1. 1
1. ORGANIZATION OVERVIEW
Larsen & Toubro Limited (L&T)is a technology, engineering, construction and m-
anufacturing company. It is one of the largest and most respected companies in India's pri-
vate sector.
Seven decades of a strong, customer-focused approach and the continuous quest for
world-class quality have enabled it to attain and sustain leadership in all its major lines of
business.
L&T has an international presence, with a global spread of offices. A thrust on
international business has seen overseas earnings grow significantly. It continues to
grow its overseas manufacturing footprint, with facilities in China and the Gulf region.
The company's businesses are supported by a wide marketing and distribution network,
and have established a reputation for strong customer support. L&T believes that
progress must be achieved in harmony with the environment. A commitment to
community welfare and environmental protection are an integral part of the corporate
vision.
ECC – the Engineering Construction and Contracts Division of L&T is India’s largest
construction organization with over 60 years of experience and expertise in the field. ECC
figures among the World’s Top Contractors and ranks 35th among top global contractors and
60th among international contractors as per the survey conducted by Engineering News Record
magazine, USA (August 2008).
Many of the country’s prized landmarks – its exquisite buildings, tallest structures,
largest airports/ industrial projects, longest flyovers, highest viaducts, longest pipelines
including many other benchmark projects have been built by ECC.
ECC’s leading edge capabilities cover every discipline of construction: civil,
mechanical, electrical and instrumentation engineering and services extend to all core
sector industries and infrastructure projects.
2. 2
2. OBJECTIVE
To achieve excellence in the field of Engineering, Procurement and Construction through
world class practice and standards in Quality, Safety and Project Management.
Highway department deals with all the construction related to the road that can be
embankment and crust construction. Before cutting or excavating the land, the most
important part is to know the reduced level of land where we have to start working.
Delhi-Agra Road Project involves six lanning of the existing road including construction
of Rail overbridged, Pedestal Underpasses, Vehicular Underpasses and Flyovers. This
highway commonly referred as Delhi-Kolkata Road runs through the states of Delhi,
Haryana, Uttar Pradesh, Bihar, Jharkhand and West Bengal.
3. 3
3. PROJECT DESCRIPTION
PROJECT TITLE : Delhi Agra Road Project
CUSTOMER : M/S Reliance Infrastructure Limited
CONSULTANT : SAI/Feedback
CONTRACTOR : Larsen & Toubro Limited
CONTRACT AGREEMENT DATE : 21/06/2012
CONTRACT VALUE : Rs 2040 crores
CONTRACT DURATION : 31Months
PROJECT START DATE : 1/10/2012
4. 4
4. SAFETY
As we know safety is now becoming more important and necessary so as to protect not only
life hazards but also materials, it becomes overly important for companies to involve into
practices that facilitate and enhance the safety of people and material on site.
On the site of The Bihar Museum we had a safety induction program that is mandatory for all
people entering on site for first time, it includes
a. An induction film that is specially made to educate the viewers about various aspects of
safety like Working at heights, Fall protection, Use of electric equipments, ladders etc.
b. Personnel Protective equipments are issued to every worker of the site and their use is
ensured by safety inspectors/maids.
c. A prep talk is organized for the benefit of the labour every morning before work is
resumed.
Apart from all these activities I was permitted to attend a special safety seminar that was
organized for L&T employs to ensure safe working conditions and following safety
rules on site. The Seminar was delivered by Mr. Das which touched upon the topics of
EHS Culture, Work Permits, Leadership, Working at heights etc.
5. 5
SAFETY APPLIANCES: HEAD PROTECTION :Every individual entering the
site must wear safety helmet, with the chinstrap fixed to the chin
FOOT AND LEG PROTECTION:
Safety footwear with steel toe is essential on site to prevent crush injuries to our
toes and injury due to striking against the object.
EYE PROTECTION:
Person carrying out grinding works, operating pavement breakers, and those involved
in welding and cutting works should wear safety goggles & face shield suitably.
Goggles, Safety Spectacles, face shield confirm to IS: 5983-‐1980.
EAR PROTECTION:
Ear Muff / Earplug should be provided to those working at places with high sound levels
(confirm to IS: 9167-1979).
HAND AND ARM PROTECTION: While handling cement and concrete & while carrying
out hot works like gas cutting, grinding & welding usage of hand gloves is a must to protect
the hand,
1. COTTON Gloves (for materials handling)--IS: 6994--1973
2. RUBEER Gloves--
18. (380/450mm long) electrical grade, tested to 15000 Volts conforming to IS:
4770 -‐1991
3. LEATHER Gloves – hot work / handling of sharp edges.
SAFETY NET
:Though it is mandatory to wear safety harness while working at height on the
working platforms, safety nets of suitable mesh size shall be provided to arrest the falling
of person and materials on need basis.
7. 7
5. PLANNING
The planning department is one of the most vital departments of construction. It not
only helps in proper coordination of various departments but also keeps a track of
progress of work and documentation.
Plans are detailed methods, formulated beforehand for doing making something. Plans lift
targets and define means of achieving them.
8. 8
CONCEPT PLANNING:
After sanction of the project from the central government, following process are required to
execute concept planning:
Tendering
Pre-Construction
Design
Construction
Operation and Maintenance
True Intelligence is not memorizing and avoiding mistakes. True Intelligence is about the
joy of learning rather than the fear of falling.
Design, Methodology and Process Selection
Logistics
Estimate-Quantities, Resources and cost.
Value Engineering.
Manpower
PROJECT PLANNING:
10. 10
KICK OFF MEETING:
First meeting with the project team to discuss the role of each team member.
Demonstrate the commitment from the management for the project.
Project vision.
Team commitments
Ground rules
Roles and responsibilities.
RESOURCE/DESIGN/DOCUMENTS:
Contract Documents-contractual hazards and risk factors.
Bill of quantities.
Site investigation report.
Tender Consideration.
Risk assessed during tender.
IDENTIFICATION OF KEY PERSONNEL:
Project Manager
Planning in-charnge
QA/QC in-charge
Section in-charges
Quarry/Crusher in-charge
P & M in-charge
Accounts and Admin in-charge
Safety in-charge
MOBILIZATION:
Action plan for mobilizing the equipment
Present location of the equipment
Tentative date of availability of the equipment
Action taken for specialized/new equipment/labor
11. 11
MATERIAL SOURCE SURVEY:
Sample collection and testing for suitability.
Core drilling to know the rock properties.
Finalization of resources based on availability of material
Quality of material
Easiness to get environmental clearance.
PROJECT FACILITY LOCATION:
Preliminary Survey.
Quarry Location
Camp Location and Strategies.
Procurement Strategy for Bulk Material.
Resource identification of P & M/Labour.
Statutory permits.
12. 12
6. QUALITY ASSURANCE & QUALITY CONTROL
Quality is the key component which propels performance and defines leadership traits. At
L&T Construction, Quality Standards have been internalised and documented in Quality
Assurance manuals. L&T Construction recognizes the crucial significance of the human
element in ensuring quality. Structured training programmes ensure that every L&T employee
is conscious of his/her role and responsibility in extending L&T Construction’s tradition of
leadership through quality. A commitment to safety springs from a concern for the individual
worker –every one of the thousands braving the rigours of construction at numerous project
sites. L&T, Buildings & Factories IC has a well-established and documented Quality
Management System (QMS) and is taking appropriate steps to improve its effectiveness in
accordance with the requirements of ISO 9001:2008. Relevant procedures established clearly
specify the criteria and methods for effective operation control and necessary resources
and information to support the operation and monitoring of these processes.
Quality is one of the most important aspects of any construction project, sadly so it is often
the most neglected aspect on many sites. The Head of Quality Department Mr.Kalyan
Chaudhry sir is experienced person and has apt knowledge to deal with any problems that
might occur in his area of operation. Under the guidance of Mr.Suman sir I had a chance to
learn about
1. Quality Plan.
2. Various test carried out on site.
3. Successfully carry out a mix design for M35 Grade of concrete.
4. To study the Working of batching plant.
13. 13
Quality Plan:-
The quality plan for any given site has certain components
General- It includes the Scope & purpose of the project, Various
definitions and Glossary of terms
Quality Management system- It includes General requirements of
process flow and mapping, Documentation (its needs and control)
Management Responsibility- It deals with the commitment of
company, Customer focus, Quality Policy, Planning, objectives,
Responsibility, Authority and communication..
Resource management – It includes Resource Provision,
o Human resource (Competence, Awareness & training)
Various Test Carried Out on Site –
The quality lab was well equipped with various instruments to carry out all
necessary tests on site. The following tests were carried out on site
o Sampling of sand, aggregate, cement.
o Moisture content and density of soil.
o Free swell index.
o Compressive strength of concrete cubes.
o Marshall test of DBM.
o Vi-cat apparatus test for testing setting time of cement.
o Core cutter for testing soil compaction and in situ moisture content.
o Impact value test on aggregates.
o Sieve analysis.
o Slump test.
o FDD(Field Dry Density)
15. 15
GRAIN SIZE ANALYSIS:
This test is done to found the percentage of gravel, sand, silt and clay in soil sample. Gravel
(75mm- 4.75mm), sand (4.75mm – 0.075 mm) and silt and clay (0.075mm passing).
PROCEDURE:
1. Take soil sample and wash it to remove dust.
2. Sieve it with 0.075 mm sieve.
3. Dry the sand and weight it W gm.
4. Do sieve analysis.
FORMAT OF SIEVE ANALYSIS
I.S.
SIEV
E
WT.RETAINE
D
(gm) W1
%
RETAINE
D
W1/W*100
CUMMULATIV
E %AGE
RETAINED
CUMMULATIV
E %AGE
PASSING
16. 16
100
mm
75
mm
50
mm
19
mm
10
mm
4.75
mm
2.36
mm
0.425
mm
0.075
mm
pan
COMPRESSIVE STRENGTHOF CONCRETE CUBES:
This test is conducted to check the compressive strength of concrete cube after 3rd day, 7th
day and 28th day of casting.
PQC(Pavement Quality Concrete)
Drain chamber
VUP casting(35 grade)
Minor bridge
Culverts
Sewer pipe Casting
PROCEDURE:
Cast the cube of 150 mm*150mm*150mm dimension mould by using fresh concrete
which is mixed according to design.
Remove the cube from mould after 24 hours and put it in water tank for curing.
Take out the cubes after 3rd day, 7th day and 28th day of casting.
17. 17
Put the cube immediately in the CTM machine and applied the load, record the load
at failure.
19. 19
7. PLANT AND MACHINERY (P & M)
Plant and Machinery is have a wide importance in construction industry. Various machine are
required to execute the work. These are listed as below:
Batching Plant
Plant maker - SCHWING STETTER.
Plant type - CP 30 MCI 70 N
Power supply - 440 V
Plant capacity - 30 m3 concrete per hour, CP 30.
Used with emergency switch.
Plant set up done by operator
Plant operator qualification - ITI Electrical.
Slurry used to make pipe slippery :
Slurry used: cement: sand: water = 500 kg: 350 kg: 300 kg .
For job exceeding 3crores, batching plant is required.
Various components of batching plant :
Cement silos : capacity - 100 metric tonnes
Eschew bucket : capacity - 0.5 m3
Pan mixture : capacity - 0.5 m3 , 25 second mixing in pan mixture.
Fly-ash - used as filler.
Admixture (Liquid state )
OPC(Ambuja cement)
PPC
Defects in Batching plant is reported to Plant and machinery department.
With PPC no fly-ash used.
OPC ambuja : 1 m3 OPC requires 50 kg fly-ash.
The whole procedure is computer aided and operated
OPC used with fly-ash instead of PPC for cost benefit.
25. 25
8. HIGHWAY DEPARTMENT
Highway departments consist of survey team, Site Engineer, Highway Engineer, DBM Engineer
and Supervisor with labour. Following activities I have seen at my project site:
Survey works
Clearing and Grubbing
Earthwork Excavation
Embankment Construction(1.105 mm)
Subgrade Construction(500 mm)
Granular Sub base Construction(150 mm)
Wet Mix Macadam Construction(250 mm)
Laying of kerb
Application of Prime Coat(at spreading of 15m3/sec )
Application of Tack Coat
Laying of DBM(50 mm)
Laying of BC(25 mm)
CROSS SECTION OF ROAD
26. 26
SURVEY WORK
Before starting of the highway construction, survey team involve in fixing the reduce levels from
the mean sea level at every 50 k.m (which is known as temporary benchmark).
Many activities done by survey team as follows:
Fixing of reduce level
Intermediate site
Offset fixing
Finished Road Level(FRL)
Alignment
I have seen and worked at following instrument at site:
Auto level
Theodolite
Staff
Dumpy level
Total Station
CLEARING AND GRUBBING:
Delhi-Agra Project of six lanning consists of taking one lane from each side means RHS & LHS.
As NH-2 already is a four lane highway. To make it six lane, clearing and grubbing construction
process is required. In clearing and grubbing process it involve clearing of trees from both side and
removal of inorganic floating, to dispose them of the ROW (Right of Way).
At the site as I seen for the service road Clearing and grubbing process involve removal of waste
soil up to depth of 1.5m and in width of 14.5m.
In water logged Areas
Removal of organic or inorganic floating over water.
Dispose them off the ROW.
Clearing of light vegetation along the road.
By Dozer/Excavator/ Hand work-150 mm or above as per the site requirement.
Dispose them off at a place outside the working area.
27. 27
EARTH WORK EXCAVATION:
After clearing and grubbing process, earth work excavation is required to excavate the top loose soil
up to the hard bed level, if a solid bed level not found then there is a soil stabilization is required.
In soil stabilization process we required to mix soil of the site/prepared soil from the plant is mixed
with fly ash or white lime in a specified, 10% of the soil quantity in 1 cubic metre surface area is
required to stabilize soil.
Following equipment’s are required for excavation:
Excavator
Bachoe
Dozer
Dumper
28. 28
For maintaining the side slope of embankment process start from the bottom level following points
are considered:
OGL(Original Ground Level)
NGL(Natural Ground Level)
After preparing NGL, the bed level should be at the same level from the required off set from centre
line of median.
After levelling the bed compaction is required to obtain Maximum Dry Density of original ground
level.
PREPARTION OF FOUNDATION/EMBANKMENT
In the preparation of embankment, we check the situ density and compare with the lab density of
the soil, if lab density found unacceptable the prepare the bed by loosening and recompaction
method.
Prepare the bed parallel to the final profile as far as possible. If the site soil not fulfil the density
requirement, we bring the soil from the borrow area and dump it to the required site and re
compaction is done to obtain required density.
If preparation of embankment involve in cutting/filling. There is a care of preparing side slopes so
that problem of slope failures not occurred in future.
For side slope compaction at site, I have seen the baby roller. Side slope compaction is done with
required barrication as per the safety recommendation.
29. 29
Properties of Material(as per Morth)
Minimum MDD not less than 1.52 gm/cc
Liquid limit<70.
Plasticity index < 45.
Swelling index (ie. Expansive clay) < 50%
Free from organic materials.
COMPACTION:
Materials more than 2/3rd the thickness of layer shall be removed.
Vibratory rollers of 80 to 100 kN static weight shall be used.
The rolling shall started from the lower edge to upper edge.
Number of passes shall be decided in trial patch.
Each pass of the roller shall overlap 1/3rd of the preceding pass.
30. 30
SOIL OF SUBGRADE CONSTRUCTION(500MM)
Soil, or earth, is a substance that both supports life and structure and supplies raw materials for
manufacturing and construction. Every structure constructed by humankind, that doesn’t float on
the oceans or orbit the planet, must ultimately be supported by either soil or rock. The most
common material used in the construction of buildings, bridges, walkways, roadways, parking
facilities, hydraulic and hydroelectric structures (reservoirs, dams, etc.) is soil.
Soil, in the engineering sense, is defined as all “unconsolidated material composed of discrete solid
particles with gases and/or liquids between” (Sowers, 1970). Generally, soil is the “loose”,
unbound material forming the top layer of the lithosphere, the outermost layer of the earth’s crust.
The solid rock layer upon which the soil layer rests is referred to as the “bedrock” and the overlying
soil is often called the “overburden”.
31. 31
Origin of Soils
In order to understand where soil comes from it is important to understand the relationship between
soils and rock. The earth’s crust is composed of these two basic types of material. Beneath this
crust of solid material lies a region of molten rock (lava) which flows like a liquid due to very high
temperatures caused by extreme pressure at this depth. Rock, lava and soil are continually cycling
from one type of material to another.
For example, igneous rock forms when lava cools after volcanic events. Sedimentary rocks form
when layers of different soil types, deposited and accumulated over many millennia (thousands of
years) consolidate into rock under the ever-increasing weight of new soil deposits. Metamorphic
rock forms from either igneous or sedimentary rock when structural, textural, chemical or mineral
changes are brought about by heat, pressure and shear forces.
Rocks on the other hand are continually producing soil through the processes of mechanical and
chemical weathering.
Mechanical weathering processes include temperature changes, frost action, rainfall, running water,
wind, ice, abrasion, seismic activity and gravity. Rock masses are split apart, ground together and
crushed by these forces which ultimately produce coarser soil particles such as gravel and sand and
also silts which are much finer. These types of soil particles are usually three-dimensional (as
opposed to flat or elongated).
Chemical weathering alters the physical and chemical rock characteristics through reactions of rock
minerals with oxygen, water, acids, salts, etc. or through processes such as oxidation, solution,
carbonation, leaching and hydrolysis
34. 34
GRANULAR SUB BASE CONSTRUCTION(150 MM)
Scope
This is a drainage layer provided over the sub grade.
Laying and compacting well-graded material on sub grade.
Material required
Natural sand, Crushed gravel, crushed stone or combination.
Depends on the grading required.
35. 35
Shall be free from organic or other deleterious constituents.
Sub-base Preparation: The sub-base should be well-graded, shaped to the desired cross-section (as
specified by the typical cross-section plans), compacted to the specified density, well-drained, free from
excessive moisture but not completely dry, and swept clean. Apply the prime coat when the base is
almost dry so that it will absorb the prime material.
Sub-base: Maximum top size should not exceed 75 mm (3 inches) (or enter other size). Gradation No.
1 will be used where the design California Bearing Ratio (CBR) is 41 to 50, No. 2 will be used where
the design CBR is 31 to 40, and No. 3 will be used where the design CBR is 30 or less. Gradation band
No. 1 or 2 may be used for lower design CBR values than specified above where no increase in price
results (or enter other ranges and standards).
Acceptable sub-base gradations are in the table below. (Add, remove and edit as needed.)
References Unified Facilities Guide Specifications (UFGS) 02721A
Description These specifications will be used for any sub-base course that
has a design CBR of between 20 and 50 or any select-
material with design CBR less than 20.
Testing American Society of Testing and Materials (ASTM) D1557
“Standard Test Methods for Laboratory Compaction
Characteristics of Soil Using Modified Effort (56,000 ft-
lbf/ft3(2,700 kN-m/m3))” will be used for maximum density
determinations if the anticipated material gradation should
contain less than 30% retained on the 19 mm (3/4 inch) sieve.
American Association of State Highway and Transportation
Officials(AASHTO) T 180, Method D will be used for the
maximum density determinations if the anticipated material
gradation should contain more than 30% retained on the 19
mm (3/4 inch) sieve. Sampling and testing shall be the
responsibility of the Contractor.
Density Density shall be field measured in accordance with ASTM D
1556, “Standard Test Method for Density and Unit Weight of
Soil in Place by Sand-Cone Method.” The base plate, as
shown in the drawing shall be used. Field density tests and
laboratory tests are generally performed at a frequency of one
36. 36
set of tests for every 1000 square meters of completed area.
Other
Testing
One of each of the following tests shall be performed on
samples taken from the placed and compacted sub-base
course. Samples shall be taken for each 1000 square meters of
each layer of material placed in each area.
a. Sieve analysis, including 0.02 mm size material
b. Field density
c. Moisture liquid limit and plasticity index
Aggregate
Quality
Aggregates shall be durable and sound, free from lumps and
balls
of clay, organic matter, objectionable coatings, and other
foreign
material. Material retained on the 4.75 mm No. 4 sieve shall
have a
percentage of wear not to exceed 50 percent after 500
revolutions when tested as specified in ASTM C131,
“Standard Test Method for Resistance to Degradation of
Small-Size Coarse Aggregate by Abrasion and Impact in the
Los Angeles Machine”.
Construction Maximum lift thickness = 150 mm. Maintenance required.
EQUIPMENTS REQUIRED FOR GSB LAYER
Grader
Roller
Tipper
Procedure
Mark point at required offset.
Fix Control pegs at every 10m along the carriage length.
Unload the approved material in mounds.
Material is uniformly spread by grader.
37. 37
Each grader runs and overlaps by at least 1/3rd of blade length.
Loose thickness should not be more than 25 % of the compacted
Water is sprinkled as per OMC determined.
Vibratory roller of 80-100 static weight is used for compaction.
Compaction commences from lower edge to upper edge.
Each pass of the roller overlaps 1/3rd of preceding pass.
Speed of roller shall not exceed 5 km per hour.
Rollling shall continue till density achieved is 98% of MDD.
The level tolerance for GSP is +/- 10 mm.
REQUIREMENTS OF SUB BASE AS PER MORTH
CBR value should be > 30.
Maximum LL:25
Maximum PI : 6
10 % fine value as per BS:812 Minimum 50 KN
Water Absorption of coarse aggregate < 2 %
It should be permeable to serve as drainage layer.
Maximum compacted thickness 200 mm
GSB DUMPING
39. 39
GSB COMPACTION UNDER PROGRESS
WET MIX MECADAM (WMM of 250 mm)
Scope
It consists of 10 mm, 20 mm, 30 mm and sand combination.
Laying and compacting clean , crushed, graded aggregate and granular material.
It laid down over the GSB layer.
Equipments required
Tipper
Sensor Paver
Roller
40. 40
Wet Mix Plant
PROCEDURE
Mark point at required off set
Fix control pegs at every 10 m along carriage length.
Water is to be sprinkled on GSB top before laying.
WMM is laid in two layers.
Thickness of each individual layer shall not be less than 75 mm.
Thickness of each individual layer shall not be more than 200 mm.
WMM material shall be produced in Wet Mix Plant.
Paving of mix is done by Sensor Paver
Loose thickness shall be kept 25 % more than compacted thickness.
41. 41
Compaction is done using Vibratory roller of 80-100 KN static weight.
Compaction commences from lover edge to upper edge.
Each pass of the roller overlaps 1/3rd of preceding pass
Speed of the roller shall not be exceed 5 km/hr.
Rolling till density obtained 98% of MDD.
Level Tolerance for wmm is +/- 10 mm.
KERB CASTING
42. 42
KERB CASTING MACHINE
PRIME COAT APPLICATION
Before laying DBM application of prime coat is required.
Mechanical brooming is required to remove dust and floats from the surface.
Application of single coat of low viscosity liquid bituminous material to a porous granular
surface.
43. 43
Material Used
Bitumen emulsion (slow setting)
TACK COAT APPLICATION
Before laying DBM layer , tack coat is applied before 10- 20 minutes of DBM application.
DENSE BITUMEN MACADAM
Equipments Required
Hot mix plant (Boraka)
Sensor paver
Tipper
Pneumatic Roller/Tandem Roller
Water tanker
44. 44
Material for DBM
Bitumen Viscosity grade (VG40 for high temp area) or (VG30 for low temp area).
Crushed Aggregate of properties
o Abrasion Value < 35 %
o Impact value < 27%
o Flakiness index-max 15%
o Elongation Index-max 20%
o Coating and stripping of Bitumen Aggregate mixture-Minimum coating 95%
o Water absorption z, 2%
o Filler (5%) should be 600 micron- 75 micron
PROCEDURE
Surface is laid in one or two layers.
Prime coat is sprayed to stabilise WMM surface.
Temperature of spraying should be 20-70 Celsius.
Quantity of liquid bituminous material should be 0.6-0.9 kgs/sqm
Rate of spray of primer shall be 0.25-0.30 kg/sqm.
Temperature should be 130-160 degree.
Loose thickness more than 20 % of compacted thickness
Initial rolling by smooth wheeled roller of 80-100 kN static weight.
Intermediate rolling by Pneumatic roller while laying 2nd layer.
48. 48
RIGID PAVEMENT
Procedure:
It is base for pavement quality concrete.
Generally M10 lean concrete paved by mechanically sensor pavor.
Compaction shall be done using vibratory rollers of 80-100 kN static weight.
Curing shall be done by spraying with liquid curing compound or by covering gunny bags.
50. 50
9. STRUCTURE DEPARTMENT
In the era of congested traffic life of metro cities, ministry of road and transport department (Morth)
recommended to construct heavy structure on state highways and national highways to remove the
problem of heavy traffic.
In many metro cities central government plan construction of bypass from outside the metro city
traffic for heavy commercial vehicles. For this construction of heavy structures like
1. Under passes/overpasses
2. Bridge
3. Flyovers
4. Culverts
In structure department engineers should be responsible to any incident at the site work. For this
purpose in the construction of bridge/flyover a continue supervision is required.
Structure team consist of senior engineer, supervisor, fitter, welder, bar binder, electrician,
mechanic and one safety engineer/supervisor should be present at the site.
I learned in this project about drawing reading of structure like culverts, bridge, vehicle
underpass/passenger underpass and bar bending schedule (BBS).
51. 51
BREAKOUT STRUCTURAL CONCRETE
1. This work shall consist of breaking out and disposing of structural concrete. All broken out
concrete and other discarded material shall be disposed of in accordance with the WASTE
DISPOSAL SITE notes found in Section A.
2. Define the breakout limits with 3/4 inch deep saw cuts.
Always salvage longitudinal steel in the wings. If the existing apron is monolithic,
salvage the steel in the bottom slab also.
3. Salvage two feet of the longitudinal rest eel in the wings and bottom slab and use in new
construction. Care shall be taken not to damage the existing longitudinal reinforcing steel during
the breakout operations. These reinforcing bars and all concrete surfaces in the breakout area on
which new concrete is to be cast shall be thoroughly cleaned by sandblasting to the satisfaction
of the Engineer prior to placement of the new concrete.
4. Any additional breakout required due to spelling or cracking of the existing structure will be
determined by the Engineer. Where additional breakout in the barrel section of the existing
structure is required, care shall be taken not to damage any of the existing reinforcing steel. All
steel will be left in place and thoroughly cleaned by sandblasting.
5. Additional breakout in existing walls or top slab will require shoring up of the parapet and top
slab, as directed by the Engineer.
6. Plans quantity payment will be full compensation for this item regardless of the quantity actually
broken out, unless measurement is ordered by the Engineer. If the Engineer orders breakout
beyond the limits shown, this additional breakout will be paid for at the contract unit price per
cubic yard for Breakout Structural Concrete. If additional breakout is caused by the Contractor’s
operations, no additional payment will be made.
52. 52
7. Breakout Structural Concrete will be paid for at the contract unit price per cubic yard. This
payment shall be full compensation for furnishing all materials, labor, tools and equipment
necessary or incidental to breaking out the structural concrete. Payment includes, but is not
limited to, excavation required to perform the required breakout, saw cutting, breaking out
concrete, cleaning and sandblasting reinforcing steel and concrete surfaces, and removing and
disposing of all waste materials to satisfactorily complete the work.
INSTALLING DOWELS IN CONCRETE
1. The epoxy resin mixture shall be of a type for bonding steel to hardened concrete and shall
conform to AASHTO M235 Type IV, Grade 3 (Equivalent to ASTM C881 Type IV, Grade 3).
2. The diameter of the drilled holes shall not be less than 1/8 inch greater, nor more than 3/8 inch
greater than the diameter of the dowels or as per the Manufacturer’s recommendations. Holes shall
not be drilled using core bits. The drilled holes shall be blown out with compressed air using a
device that will reach the back of the hole to ensure that all debris or loose material has been
removed prior to epoxy injection.
3. Mix epoxy resin as recommended by the Manufacturer and apply by an injection method as
approved by the Engineer. Beginning at the back of the drilled holes, fill the holes 1/3 to 1/2 full
of epoxy, or as recommended by the Manufacturer, prior to insertion of the steel bar. Care shall
be taken to prevent epoxy from running out of the horizontal holes prior to steel bar insertion.
Rotate the steel bar during installation to eliminate voids and ensure complete bonding of the
bar. Insertion of the bars by the dipping or painting methods will not be allowed.
4. No loads shall be applied to the epoxy grouted dowel bars until the epoxy resin has had
sufficient time to cure as specified by the epoxy resin manufacturer.
5. Embed dowels 8” into existing concrete.
6. Dowel bars shall be #6 deformed bars conforming to ASTM A615 Grade 60.
53. 53
7. The cost of drilling holes, epoxy resin, dowels, installation and other incidental items shall be
included in the contract unit price per each for Install Dowel in Concrete.
MINOR BRIDGE CONSTRUCTION AT BANCHARI
WIDENING OF THE EXISTING MINOR BRIDGE
10 mm minimum bar diameter used
Maximum of 32 mm and 25 mm diameter bars used
Cover at earth face is of 75 mm and for footing cover 75 mm
Spacing as per the design recommendation
68. 68
10. CONCLUSION
This training was very helpful to me as I got a chance to implement my theoretical knowledge of
planning and management into practical use which I learnt during my academics. I am glad that
I was a part of L&T ECC, over here I got a chance to study different aspects of planning, site
activity and quality and how execution is done on site.
It was a wonderful learning experience at L&T Construction Transportation IC’s site of L&T
project in Palwal. I gained a lot of thing regarding almost every aspect of site. I was given
exposure in almost all the departments at the site. The friendly welcome from all the employees
is appreciating, sharing their experience and giving their knowledge which they have gained in
long journey of work. I hope this experience will surely help me in my future and also in
shaping my career.
