UC-0212-FCR

FACULTY OF TECHNOLOGY (FoT),
CEPT UNIVERSITY, K. L. CAMPUS, NAVRANGPURA, AHMEDABAD- 09
PH (079) 26302470, FAX (079) 26302075, www.cept.ac.in
FACULTY IN-CHARGE:
Prof. RESHMA SHAH
Prof. DEVANSHU PANDIT
Prof. BHARGAV TEWAR
Prof. PARTH THAKER
PREPARED BY:
ARPIT ARORA (UC 0212)
NAGARNAR STEEL PLANT-JAGDALPUR, CHHATTISGARH
FINAL COMPREHENSIVE REPORT

NAGARNAR STEEL PLANT FINAL COMPREHENSIVE REPORT
CHHATTISGARH PROJECT TRAINING 2015‐16
i ARPIT ARORA FACULTY OF TECHNOLOGY Page |
(UC‐0212) C.E.P.T UNIVERSITY
ACKNOWLEDGEMENT
I feel great pleasure in putting forward my Project Training Report on Nagarnar Steel Plant, Jagdalpur,
Chhattisgarh.
I would like to take this opportunity to extend my gratitude to the H.R. Department of NMDC for
allowing me to undergo the training on their prestigious project. My sincere gratitude to the following
people for their valuable guidance and support throughout my training period.
For NMDC-
1. Mr. V.S. Prabhakar (G.M. Projects)
2. Mr. Akhbar Javed (J.G.M. Personal)
3. Mr. Loknath Mohapatra (D.G.M. Civil)
4. Mr. P. Prasanna Kumar (Sr. Manager- L&T Pachage)
5. Mr. Sanjeev Gahir (Sr. Manager- R.M.H.S. Package)
6. Mr. G. Sahu (Assistant Manager- L&T Package)
7. Mr. Naresh Babu (Manager- Surveying)
8. Mr. G. Subanna (Manager- R.M.H.S. Package)
For L&T-
1. Mr. K. Mukherjee ( InCharge- Reservoir)
2. Mr. P. Gopinath (Incharge-OHT)
3. Mr. Prabhu Datta (Incharge- RWPH)
4. Mr. N.B. Vinay Sagar, Mr. Ranjith K.B., Mr. Srinivas C.B. (Planning)
5. Mr. P. Nagamalleshwar Rao ( Q.A./Q.C. Incharge)
6. Mr. Rohit Das, Mr. David Wilson, Mr. Loknath Rao, Mr. P. Aravind
For BHEL-
1. Mr. Yogesh Prasad ( Structural Works)
2. Mr. Gautam Gulati ( Planning- Fabrication and Erection)
3. Mr. John. P ( Incharge- Fabrication)
4. Mr. Rajshekhar ( Ex. Engineer)
I would also like to thank my Panel Incharge- Prof. Reshma Shah for her valuable inputs and
support provided during the entire period of Project Training.
I would also like to acknowledge Prof. Devanshu Pandit, Prof. Bhargav Tewar, Prof. Parth
Thaker for their teachings of the various subjects that proved to be valuable in the past 3 years.
Lastly, I would like to thank my parents and younger brother for their consistent support
throughout the training period.
Special thanks to Viranj, Aashlesh, Paridhi, Niraj(especially with the final section), Kalrav
and Harshit for being there for me.

Sr.No. TOPIC Pg.No.
1 INTRODUCTION 1-8
1.1 PROJECT 1-2
1.1.1 Need For Project 1
1.1.2 About The Project 1
1.1.3 Scope Of Work 2
1.2 PROJECT LOCATION 2
1.3 PLANT LAYOUT 3
1.4 PROJECT BREAKDOWN 4
1.4.1 L&T 4
1.4.2 BHEL 4
1.5 HIGHLIGHTS OF THE PACKAGE 5
1.5.1 L&T 5
1.5.2 BHEL 5
1.6 SALIENT FEATURES& CONTRACT CONDITIONS 6
1.7 ORGANIZATION CHARTS 7-8
1.7.1 NMDC 7
1.7.2 L&T 7
1.7.3 BHEL 8
2 CONSTRUCTION METHODOLOGY 9-19
2.1 JOB LAYOUTS 9-12
2.1.1 Job Layout for Earthen Reservoir & Raw Water Pump House Area 9
2.1.2 Job Layout for Overhead Tank Area 10
2.1.3 Job Layout for Fabrication Yard 11
2.1.4 Job Layout for Silo Works 12
2.2 PROJECT PROGRESS 13
2.2.1 Project Progress from Time of Joining and Leaving 13
2.2.2 Project Progress in Terms of Cost 13
2.2.3 Month Wise Project Progress 13
2.2.4 Progress Comparison with L-2 Schedule 13
2.3
CONSTRUCTION PROCEDURES FOR OBSERVED
STRUCTURES 14-15
2.3.1 Earthen Raw Water Reservoir 14
2.3.2 Overhead Tank Beams 14
2.3.3 Raw Water Pump House 14
2.3.4 Conveyor Galleries 15
TABLE OF CONTENTS….

Sr.No. TOPIC Pg.No.
2.3.5 Silo Walls 15
2.4 CONSTRUCTION METHODOLOGY 16
2.5 MATERIALS AND SPECIFICATIONS 16
2.6 BASIC FACILITIES AT SITE 16-17
2.7 LABOUR AVAILABILITY AND DISTRIBUTION 17-18
2.7.1 L&T 17
2.7.2 BHEL 18
2.8 EQUPIMENTS AT SITE 19
2.9 FREQUENT MATERIAL TESTS AT SITE 19
3 CONSTRUCTION ACTIVITIES 20-120
3.1
CONCRETE LINING OF RAW WATER RESERVOIR 20-29
3.1.1 Activity Introduction 20-21
3.1.2 Construction Procedure 22-24
3.1.3 Analysis 25-
3.1.3.1 Timeline for the Activity 25
3.1.3.2 Quantity Calculation 25
3.1.3.3 Labour Productivity 26
3.1.3.4 Concrete Time Cycle 27
3.1.3.5 Rate Analysis 28-29
3.2 OVERHEAD TANK BEAMS 30-46
3.2.3 Analysis 43-46
3.2.3.1 Productivity Analysis 43-44
3.2.3.2 Concrete Time Cycle 45
3.2.3.3 Rate Analysis 46
3.3 COUNTERFORT AND RETAINING WALL 47-60
3.3.2.1 Counterfort Shuttering 50-52
3.3.2.2 Retaining Wall Shuttering 53-55
3.3.2.3 Concreting 56
3.3.3.1 Quantity Calculation 57-58
3.3.3.2 Productivity Table 59

Sr.No. TOPIC Pg.No.
3.4 FABRICATION OF TRESTLES 61-70
3.4.1 Activity Introduction 61
3.4.3.1 Weight Calculation 68
3.4.3.2 Time Cycle for Activity 68
3.4.3.4 Quantity Analysis 69
3.4.3.5 Consumables List 70
3.5 ERECTION OF CONVEYOR GALLERIES 71-85
3.5.3 Analysis 85
3.5.3.2 Timeline for the Activity 85
3.6 SILO R.C.C. WORKS 86-120
a. Reinforcement of Silo Wall 89-93
b. Formmwork of Silo Wall- Slip Form 94-105
c. Concreting of Silo Wall 106-107
d. Lining Works of Silo Wall 108-111
3.6.3 Analysis 112-120
3.6.3.1 Weight Calculation of Formwork Material 112-113
3.6.3.2 Slipfrom Load Calculation 114
3.6.3.3 Concrete Cycle 115-116
3.6.3.4 Lift Observation 116
3.6.3.5 Productivity Table 117-118
3.6.3.6 Rate Analysis 119-120
4 MANAGEMENT 121-131
4.1 QUALITY MANAGEMENT 121-125
4.1.1 Quality Policy of Company 121
4.1.2 Quality Assurance Plan 121
4.1.3 Quality Monitoring 122-124
4.1.4 Quality Evaluation & Records 125
4.1.5 Responsibilities of Q.A./Q.C. Engineer 125
4.2 MATERIAL MANAGEMENT 126-130
4.2.1 Material Requisition/Procurement 126-127
4.2.2 Material Receiving 127-128
4.2.3 Store Management 128
4.2.4 Materila Testing 129
4.2.5 Record Keeping 129
4.2.6 Reconciliation 129

Sr.No. TOPIC Pg.No.
4.3 BILLING MANAGEMENT 129
4.3.1 R.A. Bills 129
4.3.2 Recovery of Cement 129
4.4 SAFETY MANAGEMENT 129-130
4.4.1 Safety Policy at Site 129-130
4.4.2 Responsibility Table for Safety at Site 130
4.4.3 Safety Provision at Site 130
4.4.4 Safety Procedures in Special Cases 130
4.4.5 Reporting & Record Keeping 130
4.5 EQUIPMENT MANAGEMENT 131
4.5.1 Maintenance Register 131
4.5.2 Issue Register 131
4.5.3 Fuel Consumption & Issue Register 131
4.5.4 Payment Register for Hired Equipment 131
4.5.5 Equipment Owning & Operating Cost 132-133
4.6 MIS 131
4.6.1 Daily Progress Report 131
4.6.2 Monthly Progress Report 131
4.6.3 Non Conformance Report 131
4.6.4 Daily Labour Report 131
5 CONCUSION & SUMMARY 134
ANNEXURES

S.No. Fig.No. DESCRIPTION Pg. No.
1 1.2.01 Project Location 2
2 1.3.01 Details of Land Around Plant 3
3 1.3.02 Layout Showing Different Packages 3
4 1.6.01 Cost Distribution As Per Tender For L&T Package 6
5 1.6.02 Cost Distribution As Per Tender For BHEL Package 6
6 2.1.01
Job Layout for Earthen Reservoir & Raw Water Pump House
Area
9
7 2.1.02 Job Layout for Overhead Tank 10
8 2.1.03
Job Layout for Fabrication Yard
11
9 2.1.03
Job Layout for Silo Works
12
10 2.2.01
Project Progress from Time of Joining and Leaving
13
11 2.2.02
Project Progress in Terms of Cost
13
12 2.2.03
Month Wise Project Progress
13
13 2.2.04
Progress Comparison with L-2 Schedule
13
14 2.7.1.01 Labour Deployment for L&T 17
15 2.7.1.02 Labour Distribution for L&T 17
16 2.7.2.01 Labour Deployment for BHEL 18
17 2.7.2.02 Labour Distribution for BHEL 18
18 3.1.1.01 Location of Reservoir Activity 21
19 3.1.1.02 Layout fro Comparthment-2 21
20 3.1.2.03 Route of Transit Mixer for The Activity 22
21 3.1.2.04 Cutting of Trenches 23
FIGURE INDEX…..

22 3.1.2.05 Sand Fillingn of Trenches 23
23 3.1.2.06 Laying of LDPE Sheets 23
24 3.1.2.07 Fixing of P.R. Valves 23
25 3.1.2.08 Setup for Concreting 24
26 3.1.2.09 Final Section After Concreting 24
27 3.1.3.1.01 Timewise Distribution For The Activity 25
28 3.1.3.3.01 Labour Wise Cost Distribution 26
29 3.1.3.4.01 Waiting Time v/s Batch Number 27
30 3.1.3.4.02 Concreting Time v/s Batch Number 27
31 3.1.3.4.03 Day Wise Analysis- Concreting 27
32 3.1.3.4.04 Day Wise Analysis- Sand Filling 27
33 3.1.3.4.05 Day Wise Analysis- LDPE Laying 27
34 3.1.3.4.06 Day Wise Analysis- Wire Mesh 27
35 3.1.3.5.01 Rate Breakup For Sand Bedding 29
36 3.1.3.5.02 Rate Breakup for LDPE Sheets 29
37 3.1.3.5.03 Rate Breakup for Wire Mesh & P.R. Valves 29
38 3.1.3.5.04 Rate Breakup for Batching Plant 29
39 3.2.1.01 Water Distribution System in Plant 31
40 3.2.2.01 Procedure Step-1 for Staging 33

45 3.2.2.06 Procedure Step 6 for Staging 33
46 3.2.2.07 Typical H-Frame 34
47 3.2.2.08 Material Used for Scaffolding 34
48 3.2.2.09 Detail of B1-B4 Junction 36
51 3.2.2.12 Detail of B2/B3-B4 Junction 36
52 3.2.2.13 Beam Details 37
53 3.2.2.14 Beam Details 38
54 3.2.2.15 Procedure for Shuttering 40
55 3.2.2.16 Shuttering of Beam Junction 40
56 3.2.2.17 Shuttering of Column C-2 40
57 3.2.2.18 Route of Transit Mixer for The Activity 41
58 3.2.2.19 Layout of Concrete Pipe 42
59 3.2.2.20 Order of Concreting 42
60 3.2.3.2.01 Batch Number v/s Waitng Time 45
61 3.2.3.2.02 Batch Number v/s Delay Time 45
62 3.2.3.2.03 Batch Number v/s Concreting Time 45
63 3.2.3.3.01 Rate Breakup for Concreting 46
65 3.3.1.01 Job Layout for the Activity 48
66 3.3.1.02 Section 1-1 Showing Location of Walls 49
67 3.3.1.03 Section 2-2 Showing Location of Walls 49

68 3.3.2.1.01 Steps for Reinforcement of Counterfort 50
69 3.3.2.1.02 Placing of Vertical Plyboard 51
70 3.3.2.1.03 Section 2-2 51
71 3.3.2.1.04 Placing of Inclined Plyboard 51
72 3.3.2.1.05 Sectiion 4-4 51
73 3.3.2.1.06 External View of Counterfort Shuttering 52
74 3.3.2.1.07 Plan & Elevaation of Counterfort 52
75 3.3.2.2.01 Route of Transit Mixer for The Activity 53
76 3.3.2.2.02 Tieing & Fixing of Plyboard Boards 54
77 3.3.2.2.03 Provision of Horizontal Supports 54
78 3.3.2.2.04 Provison of Additional Support to Steel Wallers 55
79 3.3.2.2.05 Detail of Connection at Board 55
80 3.3.2.2.06 Placing of H-Beams & walkway Jaalis 55
81 3.3.2.3.01 Concrete Setup for the Activity 56
82 3.3.3.1.01 Length Derivation for Wall-1 58
87 3.4.2.01 Marking of Plates-1 63
90 3.4.2.05 Detail of Equipment for Cutting of Plate 65

91 3.4.2.06 Electric Layout for Both Welding methods 66
92 3.4.2.07 Detail of Base Plate 67
93 3.4.2.08 Detail of Splice Plate 67
94 3.4.3.2.01 Time Cycle for the Activity 68
95 3.5.1.01 Elevation of JH-J44C2 72
96 3.5.1.02 Elevation of JH-J44C2 73
97 3.5.1.03 Bottom Chord Plan of GR-4 74
98 3.5.1.04 Portal Details of GR-4 75
99 3.5.1.05 Level Plans for GR-4 76
100 3.5.1.06 Elevation of GR-6 77
101 3.5.1.07 Layout Details of GR-6 78
102 3.5.1.08 Level Plans of GR-6 79
103 3.5.2.01 Details of TR-7A, 7B, 7C 81
104 3.5.2.02 Detail D-1 82
105 3.5.2.03 Detail D-2 82
106 3.5.2.04 Detail of TR-8 83
107 3.5.2.05 Process of Erection on Site 84
108 3.5.3.2.01 Timeline for the Activity 85
109 3.6.1.01 Excavation Plan of Silo 87
110 3.6.1.02 Foundation Plan of Silo 88
111 3.6.2.01 Placing of Inner and Outer Vertical Reinforcement 90
112 3.6.2.02 Placing of Horizontal Reinforcement 91
113 3.6.2.03 Hopper Reinforcement Details 92

114 3.6.2.04 Reinforcement Detail at Junction 93
115 3.6.2.05 Placing of Inner Shutter 95
116 3.6.2.06 Placing of Inner Steel Wallers 95
117 3.6.2.07 Placing of Inner Yoke Beams 96
118 3.6.2.08 Placing of Outer Shutter Plates 96
119 3.6.2.09 Details of Yoke Beams 97
120 3.6.2.10 Details of Canculars 97
121 3.6.2.11 Placing of Outer Steel Wallers 98
122 3.6.2.12 Placing of Outer Yoke Beams 98
123 3.6.2.13 View of External Shutter Plate at Junction 99
124 3.6.2.14 Fixing of Inner Canculars 100
125 3.6.2.15 Placing of Outer Canculars 100
126 3.6.2.16 Fixing of Head Beams 101
127 3.6.2.17 Fixing of Spoke Wheel and Recovering Rods 101
128 3.6.2.18 Placing of Recovering Rod 102
129 3.6.2.19 Placing of Base Plate 102
131 3.6.2.20 Placing of Hydraulic Jack 102
132 3.6.2.21 Details of Hydraulic Jack 102
133 3.6.2.22 Components of Slip Form 103
134 3.6.2.23 Components of Slip Form 103
135 3.6.2.24 Details of Upper Platform 104
136 3.6.2.25 Section at Start of Concreting 105
137 3.6.2.26 Section after 2000mm of Concreting 105

138 3.6.2.27 Details of Lower Platform 105
139 3.6.2.28 Route of Transit Mixer 106
140 3.6.2.29 Location of Hydraulic Jacks 107
141 3.6.2.30 Insert Plate Fixing Layout 108
142 3.6.2.31 Details of Fixing of Insert Plate 108
143 3.6.2.32 Platform Details 109
144 3.6.2.33 Liner Plate Fixing Layout 109
145 3.6.2.34 Detail of Liner Plate 110
146 3.6.2.35 Step-wise Procedure for Liner Plate Fixing 111
147 3.6.2.36 Detail D-1 111
148 3.6.3.3.01 Batch Number v/s Slump 116
149 3.6.3.3.02 Batch Number v/s Waiting Time 116
150 3.6.3.3.03 Batch Number v/s Concreting Time 116
151 3.6.3.4.01 Day-wise Lift Comparison with Actual & Theoretical 116

S.No. TABLE No. DESCRIPTION Pg. No.
1 1.2.01 Details About Project Location 2
2 1.2.02 Details About Connectivity to Site 2
3 1.3.01 List of Major Packages at Site 3
4 1.5.1.01 Salient Features of L&T Package 5
5 1.5.2.01 Salient Features of BHEL Package 5
6 1.6.01 Important Contract Conditions for Both Packages 6
7 2.5.01 Frequently Used Materials & their Sources 16
8 2.7.01 Labour Comparison 18
9 2.8.01 Some Major Equipments at Site 19
10 2.8.02 Tests Carried on Site for Frequently Used Materials 19
11 3.1.1.01 Levels Encountered in the Activity 20
12 3.1.3.1.01 Timeline for the Activity 25
13 3.1.3.3.01 Labour Productivity for the Activity 26
14 3.1.3.4.01 Concrete Timw Cycle 27
15 3.1.3.5.01 Rate Analysis for Concreting 28
17 3.2.2.01 Mix Design Details 41
18 3.2.3.1.01 Productivity Table for Reinforcement 43
19 3.2.3.1.02 Prductivity Table for Shutterign & Staging 43
20 3.2.3.1.03 Productivity Table for Concreting 44
21 3.2.3.2.01 Concrete Time Cycle 45
TABLE INDEX

22 3.2.3.2.02 Ratios 45
23 3.2.3.3.01 Rate Analysis for Reinforcement 46
24 3.2.3.3.02 Rate Analysis for Shuttering 46
26 3.3.1.02 Wall Widths 47
27 3.3.3.1.01 Shuttering Quantity Calculation 57
28 3.3.3.1.02 Concreting Quantity Calculation 57
29 3.3.3.2.01 Productivity Analysis 59
30 3.3.3.3.01 Rate Analysis for Concreting 60
31 3.3.3.3.02 Rate Analysis for Shuttering 60
32 3.4.3.1.01 Weight Calcualiton of Plates Observed 68
33 3.4.3.3.01 Productivity for the Activity 69
34 3.4.3.4.01 Quantity Calculation for Welding 69
35 3.4.3.5.01 Consumables List 70
36 3.4.3.6.01 Rate Analysis for Fabrication 70
37 3.5.3.1 Productivity Table for the Activity 85
38 3.5.3.2.01 Activity-wise Time Distribution 85
39 3.6.1.01 Phase-wise Distribution 86
40 3.6.3.1.01 Dead Weight Calculation of Formwork 112-113
41 3.6.3.3.01 Concrete Cycle 115
42 3.6.3.4.01 Day-wise Lift Observed 116
43 3.6.3.5.01 Productivity Table for Reinforcement 117
44 3.6.3.5.02 Productivity Table for Lining 117

45 3.6.3.5.03 Productivity Table for Concreting 117
46 3.6.3.5.04 Productivity Table for Formwork 118
47 3.6.3.6.01 Rate Analysis for Reinforcement 119
48 3.6.3.6.02 Rate Analysis for Lining Works 119
49 3.6.3.6.03 Rate Analysis for Conceting 120
50 3.6.3.6.04 Rate Analysis for Formwork 120
51 4.1.3.01 Quality Monitoring at Site 122-124
52 4.4.2.01 Responsibility Table for Safety at Site 130
53 4.5.5.01 Owning & Operating Cost 132
54 4.5.5.02 Cost Calculation for Hired Equipment 133
55 A.01 Rate Derivation for Respective Analysis A.01
56 A.02 Sample Checklist for Activities A.02

S.No. F.C. No. DESCRIPTION P. No.
1 1.1.2.01 Project Tree 1
2 1.4.1.01 L&T Project Breakdowm Structure 4
3 1.4.2.01 BHEl Project Breakdowm Structure 4
4 1.7.1.01 NMDC Organization Chart 7
5 1.7.2.01 L&T Orgaization Chart 7
6 1.7.3.01 BHEL Organization Chart 8
7 2.3.1.01 Activity Sequence for Raw Water Reservoir 14
8 2.3.2.01 Activity Sequence for Overhead Tank Beams 14
9 2.3.3.01 Activity Sequence for Raw Water Pump House 14
10 2.3.4.01 Activity Sequence for Conveyor Galleries 15
11 2.3.5.01 Activity Sequence for Silo Wall 15
12 3.1.1.01 Sequence for Concrete Lining 22
13 3.2.2.01 Sequence for Staging Works 32
14 3.2.2.02 Flowchart for Reinforcement Activity 35
15 3.2.2.03 Flowchart for Shuttering Works 39
16 3.3.2.1.01 Sequence for Counterfort Shuttering 50
17 3.3.2.2.01 Sequence for Retaining Wall Shuttering 53
18 3.4.2.01 Flowchart for Fabrication 62
19 3.5.2.1 Sequence for Crane Erection 80
20 3.6.2.01 Sequence for Reinforcement of Silo Wall 89
21 3.6.2.02 Sequence for Shuttering of Silo Wall 94
FLOWCHART INDEX

S.No. F.C. No. DESCRIPTION P. No.
22 3.6.2.03 Sequence for Lining of Silo Wall 109
23 4.2.1.01
Procurement Procedure for Construction Material of Natural
Origin 126
24 4.2.1.02
Procurement Procedure for Manufactured Items through
Regional Office 127
25 4.2.2.01 Material Receiving Process 127
26 4.2.3.01 Store Management at Site 128

CHAPTER‐ ‐INTRODUCTION ARPIT ARORA FACULTY OF TECHNOLOGY
Page | (UC‐0212) C.E.P.T UNIVERSITY
CHAPTER# 1‐
INTRODUCTION TO SITE
1.1  PROJECT
1.2  PROJECT LOCATION
1.3  PLANT LAYOUT
1.4  PROJECT BREAKDOWN‐PACKAGE WISE
1.5  HIGHLIGHTS OF PACKAGE
1.6  SALIENT FEATURES AND CONTRACT CONDITIONS
1.7  ORGANIZATION CHARTS

CHAPTER‐ ‐ INTRODUCTION ARPIT ARORA FACULTY OF TECHNOLOGY
Page | 1 (UC‐0212) C.E.P.T UNIVERSITY
1.1 PROJECT
Construction of a 3MTPA capacity green-field Integral Steel Plant under the value addition expansion plan of NMDC Ltd.
1.1.1 NEED FOR PROJECT
With the increase in population and the emerging economies, steel demand has increased drastically from 6.5% in 2012 to 8%
in 2015. WSA has projected Indian steel demand to grow by another 7.3% in 2016 as compared to global steel use growth of
1.4% only. Rapid rise in production of steel has made India the 3rd largest producer of crude steel in 2015 and the country
continues to be the largest producer of sponge iron or DRI in the world. Keeping the global scenario and per capita steel usage
in mind, NMDC (National Mineral Development Corporation) has introduced, under it’s expansion program, the construction
of a 3MTPA capacity greenfield Integrated Steel Plant at Nagarnar, 16 km away from Jagdalpur, Chhattisgarh (Refer Fig.1.2.01)
The overall cost of the project is estimated to be Rs.20,000 crores.
1.1.2 ABOUT THE PROJECT
The project is based on HiSmelt technology and so far 16 major packages have already been awarded at a round cost of Rs.
14,000 crores (Refer Table T‐1.1.2.01). Along with the construction of the integrated steel plant, NMDC Ltd will spend Rs 10,000
crores on setting up slurry pipelines and pellet plant, among other works to facilitate the working units in the plant and reduce
dependency on railways
SOME MAJOR ACTIVITIES
RESERVOIR BED
FORMATION
SILO SLIPFORM
OVER HEAD TANK TIE
BEAMS
COUNTERFORT &
RETAINING WALL
CONVEYOR GALLERY
ERECTION
TASK
CIVIL CONSTRUCTION AND RELATED STRUCTURAL WORK FOR STEEL PLANT
PACKAGE
R.M.H.S.
COKE
OVEN
BY
PRODUCT
BLAST
FURNACE
THIN SLAB
CASTER
WATER
TREATMENT
LIME &
DOLO
S.M.S
SINTER
PLANT
PROJECT
3MTPA BROWNFIELD INTEGRAL STEEL PLANT
PROGRAMME
EXPANSION AND FORWARD INTEGRATION PROGRAMME
F.C. 1.1.2.01  FLOWCHART SHOWING PROJECT TREE

CHAPTER‐‐INTRODUCTION FACULTY OF TECHNOLOGY
Page | ‐ C.E.P.T UNIVERSITY
ARPIT ARORA
(UC0212)
3
1.3 PLANT LAYOUT
The names and approximate costs of the major packages that are on-going at present in the plant is tabulated below
Figure 1.3.01:  DETAILS OF LAND AROUND THE PLANT Figure 1.3.02:  LAYOUT SHOWING DIFFERENT PACKAGES
S.NO.
Name of
Package
Contractor
Package
Number
Cost of Work
Package (Crores)
1
Raw material
Handling System
BHEL Pkg‐01 1400
2 Coke Oven Plant BEC Pkg‐02 1800
3 By product Sri Ram EPC Pkg‐03 500
4
Reservoir and
Raw Water
Treatment Plant
L&T Pkg‐17‐01 350
5 Sinter Plant SIEMENS Pkg‐04 760
S.NO. Name of Package Contractor
Package
Number
Cost of Work
Package (Crores)
6 Blast Furnace TATA Pkg‐05 1700
7 Steel Melting Shop SIEMENS Pkg‐06 520
8 Thin Slab Caster SPCL Pkg‐07 300
9
Lime & Dolomite
Plant
IRCON Pkg‐ 08 320
The highlighted
packages are the
packages under which
the training was done.

1.1.3 SCOPE OF WORK
1.1.3.1 L&T
Design, engineering supply, erection/construction, commissioning, testing & conducting performance guarantee tests etc. of
plant & equipment etc. of Raw water reservoir, Raw water pump house and Overhead tank from December 28, 2015 to April 24,
2016.
1.1.3.2 BHEL
Design, engineering, supply, fabrication, erection/construction, cladding, testing & conducting performance guarantee tests etc.
of plant and equipment etc. of Junction House, Conveyor Galleries and Coal Handling Silos from December 28, 2015 to April
24, 2016.
1.2 PROJECT LOCATION
The project is located in the state of Chhattisgarh, Bastar district (Refer Fig. 1.2.01), having to consider the richest iron ore and
coal deposits in the country
Figure 1.2.01: PROJECT LOCATION
Some features regarding the location of the project are as follows-
CO‐ORDINATES OF LOCATION 19.07ºN, 82.03ºE
ELEVATION 552m A.S.L.
MAXIMUM TEMPRATURE 42.2ºC (APRIL 10, 2016)
MINIMUM TEMPRATURE 11.5ºC (JANUARY 4, 2016)
WEATHER CONDITIONS TROPICAL
RAINFALL JUNE‐ SEPTEMBER
NEAREST RAILWAY
STATION
AMAGUDA (2km
away)
NEAREST AIRPORT VISHAKHAPATNAM
(200km away)
NEAREST SEA PORT VISHAKHAPATNAM
(200km away)
VIA ROAD The Site lies on NH‐
43
TABLE T‐ 1.2‐1.2.01: DETAILS ABOUT PROJECT LOCATION TABLE T‐1.2.02: DETAILS ABOUT CONNECTIVITY TO SITE

CHAPTER‐ ‐INTRODUCTION FACULTY OF TECHNOLOGY
ARPIT ARORA
(UC0212)4
1.4 PROJECT BREAKDOWN
1.4.1 L&T
1.4.2 BHEL
F.C.1.4.1.01: FLOWCHART FOR L&T PROJECT BREAKDOWN STRUCTURE
F.C. 1.4.2.01: FLOWCHART FOR BHEL PROJECT BREAKDOWN STRUCTURE

CHAPTER‐ ‐ INTRODUCTION ARPIT ARORA FACULTY OF TECHNOLOGY
1.5 HIGHLIGHTS OF THE PACKAGE
1.5.1 L&T
(L&T)
CAPACITY OF RESERVOIR 5 MILLION cum.
NUMBER OF COMPARTMENTS IN
RESERVOIR
2
CAPACITY OF MAKE‐UP WATER
COMPARTMENT IN RWPH
1740 cum.
CAPACITY OF DRINKING WATER
COMPARTMENT IN RWPH
1330 cum.
CAPACITY OF OHT 2000 cum.
NUMBER OF COMPARTMENTS IN OHT 2 (MAKE‐UP+ DRINKING WATER)
1.5.2 BHEL
(B.H.E.L.)
TOTAL CAPACITY OF COAL SILOS 20,000 M.T.
NUMBER OF COAL SILOS 16
TOTAL CAPACITY OF SINTER MIX BUNKERS 5400 cum.
NUMBER OF BUNKERS 20
NUMBER OF JUNCTION HOUSES 82
NUMBER OF CONVEYOR GALLERIES 109
TABLE T‐1.5.2.01: SALIENT FEATURES OF BHEL PACKAGE
TABLE T‐1.5.1.01: SALIENT FEATURES OF L&T PACKAGE

1.6 SALIENT FEATURES & CONTRACT CONDITIONS
Name of Contractor L&T Construction B.H.E.L.
Name of Consultant MECON Ltd. MECON Ltd.
Type of Project Industrial Industrial
End Use
Supply of Drinking & Make up water in
the plant and township
Conveying of Raw Materials to
various units of Plant
Package Name Make Up & Drinking Water Project Raw Material Handling System
Package Number PKG 17‐01 PKG‐01
Cost of Package Rs. 356,85,00,000 Rs.139,50,00,00,000
Cost of Civil Works Rs. 221,01,00,000 Rs.23,56,80,00,000
Type of Contract Turnkey Contract Turnkey Contract
Type of Planning and Design Schedule Based Schedule Based
Area of Construction ( total) 125 acres 296.53 acres
Date of Project Starting 20‐Jan‐15 03‐Sep‐11
Time Frame 24 Months 30 months
Expected Completion Date 20‐Jan‐17 03‐Feb‐17
Limit of Liquidated Damage 10% of contract cost 10% of contract cost
Payment Mode Milestone Basis Milestone Basis
1%
30%
62%
1%
0% 6%
COST DISTRIBUTION AS PER
TENDER FOR L&T PACKAGE
DESIGN &
ENGINEERING
SUPPLY OF PLANT &
EQUIPMENTS AT
SITE
CIVIL ENGINEERING
WORKS
5%
42%
17%
32%
4%
0.003% 0%
COST DISTRIBUTION AS PER
TENDER FOR BHEL PACKAGE
Design &
Engineering
Supply of Plants &
Equipments at Site
Civil Engineerign
Works
Supply of
Fabricated Building
Structures
TABLE T‐ 1.6.01: IMPORTANT CONTRACT CONDITIONS FOR BOTH PACKAGES
Figure‐1.6.01: COST DISTRIBUTION AS PER TENDER FOR L&T PACKAGE Figure 1.6.02: COST DISTRIBUTION AS PER TENDER FOR BHEL

ARPIT ARORA
(UC0212)7
1.7 ORGANIZATION CHARTS
1.7.1 NMDC
1.7.2 L&T
F.C.1.7.1.01: NMDC ORGANIZATION CHART
F.C.1.7.2.01: L&T ORGANIZATION CHART

Page | 8 C.E.P.T UNIVERSITY
ARPIT ARORA
(UC‐0212)
1.7.3 BHEL
F.C.1.7.3.01: BHEL ORGANIZATION CHART

CHAPTER‐ ‐ CONSTRUCTION METHODOLOGY ARPIT ARORA FACULTY OF TECHNOLOGY
CHAPTER# 2‐
CONSTRUCTION METHODOLOGY
2.1  JOB LAYOUT
2.2  PROJECT PROGRESS
2.3  CONSTRUCTION PROCEDURES OF OBSERVED STRUCTURES
2.4  CONSTRUCTION METHODOLOGY
2.5  FREQUENTLY USED MATERIALS AND SPECIFICATIONS
2.6  BASIC FACILITIES AT SITE
2.7  LABOUR AVAILABILITY & DISTRIBUTION
2.8  LIST OF MAJOR EQUIPMENTS AT SITE

CHAPTER‐‐CONSTRUCTION METHODOLOGY FACULTY OF TECHNOLOGY
Page | 9 ‐ C.E.P.T UNIVERSITY
ARPIT ARORA
(UC0212)
2.1 JOB LAYOUTS
2.1.1 JOB LAYOUT FOR EARTHERN RESERVOIR AND RAW WATER PUMP HOUSE AREA
Figure 2.1.01: JOB LAYOUT FOR EARTHERN RESERVOIR AND RAW WATER PUMP HOUSE AREA
NOTE- THE LAYOUT FOR THE PUMP HOUSE BUILDING WILL BE PROVIDED ALONG WITH THE ACTIVITY IN PART-3 OF THIS REPORT.

CHAPTER‐
10
‐CONSTRUCTION METHODOLOGY            FACULTY OF TECHNOLOGY
ARPIT ARORA
(UC0212)
2.1.2 JOB LAYOUT FOR OVERHEAD TANK AREA
Figure 2.1.02: JOB LAYOUT FOR OVERHEAD TANK  AREA

CHAPTER‐
11
ARPIT ARORA
(UC0212)
2.1.3 JOB LAYOUT FOR FABRICATION YARD AREA
Figure 2.1.03: JOB LAYOUT FOR FABRICATION YARD AREA

ARPIT ARORA
(UC0212)
2.1.4 JOB LAYOUT FOR SILO WORKS
Figure 2.1.04: JOB LAYOUT FOR SILO WORKS

ARPIT ARORA
(UC0212)
2.2 PROJECT PROGRESS
2.2.1 PROJECT PROGRESS FROM THE TIME OF JOINING TO LEAVING
40%
23%
9%
70%
64%
45%
15%
59%
44%
58%
83% 78%
62%
19%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
% COMPLETION
MAJOR ACTIVITIES
PROJECT PROGRESS FROM DEC'15‐APRIL'16
Up to Dec'15 Up to April 16
Figure 2.2.01: PROJECT PROGRESS FROM DEC’12‐APRIL’16
2.2.2 PROGRESS COMPARISON WITH L‐2 SCHEDULE
30%
64%
40%
52%
0% 10% 20% 30% 40% 50% 60% 70%
Up to Dec'15
Up to April'16
% COMPLETION
TIME DURATION
WORK PROGRESS IN TERMS OF COST
BHEL L&T
Figure 2.2.02: PROJECT PROGRESS IN TERMS OF COST
2.2.3 MONTH WISE PROJECT PROGRESS
40%
44%
48%
54%
59%
23%
28%
35%
41%
44%
9%
15%
28%
46%
58%
70%
73%
75%
81%
83%
64%
67%
71%
73%
78%
45%
51%
55%
59%
62%
15%
15%
15%
19%
19%
0%
20%
40%
60%
80%
100%
Up to Dec'15 Up to Jan'16 Up to Feb'16 Up to March'16 Up to April'16
% PROGRESS
MAJOR ACTIVITIES
MONTH WISE PROGRESS
OVER HEAD TANK RCC WORS
RWPH RCC WORKS
RESERVOIR CONCRETE LINING
FABRICATION OF MAJOR  BUILDING
SILO RCC WORKS
Figure 2.2.03: MONTH WISE PROGRESS
2.2.2 PROJECT PROGRESS IN TERMS OF COST
82% 87%
56%
100% 100% 100% 100%
59%
44%
58%
83% 78%
62%
19%
0%
20%
40%
60%
80%
100%
120%
% COMPLETION
MAJOR ACTIVITIES
L‐2 v/s ACTUAL COMPARISON
AS PER L‐2 ACTUAL
Figure 2.2.04: L‐2 v/s ACTUAL COMPARISON

CHAPTER‐
14
ARPIT ARORA
(UC0212)
2.3 CONSTRUCTION PROCEDURES OF OBSERVED STRUCTURES
2.3.1 EARTHEN RAW WATER
RESERVOIR
2.3.2 OVERHEAD TANK BEAMS 2.3.3 RAW WATER PUMP
HOUSE
CUTTING OF TRENCHES
SAND FILLING OF 75mm
LDPE SHEET LAYING
PRESSURE RELEASE VALVES
FIXING
WELDED MESH OF 2mm
LAYING
60mm CONCRETE BEDDING
LEVELLING OF SURFACE
PROCUREMENT OF MATERIAL
SETTING UP OF PAVER MACHINE
CURING USING WET SAND BAGS
CONCRETING OF COLUMNS AT TIE
LEVEL-3
STAGING WORKS FOR BEAMS AT TIE
LEVEL 3- DOKA FORMWORK SYSTEM
FIXING OF BEAM BOTTOM
PROCUREMENT OF STAGING MATERIAL
BAR BENDING AND CUTTING
REINFORCEMENT
PLACING AND FIXING
ALLIGNMENT OF BOTTOM
WITH REINFORCEMENT CAGE
MATERIAL PROCUREMENT
FOR SHUTTERING MATERIAL
SHUTTERING OF BEAMS
PLACING OF WOODEN
SUPPORTS FOR PUMPING
SETTING UP OF CONCRETE
PUMP ETC. FOR CONCRETING
CONCRETING
CURING FOR 7 DAYS
BAR BENDING AND CUTTING
FOR COUNTERFORT
REINFORCEMENT OF
COUNTERFORT
MATERIAL PROCUREMENT
AND STACKING OF
SHUTTERING MATERIAL
SHUTTERING OF WALLS
SHUTTERING OF COUNTERFORT
PREPARATION FOR CONCRETING
CONCRETING OF WALLS
& COUNTERORT
CURING FOR 7 DAYS
F.C. 2.3.1.01: ACTIVITY SEQUENCE FOR RAW
WATER RESERVOIR F.C. 2.3.2.01: ACTIVITY SEQUENCE FOR OVERHEAD TANK BEAMS F.C. 2.3.3.01: ACTIVITY SEQUENCE FOR RAW WATER PUMP HOUSE
AA1

CHAPTER‐ ‐CONSTRUCTION METHODOLOGY FACULTY OF TECHNOLOGY
ARPIT ARORA
(UC‐0212)
2.3.4 CONVEYOR
GALLERIES
2.3.5 SILO WALL
MATERIAL PROCUREMENT ON THE
BASIS OF QUANTITY CALCULATION
FABRICATION OF THE DESIRED
ELEMENTS
DUMMY ASSEMBLY OF
THE GALLERY
LEVEL AND LINE CHECK
BEFORE FINAL BOLTING
FINAL ASSEMBLY OF THE
GALLERY
MARCHING OF CRANE ON SITE
CHECK FOR SAFETY BEFORE ERECTION
ERECTION OF GALLERY AND
FINAL BOLTING ON SITE
RING GIRDER CONCRETING
ALLIGNMENT OF STARTER
AND CONCRETING
BAR CUTTING AND BENDING FOR
SILO WALL REINF.
FIXING OF INSERT PLATES
SLIP FORM ASSEMBLY
FIXING OF HYDRAULIC
JACKS IN POSITION
MARCHING OF TOWER
CRANE IN POSITION
CONNECTION OF JACKS
WITH HYDRAULIC PUMP
CONCRETING UPTO 600mm
LIFTING OF ASSEMBLY IN ORDER OF 2
STOKES AT A TIME
F.C. 2.3.4.01: ACTIVITY SEQUENCE FOR CONVEYOR GALLERIES
F.C. 2.3.5.01: ACTIVITY SEQUENCE FOR SILO WALLS

CHAPTER‐ CONSTRUCTION METHODOLOGY ARPIT ARORA FACULTY OF TECHNOLOGY
2.4 CONSTRUCTION METHODOLOGY
Since the project is an industrial one, it comprises of numerous structures which are unique in their own design,
location, construction methodologies as well. Some of the structures with their construction procedures-
a. Raw Water Reservoir- Being an earthen reservoir, the structure has to avoid the failure of erosion by it’s
own shape. The cutting of sides is done by the front end loader at a specific angle of 30º (angle of repose) and
to ensure the prevention of leakage, LDPE sheets are laid above the ground followed by the reinforced wire
mesh. The concreting is supposed to be precise and levelled so as to avoid any undulations and therefore paver
machine is used for it to ensure consistent height of concreting.
b. Over Head Tank- This structure involves 11 storeys of repetitive construction procedure for both beams and
columns. So, the use of custom made shutter plates would be the best option to minimize the rate of shuttering
materials. For this structure, Doka Formwork System was implemented on site for staging purposes and
custom made shuttering plates were used for shuttering purpose.
c. Raw Water Pump House- The structure is at present in the foundation stage. To ensure effective and proper
construction at the foundation level, Doka Formwork System was used at site. The use of this system helps in
2 ways- the construction is more accurate and can be used for more repetitions.
d. Conveyor Galleries- For the erection of the conveyor galleries, crawler mounted crane was used at site of
capacity 150T. The weight of any conveyor gallery doesn’t exceed 45T, and it is advisable to use the crane to
only it’s 80% capacity. The area of erection is too congested for the use of 2 cranes of lesser capacity, hence
the use of a 150T crane would have been the best option.
e. Silo Wall- The silo structure is very important because it acts as a storage bin for the coal, which is to be used
in all other processes in the manufacturing process. For this structure to be accurate, the slip fom technology
would be the best option. Moreover, to ensure delayed corrosion of the silo walls, liner plates of SS are welded
on the walls once the RCC works is completed.
2.5 MATERIALS AND SPECIFICATIONS
Some of the common materials and their sources are as follows-
S.No. Material Agency B.I.S. No.
1 Cement ACC IS:456
2 Reinforcement Steel SAIL IS:1786
3 Structural Steel SAIL
4 Admixtures SIKA
5 PVC pipes and fittings Premier
6 Anti‐Termite Compounds M/s Pest Control Ltd.
7 Paints & Varnishes Asian Paints
8 Sand Approved source IS:383
9 Coarse Aggregte Approved source IS:383
TABLE T‐2.5.01 FREQUENTLY USED MATERIALS AND THEIR SORUCES
a. WATER-For curing purposes, water is used by tankers. For structures like silos and oht, tanks are placed near
the structure itself. Water is extracted from the borewells present at site.
2.6 BASIC FACILITIES AT SITE

b. ELECTRICITY-NMDC provides the electricity in the entire plant by collaboration with the state government.
Also, a small thermal plant of 25MW is been set up in the vicinity by NMDC for the same purpose.
c. QUALITY LABS- Both the contractors have quality checking labs for the inspection of frequents tests on the
construction materials. The labs are located near their package, within the plant
d. BATCHING PLANT-Each contractor has it’s own batching plant. The L&T project buys the concrete from
the batching plant sub contractor, while Prasad& Co. owns the batching plant for silo purposes.
e. MEDICAL- an exclusive container on site is provided for safety and medical attention only. Each container
consists of a first aid kit as well.
2.7 LABOUR AVAILABILITY AND DISTRIBUTION
2.7.1 L&T
2
3
3
1
8
6
6
3
4
3
2
2
189
31
5
2
7
30
52
22
18
31
14
0 20 40 60 80 100 120 140 160 180 200
Welder
Rigger
Store Helper
Electrician
Helper
MW Fitter
Carpenter
Security
Number Of Workers
Designation
LABOUR DEPLOYMENT (L&T)
Figure 2.7.1.01 LABOUR  DEPLOYMENT FOR L&T
47%
21%
32%
LABOUR DISTRIBUTION‐L&T
Unskilled Skilled Semi‐skilled
Figure 2.7.1.02 LABOUR  DISTRIBUTION FOR L&T

2.7.2 BHEL
49
33
7
51
4
1
17
8
10
61
50
206
30
12
15
70
241
0 50 100 150 200 250 300
Engineer
Supervisor I/C
Surveyor
Fabricator
Supervisor (Safety)
Others‐Fabrication
Carpenter
Security
Unskilled
Number of Workers
Designation
LABOUR DEPLOYMENT (BHEL)
Figure 2.7.1.01 LABOUR  DEPLOYMENT FOR BHEL
60%17%
23%
LABOUR DISTRIBUTION‐ BHEL
unskilled Semi skilled Skilled
Figure 2.7.2.02 LABOUR  DISTRIBUTION FOR BHEL
LABOUR L&T BHEL
SKILLED 93 91
SEMI SKILLED 146 70
UN‐SKILLED 214 241
TABLE T‐ 2.7.01 LABOUR  COMPARISON

CHAPTER‐ ‐CONSTRUCTION METHODOLOGY            FACULTY OF TECHNOLOGY
ARPIT ARORA
(UC‐0212)
S.No. Equipment Make/Model Quantity Owned/Hired
1 Excavator (0.9 cum.) KOMATSU/WL9020 19 OWNED
2 Dumper (10T) Ashok Leyland 52 OWNED
3 Dozer ESCORTS 5 OWNED
4 Grader ESCORTS 3 OWNED
5 JCB (Excavator‐Backhoe) 3DX 2 OWNED
6 Paver machine for concrete lining UniSteel/RCP 750 2 OWNED
7 Hydra ESCORTS/TRX 1250 2 OWNED
8 Trailor Ashok Leyland 1 HIRED
9 Transit Mixer (6 cum)
SCHWING
STETTER/AM 6SHC
7
OWNED
10
Batching Plant (Theoretical‐30
cum/hr, Actual‐ 22cum/hr))
SCHWING
STETTER/T 500
1
OWNED
11 Concrete Pump (46 cum/hr)
SCHWING
STETTER/BP 350D
3
OWNED
14 Roller TATA HITACHI 5 OWNED
15 Bar Bending Machine (52mm) JAYPEE/B‐52 3 OWNED
17 Light Masts 7 OWNED
18 Concrete chipping machine HILTI 5 OWNED
19 Concrete vibrator 10
20 Bar Bending Table 4 OWNED
21 Water Supply Tanker Ashok Leyland 3 HIRED
23 DG Sets CUMMINS 10 HIRED
24 Tower Crane POCLAIN & ALPHA 2 HIRED
25 WELDING MACHINE ‐ ARC MEMCO/MTW 400 87 HIRED
26 WELDING MACHINE ‐ MIG MEMCO/MTW 400 22 HIRED
27 PUG CUTTING M/C PUG 20 HIRED
28 GRINDING MACHINE BOSCH 70 HIRED
29 CRAWLER Crane 150 MT MANITOWOC 2 HIRED
Material Tests Performed Frequency of testing Method of testing
Cement
Initial and Final setting
time
For each consignment
As per IS: 4031
Mortar compression test As per IS: 4031
Consistency test As per IS: 4031
Fineness test As per IS: 4031
Fine Aggregate
Sieve analysis
Every fortnightly or every
200 cum of aggregate (
whichever is earlier)
As per IS:383
Surface moisture content As per IS:2386
Silt content As per IS:383
Specific gravity As per IS:2386
Water absorption As per IS:2386
Coarse Aggregate
Sieve analysis
Every fortnightly or every
200 cum of aggregate
(whichever is earlier)
As per IS:383
Flakiness and elongation As per IS:2386
Moisture content As per IS:2386
Specific gravity As per IS:2386
Water absorption As per IS:2386
Crushing value As per IS:2386
Concrete
Compressive strength
1 sample for 1‐5 cum‐2
nos. sample for 6‐15 m3‐
3 nos. sample for 16‐30
m3‐ 4 nos. sample for
31‐50 m3‐ 4+1 additional
Sample for each addl. 50
m3 conc.
Temprature
Each transit mixer
Slump test IS:1199TABLE T‐ 2.8.01 SOME MAJOR EQUIPMENTS AT SITE
TABLE T‐ 2.8.02 TESTS CARRIED ON SITE FOR FREQQUENTLY USED MATERIALS

CHAPTER‐ ‐ CONSTRUCTION ACTIVITIES ARPIT ARORA FACULTY OF TECHNOLOGY
CHAPTER# 3‐
CONSTRUCTION ACTIVITIES
3.1  CONCRETE LINING OF RAW WATER RESERVOIR
3.2  OVERHEAD TANK BEAMS (TIE LEVEL‐3)
3.3  COUNTERFORT & RETAINING WALL
3.4  FABRICATION OF TRESTLES
3.5  ERECTION OF CONVEYOR GALLERIES
3.6  SILO R.C.C. WORKS & LINING WORKS

CHAPTER‐‐CONSTRUCTION ACTIVITIES ARPIT ARORA FACULTY OF TECHNOLOGY
The structures covered during the training period were both civil as well as structural. On-site, the foundations are placed
under the civil department and the structural steel works falls under the mechanical department. The activities studied
during the course of training were- concrete lining of reservoir, R.C.C. works of silo by slipform method, OverHead Tank
Beams R.C.C. works, Retaining walls and counter fort formwork and concreting, fabrication, erection and assembly of
conveyor galleries. Because of page limits, the assembly of conveyor galleries and counterfort reinforcement is kept out
of the report. Therefore, the elements studied are-
• Raw water reservoir
• Overhead tank Beams
• Retaining wall and Counterfort
• Erection and fabrication of conveyor galleries
• Silo- lining and R.C.C. Works
involving activities of formwork, concreting, reinforcement, lining etc., their methodologies, productivity analysis etc. as
per the structure.
3.0 CONSTRUCTION ACTIVITIES
3.1 CONCRETE LINING OF RAW WATER RESERVOIR
3.1.1 ACTIVITY INTRODUCTION
.
ACTIVITY OBSERVED- Concrete Lining of Reservoir Bed
•Sand Bed Preparation
•LDPE Sheet Laying
•Pressure Relief Valve Fixing
•Wire Mesh Laying
•Concreting
LOCATION OF ACTIVITY- Compartment-2
CONCTRACTOR INVOLVED- L&T
LEVELS ENCOUNTERED-
GROSS CAPACITY OF COMPARTMENT- 2202234 cum
GRADE OF CONCRETE USED- M30
G.L. Ground Level 546.615 m
T.T.L Trench Top Level 547.615 m
S.B.L. Sand Bed Level 547.690 m
R.B.L. Reservoir Bed Level 547.750 m
F.G.L. Finished Ground Level 561.00 m
TABLE T‐3.1.1.1.01 LEVELS ENCOUNTERED IN THE ACTIVITY
20
TECHNICAL SPECIFICATIONS FROM THE CONTRACT
1. L&T has agreed for the maintenance of the entire project for 5 years after the package gets completed.
2. Free board given in Reservoir= 1m
3. Level of reservoir bund (planned)= 563.0m
4. Area of construction= 50 hectares(approx.)
5. pH of treated water will range from 7.5-8.2
6. Maximum TSS in treated water= 5ppm
7. Maximum TSS in pre treated water= 25ppm

CHAPTER‐ ‐CONSTRUCTION ACTIVITIES FACULTY OF TECHNOLOGY
ARPIT ARORA
(UC‐0212)
Figure ‐3.1.1.01: LOCATION OF ACTIVITY Figure ‐3.1.1.02: LAYOUT FOR COMPARTMENT ‐2

CHAPTER‐ CONSTRUCTION ACTIVITIES ARPIT ARORA FACULTY OF TECHNOLOGY
3.1.2 CONSTRUCTION PROCEDURE
.
The entire activity comprises of 4 sub activities which are then repeated in order throughout the duration of the element.
These 4 activities are-
a. Sand Bed Preparation and Trench filling
b. LDPE Sheet Laying
c. PR Valves fixing and Wire Mesh laying
d. Concreting
The sequence of activities is shown as below
BOX CASING OF P.R. VALVES
CURING AND PLACING OF BALL IN VALVES
UNCASING OF P.R. VALVES
CONCRETING OF SURFACE
PLACING OF PAVER MACHINE
PREPARATION OF CASING OF P.R. VALVES
LAYING OF WIRE MESH & TIEING
PLACING OF P.R. VALVES
HOT SEALING BY IRONING
LAYING OF LDPE SHEET
LEVEL CHECKING BY AUTO LEVEL
COMPACTION BY ROLLER
FILLING OF SAND BY FRONT END LOADER
MANUAL FILLING OF SAND
F.C.3.1.1.01 SEQUENCE FOR CONCRETE LINING FIGURE 3.1.2.03 ROUTE OF TRANSIT MIXTURE FOR THE ACTIVITY
Material Quantity per cum.
Cement 390 kg
Sand 683.8 kg
Aggregate (10mm) 486.2 kg
Aggregate (20mm) 741 kg
Water 169 kg
Admixture 3.75 kg
The concrete of grade M-30 is used
for the concrete lining, the mix
design of which is shown in the
adjacent table.
OPC-53 Grade Cement was used,

ARPIT ARORA
(UC0212)23
FIGURE 3.1.2.04 CUTTING OF TRENCHES FIGURE 3.1.2.05 SAND FILLING OF TRENCHES
FIGURE 3.1.2.06 LAYING OF LDPE SHEETS FIGURE 3.1.2.07 FIXING OF P.R. VALVES
The trenches are made at a distance of 9m from each other,
forming a grid of the trenches so as all the trenches are connected
to each other
The surface preparation is done manually and the trench filling is
done with the help of a back-line excavator. The horizontal
trenches are filled first followed by vertical trenches
After the sand bed layer is complete, the surface is then covered by a
black colored LDPE (Low Density Polymer Ethane) of thickness 250
micron, in order to provide a protective film to reduce the seepage loss
The pressure relief valves are placed at the junction of the trenches. The purpose of the
pressure relief valve is to evenly distribute the pressure from the water below the reservoir
bed so that the concrete bed doesn’t get damaged due to sudden increase in the water
pressure from below.

CHAPTER‐‐CONSTRUCTION ACTIVITIES FACULTY OF TECHNOLOGY
ARPIT ARORA
(UC0212)
FIGURE 3.1.2.08 SETUP FOR CONCRETING
FIGURE 3.1.2.09 FINAL SECTION AFTER CONCRETING
Once the surface is covered by the wire mesh, preparations are made for the concreting of the surface.
First, the PR Valves are encased with a square box on top of them so as to prevent the concrete going into the valves. The box is
made locally on site with size of 400mm. The alignment of the concrete lining is done then (Fig. 3.1.2.08).
Once the alignment is complete, the paver machine is brought into place with concrete pump in position, concreting is started.
The paver machine used can cover a maximum width of 20m. It is operated by two operators simultaneously, one on each side.
The paver machine completes two passes on each location, the first pass is for the compaction of the concrete surface and the
second pass vibrates the surface properly. The height for the machine can be set accordingly. On site the concreting was done
for a layer of 60mm.
Once the concreting is completed, after the initial setting of the concrete, the cases of the PR Valves are removed and the
concreted surface is cured by ponding.

CHAPTER‐ ‐CONSTRUCTION ACTIVITIES ARPIT ARORA FACULTY OF TECHNOLOGY
3.1.3 ANALYSIS
.
3.1.3.1 TIMELINE FOR THE ACTIVITY
Activity Duration (hrs.)
Sand Bed Preparation 4
LDPE Sheet Laying & Heat
Sealing
2.5
Placing of PR Valves in
location
4.2
Welded Wire Mesh
Laying and tieing
3
Concrete lining 14
TOTAL 28 hrs.
14%
9%
15%
11%
51%
TIME WISE DISTRIBUTION
Sand Bed
Preparation
LDPE Sheet Laying
& Heat Sealing
Placing of PR
Valves in location
Welded Wire Mesh
Laying and tieing
Concrete lining
FIGURE 3.1.3.1.01 TIME WISE DISTRIBUTION FOR THE ACTIVITYTABLE T‐3.1.3.1.01 TIMELINE FOR THE ACTIVITY
3.1.3.2 QUANTITY CALCULATION
a. SAND
Total area to be covered= 20m*100m= 2000sqm
Total volume = Volume of surface+ Volume of horizontal
pits+ Volume of vertical pits- Volume of cuboids - at
junction for double calculation.
= 2000*0.075+ 11*20*0.67*1+
2*100*0.67*1- 22*0.67*0.67*1
= 271.52 cum.
Wastage= 10%
Total volume= 298.67 cum
b. LDPE SHEET
Total area to be covered= 20m*100m= 2000sqm.
Length of sheet in 1 roll= 5 m
Width of sheet in 1 roll= 45 m
Area covered per sheet= 5*45= 225 sqm.
So, from Fig 3.1.2.06,
Area= 20*90+ 0.15*90*3+3*20*0.15+10*20-6*0.15*0.15
= 2050 sqm.
Wastage= 2%
Total area= 2091 sqm.
c. PR VALVES
From Fig. 3.1.2.07,
Total number of valves= 36
d. WELDED WIRE MESH
Width of 1 roll= 1.5 m
Length of 1 roll= 50 m
Area covered by 1 roll= 1.5*50= 75sqm.
Number of rolls required= 26
Total area required=
26*1.5*50+13*100*0.1+1*20*0.1-13*0.1*0.1
= 2082 sq.
Wastage= 2%
Total area= 2123.5 sqm
e. CONCRETE
Total area= 20m *100m=2000sqm.
Quantity of concrete= 2000*0.06= 120 cum.
Wastage= 2%
Total volume= 122.4 cum.

ARPIT ARORA
(UC‐0212)
Activity
Duration
(hrs)
Quantity
Executed
Workers Involved
Duration of Working
per Day (hrs)
Productivity per Head Unit cost per Day (Rs.) Unit cost per hour (Rs.) Total Cost(Rs.) TOTAL
Un Skilled Skilled Un Skilled Skilled Un Skilled Skilled Un Skilled Skilled Un Skilled Skilled Un Skilled Skilled
Sand Bed
Preparation
4 2200 sqm. 8 8 68.75 sqm/hr 236 333 29.5 41.625 944 944
LDPE Sheet
Laying & Heat
Sealing
2.5 2091 sqm. 10 2 8 8 83.64 sqm/hr
418.2
sqm/hr
236 333 29.5 41.625 737.5 208.125 944
Welded Wire
Mesh Laying and
tieing
4.2 2123.5 sqm. 16 8 31.60 sqm/hr 236 333 29.5 41.625 1982.4 1982.4
Placing of PR
Valves in
location
3 36 nos. 2 1 8 8 6nos/hr 12 nos./hr 236 333 29.5 41.625 177 124.875 301.875
Concrete lining 14 122.4 cum. 10 3 16 16 0.87 cum/hr 2.91 cum/hr 236 333 29.5 41.625 4130 1748.25 5878.25
TOTAL 7970.9 2081.25 10050.53
21%
79%
LABOUR WISE COST
DISTRIBUTION
SKILLED
UNSKILLED
The activity for the observed area involves the use of 6 skilled workers and 46 unskilled
workers with no repetition of the labors as the workers are distributed in different gangs.
The concreting activity requires maximum time because of the setting up of the machines
and the checks that are done before it.
NO OVERTIME CHARGES ARE GIVEN TO THE WORKERS
3.1.3.3 LABOUR PRODUCTIVITY
TABLE  T‐3.1.3.3.01: LABOUR PRODUCTIVITY FOR THE ACTIVITY
FIGURE 3.1.3.3.01: LABOUR WISE COST DISTRIBUTION

ARPIT ARORA
(UC0212)
3.1.3.4 CONCRETE TIME CYCLE
S.no
Dispatch
time from
B.P.
Arrival time
Waiting
time
Pouring
start time
Concreting
time
Slump
observed
Time of
departure
Qty.
carried
(cum)
Cum. Qty
(cum)
1 10:40 a.m. 10:55 a.m. Nil 10:56 a.m. 20 min 145 11:16 a.m. 5 5
2 11:00 a.m. 11:10 a.m. 7 min 11:17 a.m. 18 min N.A. 11:35  a.m. 5 10
3 11:17 a.m 11:30 a.m. 6 min 11:36 a.m. 16 min N.A. 11:52 a.m. 5 15
4 11:31 a.m. 11:45 a.m. 10 min 11:55 a.m. 17 min N.A. 12:12 p.m. 5 20
5 11:53 a.m. 12:07 p.m. 5 min 12:13 p.m. 17 min N.A. 12:30 p.m. 5 25
6 12:13 p.m. 12:25 p.m. 6 min 12:31 p.m. 11 min N.A. 12:42 p.m. 5 30
15 04:02 p.m. 04:20 p.m. 7 min 04;27 p.m. 18 min N.A. 04:45 p.m. 5 75
7 6
10
5 6 6 6
15
65
60
35
5 6 7 6
10 8 11
6
14
9
0
10
20
30
40
50
60
70
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
WAITING TIME
BATCH NUMBER
BATCH NUMBER v/s WAITING TIME
20
18
16 17 17
11
18
12
19
15 16
25
20
15
18
26
17
25
16
22
15
12
0
5
10
15
20
25
30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
CONCRETING TIME
BATCH NUMBER
CONCRETING TIME v/s BATCH NUMBER
FIGURE 3.1.3.4.01 WAITING TIME v/s BATCH NUMBER
FIGURE 3.1.3.4.02 CONCRETING TIME v/s BATCH NUMBER
228
114
180
120149
109
178
105
0
100
200
300
0 2 4 6 8 10
Qty. Executed (cum.)
Days
DAY WISE ANALYSIS ‐
CONCRETING
143
225
150
187
137
223
132148
0
100
200
300
0 2 4 6 8 10
Qty. Executed (cum.)
Days
SAND FILLING
1910
3000
2000
2500
1850
2980
17701980
0
2000
4000
0 2 4 6 8 10
Qty. Executed (sqm.)
Days
LDPE LAYING
1500
1930
3250
2160
2780
2000
3100
1840
0
2000
4000
0 2 4 6 8 10
Qty. Executed (sqm.)
Days
DAY WISE ANALYSIS‐
WIRE MESH
FIGURE 3.1.3.4.03 DAY WISE ANALYSIS FOR CONCRETING FIGURE 3.1.3.4.04 DAY WISE ANALYSIS FOR SAND FILLING FIGURE 3.1.3.4.05 DAY WISE ANALYSIS FOR LDPE FIGURE 3.1.3.4.06 DAY WISE ANALYSIS FOR WIRE MESH
TABLE  T‐3.1.3.4.01: CONCRETE TIME CYCLE

S.No. Item Description Unit Quantity
Unit Rate
(Rs.)
Amount
(Rs.)
1
Providing and laying of concrete of M30
Grade as per mix design in reservoir bed
including laying, compacting, vbrating,
curing, scaffolding complete in all respects
as per the direction of engineer‐in‐charge.
cum 122.4
1.1 Materials
A Concrete cum 122.4 2508.1 306986.4
B Cement bags 974 280 272720
1.2 Labour
A Skilled hrs 42 41.625 1748.25
B Unskilled hrs 140 29.5 4130
TOTAL (1.1+1.2) 585584.7
1.3 Tools & equipments
A Paver Machine hrs 14 530.94 7433.16
B Transit Miller hrs 3*5 422.28 6334.2
C Concrete pump hrs 14 369.82 5177.48
1.4
Miscellaneous costs‐ safety shoes, safety
jackets etc.
0.5%(1.1+1.2)
2927.923
1.5
Profits & Overheads
5%(1.1+1.2+1.3+1.4)
30372.87
TOTAL (1.1+1.2+1.3+1.4+1.5) 637830.3
Unit rate per cum= Total cost/Total Quatity 5211.032
3.1.3.5 RATE ANALYSIS
TABLE  T‐3.1.3.5.01: RATE ANALYSIS FOR CONCRETING

ARPIT ARORA
(UC‐0212)
83%
1%
2%
1%
13%
RATE BREAKUP FOR SAND
BEDDING
UNIT RATE= Rs. 502.83/cum
MATERIAL
LABOUR
TEP
MISELLANEOUS
87%
1%
2%
1%
9%
RATE BRAKUP FOR LDPE
SHEET     UNIT RATE=
Rs.39.09/sqm
MATERIAL
LABOUR
TEP
MISELLANEOUS
91%
2%
1%1%
5%
RATE BREAKUP FOR WIRE MESH
AND PR VALVES
UNIT RATE= Rs.62.54/sqm
MATERIAL
LABOUR
TEP
MISELLANEOUS
84%
2%
4%
1%
9%
RATE BREAKUP FOR BATCHING
PLANT
MATERIAL
LABOUR
TEP
MISELLANEOUS
FIGURE 3.1.3.5.01: RATE BREAKUP FOR SAND BEDDING FIGURE 3.1.3.5.02: RATE BREAKUP FOR LDPE SHEETS
FIGURE 3.1.3.5.04: RATE BREAKUP FOR BATCHING PLANT
FIGURE 3.1.3.5.03: RATE BREAKUP FOR WIRE MESH AND PR VALVES
NOTE- REFER Pg. No.- FOR THE INDIVIDUAL QUANTITIES OF MATERIAL, LABOUR AND TEP FOR EACH OF THE ABOVE ACTIVITY

ACTIVITY OBSERVED- Reinforcement of OHT-1 Beams
- Formwork of OHT-1 Beams
- Concreting of OHT-1 Beams
LOCATION OF ACTIVITY- Tie Level-3 (OHT-1)
3.2 OVERHEAD TANK BEAMS
.
T.O.C Top of Concrete 565.510 m
B.B.L. Beam Bottom Level 564.760 m
F.C.L. Finished Concrete Level 564.760 m
LEVELS ENCOUNTERED-
GROSS CAPACITY OF Overhead Tank- 2000 cum
BEAMS OBSERVED- B1 TO B6
CROSS SECTION OF BEAMS- 300mm*750mm
GRADE OF CONCRETE- M30
COVER USED- 30 mm
BENCHMARK LEVEL- 561.00 m
HEIGHT OF SCAFFOLDING- 4.51 m
TYPE OF SCAFFOLDING- DOKA FORMWORK
GRADE OF STEEL- Fe 500
1. 2 nos. of 2000 cum. RCC OHT are under the scope of the contractor
2. The capacity of OHT is divided as 1800 cum for M.W. and 200 cum for D.W.
3. Inside surface of OHT will be painted with epoxy paint.

ARPIT ARORA
(UC‐0212)
FIG. 3.2.1.01: WATER DISTRIBUTION SYSTEM IN THE PLANT

.
The entire activity comprises of 4 major activities-
a. Staging for reinforcement
b. Reinforcement of OHT Beams
c. Shuttering of OHT Beams
d. Concreting of OHT Beams
For staging purpose, DOKA Formwork System was used.
a. STAGING FOR REINFORCEMENT
For the staging works, DOKA system was used at site.
STEP‐7
PLACING OF BEAM BOTTOM PLACING OF WALKWAY JAALIS
STEP‐6
PLACING OF INNER WOODEN BEAMS
STEP‐5
BRACING OF INNER FRAMES PLACING OF INNER STEEL WALLERS
STEP‐4
PLACING OF INTER STEEL WALLERS & WOODEN BEAMS FRAMING OF INNER SIDES
STEP‐3
PLACING OF OUTER STEEL WALLERS & WOODEN BEAMS BRACING OF INTERMEDIATE FRAMES
STEP‐2
BRACING OF OUTER FRAME PLACING OF INTERMEDATE FRAME
STEP‐1
PLACING OF OUTER FRAME
F. C. 3.2.2.01 SEQUENCE FOR STAGING WORKS

ARPIT ARORA
(UC0212)
FIGURE 3.2.2.01 PROCEDURE STEP‐1 FIGURE 3.2.2.02 PROCEDURE STEP‐2 FIGURE 3.2.2.03 PROCEDURE STEP‐3
FIGURE 3.2.2.06 PROCEDURE STEP‐6 FIGURE 3.2.2.05 PROCEDURE STEP‐5 FIGURE 3.2.2.04 PROCEDURE STEP‐4
PLACING OF OUTER FRAMES BRACING OF OUTER FRAMES AND
PLACING OF INTERMEDIATE FRAMES
PLACING OF STEEL WALLERS IN OUTER
AND BRACING OF INTERMEDIATE FRAMES
PLACING OF WOODEN BEAMS IN OUTER, STEEL WALLERS IN
INTERMEDIATE AND PLACING OF INNER FRAMES
PLACING OF WOODEN BEAMS IN INTERMEDAITE
AND STEEL WALLERS IN INNER FRAMES
PLACING OF WOODEN BEAMS IN INNER
AND BEAM BOTTOM IN STRAIGHT BEAMS

ARPIT ARORA
(UC0212)34
FIGURE 3.2.2.07  TYPICAL H‐ FRAME
FIGURE 3.2.2.08  MATERIAL USED FOR SCAFFOLDING

b. REINFORCEMENT OF OHT BEAMS
Prior to the start of the activity of reinforcement of beams, staging for the beam bottom and the working space occurs.
Along with the staging, the process of bar bending and bar cutting were observed simultaneously.
The sequence for the activity of reinforcement is shown as below-
Once the reinforcement for all the beams was transported to the level and positioned properly, the marking of stirrups was
carried out starting from beam B4.
With the completion of marking, the stirrups for respective beams were brought at site followed by the positioning and
fixing of stirrups for beam B4, followed by the ring beams. The beam B5 and B6 were done after the completion of the
ring beams.
Once the stirrups were positioned and tied properly, the extra top and extra bottom bars were inserted following the same
order as that of the stirrups placing and fixing.
With the placing and fixing of the extra reinforcement completed, the alignment of the beam bottom in place was done
taking line from the columns casted. With the beam bottom aligned, the beams were brought down systematically starting
from the beam B4, followed by ring beams and then beams B5 and B6 respectively.
A gap of 35mm was kept between the beam bottom and the bottom reinforcement for the placing of cover.
Covers were then placed along with the oiling of the beam bottom plates.
F. C. 3.2.2.02 FLOWCHART FOR REINFORCEMENT ACTIVITY

ARPIT ARORA
(UC0212)
36
FIGURE 3.2.2.09 DETAIL OF B1‐B4 JUNCTION FIGURE 3.2.2.10 DETAIL OF B3‐B5 JUNCTION
FIGURE 3.2.2.12 DETAIL OF B2/B3‐B4 JUNCTIONFIGURE 3.2.2.12 DETAIL OF B1‐B6 JUNCTION

ARPIT ARORA
(UC0212)37
FIGURE 3.2.2.13 BEAM DETAILS

ARPIT ARORA
(UC0212)
38
FIGURE 3.2.2.14 BEAM DETAILS

c. SHUTTERING OF OHT BEAMS
Once the reinforcement is complete, the shuttering for the beam sides are taken up. F.C.3.2.2.03 shows the sequence of the
activity
For this activity, the workers were divided into 3 separate groups, each group handling 3 different compartments
(outer, intermediate, inner).
F.C.3.2.2.03 shows the sequence of the activity.
All 3 groups work simultaneously. The shuttering process starts simultaneously from both ends and filling of
additional space left by hollow box sections (used as gabdi). Always the shuttering for the column is done first
followed by the beam sides.
The shuttering is done with the help of custom made shuttering plates.
F. C. 3.2.2.03 FLOWCHART FOR SHUTTERING WORKS

ARPIT ARORA
(UC0212)40
FIGURE 3.2.2.15 PROCEDURE FOR SHUTTERING
FIGURE 3.2.2.16 SHUTTERING OF BEAM JUNCTION
FIGURE 3.2.2.17 SHUTTERING OF COLUMN C‐2

c. CONCRETING OF OHT BEAMS
Once the shuttering is completed and the checks done, preparation for concreting is done. The mix design for the
M30 Grade of concrete is shown below. The route of Transit Mixture from Batching Plant to the location is shown
in Figure 3.2.2.16.
Material Quantity per
cum.
Wastage
considered (%)
Cement 390 kg 2
Sand 683.8 kg 10
Aggregate (10mm) 486.2 kg 5
Aggregate (20mm) 741 kg 10
Water 163.8 kg -
Admixture-
SIKAMENT NS-
2051
3.52 kg 2
TABLE T‐3.2.2.01 MIX DESIGN DETAILS
FIGURE 3.2.2.18 ROUTE OF TRANSIT MIXTURE
Grade of Concrete= M-30

ARPIT ARORA
(UC0212)42
FIGURE 3.2.2.19 LAYOUT OF CONCRETE PIPE
FIGURE 3.2.2.20 ORDER OF CONCRETING

ARPIT ARORA
(UC0212)
43
3.2.3.1 PRODUCTIVITY
3.2.3 ANALYSIS
Activity
Duration
(hrs)
Quantity
Executed
(kg) Workers Involved
Duration of Working
per Day (hrs)
Productivity per Head
(kg/hr)
Unit cost per Day
(Rs.)
Unit cost per hour
(Rs.)
Total Cost
(Rs.) TOTAL
Bar Cutting
& Bar
Bending 16 11821.16 4 2 8 8 184.70563 369.4113 236 333 29.5 41.625 1888 1332.8 3220.8
Material
Handling &
Transporta
tion 4 11821.16 8 4 4 4 369.41125 738.8225 236 333 29.5 41.625 944 944
Laying &
Tieing of
Reinf. 24 11821.16 15 8 32.83656 236 333 29.5 41.625 14994 14994
2832 16326.8 19158.8
Activity
Duration
(hrs)
Quantity
Executed
Workers Involved
Effective Duration of
Working per Day (hrs)
Productivity per Head Unit cost per Day Unit cost per hour Total Cost TOTAL
Staging for
Shuttering
works including
material
transportation
and handling
40 (5
mandays)
4.51 m 10 12 5 8
0.01804
m/manhour
0.009396
m/manhour
236 333 29.5 41.625 7375 19992 27367
Shuttering
works (bottom
and sides)
including
material
transportation
and handling
32 (4
mandays)
428.2776 sqm. 10 12 5 8
2.141
sqm/manhour
1.115
sqm/manhour
236 333 29.5 41.625 5900 15984 21884
13275 35976 49251
TABLE T‐ 3.2.3.1.01: PRODUCTIVITY TABLE FOR REINFORCEMENT
TABLE T‐ 3.2.3.1.02: PRODUCTIVITY TABLE FOR SHUTTERING & STAGING

ARPIT ARORA
(UC0212)44
Activity
Duration
(hrs)
Quantity
Executed
(cum)
Workers Involved
Productivity per Head Unit cost per Day Unit cost per hour Total Cost TOTAL
Concrete pump
handling and
operation
21
(7hrs/day
for 3 days)
60.86248 1 7 0 2.898213333 236 333 29.5 41.625 0 874.65 874.65
Needle vibrator
operation
18
(6hrs/day
for 3 days)
60.86248 2 2 7 6 1.449106667 1.690624444 236 333 29.5 41.625 1239 1498.5 2737.5
Hose pipe
handling
21
(7hrs/day
for 3 days)
60.86248 1 1 7 7 2.898213333 2.898213333 236 333 29.5 41.625 619.5 874.125 1493.625
Concrete
levelling and
distribution
24
(8hrs/day
for 3 days)
60.86248 2 8 0 1.267968333 236 333 29.5 41.625 0 1998 1998
Board handling
24
(8hrs/day
for 3 days)
60.86248 3 1 8 4 0.845312222 5.071873333 236 333 29.5 41.625 2124 499.5 2623.5
TOTAL 3982.5 5744.775 9727.275
TABLE T‐ 3.2.3.1.03: PRODUCTIVITY TABLE FOR CONCRETING
12%
5%
3%
14%
20%
10%
36%
% DISTRIBUTION OF REINFORCEMENT STEEL
USED
8mm 10mm 12mm 16mm
20mm 25mm 28mm
14%
6%
3%
15%
21%
11%
30%
COST WISE DISTRIBUTION FOR
REINFORCEMENT STEEL
8mm 10mm 12mm 16mm 20mm 25mm 28mm
66.09
115.75
122.65 123.787
0
20
40
60
80
100
120
140
Day‐1 Day‐2 Day‐3 Day‐4
Qty.(sqm.)done
Days
DAY WISE SHUTTERING DONE

ARPIT ARORA
(UC0212)45
3.2.3.2 CONCRETE TIME CYCLE
S.no
Dispatch
time from
B.P.
Date Arrival time
Waiting
Time
Pouring
start time
Concreting
time
Slump
observed
Time of
departure
Delay
time
Qty.
carried
(cum)
Cum. Qty
(cum)
1 09:18 a.m. 16‐01‐16 09:37 a.m. 15 min 09:52 a.m. 20 min Slurry 10:15 a.m. 0 min 0.5 0.5
2 09:41 a.m. 16‐01‐16 10:01 a.m. 21 min 10:22 a.m. 90 min 11:54 a.m. 0 min 5 5
3 11:59 a.m 16‐01‐16 12:19 p.m. 5 min 12:24 p.m. 84 min 01:48 p.m. 25 min 4 9
4 03:10 p.m. 16‐01‐16 03:28 p.m. 2 min 03:30 p.m. 97 min 05:10 p.m. 90 min 4 13
7 09:10 a.m. 17‐01‐16 09:19 a.m. 0 min 09:20 a.m. 15 min Slurry 09:40 a.m. 0 min 0.5 21
13 09:02 a.m. 18‐01‐16 09:18 a.m. 5 min 09:23 a.m. 18 min Slurry 09:45 a.m. 0 min 0.5
15 11:54 a.m. 18‐01‐16 12:10 p.m. 4 min 12:14 p.m. 114 min 02:10 p.m. 20 min 5 50
15
21
5
2
24
16
0
3 2
21
2
15
5
16
4
12
3
0
5
10
15
20
25
30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Waiting Time (min.)
Batch Number
BATCH NUMBER v/s WAITING TIME
0 0
25
90
0 0 0
13
69
0
110
0 0 0
20
88
11
0
20
40
60
80
100
120
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Delay time (min.)
Batch Number
BATCH NUMBER v/s DELAY TIME
20
90 84
97
72
86
15
75 82
54
114
98
18
106114
124116
0
50
100
150
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Concreting time (min.)
Batch Number
BATCH NUMBER v/s CONCRETE
TIME
TABLE T‐ 3.2.3.2.01: CONCRETE TIME CYCLE
FIGURE 3.2.3.2.01 BATCH NUMBER v/s WAITING TIME
FIGURE 3.2.3.2.02 BATCH NUMBER v/S DELAY TIME
FIGURE 3.2.3.2.03 BATCH NUMBER v/s CONCRETING TIME
FORMWORK 428.2776 sqm.
REINFORCEMENT 11821.16 kg.
CONCRETE 59.66691 cum.
F/C RATIO 7.177807599 sqm/cum
R/C RATIO 198.119192 kg/cum
R/F RATIO 27.60163034 kg/sqm
TABLE T‐ 3.2.3.2.02: RATIOS

ARPIT ARORA
(UC0212)
46
3.2.3.3 RATE ANALYSIS
Unit
Rate
(Rs.)
Amount
(Rs.)
1
Providing and laying of TMT
reinforcement of Fe 500 grade
for beams at Tie Level‐3 of
OHT‐1 including cutting,
bending, transporting, placing,
tieing and checking complete in
all respects as per the direction
of engineer‐in‐charge
kg 11821.16
1.1 Materials
A Reinf. Bars of 8mm dia. kg 1466.493 42.67 62575.26
B Reinf. Bars of 10mm dia. kg 589.9005 41.6 24539.86
C Reinf. Bars of 12mm dia. kg 338.314 41.6 14073.86
D Reinf. Bars of 16mm dia. kg 1599.278 41.2 65890.25
E Reinf. Bars of 20mm dia. kg 2324.516 39.6 92050.83
F Reinf. Bars of 25mm dia. kg 1230.663 39 47995.86
G Reinf. Bars of 28mm dia. kg 4271.993 39 166607.7
H Binding Wire kg 118.21 55 6501.55
480235.2
1.2 Labour
A Skilled hrs 392 41.65 16326.8
B Unskilled hrs 96 29.5 2832
19158.8
TOTAL (1.1+1.2) 499394
1.3 Tools & Equipments
A Bar Bending Machine hr 16 500 8000
B Bar Cutting Machine hr 16 375 6000
C Other tools‐hammer, 1200.588
15200.59
1.4
Miscellaneous costs‐ safety
shoes, safety jackets etc.
0.5%(1.1+1.2)
2496.97
1.5
Profits & Overheads‐
10%(1.1+1.2+1.3+1.4)
51709.16
TOTAL (1.1+1.2+1.3+1.4+1.5) 568800.7
Unit Rate per Kg= Total
cost/Total quantity
48.11717
Unit Rate
(Rs.)
Amount(
Rs.)
2
Providing and fixing of
formwork for Overhead Tank ‐1
beams at Tie Level‐3 using
35mm thick steel shuttering
plates set, and fixing by bolts,
including allplcation of
deshuttering oil, checking of
line, level, plumb, water
tightness and deshuttering,
complete in all respects as per
the direction of site in‐charge,
exculding the scaffolding for
the provided formwork.
sqm 428.2776
2.1 Materials
A Steel shuttering plates set kg 14600
A.1 Fabrication charges kg 14600 120/20 87600
A.2 Transportation Charges kg 14600 55000
A.3 VAT Charges (5%[A.1+A.2]) 7130
149730
B Bolts kg 150 95/2 7125
2.2 Labour
A Unskilled hrs 200 29.5 5900
B Skilled hrs 384 41.625 15984
TOTAL (2.1+2.2) 178739
2.3 Tools & equipments
A
Other tools‐ tagaraas etc. [1%
of (2.1+2.2)]
1787.39
2.4
Miscellaneous costs‐ safety
shoes, safety jackets etc.
1%(2.1+2.2)
1787.39
2.5
Profits & Overheads‐
15%(2.1+2.2+2.3+2.4)
27347.07
TOTAL (2.1+2.2+2.3+2.4+2.5) 209660.8
Unit rate per sqm= Total
cost/Total Quatity
489.5443
80%
3%
7%
1%
9%
RATE BREAKUP FOR CONCRETING
MATERIAL
LABOUR
TEP
MISCELANEOUS
P&P
88%
1%
1% 1%
9%
RATE BREAKUP FOR BATCHING PLANT
MATERIAL LABOUR TEP MISCELANEOUS P&O
TABLE T‐ 3.2.3.3.01: RATE ANALYSIS FOR REINFOREMENT TABLE T‐ 3.2.3.3.02: RATE ANALYSIS FOR SHUTTERING
FIGURE 3.2.3.3.01 RATE BREAKUP FOR CONCRETING FIGURE 3.2.3.3.02 RATE BREAKUP FOR BATCHING PLANT

Page | (UC‐0212) C.E.P.T UNIVERSITY47
.
ACTIVITY OBSERVED- Formwork and Concreting of Retaining Wall (W1, W2, W3, W6)
- Formwork and Concreting of Counter Fort-1
LOCATION OF ACTIVITY- Raw Water Pump House
LEVELS ENCOUNTERED-
T.O.C Top of Concrete 547.15 m
F.L. Formwork Level 547.25 m
R.L. Raft Top Level 544.75 m
GROSS CAPACITY OF COMPARTMENTS- 1740cum (COMP.-1) and 1310 cum
(Comp.-1)
WALLS OBSERVED- W-1, W-2, W-3, W-6
NUMBER OF COUNTERFORTS OBSERVED- 5
ANGLE OF INCLINATION FOR COUNTERFORTS- 80 degrees
DIMENSION OF COUNTERFORTS- 1200mm* 4000mm
GRADE OF CONCRETE- M30
COVER USED- 30 mm
WALL NUMBER WIDTH (mm)
W-1 900
W-2 1050
W-3 1500
W-6 900
TABLE T‐ 3.3.1.01 LEVELS OBSERVED
TABLE T‐ 3.3.1.02 WALL WIDTHS
3.3 RETAINING WALL AND COUNTERFORT
1. Expected capacity of pumping of water from RWPH= 9000 cum/hr
2. Capacity of each sump compartment= 4500 cum/hr
3. Entrance of water from valve to sump will be done by sluice gate valve

ARPIT ARORA
(UC0212)48
FIGURE 3.3.1.01 JOB LAYOUT FOR THE ACTIVITY

ARPIT ARORA
(UC0212)49
FIGURE 3.3.1.02 SECTION 1‐1 SHOWING LOCATION OF WALLS FIGURE 3.3.1.03 SECTION 2‐2  SHOWING LOCATION OF WALLS

.
3.3.2.1 COUNTERFORT SHUTTERING
Once the reinforcement is completed, the activity of shuttering starts. The steps involved in this activity for counterfort
is as follows-
F.C. 3.3.2.1.01 SEQUENCE FOR
COUNTERFORT SHUTTERING
BOARD PREPARATION
VERTICAL SIDES
FORMWORK
INCLINED SIDES
FORMWORK
HORIZONTAL SUPPORTING
FOR VERTICAL SIDES
STEEL WALLERS FOR BOTH
SIDES
ADDITIONAL PROP
SUPPORT FOR WALLERS
FORMWORK CHECK
The reinforcement of counterfort is done initially. The steps involved in the activity are
depicted in Fig 3.3.2.1.01. The inclined rods and vertical rods are placed initially and
lapped properly and tied . After the vertical and inclined rods are tied, the inner stirrups
are placed at 125mm c/c and tied properly . Once the inner stirrups are in position, the
outer stirrups are placed at 125mm c/c and tied properly.
FIGURE 3.3.2.1.01 STEPS FOR REINFORCEMENT OF COUNTERFORT
The number of workers involved in the activity were- 1(Skilled) and 2 (Unskilled). The
duration of the activity was 5 days.
A setup, at site, was observed for the preparation of ply-boards used for shuttering. Each
plyboard was 1200 mm in width and with a height of 2500mm. The ply- boards were
supported by nailing wooden H-Beams behind them (4 numbers per ply-board). The
setup was then properly oiled and ready for use.
Initially, the sides were placed in position for vertical formwork, after the placing of
covers. After that, the inclined side was placed and fixed followed by the additional
horizontal support by hollow steel pipes (50mm dia.). To support the pipes, steel wallers
were placed and were supported by additional C.T. Props (4.1m) attached to a fixed
support..

ARPIT ARORA
(UC0212)51
FIGURE 3.3.2.1.02 PLACING OF VERTICAL PLYBOARD  (With Section 1) FIGURE 3.3.2.1.03 SECTION 2‐2
FIGURE 3.3.2.1.04 PLACING OF INCLINED PLYBOARD  (With Section 3) FIGURE 3.3.2.1.05 SECTION‐4

FIGURE 3.3.2.1.06 EXTERNAL VIEW OF COUNTERFORT SHUTTERING
FIGURE 3.3.2.1.07 PLAN AND ELEVATION OF COUNTERFFORT

3.3.2.2 RETAINING WALL SHUTTERING
After the reinforcement of the wall were completed, the activity of wall formwork starts. The sequence of the
activity is shown as below-
BOARD PREPARATION &
TRANSPORTATION
WALL SIDES
SHUTTERING
PLACING OF
HORIZONTAL SUPPORTS
STEEL WALLERS PLACING
AND FIXING
PLACING OF ADDITIONAL
PROPS FOR SUPPORT
TIEING AND FIXING OF
H‐FRAMES
BRACING OF H‐FRAMES
PLACING OF WALKWAY
JAALI
TIEING OF U‐BARS
Initially, the ply-boards with wooden beams are set up from both directions Fig. 3.3.2.1.01.
The left out place is filled by box steel sections as gabdi.
Once the shuttering is placed and tied, the next step was to provide horizontal support to
the shuttering. For this, hollow circular section of 50mm diameter were tied to the
shuttering (both at top and bottom) followed by the vertical bracing by placing and
fixing of steel wallers at the junctions Fig. 3.3.2.1.02
The steel wallers were then braced by the C.T. props (2 props per waller- top and
bottom). The props were fixed to an intermediate support of steel walllers on the ground
and the wallers in turn were then supported by additional props to a fixed support Fig.
3.3.2.1.03. The same assembly was used for both the sides of the wall.
After the stabilization of the shuttering, Basic H- Frames were installed to provide
accessibility and base for the concrete pump pipeline. The installation of the frames was
followed by horizontal and diagonal bracing of the frames Fig. 3.3.2.1.04.
The shuttering work was completed by placing and tieing of walk-way jaalis on the H-
Frames and placing of U-Bars between the reinforcements to maintain the space Fig.
3.3.2.1.05
Before the concreting started, the checks for line, level and plumb was done along with
the perpendicular check for junctions. For alignment check, a thread was tied to both
corners of the wall shuttering and the distances were measured at random points to
ensure the alignment. For checking the verticality, a temporary rod was tied to vertical
reinforcement and a cover block was hanged from it. The distances from top and bottom
were measured at random points to ensure verticality
F.C. 3.3.2.2.01 SEQUENCE FOR
RETAINING WALL SHUTTERING
FIGURE 3.3.2.2.01: ROUTE OF TRANSIT MIXTURE

ARPIT ARORA
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54
FIGURE 3.3.2.2.02: TIEING AND FIXING OF PLYWOOD BOARDS
FIGURE 3.3.2.2.03: PROVISION OF HORIZONTAL SUPPORTS

ARPIT ARORA
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55
FIGURE 3.3.2.2.04: PROVISION OF ADDITIONAL SUPPORTS TO STEEL WALLERS
FIGURE 3.3.2.2.05: DETAIL OF CONNECTION AT BOARD
FIGURE 3.3.2.2.06: PLACING OF H‐BEAMS AND WALKWAY JAALIS

ARPIT ARORA
(UC‐0212)
3.3.2.3 CONCRETING
Once the shuttering is completed and the checks done, preparation for concreting is done. Fig 3.3.2.3.01 shows the two observed location of transit mixture and concrete pump
(red and green). The numbers show the day wise concreting for the arranged setup. During concreting, the farthest end was completed first and then the pipeline size reduces
gradually step-by-step.
FIGURE 3.3.2.3.01: CONCRETE SETUP FOR THE ACTIVITY

3.3.3 ANALYSIS
.
3.3.3.1 QUANTITY CALCULATION
a. RETAINING WALL & COUNTERFORT SHUTTERING
TABLE T‐ 3.3.3.1.01 SHUTTERING QUANTITY CALCULATION
S.No. Description Unit Number Length Height Quantity T. Quantity
1 WALL W‐1 sqm. 1
Inner 1 27.948 2.4 67.0752 67.0752
Outer 1 24.948 2.4 59.8752 59.8752
2 WALL W‐6 sqm 1
Sides 2 6 2.4 14.4 28.8
3 WALL W‐3 sqm
Towards Compartment 1 27.948 2.4 67.0752 67.0752
Towards Valve 1 28.248 2.4 67.7952 67.7952
4 WALL W‐2 sqm 2
Inner 2*1 6 2.4 14.4 28.8
Outer 2*1 8.4 2.4 20.16 40.32
4 Counter Fort‐1 sqm 5
Inclined Portion 5 1.2 2.4 2.88 14.4
Vertical Portion
5*2
2.88
(3.1+2.67)/2
2.4 6.912 69.12
443.2608
S.No. Description Unit Number Length Width Height Quantity T. Quantity
1 WALL W‐1 cum. 1 28.848 0.9 2.4 62.31168 62.31168
2 WALL W‐6 cum 2 6 0.9 2.4 12.96 25.92
3 WALL W‐3 cum 1 28.848 1.5 2.4 103.8528 103.8528
4 WALL W‐2 cum 2 8.4 1.05 2.4 21.168 42.336
DEDUCTIONS
W‐2 and W‐3
Junction
cum 2 1.5 1.05 2.4 ‐3.78 ‐7.56
5 Counter Fort‐1 cum 5 2.88 1.2 2.4 8.2944 41.472
TOTAL 268.33248
Wastage 2%of 268.3328
TOTAL 273.7 cum
b. RETAINING WALL & COUNTERFORT CONCRETING
TABLE T‐ 3.3.3.1.02 CONCRETING QUANTITY CALCULATION

ARPIT ARORA
(UC‐0212)
FIGURE 3.3.3.1.01: LENGTH DERIVATION FOR WALL‐1 FIGURE 3.3.3.1.02: LENGTH DERIVATION FOR WALL‐3
FIGURE 3.3.3.1.03: LENGTH DERIVATION FOR WALL‐6 FIGURE 3.3.3.1.04: LENGTH DERIVATION FOR WALL‐2

ARPIT ARORA
(UC‐0212)
3.3.3.1 PRODUCTIVITYANALYSIS
Activity Duration (hrs)
Quantity
Executed
Workers Involved
Productivity per Head
(per manhour)
Unit cost per Day Unit cost per hour Total Cost TOTAL
FORMWORK
Preparation of Board
for shuttering
54
(6hrs/day for 9
days)
359.7408 sqm 2 6 3.33 sqm/hr 236 333 29.5 41.625 3186 3186
Material Hadling and
transportation
36
(4hrs/day for 9
days)
359.7408 sqm 8 6 1.25 sqm/hr 236 333 29.5 41.625 8496 8496
Placing and tieing of
formwork
72 hrs
(8 hrs/day for 9
days
359.7408 sqm 1 1 6 8 6.66     sqm/hr 4.99 sqm/hr 236 333 29.5 41.625 1593 2997 4590
Shuttering works
including material
transportation and
handling
24                  (3
mandays)
83.52 sqm 3 1 6 8 4.64 sqm/hr 3.48 sqm/hr 236 333 29.5 41.625 531 999 1530
13806 3996 17802
CONRETING
(Wall+C.F.)
Concrete pump
handling and operation
32
(8 hrs/day for 4
days)
273.70 cum 2 1 5 8 6.84 cum/hr 8.55 cum/hr 236 333 29.5 41.625 1180 1332 2512
Needle vibrator
operation
28
(7hrs/day for 4
days)
273.70 cum 2 2 5 7 6.84 cum/hr 4.88 cum/hr 236 333 29.5 41.625 1180 2331 3511
2360 3663 6023
TABLE T‐ 3.3.3.2.01 PRODUCTIVITY ANALYSIS

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