PROJECT REPORT OF RUB BOX

PROJECT REPORT ON RAIL UNDER BRIDGE (RUB) BOXIntroduction of Rail under bridge Detailing of RCCCross section detailingConcrete mix design Compression Test for concrete cubeResult and DiscussionSketches for RUBTender conditionRecord BookPlanning of WorkReferences

CONTENTSIZE OF PRECAST RCC BOX:- 4m X 3.75m

MIX DESIGN USED :-M-35

NAME OF WORK:- Construction of restricted height RUBs on LC No. C-10 between GA-GVMR station, LC No. C-16 & LC No. C-18 between GVMR-NAC under ADEN/DNA section.

Introduction DETAILING OF RCCLocationShape of barCut lengthNo. of barDiameter of bar20mm16mm10mmLC NO. 16RCC BOX NO. 018.1016 20mma1a28.108 16mmb4.8015 16mmc8.108 16mmd4.8015 20mme4.5516 16mmf12.558*2=16 20mmf22.558*2=16 20mmg10.5523*8=184 10mmg20.5522*8=17610mmg30.5522*8*2=35210mmh1.45182+176=35810mmLC No. 16BASE SLAB No.01

20mm12mmDETAILING OF RCC BASE SLAB LOCATIONSHAPE OF BARCUT LENGTHNO. OF BAR DIAMETER OF BAR5.40 X 1.531.4336 X 2=7212mm1.5310 X 2=2012mm6.551 X 2=220mm1.088+9=1712mmLC No. 16BASE SLAB No. 02 5.40 X 1.531.4336 X 2=7212mm1.5310 X 2=2012mm6.551 X 2=220mm1.086+6=1212mmLC No. 16BASE SLAB No. 02 5.40 X 2.302.2036 X 2=7212mm5.4515 X 2=3012mm6.552 X 2=420mm1.086 X 3=1812mmLOCATIONSHAPE OF BARCUT LENGTHNO. OF BAR DIAMETER OF BARLC No. 16BASE SLAB No. 045.40 X 1.531.4336 X 2=7212mm5.4310 X 2=2012mm6.551 X 2=220mm1.087+7=1412mmLC No. 16BASE SLAB No. 055.40 X 2.302.2036 X 2=7212mm5.4515 X 2=3012mm6.552 X 2=420mm1.086 X 3=1812mmLC No. 16BASE SLAB No. 065.40 X 1.531.4336 X 2=7212mm5.4310 X 2=2012mm6.551 X 2=220mm1.086 + 6=1212mmDETAILING OF RCC BASE SLAB

CROSS SECTION OF RCC BOX

POSITION OF LIFTING HOOKS

CROSS SECTION OF PRE CAST BASE SLABM-35Design stipulationCharacteristic compressive strength required= 35.0 N/mm2Maximum size of aggregate= 20 mmType of cement= OPC 43 gradeExposure condition= Moderate

MIX DESIGN DESIGN STEPS

Coarse aggregate:- 1 bagSand :- 1 bagCement:- 1 bag1.MATERIAL USED:-2.TARGATE MEAN STRENGTH :- For M-35 35+(1.65 X 6.0):- 44.90 N/mm2 (IS 10262:2009)3.WATER CEMENT RATIO (W/C):-W/C taken based on trails % experience is :- 0.434.CALCULATION OF CEMENT CONTENT:-Water content :- 186.0 literCement content :- 186.0/0.43=432.55 kg/m35.PROPORTION OF COARSE AND FINE AGGREGATE (Based on volume ) :-For concrete volume of C.A.= 0.62Volume of F.A.= 1-0.62=0.381. Volume of concrete1 m31 m32. Volume of cement (432.55/3.15)x(1/1000)0.137m3. Volume of water(186.0/1.0)x(1/1000)0.186m34. Volume of plasticizerNILNIL5. Volume of all in aggregate[A-(B+C+D)]0.677m36. Mass of coarse aggregate0.677x0.62x2.682x1031125.74kg7. Mass of fine aggregate0.677x0.38x2.560x103658.58kg8. Correction for water absorption for C.A.1125.74x(1.02/100)11.48kg9. Correction for water absorption for F.A.658.58x(2.12/100)13.96kg10. Total water186+11.48+13.96211.44kg DESIGN MIX CALCULATIONTRIAL MIX NO.123W/C Ratio0.450.430.41Cement413.33kg432.55kg453.65kgSend(F.A.)650.23kg644.62kg637.94kgAggregate(C.A.)1123.78kg1114.26kg1102.71kgWater211.66kg211.44kg211.18kgSlump44mm52mm66mmCompressive strength water 28 days43.14 N/mm245.68N/mm247.52N/mm2 TRIAL MIX DETAILS PER m3Per m3 by weight:-

By Ratio:-

RECOMMENDATIONFREE WATER CEMENTSANDAGGREAGATE211.44kg432.55kg644.62kg1114.26kgFREE W/C CEMENTSANDAGGREAGATE0.4881.01.4902.576Description of the CC Cubes

Actual Compressive Strength (in N/mm2)Average Compressive Strength(in N/mm2)15X15X15 cm34.9435.5635.7935.96COMPRESSION TEST ON CC CUBES (3 NOS.) 7 Days strength result 28 Days strength resultDescription of the CC Cubes

Actual Compressive Strength (in N/mm2)Average Compressive Strength(in N/mm2)15X15X15 cm37.3138.8238.6940.451st CASE:- 1000kN = 100 tons1kN = 1000 N x reading = 1000 x 770 For 150 x 150mm = (77x10000)/22500 = 34.94 N/mm22nd CASE:-1000kN = 100 tons 1kN = 1000 N x reading = 1000 x 790 For 150 x 150mm = (79x10000)/22500 = 35.79 N/mm23rd CASE:- 1000kN = 100 tons 1kN = 1000 N x reading = 1000 x 800 For 150 x 150mm = (80x10000)/22500 = 35.96 N/mm2Average Compressive Strength= (34.94+35.79+35.96)/3 = 35.56 N/mm2 CALCULATION (for 3 days)1st CASE: 1000kN = 100 tons 1kN = 1000 N x reading = 1000 x 840 For 150 x 150mm = (84x10000)/22500 = 37.31 N/mm22nd CASE: 1000kN = 100 tons 1kN= 1000 N x reading = 1000 x 870 For 150 x 150mm = (87x10000)/22500 = 38.69 N/mm23rd CASE:1000kN = 100 tons 1kN = 1000 N x reading = 1000 x 900 For 150 x 150mm = (90x10000)/22500 = 40.45 N/mm2Average Compressive Strength = (37.31+38.69+40.45)/3 = 38.82 N/mm2

CALCULATION (for 28 days)TEST SAMPLE REFSPECIFIED REQUIREMENTSRESULT OBTAINEDAS PER IS 8112Rock strongOPC 43 Grade CementPHYSICAL TEST

Specific Gravity 3.15--------Initial setting Time 132.0 min>30 minFinal setting Time214.0 min43.0 N/mm2 RESULT & DISCUSSION FOR CEMENTSIEVE SIZERESULT OBTAINED20.0 mmAS PER IS PARAMETERGRADINGPASSING%

(a) 40.0mm100.0(100.0)%(b) 20.0mm97.85(95-100)%(C) 10.0mm41.26(25-55)%(D) 4.75mm3.64(0-10)%Specific Gravity2.682------------Water Absorption1.02------------Flakiness Index13.20------------Impact Value18.62------------Abrasion Value20.14------------Free Surface MoistureNIL------------ RESULT & DISCUSSION FOR AGGREGATE (20mm)SPECIFIED REQUIREMENTRESULT OBTAINEDAS PER IS 383-1970 PARAMETERGRADATIONPASSING%(a) 10.0mm100.0%(100.0)%(b) 4.75mm95.12%(90-100)%(c) 2.36mm82.26%(75-100)%(d) 1.18mm63.15%(55-90)%(e)600micron42.20%(35-59)%(f) 300micron17.42%(8-30)%(g) 150micron3.81%(0-10)%Specific Gravity2.560%-----------Water absorption3.20%-----------Silt content1.70%------------Free Moisture Surface1.08% RESULT & DISCUSSION FOR SANDOrder No.Nominal Size(mm)Lot. No.Qty.Chemical Analysis2% Proof Stress (N/mm2)Tensile Strength (N/mm2)ElongationTotal elongationBending Test Rebend TestGrade 838FP BAR 10S11-02793.54C%S%P%52163020.0000.000OKOKFe 5000.220.0400.046838FP BAR 16S11-02473.470.220.0420.04053461909.2460.000OKOKFe 500838FP BAR 20S11-02494.960.190.0380.04051964620.0000.000OKOKFe 500 RESULT AND DISCUSSION FOR STEEL BAR RESULT AND DISCUSSION FOR 43 GRADE CEMENTSl.NoParticularRequirement of IS:8112-1989Test result1CHEMICAL REQUIREMENTS0.66 To 1.020.930(CaO-0.7 SO3)/(2.8 SiO2+1.2 Al2O3+0.65Fe2O3)2Al2O3/Fe2O30.66 min1.373Insoluble Residue(% by mass)3.0% max1.584Magnesia(% by mass)6.0% max1.985Sulphuric Anhydrite(% by mass)3.0% max2.486Total loss on ignition(%)5.0% max1.477Total Chloride(%)0.10% max0.01Sl No.ParticularRequirement of IS:8112-1989Test result1.PHYSICAL REQUIREMENTSNot less than 225 m2/kg332Fineness (m2/kg)2Soundness:Lechatlier Expansion (mm)10.0 max1.00Auto-clave (%)0.8 max0.0803Setting time (minutes) initial 30 min 125 final 600 max1754Compressive strength3 days23 Min30.57 days33 min40.528 days 43 min 51.05 Temperature during Testing(25-29) 0c27 CONTD. RESULT AND DISCUSSION FOR 33 GRADE CEMENTSl.NoParticularRequirement of IS:1489 (part I) -1991Test result1

CHEMICAL REQUIREMENTSI.R.=X + 4(100-X)/100Where X=% of Pozzolona used32.60Insoluble Residue(% by mass)2Magnesia(% by mass)6.0% max1.483Sulphuric Anhydrite (% by mass)3.0% max2.554Total loss on ignition(%)5.0% max1.295Total Chloride(%)0.05% max0.01Sl No.ParticularRequirement of IS:8112-1989Test result1.PHYSICAL REQUIREMENTSNot less than 300 m2/kg359Fineness (m2/kg)2SoundnessLechatlier Expansion (mm)10.0 max1.00Auto-clave (%)0.8 max0.0723Setting time (minutes) initial 30 min 155 final 600 max2054Compressive strength3 days16 Min34.57 days22 min40.528 days 33 min 46.55 Temperature during Testing(25-29) 0c27 CONTD..

FOR NIGHT BLOCK WORKINGSl.NoDescriptionQuantity1 Electric generator of 10 kV1 no. + 1 spare2 500 Watt hallozen & electric wire etc.15 no. hallozen and Electric wire for connection3 Electrician and helperAs per requirement MACHINARY REQUIRED FOR LOUNCHING IN TRAFFIC BLOCKSl.NoDescription Quantity.1Crane of 80-100 MT capacity with 2 operator on each crane and 10 skilled labour2 no. + 1 spare2 Excavator Tata Hitachi or similar with operator2 nos. 3JCB with tools & operator2 nos.4 Dumper with hydraulic lift system6 nos.5 Gas cutting equipment 2 no. + 1 spareSupply of cement by contractor at the rate for relevant NS item will be governed by the following condition:- Cement for use in the works shall be procured by the contractor from the main procedures. Cement older than 3 months from the date of manufacture shall not be accepted. Cement bags perfectly in paper bags packing should bear the following markings:- 1. Manufactures name. 2. Registered Trade Mark of manufacture, if any. 3. Type of cement. 4. Weight of each bag in kg. or No. of bags/tons. 5. Date of manufacture. Quality test certified for cement as per IS:4031 shall be furnished by the contractor.

TENDER CONDITION FOR SUPPLY OF CEMENT BY CONTRACTORRailway may also take samples during course of execution of works.Frequency of testing shall be as prescribed by the relevant IS code.Following test shall be carried out:-1. fineness2. compressive strength 3. initial and final setting time4. consistency5. soundnessIn case the sample tested do not pass the quality test conduced ,the entire batch of cement supply shall be rejected and return to the contractor.For storage of cement, the contractor shall have to construct a temporary godown of adequate capacity. The contractor shall bring the cement to the site of work only on written instructions from Gazetted office in charge of work. CONTD..It will be obligatory on the part of the contractor to weight the truck of cement in the presence of inspector in charge and supply an original copy of weight slip along with consignment.The inspector in charge will verify the quantity of cement brought to the sight of work and returned one verified weight slip to the contractor after the same is stacked inside the cement godown under his supervision.The record of cement brought to the site of work, daily consumption, daily opening balance and closing balance shall be maintained at site jointly by the inspector in charge of work and contractor or his authorized representative. The contractor shall make the cement godown available for inspection along with contractor record to the site engineer or his representative as and when required. The contractor shall ensure that after completion of the work of the contract for any reason what so ever, the temporary cement godown shall be dismantled.

CONTD..All disentailed material/debris shall be removed and the clear site shall be handed over back to railway. All the released material shall be the property of the contractor and no payment shall be made by the railways. The final bill and earnest money/security deposits shall not be released unless the godown is dismantled and the site is cleared. CONTD.. Tolerance requirement for cement Cement supplied at one time will be taken as a batch. The number of batches taken for the sample from each bags shall be as under:

Sl.NoBatch sizeSample size1100 to 150 202151 to 280323281 to 500504501 to 12008051201 to 3200 12563201 to above200 The bags in sample shall be selected as random. The specified net mass(50 kg) shall be not more than 5% of the bags in the sample. In case of truck load of 10 to 25 tons, the overall tolerance on net mass of cement shall be -0.5 to +0.5%. Any batch of cement not conforming to above tolerance will be rejected. The consumption of cement on work shall be assessed on the basis of cement constants per unit quantity of various items of work.In case of design mix of concrete of specified strength where the cement is to be used by weight by where specially ordered in the NS item rate or tender condition, a verification of +1%(max) will be allowed in the consumption of cement.Staking of cement in the godown shall be done on a layer of wooden sleepers, so as to avoid contact of cement bags with the floor. CONTD..Cement shall be stored in such a manner as to permit easy access for proper inspection. Cement should be stacked not more than 10 layers height. The stacks of cement bags shall be covered with Tarpaulin during monsoons so as to avoid the possibility of deterioration of cement by moisture in the atmosphere. Cement brought to the site from godown in excess of the requirement calculated based on the cement factors shall be taken back by the contractor on completion of the work after written approval of ADEN/XEN on proper documents.Payment as per relevant NS item will be made on the basis of quantity of cement actually consumed and the quantity calculated as per cement factors for various items.Cement actually consumed on works shall normally match the quantity calculated as per cement factors for various items.Empty cement bags will be the property of contractor. CONTD..The contractors shall satisfactorily maintain the work completed by him/them for the following period from the date of completion certificate. SUPPLY OF WATER:- As regards the supply of water the condition as laid down on the relevant chapters & annexure of the standard schedule of rates of 1996 shall apply except the right of the travelling water tanks shall be bond by the railways.For the plants and machineries for the use of contract the contractor will be required to pay such higher charges as stipulated in the northern railway schedule of rates or may be fixed by the divisional engineer.SPECIAL CONDITION OF CONTRACTSl.No.Description of workMaintenance period1Earth work & supply of materialNIL2Repair and maintenance work03 months3New works(except earth work)06 months CONTD..For mixing cement concrete where it is required to be done by the mechanical mixers by the Railway, the contractor will be debited to Rs150/mixer for each working day at site inclusive at crew staff.SOURCES OF BUILDING MATERIALS:- Stones patties ashlar will be obtained from fedoras and quarries or equivalent stone lime will be obtained from goton .All other building materials will be obtained from the nearest sources after obtaining the approved of the quality by the engineer. In case of location where it is not possible to get the material by road or working in between the section the assistance may be offered by the Railway by way of display and labor.Following records are maintained in project :- 1. Site order book. 2. Cement register. 3. Steel register. 4. Cube testing register. 5. Material passing register. 6. Sieve analysis register.1. SITE ORDER BOOK:- It is used to instruct the work agency and is required at site. PERFORMA RECORD BOOKSSl.NoDateDescription of instruction to agencyAction taken by agencySignature of agencySignature of officers of department2.CEMENT REGISTER:- It is used for day to day consumption of cement PERFORMA: 3. STEEL REGISTER:- It is maintained for records of steel as hidden measurement. PERFORMA: Sl.NoDateCement received at siteCement usedCement balanceSignature of agencySignature of officers of department Description of worksSl.No.DateLocationShape of barCut length of barNo. of barDia of bar(mm)Total lengthWt per meterTotal weightSignature of contractorCONTD..4. CUBE TESTING REGISTER:- It is used for checking compressive strength of cube for 7 days & 28 days. PERFORMA:

Sl.NoDate of castingLocationCube no.Mix used 7 Days testing 28 Days testingSignature of contractorDate of testingStrength (N/mm2)Avg. strength(N/mm2)Date of testingStrength (N/mm2)Avg. strength(N/mm2)Where Railway bank height about 2 to 3 meter from original ground level, where RUB proposed.Estimate send to head quarter for proposed RUB work.Estimate sanction for RUB by competent authority.Tender invite for RUB work by Head quarter office.Work sanctioned for RUB.Working drawing & detailed drawing received from Head quarter for sanction of work.Mix designed prepared ,which is used in work.Materials checked at site before use.Segments casting work starts before shuttering & steel reinforcementCasting of segment RCC box & base slab near level crossing where RUB site proposed as per mix concrete design.PLANNING OF WORKCuring work start 24 hours after casting and up to 28 days completely.Cube testing result taken after 7 days & 28 days after casting.Preparation of launching of RUB box.Drainage system to be provide for removing of rain water.Height gauge to be provided both sides of bridge 20m away bridge.1 in 20 slope is provided in a ramp.

CONTD..IS 383-1970:- Specification for coarse and fine aggregate from natural source for concrete. IS 2386-1963:- Methods of test of aggregate for concrete.IS 456-2000:- Code of practice for plan and reinforced concrete.IS 10262-2009:- Recommended guidelines for concrete mix design.Sp 23:- Hand work on concrete mixes.

REFERENCES