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PROJECT REPORT
on
Finishing Work at Welcome Metro Station
(Industry Name: DMRC Ltd.)
Submitted to
Amity School of Engineering And Technology
Guided by: Submitted By:
Mr. Yogesh Kaushik (Faculty Guide) Siddharth Srivastava
Mr. Harish Mishra (Industry Guide) A2315813131
Roll No.: 131
AMITY UNIVERSITY UTTAR PRADESH
GAUTAM BUDDHA NAGAR

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Declaration by the student
I, Siddharth Srivastava student of B.Tech (Civil) hereby declare that the project titled
“Finishing Work at Welcome Metro Station” at Delhi Metro Rail Corporation Limited
(DMRC), which is submitted by me to Department of Civil Engineering, Amity School Of
Engg. And Technology, Amity University Uttar Pradesh, Noida, in partial fulfillment of
requirement for the award of the degree of Bachelor of Technology in 2017, has not been
previously formed the basis for the award of any degree, diploma or other similar title or
recognition. The Author attests that permission has been obtained for the use of any copy
righted material appearing in the Dissertation / Project report other than brief excerpts
requiring only proper acknowledgement in scholarly writing and all such use is
acknowledged.
Noida
Date: Siddharth Srivastava

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Certificate by Faculty Guide
This is to certify that Mr. Siddharth Srivastava, student of B.Tech. in Civil
Engineering has carried out the work presented in the project of the summer training
entitled "Finishing Work at Welcome Metro Station" as a part of final year program
of Bachelor of Technology in Civil Engineering from Amity School of Engg. And
Technology, Amity University, Noida, Uttar Pradesh under my supervision.
Signature of Faculty Guide
(Mr. Yogesh Kaushik)
ASET, AUUP

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ACKNOWLEDGEMENT
I feel very grateful to thank all the people who have helped me directly or indirectly and
supported me in completing my training.
My deepest thanks to my faculty guide, Mr. Yogesh Kaushik, and Mr. Harish Mishra, the
mentor of the project, for guiding and correcting me with attention and care. I greatly
appreciate the efforts he took to go through my data and make necessary corrections as and
when needed.
I also express my thanks to Ms. Madhuri Kumari, The Head of Department (HOD), and Mr.
Prakhar Duggal, The Program leader (PL), for extending their support.
Words are inadequate in offering my thanks to the various helpful people of Delhi Metro Rail
Corporation Limited and Amity University for their encouragement and cooperation in
carrying out the training.
I would also thank my Institution and my faculty members without whom this project would
have been a distant reality.
Finally, yet importantly, I would like to express my heartfelt thanks to my beloved parents
for their blessings, my friends/classmates for their help and wishes for the successful
completion of this project

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ABSTRACT
The fundamental reason for undergoing summer training was to gain practical knowledge
and learn to apply the theoretical knowledge I have gained throughout my course on real life
projects. The training was an enriching experience as I got to learn many things which are
not given in books or taught in classes. This experience has improved my problem solving
skills as I have learned to tackle obstacles that one faces during construction projects. The
training has helped me gain exposure and understand what Civil Engineering is about, and
deepened my interests in this discipline. I have summarized my learnings in this project
report.

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TABLE OF CONTENTS
List of Figures 10
List of Tables 11
1. About The Organization 12
2. Introduction 13
2.1. About Pink Line 13
2.2. About the Contract 14
2.3. About the Project 15
3. Brick Masonry 16
3.1. Purpose 16
3.2. Scope 16
3.3. Material 16
3.3.1. Mechanized Autoclaved Fly-Ash Lime Brick 16
3.3.2. Bricks 17
3.3.3. Cement 17
3.3.4. Sand 17
3.3.5. Water 17
3.3.6. Mortar 17
3.3.7. Scaffolding 18
3.4. Methodology 18
3.4.1. Brick Work 18
3.4.2. Stacking of Bricks 19
3.4.3. Sampling of Bricks 19
3.4.4. Soaking of Bricks 19
3.4.5. Cement Mortar 20
3.4.6. Laying of Bricks 20
3.5. Bricks with RCC 22
3.6. Brick Joint 22
3.7. Skirting of Joints 23
3.8. Wall 23

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3.9. Doors and Windows 23
3.10. Alignment 23
3.11. Lintel and Sunshades 23
3.12. Curing 23
4. Tiling 25
4.1. Purpose 25
4.2. Scope 25
4.3. Material 25
4.3.1. Ceramic/Vitrified Tiles 25
4.4. Methodology 25
4.4.1. Preparation of surface and laying tile 25
4.4.2. Mortar and Bedding 26
4.4.3. Laying of tile on floor 27
4.4.4. Fixing wall tiles for dado/skirting 27
4.4.5. Grouting of Joints in Floor/Skirting/Dado 28
4.4.6. Cleaning 29
4.5. Planning 29
5. Waterproofing 30
5.1. Materials 30
5.1.1. Tapecrete 30
5.2. Waterproofing of Toilets 31
5.3. Waterproofing of Raft and Retaining Walls 31
5.3.1. Stage 1 31
5.3.2. Stage 2 31
5.3.3. Stage 3 31
5.4. Tests 33
6. Kota Stone and Granite Works 34
6.1. Objective 34
6.2. Methodology 34
6.2.1. Fur Granite/Kota Flooring 34
6.2.1.1. Surface and Base Preparations 34

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6.2.1.2. Laying Procedure 34
6.2.2. Polishing 36
7. Painting 37
7.1. Methodology 37
7.1.1. Paint on exterior and interior walls and on other concrete surfaces 37
7.1.1.1. Surface/Base Preparation 37
7.1.1.2. Application procedure painting works 38
7.1.2. White Washing (Lifts/Shafts etc) 38
8. Underground Water Tank 39
8.1. Objective 39
8.2. Construction Methodology 39
8.2.1. Layout Marking 39
8.2.2. Earthworks 39
8.2.3. Binding for Raft 39
8.2.4. Water proofing Stage 1 39
8.2.5. Concreting 39
8.2.6. Waterproofing from inside + tiling 39
8.2.7. Waterproofing from outside 40
8.2.8. Fixing of ladders/footrest as per requirement 40
9. Aluminum Composite Panel 41
9.1. Purpose 41
9.2. Scope 41
9.3. Material 41
9.3.1. Aluminum Composite Panel 41
9.4. Procedure 42
9.4.1. For fixing aluminum cladding sheets 42
9.4.2. Frame for installation of ACP 42
9.4.3. Application of silicone sealant 43
10. Responsibilities 44
10.1. Duties of respective individuals 44
10.2. Organizational Chart 44

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11. Safety 45
11.1. Safety guidelines 45
11.2. Emergency Response Plan 46
12. Lab Tests Performed on Various Building Materials 47
12.1. Sieve Analysis of Fine Aggregate for use in Masonry Mortars and
Concrete 47
12.2. Brick Tests 48
12.2.1. Dimension Tests 48
12.2.2. Water Absorption 48
12.2.3. Compressive Strength Test 48
12.2.4. Efflorescence Test 48
12.3.Granite and Kota Stone test 51
12.3.1. Specific Gravity 51
12.3.2. Water Absorption 51
12.3.3. Compressive Strength 51
12.3.4. Hardness Test 51
13. Conclusion 53
References 54

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LIST OF FIGURES
Figure 1.1. DMRC 12
Figure 2.1. A map of metro network 15
Figure 2.2. Under construction metro station 15
Figure 3.1. Fly Ash Bricks 16
Figure 3.2. Scaffolding on the outside of station walls 18
Figure 3.3. Types of Brick Bond 22
Figure 3.4. Vertical alignment in a brick wall 22
Figure 3.5. Wire mesh in a brick wall 24
Figure 4.1. Roughening mortar for laying tiles 26
Figure 4.2. Fixing floor tile and tapping with a wooden mallet 28
Figure 4.3. Grouting of floor tiles 29
Figure 5.1. Tapecrete 30
Figure 5.2. Applying waterproofing layer 31
Figure 6.1. Junction of polished kota and granite flooring 35
Figure 6.2. Kota stone and granite 35
Figure 6.3. Kota stones laid at platform level 36
Figure 7.1. Sanding the surface before painting 38
Figure 7.2. Whitewashing 38
Figure 9.1. Cutting ACP 42
Figure10.1. Organizational Chart 44
Figure 11.1. Posters to promote safety 45
Figure 11.2. Detailed action plan for emergencies 46

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Figure 12.1. Reporting of sieve analysis results 47
Figure 12.2. Reporting of brick test results 50
Figure 12.3. Reporting of kota stone and granite results 52
LIST OF TABLES
Table 2.1. Pink Line 13
Table 2.2. Contract Details 14
Table 3.1. Sampling of Bricks 20
Table 9.1. Approved shades for ACP 41
Table 10.1. Duties of respective individuals 44
Table 12.1. Reporting of efflorescence test results 49
Table 12.2. Mohr’s Scale of Hardness 51

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CHAPTER 1.ABOUT THE ORGANIZATION
Fig 1.1. DMRC
Delhi Metro Rail Corporation Limited (DMRC) is a state owned company with equal
participation from the Government of India and Government of National Capital Territory
of Delhi. DMRC is responsible for building and operating the Delhi Metro. Delhi Metro
is a metro system serving Delhi metropolitan area and its satellite cities of Gurgaon,
Noida, Faridabad and Ghaziabad in the NCR. Delhi Metro has been ranked second
amongst 18 international metro systems in terms of overall customer satisfaction in an
online customer survey. Delhi Metro is India’s first modern public transportation system,
which has revolutionized travel by providing a fast, reliable, safe and comfortable means
of transport.

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CHAPTER 2.INTRODUCTION
2.1 About Pink Line:
The pink line is an under construction line of Delhi Metro, a part of Delhi Metro Phase
III network. On completion, this will be the longest line with a length of 58.59
kilometers, breaking the record set by operational blue line. It will be mostly elevated
and will be covering Delhi in an almost ‘U’ shaped turn. This is also known as the
‘Ring Road Line’ as the entire line passes alongside the busy Ring Road that witnesses
massive traffic jams every day. The pink line has planned interchanges with all
operational lines of the network such as Yellow, Red, Green, Blue, Orange and Violet
lines, as well as with Hazrat Nizamuddin and Sarai Kale Khan ISBT.
Overview
Type Rapid Transit
System Delhi Metro
Status Under Construction
Locale Delhi, Ghaziabad
Terminal Stations Mukundpur
Shiv Vihar
Stations 38, Elevated: 26, Underground:12
Operation
Opened May 2017
Operator(s) Delhi Metro Rail Corporation
Character Underground and Elevated
Rolling Stock Hyundai-ROTEM Standard Gauge
Technical
Line Length 58.59 kilometers (36.41 mi), Elevated 39.48 kilometers
(24.53 mi), Underground 19.11 kilometers (11.87 mi)
Track Length 58.59 kilometers (36.41 mi)
Track Gauge Standard Gauge
Electrification 25 kV, 50 Hz through overhead catenary
Table 2.1. Pink Line

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2.2 About The Contract:
Tender No. CC-12
Item/Nature of Work Construction and design of elevated
viaduct and 6 elevated stations viz.
Krishna Nagar, East Azad Nagar,
Welcome, Zafrabad, Maujpur and
Gokulpuri
Mode of Tender Enquiry Pre-qualified
Type of Bidding Single Bid
Last Date of Receipt of Tender 13.02.2012
No. of Tender Received 10
No. and name of parties qualified after
tech. evaluation
1. M/S L&T Limited
2. M/S J. Kumar-MMS JV
3. /S IJM-IJMI UEMB JV
4. M/S SACYR Unity JV
5. M/S Simplex Infrastructures Ltd.
6. M/S HCCLtd.
7. M/S Gammon India Ltd.
8. M/S JMC-CHEC JV
9. M/S Afcons Infrastructure Limited
10. M/S OHL-Punj Lloyd JV
Date of LOA 11.04.2012
Name of Contractor JMC-CHEC JV
Value of contract (Crore) 398.34
Table 2.2. Contract Details

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2.3. About The Project:
The training focused on finishing work at Welcome Metro Station, as the construction
of structures was completed. The new elevated Welcome station (Pink Line) stands
next to an existing Welcome station (Red Line) and will serve as an interchange
station.
Fig. 2.1. A map of Metro Network. Welcome Metro Station shown in a Red Circle.
Fig. 2.2. Under construction metro station (pink box) beside existing station

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CHAPTER 3.BRICK MASONRY
3.1.PURPOSE
The purpose of this procedure is to prepare construction sequence of brick masonry as
per specifications and maintain good workmanship.
3.2.SCOPE
The procedure establishes the materials, dressing, laying, joining, curing, workmanship
etc. for Brick masonry work.
3.3.MATERIAL
3.3.1. Mechanized Autoclaved Fly-Ash Lime Brick:
These bricks shall be machine molded and prepared in plant by appropriate
proportion of fly ash and lime. The autoclaved fly ash bricks shall conform to IS
12894. Visually, the bricks shall be sound, compact, and uniform shape, free fro
visible cracks and organic matters. The bricks shall be solid with or without frog
and of 100/80mm length, 40mm width, and 10-200mm deep one of its flat side as
per IS 12894. The brick shall have smooth rectangular faces with sharp corners
and shall be uniform in shape and color. Fly ash shall conform to IS 3812 and lime
content conforms to class-C hydrated lime of IS 712. Brick work with burnt
clay/fly ash bricks conforming to IS 1077, IS 13757 of class designation 10 in
cement mortar 1:4.
Fig. 3.1. Fly Ash Bricks

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3.3.2. Bricks:
Brick shall be class designation 10 and conforms to standard specification, regular
in shape and size with sharp edges and corners. Frog of the bricks shall be less
than 1cm and greater than 2cm. Bricks should give clear metallic ringing sound
and water absorption shall not be more than 20% by weight. Bricks shall have an
average compressive strength of not less than 105 kg/sq cm.
The sampling of bricks shall be as per IS5454.
3.3.3. Cement:
Cement shall be OPC (Ordinary Portland Cement) Grade 53 conforming to IS
8112. Cement shall be fresh when delivered at site.
3.3.4. Sand:
Sand for masonry mortar shall be natural sand, crushed stone sand or crushed
gravel sand or combination of any of these conforming to IS 2116-1980. Sand shall
be hard durable, medium coarse sand, clean sharp and free from clay, sand shall
be screened/sieve by 4.75mm sieve.
3.3.5. Water:
Water used for brickwork should be clean and free from injurious amount
deleterious materials. Constructive water shall be used be used for masonry work.
It shall conform to IS 456:2000.
3.3.6. Mortar:
Cement mortar shall be done by Mechanical mixer and if hand mixing is done then
10% extra should be added according to CPWD specification. The required
quantity of water shall then be added and the mortar holds back and forth for 5 to
10 minutes with addition of water to a workable consistency. Mortar with cement
shall be used as early as possible after mixing preferably from half an hour from
the time water is added to mix or at the latest within an hour of its mixing.

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3.3.7. Scaffolding:
Scaffolding shall be rigid to withstand all dead, live and impact loads which are
likely to come on them. Scaffolding shall be provided to allow easy approach to
every part of the work. Bamboos shall not be used for external scaffolding. M/S
scaffolding chair shall be used for internal scaffolding. For exposed brick facing
double scaffolding having two sets of vertical supports shall be provided. The
supports shall be sound, strong and tied together with the horizontal pieces over
which scaffolding pieces shall be fixed.
Fig. 3.2. Scaffolding on the outside of station walls
3.4. METHODOLOGY
3.4.1. Brick Work:
 Best quality bricks should be well burnt clay/fly ash and even color.
 When struck with something r each other it will sound clearly.
 Bricks of different types, such as clay bricks, clay fly ash bricks, fly ash lime
bricks, sand lime (calcium silicate) bricks, auto-clave bricks etc. shall be
stacked separately. Bricks of different classification and size consideration
(such as conventional and modular) shall be stacked separately. Also bricks of
different types such as solid, hollow and perforated shall be stacked separately.
 Should not absorb water more than 20% by weight.

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 Good bricks should be sufficiently hard. Quality bricks should not break when
dropped flat on hard ground from a height of about one meter.
3.4.2. Stacking of Bricks:
 Bricks shall be stacked in regular tiers as and when they are unloaded to
minimize breakage and defacement.
 Bricks stacks shall be placed close to the site of work so that least effort is
required to unload and transport the bricks again by loading on pallets or in
barrows as per IS 4082.
 Bricks shall be stacked on dry firm ground.
 Clear distance between adjacent stacks shall not be less than 0.8m. Bricks of
each truck shall be put in one stack as per IS4082.
3.4.3. Sampling of Bricks:
 The bricks shall be selected and inspected for each lot separately for
ascertaining their conformity to the requirements of the relevant specification.
 The number of bricks to be selected from a lot shall depend on the size of the
lot and shall be in accordance with column 1 and 2 of table given below for
visual characteristics in all cases and dimensional characteristics if specified for
individual brick. In case dimensions are specified for a group of 20 bricks, the
scale of sampling for dimensional characteristics shall be in accordance with
col 1 and 4 of the table. All these bricks shall be selected following the methods
detailed in 3 as per IS 5454.
 Visual characteristics: All the bricks selected above shall be examined for
visual characteristics. If the number of defective bricks found in the sample is
less than or equal to the corresponding number, the lot shall be considered as
satisfying the requirements of the visual characteristics. However, if the number
of defective bricks in the sample is greater than the corresponding permissible
number of defectives, the lot shall be deemed as not having met the visual
requirements as per IS 5454.

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Table 3.1. Sampling of Bricks
No. of bricks
in the lot
For characteristics specified for
individual brick
For dimensional characteristics
specified for group of 20
bricks- No. of bricks to be
selected.
No. of bricks to
be selected
Permissible no. of
defectives in the
sample
(1) (2) (3) (4)
2001-10000 20 1 40
10000-35001 32 2 60
35001-50000 50 3 80
3.4.4. Soaking of Bricks:
 Brick shall be soaked in water before use for a period for the water to just
penetrate the whole depth of the bricks. Alternatively, bricks shall be adequately
soaked in stacks by profusely spraying with clean water.
 Soaked bricks shall be stacked on a clean place where they are not again spoiled
by dirt, earth, etc. as per IS 4082.
3.4.5. Cement Mortar:
 Make sure cement mortar is mixed properly in dry condition on a clean place.
 Check mixing ratio is properly maintained.
 Check clean drinking water is mixed.
 Make sure the mixed mortar is used within one hour after adding water, if you
want, you can maintain register for tracking mixing time and ratio.
3.4.6. Laying of Bricks:
 All loose materials, dirt and set lumps of mortar which may be laying over the
surface on which brickwork is to be freshly started shall be removed with a wire

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brush. Brick shall be laid on a full bed of mortar. The mortar joint shall be
10mm to 12mm in thickness.
 When laying the bricks shall be properly bedded and slightly pressed with
handle of trowel so that the mortar can get in to all the pores of the brick surface
to ensure proper adhesion.
 All the joints shall be properly flushed and packed with mortar so that no hollow
spaces are left. Care shall be taken to see that the required quantity of water is
added to the mortar at the mixing platform to obtain required consistency.
Addition of water during laying of the courses hall is not permitted.
 For walls two brick thick and over the joints shall be grouted at every course in
addition to bedding and flushing with mortar.
 Bricks shall be laid with frog up however when the top course is exposed, brick
shall be laid with frog down and care be taken to fill the frogs with mortar before
embedding the bricks in position.
 Not more than 12 course of bricks shall be laid in a day work.
 Raking shall be done with 6 to 10 mm depth.
 Brick masonry & RCC structure joint shall be made by putting a wire mesh of
25x25mm before plaster work activity.
 For half brick work wall shall be reinforced at every 4th
course with 2Nos. 6mm
dia bars well bedded in mortar. Top layer of masonry shall be constructed after
three days.
 All brick work shall be built in English bond with frog upward. Half brick wall
shall be built in stretcher bond.
 Header bond shall be used for walls curved on plan for better alignment. Header
bond shall also be used in foundation footings, stretchers may be used when the
thickness of wall is more.

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Figure 3.3. Types of Brick Bond
3.5. Bricks with RCC:
 Check RCC surface is properly chipped and applied grout on surface where
brick will touch with RCC.
3.6. Brick joint:
 Don’t make bricks joint bigger than half-inch.
 Make sure vertical joints in alternate courses are truly vertical depending on
“types of brick bond pattern.” Check horizontal joints are truly straight.
Figure 3.4. Vertical alignment in a brick wall

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3.7. Skirting of Joints:
 Where no pointing, plastering or other finish is indicated the green mortar shall
be neatly struck and flush. Where pointing, plastering or other finish is
indicated, the joints shall be squarely raked out to a depth not less than 10mm
for plastering and 15mm for pointing.
3.8. Wall:
 Check wall is located as per drawing at the time of making brick layout,
 Don’t make wall above 5 feet in same day
3.9. Doors and Windows opening:
 Check door and window location are kept as specified in the drawing.
 Make sure openings are bit bigger than specified in drawing.
3.10. Alignment:
 Check vertical alignment of every three courses of brick wall with plumb bob.
3.11. Lintel and sunshade:
 Check lintel and sunshade above opening are made as per design specification.
 Check sunshade dimensions are kept as per drawing.
 Make sure cat door opening is kept in wall of false ceiling as specified in the
drawing.
3.12. Curing:
 Check brick wall is cured for at least seven days with clean water.

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After making brick wall we are to start groove cutting for electrical and plumbing piping.
But this work should not be started before ending curing period of wall. Another thing, if
concrete and brick joints may develop cracks in plaster then you should use wire mesh
there before doing plaster.
Fig. 3.5. Wire mesh in brick wall

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CHAPTER 4.TILING
4.1.PURPOSE
The purpose of this procedure is laying or floor & wall tiles in the station building as
per specifications for DMRC Package CC-12.
4.2.SCOPE
This procedure covers the material for tiling work, surface preparation, mortar and
bedding, laying, grouting of joints and cleaning etc.
4.3.MATERIAL
4.3.1. Ceramic/Vitrified Tiles: The tiles shall be of approved make. The tiles shall be
flat and true to shape and free from cracks, blisters, welts, crawling, crazing spots,
chipped edges, corners or other imperfections detracting from their appearance. The
glazing shall be of uniform shape. The tiles shall be of square or rectangular of nominal
sizes as mentioned in schedule of quantities and as directed. Tolerance in thickness
shall be ±0.4mm. The underside of tiles shall not glaze on more than 5% area in order
to have proper adherence to the back.
4.4.METHODOLOGY
4.4.1. Preparation of surface and laying tile:
 Subgrade concrete or RCC slab or side brick wall/or plastered surfaces on which tiles
are to be laid shall be cleaned, wetted and mopped as specified for tile flooring or
dado.
 The bedding/backing for the tiles shall be of cement mortar 1:3 or as specified and
shall be applied and allowed to harden. The mortar shall be roughened with wire
brushes or by scratching diagonal lines 1.5mm deep at 7.5 mm center both ways.
 The back of the tiles shall be buttered with a coat of grey cement slurry paste and edges
with cement slurry and set in the bedding mortar.
 The tiles shall be tapped gently with wooden mallet and corrected to proper level and
lines.

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 The tiles shall be butt joined in pattern and joints shall be as fine as possible. The top
of skirting/dado shall be truly horizontal and joints vertical.
 After a period of curing the tiles shall be cleaned and not sound hollow when tapped.
 Tiles shall enter not less than 10mm under side skirting.
 After the tiles have been laid, surplus cement grout shall be cleaned off.
Fig. 4.1. Roughening mortar for laying tiles
4.4.2. Mortar & Bedding:
 Cement mortar for bedding shall be proportion 1:4 for vitrified tiles and 1:3 for dado
wall tiles as specified in BOQ and shall conform to the specification for materials.
 The amount of water added while preparing mortar shall be the minimum necessary
to give sufficient plasticity for laying.
 Care shall be taken in preparation of the mortar to ensure that there are no hard lumps
that would interfere with even bedding of the tiles.
 Before spreading the mortar bed, the base shall be cleaned of all dirt, scum or laitance
and loose materials and well wetted without forming any pools of water on the surface.

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 The mortar of required proportion and required thickness as per BOQ shall then be
even and smoothly spread over the base by the use of screed battens to proper level or
slope.
4.4.3. Laying of tile on floor:
 The tiling work shall be done as per the pattern directed by engineer in charge.
 Start point of tile fixing shall be followed in accordance to the drawings issued. Cut
tiles if any shall be laid along wall with necessary border pattern.
 Grey cement slurry to the back of the tile is to be applied to enure proper and full
bedding.
 The tiles shall be laid on the bedding mortar when it is still plastic but has become
sufficiently stiff to offer a fairly firm cushion for tiles.
 Tiles, which are fixed on the flooring adjoining the wall, shall be so arranged that the
surface on the round edge tiles shall correspond to the skirting or dado.
 Press gently the tiles with wooden mallet for even adherence at the back of the tiles.
Don’t use an iron hammer or some heavy material to press the tiles.
 The edges of the tiles shall be smeared with neat cement slurry and fixed in this grout
one after the other, each tile being well pressed and gently tapped with a wooden
mallet till it is properly bedded and in level with the adjoining tiles.
 There shall be no hollows in bed joints. The joints shall be kept as close as possible
and in straight line the width of the joint shall not exceed 1mm. Unless specified joint
less tiling shall be done butting the tiles with each other.
 The joints shall be grouted with white/matching color cement slurry.
4.4.4. Fixing wall tiles for dado/skirting:
 The fixing of tiles on wall surfaces shall be done only after completing fixing of the
tiles on the floor.
 The back of the tiles shall be cleaned off and covered with layer of cement slurry with
proper troweling as per manufacturer’s recommendations.

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 The edges of the tiles shall be smeared with the slurry and fixed on the wall one after
the other, each tile being well pressed and gently tapped with a wooden mallet till it is
properly fixed level with the adjoining tiles.
 While fixing tiles in dado/skirting work, care shall be taken to break the joints
vertically. The top line shall be touched up neatly with the rest of the plaster above.
 If doors, windows or other openings are located within the dado area, the corners, sill
jambs etc. shall be provided with true right angles without any error.
 The fixing shall be done from bottom of wall upward without any hollows in the bed
joints. Each tile shall be as close as possible to one adjoining. All tile faces shall be
one vertical plane.
Fig. 4.2. Fixing floor tile and tapping with a wooden mallet
4.4.5. Grouting of Joints in Floor/Skirting/Dado:
 The joints, if specified, shall be cleaned off and all dust and loose particles removed.
 Joints shall then be filled with grouts. After finishing the grouting process, after 15
minutes, wipe off excess grout with a damp sponge and polish the tiles with a soft and
dry cloth for a clean surface.
 The finished work shall not sound hollow when tapped with a wooden mallet.

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Fig. 4.3. Grouting of floor tiles
4.4.6. Cleaning:
 The tiles shall be cleaned by mild acid (however, hydrofluoric acid and its derivatives
should not be used). After the tiles have been laid in a room or the days fixing work is
completed, the surplus cement grout that may have come out of the joints shall be
cleaned off before it sets.
4.5.PLANNING
Planning, preparation and execution of the woek shall be as per a defined schedule,
following the sequence detailed mentioned above. Only latest revisions of drawings
are to be used. All concerned team shall participate in a short daily site meeting,
coordinating activities and optimizing performance.

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CHAPTER 5.WATERPROOFING
The waterproofing treatment shall be done on smooth plastered surface on brickwork only.
Portland cement shall be used for the plastering.
The plastered area shall be cured for a minimum of 7 days. Curing shall be done by
keeping wet gunny or ponding water.
The surface shall be allowed to dry for about 4 to 6 weeks after the curing period is over.
The surface on which waterproofing is to be done shall be dry, free of all dust, loose
material, laitance etc. A surface dry area shall not be constructed as being totally dry.
It should be ensured that everything where the waterproofing is worked round or into are
fixed (eg. Rainwater downtakes, etc.) in position and all pre waterproofing application
work is complete.
5.1.MATERIALS
5.1.1. Tapecrete: It is an acrylic based polymer modified cementation composite coating
system manufactured by CICO or approved equivalent.
Fig. 5.1. Tapecrete

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5.2.WATERPROOFING OF TOILETS
Waterproofing treatment of floor slabs, walls and chajjas. Roof projections, toilets,
kitchens, etc. in the building is done as described:
1. First layer of cement slurry @0.488 Kg/m2
mixed with tapecrete @0.253Kg/m2
is
applied with brush and is allowed to air dry for 4 hours.
2. Thereafter second layer of cement slurry @0.242Kg/m2
mixed with tapecrete
@0.126Kg/m2
is applied with brush and is allowed to air cure for 4 hours followed
by water curing for 48 hours.
3. A layer of 12 mm plaster as protective layer is applied if required.
Fig. 5.2. Applying waterproofing layer
5.3.WATERPROOFING OF RAFT AND RETAINING WALLS
Waterproofing of raft and retaining walls by box type waterproofing method.
External tanking of basement, trenches, tunnel, etc. is carried out using tapecrete is
stages as given below:
5.3.1. Stage 1: After the lean concrete has been laid to receive the RCC raft, a 345
mm thick brick toe wall in cement mortar 1:6 shall be constructed, on the
perimeter of the area to be water proofed. The height of this wall shall be equal
to the thickness of the RCC raft.
5.3.2. Stage 2:
Base: The external tanking treatment is carried out for the base raft over
the lean concrete in the following sequence.

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a. A layer of cement slurry mixed with tapecrete shall be spread over the
lean concrete.
i. In each layer where tapecrete is to be used it shall be mixed in the
ratio of 400 grams per 50kg of cement.
ii. Thereafter a 25mm thick bedding layer of cement mortar 1:3 mixed
with tapecrete shall be laid.
iii. Curing shall be done by spraying for 7 days.
iv. A layer of 25mm thick rough Kota stone slab of approximately
600x600mm and having minimum thickness of 20mm is laid. The
joints between the stones shall be 6-100mm. After laying the joints
shall be raked and sealed with cement mixed acrylic waterproofing
compound in ratio of 1:1.
v. A layer of cement mortar 1:4 mixed with tapecrete shall be laid and
finished smooth.
vi. The top surface is finished with stone aggregate of 10 to 12mm
nominal size by spreading @8cudm/m2
thoroughly embedded in 2nd
layer.
vii. Curing is done by spraying for 7 days.
viii. The waterproofing is turned up along the brick wall on the perimeter
of the basement raft. The work is carried out as described under
walls.
5.3.3. Stage 3: External tanking of walls
After the completion of the RCC raft and retaining walls upto the ground
floor level, external tanking of external surface of retaining walls shall be
carried out in the following sequence. The external tanking layer for the
walls has an overlap over the external tanking layer provided along the
brick toe wall in stage 2 and the joint sealed.
i. A layer of rough kota stone slabs of approximately 600x600mm and
having a minimum thickness of 20m are laid with with a gap of 20mm

33. Page | 33
between the wall and the stone. This gap is filled with cement slurry
mixed with tapecrete in ratio 1:1
ii. The joints of the stone tiles are compacted and any improperly filled
joints are raked and sealed with cement mixed with tapecrete.
iii.Curing is done by spraying for 7 days.
iv.Thereafter a 15mm thick layer of cement mortar 1:4 mixed with
tapecrete is splashed on the exterior surface of the stone wall to cover
the stone and joints thoroughly and uniformly.
5.4.TESTS
The treated area (flat and horizontal only) is tested by allowing water to stand on the
treated area to a depth of 150m for a minimum period of 48 hours. A guarantee of 15
years for waterproofing work carried out by contractor is provided on a non-judicial
stamp paper.

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CHAPTER 6. KOTA STONE AND GRANITE WORKS
6.1.OBJECTIVE
The purpose of this procedure is laying of kota and granite.
6.2.METHODOLOGY
6.2.1. Fur Granite/Kota Flooring:
6.2.1.1. Surface and Base Preparations:
 The surface is cleaned, wetted and mopped.
 Cement slurry of required workability should be spread over the concreting surface.
 Screed concrete/PCC should be laid in mix of 1:4:8. The nominal thickness of PCC
should be 100mm in proper slope.
 The bedding for the slabs shall be with cement mortar 1:4. Average thickness of the
bedding shall be 20mm.
 Curing period of PCC will be 7 days.
6.2.1.2. Laying Procedure:
 Cement mortar of the 1:4 mix shall be spread under the area of each slab, upto 20mm
thick for Kota stone and 15mm thick for granite stone. The stones are cut to the
required size and cleaned before laying.
 Over cement mortar, 5mm thick bed of cement paste of required workability will be
laid.
 The stones shall be laid on top, pressed, tapped with wooden mallet and brought to
level with the adjoining stones. It shall be lifted and laid aside. The top surface of the
mortar shall then be corrected by adding fresh mortar at hollows.
 The mortar is allowed to harden a bit and cement slurry of honey like consistency shall
be spread over the same at the rate of 44.4kg cement per square metre. The edges of
the stone already paved is buttered with grey cement with admixture of pigment to
match the shade of the stone. The stone to be paved is lowered gently back in position
bedded in level.

35. Page | 35
 Subsequent stones shall be laid in the same manner and joints between adjacent stones
is made as thin as possible and run in straight line. After each stone has been laid, they
are joined and surplus cement grout coming out of the joints of the stones is cleaned
off.
 Granite stone on wall is cladded with the help of expanded steel anchor bolt as per
specification bolted to the wall and clamped in the grove provided in the stone.
Fig. 6.1. Junction of Polished Kota and Granite Flooring
Fig. 6.2. Kota stone (left) and granite (right)

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6.2.2. Polishing:
 All granite stones shall be pre-polished and kota stones shall be polished two times
after laying on floor.
 If any slab is disturbed or damaged, it shall be refitted or replaced, properly joined and
polished. The finished floor should not sound hollow when tapped with wooden
mallet.
Fig. 6.3. Kota stones laid at platform level

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CHAPTER 7. PAINTING WORKS
7.1.METHODOLOGY
7.1.1. Paint on Exterior and Interior walls and on other concrete surfaces:
7.1.1.1. Surface/Base Preparation:
 Primer of one coat has to be applied on the plastered surface.
 Allow the primer coat to dry and get smoothened.
 Smoothen the surface by a thin coat of putty if required.
 Putty will be prepared by adding 40-50% of clean water to putty and mix thoroughly
to get homogenous mixture, this paste is allowed to stand for 15 minutes before
application. Try to use the mixed putty in 3 hours.
 Sand the surface with emery paper.
 Painting shall be deferred until the plastered wall and outer concrete surfaces are
completely dry.
 All honeycombing, cracks, pin holes, and surface defects and uneven surfaces, if any
are repaired before starting of painting to have plain and good finish.
 The wall/ceiling surfaces to be painted should be cleaned by removing masking tape
used for shuttering joints, loose particles, slurry leakages, mortar drippings, etc using
wire brush/corundum stone.
 While doing the painting works, it shall be ensured that the remaining areas to be
covered/protected properly from damages.
 Paint will be applied either by using brush or by using roller or by any other
conventional spray.

38. Page | 38
Fig. 7.1. Sanding the surface before painting Fig.7.2. Whitewashing
7.1.1.2. Application procedure painting works:
 The first coat of approved paint of required consistency to be applied in both directions
as per specification starting from top over the prepared surfaces with a brush.
 The second/final coat of paint with required consistency to be applied by brush
minimum after 24 hours of first coat is completed and cured properly.
 The finished surface is kept wet for curing.
 After completion of painting work, any paint stains on the floor/doors/windows/other
surfaces, if any, are removed and entire area is cleaned.
7.1.2. White washing (Lifts/shafts etc.):
 White wash shall be done on smoothened base surface.
 Application of white wash shall be done on both directions.
 White wash shall be done 1st
and final coat.
The finished dry surfaces shall not show any signs of cracking and peeling nor shall
it come off readily on the hand.

39. Page | 39
CHAPTER 8. UNDERGROUND WATER TANK
8.1.OBJECTIVE
This procedure covers the sequence of works involved in the construction activity of
underground water tank.
8.2.CONSTRUCTION METHODOLOGY
8.2.1. Layout Marking: Layout need to be marked before starting the
excavation, after layout marking from underground utilities are checked &
relocated if required. After confirming from all the agencies excavation is
started.
8.2.2. Earth works: Earth works need to be started with proper safety precautions
such as hard barricading, deep excavation sign boards and earth shoring to
prevent the collapse.
8.2.3. Binding for raft: After excavation, watering and proper compaction of the
earth need to be executed. After proper compaction binding can be done.
8.2.4. Water proofing-stage 1: After the lean concrete has been laid to receive
the RCC raft, a 345 mm thick brick toe wall in cement mortar 1:6 shall be
constructed, on the perimeter of the area to be water proofed. The height of
this wall shall be equal to the thickness of the RCC raft.
8.2.5. Concreting: Rest of the concreting works need to be executed as per the
latest structural drawing issued at site. Before concreting architectural water
tank drawing need to be referred for installing the provision of sleeves in
the wall.
8.2.6. Water proofing from inside+tiling: After completion of deshuttering,
concrete surface is cleaned and waterproofing is done as per methods

40. Page | 40
mentioned in waterproofing section. Inside the tank after applying
waterproofing compound, an approved tile is fixed throughout the tank
except internal roof surface.
8.2.7. Waterproofing from outside: This is executed as per waterproofing
methodology.
8.2.8. Fixing of ladders/foot rest as per requirement.

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CHAPTER 9. ALUMINUM COMPOSITE PANEL
9.1.PURPOSE
This method statement describes the detailed procedure adopted for fixing aluminum
composite panels (ACP) in the construction of the station.
9.2.SCOPE
This procedure covers the material for fixing ACP for cladding with necessary frame
works at:
i. Concourse to platform levels.
ii. Concourse to platform level, concourse area.
9.3.MATERIAL
9.3.1. Aluminum Composite Panel: The panel should consist of thermoplastic core
of antioxidant LDPE sandwiched between skins of aluminum sheet making a total
panel thickness of 4mm. The surface will be finished with PVDF based coating on top
sides and service coating on reverse side would be in polymer paint.
Table 9.1. The approved shades are as below: For external ACP works
Station Shade/Color of ACP
Krishna Nagar Station Dark grey/Stone Black-AL625
East Azad Nagar Station Metallic Rose/Copper Bronze- AL621
Welcome Pearl White AL-630
Jaffarabad Metallic rose/Copper bronze A-621
Gokulpuri Metallic rose/Copper bronze A-621
*Internal ACP will be RAL-3014 (antique pink) for all the stations.

42. Page | 42
9.4.PROCEDURE:
9.4.1. For fixing of aluminum cladding sheets need to be converted into
“cassettes” as follows:
i. Aluminum composite panel sheet is cut into the required size.
ii. A ‘V’ shaped groove of 3.2mm depth is made through the inner skin leaving a
0.3mm thick polyethylene layer and the outer 0.5mm thick aluminum skin
undisturbed. The groove is made on all 4 edges of the cut sheet
iii. Folding the sheet along the groove on all the 4 sides and punching out the
overlapping corners of the “cassette” thus formed. The return or the fold back
of this cassette for the required depth.
iv. These cassettes are then installed on a frame of the aluminum sections pre-
installed on the dead wall.
Fig. 9.1. Cutting ACP into required size and making grooves in them
9.4.2. Frame for installation of Aluminum composite panels:
i. 25x38x2mm aluminum RHS sections (runner) are installed in a vertical or
horizontal direction on the dead wall. These aluminum tube sections are

43. Page | 43
installed on aluminum brackets to facilitate movement in horizontal direction
to achieve a true line and level. Brackets are fixed to the wall to be cladded by
means of fasteners.
ii. These panels are in turn installed to these vertical or horizontal aluminum
runners by means of angle cleats pre-installed on the return or fold back of the
panels.
9.4.3. Application of (weather) silicone sealant in the grooves formed after
installation of panels:
i. A groove of dimension for
ACP to ACP: 12mmx25mm
ACP to stone cladding: varies as per site condition
ii. These grooves are sealed with silicone sealant after application of masking tape
and polyethylene backer rod.

44. Page | 44
CHAPTER 10. RESPONSIBILITIES
10.1. Duties of respective individuals
Table 10.1
Site-In charge Shall report to the Project Manager. Shall be responsible for
control, safety systems, supervisions and directions for
implementation.
Site-engineer Shall report to the Project Manager/Site-In charge. Shall carry out
the work as per the drawings and specifications.
QA/QC
Engineer
Shall report to the Project Manager. Shall carry out lab, field
inspection/checking.
10.2. Organizational Chart
Figure 10.1. Organizational Chart
PROJECT
MANAGER
Somesh Pandey
SHE MANAGER
Suman Kumar
ASE Mr. Harish
Mishra
SR. SAFETY
OFFICER Day
Nitesh Kumar
Mr. Amit- FIRST
AIDER
SAFETY OFFICER
Night Rajan
Kumar
EXECUTION
INCHARGE Kailash
Nayak
QA/QC MANAGER
Naveen Sinha
EXECUTION
ENGINEER DAY
Shivraj
SUPERVISOR Mr.
Veeru
EXECUTION
ENGINEER NIGHT
Mr. Raghuvendra
SUPERVISOR- Mr.
Paul

45. Page | 45
CHAPTER 11. SAFETY
11.1. Safety guidelines
This work shall be carried out as per the guidelines of project safety manual. However,
the following specific safety precaution shall be taken.
 Experienced team shall be engaged for all the activities.
 The tools and tackles used for the works shall have test certificates for the
safe carrying loads.
 Proper precaution and safety devices shall be used for activities like
fabrication, handling of electrically operated equipments etc.
 All site personnel shall follow the safety health and environment policy of
the company and client.
Fig. 11.1. Posters at the entry to promote safety.

46. Page | 46
11.2. EMERGENCY RESPONSE PLAN
Fig. 11.2. Detailed action plan as shown shall be followed in an event of emergency.

47. Page | 47
CHAPTER 12. LAB TESTS PERFORMED ON VARIOUS BUILDING MATERIALS
12.1. Sieve Analysis of Fine Aggregate for use in Masonry Mortars and Concrete
This test is done as per specifications given in IS:2386(Part-1)-1963. Sieve Analysis
helps to determine the particle size distribution of aggregate. In this test, different IS
standardized sieves are arranged in decreasing order of size and aggregate is passed
through them. The aggregate retained on each sieve is then weighed. The sample
should be prepared from a larger sample by quartering or by means of a sample
divider.
Fig. 12.1. Reporting of Sieve Analysis results

48. Page | 48
12.2. Brick Tests
12.2.1. Dimension Test
A number of bricks are selected at random (see sampling of bricks) to check
measurement of length, width and height. These dimensions are to be measured
in one or two lots of equal number of bricks each. Variation in dimension are
allowed only within narrow limits
12.2.2. Water Absorption
A sample number of bricks are taken and weighed dry and average weight of
the bricks is calculated. Bricks are then immersed in water for a period of 24
hours. After 2 hours of immersion, bricks are weighed again and average of the
bricks is calculated. The difference of final average weight and initial average
weight indicates the amount of water absorbed by the bricks. It should not, in
any case, exceed 20% of average weight of dry bricks.
12.2.3. Compressive Strength Test
Three number of whole bricks from sample collected should be taken and their
dimensions should be measured to the nearest 1mm. They should be
smoothened and immersed in water at room temperature for 24 hours. Remove
specimen and drain surplus moisture. Fill frog and all voids with cement mortar
(1:1). Store under damp jute bags for 24 hours filled by immersion in clean
water for 3 days. Remove and wipe any traces of moisture and test the bricks
under Compressive Testing Machine.
Compressive Strength= Maximum load at failure(N)/Average area of bed face
(mm2
).
12.2.4. Efflorescence Test
The test is conducted in a well ventilated room. The brick is placed vertically
in a dish 30cmx20cm approximately in size with 2.5 cm immersed in distilled
water. The whole water is allowed to be absorbed by the brick and evaporated

49. Page | 49
through it. After the bricks appear dry, a similar quantity of water is placed in
the dish, and the water is allowed to evaporate as before. The brick is to be
examined after the second evaporation and reported as follows:
Nil When there is no perceptible deposit of salt.
Slight When not more than 10% of the area of bric is covered with salt
Moderate When there is heavy deposit covering more than 50% of the area
of the brick but unaccompanied by powdering or flaking of the
surface
Heavy When there is heavy deposit covering more than 50% of the area
of the brick accompanied by powdering or flaking of the surface
Serious When there is heavy deposit of salts accompanied by powdering
and/or flaking of the surface and this deposition tends to increase
in the repeated wetting of the specimen
Table 12.1. Reporting of efflorescence test results

50. Page | 50
Fig. 12.2. Reporting of Brick Test results

51. Page | 51
12.3. Granite and Kota Stone test
12.3.1. Specific Gravity
The specific gravity is considered to be a measure of strength or quality of the
material. Stones having low specific gravity are generally weaker than those
with higher specific gravity values.
12.3.2. Water Absorption Test
12.3.3. Compressive Strength Test
12.3.4. Hardness Test (Mohr’s Scale)
Hardness is a measure of mineral’s resistance to abrasion and is measured
against a standard scale- Mohr’s scale of hardness. Its consists of 10 fairly
common minerals (except for diamond) of known hardness which are
numerically ordered from softest (1) to hardest (10). As common sense dictates
Mohr’s scale is based on the fact that a harder material will scratch a softer one.
By scratch test, one can determine relative hardness of an unknown material.
Table 12.2. Mohr’s Scale of Hardness
Talc
(H=1)
Gypsum
(H=2)
Calcite
(H=3)
Flourite
(H=4)
Apatite
(H=5)
Orthoclase
(H=6)
Quartz
(H=7)
Topaz
(H=8)
Corundum
(H=9)
Diamond
(H=10)

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Fig. 12.3. Report of Kota and Granite Stone Results

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CHAPTER 13. CONCLUSION
My training at DMRC has been enriching and this experience has been very valuable to
me. I enjoyed my position and gained good first-hand experience on various aspects of
Civil Engineering discipline. This training has also taught me what it is like to work at a
reputable firm at DMRC feels like, and how exciting it is to be a part of big projects. My
interests in the field of Civil Engineering have deepened even further with this experience
and it is clear that this was a great start for my dream career.
This experience has also taught me that learning is an endless process, and there is so
much left to learn.
I have acquired many skills in my arsenal and sharpened the ones that I already had
including creativity, innovation, leadership, working in a team based environment,
problem solving both on and off site.

54. Page | 54
REFERENCES
[1] DMRC Website: www.delhimetrorail.com
[2] JMC-CHEC JV Website: www.jmcprojects.com
[3] www.civilsimplified.com
[4] Wikipedia: en.wikipedia.org/wiki/Pink_Line_(Delhi_Metro)
[5] Google Maps: maps.google.com
[6] Indian Standard Codes
 IS12894: Pulverized Fuel Ash-Lime Bricks
 IS3812: Specification for Pulverized Fuel Ash
 IS712: Specification for Building Limes
 IS 1077: Common Burnt Clay Building Bricks
 IS13757: Burnt Clay Fly-Ash Building Bricks
 IS5454: Methods of Sampling of Clay Building Bricks
 IS8112: Specification for 43 Grade OPC
 IS2116-1980: Sand for Masonry Mortars
 IS456:2000: Plain and Reinforced Concrete
 IS4082: Recommendation on Stacking &Storage of Construction Materials
 IS2386(Part-1): Methods of tests for Aggregate on Concrete

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Turnitin Originality Report
 Processed on: 05-Aug-2016 22:54 IST
 ID: 693884360
 Word Count: 5363
 Submitted: 1
finishing work By Siddharth Srivastava
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