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Training report 2013

Project Report

On

“ Building 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, NoidaProject cost: 200 croresDuration: 36 monthsConsist 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 India’s largest technology, engineering, manufacturing and constructionorganization with a record of over 40 years. Jay pee is also adjudged India’s best managed andmost 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 theWorld’s the 217 Top Contractors and ranks 67th in global ranking as per the survey conducted bythe reputed international construction magazine Engineering News Record, USA (August 2011).Jay pee infra.cutting edge capabilities cover every discipline of construction – civil, mechanical, andelectrical and Cement Manufacturing and services extend to large industrial and infrastructureprojects from concept to commissioning.

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Jay Pee has played a prominent role in India’s industrial and infrastructure development byexecuting 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 andinfrastructure projects.

Complete mechanical system engineering including fabrication and erection of structuralsteel works; manufacture, supply, erection, testing and commissioning of plant andequipment; heavy lift erection; high-pressure piping; fire-fighting; HVAC and LP/ utilitypiping 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 structureabove. Foundations, basement, subfloor are some components of this area.Super structure is defined as structure above ground level. Brickwork, timber, floors, beams, slabsetc.

• 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 forcompaction 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. thereinforcement is provided as per the drawing of footing no honey combing is allowed. Properformwork 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 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:

Here, the main focus is on the estimation, management, and preparation of the reinforcement in itsusable form, before being transported to the site.

Bar bending schedule to be as per approved drawings, and reinforcement steel to be cut andbend as per approved bar bending schedule. Bars to be bent to the specified shape anddimensions, using a proper bar bender, operated by hand or power to obtain correct radii ofbends 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 bindingwire not less than 18 gauge), to make the skeleton of reinforcement rigid such that it does notget 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 maximumsize of aggregate, whichever is greater.

Cover blocks of thickness equal to the specified cover to be placed between formwork andbars made of Concrete / Cement Mortar of specified grade of concrete/ strength as those ofthe member.

Necessary stays, cover blocks, chairs, spacers, hangers, etc. or other subsidiaryreinforcement to be provided and approved by engineer, to fix the reinforcement firmly in itscorrect 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 abundle 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, thetotal cross section of the rectangular stirrup shall be 350 X 350.

Now, thus the perimeter for this shall be: Perimeter = 4 (350) mmThe minimum length of the hook (bent at 90®) is 50d which shall be actually added to the totaleffective 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 (z-axis) 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 ofacceptability.This department primarily is concerned with regular testing and quality control of materials beingused in the construction of the project. All plain concrete used in the project is M10 , and all R/Fconcrete is M25.Quality department is independent unit which works for checking the materials quality works qualityJay 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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PRE ENGINEERED BUILDING

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 SHEETSetc.

There are various components of PEB structure and is is very wide to explain so onlydescribing 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 befabricated using a pre-determined inventory of raw materials and manufacturing methods that canefficiently satisfy a wide range of structural and aesthetic design requirements. Within somegeographic 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 incustom computer aided designs, simply, Engineered Metal Buildings (EMB).

Historically, the primary framing structure of a pre-engineered building is an assembly of I-shaped members, often referred as I beams. In pre-engineered buildings, the I beams used areusually formed by welding together steel plates to form the I section. The I beams are then field-assembled (e.g. bolted connections) to form the entire frame of the pre-engineered building. Somemanufacturers taper the framing members (varying in web depth) according to the local loadingeffects. 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 localcapabilities (e.g. manufacturing, transportation, construction) and variations in material vs. labourcosts. Cold formed Z and C-shaped members may be used as secondary structural elements tofasten and support the external cladding.Roll-formed profiled steel sheet, wood, tensioned fabric, precast concrete, masonry block, glasscurtainwall 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 betweenbearing points, bay spacing, roof slope, live loads, dead loads, collateral loads, wind uplift, deflectioncriteria, internal crane system and maximum practical size and weight of fabricated members

http://en.wikipedia.org/wiki/Structural_engineering

http://en.wikipedia.org/wiki/I_beam

http://en.wikipedia.org/wiki/I_beam

http://en.wikipedia.org/wiki/Structural_engineering

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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.

THERE are various parts as well as properties of materials which are used in these kinds ofbuildings 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 600-

800 mm deep in concrete base.The base plate is used here is of thickness about 20 mm which restrain the columns to penetrateinto 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 andpreventing condensation on interior surfaces.

Cladding Insulation material

2) TRUSSESTHE main loads on trusses are dead, imposed and wind loads. the dead load is due to sheeting ordecking 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 givesthe 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 workcommencement.Observation at requirements at occupational Health safety and Environmental plan be strictlyadhered.Safety helmets, safety shoes, safety goggles, safety belt and approved overall aremandatory 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 – India’s largest construction conglomerate has itself been amatter of great pride for us. During this period of 4 weeks, we have come across the real civilengineering/ 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, incontrast to what we had previously seen in our college books. We have actually realized howobjectives are achieved in a construction site, in a systematic and optimized format, whilemaintaining premium quality.

We had hardly visited any construction sites before this practical training, and so we didn’tknow much about practical construction. However, today we can very easily recall each and everytheoretical 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 afew:

o Determination of stirrup cut length at the reinforcement yard.o Preparation of bar bending schedule for all cases.o Knowledge of shuttering and scaffolding at the formwork department (Jay Pee Formwork)o Calculation of beam bottom, beam side.o Knowledge of tackling various on-site difficulties.

o Knowledge about site safety norms.o A detailed construction methodology and on-site viewing of footing operations.o 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 CODsite. 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 constantsupervision 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 ourtraining in a very organized and systematic manner, and his timely inputs and checks have actuallyhelped 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 ofconstruction, and its feasibility and his own valuable suggestions.

We are very much thankful to Mr. P.K.Malhotra who gave us vital details about the project,relating it to the theoretical concepts and also gave us inputs on how to manage things for optimaloutput owing to his vast experience. Who very selflessly gave us all the details of the Formwork, andwould 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 periodworthwhile for us.

We are also very thankful to Mr. Hari SINGH Rathore and Mr. RaghavSinghania of qualitydepartment for guiding us. They were our mentor all the time, helping us out in each and every topicof the project, esp. clearing our design doubts, Quality controls, testing etc. and encouraging us toresearch into every detail and thereby clearing our queries.

We are highly obliged by Mr. Sumit and Mr. Sanjay who helped us in imparting knowledgeabout various important technical construction related issues selflessly, taking time out from theirbusy schedule and explain us each and every details of road construction technique.

We would also like to thank Mr.Anand ,Mr. Arib and Mr. Piyush for his vital inputs relating toreinforcement, 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, Accountsand Administration) for his guidance and constant motivating approach, which not only facilitatedour training sessions, but also made us feel comfortable all throughout the training program

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