PREPARED BY :

AMRITA CHATTERJEE
SWARNENDU BHATTACHARJEE

ADAMAS INSTITUTE OF TECHNOLOGY,

CIVIL ENGINEERING, 3RD YEAR 1
 Proposed TCS
Site

Total Land Area : 40 acres

Land demarcation co-ordinates provided by HIDCO

2
We, Amrita Chatterjee & Swarnendu Bhattacharjee are really
obliged to be a part of this vocational training programme for
our winter vacations under the expert guidance of L&T and
SPCL UJV at their proposed site at Rajarhat for TCS IT SEZ
park. We are very much thankful to Mr Amit Kumar
Bhattacharyya who gave us the opportunity to be a part of
this. Also Mr Pramod Kumar Singh to whom we were to report
all our happenings. Special thanks to Mr Abhinandan Sarkar
under whose expert guidance we were put at the site. We are
also very obliged to the other people with whom we interacted
during our stay whose names we are not able to mention here.

3
SL NO. PAGE
DESCRIPTION NUMBER

1 ACKNOWLEDGEMENT 3
2 INTRODUCTION 6
3 ABOUT ORGANIZATIONS INVOLVED 8
4 GENERAL INFORMATION 11
5 VARIOUS DEPARTMENTS 15
6 PLANNING DEPARTMENT 16
7 RESOURCE SECTION 23
8 QC/QA DEPARTMENT 26
9 SAFETY DEPARTMENT 39
10 PROCUREMENT AND STORE 46
DEPARTMENT
11 PLANT AND MACHINARY 49
DEPARTMENT
12 CONSTRUCTION METHODOLOGY 52
13 EXECUTION DEPARTMENT 56
13.1 SURVEY 57
13.2 PILING 67
13.3 EXCVATION, PILE CAP & RETAINING 73
WALL 4
13.4 RAFT, COLUMN & REINFORCEMENT 74
SL NO. PAGE
DESCRIPTION NUMBER

13.5 FORMWORK 75
13.6 CONCRETE, CURING & DE- 76
SHUTTERING
13.7 BRICKWORK, PLASTERING & 77
FACADING
14 SOME CLICKS OF THE SITE 78
15 CONCLUSION 79

5
 INTRODUCTION

It is an almost 1000 cr. project proposed by Tata Consultancy Services

(TCS) for its IT SEZ Park at Rajarhat, Newtown, Action Area – II, Kolkata
– 700156.

A Special Economic Zone (SEZ) : It is a geographical region that has

economic and other laws that are more free-market-oriented than a
country's typical or national laws. "Nationwide" laws may be suspended
inside a special economic zone.
The category SEZ covers, including free trade zones (FTZ), export
processing Zones (EPZ), free Zones (FZ), industrial parks or industrial
estates (IE), free ports, free economic zones, urban enterprise zones and
others.
Usually the goal of a structure is to increase foreign direct investment by
foreign investors, typically an international business or a multinational
corporation (MNC), development of infrastructure and to increase the
employment.

Here it’s a 32 month project which commenced from 02/04/2012 and

expected time for completion is November, 2014. It’ll provide 16000 seats
for job once completed. The contractor is to hand-over around 9000 by
February, 2014. It covers an area of around 40 acres in the heart of the
financial hub of Kolkata.

Design Consultant : L&T EDRC (Engineering Design & Research

Consultancy)

6
 DESCRIPTION DETAILS
Employer Tata Consultancy Services
Limited (TCS)
Employer’s Tata Realty and Infrastructure
Representative Limited (TRIL)
PMC Tata Consulting Engineers
Limited (TCE)
Design Consultant CANNON Design, Mumbai
MEP Consultant Spectral services Consultants
Pvt Ltd, Mumbai
Built Up area 2.25 Million Sqft (2,258,658 Sft)
-Including Basement
Type of Contract (P11 Design Build – Fixed Firm
of Vol 1) Lumpsum Price
Project Duration 32 Months (Phase I – 15.02.14 &
Phase II – 01.12.14)
Date of Issuance of 06.03.12
LOI
Date of 02.04.12
Commencement
Date of Issuance of 25.05.12
LOA
Total No. of Seats 16,723 Nos
(Occupancy)
 ABOUT

TATA CONSULTANCY SERVICES (TCS) : CLIENT

Established in 1968, Tata Consultancy Services has grown to its current

position as the largest IT services firm in Asia on the basis of its
outstanding service record, collaborative partnerships, innovation and
corporate responsibility.
We are proud of our heritage as part of the Tata Group, which founded
by Jamsetji Tata in 1868 is one of India’s most respected institutions
today.
Our mission reflects the Tata Group's longstanding commitment to
providing excellence:
To help customers achieve their business objectives by providing
innovative, best-in-class consulting, IT solutions and services.

To make it a joy for all stakeholders to work with us.

Our values: Leading change, Integrity, Respect for the
individual, Excellence, Learning and sharing.

8
LARSEN & TOUBRO LIMITED(L&T) & SHAPOORJI PALLONJI
& COMPANY LIMITED(SPCL) : CONTRACTOR (UJV)

LARSEN & TOUBRO LIMITED(L&T)

Larsen & Toubro Limited is the biggest legacy of two Danish Engineers, who built a
world-class organization that is professionally managed and a leader in India's
engineering and construction industry. It was the business of cement that brought
the young Mr.Henning Holck-Larsen and Mr S.K. Toubro into India. They arrived on
Indian shores as representatives of the Danish engineering firm F L Smidth & Co in
connection with the merger of cement companies that later grouped into the
Associated Cement Companies.

Together, Mr. Holck-Larsen and Mr. Toubro, founded the partnership firm of L&T in
1938, which was converted into a limited company on February 7, 1946. Today, this
has metamorphosed into one of India's biggest success stories. The company has
grown from humble origins to a large conglomerate spanning engineering and
construction. Engineering Construction and Contracts (ECC) Division (now L&T
Construction) was conceived as Engineering Construction Corporation Limited in
April 1944 and was incorporated as wholly owned subsidiary of Larsen & Toubro
Limited. L&T's founders Mr. Holck - Larsen and Mr. Toubro laid the foundation for
L&T Construction. It has today emerged as India's leading construction
organization.

9
LARSEN & TOUBRO LIMITED(L&T) & SHAPOORJI PALLONJI
& COMPANY LIMITED(SPCL) : CONTRACTOR (UJV)

SHAPOORJI PALLONJI & COMPANY LIMITED(SPCL)

Shapoorji Pallonji is a name which has become synonymous with trust and quality
in India as well as internationally. Over the years the Shapoorji Pallonji Group has
evolved and grown exponentially to become a huge conglomerate with multiple
business segments. With a rich legacy, a progressive outlook and a consistently
superior track record, the Group remains committed towards excellence.
The Shapoorji Pallonji Group is a dynamic enterprise which draws vital support
from its various individual entities to be able to execute turnkey projects, swiftly and
efficiently. Along with the flagship company Shapoorji Pallonji & Company Limited
(specializing in Construction, Design & Build and EPC), the other luminaries give
the SP Group its tremendous strength and capability.

Today, with over 23,000 employees and a group turn over of US $ 2.5 Billions ,
Shapoorji Pallonji Group has evolved and grown exponentially to become a huge
conglomerate with multiple business segments with a progressive outlook and a
thoroughly professional approach. The Group today has a strong presence in India
and internationally including the Middle East and Africa. With a rich legacy of 147
years and a consistently superior track record, the Shapoorji Pallonji Group remains
committed towards excellence in each domain of its operations.

10
 GENERAL INFORMATION
The Proposed TCS IT SEZ PARK, Rajarhat consists of the following
blocks as described below :
1. Block A B+G+4
2. Block B B+G+4
3. Block C B+G+4
4. Block D B+G+4
5. Block E B+G
6. Block F B+G+4
7. Block G B+G+4
8. Block H B+G+4
9. Block I B+G+15
10. Block J B+G+4
11. Block K B+G+4
12. Block L B+G+15
13. Utility Block, Guest house & Auditorium.

IT / BPO Blocks (A,B,C,D,F,G,J,K&H) DETAILS:

 B+G+4 – 9 Nos
 Plan Size – 81.4m X 27.3m (2222 Sq.m. with Core)
 Basement Level - (-) 0.45m
 Basement Height – 5.1m
 Ground Floor height – 5.4m
 Typ. Floor to floor height – 3.9 m
 Excavation depth – 4.6m
11
 UTILITY BLOCK

 Utility block (1 No) Consists of B+G+1 Floors

 It consist of STP, WTP, Chillers, HT Panel rooms, Pumps ,
Equipment and machines
 Height of (+) 15.15 m above Ground level
 Plan Size Approx.– 105 m x 56 m
 Basement Level – (-)2.0m
 STP Bottom level – (-)4.3m
 Excavation depth – 7.5m

IT TOWERS – BLOCK I & L

 B+G+15 Floors
 Height of (+) 69 m above Ground level
 Plan Size – 81.4 m x 27.3 m (2187 Sq.m.)
 Basement Level - (-) 0.45m
 Basement Height – 5.1m
 Ground Floor height – 5.4m
 Typ. Floor to floor height – 3.9 m
 Excavation depth – 5.65m

12
 GUEST HOUSE

 Guest house (1 No) Consists of G+2 Floors

 Height of (+) 17.85 m above Ground level
 Plan Size Approx.– 96 m x 34 m
 Plan area – 2500 Sq. m (Approx.)
 Ground floor height – 5.1m

AUDITORIUM

 Auditorium (1 No) Consists of G+2 Floors

 Height of (+) 21.75 m above Ground level
 Plan Size – 70 m x 37 m (Approx.)
 Ground floor height – 6.7m

13
MASTER LAYOUT – 2D:

14
 VARIOUS DEPARTMENTS OF THE PROJECT :

 PLANNING SECTION

 EXECUTION TEAM

 RESOURCE SECTION

 QUALITY DEPARTMENT

 SAFETY

 STORE

 PLANT & MACHINARY

 ACCOUNTS & BILLING

 ADMINISTRATION
15
 PLANNING DEPARTMENT
PROJECT MANAGEMENT : Project Management is the Process of
planning, organizing, and managing resources to meet project goals
and objectives.
PROJECT MANAGEMENT LIFECYCLE :
It is a Process of achieving set goals within the constraints of time, Budget and
staffing restrictions.
 Initiation : Define Project - Organization commitment -
Team Development.
 Planning : Get project information from the former
stage - Schedule, Resource and estimate the cost.
Develop a Strategy of Execution in order to meet Project
Objectives.
 Execution : Execute the set target.
 Recording the Progress & Analyzing the Performance

IMPORTANT RULES OF PLANNING:

Dealing with the client ,vender , & other 3rd party agencies about
the progress of the project & documenting total input and output
regarding this project.
Correspondence.
Managing the client contract & implementing it.
Management reports ( weekly\monthly\daily progress report ) Of
financial & physical progress is done by the planning department.
Processing of bills & measurements are done.
It maintains link between all departments ( design , store , quality
,safety ,execution , P&M ) & every department has to report to the
planning department.
PLANNING DEPARTMENT is the nodal & central point of the
project. All information & reports pass through the planning
department before being forwarded.
 16
 Contd…
One of the most important role of planning department is to
make Sequential and Parallel Activities.
An essential concept behind project planning (and Critical Path
Analysis) is that some activities are dependent on other activities
being completed first. As a shallow example, it is not a good idea to
start building this project before have designed it!
These dependent activities need to be completed in a sequence,
with each stage being more-or-less completed before the next
activity can begin. We can call dependent activities "sequential" or
"linear."
GANTT CHART: An action plan/Gantt chart is a graphic
representation of a project’s schedule, showing the sequence of
tasks, which tasks can be performed simultaneously, and the
most critical tasks to monitor. They allow you to assess how long
a project should take, determine the resources needed, and lay
out the order in which tasks need to be carried out. The
plan/chart can be used for an entire project or for a key phase of
a project.
Drawing a Gantt Chart
To draw up a Gantt Chart, follow these steps:
Step 1 – List all Activities in the Plan
Step 2 – Set up Your Gantt Chart
Step 3 – Plot the Tasks Onto the Graph Paper
Step 4 – Presenting the Analysis

17
The above is a Gantt Chart originated from Primavera. The
row marked in green is the EPS (Enterprise Project
Structure), the one in pink is the WBS(Work Breakdown
Structure) and the ones in ochre are the activities whose
details are given below each major activity.
In the above gnatt chart construction is the EPS, RCC works
is the WBS and piling & excavation ,pile cap, raft, column&
18
wall are the activities under this WBS.
 CASH FLOW
In Crores

CASH FLOW
100 1200

90

1000
80
C
U
M
M70 U
O 800 L
N A
T60 T
H I
L V
Y E
50 600
I I
N N
V40 V
O O
I I
C 400 C
E30 E

20
200

10

0 0
May'12 Aug'12 Nov'12 Feb'13 May'13 Aug'13 Nov'13 Feb'14 May'14 Aug'14 Nov'14

19
SL NO ACTIVITY STATUS

LEED – Implementation process is

1 Top soil at site.
commenced.

BIM – Implementation process is

2
commenced. Target date for Project 3D Model RIB
Live by 30.08.12.

EMS – Implementation process

3 Screen shot
commenced.

4 SEZ – Implementation commenced at site on 07.06.12.

5 Contractual & Statutory Compliances – Liaising

Consultant appointed for statutory compliances.

20
Primavera is a tool which is used for Scheduling Planning,
Monitoring and Controlling the projects and to meet budget
and time schedule.
Develop a Global resource Pool to enhance the enterprise
resource management .
o It helps in effective allocation of resources ( man, material,
machinery, money ) .
o It helps in assigning predecessors & successors in a desired
sequence & also assign duration to activities.
o At first an EPS(Enterprise Project Structure) is formed and
projects are added under it.
o Under each project a WBS(Work Breakdown Structure) is
created and activities are assigned under each project.
o Activities are linked by assigning relationships.

BIM (Building Information Modeling) A 3d Model Rib

BIM is a digital representation of physical and functional
characteristics of a facility. It gives us visual comparison
between the projected plan & actual execution of activities. It
can relate the model from Autodesk Revit & Primavera.
21
 STATUTORY APPROVAL STATUS
Approval Status

Aviation Clearance NOC received from AAI on 28.06.2010

Microwave NOC received from BSNL on 27.12.2010

Clearance

Fire NOC Provisional NOC received from

WBF&ES on 26.08.2011

Master Plan Received from WBHIDCO on 18.02.2011

Approval

Building Plan Received from NKDA on 16.09.2011

Approval Endorsed Drawing received on
09.02.2012

Environmental Received from SEIAA on 18.07.2011

Clearance

Consent to Received from WBPCB on 30.09.2011

Establish (NOC)

Water Connection Connection received from NKDA on 22

10.05.2012
The first & initial work of any planning engineer of a project is to
make MPCS (Management Program In Control System).It
consists some steps:
1. S0 – Program of works.
2. S1 – Program of invoicing.
3. S2 – Specialized agencies.
4. S3 – Scheduled of plant & machinery requirement.
5. S4 - Scheduled of staff requirement.
6. S5 - Scheduled of material requirement.
7. S6 - Scheduled of labor requirement.
8. S7 – Milestone events
9. S8 - Scheduled of direct cost.
10. S9 - Scheduled of overheads.
11. S10 – Comparison of S1 & total of S8 and S9.

In S10 we get an “S” curve, which shows us the Break-Even

point & Profit Margin.
After completing MPCS, ACE (Accepted Cost Estimate) is
done. Both EVA & ROCE (Return On Capital Employed) are
also made. Within a three months span MPCS is checked.
In every month Cost Statement, Cost Analysis, JCK (Job
Cost Report) are checked.
23
 Procurement of rebar as per specification.
 Procurement as per the Latest drawing and to match
with the construction schedule.
 Confirmation on correct receipt of materials.

 Shifting of required quantum of materials from steel yard

through gate pass
 Restriction of issue of scraps from steel yard through
indent
 Educating workmen through pep talks and close
interaction to create awareness
 Cutting plan as per BBS.

24
 RESOURCE SECTION

Resource section of the project is the nodal point between the

Planning department as well as the Execution team. It is
responsible for Man, Material & Machine at site. Unless it
mobilizes all of the above 3, it is quite difficult for the execution
team to progress. Also if it doesn’t give the necessary
feedback to the planning department, the future planning of the
project cannot be done and also the present status of the work
cannot be charted.

LABOUR DEPLOYMENT AT TCS IT SEZ PARK,

RAJARHAT AS ON 08/01/2013

SUP UNS KH WELDER/

ERVI MAS KILL CARPE C CHIP FITT F ALA GAS OPER RIG
SOR ON ED NTER HELPER PER ER HELPER SI CUTTER ATOR GER

104 68 681 122 166 63 207 335 92 19 52 30

25
26
QUALITY POLICY OF L&T
CONSTRUCTIONS

27
QUALITY POLICY OF SPCL

28
PRODUCTS TESTED HERE AS A PART OF QC/QA

 CEMENT

 SAND

 20 mm COARSE AGGREGATE

 10 mm COARSE AGGREGATE

 BENTONITE

 ADMIXTURE

 STEEL

 WATER

 BONDING AGENTS

 FLY ASH

 PLY WOOD

 CONCRETE

 BRICK

 SOIL TEST
29
 TESTS PERFORMED ON CEMENT

NORMAL CONSISTENCY

INITIAL SETTING TIME

FINAL SETTING TIME

FINENESS OF CEMENT

SPECIFIC GRAVITY TEST

CEMENT MORTAR CUBE TEST

SOUNDNESS OF CEMENT

30
 TESTS PERFORMED ON SAND

GRADATION OF SAND

BULKING OF SAND

WATER ABSORPTION &

SPECIFIC GRAVITY OF SAND

31
 TESTS PERFORMED FOR COARSE AGGREGATE

GRADATION OF COARSE AGGREGATE

WATER ABSORPTION OF COARSE

AGGREGATE

SPECIFIC GRAVITY OF COARSE

AGGREGATE

IMPACT VALUE OF COARSE

AGGREGATE

CRUSHING VALUE OF COARSE

AGGREGATE

FLAKINESS OF COARSE AGGREGATE

32
 TESTS PERFORMED FOR BENTONITE
SAMPLE DATA SHEET

Date Of Receiving=11/12/2012
Brand Name=Ashapura
Type=Sodium Based
QUALITY OF Bentonite= Pilogel
Sub Contractor Name=L&T SPCL(JV)
Challan no./Date= 489/10.12.2012
Quantity= 320 bags/16MT
Mixing Of Water = 10 kg Water+500 gm. Bentonite
Duration Of Slurry Saturation= 16 hrs.

TEST DATA

1. Density= 1.04

2. Marshcon Viscosity= 30.1

3. Ph. Value= 9

4. Sand Content
Date Of Sampling= 11.12.2012
Date Of Testing= 12.12.2012
Total Weight Of Dry Bentonite= 500
Total Weight Of Retained On 75µ = 14.3
Total Weight Of Passing Through 75µ = 485.70 33
Sand Content = 2.86% (Maximum= 7%)
Contd…

5. Differential Free Swell Index

Date Of Sampling=11.12.2012
Date Of Testing =12.12.2012
Volume In Slurry In Water =56.6
Volume In Slurry In Kerosene =6.93
Free Swell Index =716.74% (Minimum =540%)

Free Swelling Index =[(Water-Kerosene) / Kerosene] x 100

6. Liquid Limit For Bentonite

Date Of Sampling = 11.12.2012
Date Of Testing = 13.12.2012
Depth Of Penetration = 30
Container No. = 9
Weight Of Wet Bentonite + Container (gm.) = 40.70
Weight Of Dry Bentonite + Container (gm.) = 25.03
Weight Of Water (gm.) = 15.67
Empty Weight Of Container (gm.) =19.90
Weight Of Oven Dry Bentonite = 5.13
Moisture Content (%) = 305.45

COMPUTATIONS
Liquid Limit = [Moisture Content / (1.3215 – 0.23logN)]
309.17 % ( Range = 300-450%)

34
 TESTS PERFORMED FOR ADMIXTURE
TYPES OF ADMIXTURES :
 NAPTHALIGNO BASE
 POLYCARBOXYLIC BASE (PC BASE)
 POLYPHOSPHONATE BASE (PF BASE)

Here we normally don’t use the PF type admixture in India. In the

QC/QA lab only the dosage of PC and Napthaligno base
admixture is tested for in the trail mix experiment. The chemical
composition of the admixture is verified in the MTC (Material
Test Certificate) as provided by the manufacturing company at
the time of delivery.

TESTS PERFORMED FOR STEEL

The material is supplied from the manufacturing company’s

factory directly and all the necessary test reports are mentioned
in the MTC which is verified. Here only the Rolling Margin test
for steel is performed at the lab whose data sheet is given below:

35
 TESTS PERFORMED FOR BONDING AGENT

There are primarily 3 types of bonding agents viz.

 Styrene Butadiene Rubber Type
 Epoxy type (Binder and Resin)
 Polyethylene Disulphonate Type

Bonding agents are required at structural joints where new

concrete is to be applied on the surface of any old concrete. As
the cement loses it’s hydrating property after 28days of casting,
so all it’s binding properties are also lost. So bonding agents are
applied on the surfaces of the old concrete near congested
structural joints so as to bring friction into action on the surface
and allow the new concrete to bind with the old one.
Here the manufacturing company sends the TDS ( Technical
Data Sheet) from where we verify the dosage of it and verify it’s
chemical composition from the MTC provided by the
manufacturing company during the time of delivery.

TESTS PERFORMED FOR FLY ASH

Fly Ash is used as a cementitious filler material in concrete.

Here only it’s fineness is checked by wet sieving. It is passed
through 45µ IS Sieve by wet flushing and the percentage of
passing is recorded. If we get result to be more than 66%, then
the fly ash is apt to be used at site for work.
36
 TESTS PERFORMED FOR CONCRETE

1. COMPRESSIVE STRENGTH TEST:

Here the concrete is filled up in a cube of

size 150mm x 150mm x 150mm in three
layers tamping 25 times by the tamping
rod after each layer is poured in. Then it is
kept for curing and we check the
compressive strength for these concrete
cubes for 3days, 7days, 14days and 28days.
For this we use the compressive strength
machine at the lab.

2. SLUMP CONE TEST:

Here the concrete produced from each

batch is taken from the transit mixer and
is checked for slump value to ascertain its
workability. It is the most important and
immediate test for concrete at site.

37
 QUALITY ASSURANCE
Quality Assurance – Part of Quality Management focused
on providing confidence that Quality requirements will be
fulfilled.
Here each data is being scrutinized by the members from the
client side and verified for use at site. Here it is done by
documenting it in registers maintained separately for each
test. If some discrepancy is found with the test results or at
site, the client issues a NCR( Non Conformity Report) or a
NCPN( Non Conforming Product Notification). Once it has
been issued, it’s the duty of the engineers at the QA/QC dept.
to rectify it and close the NCR/ NCPN with proper
photographs as proofs proving their efficiency.
Procedures of Quality Assurance :
• Confirmation to ISO 9001:2010
• Document Control
• Mix-design prepare & submit for Third Party Approval
• Methodology
• QAP (Quality Assurance Plan, for any specific project)
• Material Test Plan
• Inspection Test Plan

38
SAFETY (EHS DEPARTMENT)

39
 SAFETY (EHS DEPARTMENT)
SAFETY is a practice or habit that is required to be developed
within the project team to execute any work by maintaining
proper safe working environment at work-place so that the work
can be executed without loss of any manpower, plants &
machineries, materials during the execution of works at site.
• The main motto of this department is “zero-accident”.
• SAFETY COMMITEE is made at every company for every
particular site.
For this project there is also a safety committee. The chairman
of this committee is the project manager of the site. The
secretary of this committee is the safety in charge & other
execution key persons are the members of the site Safety
committee

• SAFETY EQUIPMENTS
Various Personal Protective Equipment (PPE) are being used by
the site team (Staffs & worker) such as Helmet for head cover,
safety shoe to protect foot properly, Nylon Jacket).

ASSEMBLY POINT-It is a pre-established place in site where

people assembles as soon as they get information regarding any
accident & danger. At this site there are 3 assembly points all
over.
Occupational Disease-Different occupational disease can
occur during the execution of work. To avoid such hazards
company takes some precautions , these are-
Pre-medical Test
Periodic Test 40
Post-Medical Test
Contd…
INCIDENT REPORT-It is a report prepared in company’s specific
(ISO) format demonstrating the details of incident / accident
including its rout cause along with probable precautionary
measures required to be taken to arrest such incident in future.
This report is generally been sent to the concerned to make
awareness among all.

Various terms related to Safety :

SMART Specific Measurable Achievable Reasonable Time on

HIRA Hazard Identification Risk Analysis

ISO International Organization For Standardization

STEL Short Term Exposure Limit

EHS Environmental Health & Safety
SOP Safe Operation Procedure

MEP is checked at regular intervals by safety department. Different

safety tags are tied on to or stuck on various MEP’s etc according to their
present status as on date.

Third Party Inspection (TPI)-Various equipment &

machineries are been inspected regarding its performance to
work safely by the concerned outside agency & a certificate to
that extend is given by such competent authority. This
certificate is valid for 1 year for each machinery. 41
Contd…
 Various Safety Trainings are held to aware the
workers & staffs of the site. This includes many
safety quizzes, on-site demonstration about safety,
speech etc. Prizes are distributed among the staffs &
workers for the quizzes programme. Then the total
man-hour & man-days are counted till that date.
 Different Types Of Safety Trainings-Different
types of trainings are been organized by the safety
department to increase the awareness regarding
safety at project site among the site people.
 SAFETY PARK-It is a particular place where
different PPE/safety gazettes are being
demonstrated or shown, so that all workers of the
project can use the required PPE as per norms.

42
SAFETY PARK AT THE PROJECT
 QUALITY & SAFETY

QMS
PROCESS
CORPORATE
VISION

QUALITY
POLICY

QUALITY
OBJECTIVE

ORDER
FINALIZATION

PROJECT
QUALITY PLAN
PREVENTIVE
MEASURES
MOBILIZATION

TRAINING
CUSTOMER
REQUIREMENTS CUSTOMER
EXECUTION / STASIFICATION /
COMMISSIONING CUSTOMER
STATUTORY & FEEDBACK
REGULATORY
REQUIREMENTS
INTERNAL MANGEMENT
AUDIT INFORMATION
SYSTEM

REVIEW & CORRECTIVE

ACTION LEARNING
43
 QUALITY & SAFETY

Site signage:

44
 QUALITY & SAFETY

Environmental
Controlling measures:
Chute provisions to suppress the dust level in & around work
area.
Debris shall be collected and disposed off through chute
arrangement.
Provision for proper ventilation all around the work area.
Adhering to local environment Regulations & Rules.
House Keeping:
Reinforcement and formwork materials shall be stacked
properly on Stack yard/ working area
Scrap reinforcement will be collected on daily basis and
stacked in scrap yard.

Scrap yard 45
STORE AND PROCUREMENT DEPARTMENT

STORE OF P&M STORE OF SAFETY

PRODUCTS

STORE OF EXECUTION STORE OF EXECUTION46

 STORE AND PROCUREMENT

SYSTEM/ PROCEDURE FOLLOWED :

Project Converted to
User At Director/ EMR(Electro
Site Dy. Project nic Material
Manual material Director Request)
request
After approval by
After passing through
them
the purchase

Authorizatio
n In System
By Planning
Quotation is
Material floated

Supplied to
the User At A Minimum
Site Of 3 Vendors
Called
After passing quality
& Recon Code is After enquiry &
provided Rate check

Quality Material
Purchase
checked by Received
Order(PO) Is
user and/or Note(MRN) is
Raised
QC raised
After verification &
After receipt at site
Authorization
47
 The previous diagram depicts the flowchart showing us the
operational procedure of the Store with close connection with the
Purchase Dept. , Planning Dept., and others. The status of the PO
can viewed by everyone in the company portal by logging into one’s
personal portal

 The execution team then gets the materials from the Store by making
an Indent. As the material gets issued from the Store, the cost of the
said material is debited to the Project and the stock of the Store gets
reduced simultaneously after getting and issue slip issued by
competent authorities at site.

Storage Of Cement At Site

Storage Of Diesel At Site

48
 PLANT & MACHINERY (P&M DEPARTMENT)

BACKHOE LOADER (JCB) EXCAVATOR

BATCHING PLANT

CRAWLING CRANE

49
TRUCK MOUNTED BOOM PLACER HYDRAULIC RIG
 P&M DEPARTMENT

PLANN MOBIL
MACHINE
ED IZED
Batching Plant 2 2
Transit mixer ( 6 Cum capacity) 6 6
Concrete Pump / Boom Placer 5 3
Wheel Loader 2 2
Weigh Bridge(100 T, Bed 16
1 1
Mtr)
Tower Crane 6 1
Crawler Crane 10 7
JCB 6 4
Hydra 6 6
Dumper 12 12
Road Roller, 10T 1 1
Rotary rig 8 8
DMC rig 30 2250
Excavator 3 2
 OBJECTIVES OF THE P&M DEPARTMENT

The prime objectives of the P&M Department is to :

 Minimize the breakdown of machineries.
 Must be cost effective for any project.
 Must maintain a healthy environment to prevent health
hazards.

FINANCIAL CONSIDERATION OF P&M

Approximately 10% of the project cost is considered for the plant

and machineries to be utilized in completion of the project. It also
includes the hire charges for hired assets and also the own
assets, fuel cost and other miscellaneous items like filters etc.

For maintenance of these machineries,3% of the project cost is

considered.

This project houses own assets of both firms approximately

evaluated at 40-45 crores.

51
 CONSTRUCTION METHODOLOGY

STRUCTURAL SYSTEM – TOWERS

• Foundation : Pile cap & Combined raft foundation

• Typical slabs : PT Flat slab (225 mm thick) & 450mm thick

column drops

• Service cores : Frame structure with beams, Columns &

shear walls

• Raft slab top level – (-) 0.45m

• Grid Size : 8m x 11m.

52
 CONSTRUCTION METHODOLOGY

Post tensioning system:

53
 Stressing Stressing Stressing
end end end

J
F
A

Block
Block
Block
Dead end Dead end Dead end

Slab
Slab

Stitch
Stressing Stressing
Stitch

Dead end
end end

K
G
Block

Block
Block
Stressing
Dead end Dead end
end

Dead end Dead end

joint
C

L
Block

Block
Expansion
Stressing Stressing
end end
Stressing Dead end
end
D

H
`
Block

Block

Stressing
Dead end end
Slab
Stitch

Dead end
METHODOLOGY – LONGITUDINAL PT

Dead end
E
Block

Block I

Stressing Stressing

54
end end
Temporary site establishments/Site infrastructures:

BATCHING PLANT MATERIAL STOCKING

55
REINFORCEMENT YARD FORMWORK YARD
 OPERATIONAL PROCEDURE

The Operational procedure comprises of the following steps:

•Surveying
•Piling
•Excavation
•Pile cap
•Raft & Column
•Retaining wall
•Reinforcement & Formwork
•Concreting
•Curing
•De-shuttering
•Brick work & Plastering
•Electrical casings & fixtures
•Facading
•Timber/Aluminium & glass work for doors/windows
•Painting

56
 SURVEYING & LAYOUT
Surveying is art of determining the relative positions of different objects on the
surface of the earth by measuring the horizontal distances between them, and by
preparing a map to any suitable scale.
□Engineering surveying is mainly a general term that covers any survey work
carried out in connection with the construction of an engineering project, such as
a road, a building, a bridge etc.

INSTRUMENTS USED IN
SURVEYING

AUTO LEVEL AND IT’S VARIOUS

PARTS

TOTAL STATION AND IT’S 57

LEVELLING STAFF
VARIOUS PARTS
 SURVEY BEFORE STARTING THIS PROJECT
Project : TCS IT SEZ Park, Plot no.- II F/3, Rajarhat

1. Transfer of Bench-mark jointly with TCE :

This has been done by leveling instruments by Height Of

Instrument method (HI).
In the above layout the “PHE Manhole” is the Bench-mark
(BM) has been provided by HIDCO.
Reduced Level (RL) on BM =+2.750 (PHE Manhole Top)
Reduced Level (RL) at pillar-1 = +2.585
Reduced Level (RL) at pillar-2 = +3.015
58
2. Joint checking of survey with TCE :

44º 52’ 44”

Points A & C are given by

HIDCO

STATION CO-ORDINATES:

A = S 2353.963 PILLAR 1 = S 1942.452

E 763.878 E 492.184

C=S 2553.966 PILLAR 2 = S 1871.821

E 773.566 E 464.074
59
3. CLOSED TRAVERSE AFTER CHECK

After establishing the co-ordinates of the plot from Pillars 1 & 2

and the PHE Manhole, we determine the rest of the co-ordinates
of the plot which demarcate it by closed traverse with the help of
a Total Station which is depicted in the following picture

4. With the help of P4 & P5 the co-ordinates of the building

corners are determined

All points for

execution are
given by the
Survey team 60
PILING

61
 PILING

a ) Pile is an under ground load bearing conceal structure .

b) Pile can bear heavy str. load by transmitting through it’s
shaft either up to hard strata or by skin friction offered by it’s
outer most surface with adjacent soil.
c) This can be predominantly adopted where the soil is unable
to bear the heavy str. load.
d) In case of retaining the earth up to considerable depth .

In this project only bored piling & sheet piling methods are being
adopted. Here piles of 600Ø, 750Ø & 1000Ø are being constructed.

BORED PILING :

Creating a bore hole is done by scooping out the soil of

required diameter & length, then cage lowering to be done &
subsequently fill the bore hole by suitable grade of concrete.
Advantages: Most common everywhere, does not requir
heavy machineries, can be installed even in running plant,
chances of susceptibilities of adjacent str. is negligible.
Disadvantages: Area will gets slushy, continuous cleaning
of muck is very essential , time taking job.

Here at the TCS IT SEZ PARK Project we adopt the Hydraulic

Rotary Rig and Dry Mud Circulation(DMC) Rig piling methods.

62
 BORING OPERATIONS FOR CAST IN
SITU BORED PILES
Initial ground levels to be noted
Bentonite vat construction in accordance with Nos. of piles
to be installed.
Pile points to be fixed with cut pieces steel & the same shall
have to be grouted.
Conventional or rotary drilling machine to be placed nearby
& positioning.
Bentonite solution to be prepared before start the operation.

Initial boring & insertion of temporary guide casing is done by

a sludge pump.
A drain is made to allow the flow of the drilled mud to be
collected in tank.
Boring operation is done by a series of DMC pipes & chisel. to
be fitted as a earth cutter with non stop bentonite circulation.
Flush the bore hole after being reached at required depth.
Rebar cage is lowered & subsequently tremie pipe is lowered.
Check the bottom slurry’s S.G before concrete pouring.
Concreting & subsequent withdrawal of tremie pipes is done &
empty bore hole is filled with silver sand.
Bentonite wash in bore holes is compulsory to create a
cohesive layer & prevent the caving in of soil. It’s density, and
viscosity is checked regularly for reuse. It’s density must be
within 1.02 gm/cc to 1.08 gm/cc. Once it’s density limit
crosses, it is thrown away and a fresh solution is prepared.
63
SOME PARTS OF HYDRAULIC ROTARY RIG

AUGAR FOR ROTARY BUCKET CUM CUTTER

RIG FOR ROTARY RIG

SOME PARTS OF DMC RIG

SLUDGE SUMP / BAILER

CHISEL FOR CUTTING IN
CONVENTIONAL DMC
METHOD 64
PILING PROCEDURE ADOPTED AT THIS SITE

BORING IN PROGRESS

POSITIONING FOR
SLUDGE PUMP FOR
INITIAL BORING AT
PILE POINT

READY TO START
INITIAL BOARING
65
Contd …

TREMIE LOWERING IN
PROGRESS

PILE CONCRETING

BENTONITE BATH BESIDE A RIG

DIRECT MUD
CIRCULATION RIG PILING
IN PROGRESS

66
DIFFERENT STAGES OF PILE LOAD TEST
The capacity of pile before failure under heavy str. load is
treated as load bearing capacity of pile.

•Pile testing is the main part of QC/QA for piling works.

•Pile load tests are the part of pile testing.
•Purposes of pile tests: capacity, settlement & structural
integrity.
Some Clicks Of Vertical Pile Load Test

Concrete Block Arrangements of Load

Placing for Load Test Test for Pile

67
Hydraulic Pump Load Testing By Dial
Gauge
FOUNDATION SYSTEM(PILE FOUNDATION):

Piling

Excavation

Pile head
preparation

Compaction

RCC Raft
PCC
Waterproofing

PCC

Compacted Soil

Water Proofing

RCC Raft/
Pilecap

68
SHEET PILING :
It is a pile made of steel with different profile like “C” shape,
“Z”& 8mm to 12mm the . These sheets are to be driven in to
the ground by mechanical means in a series & after that
strutting arrangement to be done to increase sustainability
of sheets against active earth pressure. After raft casting,
the retaining wall to be erected & after maturity the same,
back filling to be followed & then one by one sheet piles
shall have to be removed.
Precautionary measures
a)Only for horizontal bracings & for fixing of struts, the
minimum earth work to be done first , after preloading &
wedging , again earth work to be commenced to reach
subsequent levels.
b) No gaps should be allowed between sheets & horizontal
bracings.

After being erected the

retaining wall, the back filling
in progress, then the sheets
can be removed.

69
 PROCEDURE OF SHEET PILING

Sheet pile line to be ascertained.

Sheets to be stacked at a considerable distance so as to shift the
material by frequent manner.
Either guide channel or ISMB 600 to be laid on ground on both the
side of sheets having 12mm gap between them & to be pinned in
ground for avoiding displacement while driving the sheets.
Sheet pile is to be then erected by TATA 955 crane & to be positioned
on ground then the catch hold portion of vibro hammer will grip the
sheets & started impact on sheet pile to allow to go inside of the
ground.
After driving one sheet , the next one to be erected by the same
procedure but to be inserted in to the groove of the driven sheet & the
hammering shall have to be done as usual. By this way the total area
will have to be covered with series of sheet piles.

Sheet Pile
At Stack
Yard
Corner Sheet
Pile

Hammer & Power Pack 70

ISMB 600 For
For Sheet Pilling
Supporting Sheet
PROCEDURE OF SHEET PILING

71
Contd …

72
 EXCAVATION & PILE CAP

After completing the piles, earth excavation

around the piles are done to achieve the cut off
level of the pile where the pile head is made and
the pile cap construction follows soon. For this
we normally use an Excavator(Poclain) which
after giving the required dimensions excavate
out the required volume of earth. Often the
unsound concrete is chipped off from the pile to
get a layer of fresh sound concrete and we make
the pile head at that very specific point. PCC is
done on the surface of the requisite pile head
level before waterproofing is done.
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-storey building, structure or support
base for heavy equipment. The cast concrete
pile cap distributes the load of the building
into the piles. A similar structure to a pile cap
is a "raft", which is a concrete foundation floor
resting directly onto soft soil which may be
liable to subsidence.

RETAINING WALL

A retaining wall is a structure designed

and constructed to resist the lateral
pressure of soil when there is a desired
change in ground elevation that exceeds
the angle of repose of the soil. In this site
retaining wall is constructed through
73
BLOCK-A,B,C,J.
 RAFT AND COLUMN
A raft foundation is essential a mat foundation. The purpose of a mat
foundation is when you a building built on a site with low soil bearing
conditions or when a foundation. A raft foundation is use to distribute
the buidling pressure over a large area so the soil can bear the stress.
Columns are raised from each individual pile cap first up to the
basement/ ground floor level then it’s continued further up to the project
requirement. A column is casted in 3 steps viz.
• Casting of starter
• Casting of the rest of the column up to the bottom level of the beam
formwork.
• Casting monolithically with the beam and slab.

REINFORCEMENT
After the pile head is completed then comes the part of reinforcement
for which we use rods ranging from 8mm to 32mm. For this at first the
BBS (Bar Bending Schedule) is done.
Bar-bending-schedule is the schedule of reinforcement bars prepared
in advance before cutting and bending of rebar. This schedule contains
all details of size, shape and dimension of rebar to be cut.

CONTENTS OF A BBS

• Mark and location of the member.

• Drawing reference.
• No of members.
• Bar type.
• Bar size.
• Cutting bar length.
• No of bars per member.
• Total no of bars.
• Total weight of bars.
• Shape sketch. 74
• Remarks if any.
 FORMWORK
Various Formwork Systems adopted :
1.Flex System
2.HDT System(Heavy Duty Tower System)
3.Flex Table System
4.Wall Column Formwork System
5.Staircase
6.FR Slab(Fire Resistant Slab)

Design Inputs:
1.Loads
2.Floor to Floor Height
3.GFC Drawing (Good For
Construction)

1.Design Outputs :
2.Spacing
3.Material Specification
Conventional HDT System

Table Formwork System

75
Formwork At The Site
 CONCRETING
Here concreting is done by pouring the
concrete form the transit mixer into
concrete pumps/ boom placer which
the mixer gets from the batching plant
after approval of the pour card. In case
of piles it’s poured into the hopper.
Since this is a green project, hence fly
ash is used here along with cement.
CURING

Curing on concrete surfaces is done

normally after initial setting time has
reached. It’s done in many processes
but here it’s done by the process of wet
curing by spraying water on the surfaces
by water pipes.

DE-SHUTTERING
Forms shall not be released until the concrete has achieved
a strength of at least twice the stress to which the concrete
may be subjected at the time of removal of
formwork.(According to IS 456:2000) Here De-Shuttering is
done normally done after 7 days.
76
 BRICKWORK AND PLASTERING
Masonry may be defined as the construction of building units
bonded together with mortar. As bricks are used as the building
units, we can call it brick masonry or brick-work.
Generally in our country FLEMISH BOND is used for brickwork.
Since this is a green building project, hence fly ash bricks are
used.
Plastering is the process of covering rough
surfaces of walls, columns, ceilings and
other building components with thin coat of
plastic mortar. In this project we have
observed brickwork and plastering only in
the construction of pie caps after which
water-proofing is done by water-proofing
membranes and materials.

Waterproofing here is done by the following:

1. PREPRUFE 300 R
2. BITUTHENE 3000 R
3. BITUTHENE LIQUID MEMBRANE
4. PREPRUFE TAPE HC
5. ADCOR 500 S

FACADING

Facading is the glazed glass fixtures or

glazed tile fixtures on the exterior of any
building which adds to the ambience of
the building also helps proper ventilation/
enlightens the inside of the building. 77
78
We had really enjoyed our vocational training and interaction with
the various engineers & incharges of this project. It was a great
experience to be here because we learnt a lot of things which we
couldn’t have hadn’t we come here to this site. It taught us some
latest modified methodologies which have been incorporated in
Civil Engineering applications in practical field which is never
taught in any text book. Concluding we have attached a copy of
bentonite test performed in the QC/QA laboratory and also a copy
of BBS. This practical experience has enhanced our imaginative
power and has clarified the theoretical knowledge and it’s
appropriate application with several modifications and
precautions. We have also come to know of various problems on
site and also have seen the remedies to some of them in our
presence which is of utmost importance for our future.

THANK YOU

79