INTERNSHIP REPORT

Vocational Training Report On Flyover

2/03/2024

(INTERNSHIP PERIOD : 20TH DECEMBER– 18TH JANUARY2024)

SUBMITTED BY :

ENROLLMENT NUMBER :
SEMESTER

CIVIL ENGINEERING

GUIDED BY :
MR. BALRAM SHARMA
(Senior Engineer)
 INTERNSHIP REPORT

NATIONAL AUTHORITY OF INDIA (NHAI)

Report On
Delhi-Amritsar-Katra Expressway (Phase-II Pkg-XVI) Existing Jakh
(Vijaypur)- Kunjwani section of NH-44 including spur Connectivity
to Jammu Airport (NH-144A) [Km 503+500 to km 514+500]
(INTERNSHIP PERIOD : 20TH DECEMBER– 18TH JANUARY2024)

SUBMITTED BY :

ENROLLMENT NUMBER :
SEMESTER :

BRANCH :

GUIDED BY :
MR. BALRAM SHARMA
(Senior Engineer)
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ACKNOWLEDGEMENT

The Internship opportunity I had with NHAI under Shivalaya Constrution Co.
Pvt. Ltd. was a great chance for learning and professional development.
Therefore, I consider myself as a very fortunate individual as I was provided
with such an opportunity. I am also grateful for having a chance to meet so
many wonderful people and professionals who led me though this
internship period.

I am highly indebted to Mr. Ish Gupta (Project Manager) and Mr. Balram
Sharma(Senior Engineer) for their guidance and constant supervision as well
as the kind support throughout the internship. I also extend my heartiest
thanks to all the present Engineers and staff members working at the site.
Also to the faculties who shaped my knowledge to tackle all problems in
smart and most efficient way.

I also express my gratitude towards all others who whole heartedly helped
my during my internship period.

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ABSTRACT

The report mainly consists of various parts in which I tried to explain my one
month internship experience in my hosting company, SHIVALAYA
CONSTRUCTIONS CO. PVT. LTD. The content of all chapters is broadly
explained and it is constructed from the practical basis of work.

Initially, I give details about the importance of the project in respect of

connectivity. basic concepts about Bridge especially Box Girder type.

The second part is the most important one, which explains my overall
internship experience which comprises Box Girder Bridge, Ready Mix
Concrete Plant and most importantly Post Tensioning system. This chapter is
the record of the overall work I have been executing. It gives a highlight of
what I have been doing during my internship period.

It is obvious that the internship has a positive outcome in terms of

improving skills and different abilities as a whole. The advantages and gains
of the internship are put in short and precise way to grasp the attention of
readers and evaluators.

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PREFACE

Bridge engineering is one of the most fascinating fields in civil engineering.

A successful bridge engineer has to have an appreciation of aesthetic and
economics, besides in analysis, in designing and in execution. The materials
and procedure involved in the construction of any sizeable bridge are quite
varied. For instance a box girder bridge would require a proprietary system
of prestressing/post-tensioning, high grade concrete normal reinforced
concrete for deck slab, masonry for sub-structure, piling for foundation,
neoprene for bearing, steel sheet for expansion joint, shuttering, different
construction masonry. It is therefore, evident that report of the present size
cannot attempt to cover exhaustively the entire project, but can only
highlight the essential f the project.

This report is primarily combination of bridge and road. Preference has been
made to relevant codes of practices. This report would also serve as a
reference material for new interns. I gratefully acknowledge the members
present at site for their indebtedness.

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CONTENTS

Certificate and Documentation

About NHAI

01. COMPANY OVERVIEW…………………………….

1.1. Shivalaya Constrution Co. Pvt. Ltd………….

02. INTRODUCTION……………………………………….
2.1. Project At A Glance………………………………
2.2. Importance Of Project………………………….
2.3. Project Details……………………………………..

03. SAFETY…………………………………………………….
3.1. Points to be consider For Safety………………..
04. BRIDGE……………………………………………………
4.1. Definition…………………………………………………
4.2. Component Of Bridge………………………………
4.3. Foundation Details…………………………………..
4.4. Related Image………………………………………...
05. MACHIENES….………..…(pictures clicked On Site……………………

CONCLUSION………………………………………………………………………………………………
REFERENCE………………………………………………………………………………………………….

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NHAI(National Highway Authority Of India)

National Highway Authority of India was set up by an act of the Parliament, NHAI Act,
1988 “An Act to provide for the constitution of an Authority for the development,
maintenance and management of national highways and for matter connected
therewith or incidental thereto”. It has been entrusted with National Highways
Development Project, which alongwith other minor projects, has vested in it 50329
kms of National Highways for development, maintenance and management. Our
objective is to ensure that all contract awards and procurements conform to the best
industry practices with regard to transparency of process, adoption of bid criteria to
ensure healthy competition in award of contracts, implementation of projects
conform to best quality requirements and the highway system is maintained to
ensure best user comfort and convenience.
National Highways are the arterial roads of the country for inter-state movement of
passengers and goods. They traverse the length and width of the country connecting
the National and State capitals, major ports and rail junctions and link up with
border roads and foreign highways. The total length of NH (including expressways) in
the country at present is 1,32,499 kms. While Highways/Expressways constitute only
about 1.7% of the length of all roads, they carry about 40% of the road traffic.

Mandate
NHAI is mandated to implement National Highways Development Project (NHDP)
which is India’s largest ever Highways Project in a phased manner. The National
Highways have a total length of 1,32,499 (approx) km to serve as the arterial network
of the country. Although National Highways constitute only about 2 per cent of the
road network, it carries 40 per cent of the total road traffic

Vision
To meet the Nation’s need for provision and maintenance of National Highways
network to global standards and to meet the user’s expectations in the most time-
bound and cost-effective manner, within the strategic policy framework set by the

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Government of India and thus promote economic well-being and quality of life of the
people.

1.1. Shivalaya Constrution Co. Pvt. Ltd.

Established in 1997 by its visionary directors, Shivalaya Construction Co. Pvt.
Ltd. today is considered among the elite construction and engineering
companies in the country. In last couple of decades, we have truly risen above
and beyond. By executing projects of national significance, we have proudly
integrated ourselves in the Indian Construction sector. Every new endeavour
of our company has the ultimate goal of enhancing the quality of life for
people across the country and creating new opportunities without
compromising on quality.

We have implemented projects for several government departments like PWD

of Haryana, Maharashtra, Jharkhand, Himachal Pradesh, Rajasthan, Delhi,
Madhya Pradesh, Chhattisgarh & whole of North East - Manipur, Nagaland,
Arunachal Pradesh & Mizoram as well as for NHAI, NHIDCL, NBCC, HSCC.

Currently, the company is involved in multi-billion Indian Rupee infrastructure

development projects like National, State Highways and Bridges, Government
buildings, etc. across India. We are known to successfully complete
infrastructure projects well within deadlines. As a testament to this fact, we
have been rewarded with bonus for early completion of multiple projects.

As a result of the dedication and passion of the directors and associates of the
company, combined with the purpose of helping build a better nation,
Shivalaya Construction Co. Pvt. Ltd. has graduated from being a small civil
contractor to one of the major players in various states. The revenue of the
company has increased manifold in past few years.

We credit this success to our experienced and well qualified team of civil
engineers and administration personnel who assist our directors in impeccable
execution of the tasks undertaken by the company. We trust our team to help

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our company stay aligned and qualified to our purpose, which is to help build a
better India.

2. INTRODUCTION
2.1. Project At A Glance :-
Starting Point : Jakh (Vijaypur)- Kunjwani Section
End Point : Satwari- Tawi 04
CONTRACTOR Shivalaya Construction Pvt. Ltd.

CONSULTANT NHAI

AMOUNT Approx 1800 Cr.

DATE OF START 06/10/2022

DATE OF COMPLETION DECEMBER,2025

2.2. Importance Of The Project :-

Rail-cum Road Bridge is one of the bridges that connect Jakh
(Vijaypur) to Satwari. It is one the best alternative of Mahatma
Gandhi Setu as it is not in the condition to use due to its damaged
superstructure. This Project has 12.2KM of bridge length and 18KM
of Road length, which will connect to Delhi- Amritsar-Katra
Expressway(NH44). This project will reduce the time consumption in
reaching Satwari(Jammu) from Jakh(Vijaypur).

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03. SAFETY :
To avoid accidents, better quality control, zero defects, protection of
environment and most important protection human being safety in
industry necessary.

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Fig. 3(a) Safety Equipment

3.1 POINTS TO BE CONSIDERED FOR SAFETY:

a. TBM (TOOL BOX MEETING)
b. PPE (PERSONAL PROTECTIVE EQUIPMENT)
C. LIFTING TOOLS AND TACKLE WITH THIRD PARTY INSPECTION
d. FIRE
e. WORKING HEIGHT
f. RISK ASSESSMENT
g. JOB HAZARD ANALYSIS

Fig. 3(b) Safety Room

a. TBM (TOOL BOX MEETING):

Tool box talks or meetings are probably the ideal way to recap and
supplement the safety training efforts of the organization. A tool box
meeting is a safety meeting on which a certain theme is discussed and
used to generate awareness of workplace hazards and how to prevent

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them. Toolbox meeting shall be held regularly on a weekly basis and

should be documented.

b. PPE (PERSONAL PROTECTIVE EQUIPMENT):

PPE is used by healthcare providers to protect themselves from
injury or infection. Some of the personal protective equipments
are:

• SAFETY HELMETS
• GOGGLES
• NOSE MASK
• EAR PLUG
• BOILER SUIT (REFLECTING JACKET)
• HAND GLOVES
• SAFETY SHOES

c. LIFTING TOOLS AND TACKLE WITH THIRD PARTY INSPECTION :

Third party certification means that an independent
organization has reviewed the manufacturing process of a
product and has independently determined that the final
product complies with specific standards for safety, quality or
performance. This review typically includes comprehensive
formulation/material reviews, testing and facility inspections.

d. FIRE SAFETY :
Fire safety is the set of practices intended to reduce the
destruction caused by fire. Fire safety measures include those
that are intended to prevent ignition of an uncontrolled fire and
those that are used to limit the development and of a fire after
it starts.

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e. WORKING HEIGHT SAFETY:

There should be proper facility of prevention caused by
damages due to working at height.

f. RISK ASSESSMENT:
It is the determination of quantitative or qualitative estimate of risk
related to a well-defined situation and a recognized hazard.
Quantitative risk assessment requires calculations of two components
of risk (R): the magnitude of the potential loss (L), and the probability
(p) that the loss will occur. An acceptable risk is a risk that is
understood and tolerated usually because the cost or difficulty of
implementing an effective countermeasure for the associated
vulnerability exceeds the expectation of loss. "Health risk
assessment" includes variations, such as risk as the type and severity
of response, with or without a probabilistic context.

g. JOB HAZARD ANALYSIS:

A job hazard analysis is a technique that identifies danger or

hazardous conditions and presents the means and methods to reduce
them.

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4. BRIDGES :-
- 4.1 DEFINITION:
A bridge is a structure providing passage over an obstacle without
closing the way beneath. The required passage may be for a road, a
railway, pedestrians, a canal or a pipeline. The obstacle to be crossed
may be a river, a road, railway or a valley. In other words, bridge is a
structure for carrying the road traffic or other moving loads over a
depression or obstruction such as channel, road or railway.
A bridge is an arrangement made to cross an obstacle in the form of a
low ground or a stream or a river without closing the beneath.

4.2 COMPONENTS OF BRIDGE:

4.2.1. PILING:-
Piling is done in following steps:
- Casing
- Boring
- Soundness check
- Cage lowering (reinforcement)
- Concreting

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a. PILE FOUNDATION:
Diameter = 1.2m and Depth = 20m - 40m (varies w.r.t. geo tech report
of soil ).
General descriptions of pile types.
There is a large variety of types of pile used for foundation work. The
choice depends on the environmental and ground conditions, the
presence or absence of groundwater, the function of the pile, i.e.
whether compression, uplift or lateral loads are to be carried, the
desired speed of construction and consideration of relative cost. The
ability of the pile to resist aggressive substances or organisms in the
ground or in surrounding water must also be considered. A pile is
basically a long cylinder of a strong material such as concrete that is
pushed into the ground to act as a steady support for structures built
on top of it.

Pile foundations are used in the following situations:

• When there is a layer of weak soil at the surface. This layer cannot
support the weight of the structure, so the loads of the building have
to bypass this layer and be transferred to the layer of stronger soil or
rock that is below the weak layer.
• When a structure has very heavy, concentrated loads, such as in a
high rise structure, bridge, or water tank.
• Pile foundations are capable of taking higher loads than spread
footings.

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Fig.4.2.1.1(b) Pile Installation Process

A. Pile Boring:
I. Hydraulic rig/manually operable auger should be mobilized at the
required location.
II. Four reference points (making two lines perpendicular to each
other) should be marked for checking center of pile bore during
boring of pile.
III. Initial boring of about 2.0 meters is to be done using cutting tool
of desired diameter of pile.

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IV. Then boring will be carried out according to the sub-soil

investigation report of that location. It will be done using liner,
bentonite or both.
V. The temporary guide casing, approximately 2.0 meter length with
outside diameter equivalent to nominal diameter of the pile, may
then lowered in the bore hole. In such a case dia of cutting tool
will be little less, maximum 75 mm less than outside dia of casing
for free movement in the casing pipe during operation.
Position/centerline of the guide casing pipe with reference to pile
reference points already fixed around the pile location shall be
checked to shift/adjust the casing pipe to ensure proceeding of
drilling at exact pile location without any deviation.
VI. Boring has to be done up to the founding strata as per drawings/
pre decided depth using intermittently bentonite slurry as per
requirement. In case of requirement the bore hole is then
supplied with bentonite slurry, from bentonite installation.
Bentonite circulation channel will be made from bore hole to
bentonite tank and fresh bentonite slurry will be pumped to bore
hole through hose pipes. 24 hours prior to start of pile boring,
ensure that bentonite is completely dispersed I the water and
attains required density to stabilize the sides of bore hole during
drilling. Bentonite slurry of specified quality should be circulated
continuously during boring process.
VII. Bentonite used to stabilize the sides of bore hole should be
conforming to requirements as listed in inspection and test plan.
VIII. Bentonite/ Polymer slurry is pumped by high pressure
reciprocating pumps/ vertical pump into the bore hole and the
same is allowed to overflow the bore hole. The overflow slurry
with bored mud/soil etc that comes out along with bentonite
slurry is passed through channels and is collected in sediment
tanks where sediments settle and bentonite can be re used.
necessary, the bentonite may be passed through the de sander
tank to remove sand particles before it is re used.
IX. Depth of pile shall be checked with sounding chain and exact
depth shall be recorded in the pile report.

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X. After boring upto required depth underreaming will be done using

underreamer of desirable diameter. Completion of desired bulb
cutting will be ascertained by (i) vertical movement of the handle
and (ii) using 1. shaped rod of length enough to reach upto bulb
location from approximately 2 feet above ground level and
horizontal dimension equal to 0.5 of bulb dia minus pile dia.

Fig. Boring

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B. Reinforcement Cage Lowering:

I. Prefabricated reinforcement cage prepared as per the drawings and
approved depths, is brought and kept near pile location while boring is
in progress.
II. After getting the permission from the engineer, the reinforcement cage
will be gently lifted and lowered by crane/manually into the bored
hole. Necessary concrete cover will be obtained by using the circular
cover blocks already made of the same strength as of pile.
III. If the reinforcement cage is very long i.e. not possible to handle in one
lift, the cage will be lifted one by one and spot welded at the joints and
then lowered inside the bored hole.
IV. It is to be checked whether the reinforcement cage has reached up to
bottom of the pile by measuring from the top of the cage to the ground
level.

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C. Pile Concreting:
I. The concrete placing shall not proceed if density of fluid near about the
bottom of borchole exceeds 1200 kg/m³.
II. Determination of the density of the drilling mud from the base of the
borehole shall be carried out by taking samples of fluid by suitable
slurry sample approved by the engineer in charge, in first few piles and
at suitable interval of piles thereafter and the results recorded. After
flushing is completed, tremie head should be removed and funnel
should be attached to the tremie pipe.
III. The slump of the concrete will be maintained at 100 mm to 200 mm.
Concreting operation will be carried out using the 200 mm diameter
trime pipes.
IV. Initial charge of concrete should be given in the funnel using a plug.
Total concrete quantity in the funnel should be more than the volume of
the entire pipe plus free space below the tremie. This will ensure a
water tight concrete pouring through tremie.
V. Lifting and lowering is repeated keeping sufficient concrete in funnel all
the time. As the concreting proceeds the tremie pipe are to be removed
one by one, taking care that the tremie pipe has sufficient embedment
in the concrete until the whole pipe is concreted. Sufficient head of
green concrete shall be maintained to prevent inflow of soil or water in
to concrete. Placing of concrete shall be a continuous process from the
toe level to top of pile.
VI. The concrete is poured in the funnel. As the concrete reaches the top of
the funnel, the plug is lifted up to allow the concrete to flow
corresponding to the placing of each batch of concrete.
VII. The concreting of pile is to be done up to minimum of 300 mm above
the cut off level to get good and sound concrete at cut off level. After
completion of concreting tremie, funnel and other accessories are to be
washed properly and kept greased in proper stacking condition near
next pile location.
VIII. While doing under water concreting 10% extra cement over and above
the design mix requirement should be added in each batch.

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Fig. Pile Concreting (with Trime Pie)

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Fig. Pile Concrete (Top Point)

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D. Flushing:

Fig. Polymer Container

I. After cage lowering, 200 mm diameter tremie pipes in suitable lengths

are to be lowered in the hole. The operation is done by lowering one
tremie pipe after another and connecting them threading to maintain
water tightness throughout its length till the gap between the pile base
and Tremie is between 75-100 mm. the tremie pipe is locked/supported
from top to maintain the level and funnel is attached on top.
II. The tremie head to be provided to the tremie pipe for the flushing
activity. The bore is flushed by fresh bentonite slurry through the tremie
head.

Fig. Polymer

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4.3. FOUNDATION DETAILS:

Deep Foundation Pile Foundation Friction Pile
Pile Details:
Diameter – 1200 mm (1.2m)
Length - 30 m

Fig. Reinforcement Of Pile

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Fig.4.3. Reinforcement Of Pile

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a. Casing:-
The diameter of casing is 1200mm (1.2m)
 Height of case is 3-4m
 And it is first step of piling

Fig. Case Lowering

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b. Boring:- The diameter of boring is 1200mm

 Height of bore is 31 m
 The machine use for boring is water boring drilling machine

Fig. Boring & Soundness Check:

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d. Cage Lowering :-

Lowering of three cages of 12meter height each. The diameter of the

reinforcement used to make cages are different. The lower cage has
reinforcement of dia 25 mm, the middle cage has reinforcement of 20mm and the
upper cage has Dia of 25mm. The diameter of the cage is less then 1200mm .

Fig. Cage Lowering

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05. MACHINES:

Fig. Crane Transferring Cages on Truck

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Fig. Pile Boring Machine and Auger Blade

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Fig. Hydraulic Crane

Fig. Excavator Machine

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Fig. Transit Mixer Truck (TM)

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CONCLUSION
This internship helped me to gain knowledge by
experiencing various works taking place int the site. By this
in plant training I had a opportunity to witness various
situations in the site and practically and innovatively
overcoming them in brief I learned about various new
construction
technologies and more importantly I experienced the whole
construction of laying out a span of a girder bridge. This
helped me in clearing various theoretical and practical
doubts and made me somewhat realize the future scope of
civil engineering.

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REFERENCE

a. Chellis, R.D., "Pile foundation", McGraw-Hill Book Co., New York, 1961
b. IRC: 37, "Guidelines for the design of flexible pavements", IRC, 1970.

c. IS: 2911-3-1973, Code of practice for Design and construction of Pile

Foundations, Part 3, under Reamed Pile Foundation, BIS, New Delhi.

d. IS: 456-2000, "Code of Practice for plane and reinforced concrete's".

e. IS: 2911-Part 1-sect. 1-1979, "Design and Construction of Pile

Foundations- Driven Cast in-Situ Concrete Piles".

f. IS: 5121-1969, "Safety code for Piling and other Deep Foundations".

g. IS: 456-2000, "Code of practice for Plain and Reinforced Concrete".

h. IS:383, "Specification for Coarse and Fine Aggregates".

i. IRC:6-2000, "Road Bridges Std. Specification".

j. IS:9103-1999, "Concrete Admixtures, -Specification".

k. IS:4926-2003, "Ready Mix Concrete".

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