Mukesh Patel School of Technology Management and En-

gineering, Mumbai

Final Report
On
Understanding Construction Activities

At

Premia – Residential Building

(SS Kenarc Developers and Builders)

By
Pooja Sen (M056)

I
 Final Report
Submitted in partial fulfillment of
Master of Business Administration – Technology Man-
agement

In

Civil Engineering

By

Pooja Sen (M056)

Under the supervision of

Mr. Alam Shah

(Senior Engineer)

Prof. Darshana Lade

(Faculty, Civil Department, MPSTME)

II
III
IV
 SVKM’s NMIMS

Mukesh Patel School of Technology Management & Engineering

Vile Parle (W), Mumbai - 400 056.
TECHNICAL INTERNSHIP REPORT Semester VII – MBA (TECH)

Submitted in Partial Fulfillment of the requirements for Technical Project/Training for

VII Semester MBA – (Tech).

Name of the Student: Pooja Sen

Roll No. & Batch: M056, MBA.Tech. CIVIL
Academic Year: 2019-20
Name of the Discipline: CIVIL

Name and Address of the Company: SS Kenarc Spaces LLP, Vile Parle (E)

Corporate Office: Office no. 7, 1st floor, Shantinath Shopping Centre, S V Road, Malad
(W), Mumbai-400064

Training Period: From 2nd May 2019 to 22nd June 2018

THIS IS TO CERTIFY THAT

Miss. Pooja Sen, SAP No.70491015031 has satisfactorily completed her Training,
Submitted the training report and appeared for the Presentation & Viva as required.

External Examiner Internal Examiner Head of Dept. Chairperson/Dean

Date:
Place:

Seal of the University

V
 Acknowledgement

The satiation and euphoria that accompany the successful completion of the training would
be incomplete without the mention of the people who made it possible.

I would also like to thank SS Kenarc for considering my application and giving me the
opportunity to learn.

After that, I would express my gratitude to Mr. Alam Shah, Site Mentor for a very fruitful
learning experience.
Then, I would like to thank Mr. Vithoba Tukrul who received me on the day of joining and
guided me throughout the internship period.
I would also express my thanks to Mr. Jamshed Khan, Supervisor who guided me during
the course of the project. His guidance has been certainly indispensable for my training.

My sincere thanks to my college supervisor Prof. Darshana Lade, Civil Department

(MPSTME) for her valuable suggestions and cooperation during my internship tenure.

I am greatly indebted to all of them for providing their valuable guidance at all stages of the
training, their advice, constructive suggestions, positive and supportive attitude and
continuous encouragement, without which it would not have been possible to learn and get
correct exposure.

Last but not the least I would convey my thanks to my parents who helped me in every
possible way.
I hope that I can build upon the experience and knowledge that I have gained and make a val-
uable contribution towards this industry in the coming future.

Pooja Sen
M056
MBA Tech. Civil
70491015031

VI
 List of Contents

1. Abstract 1
2. Introduction 2
2.1 About the Company 2
2.2 About the Project 3
2.3 About the Various Departments 7
3. Goals 8
4. Outline 4
4.1 Safety Departmen 4
4.2 Administration Department 10
4.3 Plant and Machinery Department 10
5. Materials Used 13
5.1 Cement 13
5.2 Aggregates 13
5.3 Flyash 15
5.4 Concrete 15
5.5.1 Tests on Concrete 16
6. Formwork 17
7. Casting 19
7.1 Shuttering 20
7.1.1 Plywood Formwork 21
7.1.2 Steel Formwork 21
7.2 Reinforcement/ Rebar 22
7.3 Pouring of Concrete 23
7.4 Curing 24
8. Casting 28
8.1 Retaining Wall 29
8.2 Rafting 31
8.3 Column Casting 32
8.4 Construction of Staircase 33
8.5 Construction of Floor Slab 41
9. References 43

VII
 List of Figures

Fig. 1: Proposed Elevation (Wing A) 1

Fig. 2: Proposed Elevation (Wing B & C) 1
Fig. 3: Detailed Section AA of Wing A 4
Fig. 4: Detailed Section BB of Wing A 5
Fig. 5: Detailed Section CC of Wing A 6
Fig. 6: Laborer wearing Safety Helmet 9
Fig 7: Jack Prop 11
Fig 8: Velar 11
Fig. 9: Panels 12
Fig. 10: Wheel Barrow 12
Fig. 11: Flash Mixer 12
Fig. 12: Metal 1 14
Fig. 13: Metal 2 14
Fig. 14: Crushed Sand 14
Fig. 15: Pharma 14
Fig. 16: Slump Cone Test 16
Fig. 17: Cube Test 16
Fig. 18: Formwork (Shuttering) 17
Fig. 19: Wooden Formwork 20
Fig. 20: Steel Formwork 21
Fig. 21: Reinforcements used on Site 22
Fig. 22: Transportation of Concrete using Wheel Barrow 23
Fig. 23: Concreting 23
Fig. 24: Curing with Hessian Cloth 24
Fig. 25: Curing at the Site 25
Fig. 26: Phases of Curing 26
Fig. 27: Retaining Wall 30
Fig. 28: Rafting (done prior) 31
Fig. 29: Column Casting 32
Fig. 30: Column Reinforcement 33
Fig. 31: Column Formwork 34
Fig. 32: Concreting using Wheel Barrow 35
Fig. 33: Basic Staircase 36
Fig. 34: Design of Staircase 37
Fig. 35: Formwork for laying the Staircase 38
Fig. 36: Formwork for Stairs 38
Fig. 37: Braces to support Formwork 39
Fig. 38: Formwork for Slab 41
Fig. 39: Wooden Formwork 42
Fig. 40: Braces to support Formwork 42
Fig. 41: Slab Casting 43

VIII
 1. Abstract

The interim report consists of three parts which provides the details of the work carried out
during Technical Internship Program till May 21, 2019 that is almost till end of third week of
Technical Internship Program. The report will indicate the knowledge and observations with
respect to practical knowledge gained during TIP as well as theoretical knowledge and prac-
tical knowledge gained in college during 3 Years of MBA Tech. Program.
This report will provide details of work done and methodology used to carry out all construc-
tion work, ensuring quality and meeting requirements of customers.
The project taken for the internship program involves construction of G+16 3-Wing Residen-
tial Building undertaken by SS Kenarc Builders and Developers. The project is named
PREMIA. The first part of the report is introduction and will give the overview of what the
project is about and what work will be done during the internship period. This will also give
an idea of organization and the work done by it. It will tell about the vision of organization,
project goals, outcome and result of this project and the total value addition to the reputation
of the company.
The second part of interim report is the main text. This part will give the details of learning
up to the end of 3 weeks of Technical Internship Program. It describes main business of the
Report and gives a detailed outline of different activities carried out, the methodology adopt-
ed to carry out the work and results obtained from the activities.
The third part includes the references that contain bibliographic information about every
source cited during making of the report. It also includes list of IS codes required for any
work to be carried out. It also contains links of websites from where certain data was ob-
tained to make report technically sound and to understand certain topics in depth.

Fig. 1: Proposed Elevation (Wing A) Fig. 2: Proposed Elevation (Wing B & C)

1
 2. Introduction

2.1 About the Company

S S Kenarc Developers LLP is a Limited Liability Partnership firm incorporated on 10 March

2015. They have successfully completed several landmark projects for residential and com-
mercial property in Mumbai. S S Kenarc Developers goes for traditional business excellence
keeping the customers and clients touch points in distinct areas such as:
• Operational Comfort and Product quality
• Customer Relationship Management
• Innovative and creative Practices and Technologies
• Customized and personalized Deliveries
• Green, Safe and Quality Construction

S S Kenarc Developers has always been an accountable citizen, fulfilling its role towards so-
ciety and taking a step to preserve the environment.

2
2.2 About the Project

PREMIA, the project undertaken by S S Kenarc Developers is a re-development project in-

volving redevelopment of a residential building. The project includes 3 residential towers in a
total land development area of 2588 square meters. The residences of PREMIA offer a range
of 3 BHK, 2 BHK & 1 BHK residences with lifts and parking space in the basement and
ground floor. The construction started on 1st January 2017 and is aimed to be completed by
June, 2022. The piling work began in August, 2018. The excavation work had been complet-
ed by November, 2018. The various activities involved in project are laying of founda-
tion(Raft) using RCC, shuttering, construction work of retaining walls along the periphery,
footing, rafting, concreting, PT(post tensioned) slab.
The main goal of the organization includes providing a favorable living space to the residents
with all the basic facilities at their best.

3
Fig. 3: Detailed Section AA of Wing A

4
Fig. 4: Detailed Section BB of Wing A

5
Fig. 5: Detailed Section CC of Wing A

6
2.3 About the Various Departments:

The report will be focusing on the following departments:

a. Safety
This department deals with the entire project safety, including the safety of the laborers,
employees as well as the environmental considerations.

b. Administration
This department includes the mobilization of a new site and deals with legal aspects, per-
missions, employee welfare, staff administration and time keeping.

c. Plant and Machinery

This department deals with everything related to plant and machinery, from procurement to
maintenance and repairs.

d. Site execution
This involves a detailed understanding of the site activities like rebar, formwork, concret-
ing, etc.

e. Quality Control
This department deals with the assurance of quality at every stage by continuous tests and
improvements.

f. Billing, Estimation and Costing

This involves the estimation and accounts of all resources such as labor, material and ma-
chinery.

g. Planning and Contracts Management

This department deals with the planning of the project and ensuring its smooth functioning
as well some legal aspects pertaining to the contracts.

7
 3. Goals

The goal helps the business leaders to develop a plan designed to achieve measurable results
in the desired time. S S Enterprises have kept some goals for this project, which help the
company to grow in their field.

The desired goals of the project are:

✓ Smart and efficient utilization of the manpower, machinery and labor resources

✓ Completion of project in the estimated time frame

✓ The desired and promised quality should be provided to the client

✓ Taking in care the health, safety and environmental considerations

8
 4. Outline

A detailed study of all activities in cross-functional departments is required to understand

the overall process smoothly and efficiently.

4.1 Safety Department

The builder provides Personal Protective Equipments to all the employees as per the
need and the work going on the site that are stated as follows:

• Head – Safety helmets are given to every person present on the site including laborers,
carpenters, interns and all the supervisors.
• Eyes – Face shield and goggles are provided during welding and concrete chipping.
• Feet – Safety shoes are worn at all time on site by laborers, carpenters and all the su-
pervisors. During the time of concreting, Gum Boots are provided to the laborers.
• Hands – The laborers wear Cotton gloves with leather palms while carrying the mate-
rial from one place to the other. Leather gloves are worn at the time of welding.

General Safety Regulations

• Physical safety – Boundaries and barricades cover all opening.

• Electrical safety – 3 pin plugs are used at the site to decrease the risk and all wires are
taken as live wires and are never directly inserted. Also all other precautions are taken
to prevent short circuit or sparking at the site.
• Fire safety – The 3 main causes of fire are Heat, Oxygen and Fuel. Therefore, Gas cyl-
inders used by the laborers for cooking food are transported using hand trolleys and
LPG cylinders are strictly prohibited at the site.

Fig. 6: Laborer wearing Safety Helmet

9
4.2 Administration Department

The role of this department involves much administration activities; the activities that I
have noticed on the site are the following:

• Labor Compliance
• Labor Accommodation
• Site Administration: Staff Administration, Legal Register, Leave Record are main-
tained at the site by the project manager.
• Time keeping
• No child (5-14 years) is working on the site as per Child Labor Act

4.3 Plant and Machinery Department

Plant and machinery is an asset that is used by a business for the purpose of carrying on
the business that deals from the initiating requirement, procurement to repair and mainte-
nance of plant and machinery.

On site, a process is followed to ensure smooth functioning:

1. Initiate Plant and Equipment Requirement for site

2. Erection and Commissioning for Plant and Machinery:

• Either from already existing inventory
• New procurement of P&M
• External hiring

3. Proper inspection of all plant and machinery by operating.

4. Putting equipment to use after arranging operational and maintenance manpower

• Recording Utilization of machinery on log book

• Recording breakdowns of machinery with the use of logging data and send
weekly breakdown report
• Executing and recording repairs
• Maintaining a schedule for maintenance and displaying monthly maintenance
schedule.
• Scheduling spare parts and consumables requirement on site based on Repair
and maintenance schedules
• Arrangement of repairs of tools and tackles available at site
• Statutory documentation for plants and maintenance of records
• Preparing the weekly P&M performance report

10
List of Props and Machinery used at the project:

1. Concrete Mixer

2. High Frequency Needle Vibrator

3. Bar Bending Machine

4. Bar Cutting Machine

5. Concrete Breaker

6. Cutter

7. Water Pump

8. Barrow Wheel

9. Jack Prop

10. Velar

11. Panels

12. Flash Mixer

Fig 7: Jack Prop Fig 8: Velar

11
Fig. 9: Panels Fig. 10: Wheel Barrow

Fig. 11: Flash Mixer

12
 5. Materials Used

5.1 Water

Generally used in mixing of concrete and curing of concrete. Pure drinking water should be
used. Water cement ratio plays an important role which influences properties such as worka-
bility, strength and durability. Adequate water cement ratio is required for production of
workable concrete. Combining water with a cement material forms a cement paste by the
process of hydration .The cement paste glues the aggregate together, fill voids within it and
makes it flow more freely.

5.2 Cement

Cement is the basic ingredient in concrete. It acts as a binding material. Therefore, selecting
the right cement brand is very important along with its grade. Ordinary Portland Cement
(OPC) is the most common type of cement used at our site. The cement brands used at our
site are Ultratech and Ambuja.
Cement is the main ingredient which binds everything together and helps in determining the
strength of the concrete. When the cement arrives at the site, field test of the cement is done.
The field test involves:
When cement is touched or rubbed in between fingers, it should give a smooth feeling. When
small quantity of cement is thrown in water, it should float some time before finally sinking.
When hand is put into the cement, the cement should feel cool. The cement should have a
greyish green color. Also, a small quantity of cement is taken and allowed to pass through a
90 micron sieve. The sieve should not retain more than 10%.
After the successful completion of these field tests the cement is allowed to enter the silo. If
any one of the field test fails the cement is rejected and not used.

5.3 Aggregates

Fine and coarse aggregates make up the bulk of a concrete mixture. Sand, Natural gravel and
crushed stones are used mainly for this purpose.
At our site the aggregates used are classified as Metal 1, Metal 2, Pharma and Crushed sand.

13
 Fig. 12: Metal 1 Fig. 13: Metal 2

Fig. 14: Crushed Sand Fig. 15: Pharma

14
5.4 Flyash

Fly ash improves the concrete workability, pump ability, cohesiveness, finish, ultimate
strength and durability. It is residue left from burning coal, which is collected on a electro-
static precipitator. There are two classes of flyash viz. ‘F’ and ‘C’. ‘F’ is made from burning
bituminous and ‘C’ is obtained from lignite.
Flyash is used as an alternative to cement till a certain extent. Flyash is used in concrete be-
cause it is cheaper than cement. It is replacement for Cement (High Volume Fly Ash). Ac-
cording of IS 3812 fly ash should not be more than 23-30% in any concrete.

5.5 Concrete

All components mentioned above plus water and admixture are added in required proportion
to form concrete. The minimum grade of concrete used at this site is M35 grade concrete.
When aggregates are mixed with dry Portland cement and water, the mixture forms fluid slur-
ry that is easily poured and moulded into shape. At our site, Alcofine material is used which
reduces the water content upto 25%, decreases the settling time, thereby increasing the
strength of concrete. The concrete is prepared in the mixture and tested. After passing the test
the concrete is poured in the barrow wheel and used for concreting. The concrete is effective
immediately after mixing within a time frame of 30 seconds to 3 hours.

15
5.5.1 Tests on Concrete

Slump Cone Test

The slump cone mould was thoroughly cleaned and oiled. Then it was placed on its platform
board and tightly fixed. The fresh concrete was then poured into the mould in 4 layers and
provided with 25 strokes after every layer. After the mould was full, it was quickly de-
molded by lifting the cone in exact vertical direction. The corresponding height was noted.
We found out that the slump was in the range of 70-80 mm which means it had medium
workability and was good to use.

Fig. 16: Slump Cone Test

Cube Test
The cubical mould with dimensions 150 mm was taken for the test. It was cleaned and oiled.
The fresh concrete was then filled in 3 layers, provided with 35 strokes after each layer. The
mould was filled and kept on site. The 7th day and 28th day reading were then taken to test its
strength.

Fig. 17: Cube Test

16
 6. Formwork
Formwork is the general term given to either temporary or permanent moulds into which
concrete or similar material are poured. It is generally made of timber or steel, the surface in
contact with the concrete being selected to give the required finish. The strength of the form-
work and its associated false work must be sufficient to support the weight of the wet con-
crete without significant distortion. Formwork is generally removed once the concrete has
gained sufficient strength. Though in some circumstances it may be left in place (called per-
manent formwork)
The selection of the correct formwork plays a very vital role in completing the structure with-
in a desired period of time with required accuracy. In order to meet the construction schedule,
a proper and detailed analysis of the structure is to be carried out before finalizing the form-
work.
Floor area, floor height & number of floors play an important role in selecting a type of
formwork.
Formwork has to be designed according to the floor plan. Although timber and steel are the
materials most commonly used for formwork, the formwork should remain sufficiently rigid
during placing and compaction of concrete. There are many other types of formwork which
could be implemented depending upon the budget & the finish required. The formwork is
never attached to the reinforcement bars; a cover is attached. Cover is a circular black disk
which is attached on the bars. The end of disc is where the formwork will be attached. There-
fore, formwork drawings are prepared taking into consideration the cover attached. Cover
size used are:
• 25mm for slab
• 40mm for column

Fig. 18: Formwork (Shuttering)

17
A good formwork should satisfy the following requirements:

1. It should be strong enough to withstand all types of dead and live loads.
2. It should be rigidly constructed and efficiently propped and braced both horizontally
and vertically, so as to retain its shape.
3. The joints in the formwork should be tight against leakage of cement grout.
4. Construction of formwork should permit removal of various parts in desired sequenc-
es without damage to the concrete.
5. The material of the formwork should be cheap, easily available and should be suitable
for reuse.
6. The formwork should be set accurately to the desired line and levels should have
plane surface.
7. It should be as light as possible.
8. The material of the formwork should not warp or get distorted when exposed to the
elements.
9. It should rest on firm base.

18
 7. Casting

Casting is a manufacturing process in which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidi-
fied part is also known as a casting, which is ejected or broken out of the mold to complete
the process.
One of the major tasks involved in construction is casting of various components. Casting
involves various steps stated as follows:

1. Shuttering
2. Reinforcement
3. Pouring Concrete
4. Curing

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7.1 Shuttering

It is a part of formwork, or you may call it as derivative of formwork. Shuttering is a vertical

temporary arrangement which is arranged to bring concrete in a desired shape.

Types of Formwork (Shuttering) for Concrete Construction:

7.1.1 Plywood Formwork

Resin bonded plywood sheets are attached to timber frames to make up panels of re-
quired sizes. The cost of plywood formwork compares favorably with that of timber
shuttering and it may even prove cheaper in certain cases in view of the following
considerations:

• It is possible to have smooth finish in which case on cost in surface finishing is

there.
• By use of large size panels it is possible to effect saving in the labor cost of fixing
and dismantling.
• Numbers of reuses are more as compared with timber shuttering. For estimation
purpose, number of reuses can be taken as 20 to 25.

Fig. 19: Wooden Formwork

20
7.1.2 Steel Formwork
This consists of panels fabricated out of thin steel plates stiffened along the edges by
small steel angles. The panel units can be held together through the use of suitable
clamps or bolts and nuts. The panels can be fabricated in large number in any desired
modular shape or size. Steel forms are largely used in large projects or in situation
where large number reuses of the shuttering is possible. This type of shuttering is con-
sidered most suitable for circular or curved structures.

Fig. 20: Steel Formwork

21
7.2 Reinforcement/ Rebar

Rebar (short for reinforcing bar), collectively known as reinforcing steel and reinforcement
steel, is a steel bar or mesh of steel wires used as a tension device in reinforced concrete and
reinforced masonry structures to strengthen and hold the concrete in compression. Concrete
is strong under compression, but has weak tensile strength. Rebar significantly increases the
tensile strength of the structure. Rebar's surface is often patterned to form a better bond with
the concrete. The plans are checked to make sure each component of the reinforcement is in
the place.

Bars of dimensions 8mm, 10mm, 12mm, 16mm, 25mm and 32mm are used at the site.

Reinforcements are checked and assembled according to the design. Grade of steel
used at site is Fe500 for all the work until now.

Fig. 21: Reinforcements used on Site

22
7.3 Pouring of concrete

Concrete pouring is a crucial process which not only needs properly qualified persons but
also considerable focus and concentrations.
If the height of these elements is large, then it is recommended to place concrete in layers.
The layer thickness ranges from 300mm to 500mm and the time between successive layers
should not exceed 30 minutes for normal weather condition and 20 minutes for hot weather
condition. Each layer should be compacted properly using vibrators.

Correct concrete pouring according to ACI 304R-00 is presented.

Fig. 22: Transportation of Concrete Fig.23: Concreting

Using Wheel Barrow

23
7.4 Curing of Concrete

Curing of concrete is defined as the process of maintaining the moisture and temperature
conditions of concrete for hydration reaction to normally so that concrete develops hardened
properties over time. The main component, which needs to be taken care, is moisture, heat
and time during curing process.

Fig. 24: Curing with Hessian Cloth

24
Curing of concrete is required for the following reasons:

• To prevent the concrete to dry out prematurely due to solar radiation and wind. This pre-
vents plastic shrinkage of concrete.

• It helps to maintain the concrete temperature by allowing the hydration process. Hydra-
tion process requires water to carry on and releases heat.

• Curing helps the concrete to harden and bond with internal materials and reinforcement.
This helps to prevent damage to bond between concrete and reinforcement due to vibra-
tion and impact.

• This helps development of impermeable, crack free and durable concrete.

• The time to start curing of concrete depends on the evaporation rate of moisture from the
concrete.

• The evaporation rate is influenced by wind, radiant energy from sunshine, concrete tem-
perature, climatic conditions, and relative humidity.

Fig. 25: Curing at the Site

25
ACI 308 – Guide to Curing Concrete suggests three phases of concrete curing.

Fig. 26: Phases of Curing

26
Initial Curing – Bleeding of Concrete:

When the concrete is placed and compacted, bleeding of water occurs and rises through the
surface of concrete due to settlement of concrete. The rate and duration of bleeding depends
on many factors including concrete mix properties, depth or thickness of concrete, method of
compaction of concrete etc. These bleed water starts to evaporate from the surface. When all
the bleeding water has disappeared from the surface, the drying of concrete starts, then initial
curing of concrete is required to minimize the moisture loss and prevent plastic shrinkage
cracks to concrete before and during finishing operations. The initial curing of concrete can
be done by techniques such as fogging or using the evaporation reducers, or by providing the
sunshades and windscreens.

Intermediate Curing:

Intermediate curing is done when the concrete surface finishing operations has been carried
out before the final setting of concrete. This happens when the required surface texture of
concrete member is achieved rapidly or when the setting of concrete is delayed.

Final Curing:

When the concrete is finished after the final setting of concrete, the final curing of concrete
should be done. This helps to prevent surface drying of concrete because the loss of moisture
from the concrete surface occurs immediately.

27
 8. Construction

Overall the task is similar for all components with slight variation depending upon type of
component; it’s utility, required strength, loads acting, and other factors.
Further in the report, all these points will be covered for some components seen during Tech-
nical Internship Program. These components include:

1. Retaining Wall
2. Raft
3. Columns
4. Slabs

28
8.1 Retaining Wall

(Construction of retaining wall was done before the commencement of my TIP)

The retaining walls are provided to resist lateral pressure the soil or material and to prevent
its sliding, eroding or moving from its position. This lateral pressure depends upon depth. It
increases as we go down. At the site, the excavation done is at different depths below the
ground level. At 15m below the ground level, magnitude of lateral pressure is very high and
can cause sliding or other deformations leading to accidents. To avoid such accidents retain-
ing walls are constructed on the border of excavations which can withstand this lateral pres-
sure. On site, the excavations made are of the depths 6.5m, 7.1m and 7.5m. The width of the
retaining wall constructed is 250mm. Concrete used for this retaining wall is of M35 grade
and is supplied by RMC companies that are – Ultratech and Ambuja to the site, as per re-
quirement. Before constructing retaining walls, waterproofing is also done. PCC is done to
provide smooth surface, followed by application of water proof sheets.
Retaining wall is constructed at the site by using following process and methodology.

I. Reinforcement
The reinforcement used on the site are TOR steel rods of different diameters ranging
from 8mm to 33mm according to the strength required and design provided by con-
sultants on basis of calculations. These reinforcements are erected with spacing of
100mm – 150mm centre to centre in between them and are joined to each other with
help of steel bending wires. Cover caps (spacers) are introduced within this rein-
forcement cage. These caps help in avoiding contact between reinforcement and shut-
tering. The steel grade is FE-500 and majorly supplied by Surya, Bhavin, Metro and
Thane Steel.

II. Shuttering / Formwork

Shuttering system used on site is RMD Shuttering, as well as conventional shuttering
(subject to availability of RMD Shuttering). It consists of Metal plates that provides
smooth shape to the retaining wall and is supported by metal legs providing good
strength. It is made sure that shuttering is properly oiled or greased before used. It in-
volves skilled laborers and carpenters in order to ensure quality and safety.

III. Concrete pouring

Concrete of grade M35 is used for construction of the retaining wall. The concrete is
mixed is a concrete mixer. It is then carried through Barrow Wheel and is poured at
required location. For proper compaction of concrete and in order avoid honeycomb-
ing defects, Needle Vibrator is used which creates vibration to force the concrete to
fill in the voids and settle with compaction.

29
IV. Curing
As, retaining wall is a vertical component, shuttering system is removed after 14
hours, and if any defects found are rectified using adequate admixtures. The retaining
wall is then cured for about a month by using Hessian Cloth. Hessian Cloths are used
as they absorb water and result in effective curing. The shuttering is removed after 14
hours and is not kept for much longer time as it may cause obstruction in curing if not
removed. The water used for curing is potable and is checked once a while using
standard procedure as given in IS Codes (IS 456) 2000.

Fig. 27: Retaining Wall

30
8.2 Rafting:

(Rafting was done before the commencement of my TIP)

It is a large reinforced concrete slab which supports many columns and wall. It is used gener-
ally for foundations of new buildings where ever favorable. Here at SS Kenarc Developers
during my Technical Internship Program, raft was casted in one layer being 150mm deep.
The concrete used for casting of raft is of M53 grade and is supplied from (Ambuja and
Ultratech). The reinforcements used are of 8mm, 10mm, 12mm, 16mm, 25mm and 32mm
dia. These reinforcements are supplied by Surya, Bhavin, Metro and Thane Steel and are
of grade 500.
The process adopted to construct the raft slab is as follows:

I. Surveying
Using Total station the boundaries are marked in accordance to drawings.

II. Reinforcement
Reinforcement bars are places perpendicular to each other throughout the area with
centre to centre spacing of 100mm – 150mm between adjacent steel rods.

III. Concreting
Concreting of rafting is done by M30 grade concrete.

IV. Curing
As, raft casting is done, curing agent is applied on the raft surface and is then covered
with Hessian Cloth. The curing is done for a period of 4 – 14 days.

Fig. 28: Rafting (done prior)

31
8.3 Column Casting

Column is a vertical member which takes complete load of the beam, slabs and the entire
structure and the floor and other area of the building is adjusted as per the requirement of the
client or owner. The size of the columns, quantity of cement sand and aggregate to be mixed,
the number of steel bars to be placed, spacing between the stirrups is all mentioned in the
structural drawing which is designed by structural designer as per the actual load on the col-
umn and considering the factor of safety. Column transfers the load of the structure of slabs
beams above to below, and finally load is transferred to the soil. Position of the columns
should be so that there are no tensile stresses developed at the cross section of the columns.
Columns location should be such that it hides in the walls partially or fully.

The process adopted to construct the RCC Column is as follows:

I. Column Layout
Column Layout is done by laying rope in the grid lines and mark the location of col-
umns.

Fig. 29: Column Casting

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II. Column Reinforcement
When marking of column location is done, the reinforcement of columns are placed
according to the structural drawing.
Horizontal Reinforcements viz. Stirrups are at a spacing of 100 – 150 mm.
At our site, the columns casted so far are 23 in number and 2 for the lifts.
Additional notes such as lap length for column steel of different diameter etc will be
given in the sheet of structural drawing.

Fig. 30: Column Reinforcement

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III. Column Formwork
Columns carry the load of structure and hence, they are critical. It is important to
align them for verticality so that load is transmitted properly. The column shuttering
should be strong enough to take the pressure of fresh concrete and remain in position
during concreting.
At our site, steel formwork is used mainly. In steel formwork, the panels are oiled pri-
or shuttering for a smooth removal after casting without any cracks. Wooden form-
work is also used in some areas.

Fig. 31: Column Formwork

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IV. Concreting of RCC Column
Concreting of RCC Column can ne done in 2 ways:
• Manually
• With the help of machine or Pump
At our site, concreting is done by manual means. The concrete mixture is carried in a
barrow wheel from the concrete mixer and then poured for casting.

Fig. 32: Concreting using Wheel Barrow

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8.4 Construction of Staircase

Staircases are a vital design element in multi-floor buildings. The basic components of a
staircase are the tread, the horizontal surface we walk on; the riser, the vertical part between
each tread and the stringer, a structural support that holds the treads in place and provides
stability. What we call a step is actually a combination of a tread and a riser, or one step up or
down from our previous position. In some cases, such as open stairs, the riser is missing and
we can see through the stairs. Other optional parts of a staircase include the nosing, banister,
and balusters. Nosing is a small part of a tread that overhangs the riser. The banister is also
called a railing or a handrail. Banister is held up by balusters, or vertical supports attached
to a tread at the bottom and the banister at the top. Sometimes to break up a long, straight
staircase or to provide a space to turn when the steps change direction, a wide platform step
called a landing is used.

Fig.33: Basic Staircase

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The process adopted for the construction of staircase is as follows:

I. Layout and Design

The first step in construction of a staircase is finalizing its plan. The dimensions are
finalized by the architect according to the bye-laws and requirement of the building.
This is a very important step as everything that happens later on depends on it. This is
included in the plan drawing of the building and is followed by the site engineers and
the workers while building a staircase. Its design should be such that it is aesthetically
pleasing, easy for vertical circulation and at the same time maintain its structural
strength. Designing of stairs requires through knowledge about design aspects and site
study. The factors that influence the design of stairs are height of the floor, width of
the stairs, risers depth, thread width, thickness of the stairs, angle of the stairs, load
applied on the stairs and many other aspects which requires a qualified engineer to de-
sign the perfect stairs.

Fig. 34: Design of Staircase

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II. Formwork
Wooden Formwork for the staircase was used on the site as it is cheap easy to handle
and fulfils the requirement of holding the concrete well enough for it to settle without
errors and defects. This formwork can also be reused if the wood is still good.
The boards used for the formwork were 2” thick, as to support the weight of the con-
crete. The whole structure of the form was supported by 4×4 posts. The wooden
boards were used to create the steps and fastened with several screws to the lateral
structure of the formwork. The formwork was supported on the floor of the basement
which was built using rubbles upon which M15 PCC was poured and then compacted
and smoothened. This allowed the pressure exerted by the staircase to divide on a
larger area uniformly.

Fig. 35: Formwork for laying Fig.36: Formwork for Stairs

the Staircase

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III. Concreting
After the formwork was built and closed tightly using screws the next step is to build
stairs by pouring the mixed concrete containing cement, sand, gravel and water into
the formwork. Concrete was poured into the formwork starting from below and then
moving upwards. This was done manually using baskets and barrow wheels. The con-
crete was poured and compacted using a concrete vibrator to fill any voids and gaps
inside the formwork and also to prevent honeycomb formation. Once the concrete is
poured it is allowed to settle and this takes 21 days. In these 21 days proper curing is
to done to prevent the cracks in stairs due to thermal expansion. After 21 days the
formwork is removed by using a hammer and a crowbar and is done very carefully as
to avoid damaging the concrete or the edges of the stairs. At last final finishing is
done according to the desired aesthetics of the building

Fig.37: Braces to support Formwork

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Component Dimension

150 mm
Riser

Tread 250 mm

Width 1500 mm

Flight Angle 40o

Table of Components of Staircase

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8.5 Construction of Floor Slab

Concrete slab, a very common and important structural element, is constructed to provide
flat, useful surfaces. It is a horizontal structural component, with top and bottom surfaces
parallel or near so.
Concrete floor slabs may be in situ or prefabricated. The in situ concrete slab floor are built
using form-work, which is commonly made of wooden planks & boards, plastic or steel.
According to work arrangement laying of RCC slab can be done in 4 stages:

I. Formwork
Formwork for reinforced concrete slabs depends on the type of slabs to be construct-
ed. The floor slabs can be structural slabs supported on a steel or concrete structural
frame, or slab-on-grade.
There are various construction aspects that were considered during the erection of
formworks.
Different materials such as wood, steel, and aluminium can be used for the formworks
of concrete floor slab. We used wooden formwork for the construction of slab on our
site.

Fig.38: Formwork for Slab

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II. Reinforcement
Concrete has a very high compressive strength, but it is low in tensile strength.
Thus, steel reinforcements are provided to increase the tensile strength of the slab
base.

Fig. 39: Wooden Formwork

Fig. 40: Braces to support Formwork

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III. Laying of Cement Concrete
Mixing, transporting, and handling of concrete were properly coordinated
with placing and finishing works. Concrete was deposited as close as pos-
sible to its final position in order to prevent segregation.

Site engineers monitored concreting properly, and looked for signs of prob-
lems. Loss of grout is the indication of improper sealing and movement of
joints. Added to that, cracking, excessive deflection, level and plumb, and
any movement were checked to prevent any problems.

Fresh concrete was compacted adequately in order to mould it within the

forms and reinforcement to eliminate stone pockets, honeycomb, and en-
trapped air. Concreting was done manually using Wheel Barrows. Vibration
method was used for consolidating the concrete at the site.

Fig.41: Slab Casting

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 9. References

• Under the guidance of Mr. Alam Khan (Senior Engineer), Abhishek Upadhyay (Site
Engineer)
• Daily Progress Reports
• Drawings available at the construction site
• https://www.dailycivil.com
• https://theconstructor.org
• https://www.designingbuildings.co.uk
• https://study.com

Standards:

• IS: 456 (2000) –Plain and reinforced concrete

• IS: 800 (2007) – General construction in steel
• IS: 516 (1959) - Methods of test for strength of concrete.

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