Acknowledgement

The Industrial Training is one of the milestones in my life. It was a great opportunity to be exposed to the
industry. There are a lot of people who helped me in many ways to complete my training successfully.
Therefore I like to pay my honest gratitude to all of them.

I got precious assistance from RDA and FSDI

staff to complete my training successfully from the very first day till the last day of training period. I would
like to remember Mr.M.Susu– PD of Wakachiku for accepting my training application and giving me the
precious chance to work as a trainee in this significant project. I pay my honest gratitude to Eng.Lalith
priyantha silva Mr.I.M.S.Waruna Kumara- Chief Engineer ,Mr.Murakami- Contraction Manager,
Mr.P.Nishantha- Engineer,Mr.Manoj-Engineer,Mr.Nuwan-Engineer,Mr.Manel-Engineer,Mr.Nalaka-
Surveyor for sharing their knowledge, spending their valuable time, helping in each and every possible
way to make my training period valuable.

Apart from the Engineers I must thank Mr.Nishantha -Quality Assurance Inspector, Mr.Sadun-Quantity
Surveyor Mr.Jeyakhanthann-Technical Officer Mr.Manoj- Superviser ,Mr.Anushkaran- Supervisor for
their support..

1
PREFACE

After having successful training at Road development authority. I have prepared this report as to
give a fair understanding about the industrial training that I have undergone three months starting
12th October 2017 and ends on 12th January 2018.

As an undergraduate I got opportunity to apply the theoretical knowledge into the industry during
this industrial training period and also got practical knowledge relevant to theoretical knowledge.
This is a good opportunity to identify the tasks and challenges that are associated with the industry.

In this report I have consolidate all the data into 3 chapters. The first chapter describes the training
establishment, its current state, organization structure and its functions. Then second chapter
includes the technical information gathered during three months of training period and different
sections I was assigned at the expressway project. In the third chapter, I have included the summary
and the conclusion about the training experiences.

2
Table of content

Certification………………………………………………………………………………..
Acknowledgement………………………………………………………………………… 01
Preface ……………………………………………………………………………………. 02
List of figures …………………………………………………………………………….
1.0 Introduction to the RDA……………………………………………………………….
1.1 Organizational structure ……………………………………………………….
1.2 Fictional divisions ……………………………………………………………
1.3 Vision of RDA…………………………………………………………………
1.4 Mission of RDA………………………………………………………………..
1.5 Goals and objectives …………………………………………………………..
1.6 Project details ………………………………………………………………….
1.7 Safety management ……………………………………………………………
1.8 Project organizing chart………………………………………………………..
2.0 Training experiences…………………………………………………………………...
2.1 Spun pile………………………………………………………………………..
2.1.1 Setting out and placing driving machine …………………………..
2.1.2 Lifting and driving if pile…………………………………………..
2.1.3 Pile extension ………………………………………………………
2.1.4 Pile driving termination ……………………………………………
2.1.5 Pile cutting …………………………………………………………
2.1.6 Construction of pile caps …………………………………………..
2.2 Pre-cast T-girder yard………………………………………………………….
2.2.1 Introduction ………………………………………………………..
2.2.2 T-girder casting bed ……………………………………………….
2.2.3 Reinforcement arrangement and installation of corrugated ducts …
2.2.4 Formwork assembling ……………………………………………..
2.2.5 Concerting …………………………………………………………
2.2.6 Tensioning …………………………………………………………
2.2.7 Grouting ……………………………………………………………

3
 2.2.8 Procedure of fluidity test ………………………………………….
2.2.9 Defects in T-girder ………………………………………………..
2.3 Laboratory …………………………………………………………………….
2.3.1 Introduction ……………………………………………………….
2.3.2 Proctor compaction test …………………………………………...
2.3.3 Sieve analysis test …………………………………………………
2.3.4 Plastic index ……………………………………………………….
2.3.4.1 To determine liquid limit (LL)…………………………….
2.3.4.2 To determine plastic limit (PL)……………………………
2.3.5 Aggregate impact value (AIV)…………………………………….
2.3.6 Los Angeles Abrasion Value test (LAAV)………………………..
2.4 Board pile foundation …………………………………………………………
2.4.1 What is pile ………………………………………………………..
2.4.1.1 End bearing piles ………………………………………….
2.4.1.2 Friction piles ………………………………………………
2.4.2 Boring process of pile ……………………………………………..
2.4.3 Mud circulating system…………………………………………….
2.4.4 Samples storage ……………………………………………………
2.4.5 Verifying shape of pile …………………………………………….
2.4.6 Reinforcement ……………………………………………………..
2.4.7 Pile concreting ……………………………………………………..
2.4.7.1 Materials …………………………………………………...
2.4.7.2 Quality ……………………………………………………..
2.4.7.3 Procedure …………………………………………………..
2.4.7.4 Tremie pipe installation ……………………………………
2.4.8 Pile hacking ………………………………………………………..
3.0 Conclusion ……………………………………………………………………………..

4
List of figures

Figure 2.1.1– setting out target

Figure 2.1.2 – pile bottom (initiating pile)
Figure 2.1.3– Vertical deviation checking
Figure 2.1.4 – pile extending
Figure 2.1.5 – pile cutting off to the level
Figure 2.1.6 – pouring concreate
Figure 2.2.1 – T-girder casting bed
Figure 2.2.2 – Reinforcement constructing
Figure 2.2.3 – Installing and checking ducts
Figure 2.2.4 – standard notification of ducts
Figure 2.2.5 – Formwork
Figure2.2.6 –Applying foam expansion agent
Figure 2.2.7 – checking formwork levels
Figure 2.2.8 – top ducts checking
Figure 2.2.9 – Shutter vibrator
Figure 2.2.10 – Poker vibrator
Figure 2.2.11 – Water curing with gunny bags
Figure 2.2.12 – Appling chemical curing agents
Figure 2.2.13 – Hydraulic jack
Figure 2.2.14 – Pressure electric oil pump
Figure 2.2.15 – Checking deflection of the girder
Figure 2.2.16 – Viscosity measuring test
Figure 2.2.17– Tendons marking for cutting
Figure 2.2.18 – Grout mixing machine
Figure 2.2.19 – Grouting pump
Figure 2.2.20 – Grout caps with inlets or outlets
Figure 2.2.21 – Sikadur-31 CF Normal
Figure 2.2.22– X-Roc Epoxy Bond Base & Hardener

5
Figure 2.2.23– Chipped surface
Figure 2.2.24 – Bonding agent applying
Figure 2.2.25 – Applying Ultra patch
Figure 2.3.1 – Cubes in water tank
Figure 2.3.2 – Cube testing
Figure 2.3.4 – Adding water to the
Figure 2.3.5 – Compacting soil soil sample
Figure 2.3.6 – After sieving
Figure 2.3.7 – Casagrande apparatus
Figure 2.3.8 – Rolling treads
Figure 2.3.9 – Aggregate impact test machine
Figure 2.3.10 – Los Angeles testing
Figure 2.3.11 – Steel spheres
Figure 2.4.1 – Rotary machine
Figure 2.4.2 – Scraper bit
Figure 2.4.3 – Rock roller bit
Figure 2.4.4 – Chisel bit
Figure 2.4.5 – Mud circulating system
Figure 2.4.6 – Soil samples
Figure 2.4.7 – De-Sander
Figure 2.4.8 – Reinforcement of pile
Figure 2.4.9 – Funnel and tremie installation
Figure 2.4.10 – Apparatus
Figure 2.4.11 – Pile concreting
Figure 2.4.12 – Pile hacking

6
1.0 Introduction to Road Development Authority ( RDA )

The functions performed by the RDA consist mainly of the maintenance and development of the
roads and bridges in the National Highway Network and the planning, design and construction of
new highways, bridges and expressways to augment the existing network.

The RDA has a responsibility for the development of the road network to cater for the on-going
overall development programme of the country. Since, Road Transport is the primary mode of
transport in the country, it is very vital that road network is adequate to developed to promote
efficient transport of people and goods. The RDA has a responsibility to plan the future road
network taking into consideration the future travel demand and formulating project proposals to
meet this demand.

The RDA being the Principal Highway Authority has a responsibility to provide a road network to
meet the social aspirations of the people in terms of mobility and safety. Since, the people at large
depend on public transport for their travel needs it is the responsibility of the RDA to maintain the
road network to a reasonable standard so that there would be un-interrupted public transport
available to them.

Since, the rehabilitation and development of the road network is undertaken with public funds at
a very high cost, it is responsibility of the RDA to ensure that the adequate economic returns are
achieved from the investments made on highway improvements. This is achieved by carrying out
feasibility studies before major projects are undertaken and followed by post evaluation of these
projects after completion.

1.1 Organizational Structure of RDA

The RDA is a major Civil Engineering Organization with specialized skills in Highway and Bridge
Planning, Design, Construction, Maintenance and Highway Safety. The organizational structure is
designed to carry out the functions assigned to the RDA and to achieve its goals and objectives.
The RDA organization under the Board of management has the Director General as the Chief
Executive Officer. The Director General is assisted by 5 Additional Director Generals and 17
Directors to carry out various functions.

7
There are 17 functional divisions in RDA each headed by a Director. Director Internal Audit
functions directly under Chairman of RDA; The Directors in charge for Mechanical division, Legal
Division & Expressway Operation & Management division operate directly under the Director
General. The rest of 14 functional divisions are managed by 4 Additional Director Generals.

Foreign funded projects in RDA are managed by Project Management Units. Each project
management unit is headed by a Project Director and they operate under the Additional Director
General for Projects. The RDA has a workforce of 4,562 employees on permanent and contract
basis comprising of engineering, technical, administrative, accounting and other support staff. In
addition it has 4,024 permanent and 2,428 contract basis labourers employed for routine
maintenance work.

1.2. Functional Divisions

1. Administration Division 2. Finance Division 3. Planning Division 4. Engineering Services

Division 5. Highway Designs Division 6. Research & Development Division 7. Training Division
8. Mechanical Division 9. Land Division 10. Environment & Social Development Division 11.
Maintenance Management and Construction Division 12. Legal Division 13. Construction
Division 14. Rural Bridge Construction Unit 15. Procurement Division 16. Expressway Operation,
Maintenance & Management Division 17. Internal Audit Division.

1.3. Vision of RDA

To upgrade the National Highway Network to meet the expectations of all stakeholders and to
make the Road Development Authority an institution of multidisciplinary excellence in Highway
Engineering.

1.4. Mission of RDA

As the premier National Organization of the road sector, to provide an adequate and efficient
network National Highways, to ensure mobility and accessibility at an acceptable level of safety
and comport, in an environment friendly manner for the movement of people and goods for the
socio-economic development of the nation.

8
1.5 Goals & Objectives

1. Achieve an adequate National Highway Network. 2. Achieve an acceptable level of mobility in

the National Highway Network. 3. Provide a high mobility expressway network. 4. Maintain the
National Highway Network at an acceptable condition. 5. Reduce road user cost. 6. Improve road
safety in the National Highway Network. 7. Ensure efficient utilization of assets and investments.
8. Ensure protection of the environment in all activities. 9. Promote organizational development.
10. Assist in the development of the local road construction industry.

1.6. Project details.

Executing Agency – Ministry of Higher Education and Highways

Client - Road Development Authority ( RDA )

Contractor - China National Aero Technology International Engineering Corporation (

CATIC – Eng )

Consultant - China Railway First Survey and Design Institute Group Co.Ltd. (FSDI)

Contract Amount - Rs.103,280,000,000.00

Date of Commencement – 19th January 2016

Date of Completion - 18th July 2019

No of interchanges - 03

9
No of Box Culverts - 84

No of Overpasses - 09

No of Underpasses -21

No of Bridges - 17

1.7 Safety management

1.7.1 INTRODUCTION
Construction industry is one of the most vulnerable industries for accidents. An accident is an unexpected
event that interfere normal working condition and lead to personal injuries or asset damages. The amounts
of sources which are potentially dangerous are high in construction industry. Hence the risk of occurrence
of an accident is high. In construction industry, there are another workplace hazards that affect the health
and hygiene of occupants and public. These accidents and health issues have become one of the major
consideration in the industry and there is a set of disciplines in practice to prevent or minimize work related
accidents and diseases.

1.7.2 Hazards
A hazard is a source that has the potential to cause damages to the occupants and public. Some work related
hazards are listed below.

• Physical hazards – heat, noise, electricity, tools and equipment, vibration, ventilation.
• Hazards associated with gravity – fall of people and objects.
• Chemical hazards – dust, plastic, pesticides, various chemical agents that are used in construction
industry.
• Biological hazards – bacteria, virus, fungi.
• Ergonomic hazards – work methods, working posture.

10
• Psychological hazards – stress, violence

All personal will be dully notified and made aware of all safety aspects pertaining to his or her work cope,
will special attention to the following,

1.7.3 Site staff and labor

All staff and labor assigned to the work will have initially gone through a safety induction. All staff and
labor will be required to wear safety helmets, safety jackets and also safety shoes. In addition, adequate
first aid supplies will be made readily available.

1.7.4 Warning sign boards, fences and barricades.

All personal shall obey information set on all signboards set up throughout the project site. Fences and
barricades will also be installed to keep out unauthorized person from entering the project site.

1.7.5 Safety patrols and safety meetings

Subject to random visits, all jobsites within the project works as well as all project personal will be
regularly monitored and evaluate for safety conformance as set out during the safety induction. Penalties
will be handed out for non con conformances or repeat offences which may lead to employment
termination. There will also be daily meeting held during the course of the works, where site safety
matters will be part of the agenda. These meetings will focus mainly or highlighting the dangers
associated with and the precautions to take for the actual works being carried out at the time.

11
1.8 Project organization chart

Project Engineer 1

Project Enginner 2

Deputy Project Director

Project Engineer 3

Land aquisiotion &

Settlement officer

Project Engineer 4 (Contract

Administration)
Senior Engineer Resettlement Assistant &
(Design&Monitoring) Development Officers (4Nos)
Project Engineer 5 (Land
Aquisition)

Land officer

Account Assistant (2Nos)

Project Accountant

Management Assistant
(2Nos)
Project Director

Management Assistant
(5Nos)

Drivers (9Nos)

Administrative Officer Office Aids (3Nos)

Personal Secretary Office Labour

Contract Specialist Administrative Assistant

IT Specialist

12
2.0 Training experiences

2.1 Spun pile

These spun piles are used in areas where soft ground treatment is required prior construction of
the embankment.

Name: PHC (Pre- tensioned Spun High – strength Concrete) pile

Classification: Friction pile

Driving method: Hydraulic drop hammer driving. Hammer details,

➢ Model – DD63
➢ Hammer weight – 6300kg
➢ Working height – (2500mm – 30000mm)
➢ Working frequency – (35 - 50) blows/min
➢ Hammer energy – 190KJ

2.1.1 Setting out & placing the driving machine

As the Spun Concrete Pile Embankment ( SCPE ) is to be constructed at paddy lands, working
platform was needed to prepare. 1m thick unclassified material was filled and roughly compacted.
6m, 10m, 12m & 15m piles were used. Pile positions were set out by the surveyor according to the
coordinates of pile positions in the working drawings by using,

• Total station
• Portable target Figure 2.1.1– setting out target

13
The pile positions were marked using pegs and lime powder.

At first, the machine was positioned to the already set out point until the hammer center align with
the pile position. The pile shoe was brushed to clear rust using steel wire brush and Bituminous
Metal Protective Coating ( BMPC ) was applied for avoiding the corrosion and dry it over 45min.
Then the pile shoe was welded to the end of first pile. Metallic hoop located at the pile end was
also coated with BMPC. And after the consulting officer was check that the pile is in good

Figure 2.1.2 – pile bottom (initiating pile)

condition of driving that it appear that only surfaces cracks not having deep cracks were on the
pile and was approved in driving.

2.1.2 Lifting & driving of pile

To lift the pile, a T – shaped rebar was set into a hole in metal plate at pile head and connected to
the hoist of the machine allowing to raised a little to tie the wire rope around the pile. All the piles
were checked for any damages or cracks on the surface. Defected piles were not allowed to be
driven. Then the steel wire rope was connected to the hoist of the machine and lifted. Pile head
was moved to the pile cap located under the hammer ( 6.3 ton ). The pile center and alignment was
checked. Keeping the pile body vertical, the centerline of the pile body, pile head & hammer were
kept in coincide. Two theodolites in orthogonal directions were used to check the alignment.

14
First, hammer the pile at a short distance to certain depth for keeping the pile toe vertical and
steady and after that the pile was start hammer according to the required drop height. Then the pile
was hammered ( 2.4m dropping height ) to the required depth maintaining the verticality of pile
and preventing crushing of pile. Two theodolites were used in two perpendicular directions to
make sure the pile is vertical at the same time during driving. It is important maintain verticality
of pile and prevent crushing the pile.

When the verticality checking by using

theodolite, it was set the vertical cross bars parallel to the pile end that hits the ground and the
horizontal movement was locked in theodolite. Then the theodolite was moved vertically from
bottom to top and the deflection was observed. The deflection observed was resettled as to make
the pile vertical. Assure the jumps of hammer normal after dropping down. Check the verticality
of the pile and pile frame at any time , adjust the pile in case of the vertical deviation over 1 in 75.

Figure 2.1.3– Vertical deviation checking

15
2.1.3 Pile extension

When the pile head over the ground 0.5 – 1.0 m, hammering was stopped and the pile was welded
for extension. The second pile was lifted like before and it was kept on the first pile. The top
section was kept straight with the bottom section. Before welding, the mud on each contact joint
was cleaned and the rust was brushed using steel wire brush. When welding, first weld 4-6 points
around the pile and the second pile was vertically adjusted. After welding the joint completely, it

Figure 2.1.4 – pile extending

was allowed to cool. Then BMPC was applied well on both metallic hoops and welding line. It
was dried for about 20 minutes using an air blower and again hammering was started like before.

2.1.4 Pile driving termination

When the pile was refused to penetrate, pile driving was stopped and checked whether final
settlement had been achieved. For that, pile was given a specific number of blows ( 6, 9 or 12 )
and penetration was recorded. Number of blows was differed according to the bearing capacity of
ground. That was repeated for 3 consecutive trials. If the penetration was less than or equal 25mm
in all those 3 trials, the pile could be terminated. If it is not achieved, pile was driven further and
the test was repeated.

16
2.1.5 Pile cutting

After the termination, the existing pile length over the ground was measured using the staff. It was
used to find out the whole driven depth of the pile. Finally, pile was cut around at the pile cut off
level using pile cutting wheels.

Figure 2.1.5 – pile cutting off to the level

2.1.6 Construction of pile caps

After cutting pile head off, the pile cap area was cleaned and compacted to make sure there is no
any loose materials. Then the pile head was covered with
a metal plate of 500mm dia. The formwork was fixed
according to the size of the pile cap and reinforcement
was arranged as per the design drawings. Then
concreting was done using Grade 30 concrete. A
polythene was laid to prevent mud contact with concrete.
Curing was done for 7 days.

Figure 2.1.6 – pouring concreate

17
2.2 Pre-cast T-girder yard

2.2.1 Introduction

18
I engaged with the inspections in T-girder yard located at VD3. Girders with span length of 29.5m,
29.7m & 29.9m for via duct 3 are casted in the girder yard, where 41 casting beds are available.
Casted T – girders are stored in the storage area prior launching. The process

2.2.2 T-girder casting bed

Casting beds are used as the bottom formwork of T – girders. Casting beds were casted by Grade
30 concrete and steel plates were welded on it to avoid any settlement during the use. Inverted arch
was maintained in casting beds with the maximum inverted arch value of -20mm, with the
deviation value within +5mm and -5mm. These levels were checked before placing reinforcement
cage by using a level machine and formwork release agent ( form oil ) was applied on the surface
after cleaning well.

Figure 2.2.1 – T-girder casting bed

2.2.3 Reinforcement arrangement and installation of corrugated ducts

Reinforcement fabrication work was done at the steel fabrication yard and delivered to the precast
yard for assembling the reinforcement cage. Reinforcement bars were stocked under shelter free
from the exposure of sunshine and rain. Reinforcement arrangement of T – girders are done in 2

19
steps as bottom and top. Reinforcement cages ( bottom R/F ) were assembled according to the
approved drawings using a steel block which was made for easiness of reinforcement arrangement.
Reinforcement bars were joined by lapping to each other maintaining the lap length according to
the approved drawings. All the projected binding wires at the outer surface of the cage were bent
into the cage to manage the cover space of 35mm.

Concrete cover blocks of cylindrical shape with the height of 35mm were fixed around the r/f cage
in appropriate manner and intervals. After arranging the bottom r/f cage it is lifted by using a

Figure 2.2.2 – Reinforcement constructing

gantry crane ( 60 Ton ) and placed on the casting bed which act as the bottom formwork.

Corrugated ducts are produced at site by a machine with raw materials of galvanized steel strips.

Figure 2.2.3 – Installing and checking ducts

20
Corrugated ducts were installed in T – girders manually at correct positions according to the co-
ordinates table as the access for strands whose tensile strength was 1860MPa. Joints of 2
corrugated ducts were well sealed by using another larger diameter ducts and tapes to avoid
penetration of slurry. Corrugated ducts were fixed to the reinforcement to prevent any deviation.
Both ends of corrugated ducts were set into spiral bars and then connected with the anchor bearing
plates.

T3

T2
T1

Figure 2.2.4 – standard notification of ducts

The notification of the tensioning duct is a standard as figure and the two ends of the T-girders
were notified as,

H – To the Hambanthota end

M – To the Matara end

21
2.2.4 Formwork assembling

Prior to the lateral formwork fixing, the positions of corrugated ducts and bottom
reinforcement were checked by the consultant. After the approval of the consultant, lateral
formwork were fixed. Gantry crane was used to lift and place formworks. Formwork was
coated with formwork release agent before installation. Formworks were connected with
each other by bolts and brackets and screwed bars. Rubber strips were placed between lateral
formworks and casting bed to prevent any leakage. Double sticky tapes were placed at the
formwork joints to provide a smooth connection. Foam expansion agent was used to seal the
holes where the reinforcement reaching out of formwork or other possible slurry leakages.

After assembling the formwork, top reinforcement was arranged. Top reinforcement and the
verticality of the formwork were checked by the consultant using a spirit level and plumb
bob. After the approval of the consultant, girder concreting was done.

Figure 2.2.5 – Formwork

Figure2.2.6 –Applying foam expansion agent

22
Figure 2.2.7 – checking formwork levels Figure 2.2.8 – top ducts checking

2.2.5 Concreting

C50/20 was used for T – girder concreting. Concrete was ready mixed at the batching plant
and transported to the site by trucks.
Slump was specified as 150mm (+ or –
25mm) according to approved mix
design and temperature was less than
32oC. Concrete cubes were casted to
test the compressive strength of
concrete. Concreting was done using a
bucket of volume about 1.7 m3 which
was lifted and moved using a gantry
crane. Prior to concreting, rubber tubes
were inserted into corrugated ducts to
avoid leakage of concrete into the duct.
Strand tendons were installed inside the
corrugated ducts before concreting.
Concrete was placed layer by layer

23
according to the relevant pouring sequence. The time gap between two concreting should be
less than initial setting time of the previous layer. In order to achieve dense concrete, shutter
vibrators and poker vibrators were used. Shutter vibrators are switched on immediately to
avoid appearing of honeycomb and to reduce entrapped air. At the beginning only shutter
vibrators were used for concrete compaction as the poker vibrators cannot reach the flange
area of the girder. During concreting, a specified personal was appointed to check the
stability of formwork supporting. Any loose or deform should be treated on time. When the
concrete level reaches the web area, poker vibrators were used and when concrete was filled
to the top level of the girder, top surface was leveled and made it rough using a broom.

Figure 2.2.9 – Shutter vibrator Figure 2.2.10 – Poker vibrator

Immediately after concreting, exposed top surface of the girder was covered with a
polythene. Lateral formwork was removed after the compressive strength of concrete reaches
21MPa. Immediately after removing formwork, the girder was fully covered with a geo
textile and curing was done by wetting them frequently through sprinkler system of water.

24
 Figure 2.2.11 – Water curing with gunny bags

Another method of curing the concrete was applying chemical curing agents in curing the around
surface of the T-girder and the top was cured by laying gunny bags and sprinkling water on it.

Figure 2.2.12 – Appling chemical curing agents

2.2.6 Tensioning

Tensioning is done when concrete compressive strength reaches 36MPa. Pre – stressing was
done within 10 days after installation of pre – stressing steel. Two stressing jacks were used
in tensioning, equipped with oil meter, oil pump, tool anchors, position limit boards and
relevant parts. Before tensioning, equipment for tensioning ( Jack & Pressure dial gauge )
were calibrated. Jack was positioned in straight portion with the tendons as the centerline of

25
the tendon of stressing and the centerline of jack coincide. During tensioning work,
protection wall behind working area was setup to prevent the equipment, strands and others
from flying out with high speed. A level machine was setup in the middle of one side of the
T – girder to measure the deflection of the girder due to stressing. Each cluster of steel tendon
was tensioned once for all.

Figure 2.2.13 – Hydraulic jack Figure 2.2.14 – Pressure electric oil pump

Before starting tensioning, all the jacks, wedges were checked for proper installation.
Tensioning was done for same tendon simultaneously from both ends. All the tendons were
tensioned up to 100% of design force.

Tensioning sequence :

T3 20% 50% 100%

T1 20% 50%

T2 20% 50% 100%

T1 50% 100%

26
After each load incensement, elongation was measured from both ends. To measure the
elongation, a steel ruler which has a zero starting at edge of the ruler was used. Before
releasing the load, the load was locked off at 0.5MPa and the elongation was recorded. After
1st incensement of load (20% of design force ), the position of wedges were marked to
confirm whether a slip was occurred or not. After tensioning, deflection of the girder was
checked. Normally around 20mm rise of middle part of girder was noticed.

The steel strands were marked and monitored accordingly. In case of slip within 5 hrs, cutting
of strands was done. In case of slip, monitoring is extended by one day and if the slip was
greater than maximum permissible value, the tendons should be released and repeat the
tensioning.

Figure 2.2.15 – Checking deflection of the girder

27
2.2.7 Grouting

Grouting was carried out within 7 days after cutting of pre – stressing strands to transfer
stress to the concrete and to protect tendons from corrosion. Strands were cut off to minimum
of 10mm from the wedge plate and grout caps were attached to all tendons at both ends. Prior
to grouting, all the ducts were flushed thoroughly with compressed air to remove all
entrapped water, dust, deleterious material and to verify any blockages. Grout was mixed at
site using a grout mixer.

Materials used :
Water 20 L

Cement 50 Kg

NS grout 225 g

Optima 410 ml
Ultratech NS ( Non – Shrink ) grout was used to avoid shrinkage and Chryso fluid optima
was used as the admixture to retard the setting of concrete. Ice cubes were added to the water
tank that used for grout mix in order to control the temperature of grout below 32oC. The
minimum mixing time was not less than 2min ( Mixing
time was 3.30min ). After mixing, grout mix was poured
to the container of pump from the grout mixer. To avoid
any blockages, grout was poured through a screen ( with
1.5mm maximum clear opening ) when introducing to the
grout pump. A sample of grout was taken from each batch
to check temperature and fluidity. Specified limit for
fluidity of grout in inlet and outlet was expected between
10 – 30 mins and the temperature of grout was kept below
32oC.

Figure 2.2.16 – Viscosity measuring test

28
2.2.8 Procedure of fluidity test

Apparatus needed :

• Marsh cone
• Beaker
• Stop watch
• Standard stand

Apparatus were placed as shown in the diagram. Grout sample was poured to the cone while
the bottom end of marsh cone was closed using the finger. When grout was filled to the
marked level of the cone, bottom end of the cone was released to pour grout to the beaker
together with starting the stop watch. Stop watch was stopped when grout when grout level
reached 1725ml of the beaker. That time period was considered as the fluidity of grout.

After confirming temperature and fluidity was within the limit, pumping of grout was carried
out while pressure of pumping was controlled within 0.7 – 1.0MPa by using a calibrated dial
gauge fixed in the pumping machine. Grouting sequence is T1 T2 T3. When the grout
pumped from one end of tendon came out from the other end, outlet sample was collected to
a bucket before closing the outlet valve. Inlet valve was closed together with the pumping
machine and fluidity of outlet sample was checked immediately.

After confirming the fluidity of outlet sample was within the limit, again grouting was started
keeping the outlet valve closed until the pressure reaches 0.8MPa. The same procedure was
continued for grouting of other tendons. Test cubes were casted to test the compressive
strength of grout.

29
Figure 2.2.17– Tendons marking for cutting Figure 2.2.18 – Grout mixing
machine

Figure 2.2.19 – Gr outing pump

Figure 2.2.20 – Grout caps with inlets or outlets

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2.2.9 Defects in T - girders

T - girders get damaged during the removal of formwork, by air voids and honey combs caused
due to various reasons such poor compaction of concrete & leakage of grout during concreting.
Two different materials were used in the beam yard to repair the beam. They are,

a. Small Honey combs & Air voids

b. Big damages caused by removal of form work

a. Small Honey combs & Air voids

First, damaged & defected parts were chipped off using light tools to remove the loose
concrete up to sound concrete. Then the Girder was cleaned by the wire brush, then after it
was cleaned by the compressed air & also if mud was sprayed on the girder during rainy time
it was washed by clean water. The contractor used
SIKADUR NORMAL 31 CF for repairing small scale
defects. It has two parts named as Part A & Part B
according to the manufacturers recommendations &
mixing ratio is 2: 1 by its volume. Part A is white colour,
Part B is grey colour & mixed by slow speed drill for 3
minutes to get the concrete grey colour uniformly.

Figure 2.2.21 – Sikadur-31 CF Normal

Then it was applied by spatula & after the setting of Sikadur surface, surface was
smoothened. One mixing was valid within 35 minutes at 30 degrees Celsius. If the air voids
were big, it was chipped, cleaned & filled by Sikadur. According to the manufacturers
recommendations the maximum layer thickness which can be applied by this material was
30mm.

b. Big damages caused by removal of form work

Big honeycomb places were cut in regular shapes up to 10mm thickness by disc cutter &
chipped. If the reinforcement was appeared after the chipping, it was cut up to the chipping
31
surface level & X-Roc Galzinc was applied as anti-corrosive agent. After, Epoxy bond was
made by the manual mixing of two components named as X-Roc Base & X-Roc Hardener
& the ratio is 3:1 by its volume.

Figure 2.2.22– X-Roc Epoxy Bond Base & Hardener

It was applied as the primer to the chipping surface. Before the dry coat of the epoxy bond,
XCALIBUR Ultra patch cement was applied by the finishing trowel. With the details of the
manufacturer, water was added to the Ultra patch & mixed by slow speed drill. If the surface
of the mortar was dry condition, X-Roc Bond cure was sprayed on the mortar surface as a
curing agent.

Figure 2.2.23– Chipped surface Figure 2.2.24 – Bonding agent applying

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 Figure 2.2.25 – Applying Ultrapatch

2.3 Laboratory

2.3.1 Introduction
Laboratory is the place to check the quality & behavior of the concrete, grout, aggregates,
soil, and cement by doing the suitable tests according to the specific standards. Some of the
tests which were done in the laboratory are, 3.4.2. Cube compressive strength test

Concrete cubes were casted at the site & taken to the laboratory from the site. Steel mold
was removed from the concrete cubes and the cubes were placed in water tanks. Water
level inside the tank should be enough to cover the top surface of the cubes. After the
specified days, three non-defected cubes were taken from the water tank before 5 minutes
of the cube test and allowed to drain off excess water. Usually this test is done for 7 days &
28 days of soaking. The weight of the 3 cubes were taken before the testing to determine
the wet density of the concrete.

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Before the testing, testing machine bearing surface was cleaned by brush. After concrete
cubes was placed at the center of the bottom plate into the compressive strength testing
machine. Other important limitations are, other opposite sides of the casting side was
placed into the machine & for the uniform stress and applied load was maintained between
4.5kN/s – 9kN/s. Before the testing concrete cube dimensions were tested but usually
dimensions were 150mm*150mm*150mm in this project. After getting the reading from
the dial gauge (force), reading was corrected according to the calibration report of the
machine. Then reading was divided by 22.5 & converted into MPa. Similarly compressive
strength of other two cubes were calculated as above
described manner & average was taken according to the
strength of three cubes.

Figure 2.3.1 – Cubes in water tank

Figure 2.3.2 – Cube testing

2.3.2 Proctor compaction test

This method of test was done to determine the relationship between the moisture content
and density of soils and aggregates when compacted in a mould with a 4.5 KN rammer
dropped from a height of 457mm ( + or – 2mm ).

Material passing through 19mm sieve was used for this test. 5 samples were prepared and
each batch was mixed thoroughly with different amount of water. Specimen was formed by
compacting the prepared sample in a mold ( with 60mm height collar attached ) in five
approximately equal layers. Each layer was compacted by 25 uniformly distributed blows
for soil and 56 blows for aggregate using a rammer with flat circular face of 50.80mm.

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After compaction, the extension collar was removed and carefully trimmed the compacted
soil / aggregate even with the top of the mold by using a straightedge. Weight of the
specimen was recorded. Then the material was removed from the mold and responsible
sample was taken and weight to determine moisture content. It was oven dried at 110oC.

Figure 2.3.4 – Adding water to the Figure 2.3.5 – Compacting soil soil
sample

2.3.3 Sieve analysis test

A sieve analysis ( or gradation test ) is a test which is done in the laboratory to determine
the particle size distribution ( gradation ) of a granular material. The result of this test was
used to describe the properties of the aggregate and to see if it is appropriate for various

35
civil engineering purposes such as selecting the appropriate aggregate for concrete mixes
etc.

Sieve analysis test was performed on a sample of aggregate taken from the stockpiles or
batching plant. At first, a sufficient sample was taken from the source and weighed. Then it
was put into 105oC temperature oven for 24 hours. Then dry weight of the sample was
measured. Pan and sieves of different sizes were cleaned before the test to remove any dust
and fine particles. Sieves were arranged in descending order from top to bottom and finally
pan was placed at the bottom ( Each lower sieve has smaller openings than the one above ).
The representative weight sample was put into the sieve which was on the top and lid was
fitted on the top of the sieves.

Finally this arrangement was placed in a mechanical sieve shaker and allowed for sieving
for some fixed amount of time ( more than 2 minutes ). After sieving, retained weight of
the each sieve was measured.

Figure 2.3.6 – After sieving

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2.3.4 PI ( Plasticity Index ) test

2.3.4.1 To determine Liquid Limit ( LL )

Material passing through 425 Micrometer test sieve are used in this test. Approximately
300g of prepared soil was placed on the glass plate and sufficient water was added and
thoroughly mixed so that the distribution of water is uniform throughout the sample. Then
the sample was placed in the cup of the apparatus ensuring the cup is resting on the base.
Sample was well pressed down to exclude any air trapped and levelled off with spatula
parallel to the base.

The soil in the cup was divided with a firm stroke of the
grooving tool along the diameter of the cup which pass
through the center of the cup. The crank was turned to
raise and drop the cup twice per second. Until the two
sides of the grooved sample come in contact at the bottom
of the groove for a distance of 13mm. The number of
blows were recorded. That should be between 40 to 50
blows for the first test. A portion of the material was
extracted
Figure 2.3.7 – Casagrande apparatus

and placed in a container for moisture content. It was weighed and oven dried at 105oC for
16 hrs.

The remaining material in the cup was returned to the glass plate and mixed with the rest of
the sample adding more water. The cup of the apparatus was cleaned and the test was
repeated to obtain 3 more moisture samples. The number of blows required to close the
groove in each tests were maintained between 30 to 40, 20 to 30, 10 to 20 respectively. The
moisture content at 25 blows was read off to the nearest 0.1% as the Liquid Limit ( LL ).

37
2.3.4.2 To determine Plastic Limit ( PL )

Sample of soil prepared for the liquid limit test was taken and allowed it to lose moisture
on the glass plate until it becomes plastic enough to be shaped into a ball. The ball of soil
was moulded between the fingers and rolled between palms of the hands until slight cracks
appear on it’s surface by the heat of the hands. Enough pressure was used to reduce the
diameter of thread to about 3mm.

When slight cracks were noticed on the surface of soil threads, they were placed into
containers and weighed to determine the moisture content. They were oven dried at 105oC
for 16 hrs. The average moisture content was calculated and expressed to the nearest whole
no. as the Plastic Limit ( PL ).

Plastic Index = Liquid Limit - Plastic Limit

( PI ) ( LL ) ( PL )

Figure 2.3.8 – Rolling treads

38
2.3.5 Aggregate Impact Value ( AIV )

This test is done to determine the Aggregate Impact Value ( AIV ) which gives a relative
measure of the resistance of an aggregate to sudden shock on impact. This method is
applicable to aggregates passing at 14.0mm test sieve and retained on a 10.0mm test sieve.

The aggregates were dried by heating at a temperature of 105oC for a period not more than
4h and cooled to room temperature before testing. The cylindrical metal measure was filled
to overflow with the aggregate by means of a scoop. Aggregate was tamped with 25 blows
of the rounded end of the tamping rod. Each blow was evenly distributed over the surface
by allowing the tamping rod to fall freely from a height of about 50mm above the surface
of the aggregate. The surplus was removed by rolling the tamping rod on the top of the
container. The net mass was recorded and the same mass was used for the 2nd test
specimen.

The aggregate impact test machine was placed on a levelled surface so that it is rigid and
the hammer guide columns are vertical. Aggregate sample was placed in the cup which was
positioned on the base of the machine and then compacted again by 25 strokes using the
tamping rod. Then the test specimen was subjected to a total of 15 blows by the hammer,
each was delivered at an interval of not less than 1s. The free fall height of the hammer was
380mm ( + or - 5mm ).

The crushed aggregate sample was removed from the cup and weighed ( M1 ). Then it was
sieved on a tray using 2.36mm test sieve. The fractions passing and retained on the sieve
were weighed to the nearest 0.1mg ( M2 & M3 respectively ). When the total mass ( M2 +
M3 ) differs from the initial mass ( M1 ) by more than 1g, the result was discarded and
further specimen was tested. The same procedure was repeated using the second specimen
of the same mass as the first specimen.

The AIV was expressed to the first decimal place for each test specimen as follows.

AIV = [ M2 / M1 ] * 100 %

The mean of 2 values determined was calculated to the nearest whole number.

39
 Figure 2.3.9– Aggregate
impact test machine

2.3.6 LAAV test ( Los Angeles Abrasion Value )

The Los Angeles test is a measure of degradation of coarse aggregates of standard gradings
resulting from a combination of actions including abrasion and grinding in a rotating steel
drum containing a specified number of steel spheres. The number of steel spheres (
46.0mm in dia. Weighing approximately 400g ) used were depend upon the grading of the
test sample.

At first, the test sample was washed and oven dried at 110oC. Then separated into
individual size fractions according to the grading table. Then test sample was placed on the
Los Angeles testing machine and started to rotate at a speed of 30 – 33 rpm for 500
revolutions. As the drum rotates, the sample and the steel spheres were picked up by a shelf
plate and carried them around until they dropped to the opposite side of the drum, creating

40
an impact – crushing effect. After the prescribed number of revolutions, the contents were
removed from the drum and sieved on
1.70mm test sieve to measure the degradation as percent loss.

Figure 2.2.1 - Steel spheres

1
Figure 2.3.10 – Los Angeles testing

2.4 Board pile foundation

2.4.1 What is pile?

A pile is basically a long cylinder of a strong material such as concrete that is pushed into
the ground to act as a steady support for structures built on top of it. Pile foundations are used, if
there is a layer of weak soil at the surface. This layer cannot support the weight of the building, so
the loads of the building have to bypass this layer and be transferred to the layer of stronger soil
or rock that is below the weak layer. As well as when a building has very heavy, concentrated

41
loads, such as in a high rise structure, bridge, or water tank. In this project has an 1800mm diameter
pile. There are two fundamental types of pile foundations (based on structural behavior), each of
which works in its own way.

2.4.1.1 End Bearing Piles

In end bearing piles, the bottom end of the pile rests on a layer of especially strong soil or
rock. The load of the building is transferred through the pile onto the strong layer. In a sense, this
pile acts like a column. The key principle is that the bottom end rests on the surface which is the
intersection of a weak and strong layer. The load therefore bypasses the weak layer and is safely
transferred to the strong layer.

2.4.1.2 Friction Piles

These piles transmit most of their load to the soil through skin friction. This process of
driving such piles close to each other in groups greatly reduces the porosity and compressibility of
the soil within and around the groups. Therefore piles of this category are sometimes called
compaction piles. During the process of driving the pile into the ground, the soil becomes molded
and, as a result loses some of its strength. Therefore the pile is not able to transfer the exact amount

42
of load which it is intended to immediately after it has been driven. Usually, the soil regains some
of its strength three to five months after it has been driven.

2.4.2 Boring process of pile

After set out the steel casing should start the boring process. In this process used two types of
machine.
1. Rotary machine (GW 22 drilling machine)

Figure 2.4.1 – Rotary machine

When starting the drilling process use this machine to drill the hole. It has two types drill
bits.

• Scraper bit-When starting the boring scraper bit is used to both scrapping and
screwing process.

43
 Figure 2.4.2 – Scraper bit

• Rock roller bit-This type of bit is used when the boring is reached the weather
rock.

Figure 2.4.3 – Rock roller bit

Chisel machine (JKL8AB)

• Chisel bit - This type of bit is used for align the bored pile whether it has any
alignment defect

44
 Figure 2.4.4 – Chisel bit

After set out the pile point, should install the steel casing. Then install the boring machine correctly
and rig should be installed very carefully on the center point.
Drilling mud
Drilling mud is very essential part of the boring process. It helps to avoid, collapsing soil into
the pile while boring. In this project use natural mud as slurry it reduces environment influence
with comparing the betonite.

2.4.3 Mud circulating system

Mud circulating system is very essential part of the boring process. In this facility,
sedimentation pit and one mud pit should be included. By using this system can make slurry
which is needing for the boring.

45
 Figure 2.4.5 – Mud circulating system

2.4.4 Sample Storage

During boring, the sample should be distributed in the sample box. After that, the sample
will be stored in a given place with marked label. Sampling shall be carried out for each bore
hole at 2.0 m intervals. By those samples can decide about the soil and whether it comes to the
terminated level or not.

Figure 2.4.6 – Soil samples

2.4.5 Verifying shape of pile

After boring process, should check out the depth of the bore hole. Using the verification cage
can verify the terminated level, diameter and verticality of bored pile.

The verifier assembled with main bar of 32mm diameter and hoop reinforcement of 25mm
diameter. Length of verifier shall be 5.9m

46
 • Verifying terminated level and diameter of bored pile

Terminated length = 42m-(0.44+0.8) m+5.9m-0.03m

=46.63m

• Verifying the vertical of bored pile

In this process check the verticality of bored pile using the total station. First of all total station
should be oriented .Then take two points of the cable, by these points can calculate the verticality.

47
These two points are taken from bottom and top of the cable and coordinates of the designed center
are given. Using these points can calculate the verticality. Verticality should not less than this
formula.750:1(V:H) it means if the vertical is 750mm and horizontal distance should 1mm.

48
 4.1.2.5 DE-SANDER

Figure 2.4.7 – De-Sander

How to separate mud of bored piles?

This is a difficult problem in the construction of bored piles. Traditional mud treatment
solution is mud precipitation method using mud pools. In the process of drilling hole, using screen
mesh to separate the small gravel, sand and other solid particles from the mud. Drilling mud form
piling discharged into the first pool, then into second pool. After natural dehydration solidifies, the
waste from the pool will be transported to the storage yard. This method is suitable for cleaning a
small amount of mud.

49
2.4.6 REINFORCEMENT

In the pile construction reinforcement cage has cylindrical shape. This cage has main bars and
stirrups. 20mm diameter bars are using for the lower part of the cage and 25m diameter bars are
using the upper part. The stirrups should be circler shape, but the bar benders use to make the
stirrups as a helical. To maintain the shape of the helical we used bar rings. These reinforcement
casts in four, five, three or two part Lap length of the pile reinforcement is 50 Ø. Covering space
of the pile is 100mm.

Figure 2.4.8 – Reinforcement of pile

2.4.7 PILE CONCRETING

2.4.7.1 Materials

• Cement

• Fine aggregates:

➢ Sand

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 ➢ Quarry dust

• Coarse aggregates:

➢ 20mm metals

• Admixtures:

➢ Optima 183N

• Fly ash (Fly ash is used to control the cooling system of concrete and increase the
workability.)

• Water

2.4.7.2 Quality

• Slump range: 180±25mm

• Temperature: < 32̊̊ c

• Covering space: 100mm

• Compressive strength: 35Nmm-2

2.4.7.3 Procedure

• After reinforcement installation slurry should check, if there is high sand content
should do the de-sanding system to remove the sand.

• Thereafter set up the tremie pipe and remove the slurry regularly to reduce the
sedimentation.

• Thereafter submerge the tremie pipe and measure the height between platform and
top of the tremie pipe.

51
 • Then the flushing is completed tremie should be removed and funnel should be
attached to the tremie pipe. When concrete pouring process is starting should insert
a basketball to get idea about the nature of the hole. If the pile wall can be collapsed
in to the hole, so that ball couldn’t reach out so can get idea about the pile.

• When starting the concrete pouring fulfill the hopper from concrete and release it
at once. There after pour the concrete regularly.

Tremies are varied by the length. Length of tremies-2.86m, 2.8m, 1m, 0.5m and
3.01m.Diameter of the tremie pipe is 300mm.Volume of the large hopper is 4m3.

Figure 2.4.9 – Funnel and tremie installation

Required apparatus for concrete pouring.

• Trime head
• Trime rest

52
• Trime cap
• Trime pipe set
• Funnel

Figure 2.4.10 – Apparatus

53
2.4.7.4 Tremie pipe installation

When tremie reach the maximum submerged level can remove the tremie relevantly and should
maintain the submerged level. Until the concreting is finishing should maintain the 300mm gap
between the tremie and concrete level. Finally it comes to the concrete top level should stop the
concreting and check the nature of the top concrete whether it good or not after considering the
nature of the concrete stop the concreting process.

54
 Figure 2.4.11 – Pile concreting

PILE HACKING

The client’s requirement is the pile should be hacked up to the cutoff level. The top area of
the pile is not in good concrete. This is the reason for the pile hacked. Normally when a pile is
being hacked up t cut off level, but if good concrete is not found, it should be further hacked until
good concrete will be found. Then after the pile is re-built (built up) up to cut off level.

Pile hacking is done by concrete breakers (jack-hammers). There are several kinds of
breakers according to the sizes. Small breakers are working electricity and large ones are working
pneumatic power. Therefore a large breaker is worked in the site and thus an air compressor is also
compulsory.

A pile breaking job is very dangerous job, because the breaker is a heavy tool with vibrating
one. The breaking person should be too much careful to work with it. Normally the pile breaking
person will be given a helper for that job. When pile is breaking small concrete particle can effect
to damage the workers. And also the compressed air hose can be demounting from the breaker and
it will move here and there. The hose edge has a steel part and when it is moving here and there,
the workers may be injured seriously.

Therefore these workers should wear with helmet, gloves, gum boots, mask and a goggle.

55
Figure 2.4.12 – Pile hacking

56
3.0 CONCLUSION

I believe that, I have achieved a lot of things more than that I expected from my training.
Now I have the self-confidence to have the responsibilities in any work regarding the
things I learnt. There were many people such as site engineers, resident engineer, and
quantity surveyors to guide me throughout the training period and without their support it
would be very hard for me to finish the training. They guided me every time, observed my
activities and encouraged in my works.

At the initial stage of the training, it was little bit difficult for me to understand the works
carried out and the terminology used at the site. Little by little I learned many things from
site during this period. So I took it my training period as a golden period of my life time
and learned as much as possible I can. I took this period to improve my knowledge on
handling different documents, drawings, inspection works on the different kind of
equipment and machinery usages and many more. By maintaining a diary, I was able to
summarize that what I have learned and what have to learn in future. I also gathered some
knowledge about consultancy & how to interact with contractors.

This training program helped me to get some contacts from many persons with different
knowledge at different stages. Projects managers, resident engineers, engineering
assistants, and TO, co-trainees in different fields and from different institutions and
universities, our subcontractors, drivers, laborers and many more. So that I learned how to
behave and associate with different kind of personals such a way that it will make proud to
IET.

The main objective of the training program is to learn a lot of things about technical,
management etc. With the help of many personals, I could learn whatever possible which is
totally fulfilling the main objective from site with the help of site engineers, engineering
assistants.

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