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I hereby declare that the project work entitled Noida Metro Project is
an authentic record of my own work carried out at Sector 147-149 , Noida as
requirements of project semester training (One semester Industrial Training) for
the award of degree of B.Tech. (Civil Engineering), Department of Civil
Engineering, Punjabi University, Patiala, under the guidance of Mr. Mudit
(SAM INDIA) and Dr. Maninder Singh (Department of Civil Engineering)
from February 1 ,2017 to May 31 , 2017.
(Signature of student)
Damandeep Singh
(11304180)
Date: ___________________
Certified that the above statement made by the student is correct to the best of
my knowledge and belief.
Head of Department
1
ACKNOWLEDGEMENT
First of all I would like to thank almighty God for the successful completion of this
project. The successful completion of this project is the result of concerted efforts, guidance
and inspiration from many people. I express my sincere gratitude to the Punjabi University,
Patiala for giving me the opportunity to undergo industrial training and to work on the project
during my final year of B.Tech.
I am grateful SAM INDIA, for providing me with an opportunity to work with them
and undertake a project of such high importance. This training and experience has not only
enriched me with technical knowledge but has also imparted the maturity of thought and
vision. Sincere thanks to all my colleagues at Noida Metro Project for their support and
assistance throughout the project.
I would like to thank the following persons for their kind suggestions and guidance
throughout the project:
I also owe my sincerest gratitude towards Dr. Maninder Singh whose constant
encouragement helped me to complete this project in the most efficient way I could.
I would also like to thank my family and friends for being with me at every hours of
need and for directly and indirectly helping me in completion of this project.
2
TECHNICAL SUMMARY
This report has been written based on the work experience gathered at Noida - Greater Metro
Rail Corporation work site at Noida. It includes all the important work stages in the execution
of the project. In present day world, metro rail network alone is a solution for smooth, cheap
and efficient means of transport. Noida & Greater Noida are fastest growing towns in
National Capital region. Noida & Greater Noida Authorities have decided to provide a world
class metro with sustainable development in the name of Noida Metro Rail Corporation
(NMRC) to facilitate mass transit & other urban transport in Noida & Greater Noida. The
project is working to Provide Safe, Reliable & Eco-Friendly Transportation Services for
people.
3
CONTENTS
1. Candidates declaration
2. Acknowledgment
3. Technical Summary
4. Contents
5. Abstract
Introduction
Salient Features
Activities
Station Monitoring
Lab and Field Testing
16. Conclusion
17. References
4
ABSTRACT
Metro rail transportation occupies a unique and world class mass rapid transit system
amongst the modern transportation means Presently, the Delhi Metro network consists of
about 218.17 Km with 164 stations along with six more stations of the Airport Express Link.
The network has now crossed the boundaries of Delhi to reach NOIDA and Ghaziabad in
Uttar Pradesh, Gurgaon and Faridabad in Haryana. Having seen the utility and efficacy of
metro rail transportation, other states have also adopted the same model eg. Metro rail in
Noida and Greater Noida, Metro Rail in Lucknow, Metro Rail in Jaipur, Metro Rail in Kochi
and Metro Rail in Mumbai etc.
I am fortunate as I have been granted permission to understand Metro rail execution in
DMRC/NMRC work sites and DMRC/NMRC authorities have been kind enough to allow me
to learn and gain experience in Metro rail execution in Noida - Greater Noida stretch. I will
remain ever indebted to DMRC/NMRC for the kind permission. The execution of metro rail
network is to be done between Noida Sector-71 in Noida to Delta Depot Station in Greater
Noida but I was allowed to understand the work from sector 147-149 of Noida city. The
stretch is totally elevated and consists of about 29.707 km track and 21 metro stations. The
metro network will be catering to approximately 65000 passengers per day.
5
Introduction to Noida Metro Rail Corporation
Everyone who has travelled by Delhi Metro wants one in his or her city. Today there
is a national resurgence in public interest in public urban transport:- Dr. Manmohan Singh
Prime Minister of India in 2006.
Delhi metro was meant to solve the Delhis traffic problems which had become
almost unmanageable. The first step to build a metro system in the city was taken in early
1990. In 1995 Government of India (GOI) and the government of national capital territory of
Delhi (GNCTD) formed the Delhi Metro Rail Corporation Ltd (DMRC) under the companies
act to construct the Delhi Metro.
Conceived as a social sector project, a significant portion of the project cost was
funded through a soft loan provided by the Japanese government through Japan Bank
International Corporation (JBIC). The rest was contributed by Government India & GNCTD
through equity.
DMRC faced any number of technical and systematic challenges during the
construction of the Metro. However due to thorough planning, an effective project design and
a we mean business culture it was able to overcome all these hurdles. In the process of
implementing the project, DMRC has gained a lot of technical expertise, which would be
used by other cities in India and abroad to builds metro system similar to Delhi Metro.
A new metro rail network will shortly be developed between Noida and Greater
Noida, measuring 29.707 KM. It will be developed at an estimated cost of Rs 5064 Crores.
The detailed Project Report (DPR) has already been prepared by Delhi Metro Rail
Construction and Noida Metro Rail Construction has been formed under the chairmen ship of
the chief Secretary of Uttar Pradesh.
6
Introduction to SAM INDIA
The construction sector has many players big & small. But when it comes to excellence and
leadership there is not much room at the top and only a few companies make the cut. One
such company is Sam INDIA the company has a strong lineage of around two decades in the
construction arena. With its experienced professionals including engineers, architects and
technocrats the company has moved from the strength to strength. A depth of management
expertise has been the companys greatest asset, which has helped it to effectively address
customer requirements. Use of cutting edge construction technology remains the pillar of the
companys growth and rising consumer popularity.
Salient Features
VISION
Our vision is to contribute to the construction of a modern India by offering state-of-the art
solutions that are both technologically superior and environmentally friendly.
MISSION
To become the preferred Construction Partner, who sustainably delivers best-in-class
solutions to meet and exceed customer needs.
We aim to accomplish this by using cutting edge construction technology and responding to
dynamic consumer requirements with passion and pro activity. We recognize the need to be
flexible and aggressive, both as individuals and as a company. Teamwork, transparency and
long-term decision-making remain the corner stones of our operations towards maximizing
value for consumers and building a strong reputation for ourselves.
7
Activities
Completed Projects
DELHI
PRADESH
Ongoing Projects
8
Literature Survey of Project
Starting from Noida city center in sector 32, the proposed metro corridor will lead towards
Greater Noida via stations in sector 50, 51, 78,101, 81 on Dadri Road, 83, 85, 137, 142,143
147, and 153 and sector 149 in Noida. It will enter Greater Noida through knowledge park II
and transverse Pari Chowk, sector alpha I and II before terminating at depot station proposed
near recreational green, knowledge park IV in Greater Noida. The metro alignment is
proposed to be elevated. The metro rail link is expected to be commissioned by December
2017.
Geometrical design norms are based on international practices adopted for similar
metro system with standard gauge on the assumption that permissible speed on the section is
limited to 85 KMPH. Planning for any higher speed is not desirable as the inter-station
distance is about is about 1 to 1.5 km and trains will not be able to achieve higher speed.
The tracks will be carried on box shaped elevated decking supported by single
circular piers generally spaced at 25 meters center and located on the median or one side of
the road.
9
Noida Metro: Proposed route
10
MATERIALS USED IN PROJECT
11
Prestressing System: Freyssinet, BBR, VSL, Dyanamic, Killick Nixon,
Tensaccial, JK Prestressing, Usha Martin, Posten, CSIL.
Reinforcement Couplers: Dextra, Moment.
Hollow Sections, Pipes: Surya Pipes, HI-Tech Pipes, JSW, JSPL, Bihar,
Ravindra Tubes.
Drainage Pipes: Tirupati Plasomatics, Duraline, REX, STIPL.
Bonding Coat: Sika, FOSROC, Sunanda Speciality coating Pvt Ltd, SWC,
TAM, BASF, CICO.
Paints: Berger, APEX, Asian, Johnson & Nicolson, Akzo Noble, PPG, Jotun.
Micro Silica: Sika, Elkem, FOSROC, MAPEI, Comiche, Star Silica, TAM,
Calipar, CICO.
Fire Resistant Paints: Akzo Noble, PPG or equivalent, Jotun.
External Acrylic Emulsion: Berger, APEX, Asian, Johnson & Nicolson.
Water Stopper Bars: Kanta Rubber, Greenstreak, Maruti, Duron.
Curing Compound: Clean Tech concur, SANAK, FOSROC, Adoadditives,
TAM, STP, SWC, CICO.
Polycarbonate sheet: M/S Gallina Acroplus, Coxwell, Poly U.
12
PROJECT MONITORING
STATION MONITORING
Staircase Supervision
Staircases Full process shown with the help of photographs clicked by me which was
fully supervised by me and drawings are also shown.
13
Outer Stairs Of Station
14
Structural Drawings Of Staircase
15
Deck Slab Supervision
16
Completed Structural Part of our Station
17
Deshuttering of Mumty Part of Station
18
LAB AND FIELD TESTING
During the course of training, I was entrusted the laboratory duties. A brief detail about field
testing carried out by me is illustrated in succeeding paragraphs.
OBJECT:
This method of test deals with the procedure for determining the silt content of sand by
sedimentation method.
APPARATUS:
TEST SAMPLES:
Materials sampled for the test should be thoroughly mixed before sampling and it should
contain sufficient moisture to prevent segregation.
PROCEDURE:
19
REPORTING OF RESULTS:
20
DETERMINATION OF SILT CONTENT IN FINE AGGREGATES (BY
WEIGHT)
OBJECT:
This method of test deals with the procedure for determining the total quantity of material
finer than 75micron IS sieve in aggregates by washing.
APPARATUS:
Balance or scale shall be sufficient capacity and sensitivity and shall have an accuracy of 0.1,
Sieves a nest of two sieves, the lower being 75-micron IS sieve and the upper
approximately 1.18mm IS sieve, Container- A pan or vessel of a size sufficient to contain the
sample covered with water and to permit of vigorous agitation without loss of any part of the
sample of water and Oven- an oven of sufficient size capable of maintaining a uniform
temperature 110C 5C.
PROCEDURE:
1. The test sample shall be dried to constant weight at a temperature of 110C 5C and
21
7. The retained materials should be dried to a constant weight at a temperature not
exceeding 110C and weighed to the nearest 0.1 percent.
REPORTING OF RESULTS:
OBJECT:
This method of test covers the procedure for the determination of particle size distribution of
fine and coarse aggregates by sieving.
APPARATUS:
22
PROCEDURE:
1. Bring the sample to an air dry condition before weighing and sieving.
2. Weigh the air dry sample and sieve successfully on the appropriate sieves starting
with the largest.
3. Each sieve shall be taken separately over a clean tray until not more than a trace
passes, but in any case for a period of not less than 2 minutes.
4. Shake with a varied motion so that the materials is kept moving over sieve surface in
frequently changing directions.
5. Light brushing of the underside of sieve with a soft brush may be used to clear the
sieve openings.
6. On the completion of sieving the material retained on each sieve together with any
materials cleaned from the mesh, shall be weighed.
23
REPORTING OF RESULTS:
24
IS sieve Weight % of Cumulative Passing IS
retained weight % retained % requirements
(gm) retained
10 0 0 0 100 100
4.75 56 9.0 9.0 91.00 90-100
2.36 66 10.61 19.61 80.39 75-100
1.18 78 12.54 32.15 67.85 55-90
600micron 75 12.06 44.21 55.79 35-59
300micron 173 27.81 72.03 22.97 8-30
150micron 132 21.22 93.25 6.75 0-10
Pan 42 6.76
Total 622
OBJECT:
This method of test covers the procedures for determining the specific gravity of aggregates
as per IS 2386 (part III).
APPARATUS:
A balance of capacity 3kg or more, readable and accurate to 0.5g, An oven to maintain a
temperature of 100C to 110C, A Pycnometer of about one litre capacity, A tray of area not
less than 325cm2 and Filter paper and funnel.
25
TEST SAMPLE:
The sample taken for test shall be approximately 500g for fine and 1000g for coarse
aggregates.
PROCEDURE:
1. A sample of about 1000g for coarse and 500g for fine aggregates shall be placed in
separate trays and water is poured in the tray such that the sample gets completely
immersed in water.
2. The temperature of water shall be maintained between 22C to 32C. The immersed
aggregates shall be agitated with rod so the entrapped bubbles get completely
removed from the aggregates.
3. Then the sample is left immersed in water for 24 hours, the water shall then be
carefully drained from the sample such that no particles get lost.
4. The sample is kept in exposed air or below fan so that the surface moisture gets
evaporated (i.e. the sample shall be stirred at frequent interval to ensure uniform
drying until no free surface moisture is seen and the material just attains a free
running condition.
5. The weight (W1) of the sample is taken which is SSD (Saturated Surface Dry
Condition) weight.
6. The SSD aggregates shall then be placed in the Pycnometer, which shall then be filled
with distilled water.
7. The hole at the top of brass cone of Pycnometer shall be closed with finger and the
trapped air shall be removed by rotating the Pycnometer on its side.
8. The Pycnometer shall be completely filled with water, wiped/dried from outside and
weighed (W2).
9. The aggregates along with water are taken out carefully on a tray.
10. The Pycnometer shall be completely filled with water, wiped/dried from outside and
weighted (W3).
11. The water present in the tray along with aggregates shall be completely drained such
that no aggregate particle get lost.
26
12. The sample with tray shall then be kept in the oven at a temperature 100C to 110C
for 24hours.It shall be cooled and weighed (W4).
REPORTING OF RESULTS:
27
S.No Description Results observed
Test1 Test 2
1 Weight of the sample at SSD condition(W1) 500g 498
2 Weight of the sample after drying (W4) 492g 491
3 Difference in weight A=(W1- W4) 8g 7
4 Absorption in%=A*100/W4 1.63 1.43
5 Average 1.53%
OBJECT:
This method of test cover the procedures for determining the moisture content of aggregates
as per IS 2386 part III.
APPARATUS:
TEST SAMPLE:
The test sample taken shall be approximately 500g for fine aggregate and 1000g for coarse
aggregates.
28
PROCEDURE:
REPORTING OF RESULTS:
BULKING OF SAND:
OBJECT:
This method of test covers the procedures for determining the necessary adjustment for
bulking of sand (fine aggregate)
APPARATUS:
A container of capacity 3 litre, A steel ruler, A steel rod 6mm in diameter, and
A 250 ml capacity measuring cylinder.
29
TEST SAMPLE:
PROCEDURE:
1. In a 250 ml- measuring cylinder, pour the damp sand and consolidate it by staking
until it reaches 200ml mark(X).
2. Fill the cylinder with water and stir the sand well (the water shall be sufficient to
submerge the sand completely).
3. It will be seen that the sand surface is now below its original level.
4. Suppose the surface is at the mark of (Y) level, therefore the %of bulking of sand due
to moisture shall be calculated as:
5. Percent bulking =(X/Y-1)*100
REPORTING RESULTS:
30
APPARATUS
Balance or scale shall be sufficient capacity and sensitivity and shall have an accuracy of 0.1
% of the weight of sample, IS Sieves of sizes 50 mm, 40 mm, 20 mm, 12.5mm, 10mm, & 6.3
mm and a Metal gauge of the pattern specified in IS 2386(Part I)-1963.
PROCEDURE
1. Sample shall be sieved in accordance with the method described as par IS 2386(Part
I)-1963 with the sieves specified in table I.
2. Separation of flaky material: Each fraction shall be gauged in turn for thickness on a
metal gauge of the pattern specified in IS 2386(Part I)-1963 or in bulk on sieves
having elongated slots. The width of the slot used in the gauge or sieve shall be of
dimensions specified for appropriate size of material.
3. Weighing of flaky material: The total amount passing the gauge shall be weighed to
an accuracy of at least 0.1 % of the weight of sample.
REPORTING RESULTS
SIZE OF AGGREGATE 20 mm, source - Kotputli.
25 20 2605 322
20 16 1887 215
16 12.5 941 121
12.5 10 461 81
10 6.3 189 32
Total 6133 771
31
The calculation & report shall be maintained in the format specified.
OBJECT
This method of test covers the procedures for determining the Elongation Index of coarse
aggregates (As per IS:2386 part I).
APPARATUS
Balance or scale shall be sufficient capacity and sensitivity and shall have an accuracy of 0.1
% of the weight of sample, IS Sieves of sizes 50 mm, 40 mm, 20 mm, 12.5mm, 10mm, & 6.3
mm and a Metal gauge of the pattern specified in IS 2386(Part I)-1963.
PROCEDURE
1. Sample shall be sieved in accordance with the method described as par IS 2386(Part
I)-1963 with the sieves specified in table I.
2. Separation of elongated material: Each fraction shall be gauged in turn for thickness
on a metal gauge of the pattern specified in IS 2386(Part I)-1963 or in bulk on sieves
having elongated slots.
3. The gauge length used shall be that specified for appropriate size of material.
4. Weighing of flaky material: The total amount passing the gauge shall be weighed to
an accuracy of at least 0.1 % of the weight of sample.
32
SIZE OF AGGREGATE 20 mm, source - Kotputli.
LENGTH GAUGE Total wt of Total wt of
Passing through IS Retained on IS Sieve sample gm sample retained
Sieve Gm
50 40 - -
40 25 - -
25 20 2605 322
20 16 1887 215
16 12.5 941 121
12.5 10 461 81
10 6.3 189 32
Total 6133 771
25 20 - -
20 16 - -
16 12.5 - -
12.5 10 481 91
10 6.3 204 32
Total 685 123
33
FINENESS OF CEMENT
OBJECT
This method of test covers the procedures for determining the fineness of cement by sieving
as represented by the weight of the residue left on a standard 90 micron IS Sieve conforming
to IS: 460-1962( As per IS 4031-1968).
APPARATUS
PROCEDURE
1. Break down any air set lumps in the cement sample if any with fingers. Place 100
gram of the cement accurately weighed on a standard IS Sieve no 9-90 micron (Wt
A).
2. Continuously sieve the sample giving circular and vertical motion for a period of 15
minutes. Mechanical sieving device may be used.
3. Weigh the residue left on the sieve (Wt B). This weight shall not exceed 10 % for
ordinary cement. Percentage of fineness of cement shall be calculated as follows &
the average shall be reported.
4. % of fineness = BxA / A
REPORTING OF RESULTS
The result & report of fineness of cement should be maintained in the format specified.
34
Description of test Sample 1 Sample 2 Sample 3
Sl
No
1 Wt of cement in grams (A) 100 100 100
2 Wt of cement retained on 90 1.5 1.6 1.7
micron sieve in grams (B)
3 % fineness 1.5 % 1.6% 1.7 %
Avg. Fineness = 1.6 %
DEFINITION
The standard consistency of cement paste is defined as that consistency which will permit the
Vicat plunger to penetrate to a point 5 to 7 mm from the bottom of the Vicats mould.
APPRATUS
35
PROCEDURE
1. Unless otherwise specified the test shall be conducted at a temperature 27+/- 2 Deg C
and relative humidity of laboratory should be 65+/-5%.
2. Prepare a paste of weighed quantity of cement (300 gms) with weighed quantity of
potable or distilled water, taking care that the time of gauging is not less than 3
minutes nor mare than 5 minutes and the gauging is completed before any sign of
setting occurs.
3. The gauging is counted from the time of adding water to the dry cement until
commencing to fill the mould.
4. Fill the Vicat mould with this paste resting upon a non porous plate.
5. Smoothen the surface of the paste making it level with the top of the mould.
6. Slightly shake the mould to expel the air.
7. In filling the mould operators hands and the blade of the gauging trowel shall only be
used.
36
8. Immediately place the test block with the non porous resting plate, under the rod
bearing the plunger.
9. Lower the plunger gently to touch the surface of the test block and quickly release,
allowing it sink into the paste. Record the depth penetration.
10. Prepare trial pastes with varying %ages of water and test as described above until the
plunger is 5mm to 7mm from the bottom of the Vicat mould.
CALCULATIONS
REPORT
Express the amount of water as a percentage by mass of dry cement to the first
place of decimal.
OBJECT
This method of test covers the procedures for determining the initial and final setting time of
cement (As per IS 4031-1968).
APPARATUS
37
PROCEDURE
1. The temperature of water and that of test room at the time of gauging
shall be within 27+/- 2 Deg C.
2. Take 500 gram of cement sample & gauge it with 0.85 times the water
required to produce cement paste of standard consistency (0.85 P).
3. Fill the paste into the Vicat mould in specified manner within 3-5
minutes.
4. Start the stopwatch the moment water is added to the cement.
1. Place the test block confined in the mould & resting on non porous plate under the rod
bearing the needle.
2. Lower the needle gently in contact with the surface of the test block & quickly release
allowing it to penetrate into test block.
3. In the beginning the needle will completely pierce the test block. Repeat this
procedure until the needle when brought in contact with the test block & release as
described above, fails to pierce the block for 5 =/- 0.5 mm measured from the bottom
of the mould.
4. The period elapsing between the time when water is added to the cement & the time at
which the needle fails to pierce the test block shall be the initial setting time.
38
3. The period elapsing between the time when water is added to the cement & the time at
which the needle makes an impression on the surface of test block while the
attachment fails to do so shall the final setting time.
ACCEPTANCE CRITERIA
OBJECT
This method of test covers the procedures for determining the compressive strength of
cement as represented by compressive strength tests on mortar cubes compacted by means of
a standard vibration machine (As per IS 4031-1968).
39
PROCEDURE
40
ACCEPTANCE CRITERIA
REPORTING RESULTS
OPC 34.11, 35.31,& 36.11 47.5, 46.5, & 45.5. 70.22, 69.62 & 69.64
JK Laxmi Avg= 35.17 Avg= 46.2 Avg = 69.76
53 Grade
OPC UltrTech 36.82, 36.12, & 34.15 50.61, 49.36 & 48.5 70.22, 69.22 & 70.12
53 Grade Avg = 35.71 Avg = 49.47 Avg = 69.88
41
COMPRESSIVE STRENGTH OF CONCRETE
OBJECT
This method of test covers the procedures for determining the compressive strength of
concrete in compression testing machine (As per IS:516).
PROCEDURE
1. Cube specimens will be manufactured and cured as per IS:516-1951. Take sample of
concrete for test specimen at the mixer or in the case of ready mixed concrete from
the transportation vehcle discharge.
2. Lightly oil the interior surface of the mould before placing concrete.
3. Place fresh concrete in the mould in three layers and rod each layer 35 times with 16
mm rod, 60 cm in length, bullet pointed at lower end. In the case of vibration care is
to taken that there is no mortar loss.
4. After the top layer has been rodded, the surface of the concrete shall be struck of with
a trowel and covered with glass plate. If needed the concrete can be compacted by
vibration.
5. Cover the moulds with wet straw or gunny bags to ensure uniform temperature and
moisture conditions during the first 24 hours. The tests shall be generally at the end of
7 days and at the end of 28 days and immediately after the removal of test specimen
from curing room.
6. Place the test specimen in the machine in such a manner that the load is applied to the
side of specimen as cast. The load shall be applied axially without shock at the rate of
approximately 140 kg per sq cm per minute.
7. Record the total load indicated by the testing machine at failure of test specimen.
Calculate the unit compressive strength in kg per sq cm using the area computed from
the measured dimensions of the test specimen. The type of failure and the appearance
of concrete shall be recorded.
42
ACCEPTANCE CRITERIA: As per IS: 516-1951
REPORTING RESULTS
43
PLANNING THE PROJECT-CASTING YARD:
The casting yard is a place where all the concrete structures like girders and pier caps are
casted/ manufactured, shifted to the stack yard and shifting to the worksite / Viaduct after
they gain their required strength.
Casting Yard
44
Batching Plant
45
Color Code for Lifting Tools and Tackles
46
PROJECT EXECUTION (PROBLEM STATEMENT)
The main scope of work where I was deployed consisted of execution of work in
casting yard, constructing I/C girders and plate-forms ,stations etc. To facilitate above, there
was a system of furnishing method statement for construction of all important activities in
metro rail construction. For example during the process of my training, I came across with
following method statements;
Method statement for construction of I Girder/C Girder.
Method statement for repair of concrete structures.
Method statement of Construction of various elements of Stations.
Out of above method statements, I observed execution of girder more closely and I
had the opportunity to understand the NMRC work culture. To my surprise I found the
method statement to be a comprehensive document which provided an in-depth knowledge of
execution stage and quality norms. The same is elaborated in detail in succeeding paragraph;
The method statement submitted by contractor M/s CEC-SAM INDIA to Noida Metro Rail
Corporation consisted of details such as purpose, scope, reference documents, definitions,
responsibilities, machinery/tools/equipment& materials, methodology, inspection & test plan,
risk assessment, environment management, and enclosures. Method statement in detail is
elaborated as below;
1. PURPOSE
The purpose of the document is to describe the work procedure to be adopted for construction
of the Pre-Tensioned U - Girder as per the design drawings in planned and systematic
manner. Furthermore this document provides sufficient information on the construction
methods including site installations, the personnel to execute the job, major machinery and
materials required, inspection and the safety and health matters considered necessary to
successfully carry out the construction.
47
2. SCOPE
To set out the requirement for Pre-Tensioned U - Girder construction works for the project
to meet all the contract requirements and contractor standards for work operation, safety,
quality and environmental compliance.
3. REFERENCE DOCUMENTS
Contract document
Good for construction drawing of Pre-Tensioned U - Girder
IS 456 for reinforced cement concrete
IS 1786 for reinforcement
IS 1343 for pre-stressing works
Bar bending schedules as prepared by Contractor and approved by DMRC.
Health, Safety and Environment plan.
Project Quality management plan.
4. DEFINITIONS
5. RESPONSIBILITIES
The proposed organization charts associated with this work are enclosed in
succeeding paragraphs.
NOIDA METRO PROJECT REPORT
48
Project Leader
Site In charge
U Girder/I
Girder
EXECUTION
SHE
49
Project Manager
Site Manager
Site Engineer
QA/ QC Engineer
Responsible for verification/inspection of all the activities in accordance with the ITP.
Ensuring that all required tests are carried out and respective records are maintained.
Reporting the result to QA/QC head.
Safety Supervisor
50
S DESCRIPTION Qty
NO
1 Batching Plant 60 Cum/hr cap 03 No + 1 standby
2 Transit Mixers 6 cum cap 20 No + 1 standby
Any other equipment, machinery, tools and plants etc wherever required to complete
the erection successfully shall be deployed.
MATERIALS
51
Batching Plant Boom Placer
52
METHODOLOGY CASTING YARD
LABORATORY
Laboratory set at casting yard equipped with all kinds of testing apparatus for testing of
aggregates, cement, and concrete & for concrete mix design. Equipment like digital balance,
cube testing machine, thermometer will be calibrated at a specified standard frequency.
53
U - GIRDER PRODUCTION SEQUENCE
54
CURING OF U-GIRDERS
Wet curing:
Curing shall be continuous over a minimum of 14 days period after concreting. Curing by
either ponding/ spraying/jetting water shall be attended un-interruptedly. Clean hessian cloth
shall be wrapped on exposed concrete surfaces shall be used for moist curing. Water shall be
sprayed to keep hessian cloth un-interruptedly moist. Frequency of wall shuttering shall be
such that, hessian cloth will not be allowed to get dried. Top of bottom shall be ponded with
water.
Slab bottom will be attended for curing over the balance period either by water sprinkling or
with approved curing compound.
Or
Membrane curing followed by wet curing:
Curing shall be continuous over a minimum of 4 days period after concreting/ concrete
attains strength of 35MPa as per the procedure mentioned above. Curing compound shall be
then sprayed over the girder surface as per manufactures recommendation and shifted to the
stacking yard.
Suitable arrangements of recycling the water during curing of all the castings at casting yard
shall be made to save water.
DESHUTTERING
Internal shuttering shall be retracted and removed using turn buckles provided after 24
hours of concreting. Only trained personals shall be deployed in retracting of turn bukles
activity. Gantry crane positioned and third party certified lifting gears shall be used for lifting
NOIDA METRO PROJECT REPORT
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of inner shutters. Inner shutter all turn buckles shall be made free and before lifting guide
rope to be provided at both ends to control the swing. Lifting will be done under lifting
supervisor. Then internal shuttering shall be cleaned and kept ready to feed in adjoining pre-
cast bed. Before shifting it to adjoining bed, it will be applied with de-moulding agent. A set
of beams supporting inner shutter sets shall be shifted to adjoining pre-cast bed using goliath
gantry crane. Required PPEs shall be provided to all workmen.
Outer shuttering shall be retracted using turn buckles and moved outward after 3-4 days of
concreting. Outer shuttering shall remain in retracted place till C-girder is shifted to stacking
yard. Then it shall be cleaned, realigned and applied with de-moulding agent to receive pre-
tied reinforcement cage along with debonding tubes.
Bottom shuttering shall be exposed only after shifting of pre-tensioned C-girders. Then it
shall be cleaned, realigned and applied with demoulding agent to receive pre-tied
reinforcement cage along with debonding tubes.
Pre-tensioned strands shall be released after only when concrete gains a minimum strength of
M35 grade. Releasing shall be done from stressing end only by using central hole stressing
jacks meant for stressing as well as for releasing. Movement of strand holding structural
beam and all C-girder shall be recorded Stress v/s Movement. For all C-girders movement
at their both ends shall be recorded. All strands shall be cut by using wheel/s as far as
possible flush with C-girder concrete faces. Trained personal shall be deployed with safety
gears (Face guard, leather hand gloves, safety shoes) for strand cutting activity. Electrical
certified portable tools to be used. Gas cutting set shall not be used for cutting the strands.
Lifting arrangement shall be proper reading to be taken before activities if required. Strand
cutting sequence shall be from stressing end towards anchor end and from outer to inner
strands symmetrically.
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INSPECTION AND TEST PLAN
Request for inspection (RFI) shall be raised for inspection to the DMRC
representative. Casting shall be done after getting clearance from the client.
Inspection Test Plan shall be followed.
RISK ASSESSMENT
Risk assessment and control measures to reduce the risk level shall be followed. All site
personal shall be provided with helmet, boots, and other personal safety devices. All safety
precautions for safe working at height shall be taken. Precautions to eliminate electrical
hazards, safety devices shall be used for all the electrical equipment used for fabrication,
erection, concreting and electrically operated hand tools etc. All site personal shall follow the
DMRC approval health, safety and environment policy/ plan.
ENVIRONMENTAL MANAGEMENT
Safety, Health and Environment plan will be followed throughout the construction
programme.
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PROBLEMS ENCOUNTERED DURING THE TRAINING:
REMEDIAL STEPS
1. For assuring the verticality of column, proper arrangement of plumb bob should be
done so that accuracy is maintained within limits. If there is still some error, then the
shuttering should be held tightly in position using steel bars and welding.
2. Sometimes, in spite of best efforts in matching the mould panels and covering the
minor gap between the panels, offsets in concrete cannot be eliminated. Though it
does not affect strength, it is a strain to eye and therefore calls for removal of it. This
can be chipped out by small chisel and area should be smoothened by grinding.
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Improving practical skill
The aim of the internship is to address more practical knowledge for student. So, I found a
practical knowledge at the site as much possible within the four months. The knowledge we
have learn in the class is helpful to get those practical or real work in the site and totally
different from the actual knowledge gained from the class. Thus I found some knowledge in
the site which helps me to work with the site environment or site peoples. Some of the
practical knowledge I gain from the training class was:
In any construction work the first stage before casting of concrete is designing and
constructing of form work. As I explained in the work procedure the formwork and false
work must be stiff and must resist the fresh concrete till the concrete gain its strength. Thus
the construction stage of form work was new to me since Im new for the practical world now
I gain practical knowledge about how it is worked and erected.
After the formwork and false work is ready the bar bending, positioning and tying work goes
next. This work is done based on the working drawing provided in the working drawings
(structural drawing) by the design team of that specified structure. In most case it was new
for me to see such work since it is a practical work only performed at the site.
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Upgrading the theoretical knowledge
The training is not only depending on the practical aspect but it also help students to upgrade
or increase knowledge on already that they have. I try to integrate the practical knowledge
with that of the theory learned in the class in different place in order to get more knowledge
than the theory we learned on the class. I got the internship class very interesting in terms of
upgrading a theoretical knowledge and I learned from the site some theories that we havent
learn in the class room by searching different related literature. Some of this is:
Quantity surveying
Structural design of shear wall and its advantage
Construction equipment
Report writing
I learned those things in exclusive cause it is hard to read and understand everything from
books and asking some peoples at site to those things ashamed me. Generally I change myself
alit bit after the internship period in my knowledge than before I took it.
Team playing skill for construction work Team works, especially for engineers, involve in
every piece of task and achieving good team playing skill is essential for Effective
completion of tasks and Increasing productivity. This skill already exists in my personality in
the campus due to different assignment and project works that I work together with student.
But this skill is more than this in the construction site. In the construction site the work is
already a team work and it needs more closeness of workers to solve problems arise in
different aspects, misunderstanding in the drawing or working methodology and consult
every work. We the student at the site also works together as a team to get more
understanding and share ideas. More or less I improve my team work status by working
together with different professionals, student and workers as a whole in the civil engineering
works and consulting.
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Improving leadership skill
Those are:-
In the site it was impossible to us to lead anything because we go to the site tolearn about the
site work and we dont have enough ability to handle such works in such short time but we
have learned how to become a good leader and the main signal of a good leader.
Finally what I take hold of is Becoming a leader isnt easy because it takes a conscious
commitment and consistent effort to develop ones leadership skills
The concept of work ethics may be summarized as the overall quality in ones behavior
towards appreciating the process of work flow and performing rather well on the job so that
this work flow will not be jeopardized in the long run. During my internship program, I could
say that I have managed to do my side of the job description with a high spirit and enthusiasm
so that there was a smooth flow of activities both in the office and on construction site. Work
ethics involve such characteristics as honesty, responsibility, reliability, accountability and
etc.
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Punctuality
Punctuality is one of the major issues that could be raised when talking about work ethics and
on my side I tried meet this criteria by attending to my working station in time so that there
will not be any delay on the activities planned for that day. The behaviour that one shows
towards his peers and colleagues is also one manifestation of the concept of work ethics.
Personally, I always respected and gave priority the employers of the company. Elements of
work ethics that worth mentioning are:-punctuality, honesty, reliability, office discipline,
corporation and responsibility.
We as a student should follow the rules and regulations set by the company and avoid
complaining any work load, activity or assignment that may arise on the site or office. It is a
pleasure of supervisors if we have a good work ethics and we are responsible for any given
tasks. Since the aim of internship is to let students know the outside environment pertinent to
their field, which includes of such the above dealt qualities, I was with the great interest that I
tried to meet my responsibilities and work ethics that I suppose to be fulfil by my side.
Conclusion
The entire period of Industrial Training has given me good & important practical exposure of
construction work. At the end of the Industrial Training under SAM INDIA, I feel myself
better equipped and ready to face the field problems related to Civil Engineering works. In
these four& half months, I have learnt how to deal with Authorities and workers under
supervision and I have become familiar with the fact that the field work is much difficult
from theoretical knowledge. But until you dont have the theoretical knowledge, the practical
work is very difficult to carry-out and understand. Working with experienced engineers has
enhanced my technical skills to a great extent for which I am grateful to them. Their
professional approach towards work is appreciable. The training has provided me with much
needed field exposure to shape up my thinking in a better way as a professional making me a
lot more capable to face the challenges of life.
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REFERENCES
Text include the details carried out through the Site engineers, Supervisors,
labourers.
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