Internship Report

BMS COLLEGE OF ENGINEERING BENGALURU
Autonomous institute, affiliated to VTU
AN INTERNSHIP REPORT
INTERNSHIP AT PRESTIGE ESTATES PROJECTS LIMITED
Submitted in partial fulfillment for the award of degree of
Master of Technology
in
Construction Technology
Submitted by
Mr. RAKESH S
1BM16CCT10
Internship Carried Out
At
PRESTIGE ESTATES PROJECTS LIMITED

PRESTIGE FALCON CITY SITE, BENGALURE
Internal guide External Guide

Dr. Mangala Keshava Swarna Swaroop A
Associate professor Assistant Vice President
BMS College of Engineering Prestige Estates Projects Ltd
DEPARTMENT OF CIVIL ENGINEERING

BMS COLLEGE OF ENGINEERING
BULL TEMPLE ROAD, BASAVANAGUDI BENGALURE
ENGALURE-560019
2017-18
DEPARTMENT OF CIVIL ENGINEERING
BMS COLLEGE OF ENGINEERING BENGALURE
Autonomous Institute, Affiliated to VTU
CERTIFICATE
This is to certify that this internship report is a bonafide work carr

carried out by
Mr. RAKESH S bearing USN 1BM16CCT10 in partial fulfillment for the award
of degree of Master of Technology in Construction Technology prescribed by
Visvesvaraya Technological University, Belagavi during the academic year of
.The internship report has been approved as it satisfies the academic
2017-18.The
requirements prescribed for the Degree of Master of Technology.
Technology
____________________ ______________________ __________________

Signature of the guide Signature of H.O.D Signature of Principal
Dr. MANGALA KESHAVA Dr. MAYA NAIK Dr. MALLIKHAR
MALLIKHARJUNA BABU K
Associate professor Professor & HOD Principal
Dept of Civil Engineering Dept of Civil Engineering BMSCE, Bengaluru
BMSCE, Bengaluru BMSCE, Bengaluru
External Viva
Name of the Examiner Signature

1.
2.
ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the mention of people who made it possible, whose constant
guidance and encouragement crowned out effort with success.
I express my deep sense of gratitude to my guide Mr. Swarna Swaroop A, Assistant

Vice president for his valuable guidance with constant encouragement at every stage of
this project work. I consider myself fortunate to have been associated with such an
eminent guide.
I extend my thanks to Mr. Ahmedulla Baig, Assistant General Manager for guiding me
throughout the course of training.
I would also like to express my gratitude to Mr. Muheeb Ahmed , Mr. Nelson,
Mr.Prashanth SP , Mr.Nithin Gowda, Mr.Sachin, Mr.vivek T, Mr.Patrick Jones,
Mr.Sumit patil, Mr.Manjesh for helping me out with some difficulties during the
course.
Thanks to Prestige Estates Project Ltd for giving me an opportunity for doing internship
at Prestige Falcon city site.
I would like to thank my internal guide Dr. Mangala Keshava for her guidance and
helpful suggestions beginning from industrial training, I thank her for thoughtful
suggestions and advices.
I would like to thank Dr. Maya Naik, HOD, Department of civil Engineering, BMSCE
who supported me in carrying out the internship in 3rd semester
I would like to thank all my lecturers and non-teaching staff of civil Engineering,
BMSCE,Bengaluru,for their support to carrying out the internship in 3rd semester
My deepest recognition goes to my beloved parents, who are helping me in all possible
ways to achieve my objectives and fulfill my dreams.
RAKESH S
DECLARATION
I, RAKESH S, student of BMSCE, Bengaluru Pursing Master of Technology in

CONSTRUCTION TECHNOLOGY hereby declare that I have completed Internship at
PRESTIGE ESTATES PROJECTS LTD of their site PRESTIGE FALCON CITY,
BENGALURE. The information provided is true & original to the best of my knowledge.
RAKESH S
1BM16CCT10
EXECUTIVE SUMMARY
The internship report in broad-spectrum contains four chapters in which I try to explain
my four months experience working with Prestige Estates Projects Ltd. The content of all
chapters is broadly explained and it is constructed from the practical basis of knowledge
acquired in four months.
In the opening chapter I gave details about the company background including its
Landmark projects, vision, mission, quality policy, Awards & Recognitions.
The second chapter is the most important chapter which explains about the project where
I got allotted to do internship in the last successive months. It includes Project details,
departments Organization structure at site and specifications.
The third chapter solely includes about the task performed includes site supervision,
components & sequence of works in aluminium formwork & concreting
This chapter also gives brief explanation about the activities where I observed and learnt.
Fourth chapter explains the main benefits of the internship in terms of different aspects
and areas. It is obvious that the internship has a plus in terms of improving skills,
technical and non technical outcomes and different abilities as a whole.
CONTENTS
CHAPTER 1 ABOUT THE COMPANY
1.1 Introduction ................................................................................................................ 1
1.2 Company’s vision ....................................................................................................... 1
1.3 Company’s mission .................................................................................................... 1
1.4 Accomplishments ....................................................................................................... 2
1.5 Landmark projects ...................................................................................................... 3
1.6 Awards & recognitions............................................................................................... 5
1.7 Quality policy ............................................................................................................. 6
CHAPTER 2 ABOUT THE PROJECT AND DEPARTMENTS
2.1 Project overview ......................................................................................................... 7
2.2 Specifications ........................................................................................................... 10
2.3 Organisation structure .............................................................................................. 12
2.4 Emergency evacuation route & logistic plan ........................................................... 12
2.5 Departments at project site PFLN ............................................................................ 13
2.5.1 Plant and Machinery (P & M) Department ............................................................... 13
2.5.2 Safety Department .................................................................................................... 18
2.5.3 Quality Department ................................................................................................... 21
CHAPTER 3 TASK PERFORMED
3.1 Building 1 Details..................................................................................................... 28
3.2 Kumkang Aluminium formwork.............................................................................. 30
3.3 Components in Kumkang Aluminium formwork .................................................... 31
3.4 Sequence of works in Aluminium formwork ........................................................... 34
3.4.1 Structural line (grid line) marking on the slab by surveyor for wall panels erections
as per the farming layout (form plan). ............................................................................... 34
3.4.2 External Working platform ....................................................................................... 35
3.4.3 Reinforcement of walls and beams (Floor & Link beam) ........................................ 35
3.4.4. Placing of sleeves for plumbing and fire fighting. ................................................... 37
3.4.5 Electrical Conduting & placing of wall panels. ........................................................ 37
3.4.6 Installation of Slab corner (SC) & Slab level (SL) panels…………………………38
3.4.7 Staircase .................................................................................................................... 39

3.4.8 Applying form oil on the slab panels ........................................................................ 40
3.4.9 Slab reinforcement & electrical conduting. .............................................................. 41
3.4.10 sunken arrangements in Aluminium formwork. ..................................................... 41
3.4.11 placing of kicker panels .......................................................................................... 41
3.4.12 Placing of cutout boards at shafts…………………………………………………42
3.4.13 other Accessories .................................................................................................... 42
3.5 Checklist for Reinforcement & Shuttering............................................................... 43
3.6 Concreting ................................................................................................................ 44
3.6.1 Concrete Grades are as follows................................................................................. 44
3.6.2 Smart Dynamic Concrete (SDC) [1] ......................................................................... 45
3.6.3 Materials used in SDC & normal concrete at project site ......................................... 45
3.6.4 Moisture Corrections ................................................................................................ 46
3.6.5 Slump test for Normal Concrete ............................................................................... 46
3.6.6 Flow test of Smart Dynamic concrete (SDC) ........................................................... 46
3.6.7 Concrete pour plan .................................................................................................... 47
3.6.8 Application of bonding agent for old concrete ......................................................... 47
3.6.9 Concreting sequence for two units (one pour) .......................................................... 48
3.6.10 Observations in concreting ..................................................................................... 48
3.7 Deshuttering of wall & slab panels .......................................................................... 49
3.8 Conventional Formwork- (ply wood, wooden runners, staging) ............................. 50
3.9 Footing Works .......................................................................................................... 51
3.10 Column Casting Procedure..................................................................................... 52
3.11 Beam & Slab Shuttering......................................................................................... 53
3.12 Stair case Shuttering ............................................................................................... 53
3.13 Ramp construction at club house ........................................................................... 54
3.14 Back filling/ Earth filling works ............................................................................ 57
3.14.1 Determination of the dry density of compacted soil by core cutter method ........... 57
3.14.2 Determination of moisture content by rapid moisture meter (IS: 2720-part-2) ...... 57
3.15 Water proofing for Balcony, utilities and toilets. ................................................... 58
3.15.1 Methodology ........................................................................................................... 58
3.16 Indian Patent Stone (IPS) flooring ......................................................................... 60
3.16.1 Methodology ........................................................................................................... 60
3.17 Gypsum Plastering ................................................................................................. 61
CHAPTER 4 TRAINING OUTCOMES
4.1 Technical outcomes……………………………………………………………......63
4.2 Non Technical outcomes…………………………………………………………..64
4.3 Improving practical skills………………………………………………………….65
4.4 Upgrading the theoretical knowledge……………………………………………..65
4.5 To develop Business contacts…………………………………………………….65
4.6 Fixing job priorities……………………….............................................................66
4.7 Communication and interpersonal skills.................................................................66
4.8 Strengthening the resume........................................................................................66
4.9 Experience and assessment.....................................................................................67
4.10 Factors to be given importance at site...................................................................67
LIST OF FIGURES
Fig No Name of the Figure Page No
1.1 Prestige Shantiniketan, Bangalore 3
1.2 The collection, UB city 3
1.3 Prestige group projects 4
2.1 Aerial view of Prestige Falcon city 7
2.2 Prestige falcon city Map location 9
2.3 Prestige falcon city Master Layout plan 9
2.4 Organisation chart for prestige falcon city at site level 12
2.5 Emergency Evacuation Route & logistic Plan 12
2.6 Rollers 14
2.7 Tough Riders( transporting concrete) 14
2.8 Passenger Cum material hoist(Builder hoist) 14
2.9 Builder hoist Permissible load chart 14
2.10 Putzmeister concrete pump 15
2.11 S205 Bobcat loader 15
2.12 Rope suspended platform/Gondola 15
2.13 Batching plant & its components 16
2.14 Aggregate recovery plant 17
2.15 Safety posters at site 18
2.16 Safety nets installation 19
2.17 Open shafts/edges protected with reinforcement mesh 19
2.18 Open edges –installation of safety nets & proper barricading 19
2.19 Safety induction to workers 20
2.20 Safety PPE 20
2.21 Construction materials tests conducted at QA/QC lab 25
2.22 Rolling margin of steel 27
3.1 Level 1 Floor plan (Ground floor) 29
3.2 Level 2 Floor plan (1st floor) 29
3.3 Typical Floor plan (2nd to 31st floor) 29
3.4 Structural line marking by surveyor 34
3.5 External working platform 35
3.6 Reinforcement of walls & Beams 35
3.7 Placing of sleeves for plumbing & fire fighting 37
3.8 Applying of Form oil 37
3.9 Electrical conduiting 37
3.10 Placing of wall panels 37
3.11 Installation order for opening (Door and window) 38
3.12 Installation of slab corner (SC & Slab level SL panels) 38
3.13 Span assembling 38
3.14 Assembled view of Beams(span), props & slab panels 39
3.15 Assembly of staircase slab panels & side panels 39
3.16 Placing of reinforcement 39
3.17 Assembly of staircase wall panels 40
3.18 Assembly of gun panels 40
3.19 Assembly tread and riser panels 40
3.20 Completed view of staircase aluminium formwork 40
3.21 Applying form oil on the slab panels 40
3.22 Slab Reinforcement & Electrical conduiting 41
3.23 Sunken arrangements 41
3.24 Placing of kicker panels 41
3.25 Placing of cutout boards at shafts 42
3.26 Soldiers, jacks & waller bracket 42
3.27 Slump test 46
3.28 Flow test 46
3.29 Placing of wire mesh along the C joint 47
3.30 Application of Bonding agent for old concrete 47
3.31 Arrangement of concrete pump & pipes 48
3.32 Staircase concreting upto midlanding 48
3.33 Concreting for slabs & walls 48
3.34 Panel puller 49
3.35 Deshuttering sequence for walls & slab panels 49
3.36 Cup lock system of staging 50
3.37 Excavation of soil as per markings given by the surveyor 51
3.38 Checking the depth ,length, breadth and level of excavated pit 51
3.39 Plain cement concrete 51
3.40 Placing of footing reinforcement with reference to markings 51
3.41 Column reinforcement & shuttering for the footing 51
3.42 Pouring, vibrating & finishing the top level of footing concrete 51
3.43 Placing of wooden runner piece at column location (shear key) 51
3.44 Column starter 52
3.45 Column casting by Peri formwork 52
3.46 Beam staging in process 53
3.47 Placing of centering sheets 53
3.48 Application of formoil & placing of reinforcement 53
3.49 Staircase reinforcement 53
3.50 Staircase shuttering 53
3.51 Ramp shuttering in process 54
3.52 Placing of reinforcement as per the structural details 54
3.53 Ramp concreting 54
3.54 Compacting concrete by needle vibrators 55
3.55 Finishing of ramp slab using aluminium straight edge 55
3.56 Curing of ramp slab using hessian cloth 55
3.57 Night concreting for Ramp slab 56
3.58 Earth filling 57
3.59 Compacting the soil in layers by using vibratory rollers 57
3.60 Core cutting method 57
3.61 Rapid moisture meter 57
3.62 Haunching with GP2 grout material 58
3.63 Bores packing with GP2 grout material 58
3.64 Water ponding test (to arrest leakages) 59
3.65 Pressure grouting machine to arrest leakages 59
3.66 Applying fosroc brush bond 59
3.67 Fix geo fabric over the coated surface 59
3.68 Laying of 20mm thick CM(1:4) mixed with Fosroc conplast 59
421 125ml/cement
3.69 IPS panel layout in chequered( divided into square) sequence 60
3.70 Pouring concrete & finishing the surface using troweling
machine 60
3.71 Mixing of gypsum & water in correct proportions 61
3.72 Fixing up of Bull marks on walls & ceiling 61
3.73 Application of gypsum on ceiling & walls 62
3.74 Completed view of Gypsum plaster 62
LIST OF TABLES
Table no Name of table Page no
2.1 Project Prestige Falcon city details 8
2.2 Builder Hoist Technical Specifications 14
2.3 Batching plant details 16
2.4 Testing frequency of construction materials 24
2.5 Rolling margin test results 27
2.6 Rolling margin tolerance as per IS 1786 27
3.1 Building 1 details 28
3.2 Chairs, Spacer bars & cover blocks 36
3.3 Concreting 44
3.4 Concrete grades for structural components 44
3.5 Materials used in SDC & normal concrete at project site 45
3.6 Mix proportions 45
INTERNSHIP AT PRESTIGE GROUP
CHAPTER 1 ABOUT THE COMPANY

1.1 INTRODUCTION
PRESTIGE GROUP
Over the last decade, the Prestige Group has firmly established itself as one of the leading
and most successful developers of real estate in India by imprinting its indelible mark
across all asset classes. Founded in 1986, the group's turnover is today in excess of Rs.
3518 Cr (for FY 15). A leap that has been inspired by CMD Irfan Razack and marshalled
by his brothers Rezwan Razack and Noaman Razack. Having completed more than 210
projects covering over 80 million sqft, currently the company has 53 ongoing projects
covering 54 million sqft and 35 upcoming projects aggregating to 48 million sqft of
world-class real estate space across asset classes. In October 2010, the Prestige Group
also successfully entered the Capital Market with an Initial Public Offering of Rs 1200cr.
Now with over 205 landmark developments across the city, the company has extended its
expertise to major cities across South India including Chennai, Hyderabad, Kochi,
Mysore, Mangalore and Goa. Giving each city an unparalleled experience with landmark
malls on the lines of 'The Forum', large townships, tech parks, hotels, luxury villas, and
SEZs. The company already has several successful completed and ongoing projects in
Chennai to its credit, spanning the commercial and retail segments. Prestige Cyber
Towers, Prestige Polygon and Prestige Palladium are three completed commercial
developments, which have received an overwhelming response. The Forum Vijaya Mall,
Chennai's largest mall was unveiled in 2013. The Prestige Group launched Chennai's first
township project - a Rs. 1,000 crore development in partnership with the Rattha Group in
2012. They also launched Prestige Silver Springs the first-of-its-kind luxury villas in the
city in 2013.
1.2 COMPANY’S VISION

To continuously exceed the expectations of our customers and employees and become a
benchmark for quality in every field the Prestige Group ventures into.
1.3 COMPANY’S MISSION

To improve customer experiences through constant innovation and understanding, with a
focus on quality and transparency of processes so that when it comes to Prestige,
customers come to expect nothing but the best from us. Every time.
BMSCE, BENGALURU Page 1

1.4 ACCOMPLISHMENTS
The Prestige Group today has become a name that is synonymous with innovation. The
company has pioneered many landmark developments and introduced many firsts to
South India:
 Prestige Acropolis: A tribute to classical Greek architecture, one of the first

Premium residential developments in Bangalore.
 Prestige Ozone: One of the first gated communities in Bangalore.
 The Forum mall: Pioneered the retail revolution in Bangalore. Globally-recognised
and probably the first successful retail mall in the country which created new
benchmarks in modern day retailing.
 Forum Value Mall: South India's first real outlet mall featuring international and
national brands.
 The Collection, UB City: South India's first luxury mall (Partnered initiative with
Vijay Mallya - UB Group).
 Prestige Golf shire: South India's first golf villa development set against the
picturesque Nandi Hills. Spread across 275 acres, the property comes complete with
ultra-luxurious mansions, a club house - Falcon Greens, a luxury spa - Quan, a
private lake and an 18 hole, championship-sized golf course. With this project, the
Prestige Group has also introduced the world-class 5-star, luxury resort hotel - The
Marriot International to Bangalore.
 Prestige Shantiniketan: South India's first wholly integrated township
development.
 Prestige Lakeside Habitat: Largest residential development by the company till
date, in terms of acreage and the total number of residences (spanning 102 acres &
consisting of 3,428 apartments and 271 villas) apart from being the biggest
upcoming residential township development in the country today. This development
introduces Disney inspired residences to Bangalore.
On the hospitality front, the Prestige Group has been credited with introducing some of
the most reputed international brands in the world to South India, such as the Hilton
Group and Marriott International for hotels; the Banyan Tree for resorts and Oakwood
for service apartments. In association with Starwood Hotels & Resorts Worldwide, the
company launched their hotel, 'The Aloft', in Cessna Business Park in 2014 and will be
launching the Sheraton Hotel in Prestige Shantiniketan in the near future.

1.5 LANDMARK PROJECTS

o Prestige Acropolis.
o Prestige Ozone
o The forum mall
o The Collection, UB city
o Prestige Shantiniketan
o Prestige Lakeside Habitat
o Prestige Oasis
o Prestige Lake vista
o Prestige Golfshire Club
o Prestige Lake Ridge
o Prestige Tranquility
Fig 1.1 Prestige Shantiniketan, Bangalore
Fig 1.2 The Collection, UB city

Fig 1.3 Prestige group projects
Reference: Annual report of prestige group 2015-2016

1.6 AWARDS & RECOGNITIONS:-

 The Prestige Group is the only developer from Bangalore to receive the reputed
FIABCI award for their software and residential facilities.
 At the Asian Brand Conclave this year, Prestige Group was awarded the "Admired
Brand of Asia" in the category of Real Estate.
 Mr. Irfan Razack was chosen as the "Admired Leader of Asia 2014-15".
 The company's Investor Relationship (IR) Programme, as was ranked Second
Best in Asia and the Best in India by the Institutional Investor (II) magazine's
2014 All Asia Executive Team Rankings.
 Prestige is the only CRISIL DA1 rated Developer in India and was recently awarded
the financial rating of A-by ICRA.
 They have also won a plethora of international and national awards over the last few
years across various categories such as;
o Cityscape Awards.
o Indian Realty Awards.
o Srishti Good Green Governance Awards.
o Pevonia Asia Spa Awards.
o Builders Association of India (BAI) Awards.
o Confederation of Real Estate Developers’ Associations of India
(CREDAI) Awards.
o Asia Pacific Hotel Awards.

1.7 QUALITY POLICY

Prestige group’s motto is Quality, Commitment and Performance.
The Scope of their Quality System is Planning, development, marketing and management
of residential, commercial and Institutional layouts.
Prestige follows a Quality Management System hierarchy that is strictly abided by in all
its residential and commercial properties in Bangalore and elsewhere. This system
includes departmental guidelines and work instructions as well as essential directions for
the quality management system from the top management, covering all requirements of
ISO 9001:2000.
To this effect, Quality Records are maintained methodically and carefully.
The group ensures that wastage during construction is as low as 5%, thus providing
optimum value for the client's money whether it is a commercial property investment or
an individual who wants to buy an apartment or villa. They adopt latest technologies for
safer, timely and reliable construction across all our properties in Bangalore and in other
cities, giving you the best bet when you buy an apartment.
The group encourages customer feedback and reviews so that corrective actions can
immediately be put in place. Their quality standards and procedures are periodically
reviewed so as to maintain continuous improvement in all areas of activities based on
customer inputs to enhance customer satisfaction.
The group’s aim is not restricted to being among the best Bangalore builders or in the
country alone but also to be as environment friendly as possible. They address
environmental safeguards and improvements in all our developments for the conservation
and development of a greener and safer environment.

CHAPTER 2 ABOUT THE PROJECT AND DEPARTMENTS

2.1 PROJECT OVERVIEW
PRESTIGE FALCON CITY is a mixed used residential project consisting of 7 residential

buildings containing 4 towers in each building. Phase I consist of 5 buildings, a club
house and a multi utility mall. Phase II consist of 2 more buildings and a school.
Each of the 5 buildings in Phase I consists of 32 floors (G+31). Building 6 and 7 of Phase
II consists of 26 floors (G+25) and 31 floors (G+30) respectively. Each building has a
helipad on top it. Each building also consists of lower basement and upper basement
completely dedicated for vehicular parking and staff office and quarters.
Apartment unit varies from 2, 2.5, 3 & 4 BHK. Area of the unit’s varying from a
minimum of 1204 sqft to a maximum of 2710 sqft. All this exactly translates into a total
of 2520 number of apartment units. Fig 2.1 gives the aerial view and table 2.1 gives the
details of the project. The location of map and master plan are presented in Fig 2.2 and
2.3 respectively.
Fig 2.1 Aerial view of Prestige Falcon City

Project name PRESTIGE FALCON CITY
Location Kanakapura Road, Bangalore
Development Type Mixed- Use Development
Development Area 48.60 Acres
Commercial development 7.60 Acres
Phases 2 Phases of construction
Client Prestige groups Ltd
Contractor JMC Projects (India) Ltd.,
Architectural consultants M/s Venkataramanan Associates
Structural consultants M/s MAHIMTURA Consultants (Bang) Pvt Ltd
PHE & FPS Consultants M/s Sampath Kumar Associates, Bangalore
MEP Contractor M/s Shobha Group, Bangalore
Landscape Consultants VIA + Signature (PI)
Electrical Consultants Power- Designs India P Ltd
Window Vendor Fenesta
Elevator Vendor (Lift works) Fujitech
Painting vendor Vibgyor/Dulux
Total cost (Approx) Rs. 1200 crores
No of towers 20 (5 Building phase 1) , 8 ( 2 Building phase 2)
Total no of flats 2520( phase 1)
Type of flats 2/2.5/3/4 BHK
Table 2.1 Project Prestige Falcon city details

Fig 2.2 Prestige Falcon City Map Location
Fig 2.3 Prestige Falcon city Master Layout Plan

2.2 SPECIFICATIONS
1. Structure
 RCC Framed Structure with RCC Shear wall.

 Cement Blocks for all Walls Wherever Needed.
2. Lobby and Staircase
 Elegant Granite/Marble Flooring and Cladding In Ground Floor Lobby.

 Vitrified Tile Flooring in Upper Floor Lobbies & Marble/Granite Cladding in Lifts.
 Textured Paint On All Lobby Walls and OBD on Ceilings.
 Kota Stone on Service Staircase & Service Lobby with Textured Paint on Walls.
3. Lifts
 2 service lifts in centre of each building

 4 passenger lifts in each building (2 per 2 towers)
4. Apartment Flooring
 Vitrified/Ceramic tiles in the foyer, living area, dining area, corridors and all
bedrooms.
 Anti-skid ceramic tiles in balconies
5. Kitchen
 Ceramic/Vitrified tiled flooring.

 Ceramic tile dado for 2 feet over a granite counter.
 Chrome plated tap with single bowl single drain steel sink.
 Ceramic/Vitrified tile flooring and ceramic dado in the utility area.
6. Maid’s Room
 Vitrified/Ceramic tile flooring and dado in the maid's room and toilet.
7. Toilets
 Anti-skid ceramic tiles for flooring with ceramic tile on walls upto false ceiling.
 Granite counter with ceramic wash basin in the master toilet.
 Pedestal wash basins in the other toilets.
 EWCs and chrome plated fittings.
 Chrome plated tap with shower mixer.

8. Painting
 Textured paint/Cement paint on external walls.

 Distemper on internal walls and ceilings.
 Enamel paint on all railings.
9. Doors and Windows
 External Doors and Windows - Aluminium/UPVC frames and sliding/openable

shutters for all external doors.
 3 track Aluminium/UPVC framed shutters with clear glass and provision for
installation of mosquito mesh shutters.
 MS designer grill, enamel painted, for ground floor apartments only.
 Internal Doors - Main door - 8 feet high opening with pre-moulded flush shutter and
frame in wood, polished on both sides.
 Other internal doors - 7 feet high with wooden frames and flush shutters.
10. Electrical
 All electrical wiring is concealed and uses PVC isolated copper wires with modular
switches.
 Sufficient power outlets and light points provided for.
 4 KW power will be provided for 2 & 2.5 Bed units.
 6.4 KW power will be provided for 3 Bed units.
 8 KW power will be provided for 4 Bed units.
 TV and telephone points provided in the living area and all bedrooms.
 Provision to install split AC in living area and in all bedrooms.
 ELCB and individual meters will be provided for all apartments.
11. Security System
 CCTV coverage and security cabins at all entry/exits.
12. DG Power
 Generator will be provided for all common services. 100% backup power will be
provided for all apartments at extra cost.

2.3 ORGANISATION STRUCTURE
Fig 2.4 Organization Chart for Prestige Falcon City at site level
2.4 EMERGENCY EVACUATION ROUTE & LOGISTIC PLAN
Fig 2.5 Emergency Evacuation Route & Logistic Plan

2.5 Departments at project site PFLN
Various departments at project site PFLN
 Plant and Machinery

 Safety
 Quality
 Execution
 Store
 QS/Billing
 Planning.
As a trainee, I was exposed to four departments within the firm for 16 weeks. The
departments are Plant & machinery, Safety, quality & Execution.
2.5.1 Plant and Machinery (P & M) Department

The need of today’s construction practice is ‘faster completion of work, faster returns of
investment’. This fast-track mode of construction has paved the way for mechanization in
construction. Prestige falcon city project site is equipped with all necessary machineries
to reach the target well within time. The project ‘Prestige falcon city’ is mechanized to
greater extent with all kinds of machineries.
The various machineries deployed for the Execution are
 Rollers
 Hydraulic Excavators cum Loaders- Back Hoe
 Stationary Concrete Pumps- 3 numbers
 Passenger cum material hoist
 Weighing Bridge
 Transit mixers (6 m³ capacity)-8 numbers.
 Needle vibrators.
 Batching plant -2 numbers.
 S205 Bobcat loader.
 Tower Crane.
 Bar Bending machine.
 Recycling wash water / aggregate recovery plant.
 Tough rider- for transporting concrete (0.4m³).

Fig 2.6 Rollers Fig2.7 Tough Rider (Transporting concrete)
Fig 2.8 Passenger cum material hoist Fig 2.9 Builder hoist permissible load chart
(Builder hoist)
SWL 1500 kg’s or 15 persons

Speed 40 m/min
Power 26 KW
Present height of lift 28 m (i.e. landing G+7th floor
Table 2.2 Builder Hoist Technical Specifications.

Concrete output 48m³/hr
Concrete pressure 106 bar
Hopper capacity 600 liters
Delivery Distance,
600 m
Horizontal
150 m
Vertical
Fig 2.10 Putzmeister Concrete Pump
Model- JCB ROBOT-100

Operating load – 929.9 Kg
Bucket capacity- 0.4 m³
Max lift height- 751.8mm
Fig 2.11 S205 Bobcat loader
Rated lifting speed 8 m/ min
Counter weight 1000 Kg’s
2500mm x
Dimensions
700mm x 1100
wire rope length 100 m x 4 falls
Power 3.6 KW
SWL (safe working

Fig 2.12 Rope suspended platform/Gondola 400 Kg’s
load)

Fig 2.13 Batching plant & its components
Table 2.3 Batching Plant details

2.5.1.1 Recycling wash water / Aggregate recovery plant at site.

After concrete is poured at a construction site, the drums of transit mixer (RMC trucks)
must be washed out to remove the left over concrete before it hardens or for the next
loading of concrete.
This left over concrete is washed in Aggregate Recovery plant to recovery the
aggregates.
Fig 2.14 Aggregate Recovery Plant

Mechanism
 Transit mixer washout concrete discharges into the charging hopper and flows in to
the washing drum.
 The drum rotates to separate the aggregates and slurry water by reverse flow
method.
 The slurry water gets collected into the slurry tank.
 The aggregates get collected through vibrating sieve.
 The agitator stirs the slurry tank in regular intervals to avoid deposition.
2.5.1.2 Internal Climbing Tower crane

To enable the operation and climbing of tower crane, two supports that comprises of steel
beams & steel brackets at every 5 levels are required to be fixed to the nearby structural
walls to restrain the mast section.
The mechanism that enables the jumping of the tower crane is hydraulic jack and a pair of
interim supports (steel brackets, steel beams).

2.5.2 Safety Department
Safety at construction site means absence of accidents and hazardous events. Safety
department in which coordination of labours is very important as their tendency of
negligence can pose threat to their life as well as others.
Safety practices followed at the site prestige falcon city are as per the Indian standards &
OSHA guidelines
2.5.2.1 General Site Safety Rules
 All persons should wear approved helmet, safety shoe and all required PPE.
 Child labour at site is strictly prohibited.
 Smoking is prohibited at work place, except in smoking zones.
 Gambling, Alcohol, drugs and unruly behavior are strictly prohibited.
 Follow all safety signs, site traffic rules and obey all instructions given by
authorized persons.
 Always maintain good housekeeping and the work area clean and tidy.
 Safety posters/placards must be displayed and followed
 Emergency escape procedures.
 Display Safety park board at entrance.
Fig 2.15 Safety Posters at site

2.5.2.2 Safety Practices observed at site
 Safety nets are installed at

every 5 floors.
 By installing safety nets
there is less probability
that the workers will be
injured if they fall.
 Protection from falling
objects/materials.
Fig 2.16 Safety Nets Installation
Fig 2.17 Open shafts/edges protected with Reinforcement mesh/polythene mesh
Fig 2.18 Open edges –installation of safety nets & proper barricading

Fig 2.19 Safety Induction to workers
Fig 2.20 Safety PPE

2.5.3 Quality Department

Quality department - responsible for QA & QC
Quality Assurance (QA) & Quality Control (QC)
 Testing the materials and products in labs.

 Ensuring the good workmanship at site.
2.5.3.1 Documents maintained at QA/QC lab
 Moisture content register

 Daily cement & Flyash Received register
 Concrete cube register.
 Rolling margin register.
 Material Rejected Register (M sand , 20 mm & 12.5 mm coarse aggregate)
 Steel, water, cement, tiles, gypsum, fly ash, Geo-text membrane etc all this
material third party test reports.
 NDT –Non destructive testing reports.
 Method Statements (Methodology) for all the civil works.
 Project Quality plan.
 Monthly quality reports.
2.5.3.2 Quality control flow chart for materials at site PFLN

2.5.3.3 Tests Conducted in Quality Lab

Tests for cement
 Standard Consistency of cement.

 Initial & Final setting time.
 Fineness of cement (90 micron IS Sieve)
 Soundness (Le-Chatelier)
 Compressive strength of cement.
Test for aggregates (CA/FA)
 Specific gravity
 Sieve analysis
 Silt content (wet sieve through 75µ)
 Flakiness index
 Elongation index.
 Aggregate impact value
 Aggregate crushing value
 Water absorption
 Moisture content
Test on Steel
 Unit weight- Rolling margin
Test on Concrete
 Fresh state-Slump test/flow test

 Hardened state- Compressive strength
2.5.3.4 Third party tests for the construction materials

Tests on Flyash
 Fineness of Flyash
 Chemical & Physical analysis
Test on steel
 Chemical & physical analysis

 Diameter.
 Area.
 Yield strength
 Gauge length.
 Ultimate load & Strength.
 Final length & percentage elongation.
 Fracture.

The mentioned tests are done as per the frequency
Sl Title Test location Frequency of test IS Codes
1 Coarse aggregate(CA) /Fine aggregate(FA)
1.1 Specific Gravity (CA/FA) Site lab
Every 50 m³
received-CA &
1.2 Sieve analysis Of aggregate
Site lab 100 m³ received-
(CA/FA) FA.
Aggregate crushing value & Every fortnight

1.3 Site lab IS 2720
impact value (CA) one test
Flakiness/Elongation conducted in site
1.4 Site lab lab
index(CA)
Selection of
Test for organic
1.5 Third party source/change of
impurities(FA)
source.
2. Cement
2.1 Fineness of cement
2.2 Standard consistency
2.3 Setting time Third party IS 4031 &

Manufacture test testing for every
2.4 Compressive strength certificate or site lab 1000MT IS 3535
test & Third party
2.5 Soundness
Every 6 months
3 Water Third party IS 456
once
4 Reinforcement steel
3 sample for
4.1 Rolling margin Site lab
each lot
Manufacturer test
Tensile test, Elongation, Bend Certificate or test Third party test IS 1786
4.2
& Rebend test report from third for every 50MT :2008
party

Chemical Third
4.3 While change of source
analysis party
5 Concrete
IS
Outside Third party for all grades (initially).
Mix design 10262
5.1 lab/Site lab In site lab- change in brand of cement
:2009
First 5 transit mixer initially after

Slump/flow test Site IS:1199
5.2 randomly
&
Compressive IS 516
5.3 Site lab Qty of concrete m³ & no of sample
strength
1-5 m³ =3, 6-15 m³ = 6, 16-30 m³ = 9, 31-50 m³ = 12 & 51 & above = 12 + 6 sample for
each 50m³ concrete
Table 2.4 Testing frequency of construction materials

2.5.3.5 Material tests conducted at QA/QC lab at site.
Fig 2.21 Construction materials (Aggregate, Cement) tests conducted at QA/QC lab
All the Tests conducted as per the Indian standards IS codes.

2.5.3.6 Quality tests for the concrete.
2.5.3.7 Quality tests for steel
Mill Certificate must contain following test results
 Lot/heat number.
 Dia of Bar mm, Quantity in MT.
 Chemical composition- Carbon, Sulphur,
phosphorous content.
 Mechanical properties- weight (Kg/m),
Proof/yield stress N/mm², Tensile strength,
Elongation, Bend & Rebend Test, Grade of steel.

2.5.3.8 Determination of rolling margin of steel (IS 1786)

Rolling margin is the deviation of actual unit weight to that of standard unit weight as per
IS standards.
Theoretical Rolling margin can be calculated as
Weight per meter = Π/4 x d² x 7850 = d²/162.
Rolling margin determination at site.
Cut 3 bars of 1 m length and determine the weight per m.

Fig 2.22 Rolling margin of steel
It should fall within tolerances given in IS 1786
Steel falling below or beyond the following tolerances should be rejected from the site.
On 14/08/2017 test results
Table 2.5 Rolling margin test results
Table 2.6 Rolling margin tolerance as per IS 1786

CHAPTER 3 TASK PERFORMED

During first few days of my industrial training I was introduced to Prestige team and the
towers which are in construction stage. It took a while to understand the activities in the
site, roles and responsibilities of prestige in the project.
3.1 Building 1 Details

6 weeks of the internship I was assigned to Building 1 region and allowed to study the
drawings and details of the building like built up area, number of floors, number of
towers and number flats in each tower and sequence of activities which are involved in
completing of these towers ,assigned me to collect all these data. Fig 3.1 to 3.2 gives the
floor plan of Building 1 and Table 3.1 gives building 1 details.
Table 3.1 Building 1 Details

Fig 3.1 Level 1 Floor Plan (Ground Floor) Fig 3.2 Level 2 Floor plan (1st Floor)
The level 1 & 2 consist of total 12 flats & 2 Lobbies (Double height space)
Fig 3.3 Typical Floor Plan (2nd to 31st Floor)

Each tower consists of 126 Flats (T 1, 2, 3 & 4) from GF to 31st floor, therefore total
number of flats in building 1 is 504 Flats.
Floor to Floor height is 3.050 m.
Ground level RL = 105.45m, Terrace finished floor level = 203.05m & Parapet
height=1.5m. Therefore total height of Building 1 is (203.05-105.45) + 1.5 = 99.1 m.
Sunken Slab is provided for Utility, Balcony and Toilets.

All Windows present in Building 1 is of height 1200mm. Sill height for windows, Duct
Door is of 900/1200mm and Lintel Height is of 2100/2400 mm.
3.2 Kumkang Aluminium formwork

Kumkang (Mivan) shuttering is a fast pace construction technique, which offers
customized aluminium formworks for better strength, finish and durability of building.
First introduced in European countries, this system of construction is gaining fame in
almost all high rise constructions in India.
Kumkang aluminium forms adopted in site is from Ground floor onwards.
Advantages
 3s system of construction-speed, strength, safety

 Walls and slabs are cast in one pour.
 Light weight forms for easy handling.
 Better concrete finishes.
 Smart dynamic concrete is used hence no need of compaction.
 Repetition are more (more than 100 times)
 Aluminium panels can be recycled (Eco friendly).
Limitations
 Requires accurate planning, since any alteration is highly difficult.

 Heat of hydration is high due to shear wall concept.
 Proves economical, only for minimum 100 repetitions.

3.3 Components in Kumkang Aluminium formwork

COMPONENT IMAGE DESCRIPTION
Wall Panel with 50mm

rocker(RK) at Bottom
Used for internal wall panels
Wall Panel without rocker

Used for External Wall panels
Wall End Panel used for Doors &

Windows.
EC (External Corner angle) used

to join 2 external wall panels at
corner area.
IC ( Internal- Corner panel) used

to join 2 internal wall panels at
corner area

Beam Soffit Panel

Used for setting up of doors &
Windows
SC Slab corner
Slab Level (SL) used to join wall

panel with slab panel.
Slab Panel
Prop Head

End Beam, Middle Beam,

Prop Head together called
Aluminum span
Steel Props (is used to support

the weight of the slab during
concrete pouring and casting. It
will remain under the prop head
until 1 level of casting)
Wedge Pin (will be used to join

the wall or slab panels together)
Wall Tie with PVC sleeve (Used

to joint the wall panel to the
opposite side’s wall panel.)
The wall tie will be inserted
inside PVC sleeve in order to
protect the wall tie to be casted
within the concrete.
Waller Bracket combined with

square pipe are used to allow the
horizontal straightness of wall
panels and to have a flat wall
surface after concrete casting.

3.4 Sequence of works in Aluminium formwork
1. Structural line
(grid line) marking
on the slab by 6.Installation of slab
Surveyor for wall corner (sc) and slab 7. Placing of stair
panels erections as level (sl) case panels
per the farming
layout (form plan).
8. applying form oil

5. electrical on the slab panels.
2. External working conduting & placing 9.slab reinforcement
platform fixing of wall panels & electrical
conduiting
3.Reinforcement of 4. placing of sleeves 10.placing of sunken

walls and beams for plumbing and fire panels , kicker panels
(floor & link beams) fighting & placing of cutout
boards at shafts (mep)
Checking & Concreting
3.4.1 Structural line (grid line) marking on the slab by surveyor for wall panels
erections as per the farming layout (form plan).
Procedure:-
Structural Line is drawn on the slab at offset

distance of 200mm from internal side of wall
with help of points given by the surveyor at
every right angle of walls (at every corner of
walls).
Surveyor locates these points with aid of total

station equipment.
The application of total station that is used by

surveyor is Stake out /Setting out process.
Stake out means process of finding the

positions of Known coordinates points.
Fig 3.4 Structural line marking by surveyor

3.4.2 External Working platform
Fig 3.5 External Working platform
Fixing of brackets at spacing of 600mm to 1200 mm distance (Spacing as provided in

bracket plan). Fig 3.5 gives external working platform view & Bracket plan.
Square steel tube and ply wood are placed on Brackets.
Entire platform is covered with safety net with aid of 20mm steel bar.
External working platform safety inspection checklist
o Is the safety brackets are secured with RCC wall?

o Is the safety brackets are fixed as per the Bracket plan?
o Is the 3 x square tubes are fixed over the safety brackets for making a working
platform?
o Is the working platform is made up of ply wood (minimum of 12 mm thickness) over
the square tube for making a proper working platform ?.
o Is the toe boards (250 mm) are provided across the edge of the working platform?
o Is the working platform are provided with double hand rails (Top & mid rails)?
o Is the Rebar (2.5 m length & 20 mm dia) is inserted into safety brackets vertically?
3.4.3 Reinforcement of walls and beams (Floor & Link beam)
Fig 3.6 Reinforcement of walls & beams

Description Photo
Steel elements which separate the

different layers of reinforcement for
Chairs members like footings and slabs and
keep them in their respective positions
while concreting.
These are steel elements which

separate the reinforcement and hold
Spacer them in position for RCC beams.
bars
Min 16 mm dia or main bar dia
whichever is greater.
It is the minimum distance of the steel

reinforcement from the concrete
Cover surface to protect the steel from
blocks weathering. It is to ensure that the steel
is completely embedded in concrete.
Table 3.2 Chairs, Spacer bars & cover blocks
Splicing
The process of joining two bars to transfer the force from one bar to another bar in an
RCC element is called as Splicing.
Splicing by lapping at PFLN site.
Grade of concrete Lap length
M 20 57D
M25 50D
M30 46D
M35 40D
M40 & ABOVE 36D

3.4.4. Placing of sleeves for plumbing and fire fighting.

PVC sleeve for PHE
service pipes
Groove
Fig 3.7 Placing of Sleeves for plumbing & Fire fighting
Sleeves are opening in the concrete that allows passage of pipes i.e. water supply pipes,
fire fighting pipes in building once finished.
3.4.5 Electrical Conduiting & placing of wall panels.
Fig 3.8 Applying of Form oil Fig 3.9 Electrical Conduting
Fig 3.10 Placing of wall panels

Installation order for opening (door, window)
1. Wall panels
2. Wall End panels
3. Beam Bottom SC
4. Beam Bottom Slab

Panel.
5. Beam Panel
Fig 3.11 Installation order for opening (Door & Window)
Note:-If installation order is not trained properly to workers, it will damage the
panels and delay the construction period.
3.4.6. Installation of Slab corner (Sc) & Slab level (SL) panels.
Slab level
Slab Corner
Fig 3.12 Installation of Slab corner (SC) & Slab level (SL) panels
Installation of beams (span), props & slab panels as per the formwork layout
Beams are assembled using the middle beam or End Beam & prop head with joint bars &
long pin. Assemble the Beams on the floor before installing them on the slab level.
Fig 3.13 span assembling

Fig 3.14 Assembled view of beams (span), props & slab panels
3.4.7 Staircase
Fig 3.15 Assembly of stair case slab panels Fig 3.16. Placing of reinforcement
& side panels.

Fig 3.17 Assembly of staircase wall panels Fig 3.18 Assembly of gun panels
Fig 3.19 Assembly of tread & riser panels Fig 3.20 Completed view of aluminium
formwork Stair case.
3.4.8 Applying form oil on the slab panels
Purpose of Form oil:
The concrete tends to stick on the

aluminum panel. Thus, by applying
form oil, it will reduce the
adhesiveness between the concrete
and the panel.
Fig 3.21 Applying form oil on the slab panels

3.4.9 Slab reinforcement & electrical conduting.
Sunken Arrangements
Fig 3.22 Slab Reinforcement & electrical conduting
3.4.10 Sunken arrangements in Aluminium formwork.

SUNKEN AREAS
To accommodate facilities like plumbing

pipes, the slab is lowered by 75mm to
150mm. Toilet – 75 mm sunken,
Balcony – 100 mm sunken, Utilities -
150mm sunken.
Spacer angles
Fig 3.23 Sunken arrangements
3.4.11 Placing of kicker panels

Placing of kicker panels on all
external wall panels, lifts and
staircase as per the kicker panel
drawing.
This kicker panels anchored to

the concrete and acts as ledge for
the wall panels for the next floor
to sit on. (Where vertical surface
Fig 3.24 Placing of kicker panels is coming)

3.4.12 Placing of cutout boards at shafts (electrical, fire, telecommunication,

plumbing shafts)
Fig 3.25 Placing of cutout boards at shafts
3.4.13 Other Accessories

Fig 3.26 shows the accessories that is soldiers, jacks & waller bracket required for the
alignment of wall panels (interior & Exterior panels)
Fig 3.26 Soldiers, Jacks & Waller bracket

3.5 Checklist for Reinforcement & Shuttering

3.5.1 Reinforcement
 Bar dia, shape of bars, dimension of bar, number of bar, cleanliness of bars.
 Check for correct placing and spacing of bars as per drawings.
 Provision of chairs, cover blocks & spacer bars.
 Lap length and location of laps.
 Check for satisfactory tying of reinforcement with binding wire.
3.5.2 Shuttering
 Horizontal alignment of wall panels (Line dory & grid line by surveyor) & inner
dimensions of rooms, doors & windows.
 Vertical alignment of internal wall panels (Plumb check).
 Vertical alignment of external wall panels (Plumb check) for straightness and
verticality of the wall.
 Whether wedge pin and flat ties have been installed correctly.
 Whether the props have been installed as per the formwork layout.
 Whether all panels have been installed.
 Check for cleanliness of the panels.
 Whether form oil has been applied on the slab panels.
 Check for the sealing of gaps, joints & holes.
 Check for completion of other preceding activities such as fixing of sleeves, electrical
conduits and other services before fixing of wall panels.
 A alignment of kicker panels
3.5.3 prior to concreting
 Check for cleanliness of the area (slab panels) to be concreted.

 Check for Provision and working condition of concrete aids such as vibrators , needle,
batching plant, transit mixer, concrete pumps & pipes.
 Sequence of concreting.
 Availability of sufficient number of moulds.
 Availability of concrete flow measurement apparatus.
 Grade of concrete & total qty of concrete required.
 Availability of manpower and materials.
 Checking level of slab using Auto level.
 Back propping.
 Nitobond application to the construction joint.

3.6 CONCRETING
The process of mixing, transporting and placing of concrete is called concreting.
Batching, Mixing In house Batching plant
Transporting Transit mixer, pump & pipe line
Placing of concrete Form work
Compaction of concrete Needle vibrators (normal concrete)
Curing Water curing- hessian cloth, spraying water.
Table 3.3 Concreting
3.6.1 Concrete Grades are as follows
Structural Components Floors Concrete Grade
Foundation to 6th floor M 45
Columns , Shear walls & Stair 7th to 12th floor M40

case
13th to 18th floor M35
19th to 24th floor M30
25th to terrace floor M25
Upper basement to M35

ground floor
Beams & slab
1st to 7th floor M45
Raft foundation M35
Foundation Retaining wall M30
Grade slab M25
Table 3.4 Concrete grades for structural components
Two types of concrete they are using at project site
 SDC-Smart Dynamic concrete (SDC)

 Normal concrete.

3.6.2 Smart Dynamic Concrete (SDC) [1]

The low fines self consolidating concrete from BASF is known as smart dynamic
concrete.
 Fits between Normal concrete (Traditional vibrated concrete) & SCC

 Contains less binder but exhibits SCC properties.
 Easy placement with no compaction
 Flow able for grades M20- M45
 Good surface finish.
3.6.3 Materials used in SDC & normal concrete at project site

Smart Dynamic concrete Normal concrete
cement ACC/Penna 53 grade cement ACC/Penna 53 grade cement
mineral admixture Fly ash from Ash Tech Fly ash from Ash Tech
coarse aggregate 20MM & 12.5 DS 20MM & 12.5 DS
fine aggregate M Sand Conforming to Zone 2 M Sand Conforming to Zone 2
chemical admixture Master Glenium 8633 (BASF) Master Polyheed 8338
Table 3.5 Materials used in SDC & normal concrete at project site
Table 3.6 Mix Proportions

3.6.4 Moisture Corrections

Moisture content is determined for M sand , 20 mm & 12.5 mm coarse aggregate by
means of oven drying method twice a day ( @ 8.00 A.M & 5.00 PM).
Testing readings are sent to Batching plant (Concrete production plant) for moisture
content corrections.
3.6.5 Slump test for Normal Concrete

Slump test is carried out as per IS code 1199:1999
Fig 3.27 Slump test
3.6.6 Flow test of Smart Dynamic concrete (SDC)

Flow range – 600 to 620 mm
Fig 3.28 Flow test
SDC is used for concreting the units (i.e. flats from G + 31st floor).
Normal concrete is using for concreting the raft foundation, isolated footings, column,
beams, flat slab.

3.6.7 Concrete pour plan

 2 flats with or without staircase & Lift concreting is equal to 1 pour.
 Total 8 concrete pours are required to complete concreting of 16 units (walls &
Slab).
 Each pour consists of 120 m³ to 175 m³.
 Construction joint will be at L/3 from support.
 Total concrete quantity for concreting of 16 units is 1050m³.
Fig 3.29 Placing of wire mesh along the C joint
3.6.8 Application of bonding agent for old concrete

Bonding agent is used for bonding fresh wet concrete and old concrete (Existing
cementitious surface).
Bonding agent used at site is FOSROC product -Nitobond EP Base & Nitobond EP
hardener.
This hardener & Base Component should be mixed in equal proportions.
Methodology
Fig 3.30 Application of bonding agent for old concrete

3.6.9 Concreting sequence for two units (one pour)
Fig 3.31 Arrangement of concrete Fig 3.32 stair case concreting upto
Pump & pipes midlanding
End
Start
Fig 3.33 Concreting for slabs & walls
3.6.10 Observations in concreting

1. Concrete pump line blockages, resulting in delay of the concreting due
 Not cleaning the pipeline properly after concreting. (After concreting pipeline
should be cleaned by ball pass.)
 Operator’s carelessness, insufficient supply of grout (or use of pump primer) to
lubricate complete pipeline length prior commencing the concrete pumping.
 Improper mix (very stiff or wet) - In bleeding concrete water is forced out of the
mix, creates blockage by jamming.
 Poor pipeline- too many bends, sharp bends and joints.
2. Tendency of the workers to keep the needle vibrators dropped at a single point for
more duration, instead of lifting and dropping at different points of concreting.

3. Concrete pipeline burst due to wear of pipes (reduce the gauge of pipeline).This can be
minimized by frequent checking of gauge and changing of the pipes which are having less
gauge.
3.7 Deshuttering of wall & slab panels

After 35 hours of concreting, Deshuttering of wall & slab panels’ activity will start
Dismantling process is a very important process. Therefore engineers should train the
workers to know the Dismantling method of walls, Beam & Slab panels.
Components required for Deshuttering

 Panel puller.
 Wall tie puller.
 PVC puller.
 Hammer.
Fig 3.34 Panel Puller
Fig 3.35 Deshuttering Sequence for wall & Slab Panels
Note:-
While de shuttering the slab panels, the steel props & prop head will not be dismantled &
disturbed.
Steel props & prop head will be dismantled only after the next level casting this is known
as BACK PROPING.

3.8 Conventional Formwork- (ply wood, wooden runners, staging)

Formwork and Centering is a temporary structure that is erected to support and contain
concrete to the required dimensions and shape, till it attains enough strength to become
self supporting.
The formwork is designed to safely support the combined loads (dead and live loads)
during concreting, without bulging or deflecting.
Materials required for conventional formwork
A) Staging- Cup -lock system, is a supporting system required to keep the form work in
position. It carries loads and transmits it to the firm surface/base.
Cup-lock system components –
1. Base jack
2. Verticals/standards of different height
3. Horizontals/ledgers of different lengths
4. Adjustable screw jack (U head)
5. Primary Waller - (ISLC – 75mm x 40mm)
6. Secondary Waller – Hollow square tube of size 50mm x 50 mm x 2.9 mm
B) Ply wood dimensions – 2.44 m x 1.22m thickness – 6mm
C) Wooden Runner size -75 mm x 50mm, Runners are used to strengthen the plywood
and to prevent the plywood from bending, warping & Bulging. Spacing & size of runners
depends on loads that will be imposed on the formwork.
D) Centering sheets @ site they are using Mivan slab panels.
Figs 3.36 Cup lock system of staging

3.9 Footing Works
Fig 3.37 Excavation of soil as per markings Fig 3.38 Checking the depth, length,
given by the surveyor. breadth and level of excavation using
measuring tapes & auto level, as per the
drawing.
3. Pouring & finishing the top level of PCC
with aluminum straight edges.
4. Curing the PCC for 24hrs
5. Markings for placing the footing and

column reinforcement.
Fig 3.39 Plain Cement concrete (PCC)
Fig 3.40 Placing of Footing reinforcement Fig 3.41 Column reinforcement &
with reference to markings shuttering for the footing
Fig 3.42 Pouring, vibrating & Finishing Fig 3.43 Placing of wooden runner
the top level of footing concrete piece at column location.(Shear Key)

3.10 Column Casting Procedure

Column Starter: Before casting column a special type of concrete arrangement is made
which is named as starter. The thickness of kicker is generally 100mm. It is given
a. To make proper alignment of the shuttering.
b. To make the column as per the grid line.
Fig 3.44 Column starter
Fig 3.45 Column casting by Peri formwork

3.11 Beam & Slab Shuttering
Fig 3.46 Beam staging in process Wooden runner is placed on steel tube
to nail the Beam Bottom plywood.
Fig 3.47 Placing of centering sheets Fig 3.48 Application of form oil &
placing of reinforcement.
3.12 Stair case Shuttering
Fig 3.49 Stair case Reinforcement Fig 3.50 Stair case Shuttering

3.13 Ramp construction at club house

 Slope – 1:8
 From S.S.L- +101.0 to +104.70m.
 Length – 28 m. Details of the Ramp construction.
 Width – 16 m.
 M40 Grade of concrete
Fig 3.51 to 3.56 gives ramp construction methodology
Fig 3.51 Ramp Shuttering in Process
Fig 3.52 Placing of reinforcement as per the structural details
Fig 3.53 Ramp concreting

Fig 3.54 Compacting Concrete by needle vibrators (Beams & Beam Column Junction)
Fig 3.55 Finishing of ramp slab using aluminium straight edge
Fig 3.56 Curing of ramp slab using hessian cloth

Fig 3.57 Night concreting for ramp slab
OBSERVATIONS
 Slump of concrete – 120 mm.(> 120 mm Reject the vehicle)

 Finishing of Ramp Slab without undulations - To achieve these good masons should
be there Proper supervision of Engineer & frequent checking of the slab thickness.
 Continues supply of concrete from the Batching plant.

3.14 Back filling/ Earth filling works

 The soil used for filling should be free from all roots, grass, shrubs, vegetation,
construction debris etc..
 Soil that is used for filling should be free from lumps.
 The soil is laid & compacted in layers of not more than 300mm thick.
 Each layer will be properly spread, watered and compacted.
 Each layer will be compacted to a min. 95% MDD at optimum moisture content.
 Compacted top layer will be dressed to required level before laying of PCC
Fig 3.58 Earth filling Fig 3.59 compacting the soil in layers by
using vibratory rollers
3.14.1 Determination of the dry density of compacted soil by core cutter method
(IS2720- part 29)
Fig 3.60 Core cutter method
3.14.2 Determination of moisture content by rapid moisture meter (IS: 2720-part-2)

(calcium carbide method)
Fig 3.61 Rapid moisture meter

3.15 Water proofing for Balcony, utilities and toilets.

Water proofing is the process of making a surface or a structural element impervious, so
that water does not pass through it.
3.15.1 Methodology
Haunching is the process of making

sharp corners/edges into a smooth
curve because to protect water
proofing membrane & to arrest the
leakages at the corners & edges.
Fig 3.62 Haunching with gp2 (non shrink grout)
Fig 3.63 Bores packing with gp2

Fig 3.64 Water ponding test Fig 3.65 Pressure grouting machine
(To arrest the leakages) to arrest leakages
Fig 3.66 Applying Fosroc Brush Bond Fig 3.67 Fix geo fabric over the coated
surface
Apply the Second Coat Fosroc Brush Bond.
Fig 3.68 Laying of 20mm thick CM (1:4) mixed with

Fosroc conplast 421 125ml/cement

3.16 Indian Patent Stone

tone (IPS)
( flooring
 Flooring which provides a good wearing properties (abrasion resistance)
resistance).
 For driveways & parking area.
area
 IPS floor thickness 40mm.
 Curing by hessian cloth, sprinkling of water for 7 days.
days
3.16.1 Methodology
IPS Concrete flooring mix proportions (kg/m³)
Cement- 275 kg/m3, Flyash -45 Kg/m3, M sand-803 Kg/m3, 12.5 coarse aggregate -1156
Kg/m3, Water-160 Kg/m3, Admixture-2.24
Admixture Kg/m3.
Glass strips fixing

done with mortar
Fig 3.69 IPS Panel layout in chequered (Divided in to squares) Sequence
Fig 3.70 Pouring concrete & finishing the surface using troweling machine

3.17 Gypsum Plastering

 Gypsum plaster (POP) on internal walls, ceiling & lobby area.
 Materials used are gypsum plaster powder (Buildon) & Buildon Bondit 151 (Bonding
agent).
 Thickness of gypsum plaster–min 6 mm to max 15 mm
Bondit 151
High performance bonding agent for gypsum on RCC surface. Do not need to hack the
RCC surface when we use Bondit for the application of gypsum.
Application Procedure
Proportion of Gypsum & Water
 In 25 kg of gypsum shall be mixed with 21 liters of water.

 The right way to mix is to add powder to water.
 The gypsum plaster should be mixed as per the capacity of the mason to consume
within 20-25 min. (Because Setting time of Gypsum is 20-25 min).
 Wastage of Gypsum can be minimized.
Fig 3.71 Mixing of gypsum Fig 3.72 Fixing up of Bull marks on walls &
& water in correct Ceiling at every 1.5 m -2m spacing (this facilitates
proportions the accurate thickness of the gypsum plaster.)

Fig 3.73 Application of gypsum on Ceiling & walls
Fig 3.74 Completed View of Gypsum Plaster

CHAPTER 4 TRAINING OUTCOMES

This training has enhanced my knowledge about the environment which is present in a
company. The entire period of four months proved to be a good source of practical
exposure. At the end of these four months now I feel myself better equipped to face the
problems in field of construction. I came to know that what environment prevails in office
and site. The friendly welcome from all the employees is appreciating, sharing their
experience and giving their peace of wisdom which they have gained in long journey of
work. Working at this site helped me to know all the major and minor aspects of
construction management. I got to know new techniques. I also learnt to tackle with the
general problems faced on site. I came to know the relationship that prevailed between
client and the contractor.
Furthermore I have learnt many things by identifying different types of construction
materials and their uses, and also learning a lot about construction process and methods
that are used in Prestige falcon city Construction site, plus by talking and asking
questions from the construction team who were guiding us at the site.
In the end, I feel myself to be more confident and independent. I also feel that this
training has given many valuable things which would help me throughout my
professional life.
4.1 Technical outcomes:
 After undergoing my internship, I came across the various departments that prevail at
the construction site like safety, plant and machinery, QA/QC & Execution etc.
 I came to know about various materials that were used at the site.
 I came to know about the process and specification of different activities starting
from reading of drawings till execution.
 I understood media of communication between client and contractor.
 Study and understanding of architectural and structural drawings.
 Reinforcement details and Bar bending schedules.
 Different waterproofing methods and techniques.
 Mass concreting process, methods & techniques
 Quality check for various materials.
 Complete understanding of aluminium formwork system
 I came to know finishing works that is gypsum plastering, tiling and door & window
fixings.

4.2 Non-Technical outcomes:
 After completing my internship my communication skills have been improved and I

find easy to communicate with people at the site.
 One main thing that I have learned through this internship is time management and
patience
 I feel much confident to deal with the problems occurring in the site.
 I now fully understand the importance of being a good team player while working in
such huge projects.
 This internship program has helped to develop my decision-making capability.
4.3 Improving Practical Skills

The objective of the internship is to address more practical knowledge and to develop
construction skills for the students. So I have learnt some of the construction skills at the
site as much possible within sixteen weeks. The skills and practical knowledge that have
learnt at the site is of totally different from the actual knowledge gained from the classes.
Some of the practical knowledge & skills that I have learnt from the industrial training
was:
 Various departments that is present in construction industry & their functions, roles
and responsibilities of each engineer working in organization.
 Safety practices & Mechanization in construction – operations of tower crane,
batching plant, aggregate recycling plant, suspended hoist platform, Builder hoist.
 The various components & sequence of works in aluminium formwork (shuttering).
 Surveying skills –column & footing markings using total station equipment. The
application of total station that is used by surveyor is Stake out /Setting out process.
 Bar Bending schedule, lap length (Splicing) and tying of the reinforcement.
 Placing of reinforcement as per the structural drawings.
 Conventional Formwork and supporting systems (staging) for the RCC structures i.e
slabs, staircase, retaining walls, columns & lifts. Thus the shuttering & staging were
new to me which I have learnt at the construction site.
 Concreting sequence –arrangement of concrete pump & pipes, pouring, compacting
and finishing activities.
 I have learnt various construction works & their standard methodologies followed at
the starting from excavation to finishing stage that are required to complete the entire
building.

4.4 Upgrading the theoretical knowledge

Upgrading & Revising the theoretical knowledge want I learnt in the classes & text books
is of very important before going to the construction site. I have spent daily 1 hour to
upgrade my theoretical knowledge & I tried to compare with practical knowledge gained
at the site. I found that so much gap exist between the industry and educational
institutions.
4.5 To Develop Business contacts

A reference from a known party in the organization can help, in our survival within the
firm and gain name.
This Internship training has provided a glimpse into the construction industry, helping in
meeting some well experienced Engineers in the field of construction. This is of great
help in future for proper job hunt. Being able to meet the heads of various departments in
the project and expand my contacts. All departments are necessarily headed by graduate.
Engineers, who are well experienced and have worked in many organizations before
working at Prestige group.
Developing business contacts is not limited to within the working company. While
training at the client end, it was also possible to get in touch with few senior engineers
from the contractor end, JMC projects (India) Ltd. In this way, the trainees now have the
contacts of professional practices of two organizations. However, this does not stop here
only. These engineers will be having contacts in other firms and the contact chain
continues. Once the trainees are good enough to be trusted for reference, they certainly
can make arrangements and propose the name to known departments of other companies
as well, which increases the probability of working at large industries.
Without such references, it is difficult for an aspiring fresher to progress in the line of
construction business. However, such references are of no use in procuring government
jobs. But since, majority of engineers ends up in private firms, working under senior
engineers, prior development of contacts and reference can give a job security and
responsibility.
At the end of training program, the interns are confident enough to get a suitable job in
private organization. Moreover, they are exposed to company activities and have an idea
of whom to contact for necessary reference.

4.6 Fixing job priorities

Undergoing the internship training has helped in figuring out what to do with one’s career
after graduation.
Tackling the on-site problems, right from the site procurement to completion of project
requires communication and interaction skills.
Dedication and involvement in work to give 100%, is the key to succeed in any work and
especially in the field of construction.
Entering an organization with good qualification and sufficient experience or training in
the construction affairs can increase the chances of reaching a higher order in the
organization.
4.7 Communication and interpersonal skills

Construction industry for this aspect consists of people of many languages. In case of
Bangalore, study shows that nearly 90% of construction workers are not from local
origin, unaware of regional language. In our site also almost all workers are from north
India with only countable number of regional engineers and workers. Hindi, English were
the languages used to communicate with the departments and its workers. t was able to
observe and learn the skills of a communicator and his ability of getting things done by
convincing the personnel. A person with good communication and interaction skills with
the knowledge of languages can overcome any kind of obstacles in order reach target.
4.8 Strengthening the resume

In addition to above discussed points, the Internship program has strengthened the resume
of individual by adding a training certificate issued by the company. This is of proof that
the trainee is aware of general practices in a multi-storey construction project. Since,
Prestige group is a reputed organization; this certificate will be of great help during
recruitment for jobs at other companies as well.

4.9 Experience and assessment

Internship is an opportunity to get into the organization and to know how the
organizations or industries are working or ongoing (i.e. Processes, methods,
maintenance), environment of organization and how a team work is important in an
organization before getting into the professional field.
After getting some knowledge and experience being in company some case studies as
provided to solve the problems by using subject knowledge which is gained during
studies. An internship case study not only uses what subject knowledge known but also
helps to implement that knowledge into the problems to solve it. It was a very good
platform for to come out of imaginary problems of books and to solve real live problems
which are facing by the organization during design or during construction.
4.10 Factors to be given importance at site

The enlisted items below are the aspects neglected in the construction work, as per my
observation, which has to be given attention.
 Sustainability Remedy is to promote usage of eco-friendly and sustainable building
materials
 Safety negligence Remedy is to make workers realize that life is more precious than
taking risks
 Quality issues while execution Remedy is to educate the workers including engineers
about the type of work and material they are dealing with.
 Hygiene Remedy is to make the workers aware of various epidemic diseases which
follow bad hygienic manners of drinking and washing hands in dirty water and also
excreting in the lonely places within the structure.
To conclude, considerable amount of professional practices were observed and
implemented during the training period. Thanks to the university and college authority as
well as training authority for providing an opportunity to relate what was studied in
theory on practical aspects.

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BMS COLLEGE OF ENGINEERING BENGALURU

Autonomous institute, affiliated to VTU

INTERNSHIP AT PRESTIGE ESTATES PROJECTS LIMITED

Submitted in partial fulfillment for the award of degree of

Internship Carried Out

PRESTIGE ESTATES PROJECTS LIMITED

Internal guide External Guide

DEPARTMENT OF CIVIL ENGINEERING

This is to certify that this internship report is a bonafide work carr

____________________ ______________________ __________________

Name of the Examiner Signature

I express my deep sense of gratitude to my guide Mr. Swarna Swaroop A, Assistant

I, RAKESH S, student of BMSCE, Bengaluru Pursing Master of Technology in

3.4.7 Staircase .................................................................................................................... 39

CHAPTER 1 ABOUT THE COMPANY

1.2 COMPANY’S VISION

1.3 COMPANY’S MISSION

BMSCE, BENGALURU Page 1

 Prestige Acropolis: A tribute to classical Greek architecture, one of the first

BMSCE, BENGALURU Page 2

1.5 LANDMARK PROJECTS

Fig 1.1 Prestige Shantiniketan, Bangalore

Fig 1.2 The Collection, UB city

BMSCE, BENGALURU Page 3

Fig 1.3 Prestige group projects

Reference: Annual report of prestige group 2015-2016

BMSCE, BENGALURU Page 4

1.6 AWARDS & RECOGNITIONS:-

BMSCE, BENGALURU Page 5

1.7 QUALITY POLICY

To this effect, Quality Records are maintained methodically and carefully.

BMSCE, BENGALURU Page 6

CHAPTER 2 ABOUT THE PROJECT AND DEPARTMENTS

PRESTIGE FALCON CITY is a mixed used residential project consisting of 7 residential

Fig 2.1 Aerial view of Prestige Falcon City

BMSCE, BENGALURU Page 7

Project name PRESTIGE FALCON CITY

Location Kanakapura Road, Bangalore

Development Type Mixed- Use Development

Development Area 48.60 Acres

Commercial development 7.60 Acres

Phases 2 Phases of construction

Client Prestige groups Ltd

Contractor JMC Projects (India) Ltd.,

Architectural consultants M/s Venkataramanan Associates

Structural consultants M/s MAHIMTURA Consultants (Bang) Pvt Ltd

PHE & FPS Consultants M/s Sampath Kumar Associates, Bangalore

MEP Contractor M/s Shobha Group, Bangalore

Landscape Consultants VIA + Signature (PI)

Electrical Consultants Power- Designs India P Ltd

Window Vendor Fenesta

Elevator Vendor (Lift works) Fujitech

Painting vendor Vibgyor/Dulux

Total cost (Approx) Rs. 1200 crores

No of towers 20 (5 Building phase 1) , 8 ( 2 Building phase 2)

Total no of flats 2520( phase 1)

Type of flats 2/2.5/3/4 BHK

Table 2.1 Project Prestige Falcon city details

BMSCE, BENGALURU Page 8

Fig 2.2 Prestige Falcon City Map Location

Fig 2.3 Prestige Falcon city Master Layout Plan

BMSCE, BENGALURU Page 9

 RCC Framed Structure with RCC Shear wall.