Presentation #BF2 (Blast Furnace #2)

CIVIL WORKS BLAST
FURNACE # 2
Dwaipayan Roy
Jasobanta Pradhan
Vivekananda Das
R. Ramesh
Parthendu Pattanayak
Liton Roy
PRESENTED
BY

TYPE OF CIVIL WORKS
1. Layout / Surveying
2. Excavation / backfilling
3. Reinforcement
4. Shuttering
5. Concreting
6. Brickwork & Plastering
7. Finishing Activities
8. RAILTRACK

LAYOUT / SURVEYING
Before starting any project work,
we have to select and layout the
area with reference to the
coordinate and level mentioned in
the drawing. Several survey
instruments like Total Station,
Theodolite, Auto level & Measuring
tape used in that work. Here we
fixed benchmark for coordinate &
level consulting with client. In our
Blast Furnace # 2 site we
considered RL 78.840 as our
±0.00 level.
TOTAL
STATION
THEODOLI
TE
AUTO
LEVEL

CONCRETE
Concrete is a homogeneous mixture of Coarse
aggregate, Fine aggregate, Binding material,
water and admixture which can be spread or
poured into moulds and forms a stone-like mass
after hardening.
COARSE
AGGREGATE
(STONE CHIPS)
FINE
AGGREGATE
(SAND)
BINDING
MATERIAL
(CEMENT)
WATER ADMIXTURE

ADVANTAGES & DISADVANTAGES OF
CONCRETE
1.Strong in compression
1.Ability to be cast
2.Economical
3.Durable
4.Fire resistant
5.Can be moulded in
any shape & size at site.
7.Compressive strength
increases with age of
concrete
1.Low tensile strength
2.Low ductility
3.Once casted cannot
be modified or reused.
ADVANTAGES DISADVANTAGES

TYPES OF CONCRETE
 PCC / Plumb concrete
PCC is Plain Cement Concrete
designed to take only compressive
loads. There is no reinforcement
provided in PCC. It is used in :
1. Mudmat to RCC column or wall
footing.
2. Pavements.
3. Filling up the extra depth of
excavation done to achieve the safe
bearing capacity of soil.
PCC WORK IN
PAVEMENT
PCC WORK FOR
FOUNDATION

TYPES OF CONCRETE
 RCC
RCC is Reinforced Cement Concrete
where the concrete is reinforced with
steel bar to take the tensile load as
concrete is poor in tension. It is more
workable than PCC. It is used in :
1. Foundation
2. Column
3. Beam
4. Slab / Floor
5. Wall
6. Hopper
7. Dome
RCC STRUCTURE

TYPES OF CONCRETE
 HRC
HRC is Heat Resistant Concrete where
the concrete does not disintegrate when
exposed to constant or cyclic heating up
to temperature of 700º C. Here we used
basalt chips and basalt dust instead of
stone chips & sand as coarse & fine
aggregate. This type of concrete is
used in :
1. Areas with extreme heat
environment.
2. Molten metal splash areas.
3. Hot material storage areas.
4. Steel Plants.
DRY SLAG PIT MADE
BY HRC

CONCRETING IN HOT WEATHER
Any operation of concreting done at atmospheric
temperature above 40º C or any operation of concreting
where the temperature of concrete at time of its
placement is expected to be beyond 40º C.
 High temperature results in rapid hydration of
cement
 Increase evaporation of mixing water.
 Greater mixing water demand to maintain
workability resulting reduction in strength.
 Large volume changes resulting in cracks.
 Cold joints :- A joint or discontinuity formed when a
concrete surface hardens before the next batch is

TEMPERATURE CONTROL FOR HOT WEATHER CONCRETING :
 Temperature of concrete can be reduced by controlling the
temperature of its ingredients as follows :
i. Shedding stock pile for coarse / fine aggregates to
protect from direct rays of Sun.
ii. Sprinkling the stock piles of coarse aggregate with cool
water and keeping them moist.
iii. By using cold water or ice cubes at the time of mixing the
concrete.
iv. Insulation of transit mixture drums by wet jute or cloth.
v. Schedule transit mixture trucks to avoid waiting time so
the concrete will not begin to set.
vi. Use sunshades in all possible locations where concrete
is to be poured.

TEMPERATURE CONTROL FOR HOT WEATHER CONCRETING :
vii. Dampen all surface areas before pouring concrete.
viii. Use thermometer extensively to monitor during mixing as
well as placing.
ix. Perform operation rapidly.
x. Delay setting time by using retarding admixtures. Ex:
Sika Plastiment – R1.
xi. Curing should be such that concrete does not loose
moisture and temperature required to gain full strength.
xii. We have considered temperature of concrete at batching
plant = 36º C and temperature of concrete during
placement = 38º C and to make this possible we have
added ice with water at the time of mixing to maintain the
temperature of water at 15º C for our BF#2 Site.

BLAST FURNACE #2 MAIN CELL FOUNDATION

TYPES OF CONCRETE
 PSC
PSC is Pre-Stressed Concrete where
the concrete’s natural weakness in
tension can be minimized by inducing
tension in pre-stressing tendons /
cables / strands inside the concrete. It
may be pre-tensioned or post-
tensioned. It is used in:
1. Girders of bridge
2. Railway Sleepers
3. Slabs of high-rise building
4. Splash bars in GCP cooling tower. PSC MEMBERS
PRESTRESSING
STRANDS

TYPES OF CONCRETE
 ADVANTAGES OF PRE-STRESSED
CONCRETE1. Section not cracked under service
load or repetitive loading and
unloading.
2. High span to depth ratio.
3. Reduce in self weight.
4. Less wear and tear
5. Suitable for rapid construction.
6. Minimizes the chances of crack.
7. Strong against deflection.
8. Suitable for precasting work.

PROPERTIES OF CONCRETE
 Characteristic Compressive
Strength :
The characteristic compressive
strength is defined as the strength of
material below which not more than 5
% of the test result are expected to
fall. It is denoted by fck. It can be
determined by concrete cube test.
Note : In the designation of concrete
mix M refers to the mix and the
number to the specified compressive
strength of (150x150x150) m3 size
cube at 28 days expressed in N/mm2.

 Compressive Strength (Cube)
Test
For the cube test we take 6 nos of steel
moulds of size (150x150x150) mm3.
Then we clean the moulds & apply the
releasing oil inside it. Then we place the
freshly mixed concrete of designed
proportion with 3 layers. Each layer
should be compacted with 35 times by a
16mm dia tamping rod. The top layer is
leveled & finished. After final setting time
the moulds will be released and the
cubes will be immersed into the water for
14 & 28 days respectively. After that the
compressive strength will be tested with
the help of CTM (Compressive strength
Testing Machine)
The cubes should gain the 70% & 90%
of the designed strength after 14 & 28
CONCRETE CUBE
MOULD
COMPRESSIVE STRENGTH
TESTING MACHINE

 Workability :
The workability is defined as the property of freshly
mixed concrete which determines the ease and
homogeneity with which it can be mixed, placed,
compacted and finished. The workability of a concrete
can be increased by increasing the water cement ratio
and adding the admixtures. But too much increasing of
w/c ratio results in decrease in strength of concrete. So
we prefer adding the admixtures.
Ex: Plasticizer, Super plasticizer.
Workability can be determined by Slump Test.

 Slump Test :
This test is carried out with a steel
mould called slump cone whose top
dia is 100 mm, bottom dia 200 mm,
height 300 mm. The slump cone is
filled in 3 layers with freshly mixed
concrete. Every layer is evenly
rodded 25 times with 16mm dia
tamping rod. Measure the slump by
determining the vertical difference
between the top of the mold and the
displaced original center of the top
surface of the specimen.
Note : If the slump value increases,
the workability of concrete also
increases. Slump value can be
maintained by using admixture

 Segregation :
Segregation refers to a separation of
the components of fresh concrete,
primarily resulting in a non-uniform
mix and ultimately a porous,
honeycombed & weekend concrete.
The primary causes of segregation
are :
1. Improper mixing
2. Improper placing
3. Over vibrating
Note : Pouring height of concrete
should be limited to 1.5 m for
concrete pump, boom placer, manual
IMPROPER CONCRETE
MIX
HONEY COMBED
CONCRETE

 Setting Time :
It is the duration of the time in which concrete starts to set and finally
gets its required shape and size. The setting time mainly depends upon
the grade of cement used and the temperature of the environment.
 Initial Setting Time :
It is the point of time when the concrete mix lost
its plasticity and stiffening to a certain degree.
Generally it is 30 mins. It is very important to
pour the concrete within its initial setting time.
By adding retarder the initial setting time can
be increased by 4 hrs. Ex: Sika Plastiment –
R1 Final Setting Time :
It is the point of time when the concrete
acquired a sufficient firmness to resist a certain
pressure. Generally it is 10 to 12 hrs. It is very
important to de-shutter the concrete walls and
columns only after its final setting time.
INITIAL SETTING
TIME
FINAL SETTING TIME

MIXING OF CONCRETE
 Nominal Mix:
The concrete mix in which no preliminary tests are
performed for the designing the mix is called the
nominal mixing. The concrete produced is called
Ordinary Concrete. The ratio for the nominal mix are as
follows :
1. M10 – 1:3:6
2. M15 – 1:2:4
3. M20 – 1:11/2:3
4. M25 – 1:1:2

MIXING OF CONCRETE
 Design Mixing:
The concrete mixing in which preliminary tests are
performed for the designing the mix for achieving the
target load is called the design mixing / trial mixing. The
concrete produced is Controlled Concrete / Ready mix
concrete. This type of mixing can be done for all grade of
concretes according to the availability of required
materials. In the project areas the ready mix concrete is
produced with the help of Ready Mix Batching Plants.

MIXING OF CONCRETE
Table for mix design detail in Cum at BF#2 Site
20mm 10mm
1 M30RCC Byweight(kg) 430 590 725 570 172 4
2 M25RCC Byweight(kg) 410 611 753 502 1884.5 2.7
3 M20RCC Byweight(kg) 380 615 768 512 184 2.2
4 M15PCC Byweight(kg) 325 596 811 540 208 N/A
5 M10PCC Byweight(kg) 228 632 847 565 155 N/A
Basaltdust
545 720 480
WATER
(Lit)
ADMIXTURE
(Lit)
REMARKS
6 M30HRC Byweight(kg) 535
Basaltaggregate
230 5
SLNO MIXGRADE DESCRIPTION CEMENT SAND
AGGREGATE

PRODUCTION OF CONCRETE
BATCHING
MIXING
PLACING
compaction
finishing
transporting
The production of concrete of uniform quality involves the
following stages :
CURING
Note : We are doing the first three processes in the Batching Plant and the rest of
the processes we are actually doing at site.

PLACING & COMPACTING OF
CONCRETE
 After mixing of concrete in batching
plant we transport the concrete by a
transit mixture to the site where the
concrete is to be poured. Then we
pour the concrete by 300 mm
layers with the help of a Concrete
Pump, Boom Placer or Manually.
Each layers should be compacted
by a needle vibrator of size 40 / 60
mm. By adequate vibrating we
avoid the chances of
honeycombing and the concrete will
be strong and durable.
BOOM PLACER
NEEDLE VIBRATOR

CURING OF CONCRETE
Curing is the process of controlling the rate
of moisture loss from concrete during
Cement hydration. Curing should be started
once the concrete reaches its final setting
time and it should be continue at least 14
days from the date of casting.
Process of curing :
 By covering the structure by hessian
cloth or jute.
 By sprinkling the water to the concrete
surface.
 By ponding the concrete structure.
 By wetting the concrete surface with wet
sand or wet saw dust.
CURING OF
CONCRETE USUING
HESSIAN CLOTH
CURING OF
CONCRETE BY

FORMWORK & SHUTTERING
 Formwork or shuttering is a die or a mould including all
supporting structures, used to shape and support the
concrete until it attains sufficient strength to carry its own
weight. We specially use a formwork system which is
completely independent and it is known by L&T
Formwork.
 Requirements of a good formwork :
 How formwork can be erected and de-shuttered fast.
 How good concrete quality and surface can be
achieved.
 What is the optimum stock of the formwork required for
the total work.
 What is the overall cost savings that can be achieved

L & T FORMWORK SYSTEM
 ADVANTAGES OF L&T FORMWORK :
 It is a very flexible system so it is easy to assemble and
dismantle.
 It is less time taking process therefore it is cost saving.
 It is virtually self aligning, therefore dimensional
accuracy is right.
 It has built in safety features and it is approved by the
International safety standards.
 It is a very rigid and strong system so that we can
achieve high quality and surface finish.
 The materials used in it can be reusable for several
times.
 In this system the amount of wastage is very little.

&
FLEX
BFS
HDT
WALL
COLUMN
CLIMBING
ACCESS
SCAFOLD
STAIR

 H-BEAM:
The h-beam is a composite member of
high strength timber and plywood. Based
on the flange to flange height there are two
types of h-beams. H-16 & H-20. The span
of h-beam also varies from 2.4m, 3.0m &
3.6m.
 Salient features of H-Beam :
i. Dimensionally stable & uniform in size.
ii. Consistent in strength.
iii. Economical & long lasting. Generally it
is used 25 to 30 times for site work.
TIMBER
PLYWOO
D
H-
BEAMS

COLUMN FORMWORK

WALL FORMWORK

FLEXI / TABLE FORMWORK

BEAM FORMING FORMWORK

HEAVY DUTY TOWER SYSTEM

ACCESS STAIR

ACCESS SACFFOLD

CLIMBING FORMWORK

SLIPFORM WORK

REINFORCEMENT
 The reinforcement is the skeleton of the reinforced
concrete structure in which it is embedded to take the
tensile load. Generally the TMT / HYSD steel bars of
different grades (Fe 415, Fe 500) are used as
reinforcement. There are different dia of bars like
8,10,12,16,20,25,28,32 and 36 mm.
 Why steel is used as
reinforcement ?
 It is cheap and easily available.
 It possesses high tensile strength
& elasticity.
 It develops good bond with
concrete. TMT BARS

CIVIL WORKS IN BLAST FURNACE AT A GLANCE
We have achieved the following in the BF#2 :
 Concrete of 62214 cum.
 Shuttering of 159142 sqm.
 Reinforcement of 5919 MT
 Brickwork of 6026 cum.
 Plastering of 67414 sqm.
 Railtrack of length 1370 m.

BLAST FURNACE #2 MAIN CELL FOUNDATION AND

BLAST FURNACE CELL FDN &
CAST HOUSE FDNS.
CAST HOUSE FLOOR

CAST HOUSE RAMP

DRY SLAG PIT

EMERGENCY OVERHEAD WATER TANK

GCP COOLING TOWER

HOT STOVE FOUNDATIONS

INBA – I & II

MAIN COOLING TOWER

MAIN ECR BUILDING

MAIN PUMP HOUSE

THICKNER A & B

RAILTRACK

Presentation #BF2 (Blast Furnace #2)

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