Industrial case study report (Final)

Industrial Case Study Report on
CONSTRUCTION OF RESIDENTIAL BUILDING
Submitted in partial fulfillment of the requirement of the degree of
Bachelor of Technology in Civil Engineering,
Jawaharlal Nehru Technological University, Hyderabad
Submitted by
N. PRANAY KUMAR (12H61A0140)
Under the guidance of
Mr B. Ravi Chand
Assistant Professor
2015-2016
DEPARTMENT OF CIVIL ENGINEERING
ANURAG GROUP OF INSTITUTIONS, VENKATAPUR, HYDERABAD

DEPARTMENT OF CIVIL ENGINEERING
ANURAG GROUP OF INSTITUTIONS
VENKATAPUR, HYDERABAD
CERTIFICATE
This is to certify that it is a bonafide report of mini project entitled Construction of
Residential Building carried out by N. Pranay Kumar (12H61A10140) of the final year
B.Tech. Civil Engineering during the academic year 2015-2016 in partial fulfillment of the
requirement for the award of the degree of Bachelor of Technology (Civil Engg.) offered by
the Jawaharlal Nehru Technological University, Hyderabad
Dr K. R. C. Reddy Mr B. Ravi Chand
HOD Guide
Date : July, 2015
Place: Hyderabad

ACKNOWLEDGEMENT
I am very thankful to Ramky group for having given me the opportunity to undertake my
industrial case study at their prestigious Ramky One Kosmos Phase-I project. It was a very
good learning experience for me to have worked at this site.
I would like to convey my heartiest thanks to Mr M. V. Rami Reddy, Head
operations, Ramky group, who heartily welcomed me for the industrial training program.
I would also like to give my heart- felt thanks to Mr K. Anjaneyulu, Project Co-
ordinator of the Ramky One Kosmos construction.
I extend my warm thanks to the Quality control engineer Mr Jan Basha Shaik, in
letting me know the various quality aspects at the construction site.
I am very thankful to Mr Tirupal, Engineer who took time of his busy schedule to
share with me his valuable experiences in the construction site and always lend an ear to my
queries and thoughts.
I express my thanks to all sections Head & the staff members of the Ramky One
Kosmos site for their kind help and support extended throughout this training and for having
made this training a memorable one.
I would like to thank Prof. M. Mutha Reddy, Principal, CVSR college of
engineering.
I express my sincere thanks to Dr K. R. C. Reddy, Head of Civil Engineering
department for his support and guidance for doing the project.
I express my deep gratitude to my guide Mr B. Ravi Chand, Assistant professor,
Department of Civil Engineering, for his guidance and care taken by him in helping me to
complete the project work successfully.

Abstract
This Industrial Case Study Report in broad-spectrum contains eight chapters in which I try to
explain my observations and experience at the construction site of Ramky One Kosmos in
Hyderabad. The content of all chapters is broadly explained and it is constructed from the
practical basis of the site work.
This report includes the description of project, ownership details, structural details
and drawings related the building as per my observation at the construction site. Then the
following chapter gives overview of materials used and their source and equipment used in
the construction site. After all those chapters this report explains the human resource
management, quantity estimation and role of safety management in the construction site.
Finally the details of the work experienced during the training period and my daily activities
are described in this report. At the end of conclusion it is found that the training was meant to
understand the deviation of the practical construction work from theoretical knowledge.

Contents
Page No.
Chapter-I Introduction 1
1.1 Description of the project 1
1.2 About the the organization 1
1.2.1 Overview 1
1.2.2 Vision, Mission and Values of the company 2
1.3 Project location 3
Chapter-II Details of the project 4
2.1 Introduction 4
2.2 Project details 5
2.3 Details of structure 5
2.4 Execution of work 6
2.5 Earth work in excavation 7
2.6 Footings 8
2.7 Backfilling 10
2.8 Columns 10
2.9 Beams and Slabs 12
2.9.1 Beams 12
2.9.2 Slab 13
2.10 Staircase 15
2.11 Lift walls 16
2.12 Retaining walls 16
2.13 Arrangement of rooms 16
2.14 Block masonry 18
2.15 Lintels 18
2.16 Plastering 18
2.17 Curing of concrete 19
2.18 Design mix data 20

2.19 Conclusion 20
Chapter- III Material Details 21
3.1 Introduction 21
3.2 Materials used 21
3.2.1 Concrete blocks 21
3.2.2 Aerocon blocks 21
3.2.3 Coarse and fine aggregates 22
3.2.4 Cement 22
3.2.5 Water 23
3.2.6 Fly ash 23
3.2.7 Admixture 23
3.2.8 Steel 24
3.2.9 Cover blocks 24
3.2.10 Shuttering or Formwork 25
3.2.11 Scaffolding 26
3.3 Source of materials 27
3.4 Testing of materials 28
3.4.1 Tests on cement 28
3.4.2 Tests on aggregates 30
3.4.3 Test on fresh concrete 32
3.4.4 Compression test 33
3.5 Equipment used 34
3.6 Batching plant 36
3.7 Conclusion 37
Chapter- IV Human Resource Management 38
4.1 Introduction 38
4.2 Project team 38
4.3 Conclusion 39

Chapter- V Estimation 40
5.1 Introduction 40
5.2 Methods of building estimate 40
5.3 Schedule of bars 41
5.4 Conclusion 43
Chapter- VI Safety Management 44
6.1 Introduction 44
6.2 Various safety measures 44
6.3 Conclusion 45
Chapter- VII Work experience 46
7.1 Introduction 46
7.2 Daily activities 46
7.3 Challenges I have faced 49
7.4 Overall benefits 49
Chapter – VIII Conclusion 50

List of figures
Page no.
Fig. 1.1: Location of the project 3
Fig. 2.1: Ramky One Kosmos phase- I project 4
Fig. 2.2: Arial view of Ramky One Kosmos Phase- I project 5
Fig. 2.3: Current position of the construction project 7
Fig. 2.4: Block- C footing details 9
Fig. 2.5: Typical isolated footing & pedestal details 9
Fig. 2.6: Typical combined footing details 10
Fig. 2.7: Block-G, Flat no. 04, Columns layout 11
Fig. 2.8: Block-G, Flat no. 04, Columns details 12
Fig. 2.9: Curtailment of bars in beams 13
Fig. 2.10: Typical slab details (Block- C) 14
Fig. 2.11: Typical curtailment details of slab reinforcement 15
Fig. 2.12: Lift walls 17
Fig. 2.13: Retaining walls 17
Fig. 2.14: Room dimension details of Block-G, 6th
floor, flat no. 04 17
Fig. 2.15: Lintel over door opening 19
Fig. 2.16: Ponding water over slab 19
Fig. 3.1: Beam cover blocks 25
Fig. 3.2 : Erection of shuttering 26
Fig. 3.3: Column formwork 26
Fig. 3.4: Scaffolding 26
Fig. 3.5: Quality control lab at the site 28
Fig. 3.6: Vicat apparatus 31
Fig. 3.7: A set of IS sieves 31
Fig. 3.8: Compression testing machine 33
Fig. 3.9: Concrete blocks stored in water before testing 33
Fig. 3.10: Back hoe 34
Fig. 3.11: Roller 34
Fig. 3.12: Crushers 35

Fig. 3.13: Tower crane 35
Fig. 3.14: Builder hoist 35
Fig. 3.15: Concrete transist mixer 35
Fig. 3.16: Concrete pumping machine 35
Fig. 3.17: Batching plant 36
Fig. 3.18: Concrete blocks making machine 36
Fig. 5.1: Details of measurement and calculation of quantities- Slab concrete 41
Fig. 5.2: Schedule of bars- RCC slab 42
Fig. 6.1: Safety nets 44
Fig. 6.2: Fire extinguishers 44
Fig. 6.3: Ambulance 44
Fig. 6.4: Project safety statistics 45
Fig. 6.5: Safety park 45
Fig. 7.1: Laying of footing reinforcement for parking ramp 47
Fig. 7.2: Laying of pedestal for parking ramp 47
Fig. 7.3: Arrangement of reinforcement in Block- C, 10th
level slab 48
Fig. 7.4: Concrete block work 48
Fig. 7.5: Plumbing work 48

List of tables
Page no.
Table 2.1: Block wise details 6
Table 2.2: Reinforcement details of slabs (Block-C) 14
Table 2.3: Client (REFL) approved design mix data sheet 20
Table 3.1: Size od cover blocks details 24
Table 3.2: Formwork removal period in the site 26
Table 3.3: Materials and their source 27
Table 3.4: Physical properties of cement (OPC 53 grade) test results 30
Table 3.5: Characteristics of fine aggregate 31
Table 3.6: Characteristics of coarse aggregate 32
Table 3.7: Recommended slumps for various concrete works (in ‘mm’) 32
Table 3.8 Compressive test results 33
Table 4.1: Project teams 39

1
Chapter - I
Introduction
1.1 Description of the project
Ramky One Kosmos is a luxurious residential project from Ramky Estates & Farms
Limited located at Nallagandla, Gachibowli, 3.5 km away from Lingampally having
longitude 78.307580 and latitude 17.460428. This is one of the ongoing residential
developments of Ramky Group.
The construction of the structure has been assigned to Ramky Infrastructure
Limited, Hyderabad.
The building has been designed by Architect Vernekar Associates Pvt. Ltd.,
Bangaluru, the structural consultants are ISA structural studio, Bangaluru, the MEP
consultants are Synergy infra Consultants Pvt. Ltd., Hyderabad and the landscape
consultants are Dhruva Associates, Bangaluru. The Project Management Consultants
(P.M.C) are CBRE India. Quality control consultants are Testwell Pvt. Ltd., Hyderabad,
National Accreditation Board for Testing and Calibration Laboratories, India and
JNTUH college of Engineering, Hyderabad.
1.2 About the Organization
1.2.1 Overview
Ramky Group is the one of the leading organization in the infrastructure development and
environment management sectors with a turnover of more than Rs. 4,500 crores. Ramky
group was founded in 1994 by Alla Ayodha Rami Reddy. The company originally
incorporated as Ramky Engineers Private Limited to undertake construction projects. Since
commencing their business they have serviced a diverse range of projects in sectors as varied
as water and waste water, transportation, irrigation, industrial parks (including SEZs), power

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transmission and distribution, residential, commercial and retail property. Headquartered in
Hyderabad, Telangana. The Ramky Group has a pan-India presence with more than 500
project locations across 23 States (including Union Territories). In overseas it has offices in
Sharjah, UAE and Singapore and it’s footprints can be seen in U.S.A, Saudi Arabia,
Vietnam, China, West Africa and Peru.
Major operations of the group are conducted through the following companies:
 Ramky Infrastructure Limited (RIL)
 Ramky Enviro Engineers Limited (REEL)
 Ramky Estates and Farms Limited (REFL)
 Ramky Finance & Investments Limited (RFIL)
 Ramky Life Sciences Limited (RLSL)
1.2.2 Vision, Mission and Values of the company
Vision
Their vision to the future is becoming a leading global enterprise in world class infrastructure
development and environment through sustainable growth.
Mission
Guided by their vision, they shall ensure quality, reliability and continuous technology
upgradation thereby enhancing the value of all stakeholders.
Values
Ramky group has following basic values:
 Integrity
 Customer Satisfaction
 Work Culture
 Employee Sense of Belonging

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 Innovation
 Safety, Health & Environment
 Social Commitment
1.3 Project Location
Fig. 1.1: location of the project

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Chapter - II
Details of the project
2.1 Introduction
Ramky One Kosmos is the ideal representation of being “close to town and close to nature”.
The Ramky One Kosmos lacated in a well developed area replete with the best of social
infrastructure, the project is located at Hyderabad in close proximity to the IT hub, Financial
District and the country’s best educational institutions including University of Hyderabad,
TATA Institute of Fundamental Research, Indian School of Business, the Sancta Maria
School and Epistemo Global School, in addition to best multispecialty hospitals such as
Citizens Hospital and American Oncology Institute as well as Outer Ring Road, Inorbit Mall
and Gachibowli Stadium.
Fig. 2.1: Ramky One Kosmos phase –I project.

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2.2 Project Details
The project is aesthetically designed with multi level green terraces, soothing views and a
host of amenities for healthy, harmonious and comfortable living. It is coming up on an area
of about 13.5 acres and the project shall be delivered in two phases. Currently, construction
of phase – I is going on an area of about 4.75 acres. Ramky Infrastructure Limited (RIL) has
started the phase – I construction in October 2013 which is of about Rs 140 crore budget.
The phase – I will have a total of 7 towers having ground + 14 floors and the builder is
offering 466 flats of the type 2 and 3 BHK. The area of the flats range from 1070 sq.ft. to
1635 sq.ft. and the builder is offering flats for a base price of Rs. 3,899 per sq. ft. The phase -
I project is scheduled to complete by October 2016.Ramky One Kosmos will have a lot of
amenities such as clubhouse built on an area of 20000 sq.ft. which will also have a swimming
pool and a gymnasium. There also is provision for AC guest rooms, a grocery store, half
basketball court, a tennis court, toddler play area and landscaped gardens.
Fig. 2.2: Describes an arial view of Ramky One Kosmos Phase –I project
2.3 Details of Structure
 The phase – I project consists of 7 towers.
 Block wise detail of the number of stories in each block:

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Table 2.1: Block wise details
Block –A 2B + G + 14 6 Flats
Block –B 1B + G + 14 5 Flats
Block –C 1B + G + 11 5 Flats
Block –D 2B + G + 14 4 Flats
Block –E 2B + G + 14 5 Flats
Block –F 2B + G + 11 4 Flats
Block –G 2B + G + 14 5 Flats
 The subsurface floors designed for parking purpose.
 These subsurface floors are well protected by retaining walls.
 Each block consists of 2 lift wells and 1 stair case.
2.4 Execution of work
1. Site/ jungle clearance
2. Markings using total station
3. Earth work excavation
4. footings
5. backfilling
6. plinth beam
7. columns
8. beams and slab
9. brick work
10. service fittings
11. plastering
12. flooring
13. tiling
14. dadoing
15. ceiling
16. finishing.

7
Fig. 2.3 : Current position of the construction project.
2.5 Earth work excavation
Once the R.L of every point is known and the top level of the plinth beam is specified in the
drawings the depth of the foundation can be determined accordingly by subtracting the
depths of plinth beam, pedestal, footing and p.c.c. The value of maximum depth is
considered and till that depth a box type excavation is done with some extra clearance to
work. Even if after the excavation to the required depth if there is no hard soil the excavation
is to be continued. Earth excavators are brought in to the location to start the work. Auto
level is to be fixed at a reference position in order to check the depth of excavation being

8
done during the process. During the excavation it is very important to consider the lift and
lead of the material as sometimes it may be used for backfilling.
At the site:
Depth of excavation: 5-6m from ground level
Soil present: Clayey soil
Rock present: Granite
2.6 Footings
Once the excavation is done now using the foundation drawing the center and four corners of
each footing in built-up area is marked using total station. And formwork is erected for
laying p.c.c for each footing. If the area at a footing has rock bed it is chipped off to a small
thickness and 25mm diameter holes are drilled into it and anchor bars of 20 mm diameter are
placed into it up to 600 mm depth and filled with lean concrete of 1:3:6 in level. If it has no
rock bed then formwork is raised and p.c.c is casted into it. Now it is cured for 7 days and
then the footing steel is laid over it after it is laid the supervisor should carefully check it and
give permission for casting. In a similar way pedestal and column is also casted. Once all the
footings are casted they are checked using the auto level for the bending and height
variations of all footings.
At the site:
Grade of concrete: M 25
Cover: 75 mm
Reinforcement: 10mm, 12mm and 16mm diameter steel bars
P.C.C. : 100 mm thick (M 7.5 grade of concrete)

9
Fig. 2.4: Block-C footings details
Fig: 2.5 Typical isolated footing & pedestal details

10
Fig.2.6: Typical combined footing details
2.7 Backfilling
The backfilling is to be done only after curing time of the footing. The backfill is to be done
in layers. Each layer of backfill should not be more than 200mm. Then each layer is
compacted to 95% of dry density at optimum moisture content.
2.8 Columns
Column is a compression member whose effective length is greater than 3 times the least
dimension of the member i.e., (leff / b)>3. Minimum eccentricity for axial loaded columns,
emin = (Unsupported length of the column/ 500) + (Lateral dimension/ 30) subjected to a
minimum of 20mm.

11
At the site:
Reinforcement: 12mm, 16mm, 20mm and 25mm diameter steel bars with stirrups of 8mm
diameter steel bar.
Stirrup spacing: 200mm center to center.
Fig. 2.7: Block – G, flat no. 04, Columns layout.

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Fig. 2.8: Block- G, Flat no. 04, Columns details.
2.9 Beams and Slabs
Beams are the horizontal members of a structure carrying transverse loads whereas Slab is a
large, thick, flat piece typically rectangular or square in shape. Beams and Slabs are laid
monolithically to achieve a consistent in the entire structure. They can also pour in non-
monolithically. Both methods will work fine as long as the construction joints are wisely
chosen.
2.9.1 Beams:
Beams are of two types based on reinforced sections. If beam reinforced on tension side in
the direction of bending is called singly reinforeced section and if reoinforced on both
tension and compression sides is called doubly reinforced beams. Different types of beams
based on support conditions are simply supported beam, cantilever beam, fixed beam,

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continous beam and overhanging beam. In side face reinforcement if total depth exceed 450
mm and beam is subjected to torsion and if total depth exeeds 750mm and beam not
subjected to torsion.
As per codal specifications: Effective span: smaller of the following two criterion. a)
Distance b/w centre to centre of supports. b) Clear distance b/w supports plus effective depth
of slab. c) For cantilevers, clear overhang + (d/2).
Fig. 2.9: Curtailment of bars in beams
2.9.2 Slab:
Types of slab:
1) Slabs spanning in one direction: Supported at two opposite ends.
2) Slabs supporting on all four side:These are futher classified into two types based on aspect
ratio (ly /lx ).
a) One way slabs: if (ly/lx) > 2. b) Two way slabs: if (ly/lx) < 2.
Loads acting on the slab are:
 Dead load of slab.
 Load of floor finish.
 Live load.
Basic values of span to effective depth ratios for spans upto 10m: Cantilever – 7, Simply
supported - 20, Continuous – 26
If two way slabs of small spans upto (3.5 m) with mild steel span to over all depth
ratios for loading class upto 3 kN/m2
are, Simply supported slabs- 35, continuous- 40

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At the site:
Grade of concrete: M20
Fig. 2.10: Typical Slab details (Block- C)
Table 2.2: Reinforcement details of slabs (Block-C)
S. No. Name Slab
thickn
ess (in
mm)
Reinforcement
along short span
Reinforcement
along long span
Bottom Top Bottom Top
1 S1 130 8mm dia -125
C/C
1- 8 mm dia
(ext)
8mm dia –
175 C/C
1-8 mm dia
(ext)
2 S2 130 8mm dia -250
C/C
1-8 mm dia
(ext)
8mm dia –
300 C/C
-
3 S3 150 8mm dia -150
C/C
1-8 mm dia
(ext)
8mm dia –
250 C/C
-

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4 S4 150 8mm dia -175
C/C
1-8 mm dia
(ext)
8mm dia –
200 C/C
1-8 mm dia
(ext)
5 S5 130 8mm dia -300
C/C
1-8 mm dia
(ext)
8mm dia –
300 C/C
1-8 mm dia
(ext)
6 S6 130 8mm dia -
200C/C
1-8 mm dia
(ext)
8mm dia –
250 C/C
1-8 mm dia
(ext)
Fig.: 2.11: Typical Curtailment details of Slab reinforcement
2.10 Staircase
A staircase is a sequence of steps and it is provided to afford the means of ascent and descent
between the floors and landings. The space or opening occupied by the stair is called stair
way. This should be located in an easily accessible to all members of the family.
The step is composed of a tread and riser. Tread is a part of the stairway that is stepped
on. Width of each tread is 300mm. The riser is a vertical portion between each tread on the
stair. Depth of each riser is 150mm or 170mm.
At the site:
Tread: 300 mm
Riser: 150mm or 170mm

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2.11 Lift walls
Lift walls are which encloses a lifting machine. The inner surface of all walls shall form a
continuous vertical surface. The lift walls shall have sufficient structural strength to support
at least the loads which may be applied by the machine, gear operations, jacks, guides and
loads in the machine.
At the site:
Reinforcement: 12mm, 16mm, 20mm and 25mm diameter steel bars
2.12 Retaining walls
A retaining wall is a structure that holds or retains soil behind it. Where the height of the
retaining wall is several feet, the earth may put considerable stress on the wall. Therefore, it
is important to build the wall according to the plans of the designer.
At the site:
Reinforcement: 10mm & 12mm diameter steel bars.
2.13 Arrangement of rooms
 Living room
 Dining hall
 Kitchen
 Bedroom
 Toilet
 Utility

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 Balcony
Fig. 2.12: Lift walls Fig. 2.13: Retaining wall
Fig. 2.14: Room dimension details of Block- G, 6th
floor, flat no. 04

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2.14 Block masonry
Block masonry is an art of individual blocks laid in and bound together by mortar in a proper
systematic manner gives homogeneous mass which can withstand forces without
disintegration. There are many rules for bonding and they are mainly related to the different
bonds such as the English bond, the Flemish bond, the Stretcher bond and the Header bond.
Bonding shall be in such a way that no vertical joint of one course is exactly over the one
below. The maximum block wall height per day should not exceed more than 12 to 14 layers.
Because the added weight by each new brick layer needs to be carried by the mortar.
At the site:
Thickness of wall: 200mm, 150mm & 100mm
2.15 Lintels
Lintel is a horizontal flexural member which spans over the openings in the walls for doors,
windows, ventilators, cupboards etc. The load of masonry above the opening is transferred to
the wall by flexural action of the lintel so that frames of doors, windows etc. are not unduly
loaded. The end bearings for the lintel should be at least 200 mm. The width of lintels is
same as that of wall.
2.16 Plastering
Plastering is the process of covering rough surfaces of walls, columns, ceilings and other
building components with thin coat of mortars to form a smooth durable surface. The coating
mortar is termed as plaster. Plastering is done to achieve the following objects:
 To protect the external surfaces against penetration of rainwater and other atmospheric
agencies.
 To give smooth surface in which dust and dirt cannot lodge.
 To give decorative effect

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 To protect surfaces against vermin.
 To conceal inferior materials or defective workmanship.
At the site:
Internal plastering: 15mm of double coat .
External plastering: 20mm of double coat.
Mortar mix: 1:5 internal; 1:4 & 1:6 external
Ceiling plastering: 12mm single coat
Fig. 2.15: Lintel over door opening Fig. 2.16: Ponding water over slab.
2.17 Curing of concrete
The development of strength of concrete is due to ‘Hydration of cement’ that takes place
only due in water filled capillaries. If strength development has to continue, water shall be
present in pores without evaporation till development of strength is complete. The
environment provided for proper hydration of cement paste in cement concrete is called
curing of concrete.
Lintel

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2.18 Design mix data
Table 2.3: Client (REFL) approved design mix data sheet
Source: Batching plant
S. No. Description of
material
Grade & weight of material in (kgs)
M7.5 M20 M25 M30
1 Cement 120 256 272 300
2 Flyash 120 64 68 70
3 20 mm aggregate 558 640 650 649
4 12mm aggregate 457 430 430 457
5 CRF (dust) 913 800 780 745
6 Admixture 1.7 2.3 2.4 3.0
7 Water 189 185 185 184
2.19 Conclusion
In this chapter I have understood that every construction project is unique in a variety of
ways. Each construction project is built as a one-of-a-kind structure or facility. The
construction of a building will consists of many separate tasks, starting with excavation for
drainage and foundation, then footings, followed by laying columns, beams, slab and soon. It
is very important however to note that there is much interdependence between these tasks,
they must be carried out in the correct sequence and the scope for overlapping them is very
limited.

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Chapter – III
Material Details
3.1 Introduction
Building materials are items and products used within the construction of building and
structures. In ideal environments, most common construction materials are very durable and
can last indefinitely. However, design or construction deficiencies or lack of proper
maintenance can result in less than ideal conditions under which construction materials will
degrade. Degradation can take many forms, including chemical reactions, consumption by
living organisms and erosion or mechanical wear. Traditional materials which are used in
construction are steel, concrete and wood.
3.2 Materials used
3.2.1 Concrete Blocks:
At the site, solid concrete blocks in the size of 400mm x 200mm x 100mm, 400mm x 150mm
x 150 mm and 400mm x 200mm x 200mm have been used for block masonry. These blocks
made with mixture of cement, dust, 6mm size aggregates and water. Concrete blocks must be
of good quality and without visible cracks for a load-bearing wall. Generally, the blocks
should be true to size and shape, with straight edges and even surface, so as to facilitate
laying them into position without using too much mortar.
3.2.2 Aerocon Blocks:
Interestingly, Aerocon blocks were used to build some walls to reduce the load acting. The
Aerocon blocks are Autoclaved Aerated concrete (AAC) blocks made with a mixture of
cement, fly ash, lime, an aerated agent and water. These blocks in the size of 600mm x

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200mm x 150mm have been used for block masonry. The characteristics of these blocks are
light weight, fire resistance, sound insulation, thermal insulation, strength and durability,
perfect finish and dimensional stability and consistent quality control. The only concern with
Aerocon block is their higher price when compared to the traditional bricks.
3.2.3 Coarse and fine aggregates
Aggregates are of two types: Fine and coarse aggregates. According to IS 383, fine
aggregates are defined as aggregate most of which will pass through 4.75 mm IS sieve and
entirely retained on 75 µ sieve and coarse aggregate is which retained on 4.75 mm sieve and
pass through 80 mm sieve. Rounded particles produce smoother mix for a given water
cement ratio. Crushing strength of good aggregate is about 299 N/mm2
.
3.2.4 Cement
Cement is a mixture of 60 to 65% lime, 16 to 25% silica and 3 to 8% alumina, which are
intimately mixed together with water to form into a slurry, which is subsequently heated,
dried, calcined and ground to a very fine powder. A small proportion of gypsum is added
before grinding in order to control the rate of setting. When water is added to cement, the
cement hydrates and during the chemical reactions, which takes place while the cement is
setting, an increase in temperature occurs and a considerable quantity of heat is generated.
Ordinary Portland Cement of 53 grade kind of cement has been used at the site.
Cement can be safely stored in bags for a few months if kept in a dry room. During the
monsoon time, the cement storage plays an even more role, since the relatively higher
humidity accelerates the deterioration process of the cement.
Ordinary Portland cement, which has been stored for over six months, should not be
used for masonry work.

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3.2.5 Water
The workability of a mortar increases as the water content of the mix is increased. Water
lubricates the mixture. However, increased water content will cause a decrease in strength,
produce cracks (shrinkage) and decrease density. Therefore, not only the quality, but equally
important the quantity of the water is important for producing a good mortar and brick
masonry work. Water should be stored where no contamination is possible. Water stored in
clean drums or covered tanks is preferred. The age of water, or the storage time does not
affect the cement mortar quality in any way.
3.2.6 Fly ash
Fly ash is one of the residues generated in combustion of coal. Fly ash comprises of fine
particles which rise with the flue gases. Fly ash, being primarily pozzolanic, can actually
replace a percentage of the Portland cement, to produce an even stronger, more durable and
more environment friendly concrete. The initial compressive strength is low but as days pass,
fly ash concrete gains more strength and eventually has a lot more strength as compared to
normal Portland cement
3.2.7 Admixture
Admixtures are additives that are introduced in a concrete mix to modify the properties of
concrete in its fresh and hardened states. Daracem927-Grace has been used in concrete mix
as an admixture agent at the site. Daracem is an aqueous solution of chemical dispersants
combined with other chemicals which increase its beneficial effects on the quality and
plasticity of a concrete mix. Daracem provides improved slump retention in flowable
concrete. It is ideal for low water/cement ratio concrete designed for high early compressive
and flexural strengths with exceptional workability and flow characteristics.

24
3.2.8 Steel
Concrete is much weaker in tension than in compression. Its tensile strength is approximately
10% of its compressive strength. Therefore, concrete is generally used in conjunction with
steel reinforcement, which provides the tensile strength in concrete members. Steel also
bonds well with concrete. The bond between steel and concrete is due to the chemistry of the
two material, which produces a chemical bond between them.
Steel particulars of 8mm, 12mm, 16mm, 20mm, 25mm and 32 mm diameter Fe 500
grade TMT steel bars have been used in the site.
3.2.9 Cover Blocks
Cover blocks are placed to prevent the steel rods from touching the shuttering plates and
there by providing a minimum cover and fix the reinforcement as per the drawings.
Sometimes it is commonly seen that the cover gets misplaced during the concreting activity.
To prevent this, tying of cover with steel bars using thin steel wires called binding wires is
recommended. Ideally, cover should have strength similar to the surrounding concrete, with
least perimeter so that chances of water to penetrate through periphery will be minimized.
Provision of minimum covers as per the Indian standards for durability of the whole structure
should be ensured.
Table 3.1: Size of cover blocks details
Structural Element Cover to reinforcement (mm)
Footing 50
Columns 40
Plinth beam 25
Retaining wall 25 for earth face & 20 for other face
Slabs 15
Lift wall 15
Beams 25

25
Fig. 3.1: Beam cover blocks
3.2.10 Shuttering or Formwork
As fresh concrete is in plastic state when it is placed for construction purpose so, it become
necessary to provide some temporary structure to confine and support the concrete till it
gains sufficient strength for self- supporting. The term shuttering or formwork includes all
forms, moulds, sheeting, shuttering planks, poles, posts, standards, struts, bolts, wedges and
all other temporary supports. Formwork shall be made to the exact dimensions within the
permissible tolerances. Required thickness and quality of plywood conforming to IS 6461
shall be used to meet the requirements of design and surface finish. For satisfactory
performance, formwork must be adequately strong and stiff to carry the loads produced by
concrete, the workers placing and finishing the concrete and any equipment or materials
supported by the forms.
Form work was removed in such a manner as would not cause any shock or vibration that
would damage the concrete. Before removal of props, concrete was exposed to ascertain that
the concrete has sufficiently hardened.
As a guideline with temperature above 20 degree following time limits should be
followed:
Cover block

26
Table 3.2: Formwork removal period in the site
Structural Component Age
Footing 1 day
Sides of beams, columns, lintels & wall 2 days
Underside of beams spanning less than 6m 14 days
Underside of beams spanning over 6m 21 days
Underside of slabs spanning less than 4m 7 days
Underside of slabs spanning more than 4m 14 days
Flat slab bottom 21 days
Fig. 3.2: Erection of shuttering Fig. 3.3: Column formwork Fig. 3.4: Scaffolding
3.2.11 Scaffolding
Scaffolding also called staging is the basis of most construction projects it is a temporary
structure used to support a work crew and materials to aid the construction, maintenance and
repair of buildings. This consists of a frame work of standards, ledgers, putlogs etc.,
constructed parallel to the wall at a distance of about 1.20 metres. The standards were placed
at 2 to 2.5m interval. Ledgers connected the standards and were provided at a vertical

27
interval of 1.2 to 1.5 m. Putlogs were placed with one end on the ledgers and other end in the
hole left in the wall, at an interval of 1.2 to 1.5m.
3.3 Source of materials
Table 3.3: Materials and their sources
Material Source
Cement ( OPC 53 grade) Nagarjuna cements ltd.
ACC cements ltd.
Birla Shakti cements ltd.
Fine aggregates (Crushed Rock Fines) Ramky One Kosmos, Nallagandla, Hyderabad.
Coarse aggregates (Angular crusher
broken coarse aggregate of max. size
10mm & 20mm)
Ramky One Kosmos, Nallagandla, Hyderabad.
Steel ( Fe 500 TMT bars)
Particulars: 8mm, 12mm, 16mm, 20mm,
25mm & 32mm
Electro steel ltd.
JSW steel ltd.
VSP steel
ESSAR steel ltd.
SAIL- Steel Authority of India.
MS Agarwal foundries (p) ltd.
Drinking water Borewell
Vengamamba supplier
Water for construction activity Vebgamamba supplier
Fly ash NTPC – Vijayawada
Solid blocks Ramky One Kosmos, Nallagandla, Hyderabad.
Aerocon Blocks Aerocon Enterprise, Hyderabad.

28
3.4 Testing of Materials
Right selection of quality materials adds to the economy and service life of a structure. The
design of structures is usually based on the presumption that each of the materials to be used
in construction of a typical structure has certain characteristics, this presumption makes its
mandatory to verify that the materials used in construction have the assumed characteristics.
This can only be ensured by regular testing of materials according to certain standards which
will provide a clear picture of material characteristics. Following are the tests which have
been performed by me at quality control lab under guidance
Fig. 3.5: Quality Control lab at the site.
3.4.1 Tests on cement
a) Fineness
 It is an index of grinding.
 Determined by sieving through 90 µ (IS sieve no. 9)
 The residue after sieving should not exceed 10% by weight for OPC.

29
b) Consistency
 Consistency of cement means the percentage of water required to make a workable
cement paste.
 Determined by Vicat’s apparatus using Vicat’s plunger (1cm diameter)
 As per Vicat’s test “ The percentage of water added to the cement at which the needle can
not penetrate 5 to 7 mm from bottom of the mould is called consistency”..
 For OPC consistency is around 30%.
c) Initial setting time
 The time at which cement starts setting process.
 Determined by Vicats’s apparatus using Vicat’s needle (1mm square needle)
 For the test cement is mixed with 0.85 times the water required for standard consistency.
 As per Vicat’s test “the time lapsed since the addition of wter to the cement up to the time
at which the needle can not penetrate 5 to 7 mm from the bottom of the Vicat’s mould.
 For OPC initial setting time should not be less than 30 minutes.
d) Final setting time
 The time at which the cement ends its setting process and becomes hard.
 Determined by Vicat’s apparatus using Vicat’s needle with annular collar of 5mm
diameter.
 As per the test “ the time lapsed since the addition of water to the cement up to the time at
which needle with annular collar can only make a mark on the hard cement surface.
 For OPC final setting time should not be more than 10 hours.
e) Soundness
 The expansion of cement due to the presence of free lime and magnesia is called un-
soundness.

30
 Determined by Le-chatlier apparatus.
 For the test cement is mixed with 0.78 times the water required for standard consistency.
 As per the test apparatus the expansion should not be more than 10mm for the cement to
be sound.
 If the expansion exceeds 10mm after standard test procedure, the cement should not be
used.
f) Specific gravity of cement:
 Using kerosene and specific gravity bottle the test is conducted at 270
C.
 For OPC specific gravity is around 3.1.
Table 3.4: Physical properties of cement (OPC 53 grade) test results.
Sl.
No.
Test Conducted Results Requirement as Per IS: 12269-
2013 (Table 3) (Foreword &
Cl. 6)
1. Initial setting time (minutes) 202 30 (minimum)
2. Final setting time (minutes) 254 600 (maximum)
3. Soundness (mm) 1 10 (maximum)
3.4.2 Tests on Aggregates
a) Grading of aggregate:
 Used to determine the particle size distribution in a sample of aggregate called gradation.
 Sieve analysis is used for gradation.
 Sieve sizes 80mm to 150 µ are used in the sieve analysis.

31
b) Fineness Modulus:
 It is an index of grading of aggregate in a given sample.
 Fineness modulus is determined by sieve analysis.
 FM = The ratio of the cumulative percentage of material retained on each sieve/ 100.
Fig. 3.6: Vicat apparatus. Fig. 3.7: A set of IS sieves
Table 3.5: Characteristics of fine aggregate
Source: Batching plant (Crusher sand) Weight of sample:1000 gms
Date of testing: 01-06-2015
IS sieve
size
Weight
retained
(gm)
Cumulative
weight retained
(gm)
% weight
retained
%weight
passing
Specifications
as per IS: 383
4.75mm 14 14 1.4 98.6 90-100
2.36mm 159 173 17.3 82.7 75-100
1.18mm 203 376 37.6 62.4 55-90
600µ 192 568 56.8 43.2 35-59
300µ 217 785 78.5 21.5 8-30
150µ 120 905 90.5 9.5 0-10
pan 95 1000 100 0 0

32
Table 3.6: Characteristics of coarse aggregates
Source: Batching plant (20 mm coarse aggregate) Weight of sample: 5000 gms
Date of testing: 01-06-2015
IS sieve
size
Weight
retained
(gm)
Cumulative
weight
retained (gm)
% weight
retained
%weight
passing
Specifications
as per IS: 383
40mm 0 0 0 100 100
20mm 406 406 8.12 91.88 85-100
10mm 3985 4391 87.82 12.18 0-20
4.75mm 598 4989 99.78 0.22 0-5
pan 11 5000 100 0 0
3.4.3 Test on fresh concrete
Workability (Slump cone test)
 Slump cone of bottom dia. 20cm, top dia. 10 cm and height 30 cm.
 Three layers of concrete. Each layer tamped for 25 times by a standard tamping rod of
16mm dia. and 60 cm, length.
 The subsidence of concrete under gravity in ‘mm’ is called slump.
Table 3.7: Recommended slumps for various concrete works (in ‘mm’)
Type of member Minimum Maximum
Mass concrete structures 25 50
Un reinforced footings 25 75
Reinforced slab beams,
foundations, footings &
walls
50 100
Pumped concrete, slip
form work
75 100

33
3.4.4 Compression test
As per BIS 15 cm cubes, cured for 7 days and 28 days crushing strength determined. Grades
are classified based on 28 day strength. Example: M15, M20, M25
Fig. 3.8: Compression testing Fig. 3.9: Concrete blocks stored
machine. in water before testing.
Table 3.8: Compressive test results
Location & Structure: Block -G – Slab Beam 10th
floor Grade of concrete: M 35
Date of casting: 27-05-2015 Date of testing: 02-06-2015
Cube No. Weight of cube
(gm)
Load applied in
(KN)
Compressive strength
(N/mm2
)
1 8235 834 37.07
2 8176 864 38.40
3 8350 816 36.27
Average Compressive strength: 37.29 N/mm2

34
3.5Equipment used
Construction equipment are one of the very important resources of modern-day construction,
especially in infrastructure projects. Such project utilize equipment for most of the works
including earthmoving operations, aggregate production, concrete production and its
placement and soon. In fact, one cannot think of any major construction activity without
involvement of construction equipment. The selection of the appropriate type and size of
construction equipment often affects the required amount of time and effort and thus the job-
site productivity of a project. The project site has observed many equipment includes:
a) Excavators
b) Back hoe
c) Earth compaction equipment
d) Smooth wheel rollers
e) Sheep foot rollers
f) Vibrators
g) Dump truck
h) Tippers
i) Trailers
j) Tower crane
k) Builder hoist
l) Concrete transist mixers
m) Concrete pumps etc.
Fig.: 3.10 Back hoe Fig. 3.11: Roller

35
Fig. 3.12: Crushers
Fig. 3.13: Tower crane Fig. 3.14: Builder hoist
Fig. 3.15: Concrete transist mixer Fig. 3.16: Concrete pumping machine

36
3.6 Batching plant
This is used for mixing different ingredients in required proportion. It consists of storage bins
with adequate separate compartments shall be provided in the batching plant for cement,
flyash, fine and coarse aggregates. Each bin compartment shall be designed and operated so
as to discharge efficiently and freely, with minimum segregation, into the weighing hopper.
Means of control shall be provided so that, as the quantity desired in the weighing hopper
shall be constructed so as to eliminate accumulations of tare materials and to discharge fully.
i) Front view ii)Back view iii) Operator’s cabin
Fig. 3.17 ( i, ii & iii): Batching plant
Fig. 3.18: Concrete blocks making machine at the site.

37
3.7 Conclusion
In the process of executing the project all the sophisticated equipment and materials have
been used. When choosing materials, it is important to recognize that a product is best from
qaulity and economical point of view.

38
Chapter –IV
Human Resource Management
4.1 Introduction
Human resource is the most valuable asset in construction industry. Human Resource
Management includes the processes that organize, manage and lead the project team.
4.2 Project team
Line and staff organization
Manager
HR
Manager
Safety
Manager
Construction
Manager
Quality
R.I.L. Director
Project Manager
Team Leader
Manager
Engineer
Supervisor
Skilled worker Unskilled worker
Senior
Engineer
Junior
Engineer

39
Table: 4.1 Project team
Person Name Role Authority Responsibility
1. Mr K.
Anjaneyulu
Project
Manager
Has the authority to
do change in project
management plan.
Will monitor the whole
work and guide the team
about any difficulty. Also
make sure that all the
tasks performed are with
in budget.
2. Mr K. Madan
Mohan
Team Leader Will lead the team Show all results to the
project manager and
solve issues between
team members.
3. Mr P. Babu
Roa
Human
Resource
Manager
Has an authority to
over see the work of
labours
Will reports to the higher
authority.
4. Mr Jan Basha
Shaik
Quality
manager
Has an authority to
check the quality of
materials use in
construction.
If any change will occue
he will report to the team
leader.
5. Mr
Mallikarjuna
Reddy
Safety
manager
Carry out safety
inspection of
building
Providing a hazard-free
workplace to the workers
of subcontractors.
4.3 Conclusion
Thus an understanding of recruitment, training and retention are the basic requirements for an
effective human resource department in the construction industry.

40
Chapter – V
Estimation
5.1 Introduction
An estimate is defined as computation or calculation of the required quantities of finished
items of work and its expenses (cost) likely to be incurred for its construction. The main
object of estimate is to know the required quantity of material, labour and cost before actual
execution. It helps an engineer to plan the construction work, for quick and proper
construction with required quality. The following data is used for preperation of an estimate:
 Drawings
 Specifications
 Rate
5.2 Methods of building estimate
The dimensions, length , breaadth and height or depth are to be taken out from the drawing-
plan, elevation ans section. From the study of drawings , the building is to imagined and
pictured in the mind and thee dimensions are to be taken out correctly. For symmetrical
foundation which is the usual case, earthwork in exacavation in foundation, foundation
concrete, brickwork in foundation and plinth and brickwork in superstructure may be
estimated by either of the following two methods:
1) Separate or individual wall method
2) Central Line method

41
Fig. 5.1: Details of Measurement and Calculation of Quantitites- Slab Concrete
5.3 Schedule of bars
The schedule of bars is a list of reinforcement bars in a tabular form giving the particulars of
bars , shape of bending with sketches, length of each, total length and total weight . For each
work type of R.C.C. work a schedule of bars is usually prepared. From the schedule of bars
the requirment of different sizes and lengths of bars may be known, and may be arabged and
bent –up during the time of construction.

42
Fig. 5.2: Schedule of bars – R.C.C. Slab

43
5.4 Conclusion
In this chhapter I have understood that for all engineering works it is required to know
beforhand the probabale quanities of different items of work in the construction activity and
its implied cost. In framing a correct estimate, care should be taken to find out the
dimensions of all the items correctly, and to avoid omissions of any kind of work or part
thereof.

44
Chapter - VI
Safety Management
6.1 Introduction
Safety concerns have always been paramount in the construction industry. Construction sites
are complex environments, with workers from multiple trades interacting in challenging
environments. The project site has observed various safety norms as per ISO standards and a
safety office is present in the project site. The company has tied up with Archana Hospital,
Miyapur 6.9km away from the construction site.
6.2 Various safety measures
Various safety measures have been taken as shown below:
Fig. 6.1 Safety Nets Fig.6.2: Fire Extinguishers Fig. 6.3: Ambulance

45
Fig. 6.4: Project safety statistics Fig. 6.5: Safety park
6.3 Conclusion
After critical and deep study of all types of activities in the construction site I found the
company thinks safety first, that is not only protecting the phisically but it benefits for the
company, do not spend extra money to recover the unwelcome accidents happened. Human
life is precious and it shoul be the constant endeavour of all stakeholders to make the
construction site a safe place to work.

46
Chapter – VII
Work experience
7.1 Introduction
Industrial case study is a class healed at site to provide an enhanced understanding of the
outside working environment before the student graduate. The main aim of this practice is
that to teach students communication with different workers or employess, to imporve their
leadership skill, team playing skill and etc. So, I found a practical knowledge at the site.
7.2 Daily activities
Day 1: (27-05-2015)
I reported to project manager of the construction site as per directions of Human Resources
of Ramky group head office. The project manager assigned me to work with qaulity control
engineer.
The quality control engineer explained me about the construction site and gave a brief details
of the organiztion background.
I went through various drawings and other documents related to the site.
Day 2: (28-05-2015)
I was introduced to the safety department. They expalined me the precautionary steps that
one should to be followed site for their own safety while working in the construction site.
I observed the foundation work of parking ramp.

47
Day 3: (29-05-2015)
I observered construction of retaining wall using related drawings.
The quality control engineer explained me various tests that they perform in the quality
control lab.
I observed the operation of concrete batching palnt.
Day 4: (30-05-2015)
I observed the laying of coulmn reinforcement, plinth beams and form work for coumns of
parking ramp.
Fig. 7.1: Laying of footing Fig. 7.2 Laying of pedastal
reinforcement for parking ramp for parking ramp
Day 5: (01-06-2015)
I observed the setting up and erection of shuttering for block- G, 10th level slab.
I performed sieve analysis test on aggregates and setting time of cement test in quality
control lab.

48
Day 6: (02-06-2015)
I observed the arrangment of steel bars in Block- C, 10th
level slab.
I performed the compressive test on concrete cubes in the quality control lab.
Fig. 7.3: Arrangement of reinforcement in Block –C, 10th
level slab.
Day 7: (03-06-2015)
I observed the block masonry work in the Block-G, 6th
level.
I observed the plumbing and electric works in the Block-A.
I visited a model flat.
Fig. 7.4: Concrete block work Fig 7.5: Plumbing work
Day 8: (04-06-2105)
I worked in planing and esttimation department.
I observed the manufacture of concrete blocks process.
I observed the operation of crushers.

49
Day 9: (05-06-2015)
I supervised the block masonry work in the Block-G, 6th
level.
Day 10: (06-06-2015)
I supervised the block masonry work in the block-G, 6th
level.
I reported to the project manager and concluded my industrial traning program.
7.3 Challenges I have faced
Construction projects are complex and time consuming undertaking that require the
interaction and cooperation of many different persons to accomplish. The construction
industry is typically divided into specialty areas, with each area requiring different skills,
resources, and knowledge to participate effectively in it. In order to integrate and work
closely in each section it is a challenging task to one person especially when he/she is fresh
or beginner. In fact some challenges may be solved by me but some are above my limit and
even the workers at the site also. The main challenges I have faced in the industrial training
period were shaortage of knowledge in some portion of the work at the site and weather
condtion of the site.
7.4 Overall Benefits
The benefits I have gained from the industrial program are:
 Improving practical skill
 Upgrading the theoretical knowledge
 Upgrading interpersonal communication skill
 Improving leadership skill
 Time management skills as well as self motivation
 Work ethics and related issues.

50
Chapter - VIII
Conclusion
The industrial training program at Ramky One Kosmos phase-I project, Nallagandla,
Hyderabad, has not only broadend my educational background but enhanced my proffesional
career. I have been fortunate enough to interact with the engineers who made me aware of
the practical aspects involved at various stages of the construction project.
I was given exposure in almost all the departments at the site. The friendly welcome
from all the engineers and employees is appreciating, sharing their experience and giving
their peace of wisdom which they have gained in long journey of work. I hope this
experience will surely help me in my future and also in shaping my career. Over all the
indutrial case study program laid sound foundation for me to start my career. It will be
definitely sensible to scale this practice up and to replicate in other disciplines as well.
From the field study report, it is evident that the construction is going on full swing,
but from according to the project monitoring chart, the project is lagging behind the schedule.
Gracing the Ramky One Kosmos, this most happening realty destination for the elite
will be a self- sufficient and all encompassing commnity where its residents will prosper
forever.

Industrial case study report (Final)

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