This is a Project Report of one month Summer Training Program held in a Steel Company

which undergoes Modernization bcoz of the old age of existing plant.

Modernization consists of building a totally new plant to increase the production to 2.5
mtpa previously which is less than 1 mtpa.

In Modernization 15 different construction company of India and 3 companies from

foreign involved with 0ne consultant company to built theses:-

Blast Furnace, Coke oven Battery: 02, by product plant, Sinter

plant, Coal & coke Handling plant, Ore handling plant, Wagon tippler: 03, Track hopper:
01, Silos, Converter, Pipe conveyor, Rolling mills & a no of conveyor and con veyor tracks.

The costs of these are estimate as 12742.77crs of Indian rupees but it is exceeded as
17,000crs. during middle age of completion.

Some important details are listed below:-

All Foundations are ?
(more than 30,000 piles).

The average depth of one pile is within 25 mtr to 30 mtr.

? 
  26 Months

  
  
  7th Mar-2008

  
 
  6th May-2010

?   

Y 1 x 7 M Tall Green Coke Oven Battery (74 Ovens).
Y 2 x 204 M2 Sinter Machines (For 80% Sinter Charge).
Y 1 x 4060 M3 (Useful Volume) Blast Furnace with Top Pressure Recovery
Turbine.
Y 3 x 150 Ton Basic Oxygen Furnace Converter.
Y 2 x 6 Strand Billet Casters.
Y 1 x 4 Strand Beam Blank / Bloom Caster.
Y 1 x 0.6 Mtpa Heavy Section Mill.
Y 1 x 1.25 Mtpa Wire Rod & Bar Mill.
Y Pipe conveyor of length app. 1.5 km
Y 12 blending bunkers of dia. 12 mtrs.
Y 3 wagon tippler and one track hopper.
|

Y
9    
´Y Project Details : Details of packages, contractual information, material
requirement etc.
´Y Work Method : Explain how construction works proceeds
´Y Manufacturing of Concrete : Explain the procedure of concrete
manufacturing.
´Y Foundation : information regarding foundation, especially about piles.
´Y Site visited :-
îY Pipe conveyor
îY Blending Bunkers
îY Wagon tippler
îY Track Hopper
îY Sinter Plant
îY Coke oven & By-product plant
îY Blast furnace

?



| ?
9
9


The steel company has envisaged enhancement of crude steel production capacity by 2.5
MTPA.

In the 2.5 MPTA new stream expansion, all raw material required for the Blast Furnace,
Sinter Plant, Coke Ovens, Lime/Dolomite calcinations plant as well as interplant
transportation of finished sinter, coke, fines generated in coke ovens & Blast Furnaces
etc shall be covered in the following four packages:

1.Y Package - 01A: Ore Handling Plant (OHP)

2.Y Package ² 01B: Coal & Coke Handling Plant
3.Y Package ² 01C: Base Mix Preparation Plant (BMP)
4.Y Package - 01D: RMHS yard Machines
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Y
 Insurance 3.14 3.05
Total (INR Crs) 579.00 528.07
Guranteed VAT/Cenvat
74.46 70.57
INR (Crs)

  26 Months

  
  
  7th Mar-2008

  
 
  6th May-2010

"  #
$?  12 Months from Contractual Finish date

| % $ :

?|?| 9 


     
% $ % $ % $

Earth work Cum 190000 105725 295725

Back filling Cum 108533 87396 195929

Disposal Cum 46291 18264 64555

PCC Cum 16444 5894 22338

RCC Cum 32010 28209 60219

Grade slab Sqm 14917 25787 40704

Shuttering Sqm 92420 90911 183331

Reinforcement MT 11654 583 17387

Brick work Cum 3788 4786 8574

Inserts & Foundn

434 298 732
Bolts MT

Piling (750 and 550

3621 3329 6950
dia) Nos

MT 9714 17240 26954

Structural Steel


Y
 Work

CGI Sheeting Sqm 69123 69529 138652

Equipment Works MT 5380 5547 10927

| "&

% $

   
?| ?|

Transfer Points 24 26

Process Buildings 7 7

W/T Complex 1 -

6343 M
6648 M long
Belt Conveyors long
57 Nos.
55 Nos.

Pipe Conveyor, 600 TPH 1320 M

-
Ore long. 1 No.

Pipe Conveyor, 200 TPH, 1450 M

-
Coke long, 1 No.

    ?| ?|

O/G 450M, O/H 1388 M,

Double Conveyor
O/H 850 M O/G 500 M

O/G 400 M,
O/H 3539 M,
Single Conveyor O/H 2750
O/G 603 M
M

Pipe Conveyor 1450 M long -

¦
  
Y
 Tall TPs 4 10

Small TPs 26 16

5 x 335 M 2 x 225 M
S/R Foundation
long long

2 x 225 M
B/R Foundation -
long

W/T Complex 1 No. -

Bunker Buildings 3 5

Crusher House 2 2

Screen House 2 1

è
  

Work Methods is the methods or a schedule according to which any construction

work takes place. This can be divided in following categories:

1.Y Survey and setting out

2.Y Excavation

3.Y Cast in-situ piling works

4.Y Reinforced Cement concrete

5.Y Back filling

6.Y Structural base grouting

7.Y Plain cement concrete

| '$   

 

Y
 1.Y The site shall be cleared from all temporary obstacles which may hinder the

progress of survey.

2.Y Initial survey will be conducted including closing of transverse and coordinates will

be marked on top of grid pillars of permanent nature which will be constructed at

site at suitable locations.

3.Y A layout plan for grid pillar shall be made.

4.Y Benchmark will also be shifted from reference grid pillar at suitable points (of

permanent nature) near the location of work to facilitate the work. 

5.Y A detail for the same will be prepared.

 (!'  

1.Y In case of mechanical excavation, care shall be taken to keep the level of

excavation suitably 150 mm above desired level. This is required not to disturb the

soil ground lying underneath. The final level is achieved by manual dressing.

2.Y Proper slope shall be maintained in the sides to hold the face of earth.

3.Y Care shall be taken to protect underground pipelines, electrical cables, drains and

other existing utilities.

4.Y Dumping of excavated soil shall not be made within 1m from edge of excavation.

5.Y If required, dewatering shall be done. Area barricading, area lighting, suitable

warning signs, proper approach ways shall be made.

6.Y After excavation, correct bottom level shall be checked as per the drawing and

shall be recorded.

ë    
)

1.Y Casing pipe driving

a.Y Pile points are to be fixed on the ground by surveyor as per approved

drawing.

b.Y Site engineer will check the point with reference to adjacent pile points

c.Y The rig is centered properly in line with pipe point vertically.
ÿ

Y
 d.Y Boring is done over pile point with regular use of water.

e.Y When the first casing is installed the horizontal displacement and verticality

of casing pipe is checked.

f.Y As boring progresses, different lengths of casing pipes are fixed.

2.Y Reinforcement

a.Y Check reinforcement cage be as per the drawing.

b.Y The pile bore shall be free from slush.

c.Y Stiffener ring and laps shall be welded.

d.Y Reinforcement cage shall be lowered in the pile bore.

e.Y 40mm PVC pipe of required number are fixed with the reinforcement during

cage lowering. It is ensured that water is filled in it.

3.Y Pile Concrete

a.Y Concrete with details ² M25, w/c ratio of 0.5, 400kg/cum is used.

b.Y Concreting is done by tremie pipe.

c.Y Casing/Tremie shall be extracted in stages by push & pull method followed by

moderate tapping of it after attaining sufficient height of concrete in the

casing. Care shall be taken that concrete shall not exceed the 25% of pile

length.

d.Y Check the theoretical and actual volume of concrete poured.

e.Y Concreting shall be stopped until it reaches 750 mm above cut-off level.

4.Y The balance depth to be filled by slag.

 * "+   

1.Y Survey

a.Y Centre line and edge line of foundation shall be transferred over base

concrete from already established reference along with reference reduced

level.

2.Y Reinforcement

·
  
Y
 a.Y Reinforcement shall be as per BBS, which is prepared as per AFC drawing.

b.Y Before concreting, dia of bars, spacing between bars, correct bends, proper

laps, curtailment of bars, type of binding wire, chairs kept in proper position,

fixing of adequate number of cover blocks are to be checked and necessary

details are to be entered in format.

c.Y Reinforcement shall be free from dirt, rust, mud and oil.

3.Y Staging and form working

a.Y Staging where required will rest on firm ground and will be well anchored.

b.Y Formwork will be designed so as to take the load of concrete poured.

c.Y Formwork shall be in line level and plumb and shall be free of holes and gaps.

d.Y Approved shuttering oil will be applied before placing of reinforcements.

e.Y Embedded items like foundation bolts and inserts will be fixed/welded to

proper line and level as per AFC drawing.

f.Y Top level (finished) of concrete will be marked with leveling instrument.

4.Y Concreting

a.Y Mix design is to be established beforehand as per drawing, specification and

relevant IS codes and approved by client.

b.Y Concrete of required grade and workability would be poured within specified

time.

c.Y For placing concrete in a slope placing will start at the bottom and move

upwards.

d.Y The vibrator needle should penetrate the layer of conc rete vertically and

into the under lying layer previously placed and vibrated if possible.

e.Y Vibrator will be withdrawn slowly so as to fill up the pocket resulting from

insertion.

f.Y Vibrator will be stopped when the concrete flattens and takes glistening

shape.

]
  
Y
 g.Y Top level of the concrete will be ensured and finished suitably.

h.Y Fresh concrete will be sampled for workability and cube testing.

i.Y Pour card is to be maintained for each pour.

5.Y Removal of formwork

a.Y Formwork will be removed after minimum period as per IS 456.

b.Y All blemishes and defects if any will be suitably rectified.

6.Y Curing

a.Y Potable water will be used for curing.

b.Y Curing will be carried out as per IS 456

c.Y For formed surfaces curing will start as soon as formwork is removed.

¦ "



1.Y Material used for earth filling will be free from clods greater than 75mm in any

direction, organic matter and other deleterious materials.

2.Y All clods of filling material shall be broken or removed if the filling material shall

contain deleterious materials and the same shal l not be used.

3.Y The spaces all around the foundation will be cleared of all debris, bricks etc

4.Y Filling shall be done in layers and each layer shall be moisture conditioned and

consolidated using mechanical means.

5.Y Wherever vibro-hammer cannot be put to use due to space constrain, hand

ramming with crow bar shall be carried out at each layer of filling.

6.Y The surface of consolidated surface shall be dressed to required level and slope.

7.Y Compaction shall be done as per specification.

8.Y Field compaction test may be done by core cutter test method.

    
# 

1.Y Before grouting concrete pedestal should be rough, clean and made thoroughly wet.

2.Y All pockets for anchor bolt shall be clean and excess water removed.

|
   
Y
 3.Y After mechanical clearance, free flowing grou ting mixture shall be poured

continuously till required thickness is obtained as per the drawing.

4.Y Remove the formwork after 24 hrs and cure surface.

ÿ ?
 +   


1.Y Preparation of bed and maintaining the level and line as per drawing and

specification.

2.Y Fixing of side shutters to required height and checking the centreline of the

foundation.

3.Y Maintaining PCC top-level as per drawing/checking with levelling instrument/and

maintaining the required thickness of PCC.

4.Y The concrete shall be made by adopting nominal concrete mix with proportions of

materials as specified in customer·s specification

5.Y Placing the concrete in specified area and tamping with metal/wooden tamping tool

and finishing with trowel.

6.Y Checking the final finish level and maintaining the record as per the spec.

7.Y Curing shall be done later.

  
  
 

9



9 

 9

a)Y BATCHING
b)Y MIXING
c)Y TRANSPORTING
d)Y PLACING
e)Y COMPACTING
f)Y CURING
g)Y FINISHING

||
   
Y
  G
9- Me surement of different m teri ls for m king concrete is known s
B tching

METHODS OF BATCHING

Y Volume Batching ² In this method the materials are measured by it·s volume.
b)YWeigh batching ² In this method the materials are measured by it·s weight.

NOTE

For most of the purposes weigh batching is preferred over volume batching because
of the following reasons

1)Y It is difficult to measure granular material in terms of volume.

2)YVolume of a moist sand in a loose condition weighs much less than the same
volume of compacted sand.
3)YAmount of solid granular material in a cubic meter is indefinite.

9

9G
9?
9

In this plant operator has to press only one or two buttons to put into motion the
weighing of all the materials, the flow of each one can be cut off when the correct
weight of material is reached. These automated plants are electrically operated on a
punched card system. In some of weighing batching equipments, recorders are fitted
which graphically record the weight of each material, which are further delivered to a
batch.

îY Water is measured by installing water meters to the main line to the mixer
through which exact quantity is supplied.

îY In modern batching plants sophisticated automatic microprocessor

îY Controlled weigh which measures both aggregate and water.

# ,-, 

MACHINE MIXING

In most of the batching plants machine mixing is used ie for mixing machine is
used.

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Process of expelling the entrapped air from the concrete. Lower is workability higher is
the air entrapped. If air does not loose than it will decrease the strength and air voids
are left which reduce the strength.

METHODS FOR COMPACTION

a)Y Hand Compaction

îY Roding
îY Ramming
îY Taming
b)YCompaction by vibration
îY Internal vibrator
îY Formwork vibrator
îY Table vibrator
îY Platform vibrator
îY Surface vibrator
îY Vibratory roller
c)Y Compaction by Pressure and Jolting
d)YCompaction by Spinning

" *,

It is defined as the process for keeping the concrete moist and warms enough so that
the hydration of cement continues. It may be described as the process of maintaining
adequate moisture content and temperature of concrete.

CURING METHODS

îY Water curing
îY Membrane curing
îY Application of heat
îY Miscellaneous

 ,,3,

|¦
   
Y
It is the final step. Finishing is not required for all the concrete operations like for
beam concreting and it is required for flooring, road pavement for these careful
finishing is required.

Surface finishes may be classified under as following

a)Y Formwork finishes
b)YSurface treatment
c)Y Applied finishes

  

It is part of structure which transmits the weight of the structure to the ground. All
structures are constructed on land is supported by foundation and therefore it may be
known as connecting link b/w structure and ground. The foundation should designed such
that -

1)Y Soil below does not fail in shear

2)YSettlement is within the safe limits



9



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 9)YCover blocks are provided on the lateral stirrups which are on the outer face of
vertical reinforcements & on the inner face of vertical reinforcements stiffeners
are provided in the form of rings.

10)Y Now the treme pipe is entered within the reinforcement cage for pouring the
concrete from the transit concrete mixer.

11)YProper greasing of the thread is done for the treme & casing.

12)Y The concrete is poured & at the same time the treme pipe is lifted.

13)Y Concrete required for these types of piles is about 0.2 m 3 per meter depth
of the pile.

14)Y Concrete is made to flow above the pile & fresh concrete must be above the
pile cutoff level.

15)Y Dowel bars projecting from piles shall be 100mm beyond the pile cut off
level.

16)Y Now the treme pipe is removed & excavation of the casing should be done
preventing necking or shearing of the concrete .

17)Y Precaution must be taken so that the spacing of the piles is more than 2.5D
(where D is the diameter of the pile).

18)Y Pile cut off level is 50mm above the bottom of the bottom of the pile cap.

?99

Ñ
-

Th Ñ
 of hs s s was o as
r an f h pls wr wll formd and
ha h dsr lng h.

Th followng s s ar prformd on pls -

)Y ? I   T :- 10% of h wok p  o b  d fo h  . A

pob   d houh h pp ud fo u aoc   of h p. Th
homo  of h coc  &   pop  a kow fom h  . Ao
h dp h  ao maud u h  fo wok p.

)Y ? Load T (A p I{: 2911 ?a 4-1985):- Fac o of af  fo h  
1.5.Th compv oad o b  d fo ach p  100KN fo 550mm &

|]
   
Y
 120KN for 600mm during working conditions & tested for a factor of safety of
1.5.

iii)Y Latera Load Test:- The atera oad to be resisted for each pie is 5KN for
550mm & 6KN for 600mm during working conditions & tested for a factor of
safety of 1.5.

iv)Y ?u Ñut Test:- The atera oad to be resisted for each pie is 30KN for 550mm
& 35KN for 600mm during working conditions & tested for a factor of safety of
1.5.


??   


We also witnessed the pipe conveyor are which falls under Raw Material Handling

System. The following were the Technical details of pipe conveyor-

1.Y Type of Foundation ² Piling

2.Y Total nos of Piles ² 168nos

3.Y Total length of Pipe Conveyor ² 1560.941mtr

4.Y Dia. of Conveyor pipe ² 300mm

5.Y Total RCC ² 1091 cubic mtr

6.Y Thickness of belt :- Top ² 06mm

Bottom ² 06mm

7.Y Belt width ² 1100mm

Speed ² 2.5m/s

Speed ² 2.75m/s (for crusher house)

8.Y Gallery :- 59nos :- span of 20 mtr ² 53 nos

span of 16 mtr ² 03 nos

span of 12 mtr ² 03 nos

9.Y Bridge :- 04nos :- span of 50mtr [T1-T2]

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 span of 32mtr [T5-T6]

span of 52mtr [T31-T34]

span of 61mtr [T47-T50]

10.Y Total no of Trestle :- 64nos

Two Leg Trestle - 39 nos.

Four Leg Trestle - 25 nos.

11.YFor iron ore:- total length ² 1329mtr

CP3 to KTP2

Capacity - 200tph

12.Y For coke:- total length ² 1450mtr

Cp3 to ktp1

Capacity ² 600tph

13.Y Weight :- Conveyor Gallery ² 490.229mt

Trestle - 303.009mt

Portal frame - 101.969mt

Bridge - 205.574mt

TÑTALWT. - || ¦mt

14.Y Total nos of Idler frame ² 4146 nos (without bridge)

15.Y Total nos of Idler ² 24876nos

16.Y Total nos of welding machine working - 12nos

  
 
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Y The pipe conveyor resembles a troughed belt conveyor at its tail end where the

material is loaded.

Y Thereupon the belt is made to pass over a series of transition idlers of varying

troughing angles to form the pipe shape.

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Blending bunkers otherwise known as silos used to temporarily store coal in raw material
handling system. This looks same as general bunkers except its foundation start from
ground level.

This area also falls under Raw Material Handling System. The following things were seen
at silos ²

îY The main foundation was Pile Foundation.

îY Over the pile foundation Pile cap was constructed and the assembly was extended
as a Mat Foundation.
îY The mat foundation was assumed as a large footing extending over a large area for
both practical and design purposes.
îY Mat foundation was used because the design indicated high proximity of adjacent
columns, i.e. they were almost overlapping.
îY The advantage of Mat Foundation here is that it distributes the loads efficiently
thereby reducing the differential settlement of the loaded structure.
îY Also, the reinforcement was extremely dense and it was tri -layered.

9
    

Type of foundation ² piling

Total no of piles ² 587

Average depth of piles ² 22 to 25mtr

Total vol. of concreting (PCC) ² 2250 m3

Dia. of rod for PCC ² 25mm

Depth of concreting ² 1.2mtr

Total no. of columns ² 129nos

Dimensions of column ² 1m x 1m

Dia of rod used for column ² 32mm

Nos of rod used in column ² 10 to 12 (each face)

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For coal coke or ore handling plant wagon tippler arrangement is provided in most

of the power plants where bottom discharge wagon are not feasible.

The wagon Tippler designed for unloading broad guage open railway by inverting

the wagon to its own centre of gravity through an angle of 1700, thereby discharging its

contents into hopper below rail. (The tippler is designed to handle wagons having a gross

load up to 110 tones, height from 2,250mm (min) to 3,735 mm (max) and a maximum

overall width of 3,500 mm. The tippler ensures handling of wagons, without any damage.

The tippler consists of two circular rings, a platform with travel rails, support

rollers, two girders as well as clamping device, which retains the wagon from the top as

well as from the side during tippling.

The tippler is driven by a drive unit located on one side of the tippler. The driver

unit consists of motor with flexible coupling, thruster operated brake, helical gearbox,

pinion and toothed rings. The type of drive is decided on the number of tips/hour

required.

The complete hydraulic equipment, including the motor and the oil tank are located

on the tippler itself and rotate along with the tippler. Top clamps and side beam are

hydraulically operated. Wagon is clamped before tippling operation. The top clamps and

side beam are lined with rubber pads throughout the length of the tippler which

reduces the pressure on wagon walls.

A loaded wagon is placed on the tippler platform by an in -haul beetle or other

means. After correct placement is achieved, the in-haul beetle returns and clears the

tippler table. The hydraulic system is now actuated, and the upper and lateral beams

rest on the wagon coping and side walls. The hydraulic system incorposrates a pressure

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hopper to control activities in hoppers. From MB-2 conveyors run to junction house (JO)

and rest of the plant.

This complete structure made of concrete is to handle 10,000 tons of Iron Ore

Material and to accommodate standing one-third rake of railway wagons (19 wagons).

In this system, the wagons are fitted with automatic gate opening system. The

gate operation i.e. opening and closing is actuated by mechanism (rail) along the track.

When a wagon content ores or coal enters on track hopper, it·s gate will be opened

automatically. Simultaneously, the rack is moving at slow speed. The speed is such that

when the wagon travels from entry point to the exit point of track hopper, the contents

of the wagon gets discharged automatically by gravity. Thus in this system, the time

taken by wagon rack to get unloaded is short.

Below track hopper paddle feeder arrangement will be provided to unload ores or

coal from bed to conveyors which is provided just below to bed. Here 4nos of paddle

feeder will be provided, two at one end and another two in other end. Each paddle

feeder has four wings.


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Almost all the work of this is being handled by, three company has been the technology
supplier for the purpose.

The Sinter Plant is expected to have the following parameters ²

îY Grating Area ² 2x204m2

îY Productivity ² 1.62 tonnes/hour
îY Foundation type - piles
îY Total no of piles ² 5445 nos
îY Total structure ²
îY Total concreting -

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Blast Furnace Proper ² 01

Stoves ² 03nos (01 stand-by)

Main Control Room,

Pump house & cooling water tank etc.

9
    

a) For Stove

Function ² The temperature of blast furnace is more than 1200 0c and raw
materials coming from other plant have temperature approx 250 0c. To increase the
temperature of raw materials for blast furnace we use stove. Her e 03 nos of stove have
constructed. Hot gas and Oxygen are used as fuel in Blast furnace.

îY Total no. ² 03nos(01 stand-by)

îY Total piles - 200nos
îY Depth of concreting ² 1.2mtr
îY Grade of concrete ² M25
îY Dia of Rod ² 32mm
îY Dia of stove - 11.2mtr
îY Height of stove - 48mtr
îY Input temp. of materials in stove ² 2500c(appx.)
îY Output temp. of materials in stove ² 14000c(appx.)

) For Blast Furnace ?roper

Function ² To convert iron ore into pig iron with use of coke, lime stone, dolomite
etc as other raw materials.

îY Total no. ² 01
îY Total piles - 603nos
îY Depth of concreting ² 4mtr
îY Volume of concreting ² 6400m3
îY Grade of concrete ² M25
îY Dia of Rod ² 32mm
îY Height of Blast Furnace ² 97mtr
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