W.E.F.

05-06-2017 to 04-07-2017

Submitted By:
Manash Protim Gogoi (B-TECH)

Department of Civil, TEZPUR

UNIVERSITY
Dated: 19-JUL-2017

Page 1 of 27
 ACKNOWLEDGEMENT

Firstly, I would like to thanks Department of Civil, Tezpur University to sent me for this
Internship programme in Assam Petrochemical Limited.
I have taken efforts in this project. However, it would not have been possible without the kind
support and help of many individuals and organizations. I would like to extend my sincere
thanks to all of them.
I am highly indebted to Maintenance and Project Department, A.P.L for their guidance and
constant supervision as well as for providing necessary information regarding the project &
also for their support in completing the project.
I would like to express my gratitude towards H.R.M Deptt & members of A.P.L for their kind
co-operation and encouragement which help me in completion of this project.
I would like to express my special gratitude and thanks to industry persons for giving me such
attention and time.
My thanks and appreciations also go to my colleague in developing the project and people who
have willingly helped me out with their abilities.

Page 2 of 27
1. INTRODUCTION……………………………..
4

2. TENDER………………………………………...
7

3. PILING

4. MAINTAINANCE……………………………..
23
A. BUILDING MAINTAINANCE……........ 23
B. ROAD MAINTAINANCE……………… 25

5. CONCLUSION…………………………………
27

Page 3 of 27
 1. INTRODUCTION
Namrup is a small town situated close to the foothills of the great Patkai Mountain Range in the extreme
southeastern part of Assam, India.
Area: 13.5 km²
Elevation: 125 m
Weather: 35°C, Wind N at 3 km/h, 59% Humidity
Population: 18,929 (2001)

The river Dilih or Disang flows through it. Namrup is situated in a picturesque location amidst wet-
paddy fields, Assamese villages, orchards, large tea-gardens and densely forested hills.
Administratively Namrup is located within Dibrugarh district and is today an important industrial town
of Assam.
It is known for its 3 main industries viz. BVFCL (Brahmaputra Valley Fertilizer Corporation Ltd.), APL
(Assam Petrochemicals Ltd.) and NTPS (Namrup Thermal Power Station).
This report has been made to deliver a brief description on the maintenance program and ongoing project of
A.P.L.

A.P.L was set up by the State Government of Assam with joint participation of Assam Industrial
Development Corporation Ltd (AIDC) and the public. Incorporated in 1971, the company was a pioneer
in the field as it was the first to manufacture petrochemicals in India using natural gas as feedstock. It
started with a small Methanol plant with Formaldehyde and a few Urea Formaldehyde resins as
downstream projects with technology supplied by Mitsubishi Gas Chemicals Co. Inc. Japan.
Commercial production began in 1976.
It is the first company in the North Eastern region to have a public issue, it is listed in The Bombay
Stock Exchange Ltd and The Guwahati Stock Exchange.
A.P.L covers about 326 bigha, having a total number of 331 quarters from A-Type to F-Type. The
details are shown in table 1.
Table 1: Numbers of buildings in different types of quarters
TYPE NUMBERS OF QUARTERS
A 1(MD Bungalow)
B 9
C 7
D+ 18
D 40
E+ 90
E double storey 20

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 E 90
F 56

The main VISION of setting up the plant was to utilize the huge reserve of Natural Gas in the Upper
Assam oil fields and also to meet the requirement of increasing national demand for Methanol and
Formalin.
Its objective is to play an important role in the economic development of Assam, North Eastern Region
and the country. Growth is the key word. The corporate vision goes even beyond the future….. And for
APL the sky is the limit.

FUTURE PLAN
A.P.L had performed the Bhoomi puja on 7th May 2017 to mark the beginning of the new Project of
500 TPD Methanol and 200 TPD Formaldehyde Plant which covers about 23.12 Acre i.e. 55 bigha.

PROJECT INFORMATION

DATA OF ASSAM PETROCHEMICALS LIMITED

A. Location
a) Village: Namrup
b) Taluka / District: Dibrugarh
c) State: Assam
d) Latitude: 27.11° North
e) Longitude: 95.21° East
f) Site Elevation: 124 m above MSL

B. The Project Site is situated in an Earthquake-prone region

a) Seismic data: As per IS 1893-2002
b) Zone: Zone-V

C. Wind Data - Maximum velocity: 160kmph

D. Ambient Air Temperature: Maximum = 380C

: Minimum = 50C
: Flow Sheet = 300C

E. Wet Bulb Temperature: 280C

F. Relative Humidity: Maximum = 95% at 37°C

: Flow Sheet = 70% at 20°C

G. Rainfall Intensity: Maximum = 50 mm/hour

H. Connectivity
a) Nearest Railway Station: Namrup 8Kms.
b) Road: 70kms from Dibrugarh by National Highway NH-37
c) Nearest Airport: 65kms from Dibrugarh Airport

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 BASED ON METHANOL PRODUCED
a. Installation of D.M.E (Di-Methyl-Ether) plant.
b. Installation of Bio-Diesel Plant.
 BASED ON Formaldehyde produced
a. Sulphonated Formaldehyde.
This is a chemical used as additive with cement for bringing down cement requirement for civil
constructions.

SULPHONATED FORMALDEHYDE

SALES SPECIFICATION
POWDER APPEARANCE brownish powder
SOLID CONTENT 92.0% min
SULFATE ASH 32.0-36.0%
WATER 8.0% max
pH 6.5-9.5(10% solution)
LIQUID APPEARANCE brownish free flowing liquid
SOLID CONTENT 30.0-50.0%
SULFATE ASH 15.0-18.0%
pH 7-9(10% solution)

PACKING 25kg or more

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 2. TENDER
INTRODUCTION
Meaning of tender: - To invite bids for a project, or to accept a formal offer such as a takeover bid.
Tender usually refers to the process whereby governments invite bids for large projects that must be
submitted within a finite deadline.
Tendering: - Tendering is a process of making an offer, bid or proposal, or expressing interest in
response to an invitation or request for tender.
E-Tender: - An internet based process wherein the complete tendering process; from advertising to
receiving and submitting tender-related information are done online. It is done when the estimated value
is above INR 5 lakhs. Bid Documents can be published and downloaded online; Bid responses can be
prepared and signed online using Digital Signatures, payments related to Bid submission can be done
online using Credit Cards, Debit Cards, Internet Banking Accounts and Cash Cards and Tender
Opening, evaluation and Award can be done online.
Types of tendering

 Open Tendering
Under open tendering the employer advertises his proposed project, and permits as many contractors as
are interested to apply for tender documents. Sometimes he calls for a deposit from applicants, the
deposit being returned ‘on receipt of a bona fide tender’. However, this method can be said to be
wasteful of contractors’ resources since many may spend time preparing tenders to no effect.

 Selective Tendering
Under selective tendering the employer advertises his project and invites contractors to apply to be
placed on a selected list of contractors who will be invited to bid for the project. Contractors applying
are given a list of information they should supply about themselves in order to ‘pre-qualify’. The
advantage to the employer is that he can select only those contractors, who have adequate experience,
are financially sound, and have the resources and skills to do the work.

 Single Tendering / Nomination basis (Negotiation Basis)

Negotiated tenders are obtained by the employer inviting a contractor of his choice to submit prices for
a project. Usually this is for specialized work or when particular equipment is needed as an extension
of existing works, or for further work following a previous contract.
Sometimes negotiated tenders can be used when there is a very tight deadline, or emergency works are
necessary.
In Assam Petrochemical Limited Single Tendering is generally adopted for the Maintenance purpose.
Moreover they did the tendering process by advertising only on their website they did not done it
through E-Tender.

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Bid: - An offer of a price given in an estimation.
Types of Bid system

 Single Bid system

In single bid system all vendors who had submitted the financial bids will be considered for evaluation
(ranking) at the time of financial bid opening. In this case name of all vendors will come in the
comparative statement but their bids may be Technically Suitable or not.

 Double Bid system

In double bid system first tender opening officials assign the tender to a Technical Member
(Convener) for evaluation of technical bids. Technical member evaluates the technical bids submitted
by vendors and mark either Technically Suitable or Technically Unsuitable against each and every
vendor. The technical member also assigns a new date/time to tender for financial bids opening. At the
time of financial bid opening only those vendors will be considered for evaluation (ranking) who had
submitted financial bids and found technically suitable by the technical member.
Bidder: - A person or organization making a formal offer of price.
Bidding: - Bidding is referred to the procurement process from the perspective of Vendors / Suppliers
interested in supplying material or providing services to the Procuring Organization.
Earnest Money Deposit: - To ensure that a Bidder does not submit a Dummy Bid or back out at time
of tender opening, Government Department collects a small refundable fee from each bidder, which is
called EMD. EMD is always in form of a Demand Draft & cheques or cash are strictly not
allowed. EMD is returned when all Bids are opened & tender is awarded.

NOTICE INVITING TENDER

Assam Petro-chemicals Limited invites bids under sealed cover in single stage two bid system i.e.
Technical Bid and Financial Bid from reliable contractor having experience and financial capabilities.

TENDER PROCESS
TENDER PROCESS INCLUDES:-
 TENDER PREPARATION
 TENDERING
 TENDER EVALUATION
Technical bid: - The process of information interchange between the consulting engineer, owner and
the vendor for the evaluation of the compliance of the bid with the technical requirements of the tender
is called as Technical evaluation of the bid.
Financial bid: - The process of price interchange between the consulting engineer, owner and the
vendor for the evaluation of the cost is called as financial evaluation of the bid.
Procedures followed in A.P.L for the Technical and financial evaluation of the bid: -

 Project definition and scoping

 Estimation of cost
 Selection process for tenderers
 Tender documentation
 Criteria for selection
 Proposal for approval (Managing Director)

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 Financial and legal vetting
 Call for tenderer
 Tender committee meeting
 Amendments to tender document
 Submission and closing of tender
 Tender analysis
 Tender clarification
 Tender selection and award
Technical bid shall contain
a) Qualification Information and supporting documents as specified in Section 2 of the Bidding
document such as quantities of work executed, commitments, machinery list, key personal list in the
formats, Bank certificate, Affidavit & Undertaking etc.
b) Earnest Money as mentioned in the NIT (package-wise).
c) Acceptance/non acceptance of Dispute Review Expert as proposed.
d) Undertaking to the effect that Bid shall remain valid for the period as specified.
Financial bid shall contain
a) Schedule of Rates (Rates to be quoted by the Bidder as per Schedule of Quantities in the NIT).
b) Form of Bids as prescribed in the Bidding document.
Analysis of the tender

 Work experience
 Completion period
 Price offered
 Ability of the company (Finance, Personnel, etc.)
 Ongoing projects
 Adequacy of the tender conditions
Criteria for selection of tender

 Conformity
 Capability
 Innovation
 Price
 Construction period
Tender rejection

 Non-compliance with tender conditions

 Details not completed/submitted
 Tender price too high (>10%), justification is required
 Tender price too low (<10%)
 Lots of work in progress
 Insufficient financial capability
 Unsatisfactory work records

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Awarding the Contract
Once the final ranking has been established, the contractor with the lowest bidder (L 1) should be
awarded the contract.
If the award of contract fails with L1 bidder during execution, or is stopped for any reason, the second
L2 bidder can be brought in, if L2 bidder agrees to execute the job with the same rate as accepted by the
L1 bidder.
Contract supervision
Continuous monitoring and auditing is required to supervise any contract. This is carried out by the
consultants appointed to supervise, they should supervise the work thoroughly and instruct the
contractor to execute the job as per the drawing as instructed and should not compromise in quality of
work.
Payments
The sequence of payments to the contractor is outlined in the tender and contract documents.
Types of payments

 Advance payments
Most contracts will require an advance payment being made to the contractor for mobilization
(establishing a site complete with offices, power, communications and water supplies, clearing the site,
establishing stockpiles of materials, moving equipment and staff to site and related initial activities). If
it is incorporated in the tender document this would be recorded as an advance payment and can
comprise some percentage (%) of the total contract amount. It can either be made as a lump sum
payment or can be proportionally recovered as routine payments are made to the contractor as the works
proceed.

 Routine progress payments

Routine payments can be agreed at contract signing and can take the form of a monthly payment based
on estimated amounts of work completed or can be based on proportion of the project being completed.
Either way, the payment requests have to be submitted by the contractor and then checked and approved
by the Engineer supervising the works.
All approved payments should be scrutinized and cleared, (if found OK); then paid quickly.

 Variation payments
In all but the simplest contracts, a sum for unexpected works or for variations to the design should be
catered for. Usually listed in the Bill of Quantities as Contingencies, this can be calculated at around 5
to 15 percent of the total contract sum.
Again all such payments should be initially approved by the engineer, scrutinized once the works have
been done and then paid quickly to the contractor.

 Final payments

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At the end of construction, the works should be inspected and signed off by the engineer. The contractor
can then demobilize and leave the site. Usually, the final payment is withheld for a period agreed in the
contract – one year is satisfactory and will give the project a chance to fill and be used before the
contractor’s liability is removed. During this period, the project should be closely monitored and
checked. Defects should be noted and rectified at his/her expense.
If the contractor is unable or unwilling to do this work, the retained sum can be used to pay another
contractor to do the work required.
Once the liability period is over, the engineer certifies the project as good, and the contractor can be
paid the balance owed.
Final inspection and measurement
This is an important activity and can be carried out by the engineer to ensure the completed project has
been built to the design and to the highest standard possible. This activity can be carried out jointly by
the engineer and the contractor to ensure there are no disputed findings but the engineer is the overall
responsible officer.
The final inspection is best completed before the contractor demobilizes to ensure that any outstanding
work noted can be completed without delay. As built drawings should be produced and kept on record.
The maintenance and safety program can then be instigated.

(TENDER PROCESS IS A VERY COMPLICATED AND IS TIME CONSUMING, HENCE A

HUGE AMOUNT OF TIME IS REQUIRED TO CARRY OUT THE ENTIRE PROCESS).

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 3. PILING
Abstract:
Pile foundations consist of piles that are dug into soil till a layer of stable soil is reached. Pile foundations
transfer building load to the bearing ground with the greater bearing capacity. Pile foundations are
useful in regions with unstable upper soil that may erode, or for large structures. Pile foundations are
often required to resist lateral loading. Lateral loads come from a variety of sources including wind,
earthquakes, waves, and ship impacts.

The lateral capacity of a pile is usually much smaller than the axial capacity and as a result groups of
piles are often installed to increase the lateral capacity of the entire foundation system. When vertical
or plumb pile groups do not provide sufficient lateral resistance the piles can be battered in order to
mobilize some of the higher axial capacity to resist the lateral load.

INTRODUCTION:
Pile foundation have been used for many years, for carrying and transferring the loads to soil considered
to be weak in structure due to the soil conditions. Therefore, the weak bearing ground was reinforced
by the use of timber piles that were manually forced into the ground, or fixed into the holes that were
filled with stones and sand. The primitive methods of pile installation were modified after the industrial
revolution, and the techniques of installation by steam or diesel driven machines were introduced. With
the advancement in the technologies of soil mechanics and other related disciplines, superior piles and
pile installation system have been developed.

NECESSITY OF PILE FOUNDATION:

 When the strata at or just below the ground surface is highly compressible and very weak to support
the load transmitted by the structure.
 When the plan of the structure is irregular relative to its outline and load distribution. It would cause
non-uniform settlement if a shallow foundation is constructed. A pile foundation is required to reduce
differential settlement.
 Pile foundations are required for the transmission of structure loads through deep water to a firm
stratum.
 Pile foundations are used to resist horizontal forces in addition to support the vertical loads in earth-
retaining structures and tall structures that are subjected to horizontal forces due to wind and earthquake.
 Piles are required when the soil conditions are such that a washout, erosion or scour of soil may occur
from underneath a shallow foundation.
 In case of expansive soil, such as black cotton soil, which swell or shrink as the water content changes,
piles are used to transfer the load below the active zone.
 Collapsible soils, such as loess, have a breakdown of structure accompanied by a sudden decrease in
void ratio, when there is increase in water content. Piles are used to transfer the load beyond the zone
of possible moisture changes in such soils.

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Classification based on the function:
Based on function or the use, piles may be classified as: -
1. End bearing pile.
2. Friction pile.
3. Compaction pile.
4. Tension pile or uplift pile.
5. Anchor pile.
6. Fender pile and dolphins.
7. Batter pile.
8. Sheet pile.
Classification based on material and composition:
1. Concrete piles:
A. Precast
B. Cast-in-situ
i. Driven piles: cased or uncased.
ii. Bored piles: pressure piles and under-reamed piles.
2. Timber piles
3. Steel piles
A. H-piles.
B. Pipe pile.
C. Sheet pile.
4. Composite pile
A. Concrete and timber.
B. Concrete and steel.
Generally Bored cast-in-situ piles will be discussed as it is being used in A.P.L for construction. Boring
is done by Hydraulic rotary. The bottom of the bore is under-reamed according to their requirements.
After boring, Bentonite (added with water) solution is added in the bore hole to prevent the collapsing
of the soil.
Main reinforcement of 20mm dia. 12 in nos. are being provided to a hole of 500mm dia. Of depth 32m
with a single helical stirrup from top to bottom. After the installation of reinforcement, the tremie
process is being followed which includes a vertical or closely vertical pipe used for the concreting of
the bore hole filled with reinforcement.
PROCEDURE FOLLOWED IN A.P.L FOR PILE CONCRETING (TREMIE PROCESS):

1. The concrete placing shall not proceed if density of fluid near about the bottom of borehole
exceeds 1250 kg/m3.
2. Determination of the density of the drilling mud from the base of the borehole shall be carried out
by taking samples of fluid by suitable slurry sample approved by the engineer in charge, in first
few piles and at suitable interval of piles thereafter and the results recorded.
3. After flushing is completed, tremie head should be removed and hopper should be attached to the
tremie pipe.
4. The slump of the concrete will be maintained at 150 mm to 200 mm.
5. Concreting operation will be carried out using the 200 mm diameter tremie pipes.

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 6. Initial charge of concrete should be given in the hopper using a plug. Total concrete quantity in
the hopper should be more than the volume of the entire pipe plus free space below the tremie.
This will ensure a water tight concrete pouring through tremie.
7. Lifting and lowering is repeated keeping sufficient concrete in hopper all the time. As the
concreting proceeds the tremie pipe are to be removed one by one, taking care that the tremie pipe
has sufficient embedment in the concrete until the whole pipe is concreted. Sufficient head of
concrete shall be maintained to prevent inflow of soil or water in to concrete. Placing of concrete
shall be a continuous process from the toe level to top of pile.
8. The concrete is poured in the hopper. As the concrete reaches the top of the hopper, the plug is
lifted up to allow the concrete to flow corresponding to the placing of each batch of concrete.
9. The concreting of pile is to be done up to minimum of 300 mm above the cut off level to get good
and sound concrete at cut off level.
10. After completion of concreting-tremie, hopper and other accessories are to be washed properly
and kept greased in proper stacking condition near next pile location.

The raising of the vertical pipe is done so that there is no possibility of any jam during pouring of the
concrete.

Approximately about 6 to 7 hours is needed to complete one pile.

TERMINOLOGY:
Allowable load: -
The load which may be applied to a pile after taking into account its ultimate load capacity, group effect,
the allowable settlement, negative skin friction and other relevant loading conditions.
Anchor pile: -
An anchor pile means a pile meant for resisting pull or uplift forces.
Bored cast-in-situ pile: -
A pile formed by boring a hole in the ground by percussive or rotary method with the use of temporary
/ permanent casing or drilling mud and subsequently filling the hole with reinforcement concrete.
Cut-off level: -
It is the level where a pile is cut-off to support the pile caps or beams or any other structural components
at that level.
Diameter of piles: -
Piles of 600mm or less in diameter are commonly known as small diameter piles while piles greater
than 600mm diameter are called large piles. Minimum pile diameter shall be 450mm.
Elastic displacement: -
This is the magnitude of the displacement of the pile head during rebound on removal of a given test
load.
This comprises of two components:
A. Elastic displacement of the soil participating in the load transfer, and
B. Elastic displacement of the pile shaft.

Factor of safety: -

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It is the ratio of the ultimate load capacity of a pile to the safe load on pile.

Gross displacement: -
The total movement of the pile top under a given load.

Initial load test: -

A test pile is tested to determine the load-carrying capacity of the pile by loading either to its ultimate
load or to twice the estimated safe load.
Initial test pile: -
One or more piles, which are not working piles, may be installed if required to assess the load-carrying
capacity of a pile. These piles are tested either to their ultimate load capacity or to twice the estimated
safe load.
Load bearing pile: -
A pile formed in the ground for the transmitting the load of a structure to the soil by the resistance
developed at its tip and / or its surface. It may be formed either vertically or at an inclination (batter
pile) and may be required to resist uplift forces.
If the pile supports the load primarily by resistance developed at the pile tip or base it is called ‘End
bearing pile’ and, if primarily by friction along its surface, then ‘Friction pile’.
Net displacement: -
The net vertical movement of the pile top after the pile has been subjected to a test load and subsequently
released.
Pile spacing: -
The spacing of the piles means the Centre-to-Centre distance between adjacent piles.
Routine test pile: -
A pile which is selected for load testing may form a working pile itself, if subjected to routine load test
up to 1 and 1.5 times the safe load.
Safe load: -
It is the load derived by applying a factor of safety on the ultimate load capacity of the pile or as
determined from load test.
Ultimate load capacity: -
The maximum load which a pile can carry before failure, that is, when the founding strata fails by shear
as evidenced from the load settlement curve or the pile fails as a structural member.
Working load: -
The load assigned to a pile as per design.
Working pile: -
A pile forming part of the foundation system of a given structure.

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Negative skin friction or drag down force: -
When a soil stratum, through which a pile shaft has penetrated into an underlying hard stratum,
compresses as a result of either it being unconsolidated or it being under a newly placed fill or as a
result of remoulding during installation of the pile, a drag down force is generated along the pile shaft
up to a point in the depth where the surrounding soil does not move downward relative to the pile shaft.
Existence of such a phenomenon shall be assessed and suitable correction shall be made to the allowable
load where appropriate.
ABOUT THE PROJECT:
Name of the project: - Piling work for Methanol Unit & offsite for Integrated Methanol and Acetic
Acid Project at Namrup, Assam.
Owner: - Assam Petro-chemicals Limited
Name of the selected Bidder: - M/s Keller Ground Engineering India Private Limited.
Andheri (E) Mumbai
Cost involvement: - Quoted Price Rs. 41, 87, 23,388/-
Evaluated Price Rs. 44, 30, 09,345/-
Time schedule for completion: - Twelve months
Type of piles: - Cast in situ bore piles (Friction Piles)
Method of boring: - Boring with Rotary Rig (Hydraulic)
Diameter of piles: - 0.50 M
Length of the pile: -Type-I-----32 M below cut off level
Type-II-----20 M below cut off level
Length of cut-off: - 1 M from F.G.L (Downwards)
Area of pile: - 0.196 Sq. M
Volume of pile: - 6.28 Cubic M
Number of piles: - Type-I-------2600Nos
Type-II--------600Nos
Designed Load Type-I-------a) Axial- 80 Ton
b) Lateral-3.5 Ton
c) Pull out-15 Ton
Type-II----- a) Vertical-35 Ton
b) Lateral-3.5 Ton
c) Pull out-15 Ton
Grade of concrete: - M-30 (with minimum cement content 400 kg/cum)

CEMENT AND ADMIXTURE

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Type OF Cement used: - Ordinary Portland Cement (OPC 43 Grade)
Type of Admixture used: - SIKA PLASTOCRATE SUPER

REPORT ON CONCRETE MIX DESIGN (M-30):

SAMPLE SUPPLIED BY: - General Manager (Projects)

Assam Petrochemicals Limited, Factory: Namrup
P.O- Parbatpur, 786623, Assam
(Through: Keller Ground Engineering India Pvt. Ltd.)
REF. NO: - BB/MSD-1/Estt-08/2015/231 DATE: -07/03/2017

DESIGN CRITERIA:

1. Characteristic Compressive Strength required in field at 28 days: - 30 MPa

2. Maximum Size of the Course Aggregate: - 20mm
3. Degree of Workability: -160-190mm, as per client guideline
100-150mm, as per IS: 456-2000 for piling works (Cl: 7.1)
4. Compacting Factor: - 0.95
5. Degree of Quality Control: - Good
6. Type of Exposure: - Moderate, as per Table: 3 of I.S: 456-2000

TEST DATA OF THE SUPPLIED MATERIALS:

1. Cement Used: - CCI, OPC 43 Grade
2. Specific Gravity of the Cement: - 3.15 (Standard Value)
3. Specific Gravity of Fine Aggregate: - 2.65
4. Specific Gravity of Coarse Aggregate: - 2.60
5. Specific Gravity of Plasticizer: - 1.145 (Manufacturer’s Value)
6. Initial Setting Time of Cement: - 57 min (minimum 30 min, as per IS: 8112-1989)
7. Final Setting Time of Cement: - 426 min (minimum 600 min, as per IS: 8112-1989)
8. Compressive Strength of Cement at 3 days: - 23.5 MPa (minimum 23 MPa, as per IS: 8112-1989)
9. Compressive Strength of Cement at 7 days: - 33.8 MPa (minimum 33 MPa, as per IS: 8112-1989)

GRADING OF AGGREGATES:

A. COARSE AGGREGATE (10mm Dn):

Sieve Size % Wt. Retained Cumulative % Wt. Cumulative %
(MM) (Gm) Retained(Gm) Wt. Passing(Gm)
20 0 0 100
12.5 9 9 91
10 14 23 77
4.75 74 97 3

OTHER TESTS:

Flakiness Index=17%
Crushing Value=34%
Deleterious material= Nil
Specific Gravity= 2.56
A. COARSE AGGREGATE (20mm Dn):
Sieve Size % Wt. Retained Cumulative % Wt. Cumulative %

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 (MM) (Gm) Retained(Gm) Wt. Passing(Gm)
40 0 0 100
20 48 48 52
10.00 52 100 0
4.75 0 100 0

OTHER TESTS:
Flakiness Index=8.36%
Crushing Value=34%
Deleterious material= Nil
Specific Gravity= 2.60
B. Combined grading using 20%20mm Dn. And 80%10.0mm Dn. CA supplied:
Sieve Size Percent passing Grading requirement Remark
(mm) (As per IS: 383-1970;
Cl: 4.1 & 4.2) for
graded aggregate of
20mm nominal
maximum size
40 100 100 Nearest possible
20 90.4 95-100 Combination to the
10 61.6 25-55 Grading requirement
4.75 2.4 0-10 achieved

C. FINE AGGREGATE:
Sieve Size % Wt. Cumulative % % Passing % Passing for Comment
Retained Wt. Retained Grading
(Gm) zone III
4.75mm 0 0 100 90-100 Sand
2.36mm 0 1 99 85-100 Conforms to
1.18mm 3 4 96 75-100 Zone-III,
600micron 26 30 70 60-79 As per
300micron 58 88 12 12-40 I.S: 383-1970
150micron 17 95 5 0-10

OTHER TESTS:
Silt content= 1.0%
Specific gravity= 2.65

TARGET MEAN STRENGTH OF THE CONCRETE AS PER IS: 456-2000:

Target strength (fck’) = Ch. Strength (fck) + k x Standard Deviation (s)*

= 30 + 1.65*5.0
= 38.25 MPa
(*The values of standard deviation is taken from table: 1 of I.S: 10262-2009)
Selection of Water-Cement Ratio:

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Three different trails are done by selecting water-cement ratio as 0.35, 0.37 and 0.39, which are less
than 0.45; hence O.K.
But the final selection is done according to 0.39.
So, the data’s provided below are based on the water-cement ratio as 0.39.

Selection of Water Content:

From Table: 2 of I.S: 10256-2009, for 20mm nominal maximum size of coarse aggregate;
Water content per m3 of concrete= 186kg = 186Lit.
Estimated water content for 190mm slump= 186 + 0.168 x 186= 217.2Lit.
As super plasticizer is used, let us reduce water content by 20%
Estimated water content= 217.2 x 0.8= 173.8Lit.
Cement Content:
W/C ratio= 0.39
Water= 173.8Lit.
Hence, Cement Content= (173.8/0.39)= 445.64Kg > 400Kg, Hence O.K.
Coarse Aggregate and Fine Aggregate Content:
From Table: 3 of I.S: 10262-2009, volume of coarse aggregate per unit volume of total aggregate
corresponding to 20mm nominal max. Size, fine aggregate of zone III and with a water-cement ratio of
0.5= 0.64
However, in the present case; since the water-cement ratio is 0.39, hence increasing the volume of C.A.
proportionally (@-/+ 0.01 per +/-0.05 change in W/C ratio); we get,
Proportion of volume of C.A. per unit volume of total aggregate= 0.662
For pump-able concrete reduce coarse aggregate by 10%= 0.662 x 0.9= 0.596
Therefore proportion of volume of F.A. per unit volume of total aggregate= 1-0.596= 0.404
Mix Calculation:
a) Volume of concrete= 1 m3
b) Volume of cement= Mass of cement/ (Sp. Gravity of cement x 1000)
= 445.64/ (3.15 x 1000)
= 0.141 m30
c) Volume of water = Mass of water/ (Sp. Gravity of water x 1000)
= 173.8/ (1.145 x 1000)
= 0.174 m3
d) Volume of chemical admixture @1.5% of mass of cement material
=6.68/ (1.145 x 1000)
=0.0058 m3
e) Volume of all-in-aggregate= 1- (0.141+0.174+0.0058)
= 0.679 m3
f) Mass of C.A. = (Volume of all-in-aggregate x proportion of volume of C.A. per unit volume of total
aggregate x Sp. Gravity of C.A. x 1000)
= (0.679 x 0.596 x 2.65 x 1000)
= 1052.2 Kg
g) Mass of F.A. = (Volume of all-in-aggregate x proportion of volume of F.A. per unit volume of total
aggregate x Sp. Gravity of F.A. x 1000)

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 = (0.679 x 0.404 x 2.65 x 1000)
= 726.94 Kg
Mix Proportions:
Water-Cement ratio = 0.39
Water = 173.8 Kg
Cement = 445.64 Kg
Fine Aggregate = 726.94 Kg
Coarse Aggregate = 1052.2 Kg, (20mm Dn= 210.44 Kg; 10mm Dn= 841.76 Kg)
Plasticizer = 7.05 Kg
Summary of proportions:
Water Cement F.A C.A. (In Kg) W/C Plasticizer
Trail No. (liters) (Kg) (Kg) 20mm 10mm Ratio (Kg)
Dn Dn
1 Quantity per m3 173.8 496.6 696.56 207.58 830.32
of concrete 0.35 7.45
Proportion --- 1 1.40 2.09
2 Quantity per m3 173.8 469.73 711.1 209.3 837.2
of concrete 0.37 7.05
Proportion --- 1 1.51 2.23
3 Quantity per m3 173.8 445.64 726.94 210.44 841.76
of concrete 0.39 6.68
Proportion --- 1 1.63 2.36

Tests for Compressive Strength:

Grade of Target Water-

Concrete Strength cement Concrete Compressive Strength Observed
N/mm2 ratio proportion Slump
At 7 days At 28 days
(N/mm2) (N/mm2)
0.35 1.0: 1.40: 2.09 26.94 80
M30 38.25 0.37 1.0: 1.51: 2.23 25.13 Results 115
0.39 1.0: 1.63: 2.36 23.76 awaited 140

SO THE FINAL PROPORTION OF THE MIX DESIGN M-30 IS AS FOLLOWS:

MATERIALS REQUIRED PER BAG OF CEMENT (50 Kg)

WATER CEMENT F.A. C.A (I) C.A. (II)
19.5 Lit. 50 Kg 81.5 Kg 23.6 Kg 94.4 Kg
0.39 1.0 1.63 0.472 1.888

To obtain 160-190 mm slump add Plasticizer @1.5% by weight of cementitious material.

Pile load test:

Three different tests are being conducted in A.P.L on 6 test piles.
Table 2: Number of Piles in different tests.

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 NAME OF THE TEST NO. OF PILES
VERTICAL LOAD TEST 3
LATERAL LOAD TEST 2
PULL-OUT TEST 1

The tests shall be performed at the cut-off level only.

A detailed report for the test result is prepared.

Vertical Load Tests on Piles:

This test will be carried out as stipulated in IS-2911 (Part IV) 1995.

Pile Head: – The pile head shall be chipped off till sound concrete is met wherever applicable. The
reinforcement shall be cut and head levelled with Plaster of Paris. A bearing plate with a hole shall be
placed on the head for the jack to rest.

Reaction: - Kentledge shall be suitably designed to get the desired reaction on the piles. Anchor piles
(if required) shall be placed at a Centre to Centre distance of 3 times the pile diameter subject to a
minimum distance of 2m.

Settlement: - 2 dial gauges for a single pile and 4 dial gauges for a group of piles with 0.01 mm
sensitivity shall be used. They shall be positioned at equal distance around the piles on datum bars
resting on immovable supports at a distance of 3D (min. of 1.5m) where D is the diameter of pile or
circumscribing circle for non-circular piles.

Application of load: - It shall be applied as specified depending on the type of test (routine / initial).
Each load shall be maintained till the rate of displacement of the pile top is either 0.1 mm in the first 30
minutes or 0.2 mm in the first one hour or 2 hours whichever occurs first. The next increment in the
load shall be applied on achieving the aforesaid criterion.
The test load shall be maintained for 24 hours.

Initial Tests: – The safe load on a single pile shall be the least of the following:
(i) 2/3rd of the final load at which the total displacement attains a value of 12 mm unless otherwise
required in a given case on the basis of nature and type of structure in which case, the safe load should
be corresponding to the stated total displacement permissible.
(ii) 50% of the final load at which the total displacement equals 10% of the pile diameter in case of
uniform diameter piles or 7.5% of the bulb diameter in case of under reamed piles.

Routine Tests – Acceptance

The maximum settlement at test load should not exceed 12 mm.
Lateral load tests on piles:

The jack should be placed horizontally, between two piles. The load on the jack shall be the same on
both the piles. The load will be applied in increments of 20% of the estimated safe load and at the cut
off level. The load will be increased after the rate of displacement is nearer to 0.1 mm per 30 minutes.
If the cut-off level is approachable, one dial gauge exactly at the cut-off level shall measure the
displacement. In case the cut-off level is not approachable, 2 dial gauges 30 cm apart vertically, shall
be set up and the lateral displacement of the cut-off level calculated by similar triangles.

The safe load on the pile shall be the least of the following:
a) 50% of the final load at which the total displacement increases to 12 mm.
b) Final load at which the total displacement corresponds to 5 mm.

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Pull-out tests on piles:

A suitable set up shall be designed to provide an uplift force to the piles. The load increments and the
consequent displacements shall be as per the case of a vertical load test.

The safe load shall be the least of the following:

a) 2/3rd of the load at which the total displacement is 12 mm or the load corresponding to a specified
permissible lift.
b) Half of the load at which the load displacement curve shows a clear break.
Integrity tests on piles:
Piles Integrity Testing is quick and simple method and it enables number of piles to be tested in a
single working day. This method provides information about continuity, defects such as cracks,
necking, soil incursions, changes in cross section and approximate pile lengths (unless the pile is very
long or the skin friction is too high). Integrity tests provide an indication of soundness of concrete but
they should be undertaken by persons experienced in the method and capable of interpreting the results
with specific regard to piling.
In piles integrity test, a small metal / hard rubber hammer is used to produce a light tap on the top of
the pile. The shock travels down the length of the pile and is reflected back from the toe of the pile and
recorded through a suitable transducer / accelerometer (also held on the top of the pile close to the point
of impact) in a computer disk for subsequent analysis.
The primary shock wave which travels down the length of the shaft is reflected from the toe by change
in density between the concrete and the sub strata. However, if the pile has any defects or discontinuities
within its length these will set up secondary reflections which will be added to the return signal.
By a careful analysis of the captured signal and a knowledge of the conditions of the ground, age of the
concrete etc. a picture of the location of such problems can be built up.
Normally more than one recording of signals is done until repeatability of signals is achieved. In case
of large diameter piles, the tests are conducted at 5-6 places to cover the entire section of the pile.
General Requirements of the piles integrity tests:
(i) Pile shall be trimmed to cut off level or sound concrete level before the test with all laitance
removed.
(ii) The area surrounding the pile should be free from standing water and should be kept dewatered
during the tests.
(iii) The cast in situ piles should not normally be tested before 14 days of casting.
(iv) The test piles, if available at site can be used for determination of pulse velocity and characteristic
or reference signal generated. This can also be done from those piles whose depth is accurately
recorded.
This method is not generally recommended by Indian Standards codes.

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 4. MAINTENANCE
Maintenance is the process of maintaining or preserving someone or something, or the state of being
maintained.
A.P.L generally use to do maintenance works such as Building, Road, etc. in their colony.
A. Building maintenance
INTRODUCTION
Building Maintenance is work undertaken to keep, restore or improve every facility i.e. every part of a
structure or building.
The objective of maintenance is: -
(i) To preserve building and services, in good operating and habitable condition.
(ii) To ensure safety of the occupants or the public at large.
(iii) Where so required to Upgrade, renovate, retrofit the facilities to improved specifications and
standards.
Maintenance aims at effective and economic means of keeping the building and services fully utilizable.
It involves numerous skills as influenced by occupancy and the performance level expected of a
building.
The repair works are classified in under mentioned categories:
1. Day to day repairs / service facilities
2. Annual repairs including preventive maintenance
3. Special repairs

Modalities of maintenance
The maintenance works are undertaken through one of the following: -
i. Directly employed labour
 Departmental labour
Departmental labor are the skilled employees of department who serves the department for their
whole life.

 Casual labour
Casual labour are employed for getting the work done departmentally for short periods generally
not exceeding a month at a time and for a specific item of work.

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ii. Through Contracts:
a. Contracts for specific works
b. Comprehensive Outsourcing
The annual repair work, and Retrofitting and Upgradation works and works of Security are generally
carried out through contracts.
Whether the work should be carried out through contract or own work force is decided on the nature of
the following: -
(a) Type of work
(b) Amount of work
(c) Expediency or urgency.

Work charged establishment: - The cost of establishment due to workers such as their pay, allowances
etc. are directly charged to the maintenance work and hence they are called work charged establishment.
Cleanliness in the Colonies
Cleanliness will be maintained in the colonies. It will be ensured, in all kinds of maintenance that after
day's work, debris is collected from the work place and deposited at suitable identified spots, where
residents / users do not throw garbage on it. Suitable provision will be made for disposal of malba on
continuous basis, so that the same is not allowed to accumulate / pile up and create unhygienic and
unsightly conditions.
Any leakage from the water supply line, sewers or unfiltered water supply line noticed in the colonies
will be repaired immediately. Water will not be allowed to stagnate on the roofs, roadside to act as
breeding place for mosquitoes. All precautions should be taken to keep the colonies neat and clean. In
case unhygienic health hazardous conditions are noticed in the portion of areas/service maintained by
local bodies, the same will be reported to them and pursued for action. Overhead tanks will be provided
with lockable covers and Mosquito proof couplings. The occupants will be advised against storage of
water in coolers not in use and apply Mosquito repellents in the Cooler's pads etc. to check spread of
Malaria.
Monitoring of maintenance
For effective maintenance and achieving client satisfaction it is necessary to monitor the maintenance
complaints at various levels.
Day to day and annual repairs
The works which are to be attended on the day to day basis such as removing chokage of drainage pipes
,manholes, restoration of water supply, repairs to faulty switches, watering of plants, lawn mowing
,hedge cutting, sweeping of leaf falls etc. are attended under day to day service facilities.
SPECIAL REPAIR
Works undertaken under special repairs: -
(i) White Washing, Colour washing, distempering etc., after completely scrapping the existing
finish and preparing the surface afresh.
(ii) (ii) Painting after removing the existing old paint from various members.
(iii) (iii) Provision of water proofing treatment to the roof. All the existing treatments known are
supposed to last satisfactorily only for a period of about ten years.
(iv) Repairs of internal roads and pavements.
(v) Repairs / replacement of flooring, skirting, dado and plaster.
(vi) Replacement of doors, window frames and shutters. Replacement of door and window fittings.

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 (vii) Replacement of water supply and sanitary installation like water tanks, WC cistern, Wash
basins, kitchen sinks, pipes etc.
(viii) Shifting of any garden feature from one site to another within building.

The building services fixtures including internal wiring, water supply distribution system etc. are
expected to last for 15-20 years. There afterwards it may be necessary to replace them after detailed
inspection.

Register of special repairs

This register shall be maintained. Complaints of special nature repairs, which cannot be attended on
daily basis, shall be transferred to this register. The special repairs to buildings shall be divided in
following Seven groups:-
(i) Concrete work.
(ii) Masonry works including plaster, flooring and brick work.
(iii) Wood work.
(iv) Steel work.
(v) Sanitary and Water supply.
(vi) Water proofing treatment.
(vii) Electrical wiring and fittings.

B. Road maintenance
INTRODUCTION
Road maintenance is a routine work performed to upkeep pavement, shoulders and other facilities
provided for road users, as nearly as possible in its constructed condition, and at least at an adequate
level of serviceability. Even with the highest possible quality of construction, maintenance is essential
to get optimum service from the pavement structure during its life period. All pavements require
maintenance as they are subjected to traffic and environmental effects. Maintenance helps in preserving
the pavement surface, and thus postpones the need for costly investments in rehabilitation.

The routine maintenance standards shall meet the following requirements:

I. Potholes on the road surface to be repaired soon after these appear or brought to his notice either
during Contractor’s monthly inspection or by the Engineer.
II. Road shoulders to be maintained in proper condition to make them free from excessive edge drop
offs, roughness, scouring or potholes.
III. Cleaning of surface drains including reshaping to maintain free flow of water
IV. Cleaning of culverts and pits for free flow of water.
V. Any other maintenance operation required to keep the road traffic worthy at all time during the
maintenance period.

Various work items for Routine Maintenance are listed below:

a. Clearing/re-shaping of road side drains.
b. Pothole filling (WBM & BT).
c. Filling up edges of asphalt surface.

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d. Dressing of berms, earth work on berms, rain cuts and dressing of earthen embankment.
e. Refixing displaced guard stones, White washing guard stones, parapets of CD works.
f. White washing and Geroo painting of trunks of trees.
g. Cutting of branches of trees etc. obstructing flow of traffic and line of sight, and cleaning
wild growth on berms.
h. Topping of W.B.M. blindage including picking of loose metal.
i. Maintenance of catch water drains.
j. Filling up local depressions, ruts, potholes and erosion control.
k. Repairing damaged edges.

Steps involved in maintenance of roadwork in A.P.L (as per SOR for Rural Roads for all divisions
under PWRD, Assam 2016-2017) are: -
1. Scarifying existing granular surface to a depth of 50mm by manual means.
2. W.B.M (subbase / base) grading 1: - using stone screening Type-A 13.2mm.
Providing, laying, spreading and compacting stone aggregates of specific sizes to water bound macadam
specification including spreading in uniform thickness, hand packing, rolling with three wheel 80-
100KN
Static roller in stages to proper grade and camber, applying and brooming, stone screening / binding
materials to fill-up the interstices of coarse aggregate, watering and compacting to the required density
Grading 1 as per technical specification clause 404.(by manual means)

3. Tack coat
Providing and applying tack coat with bitumen or emulsion (CRS-1)
Using emulsion distribution at the rate of 0.25 to 0.30kg per Sq. m on the prepared dry and hungry
bituminous surface cleaned with hydraulic broom as per technical specification clause 503.
4. Mix seal surfacing
Providing, laying and rolling of close graded premix surfacing material of 20mm thickness composed
of 11.2mm to 0.9mm (Type-A) or 13.2mm to 0.9mm (Type-B) aggregates using penetration grade
bitumen to required line, grade and level to serve as wearing course on a previously prepared base,
including mixing in a suitable plant, laying and rolling with a three wheel 8-10KN static roller and
finishing to required level and grades as per technical specification clause 509.
5. Seal coat
Providing and laying seal coat sealing the voids in a bituminous surface laid to the specified levels,
grade and cross fall using Type-A, Type-B and Type-C as per technical specification clause 510.
A. By manual measure
Case-1: Type-A (11.2mm to 2.36mm)
Bitumen (S-65)

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 5. CONCLUSION
 A very hearty thanks to our Asst. Prof. Binanda K. Nazary Sir for sending us to this Industrial
Internship.

 We conclude that while going through the entire industrial visit, the cooperation is found to be
very well organized, developed & most ideal industry in every walk of its production,
administration & management aspects.

 We extend our heartiest thanks to ASSAM PETROCHEMICAL LIMITED for allowing us for
this Industrial Training.

 We want to thank to Mr. Jayanta Sharma, Mgr. Civil (Proj.), Mr. Riju Phukan, Dy. Mgr. Civil
(Maint.), Mr. Prasanta Hazarika, Asst. Mgr. Civil (Proj.), Mr. Dimbeshwar Chetia, Eng. Civil
(Maint.), Mr. Kaustov Hazarika, Jr. Eng. Civil (Maint.) and Mr. Nipon Saikia, Jr. Eng. Civil
(Proj.) for guiding and sharing information about organization profile, On-going Project,
maintenance process at A.P. L.

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