One month industrial training program with NHAI

Industrial training presentation

1. TRAINING REPORT 06-LANE EXPRESSWAY OF VIJAPUR-KUNJWANI SECTION NH-44 DELHI-AMRITSAR-KATRA EXPRESSWAY SUBMITTED BY

2. INTRODUCTION TO PROJECT PROJECT DETAILS:- • Project Name: Development of Jakh ( Vijaypur )- Kunjwani section of NH-44 to Six-lane Expressway standards as part of Delhi-Amritsar- Katra Expressway [Design Km 503+200 to Km 515+000 of Delhi-Amritsar- Katra Expressway] including development of Kunjwani to 4h Tawi Bridge section of NH-144A to four-lane NH standards [Ch. 0+000 to 7+385 of NH-144A] as Spur Connectivity to Jammu Airport in the UT of Jammu & Kashmir on Hybrid Annuity Mode. • NH No. (New/ Old)= NE-5/NH-44, NH-144A

3. • No. of Lanes = Four or Six Lane • Length of the Project (in Km)=21.515 • Total Project Cost (in Cr) =1765 • Length of Service Road (in Km) =24.835 • Length of RCC Drain (in Km) =37.344 • No. of Minor Bridges =12 Nos. (2 New+7 Widening+3 Reconstruction) • No. of Major Bridges =3 Nos. • No. of Loops & Ramp=13 Nos. • Concessionaire Name (SPV &Parent Company) = SPV- M/s VijaypurKunjwani 5 Highways Pvt Ltd. And Parent Company- M/s Shivalaya Construction Co. Pvt. Ltd. Y

4. ABOUT THE PROJECT Delhi-Amritsar- Katra Expressway is a proposed 700-kilometer-long six-lane expressway that aims to connect Delhi with Amritsar and Katra , providing faster and more efficient transportation in northern India. The expressway is expected to reduce travel time between Delhi and Amritsar from 8 hours to just 4 hours and promote economic growth in the region by improving connectivity. • Increased employment to the local community It promotes trade and tourism and trade to the Jammu & Kashmir

5. DETAIL OF WORK AT LABORATORY 1. CONCRETE TEST SLUMP CONE TEST The slump test measures the consistency of fresh concrete before it sets . It is performed to check the workability of freshly made concrete The slump is carried out as per procedure mentioned in IS : 456 – 2000. PROCEDURE: Set up the slump cone on a flat, level surface. Ensure that the base plate is clean and free from any debris. Moisten the inside of the cone with water to prevent the concrete from sticking to the walls. Fill the slump cone in three layers, each approximately one- thirdof the cone's height and give each layer 25 blows with tamping rod . After filling and compacting all three layers, strike off the excess concrete from the top of the cone using a trowel. Lift the slump cone vertically and in a steady manner, ensuring that no lateral or twisting movement occurs.

6. Place the removed cone next to the slumped concrete and measure the distance between the original height of the cone and the highest point of the slumped concrete. This distance is known as the slump value. Record the slump value in millimetres . The slump value provides an indication of the workability of the concrete mix. Slump cone dimensions are as follows : Top diameter of cone = 10 cm Bottom diameter of cone = 20 cm Height of cone = 30 cm Tamping rod length = 60 cm Tamping rod diameter = 16 mm

7. RESULT: Slump value came out to be 210mm for M – 50 grade of concrete . Three types of slump values are as follows: 1. True slump 2. Shear Slump 3.Collapse

8. 2.COMPRESSIVE STRENGTH TEST: The compressive strength test of the concrete cube provides an idea about all the characteristics of concrete. Compressive strength of concrete depends on many factors such as water-cement ratio, etc. The test is performed as per IS 516:1959, CTM MACHINE

9. Apparatus : CTM machine, Tamping rod, Mould , Trowel, Tray Preparation of cube specimens : Making these test specimens are from the same concrete used in the field. Specimen : 5 cubes of 15 cm side, M- 55 grade PROCEDURE : 1. Representative samples of concrete shall be taken and used for casting cubes 15 cmx 15 cm x 15 cm. 15 2. The concrete shall be filled into the mould in 3 layers approximately 5 cm deep and each layer is given 35 no. of blows with tamping rod . 3. After the top layer has been compacted, the surface of concrete shall be finished level with the top of the mould using a trowel. The specimen shall be stored at site for 24h under damp matting or sack. After that, the samples shall be stored in clean water at 27+20 C, until the time of test.

10. 4. Specimen shall be tested immediately on removal from water and while they are still in wet condition. 5. The bearing surface of the testing specimen shall be wiped clean, and any loose material removed from the surface. 6. The specimen are then tested by compression testing machine after 7 days curing or 28 days curing Load should be applied gradually at the rate of 140 Kg / cm2 per minute. till the specimen fails. 7. Load at failure divided by area of specimen gives the compressive strength of concrete .

11. 3.Aggregate Impact Value Test : The Method of test: IS 2386: 1963, Part-4 Aggregate impact test is used to determine the aggregate impact value (AIV), which provides a relative measure of the resistance of a coarse aggregate to sudden shock or impact. Aggregate impact value test gives an indication of aggregate’s toughness property (i.e., property of a material to resist impact). Aggregate impact values are used to classify the stone aggregates with respect to toughness property. Apparatus : Balance, Sieves – 12.5 mm,10mm , 2.36 mm , Impact testing machine ,Tamping rod . Procedure : The test sample shall consist of aggregate the whole of which passes a 12 . 5 mm IS Sieve and is retained on a 10 mm IS Sieve.

12. Pour the aggregates to fill about just 1/3 rd depth of measuring cylinder. Compact the material by giving 25 gentle blows with the rounded end of the tamping rod. Add two more layers in similar manner, so that cylinder is full. Strike off the surplus aggregates. Transfer sample from cylinder to cup of aggregate impact testing machine and give 15 blows with the hammer The hammer is raised to height of 380 mm above the upper surface of aggregate in the cup and is allowed to free fall on specimen. Remove the crushed aggregate from the cup and sieve it through 2.36 mm IS sieves. Weigh the fraction passing through 2.36mm and percentage is calculated.

13. Aggregate Impact Value Test

14. 4.Sieve analysis for Sand : Apparatus : IS sieves ( 10, 4.75,2.36,1.18,.600,.300,.150 ) m Procedure : The whole procedure of sieve analysis is to determine the particle size distribution of the fine aggregates and determine whether it is suitable to use in concrete mixing. We prepare the sieves, by the size from biggest (4,75mm) to smallest (0.075mm). The sample is sieved by using the set of IS Sieves for 10 minutes. After the sieving is done, the aggregates on each sieve are weighed individually.Then find the cumulative weight retained.

15. WORK AT SITE PILE FOUNDATION : Pile foundations are deep foundations. They are formed by long, slender, columnar elements typically made from steel or reinforced concrete, or sometimes timber. A foundation is described as 'piled' when its depth is more than three times its breadth. Piles are columnar elements in a foundation which have the function of transferring load from superstructure through weak compressible strata onto stiffer and less compressible soils . Pile group of either 9 piles or 7 piles are used .In our case,group of 7 piles were used.

16. The depth of the pile varies which is designed according to the strata of soil, water table, and other factors that may affect the performance of the pile which was performed before the commencement of the project. Piles Layout Plan for N-78

17. The required depth of pile is determined using the load carrying capacity, which is calculated by in-situ penetration tests. These are built by making hole in the ground and then filling it with concrete. Pile Dimensions ( N – 78 ) :- Pile Diameter: 1200mm Pile Depth: 27.2m Pile cover: 75mm Pile locations are set out using pre-determined pile co-ordinate system, as per approved construction Drawing . COORDINATES OF PILES

18. Pile Boring : Then we learnt about the Pile Boring process . The survey and marking for this pile w as already done beforehand. We learnt about the machinery used and how the whole process of boring took place. The construction started by drilling a vertical hole into the soil. A rotary drilling rig or piling rig was used for the purpose of boring. The machine was outfitted with accessories like drilling tools, buckets, and grabs that help remove soil and rocks during the drilling process.Specially designed M-35 grade of concrete was used for this process

19. After concreting exacavation of soil was done upto pile cut of level .after excavation of soil PCC layer was laid on soil in order to level the soil , it act as shield for reinforce concrete against direct contact with soil and water . Then process of removal of pile takes place by chipping. Pile had depth = 1.5 to 2.5 m Reinforcement in pile cape is provided to provide structural strength and distribution of load. The dimension for pile are usually given as Length =8.7m Breadth =7.8m Depth=2.1m Alsp bottom and top reinforcement are provided, shuttering and concreting is done to finish the process .

20. CONSTRUCTION OF PIER: The Piers are the vertical support structures of a flyover. They are the intermediate supports, whose function is to transmit the forces they receive from the load-bearing elements to the foundations. There are many types of piers, and they vary according to structural design, aesthetic and economic factors. The figure below shows the dimension of the pier which is been used at the site. Length-3000mm(3metre) Breath-2000(2metre)

21. The work started with the longitudinal reinforcements. The longitudinal reinforcement steel was made up of steel bars organized longitudinally in the pier. Longitudinal reinforcement also refers to the main steel bar. The longitudinal reinforcement Helps to withstand tensile stress developed Due to eccentricity or moment

22. After the placing of the main steel bars, the traverse reinforcements, also known as stirrups, are arranged along pier’s lateral direction in ties the main steel. The transverse reinforcement holds the longitudinal bars in position during concreting. It prevents longitudinal bars from bulkling . It also gives ductility to the column.

23. SHUTTERING OF PIER: Shuttering was made of steel. The verticality of shuttering was checked by using plumb bob and thread. A cover block was provided for better finishing. The shutters were supported with the help of rods called channels. The leveling of shuttering is also done by the use of total station. The total station gives the exact coordinates at which the settlement of shuttering is corrected. The shuttering is been supported by the use of jacks such as spain jack ,coupling 32 jack and U-jack .By the use of jacks the shuttering of pier is aligned which is been directed by the total station.

24. CASTING AND CURING OF PIER:

25. Casting of pier was done by boom placer. A specially designed M50 Concrete is used. The concreting was done in stages. It was done up to 1.5m to 2m at once. Then, shuttering was done above it and is filled with concrete. The sequence continues till we reached the desired height. Curing is done by hanging gunny bags or sprinkling water at regular intervals. The Curing period is 28 to 30 days

26. CONCLUSION During Our 1-month internship training with the National Highways Authority of India (NHAI), working on the expressway flyover project has been an enriching and insightful experience. We had the opportunity to actively contribute to the construction phases of the project, gaining valuable hands-on experience in civil engineering and project management. Throughout the internship, We were exposed to the complexities of infrastructure development and the importance of adhering to strict safety and quality standards. We worked alongside experienced professionals who generously shared their knowledge and expertise, helping me develop a deeper understanding of expressway design, construction methodologies, and the overall functioning. In conclusion, our internship with NHAI on the expressway flyover project has been a transformative experience, significantly enhancing my technical knowledge and professional skills.

27. THANK YOU