Cement Mill Report

TRAINING
PROGRAM
REPORT
On
CONSTRUCTION OF
ROLLER PRESS BUILDING
Submitted by
ANKUSH KESHRIMAL KHANDELWAL
Training Institution:
J.K. CEMENT WORKS, NIMBAHERA

RAJASTHAN
Department: Civil Engineering
Under the supervision of
Mr. SHAHID KHAN

(Head of Civil Department)
JK CEMENT LTD. 2018-2019
DECLARATION
I hereby declare that the project entitled “Construction Of Roller Press Building” submitted for
the "TRAINING PROJECT ” is my original work and the project has not formed the basis for the award
of any degree, associate ship, fellowship or any other similar titles.
Yours sincerely
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. i

CERTIFICATE
This is to certify that ANKUSH KESHRIMAL KHANDELWAL of Civil Engineering has

successfully completed his One Year GRADUATE ENGINEERING TRAINING in J.K.
CEMENT WORKS in the duration from 04-June-2018 to 04-June-2019.
Mr. S.K. Rathore Mr. Shahid Khan

Unit Head Head of Civil Department
JK Cement Works, JK Cement Works,
Nimbahera, Rajasthan. Nimbahera, Rajasthan.
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. ii

ACKNOWLEDGEMENT
The extensive training program at J.K. CEMENT WORKS was a great opportunity and an exceptional
learning experience for me. It is first hands on experience and an exposure of practical world.
I got opportunity to work under the esteemed supervision of Mr. Shahid Khan (Head, Civil
Department). It was great privilege for me to work under them. I am thankful to them for their
extreme patience , to make training program fruitful for me and for rendering every possible help
to carry out this research project. I offer my gratitude to the management and staff that have spent their
precious time, expressed keen interest and given continued encouragement throughout the Project and
enabled the successful completion of my project at J. K. CEMENT WORKS.
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. iii

ABSTRACT
The young engineers program and training report in broad-spectrum contains detailed in which I
try to explain one year experience in the company. The content of my report is broadly explained and it
is constructed from the practical basis of the drawing given by the architect. The chapter one explains
about all record or history and futurity of my hosting company. So, it is give details of the company in
terms of reader can easily know and access the company. The second chapter gives you information
about the cement mill and its importance. The third chapter is most important chapter which explains
my overall training familiarity in a year. This chapter is the main chapter and I have recorded the overall
work I have been executing. It gives you a highlight of what I have been doing from past one year. The
fourth chapter explains you about the problem faced and accordingly the solution which were under
taken. It also tells you about the main benefits of the training class in terms of different aspects and
areas. It is obvious that the training has a plus in terms of improving skills and different
abilities as a whole. The advantages and gains of the training is put in short and prices way to grasp the
attention of readers and evaluators. The final chapter explains about the conclusion of work.
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. iv

TABLE OF CONTENT
DECLARATION i
CERTIFICATE ii
ACKNLOWDEGEMENT iii
ABSTRACT iv
TABLE OF CONTENT v-vii
LIST OF FIGURES vii
CHAPTER 1
NIMBAHERA PLANT…………………………………………………………………….1
CHAPTER 2
CEMENT MILL…………………………………………………………………………....2
CHAPTER 3
CONSTRUCTION PROCESS…………………………………………………………...3-41
3.1 Planning………………………………………………………………………………….4
3.2 Surveying………………………………………………………………………………...5
3.3 Layout or setting out……………………………………………………………………..6
3.3.1 Temporary bench mark………………………………………………………….6
3.3.2 Base line…………………………………………………………………………6
3.3.3 Horizontal controls………………………………………………………………7
3.3.4 Vertical controls…………………………………………………………………7
3.4 Quality…………………………………………………………………………………....8
3.4.1 Objective of quality in construction……………………………………………..8
3.4.2 Quality assurance (QA) in construction…………………………………………9
3.4.3 Quality control (QC) in construction…………………………………………….9
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. v

3.4.4 Elements of quality…………………………………………………………….10

3.4.4.1 Quality characteristics……………………………………………..10
3.4.4.2 Quality of design…………………………………………………..10
3.4.4.3 Quality of conformance……………………………………………10
3.4.5 Factor affecting construction project quality………..........................................10
3.4.5.1 Project requirement ………………………………………………..10
3.4.5.2 Construction organization………………………………………….11
3.4.5.3 Quality team………………………………………………………..12
3.4.5.4 Participation of team member……………………………………...12
3.5 Test performed………………………………………………………………………....13
3.5.1 Compressive strength test of concrete cubes…………………………………..13
3.5.1.1 Procedure for concrete cube test…………………………………...13
3.5.2 Sieve analysis test of aggregate………………………………………………...14
3.5.2.1 Procedure for sieve analysis test…………………………………....15
3.5.3 Silt content test of sand………………………………………………………....16
3.5.3.1 Procedure for silt content test………………………………………16
3.6 Excavation……………………………………………………………………………................17
3.7 PCC work………………………………………………………………………………18-19
3.8 Reinforcement work……………………………………………………………………20
3.8.1 Foundation……………………………………………………………………...20
3.8.1.1 Footing……………………………………………………………...20
3.8.1.2 Raft………………………………………………………………….21
3.8.1.3 Pedestal……………………………………………………………..22
3.8.1.4 Column……………………………………………………………...23
3.8.2 Beam…………………………………………………………………………….24
3.8.3 Slab……………………………………………………………………………...25
3.8.3.1 Types of slab………………………………………………………..25
3.8.3.2 Types of load on a slab……………………………………………..26-28
3.9 Shuttering and scaffolding……………………………………………………………...29
3.9.1 Following requirement of good formwork……………………………………...30
3.9.2 Economy in formwork…………………………………………………………..31
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. vi
3.9.3 Types of formwork in construction…………………………………………….32

3.10 Reinforced cement concrete…………………………………………………………..33
3.10.1 Properties of rcc……………………………………………………………....33
3.10.2 Purpose of rcc………………………………………………………………...34
3.10.3 Advantage of rcc……………………………………………………………...34
3.10.4 Pour, compact and finish concrete……………………………………............34-35
3.11 De-shuttering and curing………………………………………………………………36-37
3.11.1 Curing………………………………………………………………………...37
3.12 Finishing work…………………………………………………………………………38
3.13 Reconciliation………………………………………………………………………….39
3.13.1 Incorporation of materials in work…………………………………………...39
3.13.2 Joint measurements…………………………………………………………..39
3.13.3 Measurements for payment………………………………………………......39
3.13.4 Issue of materials and its reconciliation……………………………………...40
3.13.5 Reinforcement reconciliation………………………………………………...40-41
CHAPTER 4
OVERALL BENEFITS OF THE TRAINING…………………………………………………..42-45
4.1 Improving practical skills……………………………………………………………………….42
4.2 Upgrading interpersonal and communication skill……………………………………………...42
4.3 Improving team play skill……………………………………………………………………….43
4.4 Improving leadership skill………………………………………………………………………43
4.5 Work ethics and related issues………………………………………………………………….44
4.6 Entrepreneurship skill ………………………………………………………………………….44-45
CHAPTER 5
CONCLUSION……………………………………………………………………………………..47
REFERENCE ………………………………………………………………………………………48
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. vii

FIG NO. LIST OF FIGURES PAGE NO.

1 CEMENT MILL 2
2 FINDING REDUCE LEVEL 5
3 SETTING OUT BY RIGHT ANGLE METHOD 7
4 FACTOR AFFECTING QUALITY IN CONSTRUCTION 11
5 CUBE OF 10X10X10 CM 13
6 CUBE FOR TESTS 14
7 VARIOUS SIEVE 15
8 DIFFERENT LAYERS 16
9 EXCAVATION AT CEMENT MILL 17
10 PCC OF CABLE CELLAR ROOM 19
11 FOOTING AT CEMENT MILL 21
12 RAFT OF CABLE CELLAR ROOM 21
13 PEDESTAL OF ROLLAR PRESS COLUMN 22
14 COLUMN WITH 16 MM DIA 23
15 BEAM AT +10.00 M LVL 24
16 ONE WAY SLAB 25
17 TWO WAY SLAB 26
18 SLAB AT +14.80 M LVL 27
19 SCAFFOLDING FOR COLUMN SUPPORT 29
20 TIMBER FORMWORK 31
21 PLYWOOD SHUTTERING 32
22 POURING OF CONCRETE 35
23 COMPACTING OF CONCRETE 35
24 FINISHING OF CONCRETE 35
25 COLUMN AFTER REMOVAL OF SHUTTER 36
26 POND CURING 37
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. viii

CHAPTER 1
NIMBAHERA PLANT
 J.K. is a multinational organisation in India with a heritage of more than 125 years.
 At Present, JK Cement is one of the leading manufacturers of grey cement in the country with
capacity of 10.5 MnTPA.
 JK Cement Ltd is an affiliate of the multi-disciplinary industrial conglomerate JK Organisation which
was founded by Lala Kamlapat Singhania.
 The Company has over four decades of experience in cement manufacturing.
 Its operations commenced with commercial production at its first grey cement plant at Nimbahera in
the state of Rajasthan in May 1975. Subsequently the Company also set up 2 more units in Rajasthan
at Mangrol and Gotan. In the year 2009 the Company extended its footprint by setting up a green-field
unit in Muddapur, Karnataka giving it access to the markets of south-west India. In the year 2014, the
company further expanded its capacity in the north with brownfield expansion of 1.5 MnTPA
integrated unit at Mangrol and split grinding unit of 1.5 MnTPA at Jhajjar.
As a part of its new initiatives, the Company plans to increase the production capacity of Wall Putty to
keep pace with the rising demand. In this direction, the company plans to put up 6 lac tonnes capacity at
Katni in M.P. The first phase of 2 lac tonnes co commenced on 25/5/16.
ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 1

CHAPTER 2
CEMENT MILL
A cement mill is the equipment used to grind the hard, nodular clinker from the cement kiln into the
fine grey powder that is cement.
ROLLER PRESS:-
.In Cement industry roller press is used to grind clinker, limestone, slag mineral. These crushed
minerals can be easily ground, reduce the energy consumption of the grinding mills, extends the
working life of mills and all their components.
Fig 1: Cement mill

CHAPTER 3
CONSTRUCTION PROCESS
1. PLANNING
2. SURVEYING
3. LAYOUT OR SETTING OUT
4. QUALITY
5. TEST PERFORMED
6. EXCAVATION
7. PCC WORK
8. REINFORCEMENT WORK
9. SHUTTERING AND SCAFFOLDING
10. REINFORCED CEMENT CONCRETE ( RCC )
11. DE-SHUTTERING AND CURING
12. FINISHING WORK
13. RECONCILLATION

3.1 PLANNING:-
Developing the construction plan is a critical task in the management of construction. It involves the
choice of technology, the definition of work tasks, the estimation of the required resources and durations
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 for work.

3.2 SURVEYING:-
Surveying or land surveying is the technique, profession, and science of determining the terrestrial or
three-dimensional positions of points and the distances and angles between them. A land surveying
professional is called a land surveyor. These points are usually on the surface of the Earth, and they are
often used to establish maps and boundaries for ownership, locations, such as building corners or the
surface location of subsurface features, or other purposes required by government or civil law, such as
property sales.
Surveyors work with elements of geometry, trigonometry, regression analysis, physics,

engineering, metrology and the law. They use equipment, such as total stations, robotic total
stations, theodolites, 3D scanner, handheld tablets, digital levels, subsurface locators, drones, GIS, and
surveying software.
Surveying has been an element in the development of the human environment since the beginning of
recorded history. The planning and execution of most forms of construction require it. It is also used in
transport, communications, mapping, and the definition of legal boundaries for land ownership. It is an
important tool for research in many other scientific disciplines.
Fig 2: Finding Reduce Level

3.3 LAYOUT OR SETTING OUT:-
Accurate setting out is fundamental part of the construction works, and errors can be very expensive and
time consuming to correct. It should only be undertaken by competent persons, and all work should be
thoroughly checked, preferably by different personnel.
Setting out is usually undertaken once the site has been subject to a condition survey and desk study, and
has been cleared of any debris or obstructions. Works necessary to create required levels may also have
been completed before the layout process begins. The position and orientation of the structure is generally
described in architects or engineer’s drawings and defining precisely how the layout should be arranged.
Controlling dimensions and references on the plans will determine the positioning of the building, and in
particular its foundations. These include; overall length and width, distances to road centre-lines and to
other structures, internal structural measurements, approaches and rights-of-way and so on. The
controlling points of the structure can then be marked so that the construction team is able to easily
identify them. This usually consists of marking the building’s corners, horizontal and vertical positions,
using stakes and batter boards with string lines, drill holes, cut-and-fill notations, and other methods.
3.3.1 Temporary Bench Mark (TBM)

The TBM is a fixed point on a site to which all levels are related and should be established at an early
stage. Where possible the TBM should relate to an ordnance bench mark. On the site, it could relate to
any permanent fixture, such as a manhole cover or firmly-driven post.
3.3.2 Baseline
Typically the first layout task is establishing a baseline to which all the setting out can be related. The
baseline is a straight reference line in respect to which the building’s corners are located on the ground. It
often coincides with the ‘building line’, which is the boundary of the area, or the outer boundary of
a road or curb, often demarcated by the local authority.

3.3.3 Horizontal controls

These are the points that have known coordinates with respect to a specific point. Other points such as
layout corners can then be located. Plenty of control points should be used so that each point of the plan
can be precisely located on the ground.
3.3.4 Vertical controls

These enable design points to be positioned at their correct levels. The vertical control points are
established relative to specified vertical datum – often a timber post set in concrete. Horizontal and
vertical controls are generally established during the levelling phase using a theodolite or similar
instrument. For more information, see surveying instruments.
Example:-
For a simple building layout, such as a rectangle, the outline of the building is marked by cord fixed to
corner posts. A theodolite, site square or builder’s square is used to turn off 90-degree angles for the
remaining corners. Ranging rods may be required to establish a straight line between
corner posts.Corner posts are usually 50 x 50 mm timber posts driven firmly into the ground, with a nail
in the post’s centre. The outline may be marked on the ground with dry lime or similar
powder. Timber profile boards can be used at the corners. Profile boards are typically between 0.6-1 m in
height and comprise two 50 x 50 mm posts driven at least 600 mm into the ground, with a 150 x 38 mm
cross board.
Fig 3: Setting out by Right Angle Method

3.4 QUALITY:-
Quality in construction industry can be defined as the attainment of acceptable levels of performance from
construction activities. This performance would be attained when the activity meets or exceeds the
requirement of the client or the owner. The quality of any product or service is achieved when it conforms
to the desired specifications.
Achieving quality in construction industry in long run is a tough issue and has been a problem. Inefficient
or no practice of quality management procedures will result in great loss of time, money, material,
resources.
For example, in construction site, the designer would specify a particular grade of concrete. The
contractor will use the ingredients of the concrete such that the desired grade of concrete is obtained.
3.4.1 Objective of Quality in Construction
1. Satisfaction of Contract Specifications.

2. Completion of Project within Time.
3. Enhancing Customer/ Owner Satisfaction.
4. Motivation and Empowerment of Employees.
5. Avoiding Disputes and Claims.
6. Performance based on Purpose.
The Quality schemes will carry out the studies for
1. Selection of types of material and methods to be included in design,

2. Ensure design in accordance with all applicable codes and regulation
3. Control construction on the project based on standards and contracts
The method chosen will vary from the automated documented through computer to statistical
quality control in the field.

3.4.2 Quality Assurance (QA) in Construction
Quality assurance are certain schemes that is implemented in construction in order to maintain the
standard or the quality of the work in a consistent manner. Quality assurance forms the integral
management system in a construction company.
The companies generally will have a quality assurance chart that will specify various checks at different
levels. In general, a quality assurance plan will involve the following -
1. Training Programs for Workers and Employees.

2. Efficient Safety Programme.
3. Effective Procurement system to obtain quality resources and suppliers.
4. Reward scheme for innovative works.
5. A competitive career progress scheme.
3.4.3 Quality Control (QC) in Construction
Quality control in construction involves periodic inspection of the construction activities and facilities in
order to meet the desired standardisation as per the contract. Quality Control is undergone by the team of
QC engineers or special trained teams.
For example, the quality control for compaction work conducted for highway project is performed by
measuring the soil density. Slump test helps in determining the workability of the concrete.
Quality assurance forms a scheme for good management of construction activities while quality control
undergoes inspection or sampling processes.
Quality control focuses on

1. Setting and practicing specific standard for construction.
2. Determining the deviations from the standards.
3. Bringing and taking corrective measures to reduce variation.
4. Standard Improvement with time.

3.4.4 Elements of Quality

The basic element of quality in construction is
1. Quality characteristics.
2. Quality of design.
3. Quality of conformance.
3.4.4.1 Quality Characteristics

A quality characteristic is related to the parameters with respect to which quality – control processes are
judged. Quality characteristic includes strength, colours, texture, dimension, height etc. Example in
compressive strength of concrete, usability of concrete in slump, etc.
3.4.4.2 Quality of design

It refers to the quality with which the design is carried out. It primarily related to meeting the requirement
of the standard, functionally efficient system and economical maintainable system.
3.4.4.3 Quality of conformance

It is referred to the degree to which the constructed facility conformed the design and specification.
Quality of conformance is affected by field construction methodology and Inspection.
3.4.5 Factors Affecting Construction Project Quality
The quality of construction project is influenced by various factors which are mentioned below:
3.4.5.1 Project Requirements
Quality of any construction project is meeting the respective project requirements. This will satisfy the
designer’s requirements, the constructors & the owner’s requirements. Below figure-1 shows the basic
project requirements.

Fig 4: Factors Affecting Quality in Construction
3.4.5.2 Construction Organization
Based on different studies considered it is concluded that the commitment and the leadership criteria of a
construction organisation will affect the quality of the project. There is decline in construction
productivity, if the management practices are poor.

3.4.5.3 Quality Teams
A structured environment is provided by having quality teams for the project. Practices are implemented
structurally and continuously with regular quality checks. Quality teams will have structural engineers,
environmental engineers, electrical, civil engineers, architects and owners to bring quality goals.
3.4.5.4 Participation of Team Members
The participation of the quality team members are not only important in the planning stage but also during
the construction phase of the project.

3.5 TEST PERFORMED:-

There are several tests performed over cube, sand and aggregate. The necessity of the test is to check the
quality of the material used in construction. The test has a huge impact over the quality.
3.5.1 Compressive Strength Test of Concrete Cubes
For cube test two types of specimens either cubes of 15cm X 15cm X 15cm or 10cm X 10cm x 10cm
depending upon the size of aggregate are used. For most of the works cubical moulds of size 15cm x
15cm x 15cm are commonly used.
Fig 5: Cube of 10cm x 10cm x 10cm
The concrete is poured in the mould and tempered properly so as not to have any voids. After 24 hours
these moulds are removed and test specimens are put in water for curing. The top surface of these
specimen should be made even and smooth. This is done by putting cement paste and spreading smoothly
on whole area of specimen.
These specimens are tested by compression testing machine after 7 days curing or 28 days curing. Load
should be applied gradually at the rate of 140 kg/cm2 per minute till the Specimens fails. Load at the
failure divided by area of specimen gives the compressive strength of concrete.
3.5.1.1 Procedure for Concrete Cube Test
1. Remove the specimen from water after specified curing time and wipe out excess water from the surface.
2. Take the dimension of the specimen to the nearest 0.2m
3. Clean the bearing surface of the testing machine
4. Place the specimen in the machine in such a manner that the load shall be applied to the opposite sides of
the cube cast.
5. Align the specimen centrally on the base plate of the machine.
6. Rotate the movable portion gently by hand so that it touches the top surface of the specimen.
7. Apply the load gradually without shock and continuously at the rate of 140 kg/cm 2/minute till the
specimen fails
8. Record the maximum load and note any unusual features in the type of failure.
Fig 6: Cubes for Test
3.5.2 Sieve analysis Test of aggregate
For the characterization of bulk goods of different forms and sizes, the knowledge of their particle size
distributions is essential. The particle size distribution, i.e. the number of particles of different sizes, is
responsible for important physical and chemical properties such as solubility, flow ability and surface
reaction. In many industries such as food, pharmaceutics and chemistry traditional sieve analysis is the
standard for production and quality control of powders and granules. Advantages of the sieve analysis
include easy handling, low investment costs, precise and reproducible results in a comparably short time
and the possibility to separate the particle size fractions. Therefore, this method is an accepted alternative
to analysis methods using laser light or image processing.
To guarantee a high degree of reproducibility and reliability, sieve shakers and accessories have to fulfil
the requirements of national and international standards. This means that test sieves, sieve shakers and all
other measurement instruments (e.g. scales) which are used for the characterization of particle
distributions have to be calibrated and subjected to test agent monitoring as part of the quality
management system. Apart from that, it is absolutely necessary to carry out the sample preparation with

great care. Only then is it possible to achieve sieving results which allow a reliable characterization of a
product.
3.5.2.1 Procedure for sieve analysis test
1. Take a representative oven-dried sample that weighs approximately 500g.
2. If particles are lumped or conglomerated, crush the lumps but not the particles using the pestle and
mortar.
3. Determine the mass of sample accurately – Weight (g).
4. Prepare a stack of test sieves. The sieves are stacked in order, with the largest aperture size at the top,
and the smallest at the bottom. A receiver is placed under all of the sieves to collect samples.
5. Weigh all the sieves and the pan separately.
6. Pour the samples from step 3 into top of the stack of sieves and put the lid on, place the stack in the
sieve shaker and fix the clamps, adjust the timer to between 10 and 15 minutes, and switch on the
shaker.
7. Stop the sieve shaker and measure the mass of each sieve and retained soil/material.
Fig 7: Various Sieves

3.5.3 Silt content Test of sand

Silt content is a fine material which is less than 150 micron. It is unstable in the presence of water.
It is unstable in the presence of water. If we use silty sand for bonding, it will reduce the strength and cause
rework.
You may be experienced this while plastering for a roof where the mason tries to plaster the mortar where it
gets continually peel off.
Excessive quantity of silt, not only reduces the bonding of cement and fine aggregates but also affects the
strength and durability of work. You can check out this article for silt and clay properties.
3.5.2.1 Procedure for sieve analysis test
1. First, we have to fill the measuring cylinder with 1% solution of salt and water up to 50 ml.
2. Add sand to it until the level reaches 100 ml. Then fill the solution up to 150 ml level.
3. Cover the cylinder and shake it well.
4. After 3 hours, the silt content settled down over the sand layer.
5. Now note down the silt layer alone volume as V1 ml (settled over the sand).
6. Then note down the sand volume (below the silt) as V2 ml.
7. Repeat the procedure two more times to get the average.
Fig 8: Different Layers

3.6 EXCAVATION:-
Excavation is the process of moving earth, rock or other materials with tools, equipment or explosives. It
includes earthwork, trenching, wall shafts, tunneling and underground. Excavation has a number of
important applications including exploration, environmental restoration, mining and construction. Among
these, construction is one of the most common applications for excavation. Excavation is used in
construction to create building foundations, reservoirs and roads. Some of the different processes used in
excavation include trenching, digging and site development. Each of these processes requires unique
techniques, tools and machinery to get the job done right. The processes used will depend upon the
structure that will result from the construction process.
Where is excavation construction used?
Excavation construction is used during the construction process of almost every structure we encounter
throughout our lives. It is used to build the foundation for the construction of homes, roadways, and
buildings and creates reservoirs like lakes and pools that house some of our favorite summer activities. It
is also relied upon for the mining of precious metals and minerals. Excavation facilitates the construction
process and helps our important structures be built to their fullest potential by providing increased control
over the job location.
Fig 9: Excavation at Cement mill

3.7 PCC WORK:-

Plain cement concrete is the mixture of cement, fine aggregate (sand) and coarse aggregate without steel.
PCC is an important component of a building which is laid on the soil surface to avoid direct contact of
reinforcement of concrete with soil and water.
The general specifications of materials used in PCC are –
3.7.1 Coarse Aggregate
Coarse aggregate used in the PCC must be of hard broken stone of granite or similar stone, free from dust,
dirt and other foreign matter. The stone ballast shall be 20 mm in size and smaller. All the coarse material
should be retained in a 5mm square mesh and should be well graded so that the voids do not exceed 42%.
3.7.2 Fine Aggregate
Fine aggregate shall be of coarse sand consisting of hard, sharp and angular grains and shall pass through
a screen of 5 mm square mesh. Sand shall be of standard specifications, clean and free from dust, dirt and
organic matter. Sea sand shall not be used.
3.7.3 Cement
Portland Pozzolana cement (P.P.C) is normally used for plain cement concrete. It should conform to the
specifications and shall have the required tensile and compressive stresses and fineness.
3.7.4 Water
Water used shall be clean and reasonably free from injurious quantities of deleterious materials such as
oils, acids, alkalis, salts and vegetable growth. Generally, potable water shall be used having a pH value
not less than 6. The maximum permissible limits for solids shall be as per IS 456:2000 Clause.

Proportioning of Plain Cement Concrete
1. The proportioning is done based on the requirement or given specification. Generally 1:2:4 or 1:3:6 mix is
used.
2. The measurement of material can be done by weight batching or volume batching.
3. In volume batching, coarse aggregate and sand shall be measured by measuring box of 30cmx30cmx38cm
of a suitable size equivalent to one bag cement of 1/30 m3or 0.035 m3.
Advantages of Laying Plain Cement Concrete
1. Required cover to bottom reinforcement is ensured, as cover blocks rest on a firm PCC.
2. The effective depth of RCC members is achieved as the formworks can be easily, uniformly and sturdily
fixed, resulting in better dimension accuracy of foundation RCC member.
3. Reinforcement steel bars placed on PCC, are never in touch with the ground soil, which may be
chemically active and may lead to steel corrosion in the immediate future.
4. Ease in the placement of steel cages and increased productivity.
5. Concrete does not bond with ground soil (clay); PCC acts as a barrier to soil and bond well to overlayed
structural grade concrete.
Fig 10: PCC of Cable Cellar Room

3.8 REINFORCEMENT WORK:-

Rebar (short for reinforcing bar), known when massed as reinforcing steel or reinforcement steel, is
a steel bar or mesh of steel wires used as a tension device in reinforced concrete and
reinforced masonry structures to strengthen and aid the concrete under tension. Concrete is strong under
compression, but has weak tensile strength. Rebar significantly increases the tensile strength of the
structure. Rebar's surface is often deformed to promote a better bond with the concrete.
The most common type of rebar is carbon steel, typically consisting of hot-rolled round bars with
deformation patterns. Other readily available types include stainless steel, and composite bars made
of glass fibre, carbon fibre, or basalt fibre. The steel reinforcing bars may also be coated in an epoxy resin
designed to resist the effects of corrosion mostly in saltwater environments, but also land based
constructions. Bamboo has been shown to be a viable alternative to reinforcing steel in concrete
construction. These alternate types tend to be more expensive or may have lesser mechanical properties
and are thus more often used in specialty construction where their physical characteristics fulfil a specific
performance requirement that carbon steel does not provide. Steel and concrete have similar coefficient of
thermal expansion, so a concrete structural member reinforced with steel will experience minimal
differential stress as the temperature changes.
Reinforcement used in
3.8.1 FOUNDATION
Foundation consists of footing, raft, pedestal, and column.
3.8.1.1 FOOTING -
In one-way RCC footing, the reinforcement is distributed uniformly across the full width of footing.
In two-way square footings, the reinforcement extending in both directions is distributed uniformly across
the full width of the footing. But in the case of two-way rectangular footings, reinforcement is distributed
across the full width of footing in long direction. However for short direction, the reinforcement is
distributed in the central band as per calculations below. The rest reinforcement in short direction is
distributed equally on both sides of the central band.

Fig 11: Footing at Cement Mill
3.8.1.2 RAFT -
A raft foundation, also called a mat foundation, is essentially a continuous slab resting on the soil that
extends over the entire footprint of the building, thereby supporting the building and transferring its
weight to the ground.
A raft foundation is often used when the soil is weak, as it distributes the weight of the building over the
entire area of the building, and not over smaller zones (like individual footings) or at individual points.
This reduces the stress on the soil.
Fig 12: Raft of Cable Cellar room

3.8.1.3 PEDESTAL -
When structural steelworks are connected to the foundation, pedestals are normally designed to carry
loads from metal columns through the ground surface to the footings which are located below the ground
surface. With the installation of pedestals, it is the pedestals, instead of metals, which come into contact
with soils.
The purpose of the provision of pedestals is to avoid the direct contact of metal columns with soils which
may cause possible metal corrosion by soils. The soils around the pedestals should be properly compacted
to provide sufficient lateral resistance to prevent buckling of pedestals
Fig 13: Pedestal of Roller Press Column

3.8.1.4 COLUMN -
A column is a slender, vertical member that carries a superimposed load. Concrete columns, especially
those subjected to bending stresses, must always be reinforced with steel. In concrete columns, vertical
reinforcement is the principal reinforcement. However, a loaded column shortens vertically and expands
laterally; hence, lateral reinforcements in the form of lateral ties are used to restrain the expansion.
Columns reinforced in this manner are called tied columns. The ties can be 2 legged, 4 legged and 6
legged. If the restraining reinforcement is a continuous winding spiral that encircles the core and
longitudinal steel, the column is called a spiral column.
Fig 14: Column with 16mm dia
In industrial building generally 16 mm dia of reinforcement steel is used for vertical bars and 10 mm for
stirrups.

3.8.2 BEAM
Beam is a horizontal structural element that withstand vertical loads, shear forces and bending moments.
The loads applied to the beam result in reaction forces at the support points of the beam. The total effect
of all the forces acting on the beam is to produce shear forces and bending moment within the beam, that
in turn induce internal stresses, strains and deflections of the beam.
Load carried by beam -
1. Self-weight of the beam.

2. Dead load includes point load for instance column constructed on beam, distributed load for example
setting slabs on a beam.
3. Live load.
4. Torsional load.
Fig 15: Beam at +10.00 m lvl

3.8.3 SLAB
Concrete slab, a very common and important structural element, are constructed to provide flat,
useful surfaces. It is a horizontal structural component, with top and bottom surfaces parallel. Slabs
may be supported on two sides only or have beams on all four sides.
3.8.3.1 Types of Slab
One Way Slab: One way slab is a slab which is supported by beams on the two opposite sides to carry
the load along one direction. The ratio of longer span (l) to shorter span (b) is equal or greater than 2,
considered as one way slab because this slab will bend in one direction i.e. in the direction along its
shorter span
Due to the huge difference in lengths, load is not transferred to the shorter beams. Main reinforcement is
provided in shorter span and distribution reinforcement in longer span.
Fig 2.4.1- One way slab
Fig 16: One way slab

Two Way Slab: Two way slab is a slab supported by beams on all the four sides and the loads are carried
by the supports along both directions, it is known as two way slab. In two way slab, the ratio of longer
span (l) to shorter span (b) is less than 2.
In two way slabs, load will be carried in both the directions. So, main reinforcement is provided in both
direction for two way slabs.
Fig 17: Two way slab
3.8.3.2 Types of Loads on a Slab

Types of loads acting on a slab include:
1. Dead load of the slab.

2. Live load.
3. Floor finish load.
4. Earthquake loads.

Fig 18: Slab at +14.8 m lvl
Types of bars provided in slab
1. MAIN BARS
In order to transfer that bending moment developed at the bottom of the slab, Main reinforcement bar is to
Provide at the shorter span direction. That’s why
 we place main reinforcement bars at the bottom of the slab

 Also, use slightly stronger (higher) dimension bars
 we place main bars at the shorter direction
In one way slab, the slab is supported at two parallel sides where main reinforcement will be placed.
In two way slabs, the span will be supported at four ends. So there won’t be any difference in bar size.
Because each side will have to transfer the same amount of stress evenly.

2. DISTRIBUTION BARS
Distribution bars are used to resist the shear stress, cracks developed in the longer span. That’s why
 We place the distribution bars perpendicularly on top of the main bars.
 We use lesser dimension since it is only to resist the cracks developed due to shear stress on top of the
slab.
 We place them at the longer span direction.
3. EXTRA BARS
 The top reinforcement at the ends of beam above the supports is used to resist the negative moment.
 The maximum diameter of bar used in slab should not exceed 1/8 of the total thickness of slab.
 Maximum spacing of Main Bars restricted to 300 mm.
 Maximum spacing of Distribution bars restricted to 450 mm.
There are total 12 slabs in cement mill and they are as follows:
Levels: +1.0m, +5.5m, +7.2m, +11.5m, +14.8m, +21.5m, +22.8m, +27.3m, +35.0m, +38.6m, +42.0m,
+52.6m.

3.9 SHUTTERING AND SCAFFOLDING:-
The term ‘SHUTTERING’ or ‘FORMWORK’ includes all forms, molds, sheeting, shuttering planks,
poles, posts, standards, V-Heads, struts, and structure, ties, walling steel rods, bolts, wedges, and all other
temporary supports to the concrete during the process of sheeting.
Fig 19: Scaffolding for column support
Forms or moulds or shutters are the receptacles in which concrete is placed, so that it will have the desired
shape or outline when hardened. Once the concrete develops adequate strength, the forms are removed.
Forms are generally made of the materials like timber, plywood, steel, etc.
Generally camber is provided in the formwork for horizontal members to counteract the effect of
deflection caused due to the weight of reinforcement and concrete placed over that. A proper lubrication
of shuttering plates is also done before the placement of reinforcement. The oil film sandwiched between
concrete and formwork surface not only helps in easy removal of shuttering but also prevents loss of
moisture from the concrete through absorption and evaporation.
The steel form work was designed and constructed to the shapes, lines and dimensions shown on the
drawings. All forms were sufficiently water tight to prevent leakage of mortar. Forms were so constructed
as to be removable in sections. One side of the column forms were left open and the open side filled in

board by board successively as the concrete is placed and compacted except when vibrators are used. A
key was made at the end of each casting in concrete columns of appropriate size to give proper bonding to
columns and walls as per relevant IS.
The construction of formwork takes time and involves expenditure upto 20 to 25% of the cost of the
structure or even more. Design of these temporary structures are made to economic expenditure. The
operation of removing the formwork is known as stripping. Stripped formwork can be reused. Reusable
forms are known as panel forms and non-usable are called stationary forms. Timber is the most common
material used for formwork. The disadvantage with timber formwork is that it will warp, swell and shrink.
Application of water impermeable cost to the surface of wood mitigates these defects.
3.9.1 A good formwork should satisfy the following requirements:
1. It should be strong enough to withstand all types of dead and live loads.
2. It should be rigidly constructed and efficiently propped and braced both horizontally and vertically, so as
to retain its shape.
3. The joints in the formwork should be tight against leakage of cement grout.
4. Construction of formwork should permit removal of various parts in desired sequences without damage to
the concrete.
5. The material of the formwork should be cheap, easily available and should be suitable for reuse.
6. The formwork should be set accurately to the desired line and levels should have plane surface.
7. It should be as light as possible.
8. The material of the formwork should not warp or get distorted when exposed to the elements.
9. It should rest on firm base.

3.9.2 Economy in Formwork:

1. The plan of the building should imply minimum number of variations in the size of rooms, floor area etc.
so as to permit reuse of the formwork repeatedly.
2. Design should be perfect to use slender sections only in a most economical way.
3. Minimum sawing and cutting of wooden pieces should be made to enable reuse of the material a number
of times. The quantity of surface finish depends on the quality of the formwork.
Formwork can be made out of timber, plywood, steel, precast concrete or fiberglass used separately or in
combination. Steel forms are used in situation where large numbers of re-use of the same forms are
necessary. For small works, timber formwork proves useful. Fibre glass made of precast concrete and
aluminium are used in cast-in-situ construction such as slabs or members involving curved surfaces.
3.9.3 Types of Formwork (Shuttering) for Concrete Construction:
Timber Formwork:
1. well-seasoned
2. light in weight
3. easily workable with nails without splitting
4. free from loose knots
Timber used for shuttering for exposed concrete work should have smooth and even surface on all faces
which come in contact with concrete.
Fig 20: Timber Formwork

Plywood Formwork:
1. It is possible to have smooth finish in which case on cost in surface finishing is there.
2. By use of large size panels it is possible to effect saving in the labour cost of fixing and dismantling.
3. Number of reuses are more as compared with timber shuttering. For estimation purpose, number of reuses
can be taken as 20 to 25.
Fig 21: Plywood shuttering
Steel Formwork
This consist 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 forms are largely used in large
projects or in situation where large number reuses of the shuttering is possible. This type of shuttering is
considered most suitable for circular or curved structures.

3.10 REINFORCED CEMENT CONCRETE (RCC):-

Reinforced concrete (also called reinforced cement concrete or RCC) is a composite material in
which concrete's relatively low tensile strength and ductility are counteracted by the inclusion of
reinforcement having higher tensile strength or ductility. The reinforcement is usually, though not
necessarily, steel reinforcing bars (rebar) and is usually embedded passively in the concrete before the
concrete sets. Reinforcing schemes are generally designed to resist tensile stresses in particular regions of
the concrete that might cause unacceptable cracking and/or structural failure. Modern reinforced concrete
can contain varied reinforcing materials made of steel, polymers or alternate composite material in
conjunction with rebar or not. Reinforced concrete may also be permanently stressed (concrete in
compression, reinforcement in tension), so as to improve the behaviour of the final structure under
working loads. In the United States, the most common methods of doing this are known as pre-
tensioning and post-tensioning.
Reinforced cement concrete (R.C.C) is the combination of ordinary concrete with the reinforcement to
increase its compressive and tensile strength to a great extent.
Concrete is a versatile material for modern construction which is prepared by mixing well-proportioned
quantities of cement (even lime in some cases), sand, crushed rock or gravel, and water.
It has been used from foundations to the rooftops of buildings, in the construction of highways roads
traffic, and hydro-power tunnels, irrigation canals, drains, and all other conceivable structures.
3.10.1 Properties of Reinforced Cement Concrete
1. High relative strength

2. High toleration of tensile strain
3. Good bond to the concrete, irrespective of pH, moisture, and similar factors
4. Thermal compatibility, not causing unacceptable stresses (such as expansion or contraction) in
response to changing temperatures.
5. Durability in the concrete environment, irrespective of corrosion or sustained stress for example.

3.10.2 Purpose of Reinforced Cement Concrete

Concrete has a very high compressive strength, but it is low in tensile strength. Thus, when only the
compressive loads are acting on the concrete surface, then there is no need of using reinforcement in it.
But where tensile forces are also involved, as in, beams and slabs, there is a very high risk of its failure
when plain concrete is used. Steel, however, as we know, has a very high tensile strength (and also have
good compressive strength). Hence, when these two (concrete and steel) are combined together, a material
of construction is obtained that is capable of withstanding all the three types of forces likely to act upon a
structure, i.e., compressive loads, tensile stresses, and shear forces. Such a material is known
as Reinforced Cement Concrete.
3.10.3 Advantages of Reinforced Concrete (RCC)

There are 100s of advantages of Reinforced Concrete, but here we will discuss some important
advantages of Reinforced Concrete.
1. Structures made from Reinforced Concrete are durable.

2. It has a high compressive strength (due to concrete).
3. It has a high tensile strength (due to reinforcement).
4. It is resistant to fire and other climate changes.
5. Easily available almost anywhere in the world.
6. Too much expertise is not required for working on it, normal skilled labour can also do it.
7. It can be moulded in any form, shape.
8. It can be used in any part of the structure i.e., from foundation to the top roofing.
9. Repairing cost is almost nil.
10. It is more economical compared to other materials.
3.10.4 Pour, Compact and Finish Concrete
Mixing, transporting, and handling of concrete shall be properly coordinated with placing and
finishing works. In floor slab, begin concrete placing along the perimeter at one end of the work with
each batch placed against previously dispatched concrete. Concrete should be deposited at, or as close
as possible to, it’s final position in order to prevent segregation. Furthermore, fresh concrete should
be compacted adequately in order to mold it within the forms and around embedded items and

reinforcement and to eliminate stone pockets, honeycomb, and entrapped air. Vibration, either
internal or external, is the most widely used method for consolidating concrete.
Fig 22: Pouring of concrete Fig 23: Compacting of concrete
Fig 24: Finishing of concrete

3.11 DE-SHUTTERING AND CURING:-
The removal of concrete formwork is also known as strike-off or stripping of formwork. It is should be
performed when the concrete obtains adequate strength.
Special consideration should be given for formwork removal of flexural members like beams and slabs
because these members are dependent on self-load and live load even throughout construction, they may
deflect if adequate strength is not obtained to manage the loads.
While removing formworks, the following points should be taken into consideration.
1. For column/walls, vertical form works should be detached after 16 to 24 hours.

2. Soffit formwork to slab (formwork is located under the slab), the form works can be removed after 3
days. (Props should be reaffixed once the removal is done).
3. Soffit formwork to beam, the form works can be removed after 7 days. (Props should be reaffixed
once the removal is done.)
4. Beam that spans up to 4.5 m (length), the form works can be removed after 7 days.
5. Beam that spans surpassing 4.5 m (length), the form works can be removed after 14 days.
For footing, the form works can be removed after 16 to 24 hours.
For staircase, the form works can be removed after 5 days.
Fig 25: Column after removal of shutter

3.11.1 Curing
Curing of Concrete is a method by which the concrete is protected against loss of moisture required
for hydration and kept within the recommended temperature range. Curing will increase the strength
and decrease the permeability of hardened concrete. Curing is also helps in mitigating thermal and plastic
cracks, which can severely impact durability of structures.
A curing practice involves keeping the concrete damp or moist until the hydration of concrete is complete
and strength is attained. Curing of concrete should begin soon after initial setting time of concrete
or formwork/shuttering is removed and must continue for a reasonable period of time as per the specified
standards, for the concrete to achieve its desired strength and durability.
It is important to make sure an uninterrupted hydration of PCC & RC after concrete is placed and finished
in its position. Uniform temperature ought to be maintained throughout the concrete-section depth to
avoid thermal shrinkage cracks.
Why Curing of Concrete is Necessary?
1. Enhance Hydration of Concrete to achieve desired Strength

2. Improved durability of concrete by reducing cracks
3. Higher serviceability performance by increasing abrasion resistance
4. Improved microstructure by developing better hydrate gels and solid mass.
Fig 26: Pond Curing

3.12 FINISHING WORK:-
In modern construction practice for residential, public, and industrial buildings, the technology of
finishing work has changed substantially. Increasingly widespread use is being made of large
prefabricated units, structures, and parts that are delivered to the construction site in final finished form
(for example, wall panels and roof slabs, sanitary facilities, and window and door units). This
substantially reduces the post assembly finishing work. Industry has mastered production of a number of
effective finishing materials that make it possible to eliminate the most laborious and time-consuming
processes (the “wet” processes) and to improve the quality of the finish (sheets of thistle board, facing
slabs, plastic shingles, and water-resistant wallpaper).
Finishing work is carried out at construction sites by means of various types of mechanized equipment
(movable plastering and painting equipment, units for installing floors made of polymeric materials,
puttying apparatus, polishing machines, smoothing machines, paint sprayers, and vibration pumps) that
substantially facilitate and accelerate the processes of finishing buildings and reduce the number of
operations. However, finishing work is still very labor-intensive, and for residential construction it
accounts for up to 35 percent of all labor expenditures in construction and assembly operations.
Among the most labor-intensive types of finishing work are facing operations, for the purpose of covering
the front surfaces of structures with inlaid products made of natural or artificial materials. All facing
products are usually delivered to a construction site in ready-to-use form, in predetermined sizes,
coloring, and textures. Facing operations may be of the exterior or interior type, depending on the kind of
products being used and the means of attaching them to the surfaces.
Exterior facing operations consist mainly in finishing the fronts of buildings and structures with slabs and
parts made of natural stone, facing brick, or ceramic blocks; they are usually done with interior
scaffolding at the same time as the walls are being laid. The space between the wall and the facing is
filled with cement mortar. Stone facing is sometimes applied to finished walls; in this case exterior
scaffolding is used. The facing is attached to the wall by means of fasteners, which are embedded in holes
drilled in the wall, and by filling the recesses with mortar. Facings are also attached by means of steel bars
or rods. Facing must be constructed to avoid the possibility of penetration of moisture through seams.

3.13 RECONCILLATION:-
All civil Engineering works invariably require various material for incorporation and completion of
work. These materials could be procured by the Employer or the contractor. In some cases the employer
stipulates that certain materials would be issued by him and the contractor should quote for the work
accordingly. In other cases the employer may leave procurement of materials to the contractor.
In both these cases, the material need to be accounted in the bills for payment. This is a very important
function of quantity surveyors and executives. Non reconciliation will result in delay in clearance of bills
as well as recoveries as per conditions of contract. Some organization may stipulate recoveries for non-
reconciled materials at penal rates of recovery.
Other aspects:
Off cuts, Scrap, Improper bar bending, Cutting loss, Laps, Chairs, Spacers, Miscellaneous usages,
3.13.1 Incorporation of materials in work:

1. Study the drawings and specifications and prepare method statements.
2. Prepare BBS/ shop drawings for steel items to conform to Architectural/ structural drawings.
3. Get them approved by Employer/consultants.
4. Check availability of material and examine how best cutting could be done to minimize wastage.
5. Fabricate and erect.
6. Correct the BBS on incorporation in the work before pouring concrete.
3.13.2 Joint Measurements:

1. Preliminary check and approval by structural Engineer/ Architect/MEP consultant.
2. Preparation of joint measurements after checking the respective drawings and as provided at site.
3. Record any additional provisions required at site but not shown in GFC drawings.
4. Assess the quantities in the respective units as per BOQ.
3.13.3 Measurements for payment:

1. For completed items of work joint measurements will form the basis.
2. Joint measurements will be signed by both the parties.

3. For additional items of work not covered in BOQ a separate detail will be kept.
3.13.4 Issue of materials by Employer and Reconciliation in running bills:

1. Prepare the list of stores issued. If it is steel, the issue must show the weight of steel issued, the size,
length, and number of bars.
2. Alternately, the unit weight of steel shall be assessed based on actual weight of random
samples or bunch of bars. This weight need to be compared with standard weight as per BIS.
3.13.5 Reinforcement Reconciliation

TOTAL (KG ) TOTAL
WEIGHT
SR.
Structure 8 IN KG
NO. 10 12 16 20 25 28 32
UPTO +0.00M
1 LVL footings 4202 345.926 1683.831 5894.795 11726.963 12222.222 3109.926 39185.663
& column
BUKET
2 ELEVATOR 55 706.349 386.418 2911.202 4058.969
+0.00m lvl
CELLER
3 ROOM 504.391 1206.617 3116.053 4827.062
+0.00m lvl
Slab +1.00m
4 1164.712 2880.191 559.582 398.842 327.324 2635.172 7965.823
lvl
TIE +3.950M
5 LVL TIE 167.369 97.509 247.85 849.954 1362.682
BAM
Slab +5.50m
6 2428.957 9971.911 1008.386 3251.337 1759.923 4416.456 1489 4337.514 28664.264
lvl
SLAB +7.20M
7 509.95 541.854 463.303 149.100 125.453 723.22 2512.880
LVL
TIE BEAM
8 585.946 466.872 217.447 547.937 636.514 2252.722 999.266 5706.704
+10.00M LVL
COLUMN
9 +0.00M TO 6589 4979.52 23919.6 999.266 36487.386
+10.00M LVL
Level +11.50m
10 637.356 1429.618 228.806 1077.501 1474.14 4847.421
lvl

COLUMN
11 +10.0M TO 6894.269 2498.059 23919.6 33311.928
+20.0M LVL
C6,C7,C14,C1
5 COLUMN
12 5261.297 524.035 21830.955 27616.287
+20.0M TO
+30.0M LVL
Slab +12.50m
13 478.054 42.645 100.766 211.084 770.055 259.1 1861.743
lvl
SLAB
14 528.149 4255.764 1636.474 2883.019 2181.144 9653.996 1601 3940.077 26679.863
+14.80M LVL
Level +19.80+
15 , +21.50, 419.253 3303.161 205.323 247.96 2631.00 3437.00 3296 1486.00 15025.697
+22.80
Slab +27.00m
16 4700.00 6000.00 1800.00 300.00 500.00 6700.00 3500 1500.00 25000.00
lvl
Slab +35.00m
17 1000.00 4200.00 200.00 100.00 900.00 1900.00 1700 10000.00
lvl
Slab +38.60m
18 900.00 4800.00 200.00 400.00 800.00 3000.00 2700.00 12800.00
lvl
Slab +42.00m
19 600.00 2400.00 400.00 2000.00 600 6000.00
lvl
Slab +52.60M
20 700.00 1800.00 500.00 700.00 400.00 1800 5900.00
lvl
Column
21 +20.00m to 2800.00 11300.00 14100.00
+52.600m lvl
CONSUMPTION AS
40647.65 44883.83 11748.27 18332.81 31578.52 133405.09 14246 19072.05
PER BBS (KG) (A)
CONSUMPTION AS
40.648 44.884 11.748 18.333 31.579 133.405 14.246 19.072 313.914
PER BBS (MT) (A)
Tunnel insert
1 plate lugs - 3.18 3.18
civil
TOTAL USED IN
3.18 3.18
INSERT PLATE (B)
TOTAL
CONSUMPTION IN 40.65 44.88 14.93 18.33 31.58 133.41 14.25 19.07 317.09
MT (C=A+B)

CHAPTER 4
OVERALL BENEFITS OF THE TRAINING
Training is a class healed at site to provide an enhanced understanding of the outside working
environment before to graduates. Traniee like civil and urban engineering and other fields also take this
practice. The main aim of this practice is that to teach trainee communication with different workers or
employees, to improve practical skill what they learned at class, up grading the theoretical knowledge in
addition to the class, improve their leadership skill, team playing skill and etc. I have acquired much
knowledge in different tasks as explained below in different section. That different knowledge gets me a
good performance in the training period.
4.1 IMPROVING PRACTICAL SKILL

The aim of the training is to address more practical knowledge for trainees. So, I found a practical
knowledge at the office as much possible within the one month. The knowledge we have learn in the class
is helpful to get those practical or real work in the site and totally different from the actual knowledge
gained from the class. Thus I found some knowledge in the office which helps me to work with the office
environment or office people.
4.2 UPGRADING INTERPERSONAL AND COMMUNICATION SKILL

Communication is sharing or exchanging information or ideas with others in order to get some messages
and knowledge. The communications systems within the building design and construction enterprise has
taken on a large role in the achievement of profitability and efficiency. A basic understanding of
communication systems is beneficial to all building professionals and trades, as they all play a part in the
success of the construction. Construction is one of the places that ask a good communication skill either
managing every trade of work or asking what is gowning on over there. So, communication is at
important way of learning, which can be defined formally as the act, process, or experience of gaining
knowledge or skills and sharing what we know. Cool communication is important in the real
constructions world and it can appear in different forms as speaking, writing, and listening. In the office
the most things I gain is due to communication with other workers like structural engineers, site
engineers, skilled and non-skilled workers etc. in some place/case it is very difficult to talk workers and

ask them what we want because of that they underestimate us and sometimes they are not eager to tell.
But I improve and know how to communicate with different classes of workers in the site.
4.3 IMPROVING TEAM PLAYING SKILL

Team playing skill for construction work Team works, especially for engineers, involve in every piece of
task and achieving good team playing skill is essential for Effective completion of tasks and Increasing
productivity. This skill already exists in my personality in the campus due to different assignment and
project works that I work together with student. But this skill is more than this in the office. In the office
the work is already a team work and it needs more closeness of workers to solve problems arise in
different aspects, misunderstanding in the drawing or working methodology and consult every work. We
the student at the office also works together as a team to get more understanding and share ideas. More or
less I improve my team work status by working together with different professionals, student and workers
as a whole in the civil engineering works and consulting.
4.4 IMPROVING LEADERSHIP SKILL

Leadership is the process of influencing individuals or groups to accomplish an organizational goal or
mission. I have seen how each worker is controlled and organized to perform its day to day activities.
Among all other managements I have seen that human resource management is the most important one. I
have actually observed the method of controlling the working time and amount of work done by each
worker so that the work proceeds according to the work plan schedule).Leadership is a skill to guide,
control and monitor peoples. For effective leadership I understood that personal values like confidence,
effective communication and devotion are very important. In order to be good Leadership the following
criteria should be fulfilled.
Those are:-
1. Be technically proficient (skilled with different knowledge‘s).

2. Seek responsibility and take responsibility for your actions.
3. Make sound and timely decisions.
4. Know your people and look out for their well-being.
5. Keep your workers informed.

6. Develop a sense of responsibility in your workers.

7. Ensure that tasks are understood, supervised, and accomplished.
8. Use the full capabilities of your organization.
9. Being organized.
10. Able to communicate clearly and efficiently.
4.5 WORK ETHICS AND RELATED ISSUES

The concept of work ethics may be summarized as the overall quality in one‘s behaviour towards
appreciating the process of work flow and performing rather well on the job so that this work flow will
not be jeopardized in the long run. During my internship program, I could say that I have managed to do
my side of the job description with a high spirit and enthusiasm so that there was a smooth flow of
activities in the office. Work ethics involve such characteristics as honesty, responsibility, reliability,
accountability and etc. Punctuality is one of the major issues that could be raised when talking about work
ethics and on my side I tried meet this criteria by attending to my working station in time so that there will
not be any delay on the activities planned for that day. The behaviour that one shows towards his peers
and colleagues is also one manifestation of the concept of work ethics. Personally, I always respected and
gave priority the employers of the company. Elements of work ethics that worth mentioning are:-
 Punctuality
 Honesty
 Reliability
 Office discipline
 Corporation
 Responsibility.
4.6 ENTREPRENEURSHIP SKILL

Entrepreneurship can be defined as the process of involving the creation of new enterprises and that the
entrepreneur is the founder. He or she is the person who perceives the market opportunity and then has the
motivation, drive and ability to mobilize resources to meet it. A construction project mainly requires large
human, financial, physical (material and equipment) institutional (management) resources.

Entrepreneurship is special human talent that helps manage those factors of production such as technical
equipment’s and capital and takes risks of making loses. An entrepreneur is required to establish
meaningful relationship between activity and authority which is intimately related to planning function.
This type of skill is a capacity to create your own share company with other. In our consultant are a good
example or a role model for me to become an entrepreneur and work my own business rather working in
organization as employed. But to become an entrepreneur especially in our country takes a time to know
the business well and a capacity to work such work need more money that we already have before.
Meanwhile I got some advantages regarding the entrepreneurship skill and I have a dream and motivation
to become one of the greatest entrepreneur in our country in the upcoming year since the construction
industry or any other working areas as a whole.

CHAPTER 5
CONCLUSION
It was a wonderful learning experience at J.K. CEMENT WORKS for one year in Nimbahera. I gained a
lot of insight regarding almost all the departments at the site. The friendly welcome from all the engineers
is appreciating, sharing their experience and giving their peace of wisdom which they have gained in long
journey of work, I am very much thankful for the wonderful accommodation facility from J.K.
CEMENT WORKS. I hope this experience will surely help me in my future and also in shaping my
career.

REFERENCES
1. Roderick S. Merritt Jonathan T. Ricketts ―Building design and construction hand book‖ McGraw
hill, six edition, 2001.
2. W.f. CHEN, J.y.Richard LieW ―The civil engineering hand book‖ crc press, second edition, 2003
3. Su.PILLA, devadas MENON “reinforced concrete design‖ McGraw hill, second edition, 2003
4. Madan MEHTA, Walter SCARBOROUGH and Diane ARMPRIEST “building construction
principle, materials and system‖, prentice hall, second edition, 2013
5. Construction material, geotechnical, quantity survey and structural hand-outs.
6. Reinforced Concrete Vol 1 and 2 (H.J.SHAH) .
7. Structure Analysis Vol 1 (R.C. HIBBLER).
8. Design of Steel Structures (N. SUBRAMANIYUN).
9. www.wikipedia.com
10. .www.google.com

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TRAINING

ANKUSH KESHRIMAL KHANDELWAL

J.K. CEMENT WORKS, NIMBAHERA

Department: Civil Engineering

Under the supervision of

Mr. SHAHID KHAN

ANKUSH KESHRIMAL KHANDELWAL

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. i

This is to certify that ANKUSH KESHRIMAL KHANDELWAL of Civil Engineering has

Mr. S.K. Rathore Mr. Shahid Khan

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. ii

ANKUSH KESHRIMAL KHANDELWAL

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. iii

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. iv

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. v

3.4.4 Elements of quality…………………………………………………………….10

3.9.3 Types of formwork in construction…………………………………………….32

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. vii

FIG NO. LIST OF FIGURES PAGE NO.

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. viii

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 1

Fig 1: Cement mill

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 2

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 3

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 4

Surveyors work with elements of geometry, trigonometry, regression analysis, physics,

Fig 2: Finding Reduce Level

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 5

3.3 LAYOUT OR SETTING OUT:-

3.3.1 Temporary Bench Mark (TBM)

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 6

3.3.3 Horizontal controls

3.3.4 Vertical controls

Fig 3: Setting out by Right Angle Method

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 7

3.4.1 Objective of Quality in Construction

1. Satisfaction of Contract Specifications.

The Quality schemes will carry out the studies for

1. Selection of types of material and methods to be included in design,

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 8

3.4.2 Quality Assurance (QA) in Construction

1. Training Programs for Workers and Employees.

3.4.3 Quality Control (QC) in Construction

Quality control focuses on

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 9

3.4.4 Elements of Quality

3.4.4.1 Quality Characteristics

3.4.4.2 Quality of design

3.4.4.3 Quality of conformance

3.4.5 Factors Affecting Construction Project Quality

3.4.5.1 Project Requirements

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 10

Fig 4: Factors Affecting Quality in Construction

3.4.5.2 Construction Organization

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 11

3.4.5.3 Quality Teams

3.4.5.4 Participation of Team Members

ANKUSH KESHRIMAL KHANDELWAL/CE/J.K CEMENT LTD. 12

3.5 TEST PERFORMED:-

3.5.1 Compressive Strength Test of Concrete Cubes

Fig 5: Cube of 10cm x 10cm x 10cm

3.5.1.1 Procedure for Concrete Cube Test

2. Take the dimension of the specimen to the nearest 0.2m