INDUSTRIAL TRAINING:

PROJECT REPORT

PHASE 1: STUDY OF MANUFACTURE AND PRODUCTION OF CONCRETE MASONRY UNITS PHASE 2: UTILISATION OF THE MASONRY BLOCKS IN CONSTRUCTION OF AN ADMINISTRATIVE BLOCK, REINFORCED MASONRY STRUCTURE.

DHANUSH S 1BM09CV012

Certificate

This is to certify that Dhanush S (1BM09CV012) of B.M.S.College of Engineering has successfully completed his industrial training. The report entitled internship project report is an authentic report of the project work carried out by him, submitted during the academic year 2012-2013.

Signature PROJECT Evaluator

Signature Head of the Dept

ACKNOWLEDGEMENT
On completion of the internship project, I would firstly like to thank the head of the department, Dr R.V.Ranganath and the esteemed faculty of the department of civil engineering, BMSCE, Bangalore for introducing the new concept of industrial training within the coursework. The project has exposed us students to the practical domain of civil engineering. I am grateful to Dr S.Raghunath for recommending us for this project of structural masonry and being a continuous support all through. I would like to thank Mr.Ananth of Axon Concrete pvt. Limited for helping us understand the manufacture of ECMU at his plant. I am grateful to Ansh for allowing us to intern at their esteemed firm. It was a great learning experience for me to witness how the field work is carried. Special thanks to Mr.Kaushik of Ansh for the guidance and information provided throughout the internship. A special thanks to Dr. S Balasubramaniam of SVYM for the hospitality and stay provided during the training period.

CONTENTS
Phase 1: Study of manufacture and production of concrete masonry units
Introduction to ECMU Advantages of ECMU Manufacture of ECMU Storage and stacking of ECMU Zero slump mix design

Phase 2: Utilization of the masonry blocks in construction of an administrative block, reinforced masonry structure.
Marking Anti-termite treatment Foundation Block masonry Joints U-blocks for lintels and plinth beam Typical wall section Masonry piers High volume concrete for door frames Concreting Plastering

ENGINEERED CONCRETE MASONRY UNITS

INTRODUCTION

Hollow concrete blocks are substitutes for conventional bricks and stones in building construction. They are lighter than solid masonry blocks, easier to place and also confer economics in foundation cost and consumption of cement. In comparison to conventional bricks, they offer the advantages of uniform quality, faster speed of construction, lower labour involvement and longer durability. In view of these advantages, hollow concrete blocks are being increasingly used in construction activities.

ADVANTAGES OF ECMU

1) Combined with reinforcing steel and grout, engineered blocks can be used to design structures that can withstand powerful earthquakes, wind and fire. 2) The weight of the Hollow Block is much lesser as compared to a Solid Block.

3) These Blocks does not use River Sand which is a scarce commodity now. Further, Fly ash is also used to inculcate superior functional properties to the product. As such, these products are environment friendly. 4) Standard Hollow Blocks (8 " and 6 ) is being offered with M6 Grade specification (60 kg. / Sq. cm compression strength). One can work with the structural engineers and reduce steel consumption in construction substantially. 5) Because these are engineered Blocks, the dimensional accuracy and finish quality is very high. 6) These Block has additives to improve water resistance of the Block. Water Absorption is less than 8%. 7) Since the blocks are lighter the build can be more than one meter, hence increasing the productivity.

MANUFACTURE PROCESS
MATERIALS USED:
1) 2) 3) 4) 5) Cement Manufactured Sand Coarse aggregate Fly ash Chemical admixture.

The process of manufacture of cement concrete hollow blocks involves the following 5 stages: (1)Proportioning (2)Mixing (3)Compacting (4)Curing (5)Drying

(1) Proportioning: The determination of suitable amounts of raw materials needed to produce concrete of desired quality under given conditions of mixing, placing and curing is known as proportioning. As per Indian Standard specifications, the combined aggregate content in the concrete mix used for making hollow blocks should not be more than 6 parts to 1 part by volume of Portland cement. If this ratio is taken in terms of weight basis this may average approximately at 1:7 (cement : aggregate). However, there have been instances of employing a lean mix of as high as 1:9 by manufacturers where hollow blocks are compacted by power operated vibrating machines. The water cement ratio of 0.62 by weight basis can be used for concrete hollow blocks.

(2) Mixing The objective of thorough mixing of aggregates, cement and water is to ensure that the cement-water paste completely covers the surface of the aggregates. All the raw materials including water are collected in a concrete mixer, which is rotated for about 1 minutes. The prepared mix is discharged from the mixer and consumed within 30 minutes.

(3) Compacting The purpose of compacting is to fill all air pockets with concrete as a whole without movement of free water through the concrete. Excessive compaction would result in formation of water pockets or layers with higher water content and poor quality of the product. Semi-automatic vibrating table type machines are widely used for making cement concrete hollow blocks. The machine consists of an automatic vibrating unit, a lever operated up and down metallic mould box and a stripper head contained in a frame work. Wooden pallet is kept on the vibrating platform of the machine. The mould box is lowered on to the pallet. Concrete mix is poured into the mould and evenly levelled. The motorised vibrating causes the concrete to settle down the mould by approximately

1 to 1 inches. More of concrete is then raked across the mould level. The stripper head is placed over the mould to bear on the levelled material. Vibration causes the concrete come down to its limit position. Then the mould box is lifted by the lever. The moulded hollow blocks resting on the pallet is removed and a new pallet is placed and the process repeated. The machine can accommodate interchangeable mould for producing blocks of different sizes of hollow or solid blocks.

(4) Curing Hollow blocks removed from the mould are protected until they are sufficiently hardened to permit handling without damage. This may take about 24 hours in a shelter away from sun and winds. The hollow blocks thus hardened are cured in a curing yard to permit complete moisturisation for atleast 21 days. When the hollow blocks are cured by immersing them in a water tank, water should be changed atleast every four days. The greatest strength benefits occur during the first three days and valuable effects are secured up to 10 or 14 days. The longer the curing time permitted the better the product.

(5) Drying Concrete shrinks slightly with loss of moisture. It is therefore essential that after curing is over, the blocks should be allowed to dry out gradually in shade so that the initial drying shrinkage of the blocks is completed before they are used in the construction work. Hollow blocks are stacked with their cavities horizontal to facilitate thorough passage of air. Generally a period of 7 to 15 days of drying will bring the blocks to the desired degree of dryness to complete their initial shrinkage. After this the blocks are ready for use in construction work.

STACKING/STORING Proper stacking of the blocks ensures minimal damage to material while handling. 1) The blocks have to be stacked layers alternating in direction on firm and leveled ground.

2) The blocks have to checked for dimensional accuracy and the blocks deviating from the specified limit rejected 3) The stack maybe cured depending upon its age. 4) Proper hand protection gloves have be worn by the personnel during handling of blocks.

Mix design : Trial 1 : 6/7/2012 Cement Flyash Water F.A C.A 316.8 kg/m3 35.2kg/m3 204.3kg/m3 1236.4kg/m3 695.4kg/m3

w/c = 0.58 no super plasticizer added Mould 1 Strength (7 day strength ) 17.7MPa Average strength : 18.93 MPa Mould 2 18.7MPa Mould 3 21MPa

Trial 2 : 7/7/2012 Cement Flyash Water F.A C.A 290.32 kg/m3 32kg/m3 180kg/m3 1234kg/m3 663kg/m3

w/c = 0.56 no super plasticizer added

Mould 1 Strength (7 day strength ) 18.7MPa Average strength : 17.3 MPa

Mould 2 19.8MPa

Mould 3 13.5MPa

Trial 3 : 10/7/2012 Cement Flyash Water F.A C.A 175 kg/m3 145kg/m3 180kg/m3 1234kg/m3 663kg/m3

w/c = 0.56 no super plasticizer added Mould 1 Strength (7 day strength ) 10.5MPa Average strength : 10.2 MPa Mould 2 9.9MPa Mould 3 10.2MPa

Trial 4 : 11/7/2012 Cement Flyash Water F.A C.A 235 kg/m3 41.3kg/m3 155.2kg/m3 1220.4kg/m3 678.1kg/m3

w/c = 0.56 super plasticizer added = 0.1% = 2.5 ml Mould 1 Strength (7 day strength ) 14.2MPa Average strength : 10.6 MPa Mould 2 9.7MPa Mould 3 8.1MPa

Trial 5 : 17/7/2012 Cement Flyash Water F.A C.A 100 kg/m3 50kg/m3 140kg/m3 1307.3kg/m3 732.1kg/m3

w/c = 0.93 super plasticizer added = 0.15% = 2ml Strength (7 day strength ) Mould 1 Mould 2 Failure Mould 3

Trial 6 : 18/7/2012 Cement Flyash Water F.A C.A 160kg/m3 70kg/m3 150kg/m3 1243.1kg/m3 697kg/m3

w/c = 0.65 super plasticizer added : 0.3% = 1.8ml Mould 1 Strength (21 day strength ) 8.6MPa Average strength : 8.9 MPa Mould 2 8.7MPa Mould 3 9.4MPa

Trial 7 : 24/7/2012 Cement Flyash Water F.A C.A 160kg/m3 70kg/m3 140kg/m3 1356.2kg/m3 605.2kg/m3

w/c = 0.6 super plasticizer added : 0.3% = 2 ml Mould 1 Strength (15 day strength ) 9.8MPa Average strength : 7.46 MPa Mould 2 6.2MPa Mould 3 6.4MPa

Trial 8 : 30/7/2012 Cement Flyash Water 180kg/m3 60kg/m3 150kg/m3

F.A C.A

1328kg/m3 580kg/m3

w/c = 0.62 super plasticizer added : 0.1% = 2 ml Mould 1 Strength (7 day strength ) 14.2MPa Average strength : 10.6 MPa Mould 2 9.7MPa Mould 3 8.1MPa

Activities involved in Construction

I was able to gain a reasonable level of knowledge of the various steps involved in construction process by studying the technology manual and observing the corresponding activities taking place at the site . I was also able to go through and understand the various plans used for reinforcement, electrical, plumbing activities etc. Various activities have been described below .

MARKING It is the process of establishing temporary reference frames in order to ensure dimensional and positional accuracy. The temporary bench mark is established from the permanent bench mark using auto level and staff. . It has a reduced level . All other levels are taken keeping this as standard. The instruments used to carry out marking operations are : Auto Level Theodolite Total Station

ANTITERMITE TREATMENT

Anti termite treatment is applied to a building in the early stages of the construction to provide the building with a chemical barrier against the sub terranean termites. Osolin Herbal ATT was used at our site.
FOUNDATION

Trenches of width 1m and depth 1.2 meters based on SBC of the soil were made. The bottom 100mm was filled with PCC, followed by simple stone masonry in steps of 230 mm was carried out until the plinth level was reached . The plinth beam was provided with U blocks which holds the rebars and the hollow portion is grout using M20 concrete.

FOUNDATION SECTION DETAILS OF THE FOUNDATION

NOTE: ALL DIMENSIONS ARE IN MM.

BLOCK MASONRY

Mixing of Mortar The mortar has to mixed in the desired ratio using volumetric batching box measuring 330x330x300 mm. The sand should be properly sieved and care should be taken that no clay lumps or large stones are present in the mortar as it will result in reduction of structural stability. The mortar should be dry mixed first so as to achieve an uniform mixture. Care should be taken to make wet mortar in limited quantity as the wet mortar should be consumed within 30 minutes after mixing, thus reducing wastage.

Laying of Blocks: Before commencement of work center line has to be marked out in reference with drawings.

Level of each block and course laid should be Checked using a Sprit Level and Water Tube Level.

Proper line, level and plumb has be ensured while laying of blocks. All adjustments are to be done only in mid span and never at corners.

The block work has to be checked for plumb by dropping a plumb bob and double checked using a straight edge.

The blocks must be laid in a staggered manner such that vertical joints are not in a straight line which will act as a plane of weakness

JOINTS

T-JOINT

L-JOINT

CROSS JOINT

MORTAR AND BLOCK WASTAGE

1) The building must be designed modular so minimised.

that the block wastage is

2) Care should be taken to see that the blocks are laid at the hip level of the masons.

MASONRY PIERS/REINFORCED WALLS These are nothing but load bearing columns as in case of framed RCC Structures with a distinct advantage of not needing formwork and merged and the wall hence giving better stability.

U BLOCKS FOR LINTELS AND PLINTH BEAMS

U Blocks were used for lintels plinth beams eliminating the need for formwork and increasing the construction speed.

TYPICAL WALL SECTION

Note: dimensions are in mm.

As seen from the drawing the structure is supported at 3 levels namely 1) Plinth 2) Lintels 3) Wall beams And hence the stability is high.

HIGH VOLUME CONCRETE TO GROUT DOOR FRAMES

High volume concrete was used to grout frame of doors which were hollow.This concrete was aimed at getting high volume and strength parameter was not an issue and as such the aggregates were replaced by thermocol beads.

CONCRETING

FORMWORK

Forms or moulds or shutters are the receptacles on which concrete is placed, so that it will have the desired shape or outline when hardened. Once the concrete develops adequate strength, the forms are removed. Forms are generally made of the materials like timber, plywood, steel, etc. In our site plywood was used which left a form finish which enables no need for plastering.

Terms used in Reinforcement: Bar-bending-schedule

Bar-bending-schedule is the schedule of reinforcement bars prepared in advance before cutting and bending of rebars. This schedule contains all details of size, shape and dimension of rebars to be cut. Lap length

Lap length is the length overlap of bars tied to extend the reinforcement length.. Lap length about 40 times the diameter of the bar is considered safe. Laps of neighboring bar lengths should be staggered and should not be provided at one level/line.

CONCRETING 1) M20 grade concrete was pumped and placed at our site 2) Slump was 100 mm as is required for pumpable concrete 3) w/c was 0.5 4) cementitious material was 300 kg/m3 of which 33% was replaced by fly ash.

PLASTERING The hollow blocks used in the project have a very good and dimensionally accurate finish and hence this has eliminated the use of plastering thus increasing the economy of the project.