INTERNSHIP REPORT

ACKNOWLEDGEMENT

First I would like to thank, DR. Zulifqar Head of Civil Engineering Department
Univsersity of Lahore to advise me to do this internship. Secondly I would like to thank
Engineer Farakh Alvi, the Project Manager HRL (Pvt.) Ltd, Chiniot Power Plant for
giving me the opportunity to do an internship within the organization. For me it was a
unique experience to be in Chiniot and to study an interesting project. It helped me to get
back my interest in Civil Engineering and to have new plans for my future career. I also
would like all the people that worked in the project. With their patience and sincerity they
created an enjoyable working environment. Furthermore I want to thank all the Engineers
with whom I did the fieldwork experienced great things together and they have shown me
great learning parts of their project. At last I would like to thank the Engineer Sharjeel,
Planning Manager TAPL and especially thank to the Engineer Ijaz Rasool, Site Manager
TAPL, to allow me to do this interesting internship. The internship is very helpful as I
have gained my knowledge as a civil engineer and also it will support me in my job
carrier. I would like to say that it would me one of my best experiences that would remain
with me in my job career.

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CONTENTS

1) Introduction .........................................................................4
1.1) Project Description ………………………………...4

1.2) INTRODUCTION OF ORGANIZATION.....…..……4

2) Activities Participated …………………………………….5

3) Activities Observed ………………………………………..6

4) Correlation of Activities with Standards ………………..7

5) Study of Drawing, Design ……………………………….11
6) Difficulties Faced ………………………………………...12

7) Summery and Knowledge ………………………………13

8) Appendix …………………………………………………14

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LIST OF FIGURES

 (Fig # 1) Chimneys Drawing ……………………………………………..11

 (Fig # 2) Lean concrete of chimney footing ……………………………..14

 (Fig # 3) Steel mash fixing of chimney footing ………………………….14

 (Fig # 4) Poring of concrete in chimney footing ………………………...15

 (Fig # 5) Removal of formwork of chimney footing …………………….15

 (Fig # 6) Formwork of Slip forming ……………………………………...16

 (Fig # 7) Start working on Slip forming ………………………………….16

 (Fig # 8) After some days working on Slip forming ……………………..17

 (Fig # 9) Excavation and compaction of belt conveyor footing …………18

 (Fig # 10) Steel mash fixing of belt conveyor footing and columns ……..18

 (Fig # 11) Line of belt conveyor ……………………………………………19

 (Fig # 12) Poring of concrete with concrete pump and vibrator ………..19

 (Fig # 13) Tower crane and concrete pump in turbine generator desk …20

 (Fig # 14) Incident on site during transportation of soil ………………….20

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1) INTRODUCTION

1.1) PROJECT DESCRIPTION

The project is located at Bhawana, Jhang Road Chiniot, Punjab Pakistan and is Co-
generation plant, which is based on bagasse ensuring that all measures are in place to
make the Project environmentally compliant. The vision is to Contribute the development
and growth of Pakistan by being the largest innovative, high tech, environment friendly
and socially responsible company producing value added products from indigenous
available agricultural/industrial waste & by-products and renewable resources. During
120 days of crushing season, bagasse being a by-product of sugar mill process, will be the
primary fuel for the project, during rest of the year the un-utilized bagasse will be utilized
for power generation. plant offers a number of advantages apart from helping in bridging
the gap between the demand and the supply in the power sector. The bagasse based
cogeneration offers an environmentally friendly solution for additional power generation,
helps in reducing the dependence on the fossil fuels, saves on the foreign currency
outflow from the country and improves the financial position of the sugar factory. The
proposed Cogeneration plant of CPL, will export a substantial quantum of power to the
national grid. The project is being developed on fast track and is expected to be
operational by mid - 2015.

1.2) INTRODUCTION OF ORGANIZATION

I have done my internship in Habib Rafiq Pvt. Ltd, at construction of Chiniot Power
Plant Project. The idea was just start of the challenging task, brainstorming, and restless
nights.

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Habib Rafiq (Pvt.) Limited has come a long way to symbolize commitment, distinction
and professional Excellence by meeting the stringent, demanding and extra ordinary work
requirements of high engineering, national and international importance involving civil,
electrical and mechanical works for the last 55 years. The ever increasing efforts towards
attaining better and new business ventures have exposed the company to multitude of
engineering disciplines. Now it is company's prerogative to be working in infrastructure,
housing, design and environmental areas other than its strong standing in industrial
projects for power, chemicals, petro chemicals, roads, Motorways, buildings and airports.

2) ACTIVITIES PARTICIPATED

During the internship period I worked under the site Engineer. Most of the Project
activities were on peak during my entrance in the site. One of the unique and ever new
activities I have never seen before was Slip forming construction. I observed different site
activities which include the following.

 Excavation
 Soil Compaction with vibrators
 Lean concrete
 Horizontal steel mash fixing
 Column steel fixing
 Formwork
 Horizontal concrete pouring
 Column concrete pouring
 Vibrating
 Removal of Formwork
 Back filling
 Pumping
 Slip Forming

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3) ACTIVITIES OBSERVED

My duty was specifically on chimney construction and belt conveyor during my

training period. I have to observe the different activities during the construction. The
detail of these observation is given below as following.

 Excavation Monitoring
Excavation was done for belt conveyor and chimney foundation construction.
I was there to observe and enhance excavation quantity considering the safety
precautions.
 Compaction Monitoring
I ensured to achieve the desired compaction level by using sand-cone method
to determine the field density of soil.
 Lean Concrete mix design
I checked that the work is being completed according to provided mix ratios
and especially to adjust the water with atmospheric conditions.

 Steel Fixing and Formwork

I observed the steel fixing and formwork according to provided bar-bending
schedule and drawings.
 Foundation and column Concrete poring
I have to check the concrete proportions according to the mix design provided
and then I observed the concrete poring done by concrete lifter. I also observed
the Compaction done during the concrete poring process.

 Curing of concrete work.

Ordinary Sulphate resisting cement was used so that Curing was done by
polythene film to enhance speed of concrete poring and to remove formwork after
24 hours.

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 Slip Forming
One of the most interesting part of my internship was to observe the slip
forming construction for chimney construction. Slip form construction is a
construction method in which concrete is poured into a continuously moving
form. Slip forming is used for tall structures (such as bridges, towers, tall
chimneys, buildings, and dams), as well as horizontal structures, such as
roadways.

4) CORRELATION OF THE ACTIVITIES WITH STANDARDS

DETERMINATION OF SOIL COMPACTION

The Sand Cone Method, ASTM-D-4914
These test methods are used to determine the in-place density of compacted materials.
These test methods cover the determination of the in-place density and unit weight of soil
and rock using a pouring device and calibrated sand to determine the volume of a test pit.
The word “rock'' in these test methods is used to imply that the material being tested will
typically contain particles larger than 3 in. (75 mm). Determination of field density of
cohesion less soil is not possible by core cutter method, because it is not possible to
obtain a core sample. In such situation, the sand replacement method is employed to
determine the unit weight. In sand replacement method, a small cylindrical pit is
excavated and the weight of the soil excavated from the pit is measured. Sand whose
density is known is filled into the pit. By measuring the weight of sand required to fill the
pit and knowing its density the volume of pit is calculated. Knowing the weight of soil
excavated from the pit and the volume of pit, the density of soil is calculated.

Slump Test , ASTM C143-:

The slump test is the most well-known and widely used test method to characterize
the workability of fresh concrete. The inexpensive test, which measures consistency, is
used on job sites to determine rapidly whether a concrete batch should be accepted or
rejected. The test method is widely standardized throughout the world, including in

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ASTM C143 in the United States and EN 12350-2 in Europe. The apparatus consists of a
mold in the shape of a frustum of a cone with a base diameter of 8 inches, a top diameter
of 4 inches, and a height of 12 inches. The mold is filled with concrete in three layers of
equal volume. Each layer is compacted with 25 strokes of tamping rod. The slump cone
mold is lifted vertically upward and the change in height of the concrete is measured.
Four types of slumps are commonly encountered, as shown in Figure 3. The only type of
Slump permissible under ASTM C143 is frequently referred to as the “true” slump, where
the concrete remains intact and retains a symmetric shape. A zero slump and a collapsed
slump are both outside the range of workability that can be measured with the slump test.
Specifically, ASTM C143 advises caution in interpreting test results less than ½ inch and
greater than 9 inches. If part of the concrete shears from the mass, the test must be
repeated with a different sample of concrete. A concrete that exhibits a shear slump in a
second test is not sufficiently cohesive and should be rejected.

FINENESS MODULUS (ASTM. C-117-05) :

It is the cumulative percentage retained on standard sieve 150um and above, divided
by 100.It is a Single factor or an empirical number which we get from the results of sieve
analysis. The value of FM will not change if we add sieves above.

SIEVE ANALYSIS:
It is the operation of dividing the aggregate into various fractions, each consisting of
particles of same size. Or it is the operation of determination the particle size distribution
of the given specimen.

NOTE:

 5 mm is the dividing line between coarse and fine aggregate.

 Well graded coarse aggregates of large size will reduce shrinkage of concrete by
50%.

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FUNCTIONS OF SIEVE ANALYSIS:

Sieve Analysis is performed on coarse and fine aggregates In order to check their
gradation. This gradation gives an indirect measure if the workability and average particle
size.

MATERIALS USED IN CONSTRUCTION

SAND:
These are cohesion less aggregates of either, rounded sub rounded, angular, sub
angular or flat fragments of more or less unaltered rock of minerals consisting of 90% of
particles of size greater than 0.06 mm and less than 2 mm. Alternatively, these are coarse
grained cohesion less particles of silica derived from the disintegration of rock.

CEMENT:
The cement often called the magic power is a fine ground material consisting of
compound of lime, silica alumina and iron. When mixed with water it forms a paste
which hardened and bind the aggregates called the Concrete. Cement is the binder that
holds concrete and mortars together.

STEEL:
RCC stands for reinforced cement concrete. To enhance the load carrying capacity of
the concrete it is reinforced with steel bars of different diameters provided in
inappropriate manner. Such concrete is called reinforced concrete and the bars are called
the reinforcement. These bars are provided at various locations to resist the internal
forces, which are developed due to the loads acting on the structure.

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MACHINERY USED IN CONSTRUCTION

EXCAVATOR:
Excavators are heavy construction equipment consisting of a boom, stick, bucket and
cab on a rotating platform (known as the "house"). The house sits atop an undercarriage
with tracks or wheels. A cable-operated excavator uses winches and steel ropes to
accomplish the movements. They are a natural progression from the steam shovels and
often called power shovels. All movement and functions of a hydraulic excavator are
accomplished through the use of hydraulic fluid, with hydraulic cylinders and hydraulic
motors.

CONCRETE MIXER:
A concrete mixer (also commonly called a cement mixer) is a device that
homogeneously combines cement, aggregate such as sand or gravel, and water to form
concrete. A typical concrete mixer uses a revolving drum to mix the components. For
smaller volume works portable concrete mixers are often used so that the concrete can be
made at the construction site, giving the workers ample time to use the concrete before it
hardens. An alternative to a machine is mixing concrete by hand.

DUMPER TRUCK:
It is a vehicle used for carrying bulk material, often on building site. A dump truck
(or, UK, dumper truck) is a truck used for transporting loose material (such as sand,
gravel, or dirt) for construction. A typical dump truck is equipped with an open-box bed,
which is hinged at the rear and equipped with hydraulic pistons to lift the front, allowing
the material in the bed to be deposited ("dumped") on the ground behind the truck at the
site of delivery. It was used in the project to carry and transport fine and course
aggregates to the construction site.

Concrete Vibrator

Tower Crain
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5) STUDY OF DRAWING , DESIGN

Figure 1: Drawing of the chimney

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6) DIFFICULTIES FACED

In this project I obtained knowledge about the basic & advanced techniques of project
construction as well as observed the challenges and difficulties which a civil engineer has
to face during construction. A few have been listed below
 Punctuality
 Environmental challenges.
 Difficulties in testing of materials.
 Labor problems.
 Material transportation

7) SUMMARY AND KNOWLEDGE GAINED

This internship report contain about my work experience with HRL Pvt. Limited. It was
very interesting and knowledge gaining internship to me. I observed a lot of execution of
my theoretical knowledge in the field which I learnt from books. I learnt the following
skills

 The execution of different field activities on their specific schedule.

 Project manager have to look after not only the major deadlines, but also make
decision on all matters.
 The project manager is actually the coordinator of each project and is responsible
to make the project’s progress smooth and on track.
 The control of project staff and to check different fields coordination like
mechanical and electrical working together on specific activities.
 To check the coordination between different fields is appropriate.

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 In order to get good progress the quality control on project needs a very good
coordination and large quantities of man power, equipment and funds.
 The concrete should be properly prepared by mixing of sand, cement and water
according to the standards of civil engineering.
 The construction company should focus on developing the skills of labor to
increase the work speed and efficiency.

8) CONCLUSION

 Internship is a good way to execute knowledge in field.

 To understand how different things in field relate with your knowledge so it must
be a part of degree program and internship period must be increased.
 We get knowledge about the basic & advanced techniques construction as well as
observed the challenges which a civil engineer has to face during i.e. labor
problems, cost management, environmental challenges etc. We cleared our many
doubts regarding building construction.
 Internship training is a golden opportunity to learn that how engineering
knowledge obtained during study in classrooms is applied to the practical civil
engineering projects/works.
 Internship training through working with civil engineering professionals opens up
job avenues for civil engineers for various institutions.
 The internees must take full benefit of internship training program by remaining
thoroughly involved in all aspects of training like technical work, data
collection/analysis and technical documents preparation processes.

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9) APPENDIX

Figure 2: Lean of chimney footing

Figure 3: Steel mash fixing of chimney footing

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Figure 4: Poring of chimney footing

Figure 5: Removal of formwork of chimey footing

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Figure 6: Formwork of slip forming

Figure 7: Start work on slip forming

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Figure 8: After some days working on slip forming

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Figure 9: Excavation and compaction of belt conveyor footing

Figure 10: Steel mash fixing of belt conveyor footing and column

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Figure 11: Line of belt conveyor

Figure 12: Poring of concrete with concrete pump and vibrator in TG desk

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Figure 13: Tower crane and concrete pump in turbine generator desk

Figure 14: Incident on site during transportation of soil

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