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ISLAMABAD CAMPUS

DEPARTMENT OF CIVIL ENGINEERING

TITLE: Visit to

Nicholson Monument Taxila

Fauji Cement Wah

New Benazir International Airport (Fateh Jhang)

SUBMITTED TO: ENGR. WAQAR MUMTAZ

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GROUP MEMBERS

1) SYED HUSSNAIN RAZA

2) SHABAN KAYANI

3) M. MUJAHID HUSSAIN

4) MANZOOR KHAN

5) HUSSAIN KHAN

6) FARAZ AHMAD

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CONTENTS

Objective ………………………………………………………............. 5

Location Detail ………………………………………………………... 5

Material And Dimensions ……………………………………………… 5

Nicholson Monument Taxila …………………………………………... 6

John Nicholson (East India Company)…………………………………. 6

History………………………………………………………………….. 8

Grand Trunk Road (GT Road) Sadak-E-Azam ………………………... 8

Introduction …………………………………………………………….. 9

Old Pictures of GT Road Path Beneath of Nicholson Monument Taxila.. 10

Shape and Structure of GT Road ……………………………………….. 11

Photographic Evidence ………………………………………………….. 12

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VISIT 01

TIME (9:20 AM – 09:50 PM)

DATE (02-DEC-2014)

Nicholson Monument Taxila

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OBJECTIVE We visit the Nicholson Monument Taxila and practically observed the Monument Tower

and Old GT Road Construction

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To know about the material and shape adopt in these heritage structure.

To know about the procedure and techniques applied on these structures.

LOCATION DETAIL We visit Nicholson Monument which is located Margalla near Taxila

Location Map Of Nicholson Monument Taxila

MATERIAL AND DIMENSIONS In Nicholson Monument

White Granite stone slab is used

12 meter of Height

Polygon Square Shape

Down size polygon square dimension is 12 x 12 ft

Up size polygon square is 6 x 6 ft

In GT Road

Flat pieces of stone are used

Boulder and flat Stone tiles are used

Starts from Kabul Afghanistan

End City is kolkata India

1500 miles long

500 years old road

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NICOLSON MONUMENT TAXILA

JOHN NICHOLSON (EAST INDIA COMPANY)

Nicholson was born on 11 December 1822 in Lisburn, Ireland, the eldest son of Dr Alexander

Jaffray Nicholson and Clara Hogg. He studied at The Royal School of Dungannon, a public

mixed school, located in Dungannon, County Tyrone, Northern Ireland. Nicholson joined the

army of the British East India Company in 1839.

Brigadier General John Nicholson Statue John Nicholson

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NICHOLSON MONUMENT TAXILA

Nicholson Monument Taxila

HISTORY

This structure erected in1868 is a granite obelisk approximately 40 feet (12 m) in honor of Brig

Gen John Nicholson's who led the assault of Delhi but fell in the hour of victory mortally

wounded at this place. Two structures are located at the foot of Margalla pass and in the shadow

of Nicholson's obelisk. They are reproductions of classical Greek buildings. The Legendary

warrior King, Alexander the Great had passed through this area about 325 BC on his way to

Indian conquest and stayed at TAXILA, 8 km from the obelisk. The ruins of original Grand

Trunk road leading to Afghanistan which is in a semi preserved condition can also be seen in the

area below the monument.

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Nicholson monument stands out like a solitary sentinel atop the left side of the MARGALLAH

pass as you go towards TAXILA bearing the hall mark of the site where Sir John Nicholson was

fatally wounded and died on 23rd

September 1857 aged 34 years by a local known as Kala Khan.

The local story goes and is documented that one of the ancestors of SARDAR SIKANDAR

HAYAT rescued the wounded Sir John Nicholson and brought him to the safety of WAH

GARDENS and tried to tend to his wounds and look after him. Sir John Nicholson very much

moved by the hospitality and nursing care extended to him that he before his dying breath doled

out a big JAGEER (estate) to the ancestor of Sardar Sikandar Hayat. Sir Gen John Nicholson was

buried in Nicholson cemetery in Kashmir gate in New Delhi where a statue was erected in his

honor showing him holding a naked sword.

GRAND TRUNK ROAD (GT ROAD)

SADAK-E-AZAM

INTRODUCTION

The Grand Trunk Road is one of Asia’s oldest and longest major roads. For more than two

millennia, it has linked the eastern and western regions of the Indian Subcontinent connecting

South Asia with Central Asia. It runs from Chittagong, Bangladesh west to Howrah, West

Bengal in India, running across Northern Inda into Lahore in Pakistan, further up to Kabul

in Afghanistan. Its former names include UttaraPatha ("Road to North"), Shah Rah-e-

Azam ("Great Road") or Sadak-e-Azam or Badshahi Sadak.

The route spanning the Grand Trunk (GT) road existed during the Maurya Empire, extending

from the mouth of the Ganges to the north-western frontier of the Empire. The predecessor of the

modern road was rebuilt by Sher Shah Suri, who renovated and extended the ancient Mauryan

route in the 16th century. The road was considerably upgraded in the British period between 1833

and

1860.

Route Map of Grand Trunk Road

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HISTORY GT Road 1,500 mile long, nearly 500 year old much travelled road was built by Sher Shah Suri,

who had ruled North India from 1540 to 1545, in a brief hiatus in the Mughal dynasty between

Babar and Humayun, the road had commenced its journey in Peshawar, and passing through

Rawalpindi and Lahore had entered India where it continued its course through Amritsar, then

Panipat to arrived at New Delhi from where it hurried onwards to Agra, Kanpur and Allahabad,

before finally coming to rest at Calcutta.

OLD PICTURES OF GT ROAD PATH BENEATH OF NICHOLSON

MONUMENT TAXILA

Old Path of GT Road

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SHAPE AND STRUCTURE OF GT ROAD The structure of Old GT Road is adopted by Roman Road which is named as APPIAN WAY.

This is the old and First road design in history the surfacing of APPIAN WAY is made by flat

pieces of Stone and Boulders. The GT Road is same design adopted by Appian way Structure

APPIAN WAY (Rome, Italy) GT Road Beneath Nicholson (Taxila, Pakistan)

APPIAN WAY (Italy) OLD GT ROAD (Taxila)

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PHOTOGRAPHIC EVIDENCE

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VISIT 02

TIME (10:00 AM – 12:45 PM)

DATE (02-DEC-2014)

FAUJI CEMENT COMPANY LIMITED (FCCL)

(Village Jhang-Bahtar, District Attock, Pakistan)

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CONTENTS

Objectives…………………………………………………………….. 13

Location details………………………………………………………. 13

Introduction…………………………………………………………... 15

Associates companies………………………………………………… 16

Products of fauji Cement limited……………………………………… 17

Ordinary Portland Cement (OPC)…………………………………….. 17

Raw Material for OPC………………………………………………….17

Manufacturing of Ordinary Portland Cement (OPC)…………………. 18

Major Mineral constituents of Portland Cement……………………… 19

Step 1 – Quarrying……………………………………………………. 20

Step 2 - Raw Material Preparation…………………………………….. 20

Step 3 – Clinkering …………………………………………………… 20

The Kiln (Pre Heater)…………………………………………………. 20

The Cooler…………………………………………………………….. 21

Step 4 - Cement Milling……………………………………………….. 21

Step 5 – Packing Of Cement in Bags………………………………….. 21

The Role of the Laboratory……………………………………………. 21

Purpose of Laboratories………………………………………………... 22

Control Room………………………………………………………….. 22

Photo Graphic Evidence……………………………………………….. 22

Summary……………………………………………………………….. 25

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OBJECTIVES We visited this cement plant to practically observe the procedure adopted on plant

for manufacturing.

To know about the material used on plant for manufacturing of cement.

To know about the new procedures, techniques applied in this plant for

manufacturing of cement.

To know about the different types of machinery and their functions and its uses on

plant during manufacturing of cement.

LOCATION DETAILS We visit Fauji Cement Company limited village Jhang Bahter, District Attock,

which is located near Wah Cantt at the Distance of 14 KM Far away from Wah

Cantt and 51 KM from Islamabad.

Site Map of Fauji Cement Company Limited

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INTRODUCTION:- FCCL is a public listed company with authorized and paid up capital of Rs. 10 billion and Rs.

7.42 billion respectively. Consequent to financial restructuring, the Fauji Group (Fauji

Foundation, FFCL, FFBL and FOTCO), is now the principal shareholder with 49.35% of equity,

31.79% being that of Fauji Foundation.

FCCL has its cement plant at Jhang Bahtar, Tehsil Fateh Jang, District Attock in the province of

Punjab. Operating since November 1997, it is one of the most efficient and best maintained plants

in the country, functioning at high capacity utilization consistently over the last six years.

Starting at 3,000 tons per day, its capacity was enhanced to 3,700 ton per day of clinker in 2005.

The quality of Portland Cement produced at this plant is widely regarded as the best in the

country and is preferred for the construction of highways, bridges, commercial/industrial

complexes and residential buildings.

In line with expansion trends in the cement industry, Fauji Cement is in contract with Polysius, a

German cement plant manufacturing firm, for installation of the largest single line ever

commissioned in Pakistan, having a capacity of 7,200 tons clinker per day. This will significantly

enhance the annual production capacity to 3.325 million tons, up from the current 1.165 million

tons. The new line is to be commissioned shortly. FCCL has installed Pakistan's first ever Refuse

Derived Fuel (RDF) process at a cost of Rs. 320 million.

About 200-300 tons of refuse is being used per day. This project is a beacon to the entire

industrial sector of the country towards fuel economy and environment friendly practices,

besides, making compost fertilizer as a byproduct.

FAUJI FERTILIZER COMPANY

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ASSOCIATES COMPANIES:-

Fauji Fertilizer Company Limited (FFCL)

Fauji Fertilizer Bin Qasim Limited (FFBL)

Fauji Cement Company Limited (FCCL)

Fauji Kabirwala Power Company Limited (FKPCL)

Foundation Power Company Daharki Limited (FPCDL)

Mari Petroleum Company Limited (MPCL)

Fauji Akbar Portia Marine Terminal (Private) Limited (FAP)

Fauji Oil Terminal & Distribution Company Limited (FOTCO)

Pakistan Marco Phosphor S.A (PMP)

Foundation Securities (Pvt) Limited (FSL)

Askari Cement Limited (ACL)

Askari Bank Limited (ABL)

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PRODUCTS OF FAUJI CEMENT LIMITED

Ordinary Portland Cement (OPC)

Low Alkali Ordinary Portland Cement (LAOPC)

Sulphate Resistance Cement (SRC)

ORDINARY PORTLAND CEMENT (OPC) Portland cement is the most common type of cement in general use around the world,

used as a basic ingredient of concrete, mortar, stucco, and most non-specialty grout. It is

a fine powder produced by heating materials in a kiln to form what is

called clinker, grinding the clinker, and adding small amounts of other materials.

Ordinary Portland cement (OPC) which is grey in color, but a white Portland cement is

also available.

ORDINARY PORTLAND CEMENT FAUJI CEMENT BAG

RAW MATERIAL FOR OPC Lime Stone

Clay

Iron (Literate)

Retarded (Gypsum)

Coal (Fuel)

Limestone Clay Iron Literate

Retarded Coal

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MANUFACTURING PROCESS OF ORDINARY PORTLAND

CEMENT (OPC) Fauji Cement is manufactured from best quality raw materials using dry process.

Major portion of such raw ingredients consists of Limestone and Clay. The raw

materials are quarried, crushed and corrected. After which they are mixed in the

correct proportions to form the best raw mix. The raw mix is then ground in Raw

Mill and subsequently burnt in a rotary Kiln at a temperature around 1450 °C. The

raw materials undergo a number of complex chemical reactions in the burning

phase and leave the kiln as Clinker, consisting of agglomerate of clinker minerals.

Finally the clinker and gypsum (about 5 %) is ground to a fine powder called

Cement in a Cement Mill.

Mass Flow Diagram Cement by Dry Process

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Flow Chart Diagram of Dry Process of Cement

MAJOR MINERAL CONSTITUENTS OF PORTLAND CEMENT

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Step 1 - QUARRYING Limestone and a 'cement rock' such as clay or shale are quarried and brought to the

cement works. These rocks contain lime (CaCO3), silica (SiO2), alumina (Al2O3) and

ferrous oxide (Fe2O3) - the raw materials of cement manufacture.

Step 2 - RAW MATERIAL PREPARATION To form a consistent product, it is essential that the same mixture of minerals is used

every time. For this reason the exact composition of the limestone and clay is determined

at this point, and other ingredients added if necessary. The rock is also ground into fine

particles to increase the efficiency of the reaction.

Step 3 - CLINKERING The raw materials are then dried, heated and fed into a rotating kiln. Here the raw

materials react at very high temperatures to form 3CaO•SiO2 (tricalcium silicate),

2CaO•SiO2 (dicalcium silicate), 3CaO•Al2O3 (tricalcium aluminate) and 4CaO•Al2O3

•Fe2O3 (tetracalcium alumino-ferrate)

The Kiln (Pre Heater)

The kiln shell is steel, 78m long and inclined at an angle of 1 in 30. The kiln is heated by

injecting pulverized coal dust into the discharge end where it spontaneously ignites due to

the very high temperatures.

Zone 1: ( 0 - 35 min, 800 - 1100oC )

Decarbonation. Formation of 3CaO•Al2O3 above 900oC. Melting of fluxing compounds

Al2O3 and Fe2O3.

heat

CaCO3 → CaO + CO2

Zone 2: ( 35 - 40 min, 1100 - 1300oC )

Exothermic reactions and the formation of secondary silicate phases as follows:

Heat

2CaO + SiO2 → 2CaO.SiO2

Zone 3: ( 40 - 50 min, 1300 - 1450 - 1300oC )

Sintering and reaction within the melt to form ternary silicates and tetra calcium

aluminous ferrates:

Heat + time

2CaO•SiO2 + CaO → 3CaO•SiO2

Heat + time

3CaO•Al2O3 + CaO + Fe2O3 → 4CaO•Al2O3•Fe2O3

Zone 4: ( 50 - 60 min, 1300 - 1000oC )

Cooling and crystallization of the various mineral phases formed in the kiln.

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The Cooler

Immediately following the kiln is a large cooler designed to drop the temperature of the

clinker (as the fused material is now called) from 1000oC to 150oC. This is achieved by

forcing air through a bed of clinker via perforated plates in the base of the cooler.

Step 4 - CEMENT MILLING To produce the final product the clinker is mixed with gypsum (CaSO4 •2H2O), which is

added as a set retarded, and ground for approximately 30 minutes in large tube mills. The

cement flows from the inlet to the outlet of the mill (a rotating chamber), being first

ground with 60 mm then 30 mm diameter steel balls. The first grinding breaks up the

material and the second grind it to a fine powder. The amount of grinding is governed by

the volume of cement fed into the mill: the greater the volume the coarser the grind. This

has practical limits, with too much cement clogging up the mill and not enough actually

increasing the particle size. The particle size is measured by laser diffraction analysis,

and the quantity of material entering the mill adjusted accordingly. Over time the charge

(steel grinding balls) wear out, so when they reach a certain size they fall through a sieve

and then are replaced.

Step 5 – PACKING OF CEMENT IN BAGS After first four process cement are stored in big storage tanks and fill in a bags one by

one by mechanical machine process. The volume of Cement bag is 1.25 cft and 0.035

meter cube. After filling these bag cement are transported in market.

Transportation of Cement

THE ROLE OF THE LABORATORY In Fauji Cement Company Limited Three laboratories are working for testing material for

the purpose of making manufacturing of cement.

Chemical Lab

Instrumentation Lab

Physical Lab

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PURPOSE OF LABORATORIES Testing raw materials prior to blasting in the quarry and assisting with

development of quarrying strategies forms the first step in the process.

Analyzing rock samples from the raw mill at regular intervals during the day and

night and fine tuning the process to ensure chemical control is maintained

Analyzing clinker at the end of the cooler (before grinding) to ensure that the

Manufactured process meets specification.

Checking that cement mills are undertaking grinding correctly and that customers

Receive the right product.

Product development.

CONTROL ROOM In Fauji Cement Company Limited we visit the control room. Control room

Basically control all operations in all over the plant during manufacturing the

Cement by dry process step by step in Crushing, Burning and Grinding Process.

Control room connects all area of the plant and all machinery which is used for

Manufacturing for cement with the help of sensors and highly sensation cameras

And infrared rays.

PHOTO GRAPHIC EVIDENCE

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SUMMARY:-

We learn a lot from this visit. We observe and learn the techniques adopted for

manufacturing at cement plant. We also learn about raw material, fuel in the form of coal,

and all the buildings and units such as Storage Building, Mechanical assembly line, Kiln

like pre heaters, mixing and grinding units cement storage feeders, Cargo Transportation

building bays and machinery which are working in this plant for manufacturing purpose.

We also visit the quality control lab to learn and observing about the material testing and

their chemical behavior reacting as reagent during process of cement, and also visit the

plant control room and seen basic and important instruments, heavy computer hardware,

networking servers, software such as Programmable Logic Control (PLC) which controls

all plant with the help of sensors and cameras footages. In fact this visit gives us a lot of

information.

Group Photo of Abasyn University students, Teaching Faculty and Plant Faculty at the visit of

Fauji Cement Company Limited

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VISIT 03

TIME (1:45:00 PM – 4:30 PM)

DATE (02-DEC-2014)

The New Islamabad International Airport, Fateh Jhang

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CONTENTS

LOCATION DETAIL…………………………………………. 28

OBJECTIVES………………………………………………….. 28

DISTANCE FROM TWIN CITIES……………………………. 28

PARTS OF AIRPORT………………………………………….. 29

INTRODUCTION……………………………………………… 29

MAJOR NUMBERS AND MEASUREMENTS………………. 30

PASSENGER TERMINAL BUILDING………………………. 30

RUNWAY……………………………………………………… 31

DEPARTURE LEVEL BRIDGE……………………………..... 32

BOUNDARY WALL…………………………………………... 32

APRON…………………………………………………………. 33

CAR PARKING AREA………………………………………… 33

AIR TRAFFIC CONTROL TOWER…………………………... 34

THE ROLE OF THE LABORATORY………………………… 35

Material Testing Lab……………………………………………. 35

Soil Testing Lab………………………………………………… 36

SUMMARY……………………………………………………. 37

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LOCATION DETAIL The construction site of the airport is near the Rawalpindi-Fateh Jang Road near Fateh

Jang

DISTANCE FROM TWIN CITIES

20 km from Zero Point, Islamabad

23 km from Saddar, Rawalpindi

OBJECTIVES We visit the new Islamabad international airport to observe and understand the

parts of airport like passenger terminal building, runway, apron, hanger, air traffic

control tower, cargo terminal, taxiway, parking area, departure level bridge.

We visited this project to practically observe the construction procedure adopted

on site.

To know about the material used on site.

To know about the new procedures, techniques applied in this project.

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To know about the different types of construction machinery, soil and material testing

labs, concrete batching plant, asphalt batching plant and their functions and its uses on

site.

PARTS OF AIRPORT Passenger Terminal Building

Runway

Departure Level Bridge

Apron

Taxiway

Air Traffic Control Tower

Car Parking Area

Cargo Terminals

INTRODUCTION It is a joint project of Capital Development Authority (CDA), National Highway

Authority (NHA) and the Civil Aviation Authority (CAA) and designed by French

company Aéroports de Paris Ingenierie (ADPi) and CPG Corporation of Singapore. It is

being built on more than 3300 acres of land and consists of a passenger terminal building,

runways, taxiways, apron and parking bays for wide body aircraft. There will also be a

cargo terminal, air traffic control complex, fuel farm, as well as a fire, crash and rescue

facility. It would be equipped to handle all types of aircraft including the new generation

aircraft such as the Airbus A380. The airport is being developed to be at par with

international standards to serve as major hub for all aviation activities in Pakistan. The

airport will have a 180,000 m² modular terminal building which will initially be able to

handle 9 million passengers and 80,000 metric tones cargo per annum. The numbers are

expected to reach 15 million passengers by 2019 and increase to 25 million passengers by

2024. Being a new airport, a significant portion of the land has been earmarked for

commercial purposes such as duty-free shops, hotel and convention centre, air malls,

business centre, food courts, leisure and recreational facilities.

Master Plan of New Islamabad International Airport

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MAJOR NUMBERS AND MEASUREMENTS

Total Area And Total Cost

Area = 3300 Acre And Cost = 85 Billions

Boundary Wall

18.4 KM

Passenger Terminal Building (4 Level)

1 Lack Square Meter (100,000 m²)

Car Parking

2000 Vehicles

Runways (2 Nos)

Length 3658 m (3.65KM)

Width 60m

Shoulder 7.5 m (both side)

Apron / Bays

NE 970 m

Refueling System

Underground

Departure Level Bridge

3rd

Building

PASSENGER TERMINAL BUILDING The new Islamabad international airport will have a 100,000 m² modular terminal

building which will initially be able to handle 9 million passengers and 80,000 metric

tones cargo per annum.

Terminal Building under Construction

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Terminal Building

RUNWAY The new Islamabad international airport will have two runways of 3658 m (3.65 KM)

in length. 60 m in Width and 7.5m both side shoulders on runway.

Runway

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DEPARTURE LEVEL BRIDGE The new Islamabad international airport will have a departure level bridge which

provides the path to the passengers enter in the terminal building of airport.

Departure level bridge under construction

BOUNDARY WALL The new Islamabad international airport have boundary wall of 18.4 KM in total length

which covers all the 3300 Acre total area of Airport Land Site.

Boundary Wall of Airport

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APRON The new Islamabad international airport have aprons where aircrafts are standing for

loading and unloading of passengers and cargo.

Apron of Airport attaching with Terminal Building

CAR PARKING AREA The new Islamabad international airport have wide and broad car parking area where

2000 vehicles are park there.

Car Parking Area

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AIR TRAFFIC CONTROL TOWER The new Islamabad international airport have air traffic control tower which controls and

communicate with the all domestic and international aircraft flights with the help of all

advance instruments, antennas, sonar system, heavy computer hardware and software and

strong wireless communication system with satellite and aircrafts to the all over the

world.

Air Traffic Control Tower

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THE ROLE OF THE LABORATORY The construction of new Islamabad international airport laboratories plays an important

role in this construction site. There are two main testing labs are working

Material Testing Lab

Soil Testing Lab

Material Testing Lab

In this lab those materials are test which are used for construction purpose. These test

show the maximum power and output like durability, toughness, compressive and tensile

strength, workability of material. In this lab many materials are test e.g.

Slump Test of Concrete

Brick and Concrete Block Test

Beams and Columns Test

Steel Bar Test

Bitumen / Asphalt Test and inspection Concrete and Concrete Aggregate Test

Corrosion Test

Stone and Rock Test

Metal and Alloys Test

Soil Testing Lab

As the basic structural foundation for almost all construction, soil materials play an

important role in the ultimate success of a project. Whether you're working in clay, silt,

sand, gravel, peat, or loam, understanding the soil properties of your site help you make

good construction decisions. In this construction site following tests are performed as per

criteria.

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Sample Collection Disturbed Soil

Sample Collection Undisturbed Soil

Specific Gravity Test

Sieve Analysis Test

Classification of the soils

Atterberg Limits Test

Moisture Content Test

Field Density Test

Core Cutter Method Test

Sand Cone Replacement Test

CBR One Point Method Test

CBR Three Points Method Test

Standard Penetration Test Test

Compaction Test

Standard Proctor Test

Modified Proctor Test

Consolidation Test

Direct Shear Test

Hydrometer Analysis

Shrinkage Test

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SUMMARY We learn a lot from this visit. We observe and visit the parts of Airport like passenger

terminal building, departure level bridge, runway, cargo terminal, apron, car parking, and

taxiway. We also learn about and physically seen the material and other elements which

are the basic needs and used in the construction of airport. We visit material testing lab

and soil testing lab and observe the experimental techniques and procedure, tests which

are adopted in this construction site. In fact this visit gives us a lot of information.

Presentation given to the Students and Faculty of Abasyn University in Conference Room

About the Mega Project of New Islamabad International Airport by the project members