Professional Documents
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PROJECT REPORT
PREFACE
This report has been prepared after getting different theoretical and
practical training in Indian Railway Bridge Corporation from 20-06-2016
to 15-07-2016 in reference to my collage letter for summer training. The
process of training from my point of view was excellent for each section
was very useful for Civil Engineering Student with a lot of resources and
limited time schedule. There are many things in the Directorate on each
subject which can be learnt from regular training and proper guidance.
DATE-15-07-2016 GANESH
SHANKER
DECLARATION
I hereby declare that the project report on “12.2m span Composite
Girder” and “Aggregate Testing” is a record of my original work done
under the guidance of Mr. Vikrama Prasad. This project report is
submitted to Indian Railway Bridge Corporation Gorakhpur, in the
partial fulfilment of the requirements for the award of the degree of
Bachelor of Technology in Civil Engineering.
The result embodied in this report has not been submitted to any other
University or Institute for the award of any degree.
Place: Gorakhpur
Date:15-07-2016
GANESH
SHANKER
B.TECH FINAL
YEAR
CIVIL
ENGINEERING
Project Coordinator
SUBJECT INDEX
S.No. Description
1. Introduction
2. Fabrication
3. Consisting of fabrication process
Flow diagram of fabrication process
Layout of drawing
Marking and Templating
Jig and Fixture making
Cutting of plates
Tack assembly of job
Tack welding and Fillet welding
Inspection of weld
Etching test
Visual inspection
Dye penetration test
Initial assembly of the job
Drilling
Riveting
Final assembly of job
Riveting section
Final assembly section
Inspection
Painting
Metalizing
Dispatch section
4. Aggregate testing
5. Introduction
6. Sieve analysis
Water absorption
Aggregate impact value
Shape test
Flakiness index
Elongation index
7. Material suppliers
8. Acknowledgement
DESIGN OF COMPOSITE GIRDER
(WELDED TYPE)
COMPOSITE GIRDER
The RCC deck is cast in situ after launching steel girders on
substructure. Shear connectors are provided on top flange plates of
steel beams with channel sections welded all round with side fillet
welds. Shear connectors are required to make cast in situ RCC slab
and steel girder act together under load.
PROCESS
LAYOUT OF DRAWINGS
Layout is drawing of complete structure on full scale. Normally
half span is drawn on a levelled smooth concrete/steel floor. (Other
half will be the mirror image)
NOMINAL AS WELL AS CAMBER LAYOUT WILL BE
DRAWN ON THE FLOOR.
Length of the members will be kept as per camber layout. However
the jigs/masters jigs for main gussets will be fabricated using
nominal layout.
CUTTING OF PLATES
This is a operation done at the site to get the desired shape of steel
plates being use in the construction of deferent components of the
structure. Oxy-fuel gas cutting is use for this purpose at site.
Oxy-fuel cutting are processes that use fuel gases and oxygen to
cut metals.
LPG is used as fuel gas at site for the cutting purpose.
Plates are cut into desired length using …
ordinary oxy-acetylene cutting torch
pug cutting machine
profile cutting machine
galloting shear machine (faster but for plates up to 10mm
thickness)
Angles are cut into desired length using …………
shaper machine
shearing and punching machine
circular saw profile cutting machine
After cutting it should be ensured that all the edges are clean, reasonably
square and true.
ETCHING TESTS
• Etching tests on run-off coupons and at the edges of girders for
checking the root fusion and throat length.
DRILLING OF JOB
RIVETING OF JOB
The rivet holes shall be 1.5 mm greater than the diameter of the
rivet bars used. The rivets shall be made to IS:1929.
The clearance i.e. the difference in diameter between the rivets
measured under head before being heated and the rivet hole shall
not be less than 0.75mm.
All rivets shall be properly heated to straw heat for the full length
of the shank, firmly backed and closed. The head of the rivet,
particularly in long rivets, shall be heated more than the point and
in no case shall the point be heated, more than the head. Sparking
or burnt rivets shall not be used.
All loose and burnt rivets and rivets with cracks badly formed,
eccentric or deficient heads shall be cut out and replaced.
Steel for rivets should conform to is:1148 and rivet should be made
conforming to is:1929.
The rivets hole should be 1.5mm bigger than the rivet dia.
Length of rivets = grip+1.5d+1mm extra to every 4mm grip.
Compressed air pressure required at the hammer end is approx. 6 to
7 kg/sq.cm.
Heating time of rivets is 20 to 25 minutes.
All the rivets should be tested 100% by a responsible supervisor by
using testing hammer weight 110 gram.
All the defective rivets shall be distinctly marked on their heads
with paint and promptly replaced.
When all the rivets of joints have been finally passed they should
be painted with one coat of ready mixed zinc chrome primer to
is:104 followed by one coat of ready mixed paint red oxide zinc
chrome primer to is:2074.
ISNPECTION
After final finishing, identification of marking of component
(shipping mark) is done. After final inspection by
RDSO/inspecting agency, the girder parts are cleared for
metalizing/painting.
PAINTING
No part shall be painted unless inspected & passed by
RDSO/inspecting officials.
Dry film thickness shall be measured by ELCOMETER.
Before painting the surface to be painted should be prepared
carefully.
Surface preparation ………………
Manual hand cleaning
Cleaning with power driven tools
Blast cleaning
Flame cleaning (for plates>10mm thick)
PRIMER COAT :
One Coat of Ready Mixed Paint Zinc Chromate to IS:104
followed by one coat of Ready Mixed Paint Red Oxide Zinc
Chrome to IS:2074.
FINISHING COAT :
Two Coats of Red Oxide paint to IS:123 (One Coat in
Workshop before dispatch, 2nd Coat at site after errection)
METALIZING
PAINTING SECTION
Metalizing
After metal spraying ………..
one coat of etch primer to is:5666
one coat of zinc chrome primer to is:104
Two coats of aluminium paint to is:2339 (one coat in workshop
before dispatch, 2nd coat at site after errection)
DESPATCH SECTION
After metalizing and painting the members of the girders may be sent to
errection on site.
TESTING OF AGGREGATE USED IN
RAILWAY BRIDGES
INTRODUCTION
The properties of the aggregates affect both the fresh and hardened
properties of concrete. It is crucial to know the properties of the aggregates
to be used in the making of concrete in order to obtain the desired quality
in a concrete. Therefore, the tests performed on aggregates are very
important. Concrete is a composite material in which a binding material
mixed in water on solidification binds the inert particles of well graded
fine and coarse aggregates. Cement and lime are generally used as binding
materials, whereas sand cinder is used as fine aggregates and crushed
stones, gravel, broken bricks, clinkers are used as coarse aggregates.
Definitions
Aggregate -granular material used in construction. Aggregate may be
natural, manufactured or recycled.
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,
ii) Balance or scale with an accuracy to measure 0.1 percent of the weight
of the test sample
The weight of sample available should not be less than the weight given
below:-
Maximum size present Minimum weight of
(mm) (kg)
63 100
50 100
40 50
25 50
20 25
16 25
12.5 12
10.0 6
6.3 3
The sample for sieving should be prepared from the larger sample either
by quartering or by means of a sample divider.
PROCEDURE
The test sample is dried to a constant weight at a temperature
of 110 + 5oC and weighed.
The sample is sieved by using a set of IS Sieves.
On completion of sieving, the material on each sieve is
weighed.
Cumulative weight passing through each sieve is calculated
as a percentage of the total sample weight.
Fineness modulus is obtained by adding cumulative
percentage of aggregates retained on each sieve and dividing
the sum by 100.
REPORTING OF RESULTS
The results should be calculated and reported as:
The cumulative percentage by weight of the
total sample
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.
The results of the sieve analysis may be recorded graphically on a semi-
log graph with particle size as abscissa (log scale) and the percentage
smaller than the specified diameter as ordinate.
A sample chart is provided
WATER ABSORPTION
AIM
To determine the water absorption of coarse aggregates.
APPARATUS
Wire basket - perforated, electroplated or plastic coated with
wire hangers for suspending it from the balance
Water-tight container for suspending the basket
Dry soft absorbent cloth - 75cm x 45cm (2 nos.)
Shallow tray of minimum 650 sq.cm area
Air-tight container of a capacity similar to the basket
Oven
SAMPLE
A sample not less than 2000g should be used.
PROCEDURE
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.
After immersion, the entrapped air should be removed by
lifting the basket and allowing it to drop 25 times in
25seconds. The basket and sample should remain immersed
for a period of 24 + ½ hrs. afterwards.
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').
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] x 100%
Two such tests should be done and the individual and mean results should
be reported.
A sample farm for the record of the test results is given
AGGREGATE ABRASION VALUE
AIM
To determine the abrasion value of coarse aggregates.
APPARATUS
AIM
To determine the aggregate crushing value of coarse aggregates.
APPARATUS
CYLINDRICAL MEASURE AND PLUNGER
Cylindrical measure and plunger
Compression testing machine
IS Sieves of sizes - 12.5mm, 10mm and 2.36mm
PROCEDURE
The aggregates passing through 12.5mm and retained
on10mm IS Sieve are oven-dried at a temperature of 100
to110oC for 3 to 4hrs.
The cylinder of the apparatus is filled in 3 layers, each layer
tamped with 25 strokes of a tamping rod.
The weight of aggregates is measured (Weight 'A').
The surface of the aggregates is then levelled and the
plunger inserted. The apparatus is then placed in the
compression testing machine and loaded at a uniform rate so
as to achieve 40t load in 10 minutes. After this, the load is
released.
The sample is then sieved through a 2.36mm IS Sieve and
the fraction passing through the sieve is weighed (Weight
'B').
Two tests should be conducted.
REPORTING OF RESULTS
Aggregate crushing value = [B/A]x 100%
The result should be recorded to the first decimal place and the mean of
the two results reported.
SHAPE TEST
AIM
Determination of flakiness index of coarse aggregate, where the size of
the coarse aggregate are larger than 6.3mm.
PREPARATION SAMPLE
Surface dry samples is used for the test. A minimum number of 200
pieces of any specified fraction is required to do the test.
PROCEDURE
The sample is sieved through IS sieve specified in Table shown
below.
Dimension of Thickness and Length Gauge
CALCULATION
In order to calculate the flakiness index of the entire sample of
aggregates, first the weight of each fraction of aggregate passing and
retained on the specified sets of sieves is noted (Y1, Y2, Y3, Y4…..etc.).
Each piece of these are tried to be passed through the slot of the specified
thickness of the thickness gauge are found and weighed (y1, y2, y3,
y4…etc.). Then the flakiness index is the total weight of the material
retained on the various thickness gauges, expressed as a percentage of the
total weight of the sample gauged.
REPORT
Flakiness index is reported in percentage to the nearest whole number
AGGREGATE ELONGATION INDEX
AIM
For determination of elongation index of coarse aggregate, where the size
of the coarse aggregate are larger than 6.3 mm.
Length Gauge
PROCEDURE
A minimum of 200 pieces of each fraction is taken and weighed.
In order to separate elongated materials, each fraction is then
gauged individually for length in the length gauge.
The pieces of aggregate from each fraction tested which could not
pass through the specified gauge length with its long sides
elongated are collected separately to find the total weight of
aggregate retained on the length gauge from each fraction.
The total amount of elongated material retained by the length
gauge is weighed to an accuracy of 0.1% of the weight of sample.
The sample is sieved through IS sieve specified in Table shown below.
CALCULATION
In order to calculate the elongation index of the entire sample of
aggregates, first the weight of each fraction of aggregate passing and
retained on the specified set of sieves is noted (Y1, Y2, Y3, Y4…..etc.).
Each piece of these are tried to be passed through specified length of the
gauge length with its longest side and those elongated pieces which do
not pass the gauge are separated and weighed (y1, y2, y3, y4…etc.). Then
the elongated index is the total weight of the material retained on the
various length gauges, expressed as a percentage of the total weight of the
sample gauged.
REPORTS
Elongation index is reported in percentage to the nearest whole number.
3. Utile Equipments
13, Jal Tarang, Prabhat Road,
Lane No.1, Pune - 411 004
6. Commander Agencies
1466, Sadashiv Peth, Pune - 411 030.
8. DYEGLO
820/7, Shee-Krishna Kunj,
Bhandarkar Institute Road,
Pune - 411 004.
ACKNOWLEDGE
MENT