SUMMER TRAINING REPORT

Shapoorji Pallonji & Co. Ltd

Submitted By:
RAHUL PANDEY
(NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA)

Under the able Guidance of:

Mr. S. K. PANDEY

TABLE OF CONTENTS
Topic

Page no.

1) Acknowledgement......3
2) Abstract ......4
3) 1.0 INTRODUCTION
1.1 About the
Company....6
1.2 About the Project work...........8
4) 2.0 CONSTRUCTION MATERIALS
2.1 Cement.10
2.2 Sand11
2.3 Aggregate12
2.4 Admixtures 13
2.5 Reinforcement Steel13
5) 3.0 CONSTRUCTIONAL EQUIPMENTS
3.1 Total Station..15
3.2 Excavator...19
3.3 JCB21
3.4 Transit Mixer.23
3.5 Concrete Pump..25
3.6 Batching Plant...26
6) 4.0 STAGES OF CONSTRUCTION
4.1 Site Preparation (leveling)30
4.2 Site Marking..................31
4.3 Excavation.32
4.4 Sand Filling33
4.5 P.C.C...34

4.6 Foundation Base Leveling36

4.7 Bar bending, Placing and Tying36
4.8 Concreting.41
4.9Curing48
7) 5.0 CONCLUSION.50

ACKNOWLEDGEMENT
Sometimes words fall short to show gratitude, the same happened with
me during this project. The immense help and support received from
Shapoorji Pallonji Constructions & ltd. overwhelmed me during this
project.
It was a great opportunity for me to work with Shapoorji Pallonji Co. &
Ltd, a leader and pioneer in the field of construction. First and foremost, I
would like to express my deepest thanks to my parents and friends for
their kind co-operation and encouragement throughout the period which
helped me in completion of this training.
I am deeply indebted to the Project Co-ordinator Mr.Tapas Chatterjee for
giving me the opportunity to undertake this summer internship and work
here as an internee at the Shapoorji Pallonji & Co. Ltd. Since summer
internship is a part of my curriculum in my parent institute, I am glad that
he gave me a chance to work with this organisation. The industrial
internship has helped me greatly in developing and improving my
working and learning skills, besides giving me handful of experience in
the field work.
I am highly indebted to Mr. S. K. Pandey, Mr. Abhishek Das, Mr.
Nand Kumar Pani, Mr. Bhakti Mandal and more for their guidance
and constant supervision as well as for providing necessary information
regarding the project & also for their support in completing the training.
My thanks and appreciations also go to my colleagues and people who
have willingly helped me out with their abilities.

ABSTRACT

As a part of the academic requirements an industrial training program

underwent from May 13 to July 13, 2013. During the training period, the
different stages of construction of foundation of a 1000 seated hostel
building (G+3, 8 blocks) and a lecture gallery complex (G+3) were
closely studied. The construction site was inside the campus of National
Institute of Technology, Rourkela.
Due to low and different type of bearing capacity of soil, different type
of foundations were used. Some parts of hostel building was in the
drainage coarse area, for this reinforced mat-slab foundations were used
to distribute heavy load across the entire block area, to lower the contact
pressure compared to conventional spread footing. For other blocks,
isolated and combined footings were used. In the Lecture gallery
complex, isolated and continuous footings were used. The first step in the
construction process was plot-levelling, followed by marking and
excavation of soil according to engineering drawings. Sand was filled of
thickness 0.10 m, then PCC was laid of thickness 0.10 m to level the
base. Reinforcement bars of Fe-415 were used, and concrete mix for both
the footings and the columns were used of M25. Bar bending, placing &
tying of bar and frame-work was done with clear cover of 0.050 m, then
concreting was done in a proper manner. On the next day shutters were
removed and continuous curing was done for concreting work for a
period of seven days.

1.0 INTRODUCTION
1.1 About Company
Shapoorji Pallonji Co. & Ltd. is one of the leading construction
giants in India and abroad.
The companys expertise has been repeatedly showcased on
projects which involved a major advance in construction
technology or whose size was beyond the capacity of most others.
Blessed with a rich legacy and heritage, it has marched into the
new millennium with modern management skills, state-of-the-art
technology and the ideals of innovation and customer satisfaction.
Over time, Shapoorji Pallonji has built diverse civil and structural
engineering

masterpieces

like

factories,

nuclear

research

establishments, nuclear waste handling establishments, scientific

and research establishments, stadia and auditoria, airports, hotels,
hospitals, giant skyscrapers, housing complexes, townships, water
treatment plants, roads, expressways, power plants and biotech
facilities.
Shapoorji Pallonji & Co. Ltd. is just one of the jewels in the SP
Group's crown. It synergises well with other group companies to
be able to execute turnkey projects swiftly and efficiently. These
include SP Fabricators, AFCONS, Forbes, Sterling and Wilson, SP
Construction Materials Group, SP Real Estate and Samalpatti
Power Company Private Limited. Together, this conglomerate
continues to strive towards safety, quality and commitment virtues.

Shapoorji Pallonji has emerged as one of the most safety

and quality conscious construction companies. With over
3000 dedicated and qualified engineers employed by the

organization, it's not hard to imagine why Shapoorji

Pallonji:
The oldest Indian construction company with a legacy of 147
years.
The first Indian construction company to enter the Middle
East in the 1970s.
The first Indian construction company to have earned the
ISO 9001 Certification across all projects.
The first Indian company to construct two, 60 storey
residential towers in the heart of Mumbai.

1.2 About the Project Work

1.2.1 1000 SEATED HOSTEL BUILDING
Hostels are boarding school or student dormitories in resident colleges
and universities. In this type of building, rooms are provided for
residential and accommodation purposes to the students with or without
dining facilities. Other facilities may include cycle stands, gymnasium,
study room, activities room etc. Building has been designed for Ground
Floor + First floor to Third floor (G+3). Soil bearing capacity of soil is
15 T/cubic metre.
Salient features:

FLOORS

AREA

UNIT

GROUND FLOOR

9050.25

sqm

FIRST FLOOR

10070.25

sqm

SECOND FLOOR

9375.00

sqm

THIRD FLOOR

7350.00

sqm

FOURTH FLOOR

2442.00

sqm

TERRACE

284.70

sqm

TOTAL

38572.20

sqm

1.2.2 LECTURE HALL COMPLEX

FLOORS

AREA

UNIT

1933.33

Sqm

GROUND FLOOR

2579.33

Sqm

FIRST FLOOR

2579.33

Sqm

SECOND FLOOR

1534.97

Sqm

THIRD FLOOR

1399.97

Sqm

TERRACE (MACHINE ROOM &

MUMTY )

72.93

Sqm

TOTAL

10099.86

Sqm

BASEMENT

2.0 CONSTRUCTION MATERIALS

2.1Cement
Cement maybe described as a material with adhesive and cohesive
properties that make it capable of bonding mineral fragments into a
compact whole. In this process, it imparts strength and durability to
the hardened mass called concrete. The cements used in the making of
concrete are called hydraulic cements so named, because they have
the property of reacting chemically with water in an exothermic
process called hydration that results in water resistant products. The
cement often called the magic power is a fine ground material
consisting of compound of lime, silica alumina and iron. Cement is
the binder that holds concrete and mortars together. Which is why it
plays the most critical role in giving strength and durability to a
structure. Cement used for domestic buildings such as home are
basically of three types:
Portland Slag Cement: Conforming to IS 455:1989, is made by
intergrinding Portland cement clinker and granulated blast furnace
slag. It has fairly high sulphate resistance, rendering it suitable for
use in environments exposed to sulphates.
Portland Pozzolana Cement: Portland pozzolana Cement (PCC)
conforming to IS: 1489 A combination of flyash (from thermal
power plant) with clinker and gypsum. Pozzolana cement is
prepared by grinding Portland cement clinker with pozzolana. This
type of cement is largely used in marine structure.
Ordinary Portland Cement: Presently available in three different
grades i.e. C33, C43 & C53, conforming to IS 269:1989, IS
8112:1989 & IS 12269:1987 respectively. The numbers 33, 43 and

53 corresponds to the 28 day compressive strengths of cement, as

obtained from standard test on cement-sand mortar specimens. A
combination of clinker and gypsum of good quality. Ordinary
Portland cement is manufactured by first burning at a very high
temperature the mixture of calcareous (mainly calcium carbonate)
and argillaceous (mainly clay) and then grinding the calcined
product (i.e. clinker) with small amount of gypsum in to a fine
power known as ordinary Portland cement. These are most
commonly used in general concrete construction, where there is no
special durability requirement.

2.2 Sand
These are cohesion less aggregates of either, rounded sub rounded,
angular, sub angular or flat fragments of more or less unaltered rock of
minerals consisting of 90% of particles of size greater than 0.06 mm and
less than 2 mm. Alternatively, these are coarse grained cohesion less
particles of silica derived from the disintegration of rock. These are of
three types:
Coarse sand: It is one which contains 90% of particles of size greater
than 0.6 mm and less than 2 mm.
Medium sand: It is one, which contains 90& of particles of particles size
greater than 0.2 mm and less than 0.6 mm.
Fine sand: It is one, which contains 90% of particles of size greater than
0.06 mm and less than 0.2 mm.
Proper selection of sand is critical in the durability and performance of
concrete mixture. It should be:
Clear, angular and hard

 Free from clay, mica and soft, flaky material

Graded, which means it should be a mix of fine, medium and coarse
sand
Fee from contaminates like sea salt
Consistent in moisture (water) content which should not exceed 7%.
When mixing concrete the moisture content must be taken in to
consideration.
The price of sand includes three or four components-base cost,
transportation, handling and number of intermediaries. Procuring sand in
bulk directly from the source will be cheaper. Your neighborhood dealer
in this case is likely to be costlier, except when you need smaller
quantities.

2.3 Aggregate
Since aggregate occupies about three quarters of the volume of concrete,
it contributes significantly to the structural performance of concrete,
especially strength, durability and volume stability.
Aggregate is formed from natural sources by the process of weathering
and abrasion, or by artificially crushing a large parent mass.
Aggregate is generally categorized into fine aggregate(particle size
between 0.075mm and 4.75mm) and course aggregate(particle size larger
than 4.75mm) as described in IS 383:1970.
The properties should comply with the norms laid down in IS: 383-1970
Specification for course and fine aggregates from natural sources for
concrete. Aggregates should be chemically inert, strong, hard, durable, of
limited porosity (water absorption when immersed in water for 24 hours
should not be more than 10%.), free from adherent coating, clay lumps,
coal and coal residues and should contain no organic or other admixture
that may cause corrosion of the reinforcement or impair the strength or

durability of the concrete. The shape (rounded, irregular, angular and

workability requirements.
2.4 Admixtures:
Admixtures are additives that are introduced in a concrete mix to modify
the properties of concrete in its fresh and hardened states. Some
guidelines for admixtures are given in IS 9103:1999.
Admixtures are either chemical or mineral in form. They are now
being increasingly used in concrete production, particularly when there is
an emphasis on either high strength or high performance. The use of
chemical admixtures is inevitable in the production of ready-mixed
concrete, which involves transportation over large distances of fresh
concrete i.e. manufactured under controlled conditions at a batching
plant.

2.5 Reinforcement Steel

RCC stands for reinforced cement concrete. Concrete is reinforced with
steel primarily to make up for concretes in capacity for tensile resistance.
Steel embedded in concrete, called reinforcing steel, can effectively take
up the tension i.e. induced due to flexural tension, direct tension,
diagonal tension or environmental effects. Reinforcing steel also imparts
ductility to a material i.e. otherwise brittle. Steel is stronger than concrete
in compression also; and hence, concrete can be advantageously
reinforced with steel for bearing compressive stresses as well, as is
commonly done in columns. The bar sizes (nominal diameters in mm)
presently
available
in
india
are
5,6,8,10,12,16,18,20,22,25,28,32,36,40,45 and 50. Both branded and
unbranded bars are available. It is wise to buy good brands the names of
which are marked on the steel. During construction it is made sure that

steel reinforcement is provided exactly as the engineering design

specification.
Reinforcement used for project is Fe 415 (confirming to IS 1786-2008).

3.0 CONSTRUCTIONAL EQUIPMENTS

3.1 Total Station
A total station is an electronic/optical instrument used in modern
surveying. The total station is an electronic theodolite (transit) integrated
with an electronic distance meter (EDM) to read slope distances from the
instrument to a particular point. In use it is very similar to
theodolite.Total stations are mainly used by land surveyors and Civil
Engineers, either to record features as in Topographic Surveying or to set
out features (such as roads, houses or boundaries). They are also used by
archaeologists to record excavations and by police, crime scene
investigators,

private

accident

re-constructionists

and

insurance

companies to take measurements of scenes. Before using the total station,

the station must be centered and levelled. Levelling is done using the
tripod stand and the three screws provided just below the lens.
Approximate levelling is done using the tripod and accuracy can be
obtained by using foot screw. Centering of theodolite means locating a
point on the ground from where the theodolite measures distance and
angle of other points. T.S contains a special laser light located below the
body which points straight downwards on the point where theodolite is
centered.

USES OF TOTAL STATION

Coordinate measurement
Coordinates of an unknown point relative to a known coordinate

can be determined using the total station as long as a direct line of

sight can be established between the two points. Angles and
distances are measured from the total station to points under

survey, and the coordinates (X, Y, and Z or easting, northing and

elevation) of surveyed points relative to the total station position
are calculated using trigonometry and triangulation. To determine
an absolute location a Total Station requires line of sight
observations and must be set up over a known point or with line of
sight to 2 or more points with known location.
For this reason, some total stations also have a Global Navigation
Satellite System receiver and do not require a direct line of sight to
determine coordinates. However, GNSS measurements may
require longer occupation periods and offer relatively poor
accuracy in the vertical axis.

Angle measurement
Most modern total station instruments measure angles by means of
electro-optical scanning of extremely precise digital bar-codes
etched on rotating glass cylinders or discs within the instrument.
The best quality total stations are capable of measuring angles to
0.5 arc-second. Inexpensive "construction grade" total stations can
generally measure angles to 5 or 10 arc-seconds.
Distance measurement
Measurement of distance is accomplished with a modulated

microwave or infrared carrier signal, generated by a small solidstate emitter within the instrument's optical path, and reflected by a
prism reflector or the object under survey. The modulation pattern
in the returning signal is read and interpreted by the computer in
the total station. The distance is determined by emitting and
receiving multiple frequencies, and determining the integer
number of wavelengths to the target for each frequency. Most total

stations use purpose-built glass corner cube prism reflectors for the
EDM signal. A typical total station can measure distances with an
accuracy of about 1.5 millimetres (0.0049 ft) + 2 parts per million
over a distance of up to 1,500 metres (4,900 ft).
Reflector-less total stations can measure distances to any object
that is reasonably light in color, up to a few hundred meters.
Data processing
Some models include internal electronic data storage to record

distance, horizontal angle, and vertical angle measured, while

other models are equipped to write these measurements to an
external data collector, such as a hand-held computer.
When data is downloaded from a total station onto a computer,
application software can be used to compute results and generate a
map of the surveyed area. The new generation of total stations can
also show the map on the touch-screen of the instrument right after
measuring the points.
Application
Total stations are mainly used by land surveyors and Civil Engineers,
either to record features as in Topographic Surveying or to set out
features (such as roads, houses or boundaries). They are also used by
archaeologists to record excavations and by police, crime scene
investigators, private accident reconstructionists and insurance
companies to take measurements of scenes.
Mining
Total stations are the primary survey instrument used in mining

surveying.
A total station is used to record the absolute location of the tunnel
walls (stopes), ceilings (backs), and floors as the drifts of an
underground mine are driven. The recorded data are then

downloaded into a CAD program, and compared to the designed

layout of the tunnel.
The survey party installs control stations at regular intervals. These
are small steel plugs installed in pairs in holes drilled into walls or
the back. For wall stations, two plugs are installed in opposite
walls, forming a line perpendicular to the drift. For back stations,
two plugs are installed in the back, forming a line parallel to the
drift.
A set of plugs can be used to locate the total station set up in a drift
or tunnel by processing measurements to the plugs by intersection
and resection.

3.2 Excavator
Excavator is a 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 cableoperated excavator uses winches and steel ropes to accomplish the
movements. They are a natural progression from the steam shovels and
often called power shovels.
The two main sections of an excavator are the undercarriage and the
house. The undercarriage includes the blade (if fitted), tracks, track
frame, and final drives, which have a hydraulic motor and gearing
providing the drive to the individual tracks, and the house includes the
operator cab, counterweight, engine, fuel and hydraulic oil tanks. The
house attaches to the undercarriage by way of a center pin, allowing the
machine to slew 360 unhindered.
Attached to the end of the boom is the stick (or dipper arm). The stick
provides the digging force needed to pull the bucket through the ground.
The stick length is optional depending whether reach (longer stick) or
break-out power (shorter stick) is required.
On the end of the stick is usually a bucket. A wide, large capacity
(mud) bucket with a straight cutting edge is used for cleanup and
levelling or where the material to be dug is soft, and teeth are not
required. A general purpose (GP) bucket is generally smaller, stronger,
and has hardened side cutters and teeth used to break through hard
ground and rocks. Buckets have numerous shapes and sizes for various
applications. There are also many other attachments which are available

to be attached to the excavator for boring, ripping, crushing, cutting,

lifting, etc.
Max. digging depth = 5.53 m.
Max. digging height = 8.95 m.
Min. swing radius = 3.76 m.
Bucket rotation = 183 degree
Bucket tearforce = 14550 kgf

3.3 JCB

JCB is a type of construction machine with a hydraulically operated

shovel on the front and an excavator arm on the back.
An excavator is the oldest type of machine which removes earth. It
performs its work of moving the earth while the main unit is stationery.
The little effort is required to move the dead weight of the earth in
vertical plane. The lateral motion is in the horizontal plane and the effort
required is primarily required to accelerate and decelerate the bucket in
the plane. The range of the excavator is limited to the reach of the boom
carrying the boom.
The JCB runs on an engine of power 49.5 bhp @2200 RPM.

DIMENSIONS
Overall length = 5.90 m.
Wheelbase = 2.17 m.
Height = 3.61 m.
EXACAVATOR
Max. digging depth = 4.77 m.
Max. working height = 5.97 m.
Bucket rotation = 185 degree
Force applied by bucket = 5700 KN.
LOADER
Max. height = 3.23 m.
Dump height = 2.74 m.
Dig depth below ground level = 7 cm
Pay load = 1800 kg.
Lift capacity at full height = 1620 kg.

3.4 TransitMixer

Special concrete transport trucks (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.
Maximum capacity of transit mixture = 6 cu.m of concrete.

3.5 Concrete Pump

A concrete pump is a machine used for transferring liquid concrete by
pumping. There are two types of concrete pumps.
The first type of concrete pump is attached to a truck. It is known as a
trailer-mounted boom concrete pump because it uses a remote-controlled
articulating robotic arm (called a boom) to place concrete with pinpoint
accuracy. Boom pumps are used on most of the larger construction
projects as they are capable of pumping at very high volumes and
because of the labour saving nature of the placing boom. They are a
revolutionary alternative to truck-mounted concrete pumps.
The second main type of concrete pump is either mounted on a truck and
known as a truck-mounted concrete pump or placed on a trailer, and it is
commonly referred to as a line pump or trailer-mounted concrete pump.
This pump requires steel or flexible concrete placing hoses to be
manually attached to the outlet of the machine. Those hoses are linked
together and lead to wherever the concrete needs to be placed. Line
pumps normally pump concrete at lower volumes than boom pumps and
are used for smaller volume concrete placing applications such as
swimming pools, sidewalks, and single family home concrete slabs and
most ground slabs.
Speed of pumping = 30 cu.m/hour (maximum.)
Max. height it can pump = 30 metres.
Fuel consumption = 2 ltr/hour. (Diesel)
Torque = 1200 r.p.m

3.6 Batching Plant

A concrete plant, also known as a batch plant, is a device that combines

various ingredients to form concrete. Some of these inputs include sand,
water, aggregate (rocks, gravel, 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.
There are generally two types of batching plant :
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. The final product is then
transported to the job site. Central mix plants differ from ready mix
plants in that they offer the end user a much more consistent product,
since all the ingredient mixing is done in a central location and is
computer-assisted to ensure uniformity of product. A temporary batch
plant can be constructed on a large job site. A concrete plant becomes
central mix with the addition of a concrete mixer.
Concrete batching plants are widely used to produce various kinds of
concrete including quaking concrete and hard concrete, suitable for large
or medium scale building works, road and bridge works and precast
concrete plants, etc.
More recently is the availability of the mobile concrete batch plant. This
innovative device was designed for the production of all types of
concrete, mixed cements, cold regenerations and inertizations of
materials mixed with resin additives. The design includes multiple
containers that separately transport all the elements necessary for the
production of concrete, or any other mixture, at the specific job site. In

this way, the operator can produce exactly what he wants, where he
wants and in the quantity he wants through the use of an on-board
computer. Once production is started, the various components enter the
mixer in the required doses and the finished mixed product comes out
continuously ready for final use. It is also suitable for the recovery of
materials destined for landfill disposal, such as cement mixtures
regenerated from masonry rubble.The mobile batching plant is easy to
transport. It can be fixed-mounted on a truck, mounted on a truck with
tipping box or mounted on an interchangeable cradle.
Modern concrete batch plants (both ready mix and central mix,) employ
computer aided control to assist in fast, accurate measurement of input
constituents or ingredients, as well as tie together the various parts and
accessories for coordinated and safe operation. With concrete
performance so dependent on accurate water measurement, systems will
often use moisture probes to measure the amount of water that is part of
the aggregate (sand and rock) material while it is being weighed, and
then automatically compensate the mix design water target.
OBSERVATION ON THE SITE :Max. capacity of pan mixer = 0.5 m3
Average Time taken to discharge one payload (5 m3) = 15 min.

4.0 STAGES OF CONSTRUCTION

4.1 Site Preparation
Site preparation is one of the preliminary works to be done for starting
construction works. The selected construction site preparation needs to
be completed properly before the start of construction process.
The following factors are considered for the construction site preparation:
The first step of site preparation work is to remove all the scrubs or
jungle if there exists any on the site for building construction.
The whole area will be roughly leveled.
The holes of the construction site will be filled with sands or
rammed earth and leveled off as required or re-directed by the
authority.
As a part of site preparation, the trees will be cut off and their roots
are totally uprooted as directed by the authority.
Before starting the work, permanent benchmarks must be
established at a suitable point in the construction site.
The orientation and trench-lines of the building should be correctly
laid out in the construction site and the location for the storage and
stacking of the materials should be definitely set on the ground in
the site.
Site preparation also includes fixing position of the site office,
godowns, the guard and labour sheds, the access and existing roads
for trucks and carts etc.
During construction site preparation, boundary line pillars are also
to be fixed on the ground or as directed by the authority.

4.2 Site Marking

Before excavation of soil is started, the layout of the structure has to be
marked on the ground. This process is called site marking. This is very
important step, because here we begin the construction part. This also
known as surveying of site.
Surveying is the technique, profession, and science of accurately
determining the terrestrial or three-dimensional position of points and the
distances and angles between them. These points are usually on the
surface of the Earth, and they are often used to establish land maps and
boundaries for ownership or governmental purposes.
On the construction site survey work was done using Total Station
survey equipment. It is an electronic equipment which can automatically
measure horizontal and vertical distances as well as angles. It is the most
hi-tech equipment used now-a-days in surveying having a least count of
only one second. The T.S consists of a diode emitting laser light .This
laser light is reflected using a 900 prism. The time taken by the light to
travel to and back from prism gives us the distance as well as angular
measurement.
In order to determine the suitability of a site for the proposed facilities
the first stage of any project should be to carry out topographical and
geotechnical investigations. To give adequate information about the site
for design purposes we will undertake a topographical survey to obtain
precise levels data and the location of key features and existing
services. The results of the survey are shown on a scaled drawing.
Since determining the location of building on site was difficult due to
various obstacles which were present in the proposed location of
building, it was decided to first draw the layout of whole landscape in
Auto cad using survey, and then, draw the plan of building in same scale.
Then the plan was placed on the layout in CAD software and location
providing no or minimum obstacles were selected.

In land survey, the first step is to determine reference points. Reference

points are two or more fixed points which can serve as the guiding point
in rest of the survey. During survey of hostel building, edge points of hall
7 and hall 5 were selected as reference points. The T.S was placed in
between them and then using hit and trial method it was so placed that it
was lying in straight line with the corner of both the buildings. Distance
between the buildings and the machine was measured. That point became
the first station. All other stations were measured with respect to that
point. Location of all the objects were done with respect to stations.
After the site of the proposed building had been fixed, the next step
was to determine the section to be excavated for building foundation.
This was also done using T.S. Coordinate of all the edges were
determined, and fed into T.S. Then the prism was placed at an
approximate location of the point, the T.S then gave the distance by
which the prism should be moved to locate the point.

4.3 Excavation
After surveying and fixing of location of the building, the next step was
excavation of soil mass to build the foundation. On the site, excavation
was carried out mechanically. Excavators and JCBs were used for
excavating the soil. Adequate precautions were taken to see that the
excavation operations do not go beyond the boundary to be excavated
and the desired R.L is maintained. For measurement of R.L of the land
surface Auto level was used. Excavation was carried out providing
adequate side slopes and dressing of excavation bottom. Excavators are
one of the most modern machinery available for excavation work. The
excavator operating on our training site was found to excavate 15 m3 of
soil in approximately 5 minutes on an average. The two main sections of

an excavator are the undercarriage and the house. The undercarriage

includes the blade (if fitted), tracks, track frame, and final drives, which
have a hydraulic motor and gearing providing the drive to the individual
tracks, and the house includes the operator cab, counterweight, engine,
fuel and hydraulic oil tanks. The house attaches to the undercarriage by
way of a center pin, allowing the machine to slew 360 unhindered. The
excavated soil was transferred using a trailer of volume capacity 15 m3 to
a location located about 300 to 400 metre away from excavation site.
The total amount of soil excavated at lecture gallery site was around
5000 m3 which took around 2 days using one excavator. The total amount
of soil excavated at Hostel building Block G site was around 3075 m3
which took around one and a half day using one excavator. Although, the
soil strata found just below the top loose soil was dense and compact,
after going further down it was found out to be of white in color which
had a low bearing capacity. So, it was decided to fill it with sand upto a
depth of 100 m.m. in the foundation.

4.4 SAND FILLING

After the process of excavation of the proposed site the leveling work
was done by filling sand. Before laying down the P.C.C all the
foundation trenches were filled with sand up to a depth of 100 m.m.
Brick surfaces of 100 mm depth were placed in a grid pattern throughout
the trench of block G of hostel building to facilitate ease of sand filling.
JCBs were used to distribute sand throughout the foundation area, which
were brought and deposited by trailers from nearby riverbed. Sand has a
very low cohesive force and high bearing capacity thus it is provided to
facilitate uniform settlement of foundation.
Around 350 cu.m of sand was required in G and E block of hostel
building. In Lecture Gallery, the sand filling process is still in progress.

4.5 P.C.C
The mixture of cement, fine aggregate (sand) and coarse aggregate is
called plain cement concrete (PCC)
PCC is mainly used for the following purposes :
1. It is used as a protective layer for the RCC above so that water from
the RCC is not absorbed by the earth below.
2. Provides a base for the concrete and also helps workers to set out the
structure above in an easier way
3. Acts as a cover to reinforced cement concrete i.e. resist corrosion of
steel bars in footings
4. Moisture available in soil should not be absorbed by R.C.C
footings which causes corrosion of reinforcement. PCC doesnt allows
the moisture in the soil to reach to the reinforcement in the footings.
After the process of sand filling, laying of plain cement concrete that is
PCC is done. A layer of 100 mm was made in such a manner that it was
not mixed with the soil. It provides a solid base for the raft foundation

and a mix of 1:4:8 that is, 1 part of cement to 4 parts of fine aggregates
and 8 parts of coarse aggregates by volume were used in it. Plain
concrete is vibrated to achieve full compaction. Concrete placed below
ground should be protected from falling earth during and after placing.
Concrete placed in ground containing deleterious substances should be
kept free from contact with such a ground and with water draining there
from during placing and for a period of seven days. When joint in a layer
of concrete are unavoidable, and end is sloped at an angle of 30 and
junctions of different layers break joint in laying upper layer of concrete.
The lower surface is made rough and clean watered before upper layer is
laid. The P.C.C layer was generally made to extend 75 m.m in all
direction form the fixed edges of foundaton.

4.6 Foundation Base Leveling

After excavation of soil, there still exist some minor undulations at the
base of the trench. These may be formed due to the removal of large
boulders and due to the presence of burrows of rodents. Before the
reinforcements are done for the foundation, the base has to be levelled.
So a plain concrete mix is used to fill the crevices and undulations. It acts
as bedding for the foundation and as a damp-proof.

At the site, concrete was of grade M10 made using 40 mm aggregate.

The cement concrete was laid to a thickness of 0.10 m.

4.7 Bar Bending, Placing and Tying

In foundation, the load is distributed over the mat with the help of
reinforcement bars.
The main aim of bar bending schedule is to provide a way in which the

rods when cut and bended provide sufficient strength as well as to

minimize the wastage of rod.
The main requirements of a Bar Bending Schedule are as following:
1. Preparation of bar bending schedule based on the latest GFC
drawings should be done by the Engineer.
2. Bar bending schedule shall clearly specify the following:
a) Bar dia.
b) Numbers.
c) Cut-lengths.
d) Shapes.
3. Bar bending schedule shall take into account the following
field/ design requirement.
a) Desirable lap locations and staggering of laps.
b) Lap lengths.
c) Development length/ Anchorage length.
Cutting, Bending and Placing:
1. All reinforcement shall be free from loose mill scales, loose rust and
coats of paints, oil, mud or any other substances which may destroy or
reduce bond. Use wire brush to clean the reinforcement.
2. Cutting and bending shall conform to the details given in the
approved bar bending schedule.
a) Cutting of Rebar by heat is not permitted, only cutting by grinding
or shearing is permitted.
b) No heating is allowed to facilitate bending of Rebar.
3. Place the reinforcement as per GFC drawings ensuring the following
aspects properly.
a) Type & size of bar. b) Number of bars.
c) Location and lengths of laps, splices.
d) Curtailment of bars.
e) In two way reinforcement, check the direction of reinforcement in
various layers.

f) Adequate number of chairs, spacer bars and cover should be provided.

g) Size of cover blocks.
h) All the bars shall be tied with double fold 18g soft GI annealed
binding wire. 4.Reinforcement may be placed with in the following
tolerance whenever required:
a) For effective depth 200mm or less 10mm.
b) For effective depth more than 200mm 15mm.
c) The cover shall in no case be reduced by more than one third of the
specified cover or 0 /+ 10mm.
d) The cover should suit various cover requirement as per Drawing
Notes.
4. The sequence of reinforcement shall be correlated with fixing of
inserts, sleeves, conduits, anchors and formworks.
6. In walls, place accurately bent spacer bars wired to vertical or
horizontal bars between successive rows.
7. No steel parts of spacers sure allowed inside the concrete cover.
Spacer blocks made from cement, sand and small aggregate shall match
the mix proportion of the surrounding concrete. Alternatively PVC cover
blocks of approved make can be used.
8. Spacers, cover blocks should be of concrete of same strength or PVC
9. Spacers, chairs and other supports detailed on drawings, together
with such other supports as may be necessary, should be used to
maintain the specified nominal cover to the steel reinforcement.
10. Spacers or chairs should be placed at a maximum spacing of 1.0
mtrs and closer spacing may sometimes be necessary.
11. All reinforcement shall be placed and maintained in the positions
shown in the drawing by providing proper cover blocks, spacers,
supporting bars.
12. Rough handling, shock loading (Prior to embedment) and the

dropping of reinforcement from a height should be avoided.

Reinforcement should be secured against displacement.

Drawings of Different columns C1, C2, C3 (Column C1 is same as C2):

4.8 Concreting

The process of selecting suitable ingredients of concrete and determining their

relative amounts with the objective of producing a concrete of the required,
strength, durability, and workability as economically as possible, is termed the
concrete mix design. The proportioning of ingredient of concrete is governed by
the required performance of concrete in 2 states, namely the plastic and the
hardened states. If the plastic concrete is not workable, it cannot be properly
placed and compacted. The property of workability, therefore, becomes of vital
importance.
The compressive strength of hardened concrete which is generally considered to
be an index of its other properties, depends upon many factors, e.g. quality and
quantity of cement, water and aggregates; batching and mixing; placing,
compaction and curing. The cost of concrete is made up of the cost of materials,
plant and labour. The variations in the cost of materials arise from the fact that
the cement is several times costly than the aggregate, thus the aim is to produce
as lean a mix as possible. From technical point of view the rich mixes may lead
to high shrinkage and cracking in the structural concrete, and to evolution of
high heat of hydration in mass concrete which may cause cracking.
The actual cost of concrete is related to the cost of materials required for
producing a minimum mean strength called characteristic strength that is
specified by the designer of the structure. This depends on the quality control
measures, but there is no doubt that the quality control adds to the cost of
concrete. The extent of quality control is often an economic compromise, and
depends on the size and type of job. The cost of labour depends on the
workability of mix, e.g., a concrete mix of inadequate workability may result in
a high cost of labour to obtain a degree of compaction with available equipment.

Requirements of concrete mix design

The requirements which form the basis of selection and proportioning of
mix ingredients are :
a) The minimum compressive strength required from structural
consideration.
b) The adequate workability necessary for full compaction with the
compacting equipment available.
c) Maximum water-cement ratio and/or maximum cement content to give
adequate durability for the particular site conditions
d) Maximum cement content to avoid shrinkage cracking due to
temperature cycle in mass concrete.
Types of Mixes
1. Nominal Mixes
In the past the specifications for concrete prescribed the proportions of
cement, fine and coarse aggregates. These mixes of fixed cementaggregate ratio which ensures adequate strength are termed nominal
mixes. These offer simplicity and under normal circumstances, have a
margin of strength above that specified. However, due to the variability
of mix ingredients the nominal concrete for a given workability varies
widely in strength.
2. Standard mixes
The nominal mixes of fixed cement-aggregate ratio (by volume) vary
widely in strength and may result in under- or over-rich mixes. For this
reason, the minimum compressive strength has been included in many
specifications. These mixes are termed standard mixes.
IS 456-2000 has designated the concrete mixes into a number of grades as M10,
M15, M20, M25, M30, M35 and M40. In this designation the letter M refers to
the mix and the number to the specified 28 day cube strength of mix in N/mm 2.

The mixes of grades M10, M15, M20 and M25 correspond approximately to the
mix proportions (1:3:6), (1:2:4), (1:1.5:3) and (1:1:2) respectively.
3. Designed Mixes
In these mixes the performance of the concrete is specified by the designer but
the mix proportions are determined by the producer of concrete, except that the
minimum cement content can be laid down. This is most rational approach to
the selection of mix proportions with specific materials in mind possessing
more or less unique characteristics. The approach results in the production of
concrete with the appropriate properties most economically. However, the
designed mix does not serve as a guide since this does not guarantee the correct
mix proportions for the prescribed performance.
For the concrete with undemanding performance nominal or standard mixes
(prescribed in the codes by quantities of dry ingredients per cubic meter and by
slump) may be used only for very small jobs, when the 28-day strength of
concrete does not exceed 30 N/mm2. No control testing is necessary reliance
being placed on the masses of the ingredients.
Factors affecting the choice of mix proportions
The various factors affecting the mix design are:
1. Compressive strength
It is one of the most important properties of concrete and influences many other
describable properties of the hardened concrete. The mean compressive strength
required at a specific age, usually 28 days, determines the nominal watercement ratio of the mix. The other factor affecting the strength of concrete at a
given age and cured at a prescribed temperature is the degree of compaction.
According to Abrahams law the strength of fully compacted concrete is
inversely proportional to the water-cement ratio.

2. Workability
The degree of workability required depends on three factors. These are the size
of the section to be concreted, the amount of reinforcement, and the method of
compaction to be used. For the narrow and complicated section with numerous
corners or inaccessible parts, the concrete must have a high workability so that
full compaction can be achieved with a reasonable amount of effort. This also
applies to the embedded steel sections. The desired workability depends on the
compacting equipment available at the site.
3. Durability
The durability of concrete is its resistance to the aggressive environmental
conditions. High strength concrete is generally more durable than low strength
concrete. In the situations when the high strength is not necessary but the
conditions of exposure are such that high durability is vital, the durability
requirement will determine the water-cement ratio to be used.
4. Maximum nominal size of aggregate
In general, larger the maximum size of aggregate, smaller is the cement
requirement for a particular water-cement ratio, because the workability of
concrete increases with increase in maximum size of the aggregate. However,

the compressive strength tends to increase with the decrease in size of

aggregate.
IS 456:2000 and IS 1343:1980 recommend that the nominal size of the
aggregate should be as large as possible.
5. Grading and types of aggregate
The grading of aggregate influences the mix proportions for a specified
workability and water-cement ratio. Coarser the grading leaner will be mix
which can be used. Very lean mix is not desirable since it does not contain
enough finer material to make the concrete cohesive.
The type of aggregate influences strongly the aggregate-cement ratio for the
desired workability and stipulated water cement ratio. An important feature of a
satisfactory aggregate is the uniformity of the grading which can be achieved by
mixing different size fractions.
6. Quality Control
The degree of control can be estimated statistically by the variations in test
results. The variation in strength results from the variations in the properties of
the mix ingredients and lack of control of accuracy in batching, mixing, placing,
curing and testing. The lower the difference between the mean and minimum
strengths of the mix lower will be the cement-content required. The factor
controlling this difference is termed as quality control.
Mix Proportion designations
The common method of expressing the proportions of ingredients of a concrete
mix is in the terms of parts or ratios of cement, fine and coarse aggregates. For
e.g., a concrete mix of proportions 1:2:4 means that cement, fine and coarse
aggregate are in the ratio 1:2:4 or the mix contains one part of cement, two parts
of fine aggregate and four parts of coarse aggregate. The proportions are either
by volume or by mass. The water-cement ratio is usually expressed in mass.

Factors to be considered for mix design

The grade designation giving the characteristic strength requirement of
concrete.
The type of cement influences the rate of development of compressive
strength of concrete.
Maximum nominal size of aggregates to be used in concrete may be as large
as possible within the limits prescribed by IS 456:2000.
The cement content is to be limited from shrinkage, cracking and creep.
The workability of concrete for satisfactory placing and compaction is
related to the size and shape of section, quantity and spacing of
reinforcement and technique used for transportation, placing and
compaction.
Procedure
1. Determine the mean target strength ft from the specified characteristic
compressive strength at 28-day fck and the level of quality control.
ft = fck + 1.65 S
where S is the standard deviation obtained from the Table of approximate
contents given after the design mix.
2. Obtain the water cement ratio for the desired mean target using the emperical
relationship between compressive strength and water cement ratio so chosen is
checked against the limiting water cement ratio. The water cement ratio so
chosen is checked against the limiting water cement ratio for the requirements
of durability given in table and adopts the lower of the two values.
3. Estimate the amount of entrapped air for maximum nominal size of the
aggregate from the table.
4. Select the water content, for the required workability and maximum size of
aggregates (for aggregates in saturated surface dry condition) from table.
5. Determine the percentage of fine aggregate in total aggregate by absolute
volume from table for the concrete using crushed coarse aggregate.

6. Adjust the values of water content and percentage of sand as provided in the
table for any difference in workability, water cement ratio, grading of fine
aggregate and for rounded aggregate the values are given in table.
7. Calculate the cement content form the water-cement ratio and the final water
content as arrived after adjustment. Check the cement against the minimum
cement content from the requirements of the durability, and greater of the two
values is adopted.
8. From the quantities of water and cement per unit volume of concrete and the
percentage of sand already determined in steps 6 and 7 above, calculate the
content of coarse and fine aggregates per unit volume of concrete from the
following relations:

where V = absolute volume of concrete

= gross volume (1m3) minus the volume of entrapped air
Sc = specific gravity of cement
W = Mass of water per cubic metre of concrete, kg
C = mass of cement per cubic metre of concrete, kg
p = ratio of fine aggregate to total aggregate by absolute volume
fa, Ca = total masses of fine and coarse aggregates, per cubic metre
of concrete, respectively, kg, and
Sfa, Sca = specific gravities of saturated surface dry fine and coarse
aggregates, respectively
9. Determine the concrete mix proportions for the first trial mix.
10. Prepare the concrete using the calculated proportions and cast three cubes of
150 mm size and test them wet after 28-days moist curing and check for the
strength.

11. Prepare trial mixes with suitable adjustments till the final mix proportions are
arrived at.

4.9 Curing
Curing is the process of controlling the rate and extent of moisture loss from
concrete to ensure an uninterrupted hydration of Portland cement after concrete
has been placed and finished in its final position. Curing also ensures to
maintain an adequate temperature of concrete in its early ages, as this directly
affects the rate of hydration of cement and eventually the strength gain of
concrete

or

mortars.

Curing of concrete must begin as soon as possible after placement & finishing
and must continue for a reasonable period of time as per the relevant standards,
for the concrete to achieve its desired strength and durability. Uniform
temperature should also be maintained throughout the concrete depth to avoid
thermal shrinkage cracks. Also protective measures to control moisture loss
from the concrete surface are essential to prevent plastic shrinkage cracks.

In a nut shell, curing process is designed primarily to keep the concrete moist by
controlling the loss of moisture from the body of concrete, during the given
period in which it gains strength.

After placing of concrete, shutters were removed and continuous curing was
done for concreting work for seven days.

5.0 CONCLUSION
In conclusion, there were many things that Ive experienced and learned
during these 2 months of my Industrial Training at Shapoorji Pallonji Co.
& Ltd. The whole training period was very interesting, instructive and
challenging. Through this training I was able to gain new insights and
more comprehensive understanding about the real industry working
conditions and practice. The 2 months placement also has provided me
the opportunities to develop and improve my functional skills. All of this
valuable experience and knowledge that Ive gained were not only
acquired through the direct involvement in task given but also through
other aspects of the training such as work observation, interaction with
colleagues, superior, and other third party related to the company. From
what Ive undergone, I fully agree that the Industrial Training program
has achieved its entire primary objective. It is also the best way to prepare
student in facing the real working life as a result of the program Im more
confident to enter the employment world and build my future career.