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PROJECT REPORT

on

Finishing Work at Welcome Metro Station

(Industry Name: DMRC Ltd.)

Submitted to

Amity School of Engineering And Technology

Guided by: Submitted By:

Mr. Yogesh Kaushik (Faculty Guide) Siddharth Srivastava

Mr. Harish Mishra (Industry Guide) A2315813131

Roll No.: 131

AMITY UNIVERSITY UTTAR PRADESH

GAUTAM BUDDHA NAGAR

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Declaration by the student

I, Siddharth Srivastava student of B.Tech (Civil) hereby declare that the project titled

“Finishing Work at Welcome Metro Station” at Delhi Metro Rail Corporation Limited

(DMRC), which is submitted by me to Department of Civil Engineering, Amity School Of

Engg. And Technology, Amity University Uttar Pradesh, Noida, in partial fulfillment of

requirement for the award of the degree of Bachelor of Technology in 2017, has not been

previously formed the basis for the award of any degree, diploma or other similar title or

recognition. The Author attests that permission has been obtained for the use of any copy

righted material appearing in the Dissertation / Project report other than brief excerpts

requiring only proper acknowledgement in scholarly writing and all such use is

acknowledged.

Noida

Date: Siddharth Srivastava

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Certificate by Faculty Guide

This is to certify that Mr. Siddharth Srivastava, student of B.Tech. in Civil

Engineering has carried out the work presented in the project of the summer training

entitled "Finishing Work at Welcome Metro Station" as a part of final year program

of Bachelor of Technology in Civil Engineering from Amity School of Engg. And

Technology, Amity University, Noida, Uttar Pradesh under my supervision.

Signature of Faculty Guide

(Mr. Yogesh Kaushik)

ASET, AUUP

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ACKNOWLEDGEMENT

I feel very grateful to thank all the people who have helped me directly or indirectly and

supported me in completing my training.

My deepest thanks to my faculty guide, Mr. Yogesh Kaushik, and Mr. Harish Mishra, the

mentor of the project, for guiding and correcting me with attention and care. I greatly

appreciate the efforts he took to go through my data and make necessary corrections as and

when needed.

I also express my thanks to Ms. Madhuri Kumari, The Head of Department (HOD), and Mr.

Prakhar Duggal, The Program leader (PL), for extending their support.

Words are inadequate in offering my thanks to the various helpful people of Delhi Metro Rail

Corporation Limited and Amity University for their encouragement and cooperation in

carrying out the training.

I would also thank my Institution and my faculty members without whom this project would

have been a distant reality.

Finally, yet importantly, I would like to express my heartfelt thanks to my beloved parents

for their blessings, my friends/classmates for their help and wishes for the successful

completion of this project

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ABSTRACT

The fundamental reason for undergoing summer training was to gain practical knowledge

and learn to apply the theoretical knowledge I have gained throughout my course on real life

projects. The training was an enriching experience as I got to learn many things which are

not given in books or taught in classes. This experience has improved my problem solving

skills as I have learned to tackle obstacles that one faces during construction projects. The

training has helped me gain exposure and understand what Civil Engineering is about, and

deepened my interests in this discipline. I have summarized my learnings in this project

report.

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TABLE OF CONTENTS

List of Figures 10

List of Tables 11

1. About The Organization 12

2. Introduction 13

2.1. About Pink Line 13

2.2. About the Contract 14

2.3. About the Project 15

3. Brick Masonry 16

3.1. Purpose 16

3.2. Scope 16

3.3. Material 16

3.3.1. Mechanized Autoclaved Fly-Ash Lime Brick 16

3.3.2. Bricks 17

3.3.3. Cement 17

3.3.4. Sand 17

3.3.5. Water 17

3.3.6. Mortar 17

3.3.7. Scaffolding 18

3.4. Methodology 18

3.4.1. Brick Work 18

3.4.2. Stacking of Bricks 19

3.4.3. Sampling of Bricks 19

3.4.4. Soaking of Bricks 19

3.4.5. Cement Mortar 20

3.4.6. Laying of Bricks 20

3.5. Bricks with RCC 22

3.6. Brick Joint 22

3.7. Skirting of Joints 23

3.8. Wall 23

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3.9. Doors and Windows 23

3.10. Alignment 23

3.11. Lintel and Sunshades 23

3.12. Curing 23

4. Tiling 25

4.1. Purpose 25

4.2. Scope 25

4.3. Material 25

4.3.1. Ceramic/Vitrified Tiles 25

4.4. Methodology 25

4.4.1. Preparation of surface and laying tile 25

4.4.2. Mortar and Bedding 26

4.4.3. Laying of tile on floor 27

4.4.4. Fixing wall tiles for dado/skirting 27

4.4.5. Grouting of Joints in Floor/Skirting/Dado 28

4.4.6. Cleaning 29

4.5. Planning 29

5. Waterproofing 30

5.1. Materials 30

5.1.1. Tapecrete 30

5.2. Waterproofing of Toilets 31

5.3. Waterproofing of Raft and Retaining Walls 31

5.3.1. Stage 1 31

5.3.2. Stage 2 31

5.3.3. Stage 3 31

5.4. Tests 33

6. Kota Stone and Granite Works 34

6.1. Objective 34

6.2. Methodology 34

6.2.1. Fur Granite/Kota Flooring 34

6.2.1.1. Surface and Base Preparations 34

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6.2.1.2. Laying Procedure 34

6.2.2. Polishing 36

7. Painting 37

7.1. Methodology 37

7.1.1. Paint on exterior and interior walls and on other concrete surfaces 37

7.1.1.1. Surface/Base Preparation 37

7.1.1.2. Application procedure painting works 38

7.1.2. White Washing (Lifts/Shafts etc) 38

8. Underground Water Tank 39

8.1. Objective 39

8.2. Construction Methodology 39

8.2.1. Layout Marking 39

8.2.2. Earthworks 39

8.2.3. Binding for Raft 39

8.2.4. Water proofing Stage 1 39

8.2.5. Concreting 39

8.2.6. Waterproofing from inside + tiling 39

8.2.7. Waterproofing from outside 40

8.2.8. Fixing of ladders/footrest as per requirement 40

9. Aluminum Composite Panel 41

9.1. Purpose 41

9.2. Scope 41

9.3. Material 41

9.3.1. Aluminum Composite Panel 41

9.4. Procedure 42

9.4.1. For fixing aluminum cladding sheets 42

9.4.2. Frame for installation of ACP 42

9.4.3. Application of silicone sealant 43

10. Responsibilities 44

10.1. Duties of respective individuals 44

10.2. Organizational Chart 44

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11. Safety 45

11.1. Safety guidelines 45

11.2. Emergency Response Plan 46

12. Lab Tests Performed on Various Building Materials 47

12.1. Sieve Analysis of Fine Aggregate for use in Masonry Mortars and

Concrete 47

12.2. Brick Tests 48

12.2.1. Dimension Tests 48

12.2.2. Water Absorption 48

12.2.3. Compressive Strength Test 48

12.2.4. Efflorescence Test 48

12.3. Granite and Kota Stone test 51

12.3.1. Specific Gravity 51

12.3.2. Water Absorption 51

12.3.3. Compressive Strength 51

12.3.4. Hardness Test 51

13. Conclusion 53

References 54

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LIST OF FIGURES

Figure 1.1. DMRC 12

Figure 2.1. A map of metro network 15

Figure 2.2. Under construction metro station 15

Figure 3.1. Fly Ash Bricks 16

Figure 3.2. Scaffolding on the outside of station walls 18

Figure 3.3. Types of Brick Bond 22

Figure 3.4. Vertical alignment in a brick wall 22

Figure 3.5. Wire mesh in a brick wall 24

Figure 4.1. Roughening mortar for laying tiles 26

Figure 4.2. Fixing floor tile and tapping with a wooden mallet 28

Figure 4.3. Grouting of floor tiles 29

Figure 5.1. Tapecrete 30

Figure 5.2. Applying waterproofing layer 31

Figure 6.1. Junction of polished kota and granite flooring 35

Figure 6.2. Kota stone and granite 35

Figure 6.3. Kota stones laid at platform level 36

Figure 7.1. Sanding the surface before painting 38

Figure 7.2. Whitewashing 38

Figure 9.1. Cutting ACP 42

Figure10.1. Organizational Chart 44

Figure 11.1. Posters to promote safety 45

Figure 11.2. Detailed action plan for emergencies 46

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Figure 12.1. Reporting of sieve analysis results 47

Figure 12.2. Reporting of brick test results 50

Figure 12.3. Reporting of kota stone and granite results 52

LIST OF TABLES

Table 2.1. Pink Line 13

Table 2.2. Contract Details 14

Table 3.1. Sampling of Bricks 20

Table 9.1. Approved shades for ACP 41

Table 10.1. Duties of respective individuals 44

Table 12.1. Reporting of efflorescence test results 49

Table 12.2. Mohr’s Scale of Hardness 51

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CHAPTER 1. ABOUT THE ORGANIZATION

Fig 1.1. DMRC

Delhi Metro Rail Corporation Limited (DMRC) is a state owned company with equal

participation from the Government of India and Government of National Capital Territory

of Delhi. DMRC is responsible for building and operating the Delhi Metro. Delhi Metro

is a metro system serving Delhi metropolitan area and its satellite cities of Gurgaon,

Noida, Faridabad and Ghaziabad in the NCR. Delhi Metro has been ranked second

amongst 18 international metro systems in terms of overall customer satisfaction in an

online customer survey. Delhi Metro is India’s first modern public transportation system,

which has revolutionized travel by providing a fast, reliable, safe and comfortable means

of transport.

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CHAPTER 2. INTRODUCTION

2.1 About Pink Line:

The pink line is an under construction line of Delhi Metro, a part of Delhi Metro Phase

III network. On completion, this will be the longest line with a length of 58.59

kilometers, breaking the record set by operational blue line. It will be mostly elevated

and will be covering Delhi in an almost ‘U’ shaped turn. This is also known as the

‘Ring Road Line’ as the entire line passes alongside the busy Ring Road that witnesses

massive traffic jams every day. The pink line has planned interchanges with all

operational lines of the network such as Yellow, Red, Green, Blue, Orange and Violet

lines, as well as with Hazrat Nizamuddin and Sarai Kale Khan ISBT.

Overview

Type Rapid Transit

System Delhi Metro

Status Under Construction

Locale Delhi, Ghaziabad

Terminal Stations Mukundpur

Shiv Vihar

Stations 38, Elevated: 26, Underground:12

Operation

Opened May 2017

Operator(s) Delhi Metro Rail Corporation

Character Underground and Elevated

Rolling Stock Hyundai-ROTEM Standard Gauge

Technical

Line Length 58.59 kilometers (36.41 mi), Elevated 39.48 kilometers

(24.53 mi), Underground 19.11 kilometers (11.87 mi)

Track Length 58.59 kilometers (36.41 mi)

Track Gauge Standard Gauge

Electrification 25 kV, 50 Hz through overhead catenary

Table 2.1. Pink Line

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2.2 About The Contract:

Tender No. CC-12

Item/Nature of Work Construction and design of elevated

viaduct and 6 elevated stations viz.

Krishna Nagar, East Azad Nagar,

Welcome, Zafrabad, Maujpur and

Gokulpuri

Mode of Tender Enquiry Pre-qualified

Type of Bidding Single Bid

Last Date of Receipt of Tender 13.02.2012

No. of Tender Received 10

No. and name of parties qualified after

tech. evaluation

1. M/S L&T Limited

2. M/S J. Kumar-MMS JV

3. /S IJM-IJMI UEMB JV

4. M/S SACYR Unity JV

5. M/S Simplex Infrastructures Ltd.

6. M/S HCCLtd.

7. M/S Gammon India Ltd.

8. M/S JMC-CHEC JV

9. M/S Afcons Infrastructure Limited

10. M/S OHL-Punj Lloyd JV

Date of LOA 11.04.2012

Name of Contractor JMC-CHEC JV

Value of contract (Crore) 398.34

Table 2.2. Contract Details

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2.3. About The Project:

The training focused on finishing work at Welcome Metro Station, as the construction

of structures was completed. The new elevated Welcome station (Pink Line) stands

next to an existing Welcome station (Red Line) and will serve as an interchange

station.

Fig. 2.1. A map of Metro Network. Welcome Metro Station shown in a Red Circle.

Fig. 2.2. Under construction metro station (pink box) beside existing station

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CHAPTER 3. BRICK MASONRY

3.1.PURPOSE

The purpose of this procedure is to prepare construction sequence of brick masonry as

per specifications and maintain good workmanship.

3.2.SCOPE

The procedure establishes the materials, dressing, laying, joining, curing, workmanship

etc. for Brick masonry work.

3.3.MATERIAL

3.3.1. Mechanized Autoclaved Fly-Ash Lime Brick:

These bricks shall be machine molded and prepared in plant by appropriate

proportion of fly ash and lime. The autoclaved fly ash bricks shall conform to IS

12894. Visually, the bricks shall be sound, compact, and uniform shape, free fro

visible cracks and organic matters. The bricks shall be solid with or without frog

and of 100/80mm length, 40mm width, and 10-200mm deep one of its flat side as

per IS 12894. The brick shall have smooth rectangular faces with sharp corners

and shall be uniform in shape and color. Fly ash shall conform to IS 3812 and lime

content conforms to class-C hydrated lime of IS 712. Brick work with burnt

clay/fly ash bricks conforming to IS 1077, IS 13757 of class designation 10 in

cement mortar 1:4.

Fig. 3.1. Fly Ash Bricks

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3.3.2. Bricks:

Brick shall be class designation 10 and conforms to standard specification, regular

in shape and size with sharp edges and corners. Frog of the bricks shall be less

than 1cm and greater than 2cm. Bricks should give clear metallic ringing sound

and water absorption shall not be more than 20% by weight. Bricks shall have an

average compressive strength of not less than 105 kg/sq cm.

The sampling of bricks shall be as per IS5454.

3.3.3. Cement:

Cement shall be OPC (Ordinary Portland Cement) Grade 53 conforming to IS

8112. Cement shall be fresh when delivered at site.

3.3.4. Sand:

Sand for masonry mortar shall be natural sand, crushed stone sand or crushed

gravel sand or combination of any of these conforming to IS 2116-1980. Sand shall

be hard durable, medium coarse sand, clean sharp and free from clay, sand shall

be screened/sieve by 4.75mm sieve.

3.3.5. Water:

Water used for brickwork should be clean and free from injurious amount

deleterious materials. Constructive water shall be used be used for masonry work.

It shall conform to IS 456:2000.

3.3.6. Mortar:

Cement mortar shall be done by Mechanical mixer and if hand mixing is done then

10% extra should be added according to CPWD specification. The required

quantity of water shall then be added and the mortar holds back and forth for 5 to

10 minutes with addition of water to a workable consistency. Mortar with cement

shall be used as early as possible after mixing preferably from half an hour from

the time water is added to mix or at the latest within an hour of its mixing.

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3.3.7. Scaffolding:

Scaffolding shall be rigid to withstand all dead, live and impact loads which are

likely to come on them. Scaffolding shall be provided to allow easy approach to

every part of the work. Bamboos shall not be used for external scaffolding. M/S

scaffolding chair shall be used for internal scaffolding. For exposed brick facing

double scaffolding having two sets of vertical supports shall be provided. The

supports shall be sound, strong and tied together with the horizontal pieces over

which scaffolding pieces shall be fixed.

Fig. 3.2. Scaffolding on the outside of station walls

3.4. METHODOLOGY

3.4.1. Brick Work:

Best quality bricks should be well burnt clay/fly ash and even color.

When struck with something r each other it will sound clearly.

Bricks of different types, such as clay bricks, clay fly ash bricks, fly ash lime

bricks, sand lime (calcium silicate) bricks, auto-clave bricks etc. shall be

stacked separately. Bricks of different classification and size consideration

(such as conventional and modular) shall be stacked separately. Also bricks of

different types such as solid, hollow and perforated shall be stacked separately.

Should not absorb water more than 20% by weight.

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Good bricks should be sufficiently hard. Quality bricks should not break when

dropped flat on hard ground from a height of about one meter.

3.4.2. Stacking of Bricks:

Bricks shall be stacked in regular tiers as and when they are unloaded to

minimize breakage and defacement.

Bricks stacks shall be placed close to the site of work so that least effort is

required to unload and transport the bricks again by loading on pallets or in

barrows as per IS 4082.

Bricks shall be stacked on dry firm ground.

Clear distance between adjacent stacks shall not be less than 0.8m. Bricks of

each truck shall be put in one stack as per IS4082.

3.4.3. Sampling of Bricks:

The bricks shall be selected and inspected for each lot separately for

ascertaining their conformity to the requirements of the relevant specification.

The number of bricks to be selected from a lot shall depend on the size of the

lot and shall be in accordance with column 1 and 2 of table given below for

visual characteristics in all cases and dimensional characteristics if specified for

individual brick. In case dimensions are specified for a group of 20 bricks, the

scale of sampling for dimensional characteristics shall be in accordance with

col 1 and 4 of the table. All these bricks shall be selected following the methods

detailed in 3 as per IS 5454.

Visual characteristics: All the bricks selected above shall be examined for

visual characteristics. If the number of defective bricks found in the sample is

less than or equal to the corresponding number, the lot shall be considered as

satisfying the requirements of the visual characteristics. However, if the number

of defective bricks in the sample is greater than the corresponding permissible

number of defectives, the lot shall be deemed as not having met the visual

requirements as per IS 5454.

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Table 3.1. Sampling of Bricks

No. of bricks

in the lot

For characteristics specified for

individual brick

For dimensional characteristics

specified for group of 20

bricks- No. of bricks to be

selected.

No. of bricks to

be selected

Permissible no. of

defectives in the

sample

(1) (2) (3) (4)

2001-10000 20 1 40

10000-35001 32 2 60

35001-50000 50 3 80

3.4.4. Soaking of Bricks:

Brick shall be soaked in water before use for a period for the water to just

penetrate the whole depth of the bricks. Alternatively, bricks shall be adequately

soaked in stacks by profusely spraying with clean water.

Soaked bricks shall be stacked on a clean place where they are not again spoiled

by dirt, earth, etc. as per IS 4082.

3.4.5. Cement Mortar:

Make sure cement mortar is mixed properly in dry condition on a clean place.

Check mixing ratio is properly maintained.

Check clean drinking water is mixed.

Make sure the mixed mortar is used within one hour after adding water, if you

want, you can maintain register for tracking mixing time and ratio.

3.4.6. Laying of Bricks:

All loose materials, dirt and set lumps of mortar which may be laying over the

surface on which brickwork is to be freshly started shall be removed with a wire

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brush. Brick shall be laid on a full bed of mortar. The mortar joint shall be

10mm to 12mm in thickness.

When laying the bricks shall be properly bedded and slightly pressed with

handle of trowel so that the mortar can get in to all the pores of the brick surface

to ensure proper adhesion.

All the joints shall be properly flushed and packed with mortar so that no hollow

spaces are left. Care shall be taken to see that the required quantity of water is

added to the mortar at the mixing platform to obtain required consistency.

Addition of water during laying of the courses hall is not permitted.

For walls two brick thick and over the joints shall be grouted at every course in

addition to bedding and flushing with mortar.

Bricks shall be laid with frog up however when the top course is exposed, brick

shall be laid with frog down and care be taken to fill the frogs with mortar before

embedding the bricks in position.

Not more than 12 course of bricks shall be laid in a day work.

Raking shall be done with 6 to 10 mm depth.

Brick masonry & RCC structure joint shall be made by putting a wire mesh of

25x25mm before plaster work activity.

For half brick work wall shall be reinforced at every 4th course with 2Nos. 6mm

dia bars well bedded in mortar. Top layer of masonry shall be constructed after

three days.

All brick work shall be built in English bond with frog upward. Half brick wall

shall be built in stretcher bond.

Header bond shall be used for walls curved on plan for better alignment. Header

bond shall also be used in foundation footings, stretchers may be used when the

thickness of wall is more.

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Figure 3.3. Types of Brick Bond

3.5. Bricks with RCC:

Check RCC surface is properly chipped and applied grout on surface where

brick will touch with RCC.

3.6. Brick joint:

Don’t make bricks joint bigger than half-inch.

Make sure vertical joints in alternate courses are truly vertical depending on

“types of brick bond pattern.” Check horizontal joints are truly straight.

Figure 3.4. Vertical alignment in a brick wall

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3.7. Skirting of Joints:

Where no pointing, plastering or other finish is indicated the green mortar shall

be neatly struck and flush. Where pointing, plastering or other finish is

indicated, the joints shall be squarely raked out to a depth not less than 10mm

for plastering and 15mm for pointing.

3.8. Wall:

Check wall is located as per drawing at the time of making brick layout,

Don’t make wall above 5 feet in same day

3.9. Doors and Windows opening:

Check door and window location are kept as specified in the drawing.

Make sure openings are bit bigger than specified in drawing.

3.10. Alignment:

Check vertical alignment of every three courses of brick wall with plumb bob.

3.11. Lintel and sunshade:

Check lintel and sunshade above opening are made as per design specification.

Check sunshade dimensions are kept as per drawing.

Make sure cat door opening is kept in wall of false ceiling as specified in the

drawing.

3.12. Curing:

Check brick wall is cured for at least seven days with clean water.

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After making brick wall we are to start groove cutting for electrical and plumbing piping.

But this work should not be started before ending curing period of wall. Another thing, if

concrete and brick joints may develop cracks in plaster then you should use wire mesh

there before doing plaster.

Fig. 3.5. Wire mesh in brick wall

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CHAPTER 4. TILING

4.1.PURPOSE

The purpose of this procedure is laying or floor & wall tiles in the station building as

per specifications for DMRC Package CC-12.

4.2.SCOPE

This procedure covers the material for tiling work, surface preparation, mortar and

bedding, laying, grouting of joints and cleaning etc.

4.3.MATERIAL

4.3.1. Ceramic/Vitrified Tiles: The tiles shall be of approved make. The tiles shall be

flat and true to shape and free from cracks, blisters, welts, crawling, crazing spots,

chipped edges, corners or other imperfections detracting from their appearance. The

glazing shall be of uniform shape. The tiles shall be of square or rectangular of nominal

sizes as mentioned in schedule of quantities and as directed. Tolerance in thickness

shall be ±0.4mm. The underside of tiles shall not glaze on more than 5% area in order

to have proper adherence to the back.

4.4.METHODOLOGY

4.4.1. Preparation of surface and laying tile:

Subgrade concrete or RCC slab or side brick wall/or plastered surfaces on which tiles

are to be laid shall be cleaned, wetted and mopped as specified for tile flooring or

dado.

The bedding/backing for the tiles shall be of cement mortar 1:3 or as specified and

shall be applied and allowed to harden. The mortar shall be roughened with wire

brushes or by scratching diagonal lines 1.5mm deep at 7.5 mm center both ways.

The back of the tiles shall be buttered with a coat of grey cement slurry paste and edges

with cement slurry and set in the bedding mortar.

The tiles shall be tapped gently with wooden mallet and corrected to proper level and

lines.

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The tiles shall be butt joined in pattern and joints shall be as fine as possible. The top

of skirting/dado shall be truly horizontal and joints vertical.

After a period of curing the tiles shall be cleaned and not sound hollow when tapped.

Tiles shall enter not less than 10mm under side skirting.

After the tiles have been laid, surplus cement grout shall be cleaned off.

Fig. 4.1. Roughening mortar for laying tiles

4.4.2. Mortar & Bedding:

Cement mortar for bedding shall be proportion 1:4 for vitrified tiles and 1:3 for dado

wall tiles as specified in BOQ and shall conform to the specification for materials.

The amount of water added while preparing mortar shall be the minimum necessary

to give sufficient plasticity for laying.

Care shall be taken in preparation of the mortar to ensure that there are no hard lumps

that would interfere with even bedding of the tiles.

Before spreading the mortar bed, the base shall be cleaned of all dirt, scum or laitance

and loose materials and well wetted without forming any pools of water on the surface.

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The mortar of required proportion and required thickness as per BOQ shall then be

even and smoothly spread over the base by the use of screed battens to proper level or

slope.

4.4.3. Laying of tile on floor:

The tiling work shall be done as per the pattern directed by engineer in charge.

Start point of tile fixing shall be followed in accordance to the drawings issued. Cut

tiles if any shall be laid along wall with necessary border pattern.

Grey cement slurry to the back of the tile is to be applied to enure proper and full

bedding.

The tiles shall be laid on the bedding mortar when it is still plastic but has become

sufficiently stiff to offer a fairly firm cushion for tiles.

Tiles, which are fixed on the flooring adjoining the wall, shall be so arranged that the

surface on the round edge tiles shall correspond to the skirting or dado.

Press gently the tiles with wooden mallet for even adherence at the back of the tiles.

Don’t use an iron hammer or some heavy material to press the tiles.

The edges of the tiles shall be smeared with neat cement slurry and fixed in this grout

one after the other, each tile being well pressed and gently tapped with a wooden

mallet till it is properly bedded and in level with the adjoining tiles.

There shall be no hollows in bed joints. The joints shall be kept as close as possible

and in straight line the width of the joint shall not exceed 1mm. Unless specified joint

less tiling shall be done butting the tiles with each other.

The joints shall be grouted with white/matching color cement slurry.

4.4.4. Fixing wall tiles for dado/skirting:

The fixing of tiles on wall surfaces shall be done only after completing fixing of the

tiles on the floor.

The back of the tiles shall be cleaned off and covered with layer of cement slurry with

proper troweling as per manufacturer’s recommendations.

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The edges of the tiles shall be smeared with the slurry and fixed on the wall one after

the other, each tile being well pressed and gently tapped with a wooden mallet till it is

properly fixed level with the adjoining tiles.

While fixing tiles in dado/skirting work, care shall be taken to break the joints

vertically. The top line shall be touched up neatly with the rest of the plaster above.

If doors, windows or other openings are located within the dado area, the corners, sill

jambs etc. shall be provided with true right angles without any error.

The fixing shall be done from bottom of wall upward without any hollows in the bed

joints. Each tile shall be as close as possible to one adjoining. All tile faces shall be

one vertical plane.

Fig. 4.2. Fixing floor tile and tapping with a wooden mallet

4.4.5. Grouting of Joints in Floor/Skirting/Dado:

The joints, if specified, shall be cleaned off and all dust and loose particles removed.

Joints shall then be filled with grouts. After finishing the grouting process, after 15

minutes, wipe off excess grout with a damp sponge and polish the tiles with a soft and

dry cloth for a clean surface.

The finished work shall not sound hollow when tapped with a wooden mallet.

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Fig. 4.3. Grouting of floor tiles

4.4.6. Cleaning:

The tiles shall be cleaned by mild acid (however, hydrofluoric acid and its derivatives

should not be used). After the tiles have been laid in a room or the days fixing work is

completed, the surplus cement grout that may have come out of the joints shall be

cleaned off before it sets.

4.5.PLANNING

Planning, preparation and execution of the woek shall be as per a defined schedule,

following the sequence detailed mentioned above. Only latest revisions of drawings

are to be used. All concerned team shall participate in a short daily site meeting,

coordinating activities and optimizing performance.

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CHAPTER 5. WATERPROOFING

The waterproofing treatment shall be done on smooth plastered surface on brickwork only.

Portland cement shall be used for the plastering.

The plastered area shall be cured for a minimum of 7 days. Curing shall be done by

keeping wet gunny or ponding water.

The surface shall be allowed to dry for about 4 to 6 weeks after the curing period is over.

The surface on which waterproofing is to be done shall be dry, free of all dust, loose

material, laitance etc. A surface dry area shall not be constructed as being totally dry.

It should be ensured that everything where the waterproofing is worked round or into are

fixed (eg. Rainwater downtakes, etc.) in position and all pre waterproofing application

work is complete.

5.1.MATERIALS

5.1.1. Tapecrete: It is an acrylic based polymer modified cementation composite coating

system manufactured by CICO or approved equivalent.

Fig. 5.1. Tapecrete

Page | 31

5.2.WATERPROOFING OF TOILETS

Waterproofing treatment of floor slabs, walls and chajjas. Roof projections, toilets,

kitchens, etc. in the building is done as described:

1. First layer of cement slurry @0.488 Kg/m2 mixed with tapecrete @0.253Kg/m2 is

applied with brush and is allowed to air dry for 4 hours.

2. Thereafter second layer of cement slurry @0.242Kg/m2 mixed with tapecrete

@0.126Kg/m2 is applied with brush and is allowed to air cure for 4 hours followed

by water curing for 48 hours.

3. A layer of 12 mm plaster as protective layer is applied if required.

Fig. 5.2. Applying waterproofing layer

5.3.WATERPROOFING OF RAFT AND RETAINING WALLS

Waterproofing of raft and retaining walls by box type waterproofing method.

External tanking of basement, trenches, tunnel, etc. is carried out using tapecrete is

stages as given below:

5.3.1. Stage 1: After the lean concrete has been laid to receive the RCC raft, a 345

mm thick brick toe wall in cement mortar 1:6 shall be constructed, on the

perimeter of the area to be water proofed. The height of this wall shall be equal

to the thickness of the RCC raft.

5.3.2. Stage 2:

Base: The external tanking treatment is carried out for the base raft over

the lean concrete in the following sequence.

Page | 32

a. A layer of cement slurry mixed with tapecrete shall be spread over the

lean concrete.

i. In each layer where tapecrete is to be used it shall be mixed in the

ratio of 400 grams per 50kg of cement.

ii. Thereafter a 25mm thick bedding layer of cement mortar 1:3 mixed

with tapecrete shall be laid.

iii. Curing shall be done by spraying for 7 days.

iv. A layer of 25mm thick rough Kota stone slab of approximately

600x600mm and having minimum thickness of 20mm is laid. The

joints between the stones shall be 6-100mm. After laying the joints

shall be raked and sealed with cement mixed acrylic waterproofing

compound in ratio of 1:1.

v. A layer of cement mortar 1:4 mixed with tapecrete shall be laid and

finished smooth.

vi. The top surface is finished with stone aggregate of 10 to 12mm

nominal size by spreading @8cudm/m2 thoroughly embedded in 2nd

layer.

vii. Curing is done by spraying for 7 days.

viii. The waterproofing is turned up along the brick wall on the perimeter

of the basement raft. The work is carried out as described under

walls.

5.3.3. Stage 3: External tanking of walls

After the completion of the RCC raft and retaining walls upto the ground

floor level, external tanking of external surface of retaining walls shall be

carried out in the following sequence. The external tanking layer for the

walls has an overlap over the external tanking layer provided along the

brick toe wall in stage 2 and the joint sealed.

i. A layer of rough kota stone slabs of approximately 600x600mm and

having a minimum thickness of 20m are laid with with a gap of 20mm

Page | 33

between the wall and the stone. This gap is filled with cement slurry

mixed with tapecrete in ratio 1:1

ii. The joints of the stone tiles are compacted and any improperly filled

joints are raked and sealed with cement mixed with tapecrete.

iii. Curing is done by spraying for 7 days.

iv. Thereafter a 15mm thick layer of cement mortar 1:4 mixed with

tapecrete is splashed on the exterior surface of the stone wall to cover

the stone and joints thoroughly and uniformly.

5.4.TESTS

The treated area (flat and horizontal only) is tested by allowing water to stand on the

treated area to a depth of 150m for a minimum period of 48 hours. A guarantee of 15

years for waterproofing work carried out by contractor is provided on a non-judicial

stamp paper.

Page | 34

CHAPTER 6. KOTA STONE AND GRANITE WORKS

6.1.OBJECTIVE

The purpose of this procedure is laying of kota and granite.

6.2.METHODOLOGY

6.2.1. Fur Granite/Kota Flooring:

6.2.1.1. Surface and Base Preparations:

The surface is cleaned, wetted and mopped.

Cement slurry of required workability should be spread over the concreting surface.

Screed concrete/PCC should be laid in mix of 1:4:8. The nominal thickness of PCC

should be 100mm in proper slope.

The bedding for the slabs shall be with cement mortar 1:4. Average thickness of the

bedding shall be 20mm.

Curing period of PCC will be 7 days.

6.2.1.2. Laying Procedure:

Cement mortar of the 1:4 mix shall be spread under the area of each slab, upto 20mm

thick for Kota stone and 15mm thick for granite stone. The stones are cut to the

required size and cleaned before laying.

Over cement mortar, 5mm thick bed of cement paste of required workability will be

laid.

The stones shall be laid on top, pressed, tapped with wooden mallet and brought to

level with the adjoining stones. It shall be lifted and laid aside. The top surface of the

mortar shall then be corrected by adding fresh mortar at hollows.

The mortar is allowed to harden a bit and cement slurry of honey like consistency shall

be spread over the same at the rate of 44.4kg cement per square metre. The edges of

the stone already paved is buttered with grey cement with admixture of pigment to

match the shade of the stone. The stone to be paved is lowered gently back in position

bedded in level.

Page | 35

Subsequent stones shall be laid in the same manner and joints between adjacent stones

is made as thin as possible and run in straight line. After each stone has been laid, they

are joined and surplus cement grout coming out of the joints of the stones is cleaned

off.

Granite stone on wall is cladded with the help of expanded steel anchor bolt as per

specification bolted to the wall and clamped in the grove provided in the stone.

Fig. 6.1. Junction of Polished Kota and Granite Flooring

Fig. 6.2. Kota stone (left) and granite (right)

Page | 36

6.2.2. Polishing:

All granite stones shall be pre-polished and kota stones shall be polished two times

after laying on floor.

If any slab is disturbed or damaged, it shall be refitted or replaced, properly joined and

polished. The finished floor should not sound hollow when tapped with wooden

mallet.

Fig. 6.3. Kota stones laid at platform level

Page | 37

CHAPTER 7. PAINTING WORKS

7.1.METHODOLOGY

7.1.1. Paint on Exterior and Interior walls and on other concrete surfaces:

7.1.1.1. Surface/Base Preparation:

Primer of one coat has to be applied on the plastered surface.

Allow the primer coat to dry and get smoothened.

Smoothen the surface by a thin coat of putty if required.

Putty will be prepared by adding 40-50% of clean water to putty and mix thoroughly

to get homogenous mixture, this paste is allowed to stand for 15 minutes before

application. Try to use the mixed putty in 3 hours.

Sand the surface with emery paper.

Painting shall be deferred until the plastered wall and outer concrete surfaces are

completely dry.

All honeycombing, cracks, pin holes, and surface defects and uneven surfaces, if any

are repaired before starting of painting to have plain and good finish.

The wall/ceiling surfaces to be painted should be cleaned by removing masking tape

used for shuttering joints, loose particles, slurry leakages, mortar drippings, etc using

wire brush/corundum stone.

While doing the painting works, it shall be ensured that the remaining areas to be

covered/protected properly from damages.

Paint will be applied either by using brush or by using roller or by any other

conventional spray.

Page | 38

Fig. 7.1. Sanding the surface before painting Fig.7.2. Whitewashing

7.1.1.2. Application procedure painting works:

The first coat of approved paint of required consistency to be applied in both directions

as per specification starting from top over the prepared surfaces with a brush.

The second/final coat of paint with required consistency to be applied by brush

minimum after 24 hours of first coat is completed and cured properly.

The finished surface is kept wet for curing.

After completion of painting work, any paint stains on the floor/doors/windows/other

surfaces, if any, are removed and entire area is cleaned.

7.1.2. White washing (Lifts/shafts etc.):

White wash shall be done on smoothened base surface.

Application of white wash shall be done on both directions.

White wash shall be done 1st and final coat.

The finished dry surfaces shall not show any signs of cracking and peeling nor shall

it come off readily on the hand.

Page | 39

CHAPTER 8. UNDERGROUND WATER TANK

8.1.OBJECTIVE

This procedure covers the sequence of works involved in the construction activity of

underground water tank.

8.2.CONSTRUCTION METHODOLOGY

8.2.1. Layout Marking: Layout need to be marked before starting the

excavation, after layout marking from underground utilities are checked &

relocated if required. After confirming from all the agencies excavation is

started.

8.2.2. Earth works: Earth works need to be started with proper safety precautions

such as hard barricading, deep excavation sign boards and earth shoring to

prevent the collapse.

8.2.3. Binding for raft: After excavation, watering and proper compaction of the

earth need to be executed. After proper compaction binding can be done.

8.2.4. Water proofing-stage 1: After the lean concrete has been laid to receive

the RCC raft, a 345 mm thick brick toe wall in cement mortar 1:6 shall be

constructed, on the perimeter of the area to be water proofed. The height of

this wall shall be equal to the thickness of the RCC raft.

8.2.5. Concreting: Rest of the concreting works need to be executed as per the

latest structural drawing issued at site. Before concreting architectural water

tank drawing need to be referred for installing the provision of sleeves in

the wall.

8.2.6. Water proofing from inside+tiling: After completion of deshuttering,

concrete surface is cleaned and waterproofing is done as per methods

Page | 40

mentioned in waterproofing section. Inside the tank after applying

waterproofing compound, an approved tile is fixed throughout the tank

except internal roof surface.

8.2.7. Waterproofing from outside: This is executed as per waterproofing

methodology.

8.2.8. Fixing of ladders/foot rest as per requirement.

Page | 41

CHAPTER 9. ALUMINUM COMPOSITE PANEL

9.1.PURPOSE

This method statement describes the detailed procedure adopted for fixing aluminum

composite panels (ACP) in the construction of the station.

9.2.SCOPE

This procedure covers the material for fixing ACP for cladding with necessary frame

works at:

i. Concourse to platform levels.

ii. Concourse to platform level, concourse area.

9.3.MATERIAL

9.3.1. Aluminum Composite Panel: The panel should consist of thermoplastic core

of antioxidant LDPE sandwiched between skins of aluminum sheet making a total

panel thickness of 4mm. The surface will be finished with PVDF based coating on top

sides and service coating on reverse side would be in polymer paint.

Table 9.1. The approved shades are as below: For external ACP works

Station Shade/Color of ACP

Krishna Nagar Station Dark grey/Stone Black-AL625

East Azad Nagar Station Metallic Rose/Copper Bronze- AL621

Welcome Pearl White AL-630

Jaffarabad Metallic rose/Copper bronze A-621

Gokulpuri Metallic rose/Copper bronze A-621

*Internal ACP will be RAL-3014 (antique pink) for all the stations.

Page | 42

9.4.PROCEDURE:

9.4.1. For fixing of aluminum cladding sheets need to be converted into

“cassettes” as follows:

i. Aluminum composite panel sheet is cut into the required size.

ii. A ‘V’ shaped groove of 3.2mm depth is made through the inner skin leaving a

0.3mm thick polyethylene layer and the outer 0.5mm thick aluminum skin

undisturbed. The groove is made on all 4 edges of the cut sheet

iii. Folding the sheet along the groove on all the 4 sides and punching out the

overlapping corners of the “cassette” thus formed. The return or the fold back

of this cassette for the required depth.

iv. These cassettes are then installed on a frame of the aluminum sections pre-

installed on the dead wall.

Fig. 9.1. Cutting ACP into required size and making grooves in them

9.4.2. Frame for installation of Aluminum composite panels:

i. 25x38x2mm aluminum RHS sections (runner) are installed in a vertical or

horizontal direction on the dead wall. These aluminum tube sections are

Page | 43

installed on aluminum brackets to facilitate movement in horizontal direction

to achieve a true line and level. Brackets are fixed to the wall to be cladded by

means of fasteners.

ii. These panels are in turn installed to these vertical or horizontal aluminum

runners by means of angle cleats pre-installed on the return or fold back of the

panels.

9.4.3. Application of (weather) silicone sealant in the grooves formed after

installation of panels:

i. A groove of dimension for

ACP to ACP: 12mmx25mm

ACP to stone cladding: varies as per site condition

ii. These grooves are sealed with silicone sealant after application of masking tape

and polyethylene backer rod.

Page | 44

CHAPTER 10. RESPONSIBILITIES

10.1. Duties of respective individuals

Table 10.1

Site-In charge Shall report to the Project Manager. Shall be responsible for

control, safety systems, supervisions and directions for

implementation.

Site-engineer Shall report to the Project Manager/Site-In charge. Shall carry out

the work as per the drawings and specifications.

QA/QC

Engineer

Shall report to the Project Manager. Shall carry out lab, field

inspection/checking.

10.2. Organizational Chart

Figure 10.1. Organizational Chart

PROJECT MANAGER

Somesh Pandey

SHE MANAGER Suman Kumar

ASE Mr. Harish Mishra

SR. SAFETY OFFICER Day Nitesh Kumar

Mr. Amit- FIRST AIDER

SAFETY OFFICER Night Rajan

Kumar

EXECUTION INCHARGE Kailash

Nayak

QA/QC MANAGER Naveen Sinha

EXECUTION ENGINEER DAY

Shivraj

SUPERVISOR Mr. Veeru

EXECUTION ENGINEER NIGHT Mr. Raghuvendra

SUPERVISOR- Mr. Paul

Page | 45

CHAPTER 11. SAFETY

11.1. Safety guidelines

This work shall be carried out as per the guidelines of project safety manual. However,

the following specific safety precaution shall be taken.

Experienced team shall be engaged for all the activities.

The tools and tackles used for the works shall have test certificates for the

safe carrying loads.

Proper precaution and safety devices shall be used for activities like

fabrication, handling of electrically operated equipments etc.

All site personnel shall follow the safety health and environment policy of

the company and client.

Fig. 11.1. Posters at the entry to promote safety.

Page | 46

11.2. EMERGENCY RESPONSE PLAN

Fig. 11.2. Detailed action plan as shown shall be followed in an event of emergency.

Page | 47

CHAPTER 12. LAB TESTS PERFORMED ON VARIOUS BUILDING MATERIALS

12.1. Sieve Analysis of Fine Aggregate for use in Masonry Mortars and Concrete

This test is done as per specifications given in IS:2386(Part-1)-1963. Sieve Analysis

helps to determine the particle size distribution of aggregate. In this test, different IS

standardized sieves are arranged in decreasing order of size and aggregate is passed

through them. The aggregate retained on each sieve is then weighed. The sample

should be prepared from a larger sample by quartering or by means of a sample

divider.

Fig. 12.1. Reporting of Sieve Analysis results

Page | 48

12.2. Brick Tests

12.2.1. Dimension Test

A number of bricks are selected at random (see sampling of bricks) to check

measurement of length, width and height. These dimensions are to be measured

in one or two lots of equal number of bricks each. Variation in dimension are

allowed only within narrow limits

12.2.2. Water Absorption

A sample number of bricks are taken and weighed dry and average weight of

the bricks is calculated. Bricks are then immersed in water for a period of 24

hours. After 2 hours of immersion, bricks are weighed again and average of the

bricks is calculated. The difference of final average weight and initial average

weight indicates the amount of water absorbed by the bricks. It should not, in

any case, exceed 20% of average weight of dry bricks.

12.2.3. Compressive Strength Test

Three number of whole bricks from sample collected should be taken and their

dimensions should be measured to the nearest 1mm. They should be

smoothened and immersed in water at room temperature for 24 hours. Remove

specimen and drain surplus moisture. Fill frog and all voids with cement mortar

(1:1). Store under damp jute bags for 24 hours filled by immersion in clean

water for 3 days. Remove and wipe any traces of moisture and test the bricks

under Compressive Testing Machine.

Compressive Strength= Maximum load at failure(N)/Average area of bed face

(mm2).

12.2.4. Efflorescence Test

The test is conducted in a well ventilated room. The brick is placed vertically

in a dish 30cmx20cm approximately in size with 2.5 cm immersed in distilled

water. The whole water is allowed to be absorbed by the brick and evaporated

Page | 49

through it. After the bricks appear dry, a similar quantity of water is placed in

the dish, and the water is allowed to evaporate as before. The brick is to be

examined after the second evaporation and reported as follows:

Nil When there is no perceptible deposit of salt.

Slight When not more than 10% of the area of bric is covered with salt

Moderate When there is heavy deposit covering more than 50% of the area

of the brick but unaccompanied by powdering or flaking of the

surface

Heavy When there is heavy deposit covering more than 50% of the area

of the brick accompanied by powdering or flaking of the surface

Serious When there is heavy deposit of salts accompanied by powdering

and/or flaking of the surface and this deposition tends to increase

in the repeated wetting of the specimen

Table 12.1. Reporting of efflorescence test results

Page | 50

Fig. 12.2. Reporting of Brick Test results

Page | 51

12.3. Granite and Kota Stone test

12.3.1. Specific Gravity

The specific gravity is considered to be a measure of strength or quality of the

material. Stones having low specific gravity are generally weaker than those

with higher specific gravity values.

12.3.2. Water Absorption Test

12.3.3. Compressive Strength Test

12.3.4. Hardness Test (Mohr’s Scale)

Hardness is a measure of mineral’s resistance to abrasion and is measured

against a standard scale- Mohr’s scale of hardness. Its consists of 10 fairly

common minerals (except for diamond) of known hardness which are

numerically ordered from softest (1) to hardest (10). As common sense dictates

Mohr’s scale is based on the fact that a harder material will scratch a softer one.

By scratch test, one can determine relative hardness of an unknown material.

Table 12.2. Mohr’s Scale of Hardness

Talc

(H=1)

Gypsum

(H=2)

Calcite

(H=3)

Flourite

(H=4)

Apatite

(H=5)

Orthoclase

(H=6)

Quartz

(H=7)

Topaz

(H=8)

Corundum

(H=9)

Diamond

(H=10)

Page | 52

Fig. 12.3. Report of Kota and Granite Stone Results

Page | 53

CHAPTER 13. CONCLUSION

My training at DMRC has been enriching and this experience has been very valuable to

me. I enjoyed my position and gained good first-hand experience on various aspects of

Civil Engineering discipline. This training has also taught me what it is like to work at a

reputable firm at DMRC feels like, and how exciting it is to be a part of big projects. My

interests in the field of Civil Engineering have deepened even further with this experience

and it is clear that this was a great start for my dream career.

This experience has also taught me that learning is an endless process, and there is so

much left to learn.

I have acquired many skills in my arsenal and sharpened the ones that I already had

including creativity, innovation, leadership, working in a team based environment,

problem solving both on and off site.

Page | 54

REFERENCES

[1] DMRC Website: www.delhimetrorail.com

[2] JMC-CHEC JV Website: www.jmcprojects.com

[3] www.civilsimplified.com

[4] Wikipedia: en.wikipedia.org/wiki/Pink_Line_(Delhi_Metro)

[5] Google Maps: maps.google.com

[6] Indian Standard Codes

IS12894: Pulverized Fuel Ash-Lime Bricks

IS3812: Specification for Pulverized Fuel Ash

IS712: Specification for Building Limes

IS 1077: Common Burnt Clay Building Bricks

IS13757: Burnt Clay Fly-Ash Building Bricks

IS5454: Methods of Sampling of Clay Building Bricks

IS8112: Specification for 43 Grade OPC

IS2116-1980: Sand for Masonry Mortars

IS456:2000: Plain and Reinforced Concrete

IS4082: Recommendation on Stacking &Storage of Construction Materials

IS2386(Part-1): Methods of tests for Aggregate on Concrete

Page | 55

Turnitin Originality Report

Processed on: 05-Aug-2016 22:54 IST

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finishing work By Siddharth Srivastava

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