REPORT OF EDUCATIONAL VISIT
To
Construction site of
‘Godrej - Cattle Feed plant’ near VP campus Baramati
Class: TE (Civil)
th
(Date: - 7 August 2013)
TIME- 11.15 TO 1.15 PM
The Department of Civil Engineering of Vidya Pratishthan’s College of Engineering organized
educational visit to Construction Site of ‘Godrej Cattle feed plant’ near to VP Campus in M.I.D.C.
Baramati, Dist.- Pune for 78 T.E. Civil Engineering students. Visit was organized as per Pune university
guidelines and recommendations regarding syllabus of IECT for T.E Civil Engineering.
Visit was organized with the prior permission and under guidance of honorable Dr. S. B.
Deosarkar Sir (Principal, VPCOE), Prof. G. N. Narule (Head of Civil Engg Dept), by the initiative and
hard efforts of Class teacher of T.E Civil Prof. D. G. Patil (Subject teacher) & Prof. A. A. Sukhdeve.
Er. Satish Mhetre Sir of ‘Utkarsh Group-Baramati’ kindly permitted us for Visit and guided very
well during the Visit by explaining and showing every process and operation.
Students left the VPCOE Campus for visit on 7th Aug 2013 at 11.15 am. Students carefully studied
and observed the different advanced construction techniques in Civil Engineering especially ‘Tremix
concrete floor, Brick-bat water proofing technique, Concrete pumping system’.
Picture : Er. Satish Mhetre Sir explaining students about Tremix concrete flooring.
We studied following different techniques during visit.
1.
2.
3.
4.
RMC plant
Pumping of concrete
Tremix concrete flooring
Floor finishing
5.
6.
Mobile Cranes
Brick - Bat Water proofing and Concealed Plumbing
1. READY MIX CONCRETE PLANT (RMC PLANT) Concrete which is mixed at central batching plant and transported at the site by suitable means
like belt conveyor, transit mixer is called ready mixed concrete. It also gives an advantage of building the
testing facilities at one centralized location.
NECCESSITYConventional concreting method consumes time in construction of large projects. So it needs a
special type of concrete which is ready to use at site which will save time and give proper strength with
quality. RMC proves the best one in such situation.
COMPONENTS PARTS OF READY MIXED CONCRETE PLANT
1. Storage silos for cement
2. Storage of aggregate.
3. Batching plant of designed capacity
4. Testing laboratory
5. Small workshop
6. Vehicles and pumps to transport concrete to the site.
OPERATION OF READY MIXRD PLANT
1. Aggregate storage bins depending upon the no’s of sizes aggregate used are installed in the rear
side of batching plant. The bins are provided with a drag line. A crushing plant may be installed
adjacent to the batching plant to reduce transportation cost.
2. The batching plant is provided with cement silos of capacity
3. Supply of cement on silos is done by emptying cement bag in to hopper from where it is carried to
the top of silos through the screw conveyor and bucket elevator
4. The cement in silos is recycled through an interconnected screw conveyor it keeps the cement in
fresh state.
5. The plant is served by aggregate storage bins placed at rear with a drag line.
6. The exact quantities as per design mixed of all materials aggregate cement water additives are
delivered into the mixer with the use of control panel with microprocessor a computer.
7. After the completion of cycle of mixing time 40 sec, the concrete batch is discharged by opening
the bottom slide gets to the waiting transit mixer.
Picture – RMC Plant
ADVANTAGES• Accuracy of mix concrete and calibration of the components.
• Accuracy of controlling the quality of the components (cement, aggregates, water).
• Superiority of the mixing process quality due to the absence of the human error.
• Accuracy and the centrality of quality control operations.
• Avoidance of the burden of storing raw materials in site whiles the production of concrete.
• Avoidance of losing the required quality of raw materials due to poor setting and storing or due to
weathering.
• Reduction of the labor required for the work of mixing and pouring.
• Easiness of pumping concrete in high-rise.
• Easiness of concrete surface serving & leveling.
• Reduction and time saving of site works duration.
DISADVANTAGES


The materials are batched at a central plant, and the mixing begins at that plant, so the traveling
time from the plant to the site is critical over longer distances. Some sites are just too far away,
though this is usually a commercial rather than a technical issue.
Generation of additional road traffic. Furthermore, access roads and site access have to be able to
carry the greater weight of the ready-mix truck plus load. (Green concrete is approx. 2.5 tone per
m³.) This problem can be overcome by utilizing so-called 'minimix' companies which use smaller
4m³ capacity mixers able to reach more-restricted sites.
Concrete's limited timespan between mixing and going-off means that ready-mix should be placed
within 90 minutes of batching at the plant. Modern admixtures can modify that timespan precisely,
however, so the amount and type of admixture added to the mix is very important.
TRANSIT MIXERTransit mixer is very effective and popular equipment used for transportation of concrete over a long
distance vitally used in RMC plant. Transit mixer is a truck mounted mixer having capacity of 4 to 7
meter cube.
But on our site which we visited, RMC plant was on Site and concrete was transported by using concrete
pumps.
2. PUMPING OF CONCRETEIt is the method in which the fresh concrete is pumped to the area of tremix flooring. Concrete
pumps are operated by electric power. Pipeline pumping system has diameter between 100mm to 180mm.
Diameter size of 150mm was adopted for pumping of concrete on this site.
Pumpe have fully hydraulic , compact and dirt resistace control system. Hydrulic pumpes is
output regulated and hence required less power utilization at an ideal speed and pressure.
Following are the types of concrete Pump1. Pneumatic Pump
2. Piston Pump
3. Squeeze Type Pump
An output of 20 cub. m/hr of concrete for distance about 90 m horizontally and 30 m vertically can be
obtained trough the pipe diameter of 75 mm to 100 mm.
Picture – Pumping of Concrete on Site
Figure – Piston Pump
An output of 55 cub. m/hr of concrete can be pumped about 430 m horizontally and 40 m vertically trough
220 mm diameter of pipe .
ADVANTAGES OF PUMPED CONCRETE1. Concrete can be moved horizontally as well as vertically at a time.
2. It provides good quality control.
3. Concreting by pumping is most effective and sensitive method because any variation in a concrete mix
can be easily rectified at the pumping joint by observing the pumping pressure and hence there is a proper
control on consistency and workability of concrete.
4. No wastage of concrete if casting work done by pumping, but there is more wastage if concrete casting
works done manually.
5. By pumping system, concrete can be placed in inaccessible area.
6. For high-rise building, pumped concrete method is best suitable, economical and faster.
7. Pipeline for delivery of the concrete requires a very less space and can be easily removed.
8. Pump cannot be substitute for the crane on the construction job, but could certainly relive the crane for
other works.
9. This helps in saving several weeks of building time on a high-rise construction job.
Picture – Casting of Floor using Pumped Concrete
Picture – Cleaning of Concrete Pump and Pipeline
The cleaning of concrete pump and pipeline is very simple which is done by using water and sponge ball.
These were passed through the pipes immediately after the concreting work is completed and before the
hardening of concrete which is stacked inside the pipe. Connected pipes are separated after the cleaning.
Picture – Cleaning of Pipeline using Water and Sponge Ball
3. TREMIX CONCRETE FLOORING –
It is the method of solution to the problem of combining a sufficient high workable concrete with
a minimum water cement ratio offered by vacuum processing of freshly placed concrete. Such a concrete
is usually referred to as a vacuum concrete or tremix concrete floor.
It is method of removal of surplus water from the concrete to maintain optimum water cement
ratio by vacuum system so as to increase impact strength or toughness and abrasion value of wearing
course of concrete floor.
Equipment used in tremix concrete floor construction –
1. Vacuum pump with fine wire gauge or muslin cloth
2. Water separator.
3. Filtering mat.
4. Power trowel.
5. Backing piece with rubber seal.
SALIENT FEATURS –
1.
2.
3.
4.
Reduction of water content by 20 to 25%.
Reduce risk of shrinkage in concrete.
Finishing possible immediately after vacuum dewatering.
The tremix vacuum pump P 4001 is small, powerful pump that makes it possible to work with to
suction mats of 6 x 7 m =42 sq. m.
5. Standard voltage 400 V.
6. A complete suction mat consist of 1 top cover and 1 to 6 filter pads depending on the width of top
cover. Two people can easily move the top cover.
7. The standard width of pad is 1.2 m. Standard length is 2.8 to 6.8 m in intervals of 1 m .the pads are
also available in a roll of 30 m .
Picture - a vacuum concreting or Tremix concrete flooring
Picture - a Vacuum Concreting or Tremix concrete flooring
PROCEDURE OF TREMIX CONCRETE FLOOR CONSTRUCTION-
Figure - Tremix concrete flooring
1. For the last about 10 years, vacuum dewatering technique is fairly widely used in the construction of
factory floors. The technique has been adopted in a big way for the construction of GODREJ
CATTEL FEED PLANT.
2. The processes is equipment oriented. It requires formwork in the form of channels, internal vibrators,
double beam, screed board vibrator for the fool width, bull float.
3. First concrete with relatively higher water cement ratio to facilitate full compaction with needle
vibrator is poured. Then the concrete is further compacted by double beam screed vibrator.
4. Filter mat is placed and it is pressed on all four sides and effectively sealed. Within about 30min, the
vacuum pumps are started, which sucks the unwanted water, what could be termed as “WATER OF
WORKABILITY” and it thrown out.
5. Vacuum pump is run for about 20 to 30mins depending upon the thickness of concrete floor. The
concrete is placed in the number of alternate bays.
6. Then Concrete is skim floated and further power trowled and finished. Often surface hardeners are
used in conjunction with dewatering process.
7. With combine effect of vacuum dewatering and application of floor hardeners, a very good abrasion
resistant factory floor may be constructed.
APPLICATION OF VACUUM DEWATERING CONCRETE –
1.
2.
3.
4.
Picture - Tremix concrete flooring
Tremix floors are successfully used in the construction industry and in Civil Engg Projects.
It is used in parking decks.
This concrete is very strong and durable and hence it used in the industrial flooring.
It is used at the places where surface is contact with the impact loading.
4. FLOOR FINISHING
On the Construction site following machine was used for finishing the concrete floor. It is an
manually operated electric machine.
Picture – Floor Finishing
Picture- Belt Conveyor for Transportation of Materials
The passage provided in the floor for the movement of belt conveyor on which raw and finished material
are transported from one place to another place in the plant. Steel column are placed at a distance of
10feet.
Water proofing is provided to sides of ducts of belt conveyor by using Dr. Fixit chemical.
Picture - The expansion joint, provided in the flooring
The expansion joint is provided in the flooring for avoiding the thermal action. It reduces and controls the
expansion of crack in the concrete .It is filled by bitumen strip.
5. MOBILE CRANES
The mobile cranes were used for lifting heavy Machinery and parts of Oil Tank on the Site.
Other uses of Mobile Cranes 1.
2.
3.
4.
It is used to railway track laying.
It is also used in bridge repairing work.
Electrification work on railway.
For construction industries
Picture – Construction of Oil Tank using Mobile Cranes
6. BRICK - BAT WATER PROOFING AND CONCEALED PLUMBING
Quarters are constructed for the staff members of the plant. On the terrace of quarters BRICK BAT
WATER PROOFING is done to avoid entering of rain water from Terrace to inside through Slab and
joints. It is the most economical method of Water Proofing.
In that mortar is spread on the surface of terrace and then waste brick bats means piece of bricks are
placed systematically. Super plasticizers are mixed in mortar as an admixture. Then mortar is placed on
the layer of brick bat with proper slope to drain the rain water out of the terrace area.
Concealed Plumbing is provided in the Bathrooms and Toilets of Quarter and office area.
Picture – Water Proofing
Picture - Concealed Plumbing
Picture - Er. Satish Mhetre Sir of ‘Utkarsh Group-Baramati’ explaining Drawings of Project
Picture – Base and Connection for Steel Column
Steel column is supported on concrete Column base. This was fixed by using anchor bolts for
rigid fixity of steel column. The anchor bolts are placed in hole driven in concrete column base. After that
very high strength concrete is filled in the hole by grouting Technique.
Students FeedbackSite visit was very successful. Students could learn many Construction Techniques from Site Visit by
practically observing the Process and operations. Site is very nearby to College and it is very helpful to
correlate Theory and Practical applications.
We are extremely thankful to our honorable Principal Prof. Dr. S.B Deosarkar, Er. Satish Mhetre Sir of
‘Utkarsh Group-Baramati’ who kindly guided students and demonstrated all the operations. We are also
thankful to the officials of Utkarsh Group- Baramati & ‘Godrej Cattle Feed Plant’ who permitted us for
Site Visit.
Report Prepared By:Prof. Dilip G. Patil and following TE (Civil) Students1) Kudale Chaitanya Mukund
2) Kakade Vishal Dhananjay
3) Lad Akash Vasant
4) Borkar Dnyaneshwar C.