Summer Intrenship at Gammon India Ltd.

SUMMER TRAINING REPORT
(9/6/2014 5/7/2014)

Submitted by:
Mohtisham Ali
Third year undergraduate student,
Department of Civil Engineering,
INTEGRAL UNIVERSITY, LUCKNOW

ii

SUMMER TRAINING REPORT 2014 (INTEGRAL UNIVERSITY, LUCKNOW)
MOHTISHAM ALI (1100111112)

Aknowledgement
I am very thankful to GAMMON INDIA LIMITED & NATIONAL
HIGHWAYS AUTHORITY OF INDIA for given me the opportunity to
undertake my summer training at their prestigious GANGA BRIDGE AND
FLYOVER PROJECT. It was a very good learning experience for me to
have worked at this site as this project involved many unique construction
practices and challenges. I would like to convey my heartiest thanks to
Mr. MANOJ BISWAS (Project Manager), who heartily welcomed me for the
internship. I would also like to give my heart-felt thanks to Mr. U.N. SINGH
(Execution Head), Mr. RAMESH PAL (QA/QC Head), who guided and
encouraged me all through the summer training and imparted in-depth
knowledge of the project. Also I would like to thank Mr. T.K. CHATTERJEE
(Planning Head), who assisted and guided me whenever I needed help.
We also thankful and pay our sincere gratitude to Mr. Somnath Bajpai
(Executive HR), We sincere thanks to all the department heads of Gammon
India Limited for giving their precious time and valuable guidance during
my internship programme.
Last but not the least; I would like to thank all the staff at Gammon India
Limited, for being so helpful during this summer training.

Name: Mohtisham Ali

Date: 5
th
July 2014

iii


ABSTRACT

GAMMON INDIA LIMITED have developed so many project which
are so large and whose costing alot. The project Rehabilitation and
Upgradation from 75 Km to 80.60 Km of NH-25. (GANGA BRIDGE &
FLYOVER PROJECT) is important to relief from a big jams in the town of
Kanpur.

The total length of the project is 5.06 KM and the estimating cost of
the project is Rs. 159.06 Cr. In this project I was Trainee. I work on Pre-
stressed Beam. Following are important department where I work :

PLANNING
QUALITY CONTROL
PLANT
EXECUTION

iv


INDEX

S.No. CONTENTS Page No.
1.
Project Details
1
2.
Objective
2
3.
Brief Introduction of G.I.L
3
4.
Organizational Chart
9
5.
Product/Specification/Activities
11
6.
Planning Department
12
7.
System/Plan Layout
14
8.
QA / QC Department
15
9.
Plant Information
35
10.
Project Execution
40
11.
Chronological Training Dairy
47
12.
Safety Requirement
49
13.
Suggestions
51
14.
Conclusion
52
15.
References
53

1


DETAIL OF THE PROJECT

A. PROJECT NAME Rehabilitation and
Upgradation from 75 Km
to 80.60 Km of NH-25.
(GANGA BRIDGE & FLYOVER
PROJECT)
B. CLIENT
NATIONAL HIGHWAYS
AUTHORITY OF INDIA
(N.H.A.I)
C. CONTRACTOR GAMMON INDIA LTD.
D. CONSULTANT Feedback Infra Pvt. Ltd.
(F.I.P.L)
E. CONTRACT SECTION EW-II (UP-06)
F. CONTRACT LENGTH Km 75.00 to Km 80.60
G. AGREEMENT DATE 29.09.2005
H. TENDER AMOUNT INR 159.06 Cr.
I. TYPE OF CONTRACT BILLING OF QUANTITY
J. STARTING DATE 02.12.2005
K. CONTRACTUAL DATE OF
COMPLETION
01.09.2008
L. EXTENDED DATE OF COMPLETION 18.09.2014

2


OBJECTIVE

CONSTRUCTION OF PRE-STRESSED BEAM.

3


INTRODUCTION

ABOUT THE ORGANIZATION:

HISTORY:

The beginning of such a formidable company is to be found in the
vision of an equally formidable man. Mr J. C. Gammon was the
driving force behind the introduction of prestressed concrete to India.
He designed the reinforced concrete piles of the Gateway of India.
The foundations of the arch reach deep into the bedrock. With time,
he came to be known as the Sculptor of Concrete.

His foresight was fundamental to the company reaching its present
stature. His pioneering spirit led to a number of innovations that were
the first of their kind.

His enduring values continue to build the Gammon legacy.

J. C. Gammon The Legacy
Bridges like the Bonum Bridge and the Patalganga Bridge.
The Colloidal Grouting Process at Mundali Weir.
The RCC Pile Foundations for the Gateway of India.
Thin Shell Prestressed Structures of Meerut Garages.
The Hyperbolic Cooling Towers at Sabarmati

4


GAMMON GROUP :
AN OVERVIEW

Gammon India is built on a legacy that has stood the test of time.
Technological and design excellence, and a discerning eye for quality and
safety are some of the characteristics that distinguish Gammons tradition
for perfection in its areas of operation.

Gammon India is amongst the largest physical infrastructure
construction companies in India. Its track record spans significant landmark
projects built over several decades, with a prominent presence across all
sectors of civil engineering, design and construction. It has a track record of
building landmark structures, some of which have become iconic. This
includes The Gateway of India, the piling and civil foundation work for
which was successfully executed by Gammon as its maiden project way
back in 1919.

Besides its large scale of operations
in the Construction and Infrastructure
domain, Gammon has a dominant
presence in energy business in which it
operates in the hydro, nuclear and
thermal power sectors. In fact,
Gammons association with the
construction of nuclear power projects dates back to 1959 when it
completed the Pre-Stresses Concrete (PSC) Ball Tank of Indias first
Atomic Reactor Plant in Trombay.
Gammons projects cover businesses
and projects involving highways, public
utilities, environmental engineering and
marine structures. Gammons expertise
also covers the design, financing,
construction and operation of modern
bridges, viaducts, and metro rail, both on a BuiltOperateTransfer (BOT)
basis as well as contract execution. An example is the upcoming Signature
Bridge project in Wazirabad in NorthWest Delhi. This project would

5


significantly help in the efficient flow and management of traffic in the
region.

Gammon is also active in the Social Infrastructure sector through its
operations in the realty project segment. Examples include residential
complexes such as Pebble Bay and Godrej WoodsMan Estate in
Bangalore,Godrej Kalyan in Mumbai, RNA Exotica, Mumbai; Hotel
complexes such as Hotel Leela Palace, Chennai and G Staad, Bangalore
besides commercial complexes such as Galleria Mall(INXS) in Bangalore.
Gammon is also currently undertaking a major project for ISKON at Sri
Mayapur in West Bengal involving the construction of a temple complex
and a modern cultural centre.

Gammon international include a
majority holding in Franco Tosi
Meccanica, SAE Power lines, and
Sofinter group, Italy spanning the
sectors of power and industrial boilers as
well as waste and environment
management systems. Gammon has
received accolades and recognitions
from a variety of reputed institutions. Examples include the Indian Concrete
Institute Award for most outstanding concrete structure presented for the
segmental arch bridge across the River Beas (Himachal Pradesh) and the
first prize for Excellent Aesthetics for the Vidyasagar Sethu Project across
the River Hoogly in Kolkata.

Currently Gammon India has a
strong talent base of over 3350
employees on its own rolls apart from
5500 officers and staff working under its
aegis at various project sites. It further
engages more than 200,000 labour/staff on daily wage basis. Its standalone
turnover in financial year 201112 was close to US $ 1.1 billion with the
Groups turnover in excess of US $ 1.6 billion.

6


QUALITY POLICY

Gammon India is the first Construction in India to have ISO9001
certification in design as well as execution for all Civil Engineering
structures.
Gammon is committed to form seamless partnership with its
customers, so that their requirements become our challenge. Gammons
quest for excellence is achieved by its innovative engineering and quality
execution of the projects, on time, within budget, by its high performance
team which is adaptable to each project..

7


HEALTH SAFTEY AND ENVIRONMENTAL POLICY

At Gammon, extensive health and safety guidelines defined standards
for every project. Regular safety training programmes are undertaken at the
sites. Further, regular health and fitness checkup for every member of
our staff is mandatory.

We maintain a high standard of safety through meticulous risk
assessment. Gammon has a stellar record of twelve million hours of
accidentfree work at Kalpakkam. This is a consistent track record, which is
no mean achievement, since most of our initiatives take place under
hazardous geographical conditions. These are challenges that our staff can
face because of their training. They also have the assurance of a health &
safety code that is considerate and transparent. To set standards, we must
first set an example.

Gammon is an ISO 9001, ISO 14001 and OHSAS18001 certified
company. We have a number of National Safety Awards to our credit. The
concern inherent in our corporate culture inspires a sense of loyalty toward
Gammon.

WORK CULTURE

Work Culture emphasises:
Freedom to experiment
Continuous learning and training
Transparency
Quality in all aspects of work
Rewards based on performance and potential

8


TRAINING

Human Resources Department believes that Quality is the hallmark
of any successful venture. Quality Training and Development ofHuman
Resourcesisrealized through: Identifying training needs within the
Organization and designing and implementing those need based training
programs to bring about continuous upgradation of knowledge, skills and
employee attitudes.

VISION&MISSION

VISION

To Consistently build the reputation of Gammon amongst all
stakeholders as a respected and influential leader in the Construction
and Infrastructure Domain with Global Presence and Local Expertise
backed with a sustained focus on attributes of Sustainability and
Profitability and Employee engagement and Pride

To be leaders in innovation engineering, with uncompromising integrity,
timely delivery, pride and ownership and highest standards of quality to
reinforce the positioning of the organisation as Builders to the Nation.

MISSION

"To design, build and service physical infrastructure for
improved living, enhanced work environment
and swift transportation."

9


ORGANIZATIONAL CHART

CHIEF PROJECT MANAGER (C.P.M.)
PROJECT MANAGER (P.M.)
DEPUTY MANAGER (Dy. M.)
ASSISTANT MANAGER (A.M.)
ENGINEER (E.)
JUNIOR ENGINEER (J.E.)

10


PROPOSEDPROJECT

Rehabilitation and Upgradation from 75 Km to
80.60 Km of NH-25.
(GANGA BRIDGE & FLYOVER PROJECT)

KANPUR, INDIA

11


PRODUCT (S) & SPECIFICATIONS / ACTIVITIES /
CODING

Product:- Rehabilitation and Upgradation from 75 Km to 80.60 Km of
NH25.
(GANGA BRIDGE & FLYOVER PROJECT).

Specifications:- All the works shall be carried out as per standard practice
of Engineering, IScodes, I.R.C specifications and M.O.R.T.H
specifications.

Activities:- All the work consists :

1. Planning ,
2. Quality Control ,
3. Plant Information ,
4. Execution ,

12


PLANNING DEPARTMENT

Construction planning is a fundamental and challenging activity in the management
and execution of construction projects. It involves the choice of technology, the
definition of work tasks, the estimation of the required resources and durations for
individual tasks, and the identification of any interactions among the different work
tasks. A good construction plan is the basis for developing the budget and the
schedule for work. Developing the construction plan is a critical task in the
management of construction, even if the plan is not written or otherwise formally
recorded. In addition to these technical aspects of construction planning, it may also
be necessary to make organizational decisions about the relationships between project
participants and even which organizations to include in a project.
Essential aspects of construction planning include the generation of required
activities, analysis of the implications of these activities, and choice among the
various alternative means of performing activities.
In developing a construction plan, it is common to adopt a primary emphasis on either
cost control or on schedule control. Some projects are primarily divided into expense
categories with associated costs. In these cases, construction planning is cost or
expense oriented. Within the categories of expenditure, a distinction is made between
costs incurred directly in the performance of an activity and indirectly for the
accomplishment of the project. For example, borrowing expenses for project
financing and overhead items are commonly treated as indirect costs. For other
projects, scheduling of work activities over time is critical and is emphasized in the
planning process. In this case, the planner insures that the proper precedences among
activities are maintained and that efficient scheduling of the available resources
prevails. Traditional scheduling procedures emphasize the maintenance of task
precedences (resulting in critical path scheduling procedures) or efficient use of
resources over time (resulting in jobshop scheduling procedures). Finally, most
complex projects require consideration of cost and scheduling over time, so that
planning, monitoring and record keeping must consider both dimensions. In these
cases, the integration of schedule and budget information is a major concern.

13


A parallel step in the planning process is to define the various work tasks that must be
accomplished. These work tasks represent the necessary frame work to permit
scheduling of construction activities, along with estimating the resources required by
the individual work tasks, and any necessary precedences or required sequence
among the tasks. The terms work "tasks" or "activities" are often used interchangeably
in construction plans to refer to specific, defined items of work.

Planning department in Gammon India Limited uses Primavera as a powering tool for
reducing risk. Primavera gives efficiency to plan a project, identify the
resources required and identify the tasks required in a sequence, increasing probability
of delivery of the project to the time, cost and quality objectives. Primavera gives you
a powerful, visually enhanced way to effectively manage a wide range of projects and
programs. From meeting crucial deadlines, to selecting the right resources, Primavera
empowering your teams.
The initial schedule of major construction activities S0 is prepared according to the
Clients preference. S0 is the basis for all types of scheduling. Preliminary schedules
representing the monthly work estimates are prepared based on experience
considering local climate conditions, environment, learning curve, pace of work,
mobilization, etc in Primavera. Productivities of different activities are estimated and
validated during the course of execution. Man power requirement is calculated based
on these productivities. Drawings released by the Client. Revisions and change orders
are issued as and when there is a change and distributed to all the units. The planning
system is updated in the first week of every month. Two progress schedules are
maintained original schedule prepared in the starting of the project, planned schedule
which is modified according to the requirements and conditions. Actual progress is
compared with the planned schedule and in case any delay in progress is then a
Catch up schedule is prepared and executed accordingly to overcome the delay.

14


System / Plan Layout

15


QUALITY ASSURANCE & QUALITY CONTROL

DEPARTMENT

Quality is the key component which propels performance and defines leadership
traits. At GIL, Quality Standards have been internalised and documented in
Quality Assurance manuals. GIL recognizes the crucial significance of the human
element in ensuring quality. Structured training programmes ensure that every
GIL employee is conscious of his/her role and responsibility in extending
Companys tradition of leadership through quality. A commitment to safety springs
from a concern for the individual worker every one of the thousands braving the
rigours of construction at numerous project sites. Gammon India Limited has a well
established and documented Quality Management System (QMS) and is taking
appropriate steps to improve its effectiveness in accordance with the requirements of
ISO 9001:2008. Relevant procedures established clearly specify the criteria and
methods for effective operation, control and necessary resources and information to
support the operation and monitoring of these processes.

QUALITY IMPLEMENTATION AT SITE

GIL has established procedure for monitoring, measuring and analyzing of these
processes and to take necessary actions to achieve planned results and continual
improvement of these processes. It has also maintained relevant procedures to identify
and exercise required control over outsourced processes, if any Systems and
procedures have been established for implementing the requisites at all
stagesofconstructionandtheyareaccreditedtotheInternationalstandardsofISO
9001:2008, ISO 14001:2004 and OHSAS 18001:2007. GIL continues to maintain the
trail blazing tradition of meeting the stringent quality standards and adherence to time
schedules in all the projects.

16


TESTS ON CEMENT

CONSISTENCY

AIM

To determine the quantity of water required to produce a cement paste of standard
consistency as per IS: 4031 (Part 4) 1988.

PRINCIPLE

The standard consistency of a cement paste is defined as that consistency which will
permit the Vicat plunger to penetrate to a point 5 to 7mm from the bottom of the Vicat
mould.

APPARATUS

17


VICAT APPARATUS

Vicat apparatus conforming to IS: 5513 1976 Balance, whose permissible variation
at a load of 1000g should be +1.0g Gauging trowel conforming to IS: 10086 1982

PROCEDURE

i) Weigh approximately 400g of cement and mix it with a weighed quantity of water.
The time of gauging should be between 3 to 5 minutes.
ii) Fill the Vicat mould with paste and level it with a trowel.
iii) Lower the plunger gently till it touches the cement surface.
iv) Release the plunger allowing it to sink into the paste.
v) Note the reading on the gauge.
vi) Repeat the above procedure taking fresh samples of cement and different
quantities of water until the reading on the gauge is 5 to 7mm.

REPORTING OF RESULTS

Express the amount of water as a percentage of the weight of dry cement to the first
place of decimal.

INITIAL AND FINAL SETTING TIME

AIM

To determine the initial and the final setting time of cement as per IS: 4031 (Part 5)

1988.

APPARATUS

Vicat apparatus conforming to IS: 5513 1976 Balance, whose permissible variation
at a load of 1000g should be +1.0g Gauging trowel conforming to IS: 10086 1982

PROCEDURE

i) Prepare a cement paste by gauging the cement with 0.85 times the water required to
give a paste of standard consistency.

18


ii) Start a stopwatch, the moment water is added to the cement.

iii) Fill the Vicat mould completely with the cement paste gauged as above, the mould
resting on a nonporous plate and smooth off the surface of the paste making it level
with the top of the mould. The cement block thus prepared in the mould is the test
block.

INITIAL SETTING TIME

Place the test block under the rod bearing the needle. Lower the needle gently in order
to make contact with the surface of the cement paste and release quickly, allowing it
to penetrate the test block. Repeat the procedure till the needle fails to pierce the test
block to a point 5.0 0.5mm measured from the bottom of the mould . The time
period elapsing between the time, water is added to the cement and the time, the
needle fails to pierce the test block by 5.0 0.5mm measured from the bottom of the
mould, is the initial setting time.

FINAL SETTING TIME

Replace the above needle by the one with an annular attachment.

The cement should be considered as finally set when, upon applying the needle gently
to the surface of the test block, the needle makes an impression therein, while the
attachment fails to do so. The period elapsing between the time, water is added to the
cement and the time, the needle makes an impression on the surface of the test block,
while the attachment fails to do so, is the final setting time.


The results of the initial and the final setting time should be reported to the nearest
five minutes.

19


TESTS ON AGGREGATES

SIEVE ANALYSIS

AIM

To determine the Grain size analysis of coarseaggregates for Concrete Material by
sieving as per IS: 2386 (Part I) & Grain size analysis of Sand (As per Table 10002
MOST Specification).

PRINCIPLE

By passing the sample downward through a series of standard sieves, each of
decreasing size openings, the aggregates are separated into several groups, each of
which contains aggregates in a particular size range.
APPARATUS

A SET OF IS SIEVES

i) A set of IS Sieves
a). Coarse Aggregate : 20mm (Nominal Singal Size) Sizes : 40mm, 20mm, 10mm,
4.75mm.
b). Coarse Aggregate : 10mm (Nominal Singal Size) Sizes : 12.5mm, 10mm,
4.75mm, 2.36mm.

20


c). Coarse Aggregate : 20mm : 10mm and Sand (36:24:40) Sizes : 40mm, 20mm,
4.75mm, 0.600mm, 0.150mm.

ii)Balance or scale with an accuracy to measure 0.1 percent of the weight of the test
sample.
iii) A set of IS Sieve for Sand : 10mm, 4.75mm, 2.36mm, 1.18mm, 0.600mm,
0.300mm, 0.150mm.

PROCEDURE

i) The test sample is dried to a constant weight at a temperature of 110 + 5 oC
and weighed.
ii) The sample is sieved by using a set of IS Sieves.

iii) On completion of sieving, the material on each sieve is weighed.

iv) Cumulative weight passing through each sieve is calculated as a percentage of the
total sample weight.
v) Fineness modulus is obtained by adding cumulative percentage of aggregates
retained on each sieve and dividing the sum by 100.


The results should be calculated and reported as:

i) the cumulative percentage by weight of the total sample

ii) the percentage by weight of the total sample passing through one sieve and
retained on the next smaller sieve, to the nearest 0.1 percent.

21


22


23


AGGREGATE IMPACT
VALUE TEST

AIM

To determine the Aggregate Impact value of coarse aggregates as per
IS: 2386 (Part IV).

APPARATUS

24


PROCEDURE

i) The sample should be pass through 12.5mm and retained on 10mm IS sieve
weight as W
1.

ii) The sample is filled in three layers and each layer is tampered with 25 blows of
tampering rod.
iii) Then the hammer of 14 kg is allowed to fall a height of 380mm.

iv) After 15 blows, sample is taken off and sieve on 2.36mm IS sieve and weight
passing as W
2.


Impact value = [W
2
/ W
1
] x 100%

25


26


TESTS ON FRESH CONCRETE

SLUMP

AIM

To determine the workability of fresh concrete by slump test as per IS: 1199 1959.

APPARATUS

i) Slump cone

ii) Tamping rod

27


PROCEDURE

i) The internal surface of the mould is thoroughly cleaned and applied with a light
coat of oil.
ii) The mould is placed on a smooth, horizontal, rigid and non absorbent surface.
iii) The mould is then filled in four layers with freshly mixed concrete, each
approximately to onefourth of the height of the mould.
iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are
distributed evenly over the cross section).
v) After the top layer is rodded, the concrete is struck off the level with a trowel.

vi) The mould is removed from the concrete immediately by raising it slowly in the
vertical direction.
vii)The difference in level between the height of the mould and that of the highest
point of the subsided concrete is measured.
viii) This difference in height in mm is the slump of the concrete.


The slump measured should be recorded in mm of subsidence of the specimen
during the test. Any slump specimen, which collapses or shears off laterally gives
incorrect result and if this occurs, the test should be repeated with another
sample. If, in the repeat test also, the specimen shears, the slump should be
measured and the fact that the specimen sheared, should be recorded.

28


CUBE STRENGTH TEST

AIM

To determine the compressive strength of concrete cube by Compression Testing
Machine (CTM).

APPARATUS

i) CTM

29


PROCEDURE

i) The internal surface of the mould is thoroughly cleaned and applied with a light
coat of oil.
ii) The mould is placed on a smooth, horizontal, rigid and non absorbent surface.
iii) The mould is then filled in four layers with freshly mixed concrete, each
approximately to onefourth of the height of the mould.
iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are
distributed evenly over the cross section).
v) After the top layer is rodded, the concrete is struck off the level with a trowel.

vi) The mould is removed from the concrete immediately by raising it slowly in the
vertical direction.
vii)The difference in level between the height of the mould and that of the highest
point of the subsided concrete is measured.
viii) This difference in height in mm is the slump of the concrete.


The slump measured should be recorded in mm of subsidence of the specimen during
the test. Any slump specimen, which collapses or shears off laterally gives incorrect
result and if this occurs, the test should be repeated with another sample. If, in the
repeat test also, the specimen shears, the slump should be measured and the fact that
the specimen sheared, should be recorded.

30


31


OMC & MDD TEST

This test is done to determine the maximum dry density and the optimum moisture
content of soil using heavy compaction as per IS: 2720 (Part 8 ) 1983.The apparatus
used is:

i) Cylindrical metal mould it should be either of 100mm dia. and 1000cc volume or

150mm dia. and 2250cc volume and should conform to IS: 10074 1982.

ii) Balances one of 10kg capacity, sensitive to 1g and the other of 200g capacity,
sensitive to 0.01g
iii) Oven thermostatically controlled with an interior of noncorroding material to
maintain temperature between 105 and 110
o
C
iv) Steel straightedge 30cm long

v) IS Sieves of sizes 4.75mm, 19mm and 37.5mm.

PREPARATION OF SAMPLE

A representative portion of airdried soil material, large enough to provide about 6kg
of material passing through a 19mm IS Sieve (for soils not susceptible to crushing
during compaction) or about 15kg of material passing through a 19mm IS Sieve (for
soils susceptible to crushing during compaction), should be taken. This portion should
be sieved through a 19mm IS Sieve and the coarse fraction rejected after its
proportion of the total sample has been recorded. Aggregations of particles should be
broken down so that if the sample was sieved through a 4.75mm IS Sieve, only
separated individual particles would be retained.

Procedure To Determine The Maximum Dry Density And The Optimum

Moisture Content Of Soil

A) Soil not susceptible to crushing during compaction

i) A 5kg sample of airdried soil passing through the 19mm IS Sieve should be taken.
The sample should be mixed thoroughly with a suitable amount of water depending
on the soil type (for sandy and gravelly soil 3 to 5% and for cohesive soil 12 to

32


16% below the plastic limit). The soil sample should be stored in a sealed container
for a minimum period of 16hrs.

ii) The mould of 1000cc capacity with base plate attached, should be weighed to the
nearest 1g (W
1
). The mould should be placed on a solid base, such as a concrete floor
or plinth and the moist soil should be compacted into the mould, with the extension
attached, in five layers of approximately equal mass, each layer being given 25 blows
from the 4.9kg rammer dropped from a height of 450mm above the soil. The blows
should be distributed uniformly over the surface of each layer. The amount of soil
used should be sufficient to fill the mould, leaving not more than about 6mm to be
struck off when the extension is removed. The extension should be removed and the
compacted soil should be levelled off carefully to the top of the mould by means of
the straight edge. The mould and soil should then be weighed to the nearest gram
(W
2
).
iii) The compacted soil specimen should be removed from the mould and placed onto

the mixing tray. The water content (w) of a representative sample of the specimen
should be determined.
iv) The remaining soil specimen should be broken up, rubbed through 19mm IS
Sieve and then mixed with the remaining original sample. Suitable increments of
water should be added successively and mixed into the sample, and the above
operations i.e. ii) to iv) should be repeated for each increment of water added. The
total number of determinations made should be at least five and the moisture
contents should be such that the optimum moisture content at which the maximum
dry density occurs,lies within that range.
B) Soil susceptible to crushing during compaction

Five or more 2.5kg samples of airdried soil passing through the 19mm IS Sieve,
should be taken. The samples should each be mixed thoroughly with different
amounts of water and stored in a sealed container as mentioned in Part A)
C) Compaction in large size mould
For compacting soil containing coarse material upto 37.5mm size, the 2250cc
mould should be used. A sample weighing about 30kg and passing through the
37.5mm IS Sieve is used for the test. Soil is compacted in five layers, each layer

33


being given 55 blows of the 4.9kg rammer. The rest of the procedure is same as
above.


Bulk density Y(gamma) in g/cc of each compacted specimen should be calculated
from the equation,
Y(gamma) = (W2-W1)/ V

where, V = volume in cc of the mould. The dry density Yd in g/cc
Yd = 100Y/(100+w)

The dry densities, Yd obtained in a series of determinations should be plotted
against the corresponding moisture contents,w. A smooth curve should be drawn
through the resulting points and the position of the maximum on the curve should
be determined.
The dry density in g/cc corresponding to the maximum point on the moisture
content/dry density curve should be reported as the maximum dry density to the
nearest 0.01. The percentage moisture content corresponding to the maximum dry
density on the moisture content/dry density curve should be reported as the
optimummoisture content and quoted to the nearest 0.2 for values below 5
percent, to the nearest 0.5 for values from 5 to 10 percent and to the nearest whole
number for values exceeding 10 percent.

34


35


PLANT INFORMATION

BATCHINGPLANT

36


EQUIPMENT USED IN CONSTRUCTION OF PRE-STRESSED
BEAM

Shutter handling Gantry 1 nos.

37


Prestressing jack with Power pack 2 nos.

38


Grouting Pump (fressy j600, 300kg/cm
2
, 2hp) 1 nos.

Grout mixer & Agitator 1 nos.

Compressor 300 CFM 1 nos.

Concrete pump 1 nos.

Poker Vibrators with needle 4 nos.

Shutter vibrators 4 nos.

Concrete production plant 1 nos.

39


For Transportation of Concrete, steel bars, Aggregates, sand etc.
Transit Mixer (7m
3
)

Truck

40


PROJECTEXECUTION
METHOD STATEMENT FOR PRE STRESSED BEAM
I. SCOPE: This method of statement is applicable for casting of P40 to P41
(G1) super structure Beam of the project Rehabilitation and upgradation from
75.00 Km to 80.06 Km of NH25 in the town of Kanpur (including bridge across
river Ganga) to 4 lane divided carriageway configuration (contract package EW
II UP06).
II. REFERENCE:
1. Drawing nos. DCPL/KANPUR/SUP/3X26/004
DCPL/KANPUR/SUP/3X26/008
2. MoRT&H Specifications
3. Contract Document Technical specifications
III. MATERIAL AND RESOURCES :
For One Beam
1. Construction Material :
Cement (OPC 53 Grade) 140 Bags
Aggregate 20 mm 9 cum.
Aggregate 10 mm 6 cum.
Coarse Sand 9 cum.
Reinforcement Steel as per list
H T Steel (12.7mm) 1.20 ton
Sheathing Pipe 130 Rm
Anchorage 10 set
(Guide cone, Bearing Plate, Anchor Grips)
2. Plant and Equipments :
(Discussed in Plant Information)
3. Man Power :
Skilled worker for concrete breaking 4 nos.
Skilled / S.skilled workers for concreting & grouting 8 nos.
Reinforcement steel cutting and bending 6 nos.
Reinforcement steel and shuttering fixing 8 to 10 nos.
PreStressing 6 nos.

41


IV. PROCEDURE :
Form Work :
Formwork for the beam will be fabricated at the site as per approved drawing of
Beam.
It is fabricated in panels for one beam of 2 sides. For the alignment of formwork,
adjustable struts & through bolts shall be used.
Rigid working platform shall be made at beam top level eith structural steel.
STEP 1:
After completing of casting bed and pedestals, fabricated beam bottom shall be
erected and fixed as per our drawings. Uniform level of beam bottom shall be
made.
STEP 2:
One side shuttering panel shall be erected and placed over beam bottom as per
drawing and true plumb of side shuttering to be made to start making of cable
profile. Flexi foams with adhesive shall be used at joints of each panel in order to
check the leakage of cement slurry during concreting.
STEP 3: Cable Profile
Cable profile shall be marked by paint over beam bottom and side shuttering as
per drawing.
STEP 4: Reinforcement
Steel shall be fabricated in advance as per approved bar bending scheduled at
centralized bending yard. Fabricated reinforcement shall be shifted to casting
yard.
Reinforcement cage shall be fabricated in advance outside the casting bed. The
prefabricated cage shall be shifted and placed at casting bed with the help of
spreader beam and lifting Gantry as soon as bed is ready to receive
reinforcement cage for next beam.
STEP 5: Laying of Sheathing Pipe
Sheathing pipe of 75mm (or shown in approved drawing) dia. of single length
shall be laid over marked profile (ref: STEP 3). Then the pipes shall be
accurately located and tied as per drawings in both direction of vertical and
horizontal.

42


Ladders, spacers @ 2m C/C shall be provided to keep sheathing duct in position.
78mm dia. (or as suitable for sheathing pipe as per approved drawing) 150mm
long coupler shall be provided for joining sheathing ducts and at both junctions
of end Guide cone. Joints in between couplers and pipe shall be sealed with
adhesive celling tape to prevent ingress of cement slurry in to ducts during
concreting. In addition, couplers of adjacent ducts shall be staggered whenever
possible.

STEP 6: Closing of Shuttering
After checking of reinforcement and Profiling of sheathing, other side of beam
shuttering shall be shifted and erected by means of shutter handling gantry.
Shuttering shall be closed by side bolting as well as by fixing of tie angle and by
adjustable props.
STEP 7: Concreting of PSC Beam
Concrete of M50 grade shall be produced at batching plant and will be
transported by transit mixers to the casting yard.
Placing of concrete shall be done by concrete pump or concrete conveyor.

43


Concreting shall be done up to a depth of 400 mm andthe same layer will be
continued until completion of the beam.
Compaction of concreting at bottom flange, web shall be done by using shutter
vibrator and with immersion vibrator simultaneously.
Proper care shall be taken to ensure all the cables are free from concrete.
During concreting and up to 3 to 4hrs after completion of concreting, the cable
duct shall be checked by movement of the dummy pipe through it for any ingress
of concrete slurry.
STEP 8: Threading of Cables
Cutting of HT Strands shall be done with angle grinder after uncoiling of HT
Strands. Proper care shall be taken to avoid damages, kinks or bents and stacking
shall be done properly preventing ground contact.
After 3 days of concrete, threading of cable shall be started from one end to the
other end. Bundle of 12nos. HT Strands be made and same to be inserted
manually inside the Sheathing duct. Proper care shall be taken to avoid damage
to sheathing duct while threading.
STEP 9: Curing & DeShuttering
Normal curing shall be commenced after final setting of concrete i.e. 6hrs
(approx.) depending on cement. Curing shall be continued until the concrete
reaches strength 35N/mm
2

After attaining strength of 10Mpa, the vertical side shuttering of PSC girder shall
be removed and taken out of the bed with the help of gantry, to use in the second
bed.
STEP 10: PreStressing
Method of stressing: FPCC System (Proposed) or any other system
approved by Engineer
Important Points:
Stressing will be done after 10 days of concrete and achieves strength as
specified in Drawing. Number of cables to be stressed, will be as mentioned in
drawing.

44


Future cable shall be stressed after completion of stressing and if required and as
advised by the Engineer.
It is to be seen whether the extensions specified in the table account for effect of
slip at each end or not. Accordingly, no extra allowance of slip should be made.
Extension at each end during stressing operation should be equal as far as
possible, max. Difference should not exceed 5% of the prescribe extensions at
each end. In case the required extensions are not obtained at the specified
pressure, stressing should be continued till the required extensions are obtained
subjected to jack pressures not exceeding the prescribe limits.
Difference between calculated and observed tension and elongations during the
prestressing operations shall be regulated as per MORTH sec. 1807 under post
tensioning head as point a, b, c, d.
Method of Stressing
During curing of PSC Beam, arrangements for prestressing shall be started
Erect a tripod or scaffolding tower on both end of PSC Beam.
HT Strands to be physically checked to ensure the strands are free from any
friction.
Keep all strands ends at particular point approx. 750mm from the anchorage
cone.
Clean all projected HT strands by petrol and afterward give a coating of wax for
smooth operation.
Place the bearing plate on the buter face of each of the anchorage cone of PSC
Beam.
Fix the anchorage grips in each hole of bearing plates by means of pipe.
Erect the pre stressing jack at both the end and place in first cable as per the
stressing sequence and then fix the barrel and master grips in prestressing jacks.
Initial force shall be applied for tightening of jacks till slackness of the strands is
removed. A mark shall be made at each strand at a suitable distance to measure
the extensions of cables at both ends.
Incremental load shall be applied to keep control over the extensions. A seesaw
action on loading may be applied to get equal extension at both the ends.
Stressing to continue till it reaches its final extensions as per table i.

45


Afterward, all other cables shall be stressed as per sequence in above manner.
Slip of each cable shall be measured and recorded.
STEP 11: Grouting of cables in Prestressed girders
Grouting of cables shall be conducted at stacking bed as soon as it stacked there.
Materials:
Water: clean, potable water free form impurities will be used.
Cement: OPC as mentioned above
Sand: sand conforming to IS: 383 will be used.
Admixture: admixture if required conforming to IS: 9102 will be used.
Equipment:
(Discussed in Plant Information)

Mixing of Grout:
Proportions of the required materials will be measured by weight before starting
of mixing operation.
Water shall be added to the mixer followed by cement, sand & admixture /
Readymade grout mixture.
Mixing shall be done for approximately 2 to 3 min until uniform and thoroughly
blended grout is achieved.
Adequate care shall be taken to prevent any addition of water to mixed grout to
increase fluidity.
Cubes of 100mm shall be taken for verification of compressive strength.
Grouting Operations:
Grouting shall be carried out within 2 weeks of stressing of cables.
Ducts shall be flushed with water for cleaning as well as for wetting the surfaces
of the ducts walls. Water used for flushing should of same quality as used for
grouting.
After cleaning, all the water shall be drained thoroughly by vent pipe or by
blowing compressed air through duct.
Sequence of grouting shall commence from bottom to top.

46


During and after 3 to 4 hours of grouting other nonstressed cables shall be
checked manually for free movement.
All outlet points including vent openings should be kept open before to
commencement of grouting.
Injection of Grout:
After mixing grout should be kept in continuous movement and injection of
grout must be continuous without any interruptions.
Grouting shall be commenced initially with a low pressure of injection of up to
0.3Mpa increasing it until the grout come out through the other end with same
consistency as that of the grout @ injection end.
Full injection pressure (approx. 0.5Mpa) shall be maintained for a minimum of 1
min before closing the injection pipe.

TIME CYCLE:
Following is the time cycle of construction of 1 no. PSC Beam:
S.No
Activity No of Days
1. Bottom plate cleaning, leveling 0.5 day
2. Erection of outer shutter 0.5 day
3. Lowering of Pre-fabricated cage 0.5 day
4. Sheathing laying and profiling 0.5 day
5. Shutter closing and checking 0.5 day
6. Concreting 1 day
7. Waiting and de-shuttering of side shutter 1 day
8. Cable threading and Pre-stressing after 10
days
11 days
9. Lifting of Beam and vacating bed 0.5 day
TOTAL 15 days

47


CHRONOLOGICAL TRAINING DIARY
Date Description
06062014 Joining letter taken from G.I.L office.

07062014 Visit of office & site and meeting with
Engineers.
08062014 Sunday holiday.
09062014 Visit the office & study the plan of project.
(Planning Department)
10062014 Discussion with the Planning Engineers.

11062014 Study different drawing, work and contract
documents.
12062014 Meeting with Plant Engineer and Discussion
about machines.
13062014 Meeting with QC Engineer and Discussion
about Quality Policy.
14062014 Performing Sieve analysis & Aggregate
impact value Test.
16062014 Visit the site & Meeting with Execution
Engineer and Execution Team.
17062014 Visit full site and Discussion about Project
Execution with Engineers.
18062014 Construction of Prestressed Beam (G1)
start (Bottom Plate clearing and leveling).
19062014 Erection of outer shutter & Lowering of
Prefabricated cage.
20062014 Sheathing Laying and Profiling &
Shuttering Closing and Checking.

48


21062014 Visit plant and see making of Concrete and
Concreting of Beam in casting yard.
23062014 Deshuttering of side shutter & Curing of
Beam.
24062014 Curing of Beam &
Construction of Pier cap no. 43.
Construction of Pier cap no. 43.
Construction of Pile cap no. 45.
Construction of Pile cap no. 45.
28062014 Curing of Beam & Laying of Reinforcement
on deck b/w P36 to P39.
30062014 Curing of Beam & Laying of Reinforcement
on deck b/w P36 to P39.
01072014 Visit office (QC Department) and perform
Cube Test of Beam P39P40.
02072014 Cable Threading and PreStressing of Beam
after 10 days in Casting yard.
03072014 Lifting of Beam to Pier P40P41 with the
help of Gantry.
04072014 Collecting all Drawings & Preparation of
Project report.
05072014 Discussion with Project Manager about
Project Report.
07072014 Submission of Project Report to Project
Manager at G.I.L office.

49


SAFETY REQUIREMENT
SAFETY APPLIANCES
The requirement of sufficient number of safety appliances are planned well in advance
and made available at stores.
HEAD PROTECTION
Every individual entering the site must wear safety helmet, confirming to IS: 29251984
with the chinstrap fixed to the chin.
FOOT AND LEG PROTECTION
Safety footwear with steel toe is essential on site to prevent crush injuries to our toes
and injury due to striking against the object.
HEARING PROTECTION
Excessive noise causes damage to the inner ear and permanent loss of hearing. To
protect ears use ear plugs / ear muff as suitable.
EYE PROTECTION
Person carrying out grinding works, operating pavement breakers, and those involved
in welding and cutting works should wear safety goggles & face shield suitably
Goggles, Safety Spectacles, face shield confirm to IS: 59831980.
EAR PROTECTION
Ear Muff / Earplug should be provided to those working at places with high sound levels
(confirm to IS: 91671979).
HAND AND ARM PROTECTION
While handling cement and concrete & while carrying out hot works like gas cutting,
grinding & welding usage of hand gloves is a must to protect the hand,
1) COTTON Gloves (for materials handling)IS: 69941973
2) RUBEER Gloves18 (380/450mm long) electrical grade, tested to 15000
Volts conforming to IS: 47701991
3) LEATHER Gloves hot work / handling of sharp edges .

50


RESPIRATORY PROTECTION
Required respiratory protection according to the exposure of hazards to be
provided.
SAFETY NET
Though it is mandatory to wear safety harness while working at height on the working
platforms, safety nets of suitable mesh size shall
be provided to arrest the falling of person and materials on need basis.
FALL PROTECTION
To prevent fall of person while working at height, personnel engaged more than 2m
wear standard Full Body harness should be conforming to IS: 35211999 (Third
Revision).
1) Lanyard should be of 12mm Polypropylene rope and of length not more than 2m.
2) Double lanyard, based on the requirement.
SAFETY DURING STRESSING
Use hydraulic equipments supplied with a relief valve.
Place safely valve in between jacks and connection highpressure hose.
Use hosepipes in good conditions and avoid using worn out hosepipes.
Check the concrete around bearing plate and anchorage to see whether there are any
voids / honeycombing.
Do not allow anybody behind stressing devices, in line with tendon, or near hydraulic
hoses.
When the stressing works are in progress no other work should continue in the vicinity.
Health of safety systems incorporated in the stressing equipment shall be ascertained
once a week.
Display a clearly visible sign DANGERPRESTRESSING WORKS IN
PROGRESS

51


SUGGESTION

Gammon India Limited (G.I.L) is playing a vital and very
important role by giving the good and comfortable facilities of Bridges for
the Roads users and also giving the better Structures which are giving
beauty to our Country.
In this process of construction there is big jams occurs on Service
Roads. So I requested to G.I.L. to provide good moving facilities for
service lane users.
I have seen that several numbers of labour were working day &night
as to complete the project in given estimated time. The Engineers Staff was
also working very hard. Overall the Work of this Project is Satisfying its
drawing& Specifications.

52


CONCLUSION

It was a wonderful learning experience at Gammon India Limited site
Rehabilitation and Upgradation from 75 Km to 80.60 Km of NH25
(GANGA BRIDGE & FLYOVER PROJECT) for one months in
KANPUR. I gained a lot of insight regarding almost every aspect of site. I
was given exposure in almost all the departments at the site. The friendly
welcome from all the employees is appreciating, sharing their experience
and giving their peace of wisdom which they have gained in long journey
of work. I am very much thankful for the wonderful accommodation
facility from G.I.L. I hope this experience will surely help me in my future
and also in shaping my career.

53


REFERENCES

In Preparing this Project Report the following references has been taken in
accounts are :

SpecificationsofG.I.L.
SpecificationsofN.H.A.I.
Specificationsof MoRT&H.
Drawing nos. :
1. DCPL/KANPUR/SUP/3X26/004
2. DCPL/KANPUR/SUP/3X26/008
Contract Document Technical Specifications.

Summer Intrenship at Gammon India Ltd.

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SUMMER TRAINING REPORT

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