Pankaj report

A
Practical Training & Industrial Visit Seminar Report
On
WESTERN DEDICATED FREIGHT CORRIDOR
(WDFC) PROJECT
[ REWARI TO IQBALGARH ]
By
PANKAJ SHAH
University Roll No.:15EJECE041
University Enrollment No.:15E1JECEM35P041
Session 2018-19
DEPARTMENT OF CIVIL ENGINEERING
JAIPUR ENGINEERING COLLEGE
SP-43, RIICO INDUSTRIAL AREA, KUKAS, JAIPUR-302028,
RAJASTHAN, (INDIA)

DEPARTMENT OF CIVIL ENGINEERING | JEC, KUKAS
CERTIFICATION
This is to certify that the PANKAJ SHAH has done his Internship in Civil Engineering Department (CTP
1&2, PKG-A, Rewari) Larsen and Toubro Limited, from 2nd May 2018 to 16th June 2018.
He has worked on a Project titled ‘Design & construction of Civil, Building & Track works for Double Line
Railway Involving Formation, bridges, Structures, Building, Ballast On formation, Track work including
Testing & commissioning for Rewari - Iqbalgarh section’. This Project was aimed to construction of 1388
track km (excluding turnouts) of railway line, 1342 bridges, and 20 stations along with supply of all
associated equipment. This project will be executed using mechanized means of track linking and employing
the latest technology and advanced construction methodologies in railway construction.
During the internship he demonstrated good Civil Engineering skills with a self-motivated attitude to learn
new things. His performance exceeded expectation and was able to complete the work successfully on time.
We wish him all the best in his future endeavours.
Project Manager Planning Engineer Head of Department
(PKG- A), Rewari (PKG- A), Rewari (Civil Engg.) JEC, Kukas
Mr. Pankaj Panday Mr. Sanchit Guleria Mr. Anil Agarwal

ACKNOWLEDGEMENT
The internship opportunity I had with L&T construction was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was provided with
an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people
and professionals who led me though this internship period. Bearing in mind previous I am using this
opportunity to express my deepest gratitude and special thanks to Mr. Jagrat Ojha [H.R Manager] of
L&T construction who in spite of being extraordinarily busy with his duties, took time out to hear, guide
and keep me on the correct path and allowing me to carry out my project at their esteemed organization
and extending during the training. I express my deepest thanks to Mr. Pankaj Panday [Project Manager,
PKG-A, Rewari], Mr. Sanchit Guleria [Planning Engineer], Mr. Suresh Maurya [Formation Incharge],
Mr. Waseem Akram [Site Engineer(Formation)], Mr. Dharmendar Kumar Yadav [Structure
Incharge], Mr. Danish Siddique [Site Engineer(Structure)], Mr. Sitaram [Quality Incharge], Mr.
Rakesh Sharma[Quality Engineer], Mr. Umasankar Ahirwar [Safety Incharge] for taking part in useful
decision & giving necessary advices and guidance and taught us many things regarding site activity to
make the project easier. I choose this moment to acknowledge his contribution gratefully. It is my radiant
sentiment to place on record my best regards, deepest sense of gratitude to Prof. Dr. Sunita Rawat
(Director), Anil Agarwal (Head of Department, Civil Engineering), for their careful and precious
guidance which were extremely valuable for my study both theoretically and practically. I perceive as this
opportunity as a big milestone in my career development. I will strive to use gained skills and knowledge
in the best possible way, and I will continue to work on their improvement, in order to attain desired
career objectives. Hope to continue cooperation with all of you in the future.
Sincerely,
PANKAJ SHAH

TABLE OF CONTENTS
1. INTRODUCTION...................................................................................................... ………….…4
1.1. ABOUT THE ORGANISATION.................................................................................................... 4
1.1.1. INTRODUCTION……………………………………………………………................ ….……4
1.1.2. HISTORY ......................................................................................................................... ………4
2. PROJECTS AND ACTIVITIES ..................................................................................... ….…..06-12
2.1. ON THE TRACK OF PROGRESS ....................................................................................................6
2.1.1. WINNING COLLABORATION……………………………………………………......................6
2.2. PROJECT ALLIGNMENT .................................................................................................................7
2.3. SCOPE OF WORK .............................................................................................................................8
2.4. SALIENT FEATURES OF DFC PROJECT……………………………………………….……….9
2.5. PROJECT INFRASTRUCTURE……………………………………………………………………10
2.6. MULTIPLE BENEFITS FOR THE NATION, TRADE AND COMMERCE AND TO THE PEOPLE
OF INDIA……………………………………………………………………..……………………….…12
3. FORMATION………..…………………………………………………………………………….13-18
3.1. INTRODUCTION ............................................................................................................................... 13
3.2. EXECUTION OF FORMATION EARTHWORK…………………………………...……................14
3.3 BLANKET LAYER ………………..................................................................................................... 16
4. QUALITY AND CONTROL LAB….………………………………………..…………….…..…..19-31
4.1.TEST FOR SOIL………………………………………………………………………….................. 19
4.2.TEST FOR CEMENT……………………………………………………………………................... 26
4.3.TEST FOR CONCRETE ..………………………………………………………………................... 28
4.4.TEST FOR AGGREGATE…………………………………………………………………………....29
5 STRUCTURE.......................................................................................................................................32-34
5.1 GENERAL SEQUENCE OF ACTIVITIES COMMOM FOR ALL STRUCTURES………………..32
6. TRACK WORK INSTALLATION ………………………………………………………………35-36
6.1 INTRODUCTION ……………………………………………..……………………………………...35
6.1 NEW TRACK MACHINE………………………………………………………………………… ....35
7. RAIL YARD…………………………..……………………………………………………………37-38
7.1 HEAD HARDENED RAIL ………………………………………………..…………………………37
8. SLEEPER CASTING YARD……………………………………………………............................39-44
8.1 MANUFACTURING PROCESS…………………………………………………………………….39
9. CONCLUSION
10. REFERENCES

CHAPTER 1
INTRODUCTION
1.1. ABOUT THE ORGANIZATION:
.1.1 INTRODUCTION
Larsen & Toubro Limited (“Larsen & Toubro” or “L&T”) is a USD 16 billion technology, engineering,
construction, projects, manufacturing and financial services conglomerate, with global operations. It
addresses critical needs in key sectors – infrastructure, construction, defence, hydrocarbon, heavy
engineering, power, ship-building, aerospace, electrical & automation, mining and metallurgy. L&T’s
integrated capabilities span the spectrum of ‘design to deliver’ solutions. Over seven decades of a strong,
customer-focused approach and a sharp focus on world-class quality have enabled it to maintain a leadership
position in its major lines of business.
The Company has manufacturing facilities and offices in several countries, and a global supply chain. It
delivers landmark projects and products, helping clients in 30 countries to create long-term progress and
economic growth. Characterized by professionalism, high standards of corporate governance and
sustainability, L&T continues to evolve, seeking better ways of engineering to meet emerging challenges.
1.1.2 HISTORY
Larsen & Toubro Limited is the biggest legacy of two Danish Engineers, who built a world-class
organization that is professionally managed and a leader in India's engineering and construction industry. It
was the business of cement that brought the young Henning Holck-Larsen and S.K. Toubro into India. They
arrived on Indian shores as representatives of the Danish engineering firm F L Smidth & Co in connection
with the merger of cement companies that later grouped into the Associated Cement Companies.
Together, Holck-Larsen and Toubro founded the partnership firm of L&T in 1938, which was converted into
a limited company on February 7, 1946. Today, this has metamorphosed into one of India's biggest success
stories. The company has grown from humble origins to a large conglomerate spanning engineering and
construction.
Larsen & Toubro Construction is India’s largest construction organization. Many of the country's prized
landmarks - its exquisite buildings, tallest structures, largest industrial projects, longest flyover, and highest
viaducts - have been built by it. Leading-edge capabilities cover every discipline of construction: civil,
mechanical, electrical and instrumentation.
L&T Construction has the resources to execute projects of large magnitude and technological complexity in
any part of the world. The business of L&T Construction is organized in six business sectors which will

primarily be responsible for Technology Development, Business Development, International Tendering and
work as Investment Centers. Headquarters in Chennai, India. In India, 7 Regional Offices and over 250
project sites. In overseas it has offices in Gulf and other overseas locations.
1.2. L&T Construction
Ranked among the world’s top 30 contractors, L&T Construction contributes significantly to building the
image and stature of Larsen & Toubro across the world. It drives L&T’s reputation as ‘the builder of the
India of the 21st century’. Many landmark projects in India – and increasingly overseas – bear L&T
Construction’s indelible stamp of excellence, reflecting a track record spanning over seven decades. The
multiple businesses of L&T Construction have distinct but complementary capabilities, addressing different
segments of infrastructure and industry. L&T Construction executes projects on a turnkey basis, with single
source responsibility. It adopts innovative design engineering and has access to a global supply chain.
Mechanisation and the ability to mobilise large, highly trained crews enable it to meet stringent deadlines
and rigorous standards. At every project site and establishment of L&T Construction, the highest priority is
accorded to the environment, health and safety. A safe work culture is intensively propagated to conform to
– and even surpass – international standards.

CHAPTER 2
PROJECTS AND ACTIVITIES
2.1 ON THE TRACKS OF PROGRESS:
Logistic management is going through a sea-change with India’s largest and the first-of-its-kind project in
the rail sector to augment the rail infrastructure to increase share in rail freight market by offering customers,
a guaranteed, faster transit at economic tariff. Dedicated Freight Corridor Corporation of India Limited
(DFCCIL) - a Special Purpose Vehicle set-up under the administrative control of Ministry of Railways is
undertaking planning and development, mobilization of financial resources and construction, maintenance
and operation of Dedicated Freight Corridors connecting different states of the country.
In the first phase, DFCCIL will be constructing two corridors - the Western Dedicated Freight Corridor
(WDFC) and Eastern Dedicated Freight Corridor (EDFC) - spanning a total length of about 3322 route km.
The DFC project on the Western and Eastern routes is one of the most ambitious projects that Indian
Railways has ever taken up and once completed, would meet the transport requirements of the two busy
trunk routes for the next 15 to 20 years.
The WDFC (1483 km) will be from Jawaharlal Nehru Port (JNPT) in Mumbai to Tughlakabad and Dadri
near New Delhi and would cater largely to the container transport requirements between the existing and
emerging ports in Maharashtra and Gujarat and passes through the states of Haryana and Rajasthan.
2.1.1 WINNING COLLABORATION:
Sojitz - L&T Consortium (WDFC: Rewari - Iqbalgarh Section)
A part of the Western Dedicated Freight Corridor has been secured by a consortium of Sojitz Corp., Japan
and Larsen and Toubro Limited, India. Sojitz Corporation, a general trading company conducts its
operations in about 50 countries through 505 consolidated subsidiaries and affiliated companies all over the
world. Sojitz’ business activities are wide- ranging encompassing machinery, aerospace, energy and mineral
resources, chemicals and plastics, etc.
L&T, India’s largest engineering, technology, construction and manufacturing organization has established
itself as a unique service provider delivering turnkey solutions for all types of railway projects. The Railway
Strategic Business Group of L&T has taken the lead in rail construction by introducing pioneering

techniques, resulting in execution of projects with innovation, quality and speed. The combination of the
distinct strengths of these two companies will help create one of the finest rail infrastructures in the country.
The EPC order involves construction of 626 km of a double track corridor from Rewari in Haryana to
Iqbalgarh in Gujarat, via Rajasthan, spanning three states. This is the country’s largest project awarded so
far in the rail sector and the first-of-its-kind in India.
2.2 PROJECT ALLIGNMENT:

2.3 SCOPE OF WORK

2.4 SALIENT FEATURES OF DFC PROJECT

2.5 PROJECT INFRASTRUCTURE

2.6 Multiple Benefits for the Nation, Trade & Commerce and to the people of India

CHAPTER 3
FORMATION
3.1 INTRODUCTION
3.1.1 OBJECTIVE
Main objectives of soil survey and investigation are as follows :-
 To determine soil type with a view to identify their suitability for earthwork in formation and to
design the foundation for other structures.
 To avoid troublesome spots, unstable hill sides, swampy areas, soft rock areas, peat land etc.
 To determine method of handling and compaction of subgrades.
 To identify suitable alignment for embankment and cutting from stability, safety, economy in
construction and maintenance consideration.
 To identify suitable borrow area for desired quality and quantity of subgrade and blanket material.
 To determine depth of various strata of soil and bed rock level.
 To determine ground water table position and its seasonal variation and general hydrology of area
such as flood plains, river streams, etc.
 To determine behaviour of existing track of road structure nature and causes of geo-technical
problems in them, if any.

3.2 EXECUTION OF FORMATION EARTHWORK
3.2.1 Clearing and grubbing and stripping
3.2.2 Selection of borrow pits
3.2.3 Excavation for formation in cutting

3.2.3 Excavation for Drains, Ditches, Streams
3.2.3 Compaction of earthwork

3.3 Blanket Layer
3.3.1 Requirement to achieve functions of Blanket Layer

3.3.2 Manufacturing of Blanket Material

Chapter 4
QUALITY & CONTROL LAB
4.1 TEST FOR SOIL
4.1.1 TEST PROCEDURE FOR DETERMINATION OF DRY DENSITY OF FINE, MEDIUM &
COARSE-GRAINED SOILS BY SAND REPLACEMENT METHOD
 PURPOSE OF TESTING:
This test is done for determining of the dry density (in g/cm3
) of fine, medium & coarse- grained soils by
sand replacement method.
 CODAL REFERANCE:
 IS : 2720 Part 2 Method for sampling soil.
 IS : 2720 Part -XXVIII Determination of dry density of soil in place by core – cutter method.
 TEST EQUIPMENTS:
 Large sand pouring cylinder, conforming toIS: 2720 Part –XXVIII.
 Tools for excavating holes.
 Cylinder calibrating container.
 Wt balance.
 Metal containers.
 Metal tray of 450sq mm area & 50mm deep with a 200mm dia hole at center.
 Uniformly graded natural sand passing 1.0mm sieve & retained on 600micron IS Sieve.
 CALIBRATION OF APPARATUS:
 First measure volume of the calibrating container (V) in cc.
 Measure the wt of calibrating container.
 Close the shutter of the container & pour the above described sand into the cone at the bottom of the
container.
 Then remove the sand from the cone & take wt (W2).
 Pour sand into the poring cylinder & take wt of both, sand + pouring cylinder (W1).
 Then place the cylinder on the known volume-calibrating container & open the shutter to allow to
run out the sand into the cylinder. After fully pouring the container close the shutter & remove it carefully.
 Then take wt of the cylinder & sand after pouring (W3).

 Weight the sand to fill the calibrating container (Wa).
 So bulk density of sand Bds=(Wa/V) X 1000 kg/cum.
PROCEDURE OF SAMPLING:
 Choose a flat & level area approximately 60 cm2
, at the place where the soil is to be tested.
 Then the metal tray with central hole place on the prepare surface.
 Then excavate a hole using the hole on the tray as the pattern, to the depth of the layer to be tested
upto a maximum of 250mm.
 Collect carefully the soil sample from the hole & Keep the soil sample in a poly pack for further
moisture testing.
 Remove the metal tray & place the pouring cylinder just over the excavated hole.
 First Pour a known wt of sand into the cylinder & measure the wt of sand & cylinder before
pouring.
 Then open the shutter & allow to running out the sand into the hole.
 Close the shutter when no further movement of sand takes place.
 Continue this process at least twice more.
 TEST PROCEDURE:
 First weight the soil sample collects from the hole (Ww).
 Measure the wt sand + cylinder after pouring.
 Check the moisture content (Wm) by thermostatically hot air oven .
 CALCULATIONS:
 Weight of wet soil from the hole (Ww), in gm.
 Weight of sand (+ cylinder) before pouring (W1), in gm.
 Weight of sand (+ cylinder) after poring (W4), in gm.
 Weight of sand in hole (Ws) = W1 – W4 – W2, in gm.
 Bulk density Bd= ( Ww/Ws ) x Bds , in kg/m3
.
 Water content container No.
 Weight of soil for water content determination (Wa), in gm.
 Weight of oven dried soil (Wb), in gm.
 Water content w = Wa – Wb x 100 (%)
Wa
 Dry density Db= 100 Bd kg/cum
100+W

4.1.2 DETERMINATION OF CBR FOR SOIL
Laboratory determination of CBR to establish the procedure for the testing of CBR
IS – 2720 (Part 16): laboratory determination of CBR
 APPARATUS:
 Moulds (150mm dia& 175mm ht.) with Base plate, stay rod & wing
 Nut with collar (50mm ht.)
 Spacer Disc (148mm dia)
 Metal Rammer (4.89 kg with 450mm drop)
 Expansion Measuring Apparatus (Swelling)
 Weights
 Loading Machine (min 5000kg capacity & rate of loading =1.25mm/min) with penetration plunger
(50mm dia)
 Dial gauges with LC 0.01mm
 Perforated plate
 Graduated cylinder
 Cutting edge
 PROCEDURE:
(A) MOULD PREPARATION:
 First find out moisture density relation of soil, as per IS:2720 (Part-8)
 Take soil sample of about 5000 gms& add water in it as per OMC found.
 Fill the 3 CBR mould in 5 layers with 55 blows with 4.89 kg hammer.
 Put filter paper on mould with spacer disc on it.
 Put surcharge weight of 5kg on prepared mould& put those mould into water tank for soaking.

 Put Expansion Measuring apparatus on those moulds& take initial reading.
(B) TESTING OF CBR:
 Take out CBR moulds after 4 days soaking & get air dried for 15 minutes, check swelling gauge reading.
 Place the CBR mould into CBR Testing machine & give the initial load as per IS-2720 (Part-16) with
penetration plunger.
 Take the reading of loading proving ring (CBR machine) at 0,0.5,1.0,1.5,2.0,2.5, 3.0,4.0,5.0,7.5,10 & 12.5
mm penetration for all three moulds respectively (rate of loading =1.25mm/min).
 Multiply the proving ring reading with proving ring factor (from calibration of loading machine) which
gives load values for different penetration &mould.
 Draw a graph between load v/s penetrations & make a smooth curve of it.
 Take out the load values at 2.5 mm & 5.0 mm penetration for different moulds.
 Calculate the CBR by the below formula.
PT
CBR = ------- x100
PS
Where,
PT- Corrected unit test load corresponding to the chosen penetration from the load penetration curve.
PS – Unit standard load for the same depth of penetration as for PT taken from the standard table.
(Generally the CBR value at 2.5mm penetration will be greater than that at 5mm penetration and the same
value of CBR taken for design.)
 STANDARD LOADS FOR CBR TEST:

 REPORT:
The CBR value shall then be reported correct to the first decimal place. The details shall be reported in
prescribed proforma
 CBR of specimen at 2.5 mm penetration
 CBR of specimen at 5 mm penetration
 CBR of specimen at …….Penetration
 Results of repeat test, if conducted :

4.1.3 DETERMINATION OF LIQUID LIMIT FOR SOIL (USING CONE
PENETROMETER)
For determination of the liquid limit of soil using cone penetrometer.
IS : 2720(Part 5) Methods of test for soils : Determination of liquid and plastic limit.
 APPARATUS:
 Oven
 Balance (0.01g accuracy)
 Sieve [425 micron]
 Cone penetrometer
 PREPARATION SAMPLE:
 After receiving the soil sample it is dried in air or in oven (maintained at a temperature of 600
C). If
clods are there in soil sample then it is broken with the help of wooden mallet.
 DETAIL PROCEDURE:
 About 150 gm. of air dried soil from thoroughly mixed portion of material passing 425 micron IS
sieve is obtained.
 Distilled water is mixed to the soil to form a uniform paste.
 Then the wet soil paste is transferred to the cylindrical cup of cone penetrometer apparatus, ensuring
that no air is trapped in this process.
 Finally the wet soil is leveled up to the top of the cup and placed on the base of the cone
penetrometer apparatus.
 The penetrometer is so adjusted that the cone point just touches the surface of the soil paste in the
cup and the initial ready is to be taken.
 The vertical clamp is then released allowing the cone to penetrate into soil paste under its own
weight for 5 seconds. After 5 seconds the penetration of the cone is noted to the nearest millimeter.
 The test is repeated at least to have four sets of values of penetration in the range of 14 to 28 mm.
 The exact moisture content of each trial is determined
 CALCULATION:
A graph representing water content on Y – axis and the cone penetration on X – axis is prepared. A best
fitting straight line is then drawn.
The moisture content corresponding to cone penetration of 20 mm. is taken as the liquid limit of the
soil.

 REPORT:
The liquid limit is to be reported to the nearest first decimal place.
 PRECAUTIONS:
 Soil used for liquid limit determination should not be oven dried prior to testing.
 After mixing the water to the soil sample , sufficient time should be given to permeate the water
throughout out the soil mass
 Wet soil taken in the container for moisture content determination should not be left open in the air,
the container with soil sample should either be placed in desiccators or immediately be weighed.

4.2 TEST FOR CEMENT
4.2.1 TEST PROCEDURE FOR DETERMINATION OF COMPRESSIVE STRENGTH OF
CEMENT
This test is done for determining the Compressive strength of cement.
 IS: 4031, Part-6: Method of Physical testing for hydraulic cement, Determination of Compressive
strength Compressive strength hydraulic cement.
 IS: 650: Specification for the standard sand for testing cement.
 IS: 10086: Specification for gauging trowel.
 IS: 10080: Specification for the apparatus to measure the length change of hardened cement paste,
mortar & concrete.
 Vibration machine should be conformed IS: 10080.
 Poking rod.
 Three types standard sand conforming IS : 650
 Cube moulds of size 70.6 mm, conforming IS: 10086.
 Gauging trowel.
 Wt balance.
 Graduated cylindrical glass jar.
 Poking rod (made off rubber).
 Compression Testing Machine 500 kN
 TEMPERATURE & HUMIDITY:
 The temperature of the gauging room, dry materials & water should be maintained at 27+20
C &
relative humidity required 65± 5%.
 PREPARATION OF TEST SAMPLE:
 The material for each cube is to be mixed separately & the quantity of cement, standard sand &
water required as bellow: -
a. Cement : 200 gm
b. Standard sand 600 gm ( 200gm of each grade )
c. Water = ( P/4 +3 ) x weight of cement & standard sand , gms
100
Where P is the % of water required to produce a paste of standard consistency.
 Place the cement & sand mixer on a non-porous plate & mix it dry with a gauging trowel for one
minute properly.
 Then mix the water of above described quantity, with the cement to make a uniform mortar.
 The mixing time should not be less than 3 min & the time taken to obtain a uniform color not
exceed four minute.

 NUMBER OF SPECIMENS:
 Three samples are required for each period of curing 3, 7 & 28days.
 MOULDING THE SPECIMEN:
 At the time of assembling the moulds ready for use, the joints are to be coated by thin layer of
Lubricant. Apply thin coating of mould oil on the interior faces of the mould.
 Then place the mould on the table of vibration machine & hold it firmly in position by means of
suitable clamp.
 Immediately after mixing start the vibration machine &placethe mortar in the cube & prod 20 times
by means of poking rob in about 8 sec to ensure the elimination of entrapped air & honey combing.
 The period of vibration should not be less than 2 minute & the specified speed 12000 + 400 times
per minute.
 At the end of the vibration, remove the mould then finish & make smoothing the top surface of the
specimen by a trowel.
 CURING THE SPECIMEN:
 Keep the filled mould for 24 hrs for Setting .
 At the end of that period remove the specimen from the mould & immediately submerge in clean
fresh water & Cure it until testing.
 TESTING OF THE CEMENT CUBE:
 Test three cubes for compressive strength for each period of curing of 3, 7 & 28 days.
 Bearing surface of testing machine should be wiped clean & the loose materials from the surface of
specimens should also be removed.
 Cube specimens should be placed in such a manner that the load shall be applied to perpendicular
face of cast.
 The axis of the specimens should be carefully aligned with the center of the thrust.
 Record the maximum load applied to the specimen.
 CALCULATIONS:
 The measured compressive strength of the specimen = P/A ( Kg/cm2
,N/mm2
or MPa)
P = Max load applied to the specimen during the test
A = Cross sectional area of the specimen

4.3 TEST FOR CONCRETE
4.3.1 TEST PROCEDURE FOR COMPRESSIVE STRENGTH TEST OF CONCRETE
SPECIMENS
This test is done to determine compressive strength of concrete specimens.
 IS 516 : Methods of test for strength of concrete
 IS 1199 : Method of sampling and analysis of concrete
 Compression Testing Machine 2000 kN
 Cube (15x15x15)cm & (10x10x10) cm3
& Cylinder (15x300)cm
 AGE AT TEST:
 Test is conducted at recognized ages of the test specimens, the more common being 7&28 days.
 The age is calculated from the time of addition of water to the dry ingredients.
 NUMBER OF SPECIMENS:
At least three specimens is required for testing at each specified age.
 TEST PROCEDURE:
 Specimens are to be stored in water & should be tested immediately on removal from the water &
should maintain the wet condition until testing.
 Bearing surface of testing machine should wipe cleaned & the loose materials from the surface of
specimens should also be removed.
 Cube specimens should be placed in such a manner that the load shall be applied to opposite sides as of
cast.
 The axis of the specimens shall be carefully aligned with the center of the thrust.
 The maximum load applied to the specimen shall be recorded.
 CALCULATIONS:
 The measured compressive strength of the specimen = P/A ( Kg/cm2
,N/mm2
or MPa)
P = Max load applied to the specimen during the test
A = Cross sectional area of the specimen
 Average of three values is taken as representative of the batch.
 Individual variation should not be more than + 15 % of the Average.

4.4 TEST FOR AGGREGATE
4.4.1 TEST PROCEDURE FOR DETERMINING OF AGGREGATE ABRASION VALUE
This test is done to determine of abrasion value of coarse aggregates.
 IS: 2386 Part 4 Test of aggregate for concrete, mechanical properties.
 IS: 460: Specification for test sieve.
 IS: 383: Specification for Coarse & Fine aggregates.
 TEST EQUIPMENT:
 Los Angeles machine, comprising :
 A hollow steel cylinder, having dia of 700mm and inside length of 500mm.
 Connected stub shaft attached with the cylinder to mount and rotate in its horizontal axis.
 An opening at top of the cylinder to introduce the sample.
 A steel lid to cover the opening.
Removable steel self-connected inside the cylinder.
 IS Sieves ( 80,63,50,40,25,20,12.5,10,6.3,4.75,2.36 & 1.70mm).
 Abrasive charge: at least 12 nos having dia 48mm and wt between 390gm to 445gm.
 PREPERATION OF TEST SAMPLE:
 The test sample is to be cleaned and dried in oven at a temperature of 105 to 1100
C.
 The grading of those aggregate which are most nearly representing the aggregate used for the work.
Table no: 1
SIEVE SIZE WEIGHT IN gm. OF TEST SAMPLE FOR GRADE
Passing
(mm)
Retained on (mm) A B C D E F G
80 63 2500
63 50 2500
50 40 5000 5000
40 25 1250 5000 5000
25 20 1250 5000
20 12.5 1250 2500
12.5 10 1250 2500
10 6.3 2500
6.3 4.75 2500
4.75 2.36 5000
Table no: 2 – Number of abrasive charges:
Grading No. of
spheres
Weight of Charge in
gms
No. of Revolutions
A 12 5000 + 25 500
B 11 4584 + 25 500
C 8 3330 + 20 500
D 6 2500 + 15 500

E 12 5000 + 25 1000
F 12 5000 + 25 1000
G 12 5000 + 25 1000
 TEST PROCEDURE:
 Select the Suitable Grade & Weight of sample from the above table, dried in oven (A).
 First open the upper cover plate and place the aggregate samples in it along with the specified no. of
abrasive charges.
 The speed of rotation of the machine should be controlled within 20 to 33 rev/min.
 After completion of abrasion, discharge the tested material on a tray.
 Then separate the test sample by sieving with 1.7mm IS sieve.
 The material coarser than the 1.7mm IS Sieve shall be then washed and dried in oven at 105 to 1100
C.
 Take weight the oven dry aggregate to the nearest gms.(B)
 CALCULATION:
 Aggregate abrasion value = B/A x 100 (%)
B = weight of fraction passing 1.7mm IS Sieve.
A = Weight the oven dried sample.
4.4.2 TEST PROCEDURE FOR DETERMINING OF AGGREGATE IMPACT VALUE
This test is done to determine of impact value of coarse aggregates.
 IS: 2386 Part 4 Test of aggregate for concrete, mechanical properties.
 IS: 460: Specification for test sieve.
 IS: 383: Specification for Coarse & Fine aggregates.
 TEST EQUIPMENT:
 An impact value apparatus comprising the following –
 It should be supported on a level and plane concrete floor or stone block.
 A cylindrical steel cup of internal dimension (102mm dia and 50mm depth).
 A metal hammer weighing 13.5kg to 14.0 kg, cylindrical shape of dia 10cm and 5cm long.
 Hammer should be fall freely between the vertical guides from a height of 380 + 5.0 mm on to the test
sample in the cup.
 IS Sieves of size 12.5, 10 and 2.36 mm
 A metal measure, tarred to the nearest gm (internal dia 75mm & depth 50mm).
 Wt balance accuracy of 0.1gm.
 Tamping rod.
 Oven.
 PREPERATION OF TEST SAMPLE:
 The test sample consist of aggregate the whole of which passes the IS sieve 12.5-mm and retained on 10-
mm.
 Then make dry the sample in an oven at a temperature 100 to 1100
C for a period 4 hrs.
 After that, cool the sample and then place it in the cup in 3 layer and compact each layer by tamping 25
times with the tamping rod.
 Then remove the test sample from the cup and take weight (A).
 Repeat the above process twice more.

 TEST PROCEDURE:
 Place the impact machine on rigid floor or any level plate without wedging and packing.
 Fix the cup firmly in position on the base of the machine and place test sample in it and compact by a
single tamping rod.
 Then raise the hammer to a height of 380mm from the top surface of aggregate and allow it to fall free on
the aggregate.
 Continue the above process 15 times, each fall being delivered at 1 sec interval.
 Collect the crushed aggregate from the cup and sieve the whole sample with 2.36mm IS Sieve.
 Then weigh the fraction passing on the sieve to an accuracy of 0.1gm (B).
 Again weigh the fraction retained on the sieve (C).
 Tabulate the results as specified below.
 CALCULATION:
 Aggregate Impact value = B/Ax 100 (%)
B = weight of fraction passing 2.36mm IS Sieve.
A = weight the oven dried sample.

CHAPTER 5
STRUCTURE
5.1 GENERAL SEQUENCE OF ACTIVITIES COMMOM FOR ALL
STRUCTURES
1. SITE PREPARATION
Prior to construction, work sites within the proposed boundary shall be prepared to
mobilise workers, equipment and materials. This would include clearing, grubbing, grading,
demarcation of the construction site work area followed by mobilisation of initial equipment and materials.
The locations where infringement into IR structure is identified, separate drawings for the required
construction methods (if necessary) as provided shall be referred.
SETTING OUT
The setting out of works shall be carried out to fix center line of the bridge structure at regular intervals in
plain and all curves. These marks shall be maintained until the work is completed. The work shall be carried
out in two steps:
a. Working out co-ordinates of reference points and pre-determined survey points for establishing the survey
control pedestals.
b. Actual survey – fixing of pier locations according to conformity survey.
Based on the above, important control points shall be established at such locations suitable
for further survey and protected till the end of the construction work. Control points shall be
Marked with its northing and easting. Coordinates for each work point such as pile locations
etc. shall be worked out and tabulated for further use at site. All the survey to establish work
points shall be closed to designated or known control points every time and error, if any, shall
be distributed.
 BED PREPARATION FOR MOULD ASSEMBLY
Casting bed shall be located as per the casting yard layout drawings. The base shall be prepared by laying
well compacted soil or CLSM (controlled low strength materials) wherever required to achieve the SBC
mentioned in the drawings. Longitudinal slope of 1:500 and cross slope of 1:100 shall be ensured and
sufficient drains shall be provided along the length as necessary to avoid water logging. PCC of 75mm thick
shall be laid wherever required. The concrete pedestals shall be placed and aligned at I-girder casting
locations. Base channels shall be placed over the concrete pedestals and fastened with bolts at Igirder casting
locations and shall be placed over PCC for box structures. Foot adaptor for alignment props shall be fixed at
ends of the base channel for girders and over PCC for box structures
FABRICATION AND FIXING OF SHUTTERS
Shutters shall be fabricated as per the fabrication drawings. Bottom shutters surface undulations shall
be removed. Zig shall be fabricated as per the shutter profile. Necessary hooks shall be provided for
handling. Tie rod location shall be marked as per drawing and holes shall be made in the shutter panels. The
bottom shutters shall be fixed within the tolerance limits. Bottom shutters shall be placed, aligned to the
required line and level and welded to the base channel.
All shutter joints shall be applied with approved sealant and Masking tape The side shutters shall be
cleaned. Shuttering oil shall be applied and erected in sequence as specified in the shutter GA drawings.
Shutters and supports (Alignment Props) shall be fixed as specified in the drawing and aligned to the line

and level. For I-girders, initially side shutters shall be fixed on only one side. Side shutters for the other side
shall be made ready to be fixed. Bursting reinforcement shall be fixed and the duct with end anchorages
shall be fixed along with end block. After inspection of cable ducts, the other side shutter shall be fixed
along with End stoppers (along with anchorages) and diaphragm location shutters. Foam sheet shall be fixed
at all the joints (vertical & Horizontal) of side shutters to avoid slurry leakage during concrete. All corners/
edges shall be provided with suitable size triangular beading fixed to the shuttering if required. The vertical
and horizontal panels at the edge shall be provided with rubber gasket to avoid leakage if required. The
suitable inserts shall be provided if required in the bottom slab/ flange for fixed/ free bearing assembly as
per GAD drawings. Air vents shall be provided in sheathing to avoid entrapment of air during grouting of
prestressed tendons. Levels of shutters shall be checked using plumb bob and level tubes. Separate drawings
shall be referred for provision of jacking arrangement in the girders required for side shifting of the same.
Approved structure drawings shall be referred for Stressing installations. The walk way for girder shall be
fixed for concreting works and shall be free from
 COMPLETION OF FORMWORK AND EMBEDMENT
The correctness of co-ordinates of the duct shall be verified using the drawings. PVC pipes around tie
rods shall be inserted along with cones to avoid the entry of slurry into tie rod grooves during concreting.
Diaphragm Dowels shall be fixed after completion of formwork. The bars shall be placed in the specified
locations as per drawings.
 PREPARATION FOR CONCRETING
Working platform for concreting shall be fixed. The hand rail and toe board shall be fixed properly for
the movement of work men. Availability of sufficient lighting, water, cover sheets etc., shall be ensured
before starting of concreting. The condition of mould vibrators and poker vibrators shall be checked. Proper
cleaning inside the mould shall be done ensuring that any binding wire pieces, spare cover blocks or any
piece of reinforcement is not left inside.

 CONCRETING
Concrete of required grade received from batching plant shall be placed either with concrete bucket
arrangement or concrete pump / boom placer. Height of raise of concrete shall not be more than 1.0m. The
concrete shall be poured in layers. During concreting, vibration shall be done properly by using mould
vibrator and needle vibrator to ensure proper compaction. Compaction using 40mm / 63mm needle in the
cover portion shall be followed after compacting with mould vibrator and poker vibrator to reduce /
eliminate bug holes. The top surface shall be finished and laitance shall be removed using wire brush to
make construction joint or the surface of the hardened concrete shall be chipped in order to expose the
coarse aggregate particle for goof bonding with the fresh concrete. The levels and alignment shall be
checked after concreting.
 DESHUTTERING
All de-shuttering works shall be done as per IS 14687:1999 and requirements mentioned in approved
structural requirements. After concreting, the shutters shall to be loosened according to the stripping time of
each precast segment. The de-shuttering shall be done as per separate construction sequence drawings. The
removed shutters shall be handled with gantry or by manual means according to the size and weight of the
shutter. The shutters shall be cleaned with suitable tools to remove the adherent material present on the
surface of the shutters. After cleaning, the shutters shall be made ready for the next casting.
 CURING
Curing shall be done using curing compounds for the precast segments. Necessary number of companion
test cubes shall be cast in order to ascertain the compressive strength of test cubes before de-shuttering.
Proper curing shall be done to avoid shrinkage cracks and to facilitate consolidation of concrete / hydration
reaction during the hardening stage of the concrete. The required number of test cubes shall be cast in order
to do wet curing as per IS:516 and curing compound shall be applied on the test cubes in order to ascertain
the compressive strength of concrete which are water cured / cured with the application of curing compound.

CHAPTER 6
TRACK WORK INSTALLATION
Mechanized method of track laying is used using NEW TRACK CONSTRUCTION (NTC) machine. This
will involve:
 Laying of rail panels of 250m/260m welded by stationary FBW plant under control conditions in depot
 Track linking/ threading to be done by NTC machine
 Use of tamping machines, dynamic track stabilizers and shoulder ballast compactors for making track fit
for traffic movement
 The mechanized track laying will include welding, destressing using mobile FBW machine, fastening,
laying of concrete sleepers, ballasting including tamping & compaction (suitable for 25 tonnes axle load
@max permissible speed of 100kmph for Main lines and 50kmph for other lines), track boards and signage.
 Contractor will transport 250m/260m panels from welding depot to laying site by special rakes/ track laying
train.
 The rail panels will be welded by FBW machine. Use of thermic welding is restricted to special locations in
exceptional cases and with prior consent of the engineer and approval of the employer.
 The destressing will be carried out by deploying mobile FBW plant especially fitted for destressing
operations within the neutral temperature range for each section as per LWR Manual of IR.
 Track boards and signage will include but not limited to kilometer posts, hectometer posts, gradient posts,
curve posts, transition curve posts, fouling marks, bridge no. plaques, station name boards, jurisdiction
boards, etc.
 Track work installation by NTC shall be done as per Method statement Track installation with NTC.
PREPARATION OF FORMATION BED LAYING OF BOTTOM BALLAST BED

LEVELLING DONE BY GRADER LAYING OF SLEEPERS BY NTC MACHINE
TEST OF SPACING: 600mm+/-10mm LAYING OF RAIL PANELS
BALLAST HOPPER SLOW TAMPING MACHINE (STM)

CHAPTER 7
RAIL YARD
 HEAD HARDENED (HH) RAILS
 HH RAILS: 110 UTS (1080 MPa)
 INDIGENEOUS RAILS: 90 UTS (880 MPa)
 HH rails comes in a bundle of 3 i.e. 1 bundle=3 rails
 (Weight of a single rail=1500kg [60x25]
 Weight of a bundle=4500kg [1500x3])
BUNDLE OF 3 RAILS
 SPECIFICATIONS-
Approved lengths: 23m/25m
Unit weight of rails: 60 kg/m
 SINGLE RAIL PANEL:
Consists of 10 HH-Rails (230m/250m), 9 flash butt welds
In WDFC, the complete railway line is CWR (CONTINUOUSLY WELDED RAIL) i.e. no fish plate joints.
Therefore, only flash butt welded joints are present (except some places, where thermite welding is done)
 RAIL YARD
 There are 3 sets of gantries (6 gantries) working in synchronization for unloading of HH-Rails on
stacking beds

 There is 1 flash butt welding machine for welding of rails to construct panels
 (Waste generated on FBW of two rails=900grams approx.)
FBW MACHINE
 There are 21 gantries i.e. 42 lifting points for carrying railway panels working in synchronization

CHAPTER 8
SLEEPER CASTING YARD
 MANUFACTURING PROCESS
1. MOULD PREPARATION
 NUMBER OF MOULDS: 50x8 moulds (50 moulds in 8 rows laid parallel to length of bed) i.e. 400
sleepers can be accommodated for one round of casting in each bed [1 GANG MOULD=8
SLEEPERS]
 Track laid along the mould supporting structure-to facilitate the movement of baffle extracting
machine, casting machine, cutting machine and de-moulding machine
 CLEANING: Manual cleaning using hand tools (putty knives, brush, sandpaper, hessian cloth, etc.)
 OILING OF MOULDS: Done by specified mould oil, either manually or by spray machine
CLEANING & OILING OF MOULDS
2. SGCI INSERT FIXING
 PLACEMENT OF CAST SHOULDERS: Cast shoulders distributed over the moulds with the help of
baffle extracting machine
 Shoulders fitted and locked with spring lock pins in the pocket indicating correct position
3. BAFFLE AND HTS WIRE PLACING
 Total number of pre-tensioned wires in a sleeper: 20 (which is 18 in IR sleepers)

BAFFLE MACHINE PRE-TENSIONED WIRES IN MOULD
 Bottom layer of finger type baffles shall be placed in position b/w moulds (at 49 locations)
 Thereafter, eight wires belonging to the bottom layer of every sleeper i.e. total 64 wires of all the
eight rows shall be fixed in first round
 Initial tensioning should be shall be completed on those 64 wires.
 Intermediate baffles are placed in 3 consecutive layers, followed by placement of the remaining 96
wires, after which, the top layer of baffle plates shall be placed in position.
PLACEMENT OF BAFFLE PLATES FOR POSITIONING OF HTS WIRES
 Barrels and wedges are used for holding HTS strands in position
 Fixing shall be done manually

BARREL WEDGES (FIXING WIRES AT THE ENDS)
4. STRESSING OF WIRES
APPLICATION OF PRE-STRESSING FORCE:
Stressing of wires is done in 2 stages:
 STAGE 1ST : All the individual 160 wires are pulled from fixed block end for initial tensioning (as
per load calculation received from QC department) using tensioning gun from fixed block end
[11kN]
PRE-TENSIONING OF HTS WIRES BY TENSIONING GUN
 STAGE 2ND: Final tensioning is done altogether in 160 wires from another end for 600mm elongation,
from movable block end using two cylindrical jacks (capacity 500kN) (29kN per strand,580kN per
sleeper and 4640kN for entire 8 gang mould i.e. 580x8) [18kN]

 In case, if any, wire gets snapped or slippage occurs during final stressing, snapped/slipped wire should
be inserted and stressed
 After achieving desired 600mm elongation in first stage, complete load of 29kN is given in wire from
twin acting jack with power assembly
5. CONCRETE PLACING
 Transportation of concrete to casting machine: Via concrete buckets mounted on tractor trolleys
 These casting machine buckets shall feed the concrete mix into 1 Gang mould i.e. 8 sleepers at a time
 During feeding, vibration is done through vibrators fitted on the bottom of the moulds
 400 sleepers are casted in one line/bed = 1 Batch

CONCRETE POURING VIA CASTING MACHINE
6. STEAM CURING
 CURING: After casting over the bed, sleepers are covered with a tarpaulin sheet to prevent loss of
moisture and create suitable enclosure for steam curing
 Steam curing cycle is fully automatic with servo controlled valve.
TARPAULIN COVERING STEAM CURING
7. DE-MOULDING AND TRANSFER OF PRESTRESS
 DE-STRESSING OF HTS STRANDS- After curing, stressing abutments shall be released by operating
the jacks at the ends i.e. strands will be relaxed b/w the sleepers.
 DE-MOULDING- Done 8 numbers at a time by De-Moulding Machine. De-moulded sleepers shall be
placed rotated upside-up over the empty moulds. (If kept in more than one layers, wooden battens of 50
sq. section should be used for separation of sleepers)

DE-MOULDING BY DEMOULDING MACHINE
LOADING OF SLEEPERS USING GANTRY CRANES

CONCLUSION
My internship in L&T was the first instance of me working in any professional field. So I
feel lucky to have L&T as the place of my first work experience. I had no idea of the challenge to be
faced after putting my foot in the professional world. The Job was demanding but I did my best to
create value for the company and for myself as well.
There are many memorable moments and awkward situations I faced working in the
company. I would like to mention few of them which brought considerable change in my perception
of the world around me. The friendly welcome from all the employees is appreciating, sharing their
experience and giving their peace of wisdom which they have gained in long journey of work.
Before my internship started my ideas did not match the experiences have gained during my
internship. There is a big difference in the college projects and the tasks and activities during the
actual work. In college we learn how to describe the work in projects, where in work you learn how
to implement them in reality. This internship was definitely an introduction to the actual work field
for me. I have learned to work in a business organisation and apply my knowledge into practice. I
learned a lot from the different interns that I have been working with during my internship. Each
intern had a different educational background and that made it interesting for me. By working with
them I got to learn from them and become aware educational background.
My mentor during my internship was Mr. Sanchit Guleria, whom I have also learned a lot
from him during my internship. As a Planning Head, he has lots of knowledge in management of all
works going through the site. And not only the mentor, was everyone working as a team teaches me
a great lession about working as a team in such conditions in which they are expertise. I am very
much thankful to them. I have tried to learn as much as possible from all of them and the interns
during my internship.
This internship was definitely beneficial for me and I’m grateful and thankful that I got to
experience and learn many things.
Thank You

REFERENCES
1. IS : 2720 Part 2 Method for sampling soil.
2. IS : 2720 Part -XXVIII Determination of dry density of soil in place by core – cutter method.
3. IS – 2720 (Part 16): laboratory determination of CBR
4. IS : 2720(Part 5) Methods of test for soils : Determination of liquid and plastic limit.
5. IS: 4031, Part-6: Method of Physical testing for hydraulic cement, Determination of Compressive
strength Compressive strength hydraulic cement.
6. IS: 650: Specification for the standard sand for testing cement.
7. IS: 10086: Specification for gauging trowel.
8. IS: 10080: Specification for the apparatus to measure the length change of hardened cement paste,
mortar & concrete.
9. IS 516 : Methods of test for strength of concrete
10. IS 1199 : Method of sampling and analysis of concrete
11. IS: 2386 Part 4 Test of aggregate for concrete, mechanical properties.
12. IS: 460: Specification for test sieve.
13. IS: 383: Specification for Coarse & Fine aggregates.
14. IS 1200 (Part 15) 1987 Part 15- painting, polishing, varnishing.
15. Agbossou A., Michel L., Lagache M., Hamelin P., Strengthening Slabs Using Externally-Bonded Strip
Composites: Analysis of Concrete Covers on the Strengthening. Composites: Part B, 39, 1125-1135
(2008).
16. Bejan L., Ţăranu N., Bârsănescu P., Cioară L., Mocanu F., Probleme moderne ale structurilor composite.
Ed. CERMI, Iaşi, 2006. Casadei P., Nanni A., Ibell T., Experiments on Two-Way RC Slabs with
Openings Strengthened with CFRP Laminates. CIES 03-39, Center for Infrastruct. a. Engng. Studies,
Missouri Univ. of Sci. A. Technol., Rolla, Missouri, USA, 2004.
17. W.B. Mckay; J.M. Mckay Building Construction Vol. II (Fourth Edition) . Orient Longman Private
Limited. p. 32.
18. Time saver standards for building types by "Joseph De Chiara" Mcgraw hill education.

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