Summer Training\Internship Report

(19th may -28th June 2014)

Bihar Museum Project Site, Patna,

Submitted by:-

Kishore Anand

Dept. of Civil Engg.

BE/15290/11

Contents Acknowledgement Introduction

About L&T B&F (ECC contractor)About BCD, BIHAR (client)

About the project EHS and safety induction policies Materials EXECUTION(Block B)

Pile foundationGrade slab preparationFlat slabs

Quality Control/Quality AssurancePQPLab testsInternal material Investigation reportsQuality checks photographs

Formwork Batching Plant

Trial mix designs Conclusion

Acknowledgement

I am very thankful to LARSON AND TOUBRO CONSTRUCTION and BUILDING CONSTRUCTION DEPT. GOB for having given the opportunity to undertake my summer training at their prestigious BIHAR INTERNATIONAL MUSEUM PROJECT SITE, PATNA. It was a very good learning experience of construction practices, equipment; challenges field test, site execution and supervision. I would like to thank ER. Kamala Kant Jha, Technical Secretary to Chief Engineer (South) & Technical Secretary to Engineer-in-Chief who sanctioned my summer training at their BIHAR MUSEUM site, which is one of the flagship project undertaken by GOVERNMENT OF BIHAR.

I would also like to give heartfelt thanks to Mr Suresh Sethi, Planning Engineer, who formulated my training schedule and constantly guided me whenever I needed help. And most importantly I would like to thank Mohanty sir, Abhishek sir (block B), Rangarao and Prasanto sir (QA/QC) , and all other staffs of L&T B&F who shared their valuable experiences.

Kishore Anand

Date: June 21St 2014

Introduction

About the L&T constructionHolck-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 India’s 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 played a prominent role in India’s 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 ICBuildings & Factories ICInfrastructure ICMetallurgical & Material Handling ICPower Transmission & DistributionHeavy EngineeringShipbuildingPowerElectrical & AutomationMachinery & Industrial Product• Machinery & Industrial Product

BUILDING & FACTORIES

The Buildings & Factories Independent Company is equipped with the domain

Knowledge , requisite expertise and wide-ranging experience to undertake

Engineering, Procurement and Construction (EPC) of all types of building and factory

Structures.

• Commercial Buildings & Airports

• Residential Buildings & Factories

Building Construction Department, GOB

HISTORY Before the year 1982, Road Construction, Building Construction and Rural Engineering Organisation were all under the Public Works Dept. (PWD). In the administrative view, Public Works Dept. was split into three different departments named: Road Construction Dept., Building Construction Dept. and Rural Engineering Organisation Dept. by the Cabinet Secretariat and Co-ordination Department's Memorandum No. CS-2-M2-10157/80-878, Patna dated 16th March, 1982.

 

In this way, the Building Construction Department came into existence in the year 1982. Its head-quarter is located at Visheshwaraiya Bhawan, Jawahar Lal Nehru Marg, Bailey Road, Patna - 800 015.

OBJECTIVE1. Planning and designing building network to provide optimized connectivity to residential

and non-residential govt. buildings of different departments.

2. Construction, renovation, upgradation and maintenance of residential and non-residential govt. buildings of different departments.

About the Project

Project details:Project Name:- Bihar Museum, patna, BiharClient:- Building Construction Department, GOBECC contractor:- L&T Constructions B&FArchitectural design consultant:- Fumihiko Maki+ and Maki Associates, Tokyo, JapanArchitect of Record: - OPOLIS, MumbaiEngineering consultants:- Mahendra Raj Consultant private Limited. MEP consultants:- Design BureauBudget:- 498.49 croreArea:- 13.7 acreDate of start:- 7/9/2013Date of finish:- 22/3/1015Location:- At Hartali more, Bailey Road, PatnaBuilding:- 25000 sq.m of built-up area , all G+1 except administrative block(G+4)Construction blocks:- Block A to IZones:- children’s museum, entrance lobby, auditorium, permanent exhibition etc.

About the museum:-The design of Bihar Museum, Patna has been conceived and developed as a “campus”, an interconnected landscape of buildings and exterior spaces. Each of the program elements –entrance and event spaces, museum exhibition spaces, administration, and children’s educational zone- has been given a distinct presence and recognizable form within the complex. These programs are linked together via a series of interior and exterior courtyards and corridors, ensuring that the interior retains a strong sense of connection to the surrounding landscape. The museum’s exterior is characterized by extensive use of weathering steel, a durable material that reflects the coloration of its context and creates a dignified contrast to the surrounding greenery. The weathering steel symbolizes India’s historical achievements in metallurgy as well as its current and future prominence within the international steel industry- of which Bihar’s rich natural resources have played a critical role.

Work involves the complete Foundation works, RCC works, Waterproofing works, Internal and External Finishing works, MEP works and Site Development works. The site development area is 13.5 acres and the proposed built up area is 25000 SQM. Majority of (G+1) structure with a very small portion being G+4.Floor to floor height is ranging from 4.2m to 9.0m. Quality and standard execution to achieve appropriate GRIHA rating.

Basic Finishes:

Structural Finishing: RCC/MS

Flooring: Granite/Rubber/Vitrified tiles/ Wood

Internal Wall Surfaces: Gypsum /Paint/ Wood Panel/ Stone/ Plaster

External Wall Surfaces: Sandstone/ Limestone/ Granite cladding/

Corten steel panels/Terracotta

Ceilings: Gypsum/ Grid Ceilings/ Wood

Doors/ Windows: MS/ TW/ Aluminium/ SS/ Double glazed

External Areas: Green roofs/ Landscape/ Granite Pavements

/Plantations

Roads: Pervious concrete/ paver blocks/ Cobblestones

EHS and safety induction policies

EHS control and activities Every person should attend safety induction session and obtain PPE(Personal Protection Equipment) before entering the worksite.Open rooftops and excavated pits are well barricaded with iron poles and nylon mesh.Safety instruction is conveyed to works via hoardings, circulars, open sessions with workers and quizzes. Use of eye protection equipment to the workers engaged in welding, cutting, chipping and grinding.Working above two meters full body harness and anchoring the lanyard of full body harness to Firm support.No one is allowed to take rest below any vehicle.

Figure 1 barricading open rooftops with struts and Nylon mesh

Figure 2 hoarding displaying safety instruction and barricading along excavated pits

Figure 3 Personal protection units (PPE) displayed on site

Materials

1. Extruded Polystyrene (EPS or XPS) Insulation Excellent damp proof performance, which is because EPS is incorporated in walls.  Fire-resistant and toxic-gas-free

2. Cladding MaterialCladding is the application of one material over another to provide a skin or layer intended to control the infiltration of weather elements, or for aesthetic purposes. Cladding does not necessarily have to provide a waterproof condition but is instead a control element.

Benefits

Faster programme times - not affected by weather or labour shortages.

Improves build ability.

Early enclosure of dry envelope enables follow-on trades to start sooner.

Produces a high standard of workmanship in factory conditions - reduces potential for accidents, addresses on-site skill shortage.

Has a high quality finish that can be left exposed - concrete's thermal properties can be exploited in low-energy buildings.

Figure 4 Different samples wall cladding material to be employed

Fly ash bricks Constituents are cement (10 to 15%), stone dust(50 to 60%) and rest is fly ash. These are machine made bricks manufactured by vibratory and rolling press. These bricks are dried for 1 to 2 days, and the cured at 24 deg C for 21 days. At museum site non- modular bricks (230x70x10), which was custom made as per order, are

being used. Class 10 bricks being used at Bihar museum site, here 10 is compressive strength 10N/mm2

Benefits Bricks are uniform in shape, therefore less mortar and plaster thickness is required. It is environment friendly and uses by product from the Electro Static Precipitator

(ESP) of thermal power plant. Efflorescence value is very low. Fly ash bricks are also bacterial and fungal resistant. Low water absorption value (less than 20%), thus fly ash bricks doesn’t absorb water

from mortar. Better adherence with the mortar because of cement content in fly ash bricks. High strength fly ash (up to 15 N/mm2) can be obtained, while in case of conventional

clay bricks its up to 5 N/mm2

Execution (block B)

Pile Foundation Pile dia-: 500 mm Pile depth -: 25 meter Type of pile :- RCC bored cast in-situ by conventional method (DMC method) Type of cover block: - circular cover block to facilitate lowering. Clear cover:- 75 mm Main and helical bars: - as per BBS of that pile no. Grade of concrete mix :- M30 Slump required:- 150 to 180 Bentonite solution used of specific gravity 1.12 - 1.15 at the time of boring and 1.05

at the time of flushing bored tip, just before concreting.

Steps involved from boring to casting of pedestal

1. Bore hole of required dia up to target depth is bored via mechanical operated auger, in the presence of Bentonite solution (to facilitate direct mud circulation) of appropriate specific density (1.12).

2. Cylindrical reinforcement (welded laps and with helical ties) cage is lowered into the hole.

3. Circular cover blocks (75mm clear cover) are used to ease the lowering.4. Concreting is done with tremie method.5. Generally concreting is done above required level (cut off level), and later chipped off

, due to high concentration of slush and mud in top layer. 6. A layer of PCC (nominal mix 1:4:8) is casted around pile cap to facilitate

reinforcement of pile cap.

7. Pedestal reinforcement and foundation beam are also done along with pile cap reinforcement.

8. Finally pile cap and foundation beam is casted as a monolithic unit.9. If combined concreting is not possible dowels are left in pile cap for foundation

beam.

Figure 5 PCC layer prior to chipping and pile cap reinforcement

Figure 6 chipping off concrete up to cut off level

Figure 7 pile cap reinforcement in progress. Notice the DOWEL rebar left in already casted pile cap (left)

Preparation of Grade Slab1. Compaction (by roller and mechanical vibrator) of soil over which filling is to be

done.2. Field Dry Density test (by core cutter method) is carried out to check percentage

compaction relative to the MDD (Maximum dry density) value.3. The respective area is filled up with sand (Ganga sand) up to 200 mm thickness over

well compacted soil.4. Anti-termite treatment is then done. For which 300 mm depth hole are made in sand

of 20 dia at a spacing of 100 mm. the holes are filled up with anti-termite solution(Chlorpyrifos) on an avg. of 5 liters per square meters.

5. Above anti-termite treatment, respective area is filled with sand up to 100 mm.6. Above sand layer boulder layer is filled up up to 300 mm thickness.7. Boulder gaps are filled with coarse and fine aggregate.8. Above boulder layer, PCC is laid as per thickness mentioned in GFC drawing.9. Above PCC, RCC grade slab is laid out.

Illustrative photos regarding various stages of grade slab preparation

Figure 8 boulder layer( 300 mm) above compacted sand

Figure 9 anti-termite treatment

Figure 10 reinforcement of RCC grade slab

FLAT SLABSFlat Slabs are reinforced concrete slab supported directly by concrete columns without the use of beams.

Figure 11 Flat slabs with drop panel and column head. Slab is thickened around column to resist punching shear

Benefits of flat slab:-

Flexibility in room layout:- Architect can introduce partition wall any where required

Saving in building height:- Lower storey height will reduce building weight due to lower partitions and cladding

to façade. reduce foundation load

Shorter construction time:- Flat plate design will facilitate the use of big table formwork to increase productivity.

Ease of installation Mechanical and Electrical services.

Disadvantages of Flat slabs:-

Punching shear:- TO resist punching shear failure shear reinforcement in the form of shear heads, shear studs or stirrup cages are to be embedded in the slab to enhance shear capacity.

Buildings with flat plate design are generally less rigid. Frame action is insufficient to resist lateral loads in high rise buildings.

QA/QC

Project Quality Plan(PQP)To address all the quality requirements, standards and quality assurance mechanisms in a project, a document called 'project quality plan' is developed by the project team. This plan acts as the quality bible for the project and all the stakeholders of the project should adhere to the project quality plan.

Components of project quality plan:-

This describes how the management is responsible for achieving the project quality. The project quality plan should describe a way to manage and control the documents

used in the project. Testing and Quality Assurance Periodic quality audits to measure the adherence to the quality standards.

Figure 12 Snaps from PQP illustrating quality standards to be implemented

Field quality program:-A Field Quality Assurance plan refers to the quality document that lists the checks and tests to be performed on the equipment at the various stages of the erection and commissioning at site.

It may be broken into two type:

1. Material testing report sent by the manufacturer of the material received at site. It involves materials like admixture, rebar, grout materials, acid resistant bricks, anti-termite chemicals, paints, water proofing, XPS foams etc. Quality(chemical and physical) assessment of the material AT SITE is highly uneconomical, so QA/QC department has to depend on MATERIAL TESTING REPORTS sent by the manufacturer.

Figure 13 SAIL's internal Testing Report : - this report is showing chemical analysis and mechanical tests like yield strength, ultimate tensile strength, Elongation test, Bend test, Rebend test etc.

2. Materials tested in QA/QC lab of site:- It includes cement test( fineness, consistency, initial and final setting time, soundness test, compressive strength etc.), aggregate tests (sieve analysis, impact test, moisture content, crushing value, bulk density, flakiness test etc.) water, concrete etc. These tests are to be executed in accordance to the schedule.

Figure 14 Field Quality Plan for cement

LAB TESTSAGGREGATE TEST

 In this test we find out the percentage of the weight of the aggregate sample which gets crushed with respect to the total weight of the sample. This percentage is known as the aggregate impact value and more the aggregate impact value less is the toughness of the road aggregates and vice versa.

Figure 15 Impact value tester in QA/QC lab

FLAKINESS AND ELONGATION INDEX TEST

Flakiness Index is the percentage by weight of particles in it, whose least dimension (i.e. thickness) is less than three-fifths of its mean dimension. Elongation Index is the percentage by weight of particles in it, whose largest dimension (i.e. length) is greater than one and four-fifths times its mean dimension.

CEMENT TESTStandard Consistency of Cement

Consistency means amount of water needed to prepare a plastic mix. .It is necessary to find the consistency because amount of water present in the cement paste may affect the setting time. Standard consistency is indicated by the vicat plunger reading (5 to 7) from the bottom of mould.

Figure 16 Standard Consistency of cement using Vicat’s apparatus with 10 MM DIA plunger

Initial and final setting time

Initial setting time is that time period between the time water is added to cement and time at which 1 mm square section needle fails to penetrate the cement paste, placed in the Vicat’s mould 5 mm to 7 mm from the bottom of the mould.

Final setting time is that time period between the time water is added to cement and the time at which 1 mm needle makes an impression on the paste in the mould but 5 mm attachment does not make any impression.

Figure 17 Initial setting time determination with 1 MM plunger needle

Compressive test of cement

Figure 18 Casting of Concrete Mortar cube using sands of Grade I, II and III.

Quality checks photographs

Figure 19 Poor compaction beneath PCC of plinth beam

Figure 20 REJECTED Boulders due to the presence of large Mica content (reddish). This type of boulders, if used in grade slab, would disintegrate with time.

Formwork and scaffolding

Pre Check

1 Check if the shutters are properly cleaned by removing the concrete/ mortar and

Protruding nails.

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 de-shuttering can

be done easily including provision for re-propping, 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.

19. Check all the inserts/embedment 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

Batching plant

My Learning Experience/ConclusionIt was a wonderful learning experience at L&T Construction B&F’s site of L&T Project for six weeks in Patna .It was good to be part of L&T and witness their work culture and standard. I learned a lot of intricacies of site execution.

For a lay man, a construction site may appear in chaotic state but with efficient management it could be in systematic and orderly, as in the case of L&T’s worksite. At work site I observed practical application of various engineering departments. I gained a lot of insight of about supervision and execution, which included Safety, Earthwork, Formwork and Scaffolding, Reinforcement, Piling, Concreting, QA/QC, Trial mixes and batching plant operation.

Apart from technical stuff, L&T employees shared their invaluable accounts of working at other worksite. Graduate engineering trainees shared their placement interviews experience and also suggested helpful career tips. What I liked most was the younger brother like attitude of employees towards student trainees. I hope these experiences would be cherished for long time and would help in shaping my career.