ISLAMABAD CAMPUS

DEPARTMENT OF CIVIL ENGINEERING

TITLE: Visit to

Nicholson Monument Taxila

Fauji Cement Wah
New Benazir International Airport (Fateh Jhang)

SUBMITTED TO:

ENGR. WAQAR MUMTAZ

GROUP MEMBERS
1) SYED HUSSNAIN RAZA
2) SHABAN KAYANI
3) M. MUJAHID HUSSAIN
4) MANZOOR KHAN
5) HUSSAIN KHAN
6) FARAZ AHMAD

CONTENTS

Objective .............

Location Detail ...

Material And Dimensions

Nicholson Monument Taxila ...

John Nicholson (East India Company).

History..

Grand Trunk Road (GT Road) Sadak-E-Azam ...

Introduction ..

Old Pictures of GT Road Path Beneath of Nicholson Monument Taxila.. 10

Shape and Structure of GT Road .. 11

Photographic Evidence .. 12

VISIT 01
TIME
DATE

(9:20 AM 09:50 PM)

(02-DEC-2014)

Nicholson Monument Taxila

OBJECTIVE
We visit the Nicholson Monument Taxila and practically observed the Monument Tower
and Old GT Road Construction

To know about the material and shape adopt in these heritage structure.

To know about the procedure and techniques applied on these structures.

LOCATION DETAIL
We visit Nicholson Monument which is located Margalla near Taxila

Location Map Of Nicholson Monument Taxila

MATERIAL AND DIMENSIONS

In Nicholson Monument
White Granite stone slab is used
12 meter of Height
Polygon Square Shape
Down size polygon square dimension is 12 x 12 ft
Up size polygon square is 6 x 6 ft
In GT Road
Flat pieces of stone are used
Boulder and flat Stone tiles are used
Starts from Kabul Afghanistan
End City is kolkata India
1500 miles long
500 years old road

NICOLSON MONUMENT TAXILA

JOHN NICHOLSON (EAST INDIA COMPANY)

Nicholson was born on 11 December 1822 in Lisburn, Ireland, the eldest son of Dr Alexander
Jaffray Nicholson and Clara Hogg. He studied at The Royal School of Dungannon, a public
mixed school, located in Dungannon, County Tyrone, Northern Ireland. Nicholson joined the
army of the British East India Company in 1839.

Brigadier General John Nicholson Statue

John Nicholson

NICHOLSON MONUMENT TAXILA

Nicholson Monument Taxila

HISTORY
This structure erected in1868 is a granite obelisk approximately 40 feet (12 m) in honor of Brig
Gen John Nicholson's who led the assault of Delhi but fell in the hour of victory mortally
wounded at this place. Two structures are located at the foot of Margalla pass and in the shadow
of Nicholson's obelisk. They are reproductions of classical Greek buildings. The Legendary
warrior King, Alexander the Great had passed through this area about 325 BC on his way to
Indian conquest and stayed at TAXILA, 8 km from the obelisk. The ruins of original Grand
Trunk road leading to Afghanistan which is in a semi preserved condition can also be seen in the
area below the monument.

Nicholson monument stands out like a solitary sentinel atop the left side of the MARGALLAH
pass as you go towards TAXILA bearing the hall mark of the site where Sir John Nicholson was
fatally wounded and died on 23rd September 1857 aged 34 years by a local known as Kala Khan.
The local story goes and is documented that one of the ancestors of SARDAR SIKANDAR
HAYAT rescued the wounded Sir John Nicholson and brought him to the safety of WAH
GARDENS and tried to tend to his wounds and look after him. Sir John Nicholson very much
moved by the hospitality and nursing care extended to him that he before his dying breath doled
out a big JAGEER (estate) to the ancestor of Sardar Sikandar Hayat. Sir Gen John Nicholson was
buried in Nicholson cemetery in Kashmir gate in New Delhi where a statue was erected in his
honor showing him holding a naked sword.

GRAND TRUNK ROAD (GT ROAD)

SADAK-E-AZAM
INTRODUCTION
The Grand Trunk Road is one of Asias oldest and longest major roads. For more than two
millennia, it has linked the eastern and western regions of the Indian Subcontinent connecting
South Asia with Central Asia. It runs from Chittagong, Bangladesh west to Howrah, West
Bengal in India, running across Northern Inda into Lahore in Pakistan, further up to Kabul
in Afghanistan. Its former names include UttaraPatha ("Road to North"), Shah Rah-eAzam ("Great Road") or Sadak-e-Azam or Badshahi Sadak.
The route spanning the Grand Trunk (GT) road existed during the Maurya Empire, extending
from the mouth of the Ganges to the north-western frontier of the Empire. The predecessor of the
modern road was rebuilt by Sher Shah Suri, who renovated and extended the ancient Mauryan
route in the 16th century. The road was considerably upgraded in the British period between 1833
and
1860.

Route Map of Grand Trunk Road

HISTORY
GT Road 1,500 mile long, nearly 500 year old much travelled road was built by Sher Shah Suri,
who had ruled North India from 1540 to 1545, in a brief hiatus in the Mughal dynasty between
Babar and Humayun, the road had commenced its journey in Peshawar, and passing through
Rawalpindi and Lahore had entered India where it continued its course through Amritsar, then
Panipat to arrived at New Delhi from where it hurried onwards to Agra, Kanpur and Allahabad,
before finally coming to rest at Calcutta.

OLD PICTURES OF GT ROAD PATH BENEATH OF NICHOLSON

MONUMENT TAXILA

Old Path of GT Road

SHAPE AND STRUCTURE OF GT ROAD

The structure of Old GT Road is adopted by Roman Road which is named as APPIAN WAY.
This is the old and First road design in history the surfacing of APPIAN WAY is made by flat
pieces of Stone and Boulders. The GT Road is same design adopted by Appian way Structure

APPIAN WAY (Rome, Italy)

GT Road Beneath Nicholson (Taxila, Pakistan)

APPIAN WAY (Italy)

OLD GT ROAD (Taxila)

10

PHOTOGRAPHIC EVIDENCE

11

VISIT 02
TIME
DATE

(10:00 AM 12:45 PM)

(02-DEC-2014)

FAUJI CEMENT COMPANY LIMITED (FCCL)

(Village Jhang-Bahtar, District Attock, Pakistan)

12

CONTENTS

Objectives.. 13

Location details. 13

Introduction... 15

Associates companies 16

Products of fauji Cement limited 17

Ordinary Portland Cement (OPC).. 17

Raw Material for OPC.17

Manufacturing of Ordinary Portland Cement (OPC). 18

Major Mineral constituents of Portland Cement 19

Step 1 Quarrying. 20

Step 2 - Raw Material Preparation.. 20

Step 3 Clinkering 20
The Kiln (Pre Heater). 20
The Cooler.. 21

Step 4 - Cement Milling.. 21

Step 5 Packing Of Cement in Bags.. 21

The Role of the Laboratory. 21

Purpose of Laboratories... 22

Control Room.. 22

Photo Graphic Evidence.. 22

Summary.. 25

13

OBJECTIVES
We visited this cement plant to practically observe the procedure adopted on plant
for manufacturing.

To know about the material used on plant for manufacturing of cement.

To know about the new procedures, techniques applied in this plant for
manufacturing of cement.

To know about the different types of machinery and their functions and its uses on
plant during manufacturing of cement.

LOCATION DETAILS
We visit Fauji Cement Company limited village Jhang Bahter, District Attock,
which is located near Wah Cantt at the Distance of 14 KM Far away from Wah
Cantt and 51 KM from Islamabad.

Site Map of Fauji Cement Company Limited

14

INTRODUCTION:FCCL is a public listed company with authorized and paid up capital of Rs. 10 billion and Rs.
7.42 billion respectively. Consequent to financial restructuring, the Fauji Group (Fauji
Foundation, FFCL, FFBL and FOTCO), is now the principal shareholder with 49.35% of equity,
31.79% being that of Fauji Foundation.
FCCL has its cement plant at Jhang Bahtar, Tehsil Fateh Jang, District Attock in the province of
Punjab. Operating since November 1997, it is one of the most efficient and best maintained plants
in the country, functioning at high capacity utilization consistently over the last six years.
Starting at 3,000 tons per day, its capacity was enhanced to 3,700 ton per day of clinker in 2005.
The quality of Portland Cement produced at this plant is widely regarded as the best in the
country and is preferred for the construction of highways, bridges, commercial/industrial
complexes and residential buildings.
In line with expansion trends in the cement industry, Fauji Cement is in contract with Polysius, a
German cement plant manufacturing firm, for installation of the largest single line ever
commissioned in Pakistan, having a capacity of 7,200 tons clinker per day. This will significantly
enhance the annual production capacity to 3.325 million tons, up from the current 1.165 million
tons. The new line is to be commissioned shortly. FCCL has installed Pakistan's first ever Refuse
Derived Fuel (RDF) process at a cost of Rs. 320 million.
About 200-300 tons of refuse is being used per day. This project is a beacon to the entire
industrial sector of the country towards fuel economy and environment friendly practices,
besides, making compost fertilizer as a byproduct.

FAUJI FERTILIZER COMPANY

15

ASSOCIATES COMPANIES:

Fauji Fertilizer Company Limited (FFCL)

Fauji Fertilizer Bin Qasim Limited (FFBL)

Fauji Cement Company Limited (FCCL)

Fauji Kabirwala Power Company Limited (FKPCL)

Foundation Power Company Daharki Limited (FPCDL)

Mari Petroleum Company Limited (MPCL)

Fauji Akbar Portia Marine Terminal (Private) Limited (FAP)

Fauji Oil Terminal & Distribution Company Limited (FOTCO)

Pakistan Marco Phosphor S.A (PMP)

Foundation Securities (Pvt) Limited (FSL)

Askari Cement Limited (ACL)

Askari Bank Limited (ABL)

16

PRODUCTS OF FAUJI CEMENT LIMITED

Ordinary Portland Cement (OPC)

Low Alkali Ordinary Portland Cement (LAOPC)

Sulphate Resistance Cement (SRC)

ORDINARY PORTLAND CEMENT (OPC)

Portland cement is the most common type of cement in general use around the world,
used as a basic ingredient of concrete, mortar, stucco, and most non-specialty grout. It is
a fine powder produced by heating materials in a kiln to form what is
called clinker, grinding the clinker, and adding small amounts of other materials.
Ordinary Portland cement (OPC) which is grey in color, but a white Portland cement is
also available.

ORDINARY PORTLAND CEMENT

FAUJI CEMENT BAG

RAW MATERIAL FOR OPC

Lime Stone
Clay
Iron (Literate)
Retarded (Gypsum)
Coal (Fuel)

Limestone

Clay

Retarded

Iron Literate

Coal

17

MANUFACTURING PROCESS OF ORDINARY PORTLAND

CEMENT (OPC)
Fauji Cement is manufactured from best quality raw materials using dry process.
Major portion of such raw ingredients consists of Limestone and Clay. The raw
materials are quarried, crushed and corrected. After which they are mixed in the
correct proportions to form the best raw mix. The raw mix is then ground in Raw
Mill and subsequently burnt in a rotary Kiln at a temperature around 1450 C. The
raw materials undergo a number of complex chemical reactions in the burning
phase and leave the kiln as Clinker, consisting of agglomerate of clinker minerals.
Finally the clinker and gypsum (about 5 %) is ground to a fine powder called
Cement in a Cement Mill.

Mass Flow Diagram Cement by Dry Process

18

Flow Chart Diagram of Dry Process of Cement

MAJOR MINERAL CONSTITUENTS OF PORTLAND CEMENT

19

Step 1 - QUARRYING
Limestone and a 'cement rock' such as clay or shale are quarried and brought to the
cement works. These rocks contain lime (CaCO3), silica (SiO2), alumina (Al2O3) and
ferrous oxide (Fe2O3) - the raw materials of cement manufacture.

Step 2 - RAW MATERIAL PREPARATION

To form a consistent product, it is essential that the same mixture of minerals is used
every time. For this reason the exact composition of the limestone and clay is determined
at this point, and other ingredients added if necessary. The rock is also ground into fine
particles to increase the efficiency of the reaction.

Step 3 - CLINKERING
The raw materials are then dried, heated and fed into a rotating kiln. Here the raw
materials react at very high temperatures to form 3CaOSiO2 (tricalcium silicate),
2CaOSiO2 (dicalcium silicate), 3CaOAl2O3 (tricalcium aluminate) and 4CaOAl2O3
Fe2O3 (tetracalcium alumino-ferrate)
The Kiln (Pre Heater)
The kiln shell is steel, 78m long and inclined at an angle of 1 in 30. The kiln is heated by
injecting pulverized coal dust into the discharge end where it spontaneously ignites due to
the very high temperatures.
Zone 1: ( 0 - 35 min, 800 - 1100oC )
Decarbonation. Formation of 3CaOAl2O3 above 900oC. Melting of fluxing compounds
Al2O3 and Fe2O3.
heat
CaCO3

CaO + CO2
Zone 2: ( 35 - 40 min, 1100 - 1300oC )
Exothermic reactions and the formation of secondary silicate phases as follows:
Heat
2CaO + SiO2

2CaO.SiO2
Zone 3: ( 40 - 50 min, 1300 - 1450 - 1300oC )
Sintering and reaction within the melt to form ternary silicates and tetra calcium
aluminous ferrates:
Heat + time
2CaOSiO2 + CaO

3CaOSiO2
3CaOAl2O3 + CaO + Fe2O3

Heat + time

4CaOAl2O3Fe2O3

Zone 4: ( 50 - 60 min, 1300 - 1000oC )

Cooling and crystallization of the various mineral phases formed in the kiln.

20

 The Cooler
Immediately following the kiln is a large cooler designed to drop the temperature of the
clinker (as the fused material is now called) from 1000oC to 150oC. This is achieved by
forcing air through a bed of clinker via perforated plates in the base of the cooler.

Step 4 - CEMENT MILLING

To produce the final product the clinker is mixed with gypsum (CaSO4 2H2O), which is
added as a set retarded, and ground for approximately 30 minutes in large tube mills. The
cement flows from the inlet to the outlet of the mill (a rotating chamber), being first
ground with 60 mm then 30 mm diameter steel balls. The first grinding breaks up the
material and the second grind it to a fine powder. The amount of grinding is governed by
the volume of cement fed into the mill: the greater the volume the coarser the grind. This
has practical limits, with too much cement clogging up the mill and not enough actually
increasing the particle size. The particle size is measured by laser diffraction analysis,
and the quantity of material entering the mill adjusted accordingly. Over time the charge
(steel grinding balls) wear out, so when they reach a certain size they fall through a sieve
and then are replaced.

Step 5 PACKING OF CEMENT IN BAGS

After first four process cement are stored in big storage tanks and fill in a bags one by
one by mechanical machine process. The volume of Cement bag is 1.25 cft and 0.035
meter cube. After filling these bag cement are transported in market.

Transportation of Cement

THE ROLE OF THE LABORATORY

In Fauji Cement Company Limited Three laboratories are working for testing material for
the purpose of making manufacturing of cement.
Chemical Lab
Instrumentation Lab
Physical Lab

21

PURPOSE OF LABORATORIES
Testing raw materials prior to blasting in the quarry and assisting with
development of quarrying strategies forms the first step in the process.

Analyzing rock samples from the raw mill at regular intervals during the day and
night and fine tuning the process to ensure chemical control is maintained

Analyzing clinker at the end of the cooler (before grinding) to ensure that the
Manufactured process meets specification.

Checking that cement mills are undertaking grinding correctly and that customers
Receive the right product.

Product development.

CONTROL ROOM
In Fauji Cement Company Limited we visit the control room. Control room
Basically control all operations in all over the plant during manufacturing the
Cement by dry process step by step in Crushing, Burning and Grinding Process.
Control room connects all area of the plant and all machinery which is used for
Manufacturing for cement with the help of sensors and highly sensation cameras
And infrared rays.

PHOTO GRAPHIC EVIDENCE

22

23

24

SUMMARY:We learn a lot from this visit. We observe and learn the techniques adopted for
manufacturing at cement plant. We also learn about raw material, fuel in the form of coal,
and all the buildings and units such as Storage Building, Mechanical assembly line, Kiln
like pre heaters, mixing and grinding units cement storage feeders, Cargo Transportation
building bays and machinery which are working in this plant for manufacturing purpose.
We also visit the quality control lab to learn and observing about the material testing and
their chemical behavior reacting as reagent during process of cement, and also visit the
plant control room and seen basic and important instruments, heavy computer hardware,
networking servers, software such as Programmable Logic Control (PLC) which controls
all plant with the help of sensors and cameras footages. In fact this visit gives us a lot of
information.

Group Photo of Abasyn University students, Teaching Faculty and Plant Faculty at the visit of
Fauji Cement Company Limited

25

VISIT 03
TIME
DATE

(1:45:00 PM 4:30 PM)

(02-DEC-2014)

The New Islamabad International Airport, Fateh Jhang

26

CONTENTS

LOCATION DETAIL. 28

OBJECTIVES.. 28

DISTANCE FROM TWIN CITIES. 28

PARTS OF AIRPORT.. 29

INTRODUCTION 29

MAJOR NUMBERS AND MEASUREMENTS. 30

PASSENGER TERMINAL BUILDING. 30

RUNWAY 31

DEPARTURE LEVEL BRIDGE..... 32

BOUNDARY WALL... 32

APRON. 33

CAR PARKING AREA 33

AIR TRAFFIC CONTROL TOWER... 34

THE ROLE OF THE LABORATORY 35

Material Testing Lab. 35
Soil Testing Lab 36

SUMMARY. 37

27

LOCATION DETAIL
The construction site of the airport is near the Rawalpindi-Fateh Jang Road near Fateh
Jang

DISTANCE FROM TWIN CITIES

20 km from Zero Point, Islamabad

23 km from Saddar, Rawalpindi

OBJECTIVES

We visit the new Islamabad international airport to observe and understand the
parts of airport like passenger terminal building, runway, apron, hanger, air traffic
control tower, cargo terminal, taxiway, parking area, departure level bridge.

We visited this project to practically observe the construction procedure adopted

on site.
To know about the material used on site.

To know about the new procedures, techniques applied in this project.

28

To know about the different types of construction machinery, soil and material testing
labs, concrete batching plant, asphalt batching plant and their functions and its uses on
site.

PARTS OF AIRPORT

Passenger Terminal Building

Runway
Departure Level Bridge
Apron
Taxiway
Air Traffic Control Tower
Car Parking Area
Cargo Terminals

INTRODUCTION
It is a joint project of Capital Development Authority (CDA), National Highway
Authority (NHA) and the Civil Aviation Authority (CAA) and designed by French
company Aroports de Paris Ingenierie (ADPi) and CPG Corporation of Singapore. It is
being built on more than 3300 acres of land and consists of a passenger terminal building,
runways, taxiways, apron and parking bays for wide body aircraft. There will also be a
cargo terminal, air traffic control complex, fuel farm, as well as a fire, crash and rescue
facility. It would be equipped to handle all types of aircraft including the new generation
aircraft such as the Airbus A380. The airport is being developed to be at par with
international standards to serve as major hub for all aviation activities in Pakistan. The
airport will have a 180,000 m modular terminal building which will initially be able to
handle 9 million passengers and 80,000 metric tones cargo per annum. The numbers are
expected to reach 15 million passengers by 2019 and increase to 25 million passengers by
2024. Being a new airport, a significant portion of the land has been earmarked for
commercial purposes such as duty-free shops, hotel and convention centre, air malls,
business centre, food courts, leisure and recreational facilities.

Master Plan of New Islamabad International Airport

29

MAJOR NUMBERS AND MEASUREMENTS

Total Area And Total Cost

Area = 3300 Acre And Cost = 85 Billions

Boundary Wall
18.4 KM

Passenger Terminal Building (4 Level)

1 Lack Square Meter (100,000 m)

Car Parking
2000 Vehicles

Runways (2 Nos)
Length 3658 m (3.65KM)
Width 60m
Shoulder 7.5 m (both side)

Apron / Bays
NE 970 m

Refueling System
Underground

Departure Level Bridge

3rd Building

PASSENGER TERMINAL BUILDING

The new Islamabad international airport will have a 100,000 m modular terminal
building which will initially be able to handle 9 million passengers and 80,000 metric
tones cargo per annum.

Terminal Building under Construction

30

Terminal Building

RUNWAY
The new Islamabad international airport will have two runways of 3658 m (3.65 KM)
in length. 60 m in Width and 7.5m both side shoulders on runway.

Runway

31

DEPARTURE LEVEL BRIDGE

The new Islamabad international airport will have a departure level bridge which
provides the path to the passengers enter in the terminal building of airport.

Departure level bridge under construction

BOUNDARY WALL
The new Islamabad international airport have boundary wall of 18.4 KM in total length
which covers all the 3300 Acre total area of Airport Land Site.

Boundary Wall of Airport

32

APRON
The new Islamabad international airport have aprons where aircrafts are standing for
loading and unloading of passengers and cargo.

Apron of Airport attaching with Terminal Building

CAR PARKING AREA

The new Islamabad international airport have wide and broad car parking area where
2000 vehicles are park there.

Car Parking Area

33

AIR TRAFFIC CONTROL TOWER

The new Islamabad international airport have air traffic control tower which controls and
communicate with the all domestic and international aircraft flights with the help of all
advance instruments, antennas, sonar system, heavy computer hardware and software and
strong wireless communication system with satellite and aircrafts to the all over the
world.

Air Traffic Control Tower

34

THE ROLE OF THE LABORATORY

The construction of new Islamabad international airport laboratories plays an important
role in this construction site. There are two main testing labs are working
Material Testing Lab
Soil Testing Lab
Material Testing Lab
In this lab those materials are test which are used for construction purpose. These test
show the maximum power and output like durability, toughness, compressive and tensile
strength, workability of material. In this lab many materials are test e.g.

Slump Test of Concrete

Brick and Concrete Block Test
Beams and Columns Test
Steel Bar Test
Bitumen / Asphalt Test and inspection
Concrete and Concrete Aggregate Test
Corrosion Test
Stone and Rock Test
Metal and Alloys Test

Soil Testing Lab

As the basic structural foundation for almost all construction, soil materials play an
important role in the ultimate success of a project. Whether you're working in clay, silt,
sand, gravel, peat, or loam, understanding the soil properties of your site help you make
good construction decisions. In this construction site following tests are performed as per
criteria.

35

Sample Collection Disturbed Soil

Sample Collection Undisturbed Soil
Specific Gravity Test
Sieve Analysis Test
Classification of the soils
Atterberg Limits Test
Moisture Content Test
Field Density Test
Core Cutter Method Test
Sand Cone Replacement Test
CBR One Point Method Test
CBR Three Points Method Test
Standard Penetration Test Test
Compaction Test
Standard Proctor Test
Modified Proctor Test
Consolidation Test
Direct Shear Test
Hydrometer Analysis
Shrinkage Test

36

SUMMARY
We learn a lot from this visit. We observe and visit the parts of Airport like passenger
terminal building, departure level bridge, runway, cargo terminal, apron, car parking, and
taxiway. We also learn about and physically seen the material and other elements which
are the basic needs and used in the construction of airport. We visit material testing lab
and soil testing lab and observe the experimental techniques and procedure, tests which
are adopted in this construction site. In fact this visit gives us a lot of information.

Presentation given to the Students and Faculty of Abasyn University in Conference Room
About the Mega Project of New Islamabad International Airport by the project members

37