REPORT OF INDUSTRIAL TRAINING

At

Submitted by

KRISHNA MURARI KANDU 1252100009

In partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY IN

CIVIL ENGINEERING

DEPARTMENT OF CIVIL ENGINEERING

KOTHIWAL INSTITUTION OF TECHNOLOGY &

PROFESSIONAL STUDIES MORADABAD

Contents Page

Acknowledgement 1

Chapter 1 Introduction

General Overview of the Site 2

Chapter 2 Training Highlights

2.1 Introduction 4

2.2 Double Deck Stabling Yard 4

2.3 Boundary Wall 10

2.4 Bar Bending Schedule (BBS) 11

Chapter 3 Various Tests Performed

3.1 Introduction 14

3.2 At the site 14

3.3 Tests in the Lab 18

Chapter 4 Conclusions 27

About Delhi Metro Rail Corporation Ltd. (DMRC) 28

References 30

ACKNOWLEDGEMENT

I would like to express my sincere gratitude to Delhi Metro Rail Corporation Ltd. for

having given me the opportunity to undertake my industrial training at their Vinod Nagar

Station Yard project in Line 7, Site CC-86 at Ghazipur, New Delhi.

I acknowledge my thanks to Mr. Asghar Ali (Project Manager 4D) & Mr. Ankit Jindal

(XEN/4D) for his guidance and constant supervision which helped me in my training

successfully.

I would also like to express my gratitude towards the assistant engineer Mr. Manoj

Chauhan, junior engineers Mr. Govind, Mr. Umesh and all the supervisors of the YFC

Group for their co-operation and encouragement which helped me in completion of this

training project.

Chapter 1- INTRODUCTION

GENRAL OVERVIEW OF THE SITE

Delhi Metro was the first modern rapid transport system to be started in India. Right now

the Phase 3 of the metro work is going on which has 2 new lines coming up and the

extension of other lines is going on. My site was Vinod Nagar Depot which lies in Line 7

between stations Vinod Nagar and I. P. Extension. Here a double deck station yard is

being made for repair work of metro trains and parking them in the night. A metro line

from the I.P Extension station connects the stabling yard.

DMRC has handed the construction work of the site to other companies name YFC

Construction and KCC. These 2 private companies are allotted specified work which is

done under the jurisdiction of DMRC official present at the site just to inspect the work

and make sure everything is going as per the plan. The design as given by the contractors

needs to be checked by the DMRC official only after which any construction process gets

started.

The work on the site started on early march of 2015, during my training the initial phases

of the project was going on like the foundation of the double deck stabling yard and the

boundary. The site is set to be completed by June 2016. During the course of time staff

quarters and water tank has to be made only of whose drawing were approved at the time

of my internship, while construction was yet to be started.

The double deck stabling yard is proposed with the ground floor proposed for the offices

and the car parking of the employees while the first and the second floor are used for

parking the metro train during the night time. Along with the stabling yard a workshop

building is to be made in the station yard only. It is made along the boundary wall just

before the stabling yard. While contract of stabling yard is under YFC Construction rest

of all the work is undertaken by the KCC. These include boundary wall, staff quarters,

workshop building and even the water tanks.

The electronic part of the stabling yard is taken be the SIEMENS which include the

introduction of poles for the electricity to pass through on which the metro runs. The

horizontal section of the stabling yard is shown below along with the elevation.

Chapter 2- TRAINING HIGHLIGHTS

2.1 INTRODUCTION

This chapter aims at explaining all the basic procedure that was carried out at the site

during the time of training. It gives brief step by step method that was followed at the site

for stabling yard and the boundary wall. It also tells about the construction of bar bending

schedule (BBS) from the drawing given by the designer which makes it easier to make

the reinforcement for the worker.

2.2 DOUBLE DECK STABLING YARD

Pile foundation is used for the foundation of the yard. It is a form of Deep foundation.

Deep foundation is a type of foundation which transfers building loads to the hard strata,

rocks deep down from the surface of the earth. A pile is a vertical structural element of a

deep foundation driven deep into the ground at the building site.

Pile foundation consists of two components

1. Single or group of piles

2. Pile cap

The selection of type of pile foundation is based on site investigation report. Site

investigation report suggests the need of pile foundation, type of pile foundation to be

used and depth of pile foundation to be provided. The cost analysis of various options for

use of pile foundation should be carried out before selection of pile foundation types.

2.2.1 Piling

The type of pile used was bored cast in-situ piles (means they are casted on the site

only). The various steps which are involved in this type of piling are explained below

I. Surveying

It is the very first step to be done on site. Based on the drawing which is made by

the designer the points are marked on the field where piling operation is to be

performed. The point are marked by using Auto level by taking a fixed point and

then marking the appropriate point as given by to the surveyor. From the center of

the point where piling has to be done and reference points at a distance of 2m

along all the four sides (making 2 lines perpendicular to each other) are marked for

future reference of locating the points.

II. Pile Boring

After the surveyor has marked the points, boring is started with the help of rig

machine. The four reference points are taken into consideration while making a

hole with the rig machine so that the pile is at the required position. The hole of

about 3m is made initially so that the casing can be installed initially. The casing

of 1000mm diameter was used and the length of the casing pipe used was 4m long.

Casing pipe is used to make sure that the borehole made is vertical down the

ground and not inclined. While lowering the casing pipe position of the guide

casing pipe with reference to pile reference points already fixed around the pile

location shall be checked to shift or adjust the casing pipe to ensure proceeding of

drilling at exact pile location without any deviation. After the casing is installed

the reference points are not required and can be removed. Now boring is continued

till the required depth of as per the drawing is not achieved (Ranging from 25m to

40m in the site). Depth of the hole can be checked with the help of a sounding

chain which the exact value of the depth of hole.

III. Bentonite Addition Bentonite is an absorbent aluminium phyllosilicate, impure clay consisting mostly

of montmorillonite. The absorbent clay was given the name bentonite by Wilbur

C. Knight in 1898, after the Cretaceous Benton Shale near Rock River, Wyoming

in America. Bentonite is added to the borehole while boring is going on. Before

putting it in the bore the bentonite is mixed with water to form a solution.

Bentonite is used to stabilize the sides of the bore hole while boring so that the soil

from the sides does not come out. Various properties of bentonite should be

checked on regular basis to see whether the solution is proper or not otherwise the

soil on the sides may fall out leading to reduction in depth of borehole thereby

reducing strength carrying capacity of the pile

The various properties and there range are given below

Ph. Value- 9 to 12

Density- 1.03 to 1.10

Sand content- 0 to 3% if bentonite is being reused

0% if bentonite is fresh

Viscosity- 30 to 35 sec

IV. Reinforcement Cage Lowering

Prefabricated reinforcement cage is prepared as per the bar bending

schedule(BBS) which is prepared from the drawing and kept near the pile location

while boring work is going on. As for higher depth the reinforcement cage is very

long, the cage is lifted one by one and spot welded at the joints and lowered in the

borehole with the help of a crane.

V. Flushing

Flushing is basically removal of all the sediments which might have settled on the

founding strata. After cage lowering, 250 mm diameter tremie pipes in suitable

lengths are to be lowered in the hole. The operation is done by lowering one

tremie pipe after another and connecting them threading to maintain water

tightness throughout its length till the gap between the pile base and Tremie is

between 100-150 mm. the tremie pipe is locked and supported from top to

maintain the level. The tremie head is to be provided to the tremie pipe for

flushing activity. The bore is flushed by fresh bentonite slurry through the tremie

head. All the sediments come to the top with the bentonite solution and are

removed. Flushing is carried on till the required sounding is not received.

VI. Pile Concreting

It is the final step in piling. After flushing is completed the tremie head is removed

and funnel is inserted through which concrete can be inserted in the bore hole.

M35 grade concrete is used in piling. When the slump arrives from the batching

plant the slump should be checked and it is maintained from 160 to 200mm.

Concrete is filled in the tremie pipe and the funnel from the truck. Lifting and

lowering is repeated keeping sufficient concrete in the funnel. As the concrete is

added tremie pipe are removed one by one taking care tremie pipe is sufficient

embedment in the concrete until whole concreting is completed. It is done to

prevent inflow of soil and bentonite in concrete which will lead to reduction in

strength. The concreting is done up to 500mm above the cut off level to get good

sound concrete at the cut off level.

Regular sounding needs to be done to make sure that the concrete is being poured

properly and there is chocking in the pipe. A truck from the batching plant has

approximate 5m3 of concrete in it. If there is chocking the whole tremie pipe is to

be removed and source causing the chocking is identified. After rectifying the

cause the sounding is done and sounding length plus 1m of tremie pipe is only

inserted inside the bore and concreting is continued.

Rig machine used for boring Reinforcement cage being inserted in the bore

Spot welding being done to join 2 reinforcement

Tremie Pipe used in flushing and concreting

2.2.2 Pile Cap

A pile cap is a thick concrete mat that rests on concrete or timber piles that have been

driven into soft or unstable ground to provide a suitable stable foundation. It usually

forms part of the foundation of a building, typically a multi-story building, structure or

support base for heavy equipment. The cast concrete pile cap distributes the load of the

building into the piles. Usually the load to be supported exceeds the bearing capacity of a

single pile so a group of piles are used. In the site there were combinations of 3, 4 and 6

piles constructed together (based on the design given by the designer). Thus it is

economical to provide a single large cap for all the piles closely placed together, thus

forming a pile raft.

After the pile is set, the ground around the pile is excavated to make the pile cap. Around

2m below the ground was excavated out and chipping of the top 1.5 meter of the pile is

done. This is done because the top of the pile is considered to be not of required strength.

It contains along with concrete mixture of bentonite and soil that was bored. After that a

layer of PCC (Plain Cement Concrete) is applied for around 10cm to provide a firm and

even base at the bottom so that the load can be distributed equally.

Then based on the design the reinforcement is provided. For a 4 piles, size of the pile cap

adopted was 4.4*4.4m2

and 6 piles, size of pile cap adopted was 7.6*4.4m2. The grade of

concrete used was M30 and cover of 60mm was used. After putting the reinforcement,

the shuttering is provided and concrete is poured. After the concrete set shuttering is

removed and regular curing is done.

Ground is excavated ready for chipping

Reinforcement cage for a pile cap with 6 piles

1.2.3 Pier

Piers are nothing but columns. A pier is a raised structure typically supported by well-

spaced piles or pillars. There were rectangular piers of 1100mm*1300mm used

throughout the stabling yard. They basically help in transfer of load from the top slab to

the pile cap through which it can be distributed below the earth surface by piles.

Construction of piers starts before concreting the pile cap as the reinforcement start from

beneath the ground. They are vertically long structures which are provided by shuttering

while concreting. M40 grade of concrete is used in piers and curing needs to be done so

that the concrete set properly.

While providing the shuttering for the pier, the verticality of the pier needs to be checked

so that the pier is vertically upward and does not tilt. To check this after providing the

shuttering, 2 small threads are dropped on each side of the shuttering from the top to the

bottom most point. Then with the help of tape the distance between the wire and the

shuttering is measured at some distance below the top and somewhere above the bottom.

It should be same. It is checked at all the four sides and if correct means the pier is

vertical. Then concreting can be started with the help of a pump.

Reinforcement cage for pier being prepared

2.3 BOUNDARY WALL

The base of the boundary wall

constructed along the depot was made of

isolated footing or piling depending on

the on the soil surface and the area of the

depot. But isolated footing was over

piling where both are possible as it is

cheaper. The height of the boundary wall

was constructed of height 4m.

Piling is expensive as lot of fuel is

required in boring a hole in the ground.

But the place where sand is loose footing

is used. In the site both the methods were

used. For piling a casing of 750mm

diameter was used and the bore length

was 18-20m depending on place to place.

M30 grade of concrete was used.

Prefabricated vertical slabs fixed on the wall

While in case of footing, strip footing was used as the base and then column

reinforcement was raised. After the columns were raised to the desired height

prefabricated vertical slabs prepared at the batching plant were brought to the site and

were fixed (as shown in the above fig.)

After fixing the vertical slab the reinforcement of the column and the slab are joined

together and the column is filled with concrete and allowed to set. Regular curing is done

throughout the week so that it can properly set. While in case of piling after constructing

the pile the whole framework of the wall reinforcement is assembled and then shuttering

is provided and concrete is poured. On the site the area near the slums piling was used as

huge area could not be dough out to make the strip footing.

2.4 BAR BENDING SCHEDULE

Bar bending schedule (BBS) provides the reinforcement calculation for the reinforced

concrete beam. This chart gives a clear picture of the bar cutting length, diameter of the

bar, bar mark, type of bar, location of the bar, bar bend etc. It is made from the drawing

given by the designer.

It is given to the laborers to give them the idea of how much length long the

reinforcement bar is to be cut to make the desired reinforcement cage. It also gives the

contractor the total length of different bars to be required for the whole project and the

weight of each cage. It is usually prepared by software as the calculation are very

complex for that of pile cap as a lot of reinforcement are to be constructed.

On the site the bar of length 12m provided so for piling the bar were needed to be

overlapped and site welding was carried. A bar bending schedule of a pile is shown

below along with the design as given by the designer on the basis of which it is made.

Chapter 3- VARIOUS TESTS PERFORMED

3.1 INTRODUCTION3

This chapter aims at explaining the various that are performed both at the site and the lab

to ensure the quality of the sample being used is good and building can hold the load

successfully.

3.2 TESTS PERFORMED AT SITE

These tests were conducted at the site because it was required to be performed at the time

of construction. These include the entire test on bentonite, the slump test and the test on

the pile after its formation.

3.2.1 Test on Bentonite

Bentonite is a very important component used in piling. Its basic properties like Ph.,

density, viscosity and sand content needs to be checked regularly (4 to 5 times a day).

1. Ph. Value

For checking the ph. of the bentonite solution, the ph. paper is dipped in the

bentonite solution which changes the color of the ph. paper. Then the color is

compared with those on the ph. table and value is found out. Its value should be

around 9.

2. Viscosity

For finding the viscosity of the solution mars cone is used. Around 950ml of the

bentonite solution is taken in a measuring cylinder. Then it is poured in the mars

cone and at the same time the stopwatch is started. The time taken by the bentonite

solution to pass through the cone is noted. This time is the viscosity of the solution

and the value should be 30- 35 sec.

3. Density

For finding the density of the bentonite solution barometer is used. The solution is

taken in measuring cylinder and barometer is inserted in it. When the barometer

stops moving the value on the barometer is checked which gives the density of the

solution.

4. Sand Content

The percentage of sand content needs to be checked to make sure that the

bentonite solution is pure. It is checked with the help of sand kit. It has 2 parts a

hollow plastic cylinder with a 200micron sieve and measuring cylinder which is

conical from the bottom. The conical measuring cylinder has markings in the

conical section a small line in the cylindrical section.

Procedure:-The hollow cylinder is kept above the other cylinder and the solution

is passed through it till the mark in the cylinder. Then water is added to it. The

hollow cylinder is removed and the solution in the bottom container is removed

and washed. The hollow cylinder is then reversed and put over the container. Now

water is poured in the hollow cylinder and as it is reversed, the sand which is

present in the sieve comes in the container with water. As sand is heavier than

water it comes and settles down. From the marking in conical section, the sand

content percentage is found.

The sand content for newly prepared bentonite solution should generally be 0%

but till 1% is allowed. For bentonite solution which is being re-used after passing

through the desander then around 3% sand content is allowed.

3.2.2 Sounding

Sounding is done to find out the height

of the borehole dough during piling

operation. It is done with the help of a

sounding chain which is either a steel

chain or a plastic chain with a metal

piece at the bottom. The chain is inserted

in the borehole to the depth more than

the depth of bore hole. It is regularly

stretched, and when suddenly a force is

required to stretch the chain that point

w.r.t casing top level is marked and

measured with the help of a measuring

tape.

Steel sounding chain

3.2.3 Slump Test

Slump test is an empirical test used to measure the workability of fresh concrete. It

basically determines the state of fresh concrete also refers to the ease with which the

concrete flows. The workability of concrete is affected by the consistency of the concrete.

So it basically measures the wetness or consistency of the concrete.

Procedure: A slump kit is taken consisting of a frustum of a cone having bottom

diameter of 20cm and top diameter of 10cm and a height of 30cm open at both end also

known as the slump cone, a bullet end metal rod for tamping. The cone is placed on a

non-absorbent surface. The cone is filled with fresh concrete in 4 layers, after each layer

tamping is done with the rod by providing 25 stokes. After the concrete is fully filled, the

mould (cone) is carefully lifted vertically upward, so as to not disturb the concrete cone.

After lifting the concrete subsides, this subsidence is measured with the help of a scale

and is known as slump.

The value of slump considered workable is 160-200mm. Slump of each and every truck

arriving to the site is done. This test being done at the batching plant is done here again to

make sure that the workability does not change during transportation.

3.2.4 Pile Integrity Test

This is a very important test as pile being below the ground, basically invisible it is

difficult to find its integrity. This test basically test the integrity so as to find out the flaws

before it can lead to any serious damage. This test is done before laying the pile cap, just

after the chipping process is done. It is also known as Low strain impact integrity test as

we only use a small hammer.

Procedure: The pile head is first leveled and should be smooth. The equipment required

is a rubber tipped hand-held hammer with sensor, a sensor and a receiver. As there were

circular piles formed the test was conducted at 3 spots in a single pile. The sensor is

attached with an adhesive material on the pile top. The rubber tipped hammer is used to

generate a “low strain” compressive impact wave. The readings are received in the

receiver in the form of waves by which we can find out the integrity.

Limitation: The major limitations are that it cannot detect gradually increased or

decreased diameter or the curved piles. Even gradual material change cannot be detected.

Pile integrity test helps us in detecting large inclusion of other material than concrete,

cracks, joints and increase or decrease in cross-section. If there are large undulation in the

receiver the pile may have to be rejected and has to be constructed again

3.2.5 Pile Load Teat

It is the most important test in pile which helps us in determining the settlement of pile

under a given amount of load. The load provided is generally more than the load which

the pile is supposed to sustain. There are 2 types of load test which are adapted, initial

loading test and routine loading test. All these tests are performed on completion of 28

days of casting of pile and these tests are performed from the casing top level.

The procedure for both the tests is the same only the amount of load to be applied is

different in both the cases. The initial/normal load test on piles is conducted to confirm

the design load and to provide the guidelines for setting up limits of acceptance for

routine test piles. In this the load is 2.5 times the safe load carrying load capacity for

which the pile is designed. The routine load test is conducted frequently to check

random piles. In cannot be done on every pile as it takes long time. In this the load is 1.5

times the safe load carrying capacity for which the pile is designed.

Procedure: A bearing plate with a hole shall be placed on the head for the jack to rest. 2

dial gauges for a single pile and 4 dial gauges for a group of piles with 0.01 mm

sensitivity shall be used. Kentledge shall be suitably designed to get the desired reaction

on the piles. The dial gauge is positioned at equal distance around the piles on datum bars

resting on immovable supports at a distance of 3m. The test should be carried out by

applying a series of vertical downward incremental load each increment being of about

20 percent of safe load of the pile. Each load is to be maintained till the rate of

displacement of the pile top is either 0.1 mm in the first 30 minutes or 0.2 mm in the first

one hour or 2 hours whichever occurs first. The next increment in the load is to be

applied on achieving the aforesaid criterion. The load is maintained for 24 hours and then

it is removed gradually. The settlement/displacement is measured with the help of the dial

gauge.

The normal load test helps in finding the safe load for that pile on the bases of which we

can make the necessary changes required changes to get the desired safe load. The safe

load is the least of

1) 2/3rd

of the final load at which the total displacement attains a value of 12 mm

unless otherwise required in a given case on the basis of nature and type of

structure in which case, the safe load should be corresponding to the stated total

displacement permissible.

2) 50% of the final load at which the total displacement equals 10% of the pile

diameter in case of uniform diameter piles or 7.5% of the bulb diameter in case of

under reamed piles.

While for the routine test the maximum settlement should not exceed 12mm or else pile

will fail.

3.3 TESTS PERFORMED IN LAB

Most of the tests are performed in the lab except which were required during construction

as mentioned above. These include the tests on cement, coarse aggregate, fine aggregate

and admixtures before they are mixed together to form concrete which is used at the site.

Some of them are generally instantly when the sample arrives usually at night.

3.3.1 Test on cement

There were various tests that were conducted on cement to find out the quality of cement

being used. As doing tests on every bag would take a long time, these test were carried

out per 1000 bags.

1. Standard Consistency

It is that consistency which will permit a vicat plunger having 10 mm diameter and

50 mm length to penetrate to a depth of 33-35 mm from top of the mould.

Procedure:

400 g of cement is taken and placed in a enameled tray.

Mix about 25% water by weight of dry cement thoroughly to get a cement

paste.

Fill the vicat mould, resting upon a glass plate, with this cement paste.

After filling the mould completely, smoothen the surface of the paste,

making it level with top of the mould.

Place the whole assembly (i.e. mould + cement paste + glass plate) under

the rod bearing plunger.

Lower the plunger gently so as to touch the surface of the test block and

quickly release the plunger allowing it to sink into the paste.

Measure the depth of penetration and record it.

Prepare trial pastes with varying percentages of water content and follow

the steps (2 to 7) as described above, until the depth of penetration becomes

33 to 35 mm.

By the above method the amount of water (%) to be added to get cement of

required consistency is found out which between 28-32% was allowable.

2. Initial & Final Setting Time

Initial setting time is that time period between the time water is added to cement

and time at which 1 mm square section needle fails to penetrate the cement paste,

placed in the Vicat’s mould 5 mm to 7 mm from the bottom of the mould. While

Final setting time is that time period between the time water is added to cement

and the time at which 1 mm needle makes an impression on the paste in the mould

but 5 mm attachment does not make any impression.

Procedure:

The first step of preparing the mould is same as that of in case of finding

the consistency. Only in this case the stop watch is started when water is

added to the cement (t1).

For initial setting time place the test block confined in the mould and

resting on the non-porous plate, under the rod bearing the needle. Lower the

needle gently until it comes in contact with the surface of test block and

quick release, allowing it to penetrate into the test block. In the beginning

the needle completely pierces the test block. Repeat this procedure i.e.

quickly releasing the needle after every 2 minutes till the needle fails to

pierce the block for about 5 mm measured from the bottom of the mould.

This time is recorded (t2).

For final setting time, the needle of the Vicat’s apparatus is replaced by the

needle with an annular attachment. The cement is considered finally set

when upon applying the final setting needle gently to the surface of the test

block; the needle makes an impression thereon, while the attachment fails

to do so. This time is recorded (t3).

The initial and the final time can be calculated by the formulae:

Initial setting time=t2-t1, Final setting time=t3-t1

3. Compressive Strength

It is the strength which a cube of cement mixture can after being moulded. It is

determined by compressive strength test on mortar cubes compacted by means of a

standard vibration machine. The specimen is in the form of cubes

70.6mm*70.6mm*70.6mm.

Procedure: Standard sand used for preparation of cement mortar. 200g of cement

and 600g of sand are mixed thoroughly. Add 11% of water and mix thoroughly to

obtain uniform color. Fill the mortar in the mould and keep it on the vibrator by

clamping it. Vibrate it for 2min so that the mortar is fully compacted. Allow it to

set and after 24hrs remove the mould and keep the mortar in water. Take it out

only for testing. The strength after 3, 7 &28 days is carried out.

The mortar is taken out of water and compressive strength is found out by apply

force till a crack appears (fails). The value after 28 days should be around 53Mpa.

If not the cement is not proper and needs to be replaced.

Vibrator to prepare mould of mortar

Vicat’s apparatus

3.3.2 Tests on Coarse Aggregate

Coarse aggregate are granular element more than 4.75mm in size. They are very

important in formation of concrete. They generally range between 9.75 to 37.5mm in

diameter. In the site crushed coarse aggregate were used. They were used in 2 different

sizes basically 10mm coarse aggregate and 20mm coarse aggregate. It basically specifies

the maximum size of the aggregate to be used. There were various test to be performed

on them which are given in detail below.

1. Sieve Analysis

Sieve analysis (or gradation test) is a practice or procedure used to assess

the particle size distribution (also called gradation) of a granular material. The

size distribution is often of critical importance to the way the material performs in

use. A sieve analysis can be performed on any type of non-organic or organic

granular materials including sands, crushed rock, clays, granite, feldspars, coal,

soil, a wide range of manufactured powders, grain and seeds, down to a minimum

size depending on the exact method. This method was basically used to make sure

that the grading of soil is ok and make sure no particle of size more than 10mm is

found in 10mm coarse aggregate. This test is done every day.

Procedure: All the sieves are taken and arranged in ascending order with the

highest diameter on the top. 1kg of sample is taken and poured on the top sieve

and the lid is covered. It is shaken with the sieve shaker and then weight of sample

in each sieve is found out. A sample of reading for 10mm sieve is given below.

Sieve Size

Retained weight

% Retained Weight

Cumulative % Retained

Cumulative % passing IS Limits

10mm 0 0 0 100 100

4.75mm 77 7.7 7.7 92.3 90-100

2.36mm 51 5.14 12.84 87.16 75-100

1.18mm 81 8.11 20.95 79.05 55-90

600 Micr 268 26.86 47.81 52.19 35-59

300 Micr 247 24.79 72.7 27.4 8-30

150 Micr 221 22.18 94.88 5.12 0-10

Pan 51 5.12 100 0 0

2. Flakiness and Elongation Index

This test is used to determine the particle shape of the aggregate and each particle

shape being preferred under specific conditions. The significance of flakiness &

elongation index is as follows:

The degree of packing of the particles of one size depends upon their

shape.

Due to high surface area to volume ratio, the flaky and elongated particles

lower the workability of concrete mixes.

Flaky and elongated particles are considered undesirable for base coarse

construction as they may cause weakness with possibilities of braking

down under heavy loads.

Procedure: This test is only performed once a month as it is a very long process

and may even take a day to finish. First the sample is to be passed through the

sieve. Then the particles are arranged into particle size group eg. Those which pass

through 25mm sieve but not from 20mm are in one group, those which pass

through 20mm but from 16mm in one group and so on. Then 200 aggregates from

each group are taken and there weights of each group are noted down and total

weight is calculated. Then for elongation index each particle is passed through the

group of their sizes which is written on the instrument. If it passes it is ok or else it

is elongated. The weight of elongated aggregate is noted down for each group. For

flakiness index each particle is passed through a hole of its respective size as

mention on the instrument. If it passes it is flaky or else not. The weight of flaky

particle is found out for each group. A sample of reading for 20mm aggregate is

given in the table below.

Sieve size

200 Pieces of total weight

weight of flaky aggregate

weight of elongated aggregate

25-20 2693 475 224

20-16 1986 237 832

16-12.5 899 179 323

12.5-10 489 111 290

10-6.3 170 57 113

TOTAL 6237 1059 1782

Flakiness index= (1059/6237)*100 =16.98%

Elongation index= (1782/6237)*100 =28.57%

The acceptable value for both are 25%, which means the sample is okay and can

be used. The equipment’s are shown below.

3. Impact or Crushing Value Test

This test is done to determine the aggregate impact value of coarse aggregates.

The property of a material to resist impact is known as toughness. The aggregates

should therefore have sufficient toughness to resist their disintegration due to

impact of frequent movement of trains. This characteristic is measured by impact

value test. The aggregate impact value is a measure of resistance to sudden impact

or shock, which may differ from its resistance to gradually applied load.

Procedure: The test sample consists of aggregates sized 10.0 mm 12.5 mm.

Aggregates may be dried by heating at 100-110° C for a period of 4 hours and

cooled.

Sieve the material through 12.5 mm and 10.0mm IS sieves. The aggregates

passing through 12.5mm sieve and retained on 10.0mm sieve comprises the

test material.

Pour the aggregates to fill about just 1/3rd

depth of measuring cylinder.

Then compact the material by giving 25 gentle blows with the rounded end

of the tamping rod.

Add two more layers in similar manner, so that cylinder is full. Strike off

the surplus aggregates and the net weight of the aggregate is measured in

grams (W)

Bring the impact machine to rest without wedging or packing up on the

level plate, block or floor, so that it is rigid and the hammer guide columns

are vertical.

Fix the cup firmly in position on the base of machine and place whole of

the test sample in it and compact by giving 25 gentle strokes with tamping

rod. Then the hammer is raised above the surface of aggregate sample in

the cup and allowed to fall freely on the sample giving 15 very quickly.

Remove the crushed aggregate from the cup and sieve it through 2.36 mm

IS sieves until no further significant amount passes in one minute. Weigh

the fraction passing the sieve to an accuracy of 1 gm. Also, weigh the

fraction retained in the sieve.

Below is the table showing the observation of the impact value test conducted as

on 19/6/2015

Measured weight

Sample Weight 326g

2.36mm sieve retained weight 273g

2.36mm sieve passing weight 53g

Impact value = (53/326)*100 = 16.26%

The acceptance limit for impact value is 25%. So the sample is within the

requirement limit and the sample is good

4. Dry Loose Bulk Density Test (DLBD)

It is a method to basically find the bulk density of the aggregate. The bulk density

is the weight of material in a given volume. The bulk density of an aggregate is

affected by several factors, including the amount of moisture present and the

amount of effort introduced in filling the measures. In this test the bulk density is

found of loose aggregate and not compacted aggregate.

Procedure: The volume of the cylindrical metal is measured by pouring water into

the metal measure and volume “V” is recorded in liter. Fill the cylindrical measure

to overflowing by means of a shovel or scoop, and then level the top surface of the

aggregate in the metal measure, with a straightedge or tamping bar. The weight of

the aggregate in the measured and recorded (Wkg).

Below shows observation of DLBD test on sample that came 20/6/2015 based on

the test conducted on the basis of the above procedure.

The results for the above tests are

For 20mm Aggregate, DLBD= (14.61/10.52)*1000 =1388.78kg/m3

For 10mm Aggregate, DLBD= (13.96/10.52)*1000 =1326.99kg/m3

For 20mm+10mm Aggregate (60:40), DLBD= (14.985/10.52)*1000 =1424kg/m3

The maximum acceptable value 1500kg/m3. As all the reading are below this

range the aggregate are as per the required quality.

Volume of bucket 10.52L

Weight of bucket 5.23Kg

For 20mm Aggregate

Weight of bucket + Aggregate 19.84Kg

Weight of Aggregate 14.61Kg

For 10mm Aggregate

Weight of bucket + Aggregate 19.19Kg

Weight of Aggregate 13.96Kg

For 20mm + 10mm Aggregate (60:40)

Weight of bucket + Aggregate 20.215Kg

Weight of Aggregate 14.985Kg

5. Specific Gravity

Specific gravity is the ratio of the density of a substance to the density (mass of the

same unit volume) of a reference substance. Basically specific gravity is the ratio

of the weight of a volume of the substance to the weight of an equal volume of the

reference substance.

Procedure: The specific gravity of the coarse aggregate is found out with the help

of pycnometer. 2kg of sample is taken and washed properly to remove any dust

particle. The weight of empty pycnometer is noted (w1). The pycnometer is then

filled with little more than 1/3rd

of coarse aggregate. It is weighed (w2). The rest is

filled with water and covered at the top. Any air pocket if there is found out by

rolling and then removed. It is then weighed (w3). Then the pycnometer is cleaned

filled with only water and weighed (w4).

Specific gravity is given by

S.G. = (w2-w1)/[(w4-w1)-(w3-w2)]

3.3.3 Test on Fine Aggregate

Fine aggregate is natural sand which has been washed and sieved to remove particles

larger than 5 mm. The reason for using a mixture of fine and coarse aggregate is that by

combining them in the correct proportions, a concrete with very few voids or spaces in it

can be made and this reduces the quantity of comparatively expensive cement required to

produce a strong concrete. Most of the tests conducted in case of fine aggregate are same

as that of coarse aggregate. The tests conducted in the lab are given below in detail.

1. Sieve Analysis This process is basically done to get the rough idea of classification of fine

aggregate and check whether they are as per the IS requirement or not. The

procedure of conducting remain the same with just sizes of sieve changing with

10mm being the largest and 150 micron the smallest

Sieve size

Weight Retained

% Weight Retained

Cumulative % Weight Retained

% Passing IS Limits

10mm 0 0 0 100 100

4.75mm 21 2.1 2.1 97.9 90-100

2.36mm 75 7.5 9.6 90.4 75-100

1.18mm 77 7.7 17.3 82.7 55-90

600 micron 127 12.7 30 70 40-75

300 micron 232 23.2 53.2 46.8 18-45

150 micron 371 37.1 90.3 9.7 0-20

Pan 97 9.7 100 0 0

2. Silt Content by Weight This experiment is used to determine the quantity of silt in fine aggregate. Silt if

present in fine aggregate form a coating thus preventing a good bond between

cement and the aggregates. If present in large quantities, result in the increase

water-cement ratio and finally affecting the strength of concrete. For conducting

the experiment a 250ml measuring cylinder is required

Procedure: Fill 1% solution of common salt and water in the measuring cylinder

up to 50 ml mark. Then fine aggregate to be tested is added to this solution till the

level of the salt solution shows 100 ml mark. More salt solution is added to take

the level up to 150 ml mark. Shake the mixture of sand and salt solution well and

keep it undisturbed for about 3 hours. Readings are taken at 10min, 30min and

3hrs.

The silt being of finer particles than sand, will settle above the sand in a form of

layer.

Observation:

Silt content by volume

After 10 minutes, Silt = [(114-102)/114]*100 =10.52%

After 30 minutes, Silt = [(110-102)/110]*100 =7.27%

After 3 hours, Silt = [(108-102)/108]*100 =5.56%

The silt content after 10min should be 10-12% and after 3hrs should be 8% max as

per the guidelines. So the sample does not have very high amount of silt present in

it.

3. Moisture Content It is the amount of water that can be absorbed by an aggregate. The total moisture

content is the sum of the absorbed moisture and the free surface moisture. It is

important to measure the moisture concrete as it affects the property of fresh and

hardened concrete. The moisture content should be around 10% only not affect the

concrete.

Procedure: It has a very easy process. A quantity of sample is taken and

measured (w1). The sample is then kept in the oven for 24hrs to dry up. Then the

sample is again measured (w2).

Moisture Content = (w1-w2)/w2

Two other test for fine aggregate are there, specific gravity and DLBD test whose process

is exactly same as that in case of coarse aggregate.

Chapter 4- CONCLUSION

The whole industrial training was a very good learning experience which helped me get

an idea about how the things are done in the field. With the help of this training and the

report a lot can be learned about the various types of foundation that are being used and

the reasons for using a particular foundation over the other.

It also tells about the importance of various parameters that are to be kept in mind and

slight neglectance can lead to hazardous impact in the future. Everything from the

material provided to the process of getting to the end product from the material is very

important in construction. All the tests need to be performed to the exact requirement

under appropriate condition to get the desired results.

On the other hand safety should also be kept in mind and all the safety equipment

including helmet, safety shoes and jacket needs to be worn whenever the person is

present at the site and safety instruction needs to be taken from the safety person in

charge before going to the site.

None of the data recorded should be manipulated, but proper solution should be provide

to correct that data then only as slight manipulation can lead to loss of both life and

property in the near future.

ABOUT DELHI METRO RAIL CORPORATION

The Delhi Metro is a metro system serving New Delhi and its satellite cities of Gurgaon,

Noida, Faridabad and Ghaziabad of the National Capital Region in India. Delhi Metro

has been ranked second among 18 international Metro systems in terms of overall

customer satisfaction in an online customer survey. Delhi Metro Rail

Corporation Limited (DMRC), a state-owned company with equal equity participation

from Government of India and Government of National Capital Territory of Delhi built

and operates the Delhi Metro. However, the organization is under administrative control

of Ministry of Urban Development, Government of India. Besides construction and

operation of Delhi Metro, DMRC is also involved in the planning and implementation of

metro rail, monorail and high-speed rail projects in India and providing consultancy

services to other metro projects in the country as well as abroad.

Planning of metro started in 1984, when the Delhi Development Authority (DDA) and

the Urban Arts Commission came up with a proposal of developing a multi-modal

transport system in the city. The Government of India & The Government of Delhi

jointly set up the Delhi Metro Rail Cooperation (DMRC) on March 5, 1995 with Dr. E.

Shreedharan as the managing director. Construction started in 1998, and

The first section on the Red Line was opened in 2002

Followed by the Yellow Line in 2004

The Blue Line in 2005, its branch line 2009

The Green Line and Violet Line in 2010 and

The Airport Line in 2011

The metro is a combination of elevated, at grade and underground lines and uses both

broad gauge and standard gauge rolling stock. It has a total of 138 stations out of which

96 are elevated stations, 37 are underground stations and 5 are at grade stations including

9 interchange station. The Delhi Metro Rail Cooperation has been certified by the United

Nations as the first metro rail and rail based system to get carbon credits for reducing

greenhouse gas emission.

It has brought revolutionary change in the city transport. It has reduced time travel and

also got down the pollution level by around 50%.

Overview of the Delhi Metro Routes

REFERENCES

www.civilengg.com www.wikipedia.com Civilblog.org www.concreteconstruction.net Various IS Coded

IS 4031 for cement test

IS 2386 for coarse aggregates

IS 2306 for fine aggregate

IS 2911 for piles

IS 1199 & IS 3085 for concrete