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Acknowledgement
I would like to take this opportunity to express my sincere gratitude to all those
who gave their co-operation to succeed my industrial training.
I would like to express my heartfelt thanks to the Mr.Primal Weersooriya for his
invaluable dedication to succeed this program, & also to the staff of the department of Civil
Engineering, Sri Lanka Institute of Information Technology.
I wish to acknowledge to the Directors of SP-Sieera Joint Venture Pvt (Ltd). I
had their support in various ways .Specially I would like to thank Project Manager
Mr.D.V.S.Raju and my sincere gratitude to the manager contract Mr.D.W.A.P. Liyanage and
construction manager Mr.B.Shyamalan,Planing engineer Mr.G.Prasanthan and Site engineer
Mr. ATHAUDA A.R.S.P.B. , Engineers , Assistant Site Engineers ,Technical Officers
,Quantity Surveyors, draftsman , accounts clerks, admin officers, store keepers &
supervisors. They help me a lot in several ways to get real practical experiences which were
adopted in the organization, regarding construction, management, administration and so on.
Finally I would like to thank my dear parents who have brought me up in higher
education. And my thanks go to each every person who in whatever way assisted me in my
industrial training.
Contents
Abstract
Acknowledgment
List of Figures
List of Tables
1.0)
Introduction
1.1) Vision and mission
1.2) Company Background/history
1.3) Management
2.0)
Training Experience
2.1) Formwork
2.2) Yyy
2.3)
3.0)
Conclusion
References
Appendices
1.0)
Introduction
1.1)
VISSION STATEMENT
MISSION STATEMENT
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
1.1)
Company Background/History
The Shapoorji Pallonji Group (SP Group) is a Mumbai based business
Project Overview
Project
: Proposed Multi-Storeyed
Description
1.2)
Management
Constructon
ManagerStructure
Senior Site
Engineer
(Formwrok)
Asst.Engineers
Forman
Senior Site
Engineer(reba
r)
Asst.Engineer
s
TO
Surveyor
Asst.Surveyo
r
Engineer
Manager QA/QC
QA/QC Engineer
Forman
GENERAL MANAGER
Planniing
Engineer
Document
Controller
Technical
Coordinator
Draftsmans
PROJECT
MANAGER
QS Billing
Manager
Commercial
QS Contract
Construction
ManagerFinshing
Site engineer
Engineer
MEP
Store Keeper
Manager Admin
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Safety
Manager
Accountant
Safety Officer
Forman
2.0)
Training Experience
2.1) Formwork
A rigid structure or mould fixed temporarily which is retained size, shape and the
position of Structural elements (Column, Walls, Beam, and Slab) until set up fresh concrete.
Formwork is the single largest cost component in the concrete building. In some situation
cost of formwork is higher than steel and concrete. Selection of suitable formwork mainly
depends on project quality, time and cost of erecting and removing, safety of formwork and
direct and indirect costs. Formwork should be easily fabricate, easily erect and remove and
more times reuse. There are two types of formwork solution, which are
2.1.1)
fast material planning as well as easy storage in the stockyard and on the construction site.
Permissible fresh concrete pressure The LIWA has been designed for a fresh concrete
pressure of 50 kN/m.
Components and Uses
Figure 2
Figure 3
kicker
braces to LIWA elements.
Figure 4
Figure 5
Wing Nut
Tie Rod
Figure 6
Figure 7
reinforcement. Lightweight
characteristic of LIWA panels which help to shutter two carpenters only to cover the column.
When shuttering LIWA panel good practice to remember panel should have at least 200mm
outer from the edge of the element to connect Corner Connector orthogonal to other side of
panel. Its important to supervise wedge clamps are fixed in three positions of the two panels
align them. When casting element is large Tie rods have to install where two LIWA panel
touching with Wing Nut. These Tie rods are cut more than (column size + 250mm). Two side
of form are propped from one long adjustable prop and short prop. Top long prop used to
adjust the formwork verticality. And short kicker prop used to positioning formwork in
correct location. Check top formwork dimension accuracy, plumb of formwork, close
leakages are some of good trait to practice before inspection start.
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maximum Girders spacing is 0.3m. Two Steel Waler are supported to Girders about 1.435m
apart in 3m high panel. Two L-shaped VARIO panels are joining and tightening by Tie rods.
Common problems arising during the job are;
Wedge
Figure 9
Figure 10
11
Base Plate
Anchor Bolt
11
VT Figure
20 Formwork
Girder
Figure 12
Used in slab soffit forming (MULTFLEX) as primary and secondary support and
VARIO Panel design.
Available sizes are 3.9m, 3.6m, 2.9m, 2.65m, 2.45, 2.15m, 1.45m.
Weight about 5.9 kg/m.
Permissible bearing force 11KN.
Figure 12
Vario Coupling
Steel Walers
Figure 13
2.9
m
12
Steel Walers
18mm Plywood
1.2
m
Base Plate
One end connect to waler and other end base plate. Used for aligning PERI
formwork systems.
Extension length L = 1.28 - 2.10 m
2.1.3)
from fresh concrete. Typically design of shear walls formwork Engineer should understand to
design shear wall without fail until gain sufficient strength. Shear walls have large amount
concrete volume, therefore exert pressure is high.
Due to time wasting in conventional wall formwork VARIO Panels are
designed required shapes and used at site. MOL Project has 10 shear walls and from them 8
walls are anchored with column. Following figure shows corner shear wall in MOL Project
J/H-2. Shear wall consist of one long panel (outer panel), 04 L-shaped panels and one straight
panel. Initially outer long panel lift from crane and slowly cover the Reinforcement to correct
position and lock temporary. Before shuttering the panel marking is done the position of
outer panel edges on the kicker for convenience. Because outer panel heavier difficult adjust
after shuttering and panel (cross section about 400mm at the corners) inserting space
insufficient due to 400m from external scaffolding to concrete finish. Thoroughly have to
ensure that below external scaffolding are anchored from wall supports. Other interior panels
are shuttered according to PERI drawings to correct position. Filler (a gap between panel)
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should be uniform gap because outer L-shaped panel hasnt any support and that panel plumb
depends on filler adjustment. After closing all panels angle distance of 4300mm should have
to check at the top and all other dimensions
also checked. Plumbing are done same as
others and ensure that tie rods are tightened
and gaps are closed.
2.1.3)
Beam formwork
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Next step is setup the side board of beam formwork. These side board are sawed
height of sides of beam plus 60mm to nailed soffit formwork runner. Side board height also
can be determined as follow,
Sideboard Height = Beam depth Slab Tk. Plywood Tk.
If there is Drop where; slab to beam Drop amount should be added and beam to slab
Drop amount should be subtracted.
Carpenters measure that height from steel tape and nailed 2nails half on the board.
And to of the side board 2X2 runners are fixed to support top slab form. When carpenter
work that supervisor instruct to wear safety harness. After fixed one side of form, hammer
drill used to make holes at the bottom of side form in 500 or 600mm spacing. For insert
separates (thread bar with p-cones) make sure resist lateral pressure of wet concrete. For
higher depth beams two separates are inserted where top and bottom of side form. These
thread bar cut 15mm less than beam width. Beam side forms are locked after lowered beam
reinforcement. Two workers need for lock used 6000mm GI pipes along Side form and two
2X2 runners are placed and locked with form ties vertically across the GI pipes.
Components and Uses
Form tie
15
thread bar
2x2
PVC pipe
form tie
GI pipe
plywood
bottom board
acro-jack
Figure 3
Time
24 hours
5 days
Props to Slab
11 days
Props to Beam
16 days
8 days
28 days
The blocks should be laid to a regular bond, usually half bond where possible.
Under no circumstances should the blocks be laid to a bond of less than a quarter bonds.
Corners may be bonded by cutting standard blocks. Wall junctions are normally bonded, or
ties can be used with a straight joint. If it is not convenient to build a junction wall at the
same time as the main wall, some provision must be made to allow the junction wall to be
bonded to the main wall. Indents may be left to allow bonding to occur at a later stage
For the supporting of block wall stiffener columns shall be introduced besides
timber door openings, edge of cantilever filler walls and at some corners of walls. If the
length of filler walls exceeds 5m one intermediate stiffener column shall be introduced. Tie
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beams at lintel level shall also be introduced along filler walls. The mortar using in block
work construction shall be 1:5 cement sand mortar. Blocks should be kept dry before use.
Estimated quantity for the block work construction would be 13 blocks in every square meter
of wall surface area.
Cross joint
Wall joint
Bed joint
Header course
Stretcher bond
Stretcher coursePerpend
English bond
Types of Blocks
17kg
37kg
200mm
mmm
400mm
mmm
200mm
mmm
200mm
mmm
400m
m
Cement
17
100mm
mmm
Sand
Concrete
12 mm thick Regiform
To initiate masonry work, floor shall be handed over to finishing team by structural
team. All minor structural work, defects should be completed as given in the
specifications/proposals and slab shall be clean and free of concrete, form work debris
prior to hand over.
Before commencing setting out work, the slab surface should be clean thoroughly to
achieve lump free surface. The surface should be free from dust, mud, grout or oil etc.
To achieve this, an air compressor can be used together with water jet if required or
any other suitable method.
As indicated in the Shop drawings, the block wall lines associated with 300mm or
suitable offset lines shall be marked on the floor. The openings and stiffener column
locations should also be marked at the same time. Attention should be drawn to
thickness of wall sections since the thickness can be varying from place to place.
Responsible officer for block work should raise a check list/ RFI to check setting out.
It shall be checked by the quality officer. He should consider the wall and stiffener
column locations, wall thicknesses, duct openings and MEP sleeves. Upon the
satisfaction of QA/QC team, Consultant Engineers shall be called for inspection of
setting out.
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Once the approval is given, formwork for concrete ledges at bathrooms shall be
started. Meanwhile required wall areas on the slab and faces of shear wall shall be
chipped to have proper bonding.
The reinforcement of the stiffener columns should as per the approved drawings.
Starter bars of stiffener columns shall be dowelled to slab by drilling sufficient length.
The drilled holes shall be clean by using a manual air pump. Initially Concressive
1441S epoxy bonding agent shall be used to dowel reinforcement bars. When the
stocks available Meyco Flowcable high strength admixture is expected to use for
dowelling. RFI shall be raised and consultants are called for inspection prior to start
dowelling reinforcement bars.
Electrical conduits and plumbing pipes in vertical direction should be firmly fixed to
floor inserts before concreting ledge or before laying 1 st block layer. They should be
arranged in middle of cement blocks unless there is a special reason. It is important to
ensure the stability of cement blocks.
Then bath room ledges shall be concreted and first course of block wall shall be laid.
QA/QC team shall be called for inspection of first course. If there any rectification
regarding alignment, bonding pattern, thickness of the base course, etc shall be
corrected immediately.
After the inspection is passed, the remaining block work shall be continued. Special
care shall be taken to ensure the verticality of the wall when the block wall is
continuing upwards. The maximum wall height to be cast in particular day would be
1200 mm. The wall termination should be done ensuring the bond to be kept by
I.
II.
As per the requirement arises to keep the bond pattern, forming joints, openings the
cut blocks will be used. In any time should not use a cut block smaller than half of the
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standard block. The thickness of thin-bed mortar joints shall be kept around 10mm ~
15mm.
While the wall is being continuously constructed, special attention should be paid for
the size of the door/window openings, locations of the MEP provisions etc.
Care should be taken not to break cement blocks while making holes for
conduit/pipes and laying the blocks through them. Special attention is required to
protect conduits and pipes while block work in progression.
With the proper continuation of work, wall should be leveled at the lintel bottom or
tie beam bottom level.
At this stage QA/QC team should be called for inspection of level of the lintels and
verticality of walls. Approval for casted wall section should be obtained before
concreting stiffener columns and concreting the lintel/tie beams.
If the height of the stiffener column is more than 2.0 m, column should be casted in
two lifts.
The rebar of the tie beam/lintel should be as per the drawings. Those should be drilled
in to the shear walls using drilling machine where necessary. The epoxy bonding
agent shall be used as the bonding material.
After the concreting is finished, the remaining block walls can be continued upwards.
When the wall shall be finished at the required level (mostly at the bottom of the
beam), re-check should be done about the alignment and verticality of the wall.
6mm thick rigiform strip shall be provided between beam soffit and top most block
layer to avoid cracks due to settlements or axial shortening.
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constructed at different rates or times, the intersections between those sections shall be either
raked back or tied with metal ties so that monolithic structural action is obtained in the
completed work.
2.2.1) Plastering
The purpose of plastering the walls inside buildings is to provide a surface
that is sound and of good appearance. The plastering is generally done to get smooth surface
before painting. It should commence after the completion of ceiling and should be started
from the top and worked towards the floor. Normally the mix ratio for plastering of block
work and brick work is 1:1:5 cement: sand: water. Internal walls are in smooth finish and
external plastering is in rough finish. In the internal plastering to get the smooth finish on the
coat lime putty is applied
.
Plaster is a fine paste of cement, lime and sand with water. A good plaster has
to be smooth non-absorb, washable, fire resisting and not affected by temperature or climatic
changes.
Procedure
The surface of the plastering wall washed with water and it was kept wet till applying
plaster.
Mortar should be applied between the gauges to slightly more than the required
thickness.
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The plaster should be well pressed into the joints, leveled and brought to a smooth
surface by working a wooden straight reaching across the gauges with small upward
and sideways movement.
Finally surface should be finished rightly with a wood float or trowel according to the
type of finish required.
In my site an inch thickness reform piece was used to get smooth surface as an alternative
for wood float. But quality depends on the skill of labor.
2.3)
Reinforcement
A concrete member is reinforced with the prime intension of increasing its tensile
capacity though in certain instances the reinforcing is done to increase the compression
capacity. The main concrete reinforcing material being used in the industry at present is steel.
As civil engineers we are expected to carry out our work at the minimum cost yet ensuring
the safety aspects of building. Therefore, in the process of reinforcing a structural element we
should use the optimum quantity at the correct places while ensuring the safety aspects
expected. Hence the practical exposure gained in this area would definitely be useful in the
future.
The standard that governs the reinforcement work are BS 4466 and BS 8110. Bars
should be cut and bent correctly and accurately on an approved type of cutting and bending
apparatus, to the size and shape shown on the details Drawings or the consultant approval.
RC Fabric
22
Bar Type
Characteristic
Length of a
Strength (N/mm2)
bar (m)
Twisted Tor
steel bars
Ribbed Tor
steel bars
Plain Mild
steel bars
BRC Fabric
Available sizes
10mm, 12mm, 16mm, 20mm,
460
380
250
6m
9m
Bundles of
1900kg
25mm, 32mm,
40mm(diameter)
10mm, 12mm, 16mm, 20mm
(diameter)
6mm, 10mm (diameter)
Panels of size12/ 8/
250
Mild Steel
The strength of this steel is 250 N/mm 2. This is a soft carbon steel and easy to work
with it. These bars are used in reinforced concrete slabs, beams, columns, foundations etc.
these are plain round bars and diameter varies from 6mm-32mm.
Tor Steel
The strength of this steel is 450 N/mm2. Diameter varies from 10mm-35mm. These
bars have helical ribs running along the surface of the bar.
The designs have been done taking the characteristic strength of the Tor steels bars as
460N/mm2 and the value for Chinese bar is less than that. Therefore a safety factor of 1.5 is
applied and hence more bars are used accordingly.
Bar Identification
23
16
17
Bar mark
200
Inner or outer
SpacingTop or bottom
12
16
diameter in mm
17
bar mark
200
T1
B2
B1
T1
T2
B1
B2
Bars
Bars
Bars
Bars
placed
placed
placed
placed
as
as
as
as
Storage of Reinforcement
24
Lapping of bars
Once the reinforcement bars are placed in position as required by the drawing the
bars crossing one another shall be tied together at every intersection. The binding is done
with two stands of GI wire 0.90mm to 1.60mm thickness twisted tight to make the skeleton
of the steel work rigid so that the reinforcement does not get displaced during the pouring of
concrete. The end of the binding wire has to be bent back, away from the forms and in to the
body of the concrete. If spacing of bars is less than 300 mm in each direction, alternate
intersection may be tied.
Laps
Bars of full length shall be used as much as possible yet this is not always
practical and thus lapping of bars is done
Lap lengths used in our site are
52* diameters of bar - for vertical structural elements
45 * diameters of bar for horizontal structural elements
All the laps of a particular column or a wall should not be at the same level and it
should be staggered at least in alternative bars. This would avoid any structural weakness due
to lap and to avoid unnecessary steel congestion at the position. Also in beam reinforcement
lap of the bottom layer of bars should not be in the middle and lap of the top layer should not
be in the corners or any junction.
25
In our site we used a new method to lap the vertical column bars (each are 40
mm diameter) that method called MOMENT BARBREAK COUPLER.
S (1.0mm) 50mm
T (2.5mm) 50mm
L (1.0mm) 115mm
Stirrup
Concrete has a limited amount of resistance, to shear failure. When
exceeded this failure it should be provide extra resistance by reinforcement. For that task we
can use stirrups or inclined bars or both. Stirrups are not required only for shear resistance.
Also these are used for minimize shrinkage, cracking and to form a cage for easy handling.
Stirrups were made by using mild steel. In our site 6mm and 10mm mild steel used for
stirrups.
2.4)
Safety
Safety is not a simple word just ignore in the construction site which cause
serious injuries or permanent disable during the construction activities. In the records shows
that many of injuries or permanent disable or fatal have been happened around construction
sites in past decades. Therefore Site Safety management is essential in any large scale to
small scale projects. Builder or Contractor first priority is fulfil safety measurements in the
Site and ensure safe place or environment to workers. Workers have right to work in safe area
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