civil enginnering industrial training report to the work of delho metro rail ltd.

1. REPORT OF INDUSTRIAL TRAINING
At
Submitted by
KRISHNA MURARI KANDU
1252100009
In partial fulfillment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING
DEPARTMENT OF CIVIL ENGINEERING
KOTHIWAL INSTITUTION OF TECHNOLOGY
&
PROFESSIONAL STUDIES
MORADABAD

2. Contents Page
Acknowledgement 1
Chapter 1 Introduction
General Overview of the Site 2
Chapter 2 Training Highlights
2.1 Introduction 4
2.2 Double Deck Stabling Yard 4
2.3 Boundary Wall 10
2.4 Bar Bending Schedule (BBS) 11
Chapter 3 Various Tests Performed
3.1 Introduction 14
3.2 At the site 14
3.3 Tests in the Lab 18
Chapter 4 Conclusions 27
About Delhi Metro Rail Corporation Ltd. (DMRC) 28
References 30

3. ACKNOWLEDGEMENT
I would like to express my sincere gratitude to Delhi Metro Rail Corporation Ltd. for
having given me the opportunity to undertake my industrial training at their Vinod Nagar
Station Yard project in Line 7, Site CC-86 at Ghazipur, New Delhi.
I acknowledge my thanks to Mr. Asghar Ali (Project Manager 4D) & Mr. Ankit Jindal
(XEN/4D) for his guidance and constant supervision which helped me in my training
successfully.
I would also like to express my gratitude towards the assistant engineer Mr. Manoj
Chauhan, junior engineers Mr. Govind, Mr. Umesh and all the supervisors of the YFC
Group for their co-operation and encouragement which helped me in completion of this
training project.

4. Chapter 1- INTRODUCTION
GENRAL OVERVIEW OF THE SITE
Delhi Metro was the first modern rapid transport system to be started in India. Right now
the Phase 3 of the metro work is going on which has 2 new lines coming up and the
extension of other lines is going on. My site was Vinod Nagar Depot which lies in Line 7
between stations Vinod Nagar and I. P. Extension. Here a double deck station yard is
being made for repair work of metro trains and parking them in the night. A metro line
from the I.P Extension station connects the stabling yard.
DMRC has handed the construction work of the site to other companies name YFC
Construction and KCC. These 2 private companies are allotted specified work which is
done under the jurisdiction of DMRC official present at the site just to inspect the work
and make sure everything is going as per the plan. The design as given by the contractors
needs to be checked by the DMRC official only after which any construction process gets
started.
The work on the site started on early march of 2015, during my training the initial phases
of the project was going on like the foundation of the double deck stabling yard and the
boundary. The site is set to be completed by June 2016. During the course of time staff
quarters and water tank has to be made only of whose drawing were approved at the time
of my internship, while construction was yet to be started.
The double deck stabling yard is proposed with the ground floor proposed for the offices
and the car parking of the employees while the first and the second floor are used for
parking the metro train during the night time. Along with the stabling yard a workshop
building is to be made in the station yard only. It is made along the boundary wall just
before the stabling yard. While contract of stabling yard is under YFC Construction rest
of all the work is undertaken by the KCC. These include boundary wall, staff quarters,
workshop building and even the water tanks.
The electronic part of the stabling yard is taken be the SIEMENS which include the
introduction of poles for the electricity to pass through on which the metro runs. The
horizontal section of the stabling yard is shown below along with the elevation.

6. Chapter 2- TRAINING HIGHLIGHTS
2.1 INTRODUCTION
This chapter aims at explaining all the basic procedure that was carried out at the site
during the time of training. It gives brief step by step method that was followed at the site
for stabling yard and the boundary wall. It also tells about the construction of bar bending
schedule (BBS) from the drawing given by the designer which makes it easier to make
the reinforcement for the worker.
2.2 DOUBLE DECK STABLING YARD
Pile foundation is used for the foundation of the yard. It is a form of Deep foundation.
Deep foundation is a type of foundation which transfers building loads to the hard strata,
rocks deep down from the surface of the earth. A pile is a vertical structural element of a
deep foundation driven deep into the ground at the building site.
Pile foundation consists of two components
1. Single or group of piles
2. Pile cap
The selection of type of pile foundation is based on site investigation report. Site
investigation report suggests the need of pile foundation, type of pile foundation to be
used and depth of pile foundation to be provided. The cost analysis of various options for
use of pile foundation should be carried out before selection of pile foundation types.
2.2.1 Piling
The type of pile used was bored cast in-situ piles (means they are casted on the site
only). The various steps which are involved in this type of piling are explained below
I. Surveying
It is the very first step to be done on site. Based on the drawing which is made by
the designer the points are marked on the field where piling operation is to be
performed. The point are marked by using Auto level by taking a fixed point and
then marking the appropriate point as given by to the surveyor. From the center of

7. the point where piling has to be done and reference points at a distance of 2m
along all the four sides (making 2 lines perpendicular to each other) are marked for
future reference of locating the points.
II. Pile Boring
After the surveyor has marked the points, boring is started with the help of rig
machine. The four reference points are taken into consideration while making a
hole with the rig machine so that the pile is at the required position. The hole of
about 3m is made initially so that the casing can be installed initially. The casing
of 1000mm diameter was used and the length of the casing pipe used was 4m long.
Casing pipe is used to make sure that the borehole made is vertical down the
ground and not inclined. While lowering the casing pipe position of the guide
casing pipe with reference to pile reference points already fixed around the pile
location shall be checked to shift or adjust the casing pipe to ensure proceeding of
drilling at exact pile location without any deviation. After the casing is installed
the reference points are not required and can be removed. Now boring is continued
till the required depth of as per the drawing is not achieved (Ranging from 25m to
40m in the site). Depth of the hole can be checked with the help of a sounding
chain which the exact value of the depth of hole.
III. Bentonite Addition
Bentonite is an absorbent aluminium phyllosilicate, impure clay consisting mostly
of montmorillonite. The absorbent clay was given the name bentonite by Wilbur
C. Knight in 1898, after the Cretaceous Benton Shale near Rock River, Wyoming
in America. Bentonite is added to the borehole while boring is going on. Before
putting it in the bore the bentonite is mixed with water to form a solution.
Bentonite is used to stabilize the sides of the bore hole while boring so that the soil
from the sides does not come out. Various properties of bentonite should be
checked on regular basis to see whether the solution is proper or not otherwise the
soil on the sides may fall out leading to reduction in depth of borehole thereby
reducing strength carrying capacity of the pile
The various properties and there range are given below
 Ph. Value- 9 to 12
 Density- 1.03 to 1.10
 Sand content- 0 to 3% if bentonite is being reused
0% if bentonite is fresh
 Viscosity- 30 to 35 sec
IV. Reinforcement Cage Lowering

8. Prefabricated reinforcement cage is prepared as per the bar bending
schedule(BBS) which is prepared from the drawing and kept near the pile location
while boring work is going on. As for higher depth the reinforcement cage is very
long, the cage is lifted one by one and spot welded at the joints and lowered in the
borehole with the help of a crane.
V. Flushing
Flushing is basically removal of all the sediments which might have settled on the
founding strata. After cage lowering, 250 mm diameter tremie pipes in suitable
lengths are to be lowered in the hole. The operation is done by lowering one
tremie pipe after another and connecting them threading to maintain water
tightness throughout its length till the gap between the pile base and Tremie is
between 100-150 mm. the tremie pipe is locked and supported from top to
maintain the level. The tremie head is to be provided to the tremie pipe for
flushing activity. The bore is flushed by fresh bentonite slurry through the tremie
head. All the sediments come to the top with the bentonite solution and are
removed. Flushing is carried on till the required sounding is not received.
VI. Pile Concreting
It is the final step in piling. After flushing is completed the tremie head is removed
and funnel is inserted through which concrete can be inserted in the bore hole.
M35 grade concrete is used in piling. When the slump arrives from the batching
plant the slump should be checked and it is maintained from 160 to 200mm.
Concrete is filled in the tremie pipe and the funnel from the truck. Lifting and
lowering is repeated keeping sufficient concrete in the funnel. As the concrete is
added tremie pipe are removed one by one taking care tremie pipe is sufficient
embedment in the concrete until whole concreting is completed. It is done to
prevent inflow of soil and bentonite in concrete which will lead to reduction in
strength. The concreting is done up to 500mm above the cut off level to get good
sound concrete at the cut off level.
Regular sounding needs to be done to make sure that the concrete is being poured
properly and there is chocking in the pipe. A truck from the batching plant has
approximate 5m3
of concrete in it. If there is chocking the whole tremie pipe is to
be removed and source causing the chocking is identified. After rectifying the
cause the sounding is done and sounding length plus 1m of tremie pipe is only
inserted inside the bore and concreting is continued.

9. Rig machine used for boring Reinforcement cage being inserted in the bore
Spot welding being done to join 2 reinforcement
Tremie Pipe used in flushing and concreting

10. 2.2.2 Pile Cap
A pile cap is a thick concrete mat that rests on concrete or timber piles that have been
driven into soft or unstable ground to provide a suitable stable foundation. It usually
forms part of the foundation of a building, typically a multi-story building, structure or
support base for heavy equipment. The cast concrete pile cap distributes the load of the
building into the piles. Usually the load to be supported exceeds the bearing capacity of a
single pile so a group of piles are used. In the site there were combinations of 3, 4 and 6
piles constructed together (based on the design given by the designer). Thus it is
economical to provide a single large cap for all the piles closely placed together, thus
forming a pile raft.
After the pile is set, the ground around the pile is excavated to make the pile cap. Around
2m below the ground was excavated out and chipping of the top 1.5 meter of the pile is
done. This is done because the top of the pile is considered to be not of required strength.
It contains along with concrete mixture of bentonite and soil that was bored. After that a
layer of PCC (Plain Cement Concrete) is applied for around 10cm to provide a firm and
even base at the bottom so that the load can be distributed equally.
Then based on the design the reinforcement is provided. For a 4 piles, size of the pile cap
adopted was 4.4*4.4m2
and 6 piles, size of pile cap adopted was 7.6*4.4m2
. The grade of
concrete used was M30 and cover of 60mm was used. After putting the reinforcement,
the shuttering is provided and concrete is poured. After the concrete set shuttering is
removed and regular curing is done.
Ground is excavated ready for chipping

11. Reinforcement cage for a pile cap with 6 piles
1.2.3 Pier
Piers are nothing but columns. A pier is a raised structure typically supported by well-
spaced piles or pillars. There were rectangular piers of 1100mm*1300mm used
throughout the stabling yard. They basically help in transfer of load from the top slab to
the pile cap through which it can be distributed below the earth surface by piles.
Construction of piers starts before concreting the pile cap as the reinforcement start from
beneath the ground. They are vertically long structures which are provided by shuttering
while concreting. M40 grade of concrete is used in piers and curing needs to be done so
that the concrete set properly.
While providing the shuttering for the pier, the verticality of the pier needs to be checked
so that the pier is vertically upward and does not tilt. To check this after providing the
shuttering, 2 small threads are dropped on each side of the shuttering from the top to the
bottom most point. Then with the help of tape the distance between the wire and the
shuttering is measured at some distance below the top and somewhere above the bottom.
It should be same. It is checked at all the four sides and if correct means the pier is
vertical. Then concreting can be started with the help of a pump.

12. Reinforcement cage for pier being prepared
2.3 BOUNDARY WALL
The base of the boundary wall
constructed along the depot was made of
isolated footing or piling depending on
the on the soil surface and the area of the
depot. But isolated footing was over
piling where both are possible as it is
cheaper. The height of the boundary wall
was constructed of height 4m.
Piling is expensive as lot of fuel is
required in boring a hole in the ground.
But the place where sand is loose footing
is used. In the site both the methods were
used. For piling a casing of 750mm
diameter was used and the bore length
was 18-20m depending on place to place.
M30 grade of concrete was used. Prefabricated vertical slabs fixed on the wall

13. While in case of footing, strip footing was used as the base and then column
reinforcement was raised. After the columns were raised to the desired height
prefabricated vertical slabs prepared at the batching plant were brought to the site and
were fixed (as shown in the above fig.)
After fixing the vertical slab the reinforcement of the column and the slab are joined
together and the column is filled with concrete and allowed to set. Regular curing is done
throughout the week so that it can properly set. While in case of piling after constructing
the pile the whole framework of the wall reinforcement is assembled and then shuttering
is provided and concrete is poured. On the site the area near the slums piling was used as
huge area could not be dough out to make the strip footing.
2.4 BAR BENDING SCHEDULE
Bar bending schedule (BBS) provides the reinforcement calculation for the reinforced
concrete beam. This chart gives a clear picture of the bar cutting length, diameter of the
bar, bar mark, type of bar, location of the bar, bar bend etc. It is made from the drawing
given by the designer.
It is given to the laborers to give them the idea of how much length long the
reinforcement bar is to be cut to make the desired reinforcement cage. It also gives the
contractor the total length of different bars to be required for the whole project and the
weight of each cage. It is usually prepared by software as the calculation are very
complex for that of pile cap as a lot of reinforcement are to be constructed.
On the site the bar of length 12m provided so for piling the bar were needed to be
overlapped and site welding was carried. A bar bending schedule of a pile is shown
below along with the design as given by the designer on the basis of which it is made.

16. Chapter 3- VARIOUS TESTS PERFORMED
3.1 INTRODUCTION3
This chapter aims at explaining the various that are performed both at the site and the lab
to ensure the quality of the sample being used is good and building can hold the load
successfully.
3.2 TESTS PERFORMED AT SITE
These tests were conducted at the site because it was required to be performed at the time
of construction. These include the entire test on bentonite, the slump test and the test on
the pile after its formation.
3.2.1 Test on Bentonite
Bentonite is a very important component used in piling. Its basic properties like Ph.,
density, viscosity and sand content needs to be checked regularly (4 to 5 times a day).
1. Ph. Value
For checking the ph. of the bentonite solution, the ph. paper is dipped in the
bentonite solution which changes the color of the ph. paper. Then the color is
compared with those on the ph. table and value is found out. Its value should be
around 9.
2. Viscosity
For finding the viscosity of the solution mars cone is used. Around 950ml of the
bentonite solution is taken in a measuring cylinder. Then it is poured in the mars
cone and at the same time the stopwatch is started. The time taken by the bentonite
solution to pass through the cone is noted. This time is the viscosity of the solution
and the value should be 30- 35 sec.
3. Density
For finding the density of the bentonite solution barometer is used. The solution is
taken in measuring cylinder and barometer is inserted in it. When the barometer
stops moving the value on the barometer is checked which gives the density of the
solution.

17. 4. Sand Content
The percentage of sand content needs to be checked to make sure that the
bentonite solution is pure. It is checked with the help of sand kit. It has 2 parts a
hollow plastic cylinder with a 200micron sieve and measuring cylinder which is
conical from the bottom. The conical measuring cylinder has markings in the
conical section a small line in the cylindrical section.
Procedure:-The hollow cylinder is kept above the other cylinder and the solution
is passed through it till the mark in the cylinder. Then water is added to it. The
hollow cylinder is removed and the solution in the bottom container is removed
and washed. The hollow cylinder is then reversed and put over the container. Now
water is poured in the hollow cylinder and as it is reversed, the sand which is
present in the sieve comes in the container with water. As sand is heavier than
water it comes and settles down. From the marking in conical section, the sand
content percentage is found.
The sand content for newly prepared bentonite solution should generally be 0%
but till 1% is allowed. For bentonite solution which is being re-used after passing
through the desander then around 3% sand content is allowed.
3.2.2 Sounding
Sounding is done to find out the height
of the borehole dough during piling
operation. It is done with the help of a
sounding chain which is either a steel
chain or a plastic chain with a metal
piece at the bottom. The chain is inserted
in the borehole to the depth more than
the depth of bore hole. It is regularly
stretched, and when suddenly a force is
required to stretch the chain that point
w.r.t casing top level is marked and
measured with the help of a measuring
tape.
Steel sounding chain
3.2.3 Slump Test
Slump test is an empirical test used to measure the workability of fresh concrete. It
basically determines the state of fresh concrete also refers to the ease with which the

18. concrete flows. The workability of concrete is affected by the consistency of the concrete.
So it basically measures the wetness or consistency of the concrete.
Procedure: A slump kit is taken consisting of a frustum of a cone having bottom
diameter of 20cm and top diameter of 10cm and a height of 30cm open at both end also
known as the slump cone, a bullet end metal rod for tamping. The cone is placed on a
non-absorbent surface. The cone is filled with fresh concrete in 4 layers, after each layer
tamping is done with the rod by providing 25 stokes. After the concrete is fully filled, the
mould (cone) is carefully lifted vertically upward, so as to not disturb the concrete cone.
After lifting the concrete subsides, this subsidence is measured with the help of a scale
and is known as slump.
The value of slump considered workable is 160-200mm. Slump of each and every truck
arriving to the site is done. This test being done at the batching plant is done here again to
make sure that the workability does not change during transportation.
3.2.4 Pile Integrity Test
This is a very important test as pile being below the ground, basically invisible it is
difficult to find its integrity. This test basically test the integrity so as to find out the flaws
before it can lead to any serious damage. This test is done before laying the pile cap, just
after the chipping process is done. It is also known as Low strain impact integrity test as
we only use a small hammer.
Procedure: The pile head is first leveled and should be smooth. The equipment required
is a rubber tipped hand-held hammer with sensor, a sensor and a receiver. As there were
circular piles formed the test was conducted at 3 spots in a single pile. The sensor is
attached with an adhesive material on the pile top. The rubber tipped hammer is used to
generate a “low strain” compressive impact wave. The readings are received in the
receiver in the form of waves by which we can find out the integrity.
Limitation: The major limitations are that it cannot detect gradually increased or
decreased diameter or the curved piles. Even gradual material change cannot be detected.
Pile integrity test helps us in detecting large inclusion of other material than concrete,
cracks, joints and increase or decrease in cross-section. If there are large undulation in the
receiver the pile may have to be rejected and has to be constructed again
3.2.5 Pile Load Teat
It is the most important test in pile which helps us in determining the settlement of pile

19. under a given amount of load. The load provided is generally more than the load which
the pile is supposed to sustain. There are 2 types of load test which are adapted, initial
loading test and routine loading test. All these tests are performed on completion of 28
days of casting of pile and these tests are performed from the casing top level.
The procedure for both the tests is the same only the amount of load to be applied is
different in both the cases. The initial/normal load test on piles is conducted to confirm
the design load and to provide the guidelines for setting up limits of acceptance for
routine test piles. In this the load is 2.5 times the safe load carrying load capacity for
which the pile is designed. The routine load test is conducted frequently to check
random piles. In cannot be done on every pile as it takes long time. In this the load is 1.5
times the safe load carrying capacity for which the pile is designed.
Procedure: A bearing plate with a hole shall be placed on the head for the jack to rest. 2
dial gauges for a single pile and 4 dial gauges for a group of piles with 0.01 mm
sensitivity shall be used. Kentledge shall be suitably designed to get the desired reaction
on the piles. The dial gauge is positioned at equal distance around the piles on datum bars
resting on immovable supports at a distance of 3m. The test should be carried out by
applying a series of vertical downward incremental load each increment being of about
20 percent of safe load of the pile. Each load is to be maintained till the rate of
displacement of the pile top is either 0.1 mm in the first 30 minutes or 0.2 mm in the first
one hour or 2 hours whichever occurs first. The next increment in the load is to be
applied on achieving the aforesaid criterion. The load is maintained for 24 hours and then
it is removed gradually. The settlement/displacement is measured with the help of the dial
gauge.
The normal load test helps in finding the safe load for that pile on the bases of which we
can make the necessary changes required changes to get the desired safe load. The safe
load is the least of
1) 2/3rd
of the final load at which the total displacement attains a value of 12 mm
unless otherwise required in a given case on the basis of nature and type of
structure in which case, the safe load should be corresponding to the stated total
displacement permissible.
2) 50% of the final load at which the total displacement equals 10% of the pile
diameter in case of uniform diameter piles or 7.5% of the bulb diameter in case of
under reamed piles.
While for the routine test the maximum settlement should not exceed 12mm or else pile
will fail.

20. 3.3 TESTS PERFORMED IN LAB
Most of the tests are performed in the lab except which were required during construction
as mentioned above. These include the tests on cement, coarse aggregate, fine aggregate
and admixtures before they are mixed together to form concrete which is used at the site.
Some of them are generally instantly when the sample arrives usually at night.
3.3.1 Test on cement
There were various tests that were conducted on cement to find out the quality of cement
being used. As doing tests on every bag would take a long time, these test were carried
out per 1000 bags.
1. Standard Consistency
It is that consistency which will permit a vicat plunger having 10 mm diameter and
50 mm length to penetrate to a depth of 33-35 mm from top of the mould.
Procedure:
 400 g of cement is taken and placed in a enameled tray.
 Mix about 25% water by weight of dry cement thoroughly to get a cement
paste.
 Fill the vicat mould, resting upon a glass plate, with this cement paste.
 After filling the mould completely, smoothen the surface of the paste,
making it level with top of the mould.
 Place the whole assembly (i.e. mould + cement paste + glass plate) under
the rod bearing plunger.
 Lower the plunger gently so as to touch the surface of the test block and
quickly release the plunger allowing it to sink into the paste.
 Measure the depth of penetration and record it.
 Prepare trial pastes with varying percentages of water content and follow
the steps (2 to 7) as described above, until the depth of penetration becomes
33 to 35 mm.
By the above method the amount of water (%) to be added to get cement of
required consistency is found out which between 28-32% was allowable.
2. Initial & Final Setting Time
Initial setting time is that time period between the time water is added to cement
and time at which 1 mm square section needle fails to penetrate the cement paste,
placed in the Vicat’s mould 5 mm to 7 mm from the bottom of the mould. While
Final setting time is that time period between the time water is added to cement

21. and the time at which 1 mm needle makes an impression on the paste in the mould
but 5 mm attachment does not make any impression.
Procedure:
 The first step of preparing the mould is same as that of in case of finding
the consistency. Only in this case the stop watch is started when water is
added to the cement (t1).
 For initial setting time place the test block confined in the mould and
resting on the non-porous plate, under the rod bearing the needle. Lower the
needle gently until it comes in contact with the surface of test block and
quick release, allowing it to penetrate into the test block. In the beginning
the needle completely pierces the test block. Repeat this procedure i.e.
quickly releasing the needle after every 2 minutes till the needle fails to
pierce the block for about 5 mm measured from the bottom of the mould.
This time is recorded (t2).
 For final setting time, the needle of the Vicat’s apparatus is replaced by the
needle with an annular attachment. The cement is considered finally set
when upon applying the final setting needle gently to the surface of the test
block; the needle makes an impression thereon, while the attachment fails
to do so. This time is recorded (t3).
The initial and the final time can be calculated by the formulae:
Initial setting time=t2-t1, Final setting time=t3-t1
3. Compressive Strength
It is the strength which a cube of cement mixture can after being moulded. It is
determined by compressive strength test on mortar cubes compacted by means of a
standard vibration machine. The specimen is in the form of cubes
70.6mm*70.6mm*70.6mm.
Procedure: Standard sand used for preparation of cement mortar. 200g of cement
and 600g of sand are mixed thoroughly. Add 11% of water and mix thoroughly to
obtain uniform color. Fill the mortar in the mould and keep it on the vibrator by
clamping it. Vibrate it for 2min so that the mortar is fully compacted. Allow it to
set and after 24hrs remove the mould and keep the mortar in water. Take it out
only for testing. The strength after 3, 7 &28 days is carried out.
The mortar is taken out of water and compressive strength is found out by apply
force till a crack appears (fails). The value after 28 days should be around 53Mpa.
If not the cement is not proper and needs to be replaced.

22. Vibrator to prepare mould of mortar Vicat’s apparatus
3.3.2 Tests on Coarse Aggregate
Coarse aggregate are granular element more than 4.75mm in size. They are very
important in formation of concrete. They generally range between 9.75 to 37.5mm in
diameter. In the site crushed coarse aggregate were used. They were used in 2 different
sizes basically 10mm coarse aggregate and 20mm coarse aggregate. It basically specifies
the maximum size of the aggregate to be used. There were various test to be performed
on them which are given in detail below.
1. Sieve Analysis
Sieve analysis (or gradation test) is a practice or procedure used to assess
the particle size distribution (also called gradation) of a granular material. The
size distribution is often of critical importance to the way the material performs in
use. A sieve analysis can be performed on any type of non-organic or organic
granular materials including sands, crushed rock, clays, granite, feldspars, coal,
soil, a wide range of manufactured powders, grain and seeds, down to a minimum
size depending on the exact method. This method was basically used to make sure
that the grading of soil is ok and make sure no particle of size more than 10mm is
found in 10mm coarse aggregate. This test is done every day.
Procedure: All the sieves are taken and arranged in ascending order with the
highest diameter on the top. 1kg of sample is taken and poured on the top sieve
and the lid is covered. It is shaken with the sieve shaker and then weight of sample

23. in each sieve is found out. A sample of reading for 10mm sieve is given below.
Sieve
Size
Retained
weight
% Retained
Weight
Cumulative %
Retained
Cumulative
% passing IS Limits
10mm 0 0 0 100 100
4.75mm 77 7.7 7.7 92.3 90-100
2.36mm 51 5.14 12.84 87.16 75-100
1.18mm 81 8.11 20.95 79.05 55-90
600 Micr 268 26.86 47.81 52.19 35-59
300 Micr 247 24.79 72.7 27.4 8-30
150 Micr 221 22.18 94.88 5.12 0-10
Pan 51 5.12 100 0 0
2. Flakiness and Elongation Index
This test is used to determine the particle shape of the aggregate and each particle
shape being preferred under specific conditions. The significance of flakiness &
elongation index is as follows:
 The degree of packing of the particles of one size depends upon their
shape.
 Due to high surface area to volume ratio, the flaky and elongated particles
lower the workability of concrete mixes.
 Flaky and elongated particles are considered undesirable for base coarse
construction as they may cause weakness with possibilities of braking
down under heavy loads.
Procedure: This test is only performed once a month as it is a very long process
and may even take a day to finish. First the sample is to be passed through the
sieve. Then the particles are arranged into particle size group eg. Those which pass
through 25mm sieve but not from 20mm are in one group, those which pass
through 20mm but from 16mm in one group and so on. Then 200 aggregates from
each group are taken and there weights of each group are noted down and total
weight is calculated. Then for elongation index each particle is passed through the
group of their sizes which is written on the instrument. If it passes it is ok or else it
is elongated. The weight of elongated aggregate is noted down for each group. For
flakiness index each particle is passed through a hole of its respective size as
mention on the instrument. If it passes it is flaky or else not. The weight of flaky
particle is found out for each group. A sample of reading for 20mm aggregate is
given in the table below.

24. Sieve
size
200 Pieces of
total weight
weight of flaky
aggregate
weight of
elongated
aggregate
25-20 2693 475 224
20-16 1986 237 832
16-12.5 899 179 323
12.5-10 489 111 290
10-6.3 170 57 113
TOTAL 6237 1059 1782
Flakiness index= (1059/6237)*100 =16.98%
Elongation index= (1782/6237)*100 =28.57%
The acceptable value for both are 25%, which means the sample is okay and can
be used. The equipment’s are shown below.
3. Impact or Crushing Value Test
This test is done to determine the aggregate impact value of coarse aggregates.
The property of a material to resist impact is known as toughness. The aggregates
should therefore have sufficient toughness to resist their disintegration due to
impact of frequent movement of trains. This characteristic is measured by impact
value test. The aggregate impact value is a measure of resistance to sudden impact
or shock, which may differ from its resistance to gradually applied load.

25. Procedure: The test sample consists of aggregates sized 10.0 mm 12.5 mm.
Aggregates may be dried by heating at 100-110° C for a period of 4 hours and
cooled.
 Sieve the material through 12.5 mm and 10.0mm IS sieves. The aggregates
passing through 12.5mm sieve and retained on 10.0mm sieve comprises the
test material.
 Pour the aggregates to fill about just 1/3rd
depth of measuring cylinder.
Then compact the material by giving 25 gentle blows with the rounded end
of the tamping rod.
 Add two more layers in similar manner, so that cylinder is full. Strike off
the surplus aggregates and the net weight of the aggregate is measured in
grams (W)
 Bring the impact machine to rest without wedging or packing up on the
level plate, block or floor, so that it is rigid and the hammer guide columns
are vertical.
 Fix the cup firmly in position on the base of machine and place whole of
the test sample in it and compact by giving 25 gentle strokes with tamping
rod. Then the hammer is raised above the surface of aggregate sample in
the cup and allowed to fall freely on the sample giving 15 very quickly.
 Remove the crushed aggregate from the cup and sieve it through 2.36 mm
IS sieves until no further significant amount passes in one minute. Weigh
the fraction passing the sieve to an accuracy of 1 gm. Also, weigh the
fraction retained in the sieve.
Below is the table showing the observation of the impact value test conducted as
on 19/6/2015
Measured weight
Sample Weight 326g
2.36mm sieve retained
weight 273g
2.36mm sieve passing
weight 53g
Impact value = (53/326)*100 = 16.26%

26. The acceptance limit for impact value is 25%. So the sample is within the
requirement limit and the sample is good
4. Dry Loose Bulk Density Test (DLBD)
It is a method to basically find the bulk density of the aggregate. The bulk density
is the weight of material in a given volume. The bulk density of an aggregate is
affected by several factors, including the amount of moisture present and the
amount of effort introduced in filling the measures. In this test the bulk density is
found of loose aggregate and not compacted aggregate.
Procedure: The volume of the cylindrical metal is measured by pouring water into
the metal measure and volume “V” is recorded in liter. Fill the cylindrical measure
to overflowing by means of a shovel or scoop, and then level the top surface of the
aggregate in the metal measure, with a straightedge or tamping bar. The weight of
the aggregate in the measured and recorded (Wkg).
Below shows observation of DLBD test on sample that came 20/6/2015 based on
the test conducted on the basis of the above procedure.
The results for the above tests are
For 20mm Aggregate, DLBD= (14.61/10.52)*1000 =1388.78kg/m3
For 10mm Aggregate, DLBD= (13.96/10.52)*1000 =1326.99kg/m3
For 20mm+10mm Aggregate (60:40), DLBD= (14.985/10.52)*1000 =1424kg/m3
The maximum acceptable value 1500kg/m3
. As all the reading are below this
range the aggregate are as per the required quality.
Volume of bucket 10.52L
Weight of bucket 5.23Kg
For 20mm Aggregate
Weight of bucket +
Aggregate 19.84Kg
Weight of Aggregate 14.61Kg
For 10mm Aggregate
Weight of bucket +
Aggregate 19.19Kg
Weight of Aggregate 13.96Kg
For 20mm + 10mm Aggregate (60:40)
Weight of bucket +
Aggregate 20.215Kg
Weight of Aggregate 14.985Kg

27. 5. Specific Gravity
Specific gravity is the ratio of the density of a substance to the density (mass of the
same unit volume) of a reference substance. Basically specific gravity is the ratio
of the weight of a volume of the substance to the weight of an equal volume of the
reference substance.
Procedure: The specific gravity of the coarse aggregate is found out with the help
of pycnometer. 2kg of sample is taken and washed properly to remove any dust
particle. The weight of empty pycnometer is noted (w1). The pycnometer is then
filled with little more than 1/3rd
of coarse aggregate. It is weighed (w2). The rest is
filled with water and covered at the top. Any air pocket if there is found out by
rolling and then removed. It is then weighed (w3). Then the pycnometer is cleaned
filled with only water and weighed (w4).
Specific gravity is given by
S.G. = (w2-w1)/[(w4-w1)-(w3-w2)]
3.3.3 Test on Fine Aggregate
Fine aggregate is natural sand which has been washed and sieved to remove particles
larger than 5 mm. The reason for using a mixture of fine and coarse aggregate is that by
combining them in the correct proportions, a concrete with very few voids or spaces in it
can be made and this reduces the quantity of comparatively expensive cement required to
produce a strong concrete. Most of the tests conducted in case of fine aggregate are same
as that of coarse aggregate. The tests conducted in the lab are given below in detail.
1. Sieve Analysis
This process is basically done to get the rough idea of classification of fine
aggregate and check whether they are as per the IS requirement or not. The
procedure of conducting remain the same with just sizes of sieve changing with
10mm being the largest and 150 micron the smallest
Sieve
size
Weight
Retained
% Weight
Retained
Cumulative %
Weight Retained
%
Passing IS Limits
10mm 0 0 0 100 100
4.75mm 21 2.1 2.1 97.9 90-100
2.36mm 75 7.5 9.6 90.4 75-100
1.18mm 77 7.7 17.3 82.7 55-90
600
micron 127 12.7 30 70 40-75
300
micron 232 23.2 53.2 46.8 18-45
150
micron 371 37.1 90.3 9.7 0-20
Pan 97 9.7 100 0 0

28. 2. Silt Content by Weight
This experiment is used to determine the quantity of silt in fine aggregate. Silt if
present in fine aggregate form a coating thus preventing a good bond between
cement and the aggregates. If present in large quantities, result in the increase
water-cement ratio and finally affecting the strength of concrete. For conducting
the experiment a 250ml measuring cylinder is required
Procedure: Fill 1% solution of common salt and water in the measuring cylinder
up to 50 ml mark. Then fine aggregate to be tested is added to this solution till the
level of the salt solution shows 100 ml mark. More salt solution is added to take
the level up to 150 ml mark. Shake the mixture of sand and salt solution well and
keep it undisturbed for about 3 hours. Readings are taken at 10min, 30min and
3hrs.
The silt being of finer particles than sand, will settle above the sand in a form of
layer.
Observation:
Silt content by volume
After 10 minutes, Silt = [(114-102)/114]*100 =10.52%
After 30 minutes, Silt = [(110-102)/110]*100 =7.27%
After 3 hours, Silt = [(108-102)/108]*100 =5.56%
The silt content after 10min should be 10-12% and after 3hrs should be 8% max as
per the guidelines. So the sample does not have very high amount of silt present in
it.
3. Moisture Content
It is the amount of water that can be absorbed by an aggregate. The total moisture
content is the sum of the absorbed moisture and the free surface moisture. It is
important to measure the moisture concrete as it affects the property of fresh and
hardened concrete. The moisture content should be around 10% only not affect the
concrete.
Procedure: It has a very easy process. A quantity of sample is taken and
measured (w1). The sample is then kept in the oven for 24hrs to dry up. Then the
sample is again measured (w2).
Moisture Content = (w1-w2)/w2
Two other test for fine aggregate are there, specific gravity and DLBD test whose process
is exactly same as that in case of coarse aggregate.

29. Chapter 4- CONCLUSION
The whole industrial training was a very good learning experience which helped me get
an idea about how the things are done in the field. With the help of this training and the
report a lot can be learned about the various types of foundation that are being used and
the reasons for using a particular foundation over the other.
It also tells about the importance of various parameters that are to be kept in mind and
slight neglectance can lead to hazardous impact in the future. Everything from the
material provided to the process of getting to the end product from the material is very
important in construction. All the tests need to be performed to the exact requirement
under appropriate condition to get the desired results.
On the other hand safety should also be kept in mind and all the safety equipment
including helmet, safety shoes and jacket needs to be worn whenever the person is
present at the site and safety instruction needs to be taken from the safety person in
charge before going to the site.
None of the data recorded should be manipulated, but proper solution should be provide
to correct that data then only as slight manipulation can lead to loss of both life and
property in the near future.

30. ABOUT DELHI METRO RAIL CORPORATION
The Delhi Metro is a metro system serving New Delhi and its satellite cities of Gurgaon,
Noida, Faridabad and Ghaziabad of the National Capital Region in India. Delhi Metro
has been ranked second among 18 international Metro systems in terms of overall
customer satisfaction in an online customer survey. Delhi Metro Rail
Corporation Limited (DMRC), a state-owned company with equal equity participation
from Government of India and Government of National Capital Territory of Delhi built
and operates the Delhi Metro. However, the organization is under administrative control
of Ministry of Urban Development, Government of India. Besides construction and
operation of Delhi Metro, DMRC is also involved in the planning and implementation of
metro rail, monorail and high-speed rail projects in India and providing consultancy
services to other metro projects in the country as well as abroad.
Planning of metro started in 1984, when the Delhi Development Authority (DDA) and
the Urban Arts Commission came up with a proposal of developing a multi-modal
transport system in the city. The Government of India & The Government of Delhi
jointly set up the Delhi Metro Rail Cooperation (DMRC) on March 5, 1995 with Dr. E.
Shreedharan as the managing director. Construction started in 1998, and
 The first section on the Red Line was opened in 2002
 Followed by the Yellow Line in 2004
 The Blue Line in 2005, its branch line 2009
 The Green Line and Violet Line in 2010 and
 The Airport Line in 2011
The metro is a combination of elevated, at grade and underground lines and uses both
broad gauge and standard gauge rolling stock. It has a total of 138 stations out of which
96 are elevated stations, 37 are underground stations and 5 are at grade stations including
9 interchange station. The Delhi Metro Rail Cooperation has been certified by the United
Nations as the first metro rail and rail based system to get carbon credits for reducing
greenhouse gas emission.
It has brought revolutionary change in the city transport. It has reduced time travel and
also got down the pollution level by around 50%.

31. Overview of the Delhi Metro Routes

32. REFERENCES
 www.civilengg.com
 www.wikipedia.com
 Civilblog.org
 www.concreteconstruction.net
 Various IS Coded
 IS 4031 for cement test
 IS 2386 for coarse aggregates
 IS 2306 for fine aggregate
 IS 2911 for piles
 IS 1199 & IS 3085 for concrete