civil engineering

1. NTPC GADARWADA – TRAINING
REPORT
-Himanshu Rajput
B Tech. 2nd year,
Dept. of Civil Engg.,
Indian Institute of technology
Kanpur10/6/17

2. OVERVIEW
CIVIL
WORK
Ash
dyke Weir Main
plant
Fabrication Erection Chimney
Site leveling
&
Infrastructure
Transportation
Flexible
pavement Rigid pavement
Bridge
Site
leveling
Drain &
Diversion
drain
Pre-
engineered
structure
Boundary
Wall
Coal
Handling
Plant
Water
Treatment
Plant
Cooling
tower
Field Quality
Assurance
Township

3. NTPC GA DA RWA DA LAYOUT
`Township
Main Plant
Ash Dyke
Water Reservoir
Fabrication yard
CT
CHP
WTP
switchyard

4. TESTING
TESTING OF CONCRETE
1) Compressive Testing Machine
• 1 set cast- 6 cubes, with frequency 50 𝑚3.
• Cube size 150*150*150 𝑚𝑚3
• Rate of loading 140kg/𝑐𝑚2 .min
• 3 days, 7 days, 28 days CT from the date
of casting
• 7 days- min. 70% strength
28 days- (Grade)+3

5. 2 Fresh Concrete - Slump Test
• Slump is a measurement of concrete's workability, or fluidity.
• It's an indirect measurement of concrete consistency or
stiffness.
• The slump test is used to ensure uniformity for different
batches of similar concrete under field conditions and to
ascertain the effects of plasticizers on their introduction.

6. Core Cutter – Partially Destructive Test
• Diameter of core should be atleast 3 times greater the max nominal size of
course aggregate and not less than 2 times of MNS of CA.
• Cores to be tested within 7 days of coring.
• Cube strength = 1.25 * Cylinder strength
• to determine the compressive strength of in-place concrete as per the
standards of IS: 456.

7. REBOUND HAMMER- NDT
• Surface property test
• Harder the surface, greater is the rebound.
• Compressive strength

8. CEMENT
The OPC cement is available in 3 grades:
33 Grade
43 Grade
53 Grade
Ordinary Portland Cement
White Cement
White Cement and Grey Cement are usually compared on five terms which are as follows:
1. Raw Material: Grey colour of the cement is mainly due to high content of oxides of iron, manganese
and chromium which are present in limited amount in white cement.
2. Strength and Setting Time: Its setting behavior and strength development are essentially the same as
those expected in grey cement.
3. Fineness: White cement is usually finer than grey cement and thus, gives better finishing.
4. Cost: Due to more complex manufacturing process of white cement, it is expensive than grey cement.
In India, white cement is usually around Rs. 20 per kg costlier than grey cement.
5. Uses: White cement due to its whiteness is mainly used for architectural beauty, interior and exterior
decorations, floorings, ornamental concrete products such as idols while grey cement is mostly used for
construction purposes.

9. Portland Pozzolana Cement is ideally suited for the following
construction:
+ Hydraulic structures.
+ Mass concreting works.
+ Marine structures.
+ Masonry mortars and plastering.
+ Under aggressive conditions.
For PPC cement there is only one grade which gives a minimum
compressive strength of 33 MPa after 28 days when mixed with standard
sand.
Portland Pozollana Cement

10. FST needle
Testing of cement
Vicat Test
• IS 5513,IS 4031- Part 4 & 5
• Initial Setting Time
• Final Setting time
• Consistency
 400 gm cement + water (starting with 32%)
 Plunger – Dia= 10∓0.05 mm, Len=50∓1 mm
 Depth of Penetration = 5-7mm
 Consistency= (Quantity of water for 5-7 mm
penetration/Weight of cement) X 100
Standard consistency
plungerIST needle

11. Nominal & Design Mix of Concrete
Nominal Mix Concrete
• The wide use of concrete as construction materials has
led to the use of mixes of fixed proportion, which ensures
adequate strength. These mixes are called nominal mixes.
• They offer simplicity and Under normal circumstances,
has margin of strength above that specified.
• Nominal mix concrete may be used for concrete of
grades M5, M 7.5, M10, M15 and M20.
Design Mix Concrete
• The concrete mix produced under quality
control keeping in view the strength, durability,
and workability is called the design Mix.
• Others factors like compaction equipment's
available, curing method adopted, type of
cement, quality of fine and coarse aggregate
etc. have to be kept in mind before arriving at
the mix proportion.
• The design mix or controlled mix is being
used more and more in variety of important
structures, because of better strength, reduced
variability, leaner mixed with consequent
economy, as well as greater assurance of the
resultant quality.

12. If air content increase
slump increase and
hence water content is to
be decreased
If W/C increase water being
constant cement decreases hence no
of cement fines decreases and we
increase sand fines

13. T E S T I N G O F B R I C K S
S A M P L I N G
Sampling of 10 bricks from a lot
Brick making plant

14. 1) Water absorption
2) Compression
3) Warpage
4) Efflorescence
Brick Testing

15. TESTING OF SOIL
Liquid Limit test (Cassagrande’s Apparatus)
 This test is done to determine the liquid limit of soil as per IS: 2720 (Part 5) – 1985.
 The liquid limit of fine-grained soil is the water content at which soil behaves
practically like a liquid, but has small shear
strength.
 About 120g of the specimen passing through 425µm IS Sieve is mixed thoroughly
with distilled water. Keep it for 24 hrs. in case of clayey soil.
 Revolution rate of crank= 2 rev./sec

16. Proctor Test
 This method covers the determination of the
relationship between the moisture content and
density of soils.
 Start with 4% then add 2% water each time.
 After weighing of proctor take some sample
for moisture content.
 Wet density gm/cc =weight of compacted soil
/ 944
 Dry density= wet density/(1+w)
 Plot MDD vs. OMC graph.

17. Core Cutter Test
 This test is done to determine the in-situ dry density
of soil by core cutter method as per IS: 2720 (Part
XXIX) – 1975.
 approximately 30cm square of the soil layer to be
tested should be exposed and levelled
 Wet density gm/cc =weight of compacted soil / Vol.
of core
 Dry density= wet density/(1+w)

18. TESTING OF STEEL
Bend –Rebend test
The reason for using this method is that the content of free nitrogen arises in the steel smelt at
high temperatures and when feeding it with nitrogen containing gases. If the content of free
nitrogen is too high, it will effect the ductility after cold-working and ageing.
Bending Rebending

19. Test piece A test piece of sufficient length is cut or sawn from the bar. If test pieces are taken
from welded fabrics they shall not contain any heat affected zones (HAZ).
Bending the test piece shall be bent over a mandrel not greater than 10 times dia of test piece.
The angle after unloading shall be 90°. The time to complete the bending shall be at least 1 sec.
Artificial ageing The bent test piece is artificially aged at +100 °C for two hours (2 h) in still air
furnace or half an hour in boiling water followed by free cooling in air, to ambient temperature.
As option a temperature of +250 °C for half an hour (0.5 h) can also be used.
Rebending The bent and aged test piece shall be rebent. The distance between the support
rollers shall allow the rebend to take place within the bent area until the angle after unloading is
reduced to less than 70°.
Inspection After rebending, no fracture, transverse or oblique cracks visible to the naked eye shall
occur on the test piece.
TEST PROCEDURE

20. REINFORCEMENT
Cold Water ducts
( CW ducts )
Mat – raft

21. Deck sheeting- permanent formwork
Steel analyzing Ribs-concrete gripping
rings
Chair

22. FOUNDATIONS
Shallow foundation
Raft FoundationCombined Footing
M25

23. Isolate footing Strip footing

24. Deep Foundation
 Bentonite powder + water is used for flushing
 Reqd. density 1.05 gm/𝑐𝑚3
Pile Foundation Bentonite Powder

25. FORMWORK & CURING
Formwork ( shuttering ) Curing with Gunny bags

26. ASH DYKE
ASH
Bottom Ash (20%)
Settles down; water
is then pumped
out
Fly Ash (80%)
High Concentrated
Slurry
Ash carrying pipe pedestal
+ water
& to dyke + water
Earth
Sand
Toe drain

27. Ash dyke Layout
Ash dyke section
Toe drain
sand
earth
Key / Cut-
off trench

28. Special features of Cut-off trench :-
To avoid piping effect – does not allow the water to seep thru the
bottom
To provide strength to the whole embankment (similar to shear key in
column)
To channel the seeped water to the sand embankment.
 Use of Bentonite:-
 To reduce the permeability of soil and hence make it impervious.
 Gives clayey effect to soil and reduce
seepage.

29. WEIR
Narmada weir
A weir is a barrier across the horizontal
width of the river that alters the flow
characteristics of the water and usually
results in a change in the vertical height of
the river level. There are many designs of
weir, but commonly water flows freely
over the top of the weir crest before
cascading down to a lower level

30. • Generally ogee shaped weirs are provided for the spillway of a storage
dam.
• The crest of the ogee weir is slightly rises and falls into parabolic form.
• Flow over ogee weir is also similar to flow over rectangular weir.
Ogee – Shaped weir

31. MAIN PLANT - FABRICATION
Cutting

32. Welding
Types of welding:-
1) Arc welding
i. Power supply used to create an electric arc b/w
electrode and base material.
ii. Generally SMAW: uses consumable electrode with
coating.
iii. GMAW or MIG welding: alongwith the electrode a
shielding gas (mixture of Ar & CO2 ) is also fed
2) Gas Welding
i. Focused high temperature flame is generated by gas
combustion to melt the workpiece and the filler.
ii. Most common : Oxy-fuel welding where acetylene
is combusted in oxygen.
Fabrication rods of two types:-
i. E6013 – thin plates (<20mm)
ii. E7018 – thick plates (upto 40mm)

33. NDT test for welding
Dye Penetration test
 Dye Penetrant is a NDT (Non Destructive Testing) method.
 kits come in 3 parts, usually in aerosol cans - A cleaner, a
penetrant, and a developer.
cleaner penetrant developer

34.  Blasting
• To remove the first layer mill scales
• Cu-Fe grit is used.
• 50 : 50 old and new grit.
• Safer & more environmental friendly than sand
• Swedish comparator is used to check the desired roughness.
Blasting
Before blasting
Cu-Fe grit
After blasting

35.  Painting
• Within 4-5 hours of blasting.
• Primer comes in powder/paste. Mixed with thinner in proper ratio.
• Layers of paints
i. Zinc Silicate primer (min. 75μ)(blue)
ii. Micaceous Iron Oxide (75 μ)( red) (MIO)
iii. Finish Coat (75 μ)
iv. Final Finish (25 μ)

36. MAIN PLANT - ERECTION
Turbo Generator foundation ( TG foundation )
• Foundation for vibrating machines
• Earthquake resisting

37. Chimney shell
Foundation
Pile
Raft
Reinforced Mat
shell
No reinforcement
M25 PPC
M30 OPC

38. S I T E L E V E L I N G
Total station is a theodolite with an Electronic Distance
Measurement Device. Total station has also been one of the reasons
behind the drastic change of technology in the surveying field.
Leveling Survey: This type of survey is used to determine
the vertical distances (elevations) and relative heights of points
with the help of an instrument known as level
level
TS theodolite

39. ROADS
RIGID PAVEMENT
A rigid pavement is constructed from cement
concrete or reinforced concrete slabs. Grouted
concrete roads are in the category of semi-
rigid pavements.
The design of rigid pavement is based on
providing a structural cement concrete slab of
sufficient strength to resists the loads from
traffic. The rigid pavement has rigidity and
high modulus of elasticity to distribute the
load over a relatively wide area of soil.
Minor variations in subgrade strength have
little influence on the structural capacity of a
rigid pavement. In the design of a rigid
pavement, the flexural strength of concrete is
the major factor and not the strength of
subgrade. Due to this property of pavement,
when the subgrade deflects beneath the rigid
pavement, the concrete slab is able to bridge
over the localized failures and areas of
inadequate support from subgrade because of
slab action.
M30
Paving quality concrete
(PQC)
Dry lean concrete (DLC)
Tie bars
Jointed plain concrete pavement (JPCP)

40. Dowel Bars (longitudinal)
Contraction Joint
To prevent cracks in slab due to contraction and
expansion
crack
Rubber lining

41. Flexible pavement
‫ם‬ Seal coat is a thin surface treatment used to water- proof
the surface and to provide skid resistance.
Tack coat is a very light application of asphalt emulsion
diluted with water. And It provides bonding between two
layers of binder course.
Prime coat is an application of low viscous cutback
bitumen to an absorbent surface like granular bases on which
binder layer is placed and provides bonding between two
layers.
Surface course is the layer directly in contact with traffic loads and are constructed with dense graded asphalt concrete.
Binder course purpose is to distribute load to the base course. Binder course requires lesser quality of mix as compared to
course above it.
Base course provides additional load distribution and contributes to the sub-surface drainage.
Sub-base course the primary functions are to provide structural support, improve drainage, and reduce the intrusion of
fines from the sub-grade in the pavement structure
Sub-grade The top soil or sub-grade is a layer of natural soil prepared to receive the stresses from the layers above

42. objectives of providing camber are:
Protection of the road surface, especially
for gravel and bituminous roads by
draining the unwanted water as quickly
as possible.
Protection of the subgrade by providing
good drainage conditions.
For safety considerations, as wet
pavement conditions are quite
undesirable from safe driving point of
view.

43. Shakkar river Bridge
Top plug
Pier / Column
Bearing
Deck beam
Pier cap
Post-cast simply
supported beam
Clam shell machine to dig earth

44. Causeway HTS wires and post-stressed

45. Trapezoidal drain
Rectangular drain
Diversion drain

46. Culvert
A culvert is a structure that allows water to
flow under a road, railroad, trail, or similar
obstruction from one side to the other side.
Typically embedded so as to be surrounded
by soil, a culvert may be made from
a pipe, reinforced concrete or other material
Sewer & Man
hole
Box –type culvert

47. Pre-engineered construction
1. The primary framing structure of a pre-engineered building is an assembly of I-shaped
members, often referred as I-beams. In pre-engineered buildings, the I beams used are
usually formed by welding together steel plates to form the I section. The I beams are
then field-assembled (e.g. bolted connections) to form the entire frame of the pre-
engineered building.
2. Pre-Engineered Buildings can be adapted to suit a wide variety of structural
applications, the greatest economy will be realized when utilizing standard details. An
efficiently designed Pre-Engineered Building can be lighter that the conventional steel
buildings by up to 30%
RAFTER - a beam forming part of the internal
framework of a roof.
Metal beam
pcc
sheeting

48. Boundary wall
Retaining wall ( RCC )
Loose soil
RCC column
Brick masonry
( English bond )
Pre-cast pre-stressed concrete slabs
M25

49. Coal Handling Plant ( CHP )
Turning Point (TP)
Wagon tippler
Not in gadarwada

50. WATER TREATMENT PLANT ( WTP )
Water reservoirSettling tank
Salt peter treatment of foundation – for soils
containing salts
Aerator
Bitumen coated

51. COOLING TOWERS
1. The cooling tower is one of the most important device in chemical industries for
example when the hot water come from heat exchanger we use the cooling tower to
cool it.
2. The purpose of cooling tower is to cool relatively warm water by contacting with
unsaturated air. The evaporation of water mainly provides cooling. In a typical
water cooling water tower, warm water flows countercurrent to an air stream.
3. Typically, the warm water enters the top of packed tower and cascades down
through the packing, leaving at the bottom.

52. Fill –
increase surface area
for evaporation
Made of plastic
fill
Cold water
Cold water channel
Wall to control speed of
flow

53. TOWNSHIP
Water body
stadium
D-type
C-type
B-type
Hospital
school
Shopping complex

54. 1. Foundation
2. Plinth
3. DPC ( damped proof course)
4. Floor
5. Walls
6. Openings
7. Stairs
8. Roof
9. Surface finish

55. Plinth
Min grade M20
Plinth beam
A plinth is normally constructed just above the
ground level and immediately after the foundation. It
raises the floor above the ground level and herewith
prevents surface water from entering the building
Ground beam

56. Plinth beam advantage-
1.Prevent leaking of water into foundation - To prevent a house from settling it is critical that no water be leaked into
foundation. Being made of cement, plinth beam is impervious and therefore prevents water from rain, flooding, etc.
from leaking into foundation.
2. Provides support for walls - For load bearing houses, walls carry the weight of the house. Plinth beam provides solid
footing to raise those walls.
3. Holds house together - Since plinth beam sits across the periphery of the house, it provides binding force across
rooms. For example, without plinth beam it is possible for one of the rooms to settle thus creating uneven floor level.
Plinth beam prevents that from happening.
Damped Proof Course ( DPC ) min thickness 25mm
Damp proof course is a layer of water proofing material such as asphalt or waterproof cement.
Walls are constructed above the damp proof course. Damp proof course prevents surface water
from rising into the walls.
Dampness reduces the strength of the walls and creates unhealthy living conditions. Also it
affects the paint and plaster and increasing the cost of maintenance. Damp proofing layer is not
required where a plinth beam is constructed, because the plinth beam already performs like a
DPC.

57. Back filling & Plinth filling
Tempering and rammering of
soil
Sand filling
PCC
FILLING MATERIAL FREE FROM LUMPS, ROOTS, VEGETATION, HARMPUL SALTS, ORGANIC
MATERIALS ETC.
1 : 3 : 6 c : fa : ca

58. TYPES OF FLOORING
•CARPETS AND RUGS
•VINYL FLOORING
Vinyl composition tile (VCT) is a finished flooring material used primarily in commercial and
institutional applications.
Types of tiles-
a) Vitrified tiles - Vitrified tiles are ceramic tiles with high percentage of vitrification and less amount of water
absorption. Vitrification is nothing but a development of glass phase inside the tile during firing process.
b) Ceramic tiles- High wear resistance with low density.
c) Porcelain tiles
•GLASS FLOORING
Glass floors are made with transparent glass when it is useful to view something from above or below; whereas translucent
glass is used when there is no need to view through.

59. •WOODEN FLOORING
This type of flooring is generally use for special purpose floor example auditorium, hospital etc.
•STONE FLOORING
Marble- •Costliest and best marble is the Makrana white
•White base marble price ranges from Rs.30/- to Rs.400/- sq. ft.
Granite - Hardest type of stone- very difficult to cut and polish
Slate - Resistant to wearing, discoloring or fading
Kotah & Sandstone - used as hard flooring suited for pathways, factory sheds, offices
and other common spaces.
•BRICK FLOORING
White marble
granite
Kotah Stone

60. Walls & Openings
English bond
a bond used in brickwork consisting of
alternate courses of stretchers and headers.
column
Brick work
OPENINGS
Openings are normally provided in the walls as door, windows and
ventilators. Doors provide access; windows and ventilators provide light
and ventilation.
Lintels are constructed just above the openings. It is normally a stone
slab or a concrete slab.
Sill is the part of the wall that is just below the window.
Lintels are constructed to hold up the walls above the openings. In
earthquake prone areas a continuous lintel beam is provided all over the
walls.
jamb
soffit

61. Testing of Wood
Teak wood for door frames in
Guest house Digital Moisture meter – value
should not be greater than 12%

62. Stairs
Staircase parts formwork

63. ROOF
A flat roof is not truly flat but
angled slightly to allow for water
runoff. It is the cheapest to build
initially but will cost you much
more than other roof types in
maintenance costs.
M30- water
retaining
structure on
roof

64. Surface finish
Wet finishes
Plaster
Paint
Wallpaper
One of the major problems with wet finishes is
that considerable “drying out time” is required
for the building plus expansion shrinkage
problems with timber components.
Dry finishes
Plaster board
Timber panelling
Carpet
The greatest advantage of dry finishes when
compared to wet finishes is that no shrinkage will
occur during the dry out process
Internal Plastering one or two coats of sand and cement with a finish coat of gypsum plaster on
brick or block walls
Mortar plaster
Mortar
plaster
Gypsum
plaster
Plaster grooves-prevent
cracks1: 6 wall
1: 3 ceiling

65. Paint finish
objectives of painting are:-
Preservation
appearance
hygiene
A painting system for a given material usually consists of:-
Paint Primer Adheres well to the background and evens out the surface porosity. With ferrous
metals, controls rust. Care must be taken to choose suitable primer for the material to be
covered.
Undercoat Adheres to the primer, builds up the paint thickness and obliterates surface
irregularities. The undercoat should bring the surface to a suitable colour for receiving the
finishing coat. Two coats of undercoat are usually required.
Finish Adheres to the undercoat and provides a protective layer, colour and surface texture.

66. Important site machines
& tools
Excavator / power shovel
Concrete pump
Batching Plant

67. Bull Dozer
Back Hoe
Spreading earth and clearing landfills
Pneumatic type roller
Smooth type roller
Drag line
In wet soils
Hard rock below working surface

68. Hoe trowel Measuring tape
Plumb Bob
Wheel barrow Float Line level
DrillJack planePolisherPutty Knife

69. CONCLUSION
Overall, I had a fantastic experience while training with the engineers
of NTPC and JMC. I feel extremely fortunate to be a part of the
Maharatna company of India for a month. This summer training
helped me grow a lot and get a deeper look into the construction field.
The summer training program in NTPC is unique because of more
exposure we get in the company.
!!! THANKYOU !!!