1. REPORT ON ONSITE
VOCATIONAL
SUMMER TRAINING
AT MACKINTOSH
BURN LIMITED
TRAINEE : RAJNISH KUMAR
ROLL NO:-001310601013
(JADAVPUR UNIVERSITY, CONSTRUCTION
ENGINEERING DEPARTMENT)
THIS REPORT ENTAILS THE VARIOUS POSSIBLE EXPERIENCES THAT CAN BE
GAINED AT SITE WHILE WORKING WITH ONE OF THE LEADING
CONSTRUCTION COMPANIES OF INDIA.
2015
THIRD YEAR, JU
01.09.2015

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Project: Hosiery Park site
Location : jagadisHPur, HowraH
coordinates : 22°39'15.8"n 88°17'59.2"e

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ACKNOWLEDGEMENT
We feel grateful to each and every individual without whose help it was impossible for us to complete this one
month summer training at Mackintosh Burn Ltd.
We gratefully acknowledge respected Technical Director, Admin in charge, respected project managers, the
safety officials, respected construction managers , respected senior and junior engineers of the site who has
always been helping us to gain several experiences.
OBJECTIVE OF THE TRAINING :
To investigate and hence comprehend various finishing works presently being carried out on-site.
 To gain technical know-how while working with a renowned construction company
 To understand and hence mitigate various practical problems encountered at site
ABOUT THE PROJECT:
 Location : Jagadishpur , Howrah
 Construction type : Foundation piling layout
 Mentors : Partha Sinha sir and Manash sir.
 Client : Govt. of West Bengal
 Consultant/Contractor : Mackintosh burn ltd.

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AIM OF THE PROJECT:
The project aims to construct a hosiery and textile cluster, the state government realising the
employment potential of the textile and hosiery sector, has begun to take special interest in this sector.
LOCATION OF SITE:
The site is located nearly 8 km from Bally Railway Station to Kona Expressway on NH6. It is situated
Dankuni Industrial Zone where Govt. is eyed for development. This is an joint venture project where Wes
Bengal Hosiery Development Corporation and Govt. of West Bengal are two partners. Their aim is to take
all Hosiery Industries in an umbrella from where they can operate easily. Mackintosh Burn Ltd. is the
contractor here.
SITE:
The site is located nearly 2 km inside of NH6. The area is nearly 450 arcs. As it is located in Howrah
district, the land is fairly leveled with mild slope. The soil is Alluvial covered with thick vegetation.
ACTIVITIES: Mainly three types of activities are going on in this site when we attended there.
1) Piling work
2) Load test of pile
3) Hume pipe laying for storm water drainage system.
.
1)Piling work:
Piling work at G.D. building was going on at our training period. It was Cast-In-Situ bore pile. The
diameter of pile is 600mm and depth 26m. Load capacity of each pile is 74 tone. The method used
for boring is chisel boring using water jet. A tripod is fixed above the pile centre from which a
chisel is hanging through pulley. This chisel is connected with a winch through a wire rope and
DMC pipes. DMC pipes are connected with water pump hose which circulates water. A big vat was
made where Bentonite mixed water is kept. The pump is connected here and Bentonite mixed
water is rotate in bore hole when the chisel goes on hammering. When the bore reach at required
depth, DMC pipes with chisel is pulled out. It takes nearly 16 hours to reach required depth. After
pulling out chisel, reinforcement cage is inserted inside the bore. These reinforcement cages are
helical one and have 3 parts. All members are welded properly. The cages are inserted one by one
carefully and welding is done on spot in every cage joint. Reinforcement in upper cages is higher
compared to lower cages. After placing reinforcement properly, Treme pipes are passed through
the cage. These pipes go up to bore length keeping 300mm gap at bottom. The uppermost Treme
pipe covered with a lead. This lead is connected with a fresh water supply pump by hose. Fresh
water is injected through Treme to wash the bore hole and cleaning from excess mud and
Bentonite. Lactometer is used to check the sp.gr. of water. When the reading reached to 1.05,

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washing stopped. Then the lead is opened and funnel like choot is fixed. Through this choot,
concrete is poured. For proper compaction , these tremes are continuously jacked and removal of
treme is made step by step. Concrete fills the bore upto cut off level.
4 PHASES INVOLVED IN BORED CAST-IN-SITU PILE CONSTRUCTION
WORK
Piles can either be driven into the ground (driven piles) or be installed in a predrilled hole (bored
piles or drilled shafts). The construction of bore cast in situ concrete pile consists of 4 primary
phases
1.Pile boring,
2.Reinforcement cage lowering,
3.Flushing
4.Pile concreting.

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1. PILE BORING
A) Hydraulic rig/manually operable auger should be mobilized at the required location
B) Four reference points (making two lines perpendicular to each other) should be marked for checking
centre of pile bore during boring of pile.
C) Initial boring of about 2.0 meters is to be done using cutting tool of desired diameter of pile
D) Then boring will be carried out according to the sub-soil investigation report of that location. It will
be done using liner, bentonite or both.
E) The temporary guide casing, approximately 2.0 meter length with outside diameter equivalent to
nominal diameter of the pile, may then lowered in the bore hole. In such a case dia of cutting tool
will be little less, maximum 75 mm less than outside dia of casing for free movement in the casing
pipe during operation.
F) Position / centerline of the guide casing pipe with reference to pile reference points already fixed
around the pile location shall be checked to shift/adjust the casing pipe to ensure proceeding of
drilling at exact pile location without any deviation.
G) Boring has to be done up to the founding strata as per drawings/ pre decided depth using
intermittently bentonite slurry as per requirement. In case of requirement the bore hole is then
supplied with bentonite slurry, from bentonite installation. Bentonite circulation channel will be
made from bore hole to bentonite tank and fresh bentonite slurry will be pumped to bore hole
through hose pipes. 24 hours prior to start of pile boring, ensure that bentonite is completely
dispersed I the water and attains required density to stabilize the sides of bore hole during drilling.
Bentonite slurry of specified quality should be circulated continuously during boring process.
H) Bentonite used to stabilize the sides of bore hole should be conforming to requirements as listed in
inspection and test plan. Density of bentonite solution should be checked during boring operation to
ensure that the density is about 1.05 g/cc to 1.10 g/cc, marsh cone viscosity 30 to 40 and pH value
9.5 to 12.
I) Bentonite slurry is pumped by high pressure reciprocating pumps/ vertical pump into the bore hole
and the same is allowed to overflow the bore hole. The overflow slurry with bored mud/soil etc that
comes out along with bentonite slurry is passed through channels and is collected in sediment tanks
where sediments settle and bentonite can be re used. If necessary, the bentonite may be passed
through the de sander tank to remove sand particles before it is re used.
J) Depth of pile shall be checked with sounding chain and exact depth shall be recorded in the pile
report.
K) After boring upto required depth underreaming will be done using underreamer of desirable
diameter. Completion of desired bulb cutting will be ascertained by (i) vertical movement of the
handle and (ii) using L shaped rod of length enough to reach upto bulb location from approximately
2 feet above ground level and horizontal dimension equal to 0.5 of bulb dia minus pile dia.
2. REINFORCEMENT CAGE LOWERING
1. Prefabricated reinforcement cage prepared as per the drawings and approved depths,
is brought and kept near pile location while boring is in progress.

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2. After getting the permission from the engineer, the reinforcement cage will be gently lifted and
lowered by crane/manually into the bored hole. Necessary concrete cover will be obtained by
using the circular cover blocks already made of the same strength as of pile.
3. If the reinforcement cage is very long i.e. not possible to handle in one lift, the cage will be lifted
one by one and spot welded at the joints and then lowered inside the bored hole.
4. It is to be checked whether the reinforcement cage has reached up to bottom of the pile by
measuring from the top of the cage to the ground level.
3. FLUSHING
1. After cage lowering, 200 mm diameter tremie pipes in suitable lengths are to be lowered in
the hole. The operation is done by lowering one tremie pipe after another and connecting them
threading to maintain water tightness throughout its length till the gap between the pile base and
Tremie is between75 – 100 mm. the tremie pipe is locked/supported from top to maintain the
level and funnel is attached on top.
2. The tremie head to be provided to the tremie pipe for the flushing activity. The bore is flushed
by fresh bentonite slurry through the tremie head. The pumping for flushing is done by use of
mud circulation pump. Flushing will be done to remove all the loose sediments which might
have accumulated on the founding strata. Further, the flushing operation shall be continued till
the consistency of inflowing and out flowing slurry is similar.
4.PILE CONCRETING
1. The concrete placing shall not proceed if density of fluid near about the bottom of borehole
exceeds 1250 kg/m3
.
2. Determination of the density of the drilling mud from the base of the borehole shall be carried
out by taking samples of fluid by suitable slurry sample approved by the engineer in charge, in
first few piles and at suitable interval of piles thereafter and the results recorded.
3. After flushing is completed, tremie head should be removed and funnel should be attached to the
tremie pipe.
4. The slump of the concrete will be maintained at 150 mm to 200 mm.
5. Concreting operation will be carried out using the 200 mm diameter trmie pipes.
6. Initial charge of concrete should be given in the funnel using a plug. Total concrete quantity in
the funnel should be more than the volume of the entire pipe plus free space below the tremie.
This will ensure a water tight concrete pouring through tremie.
7. Lifting and lowering is repeated keeping sufficient concrete in funnel all the time. As the
concreting proceeds the tremie pipe are to be removed one by one, taking care that the tremie
pipe has sufficient embedment in the concrete until the whole pipe is concreted. Sufficient head
of green concrete shall be maintained to prevent inflow of soil or water in to concrete. Placing of
concrete shall be a continuous process from the toe level to top of pile.
8. The concrete is poured in the funnel. As the concrete reaches the top of the funnel, the plug is
lifted up to allow the concrete to flow corresponding to the placing of each batch of concrete.
9. The concreting of pile is to be done up to minimum of 300 mm above the cut off level to get
good and sound concrete at cut off level.
10. After completion of concreting tremie, funnel and other accessories are to be washed properly
and kept greased in proper stacking condition near next pile location.

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11. While doing under water concreting 10% extra cement over and above the design mix
requirement should be added in each batch.
2) Load test of pile
Routine load test of pile is done here. The pile load capacity is 74 tones. So the test load was 1.5
times of design load i.e.111. a safe cantilege is made to support this test load . this cantilege is
made of a frame of ISMB and then heaped with sand bags. Pressure Gauge and Dial Gauges are
fixed on pile head. Datum bars are also fixed to measure settlement. Load is exerted through
Pressure gauge with the increment of @20% of test load. Reading of settlement is taken with the
increase of load. After final load is put, is kept for 24 hours to get the final settlement. Taking the
final settlement, load is released in same manner.
Load tests on piles are conducted on completion of 28 days after casting of piles. Two types of tests namely
initial and routine tests, for each type of loading viz. vertical, horizontal (lateral) pull out, are performed on
piles.
INITIAL TESTS ON PILES:
This test is performed to confirm the design load calculations and to provide guidelines for setting
up the limits of acceptance for routine tests. It also gives an idea of the suitability of the piling
system. Initial Test on piles are to be carried out at one or more locations depending on the number
of piles required.
Load applied for the initial (cyclic) load test is 2.5 times the safe carrying capacity of the pile.
Loading for Initial Tests is conducted as per Appendix ‘A’ Clause 6.3of IS-2911 Part IV.
ROUTINE TESTS ON PILES:
Selection of piles for the Routine Test is done based on number of piles required subject to
maximum of ½% of total number of piles required. The number of tests may be increased to 2%
depending on the nature / type of structure. The test load applied is 1½ times the safe carrying
capacity of the pile. The Maintained load method as described in Clause 6.2 of IS-2911 (Part
IV) – 1985 shall be followed for loading for the Routine Tests.
This test will be performed for the following purposes:
a) To ensure the safe load capacity of piles
b) Detection of any unusual performance contrary to the findings of the Initial Test.
The tests shall be performed at the cut-off level only. A detailed report for the test result is
prepared.
VERTICAL LOAD TESTS ON PILES

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This test will be carried out as stipulated in IS-2911 (Part IV) 1995.
Pile Head – The pile head shall be chipped off till sound concrete is met wherever applicable.
The reinforcement shall be cut and head levelled with Plaster of Paris. A bearing plate with a
hole shall be placed on the head for the jack to rest.
Reaction- Kentledge shall be suitably designed to get the desired reaction on the piles. Anchor
piles (if required) shall be placed at a centre to centre distance of 3 times the pile diameter
subject to a minimum distance of 2 M.
Settlement- 2 dial gauges for a single pile and 4 dial gauges for a group of piles with 0.01 mm
sensitivity shall be used. They shall be positioned at equal distance around the piles on datum
bars resting on immovable supports at a distance of 3D (min. of 1.5 m) where D is the diameter
of pile or circumscribing circle for non-circular piles.
Application of load- It shall be applied as specified depending on the type of test (routine /
initial). Each load shall be maintained till the rate of displacement of the pile top is either 0.1 mm
in the first 30 minutes or 0.2 mm in the first one hour or 2 hours whichever occurs first. The next
increment in the load shall be applied on achieving the aforesaid criterion.
The test load shall be maintained for 24 hours.
Initial Tests– The safe load on a single pile shall be the least of the following:
(i) 2/3rd
of the final load at which the total displacement attains a value of 12 mm unless
otherwise required in a given case on the basis of nature and type of structure in which case, the
safe load should be corresponding to the stated total displacement permissible.
(ii) 50% of the final load at which the total displacement equals 10% of the pile diameter in case
of uniform diameter piles or 7.5% of the bulb diameter in case of under reamed piles.
Routine Tests – Acceptance
The maximum settlement at test load should not exceed 12 mm.
LATERAL LOAD TESTS ON PILES:
The jack should be placed horizontally, between two piles. The load on the jack shall be the same on
both the piles. The load will be applied in increments of 20% of the estimated safe load and at the
cut off level. The load will be increased after the rate of displacement is nearer to 0.1 mm per 30
minutes. If the cut-off level is approachable, one dial gauge exactly at the cut-off level shall measure
the displacement. In case the cut-off level is not approachable, 2 dial gauges 30 cm apart vertically,
shall be set up and the lateral displacement of the cut-off level calculated by similar triangles.
The safe load on the pile shall be the least of the following:

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a) 50% of the final load at which the total displacement increases to 12 mm.
b) Final load at which the total displacement corresponds to 5 mm.
PULL OUT TESTS ON PILES:
A suitable set up shall be designed to provide an uplift force to the piles. The load increments and
the consequent displacements shall be as per the case of a vertical load test.
The safe load shall be the least of the following:
a) 2/3rd of the load at which the total displacement is 12 mm or the load corresponding to a
specified permissible lift.
b) Half of the load at which the load displacement curve shows a clear break.
3) Hume pipe laying for storm water drainage system
Hume pipe is laying to drain out the storm water of the area. Layout of Hume pipe is along the
service road. So it is necessary to complete the Hume pipe work before starting road works. The
diameter of Hume pipes are 250,300 or 450mm depends upon the road width. It is laid
maintaining a proper slope. Intermittent Catch pits and Inspection are also made simultaneously.
Conclusion: it is not possible to learn the activities in this vast site in one month only. We only
learn some basics of Civil Engineering in this month. Hope this will help us in future.
A BRIEF EXTRA STE EXPERIENCES:
SAFETY:
SPCL has a definite company policy regarding safety of its employees and workers
 Appointment of safety personnel for the project and the formation of a safety committee on site.
 Review of specifications to identify appropriate safety standards and special safety conditions.
 Hazard analysis.
 Emergency plan for obtaining medical assistance, ambulance and direction for rescue operation.
 Safety induction training for every worker, to make them aware of the safety rules and procedures.
 Display of safety signage and caution boards and awareness posters.
 Periodic safety inspection and compliance of observations
 Accident reporting and investigation.

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 Analysis of accidents.
 Safety audit and compliance
QUALITY ASSURANCE AND QUALITY CONTROL:
The company has a well defined quality policy which is to be executed all over its projects as the company is committed
to its customers to meet their expectations in terms of quality and hence the following measures are taken:
 Optimal utilization of men, machine, finance and resources.
 Provision of safe working environment.
 Planning systems for effective implementation.
 Strong organizational support through human resource.
 Development of reliable vendors for higher degree of quality assurance.
 Adherence to project completion schedules.
BIBLIOGRAPHY
www.google.co.in
https://en.wikipedia.org/
Construction Technology by S.Saraswati
NPTEL

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CONCLUSION
Thus through this training of one month with MBL, we learnt a lot about how things go in practise, what are the
problems evoked at the site and above all what are the solutions to those problems faced at site.
The objective with which we have entered into working with this company is believed to have been fulfilled. Not only
that, we also learnt about various site attitude and behaviours, safety provisions and above all understood our subject
construction engineering in a more better fashion.
It was truly a pleasant experience working with MBLPvt. Ltd.
THANK YOU –
(TEAM).

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