R.N.

Modi Engineering College

Kota

A
Practical summer
training report
on
Construction of Reactor Building And cooling tower
NPCIL at R.R. site Rawatbhata

FROM 04-06-2012 TO 03-07-2012

SUBMITTED BY:-
SUBMITTED TO :-
 GULAMUS SAQLAIN MANSURI 09ERNCE016 Dr. PRIYANKA PANDEY
 KETAN TAK 09ERNCE024 HOD
 MOHAMMED SUHAIL KHAN 09ERNCE028 CIVIL ENGG DEPARTMENT
 RAJENDRA KUMAR MEENA 09ERNCE039
 VISHVENDRA SINGH 09ERNCE059

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 CONTENTS
 Introduction
 Geology of the Site
 Blasting
 Excavation
 Drilling
 Grouting
 Construction of foundation
 Reinforcement Work
 Placing of concrete
 Precautions used at the time of Concrete Pouring
 Water proofing
 Plants(Batching plant, Crushing plant, ice plant, sand
washing plant)
INTROUDUCTION
NAME OF WORK: Construction of Reactor Building And cooling tower
NPCIL at R.R. site Rawatbhata

COMPANY NAME: HINDUSTAN CONSTRUCTION

COMPANY LTD.

LOCATION: Right bank of Chambal River in Kherli block

Tehsil- Rawatbhata & 64 KM from Kota (Rajasthan).

Latitude 24° 52’ N Longitude 75° 37’ E

• In RAPP-78, two units of 1400 megawatt, Unit-7&8 construction was started from
year 2010.
• 12000 carore has been invested in construction of unit-78.
• This is the 25th unit of country and 7th and 8th unit of RAJASTHAN.
• Till 2016, energy will be produced in the unit.
• The capacity of RAPP will increased till 2580 megawatt.
• 700 megawatt power is for Rajasthan and 1400 megawatt power for north power
grid.
SITE DETAILS
GEOLOGICAL SITE:- Sloping of the Chambal river gently sloping terrain with rock
available within rock few centimeters of the surface.

ROCK TYPE:- Predominantly Quartzite Sand stone.

Temperature:- Maximum dry bulb temperature 48.7°C; Minimum 3.9°C .

Humidity:- Maximum RH=100% ; Minimum RH=1%

SEISMOLOGY:- The site falls in Zone II as per zoning map of India

(IS 1893 – 2002 Part I)

. The site is lie in active seismic zone.

. Earthquake intensity VI or less
. Mercalli Intensity scale
 GEOLOGY OF SITE

• The rock is predominantly Quartzite sand stone generally hard and compact with
interblended shale seams and clay strain.
• About 15lakh cubic meter of hard rock has to be excavated by drilling and
blasting method for site grading and foundation excavation.
• The excavation site is located close to operating nuclear plant.
BLASTING
Blast Details-

Size of Blast-115mm diameter.

Drilling Machine- IR Crawler/ Tire mounted.

Burden- About 2.0m to 3.0m. (Burden<Spacing)

Spacing- About 2.5m to 3.5 m.

No. of Holes- 8 to 61.

Depth- 3m to 9m.

Explosive- Raj blast (83mm dia , 2.78Kg Booster and 450mm long)

Charge per hole- 11Kg to 61 Kg depending on depth of hole

 BLASTING
EXPLOSION USED
• Detonator & fused wire.
(In under water excavation an electric detonator shall be used. )
• Black powder(Gun Powder)
( In dry weather and normal dry excavation gun powder is
used in granular form)

• Gun powder in granular form may be used in hole 1500mm

to 1650mm deep, and 30 to 40mm dia.
 EXCAVATION
Companies working in excavation at Reactor Building site-

1- SIBY 1000 cum/8hr.

2- MCC 550 cum/8hr.

3- KCPL 1000 cum/8hr.

 DRILLING
Scope of drilling :-
 Collection of soil and rock
samples
 Making holes for blasting
purpose
Equipment Required-
DRILLING
1. Total Station
2. Auto Level

3. Rotary Drilling Rigs(Vol. 90, Long layer, KLR tractor, Mounted Hydraulic drilling
rig).

4. Tripod set with pulley.

5. Drilling rod.

6. “Double Barrel Core Tube”

of 1.5m and 3.0m length.

7. Starting barrel of 200mm-500mm length.

8.Triplex/Water Pump.

9.Measuring Tape (3m and 30m).

10.Pressure gauge.
 GROUTING
Purpose of grouting :-

 To consolidate
underground rock
surface.

 To prevent the seepage of

water

 To fill up the sub surface

voids in between rock
layers.
(If it is not done seepage of water
continue which will cause the damage
of water proofing surface as well as
planter reinforcement.)
Grouting
Consolidation Grouting is the process of filling the cracks

Holes in Grouting:

There are three types of holes.

1. Primary Hole

2. Secondary Hole.

3. Tertiary Hole.

• Pattern of Primary Hole at 6m distance from one hole to another hole.

• Small holes are Secondary Hole at 3m distance from big hole to small hole.

Cold Drilling: 100 m depth.

Instruments Used in Grouting-

i. Grouting Pump.

ii. Pressure Gauge.

iii. Water Meter.

iv . Rubber Packer (Diameter of rubber = 110 mm.).

v. Agitator.

vi. Mixing Drum.

Applied Pressure At 0m to 3m height= 1Kg/m3

At 3m to 9m height=2.5Kg/m 3

Plugging -It is the process to fill the hole with sand and cement in ratio of (1:2).

Grout Mix - Grout Mix is the mix of sand and cement in ratio of (1:2,1:15,1:10,1:5,1:.05,etc.)

PURPOSE OF GROUTING: -
CONSTRUCTION OF FOUNDATION
RAFT FOUNDATION

Raft foundation is type of land-

based foundation that protects
against settlement and
the liquefaction of soft soil due to
seismic activity. It was a necessary
innovation in the development
of tall buildings in the wet soil
of Chicago in the 19th century,
where it was developed by John
Wellborn Root who came up with
the idea of interlacing the concrete
slab with steel beams
Reinforcement Work
REINFORCEMENT WORK
REINFORCEMENT DETAILS
 Material : HYSD bar & TMT bar Fe500 to IS 1786.

 Storage : Reinforcement steel shall not be keep directly contact with ground,
It is kept on timber sleepers or concrete pedestal.

 Bending of Reinforcement -The reinforcement bar shall be cold bent at

appropriate radius of minimum 6D using “Bar Bending Machine” with proper
mandrill. Load shall be applied gradually on bar.

 Lying of Reinforcement : Chair/ Spacer made up of reinforcement steel

bar shall be provided to keep the bars in position.

 Spacing : R*Ø.

 36 mm Ø bar is used for reinforcement of grade Fe 500 in

construction of Reactor Building
TYPES OF BARS USED IN CONSTRUCTION
Pumping of Concrete
Boom Placer

Truck loaded transits mixer

PLACING OF CONCRETE
• CONCRETE CAN BE PLACED BY PUMPING. Boom placing Crain

• A concrete pump is a machine

used for transferring
liquid concrete by pumping to
any height.

PLACING OF CONCRETE BY BOOM PLACER

PLACING OF CONCRETE
• The first type of concrete pump is
attached to a truck.

• It is known as a trailer-mounted
boom concrete pump because it
uses a remote-controlled
articulating robotic arm (called
a boom) to place concrete with
pinpoint accuracy.

• Boom pumps are used on most of

the larger construction projects as
they are capable of pumping at
very high volumes and because of
the labor saving nature of the
placing boom.

• They are a revolutionary

alternative to truck-mounted
concrete pumps
Pouring of Concrete
Precautions used at the time of
Pouring of Concrete
 The site should be properly Air Washed
 Climatic Condition
 Material used should be homogeneous & of good Quality
 Shuttering of the site should be properly fixed
Temperature of Concrete at different positions:-
 At mixing site :- below 12 degree Celsius
 At pumping site :- 17 to 19 degree Celsius
 At pouring site :- 19 to 21 degree Celsius
 Cont…………

 Plunger or Vibrator should be properly used at the site

 Compaction of Concrete shoul be proper
 Spray of Green Cutting before setting of Concrete
 Spray of Water jet on moderate set concrete for
formation of rough surface for next pouring
Spray of Green Cutting Solution

In this method retarder can be spread into the placed concrete.

Such as to prevent the concrete to harder at upper layer. Such that the next layer can be
placed upon it.
Before the placing of new concrete the retarder can be removed by spraying water with
very high pressure such as to prepare the rough surface.
 Water Proofing
Water Proofing in Horizontal Surface
a. 20 mm. thick leveling coarse(Screed) of 1 part of cement,4 part of sand by volume with
“SIKA Latex", Water/Cement ratio should be 0.5.

b. 1st coat of” Acrylic Polymer”.

c. 1st layer of fiber glass cloth reinforcement o.2mm thick.

d. Repeat process for 5 layer of Acrylic Polymer” material sandwich with 4 layer of
fiber glass.

e. Total thickness of water proofing shall be 3 to 4 mm.

f. Completion of final layer of water proofing and a gap of manufacturer before

application of 20mm thick protective layer of 1:4 cement and sand ratio by volume
with chicken mesh wire.

g. 7 days curing after plaster

 Water Proofing in Vertical Surface

a. Concrete surface will be clear with wire brush to remove laitance of cement mortar,
fungi, algae, oil substance
b. 1st coat of acrylic polymer.

c. 1st layer of fiber glass coat reinforcement 0.2 mm thickness.

d. Repeat five layer of acrylic cementious material sandwich with four layer of fiber
glass.

e. Total thickness of waterproofing membrane shall be 3 to 4 mm.

f. Before 115mm brick wall sufficient curing shall be done.

g. 115mm protective brick wall with cement mortar 1:6 will be build outside the RC
wall/raft.

h. Curing shall be 7 days minimum.

 BATCHING PLANT
Capacity of Batching Plant- 120m3/hr.

Aggregate Store-40m3

Admixture Concrete-
Cement+Additive+Water+Ice+Aggregate

Storage Bin-
1. 10mm aggregate
2. 20mm aggregate
3. Sand-20mm aggregate
(Crush Sand and Natural Sand both)

Aggregate wear load cell (Capacity)-

5000 Kg/load*104
Conveyer- Feed the material in in bins.
Mixer- Mixer is used to mix the mixer (Flyash+Cement+Aggregate+Sand)
Capacity of mixer batch- 3 m3
ICE PLANT
Ice Plant- 20 ton

Temperature in Ice Maker- (-30°C to -33°C)

Storage Container- 100 ton.

Maximum capacity of Plant- 60m3

Maximum batch capacity- 1.25m3

Transit Mixer- Concrete is being transport to by transit mixer of 600m3 capacity.

We take 15 days calibration. Ammonia(NH3) is used for condensing the ice.

ICE maker consist of :

A. Vapor compression system
B. Receiver
C. Compressor
D. Condenser
E. Ice cutting motor.
In RCC & PCC we used M45 concrete.
CRUSHING PLANT
Crushing of stones in machine as per requirement of size of aggregate.

BC-1 Jaw Crusher

- To crush 82-100mm size boulders.

BC-2 Chock Pile

- Hydro cone Crusher- 10, 20, 40mm size aggregate.

BC-6 Screen-1
for greater than 40mm size aggregate.

BC-7 VSI Hopper

(Vertical Shaft Impector) is used for stock the aggregate.

BC-8 VSI Crusher

(Vertical Shaft Impector) is used for plane the aggregate.

Screen-2 for 40,20,10,4.75mm size aggregate.

 SAND WASHING PLANT
Process Of Sand Washing Plant :
SAFTEY TOOLS
 TESTS IN LABORATORY
1. Compression Testing Machine(CTM)
2. Flexural Test of Concrete for Beam
3. Soundness Test of Cement
4. Aggregate Abrasion Test
5. Workability or Slump test on Concrete
6. Air Content Test on Concrete
7. Flakie longation Test
8. Sieve analysis of coarse aggregate
9. Sieve analysis of fine aggregate
10. Sand present in aggregate
Workability/Slump test on cement
1. Collect the sample on non absorbent metal plate or tray and mix it thoroughly.

2. Clean the internal surface of cone slump.

3. Fix the cone firmly to its base plate with help of clamping screw and place it at
horizontal surface.

4. Fill the mould with concrete sample in four layers each layer approximately ¼ cone
height.

5. Compact each layer with 25 strokes by tamping rod.

6. Release the clamping screw and lift the cone slowly and carefully in vertical direction
from the concrete.

7. Place the cone inverted at the side of concrete.

8. Measure the difference of height between top of cone top of plastic concrete.

1 of concrete in mm.
9. Record the value as slump 34
Air Content test on Concrete
1. Collect the sample on nonabsorbent metal plate and mix it thoroughly.
2. Fill the container in three equal layers and compact each layer with 25 strokes by
tamping rod.

3. Close main air valve of air receive of top LID open both the pet clocks of top LID.

4. Place LID on container and close the four toggle clamp.

5. Pour water into funnel until water comes out of petcock.

6. Close both the petcock and air bleeder valve.

7. Gently pump air into receiver until gauge needle comes in line marked on gauge.

8. Top gauge gently and open main air valve.

9. Allow the needle to come to rest and take the reading.
10. Report this reading is present of air entered in concrete.
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Compression Testing Machine
USE- Compressive strength test on concrete remove before 24hrs. Whenever cube is
coated.

NOTE:- Load in UTM=140 Kg/cm2. Size of Cube Mould=15x15x15 cm. PROCEDURE-

1. Remove the specimen from curing tank.

2. Place the specimen in Compression Testing Machine (CTM), Capacity-

3000KN.

3. Place the cube so that caste face shall not be at top or bottom.

4. In case so that cast face shall not be capped using Sulphur Capping. “Sulphur Capping
is for the finishing of cube layer.”

5. Align the axis of specimen with center of thrust of spherically seated platen

6. Apply the load till specimen break or crack

7. Record the max load applied.
8. Calculate compressive strength.
Compressive Strength = Load/Area. Unit-N/mm2