jipmer phase ii project

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TRAINING 2 JIPMER Phase II Project LARSEN &TOUBRO Limited VISIT DETAILS: Company Name : Larsen &Toubro Limited Address : Jipmer Campus Tel.: 0413-2677684 0413-2677139 Fax: +91 (0)413 2677727 Date of Visit : 1.06.2012 – 29.06.2012 Time of Visit : 10 AM – 5 PM

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Page 1: JIPMER Phase II Project

TRAINING 2

JIPMER Phase II Project

LARSEN &TOUBRO Limited

VISIT DETAILS:

Company Name : Larsen &Toubro Limited

Address : Jipmer Campus

Tel.: 0413-2677684

0413-2677139

Fax: +91 (0)413 2677727

Date of Visit : 1.06.2012 – 29.06.2012

Time of Visit : 10 AM – 5 PM

Page 2: JIPMER Phase II Project

COMPANY

Larsen & Toubro (L&T) is India’s largest technology, engineering, manufacturing and construction organization with a track record of over seven decades. L&T is also one of India’s best managed and most respected companies on various attributes of customer delight and shareholder values.

L&T’s Construction arm - L&T Construction - is the largest constructionorganization in the country and finds its unique position (29th rank as per ENR,USA – August 2011) among the world’s 225 top contractors.

L&T’s Buildings & Factories Independent Company (B&F IC), one among the four newly reorganized Independent companies is equipped with the domainknowledge, requisite expertise and wide-ranging experience to undertakeEngineering, Procurement and Construction (EPC) of all types of building andfactory structures through its dedicated Business Units (BU).

1. Airports: The Business Unit undertakes end to end responsibilities in design

and turnkey construction of major airports including all associated airportfacilities.

2. IT and Institutional Space : The BU provides concept to commissioningsolutions for IT Parks, office space including high rise towers and greenbuildings. It also undertakes design and construction of educationalinstitutions, metro stations, sports stadiums, exhibition / convention centers andother public buildings.

3. Health & Leisure : The BU undertakes design and construction of hospitalsincluding procurement, installation and commissioning of medical equipment.In the Leisure segment, L&T undertakes turnkey construction of internationalclass hotels, entertainment centers, serviced apartments, commercial malls andmixed use developments.

4. Residential Buildings : L&T’s expertise in residential buildings cover designand construction of large townships and high rise apartments through twobusiness units - Elite Housing and Affordable & Mass Housing.

5. Factories : L&T offers turnkey design and construction services for factoriesunder two segments - Cement and Heavy & Light Engineering Plants.

Page 3: JIPMER Phase II Project

Recent Projects:

1. Parliament Library building, New Delhi2. Serene County – a residential township in Hyderabad3. Illuminated view of Dalmia Cement in Tamil Nadu4. Asia’s largest automated dairy Plant at Gandhinagar,Gujarat5. Cyber Towers – Phase I of HITEC City in Hyderabad6. Grand Hyatt Hotel, Mumbai7. Sri Sathya Sai Institute of Higher Medical Sciences atWhitefield near Bangalore

PROJECT DETAILS

Design And Architecture : L&T Edrc, Pondicherry.Execution : L&T Ltd, Ecc Division.Contract Value ` : 359 CroresContractual Duration : 24 Months

Jipmer Phase II Project-

A Teaching Block - 16950 Sq.M A Women & Children Hospital - 29170 Sq.M A Hostels Complex - 29176 Sq.M Augmentation Of The Existing Facilities

TRAINING:

SAFETY

At L&T ECC Division, Environment, Health & Safety (EHS) is given the highest priority. Besides the enforcement of engineering measures and management controls, Personal Protective Equipment, as per need of the operations are provided. Awareness among employees is created and sustained through regular training

Page 4: JIPMER Phase II Project

programs. Systems are rigorously implemented to ensure high standards of Environment, Health & Safety at the jobsites.

Personal protective equipment:

Helmet ::

Face Shield

Goggles

Page 5: JIPMER Phase II Project

Nose Mask

Leather Gloves

Ear Plug

Page 6: JIPMER Phase II Project

Shoes Cotton Gloves Gumboot

Fall Protection:

Scaffolds

Safety Belts

Safety Net

Page 7: JIPMER Phase II Project

Hand Rails Mobile Scaffolds

FIRE EXTINGUISHER:

Different types of fire extinguishers are used for each classes. The Types of extinguishers available are:

DCP fire extinguisher - used for CLASS A, B, C fires.Foam extinguisher - used for CLASS B fires.Carbon Dioxide Extinguisher - used for CLASS A, B fires.

The different types of class are:

CLASS A- Cloth, Wood.CLASS B- Liquids like Petrol, Diesel, Paint.CLASS C- Electrical equipments.CLASS D- Metals l ike Potassium, Magnesium.

QUALITY

Quality control is a process by which entities review the quality of all factors involved in production. In project management

Page 8: JIPMER Phase II Project

quality control requires the project manager and the project team to inspect the accomplished work to ensure it 's alignment with the project scope. In practice, projects typically have a dedicated quality control team which focuses on this area.

Various tests have to be done on the materials used in the construction works.

1.Aggregates:

The tests done on aggregates are:

o Grading o Bulk Densityo Specific gravityo Absorptiono Bulkingo Aggregates crushing valueo Aggregates impact value

As sand is not available with the required properties, it is replaced by quarry dust which is very cheap.

2.Cement:

The grades of cement available are 33, 43 &53 grades.The 53 grade is more commonly used at present.

Tests done on cement are:

o Soundness test o Compressive Strengtho Specific Gravity testo Consistencyo Initial & Final Setting Time

Page 9: JIPMER Phase II Project

3.Concrete:

The grades of concrete available are:M5, M10, M15, M20, M25, M30, M35, M40, M50, M55.M5 & M10 are used for the PCC works.M20 and above are used for beams, columns and slabs.The density of the concrete is 2400kg/m 3

Tests done on the concrete are:

o Slump testo Vee-Bee testo Flow testo Compacting factor testo Compressive Strengtho Tensile Strengtho Flexural Strength

The Slump Test is more commonly used at the site work.

4.Reinforcement Bars:

The types of bars available are Fe250, Fe415, Fe500 & Fe550.Fe500 & Fe415 is most commonly used.

Test done on these bars are:

o Tensile Stength

5.Bricks:

Fly ash bricks are used in this site due to the economy. Lime is used as the binder.

Tests done on bricks are:

o Absorption test

Page 10: JIPMER Phase II Project

o Hardness testo Effloresenceo Compressive Strength testo Soundness test

PLANT AND MACHINERY

Larsen and Toubro have their own Plant and Machinery unit to take care of most of the machinery and batching plant requirements of the construction sites. The machinery are maintained according to ISO standards and so the relevant documents for each machinery, as required by ISO, is maintatined by the P&M in-charge of the site. A few of the equipments present at the JIPMER site are:

Concrete batching plant Boomtruck Bobcat Crane Wheel loader Vibratory compactor Compactor Air Compressor Sand Seiver Dewatering Pump Submersible Pump Bar bending Machine Bar cutting machine Cement Feeding Pump Planer Circular Saw machine Builder Hoist Suspended Platform Plastering Machine Plate Compactor Welding Generator

Page 11: JIPMER Phase II Project

FORMWORK

Formwork is a die or a mould including all supporting structures, used to give a definite shape and support to the concrete until it attains sufficient strength to carry its own weight. The formwork is a kind of “baking tin”, which holds the concrete until it hardens to attain the required shape and size.

SAFETY IN USING FORMWORK

Safety is ensured if-

Components are l ight in weight for manual handling. Loose or dangling/hanging components are minimal. Minimum operations are involved in each reuse. Individual components are self standing. System facil itates fixing and removal at each location without

the use of sophisticated tools and tackles. Usage of appropriate of tools. Erection and dismantling is done as per the procedure or

methodology. Proper housekeeping and stacking of materials. Inspection of materials condition before usage.

The type of formwork used in the Jipmer phase II project is Plywood Formwork.

FINISHING WORKS:

It involves:

• Wall tiling• Floor tiling• Sunken & Water proofing• Painting

Page 12: JIPMER Phase II Project

Wall Tiling:

• After the completion of plumbing, sanitary and electrical works.• The surface is roughened, marking is done as per the layout.• Then slurry is prepared & applied.• Til ing is done.

Floor Tiling:

• Base concrete level is checked• Surface is prepared• Mix proportion is done• Til ing is done• Skirting is done for 13mm

Sunken proofing:

• Water tightness of RC slab by water ponding for 24 hours is done• If leakage is found pressure grouting is done.• Surface is prepared• Chamfering 50mm with cement mortar admixed with mix bond • Applying of first coat• Second coat is applied• Test is done and further finishing is done.

Water Proofing:

Water proofing is done over podium areas ,water tanks, exterior walls and over basement walls & slabs.

PLANNING

SCHEDULING: Scheduling is the process of planning with respect to time and cost. It is an important process. Every first day of the month meeting is conducted and all the site engineers will discuss on the plans

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Based on time, scheduling can be classified into seven types: Invoice schedule Material schedule Labor schedule Plant and machinery schedule Staff schedule Special agency schedule Overhead schedule

Based on cost, schedule can be classified into four types namely: Material schedule Labor schedule Plant and machinery schedule Overhead schedule

BUILDING CONSTRUCTION:

There are two basic parts in a building namely: Substructure or foundations Superstructure

Sub-structure or foundation is the lower portion of the building, usually located below the ground level, which transmits the loads of the super-structure to the supporting soil. Super-structure is that part of the structure which is above ground level, and which serves the purpose of its intended use.

SUB-STRUCTURE:

1) Excavation marking: The area to be excavated is marked on ground by referring the design of the plan. If the surface is plain the area to be excavated is marked by placing rods at known coordinates and the rods are connected by using ropes in order to locate the point. If the surface is not plain, points are located using total station.

2) Excavation:

Page 14: JIPMER Phase II Project

It is done by using in the case of shallow foundation. For pile foundation, piles are directly inserted into the ground without excavating after soil investigation.

3) Marking for footing: The center and boundary of footing are marked on ground as excavation marking is done.

4) Plain Cement Concrete (PCC) laying: PCC is laid to a depth of 75 to 100 mm before the footing is laid.

5) Columns and footings marking: The center of column and position of reinforcement for footing is marked on the PCC.

6) Footing reinforcement: The reinforcement for footing is first laid over the PCC layer as per the given length in the design.

7) Column reinforcement: After the footing reinforcement for bottom pad and top pad is laid, reinforcement is erected for column till the plinth level.

8) Shuttering for footing: When the reinforcement is laid, the side shuttering is done before the concrete is poured into it.

9) Concrete pouring: Concrete is poured in the footing and vibration is done. Side shuttering is removed after one day and the concrete is cured.

10) Starter: The position of the starter is marked on footing. The shuttering for starter is done and the concrete is poured and cured.

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11) Column shuttering and concreting: The column shuttering is done till plinth level and the concrete is filled into it. The shuttering is removed and concrete is cured.

12) Backfilling: Then the excavated area is filled with soil and compacted till the existing ground level.

13) Plinth beam: PCC: Over the compacted soil layer, plain cement concrete is poured and

leveled. Reinforcement: The steel rods are placed rightly according to the design. Shuttering: The bottom and side shuttering is done after reinforcement. Concreting: The concrete is poured into it.

Page 16: JIPMER Phase II Project

SUPER-STRUCTURE: 1) Starter:

The starter is marked, shuttered, and the concrete is laid over it and cured.

2) Column reinforcement: After the starter is laid, reinforcement of column is done as per the design.

3) Shuttering and concreting: The reinforcement is laid and the shuttering is done till the lintel level. Concrete is poured into it and curing is carried out.

4) Lintel beam: Shuttering: The bottom shuttering is done before reinforcement and side

shuttering is done after reinforcement. Reinforcement: The reinforcement for lintel beam is carried out as per the

design. Concreting: The concrete is poured into it and correspondingly curing is

done.

5) Reinforcement of column: The reinforcement of column is carried out till parapet wall if it is a one storey building. If not, reinforcement is carried out till the lintel level of next floor.

Page 17: JIPMER Phase II Project

6) Shuttering and concreting: The shuttering for the column is carried out till roof bottom and the concreting is done.

7) Slab: Shuttering: From the existing ground level, the centering rods are placed

till the roof bottom and the bottom shuttering is placed. Reinforcement: The reinforcement for slab is laid over the shuttered

surface as per the design. Service works: The service works such as pipe laying, low voltage (LV), heat

ventilation air conditioning (HVAC) are located according to the design. Side shuttering: Before concreting, the side shutters are placed. Concreting: The concrete is filled unto the required level and vibration is

done in order to avoid the honey comb.

8) Shuttering and filling for parapet column: The parapet’s column is shuttered till the required height (approximately 3 ft) and filled with lean concrete, a brick mix, if the building is raised in future. It will be filled with ordinary concrete if there is no further raise in building in future.

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9) Brick wall for parapet: The parapet wall is raised by laying brick layers. For every three layers hoop reinforcement is provided. The verticality of the wall is checked by using plumb bob.

10) Weathering course: The weathering course such as brick jelly coating is laid over the slab for water absorption with particular sloping to drain the rain water.

11) Brick work till floor finished level: From the plinth level, brick walls are raised till floor finished level and the area is backfilled with soil and corresponding compaction and consolidation is made.

12) PCC layer: Over the compacted soil layer, a layer of plain cement concrete is laid for a depth of 100 mm.

13) Brick work for walls: First the brick work is laid till the lintel level after checking the openings for doors, windows and ventilators. Then it is preceded till the roof bottom.

14) Service works and frames fixed: The frames for doors, windows and ventilators are fixed. Service works such as fixing of switch boxes, hangers for fan, pipe lines are done.

15) Plastering:

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The plastering of walls is done with cement mortar to a depth of 6 mm for roof and 10 mm for walls.

16) White washing or painting: A coating of white wash or paint is applied over the plastered surface.

17) Floor finish: Over the PCC layer in the floor, the floor finish is done using the materials such as tile, marble, mosaic, granite.

18) Painting: A second layer of paint is applied over the coated surface of wall.