Construction of flyover including rotary and approach

1. CONSTRUCTION OF FLYOVER IN PATNA
Project report submitted in fulfilment of requirement
Bachelor of Technology
Submitted by
Akhilesh Rajput (1403016)
Narayan Gupta (1403037)
Mahendra Kumar (1403089)
Under the guidance of
Er. Rakesh Kumar & Er. Kamal Kant
(Project engineer BRPNNL Patna)
Training undertaken at
Bihar Rajya Pul Nirman Nigam Limited Patna
DEPARTMENT OF CIVIL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY PATNA
MAY 2018

2. PROJECT EVALUATION SHEET
THE
PROJECT ENTITLED
CONSTRUCTION OF FLYOVER IN PATNA
Submitted by
AKHILESH RAJPUT (1403016)
NARAYAN GUPTA (1403037)
MAHENDRA KUMAR (1403089)
EXAMINED AND FOUND ………………………………….... FOR THE AWARD OF
THE DEGREE OF BACHELOR OF TECHNOLOGY IN CIVIL ENGINEERING.
INTERNAL EXAMINER EXTERNAL EXAMINER HEAD OF DEPARTMENT
DEPARTMENT OF CIVIL ENGINEERING,
NATIONAL INSTITUTE OF TECHNOLOGY PATNA
MAY 2018

3. i
ACKNOWLEDGEMENT
A vocational training is a golden opportunity for learning and enhancing the practical
knowledge of any profession. We consider our self very lucky to have so many
wonderful people through this project. First of all we would like to thank the family and
friends who encourage and support us to be more skilled in our academic. We are very
thankful to BIHAR RAJYA PUL NIRMAN NIGAM LIMITED (BRPNNL) for giving
us the opportunity of vocational training in their working area. It was a very good
learning experience for us to work at this area. I would like to convey my heartiest
thanks to project engineer Er. Rakesh Kumar, Er. Kamal Kant and all the Faculty
members of Department of Civil Engineering at National Institute of Technology Patna,
who made it all possible. I would also thank Er. Sanjay Gupta, Er. Ujjwal Raj, Er. Ajeet
Kumar and Rajesh Kumar for their endless support at site and in his office by consulting
me how to do things at site, all teachers of Civil Engineering who brought us to our
present performance and shape us like this during the last four successive years, special
thanks to our prof. Sanjay Kumar for guiding us to do training at BRPNNL. Before I
finish I would like to give my deepest thanks to all workers from the contractor Rachna
Construction Co. starting from Engineers to daily labors .Also for those who do not
listed in the above but support me in different areas I would like thank all. Support and
guidance is an important point in our success of training. We have highly benefited by
this training and have gained a lot of knowledge about the various process and technique
used in construction of flyover.

4. ii
ABSTRACT
The training report in broad spectrum contains thirteen chapters in which we
tried to explain our four months learning experience in the running project, construction
of flyover in R-block and Krabigahiya. The content of all section is broadly explained
and it is made from the practical basis of the site work of weekly basis.
In first chapter, we wrote the detail of project and introduction of client and
contractor. In the second chapter, we wrote about the basic term of grade separator abd
different part of flyover. In the third chapter, we wrote the different steps involves in
construction of flyover and surveying done in project.
Forth chapter of this report has detailed procedure involved in construction of
foundation. Like piling, chipping, pouring, testing, reinforcement and curing. Fifth
chapter is similar to forth chapter but it have the procedure about construction of
substructure.
Sixth chapter has the detail of material used in this construction like concrete
and steel. Chapter seven has detail about the various tests performed on site or lab to
confirm the quality of construction. In the chapter eight, there is the safety measurement
taken at site for worker and other people affected by this construction.
Chapter nine of this report have idea of reinforcement yard and chapter ten have
some view of batching plant and lab. Chapter eleven have some photographs of
machines and tools used during construction of flyover.
In the chapter twelve we wrote the conclusion of our four month training and
what we learned during this period. Chapter thirteen contains the references what is
used for making this report.
After reading all the chapters, one can easily understand basics of flyover
construction procedure, dimension and minimization of the cost of the project.

5. iii
CONTENTS
 Acknowledgement i
 Abstract ii
 Contents iii
 List of pictures v
1. INTRODUCTION 1-3
General 1
Detail of project 2
About the client 2
About the contractor 3
2. LITERATURE REVIEW 4-6
Bridge 4
Approach 4
Flyover 4
Foundation 5
Substructure 5
Superstructure 5
Service road 6
3. PLANNING AND EXECUTION 7-11
Sequence of construction 7
Surveying 7
Drawing and BBS 9
4. CONSTRUCTION OF FOUNDATION 12-19
Pile 12
Bentonite 12
Reinforcement of pile 13
Concrete for pile 15
Pile cap 15
Reinforcement of pile cap 16
Formwork 18
Concrete and curing of pile cap 18
5. CONSTRUCTION OF SUBSTRUCTURE 20-22

6. iv
Pier shaft 20
Reinforcement of pier 20
Concrete for pier 21
Curing 22
6. MATERIAL AND QUALITY CONTROL 23
Material 23
Lap length 23
Quality control 23
7. TEST 24-26
Workability 24
Compressive strength 24
Pile load test 25
Pile integrity test 25
8. SAFETY 27
9. REINFORCEMENT YARD 28-29
10. BATCHING PLANT AND LAB 30-31
11. MACHINE AND TOOLS 32-36
12. CONCLUSION 37
13. REFERENCE 38

7. v
List of pictures
1. Map view of R-Block Site
2. Map view of Karbigahiya site
3. Parts of flyover
4. Circular mark on ground with nail
5. Auto level to mark the RL
6. Total Station to mark coordinate
7. Drawing and detailing of a pile cap
8. BBS of a pier shaft
9. Auger and liner
10. Excavation of soil
11. Tank for mixing of bentonite and
water
12. Bentonite
13. Reinforcement cage for pile
14. Cage into borehole
15. Insertion of cage into borehole
16. Manner of pouring of concrete
17. Excavation of soil for pile cap
18. Chipping of unsound concrete
19. Scaffolding to assemble the
reinforcement
20. Reinforcement of Pile Cap.
21. Formwork into the side of pile cap
22. Pouring and compaction of
concrete
23. Curing of pile cap
24. Reinforcement for first lift of pier
25. Pouring of concrete through pump
26. Curing of pier
27. Slump cone test
28. cube for testing
29. Arrangement in pile load test
30. Pile integrity test
31. Pattern of wave and graph in PIT
32. Man working with helmet & belt
33. Instruction board
34. Barricading
35. Steel bar at yard
36. Bar cutter
37. Bar bending machine
38. Threading machine
39. Threaded bar
40. Fabrication unit
41. Storage of aggregate
42. Storage of cement
43. Tank of superplasticizer
44. Mixing point of plant
45. Batching plant
46. Testing machine in lab
47. Trailer concrete pump
48. Backhoe loader
49. Crawler crane
50. Hydraulic crane
51. Hydraulic rig machine
52. Water tanker
53. Transit mixer
54. Tremie pipe
55. Liner
56. Bucket auger
57. Needle vibrator
58. Funnel
59. Concrete breaker

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Chapter 1
INTRODUCTION
1.1 General
As the traffic on the road is increasing day by day and we don’t have any space left in
two dimensions, then the only option is to go in the third dimension and that is done
through flyover. For the ease of movement of vehicle, two or more than two such point
is selected which have high traffic and is connected via flyover to provide separate way
of connectivity. This report is prepared on the construction of flyover of two separate
site, one is R- block and other is Karbigahiya. Both the site is connected by already
constructed Mithpur over bridge. These two bridges will connect R-Block to
Karbigahiya via Mithpur over bridge.
Pic. 1 Map view of R-Block Site
Note- Blue lines on Pic.1 and Pic.2 are indicating the route of flyover.

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Pic. 2 Map view of Karbigahiya site
1.2 Detail of project
Name-
I. Construction of flyover Connecting Mithapur flyover to Bhikhari Thakur
flyover via R-Block junction with elevated rotary
II. Construction of flyover Connecting Mithapur flyover to Chiraiyatand flyover
via karbigahiya
Client-
Bihar Rajya Pul Nirman Nigam Ltd. Patna
Contractor-
Rachna Construction Co. Bharuch, Gujrat
1.3 About the client
Client of this project is Bihar Rajya Pul Nirman Nigam Ltd. (BRPNNL). BRPNNL was
formed on 11th June, 1975 under Indian Company Act, 1956 as a Govt. Company.
It’s main objective are-
o Construction of Bridges/Roads
o Maintenance of Bridges
o Toll Collection

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The Nigam is registered as a Public Company under Indian Company Act, 1956 and it
is a Govt. Company as total share capital of Rs.500 Lakhs is pledged in the name of
Governor of Bihar. The Nigam is governed by Managing Director on behalf of Board
of Directors nominated by the Govt. under guidelines set by Memorandum of
Association and Articles of Association along with work rules mentioned therein.
Concept of Working Bridges are constructed departmentally by the Nigam on the basis
of current Schedule of Rates (SoR) sanctioned for Works Department. As the work is
done departmentally, cost incurred is less as compared to work done by contractors.
1.4 About the contractor
Contractor of this project is Rachna Construction Co. Bharuch, Gujrat.
Company collaboratively facilitate engineer, and disseminate construction services
fostering the world’s ethical, social, economic, and intellectual growth, using
progressive and diverse techniques on the cutting edge of the construction industry.
Every aspect of how work has been built to fulfil mission to make lasting contributions
to people, communities, and the construction industry. From company’s commitment
for its valuable employee’s teamwork to a continued commitment to hard work and
performing with excellence.

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Chapter 2
LITERATURE REVIEW
A student must have some basic knowledge about the topic which is chosen for
vocational training. Some terms related to construction of flyover is there. This
literature is taken mostly from Indian Standard Code.
2.1 Bridge
Bridge is a structure for carrying the road traffic or other moving loads over a
depression or obstruction such as channel, river, road or railway.
2.2 Foot Over Bridge
The foot over bridge is a bridge exclusively used for carrying pedestrians, cycles and
animals.
2.3 Grade Separator
Grade separator is a form of intersection in which one or more conflicting movements
on intersecting ground transport facility such as road, rail, pedestrian way or cycle path
are segregated in space. Flyover, Railway over bridges, under bridges, subways and
under passes both for vehicular and pedestrian traffic are all grade separators and will
be reckoned as such.
2.4 Clearance
Clearance is the minimum vertical or horizontal distance between boundaries at a
specified position of a bridge structure/grade separator available for passage of
vehicles.
2.5 Length of Bridge
The length of a bridge structure will be taken as the overall length measured along the
center line of the bridge from end to end of the bridge from face to face of dirt wall.
2.6 Approach
A part of road which connects the existing road to the abutment of the bridge on each
side.
2.7 Road Over Bridge – ROB
A bridge over the rail line for the purpose of crossing it without interruptions with
approaches on both sides is commonly called as Road Over Bridge - ROB.

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2.8 Flyover
A bridge over another road for allowing cross traffic without interruption with its
approaches on both sides is commonly called as Flyover.
Pic. 3 Parts of flyover
2.8.1 Foundation Part-
2.8.1.1 Pile-
The function of pile is to transfer the load to the soil. Three types of pile are there: - 1.
End bearing pile 2. Friction pile 3. End bearing and friction pile In this project we used
End bearing Pile, some parts of the load transferred by the pile by end of pile and
remaining load is by the friction between pile and the surface of soil around the pile.
2.8.1.2 Pile cap-
Piles usually exists as a group which are all integrated by means of a pile cap.
2.8.2 Substructure Part-
2.8.2.1 Pier-
It is a raised structure typically supported by well-spaced piles or the pile cap. It can be
made by wooden concrete, steel, mixed, but in this project we use concrete pier with
well-maintained iron rod.
2.8.2.2 Pier cap-
The upper or bearing part of the pier, usually made of concrete or hard stone; designed
to distribute concentrated loads evenly over the area of pier. The width of pier cap
depends upon the width of carriageway, its size depends upon the live load and dead
load bridge capacity.

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2.8.3 Superstructure Part-
2.8.3.1 Wearing surface-
consists of the deck structure itself, which support the direct loads due to traffic and all
the other permanent and variable leads to which the structure is subjected. Also known
as carriageway. Width of carriageway depends upon number of lane of flyover. For
intermediate carriage -5.5 m and for two lane-7.5 m
2.8.3.2 Bearing-
Bridge bearings are used to transfer forces from the superstructure to substructure,
allowing the following types of movements of the superstructure Translational
movements; are displacements in vertical and horizontal directions due to in-place or
out-of- place forces like wind and self-weight. Rotational movements; cause due to
moments. Until the middle of this century, the bearings used considered of following
types: - pin, roller, rocker, metal sliding etc.
2.8.3.3 Girder-
It is support of carriageway between two piers, it is of many types like box shape, Z
shape, I-shape and many other forms.
2.8.3.4 Crash barrier-
A strong fence at the side of carriageway, intended to reduce the risk of serious
accidents.
2.9 Safety Kerb
A safety kerb is a roadway kerb widened to provide for occasional pedestrian refuge.
2.10 Super-elevation (Cant or Banking)
Super-elevation is the transverse inclination given to the cross-section of a carriageway
at a horizontal curve in order to reduce the effects of centrifugal force on a moving
vehicle.
2.11 Interchange
An interchange is a grade separated intersection with connecting roadways (ramps and
loops) for turning traffic between highway approaches.
2.12 Service Road (SR)
A Service Road is an auxiliary road that runs parallel to a controlled access highway
that provides access for the adjoining property at a few selected places.

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Chapter 3
PLANNING AND EXECUTION OF PROJECT
The requirement of a grade separator, its shape, size, type and configuration at any
location is decided by collecting sufficient relevant data and information and analyzing
it with respect to volume, intensity and type of traffic, loadings, climatic conditions and
geotechnical investigations, space restraints and limitations because of underground
and overhead utilities services and available geometries, traffic regulation during
construction etc.
All this data as discussed subsequently, should be collected and then studies and
investigations should be properly and adequately done for deciding the various
parameters for planning, layout, design and construction and maintenance etc.
3.1 Sequence of construction
 Surveying
 Analysis and design of the structure
 Piling and Pile cap Construction
 Construction of Pier shaft and Pier cap
 Construction of Pedestal and seismic stopper
 Launching and gluing of segments
 Construction of road over bridge
In the duration of this training we got knowledge about the foundation and substructure
of flyover. Work of superstructure is not started. As listed above first step is surveying
for construction of flyover, here is some key point of surveying.
3.2 Surveying (Topographical Survey)
Digital terrain modeling (DTM), also known as digital elevation modeling, is the
practice of creating a digital representation of ground topography and terrain. Although
maps depicting topographical information have been produced for hundreds of years,
it is only recently that such elevation data has been collected in such a precise digital
form as to allow the creation of digital models of the topography of the land.
Topography is used to determine the position of any point in both the horizontal and
vertical coordinates. Various maps are studied and then detailed is done by Total station
(TS) and layouts are given on AutoCAD. By using AutoCAD we can find the

15. 8 | P a g e
coordinates (north, east) and reduce
level of any point. Coordinates of any
point is marked with the help of Total
station. Reduce level (RL) is marked by
using Auto level.
Pic. 4 Circular mark on ground with
nail to represent a particular
coordinate and RL
As shown in Pic.4, such marking is done
in many locations within the area of site.
Such Points are essential to check the
accuracy of construction and to check
the deviation to minimize it. These
marking is also done to indicate the
center of pile to start the construction of
foundation.
Pic. 5 Auto level to mark the RL
In Pic.5 and Pic.6, two instrument Auto Level and Total Station are shown. Auto level
is used to determine the Reduce Level (RL) of different location with respect to known
RL.

16. 9 | P a g e
Pic. 6 Total Station to mark coordinate
Surveying is an essential part of any construction. For any mega project like this flyover
it is necessary to have minimum possible deviation from actual design. Now a days
surveying is done using Auto Level and Total Station for faster and accurate
measurement. After surveying, construction is started with proper safety and adequate
quality of material.
3.3 Drawing and BBS
Detailed drawing of this project is prepared by TCPL-ITL JV, TANDCN
CONSULTANTS PVT LTD and IIT ROORKEE. All the drawing is approved by
engineers and consultants and sent to BRPNNL Patna. Then drawing is analyzed by
site engineer and Bar Bending Schedule (BBS) is made. Calculation of volume is done
for the calculation of amount of concrete which will be required for casting. BBS is
made for required type and amount of different steel.

17. 10 | P a g e
Pic. 7 Drawing and detailing of a pile cap

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Pic. 8 BBS of a pier shaft
BBS is made after analyzing the drawing and BBS is forwarded to the yard to prepare
the reinforcement. BBS is important from the supervision point of view. A supervisor
of reinforcement yard needs a simple format so that he can prepare the required
reinforcement for a particular part of the structure.

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Chapter 4
CONSTRUCTION OF FOUNDATION
Foundations are the structures which are constructed below existing ground level. It
sustains the loads coming from the sub structures and superstructures. Bridges had to
carry a big load so PILE FOUNDATION are preferred. There are two part of foundation
pile and pile cap as shown in Pic.3. Out of various type of pile, Bored cast in-situ
concrete pile is constructed in this site. BIS code for this type of pile is IS 2911, Part 1,
Section 2:2010.
4.1 Pile
Soil is excavated using auger at located point. To make
pile vertical and for ease of excavation, a liner of length
2 to 3m is inserted. Liner also prevent the loose soil of
bore from collapsing. Hydraulic rig machine is a
multitasking machine in construction of piling.
Pic. 10 Excavation of soil
4.2 Bentonite
The action of bentonite or drilling mud in stabilizing the sides of bore holes is primarily
due to thixotropic property of bentonite. The thixotropic property of bentonite
suspension permits the material to have the consistency of a fluid when introduced into
a trench or hole. When left undisturbed it forms a jelly like membrane on the borehole
wall and when agitated it becomes a fluid again.
Pic. 9 Auger and liner

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Pic. 12 Bentonite
The bentonite suspension shall be made by mixing it with fresh water using a pump for
circulation. The density of the freshly prepared bentonite suspension shall be between
1.03 and 1.10 g/ml depending upon the pile dimensions and the type of soil in which
the pile is to be bored. The density of bentonite after contamination with deleterious
material in the bore hole may rise up to 1.25 g/ml. This should be brought down to at
least 1.12 g/ml by flushing before concreting. Density is checked by hydrometer at site.
The pH value of the bentonite suspension shall be between 9 and 11.5.
4.3 Reinforcement of pile
The design of the reinforcing cage varies
depending upon the installation
conditions, the nature of the subsoil and
the nature of load to be transmitted by the
shaft-axial, or otherwise.
The minimum area of longitudinal
reinforcement of any type or grade within
the pile shaft shall be 0.4 percent of the
cross-sectional area of the pile shaft. The
minimum reinforcement shall be provided
throughout the length of the shaft. Cage
for pile is formed. Detailing is taken from
drawing and bar bending schedule of pile.
Pic. 11 Tank for mixing of bentonite and water
Pic. 13 Reinforcement cage for pile

21. 14 | P a g e
Cage is shifted into borehole using rig machine.
Generally the reinforcement cage is made into
three part due to greater length and variation of
diameter of rebar along length. Different part of
cage is welded at the time of shifting. Clear
cover is provided using cover block for the
safety of reinforcement from corrosion. Proper
spacing of rebar is checked by measuring tape.
Pic. 15 insertion of cage into borehole
Pic. 14 cage into borehole

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4.4 Concrete for pile
There are several
essential parameter to
be checked at the time
of pouring of
concrete.in this
project, grade of
concrete is M35 in
pile. This concrete is
self-compacting
concrete (SCC). The
slump should be 150
to 180 mm at the time
of pouring. Slump of
concrete is checked
with slump cone after
manufacture of
concrete at batching
plant and before the casting of pile at site. Tremie pipe is inserted into borehole and
flushing is done using bentonite slurry. Concreting is done up to minimum 600mm
above the cutoff level and pouring of concrete is done using transit mixture through
hopper. Tremie pipe is used to prevent the concrete from segregation. Batching plant
of company is located at Saguna More Patna. Concrete is transported to site through
transit mixture (TM) approximately in 30 minutes. Workability, time of batching of
concrete, time of reaching of TM, time of casting and some other information is
recorded at pouring card for future reference. Sample of concrete is collected to check
compressive strength after 28 days.
4.5 Pile Cap
Piles usually exists as a group which are all integrated by means of a pile cap. Soil is
excavated by soil excavator machine in the proposed area of pile cap. Now there is
some unsound concrete on the top of every pile which is chipped by hand hammer or
Pic. 16 manner of pouring of concrete

23. 16 | P a g e
small hand cutter and vibrator. Chipping is done up to cutoff level so that bottom level
of pile cap is achieved.
Pic. 17 Excavation of soil for pile cap
After chipping of unsound concrete, ground is leveled and PCC of depth 100 mm is
done for further work. Grade of PCC is M15.
Pic. 18 Chipping of unsound concrete
4.5 Reinforcement of Pile cap
Reinforcement of pile cap is a complex task and is done very carefully. It requires high
skilled worker. Scaffolding is prepared above the PCC with proper space to arrange the
bar.

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Pic. 19 Scaffolding to assemble the reinforcement
Reinforcement of Pile cap is assembled as per given in drawing and Bar Bending
Schedule (BBS) of pile cap. Reinforcement of pile cap has different diameter of bar
from 12mm to 32mm. There are four type of bar in pile cap 1) bottom bar (main bar),
2) top bar, 3) side bar, 4) stirrups. Vertical bar of substructure is also assembled into
pile cap. Proper spacing between bars and tying of every bar is also checked carefully.
Pic. 20 Reinforcement of Pile Cap.

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Lapping of bars, length of L of top and bottom bar and length of hook of stirrups bar
are also checked thoroughly. Tying of bottom bar with stirrups is very difficult task
which is done by skilled workers. Finally verification of reinforcement is done by
matching the drawing and provided reinforcement at site.
4.6 Formwork
Formwork is an important part of any construction which require proper supervision.
A good formwork leads to smooth surface of concrete, proper clear cover in concrete
and prevent the bleeding of concrete. Cleaning and lubrication of formwork is done and
assembling of formwork with clear cover of 75mm.
Pic. 21 Formwork into the side of pile cap
4.7 Concrete and curing of pile cap
Pile cap is relatively a big part of flyover because it requires high amount of steel and
concrete. Pouring of concrete and compaction of concrete using immersion vibrator is
done in supervision of chief engineer. Workability is checked by slump test before
pouring and sample is collected for compressive strength. Needle vibrator of adequate
diameter is used to compact the concrete. Surface of pile cap is levelled manually to
make it smooth. Formwork is removed after 2 days of casting and then curing is done
for minimum 14 days with proper arrangement. After 28 days three coat of coal tar
epoxy is applied on the surface of pile cap to make the pile cap impermeable. Coal tar
epoxy is applied if grade of concrete is M35. To avoid the use of coal tar epoxy, grade
of concrete is increased up to M40 to make the pile cap impermeable. Share key is
formed at the construction joint to provide proper bonding between pile cap and pier
shaft.

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Pic. 22 pouring and compaction of concrete
Curing is essential to overcome the heat of hydration. Heat released during the
hardening of concrete leads to development of cracks. Curing is done continuously for
at least 14 days.
Pic. 23 Curing of pile cap

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Chapter 5
CONSTRUCTION OF SUBSTRUCTURE
Substructure is that part of the structure, i.e. pier shaft pier cap and abutments, which
supports the superstructure and which transfers the structural load to the foundations.
4.1 Pier Shaft
It is a raised structure typically supported by well-spaced pile cap. It can be made by
wooden concrete, steel, mixed, but in this project we use concrete pier with well-
maintained reinforcement. Different pier shaft has different height from each other. Pier
shaft is constructed in two parts, 1) lower lift and 2) upper lift. Maximum height of pier
is 9 meter so first lift is constructed for 4.5m and rest of the part is constructed in second
lift.
4.2 Reinforcement of Pier
After checking the location of pier through total station, reinforcement of first lift is
assembled with proper spacing.
Pic. 24 reinforcement for first lift of pier

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Vertical bar, ring bar and link bar is matched with drawing and BBS. For any column,
it is essential to check the hook of ring and link bar. Same processes is repeated for
second lift after the construction of first lift.
After completing the reinforcement, cleaned and lubricated formwork is applied for
pouring of concrete. Clear cover is maintain by inserting the cover block of 75 mm.
True vertical is checked by plum bob. And required correction is done with rope and
jack.
4.3 concrete for pier
Concrete is poured from top of the column through pump and transit mixture. Grade of
concrete is M50 and workability is between 140 and 180mm. workability is checked
by slump cone and sample is collected for compressive strength before pouring.
Concrete is vibrated with immersion vibrator. A vertical pipe is used for pouring the
concrete which prevent the concrete from segregation. Provision of using this pipe is
as per IS456 states maximum free fall of concrete should be 1.5m.
Pic. 25 Pouring of concrete through pump
Process of reinforcement, formwork and pouring are repeated for second lift.

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4.4 Curing
Pic. 26 Curing of pier
Curing of pier is done for 28 days after removal of formwork. Jut bag is applied on pier
and water is sprinkled for curing.

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Chapter 6
MATERIAL AND QUALITY CONTROL
Here is the list of material used and some test of site to check the quality of material.
6.1 Material
Concrete material
 Pile M 35
 PCC M 15
 Pile cape M 40
 Pier shaft M 50
Clear cover to the reinforcement shall be
 Pile cape - 75mm
 Pile - 75mm
 Pier - 50/75mm
Steel
 TMT bar (Fe 500D)
6.2 Lap length
 Pile = 54d
 Pile cape = 51d( for bottom and side face reinforcement)
=78d (for top face reinforcement)
 Pier = 44d
d- Diameter of smaller bar being lapped
6.3 Quality Control
Quality of Concrete
 workability and strength
 compaction of concrete using immersion vibrator (IS 3558:1983)
 curing
Steel
Reinforcement as per drawing and BBS, diameter and length of bar, spacing of bar, lap
length, binding of bar, development length, coupler, clear cover.
Other material
 Lubricant, bentonite, coal tar epoxy, paint etc. Expire date of chemicals is checked.

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Chapter 7
TEST
7.1 Workability
Workability is a property of freshly
mixed concrete. Workability of concrete
simply means the ability to work with
concrete. The ease of placing,
compacting, and finishing of concrete in
the desired manner is called its
workability. Workability of concrete is
checked by slump cone. Slump cone of
bottom diameter 20cm, top diameter
10cm and height 30cm at three layers of
concrete .Each layer tamped for 25 times
by a standard tamping rod of 16mm
diameter and 60 cm length. The
subsidence of concrete under gravity in
“mm” is SLUMP. Workability of
concrete is checked before pouring of
concrete for every TM and recoded on
pouring card.
7.2 Compressive strength
Compressive Strength of concrete is
defined as the Characteristic strength of
150mm size concrete cubes tested at 28
days. Sample is collected before casting
and sent to lab for testing. Sample is kept
in same environment and same curing at
site for 28 days then they are checked at
lab. Compressive strength is important
to know the actual strength of structure.
We also perform some non-destructive
Pic. 27 Slump cone test
Pic. 28 cube for testing

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test on site to know the compressive strength but this cube test is essential from other
point of view of concrete properties.
7.3 Pile load test
Routine test is done as per IS 2911 (part 4):1985. It is carried out on a working pile
with a view to check whether pile is capable of taking the working load assigned to it.
The number of tests may generally be one-half percent of the total number of piles
required. In this test compression load is applied to the pile top by means of a hydraulic
jack against rolled steel joist and suitable load frame capable of providing reaction and
the settlement is recorded by dial gauges. Maximum allowable settlement is 12 mm.
Pic. 29 Arrangement and measurement of settlement in pile load test
7.4 Pile integrity test
Sometimes there is possibility of defect in pile. Since pile has high depth and it can not
be checked manually. Nondestructive pile integrity test (PIT) using low strain integrity
test is done as per IS 14893:2001. This test is performed for confirming the integrity of
pile upto full depth. This test provide the information about the integrity of pile and if
there is any defect in pile, result of this graph clearly indicates in graph. This is a system
of assessing the integrity of piles by the use of low stress wave imparted to the pile
shaft and is also known as Sonic Integrity or Sonic Echo Test.

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Impulses or vibrations are
applied to the pile and
measurements made of
timings and attenuation of
reflected signals. Non-
Destructive Testing of
piles does not provide the
load carrying capacity of
piles.
Pic. 30 Pile integrity test
Pic. 31 Pattern of wave and graph in different case of pile

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Chapter 8
SAFETY
“Safety first” Every construction work is done with this line keeping in mind. Safety of
people should be the first priority of any construction work.
 Helmet, jacket and shoes for all employs and worker
 Barricading, Instruction board, light, reflector, safety cone, flag
 safety belt is used if any worker is at height more than 2m from ground
Pic. 34 Barricading and instruction board
Pic. 32 man working with helmet and belt Pic. 33 instruction board

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Chapter 9
REINFORCEMENT YARD
Reinforcement of concrete is done using steel bar. Some space at site is provided to
reinforcement yard for storage, cutting, bending and threading of steel bar. Space is
selected for convenience in transportation and safety of material.
Pic. 35 steel bar at yard
Pic. 37 Bar bending machinePic. 36 Bar cutter

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Pic. 39 Threaded bar
There is also a fabrication unit in which all the formwork and truss for support is
fabricated. In this unit, cutting machine, drilling machine and other sophisticated
machine related to steel work is present.
Pic. 40 Fabrication unit
Pic. 38 Threading machine

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Chapter 10
BATCHING PLANT AND LAB
Concrete is prepared at batching plant. This batching plant has computerized system to
prepare the concrete of required grade.
Pic. 42 storage of cement
Pic. 44 mixing point of plant
For the testing of material, testing machine is there. Various tests on fine aggregate,
coarse aggregate, cement and superplasticizer are conducted to ensure the quality of
material. Compressive strength is also checked at lab after 28 days of cast cube of site.
Pic. 41 storage of aggregate
Pic. 43 Tank of superplasticizer

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Pic. 45 Batching plant
Pic. 46 Testing machine in the laboratory of company

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Chapter 11
MACHINE AND TOOLS
Every construction is done with various machines and tools. Some of them are listed
here with picture.
Pic. 47 Trailer Concrete Pump
Pic. 48 Backhoe loader

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Pic. 49 Crawler crane
Pic. 50 Hydraulic Crane

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Pic. 51 Hydraulic rig machine
Pic. 52 Water tanker

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Pic. 54 Tremie pipe
Pic. 55 Liner
Pic. 57 Needle vibrator
Pic. 53 Transit mixer
Pic. 56Bucket Auger

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Pic. 59 Concrete breaker
Pic. 58 Funnel

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Chapter 12
CONCLUSION
Practice makes a person perfect and this quote is absolutely correct for professional life.
After completing this four month training as a major project of last semester, we have
leant a lot in field of construction. Construction of flyover plays an important role in
urban development. Flyover makes transportation very easy. It becomes very difficult
task when there is a project inside the city. R-block and Karbigahiya are the busiest
route of Patna. In construction of flyover, construction of foundation requires large area
that interrupt the already running traffic. We have learnt mainly the construction of
foundation and substructure of flyover. After the completion of this training, we are
able to handle the situation of site for construction of flyover. Some point what we
learned in the site,
 To analyze the drawing of project and to prepare the BBS from drawing.
 Calculation of required concrete, steel and other material
 Surveying for accuracy of position of different part
 Various site test to ensure the quality of construction
 Safety check for efficient work
 Management of running traffic with the help of local police
 Handling of existing structure like sewer, underground cables and statue.
 Maintenance of data for completed structure

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Chapter 13
REFERENCES
 IS 456:2000, Code of practice for plain and reinforced concrete, Bureau of Indian
Standards, New Delhi.
 IS 2911 (Part 1/Sec 2):2010, Design and construction of pile foundations-code of
practice (bored cast in-situ concrete piles), Bureau of Indian Standards, New Delhi.
 IS 2911 (part 4):1985, Codes of practice for design and construction of pile
foundations – load test on piles, Bureau of Indian Standards, New Delhi.
 IS 14893:2001, Non-destructive integrity testing of piles (NDT) – Guidelines,
Bureau of Indian Standards, New Delhi.
 IS 3558:1983, Code of practice for use of immersion vibrators for consolidating
concrete, Bureau of Indian Standards, New Delhi.
 IRC SP 90:2010, Manual for grade separators & elevated structures, Indian Roads
Congress, New Delhi.
 Google map, www.gmap.com
~ THE END ~