A

Summer Training Report

on
Hazaribagh Medical College
Completed at

Shapoorji Pallonji Engineering and Construction

Duration – 28th May’18 to 11th July’18

Submitted
by
Anamika
Roll no.- 15EYTCE009
B. tech Final year

Department of Civil Engineering

Yagyavalkya Institute of Technology
1
 CERTIFICATE

This is to certify that Miss Anamika, student of Bachelors of Technology in Civil

Engineering (Final year), Yagyavalkya Institute of Technology, Jaipur. She has
undergone her Summer Training in M/s Shapoorji Pallonji Engineering and
Construction from 28 May 2018 to 11 July 2018.

During this period, I found her to be very co-operative, sincere and diligent.

I wish her good luck and success for all her future assignment’s.

------------------------------------------
Mr. Samir Halder
Project In-charge

Hazaribagh Medical College Project

Hazaribagh, Jharkhand.

2
 Declaration
I hereby declare that this project report entitled “Construction of HAZARIBAGH
MEDICAL COLLEGE” is an authentic record of work carried out at
HAZARIBAGH as requirement of 45 days training under the guidance of
Project-In-Charge Mr. Samir Halder during 28th May 18 to 11th July 18.

Date: 11th July 18

Submitted By:
Anamika
15EYTCE009
YIT, Jaipur

3
 Acknowledgement
The satiation and euphoria that accompany the successful completion of my training would be
incomplete without the mention of people who made it possible.

I am very much thankful to M/s Shapoorji Pallonji Engineering and Construction for
giving me the opportunity to undertake my summer training at their prestigious Hazaribagh
Medical College project.

I would like to record my profound, keen reference and kind gratitude to Mr. Samir
Halder (Project Manager, DGM- Projects) who heartily welcomed me for the internship and
provided me the opportunity to work with finest site team.

I would like to take the opportunity to thank and express my deep sense of gratitude to
my mentor Mr. B Bhawal (Contracts) and my faculty mentor Mr. Sameerul Hasan (Planning)
and Mr. S Jana (Planning) for their valuable guidance at all stages of the study, their advice,
constructive suggestions, positive and supportive attitude and continuous encouragement,
without which it would have not been possible to complete the training.

The following members of the team have been really kind to assist me during the
internship period:

Mr. P Sarkar (Commercial)

Mr. A Sarkar (Commercial)

Mr. Bijoy Behera (Construction Manager)

Mr. Basanta Chakraborty (HSE in charge)

Mr. A. Panda (MEP)

Mr. A. Pagal (PNM)

Mr. Kartick Barman (Surveyor)

Mr. S. Poddar (Execution)

I owe my wholehearted thanks and appreciation to the entire staff of the company for
their cooperation and assistance during the course of my training.

4
 Contents

Sn.no. Topics Page no.

1. About the Company 7-10
2. Introduction 11-14
2.1 Architectural view 11
2.2 Site layout plan 12
2.3 About the Project 13
2.4 Brief Introduction to the Project 14
3. Departments 15
3.1 Administration 16
3.2 Contracts department 17-21
3.2.1 Important contractual terms 17
3.2.2 Project Information 18
3.2.3 Key conditions of contract 19-20
3.3 Planning department 21-26
3.3.1 Components of planning 22-25
3.3.2 Roles and Responsibilities 25-26
3.4 Commercial department 26-30
3.4.1 Roles and Responsibilities 26-27
3.4.2 Some Definitions 27
3.4.3 Procedure for preparation of PS module 27
3.4.4 Procedure for preparation of MM module 28
3.4.5 Procedure for preparation of bill 28
3.4.6 Procedure for preparation of SD module 28-29
3.5 Execution department 29-37
3.5.1 Reinforcement 30-32
3.5.2 Formwork 32-34

5
Sn. No. Topics Page no.
3.5.3 Concreting 34
3.5.4 Stages of Construction 34-37
3.6 QA/QC department 37-40
3.6.1 Quality 37
3.6.2 Quality Assurance 37
3.6.3 Quality Control 37
3.6.4 WMS 38
3.6.5 Tests performed on Aggregates 38
3.6.6 Tests performed on Cement 38
3.6.7 Tests performed on Concrete 38
3.6.8 Tests performed on Bricks 38
3.6.9 Mix Design 39
3.7 Health Safety and Environment 40-42
3.8 Surveyor department 43
3.9 Plant and Machinery department 44-46
3.10 MEP department 47-48
3.11 Store and Purchase department 49-50
4. Site Observations 51-52
5. Practical work 53
6. Conclusion 54
7. Pictorial Report 55-66

6
 About the Company
The Shapoorji Pallonji Group (SP Group) is a business conglomerate in India which works
in the following areas.

Construction

Real estates

Textiles

Engineering goods

Home appliances

Shipping

Publications

Power

Biotechnology

Shapoorji Pallonji is regarded as "one of India's most valuable private enterprises." The US$2.5
billion Shapoorji Pallonji Group have two listed companies, Forbes & Company Ltd. and
Gokak Textiles.

 147 years of rich legacy as an Engineering & Construction Company with unmatchable
delivery record.
 Group Turnover of INR 12500 Crores (US$ 2.5 Billion), with 23,000 Employees.
 Headquartered in Mumbai, strong presence across India and in the Middle East, Africa,
South East, Asia & the Caribbean.

7
 Shapoorji Pallonji – Engineering & Construction
Introduction
 147 years of rich legacy as an Engineering & Construction Company with unmatchable
delivery record.
 Headquartered in Mumbai strong presence across India and in the Middle East, Africa,
South East Asia & the Caribbean.
 FIRST Construction Company to receive ISO Certification in India
 Developers of the Tallest Residential Towers in India.
 Revenue: 28,320 Crore, (USD 4.2 Billion) in 2016
 Certified for ISO 9001:2008, ISO 14001:2004 and BS OSHAS 18001:2007

SP E&C- Pan India & International Presence.

INDIA INTERNATIONAL
AHMEDABAD UAE
BENGALURU MAURITIUS
CHENNAI OMAN
DELHI GHANA
HYDRABAD KUWAIT
KOLKATA SAUDI ARABIA
MUMBAI QATAR
NAGPUR ALGERIA
NASHIK SRI-LANKA
PUNE GUYANA

8
 SP E&C- VISION, MISSION & VALUES

VISION
Fostering an environment that helps in the creation of knowledge and its application to
work, we seek to excel in all our business activities and strive to build Shapoorji Pallonji
into a creative organization.”

VALUES

CORE VALUES
- Trust & Reliability
- Nurture People
- Adaptive & Agile

WORK VALUES
- Quality
- Service
- Innovation

SERVICE VALUES
- Relationship with stake holders
- Synergy to enhance group value
- Environmental & Social responsibility

MISSION

“Shapoorji Pallonji & Co. Ltd. will be the company of first choice in the Construction
Industry. We shall be driven by our commitment to Customer Satisfaction.”

9
 CSR VISION
“Creating a Sustainable and Responsible business”

Management System Certifications

ISO 9001:2008
ISO 14001:2004
BS OHSAS 18001:2007
CSR- Corporate Social Responsibility

10
 Introduction

(Fig No:1: Architectural View)

11
(Fig No:2: Site layout Plan)

12
 About the Project
a. Name of project: Construction of Medical Colleges at Hazaribagh at Jharkhand
b. Name of client: Jharkhand State Building Construction Corporation ltd, Ranchi
c. Type of contract: Item Rate Contract
d. Agreement value: Rs.647,82,83,516.00
e. Duration: 30 months
f. Structure names:
 Medical College Building (G+4) (1no.)
 Boys hostel (G+8) (1no.)
 Girls hostel (G+8) (1no.)
 Residential quarters / staff quarters (s+7, s+8) (2nos.)
 Road work
 Landscaping work
g. Total project area: 25 acres or 101171.45sqm
h. Scope of works: Civil work, Water supply, Sanitary works, Electrification,
Firefighting, HVAC, ELV and supply & installation of Medical Equipment,
Furnitures, etc.
i. Start date: Agreement date- 11.01.2017
j. End date: 30 months from NTP
k. Location: Dumka/ Hazaribagh/ Palamu at Jharkhand
l. Project layout: 05 nos. block in each project
m. Ground coverage area:
 Block medical college- 4977sqm
 Block- boys hostel- 1309 sqm
 Block- girls hostel- 1309 sqm
 Residential quarters- 658 sqm

13
 BRIEF INTRODUCTION TO THE PROJECT

Jharkhand Government has laid the foundation for its 3 new Medical Colleges at Hazaribagh,
Palamu and Dumka costing around 600 Crore INR, while 60% of the budget shall be
reimbursed by central government rest 40% shall be taken care by the state government. Of the
total budget 215.96 Crore INR has been sanctioned for Hazaribagh Medical College.

The Medical College total project will be developed in two phases.

 The first phase would include Medical College Building, 2 Staff Quarter,
Boys' Hostel, and a Girls' Hostel.
 The Second Phase would include the Construction of 500 beds Hospital with
Emergency and Trauma Centre.

Medical College Building would a G+4 building which would have the
Classrooms, Labs, Professor's chambers, Gymnasium, Food-court, and Reception
Hall. The Building would be divided into 5 pours having total floor area of
22040.40 sq. m.

There would be two Staff Quarters, one would be S+7 other would be S+8,
each Staff Quarter would have Ground Floor as parking space, and each floor
would have 4 flats, (each 2BHK + Study Room), total floor area of S+7 Staff
Quarter would be 3894.547 sq. m, and that of S+8 Staff Quarter Would be
4450.911 sq-m.

The Girls' and Boys' Hostel Would be G+8 buildings, both the buildings
would have 27 rooms at the ground floor along with Kitchen and Dining Area,
there would be 28 rooms from 2nd floor onwards, with toilet, bathroom, and
laundry area at each floor including the ground floor. The total Floor area of each
buildings will be 8344.721 sq. m.

14
 Departments

 Administration

 Contracts

 Planning

 Commercial

 Execution

 QA/QC

 Health safety and environment

 Accounts

 Surveyor

 Plant and Machinery

 Mechanical Electrical and Plumbing

 Store and Purchase

15
 Administration

Most administrative assistant duties revolve around managing and distributing information
within an office. This generally includes answering phones, taking memos and maintaining
files.

Roles of Administration Department:

 Arranging office setup

 Arranging facilities such as staff guest house, transportation, food, water, toilet, etc
 Housekeeping in office area
 Handling legal formalities regarding the project such as filling of form five (under
BOC act)
 Handling security of the office

Labour related:

 Arrangement of labour colony (capacity- 800)

 Arranging food, water, toilet, etc
 Labour entry worksheet
 Coordination with the labour camp boss
 Recording documents: undertaking form, fitness certificate, wages compliance, govt.
forms

16
 Contracts Department

Definition: Agreement which is Enforceable by law is called a contract.

Necessary conditions (CCCL): Consent

Competent

Consideration

Legal

Note: The contract law of 1872 is followed in India except J&K.

Important Contractual Terms:

 Contract Duration:
30 months including mobilization period from the Date of issuance of LOA (27 Dec
2016)

 Contract Value:
215.96 crore INR (inclusive of all taxes & duties)

 Type of Contract:
Item- rate
 Defects Liability Period:
365 days from the date of completion

17
 Project Information

NAME OF Construction of Medical Colleges at Hazaribagh at Location Dumka /

PROJECT: Jharkhand. Hazaribagh /
Palamu at
Jharkhand.

TYPE Medical College & Contract Rs. Project 05 Nos Block in

ancillaries. value 647,82,83,516.0 Layout Each Project
0

CONTRACT Item Rate Contract Start Date Dumka / Total Area: 101171
Agreement Hazaribagh Sqm.
Date:11.01.2017, / Palamu Ground Coverage
NTP Area: 8145 Sqm
(only building)
BUA- 50464 Sqm

SCOPE OF Civil Work, Water Duration 30 Months Block Ground Coverage

WORKS Supply, Sanitary Medical Area: 5005 Sqm
Works, College BUA: 22868 Sqm
Electrification, (G+4) 01 No
firefighting, HVAC,
ELV and Supply & End Date 30 months from Block- Boys Ground Coverage
Installation of NTP Hostel(G+8) Area: 951 Sqm
Medical 01 No BUA: 8227 Sqm
equipment’s,
Furnitures, etc. Block- Girls Ground Coverage
Hostel(G+8) Area: 951 Sqm
01 No BUA: 8227 Sqm

Block- Ground Coverage

Residential Area: 1238 Sqm
Quarters BUA: 11142 Sqm
(G+8) 02 No

18
 Key Conditions of Contract

Sl DESCRIPTION FINAL CONDITIONS (AS PER CONTRACT)

no
.
1 Client Jharkhand State Building Construction Corporation Ltd. Ranchi.

2 Type of Contract Item Rate

3 Built-up Area 50464 Sqm.
4 Scope of Civil Works, Water Supply, Sanitary Works, Electrification, firefighting, HVAC
Contract and Supply & Installation of Medical equipment’s
5 Architects Not Mentioned

6 Structural / RCC Hospitech Management Consultants Pvt. Ltd.

Consultants UG-64, World Trade Centre, Barakhamba Avenue, Connaught Place,
New Delhi - 110001
7 Project Hospitech Management Consultants Pvt. Ltd.
Management UG-64, World Trade Centre, Barakhamba Avenue, Connaught Place,
Consultants New Delhi - 110001
8 Earnest Money Rs. 5,88,98,723.30/- in the form of Bank Guarantee from any Scheduled
Deposit Indian Bank valid for 45 days beyond the validity of the bid.

9 Project Duration 30 months

10 Validity of Tender Bids shall remain valid for a period not less than 120 days after the
deadline date for bid submission
11 Mobilization 10% of the Contract price.
Advance On submission of unconditional Bank Guarantee, (to be drawn before the
end of 20% of Contract period).
The contractor may furnish four bank guarantees of 2.5% each, valid for
full period.
12 Recovery of Mob . Deductions shall commence in the next Interim Payment Certificate
Advance following that in which the total of all such payments to the Contractor has
reached not less than 20 per cent of the Contract Price or 6 (Six) months
from the date of payment of first instalment of advance, whichever period
concludes earlier, and shall be made at the rate of 20 per cent of the
amounts of all Interim Payment Certificates until such time as the loan has
been repaid, always provided that the loan shall be completely repaid prior
to the expiry of the original time for completion.
Interest will be charged @10% Per Annum on the advance payment after
six months on the remaining advance.
13 Performance 2% of the Contract price plus additional security for unbalanced Bids in the
Guarantee form of bank guarantee from any of the branches of Scheduled Bank in
India

19
14 Release of Valid until 28 days from the date of expiry of the Defect Liability Period.
Performance
Guarantee
15 Retention Money Cash Retention @ 9% from each bill subject to a maximum of 8% of final
contract price.
Release of Retention:
On Completion of the whole of the Works half the total amount retained
is repaid to the Contractor and half when the Defects Liability Period has
passed. On completion of the whole works, the contractor may substitute
retention money with an “on demand” Bank guarantee.
16 Release of On completion of the whole works, the contractor may substitute retention
Retention Money money with an “on demand” Bank guarantee
17 Water & Power Water and Power SPCPL Scope

18 Labour To be arranged by contractors at his own cost but JSBCCL will facilitate
Accommodation
19 Facilities to be Not Mentioned
given to Client
20 Variation limit If the final quantity of the work done differs from the quantity in the Bill of
Quantities for the particular item by more than 25 percent provided the
change exceeds 1% of initial Contract Price, the Engineer shall adjust the
rate to allow for the change, duly considering.
(a) justification for rate adjustment as furnished by the contractor,
(b) economics resulting from increase in quantities by way of reduced
plant, equipment, and overhead costs,
The Engineer shall not adjust rates from changes in quantities if thereby
the
Initial
Contract Price is exceeded by more than 15 percent, except with the
Prior approval of the Employer.
The Contractor shall provide the Engineer with a quotation (with
breakdown of unit rates) for carrying out the Variation when requested to
do so by the Engineer. The Engineer shall assess the quotation, which
shall be given within seven days of the request or within any longer
period stated by the Engineer and before the Variation is ordered.
21 Extra Items If the cost per unit of quantity changes, or if the nature of timing of the
work in the Variation does not correspond with items in the Bill of
Quantities, the quotation by the contractor shall be in the form of new
rates for the relevant items of work.
If the Contractor’s quotation is unreasonable, the Engineer may order the
Variation and make a change to the Contract Price which shall be based on

20
 Planning Department
A good construction plan is the basis for developing the budget and the schedule for
work. In addition to these technical aspects of construction planning, it may also be necessary
to make organizational decisions about the relationships between project participants and even
which organizations to include in a project.”

Construction planning is a fundamental and challenging activity in the management

and execution of construction projects. It involves the choice of technology, the definition of
work tasks, the estimation of required resources and duration for individual tasks, and the
identification of any interactions among the different work tasks. A good construction plan is
the basis for developing the budget and the schedule of work. Developing the construction plan
is a critical task in the management of construction, even if the plan is not written or otherwise
formally recorded.

(Fig No:3: Alternative Emphases in Construction Planning.)

21
Components: -
The primary components of a project management plan are: -

 Critical Success Factors

 Deliverables
 Work Breakdown Structure
 Schedule
 Budget
 Quality
 Human Resources Plan
 Stakeholder List
 Communication
 Risk Register & opportunity Register
 Procurement Plan
 Tracking and Monitoring

Critical Success Factors

Since a project is defined as a temporary endeavour, time and cost are usually high on the
success criteria list. Other items that can define project success are:

 Deadlines
 Budget
 Quality standards
 End user benefits
 Minimal change orders
 Low rate of product rejections
 Employee satisfaction

Deliverables

Deliverables are the products, services, or results that the project is commissioned to
produce.

22
Work Breakdown Structure

The foundation of the effective management of project starts with the creation of a
WBS, which is a logical subdivision of the project into tasks. Management of the project
is then done on a task by task basis.

Schedule

Since projects have a defined beginning and end, the schedule is usually an important
piece of puzzle. Developing a project schedule does not have to be a major undertaking
involving expensive project management software. Whatever accomplishes the goal of
communicating the project milestones and deadlines to the applicable stakeholders is good
enough.

Microsoft Project is widely used across all industries.

Budget

The process of making an estimate of the cost to be incurred in all the activities involved
and preparing a budget so as to get an approximate value of the project is called budgeting.

The PSE (pre-start estimates) is prepared before the starting of any project to show the
approximate value of project to the client.

Quality

When a project produces a deliverable, there are always quality standards in play. There
are several aspects to quality management:

 Determining quality standards

 Developing a strategy to meet the standards (quality assurance)
 Measuring quality (quality control)

23
Human Resources Plan

The project team members are often one of the most critical components in the chain
of successful projects. The human resources portion of the project should contain
following items:

 Resource Requirements
 Project Team Acquisition
 Training and Development
 Management

Stakeholder list

A proper stakeholder analysis includes a classification of the stakeholder’s power to

influence the project as well as their level of interest in it.

Communication

The project management plan should contain a list of formal communication that are
core to the project.

Risk Register

Importance of a risk is defined by two factors:

 Probability
 Impact

The risk register contains the following fields:

 Description of risk
 Probability
 Impact
 Priority
 Triggers
 Response plan

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 Procurement Plan

The procurement process goes like this:

 Develop a Statement of Work (SOW)

 Perform the Procurement
 Progress Payments

Tracking and Monitoring

The tracking and monitoring of any project is done in the form of two terms namely
progress and cost.

Tracking based on Cost

It involves two factors:

 Cash flow
 Profit and Loss

Tracking based on Progress

 Daily Progress Report (DPR)

 Weekly Progress Report (WPR)
 Monthly Progress Report (MPR)
 Delay Analysis

Role & Responsibilities of Planning Engineer

 Preparation of Master Construction Program

 Daily, Weekly & Monthly Programs
 Progress Monitoring - Progress reports collection, review & analysis
 Monitoring Delay Analysis (attributable to SPCPL – discussed in meeting with client)
 Resources Planning - Material Procurement Plans
 Technical support to field construction
 Co-ordination with Purchase Engineer

25
  Review of Purchase Orders for Site Purchases
 Delay analysis
 Preparation for Monthly Review Meeting
 Liaison with clients & consultants
 Contract Monitoring
 Vendor Development (if responsible for Purchases)
 MIS & Performance Reports
 Reconciliation of Construction Materials prepared & submitted to Stores by 5th of
every month

Commercial Department
Definition: Commercial relates to commerce or general business activity.

Identification and development of business opportunities and profitable management

of projects and contracts, from inception to completion is commercial management.

Contract type: Item- Rate

Item Rate Work: The payment is done on the basis of the quantified work i.e. the work that
can be measured and the labours carrying out such work are paid based on their per unit rate.
This rate varies from time to time based on the market situations including market rate, site
conditions, activity involved and productivity of the labour. On the basis of market rate only
the subcontractors are also paid.

Roles and Responsibilities:

 Preparation of Pre- Start Estimate

 Billing of quantities
 Preparation of PS (Project Structure) module
 Preparation of MM (Material Management) module
 Preparation of SD module
 Rate analysis

26
  Analysis of extra items claimed
 Comparison between client verses contractor bill
 Preparation of work order
 Preparation of budget after preparation of PSE

Some Definitions:
Direct Cost: The cost which is directly included in the budget is known as Direct Cost. Direct
Cost includes cost of items such as: material, labour, depreciation cost, plant, etc.

Indirect Cost: This includes: staff salary, infra- site setup, vehicle cost, borewells, etc.

Indirect cost is of two types: 1. Fixed indirect cost

2. Variable indirect cost

Settlement Cost: The cost which is added to the budget to settle direct and indirect cost.

Procedure for preparation of PS module:

Step 1: The cost is divided into three types:

 Direct cost
 Indirect cost
 Procurement/ settlement cost

Step 2: The work is divided according to the scope of work such as civil work, mechanical,
plumbing etc.

Step 3: The divided work is again divided into sub groups.

Step 4: The rate analysis of divided works is done.

Note: The main points to be considered in the preparation of PS module are:

27
  Plant
 Labour
 Material
 Sub- contractor

Procedure for preparation of MM module:

Step 1: PR (Purchase Requisition) is prepared.

Step 2: RFQ (Request for Quotation) is sent.

Step 3: PO (Purchase Order) is prepared.

Step 4: Approval is taken at different levels.

Procedure for preparation of Bill:

Step 1: Service entry

Step 2: Document register

Step 3: Bill parking

Step 4: Approval

Step 5: Payment

Procedure for preparation of SD module:

Step 1: Client Bill is taken

Step 2: MB (Measurement Book) is prepared.

Step 3: PI (Performa Invoice) is created.

Step 4: Certified bill is uploaded.

28
Step 5: TI (Tax Invoice) is created.

Sent 6: Finally, the module is sent to accounts department.

Execution Department

Execution is the phase in which the plan designed in the prior phases of the project is put into
action. Construction starts with planning, design, and financing; it continues until the project
is built and ready for use. Those involved with the design and execution must consider zoning
requirements.

Basically, the execution work of every element is divided into three parts:

 Reinforcement
 Formwork
 Concreting

Challenges faced during execution:

 Unskilled Bar-benders was having lack of knowledge about 2legged and 4legged
stirrups, causing a wrong reinforcement design.
 Poor shuttering material used by Sub-contractor at Boys and Girls hostel, creating an
uneven and nonuniform surface, Also the local sub-contractor was unexperienced to
execute such large scope of work which created labour handling and safety problems.
 Continuous Design change in GFC drawing caused a lot of problem after completion
of slab, especially in case of cut-outs, sleeves, plumbing duct and lintel.

Solution:
 Proper cross-check must be done by supervisors and site engineers while the bar tying
of reinforcement is carried out.
 SPCL gave its own shuttering material for concreting work, once they realized the poor
quality due to materials used by Sub-Contractor.

29
  Proper training of unskilled workers and induction programs for new workers to avoid
safety hazards.
 On time delivery of GFC drawings must be provided by Consultancy, Multiple
revisions in drawings should be avoided.
 Engineers to utilize item rate subcontractor labour for work within their scope and
supply subcontractors preferably for work out of scope of project e.g shifting of
materials. This was tried to be implemented by informing detailed plan including which
subcontractor to be deployed when and where exactly.

Reinforcement:

Steel: Steel are a large family of metals and all of them are alloys in which iron is mixed with
carbon and other elements. Steel are described as mild, medium, or high carbon steels
according to the percentage of carbon they contain, although this is never greater than 1.5%

Types of reinforcements:

The types of reinforcements used in construction are:

 Fe 250- It is mild steel. It is good for tension only.

 Medium tensile steel- Not much use in concreting.
 Fe 415- Good as it has resistance to torsion as well as tension.
 Fe 500 D, 600 D etc.- The D represents ductile. They have good ductile property and
are reliable for tension, compression, and torsion.

At Hazaribagh Medical College, Fe 500 is being used.

The process of reinforcement works involves the following procedures:

Indent > Storage > Cutting > Bending > Binding > Placing in position

30
Main Component of Reinforcement:

 Main Bar
 Distribution Bar
 Stirrup
 Chairs
 Binding Wires

Cover:
Cover blocks are used to provide proper spacing between the reinforcement embedded
in the concrete and the outer face of concrete exposed to atmosphere (in case of columns) and
soil or earth (in case of foundations).

The various provision of cover to the reinforcements depends upon the type of structure
to be built. Some of them are as follows:

Footing- 50mm

Column- 40mm

Beam- 25mm

Slab- 20mm

RCC wall- 25mm

Raft- 50mm

CHAIRS:
Chairs are used to provide correct spacing between the horizontal reinforcement. They
are placed to keep the reinforcement at a set distance from the formwork surface and to keep
the bars in place during concrete placing and compaction. Types of spacers can be plastic
spacers or steel spacers. The number of chairs provided in 1m2 area is 1(least quantity).

Number of Bars:
To calculate the numbers of bars to be provided in a given length say “L” the following
formula is used:

31
If say 20mm diameter bars with c/c spacing of 200 mm are provided, then

No. of bars = (L (in mm)/200) +1

Unit Weight of a Bar:

The unit weight of any steel rod of say “d” diameter is calculated with the help of a
formula: Unit weight of steel bar = d2/162

Bar Bending Schedule:

BBS is a list of reinforcement bars for a given reinforced concrete work item and is
presented in a tabular form for easy visual reference.

Deductions for Bar Bending:

For steel rods of diameter 10mm or less the deduction made is 1d for every 90˚ bend.

For steel rods of diameter more than 10mm the deduction made is 2d for every 90˚
bend.

Stirrups:
There are 3 types of stirrups: Master ring, Middle ring, Hook.

When stirrups are tied some extra length is given after the bend. It is also called a hook.
The length of such an extension varies as per the diameter of the bar. At least 75mm length
should be given to such a bend. Generally, for master rings and middle rings this length is taken
as 24d and for hook it is taken as 100mm on both sides.
Hook- 10d

Formwork:

Formwork is the term used for the process of creating a temporary mould into which
concrete is poured and formed. Traditional formwork is fabricated using timber, but it can also
be constructed from steel, glass fibre reinforced plastics and other materials.

32
The type of formwork used in this project is conventional timber ply with cup lock scaffolding,
NOVA formwork for column.

Cup-lock Scaffolding:

Cup-lock galvanized scaffold system is a well- proven heavy- duty support system, yet
one which is relatively light and easy to assemble.

The components of cup lock system are:

 Base Plate-
The bottom most component of the system on which all the other components are supported.
It has a depth 150mm.

 Horizontal bracing-
These are horizontal supports provided to the vertical members so that the system does not
spread out. These are provided at 500mm from the bottom and 500mm from the top and in the
middle, these should be provided as required according to the design. They come in various
lengths for e.g. 1.2m, 1.5m, 1.8m etc.

 Vertical bracing-
These are the vertical members which take the vertical loads and transfer them on to the base.
They come in various lengths for e.g. 1.5m, 3m etc.

 U-head-
The top most component of the system which supports the secondary beam of the table form
wherever extra support is needed when casting of slab is done.

De-Shuttering of Formwork:

The process of removing the formwork after the concrete poured in it achieves suitable
strength is called stripping. Generally, the stripping time given for columns is 16-24 hrs and
that for slab is minimum 7 days.

De-shuttering time:

Vertical soffit/ column- 16 to 24 hrs

33
Beam- 21 days (for length greater than 6.5m)

14 days (for length less than 6.5m)

Slab- 14 days (for length greater than 4.5m)

7 days (for length less than 4.5m)

Concreting:

The process of pouring concrete in the prepared mould of formwork is known as concreting.

Stages of Construction:

 Excavation:

Methodology:

Excavation work was carried out up to the formation level as per GFC drawings.
Sufficient working space of 1000mm all around the excavated pit as per site requirement
was kept. Side slope of the excavated pit maintained according to the site-condition as well
as the working weather condition, as per the GFC drawings, specifications and as per the
instruction of the Engineer-in-charge. In case of loose soil, sides of the excavation have
been suitably sloped and necessary shoring/strutting has been fixed to avoid collapse.
Necessary dewatering pumps has been used if water is being staged. Excavated earth has
been disposed of to designated locations and it is within 50 meters from the place of
excavated location. Some quantity of excavated earth has been retained at site for
backfilling purpose as directed in technical specification, instruction of the Engineer-in-
charge. If excavation has gone deeper than the required level, extra depth has been brought
to the level by backfilling using approved filling material with proper compaction.

Machineries:

Excavation work was undertaken by Earth Excavator, JCB & Dumpers. (Manually
where & when require).

34
 EQUIPMENT REQUIRED

 Theodolite / Total Station,

 Levelling Instrument
 Excavator & Rock breaker
 Dumper
 Dewatering pump

 Back – Filling:
Back-filling is the process of putting soil back inside a trench or in a foundation when
the excavation has been completed.
Machineries:
 Excavator
 Dumper
 Roller
 Backhoe loader
 Concreting work
Methodology:
Concreting commenced only after formwork/Brick shuttering is approved,
reinforcement is recorded, different conduits for (i.e electrical, fire-fighting line etc.)
services and permission to proceed with concreting has been approved in writing from
the EIC.

In case of deep trenches and footings, it was done with the help of chutes. In the case
of reinforced concrete work, the concrete was carefully consolidated and packed round
the reinforcement and care was taken to ensure that reinforcement is not displaced
during the placing and compaction of concrete. If reinforcement moves out of its place,
it must be brought back in position immediately.

 Curing:

When the concrete begins to harden i.e. two to four hours after compaction, the exposed
surfaces were kept damp with moist gunny bags, sand or any other material approved by
the EIC. 24 hours after compaction, the exposed surface was kept continuously in damp or

35
 wet conditions by ponding or by covering with a layer of sacking, canvass, hessian cloths,
or similar absorbent materials and kept constantly wet for at least 7 days where ordinary
Portland cement is used and 7 days, where admixtures or blended cements are used (PPC
cement etc.) is used from the date of placing of concrete.

 Water Proofing

Waterproofing is the process of making a structure waterproof or water resistant so that

it remains relatively unaffected by water or resisting the ingress of water under specified
conditions.

Machineries:

 Automatic double seal welding machine, Leister Twining.

 Hot air manual welding guns.
 Air blower.
 Vacuum pressure testing kit.
 Pressure testing kit for double scams welding.
 Seam problem for testing the welded joint
 6mm brass roller.
 Roller and scissor.

Materials used:

 BASF Master Emaco (for sunken slab)

 SIKA 101H (for roof slab)

Methodology:

Applying Master Emaco-

Apply Master Seal 501, by brush on to the prepared surface in two coats each of
1kg/m2, the second coat applied at right angles to the first, 3-4hours later.

In high water table situations, especially in basement concrete, Master Seal 501 is also
recommended to be applied as a dry shake on to the PCC just before casting the RCC slab.

36
 For old concrete, brickwork and granulated blocks, replace the second slurry coat with
a MASTERSEAL 502 render of 5 – 10mm thickness.

Applying SIKA 101H

Sika 101 h, capillary waterproofing system (ready to use crystallizing waterproofing

system and moisture seal for mortar and concrete) to be applied as per direction of EIC and
technical datasheet to be followed. Sika 101 h to be sprinkled uniformly over freshly laid
concrete ( no waiting time required after concreting for waterproofing) @~1.8kg/m2 as a dry
shake. To finish the top surface with trowel and wooden block carefully to get it absorbed in
the top layer of concrete. To allow the concrete roof for air cure of 24 hrs and to be ponded for
normal curing.

Quality Assurance & Quality Control Department

Quality:
The totality of the attributes of a building that enables it to satisfy the needs, including
the way in which individual attributes (external attributes; performance attributes; and aesthetic
attributes) are related, balanced, and integrated in the whole building and its surroundings

Quality Assurance:
A systematic way of ensuring that all those planned and organized activities happen in
the way they are planned thus providing adequate confidence that a product or service will
satisfy the given contract specific requirements.

Quality Control:
The planned and specified actions and operational techniques and activities that are
necessary and used to fulfil the requirements of quality as specified.

37
Work Method Statements (WMS):
The document showing the procedure of how any particular task has to be carried out is the
method statement for that task. Method statements are prepared for following activities:
 Excavation
 Backfilling in pits
 Anti-Termite Treatment
 Waterproofing
 Reinforcement
 Formwork (Shuttering & De-shuttering)
 Concreting
 RCC repairs
 Rebar work

Tests performed on Aggregates:

 Sieve Analysis
 Water Absorption test
 Aggregate Impact Value test
 Aggregate Crushing Value test

Tests performed on Cement:

 Fineness test
 Consistency test
 Initial and Final setting time

Tests performed on Concrete:

 Slump test
 Compressive strength test

Tests performed on Bricks:

 Absorption test
 Crushing Strength test

38
  Toughness test

Mix- Design:

The common method of expressing the proportions of ingredients of a concrete mix is in terms
of parts or ratios of cement, fine and coarse aggregates. For e.g. A concrete mix of proportions
1:2:4 means that if the mix contains one part of cement then it contains two parts of fine
aggregates and four parts of coarse aggregates.
They may be by volume or by mass. Based on the cement proportion the water content is also
decided.

Designation of grade used at Hazaribagh Medical college Project:

The grade of concrete is M25. This means that the mix containing proportions as specified for
M25, when casted in cubes will give a characteristic compressive strength of 25 N/mm 2 after
28 days.

At Hazaribagh Medical College Project, M25 is being used.

39
 Health Safety and Environment
Construction work is a hazardous land-based job. This work includes many hazardous
task and conditions such as working with height, excavation, noise, dust, power tools and
equipment. The most common fatalities are caused by the fatal four: falls, being struck by an
object, electrocutions, and being caught in between two objects. Within the field of
construction, it is important to have safe construction sites.

A thing is provisionally categorized as safe if its risks are deemed known and, in the
light of that knowledge, judged to be acceptable. In any working construction site safety is
considered as the most important aspect whether it be the safety of the people working on site
or the safety of all the machines, tools and equipment along with safety in their handling and
operations.

SPCPL issues PPEs to all the members to maintain safety.

PPEs include:

 Helmet
 Safety shoes
 Reflective jacket

Correspondingly, it is the part of SPCPL Culture that

 Each employee of company is responsible for Safety and Health.

 All Safety equipment issued by the company must always be used as

intended.

 Supervisors sees that rules, procedures are observed by their crews, and
immediately enforce appropriate corrective measures whenever
violations are observed.

Shapoorji Pallonji is fully committed to maintain a safe working

environment, be it the safety of the employees, subcontractor, equipment, or

40
 even the community at large. Their untarnished and excellent safety record
is best exemplified by the trust invested in us by such safety-conscious
clients like Shell, BP Solar etc. In fact, companies like Glaxo Smith Kline
even extended a special appreciation letter acknowledging our exemplary
safety standards.

As a standard practice, following are prerequisites at SPCPL to commence any

project

 Appointment of safety personnel for the project and the formation of a

Safety Committee on site

 Review of specifications to identify appropriate safety standards and

special safety conditions

 Hazard analysis

 Emergency plan for obtaining medical assistance, ambulance and

direction for rescue operation

 Safety induction training for every worker, to make them aware of the
safety rules and procedures

 Inspection, testing and certification of tools and equipment

 Display of safety signage caution boards and awareness posters

 Periodic Safety inspection and compliance of observations

 Accident Reporting and investigation

 Analysis of accidents

HSE checklists:

 To govern and check the activities if they are carried out in a safe manner or
not, checklists are provided to the HSE officer according to which such activities can
be checked. These checklists are given for every activity and the frequency with which
every activity needs to be checked is also specified. To give examples, some of the
points are given that should be checked in the corresponding activities.

41
  First Aid Box, Safety Requirement for Concrete Pouring on Construction Site,
Monitoring checklist for scaffolding, diesel/HFL storage, DG set, mobile crane
operation, equipment/vehicle fitness, Concrete pump, fire extinguisher,
inspection checklist, for portable chop saw machine, Full Body Safety Harness
inspection, Operations of power hand tool & other equipment, excavation,
electrical works, machine safeguarding, ladders, PPE, general housekeeping for
site & store, working at height, ambulance van checklist.

Accident Costs:
There are 2 costs-

 Direct Cost-

The costs which are incurred in providing compensation for accidents, paying medical bills on
behalf of the injured etc.

 Indirect Cost-

The costs which are incurred in the form of re-training, property damage, equipment damage,
production delays, supervisory time etc.

Equipment provided for safety from height work:

 Safety nets
 Harness
 Ladders
 Scaffoldings
 Barricading

42
 Surveyor Department
 Understanding role of surveying department in a project.

 Before execution, providing markings, levels, distances as required for initial setting out,
footings i.e. stake out reference point and markers according to suitable coordinate system
selected for the project.
 During execution, checking levels of slabs, column starters, large span beams, walls and
other elements (any kind of measurements throughout the project); As height of structure
increases, new control base used.
 After execution, preparation of as-built drawings.

 Study of plot layout from survey point of view as per drawings given by consultant,
Understanding superimposition of drawings (since Architectural North direction different
from True North)
 Bench mark with respect to Hazaribagh Central Jail

 Learning how to use Total Station (Trimble 3600 series) to measure level, distance and
angle together
(useful for shuttering, placing reinforcement considering required cover)
 Tripod stand levelled and centred
 Prism (18 mm constant) to be viewed from the eye piece of total station
 Stick used to adjust height of prism
 Program 20 – to set machine
 Program 26 – to measure distance between two points
 Program 43 – to save co-ordinates (Easting & Northings)
 Entry in field book

Learning use of Auto-level (Sokkia) to check slab level (calculation of RL)

On this site, 2 total stations & 1 auto level used.

43
 Plant and Machinery Department

Introduction
The Plant and Machinery (PNM) department in any construction company acts like a
support system in providing services required through tools, equipment, machines, plants,
logistics etc. It deals with the operation, maintenance, working, repair, feasibility, and erection
and dismantling of all the procured tools, equipment, and machinery on the site.

This department handles the functioning, maintenance of all the machineries apart from
hand tools used on the site. Every site of SPCPL has a PNM Department which is managed by
a mechanical engineer. 0.25% of monthly turnover of site is used for PNM maintenance.

Initially, a budget is made specifically for PNM department, keeping in mind available
machines (assets), and plans to hire the machines not available.

This requirement sheet is decided by the planning department with coordination of

PNM department.

The factors considered are:

 Type of the project

 Scale of the project

 Budget of the project

 Availability of the machinery in the regional workshop and which site has the greater
need
 Depreciation charged

Depreciation Charges:
This is a major factor considered during hiring a machine. Depreciation of machine is
based on the Date of purchase. For the first 5 yrs. depreciation charged is 2.75% of the purchase
value after that it decreases 1.5% and slowly up to 0%.

Notable machineries used Bar Bending and cutting machine

44
 It was purchased and deployed to site after 15 days of the initialization of civil works.
As its cost is less compared to other machineries it was site purchased.

Cost- 2.5 lakhs

Some Type of Major and Minor Machinery Used on This Site Were:

MAJOR Machinery
 Mobile Tower Crane
 Transit Mixer 3 nos.
 Pick & Carry Crane (Hydra)
 Cummins 125 Kva DG Set
 Kirloskar 40 Kva DG Set
 JCB Backhoe loader
 Concrete Pump (2+1), BP 350D,
 Universal RM 800-1
 Star Bus
 Light Mast
 Batching Plant (Scope of ACC), CP 30
 Material/Builder Hoist 8 nos.

Hire Charges-

For hire charges two types of dates are considered, one is mobilization date i.e. the date
on which a particular tool or machine was moved on to the site and the other is the
commissioning date i.e. the date from which the functioning and working of that tool or
machine begins.

Maintenance Charges-
PNM maintenance = 0.25% cost of monthly turnover

Operation Charges-
Depreciation- cost 2.75% of appreciation value p.m., 1st 5 years, after that depreciation
value goes on decreasing.

45
 Reports:

There are few reports that are submitted by the PNM department.
 MEPR (Monthly Equipment Performance Report) and Follow Up.

 Tentative Hire Cash Out Flow on Monthly Basis.

 Man, Power Allocation.

 Externally Hired Equipment Performance Report.

 PNM Requirement list

 PNM External Hiring requisition

 Monthly performance report

 Weekly breakdown report

 PNM maintenance schedule

 Job cards

 Monthly breakdown

 Installation commissioning

 Repair assessment (repairs done in PNM workshop)

 Spare parts and consumables

 Utilization recording

 Master and physical verification

 Hiring from external agencies

 Maintenance record

 Strategic installation, erection and dismantling

 Insurance provision

 Diesel Reconciliation

46
 MEP Department
Mechanical, electrical and plumbing (MEP) refers to these aspects of building design and
construction. In commercial buildings these aspects are often designed by an engineering firm
specializing in MEP.

Cost Distribution

ITEM COST (Rs.)

Medical Equipment 146225675
Furnitures 159519113
S&P 73889763
Heating System 12113105
Electrical 84858688
HVAC 50869041
Fire Fighting 22191227
ELV 15481300
Lift 20787904

SCOPE:

 Electrical

 HVAC

 Fire Fighting System (Fire detection/Alarm System)

 Public Addressing System

 Audio/Visual System

 ELV (Electrical Low Voltage) Data/LAN/Telephone/CCTV

 Sanitary and Plumbing (SnP), Borewell

 Lightening Arrester System

 Solar Heater and Power Generation

 BMS (Building Management System)

 Lift/Elevator

 Medical Equipment and Furnitures

47
ROLES AND RESPONSIBILITY OF MEP DEPARTMENT
 Study of Drawing and follow the drawing for execution of work.

 Check for faults in drawing writing an RFI to clients and getting a final decision from client.

 Preparation of Soft Drawing and collection of As-Built drawing from vendors.

 Maintaining Quality as per company standards and IS standards.

 Following Client Specification and Approved makes (for vendor selection).

 Manpower and Material planning for execution, (material for own scope and subcontractors
scope), Quantity Surveying of material under own scope is carried by MEP engineers.
 Indent (Planning – Purchase Requisition – Purchase Order), PSE (Pre-Start Estimate), DC
(Direct Cost), variance between present cost and DC is calculated to allot PO, If present
cost > DC then negotiation.
 Follow Up Material delivery at site as soon as possible.

48
 Store and Purchase Department

Role of Site Stores & Warehousing:

 Material Request & Issue to site

 Material Transfers between sites
 Receipt & inspection of delivered material to site
 Material Storage
 Sale & Disposal of scrap material
 Store’s Inventory Verification
 Stock Closure

Responsibilities of Stores Officer:

 Arrangement of unloading vehicle

 All SAP entry & excel report as per indent book & requirement
 Co-ordination with site management & RO management & vendors for delivery

 Store Closure

Responsibilities of Stores Assistant:

 Daily Material Received record

 All documents file
 Diesel register
 Checklists
 All material loading & unloading (shuttering, steel, cement etc.)

Documentation:
 Material Transfer Voucher
 Material Received
 Checklists
 Material test Certificates
 Rejected Material File
 WBS Number

49
 Debit Note
 Rental Basis Material (e.g. scaffolding on hire basis)
 Contractor Return Material e.g. PPEs
 Challan File
 Diesel Register
 Issue Slip
 Daily invoice
 Raw material
 Daily Received Material (Gate Entry No.)

50
 Site Observations
Things observed during site visit:

 Hacking
 Nova shuttering
 Formwork
 Slab reinforcement
 Slab concreting
 Stair reinforcement
 Electrical conduits
 Chipping
 Reinforced brick work
 Plinth beam in boy’s hostel
 Concrete pumping
 Bar bending machine
 Concrete wastage
 CT props
 Cup-locks scaffolding
 Safety nets
 Lintel beams
 Door shutters
 Sunken Slab
 U-head
 Cover blocks
 Chair bars
 Expansion joints
 Mobile tower crane
 Transit mixer
 Pumping machine
 JCB machine
 Bar cutting machine
 Overhead protection
 Brick work

51
 Pneumatic Roller
 Juggling
 Staging
 Batching plant
 Cement storage

52
 Practical Works
Practical works performed during training period:

 Studied architectural drawings

 BBS (Bar Bending Schedule) of Medical College Building
 Survey (using levelling machine and total station)
 Compressive strength of concrete cube (15cm *15cm*15cm) at 7 days
 Quantity Estimation of flooring details of Medical College
 BOQ wise flooring quantity of Medical College
 Auto Cad drawing of typical stair section
 Auto Cad drawing of typical road section
 Study of single shutter and double shutter door
 Subcontractor billing
 Auto Cad drawing of roof section
 Auto Cad drawing of Building Elevation

53
 Conclusion

From the field study report, it is evident that the construction activity is going on full swing
using all the safety norms as per ISO. It was a wonderful experience. I gained a lot of insight
regarding several aspect of site. I was given exposure in almost all the departments at the
site.

As an undergraduate, I would like to say that this training program was an excellent
opportunity for me to experience the things that I could have never gained through going
straight into a job. I am grateful to M/s Shapoorji Pallonji Engineering & Construction pvt.
Ltd. for giving me this wonderful opportunity.

The main objective of this 45 days summer training was to provide an opportunity to
identify, observe and practice how engineering is applicable in the real industry. It was not
only to get experience on technical practices but also to observe management practices and
to interact with fellow workers.

I hope this exposure and experience will surely help me in mere future and also in shaping
my career.

54
Pictorial Report of Hazaribagh Medical College Project

55
 1. Anti-termiting process 2. Spreading chemical

3. Concreting of slab after anti-termiting 4. Slab after concreting

5. Brick stacking 6. Brick wall const.

56
 7. Brick wall 8. r/f brick wall 9. Brick grooves

10. Transit mixer 11. Pumped concrete

12. Cover block 13. Slab concreting

57
 14. Boundary wall 15. Slab concreting along with column r/f

16. Concrete pumping 17. Plinth beam

18. CT props 19. Nova shuttering formwork for column 20. Side support to formwork

58
 21. Staging 22. Steel yard

23. Cup-lock scaffolding 24. Horizontal ledger

25.conduits 26. Cut-out for conduit 27. Conduits

59
 28.Plaster blocks 29. Chipping

30. Plastered wall 31. Soil compactor

32. Hacking 33. Hacking process 34. Bar bending machine

60
 35. Transit mixer 36. Mobile crane

37.Chair bar 38. Beam R/F 39. Slab R/F

40. Cover block 41. Stirrups

61
 42.RMC plant 43. Rubble soling of road

44. Rubble soling 45. Excavation for road work

46.Safety net 47. Retaining net 48. Safety helmet and

reflective jacket used by labour

62
 49. Ladder 50. Safety net

51. Harness for height work 52. Safety norms for electric supply box 53. Safe ingress

54. Stair barricading 55. Cover for cutouts 56. Safe unloading of bricks

63
 57.Steel bars 58. Cement storage 59. Wooden battens

60. Fine aggregates 61. Plumbing material

62. Steel yard 63. Marked level 64. Tripod stand

64
 65. Total station 66. Insertion of R/F by grouting

67.Master Emaco SBR 2 68. Sika 101H

65
69. Slab after waterproofing 70. Process of waterproofing 71. Master Emaco emulsion

72. Wood obtained from clearing land 73. Scrap Yard

66