SUMMER TRAINING PROJECT REPORT

UNDER THE GUIDANCE OF

Mr. Vikrama Prasad

(Sr. Section engineer)

SUMMER TRAINING REPORT

From 20-06-2016 to 15-07-2016

On

DESIGN OF 12.2m SPAN

COPMOSITE GIRDER (WELDED TYPE)

&

AGGREGATE TESTING

At

BRIDGEWORKSHOP

N.E. RAILWAY GORAKHPUR

Submitted for Partial fulfilment of award of degree of

Bachelor of Technology In CIVIL ENGINEERING

SUBMITTED TO- SUBMITTED BY-

DEPARTMENT OF CIVIL ENGINEERING GANESH SHANKER

R.E.C. AZAMGARH B.TECH FINAL YEAR

PREFACE

This report has been prepared after getting different theoretical and

practical training in Indian Railway Bridge Corporation from 20-06-2016

to 15-07-2016 in reference to my collage letter for summer training. The

process of training from my point of view was excellent for each section

was very useful for Civil Engineering Student with a lot of resources and

limited time schedule. There are many things in the Directorate on each

subject which can be learnt from regular training and proper guidance.

A little knowledge which I could get from this training, I am trying

to re-produce some of them in following pages. Any error in making

deliberations may please be ignored.

DATE-15-07-2016 GANESH SHANKER

DECLARATION I hereby declare that the project report on “12.2m span Composite Girder” and “Aggregate Testing” is a record of my original work done under the guidance of Mr. Vikrama Prasad. This project report is submitted to Indian Railway Bridge Corporation Gorakhpur, in the partial fulfilment of the requirements for the award of the degree of Bachelor of Technology in Civil Engineering.

The result embodied in this report has not been submitted to any other University or Institute for the award of any degree.

Place: Gorakhpur

Date:15-07-2016

GANESH SHANKER

B.TECH FINAL YEAR

CIVIL ENGINEERING

ROLL NO.: 1373600019

CERTIFICATEThis is to certify that Ganesh Shanker(1373600019) has carried out the project work Entitled “12.2 m span Composite girder (Welded type)” &“Aggregate Testing”for the award of Bachelor of Technology in Civil Engineering from Rajkiya Engineering College, Azamgarh (736) under my supervision. The Project embodies results of original work, and studies are carried out by the student himself and the contents of the project do not form the basis for the award of any other degree to the candidate or to anybody else from this or any other University/Institution.

MR. VIKRAMA PRASAD

(Sr. Section Engineer N.E.Railway)

Project Coordinator

SUBJECT INDEX

S.No. Description

1. Introduction

2. Fabrication

3. Consisting of fabrication process

Flow diagram of fabrication process

Layout of drawing

Marking and Templating

Jig and Fixture making

Cutting of plates

Tack assembly of job

Tack welding and Fillet welding

Inspection of weld Etching test Visual inspection Dye penetration test

Initial assembly of the job Drilling Riveting

Final assembly of job Riveting section Final assembly section Inspection Painting Metalizing Dispatch section

4. Aggregate testing

5. Introduction

6. Sieve analysis Water absorption Aggregate impact value Shape test

Flakiness index Elongation index

7. Material suppliers

8. Acknowledgement

DESIGN OF COMPOSITE GIRDER

(WELDED TYPE)

COMPOSITE GIRDERThe RCC deck is cast in situ after launching steel girders on substructure. Shear connectors are provided on top flange plates of steel beams with channel sections welded all round with side fillet welds. Shear connectors are required to make cast in situ RCC slab and steel girder act together under load.

In a composite girder system the concrete acts together with the steel to createa stiffer, lighter, less expensive structure.

COMPONENTS OF COMPOSITE GIRDER

RCC deck (Cast in situ at the site of bridge) with shear connectors embedded in the slab.

Steel beams with shear connectors welded on top flange (Fabricated in workshop).

Cross frames Bearings

ADVANTAGES OF USING STEEL FOR GIRDERS Reduced dead loads. More economic foundations. Simpler erection procedures. Shorter execution time. Faster and easier rehabilitation. Durability.

FABRICATIONTHE PROCESS OF BUILDING UP/PUTTING TOGETHER, PROPERLY SHAPED INDIVIDUAL COMPONENTS (ROLLED SECTION & PLATES) TO FORM THE DESIRED STRUCTURE.

Tested steel of required quality Appropriate design and drawings Well eqquiped workshop Experienced and skilled staff Inspection at every stage

TESTED STEEL OF REQUIRED QUALITY IS:2062, Quality “A” Grade Designation E250 (Fe 410 W) as

rolled semi-killed or killed shall be used for foot-over bridges and other structures subjected to non-critical loading.

Is:2062-2011 gr.-b0 fully killed and normalized – for welded girders subjected to railway loading

(If service temp. Does not fall below 0 degree centigrade). Plates less than 12mm thick need not be normalized. Plates more than 12mm thick should be normalized and

ultrasonically tested. Is:2062 gr.-c fully killed and normalized – for welded/ girders

subjected to railway loading (If service temp. Fall below 0 degree c).

Plates less than 12mm thick need not be normalized. Plates more than 12mm thick should be normalized and

ultrasonically tested.

APPROPRIATE DESIGN AND DRAWINGS Work should be executed as per approved drawings. All the drawings should be checked thoroughly before starting

execution.

If any particular section is not available, the possibility of using alternative section may be explored.

MAINLY CONSISTING OF FABRICATION PROCESS Layout of drawings Marking and templating Jig and fixture making Cutting of plates TACK ASSEMBLY OF I-section Saw welding of I-section Inspection of weld Initial assembly of job Cutting of stiffener Drilling of job Riveting of job Stud welding FINAL ASSEMBLY OF JOB Inspection of job Metalizing of job Painting

FLOW DIAGRAM OF FABRICATION

PROCESS

LAYOUT OF DRAWINGS Layout is drawing of complete structure on full scale. Normally

half span is drawn on a levelled smooth concrete/steel floor. (Other half will be the mirror image)

NOMINAL AS WELL AS CAMBER LAYOUT WILL BE DRAWN ON THE FLOOR.

Length of the members will be kept as per camber layout. However the jigs/masters jigs for main gussets will be fabricated using nominal layout.

MARKING & TEMPLATING The template shall be used for marking of cutting material and as

well as profile machining for girders of railway loading.

Templates shall be used for marking of drilling holes in steel structures other than girder of Railway loadings.

JIG AND FIXTURE MAKING

Jigs are the device used in the mass production of standard jobs for drilling holes without marking. Jig is the member with drilled holes of one component, so that by placing this jig over the component, holes can be drilled in the component

For guiding the drilling toll and to prevent oversizing holes of jig, bushes are provided over the jigs. The internal dia. Of bushes should be within tolerance –0.0mm TO +0.1mm. When the bores exceed a tolerance of -0.0mm TO +0.4mm, the bushes shall be rejected.

For every working jig, one master plate should be fabricated. This master plates is used only for checking the working jigs. Tolerance for checking jigs from master plates shall be +0.0mm TO -0.13mm.

CUTTING OF PLATES This is a operation done at the site to get the desired shape of steel

plates being use in the construction of deferent components of the structure. Oxy-fuel gas cutting is use for this purpose at site.

Oxy-fuel cutting are processes that use fuel gases and oxygen to cut metals.

LPG is used as fuel gas at site for the cutting purpose.

Plates are cut into desired length using …

ordinary oxy-acetylene cutting torch pug cutting machine profile cutting machine galloting shear machine (faster but for plates up to 10mm

thickness) Angles are cut into desired length using …………

shaper machine shearing and punching machine circular saw profile cutting machine

Cutting allowance …………

3mm up to 12mm thick plates 6mm for than 12mm thick plates

After cutting it should be ensured that all the edges are clean, reasonably square and true.

PUG CUTTING MACHINEPug cutting machine is automated flame cutting machine

which is used for cutting of ferrous metal sheets and plates. An aluminium track is designed over which the machine moves and the speed of this machine can be adjusted according to the thickness of the cutting metals by electronic control switch.

TACK ASSEMBLY OF JOB

Job in fixture

-

Steel sections after cutting to a required size and strengthening will be brought to this process for temporary assembly with tack welding to form a member so that it will be placed in fixture will be placed over tack assembly member and prepared for saw welding.

TACK WELDING – MMAW

TACK welding is to be done by AC welding transformer set as on following-

Electrode:- 4 mm dia: type- a2, 4212x

Class- irs-m-28/2002

Current :- AC

Current IN (amp.) :- 180 (approximate)

Arc voltage (v) :- 80 (approximate)

FILLET WELDING by SAW M/C

Fillet welding 6mm to 10 mm welding is to be done by automatic submerged arc welding machine as on following approximate)-

4 mm copper coated wire class-IRS- M-39 / 2001 is used.

Flux class- IRS- m-39 / 2001is used.

Current in :- dc

Current IN (amp.) :- 500 to 600

Arc voltage (v) :- 32 to 34

Wire feed speed (m/min) :- 2.550 to 3.200

Travel speed of SAW (m/min) :- 0.375 to 0.475

INSPECTION OF WELD Macro etching test - yes

Visual test – yes

Weld gauge - yes

Dye penetration-yes

ETCHING TESTS• Etching tests on run-off coupons and at the edges of girders for checking the root fusion and throat length.

• Etching tests are conducted on smooth, clean surface by:

Applying 2 % nitric acid. Cleaning it with water. Cleaning it with alcohol

• Then check the leg length, throat and penetration and recording the details in Etching Test Register

VISUAL INSPECTION

The finished welds shall be visually inspected and shall conform to the size and contour specified in the drawing.

The following types of defects can be detected during visual

inspection.

Weld defects at the surface such as blow holes, pipes,

exposed porosity, exposed inclusions, etc.

Surface cracks in the weld metal or in the parent metal

adjacent to it.

Damage to the parent metal such as undercut, burning,

overheating, etc.

Profile defects such as excessive convexity, concavity or

unequal leg lengths etc.

Incorrect finish, uneven welds, spatter, etc

DYE PENETRANT TEST In the dye or liquid penetrant testing, a suitable liquid penetrant is

applied to the surface of the portion under examination and remains there for a sufficient time to allow the liquid in to any defect open at the surface.

After the penetration time, the excess penetrant which remains on the surface is removed.

Then, a light colour absorbent called developer is applied on the surface.

This developer acting as a blotter draws out a portion of penetrant which had earlier seeped in to the surface opening.

As the penetrant is drawn out, it diffuses in to the coating of the developer forming the indication of the surface discontinuities as a flaws

Figure: (a) DPT KIT (b) DPT PROCESS

(a)Defects noticed in D.P. Test (b) Blow hole (Enlarged view) (c)After rectification of defects

Dye Penetrant Inspection (DPI), also called Liquid Penetrant Inspection (LPI) or Liquid Penetrant Testing (PT), is a widely applied and low-cost inspection method used to locate surface-breaking defects in all non-porous materials (metals, plastics, or ceramics).The Penetrant may be applied to all non-ferrous materials and ferrous materials, but for inspection of ferrous components magnetic-particle inspection may be preferred for its subsurface detection capability.

Commonly, DPI is used to detect cracks, surface porosity, lack of penetration in welds and defects resulting from in-service conditions (e.g. Fatigue cracks of components or welds) in castings, forgings, and welding surface defects.

.

. .The basic steps are: Clean the part  Apply the Penetrant and allow dwelling Remove excess Penetrant. Apply a developer and allow developing Read the part for indications. 6) Clean the part.

INITIAL ASSEMBLY OF JOB All the surfaces which will be in permanent contact shall be

throughly cleaned by grinding to remove paint, mill scale, dust etc. Zinc chrome red oxide priming to is:2074 should be applied immediately after cleaning

DRILLING OF JOB

• Drilling through jigs and supporting by fixture. This method is used for open web girders

• Jigs should be removed from the component after all holes are drilled otherwise it will be very difficult to drill left over holes at later stage

• All burrs left by the drill and sharp edge of all the rivet holes completely removed.

• The rivet holes shall be 1.5 mm greater than the diameter of the rivet bars used.

RIVETING OF JOB

The rivet holes shall be 1.5 mm greater than the diameter of the rivet bars used. The rivets shall be made to IS:1929.

The clearance i.e. the difference in diameter between the rivets measured under head before being heated and the rivet hole shall not be less than 0.75mm.

All rivets shall be properly heated to straw heat for the full length of the shank, firmly backed and closed. The head of the rivet, particularly in long rivets, shall be heated more than the point and in no case shall the point be heated, more than the head. Sparking or burnt rivets shall not be used.

All loose and burnt rivets and rivets with cracks badly formed, eccentric or deficient heads shall be cut out and replaced.

Steel for rivets should conform to is:1148 and rivet should be made conforming to is:1929.

The rivets hole should be 1.5mm bigger than the rivet dia.

Length of rivets = grip+1.5d+1mm extra to every 4mm grip.

Compressed air pressure required at the hammer end is approx. 6 to 7 kg/sq.cm.

Heating time of rivets is 20 to 25 minutes.

All the rivets should be tested 100% by a responsible supervisor by using testing hammer weight 110 gram.

All the defective rivets shall be distinctly marked on their heads with paint and promptly replaced.

When all the rivets of joints have been finally passed they should be painted with one coat of ready mixed zinc chrome primer to is:104 followed by one coat of ready mixed paint red oxide zinc chrome primer to is:2074.

FINAL ASSEMBLY OF JOB

RIVETTING SECTION Details of rivet checking to be maintained as per rivet checking

register (item no.-2 of appendix-i of b1-2008.

FINAL ASSEMBLY SECTION Final finishing of length, profile, notches etc.

Fixing of fitting for site connections.

All the defects should be rectified

Final check & inspection

Final assembly includes accurate machining of end profile of component.

All the members should be correctly marked before dispatch to facilitate easier erection.

ISNPECTION After final finishing, identification of marking of component

(shipping mark) is done. After final inspection by RDSO/inspecting agency, the girder parts are cleared for metalizing/painting.

PAINTING No part shall be painted unless inspected & passed by

RDSO/inspecting officials.

Dry film thickness shall be measured by ELCOMETER.

Before painting the surface to be painted should be prepared carefully.

Surface preparation ………………

Manual hand cleaning Cleaning with power driven tools Blast cleaning Flame cleaning (for plates>10mm thick)

Painting in areas where there is no service corrosion ……………..

PRIMER COAT : One Coat of Ready Mixed Paint Zinc Chromate to IS:104

followed by one coat of Ready Mixed Paint Red Oxide Zinc Chrome to IS:2074.

FINISHING COAT : Two Coats of Red Oxide paint to IS:123 (One Coat in

Workshop before dispatch, 2nd Coat at site after errection)

METALIZING

As per appendix –vii of b1-2008

Surface shall be cleaned and roughened by compressed air blasting with a suitable abrasive material as per is:6586

After cleaning the surface, metal spraying should be done by wire method using 2 to 5mm aluminium wire. The purity of aluminium should be 99.5% conforming to IS: 2590.

The min. Thickness of al coating should be 110 micron and average thickness should be 150 micron. The specified thickness should be applied in min.2 layers.

atleast 01 layer of the coating must be applied within 4 hrs. Of blasting. The surface must be finished to specified thickness within 8 hours of blasting. Spray coating shall be uniform texture and free from lumps, coarse areas etc.

WELL EQUIPPED WORKSHOP

PAINTING SECTION Metalizing

After metal spraying ………..

one coat of etch primer to is:5666

one coat of zinc chrome primer to is:104

Two coats of aluminium paint to is:2339 (one coat in workshop before dispatch, 2nd coat at site after errection)

DESPATCH SECTIONAfter metalizing and painting the members of the girders may be sent to errection on site.

TESTING OF AGGREGATE USED IN

RAILWAY BRIDGES

INTRODUCTION

The properties of the aggregates affect both the fresh and hardened properties of concrete. It is crucial to know the properties of the aggregates to be used in the making of concrete in order to obtain the desired quality in a concrete. Therefore, the tests performed on aggregates are very important. Concrete is a composite material in which a binding material mixed in water on solidification binds the inert particles of well graded fine and coarse aggregates. Cement and lime are generally used as binding materials, whereas sand cinder is used as fine aggregates and crushed stones, gravel, broken bricks, clinkers are used as coarse aggregates.

Definitions

Aggregate -granular material used in construction. Aggregate may be natural, manufactured or recycled.

Natural aggregate - aggregate from mineral sources which has been subjected to nothing more than Mechanical processing. Manufactured aggregate - aggregate of mineral origin resulting from an industrial process involving Thermal or other modification. Recycled aggregate -aggregate resulting from the processing of inorganic material previously used in Construction. Aggregate size - designation of aggregate in terms of lower (d) and upper (D) sieve sizes expressed As d/DFine aggregate - designation given to the smaller aggregate sizes with D less than or equal to 4 mm Coarse aggregate - designation given to the larger aggregate sizes with D greater than or equal to 4 mm and d greater than or equal to 2 mm. All-in aggregate - aggregate consisting of a mixture of fine and coarse aggregates. Fines - particle size fraction of an aggregate which passes the 0,063 mm sieve. Grading - particle size distribution expressed as the percentages by mass passing a specified set of sieves.The aggregate should have the following properties

STRENGTH: The concrete should be able to withstand the stresses that it is subjected to. It is quite strong in compression but weak in tension.

DURABILITY: It should be durable enough to resist the effect of weathering agents.

RESISTANCE TO WEAR AND TEAR: when used in floors and in the construction of roads the concrete should be able to withstand abrasive forces.

WORKABILITY: It should be easily workable.

SIEVE ANALYSIS

AIMTo determine the particle size distribution of fine and coarse aggregates by sieving as per IS: 2386 (Part I) - 1963.PRINCIPLEBy passing the sample downward through a series of standard sieves, each of decreasing size openings, the aggregates are separated into several groups, each of which contains aggregates in a particular size range.

APPARATUS

A SET OF IS SIEVESi) A set of IS Sieves of sizes - 80mm, 63mm, 50mm, 40mm,31.5mm, 25mm, 20mm, 16mm, 12.5mm, 10mm, 6.3mm,4.75mm, 3.35mm, 2.36mm, 1.18mm, 600m, 300m, 150mii) Balance or scale with an accuracy to measure 0.1 percent of the weight of the test sampleThe weight of sample available should not be less than the weight given below:-

Maximum size present

in substantial

proportions

(mm)

Minimum weight of

sample despatched

for testing

(kg)

63

50

40

25

20

16

12.5

10.0

6.3

100

100

50

50

25

25

12

6

3

The sample for sieving should be prepared from the larger sample either by quartering or by means of a sample divider.PROCEDURE

The test sample is dried to a constant weight at a temperature of 110 + 5oC and weighed.

The sample is sieved by using a set of IS Sieves. On completion of sieving, the material on each sieve is

weighed. Cumulative weight passing through each sieve is calculated

as a percentage of the total sample weight. Fineness modulus is obtained by adding cumulative

percentage of aggregates retained on each sieve and dividing the sum by 100.

REPORTING OF RESULTSThe results should be calculated and reported as:

The cumulative percentage by weight of the total sample

The percentage by weight of the total sample passing through one sieve and retained on the next smaller sieve, to the nearest 0.1 percent.

The results of the sieve analysis may be recorded graphically on a semi-log graph with particle size as abscissa (log scale) and the percentage smaller than the specified diameter as ordinate.A sample chart is provided

WATER ABSORPTION

AIMTo determine the water absorption of coarse aggregates.APPARATUS

Wire basket - perforated, electroplated or plastic coated with wire hangers for suspending it from the balance

Water-tight container for suspending the basket Dry soft absorbent cloth - 75cm x 45cm (2 nos.) Shallow tray of minimum 650 sq.cm area Air-tight container of a capacity similar to the basket Oven

SAMPLEA sample not less than 2000g should be used.PROCEDURE

The sample should be thoroughly washed to remove finer particles and dust, drained and then placed in the wire basket and immersed in distilled water at a temperature between 22 and 32oC.

After immersion, the entrapped air should be removed by lifting the basket and allowing it to drop 25 times in 25seconds. The basket and sample should remain immersed for a period of 24 + ½ hrs. afterwards.

The basket and aggregates should then be removed from the water, allowed to drain for a few minutes, after which the aggregates should be gently emptied from the basket on to one of the dry clothes and gently surface-dried with the cloth, transferring it to a second dry cloth when the first would remove no further moisture. The aggregates should be spread on the second cloth and exposed to the atmosphere away from direct sunlight till it appears to be completely surface-dry. The aggregates should be weighed (Weight 'A').

The aggregates should then be placed in an oven at a temperature of 100 to 110oC for 24hrs. It should then be removed from the oven, cooled and weighed (Weight 'B').

REPORTING OF RESULTSWater absorption = [A/B] x 100%

Two such tests should be done and the individual and mean results should be reported.A sample farm for the record of the test results is given

AGGREGATE ABRASION VALUE

AIMTo determine the abrasion value of coarse aggregates.APPARATUS

LOS ANGLES MACHINE Los Angles abrasion testing machine IS Sieve of size - 1.7mm Abrasive charge - 12 nos. cast iron or steel spheres

approximately 48mm dia. and each weighing between 390 and 445g ensuring that the total weight of charge is 5000 + 25g

OvenPREPARATION OF SAMPLEThe test sample should consist of clean aggregates which has been dried in an oven at 105 to 110oC to a substantially constant weight and should conform to one of the grading shown in the table below:

PROCEDUREThe test sample and the abrasive charge should be placed in the Angles abrasion testing machine and the machine rotated at a speed of 20 to 33 revolution/minute for 1000 revolutions. At the completion of the test, the material should be discharged and sieved through 1.70mm IS Sieve.Tolerance of +2 percent permitted.

REPORTING OF RESULTS The material coarser than 1.70mm IS Sieve should be

washed, dried in an oven at a temperature of 100 to 110oC to a constant weight and weighed (Weight 'B').

The proportion of loss between weight 'A' and weight 'B' of the test sample should be expressed as a percentage of the original weight of the test sample. This value should be reported as,

Aggregate abrasion value = [(A – B)/A]x 100%A sample farm for the record of the test results is

AGGREGATE IMPACT VALUEAIMTo determine the aggregate impact value of coarse aggregates.APPARATUS

AGGREGATE IMPACT TEST MACHINE Impact testing machine conforming to IS: 2386 (Part IV) -

1963 IS Sieves of sizes - 12.5mm, 10mm and 2.36mm. A cylindrical metal measure of 75mm dia. and 50mm depth. A tamping rod of 10mm circular cross section and 230mm

length, rounded at one end Oven

PREPARATION OF SAMPLE The test sample should conform to the following grading:

Passing through 12.5mm IS Sieve 100% Retention on 10mm IS Sieve 100%

The sample should be oven-dried for 4hrs. at a temperature of 100 to 110oC and cooled.

The measure should be about one-third full with the prepared aggregates and tamped with 25 strokes of the tamping rod.

A further similar quantity of aggregates should be added and a further tamping of 25 strokes given. The measure should finally be filled to overflow, tamped 25 times and the surplus aggregates struck off, using a tamping rod as a straightedge. The net weight of the aggregates in the measure should be determined to the nearest gram (Weight 'A').

PROCEDURE The cup of the impact testing machine should be fixed firmly

in position on the base of the machine and the whole of the test sample placed in it and compacted by 25 strokes of the tempering rod.

The hammer should be raised to 380mm above the upper surface of the aggregates in the cup and allowed to fall freely onto the aggregates. The test sample should be subjected to a total of 15 such blows, each being delivered at an interval of not less than one second.

REPORTING OF RESULTS The sample should be removed and sieved through a 2.36mm IS

Sieve. The fraction passing through should be weighed (Weight 'B'). The fraction retained on the sieve should also be weighed (Weight 'C') and if the total weight (B+C) is less than the initial weight (A) by more than one gram, the result should be discarded and a fresh test done.

The ratio of the weight of the fines formed to the total sample weight should be expressed as a percentage.

Aggregate impact value = [A/B] x100% Two such tests should be carried out and the mean of the results

should be reported.A sample proforma for the record of the test results is

AGGREGATE CRUSHING VALUE

AIMTo determine the aggregate crushing value of coarse aggregates.APPARATUS

CYLINDRICAL MEASURE AND PLUNGER Cylindrical measure and plunger Compression testing machine IS Sieves of sizes - 12.5mm, 10mm and 2.36mm

PROCEDURE The aggregates passing through 12.5mm and retained

on10mm IS Sieve are oven-dried at a temperature of 100 to110oC for 3 to 4hrs.

The cylinder of the apparatus is filled in 3 layers, each layer tamped with 25 strokes of a tamping rod.

The weight of aggregates is measured (Weight 'A'). The surface of the aggregates is then levelled and the

plunger inserted. The apparatus is then placed in the compression testing machine and loaded at a uniform rate so as to achieve 40t load in 10 minutes. After this, the load is released.

The sample is then sieved through a 2.36mm IS Sieve and the fraction passing through the sieve is weighed (Weight 'B').

Two tests should be conducted.

REPORTING OF RESULTS

Aggregate crushing value = [B/A]x 100%The result should be recorded to the first decimal place and the mean of the two results reported.

SHAPE TEST

AGGREGATE FLAKINESS INDEX VALUE

AIMDetermination of flakiness index of coarse aggregate, where the size of the coarse aggregate are larger than 6.3mm. 

EQUIPMENT & APPARATUS Thickness gauge Sieves [63, 50, 40, 31.5, 25, 20, 16, 12.5, 10 & 6.3mm] Balance [0-10 kg]

Thickness gauge

PREPARATION SAMPLESurface dry samples is used for the test. A minimum number of 200 pieces of any specified fraction is required to do the test. 

PROCEDUREThe sample is sieved through IS sieve specified in Table shown below.

Dimension of Thickness and Length Gauge

A minimum of 200 pieces of each fraction is taken and weighed. In order to separate flaky materials, each fraction is then gauged

individually for thickness on a thickness gauge.  The total amount of flaky material retained by the thickness gauge

is weighed to an accuracy of 0.1% of the weight of sample. 

CALCULATIONIn order to calculate the flakiness index of the entire sample of aggregates, first the weight of each fraction of aggregate passing and retained on the specified sets of sieves is noted (Y1, Y2, Y3, Y4…..etc.). Each piece of these are tried to be passed through the slot of the specified thickness of the thickness gauge are found and weighed (y1, y2, y3, y4…etc.). Then the flakiness index is the total weight of the material retained on the various thickness gauges, expressed as a percentage of the total weight of the sample gauged.

REPORTFlakiness index is reported in percentage to the nearest whole number

AGGREGATE ELONGATION INDEX

AIMFor determination of elongation index of coarse aggregate, where the size of the coarse aggregate are larger than 6.3 mm. 

EQUIPMENT & APPARATUS Length gauge Sieves(63mm,50mm,40mm,31.5mm,25mm,20mm,16mm,12.5mm

,10mm) Balance (0-10kg) Oven (3000c)

Length Gauge

TEST SAMPLE PREPARATIONSurface dry samples is used for the test. A minimum number of 200 pieces of any specified fraction is required to do the test. 

PROCEDURE A minimum of 200 pieces of each fraction is taken and weighed. In order to separate elongated materials, each fraction is then

gauged individually for length in the length gauge. The pieces of aggregate from each fraction tested which could not

pass through the specified gauge length with its long sides elongated are collected separately to find the total weight of aggregate retained on the length gauge from each fraction.

The total amount of elongated material retained by the length gauge is weighed to an accuracy of 0.1% of the weight of sample.

The sample is sieved through IS sieve specified in Table shown below.

 

CALCULATIONIn order to calculate the elongation index of the entire sample of aggregates, first the weight of each fraction of aggregate passing and retained on the specified set of sieves is noted (Y1, Y2, Y3, Y4…..etc.). Each piece of these are tried to be passed through specified length of the gauge length with its longest side and those elongated pieces which do not pass the gauge are separated and weighed (y1, y2, y3, y4…etc.). Then the elongated index is the total weight of the material retained on the various length gauges, expressed as a percentage of the total weight of the sample gauged.

REPORTSElongation index is reported in percentage to the nearest whole number. 

SAFETY & PRECAUTIONS Use hand gloves while removing containers from oven after

switching off the oven. Use safety shoes, mask & aprons at the time of test.

LIST OF SUPPLIERS OF MATERIAL TESTING EQUIPMENTS ALONGWITH

THEIR ADDRESSES1. AIMIL Ltd.Malhotra House, Walchand Hirachand Marg,Opp. to G.P.O. Fort, Mumbai - 400 001.

2. Testwell Scientific Instrument Pvt. Ltd.5, Nand Dham, Ground Floor,Plot No. 270, Sion Cementary Road, Sion (W) - 400 022.

3. Utile Equipments13, Jal Tarang, Prabhat Road,Lane No.1, Pune - 411 004

4. Lawerence & Mayo (India) Pvt. Ltd.3, Dr. Ambedkar Road, Pune - 411 001.

5. Laxmi Sales & Agencies84, Pannalal Nagar, Amaravati - 444 605.

6. Commander Agencies1466, Sadashiv Peth, Pune - 411 030.

7. M/s Rout Scientific & General Traders17/B, Ashiwini Society, Behind Hotel Monali,Wakadewadi, Pune - 411 005.

8. DYEGLO820/7, Shee-Krishna Kunj,Bhandarkar Institute Road,Pune - 411 004.

ACKNOWLEDGEMENT

I express my sincere gratitude to Executive Director/ Bridge

Corporation, all Directors of the Directorate along with Assistant

Engineers associated with this summer training for his proper guidance,

useful suggestions and timely treatment where ever required during the

entire training. My best wishes to Director Bridge Corporation for giving a

chance for this summer training and know about bridge structures in Indian

Railways. My special thanks goes to Mr. Vikrama Prasad (Sr. Section

Engineer) for guiding us in course of this project and suggesting us the

ways and means to enhance it. He has been very helpful and a great source

of inspiration during the entire project. I wish to extend my sincere thanks

for his excellent guidance and suggestions for the successful completion of

my project work.

THANKS A LOT