INTERNSHIP REPORT

Department Of Civil Engineering

ITM UNIVERSITY, GWALIOR

A report submitted in partial fulfillment of the

requirements of the award of degree of

BACHELOR OF TECHNOLOGY IN
CIVIL ENGINEERING.

Submitted By: Submitted To:

Voice Raj Meena Department of Civil
BETN1CE21009 Engineering School of
B.TECH CIVIL Engineering and
(7th semester) Technology,
ITM UNIVERSITY
Gwalior (MP)
CERTIFICATE
 DECLARATION

I hereby declare that the Industrial Training Report on “Water Tank

Storage & Supply” in B.tech ,Civil Engineering was done only by
me, and it is an authentic record of my own work of Industrial
Training during the period from 08/08/2024 to 05/09/2024 for the
award of degree of B.Tech. (Civil Engineering), ITM University,
Gwalior.
under the guidance of “Mr. Shashank Gupta”.

Name : Voice Raj Meena

Roll No. : BETN1CE21009
Semester : 7th Semester
 AKNOWLEDGEMENT

First and foremost, I wish to express my sincere thanks and gratitude to

my esteemed Mentor “Saurabh Sir” who has contributed so much for
successful completion of my Industrial Training by his thoughtful
reviews and valuable guidance at the construction site.
Next, I would like to tender my sincere thanks to “Dr. Mukesh
Pandey” (Head of Civil Engineering Department) for his co-operation
and encouragement.

Name : Voice Raj Meena

Roll No. : BETN1CE21009
Semester : 7th Semester
 TABLE OF CONTENT
1. Introduction……………………………......1

2. Objective…………………………………..2

3. Components of Fly Over………………….3

4. Site Images………………………………...6

5. Tools and Technologies Used……………..8

6. Software Used……………...……………..15

7. Technique and Construction……………..16

8. Problem Identification/Case Study………18

9. Conclusion……………………………….19

10. References…………………………...….20
 INTRODUCTION

This report documents the industrial training undertaken at a

construction site in Gwalior, Madhya Pradesh, focusing on the
construction of Four Lane Elevated Road ( Fly Over On Swarn
Rekha Nalla From Iiitm College To Maharani Laxmibai
Pratima).The Bridge cost has reached over Rs700 Crores. The training
was conducted under the supervision of Saurabh sir from 08/08/24 to
05/09/24.

The construction of the flyover bridge aims to enhance traffic

management and improve connectivity in the city without going
through congested areas, thus allowing faster passage. The foundation,
being the most critical structural component, ensures the flyover's
stability, durability, and capacity to bear dynamic loads.

The objective of this training was to gain hands-on experience in

various aspects of foundation construction, including geotechnical
investigations, excavation, reinforcement placement, concrete pouring,
and quality assurance processes. Additionally, the training emphasized
adhering to safety protocols and understanding project management
practices on-site.

This report provides an overview of the training experience, highlights

the processes involved in flyover foundation construction, and reflects
on the challenges and learning outcomes during the project. It talks
about the significance of applying engineering knowledge to solve
practical problems in infrastructure development.

1
 OBJECTIVE
1. Understanding Structural Components:
•To study the design, function, and construction techniques of
the lower parts of a flyover bridge, including foundations, piers,
and abutments.
2. Application of Engineering Principles:
•To apply theoretical knowledge of civil engineering to practical
tasks such as load analysis, soil testing, and structural design.
3. Gaining Practical Skills:
•To acquire hands-on experience in excavation, reinforcement
placement, shuttering, and concrete pouring for the lower
structural components.
4. Learning Construction Techniques:
•To observe and participate in the use of construction equipment
and machinery, such as cranes, batching plants, and piling rigs,
during the building of lower parts.
5. Ensuring Quality Control:
•To understand and implement quality assurance practices,
including material testing (e.g., concrete strength, slump tests)
and inspection of work alignment and standards.
6. Observing Safety Practices:
•To learn and adhere to safety protocols and measures, ensuring
a safe working environment during all phases of construction.
7. Understanding Project Management:
•To gain insight into the scheduling, resource management, and
coordination required to execute construction activities
efficiently.
8. Recognizing Environmental Impact:
•To observe measures taken to minimize environmental impact
during excavation, material handling, and other construction
processes.

2
COMPONENTS OF FLY OVER

3
 COMPONENTS OF FLY OVER

1. Pile: Piles are long, slender columns driven or drilled deep into the
ground to provide support for bridge foundations. They transfer the
load of the bridge to stable soil or bedrock, especially in weak or
unstable ground conditions. Piles can be made of concrete, steel, or
timber, and are essential for ensuring the stability and durability of a
bridge structure.

2. Pile Cap: A pile cap is a thick, reinforced concrete slab that sits on
top of a group of piles, distributing the loads from the bridge structure
evenly across the piles beneath. It provides stability and ensures that
the forces from the superstructure are transferred to the piles.

3. Pier: A pier is a vertical support structure which acts like a column

in a bridge that carries the loads from the superstructure (deck) and
transfers them to the foundation. Piers are typically made of reinforced
concrete or steel and are spaced at regular intervals along the bridge.
They help maintain the bridge’s stability, particularly in long-span
bridges, by supporting the weight and forces acting on the structure

4. Pier cap: A pier cap is a reinforced concrete structure placed on top

of a pier, designed to distribute the load from the bridge deck to the
pier. It acts as a connection between the pier and the superstructure,
ensuring even load transfer.

5. Pedestal: A pedestal is used with girders to support the bearings

that connect the superstructure to the pier or abutment. The pedestal
provides a stable foundation for the bearings, allowing controlled
movement of the girders due to temperature changes or traffic loads. It
ensures even load distribution from the girders to the supporting piers
or foundation.

4
 COMPONENTS OF FLY OVER

6. Girders: Girders are the primary horizontal load-bearing elements

in a bridge, designed to support the weight of the bridge deck and
traffic loads. They are typically made of steel, concrete and are Pre-
Stressed for large bridges. Girders span between piers and are
supported by bearings, allowing for movement. They transfer loads to
the foundation, ensuring the bridge’s structural stability.

7. Slabs: Slabs in a bridge are flat, horizontal surfaces that form the
bridge deck, supporting traffic loads. They are typically made of
reinforced concrete and serve as the primary surface for vehicles and
pedestrians. Slabs are designed to distribute loads from traffic and the
superstructure evenly to the supporting girders or beams. They are
subject to bending, shear, and compressive forces, which must be
carefully considered in the design. Slabs ensure the stability of the
bridge and maintain a smooth, durable surface for movement.

8. Parapets: A parapet is a protective barrier or wall installed along

the edges of a bridge to prevent vehicles, pedestrians, or objects from
falling off the structure. Typically made from reinforced concrete or
steel, parapets provide safety by absorbing impact during accidents
and redirecting forces away from the bridge. They are designed to
withstand high-impact forces and can also serve as noise barriers. In
addition to safety, parapets may include features such as lighting,
signage, or aesthetic designs to enhance the bridge's functionality and
appearance.

9. Abutment: An abutment is a supporting structure at either end of a

bridge that connects the bridge to the land. It transfers loads from the
bridge superstructure to the foundation and retains the earth behind it.
Made of reinforced concrete or masonry, abutments also provide
support for the bridge's approach and prevent soil erosion and
movement.
5
SITE IMAGES

6
SITE IMAGES

7
TOOLS AND TECHNOLOGIES USED
Many Different types of tools were used in the construction of Fly Over
, which are as follows:-

Cement : Lots of bags of cements were used in the construction as

cement is the most basic binding material needed for construction work.
They were present in yellow bags lying near the construction site

Gantry/Goliath Crane : A very large sized gantry crane was used to

place girders from one place to another and load them onto trucks , so
they can be transported from the plant to actual site

8
 TOOLS AND TECHNOLOGIES USED
Reinforcements : Long reinforcements were present at site for different
parts of bridge components and also for prestressing the girders.

Girders : Prestressed Girders used above the pier caps to transfer load
from slab to soil. Girders which were prestressed where made to rest on
ground for 28 days to gain strength before loading them onto trucks.

9
 TOOLS AND TECHNOLOGIES USED
Pre-Tensioning Setup: A special plant was used to Pretension the
girders used for making shorter girders. Pre-tensioning is a process in
prestressed concrete where steel tendons are tensioned before concrete
is poured. Tendons are anchored at each end of a casting bed and
stretched to a specified force. Concrete is poured and allowed to cure,
bonding to the tendons. Once cured, the tension is released,
compressing the concrete and enhancing its strength and durability.

Post-Tensioning Setup: Post tension girders were made on site and are
used for making longer girders. Post-tensioning involves placing steel
tendons inside ducts within a concrete structure before pouring. After
the concrete cures, tendons are tensioned using hydraulic jacks and
anchored at the ends. This induces compressive stress in the concrete,
counteracting tensile forces during use. Post-tensioning allows for
longer spans, reduced material use, and greater structural flexibility.

10
 TOOLS AND TECHNOLOGIES USED
Soil Stabilization: Soil was stabilized using cement over sand to keep
the iron supports sturdy and in place. Cement reacts with water and soil
particles, forming a hard matrix that binds the particles together.

Shuttering: Metal shuttering was used at the site. Shuttering is a

temporary mold used in construction to hold freshly poured concrete
until it sets and gains sufficient strength. It shapes the concrete to the
desired design. Shuttering ensures stability, prevents leakage, and
maintains surface finishes, playing a vital role in structural integrity and
appearance.

11
 TOOLS AND TECHNOLOGIES USED
Metal Supports and Scaffolding: Metal supports were used to keep
the pier cap in its place and place reinforcement and shuttering till the
concrete hardens. Scaffolding was used to support workers and
materials during construction.

Concrete Mixer: A concrete mixer truck is a specialized vehicle

designed to transport and mix concrete during transit. It featured a
rotating drum mounted on the truck that continuously rotated to prevent
the concrete from setting. The drum Contained mixed fresh concrete. It
was used during the entire construction work.

12
 TOOLS AND TECHNOLOGIES USED
Construction Lights: Heavy duty construction lights were used to
keep the construction area well lit and allow for the construction to be
done in night as well. They are light weight and easy to carry
everywhere.

Electric Saw: A high watt electric saw was used at the site to cut the
reinforcements into desired shape and size. Electric saws provide
precision, speed, and ease of use, making them essential for tasks such
as cutting beams, pipes, or flooring. They increase productivity and
reduce manual labor, contributing to more efficient and accurate
construction work.

13
 TOOLS AND TECHNOLOGIES USED
Cement Cover blocks: Cement cover blocks are small, precast
concrete elements used in construction to ensure adequate coverage of
reinforcement bars (rebars) in reinforced concrete structures. They are
placed between the reinforcement and the surface of the concrete to
protect the steel from corrosion, ensure proper bonding with the
concrete, and maintain the desired structural strength. Cement cover
blocks help maintain the durability of the structure by providing
consistent spacing, preventing exposure of the reinforcement to
environmental elements like moisture.

14
 SOFTWARE USED
AUTOCAD was used for the creation of design drawings of the
overhead water tank. It was used to give detailed drawings which had
design specifications and the types of reinforcement etc.

Some examples of these drawings are as follows:

15
TECHNIQUE AND CONSTRUCTION
1. Preliminary Works:
The process begins with site surveys and investigations, including
topographical and geotechnical studies, to assess ground conditions
and design requirements. Detailed planning and design follow,
incorporating load calculations, structural requirements, and
environmental considerations.

2. Foundation Construction:
The foundation, crucial for stability, is constructed based on soil
conditions. Since the soil was unstable and lacked shear strength deep
foundation was used , specifically pile foundation. Excavation is
performed to the required depth as needed to bear the load of bridge
and vehicles above it, followed by placing reinforcement and
formwork. Concrete is then poured, compacted, and cured.

3. Substructure Construction:
This includes constructing piers and abutments on top of pile
foundation, which provide vertical and lateral support to the bridge.
Reinforced concrete is used for strength and durability. Bearings are
installed on piers to allow controlled movement of the superstructure
due to thermal expansion and dynamic forces. Pier Caps are
constructed on top of piers to carry incoming load from superstructure.

4. Superstructure Construction:
The superstructure of a flyover bridge consists of elements such as
girders, the deck, and the supporting components. Construction begins
after the foundation and substructure are completed. Pre-Stressed
Concrete Girders were used to provide additional strength and stability
at lower cost for such a large-scale project. They are installed to span
between the piers using cranes and transfer load from the slab to the
piers. The bridge deck is constructed using cast-in-situ concrete, with
expansion joints installed to accommodate movement of concrete
without producing cracks.
16
TECHNIQUE AND CONSTRUCTION
5. Finishing Works:
The deck is paved with asphalt to create flexible pavement, and lane
markings, parapets, crash barriers, railings, and lighting are added for
functionality and safety. Drainage systems are also installed to prevent
water accumulation.

6. Quality Assurance and Safety:

After the construction of a flyover bridge, quality checks are
conducted to ensure the structure’s integrity and safety. This includes
visual inspections for cracks, misalignments, and defects in
components like piers, girders, and the deck. Concrete testing is
performed, including compressive strength tests on sample cubes to
verify that the concrete meets design specifications. Reinforcement
checks ensure proper placement and bonding of steel. Load testing is
often carried out to confirm the bridge can handle anticipated traffic
loads. Finally, safety features such as railings, drainage systems, and
signage are thoroughly examined for functionality and compliance
with standards.

17
 PROBLEM
IDENTIFICATION/CASE STUDY

The fly over is still under construction and work is ongoing, Following
were the problems/complexions that occurred during my visit that
should be improved upon, such as:

• The Workers were not wearing proper safety equipment.

• Masks were not used by workers.
• Cement was not of good quality.
• Reinforcements were lacking in quality.
• Scaffoldings were not safe to use.
• Equipment were rusty.
• No proper hygiene among workers.
• Construction was going at very slow pace.
• More efficient equipment like Pipe concrete system should have
been used.

18
 CONCLUSION

Observing the construction of a water tank is a unique and insightful

experience that provided a firsthand look into the intricate processes
involved in bringing this essential infrastructure to life. I was able to
learn a lot from this experience and noticed the following things:

During the course of the internship, I gained a thorough understanding

of the various phases involved in bridge construction, from initial
design and site preparation to the construction of the foundation,
substructure, and superstructure.

One of the key aspects I learned was the importance of foundation

work, particularly the use of pile foundations in areas with weak soil. I
was involved in observing the process of placing piles, setting up
formwork, and pouring concrete. Additionally, I learned about the
critical role of piers and abutments, which provide essential support to
the bridge and transfer loads from the superstructure to the ground.

Construction of Fly Over was no easy task, and a lot of hard work and
labor was needed to get it done. The Fly Over allows for smooth
traversing across the Gwalior district as it bypasses the old market and
housing area, Thus increasing productivity and reducing overall traffic
over the area.

It was a wonderful learning experience for me, and I hope to study even
more construction projects in the coming years in order to become a
successful engineer.

19
 REFRENCES

These were the references used in the creation of this report :-

• https://www.wikipedia.org/
• https://www.slideshare.net/
• https://iarjset.com/
• https://theconstructor.org/
• https://civilguidelines.com/
• https://www.scribd.com/

20