Industrial Case Study Report on

CONSTRUCTION OF RESIDENTIAL BUILDING

Submitted in partial fulfillment of the requirement of the degree of

Bachelor of Technology in Civil Engineering,

Jawaharlal Nehru Technological University, Hyderabad

Submitted by

N. PRANAY KUMAR (12H61A0140)

Under the guidance of

Mr B. Ravi Chand

Assistant Professor

2015-2016

DEPARTMENT OF CIVIL ENGINEERING

ANURAG GROUP OF INSTITUTIONS, VENKATAPUR, HYDERABAD

DEPARTMENT OF CIVIL ENGINEERING

ANURAG GROUP OF INSTITUTIONS

VENKATAPUR, HYDERABAD

CERTIFICATE

This is to certify that it is a bonafide report of mini project entitled Construction of

Residential Building carried out by N. Pranay Kumar (12H61A10140) of the final year

B.Tech. Civil Engineering during the academic year 2015-2016 in partial fulfillment of the

requirement for the award of the degree of Bachelor of Technology (Civil Engg.) offered by

the Jawaharlal Nehru Technological University, Hyderabad

Dr K. R. C. Reddy Mr B. Ravi Chand

HOD Guide

Date : July, 2015

Place: Hyderabad

ACKNOWLEDGEMENT

I am very thankful to Ramky group for having given me the opportunity to undertake my

industrial case study at their prestigious Ramky One Kosmos Phase-I project. It was a very

good learning experience for me to have worked at this site.

I would like to convey my heartiest thanks to Mr M. V. Rami Reddy, Head

operations, Ramky group, who heartily welcomed me for the industrial training program.

I would also like to give my heart- felt thanks to Mr K. Anjaneyulu, Project Co-

ordinator of the Ramky One Kosmos construction.

I extend my warm thanks to the Quality control engineer Mr Jan Basha Shaik, in

letting me know the various quality aspects at the construction site.

I am very thankful to Mr Tirupal, Engineer who took time of his busy schedule to

share with me his valuable experiences in the construction site and always lend an ear to my

queries and thoughts.

I express my thanks to all sections Head & the staff members of the Ramky One

Kosmos site for their kind help and support extended throughout this training and for having

made this training a memorable one.

I would like to thank Prof. M. Mutha Reddy, Principal, CVSR college of

engineering.

I express my sincere thanks to Dr K. R. C. Reddy, Head of Civil Engineering

department for his support and guidance for doing the project.

I express my deep gratitude to my guide Mr B. Ravi Chand, Assistant professor,

Department of Civil Engineering, for his guidance and care taken by him in helping me to

complete the project work successfully.

Abstract

This Industrial Case Study Report in broad-spectrum contains eight chapters in which I try to

explain my observations and experience at the construction site of Ramky One Kosmos in

Hyderabad. The content of all chapters is broadly explained and it is constructed from the

practical basis of the site work.

This report includes the description of project, ownership details, structural details

and drawings related the building as per my observation at the construction site. Then the

following chapter gives overview of materials used and their source and equipment used in

the construction site. After all those chapters this report explains the human resource

management, quantity estimation and role of safety management in the construction site.

Finally the details of the work experienced during the training period and my daily activities

are described in this report. At the end of conclusion it is found that the training was meant to

understand the deviation of the practical construction work from theoretical knowledge.

Contents

Page No.

Chapter-I Introduction 1

1.1 Description of the project 1

1.2 About the the organization 1

1.2.1 Overview 1

1.2.2 Vision, Mission and Values of the company 2

1.3 Project location 3

Chapter-II Details of the project 4

2.1 Introduction 4

2.2 Project details 5

2.3 Details of structure 5

2.4 Execution of work 6

2.5 Earth work in excavation 7

2.6 Footings 8

2.7 Backfilling 10

2.8 Columns 10

2.9 Beams and Slabs 12

2.9.1 Beams 12

2.9.2 Slab 13

2.10 Staircase 15

2.11 Lift walls 16

2.12 Retaining walls 16

2.13 Arrangement of rooms 16

2.14 Block masonry 18

2.15 Lintels 18

2.16 Plastering 18

2.17 Curing of concrete 19

2.18 Design mix data 20

2.19 Conclusion 20

Chapter- III Material Details 21

3.1 Introduction 21

3.2 Materials used 21

3.2.1 Concrete blocks 21

3.2.2 Aerocon blocks 21

3.2.3 Coarse and fine aggregates 22

3.2.4 Cement 22

3.2.5 Water 23

3.2.6 Fly ash 23

3.2.7 Admixture 23

3.2.8 Steel 24

3.2.9 Cover blocks 24

3.2.10 Shuttering or Formwork 25

3.2.11 Scaffolding 26

3.3 Source of materials 27

3.4 Testing of materials 28

3.4.1 Tests on cement 28

3.4.2 Tests on aggregates 30

3.4.3 Test on fresh concrete 32

3.4.4 Compression test 33

3.5 Equipment used 34

3.6 Batching plant 36

3.7 Conclusion 37

Chapter- IV Human Resource Management 38

4.1 Introduction 38

4.2 Project team 38

4.3 Conclusion 39

Chapter- V Estimation 40

5.1 Introduction 40

5.2 Methods of building estimate 40

5.3 Schedule of bars 41

5.4 Conclusion 43

Chapter- VI Safety Management 44

6.1 Introduction 44

6.2 Various safety measures 44

6.3 Conclusion 45

Chapter- VII Work experience 46

7.1 Introduction 46

7.2 Daily activities 46

7.3 Challenges I have faced 49

7.4 Overall benefits 49

Chapter – VIII Conclusion 50

List of figures Page no.

Fig. 1.1: Location of the project 3

Fig. 2.1: Ramky One Kosmos phase- I project 4

Fig. 2.2: Arial view of Ramky One Kosmos Phase- I project 5

Fig. 2.3: Current position of the construction project 7

Fig. 2.4: Block- C footing details 9

Fig. 2.5: Typical isolated footing & pedestal details 9

Fig. 2.6: Typical combined footing details 10

Fig. 2.7: Block-G, Flat no. 04, Columns layout 11

Fig. 2.8: Block-G, Flat no. 04, Columns details 12

Fig. 2.9: Curtailment of bars in beams 13

Fig. 2.10: Typical slab details (Block- C) 14

Fig. 2.11: Typical curtailment details of slab reinforcement 15

Fig. 2.12: Lift walls 17

Fig. 2.13: Retaining walls 17

Fig. 2.14: Room dimension details of Block-G, 6th

floor, flat no. 04 17

Fig. 2.15: Lintel over door opening 19

Fig. 2.16: Ponding water over slab 19

Fig. 3.1: Beam cover blocks 25

Fig. 3.2 : Erection of shuttering 26

Fig. 3.3: Column formwork 26

Fig. 3.4: Scaffolding 26

Fig. 3.5: Quality control lab at the site 28

Fig. 3.6: Vicat apparatus 31

Fig. 3.7: A set of IS sieves 31

Fig. 3.8: Compression testing machine 33

Fig. 3.9: Concrete blocks stored in water before testing 33

Fig. 3.10: Back hoe 34

Fig. 3.11: Roller 34

Fig. 3.12: Crushers 35

Fig. 3.13: Tower crane 35

Fig. 3.14: Builder hoist 35

Fig. 3.15: Concrete transist mixer 35

Fig. 3.16: Concrete pumping machine 35

Fig. 3.17: Batching plant 36

Fig. 3.18: Concrete blocks making machine 36

Fig. 5.1: Details of measurement and calculation of quantities- Slab concrete 41

Fig. 5.2: Schedule of bars- RCC slab 42

Fig. 6.1: Safety nets 44

Fig. 6.2: Fire extinguishers 44

Fig. 6.3: Ambulance 44

Fig. 6.4: Project safety statistics 45

Fig. 6.5: Safety park 45

Fig. 7.1: Laying of footing reinforcement for parking ramp 47

Fig. 7.2: Laying of pedestal for parking ramp 47

Fig. 7.3: Arrangement of reinforcement in Block- C, 10th

level slab 48

Fig. 7.4: Concrete block work 48

Fig. 7.5: Plumbing work 48

List of tables

Page no.

Table 2.1: Block wise details 6

Table 2.2: Reinforcement details of slabs (Block-C) 14

Table 2.3: Client (REFL) approved design mix data sheet 20

Table 3.1: Size od cover blocks details 24

Table 3.2: Formwork removal period in the site 26

Table 3.3: Materials and their source 27

Table 3.4: Physical properties of cement (OPC 53 grade) test results 30

Table 3.5: Characteristics of fine aggregate 31

Table 3.6: Characteristics of coarse aggregate 32

Table 3.7: Recommended slumps for various concrete works (in ‘mm’) 32

Table 3.8 Compressive test results 33

Table 4.1: Project teams 39

1

Chapter - I

Introduction

1.1 Description of the project

Ramky One Kosmos is a luxurious residential project from Ramky Estates & Farms

Limited located at Nallagandla, Gachibowli, 3.5 km away from Lingampally having

longitude 78.307580 and latitude 17.460428. This is one of the ongoing residential

developments of Ramky Group.

The construction of the structure has been assigned to Ramky Infrastructure

Limited, Hyderabad.

The building has been designed by Architect Vernekar Associates Pvt. Ltd.,

Bangaluru, the structural consultants are ISA structural studio, Bangaluru, the MEP

consultants are Synergy infra Consultants Pvt. Ltd., Hyderabad and the landscape

consultants are Dhruva Associates, Bangaluru. The Project Management Consultants

(P.M.C) are CBRE India. Quality control consultants are Testwell Pvt. Ltd., Hyderabad,

National Accreditation Board for Testing and Calibration Laboratories, India and

JNTUH college of Engineering, Hyderabad.

1.2 About the Organization

1.2.1 Overview

Ramky Group is the one of the leading organization in the infrastructure development and

environment management sectors with a turnover of more than Rs. 4,500 crores. Ramky

group was founded in 1994 by Alla Ayodha Rami Reddy. The company originally

incorporated as Ramky Engineers Private Limited to undertake construction projects. Since

commencing their business they have serviced a diverse range of projects in sectors as varied

as water and waste water, transportation, irrigation, industrial parks (including SEZs), power

2

transmission and distribution, residential, commercial and retail property. Headquartered in

Hyderabad, Telangana. The Ramky Group has a pan-India presence with more than 500

project locations across 23 States (including Union Territories). In overseas it has offices in

Sharjah, UAE and Singapore and it’s footprints can be seen in U.S.A, Saudi Arabia,

Vietnam, China, West Africa and Peru.

Major operations of the group are conducted through the following companies:

Ramky Infrastructure Limited (RIL)

Ramky Enviro Engineers Limited (REEL)

Ramky Estates and Farms Limited (REFL)

Ramky Finance & Investments Limited (RFIL)

Ramky Life Sciences Limited (RLSL)

1.2.2 Vision, Mission and Values of the company

Vision

Their vision to the future is becoming a leading global enterprise in world class infrastructure

development and environment through sustainable growth.

Mission

Guided by their vision, they shall ensure quality, reliability and continuous technology

upgradation thereby enhancing the value of all stakeholders.

Values

Ramky group has following basic values:

Integrity

Customer Satisfaction

Work Culture

Employee Sense of Belonging

3

Innovation

Safety, Health & Environment

Social Commitment

1.3 Project Location

Fig. 1.1: location of the project

4

Chapter - II

Details of the project

2.1 Introduction

Ramky One Kosmos is the ideal representation of being “close to town and close to nature”.

The Ramky One Kosmos lacated in a well developed area replete with the best of social

infrastructure, the project is located at Hyderabad in close proximity to the IT hub, Financial

District and the country’s best educational institutions including University of Hyderabad,

TATA Institute of Fundamental Research, Indian School of Business, the Sancta Maria

School and Epistemo Global School, in addition to best multispecialty hospitals such as

Citizens Hospital and American Oncology Institute as well as Outer Ring Road, Inorbit Mall

and Gachibowli Stadium.

Fig. 2.1: Ramky One Kosmos phase –I project.

5

2.2 Project Details

The project is aesthetically designed with multi level green terraces, soothing views and a

host of amenities for healthy, harmonious and comfortable living. It is coming up on an area

of about 13.5 acres and the project shall be delivered in two phases. Currently, construction

of phase – I is going on an area of about 4.75 acres. Ramky Infrastructure Limited (RIL) has

started the phase – I construction in October 2013 which is of about Rs 140 crore budget.

The phase – I will have a total of 7 towers having ground + 14 floors and the builder is

offering 466 flats of the type 2 and 3 BHK. The area of the flats range from 1070 sq.ft. to

1635 sq.ft. and the builder is offering flats for a base price of Rs. 3,899 per sq. ft. The phase -

I project is scheduled to complete by October 2016.Ramky One Kosmos will have a lot of

amenities such as clubhouse built on an area of 20000 sq.ft. which will also have a swimming

pool and a gymnasium. There also is provision for AC guest rooms, a grocery store, half

basketball court, a tennis court, toddler play area and landscaped gardens.

Fig. 2.2: Describes an arial view of Ramky One Kosmos Phase –I project

2.3 Details of Structure

The phase – I project consists of 7 towers.

Block wise detail of the number of stories in each block:

6

Table 2.1: Block wise details

Block –A 2B + G + 14 6 Flats

Block –B 1B + G + 14 5 Flats

Block –C 1B + G + 11 5 Flats

Block –D 2B + G + 14 4 Flats

Block –E 2B + G + 14 5 Flats

Block –F 2B + G + 11 4 Flats

Block –G 2B + G + 14 5 Flats

The subsurface floors designed for parking purpose.

These subsurface floors are well protected by retaining walls.

Each block consists of 2 lift wells and 1 stair case.

2.4 Execution of work

1. Site/ jungle clearance

2. Markings using total station

3. Earth work excavation

4. footings

5. backfilling

6. plinth beam

7. columns

8. beams and slab

9. brick work

10. service fittings

11. plastering

12. flooring

13. tiling

14. dadoing

15. ceiling

16. finishing.

7

Fig. 2.3 : Current position of the construction project.

2.5 Earth work excavation

Once the R.L of every point is known and the top level of the plinth beam is specified in the

drawings the depth of the foundation can be determined accordingly by subtracting the

depths of plinth beam, pedestal, footing and p.c.c. The value of maximum depth is

considered and till that depth a box type excavation is done with some extra clearance to

work. Even if after the excavation to the required depth if there is no hard soil the excavation

is to be continued. Earth excavators are brought in to the location to start the work. Auto

level is to be fixed at a reference position in order to check the depth of excavation being

8

done during the process. During the excavation it is very important to consider the lift and

lead of the material as sometimes it may be used for backfilling.

At the site:

Depth of excavation: 5-6m from ground level

Soil present: Clayey soil

Rock present: Granite

2.6 Footings

Once the excavation is done now using the foundation drawing the center and four corners of

each footing in built-up area is marked using total station. And formwork is erected for

laying p.c.c for each footing. If the area at a footing has rock bed it is chipped off to a small

thickness and 25mm diameter holes are drilled into it and anchor bars of 20 mm diameter are

placed into it up to 600 mm depth and filled with lean concrete of 1:3:6 in level. If it has no

rock bed then formwork is raised and p.c.c is casted into it. Now it is cured for 7 days and

then the footing steel is laid over it after it is laid the supervisor should carefully check it and

give permission for casting. In a similar way pedestal and column is also casted. Once all the

footings are casted they are checked using the auto level for the bending and height

variations of all footings.

At the site:

Grade of concrete: M 25

Cover: 75 mm

Reinforcement: 10mm, 12mm and 16mm diameter steel bars

P.C.C. : 100 mm thick (M 7.5 grade of concrete)

9

Fig. 2.4: Block-C footings details

Fig: 2.5 Typical isolated footing & pedestal details

10

Fig.2.6: Typical combined footing details

2.7 Backfilling

The backfilling is to be done only after curing time of the footing. The backfill is to be done

in layers. Each layer of backfill should not be more than 200mm. Then each layer is

compacted to 95% of dry density at optimum moisture content.

2.8 Columns

Column is a compression member whose effective length is greater than 3 times the least

dimension of the member i.e., (leff / b)>3. Minimum eccentricity for axial loaded columns,

emin = (Unsupported length of the column/ 500) + (Lateral dimension/ 30) subjected to a

minimum of 20mm.

11

At the site:

Grade of concrete: M 30

Reinforcement: 12mm, 16mm, 20mm and 25mm diameter steel bars with stirrups of 8mm

diameter steel bar.

Stirrup spacing: 200mm center to center.

Fig. 2.7: Block – G, flat no. 04, Columns layout.

12

Fig. 2.8: Block- G, Flat no. 04, Columns details.

2.9 Beams and Slabs

Beams are the horizontal members of a structure carrying transverse loads whereas Slab is a

large, thick, flat piece typically rectangular or square in shape. Beams and Slabs are laid

monolithically to achieve a consistent in the entire structure. They can also pour in non-

monolithically. Both methods will work fine as long as the construction joints are wisely

chosen.

2.9.1 Beams:

Beams are of two types based on reinforced sections. If beam reinforced on tension side in

the direction of bending is called singly reinforeced section and if reoinforced on both

tension and compression sides is called doubly reinforced beams. Different types of beams

based on support conditions are simply supported beam, cantilever beam, fixed beam,

13

continous beam and overhanging beam. In side face reinforcement if total depth exceed 450

mm and beam is subjected to torsion and if total depth exeeds 750mm and beam not

subjected to torsion.

As per codal specifications: Effective span: smaller of the following two criterion. a)

Distance b/w centre to centre of supports. b) Clear distance b/w supports plus effective depth

of slab. c) For cantilevers, clear overhang + (d/2).

Fig. 2.9: Curtailment of bars in beams

2.9.2 Slab:

Types of slab:

1) Slabs spanning in one direction: Supported at two opposite ends.

2) Slabs supporting on all four side:These are futher classified into two types based on aspect

ratio (ly /lx ).

a) One way slabs: if (ly/lx) > 2. b) Two way slabs: if (ly/lx) < 2.

Loads acting on the slab are:

Dead load of slab.

Load of floor finish.

Live load.

Basic values of span to effective depth ratios for spans upto 10m: Cantilever – 7, Simply

supported - 20, Continuous – 26

If two way slabs of small spans upto (3.5 m) with mild steel span to over all depth

ratios for loading class upto 3 kN/m2 are, Simply supported slabs- 35, continuous- 40

14

At the site:

Grade of concrete: M20

Fig. 2.10: Typical Slab details (Block- C)

Table 2.2: Reinforcement details of slabs (Block-C)

S. No. Name Slab

thickn

ess (in

mm)

Reinforcement

along short span

Reinforcement

along long span

Bottom Top Bottom Top

1 S1 130 8mm dia -125

C/C

1- 8 mm dia

(ext)

8mm dia –

175 C/C

1-8 mm dia

(ext)

2 S2 130 8mm dia -250

C/C

1-8 mm dia

(ext)

8mm dia –

300 C/C

-

3 S3 150 8mm dia -150

C/C

1-8 mm dia

(ext)

8mm dia –

250 C/C

-

15

4 S4 150 8mm dia -175

C/C

1-8 mm dia

(ext)

8mm dia –

200 C/C

1-8 mm dia

(ext)

5 S5 130 8mm dia -300

C/C

1-8 mm dia

(ext)

8mm dia –

300 C/C

1-8 mm dia

(ext)

6 S6 130 8mm dia -

200C/C

1-8 mm dia

(ext)

8mm dia –

250 C/C

1-8 mm dia

(ext)

Fig.: 2.11: Typical Curtailment details of Slab reinforcement

2.10 Staircase

A staircase is a sequence of steps and it is provided to afford the means of ascent and descent

between the floors and landings. The space or opening occupied by the stair is called stair

way. This should be located in an easily accessible to all members of the family.

The step is composed of a tread and riser. Tread is a part of the stairway that is stepped

on. Width of each tread is 300mm. The riser is a vertical portion between each tread on the

stair. Depth of each riser is 150mm or 170mm.

At the site:

Tread: 300 mm

Riser: 150mm or 170mm

Grade of concrete: M20

16

2.11 Lift walls

Lift walls are which encloses a lifting machine. The inner surface of all walls shall form a

continuous vertical surface. The lift walls shall have sufficient structural strength to support

at least the loads which may be applied by the machine, gear operations, jacks, guides and

loads in the machine.

At the site:

Grade of concrete: M 30

Reinforcement: 12mm, 16mm, 20mm and 25mm diameter steel bars

2.12 Retaining walls

A retaining wall is a structure that holds or retains soil behind it. Where the height of the

retaining wall is several feet, the earth may put considerable stress on the wall. Therefore, it

is important to build the wall according to the plans of the designer.

At the site:

Grade of concrete: M20

Reinforcement: 10mm & 12mm diameter steel bars.

2.13 Arrangement of rooms

Living room

Dining hall

Kitchen

Bedroom

Toilet

Utility

17

Balcony

Fig. 2.12: Lift walls Fig. 2.13: Retaining wall

Fig. 2.14: Room dimension details of Block- G, 6th

floor, flat no. 04

18

2.14 Block masonry

Block masonry is an art of individual blocks laid in and bound together by mortar in a proper

systematic manner gives homogeneous mass which can withstand forces without

disintegration. There are many rules for bonding and they are mainly related to the different

bonds such as the English bond, the Flemish bond, the Stretcher bond and the Header bond.

Bonding shall be in such a way that no vertical joint of one course is exactly over the one

below. The maximum block wall height per day should not exceed more than 12 to 14 layers.

Because the added weight by each new brick layer needs to be carried by the mortar.

At the site:

Thickness of wall: 200mm, 150mm & 100mm

2.15 Lintels

Lintel is a horizontal flexural member which spans over the openings in the walls for doors,

windows, ventilators, cupboards etc. The load of masonry above the opening is transferred to

the wall by flexural action of the lintel so that frames of doors, windows etc. are not unduly

loaded. The end bearings for the lintel should be at least 200 mm. The width of lintels is

same as that of wall.

2.16 Plastering

Plastering is the process of covering rough surfaces of walls, columns, ceilings and other

building components with thin coat of mortars to form a smooth durable surface. The coating

mortar is termed as plaster. Plastering is done to achieve the following objects:

To protect the external surfaces against penetration of rainwater and other atmospheric

agencies.

To give smooth surface in which dust and dirt cannot lodge.

To give decorative effect

19

To protect surfaces against vermin.

To conceal inferior materials or defective workmanship.

At the site:

Internal plastering: 15mm of double coat .

External plastering: 20mm of double coat.

Mortar mix: 1:5 internal; 1:4 & 1:6 external

Ceiling plastering: 12mm single coat

Fig. 2.15: Lintel over door opening Fig. 2.16: Ponding water over slab.

2.17 Curing of concrete

The development of strength of concrete is due to ‘Hydration of cement’ that takes place

only due in water filled capillaries. If strength development has to continue, water shall be

present in pores without evaporation till development of strength is complete. The

environment provided for proper hydration of cement paste in cement concrete is called

curing of concrete.

Lintel

20

2.18 Design mix data

Table 2.3: Client (REFL) approved design mix data sheet

Source: Batching plant

S. No. Description of

material

Grade & weight of material in (kgs)

M7.5 M20 M25 M30

1 Cement 120 256 272 300

2 Flyash 120 64 68 70

3 20 mm aggregate 558 640 650 649

4 12mm aggregate 457 430 430 457

5 CRF (dust) 913 800 780 745

6 Admixture 1.7 2.3 2.4 3.0

7 Water 189 185 185 184

2.19 Conclusion

In this chapter I have understood that every construction project is unique in a variety of

ways. Each construction project is built as a one-of-a-kind structure or facility. The

construction of a building will consists of many separate tasks, starting with excavation for

drainage and foundation, then footings, followed by laying columns, beams, slab and soon. It

is very important however to note that there is much interdependence between these tasks,

they must be carried out in the correct sequence and the scope for overlapping them is very

limited.

21

Chapter – III

Material Details

3.1 Introduction

Building materials are items and products used within the construction of building and

structures. In ideal environments, most common construction materials are very durable and

can last indefinitely. However, design or construction deficiencies or lack of proper

maintenance can result in less than ideal conditions under which construction materials will

degrade. Degradation can take many forms, including chemical reactions, consumption by

living organisms and erosion or mechanical wear. Traditional materials which are used in

construction are steel, concrete and wood.

3.2 Materials used

3.2.1 Concrete Blocks:

At the site, solid concrete blocks in the size of 400mm x 200mm x 100mm, 400mm x 150mm

x 150 mm and 400mm x 200mm x 200mm have been used for block masonry. These blocks

made with mixture of cement, dust, 6mm size aggregates and water. Concrete blocks must be

of good quality and without visible cracks for a load-bearing wall. Generally, the blocks

should be true to size and shape, with straight edges and even surface, so as to facilitate

laying them into position without using too much mortar.

3.2.2 Aerocon Blocks:

Interestingly, Aerocon blocks were used to build some walls to reduce the load acting. The

Aerocon blocks are Autoclaved Aerated concrete (AAC) blocks made with a mixture of

cement, fly ash, lime, an aerated agent and water. These blocks in the size of 600mm x

22

200mm x 150mm have been used for block masonry. The characteristics of these blocks are

light weight, fire resistance, sound insulation, thermal insulation, strength and durability,

perfect finish and dimensional stability and consistent quality control. The only concern with

Aerocon block is their higher price when compared to the traditional bricks.

3.2.3 Coarse and fine aggregates

Aggregates are of two types: Fine and coarse aggregates. According to IS 383, fine

aggregates are defined as aggregate most of which will pass through 4.75 mm IS sieve and

entirely retained on 75 µ sieve and coarse aggregate is which retained on 4.75 mm sieve and

pass through 80 mm sieve. Rounded particles produce smoother mix for a given water

cement ratio. Crushing strength of good aggregate is about 299 N/mm2.

3.2.4 Cement

Cement is a mixture of 60 to 65% lime, 16 to 25% silica and 3 to 8% alumina, which are

intimately mixed together with water to form into a slurry, which is subsequently heated,

dried, calcined and ground to a very fine powder. A small proportion of gypsum is added

before grinding in order to control the rate of setting. When water is added to cement, the

cement hydrates and during the chemical reactions, which takes place while the cement is

setting, an increase in temperature occurs and a considerable quantity of heat is generated.

Ordinary Portland Cement of 53 grade kind of cement has been used at the site.

Cement can be safely stored in bags for a few months if kept in a dry room. During the

monsoon time, the cement storage plays an even more role, since the relatively higher

humidity accelerates the deterioration process of the cement.

Ordinary Portland cement, which has been stored for over six months, should not be

used for masonry work.

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3.2.5 Water

The workability of a mortar increases as the water content of the mix is increased. Water

lubricates the mixture. However, increased water content will cause a decrease in strength,

produce cracks (shrinkage) and decrease density. Therefore, not only the quality, but equally

important the quantity of the water is important for producing a good mortar and brick

masonry work. Water should be stored where no contamination is possible. Water stored in

clean drums or covered tanks is preferred. The age of water, or the storage time does not

affect the cement mortar quality in any way.

3.2.6 Fly ash

Fly ash is one of the residues generated in combustion of coal. Fly ash comprises of fine

particles which rise with the flue gases. Fly ash, being primarily pozzolanic, can actually

replace a percentage of the Portland cement, to produce an even stronger, more durable and

more environment friendly concrete. The initial compressive strength is low but as days pass,

fly ash concrete gains more strength and eventually has a lot more strength as compared to

normal Portland cement

3.2.7 Admixture

Admixtures are additives that are introduced in a concrete mix to modify the properties of

concrete in its fresh and hardened states. Daracem927-Grace has been used in concrete mix

as an admixture agent at the site. Daracem is an aqueous solution of chemical dispersants

combined with other chemicals which increase its beneficial effects on the quality and

plasticity of a concrete mix. Daracem provides improved slump retention in flowable

concrete. It is ideal for low water/cement ratio concrete designed for high early compressive

and flexural strengths with exceptional workability and flow characteristics.

24

3.2.8 Steel

Concrete is much weaker in tension than in compression. Its tensile strength is approximately

10% of its compressive strength. Therefore, concrete is generally used in conjunction with

steel reinforcement, which provides the tensile strength in concrete members. Steel also

bonds well with concrete. The bond between steel and concrete is due to the chemistry of the

two material, which produces a chemical bond between them.

Steel particulars of 8mm, 12mm, 16mm, 20mm, 25mm and 32 mm diameter Fe 500

grade TMT steel bars have been used in the site.

3.2.9 Cover Blocks

Cover blocks are placed to prevent the steel rods from touching the shuttering plates and

there by providing a minimum cover and fix the reinforcement as per the drawings.

Sometimes it is commonly seen that the cover gets misplaced during the concreting activity.

To prevent this, tying of cover with steel bars using thin steel wires called binding wires is

recommended. Ideally, cover should have strength similar to the surrounding concrete, with

least perimeter so that chances of water to penetrate through periphery will be minimized.

Provision of minimum covers as per the Indian standards for durability of the whole structure

should be ensured.

Table 3.1: Size of cover blocks details

Structural Element Cover to reinforcement (mm)

Footing 50

Columns 40

Plinth beam 25

Retaining wall 25 for earth face & 20 for other face

Slabs 15

Lift wall 15

Beams 25

25

Fig. 3.1: Beam cover blocks

3.2.10 Shuttering or Formwork

As fresh concrete is in plastic state when it is placed for construction purpose so, it become

necessary to provide some temporary structure to confine and support the concrete till it

gains sufficient strength for self- supporting. The term shuttering or formwork includes all

forms, moulds, sheeting, shuttering planks, poles, posts, standards, struts, bolts, wedges and

all other temporary supports. Formwork shall be made to the exact dimensions within the

permissible tolerances. Required thickness and quality of plywood conforming to IS 6461

shall be used to meet the requirements of design and surface finish. For satisfactory

performance, formwork must be adequately strong and stiff to carry the loads produced by

concrete, the workers placing and finishing the concrete and any equipment or materials

supported by the forms.

Form work was removed in such a manner as would not cause any shock or vibration that

would damage the concrete. Before removal of props, concrete was exposed to ascertain that

the concrete has sufficiently hardened.

As a guideline with temperature above 20 degree following time limits should be

followed:

Cover block

26

Table 3.2: Formwork removal period in the site

Structural Component Age

Footing 1 day

Sides of beams, columns, lintels & wall 2 days

Underside of beams spanning less than 6m 14 days

Underside of beams spanning over 6m 21 days

Underside of slabs spanning less than 4m 7 days

Underside of slabs spanning more than 4m 14 days

Flat slab bottom 21 days

Fig. 3.2: Erection of shuttering Fig. 3.3: Column formwork Fig. 3.4: Scaffolding

3.2.11 Scaffolding

Scaffolding also called staging is the basis of most construction projects it is a temporary

structure used to support a work crew and materials to aid the construction, maintenance and

repair of buildings. This consists of a frame work of standards, ledgers, putlogs etc.,

constructed parallel to the wall at a distance of about 1.20 metres. The standards were placed

at 2 to 2.5m interval. Ledgers connected the standards and were provided at a vertical

27

interval of 1.2 to 1.5 m. Putlogs were placed with one end on the ledgers and other end in the

hole left in the wall, at an interval of 1.2 to 1.5m.

3.3 Source of materials

Table 3.3: Materials and their sources

Material Source

Cement ( OPC 53 grade) Nagarjuna cements ltd.

ACC cements ltd.

Birla Shakti cements ltd.

Fine aggregates (Crushed Rock Fines) Ramky One Kosmos, Nallagandla, Hyderabad.

Coarse aggregates (Angular crusher

broken coarse aggregate of max. size

10mm & 20mm)

Ramky One Kosmos, Nallagandla, Hyderabad.

Steel ( Fe 500 TMT bars)

Particulars: 8mm, 12mm, 16mm, 20mm,

25mm & 32mm

Electro steel ltd.

JSW steel ltd.

VSP steel

ESSAR steel ltd.

SAIL- Steel Authority of India.

MS Agarwal foundries (p) ltd.

Drinking water Borewell

Vengamamba supplier

Water for construction activity Vebgamamba supplier

Fly ash NTPC – Vijayawada

Solid blocks Ramky One Kosmos, Nallagandla, Hyderabad.

Aerocon Blocks Aerocon Enterprise, Hyderabad.

28

3.4 Testing of Materials

Right selection of quality materials adds to the economy and service life of a structure. The

design of structures is usually based on the presumption that each of the materials to be used

in construction of a typical structure has certain characteristics, this presumption makes its

mandatory to verify that the materials used in construction have the assumed characteristics.

This can only be ensured by regular testing of materials according to certain standards which

will provide a clear picture of material characteristics. Following are the tests which have

been performed by me at quality control lab under guidance

Fig. 3.5: Quality Control lab at the site.

3.4.1 Tests on cement

a) Fineness

It is an index of grinding.

Determined by sieving through 90 µ (IS sieve no. 9)

The residue after sieving should not exceed 10% by weight for OPC.

29

b) Consistency

Consistency of cement means the percentage of water required to make a workable

cement paste.

Determined by Vicat’s apparatus using Vicat’s plunger (1cm diameter)

As per Vicat’s test “ The percentage of water added to the cement at which the needle can

not penetrate 5 to 7 mm from bottom of the mould is called consistency”..

For OPC consistency is around 30%.

c) Initial setting time

The time at which cement starts setting process.

Determined by Vicats’s apparatus using Vicat’s needle (1mm square needle)

For the test cement is mixed with 0.85 times the water required for standard consistency.

As per Vicat’s test “the time lapsed since the addition of wter to the cement up to the time

at which the needle can not penetrate 5 to 7 mm from the bottom of the Vicat’s mould.

For OPC initial setting time should not be less than 30 minutes.

d) Final setting time

The time at which the cement ends its setting process and becomes hard.

Determined by Vicat’s apparatus using Vicat’s needle with annular collar of 5mm

diameter.

As per the test “ the time lapsed since the addition of water to the cement up to the time at

which needle with annular collar can only make a mark on the hard cement surface.

For OPC final setting time should not be more than 10 hours.

e) Soundness

The expansion of cement due to the presence of free lime and magnesia is called un-

soundness.

30

Determined by Le-chatlier apparatus.

For the test cement is mixed with 0.78 times the water required for standard consistency.

As per the test apparatus the expansion should not be more than 10mm for the cement to

be sound.

If the expansion exceeds 10mm after standard test procedure, the cement should not be

used.

f) Specific gravity of cement:

Using kerosene and specific gravity bottle the test is conducted at 270 C.

For OPC specific gravity is around 3.1.

Table 3.4: Physical properties of cement (OPC 53 grade) test results.

Sl.

No.

Test Conducted Results Requirement as Per IS: 12269-

2013 (Table 3) (Foreword &

Cl. 6)

1. Initial setting time (minutes) 202 30 (minimum)

2. Final setting time (minutes) 254 600 (maximum)

3. Soundness (mm) 1 10 (maximum)

3.4.2 Tests on Aggregates

a) Grading of aggregate:

Used to determine the particle size distribution in a sample of aggregate called gradation.

Sieve analysis is used for gradation.

Sieve sizes 80mm to 150 µ are used in the sieve analysis.

31

b) Fineness Modulus:

It is an index of grading of aggregate in a given sample.

Fineness modulus is determined by sieve analysis.

FM = The ratio of the cumulative percentage of material retained on each sieve/ 100.

Fig. 3.6: Vicat apparatus. Fig. 3.7: A set of IS sieves

Table 3.5: Characteristics of fine aggregate

Source: Batching plant (Crusher sand) Weight of sample:1000 gms

Date of testing: 01-06-2015

IS sieve

size

Weight

retained

(gm)

Cumulative

weight retained

(gm)

% weight

retained

%weight

passing

Specifications

as per IS: 383

4.75mm 14 14 1.4 98.6 90-100

2.36mm 159 173 17.3 82.7 75-100

1.18mm 203 376 37.6 62.4 55-90

600µ 192 568 56.8 43.2 35-59

300µ 217 785 78.5 21.5 8-30

150µ 120 905 90.5 9.5 0-10

pan 95 1000 100 0 0

32

Table 3.6: Characteristics of coarse aggregates

Source: Batching plant (20 mm coarse aggregate) Weight of sample: 5000 gms

Date of testing: 01-06-2015

IS sieve

size

Weight

retained

(gm)

Cumulative

weight

retained (gm)

% weight

retained

%weight

passing

Specifications

as per IS: 383

40mm 0 0 0 100 100

20mm 406 406 8.12 91.88 85-100

10mm 3985 4391 87.82 12.18 0-20

4.75mm 598 4989 99.78 0.22 0-5

pan 11 5000 100 0 0

3.4.3 Test on fresh concrete

Workability (Slump cone test)

Slump cone of bottom dia. 20cm, top dia. 10 cm and height 30 cm.

Three layers of concrete. Each layer tamped for 25 times by a standard tamping rod of

16mm dia. and 60 cm, length.

The subsidence of concrete under gravity in ‘mm’ is called slump.

Table 3.7: Recommended slumps for various concrete works (in ‘mm’)

Type of member Minimum Maximum

Mass concrete structures 25 50

Un reinforced footings 25 75

Reinforced slab beams,

foundations, footings &

walls

50 100

Pumped concrete, slip

form work

75 100

33

3.4.4 Compression test

As per BIS 15 cm cubes, cured for 7 days and 28 days crushing strength determined. Grades

are classified based on 28 day strength. Example: M15, M20, M25

Fig. 3.8: Compression testing Fig. 3.9: Concrete blocks stored

machine. in water before testing.

Table 3.8: Compressive test results

Location & Structure: Block -G – Slab Beam 10th

floor Grade of concrete: M 35

Date of casting: 27-05-2015 Date of testing: 02-06-2015

Cube No. Weight of cube

(gm)

Load applied in

(KN)

Compressive strength

(N/mm2)

1 8235 834 37.07

2 8176 864 38.40

3 8350 816 36.27

Average Compressive strength: 37.29 N/mm2

34

3.5Equipment used

Construction equipment are one of the very important resources of modern-day construction,

especially in infrastructure projects. Such project utilize equipment for most of the works

including earthmoving operations, aggregate production, concrete production and its

placement and soon. In fact, one cannot think of any major construction activity without

involvement of construction equipment. The selection of the appropriate type and size of

construction equipment often affects the required amount of time and effort and thus the job-

site productivity of a project. The project site has observed many equipment includes:

a) Excavators

b) Back hoe

c) Earth compaction equipment

d) Smooth wheel rollers

e) Sheep foot rollers

f) Vibrators

g) Dump truck

h) Tippers

i) Trailers

j) Tower crane

k) Builder hoist

l) Concrete transist mixers

m) Concrete pumps etc.

Fig.: 3.10 Back hoe Fig. 3.11: Roller

35

Fig. 3.12: Crushers

Fig. 3.13: Tower crane Fig. 3.14: Builder hoist

Fig. 3.15: Concrete transist mixer Fig. 3.16: Concrete pumping machine

36

3.6 Batching plant

This is used for mixing different ingredients in required proportion. It consists of storage bins

with adequate separate compartments shall be provided in the batching plant for cement,

flyash, fine and coarse aggregates. Each bin compartment shall be designed and operated so

as to discharge efficiently and freely, with minimum segregation, into the weighing hopper.

Means of control shall be provided so that, as the quantity desired in the weighing hopper

shall be constructed so as to eliminate accumulations of tare materials and to discharge fully.

i) Front view ii)Back view iii) Operator’s cabin

Fig. 3.17 ( i, ii & iii): Batching plant

Fig. 3.18: Concrete blocks making machine at the site.

37

3.7 Conclusion

In the process of executing the project all the sophisticated equipment and materials have

been used. When choosing materials, it is important to recognize that a product is best from

qaulity and economical point of view.

38

Chapter –IV

Human Resource Management

4.1 Introduction

Human resource is the most valuable asset in construction industry. Human Resource

Management includes the processes that organize, manage and lead the project team.

4.2 Project team

Line and staff organization

Manager

HR

Manager

Safety

Manager

Construction

Manager

Quality

R.I.L. Director

Project Manager

Team Leader

Manager

Engineer

Supervisor

Skilled worker Unskilled worker

Senior

Engineer Junior

Engineer

39

Table: 4.1 Project team

Person Name Role Authority Responsibility

1. Mr K.

Anjaneyulu

Project

Manager

Has the authority to

do change in project

management plan.

Will monitor the whole

work and guide the team

about any difficulty. Also

make sure that all the

tasks performed are with

in budget.

2. Mr K. Madan

Mohan

Team Leader Will lead the team Show all results to the

project manager and

solve issues between

team members.

3. Mr P. Babu

Roa

Human

Resource

Manager

Has an authority to

over see the work of

labours

Will reports to the higher

authority.

4. Mr Jan Basha

Shaik

Quality

manager

Has an authority to

check the quality of

materials use in

construction.

If any change will occue

he will report to the team

leader.

5. Mr

Mallikarjuna

Reddy

Safety

manager

Carry out safety

inspection of

building

Providing a hazard-free

workplace to the workers

of subcontractors.

4.3 Conclusion

Thus an understanding of recruitment, training and retention are the basic requirements for an

effective human resource department in the construction industry.

40

Chapter – V

Estimation

5.1 Introduction

An estimate is defined as computation or calculation of the required quantities of finished

items of work and its expenses (cost) likely to be incurred for its construction. The main

object of estimate is to know the required quantity of material, labour and cost before actual

execution. It helps an engineer to plan the construction work, for quick and proper

construction with required quality. The following data is used for preperation of an estimate:

Drawings

Specifications

Rate

5.2 Methods of building estimate

The dimensions, length , breaadth and height or depth are to be taken out from the drawing-

plan, elevation ans section. From the study of drawings , the building is to imagined and

pictured in the mind and thee dimensions are to be taken out correctly. For symmetrical

foundation which is the usual case, earthwork in exacavation in foundation, foundation

concrete, brickwork in foundation and plinth and brickwork in superstructure may be

estimated by either of the following two methods:

1) Separate or individual wall method

2) Central Line method

41

Fig. 5.1: Details of Measurement and Calculation of Quantitites- Slab Concrete

5.3 Schedule of bars

The schedule of bars is a list of reinforcement bars in a tabular form giving the particulars of

bars , shape of bending with sketches, length of each, total length and total weight . For each

work type of R.C.C. work a schedule of bars is usually prepared. From the schedule of bars

the requirment of different sizes and lengths of bars may be known, and may be arabged and

bent –up during the time of construction.

42

Fig. 5.2: Schedule of bars – R.C.C. Slab

43

5.4 Conclusion

In this chhapter I have understood that for all engineering works it is required to know

beforhand the probabale quanities of different items of work in the construction activity and

its implied cost. In framing a correct estimate, care should be taken to find out the

dimensions of all the items correctly, and to avoid omissions of any kind of work or part

thereof.

44

Chapter - VI

Safety Management

6.1 Introduction

Safety concerns have always been paramount in the construction industry. Construction sites

are complex environments, with workers from multiple trades interacting in challenging

environments. The project site has observed various safety norms as per ISO standards and a

safety office is present in the project site. The company has tied up with Archana Hospital,

Miyapur 6.9km away from the construction site.

6.2 Various safety measures

Various safety measures have been taken as shown below:

Fig. 6.1 Safety Nets Fig.6.2: Fire Extinguishers Fig. 6.3: Ambulance

45

Fig. 6.4: Project safety statistics Fig. 6.5: Safety park

6.3 Conclusion

After critical and deep study of all types of activities in the construction site I found the

company thinks safety first, that is not only protecting the phisically but it benefits for the

company, do not spend extra money to recover the unwelcome accidents happened. Human

life is precious and it shoul be the constant endeavour of all stakeholders to make the

construction site a safe place to work.

46

Chapter – VII

Work experience

7.1 Introduction

Industrial case study is a class healed at site to provide an enhanced understanding of the

outside working environment before the student graduate. The main aim of this practice is

that to teach students communication with different workers or employess, to imporve their

leadership skill, team playing skill and etc. So, I found a practical knowledge at the site.

7.2 Daily activities

Day 1: (27-05-2015)

I reported to project manager of the construction site as per directions of Human Resources

of Ramky group head office. The project manager assigned me to work with qaulity control

engineer.

The quality control engineer explained me about the construction site and gave a brief details

of the organiztion background.

I went through various drawings and other documents related to the site.

Day 2: (28-05-2015)

I was introduced to the safety department. They expalined me the precautionary steps that

one should to be followed site for their own safety while working in the construction site.

I observed the foundation work of parking ramp.

47

Day 3: (29-05-2015)

I observered construction of retaining wall using related drawings.

The quality control engineer explained me various tests that they perform in the quality

control lab.

I observed the operation of concrete batching palnt.

Day 4: (30-05-2015)

I observed the laying of coulmn reinforcement, plinth beams and form work for coumns of

parking ramp.

Fig. 7.1: Laying of footing Fig. 7.2 Laying of pedastal

reinforcement for parking ramp for parking ramp

Day 5: (01-06-2015)

I observed the setting up and erection of shuttering for block- G, 10th level slab.

I performed sieve analysis test on aggregates and setting time of cement test in quality

control lab.

48

Day 6: (02-06-2015)

I observed the arrangment of steel bars in Block- C, 10th

level slab.

I performed the compressive test on concrete cubes in the quality control lab.

Fig. 7.3: Arrangement of reinforcement in Block –C, 10th

level slab.

Day 7: (03-06-2015)

I observed the block masonry work in the Block-G, 6th

level.

I observed the plumbing and electric works in the Block-A.

I visited a model flat.

Fig. 7.4: Concrete block work Fig 7.5: Plumbing work

Day 8: (04-06-2105)

I worked in planing and esttimation department.

I observed the manufacture of concrete blocks process.

I observed the operation of crushers.

49

Day 9: (05-06-2015)

I supervised the block masonry work in the Block-G, 6th

level.

Day 10: (06-06-2015)

I supervised the block masonry work in the block-G, 6th

level.

I reported to the project manager and concluded my industrial traning program.

7.3 Challenges I have faced

Construction projects are complex and time consuming undertaking that require the

interaction and cooperation of many different persons to accomplish. The construction

industry is typically divided into specialty areas, with each area requiring different skills,

resources, and knowledge to participate effectively in it. In order to integrate and work

closely in each section it is a challenging task to one person especially when he/she is fresh

or beginner. In fact some challenges may be solved by me but some are above my limit and

even the workers at the site also. The main challenges I have faced in the industrial training

period were shaortage of knowledge in some portion of the work at the site and weather

condtion of the site.

7.4 Overall Benefits

The benefits I have gained from the industrial program are:

Improving practical skill

Upgrading the theoretical knowledge

Upgrading interpersonal communication skill

Improving leadership skill

Time management skills as well as self motivation

Work ethics and related issues.

50

Chapter - VIII

Conclusion

The industrial training program at Ramky One Kosmos phase-I project, Nallagandla,

Hyderabad, has not only broadend my educational background but enhanced my proffesional

career. I have been fortunate enough to interact with the engineers who made me aware of

the practical aspects involved at various stages of the construction project.

I was given exposure in almost all the departments at the site. The friendly welcome

from all the engineers and employees is appreciating, sharing their experience and giving

their peace of wisdom which they have gained in long journey of work. I hope this

experience will surely help me in my future and also in shaping my career. Over all the

indutrial case study program laid sound foundation for me to start my career. It will be

definitely sensible to scale this practice up and to replicate in other disciplines as well.

From the field study report, it is evident that the construction is going on full swing,

but from according to the project monitoring chart, the project is lagging behind the schedule.

Gracing the Ramky One Kosmos, this most happening realty destination for the elite

will be a self- sufficient and all encompassing commnity where its residents will prosper

forever.