INDUSTRIAL TRAINING REPORT

On
BUILDING CONSTRUCTION
Undertaken At
NCUBE PLANING AND DESIGN PVT LTD
Submitted in partial fulfillment of the
requirement for the award of the degree of
BACHELOR OF TECHNOLOGY
In
CIVIL ENGINEERING
Supervised By
Mr. Somdutt Sharma
(Sr. Project Manager)
Submitted By
Pawan Mehta
4871889
Session 2013-2017

DEPARTMENT OF CIVIL ENGINEERING

DRONACHARYA COLLEGE OF
ENGINEERING
Affiliated to MAHARISHI DAYANAND
UNIVERSITY, ROHTAK

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 Certificate
This is to certify that Industrial training report entitled "Construction of Delhi Police
Headquarter" by PAWAN MEHTA (16702), at "Ncube Planning and Design Pvt
Ltd" is an original work and the same has not been submitted to any other institute
for the award of any other degree. A Presentation of the Industrial Training report was
made on "Construction of Delhi Police Headquarter" and the suggestions as
approved by the faculty were duly incorporated. The project has been submitted in
partial fulfillment of the requirements for the degree of Bachelor of Technology in
Civil Engineering of the Maharshi Dayanand University, Rohtak, Haryana, during the
academic year 2016-17.

Prof. Vineet Kumar Mishra

Head of Department (Civil Engg.)

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Performance Report

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 Acknowledgement

I take this opportunity to express a deep sense of gratitude to my Head of Department

Prof. Vineet Kumar Mishra for giving me the opportunity to complete my industrial
training. It would never be possible for us to take this project to this level without his
innovative ideas and his relent less support and encouragement. I also would like to
thank teachers without them it would have not been possible.

I take this opportunity to express a deep sense of gratitude to Mr. Somdutt Sharma
sir, Sr. Project Manager, Ncube Planning and Design Pvt Ltd, for his cordial
support, valuable information and guidance, which helped me in completing this task
through various stages.

I am obliged to Mr. Manmohan Nautiyal sir, Mr. Praveen Kant sir and. Mr. Sunil
Nigam sir for guidance by them in their respective fields and for encouraging me. I
am grateful to Ncube Planning and Design Pvt Ltd member for their cooperation
during the period of my Industrial Training.

PAWAN MEHTA
4871889
(CIVIL-VIII Semester)

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 Abstract
The Industrial Training (I.T) program enables students to go out and gain more
practical knowledge of what they have been taught in course (Bachelor of
Technology) in graduation and to acquire industry based skills.

Office work procedure covering introduction to work ethics, procedure of work

execution, architectural and structural drawing was explained with the relevant signs
and symbols representing various items on such drawing.

Site work for the period of training was undertaken at the Delhi Police Headquarter
Site. The project consists of office, residential, utility building, road and drainage
works, as well as external electrification and landscaping of the premises.

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 Dedication
This report is dedicated to my parents my inspiration without whom I would have not
been reached at this stage.
I would also like to dedicate this report to all the people who are behind this industrial
training program whether the inspirational Ncube Planning and Design Pvt Ltd
members or the college faculty.

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 Contents
Certificate .......................................................................................................... ii

Performance Report .......................................................................................... iii

Acknowledgement ............................................................................................ iv

Abstract ............................................................................................................. v

Dedication ........................................................................................................ vi

Contents .................................................................................................................. vii

Content for Tables ............................................................................................ ix

Content for Figures ............................................................................................ x

1 Introduction ....................................................................................................... 1

1.1 About Company ............................................................................................................ 1

1.2 Aims and Objective ....................................................................................................... 1
1.3 Scope of the report ....................................................................................................... 2
2 Introduction to Project ....................................................................................... 3

2.1 Objectives ..................................................................................................................... 3

2.2 Site Description ............................................................................................................. 3
2.3 Building codes ............................................................................................................... 4
2.4 Floor Configuration ....................................................................................................... 4
3 Introduction to Structural Design ....................................................................... 7

3.1 Sub Structure ................................................................................................................ 7

3.2 Superstructure .............................................................................................................. 8
3.3 Standard Codes ........................................................................................................... 10
3.4 Design loads ................................................................................................................ 10
3.5 Imposed load (Live load) ............................................................................................. 11
3.6 Wind load .................................................................................................................... 12
3.7 Temperature load ....................................................................................................... 12
3.8 Seismic Load ................................................................................................................ 13
3.9 Fire resistance of members ........................................................................................ 13
3.10 Environmental exposure .......................................................................................... 14
4 Building Materials ........................................................................................... 15

4.1 Cement........................................................................................................................ 15
4.2 Aggregate .................................................................................................................... 18
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 4.3 Water .......................................................................................................................... 18
4.4 Admixtures .................................................................................................................. 18
4.5 Concrete ...................................................................................................................... 20
4.6 Reinforcement (Steel Bar) .......................................................................................... 23
4.7 Brick ............................................................................................................................ 26
4.8 Damp Proofing Material ............................................................................................. 28
5 Structural Elements .......................................................................................... 30

5.1 Column ........................................................................................................................ 30

5.2 Retaining wall.............................................................................................................. 32
5.3 Shear wall .................................................................................................................... 32
5.4 Beam ........................................................................................................................... 33
5.5 Concrete Slab .............................................................................................................. 34
6 Formwork ........................................................................................................ 37

6.1 Formwork Requirements ............................................................................................ 37

6.2 Method for Formwork ................................................................................................ 38
6.3 Formwork Types ......................................................................................................... 39
6.4 Formwork Materials ................................................................................................... 40
6.5 Order and method of removing formwork: ................................................................ 42
7 Tests for quality check ..................................................................................... 43

7.1 Test on Cement ........................................................................................................... 43

7.2 Tests on Aggregate ..................................................................................................... 45
7.3 Tests on Concrete ....................................................................................................... 47
7.4 IN-SITU DRY DENSITY .................................................................................................. 49
8 Conclusion....................................................................................................... 50

Bibliography .................................................................................................... 51

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 Content for Tables
Table 2-1 Floor Configuration of Tower. .................................................................. 4
Table 2-2 Floor Configuration of Residential building ............................................... 6
Table 3-1 Structure system ...................................................................................... 10
Table 3-2 Various IS Codes ..................................................................................... 10
Table 3-3 Unit weight of material ............................................................................ 11
Table 3-4 Imposed loads .......................................................................................... 12
Table 3-5 Primary Loads ......................................................................................... 13
Table 4-1 Grade of concrete..................................................................................... 21
Table 4-2 Mix design being used at site ................................................................... 21
Table 4-3 Classes of bricks with their properties ...................................................... 27
Table 6-1 Sizes of timber members .......................................................................... 41
Table 6-2Period of removal of formwork ................................................................. 42

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 Content for Figures
Figure 2-1 Top view of site ........................................................................................ 4
Figure 2-2 Office building layout ............................................................................... 5
Figure 2-3 Basement layout plan ............................................................................... 5
Figure 3-1 Sub structural work .................................................................................. 7
Figure 3-2 Superstructure .......................................................................................... 9
Figure 4-1 Strength comparison between OPC, PPC and Rapid hardening cement ... 17
Figure 4-2 Slab concreting ....................................................................................... 22
Figure 4-3 Method of compaction ............................................................................ 23
Figure 4-4Slab reinforcement and PT tendons.......................................................... 24
Figure 4-5 Overlapping of Bars ............................................................................... 25
Figure 4-6 Rebaring work ........................................................................................ 26
Figure 4-7 Block Work of 200mm thickness ............................................................ 28
Figure 4-8 Bitumen membrane for water proofing is being covered with Screte of 25
mm thickness ........................................................................................................... 29
Figure 5-1 Retaining wall of thickness 400mm ........................................................ 32
Figure 5-3 One way slab with beams ....................................................................... 35
Figure 5-4 Two way slab with beams ....................................................................... 35
Figure 5-5 Flat slabs ................................................................................................ 36
Figure 6-1Formwork for slab and beam ................................................................... 37

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 1 Introduction
The industrial training (I.T) program is designed to acquaint students with the
practical or hands-on knowledge of the past, present and the future. By the past, it
affords the student an opportunity to witness practically what they have read in books
i.e. the reality of the 100% assumption of the theories. It also affords students the
current knowledge of what the field works is all about, getting familiar with new
advancement in technology. The future refers to foreknowledge of what should be
expected when he/she begins to practice the profession. Furthermore, it avails the
students an opportunity to learn inter-and intra personal relationship, administrative
skills, site management identification of equipment among other opportunities.
This report entails some of the experience I was able to acquire in my short period of
attachment.

1.1 About Company

NELSON India, a licensee of NELSON, has more than 80 professionals in Asia-Pac.
Nelson have been in India for the last eight years their primary focus has been to
deliver quality and “best in class” design and consulting services to their clients.
Local operations are under the leadership of Amit Ramani, Managing Director of
India.

Specialties
Architecture, Master Planning, Work place Strategies, Interior Design, Engineering,
Design & Build and Project Management.
Website
https://www.nelsononline.com
Headquarters
A16, 2nd floor, Qutab Institutional Area, Aruna Asaf Ali Marg, New Delhi (110067)

1.2 Aims and Objective

 It gives student the opportunity of putting some of their skills in to practices.
 It Provides students with the opportunity to apply their knowledge in real work
situation thereby bridging the gap between theory and practice.

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  It Exposes students to handling of equipment and machinery that may not be
readily available in their institutions of learning.
 It serves as a link between student and industry.
 It enables student to interpret some technical terms more easily.
 It provides student the opportunity to prepare for employment after
graduation.

1.3 Scope of the report

The scope of this report is basically to present in details of various activities carried
out in Nelson India at Delhi Police Headquarter Site, as well as provide the general
background knowledge about the aspects of civil engineering applied while
undergoing the industrial training program.

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 2 Introduction to Project
The proposed development for Delhi Police Headquarter is envisaged as a modern
office building which provides a strong identity of Delhi Police as an organization
providing safety and security for its citizen. Design also should be in harmony of its
natural surroundings and achieve a green building rating like GRIHA or equivalent.
The project includes Headquarter office with 500 seats auditorium, a residential block
for officers and utility building. Headquarter building will be built as a twin tower
connected on lower floors with proper designed landscape.
Main building will consist of an auditorium, cafeteria, traffic control room and
offices.

2.1 Objectives
 To create a modern iconic structure for Delhi Police which is harmonious to
its architectural surrounding of Delhi?
 To design a building which provide working environment for its user.
 Green development sensitive towards its environment.

2.2 Site Description

Total area of land as on paper is 32748.32 sqmt. (8.092 Acre) located near Patel
Chowk Metro station in Lutyen’s Delhi.
The site is approx 280 mt. from extreme point of Jantar Mantar. As per ASI
guidelines, any building between 200 to 300mt from heritage monuments will be
permitted height between 25 to 50 mt however the design of building is planned
outside 300 mt. distance.
From the soil investigation report, strata of moderate safe bearing are available at the
foundation depth of 10.5 mt.

2.2.1.1 Roads
The plot is bounded on three sides by 16 mt. wide main roads namely Parliament
Street, Jai Sing road and Ashoka road.

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Figure 2-1 Top view of site

2.3 Building codes

 The Building Bye Laws for UT of Delhi 1983.
 NBC of India (NBC
(NBC-2005)
 CPWD specification Handbook.
 National fire protection association (NFPA) 101-
101 life safety handbook.

2.4 Floor Configuration

2.4.1.1 Headquarter Building

Twin tower configuration consists of basement, Ground floor and seventeen floors.
floors
Interconnectivity betweenn towers have been provided at GF to 3rd floor and 10th to
14th floor.
Lower basement height 4.5m
Upper basement height 6.6m
Office floor height 3.65
Total Floor Area Ratio (FAR) 55877.13sqm
Built up Area 56338sqm
Table 2-1 Floor Configuration of Tower.

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Figure 2-2 Office building layout

Basement It is for parking and approx 2-% area is to be used for services required,
like STP, rainwater harvesting tank, fan rooms, electrical panel and underground
storage tank for domestic and fire.

Figure 2-3 Basement layout plan

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Ground Floor (GF) VIP entrance lobby with 200 seater cafeteria and 200seater
executive dining with its kitchen and business centre. There is 500seater auditorium in
the space between towers.
1st to 3rd floor Both tower comprises of office area while central block consist of
auditorium with its services.
4th to 9th floor VIP lobby area and auditorium converted into terrace on the 4th floor.
Both towers are disconnected.
10th to 14th These floors of both towers are connected with each other. 14th floor is
dedicated as commissioner’s floor with his office being located on topmost level of
the bridge area.
15th to 17th Similar to 8th and 9th floor. Topmost floor has a gym and recreational
club which opens towards terrace.

2.4.1.2 Residential Building (Stilt + 6 floor)

Stilt parking height 3m
Floor height 3.3 m
Total FAR 2605.88sqm
Built up area 3303.29sqm
Table 2-2 Floor Configuration of Residential building

Stilt Covered parking for 14 cars.

Floor Three BHK with servant quarter, having independent entry from lobby.

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 3 Introduction to Structural Design
The structure of a building is the part which is responsible for maintaining the shape
of the building under the influence of the forces to which it is subjected. A building
must be designed to safely withstand the most severe combination of forces or loads
likely to be applied during its lifetime. Building consists of many structural
components. Generally, structural components are divided into two categories-

 Sub Structure
 Super Structure

3.1 Sub Structure

The structure below ground level is called sub structure. Sub structure can also be
divided into two parts- a) Foundation and b) Plinth

Figure 3-1 Sub structural work

3.1.1.1 Foundation
The most lower part of the building. The main function of the foundation is to transfer
load to sub soil. It is the most important part of structure. Most of the failure of a
structure may happen due to foundation failure. Foundations are generally considered
either shallow or deep. Foundation should be strong enough to meet the following
requirements-
 It should be strong enough to distribute the load to sub soil.

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  It is capable to support structure.
Shallow foundations, often called footings, are usually embedded about a meter or so
into soil. One common type is the spread footing which consists of strips or pads of
concrete (or other materials) which extend below the frost line and transfer the weight
from walls and columns to the soil or bedrock.
Deep foundation is used to transfer the load of a structure down through the upper
weak layer of topsoil to the stronger layer of subsoil below. There are different types
of deep footings including impact driven piles, drilled shafts, caissons, helical piles,
geo-piers and earth stabilized columns.
According to final soil investigation report available for the site, strata of
moderate safe bearing capacity is available at depth of 12.35m below Ground
level (NGL).
Therefore raft foundation was provided. Gross bearing capacity is 48.5 T/sqm.
Plinth
The part between surrounding ground level and ground floor of the building is called
plinth. The purposes of the plinth are-
 Transfer the incoming load from super structure to the foundation.
 Provide damp proof to the building
 Support the back filling as a retaining wall.
 Plinth also increases the esthetical look of the building.

3.2 Superstructure
The part above plinth level is called super structure. Super structure contains many
other structural components. Such as-
 Wall
 Floor/Slab
 Lintel and sunshade
 Step and stair
 Roof
Wall is used to separate the usable area of floor for different purpose. Such as
bedroom, bathroom, kitchen, living etc. Other prime purpose of wall is to provide
privacy and security.

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Figure 3-2 Superstructure

Floor, the main purpose of floor is to provide better living space and support of
occupants, furniture and other equipment of a building. The purpose of making
different floor in different level of a building is to create more accommodation within
limited space. Floor should be strong, durable, damp prove and heat protected.
Lintel and Sunshade, Lintel is provided for the purpose of supporting wall above
door or window opening. Sunshade is generally combined with lintel above window
opening to protect rain and sun.
Step and Stair, Stair is made for easy communication among various floors of a
building. Stair consists of steps. Steps height should be comfortable enough for
vertical movement.
Roof, the top most part of a building is the roof. Roof is build for the purpose of
enclosing and protects the living area/floor area from weather effect. Roof should be
stable, durable and weather resistant.
Two tower and bridge require column free space, more flooring to ceiling height.
Also ease and speed of construction are the important parameter while making a
choice for particular system of superstructure.

Type of System Beam slab system Flat slab with drop Flat slab without
system drop system
Clear height Less More Maximum

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Ease of construction Less More Maximum
Speed of construction Moderate Fast Faster
Performance under Better Moderate Poor
seismic load
Fire resistance Good Good Good
Cost of construction Marginally less More Expensive
Table 3-1 Structure system

According to above table Flat slab with drop system is considered more suitable and
is being provided at site according to design.

3.3 Standard Codes

IS:456-2000 Code of Practice for PCC and RCC
IS:800-2007 Code of Practice for General Construction in Steel
IS:3370-2009 Code of Practice for Concrete Structure For Storage of Liquid
IS:875-1987 Code of Practice for Design loads of building and structure
(except Earthquake)
IS:2911-1979 Code of Practice for design and construction of pile
foundation
IS:1904-1986 Code of Practice for design and construction of foundation in
soil
IS:1893-2002 Criteria for earthquake resistant design of structure
IS:13920-1993 Code of Practice for ductile detailing of RCC structure
subjected to seismic force
IS:383-1920 Specification for course and fine aggregate
IS:1786-1985 Specification for High strength Steel deformed bars
Table 3-2 Various IS Codes

3.4 Design loads

A building has to perform many functions satisfactorily. Amongst these functions are
the utility of the building for the intended use and occupancy. Structural safety, fire
safety and compliance with hygienic, sanitation, ventilation and daylight standards.
The design of the building is dependent upon the minimum requirements prescribed
for each of the above functions. The minimum requirements pertaining to the
structural safety of buildings are being covered in this code by way of laying down
minimum design loads which have to be assumed for dead loads, imposed loads,
snow loads and other external loads, the structure would be required to bear. Strict
conformity to loading standards recommended in this code, it is hoped that it will not
only ensure the structural safety of the buildings which are being designed and
10
constructed in the country and thereby reduce the hazards to life and property caused
by unsafe structures, but also eliminate the wastage caused by assuming unnecessarily
heavy loadings. (IS:1857-1987 )
Various types of loads on structure are
 Dead load
 Imposed load
 Wind load
 Snow loads
 Special loads and loads combination
 Seismic loads

3.4.1.1 Dead load

Dead loads to be assumed in the design of buildings and same as given in the-form of
unit weight of materials. The unit weight of other materials that are likely to be stored
in a building are also included for the purpose of load calculations due to stored
materials.
Dead load of various materials extracted from (IS : 875 ( Part 1 ) - 1987 ) as
follows.
Material Nominal size or Weight/Mass
Thickness kn kg per
PCC 23m
RCC 24
Floor Finish 2.0
Water proofing 2.5
Brick Masonry 20
230 mm 5.1
115mm 2.8
Concrete block 20
200mm 4.6
Table 3-3 Unit weight of material

3.5 Imposed load (Live load)

The load assumed to be produced by the intended use or occupancy of a building,
including the weight of movable partitions, distributed, concentrated loads, load due
to impact and vibration, and dust load but excluding wind, seismic, snow and other
loads due to temperature changes, creep, shrinkage, differential settlement, etc.
Imposed loads for building shall be taken as per the (IS : 875 ( Part 2 ) - 1987) are as
follows.
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 Area Weight/Area(kn/𝒎𝟐 )
Office area (including storage) 4.0kn/𝑚
Passages/corridors/staircase/service area 4.0kn/𝑚
Electrical room 7. kn/𝑚
Kitchen/Cafeteria/dining room 3.0 kn/𝑚
Toilets 2.0 kn/𝑚
Terrace(accessible) / podium 1.5 kn/𝑚
Terrace(Inaccessible) 0.75 kn/𝑚
Parking(stacked) 6.0 kn/𝑚
Single parking/ ramp 5.0 kn/𝑚
Auditorium 4.0 kn/𝑚
Projector room 5 kn/𝑚
Auditorium roof 5 kn/𝑚
Table 3-4 Imposed loads

3.6 Wind load

Wind is air in motion relative to the surface of the earth. The primary cause of wind is
traced to earth’s rotation and differences in terrestrial radiation. The radiation effects
are primarily responsible for convection either upwards or downwards. The wind
generally blows horizontal to the ground at high wind speeds. Since vertical
components of atmospheric motion are relatively small, the term ‘wind’ denotes
almost exclusively the horizontal wind, vertical winds are always identified as such.
The wind speeds are assessed with the aid of anemometers or anemographs which are
installed at meteorological observatories at heights generally varying from 10 to 30
meters above ground. Winds loads are considered on basis of (IS : 875 ( Part 3 ) -
1987).
Basic wind speed for Delhi (Vb) is 47m/s.

3.7 Temperature load

Expansion and contraction due to changes in temperature of the materials of a
structure shall be considered in design. Provision shall be made either to relieve the
stress by provision of expansion/contraction joints in accordance with IS:3414-1968*
or design the structure to carry additional stresses due to temperature effects as
appropriate to the problem.

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As per IS: 875 (part5) and IRC:6-2010, for expansion and contraction due to change
in the temperature of the material of the structure due to daily or seasonal fluctuations
in the temperature.
For Delhi as per IRC: 6-2010
 Maximum air shed Temperature = 47°C
 Minimum air shed Temperature = -1.5°C
 Mean Temperature = 22.75°C
 Temperature at which the structure is effectively restrained = mean + 10
= 22.75+10
= 32.75°C
Variation in temperature
 Maximum = 47-32.75 = 32.75°𝑐
 Minimum = -1.5-32.75= -34.75°C

3.8 Seismic Load

Designing and detailing shall be in accordance with IS: 1893 (part1):2002 and
IS:13920-1993.
Type of load Abbreviation
Dead load DL
Live load LL
Wind load in positive X direction WLxp
Wind load in negative X direction WLxn
Wind load in positive Y direction WLyp
Wind load in negative Y direction WLyn
Seismic load in X drection EQx
Seismic load in Y drection EQy
Maximum temperature load TL max
Minimum temperature load TL min
Table 3-5 Primary Loads

3.9 Fire resistance of members

All structure will design for two hours fire rating. The requirement for fire resistance
is met by adopting the minimum structural dimensions and clear cover to
reinforcement.
Minimum dimension of structural member and nominal cover to reinforcement is
being provided as given in (IS:456-2000).

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3.10 Environmental exposure
The site is situated in Delhi which receive moderate rainfall also it is away from sea
coast. Soil investigation also indicates that sulphate and chloride content are well
within permissible limits; hence the building is designed for moderate exposure.
Minimum nominal cover to the structural members like Retaining wall which are in
contact with soil is not less than 45mm and for UG tank and STP which are in contact
with water and footing shall be minimum 50mm. for all structure in superstructure the
minimum cover to the reinforcement shall be 30mm.

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 4 Building Materials
Building material is any material which is used for construction purposes. Many
naturally occurring substances, such as clay, rocks, sand, and wood are used to
construct buildings. Apart from naturally occurring materials, many man-made
products are in use, some more and some less synthetic. The manufacture of building
materials is an established industry in many countries and the use of these materials is
typically segmented into specific specialty trades, such as carpentry, insulation,
plumbing, and roofing work. The quality and effectiveness of building materials used
in the construction and their storage are as important as the other phases of building
activity like planning, designing and constructing the building itself.

Historically choice of building materials was determined by what was locally

available, appropriateness to geo-climatic conditions and affordability of users. In
recent past, different initiatives have been taken in the areas of research and
development, standardization, and development and promotion of innovative
materials. A review of the recent trends indicates that the growth in the area of
building materials covers emerging trends and latest developments in the use of
wastes, mineral admixtures in cement and concrete, substitutes to conventional
timber, composite materials and recycling of wastes, at the same time ensuring
desired response of materials to fire, long term performance and durability. In
addition to these developments, the future decade may witness development of
specific materials which may be structured and designed to meet needs to specially
developed construction technologies, such as, for disaster prone areas or aggressive
climatic and industrial situations. (STANDARDS, 2005)

4.1 Cement
Cement is a binder, a substance used in construction that sets, hardens and adheres to
other materials, binding them together. Cement is seldom used solely, but is used to
bind sand and gravel (aggregate) together. Cement is used with fine aggregate to
produce mortar for masonry, or with sand and gravel aggregates to produce concrete.
 The initial setting time of cement = 30 minutes (1/2 hr)
 The final setting time of cement = 10 hrs.

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4.1.1.1 Types of Cement
 Ordinary Portland cement
 Portland slag cement
 Portland Pozzolana cement
 Masonry cement
 High alumina cement for
 Super sulphated cement
 Rapid hardening Portland cement
 white Portland cement
 Hydrophobic Portland cement
 Sulphate resisting Portland cement
 Low heat Portland cement

4.1.1.2 Ordinary Portland Cement

Ordinary Portland cement (OPC) is by far the most important type of cement. Prior to
1987, there was only one grade of OPC which was governed by IS 269-1976. After
1987 higher grade cements were introduced in India. The OPC was classified into
three grades, namely 33 grade, 43 grade and 53 grade depending upon the strength of
the cement at 28 days when tested as per IS 4031- 1988. If the 28 days strength is not
less than 33N/mm2, it is called 33 grade cement, if the strength is not less than
43N/mm2, it is called 43 grade cement, and if the strength is not less then 53 N/mm2,
it is called 53 grade cement. But the actual strength obtained by these cements at the
factory is much higher than the BIS specifications. (SHETTY, 2005)

4.1.1.3 Portland Pozzolana Cement

Portland Pozzolana cement (PPC) is manufactured by the inter grinding of OPC
clinker with 10 to 25 per cent of pozzolanic material (as per the latest amendment, it
is 15 to 35%). A pozzolanic material is essentially a siliceous or aluminous material
which while in itself possessing no cementitious properties, which will, in finely
divided form and in the presence of water, react with calcium hydroxide, liberated in
the hydration process, at ordinary temperature, to form compounds possessing
cementitious properties. The pozzolanic materials generally used for manufacture of
PPC are calcined clay or fly ash. Fly ash is a waste material, generated in the thermal
power station, when powdered coal is used as a fuel.

16
Portland pozzolana cement produces less heat of hydration and offers greater
resistance to the attack of aggressive waters than ordinary Portland cement. It is
important to appreciate that the addition of pozzolana does not contribute to the
strength at early ages. Strengths similar to those of ordinary Portland cement can be
expected in general only at later ages provided the concrete is cured under moist
conditions for a sufficient period. Technically PPC has considerable advantages over
OPC when made by using optimum percentage of right quality of fly ash.

Figure 4-1 Strength comparison between OPC, PPC and Rapid hardening cement

Grading of PPC
In many countries, PPC is graded like OPC depending upon their compressive
strength at 28 days. In India, so far PPC is considered equivalent to 33 grade OPC,
strength wise, although some brand of PPC is as good as even 53 grade OPC. Many
cement manufacturers have requested BIS for grading of PPC just like grading of
OPC. They have also requested for upper limits of fly ash content from 25% to 35%.
Recently BIS has increased the fly ash content in PPC from 10–25% to 15–35%.
Application
Portland pozzolana cement can be used in all situations where OPC is used except
where high early strength is of special requirement. As PPC needs enough moisture
for sustained pozzolanic activity, a little longer curing is desirable. Use of PPC would
be particularly suitable for the following situations:
 For hydraulic structures.
 For mass concrete structures like dam, bridge piers and thick foundation.
 For marine structures.
 For sewers and sewage disposal works etc.

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4.2 Aggregate
Aggregates are the important constituents in concrete. It is a broad category of coarse
particulate material used in construction like sand, gravel, crushed stone, slag etc.
They give body to the concrete, reduce shrinkage and effect economy. The mere fact
that the aggregates occupy 70–80 per cent of the volume of concrete, their impact on
various characteristics and properties of concrete is undoubtedly considerable.

4.2.1.1 Types of Aggregate

 Coarse Aggregate (size greater than 4.75mm)
 Fine Aggregate (size Smaller than 4.75)
The nominal maximum size of coarse aggregate should be as large as possible within
the limits specified but in no case greater than one-fourth of the minimum thickness of
the member, provided that the concrete can be placed without difficulty so as to
surround all reinforcement thoroughly and fill the comers of the form. For most work,
20 mm aggregate is suitable. Where there is no restriction to the flow of concrete into
sections, 40 mm or larger size may be permitted. In concrete elements with thin
sections, closely spaced reinforcement or small cover, consideration should be given
to the use of 10 mm nominal maximum size. Coarse and fine aggregate shall be
batched separately.

4.3 Water
It is an important ingredient of concrete because it combines with cement and forms a
binding paste. The paste thus formed fills up the voids of the sand and coarse
aggregate bringing them into close adhesion.
Water used for mixing and curing shall be clean and free from injurious amounts of
oils, acids, alkalis, salts, sugar, organic materials or other substances that may be
deleterious to concrete or steel. Potable water is generally considered satisfactory for
mixing concrete. The pH value of water shall be not less than 6.
In this project source of water is a bore well which is closely spaced to the building.
The quality of water is good and can be used for drinking purpose also.

4.4 Admixtures
A material other than water, aggregates, and hydraulic cement and additives like
pozzolana or slag and fiber reinforcement used as an ingredient of concrete or mortar

18
and added to the batch immediately before or during its mixing to modify one or more
of the properties of concrete in the plastic or hardened state.
The different types of admixtures:
Chemical admixtures are materials in the form of powder or fluids that are added to
the concrete to give it certain characteristics not obtainable with plain concrete mixes.
In normal use, admixture dosages are less than 5% by mass of cement and are added
to the concrete at the time of batching/mixing the common types of admixtures are as
follows:
Accelerators speed up the hydration (hardening) of the concrete accelerating
admixtures are especially useful for modifying the properties of concrete in cold
weather.
Retarders slow the hydration of concrete and are used in large or difficult pours
where partial setting before the pour is complete is undesirable..
Air entraining agents add and entrain tiny air bubbles in the concrete, which reduces
damage during freeze-thaw cycles, increasing durability.
Plasticizers increase the workability of plastic or "fresh" concrete, allowing it be
placed more easily, with less consolidating effort. Plasticizers can be used to reduce
the water content of a concrete while maintaining workability and are sometimes
called water-reducers due to this use. Such treatment improves its strength and
durability characteristics.
Pigments can be used to change the color of concrete, for aesthetics.
Corrosion inhibitors are used to minimize the corrosion of steel and steel bars in
concrete.

4.4.1.1 Mineral Admixtures and Blended Cements

Inorganic materials that have pozzolanic or latent hydraulic properties, these
very fine-grained materials are added to the concrete mix to improve the properties of
concrete (mineral admixtures), or as a replacement for Portland cement (blended
cements). Products which incorporate limestone, fly ash, blast furnace slag, and other
useful materials with pozzolanic properties into the mix, are being tested and used.
This development is due to cement production being one of the largest producers (at
about 5 to 10%) of global greenhouse gas emissions, as well as lowering costs,
improving concrete properties, and recycling wastes. Mineral admixtures are Fly ash
Ground granulated, blast, furnace slag, Silica fume, Carbon nanofibres.

19
Admixtures should not impair durability of concrete nor combine with the constituent
to form harmful compounds nor increase the risk of corrosion of reinforcement. The
workability, compressive strength and the slump loss of concrete with and without the
use of admixtures shall be established during the trial mixes before use of admixtures.

4.5 Concrete
Concrete production is the process of mixing together the various ingredients—water,
aggregate, cement, and any additives—to produce concrete. Concrete production is
time-sensitive. Once the ingredients are mixed, workers must put the concrete in place
before it hardens. In modern usage, most concrete production takes place in a large
type of industrial facility called a concrete plant, or often a batch plant.
In general usage, concrete plants come in two main types, ready mix plants and
central mix plants. A ready mix plant mixes all the ingredients except water, while a
central mix plant mixes all the ingredients including water. A central mix plant offers
more accurate control of the concrete quality through better measurements of the
amount of water added, but must be placed closer to the work site where the concrete
will be used, since hydration begins at the plant.

4.5.1.1 Concrete Mix Design

The process of selecting suitable ingredients of concrete and determining their relative
amounts with the objective of producing a concrete of the required, strength,
durability, and workability as economically as possible, is termed the concrete mix
design.
Requirements of concrete mix design
 The requirements which form the basis of selection and proportioning of mix
ingredients are :
 The minimum compressive strength required from structural consideration
 The adequate workability necessary for full compaction with the compacting
equipment available.
 Maximum water-cement ratio and/or maximum cement content to give
adequate durability for the particular site conditions
 Maximum cement content to avoid shrinkage cracking due to temperature
cycle in mass concrete.

20
 Grade Designation Specified characteristic Compressive Strength of 150
mm cube at 28 days in N/𝒎𝒎𝟐
M10 1O
Ordinary M15 15
Concrete M20 20
M25 25
M30 30
M35 35
Standard M40 40
Concrete M45 45
M50 50
M55 55
M60 60
M65 65
High Strength
Concrete M70 70
M75 75
M80 80
Table 4-1 Grade of concrete

Mix Design for 1 cumec

Material M55 M50 M45 M40 M35 M30
Cement (kg) 470 435 415 390 345 320
Fly ash (kg) 60 60 50 60 75 70
Water (Lt) 164 163 168 170 172 164
Fine Agg (kg) 580 595 615 640 665 700
10 mm (kg) 590 600 595 585 572 568
20mm (kg) 590 600 595 585 572 568
Admixture (kg) 2.65 2.55 2.40 2.30 2.10 1.95
Density 2455.5 2440.4 2432.3 2432.3 2403.1 2391.35
Table 4-2 Mix design being used at site

In the designation of concrete mix M refer to the mix and the number to the specified
compressive strength of 150 mm size cube at 28 days, expressed in N/𝑚𝑚2 .
At site M10 is being used for PCC, M35 is being used for slab, M45 is being used for
vertical members like shear walls, columns and as well as for drop panel of slab.

4.5.1.2 RCC
Its full name is reinforced cement concrete. RCC is concrete that contains steel bars,
called reinforcement bars, or rebars. This combination works very well, as concrete is

21
very strong in compression, easy to produce at site, and inexpensive and steel is very
strong in tension.

4.5.1.3 Placing of Concrete

1. Concrete pump with pipeline is used for conveyance of concrete to the
pouring area.
2. Concrete for the slab is placed in approx. 400mm-450mm thick layers
each. Each layer is compacted before the next layer is placed.
3. Concrete is carefully worked around all reinforcement and embedded
fixtures and corner of formwork.
4. The top surface of the concrete is leveled with aluminum box section of
3m long followed by steel trowel to produce the required surface finish.
5. Concrete placing is uninterrupted until placing of a section as defined by
construction joints is completed.
6. The concrete at the surface of cold joints is cleaned with a high pressure
air water jet before the concrete achieves a primary set to provide an
irregular clean surface free from laitance. Prior to restarting concreting, the
surface will be wetted.
7. Maximum free fall of concrete will be limited to 1.5m.
8. The temperature of the concrete should not exceed the limiting
temperature mentioned in the plan.

Figure 4-2 Slab concreting

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4.5.1.4 Compaction of concrete
Concrete is compacted during placing by immersion vibrators. An immersion vibrator
is operated in a near vertical position, and it penetrates the full length of the layer of
concrete placed and just into the layer below to stitch in between. Vibration will be
applied continuously until the expulsion of air has practically ceased. The vibrators
will be withdrawn slowly to avoid the formation of voids. During the compaction care
should be taken to avoid the displacement of reinforcement, formwork, pre-fixed
pipes, etc. A minimum of one standby vibrator will be provided during concreting.

Figure 4-3 Method of compaction

4.6 Reinforcement (Steel Bar)

Rebar (short for reinforcing bar), collectively known as reinforcing steel and
reinforcement steel is a steel bar or mesh of steel wires used as a tension device in
reinforced concrete and reinforced masonry structures to strengthen and hold the
concrete in tension. Rebar's surface is often patterned to form a better bond with the
concrete.
Concrete is a material that is very strong in compression, but relatively weak
in tension. To compensate for this imbalance in concrete's behavior, rebar is cast into
it to carry the tensile loads. Most steel reinforcement is divided into primary and
secondary reinforcement, but there are other minor uses:
 Primary reinforcement refers to the steel which is employed to guarantee the
resistance needed by the structure as a whole to support the design loads.
 Secondary reinforcement, also known as distribution or thermal reinforcement
is employed for durability and aesthetic reasons, by providing enough
localized resistance to limit cracking and resist stresses caused by effects such
as temperature changes and shrinkage.
 Rebar is also employed to confer resistance to concentrated loads by providing
enough localized resistance and stiffness for a load to spread through a wider
area.

23
  Rebar may also be used to hold other steel bars in the correct position to
accommodate their loads.
Masonry structures and the mortar holding them together have similar properties to
concrete and also have a limited ability to carry tensile loads. Some standard masonry
units like blocks and bricks are made with voids to accommodate rebar, which is then
secured in place with grout. This combination is known as reinforced masonry.
At the site the high strength steel bars of 500D and T.M.T. (Thermo Mechanically
Treated) bars of diameter 8 mm, 10 mm, 12mm 16 mm, 20mm, 25mm & 32 mm as
per requirement of design is being used.

Figure 4-4Slab reinforcement and PT tendons

4.6.1.1 METHOD FOR REINFORCEMENT WORK

 All reinforcement shall be placed above the ground by using PVC cover block
or concrete blocks.
 For reinforcement, care shall be taken to protect the reinforcement from
exposure to saline atmosphere during storage, fabrication and use.
 Bars shall be cut and bent to shape and dimension as shown in bar bending
schedule based on Good For Construction (GFC) drawings.
 Reinforcement shall be tied as per the latest GFC drawing.
 Unusable cut rods and scrap reinforcement shall be properly placed at yard.

4.6.1.2 BAR BENDING SCHEDULE

 Prepare bar bending schedule based on the latest GFC drawings and to be
submitted to Engineer for review
24
  Bar bending schedule shall clearly specify the following:
a. Bar diameter,
b. Numbers,
c. Spacing
d. Cut-lengths,
e. Shapes.
 Bar bending schedule shall take into account the following field/ design
requirement.
a. Desirable lap locations and staggering of laps.
b. Lap lengths.
c. Development length/ Anchorage length.

4.6.1.3 Overlapping of Bars

Staggering of reinforcement shall be carried out in such a manner that not more than
50% lapping be provided at any section.

Figure 4-5 Overlapping of Bars

4.6.1.4 REBARING
Rebaring is the method of insertion of steel bars when:-
 There is change in design or there is some extension of present structure.
 When steel rod as per has been not installed and to install the same rebaring.
Mostly HILTI chemical are used for rebaring at site.

25
Figure 4-6 Rebaring work

Steps involved:-
 Drilling in the existing structure as per drawing
 Cleaning of holes by ELE blower
 Filling of chemical in well cleaned holes
 Then inserting bars slowly inside the holes

4.7 Brick
A brick is building material used to make walls, pavements and other elements in
masonry construction. Traditionally, the term brick referred to a unit composed of
clay, but it is now used to denote any rectangular units laid in mortar. A brick can be
composed of clay-bearing soil, sand, and lime, or concrete materials. Bricks are
produced in numerous classes, types, materials, and sizes which vary with region and
time period, and are produced in bulk quantities. Two basic categories of bricks are
fired and non-fired bricks. The unburnt or sun-dried bricks are those bricks which are
dried with the help of heat that is received from sun after the process of moulding.
The unburnt bricks can only be used in the construction of simple temporary and
cheap structures. Unburnt bricks should not be used at places exposed to heavy rains.
Bricks used in masonry can be of two types
 Traditional bricks (size 23cm*11.4cm*7.6cm)
 Modular bricks (size 19cm*9cm*9cm)
 Concrete block (62.5cm*22.5cm*20cm)

26
4.7.1.1 Classes of Bricks
Class of brick Strength in kg/𝒄𝒎𝟐 Water absorption after 24 hours in
water
First class bricks 105 ≤20%
Second class bricks 70 ≤22%
Third class bricks 30 ≤25%
Table 4-3 Classes of bricks with their properties

At site first class traditional bricks are being used for brick masonry is being used for
drainage at basement and brick work below DPC layer. Block work is being used for
partition walls of thickness 200mm and 100mm.

4.7.1.2 Laying of Blocks

 Stand and set lumbers with straight edges along the vertical line of wall face to
vertical alignment of the work.
 Then stretch a string line indicting the top level of the starting course
 Top of concrete slab, from which block are laying up, should be kept clean
and wet.
 Lay the blocks for the course with a uniform thickness of horizontal joint.
 Standard length of block is 400mm and in case a cut unit is required to make
up the course, place that unit made of standard unit at least one block away
from the concrete column, quoins of the wall or service openings including
doors and windows.
 After finishing the course, carry out jointing with the steel trowel to strike off
joints slightly lower than the block face in case plastering or rendering are not
required at a later stage. However, only where plastering is required, take out
joints to a depth of between 10mm to 15mm as the works proceeds, to give an
adequate key to plastering.
 Repeat sequence for the next course.

27
Figure 4-7 Block Work of 200mm thickness

4.8 Damp Proofing Material

Damp proofing is defined by the American Society for Testing and Materials (ASTM)
as a material that resists the passage of water with no hydro-static pressure and
waterproof as a treatment that resists the passage of water under pressure.[1]
Generally damp proofing keeps moisture out of a building where vapor barriers keep
interior moisture from getting into walls.
Damp proofing is accomplished several ways including:
Damp-proof course (DPC) is a barrier through the structure by capillary action such
as through a phenomenon known as rising damp. Rising damp is the effect of water
rising from the ground into property. The damp proof course may be horizontal or
vertical. ADPC layer is usually laid below all masonry walls, regardless if the wall is
a load bearing wall or a partition wall.
Damp-proof membrane (DPM) is a membrane material applied to prevent moisture
transmission. A common example is polyethylene sheeting laid under a concrete slab
to prevent the concrete from gaining moisture through capillary action. A DPM may
[4]

be used for the DPC.

Integral damp proofing in concrete involves adding materials to the concrete mix to
make the concrete itself impermeable.
Surface coating with thin water proof materials for resistance to non-pressurized
moisture such as rain water or a coating of cement sprayed on such as sortcrete which
can resist water under pressure. (damp proof)

28
Water proofing materials are butyl rubber, hot bitumen, plastic sheets, bituminous
sheet, sheet of lead, copper, mastic asphalt and Mortar with waterproofing
compounds.
At site water proofing compounds, hot bitumen and bitumen sheets are being used as
a water proofing material. Screte of 25mm is being provided above the bitumen
membrane in water proofing of slab.

Figure 4-8 Bitumen membrane for water proofing is being covered with Screte of 25 mm thickness

29
 5 Structural Elements
Those members that are interconnected in such a way so as to constitute a structure
are called structural elements.

5.1 Column
Column is a vertical member which takes complete load of the beam, slabs and the
entire structure and the floor and other area of the building. A column is a vertical
member which effectively takes load by compression. Basically column is a
compression member as load acts along its longitudinal axis. Bending moment may
occur due to wind earthquake or accidental loads.
Column transfers the load of the structure of slabs beams above to below, and finally
load is transferred to the soil. Position of the columns should be so that there are no
tensile stresses developed at the cross section of the columns. Columns location
should be such that it hides in the walls partially or fully.

5.1.1.1 Classification of RCC Column

Classification based on Shapes
 Circular for exposed outside for good architecture view
 Square or rectangular traditional for any structure
Classification based on length
 Short column – if L/B<=12
 Long column – if L/B > 12
Where L is the height and B is width of the column.

Generally, floor height is approximately 3 m or 10 feet, L/B ratio will be less than 12,
so in maximum cases short column is placed. In case where height of floor is more
than 3 m or 10 feet, we need to check L/B ratio so result may be long or short column.
Generally, on long column there are more forces generated so should be designed
carefully.

5.1.1.2 Size of Columns at Site

 900mm*1100mm (basement to ground floor)
 800mm*1000mm (1st floor till 7th floor)

5.1.1.3 Steps for Construction of RCC Columns

 Column layouts
 Column reinforcement work

30
  Column formwork
 Pouring of concrete
Layout of Columns
Column layouts are done by laying rope in the grid lines and mark the location of
columns

Column Reinforcement
Column reinforcement works needs following checklist on site:
 Check the numbers and diameter of vertical bars
 Spacing between vertical bars
 Check Development length which depends on diameter of bar
 Lapping in alternate bars should come at same height.
 Lapping should not come inside beam or slab.
 Lapping should be at l/3 or 2l/3 of column as per structural notes
 Spacing between stirrups is as per the drawing
 Hook should be bend properly at right angles.
 Check the stirrups corner. Vertical bar should come at right angle edge of
stirrup properly bound with binding wire.
Concreting of RCC Column
 Concreting of an RCC column can be done manually or with the help of
machine or pump
 Following points to be followed during and after concreting:
 For less quantity machine mix concrete is done and for larger quantity ready
mix concrete (RMC) is ordered.
 Approval of placing concrete whether by pump or manually has to be taken
from client.
 Concrete should be poured up to slab bottom; the remaining column gets
concreted during pouring of slab & beam.
 Mechanical vibrator to be compulsorily used in the column but excess
vibration can cause segregation. Each layer should be thoroughly compacted.
 Proper cover as per structural drawings to be maintained.
 Temperature should be below 30 degree while pouring concrete.
 After the pouring of concrete and vibrating it with the help of a vibrator the
horizontality and verticality of column to be checked.

31
5.2 Retaining wall
A retaining wall is a structure designed and constructed to resist the lateral pressure of
soil, when there is a desired change in ground elevation that exceeds the angle of
repose of the soil.
A retaining wall is a structure that retains (holds back) any material (usually earth)
and prevents it from sliding or eroding away. It is designed so that to resist the
material pressure of the material that it is holding back.
Concrete Cantilever retaining wall
At site cantilever retaining wall is constructed. This consists of a wall which is
connected to foundation. A cantilever wall holds back a significant amount of soil, so
it must be well engineered. They are the most common type used as retaining walls.
Cantilever wall rest on a slab foundation. This slab foundation is also loaded by back-
fill and thus the weight of the back-fill and surcharge also stabilizes the wall against
overturning and sliding.

Figure 5-1 Retaining wall of thickness 400mm

5.3 Shear wall

Shear wall a rigid vertical diaphragm capable of transferring lateral forces from
exterior walls, floors, and roofs to the ground foundation in a direction parallel to their
planes. Examples are the reinforced-concrete wall or vertical truss. Lateral forces

32
caused by wind, earthquake, and uneven settlement loads, in addition to the weight of
structure and occupants; create powerful twisting (torsional) forces. These forces can
literally tear (shear) a building apart. Reinforcing a frame by attaching or placing a
rigid wall inside it maintains the shape of the frame and prevents rotation at the joints.
Shear walls are especially important in high-rise buildings subject to lateral wind and
seismic forces.

5.3.1.1 POSITIONING OF SHEAR WALLS:

The shape and plan position of the shear wall influences the behavior of the structure
considerably. Structurally, the best position for the shear walls is in the centre of each
half of the building. This is rarely practical, however, since it dictates the utilization
of the space, so they are positioned at the end.
This shape and position of the walls give good flexural stiffness in the short direction,
but relies on the stiffness of the frame in the other direction.
This arrangement provides good flexural stiffness in both directions, but may cause
problems from restraint or shrinkage. As does this arrangement with a single core, but
which does not have the problem from restraint of shrinkage.
However, this arrangement lacks the good torsional stiffness of the previous
arrangements due to the eccentricity of the core.
If the core remains in this position then it must be designed explicitly for the torsion.
It is far preferable to adopt a symmetrical arrangement to avoid this.

5.4 Beam
A beam is a structural element that primarily resists loads applied laterally to the
beam's axis. Its mode of deflection is primarily by bending. The loads applied to the
beam result in reaction forces at the beam's support points. The total effect of all the
forces acting on the beam is to produce shear forces and bending moments within the
beam, that in turn induce internal stresses, strains and deflections of the beam. Beams
are characterized by their manner of support, profile (shape of cross-section), length,
and their material.

5.4.1.1 Classification Based on Supports

Simply supported - a beam supported on the ends which are free to rotate and have
no moment resistance.
Fixed - a beam supported on both ends and restrained from rotation.
33
Over hanging - a simple beam extending beyond its support on one end.
Double overhanging - a simple beam with both ends extending beyond its supports
on both ends.
Continuous - a beam extending over more than two supports.
Cantilever - a projecting beam fixed only at one end.
Trussed - a beam strengthened by adding a cable or rod to form a truss.

5.4.1.2 Size of beams at site

 400-600mm
 250*450mm
 200*450mm
 450*600mm
 300*600mm
 350*600mm
 425*425mm
 500*600mm
 400*750mm
 400*850mm
 600*600mm
 600*450mm
 1000*1100mm

5.5 Concrete Slab

Structural Concrete Slabs are constructed to provide flat surfaces, usually horizontal,
in building floors, roofs, bridges, and other types of structures. The slab may be
supported by walls, by reinforced concrete beams usually cast monolithically with the
slab, by structural steel beams, by columns, or by the ground. The depth of a slab is
usually very small compared to its span. Slabs whose thickness ranges from 100 to
500 mm are most often used for the construction of floors and ceilings. Thin concrete
slabs are also used for exterior paving purpose.

5.5.1.1 Classification or Type of Concrete Slab

In general, slabs are classified as being one-way or two-way. Slabs that primarily
deflect in one direction are referred to as one-way slabs. When slabs are supported by
columns arranged generally in rows so that the slabs can deflect in two directions they
are usually referred to as two-way slabs.
34
One way and two way slabs
One more definition regarding one-way and two –way slab is that if one direction
span to other direction span ratio (or more precisely if longer dimension to shorter
dimension ratio) is greater than 2 it is termed as two way slab, otherwise if less than
two it is termed as two-way slab.

Figure 5-2 One way slab with beams

Two way Slabs

Two way slabs may be strengthened by the addition of beams between the columns,
by thickening the slabs around the columns (drop Panels), and by flaring the columns
under the slabs (Column Capitals).

Figure 5-3 Two way slab with beams

Flat Plates Slab

These are solid concrete slabs of uniform depths that transfer loads directly to the
supporting columns without the aid of beams or capitals or drop panels.

35
 Figure 5-4 Flat slabs

At site one way, two way and flat slab with drop panel is being provided. Having
thickness of 210mm, 350mm and 450mm according to design.

36
 6 Formwork
Formwork is the term given to either temporary or permanent molds into which
concrete or similar materials are poured. In the context of concrete construction, the
false work supports the shuttering molds.

Figure 6-1Formwork for slab and beam

6.1 Formwork Requirements

Formwork is made from different materials, and requires great skill and experience in
its manufactures. To produce concrete forms that meet all job requirements, the
construction engineer must understand the characteristics, properties, and behaviors of
the materials used, be able to estimate the loads applied to the forms, and be familiar
with the advantages and shortcomings of various forming systems.

6.1.1.1 Major Objectives in Designing Formwork

Economy: The main materials of the reinforced concrete work are concrete,
reinforcement and formwork, so the total cost can be approximately distributed
among the three items. Economy should be considered when planning the formwork
for a concrete structure.
Quality: Forms must be designed and built with sufficient stiffness and accuracy so
the size, shape, position, and finish of the cast concrete are attained within the
required tolerances. The quality of the formwork itself has a direct impact on safety,
accidents, and failures. Correctly designed formwork will ensure that the concrete

37
maintains the desired size and shape by having the proper dimensions and being rigid
enough to hold its shape under the stresses of the concrete.
Safety: Formwork operations are risky, and workers are typically exposed to unsafe
working conditions. Partial or total failure of concrete formwork is a major
contributor to deaths, injuries, and property damages within the construction industry.
Forms must be built with sufficient strength and factors of safety so they are capable
of supporting all dead and live loads without collapse or danger to workers and to the
concrete structure.
Speed and Time: Speed of construction is defined as the rate in which concrete
building is raised and can be expressed in terms of number of floors erected per week
or months. Speed of construction can be also measured in terms of inches or
millimeters of concrete poured per hour. Formwork operations can control the pace of
construction projects.

6.2 Method for Formwork

6.2.1.1 Pre Check

 Check if the shutters are properly cleaned by removing the concrete/ mortar
and protruding nails.
 Formwork shall be made to the exact dimensions within the permissible
tolerances as mentioned below.
 Required thickness and quality of plywood conforming to IS 6461 shall be
used to meet the requirements of design and surface finish.
 For beam bottom & sides, proper size of timber at required spacing shall be
provided to take the design loads/ pressure considering sleeves, conduit
anchors &inserts.

6.2.1.2 Erection of Formwork

1. Sufficiently rigid and tight to prevent the loss of grout or mortar from the
concrete.
2. Capable of providing concrete of the correct shape and surface finish within
the specified tolerance limits.
3. Soffits forms capable of imparting a camber if required.
4. Erect staging/shuttering as per drawing/sketches in such a way that de-
shuttering can be done easily including provision for re-propping, if planned.
5. Check the location, line, level, plumb and dimensions of the formwork to
ensure that the deviations are within the permissible limits.

38
 6. Provide bracing at proper places as per formwork scheme to take care of
lateral loads.
7. Apply mould oil/other coatings as release agents before reinforcement steel is
placed.
8. Check all the shutters are properly aligned and fixed firmly with required
lateral supports and ties.
9. Check all the spanning members have proper bearing at the supports.
10. Wedges or jacks shall be secured in position after the final check of alignment.
11. Forms shall be thoroughly cleaned of all dirt, mortar and other matters such as
metals, blocks, saw dust and foreign materials before concreting.
12. Check all the gaps/openings are properly closed to avoid leakages.
13. Check all the inserts/embedment and openings are exactly placed as per the
drawings.
14. In case of leakages, bulging and sagging immediate actions shall be taken by
tightening wedges or adjusting by jacks which must be done before the
concrete takes its initial set.

6.3 Formwork Types

Formwork components can be assembled in a wide variety of systems for casting
many structural shapes. The terms formwork and falsework are often used in
combination. Formwork system can be generally classified as Vertical Systems (wall
and column) and Horizontal Systems (slab and beam). The material serving as the
contact face of forms is known as sheathing and it is used in both the vertical and
horizontal systems.

6.3.1.1 Formwork Horizontal Systems

Horizontal formwork systems are used to temporarily support horizontal concrete
work such as concrete beams and slabs.
Formwork for Concrete Slabs (soffit formwork)
Conventional wood systems for horizontal concrete work are made of plywood or
lumber sheathing for decking. Sheathing is supported by horizontal members called
joists or runners. Joists are supported by another set of horizontal members
perpendicular to the joists, called stringers (bearer or secondary beams). The stringers
are supported by vertical members called shores (PROP). Vertical timber shores can
be replaced by the scaffold type, which has been proven to be more efficient because

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of its high number of reuses and its height, which means that no splicing is typically
required.
Formwork for Concrete Beams
Formwork for beams consists of a bottom and two sides (open through section) in
addition to their supporting elements. The bottom is typically made of ply wood or
lumber sheathing. The bottom is supported by and fastened to horizontal joists. Beam
sides are also made of plywood or lumber sheathing.
Beam forms must be designed and constructed to safely support the vertically applied
dead loads and live loads as described above.

6.3.1.2 Formwork Vertical Systems

Vertical formwork systems are those used to form the vertical supporting elements of
the structure such as columns and walls. The functions of the vertical supporting
systems are to transfer the floor loads to the foundation and to resist the lateral wind
and earthquake loads.

Formwork for Column Systems

Column-form materials tend to vary with the column shape. Wood or steel is often
used with square or rectangular columns. Round column forms, more typically pre-
manufactured in a range of standard diameters, are available in steel, paperboard, and
fiber-reinforced plastic. Square and rectangular forms are composed of short-span
bending elements contained by external ties or clamps.
Formwork for Wall System
Wall forms principally resist the lateral pressures generated by fresh concrete as a
liquid or semi-liquid material. The pressures can be quite large; certainly many times
the magnitude of live loads on permanent floors. Thus, wall form design often
involves closely spaced and well-supported members. A concrete form tie is a tensile
unit connecting opposite sides of the form and providing a link for equilibrium. Form
ties are usually steel, although some fiber-reinforced plastic ties are also available.

6.4 Formwork Materials

The selection of materials suitable for formwork should be based on the price, safety
during construction, and the quality required in the finished product. The selection of

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materials suitable for formwork should be based on the price, safety during
construction, and the quality required in the finished product.

6.4.1.1 Timber Formwork:

Timber for formwork should satisfy the following requirement:
It should be
 well seasoned
 light in weight
 easily workable with nails without splitting
 free from loose knots
Timber used for shuttering for exposed concrete work should have smooth and even
surface on all faces which come in contact with concrete.

Normal sizes of members for timber formwork:

sheeting for slabs, beam, column 25 mm to 40mm thick
side and beam bottom
Joints, ledges 50 x 70 mm to 50 x 150 mm
Posts 75 x 100mm to 100 x 100 mm
Table 6-1 Sizes of timber members

6.4.1.2 Plywood Formwork

Resin bonded plywood sheets are attached to timber frames to make up panels of
required sizes. The cost of plywood formwork compares favorably with that of timber
shuttering and it may even prove cheaper in certain cases in view of the following
considerations:
 It is possible to have smooth finish in which case on cost in surface finishing
is there.
 By use of large size panels it is possible to effect saving in the labor cost of
fixing and dismantling.
 Numbers of reuses are more as compared with timber shuttering. For
estimation purpose, number of reuses can be taken as 20 to 25.

6.4.1.3 Steel Formwork

This consists of panels fabricated out of thin steel plates stiffened along the edges by
small steel angles. The panel units can be held together through the use of suitable
clamps or bolts and nuts. The panels can be fabricated in large number in any desired
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modular shape or size. Steel forms are largely used in large projects or in situation
where large number reuses of the shuttering is possible. This type of shuttering is
considered most suitable for circular or curved structures.
Steel forms compared with timber formwork:
 Steel forms are stronger, durable and have longer life than timber formwork
and their reuses are more in number.
 Steel forms can be installed and dismantled with greater ease and speed.
 The quality of exposed concrete surface by using steel forms is good and such
surfaces need no further treatment.
 Steel formwork does not absorb moisture from concrete.
 Steel formwork does not shrink or warp.

6.5 Order and method of removing formwork:

The sequence of orders and method of removal of formwork are as follows:
 Shuttering forming the vertical faces of wall 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.
S.No Description of structural member Period of time (Days)

1 Walls, columns and vertical sides of beams 1to 2

2 Slabs (props left under) 3
3 Beam soffits (props left under) 7
4 Removal of props to slabs

(a) For slabs spanning upto 4.5 m 7

(b) For slabs spanning over 4.5 m 14
5 Removal of props to beams and arches

(a) Spanning upto 6 m 14

(b) spanning over 6 m 21
Table 6-2Period of removal of formwork

Rapid hardening cement, warm weather and light loading conditions allow early
removal of formwork. The formwork should under no circumstances be allowed to be
removed until all the concrete reaches strength of at least twice the stresses to which
the concrete may be subjected at the time of removal of formwork. All formworks
should be eased gradually and carefully in order to prevent the load being suddenly
transferred to concrete.
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 7 Tests for quality check
7.1 Test on Cement

7.1.1.1 Consistency
AIM
To determine the quantity of water required to produce a cement paste of standard
consistency as per IS: 4031 (Part 4) - 1988.
PRINCIPLE
The standard consistency of a cement paste is defined as that consistency which will
permit the Vicat plunger to penetrate to a point 5 to 7mm from the bottom of the Vicat
mould.
APPARATUS
Vicat apparatus conforming to IS: 5513 - 1976 Balance, whose permissible variation
at a load of 1000g should be +1.0g Gauging trowel conforming to IS: 10086 - 1982
PROCEDURE
i. Weigh approximately 400g of cement and mix it with a weighed quantity of
water.
ii. The time of gauging should be between 3 to 5 minutes.
iii. Fill the Vicat mould with paste and level it with a trowel.
iv. Lower the plunger gently till it touches the cement surface.
v. Release the plunger allowing it to sink into the paste.
vi. Note the reading on the gauge.
vii. Repeat the above procedure taking fresh samples of cement and different
quantities of water until the reading on the gauge is 5 to 7mm.
REPORTING OF RESULTS
Express the amount of water as a percentage of the weight of dry cement to the first
place of decimal.

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7.1.1.2 Initial and Final Setting Time
AIM
To determine the initial and the final setting time of cement as per IS: 4031 (Part 5) -
1988.
APPARATUS
Vicat apparatus conforming to IS: 5513 - 1976 Balance, whose permissible variation
at a load of 1000g should be +1.0g Gauging trowel conforming to IS: 10086 - 1982
PROCEDURE
i) Prepare a cement paste by gauging the cement with 0.85 times the water
required to give a paste of standard consistency.
ii) Start a stop-watch, the moment water is added to the cement.
iii) Fill the Vicat mould completely with the cement paste gauged as above, the
mould resting on a non-porous plate and smooth off the surface of the paste
making it level with the top of the mould. The cement block thus prepared in
the mould is the test block.
INITIAL SETTING TIME
Place the test block under the rod bearing the needle. Lower the needle gently in order
to make contact with the surface of the cement paste and release quickly, allowing it
to penetrate the test block. Repeat the procedure till the needle fails to pierce the test
block to a point 5.0 ± 0.5mm measured from the bottom of the mould . The time
period elapsing between the time, water is added to the cement and the time, the
needle fails to pierce the test block by 5.0 ± 0.5mm measured from the bottom of the
mould, is the initial setting time.
FINAL SETTING TIME
Replace the above needle by the one with an annular attachment.
The cement should be considered as finally set when, upon applying the needle gently
to the surface of the test block, the needle makes an impression therein, while the
attachment fails to do so. The period elapsing between the time, water is added to the
cement and the time, the needle makes an impression on the surface of the test block,
while the attachment fails to do so, is the final setting time.
REPORTING OF RESULTS
The results of the initial and the final setting time should be reported to the nearest
five minutes.

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7.2 Tests on Aggregate

7.2.1.1 Sieve Analysis

AIM
To determine the particle size distribution of fine and coarse aggregates by sieving as
per IS: 2386 (Part I) - 1963.
PRINCIPLE
By 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 SIEVES
i) 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,
600μm, 300μm, 150μm and 75μm
ii) Balance or scale with an accuracy to measure 0.1 percent of the weight of the
test sample
PROCEDURE
i) The test sample is dried to a constant weight at a temperature of 110 + 5oC
and weighed.
ii) The sample is sieved by using a set of IS Sieves.
iii) On completion of sieving, the material on each sieve is weighed.
iv) Cumulative weight passing through each sieve is calculated as a percentage of
the total sample weight.
v) Fineness modulus is obtained by adding cumulative percentage of aggregates
retained on each sieve and dividing the sum by 100.
REPORTING OF RESULTS
The results should be calculated and reported as:
i) The cumulative percentage by weight of the total sample
ii) The percentage by weight of the total sample passing through one sieves and
retained on the next smaller sieve, to the nearest 0.1 percent.

45
7.2.1.2 Water Absorption
AIM
To determine the water absorption of coarse aggregates as per IS: 2386 (Part III) -
1963.
APPARATUS
i) Wire basket - perforated, electroplated or plastic .
ii) Water-tight container for suspending the basket
iii) Dry soft absorbent cloth - 75cm x 45cm (2 nos.)
iv) Shallow tray of minimum 650 sq.cm area
v) Air-tight container of a capacity similar to the basket
vi) Oven
PROCEDURE
i) The sample should be thoroughly washed to remove finer particles and dust,
ii) drained and then placed in the wire basket and immersed in distilled water at a
iii) Temperature between 22 and 32oC.
iv) After immersion, the entrapped air should be removed by lifting the basket
and allowing it to drop 25 times in 25 seconds. The basket and sample should
remain immersed for a period of 24 + 1 2 hrs. afterwards.
v) 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').
vi) 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 RESULTS
Water absorption = [(A-B)/B] x 100%

46
7.3 Tests on Concrete

7.3.1.1 Slump test

AIM
To determine the workability of fresh concrete by slump test as per IS: 1199 - 1959.
APPARATUS
Slump cone, tamping rod
PROCEDURE
i) The internal surface of the mould is thoroughly cleaned and applied with a
light coat of oil.
ii) The mould is placed on a smooth, horizontal, rigid and non- absorbent surface.
iii) The mould is then filled in four layers with freshly mixed concrete, each
approximately to one-fourth of the height of the mould.
iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes
are distributed evenly over the cross- section).
v) After the top layer is taped, the concrete is struck off the level with a trowel.
vi) The mould is removed from the concrete immediately by raising it slowly in
the vertical direction.
vii) The difference in level between the height of the mould and that of the highest
point of the subsided concrete is measured.
This difference in height in mm is the slump of the concrete.
REPORTING OF RESULTS
The slump measured should be recorded in mm of subsidence of the specimen during
the test. Any slump specimen, which collapses or shears off laterally gives incorrect
result and if this occurs, the test should be repeated with another sample

7.3.1.2 Compressive strength test/cube test

Out of many test applied to the concrete, this is the outmost important which gives an
idea about all the characteristics of concrete.
Preparation of cube specimens
MOULD
The mould shall be of size 15cm X 15cm X 15cm for the maximum nominal size of
aggregate not exceeding 40mm. Each mould shall be provided with base plate having
a plane surface and made of non-absorbent material.
SAMPLE OF CONCRETE

47
Sample of concrete for the test specimen shall be taken at the mixer or in the case of
ready mixed concrete from the transportation vehicle discharge or as directed by
Engineer-in-charge.

SAMPLING

i) Clean the mould and apply oil.

ii) Fill the concrete in the mould in layer approximately 5cm thick.
iii) Compact each layer with not less than 35 strokes per layer using a tampering
rod (steel bar 16mm diameter and 60cm long, bullet pointed at lower end)
iv) Level the top surface and smoothen it with trowel

CURING
The tests specimens are then stored in moist air for 24 hours and after this the
specimens are marked and removed from the molds and kept submerge in clear fresh
water until taken out prior to test.

TESTING PROCEDURE
i) Remove the specimens from the water after specified time and wipe out excess
water from the surface
ii) Take the dimension of the specimen to the nearest 0.2m
iii) Clean the bearing surface of the testing machine
Fig: cube testing
iv) Place the specimen in the machine in such a manner that the load shall be
applied to the opposite side of the cube cast.
v) Rotate the movable portion gently by hand so that it touches the top surface of
the specimen
vi) Apply the load gradually without shock and continue till the specimen fail

vii) Record the maximum load and note any unusual features in the type of failure.

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7.4 IN-SITU DRY DENSITY

7.4.1.1 CORE CUTTER METHOD

AIM
To determine the in-situ dry density of soil by core cutter method as per IS: 2720 (Part
XXIX) - 1975.
APPARATUS
Cylindrical core cutter, Steel dolley, Steel rammer, Balance with an accuracy of 1g,
Straightedge, Square metal tray - 300mm x 300mm x 40mm, Trowel
PROCEDURE
i) The internal volume (V) of the core cutter in cc should be calculated from its
ii) Dimensions which should be measured to the nearest 0.25mm.
iii) The core cutter should be weighed to the nearest gram (W1).
iv) A small area, approximately 30cm square of the soil layer to be tested should
be exposed and leveled. The steel dolly should be placed on top of the cutter
and the latter should be rammed down vertically into the soil layer until only
about 15mm of the dolly protrudes above the surface, care being taken not to
rock the cutter. The cutter should then be dug out of the surrounding soil, care
being taken to allow some soil to project from the lower end of the cutter. The
ends of the soil core should then be trimmed flat in level with the ends of the
cutter by means of the straightedge.
v) The cutter containing the soil core should be weighed to the nearest gram
(W2).
vi) The soil core should be removed from the cutter and a representative sample
should be placed in an air-tight container and its water content (w) determined.
REPORTING OF RESULTS
Bulk density of the soil γ = (W2 −W1)/V g /cc
Dry density of the soil γd = [100γ/100+w] g c

49
 8 Conclusion
In conclusion, there were many things that I have experienced and learned during the
four month of my Industrial Training at Nelson India. The whole training period was
very interesting, instructive and challenging.
Through this training I was able to gain new insights and more comprehensive
understanding about the real industry working condition and practice. The four month
of duration also has provided me the opportunities to develop and improve my
functional skills. All of these valuable experiences and knowledge that I have gained
were not only acquired through the direct involvement in task given but also through
other aspect of the training such as work observation, interaction with colleagues,
superior, and other people related to the field.
From what I have undergone, I am very sure that the industrial training program has
achieved its entire primary objectives. It is also the best way to prepare students to
face the real working life. As a result of the program now I am more confident to
build my future career.

50
 Bibliography
damp proof. (n.d.). Retrieved from https://en.wikipedia.org:
https://en.wikipedia.org/wiki/Damp_proofing
IS : 875 ( Part 1 ) - 1987 . Dead load.
IS : 875 ( Part 2 ) - 1987. Imposed Load.
IS : 875 ( Part 3 ) - 1987. Wind Load.
IS:1857-1987 . Design Loads.
IS:456-2000. Code for desing of concrete and RCC structure.
STANDARDS, B. O. (2005). NATIONAL BUILDING CODE OF INDIA 2005 .

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