Construction of Workshop, Library and Guest house Building 2019-2020

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANASANGAMA, BELAGAVI-590018

An Internship Report on
Construction of Workshop, Library and Guest house Building

Submitted in partial fulfillment of the requirement for the award of the degree of
BACHELOR OF ENGINEERING
IN
CIVIL ENGINEERING

SUBMITTED BY,
RACHITHA B R
4GH17CV405

Internship Carried Out at

PUBLIC WORK DEPARTMENT

Internal Guide External Guide

Dr. Prashanth S Mr. Prakasha & Mr. Raghu
Head of the Department Public Work Department
Dept. of Civil Engg Hassan-573201
GEC, Hassan-573201
GOVERNMENT ENGINEERING
COLLEGE, HASSAN-573201

2019-2020

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GOVERNMENT ENGINEERING COLLEGE

HASSAN-573201
Department of Civil Engineering

CERTIFICATE
Certified that the Internship work entitled “Construction of Workshop, Library and

Guest house Building” carried out by Ms. RACHITHA B R, bearing USN-4GH17CV405, is a

bonafide student of GOVT. ENGINEERING COLLEGE, in partial fulfillment for the award of
Bachelor Degree in Civil Engineering of the Visvesvaraya Technological University, Belagavi
during the year 2019-20. It is certified that all corrections/suggestions indicated for Internal
Assessment have been incorporated in the report deposited in the departmental library. The Internship
report has been approved as it satisfies the academic requirements in respect of Internship prescribed
for the B.E Degree.

SIGNATURE OF THE GUIDE SIGNATURE OF HOD

& CO-ORDINATOR Dr. PRASHANTH S

Dr. PRASHANTH S

External viva

Name and Signature of Examiners with date

1.

2.

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ACKNOWLEDGEMENT
Completing an Internship right on schedule is no doubt, a demanding and daunting task. I was
fortunate to have the assistance of some teachers in this effort.
I pay my respect to, Dr. M.G. Venkateshmurthy, the Technical Director, who had given me the
moral support in successful completion of my Internship.
I would like to have the pleasure of acknowledging the individuals at my institution for their help.
With immense pleasure, I would like to thank my college in general and beloved Principal,
Dr. K C RAVISHANKAR GEC Hassan, for giving me the moral support in successful completion of
my Internship.
I wish to thank Dr. PRASHANTH S Asst. Professor & Head of the Department of Civil
Engineering, GEC, Hassan for all the support.
I wish to thank my guide Mr. PRASHANTH S, Head of Department of Civil Engineering for
individual help, he has rendered me.
I would like to convey my sincere gratitude to Mr. Prakasha & Mr.Raghu (Assistant Executive
Engineers) who directed me in this Internship work project and gave an insight in it to what the project
is all about.
I extend thanks to all the teaching & non-teaching staff of Department of Civil Engineering, for
their support throughout the Internship work.
I am very thankful to Public Work Department for giving me the opportunity to undertake my
internship training at their Department. It was a very good learning experience for me to work in the
project which is involving many new and unique construction techniques and challenges.
I would like to express my gratitude to the authors of all those books and websites that I have
referred in due course of seeking the latest information to enhance the power of my project work to meet
the latest trends.

RACHITHA B R

4GH17CV405

DEPT. OF CIVIL ENGINEERING

GEC, HASSAN

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ABSTRACT
All the building structures are composed of different type of materials. These materials are
called building materials or engineering materials and sometimes construction materials also.
The material cost in the building ranges from 30 to 50 percentage of the total cost of the project.
The report mainly focused on the classification, technical standards and knowledge of properties of
civil engineering materials. And also discuss the properties, requirements, characteristics and related
behavior of the building materials.

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CONTENT
SL.NO INDEX PAGE NO.

1 ABOUT THE COMPANY 11

2 OBSERVATIONS AT SITE 12-16

2.1 MATERIALS REQUIRED 12-15

2.2 PROTECTIVE EQUIPMENTS 16

3 MARKING AND EXCAVATION 17-19

LOCATION AND LEVEL SETTING
3.1 17
SITE MARKING
3.2 17
EXCAVATION
3.3 18
PLAIN CEMENT CONCRETE
3.4 19

4 FOUNDATION AND MASONRY WORK 20-30

FOUNDATION AND FOOTING
4.1 20
POSITIONING OF COLUMNS
4.2 21-25
MASONRY WORKS
4.3 26
LINTEL AND CHEJJA
4.4 27-28
CHEJJA
4.5 29

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5 SHUTTERING AND CONCRETING 31-36

5.1 SHUTTERING AND DE-SHUTTERING 30

31
5.2 REINFORCED CEMENT CONCRETE

5.3 STAIRCASE 32-34

6 PLASTERING 35-36

POINTS TO REMEMBER 37

CONCLUSION 38

REFERENCE 39

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LIST OF FIGURES:

FIGURE
INDEX PAGE No.
No.
1.1 PLAN OF THE BUILDING 11
2.1 STONES 14
2.2 BRICKS 15
2.3 PROTECTIVE EQUIPMENTS 16
3.1 LEVEL SETTING 17
3.2 SITE MARKING FOR FOUNDATION 17
3.3 EXCAVATION 18
3.4 PCC WORKS 19
4.1 PLACING OF FOOTING &COLUMN 21
REINFORCEMENT

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4.2 POSITIONING OF COLUMNS 21

4.3 PLACING OF COLUMN REINFORCEMENT 22
4.4 STARTERS 23
4.5 SHUTTERING OF COLUMN 24
4.6 BRICK WORK AT SITE 26
4.7 LINTEL 28
4.8 CHEJJA PROJECTION 29
5.1 PLAN 30
5.2 STAIRCASE SHUTTERING AND 30
REINFORCEMENT PLACING
5.3 REGULAR BEAM 31
5.4 SLAB SHUTTERING 32
6.1 PLASTERING 36

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LIST OF TABLES:
Table INDEX PAGE No.
No.
6.1 PLASTERING PROPORTIES 36

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CHAPTER: 01

ABOUT THE COMPANY

1.1 INTRODUCTION ABOUT COMPANY:

Government of Karnataka
Public Work Department
Hassan-573201

1.1.1 BRIEF HISTORY:

The public work department is a government department that is responsible for buildings,
roads, irrigation and railways. Public work department performs major role in planning, designing,
construction and maintenance of government buildings which constitute the capital assets of the state.
The present project covers an overall area of 7212sqm with an investment of 19.7crore, which
includes construction of workshop, library and a guest house. The department owns a wide variety
of construction machineries, transport and various facilities. Apart from this; they have experienced
professional public work department officers who are well versed in completion of projects
sanctioned by government.
1.1.2 COMPANY ADDRESS:
Public work department
Bangalore –Mangalore Road
Hassan-573201
1.1.3 PROJECT DETAILS
NAME OF THE PROJECT: - Construction of Workshop, Library and Guest house Building
NAME OF THE COMPANY: - DJPR CONSTRUCTIONS (P) Ltd. (No.74-6-7, Ayyappanagar, Vijayawada, AP)
NAME OF THE CONTRACTOR: - Sri. Jaya Prakasha Rao Duggirala
DATE OF RECKONING OF THE PROGRESS: - 01/03/2019
STIPULATED DATE OF COMPLETION: - 31/08/2020
ESTIMATED AMOUNT: - 19.7 Crore
FIRST PARTY: - DJPR Constructions private limited
SECOND PARTY: - Executive Engineer PWD and IWTD Hassan division
DATE OF TENDER ANNOUNCEMENT: - 31/10/2014
TENDER NUMBER: -25:2018-2019

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CHAPTER: 02
OBSERVATION AT SITE:
2.1 BUILDING MATERIALS USED:
The basic construction materials include cement, steel, sand, water, ready mix concrete,
binding wires, building stones, coarse aggregates, fine aggregates, bricks, blocks etc. Any material
used in building construction has to be selected carefully to ensure safety and long-lasting life of the
building.
Other materials used in the construction of any building in later stages may include plywood,
doors and windows, floor and roof tiles, white cement, paints and varnishes, adhesives etc. All the
building construction materials come in different grades, Sizes and Brands which are used for
different purposes in construction based on their functionality and strength.

2.1.1 CEMENT:
The cement, often called the magic powder is a fine ground material consisting of compound of lime,
silica, alumina and iron. When mixed with water it forms a paste which hardened and bind the
aggregates (sand, gravel, crushed rock, etc) together to form a durable mass called as Concrete.
Cement is the binder that holds concrete and mortar together. That is why it plays the most critical
role in giving strength and durability to the building. Cement used for residential building is basically
of three types:
➢ PORTLAND SLAG CEMENT:
Conforming to IS: 455, it is a combination of good quality blast furnace slag from the iron steel
industry with clinker.
➢ PORTLAND POZZOLANA CEMENT:
Conforming to IS: 1489, it is a combination of fly ash (from thermal power plant) with clinker and
gypsum. Pozzolana cement is prepared by grinding Portland cement clinker with pozzolana. This
type of cement is largely used in marine structure.
➢ ORDINARY PORTLAND CEMENT:
33 grades conforming to IS: 269, 43 grade conforming to IS: 8112 and 53 grade conforming
to IS: 12269. It is a combination of clinker and gypsum of good quality. OPC is manufactured by
first burning at a very high temperature. The mixture of calcareous (mainly calcium carbonate) and
argillaceous (mainly clay) and then grinding the product (i.e,clinker) with small amount of gypsum
into a fine power known as Ordinary Portland Cement.

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➢ ORDINARY PORTLAND CEMENT OF GRADE 43 HAS BEEN USED IN THE

CONSTRUCTION WORK OF OUR PROJECT.
Good quality cement has the following features:
• Reduced water requirement
• Improve Workability
• Less permissible to moisture
• Improved resistance to acid and chlorides
• Reduced heat of hydration
• Easier to finish
• Reduced shrinkage
• Reduced leaching problems because it has low content of free lime

2.1.2 SAND:
These are cohesion less aggregates of either, rounded sub rounded, angular, sub angular or
flat fragments of more or less unaltered rock of minerals consisting of 90% of particles of size greater
than 0.06mm and less than 2mm. Alternatively, these are coarse grained cohesion less particles of
silica derived from the disintegration of rock. The silt content in sand sample should be less than or
equal to 8%. These are of three types:
➢ COARSE SAND:
It is one which contains 90% of particles of size greater than 0.6mm and less than 2 mm
➢ MEDIUM SAND:
It is one, which contains 90 & of particles of particles size greater than 0.2 mm and less than 0.6
mm
➢ FINE SAND:
It is one, which contains 90% of particles of size greater than 0.06mm and less than 0.2mm.
Proper selection of sand is critical in the durability and performance of concrete mixture. It should
be clear, angular and hard, free from clay, mica and soft, flaky material graded, which means it should
be a mix of fine, medium and coarse sand free from contaminates. Contaminants such as sea salt are
consistent in moisture (water) content which should not exceed 7%. When mixing concrete the
moisture must be taken into consideration.
The price of sand includes three or four components-base cost, transportation, handling and number
of intermediaries. Procuring sand in bulk directly from the source will be cheaper. Your
neighbourhood dealer in this case is likely to be costlier, except when you need smaller quantities.

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2.1.3 BUILDING STONE:

Building stones are obtained from the rocks occurring in nature. The stones are used into
construct the foundation, super structure and many of the building components. The various stones
derived from these types of rocks are as follows:

➢ PROPERTIES OR REQUIREMENT OF GOOD BUILDING STONE:

A good building stone should possess several characteristics such as high strength (crushing
strength > 1000kg/cm), high durability, sufficient hardness (coefficient of hardness > 14), high
resistance to wear, good fire resistance, specific gravity more than 2.7, crystalline structure, high
impact value (toughness index > 13), low water absorption (percentage absorption after 24hour less
than 0.6), weather resistance and better appearance.

FIGURE 2.1: STONES

2.1.4 BRICKS:
Bricks are distinguished by their base (row) material and size. Modular bricks, rarely used
because they are not easily available, come in the size 200mm X 100mm X100mm (including mortar
thickness). Fly ash bricks, sometimes also come in modular form conventional bricks have a frog
(depressed/raised portion) on one of the larger surface bearing the manufacturers brand. These also
provide a good mechanical key for bonding (lock ability) with mortar. The modular bricks do not
have the frog on them. Fly ash bricks exhibit almost similar mechanical properties as burnt clay
bricks. Exposed brick work with precise pointing is possible if the shapes are perfect.

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FIGURE 2.2: BRICKS

2.1.5 MATERIALS USED:

Major construction material specifications for the project are concrete grade M20 for PCC
work, M25 for Shear walls, slabs and Staircases, Steel used is Fe 550 and concrete is used through
mix concrete.
Steel bars used in beam is 16mm dia, for rcc 12mm dia and 10mm dia, for stirrups 10mm dia,
for plinth 12mm dia.
Cement: 43 grade Ordinary Portland Cement.
Fine aggregate: River sand of different sieves were used for slab and mason work.
Coarse aggregate: 20mm aggregate and 40mm aggregate down size are used for concrete work. Size
stones were used in site for construction work.

2.2 PERSONAL PROTECTIVE EQUIPMENTS:

PPE is equipment that will protect the user against health or safety risks at work. It can include
items such as safety helmets, gloves, eye protection, high-visibility clothing, safety footwear
and safety harnesses. It also includes respiratory protective equipment (RPE).

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FIGURE 2.3: PROTECTIVE EQUIPMENTS

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CHAPTER: 03
MARKING AND EXCAVATION
3.1 LOCATION AND LEVEL SETTING:
The art of determining the relative height of different points on or below the surface of the
earth is known as levelling.

FIGURE 3.1: LEVEL SETTING

3.2 SITE MARKING:

Site marking is one of the starting points of the construction. Marking out is the process of
transforming a design or pattern to a work piece, as the first step in the construction process.

FIGURE 3.2: SITE MARKING FOR FOUNDATION

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3.3 EXCAVATION:
Excavation is the process of moving the earth, rock or the other materials with tools or equipment.
It includes earthwork, trenching etc. Excavation is used in the construction to create building
foundations, roads. Some of different process used in excavation include trenching, digging,
dredging and site development. Each of this process requires unique techniques, tools and
machinery to get the job done. The process used will depend upon the structure that will result
from the construction process.

This is the process of digging earth on site where the foundation is to be laid.
➢ Setting out corner benchmarks.
➢ Surveying ground and top levels.
➢ Excavation to approved depth.
➢ Trimming.
➢ Dressing the loose soil.

FIGURE 3.3: EXCAVATION

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3.4 PLAIN CEMENT CONCRETE (PCC):

PCC in foundation uses to provide a plain surface beneath the footing and also to improve bearing
capacity of underlying surface of footing, thickness of pcc select on the basis of soil characteristics.
Any RCC work will be followed after PCC. It helps in enhancing the bearing capacity of soil
PCC is done so as to provide a strong & stable base for foundation and to avoid direct contact of
foundation with soil. The mix proportion of PCC is 1:4:8.

The thickness of PCC provided is 100mm; wooden rammer is used for compaction and finishing.
It is also help in following ways:
• Required cover to bottom reinforcement is ensured, as cover blocks rest on a firm PCC.
• The effective depth of RCC members is achieved as the formworks can be easily, uniformly
and studily fixed, resulting in better dimension accuracy of foundation RCC member.
• Reinforcement steel placed on a PCC, are never in touch with ground soil, which may be
chemically active may lead steel corrosion in immediate future (when in contact with ground
soil).
• Ease placement of steel cage and increase productivity.

The plain concrete bed provided at the bottom of the foundation is made of one part of cement four
part of sand and eight parts of coarse aggregate. The maximum size of the aggregate is 40mm.

FIGURE 3.4: PCC WORK

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CHAPTER: 04
FOUNDATION AND MASONRY WORK
4.1 FOUNDATION AND FOOTING:
Foundation is the lowest-bearing part of a building, typically below the ground level.
Foundation is an important part of the structure which transfers the load of the structure to the
foundation soil. The foundation distributes the load over a large area. So, that pressure on the soil
does not exceed its allowable bearing capacity and restricts the settlement of the structure within the
permissible limits. Foundation increases the stability of the structure.

4.1.1 MAIN FUNCTIONS OF FOUNDATIONS:

1. Distribution of loads
2. Stability against sliding & overturning
3. Minimize differential settlement
4. Safe against undermining
5. Provide level surface
6. Minimize distress against soil movement.

4.1.2 CHECKING:
• Before placing of concrete, dimension of footing like length, width, diagonal of footing,
lateral support provided for footing shuttering, slurry tightness of shuttering and spacing of
reinforcement bars are checked.

• If everything is ok according to plan then heading towards placing of M20 concrete.

• At the time of placing of concrete we check the slump value, w/c ratio and rate of compaction
etc

• After placing of concrete the top portion is made rough for better bonding of second step.

• On the next day the second step concrete is placed with all precautions taken for first step.

• On next day of casing is written on the footing with paint, the foundation is cured for 28 days

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FIGURE 4.1: PLACING OF FOOTING AND COLUMN REINFORCEMENT

4.2 POSITIONING OF COLUMNS:

Columns should preferably be located at or near the corners of a building, and the intersection of
beams/walls. Select the position of columns so as to reduce bending moments in beams. Avoid larger
centre- to- centre distance between columns.

FIGURE 4.2: POSITIONING OF COLUMNS

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4.2.1 PLACING OF COLUMN REINFORCEMENT:

In positioning of column, placingthe column reinforcement in the right place and keeping it there
during concrete placement is critical to the structure's performance. Reinforcement should be
placed as shown on the placing drawings. There, the detailer will indicate the number of bars, bar
lengths, bends, and positions.

4.2.2 STEP FOLLOWED FOR COLUMN REINFORCEMENT:

➢ The centre line and column size is marked on bed concrete.
➢ Mat is placed in position with 40mm aggregates as cover blocks.
➢ The column reinforcement is placed on the mat and the verticality is checked using the
plumb bob.
➢ Then the reinforcement is supported with the formwork and tied firmly.

FIGURE 4.3: PLACING OF COLUMN REINFORCEMENT

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4.2.3 FIXING OF WOODEN FRAME FOR STARTER:

• The wooden exact to the dimension of the column i.e., inner to inner was made.
• Then the frame was fixed in the extended reinforcement of the column.
• The height of the frame was about two inch.
• Then the concrete was filled in that frame and removed after 24hours. Now that two inch of
column concrete was the standard dimension of the column and that is called as starter.
• Now with the help of that starter the shuttering of the column erected along with the side
support.

COLUMN STARTER RETAINING WALL STARTER

FIGURE 4.4: STARTERS

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4.2.4 SHUTTERING OF COLUMN:

The form consists of panels fabricated out of thin steel plates stiffened along the edges by small steel
angles.
The panel units can be held together through the use of suitable clamps or bolts and nuts.
The panels can be fabricated in large number in any desired modular shape or size.
Steel shattering is more suitable for circular or curved structures.

FIGURE 4.5: SHUTTERING OF COLUMN

4.2.5 COLUMN SHUTTERING MATERIALS (STEEL SHUTTER):

• Tan bolts
• Nuts
• Screw
• Steel props
• C- clamps

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• Column form made of steel sheet

• Nails

4.2.6 FIXATION OF COLUMN:

• To clean the sheet form with steel scraper in order to make it free of rust or other foreign
materials.
• Do apply either mobile or thin tar to the form for avoiding sticking of concrete.
• Tighten column shutter and nut.
• Tightness of nut and bolt should be checked.
• Vertical placement is checked by plum bob.
• Maintain clear cover 40 mm by using cover blocks.

4.2.7 CHECKING OF COLUMN SHUTTERING:

• Vertical alignment of column shutter was checked by using plum bob.
• The joints in the form work should be tight against leakage of cement grout.
• Checking the forms is cleaned and oiled.
• Check the vertical alignment of longitudinal bar and a tie bar.

4.2.8 CARE SHOULD BE TAKEN DURING COLUMN SHUTTERING:

• The side steel board should be straight and it was checked with the help of plumb bob.
• The inner dimension of the shuttering should be uniformly maintained.
• The steel boards should be tight so that it should not open during concreting and compacting.
• The shuttering should not be done to the whole column at once.
• Once the shuttering is done the height should not be more that 1.5 meter, so that the
compaction cannot be done properly and it may lead to honey comb structure.
• Then again next level of shuttering should be done.
• The final shuttering should be 1ft. below the beam bottom level because if it is up to the beam
bottom level the bond between the column and beam will not happen and also the
reinforcement at the beam column intersection cannot be inserted properly.

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4.3 MASONRY WORKS:

Masonry consists of building structures by laying individual masonry units
(BRICKS, CONCRETE BLOCKS).Normally the masonry units are laid with cement mortar, which
binds them together to create a structure. Masonry construction can provide walls at economical
prices. Masonry is generally a highly durable form of construction. However, Materials used, the
quality of the mortar and workmanship, and the pattern in which the units are assembled can
substantially affect the durability of the overall masonry construction.

BRICK WORK: Ensure you are using good quality bricks. The bricks shouldbe soaked in water
prior to use. However, a light moistening with water may be done to avoid absorption of water from
the cement mortar. Before commencing masonry work, the line out shall be carried out for the entire
area using a steel tape.The mortar proportions shall be either 1:4 or 1:6. The thickness of mortar joints
shall be 10 mm both horizontally and vertically. The mortar shall be spread over the entire top surface
of the brick. The mortar shall be raked out from the joints with a trowel of each course and is laid to
a depth of 10mm to 12 mm, so as to ensure the good bond for the plaster. The height of the wall to
be done in a day’s work shall be restricted to 1 meter. The first course of masonry shall be laid with
great care, making sure that it is properly aligned, levelled and plumbed. 7 days of curing should be
done.

❖ SIZE OF THE BRICK USED : 9 inch x 4.5 inch x 3 inch.

❖ THICKNESS OF MORTER JOINT : 1cm.
❖ THICKNESS OF THE BRICK WALL : 9 inch. OR 230mm.

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FIGURE 4.6: BRICK WORK AT SITE

4.4 LINTEL AND CHEJJA:

LINTEL: Openings for doors, windows or cupboards etc. Must be bridged over by some
means to support the masonry above. The support to the load above the opening is usually given by
providing either an arch or a lintel. Lintel acts as a beam and transfers the load vertically to the
supporting walls. The ends of lintels are built into the masonry so as to convey the weight carried by
them to the masonry in jambs. The amount of bearing which the supports provide for the ends of
lintel is an important factor. Lintels are made of various materials such as wood, stone, brick,
reinforced brick, steel and reinforced cement concrete.

At the time of our entry to the site, lintel process was under construction. Lintel is a horizontal
structural member that takes the vertical loads and transfers the upcoming load to the columns and
wall. Lintel is generally provided above the openings.

There are many types of lintel namely,

1) STONE LINTEL
2) RCC LINTEL
3) BRICK LINTEL
4) REINFORCED BRICK LINTEL
5) STEEL LINTEL

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1) STONE LINTEL: This type of lintel is mainly used in this area where the stone is
abundantly available. Its use is mainly confined to stone masonry structures. There are
some disadvantages of using stone lintel. Firstly, its high cost and secondly its inability to
withstand excessive transverse stress.
2) RCC LINTEL: At present, reinforced concrete lintels are very common in use because
of their durability, rigidity, strength, and fire resisting properties. They are suitable for
heavy loads and larger span also they are economical and easy in construction. The main
advantage of the RC lintel is being the adaptability to suit any size and shape.
3) BRICK LINTEL: Brick lintel is constructed with hard, well burnt first class bricks. It
can be formed as bricks on end, bricks on edge and coursed bricks laid horizontally over
openings. This type of lintel is used when the opening is small (less than 1 m) with light
loadings condition.
4) REINFORCED BRICK LINTEL: Heavy loadings and larger span length are the
problems for brick lintels. These can be overcome by using the reinforcement bars.
Reinforced brick lintels thus provide more support than the brick lintels.

5) STEEL LINTEL: Steel lintels can be suitable when the superimposed loads are heavy
and the opening gaps are large. Steel lintels are more preferable when the depth of lintel plays
an important role because the designer cannot ignore the depth of reinforced concrete lintels
due to heavy loads. These lintels consist of channel sections or rolled steel joists

❖ TYPE OF LINTEL USED: REINFORCED CEMENT CONCRETE LINTEL.

❖ WIDTH OF LINTEL: 230mm.
❖ DEPTH OF LINTEL: 150mm.
❖ STEEL USED : Fe-500MPa (10mm diameter as main bars and for stirrups )

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FIGURE 4.7: LINTEL

4.5 CHEJJA:
It is the projecting or overhanging eaves or cover of a roof usually supported on a large carved
brackets or projected as a cantilever from walls and also projected with the support of lintels.
➢ Usually protects from external sunlight.
➢ Also protects from rain water entering into the building.
➢ It also serves as the aesthetic decoration with little design on it from architectural point of
view.

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FIGURE 4.8: CHEJJA PROJECTION

Projection from wall: - 0.37 metre

Thickness of the Chejja: - At support -0.075 metre

At free end -0.05 metre

CHAPTER: 05
SHUTTERING AND CONCRETING

5.1 SHUTTERING AND DE-SHUTTERING:

SHUTTERING: The process of utilizing different materials like Wood, Metal and Plastic etc. to
form a temporary structure to contain and facilitate the setting of concrete .The process should be
done in such a way that the temporary structure can be easily retrieved.

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FIGURE 5.2: SLAB SHUTTERING

DE-SHUTTERING: The process of removing the temporary structure built to facilitate setting of
concrete with minimal damage of the materials used so it can be reused.

5.1.1 TYPES OF SHUTTERING:

The types of shuttering can be classified on the basis of materials used

a. CONVENTIONAL SHUTTERING:

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This is the most widely used kind of shuttering. This type of shuttering uses the timber,
plywood, metal sheets and metal or timber props to form a temporary structure.

b. ALUMINUM OR MAYWAN SHUTTERING:

In this type of shuttering the moulds are prefabricated in aluminum as per design with all the
necessary things in place. The mould is placed the reinforcements are placed in position the
concrete is poured .The finish obtained does not need any plastering. The beams, slabs,
columns, walls all of them can be cast at a time.
The drawbacks are the moulds are costly; it should at least be used 25 times just to retrieve
the money invested. The moulds can cast only a single type of floor, making any changes
needs expert welders. To top this off a contractor should be told to use a single brand of
cement to ensure uniform color.

c. PVC SHUTTERING OR DSCAFF SHUTTERING:

This kind of shuttering employs PVC panels instead of wood or metal sheets. This shuttering
did not see any success due to excessive breakages and UV stabilization issues.

d. LOST SHUTTERING:
Shuttering materials cannot be retrieved due to some kind of obstruction or the shuttering
itself is embedded inside the concrete, this is known as lost shuttering
Some places where lost shuttering may be seen:
• Corrugated sheets while construction of mezzanine floors
• In Dog legged staircase where the stairs meet the slab
• Holes made to house anchor fasteners
• When the labourers employed is not skilled to know how to remove the shuttering at
the critical places

5.1.2 THINGS TO BE KEPT IN MIND WHILE DOING CONVENTIONAL

SHUTTERING:
• The formwork should be easily removed to minimize the damage.
• The materials should reuse at least 7 times to retrieve the money invested and reap profits.
• The runners should be nailed to the ply longitudinally rather than laterally
• The length of nails used should be justified.

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• Different batches of materials should be painted in different colors to keep them in check.
• Pre camber should be provided to impart a sense of strength to structure. Rolling margins
must be provided.
• If the slab to be cast is more than 40m, 1m width of expansive strip should be provided.
• The metal truss spans should not be propped.
• Oil based shuttering oil should be used only in rainy season and the rest of the time water
based shuttering should be used.
• Duct tape should be used in joints while casting slabs to avoid bleeding of concrete.

5.1.3 THINGS TO BE KEPT IN MIND WHILE DOING DE-SHUTTERING:

1. Stripping time
• Formwork Columns -16-24hours.
• Formwork Beams - 7 days (props should be re fixed immediately after removal of formwork).
• Props Slabs - <4.5m 7days and >4.5m 14 days.
• Props for Beams -<6m 14 days and >6m 21 days.

2. Props that have been re fixed should be policed so that the props are not removed before the
specified time period.
3. The labour should be skilled so as to minimize the damage to the shuttering material.
4. If Oil based shuttering is used the concrete surface should be thoroughly washed with water.
5. To avoid the surface smoothness mats made of they are being used.

5.2 REINFORCED CEMENT CONCRETE:

RCC Stands reinforced concrete for cement.RCC is concrete in which steel bars are embedded, that
strengthen Plates, the material. The advantage of RCC as a good compressive stresses (because of
concrete) and also as a good tensile stress (because of steel).

5.2.1 REGULAR BEAM:

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Regular beam is structural member which is normally placed horizontally it provides resistance to
bending when loads are applied on it. The thickness of the slab is greater the slab thickness

FIGURE 5.3: REGULAR BEAM

5.3 STAIRCASE:

A Stair is one in a flight of stairs. In buildings, stairs are a term applied to a complete flight of steps
between two floors. A staircase is one or more flights of stairs leading from one floor to another,
and includes landings, newel posts, handrails, balustrades and additional parts.

5.3.1 PROCEDURE FOR CONSTRUCTION OF STAIRS:

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1. Measure the height of the area where you will install the stairs.
2. Divide the total rise by the typical rise per step.
3. Divide the total rise by the number of steps to get the actual rise per step.
4. Establish the run of each step.
5. Find the total run of the staircase.
6. Decide if your steps need landing.
7. Woods are arranging and shuttering is done according to the shape of steps.
8. Formwork cleaned and watered.
9. Concrete mix is laid, properly compacted, and proper curing is done.
10. After few days shuttering is removed.

FIGURE 5.4: STAIRCASE SHUTTERING AND REINFORCEMENT PLACING

Type of staircase : Dog legged staircase

Riser : 7 inch
Thread : 10inch
Material used for staircase : Reinforced cement concrete staircase

CHAPTER: 06
PLASTERING WORK
Prior to plastering ensure that wall is clean and free from dust and many loose part of mortar from
brick laying process. Sprinkle the water on the surface to ensure better sticking of plaster. Using
trowel scoop an amount of plaster which could hold by hack. Then collect half that amount from the

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hack, onto the trowel, using slice and then flick of wrist to scoop it up with a mortar mixture facing
upwards. While starting at the bottom of the wall, use nice and smooth strokes with the trowel and
press the mortar onto the wall and try to distribute the plaster evenly on required area. Allow the
plaster to dry. Scratching should be done after some hardness is achieved if in case another layer of
plaster is needed or if wall tiles are to be laid. There may be also defects in plastering such as

• CRACKS: This may be due to old surface is not properly dressed, bad workmanship, and
due to expansion and shrinkage in plastering coat during drying.
• EFFLORESCENCE: This is due to soluble salts present sometimes in plaster making
material and bricks. They appear on the plastered surface in white patches and produce ugly
appearance. It may be removed by brushing and washing several times.
• BLISTERING OF PLASTERED SURFACE: It is small patches which swell out beyond
the plastered surface like boils.
• FALLING OUT OF PLASTER: Due to excessive thermal variation in plaster, inadequate
bonding between coats of plaster and due to imperfection adhesion of the plaster to the
background.

All these defects can be minimized by continuous damping of the plastering, even mixing of the
plaster and good workmanship

TABLE NO-6.1: PLASTERING PROPORTIONS

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FIG.6.1: PLASTERING WORK

POINTS TO REMEMBER:-
a) TOLERANCE LEVEL:

1. For wall
➢ Vertical deviation +2 mm, -2 mm
➢ Horizontal deviation 0 mm

2. For beam and slab

➢ Departure from intended horizontal position +2 mm or -2 mm
➢ Departure from intended vertical position +2 mm or -2 mm

b) PRECAUTION:

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1. Specific items that cannot be compromised are:

➢ Zero tolerance on partition walls.
➢ Dividing boundary line between units.
➢ External building lines.
➢ Staircase dimension.
➢ HS internal dimensions.

2. Alignment priority
➢ Alignment of grooves.
➢ Uniformity of grooves.
➢ Horizontality of architectural treatment, brick tile.

CONCLUSION
➢ This internship training is to provide an opportunity to the undergraduates to identify, observe
and practice how engineering is applicable in the Construction field. It is not only to get
experience on technical practices but also to observe management practices and to interact with
field workers.
➢ It was an opportunity to learn the way of work in an organization, the importance of being
punctual, the importance of maximum commitment and the importance of team spirit.
➢ Overall this internship was to investigate how a structure is constructed within its desired
properties and to get knowledge about the basic & advanced techniques of building construction
as well as saw the challenges which a Civil Engineer has to face during construction labour
problems, cost management, environmental challenges etc.

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REFERENCES
IS CODE:
➢ IS:383, Indian standards specification for coarse and fine aggregates from natural sources for
concrete, Bureau of Indian Standards, New Delhi, 1970.

➢ IS:10262, recommended guidelines for concrete mix design, Bureau of Indian Standards,
New Delhi, 1999.

➢ IS:456, Plain and reinforced concrete-code of practice, Bureau of Indian Standards, New
Delhi, 2000.

TEXT BOOKS:
1. Building material and construction: 10th edition: 1984 - B.C.Punmia.

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2. Building material and construction technology: 33rd edition: 2007 - Rangwala.

3. The studying footing details by the reference book - Dr. Rajendraprasad.
4. Construction Technology Theory and Practice: 6th edition: 2012 - M S Shetty.
5. Building materials & Construction Technology: 2013-2014 - H S Vishwanath.

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