Training Report

CONSTRUCTION OF A NEW BUILDING AT 5/1 CHOWRINGEE

PLACE, IN PLACE OF OLD CHAPLIN CINEMA HALL

TRAINERS’ NAME:
MR. SUNIT KUMAR SAHA (Asst. Engg., KMC)
MR. PRITAM DAS (Asst. Engg., KMC)

Institute: West Bengal Survey Institute

Duration: 27th December 2019 - 14th January 2020
 Trainees’ name:
1. AKASH DHARA

2. SWAPNASISH SARKAR

3. AROJIT GHARA

4. ASISH ROY

5. SUPARNA KUNDU

6. SANKET AICH

7. PARIKHIT MANDAL

8. GAURAV MISHRA

9. BIJAY SHANKAR SHAW

10. SURAJIT HAZRA

11. SOURAV GHOSH

12. TANIMA PORE

13. AYESHA KHATUN

14. BISWASANI VERMA

15. MANOTOSH MONDAL

 Acknowledgement

I would like to express my special thanks of gratitude

to MR. JYOTIPRAKASH SARKAR, MR. SUNIT KUMAR
SAHA, MR. PRITAM DAS as well as our teachers who
gave us the golden opportunity to do this wonderful
project, which also helped me in doing a lot of
research and I came to know about so many new
things I am really thankful to them.
Secondly I would also like to thank my friends who
helped me a lot in finalizing this project within the
limited time frame.

PROJECT DETAILS
Name of project: CONSTRUCTION OF A NEW BUILDING
AT 5/1 CHOWRINGEE PLACE, IN PLACE OF OLD CHAPLIN
CINEMA HALL
Client: Kolkata Municipal Corporation (KMC)
Contractor Name: M/S Essem Enterprise
Designer: Jadavpur University
Specification of Pile:
 Type of Piling: Direct Mud Circulation (DMC)
 Grade of Concrete: M30
 Grade of Reinforcement: Fe500
 Load Capacity: 52MT
 Dia of Pile: 500 mm
 Shaft Length: 24.2(as per drawing)
 Spacing of Pile: 2.5d – 3d
 Depth of Pile Cap: 1.2m, 1.3m, 1.4m, 1.5m.
 Number of piles:113
 Number of Pile Caps:21 (2combined)
 Dia of Main Reinforcement of Pile: 16mm, 12mm
 Dia of Link Reinforcement: 8mm
 Depth of Boring: -28m
PILE FOUNDATION
Introduction:
Piles are columnar structure, the most common type of deep
foundation, where the depth of foundation is much greater than the
width of the foundation. The load of the structure is transmitted by
the piles to hard stratum below or it is resisted by the friction
developed on sided of the piles.
It is used;
1. Where the soil is compressible,
2. Where the soil is water logged and
3. When stratum of required bearing capacity is at greater depth
The major uses of piles:
o To carry vertical compression loads,
o To resist uplift loads
o To resist horizontal or inclined loads
 Method of installation of piles: Driven (displacement) piles or
Bored (replacement) piles.
 Type of material used for piling: Concrete, steel, timber etc.
 Setting up piles: Depending up on the setting up principle, piles
can be of two types, e.g. Displacement type and Replacement
type.
 For displacement piling method, piles are driven into the
ground pushing the soil out of its way. Displacement piling is
good for contaminated sites where it costs a lot to move the
soil out.
 Using the replacement piling method, muck is dug out and
replaced with the pile. Much bigger piles can be casted by
replacement method.
 Direct Mud Circulation (DMC).
 Direct Mud Circulation (DMC) piling is an example of
replacement piling method. The basic principle of DMC piling
lies in the fact that the soil layers generally become harder to
penetrate with depth, so to soften the hard soil layers deep
below the ground, water jet streams are used. Then a chisel is
used to cut the soul. Bore holes are dug as per the clients
requirements, ensuring that the subsoil in it does not collapse
by using Bentonite slurry or other compounds. Then a
reinforcement cage is lowered and concrete is filled from the
bottom of the bore hole with the help of Tremie pipes. The
concrete is usually left to harden for 28 days.
 A DMC apparatus basically comprises a Tripod with pulley, a
winch machine, wire-rope, Chisel, drill pipes, Tremie pipes, a
Vertical pump and a pit where Bentonite powder is mixed with
fresh water.
 Field Procedure DMC Piling
o For executing DMC piling method which is approved as per IS
2911 under specifications of bored cast in situ piles. The
positioning of points where the piles are proposed to set up,
are checked by the surveyor.
 DMC piling Rig set up and initiation of boring using the
Bailer
o After the point for boring operation is set out by the surveyor
the tripod is paced such that each side legs are at least 1.5m
away from the point, keeping the center of borehole exactly in
the center.
o The bailer is then attached with the rope and the boring
operation is initiated.
o After bailer reaches its full length into the soil, the guide casing
is inserted into the hole for farther operations.
 Insertion of the Guide Casing
o To prevent the side collapse and caving in, a guide casing is
placed on the top of the borehole and hammered by the bailer
to insert into the soil. This will be withdrawn after concreting is
over.
 Boring with Chisel
o Once the guide casing is placed, the boring is started with
chisel.
o The chisel has 4 nozzles from where water jet is forced on the
hard soil later as the boring progresses.
 Progression of boring and addition of DMC pipe
o DMC pipe are added one after another as the depth increases.
o The DMC head are attached on top of the DMC pipe which has
the plunge which receives the water from delivery hose.
o The whole system is pulled up the rope and the D-Shackle with
the help of the winch system and then left to fall free, so that
the chisel at the bottom cuts the soil and the boring progresses.
o The loose soil produced by boring, mixes with water and comes
up and is stored in the wash bat, where the soil gets
precipitated and the water is again usable
 Taking out of the DMC pipe and Chisel and Insertion of the
reinforcement cage
o After the boring is complete up to the desired depth, the DMC
pipe are removed one by one using the DMC fork and the chisel
is also removed .
o Then the steel reinforcement cage is inserted and welded
where ever there are joints.
 Concreting and Finalization of the process
o The tremie pipes are inserted one by one using the tremie fork
and then the bore hole is washed with the Bentonite water and
the Muck is completely removed and the hole is filled with
bentonite slurry.
o The Transit mixer arrives and the hopper is attached on top of
the tremie pipe.
o The TRANSIST MIXTURE puts concrete mix into the hopper and
the valve opens. the bore hole is gradually filled with concrete
which is compacted by gradual vibration of tremie pipes. This
filling of concrete from the bottom is done to avoid segregation
of the concrete mix.
o As the concrete fills the hole from bottom , Bentonite slurry
escapes the hole. The tremie pipes are detached one by one
and thus the hole gets filled completely.
o After the hole is fully filled , the concrete is left 28 days to gain
full strength . After 28 days the guide casing is removed and the
pile is ready.
 Why is bentonite used in piling?
 During boring for pile, the side of the bore hole is subjected to
various types of forces & pressure like active earth pressure,
overburden pressure, hydrostatic pressure, pore pressure due
to underground water, etc. due to which the side of bore
becomes unstable and start collapsing if the soil strata is weak.
 In order to stabilize the side of bore the supporting fluid is to be
used to counter the above pressure. The commonly USED
SUPPORTING FLUID FOR STABILIZING IS BENTONITE.
 What is Pile cut-off Level?
 Pile Cut-off level is the actual level at which the piles below pile
cap are made to be at the same level. The concrete of pile is
cut-off at the specified level given in the specifications or
drawings (usually around 75 mm) while the steel is kept
projected in-to the pile cap to make an effective bond between
pile cap and piles.
 Why pile is trimmed or cut? 
 Piles are casted with high slump concrete, during the
concreting of piles, there is a chance that fines from concrete
might accumulate at the top and also if there is any
contaminated boring debris ,slush in the bored pile, it will also
come up during concreting.
So the concreting of pile is basically overflowed to take out all
impurities.
 After casting of the piles, the top portion of the pile is chipped
out till the pile cap or beam bottom level.
 Traditionally the cropping or trimming process to achieve the
required cut off level is done using a jackhammer or hand- arm
vibration syndrome (HAVS).
 Pile load test:-
Static load tests were performed during the test phase of each
contract to verify the design assumptions and load-carrying
capacity of the piles. Static loads were applied and maintained
using a hydraulic jack were measured with a load cell.
Procedure:-
Trench around pile was selected.
Around the outer side of the trench, sand bags were placed at a
certain height on the I- section supports. The I-section was also
selected based on the required sand bag loads.
Those I-sections were placed at a particular spacing.
Between I- sections, reinforcement were provided to fill up the
spacing between I-sections.
Arrangement of sand bags were stacked in a pyramidal gesture
to resist the sand bags from slipping away. Thus, the dimension
of the uppermost layer is minimum and almost equal to trench
dimension in lower portion.
Hydraulic jack was placed over the central axis of the pile and 4
dial gauges were placed at 4 corners.
Box with pressure gauge was also set up outside the trench to
put the pressure of sand bags on the jack. This loading
phenomenon is followed by Reaction Loading process (where
the loads on trench gives the pressure on load cell via bearing
plate. Hydraulic jack conveys the load downward again by the
downward reaction of Load Cell, on Loading Plate).
Primarily 25% of the allowable design load was applied in every
half an hour up to 200% of the design load, in certain time
interval of 30 min. Reading has been noted after a interval of 15
min. after changing the load.
Pressure was recorded from pressure gauge and the deflection
from the average of all 4 dial gauges
The maximum applied load, the load is maintained for minimum
of one hour until the settlement is not greater than 0.254 mm
or 1 inch
Now, 25% load is removed in every 15 minutes until zero load is
reached. Longer time span may be used for more accuracy but
each have to be same.
Rebound was measured at zero load for minimum one hour.
 Methods to check whether the structure is vertical or not
Plumb-Bob Technique:
We usually take a plumb bob to check the alignment (in this
case verticality of the column). Plumb bob tied to a rod and
placed above the column shutter. It is seen that the rod is
projected out and the plumb line is seen to be some distance
apart from the column face. We check the plumb line distance
from shutter face using a tape at three positions (normally top,
middle and bottom). If all the readings are the same, then the
column shutter is aligned with the plumb line and is vertical. If
not we will adjust accordingly to make it vertical.

 Grout is any viscous (thick and sticky liquid which does not flow
easily), packable material that can be used to fill the space
between two elements for bonding them or to create a water-
tight seal.
 Grout is generally a mixture of cement, sand and water used to
fill gaps. They are used in the repair of concrete cracks, fill
seams and gaps in tiles, seal and fill gaps for waterproofing, and
for soil stabilization. It is also used for giving extra strength to
the foundations of load-bearing structures.
Grouts are used in a variety of application such as repair of
cracks, water – stopping in submerged structures such as
canals, tunnels, etc., fill seams between tiles, and for stabilizing
soil.
 Guniting is the most effective process of repairing concrete
work which has been damaged due to inferior work or other
reasons. It is also used for providing an impervious layer. The
cement is mixed with slightly moist sand and then necessary
water is added as the mixture.  A cement gun is used to deposit
this mixture on the concrete surface under a pressure of about
20 to 30 N/cm2. A regulating valve is provided to regulate the
quantity of water. The surface to be treated is cleaned and
washed. The nozzle of gun is generally kept at a distance of
about 750 mm to 850 mm from the surface to be treated and
the velocity of nozzle varies from 120 to 160 m/sec.

 Sandblasting is basically used to clean the surface of any

material, mainly for the metallic surface. It is one of the most
efficient and quick method which uses compressed air to blast
 fine sand through a nozzle to shape and smooth surface of any
foreign material. It is well suited for the removal of rust which
causes property damage.

 It is used not only to remove rust but to prepare surface for
high performance coatings or to treat final products to give
them luster and surface texture desired by the retail consumer.
Materials used in sand blasting are sand, copper slog, steel grit,
pieces of walnut, powder abrasive, pieces of avocado and many
others.

 Sika® Rustop is cement bound synthetic resin modified 2-

component coating for corrosion protection on reinforcement
and concrete. Ideally suited to rehabilitate corroded
reinforcement.
 Sika® Rustoff 100 is a single component liquid that removes
rust and prevents further rusting of steel structures by
providing a passivating coat.
 What will be the individual quantity of ingredient of 1 m3 M20
grade concrete?
•  M20  = 1:1.5:3 (Ratio)
• volume of dry Concrete = 1.54 to 1.57 times Volume of wet
concrete
• Now calculations is as follows for 1cum of Concrete work
• ratio Sum = 1+1.5+3=5.5 
• Volume of cement = (1/5.5) x 1.54 = 0.28 m3
• Volume of 1 bag of cement =0.0347 m3
• No. of cement bag required =(0.28/0.0347)=8.07=8.1 bags
• Volume of sand require = (1.5/5.5) x 1.54 = 0.42 m3
• Volume of coarse aggregate require = (3/5.5) x 1.54 = 0.84 m3

 To calculate the cement and sand for 100 m2 plastering area in

1:5 ratio and 12 mm thickness.
• Volume of cement mortar required = ( Plastering Area x
thickness )   = 100 m2 x 0.012m = 1.2 m3
• Add 20% extra Quantity for Filling of joints, Depressions &
Wastage
∴Volume of plaster = 1.2 x 1.2=1.44m³
• Dry volume of plaster = Wet volume x 1.33=1.44 x 1.33=1.92 m3
• Cement : Sand (Ratio) = 1 : 5 ( Total = 1+5 = 6 Parts )    
• Cement required=1.92 x 1/6=0.32 m3 =(0.32/0.0347)=9.23 bags
• Sand required =1.92 x 5/6=1.6 m3
 What will be the individual quantity of ingredients of a 10 m3
modular brick work with 1:5 cement mortar ratio?
• Volume of 1 brick =(0.19 m x 0.09 m x 0.09 m) = 0.001539 m3
• Volume of 1 brick with mortar = 0.2m x 0.1m x 0.1m=0.002 m3
• No of bricks in 10 cum =10/0.002= 5000 bricks
• Volume covered by 5000 bricks in 10 m3 Volume = (Bricks
number x Volume of 1 brick)
• 5000 Bricks Volume  = 5000 x 0.001539 = 7.70 m3
• Mortar volume = 10 – 7.7 = 2.3 m3 (wet volume)
• Now add 15% extra for frog filling ( brick binding and wastage),
total volume of set mortar =2.3 x 1.15 =2.65 m3
• Dry Volume = 2.65 x 1.33= 3.525 m3 (dry Volume).
• Cement required= (3.525 x 1/6)= 0.58 m3 =(0.58/0.0347)=
16.93= 17 bags
• Sand required= (3.525 x 5/6)= 2.93 m3
 The Tender process
Tendering process can be defined as the process of procuring
goods, works or service by government organizations or
corporations such as State/Central govt. ministries, by releasing
their requirement document - Tender notice and inviting
relevant interested parties to take part in bidding.
 Conclusion

As an undergraduate of the West Bengal Survey Institute I would like to

say that this training program is an excellent opportunity for us to get
to the ground level and experience the things that we would have
never gained through going straight into a job. I am grateful to our
college, KMC (Civil department) for giving us this wonderful
opportunity. I have gained lots of knowledge and experience needed to
be successful.

During this period, we got the opportunity to visit construction site

which had which is in progress, guided by MR. JYOTIPRAKASH SARKAR
(Executive engg.,KMC),MR. SUNIT KUMAR SAHA(Asst. Engg.,KMC ),
MR. PRITAM DAS (Asst. Engg.,KMC).

This industrial training taught and explained to us about the procedure,

methods to follow, interpretation of design and mechanism behind the
working principle.
We are also told about the various safety measures and precautions
that were to be adopted by everyone at any site, so that nobody gets
injured or harmed.