Internship report 2015 (1)

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Internship report

A Project Report for the internship

8/07/2015 -7/8/2015

By

Navneet Kumar-(13BCL0322)

Submitted to

Internal guide: Muthukumar M

Associate Professor, SCALE, VIT University

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The Bihar Museum Project Patna

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L&T Construction, B&F IC

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Acknowledgement

I wish to express my sincere gratitude to my guide Mr. Suresh Kumar Sethi for his guidance, I

also thank the project manager Mr. Ashok Kumar for providing the opportunity to do the

internship and project work at “Patna museum project”.

I sincerely thank Mr. M R Das, Mr. S K Das, Mr. Vikram Kumar, Mr. Amit pal, Mr. Eliyaz

Khan for the guidance and encouragement provided during the training period.

I also thank Mr. Kamlesh sir for the guidance in completing the project.

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Index

Chapter page no.

1. About company 6-7

2. About project 8-12

3. EHS 13-22

4. Structural work 23-27

5. Finishing 27-46

6. QA/QC 46-53

7. Summary 54

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Chapter 1

About company….

Larsen & Toubro Limited (L&T) is a technology, engineering, construction and

manufacturing company. It is one of the largest and most respected companies in India's private

sector.

Seven decades of a strong, customer-focused approach and the continuous quest for world-class

quality have enabled it to attain and sustain leadership in all its major lines of business.

L&T has an international presence, with a global spread of offices. A thrust on international

business has seen overseas earnings grow significantly. It continues to grow its overseas

manufacturing footprint, with facilities in China and the Gulf region.

The company's businesses are supported by a wide marketing and distribution network, and have

established a reputation for strong customer support. L&T believes that progress must be

achieved in harmony with the environment. A commitment to community welfare and

environmental protection are an integral part of the corporate vision.

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OPERATING DIVISIONS

The following are the operating divisions of Larsen & Toubro:

Building and Factories

Transportation Infrastructure

Heavy Civil Infrastructure

Power Transmission and Distribution

Renewable Energy

Water & Effluent Treatment

Smart World & Communication

L&T Geostructure

Metallurgical & Material Handling

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Chapter 2: About project

2.1 The Bihar Museum Project.

Name of project: Bihar Museum Project

Location of project: southern flank of Jawaharlal Nehru marg, bailey road,

Patna

Date of commencement: 3rd June 2013

Project value and current: 280cr.

Current workman strength: 1300. Area of project: 25000 m2

Architectural design: Maki &Associates (Japan), Opolis architect (Mumbai)

Construction Company: L&T constructions B&F IC.

Consultants: Lord cultural resources (Canada based consultancy)

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2.2 General site layout plan.

Figure -1

Location of the project:

Front side of project: Bailey road

Back side of project: south bailey road

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Figure -2

The construction area is divided into two zones; zone 1 and zone 2. Zone 1 have four blocks

1-Block A

2-Block B

3-Block C

4-Block J

Zone 2 has six blocks

1-Block D 4- Block G

2-Block E 5-Block H

3-Block F 6-Block k

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2.3 Master plan

Figure -3

2.4 Description of blocks

Block Description Structural system Max. Height

Block A G+1 Conventional Slab system +12.6m

Block B G+1 Conventional Slab system +11.4m

Block C G+5 Conventional & Flat Slab system +26.45m

Block D G+1 Conventional & Flat Slab system +7.2m

Block E G+1 Conventional & Flat Slab system +7.2m

Block F G+2 Conventional Slab + Precast System +18.6m

Block G G+2 Conventional Slab + Precast System +18.6m

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Block H G+2 Conventional Slab + Precast System +18.6m

Block J G+1 Conventional Slab system +7.2m

Block K G+1 Elevated connecting Bridge +13.05m

The museum will bring the region’s thousand years history into focus, inspiring local residents

and visitors from across the globe to explore Bihar’s rich heritage, historic sites and cultural

attractions.

The proposal for Bihar museum includes four core exhibition galleries, educational, lobby,

administrative and permanent gallery.

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Chapter 3 :Environmental, health and safety department

Cluster EHS manager- Sujit Saha

EHS in charge – M R Das

EHS engineer – Rajeev Kumar

EHS inspector –

1. Maniksenapati

2. Sachidanand

3. Sanjayesrivastav

4. Dinesh kr. Sukhla

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3.1 Activities at site...

1. Shuttering, Rebar tying and Concreting of Column, wall and Slab at UG Sump

2. Stone Cladding & Structural glazing

3. Masonry work at site

4. Material shifting

5. Structural Fabrication & Erection.

6. Rebar cutting, bending and handling at Steel yard

7. Making at carpentry workshop

8. Waterproofing

9. Flooring

3.2 Certificate

The quality management system has been certified to ISO 9001-2008 slandered by LRQU.

EHS management also certified to ISO 14001 and OHSAS 18001.

ISO 14001

The ISO 14000 family of standards provides practical tools for companies and organizations of

all kinds looking to manage their environmental responsibilities.

ISO 14001:2004 and its supporting standards such as ISO 14006:2011 focus on environmental

systems to achieve this. The other standards in the family focus on specific approaches such as

audits, communications, labeling and life cycle analysis, as well as environmental challenges

such as climate change.

OHSAS 18001

OHSAH 18001 is an international health and safety management system specification.

It exists to help all kinds of organizations put in place demonstrably sound occupational health

and safety performance. It is a widely recognized and popular occupational health and safety

management system

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3.3 General approach to EHS management.

The general approach to EHS management as per international standards ISO 14001 and OHSAS

18001 is based on the methodology called "Plan-Do-Check-Act".

PDCA in the EHS context can briefly be described as follow:-

-Plan, document the organization’s overall EHS aims and objectives in a policy statement,

identify and register environmental aspects and impacts and occupational health and safety risks

as well as regulatory requirements.

-Do, define EHS objectives and targets, and implement suitable strategic initiatives to deliver

results in accordance with the organization’s EHS policy and legal requirements.

-Check, monitor and measure the results against policy, objectives, targets and legal and other

requirements.

-Act, take action to continually improve the performance of the EHS management system

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3.4 Basic safety rules:-

Should adhere to wear required PPEs.

-safety helmet

-safety jacket

-safety footwear

No loose cloths. Follow dress code.

No Smoking at Site premises.

Do not lean on edge protection handrails.

Keep away from the electrical network

Understand the safety signs and respect the barricades

Do not enter into the area where barricading is done.

Beware of moving vehicles inside the site.

Never stand in the area where overhead work is happening.

Do not throw any materials from height.

Don’t leave any loose materials at height.

Do not work or enter into the area where there is no light source.

Do not sit / sleep on the wall / floor edges.

While climbing on any ladder / scaffolding / shuttering, take the help of any responsible

person of that area.

Do not misuse or damage any equipment / arrangement made in the interest of health,

safety and environment.

Do not run at site unless there is an emergency.

Do not touch any electrical equipment.

Electrical apparatus should not be altered.

Never come under the suspended load. (Watch for tower crane movement)

3.5 Potential hazards at site

Height works

Hot works

Electricity

Movement of Earth Moving Equipment’s / Vehicle (Traffic)

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3.6 EHS practices followed at site.

1. Environment:-

Figure -5 Tree restoration at site campus

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2. Health:-

Figure -6 Medical checkup by visiting doctor.

3. Safety

Figure -7 Use of safety net

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Figure -8 fire extinguishers at workmen colony

Figure -9 external platform arrangment.

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Figure -10 Block c periphery covered with safety net for trapping material

Figure -11 Safety net at Block A

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Chapter 4 :Structural work

4.1 Boundary wall:-

Structural detail

Height of PCC =100mm

Height of RCC =300mm

Wall thickness =250mm

Total height = 2400mm

Reinforcement dia.= 10mm

Footing width =1250mm

Grade of PCC =M15

Grade of RCC =M30

Workability =120±25

Exposer type = moderate

Method of concrete placing =pumping

Characteristic compressive strength @ 28 days= 30N/mm2

Target strength =

Assumed std. deviation = 5.0 as per as the IS 456:2000 table 8

=fck+t*SD

=30+1.65*5

=38.25N/mm2

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Figure -12 Boundary wall

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Structural drawing of boundary wall

Figure -13

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4.2 Water feature

Height of PCC =100mm

Height of RCC =100mm and 150 mm

Vertical reinforcement bar of parapet wall = 8mm (dia.)

Horizontal reinforcement bar of parapet wall =10mm

Reinforcement bar of drop wall

Main bar dia. =10 mm

Binder =10 mm

Slab reinforcement bar dia. =10 mm

Structural drawing-

Figure -14

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Pool section detail-

Figure -15

Figure -16 Water feature in front of Block A

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chapter 5: finishing

1. Water proofing

- Toilet water proofing

- Roof water proofing

2. Cladding

- Sandstone cladding

- Granite cladding

- Cotton steel cladding

- Terracotta cladding

3. Flooring

- Granite flooring

-Kota stone flooring

- Terrazzo flooring

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5.1 Water proofing

5.1.1 Roof water proofing

Material required:

1. Hydrocem 7. Geo textile membrane

2. CEBEX 100 8. Tikidan APP membrane

3. Cement 9. Bitumen primer

4. Sand 10. PVC pipe

5. Perlite 11. Stone

6. XPS board 12. polymer

Plant and equipments:-

Bosch drill machine, hammer, grouting pump machine, chisel, gas torch flame, batching

containers.

Step performed in water proofing:

1. Preparation of surface

-Clean the surface properly; no dust material should be present on the surface.

- All damage surface and cracks should be repaired

- Level the surface.

- Pond the base slab with water to check linkages for 48 hours.

-find out the leakage point.

- open the area of leaking point , joints, cracks in form of grooves of approximately 25 mm width

1.Injection grouting with CEBEX100

- drill the holes in crack.

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- fix thePVC nozzle in the drilling hole vertically in joints and inclined in the crack surface.

- using the grouting pump, inject grouting material ex- cement slurry, CEBEX100 into PVC

nozzle.

CEBEX100 grouting admixture of 225 gm per bag of Cement.

- cut the nozzle after grouting.

- make the surface of roof wet prier to application of polymer modified cement coating.

3.Hydrocem coating

Preparation of hydrocem solution.

- It is a mixing of two compounds in ratio of 1:1.

1) Liquid hydrocem.

2) Powder hydrocem.

-After adding stir the mixture

-No water or other material should add into the mixture.

- Two coating of hydrocem should be applied with the drying interval of 4 hours.

-Ponding should be done for 3 days to test water tightening.

4.Perlite concrete layer

MIX DESIGN

Cement =280kg/m3, perlite =150 kg/m3, water =297 kg/m3, microair720 = 7 lit/m3

Ratio of mix per bag of perlite

Cement: perlite: water: microair720=31.73:17:33.66:0.793

- mix the ingredient in the given mix design ratio

- Clean the surface, the surface should not have water.

- laying of perlite concrete approximate density 1200 kg per m3.

-Maintain a slope and the thickness should vary from 75-150 mm.

5.Laying of screed

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Mix design

Cement: sand = 1: 4.

Width of screed = 25 mm over the perlite concrete.

Finishing of screed should be smooth.

Curing should be done for three days.

6.Tikidan APP membrane

-apply bitumen primer coating throughout the roof; 0.2lit to 0.3 lit per sq. is consumed.

-laying tikidan APP membrane over the primer coating

-thickness of APP membrane is 4 mm.

- lay APP membrane on the same day when the primer is done

- Fuse the thermo fusible on the bottom side of membrane with gas torch flame should be moved

in shape of L.

- applyabout 75% of heat to the raft and 25% to the membrane.

- When the film melt immediately role the membrane forward and press firmly.

7. XPS board

Thickness of board = 75 mm

-Laying ofXPS board on tikidan APP membrane.

8. Vapour barrier sheet

- Installation of 400 microns thick vapour barrier PVC sheets over XPS board

9. layer of geotextile membrane

Place geotextile membrane over vapoursheet.

10. Concrete screed

-Place 50 mm thickness of concrete screed over the geo textile cloth.

-Curing of concrete screed for seven days

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11.use of micro concrete.

Cut out /periphery joints of pipe to be filed with micro concrete.

Layer wise drawing for roof water proofing

Figure -17

.

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Figure -18 Drilling at leakage points

Figure -19 Grouting process at cracks

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Figure -20 Grouting at joints

Figure -21 Hydrocem coating

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Figure -22 Perlite concerte

Figure -23 Screed layer and Tikidan

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5.1.2 Water proofing treatments to toilet and other wet area…

Procedure.

- Preparation of surface with the help of brush and thoroughly clean.

- All damage should be repaired

- Highly undulated surface should be drilled to make concrete smooth for application.

- Ponding should be done for 48 hours.

-mark the leaking point with the help of chalk

- drill the leaking point with the Bosch drilling machine and joints.

- Fix the nozzle in drilled area.

- Using grouting pump inject grouting material ex- cement slurry, CEBEX100 into PVC nozzle.

- cut the nozzle after grouting.

- making the surface wet prior to application of polymer.

-apply two coating of hydrocem with the interval of four hours on the surface.

- apply two coating of hydrocem with the interval of four hours on the wall up to one meter

height

- Basecoat plaster of average 12 to 15 mm thick in cement mortar ratio 1:3 on masonry wall as a

base coat.

- Junction of wall and floor sealed by applying of strip polyester or polypropylene mesh of 100

mm wide embedded between 2 coat of hydrocem coating.

-protective screed 20-25 mm in C: M=1:3 on the floor area

-provide the treatment in chases in the wall.

-fill the Cut out /periphery joints of pipe to be filed with micro concrete.

-periphery joint of pipe should be sealed with P.J sealant or silicon sealant.

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5.2 Cladding

5.2.1 Sandstone dry cladding

Materials used:-

1. Sand stone

-Honed sand stone

-sort sand stone

2. Clips

3. Anchor

4. Fasteners

5. Approved laticrete sealer for protective layer.

Dimension of stone used at site:

Honed sandstone-895mm*295mm

Sort sandstone-595mm*295mm

Equipments:-

Grinder, drill machine, steel hammer, Rubber hammers, Scaffolding, Level machine, plumb bob,

etc.

Procedure:-

- The unloading of sandstone at the site should be done carefully to avoid any damage to the

sandstone

- Material should be directly delivered to the storage.

- QA/QC Engineer would check the Quality of material. The damage material should be kept

separately and good material should be kept at other storage.

- Stone dimension shall be verified before fabrication of work.

- Using brush and acid type cleaning agent to clean the sand stone

- Apply the sealer in the cold environment ex. evening or morning, on all six faces.

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- 24 hours of curing of sealer should be done.

- QA/QC engineer will check the quality of sealer on all six faces and approved stone is used in

cladding and rejected stone will be applied sealer again.

-after doing marking of proper level, first the S.S clamp are fixed with SS anchor fastener on the

wall with the drill and hammer.

- Then drilling is done on the stone to put the clamp inside.

- Stone are fixed as per as the drawing.

- Generally two clamps are used.

- The minimum gap between wall and cladding should be 100mm.

- 5mm clear groove is maintained in between two stones in both horizontal and vertical direction

as per as the drawing.

- After completion of one elevation, it should be properly checked for vertically with plumb bob.

- Final cleaning should be done with clear water.

Figure -24 putting the sandstone

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Figure -25 Cladding of sand stone on external area.

Figure -26 Block J External Sand Stone cladding.

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5.2.2 Black Granite cladding

Size of granite blocks used at site: -1195 mm*895mm*30 mm

Material used:-

1. Black granite

2. Anchor

3. Fasteners

4. Approved laticrete sealer for protective layer.

5. Clamps

Equipments:-


etc.

Procedure:-

- The unloading of granite at the site should be done carefully to avoid any damage to the

granite.

- Granite dimension should be verified before installation of work.

- Apply the sealer in the cold environment ex. evening or morning, on all six faces and 24 hours

of curing of sealer should be done.

-after doing marking of proper level, first the S.S clamp are fixed with SS anchor fastener on the

wall with the drill and hammer.

- Then drilling is done on the granite to put the clamp inside.

- Granite are fixed as per as the shop drawing.

- Generally three clamps are used.

- The minimum gap between wall and cladding should be 100mm.

- 5mm clear groove is maintained in between two granite in both horizontal and vertical

direction as per as the drawing.

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- After completion of one elevation, it should be properly checked for vertically with plumb bob.

- Final cleaning should be done with clear water.

Granite cladding.

Figure -27 Granite cladding

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5.2.3 Terracotta cladding:-

Materials:-

1. Terracotta

2. Anchor Fastener

3. SS clamps.

4. Cement

5. sand

Equipments:-


etc.

Dimension of Terracotta used at site:-590mm*90mm*65mm

Procedure:-

-Approved drawing is used for cladding work

-Location and orientation marking on vertical plane is done so that they are right side up when

the unit is installed.

-the bricks are put one by one keeping 10 mm groove both in horizontal and vertical direction.

Figure -28 Terracotta cladding

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5.3 Flooring

5.3.1 Granite flooring

Materials:-

1. Granite

2. Laticrete 190 sealer

Dimension of granite used at site

-600mm X 600mm*30mm

-300mm*300mm*30mm

-1200mm*600mm*30mm

Equipments:-

-Trowel

- Wooden/rubber hammer

-laser level instrument

-stone cutting tool

-spirit level

-Straight Edge

Procedure:-

-unloading of granite stone should be done carefully.

- QA/QC engineer would check the Quality of material. The damage material should be kept


- carry out post check on level of screed concrete where flooring should be done and review the

minimum thickness of tile.

-the surface/substrate should be cleaned to remove any dirty stain and other foreign material

before installation.

- Proper care should be taken for interface with other associate finish.

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-coating of Laticrete190 sealer in all six sides of stone should be advanced before 24 hours of

fixing.

-The granite should be laid down on the floor as per as the drawing.

-After preparing the adhesive, it should be laid on the floor to the required level of thickness as

per as the manufacture specifics.

- 3mm spacers should be used as per as the drawing.

- Then stone should be put over the already laid adhesive checking periodically that the good

contact is maintained with the back of each stone to ensure zero voids.

- The line, level, joint evenness, hollowness and slope should be checked during installation.

-The joints are cleaned with brush to remove mortar and dust.

-Start the polishing after 10 days of lying of stone.

Figure -29 Granite flooring at J block

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5.3.2 Kota stone flooring:-

Material:-

1. Kota stone

2. Sand

3. Cement

Equipments:-

-Trowel

- Wooden/rubber hammer

-auto level

-stone cutting tool

-spirit level

-Straight Edge

Procedure:-

-unloading of Kota stone should be done carefully.

-QA/QC officer would check the Quality of material. The damage material should be kept


- carry out post check on level of screed concrete where flooring should be done and review the

minimum thickness of tile.

-the surface/substrate should be cleaned to remove any dirty stain and other foreign material

before installation.

- Proper care should be taken for interface with other associate finish.

-laying cement mortar (sand: cement =1:4) over surface of thickness 30 mm.

-Press stone firmly into position with slide twisting action.

- insure no voids behind stone when solid bed fixing.

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-joints should be cleaned and grout the same with slurry.

- check the line and kevel joint’s evenness, hollowness, and slope during installation.

- 7 days of curing should be done.

- start the polishing after 10 days; and polish the surface till up to the level.

- clean the surface

Figure -35 Kota stone cleaning at c block

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Chapter 6: Quality Assurance/ Quality Control

QA/QC in charge – SK Das

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6.1 QUALTIY PLANNING

Quality Objectives

The Quality objectives are derived from Quality policy. Table 5.1 below enumerates a list of

Suggested Quality Objectives for operations applicable at project site. Various units /

departments and individuals at functional level would derive list of objectives from the table.

For the project sites the objectives are set at the time of project commencement. The progress is

reviewed at site.

No Objective Measure

Target Report

frequency

1 Customer

Value

Product Quality Rating

Customer feedback

Pre-commissioning Obligations

Quarterly

2 Process

Plan vs. Actual:

Project milestones

Financial performance

Cost prudence

Safety Records

Monthly

3 Improvements

Safety performance

Cycle Time

Cost of poor Quality

Wastage Reduction

Product Quality rating

Monthly

4 Leadership Development of future leaders

Half-yearly

5 Motivation

New initiatives

Innovations

Staff training effectiveness – evaluation

Quarterly

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6 Partnerships

Assimilation of technology from JV

partners.

Vendors developed

Performance evaluation of vendors – of

site purchases

Performance evaluation of sub-contractors

Quarterly

Suggested Quality Objectives

The desired / target values are set based on the following:

- Past performance in similar jobs;

- Growth over period of time;

- Contractual commitments;

- Aligning to annual financial budgets/ accepted costs as per ACE;

- Meeting the PQP requirements.

For each of the key position value drivers are defined, monitored and measured which adds up to

the Quality objectives for the function. Similarly, the target objectives of a department / unit are

attained through value drivers of the key positions.

6.2 Quality Management System Planning

Objective:-

Establish a procedure to plan, monitor and achieve Quality Management System planning in

order to fulfil customer requirements, statutory requirements and organization objectives based

on contractual requirement.

Sl.

No. Procedure Steps Responsibility

1.

Prepare strategy for the project to ensure

a. Quality of product

b. Safety

c. Timely delivery

Site Engineer

Site Engineer

Planning Engineer

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Sl.

No. Procedure Steps Responsibility

2

Convert the strategy into initiatives for the site team and

establish Quality Objectives for each position of the project

and periodically review as planned. PI

3. Document the needs / expectations of customer, organization

and statutory bodies in PQP and implement. All Sections

4 Evaluate process and product performance by Audits. All sections

5 Improve performance of process and products following

management review meeting. All sections

6 Maintain system integrity during changes in PQP for

improvement. MR (Site)

Some test performs in quality lab:

Moisture content, silt content, cube test, brick test, sieve analysis, sand gradation, cement

fineness test, consistency of cement, setting time of cement, compressive strength of cement etc.

6.3 Quality control during cladding:-

During our visit at site we performed many quality checks.

Following procedures are involved in the Quality check of cladding.

- Quality check should be done by QA/QC inspector and material inspection report shall be

raised to engineer for their approval.

- Color, texture, chip up, size, diagonal size, thickness, height, and length of stone should be

checked.

- Sealer coating should be checked by the QA/QC inspector in all six faces

-If stone absorbs water it means that sealer coating is not done properly.

- Alignment of cladded wall should be checked

Quality check of granite

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Figure -30 Quality check of granite

Granite absorbs water, sealer coat not done properly

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6.4 Quality control of water proofing:-

QA/QC officer should know about the construction program and should attained all inspection

point and record all result of inspection.

6.5 Some tests performed in the lab of QA/QC

6.5.1 Cube test:-

Size of cube use =15*15*15

Grade of cube =M35

Compressive strength of cube is checked:-

Results:( in N/mm2)

40.67, 38.92, 34.25, 41.73, 29.2,

Maximum target Strength= Average compressive strength+ risk factor* stander deviation

=35+1.65*5

=43.25 N/mm2

Minimum target Strength = Average compressive strength- risk factor* stander deviation

=35-1.65*5

=26.75 N/mm2

Remark:

The cube is safe for use as it lies between maximum and minimum target strength

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6.5.2 Brick test:-

Following procedure are followed in the brick test

Size

- Measure the length, breadth and depth of the bricks and using the data calculate average size of

the bricks

Compressive strength

- Find out the area of Bricks and find out the compressive load.

- using above data to calculate average strength.

Water Absorption

- Find out weight of dry bricks (w1)

- find out Weight of wet Bricks (w2)

W= (w2-w1)/w1 *100

Using above formula calculate average water absorption of bricks.

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Chapter 7 :Summary

As a civil engineering student I got a very wonderful opportunity to come over here in this

“Bihar Museum Project”. The methods used at the construction site have which I have seen here

have helped me a lot and will do in future.

During the training period I have learned a lot about how the work is executed on the site. Under

the guidance of site Engineers I have gained a lot of practical Experience

During my training period I have mostly focused on structural work, waterproofing, cladding,

and flooring. L&T have one of the best safety methods during the construction and I have

learned a lot about the safety rules of site.

The quality of construction which L&T provides is one of the best in the country, I have learned

about the different QA/QC approach which the company uses in construction.

Internship report 2015 (1)

Engineering