REPORT

ON

INDUSTRIAL TRAINING

AT

RELIANCE INDUSTRIES LIMITED

Submitted by

JAY ZUMKHAWALA

CL - 83, ID - 11CLUON076

for the partial fulfillment of the award of the degree

BACHELOR OF TECHNOLOGY
(CIVIL ENGINEERING)

Department of Civil Engineering

Faculty of Technology

DHARMSINH DESAI UNIVERSITY

NADIAD-387001
April-2015

1
 CERTIFICATE

This is to certify that the Report submitted herewith is record of the work carried
out for B.Tech Semester VIII Civil by

JAY B ZUMKHAWALA

ID No.11CLUON076, B. Tech. Sem VIII (Civil Engg.) : 2014-15

It embodies bonafide work carried out by him at the Reliance Industries Limited,
Jamnagar, under my guidance and supervision during B.Tech Semester VIII
training program.

2
 Acknowledgement

Todays world demands competition, so along with having theoretical knowledge.It is

very important for an engineer to have practical knowledge as well. Everyone learns
something to implement it at a certain stage. Especially in the field of Civil
Engineering, there is a vast difference in learning something theoretically and
practically, as compared to other fields. It is very necessary for a student to know,
how to implement the theoretical knowledge when he or she goes into the field.

First of all I am greatly thankful to Dr. H. M. Desai, The Vice Chancellor of

Dharmsinh Desai University, Nadiad, who introduced the system of the industrial
training in the final semester of our college. This gives us great opportunity to be
familiar with the industrial scenario of the field. I am also thankful to our college
library for providing literature review facilities.

I would like to thank The Head of Civil Department, Prof. K. N. Sheth for his valuable
guidance and support during the entire training Period. I would also like to thank
Prof. J. B. Ranpura who continuously inspired and helped me during my industrial
training. Without his help, this project report would not have been possible. I am
indebted to him for his valuable help in preparing the project report. I am also
thankful to other Professors of the Civil Engineering Department who has always
guided me throughout my studies and taught me the essence and roots of Civil
Engineering.

I am very thankful to the management of Reliance Industries Limited for giving me an

opportunity and platform to perform in a world class organization.

Now, I would like to take this opportunity to thank Mr. Mihir Chauhan (HR-J-3), who
gave me an opportunity to do training in the Worlds Largest Project.

Then I would like to thank Mr. Jignesh Bhatt (Lead (GM), J-3 Civil Inspection), for
continuously guiding and helping me in my training.

I would also like to thank Mr. Ankur Vaghasia (Manager), Mr. Shashikant Raut
(Manager) and Mr. Debi Nanda (Manager) at our site who guidedme through the key
aspects of Civil Engineering and teaching me the all the practical knowledge.

3
I would also like to thank all those people at the site and around who have helped
me out in completing the training successfully.

Last but not the least I would like to thank my Parents for providing moralsupport and
guidance throughout my training.

Yours Thankfully,

Jay Zumkhawala

Dharamsinh Desai University

Nadiad

4
 ABSTRACT

With increasing Globalization, there has been up gradation in peoples thinking about
quality. Dharmsinh Desai University has put up right step in the direction of
generation of better quality engineers by providing practical training programme with
professional organization for undergraduate students. Afte rundergoing four months
of industrial training with professional organization, I feel myself having graduated in
complete sense.

Civil Engineering without training is just like a building without foundation. So,it gives
me immense pleasure in submitting this project report on J-3 Project, at Reliance
Industries Limited, Jamnagar. I feel great for having undergone my training at
Reliance Industries Limited, a Fortune 500 Company.

Industrial training helped me to bridge fundamental gap between theoretical

knowledge and practical knowledge. It made me realize that the theory learnt during
my academic curriculum was akin to an infrastructure, on which superstructure could
be built only through practical work.

The training helped me to understand how theory can be gainfully applied and
enhanced my confidence as a civil engineer.

Dharamsinh Desai University

Nadiad

5
 CONTENTS
CERTIFICATE 02

ACKNOWLEDGEMENT 03

ABSTRACT 04

Chapter 1:

Company Profile
1.1 Over view 08
1.2 Major Associate 10
1.3 Milestone 17
1.4 Commitments 17
1.5 Jamnagar Complex 23
1.6 Refineries 25
1.7 Products 25

Chapter 2:

Project Details
2.1 Over View 26
2.2 Plot Plan 28
2.3 Details of J-3 29
2.4 Major Plant Details 30

Chapter 3:

Quality Control
3.1 Vision 31
3.2 Purpose 32
3.3 Scope 32
3.4 Quality Assurance System 33
3.5 CMTL 34
3.6 Inspection & Testing 35
3.7 Check List 36
3.8 ITP 44

Chapter 4:

Material Management
4.0 General 49
4.1 Cements 50
4.2 Aggregates 52
4.3 Water 52

6
4.4 Admixtures 52
4.5 Reinforcement 52
4.6 Concrete Mix Requirement 53
4.7 Plum Concrete 54
4.8 Control of Concrete Quality 54
4.9 Test of Fresh Concrete 55
4.10 Transport & Placing 56
4.11 Compaction & Vibration 57
4.12 Curing 57
4.13 Mass Concreting 58
4.14 Batching Plant 61

Chapter 5:

Construction Activities
5.1 Location 62
5.2 Function 63
5.3 Building Details 63
5.4 Grade Slab 64
5.5 Activities Inspected 64
5.6 Mezzanine Floor 68
5.7 Pre Concrete Checks 68
5.8 Post Concrete Checks 69

Chapter 6:

Equipments & Machines

6.1 Over View 72
6.2 Few Equipments 72

Chapter 7:

Safety
7.1Company Policy 80
7.2 Various Definations 81
7.3 Personal Protective Equipments 82
7.4 First Aid Equipment 85
7.5 Safety Measures in Working at Height 86
7.6 Safety Measures in Erection & Dismantling Of Steel 87
7.7 Conclusion 91

Self Assessment 92

7
 Chapter 1

Company Profile

1.1 Over view

The Reliance Group, founded by Shri Dhirubhai H. Ambani (1932-2002), is India's

largest private sector enterprise, with businesses in the energy and materials value
chain. Group's annual revenues are in excess of US$ 66 billion. The flagship
company, Reliance Industries Limited, is a Fortune Global 500 company and is the
largest private sector company in India.

Starting with textiles in the late seventies, Reliance pursued a strategy of backward
vertical integration - in polyester, fiber- intermediates, plastics, petrochemicals,
petroleum refining and oil and gas exploration and production - to be fully integrated
along the materials and energy value chain.

The Group's activities span exploration and production of oil and gas, petroleum
refining and marketing, petrochemicals (polyester, fiber intermediates, plastics and
chemicals), textiles, retail, infotel and special economic zones.

8
 Reliance enjoys global leadership in its businesses, being the largest
polyester yarn and fiber producer in the world and among the top five to ten
producers in the world in major petrochemical products.
The group is present in many business sectors across India including
petrochemicals, construction, communications, energy, health care, science
and technology, natural resources, retail, textiles, and logistics. RIL is the
second-largest publicly traded company in India by market capitalization. The
company is Ranked No. 99 on the Fortune Global 500 list of the
world's biggest corporations, as of 2013. RIL contributes approximately 14%
of India's total exports.
The number of share-holders in RIL is approx. 3 million. The promoter group,
Ambani family, holds approx. 45.34% of the total shares whereas the
remaining 54.66% shares are held by public shareholders, FII and Corporate
bodies.
The Company believes that strategy is also important in maintaining a
domestic market leadership position in its major product lines and in providing
a competitive advantage.

The Company has the Worlds largest refining capacity at any single location.

The Company is:

Largest producer of Polyester Fiber and Yarn

5th largest producer of Paraxylene (PX4)

5th largest producer of Polypropylene (PP)
8th largest producer of Purified Terephthalic Acid (PTA) and Mono Ethylene
Glycol (MEG)

9
1.2 MAJOR ASSOCIATE :

Reliance Industrial Infrastructure Limited

MAJOR SUBSIDIARIES & ASSOCIATES :

1. Reliance Netherlands B.V.

2. Reliance Retail Limited

3. Reliance Jamnagar Infrastructure Limited

4. Reliance Haryana SEZ Limited

5. Reliance Industrial Investments and Holdings Limited

6. Reliance Ventures Limited

7. Reliance Strategic Investments Limited

8. Reliance Exploration and Production DMCC

9. Reliance Industries (Middle East) DMCC

10. Reliance Commercial Associates Limited

11. RIL (Australia) Pty Ltd

12. Recron (Malaysia) Sdn Bhd

13. Gulf African Petroleum Corporation (Mauritius)

14. GAPCO Tanzania Limited

15. GAPOil Tanzania Limited

10
16. GAPCO Kenya Limited

17. Trans energy Kenya Limited

18. GAPCO Uganda Limited

19. GAPCO Rwanda Sarl

20. GAPOil (Zanzibar) Limited

21. Reliance Fresh Limited

22. Retail Concepts and Services (India) Limited

23. Reliance Retail Insurance Broking Limited

24. Reliance Dairy Foods Limited

25. Reliance Retail Finance Limited

26. RESQ Limited

27. Reliancedigital Retail Limited

28. Reliance Financial Distribution and Advisory Services Ltd.

29. Reliance Hypermart Limited

30. Reliance Retail Travel & Forex Services Limited

31. Reliance Brands Limited

32. Reliance Wellness Limited

33. Reliance Footprint Limited

11
34. Reliance Integrated Agri Solutions Limited

35. Reliance Trends Limited

36. Reliance Lifestyle Holdings Limited

37. Reliance Universal Ventures Limited

38. Reliance Autozone Limited

39. Strategic Manpower Solutions Limited

40. Reliance Gems and Jewels Limited

41. Delight Proteins Limited

42. Reliance F&B Services Limited

43. Reliance Agri Products Distribution Limited

44. Reliance Leisures Limited

45. Reliance Retail Securities and Broking Company Limited

46. Reliance Home Store Limited

47. Reliance Trade Services Centre Limited

48. Reliance Food Processing Solutions Limited

49. Reliance Supply Chain Solutions Limited

50. Reliance Loyalty and Analytics Limited

51. Reliance Digital Media Limited

12
52. Reliance-Grand Optical Private Limited

53. Reliance Vantage Retail Limited

54. Reliance People Serve Limited

55. Reliance Infrastructure Management Services Limited

56. Reliance Petro investments Limited

57. Reliance Universal Commercial Limited

58. Reliance Global Commercial Limited

59. Wave Land Developers Limited

60. Reliance Global Business B.V.

61. Reliance Global Energy Services Limited

62. Reliance Gas Corporation Limited

63. Reliance Global Energy Services (Singapore) Pte. Ltd

64. Reliance Polymers (India) Limited

65. Reliance Polyolefin Limited

66. Reliance Aromatics & Petrochemicals Private Limited

67. Reliance Energy and Project Development Private Limited

68. Reliance Chemicals Limited

69. Reliance Universal Enterprises Limited

13
70. Reliance One Enterprises Limited

71. Reliance Personal Electronics Limited

72. International Oil Trading Limited

73. Reliance Review Cinema Limited

74. Reliance Replay Gaming Limited

75. Reliance Nutritional Food Processors Limited

76. Reliance Commercial Land & Infrastructure Limited

77. Reliance Eminent Trading & Commercial Private Limited

78. Reliance Progressive Traders Private Limited

79. Reliance Prolific Traders Private Limited

80. Reliance Universal Traders Private Limited

81. Reliance Prolific Commercial Private Limited

82. Reliance Comtrade Private Limited

83. Reliance Ambit Trade Private Limited

84. Reliance Corporate IT Park Limited

85. Reliance Petro Marketing Limited

86. LPG Infrastructure (India) Limited

87. RIL USA Inc.

14
88. Reliance Corporate Centre Limited

89. Reliance Corporate Services Limited

90. Reliance Convention and Exhibition Centre Limited

91. Central Park Enterprises DMCC

92. Reliance International B.V.

93. Reliance Oil and Gas Mauritius Limited

94. Reliance Exploration and Production Mauritius Limited

95. Reliance Holding Cooperatief U. A.

96. Reliance Holding Netherlands B. V.

97. Reliance International Gas B. V.

98. Reliance Exploration and Production B. V.

99. Reliance Exploration and Production Limited

100. Reliance Holding USA, Inc.

101. Reliance Marcellus LLC

102. Reliance Strategic (Mauritius) Limited

103. Indiawin Sports Private Limited

104. Reliance Eagleford Midstream LLC

105. Reliance Ealgeford Upstream LLC

15
106. Reliance Eagleford Upstream GP LLC

107. Reliance Eagleford Upstream Holding LP

108. Infotel Broadband Services Limited

109. Mark Project Services Private Limited

110. Reliance Energy Generation and Distribution Limited

111. Reliance Marcellus II LLC

112. Reliance Industries Investment and Holding Private limited

113. Reliance Security Solutions Limited

114. Reliance Office Solutions Private Limited

115. GenNext Innovation Ventures Private Limited

116. Reliance Home Products Limited

117. Reliance Style Fashion India Limited

118. Reliance Styles India Limited

119. Infotel Telecom Limited

120. Rancore Technologies Private Limited

16
1.3 MILESTONE :

Starting as a small textile company, Reliance has in its journey crossed

several milestones to become a Fortune 500 company in less than 3 decades.
Reliance continues to cross newer & bigger milestones in its quest for what is
known as "Growth is Life".

FINANCIAL MILESTONE :

RILs Revenues for FY 2012-13 were Rs. 371,119 crore ($ 68.4 billion), Net Profit
was Rs. 21,003 crore ($ 3.9 billion), Net worth was Rs.176,766 crore and Total
Assets were Rs.318,511 crore, unparalleled in the Indian Private Sector.
Exports for FY 2012-13 were Rs.239,226 crore ($ 44.1 billion), 14% of Indias
total exports.
RIL declared Dividend of 90%. Payout of Rs. 3,092 crore, one of the highest in
the Indian Private Sector.
During the year, RIL signed $ 4.5 billion equivalent facilities, backed by Export
Credit Agencies, which included:
$ 2 billion equivalent facility from Euler Hermes, the German Export Credit
Agency
$ 2 billion facility from the Export- Import Bank of the United States of America
$ 500 million equivalent facility from Korea Trade Insurance Corporation, the
South Korean Export Credit Agency
In January 2013, RIL issued $ 800 million (5.875%) Senior Perpetual Notes. The
Notes have no fixed maturity date and the Company will have an option, from
time to time, to redeem the Notes, in whole or in part, on any semi-annual interest
payment date on or after February 5, 2018 at 100% of the principal amount plus
accrued interest.

1.4 COMMITMENTS:

1. VALUES AND BEHAVIOUR

Customer Value
Ownership Mindset
Respect
Integrity
One Team
Excellence

17
 2. QUALITY

Reliance is committed to meeting customer requirements through continual

improvement of its quality management systems.
Reliance shall sustain organizational excellence through visionary leadership and
innovative efforts.

3. RESEARCH & DEVELOPMENT

In order to sustain and enhance profitable growth, RIL aspires to become a

developer of leading edge technologies and continues to be an efficient user of
technology.
RIL intends to create world-class physical and intellectual capabilities, with some
of the leading scientists bolstering its innovation agenda. The Company focuses
its attention to fundamental R&D for sustainability of its business, advanced
technical services, enhancing internal capability to develop basic engineering
packages, and in building capabilities.
RIL is involved in some cutting-edge technologies like fuel cells, carbon fibers,
bio-fuels, and gasification of several types of feedstock. RIL is the sole industry
partner in the New Millennium Indian Technology Leadership Initiative (NMITLI)
project on indigenous Fuel Cell Technology Development.

4. HEALTH, SAFETY & ENVIRONMENT

Safety of person over rides all production targets is the Health, Safety &
Environment policy of Reliance.
Reliance believes that all injuries, occupational illnesses as well as safety and
environmental incidents are preventable.
Reliance shall strive to be a leader in the field of management of Health, Safety &
Environment.
Protection of Environment is of prime concern and an important business
objective at Reliance.
With a leading role in providing competitive goods and services in the materials
and energy value chains and infrastructure in India, Reliance is conscious of its
responsibility towards creating, maintaining and ensuring a safe and clean
environment for sustainable development.

5. HUMAN RESOURCE DEVELOPMENT

In FY-13, RIL enhanced delivery over the last year by ensuring 1,950,395 man
hours of learning activities at its manufacturing divisions. Going forward, RIL will
focus on building specialist skills and multiple cadres in the organization to
support its goals and aspirations. Additionally, several thousand man-hours of
developmental intervention was undertaken to train the leadership teams on

18
 developing the second-line, compensation and benefits, executive coaching,
rewards and recognition programs and interviewing & selection.

6. SOCIAL RESPONSIBILITY & COMMUNITY DEVELOPMENT

RIL's contribution to the community are in areas of health, education,

infrastructure development (drinking water, improving village infrastructure,
construction of schools etc.), environment (effluent treatment, tree plantation,
treatment of hazardous waste), relief and assistance in the event of a natural
disaster, and miscellaneous activities such as contribution to other social
development organizations etc. RIL's CSR teams across its manufacturing
divisions interact with the neighboring community on regular basis.

7. SUSTAINIBILITY REPORT

We have embraced sustainability as our core business strategy. We believe

sustainability is the very foundation of lasting success. We will use sustainability
principles to drive process innovation, new product development, improving
manufacturing efficiencies and reducing material and energy consumption. This
commitment is backed by active initiatives on the ground.

AWARDS:

CORPORATE RANKING & RATINGS

RIL continues to be featured, for the sixth consecutive year, in the Fortune Global
500 list of the World's Largest Corporations, ranking for 2010 is as follows:
Ranked 175 based on Revenues
Ranked 100 based on Profits
RIL is ranked 68th in 2010, in the Financial Times' FT Global 500 list of the
world's largest companies (up from previous year's 75th rank).
RIL has been ranked at 20th position, on the basis of sales, in the ICIS Top 100
Chemicals Companies list. RIL is the only Indian company in the world's Top 20
chemical companies in the global ranking. RIL has also been named as the 8th
biggest gainer in the list in terms of operating profits.
RIL is the only Indian company to get a perfect score from CLSA Asia-Pacific
Markets (CLSA) in a list of Asia's best companies in terms of CSR and termed
the Company as the region's 'Corporate Good Guy'. In its 'Ethical Asia' 2010
report, CLSA has named RIL among its top picks for providing very good data
and going well beyond required disclosure.
RIL is rated as the 33rd 'Most Innovative Company in the World' in a survey

19
 conducted by the US financial publication- Business Week in collaboration with
the Boston Consulting Group (BCG). Further, in 2010, BCG has ranked RIL
second amongst the world's 10 biggest, 'Sustainable Value Creators', companies
for creating the most shareholder value for the period 2000 to 2009.
International Refiner of the Year in 2013 at the HART Energys 27th World
Refining & Fuel Conference. This is the second time that RIL has received this
Award for its Jamnagar Refinery, the first being in 2005.
According to survey conducted by Brand Finance in 2013, Reliance is the second
most valuable brand in India.
The Brand Trust Report ranked Reliance Industries as the 7th most trusted brand
in India in 2013 and 9th in 2014.
RIL was certified as 'Responsible Care Company' by the American Chemistry
Council in March, 2012.
RIL was ranked at 25th position across the world, on the basis of sales, in the
ICIS Top 100 Chemicals Companies list in 2012.
RIL was awarded the National Golden Peacock Award 2011 for its contribution in
the field of corporate sustainability.
In 2009, Boston Consulting Group (BCG) named Reliance Industries as the
world's fifth biggest 'sustainable value creator' in a list of 25 top companies
globally in terms of investor returns over a decade.
The company was selected as one of the world's 100 best managed companies
for the year 2000 by IndustryWeek magazine.
From 1994 to 1997, the company won National Energy Conservation Award in
the petrochemical sector.

PROJECT MANAGEMENT

E&P Division received the Petrotech-2010 Special Technical Award in the

'Project Management' category for completion of their Krishna Godavari
Basin project ahead of schedule.

HEALTH, SAFETY & ENVIRONMENT

Allahabad Manufacturing Division received a rating of 90% for its environmental

initiatives from British Safety Council in 2010.
Barabanki Manufacturing Division received '5 Star Rating on BSC Environment'
from British Safety Council in 2010.
Dahej Manufacturing Division received the 'National Award for the Prevention of

20
 Pollution in Petrochemicals Sector' for its excellence in environment practices
from the Ministry of Environment & Forests, Government of India, in 2010.
Dahej Manufacturing Division received "Our Cup of Joy India's Best Practices on
Water Confederation of Indian Industry (CII) October 2010" Award for the Best
practice of water conservation of "Utilizing Cooling Tower Blow Down water for
Irrigation Purpose".
Hazira Manufacturing Division received the DuPont Safety Award for outstanding
initiatives towards workplace safety enhancements and accident prevention in
2010, thus making RIL the first Indian / Asian company to win this award.
Hazira Manufacturing Division received the British Safety Council's (BSC), Five
Star Environment Award for its "beyond compliance" initiatives, best
environmental practices, innovations and resource conservation efforts in 2010.
Jamnagar Manufacturing Division Domestic Tariff Area (DTA) Refinery received
the 'Golden Peacock Award for Occupational Health & Safety' for pace setting
performance in OH and Safety in 2010.
Jamnagar Manufacturing Division DTA Refinery won the "Greentech Platinum
Award (2010)" Safety Category, in Petroleum Refinery Sector for its outstanding
Achievement in Safety Management.
Jamnagar Manufacturing Division has been granted by The National
Accreditation Board for Laboratories (NABL), Ministry of Science & Technology;
Government of India, "NABL accreditation" based on ISO 15189: 2007 for the
DAOH & FWC Medical Laboratory.
Jamnagar Manufacturing Division Special Economic Zone (SEZ) Refinery
received '5 Star Award for Health& Safety' from British Safety Council for
sustained performance in Health & Safety in 2010.
Jamnagar Manufacturing Division SEZ Refinery has won the prestigious
'Greentech Environment Excellence Award 2010' in Gold Category in Petroleum
Refinery Sector for its best practices in Environment Management.
Jamnagar Manufacturing Division SEZ Refinery has been selected as the winner
of the "10th Annual Greentech Safety Award 2011", in Platinum Category in the
Petroleum Refinery Sector.

Technology, Patents, R&D and Innovation

Nagpur Manufacturing Division received the 'Innovation Quest 2010 Trophy'
instituted by the Indian Institution of Industrial Engineering. Technology, Patents,
R&D and Innovation
E&P's KG-D6 won the 'Innovation for India Awards 2010' instituted by the Marico
Innovation Foundation for their combined synthesis of advanced technologies,
extreme engineering, innovative execution, yielding unprecedented results and
impact on India's energy security.
Hazira Manufacturing Division won the Indian Chemical Council Award for

21
 chemical plant design and engineering in 2010.

RETAIL
Reliance Footprint received the Retailer of the Year Award in the Non Apparel
and Footwear category at Asia Retail Congress 2010.
Reliance TimeOut received the Retailer of the Year Award in the Leisure
Category at Asia Retail Congress 2010.
Vision Express was bestowed the 'Award 2010' for its contribution by the
Netherlands India Chamber of Commerce and Trade in 2010.

SUSTAINABILITY
Jamnagar Manufacturing Division won the 'Golden Peacock Global Award for
Sustainability for the year 2010'.

22
1.5 JAMNAGAR COMPLEX

OVER-VIEW:

Reliance Industries Ltd., Jamnagar complex is Worlds Largest

Refinery & Petrochemical Complex.

Location:

Situated on the northwest coast of India, the integrated refinery-cum

petrochemicals complex of Reliance is located at village Motikhavdi,
LalpurTaluka, Jamnagar District, in the state of Gujarat. The complex,
23
 approximately 25 kilometers from the city of Jamnagar, is in proximity to
the Gulf of Kutch, a sheltered bay close to the Middle-East crude oil
sources.

1.6 Refineries:

1) Domestic Tariff Area (DTA) :

This refinery was dream project of Sh. DhirubhaiAmbani which started

on14th July, 1999 with refined crude oil at a capacity of 668,000 barrels
per day.
All the products are supplied to Indian companies for domestic use.
IOCL, HP, BP, etc, are major domestic buyers for products like petrol,
diesel, LPG, Polymers, etc.

2) Special Economic Zone (SEZ) :

On 25th Dec, 2008 RIL announced the commissioning of its new refinery
at same venue in Special Economic Zone.
It was completed in the record period of 36 months, with Worlds Most
Complex Refinery Tag with capacity of 580,000 barrels of crude oil per
stream day (BPSD).
All the products of this refinery are 100% exported to more than 26
countries including USA & Europe.

Refining Capacity :

DTA 668,000 (BPSD)

SEZ 580,000 (BPSD)
Total 1,240,000 (BPSD)

Area:

Total area acquired by RIL is 20,000 acres.

Name Area in Acres

DTA 3100
SEZ 3850
J-3 4100
Township 450
Total (constructed) 11,500

24
Few Facts :

RILs annual turn-over is about US $68.4 Billion.

Net profit is Rs. 21,003 crores.
76% of profit is generated from Jamnagar complex.
Highest exports were recorded of US $44.1 Billion, (Rs. 239,226 crores),
which was 14% of total Indian exports.
Total number of employees working at Jamnagar refinery is 7000.
About other 3000 employees are working on contract basis.
Reliance Greens (township) is home to more than 5000 families.
It has a state of art Medical Center, school and two civic centers with
world-class sports activities.

1.7 Products from Jamnagar and their usage:

Diesel Industrial & transportation fuel

Kerosene Domestic fuel
ATF Aviation turbine fuel
LDO Power Plant fuel
LAB feedstock Manufacture of LAB
LPG Industrial and domestic fuel
Gasoline Light motor vehicle fuel
Naphtha Petrochemical feed stock
Coke Power plant fuel
Sulphur Manufacture of Sulphuric acid
TAME Octane booster
Benzene Petrochemical feed stock
Paraxylene Manufacture of PTA
Orthoxylene Petrochemical feed stock
Propylene Petrochemical feed stock
PP Plastic products

25
 Chapter 2
PROJECT DETAILS

JAMNAGAR COMPLEX-3

2.1 Over view

Reliance's Jamnagar complex represents the largest industrial project ever

implemented by anyone from the Indian corporate sector.
The Jamnagar complex is a fully integrated manufacturing facility, with a
petroleum refinery complex, an aromatics/petrochemical complex, a power
generation complex and a port and terminal complex that provides access
to a pipeline network. The high degree of integration at the Jamnagar

26
 complex allows for feedstock and product linkages that continue to lead to
higher efficiencies and enhanced value addition.

Area :

The j-3 project will cover approximately 4100 acres of land.

Cost :

The project cost is estimated at Rs. 75,000 Crores.

It is the Worlds Costliest and Largest Project in current times.

Date of commencement April 2012

Date of Completion July 2015 (1st phase).

Project is divided into 3 phases.

Name Refinery Start Up

Phase-1 (PX4) July 2015
Phase-2 (C2) February 2016
Phase-3 (Gasification) February 2016

The 3 main areas of plant construction are :-

1. Paraxylene
2. Gasification
3. C2 Complex

27
2.2 PLOT PLAN OF J-3

28
2.3 Few details of the J-3 Project.

UOM Total Qty.

Discipline
Concreting M 20.0 Lac
Structural Fabrication MT 1.9 Lac
Piping-UG RM 72.9 Lac
Piping-AG RM 191.8 Lac

J3 Civil Material

Discipline UOM Total Qty.

Cement MT 8.0 Lac (160 Lac Bags)
Aggregate (Conc+road) MT 28 Lac (1.4 Lac Truck
Trip)
Good sand MT 15.4 Lac
Rebar MT 3.21 Lac
Anchor Bolts Nos. 25,000
Structural Bolts Nos. 4,50,000
Grout MT 1265
PVC Pipes km 43

Description DTA + MTF SEZ Total

In Acres In Acres In Acres
Plant Area 1325 345 1670
Infrastructure 1585 845 2430
Total 2910 1190 4100

There are in total 12 Plants.

1. Paraxylene (PX4)
2. Pet-Coke Gasification
3. Linear Low Density PolyEthylene (LLDPE)
4. Low Density PolyEthylene (LDPE)
5. Mono Ethylene Glycol (MEG)
6. Multi-Effect Distillation (MED)
7. Refinery Off Gas Cracker (ROGC)

29
 8. Air Separation Unit (ASU)
9. Sulphur Recovery Unit (SRU)
10. Butyl Rubber Unit (BRU)
11. Sea Water Reverse Osmosis (SWRO)
12. High Purity IsoButylene (HPIB)

2.4 Major Plant Details

C2 Complex, MEG plant

Plot Area- 270m X 280 m 75,600 (19) Sq m (Acre)

Total Concrete 27,825 M
Wt. of Anchor Bolts 220 MT
Structural Steel 1565 MT
Sub Station 96m X 24m
PIB 36m X 10m

C2 Complex, LLDPE

Plot Area- 319m X 316m 1,00,804 (25) Sq m (Acre)

Total Concrete 40,943 M
Wt. of Anchor Bolts 15 MT
Non Shrink Grout 150 M
Epoxy Grout 4 M
Precast 3000 MT
Sub Station 102m X 36m
PIB 40m X 15m

Paraxylene

Plot Area 2,38,541 (59) Sq m (Acre)

Concrete 98,380 M
Structural Steel 11963 MT
Sub Station 03 Nos
PIB 02 Nos

Gasification- DTA + SEZ

Plot Area- 400m X 2,28,000 (57) Sq m (Acre)

570M each
Total Concrete 3,35,230 M
Structural Steel 62886 MT
PIB 20 Nos.

30
 Chapter 3
QUALITY CONTROL

3.1 Vision

To execute Construction Activities meeting specified

Quality Standards in shortest possible time using
latest Construction techniques & technology with no
rework
Quality is never an accident; it is always the result of intelligent efforts

If you cannot describe what you are doing as a process, you do not know
what you are doing

31
 There is an independent, fully functioning Quality Material Department.
They inspect all the various structures, foundations, concrete, aggregates,
and finished items, wrt the specifications.

3.2 Purpose

The purpose of the Plan is to define the Construction quality management system
for ensuring and demonstrating that the service and plant provided under the
control of Project management team, conform to the specified requirements in
the project specification.
The Construction Quality Plan is the principal quality document for the Reliance
Construction Group. The Plan is based on the Project requirements and
ISO9001:2008, and provides the quality practices and resources relevant to the
Construction Quality Management.
The Construction Quality Plan (hereafter referred to as the Plan) describes the
Construction organization and responsibilities and contains both the Quality
Assurance and Quality Control Systems.
The Plan is a Construction Management document to demonstrate that Reliance
Construction Management Group have specified the objectives and vision,
established a system of procedures to accomplish them; assigned duties,
delegated authority, and set up suitable testing, inspection, examination, and
audit program to verify that required standards of performance have been
achieved.

3.3 Scope

The scope of this plan includes all J3 Project(s) specific activities of

Construction Management from Contracting up to Final Testing and
Handover to Steady State.
The plan is applicable to all the functions/departments, involved directly or
indirectly in influencing the quality of construction management activities
including support services such as contracts, HR and Training.
The Plan also applies to all suppliers, contractors and their sub-tiers who
shall be required to comply with the Construction quality system. It will be
preferred but not be mandatory for all the suppliers and contractors to hold
formal quality approval certificates; but they must have acceptable,
documented work systems consistent with their scope of work, verified by
the Area Manager Construction Quality Control (CQ Head).

32
3.4 Quality Assurance System

The construction quality assurance system is applied to all activities under the
scope of construction management services including monitoring, inspection and
testing.

The construction quality assurance system is implemented through following

documents:

This Quality Plan, which defines the objectives and demonstrates how the
system is applied to meet the intent of Construction Quality Management
The Quality Plan is reviewed by the Reviewing Authority in every Six
months to verify the effectiveness and revised, if required.
Construction Procedures including the quality control procedures which
specify the activities and responsibilities and provide the direction to meet
the Reliance required quality standards. These procedures are required to
be tailor made w.r.t. specific job.
Work Instructions/Method Statements which define the detailed methods
forthe performance of the specific activities and for the preparation of
project deliverables, and the associated quality controls described in this
Plan.
Inspection and test plans/checklist which define the different stages of
inspection/checking and the degree of involvement of different
persons/functions and the reporting formats where the record of checking
will be documented.
The Quality Assurance System is developed and maintained by Area
Manager Construction Quality Control (hereafter referred as CQ Head)
who reports directly to the Head Construction. CQ Head has the authority
and responsibility for monitoring that the quality requirements of
Construction activities are implemented and maintained. CQ Head is
independent of all other construction managers and not accountable for
the construction progress. CQ Head is therefore free to audit and examine
all areas of the construction management, to highlight all non-compliances
identified and to ensure that agreed corrective actions are taken.

33
Construction Quality Objectives

Quality Objectives have been derived from Project Quality Concept to

translate the Quality Vision into working system. Every Sector Heads /
Functional Heads shall focus their activities to monitor and achieve the
Construction Quality Objectives.

Control of Materials:-

Responsibility:- Warehouse Head / Sector Heads / Area Managers and team

All Vendor, for site procured items and bulk procurement, shall be pre-qualified
as per procedure for Vendor Quality System Evaluation and Approval

All materials shall be purchased from qualified supplier with test

certificates, duly certified by TPIA/Reliance as per Purchase Order
Requirements. Materials shall be inspected for compliance as per
procedure for material inspection at warehouse (CMC)
All consumable which forms the part of the final product of construction
work shall be procured only from approved Vendor. However, based on
the performance, CQ Head may carry out further testing of all such
consumable to verify the conformance.

3.5 Civil Material Testing Laboratory (CMTL)

Responsibility: -CQ Head / CMTL-Quality Lead & team (CMTL Group)

All the civil construction materials like, concrete, soil, sand, cement, water,
aggregates, insulation, bricks, refractory, fire proofing materials, epoxy
grouts, admixtures, curing compounds, etc. shall be tested at CMTL.
Design mix shall be prepared and approved before start of the job. CMTL-
Quality lead shall ensure availability of approved inspection and test
procedures.
Resources required like, inspection instruments, manpower, etc. shall be
estimated and availability shall be ensured. Civil construction work related

34
 trainings shall be conducted as required. CMTL group shall perform
audit/surveillance on concrete batching plants and crusher units.
For the site procurement items, CMTL group shall perform vendor
evaluation and vendor inspection, as required.

3.6 Inspection and Testing

Responsibility:- Respective Discipline Leads / Sr. Engineers / Engineers

Contractor shall be responsible for preparation and implementation of job

specific Inspection and Test plan based on standard Inspection and test
plan of PMT.
All concerned engineers shall carry-out Inspection as per job specific
Inspection andTest plan (ITP) during various phases of execution and
ensure rectification of the deficiency before the work is allowed to be
passed-on for next operation. All standard Quality Procedures, ITPs and
reporting formats are available.
For the purpose of Construction Supervision, implementation of Inspection
& Test Plans, preparation/compilation of Records, activity wise
responsibilities shall be as per details of Annexure 1 & 2. All lesson
learnt during previous projects are recorded and responsibilities defined to
prevent recurrence.
Area construction Quality Lead is also responsible for carrying out
surveillance of all work and publish nonconformance when identified
during surveillance. Area Manager and his team will be responsible for
implementation of corrective action on those identified nonconformities.
Incident Reporting: - Wherever rework is involved due to nonconforming
product/process, concerned discipline engineer shall be responsible to
record the rework to facilitate proper analysis and necessary corrective
action to avoid such problems in the future. It is mandatory to report all
such incidents to the overall interest of the project to initiate necessary
corrective and preventive action well in time. The incident log/register will
be maintained by respective construction contractor.

Quality Audit/Surveillance

Responsibility: -CQ Head and his team supported by Sector Heads / Area
Manager and his team.

35
 Periodic scheduled quality audits shall be conducted on each contractor,
based on discipline and complex as per audit schedule. Construction
Quality achievement status will be reported along with other observations
and noncompliance in the Audit Report.
In addition to the scheduled audit, planned and unplanned surveillance will
be carried out for each contractor complex to verify the maintenance of the
agreed quality system.
Any noncompliance observed during the planned and unplanned
surveillance will be reported with root cause analysis and responsibility.

3.7 Check list

Building - Civil Activity Check List

Seismic
Category 3
Analysis
General 01.10.2014
Concrete
M30
Grade

Sr No Activity Items Check Points Records

1 Excavation
Founding Ensure that founding level embedded 500 mm
1.1
level minimum in design strata
If loose strata found, excavation to be
continued up to hard strata and filled with
blind concrete.
2 Backfilling
Compacted
2.1 > 90% modified proctor density CMTL record
Field Density
Ensure that Anti termite treatment completed
before backfilling
Pre concrete
3
check
Expansion
3.1 50/75 mm gap to be provided
Joint
Extruded Polystyrene filler board to be used
up to full depth
Ensure that dowels for mullions, lintels,
3.2 Dowels parapet wall, grade slab etc is provided as per
drawing.

36
 Insert Plates
For roof access ladder, angles for cut out in
3.3 Provision to
slabs etc
be checked
For Instrument/electrical cable tray
installation purpose on both side (Internal &
External side) if any.
Construction joints adopted at site (not given
3.4 Joints in drawing) if any to be reviewed before As built record
concreting
4 Reinforcement
Rebar No of rebar, ties, links to be checks as per
4.1
Placement drawing
Rebar Lap Rebar >= 25 mm, Type 2 mechanical coupler
4.2
Details to be used.
Rebar< 25 mm , 50D lap length to be
provided.
Not more then 50% joint come at single
location
Embedment Ensure that it is not less than Development
4.3
Length Length.
It is the minimum distance between
4.4 Rebar Cover outermost reinforcement (including links) &
nearest concrete surface.
Only PVC cover to be used @ 1 m c/c.
Foundation - 75 mm, Col & Beam - 50 mm,
Wall & Slab - 30 mm
Tolerance to cover - +10 mm & -0 mm
Hook & Bend Min hook length is required 10d. Not less than
4.5
Details 75 mm
Bend angle for stirrups to be 135 degree
Bend angle for links to be 90 degree
Around Opening/Cutouts as per standard
4.6 Extra Rebar
drwg
5 Shuttering
5.1 Finish F2 type.
Chamfer of size 25X25 mm to be formed
Removal Wall, Column or any Vertical face - 24 to 48
5.2
Time hours
Removal of props under slab - 7 days(up to 4.5
m) & 14 days (above 4.5 m).
Removal of props under beam - 14 days(up to
6 m) & 21 days (above 6 m).
Tie road with cone arrangement only be
5.3 Tie-rod
allowed.

37
 Tie rod with metal water stopper shall be used
for water retaining structures.
If rebar is used as tie rod, minimum 50 mm
concrete to be chipped out for rebar cutting
and then finish surface with non-shrink grout.
After shuttering removal, cone to be removed
& fill space with non-shrink grout GP1 or GP2
along with bond coat.
After grout, finish surface must be in true
vertical.
Concreting
6
Work
Max free fall - 1.5 m, Max concrete
6.1 Placement temperature: 30 Celsius for mass concrete &
35 Celsius for normal concrete.
Cube Strength, W/C ratio, Slump data,
6.2 Test Reports CMTL record
Temperature to be kept for record
Date of
6.3 To be recorded Site Data
casting
Curing
6.5 Method & Curing compound or Wet covering
Period
7-10 days for OPC cement
More curing period require incase of PPC, PSC
cement used.
Post concrete
7
check
Concrete surface to be checked for Observation
7.1 Condition
honeycombing, cracks etc. report
If found damage, repairs to be done
immediately as per standard method.
Cube test reports to be reviewed for final
7.2 Strength
strength.
Sufficient time is given or not prior further job
7.3 Curing
or loading.
8 Block Masonry
AAC blocks not to be used for foundation &
8.1 General
below damp proof course.
200 mm thk AAC (Autoclaved Aerated
Concrete) Block full height partition. Data
CMTL/Vendor
8.2 Internal Wall related Density, Compressive strength, Water
Docs
Absorption, Drying Shrinkage, Moisture
Movement to be kept for record.

38
 Density - 650 to 750 kg/CUM, Compressive
strength - 4 to 5 N/mm2.
CM - 1:6 for joints in AAC block.
Provision of 2 no's of 12 dia HYSD bar @ every
Mullions &
5th layer of block to be provided. Embedded
8.3 Intermediate
in column by means of drilling & grouted
Beams
properly.
Provision of Mullions @ every 2 m with size
200*115 having 4-8 dia HYSD bars. Rebar of
mullions should connected with beam rebar's.
External 200 mm/ 400 mm thk AAC Block wall in 1:6
8.4
Walls mortar.
Transformer
8.5 RCC wall, thk as per drawing.
wall
At intersecting walls, pockets to be left out at
8.6 Joints maximum 200 vertical face and make it close
with intersecting wall.
Min 200 mm bearing to be provided in
8.7 Lintel
masonry work for doors/windows/ventilators
Min 300 mm bearing to be provided in
masonry work for rolling shutters
Lintel which house metal door, provision for
grouting metal hollow frame to be provided
by introducing pipe in lintel.
Expansion Joint to be sealed with aluminum flashing in V
8.8
Joint groove.
Curing
8.9 Method & Min 7 days
Period
Plastering
9
Work
9.1 Material Cement - 43 grade OPC
Fine Aggregates - Natural sand, Crushed stone,
crushed gravel sand. Max allowable clay, silt is
5% be weight.
Fineness of sand : Passing through 4.75 mm &
retained on 150 micron sieve
For external plaster Recron 3S fibers of 6 mm
long to be added by .25% of cement weight.
At the junction of bricks & RCC, galvanized
chicken mesh <50 mm to be provided by
minimum 300 mm overlap on joints.
Undercoat
9.2 Surface to be rough or hacked.
Plaster

39
 Mix Proportion 1:5
Thickness - 10-15 mm
Finishing
9.3 Mix Proportion 1:3
Coat
Thickness - 03-8 mm, tolerance (-)3 mm
Sand Face Within 48 hours of undercoat laying
Sand Passing through 3 mm to be used
Surface to be trowelled and sponge floated to
bring sand on surface
Plain Surface is finish plain with trowel.
Neeru Finish Lime putty paste having 3 mm thickness.
Undercoat CM - 1:4
Make surface plain & cured for 10 days.
Neat cement Neat cement coating (1 kg/sqm) to be applied
Punning on undercoat.
Rough Cast
1:01:01 (cement : sand : gravel 3to 6 mm size)
Plaster
thickness - 10 to 12 mm
8 mm * 8 mm Grooves in external face as per
9.4 Grooves
drawing
Drip mold in chajja& slab projection to be
provided
Curing
9.5 Min 7 days
Period
Door,
10 Windows &
Ventilators
Fire rating
Hollow metal pressed steel doors for main
10.1 Material certificate from
entry.
vendor
All door of switchgear room should open
inside.
Check all accessories are fixed as per schedule
10.2 Installation
and in well operating condition
Ensure that metal frame is grouted with
mortar.
Door heading to be checked
Joints of wall
10.3 No void/space permitted
& door
Plumbing
11
Work
11.1 Material 15 to 25 mm GI pipe medium class
Exposed pipes & fittings are painted with 2
11.2 Installation
coats of aluminum paint

40
 Concealed pipes and fittings are painted with
anticorrosive bituastic paint
Clamping to be done at 2.00 meter interval
Ensure that 1 gate valve to be there for toilet
11.3 Inspection
system
Lines should be tested to a operating pressure
(get value from operation ) hydraulic pressure
but not less than 5 kg/cm2
Test time : 30 min minimum
Drainage
12
System
12.1 Material 50 & 75 mm soil UPVC pipe, type B
12.2 Installation Should be fixed with mortar in floor
12.3 Inspection Water tightness to be checked at joints
Outlet of acid drain to be checked
Oil collection system to be checked in
transformer yard
Water
13 Warranty Docs
Proofing
Ensure Pond test to be carried out and arrest
13.1 Roof Slab Pond Test Report
leak if any.
Surface should be free of cracks, loose
material, oil, grease.
Screed Slop to be checked. (Typ 1:100, Min 1:120)
No undulation permitted. Repaired if any.
Curing time - 7 days
Membrane Primer application & allow to cure
Membrane laid in such a way that length is
perpendicular to water flow.
Membrane lapping details. End lap = 100 mm ,
Longitudinal lap = 75 mm
Proper ceiling of membrane in parapet wall
within groove (65 mm deep, 75 mm width) at
least 150 mm above FFL.
Pack groove with sealant or mortar.
Where parapet walls of height 450 mm ,
membrane should cover entire wall top &
ended at 100 mm down on outer surface
Protective M15 screed with 300*300*8 groove pattern
Layer finish
Toilet
13.2 RCC surface to be hacked properly
Sunken Slab
Sub Base Cement slurry with water proofing compound
20 mm thk 1:3 plaster, allow for 7 day curing

41
 Bitumen Shall be applied @ 1.7 kg/sq.mt area
400 micron PVC sheet with 100 mm lap to be
laid on bitumen
Joint of PVC sheet to be sealed with bitumen
Base Fill the porting with feeling material & cast
Concrete grade slab
Apply bitumen & PVC sheet as above once
again
20 mm thk 1:3 plaster, allow for 7 day curing
& tiling the surface
Rain Water
14 Down take
Pipe
UPVC of Type A , 150 dia having minimum
14.1 Material
weight 4 kg/rmt
Invert level to be flushed or slightly down to
14.2 Fixing
slab level.
Membrane to be applied at inlet by 100 mm
depth.
Cast iron grating to be installed at inlet of
pipe.
All joints to be watertight.
Proper fixing by clamming of PVC clamp @ 2.5
meter interval to be checked.
At downstream end, 45 degree elbow to be
provided.
Down take pipe should be rest on splash slab.
15 Step & Ramp
15.1 Step Finish with anti-skid grooves
15.2 Ramp Gradient < 10 %
Broom finish
Removable handrails to be provided.
16 Epoxy Paint MSDS
Surface preparation requirement, application
of layers with minimum curing time to be
16.1 Application
checked as per manufacture's
recommendation.
DFT to be verified. Varies between 100 micron
16.2 Thickness
to 150 micron.
17 Painting Work MSDS
Review material data sheet. Dilution mix
17.1 Material
proportion to be verified.
Surface Must be dry, clean and free from foreign
17.2
Preparation material.

42
 If any cracks found, must be repaired with
approved method.
Total area to be covered with giving proper
17.3 Primer
curing time.
17.4 Layers 1St & 2nd coat to be verified.
Plinth
18
Protection
18.1 General Width - 1.2 meter having slop, Broom finish
19 Cable Trench
Block work having 20 mm thk 2 coat sand
19.1 Side wall
cement render and painted finish.
Trench to be filled with sand with proper
19.2 Sand Filling
compaction
19.3 Top finish 75 mm thk cement sand screed.
Ensure that all pipes & ducts openings are
19.4 Closure
packed/closed with sand. No space allowed.

43
3.8 Inspection & Test Plan for Structures

44
45
46
47
48
 Chapter 4
Material Specifications
4.1 General

The materials are provided by RIL. The materials which are used at the site,
must be as per the specifications.
The materials used, must be as per the drawings and approved by the RIL.
Cement, Concrete, AAC blocks, etc are all provided by the RIL.
There are 10 Batching plants on site, to meet the daily requirements of
concreting.
There are boom placers, for concreting at heights and at a faster rate

Various material specifications are listed below :-

4.2 Cements

Cement delivered hot from the factory shall not be used at temperature in
excess of about 77C.
Tests and Analyses

Manufacturers certificates shall be provided confirming that cement delivered

to the site has been tested and found to comply with the requirements of the
appropriate Standard. Cement vendor approval shall be based on QMS audit
& compliance of sample results. Cement of the vendor can be used prior to
receipt of test certificate with approval. If subsequent tests on any
consignment of cement show it not to comply with Specification requirements,
then the whole consignment shall be removed immediately from the site
notwithstanding the manufacturers certificate results. Access to the cement
store shall be provided during working hours for the purpose of sampling the
cement for further testing.

Cement Store

Cement shall be kept at all times in covered storage in an approved manner.

No cement shall be kept on the site longer than three months before use. Any
cement which is stored on site in excess of 90 days shall be tested in
accordance with relevant Standard prior to use. Sufficient cement for one

49
 weeks consumption shall be available at all times. Cement shall be used in
the sequence in which it is delivered. Not more than 12 bags shall be stacked
vertically. The cement store for bagged cement shall be a weatherproof
building or shed, ventilated, lit and free of dampness. The store temperature
shall not exceed 400C. The cement shall be stored in such a manner as to
permit easy access for proper inspection and identification. The size shall be
sufficient to hold enough cement for continuous execution of the works. Bags
for cement shall be lined in polythene or other dampproof material. If cement
in bulk is to be used, prior approval must be obtained. It shall be stored in
silos purposemake for storage of cement. The cement bags shall be stacked
off the floor on wooden planks in such a way as to keep about 150mm to
200mm clear above the floor.

4.3 Aggregates

General

All aggregates shall be from approved sources and shall comply with IS 383.
Fine and coarse aggregates shall be considered separate ingredients; both
shall meet the grading requirements of IS 383.
Aggregates shall be clean, hard, durable, chemically inert and impermeable.
They shall be free from adherent coatings, laminated particles or admixtures
of materials likely to be deleterious to the concrete.
Aggregate having a cubical particle shape is critical to ensure good workability
and low water cement ratio. The maximum flakiness index shall be limited to
35%. Dune and beach sand shall not be used for fine aggregate.
In general, course aggregate shall be max. 20mm. However, this may be
increased to a maximum of 40mm for certain structures/foundations, as
shown on the drawings or directed by the Construction Manager in the field. In
thin sections with closely spaced reinforcement, consideration shall be given
to use of 10mm nominal maximum size. In such a case, minimum cement
content shall be increased by 40 kg/m3.

Sampling and Testing of Aggregates

Sampling and testing of aggregates shall be carried out in accordance with IS

2386. If adequate laboratory facilities do not exist on site, samples must be
sent to a convenient approved testing laboratory. Samples of fine and coarse
aggregate shall be sent in laboratory for tests.
Aggregates shall be tested in accordance with IS 2386 or be obtained from a
supplier whose aggregates have previously been proven to meet these
requirements. Compliance certificates shall be submitted for approval. The
soundness tests of fine and coarse aggregates shall be carried out as per IS
2386 (Part V). Either Sodium or Magnesium Sulphate may be used. The
acceptance criteria recommended in IS 383, section 3.6 after 5 cycles
(depending on the chemical used) shall be adopted.

50
 When aggregates have been approved, the entire supply of each type shall
be secured from the approved source. Testing shall be carried out at the
frequency specified below to ensure that the same quality and grading of the
material is being maintained.
Any aggregates that do not meet the requirements of the relevant standards
shall not be used in the works.
Tests shall be carried out from each source at the following frequency:
1) Tests for clay, silt and dust, absorption, flakiness and sieve analysis shall be
carried out on every 300 tons of fine aggregate and 300 tons of coarse
aggregates delivered to the site.

2) Tests for aggregate crushing value, impact value, abrasion value, crushing
strength, 10% fines value shall be carried out before work commences and in
accordance with quality plan.

3) Chemical analysis shall be carried out on every 3000 tons delivered to the
site.

4) Silt and clay content for fine aggregate shall not be more than 7% measured
by volume.

5) The site engineers shall increase frequency of testing if materials are judged
to be of variable quality. The site engineer can decrease the frequency of
testing if quality of material is consistent but this shall only be done with the
agreement of the design office.

6) Moisture content shall be checked prior to batchup.

7) Coarse and fine aggregate should be tested for Potential Alkali Reactivity in
accordance with ASTM Standards C1260. Petrographic examination shall be
undertaken in accordance with IS 2386 (Part 8). The petrographic analysis shall be
carried out minimum once for each source.

Acceptance of Aggregates

The site engineer has the right to reject any materials that do not meet the
requirements of this Specification.

Storage of Aggregates

Sufficient quantities of each type of aggregate shall be maintained on site at

all times to ensure continuity of work.
Each type and grading of aggregate shall be stored separately in such a
manner that mixing of the various size particles shall not occur. The floors of
the storage areas at the batching plants shall be of concrete or other

51
 approved material, and shall be sloped sufficiently to ensure adequate
drainage of surplus waters.

4.4 Water

Water used for the following purpose shall be free of injurious amount of oil,
acids, alkalis, salts, sugar, organic materials and litter in suspension
conforming to clause 5.4 of IS 456 and shall be tested as given in IS 3025.
The pH value of water shall be not less than 6.

4.5 Admixtures

General
An admixture is added in quantities generally less than or equal to 5% by
mass of the cement before or during mixing or during an additional mixing
operation.
Sample of packed admixtures shall be obtained as per IS 3535. Compatibility
with the type of cement used shall be proven by the Contractor. If two or more
admixtures are used simultaneously in the same concrete mix, data should be
provided by the Contractor to evaluate the interaction and compatibility.
The admixtures shall not contain chlorides and shall be protected against
contamination, evaporation, damage, freezing and from temperature changes.

Superplasticisers

In hot weather, after trials and approval, a naphthalene Sulphate retarding

superplasticiser can be used to increase workability of the concrete and retard
the initial set. It shall comply with IS 1199 and IS 8142 respectively.
Superplasticisers to ASTM C 494 will also be acceptable. However, any of
these used shall be of approved brands. Confirmation shall be obtained that
the superplasticiser is compatible with cement, any pozzolana which is used.

4.6 Reinforcement

The steel for main and secondary reinforcement shall be any of the following:
In general steel for main and secondary reinforcement shall be high yield
deformed bars of grade Fe 500 for rebars up to 16mm diameter and Fe 500D
for rebars 20mm, 25mm,32mm,40mm dia.
The Manufacturer shall submit the material test certificates giving the results
of mechanical and chemical tests as per Inspection Test Plan (ITP).
All reinforcing bars shall be stored on the site on supports suitably spaced and
at sufficient height to keep the steel clear of the ground. Storage area should
be blinded with concrete and stock piles covered to prevent bars being coated
by wind born salt.

52
 Reinforcement shall have all scale and rust removed and after such treatment
the steel shall remain within the limits of over and underweight as specified.
The steel shall not be coated with any grease, oil, paint or preservative or any
substance likely to inhibit the bond with concrete.

Cutting and Bending

Reinforcement shall be cut and bent in accordance with IS 2502. Bars shall
not be subjected to shock loading or mechanical damage. Rebending or
straightening of bars is not permitted. In general reinforcement shall be bent
cold. Reinforcement bars shall not be rebent or straightened without the
engineers approval.

Placing and Fixing

The reinforcing bars, ties, links, stirrups and all other reinforcing shall be
positioned and rigidly fixed in the position shown on the drawings. Corner bars
in columns and beams shall be cranked for the entire length of the lap such
that the minimum cover requirements are achieved and the true alignment of
the reinforcement is maintained.
Reinforcement shall be supported on PVC spacers of a size to give the
correct cover to the reinforcement. Spacers and chairs shall be placed at a
maximum spacing of 1m. The reinforcement shall be placed within the
tolerances of 5mm.

Cover
The cover to reinforcement shall be measured as the minimum distance
between the outside of the outermost reinforcement, (including links), and the
nearest finished surface of the concrete members (excluding finishes). The
position of reinforcement should be checked before and during concreting,
and particular attention given to maintaining the cover as specified. Unless
specified otherwise the actual concrete cover should not deviate from the
required nominal cover by +10 mm/0 mm.
Welding of Reinforcement shall only be allowed under special circumstances
and only after carbon content of the bar is checked. This is subject to the
approval of the EngineerInCharge.

4.7Concrete Mix Requirements

Measurement of Materials
The materials used in the concrete shall be proportioned by weight, by means
of an approved weight batching machine. Due allowance shall be made for
the water content of the aggregates when determining the amount of mixing
water to meet the specified water/cement ratio for the mix.
Cement when contained in bags, shall be used in such a way that each batch
of concrete requires a number of whole bags. When the cement is stored in
bulk a separate weighing device shall be provided for cement. The measuring
device shall be approved before use and calibrated at regular intervals.
Coarse and fine aggregates shall be proportioned separately by weight in an
approved weigh batching machine.

53
 4.8Plum concrete
Stone aggregates of size up to 0.001 m3, but less than 1/3 of the least
dimension to be concreted, called plums, shall be used as aggregate. These
plums shall be subject to the same acceptability tests which are applicable to
the normal aggregates. The volume of plums shall not exceed 20% of the total
volume of the finished concrete, and they shall be well dispersed throughout
the mass. This shall be achieved by placing a layer of normal concrete, then
spreading the plums, followed by another layer of concrete around the plum.
Care must be taken to ensure that no air is trapped underneath the stones
and that the concrete does not work away from their underside. The plums
must have no adhesive coating.

Initial Setting Time

The initial setting time shall be not less than 30 min after the produced
concrete is discharged into the forms and with a maximum time between
mixing and completion of placing concrete shall not exceed 1 hour, the total
time between mixing and initial set shall be a minimum of 1 hour. There shall
be a maximum setting time of 6 hours.

Slump

The slump of the structural concrete mixes shall be such that the concrete can
be transported, placed into the forms, and compacted without segregation in
accordance with Section 8.0 provided that a superplasticiser is not used in the
mix, the permissible slump should be 75 mm.

4.9Control of Concrete Quality

Records shall be kept, and a copy supplied of the mix details and position in
the works of all batches of concrete and of all samples taken for cubes, cores
and other specimens. These records shall include but not be limited to:
Date and time of pour
Ambient temperature and humidity
Cement type manufacture and quantity
Volume of pour
Concrete temperature (in position)
Aggregate type, source and proportions
Admixture details
Water/Cement ratio
Position in the work (e.g. Drawing No.)
Rate of pour
Slump
Method of placement

54
 Mixing of Concrete

All concrete shall be mixed in a batch mixer of approved design complying

with IS1791 where applicable, with an automatic water measuring device and
maintained in good order. The mixer and mixing platform shall be suitably
protected from the wind to prevent loss of cement. The mixer shall be fitted
with the manufacturers plate, stating the rated capacity and the
recommended number of revolutions per minute. Batching of cement and
aggregates shall be by weight. Water shall be measured by volume or weight,
but in either case the delivery shall be a predetermined amount to ensure the
correct water/cement ratio. The mixer shall be fitted with an approved
accurate mechanism for weighing the cement, fine aggregate and coarse
aggregate separately. Periodic checks shall be made to confirm the accuracy
of the weighing equipment which shall be within + 3% of the quantity of
cement. The mixing shall be done for the period recommended by the mixer
manufacturer, or until the concrete is ofuniform colour and consistency,
whichever period is longer. The entire batch is to be discharged before
recharging. Whenever there is a change in the type of cement in use or
mixing is stopped for more than half an hour, the churn of the mixer must be
thoroughly washed out with clean water of quality as specified. A competent
operator shall be in continuous control of the mixer. Tampering shall not be
allowed.

4.10Tests on Freshly Made Concrete

Crushing Strength Tests for Structural Grades

Sampling, curing and testing shall be carried out.

All samples shall be clearly marked with their identification and accurate records
shall be supplied to the CONSTRUCTION MANAGER.
These records shall include :-
Identification of test cube
Date and time of sampling
Method of sampling used
Mix designation
Location of sample after batching (e.g. Drawing No,)
Temperature and weather conditions
Method of compaction
Date of testing
Cement type and source
Volume of pour
Age of sample in days
Weight of sample in kg
Density in kg/m3
Crushing load in Newton
Crushing strength N/mm2
Signature of person taking sample

55
 Signature of person carrying out tests
If any test results fail to comply with the above then the quantity of concrete
represented by the results shall be at risk, and may be required to be removed
and replaced.

Standard Deviation
The 28 days cube crushing results shall be grouped consecutively in different
groups and each group shall have standard deviation as specified. If the
standard deviation is greater than this, the concrete production shall be
reviewed.

4.11Transport and Placing

Transporting Concrete
Concrete, after being discharged from the mixer shall be transported as
rapidly as possible to its final position in the works by approved means which
shall prevent adulteration, segregation, loss of workability or contamination of
the ingredients.
The Rotating Drum Mixer trucks that convey the concrete shall at alltime be
kept clean and free from hardened or partially hardened concrete. During hot
or cold weather suitable methods shall be adopted to reduce the loss of water
by evaporation or heat loss as case may be. The addition of water at the point
of discharge is prohibited. Chutes, spouts, skips and pumps will be permitted
for placing concrete subject to approval.

Inspection
Concrete shall not be placed unless the positioning, fixing and condition of the
reinforcement and any other items to be embedded, the cleanliness,
alignment and suitability of the containing surfaces have all been previously
examined and approved. Adequate time shall be allowed for inspection when
scheduling concrete pours.

Placing of Concrete
The concrete shall be placed in the positions and sequence shown on the
drawings and be deposited as near as possible to its final position in such a
manner as to avoid segregation of the concrete or displacement of the
reinforcement or formwork. It shall be mechanically compacted unless
otherwise directed. The concrete shall be placed and compacted before initial
setting of concrete commences and should not be subsequently disturbed.
Every precaution shall be taken to prevent the formwork and reinforcement
moving during the placing or setting of the concrete and any remedial work
that is necessary shall be executed promptly. As a general guidance, the
maximum permissible free fall of concrete may be taken as 1.5m.
The work shall be organized so that the placing of concrete is efficient and
continuous between specified or approved construction joints. In horizontal

56
 sections, when the placing of concrete has been interrupted and delayed so
that concrete has gained its initial set and cannot be adequately worked or
compacted, the surface of the unfinished concrete shall be thoroughly
cleaned, preferably by air and water jetting, to expose but not damage the
aggregate. After drying the surface shall be washed with cement grout
immediately before fresh concrete is added. The first layer of new concrete
placed shall not exceed 150 mm in depth and particular care shall be taken
with the compaction of this layer to ensure a good bond.

4.12Compaction and Vibration

Full compaction of the concrete shall be achieved throughout the entire depth
of the layer.
It shall be thoroughly worked against the formwork and around the
reinforcement; successive layers shall be thoroughly bonded together. Air
bubbles formed during the mixing and casting shall be expelled, particular
care shall be taken where sloping soffits occur.
Unless directed otherwise, approved power driven poker vibrators shall be
inserted vertically at such distances apart or applied in such a manner as to
ensure that the concrete is satisfactorily and uniformly compacted. Immersion
vibrators shall penetrate the full depth of the layer, and when the underlying
layer is of fresh concrete, shall enter and revibrate that layer to ensure that
successive layers are bonded together. Over vibration causing segregation,
surface laitance or leakage through formwork shall be avoided. Immersion
vibrators shall be withdrawn slowly to prevent the formation of voids. Vibrators
shall not be used to work the concrete along the forms, or in such a way as to
segregate the mix, damage formwork, other parts of the works, or displace the
reinforcement. External vibrators shall not be used without obtaining approval
for the formwork design and the configuration of the vibrators.

4.13Curing

General
Curing shall be continued for at least seven days from the date of placing
concrete in case of OPC. The period of curing shall not be less than 10 days
for concrete exposed to dry and hot weather conditions. All water used for
curing shall be of the same quality as that specified above. Sea water shall
not be used.

Horizontal Surfaces (Slabs)

Horizontal surface shall be saturated with water as soon as practical after the
concrete has been placed. The surface shall then be bunded and flooded with
water or draped with wet hessian and kept continuously wet for the length of
the curing period.

Vertical Surfaces
57
 Vertical surfaces shall be draped with wet hessian as soon as formwork is
removed, and kept in contact with the concrete and continuously wet for the
length of the curing period. Polythene sheet shall be used to protect against
drying winds.

Curing Compound
Approved curing compounds may be used only where conventional curing by
water cannot be resorted to, following approval of the Engineerincharge. For
concrete containing Portland pozzolana cement, Portland slag cement or
mineral admixture, period of curing may be increased. Curing compounds
shall conform to India standards and shall be applied in accordance with the
manufacturers instructions to provide a water loss not greater than 0.55
kg/m2 in 72 hours.

4.14Mass Concreting (Critical Large Foundations)

General
The heat of hydration during concreting shall be controlled by using methods
to prevent hightemperature differential between the interior of the concrete
and any outside face. The heat of hydration shall not cause a temperature
differential greater than 20C for thicknesses up to 1 m or 15C for
thicknesses over 1 m. 9.6.2. Recommended remedial measures for controlling
the temperature of concrete:
1. Methods to precool concrete include shading and sprinkling the aggregate
piles, use of chilled mixing water and replacing a portion of mix water with
flaked ice.

2. The form work and the top surface of the structure must be adequately
insulated with polystyrene or urethane. Additional insulation is needed at
edges and corners.

3. After the concrete has been placed, its peak temperature in any part of the
concrete mass shall not rise above 70C.

4. Insulating Surface by use of 25mm thick expanded synthetic material, such as

polystyrene or polyurethane or 50mm thick high density thermocole. The
curing shall not be done by spraying or ponding of water as these have rapid
cooling effect.

5. The risk of early thermal cracking may be minimised through use of concrete
mixtures with low coefficient of thermal expansion, crushed aggregate with
rough surfaces that provide increased tensile strength and certain types of Fly
ash and GGBFS which retards or reduce the rate of hydration. Higher
fineness of cement leads to more rapid hydration. Therefore, it is desirable to
avoid cements with a high specific surface.

58
 6. Reducing the temperature by using low content of cement with high proportion
of Pozzolana. The usage of super plasticizers to prevent potential cold joints.

7. Use aggregates higher than 20mm size, if reinforcement and piping

embedments permits.

8. It is recommended that concreting begin early evening (say 4pm) and

continue through the late evening / night and (if required) into early morning.

Prior to commencement of above work EIC Approval is required on following things:

1. Concrete Mix Details, including heat of hydration and specific heat characteristics
of cementitious constituents, expected concrete temperature rise and the proposed
initial concrete placing temperature.
2. Concrete Pouring procedure
3. Form work type and insulation
4. Location of Thermocouples installed on reinforcement cage.
5. Curing details related to temperature effects
6. Maximum and minimum concrete placing temperatures
7. Minimum and maximum times before formwork is stripped
8. Any additional methods for controlling the concrete temperature
9. Concrete temperature monitoring proposals

Concreting Procedure:

1. Each layer of concreting may not be more than 400mm to 450mm in thickness
and several vibrators should be kept ready for this operation. Ensure to
return to the earlier location WITHIN 2 HOURS to achieve good bond
between the two layers.

2. Use well designed chutes to deliver and deposit concrete.

3. The initial placing temperature of concrete shall be measured by inserting a

calibrated probetype thermometer, with1C accuracy, into each delivery of
the concrete at the time of discharge from the vehicle transporting it or not
later than 15 minutes thereafter. The thermometer shall be calibrated weekly.

4. Temperature of concrete shall be measured at bottom (around the bottom

reinforcement layer), mid depth of the raft and at the top (actually within the
top 150mm) of raft for each pour. Have a backup thermocouple for the
central thermocouple (raft middepth).

5. Measure temperature every hour for the first 72 hours with the first reading
one hour after completion of entire concreting of the pour under consideration.

6. Subsequently, measure temperature every 6 hours for the next 12 days.

Hence the last measurement will be exactly 15 days after completion of entire

59
 concreting of the pour under consideration. Prepare temperature graphs for
the entire operation up to 15 days after completion of concreting.

7. Also measure the ambient temperature as well as the concrete surface

temperature with the above temperatures and plot as part of the graph.

8. The thermocouples shall be suitably robust to withstand concrete placing, and

be adequately protected and firmly fixed in position on the reinforcement
cage. The thermocouples shall not be placed closer than300mm to any
cooling water pipes to ensure that they give representativetemperature
readings.

9. The output of the thermocouples shall be continuously recorded using an

automated data logger. The power supply to the data logger shall be
noninterruptible and the equipment shall be maintained and checked at least
twice per day to ensure that they are operating satisfactorily.

10. 10. The thermocouples shall be calibrated in conjunction with the working and
backup data loggers and calibration results shall be submitted at least 7 days
prior to incorporation within works.

11. After installation of the thermocouples within the pour and immediately prior to
concreting, the thermocouples shall be checked by comparing the relative
ambient temperature readings. Any damaged or malfunctioning
thermocouples shall be replaced prior to the commencement of concreting.

12. The output from the data loggers shall be down loaded daily. Electronic file
and hardcopy of data shall be submitted to the Engineer daily.

13. Insulation shall be maintained until the temperature differential has been
reduced to 10C.

Classification of Earth Encountered in Earthwork

Soils:
Any strata which can be easily excavated by appropriate manual method of
excavation is called as soil. Generally strata such as sand, gravel, loam, silt,
clay, mud, black cotton, etc are classified as soils. Such strata may be
excavated manually or using earth moving equipments depending upon the
extent of work to be done and clearances available for ease of maneuvering
of men & equipment.
Soft or weathered rock:
Rock which can be excavated by splitting with crow bars or picks or with
buckets of excavators and does not require blasting, wedging or chiseling or

60
 similar means for excavation is classified as soft or weathered rock. Strata
such as lime stone, sand stone, hard laterite, hard conglomerate and flakey
murum are examples of soft or weathered rocks.

Hard rock:

Rocks or large boulders which cannot be excavated by splitting with crow bars or
picks or with buckets of excavators but require either chiseling or blasting are
classified as hard rocks. Examples of hard rock are quartzite, granite, basalt etc.

4.15Batching Plant

There are in total 10 batching plants in the j-3 project.

The capacity of each plant is 60 cumec per hour.
The target is to achieve concreting of 1850 cumec per day.
All the batching plants are governed by RIL.
The millers have capacity of 6-9cumec.
There are boom placers for speedy concreting, which can be elevated to a
height of 36m and having capacity of 65 cumec per hour.

61
 Chapter 5
CONSTRUCTION ACTIVITIES

There were two sites, which I inspected during my training period.

1. Cracker Control Center

2. Cooling Tower (PX4)

Cracker Control Center

5.1Location
It is situated in C2 Complex, of Refinery Off Gas Cracker (ROGC) Plant.

i. Dimensions
Its dimensions are, L = 49.800mt B = 49.800mtH = 17.000mt.

62
 When I joined : Ground floor was about to cast.
When I left : 1st floor slab casted and roofs reinforcement tied.

5.2Function

It is one of the most critically important building in the refining process.

It is also known as Heart of the refinery.
As, the entire refining process and the mechanism is automated, Control
Center serves as the back bone for it.
Control Center comprises of huge sized monitor screens and various types of
machines.
Center, works for 24X7, 365 days, which is monitored by specialized persons
who have adequate knowledge and experience.
All the machines, valves, production mechanism are carried out from this unit.
Hence, lot of quality and inspection measures have to be taken care of, while
it is being constructed.
The design of this building is such that, it is a blast proof building made
entirely of RCC.
The blast proof doors are specially manufactured and imported from
Netherlands.
There are no windows or vents provided, so as to provide blast proof
mechanism.

5.3 Building details

Depth of Foundation = 3.2 Mt.

Total height = 17.2 Mt.
1st floor height = 7.2 Mt.
Quantity of Concrete in footing = 8000 cumec
Raft foundation was designed.
The standards in RIL is such that the excavation shall be done till zone-3, i.e.
a rocky surface.
Even though if the zone-3 is much deeper than the depth of foundation,
excavation shall must be done till rocky ground strata is found.
Plum concreting from zone-3 till the depth of foundation has to be done.
Plum concreting contains aggregates of size 60mm.
After plum concreting, a thin layer of 100mm PCC is done.
On this layer of PCC, Raft foundation is casted.
63
5.4Grade slab :-

Thickness of slab = 200 mm.

There are many different types of levels in the grade slab.
Maximum slab is at TOC, 1.065, which is in the periphery.
The central area which is a void, has the TOC of 0.600.
TOC are different so as to form a false floor, which facilitates passing of
various cables and wires.
Concrete, M40 = 150 cumec
Concrete, M20 = 500 cumec
Blinding Concrete, M10 = 200 cumec
Total reinforcement = 43.6 MT.
The structural drawing is prepared by JACOBS.
Grade slab will comprise of monitoring room, engineer room, toilet, HVAC
room, etc.
It has expansion joint at every 7.5 mt, horizontally, with thickness of 120mm.

5.5 Activities Inspected

i. Anti-termite treatment

Pre-construction Anti-termite treatment was done by EPCORN.

The chemical used for the treatment is Chlorpyriphos 20% EC.

Equipments Used :Sprayers& Sprinklers will be used to ensure proper

penetration of chemicals into the earth.

Guarantee :10 years

In case of ground floor dwelling of termite infestation during the guarantee

period, the company shall undertake to treat the termite infestation without
any extra cost.
Procedure :

This treatment will start after the foundation and the plinth beam work is over.

1. Treatment of plinth filling :-

In the plinth filling holes upto 500mm deep and 150mm centres will be made
along all the beams & columns. The chemical emulsion will be
poured/sprayed @ 7.5 Ltr/Sqmts of the vertical surface into these holes.

64
 The top surface of consolidated earth in plinth filling new soil level below
ground floor slab shall be treated with chemical emulsion @ 5.0 Ltr/Sims.

2. Treatment of soil along External Perimeter of Building :-

After the building is completed the soil along the external perimeter of the
bldg. shall be treated by digging holes upto a depth of 300mm and 150mm
centres. The chemical emulsion shall be sprayed @ 7.5 Ltrs/Sqmts. of
Vertical surface.

3. Treatment of soil surrounding pipe wastes & conduits :-

When pipes, wastes and conduits enter the area of foundation, the soil
surrounding the point of entry shall be loosened around each pipe, wastes or
conduits for a distance of 150mm and to a depth of 75mm and loosened soil
shall be treated with chemical emulsion by spraying.

4. Treatment for expansion joints :-

Expansion joints at ground level are one of the biggest hazard for termite
infestation to the bdg. The soil around these joints are to be treated @ 2.0 Ltr
per linear meter after the sub grade has been laid.

5. Spraying equipment :-

A watering can or pressure pump shall be used for spraying to facilitate

uniform distribution of chemical emulsion to surface.

ii. Expansion joint

Expansion joints are provided to safely absorb the heat-induced expansion

and contraction of construction materials, to absorb vibration, to hold parts
together, or to allow movement due to ground settlement or earthquakes.
As it is a very critical building, expansion joint plays a very important role.
At the joint, the rods get terminated.
Building faces, concrete slabs, expand and contract due to warming and
cooling from seasonal variation, or due to other heat sources. If they are not
allowed to expand than, they would crack under the stress induced.
Expansion joint shall be filled with fiber boards of 25-30mm thickness.

65
 Fiber board shall be filled with gunning phosphide, which prevents any
leakages.

iii. Construction joint :-

It is provided when concreting is done in layers.

The rods are continuous.
There is a joint of concrete in the structure.

iv. Control Joint :-

Control joints are planned cracks which allow for movements caused by
temperature changes and drying shrinkage. If the concrete does crack-you
want to have an active role in deciding where it will crack and that it will crack
in a straight line instead of randomly.
At bottom there is a reinforcing bar provided for the bonding, where as the top
there is no reinforcement.
There is a 20mm deep and 12mm wide sawcut is made, which is filled with
sealing compound

v. Grouting

Grout is a construction material used to embed rebars in masonry walls,

connect sections of pre-cast concrete, fill voids, and seal joints. Grout is
generally a mixture of water, cement, sand. Itis applied as a thick emulsion
and hardens over time. Unlike other structural pastes such as plaster or joint
compound, grout, when mixed and applied correctly, creates a waterproof
seal.
Main varieties include: tiling grout (either urethane, cement-based or epoxy),
flooring grout, resin grout, non-shrink grout, structural grout and thixotropic
grout.
There are 3 types of grouts used on site.

1. GP1 (M40)
2. GP2 (M60)
3. GP3 (M70)

66
 4. GP4 (M90)

Non Shrink Grout type 1 GP1 :-These type of grout are generally used for steel
structures, towers, vessels, small pumps and all non-vibrating machineries. But
the application shall be as per the drawings.

The grout shall be a proprietary nonshrinkable, freeflow cementitious grout

witha minimum compressive strength at least equal to that of the foundation
concretebut not less than 30 N/mm2 at 7 days and 40 N/mm2 at 28 days.

Non Shrink Grout Type G2 :- This type of grout shall be used, in general, for
precast concrete structures compressors and other heavy equipment subject to
vibration and for column bearing plates of heavy structures.

The grout shall be a proprietary nonshrinkable cementitious high strength

grout,e.g. FOSROCs Conbextra GP2 or MCBeauchemie Emcekrete or
similarapproved by the DEC. The specific locations for application shall be as
shown onthe drawings.
The minimum compressive strength of the grout shall be 50 N/mm2 at 7 days
60 N/mm2 at 28 days. The flexural strength of the grout must exceed 9
N/mm2 at28 days.

Epoxy Grout Type 1

Epoxy resin free flow grout with minimum compressive strength of 70MPa in
3days.

Epoxy Grout Type 2

Epoxy resin free flow grout with minimum compressive strength of 90MPa in
3days.

vi. Wall tie-rods(specs)

The walls are 500mm thick RCC walls

The reinforcement provided is of 2, 25mm dia bars and 2, 16mm dia bars.
The links are of 10mm dia at every 100mm.
For 25mm dia bars, couplers are used. (lapping is not allowed)
Threaded tie rod with cone arrangement is used on site. Cone can be metallic
or PVC type with appropriate dimensions. Space of the cone portion after the

67
 removal of cone shall be filled with non-shrink type of grout, immediately after
the form work is removed.

5.6 Concreting specs for Mezzanine Floor

Concrete, M40 = 900 cumec (Mass Concreting)

Reinforcement = 169.2 MT
32 mm bars = 5.100 MT
25 mm bars = 150.000 MT
16 mm bars = 9.000 MT
10 mm bars = 5.100 MT
The walls are 500 mm thick RCC walls.
Walls are continuously casted of height 2.5mt.

5.7Pre-Concreting checks

vii. Formwork Erection

Doka formwork for slabs/wallo in structures shall beof sufficient thickness to

sustain allconstruction loads plus the weight of fresh concrete between
supporting beamswithout excessive deflection. The underside of the sheet
shall be coated with approved corrosive resistant paint.
Before concreting is commencing the forms and previously cast concrete shall
be thoroughly cleaned and free from all sawdust, tie wire, shavings, dust, dirt
andother debris. Temporary openings shall be provided where necessary to
drainaway water and remove rubbish.

viii. Reinforcement check

Checking of activities like, spacing of rods, alignment of rods, checking of the

reinforcement provided as per drawings.
Coupler used for joining the rods, has designed threads or not.
Down-take pipes installed are at exact location or not.
Void or cut out which are placed, are at the exact location or not.
Floor drain pipes are installed at exact location and are of specified quality or
not.
The joints in the pipes are sealed or not.
Minimum cover for concrete that is 50mm is left or not.

68
 The rods are properly cleaned with wire brush before concreting.

ix. Shear reinforcement

It has to be provided at all the locations where column or cutouts are

present.
Extra reinforcing bars of 32mm dia are provided on top and bottom in all the
four directions.

x. Coupler

Couplers are used in rods having diameter greater than 25mm dia.
It is used to connect two rods.
It is used because in steel of higher diameter, it is advisable to use couplers
instead of lapping, as it increases the strength and is easy to assemble.
The drawback of staggering is removed.
The tensile strength of coupler assembly should be 620 Mpa and compressive
strength shall be 510 Mpa.
There is 20mm gap between the two rods in coupler system.
The threads on rods should must be done by machine.

5.8Post Concreting checks

xi. Removal of Forms

All formwork shall be removed without damage to the concrete including

removalwithout shock to prevent impact load on the partially hardened
concrete.
Materials and plant should not be placed on any new construction in such
manneras to cause damage, and not until concrete has achieved the required
strength totake the additional construction loads required.
Soffit/Doka forms shall not be struck until the concrete has reached as a
minimum atleast double the strength required to carry its own weight plus any
othertemporary loads which may be applied, whichever is the greater.
The concretestrength shall be assessed from tests on cubes cured under
similar conditions tothe concrete in the structure.

69
 Wall, columns 24 to 48 hours as may
and vertical faces be decided by the
of all structural
engineer in charge.
members
Slab (props left 3 days

under)
Beam Soffits 7 days

(props left under)

Removal of props
under slabs

Spanning up to
4.5 m 7 days
Spanning over 4.5m 14 days
Removal of props
under beams

Spanning up to 6m 14 days
Spanning over 6m 21 days

xii. Curing by water ponding(vaata)

Curing shall be continued for at least seven days from the date of placing
concretein case of OPC. The period of curing shall not be less than 10 day for
concreteexposed to dry and hot weather conditions
Horizontal surface shall be saturated with water as soon as practical after
theconcrete has been placed. The surface shall then be bunded and flooded
withwater or draped with wet hessian and kept continuously wet for the length
of thecuring period.
Vaata are formed to retain the water. Approximately an area of 15m X 8M is
flooded with water for curing.

Vertical Surfaces

Vertical surfaces shall be draped with wet hessian as soon as formwork

isremoved, and kept in contact with the concrete and continuously wet for
thelength of the curing period. Polythene sheet shall be used to protect
againstdrying winds.

70
xiii. Cracks checking and repairing

After the curing period is over, the surface is checked for any cracks/honey
combing.
If any cracks are found, than that crack has to be opened.
Chisel the crack in U shape, of depth double the width of crack.
The area is thoroughly cleaned using air compressor
The cracks are sealed using Polymer Modified Morta(PMM, 1:3) mixed with
water proofing compound, of the below approved companies.
FORSOC
SIKA INDIA
BASF

xiv. Column starter check and witnessed

After the slab is casted, after proper curing period, the column which has to be
erected further, is tied.
100mm height of column is casted.
The level and checks are done using line and dori, survey machine and plumb
bob.

71
 Chapter 6
Equipments & Machines

6.1 Over view:

There are more than 3200 cranes of various capacities for lifting, carrying
steel structural members, pre-cast members, scaffolding materials, etc.
There are approximately 15000 trucks used for the construction.
The scrappers, rollers, JCB, rollers, boom placers, transits mixer of
different sizes and quantities.

6.2 Few of the equipments are:-

1. Manitowoc 18000

72
 It can lift upto 750 t.
Maximum height of boom is 158 m.
Its dead weight is 850 t.
Model Length: 20.98" (533mm)
Model Width: 7.99" (203mm)
Model Height: 67.01" (1702mm).

2. Fuwa QUY100A

Its a Chinese company, having various types of crawler, tower cranes.

Max. lifting capacity 100 t.
Total weight 114 t.
Boom Length 18-72m.
Boom elevating angle 0-80 degree.

3. Fuwa QUY80A crawler type

Crawler mounted
Capacity: 80 MT
Boom: 58 Meter
Total weight: 83 t

4. SANY SCC3200

73
 Carrying Capacity 320 t.
Boom length: 18-84 m
Engine power: 298 KW
Boom angle: 30-85 degree
Weight: 340t
Ground pressure: 0.17 MPa

5. Zoomlion Crawler crane ZLJ5455

Carrying Capacity 700 t.

Boom length: 12.2-44.2 m.
Engine power: 276 KW.
Working radius: 3-32m
Torque: 16000rpm
Weight: 340t

74
 6. Putzmeister Bloom Placer

Vertical Reach: 41.6 m

Horizontal Reach: 37.6 m
Reach Depth: 30.7 m
Output: 92 cumec
Hydraulic system

7. Liebherr Crane

Maximum lifting capacity: 600 t

Height: 24-144m
Travel speed: 1.36 kmph

75
 Total counterweight: 565 t

8. Hyundai 270R Scrapper

Maximum Digging Reach: 9.5m

Boom Length: 5.6m
Max. Dumping height: 6.5m
Max. Swing radius: 3.7m
Operating weight: 21.2 t
Bucket capacity: 0.92 cumec

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 9. Mammoet Crane

Worlds heaviest crane

Used for lifting, Toluene Column of height 110m
Weight of the Column: 1200 t
Total weight of the Crane: 3200 t
Per day Rent : Rs. 25,00,000
Shipped from L&T, Hazira.
Assembled on site.
Cannot be mobilized.

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8. Greaves Transist Mixer

Capacity: 9 cumec
Discharge opening dia: 1140mm
Total weight: 4700 kg
Tank Capacity: 600 liter
Rotation speed :0-14 rpm
Time taken: 18-20 mins

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 Chapter 7
Safety Measures

Safety of person over rides all the production targets

is the safety policy of Reliance

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7.1 Company Policy

Reliance is committed to:

Conduct all its activities in such a manner as to avoid harm to employees,

contractors and the community.
Promote occupational health of its employees and contractors.
Improve continuously its environment practices and performance.
Minimize adverse impact on environment and risks to the community that
arise due to its operations and during transport and distribution of its goods.
Utilize energy resources in a responsible and efficient manner so as to reduce
emissions and generation of effluent and waste products.
Comply with all statutory requirements concerning Health, Safely and
Environment.
Create a culture of learning and practicing Health, Safety and Environment
systems, procedures, and practices among all its employees and contractors.

Reliance strives to achieve these objectives by:

Designing plants with proper and adequate safeguards for ensuring process
safety.
Carrying our process and operational changes through well-defined system
and strict adherence to the same.
Following effective use of safe working procedures and practices for
operation, maintenance, inspection and emergency situation.
Reviewing regularly and updating of systems and procedures.
Training and validating employees and contractors on health and safety
practices.
Conducting all work in a safe manner and to ensure integrity of the assets, by
providing personal protective equipment, tools and tackles.
Auditing periodically internal and external work procedures and practices.
Investigating all incidents relating to Health, Safety and Environment,
including minor ones near misses, followed by implementation of corrective
measures.
Communicating learning from investigation of incidents, internal and external,
to all employees and taking steps to prevent such occurrences in its works.
Identifying and evaluating health risks related to operations and carrying out
pre-employment and periodic medical check-up of its employees.
Implementing programs and appropriate protective measures to control such
risks.

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 Continuously monitoring work environment and plant effluents-gas, liquid and
solid and taking measures to achieve better environment performance.
Interacting with local communities on operations, likely hazards and
emergency response systems.
Keeping abreast of latest international codes, standards and practices and
adopting the same where applicable.

7.2 Various Definations:

1. Man-Hour Worked:

The total no. of employee hours worked by all employees working in the
premises. It should be calculated from the payroll or time clock record
including overtime.
When it is not applicable, shall be estimated by multiplying total man days
worked for period covered by the no. of hours worked/day

2. Safe-Man Hours:

The total no. of employee hours worked by all the employees in which no
accident is reported. It is calculated per month.

3. Safe Man Day:

It is calculated by cumulative safe man-hours divided by 8

Thus, it gives safe man-day. It can be calculated per week or month.

4. Man Days Left:

The day on which injury occurred or the day the injured person returned to
the work are not included as many days are lost, but all intervening
calendar days( including Sundays or days off or shutdown).

5. Accident

An unintended event arising out of job related activities occurring at a work

place which causes death to a person or is such a serious nature that it is
likely to result in loss of time/vision or permanent total disablement or
which causes a bodily injury by reason of which the injured person is
prevented from working immediately following the event.

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7.3 PPE- (Personal Protective Equipments):

Safety appliances are provided to protect the workmen from possible injury
during execution of jobs. The safety appliances required for different jobs
confirming to the standard are provided at site as under.

Head Helmet
Eyes & Face Protective goggles, Face shields &
Welders Hood.
Ears Ear plugs
Respiratory Sysytem Dust Masks
Hands & Arms Heat/Chemicals/sharp resistant Gloves
Trunk Safety Harness/Fluorescent jacket
Feet & legs Safety Shoes

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Helmets:

Fiber glass HDP etc material used helmet is available. It should be 450
Gms and should be moist, shock and fire proof. It should withstand 20C
to 50C temperature. If plumb bob of 50 g weight with conical steel point is
dropped form a height of 3m, it should not pierce and dent.

Belts:

It consist of one body belt and two should strap made from strong closely
woven approximately 50mm wide, 6 ply of cotton webbing with 3m long
12mm diameter tested quality polypropylene rope.
D-ring is provided at the back of these safety belts and lifeline is directly
attached from back of this D-ring.Relative code IS 3521:1965.

Goggles:

For chippers, grinders and hammer men, clear glass 50mm diameter with
shutter proof toughened glass.

Gloves:

All labour: Made of chronic leather 450mm long with five fingers double
stitching for joints. The fit of fingers is such that ample room is provided.
Electricians: Made up of rubber 380 mm / 450 mm long tested to 15000V.
For material handling: Leather cum canvas. Double leather for palm and
single leather for five finger type and of double stitching. Relative Code: IS
4770:1968.

Dust mask:

Cloth dust mask flannel type made of netting cloth outside and fine
canvas, cloth inside sandwiched with 3mm foam padding, enclosing the
mouth and nose, with elastic head strap, ensuring safe breathing in duty.
Safety net:
6mm diameter with twin rope inside for 50 mm * 50 mm meshing with
provision for intermediate rope of 12mm diameter every 1m and 20mm
diameter rope on all four sides, with provision for trying the net at every
1m. All ropes should be made and tested quality polypropylene rope.
There should not be any joint in the mesh. It should withstand a load of
500Kg on 3.5m span. Relative code: IS 5175:1992.
A safety net should pass through a drop test which specifies that the
deflection should not be more than 2m or half the length of shortest side
when a sand bag of 140kg mass is dropped successively 3 times on to the
center of the net from a height of 50 feet.

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GENERAL SAFETY INDUCTION PROGRAMME:

Purpose:

To identify unsafe condition / unsafe act which may lead to accidents,

especially part of a plant or machinery or equipment as well as the
activities being undertaken during the execution of a job and also to
suggest suitable remedial action to correct the unsafe condition or unsafe
act.

Procedure:

Site safely officer conducts physical inspection of the work places

referring to the standard safety checklists and also look for any other
unspecified hazards. He identifies all conformities and non-conformities in
respect of physical conditions and practices and specifies them with
respect to the safety procedures. Positive / negative remarks on the
checklist as the case may be.
He circulates the copy of the safety inspection report to the concern
workplace. Engineers for taking necessary connective actions and follows
up implementation for the suggested safety measures.

Tool Box Talk, Safety Training, Safety Meeting:

Tool box talk shall be conducted daily by site supervisor at site & every
worker shall attend the same. Safety training shall be conducted as per job
requirement. Various safety awareness programs should be conducted at
site which includes:

1. Safety awards to Safe Workers

2. Safety competition etc.

B. Fire Prevention & Protection:

1. It is difficult to fight the fire rather than prevent it. Do not allow any situation
due to which fire takes place.

2. Maintain good housekeeping at site.

3. Maintain all firefighting equipment in good condition to use it in emergency.

4. Temporary or shift electrical wiring and overloading should be avoided.

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 5. Cigarette/tobacco/guthka are strictly prohibited.

6. Carry out fabrication in fire safe area with concrete or metal plate floors.

7. No welding or cutting should be done on a surface until various building

materials likewood, card board, straw, oil, paints, asphalts, bitumen etc., have
been removed.

8. Suitable firefighting equipment are provided at site to take care of fire

contingencies.

9. Necessary maintenance of firefighting equipment should be done

periodically based onmanufactures instruction manual.

C. Hygiene, Sanitation & Housekeeping:

Maintain good hygienic conditions at the site which will provide healthy
atmosphere.
Sanitation: Always make use of toilet facility at site &maintain its
cleanliness.
House Keeping: Place everything at its place. It plays major role in
accidentprevention. Keep your work place clean & tidy. Remember
Cleaner place is a saferplace. Good housekeeping is an important tool;
for accident prevention. Theimportant measures are to be undertaken.

D. Emergency Procedure:

1. Stop the work; switch off the machines, equipment, vehicles at site.

2. Assemble at assembly point for head counting.

3. Follow the instruction from supervisor.

7.4 FIRST AID EQUIPMENT:

Fully equipped first aid box is made available new site having adequate
supply ofvarious types of bandages, potassium permanganate solution or
crystals etc. The contents offirst aid box should be replenished as and
when required.

First Aid Kit

Assorted adhesive dressing

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 Paper tissues
Triangular bandage
One inch roller bandage
Three inch roller bandage
Cotton wool
Scissors
Safety pins
Small size prepared sterile dressing Lint or gauge, plain white salt volatile
or smelling salt
Tablet for Headache, Pain killer, Fever, Diarrohea

Training and appraisal Program:

In between 4th march to 10th march, celebration of national safety week
held at the site.
On all six days, some competition and some safety induction programmes
held at the site. Onthe last day, appraisal function was held and the best
safety award given to some labor andsome employee. One Slogan writing
competition held at the site.
Each construction activity is checked before done as is it safe for the
work? If it seemssafe for working, only then it is to be done. For scaffolding
work, after approved tag by safetyengineer, it can be used by the workers.
Safety Exhibition Safety training.

7.5 SAFETY MEASURES IN WORK AT HEIGHT:

All roof-work operations should be pre-planned and properly supervised.

Work at height should only be undertaken by workers who are physically
andpsychologically fit and have the necessary knowledge and experience
for such work.
Work on height should not be carried on in weather conditions that
threaten the safetyof workers.
Crawling boards, walkways and roof ladders should be securely fastened
to a firmstructure.
Roofing brackets should fit the slope of the roof and be securely
supported.
Where it is necessary for a person to kneel or crawl near the edge of the
roof anintermediate rail should be provided unless other precautions, such
as the use of asafety harness, are taken.
On a large roof where work does not have to be carried out at or near the
edge, asimple barrier consisting of crossed scaffold tubes supporting a
tubing guard-rail maybe provided. Such barriers should be positioned at
least 2 m from the edge.

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 All covers for openings in roofs should be of substantial construction and
be securedin position
Roofs with a slope of more than 1 in 10 should be treated as sloping.
When work is being carried out on sloping roofs, sufficient a suitable
crawling boardsor roof ladders should be provided and firmly secured in
position as soon as ispracticable.
During extensive work on the roof, strong barriers or guard-rails and toe-
boardsshould be provided to stop a person from falling off the roof.
Where workers are required to work on or near roofs or other places
covered withfragile material, through which they are liable to fall, they
should be provided withsufficient suitable roof ladders or crawling boards
strong enough, when spanningacross the supports for the roof covering, to
support those workers.
A minimum of two boards should be provided so that it is not necessary for
a personto stand on a fragile roof to move a board or a ladder, or for any
other reason.
To prevent danger, suitable material such as steel wire mesh should be
placed inposition before any roof sheeting of asbestos cement or other
fragile material is placedupon it.
Purling or other intermediate supports for fragile roofing material should
besufficiently close together to prevent danger.
Where a valley or parapet of a fragile roof is used for access, protection
against fallingthrough the fragile material should be provided by covering
the adjacent fragilematerial to a minimum distance of 1 m up the roof.
Building with fragile roofs should have a warning notice prominently
displayed at the approaches to the roof.

7.6 SAFETY MEASURES IN ERECTION AND DISMANTLING STEEL

AND PREFABRICATED STRUCTURES:

As far as practicable the safety of workers employed on the erection and
dismantling ofsteel and prefabricated structures should be ensured by
appropriate means, such asprovision and use of:

(a) Ladders, gangways or fixed platforms.

(b) Platforms, buckets, boatswains chairs or other appropriate means

suspendedform lifting appliances.

(c) Safety harnesses and lift lines, catch nets or cat platforms.

(d) Power operated mobile working platforms.

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 Steel and prefabricated structures should be so designed and made that they
can besafely transported and erected, and if required by national laws and
regulations eachunit should be clearly marked with its own weight.

In addition to the need for the stability of the part when erected, when
necessary toprevent danger the design should explicitly taken into
account:

(a) The conditions and methods of attachment in the operations of transport,

storingand temporary support during erection or dismantling as applicable.

(b) Method for the provision of safe guards such as railings and working
platforms,and, when necessary, for mounting them easily on the structural
steel orprefabricated parts.

The hooks and other devices built in or provided on the structural steel or
prefabricatedparts that are required for lifting and transporting them should
be so shaped,dimensional and positioned as:

(a) To withstand with a sufficient margin the stresses to which they are
subjected;

(b) Not to set up stresses in the part that could cause failures, or stresses in
thestructure itself not provided for in the plans and be designed to permit
easyrelease from the lifting appliance. Lifting points for floor and staircase
unitsshould be located (recessed if necessary) so that they do not protrude
above thesurface;

(c) To avoid imbalance or distortion of the lifted load.

Prefabricated parts made of concrete should not be stripped or erected

before theconcrete has set and hardened sufficiently to the extent
provided for in the plans, andbefore use should be examined for any sign
of damage which may indicate weakness.
Store places should be so constructed that:

There is no risk of structural steel or prefabricated parts falling or overturning;

(b) Storage conditions generally ensure stability and avoid damage having
regardto the method of storage and atmospheric conditions;

(c) Racks are set on firm ground and designed so that units cannot
moveaccidentally.

While they are being stored, transported, raised or set down, structural
steel orprefabricated parts should not be subjected to stresses prejudicial
to their stability.

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 Lifting hooks should be of the self-closing type or of a safety type and
should have themaximum permissible load marked on them.
Tongs, clamps and other appliances for lifting structural steel and
prefabricated partsshould:

(a) Be of such shape and dimensions as to ensure a secure grip without

damagingthe part;

(b) Be marked with the maximum permissible load in the most unfavorable
liftingconditions.

Structural steel or prefabricated parts should be lifted by methods or

appliances thatprevent them from spinning accidentally.
When necessary to prevent danger, before they are raised from the
ground, structuralsteel or prefabricated parts should be provided with
safety devices such as railings andworking platforms to prevent falls of
persons.
While structural steel or prefabricated parts are being erected the workers
should beprovided with and use of appliances for guiding them as they are
being lifted and setdown, so as to avoid crushing of hands and to facilitate
the operation.
Before it is released from the lifting appliance a raised structural steel or
prefabricatedpart should be so secured and wall units so propped that
their stability cannot beimperiled, even by external agencies such as wind
and passing loads, in accordancewith national laws and regulations.
At workplace adequate instruction should be given to the workers on the
methods,arrangements and means required for the storage, transport,
lifting and erection ofstructural steel or prefabricated parts, and before
erection starts a meeting of all thoseresponsible should be held to discuss
and confirm the requirements for safe erection.
During transport, attachments such as slings and stirrups mounted on
structural steel orprefabricated parts should be securely fastened to the
parts.
Structural steel or prefabricated parts should be so transported that the
conditions donot affect the stability of the parts on the means of transport
result in jolting, vibrationor stresses due to blows, or loads of material or
persons.
When the method of erection does not permit the provision of other means
of protectionagainst falls of persons, the workplaces should be protected
by guard-rails, and ifappropriate by toe-boards.
When adverse weather conditions such as snow, ice and wind or reduced
visibilityentail risks of accidents the work should be carried on with
particular care, if necessary,interrupted.
Structures should not be worked on during violent storms or high winds, or
when theyare covered with ice or snow, or are slippery from their causes.

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 If necessary to prevent danger, structural steel parts should be equipped
withattachments for suspended scaffolds, lifelines or safety harnesses and
other means ofprotection.
The risks of falling, to which workers moving on high or sloping girders are
exposed,should be limited by all means of adequate collective protection
or, where this isimpossible, by the use of a safety harness that is well
secured to a sufficiently strongsupport.
Structural steel parts that are to be erected at a great height should as far
as practicablebe assembled on the ground.
When structural steel or prefabricated parts are being erected, a
sufficiently extended area underneath the work-place should be barricaded
or guarded.
Steel trusses that are being erected should be adequately shored, braced
or guyed untilthey are permanently secured in position.
No load-bearing structural member should be dangerously weakened by
cutting, holing or other means.
Structural members should not be forced into place by the hoisting
machine while anyworker is in such a position that he could be injured by
the operation.
Open-web steel hoists that are hoisted singly should be directly placed in
position andsecured against dislodgment.

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7.7 CONCLUSION:

The rate of accident in construction industry is relatively high when compared to

othermanufacturing industry such as engineering, pharmaceutical, chemical etc. This
ismainly due to the nature of the civil engineering works and also partly due to
thedifference and disparity in training and skill of the workers employed in the
saidindustries. It is, therefore, imperative that workers employed in the
constructionindustry are provided basic training in their respective trades and
vocations. Further, itis essential that they are made safety conscious by the
supervisors and engineers underwhom they are directly working.

It is reported, in western advanced country based on the statistics, that in

recent yearsthe rate of fatal accidents due to collapse of excavation is 10% of
total accidents in thework of excavations. It is quite high when compared to
0.5% fatal accidents of totalaccidents in the construction industry as a whole.
Further, it has been also reported thatdue to continuing increase in
mechanization of the construction work, there has beenincrease in the
number of accidents concerned with transport and mobile plant.
Thisemphasizes the need to adhere to safety measures in excavation,
underpinning anddemolition.
By far the largest proportion of accidents and casualties in civil and
structuralengineering field are not from structural failures during the working
life of the buildingor structure, but during construction, maintenance and
demolition of the same.

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SELF ASSESSMENT

During my practical training I came to know that Theoretical and Practical

Knowledgeare two sides of a coin, which are supported by each other.
Through practical training I actually learnt the way of executing various
constructionactivities on the site.
Industrial Training also helped me to know how the unforeseen conditions are
identifiedand resolved at site.
The main important thing which I learned during the entire training is the
liaison between different agencies (Client, Architecture, Contractor and
Consultant, Design Engineering Company) involvedin the project.
I learnt how latest technologies are implemented on site with the help of
experts, drawings reviewing, importance of asset monitoring, coordinating
with various departments like mechanical, electrical, etc.
I came to know that, along with perfect planning and drawings, a very
accurateexecution and quality check is necessary for desired result.
I feel more confident after being able to gain large amount of Knowledge and
insightof the Construction Sector.
After taking industrial training from Owner side, I came to know that most of
the project cannot complete in the time decided at the time of tendering. So at
the time oftendering, inclusion of more markup helps to complete the project
on schedule.
For getting better work and desired result, the appraisal is necessary to the
engineersand supervisor.
So, this training has induced a lot of self-confidence in me. Thus, this
IndustrialTraining was really a step ahead for my future development.

After training, I realized that in a small or a big construction company,

management isvery much necessary. The haphazard work at any construction
firm lead to latecompletion of project or lead to increase project cost.

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