DMRC HOSPTAL PROJECT,VASANT KUNJ Construction of ILBS Ph: 2

TRAINING REPORT

SUBMITTED BY GAURAV ARORA

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INDEX
S. NO.
01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

TOPIC
Acknowledgement Project overview Prospective views Layout of site Project highlights Site safety rules General Specifications Construction Process Excavation Plain Cement Concrete Water Proofing Laying of Foundation Column Erection and Concreting Beam and Slab casting Scaffolding Shuttering Quality control Lab Some Important Test Results Mix Design M-40 Materials Used in Construction Aggregates Brickwork Machinery Used in Construction Progress report

PAGE NO.
03 05 06 07 08 09 11 12 14 16 17 18 20 22 24 25 27 29 37 39 41 43 45 49

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ACKNOWLEDGEMENT

implex infrastructures Ltd is one of the leading construction companies in India. It was a great experience to be a part of this esteemed organization as trainees. During this short training of 7 weeks, we have been guided by many staff members here at the ILBS Phase-(II) site. We are highly thankful to all the staff to have taken the time off from their busy schedule for explaining each and every minor detail. First and foremost, we are highly obliged to Mr.N.K.Gautam (project manager)for permitting us to actually join the training, and his constant supervision due to which we have come a long way in building a sound practical knowledge. Next, we would like to thank Mr.D. V. Singh (Dy. Project manager) who gave us vital details about the project, relating it to the theoretical concepts and also gave us inputs on how to manage things for optimal output owing to their vast experience, and their timely inputs and checks have actually helped me go into every detail of the project. We are very much thankful to Mr.H.K.Batacharia (QA/QC incharge and various executive engineers, supervisors, foremen at different blocks, who very selflessly gave us all the details of the construction methodology, and would take out their valuable time to answer all our queries. They have really guided us all along the project and have taken pains so as to make this training period worthwhile for us. we would also like to thank all other staff members of simplex infrastructuresfor providing us with the necessary details for our training. Last, but not the least, we would like to thank all the DMRC (Client) members and staff at the ILBS phase-II site for their cooperation.

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P R O J E C T OV E R V I E W
Name of Work: Sciences (structural work) (Phase-II), D-1, Vasant Kunj, New Delhi. Owner: Occupant: Directorate of Health Services, GVCTD PD/ILS, Dr. S.K. Sareen DMRC Ltd. Construction of Institution of Liver and Binary

Project Management Consultant: Master Consultant: Ahmadabad. Estimated Cost: Plot Area: Period of Completion: Total Build up Area:

M/s Gautam Shah & Associates, 121.52 crs. 2.63+.423=3.043 ha 18 months 83655 m2

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PROSPECTIVE VIEWS

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PROJECT HIGHLIGHTS AREA DETAILS AS PER DRAWING-ILBS(PH-II) S. NO . 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. BLOCK/BUILDING PARKING PLAZA-6 PARKING PLAZA-7 PARKING PLAZA-8 CLINICAL BLOCK-1 CLINICAL BLOCK-2 ACADEMIC BLOCK ATRIUM BLOCK VIVARIUM BLOCK SERVICE YARD LINEAR AND SUNKEN COURT YARD TOTAL RAFT AREA AT L/BASEMENT RAFT AREA (m2) 1575.45 1047.00 1554.33 1927.10 1141.38 1500.73 1946.96 2624.76 BUILDING AREA AT L/BASEMENT (m2) 1575.45 965.07 1373.90 1854.33 1141.38 1300.00 1946.96 2334.22 BUILDING AREA AT U/BASEMENT (m2) 1575.45 1126.42 1617.76 1854.33 1141.38 1300.00 1946.96 2163.00 730.00 668.51 BUILDING AREA AT GROUND FLOOR(m2)

1854.33 1141.38

13317. 71

12682.80

S. NO . 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14.

NAME OF BLOCK NURSES HOSTEL INTERNS HOSTEL ACADEMIC BLOCK ADMIN PARKING-6 PARKING-7 PARKING-8 CLINICAL BLOCK-1 CLINICAL BLOCK-2 ATRIUM VIVARIUM CONNECTING BRIDGES MECH AREA MISCELLANEOUS TOTAL

BUILT UP AREA(m2) 4879 5756 7496 1027 2892 1892 2754 31165

NO. OF FLOORS G+7 G+8 G+5 3 FLOORS 2 BSMNT 2 BSMNT 2 BSMNT 2B+G+5 2B + G+5 2B+ G+5 G+3 ALL FLOORS WITH PHASE-I UB

14404 1674 5603 4133 83677

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SITE SAFETY RULES

Manager/Engineer/Supervisors Responsibilities at the site

1. Understand the companys and clients safety plan fully and follow the same in their day to day work activities. 2. Be familiar and show commitment to the implementation of our companys Health & Safety Plan. 3. Ensure that all persons undergo Health & Safety training before they are deployed at the site. 4. Ensure that employees working under them implement relevant requirements of this safety plan 5. Giving safety instructions to their workmen on a daily basis as a part of the job instructions, highlighting the possible hazards of the days work and the precautions to be taken. 6. Ensuring that the technicians under them are issued with necessary PPEs and they use the same. 7. Identify weakness and deficiencies in job procedures, rectified these if possible and where necessary refer these to the Project Manager / Safety Representatives. 8. Keep their work area neat and clean, especially at heights free from loose materials 9. Promote the continuous improvement of Health & Safety performance. 10.Verifying the third party test certificates while hiring cranes of any lifting appliances for their validity. 11.Preventing horseplay of workmen. 12.Organizing and conducting tool box talks to their workmen every day. 13.Identifying and eliminating all unsafe conditions in their respective work area by carrying out safety inspection every day. 14.Take suitable corrective measures to rectify the unsafe observations pointed out by safety Engineers in his inspection report. 15.Inform their Respective Manager & Safety Representatives about ACCIDENT, NEAR-MISS & FIRST AID Case.

SAFETY IS THE RESPONSIBILITY OF EVERYBODY BE SAFE ALWAYS

GO FOR ZERO ACCIDENT

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SITE SAFETY RULES

1. OPERATIVES Make sure you attend a site safety introduction prior to commencing work. Safety Helmets, High visibility vests and safety footwear are mandatory on site. Possession and consumption to Alcohol/drugs is prohibited. Smoking prohibited at work areas.

2. WORK AREAS Do not cross barriers or no entry areas. Keep your work area clean, tidy and maintain good housekeeping. All openings should be covered. Scaffolding only to be erected dismantled or altered by an authorized competent person. Use ladder, never climb on scaffolds. Never remove guard rails. Never tamper with Electrics. Only authorized person should operate electrical power tools. 3. UNPLANNED EVENTS Report all accidents including near misses. Know the best means of escape from your work area and your assembly point in case of emergency. Use proper fire extinguisher to extinguish the fire. 4. PLANT & EQUIPMENT Only authorized operators and drivers should operate plant/equipment /vehicle. Always use the right tool for the right job. 5. GENERAL Follow safety signs, instructions and site safety rule. Inform your supervisor, if something is in unsafe in your activity. Never carry out any operations, which may cause danger or injury to any person or loss of property. WE TAKE PRIDE IN EVERYONE RETURNING HOME SAFELY EVERYDAY

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GENERAL SPECIFICATION
DE-SHUTTERING PERIOD IN NORMAL CIRCUMSTANCES Forms shall be removed after expiry of the following period. 1. Walls, columns, vertical faces for all structural members including sides of beams 24 Hrs 2. Slabs Spanning up to 4.5 m Spanning over 4.5 m Spanning up to 6 m Spanning over 6 m - 7 Days -14 Days -14 Days -21 Days

3. Beams and arches

NOTE FOR R.C.C. WALLS 1. Concrete grade for shear walls and retaining walls shall be M45. 28 days cube strength shall be 45 N/mm2, unless specified otherwise. 2. Clear cover to main steel shall be 30 mm in retaining wall and shear wall. 3. Horizontal steel links to be provided to keep wall steel in proper position.

NOTE FOR R.C.C. BEAM AND SLAB 1. Concrete grade for beam and slab shall be M45. 28 days cube strength shall be 45 N/mm2, unless specified otherwise. 2. Clear cover to main steel shall be 35 mm in beam and 30 mm in slab.

NOTE FOR COLUMN 1. Concrete grade for column shall be M45. 28 days cube strength shall be

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45 N/mm2, unless specified otherwise. 2. Clear cover to main steel shall be 40 mm in column. 3. Suspender bars shall not be applied. The supporting beam has achieved by full development length. Support of beam supported by supported by suspender members shall not be removed until the supporting beam has achieved full specified strength. 4. Lapping of bars/additional bars shall be lapped only in lapping zone (not more than 50% of bars shall be lapped at any section) NOTE FOR R.C.C FOOTING 1. SBC is considered as 20 T/m2 at a depth of 3 m from NGL for Nurse hostel. 2. SBC is considered as 32 T/m2 at a depth of 7 m from NGL for hospital building. 3. Concrete grade for footing shall be M30. 28 days cube strength shall be 30 N/mm2, unless specified otherwise. 4. Clear cover shall be 50 mm. NOTE FOR R.C.C. WORKS 1. All concrete shall be machine mixed and machine vibrated. 2. Steel chairs shall be provided to keep top steel of slab in position. 3. T- indicates high yield strength deformed bars confirming to IS:1786 or equivalent with 0.2% proof stress of 500 N/mm2 as specified in D.B.R. 4. Lap length shall be 36 times the dia of bars for M45, and 46 times for M30 concrete mix. 5. Curing of concrete members shall be carried out for a minimum period of 12 days after casting by jute bags kept constantly wet or such other means. 6. Reinforcement shall be adjusted suitably at the site for providing clearances for thinnest unless specified otherwise on drawing. 7. PCC used shall be of 1:3:6 mix. 8. No lap should be provided in 2 times effective depth of beam from face of support.

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CONSTRUCTION PROCESS
Construction process undergoes by this series.
1. Site clearance&decommissioning

2. Demarcation of site 3. Positioning of central coordinate & layout 4. Excavation 5. Plain cement concrete
6. water proofing

7. Layout of foundation 8. Column erection 9. Beam and slab

Site Clearance& Decommissioning- Site clearance means removing all the buildings and facilities from a site. It might also include ground remediation where soil has been contaminated radiologically or by other agents. Decommissioning is the process related to decontaminating and removing buildings or other structures; and clean up is concerned with ground remediation of contaminated land. Site clearance is, therefore, a combination of decommissioning and cleans up. Demarcation of Site- The whole area on which construction is to be done is marked so as to identify the construction zone. In our project, area was chosen and the respective marking was done.The marking is done on bases of points given by surveyors. Positioning of Central coordinate and layout- The centre point was marked with the help of a thread and plumb bob as per the grid drawing. With

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respect to this center point, all the other points of columns were to be decided so its exact position is very critical.

EXCAVATION
Excavation was carried out both manually as well as mechanically. Normally 12 earth excavators were used for excavating the soil. Adequate precautions are taken to see that the excavation operations do not damage the adjoining structures. Excavation is carried out providing adequate side slopes and dressing of excavation bottom. The soil present beneath the surface was too clayey so it was dumped and was not used for back filling. The filling is done in layer not exceeding 20 cm layer and then its compacted. Depth of excavation was -11.50mtr from Ground Level. Excavation is done at angle of 45.The advantage to excavate the site on 45 is that the side soil doesnt fall in excavated area. The excavation is done by excavators and the excavated soil is transported by truck. Drawings Required 1. Centerline Drawing 2. Layout Plan Scope of the work:

Setting out of corner benchmarks. Survey for ground levels. Survey for top levels Excavation to approved depth. Dressing of loose soil. Making up to cut off level

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Constructing dewatering wells and interconnecting trenches. Marking boundaries of the building. Constructing protection bunds and drains

Removal of Excess Soil Estimate the excavated stuff to be re-utilized in filling, gardening, preparing roads, etc.As far as possible try to carry excavation and filling simultaneously to avoid double handling. Select and stack the required material in such a place that it should not obstruct other construction activities. The excess or unwanted material should immediately be carried away and disposed off by employing any of the following methods.

Departmental labour. Tractor. Trucks.

QUALITY CHECKS FOR EXCAVATION

Recording initial ground level and check size of bottom. Disposal of unsuitable material for filling. Stacking suitable material for backfilling to avoid double handling. Strata classification approval by competent authority. Dressing bottom and sides of pits as per drawing with respect to centerline. Necessary safety measures observed.

QUALITY CHECKS FOR FILLING

Recording initial ground level Sample is approved for back filling. Necessary marking/ reference points are established for final level of backfilling. Back filling is being carried out in layers (15cm to 20cm). Required watering, compaction is done. Required density is achieved.

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FIGURE 1 EXCAVATOR IN ACTION

PLAIN CEMENT CONCRETE (P.C.C)

After the process of excavation, laying of plain cement concrete that is PCCis done. A layer of 75mm was made in such a manner that it was not mixed with the soil. It provides a solid base for the raft foundation and a mix of 1:4:8 that is, 1 part of cement to 4 parts of fine aggregates and 8 parts of coarse aggregates by volume were used in it. Plain concrete is vibrated to achieve full compaction. Concrete placed below ground should be protected from falling earth during and after placing. Concrete placed in ground containing deleterious substances should be kept free from contact with such a ground and with water draining there from during placing and for a period of seven days. When joint in a layer of concrete are unavoidable, and end is sloped at an angle of 30 and junctions of different layers break joint in laying upper layer of concrete. The lower surface is made rough and clean watered before upper layer is laid Materials and Tools used

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Auto level instrument Wooden /Steel rammer Mixer machine

Scope of work

Verifying levels and dimension Ramming the earth surface Placing the concrete. Ramming and finishing the concrete surface

Working Procedure

Excavation levels and dimensions to be checked as per drawings. Remove all the loose earth from the pits. Do water sprinkling and ramming the cleaned surface of pit by mechanical rammer. Do the shuttering by planks and runners wherever if necessary. Mix the concrete with required proportion and water cement ratio by mechanical mixer machine and place the same in to pits. Poured surface to be rammed and finished smoothly.

WATER-PROOFING
The moisture present in the ground or rain water may penetrate into the building from below, from side and also sometimes from the top of its roof, causing the structure to remain in damp condition and thus deteriorating the structure as a whole. It is therefore, very essential to prevent any moisture penetrating into a building now-a-days, care is taken while designing and constructing any building so that dampness can be prevented from affecting it and its inhabitants. There are various methods of water-proofing but at our site Kota stone with grouting is used as water-proofing because they are very impervious. METHODS OF WATER-PROOFING After laying P.C.C (75 mm thick) first we clean the surface by the help of blower.

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After cleaning the surface the cement sand mortar is prepared. We add 1 litre Siko in 1 bag cement and the same is applied in 25 mm thick layer. Then Kota stone is laid in cement mortar (1:4) (25 mm thick). After laying Kota stone gap between stone and P.C.C is filled with slurry. And then 25 mm protection coat of cement plaster is applied.

KOTA STONE IS USED AS WATER-PROOFING MATERIAL BECAUSE 1. 2. 3. 4. It It It It 5. It is impervious to moisture. is durable. does not disintegrate under loading. provide uniform and homogeneous layer. is easily available.

LAYING

OF

FOUNDATION

At our site, Raft foundations are used to spread the load from a structure over a large area, normally the entire area of the structure. Mat foundations are used to distribute heavy column and wall loads across the entire building area, to lower the contact pressure compared to conventional spread footings. Mat foundations can be constructed near the ground surface, or at the bottom of basements. In high-rise buildings, mat foundations can be several meters thick, with extensive reinforcing to ensure relatively uniform load transfer.Raft foundations have the advantage of reducing differential settlements as the concrete slab resists differential movements between loading positions. They are often needed on soft or loose soils with low bearing capacity as they can spread the loads over a larger area.

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In laying of raft foundation, special care is taken in the reinforcement and construction of plinth beams and columns. It is the main portion on which ultimately whole of the structure load is to come. So a slightest error can cause huge problems and therefore all this is checked and passed by the engineer in charge of the site. METHOD OF LAYING OF FOUNDATION

First we study the drawing. After study the drawing B.B.S. (BAR BENDING SCHEDULE) is prepared by the engineer. Then the B.B.S. is passed at senior level. After B.B.S. is passed reinforcement is prepared by reinforcement gang at steel yard with the help of bar bending machine, bar cutting machine etc. When reinforcement is prepared it is taken to the site (at working place) with the help of tractor, tower crane, manually. Then formwork is prepared for foundation by carpenter gang. Then the reinforce bar is tied as per drawing specifications by reinforcement gang under supervision of engineer. Cover blocks are providing at bottom, sides and ends of foundation of 50mm. After completing the reinforcement it is checked by the senior officers. When the reinforcement is passed, we ready for next step of concreting. The depth of foundation at our site including finishing: - 11.50 meters Steel reinforcement used in foundation: - T20, T25 &T32 Concrete Grade used in foundation: - M30

COLUMN ERECTION AND CONCRETING

Concrete columns are used for carrying loads of a building. They transfer the same to a suitable soil bearing capacity. They carry loads horizontally, vertically and laterally. They can be erected as free standing, used for hanging gates. Alternatively they can be incorporated within the walls of a building

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structure. Concrete columns are made from steel and concrete cast in a formwork. These are done in circular, rectangular or square shapes. METHODS OF COLUMN ERECTION: In erecting concrete columns the load to be carried is considered. This determines the size of column and type of reinforcement to use. After that surveyor give us some point for starter of column. Then the starter is provided as per points. Formwork of the required column size is formed first aside. The steel should be free from oils and rust. Use binding wire to tie together all steel. Its important to cast concrete in lifts. This should not exceed two thousand five hundred millimeters in height. When the steel work is complete, then form work assembly starts. The formwork for erecting a column is fixed by opening the sides. Its then slid to have the steel inside the box. Once the box is upright, the form work is then fastened and supported on all sides. Concrete is then poured and vibrated until it reaches the top of the box. It is left for seven days. Curing is done from the top. After seven days the form work is then removed to expose the cast column. This is continuously cured for another seven days.

CARE TAKEN WHILE COLUMN ERECTION A proper tie of reinforcement is done. Lap length should by according to drawing. Cover blocks are provided at suitable intervals. Board used should not be in damage condition. Staging should be done properly. Alignment should be proper. REINFORCEMENT USED IN COLUMNT16, T20, T25, & T32 STIRRUPS (RINGS), LINKS USED: -T8 & T10

FIGURE 2 COLUMN DRAWING

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VARIOUS SIZES OF COLUMN USED ON SITE: 1200 mm 750 mm 300 mm 600 mm 300 mm 750 mm 300 mm 950 mm 600 mm 600 mm 300 mm 900 mm 950 mm 600 mm 900 mm 600 mm 600 mm 750 mm 1300 mm 300 mm

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Fig. showing Column reinforcement

column curing

(Stirrups)

Wet Jute bags used for curing

BEAM AND SLAB CASTING

MATERIALS AND MACHINERY USED

Batching plant. Transit mixer Concrete pump Vibrators Chute and CI Pipes

SCOPE OF WORK

Marking the slab Placing the reinforcement Form work for slab Placing the concrete

REINFORCEMENT It shall be as per BBS prepared according to approved drawing. The R/F shifting and binding shall be started as soon as shuttering is completed. R/F binding shall continue as formwork and shuttering work is progresses. PRODUCTION AND PLACEMENT OF CONCRETE Stock of material shall be sufficient to start the concrete. It shall be ensured by stores/purchase dept. that concreting is not stopped on account of materials. All plant and machinery are checked and made in working conditions. Proper walkways/platforms shall be arranged so that the supports of the pipeline and manpower are not directly stand on reinforcement. Sufficient carpenters along with supervisor shall inspect the behavior of supports below the slab during the casting. Extra Props shall be stocked below slab to provide additional supports in case of any failure of supports. CURING

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The curing shall be started immediately after thumb set of the concrete laid. Final curing shall be done by ponding and stacking water for minimum period of 7 days.

FIGURE 3-BEAM AND SLAB REINFORCEMENT

Mechanical vibrator

FIGURE 4 CONCRETING OF SLAB

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SCAFFOLDING
Scaffolding is a temporary structure used to support people and material in the construction or repair of buildings and other large structures. It is usually a modular system of metalpipes or tubes, although it can be made out of other materials. Bamboo is still used in some Asian countries. The purpose of a working scaffold is to provide a safe place of work with safe access suitable for the work being done.

SHUTTERING
Shuttering or form work is the term used for temporary timber, plywood, metal or other material used to provide support to wet concrete mix till it gets strength for self support. It provides supports to horizontal, vertical and inclined surfaces or also provides support to cast concrete according to required shape and size. The form work also produces desired finish concrete surface. Shuttering or form work should be strong enough to support the weight of wet concrete mix and the pressure for placing and compacting concrete inside or on the top of form work/shuttering. It should be rigid to prevent any deflection in surface after laying cement concrete and be also sufficient tight to prevent loss of water and mortar form cement concrete. Shuttering should be easy in handling, erection at site and easy to remove when cement concrete is sufficient hard. Generally there are three types of shuttering.

Steel Shuttering Wooden Planks Shuttering Temporary Brick Masonry Shuttering

FIGURE 5BASIC SCAFFOLD DIMENSIONING TERMS. NO BOARDS, BRACING OR COUPLERS SHOWN

WOODEN PLANK

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SHUTTERING:Generally wooden planks shuttering is used by contractors because this shuttering is cheap and easily available. But this type of shuttering affects the strength of concrete and has some disadvantages which are given below. DISADVANTAGES

This is not water tight shuttering as the size and thickness of planks differ and are not of same size. Due to this difference the water and cement flow to the ground from joints and reduce the strength of concrete. Bottom level of RCC slab is not in straight line and the surface being uneven, the thickness of plaster is more which remains weak. Due to leakage of cement slurry through joints, earth work below 'Ballies may settle and create problems. In some cases wooden planks cannot bear the weight of concrete. Due to low strength there is bending or deflection in wooden planks. Sometimes the planks may break.

PRECAUTIONS FOR VERTICAL SUPPORTS FOR RCC BEAMS, SLABS ETC

The 'Ballies used for vertical support should not be less than 6'' dia and these should be in one length without joints. Never allow bricks support of more than one or two bricks below a 'balli' to make required height. Cross Ballies or bracing should be done for better support to beam as well as slab. The wooden batten used below the plate should not be less than 5'' in height. At the time of concreting one carpenter with helper having spare ballies, nails etc. should be deputed for watching any disturbances in ballies under shuttering.

REMOVAL OF SHUTTERING As a guideline, with temperature above 20 degree following time limits should be followed:

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STRUCTURAL COMPONENT Footings Sides of beams, columns, lintels, wall Underside of beams spanning less than 6m Underside of beams spanning over 6m

Age 1 day 2 days 14 days 21 days Underside of slabs spanning less than 7 days 4m Underside of slabs spanning more than 14 4m days Flat slab bottom 21 days

FIGURE 6 SLAB FORMWORK

QU A L I T Y C O N T R O L
Instruments in lab:

FIGURE 7 VICATS APPARATUS

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1. Baby Mixture machine 2. Mechanical platform vibrator 3. Sieve shaker 4. CTM (compression testing machine) 5. Electric oven 6. Aggregate impact value testing machine 7. Rapid moisture meter 8. Flakiness index testing equipment 9. Elongation index testing equipment 10. 11. 12. 13. 14. Weighing balance 15Kg max. Hot pan Vicats apparatus Pyconometer IS standard seives

15. Cubes 70.6 X 70.6 X 70.6 and 150 X150 X 150

FIGURE 14 CTM

FIGURE 13 BABY MIXER

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Various tests conducted: S. No. 01. MATERIALS Stones chips 20 mm 10 mm TESTS Gradation AIV Flakiness and elongation Specific gravity Bulk density Water absorption Gradation Silt content Moisture content Specific gravity Fineness Standard consistency Initial and final setting time Compressive strength Dimensional Compressive strength Water absorption Efflorescence Ash content pH value Specific gravity Silt content Chloride content Dimensional pH chloride Slump test Compressive strength IS CODES IS. 383-1970 IS 2386 PART II IS.2386 PART II IS. 2386 ( Part-iii )1968 IS 2386 IS. 383-1970 IS.383-1970 IS IS IS IS 2386 PART II 4031-1968 4031-1968 4031-1968.

02.

Sand Yamuna sand Banas sand Cement Ultra tech53G ACC-43G Vikram-43 grade Fly ash and clay bricks

03.

IS 4031-1968 IS.3495-1992

04.

05.

Admixtute

IS 9103-2007

06. 07. 08

Kota stones Water Concrete

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SOME IMPORTANT TEST RESULTS

Project : Construction of Institute of Liver & Biliary Sciences (ILBS) Ph-II (Structural Work) At Vasant Kunj, New Delhi. Client : Delhi Metro Rail Corporation Ltd. Contractor : Simplex Infrastructures ltd. Form No Sample Details Date Of Sampling Source/Location : 03/06/2011 : kothputli /stockyard Date Of Testing Tested By : SIL/QA/LAB/F-06 Rev : Ro Testing Details : 03/06/2011 : sieve set Testing Method: IS. 383-1970

Quantity Of Sample : 5000gm Frequency :- Weekly

Name Of Laboratory:ILBS Field Lab

GRADATION OF 20mm MSA

Sieve Size (mm) 40 20 10 4.75 Pan
Results Remarks

Weight Retained (gm) 0 0 4960 20 8

Cum. Weight Retained 0 0 4960 4980 4988

% Retained 0 0 99.43 99.83 ---

% Of Passing 100 100 0.57 0.17 ---

Specified Limits (%) 100 85 - 100 0 - 20 0-5 ---

: - Acceptable / Not Acceptable : - ____found ok________

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Project : Construction of Institute of Liver & Biliary Sciences (ILBS) Ph-II (Structural Work) At Vasant Kunj, New Delhi. Client : Delhi Metro Rail Corporation Ltd. Contractor : Simplex Infrastructures ltd. Form No Sample Details Date Of Sampling Source/Location : 03/06/2011 : kothputli/stockyard Date Of Testing Tested By : SIL/QA/LAB/F-06 Rev : Ro Testing Details : 03/06/2011 : A .I.V apparatus :ILBS Field Lab Testing Method: IS. 383-1970

Quantity Of Sample : 5000gm Frequency :- Weekly

Name Of Laboratory

AGGREGATE IMPACT VALUE TEST

Description Weight of Surface Dry Sample Passing Is Sieve 12.5mm But Retained on Is Sieve 10.0mm (W1) gm Weight Passing Through Is Sieve 2.36mm After the Test (W2) gm Weight Retained over Is Sieve 2.36mm After the Test (W3) gm A.I.V (%) = (W2 / W1) X 100 Average Value Of A.I.V. (%) Trial 1 345 71 274 20.58 Trial 2 352 76 276 21.59 20.58 Trial 3 348 71 277 20.40

Results : - Acceptable / Not Acceptable Limits : - Not more than 30 % for wearing surfaces & 45 % for Non wearing surfaces. Remarks : - ___Found ok_______________________________

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Project (ILBS) Client Contractor Form No Sample Details Date Of Sampling Source/Location : 08/06/2011

: Construction of Institute of Liver & Biliary Sciences Ph-II (Structural Work) At Vasant Kunj, New Delhi. : Delhi Metro Rail Corporation Ltd. : Simplex Infrastructures ltd. : SIL/QA/LAB/F-06 Date Of Testing Tested By Rev : Ro Testing Details : 08/06/2011 : sieve set :ILBS Field Lab Testing Method: IS. 383-1970

: kothputli /stockyard

Quantity Of Sample : 5000gm Frequency :- Weekly

Name Of Laboratory

GRADATION OF 10mm MSA

Sieve Size Weight (mm) Retained (gms) 12.5 10 4.75 2.36 Pan
Results Remarks

Cum. Weight Retained 0 130 4717 4934 4954

% Retained 0 2.62 95.21 99.21 ---

% Of Passing 100 97.38 4.79 0.41 ---

Specified Limits (%) 100 85 - 100 0 - 20 0-5 ---

0 130 4587 217 20

: - Acceptable / Not Acceptable : - _found ok

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Project Client Contractor Form No Sample Details Date Of Sampling Source/Location Frequency :- Weekly

: Construction of Institute of Liver & Biliary Sciences (ILBS) Ph-II (Structural Work) At Vasant Kunj, New Delhi. : Delhi Metro Rail Corporation Ltd. : Simplex Infrastructures ltd. : SIL/QA/LAB/F-06 Date Of Testing Tested By Rev : Ro Testing Details : 09/06/2011 : apparatus Testing Method: IS. 383-1970

: 09/06/2011 : kothputli/stockyard

Quantity Of Sample : 2*5000gm

Name Of Laboratory :ILBS Field Lab

FLAKINESS+ ELONGATION INDEX TEST

Weight of Weight of Sample Sample Weight of Passing Retained Sample Passin Through Through Retained (W) g Flakiness Flakiness Gauge (A) Gauge (B)
63 50 40 31.5 25 20 16 12.5 10 Total 50 40 31.5 25 20 16 12.5 10 6.3 ------------1526 1268 1056 768 489 5107 -------------156 168 156 124 98 702 ------------1370 1100 900 644 391

Sieve Size (mm)

Weight of Sample Passing Through Elongation Gauge (C)

------------1205 912 735 515 306

Weight of Sample Retained Through Elongation Gauge (D)

------------165 188 165 129 85 732

Remarks

maximum 30%

Results

:- A) Flakiness Index = ____13.75% B) Elongation Index = ____14.33% C) Flakiness + Elongation = _28.08% Limits : - Not More Than 35%

Remarks : - found ok

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Project Client Contractor Form No Sample Details Date Of Sampling Source/Location Frequency :- Weekly

: Construction of Institute of Liver & Biliary Sciences (ILBS) Ph-II (Structural Work) At Vasant Kunj, New Delhi. : Delhi Metro Rail Corporation Ltd. : Simplex Infrastructures ltd. : SIL/QA/LAB/F-06 Date Of Testing Tested By Rev : Ro Testing Details : 08/06/2011 : sieve set Testing Method: IS. 383-1970

: 08/06/2011 : Yamuna nagar

Quantity Of Sample : 1500gm

Name Of Laboratory :ILBS Field Lab

GRADATION OF FINE AGGREGATE

Sieve Size (mm) 10 4.75 2.36 1.18 0.6 0.3 0.15 PAN Weight Retained (gms) 0 82 120 110 432 496 166 82 % of Cum. Weight % Passin Retained Retained g 0 82 202 312 744 1240 1406 1488 0 5.51 13058 20.97 50.00 83.33 94.49 ---100 86.42 79.03 50.00 16.67 5.51 ---Specified Limits (%) Zone I 100 Zone II 100 Zone III 100 Zone IV 100

94.49 90 - 100 90 - 100 90 - 100 95 - 100 60 - 95 75 - 100 85 - 100 95 - 100 30 - 70 15 - 34 05 20 0 - 10 ----55 - 90 35 - 59 08 - 30 0 - 10 ----75 - 90 60 - 79 12 40 0 - 10 ----90 - 100 80 - 100 15 - 50 0 - 15 -----

Results Remarks confirmed___________________

: - Accepted/ Not Accepted : - _____found ok_/zone-II

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Project Client Contractor Form No Sample Details Date Of Sampling Source/Location Frequency :- Weekly

: Construction of Institute of Liver & Biliary Sciences (ILBS) Ph-II (Structural Work) At Vasant Kunj, New Delhi. : Delhi Metro Rail Corporation Ltd. : Simplex Infrastructures ltd. : SIL/QA/LAB/F-06 Date Of Testing Tested By Rev : Ro Testing Details : 03/06/2011 :ultratech opc 53G Testing Method: IS. 383-1970

: 03/06/2011 :khor-neemuch

Quantity Of Sample :2000gm

Name Of Laboratory :ILBS Field Lab

FINENESS TEST OF CEMENT

Serial No. 01 02 03 Weight of Cement Sample (W1) 200 200 200 Weight of Residue (W2) 7 6 6 % Weight of Residue (W2/W1)*100 3.50 3.00 3.00 3.167 Average % of Residue

Specified Limits Results Remarks

: - Not More Than 10 % : - Acceptable / Not Acceptable : - _____found ok___________

Project Client Contractor

: Construction of Institute of Liver & Biliary Sciences (ILBS) Ph-II (Structural Work) At Vasant Kunj, New Delhi. : Delhi Metro Rail Corporation Ltd. : Simplex Infrastructures ltd.

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Form No Sample Details Date Of Sampling Source/Location Frequency :- Weekly

: SIL/QA/LAB/F-06 Date Of Testing Tested By

Rev : Ro Testing Details : 24/06/2011 : vicats apparatus Testing Method: IS. 383-1970

: 24/06/2011 : khor- neemuch

Quantity Of Sample : 2000gm

Name Of Laboratory :ILBS Field Lab

INITIAL AND FINAL SETTING TIME OF CEMENT

Quantity of Water Added (ML) 95.2 Depth Of Penetration From Bottom 3 4 5 ---150 ---Not Less than 30 Minutes 230 Not More than 600 minutes

Trial No. 01

Time (Minutes) 3:15 4:30 5:10 5:45 7:05

Initial Setting Final Setting

Specified Limits

Results Remarks

: - Acceptable / Not Acceptable : - ____found ok_________________

Project Client Contractor Form No Sample Details

: Construction of Institute of Liver & Biliary Sciences (ILBS) Ph-II (Structural Work) At Vasant Kunj, New Delhi. : Delhi Metro Rail Corporation Ltd. : Simplex Infrastructures ltd. : SIL/QA/LAB/F-06 Rev : Ro Testing Details

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Date Of Sampling Source/Location Frequency :- Weekly

: 24/01/2011 : khor- neemuch

Date Of Testing Tested By

: 24/06/2011 : vicats apparatus

Quantity Of Sample : 2000gm

Name Of Laboratory :ILBS Field Lab Testing Method: IS. 383-1970

CONSISTENCY TEST OF CEMENT

Trial No. 01 02 03 Weight Of Cement 400 400 400 Quantity Of Water Added (Ml) 116 112 114 % Of Water Added 29.0 28.0 28.5 Needle Penetration From Bottom 3 5 6

Limits

: - 5 To 7 mm from Bottom Result : - Acceptable / Not Acceptable

Remarks : - ____found ok_________________

D E S I G N M I X M- 4 0
MATERIAL S Cement Sand 20 mm Agg. WT. FOR 1m3 380 637.10 671.06 WATER MOISTUR ABSORTIO E N CONTENT 1.2 4.8 0.3 0.3 CORRECT ED WT. 380 660.16 671.06 WT. FOR 12 Kg CEMENT 12 20.847 21.191

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10 mm Agg. Water Admixtur e Fly Ash

447.37 171 1.2% 80

0.4 -

0.4 -

447.30 147.95 5.52 80

14.128 4.672 0.172 2.526

SLUMP (Starting time- 03:35 PM) 0 MINS 185 mm 30 MINS- 110 mm 60 MINS- 90 mm 90 MINSSURFACE AREA OF MOULD= 22500 mm2 STRENGTH 150*150*150 mm3 CUBE ID HAH1 HAH2 HAH3 HAH4 HAH5 HAH6 HAH7 NOTE: WEIGHT(g m) 8360 8360 8400 8440 8420 8440 8400 DENSITY(g/c LOAD(kN c) ) 2.47 2.47 2.48 2.50 2.49 2.50 2.48 1290 860 1400 1530 870 1390 920 VOLUME OF MOULD= 7 DAYS STRENGTH(M Pa) 38.26 38.67 40.80 28 DAYS STRENGTH(M Pa) 57.33 62.22 68.00 61.78 -

Sudden loss of slump in half an hour i.e. lower retention period The cause for this is lesser admixture (0.1% less)

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THE SLUMP TEST

FIGURE 9 SLUMP CONE

FIGURE 8

FIGURE 10CONCRETE TESTING - SKETCH SHOWING THE METHOD OF TESTING THE AMOUNT OF WATER IN A GIVEN MIX, CALLED THE SLUMP TEST.

MATERIALS USEDINCONSTRUCTION
CEMENT

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In the most general sense of the word, a cement is a binder, a substance that sets and hardens independently, and can bind other materials together. Cement used in construction is characterized as hydraulic or non-hydraulic. Hydraulic cements (e.g.,Portland cement) harden because of hydration, chemical reactions that occur independently of the mixture's water content; they can harden even underwater or when constantly exposed to wet weather. The chemical reaction that results when the anhydrous cement powder is mixed with water produces hydrates that are not water-soluble. Non-hydraulic cements (e.g., lime and gypsumplaster) must be kept dry in order to retain their strength. The most important use of cement is the production of mortar and concretethe bonding of natural or artificial aggregates to form a strong building material that is durable in the face of normal environmental effects. The Bureau of Indian Standards (BIS) has classified OPC in three different grades The classification is mainly based on the compressive strength of cement-sand mortar cubes of face area 50 cm2 composed of 1 part of cement to 3 parts of standard sand by weight with a water-cement ratio arrived at by a specified procedure. The grades are 33 grade 43 grade 53 grade

The grade number indicates the minimum compressive strength of cement sand mortar in N/mm2 at 28 days, as tested by above mentioned procedure.

PORTLAND CEMENT:
Cement is made by heating limestone (calcium carbonate), with small quantities of other materials (such as clay) to 1450 C in a kiln, in a process known as calcination, whereby a molecule of carbon dioxide is liberated from the calcium carbonate to form calcium oxide, or quicklime, which is then blended with the other materials that have been included in the mix . The resulting hard substance, called 'clinker', is then ground with a small amount of gypsum into a powder to make 'Ordinary Portland Cement', the most commonly used type of cement (often referred to as OPC).

THE SETTING OF CEMENT

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Cement sets when mixed with water by way of a complex series of hydration chemical reactions still only partly understood. The different constituents slowly hydrate and crystallize while the interlocking of their crystals gives to cement its strength. After the initial setting, immersion in warm water will speed up setting. In Portland cement, gypsum is added as a compound preventing cement flash setting. The time it takes for cement to set varies; and can take anywhere from twenty minutes for initial set, to twenty-four hours, or more, for final set.

FIGURE 11 CEMENT GODOWN

STORAGE OF CEMENT: It needs extra care or else can lead to loss not only in terms of financial loss but also in terms of loss in the quality. Following are the dont that should be followed Do not store bags in a building or a godown in which the walls, roof and floor are not completely weatherproof. Do not store bags in a new warehouse until the interior has thoroughly dried out. Do not be content with badly fitting windows and doors, make sure they fit properly and ensure that they are kept shut. Do not stack bags against the wall. Similarly, dont pile them on the floor unless it is a dry concrete floor. If not, bags should be stacked on wooden planks or sleepers. Do not forget to pile the bags close together

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Do not pile more than 15 bags high and arrange the bags in a headerand-stretcher fashion. Do not disturb the stored cement until it is to be taken out for use. Do not take out bags from one tier only. Step back two or three tiers. Do not keep dead storage. The principle of first-in first-out should be followed in removing bags. Do not stack bags on the ground for temporary storage at work site. Pile them on a raised, dry platform and cover with tarpaulin or polythene sheet.

AGGREGATES
The aggregates normally used for concrete arenatural deposits of sand and gravel, where available. Insome localities, the deposits are hard to obtain and largerocks must be crushed to form the aggregate. Crushedaggregate usually costs more to produce and will requiremore cement paste because of its shape. More care mustbe used in handling crushed aggregate to prevent poormixtures and improper dispersion of the sizes throughthe finished concrete. At times, artificial aggregates,such as blast-furnace slag or specially burned clay, areused. TYPES OF AGGREGATE. Aggregates aredivided into two types as follows:

FINE AGGREGATE. Fine aggregate isdefined as material that will pass a No. 4 sieve and will,for the most part, be retained on a No. 200 sieve. Forincreased workability and for economy as reflected byuse of less cement, the fine aggregate should have arounded shape. The purpose of the fine aggregate is tofill the voids in the coarse aggregate and to act as aworkability agent. COARSE AGGREGATE. Coarse aggregate is a material that will pass the 3-inch screen and will be retained on the No. 4 sieve. As with fine aggregate, for increased workability and economy as reflected by the use of less cement, the coarse aggregate should have a rounded shape. Even though the definition seems to limit the size of coarse aggregate, other considerations must be accounted for.

When properly proportioned and mixed with cement, these two groups yield an almost void less stone that is strong and durable. In strength and durability, aggregate must be equal to or better than the hardened cement to withstand the designed loads and the effects of weathering. It can be

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readily seen that the coarser the aggregate, the more economical the mix. Larger pieces offer less surface area of the particles than an equivalent volume of small pieces. Use of the largest permissible maximum size of coarse aggregate permits a reduction in cement and water requirements. One restriction usually assigned to coarse aggregate is its maximum size. Larger pieces can interlock and form arches or obstructions within a concrete form. That allows the area below to become a void, or at best, to become filled with finer particles of sand and cement only. That results in either a weakened area or a cement-sand concentration that does not leave the proper proportion to coat the rest of the aggregate.The capacity of the mixing equipment may also limit the maximum aggregate size. GRADATION. Gradation of aggregate refers to the amount of each size of particle used in the mix. Too large a proportion of coarse aggregate leaves voids that require more cement paste to fill. That affects theeconomy of the mix. Too much fine aggregate, besides preventing a good bonding, also increases the surface area that must be coated with cement paste. That weakens the concrete. Good gradation results in a dense mass of concrete with a minimum volume of voids, an economical mix, and a strong structure. Optimum strength, watertightness, and

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durability in the hardened concrete require careful control of aggregate gradation.

FIGURE 12 FINE AGGREGATE FIGURE 13 COARSE AGGREGATE

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BRICKWORK
Brickwork is masonry produced by a bricklayer, using bricks and mortar to build up brick structures such as walls. Brickwork is also used to finish corners, door and window openings etc. in buildings made of other materials. Bricks can be of two types. These are:

Traditional Bricks-The dimension of traditional bricks vary from 21 cm to 25cm in length,10 to 13 cm in width and 7.5 cm in thickness in different parts of country.The commonly adopted normal size of traditional brick is 23 X 11.5 X 7.5 cm with a view to achieve uniformity in size of bricks all over country. Modular Bricks- Indian standard institution has established a standard size of bricks such a brick is known as a modular brick. The normal size of brick is taken as 20*10*10 cm whereas its actual dimensions are 19*9*9 cm masonry with modular bricks workout to be cheaper there is saving in the consumption of bricks, mortar and labour as compared with masonry with traditional bricks.
OF BRICK MASONRY

STRENGTH

The permissible compressive stress of brick masonry depends upon the following factors: 1. Type and strength of brick. 2. Mix of motor. 3. Size and shape of masonry construction.

The strength of brick masonry depends upon the strength of bricks used in the masonry construction. The strength of bricks depends upon the nature of soil used for making and the method adopted for molding and burning of bricks .since the nature of soil varies from region to region ,the average strength of bricks varies from as low as 30kg/sq cm to 150 kg /sq cm. There are many checks that can be applied to see the quality of bricks used on the site.Normally the bricks are tested for Compressive strength, water absorption, dimensional tolerances and efflorescence. However at small construction sites the quality of bricks can be assessed based on following, which is prevalent in many sites.

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Visual check Bricks should be well burnt and of uniform size and color. Striking of two bricks together should produce a metallic ringing sound. It should have surface so hard that cant be scratched by the fingernails. A good brick should not break if dropped in standing position from one metre above ground level. A good brick shouldnt absorb moisture of more than 15-20% by weight, when soaked in water For example; a good brick of 2 kg shouldnt weigh more than 2.3 to 2.4 kg if immersed in water for 24 hours.
TO BE TAKEN IN BRICK MASONRY WORK :-

PRECAUTIONS

Bricks should be soaked in water for adequate period so that the water penetrates to its full thickness. Normally 6 to 8 hours of wetting is sufficient.

A systematic bond must be maintained throughout the brickwork. Vertical jointsshouldnt be continuous but staggered. The joint thickness shouldnt exceed 1 cm. It should be thoroughly filled with the Cement mortar 1:4 to 1:6 (Cement: Sand by volume).

All bricks should be placed on their bed with frogs on top (depression on top of the brick for providing bond with mortar). Thread, plumb bob and spirit level should be used for alignment, verticality andhorizontality of construction. Joints should be raked and properly finished with trowel or float, to provide good bond. A maximum of one meter wall height should be constructed in a day. Brickwork should be properly cured for at least 10 days.

FIGURE 14 BRICKWORK AT SITE

English Bond

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MACHINERY USED IN CONSTRUCTION

CONCRETE MIXER A concrete mixer (also commonly called a cement mixer) is a device that homogeneously combines cement, aggregate such as sand or gravel, and water to form concrete. A typical concrete mixer uses a revolving drum to mix the components. For smaller volume works portable concrete mixers are often used so that the concrete can be made at the construction site, giving the workers ample time to use the concrete before it hardens. An alternative to a machine is mixing concrete or cement by hand. This is usually done in a wheelbarrow; however, several companies have recently begun to sell modified tarps for this purpose. The concrete mixer was invented by ColumbusindustrialistGebhardt Jaeger.

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FIGURE 15 A WHEEL MOUNTED TRANSIT MIXER

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TOWER CRANE Tower cranes are a modern form of balance crane that consist of the same basic parts. Fixed to the ground on a concrete slab (and sometimes attached to the sides of structures as well), tower cranes often give the best combination of height and lifting capacity and are used in the construction of tall buildings. The base is then attached to the mast which gives the crane its height. Further the mast is attached to the slewing unit (gear and motor) that allows the crane to rotate. On top of the slewing unit there are three main parts which are: the long horizontal jib (working arm), shorter counter-jib, and the operators cab. In order to hook and unhook the loads, the operator usually works in conjunction with a signaller (known as a 'dogger', 'rigger' or 'swamper'). They are most often in radio contact, and always use hand signals. The rigger or dogger directs the schedule of lifts for the crane, and is responsible for the safety of the rigging and loads. A tower crane is usually assembled by a telescopic jib (mobile) crane of greater reach (also see "self-erecting crane" below) and in the case of tower cranes that have risen while constructing very tall skyscrapers, a smaller crane (or derrick) will often be lifted to the roof of the completed tower to dismantle the tower crane afterwards.

FIGURE 16 TOWER CRANE AT SITE

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BATCHING PLANT
Concrete Plant, also known as a Batch Plant, is a device that combines various ingredients to form concrete. Some of these inputs include sand, water, aggregate (rocks, gravel, etc.), fly ash, potash, cement, and other ingredients to create concrete. There are two types of concrete plants, ready mix plants and central mix plant. A concrete plant can have a variety of parts and accessories, including but not limited to: mixers (either tilt-up or horizontal (or in some cases, both), cement batchers, aggregate batchers, conveyors, radial stackers, aggregate bins, cement bins, heaters, chillers, cement silos, batch plant controls, and dust collectors (to minimize environmental pollution). The following guidelines apply to the operation of batch plants: All personnel working in the batch plant area should wear hard hats at all times. While persons are working in conveyor line areas, the switches and controls should be secured and tagged so that no one can engage them until all personnel are clear . When hoppers are being loaded, personnel should stay away from the area of falling aggregate. The scale operator should be the only person on the scale platform during batching operations. Housekeeping of the charging area is important. Personnel should do everything possible to keep the area clean and free of spoiled material or overflow. Debris in aggregate causes much of the damage to conveyors. Keep the material clean at all times.

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FIGURE 17 BATCHING PLANT

Bar

Cutting Machines
Reinforced bars are cut with the help of cutting machines (Mechanical hydraulic) which are available with 32 mm diameter to steel. Additionally, its main body is manufactured from 30 mm thick MS plate and has well lubricated heavy-duty gears used for smooth functioning. These are available with clutch systems for safety purpose and its blades can be easily replaced and saves time

Bar Bending Machines

Reinforced bars are bending with highly effective electro hydraulic drive enabled bar bending machines. These machines have predefined bend angle settings for faster bending of rods. Our bar bending machine have got minimum bending radius as small as 2d area and maximum bending angle of 180 degrees. Durable and strong these bending machines work with 5 to 6rpm. Features

Electro hydraulic drive compact & reliable design. Automatic bend angle setting for production run. Safe bending speed: 5 to 6 rpm. Hardened tooling for long life.

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FIGURE 18 BAR CUTTING MACHINE

FIGURE 19 BAR BENDING MACHINE

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Simplex Infrastructures Ltd.

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