Training report

Project Report On Building

2013

construction

In partial fulfillment of the requirements for the degree of

Bachelor of technology
2010-2014

Submitted by

Nadeem Khan
Selaqui Academy of Higher Education, Dehradun

Affiliated to Uttarakhand Technical University, Dehradun Acknowledgement

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Index:

Overview Proposed view of CCE-COD SITE Plan Over View of Pre Enginneering Building

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Project details: Project name is KASSIA, J P Sports center, Noida

Project cost: 200 crores Duration: 36 months Consist of 102 towers out of which 32 are G+2 & remaining are G+6

Main Works Road Works Structural Work Pre-engineered Building Work Quality assurance & Quality control Drainage Water supply works Electrical Works

Introduction:
Jay pee infratech is Indias largest technology, engineering, manufacturing and construction organization with a record of over 40 years. Jay pee is also adjudged Indias best managed and most respected company on various attributes of customer delight and shareholder value. Jay pee infratech is the largest construction organization in the country. It figures among the Worlds the 217 Top Contractors and ranks 67th in global ranking as per the survey conducted by the reputed international construction magazine Engineering News Record, USA (August 2011). Jay pee infra.cutting edge capabilities cover every discipline of construction civil, mechanical, and electrical and Cement Manufacturing and services extend to large industrial and infrastructure projects from concept to commissioning.

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Jay Pee has played a prominent role in Indias industrial and infrastructure development by executing several projects across length and breadth of the country and abroad. Jay pee Infratech 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. Cement manufacturing

MAINWORKS:

.1 STRUCTURAL WORKS The structural work is executed in two parts mainly sub structure and super structure. Sub structure is that part which is constructed below the Ground level used to support the structure above. Foundations, basement, subfloor are some components of this area. Super structure is defined as structure above ground level. Brickwork, timber, floors, beams, slabs etc. SUBSTRUCTURE FOOTING COLOUMN

Footing is provided to transfer the load from structure to soil. The foundation is provided in whole campus is of type shallow foundations and normal footing. The typical section is shown below

Procedure for laying foundation.

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Excavation of soil below desired depth Compaction of base Reinforcing mesh is prepared. Form work and placement of reinforcement of coloumn and base. Placement of concrete. Curing of concrete

After the whole procedure backfilling is done in layers by providing adequate amount of water for compaction and left for some time and then compacted by mechanical means. The steel of grade fe-500D is used for all structural works and cement of grade OPC-43 is used. the reinforcement is provided as per the drawing of footing no honey combing is allowed. Proper formwork is used here

. Fig.Laying of footing base 2 FORMWORK USED The new Methodology is used here named as ALUFO System for form works. This is the very new system of its type and very effective system used here by L&T FRAMES TO SUPPORT FORMWORK

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Fig ------H beams

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STEEL WALER

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Support

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brackets

CT props

U HEADS

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STEEL SHUTTERING

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Shuttering and formwork ALUFO system 3- SHUTTERING All the shuttering being used in the project is of wooden ply, 12mm, or 20mm and Steel plates. 12mm is for the slab bottom, column boxes, etc. 20mm is only for beam bottom. 4- REINFORCEMENT:

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Here, the main focus is on the estimation, management, and preparation of the reinforcement in its usable form, before being transported to the site. Bar bending schedule to be as per approved drawings, and reinforcement steel to be cut and bend as per approved bar bending schedule. Bars to be bent to the specified shape and dimensions, using a proper bar bender, operated by hand or power to obtain correct radii of bends and shape. Reinforcement bars to be placed accurately in position as shown in the drawings. The bars, crossing one another to be tied together at every intersection with binding wire (Dia. of binding wire not less than 18 gauge), to make the skeleton of reinforcement rigid such that it does not get displaced during placing of concrete or any other operation and lap length must be provided more than 500 mm and as per IS for different dia. of bars. The minimum dia. of spacer bar to be 8mm to a maximum of main reinforcement or maximum size of aggregate, whichever is greater. Cover blocks of thickness equal to the specified cover to be placed between formwork and bars made of Concrete / Cement Mortar of specified grade of concrete/ strength as those of the member. Necessary stays, cover blocks, chairs, spacers, hangers, etc. or other subsidiary reinforcement to be provided and approved by engineer, to fix the reinforcement firmly in its correct position. Laps to be staggered.

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Fig.(on the left: shows the apparatus to bend the stirrups at the proper angle) (on the right: shows a bundle of stirrups which have been bent as per their requirement) 5- Cut Length:

The formula used to calculate the cut length is as follows: Suppose if the total cross section of the member is 400 X 400, with a clear cover of 50mm, then, the total cross section of the rectangular stirrup shall be 350 X 350. Now, thus the perimeter for this shall be: Perimeter = 4 (350) mm The minimum length of the hook (bent at 90) is 50d which shall be actually added to the total effective cut length.

PREPRATION OF WORK The various different processes which were encountered in the department during the training were: Preparation of bar bending schedule (BBS) Supervising the construction work according to GRID nos. (Grid H,J,K,L)- At level 4450 etc. Calculation of beam bottom. Calculation of beam shuttering side. Calculation of beam top level, slab top level.

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6- CASTING OF COLUMNS FOR CAR PARKING The height is maintained by drawing for this 4-5 temporary benchmark is made from which height (zaxis) is maintained Steps to be carried: Excavation already done for base. Fixing the column reinforcement to the mesh of footing. Providing the formwork around the mesh to support and fill the concrete in it. The cover blocks are used in it to maintain proper cover the minimum thickness of cover for columns is 40 mm as per IS 456:2000 The concrete of grade M-25 of Slump value 90-100 mm is used. Bars are provided from top to some height for further expansion of structure. Template is provided over column in which hole is provided for fixing anchor bolts and space is provided for shear key.

Section is shown below of template

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7-Things to be remember: a) During casting of column Starter must be provided and checked. Distance between two columns must be checked Column verticality must be maintained and checked by plumb bob. Spacing of reinforcement is maintained.

b) During casting of template. Distance from centre line is maintained. Top level of anchor bolt must be checked. Distance of bolt in diagonal as well as horizontal direction must be checked and no variation is allowed. Arresting of bolt is done carefully. Center line and level checking is must.

c) CASTING OF SLAB and BEAMS The casting of slab is done very carefully. d) Requirements for slab work. Proper BBS of slab. Development length and proper bending of reinforcement is done and length must be checked. Proper shuttering and support is given to maximum deflection section. The reinforcement is provided as per the drawing and care must be taken for extra reinforcement, rings, and shear reinforcement. The concrete is placed with the help of concrete discharge pump whose rate of discharge is 30 m3 per hour.

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U HEAD

shuttering plate

H BEAM

CT prop

REINFORCEMENT

Shuttering, and reinforcement is shown.

PUMP AND CONCRETE CARRYING MACHINE (TRANSIT Mixer) DURING CASTING

8-QUALITY:

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Quality means excellence. It is thus a philosophy rather than a mere attribute. The difference between two objects is judged by their qualities. We set some standards which determine the level of acceptability. This department primarily is concerned with regular testing and quality control of materials being used in the construction of the project. All plain concrete used in the project is M10 , and all R/F concrete is M25. Quality department is independent unit which works for checking the materials quality works quality Jay Pee is known for its quality work.

The various investigations being done in the department include: Silt and clay test. Sieve analysis test Specific gravity test Impact value test Flakiness test on coarse aggregates Moisture content test Tests for acidity, alkalinity & solid content. Compression strength (cube) test. Slump test. Initial setting and final setting. Cement consistency test. Fine aggregate testing. Specific gravity. Sieve analysis. Bulk density and water absorption.

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Check list for different tests of different materials All these tests are done as per INDIAN STANDARDS

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Different equipments shown which are as per IS FOR QUALITY ASSURANCE

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BATCHING PLANT The concrete used for all construction work is READY MIXED CONCRETE i.e. the concrete is prepared in the batching plant and then transported to the site. MAIN POINTS: The procedure for mixing the constituents is WEIGHT mixing. The design is done as MIX Design and procedure is followed as per IS-10262-2009. The concrete is also mixed with admixture to increase the slump value and also increase initial setting time. The special material RECRON is also used in concrete in M-15 and more. The concrete is transported through concrete transporting machine mainly named as transit mixer. Cement in the batching plant is coming from SILO.

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PRE ENGINEERED BUILDING

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PEB is used now days very widely due to its strength, durability, ease to assemble, transportation. In general PEB IS STEEL STRUCTURES made up of ISMB, PURLINS.GIRTS, and SHEETS etc. There are various components of PEB structure and is is very wide to explain so only describing only some special features of PEB structure which is used in COD. In structural engineering, a pre-engineered building (PEB) is designed by a manufacturer to be fabricated using a pre-determined inventory of raw materials and manufacturing methods that can efficiently satisfy a wide range of structural and aesthetic design requirements. Within some geographic industry sectors these buildings are also called Pre-Engineered Metal Buildings (PEMB) or, as is becoming increasingly common due to the reduced amount of pre-engineering involved in custom computer aided designs, simply, Engineered Metal Buildings (EMB). Historically, the primary framing structure of a pre-engineered building is an assembly of Ishaped members, often referred as I beams. In pre-engineered buildings, the I beams used are usually formed by welding together steel plates to form the I section. The I beams are then fieldassembled (e.g. bolted connections) to form the entire frame of the pre-engineered building. Some manufacturers taper the framing members (varying in web depth) according to the local loading effects. Larger plate dimensions are used in areas of higher load effects. Other forms of primary framing can include trusses, mill sections rather than 3-plate welded, castellated beams, etc. The choice of economic form can vary depending on factors such as local capabilities (e.g. manufacturing, transportation, construction) and variations in material vs. labour costs. Cold formed Z and C-shaped members may be used as secondary structural elements to fasten and support the external cladding. Roll-formed profiled steel sheet, wood, tensioned fabric, precast concrete, masonry block, glass curtainwall or other materials may be used for the external cladding of the building. In order to accurately design a pre-engineered building, engineers consider the clear span between bearing points, bay spacing, roof slope, live loads, dead loads, collateral loads, wind uplift, deflection criteria, internal crane system and maximum practical size and weight of fabricated members

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A PEB structure is shown above. COMPONENETS OF PEB

It is clearly be identified that PEB structure are very heavy structures and can bear very heavy loads. They are not much affected by atmosphere, temperature

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Special care should be done while assembling the PEB.

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THERE are various parts as well as properties of materials which are used in these kinds of buildings some of them are given below:THESE structures are widely classified as primary and secondary structures. a) Purlins: THE purlin used here is z type purlin of steel. The spacing of purlin is same as distance between trusses. It is a part of roof bracing system. b) Girts : The girts are also of same shape. Girts are member of wall bracing system. The main function of girt is to transfer the wind load from wall to primary frame.

Fig of purlins are shown..

C) Anchor bolts and base plate:

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The anchor bolt is shown it is used to support the whole structure from overturning. it is approx 600800 mm deep in concrete base. The base plate is used here is of thickness about 20 mm which restrain the columns to penetrate into the concrete and it also gives the support to column to tie.

Anchor bolts

base plate

c) Steel or aluminium decking or cladding:

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The structural deck transmits the gravity,wind, and earthquake forces to the roof framing. Thermal insulation is used for reducing heating and cooling costs,increasing thermal comfort and preventing condensation on interior surfaces.

Cladding

Insulation material

2) TRUSSES THE main loads on trusses are dead, imposed and wind loads. the dead load is due to sheeting or decking and the fixtures, insulation, felt etc.

Shear key

Gusset plate

PLANTS AND MACHINERY

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Now days plant and machinery plays an very prominent role in civil engineering construction it gives the speed, accuracy to the construction job. It also make the profession profitable. The plants and machines which are used at current site is like : Concrete paving machine Bitumen paving machine Scraper/grader Excavator Smooth wheeled rollers of 10tonnes and 4.5 tonnes Bulldozer Power shovel

Excavator cum back hoe (L&T Case)

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Mechanical finisher

Grader/scraper

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Excavator (poclain)

Transit Mixer

9 SAFETY:

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Safety and permit to work requirement shall be observed strictly. All personnel involve in the work shall be briefed on site safety regulations prior to work commencement. Observation at requirements at occupational Health safety and Environmental plan be strictly adhered.Safety helmets, safety shoes, safety goggles, safety belt and approved overall are mandatory at work site as per site safety requirements. All equipments& material shall be checked by the Safety Officer before start of work. The safety divison is widely known as EHS i.e. ENVIRONMENT HEALTH AND SAFETY.

CONCLUSION:
The thought of being with Jay Pee Indias largest construction conglomerate has itself been a matter of great pride for us. During this period of 4 weeks, we have come across the real civil engineering/ construction practices, and that too of the highest quality. From the very first day itself, we have been exposed to an all together different environment, in contrast to what we had previously seen in our college books. We have actually realized how objectives are achieved in a construction site, in a systematic and optimized format, while maintaining premium quality. We had hardly visited any construction sites before this practical training, and so we didnt know much about practical construction. However, today we can very easily recall each and every theoretical concept of our civil engineering books, and can see it happen here, in the real world. We have come across so many practical aspects that it is difficult to recall. However to enlist a few: o o o o o o o o Determination of stirrup cut length at the reinforcement yard. Preparation of bar bending schedule for all cases. Knowledge of shuttering and scaffolding at the formwork department (Jay Pee Formwork) Calculation of beam bottom, beam side. Knowledge of tackling various on-site difficulties. Knowledge about site safety norms. A detailed construction methodology and on-site viewing of footing operations. Knowledge of excavation and a practical know-how of how to maintain a proper angle of repose during excavation. o Knowledge of mix design at the quality lab and study of the various quality tests which are essential prior to concreting.

ACKNOWLEDGEMENTS:

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During this short training of 4 weeks, we have been guided by many staff members here at the COD site. Weare highly thankful to all the staff to have taken the time out from their busy schedule for explaining each and every minor detail. First and foremost, we are highly obliged by Mr. A. K. SINGH (Project Manager) for permitting us to actually join the training, and his constant supervision due to which we have come a long way in building a sound practical knowledge. Next, we would like to thank Mr. SandeepKhanna (Construction Manager) who actually paced our training in a very organized and systematic manner, and his timely inputs and checks have actually helped us go into every detail of the project. We are also highly grateful to Mr.Akeel Ahmed (planning head) who very selflessly took out time to enlighten us about the various aspects of construction, and its feasibility and his own valuable suggestions. We are very much thankful to Mr. P.K.Malhotrawho gave us vital details about the project, relating it to the theoretical concepts and also gave us inputs on how to manage things for optimal output owing to his vast experience. Who very selflessly gave us all the details of the Formwork, and would take out his valuable time to answer all our queries, even thought how childish they would be. He has really guided us all along the project and has taken pains so as to make this training period worthwhile for us. We are also very thankful to Mr. Hari SINGH RathoreandMr. RaghavSinghania of quality department for guiding us. They were our mentor all the time, helping us out in each and every topic of the project, esp. clearing our design doubts, Quality controls, testing etc. and encouraging us to research into every detail and thereby clearing our queries. We are highly obliged by Mr. Sumit and Mr. Sanjay who helped us in imparting knowledge about various important technical construction related issues selflessly, taking time out from their busy schedule and explain us each and every details of road construction technique. We would also like to thank Mr.Anand ,Mr. Ariband Mr. Piyush for his vital inputs relating to reinforcement, slab casting , etc. and guiding us during the project. Last, but not the least at all, We are highly grateful to Mr. N.K.Sinha (Manager, Accounts and Administration) for his guidance and constant motivating approach, which not only facilitated our training sessions, but also made us feel comfortable all throughout the training program