Department of Civil Engineering 2015

1. INTRODUCTION

The Industrial training gives us an idea about how basic structures of a building are
constructed. They include foundation, basement, brick masonry, roofing and
finishing.
Foundation comes under the substructure and it provides a firm support for the
superstructure. Basement provides an housing for the walls. Walls are made using
brick masonry. Roofing provides cover to top of building and is done using concrete.

1.1. WORK-CONSTRUCTION OF A COMMERCIAL BUILDING.

(Note: The detailed plan, section, elevation and site plan of the commercial building is
provided in the appendix.)

1.1.1 INTRODUCTION

The construction was that of a commercial building consisting of two floors (ground
floor and first floor).The training was under the chief architect of the building, Mr.
Wilson George.
The training period at this site was from 24-06-2015 to 03-07-2015.Each day the work
duration ranged from 8:30am to 4:30pm with gaps for breakfast and lunch. The
building was constructed by a contractor whose work was supervised by the above
architect.

Table No: 1: Specifications

District Alappuzha
Taluk Karthikappally
Village Keerickad
Panchayat Pathiyoor
Ward No XVII
Sy.No 311/4,311/12,311/13,311/14
Area of land 22.00 Acres

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The area calculations are also provided below:

Table No: 2: Area Calculations

FLOORS PLINTH AREA FLOOR AREA

Ground Floor 647.37 517.89
First floor 647.37 517.89
Verandah 225.08 -
Total Area 1519.82 1035.78

The construction reached the stage of curing of foundation at the start of training .The
work began with a side portion of the proposed building. On the starting day shutters
used for foundation concreting were not yet removed. This is shown in fig1.A

Fig 1.: Foundation after 3 days curing.

Construction of foundation

This portion of the building consisted of 12 columns provided with column step
footing and the walls had a foundation of PCC course of mix 1:3:6.. After the initial
set out, excavation was done for the column footing of size 180x180x160cm for all 12
columns.
Column footing was made of four steps below ground level.
First step: Size: 180x180x20

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Mix used: PCC-1:3:6

Second step: Size: 150x150x20
Mix used: RCC-1:1.5:3
Distribution bar-Thickness-10mm, placed at a gap of 15cm, forming a
net.
Third step: Size: 90x90x30cm
Mix used: PCC-1:3:6
Fourth step: Size: 60x60x60cm
Mix used: PCC-1:3:6.

Note: Each room has a dimension of 560x400 and rooms abutting the side of road
were to be provided with rolling shutters instead of walls.
Foundation for walls ran a depth of 60cm.Mix used for concreting was
1:3:6.Compaction during concreting was done by steel rod and internal vibrator. The
foundation was allowed to cure for 3 days.

1.1.2 WORK AT SITE DURING THE TRAINING PERIOD

1) Construction of RCC plinth beam

Steps: 1. Laying of steel reinforcement

2. Shuttering
3. Concreting
4. Curing
1.) Laying of Steel reinforcement: Plinth beam of cross sectional area 25x50 was
proposed to be constructed. The main distribution bar for the plinth beam is of 20mm
diameter. The four main bars formed the initial framework of reinforcement. Main
bars from the column were also 20mm diameter. Column bars were 6 in number.
Stirrups were provided, before laying steel bars for plinth beam, at bottom of column
to prevent bending due to wind load. Main bars of the beam were joined to the main
bars of column by winding wires.

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Fig 2. Column reinforcement showing main bars

Fig 3: Distribution bars of beam winded to main bars of column

After laying the four main bars over a wall the two bars were joined to two lower bars
using stirrups. Stirrups were of size 8mm.Stirrups were provided to attain a compact
form of reinforcement and to attain efficiency in holding of cured concrete without
future cracks.

Between two columns stirrups were arranged throughout the span of plinth beam in a
particular way. After providing a clearance of 5cm at both edges, for a length of L/4
from both sides, stirrups were placed 10cm apart. For the rest of the side, towards
middle, stirrups were placed 20cm apart. This arrangement was done for better
distribution of load from columns to foundation.

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Fig 4: Stirrups placed over plinth beam distribution bars

At the base a double layer of distribution bars were laid to counter the tensile force at
bottom. Double layer was provided at a distance of 1 inch apart. For the 50cm sides of
the plinth beam a distribution bar of 10mm was placed to resist forces on sides. One
extra main distribution bar was placed at middle of top and bottom 25cm side .In total
the steel reinforcement contained 8 main distribution bars and two side distribution
bars. Bottom distribution bars of plinth beam were extended to a length of 60cm
outside the beam ends by lapping extra bars of same size. This was done in case of
any future extension, so that the extra bars can be lapped from these existing bars.

Vertical main bars of 10mm diameter was placed 20cm apart throughout the plinth
beam for attaining a binding between floor concrete and basement. The vertical bars
can be bend to the floor during its concreting to achieve increased strength of floor.

2. Shuttering: After laying all reinforcement bars and checking whether they were all
tied properly using winding wires, shuttering work started. A covering of 2.5cm was
provided at bottom using concrete covering block. Steel shutters were used .Shutters
were placed after providing a covering of 2.5cm on both sides using covering blocks.
Shutters were held straight by using steel jackies and wood pieces. Shutter pieces
were joined together by winding wires.

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Fig 5: Shuttering for plinth beam

Fig 6: Covering block provided in shutter

3.) Concreting: The mix used for concreting was of 1:1.5:3.The mix was taken by
volume batching as for one packet of cement, two bags of m-sand and four bags of
metal. Metal and m-sand before being taken were checked for any unwanted
substances that may affect the strength of concrete like plastics, grass etc. Water was
added only upto that level which will ensure adequate workability. If the mix was
more workable it was compensated by adding cement powder.

Before pouring concrete, grout (a paste of cement and water) was poured to the
foundation top to attain sufficient grip between concrete and floor. The concrete used

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was machine mixed. After placing the concrete each time, it was compacted at first
using steel rod and then by using an internal vibrator. Internal vibrator was used only
for a maximum of 20sec at a particular place.

Else it may lead to honeycomb (a form of failure in concrete due to excessive use of
vibrator) at sides of basement after setting completely. If honeycombs are present it
can be compensated by applying mortar on it.

Honeycomb is a form of segregation. If not attended honeycomb can affect the

strength of concrete.

Fig 7: Placing of concrete

Fig 8: Compaction using hand rod

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Fig 9. Compaction of concrete using internal vibrator

4.) Curing: Curing of concrete was meant for 3days.

Fig 10: Basement after curing

1.1.3 FUTURE WORKS:

1.) RCC column concreting: Columns are raised 1m above the first floor level. Mix
used is 1:1.5:3.Concreting is done after providing proper covering. Steel bars is
of 20mm diameter

2.) RCC beam concreting: Cross sectional area is 25x50cm.Beam is of mix 1:1.5:3.

3.) RCC slab concreting: Slab is of mix 1:1.5:3.Its concreted after proper covering.
Steel reinforcement is provided with 8mm bars.

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4.) Brick masonry of side walls: Hollow bricks are used for masonry works. To fill
the spaces in between bricks mortar of cement is to sand ratio 1:6.

5) Providing partition walls for shops if any.

6.) Construction of second floor from existing beams and columns.

7.) Plastering of walls: Cement mortar of ratio 1:6 is used. Level is checked for one
side using plumb bob and rod.

8.) Provision for plumbing and electrical fittings.

9.) Applying white cement over walls.

1.2 WORK-BRICK MASONRY OF A DOUBLE STORIED RESIDENCE.

1.2.1 INTRODUCTION
After the training at previous place, the training continued at a double storied
residential building near Kayamkulam. Training period was from 3rd July, 2015 to 5th
July, 2015. Training was under the site supervisor Engr. Libin John.
The foundation and basement of the house was done few years before.

Foundation
Foundation was of random rubble masonry on a initial PCC course of 1:4:8.PCC
course was of 80cm and 20cm thickness. Foundation ran a depth of 60cm and a width
of 60cm.
Basement
Basement was of random rubble masonry. Basement ran a depth of 45cm,with a width
of 40cm.A layer of belt concrete was made over the basement of PCC course with a
mix ratio, 1:1.5:3.
1.2.2 WORK AT SITE DURING TRAINING

Brick masonry was being done during the time of site visit. Three to four courses
were laid during a day. Cement to mortar ratio was 1:5. Level was checked using
plumb bob and rod. Bond used for masonry was that which ensured maximum
interlocking property. At the door level it was proposed to have a concrete belt of 5cm
thickness. Bricks used were of nominal size 19x9x9cm.

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On a day only 4 to 5 courses were laid as a concern over stability.

Fig 11: Laying of brick walls

1.2.3 FUTURE WORK: The construction was of a two storied residence. After
completing the brick masonry of walls, roof slab has to be concreted. Roof slab is of
thickness 10mm of RCC layer with mix ratio 1:1.5:3.

Ground floor to first floor height is 3.4m.Both floors are to be connected with a stair
case of quarter turn. Rise is 18cm and thread is 25cm.After completing the brick
masonry of first floor , a roof slab of 10cm thickness was o be laid with a RCC work
of 1:1.5:3.

Detailed ground floor and first floor plan, section and elevation are provided below,

Fig 12. Ground floor plan. Fig 13. First floor plan.

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Fig 14 Sectional view Fig 15 Elevation

1.3 WORK-BRICK MASONRY AND CONCRETE WATER TANK

CONSTRUCTION OF A COMMERCIAL BUILDING.

1.3.1 INTRODUCTION
Construction was that of a commercial building of three floors. The training period
was from
6th July, 2015 to 8th July, 2015. Training was under the site supervisor Engr. Libin
John.
1.3.2 WORK AT SITE DURING TRAINING

1. Brick Masonry: Brick masonry was done using hollow bricks and clay bricks. The
sides of rolling shutters were extended using brick work. For the above work sides of
the plastering over column had to be chipped and grout was applied as to provide
proper grip.
After each course level were checked using plumb bob and steel rod. Cement mortar
used was of mix ratio 1:5.Each day 3-4 courses were only laid due to stability
concerns.

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Fig: 16: Checking of level using Fig 17: Brick Masonry work
plumb bob

2. Concrete water tank construction

Introduction:

A concrete water tank of carrying capacity 1000litres was proposed to be constructed

on top of the fourth floor.

Steel reinforcement

The base of the water tank was of double layer. The net was formed by bars of size
10mm.The sides of the tank was to have a height of 1m.The spacing of net along
horizontal was 10cm and through vertical was 15cm.Covering blocks of 1.5 inch was
provided at bottom. Bars were tied together by winding wires.

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Fig 18: Steel reinforcement of water tank

At the ends of floor, bottom distribution bars were bend upwards to form main bars of
sides.

Distribution bars were also laid sideways.

Shuttering

After laying the steel reinforcement for RCC concrete tank, steel and wood shutters
were provided on sides. The floor was to be concreted first. The bottom thickness was
10cm.

Concreting of floor

The floor was concreted at first before the side walls of the water tank. The mix ratio
was 1:1.5:3.The concrete was hand mixed.

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Fig 19: Floor RCC concreting

Grout was applied on the floor for adequate grip between concrete and floor. Extra
bars were used as distribution bars. They were laid in a diagonal fashion. If the mix
was more workable it was compensated by adding cement so that water to cement
ratio remains same.

Vibrator was used at all sides for not less than 20sec in order to ensure proper
compaction. Steel rods were also used for the same. Before concreting the side walls
of tank the floor was allowed to set for 3-4 hours.

After setting of floor, shutters were laid for side walls. Concrete mix was then poured
and compacted using internal vibrator. It was then allowed to cure for 3 days.

Fig 20: Side shuttering for concrete tank wall

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Table No: 3: List of building material and their cost as per date of construction

Building Material Manufacturer Cost

1. Cement Ultra tech – Rs.450/Bag
Ramco- Rs.420/Bag
2.M-sand - Rs 62/cft
3.Metal - Rs 42/cft
(All rates provided are an average value over a week. Material cost was changing
daily )

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2. CONCLUSION

The industrial training for 15 days equipped me with the practical knowledge of
construction of concrete structures like beam, slab, columns, etc. Language would be
a great problem for communication with labourers, thus giving me the need for
knowing Hindi.

It gave me idea about terminologies like concrete covering block, lapping, concrete
belt. Site engineer gave me the instructions for working as a site supervisor.

1. He/ She has to assure for quality of construction.

2. He/ She has to assure safety quality of construction.

3. He/ She has to make note of all mistakes during construction.

To put it in a nut shell, this training helped me a lot in improving my managing skills
and practical knowledge.

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3. REFERENCE

Reference to books

1. M.S.Shetty- Concrete Technology-Theory and Practice

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4. APPENDIX

1. Drawing of the commercial building as said , containing plan, section, elevation

and site plan

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