INDUSTRIAL TRAINING REPORT

Done by

Roll No.:1154500010

At

Simplex Infrastructures Ltd.SIMPLEX HOUSE, 27 SHAKESPEARE SARANI,

KOLKATA-700017

KIRAN SURESH

Submitted to

Jahangirabad Institute of technologyDepartment of Civil Engineering

Acknowledgement

It is always a pleasure to remind the fine people in the Engineering program for their sincere guidance I received to uphold my practical as well as theoretical skills in engineering.

Firstly I would like to thank MR MD RAFIQUE KHWAJA (Director of JIT) for meticulously planning academic curriculum in such a way that students are not only academically sound but also industry ready by including such industrial training patterns.

I express my immense pleasure and deep sense of gratitude to MR. RAVI RAWAT (HOD CIVIL) for his guidness and others with me and also helped me in completion of task.

Finally, I would also like to thanks MR Subrata Kundu (Site- In charge)for giving me this opportunity and guiding me during the course of the training.

CONTENTS

IntroductionDetails of the ProjectCompany ProfileDetailsFormworkDiagramsplansPlant and machineriesQuality control of siteSite executionSafetyMaterial managementConclusion

INTRODUCTION We have been assigned GODREJ PRAKRITI HOUSING COMPLES III

construction sites for field study by the company.14,78,600sq ft. residential project located in Godrej PrakritI,Girja More, B.T. Road,Sodepur, Kolkata-700115 .This is a 39 month project with a total value of 274 crores.In our phase named GODREJ PRAKRITI, Phase III

There are 8 number of residential towers being constructed in this namely K, M, N, O, P, Q, R and G blocks.R, O and N blocks are of floor area 880 sq. meter each consisting of (B+G+19)

K, P and Q blocks are of floor area 872 sq. meter each consisting of (B+G+19)

M block of floor area 731 sq. meter and consists of (B+G+4).

G block of floor area 870 sq. meter and consists of (G+19).

DETAILS OF THE PROJECT

ABOUT THE PROJECT:• .GODREJ PRAKRITI, Phase III• There are 8 number of residential towers being constructed in this

namely K, M, N, O, P, Q, R and G blocks.• R, O and N blocks are of floor area 880 sq. meter each consisting

of (B+G+19)• K, P and Q blocks are of floor area 872 sq. meter each consisting of

(B+G+19)• M block of floor area 731 sq. meter and consists of (B+G+4).

• G block of floor area 870 sq. meter and consists of (G+19).

• Number of Flats : 1210• Type of Contract : Lump Sum Contract

COMPANY PROFILE: Company is an ISO family since 2004. Introduced cast in situ driven piles in India. An ISO 9001:2008 approved company certified by Bureau of Indian

Standards. Employs 8110 people and has Capital Equipment of Rs.1296 Corers

as of FY, 10. Ranked 7th among “India’s Top 10 Infrastructures Companies” by

Construction Week. Recognized by World Confederation of Businesses as “Inspirational

Company with all its Rights & Privileges” in 2010. Awarded by International BID Quality Summit, New York the

“International Quality Summit Award in Gold Category” for achievement in Quality & Excellence in 2009.

Major construction works taken up by company in India and abroad are Industrial construction, Infrastructures, Power Plants, Fly-overs etc.

Has many office branches in India and abroad.

DETAILS OF FIELD STUDY

DETAILS OF STRUCTURE

Work Progress - 7th floor

Floor Area 872 sq. meter

No. of floors - B+G+19

No. of staircase - 2

No. of lift - 3

Per floor 8 nos. of flat

P Block

P Block General Plan

O BLOCK

Work Progress - 12th floor

Floor Area 880 sq. meter

No. of floors - B+G+19

No. of staircase - 2

No. of lift – 3 (2 for general and 1 for emergency and freight)

Per floor 4 nos. of 2BHK, 2nos. of 2.5 BHK & 4 nos. of 3BHK

O BLOCK GENERAL PLAN

Formwork

• Purpose:Shuttering or formwork is the temporary arrangement by wood/steel/ply to hold concrete in required shape and size up to certain period for gaining adequate strength of the concrete. Shuttering mainly costs 25-40% of the total cost of the project. The Shuttering and Formwork is often similarly used but there is a little difference in it in terms of materials to be used. In shuttering generally plywood is used by in the case of Formwork heavier sections like battens, Waller are used.

Material Used: Steel plate and channel Battens (75mm X 100mm and 50mm X 75mm) Plywood of different thickness(Generally Film Face Ply of 2440mmX1220 mm

cross sections are available) Soft pine Runner Hard Wood Runner MS Wailer MS Channel Acrow Span Vertical adjustable prop Cup lock System( length- 0.5m to 3.5m available) H-frame Clamps Wing Nut Base Plate Sole Plate Tie Rod Nail Binding Wire (18-22 gauge dia. bar used in site)

Principal Apparatus Used:

Hammer Crow-bar Crane Plum Bob Measuring Tape Right Angle Rope

PPE to be used: Head Gear Safety Shoe Safety Harness Hand Gloves Apron Goggles Nose Mask Life line to be placed in case of working in sufficiently higher level from

ground Safety nets are to be provided at levels where upper floors are engaged for

work to safeguard any material falling from height and hence protects the worker working at ground.

SOME DIAGRAMS OF FRAME WORK

Fig: Formwork of a Typical Staircase

Fig: Formwork of a Shear-wall (Sideview)

.

Formwork of a Column(Isometric view)

: Formwork Junction of two Shearwall

.

Formwork of a column (Plan) Formwork Junction of two Shearwall

.

Formwork of a column (Plan) Formwork

.Formwork of a beam Formwork of a Slab

Cover provided to Reinforcement:

Clear Cover

Beams 25mm

Columns 40mm

Floor/Roof Slab 20mm

Wall 25mm

Pile 50mm

Pile Cap bottom 75mm

Member/Structure 50mm

End of reinforcement bar 25mm or twice the diameter of bar whichever

is grater

DETAILS OF FORMWORK OF A COLUMN

General plan of a Pile Cap

a

b

General plan of a Pile Cap

Measurement of the Quantities for the Pile Cap (6BP1)

R.C Detail of Plan

Section 2-2

Est ima t ion of Pil e Ca p(MKD.:-6BP1)

Sl. No. Description of

Item Length(m) Width(m) Depth(m)

Estimated

Quantity Unit

1 Excavation 4.8 3.3 1.1 17.424 m3

2 BFS 4.3 2.8 _

12.04 m2

3 PCC 4.3 2.8 0.075 0.903 m3

4 RCC 3.8 2.3 0.95 8.303 m3

5 Shuttering 3.8 2.3 0.96 11.59 m2

Formulas to Determine Quantities of Various Works for a Pile Cap

1. Excavation = [(a + 2x0.5) x (b + 2x0.5) x (d + 0.15 – 0.25)] m^3

2. Brick Flat Soling (BFS) = [(a + 0.25x2) x (b + 0.25x2)] m2

3. Plain Cement Concrete (PCC) = [(a + 0.25x2) x (b + 0.25x2) x 0.075] m3

4. Reinforced Cement Concrete (RCC) = [a x b x (d – 0.25)] m3

5. Shuttering = [(a + b) x 2 x (d – 0.25)] m2

6. Bar bending schedule (BBS).

Bar Bending schedule

A

C

B

Theoretical Bending of a Bar

C= are length, C= (b-B)+(a-A)-2D

D= Diam

b

Sl.

NoBar Mark Size/ Shape

Diameter (mm)

dNo

Length(mm)

(a+2b)

Cutting Length (mm)

(a+2b-2*2d)

Total

Length(m)

Unit Wt.

(kg/m)

Total

Weight(ton)

1 T/Ta=2144

b=300

12 26 2744 2696 70.096 0.8928 0.06258

2 B/Ta=3644

b=300

12 16 4244 4196 67.136 0.8928 0.05994

3 T/Ba=3676

b=105916 16 5794 5730 91.68 1.5872 0.14551

4 B/Ba=2176

b=107516 26 4326 4262 110.812 1.5872 0.17588

5 Skin Bar a=2200

b=2150

12 6 6500 6452 38.712 0.8928 0.03456

PLANT AND MACHINERIES:

Serial No Machineries Company Name Capacity

1 Batching Plant SchwingStetter 30m3/hr

2 Transit Mixture Tata, Ashok Leyland 6m3

3 Concrete Pump Schwing Stetter 50m3/hr

4 Hydra ACE 11tons

5 Backhoe Loader JCB 1m3

6 Bar Cutting Machine Jaymac, Jaypee C-42

7 Bar Bending Machine Jaymac, Jaypee B-42

8 Electric Vibrator -------- 2HP

.

Fig: Bar Cutting Machine Fig: Hydra (Acer-Hyno)

Capacity of Bar bending machine Bar Bending Machine Transit Mixer receiving concrete

Bucket of batching plantScrapper in the Batching plant

Concrete Batching plant

Automated control machine of Batching Plan

Tower Crane Concrete pouring Bucket

Concrete Pump( receives concrete from mixer)

Passenger Hoist Winching Machine

Quality control at site:

1. Quality Testing of Materials: The materials is mainly cement, fine aggregate, coarse aggregate, water, admixtures, concrete and reinforcement bars. These materials are tested in the quality control laboratory by following their test specifications according to their respective IS Codes.2. Quality Assurance: The test results of respective materials are obtained and checked whether they lie within their acceptance limits specified codes. Then they are assured.

1. Cement (IS 4031)Determination of Normal Consistency.,, ,, Initial and Final Setting time.,, ,, Fineness of Cement.,, ,, Compressive Strength Test.IS SPECIFICATIONS: Initial Setting time: Should not be less than 30 minutes.Final Setting time: < 600 minutes.Observation: Cement Brand used in Site: Konark

Type of Cement : Portland Slag CementNormal Consistency of cement: 36%

Water Content(%) Penetration(mm)

30 12

32 10

34 8

36 5

Initial Setting Time: 140 minutes, Final Setting Time: 240 minutes.

Fig - Test Set Up for Initial & Final Setting Time

Test Set Up for Consistency

2) Coarse Aggregates (IS 2386)Sieve Analysis of Aggregates(10mm & 20mm).Aggregates Impact Value.Water Absorbption Test.Specific Gravity by Pycnometer.

Pyconometer

3. Sand (IS- 383)Grading or Sieve Analysis of SandSlit and clay content

Sieve Analysis(For fine aggregate

4. Concrete(IS-456)Compressive Strength testWorkability test5. BrickDimension check of bricksCompressive Strength Check of bricksMaterial:Brick, Cement Sand mortar.Apparatus: Compressive Strength testing machine

Avg. Compressive Strength of Sample: 10.41 N/mm^2

e: 10.41 N/mm^2

SampleafterFailure(Sand filling is

used)

Sample before Failure

Compressive Strength Testing Machine

6. Steel (IS-1786)Rolling Margin test of Reinforcement BarIS Specification: For 8¤-12¤- ±7%

For12¤-20¤ - ±5%For above 20¤- ±3%

Reading at Site: For 10mm dia. Bar unit weight= 617gm/m runBrand name: Rashmi TMT 500+.

SITE EXECUTION

Execution is the discipline of planning, organizing, motivating, and controlling resources to achieve specific goals at construction site as per the scheduled planning. A project is a temporary endeavour with a defined beginning and end

Requirements: Excavator Rollers for Soil Compaction if any (Smooth Wheeled or

Pneumatic or Sheep-foot) Shovel, Spade & Bucket, Auto Level or Total Station if available for knowing RL, Measuring Staff Measuring Tape

SAFETY

Safety Personal Protective Equipments( PPE ):

In a particular site if personal safety is maintained by every personnel then the total accident in the site can be controlled. It is just acts like a pyramid, personal safety is in the base level so if it is controlled

then other accidents can be controlled simultaneously.

Sl No. Description Picture

1

Safety Helmets are used to protect

the head from falling materials in

construction site.

2

Safety Shoes which give us

protection on site, it has a steel plate to

its tow and protect our feet up to an

extent when a material sudden fails to

our feet. It is a very important

equipment in PPE.

3

Safety belt & Full body Harness is very useful in

construction work, it used by labor

when working at heights to reduce

risk of falling particularly when they

are in formwork placing or plastering

of exterior parts.

etc

Safety controlling at site

Followings are some of the many precautionary/safety measures that are to be taken at a construction site – Water spray on fly ash in order to prevent dust. Saline water is to be provided to workmen during summer to avoid heat related

illness. Proper rest is taken at intervals. Personal Protective Equipment (PPE) is provided and worn by construction workers at

site. PPE includes hard hats/helmets, Safety Shoes, Goggles, Masks, Gloves, etc. Medical and First Aid facilities is there. When working at heights, workers should wear double lanyard full body harness being

anchored. Safety helmets, fall arrester, etc. are used. Earth Leakage Circuit Breaker (ELCB) and Residual Current Circuit Breaker (RCCB) are

used in electric installations to avoid electric shock. Check for connection and body earthing of machineries. Transporting Vehicles must not exceed the speed limits (usually 15 Km/h max) to avoid

accidents by vehicles. For the same reason, use of mobile phones at site is minimized. Employees are to remain at a safe distance from all equipment while it is operational. Inspection of the equipment is done before every use. Checking Fire Extinguishers. Hygienic condition of labor hutment. Checking drinking water test report. Safety training program is in practice. Safety Award for safety motivation is conducted. Daily safety observation and correction is done.

Materials Management

Profit Centre With the process of liberalization and opening up of global economy, there

has been a drastic change in the business environment, resulting in organization exposed to intense competition in the market place, Indian organizations have been working out various strategies to face the above challenges and to cut down operational cost to remain competitive. Progressive management have since recognized that materials management can provide opportunities to reduce operating cost and can be treated as a profit center.

On an average, half the sales income is spent on materials. Suppose a firm is spending 50% of its volume on materials and the profits are 10% of sales volume. A 2% reduction in materials cost will boost the profits to 11% of sales or the profits will be increased by 10%. To achieve the same increase in profit through sales efforts, a 10% increase in sales volume will be necessary. In other words, compared to sales volume, material cost has five times the average on profits. Organizations earn or loose large sums depending on how effective are their material management

CONCLUSION

The training programme helped in gathering the practical work procedure alongside with furnishing the theoretical knowledge learnt till date. The programme was scheduled and comprised of five different sections – Safety, Planning, Billing, Quality Control and Site Execution. The importance of safe working, adopting safety measures and preparedness for any unknown sudden accidents at site were explained in the safety department. The work of the planning engineer and the procedure of a proper planning and scheduling of the construction work, these knowledge were shared in the planning department. Billing department enriched us with the financial knowledge, quantification of any work and their collaboration with the planning department. The purpose of the quality control department, continuous checking of the materials at the site and preparation of design mixes were taught. Finally all the gathered knowledge were practically viewed during site execution of different blocks. Shuttering procedure, different construction works, machineries and all the safety measures adopted were clearly explained. Apart from technical knowledge we were grateful enough for the engineers who shared their work experience with us. There are a lot of things which cannot be learnt from any books or institution but an exposure to such a construction site can only provide. Such construction site related essential terms & knowledge of work will help us throughout our work life

THANK YOU