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CONTENTS:
1. JENO MARAN CONSTRUCTIONS PVT LIMITED, PUDUCHERRY 2. LARSEN & TOURBO ENGINEERING CONSTRUCTION AND CONTRACTS DIVISION- FORMWORK FACTORY
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CONTENTS: Thirumala RMC Plant, Puducherry Post Tensioning Beam at Lakshmi Mahal, Eripakkam, Puducherry Pile Foundation at Jeno Galaxy Apartment , Krishna Nagar, Puducherry Lectures on Auto-CAD, STAAD PRO, Estimation , Costing and Valuation
Cement Water fine aggregate Coarse aggregate(20mm) Coarse aggregate(12mm) Admixture (Fosroc)
Yield Testing fresh concrete RAW MATERIALS Selection /sourcing Testing Storage Space requirement DELIVERY PLACING: Mode Rate
RMC experts RMC experts Single place Limited area Transit mixer
Manual/hoist/crane 3m3/hr
Tendons (a group of pre-stressing cables), Hydraulic jack (monojack) of 25 tons capacity, the cables are inserted through the wedge block placed on duct provided with a given profile. LOAD APPLIED: The ultimate load of the cable is 180 kN/m2 But only 75% load is applied. Stress= (Load/area) *jack loss Ramp area of the jack =37.09cm2 Jack loss=2% Stress= (186X1000X0.75X1.02)/ (37.09X102) =38.36 N/mm2 Therefore load to be applied to the cables =39KN At one edge of the beam, the duct is provided and the prestressed and the other end is called the dead end of bulb end. At the dead end, the tendons will be stretched like a flower to prevent the tendons to enter back due to tension. PROCEDURE:
1. Concrete cube testing is done here to obtain strength of 26N/mm2 before tensioning. 2. Initial load of 100 bar pressure is given to the rods to release the twisted of moved
tendons inside beams. 3. Marking is done from the casting. 4. Then 39kN load is given to the cables through monojack and the elongation is observed i.e. distance from the casting to the outside. 5. Grouting: It is done for filling gaps on the beam by using a paste of Ordinary Portland Cement slurry+ cornplast are used.
Secondary reinforcements: 8mm diameter. Secondary reinforcement of ring type with cover: 45mm. Diameter of steel rod in pile-12mm Spacing of rings-a) bottom to top (for 23 feet)-0.2m b) last 3feet -0.15m
For 9X1 columns( 6 nos)- triple pile of 1.25feet diameter is to be provided For 9X9 columns (39 nos)-double pile of 1.25 feet diameter is to be used. For 9X9 column (1 no)-single pile of 1.5feet diameter is to be used.
Placing of reinforcements: 1. The reinforcements was placed inside the casing before concreting the casing .The prepared reinforcements was taken and placed inside the casing using hook. 2. The provided cover block helps to maintain the cover distance and provides the rigidity to the reinforcement all along the length of casing. 3. The prepared reinforcement is placed in position as shown in figure. 4. After placing the reinforcements, it is held in position till concreting the casing.
Casing details: CASING Large casing Small casing AUGER Large auger Small auger HEIGHT 2.1m 8.3m DIAMETER 0.43m 0.38m
INTRODUCTION: In the training programme of six days, I learnt the Planning, Production and Despatch of Formworks and scaffolds using Steel, Aluminium and Timber in L&T-E.C.C-Formwork factory. L&T Formwork Business Unit, offers Total Formwork Solutions for all types of reinforced concrete structures for varied applications. Formwork gives form or shape to concrete and also it supports the weight of concrete until it attains sufficient strength to carry its own weight and it ensures speedy construction with high levels of accuracy and superlative concrete finish together with enhanced productivity. FORMWORK AND SCAFFOLDS: Formwork is a mould used for the construction of concrete beams, columns and walls.
Scaffold is used for safe construction considering the safety of labourers, for climbing and working. PLANNING: This is the common process in the manufacture of formworks. It involves order booking, getting raw materials, obtaining design,schedule and despatch. Constant follow-up is done to make the work according to scheduled time. PRODUCTION OF STEEL FORMWORK: 1. Cutting the steel pipes or rods of desired length (using band saw). 2. Punching holes in them(using drilling machine) 3. Threading the pipes 4. Bending of steel plates 5. After making the required shape, the components are painted. PAINTING OF STEEL COMPONENTS: Degreasing of components water rinsing derusting water rinsing phospating using zinc air drying paint dipping paint dryer. Since dipped in paint, the whole component gets protected from environmental conditions. Before painting, welding of joints is done by Metal Active Gas(MAG) welding, carbon di oxide is used. There is no formation of flux. SYSTEMS USED IN STEEL FORMWORK: Mock-ups for beam, column and wall are made of steel and timber. These include Flex system, Beam forming system, Wall column system, Access scaffold system, Climbing scaffold, Heavy duty tower system.
FLEX SYSTEM
QUALITY ASSURANCE AND CONTROL: Different tests are done on the components of formwork both physical and chemical test namely Hardness test, Finding different values of threader pipe using Profile projector.
Chemical analysis involves using Spectrometer to find 19elements in steel including carbon content by wet analysis for accurate value. Costing of formwork: Cost of material per use=(cost of materials-scrap value)/number of repetitions Cost of material for an item in the project=(cost of material-(scrap value *period of use))/life of material
PRODUCTION OF ALUMINIUM AND TIMBER FORMWORK: There are 12 systems of timber formworks used here which are composed of H-beams made of plywood and timber. The timber used here are spruce and rubber wood which are the plantation timber recommended by the Government for use. The h-beams are of size H16 and H-20. H-BEAMS MADE OF TIMBER AND PLYWOOD
The timber is seasoned and treated to reduce the moisture content from 6 to 12%. DEFECTS IN TIMBER: The defects in timber were observed in the timber workshop of L&T formwork factory which are us follows, the seasoning and
treatment of timber reduces these defects and the H-beams are produced
TIMBER CRACKS
PRODUCTION PROCEDURE: Timber and plywood are cut ,where they have defects,to required length. 2. Finger jointing is done and the timber pieces are joined using Phenol Resorcinol Formaldehyde resin(PRF). 3. The timber is checked whether it is treated . 4. Same procedure is done for plywood 5. Timber and plywood are joined as H-beam using Beam press machine 6. Painting is done by spraying 7. Testing is done for tensile strength,flexure strength
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TESTING OF HBEAMS
ALUMINIUM FORMWORK: Aluminium used here is an alloy of magnesium. The three systems produced here are a) aluminium frame with plywood sheathing,b)Aluminium frame with aluminium sheathing,c) aluminium frame with plastic sheathing. SAFETY MEASURES IN FACTORY: 1.Treatment of Effluents: Bio-assay test is done to reduce the acidity of effluents from formwork factory of pH 3to 10 and 11 of alkalinity. Effluents in reaction tank settling tank sludge removal collection tank(pH 7.5 to 8.5),effluent treated trade water used for growing plants air receiver 2. Hcl Scrubber: The gases coming out from the painting process are sent into atmosphere after neutralizing them using NaOH(caustic soda),the pollution control board approved 70 mg ,but only 0.67 mg is let out.
INTRODUCTION: In the training programme of six days, I learnt the Planning, Production and Despatch of Formworks and scaffolds using Steel, Aluminium and Timber in L&T-E.C.C-Formwork factory. L&T Formwork Business Unit, offers Total Formwork Solutions for all types of reinforced concrete structures for varied applications. Formwork gives form or shape to concrete and also it supports the weight of concrete until it attains sufficient strength to carry its own weight and it ensures speedy construction with high levels of accuracy and superlative concrete finish together with enhanced productivity. FORMWORK AND SCAFFOLDS: Formwork is a mould used for the construction of concrete beams, columns and walls.
Scaffold is used for safe construction considering the safety of labourers, for climbing and working. PLANNING: This is the common process in the manufacture of formworks. It involves order booking, getting raw materials, obtaining design,schedule and despatch. Constant follow-up is done to make the work according to scheduled time. PRODUCTION OF STEEL FORMWORK: Timber and plywood are cut ,where they have defects,to required length. 2. Finger jointing is done and the timber pieces are joined using Phenol Resorcinol Formaldehyde resin(PRF). 3. The timber is checked whether it is treated . 4. Same procedure is done for plywood 5. Timber and plywood are joined as H-beam using Beam press machine 6. Cutting the steel pipes or rods of desired length (using band saw). 7. Punching holes in them(using drilling machine) 8. Threading the pipes 9. Bending of steel plates 10.After making the required shape, the components are painted.
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PAINTING OF STEEL COMPONENTS: Degreasing of components water rinsing derusting water rinsing phospating using zinc air drying paint dipping paint dryer. Since dipped in paint, the whole component gets protected from environmental conditions.
Before painting, welding of joints is done by Metal Active Gas(MAG) welding, carbon di oxide is used. There is no formation of flux. SYSTEMS USED IN STEEL FORMWORK: Mock-ups for beam, column and wall are made of steel and timber. These include Flex system, Beam forming system, Wall column system, Access scaffold system, Climbing scaffold, Heavy duty tower system.
FLEX SYSTEM
QUALITY ASSURANCE AND CONTROL: Different tests are done on the components of formwork both physical and chemical test namely Hardness test, Finding different values of threader pipe using Profile projector. Chemical analysis involves using Spectrometer to find 19elements in steel including carbon content by wet analysis for accurate value. Costing of formwork: Cost of material per use=(cost of materials-scrap value)/number of repetitions Cost of material for an item in the project=(cost of material-(scrap value *period of use))/life of material PRODUCTION OF ALUMINIUM AND TIMBER FORMWORK: There are 12 systems of timber formworks used here which are composed of H-beams made of plywood and timber. The timber used here are spruce and rubber wood which are the plantation timber recommended by the Government for use. The h-beams are of size H16 and H-20.
The timber is seasoned and treated to reduce the moisture content from 6 to 12%. DEFECTS IN TIMBER: The defects in timber were observed in the timber workshop of L&T formwork factory which are us follows, the seasoning and treatment of timber reduces these defects and the H-beams are produced
TIMBER CRACKS
PRODUCTION PROCEDURE: Timber and plywood are cut ,where they have defects,to required length. 2. Finger jointing is done and the timber pieces are joined using Phenol Resorcinol Formaldehyde resin(PRF). 3. The timber is checked whether it is treated . 4. Same procedure is done for plywood 5. Timber and plywood are joined as H-beam using Beam press machine 6. Painting is done by spraying 7. Testing is done for tensile strength,flexure strength
1.
TESTING OF HBEAMS
ALUMINIUM FORMWORK: Aluminium used here is an alloy of magnesium. The three systems produced here are a) aluminium frame with plywood sheathing,b)Aluminium frame with aluminium sheathing,c) aluminium frame with plastic sheathing.
SAFETY MEASURES IN FACTORY: 1.Treatment of Effluents: Bio-assay test is done to reduce the acidity of effluents from formwork factory of pH 3to 10 and 11 of alkalinity. Effluents in reaction tank settling tank sludge removal collection tank(pH 7.5 to 8.5),effluent treated trade water used for growing plants air receiver 2. Hcl Scrubber:
The gases coming out from the painting process are sent into atmosphere after neutralizing them using NaOH(caustic soda),the pollution control board approved 70 mg ,but only 0.67 mg is let out.
ESTIMATION OF A PLAN: The detailed estimation is done based on the Pondicherry Schedule of Rates(PSR) for a Pump house plan. The quantities are arrived using a software used exclusively in P.W.D
TENDERING PRACTISE: Preparation of preliminary estimate government order detailed technical estimate Notice Inviting Tender
CLASSES OF TENDERING: Percentage rate tender(small projects) upto 5 lakhs. 2. Item rate tender (5to 10 lakhs) 3. Lumpsum tender(10lakhs to crores) 4. Public-Private Partnership
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E-TENDERING: I attended the pre-bid meeting of the first project through etendering for the BALANCE WORK OF CONSTRUCTION OF BRIDGE IN ARIYANKUPPAM in which they discussed on the details of the work to be completed, the construction work was stopped due to the sinking of pier-4and land acquisition problems on the approach roads of the bridge, the balance work includes the pier-5, abutments, carriageway, retaining wall.
DETAILS: Its a four-lane bridge across NH 45-A Span-6spans(2 abutments and 4 piers) STAAD ANALYSIS: Seismic analysis the pump house is carried out using STAAD Pro software licensed to P.W.D,Puducherry,based on IS 1893 for basic load cases and combination load cases and the analysis report is attached here