Summer Internship Report L&T

6/14/2019 Summer internship report L&T
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HR POLICY 9
WORK CULTURE Work Culture emphasises: • Freedom to experiment • Continuous learning and training ...
MISSIONTo achieve excellence in the field of Engineering, Procurement and Constructionthrough world class practice and sta...
PROPOSED – PROJECT CAR MANUFATURING FACILITY FOR FORD INDIA PVT LTD, AHMEDABAD, INDIA. ...
THE PROJECT DETAILSPROJECT - CAR MANUFATURING FACILITYCLIENT - M/S. FORD INDIA PVT LTD.CONSULTANT - KAJIMA INDIA PVT
LTDCO...
BRIEF INTRODUCTION OF PROJECTFord India has laid the foundation for its new US $1 billion state-of-the-art, integratedmanu...
EHS DEPARTMENT GENERAL EHS RULES &REGULATIONS 1. No workmen below 18 years and above 5...
12. Adequate illumination at workplace shall be ensured before starting the job at night....
27. No children shall be allowed to enter the workplace. 28. Workwomen are not allowed ...
50. Those who are violating the safety norms will be penalized. 51...
• EYE PROTECTION Person carrying out grinding works, operating pavement breakers, and those ...
1) Lanyard should be of 12mm Polypropylene rope and of length not more than 2m. ...
QUALITY ASSURANCE & QUALITY CONTROL DEPARTMENT ...
on PDCA (Plan, Check, Do and Act) Principle. The Project Quality Plan comprises oftwo sections: A. VOLUME ISCOPE: ...
VICAT APPARATUSVicat apparatus conforming to IS: 5513 - 1976 Balance, whose permissible variationat a load of 1000g should...
ii) Start a stop-watch, the moment water is added to the cement.iii) Fill the Vicat mould completely with the cement paste...
TESTS ON AGGREGATES SIEVE ANALYSISAIMTo determine the particle size distribution of fine...
REPORTING OF RESULTSThe results should be calculated and reported as:i) the cumulative percentage by weight of the total s...
iii) The basket and aggregates should then be removed from the water, allowed todrain for a few minutes, after which the a...
iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes aredistributed evenly over the cross- sec...
PREPARATION OF SAMPLEA representative portion of air-dried soil material, large enough to provide about 6kgof material pas...
iv) The remaining soil specimen should be broken up, rubbed through 19mm IS Sieveand then mixed with the remaining origina...
moisture content and quoted to the nearest 0.2 for values below 5 percent, to thenearest 0.5 for values from 5 to 10 perce...
REPORTING OF RESULTSThe water content w = [(W2 − W3) ×100%] /(W3 −W1) CALCIUM CARBIDE METHOD(RAPID MOISTURE METER TE...
absorbent (Calcium Carbide) inside the chamber.iv) Transfer the weighed soil from the pan to the cup.v) Hold cup and chamb...
iv) Balance, with an accuracy of 1gv) Straightedgevi) Square metal tray - 300mm x 300mm x 40mmvii) TrowelPROCEDUREi) The i...
properties in the most economical way.With advent of high-rise buildings and pre-stressed concrete, use of higher grades o...
concrete with lower densities.What is mix design?Concrete is an extremely versatile building material because, it can be d...
design to the mix design laboratory: -Grade of concrete (the characteristic strength)Workability requirement in terms of s...
the strength of concrete for the same water/cement ratio. In other words a higherstrength of cement permits use of higher ...
The sieve analysis is done by passing sand through a set of standard sieves andfinding out cumulative passing percentage t...
reinforcement bars. Maximum size of coarse aggregate should be 5 mm less than clearcover or minimum distance between the r...
the compactability of concrete.c) Shape of coarse aggregate: Coarse aggregates can have round, angular, orirregular shape....
this water/cement ratio of 0.38, evaporates leaving cavities in the concrete. Thesecavities are in the form of thin capill...
Proportion of fine aggregates to coarse aggregate depends on following:i. Fineness of sand: Generally, when the sand is fi...
Plasticizers are used for moderate increase of workability whereas super plasticizersare used where very large increase in...
Concrete Mix Design MethodsThe basic objective of concrete mix design is to find the most economical proportions(Optimisat...
BATCHING PLANT 46
PROJECT EXECUTIONMETHOD STATEMENT FOR CIVIL AND MECHANICAL 1. METHOD STATEMENT FOR CIVIL METHOD STATEMENT FO...
2. IS 456 & IS 6461(Part 5) 3. Tender Document METHOD STATEMENT FOR BOLTS PROCUREMENT & FIXATION ...
4.Reinforcement shall be tied as per the latest GFC drawing and any extra barsprovided at site shall be recorded in the po...
g) Size of cover blocks.h) All the bars shall be tied with double fold 18g soft GI annealed binding wire.4.Reinforcement m...
2.Formwork shall be made to the exact dimensions within the permissible tolerancesas mentioned below.3.Required thickness ...
19.Check all the inserts/embedments and openings are exactly placed as per thedrawings.20.In case of leakages, bulging and...
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1. 1. SUMMER INTERNSHIP REPORT (7/5/2012 -‐ 24/6/2012)
Submitted by:-‐ Umed Paliwal Second
Undergraduate Student, Department of Civil Engineering, Indian Institute of Technology Kanpur 1
2. 2. INDEX ______________________________________________________________________ Sno.
Contents Page no. 1 Aknowldgement 3 2 Introduction 4 3 EHS Department 15 4 QA/QC Department 21 5
Project Execution 47 6 Planning 57 7 Conclusion 59
______________________________________________________________________ 2
3. 3. Aknowldgement I am very thankful to LARSEN & TOUBRO CONSTRUCTIONS BUILDINGS & FACTORIES INDIPENDENT
COMPANY (L&T CONSTRUCTION, B&F IC) for having given me the opportunity to undertake my summer training at their prestigious
FORD INDIA PVT LTD, # 2 PROJECT. It was a very good learning experience for me to have worked at this site as this project
involved many unique construction practices and challenges. I would like to convey my heartiest thanks to Mr. Ashutosh Tripathi, L&T
Construction. Ahmadabad Cluster Project Manager Factory Division, who heartily welcomed me for the internship. I would also like to give my
heart-‐felt thanks to Mr. S. K. Basu, Project Co-‐Ordinator, Mr. Sudeep Ghosh ,QA/QC Head who guided and encouraged me all through the
summer training and imparted in-‐depth knowledge of the project. Also I would like to thank Mr. G. M. Mir, Planning Head, who assisted and
guided me whenever I needed help. I would like to thank all the department heads of L&T Construction, B&F IC, for giving their precious
time and valuable guidance during my internship programme. Last but not the least; I would like to thank all the staff at L&T Construction , B&F
IC, for being so helpful during this summer training. Name: Umed Paliwal Date: 16th June 2012 3
4. 4. INTRODUCTIONABOUT THE ORGANIZATION:Larsen & Toubro Limited is the biggest legacy of two Danish Engineers, who built aworld-class
organization that is professionally managed and a leader in Indiasengineering and construction industry. It was the business of cement that brought theyoung
Henning Holck-Larsen and S.K. Toubro into India. They arrived on Indianshores as representatives of the Danish engineering firm F L Smidth & Co inconnection
with the merger of cement companies that later grouped into theAssociated Cement Companies.Together, Holck-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 hasmetamorphosed into one of Indias biggest success stories. The
company has grownfrom humble origins to a large conglomerate spanning engineering and construction.Larsen & Toubro Construction is India’s largest
construction organisation. Many ofthe countrys prized landmarks - its exquisite buildings, tallest structures, largestindustrial 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 the resources to execute projects of large magnitude andtechnological complexity in any part of the world. The business of L&T Constructionis organized in six
business sectors which will primarily be responsible forTechnology Development, Business Development, International Tendering and workas Investment Centres.
Head quarters in Chennai, India. In India, 7 Regional Officesand over 250 project sites. In overseas it has offices in Gulf and other overseaslocations.L&T
Construction’s cutting edge capabilities cover every discipline of construction –civil, mechanical, electrical and instrumentation engineering and services extend
tolarge industrial and infrastructure projects from concept to commissioning. 4
5. 5. L&T Construction has played a prominent role in India’s industrial and infrastructuredevelopment by executing several projects across length and breadth of the
countryand abroad. For ease of operations and better project management, in-depthtechnology and business development as well as to focus attention on domestic
andinternational project execution, entire operation of L&T Construction is structuredinto four Independent Companies. • Hydrocarbon IC • Buildings & Factories
IC • Infrastructure IC • Metallurgical & Material Handling IC • Power Transmission & Distribution • Heavy Engineering • Shipbuilding • Power • Electrical &
Automation • Machinery & Industrial ProductBUILDING & FACTORIESThe Buildings & Factories Independent Company is equipped with the
domainknowledge, requisite expertise and wide-ranging experience to undertakeEngineering, Procurement and Construction (EPC) of all types of building and
factorystructures. • Commercial Buildings & Airports • Residential Buildings & FactoriesRESIDENTIAL BUILDINGS & FACTORIESL&T undertakes turnkey
construction of a wide range of residential buildings andfactory structures. Projects are executed using the cutting edge technology,sophisticated construction
equipment and project management tools for quality, safetyand speed. • Residential Building • Factories 5
6. 6. FACTORIESL&T offers design and turnkey construction of heavy and light factories, cement &plants including Defence Projects using the latest construction
technology, with afocus on Quality, Safety and Speed. The spectrum covers • Heavy & Light Factories (HLF) –Automobile & Ancillary Factories, Glass plants,
Food processing Factories, Pharmaceutical plants, Warehouses & Logistics Parks, Workshop Complexes, Solar thin film manufacturing units, etc. • Cement &
Plants (C&P) – Cement Plants, Sugar Plants, Distillery Plants, Food Grain storage structures, Pulp & Paper Mills, Textile Mills etc. • Defence – Construction of
Manufacturing Facilities and Warehouse Facilities for Defence.SERVICE SPECTRUML&T Construction’s range of services includes: • Pre-engineering, feasibility
studies and detailed project reports. • Complete civil and structural construction services for all types of buildings, industrial and infrastructure projects. • Complete
mechanical system engineering including fabrication and erection of structural steel works; manufacture, supply, erection, testing and commissioning of plant and
equipment; heavy lift erection; high-pressure piping; fire-fighting; HVAC and LP/ utility piping networks. • Electrical system design, project electrification,
automation and control system including instrumentation for all type of industrial and telecom projects. • Design, manufacture, supply and installation of EHV
switchyards, transmission lines. 6
7. 7. QUALITY POLICYAt L&T, Environment, Health & Safety (EHS) is given the highest priority. The EHSpolicy enunciated by the Corporate Management lays
emphasis on Environment,Health and Safety through a structured approach and well defined practices. Systemsand procedures have been established for
implementing the requisites at all stages ofconstruction and they are accredited to the International standards of ISO 9001:2008,ISO 14001:2004 and OHSAS
18001:2007. 7
8. 8. 1.1 HEALTH SAFTEY AND ENVIRONMENTAL POLICY 8
9. 9. HR POLICY 9
10. 10. WORK CULTURE Work Culture emphasises: • Freedom to experiment • Continuous learning and training • Transparency • Quality in all aspects of work •
Rewards based on performance and potentialTRAINING Human Resources Department believes that Quality is the hallmark of any successfulventure. Quality
Training and Development of Human Resources is realized through:Identifying training needs within the Organization and designing and implementingthose need
based training programs to bring about continuous up-gradation ofknowledge, skills and employee attitudes.VISION & MISSIONVISIONL&T shall be
professionally managed Indian multinational committed to totalcustomer satisfaction and enhancing shareholder value. L&T shall be an innovativeentrepreneurial
and empowered team constantly creating value and attaining globalbenchmarks. L&T shall foster a culture of caring trust and continuous learning whilemeeting
expectations of employees, stakeholders and society. 10
11. 11. MISSIONTo achieve excellence in the field of Engineering, Procurement and Constructionthrough world class practice and standards in quality, Safety and
ProjectManagement. 11
12. 12. PROPOSED – PROJECT CAR MANUFATURING FACILITY FOR FORD INDIA PVT LTD, AHMEDABAD, INDIA. 12
13. 13. THE PROJECT DETAILSPROJECT - CAR MANUFATURING FACILITYCLIENT - M/S. FORD INDIA PVT LTD.CONSULTANT - KAJIMA INDIA PVT
LTDCONTRACTOR - L&T CONSTRUCTION BUILDING &FACTORIESTYPE OF CONTRACT – LUMPSUM CONTRACTCONSTRUCTION PERIOD –
DEFECT NOTIFICATION PEROD - 365 DAYSPROJECT COMPONENT - • ENGINE SHOP • PAINT SHOP • TCF SHOP • BODY SHOP • STAMPING •
ROAD AND ADMIN BUILDINGPACKAGE UNDER L&T - • ENGINE PLANT • PAINT SHOP –PILING WORK • TCF SHOPPROJECT LOCATION AND
AREA – SANAND AHMEDABAD, NEAR TATA NANO PLANT AREA UNDER SCOPE – 460 ACRESCONSULTANT – KAJIMA INDIA PVT LTD 13
14. 14. BRIEF INTRODUCTION OF PROJECTFord India has laid the foundation for its new US $1 billion state-of-the-art, integratedmanufacturing facility in Sanand
and its future growth on the subcontinent. The totalarea of the plant is 406-acre. • Ford India Sanand facility will deploy global best practices and technology
including a state-of-the-art Paint Shop • Ford India’s Sanand facility attracts 19 world-class supplier manufacturers to dateFord India is laying the foundation for its
new US $1 billion state-of-the-art,integrated manufacturing facility in Sanand and its future growth on the subcontinent.It will be complete in 2014; the integrated
manufacturing facility will have thecapacity to produce an additional 240,000 new Ford vehicles and 270,000 engines peryear for Indian customers and for export
market.The new state-of-the-art assembly plant will be fully integrated to support stamping,body assembly, paint, trim and final assembly. The paint shop will
utilize Ford’senvironmentally friendly rotational dip technology and 3-Wet technology paintprocesses, which will improve paint quality, depth and durability, as
well assignificantly reducing Volatile Organic Compounds, CO2 emissions and waste.The idea behind selecting Sanand as project site is, the way the Chennai Port
servedthe company’s markets in the East and South East Asia, the Gujarat terminal, or aroll-on roll-off (RoRo) facility, could be used for exports to the western
markets likeMexico, South Africa and the Middle East as and when necessary.Plus, the State Government has also prioritized land adjacent to the site for
supplieroperations. It will be protected by the local government in order to attract and locateautomotive suppliers within close proximity of both the plants.The
project has divided into various packages; L&T has received three packages: firstpackage is Paint shop(Piling work) , second package Engine and third package is
TCF.The location of project makes it more important due to TATA NANO PLANT by sideand upcoming MARUTI PLANT. 14
15. 15. EHS DEPARTMENT GENERAL EHS RULES &REGULATIONS 1. No workmen below 18 years and above 58 years of age shall be engaged
for a job. 2. All workmen shall be screened before engaging them on the job. Physical fitness of the person to certain critical jobs like working at
height or other dangerous locations to be ensured before engaging the person on work. The final decision rests with the site management to reject
any person on the ground of physical fitness. 3. Visitors can enter the site after EHS induction with the visitor pass. He should be provided Safety
helmet & safety Shoes, also he should be accompanied with the responsible person of that area. 4. Smoking is strictly prohibited at workplace. 5.
Sub-‐contractors shall ensure adequate supervision at workplaces. They shall ensure that all persons working under them shall not create any hazard
to self or to the co-‐workers. 6. Nobody is allowed to enter the site without wearing safety helmet. Chinstrap of safety helmet shall be always on.
7. No one is allowed to work at or more than two-‐meter height without wearing full body harness and anchoring the lanyard of full body harness
to firm support preferably at shoulder level. 8. No one is allowed to enter into workplace and work at site without adequate foot protection
(including female worker). 9. Usage of eye protection equipment shall be ensured when workmen are engaged for grinding, chipping, welding and
gas cutting. For other jobs, as and when site safety co-‐ordinator insists eye protection has to be provided. 10. All PPEs like shoes, helmet, full
body harness etc. shall be arranged before starting the job as per recommendation of the EHSO. 11. Rigid barrication must be provided around the
excavated pits, and barrication shall be maintained till the backfilling is done. Safe approach is to be ensured into every excavation. 15
16. 16. 12. Adequate illumination at workplace shall be ensured before starting the job at night. 13. All the dangerous moving parts of the portable/fixed
machinery being used shall be adequately guarded. 14. Ladders being used at site shall be adequately secured at bottom and top. Ladder shall not
be used as work platforms. 15. Erection zone and dismantling zone shall be barricaded and nobody will be allowed to stand under the suspended
loads. 16. Horseplay is completely prohibited at workplace. Running at site is completely prohibited except in case of emergency. 17. Material shall
not be thrown from the height. Proper arrangement of Debris Chute can be installed. 18. Other than the electrician possessing B licence with red
helmet, no one is allowed to carryout electrical connection, repairs on electrical equipment or other job related thereto. 19. Inserting of bare wires
for tapping the power from electrical socket is completely prohibited. 20. All major, minor accidents near misses and unhygienic conditions must be
reported. 21. All scaffoldings/ work platform shall meet the requirement. The width of the working platform and fall protection arrangement shall be
maintained as per the Standard. All tools and tackles shall be inspected before use. Defects to be reported immediately. No lifting tool&tackle to be
used unless it is certified by the concerned Engineer Incharge / P&M engineer. 22. Good house keeping to be maintained. Passage shall not be
blocked with materials. Material like bricks shall not be stacked to the dangerous height at workplace. 23. Debris, scrap and other material to be
cleared then and there from the work place and at the time of closing of work every day. 24. Contractors shall ensure that all their workmen are
following safe practices while travelling in the company’s transport and staying at company’s accommodations. 25. Adequate fire fighting equipment
shall be made available a workplace and persons to be trained in fire fighting techniques with the co-‐ordination of EHSO. 26. All the unsafe
conditions, unsafe act identified by the contractors, reported by site supervisor and / or safety personnel to be corrected on priority basis. 16
17. 17. 27. No children shall be allowed to enter the workplace. 28. Workwomen are not allowed to work at high-‐risk areas. 29. Other than the
Driver/operator, no one shall travel in a tractor / tough rider etc. 30. Wherever the vehicle/equipment has to work near or pass through the
overhead electrical lines, the goal post shall be installed. 31. Identity card should always be displayed and shown when demanded. 32. Any person
found to be interfering with or misusing fixtures, fittings or equipment provided in the interest of health, safety and welfare would be excluded from
site.( like using helmet and fire bucket for carrying the material, removing the handrails, etc.) 33. Visitors must use safety helmet before entering the
Site. 34. Safety signs and notices must be displayed and followed. 35. Transistor radios or personal stereos / Walkman must not be used. 36. All
site personnel, for their own safety and for the safety of others, are required to fully comply with the agreed safety systems/ procedures and
working method. 37. Consumption of alcohol and drugs is prohibited. 38. No person is to operate any mechanical / Electrical equipment unless they
have been authorized and have been certified as competent. 39. Take Food only at the designated area (like dinning, Rest Room etc). The Waste
food, PVC/Paper covers need to be dumped in the Dustbin. The House keeping gang on regular intervals will clear this. Also hand / vessels should
be washed in the same area with proper drainage. 40. No workers should enter the site with lunghies and dhotis. 41. No body should sit / sleep
on the floor edges. 42. Don’t enter inside the room where there is no light. 43. Don’t take shelter under the vehicle or in an electrical installation
rooms. 44. Look for warnings signs, caution boards and other notices. 45. Must be aware about the locations of the first aid canter, fire
extinguisher, emergency assembly point and emergency siren. 46. No floor opening, floor edges should be left unguarded 47. Training is must for
all scaffolders and only trained scaffolders should make platforms. 48. Don’t keep loose materials at height. 49. Permission should be taken for all
earthworks from P&M Department. 17
18. 18. 50. Those who are violating the safety norms will be penalized. 51. Female workers should not be engaged on work between 7.P.M. To 8 A.M.
52. Physical fitness check shall be carried out for crane operators & Drivers. 53. PPE Shall is provided to visitors at gate. 54. No
smoking sign boards shall be kept at flammable and combustible material Storage places.
55. Debris, scrap and other materials shall be disposed daily at closing hours of the day by the same crew. 56.
Environment poster shall be displayed at site as and when required Depending upon the activities in progress. 57.
Fire points should be placed at all required areas Use of Personal Protective Equipment and safety
devices relevant to site activities. • SAFETY APPLIANCES The requirement of sufficient number of safety appliances are planned well in advance and
made available at stores. • HEAD PROTECTION Every individual entering the site must wear safety helmet, confirming to IS: 2925-‐ 1984 with the
chinstrap fixed to the chin. • FOOT AND LEG PROTECTION Safety footwear with steel toe is essential on site to prevent crush injuries to our toes
and injury due to striking against the object. • HEARING PROTECTION: Excessive noise causes damage to the inner ear and permanent loss of
hearing. To protect ears use ear plugs / ear muff as suitable 18
19. 19. • EYE PROTECTION Person carrying out grinding works, operating pavement breakers, and those involved in welding and cutting works should
wear safety goggles & face shield suitably. Goggles, Safety Spectacles, face shield confirm to IS: 5983-‐1980. • EAR PROTECTION Ear Muff /
Earplug should be provided to those working at places with high sound levels (confirm to IS: 9167-1979). • HAND AND ARM PROTECTION: While handling
cement and concrete & while carrying out hot works like gas cutting, grinding & welding usage of hand gloves is a must to protect the hand, 1) COTTON Gloves
(for materials handling)-‐IS: 6994-‐1973 2) RUBEER Gloves-‐18” (380/450mm long) electrical grade, tested to 15000 Volts conforming to IS: 4770-‐
1991 3) LEATHER Gloves – hot work / handling of sharp edges • RESPIRATORY PROTECTION Required respiratory protection according to the
exposure of hazards to be provided. • SAFETY NET Though it is mandatory to wear safety harness while working at height on the working
platforms, safety nets of suitable mesh size shall be provided to arrest the falling of person and materials on need basis. • FALL PROTECTION:
To prevent fall of person while working at height, personnel engaged more than 2m wear standard Full Body harness should be conforming to
IS: 3521-‐1999(Third Revision). 19
20. 20. 1) Lanyard should be of 12mm Polypropylene rope and of length not more than 2m. 2) Double lanyard, based on the requirement. 20
21. 21. QUALITY ASSURANCE & QUALITY CONTROL DEPARTMENT Quality is the key component which propels performance and defines leadershiptraits. At
L&T Construction, Quality Standards have been internalised anddocumented in Quality Assurance manuals. L&T Construction recognizes the crucialsignificance
of the human element in ensuring quality. Structured trainingprogrammes ensure that every L&T employee is conscious of his/her role andresponsibility in
extending L&T Construction’s tradition of leadership throughquality. A commitment to safety springs from a concern for the individual worker –every one of the
thousands braving the rigours of construction at numerous projectsites. L&T, Buildings & Factories IC has a well-established and documented QualityManagement
System (QMS) and is taking appropriate steps to improve itseffectiveness in accordance with the requirements of ISO 9001:2008. Relevantprocedures established
clearly specify the criteria and methods for effective operation,control and necessary resources and information to support the operation andmonitoring of these
processes.QUALITY IMPLEMENTATION AT SITEL&T, Buildings & Factories IC has established procedure for monitoring, measuringand analyzing of these
processes and to take necessary actions to achieve plannedresults and continual improvement of these processes. It has also maintained relevantprocedures to
identify and exercise required control over outsourced processes, if any.Systems and procedures have been established for implementing the requisites at allstages
of construction and they are accredited to the International standards of ISO9001:2008, ISO 14001:2004 and OHSAS 18001:2007. L&T continues to maintain
thetrail blazing tradition of meeting the stringent quality standards and adherence to timeschedules in all the projects.PROJECT QUALITY PLAN (PQP):The
Project Quality Plan is prepared and formulated as a Management Summary ofQuality related activities required to meet the terms of contract. This Quality plan
setsout the Management practices and describes the Quality Management System based 21
22. 22. on PDCA (Plan, Check, Do and Act) Principle. The Project Quality Plan comprises oftwo sections: A. VOLUME ISCOPE: The contents of this document are
applicable to “SHOP CONSTRUCTION FOR M/s. FORD INDIA Pvt. Ltd.” and “Construction of Civil and Structural works for M/s. FORD INDIA Pvt. Ltd. At
Sanand, Gujarat” that will be carried out by Larsen & Toubro Limited, Buildings & Factories IC for FIPL. In preparation of this document, due regard has been paid
to the requirements of ISO 9001: 2008 series of System Standards.PURPOSE: This Project Quality Plan is prepared and formulated as a Management Summary of
Quality related activities required to meet the terms of contract. This Quality plan sets out the Management practices and describes the Quality Management
System. TESTS ON CEMENT CONSISTENCYAIMTo determine the quantity of water required to produce a cement paste of standardconsistency as per IS: 4031
(Part 4) - 1988.PRINCIPLEThe standard consistency of a cement paste is defined as that consistency which willpermit the Vicat plunger to penetrate to a point 5 to
7mm from the bottom of the Vicatmould.APPARATUS 22
23. 23. VICAT APPARATUSVicat apparatus conforming to IS: 5513 - 1976 Balance, whose permissible variationat a load of 1000g should be +1.0g Gauging trowel
conforming to IS: 10086 - 1982PROCEDUREi) Weigh approximately 400g of cement and mix it with a weighed quantity of water.The time of gauging should be
between 3 to 5 minutes.ii) Fill the Vicat mould with paste and level it with a trowel. iii) Lower the plungergently till it touches the cement surface.iv) Release the
plunger allowing it to sink into the paste.v) Note the reading on the gauge.vi) Repeat the above procedure taking fresh samples of cement and differentquantities of
water until the reading on the gauge is 5 to 7mm.REPORTING OF RESULTSExpress the amount of water as a percentage of the weight of dry cement to the
firstplace of decimal. INITIAL AND FINAL SETTING TIMEAIMTo determine the initial and the final setting time of cement as per IS: 4031 (Part 5)
-1988.APPARATUSVicat apparatus conforming to IS: 5513 - 1976 Balance, whose permissible variationat a load of 1000g should be +1.0g Gauging trowel
conforming to IS: 10086 - 1982PROCEDUREi) Prepare a cement paste by gauging the cement with 0.85 times the water required togive a paste of standard
consistency 23
24. 24. ii) Start a stop-watch, the moment water is added to the cement.iii) Fill the Vicat mould completely with the cement paste gauged as above, the mouldresting on
a non-porous plate and smooth off the surface of the paste making it levelwith the top of the mould. The cement block thus prepared in the mould is the testblock.
INITIAL SETTING TIMEPlace the test block under the rod bearing the needle. Lower the needle gently in orderto make contact with the surface of the cement
paste and release quickly, allowing itto penetrate the test block. Repeat the procedure till the needle fails to pierce the testblock to a point 5.0 ± 0.5mm measured
from the bottom of the mould . The timeperiod elapsing between the time, water is added to the cement and the time, theneedle fails to pierce the test block by 5.0 ±
0.5mm measured from the bottom of themould, is the initial setting time. FINAL SETTING TIMEReplace the above needle by the one with an annular
attachment.The cement should be considered as finally set when, upon applying the needle gentlyto the surface of the test block, the needle makes an impression
therein, while theattachment fails to do so. The period elapsing between the time, water is added to thecement and the time, the needle makes an impression on the
surface of the test block,while the attachment fails to do so, is the final setting time.REPORTING OF RESULTSThe results of the initial and the final setting time
should be reported to the nearestfive minutes. 24
25. 25. TESTS ON AGGREGATES SIEVE ANALYSISAIMTo determine the particle size distribution of fine and coarse aggregates by sieving asper IS: 2386 (Part I) -
1963.PRINCIPLEBy passing the sample downward through a series of standard sieves, each ofdecreasing size openings, the aggregates are separated into several
groups, each ofwhich contains aggregates in a particular size range.APPARATUSA SET OF IS SIEVESi) A set of IS Sieves of sizes - 80mm, 63mm, 50mm, 40mm,
31.5mm, 25mm, 20mm,16mm, 12.5mm, 10mm, 6.3mm, 4.75mm, 3.35mm, 2.36mm, 1.18mm, 600µm,300µm, 150µm and 75µmii)Balance or scale with an
accuracy to measure 0.1 percent of the weight of the testsamplePROCEDUREi) The test sample is dried to a constant weight at a temperature of 110 + 5oC
andweighed.ii) The sample is sieved by using a set of IS Sieves.iii) On completion of sieving, the material on each sieve is weighed.iv) Cumulative weight passing
through each sieve is calculated as a percentage of thetotal sample weight.v) Fineness modulus is obtained by adding cumulative percentage of aggregatesretained
on each sieve and dividing the sum by 100. 25
26. 26. REPORTING OF RESULTSThe results should be calculated and reported as:i) the cumulative percentage by weight of the total sampleii) the percentage by
weight of the total sample passing through one sieve andretained on the next smaller sieve, to the nearest 0.1 percent. WATER ABSORPTIONAIMTo determine the
water absorption of coarse aggregates as per IS: 2386 (Part III) -1963.APPARATUSi) Wire basket - perforated, electroplated or plastic coated with wire hangers
forsuspending it from the balanceii) Water-tight container for suspending the basketiii)Dry soft absorbent cloth - 75cm x 45cm (2 nos.)iv) Shallow tray of minimum
650 sq.cm areav) Air-tight container of a capacity similar to the basketvi) Oven SAMPLE A sample not less than 2000g should be used.PROCEDUREi) The
sample should be thoroughly washed to remove finer particles and dust,drained and then placed in the wire basket and immersed in distilled water at atemperature
between 22 and 32oC.ii) After immersion, the entrapped air should be removed by lifting the basket andallowing it to drop 25 times in 25 seconds. The basket and
sample should remainimmersed for a period of 24 + ⁄ hrs. afterwards. 26
27. 27. iii) The basket and aggregates should then be removed from the water, allowed todrain for a few minutes, after which the aggregates should be gently emptied
from thebasket on to one of the dry clothes and gently surface-dried with the cloth,transferring it to a second dry cloth when the first would remove no further
moisture.The aggregates should be spread on the second cloth and exposed to the atmosphereaway from direct sunlight till it appears to be completely surface-dry.
The aggregatesshould be weighed (Weight A).iv) The aggregates should then be placed in an oven at a temperature of 100 to 110oCfor 24hrs. It should then be
removed from the oven, cooled and weighed (Weight B).REPORTING OF RESULTSWater absorption = [(A-B)/B] x 100% TESTS ON FRESH CONCRETE
SLUMPAIMTo determine the workability of fresh concrete by slump test as per IS: 1199 - 1959.APPARATUSi) Slump coneii) Tamping rodPROCEDUREi) The
internal surface of the mould is thoroughly cleaned and applied with a lightcoat of oil.ii) The mould is placed on a smooth, horizontal, rigid and non- absorbent
surface.iii) The mould is then filled in four layers with freshly mixed concrete, eachapproximately to one-fourth of the height of the mould. 27
28. 28. iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes aredistributed evenly over the cross- section).v) After the top layer is rodded,
the concrete is struck off the level with a trowel.vi) The mould is removed from the concrete immediately by raising it slowly in thevertical direction.vii)The
difference in level between the height of the mould and that of the highestpoint of the subsided concrete is measured.viii) This difference in height in mm is the
slump of the concrete.REPORTING OF RESULTSThe slump measured should be recorded in mm of subsidence of the specimen duringthe test. Any slump
specimen, which collapses or shears off laterally gives incorrectresult and if this occurs, the test should be repeated with another sample. If, in therepeat test also,
the specimen shears, the slump should be measured and the fact thatthe specimen sheared, should be recorded. OMC & MDD TESTThis test is done to determine
the maximum dry density and the optimum moisturecontent of soil using heavy compaction as per IS: 2720 (Part 8 ) – 1983.The apparatusused is:-i) Cylindrical
metal mould – it should be either of 100mm dia. and 1000cc volume or150mm dia. and 2250cc volume and should conform to IS: 10074 – 1982.ii) Balances – one
of 10kg capacity, sensitive to 1g and the other of 200g capacity,sensitive to 0.01giii) Oven – thermostatically controlled with an interior of noncorroding material
tomaintain temperature between 105 and 110oCiv) Steel straightedge – 30cm longv) IS Sieves of sizes – 4.75mm, 19mm and 37.5mm 28
29. 29. PREPARATION OF SAMPLEA representative portion of air-dried soil material, large enough to provide about 6kgof material passing through a 19mm IS
Sieve (for soils not susceptible to crushingduring compaction) or about 15kg of material passing through a 19mm IS Sieve (forsoils susceptible to crushing during
compaction), should be taken. This portion shouldbe sieved through a 19mm IS Sieve and the coarse fraction rejected after itsproportion of the total sample has
been recorded. Aggregations of particles should bebroken down so that if the sample was sieved through a 4.75mm IS Sieve, onlyseparated individual particles
would be retained.Procedure To Determine The Maximum Dry Density And The OptimumMoisture Content Of SoilA) Soil not susceptible to crushing during
compaction –i) A 5kg sample of air-dried soil passing through the 19mm IS Sieve should be taken.The sample should be mixed thoroughly with a suitable amount
of water dependingon the soil type (for sandy and gravelly soil – 3 to 5% and for cohesive soil – 12 to16% below the plastic limit). The soil sample should be stored
in a sealed containerfor a minimum period of 16hrs.ii) The mould of 1000cc capacity with base plate attached, should be weighed to thenearest 1g (W1 ). The
mould should be placed on a solid base, such as a concrete flooror plinth and the moist soil should be compacted into the mould, with the extensionattached, in five
layers of approximately equal mass, each layer being given 25 blowsfrom the 4.9kg rammer dropped from a height of 450mm above the soil. The blowsshould be
distributed uniformly over the surface of each layer. The amount of soilused should be sufficient to fill the mould, leaving not more than about 6mm to bestruck off
when the extension is removed. The extension should be removed and thecompacted soil should be levelled off carefully to the top of the mould by means ofthe
straight edge. The mould and soil should then be weighed to the nearest gram(W2).iii) The compacted soil specimen should be removed from the mould and placed
ontothe mixing tray. The water content (w) of a representative sample of the specimenshould be determined. 29
30. 30. iv) The remaining soil specimen should be broken up, rubbed through 19mm IS Sieveand then mixed with the remaining original sample. Suitable increments of
watershould be added successively and mixed into the sample, and the above operations i.e.ii) to iv) should be repeated for each increment of water added. The total
number ofdeterminations made should be at least five and the moisture contents should be suchthat the optimum moisture content at which the maximum dry
density occurs,lies within that range.B) Soil susceptible to crushing during compaction –Five or more 2.5kg samples of air-dried soil passing through the 19mm IS
Sieve,should be taken. The samples should each be mixed thoroughly with differentamounts of water and stored in a sealed container as mentioned in Part A)C)
Compaction in large size mould –For compacting soil containing coarse material upto 37.5mm size, the 2250cc mouldshould be used. A sample weighing about
30kg and passing through the 37.5mm ISSieve is used for the test. Soil is compacted in five layers, each layer being given 55blows of the 4.9kg rammer. The rest of
the procedure is same as above.REPORTING OF RESULTSBulk density Y(gamma) in g/cc of each compacted specimen should becalculated from the
equation,Y(gamma) = (W2-W1)/ Vwhere, V = volume in cc of the mould.The dry density Yd in g/ccYd = 100Y/(100+w)The dry densities, Yd obtained in a series
of determinations should be plotted againstthe corresponding moisture contents,w. A smooth curve should be drawn through theresulting points and the position of
the maximum on the curve should be determinedThe dry density in g/cc corresponding to the maximum point on the moisturecontent/dry density curve should be
reported as the maximum dry density to thenearest 0.01. The percentage moisture content corresponding to the maximum drydensity on the moisture content/dry
density curve should be reported as the optimum 30
31. 31. moisture content and quoted to the nearest 0.2 for values below 5 percent, to thenearest 0.5 for values from 5 to 10 percent and to the nearest whole number for
valuesexceeding 10 percent. WATER CONTENT OVEN DRYING METHODAIMTo determine the water content in soil by oven drying method as per IS: 2720
(Part II)- 1973.PRINCIPLEThe water content (w) of a soil sample is equal to the mass of water divided by themass of solids.APPARATUSi) Thermostatically
controlled oven maintained at a temperature of 110 ± 5oCii) Weighing balance, with an accuracy of 0.04% of the weight of the soil takeniii) Air-tight container
made of non-corrodible material with lidiv) TongsSAMPLEThe soil specimen should be representative of the soil mass. The quantity of thespecimen taken would
depend upon the gradation and the maximum size of particlesas under:PROCEDUREi) Clean the container, dry it and weigh it with the lid (Weight W1).ii) Take the
required quantity of the wet soil specimen in the container and weigh itwith the lid (Weight W2).iii) Place the container, with its lid removed, in the oven till its
weight becomesconstant (Normally for 24hrs.).iv) When the soil has dried, remove the container from the oven, using tongs.v) Find the weight W3 of the container
with the lid and the dry soil sample. 31
32. 32. REPORTING OF RESULTSThe water content w = [(W2 − W3) ×100%] /(W3 −W1) CALCIUM CARBIDE METHOD(RAPID MOISTURE METER
TEST)AIMTo determine the water content in soil by calcium carbide method as per IS: 2720(Part II) - 1973.PRINCIPLEIt is a method for rapid determination of
water content from the gas pressuredeveloped by the reaction of calcium carbide with the free water of the soil. From thecalibrated scale of the pressure gauge the
percentage of water on total mass of wet soilis obtained and the same is converted to water content on dry mass of soil.APPARATUSi) Metallic pressure vessel,
with a clamp for sealing the cup, alongwith a gaugecalibrated in percentage water contentii) Counterpoised balance, for weighing the sampleiii) Scoop, for
measuring the absorbent (Calcium Carbide)iv) Steel balls - 3 steel balls of about 12.5mm dia. and 1 steel ball of 25mm dia.v) One bottle of the absorbent (Calcium
Carbide)PREPARATION OF SAMPLESand - No special preparation. Coarse powders may be ground and pulverized.Cohesive and plastic soil - Soil is tested with
addition of steel ball in the pressurevessels.The test requires about 6g of sample.PROCEDUREi) Set up the balance, place the sample in the pan till the mark on the
balance armmatches with the index mark.ii) Check that the cup and the body are clean.iii) Hold the body horizontally and gently deposit the levelled, scoop-full of
the 32
33. 33. absorbent (Calcium Carbide) inside the chamber.iv) Transfer the weighed soil from the pan to the cup.v) Hold cup and chamber horizontally, bringing them
together without disturbing thesample and the absorbent.vi) Clamp the cup tightly into place. If the sample is bulky, reverse the aboveplacement, that is, put the
sample in the chamber and the absorbent in the cup.vii) In case of clayey soils, place all the 4 steel balls (3 smaller and 1 bigger) in thebody alongwith the
absorbent.viii) Shake the unit up and down vigorously in this position for about 15 seconds.ix) Hold the unit horizontally, rotating it for 10 seconds, so that the balls
roll aroundthe inner circumference of the body.x) Rest for 20 seconds.xi) Repeat the above cycle until the pressure gauge reading is constant and note thereading.
Usually it takes 4 to 8 minutes to achieve constant reading. This is the watercontent (m) obtained on wet mass basis.xii) Finally, release the pressure slowly by
opening the clamp screw and taking thecup out, empty the contents and clean the instrument with a brush.REPORTING OF RESULTSThe water content on dry
mass basis,W = (m/100 – m)*100% IN-SITU DRY DENSITY CORE CUTTER METHODAIMTo determine the in-situ dry density of soil by core cutter method as
per IS: 2720 (PartXXIX) - 1975.APPARATUSi) Cylindrical core cutterii) Steel dolleyiii) Steel rammer 33
34. 34. iv) Balance, with an accuracy of 1gv) Straightedgevi) Square metal tray - 300mm x 300mm x 40mmvii) TrowelPROCEDUREi) The internal volume (V) of the
core cutter in cc should be calculated from itsdimensions which should be measured to the nearest 0.25mm.ii) The core cutter should be weighed to the nearest gram
(W1).iii) A small area, approximately 30cm square of the soil layer to be tested should beexposed and levelled. The steel dolly should be placed on top of the cutter
and thelatter should be rammed down vertically into the soil layer until only about 15mm ofthe dolly protrudes above the surface, care being taken not to rock the
cutter. Thecutter should then be dug out of the surrounding soil, care being taken to allow somesoil to project from the lower end of the cutter. The ends of the soil
core should thenbe trimmed flat in level with the ends of the cutter by means of the straightedge.iv) The cutter containing the soil core should be weighed to the
nearest gram (W2).v) The soil core should be removed from the cutter and a representative sample shouldbe placed in an air-tight container and its water content
(w) determined as in Para 5.1.REPORTING OF RESULTSBulk density of the soil γ = (W2 −W1)/V g /ccDry density of the soil γd = [100γ/100+w] g cc MIX
DESIGNConcrete is the basic engineering material used in most of the civil engineeringstructures. Its popularity as basic building material in construction is
because of, itseconomy of use, good durability and ease with which it can be manufactured at site.The ability to mould it into any shape and size, because of its
plasticity in green stageand its subsequent hardening to achieve strength, is particularly useful.Concrete like other engineering materials needs to be designed for
properties likestrength, durability, workability and cohesion. Concrete mix design is the science ofdeciding relative proportions of ingredients of concrete, to
achieve the desired 34
35. 35. properties in the most economical way.With advent of high-rise buildings and pre-stressed concrete, use of higher grades ofconcrete is becoming more common.
Even the revised IS 456-2000 advocates use ofhigher grade of concrete for more severe conditions of exposure, for durabilityconsiderations. With advent of new
generation admixtures, it is possible to achievehigher grades of concrete with high workability levels economically. Use of mineraladmixtures like fly ash, slag,
meta kaolin and silica fume have revolutionised theconcrete technology by increasing strength and durability of concrete by many folds.Mix design of concrete is
becoming more relevant in the above-mentioned scenario.However, it should be borne in mind that mix design when adopted at site shouldbe implemented with
proper understanding and with necessary precautions.Durocrete mix design manual is an attempt to increase the awareness among theusers, about concrete mix
design. It is made with intention of serving as readyreckoner for personnel, implementing mix design at site.Advantages of mix designMix design aims to achieve
good quality concrete at site economically.I. Quality concrete means Better strength Better imperviousness and durability Denseand homogeneous concreteII.
Economya) Economy in cement consumptionIt is possible to save up to 15% of cement for M20 grade of concrete with the help ofconcrete mix design. In fact
higher the grade of concrete more are the savings. Lowercement content also results in lower heat of hydration and hence reduces shrinkagecracks.b) Best use of
available materials:Site conditions often restrict the quality and quantity of ingredient materials. Concretemix design offers a lot of flexibility on type of aggregates
to be used in mix design.Mix design can give an economical solution based on the available materials if theymeet the basic IS requirements. This can lead to saving
in transportation costs fromlonger distances.c) Other properties:Mix design can help us to achieve form finishes, high early strengths for earlydeshuttering, concrete
with better flexural strengths, concrete with pumpability and 35
36. 36. concrete with lower densities.What is mix design?Concrete is an extremely versatile building material because, it can be designed forstrength ranging from M10
(10Mpa) to M100 (100 Mpa) and workability rangingfrom 0 mm slump to 150 mm slump. In all these cases the basic ingredients ofconcrete are the same, but it is
their relative proportioning that makes thedifference.Basic Ingredients of Concrete: -1. Cement – It is the basic binding material in concrete. 2. Water – It hydrates
cement and also makes concrete workable.3. Coarse Aggregate – It is the basic building component of concrete.4. Fine Aggregate – Along with cement paste it
forms mortar grout and fills the voidsin the coarse aggregates.5. Admixtures – They enhance certain properties of concrete e.g. gain of strength,workability, setting
properties, imperviousness etcConcrete needs to be designed for certain properties in the plastic stage as well as inthe hardened stage.Properties desired from
concrete in plastic stage: -Workability Cohesiveness Initial set retardationProperties desired from concrete in hardened stage: -Strength Imperviousness
DurabilityConcrete mix design is the method of correct proportioning of ingredients ofconcrete, in order to optimise the above properties of concrete as per
siterequirements.In other words, we determine the relative proportions of ingredients of concreteto achieve desired strength & workability in a most economical
way.Information required for concrete mix designThe site engineer should give following information while giving material for mix 36
37. 37. design to the mix design laboratory: -Grade of concrete (the characteristic strength)Workability requirement in terms of slumpOther properties (if required): -i.
Retardation of initial set (to avoid cold joints in case of longer leads or for readymix concrete) ii. Slump retention (in case of ready mix concrete) iii. Pumpability
(In case of ready mix concrete)iv.Acceleration of strength (for precast members or where early deshuttering isdesired) v. Flexural strength (normally required for
concrete pavements)Ascertain whether condition of exposure to concrete is mild, moderate severe or verysevere. Proper investigation of soil should be done to
ascertain presence of sulphates& chlorides, in case of doubt.Following factors indicate degree of control at site: -Batching – weigh batching / volume batching.Type
of aggregates – whether mixed graded aggregate will be used or 20mm, 10mmaggregates will be used separately.Testing of concrete – whether casting & testing of
concrete cubes will be doneregularly at site.Source of aggregate – whether sources of sand and aggregate will be standardised orlikely to change
frequently.Supervision – whether qualified staff will be present to supervise concreting work andmake necessary corrections e.g. correction for moisture in sand and
changes inmaterial properties.Site laboratory – whether the site will have necessary laboratory equipment likesieves, weighing balance etc. to check material
properties.Material properties and how they affect mix design Cementa) Strength/grade of cement: Grade of cement e.g. 43 grade or 53 grade caninfluence the mix
design. Grade of cement indicates minimum strength of cement inN/mm2 tested as per standard conditions laid down by IS codes (OPC 43 grade – IS8112-1989,
OPC 53 grade – IS 12269 – 1987 e.g. a 43 grade cement should giveminimum strength of 43 N/mm2 at 28 days). Higher the strength of cement, higher is 37
38. 38. the strength of concrete for the same water/cement ratio. In other words a higherstrength of cement permits use of higher water/cement ratio to achieve the
samestrength of concrete. The IS 10262 - 1982 for mix design gives the different curves ofcement based on the actual strength of cement on 28th day. These cement
curves givewater/cement ratio required to achieve a given target strength. Information on gradeof cement may not be as useful as the actual 28days strength of
cement. This isbecause some of the 43 grade cements practically give strengths more than 53N/mm2. When a 53-grade cement is stored for a long time, its strength
maydeteriorate and become equivalent to 33 grade or 43 grade cement. Thus 28 daysstrength of cement is required to select the cement curve before starting the
mixdesign. Finding the 28 days strengths of cement consumes time. It is not practical inmany cases to wait for 28 days strength of cement to start the mix design. In
suchcases 28 days strength reports of the manufacturers may be used and can besupplemented by accelerated strength of cement found by reference mix
methodgiven in IS 10262 Apart from strength of cement, the type of cement e.g. OrdinaryPortland Cement, pozzolona cement (blended cement) etc, is also
important factoraffecting the gain of strength. Blended cements achieve strengths later than OrdinaryPortland Cements and require extended curing period.
However, use of these cementsresult in more durable concrete by offering greater resistance to sulphate and chlorideattacks.b) Initial & Final setting time of cement:
The initial setting time of cement indicatesthe time after which the cement paste looses its plasticity. Operations like mixing,placing and compaction should be
completed well before the initial setting time ofcement .The minimum initial setting time specified by IS 456 –2000 (Clause 5.4.1.3page no 14 and IS 8112-1989
page 2) is 30 minute. Most of the cements producedtoday give an initial set of more than 60 minutes. Beginning of hardening of cementpaste indicates the final
setting of cement. The maximum limit for final settingpermitted by IS 8112: 1989 (Clause 6.3. page 2) is 600 minute. Most of the cementsproduced today give a
final setting of between 3 to 5 hours. Curing can be startedafter final setting of cement. The initial setting and the final setting can be extendedby use of retarders in
order to avoid cold joints when lead-time for placing concrete islonger.Fine Aggregates a) Gradation of fine aggregates: The gradation of sand is given by sieve
analysis. 38
39. 39. The sieve analysis is done by passing sand through a set of standard sieves andfinding out cumulative passing percentage through each sieve. The IS 383 –
1970classifies fine aggregates in 4 zones starting from zone I representing coarse sand, tozone IV representing the finest sand. The limits of cumulative percentage
passing foreach sieve for above zones are given in table 4 of IS 383 The fineness of sand foundby sieve analysis governs the proportion of sand in concrete .The
overall fineness ofsand is given by factor called fineness modulus. Fineness Modulus is given bydivision of the summation of cumulative retained fractions for
standard sieves up to150-micron sieve size by 100.c) Silt Content by weight: This is found by wet-sieving of sand and material passing75 micron sieve is classified
as silt. This silt affects the workability of concrete,results in higher water/cement ratio and lower strength. The upper limit for 75-micronsieve in case of sand is 3%
by weight. This limit has however been extended to 15%in case of crushed sand in IS 383 – 1970 Table 1Coarse Aggregatea) Maximum size of coarse aggregate:
Maximum size of aggregate is the standardsieve size (40mm, 25mm, 20mm, 12.5mm, 10mm) through which at least 90% ofcoarse aggregate will pass. Maximum
size of aggregate affects the workability andstrength of concrete. It alsoinfluences the water demand for getting a certain workability and fine aggregatecontent
required for achieving a cohesive mix. For a given weight, higher themaximum size of aggregate, lower is the surface area of coarse aggregates and viceversa. As
maximum size of coarse aggregate reduces, surface area of coarse aggregateincreases. Higher the surface area, greater is the water demand to coat the particlesand
generate workability. Smaller maximum size of coarse aggregate will requiregreater fine aggregate content to coat particles and maintain cohesiveness of
concretemix. Hence 40 mm down coarse aggregate will require much less water than 20 mmdown aggregate. In other words for the same workability, 40mm down
aggregate willhave lower water/cement ratio, thus higher strength when compared to 20mm downaggregate. Because of its lower water demand, advantage of
higher maximum size ofcoarse aggregate can be taken to lower the cement consumption. Maximum size ofaggregate is often restricted by clear cover and minimum
distance between the 39
40. 40. reinforcement bars. Maximum size of coarse aggregate should be 5 mm less than clearcover or minimum distance between the reinforcement bars, so that the
aggregates canpass through the reinforcement in congested areas, to produce dense and homogenousconcrete.It is advantageous to use greater maximum size of
coarse aggregate for concretegrades up to M 35 where mortar failure is predominant. Lower water/cement ratio willmean higher strength of mortar (which is the
weakest link) and will result in higherstrength of concrete. However, for concrete grades above M40, bond failure becomespredominant. Higher maximum size of
aggregate, which will have lower area ofcontact with cement mortar paste, will fail earlier because of bond failure. Hence forhigher grades of concrete (M40 and
higher) it is advantageous to use lower maximumsize of aggregate to prevent bond failure.The fineness modulus of sand varies from 2.0 to 4.0; higher the FM
coarser is thesand.Type of SandFine Medium Coarse- FM- 2.0 to 2.8 - 2.8 to 3.2 - 3.2 and aboveb) Specific gravity of fine aggregates: This is the ratio of solid
density particles tothe density of water. Higher the specific gravity, heavier is the sand particles andhigher is the density of concrete. Conversely a lower specific
gravity of sand willresult in lower density of concrete. Specific gravity of sand is found with help ofpycnometer bottles. The specific gravity of fine aggregates
found in Pune regionvaries from 2.6 to 2.8.b) Grading of coarse aggregate: The coarse aggregate grading limits are given in IS383 – 1970 - table 2, Clause 4.1 and
4.2 for single size aggregate as well as gradedaggregate. The grading of coarse aggregate is important to get cohesive & denseconcrete. The voids left by larger
coarse aggregate particles are filled by smallercoarse aggregate particles and so on. This way, the volume of mortar (cement-sand-water paste) required to fill the
final voids is minimum. However, in some cases gapgraded aggregate can be used where some intermediate size is not used. Use of gap-graded aggregate may not
have adverse effect on strength.By proper grading of coarse aggregate, the possibility of segregation is minimised,especially for higher workability. Proper grading
of coarse aggregates also improves 40
41. 41. the compactability of concrete.c) Shape of coarse aggregate: Coarse aggregates can have round, angular, orirregular shape. Rounded aggregates because of
lower surface area will have lowestwater demand and also have lowest mortar paste requirement. Hence they will resultin most economical mixes for concrete
grades up to M35. However, for concretegrades of M40 and above (as in case of max size of aggregate) the possibility of bondfailure will tilt the balance in favour
of angular aggregate with more surface area.Flaky and elongated coarse aggregate particles not only increase the water demandbut also increase the tendency of
segregation. Flakiness and elongation also reducethe flexural strength of concrete. Specifications by Ministry of Surface Transportrestrict the combined flakiness
and elongation to 30% by weight of coarse aggregates.d) Strength of coarse aggregate: Material strength of coarse aggregate is indicatedby crushing strength of
rock, aggregate crushing value, aggregate impact value,aggregate abrasion value. In Maharashtra the coarse aggregates are made of basaltrock, which has strengths
in excess of 100 N/mm2. Hence aggregates rarely fail instrength.e) Aggregate Absorption: Aggregate can absorb water up to 2 % by weight when inbone dry state,
however, in some cases the aggregate absorption can be as high as 5%.Aggregate absorption is used for applying a correction factor for aggregates in drycondition
and determining water demand of concrete in saturated surface drycondition.Decision Variables in Mix DesignA. Water/cement ratio B. Cement content C. Relative
proportion of fine & coarseaggregates D. Use of admixturesA. Water/cement ratioWater to cement ratio (W/C ratio) is the single most important factor governing
thestrength and durability of concrete. Strength of concrete depends upon W/C ratiorather than the cement content. Abram’s law states that higher the water/cement
ratio,lower is the strength of concrete. As a thumb rule every 1% increase in quantity ofwater added, reduces the strength of concrete by 5%. A water/cement ratio
of only0.38 is required for complete hydration of cement. (Although this is the theoreticallimit, water cement ratio lower than 0.38 will also increase the strength,
since all thecement that is added, does not hydrate) Water added for workability over and above 41
42. 42. this water/cement ratio of 0.38, evaporates leaving cavities in the concrete. Thesecavities are in the form of thin capillaries. They reduce the strength and
durability ofconcrete. Hence, it is very important to control the water/cement ratio on site. Everyextra lit of water will approx. reduce the strength of concrete by 2
to 3 N/mm2and increase the workability by 25 mm. As stated earlier, the water/cement ratiostrongly influences the permeability of concrete and durability of
concrete.B. Cement contentCement is the core material in concrete, which acts as a binding agent and impartsstrength to the concrete. From durability
considerations cement content should not bereduced below 300Kg/m3 for RCC. IS 456 –2000 recommends higher cementcontents for more severe conditions of
exposure of weathering agents to the concrete.It is not necessary that higher cement content would result in higher strength. In factlatest findings show that for the
same water/cement ratio, a leaner mix will give betterstrength. However, this does not mean that we can achieve higher grades of concreteby just lowering the
water/cement ratio. This is because lower water/cement ratioswill mean lower water contents and result in lower workability. In fact for achieving agiven
workability, a certain quantity of water will be required. If lower water/cementratio is to be achieved without disturbing the workability, cement content will have
tobe increased. Higher cement content helps us in getting the desired workability at alower water/cement ratio. In most of the mix design methods, the water
contents toachieve different workability levels are given in form of empirical relations.Water/cement ratios required to achieve target mean strengths are
interpolated fromgraphs given in IS 10262 Clause 3.1 and 3.2 . The cement content is found as follows:-Cement content (Kg/m3) =Water required achieving
required workability (Lit/m3)Water/cement ratioThus, we see that higher the workability of concrete, greater is cement contentrequired and vice versa. Also, greater
the water/cement ratio, lower is the cementcontent required and vice versa.C. Relative proportion of fine, coarse aggregates gradation of aggregatesAggregates are
of two types as below:a. Coarseaggregate(Metal): Theseareparticlesretainedonstandard IS 4.75mm sieve.b. Fine aggregate(Sand): These are particles passing
standard IS 4.75mm sieve. 42
43. 43. Proportion of fine aggregates to coarse aggregate depends on following:i. Fineness of sand: Generally, when the sand is fine, smaller proportion of it isenough to
get a cohesive mix; while coarser the sand, greater has to be its proportionwith respect to coarse aggregate.ii. Size & shape of coarse aggregates: Greater the size of
coarse aggregate lesser isthe surface area and lesser is the proportion of fine aggregate required and vice versa.Flaky aggregates have more surface area and require
greater proportion of fineaggregates to get cohesive mix. Similarly, rounded aggregate have lesser surface areaand require lesser proportion of fine aggregate to get
a cohesive mix.iii. Cement content: Leaner mixes require more proportion of fine aggregates thanricher mixes. This is because cement particles also contribute to
the fines in concrete.D. Use of admixturesNow days, admixtures are rightly considered as the fifth ingredient of concrete. Theadmixtures can change the properties
of concrete. Commonly used admixtures are asfollows:i. Plasticisers & superplasticisersii. Retardersiii. Acceleratorsiv. Air entraining agentsv. Shrinkage
compensating admixturesvi. Water proofing admixturesi. Plasticisers & super plasticisersPlasticisers help us in increasing the workability of concrete without
addition ofwater. It means that we can achieve lower water/cement ratio without reducing theworkability at the same cement content. Cement particles tend to form
flocs trapping apart of mixing water in them. Hence not all the water added is useful for generatingworkability. Plasticisers work as dispersion agents (de flocculent)
releasing the watertrapped in the flocs resulting in workability. Use of plasticisers is economical as thecost incurred on them is less than the cost of cement saved;
this is more so in concretedesigned for higher workability.Compatibility of plasticisers with the cement brand should be checked before use.Also plasticiser should
not be added in dry concrete mix. 43
44. 44. Plasticizers are used for moderate increase of workability whereas super plasticizersare used where very large increase in workability is required. Plasticizers are
normallylignosulphonated formaldehydes and are normally added in small dosages. This isbecause large dosage can cause permanent retardation in concrete and
adversely affectits strength. Super plasticizers are naphthalene or melamine based formaldehyde.They can be used in large dosages without any adverse effect on
concrete. This iscontrary to popular perception that term super plasticizers means more potent, hencelower dosage is required when compared to normal
plasticizers. In practice superplasticizers are used in large dosages for generating higher workability and betterslump retention. Compatibility of plasticizers with
cement should be ascertainedbefore use in concrete. Since action of plasticizers is based on ionic dispersion certainplasticizers are more effective with certain
cements, thus requiring lower dosages.Non-compatible plasticizers if used, will not adversely affect the concrete, but its highdosage will make it uneconomical for
use.ii. Retarders:They are used for retarding (delaying) the initial setting time of concrete. This isparticularly required when longer placing times are desired as in
case of ready mixedconcrete. Retarders are commonly used to prevent formation of cold joints whencasting large concrete. Retarders are normally added in lower
dosages as largedosages can cause permanent retardation in concrete. Retarders are recommended incase of hot weather concreting to prevent early loss of slump. It
is important to notethat retarders reduce early strength of concrete e.g. 1-day and 3-day strength.However, 28 days strength is not affected.iii. AcceleratorsThey are
used for accelerating the initial strength of concrete. Typical acceleratorsincrease the 1-day (up to 50 %) and 3-days (up to 30 %) strength of concrete. Most ofthe
accelerators show little increase for 7 days strength. For this reason, acceleratorsare commonly used in precast concrete elements for early removal of
moulds.Accelerators may not be much useful for early deshuttering where early strengths arerequired in range of 5 to 7 days. This is because accelerators are
expensive and theirability to increase strengths decreases after 3-5 days. A better option for earlydeshuttering would be the use of plasticizers, reducing the
water/cement ratio andachieving a higher grade of concrete. It is believed that accelerators may causeretrogression of strength after 28 days when compared with
normal concrete. 44
45. 45. Concrete Mix Design MethodsThe basic objective of concrete mix design is to find the most economical proportions(Optimisation) to achieve the desired end
results (strength, cohesion, workability,durability, As mentioned earlier the proportioning of concrete is based on certainmaterial properties of cement, sand and
aggregates. Concrete mix design is basically aprocess of taking trials with certain proportions. Methods have been developed toarrive at these proportions in a
scientific manner. No mix design method directlygives the exact proportions that will most economically achieve end results.These methods only serve as a base to
start and achieve the end results in thefewest possible trials.The code of practice for mix design-IS 10262 clearly states following: - The basicassumption made in
mix design is that the compressive strength of workableconcretes, by and large, governed by the water/cement ratio. Another most convenientrelationship
applicable to normal concrete is that for a given type, shape, size andgrading of aggregates, the amount of water determines its workability. However, thereare
various other factors which affect the properties of concrete, for example thequality & quantity of cement, water and aggregates; batching; transportation;
placing;compaction; curing; etc. Therefore, the specific relationships that are used inproportioning concrete mixes should be considered only as the basis for trial,
subjectto modifications in the light of experience as well as for the particular materials usedat the site in each case. Different mix design methods help us to arrive at
the trial mixthat will give us required strength, workability, cohesion etc. These mix designmethods have same common threads in arriving at proportions but their
method ofcalculation is different. Basic steps in mix design are as follows:Find the target mean strength.Determine the curve of cement based on its
strength.Determine water/cement ratio. Determine cement content.Determine fine and coarse aggregate proportions 45
46. 46. BATCHING PLANT 46
47. 47. PROJECT EXECUTIONMETHOD STATEMENT FOR CIVIL AND MECHANICAL 1. METHOD STATEMENT FOR CIVIL METHOD STATEMENT FOR
SURVEY WORKS OBJECTIVE: To formulate guidelines for Setting out and routine surveyworks REFERENCE: 1. Drawing 2. Technical Specifications for Civil
works 3. Inspection and test plan 4. Survey Layout showing control stations MAJOR EQUIPMENTS: Calibrated Auto - level, Theodolite (LC-1"), Total Station
and necessary measuring tools METHOD STATEMENT FOR BUILDING UP OF PILES UPTO CUTOFF LEVEL OBJECTIVE: Building up of Plies up-to cut-off
levels REFERENCE: 1. Drawing 2. Technical Specifications for Civil works 3. Technical Data sheet of Nitobond EP METHOD STATEMENT FOR
REINFORCEMENT WORK 1. OBJECTIVE: This procedure covers method for cutting, bending and tying of reinforcement and inspection of works. 2.
REFERENCE: Reinforcement placing and handling shall be as per IS-456 MAJOR EQUIPMENTS: Bar cutting & bending machines, rebar tying tool. METHOD
STATEMENT FOR FORMWORK 1. OBJECTIVE: This Procedure covers fixing and removal of formwork and checking of formwork. 2. REFERENCE: 1.
Approved Drawings 47
48. 48. 2. IS 456 & IS 6461(Part 5) 3. Tender Document METHOD STATEMENT FOR BOLTS PROCUREMENT & FIXATION 1. OBJECTIVE: This Procedure
covers procuring and fixing of bolts. 2. REFERENCE: 1. Tender Specification 2. Approved Drawings METHOD STATEMENT FOR CONCRETING WORKS 1.
OBJECTIVE: This Procedure covers fixing and removal of formwork and checking of formwork. 2. REFERENCE: 1. Tender Specification 2. Approved Drawings
3. IS 10262, IS 3370 & IS 456 4. IS 383 METHOD STATEMENT FOR BACKFILLING 1.OBJECTIVE: The scope of back-filling covers the filling in plinths,
pits, trends, depressions in layers 200mm thick including watering and compaction by Roller / plate compactor. 2. REFERENCE: 1. Drawing 2. Bill of Quantities
METHOD FOR REINFORCEMENT WORK1.All reinforcement shall be placed above the ground by using wooden sleepers orconcrete blocks.2.For
reinforcement, care shall be taken to protect the reinforcement from exposure tosaline atmosphere during storage, fabrication and use.3.Against requirement from
site, bars shall be cut and bent to shape and dimension asshown in bar bending schedule based on Good For Construction (GFC) drawings. 48
49. 49. 4.Reinforcement shall be tied as per the latest GFC drawing and any extra barsprovided at site shall be recorded in the pour card/ lap register.5.Unusable cut
rods and scrap reinforcement shall be properly placed at yard.Bar Bending Schedule:1.Prepare bar bending schedule based on the latest GFC drawings and to be
submittedto Engineer for review2.Bar bending schedule shall clearly specify the following:a) Bar dia.b) Numbers.c) Cut-lengths.d) Shapes.3.Bar bending schedule
shall take into account the following field/ designrequirement.a) Desirable lap locations and staggering of laps.b) Lap lengths.c) Development length/ Anchorage
length.Cutting, Bending and Placing:1.All reinforcement shall be free from loose mill scales, loose rust and coats of paints,oil, mud or any other substances which
may destroy or reduce bond. Use wire brushto clean the reinforcement.2.Cutting and bending shall conform to the details given in the approved bar
bendingschedule. a) Cutting of Rebar by heat is not permitted, only cutting by grinding or shearing ispermitted. b) No heating is allowed to facilitate bending of
Rebar.3.Place the reinforcement as per GFC drawings ensuring the following aspectsproperly.a) Type & size of bar. b) Number of bars.c) Location and lengths of
laps, splices.d) Curtailment of bars.e) In two way reinforcement, check the direction of reinforcement in various layers.f) Adequate number of chairs, spacer bars
and cover blocks. 49
50. 50. g) Size of cover blocks.h) All the bars shall be tied with double fold 18g soft GI annealed binding wire.4.Reinforcement may be placed with in the following
tolerance whenever required:a) for effective depth 200mm or less ±10mm.b) for effective depth more than 200mm ±15mm.c) The cover shall in no case be reduced
by more than one third of the specified coveror 0 /+ 10mm.d) The cover should suit various cover requirement as per Drawing Notes.5.The sequence of
reinforcement shall be correlated with fixing of inserts, sleeves,conduits, anchors and formworks.6.In walls, place accurately bent spacer bars wired to vertical or
horizontal barsbetween successive rows.7.No steel parts of spacers sure allowed inside the concrete cover. Spacer blocks madefrom cement, sand and small
aggregate shall match the mix proportion of thesurrounding concrete. Alternatively PVC cover blocks of approved make can be used.8.Spacers, cover blocks should
be of concrete of same strength or PVC9.Spacers, chairs and other supports detailed on drawings, together with such othersupports as may be necessaray, should be
used to maintain the specified nominalcover to the steel reinforcement.10.Spacers or chairs should be placed at a maximum spacing of 1.0 mtr and closerspacing
may sometimes be necessary.11.All reinforcement shall be placed and maintained in the positions shown in thedrawing by providing proper cover blocks, spacers,
Supporting bars.12.Rough handling, shock loading (Prior to embedment) and the dropping ofreinforcement from a height should be avoided. Reinforcement should
be securedagainst displacement. METHOD FOR FORMWORKPre Check1.Check if the shutters are properly cleaned by removing the concrete/ mortar
andprotruding nails. 50
51. 51. 2.Formwork shall be made to the exact dimensions within the permissible tolerancesas mentioned below.3.Required thickness and quality of plywood
conforming to IS 6461 shall be used tomeet the requirements of design and surface finish.4.For beam bottom & sides, proper size of timber at required spacing shall
beprovided to take the design loads/ pressure considering sleeves, conduit anchors &inserts.Erection of formwork5.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 thespecified 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 uponthe type of finish specified.9.Erect
staging/shuttering as per drawing/sketches in such a way that deshuttering canbe done easily including provision for repropping, if planned.10.Check the location,
line,level,plumb and dimensions of the formwork to ensurethat the deviations are within the permissible limits.11.Provide bracing at proper places & intervals as
specified by the manufacturer or asper formwork scheme to take care of lateral loads.12.Apply mould oil/other coatings as release agents before reinforcement steel
isplaced.13.Wire ties passing through beams,columns and walls shall not be allowed .In theirplace 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 lateralsupports 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 asmetals, blocks, saw dust and foreign materials before concreting if
required throughclean-out openings.18.Check all the gaps/openings are properly closed to avoid leakages. 51
52. 52. 19.Check all the inserts/embedments and openings are exactly placed as per thedrawings.20.In case of leakages, bulging and sagging immediate actions shall be
taken bytightening wedges or adjusting by jacks which must be done before the concrete takesits initial set.Removal of Forms21.Formwork components shall not be
dropped but shall be lowered without damageto the components and structures. All the removed formwork materials shall bethoroughly scarped, cleaned
immediately and stacked properly for reuse.22.All forms shall be removed after the minimum period stipulated mentioned belowwithout damage to the concrete
including removal without shock as per IS 456 METHOD FOR BACKFILLING1. Backfilling area shall be free from foreign matters (ie. wooden scraps ,
plywoodpieces rebar bits etc) and tie rods recesses shall be rendered with polymer based nonshrink compound with a subsequent application of curing compound on
them.2.Filling around foundation or other places indicated shall be done with approvedmaterial obtained from excavation or approved materials brought from out
side.3.The material shall be good quality soft or hard murrum or Panna sand or otherapproved back filling material.Back filling soil shall be free from black cotton
soil.4.Filling shall be done in layers not exceeding 20 cms thick and each layer shall bewatered adequately and consolidated properly by rollers or pneumatic
rammers 8 to10 tonnes wherever conditions permit. If it is not possible, the consolidation shall bedone by hand rollers/ heavy pneumatic/ hand rammers/ plate
compactor.5.The surface of the filling shall be finished to lines and levels as required.6.The approved materials shall be plced in layers, not exceeding 200mm in
depthbefore compaction and shall be compacted to minimum 95% dry density. Layersplaced in the top 300mm of the fill shall be compacted to 98% of maximum
drydensity.No of Samples:(i)For foundation filling - one for every 10 foundation for each compacted layer.(ii)For area filling one for every 1000 sqm area for each
compacted layer. 52
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QUALITY ASSURANCE & QUALITY CONTROL DEPARTMENT ...

Summer internship report L&T

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Summer internship report L&T

Umed Paliwal, Business Analyst at Axtria India Pvt. Ltd.

Published on Apr 14, 2013

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