4 Final Report

NMPT Internship Report
CHAPTER 1
COMPANY PROFILE
1.1 GENERAL
The Mangalore Harbour Projects Started in 1962, was completed in May, 1974. Till 31st March
1980, the Government of India centrally administered both Project and the Port.
On 1st April 1980, the Port Trust Board was set up under the Major Port Trust Act, 1963. Since
then Port has been functioning as the 10th Major Port Trust and has fallen in line with other
Major Port Trusts functioning in the country.
The New Mangalore Port, the only Major Port of Karnataka was declared as the 9th Major Port
on 4th May 1974.The Provisions of the Major Port Trust Act 1963 were applied to NMPT with
effect from 1-4-1980.
The New Mangalore Port is an artificial lagoon harbour located mid way between Mormugao
and Cochin on the West-Coast of India. The port was declared as the ninth major port during
May 1974 and was commissioned during May 1975. The provisions of the Major Port Trust
Act, 1963 were extended to this port with effect from April,1980. Figure 1.1 shows the location
of the port. The Port has been developed in three stages.
Since then the Port has been functioning as a catalyst for the economic development of this
region and cater the needs of the shippers. Over the years the Port has grown from the level of
handling less than a lakh tones of traffic during the inception period to 39.40 million tones.
The major commodities exported through the Port are Iron Ore Concentrates & Pellets, Iron
Ore Fines, POL Products, Granite Stones, Containerized Cargo, etc. The major imports of the
Port are Crude and POL products, LPG, Coal, Limestone, Timber logs, Finished Fertilizers,
Liquid Ammonia, Phosphoric Acid, Other Liquid Chemicals, Containerized cargo, etc.
Dept. of Civil Engineering, BIT, Mangalore Page 1

NMPT has been committed to quality, innovation, design, professionalism, honesty,

transparent and fair business dealings. They have completed several prestigious projects in
and around the port.
Figure 1.1: New Mangalore Port Trust
1.2 WORK STRATERGY
The New Mangalore Port has been ever responsive to the changing needs of maritime trade.
The route to success is paved with adoption of modern technology and providing quality
services. Immediate attendance to ships – Berth on arrival is provided. Round-the-
clock navigation and berthing and unberthing of ships is done. They have Green channel
delivery for Star Trading Houses. There is an uninterrupted supply of power. NMPT has a high
security coverage for the protection of ships and cargo. Sufficient covered and open storage
area near the berth for storage of cargo. There Ample open storage area inside the Security
Compound Wall.
1.3 BUSINESS POLICY
The NMPT’s Commitment and endeavor is to provide best services to the satisfaction of the
customers. Port users are our valued customers and our partners in the growth of the port.

1.4 QUALITY POLICY
NMPT is committed to provide safe and cost effective services related to Seaport facilities at,
meeting applicable Statutory and Regulatory requirements. Figure 1.2 represents logo of New
Mangalore Port Trust.
They also strive for protection of Environment, Service excellence and enhancement of
Customer satisfaction through the use of an effective Quality Management System and
Continual improvement of all our processes.
Figure 1.2: Logo of New Mangalore Port Trust.
1.5 VISION AND MISSION OF THE COMPANY

1.5.1 Vision of the Company
To be a professional provider of Port Infrastructure and services of world class standards.
1.5.2 Mission of the Company
To become one of the leading liquid and multicar go port in India by adopting the state of the
act technology Infrastructure and cargo handling system, complying environmental, social,
safety and security standards.

CHAPTER 2
ABOUT THE COMPANY
2.1 ABOUT THE DEPARTMENT
Being an ISO 9001: 2000 port, the New Mangalore Port strives to provide efficient service to
its customers through its specialized departments/divisions. The main functions of the
departments/divisions are explained in this section.
2.2 ADMINISTRATION DEPARTMENT

The Administration Department looks after the general administration, human resources
development and management in New Mangalore Port, conducting board meetings, Public
Relation, all personnel matters of Ministerial Staff and officers, training, co-ordination,
Implementation/promotion of Official Language Hindi monitoring court cases in different
courts and maintaining harmonious Industrial Relations.
2.3 CIVIL ENGINEERING DEPARTMENT

Main functions and responsibilities of Civil Engineering Department are construction and
maintenance of wharves, transit sheds, various buildings, roads including residential
accommodations in the Port area and the Management of Port estate. Dredging is also carried
out by Civil Engineering Department. The Water supply both for wharf and quarters of NMPT
is under the Civil Engineering Department. The planning and development project in future
construction is also with the Civil Engineering Department.
2.4 SAFETY DEPARTMENT
Safety is very important in construction industry. Human life is irreplaceable, which is

susceptible of minor infections. Now a day it has become common to hear accident on the
construction industry. More accidents are becoming redundant the responsibility of the
contractors and the attention to give to safety of the workers is progressing to be paramount.
Therefore, it cannot be denied to work on increasing the safety condition of the site. The most
effective way of avoiding risks is the preventive strategy.

As the health professionals use to say “prevention is better than cure”, it is more than
reasonable to be abide by such motto. Less concerned safety rule, regulation and training are
among the problem in the site.
Safety of all working staffs and visitors should be observed to a highest care. Infliction of
injury shall be minimized. For this prior readiness is very important. The safety management
is carried out with a special superintendent to be assigned on site. The superintendent will be
assisted with a dresser to be employed for the site. Safety of the workers and visitors will be
managed in the following strategies.
2.4.1 General Rules
 The work should start daily at 8:30 hours.

 Labour entry should be made at main gate by (subcontractor) authorized
representative.
 Workers below 18 years and above 60 years should not be allowed for work.
 Physically handicapped persons are strictly restricted for the work.
 Liquor / Alcoholic substances consumption is strictly prohibited.
 Worker should not drink contaminated water. They should drink only municipality
water available at site.
 The building should be free from all debris at all times. After the day’s work all the
debris should be collected and stored in the bags. Defaulters will be penalized.
2.4.2 General Safety Rules
 While at site, everybody should wear safety helmets and safety shoes, while working
at height, safety belts must be used and it should be hooked at a permanent structure
at higher level (minimum 1 meter).
 Masons and their helpers must use hand gloves to protect their hands.
 Carpenters / bar benders must use safety goggles while nailing / cutting rods.
 Every subcontractor must have first aid box with cotton, iodine (tincture) and
bandage cloth.
 All Electrical bulbs, lights should be switched off after their day’s works.

2.4.3 Form Work /Concreting
 All site Mix Concrete to be done after sand sieving.

 All Binding Wire Nails loose materials, chipping and saw dust shall be removed
from the interior of the forms before the concrete is placed.
 The form work in contact with the concrete shall be cleaned and thoroughly wetted
and treated with none staining oil or any other approved materials.
 All joints in shuttering shall be leak proof.
 All form work shall be removed without shock or vibration and shall be eased off
carefully in order to allow the structure to take up its load gradually.
 While de-shuttering, any honey comb observed to be rectified immediately without
any cost.
 Providing adequate number of props at suitable spacing so as to support the weight
of wet concrete, work men pouring, vibrator due to equipments till form work is
removed.
 Any leftover concrete should used and no wastage is to be allowed.
 Shear keys are to be provided at the beginning of every concreting.
 Cost of rectification work for bulging of concrete surface, slurry leakages etc
because of bad workmanship improper support by the contractor shall be debited to
their account as per actual
2.4.4 Reinforcement Steel
 Straightening, cutting, bending, conveying, hoisting and laying in position.

 Providing 18G back annealed binding wires in two folds at every intersection of two
rods.
 Providing PVC cover blocks as specified.
 Works at all heights and situation.
 Binding wire to be consumed at 2KG/MT.

2.5 MECAHNICAL ENGINEERING DEPARTMENT
The mechanical Engineering Department is responsible for the procurement, operation,

maintenance and disposal of mechanical and electrical equipments of the Port. The wharf
cranes, mobile cranes, Fork Lift Trucks, Weigh Bridges, Diesel generator and other
equipments are regularly serviced and maintained to offer round the clock service to the port
users. Besides, the central stores division procures various spares and consumables from time
to time on need basis. Also, the unserviceable and condemned machinery, machinery parts,
vehicles and other relate scrap is disposed off through central stores. All Port vehicles are
serviced and repaired periodically to ensure availability throughout.
2.6 TRAFFIC DEPARTMENT
The main functions of Traffic Department are planning for the vessel to be Berthed and
the vessel movements. Planning for cargo / handling, loading / unloading, operation of ship,
transit operation, receipt and delivery operation, yard / warehouse storage operation, railway
operation for the movement of cargos. Some of the commercial functions of traffic department
are generating and furnishings data for collecting cargo related charges like wharf age,
equipment related charges, demurrage as well as documentation aspects. The department takes
care of marketing functions, management services, dock safety units are working under the
traffic manager.
2.7 MARINE DEPARTMENT
The main functions of Marine Department are general conservancy and waterfront operations
pertaining to Pilotage of ships of this Port and ensure safety and look after firefighting
arrangements, providing tugs, pilots for piloting vessels, maintain tugs and all floating crafts
in a good condition for service. Deputy conservator is also responsible for crisis management,
VTMS & ISPS.

2.8 FINANCE DEPARTMENT

Important functions of Finance Department are general accounting, revenue collection,
establishment, contractual payments, cost analysis, budgeting, auditing and advising to the
Chief executives regarding financial matters. EDP unit is also functioning under this
department.
2.9 MEDICAL DEPARTMENT

The Port Trust Hospital is extending medical facilities not only to the Port employees/dock
workers and their families but also to the CSIF Resident Audit Office Staff and their families,
Pensioners and also coast guard, radio wind observatory, customs on payment basis and also
extending emergency treatment for outsiders. Some of the major /minor surgeries are being
carried out in the PTH Operation theatre.
2.10 VIGILANCE DEPARTMENT

A close monitoring is maintained by the chief Vigilance Officer of the port trust on the various
activities of the Port where corrupt practices are likely to be committed by the employees. All
complaints received by the Vigilance are promptly and properly investigated and action taken
as per rule. Port users /employees can submit complaints regarding misuse of Port fund or
corruption to the Chief Vigilance Officer. Vigilance Department is also closely involved in
system improvement to prevent corruption in different areas.
2.11 QUALITY DEPARTMENT
Quality of the products in construction site is very important. The company quality assurance
manager is the representative of the project and had the responsibility for the implementation
and maintenance of the quality management system. The quality control manager has the
responsibility of the coordination and inspection of all procured items for site. Quality
assurance manager ensures the quality of the site installations is consistent with the company’s
policy requirements together with national and international standards and the customer
specification. Manager ensures the verification of documentation and certificates for materials
purchased by vendors and also reviewing of site purchase orders to ensure that the applicable
requirements are met.

Good quality material is implemented on site is very necessary. The maintenance of the quality
of the work is the main objective of the company. The company quality management system
performs various activities to maintain the quality of the work and materials. The quality
manager ensures the quality of the site works and respective materials that are procured at the
site.
2.11.1 Tests Conducted on Site
The quality management team ensures the verification of various materials purchased from
vendors by conducting respective tests according to the standard specification. The various
tests conducted in the site are as follows
2.11.2 Sieve Analysis
Sieve analysis is one of the main tests conducted to determine the size range of the particles.
 It is one of the mechanical analyses for the determination of size range of particles
present in aggregates.
 It is for particle size larger than 0.075mm in diameter.
 Sieve analysis consists of shaking the sample through a set of sieves that have
progressively smaller openings.
2.11.3 Slump Test
Slump test is conducted in the RMC plant itself. In rear cases if needed then only in site also
test will be conducted. In the time of concreting slump value of concrete at RMC plant is
maintained about 120±5 and there may be slight variation may occur. In case of major variation
due to atmospheric condition or may be traffic condition there may be delay in the supply of
concrete to the site, in this case RMC plant experts will suggest site engineers to put some
water and then to use.
Slump test is the most widely used test in the field and laboratory which is used to check the
consistency of concrete used at a construction site. It provides useful information on the
uniformity in the day to day or even hour to hour production of concrete. The main apparatus
used for this test was 30cm height, 20 cm bottom width and 10cm top width cylindrical cone,
60cm tamping rod and iron plate. The workability depends on the reversed gap between the
cone and the fresh concrete after tamping and removing the cone.
The workability is classified as:
Very low when height is 0-25mm
Low when the height is 25-50mm
Medium when the height is 50-100mm
2.12 MATERIALS
In construction site different types of materials are used and it is the main constituents of the
construction. The material will be supplied from same company or from contractor side as per
work order and total budget project. The materials supplied to the site will be tested in site
itself before handover. The quality control department will take responsible for all the materials
quality. The total project quality depends upon the quality control department. To find the
materials quality status the tested material values will be recorded daily if it is daily loaded for
example concrete blocks. Different materials will be supplied in bulk process. Ex cement, steel,
sand, aggregates, etc., if the materials are not supplied correctly to the site and this is not good
for both company and the contractor. Figure 2.1 shows Materials Collected in the NMPT Site.
Figure 2.1: Materials Collected in the Site
2.13 BERTHING FACILITIES

● 15 Berths

● Draught up to 14 meters
● Total capacity -77.77 million tons per annum
Table 2.1shows the Berth Details
Table 2.1: Berth Details
Sl. No. Name of Type of Berth Length of Berth

Berth (in meters) (in Metric Tons)
1 Berth No. 1 Gen. Cargo 125

4 Berth No. 4 Gen. Cargo/Liq. 198
Ammonia/Phos. Acid
5 Berth No. 5 Gen. Cargo/Bulk 198
Cement/Edible oil
9 Berth No. 9 Coal/(UPCL) 300
10 Berth No. 13 LPG/POL 330
11 Berth No. 14 Crude Oil 320
12 Berth No. 15 Crude Oil /POL Products 320
13 Berth No. 16 POL/Chemicals 320
14 Berth No. 17 Crude Oil/POL Products 350
15 Berth No. 18 Iron Ore 300
16 Single Point Crude Oil _
Mooring (SPM)
 Storage capacity
Covered: 55,000 sq meters, liquid: 2, 00,000 sq meters
● Land area: 2032 acres
● Waterfront: 320 acres

● 14 Railway lines
2.14 ON GOING PROJECTS

As part of the NMPT master plan, several projects have been identified which need to be taken
up in phased manner to commensurate traffic. The proposed phasing, capacity addition and the
likely investments are discussed in paragraphs below. It may be noted that apart from these
projects there could be several other projects which port would be implementing as part of the
routine operations and maintenance of the port facilities. Further, the phasing proposed is not
cast in stone as the port master plan is a dynamic document and could be reviewed periodically
and revised based on the economic scenario and demand for port at that particular point of
time. The requirement and rationale of these projects are discussed in brief in the sections. The
details of the projects which have already been awarded and development is ongoing are given
below in the Table 2.2. However, Figure 2.2 shows Port Layout along with Ongoing
Developments in NMPT.
Table 2.2: The details of the projects which have already been awarded and
development is ongoing
Investment Capacity Mode
S.
Project Name Required Addition of
No
(INR in Crores) (MTPA) Implementation
Mechanization of Berth
1. 469.46 6.73 PPP
12

Figure 2.2: Port Layout along with Ongoing Developments
2.14.1 Projects to be completed by Year 2020
The detail of the project which are envisaged to be completed by 2020 are given below in the
Table 2.3.
Table 2.3: Berth Details
S. Project Name Investment Capacity Mode of

No required addition(MTPA) Implementation
(INR in
Crs)
Development of 30 acres
of stack yard and ancillary
1 25.00 - Port’s fund
roads for parking of Ro-
Ro cargoes and cars
Utilization Berth 8 and
Backup area as Container
2 277.19 4.0 lakh TEU’s PPP
Terminal
Deep water break bulk

berth adjacent to ore berth
3 150.00 5.0 Port’s fund

The 2020 port layout plan with the above mentioned projects is as shown in the Figure 2.3.
Figure 2.3: 2020 Port development plan
2.14.2 Project to be Completed by Year 2025

The details of projects which are envisaged to be completed by year 2025 are given below in
the Table 2.4 and Figure 2.4 represents construction of Storage Shed.
Table 2.4: Projects to be completed by year 2025
Sl. No Project Name Investment Capacity Mode of

required (INR Addition implementation
in Crore) (MTPA)
1 Deepening of Eastern dock 1200 3.0 Port’s funds
2 FSRU for LNG handling 2500 2.0 PPP
3 Mechanised Fertilizer Handling 155 3.0 PPP

Facility
4 Mechanized Food Grain Handling 120 0.5 PPP
Facility
5 Development of Berth 10 for 500 5.0 PPP
Handling bulk cargo
6 Additional Storage area for bulk 50 - Port’s funds
cargoes

Figure 2.4: Construction of Storage Shed

CHAPTER 3
TASK PERFORMED
The work was classified into office work and site works, mostly the work was executed on the
site is supervising. In the period of four weeks internship various Office works were
experienced that include Reading, understanding and adding extra needs for plan if required
using CAD drawings, Estimation, Quantity measurements.
3.1 SITE WORK
The site work was the very important task because the internship main objective lies over there.
Since it was a central government-based port entry to the site was with the supervision of the
senior engineers only and company will not allow to visit site daily because of security reason.
Within a short time involved in different site works to gain more knowledge about the working
environment in the site.
The site works have been through four-month internship period was in the super structure work
exclusively. A normal building consists of two parts in general this are the super structure and
the sub structure. Any structure below the ground floor slab level including the basement,
retaining walls, ground slab, grade beam, and foundation is called a substructure. Super
structure is the part of a building which extend above the grade beam or everything above the
sub structure includes slab, column, walls, roof etc. the purpose of the super structure is to
enclose and divide space as well as spread load safely in to the sub structure.
3.1.1 Concrete Form Work
As fresh concrete is in plastic state when it is placed for construction purpose so, it becomes
necessary to provide some temporary structure to confine and support the concrete till it gains
sufficient strength for self-supporting. This temporary structure is called form work. Concrete
formwork serves as a mould to produce concrete elements having a desired size and
configuration. It is usually erected for this purpose and then removed after the concrete has
cured to a satisfactory strength. In some cases, concrete forms may be left in place to become
part of the permanent structure. For satisfactory performance, formwork must be adequately

strong and stiff to carry the loads produced by the concrete, the workers placing and finishing
the concrete, and any equipment or materials supported by the forms. Dismantling of the
formwork commenced after the allowable dates have elapsed since the day of the concrete
casting.
Accordingly, column and side formworks will be dismantled after 16 hours elapsed from the
concrete casting and other soffit formworks should stay in position until the concrete gets
cured. The dates of dismantling for the soffit formworks were shortened by the use of fast
curing concrete admixtures. The use of these admixtures will allow them to move fast forward
with the construction and immediate utilization of the formwork on other successive structures.
The formworks of any type and of any place will be required:

 To be rigid enough to confine plastic concrete at the lines grades and dimensions
indicated on the form plans without bulging or sagging under the load,
 To be constructed as mortar tight as possible to prevent the loss of concrete ingredients
throughout the joints between the sections, and
 To be easy to remove with minimal damage to the concrete surface.
In case of failure to attain the required strength the conventional date of dismantling the
formwork will be respected.
3.1.2 Block Work
Construction of solid blocks bonded together with mortar is termed as block masonry. The
strength of the block work primarily depends upon quality and strength of the blocks, types of
mortar and the method of bonding adopted in construction. Mortar not only acts as a cementing
material but also imparts strength to the work by holding the individual blocks together to act
as a homogeneous mass. Mortar usually a mixture of cement and sand or lime and sand or the
mixture of three. The strength of the masonry also depends on the nature of workmanship and
supervision.

The general principle which would be observed for a sound block masonry construction is
given below.
 The blocks used in a good work should be sound, hard and well burnt with uniform
size, shape and colour. They should have no cracks or flaws and a fractured surface
should be free from holes, grit or lumps of lime etc.,
 The floor shall be cleaned for any dirt or unwanted materials.
 The marking of the block wall shall be made with the proper supervision of the engineer
using the respective drawings and specifications.
 Concrete bed layer shall be laid and above which the first layer of the block will be
placed with proper spacing of mortar. The blocks should be slightly pressed into the
bed mortar while laying so as to ensure proper adhesion.
 All the courses should be laid truly horizontal and all the vertical joints should be truly
vertical.
 All the joints should be properly flushed and filled with mortar so that no cavity is left
in between.
 Half block partition walls should be reinforced with suitable reinforcement placed at
every third or fourth course of the block work. The reinforcement may be in form of
mild steel bars, flat bars, expanded mesh etc.,
 All the finished masonry work should be kept wet for at least 7 days.
 Plastering should be done after about 28 days of completion of block masonry. This
permits adequate time for the shrinkage in masonry and concrete to take place before
plastering operation is carried out.
Different block sizes used in site and details of blocks required for block works of about 1m 3
volume are shown in the Table 3.1.
Table 3.1: Different block sizes are used in site
Sl. No Block Sizes

1 16”X8”X8”
2 16”X8”X6”
3 16”X8”X4”

3.1.3 Plastering
This is a process of covering rough surfaces with a plastic material to obtain an even, smooth,
regular, clean and durable surface. Plastering conceals defective workmanship and covers up
unsound and cheap quality material. Plastering is required to provide a satisfactory base for
decorating the surface by white washing, colour washing, painting. The plaster is made by
working together a mixture of building materials which may be cement, lime or clay, fine
aggregate and water. Fine sand is often recommended for plastering and it should be so graded
that it does not pass by more than 5% through a sieve. Sand used should be clean, sharp and
free from deleterious matter. Plastering was done in two coats for external wall and single coat
for internal wall. External wall 2 coats because one coat is with only mortar and the other outer
coat is of mortar with weather proof course. 100 to 150 sqft/day work is completed by the
workers. Table 3.2 showing details of plastering.
Preparation of the surface for plastering

 The durability of the plaster depends to a great extent upon its adhesion with the block
masonry. The preparation of surface for plastering is therefore of prime importance.
 All the projections which extend by more than 30mm from the general surface of the
masonry wall face are knocked off to obtain surface and this also helps to reduce
consumption of plaster.
 In order to obtain a good key for the plaster with the wall surface, all the joints in the
masonry are raked out for depth of at least 13mm.
 Dust or loose mortar is brushed out of the raked joints. The surface is rendered free
from oily/greasy spots.
 The surface is thoroughly washed with water and kept wet before paltering is
commenced.
Table 3.2: Details of plastering
Plastering Ratio Thickness

Ceiling Plastering 1:3 20 mm
Internal Plastering 1:4 20 mm
External Plastering

1st Coat 12 mm
1:5
2nd Coat 8 mm
 To ensure required thickness and a true surface, bull mark of plaster is first of all
applied horizontally and vertically at about 1.8m apart over the entire surface. This
surface patches of plaster serves as gauges for maintain even thickness of the plaster
being applied.
 Mortar is then applied on the wall between the screed and trowel.
3.1.4 Reinforcement Work
Concrete is much weaker in tension than in compression. Its tensile strength is approximately
10% of its compressive strength. Therefore, concrete is generally used in conjunction with
steel reinforcement, which provides the tensile strength in a concrete member. The use of plain
concrete without steel reinforcement is limited to pavements and some slabs-on-ground. Steel
is the ideal material to complement concrete because the thermal expansion of both materials
is the same. In other words, when heated or cooled, both steel and concrete expand or contract
equally. Consequently, no stress is caused by differential expansion or contraction. Composite
materials that expand differentially are subjected to such stresses.
Steel also bonds well with concrete. In a composite material, the bond between two materials
is necessary for it to function as a single material. The bond between steel and concrete is due
to the chemistry of the two materials, which produces a chemical bond between them.
Additionally, as water from concrete evaporates, it shrinks and grips the steel bars, making a
mechanical bond.
The mechanical bond is enhanced by using reinforcing bars, or rebar, that have surface
deformations. Because a mechanical bond is a function of the area of contact between the two
materials, surface deformations increase that area, thereby increasing the bond. For the same
reason, rebar that have a light, firm layer of rust bonds better with concrete. Rust that is
produced by leaving rebar outdoors on a construction site for a few days or weeks is not
objectionable as long as the rust is not loose or flaky.

Loose and flaky crust should be scraped using burlap or a piece of cloth. Excessively rusted
rebar should not be used. Reinforcement grade of Fe 500 is extensively used in the projects in
the range of 8mm to 25mm were used in the projects. Before bulk purchase and transporting
to the site they were conduct tensile strength test from the store, by taking sample from a place
where they are intending to supply the material. Such sampling will involve the Consulting
Office and the result will be communicated. When they receive approval, as it fulfils the
expected minimum tensile strength, they proceed to the purchase of the same. Place of deposit
was made ready before its arrival on site where it should be damped.
A platform elevated from the top surface of the soil, that would ensure the avoidance of
minimum contact were prepared. Then placed there, and was protected from any detrimental
moisture, grease or oil or other substances that may affect its quality. Shop drawing or bar
schedule was produced by the Office Engineer, in accordance to the structural design. This
shop drawing or bar schedule was submitted to the Resident Engineer and upon his approval
mass production will be induced.
Bar bending workshop were situated in a place where it could be close to the site where the
bar is going to be placed in position. The bending of all types of reinforcement bars was take
place within the workshop. Except the column reinforcement bars all was tied and placed in
position exactly in a position where they are intended to be situated. On the sub-structure work
hauling was performed by labour. But on the super structure it is through the help of the mobile
crane, that the required amount and type of reinforcement bar will be conveyed. After placing
in position of the reinforcement bar and before the concrete pouring any dust particle was
removed or cleaned. On horizontal structures like the reinforced concrete in order to maintain
the allowable concrete cover depth or thickness concrete spacers was produced and cured and
placed in position.
3.1.5 Cover
Cover is minimum spacing that should be maintained between each length of bar as well as the
spacing between the bar and shuttering.

Providing cover ensures flow of concrete through all portions and spaces between the rebar
mesh and cage. If the correct cover has been provided the rebar will be evenly distributed
throughout the RCC structure after concrete has been placed. It protects the steel reinforcement
from getting corroded and helps in firefighting being a bad conductor of heat.
3.1.6 Concreting
Concrete is a composite consisting of the dispersed phase of aggregates (ranging from its
maximum size coarse aggregates down to the fine sand particles) embedded in the matrix of
cement paste. This is a Portland cement concrete with the four constituents of Portland cement,
water, stone and sand. Concrete used in site are both site mix and RMC.
These basic components remain in current concrete but other constituents are now often added
to modify its fresh and hardened properties. This has broadened the scope in the design and
construction of concrete structures. It has also introduced factors that designers should
recognize in order to realize the desired performance in terms of structural adequacy,
constructability, and required service life. These are translated into strength, workability and
durability in relation to properties of concrete.
In addition, there is the need to satisfy these provisions at the most cost-effective price in
practice. Since our building is a reinforced concrete structure the concrete work was
commenced every day for constructing/development of every part of the building. The
constituents of modern concrete have increased from the basic four (cement, water, stone, and
sand) to include both chemical and mineral admixtures.
These admixtures have been in use for decades, first in special circumstances, but have now
been incorporated in more and more general applications for their technical and at times
economic benefits in either or both fresh and hardened properties of concrete.
Different concrete mixes are used in different works. Details are given below
 M15 is used for PCC.
 M25 is used for footings, slabs, beams and columns.
 M30 and M40 are used for slab.
 The cement used is Chetinad40 grade, OPC.

Quantity of Materials like blocks, cement, fine aggregate, coarse aggregate and steel bars
required for block work, slab concreting, column concreting, beam concreting of about 1m 3
areas is as follows.
3.1.7 Cement
Cement may be described as a material with adhesive and cohesive properties that make it
capable of bonding mineral fragments (aggregates) into a compact whole. In this process, it
imparts strength and durability to the hardened mass called concrete. The cements used in the
making of concrete are called hydraulic cements so named, because they have the property of
reacting chemically with water in an exothermic (heat generating) process called hydration that
results in water resistant products.
The products of hydration form a viscous cement paste, which coats the aggregate surfaces and
fills some of the void spaces between the aggregate pieces. The cement paste loses consistency
(stiffens) on account of gradual loss of free water, adsorption and evaporation and subsequently
sets, transforming the mixture into a solid mass. If the consistency of the cement paste is either
excessively harsh or excessively wet, there is a danger of segregation, i.e., the aggregate tends
to separate out of the mix; this will adversely affect the quality of the hardened concrete and
result in a honeycomb appearance. The freshly set cement paste gains strength with time
(hardens), on account of progressive filling of the void spaces in the paste with the reaction
products, also resulting in a decrease in porosity and permeability.
3.1.8 Aggregate
Since aggregate occupies about three-quarters of the volume of concrete, it contributes

significantly to the structural performance of concrete, especially strength, durability and
volume stability. In general, aggregates in concrete have been grouped according to their sizes
into fine and coarse aggregates. The separation is based on materials passing or retained on the
nominally 5 mm (ASTM No. 4) sieve. It is common to refer to fine aggregate as sand and
coarse aggregate as stone.

Traditionally, aggregates are derived from natural sources in the form of river gravel or crushed
rocks and river sand. Fine aggregate produced by crushing rocks to sand sizes is referred as
manufactured sand.
3.1.9 Admixtures
Admixtures are additives that are introduced in a concrete mix to modify the properties of
concrete in its fresh and hardened states.
Fast curing admixtures allow curing the concrete within 3 to 5 days after the date of pouring
the concrete. Such application will only be made after the conduct of the test and the
satisfaction of the Engineer. The amount of the admixture to be added varies in accordance to
the manufacturer’s specification. All relevant documents and specifications will be available
before conducting the mix design and test for approval. After the satisfaction of the Supervisor
the Contractor will execute the successive duties. If the use of admixtures ensures the early
curing of the concrete structure, the date of removal of the formwork will be dictated
accordingly.
3.1.10 Water
Water has a significant role to play in the making of concrete in mixing of fresh concrete and
in curing of hardened concrete. Table 3.3 shows material rates.
Table 3.3: Material Rates
Steel Rate Rs 41/kg

Cement Rs355/Bag
CA Rs 31/cft
FA Rs 25/cft
In order to ensure proper strength development and durability of concrete, it is necessary that
the water used for mixing and curing is free from impurities such as oils, acids, alkalis, salts,
sugar and organic materials. Water that is fit for human consumption (i.e., potable water) is
generally considered to be suitable for concreting. However, when the portability of the water
is suspect, it is advisable to perform a chemical analysis of the water.

3.1.11 RMC Placement Method
Concrete that has been used in the site is Ready Mix Concrete from RMC Ready Mix India,
Mangalore. The road distance between RMC plant to the site is about 6 km’s and the duration
is about 15 mins. Truck used to transfer concrete from plant to the site is of 7m3 capacity. Table
3.4 and 3.5 show RMC Details and RMC rates, respectively.
Table 3.4: RMC details
Cement OPC (43 & 53 Grade)

Aggregate 20mm
Admixture HWRA
Slump 120 +/- 25mm
Ready Mix Concrete placement method is as follows.

 When transit truck arrived to the site, the concrete transport certificate was checked for
desired properties of concrete and time duration of transport.
 Concrete was delivered to the site and discharged from the truck completely in the form
ready for vibration within 1-1/2 hours after batching.
 Concrete was placed in maximum 15 minutes after its arrival to the site, and the
finishing of placement would take place before the cement starts setting.
 Concrete was stored/ deposited as near as possible to its final position using crane
hoisted buckets, concrete pumps, chutes etc.,
 If the concrete, due to transport, was segregated. It would be mixed again and clean
platforms, without adding water; if not the batch would be refused.
 Concrete shall be placed to prevent segregation. The free fall of concrete should in no
case exceed 1.5m.
 The concrete should be spread and deposited in horizontal uniform thick layers.
 Concrete was then compacted using needle vibrators.
 Concreting was continuously done to avoid planes of weakness.

Table 3.5: RMC Rates
RMC Rate
M10 Rs 3000/cum
M15 Rs 3700/cum
M20 Rs 4200/cum
M25 Rs 4200/cum
M30 Rs 4600/cum
M40 Rs 5000/cum
3.1.12 De-shuttering
It is a process of removal of shuttering after concrete achieves required strength. The sequence
of orders and method of removal of form work are as follows
 Shuttering forming the vertical faces of walls beams and column sides should be
removed first as they bear no load but only retain the concrete.
 Shuttering forming soffit of slabs should be removed next.
 Shuttering forming soffit of beams, girders or other heavily loaded shuttering should
be removed in the end.
3.2 DREDGING
Dredging is the operation of removing material from one part of the water environment and
relocating it to another. In all but a few situations the excavation is undertaken by a specialist
floating plant, known as a dredger. Dredging is carried out in many different locations and
for many different purposes, but the main objectives are usually to recover material that has
some value or use, or to create a greater depth of water.
3.2.1 Maintenance
Dredging to deepen or maintain navigable waterways or channels which are threatened to

become silted with the passage of time, due to sedimented sand and mud, possibly making

them too shallow for navigation. This is often carried out with a trailing suction hopper dredge.
Most dredging is for this purpose, and it may also be done to maintain the holding capacity of
reservoirs or lakes.
3.2.2 Land Reclamation
Dredging to mine sand, clay or rock from the seabed and using it to construct new land
elsewhere. This is typically performed by a cutter-suction dredge or trailing suction hopper
dredge. The material may also be used for flood or erosion control.
3.2.3 Capital dredging
Dredging carried out to create a new harbor, berth or waterway, or to deepen existing facilities
in order to allow larger ships access. Because capital works usually involve hard material or
high-volume works, the work is usually done using a cutter suction dredge or large trailing
suction hopper dredge; but for rock works, drilling and blasting along with mechanical
excavation may be used.
3.2.4 Preparatory
Dredging work and excavation for future bridges, piers or docks or wharves, This is often to
build the foundations.
3.2.5 Winning construction materials

Dredging sand and gravels from offshore licensed areas for use in construction industry,
principally for use in concrete. This very specialist industry is focused in NW Europe, it uses
specialized trailing suction hopper dredgers self-discharging the dry cargo ashore. To reclaim
areas affected by chemical spills, storm water surges (with urban runoff), and other soil
contaminations, including silt from sewage sludge and from decayed matter, like wilted plants.
Disposal becomes a proportionally large factor in these operations.

Figure 3.1: Method of Dredging
3.3 PILE FOUNDATION
A pile is basically a long cylinder of a strong material such as concrete that is pushed into the
ground to act as a steady support for structures built on top of it. When there is a layer of weak
soil at the surface. There are two fundamental types of pile foundations (based on structural
behaviour), each of which works in its own way.
End Bearing Piles: In end bearing piles, the bottom end of the pile rests on a layer of especially
strong soil or rock. The load of the building is transferred through the pile onto the strong layer.
3.3.1 Types of pile foundation
Followings are the types of pile foundation used in construction:
• Based on Function or Use. Sheet Piles. Load Bearing Piles. End bearing Piles. Friction
Piles. Soil Compactor Piles.
• Based on Materials and Construction Method. Timber Piles. Concrete Piles. Steel
Piles. Composite Piles.

3.3.2 Pile foundation Uses
Pile foundations are principally used to transfer the loads from superstructures, through weak,
compressible strata or water onto stronger, more compact, less compressible and stiffer soil or
rock at depth, increasing the effective size of foundation and resisting horizontal loads
3.3.3 Necessity of Pile Foundation
The pile is a structural member that is made of concrete, timber or steel. They are used to
construct a foundation, which are deep and of course which cost more than
shallow foundations. Despite the cost, the uses of piles are needed to achieve structural safety.
3.3.4 Factors Affecting Selection of Pile Foundation Type
• Type and loads from the superstructure.

• Properties of soil.
• The depth of the soil layer capable of supporting the piles.
• Variations in length of pile required.
• Availability of materials.
• Durability required.
• Available equipment for pile driving.
• Budget.

3.3.5 Pile Reinforcement
Figure 3.2: Materials Collected in the Site
Figure 3.3: Layout of Pile

Figure 3.4: Construction of Pile Foundation
Figure 3.5: Pile Pointing

Figure 3.6: Dewatering

CHAPTER 4
REFLECTION
Internship at NMPT experience was good, as I got opportunity to apply my theory
knowledge to practical aspects which I studied in Civil Engineering domain. I got a chance to
understand how corporate would actually works, the risk which should be taken to expand the
business. I have gained new knowledge, skills and met many strong and experienced
engineering personalities and also got insight into professional practice. The facilities which
are given in NMPT like medical care, pension, residential quarters, HRA to employees who
are not residing in NMPT colony etc. makes it different from others.
4.1 PERFORMANCE DURING ACCOMPLISHING WORK
Got involved in different site works to gain more knowledge about the working
environment at the site and improved myself. Since the site work is very repetitive, I have been
working in different sections to get involved in different kinds of works and especially the
work tasks I had been performing in the office were very impressive because of exposure to
quantity works, cost estimation and report writing etc. which I was not aware of. In general, in
the last one month I performed all my duties with good manners and gained knowledge of the
practical application of the theoretical aspects learnt.
4.2OVERALL BENEFITS OF THE INTERNSHIP
4.2.1Technical outcomes
Some of the practical knowledge I gained from the internship are:
a. Construction of formwork and false work for some reinforced concrete structure.
Construction stage of form work was new to me. I gained knowledge about
construction of form work along with maintenance of the materials at the site. And also,
I came to know that in any construction work the first stage before casting of concrete
is designing and constructing of form work and this should be stiff and must resist the
fresh concrete till the concrete gain its strength.

b. Bar bending, positioning, splicing and tying, according the specified drawing.
After the formwork and false work, it should be followed by bar bending, positioning
and tying work. This work is done based on the working drawing provided in the
working drawings (structural drawing) by the design team of that specified structure.
c. Casting and pouring of reinforced concrete structure and equipment used for
casting.
Concrete is a vital material in any construction of reinforced concrete structure. Thus,
it is mandatory to know concreting in practice including how it is treated, placed
(poured), mixed and the equipment used for the concreting work. I got the chance to
see all the procedures of concreting work.
d. Knowledge about dredging and pile foundation works
Gained knowledge about dredging process which is carried out in NMPT. And also
observed the reinforcement form work and construction procedure of pile structures.
e. Different construction equipment (machines) and their use in construction site.

Machines are capable of handling tough work which may be beyond the scope of
human labour to be performed. They can be expected to work with fair degree of
effectiveness even under adverse weather, climate or topographical conditions. I
generally know how equipment’s are used in the site including their specific purpose.
4.2.2 Non-Technical outcomes
a. Upgrading inter personal communication skill
Communication is sharing or exchanging information or ideas with others in order to

get some messages and knowledge. The communications systems within the building
design and construction enterprise has taken on a large role in the achievement of
profitability and efficiency. A basic understanding of communication systems is
beneficial to all engineering professionals. Communication is an important way of
learning which can be defined formally as the act, process or experience of gaining
knowledge or skills and sharing what we know. Good communication is important and
it can appear in different forms as speaking, writing, and listening. This internship has
provided me the opportunity to improve my verbal communication and how to behave
well in the working environment. The non-verbal communication consists of facial

expressions, body language and hand gestures. This skill is also very important part of
communication, especially when communicating with the people of higher position. It
may not be completely learnt but it has certainly improved.
b. Improving team playing skill
The ability to work well with others, gain consensus, and get projects launched and
completed is one of the most important assets that can bring to a job.Good team playing
skill is essential for effective completion of tasks and increasing productivity. In the
construction site the work is already a team work and it needs more closeness of
workers to solve problems. I was finding difficulty in understanding the drawings and
handling the materials at site, but finally engineers and the operators helped me to
overcome these problems. With the help of them I was able to complete the task
assigned well within the specified time.
c. Improving leadership skill
Leadership is the process of influencing individuals or groups to accomplish an

organizational goal or mission. I have seen how each worker is controlled and
organized to perform day to day activities. Among all other managements I came to
know that human resource management and time management are the most important.
I observed the method of controlling the working time and amount of work done by
each worker so that the work proceeds according to the plan or schedule. I understood
that for effective leadership personal values like confidence, effective communication
and devotion are very important.
d. Self-confidence
This whole experience has given confidence of learning different things than the usual
subject-oriented matter.
CHAPTER 5
CONCLUSIONS
An internship is a form of experiential learning that integrates knowledge and theory learned
in classroom with practical application and skill development in professional settings which
give us the opportunity to gain valuable applied experience. This internship helped me to
involve in live project, interact with different working environment and with workers or
employees, to improve practical skill by implementing what I have learnt in class, in addition
with this up grading the theoretical knowledge, improve my leadership skill, team playing skill
etc. And this also made me to gain relevant work experience, professional network and
provided career-building experience. I had the opportunity to identify my skills and discover
my interests. I gained more insights about the industry.

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NMPT Internship Report

Dept. of Civil Engineering, BIT, Mangalore Page 1

NMPT has been committed to quality, innovation, design, professionalism, honesty,

Figure 1.1: New Mangalore Port Trust

1.2 WORK STRATERGY

1.3 BUSINESS POLICY

Dept. of Civil Engineering, BIT, Mangalore Page 2

1.4 QUALITY POLICY

Figure 1.2: Logo of New Mangalore Port Trust.

1.5 VISION AND MISSION OF THE COMPANY

To be a professional provider of Port Infrastructure and services of world class standards.

1.5.2 Mission of the Company

Dept. of Civil Engineering, BIT, Mangalore Page 3

ABOUT THE COMPANY

2.1 ABOUT THE DEPARTMENT

2.2 ADMINISTRATION DEPARTMENT

2.3 CIVIL ENGINEERING DEPARTMENT

2.4 SAFETY DEPARTMENT

Safety is very important in construction industry. Human life is irreplaceable, which is

Dept. of Civil Engineering, BIT, Mangalore Page 4

2.4.1 General Rules

 The work should start daily at 8:30 hours.

2.4.2 General Safety Rules

Dept. of Civil Engineering, BIT, Mangalore Page 5

2.4.3 Form Work /Concreting

 All site Mix Concrete to be done after sand sieving.

2.4.4 Reinforcement Steel

 Straightening, cutting, bending, conveying, hoisting and laying in position.

Dept. of Civil Engineering, BIT, Mangalore Page 6

2.5 MECAHNICAL ENGINEERING DEPARTMENT

The mechanical Engineering Department is responsible for the procurement, operation,

2.6 TRAFFIC DEPARTMENT

2.7 MARINE DEPARTMENT

Dept. of Civil Engineering, BIT, Mangalore Page 7

2.8 FINANCE DEPARTMENT

2.9 MEDICAL DEPARTMENT

2.10 VIGILANCE DEPARTMENT

2.11 QUALITY DEPARTMENT

Dept. of Civil Engineering, BIT, Mangalore Page 8

2.11.1 Tests Conducted on Site

2.11.2 Sieve Analysis

2.11.3 Slump Test

Figure 2.1: Materials Collected in the Site

2.13 BERTHING FACILITIES

Dept. of Civil Engineering, BIT, Mangalore Page 10

Table 2.1: Berth Details

Sl. No. Name of Type of Berth Length of Berth

1 Berth No. 1 Gen. Cargo 125

● Waterfront: 320 acres

2.14 ON GOING PROJECTS

Dept. of Civil Engineering, BIT, Mangalore Page 12

Figure 2.2: Port Layout along with Ongoing Developments

2.14.1 Projects to be completed by Year 2020

Table 2.3: Berth Details

S. Project Name Investment Capacity Mode of

Deep water break bulk

Dept. of Civil Engineering, BIT, Mangalore Page 13

Figure 2.3: 2020 Port development plan

2.14.2 Project to be Completed by Year 2025

Sl. No Project Name Investment Capacity Mode of

2 FSRU for LNG handling 2500 2.0 PPP

3 Mechanised Fertilizer Handling 155 3.0 PPP