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INTERSNSHIP REPORT ON PRTESTIGE ROYALE GARDENS ,BENGALURU 2015-16
A REPORT
ON
SUMMER INTERNSHIP PROJECT AT PRESTIGE ROYALE GARDENS
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS OF
BACHELOR IN ENGINEERING
IN
CIVIL ENGINEERING
By:
SHIVAKUMAR MANGLOOR
VENKATESH SURYAWANSHI
SAGAR K S
UNDER THE GUIDANCE OF
Mr.C.R.Manjunath Mr. Manish Shashikant Dr. Aravind H Bhashyam

Senior AGM, Assistant Professor, Prof & HOD,
Prestige Real Estates Pvt.Ltd Dept. of Civil Engg. Dept. of Civil Engg.
Bengaluru BMSIT&M, Bengaluru BMSIT&M, Bengaluru
2015-2016
BMS INSTIUTE OF TECHNOLOGY & MANAGEMENT
DEPARTMENT OF CIVIL ENGINEERING
AVALAHALLI, YELAHANKA
BENGALURU-560064
DEPARTMENT OF CIVIL ENGINEERING,BMSIT&M,BENGALURU 1
ACKNOWLEDGEMENT
We would like to thank Mr. K.B. Srinivas, Senior Vice President- Projects, Prestige Prestige Real
Estates Pvt Ltd for providing this internship opportunity.
Our deep scene of gratitude goes to Mr. Milan khurana ,CHRO for his encouragement throughout the
internship period. I would like to thank Mr.C.R.Manjunath, Senior AGM, Mr.Venugopal, Senior
Project Manager and Mr.Sudendra, Project Manager, Prestige Royal Garden Site, Avalahalli, who
had been a source of inspiration and for their timely guidance in the conduct of our training.
We also thank Mr.Azharuddin.N, Site Engineer for all his valuable assistance during
training.
We would like to thank the Project team of Prestige Real Estates Pvt.Ltd at Prestige Royal
Garden Site, and Project team of NCCCL for their valuable and timely guidance in carrying out the
training work at the site.
It’s our immense pleasure in thanking Dr.Mohan Babu.G.N, Principal, BMSIT&M for having us
permitted us to take this internship with Prestige Real Estates Pvt Ltd at Prestige Royale Garden,
Bengaluru.
We owe my gratitude to Dr.R.V.Ranganath, Former Principal BMSIT&M for his constant support
and guidance.
Words are inadequate to thank Dr.Aravindh.H.Bhashyam, Professor & HOD, Department of Civil
engineering, BMSIT&M for all his able guidance the internship with Prestige Real Estates Pvt Ltd.
under their Prestige Royale Garden, Bangalore.
Our deep sense of gratitude to all the Faculty members of the Department for their encouragement and
able guidance which has helped us in completing the internship course in time.
DATE-
Shivakumar Mangaloor,
Venkatesh Suryawanshi
Sagar K S

DECLARATION
We hereby declare that the work which is prescribed in this report entitled
“SUMMER INTERNSHIP PROJECT” in partial fulfillment of the requirement
for the award of Bachelor of Engineering in Civil Engineering is an authentic record of
our work carried out between July 2015 to Aug 2015 at “PRESTIGE REAL ESTATE(P)
LTD” under the supervision of Mr.C.R.MANJUNATH, Project AGM, Prestige
Royale Gardens, Bengaluru and Mr. MANISH SHASHIKANT, Assistant Professor,
Dept. of Civil Engineering, BMS Institute of Technology & Mgmt., Bengaluru.
Date:
Shivakumar Mangaloor,
Venkatesh Suryawanshi
Sagar K S

CONTENTS
1- INTRODUCTION……………………………………………………………………………………………………….12
1.1-BACKGROUND OF THE COMPANY ….....................................................................................................12
1.2-CORPORATE VALUES OF THE COMPANY .............................................................................................13
1.3-PROJECT DESCRIPTION-CONCEPT ……….................................................................................................14
1.4-PROJECT DETAILS.......................................................................................................................................15
1.5-UNIT LOCATION ..........................................................................................................................................16
1.6-SOME OF THE PROJECTS DEVELOPED BY PRETIGE GROUPS .........................................................17
1.7-ON GOING PROJECTS BY PRESTIGE .......................................................................................................18
2 -DIFFERENT DEPARTMENTS AT THE SITE ...............................................................................................20
2.1-DIFFERENT DEPARTMENTS AT THE SITES ...........................................................................................20
2.2-QA/QC DEPARTMENT .................................................................................................................................22
3-SAFETY AND ITS PRACTISE.........................................................................................................................25
3.1-SAFETY ..........................................................................................................................................................25
3.2- WORK AND WORKER SAFETY SERIES..................................................................................................26
3.3- FALL PROTECTION ....................................................................................................................................26
3.4-LADDERS .......................................................................................................................................................27
3.5- PATHWAY ....................................................................................................................................................28
3.6-CRANES..........................................................................................................................................................28
3.7-HAZARD COMMUNICATION .....................................................................................................................29
3.8-SAFETY CHECKLISTS .................................................................................................................................30
3.9-PERSONAL PROTECTIVE EQUIPMENTS (PPE) ......................................................................................31
3.10-SCAFFOLIDINS ...........................................................................................................................................32

3.11-ELECTRIAL SAFETY .................................................................................................................................33
3.12-FLOOR AND WALL OPENINGS ..............................................................................................................33
4-LABS AT THE SITE…………………………………………..………………………………………….… 36
4.1-FLOOR PLAN OF QA/QC LAB ....................................................................................................................37
4.2-SLUMP CONE TEST .....................................................................................................................................39
4.3-CORE CUTTING ............................................................................................................................................43
4.4-COMPRESSIVE STRENGTH TESTING EQUIPMENT ...............................................................................43
4.5-SIEVE ANALYSIS MACHINE......................................................................................................................43
4.6-RAPID MOISTURE METER..........................................................................................................................43
4.7-SLUMP CONE ................................................................................................................................................44
4.8-CALIBARATION DETAILS OF THE INSTRUMENTS [6] .......................................................................45
5-SITE EXECUTIONAL ASPECTS.....................................................................................................................48
5.1-EXCAVATION ...............................................................................................................................................48
5.2-SCAFFOLDING..............................................................................................................................................57
5.3-FORMWORK..................................................................................................................................................52
5.4-REINFORCEMENT LAYING........................................................................................................................54
5.5-CONCRETING ...............................................................................................................................................58
5.6-PLAIN CEMENT CONCRETE ......................................................................................................................60
5.7-CURING ..........................................................................................................................................................61
5.8-CONCRETE BLOCKS AND CMU ................................................................................................................62
5.9-PLASTERING .................................................................................................................................................64
5.10-MATERIALS ................................................................................................................................................70
5.10(a)-Cement ..................................................................................................................................................70
5.10(b) Aggregates.............................................................................................................................................71

5.10(c)-Concrete ................................................................................................................................................72
6-EQUIPMENTS AND INSTRUMENTS ...............................................................................................................75
6.1-BATCHING PLANT .........................................................................................................................................75
6.3-EXCAVATORS ................................................................................................................................................77
6.4-TOWER CRANE................................................................................................................................................77
6.5-CONCRETE DRILLER .....................................................................................................................................79
6.6-VIBRATOR ........................................................................................................................................................79
6.7-DUMPY LEVEL ................................................................................................................................................80
7-CONCLUSION .....................................................................................................................................................83
8-APPENDIX ...........................................................................................................................................................86

LIST OF FIGURES
Figure 1- unit location of the project………………………………………………..……16
Figure 2-Project planning .................................................................................................. 21
Figure 3-Safety.................................................................................................................. .25
Figure 4-Safety nets tied around the periphery of the building to prevent the accidents
caused due to falling of materials from heights ............................................................... .27
Figure 5- View of crane tower ......................................................................................... .29
Figure 6-Safety boards displayed at the board ................................................................ .30
Figure 7-View of personal protective Equipments .......................................................... 31
Figure 8- A view of Helmets-Hard Hats a part of Personal Protective Equipment......... 32
Figure 9- A View of Safety boards at the entrance of sit .................................................34
Figure 10-Layout of QA&QC lab at the site ................................................................... 36
Figure 11-Testing the workability of the concrete mix using slump cone ...................... 37
Figure 12-Slump cone test-cone removed ....................................................................... 38
Figure 13-Cylindrical mould being drilled into ground to determine density................. 41
Figure 14- A View of a Rapid moisture meter ................................................................ 44
Figure 15-A View of Slump cone.................................................................................... 45
Figure 16-Ground is excavated based on the need and type of foundation..................... 49
Figure 17-A View of Tractor shovel (loading shovel) .................................................... 50
Figure 18-A View of back hoe ........................................................................................ 50
Figure 19-A View of Dumper truck ................................................................................ 51
Figure 20-A View of scaffolding..................................................................................... 52

Figure 21-A View of formwork at the site ....................................................................... 54
Figure 22-A View of reinforcement bars………………………………………………..56

Figure 23-Pouring of concrete for footing ...................................................................,.... 66
Figure 24- A view of PCC bed for Foundation(Plain cement concrete) .......................... 61
Figure 25-Curing and use of curing compound ................................................................62
Figure 26- Concrete Block-Standard Sizes....................................................................... 63

.
Figure 27- A view of wall after block work is executed ....................................................63
Figure 28- plastered surface just after 1st coat application ............................................,. 64
Figure 29- plastered surface just after 1st coat application ..............................................65
Figure 30-Tools used for plaster .......................................................................................70
Figure 31- A view of in-house batching plant at the site...................................................75
Figure 32- A view of Transit Mixer...................................................................................76
Figure 33-Excavators ........................................................................................................78
Figure 34-A View of Concrete Driller.............................................................................79
Figure 35-A View of concrete Needle Vibrator ................................................................80
Figure 36- A view of Dumpy Level to check levels after excavation is done ................ 81
Figure 37- Aerial view of Prestige Royale Gardens, Doddaballapura road Bangalore.. ...86
Figure38- TYPE –A 1BHK ...............................................................................................87
Figure39- TYPE-B 1 BHK .............................................................................................. 88
Figure-40 TYPE-C 1 BHK .............................................................................................. 89
Figure-41 TYPE-D1BHK ................................................................................................ 90

Figure-42 TYPE-E 2BHK................................................................................................ 91
Figure-43TYPE-F 2 BHK ................................................................................................ 92
Figure-44 TYPE-G 2 BHK .............................................................................................. 93
Figure-45TYPE-H 2 BHK ............................................................................................... 94
Figure-46 TYPE-J 2 BHK ............................................................................................... 95
Figure-47 TYPE-J 3BHK ................................................................................................ 96
Figure-48 TYPE-K 3 BHK .............................................................................................. 97
Figure-49 Club house....................................................................................................... 98
Figure-50 Entrance Lobby ............................................................................................... 99
Figure-51 Grand Entrance...............................................................................................100
Figure-52 Kitchen ...........................................................................................................101
Figure-53 Living Room ..................................................................................................102
Figure-54 Master Bedroom .............................................................................................103
Figure -55 Swimming Pool .............................................................................................104

LIST OF TABLES
Table 1-Statistical data showing the facility provided for car parking … … . . . ..….….15
Table 2-core cutting tabulation………………………………………………………...42
Table 3-The minimum required % elongations for these bars……………...................58

CHAPTER-1

1- INTRODUCTION
1.1-BACKGROUND OF THE COMPANY [01]
The Prestige group owes its origin to Mr.Razack Sattar, who envisioned a success story waiting
to take shape in a retail business in 1956 itself. Since its formation in 1986, Prestige estates
projects has grown swiftly to become one of India’s leading property developers, helping shape
the skyline across the residential, commercial, retail, leisure and hospitality sectors.
Prestige Court on K.H. Road in Bengaluru set the pace for the Group's rapid growth which now
stands at over 184 Completed Projects spanning a total developed area of over 60.74 million sqft.
It also has another 57 ongoing projects comprising around 59.24 million sqft & 43 upcoming
projects totaling 44.11 million sq ft. which include Apartment Enclaves, Shopping Malls.
Prestige Constructions, an ISO 9001:2000 certified company is the only Real Estate Developer in
Bangalore to have won the reputed FIABCI Award for its software and residential facilities.
Prestige was also recently awarded the Crisil DA1 Developer Rating in recognition of the
quality of their projects and the ability to deliver completed projects in a timely manner, making
them the ONLY Property Developer across India to have received this distinction.
Today, Prestige stands as a giant and with aggressive growth plans across the Residential,
Commercial, Retail and Hospitality Sectors in Bengaluru, Goa, Hyderabad, Mangalore, Cochin

1.2-CORPORATE VALUES OF THE COMPANY

Vision
To continuously exceed the expectations of our customers and employees and become a
benchmark for quality in every field the Prestige Group ventures into.
Mission
To improve customer experiences through constant innovation and understanding, with a focus
on quality and transparency of processes so that when it comes to Prestige, customers come to
expect nothing but the best from us every time.
Passion
Passion is our strongest motivator. We are alert to new ideas, eager to learn more and positive
towards setbacks. We are driven to break barriers and set new benchmarks. Passion pushes us to
explore possibilities so we can give our customers more than they expect.
Quality
Our focus on quality borders on the obsessive. At Prestige, it's not just a catchphrase, but a way
of life. And so we dedicate every minute in the pursuit of it, stopping short of nothing to ensure it
reflects in all we do.
Greener pasture
Our focus on quality borders on the obsessive. At Prestige, it's not just a catchphrase, but a way
of life. And so we dedicate every minute in the pursuit of it, stopping short of nothing to ensure it
reflects in all we do.
Quality policy
Prestige Estates Project (P) Ltd. is committed to:
 Providing broad spectrum real estate solutions.

 Meeting and exceeding customer needs and expectations.
adopting latest technologies for safer, timely and reliable construction
 Ensuring conservation and development of eco-friendly environment.
Contributing to the welfare of society.
 Making continuous improvement in all areas of activities based on customer inputs to
enhance customer satisfactions

1.3-PROJECT DESCRIPTION-CONCEPT
Prestige Royale Gardens is an upcoming high rise residential project at Doddaballapura main
road near BMSIT, Bengaluru, set amidst 22acres 6.5guntas. It is a cluster of integrating flats of
areas ranging from 602sqft-1700sqft of 1.2 and 3 bedroom flats.
Located in Avalahalli, Doddaballapura main road with all possible convinces. The project comprises a
1696 premium 2BHK and 3BHK apartments. Approximately 54% of vaastu is considered for individual
flats and maximum privacy is ensured for all the flats, amenities includes a premium club house,
swimming pools, children play area and recreational center of the layout is encased among the high
rise towers breaking the monotony of tall silhouette.
DESIGN DESCRIPTION:
ARCHITECTURE
The overall property is 22acres 6.5guntas. The North side of the site is the Doddaballapura
main road and the rear side is the railway track and private developments on other two
sides. The primary access to the site is through Doddaballapura road which forms the longest
boundary.
The site is basically a flat land and the road levels which are much higher than the site have a
difference off approximately 3m from the centre of the existing road to the site.
The proposed residential building is basement + stilt parking + 16 and 18 floor structures.
Consist of 1696 number of apartments of 174356sqft to 8750sqft in 13 towers named from 1 to
13.
The towers 1, 2 and 5-14 are cluster of 2 BHK, 2.5 BHK and 3 BHK flats. The tower 3 and 4 are
the 1 BHK and 2 BHK flats. Each of the towers is serviced with separate services and passenger
elevators, fire staircases, fire protection, electrical, communication, plumbing shafts etc. The
internal lift lobbies are well ventilated either with lobby openings or interior courtyards
throughout the building.
LANDSCAPE AND SITE PLANNING
Club house and swimming pool is surrounded by 16 and 18 high rise apartment towers
overlooking the central courtyard area. A fire drive way runs along the periphery of the tower
linking a 9m wide driveway connecting the ground level to the podium were all the towers have
been placed. Peripheral planting is taken care of excluding the areas of power house.
Rain water harvesting and solar water heaters are planned to conserve energy and create

symbiosis between nature and architecture.

BASIC LOCAL BYE LAWS TO BE CONSIDERED DURING DESIGN
The building blocks are individual towers with partially interconnected blocks and a club
house. The tower starts from the podium level. As per the local fire norms, 8m driveway is
provided along the periphery of the tower.
CAR PARK STATEMENT
Table 1-Statistical data showing the facility provided for car parking
Total no of cars 1696

10% of visitors cars 169
Total 1865
Parking provided
Basement 950
Stilt parking 852
Basement parking 162
Total 1965
1.4-PROJECT DETAILS
Clients-Prestige Estates Projects
Contractor-New Consolidated Construction Co. Limited
(NCCCL) Structural consultants-Mahimtura consultants’ pvt.ltd
PHE & fire consultants-Design Tree Service Consultants pvt
ltd Electrical consultants -Sripeksha Engineering
Landscape consultants-OIKOS
Commencement of work-2nd Nov
2013 Started-11th Nov 2014
End of the project-31st Dec 2016
Total units-1696
1BHK-188no’s
2 BH- 788no’s
2.5BHK360no’s
3 BHK-360no’s

Area
Plot area-22acreas guntas

Built up area-32,05601sqft
Salable area-22,59424 sqft
1.5-UNIT LOCATION
Figure 1- Unit location of the project

1.6-SOME OF THE PROJECTS DEVELOPED BY PRETIGE GROUPS [05]

These projects include resendtial and a commercial building which meets the customers needs
even today and stand as a landmark.
Residential developments by Prestige Group.
 Prestige Acropolis – Koramangala, Bengaluru.

 Prestige El Dorado & El Palacio - Edward Road, Bengaluru..
 Prestige Exotica - Cunningham Road, Bengaluru.
 Prestige Greenwoods - Old Madras Road, Bengaluru.
 Prestige Monte Carlo – Yelahanka, Bengaluru.
Some of the well-known commercial developments of Prestige group.

 Prestige Atrium - Central Street, Bengaluru..
 Prestige Center - Commercial Street, Bengaluru.
Prestige Obelisk - Kasturba Road, Bengaluru.
 Prestige Sapphire – Jayanagar Bengaluru.
 Prestige Tech Park II Electra - Sarjapur - Marathahalli ORR
 Prestige Tech Park III - Sarjapur - Marathahalli ORR, Bengaluru.
Malls
 The Forum (shopping mall) -Koramangala, Bengaluru.
 The Forum Value (Shopping Mall) - Whitefield, Bengaluru.
 The Forum Vijaya (Shopping Mall), Chennai
The Forum (Shopping Mall), Hyderabad
 The Forum Fiza(Shopping Mall), Mangaluru.
Leisure and hospitality
 Angsana Oasis Spa & Resort, Bengaluru.

 Transit Food Lounge - Located at Forum Mall at Koramanagala, Bengaluru.

 Prestige Golf shire Club

1.7-ON GOING PROJECTS BY PRESTIGE

Prestige Group has 61 projects lined up from commercial offices to malls .some of them are
listed below
Residential developments
 Prestige Golfshire, Nandi Hills, Bengaluru.
 Prestige White Meadows, White field, Bengaluru.
 Prestige Sunnyside, Bengaluru.
 Prestige Royale Gardens, Yelahanka, Bengaluru.
 Prestige Silver Spring - OMR, Chennai
 Prestige Downtown - K K Nagar, Chennai
 Prestige Lakeside Habitat - Whitefield, Bengaluru.
 Prestige Gulmohar, Horamavu, Bengaluru. (Recently Launched)
 Prestige Bagmane Temple Bells, Rajarajeshwari Nagar, Bengaluru. (Recently Launched)
Commercial developments
 Prestige Khoday Towers - Raj Bhavan Road,
Bengaluru.
 Malls
Several malls are under construction from Prestige Group in joint ventures all over southern
India.
 Forum Sujana Mall, Hyderabad
 Forum Mall, Mysuru
 Forum Thomsun Mall, Kochi
UPCOMING PROJECT
 Prestige Falcon City - Kanakapura main raod, Bengaluru

CHAPTER-2

2 -DIFFERENT DEPARTMENTS AT THE SITE
2.1-DIFFERENT DEPARTMENTS AT THE SITES

The term ‘Construction’ does not only denotes physical activities involving men, materials and
machinery but also covers the entire gamut of activities from conception to realization of a
construction project. Thus, management of resources such as men, materials, machinery requires
effective planning and scheduling of each activity.
Planning, scheduling is an important part of the construction project management. Planning and
scheduling of construction activities helps engineers to complete the project in time and within
the budget.
Construction Management:
Management is the science and art of planning, organizing, leading and controlling the work
of organization members and of using all available organization resources to reach stated
organizational goals.
Construction management deals with economical consumption of the resources available in the
least possible time for successful completion of construction project. ‘Men’, ‘materials’,
‘machinery’ and ‘money’ are termed as resources in construction Management.
Objectives of Construction Management:
The main objectives of construction management are,
 Completing the work within estimated budget and specified time.

 Maintaining a reputation for high quality workmanship
 Taking sound decisions and delegation of authority
 Developing an organization that works as a team.

The functions of Construction Management are
 Planning
 Scheduling
 Organizing
 Staffing
 Directing
 Controlling
 Coordinating
Figure 2-Project plannin

Importance of construction project planning:
 Planning helps to minimize the cost by optimum utilization of available resources.
 Planning reduces irrational approaches, duplication of works and inter departmental

conflicts.
 Planning encourages innovation and creativity among the construction managers.
 Planning imparts competitive strength to the enterprise.
2.2-QA/QC DEPARTMENT
Quality Control in any project construction site is as important as any other project related
activity such as design, execution (of construction activities), planning and so on. Quality control
succeeds quality assurance. This site has a number of useful articles on diverse quality related
topics like definitions of quality control and quality assurance, various QC laboratories testing
apparatus (or equipments) relevant to civil work in construction sites, calibration of laboratory
equipments.
Once the required quality personnel for a project are available, the first and for most
responsibility for them is to set the “quality” ball rolling, i.e., to set the process of ensuring
quality in motion. The “quality” domain broadly consists of two sub domains namely quality
control and quality assurance. A major step in setting the “quality” ball in motion is to create the
very important sub domain called QA. Unless QA is in place QC can’t be initiated and continued
properly.
That’s because QA means creating the necessary quality framework so that using that or taking
guidance from it the process of QC can be successfully initiated, continued and completed in a
systematic and timely manner. Performing QA or creating the QA framework means identifying
all the quality parameters or quality targets for a project; identifying and obtaining all existing
general quality documents such as codes, specifications, local quality related regulations or
norms (if any) relevant to the project; preparing new project specific quality documents such as
Project Quality Plan or Quality Assurance Plan, Inspection & Testing Plans (ITPs), Quality
forms

Equipped with these QA documents and the necessary quality control personnel such as QC
manager, QC engineers, laboratory technicians etc., the process of quality control can now be set
in motion. Of course, one of the most important steps into this is establishing a good quality
control laboratory at the project site at a convenient location. That’s a must for any mid-sized to
large construction project.
For a small project or one involving quite less civil works, it could be more practical or
economical to get the quality tests done in some other QC laboratory existing nearby rather than
establishing a new one. For a large project site a fully-fledged QC laboratory is the backbone of
most of the QC activities. In fact, often there is more than one laboratory in such project sites.
An effective quality control laboratory is incomplete without all or, at least, most of the quality
control laboratory apparatus or equipments relevant to the civil construction activities in the
project. High-quality laboratory apparatus of reputed brands are of utmost importance for a
standard QC laboratory. Several lists of important civil quality control laboratory equipments
have been already mentioned in some of the earlier posts in this site. Note that sometimes even in
a reasonably-sized project it could make more sense to rent certain quality tests to other testing
agencies or laboratories
Establishing the site quality control laboratory is the responsibility of the QC personnel. Once
the QC laboratory facility is in the place the QC manager, inspectors etc. need to follow the
already established QA framework / guidelines. This includes, but is not limited to, conducting
all the necessary laboratory tests as per codes, specifications etc. at prescribed frequencies;
periodic calibration and maintenance of testing and measuring equipments (or instruments), QC
documentation, reporting, quality review meetings and so on. This also often includes other
quality control activities like quality audits, training personnel on quality matters, reviewing or
improving the existing QA framework etc.Ideally, fully-fledged quality assurance and quality
control divisions should operate in a project separately. Many organizations or projects have
these.

CHAPTER-3

3-SAFETY AND ITS PRACTISE
3.1-SAFETY
Figure 3-Safety
Safety is very important in all industries, but there are some types of businesses which must take
extra care to make safety a priority. One of these is construction.
Here are Safety Shop’s top five of the most pressing reasons why construction sites need to take
health and safety seriously.
A worker or visitor could be injured
This is the most important reason to invest in health and safety equipment and training on
Construction sites – because people could be injured or even die as a result of a construction
accident.
The construction industry is the most dangerous to work in
Last year, a Health and Safety Executive (HSE) report revealed that there were 50 fatal injuries
to construction workers and 36,000 cases of work-related ill health within the industry.
Construction business owners need to develop health and safety policies and implement

measures to tackle the unique challenges faced within the industry, to try to reduce worker
injuries and deaths.
Working days are lost because of health and safety failings
The HSE report from 2010/11 also revealed that around 2.3 million working days were lost as a
result of workplace injury. This is costing the construction industry a lot of money, as Well as
hampering progress.
Businesses can be fined, sued or banned from operating
If the HSE finds that unsafe working practices are being carried out on your construction site, it
can issue fines and prohibition notices and it can even prosecute. Similarly, workers who are
injured can file compensation lawsuits against you, which also hurts the business financially.
Projects can be compromised
If a serious accident takes place on your site, this could halt progress on the project, potentially
losing the business the contract.
3.2- WORK AND WORKER SAFETY SERIES

Nearly 6.6 million people work at approximately 2, 52,000 construction site across the world on
any given day. The fatal injury rate for the construction industry is higher than the national
average in the category for all the industry. [6]
Potential hazards for the workers in construction include:
• Falls from height
• Scaffold collapse
3.3-FALL PROTECTION
Hazard: Each year, falls consistently account for the greatest number of fatalities in the
construction industry. A number of factors are often involved in falls, including unstable

working surfaces, misuse or failure to use fall protection equipment and human error. Studies
have shown that using guardrails, fall arrest systems, safety nets, covers and restraint systems
can prevent many deaths and injuries from falls.
Solutions:
• Consider using aerial lifts or elevated platforms to provide safer elevated working surfaces;
• Erect guardrail systems with toe boards and warning lines or install control line systems to
protect workers near the edges of floors and roofs;
Figure 4-Safety nets tied around the periphery of the building to prevent
the accidents caused due to falling of materials from heights
3.4-LADDERS
Hazard: Ladders and stairways are another source of injuries and fatalities among construction
workers. OSHA estimates that there are 24,882 injuries and as many as 36 fatalities per year due
to falls on stairways and ladders used in construction. Nearly half of these injuries were serious
enough to require time off the job.
Solutions
Use the correct ladder for the task.
Have a competent person visually inspect a ladder before use for any defects such as:.
 Never load ladders beyond the maximum intended load or beyond the manufacturer's
rated capacity.
 Be sure the load rating can support the weight of the user, including materials and tools.
 Avoid using ladders with metallic components near electrical work and overhead
power lines.
3.5- PATHWAY
Hazard: Slips, trips and falls on stairways are a major source of injuries and fatalities among
construction workers.
Solutions:
• Stairway treads and walkways must be free of dangerous objects, debris and materials.
• Slippery conditions on stairways and walkways must be corrected immediately.
• Make sure that treads cover the entire step and landing.
3.6-CRANES
Hazard: Significant and serious injuries may occur if cranes are not inspected before use and if
they are not used properly. Often these injuries occur when a worker is struck by an overhead
load or caught within the crane's swing radius. Many crane fatalities occur when the boom of a
crane or its load line contact an overhead power line.
Solutions:
• Check all crane controls to insure proper operation before use.
• Inspect wire rope, chains and hook for any damage.
• Know the weight of the load that the crane is to lift.
• Ensure that the load does not exceed the crane's rated capacity.
• Raise the load a few inches to verify balance and the effectiveness of the brake system.

Figure 5- View of crane tower

3.7-HAZARD COMMUNICATION
Hazard: Failure to recognize the hazards associated with chemicals can cause chemical burns,
respiratory problems, fires and explosions.
Solutions:
• Maintain a Material Safety Data Sheet (MSDS) for each chemical in the facility.
• Make this information accessible to employees at all times in a language or formats that
are clearly understood by all affected personne

• Train employees on how to read and use the MSDS.
• Follow manufacturer's MSDS instructions for handling hazardous chemicals.
• Train employees about the risks of each hazardous chemical being used.
• Provide spill clean-up kits in areas where chemicals are stored.
• Provide proper personal protective equipment and enforce its use.
Figure 6-Safety boards displayed at the board
3.8-SAFETY CHECKLISTS
The following checklists may help you take steps to avoid hazards that cause injuries, illnesses
and fatalities. As always, be cautious and seek help if you are concerned about a potential
hazard.

3.9-PERSONAL PROTECTIVE EQUIPMENTS (PPE)
Figure 7-View of personal protective Equipments
Eye and Face Protection
• Safety glasses or face shields are worn anytime work operations can cause foreign objects
getting into the eye such as during welding, cutting, grinding, nailing (or when working with
concrete and/or harmful chemicals or when exposed to flying particles).
• Eye and face protectors are selected based on anticipated hazards.
• Safety glasses or face shields are worn when exposed to any electrical hazards including
work on energized electrical systems.
Foot Protection
• Construction workers should wear work shoes or boots with slip-resistant and puncture-
resistant soles.
• Safety-toed footwear is worn to prevent crushed toes when working around heavy equipment
or falling objects.
Hand Protection
• Gloves should fit snugly.
• Workers wear the right gloves for the job (for example, heavy-duty rubber gloves fo

concrete work, welding gloves for welding, insulated gloves and sleeves when exposed to
electrical hazards).
Head Protection
• Workers shall wear hard hats where there is a potential for objects falling from above, bumps
to their heads from fixed objects, or of accidental head contact with electrical hazards.
• Hard hats are routinely inspected for dents, cracks or deterioration.
• Hard hats are replaced after a heavy blow or electrical shock.
• Hard hats are maintained in good condition.
Figure 8- A view of Helmets-Hard Hats a part of Personal Protective

Equipment
3.10-SCAFFOLIDINS
• Scaffolds should be set on sound footing.
• Damaged parts that affect the strength of the scaffold are taken out of service.
• Scaffolds are not altered.

• Scaffolds are not moved horizontally while workers are on them unless they are designed to
be mobile and workers have been trained in the proper procedures.
• Employees are not permitted to work on scaffolds when covered with snow, ice, or other
slippery materials.
• Scaffolds are not erected or moved within 10 feet of power lines.
3.11-ELECTRIAL SAFETY
• Work on new and existing energized (hot) electrical circuits is prohibited until all power is
shut off and grounds are attached.
• An effective Lockout/Tag out system is in place.
• Frayed, damaged or worn electrical cords or cables are promptly replaced.
• All extension cords have grounding prongs.
• Protect flexible cords and cables from damage. Sharp corners and projections should be
avoided.
3.12-FLOOR AND WALL OPENINGS

• Floor openings (12 inches or more) are guarded by a secured cover, a guardrail or equivalent
on all sides (except at entrances to stairways).
• Toe boards are installed around the edges of permanent floor openings (where persons may
pass below the opening).
Use of sign boards help in maintaining the safety the great extent. The picturised
description of safety and its hazards help in creating the awareness among the unskilled
labours. Safety sign boards are set up throughout the site

Figure 9- View of Safety boards at the entrance of site

CHAPTER-4

4-LABS AT THE SITE
4.1-Floor plan of QA/QC lab
Figure 10-Layout of QA&QC lab at the site
1-slump cone, core cutting instruments, rapid moisture absorption meter
2-oven
3-manual sieve analysis machine
4-cupboard
5-compression testing machine(CTM)
6-weighingbmachine
E-entranc

TESTS CONDUCTED BY QA/QC LAB
4.2-SLUMP CONE TEST
Figure 11-Testing the workability of the concrete mix using slump cone
The concrete slump test is an empirical test that measures the workability of fresh concrete.
More specifically, it measures the consistency of the concrete in that specific batch. This test is
performed to check the consistency of freshly made concrete. Consistency is a term very closely
related to workability. It is a term which describes the state of fresh concrete. It refers to the ease
with which the concrete flows. It is used to indicate the degree of wetness. Workability of
concrete is mainly affected by consistency i.e. wetter mixes will be more workable than drier
mixes, but concrete of the same consistency may vary in workability. It is also used to determine
consistency between individual batches.
The test is popular due to the simplicity of apparatus used and simple procedure. Unfortunately,
the simplicity of the test often allows a wide variability in the manner that the test is performed.
The slump test is used to ensure uniformity for different batches of similar concrete under field
conditions, and to ascertain the effects of plasticizers on their introduction.

APPARATUS
Metal mould, in the shape of the frustum of a cone, open at both ends, and provided with the
handle, top internal diameter 4 in (102 mm), and bottom internal diameter 8 in (203 mm) with a
height of 1 ft (305 mm). A 2 ft (610 mm) long bullet nosed metal rod, 5/8in (16 mm) in diameter.
PROCEDURE
Height measurement
The test is carried out using a mould known as a slump cone or Abrams cone. The cone is placed
on a hard non-absorbent surface. This cone is filled with fresh concrete in three stages, each time
it is tamped using a rod of standard dimensions. At the end of the third stage, concrete is struck
off flush to the top of the mould. The mould is carefully lifted vertically upwards, so as not to
disturb the concrete cone. Concrete subsides. This subsidence is termed as slump, and is
measured in to the nearest 5 mm if the slump is <100 mm and measured to the nearest 10 mm if
the slump is >100 mm.
Figure 12-Slump cone test-cone remove

4.3-CORE CUTTING
DRY DENSITY OF SOIL BY CORE CUTTER METHOD
A cylindrical core cutter is a seamless steel tube. For determination of the dry density of the soil,
the cutter is pressed into the soil mass so that it is filled with the soil. The cutter filled with the
soil is lifted up. The mass of the soil in the cutter is determined. The dry density is obtained as
N/m3
where M= mass of the wet soil in the cutter
V= internal volume of the cutter
w= water content.
Equipment:
1. Cylindrical core cutter, 100mm internal diameter and 130mm long
2. Steel rammer, mass 9kg, overall length with the foot and staff about 900mm.
3. Steel dolley, 25mm high and 100mm internal diameter
4. Weighing balance, accuracy 1g.
5. Palette knife
6. Straight edge, steel rule etc
Procedure
1. Determine the internal diameter and height of the core cutter to the nearest 0.25mm
2. Determine the mass (M1) of the cutter to the nearest gram.
3. Expose a small area of the soil to be tested. Level the surface, about 300mm square in area.

4. Place the dolley over the top of the core cutter and press the core cutter into the soil mass
using the rammer. Stop the pressing when about 15mm of the dolley protrudes above the soil
surface.
5. Remove the soil surrounding the core cutter, and take out the core cutter. Soil would project
from the lower end of the cutter.
6. Remove the dolley. Trim the tip and bottom surface of the core cutter carefully using a straight
edge.
7. Weigh the core cutter filled with the soil to the nearest gram (M2).
8. Remove the core of the soil from the cutter. Take a representative sample for the water content
determination.
9. Determine the water content.

Figure 13-Cylindrical mould being drilled into ground to determine densit

Observation and calculations:
Table 2-core cutting tabulation
Sl. No. Observations an Calculations Determination No.

1 2 3
Observation
1 Internal diameter in mm 100 100 100
2 Internal height in mm
129.75 129.75 129.75
3 Mass of empty core cutter (M1) in g 1130 1130 1130
4 Mass of core cutter with soils (M2) 3120 3122 3119
Calculations
5 M=M2 – M1 in g 1990 1992 1989
6 Volume of cutter V in cc 1019.05 1019.05 1019.05
7 Water content in % 17075 17.76 17.73
8 Dry density using formula 1.66 1.66 1.66
Result:
Dry density of the soil= 1.116g/ml

4.4-COMPRESSIVE STRENGTH TESTING EQUIPMENT

Compressive Strength Testing Equipment to test cement, brick and concrete. The range these
includes manually (Hand) Operated, Semi Automatic Compression Testing Equipment,
Electrically Cum Manually Operated equipment and more. These strength testing equipment
are extremely handy and are easy to use for testing cement, concrete and mortar cubes.
4.5-SIEVE ANALYSIS MACHINE

Sieve analysis helps to determine the particle size distribution of the coarse and fine aggregates.
This is done by sieving the aggregates as per IS: 2386 (Part I) – 1963. In this we use different
sieves as standardized by the IS code and then pass aggregates through them and thus collect
different sized particles left over different sieves.
The apparatus used are –

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 to determine particle size distribution of Aggregates.
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.
4.6-RAPID MOISTURE METER

Moisture meters are used to measure the percentage of water in a given substance. This
information can be used to determine if the material is ready for use, unexpectedly wet or dry, or
otherwise in need of further inspection.
Wood and paper products are very sensitive to their moisture content. Physical properties are
strongly affected by moisture content. Dimensioning also changes with moisture conten

Figure 14-View of a Rapid moisture meter

Moisture meters are used to measure the percentage of water in a given substance. This
information can be used to determine if the material is ready for use, unexpectedly wet or dry, or
otherwise in need of further inspection.
Wood and paper products are very sensitive to their moisture content. Physical properties are
strongly affected by moisture content. Dimensioning also changes with moisture content.
4.7-SLUMP CONE
The concrete slump test is an empirical test that measures the workability of fresh concrete.
More specifically, it measures the consistency of the concrete in that specific batch. This test is
performed to check the consistency of freshly made concrete. Consistency is a term very closely
related to workability. It is a term which describes the state of fresh concrete. It refers to the ease
with which the concrete flows. It is used to indicate the degree of wetness. Workability of
concrete is mainly affected by consistency i.e. wetter mixes will be more workable than drier
mixes, but concrete of the same consistency may vary in workability.
It is also used to determine consistency between individual batches. The test is popular due to the
simplicity of apparatus used and simple procedure. Unfortunately, the simplicity of the test oft

allows a wide variability in the manner that the test is performed. The slump test is used to
ensure uniformity for different batches of similar concrete under field conditions, and to
ascertain the effects of plasticizers on their introduction. In India this test is conducted as per IS
specification.
The slump test result is a slump of the behavior of a compacted inverted cone of concrete under
the action of gravity. It measures the consistency or the wetness of concrete.
Figure 15-View of Slump cone
4.8-CALIBARATION DETAILS OF THE INSTRUMENTS [6]

Calibration is a comparison between measurements – one of known magnitude or correctness
made or set with one device and another measurement made in as similar way as possible with a
second device. The device with the known or assigned correctness is called the standard.
The second device is the unit under test, test instrument, or any of several other names for the
device being calibrated.
The formal definition of calibration by the International Bureau of Weights and Measures is the
following: "Operation that, under specified conditions, in a first step, establishes a relation

between the quantity values with measurement uncertainties provided by measurement standards
and corresponding indications with associated measurement uncertainties (of the calibrated
instrument or secondary standard) and, in a second step, uses this information to establish a
relation for obtaining a measurement result from an indication.
Instruments in QC lab and mode of calibrations

1) Slump cone-calibration is not done.
2) CTM-using deflection meter.
3) Rapid absorption meter-using deflection meter.
4) Weighing machine-using standard weights by govt.meteorology dept.
5) manual sieve vibrator-no calibration.
6) Core cutter-using vernier calipers.
7) Auto level-using two peg method.
8) Total station -.
*calibrations are done in regular interval and values obtained are compared with standard values.
* Errors in reading are adjusted.

CHAPTER-5

5-SITE EXECUTIONAL ASPECTS

5.1-EXCAVATION
Excavation means to loosen and .take out materials leaving space above or below ground.
Sometimes in civil engineering term earthwork is used which include backfilling with new or
original materials to voids, spreading and leveling over an area.
Excavation and earthmoving plants
 Advantages of using mechanical plant in excavation:
a) Work done quicker.
b) Avoids dangerous condition of work by human workers, say, and existence of ground water
or collapse of soil.
c) Achieve greater depth.
d) Use fewer manpower and work done in lower cost (for larger scale work only) .
 Disadvantages of using mechanical plant in excavation:
a) Involve larger running and maintenance costs.
b) Require a larger operating area.
c) Access provision to working area.
d) Less flexible in work planning.
e) Idling time increase cost of work.
 Brief description of plants
1. Face shovel excavators – This can be have cable or hydraulic operated, mounted on wheel or
track .They are fitted with bucket which faces away from the machine. They are used for
loosening, excavating vertical or near-vertical soil above the machine base level. They are not
suitable for horizontal or below ground excavation.
2. Backactors (Backhoe) – They are used for below ground level excavation. The bucket acts
downwards and drags towards the machine and tilted upwards to hold the loads. They are used
mainly as trench or large scale open excavation, but sometimes they are also used as loading

machines.
3. Tractor shovel (loading shovel) – This machine is similar to a bulldozer but has a hydraulic
operated bucket in place of the blade. Materials above the base of vehicle can be lifted and
unload onto a dump truck or onto a spoil heap .The bucket size varies from 0.5m 3 to 3or 4m3
depending on capacity of machine.
Figure 16-Ground is excavated based on the need and type of foundation

Figure 17-View of Tractor shovel (loading shovel)
Figure 18-View of back hoe
4. Dumper truck – Designed for large-capacity loads to be carried over a long distances on or
off site. Normal capacity ranging from 5m3 to 15m3 some even up to 50m3or abov

Figure 19-View of Dumper truc
5.2-SCAFFOLDING
Scaffolding, also called scaffold or staging is a temporary structure used to support a work crew
and materials to aid in the construction, maintenance and repair of buildings, bridges and all
other man- made structures
Scaffolding is also used in adapted forms for formwork and shoring, grandstand seating, concert
stages, access/viewing towers, exhibition stands, ski ramps, half pipes.
There are four main types of scaffolding used worldwide today.
These are tube and caplar (fitting) components, prefabricated modular system scaffold
components, H-frame / facade modular system scaffolds, and timber scaffolds. Each type is
made from several components which often include:
 A base jack or plate which is a load bearing base for the scaffold.
 The standard which is the upright component with connector joins.
 The ledger (horizontal brace).
 The transom which is a horizontal cross section load bearing component which holds
the batten, board or decking unit.

 Batten or board decking component used to make the working platform.
 Brackets used to extend the width of working platforms.
Figure 20-View of scaffolding
5.3-FORMWORK
It is the term given to either temporary or permanent moulds into which concrete or similar
materials are poured. In the context of concrete construction, the false work supports the
shuttering moulds.
Formwork comes in several types:
Traditional timber formwork- The formwork is built on site out of timber and plywood or
moisture-resistant particleboard. It is easy to produce but time-consuming for larger structures,
and the plywood facing has a relatively short lifespan. It is still used extensively where the
labour costs are lower than the costs for procuring reusable formwork. It is also the most flexible
type of formwork, so even where other systems are in use, complicated sections may use it.
Re-usable plastic formwork. These interlocking and modular systems are used to build widely
variable, but relatively simple, concrete structures. The panels are lightweight and very robust.
They are especially suited for low-cost, mass housing schemes.
Permanent Insulated Formwork. This formwork is assembled on site, usually out of insulating
concrete forms (ICF). The formwork stays in place after the concrete has cured, and may provide
advantages in terms of speed, strength, superior thermal and acoustic insulation, space to run

utilities within the EPS layer, and integrated furring strip for cladding finishes.
″Coffor″ is a structural stay-in-place formwork system to build constructions in concrete. It is

composed of two filtering grids reinforced by vertical stiffeners and linked by articulated
connectors that can be folded for transport. A standard panel 1.10 m x 2.70 m (3' 8 x 9) weighs
32.7 kg (72 lbs) and can be carried by hand or by any means of machine. After Coffor is placed,
concrete is poured between the grids: excess water of concrete is eliminated by gravity and air is
also eliminated. Coffor remains in the construction after concrete is poured and acts as
reinforcement. Any type of construction can be built with Coffor: individual houses, multi-story
buildings including high-rise buildings, industrial, commercial or administrative buildings.
Several types of civil works can be done with Coffor. Coffor is delivered completely assembled
from the factory. No assembly is necessary on the construction site.
Stay-In-Place structural formwork systems. This formwork is assembled on site, usually out
of prefabricated fiber-reinforced plastic forms. These are in the shape of hollow tubes, and are
usually used for columns and piers. The formwork stays in place after the concrete has cured and
acts as axial and shear reinforcement, as well as serving to confine the concrete and prevent
against environmental effects, such as corrosion and freeze-thaw cycles.
Flexible formwork. In contrast to the rigid moulds described above, flexible formwork is a
system that uses lightweight, high strength sheets of fabric to take advantage of the fluidity of
concrete and create highly optimized, architecturally interesting, building forms. Using flexible
formwork it is possible to cast optimized structures that use significantly less concrete than an
equivalent strength prismatic section, thereby offering the potential for significant embodied
energy.

Figure 21-View of formwork at the site
5.4-REINFORCEMENT LAYING
Rebar (short for reinforcing bar), also known as reinforcing steel, 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

Clear cover to main reinforcement practiced at the site

Footings: 50 mm
Raft foundation Top: 50 mm
Raft foundation Bottom/ sides: 75 mm
Strap Beam: 50 mm
Grade Slab: 20 mm
Column: 40 mm (d>12mm) 25 mm (d= 12mm)
Shear Wall: 25 mm
Beams: 25 mm
Slabs: 15 mm or not less than diameter of the bar.
Flat Slab: 20 mm
Staircase: 15 mm
Retaining Wall on Earth: 20/ 25 mm
Water retaining structures: 20 / 30 mm
Sunshade (Chajja): 25 mm
Hook for stirrups is 9D for one side
 No. of stirrups = (clear span/Spanning) + 1
 For Cantilever anchorage length for main steel is 69D
 “L” for column main rod in footing is minimum of 300mm
 Chairs of minimum 12 mm diameter bars should be used.
 Minimum diameter of dowel bars should be 12 mm
 Lap slices should not be used for bar larger than 36 mm.
 In steel reinforcement binding wire required is 8 kg per MT.
 Lapping is not allowed for the bars having diameters more than 36 mm.
 Minimum numbers of bars for a square column are 4 and for circular column are 6.
 As per IS 456-2000
 Longitudinal reinforcement should not be less than 0.8% and more than 6% of gross C/
As per IS 456-2000
 Weight of rod per meter length = d2/162 where d is the diameter in mm
Figure 22-View of reinforcement bars erected

In case of spacing of bars
Provide the diameter of the bar, if the diameters of the bar are equal.
Provide the diameter of the larger bar, if the diameter is unequal.
5mm more than the nominal maximum size of the coarse aggregate.
Brief insight on Reinforcement Steel commonly used in Reinforced Cement Concrete (RCC)

work in various construction sites in India is presented. The details would be pretty much same
for any project outside India too.
Steel commonly used are
a) Mild Steel (MS) bars conforming to IS-432, Part-I
b) High Yield Strength Deformed (HYSD) bars. Two types of HYSD bars
are: 1) Hot Rolled HYSD bars conforming to IS-1139.
2) Cold Worked HYSD bars conforming to IS-1786. These are also known as Cold Twisted
Deformed (CTD) bars or Tor steel. The most commonly used HYSD bars for RCC work are
the CTD bars. A very important property of reinforcement bars, also known as rebars, the
Yield Stress or Characteristic Strength. For HYSD bars, this is also known as 0.2% proof
stress. This is because unlike for MS bars the yield zone of HYSD bars in the Stress Vs
Strain plot is not well defined. Hence, the stress corresponding to a strain of 0.2% obtained
by drawing a line parallel to the straight portion of the stress Vs strain plot is considered as
the Yield Stress or Yield strength for HYSD bars as this gives a fairly consistent value. Yield
Stresses or Yield
Strengths for various re-bars are:
a) For MS bars = 250 N/mm2 . These are thus known as Fe 250 Grade bars also. For these
bars, the permissible tensile & compressive stresses for design purposes are specified to be
140 & 130 N/mm2 by IS-432, depending on type of members.
b) For CTD bars = 415 N/mm2 (Fe 415 or Tor 40) & 500 N/mm2 (Fe 500 or Tor
50). Allowable stresses for these bars have been standardized by IS-1786 as
1) for Fe 415 grade, permissible tensile stress = 230 N/mm2 & permissible compressive
stress = 190 N/mm2.
2) For Fe 500 grade, permissible tensile stress = 275 N/mm2

Table 3-The minimum required % elongations for these bars are
Bar type & Diameter MS bars Grade-I HYSD/CTD bars
Dia. less than 10mm 20 14.5

Dia. greater than or equal to 10mm 23 14.5
5.5-CONCRETING
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.
A concrete plant consists of large storage hoppers for various reactive ingredients like cement,
storage for bulk ingredients like aggregate and water, mechanisms for the addition of various
additives and amendments, machinery to accurately weigh, move, and mix some or all of those
ingredients, and facilities to dispense the mixed concrete, often to a concrete mixer truck.
Modern concrete is usually prepared as a viscous fluid, so that it may be poured into forms,
which are containers erected in the field to give the concrete its desired shape. There are many
different ways in which concrete formwork can be prepared, such as Slip forming and Steel plate
construction. Alternatively, concrete can be mixed into dryer, non-fluid forms and used in
factory settings to manufacture precast concrete products. There is a wide variety of equipment
for processing concrete, from hand tools to heavy industrial machinery

Whichever equipment builders’ use, however, the objective is to produce the desired building
material; ingredients must be properly mixed, placed, shaped, and retained within time
Constraints. Once the mix is where it should be, the curing process must be controlled to
ensure that the concrete attains the desired attributes. During concrete preparation, various
technical details may affect the quality and nature of the product.
When initially mixed, Portland cement and water rapidly form a gel of tangled chains of
interlocking crystals, and components of the gel continue to react over time. Initially the gel is
fluid, which improves workability and aids in placement of the material, but as the concrete sets,
the chains of crystals join into a rigid structure, counteracting the fluidity of the gel and fixing
the particles of aggregate in place
During curing, the cement continues to react with the residual water in a process of hydration.
In properly formulated concrete, once this curing process has terminated the product has the
desired physical and chemical properties. Among the qualities typically desired, are mechanical
strength, low moisture permeability, and chemical and volumetric stability.
Thorough mixing is essential for the production of uniform, high-quality concrete. For this
reason equipment and methods should be capable of effectively mixing concrete materials
containing the largest specified aggregate to produce uniform mixtures of the lowest slump
practical for the work.
Separate paste mixing has shown that the mixing of cement and water into a paste before
combining these materials with aggregates can increase the compressive strength of the resulting
concrete.
The paste is generally mixed in a high-speed, shear-type mixer at a w/cm (water to cement ratio)
of 0.30 to 0.45 by mass. The cement paste premix may include admixtures such as accelerators
or retarders, super plasticizers, pigments, or silica fume. The premixed paste is then blended with
aggregates and any remaining batch water and final mixing is completed in conventional conc

Figure 23-Pouring of concrete for footing
5.6-PLAIN CEMENT CONCRETE

Materials and Tools used at the site
 Auto level instrument
 Wooden or steel rame
 Mixer machine
Working Procedure
Excavation levels and dimensions to be checked as per drawings. Remove all the loose earth
from the pits. Do water sprinkling and ramming the cleaned surface of pit by mechanical
rammer. Do the shuttering by planks and runners wherever if necessary. Mix the concrete with
required proportion and water cement ratio by mechanical mixer machine and place the same in
to pits. Poured surface to be rammed and finished smoot

Figure 24- A view of PCC bed for Foundation(Plain cement concrete)
5.7-CURING
In all but the least critical applications, care must be taken to properly cure concrete, to achieve
best strength and hardness. This happens after the concrete has been placed. Cement requires a
moist, controlled environment to gain strength and harden fully. The cement paste hardens over
time, initially setting and becoming rigid though very weak and gaining in strength in the weeks
following. In around 4 weeks, typically over 90% of the final strength is reached, though
strengthening may continue for decades. The conversion of calcium hydroxide in the concrete
into calcium carbonate from absorption of CO2 over several decades further strengthens the
concrete and makes it more resistant to damage. However, this reaction, called carbonation,
lowers the pH of the cement pore solution and can cause the reinforcement bars to corrode.
Hydration and hardening of concrete during the first three days is critical. Abnormally fast
drying and shrinkage due to factors such as evaporation from wind during placement may lead to
increased tensile stresses at a time when it has not yet gained sufficient strength, resulting in
greater shrinkage cracking.

Figure 25-Curing and use of curing compound

During this period concrete must be kept under controlled temperature and humid atmosphere. In
practice, this is achieved by spraying or ponding the concrete surface with water, thereby
protecting the concrete mass from ill effects of ambient conditions. The picture to the right
shows one of many ways to achieve this, ponding – submerging setting concrete in water and
wrapping in plastic to contain the water in the mix. Additional common curing methods include
wet burlap and/or plastic sheeting covering the fresh concrete, or by spraying on a water-
impermeable temporary curing membrane.
Properly curing concrete leads to increased strength and lower permeability and avoids cracking
where the surface dries out prematurely. Care must also be taken to avoid freezing or overheating
Due to the exothermic setting of cement. Improper curing can cause scaling, reduced strength,
poor abrasion resistance and cracking
5.8-CONCRETE BLOCKS AND CMU

Concrete Masonry Units (CMU), or Concrete Blocks, comes in a variety of sizes. CMUs are
identified by their depth - i.e. the thickness of the wall they create. For instance, a 6" CMU is
nominally 6" deep. As with brick, CMUs have actual dimensions and nominal dimensions.
The CMU is the actual dimension plus the width of the mortar joint. Typical CMU mortar

joints are 3/8". The nominal dimension works within the 4" grid that other construction
materials follow.
Figure 26- Concrete Block-Standard Sizes
Figure 27- A view of wall after block work is executed

5.9-PLASTERING
It refers to construction or ornamentation done with plaster, such as a layer of plaster on an
interior or exterior wall structure, or plaster decorative moldings on ceilings or walls. This is also
sometimes called pargeting. The process of creating plasterwork, called plastering
While most tools have remained unchanged over the centuries, developments in modern
materials have led to some changes. Trowels, originally constructed from steel, are now available
in a polycarbonate material that allows the application of certain new, acrylic-based materials
without staining the finish. Floats, traditionally made of timber (ideally straight-grained, knot-
free, yellow pine), are often finished with a layer of sponge or expanded polystyrene.
Interior plastering techniques
Smooth
The home owner and the plasterer's boss will usually decide beforehand what styles they will use
in the house. Typically walls are smooth and sometimes ceilings. Usually a homeowner will opt
to have the ceilings use a "texture" technique as it is much easier, faster, and thus cheaper than a
smooth ceiling.
Figure 28- plastered surface just after 1st coat application

The plasterer quotes prices based on techniques to be used and board feet to be covered to the
contractor or homeowner before work begins. The board feet is obtained by the hangers or
estimated by the head subcontractor by counting the wallboards that come in an industry
standard of 8' to 12' long. He then adds in extra expenses for soffits and cathedral ceilings.
Ceiling second or first
Typically if the ceiling is to be smooth it is done first, before the walls. If it is to be textured, it is
done after the walls.
The reason for this is that invariably when a ceiling is being worked on plaster will fall and
splash onto the walls. However a texture mix doesn't need to be smoothed out when it starts to
set:
 Thus a retardant such as "Cream of tartar" can be used to prolong the setting time,
and is easily scraped off the walls.
 And since time is not as restraining of a factor on textured ceilings a large mix, or
back-to-back mixes can be done and all ceilings covered at the same time.
 Another reason is that a bird is usually run along the top corner after doing a smooth
ceiling, and then it is easier to maintain this edge by doing the wall last. But a
textured ceiling normally doesn't need to be birded, only blended in with a very wet
paint brush. In this case the wall is done first and the corner formed with the bird.
Scratching
 The first thing the plasterer tends to do is go over all the mesh-taped seams of the
walls he is about to cover; in a very thin swatch. The wallboard draws moisture out of
this strip so when the plasterer goes over it again when doing the rest of the wall it will
not leave an indented seam that needs further reworking.
 He then fills in the area near the ceiling so he will not have to stretch to reach it during
the rest of the wall; and he forms the corner with his bird. This saves much needed time
as this process is a race against the chemical reaction.
Laying on
 From the mix table the plasterer scoops some "mud" onto the center of his hawk with his
trowel. Holding the hawk in his off-hand and his trowel in his primary the plasterer
then scoops a bulging roll of plaster onto his trowel. this takes a bit of practice to master
especially with soupy mixes.
Then holding the trowel parallel to the wall and at a slight angle of the wrist he tries to uniformly
roll the plaster onto the wall. In a manner similar to a squeegee. He starts about an inch above the
floor and works his way upwards to the ceiling. Care is taken to be uniform as possible as it
helps in the finishing phase.
Knocking down
Depending on the setting time of the plaster. Once the moisture of the plaster starts to be drawn
by the board a second pass is made. This is called knocking down. It is much like applying paint
with a roller in wrist action and purpose. To smooth out any lines and fill in any major voids that
will make extra work once the plaster starts to truly set. Very little pressure is applied and the
trowel is kept relatively flat towards the wall.
Setting
Sometimes an accelerant will be added to a mix to hasten the time delay from the initial mixing
phase to when the plaster starts to set. This is normally done on cold days when setting is
delayed or for small jobs to minimize the wait.
Once the plaster is on the wall and starts to set (this can be determined by the table that sets
first), the plasterer gingerly sprinkles water onto the wall; this helps to stall the setting and to
create a slip. He then uses his trowel and often a wetted felt brush held in the opposite hand and
lightly touching the wall ahead of the trowel to work this slip into any small gaps (known as
"catfaces") in the plaster as well as smooth out the rough lay-on and flatten any air bubbles that
formed during setting.
This is a crucial time because if the wall gets too hard it is nearly impossible to fill in any gaps as
the slip will no longer set with the wall and will instead just dry and fall out. This leads to the
need of what is called "grinding" as one must go over the hard wall again and again trying to
smooth out the hardened wall and any major catfaces must be filled in with contour putty, joint
compound, or reworked by blending in a fresh, thin coat.
The finished wall will look glossy and uniformly flat and is smooth to the touch. After a few
days it will become chalky white and can then be painted over.

The final moments are the most frantic if it is smooth or if the mix sets quicker than anticipated.
If this happens it is said the mix has "snapped" and is normally due to using old product or
various types of weather (humidity or hot days can cause plaster to set quicker). Normally only
three or four mixes are done in a day as plastering is very tiring and not as effective under
unnatural lighting in the months with early dusk.
Seasons
Plastering is done year round but unique problems may arise from season to season. In the
summer, the heat tends to cause the plaster to set faster. The plaster also generates its own heat
and houses can become quite hellish. Typically the plaster crew will try to arrive at the house
well before dawn.
In winter months, short days cause the need of artificial lighting. At certain angles these lights
can make even the smoothest wall look like the surface of the moon. Another dilemma in the
winter months needs to use propane jet heaters (which can stain the plaster yellowish but do not
otherwise hurt it), not just to keep the plasterers warm but to also prevent the water in the mix
from freezing and generating ice crystals before the plaster has time to set. Also if the water hose
is not thoroughly drained before leaving it can freeze over night and be completely stopped up in
the morning.
Texture
Texturing is usually reserved for closets, ceilings and garage walls
Typically a retarding agent is added to the mix. This is normally cream of tartar (or "Dope" in the
plasterer's jargon) and care must be taken with the amount added. Too much and the mix may
never set at all. However the amount used is often estimated; much the way one adds a dash of
salt to a recipe. You add a small scoop of retarder, dependent on the size of the mix. Retardant is
added so that larger mixes can be made, since the texture technique doesn't require the person to
wait until it starts to set before working it.
The lay-on phase is the same as smooth but it is added with a thicker coat. Once the coat is on
uniformly the plasterer then goes back and birds his corners. Staying away from the corner he
then gets a trowel with a nice banana curve in it and starts to run it over the wall in a figure eight
or ess pattern, making sure to cross all areas at least once. He adds a little extra plaster to his
trowel if needed. The overall effect is layers of paint-like swaths over the whole of the ceiling or
wall. He can then just walk away and let it set with care taken not too leave any globs and to
make sure the corners look smooth and linear.
If a wall is to be smooth and the ceiling textured, typically the wall is done first, then the ceiling
after the wall has set. Instead of rebirding the ceiling (which would have been done when th

wall was laid on), a clean trowel is held against the wall and its corner is run along the ceiling to
"cut it in" and clean the wall at the same time
Figure 29- plastered surface just after 1st coat application

Ceilings
Stilts are often required to plaster most ceilings and it is typically harder to lay-on and work than
walls. For short ceilings one can also work with milk crates. The difficulty of working upside
down often results in plaster bombs splattering on the floors, walls and people below.
This is why smooth ceilings, that use no retardant and sometimes even accelerant, are done
before the walls. Retarded plaster can easily be scraped off a smooth plaster wall when wet. Any
splatters from a smooth ceiling can easily be scraped off bare blue board but not from an already
plastered wall. Care must be taken when standing under your trowel or another plasterer.
The general difficulty of working a smooth ceiling fetches a higher cost. The technique is the
same as a smooth wall but at an awkward angle for the plasterer.
External plastering
Main article: Stucco Stucco is a term loosely applied to nearly all kinds of external plastering,
whether composed of lime or of cement. At the present time it has fallen into disfavor, but in the early
part of the 19th century a great deal of this work was done. Cement has largely superseded lime for
this work. The principal varieties of stucco are common, rough, trowelled and bastard

 Common stucco for external work is usually composed of one part hydraulic lime and
three parts sand. The wall should be sufficiently rough to form a key and well wetted
to prevent the moisture being absorbed from the plaster.
 Rough stucco is used to imitate stonework. It is worked with a hand float covered with
rough felt (a stiff bristled brush can also be used), which forms a sand surface on the
plaster. Lines are ruled before the stuff is set to represent the joints of stonework.
 Trowelled stucco, the finishing coat of this work, consists of three parts sand to two
parts fine stuff. A very fine smooth surface is produced by means of the hand float.
 Bastard stucco is of similar composition, but less labor is expended on it. It is laid on in
two coats with a skimming float, scoured off at once, and then trowelled.
 Colored stucco: lime stucco may be executed in colors, the desired tints being obtained
by mixing with the lime various oxides. Black and grays are obtained by using forge
ashes in varying proportions, greens by green enamel, and reds by using litharge or
red lead, and blues by mixing oxide or carbonate of copper with the other materials.
Main article: Roughcast
Roughcast or pebbledash plastering is a rough form of external plastering in much use for
country houses. In Scotland it is termed "harling". It is one of the oldest forms of external
plastering. In Tudor times it was employed to fill in between the woodwork of half-timbered
framing. When well executed with good material this kind of plastering is very durable.
Roughcasting is performed by first rendering the wall or laths with a coat of well-haired coarse
stuff composed either of good hydraulic lime or of Portland cement. This layer is well scratched
to give a key for the next coat. The second coat is also composed of coarse stuff knocked up to a
smooth and uniform consistency. Two finish two techniques can be used:
 Dry dash: while the first coat is still soft, gravel, shingle or other small stones are
evenly thrown on with a small scoop and then brushed over with thin lime mortar to
give a uniform surface. The shingle is often dipped in hot lime paste, well stirred up, and
used as required.
 Wet dash: the traditional roughcast, harling the scratch or undercoat is left to cure and in
the final coat the gravel/aggregate is mixed with the lime and sand and thrown on

5.10-MATERIALS
5.10(a)-Cement
Cement is a binder, a substance that sets and hardens and can bind other materials together. The
word "cement" can be traced back to the Roman term opus caementicium, used to
describe masonry resembling modern concrete that was made from crushed rock with burnt
lime as binder. The volcanic ash and pulverized brick supplements that were added to the burnt
lime, to obtain a hydraulic binder, were later referred to as cementum, cimentum, cäment,
and cement.
Figure 30-Tools used for plaster
Cements used in construction can be characterized as being either hydraulic or non-hydraulic,

depending upon the ability of the cement to set in the presence of water (see hydraulic and non-
hydraulic lime plaster).
Non-hydraulic cement will not set in wet conditions or underwater; rather, it sets as it dries and
reacts with carbon dioxide in the air. It can be attacked by some aggressive chemicals after
setting.
Hydraulic cements set and become adhesive due to a chemical reaction between the dry
ingredients and water. The chemical reaction results in mineral hydrates that are not very water-

soluble and so are quite durable in water and safe from chemical attack.
This allows setting in wet condition or underwater and further protects the hardened material
from chemical attack (e.g., Portland cement). The chemical process for hydraulic cement found
by ancient Romans used volcanic ash (activated aluminum )with lime (calcium oxide).
The most important uses of cement are as a component in the production of mortar in masonry,
and of concrete, a combination of cement and an aggregate to form a strong building material.
5.10(b) Aggregates
Main article: Construction aggregate
Construction aggregate, or simply "aggregate", is a broad category of coarse particulate

material used in construction, including sand, gravel, crushed stone, slag, recycled
concrete and geo-synthetic
Aggregates. Aggregates are the most mined materials in the world. Aggregates are a
component of composite materials such as concrete and asphalt concrete; the aggregate serves
as reinforcement to add strength to the overall composite material. Due to the relatively high
hydraulic conductivity value as compared to most soils, aggregates are widely used in
drainage applications such as foundation and French drains, septic drain fields, retaining wall
drains, and road side edge drains. Aggregates are also used as base material under
foundations, roads, and railroads. In other words, aggregates are used as a stable foundation or
road/rail base with predictable, uniform properties (e.g. to help prevent differential settling
under the road or building), or as a low-cost extender that binds with more expensive cement
or asphalt to form concrete.
Fine and coarse aggregates make up the bulk of a concrete mixture. Sand, natural gravel
and crushed stone are used mainly for this purpose. Recycled aggregates (from construction,
demolition, and excavation waste) are increasingly used as partial replacements of natural
aggregates, while a number of manufactured aggregates, including air-cooled blast furnace slag
and bottom ash are also permitted.
The presence of aggregate greatly increases the durability of concrete above that of cement,
which is a brittle material in its pure state. Thus concrete is a true composite material.
Redistribution of aggregates after compaction often creates in homogeneity due to the influence
of vibration. This can lead to strength gradients
Decorative stones such as quartzite, small river stones or crushed glass are sometimes added to
the surface of concrete for a decorative "exposed aggregate" finish, popular among landscape
designers.
5.10(c)-Concrete
After concrete has been mixed, transported and placed, it contains entrapped air in the form or
voids. The object of compaction is to get rid of as much as possible for this unwanted entrapped
air; down to less than 1% is usually the aim.
The amount of entrapped air is related to the workability: concrete with a 75 mm slump contains
about 5 % air, while concrete of 25 mm slump contains about 20 %. This is why a low-slump
concrete requires more comp active effort-either a longer time or more vibrators compared with a
concrete with a higher slump.
Reasons for Removing Air
Voids reduce the strength of the concrete. For every 1 % of entrapped air, the strength falls by
about 5 to 6 %. So a concrete with, say, 3 % voids will be about 15-20 % weaker than it should
be. Voids increase the permeability, which in turn reduces the durability. If the concrete is not
dense and impermeable, it will not be watertight, it will be less able to withstand mildly
aggressive liquids, and any exposed surfaces will weather badly; in addition, moisture and air are
more likely to get to reinforcement and cause it to rust.
Voids reduce the contact between the concrete and the reinforcement and other embedded
metals; the required bond will then not be achieved and the reinforced member will not be as
strong as it should be.
Voids produce visual blemishes such as blowholes and honeycombing on stuck surfaces.
Fully compacted concrete will be dense, strong, durable and impermeable. Badly compacted
concrete will be weak, non-durable, honeycombed and porous. The air must be removed.
Vibration
Roding, spading is all ways of removing air from concrete to compact it, but the best and
quickest method is vibration.
When a concrete mix is vibrated it is "fluidized", which reduces the internal friction between the
aggregate particles. The fluidization of concrete allows entrapped air to rise to the surface, and
the concrete becomes denser.
With a properly designed cohesive mix, segregation and bleeding will be minimized. With an

over-wet mix, the larger aggregate pieces may settle during compaction, with the result that a
weak layer of laitance will finish up on the surface; if this does happen, the laitance must be
removed. It therefore pays to see that mix is right in the first place!
Vibrators
These are mobile items of mechanical plant used to vibrate (shake) air out of fresh concrete.
There are 2 major types of vibrators:
 External vibrators (Form vibrators)

 Internal vibrators (Poker/Immersion vibrators)
All types of vibrators have motors, which can be driven by:
 Compressed air
 Main supply electricity (230 or 400V & 50Hz) motors
 High frequency electricity motors

CHAPTER-6

6-EQUIPMENTS AND INSTRUMENTS

6.1-BATCHING PLANT
A concrete plant, also known as a batch plant or batching plant, is a device that combines various
ingredients to form concrete. Some of these inputs include sand, water, aggregate etc.), fly ash,
potash and cement. There are two types of concrete plants: ready mix plants and central
mix plants. A concrete plant can have a variety of parts and accessories, including but not limited
to: mixers (either tilt-up or horizontal or in some cases both), cement batchers, aggregate
batchers, conveyors, radial stackers, aggregate bins, cement bins, heaters, chillers, cement silos,
batch plant controls, and dust collectors (to minimize environmental pollution).
The center of the concrete batching plant is the mixer. There are three types of mixer: Tilt, pan,
and twin shaft mixer. The twin shaft mixer can ensure an even mixture of concrete and large
output, while the tilt mixer offers a consistent mix with much less maintenance labor and cost.
A ready mix plant combines all ingredients except for water at the concrete plant. This mixture is
then discharged into a ready mix truck (also known as a concrete transport truck). Water is then
added to the mix in the truck and mixed during transport to the job site.A central mix plant
combines some or all of the above ingredients (including water) at a central location
Figure 31- A view of in-house batching plant at the sit

6.2-TRANSIT MIXER
Special concrete transport trucks (in–transit mixers) are made to transport and mix concrete up to
the construction site. They can be charged with dry materials and water, with the mixing
occurring during transport. They can also be loaded from a "central mix" plant, with this process
the material has already been mixed prior to loading. The concrete mixing transport truck
maintains the material's liquid state through agitation, or turning of the drum, until delivery. The
interior of the drum on a concrete mixing truck is fitted with a spiral blade. In one rotational
direction, the concrete is pushed deeper into the drum. This is the direction the drum is rotated
while the concrete is being transported to the building site. This is known as "charging" the
mixer. When the drum rotates in the other direction, the Archimedes screw -type arrangement
"discharges", or forces the concrete out of the drum. From there it may go onto chutes to guide
the viscous concrete directly to the job site. If the truck cannot get close enough to the site to use
the chutes, the concrete may be discharged into a concrete pump, connected to a flexible hose, or
onto a conveyor belt which can be extended some distance (typically ten or more meters). A
pump provides the means to move the material to precise locations, multi-floor buildings, and
other distance prohibitive locations. Buckets suspended from cranes are also used to place the
concrete. The drum is traditionally made of steel but on some newer trucks as a weight reduction
measure, fiber glass has been used.
Figure 32- A view of Transit Mixer

6.3-EXCAVATORS
Excavators are heavy construction equipment consisting of a boom, stick, bucket and cab on a
rotating platform known as the "house”. The house sits atop an undercarriage with tracks or
wheels. A cable-operated excavator uses winches and steel ropes to accomplish the movements.
They are a natural progression from the steam shovels and often called power shovels. All
movement and functions of a hydraulic excavator are accomplished through the use of hydraulic
fluid, with hydraulic cylinders and hydraulic motors. Due to the linear actuation of hydraulic
cylinders, their mode of operation is fundamentally different from cable-operated excavators.
TERMINOLOGY
Excavators are also called diggers, mechanical shovels, or 360-degree excavators (sometimes
abbreviated simply to 360). Tracked excavators are sometimes called "track hoes" by analogy to
the backhoe.
USAGE
Excavators are used in many ways:
 Material handling
 Brush cutting with hydraulic attachments
 Forestry work
 Demolition
 General grading/landscaping
Hydraulic excavator capabilities have expanded far beyond excavation tasks with buckets. With
the advent of hydraulic-powered attachments such as a breaker, a grapple or an auger, the
excavator is frequently used in many applications other than excavation. Many excavators
feature a quick coupler for simplified attachment mounting, increasing the machine's utilization
on the jobsite. Excavators are usually employed together with loaders and bulldozers. Most
wheeled, compact and some medium-sized (11 to 18-tonne) excavators have a backfill (or
dozer) blade. This is a horizontal bulldozer like-blade attached to the undercarriage

Figure 33-Excavators
6.4-TOWER CRANE
A crane is a type of machine, generally equipped with a hoist rope, wire ropes or chains,
and sheaves, that can be used both to lift and lower materials and to move them horizontally. It is
mainly used for lifting heavy things and transporting them to other places. It uses one or more
simple machines to create mechanical advantage and thus move loads beyond the normal
capability of a human. Cranes are commonly employed in the transport industry for the loading
and unloading of freight, in the construction industry for the movement of materials and in the
manufacturing industry for the assembling of heavy equipment.
Cranes exist in an enormous variety of forms – each tailored to a specific use. Sometimes sizes
range from the smallest jib cranes, used inside workshops, to the tallest tower cranes, used for
constructing high buildings. Mini-cranes are also used for constructing high buildings, in order to
facilitate constructions by reaching tight spaces. Finally, we can find larger floating cranes,
generally used to build oil rigs and salvage sunken ships.

6.5-CONCRETE DRILLER
Figure 34- View of Concrete Driller

The rotary hammer drill (also known as a rotary hammer, roto hammer drill or masonry drill)
combines a primary dedicated hammer mechanism with a separate rotation mechanism, and is
used for more substantial material such as masonry or concrete. Generally, standard chucks and
drills are inadequate and chucks such as SDS and carbide drills that have been designed to
withstand the percussive forces are used. Some styles of this tool are intended for masonry
drilling only and the hammer action cannot be disengaged. Other styles allow the drill to be used
without the hammer action for normal drilling, or hammering to be used without rotation for
chiseling.
6.6-VIBRATOR
It essentially consists of a steel tube (with one end closed and rounded) having an eccentric
vibrating element inside it. This steel tube called poker is connected to an electric motor or a
diesel engine through a flexible tube. They are available in varying from 40 to 100 mm diameter.
The diameter of the poker is decided from. The frequency of vibration varies up to 15000 rpm.
However a range between 3000 to 6000 rpm is suggested as a desirable minimum with an
acceleration of 4g to 10g.The normal radius of action of an immersion vibrator is 0.50 to 1.0m.
However, it would be preferable to immerse the vibrator into concrete at intervals of not more
than 600mm or 8 to 10 times the diameter of the poker.

Figure 35- View of concrete Needle Vibrator

6.7-DUMPY LEVEL
A dumpy level, builder's auto level, leveling instrument, or automatic level is an optical
instrument used to establish or check points in the same horizontal plane. It is used
in surveying and building with a vertical staff to measure height differences and so
transfer, measure and set heights.
Operation
The level instrument is set up on a tripod, and, depending on the type, either roughly or
accurately set to a leveled condition using foot screws (leveling screws). The operator looks
through the eyepiece of the telescope while an assistant holds a tape measure or
graduated staff vertical at the point under measurement. The instrument and staff are used to
gather and/or transfer elevations (levels) during site surveys or building construction.
Measurement generally starts from a benchmark with known height determined by a previous
survey, or an arbitrary point with an assumed height.
Variants
Levelers for use by hand. The term dumpy level endures despite the evolution in design.
A dumpy level is an older-style instrument that requires skilled use to set accurately. The

instrument requires to be set level in each quadrant, to ensure it is accurate through a full 360°
traverse. Some dumpy levels will have a bubble level ensuring an accurate level.
Figure 36- A view of Dumpy Level to check levels after excavation is done
A variation on the dumpy and one that was often used by surveyors, where greater accuracy and
error checking was required, is a tilting level. This instrument allows the telescope to be
effectively flipped through 180°, without rotating the head. The telescope is hinged to one side of
the instrument's axis; flipping it involves lifting to the other side of the central axis (thereby
inverting the telescope). This action effectively cancels out any errors introduced by poor setup
procedure or errors in the instrument's adjustment. with a standard builder's level by rotating
it through 180° and comparing the difference between spirit level bubble positions

CHAPTER-7

7-CONCLUSION
The primary objective of this report is a description of practical knowledge obtained during the
internship period of 31 days at PRESTIGE ROYALE GARDENS BENGALURU construction site.
I closely studied the practical application of various aspects of construction during my stay such as
 reading of drawings
 execution
 Safety
 Quality
 planning
 estimation
 plant & maintenance
 Management (Material, labour, etc)
The following conclusion can be drawn
 I understood the difference between the theoretical and practical approach to execute various
construction activities. Practical knowledge reinforced with theoretical knowledge was a must to
commence, track activities in construction at the site.
 Safety, a very important component of construction that is the most neglected part at the sites
generally. I understood the importance of PPE’s, measures that should be taken for various tasks to
ensure the utmost safety of all workers at the site especially with respect to the various works
executed at heights.
 Similar to safety, quality is also one which is not taken care of properly especially at the
construction. Quality can be ensured by strictly adhering to few procedures such as regular testing
of raw materials, inspection of work, checklists, proper documentation, calibration, action on the
previous problems encountered w.r.t quality. I was exposed to the following aspects which helped
to gain sufficient knowledge and importance of quality in construction.
 Execution of Activities whether it is concreting, bar bending, placing of reinforcement, block work,
shuttering, excavation or plastering is a challenging task as many constraints are involved w.r.t
labour, materials, manpower, machinery, etc. The do and don’ts, procedure to be strictly followed
before, during, after completion of respective tasks are a part of this activity. I gained a good
knowledge on the evectional aspects.
 Generally the activities involved in construction are interlinked and some activities need to be
started/ executed in tandem. Moreover, with various resources such as manpower, money materials,
machinery involved in a complex project, it becomes necessary to manage all these aspects by
coordinating with different agencies and persons. This aspect part of construction management is
very important for the successful completion of project within schedule and a budget. I was very
briefly exposed to this aspect also.
 Any project to be executed properly requires the understanding of construction drawings of various
components failing which mistakes can lead to disasters. This aspect was clearly explained to me
during the stay at the site and I also understood this aspect clearly.
Overall, it was a nice experience for me to interact with the various skills of people at the site ranging
from helper to the General Manager. Exposures to various aspects of the construction have changed my
thinking. The practical knowledge will be helpful to me in understanding, reinforcing the theoretical
concepts

CHAPTER-8

8-APPENDIX
Figure-37 Aerial view of Prestige Royale Gardens, Doddaballapura road, Bangalore

Figure-38 TYPE –A 1BHK

Figure-39 TYPE-B 1 BHK

Figure-40 TYPE-C 1 BHK

Figure -41 TYPE-D1BHK

Figure-42 TYPE-E 2BHK

Figure-43TYPE-F 2 BHK

Figure-44 TYPE-G 2 BHK

Figure-45TYPE-H 2 BHK

Figure-46 TYPE-J 2 BHK

Figure no-47 TYPE-J 2 BHK

Figure-48 TYPE-K 3 BHK

Figure-49 Club house

Figure-50 Entrance Lobby

Figure-51 Grand Entrance

Figure-52 Kitchen

Figure-53 Living Room

Figure-54 Master Bedroom

Figure no-55 Swimming Pool

Fig56-Tower Prespective

INTERNSHIP REPORT ON PRESTIGE ROYALE GARDENS, BENGALURU
DEPARTMENT OF CIVIL ENGINEERING, BENGALURU. Page 96

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INTERSNSHIP REPORT ON PRTESTIGE ROYALE GARDENS ,BENGALURU 2015-16

Mr.C.R.Manjunath Mr. Manish Shashikant Dr. Aravind H Bhashyam

DEPARTMENT OF CIVIL ENGINEERING,BMSIT&M,BENGALURU 2

DEPARTMENT OF CIVIL ENGINEERING,BMSIT&M,BENGALURU 3

1.1-BACKGROUND OF THE COMPANY ….....................................................................................................12

1.2-CORPORATE VALUES OF THE COMPANY .............................................................................................13

1.3-PROJECT DESCRIPTION-CONCEPT ……….................................................................................................14

1.5-UNIT LOCATION ..........................................................................................................................................16

1.6-SOME OF THE PROJECTS DEVELOPED BY PRETIGE GROUPS .........................................................17

1.7-ON GOING PROJECTS BY PRESTIGE .......................................................................................................18

2 -DIFFERENT DEPARTMENTS AT THE SITE ...............................................................................................20

2.1-DIFFERENT DEPARTMENTS AT THE SITES ...........................................................................................20

2.2-QA/QC DEPARTMENT .................................................................................................................................22

3-SAFETY AND ITS PRACTISE.........................................................................................................................25

3.2- WORK AND WORKER SAFETY SERIES..................................................................................................26

3.3- FALL PROTECTION ....................................................................................................................................26

3.5- PATHWAY ....................................................................................................................................................28

3.7-HAZARD COMMUNICATION .....................................................................................................................29

3.8-SAFETY CHECKLISTS .................................................................................................................................30

3.9-PERSONAL PROTECTIVE EQUIPMENTS (PPE) ......................................................................................31

DEPARTMENT OF CIVIL ENGINEERING,BMSIT&M,BENGALURU 4

3.12-FLOOR AND WALL OPENINGS ..............................................................................................................33

4-LABS AT THE SITE…………………………………………..………………………………………….… 36

4.1-FLOOR PLAN OF QA/QC LAB ....................................................................................................................37

4.2-SLUMP CONE TEST .....................................................................................................................................39

4.3-CORE CUTTING ............................................................................................................................................43

4.4-COMPRESSIVE STRENGTH TESTING EQUIPMENT ...............................................................................43

4.5-SIEVE ANALYSIS MACHINE......................................................................................................................43

4.6-RAPID MOISTURE METER..........................................................................................................................43

4.7-SLUMP CONE ................................................................................................................................................44

4.8-CALIBARATION DETAILS OF THE INSTRUMENTS [6] .......................................................................45

5-SITE EXECUTIONAL ASPECTS.....................................................................................................................48

5.6-PLAIN CEMENT CONCRETE ......................................................................................................................60

5.8-CONCRETE BLOCKS AND CMU ................................................................................................................62

DEPARTMENT OF CIVIL ENGINEERING,BMSIT&M,BENGALURU 5

6-EQUIPMENTS AND INSTRUMENTS ...............................................................................................................75

6.1-BATCHING PLANT .........................................................................................................................................75

6.5-CONCRETE DRILLER .....................................................................................................................................79

6.7-DUMPY LEVEL ................................................................................................................................................80

DEPARTMENT OF CIVIL ENGINEERING,BMSIT&M,BENGALURU 6

Figure 5- View of crane tower ......................................................................................... .29

Figure 6-Safety boards displayed at the board ................................................................ .30

Figure 7-View of personal protective Equipments .......................................................... 31

Figure 8- A view of Helmets-Hard Hats a part of Personal Protective Equipment......... 32

Figure 9- A View of Safety boards at the entrance of sit .................................................34

Figure 10-Layout of QA&QC lab at the site ................................................................... 36

Figure 12-Slump cone test-cone removed ....................................................................... 38

Figure 13-Cylindrical mould being drilled into ground to determine density................. 41

Figure 14- A View of a Rapid moisture meter ................................................................ 44

Figure 15-A View of Slump cone.................................................................................... 45

Figure 16-Ground is excavated based on the need and type of foundation..................... 49

Figure 17-A View of Tractor shovel (loading shovel) .................................................... 50

Figure 18-A View of back hoe ........................................................................................ 50

Figure 19-A View of Dumper truck ................................................................................ 51

Figure 20-A View of scaffolding..................................................................................... 52

Figure 21-A View of formwork at the site ....................................................................... 54

Figure 22-A View of reinforcement bars………………………………………………..56

Figure 25-Curing and use of curing compound ................................................................62

Figure 26- Concrete Block-Standard Sizes....................................................................... 63

Figure 30-Tools used for plaster .......................................................................................70

Figure 31- A view of in-house batching plant at the site...................................................75

Figure 32- A view of Transit Mixer...................................................................................76

Figure 33-Excavators ........................................................................................................78