CIVIL ENGINEERING INTERNSHIP FULL REPORT ON BUILDING CONSTRUCTION

CONSTRUCTION OF DISTRICT CONTROL BUILDING, CENTRAL STORE BUILDING & 33/11KV POWER SUBSTATION CONTROL ROOM AT CHAPRA,BIHAR



An Internship Report submitted in partial fulfilment of the

requirements for the degree

of


B.Tech (Civil Engineering)


by


VIJAY KUMAR SINGH
13BCL0001


VIT UNIVERSITY
VELLORE – 632 014, TAMILNADU

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CONSTRUCTION OF DISTRICT CONTROL B UILDING,
CENTRAL STORE BUILDING & 33/11KV POWER
SUBSTATION CONTROL ROOM AT CHAPRA,BIHAR



An Internship Report submitted in partial fulfilment of the

requirements for the degree

of


B.Tech (Civil Engineering)


by


VIJAY KUMAR SINGH
13BCL0001


VIT UNIVERSITY
VELLORE – 632 014, TAMILNADU










Submitted to
VIT University
May 2016

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SCALE







This is to certify that the thesis entitled “CONSTRUCTION OF DISTRICT CONTROL
BUILDING, CENTRAL STORE BUILDING AND 33/11KV POWER SUBSTATION
CONTROL ROOM AT CHAPRA, BIHAR” is submitted by VIJAY KUMAR SINGH
(13BCL0001) to the SCALE, VIT University, Vellore, for the award of the degree in B.Tech is a
bonafide record of work carried out by him under my supervision. The contents of this thesis, in
full or in parts have not been submitted to any other Institute or University for the award of any
degree or diploma.


Guide Programme Manager



Internal Examiner External Examiner

BONAFIDE CERTIFICATE

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ACKNOWLEDGEMENTS

I would like to thank Mr. Ashutosh, my guide for the projects, for providing me with the
opportunities of studying, learning and gaining practical experience in various fields during the
period of training. His invaluable suggestions not only helped me to reach the successful
completion of the tasks assigned, but also made me learn a lot. I would like to give special thanks
to Prof. S.V. Saladi Subbarao for helping me throughout with his wise suggestions, innovative
ideas and whole-hearted help. I want to thank Mr. Senthil Kumar, Mr. Yogesh Tandel, Mr.
Rutvik Pawgi, Mr. R.B.Gosalkar, Mr. B.Viswanath and all others in the department who helped
me during my work here. And finally I would like to thank the HR department of North Bihar
Power Distribution Company (NBPDCL) limited, Chapra (Bihar) and my institute, VIT
UNIVERSITY ,Vellore, for giving me the opportunity to have a precious and rewarding
experience of training in the prestigious industryof North Bihar Power Distribution Company
(NBPDCL) limited, Chapra (Bihar)

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ABSTRACT

NBPDCL is a company registered under the provisions of Companies Act 1956 and isa fully
owned subsidiary Company of BSPHCL.
The Company is engaged primarily in the business of distribution of Electricity. It has been
vested with the distribution assets, interest in property, rights and liabilities of the erstwhile
BSEB necessary for the business of distribution inits area of distribution comprising of all 21
districts of North Bihar
In order to fulfill the obligations of the Distribution licensee as mandated under the provision of
Bihar State Electricity Reforms Transfer Scheme 2012 and Electricity Act 2003, the main objects
to be pursued by the company are:-

 To undertake the activities of distribution to all consumers irrespective of the voltage, provision,
supply, wheeling, purchase, sale, import, export and trading of electricity, introduce open access
in distribution as per the Electricity Act2003 and/or the directions of the regulator.

 To plan, develop, acquire, establish, construct, erect, lay, hire, lease, buy, sell, operate, run,
manage, maintain, enlarge, alter, renovate, modernize, work and use a power distribution system
network in all its aspects including amongst others various voltage lines and associated sub -
stations, including distribution centers, cables, wires, accumulators, plants, motors, meters,
apparatus, computers and materials connected with sub -transmission, distribution, supply of
electrical energy, ancillary services, telecommunication and telemetering equipments.
The points covered were:
1. How civil engineering is required for electrical field?
2. The way how we would go for next 28 days.
3. Construction sites and nature of work which included
a. Construction of District Control Room Building(G+3)
b. Central Store Building
c. New 33/11kv power sub station control room.

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CONTENTS
Chapter No Topic Page No.
1 Introduction 6

2 Details of the project
2.1 Site location 9
2.2 Site map 11


3 Details of G+3 building 14


4 Detail of Central Store Building
4.1 Batching Plant 28
4.2 Laying of columns 31

5 Construction of Power Sub Station
5.1 Electrical Drawing 34
5.2 Layout Design 34
5.3 Design Calculations 35
5.4 Civil Drawings and Civil Calculations 35

6 Conclusion 37


7 Certificate 38

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1. INTRODUCTION

NBPDCL is a company registered under the provisions of Companies Act 1956 and isa fully
owned subsidiary Company of BSPHCL.
The Company is engaged primarily in the business of distribution of Electricity. It has been
vested with the distribution assets, interest in property, rights and liabilities of the erstwhile
BSEB necessary for the business of distribution inits area of distribution comprising of all 21
districts of North Bihar (namely 1.West Champaran, 2. East Champaran, 3. Sitamadhi, 4.
Sheohar, 5. Muzaffarpur, 6.Vaishali, 7. Saran, 8. Siwan, 9. Gopalgunj, 10. Mahubani, 11.
Darbhanaga, 12. Samastipur,13. Begusarai, 14. Khagaria, 15. Saharsa, 16. Supaul, 17.
Medhepura, 18. Araria,19. Katihar, 20. Purnea and 21. Kishangunj).
The Company has been given the status of a Distribution licensee as per Section14 of the
Electricity Act 2003. In order to fulfill the obligations of the Distribution licensee as mandated
under the provision of Bihar State Electricity Reforms Transfer Scheme 2012 and Electricity Act
2003, the main objects to be pursued by the company are:-

 To undertake the activities of distribution to all consumers irrespective of the voltage, provision,
supply, wheeling, purchase, sale, import, export and trading of electricity, introduce open access
in distribution as per the Electricity Act2003 and/or the directions of the regulator.

 To plan, develop, acquire, establish, construct, erect, lay, hire, lease, buy, sell, operate, run,
manage, maintain, enlarge, alter, renovate, modernize, work and use a power distribution system
network in all its aspects including amongst others various voltage lines and associated sub -
stations, including distribution centers, cables, wires, accumulators, plants, motors, meters,
apparatus, computers and materials connected with sub -transmission, distribution, supply of
electrical energy, ancillary services, telecommunication and telemetering equipments.

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 To tender, finalise and execute Power Purchase Agreements and other agreements for sale or
purchase of electricity with generating companies, trading companies, other distribution
companies, Central and State generating authorities, departments or companies, societies, other
States, utilities, Independent Power Producers and other Persons.

 To undertake Rural Electrification schemes in the licensed area.

 Any other work incidental to the objectives & functions of the company.

The Power sector in Bihar is currently undergoing sea change. The Power sector in Bihar is
growing at a faster rate to achieve national level of per capita consumption. The pace of
economic development along with increasing power demand would require additional
generating capacity as well as adequate distribution network infrastructure to cater the current
demand and future load growth. In an effort to reduce losses in power distribution sector,
improve customer service and reliability of power supply, the Distribution Companies of Bihar
has undertaken a preliminary study to identify distribution sector constraints from 33 kV line
up to distribution transformer level, in course of further study it has been identified that the
present distribution system of Bihar suffers from serious constraints in distribution
infrastructure due to which against as peak load requirement of 3000 MW the existing system
is capable of meeting load to the extent of 2300 MW - 2400 MW only. The distribution
infrastructure required for meeting the existing constraints and peak load requirement of FY
2013-14 has been covered under Phase-I of the scheme. The major action plans for
strengthening of Power Distribution system and removal of distribution constraints distribution
system under BRGF Phase-I are as follows:
 New 33 kV lines and strengthening of existing 33 kV feeders;
 Additional PSS/Augmentation of existing Power Sub Stations capacities;
 Strengthening of protective systems in Power sub- stations;
 Provision of capacitor Banks in selected Power Sub stations;
 New 11 kV lines & strengthening of existing 11 kV feeders;
 Sectionalisation of 33 kV & 11 kV lines and provision of fault passage indicators(F.P.I.);

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 Additional D.T./ Augmentation of existing Distribution Transformer capacities;
 Protection of Distribution Transformers and provision of individual isolators
(A.B.switch) on existing DTs;
 Strengthening of L.T. lines (removal of Bans- Balla);
 Use of phase separators in L.T. Lines & Guard wires in H.T. lines;
In the second phase of BRGF scheme, the outlook of the Distribution Companies is to remove
distribution constraints arising on account of the followings:
 Peak demand of 5620 MW (2016-17) as projected by CEA;
 Upcoming agriculture load as envisaged under “Krishi Road Map”
Sub-transmission network requirement for renewable energy sources such as Solar Energy
etc.
The major action plans for strengthening of Power Distribution system and removal of
distribution constraints distribution system are as follows:
 New 33 kV lines and strengthening of existing 33 kV feeders;
 Additional PSS/Augmentation of existing Power Sub Stations capacities;
 Strengthening of protective systems in Power sub- stations;
On the first day, the nature of work has been explained.
The points covered were:
1. How civil engineering is required for electrical field?
2. The way how we would go for next 28 days.
3. Construction sites and nature of work which included
a. Construction of District Control Room Building(G+3)
b. Central Store Building
c. New 33/11kv power sub station control room.

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2. DETAIL OF THE PROJECT


All the three project was being done in Chapra District of Bihar. The Construction of District
Control Room Building(G+3) was being done in the center of city, near to both railway station
and bus stand whereas the central store building construction was done near the electric supply
board authority present storeroom.
The power substation construction was being done at the outskirt of city. The site location are as
follows-

2.1 SITE LOCATION

1. District Control Room Building(G+3)

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2. CENTRAL STORE ROOM LOCATION



3. POWER SUBSTATION LOCATION

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2.2 SITE MAP

District Control Room Building(G+3)

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CENTRAL STORE ROOM

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POWER SUB STATION

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3. DETAIL REPORT ON CONSTRUCTION OF G+3 BULDING


SEQUENCE OF STRUCTURE WORK
1) Site Clearance
2) Demarcation of Site
3) Positioning of Central coordinate ie (0,0,0) as per grid plan
4) Surveying and layout
5) Excavation
6) Laying of PCC
7) Bar Binding and placement of foundation steel
8 ) Shuttering and Scaffolding
9) Concreting
10) Electrical and Plumbing
11) Deshuttering
12) Brickwork
13) Doors and windows frames along with lintels
14) Wiring for electrical purposes
15) Plastering
16) Flooring and tiling work
17) Painting
18) Final Completion and handing over the project

CONSTRUCTION PROCESS AND MATERIALS USED

Site Clearance– The very first step is site clearance which involves removal of grass and
vegetation along with any other objections which might be there in the site location.
Demarcation of Site– The whole area on which construction is to be done is marked so as to
identify the construction zone. In our project, a plot of 450*350 sq ft was chosen and the
respective marking was done.
Positioning of Central coordinate and layout– The centre point was marked with the help of a
thread and plumb bob as per the grid drawing. With respect to this center point, all the other
points of columns were to be decided so its exact position is very critical.
Excavation
Excavation was carried out both manually as well as mechanically. Normally 1-2 earth
excavators (JCB’s) were used for excavating the soil. Adequate precautions are taken to see that
the excavation operations do not damage the adjoining structures. Excavation is carried out
providing adequate side slopes and dressing of excavation bottom. The soil present beneath the

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surface was too clayey so it was dumped and was not used for back filling. The filling is done in
layer not exceeding 20 cm layer and than its compacted. Depth of excavation was 5’4” from
Ground Level.



PCC – Plain Cement Concrete
After the process of excavation, laying of plain cement concrete that is PCC is done. A layer of 4
inches was made in such a manner that it was not mixed with the soil. It provides a solid bas for
the raft foundation and a mix of 1:5:10 that is, 1 part of cement to 5 parts of fine aggregates and
10 parts of coarse aggregates by volume were used in it. Plain concrete is vibrated to achieve full
compaction. Concrete placed below ground should be protected from falling earth during and
after placing. Concrete placed in ground containing deleterious substances should be kept free
from contact with such a ground and with water draining there from during placing and for a
period of seven days. When joint in a layer of concrete are unavoidable, and end is sloped at an
angle of 30 and junctions of different layers break joint in laying upper layer of concrete. The
lower surface is made rough and clean watered before upper layer is laid.

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LAYING OF FOUNDATION
At our site, Raft foundations are used to spread the load from a structure over a large area,
normally the entire area of the structure. Normally raft foundation is used when large load is to
be distributed and it is not possible to provide individual footings due to space constraints that is
they would overlap on each other. Raft foundations have the advantage of reducing differential
settlements as the concrete slab resists differential movements between loading positions. They
are often needed on soft or loose soils with low bearing capacity as they can spread the loads
over a larger area.
In laying of raft foundation, special care is taken in the reinforcement and construction of plinth
beams and columns. It is the main portion on which ultimately whole of the structure load is to
come. So a slightest error can cause huge problems and therefore all this is checked and passed
by the engineer in charge of the site.

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Apart from raft foundation, individual footings were used in the mess area which was extended
beyond the C and D blocks.



CEMENT
Portland cement is composed of calcium silicates and aluminate and aluminoferrite It is obtained
by blending predetermined proportions limestone clay and other minerals in small quantities
which is pulverized and heated at high temperature – around 1500 deg centigrade to produce
‘clinker’. The clinker is then ground with small quantities of gypsum to produce a fine powder
called Ordinary Portland Cement (OPC). When mixed with water, sand and stone, it combines
slowly with the water to form a hard mass called concrete. Cement is a hygroscopic material
meaning that it absorbs moisture In presence of moisture it undergoes chemical reaction termed
as hydration. Therefore cement remains in good condition as long as it does not come in contact
with moisture. If cement is more than three months old then it should be tested for its strength
before being taken into use.
The Bureau of Indian Standards (BIS) has classified OPC in three different grades The
classification is mainly based on the compressive strength of cement-sand mortar cubes of face
area 50 cm2 composed of 1 part of cement to 3 parts of standard sand by weight with a water-
cement ratio arrived at by a specified procedure. The grades are
(i) 33 grade
(ii) 43 grade
(iii) 53 grade

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The grade number indicates the minimum compressive strength of cement sand mortar in
N/mm2 at 28 days, as tested by above mentioned procedure.
Portland Pozzolana Cement (PPC) is obtained by either intergrinding a pozzolanic material with
clinker and gypsum, or by blending ground pozzolana with Portland cement. Nowadays good
quality fly ash is available from Thermal Power Plants, which are processed and used in
manufacturing of PPC.

ADVANTAGES OF USING PORTLAND POZZOLANA CE MENT OVER OPC
Pozzolana combines with lime and alkali in cement when water is added and forms compounds
which contribute to strength, impermeability and sulphate resistance. It also contributes to
workability, reduced bleeding and controls destructive expansion from alkali-aggregate reaction.
It reduces heat of hydration thereby controlling temperature differentials, which causes thermal
strain and resultant cracking n mass concrete structures like dams. The colour of PPC comes
from the colour of the pozzolanic material used. PPC containing fly ash as a pozzolana will
invariably be slightly different colour than the OPC.One thing should be kept in mind that is the
quality of cement depends upon the raw materials used and the quality control measures adopted
during its manufacture, and not on the shade of the cement. The cement gets its colour from the
nature and colour of raw materials used, which will be different from factory to factory, and may
even differ in the different batches of cement produced in a factory. Further, the colour of the
finished concrete is affected also by the colour of the aggregates, and to a lesser extent by the
colour of the cement. Preference for any cement on the basis of colour alone is technically
misplaced.
SETTLING OF CEMENT
When water is mixed with cement, the paste so formed remains pliable and plastic for a short
time. During this period it is possible to disturb the paste and remit it without any deleterious
effects. As the reaction between water and cement continues, the paste loses its plasticity. This
early period in the hardening of cement is referred to as ‘setting’ of cement.
INITIAL AND FINAL SETTING TIME OF CEMENT
Initial set is when the cement paste loses its plasticity and stiffens considerably. Final set is the
point when the paste hardens and can sustain some minor load. Both are arbitrary points and
these are determined by Vicat needle penetration resistance
Slow or fast setting normally depends on the nature of cement. It could also be due to extraneous
factors not related to the cement. The ambient conditions play an important role. In hot weather,
the setting is faster, in cold weather, setting is delayed Some types of salts, chemicals, clay, etc if
inadvertently get mixed with the sand, aggregate and water could accelerate or delay the setting
of concrete.

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STORAGE OF CEMENT



It needs extra care or else can lead to loss not only in terms of financial loss but also in terms of
loss in the quality. Following are the don’t that should be followed –
(i) Do not store bags in a building or a godown in which the walls, roof and floor are not
completely weatherproof.
(ii) Do not store bags in a new warehouse until the interior has thoroughly dried out.
(iii) Do not be content with badly fitting windows and doors, make sure they fit properly and
ensure that they are kept shut.
(iv) Do not stack bags against the wall. Similarly, don’t pile them on the floor unless it is a dry
concrete floor. If not, bags should be stacked on wooden planks or sleepers.
(v) Do not forget to pile the bags close together
(vi) Do not pile more than 15 bags high and arrange the bags in a header-and-stretcher fashion.
(vii) Do not disturb the stored cement until it is to be taken out for use.
(viii) Do not take out bags from one tier only. Step back two or three tiers.
(ix) Do not keep dead storage. The principle of first-in first-out should be followed in removing
bags.
(x) Do not stack bags on the ground for temporary storage at work site. Pile them on a raised, dry
platform and cover with tarpaulin or polythene sheet.
COARSE AGGREGATE
Coarse aggregate for the works should be river gravel or crushed stone .It should be hard, strong,
dense, durable, clean, and free from clay or loamy admixtures or quarry refuse or vegetable
matter. The pieces of aggregates should be cubical, or rounded shaped and should have granular

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or crystalline or smooth (but not glossy) non-powdery surfaces.Aggregates should be properly
screened and if necessary washed clean before use.
Coarse aggregates containing flat, elongated or flaky pieces or mica should be rejected. The
grading of coarse aggregates should be as per specifications of IS-383.
After 24-hrs immersion in water, a previously dried sample of the coarse aggregate should not
gain in weight more than 5%.
Aggregates should be stored in such a way as to prevent segregation of sizes and avoid
contamination with fines.
Depending upon the coarse aggregate color, there quality can be determined as:
Black => very good quality
Blue => good
Whitish =>bad quality

FINE AGGREGATE
Aggregate which is passed through 4.75 IS Sieve is termed as fine aggregate. Fine aggregate is
added to concrete to assist workability and to bring uniformity in mixture. Usually, the natural
river sand is used as fine aggregate. Important thing to be considered is that fine aggregates
should be free from coagulated lumps.
Grading of natural sand or crushed stone i.e. fine aggregates shall be such that not more than 5
percent shall exceed 5 mm in size, not more than 10% shall IS sieve No. 150 not less than 45%
or more than 85% shall pass IS sieve No. 1.18 mm and not less than 25% or more than 60% shall
pass IS sieve No. 600 micron.
BRICKWORK
Brickwork is masonry done with bricks and mortar and is generally used to build partition walls.
In our site, all the external walls were of concrete and most of the internal walls were made of
bricks. English bond was used and a ration of 1:4 (1 cement: 4 coarse sand) and 1:6 were used
depending upon whether the wall is 4.5 inches or 9 inches. The reinforcement shall be 2 nos.
M.S. round bars or as indicated. The diameter of bars was 8mm. The first layer of reinforcement
was used at second course and then at every fourth course of brick work. The bars were properly
anchored at their ends where the portions and or where these walls join with other walls. The in
laid steel reinforcement was completely embedded in mortar.
Bricks can be of two types. These are:
1) Traditional Bricks-The dimension if traditional bricks vary from 21 cm to 25cm in length,10
to 13 cm in width and 7.5 cm in height in different parts of country .The commonly adopted
normal size of traditional brick is 23 * 11.5*7.5 cm with a view to achieve uniformity in size of
bricks all over country.
2) Modular Bricks– Indian standard institution has established a standard size of bricks such a
brick is known as a modular brick. The normal size of brick is taken as 20*10*10 cm whereas its
actual dimensions are 19*9*9 cm masonry with modular bricks workout to be cheaper there is

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saving in the consumption of bricks, mortar and labour as compared with masonry with
traditional bricks.
STRENGTH OF BRICK MAS ONRY
The permissible compressive stress in brick masonry depends upon the following factors:
1. Type and strength of brick.
2. Mix of motor.
3. Size and shape of masonry construction.
The strength of brick masonry depends upon the strength of bricks used in the masonry
construction. The strength of bricks depends upon the nature of soil used for making and the
method adopted for molding and burning of bricks .since the nature of soil varies from region to
region ,the average strength of bricks varies from as low as 30kg/sq cm to 150 kg /sq cm the
basic compressive stress are different crushing strength.

There are many checks that can be applied to see the quality of bricks used on the site.Normally
the bricks are tested for Compressive strength, water absorption, dimensional tolerances and
efflorescence. However at small construction sites the quality of bricks can be assessed based on
following, which is prevalent in many sites.
• Visual check – Bricks should be well burnt and of uniform size and color.
• Striking of two bricks together should produce a metallic ringing sound.
• It should have surface so hard that can’t be scratched by the fingernails.
• A good brick should not break if dropped in standing position from one metre above ground
level.
• A good brick shouldn’t absorb moisture of more than 15-20% by weight, when soaked in water
For example; a good brick of 2 kg shouldn’t weigh more than 2.3 to 2.4 kg if immersed in
water for 24 hours.

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PRECAUTIONS TO BE TAK EN IN BRICK MASONRY WORK
• Bricks should be soaked in water for adequate period so that the water penetrates
to its full thickness. Normally 6 to 8 hours of wetting is sufficient.
• A systematic bond must be maintained throughout the brickwork. Vertical joints
shouldn’t be continuous but staggered.
• The joint thickness shouldn’t exceed 1 cm. It should be thoroughly filled with the
cement mortar 1:4 to 1:6 (Cement: Sand by volume)
• All bricks should be placed on their bed with frogs on top (depression on top of the
brick for providing bond with mortar).
• Thread, plumb bob and spirit level should be used for alignment, verticality and
horizontality of construction.
• Joints should be raked and properly finished with trowel or float, to provide good bond.
• A maximum of one metre wall height should be constructed in a day.
• Brickwork should be properly cured for at least 10 days
REINFORCEMENT
Steel reinforcements are used, generally, in the form of bars of circular cross section in concrete
structure. They are like a skeleton in human body. Plain concrete without steel or any other
reinforcement is strong in compression but weak in tension. Steel is one of the best forms of
reinforcements, to take care of those stresses and to strengthen concrete to bear all kinds of loads
Mild steel bars conforming to IS: 432 (Part I) and Cold-worked steel high strength deformed bars
conforming to IS: 1786 (grade Fe 415 and grade Fe 500, where 415 and 500 indicate yield
stresses 415 N/mm2 and 500 N/mm2 respectively) are commonly used. Grade Fe 415 is being
used most commonly nowadays. This has limited the use of plain mild steel bars because of
higher yield stress and bond strength resulting in saving of steel quantity. Some companies have
brought thermo mechanically treated (TMT) and corrosion resistant steel (CRS) bars with added
features.
Bars range in diameter from 6 to 50 mm. Cold-worked steel high strength deformed bars start
from 8 mm diameter. For general house constructions, bars of diameter 6 to 20 mm are used
Transverse reinforcements are very important. They not only take care of structural requirements
but also help main reinforcements to remain in desired position. They play a very significant role
while abrupt changes or reversal of stresses like earthquake etc.
They should be closely spaced as per the drawing and properly tied to the main/longitudinal
reinforcement
TERMS USED IN REINFORCEMENT

BAR-BENDING-SCHEDULE
Bar-bending-schedule is the schedule of reinforcement bars prepared in advance before cutting
and bending of rebars. This schedule contains all details of size, shape and dimension of rebars to
be cut.

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LAP LENGTH
Lap length is the length overlap of bars tied to extend the reinforcement length.. Lap length about
50 times the diameter of the bar is considered safe. Laps of neighboring bar lengths should be
staggered and should not be provided at one level/line. At one cross section, a maximum of 50%
bars should be lapped. In case, required lap length is not available at junction because of space
and other constraints, bars can be joined with couplers or welded (with correct choice of method
of welding).
ANCHORAGE LENGTH
This is the additional length of steel of one structure required to be inserted in other at the
junction. For example, main bars of beam in column at beam column junction, column bars in
footing etc. The length requirement is similar to the lap length mentioned in previous question or
as per the design instructions
COVER BLOCK
Cover blocks are placed to prevent the steel rods from touching the shuttering plates and there by
providing a minimum cover and fix the reinforcements as per the design drawings. Sometimes it
is commonly seen that the cover gets misplaced during the concreting activity. To prevent this,
tying of cover with steel bars using thin steel wires called binding wires (projected from cover
surface and placed during making or casting of cover blocks) is recommended. Covers should be
made of cement sand mortar (1:3). Ideally, cover should have strength similar to the surrounding
concrete, with the least perimeter so that chances of water to penetrate through periphery will be
minimized. Provision of minimum covers as per the Indian standards for durability of the whole
structure should be ensured.
Shape of the cover blocks could be cubical or cylindrical. However, cover indicates thickness of
the cover block. Normally, cubical cover blocks are used. As a thumb rule, minimum cover of 2”
in footings, 1.5” in columns and 1” for other structures may be ensured.
Structural
element
Cover to
reinforcement
(mm)
Footings 40
Columns 40
Slabs 15
Beams 25
Retaining
wall
25 for earth
face
20 for other
face

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THINGS TO NOTE
Reinforcement should be free from loose rust, oil paints, mud etc. it should be cut, bent and fixed
properly. The reinforcement shall be placed and maintained in position by providing proper
cover blocks, spacers, supporting bars, laps etc. Reinforcements shall be placed and tied such
that concrete placement is possible without segregation, and compaction possible by an
immersion vibrator.
For any steel reinforcement bar, weight per running meter is equal to d*d/162 Kg, where d is
diameter of the bar in mm. For example, 10 mm diameter bar will weigh 10×10/162 = 0.617
Kg/m
Three types of bars were used in reinforcement of a slab. These include straight bars, crank bar
and an extra bar. The main steel is placed in which the straight steel is binded first, then the
crank steel is placed and extra steel is placed in the end. The extra steel comes over the support
while crank is encountered at distance of ¼(1-distance between the supports) from the
surroundings supports.
For providing nominal cover to the steel in beam, cover blocks were used which were made of
concrete and were casted with a thin steel wire in the center which projects outward. These keep
the reinforcement at a distance from bottom of shuttering. For maintaining the gap between the
main steel and the distribution steel, steel chairs are placed between them
SHUTTERING AND SCAFFOLDING
DEFINITION
The term ‘SHUTTERING’ or ‘FORMWORK’ includes all forms, moulds, sheeting, shuttering
planks, walrus, poles, posts, standards, leizers, V-Heads, struts, and structure, ties, prights,
walling steel rods, bolts, wedges, and all other temporary supports to the concrete during the
process of sheeting.

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FORM WORK
Forms or moulds or shutters are the receptacles in which concrete is placed, so that it will have
the desired shape or outline when hardened. Once the concrete develops adequate strength, the
forms are removed. Forms are generally made of the materials like timber, plywood, steel, etc.
Generally camber is provided in the formwork for horizontal members to counteract the effect of
deflection caused due to the weight of reinforcement and concrete placed over that. A proper
lubrication of shuttering plates is also done before the placement of reinforcement. The oil film
sandwiched between concrete and formwork surface not only helps in easy removal of shuttering
but also prevents loss of moisture from the concrete through absorption and evaporation.
The steel form work was designed and constructed to the shapes, lines and dimensions shown on
the drawings. All forms were sufficiently water tight to prevent leakage of mortar. Forms were
so constructed as to be removable in sections. One side of the column forms were left open and
the open side filled in board by board successively as the concrete is placed and compacted
except when vibrators are used. A key was made at the end of each casting in concrete columns
of appropriate size to give proper bondings to columns and walls as per relevant IS.



CLEANING AND TREATMENT OF FORMS
All rubbish, particularly chippings, shavings and saw dust, was removed from the interior of the
forms (steel) before the concrete is placed. The form work in contact with the concrete was
cleaned and thoroughly wetted or treated with an approved composition to prevent adhesion
between form work and concrete. Care was taken that such approved composition is kept out of
contact with the reinforcement.
DESIGN

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The form-work should be designed and constructed such that the concrete can be properly placed
and thoroughly compacted to obtain the required shape, position, and levels subject
ERECTION OF FORMWORK
The following applies to all formwork:
a) Care should be taken that all formwork is set to plumb and true to line and level.
b) When reinforcement passes through the formwork care should be taken to ensure close
fitting joints against the steel bars so as to avoid loss of fines during the compaction of
concrete.
c) If formwork is held together by bolts or wires, these should be so fixed that no iron is
exposed on surface against which concrete is to be laid.
d) Provision is made in the shuttering for beams, columns and walls for a port hole of
convenient size so that all extraneous materials that may be collected could be
removed just prior to concreting.
e) Formwork is so arranged as to permit removal of forms without jarring the concrete.
Wedges, clamps, and bolts should be used where practicable instead of nails.
f) Surfaces of forms in contact with concrete are oiled with a mould oil of approved
quality. The use of oil, which darkens the surface of the concrete, is not allowed. Oiling
is done before reinforcement is placed and care taken that no oil comes in contact with
the reinforcement while it is placed in position. The formwork is kept thoroughly wet
during concreting and the whole time that it is left in place.
Immediately before concreting is commenced, the formwork is carefully examined to
ensure the following:
a) Removal of all dirt, shavings, sawdust and other refuse by brushing and washing.
b) The tightness of joint between panels of sheathing and between these and any hardened core.
c) The correct location of tie bars bracing and spacers, and especially connections of
bracing.
d) That all wedges are secured and firm in position.
e) That provision is made for traffic on formwork not to bear directly on reinforcement
steel.
VERTICALITY OF THE STUCTURE
All the outer columns of the frame were checked for plumb by plumb-bob as the work proceeds
to upper floors. Internal columns were checked by taking measurements from outer row of
columns for their exact position. Jack were used to lift the supporting rods called props
STRIPPING TIME OR REMOVAL OF FORMWORK
Forms were not struck until the concrete has attained a strength at least twice the stress to which
the concrete may be subjected at the time of removal of form work. The strength referred is that
of concrete using the same cement and aggregates with the same proportions and cured under
conditions of temperature and moisture similar to those existing on the work. Where so required,
form work was left longer in normal circumstances

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Form work was removed in such a manner as would not cause any shock or vibration that would
damage the concrete. Before removal of props, concrete surface was exposed to ascertain that the
concrete has sufficiently hardened. Where the shape of element is such that form work has re-
entrant angles, the form work was removed as soon as possible after the concrete has set, to
avoid shrinkage cracking occurring due to the restraint imposed. As a guideline, with
temperature above 20 degree following time limits should be followed:
Structural
Component
Age
Footings 1 day
Sides of
beams,
columns,
lintels, wall
2 days
Underside
of beams
spanning
less than
6m
14 days
Underside
of beams
spanning
over 6m
21 days
Underside
of slabs
spanning
less than
4m
7 days
Underside
of slabs
spanning
more than
4m
14 days
Flat slab
bottom
21 ays

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4. DETAIL REPORT ON CENTRAL STORE BUILDING CONSTRUCTION

The soil was expansive in nature for this site. Soil characteristics plays a vital role for any
construction meanwhile it is highly unpredictable in nature.Expansive soils are problematic in
nature due to their tendency to swell in prescence of moisture and to shrink in moisture
absence.Chen(1988) describes expansive soils as soils which swells or increase its volume.
Expansive soils are highly problematic because of the nature of soils to undergo large changes in
volume due to variations in the moisture content. It cover approximately 20% of total land area
in India. Changes in volume resulting from variations in moisture in expansive soils and
expansive soil subgrades causes damage to structures, highway pavements and other civil
engineering infrastructures. So, the sand cusion method was adopted here for preventing it from
damages.

4.1 BATCHING PLANT:
M40 concrete mix is used here for the construction of structure. A separate batching plant is
present near the site for the construction of lake verandahs and hill crest structures.


Figure 4.1 batching plant with a transit mixer

Figure 4.2, 4.3 describes the control panel and closer look to batching plant respectively.

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A Transit mixer is used to transfer concrete from batching plant to the work site.It carries
around 7cubic mtr volume of concrete and takes about 15 min to load.
The main components of batching plant are
 Control panel
 Silos
 Cement storage godown
 Small tower crane for pushing ingredients into mix using trayThe batching plant consists
of silos which are used to store flyash and chemicals accelerators and retarders.
M15 M20 M25 M30 M35 M40
KG KG KG KG KG KG
CA I 564 538 534 526 521 494
CA II 664 576 572 564 558 529
FA II 725 738 727 710 697 636
CEMENT 256 284 304 326 351 433
FLY ASH 76 82 88 94 101 126
WATER 180 180 175 180 170 180
CH.
ADMIX
.8-1.2 % .8-1.2% .8-1.2% .8-1.2% .8-1.2% .8-1.2%
W/B
RATIO
.54 .49 .44 .42 .37 .32

Table 4.1 A Table describing Mix Design Per Cubic Meter for various mix designs
The ingredients used in preparation of concrete are coarse aggregate I, II and fine
aggregate (pit sand, dead river sand),cement, fly ash, water ,chemical admixtures .The W/B
Ratio of M40 Mix is 0.32
The chemical admixtures used are MYK Save mix SP

4.2 Q/A & Q/C LAB (Quality assurance &quality control lab):
In this lab the quality and strength of various building materials like cement, sand,
concrete, water, coarse aggregate are tested using various testing machines and apparatus like
 vicat apparatus,
 Compression testing machine
 flakiness and elongation index gauges,
 volume measuring jars
 digital weighing scale(20kg max. and 2gm accuracy)
 sample collecting trays
 pycnometer

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Figure 4.4,4.5 describes view of QA/QC lab and frame work for concrete cubes for testing
respectively.

Figure 4.6 describes the view of curing tank near qa/qc lab

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4.3 LAYING OF COLUMNS:



Figure 4.7 represents view of various columns from below ground surface



Figure 4.8,4.9 describes frame work for column concreting and tor rings respectively.

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Columns are laid under utmost care. steel rods are firmly placed and these are connected using
different types of TOR RINGS with the help of binding wire. About 8 Tor rings are provided at
spacing in every column. Basically tor rings are of different types like rectangular, square type,
triangular, trapezoidal used for connecting various amount of steel rods.tie rod, ropes are used to
place the shutters firmly around the column where the concrete is to be laid. Once the shutter is
firmly placed then the concrete is filled manually till 0.5 mtr in order to avoid HONEY
COMBING. M40 grade concrete is used for laying columns. The date on which concreting is
done to a column is written on column so that care has to be taken to cure it for 14 days

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5. CONSTRUCTION OF POWER SUBSTATION
A substation is a part of an electrical generation, transmission, and distribution system.
Substations transform voltage from high to low, or the reverse, or perform any of several other
important functions. Between the generating station and consumer, electric power may flow
through several substations at different voltage levels.
Substations may be owned and operated by an electrical utility, or may be owned by a large
industrial or commercial customer. Generally substations are unattended, relying on SCADA for
remote supervision and control.
A substation may include transformers to change voltage levels between high transmission
voltages and lower distribution voltages, or at the interconnection of two different transmission
voltages. The word substation comes from the days before the distribution system became a grid.
As central generation stations became larger, smaller generating plants were converted to
distribution stations, receiving their energy supply from a larger plant instead of using their own
generators. The first substations were connected to only one power station, where the generators
were housed, and were subsidiaries of that power station.

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we have been taught about
1 Electrical Drawings
1.0 Metering & Protection SLD for 33/11KV substation.
1.1 Single line diagram of 415V ACDB
1.2 Single line diagram of 30V DCDB
1.3 Single line diagram of 415V Main
Lighting distribution
1.4
Single line diagram of 415V BM.
The trainer was AE and Junior Engineer of division

2 Layout Drawings
2.0 Electrical Layout plan & elevation for 33/11KV substation.
2.1 Earthing Layout for 33/11KV substation.
2.2 Cable trench Layout for 33/11KV substation.
2.3 DSLP Layout for 33/11KV substation.
2.4 Equipment and Cable trench layout of Control Room.
2.5 Outdoor Illumination Layout for 33/11KV substation.
2.6 Illumination Layout for Control Room.
2.7 Earthing Layout for Control Room.
2.8
Erection Key Diagram for switchyard with BOQ of clamps
and connectors.
2.9 Illumination Layout for Guard Room.
2.10 Earthing notes and details
2.11 Lighting notes and details

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3.0 Design Calculations
3.1 Earthing calculation for 33/11KV substation.
3.2 DSLP calculation for 33/11KV substation.
3.3
Outdoor illumination calculation for 33/11KV
substation.
3.4
Control room illumination calculation for 33/11KV
substation.
3.5 Cable Sizing Calculation
3.6 Power Cable schedule and interconnection
3.7 Control Cable schedule and interconnection
3.8 PS class CT sizing calculation



4 CIVIL Drawings & Design Calculations
4.1
Architectural layout, Foundation Plan & Elevation for
Control room.
4.2 Foundation Plan & Elevation for Boundary wall.
4.3
Foundation Plan & Elevation of 33KV Current
Transformer.
4.4
Foundation Plan & Elevation of 33KV Potential
Transformer.
4.5
Foundation Plan & Elevation of 30KV Lightning
Arrester.
4.6 Foundation Plan & Elevation of 33KV Isolator.
4.7 Foundation Plan & Elevation of 33KV VCB.
4.8
Foundation Plan & Elevation of 11KV Current
Transformer.
4.9
Foundation Plan & Elevation of 11KV Potential
Transformer.
4.10
Foundation Plan & Elevation of 11KV Lightning
Arrester.

4.11 Foundation Plan & Elevation of 11KV Isolator.
4.12 Foundation Plan & Elevation of 11KV VCB.
4.13 Foundation Plan & Elevation of 33KV Line gantry

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tower.
4.14
Foundation Plan & Elevation of 33KV Bus gantry
tower.
4.15
Foundation Plan & Elevation of 11KV Line gantry
tower.
4.16
Foundation Plan & Elevation of 11KV Bus gantry
tower.
4.17
Foundation Plan & Elevation of 10 MVA
Transformer.
4.18
Foundation Plan & Elevation of 100KVA
Transformer.
4.19
Foundation Plan & Elevation of Transformer oil Soak
Pit.
4.20 Layout Plan & Elevation of Road.
4.21 Layout Plan & Elevation of Drain & Culvert.

4.22 Foundation Plan & Elevation of Guard Room.
4.23
Layout Plan & Elevation of outdoor cable trench and
cover slab
4.24 Details of Fence and Fence gate
4.25 Details of Main gate
4.26 Details of Septic tank and Soak pit
4.27
Layout plan and details of water supply arrangement
and OH tank
4.28 Civil Design calculations
4.29 Overall foundation layout of Switchyard.

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6. CONCLUSION


As an undergraduate of the VIT University, I would like to say that this training program is an
excellent opportunity for us to get to the ground level and experience the things that we
would have never gained through going straight into a job. I am grateful to the VIT University
and North Bihar Power Distribution Company (NBPDCL) limited, Chapra (Bihar) for giving us
this wonderful opportunity.
The main objective of the industrial training is to provide an opportunity to undergraduates to
identify, observe and practice how engineering is applicable in the real industry. It is not only to
get experience on technical practices but also to observe management practices and to interact
with on field workers. It is easy to work with sophisticated machines, but not with people. The
only chance that an undergraduate has to have this experience is the industrial training period. I
feel I got the maximum out of that experience. Also I learnt the way of work in an organization,
the importance of being punctual, the importance of maximum commitment, and the importance
of team spirit. The training program having three destinations was a lot more useful than staying
at one place throughout the whole six months. In my opinion, I have gained lots of knowledge
and experience needed to be successful in a great engineering challenge, as in my opinion,
Engineering is after all a Challenge, and not a Job.

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7. CERTIFICATE