INDUSTRIAL

BUILDINGS

HARISH KUMAR
Framework
Project Manager (S)

Site Office Concrete Plant Project Site

• Administration • Administration Contd.,

• Quantity Surveyor • Billing
• Billing • Stores
• Stores • Electrical
• Canteen • Mechanical
• Transportation
• Plant operators
 Framework (Contd.,)
Project Site

Civil Health & Safety Electrical Mechanical Quality Survey

Control

Asst. Project Manager Safety Manager Electrical Mechanical QC

Engineer Engineer Sr. Surveyor
Engineer
Sr. Project Engineer Safety Executive Electrical Sr. Mechanic Supervisor Surveyor
Supervisor
Project Engineer Safety Officer Assistants Assistants Assistants
Assistants
Asst. Engineer Safety Supervisor

Safety Assistant
Junior Engineer
Site Supervisor / Steward
Trainees
Setting up Project Site
• Procuring Land for Setting Up Site Office  Steel Yard
• Pooja  Scrap Yard
• Mobilization
 Diesel Yard
• Setting up,
 Generator Area
 Site office
 Curing Water Tank Setup
 Stores
 Electrical Room  Toilets (Staff & Labor)
 Mechanical Room  Drinking Water points
 QC/QA Room • Gathering all the Staffs
 Canteen
• Gathering Labors (Skilled & Un-Skilled, Carpenter, Bar-
 Labor Rest Area bender, Fitter/Welder)
 Labor Shed • Gathering Machineries (Excavator, Back hoe Loader,
 Parking Shed Tractor trailers, Water tankers, Tipper Trucks, 15 ton
 Occupational Health & Safety Office Roller, Dozer, Busses, Vans & Cars).
 Carpenter Yard
Initial Stages of
Construction
• Analyzing the drawings
• Preparing the working methodology and Schedules
• Client / PMC approval
• Survey works
 Constructing Bench Mark Pillars
 Transferring Coordinates & Levels onto the Pillars
 Traverse Closing
 Protection to Bench Mark Pillars
 Client / PMC approval
Stages of Construction (Commercial
Buildings)
• Excavation • Handover to PEB
• Pcc
• Footing shuttering • Steel Column, Beam, Deck Slab
• Footing & Pedestal reinforcement erection
• Footing concrete • Grouting
• Anchor bolt & Template fixing
• Pedestal Shuttering • Puff panel
• Concreting • Roofing Sheet
• Curing
• Backfilling
• Flooring
• Plinth Beam Pcc • Deck Slab Reinforcement & Concrete
• Plinth Beam Reinforcement
• Shuttering
• Fire & Smoke sensors
• Concreting • Electricals & Mechanical & Plumbing
• De shuttering
• Interior works
• Curing
• Backfilling • Exterior Works
Responsibilities of an Engineer
in Site
• Analyze the drawing • Labors required
• Prepare the quantities of work • Machineries required
Earth work/excavation • Execution of the project
Pcc • Maintaining good relation with
Reinforcement client
Shuttering • Preparing contractor bills
Rcc • Quality of work
Anchor bolts • Safety In work
Templates • On time completion
A day in life of an Engineer in Site
• Travelling to Site • Footing / Pedestal / Column
• Breakfast Reinforcement, shuttering
• Collecting Materials from Stores (Auto level, • Client checking
Vibrators, Dewatering pump, Cutting machine, etc.)
• Tool Box Meeting & NMR Report • Casting
• Dividing labors & explaining the work • Block work
• Curing work • Backfilling
• Instructing Surveyor to mark the points of
excavation, pcc, footing, pedestal / column starters. • Bolt Fixing
• Instructing excavators to excavate • De shuttering & touchup
• Checking levels of excavation • Report to Superior for next day’s plan &
• Manual dressing & compacting Requirements
• Preparing for Pcc
• Housekeeping
• Client checking
• Pouring Pcc • Site Diary
• Back to room
ACTIVITIES
& PROBLEMS FACED IN SITE
Excavation
• Points to check • Safety points
Survey points Permit from client for
Extra working space excavation
Hard rock Barrication materials
Bottom levels Signal man for excavators
Method of excavation
Transporting removed soil
Excavation (contd.,)
PCC
• Points to check • Safety points
Levels Rebar cap if bars are used as
Earth dressing & compaction supports
Survey points Ladder access
Shuttering Lighting
Thickness of pcc
Check list
Grade of pcc
Straightness & dimensions of pcc
Footing
• Points to check • Problems faced
Levels
Incorrect survey points
Survey points
Dimensions Improper dimensions
Reinforcement Plumb out for shuttering
Cover
Plumb & straightness of shuttering
Insufficient cover
Supports Improper compaction
Leaks Faulty reinforcement rods /
Water seepage spacing / lapping
Vibrators
Grade of concrete
Cracks over footing after casting
key
Pedestal
• A column is said to be a pedestal if its height is lesser than 3 times the least lateral dimension.
• Points to check
Top level of footing
Top level of pedestal
Bolt top levels
Bolt coordinates
Template levels
Survey points
Dimensions
Plumb
Compaction / finishing
Supports
Dowel bars for plinth beams
Lokfix
• Chemical used to bond concrete & steel.
• Horizontal & vertical separate.

Procedure:
• Drill holes 2 mm to 4 mm greater than bar diameter.
• Clean using air blower
• Mix and prepare the chemical and grout into the hole
• Fix the rods
Backfilling

• Points to consider
Quality of soil
Dewatering in footing
Boulders & cobbles
Levels of compaction
Evenness of levels
Core cutter test for finding density of soil
Moisture test by Calcium Carbide method (IS 2720 part 2)
Plinth beam
• Points to check
Levels
Dimensions
Plumb
Reinforcements
Clear cover
Lap length
Alignment
Compaction
Top surface
Bonding between old & new
concrete
• It is highly impossible to concrete the entire length of a beam or slab at the
same time, hence bonding between new and old surfaces is equally
important.
• Fosroc Nitobond EP is a chemical widely used to bond old concrete surface
and fresh concrete surface

Procedure:
1. Hogging the surface and making it rough.
2. Cleaning using air blower.
3. Apply coats of nitobond using brush before concreting.
Hand over to PEB
Grouting
• Grouting is done under the base plate of steel column with a non-shrink cement which
can withstand dynamic loads and high compressive force
• Fosroc GP2 is a widely used material for grouting up to 100 mm thickness.

Procedure:
1. Clean the surface using air blower
2. Shuttering around pedestal
3. Packing gaps using cement
4. Mixing GP2 and water for consistency
Pourable – 4.125 liters per bag (25 kg)
Flowable – 4.5 liters per bag (25 kg)
5. Pour into the cast and tap the shutter surface gently.
Flooring / Cement Concrete Roads
• Process involved
1) Soil cutting, levelling, compacting
2) Gsb filling, compaction
3) Wetmix filling, compaction (optional)
4) LDPE / HDPE sheet
5) Expansion pads
6) Reinforcements
7) Flooring channel fixing
8) Concreting
9) Floor hardener
10) Finishing the surface / Brooming
11) Curing
12) Groove cutting
13) Epoxy filling
14) Bitumen filling
Floor hardener
• Floor hardener is a cementitious material sprayed over semi-wet concrete
surface and finished using trowel.
• It improves the abrasion resistance and durability of the concrete floor
• Fosroc nitoflor hardener is widely used for industrial floorings.

Procedure
1. Cast the flooring as usual, after levelling spray nitoflor hardener at 3 to 7
kg/sqm depending on purpose.
2. After some time apply rough disc finish.
3. And later trowel finish.
Deck slab
• Deck slab is nothing but a roof slab of a pre engineered building.
• The bottom of the deck slab will be of a corrugated steel sheet over
which shear studs are fixed by stud welding and later reinforcements
are tied up and concreted.
• The deck slab may be of single or double layer where the second layer
may be seamless flooring (fibre reinforced concrete) for extreme
durability and abrasive industrial floors.
• The surface of the deck slab may be finished surface or tiled or
marble flooring.
Raft foundation
• Raft foundation is a type of shallow foundation.
• It is generally adopted when the column spacing are very low such
that the footings over lap and in cases like individual or combined
footings wont be enough for proper load distribution.
• In such cases the entire area is taken into consideration.
• Machinery foundations also use rafts for proper load distribution.
Bituminous Roads
• Bituminous road pavement is a flexible • Points to consider
pavement, widely adopted due to its cost of
construction, time of construction. Levels
• Bitumen is a bi product of petroleum. Subgrade conditions
Thickness of each layer of
Procedure
pavement
1. The subgrade is prepared using gsb and
wetmix Proper compaction
2. A thick coat of DBM is made with Proper camber
slope/camber considerations
3. Top coat of BC is made. Super elevation levels
4. Compacted with a 10 ton roller Spraying dust
Stone Pitching
• Pitching of stone is done using random rubble boulders and cement mortar on the
sides of an embankment to protect the soil erosion.
• The size of the boulders are greater than 300 mm.
• 1:4 or 1:3 cement mortar is used for bonding between the stones

Procedure:
1. The soil on the sides of the embankment are cut into proper shape and well
compacted.
2. The random rubble boulders are placed from bottom to top order with cement
mortar packing.
3. The slope of the embankment is maintained.
Kerb / Curb wall
• Kerb wall is a small wall kind of structure built along the side of the pavement mainly for
aesthetic view and for separating the pavement from the other side of the road and also
provide space for foot paths.
• They are generally 150 to 200 mm in height and 100 to 150 mm in width.
• They either may be precast or cast in site.

Procedure
1. Excavation should be done for 200 mm deep
2. Pcc laying of 50 mm thickness
3. Placing the precast kerb blocks along the road alignment (or)
4. Reinforcement for kerb
5. Shuttering
6. De-shuttering & finishing the surface
7. Backfilling
8. Painting if necessary
Storm Water Drain
• The purpose is to drain the water in main canal using gravity flow.

Procedure
1. Excavation
2. Ldpe or Hdpe sheet
3. Pcc
4. Reinforcement
5. Raft concreting
6. Edge angle fixing
7. Wall shuttering
8. Wall concreting
9. Gratings / Top Slab with manhole covers
Hume pipe laying
• Hume pipe is a reinforced cement concrete pipe, available in various
diameters from 80 mm to 1800mm.
• The joints may be socket and spigot type or of collar type.
• It has various applications like routing pipeline or cable under
pavements, draining water, transporting water, etc.

Procedure
1. Excavation as per slope.
2. Pcc (design consideration).
3. Fixing pipes.
4. Encasing with cement concrete / soil filling
Height work
• As the name suggests, working at height above 1.5 m is called height work.
• For doing height in work scaffoldings are preffered.

Safety points
Proper scaffolding
Bracing supports
Scaffolding checklist
Full body harness (safety belt)
Sign boards
Helmet
Shoes
Trained height work labours
Scaffolding
• Scaffolding is prepared to provide platform for working at heights.
• Scaffolding may be done using timber or steel pipes.
• Since timber has limitations, steel scaffolding are preferred in industrial sectors, but in
residential timber is used for its cost effectiveness.
• Steel scaffolding materials (cup lock type)
1. Standard pipe (3 m to 1 m)
2. Ledger Pipe (1.8 m)
3. Transom pipe (1.2 m)
4. Spigot pin
5. Base jack
6. U – Jack
7. Steel Valor
8. Bracing Pipes
9. Swivel clamps
10. Gratings / jaali / platforms
Confined Space Works
• Spaces where air circulation is minimal is called a confined space. Like
water tanks, sewers, silos, tunnels, closed containers, etc
• While working in confined space the air quality must be checked and
proper air circulation methods (inlet and exhaust fans) and lighting
should be provided.
Building Demolition
• Points to Consider
The surrounding area should be barricaded.
People should be informed of the process.
Machinery should be checked.
All electrical lines, water lines, sewer lines, LPG lines should be
disconnected
Spraying water to prevent dust.
Proper removal of reinforcements.
Proper disposal of debris.
THANK YOU