Visit To A Construction Site

SITE NAME: PRAMUKH ELYSIUM

SITE DEVELOPER : PSY PROJECTS, GANDHINAGAR

SITE ADDRESS: Pramukh Elysium,

Beside Zion Bungalows,Opp. Pramukh
Oasis, S.G. Road, Sargasan,
Gandhinagar. (T.P. Scheme no.-9)

SITE WEBSITE: www.psyprojects.com/www.pramukhelysium.com

CONTACT NUMBER:- 090991 69633, 09638151010

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Materials listed out during site visit:-
A)Concrete Materials:
1) Cement
2) Fine aggregate
3) Coarse aggregates

B)Masonry Materials:-
1) Brick blocks
2) Stone blocks
3) Gypsum blocks
4) Mortar

C)Metals:-
1) Iron
2)Steel
3)Aluminium

D)Wood and Plastics

E)Finishing Materials:-
1)Ceramic Tiles
2)Glass

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Importance and uses of all the above listed materials are as follows:-

A)Concrete
1)Cement:-
A cement is a binder, a substance used in construction that sets and hardens and
can bind other materials together. The most important types of cement are used
as a component in the production of mortar in masonry, and of concrete, which is
a combination of cement and an aggregate to form a strong building material.
Cements used in construction can be characterized as being
either hydraulic or non-hydraulic, depending upon the ability of the cement to
set in the presence of water
Uses of cement are:

1. It is used in mortar for plastering, masonry work, pointing, etc.

2. It is used for making joints for drains and pipes.
3. It is used for water tightness of structure.
4. It is used in concrete for laying floors, roofs and constructing lintels, beams,
stairs, pillars etc.
5. It is used where hard surface is required for the protection of exposed
surfaces of structures against the destructive agents of the weather and
certain organic or inorganic chemicals.
6. It is used for precast pipes manufacturing, piles, fencing posts etc.
7. It is used in the construction of important engineering structures such as
bridges, culverts, dams, tunnels, light houses etc.
8. It is used in the preparation of foundations, water tight floors, footpaths
etc.
9. It is employed for the construction of wells, water tanks, tennis courts,
lamp posts, telephone cabins, roads etc.

2)Aggregates:

Aggregates are inert granular materials such as sand, gravel or crushed stone that
are an end product in their own right. They are also the raw materials that are an
essential ingredient in concrete. For a good concrete mix, aggregates need to be

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 clean, hard, strong particles free of absorbed chemicals or coatings of clay and
other fine materials that could cause the deterioration of concrete.In the UK we
are self-sufficient in aggregates and produce 99.98% of all that we
consume. Aggregates, which account for 60 to 75 percent of the total volume of
concrete, are divided into several distinct categories, and are either coarse or
fine:

Coarse aggregates:-Coarse aggregates are particles greater than 4.75mm, but

generally range between 9.5mm to 37.5mm in diameter. They can either be from
Primary, Secondary or Recycled sources. Primary, or 'virgin', aggregates are either
Land- or Marine-Won. Gravel is a coarse marine-won aggregate; land-won coarse
aggregates include gravel and crushed rock. Gravels constitute the majority of
coarse aggregate used in concrete with crushed stone making up most of the
remainder.

Secondary aggregates are materials which are the by-products of extractive

operations and are derived from a very wide range of materials

Recycled concrete is a viable source of aggregate and has been satisfactorily used
in granular subbases, soil-cement, and in new concrete. Recycled aggregates are
classified in one of two ways, as:

1. Recycled Aggregate (RA), or as

2. Recycled Concrete Aggregate (RCA).

Fine aggregates:-Fine aggregate are basically sands won from the land or the
marine environment. Fine aggregates generally consist of natural sand or crushed
stone with most particles passing through a 9.5mm sieve. As with coarse
aggregates these can be from Primary, Secondary or Recycled sources.

Lightweight aggregates:-Lightweight aggregates are manufactured from natural

materials or from the manufacture or processing of industrial by-products. The
required properties of the lightweight concrete will have a bearing on the best
type of lightweight aggregate to use.

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1) Brick Masonry:-

A brick is building material used to make walls, pavements and other elements in
masonry construction. ... A brick can be composed of clay-bearing soil, sand, and
lime, or concrete materials.

Brick plays very important role in the field of civil engineering construction. Bricks
are used as an alternative of stones in construction purpose. Here some main
uses of construction brick are given below.

 Construction of walls of any size

 Construction of floors
 Construction of arches and cornices
 Construction of brick retaining wall
 Making Khoa (Broken bricks of required size) to use as an aggregate in
concrete
 Manufacture of surki (powdered bricks) to be used in lime plaster and lime
concrete

2)Stone masonry:-

Stone is the one of the major building materials. It is a versatile material and
hence it can be used from the foundation to the parapet in a building and hence
the scope comprises the study of use of different stones at these places.Stone has
been used as a building material for thousands of years. It has long been
recognised as a material of great durability and superior artistic quality, the
foremost choice for buildings associated with status, power and religion.

Uses of stones:

 Sandstone is a popular stone with sculptors.

 Good and durable construction material
 Thresholds and steps in manor houses
 War memorials in the 19th and 20th centuries
 Limestone for burning lime and also for manufacture of cement
 Limestone as a flux in blast furnaces
 Insulators in electrical appliances

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3)Mortar:-

Mortar is used to hold building materials such as brick or stone together. It is

composed of a thick mixture of water, sand, and cement. The water is used to
hydrate the cement and hold the mix together. The water to cement ratio is
higher in mortar than in concrete in order to form its bonding element.

4)Gypsum Blocks:-

Gypsum block is a massive lightweight building material composed of solid

gypsum, for building and erecting lightweight fire-resistant non-load bearing
interior walls, partition walls, cavity walls, skin walls and pillar casing indoors.
Gypsum blocks are composed of gypsum plaster, water and in some cases
additives like vegetable or wood fiber for greater strength. Partition walls made
from gypsum blocks require no sub-structure for erection and gypsum adhesive is
used as bonding agent, not standard mortar. Because of this fundamental
difference, gypsum blocks shouldn't be confused with the
thinner plasterboard (also known as wallboard or gypsum board) used for
paneling stud walls.

C)Metals:-

Chosen for their durability, strength and resistance to weather, metals used in the
construction industry serve a wide range of functions. The most common of them
are carbon steel, aluminum, copper tubing and stainless steel, which each have
their particular qualities and ideal uses. As a whole, however, these metals are
ubiquitous in the world of buildings and architecture, in applications both small
and large.

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Carbon steel is one alloy that is prized in
the construction industry for its hardness
and strength. It is typically used to make
beams for structural framework, plates for
highway construction, and rectangular
tubing for welded frames trailer beds, and
bridges. It is also a material of choice to
make rebar and hollow structural sections
(HSS). Made by mixing carbon and iron
together, carbon steel is classified on a
scale of “mild” to “very high,” depending
on how much carbon is present in the
metal.

Aluminum is also commonly used in the industry because it is resistant to

corrosion, highly conductive and ductile. Because it is resistant to harsh weather,
the metal is used in windows, doors, and wire, as well as outdoor signage and
street lights.Mainly metals usd in construction work in India are 1)Iron 2) Steel 3)
Aluminium

D)Wood and Plastics

Wood-plastic composites are still new materials relative to the long history of
natural lumber as a building material. The most widespread use of WPCs in North
America is in outdoor deck floors, but it is also used for railings, fences,
landscaping timbers, cladding and siding, park benches, molding and
[3]
trim, window and door frames, and indoor furniture. Wood-plastic composites
were first introduced into the decking market in the early 1990s.
Manufacturers[who?] claim that wood-plastic composite is more environmentally
friendly and requires less maintenance than the alternatives of solid wood treated
with preservatives or solid wood of rot-resistant species. These materials can be
molded with or without simulated wood grain details

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E)Finishing Materials:-

1)Ceramic Tiles: ceramic tiles have quickly become one of the most popular types
of materials used in a home but often times home owners don’t understand
exactly what they are. Ceramic tile is made up of sand, natural products, and
clays and once it has been moulded into shape they are then fired in a kiln. When
making ceramic tiles they can either be glazed or unglazed, but the majority of
homeowners have glazed ceramic tiles in their home. With their increasing
popularity, there are hundreds of different designs of ceramic tiles. If you are
considering changing your flooring, it is important to consider the advantages
associated with using these tiles in your home.

2)Glass :The "Glass and Glazing" section of construction specifications contains a

wide range of materials. These may include sheet glass, plate glass, heat- and
glare-reducing glass, insulating glass, tempered glass, laminated glass, and various
transparent or translucent plastics. Also included may be ceramic-coated,
corrugated, figured, and silvered and other decorative glass. Additional materials
may include glazier’s points, setting pads, glazing compounds, and other
installation materials.

Its uses are:

1)Sheets/Window

2)Plate

3)Heat abortion

4)Glare reflection

5)insulation and safety

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 MANUFACTURING SITE VISIT

Site:- SIWQ (Sayaji Iron Works Quarry)

Site Adrress:- Sayaji Iron Works Quarry Pvt. Ltd.

Udalpur crossing, Sevalia, Mahisagar.

Date of Visit:- 20/08/2016 (Saturday)

Time of visit:- 10am – 3:30pm

Weather:- Moderate Rainy

Total Area:- 289 Acres

Mined:- 37 Acres

Forest:- 106 Acres

Official Accompanying:- Bharat Patel

General Manager(Explosive and Production)

Exp:- 21yrs, Contact:- 9099044020

Purpose of Visit:- In order to know more about the quarrying and

Crushing Unit of Capacity 250 tons per hour.

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 Introduction:

On August 20, as per the requirement of our BCM project work we went on a
visit to a manufacturing site i.e. a quarrying unit also comprising of a crusher
unit for manufacturing of aggregates of different sizes.

The visit included a full trip around the premises and some of the key locations
where we got to learn important things are:

 Operating base where all staffs were present.

 Blasting point where blasting of rocks was organized.
 Explosive materials and other chemicals storage room.
 Crusher setup.
 Whole process from raw material to aggregates of different sizes.
 Control room of all the processes.
 Near the heaps of aggregates.
 Workshop for repairing all heavy machineries involved.
 Green areas covering the remaining areas.

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 Objective and Focus of Site visit:-

As per the guidelines of our project we first visited a construction site and
listed out several materials which are being used in the construction activities.
From those materials we selected two important materials on which we need
to throw some more light. Those two materials are Coarse aggregates and
cements. So in order to do so we decided to visit the manufacturing unit of
Cement as well as coarse aggregates i.e. JK Laxmi Cement and SIWQ mines
respectively. Hence our main objective and focus of this visit is to know more
about coarse aggregates and their way of manufacturing also including the
factors affecting their formation. We also wanted to know more about the
machineries involved in these kind of operations.

Prior to our visit we have informed the concerned official at that quarrying
plant so that they can do the preparation for performing the task of blasting
the rocks and explain the whole process of blasting. The whole process of
blasting is a tedious one since several things are need to be done with proper
care including the explosion work.

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 General Observations:-
1.From the mines the kind of rock that we get is basalt. Basalt is a
common extrusive igneous (volcanic) rock formed from the rapid cooling of
basaltic lava exposed at or very near the surface of a planet or moon. Flood
basalt describes the formation in a series of lava basalt flows. By definition,
basalt is an aphanitic (fine-grained) igneous rock with generally 45-55% silica
(SiO2) and less than 10% feldspathoid by volume, and where at least 65% of
the rock is feldspar in the form of plagioclase. It is the most common volcanic
rock type on Earth, being a key component of oceanic crust as well as the
principal volcanic rock in many mid-oceanic islands, including Iceland, and the
islands of Hawaii. Basalt commonly features a very fine-grained or glassy
matrix interspersed with visible mineral grains. The average density is 3.0
gm/cm3. Basalt is defined by its mineral content and texture, and physical
descriptions without mineralogical context may be unreliable in some
circumstances. Basalt is usually grey to black in colour, but rapidly weathers to
brown or rust-red due to oxidation of its mafic (iron-rich) minerals into
hematite and other iron oxides and hydroxides. Although usually characterized
as "dark", basaltic rocks exhibit a wide range of shading due to regional
geochemical processes.

2. Whole blasting process is carried out by the method of drilling and blasting.
Drilling and Blasting is the controlled use of explosives and other methods such
as gas pressure blasting pyrotechnics, to break rock for excavation. It is
practiced most often in mining, quarrying and civil engineering such as dam or
road construction. The result of rock blasting is often known as a rock cut.
Drilling and Blasting currently utilizes many different varieties of explosives
with different compositions and performance properties. Higher velocity
explosives are used for relatively hard rock in order to shatter and break the
rock, while low velocity explosives are used in soft rocks to generate more gas
pressure and a greater heaving effect.

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 3. Loading and transporting of all the blasted material from the point of
blasting to starting point of crushing unit.

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 4. Construction aggregate, or simply "aggregate", is a broad category of coarse
particulate material used in construction, including sand, gravel, crushed
stone, slag, recycled concrete and geosynthetic aggregates. Aggregates are the
most mined materials in the world. Aggregates are a component of composite
materials such as concrete and asphalt concrete; the aggregate serves as
reinforcement to add strength to the overall composite material. Due to the
relatively high hydraulic conductivity value as compared to most soils,
aggregates are widely used in drainage applications such as foundation and
French drains. Aggregates are also used as base material under foundations,
roads, and railroads. In other words, aggregates are used as a stable
foundation or road/rail base with predictable, uniform properties (e.g. to help
prevent differential settling under the road or building), or as a low-cost
extender that binds with more expensive cement or asphalt to form concrete.

Types of aggregates:

1.Fine aggregates i.e. dust (300micron and greater)

2 Coarse aggregates

 Kapachi 10-40 mm
 Grit 4.72mm- 10 mm

50mm and 30mm aggregates

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 Very small aggregates.

Summary:-
Overall from this visit to the mines we learnt about several things that will be very
helpful for us in our coming future:

1. About different kind of license and other permission that are required for
the working of a mine.
2. How is blasting done with the help of several chemicals.
3. What are the precautions that we need to keep in mind while storing the
explosives at our site.
4. The kind of heavy machineries that are required for quarrying.
5. About the basalt rock since it is basic raw product for our site.
6. How the crushing unit functions.
7. What is done to the land area after completion of mining.
8. About different types of coarse aggregates and their demand.

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 Visit to a manufacturing unit :
Purpose : To get the knowledge about the manufacturing process of
Cement.

“J.K. LAKSHMI CEMENT LTD.”

A visit to the J.K. Lakshmi cement LTD. Was arranged by the institute
of Technology , Nirma university to give some idea to the students about the
manufacturing of cement. The date of the visit was 24th October,2016. The unit
which we visited was basically one of the gridding unit of J. K. Lakshmi cement.
This unit is situated in Kalol ,Gujarat. They also have these type of Grinding unit in
jhajjhar & Haryana. They are recently producing OPC 53 and PPC cement as they
have told us about it.

The manufacturing unit which is located in Sirohi, Rajasthan has

been rated among the top Greenest Cement Plants of India. Limestone which
are being used in the manufacturing of this Cement is known to be of a higher
quality which results in the higher strength and durability of the OPC 53 and
PPC. This manufacturing plant uses extreme modern technology and imported
machinery.

These are some awards won by J.K. Lakshmi cement LTD. :

 the Productivity Excellence Award 2007-08

 Energy Conservation Award 2008, NCB award 2007
 Building Leadership Award 2007
 National Award for Environmental Excellence & Energy Management
2007
 ICWAI National Award 2007 for Excellence in Cost Management
And many others.

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 Manufacturing procedure of cement:

As, they have different basic plants in different area. So, they are arranging
the materials form their one plant to another (Based on the type plant).

 The basic raw material for the production of any cement which is
Clinker , They are bringing it from their mother plant Sirohi
(Rajasthan).
 Some % of Fly Ash which is required , they get it from thermal power
plant , Gandhinagar.
 Gypsum from Ahemedabad.

In the plant, they have different sections to store these raw materials. Like an
example they have 2 silos , which have the capacity of storing 30-150 ton. Then,
they have system of automatic way bridge to load and unload the truck carrying
materials. Truck of clinker unload in storage yard & Also same for gypsum. Now
both the materials are transferred for grinding through conveyor belt for the
grinding purpose. Ball mill is used for crushing the clinker ,meanwhile they add
gypsum through it. It is the procedure for OPC . For ,PPC they add Fly ash
according to the fixed proportion. Then, it is transferred to the silos. Then ,the
batching process is done . Packing of the cement bags take place at the end.

Testing of the cement :

Before sending the cement bags for any type of the use ,they
check the various properties of the cement ,which they have produced. They have
their own laboratory which is probably named as Chemical Lab, and their own
engineers to check properties. It includes Physical and Chemical tests.

1. Physical Tests: These are some physical characteristics of the

cement to be checked.

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  initial setting time :- 30 minutes (Which is the standard value)

 final setting time :- 600 minutes ( 10hrs)

 Compressive Strength of cement :-

 at 3, 7, 28 days
 proportion 1:3(cement: sand)
 Soundness test :- 1-2 mm
 Sieve analysis for fineness of the cement :
 45, 90 micron sieve size

2) Chemical Test: -
Chemical composition :

At 25 degree temperature

Content of lime 62-63 %

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 SILOS

 After watching laboratory tests we moved to visit the processing plant. At

there we visited clinker filled in silos. We have seen three big silos placed in
raw. They have nicely explained us about that three silos. The first one
contains clinker only. The last one contains gypsum only. And the middle
one is the spare silo. They use it as per the requirement whether it may
contains clinker or gypsum. The amazing thing is that they are connected to
the ball mill with gauge line.

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 BALL MILL

 Ball mill is the equipment used to grind hard, nodular clinker from the
cement kiln into the fine grey powder that is cement. Most cement is
currently ground in ball mill and also vertical roller mills which are more
effective than ball mills.
 Generally the ball mill has 10MW supply. It means that the revolution of
motor connected with ball mill has around 800rpm. And the revolution of
ball mill is around 16rpm. They have nicely explained us about components
of ball mill.

 Motor speed = 800rpm

 Diameter = 5 meters
 Size of balls(chamber 1) = 60-80 mm
 Size of balls(chamber 2) = 15-40 mm
 Ball mill speed = 16rpm

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  After that the clinker with gypsum finely crushed powder move to
the packing plant.

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 PACKING PLANT

 We visited to the packing plant which was in campus of cement plant. J K

Lakshmi has used new technology at their plant to placing the cement bags
into the truck. They have also used great technology to pack the cement
bags.
 They have used roller conveyer belt on which cement bags can be carry out
to the next station. At next station they are using specially designed
machine to place the cement bags into the truck. The machine itself can fit
into the truck and from conveyer belt it ascends the bags into truck layer by
layer. this technology has reduced the labour work.

RAIN HARVESTING SYSTEM

 J K Lakshmi also made a rain harvesting system inside it’s plant. so that they
can use that water in needy days. Also they have set up a sewage plant
from which they can make a fertilizer and use it to grow more greenery. In
short we can say it is green plant.

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