the very values that form an integral part of it. The Company is
committed to providing a safe and healthy working environment through TPM
7
(Total Productive Maintenance), Safety Excellence journey & Climate Change
initiatives. In fact, the Indian Steel & Wire Product Ltd aspires to be a benchmark
in safety and health performance in its business sector. Having more than 800
employees on its roll, ISWPL has undertaken several improvement initiatives;
employee engagement programmes; TPM and L&D Safety Environment, as well
as employee diversity and inclusion. ISWPL has received the TPM Excellence
Award, TBEM Award, CII HR Excellence awards for its commitment to excellence
standards and focused improvements.
Spread over 300 acres, comprising the Plant and a township, ISWPL boasts of a
vast infrastructure with more than 800 houses, a school with approximately
2500 children, a 20-bed hospital, Sports Complex and Water Purification Plant.
Customer service forms an integral part of the ISWP culture. Having adopted the
3D concept of Develop, Deliver and Delight in line with the Tata group initiative,
the company leaves no stone unturned to understand the needs of the
customers, and deliver quality products and services. Towards this end,
customised product solution, like customized product development in the rolls
and welding industry has been introduced. ISWPL is accredited with ISO 9001,
ISO 14001 & OHSAS 18001.
For ISWP, it has been a long journey, strewn with impediments. But it has shown
fortitude and remained steadfast in its endeavour to improve the quality of life
of the communities it serves in. It strives to empower the underprivileged and
the AA community by educating and creating employment opportunities for
them under its Affirmative Action Programme.

Vision & Mission

VISION 2020
To emerge as a prominent and leading downstream steel long products
company through:
Products: Be the preferred supplier of innovative and high-quality rods, wires,
wire products and rolls & castings.
People: Become an employer of choice in the Tata Steel group.
Planet: Be a benchmark in safety, health & environmental stewardship within
the Tata Steel group.
Profit: Double the profits and revenue to achieve a minimum ROIC of 22% by
2020.

8
 ISWPL VALUES

Tata group companies

have always been
values-driven. In line
with the Group value,
ISWPL has also
adopted four core
values to direct the
growth and business
of the companies. The
four core ISWPL values
underpinning the way
we do business are:
Respect for Individual: We must be caring, show respect, compassion and
humanity for our colleagues and customers around the world, and always work
for the benefit of the communities we serve.
Integrity: We must conduct our business fairly, with honesty and transparency.
Everything we do must stand the test of public scrutiny.
Credibility: We must execute all operation and activities with competency and
thoroughness.
Excellence: We must constantly strive to achieve the highest possible standards
in our day-to-day work and in the quality of the goods and services we provide.

9
 The Five Major Business Verticals
Committed to quality products and high standards of functioning, ISWPL has
created a niche for itself in the category of Long Product segments and
Welding Consumable Industry. Its wealth of experience, expertise and state-of
–the-art technology, has uniquely positioned the Company to meet the most
exacting needs of industries.
1. ISWPL has a Wire Rod Mill with a capacity of 240000 MT of “finished
goods” per annum. It is, indeed the only mill in India, which can produce
6mm TMT Rebars. The Mill is presently into producing wire rods and
TMT rebars exclusively for Tata Steel Long Products Division.
2. The Wire Mill at ISWPL has competence to produce 50000 MT wires per
annum. The Mill is primarily into the production of H B Wires, Barbed
Wires, P C Wires and Galvanized Wires for the Tata Steel Wire Division.
From FY 18 it has ventured into the production of Chain link and Binding
wire.
3. ISWPL has forward integrated the business to produce Stick Electrodes
and MIG Wire and markets this line of products under the brand name
“SPARK”.
4. ISWPL also produces Mild Steel Nails that are sold under the brand name
“SPARK” and has supplies across public and private industrial sector.
5. JEMCO, a division of ISWPL, is in the business of Rolls, Engineering
Castings, and Zinc Dross Refining, it has an approximate annual capacity
of 5000 MT. JEMCO caters the customer base which spread PAN India
and also exports to the Middle East and Turkey.

Products

• Spark Welding Electrodes

o Electrodes for Structural & Equipment
Fabrication
o Stainless Steel Welding Electrodes
o Electrodes for dissimilar welding &
buffer layers

10
 o Hard facing Electrodes
• Spark MIG Welding Wire
o 0.8mm / 1.0mm / 1.2mm
• SPARK NAILS
o Spark Nails

• JEMCO ROLLS & CASTINGS

o Solid Metallurgical Rolls
o Non-Metallurgical Rolls
o Power Plant Castings
o Conventional Engineering Castings

Plant and Project Location:

The Indian Steel & Wire Products Limited
Telco Works, Jamshedpur-831004
Jharkhand, India

11
Distance from Highway: 13.6 KM
Distance from Railway Station: 3.5 KM
Proposed Land Area: 0.31 Acres
Land: Leased from TATA STEEL, already a Factory Licenced Premises
Proposed Manpower:
Officers :1
Staff :3
Contractor Employees : 30
Total : 34
Type of Organisation: Public Limited Company
Full Address of Registered Office:
Name & Address of Occupier: Mr. Neeraj Kant
Indiranagar, Jamshedpur-831008 Jharkhand
Type of Industry as per the
Factories Act & Rules : Hazardous Process Industry

ENVIRONMENTAL CONSIDERTAION –ASPECT/IMPACT

Rain Water Harvesting: The site is already having facility for the Rain Water
Harvesting as an integral part of the plant. There will be no additional Rain Water
lead for the site, hence there is as such decision to not to go for additional Rain
Water Harvesting.
Air Pollution : No stack emission from process
No fugitive emission from the process
Water spray on road and site during construction
Ambient air quality analysis as per the CPCB norms
within prescribed limited pre and post construction
Noise : Ambient Noise at boundary wall will comply with the
JSPCB/CPCB standard.

Tree Plantation & Gardening: Three tire tree plantation in the open area.
25% of total land area is full of greenery.

Use of energy efficient lights: To save energy use LED lights for illumination.

12
Soil : No oil/chemical to be kept directly on soil
Natural slope of soil will not be disturbed for the
unconstructed area for the Rain Water and taking care
of Soil erosion.
Lubrication oil: lube oil should be kept in confined (defined) area, used oil
should not be kept directly in on soil it must be store
and kept in barrel. Spillage must be prevented on shop
floor to prevent incident.
Waste Management:

Solid waste control Measure

1. Scrap generated in the process and through rejection will be collected and
stored separately and will be auctioned.
2. Saw dust will be used during polishing of nail will be reused or either it
will have kept in saw dust -bin.
3. Saw dust must be kept for cleaning of shop floor and it is used to soak up
liquid spills.
Liquid Waste control Measure
Used oil generated in the process will be collected in steel drum and will
be stored in concrete floor with secondary containment. It will be
auctioned to authorised recycler.
Municipal Waste
Managed through JUSCO.
Battery Management
We have buy-back system wherein the authorised recycler replaces the
old batteries with new batteries.
Electrical & Electronic Waste:
Will be sold only to the authorised party from pollution control board.
Quality Management System:
JEMCO is an IMS certified company with ISO: 9001, EMS: 14001 and
OHSAS: 18001

Safety, Health & Environment:

Compliance of all applicable Act & Rules and as per ISWPL procedure. Pre-Start
Safety Review (PSSR) will be done. No change/deviation from the approved
ISWPL design. Legal requirements matrix to be approved by Project Division, HR,
SHE, Electrical & Legal Head.

13
 Legal Matrix
Project: Installation of Nail mill Facility at ISWP of capacity 100 MT/Month
Applicable Not Applicable
A NA

Atomic Energy Regulatory Board

Atomic Energy NA
Chief inspector of Boiler
Boiler Certification NA
Chief Inspector of Factories A
Plan Approval A
Stability Certificate A
Civil Aviation
National Airport Authority! Director General of Civil Aviation NA
Controller of Explosives
Explosive License for Static Pressure Vessels NA
Forest Department
Forest Clearance for Diversion of Forest land NA
Jharkhand State Pollution Control Board
CTO A
Legal Metrology Department
Calibration and stamping of weights and measures A
Ministry of Environment & Forests NA
CTE
State Electricity Board
Approval from Electrical Inspector NA
Wireless Planning & Coordination Wing
Licence to possess Wireless Telegraph Apparatus NA

14
 INTRODUCTION

Wire Nails
A nail consists of a metal rod or shank, pointed at one end and usually having a
formed head at the other, that can be hammered into pieces of wood or other
materials to fasten them together. A nail is usually made of steel, although it can
be made of aluminium, brass, or many other metals. The surface can be coated
or plated to improve its corrosion resistance, gripping strength, or decorative
appearance. The head, shank, and point may have several shapes based on the
intended function of the nail today, most are used in residential housing
construction. The average wood frame house uses between 20,000 and 30,000
nails of various types and sizes. Nails are divided into three broad categories
based on their length. In general nails under 1 inch (2.5 cm) in length are called
tacks or brads. Nails 1-4 inches (2.5-10.2 cm) in length are called nails, while
those over 4 inches (10.2 cm) are some-times called spikes. These categories are
roughly defined, and there is considerable crossover between them.

15
 NAIL STANDARDS

Nail Dimension
Nails Specification Nails sheet No - EPA/QA/NAIL03

Nails Length Shank

Head Tip length
in inch diameter
Sl. Nails Size Diameter in
in mm in mm Nails Polish should be
No. in Gauge Min. Max. mm (Tol.
(Tol. +/- (Tol. +/-
(From) (To) +/-0.20)
0.08 0.20)
1
1 14 G 1" 2.02 4.04 4.00 Bright polish
1/2"
1
2 13 G 1" 2.24 4.48 4.48 Bright polish
1/2"
3 12 G 1 1/2" 2" 2.64 5.28 5.28 Bright polish
2
4 11 G 1 1/2" 3.06 6.12 5.92 Bright polish
1/2"
5 10 G 1 1/2" 3" 3.43 6.174 6.48 Bright polish
6 9G 1 1/2" 3" 3.66 6.588 6.30 Bright polish
7 8G 1 1/2" 4" 4.11 7.398 6.40 Bright polish
Note- Eccentricity & orality of the center of the nail head from axis of shank shall be maximum 10
percent of shank diameter- Max.

Note :- Above nails standard & specfication as per customer requirement and IS723

16
Process Description-Nail mill

List of Major Machine/Equipment:

1. Nail machine (N1) – 4 Nos.
2. Nail machine (N2) – 3 Nos.
3. Nail machine (N3) – 4 Nos.
4. Nail polishing machine (Barrel 500kg)– 1 Nos.
5. Nail polishing machine (Barrel 250kg)– 2 Nos
6. Grinding machine – 2 Nos.

In the process Raw material to be used is Ms wire size – (2mm to 4mm), quantity
(100MT/ Month) of finished product (Nails). No additional manpower and Power
will be required for this process. Nails is produced by scrap TMT and butt
welding, production processes which are described below in details.
Most nails are made from coils of metal wire. The wire is fed into a nail making
machine which can produce up to 700 nails per minute the nails may then be
further twisted of formed, cleaned, finished and packaged.

17
 Forming
1) Wire is drawn from a coil and fed into the nail-making machine where it is
gripped by a pair of gripper dies. The shape of the head of the nail has been
machined into the end of the dies.
2) While the dies clamp the wire in place, the free end of the wire is struck by a
mechanical cold forging. This deforms the end of the wire into the die cavity to
form the head of the nail.

3) With the wire still clamped in the dies, a set of shaped cutters strike the
opposite end of the nail, forming the point and cutting the nail free from the rest
of the wire coming off the coil.

18
4) The dies open and an expelling mechanism knocks the nail into a collection
pan below the machine. The free end of the wire is drawn from the coil and fed
into the machine. The cycle then begins again.

Plant Capacity: 100 MT//Month

Raw Materials Storage Capacity: 100 MT/Month
Production Capacity: 100 MT/Month
Products Quality:
The quality parameters include shank diameter±0.08, head Diameter Tolerance
± 0.20, Tip length± 0.20, Coil weight-47kg.
Finished Product Storage Capacity: 100 MT/Month

Quality Control
Raw materials must meet certain standards for chemical composition, yield strength,
hardness, corrosion resistance and other properties. These are usually certified by the
company supplying the wire and may be independently checked by the nail
manufacturer.
During manufacture, nails must also meet certain specifications regarding dimensions
and properties. These are achieved using a method known as statistical process
control, which periodically samples the dimensions and properties of the nails being
produced and evaluates any changes through statistical analysis techniques.

The Future
The demand for mass-produced commodity nails is dependent on the fluctuations in
the housing market, which varies with the economy. Demand for these nails is also
subject to competition from foreign manufacturers, further reducing profits.
The demand for specialty nails, on the other hand, is expected to continue to grow and
be profitable. New building materials, such as composite wood-fibre and cement-
based siding and roofing, require new specialty nails. New corrosion-resistant coatings
for nails are also being developed.
One unique new nail market is the result of the increase in building restoration and
preservation efforts throughout the country. One nail factory in Massachusetts makes
old-fashioned cut nails. They estimate that 20% of their work is in producing a variety
of these nails for use in authentic building restoration projects.

19
 Details of Installation procedure
• Introduction to Foundation

Machine foundations are

special types of foundations
required for machines,
machine tools and heavy
equipment’s which have
wide range of speeds, loads
and operating conditions.
These foundations are
designed considering the
shocks and vibrations
(dynamic forces) resulting
from operation of
machines.
Machine Foundation is
subjected to dynamic
loads. These loads develop
the vibratory motions
which will transmit into
the soil below the
Machine Foundation foundation. The effect on
soil caused by these vibrations is analysed
using principles of soil dynamics and theory
of vibration. In this project total 11 machines
N1(3), N2(4), N3(4) are setup and three
polishing machines and other two grinding
machines total 16 power outputs are used in
PDB. cables are laid through trenches.
According to the specifications given by
manufacturer of the machine depth and
height of the foundation are designed. Block
Type Machine Foundation are constructed
for machine foundation. It consists of a
pedestal resting on a footing have has large
mass and a small natural frequency.
PDB foundation

20
 • Drawing/ Designing
Design Approach for Machine Foundation
The dimensions of machine foundations are fixed according to the operational
requirements of the machine. The overall dimensions of the foundation are
generally specified by the manufacturers of the machine. If there is choice to the
foundation designer, the minimum possible dimensions satisfying the design
criteria should be chosen. Once the dimensions of the foundation are decided
upon, and site conditions are known, the natural frequency of the foundation-
soil system and the amplitudes of motion under operating conditions have to be
determined. The requirements specified in the previous subsection should be
satisfied to the possible extent for a good design. Thus, the design procedure is
one of ‘trial and error’. The specific data required for design vary for different
types of machines. However, certain general requirements of data may be given
as follows: i) Loading diagram, showing the magnitudes and positions of static
and dynamic loads exerted by the machine. ii) Power and operating speed of the
machine. iii) Line diagram showing openings, grooves for foundation bolts,
details of embedded parts, and so on. iv) Nature of soil and its static and dynamic
properties, and the soil parameters required for the design.
It is the first and most important step towards the construction of a structure.
Designing of the foundation for the machine is done in accordance to fulfil some
mandatory requirements. They are as follows-

1. The foundation should be able to carry the superimposed loads without

causing shear or crushing failure.
2. The settlements should be within the permissible limits.
3. The combined centre of gravity of machine and foundation should, as far as
possible, be in the same vertical line as the centre of gravity of the base plane.
4. No resonance should occur, hence the natural frequency of the foundation–
soil system should be either too large or too small compared to the operating
frequency of the machine. For low-speed machines, the natural frequency
should be high.
5. The amplitudes under service conditions should be within permissible limits
which are prescribed by the machine manufacturers.
6. All rotating and reciprocating parts of a machine should be so well balanced
as to minimize the unbalanced forces or moments.

21
7. Where possible, the foundation should be planned in such a manner as to
permit a subsequent alteration of natural frequency by changing base area or
mass of the foundation as may subsequently be required.

From the practical point of view, the following requirements should be

fulfilled.

1. The groundwater table should be as low as possible and groundwater level

deeper by at least one-fourth of the width of foundation below the base plane.
This limits the vibration propagation, groundwater being a good conductor of
vibration waves.
2. Machine foundations should be separated from adjacent building
components by means of expansion joints.
3. Any steam or hot air pipes, embedded in the foundation must be properly
isolated.
4. The foundation must be protected from machine oil by means of acid-resisting
coating or suitable chemical treatment.
5. Machine foundations should be taken to a level lower than the level of the
foundations of adjoining buildings.

Following are the site plan and sectional drawings of Machine and PDB made
in AutoCAD

Fastener Mill plan

22
Site Plan drawing of the machine foundation

sectional view of machine foundation

23
24
 Plan view of PDB

sectional view of PDB

ISA 55x55x5

Brickwork
PCC

25
• Cost Estimation

26
Total cost of the civil work is Rs3,69,232.41 including flooring and office.

27
 • Planning

According to planned schedule before starting of construction was on 26th may

but it delays and ends on 7th June. This schedule is prepared in MS Project and
updated daily.

Work schedule planned before starting of construction.

Work schedule updated on 4th June.

28
 Execution

• Earthwork in excavation
-Clearance (utility
detection and trial
trench)
-Layout
-Concrete dismantling
• PCC 1:3:6
• Brickwork
• Plastering and cement
punning
• Shuttering
• Reinforcement,
bending, binding and
concreting
• Backfilling
• Non-shrink grouting
• Disposal of all surplus
debris

29
 • Earthwork in excavation
Process of earthwork is to excavate
the existing land to a suitable level
so that construction may begin. It
includes land clearance, levelling of
ground. Depth of earthing is 0.355m
for machine foundation and 0.9m
for PDB. Initial earthing is carried by
heavy machinery excavator JCB.

• Land Clearance
By Utility Detector
The Underground Utility
Detection equipment offered covers
an entire range of equipment
required for locating Buried Pipes
and Cables. The detection of utilities
running below the ground is
crucial before any digging or
excavation activity is undertaken.
The Cable Avoidance Tools/Locators
range from basic models to high
precision ones with multifrequency
detection capability and other advanced additional features such as all
Scan Modes, Datalogging, Bluetooth etc. The Ground Penetrating Radar
models available represent the latest generation technology ideal for
mapping of metallic and non –metallic utilities over massive areas.

By trial trench method

A trial pit is used for obtaining information on the subsurface soil conditions. It
allows logging of the various soils types and soil sampling. Typical size of trial
pits has minimum base plan area of 1.5m2 depth up to 1m and width 150cm.Trial
trench serves the same purpose of trial pit except that they differ in size and
dimension. For instance, the length of a trial trench is normally larger than its
width to cater for its “trench” shape.

30
Utility clearance form

31
 • Layout & Survey
The objectives of
surveying for building
construction is to lay out
the proposed structure
according to prepared
plans and to mark the
controlling points of the
structure in the manner
that is most useful to the
construction forces.
Foundation is positioned
according to the
controlling dimensions Method of laying perpendicular from
and references appearing baseline
on prepared plans.
(1) Establish baseline AB and locate CD by Measurement.
(2) At point C, turn 90 degrees from B and
locate corner stakes E and F by
measurement.
(3) Locate points H and G from point D in the same way.
2 2
(4) Check diagonals (EH and FG) by the formula sq. root(a +b ), (where c is the
diagonal and a and b are the two sides.)

• Concrete Dismantling

Concrete layer removal done prior

to excavation in already existing
plant.
Manual dismantling
by jackhammer

32
 It takes small bites with a jackhammer to crack the
concrete. Jackhammers comes with an
assortment of bits; the point concentrates the
jackhammer’s force and cracks the concrete faster
than the wider bits can. If cracking off large pieces
is tried, the jackhammer literally drills itself into
the concrete and gets stuck.

The for construction of l

Pry out concrete chunks Loosen locked-
together chunks of concrete. A mattock is the
perfect tool for prying them apart or pulling
them up.

Snip reinforcement wire Snip through wire

mesh to separate chunks of concrete. Bolt
cutters are the best tool for this job; don’t even
try using a wire cutter.

• PCC M10(1:3:6)

Plain Cement Concrete (PCC) is

a construction material
generally used as a binding material and is composed of cement,
(commonly Portland Cement) and other cementitious materials such as
fly ash and slag cement, aggregate (generally a coarse aggregate made of
gravels or crushed rocks such as limestone or granite). It is strong in taking
compression and weak in taking tension. It doesn’t have reinforcement
like RCC.
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 NOMINAL MIX DESIGN FOR PCC
In nominal mix method, materials are proportioned based on prescribed
proportions to attain the different grade of concrete. They are easier to
practice on the site hence they are used to produce ordinary concrete (up to
M20 grade).

Total wet volume for PCC as calculated in cost estimation chart = 5.45cum
Dry Volume = 5.45*1.55
= 8.4475cum
(Total volume of cement sand and aggregate required to prepare 1 cubic meter of concrete is 1.55
cubic meters)

Cement sand and aggregate ratio for M10 grade concrete is 1:3:6

• Cement = 1 Part
• Sand = 3 Part
• Aggregate = 6 Part
• Total Parts = 1 + 3 + 6= 10

Let’s calculate material required for M10 grade to prepare 8.4475cum

concrete.
Volume of 1 part= (8.4475/10)
= 0.84475 cum
Volume of cement= Ratio x1 part
= 1 x 0.84475
= 0.84475 cum
Volume of sand= Ratio x 1 part
= 3 x 0.84475
= 2.534 cum
Volume of aggregate= Ratio x 1 part
= 6 x 0.84475
= 5.0685 cum
Cement is often bought in 50kg bags hence we must convert our
calculated quantity to bags.

Weight of cement = volume x density= 0.84475x 1440

= 1217kg

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No of cement bags required = 1217/50 =25bags
Hence, we require nearly 25 bags to prepare 8.4475 cubic meter of
M10 grade concrete.
Aggregates are often bought in Units through lorries and tippers.
One cubic meter is 35.32 Cubic feet. One unit is equal to 100 cubic
feet.
Sand in cft = Volume x 35.32
= 2.534 x 35.32
= 90 cft

Hence, we require 90 cft of aggregate to prepare 8.4475 cum of M10

grade
Aggregate in cft= Volume of sand x 2
=90 cft x 2
= 180 cft
Hence, we require 180 cft of aggregate to prepare 8.4475 cum of
M10 grade concrete.

• Brickwork
Fly ash bricks are used for
construction. (FAB) is a building
material, specifically masonry units,
containing class C or class F fly ash
and water. Compressed at 28 MPa
(272 atm) and cured for 24 hours in
a 66 °C steam bath, then toughened
with an air entrainment agent,
the bricks last for more than 100
freeze-thaw cycles. Bricks are
required to be properly soaked into
the water so that it doesn’t absorb
water from mortar. The right mortar
mix is prepared using good grade
sand in the mix. The sand is free of

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clayey material, otherwise it creates a paste that could expand and contract as
water dries up.
English Bond is the type of brick bond used for the brickwork in foundation.
First Course – Course of Stretchers.
Second Course – Course of Headers with Quoin Closure (refer the image), it is
known as English brick bond

Calculation for brickwork

• The size of the modular brick is 220 X 105 X 65

• Mortar Thickness is 10mm
Volume of bricks with mortar
Volume of 1 brick with mortar = 230 X 115 X 75 (10 mm mortar thickness on all
sides)
= 0.23 X 0.115 X 0.075
Volume of brick with mortar = 0.002 Cum (m3)
Therefore, Number of bricks required for 1 cubic metre = 1/0.001983 = 500 No’s
Therefore, Number of bricks required for 10.881 cum = 504.3*10.881
= 5490bricks
Volume of bricks without mortar
Volume of 1 brick without mortar = .22 X .105 X .065
= 0.0015015 Cum (m3)
Volume of 5440 bricks without mortar = 5490X 0.0015015Cum
Volume of bricks without mortar for 10.881 cum = 8.243 Cum (m3)
Therefore,
Required amount of cement mortar = 10.881 Cum – Volume of bricks without
mortar
= 10.881 – 8.243
Required amount of cement mortar = 2.6377 Cum (m3) (Wet Condition)

Dry volume of a mortar = 2.6377 cum X 1.55 = 4.088 cum

We know the mortar ratio is 1:6 (1-part Cement & 6 Part Sand = 7 Part)
Required amount Cement quantity in brickwork = 4.088 X 1/7 X 1440 kg
= 840kg
Required amount Cement quantity = 782kg = 17 bags (50 Kg bag)
Required amount of Sand = 4.088X 6/7 = 3.5 Cubic metre (m3)

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 • Plastering and cement punning
Plasterwork refers to construction or ornamentation done with plaster,
such as a layer of plaster on an
interior or exterior wall
structure, or plaster decorative
mouldings on ceilings or walls
Punning, sometimes called
skim coating is the application
of a thin coating of plaster,
grout, cement or adobe to the
top or vertical surfaces of a wall
or floor to even and detail the
surface and to add texture or
colour using a finishing trowel.

Calculation of cement and sand for plastering

Total surface area for plastering = 10.32sqm (PDB)
14.26sqm (machine foundation)
= 24.58 sqm
Thickness of plaster = .015m
Volume of plaster = .015*24.58 =0.3687 cum
Ratio of cement to sand used in plaster is 1:6
Therefore,
dry weight of cement= 0.3687/7*1440*1.3
=98.60kg
No. of cement bags is nearly = 98.60/50 = 2bags
Volume of sand = .368/7*6
=.31cum
Volume of sand in cft = .31 x 35.32
=11.16cft

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 • Shuttering
temporary or permanent
moulds into which
concrete or similar
materials are poured to
support the vertical
surface. In the context of
concrete construction,
Wooden Plyboard shuttering
the falsework supports
the shuttering moulds.

General required Features for shuttering material:

• Efficient & safer to use
• Easy installation & removing
• Anti-slip & skid feature
• Corrosion resistance
• Moisture resistant

• Reinforcement bending and binding

Reinforced concrete (RC) (also called reinforced cement concrete or RCC) is
a composite material in which concrete's relatively low tensile
strength and ductility are counteracted by the inclusion of reinforcement
having higher tensile
strength or ductility.
Binding of steel bars(rebars) for The reinforcement is
flooring. usually, though not
necessarily, steel
reinforcing bars (rebar)
and is usually
embedded passively in
the concrete before
the concrete sets.
Reinforcing schemes
are generally designed
to resist tensile stresses in particular regions of the concrete that might
cause unacceptable cracking and/or structural failure.

38
For a strong, ductile and durable construction the reinforcement needs to have
the following properties at least:

• High relative strength

• High toleration of tensile strain
• Good bond to the concrete, irrespective of pH, moisture, and similar factors
• Thermal compatibility, not causing unacceptable stresses in response to
changing temperatures.
• Durability in the concrete environment, irrespective of corrosion or
sustained stress

Bar bending schedule

8mm diameter reinforcements are used for RCC with centre to centre distance
as 150mm.They are placed straight like a mat without any bending. 18gauge
binding wire is used for binding to a mat. 50mm of clear cover is given at all the
ends of rebars.
Total no. of reinforcements required for the machine foundation can be given
as follows-
Length = 22.466m, width = 13m

NOMINAL MIX DESIGN FOR RCC

In nominal mix method, materials are proportioned based on prescribed
proportions to attain the different grade of concrete. They are easier to
practice on the site hence they are used to produce ordinary concrete (up to
M20 grade).
Total wet volume for RCC as calculated in cost estimation chart = 13.297cum
Dry Volume = 13.297*1.55
= 20.61cum
39
 (Total volume of cement sand and aggregate required to prepare 1 cubic meter of concrete is 1.55
cubic meters)

Cement sand and aggregate ratio for M10 grade concrete is 1:1.5:3

• Cement = 1 Part
• Sand = 1.5 Part
• Aggregate = 3 Part
• Total Parts = 1 + 1.5 + 3= 5.5
• Let’s calculate material required for M20 grade to prepare 20.61cum concrete.

Volume of 1 part= (20.61/10)

= 2.061 cum
Volume of cement= Ratio x1 part
= 1 x 2.061
= 2.061cum
Volume of sand= Ratio x 1 part
= 1.5x2.061
= 3.0915 cum
Volume of aggregate= Ratio x 1 part
= 3 x 2.061
= 6.183 cum
Cement is often bought in 50kg bags hence we must convert our
calculated quantity to bags.

Weight of cement = volume x density= 2.061 x 1440

= 2967.84kg

No of cement bags required = 2967.84/50 =60bags

Hence, we require nearly 60 bags to prepare 20.61cubic meter of

M20 grade concrete.
Aggregates are often bought in Units through lorries and tippers.
One cubic meter is 35.32 Cubic feet. One unit is equal to 100 cubic
feet.
Sand in cft = Volume x 35.32
= 3.0915 x 35.32
= 109.19 cft

40
 =1.09 unit
Hence, we require 110 nearly cft of aggregate to prepare 20.61cum
of M20 grade
Aggregate in cft= Volume of sand x 2
=109.19 cft x 2
= 218 cft
= 2.18 unit
Hence, we require 218 cft of aggregate to prepare 20.61cum of M20
grade concrete.

• Backfilling
The excavated earth is used for
backfilling the extra excavated portion
of 600mm surrounding the foundation
that was unearthed for workability
purpose. After backfilling flooring and
concreting is done to level the surface
Portion to be
surrounding the foundation.
backfilled
Good backfill should be well-
compacted and stable to ensure it
won’t settle over time and won’t apply

too much pressure to the basement

walls. It should be coarse, well-
draining material to help keep the
basement dry. Site soils are fine if the
natural soil in the area is mainly sandy
or gravelly, but if it contains clay or
organic material then it is not used.

41
 • Non-shrink Grouting
Non-shrink grout is a hydraulic cement grout that, when hardened under
stipulated test conditions, does not
shrink, so its final volume is greater than
or equal to the original installed volume.
It is often used as a transfer medium
between load-bearing members. SIKA214
Is used for grouting in the pockets of
machine foundation for fastening nuts to
the machine.
Typical characteristics
• Often sets rapidly
• Usually a pre-mix product that
needs only to be mixed with [water]
• Includes ingredients to
compensate against cement stone
shrinkage
• Use of shrinkage compensating
ingredients can result in volume
increase over time.

• Sika 214

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 • Disposal of debris

Construction waste is any material on a jobsite leftover like rebar, earthing soil,
Broken bricks, aggregates etc. These materials, and any others used, require
special handling to properly dispose of them. If it’s used in building,
manufacturing, or anything in between, then best use is made out of it.

43
 Final glimpse of the completed project

Power Distribution Board

Sufficient spacing is given for

serviceability

44
 Conclusion & Suggestions

There had been an erratic growth of the indigenous industry from past years.
Since the manufacture of wire nails could be undertaken on a small scale
or even on a cottage scale, there is a mush room growth of nail making
units in operation. During manufacture, nails must also meet certain
specifications regarding dimensions and properties. This project doesn’t involve
high installation capital neither much man force is required for production, it
has easy mechanism and long-term profit benefits Thus, as an entrepreneur this
project offers an exciting opportunity for profit gain.
Machine foundation for nail plant designed as block type that consists of a
pedestal resting on a footing have has large mass and a small natural frequency.
Since vibrations produced are very nominal by this machine therefore vibration
analysis was not given much focus and was designed simply by load diagrams
and specification given by manufacturer.
Being a part of an industrial project and being physically present of site has
helped me greatly in gaining practical experience about execution stage of the
project. Preparing nominal designs for concrete, and bar bending schedule for
reinforcement and analysis of design has helped me in evaluating and estimating
cost of the project
Some of the suggestions are-
• If bonds in brick work are not arranged properly, then a continuous
vertical joint will result. This is called an unbonded wall having little
strength and stability so proper bonding of bricks should be done.
• Foundation is subjected to dynamic loads. These loads develop the
vibratory motions which will transmit into the soil below the foundation.
The effect on soil caused by these vibrations is analysed using principles
of soil dynamics and theory of vibrations. The foundation should be able
to carry the superimposed loads without causing shear or crushing failure
Therefore vibrational analyses of foundation should be done which was
not done for this project.
• It is a common tendency to make bricks wetted by spraying water. That
is harmful for quality brick work. Bricks should be completely saturated
with water. It should be soaked until it doesn’t absorb single drop of

45
 water. Normally it takes 8 to 12 hours to completely saturated. Making
temporary soaking tank Using a plastic drum initially for soaking bricks till
the soaking tank is ready. bricks in plastic drum should be soaked for 12
hours and taken out from drum one hour before starting brick work to
sweep out the excess water from bricks. But no such tank was made.
• Alignment of pockets was also not done proper due to negligence of
contractor which results in problems in final installation of the machine.
• Levelling of the surface was also not proper so spirit level test should be
done after certain levels of construction so that at end it doesn’t have
undulations.

Bibliography

• Books
Loveday Jr., Amos J. The Rise and Decline of the American Cut Nail
Industry. Greenwood Press, 1993.
Vila, Bob. This Old House Guide to Building and Remodelling Materials. Warner
Books, 1986.

• Periodicals
Johnson, Duane. "Nails Get a Better Grip." The Family Handyman, September 1994,
p. 16.
Whorf, Amy. "A Thumbnail History of Nails." Country Living, June 1993, p. 72.
— Laurel M. Sheppard

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