R.N.

MODI ENGINEERRING COLLEGE,

KOTA

A Practical Summer Training Report

On

Construction of Reactor Building at RAPP-

7&8
In
HINDUSTAN CONSTRUCTION
COMPANY LTD.

Submitted as a Partial fulfillment

Of the B.Tech program In CIVIL ENGINEERING of

Rajasthan Technical University, Kota

2012-2013
SUBMITTED BY: SUBMITTED TO:

Name: KETAN TAK Mrs. PRIYANKA PANDE

Roll no.: 09ERNCE024 HOD

YEAR: IVth YEAR CIVIL ENGINEERING

BRANCH: CIVIL
R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- ..
B.TECH IV YEAR (CE) BATCH:-A-1
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- ..
B.TECH IV YEAR (CE) BATCH:-A-1

TABLE OF CONTENTS
S.No. PARTICULARS
1. Introduction About the Company.
2. Introduction About the Project.
3. Safety Training.
4. Geology of Site.
5. Blasting Process.
6. Excavation Process.
7. Drilling Process.
8. Grouting Process.
9. Test in Laboratory.
10. Water Proofing.
11. Survey during work.
12. Reinforcement Work.
13. Batching Plant.
14. Crushing Plant.
15. Sand Washing Plant.
16. Conclusion.
R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 01
B.TECH IV YEAR (CE) BATCH:-A-1

PREFACE
Project gives an opportunity to implement the principles and
knowledge practically. The experience that one gets
wonderful because what one studies in books is different
from what one fact in the field.

A Project helps a student in getting acquainted with the

manner in which his Knowledge is being practically used and
this is normally different from what one has learnt from
books. Hence, when one switches from the process of
learning to that of implementation his knowledge, he finds an
abrupt change.
This is exactly why project during the B.Tech. Curriculum
becomes all the more important.
Imagine large drives used in Site , they are really effective
and helpful. Also imagine of we could control different
machine and equipment at site or industry by using another
device. My training included these basic and some important
engineering needs in an industry.
R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 02
B.TECH IV YEAR (CE) BATCH:-A-1

1.
INTRODUCTION ABOUT THECOMPANY
TheHINDUSTAN CONSTRUCTIONCOMPANY INDIALTD. Is the
dignified and indeligible company of India. This company was
established in 27thJan,1926 near MUMBAI with the golden hand
of WALCHAND HIRACHAND, son of cloth merchant in
Sholapur, Maharashtra.

It was the first company in India to be certified for ISO 9001,

ISO 14001, OHSAH 18001 for its quality, environmental and
occupational health and safety management systems. The
company is headed by Mr. Ajit Gulabchand, Chairman and
Managing Director.
The HCC Family- In the HCC family there is big part of engineers
comes not only Civil Engineers but also Mechanical Engineers,
Electrical Engineers and many more….
In HCCFamily there isMore than 3000 Office, 2000 Engineers, 35000
Employees and also More than 21000 workers and many more investors
are
executed in the company.
In the RAPP-78 site there is more than about 115 employees
are working. TheHINDUSTAN CONSTRUCTIONCO.INDIA
LTD. Is the ultimate company in field of construction. company in field
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 03
B.TECH IV YEAR (CE) BATCH:-A-1

of construction. This company relates with the Engineering,

Construction, Realestate, Infrastructure.
Annual Turnover of company in year 2010-11 is about 7000 carore.

Some major projects undertaken by HCC include:

 Bandra-worli Sea link, Mumbai.

 Ennore Breakwaters, Tamil Nadu
 Kudankulam Nuclear Power Plant, Tamilndu
 Rajasthan Atomic Power Station, Rajasthan
 Mumbai Pune Expressway.
 Godavari Rail Bridge, Andhra Pradesh
 Nathpa Jhakri Hydro-electric Project: Construction of
head race tunnel and surge shaft, with Impregilo SPA
 across the River Yamuna, India, with Hyundai
Engineering and Construction.
 Delhi Metro Project: Underground Metro Corridor with
Kumagaigumi Co. Limited, Japan, Skanska AB, Sweden, and
Corporation, Japan,
 Lavasa hill city, Pune
AND MANY MORE……….
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 04
B.TECH IV YEAR (CE) BATCH:-A-1

2.
ABOUTTHE PROJECT- &
TECHNICAL SPECIFICATION
1. PROJECT:- Two units of 700 MWe PHWR type nuclear
reactors.
2. LOCATION:- Right bank of Chambal River in Kherli
block
Tehsil- Rawatbhata & 64 KM from Kota (Rajasthan).\

Latitude 24° 52’ N Longitude 75° 37’ E

3. ACCESS:- Rajasthan Atomic Power Station 1 & 2.

Station Director, NPCIL Rawatbhata, Rajasthan,
Site,Post Office: Anushakti, Via Kota, Rajasthan, PIN : 323303.

4. GEOLOGICAL SITE:- Sloping of the Chambal river

gently sloping terrain with rock available within rock few
centimeters of the surface.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 05
B.TECH IV YEAR (CE) BATCH:-A-1

ROCK TYPE:- Predominantly Quartzitic Sand stone.

5. METROLOGICAL DATAS:- Predominant direction SW
& SSW sector.

(a). Wind direction speed:- P=3-5km/hr. ; Q=6-11km/hr.

(b).Rainfall:- Average 826.8mm, highest 1273.5mm,

lowest 427.5mm

I. Temprat
ure:- Maximum dry bulb temperature 48.7°C; Minimum 3.9°C
.(d). Humidity:- Maximum RH=100% ; Minimum RH=1%

6. SEISMOLOGY:- The site falls in Zone II as per zoning map

of India
(IS 1893 – 2002 Part I)
. The site is lie in active seismic zone
. Earthquake intensity VI or less
.Mercalli Intensity scale
. Zero peak period horizontal ground acceleration is of the order of
0.10g for safe shut down earthquake condition & 0.5g for operating
basis earthquake condition.
.Site shall be considered to lie in an active seismic zone.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 06
B.TECH IV YEAR (CE) BATCH:-A-1

7. Site Inspection:- For familiarized.

8. Site conditions:-

. Rock type – The pre- Cambrian types belongs to Vindhyan system.

. Major types are following rock:-
a. Sand stone with clay matrix.
b. Sand stone with ferruginous matrix
c. Quartzitic sand stone with very little matrix
d. Quartzitic sand stone with no matrix.

9.SCOPE OF WORK:- Work purposed for contract are for two

units.
i.Deforestation including removal of tree stumps, exacavation in all type
of soil ,soft rock, hard rock for buildings including control blasting.
a. Nuclear Building no. 7&8 (contains Reactor Building, Reactor
Auxiliary Building, Spent Fuel Storage Bay).
b. Turbine Building no. 7&8.
c. Control Building common two units 7&8.
d. Station Auxiliary Building no. 7A, 7B, 8A, 8B.
e. Underground trenches/tunnels.
f. Safety related pump house, Safety related electrical house,
Connecting channels, tunnels & cable trenches.
g. Ventilation stack, Stack monitoring room & exhaust collection
house.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 07
B.TECH IV YEAR (CE) BATCH:-A-1

l. Waste Management & exhaust ventilation building.

m. Diesel Oil Storage Area (DOSA).
n. New fuel storage/Handling & Mechanical workshop building.
o. Switchyard.
p. Hard stand, station & approach roads, plant security wall,
retaining wall, surface drain, plant drain & monitoring pond.
q. Induced Draft Cooling Tower (IDCT).
r. Emergency Make up water pool.
s. Guard house, Control Auxiliary Building & Administration
building etc.
t. Other miscellaneous structure/building, street light pools,
buried piping & outdoor, foundations etc.
i. Backfilling of areas.
i. Mud mat PCC.
iv. Consolidation grouting of road works.
v. Construction of 16 m. wide station roads, hard stands for heavy duty
crane, other station & approach roads.
vi. After excavation & observation holes additional field investigation,
confirmatory sub soil geotechnical investigation required.
v i. Line drilling & Pre shearing in the rock wherever specified.
v i. Excavation in rocks with or without blasting (rock
breakers/hydraulic splitting etc.
ix. Dewatering of remove ground water, rain water & construction
water.
x. Construction of building & other installation.
xi. Fabrication, water proofing treatment, preparation of embedment &
testing of rock anchors.
x i. Production of concrete various grading (Normal/Heavy/Self
compacting concrete) in fully computerized batching plant & placing
with concrete pumped/placer booms/tower cranes etc. in various main
plant building.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 08
B.TECH IV YEAR (CE) BATCH:-A-1

10. Scope of work (Detailed):-

Two Reactor Building at the center of respective of Nuclear building are
located at 108m c/c distance.
I. Site layout.

Two Reactor buildings each of 700 MWe.

II.Nuclear Building
a. Raft
b. Reactor Building consist of Inner Containment Wall (ICW)
& Outer Containment Wall (OCW).
c. Reactor Auxiliary Building consist Spent Fuel Storage Bay
(SFSB).

Nuclear Building is founded on a common raft having top elevation at

90000mm in general except for Reactor Building portion where to E.L.
91700mm.

III. Nuclear Building Raft:-

Raft is founded on competent rock foundation
system. Raft in Reactor Building 100m ×
100m.
Depth 7.7m. in which various.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 09
B.TECH IV YEAR (CE) BATCH:-A-1

Rooms & Water storage galleries present.

At Nuclear Building raft thickness 3.5m.
Top E.L. 91700mm inside Reactor Building.
90000mm in the rest Reactor
Building. Temperature 19◦C at
raft.

IV. Reactor Building:-

A. Internal Structure:- It consists of mainly cross walls of different
sizes, slabs, columns, foundation of different
equipments &
miscellaneous steel structure.
B. Internal Containment Structure:- Prestressed concrete cylindrical
wall of 850mm thick. Prestressed concrete Dome of 750mm thick which
increase to approximately 1200mm at it is springing.
Internal diameter of ICW is 49.50m & the mean radius of
curvature of the Dome is 37.175.
Ring beam connected to ICW to the IC Dome is 5.0m deep &
2.0m thick.
ICW thick to 1.4m over a height of 4.2m from raft junction. The ICS
is providing with two airlocks viz. Main Air Lock
(MAL) & Auxiliary Air Lock (AAL).
Main Air Lock (MAL) & Auxiliary Air Lock (AAL).
V. Outer Containment Structure:-
OCW of 600mm thick & segmental Dome of 230mm thickness of RC.
Inner diameter of OCW 54.74m & mean radius of curvature 41.95m.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 10
B.TECH IV YEAR (CE) BATCH:-A-1

VI. MAL & AAL

VII. Reactor Auxiliary Building (RAB) formed structure
VIII. Control Building (CB) & Station Auxiliary Building (SAB)
Building is four stories.
E.L. 92000mm & E.L.100000mm at basement raft.
E.L. 106000mm, E.L. 111000mm, E.L. 116000mm & E.L.
124000mm at floors.
IX. Heavy water upgrading plant building
X. Safety related pump house
XI. Fire water pump house
XII. Safety related Electrical house
XIII. Waste Management & Exhaust ventilation Buildings
XIV. DYKE area
XV. Fuel handling & mechanical workshop
XVI. Diesel oil storage area
XVII. Ventilation stock
XVIII. Tunnel & trenches

11.Dewatering
12.Sewage treatment plant
13.Material & Service by NPCIL
14.Drawing
15.Specifications
16.Layout
17.Quantities
18.Rates:- Labor, materials, tools & plant appliances,Transport,
equipment, taxes, duties, devices & octopi.
19. Testing Requirements for construction materials.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 11
B.TECH IV YEAR (CE) BATCH:-A-1

3. SafetyTraining
In safety training safety instructor tell us of use of safety
equipment at construction site.

CUSTOM HARD HATS SAFETY VESTS

WORK GLOVES FALL PROTECTION

SAFETY GLASSES SAFETYSHOES

 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 12
B.TECH IV YEAR (CE) BATCH:-A-1

4. Geologyof Site
The rock is predominantly Quartzite sand stone
generally hard and compact with inter bedded
shale seams and clay strain. The site investigation
of the foundation rock carried out by drilling and
coring has sand stone to a depth of over 6m and
drilling core in rock up to of 3m below ground
surface.
NPCIL awarded the construction of nuclear plant
7&8 at RAPP, to HCC. As part of this work, about
15lakh cubic meter of hard rock has to be excavated
by drilling and blasting method for site grading and
foundation excavation. The excavation site is located
close to operating nuclear plant.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 13
B.TECH IV YEAR (CE) BATCH:-A-1

5. Blasting
Blast Details-
Size of Blast- 115mm diameter.
Drilling Machine- IR Crawler/ Tire mounted.
Burden- About 2.0m to 3.0m. (… Burden<Spacing)
Spacing-About 2.5m to 3.5 m.
No. of Holes- 8 to 61.
Depth-3m to 9m.
Explosive-Raj blast (83mm dia, 2.78Kg Booster and 450mm long)
Charge per hole-11Kg to 61Kg depending on depth of hole.

Peak particle velocity, V=k (D/Q½)b

V= Peak particle velocity (mm/sec.)
D=radial distance from blast monitoring station (m) Q=max. Chargeper
delay (Kg.)K and b=site constant

Explosion Used-
Detonator and Fuse Wire
In under water excavation an electric detonator shall be used.
In dry weather and normal dry excavation, ordinary low explosive
black powder (Gun Powder) in granular form may be used. Granular
black blasting powder in small charges (as in hole 1500mm to
1650mm deep, and 30 to
40mm dia.). As per use the size of hole increased about 150mm.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 14
B.TECH IV YEAR (CE) BATCH:-A-1

6. EXCAVATION
Excavation- Excavation carried out in two stages-
1- Excavation comprising of area.
2- Excavation are completed and accepted by engineer.

Companies working in excavation at Reactor

Building site-

1. SIBY 1000cum/8hr.

2. MCC 550cum/8hr.

3. KCPL 1000cum/8hr.

7. Drilling
Scope of Drilling-
1. Erection of rotary drilling rigs at required location.
2. Collection of soil and rock samples.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 15
B.TECH IV YEAR (CE) BATCH:-A-1

3. Testing of rock and soil sample.

4. Storage of core in boxes.
5. Preparation of report.

Purpose of Drilling-
1. To find geological information.
2. Description of extent and nature of sub-surface material.
3. Soil/Rock characteristics.
4. Depth of ground water table.

Equipment Required-
1. Total Station
2. Auto Level
3. Rotary Drilling Rigs (Vol. 90, Long layer, KLR tractor, Mounted
Hydraulic drilling rig).
4. Tripod set with pulley.
5. Drilling rod.

6. “Double Barrel Core Tube” of 1.5m and 3.0m length.

 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 16
B.TECH IV YEAR (CE) BATCH:-A-1

7. Starting barrel of 200mm-500mm length.

8. Triplex/Water Pump.
9. Measuring Tape (3m and 30m).
10. Pressure gauge.

Procedure-
1. Survey of area. Survey for Borehole drilling.
2. Drilling in overburden soil-
a) Machine set up at borehole location.
b) Borehole drilling by hydraulic rotary drilling rig of 100mm dia.
c) Temporary casing will be provided to support of the borehole,
when drilled through loose, very soft soil to avoid collapse of
borehole.
3. Rotary drilling in rock-
a) Method.
b) Drill rod and core barrels
c) Drilling Fluid-Clean potable water
d) Type of Bit-Diamond tippedcore bit
e) Drilling Run-Not exceed 3m in length.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 17
B.TECH IV YEAR (CE) BATCH:-A-1

Precautions-
1) To prevent surface water into pit.
2) Warning signboard and safety barricade provided.
3) Powder connection will be protected.
4) Grouting.

8. Grouting
Consolidation Grouting is the process of filling the cracks. Holes
in Grouting- There are two types of holes
i. Primary Hole
ii. Secondary Hole
iii. Tertiary Hole

Pattern of Primary Hole at 6m distance from one hole to another hole.

Small holes are Secondary Hole at 3m distance from big hole to small
hole.
Cold Drilling- 100m depth.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 17
B.TECH IV YEAR (CE) BATCH:-A-1

Instruments Used in Grouting-

i. Grouting Pump

ii. Pressure Gauge

iii. Water Meter

iv. Rubber Packer (Diameter of rubber=110mm.)

iv. Agitator

v. Mixing Drum

Applied Pressure- At 0m to 3m height=1Kg/m3

At 3m to 9m height=2.5Kg/m3

Plugging-It is the process to fill the hole with sand and cement
in ratio of (1:2).

Grout Mix- Grout Mix is the mix of sand and cement in ratio of
(1:2,1:15,1:10,1:5,1:.05,etc.).

NOTE- “ Before Grouting, it is mandatory to find out the Lussion

Value by conducting the Perculation Test, based on L.V. the Grout
Mix can be decided.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 19
B.TECH IV YEAR (CE) BATCH:-A-1

Q. Why Grouting is done?

Ans. To consolidate underground rock surface. In underground rock

surface there may be different type of cracks and faults. Which causes

sub surface flow of water. To fill up these cracks “Grouting” is carried

out.

Purpose of Grouting-

To fill up the sub surface voids in between rock layers. If it is not done

seepage of water continue which will cause the damage of water

proofing surface as well as planter reinforcement.

Procedure of Grouting-

1. Primary Holes-
a) Spacing of holes- 6m c/c.
b) Depth of holes- 9m(from existing ground level)
c) 1st Stage- 1] Perculation from 3 to 9m depth.
d) 2nd Stage- 1] If there cracks or voids or faults is there a cer
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 20
B.TECH IV YEAR (CE) BATCH:-A-1

2] Grout the hole from 3 to 9m depth as required corresponding to

loosen value.
3] When computed plug the hole from 3 to 9m.
4] Now process the perculation from 0 to 3m depth.
5] Grout and plug the hole as loosen value obtain. e) Grout and plug all
the primary holes.

2. Then go for Secondary Holes- The secondary hole will be

in between primary holes. The grouting and pluging will be same as
primary holes.

3. If loosen value is there in secondary holes we have to proceed for

tertiary holes.
R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 21
B.TECH IV YEAR (CE) BATCH:-A-1

9 . TESTING LABORATORY
Introduction of Concrete testing lab-
1. Compression Testing Machine(CTM)
2. Flexural Test of Concrete for Beam
3. Soundness Test of Cement
(Expansion of Cement, ”Le Chatelier’s Principal”)
4. Aggregate Abrasion Test
5. Workability or Slump test on Concrete
6. Air Content Test on Concrete
7. Flakie longation Test
8. Sieve analysis of coarse aggregate
9. Sieve analysis of fine aggregate
10. Sand present in aggregate
R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 22
B.TECH IV YEAR (CE) BATCH:-A-1

CONCRETE TESTING\LAB

Experiment-1
Compression Testing Machine
USE- Compressive strength test on concrete remove
before 24hrs. Whenever cube is coated.
NOTE:- Load in UTM=140
Kg/cm2. Size of Cube
Mould=15x15x15 cm.

PROCEDURE-
1. Remove the specimen from curing tank.
2. Place the specimen in Compression Testing Machine (CTM),
Capacity-
3000KN.
3. Place the cube so that caste face shall not be at top or bottom.
4. In case so that cast face shall not be capped using Sulphur
Capping. “Sulphur Capping is for the finishing of cube
layer.”
5. Align the axis of specimen with center of thrust of spherically seated
platen
6. Apply the load till specimen break or crack.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 23
B.TECH IV YEAR (CE) BATCH:-A-1

7. Record the max load applied.

8. Calculate compressive strength.
Compressive Strength = Load/Area. Unit-N/mm2
Note- Taping bar is used for cube is 25 times and 35 times.

TAPING BAR- 16mm Diameter & 700mm Long.

CONCRETE TESTING LAB

Experiment-2
Flexural Test of Concrete for Beam
1. Specimen shall be 700x150x150mm concrete beam.
2. Specimen shall be cured by submerging in clean water upto time of
testing.
3. Bearing surface of the supporting and loading rollers shall be
wiped clean, any loose sand or other material removed from
surface of specimen.
4. The specimen shall be wiped clean, any loose sand or other
material removed from the surface of specimen.
R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 24
B.TECH IV YEAR (CE) BATCH:-A-1

5. The specimen shall then be placed in the machine in such a

manner that the load shall be applied to uppermost surface as
caste in mould, along two lines spaced 200mm apart. The axis of
specimen shall be carefully aligned with axis of loading device.
6. The fiber stresses increases at application 7Kg/sq./min that is at the
rate of loading 4KN/min for the 150 mm specimen.
7. The load shall be increased until the specimen fails, and the
maximum load applied during the test.

The flexural strength of specimen shall be expressed as modulus

of rupture fb.
fb = Pl/bd2

P=Load (N), l=Length of specimen (mm), b=width of specimen (mm),

d=depth of specimen (mm).
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 25
B.TECH IV YEAR (CE) BATCH:-A-1

CONCRETE TESTING LAB

Experiment-3
Soundness test of Cement
(Expansion of cement)
Initial reading Final reading
(Specific Gravity of Cement)-
Le-Chatelier flask-Standard Le-Chatelier flask conforming to IS 4301,
shall be used.

Analytical balance-Electronic balance of accuracy (± 0.1g) shall

be used. Procedure-
1. Kerosene, free of water having a specific gravity not less than
0.731 shall be used in specific gravity determination.
2. The flask shall be filled with kerosene to a point on the stem
between the 0 and 1-ml mark.
3. Inside the flask above the level of the liquid shall be dried.

4. First reading shall be recorded.

 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 26
B.TECH IV YEAR (CE) BATCH:-A-1

5. A weighted quantity of cement (about 65g for Portland cement)

shall then be introduced in small amount at the same temp. as the
liquid.
6. Care shall be taken to avoid splashing and has been
introduced, the stopper has been introduced.
7. The stopper shall be placed in the flask and the flask rolled in
inclined position or gently whirled in the horizontal circle, so as
to free the cement from air until no further air bubbles rise to
surface of the liquid.
8. If proper amount of cement has been added the level of liquid will
be in its final position at some point of upper series of graduations.
9. The final reading shall be taken.
10. The flask shall be kept in constant temperature room for
sufficient interval before making either of the reading so as to
avoid variation greater than 0.2°C in temperature of the liquid in
the flask.
11. The difference between the first and final reading represent the
volume of liquid displace by the mass of cement used in test.

The Specific Gravity shall be calculated as-

Mass of cement in (gms)

= --------------------------------
Displaced volume in cm3
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 27
B.TECH IV YEAR (CE) BATCH:-A-1

CONCRETE TESTING LAB

Experiment-4
Workability/Slump test on cement
1. Collect the sample on non absorbent metal plate or tray
and mix it thoroughly.
2. Clean the internal surface of cone slump.
3. Fix the cone firmly to its base plate with help of clamping screw
and place it at horizontal surface.
4. Fill the mould with concrete sample in four layers
each layer approximately ¼ cone height.
5. Compact each layer with 25 strokes by tamping rod.
6. Release the clamping screw and lift the cone slowly and
carefully in vertical direction from the concrete.
7. Place the cone inverted at the side of concrete.
8. Measure the difference of height between top of cone top
of plastic concrete.
9. Record the value as slump of concrete in mm.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 28
B.TECH IV YEAR (CE) BATCH:-A-1

CONCRETE TESTING LAB

Experiment-5
Air Content test on Concrete
1. Collect the sample on nonabsorbent metal plate and mix it
thoroughly.
2. Fill the container in three equal layers and compact each layer with
25 strokes by tamping rod.
3. Close main air valve of air receive of top LID open both the pet
clocks of top LID.
4. Place LID on container and close the four toggle clamp.
5. Pour water into funnel until water comes out of petcock.
6. Close both the petcock and air bleeder valve.
7. Gently pump air into receiver until gauge needle comes in line marked
on gauge.
8. Top gauge gently and open main air valve.
9. Allow the needle to come to rest and take the reading.
10. Report this reading is present of air entered in concrete.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 29
B.TECH IV YEAR (CE) BATCH:-A-1

\ 10. WaterProofing
Water Proofing in Horizontal Surface -

a. 20 mm. thick leveling coarse(Screed) of 1 part of cement,4 part

of sand by volume with “SIKA Latex” , Water/Cement ratio should
be 0.5.
b. 1st coat of” Acrylic Polymer”.
c. 1st layer of fiber glass cloth reinforcement o.2mm thick.
d. Repeat process for 5 layer of Acrylic Polymer” material
sandwich with 4 layer of fiber glass.
e. Total thickness of water proofing shall be 3 to 4 mm.
f. Completion of final layer of water proofing and a gap of
manufacturer before application of 20mm thick protective layer
of 1:4 cement and sand ratio by volume with chicken mesh wire.
g. 7 days curing after plaster.

Water Proofing in Vertical Surface-

a. Concrete surface will be clear with wire brush to remove
laitance of cement mortar, fungi, algae, oil substance.
b. 1st coat of acrylic polymer.
c. 1st layer of fiber glass coat reinforcement 0.2 mm thickness.
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 30
B.TECH IV YEAR (CE) BATCH:-A-1

d. Repeat five layer of acrylic cementious material sandwich with four

layer of fiber glass.
e. Total thickness of waterproofing membrane shall be 3 to 4 mm. f.
Before 115mm brick wall sufficient curing shall be done.
g. 115mm protective brick wall with cement mortar 1:6 will be build
outside the RC wall/raft.
h. Curing shall be 7 days minimum.

11. SURVEYING DURING

WORK
1-AutoLevel
2-Total Station

1-AUTO LEVEL

ApparatusUsed-Tripod,Auto-level,Prism,Shaft, Measuring
Tap etc.
Procedure-forTemporaryarrangement
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 31
B.TECH IV YEAR (CE) BATCH:-A-1

1)Setthetripodinlevel(3legsarelevelandequal).
2)Setauto levelontripod.
3)Setbubbleincenter.
4)Read thereading in cross hair level.

ObservationTable forCalculation-

Synod. B.S. I.S. F.S. H.I. R.L.

B.S.-Back Sight
I.S.-Intermediate Sight Height of Instrument R.L.-Reduced
Level F.S.-Fore Sight Formulae-

H.I. =R.L.+B.S.
R.L. = I.S.- H.I.
F.S. = H.I. – R.L. of staff in fore direction
2-TOTAL STATION
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 32
B.TECH IV YEAR (CE) BATCH:-A-1

12. ReinforcementWork
Material- HYSD bar and TMT bar Fe 500 to IS 1786.
In Fe 500 steel elongation not more than 14.5% ultimate
tensile strength of bar 15% more than actual 0.2%
proof stress/yield stress.
Storage-Reinforcement steel shall not keep direct contact
with ground; it is kept on timber sleepers or concrete
pedestal. Bending of Reinforcement-The reinforcement
bar shall be
cold bent at appropriate radius of minimum 6D using
“Bar Bending Machine” with proper mandrill. Load
shall be applied gradually on bar.
Lying of Reinforcement- The bars are placed as
according to reinforcement diagram. Chair/ Spacer
made up of reinforcement steel bar shall be provided to
keep the bars in position. The radius of bent is less than 6
times the diameter for HYSD TMT bars. Reinforcement
shall be tied with each other 16 gauge where the spacing
of re-bars is greater than
300mm both ways. If spacing of the bars is less than
300mm, only alternate joint shall be tied both ways.
Spacing- R*Ø
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 33
B.TECH IV YEAR (CE) BATCH:-A-1

Q. Why we use Fe 500 bar, not use Fe 415 bar in

construction of Reactor Building?

Ans. Because the strength of Fe500 is more than Fe 415 bar.

TypesofBarsusedinconstructionofReactorBuilding:-
S.No. Name of Bar Diameter of Type of Bar

1. Straight Bar 8MM TMT(Fe500)

2. Straight Bar 10MM TMT(Fe500)
3. Straight Bar 18MM TMT(Fe500)
4. Straight Bar 20MM TMT(Fe500)
5. Straight Bar 32MM TMT(Fe500)
6. Straight Bar 36MM TMT(Fe500)
7. Chair Bar 36MM TMT(Fe500)
8. Lap Bar 36MM TMT(Fe500)
9. Radial Bar 36MM TMT(Fe500)
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 34
B.TECH IV YEAR (CE) BATCH:-A-1

13. Batching Plant

Capacity of Batching Plant- 120m3/ hr.

Aggregate Store-40m3
Admixture Concrete- Cement+Additive+Water+Ice+Aggregate

Storage Bin-

1. 10mm aggregate
2. 20mm aggregate
3. Sand-20mm aggregate(Crush Sand and Natural Sand both)

Aggregate wear load cell (Capacity)- 5000 Kg/load*104

Conveyer- Feed the material in bins.
Mixer- Mixer is used to mix the mixer
(Flyash+Cement+Aggregate+Sand) Capacity of mixer batch-
3m3
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 35
B.TECH IV YEAR (CE) BATCH:-A-1

Cylo- Cylo is used for the fly ash.

Capacity-200 ton. Total 12 Cyno is used
in HCC. Ice Plant-20 ton
Temperature in Ice Maker- (-30°C to -33°C).

Storage Container- 100 ton.

Maximum capacity of
Plant- 60m3. Maximum
batch capacity-1.25m3
Transit Mixer-Concrete is being transport to by transit mixer
of 600m3 capacity.
We take 15 days calibration.

Ammonia(NH3) is used for condensing the ice .

Ice maker consist of -

a. Vapor compression System. b. Receiver
c. Compressor d. Condenser
e. Ice cutting motor
 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 36
B.TECH IV YEAR (CE) BATCH:-A-1

14. CRUSHING
PLANT
Crushing of stones in machine as per requirement of size of aggregate.
BC-1 Jaw Crusher- To crush 82-100mm size boulders.
BC-2 Chock Pile- Hydrocone Crusher- 10, 20, 40mm
size aggregate.
BC-6 Screen-1 for greater than 40mm size aggregate.
BC-7 VSI Hopper(Vertical Shaft Impector) is used for stock the
aggregate.
BC-8 VSI Crusher(Vertical Shaft Impector) is used for plane the
aggregate.

Screen-2 for 40,20,10,4.75mm size aggregate.

 R.N. MODI ENGINEERING COLLEGE, KOTA
RAJASTHAN TECHNICAL UNIVERSITY
NAME: KETAN TAK
ROLL NO. :- 09ERNCE024 PAGE NO:- 36
B.TECH IV YEAR (CE) BATCH:-A-1

15. Sand Washing Plant

Process of washing sand in plant:-

16. CONCLUSION
On concluding the training report , I would like to say that I got a
good overview of NPCIL & HINDUSTAN CONSTRUCTION CO. LTD.
I learn about the practical knowledge at site. I learnt about many
instrument at the site. I think this training will come good in future use.
Apart from my area of project I also got an idea that “ How to do
work at construction site”, which is important in my future.