PROJECT REPORT

ON
ELEVATED METRO RAIL SYSTEM

RAPID METRO RAIL (SIKANDERPUR TO SEC-56.),

GURGAON

6 WEEKS TRAINING FROM 18TH MAY 2015- TO 4TH

JULY 2015

SUBMITTED BY:
RISHABH DOGRA
(Btech-civil 2013-17, A2315813114)

SUBMITTED TO:

1
 MR. R.K TOMAR

ACKNOWLEDGEMENT

The summer internship process at the organization has been a successful learning platform with the help
of the whole team who provided the required assistance to utilize each day of the internship for a good
learning in the field of Planning and Execution of the project.

I would like to express my sincere gratitude to Mr. ASHOK KUMAR AHUJA (CPM Civil for Rapid
Metro rail project ) for giving me an engineering opportunity to get trained and also the Team Members who
helped me throughout the internship period to gain the knowledge which dealt with various aspects of civil
engineering from construction point of view.

I am also very thankful to our HOD Ms. Madhuri Kumari and my faculty guide Mr. R.K Tomar for giving
me assistance.

2
 INTRoDUCTIoN
Infrastructure Leasing & Financial Services Limited (IL&FS) is one of India's leading infrastructure
development and finance companies. IL&FS was promted by the Central Bank of India (CBI), Housing
Development Finance Corporation Limited (HDFC) and Unit Trust of India (UTI). over the years, IL&FS has
broad-based its shareholding and inducted Institutional shareholders including State Bank of India, Life
Insurance Corporation of India, ORIX Corporation Japan.
IL&FS has a distinct mandate - Catalyzing the development of infrastructure in the country. The
organization has focused on the commercialization and development of infrastructure projects and
creation of value added financial services .From concept to execution, IL&FS houses the expertise to
provide the complete array of services necessary for successful project completion: visioning,
documentation, development, finance, management, technology and execution. During the internship
period, the development of Rapid Metrorail Gurgaon has been the major project of IL&FS
Transportation (India) Ltd.
ITNL

IL&FS Transp0rtati0n Netw0rks Ltd. (ITNL) is an established IS0 9000:2001 surface transp0rtati0n
infrastructure c0mpany, and is 0ne 0f the largest private sect0r B0T r0ad 0perat0rs in India. ITNL is a
devel0per, 0perat0r and facilitat0r 0f surface transp0rtati0n infrastructure pr0jects, taking pr0jects fr0m
c0nceptualizati0n thr0ugh c0mmissi0ning t0 0perati0ns and maintenance. ITNL was inc0rp0rated in 2000
by IL&FS, an infrastructure devel0pment and finance c0mpany, in 0rder t0 c0ns0lidate their existing r0ad
infrastructure pr0jects and t0 pursue vari0us new pr0ject initiatives in the area 0f surface transp0rtati0n
infrastructure. In March 2008, ITNL c0mmenced internati0nal 0perati0ns thr0ugh the acquisiti0n 0f Elsamex
S.A. ("Elsamex"), a pr0vider 0f maintenance services primarily f0r highways and r0ads in Spain and 0ther
c0untries .Since incepti0n, ITNL has been inv0lved in the devel0pment, 0perati0n and maintenance 0f
nati0nal and state highways, r0ads (including urban r0ads),fly0vers and bridges in Andhra Pradesh,
Delhi, Gujarat, Maharashtra, Karnataka, Uttar Pradesh, Kerala, Jharkhand and Rajasthan.

ITNL Ens0 Rail Systems (IERS) is n0w successfully w0rking 0n the Rapid Metr0rail Gurga0n pr0ject. The
Rapid Metr0rail Gurga0n is an under c0nstructi0n rapid transit system in the city 0f Gurga0n, Haryana, linked
with Delhi Metr0.

The system will be India's first privately 0wned and 0perated metr0 and is sec0nd awarded public-private
partnership metr0 pr0ject after the Hyderabad Metr0.

3
 Rapid Metr0rail Gurga0n S0uth Ltd. The Rapid Metr0rail Gurga0n S0uth Ltd. (RMGL) is an
under c0nstructi0n rapid transit system in the Indian city 0f Gurga0n, Haryana, linked with Delhi
Metr0. The system will be India's first privately 0wned and 0perated metr0 and its sec0nd awarded
public-private partnership metr0 pr0ject after the Hyderabad Metr0. The metr0 is designed t0 carry
30,000 passengers per h0ur. Three-c0ach trains will 0perate at 3-minute intervals, with a capacity
0f 1010 passengers per train. The trains will have a maximum speed 0f 90 km/h, but will 0perate at
an average speed 0f 30 km/h. The fares have been fixed at Rs.10 f0r any ride.

The company is certified with the following :

ISO : 9001 for Quality Management Systems

ISO : 14001 for Environment Control System

OHSAS : 18001 for occupational Health and Safety Systems

Stations

The section between Sikanderpur and Sector 56 will be double-tracked throughout . depot of this route will
be constructed near AIT chowk.

Sikanderpur (interchange with Delhi Metro via 9km walkway)

DLF Phase I
Shushant lok
Sector 53,54
AIT chowk
Sector 55,56

CONTENTS

4
 1. FOUNDATIONS ...
.1
1.1 DEEP FOUNDATION-PILE
FOUNDATIONS..1
1.2 SHALLOW
FOUNDATIONS.6

2. STATIONS-CONCOURSE SLABS AND

PLATFORMS.8
2.1 BASIC TERMS..
.9
2.2 BEAMS AND COLUMNS
REINFORCEMENT12
2.3 SAFETY
EQUIPMENTS..15

3. TESTS ON CONCRETE AND

CEMENT16
3.1 CONCRETE TESTING.
..16
3.1.1 SLUMP TEST-WORKABILITY TEST..
..16
3.1.2 COMPRESSIVE STRENGTH TEST..
..17
3.2 CEMENT
TESTING.1
8
3.2.1 NORMAL OR STANDARD CONSISTENCY TEST.
.18
3.2.2 TEST FOR SOUNDNESS...
.19
3.2.3 TEST FOR SETTING TIME..
..19
3.2.4 COMPRESSIVE STRENGTH..
19
3.2.5 LOAD TEST ON PILE.
...20

4. CASTING YARD.
..20

5
CONCLUSION

REFERENCES

1. FOUNDATIONS

A foundation is used to support a building or structure and transmits loads directly to the underlying soil or
rock. It must satisfy two fundamental requirements. Firstly, it must provide an adequate factor of safety
against failure of the supporting strata. Secondly, any resulting settlement should not be detrimental or
interfere with the function of the structure. Foundations can be split into two main types, shallow foundations
and deep foundations.

Shallow foundations are foundations which are not very deep from the ground level. It can be used only on
those surfaces where the underlying soil is capable of supporting the load of the structure. These are further
divided into strip footings, combined footings, raft or mat foundation, individual footings. A deep
foundation is used to transfer loads from a structure above ground through upper weak strata of soil to a more
competent one at depth, beyond which shallow foundations become both impractical and uneconomic. Types
of deep foundation are Pile foundation, Well foundations, Pier foundations.

1.1 Deep foundation- Pile foundation

Pile foundation is a type of deep foundation in which a group of straight solid cylinders of
concrete is used to transfer the load of structure to the hard strata present deep beneath ground
level. In this a group of minimum two piles placed under a single pile cap is used to convey loads.

Instruments and machines used:-

6
 Rig Machine- It is used for boring deep into ground, it has different ranges that how deep
it can bore. It consists of a Kelly which is cylindrical and goes in the bore, A Rotary which
is used to rotate the Kelly for boring.

Bucket- Bucket is the one which is used for digging. It is connected with Kelly and rotated
by Rotary.

Augur Augur is fitted at place of bucket if upper surface is very hard or if its a road
surface. In hard surfaces like these Augur is used to dig the initial 2/3 meters, and then
bucket continues.

7
 Casing- Casing is a hollow cylinder used to maintain the verticality of the bore. It is of
different depths varying from 2-6 meters. Its diameter is equal to the diameter of pile.
Driving the casing is very main starting step of piling. Thee given point should not get
dislocated while driving casing in.

Hopper Hopper is a funnel shaped cone use for pouring and vibrating concrete during
piling. It has different joints so that while pouring height from which concrete is falling
should not exceed 1.5 meters.

Different steps in piling are:-

8
a) Trenching- Very first thing to be checked before starting to bore are the underground wires and
pipelines. So 2.5 meter trenching is done to ensure whether any connectivity wires or pipelines
are not blocking the pile passage. If there are connectivity wires then they are moved because
changing a pile location means many changes in the approved plan which needs time as well as
resources. During designing also the maps are considered to avoid all such underground pipelines.

b) Locating the point- The exact point is given by the surveyor using the coordinate system of the
plan. Being in execution work, we have to take care that point does not get dislocated while
piling, otherwise pile will fail.

c) Driving the casing- Using rig machine, casing is derived which has center same as center of pile.
Here a lot of care is required. To mark the point triangulation system is used. From the given point
two fix distances are taken and point is marked suppose 2 meter is marked from one end of casing
and the other 2 meter is marked just 90 degrees to it. By forming a right triangle, length of third
side is calculated. While driving in the casing, these distances are regularly checked and
accordingly instructions are given to rig machine operator to move the casing in required
direction.

d) Boring- Casing used on our site was 2.5 meters. Through it, rest is bored by bucket. Depth to
which it is to be digged is calculated. In the design we are given the length of pile which is
required after chipping, it is known as Shaft length. And also founding level is given to us,
founding level is the level upto which we have to dig, it is with reference to permanent
Benchmark. So by adding these two we get the Cut off length level. Then using Dumpy level we
calculate the casing top level. The difference between Casing top level and cut off length level
gives us the chipping length which is not required but very important.

9
e) Sounding- When boring is completed, on the Rig machine is displayed the depth of that bore. But
depth of the bore is checked by chain sounding. A chain with heavy load inserted on one side is
allowed to go deep into the bore, then it is measured by a measuring tape, that exactly how much
is our bore. It is for a crosscheck because display on Rig machine is according to the rotations
made by machine, so there can be differences between actual and observed reading.

f) Addition of polymer Bentonite- while digging there is a chance of sub soil collapse. So Bentonite
+ NaOH is added so that it forms a layer type coating with soil and prevents it from collapsing.
While NaOH is added just to maintain neutrality of medium. By adding Bentonite soil does not
collapse. The added polymer is first tested for its Viscosity (internal property of fluid which
resists flow) by the apparatus called Marsh Cone Viscosity Apparatus. It is a simple hollow cone,
bentonite is poured in it keeping the open end closed. Once bentonite is poured, the end is open
and time is noted that how much time it takes to flow back to the same vessel by which it was
poured. Expected time is 55-70 seconds. If result is not between it, it is diluted or concentrated
accordingly.

10
g) Reinforcement for piles- Reinforcement is put in the bore with the help of Rig machine. Standard
size of bars is 12 meter, for depths more than these, they are overlapped and overlapping length is
50 * diameter if bar (i.e. 50 times the dia of bar).

h) Slurry coat- After inserting reinforcement, now it needs concreting/casting. But before concrete
Slurry is required. Slurry has two main functions- It forms a coating on steel so that bars do not
corrode fast. And it breaks the contact of Bentonite and steel otherwise it would disturb in
concrete-steel bond. So when slurry is put in, bentonite overflows out of the bore, it is pumped
back to container tank for recycled use.

11
 i) Concrete-Concrete of suitable grade is then poured by Miller through hopper. Hopper is always
1.5 meter deep in concrete so it also acts as vibrator for it. Generally M-35 is used.

j) Chipping- Now after concreting, Sound concrete of lower strength is pulled upwards so around 1
meter from top, the concrete present is of lower strength, and hence chipping is done. It should be
minimum 1 meter. But it is calculated by finding difference of Casing top level and Cut off level.
So around 1-2 meter of pile from top is chipped i. e. broken. So chipping is a very important step
and that is the reason for casting a pile more than the required shaft length.

k) Grouping- In the same way groups of piles are completed. Members of group depends it varies
from minimum 2 members to 10 members also. Then after chipping of a pile group, pile cap
reinforcement is done.

l) Pile cap- A thick base connecting the group of piles and base for further construction of structure
is called pile cap. It is generally 1-2 meters thick solid, it combines group of piles and from the
center of the pile cap, base of Pier to be constructed is made. Development length for piers is left
from center of pile cap.

1.2 Shallow foundations- Raft foundation

Raft foundation is a thick concrete slab reinforced with steel which covers the entire contact area of the structure
like a thick floor. Sometimes area covered by raft may be greater than the contact area depending on the bearing
capacity of the soil underneath. Sometimes inverted main beams and secondary beams are used to carry column
loads that require thicker foundation slab considering economy of the structure. Raft foundation is required
where soils have low bearing capacity and have to support heavy structural loads. Normally structures on marshy
12
land, soft clay and land that are made up of sanitary land fill or other materials (like debris, unconsolidated soil
and solid waste etc. where differential settlement is suspected)-require raft foundation. In other words, where
deep foundation like pile foundation are not economical and feasible and isolated column footing is
impracticable due to large footing size or over-lapping of neighbor footing , raft foundation is the economical
solution.[1]

Different types of Shallow foundations are-

a) Isolated/Spread footing- When footing is provided to support individual columns, it is called spread
footings.

b) Strap footing- It consists of two isolated footings connected with a strap of concrete. Here, beams were
also used as a Strap.

c) Combined footing- When there are less space between two columns, there isolated footings will overlap,
then combined footing is used, so footing from which there are more than one column is called combined
footing.

13
d) Mat/Raft foundation- It is a large slab supporting a number of columns and walls under the complete
structure or upto a certain length of structure.

..

2. STATIONS- CONCOURSE SLABS AND PLATFORMS

Live load on stations is even more than rest viaduct area and comparesd to other structural components.
So slabs on concourse level and on platform level require good level of strength. Two types of bars are
basically used in their constructions- TMT Bars (Thermomechanically treated bars) and second type are
HYSD bars (High yielding strength deformed bars). During the manufacture of TMT bars, the hot rod is
passed through a water sprinkling arrangement to create a distinct layering of various hardness across the
section. This produces a hard anticorrosive outer layer, a relatively soft intermediate layer and softest
core. This structure gives advantages to TMT steel over HYSD by means of its weldability, zero flaws on
the surface and many more. Until around 2005-2006, HYSD was widely used as rebars (reinforcement
bars) in building structures. Since the mass commercialization of TMT steel, HYSD is not preferred
today. [2]

14
2.1 Basic Terms

Cover- When shuttering is done below the reinforcement, some space is left so that
concrete can enter properly on the below surface and the bars get proper concrete cover.
Otherwise if shutter exactly touches the bars, then that much part of beam bars will be left
without concrete cover. Due toit bars will corrode faster and it will not be a good finish,
bars will be flashing out of concrete.

Standard cover used was 50 mm for beams and 25 mm for slabs and 50 mm for columns.
Cover blocks may be of rubber or concrete.

SFR (Side face Reinforcement)- Along with toplayer and bottom layer bars , side face
reinforcement is also provided in beams for better concrete hold and otherwise the beam
can develop cracks on side faces. On each face of beam, SFR is provided as mentioned in
drawing. Sectional view of bars in a beam when seen from front- all bars in direction
perpendicular to paper/screen.

15
 Scaffolding: - Scaffolding also called staging are temporary structures used to support
shutters and to assist labour to work on greater heights. Scaffolding was made by Ledger
Rods (iron rods) of 1 meter each. Forming a 3-D cube of dimension (1*1*1) m 3. ISMB
Rods- Steel rods of I-cross section were also used for shuttering above ledger rods.
Bracing- Extra support given to Ledger rods.

Dowels-each time when structure is reinforced, some extra steel known as Dowel is left
for further extension which gives good grip to new casted concrete. The left over parts are
bonded with newly placed bars, so it gives continuation to the structure and better hold.

16
 The bars standing vertically straight in the picture are called Dowels.

Cut outs - Blocks which are left for electronic purpose because in such a huge project
casting of slab and electrical work cannot go hand to hand.

Anticrash Barrier- Barrier surrounding the pier to avoid direct collision impact on our pier
support or on main beams.

Curing compound :- Curing compounds are designed to minimize the loss of water due to
concrete cure, producing concrete which is free of crack, has dense stain-resistant surface
and has minimum porousity to prevent ingress of water and other corrosive elements.

Epoxy Bonding Agents- For binding Old concrete surface to new concrete surface.

Curtailments: - Curtailments are the extra layer of bars just beneath the top layer or just
above the bottom layer. It is just another layer of bars present at corners of beam, not
usually present in center. In beams, Shear force is maximum at the ends and Bending
moment is maximum at the center. So for resisting the maximum shear force, extra bars
are required especially at the end, if they are provided then Bending moment gets self-
controlled in the center. Also at the top of beam, concrete is under compression and at the
bottom of beam it is under tension. So curtailments are must at the top to decrease tension
at bottom, as tensile strength of concrete is only 10 % of its compressive strength. The
bars just below the top layers are top curtailments.

17
2.2 BEAMS AND COLUMNS REINFORCEMENT
In beams- Stirrups (commonly also called as rings) are a very important part. One of the minor
functions of stirrups is to bind the bars to keep them in position. But if this was the only use so
very less stirrups would be enough for this purpose. So it has another major concept.
At the top of the beam shear stress is compressive in nature, but the same stress conveys tensile
load at beam bottom, so beam is always very prone to failure from bottom. So for this, stirrups or
rings are used to distribute the shear stress throughout the cross-section of beam and decrease its
impact on beam bottom. Along with the stirrups, the side face reinforcement bars also provide
good bearing for stress distribution throughout the cross-section. In the picture, the bars in the
ring pattern over the four main bars are stirrups.

Another important component of shuttering is Tie Rods. To hold two shutters on position so that
they do not move or get loose while concreting are called Tie rods. Now just for binding the

18
shutters if we use steel bars, it is uneconomical. So hollow PVC pipes are inserted and inside
them steel rods are inserted and tied by big nut. Then after concrete is poured, while de-
shuttering, nut is open and steel rods are taken out to be reused and PVC are left as it is because
they get set.

Figure- Big nuts

Figure- The white PVC rod, tie rod with steel rod inside it.
Columns- Columns used were generally classified into three types- Rectangular columns, Circular
columns, Floating columns. Circular columns are better because they have greater torsion bearing
tendency due to their circular cross-section, torsion bearing capacity is lesser in rectangular
columns. Floating columns are those which are built from beams, that is they are small and less
load bearing columns built generally from one slab to another starting from a beam or a wall, they
are not supported on pile cap i.e. they do not have any link with foundation.
19
D-columns- In this project D-columns were also used. Some of them were double D columns with
elliptical cross-section again for better torsion bearing and load capacity. Another type were
columns with some gap in between, this gap was expansion joint. This cavity in between served
as expansion joint as well as it also separated the spans of structure, to prevent whole structure to
be continues.

Confining Zone-Same as beams, shear force at ends of columns is maximum and it is lower in
center. So confining zone of every column is defined where there should be no overlapping in this
zone, so overlaps if required are given in center portion, not in confining zone. This zone was
different for different columns, suppose if confining zone was 1500 mm, then column is divided
into three zones, first zone (Z1) from base to 1500 mm upwards and third zone (Z3) 1500 mm
down from column top. Second zone was in between Z1 and Z3. Also in these zones stirrups
installed were more in number is compared to center.
Use of stirrups in columns- When column takes load, on excessive loading it shows buckling
tendency, so stirrups prevent it from buckling, though columns are designed in such a way that
they will never deflect.

One way slab and Two way slab: -

One way slab is supported on two opposite side only thus structural action is only at one
direction. Total load is carried in the direction perpendicular to the supporting beam. Ratio
of longer span (l) to shorten span (b) is greater than 2, then the slab will be considered as
one way slab. Because due to the huge difference in lengths, load is not transferred to the
shorter beams. Main reinforcement is provided in only one direction for one way slabs.

20
 Two way slabs are the slabs that are supported on four sides and the ratio of longer span (l)
to shorter span (b) is less than 2. In two way slabs, load will be carried in both the
directions. So, main reinforcement is provided in both directions for two way slabs. [3]

2.3 Safety equipments

Safety helmet- for safety of head
Safety shoes- hard soal, hard finish shoes to avoid penetration of sharp materials.
Safety jacket- shiny jacket so that man is not left unseen, these jacket reflect when light
falls on them.
Indications- proper indication especially while de-shuttering is important.
First aid box- Every site should have proper first aid box, with antiseptics and all general
medicines available.
Nose masks- On some sites nose marks are important so that dust and pollution is not
inhaled.
Safe distance from machines
Safe distance when work in in progress
Safety belt- This belt is used for tying up when working on a height or working over
hanged.
Gloves- if we touch suddenly hot object and to avoid contact of skin to materials

21
 Fire extinguisher
Ear plugs- For sights where there is too much and continues noise.
Welding glasses for welding
Glasses to avoid vision impairments

..

3. TESTS ON CONCRETE AND CEMENT

3.1 Concrete Testing
Cement concrete is a major building material used in modern constructions. In many places, it is
prepared on site by hand mixing or machine mixing. But now it is also available as factory made
product known as RMC (Ready mixed concrete). Ingredients of concrete:-
Cement, fine aggregates (sand), Coarse aggregates (broken stones or gravel), water.

3.1.1 Slump Test Workability Test

The standard apparatus for the test is the Slump cone. Workability is simply the ease or
difficulty by which concrete can be handled and placed. IS 456 gives workability in terms of
slump.
The slump cone is placed on a G.I sheet with person conducting the test standing with his foot
placed on each footing. The cone is first filled with one-fourth of its volume concrete and
rodded by tamping rod 16 mm in diameter and 60 cm in length. The cone is thus filled in four
layers with regular rodding. The top level of concrete is finally stuck off so that cone is full of
concrete. The cone is then gradually lifted and concrete is allowed to slump. Here slump upto
150 + - 25 mm was accepted in slab work on station.

Slump in mm Workability and uses Compaction factor

Very stiff No slump 0.70
0-25 Stiff-to be used with 0.75
vibration
25-50 Stiff plastic- mass concrete 0.85
75-100 Plastic- normal RCC work 0.90
150-175 Flowing- for cast in situ 0.95
pilework

Table 1: classification of concrete mixes

22
 Compaction factor test: -A stiff concrete will give no slump. To test harsh (no slump
concretes), the compaction factor test is used. The test consists of placing the freshly-
cast concrete in a cone at a higher level, it being allowed to fall freely to a lower cone
at a lower level and then to a cylinder placed below it at a fixed distance. The ratio of
weights of concrete filling the concrete by this fall to the weight of concrete that can
be filled in the cone by vibration is the compaction factor. The relation between slump
and compaction factor is shown in table 1.

3.1.2 Compression test/Compressive strength test on concrete

The compressive strength test is used for specifying grade of concrete in design and for
quality assessment. Testing is done in 150*150*150 mm cubes. Before casting, samples are
taken from site itself.
Sampling-The scale of sampling varies with quantity of work.
Preparation of specimen- Approx. equal proportions of concrete during the discharge
from mixer is taken and mixed. The specimens are made in 150 mm cube moulds.
Curing and storage- The cubes are first cured under wet straw or gunny for the first 24
hours. Then they are demoulded and stored in room temperature for 7-28 days till it is
to be tested under saturated conditions.
Method of testing- The dimension of cubes are first measured and cubes are also
weighed and tested in a machine. The load is applied on side face as cast because top
face is manually finished so it is never plain, so it takes point load. While face side to
it are plain (machine finished) so it takes UDL. The load in N/mm2 gives the strength.
[4]

23
3.2 Tests on cement
The physical test are specified in parts 1 to 11 of IS 4031. In college or site laboratories, only
physical tests are carried out. Chemical test are carried out in cement laboratories/ factories.

3.2.1 Test for Normal or standard consistency: -

Many tests for cement like soundness, setting time are to be carried out with cement to which
water required to produce what is called normal consistency. Normal consistency is
determined by apparatus called Vicats needle. It is the consistency at which the Vicat plunger
G of 10 mm diameter and 50 mm length will penetrate 33-35 mm within 3 to 5 minutes of
mixing. Three trials are carried out with varying distilled water from 24 to 27 percent.

3.2.2 Test for soundness:-

24
 The soundness test is an indication of excess of lime caused by inadequate burning of cement
or excess of magnesia or sulphates. Excess of these substances is harmful and thus , not
allowed in cements. Test is conducted by Le-chateliers apparatus. Le-chateliers apparatus
shows unsoundness due to lime only. Unaerated cement paste at normal consistency is first
tested for expansion. If the test results does not satisfy requirement of 10 mm expansion,
another test shall be conducted after aeration. The expansion of aerated cement test should not
be more than 5 mm.
Cement paste with normal consistency is filled into the moulds. After covering both sides with
glass, it is first placed in water of temperature 24-35 degree for 24 hours. It is taken out and
distance between pointers is measured. The mould is then placed in water and water is heated
to the boiling point in 30 minutes. The boiling of water is continued for one hour. The mould
is then removed and after cooling, the distance between points is again measured.

3.2.3 Test for setting time

The setting time is also determined by Vicats needle on cement paste of normal consistency.
For this test we use 1 mm square needle (needle c). For this needle, the time to penetrate 33-
35 mm is taken as initial setting time. For final setting time we use special needle F (5mm
diameter) and the time at which it penetrates not more than 0.5 mm is Final set time.

3.2.4 Compressive strength

Compressive strength of cement is determined from cubes of face 50 cm 2 in area (7.06 cm
cubes) made of cement mortar with one part of cement and three parts of standard sand by
weight and water corresponding to 25% normal consistency. Plus 3% of combined weight of
cement and sand. Strength in 3, 7 and 28 days is taken, average strength of each is taken.[5]

3.3 Load test in pile foundation:-

It is type of impact test to check whether pile is taking the design load or not. Load equal to
design/expected load is arranged for impact testing on top of pile. 3 impacts are given from height
1 m, 1.5 m, 2 m. Then the displacement of pile if any is checked due to these impacts. The

25
 maximum displacement allowed is 10 mm otherwise the pile fails and needs to be recasted or plan
needs change.

..

4. CASTING YARD
Pre-stressing system is used s0 that steel is prepared t0 take heavy l0ads like in a metr0. In casting yard,
precasted h0ll0w girders are made, als0 design mixes are prepared and tested. T0 prevent girders fr0m
deflecti0n, pre-stressing technique is 0f great use. It is d0ne by tw0 types- 1. Pre-tensi0ning and 2. P0st-
tensi0ning. B0th the meth0ds were used in the casting yard 0f rapid metr0. It was d0ne using HT strands
which have high strength upt0 1700 N/mm2.
In pre-tensi0ning system, the high-strength HT strands are pulled between tw0 end abutments pri0r t0 the
casting 0f c0ncrete. The abutments are fixed at the ends 0f a pre-stressing bed. 0nce the c0ncrete attains
the desired strength, the HT strands are cut l00se fr0m the abutments. The prestress is transferred t0 the
c0ncrete fr0m the HT strands, due t0 the b0nd between them. During the transfer 0f prestress, the
member underg0es elastic sh0rtening. If the HT strands are l0cated eccentrically, the member is likely t0
bend and deflect (camber). The vari0us stages 0f the pre-tensi0ning 0perati0n are summarized as f0ll0ws.
1) Fixing 0f HT strands against the end abutments
2) Placing 0f jacks
3) Applying tensi0n t0 the HT strands
4) Casting 0f c0ncrete
5) Cutting 0f the HT strands.
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During the cutting 0f the HT strands, the prestress is transferred t0 the c0ncrete with elastic sh0rtening
and camber 0f the member. [6]
Camber- The upward deflecti0n 0f steel is called camber, this attained shape helps t0 take better l0ads,
camber is als0 sh0wn in figure.

In p0st-tensi0ning systems, the ducts f0r the tend0ns are placed al0ng with the reinf0rcement bef0re the
casting 0f c0ncrete. The tend0ns are placed in the ducts after the casting 0f c0ncrete. The duct prevents
c0ntact between c0ncrete and the tend0ns during the tensi0ning 0perati0n. Unlike pre-tensi0ning, the
tend0ns are pulled with the reacti0n acting against the hardened c0ncrete.
The vari0us stages 0f the p0st-tensi0ning 0perati0n are summarized as f0ll0ws.
1) Casting of concrete.
2) Placement of the tendons.
3) Placement of the anchorage block and jack.
4) Applying tension to the tendons.
5) Seating of the wedges.
6) Cutting of the tendons. [7]

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.

REFERENCES
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 [1]- Civil-engg-world.blogspot.in

[2]- www.quora.com

[3]- civilengineersforum.com

[4]- Chapter 11, cement concrete, Building Material- P.C Varghese

[5]- Chapter-5 Cement, Building Material- P.C Varghese

[6]- nptel.ac.in, pre-tensioning_system.pdf

[7]- nptel.ac.in, post-tensioning_system.pdf

CONCLUSION

My experience at IL & FS RAIL LIMITED (IRL) has been valuable. I thoroughly enjoyed my position and
gained a good experience of various aspects of a firm in the field of Construction. Being in the 5 th semester of
Btech-Civil and 6 weeks trainee, it is clear that this was great start to my dream career. But it also shows that
there is too much left for learn, many things to learn ahead.

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The internship period of 6 weeks has been an excellent opportunity for me to earn good hands on experience in
the different field of civil engineering.

I acquired many new skills and developed many already existing skills including innovativeness and creativity,
working in a team based environment and dealing with onsite as well as offsite challenges.

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