Internship Report_Vishak

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INTERNSHIP REPORT
RMZ - GALLERIA PROJECT
10/07/2013 – 12/08/2013
SUBMITTED BY:
Vishak.O
USN: 1BI10CV088
Final Year Civil Engg. (UG)
Dept. Of Civil Engg.
Bangalore Institute of Technology

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INDEX
1. Declaration 3
2. Acknowledgement 4
3. Purposeof the project 5
4. About Larsen & Toubro 6
5. Quality Policy 10
6. EHS Policy 12
7. HR Policy 13
8. Introduction to the Project 17
9. Quality Control / Quality Assurance 21
10. Lab Experiments 23
11. Mix Design 48
12. ProjectExecution – Method Statements 60
13. Formwork 69
14. Conclusion 73

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DECLARATION
I, Vishak.O hereby declarethat this project has been completed to the best of my
abilities during the time 10/07/2013 to 12/08/2013. This reportis a pre-requisite
to successfulcompletion of my one month long internship session at RMZ Galleria
Projectin Yelahanka, Bangalore as part of my Final Year Undergraduate
Programmeat Bangalore Instituteof Technology, Bangalore. This is an accurate
record of my work and all details contained in this report are within my full
knowledgeand awareness.
Mrs. Sumeet Kaur
(Cluster HR Manager, L&T ECC Division )

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ACKNOWLEDGEMENT
I, Vishak.O would liketo express my utmost gratitude to Larsenand Toubro
Constructions Buildings andFactories Independent Company ( L&T Construction,
B&F IC ) for having given me this opportunity to undertakemy Internship at
prestigious RMZ Galleria Projectin Bangalore.
This was a fantastic learning experience during the courseof the one month I was
part of it. The very unique and sophisticated construction practices and challenges
employed in the projectwas
I would like to thank my College and Principal Dr. K.R Suresh, Placement Officer
Dr. AswathM.Uand HOD Civil Engg. Dr. A.G Nataraj for having given me the
opportunity to work in this project.
I also wantto express my heartiest thanks to the Project Headof RMZ Galleria,
Mr. K. Nataraj, Chief Engineer Mr. Nagaraj and Cluster HR Manager Mrs. Sumeet
Kaur for their supportand help.
I would like to thank Mr. Ravi, Mr. Pankaj Thakur, Mr. N.Rajesh, Mr. Mahesh,
Mr. Kishore, Mr. Rithwik K Nair, who helped me positively in spite of their busy
schedules. And last but not the least I also thank all other heads, engineers, staff
and workers of the projectwho helped me at somepoint of time during the
courseof my project.
Thank You OneAnd All

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PURPOSE OF THE PROJECT
The project has been undertaken by me to acquire knowledgeon the latest
construction techniques being employed, sophisticated construction equipment,
application of theoretical know-how on the site, a thorough understanding of
formwork employment, reinforcementspecifications and layouts of slabs, beams
and columns.
The project also stresses on the importanceof safety, and the need to protect
lives, safeguard construction equipment and not endanger the environment in the
process of construction activity.
This projectis basically an overview of a few of the constructionalas well as non-
constructionalelements/practices involved in the RMZ Galleria Project. The
projectprimarily involves material testing, formwork study, concreteand
batching plant study, reinforcementdetail study including Bar Bending and most
importantly site inspection and understanding of how theoretical procedures are
broughtinto practice at site.

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ABOUT LARSEN & TOUBRO
Larsen & Toubro Limited is the biggest legacy of two Danish Engineers, who built a
world-class organization thatis professionally managed and a leader in India's
engineering and construction industry. Itwas the business of cement that brought
the young Henning Holck-Larsen and S.K. Toubro into India.
They arrived on Indian shores as representatives of the Danish engineering firm F
L Smidth & Co in connection with the merger of cement companies that later
grouped into the Associated Cement Companies.
Together, Holck-Larsen and Toubro, founded the partnership firmof L&T in 1938,
which was converted into a limited company on February 7, 1946. Today, this has
metamorphosed into one of India's biggestsuccess stories. Thecompany has
grown fromhumble origins to a large conglomerate spanning engineering and
construction
Seven decades of a strong, customer-focused approach and thecontinuous quest
for world-class quality have enabled it to attain and sustain leadership in all its
major lines of business.
L&T has an international presence, with a global spread of offices. A thruston
international business has seen overseas earnings grow significantly. Itcontinues
to grow its overseas manufacturing footprint, with facilities in China and the Gulf
region. The company's businesses aresupported by a wide marketing and
distribution network, and haveestablished a reputation for strong customer
support. L&Tbelieves that progress mustbeachieved in harmony with the
environment. A commitment to community welfareand environmental
protection are an integral part of the corporate vision.

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Operating Divisions:
 Engineering & Construction Projects (E&C)
 Heavy Engineering (HED)
 Engineering Construction & Contracts (ECC)
 Electrical & Electronics (EBG)
 Machinery & IndustrialProducts (MIPD)
 Information Technology & Engineering Services
The following are the ventures of L&T:
 Hydrocarbon IC
 Buildings & Factories IC
 InfrastructureIC
 Metallurgical & Material Handling IC
 Power Transmission & Distribution
 Heavy Engineering
 Shipbuilding
 Power
 Electrical & Automation
 Machinery & IndustrialProduct
BUILDING & FACTORIES
The Buildings & Factories IndependentCompany is equipped with the domain
knowledge, requisite expertise and wide-ranging experience to undertake
Engineering, Procurementand Construction (EPC) of all types of building and
factory structures.
• Commercial Buildings & Airports
• Residential Buildings & Factories

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RESIDENTIAL BUILDINGS &FACTORIES
L&T undertakes turnkey construction of a wide range of residential buildings and
factory structures. Projects areexecuted using the cutting edge technology,
sophisticated construction equipment and project management tools for quality,
safety
and speed.
• Residential Building
• Factories
FACTORIES
L&T offers design and turnkey construction of heavy and light factories, cement &
plants including Defence Projects using the latest construction technology, with a
focus on Quality, Safety and Speed. The spectrumcovers the following
• Heavy & Light Factories (HLF) –Automobile& Ancillary Factories, Glass
plants, Food processing Factories, Pharmaceuticalplants, Warehouses &
Logistics Parks, Workshop Complexes, Solar thin film manufacturing units,
etc.
• Cement & Plants (C&P) – Cement Plants, Sugar Plants, Distillery Plants,
Food Grain storagestructures, Pulp & Paper Mills, Textile Mills etc.
• Defence –Construction of Manufacturing Facilities and WarehouseFacilities for
Defence.

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QUALITY POLICY
At L&T, Environment, Health & Safety (EHS) is given the highest priority. The EHS
policy enunciated by the Corporate Management lays emphasis on Environment,
Health and Safety through a structured approach and well defined practices.
Systems and procedures havebeen established for implementing the requisites at
all stages of construction and they are accredited to the Internationalstandards
of ISO 9001:2008, ISO14001:2004 and OHSAS 18001:2007.

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WORK CULTURE
Work Culture emphasizes :
 Freedom to experiment
 Continuous learning and training
 Transparency
 Quality in all aspects of work
 Rewards based on performanceand potential
TRAINING
Human Resources Department believes that Quality is the hallmark of any
successfulventure. Quality Training and Development of Human Resources is
realized through Identifying training needs within the Organization and designing
and implementing those need based training programs to bring about continuous
up-gradation of knowledge, skills and employee attitudes.

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VISION & MISSION
VISION
L&T shall be professionally managed Indian multinational committed to total
customer satisfaction and enhancing shareholder value. L&T shall be an
innovative entrepreneurial and empowered team constantly creating value and
attaining global benchmarks. L&Tshallfoster a culture of caring trustand
continuous learning while meeting expectations of employees, stakeholders and
society.
MISSION
To achieve excellence in the field of Engineering, Procurementand Construction
through world class practice and standards in quality, Safety and Project
Management

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INTRODUCTION TO THE PROJECT
Name: L&T – RMZ Galleria
Location: Yelahanka New Town,
Opp. Yelahanka Traffic Police Station,
Bangalore
Project Component Structures: Residential Block ( Ground floor + 18F ) – A,B,C,D
Hotel Block
Office and Retail Block
Client: RMZ Corp
Contractor: Larsen & Toubro Construction, B&F IC
Consultant: Manucons
Architects: DP Architects PTE Ltd
Landscape Architects: Sitetectonix
ConstructionDeadline: February 2014

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The RMZ Galleria is a state of the art multi-luxury project located at Yelahanka
New Town, Bangalore along its northern flanks. This successful venture is the
combined effort of Larsen & Toubro and RMZ Corp. Located in the vicinity of the
New Airport Road, RMZ Galleria boasts 4 humungous residential towers, named
Sienna, Amber, Coral and Citrine together carrying 322 aesthetically designed
homes.
Flanked on its northern end is the spacious and immensely facilitated office block
clubbed with the by the much awaited shopping mall, claimed to be one among
Asia’s finest. RMZ Galleria is more than just any shopping mall; it’s a unique
lifestyle experience. Its international façade and multi-experiential retail outlets
make RMZ Galleria a world-class shopping destination.
This 1 million sq ft destination mall provides a delightfully shopping experience
with its 9 screen PVR cinema, 1 lac sq. ft Hyper City hypermarket and anchor
department stores such as Shoppers Stop, Westside and Debenhams. With
extensive food offerings and over 200 stores you will be spoilt for choice ensuring
that every visit of yours is like your first one – brimming with memories,
experiences and moments.
The strategic location of RMZ Galleria in the heart of a large catchment
population, midway from the city center and the new international airport will be
critical in driving visitors to the mall. In addition, RMZ Galleria also has superior
connectivity with the Metro rail project.
On the northernmostwing towers the luxurious 4-star Hotel Block equipped with
facilities offering an out-of-the-world living experience and an unbeatable cuisine
for every check-in.

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QUALITY CONTROL / QUALITY ASSURANCE
Quality is the key componentwhich propels performanceand defines leadership
traits. At L&T Construction, Quality Standards havebeen internalized and
documented in Quality Assurancemanuals. L&TConstruction recognizes the
crucial significanceof the human element in ensuring quality. Structured training
programmes ensurethat every L&T employee is conscious of his/her role and
responsibility in extending L&T Construction’s tradition of leadership through
quality. A commitment to safety springs froma concern for the individual worker
– every one of the thousands braving the rigors of construction at numerous
projectsites. L&T, Buildings & Factories IChas a well-established and documented
Quality Management System(QMS) and is taking appropriatesteps to improveits
effectiveness in accordancewith the requirements of ISO 9001:2008. Relevant
procedures established clearly specify the criteria and methods for effective
operation, control and necessary resources and information to supportthe
operation and monitoring of these processes.
QUALITY IMPLEMENTATION ATSITE
L&T, Buildings & Factories IChas established procedurefor monitoring, measuring
and analyzing of these processes and to take necessary actions to achieve
planned results and continual improvement of these processes. Ithas also
maintained relevant procedures to identify and exercise required control over
outsourced processes, if any.
Systems and procedures havebeen established for implementing the requisites at
all stages of construction and they are accredited to the Internationalstandards
of ISO 9001:2008, ISO14001:2004 and OHSAS 18001:2007. L&Tcontinues to
maintain the trail blazing tradition of meeting the stringentquality standards and
adherence to time schedules in all the projects.

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PROJECT QUALITY PLAN (PQP):
The Project Quality Plan is prepared and formulated as a Management Summary
of Quality related activities required to meet the terms of contract. This Quality
plan sets out the Management practices and describes the Quality Management
Systembased 22 on PDCA (Plan, Check, Do and Act) Principle. The ProjectQuality
Plan comprises of two sections:
A. VOLUMEI
SCOPE:
The contents of this document are applicable to “RMZ Galleria” and “Construction
of Civil and Structuralworks for, L&TRMZ Galleria Project” that will be carried out
by Larsen & Toubro Limited, Buildings & Factories ICfor RMZ Corp. In preparation
of this document, due regard has been paid to the requirements of ISO 9001:
2008 series of SystemStandards.
PURPOSE:
This ProjectQuality Plan is prepared and formulated as a Management
Summary of Quality related activities required to meet the terms of contract.
This Quality plan sets out the Management practices and describes the Quality
Management System.

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Tests conductedinthe Material Testing Labinthe QC/QA Dept.
Exp. No: Name of Experiment Page No: Date:
1 Sieve Analysis of 12mm
aggregates
25 11-07-2013
2 Sieve Analysis of 20mm
aggregates
27 11-07-2013
3 Determination of Specific
Gravity using Pycnometer
29 11-07-2013
4 Flakiness Index 31 12-07-2013
5 Determination of silt content
in sand
33 12-07-2013
6 Determination of silt content
in sand – Wet sieve analysis
34 15-07-2013
7 Water absorption test –
crushed sand
35 15-07-2013
8 Sieve Analysis of fine
aggregates – Crushed sand
36 16-07-2013
9 Setting time of cement 38 16-07-2013
10 Fineness of cement 40 17-07-2013
11 Slump test for concrete 42 17-07-2013
12 Bulk density test of 20mm
aggregates
44 18-07-2013
13 Bulk density of 10mm
aggregates
45 18-07-2013
14 Bulk density of crushed sand 46 19-07-2013
15 Density of blocks – 8 inch 47 19-07-2013

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EXP NO: 1
NAMEOF EXPERIMENT: SIEVEANALYSIS OF 12MMAGGREGATES
REFERENCE : IS 2386 - PART1, 1977
AIM : To determine the gradation of aggregates / fineness modulus of aggregates.
APPARATUS: Heating apparatus or hot air oven, weighing machine, IS standard
sieves , camel brush, tray.
PROCEDURE :
a) Take about 2kg of sample, i.e. 12mmaggregates.
b) Preparetest sample froma larger sample by quartering or by means of sample
divider.
c) Weigh the air dried sample and successively sieveon the appropriatesieve
starting with the largest.
d) Shakeeach sieve separately over a clean tray until not more than a trace
persists.
e) Brush lightly with a light camel hair brush on the 150u and 75u sieves to
prevent blocking of apertures.
f) Plot the weight of each tray after sieving and find out fineness modulus.
OBSERVATIONS :
Weight of dried aggregates = 2kg
Fineness Modulus = Sum of cumulative % retained + 5
100

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TABULAR COLUMN :
Sl No : Size of sieve: Retention
Weight (kg)
% Retention Cumulative %
Retention
Cumulative %
passing
1 20 0 0 0 100
2 10 67 3.35 3.35 96.65
3 4.75 1669 83.45 86.3 13.2
4 2.36 157 7.85 94.65 5.35
5 PAN 107 5.35 100 0
Fineness modulus = 284.8 + 5 = 7.848
100
RESULT : The fineness modulus of the given aggregate is found to be 7.848

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EXP NO: 2
NAMEOF EXPERIMENT: SIEVEANALYSIS OF 20MMAGGREGATES
AIM : To determine the gradation of aggregates / fineness modulus of aggregates.
PROCEDURE :
a) Take about 2kg of sample, i.e. 12mmaggregates.
b) Preparetest sample froma larger sample by quartering or by means of sample
divider.
c) Weigh the air dried sample and successively sieveon the appropriatesieve
d) Shakeeach sieve separately over a clean tray until not more than a trace
persists.
e) Brush lightly with a light camel hair brush on the 150u and 75u sieves to
f) Plot the weight of each tray after sieving and find out fineness modulus.
OBSERVATIONS :
Fineness Modulus = Sum of cumulative % retained + 4
100

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TABULAR COLUMN :
Weight (kg)
Retention
Cumulative %
passing
1 20 50 2.5 2.5 97.5
2 10 1672 83.6 86.1 13.9
3 4.75 227 11.35 97.45 2.55
4 PAN 50 2.55 100 0
Fineness modulus = 286.05 +4 = 6.860
100

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EXP NO: 3
NAMEOF EXPERIMENT: DETERMINATIONOF SPECIFICGRAVITYUSING
PYCNOMETER
REFERENCE : IS 2720 - PART3 ( sec 1 ), 1980
AIM : To determine the specific gravity of the sample.
APPARATUS: Pycnometer, conicalbrass cap, washer.
PROCEDURE :
a) Clean pycnometer and dry it.
b) Find mass M1 of the pycnometer, washer and brass cap.
c) Take out 500gm of the oven dried sample and put it in the pycnometer.
d) Find the mass of the pycnometer filled with oven dried sample( M2 ).
e) Fill pycnometer to half its height with distilled water and mix it thoroughly with
a glass rod.
f) Add more water and stir it.
g) Replace the screw top and fill the pycnometer up to the hole in the conical top.
Dry the pycnometer fromoutside and find the mass M3.
h) Empty the pycnometer, clean it thoroughly and fill it with distilled water upto
the hole of the conical cap and find the mass ( M4 ).
CALCULATION :
Specific Gravity G = M2-M1
(M1-M2) - (M4-M3)

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OBSERVATIONS :
Mass of clean dry pycnometer + washer + cap = 667gm ------M1
Mass of pycnometer + Sample = 1167gm ------M2
Mass of pycnometer + sample + water = 1798gm ------M3
Mass of pycnometer + water = 1478gm ------M4
Specific Gravity G = 1167-667 = 2.78
(667-1167)-(1798-1478)
RESULT : The specific gravity of given aggregates is found to be 2.78

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EXP NO: 4
NAMEOF EXPERIMENTFLAKINESS INDEX
REFERENCE : IS 2386 - PART1
AIM : To determine the flakiness index of the given coarseaggregate.
SIGNIFICANCE : Coarseaggregates with moreflaky particles will adversely affect
the strength of concrete.
DEFINITION : It is the percentage by weight of particles in it whoseleast
dimension ( thickness ) is lesser than 3/5th
of their mean dimension.
APPARATUS: Balance, metal gauge, sieve.
PROCEDURE :
a) Take a sample of about2kg.
b) Divide the sample into 4 quadrants.
c) Select 2 opp quadrants and sieve them through the sieves arranged in the
following order – 63mm, 50mm, 40mm, 31.5mm, 20mm, 16mm, 12.5mm, 10mm,
6.3mm
d) Take the aggregate sample sieved through 63mmand retained in 50mmsieve.
Find the weight W1
e) Pass that sample through 63-50mmsizeof thickness gauge. Let the weight of
particles passing through 63-50mmslotof thickness gaugebe w1.
f) Repeat the same procedurewith 50-40mm, 40-31.5mmand likewise.

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OBSERVATION TABLE:
CALCULATION :
Flakiness Index= 12 + 115 + 60 + 15 * 100 = 10.18%
334 + 1010 + 469 + 172
RESULT : The flakiness index of given coarseaggregates is found to be 10.18%
Size of aggregate ( IS sieve ) Individual weight retained
betweensieve ( W1)
Weight of sample passing
throughrespective slotof
gauge ( w1 )
20mm - 16mm 334gm 12gm
16mm - 12.5mm 1010gm 115gm
12.5mm - 10mm 469gm 60gm
10mm - 6.3mm 172gm 15gm
Flakiness Index = ( w1 + w2 + w3 + ….. ) * 100
( W1 + W2 + W3 + … )

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EXP NO: 5
NAMEOF EXPERIMENT: DETERMINATIONOF SILTCONTENTINSAND.
AIM : To determine the silt content of the given coarseaggregate.
APPARATUS: Measuring Jar, scale
PROCEDURE :
a) Fill the jar with 100mlwater.
b) Add to it 3-4 tablets of NaOH and prepare NaOH solution.
c) Add a sampleof sand in the measuring jar up to a height of 100ml
approximately.
d) Stir contents in the jar thoroughly and allow it to settle for 10-15 minutes.
e) Measure height of sand layer ( d1 ) and height of silt layer ( d2 ).
CALCULATION :
d1 = 2.6cm
d2 = 0.18cm
Silt Content ( % ) = 0.18 * 100 = 6.92%
2.6
RESULT : The silt content presentin the given sample is found to be 6.92%
Silt Content = d2 * 100
d1

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EXP NO: 6
NAMEOF EXPERIMENT: DETERMINATIONOF SILTCONTENTINSAND – WET
SIEVING METHOD
AIM : To determine the silt content of the given coarseaggregate using wet sieve
method
APPARATUS: IS –75u sieve, distilled water, heating apparatus, weighing balance
PROCEDURE :
a) Take about 300gm of clean sand.
b) Dry it for about 15mins to remove any water content.
c) Take an 1S 75u sieve and empty the sand in it.
d) Take clean distilled water and wash the sand.
e) Keep washing till clear water flows out of the sieve.
f) Dry the sand collected in the sieve such that all water gets removed.
g) Weigh the sand ( W2 ).
CALCULATION :
W1 = 300gm
W2 = 280gm
Percentage of silt = 300-280*100 = 6.67%
300
RESULT : The silt content presentin the given sample is found to be 6.67%
Percentage of silt = W1-W2 *100
W1

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EXP NO: 7
NAMEOF EXPERIMENT: WATER ABSORPTIONTEST – CRUSHED SAND
REFERENCE : IS 2185 Part 1, 1979
AIM : To determine the water absorption of fine aggregates – crushed sand.
APPARATUS: Heating apparatus/hotair oven, weighing balance, glass jar, distilled
water.
PROCEDURE :
a) Completely immerse the test sample in clean water at a roomtemperature of
27 degrees for 24 hours.
b) Remove the sample fromwater and wipe out any traces of water with a clean
cloth.
c) Find its weight (M1).
d) Heat the samplein oven at a temperature of 100Cfor not less than 24hrs till it
substantially becomes a constantmass.
e) Weigh the sample immediately and record its weight (M2)
CALCULATION :
M1 = 500gm
M2 = 520gm
Percentage of silt = 520-500*100 = 4.00%
500
RESULT : The water absorption of given sample is found to be 4.00%
Water absorption = M2-M1 * 100
M1

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EXP NO: 8
NAMEOF EXPERIMENT: SIEVEANALYSIS OF FINEAGGREGATES –CRUSHED SAND
AIM : To determine the gradation of aggregates / fineness modulus of fine
aggregates.
PROCEDURE :
a) Take about 1kg of sample, i.e. crushed sand fine aggregates.
b) Weigh the air dried sample and successively sieveon the appropriatesieve
c) Shakeeach sieve separately over a clean tray until not morethan a trace
persists.
d) Brush lightly with a light camel hair brush on the 150u and 75u sieves to
e) Plot the weight of each tray after sieving and find out fineness modulus.
OBSERVATIONS :
Fineness Modulus = Sum of cumulative % retained
100

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TABULAR COLUMN :
Weight (kg)
Retention
Cumulative %
passing
1 4.75 16 1.6 1.6 98.4
2 2.36 183 18.3 19.9 80.1
3 1.18 230 23.0 42.9 57.1
4 600u 164 16.4 59.3 40.7
5 300u 228 22.8 82.1 17.9
6 150u 157 15.7 97.8 2.2
7 PAN 22 2.2 100 0
Fineness modulus = 403.6 = 4.036
100

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EXP NO: 9
NAMEOF EXPERIMENT: SETTING TIMEOF CEMENT
REFERENCE : IS 4031 - PART5
SIGNIFICANCE: This test gives a judgment aboutthe available time for
transportation, placing of concrete, commencement of curing and stripping.
AIM : To determine initial and final setting time of cement using Vicat apparatus.
APPARATUS: Vicatapparatus of mould dia80mmand height 40mm, weights and
balance, trowel, initial and final setting time needle, time watch.
PROCEDURE :
a) Take about 400gm of cement and 85% of water required for making cement
paste of normalconsistency.
b) The paste shall be gauged and filled into the vicat mould in specified manner
within 3-5 minutes.
c) Start the time watch the moment water is added to the cement. The
temperature of water and that of the test room at the time of gauging shall be
around 27o
C.
d) When the needle for initial setting time is broughtin contact with the top
surfaceand released quickly fails to penetrate the 5-7mmmeasured fromthe
bottom of the mould is taken as initial setting time.
e) When the needle for final setting time placed gently on the surfacemakes an
impression on the paste but the circular cutting edge of the attachment fails to do
so, it is taken as final setting time.

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OBSERVATIONS :
Weight of cement
(gm)
Water Initial setting time
(min)
Final setting time
(min)
250 63.75 32 300
LIMIT : As per IS 4031 Part5, 1998
a) Initial setting time should not be less than 30 minutes.
b) Final setting time should not be greater than 600 minutes.
Weight of cement taken = 250gm
Weight of water to be taken = 30% of weight of cement
= 0.30 * 0.85 * 250
= 63.75gm
RESULT: The initial setting time is found to be 32 minutes and final setting time as
300 minutes

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EXP NO: 10
NAMEOF EXPERIMENT: FINENESS OF CEMENT
REFERENCE : IS 4051, Part1
AIM : To determine the fineness of cement.
SIGNIFICANCE: Fineness of cement has an important bearing on the rate of
hydration and hence on the rate of gain of strength and rate of evolution of heat.
Finer cement offers a greater surfacearea for hydration and hence faster and
greater development of strength.
DEFINITION: The area of cement particles of particular cement weight.
APPARATUS: IS sieveno : 9 ( 90 u ), PAN, balance and weights.
PROCEDURE :
a) Weight correctly 100gm of cement ( W1 ).
b) Take sample on IS 90 sieve.
c) Break down the air set lumps.
d) Sieve the sample by giving circular and vertical motion for 15mins.
e) Weigh residue left on the sieve ( W2 ).
CALCULATION :
Fineness of cement = ( W1-W2 ) * 100

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Weight of sample
(W1 gm)
Weight of residue
(W2 gm)
Percentage Residue
(W2/W1 * 100)
Average%
100 4.1 4.1
4.033100 3.9 3,9
100 4.1 4.1
W1 = 100gm
W2 = 4.1 + 3.9 + 4.1 = 4.033
3
Fineness of cement = ( 100-4.033 ) *100 = 96.00%
RESULT : The fineness of given cement is found to be 96.00%
Residue by weight = 4.00%

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EXP NO: 11
NAMEOF EXPERIMENT: SLUMP TEST FOR CONCRETE
REFERENCE : ISI 199
AIM : To determine working ability of fresh concrete.
APPARATUS:
a) Mould
Top Diameter: 100mm
Bottom Diameter: 200mm
Height: 300mm
Thickness: 1.6mm
b) Tamping Rod
Dia: 16mm
Length: 600mm
Shape: Rounded at one end
PROCEDURE :
a) Fill the mould in 4 layers.
b) Tamp each layer 25 times with the rounded end of the tamping rod.
c) The tamping should be uniformly distributed and for the second and
subsequentlayers, the tamping rod shall penetrate into the underlying layers.
d) Strikeoff the mould in the vertical direction.
e) Removal should be done only in the vertical direction.
f) Measurethe differencein levels between the height of mould and that of the
highest point of the subsided concrete.
g) This difference in mm is recorded as the slump of concrete.

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OBSERVATIONS :
Height of concrete in mould = H1 = 300mm
Height of subsided concrete = H2 = 150mm
Differencein levels = H1 – H2 = 300-150 =150mm
RESULT : The slump of concrete is found to be 150mm.

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EXP NO: 12
NAMEOF EXPERIMENT: BULK DENSITYOF 20MMAGGREGATES
AIM : To find the bulk density of 20mmaggregates.
APPARATUS: Bulk density cylinder, weighing machine.
PROCEDURE :
a) Clean the bulk density cylinder and find its volume.
b) Find its empty weight W1.
c) Fill it up to the brim with 20mmoven dried aggregates.
d) Aggregates shouldn’tbe compacted.
e) The height of drop shouldn’tbe more than 30-50cm.
f) Find the new weight of cylinder + aggregates W2.
CALCULATIONS :
Bulk density of aggregates = W2 – W1
Volume
OBSERVATIONS:
Empty weight of cylinder (W1) = 7.96kg
Weight of cylinder + 20mmaggregates = 28.39kg
Volume of container (V) = 15.3 litres
= 0.0153m3
Density = Mass = (28.39 –7.96) *100 = 1385.29kg/m3
Volume 0.0153
RESULT: The bulk density of the given aggregates is found to be 1385.29kg/m3
.

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EXP NO: 13
NAMEOF EXPERIMENT: BULK DENSITYOF 10MMAGGREGATES
AIM : To find the bulk density of 10mmaggregates.
PROCEDURE :
c) Fill it up to the brim with 10mmoven dried aggregates.
CALCULATIONS :
Volume
OBSERVATIONS:
Weight of cylinder + 10mmaggregates = 27.14kg
= 0.0153m3
Density = Mass = (27.14 –7.96) *100 = 1278.67kg/m3
Volume 0.0153
.

46
EXP NO: 14
NAMEOF EXPERIMENT: BULK DENSITYOF CRUSHED SAND AGGREGATES
AIM : To find the bulk density of crushed sand aggregates.
PROCEDURE :
c) Fill it up to the brim with oven dried aggregates.
CALCULATIONS :
Volume
OBSERVATIONS:
Weight of cylinder + crushed sand aggregates = 31.83kg
= 0.0153m3
Density = Mass = (31.83 –7.96) *100 = 1591.33kg/m3
Volume 0.0153
.

47
EXP NO: 15
NAMEOF EXPERIMENT: DENSITYOF BLOCKS
AIM : To determine density of blocks.
APPARATUS: Block of side8 inch, weighing machine, heating arrangement/hotair
oven.
PROCEDURE :
a) Select 3 blocks at random.
b) Dry the sample to constantmass in a suitable oven heated to 100o
C.
c) After cooling the blocks to room temperature, measure the dimensions of each
block in cms (to nearest mm) and overall volume computed in cm3
.
d) Weigh the block in kg to the nearest10kg and calculate the density of each
block.
CALCULATIONS :
Density of block = Mass of block in kg
Volume of block in cm3
OBSERVATIONS:
Mass of the block = 32.57 kg
Volume of the block = 20cm* 20cm* 40cm= 16000cm3
=0.016m3
Density of the block = 32.57 *106
= 2035.63kg/m3
16000
RESULT: The density of the given block is found to be 2035.63kg/m3
.

48
MIX DESIGN
Concrete is the basic engineering material used in mostof the civil engineering
Structures. Its popularity as basic building material in construction is becauseof,
its economy of use, good durability and ease with which it can be manufactured
at site.
The ability to mould it into any shapeand size, because of its plasticity in green
stage and its subsequenthardening to achieve strength, is particularly useful.
Concrete like other engineering materials needs to be designed for properties like
strength, durability, workability and cohesion.
Concrete mix designis the science of deciding relativeproportionsof
ingredients of concrete, toachieve the desired properties inthe most
economical way.
With advent of high-risebuildings and pre-stressed concrete, useof higher grades
of concrete is becoming more common. Even the revised IS 456-2000 advocates
use of higher grade of concrete for more severeconditions of exposure, for
durability considerations. With advent of new generation admixtures, it is
possibleto achieve higher grades of concrete with high workability levels
economically. Use of mineral admixtures like fly ash, slag, meta kaolin and silica
fume have revolutionized the concrete technology by increasing strength and
durability of concrete by many folds. Mix design of concrete is becoming more
relevant in the above-mentioned scenario.
However, it shouldbe borne in mind that mix designwhenadoptedat site
should be implementedwithproper understanding andwithnecessary
precautions.
Durocrete mix designmanual is an attempt toincrease the awareness among
the users, about concrete mix design. It is made withintentionof serving as
ready reckoner for personnel, implementing mix designat site.
Advantages of mix design
Mix design aims to achieve good quality concrete at site economically.
I. Quality concrete means Better strength Better imperviousness and durability
Denseand homogeneous concrete

49
II. Economy
a) Economy in cement consumption
Itis possibleto save up to 15% of cement for M20 grade of concrete with the help
of concrete mix design. In facthigher the gradeof concrete more are the savings.
Lower cement content also results in lower heat of hydration and hence reduces
shrinkagecracks.
b) Best use of available materials:
Site conditions often restrict the quality and quantity of ingredient materials.
Concrete mix design offers a lot of flexibility on type of aggregates to be used in
mix design.
Mix design can give an economical solution based on the available materials if
they meet the basic IS requirements. This can lead to saving in transportation
costs from longer distances.
c) Other properties:
Mix design can help us to achieve formfinishes, high early strengths for early
deshuttering, concrete with better flexural strengths, concretewith pumpability
and concrete with lower densities.
What is mix design?
Concrete is an extremely versatile building material because, it can be designed
for strength ranging fromM10 (10Mpa) to M100 (100 Mpa) and workability
ranging from0 mm slump to 150 mmslump. In all these cases the basic
ingredients of concrete are the same, but it is their relativeproportioning that
makes the difference.
Basic Ingredients of Concrete :
1. Cement – Itis the basic binding material in concrete.
2. Water – Ithydrates cement and also makes concrete workable.
3. CoarseAggregate – Itis the basic building component of concrete.
4. Fine Aggregate– Along with cement paste it forms mortar groutand fills the
voids in the coarseaggregates.
5. Admixtures – They enhance certain properties of concrete e.g. gain of strength,
workability, setting properties, imperviousness etc.
Concrete needs to be designed for certain properties in the plastic stageas well as
in the hardened stage.

50
Properties desiredfromconcrete inplastic stage: -
Workability Cohesiveness Initialset retardation
Properties desiredfromconcrete inhardenedstage: -
Strength ImperviousnessDurability
Concrete mix designis the methodof correct proportioning of ingredients of
concrete, inorder to optimize the above properties of concrete as per site
requirements.
In other words, we determine the relative proportions of ingredients of
concrete toachieve desiredstrength&workability ina most economical way.
Informationrequiredfor concrete mix design
The site engineer should give following information while giving material for mix
design to the mix design laboratory: -
Grade of concrete (the characteristic strength)
Workability requirement in terms of slump
Other properties (if required): -
i. Retardation of initial set (to avoid cold joints in case of longer leads or for ready
mix concrete)
ii. Slump retention (in caseof ready mix concrete)
iii. Pumpability (In caseof ready mix concrete)
iv. Acceleration of strength (for precastmembers or where early deshuttering is
desired)
v. Flexural strength (normally required for concrete pavements)
Ascertain whether condition of exposureto concrete is mild, moderate severe or
very severe. Proper investigation of soil should be done to ascertain presenceof
sulphates & chlorides, in case of doubt.
Following factors indicate degree of controlat site: -
Batching – weigh batching / volume batching.
Type of aggregates – whether mixed graded aggregate will be used or 20mm,
10mmaggregates will be used separately.
Testing of concrete – whether casting & testing of concrete cubes will be done
regularly at site.
Sourceof aggregate – whether sources of sand and aggregate will be
standardized or likely to changefrequently.

51
Supervision – whether qualified staff will be presentto superviseconcreting work
and make necessary corrections e.g. correction for moisturein sand and changes
in material properties.
Site laboratory – whether the site will havenecessary laboratory equipment like
sieves, weighing balance etc. to check material properties.
Material properties andhowthey affect mix designCement
a) Strength/grade of cement: Gradeof cement e.g. 43 grade or 53 grade can
influence the mix design. Gradeof cement indicates minimum strength of cement
in N/mm2 tested as per standard conditions laid down by IS codes (OPC43 grade
– IS 8112-1989, OPC53 grade– IS 12269 –1987 e.g. a 43 gradecement should
give minimum strength of 43 N/mm2 at 28 days). Higher the strength of cement,
higher is the strength of concrete for the same water/cement ratio. In other
words a higher strength of cement permits use of higher water/cement ratio to
achieve the samestrength of concrete. The IS 10262 - 1982 for mixdesign gives
the differentcurves of cement based on the actual strength of cement on 28th
day. These cement curves give water/cement ratio required to achieve a given
target strength. Information on grade of cement may not be as usefulas the
actual 28days strength of cement. This is because someof the 43 gradecements
practically give strengths morethan 53 N/mm2. When a 53-gradecement is
stored for a long time, its strength may deteriorate and become equivalent to 33
grade or 43 grade cement. Thus 28 days strength of cement is required to select
the cement curvebefore starting the mix design. Finding the 28 days strengths of
cement consumes time. Itis not practical in many cases to wait for 28 days
strength of cement to start the mix design. In such cases 28 days strength reports
of the manufacturers may be used and can be supplemented by accelerated
strength of cement found by reference mix method given in IS 10262 Apartfrom
strength of cement, the type of cement e.g. Ordinary Portland Cement, pozzolona
cement (blended cement) etc., is also importantfactor affecting the gain of
strength. Blended cements achieve strengths later than Ordinary Portland
Cements and require extended curing period. However, useof these cements
result in more durableconcrete by offering greater resistanceto sulphates and
chloride attacks.
b) Initial & Final setting time of cement: The initial setting time of cement
indicates the time after which the cement paste loses its plasticity. Operations like
mixing, placing and compaction should be completed well before the initial

52
setting time of cement .The minimum initial setting time specified by IS 456 –2000
(Clause5.4.1.3 pageno 14 and IS 8112-1989 page2) is 30 minute. Most of the
cements produced today give an initial set of more than 60 minutes. Beginning of
hardening of cement paste indicates the final setting of cement. The maximum
limit for final setting permitted by IS 8112: 1989 (Clause6.3. page2) is 600
minute. Most of the cements produced today give a final setting of between 3 to
5 hours. Curing can be started after final setting of cement. The initial setting and
the final setting can be extended by useof retarders in order to avoid cold joints
when lead-time for placing concrete is longer.
Fine Aggregates
a) Gradation of fine aggregates: Thegradation of sand is given by sieveanalysis.
The sieve analysis is done by passing sand through a set of standard sieves and
finding out cumulative passing percentage through each sieve. The IS 383 –1970
classifies fine aggregates in 4 zones starting fromzoneI representing coarsesand,
to zone IV representing the finest sand. The limits of cumulative percentage
passing for each sieve for above zones aregiven in table 4 of IS 383 Thefineness
of sand found by sieveanalysis governs the proportion of sand in concrete .The
overall fineness of sand is given by factor called fineness modulus. Fineness
Modulus is given by division of the summation of cumulative retained fractions
for standard sieves up to 150-micron sievesizeby 100.
c) Silt Content by weight: This is found by wet-sieving of sand and material
passing 75 micron sieve is classified as silt. This silt affects the workability of
concrete, results in higher water/cement ratio and lower strength. The upper limit
for 75-micron sievein caseof sand is 3% by weight. This limit has however been
extended to 15% in case of crushed sand in IS 383 –1970 Table 1
Coarse Aggregate
a) Maximum size of coarse aggregate: Maximumsize of aggregate is the standard
sieve size(40mm, 25mm, 20mm, 12.5mm, 10mm)through which atleast 90% of
coarseaggregate will pass. Maximum sizeof aggregate affects the workability and
strength of concrete. Italso influences the water demand for getting a certain
workability and fine aggregate content required for achieving a cohesivemix. For
a given weight, higher the maximum size of aggregate, lower is the surfacearea of
coarseaggregates and vice versa. As maximum sizeof coarseaggregate reduces,

53
surfacearea of coarseaggregate increases. Higher the surfacearea, greater is the
water demand to coat the particles and generate workability. Smaller maximum
sizeof coarseaggregate will require greater fine aggregate content to coat
particles and maintain cohesiveness of concrete mix. Hence 40 mm down coarse
aggregate will require much less water than 20 mm down aggregate. In other
words for the same workability, 40mmdown aggregatewill have lower
water/cement ratio, thus higher strength when compared to 20mmdown
aggregate. Becauseof its lower water demand, advantageof higher maximum
sizeof coarseaggregate can be taken to lower the cement consumption.
Maximum size of aggregate is often restricted by clear cover and minimum
distance between the reinforcementbars. Maximum size of coarseaggregate
should be 5 mm less than clear cover or minimum distance between the
reinforcement bars, so that the aggregates can pass through the reinforcementin
congested areas, to producedense and homogenous concrete.
Itis advantageous to usegreater maximum size of coarseaggregatefor concrete
grades up to M 35 where mortar failure is predominant. Lower water/cement
ratio will mean higher strength of mortar (which is the weakest link) and will
result in higher strength of concrete. However, for concrete grades aboveM40,
bond failure becomes predominant. Higher maximum size of aggregate, which
will have lower area of contact with cement mortar paste, will fail earlier because
of bond failure. Hence for higher grades of concrete (M40 and higher) it is
advantageous to uselower maximum sizeof aggregate to prevent bond failure.
The fineness modulus of sand varies from 2.0 to 4.0; higher the FM coarser is the
sand.
Type of Sand
Fine Medium Coarse
- F M
- 2.0 to 2.8 - 2.8 to 3.2 - 3.2 and above
b) Specific gravity of fine aggregates: This is the ratio of solid density particles to
the density of water. Higher the specific gravity, heavier is the sand particles and
higher is the density of concrete. Conversely a lower specific gravity of sand will
result in lower density of concrete. Specific gravity of sand is found with help of
pycnometer bottles. The specific gravity of fine aggregates found in Pune region
varies from2.6 to 2.8.

54
b) Grading of coarse aggregate: Thecoarseaggregate grading limits are given in
IS 383 – 1970 - table 2, Clause 4.1 and 4.2 for single size aggregate as well as
graded aggregate. The grading of coarseaggregate is important to get cohesive&
dense concrete. The voids left by larger coarseaggregate particles are filled by
smaller coarseaggregate particles and so on. This way, the volume of mortar
(cement-sand water paste) required to fill the final voids is minimum. However, in
some cases gap graded aggregate can be used where someintermediate size is
not used. Use of gap graded aggregate may not haveadverseeffect on strength.
By proper grading of coarseaggregate, the possibility of segregation is minimized,
especially for higher workability. Proper grading of coarseaggregates also
improves the compactability of concrete.
c) Shape of coarse aggregate: Coarseaggregates can have round, angular, or
irregular shape. Rounded aggregates because of lower surfacearea will have
lowest water demand and also have lowest mortar paste requirement. Hence
they will result in most economical mixes for concrete grades up to M35.
However, for concrete grades of M40 and above (as in case of max sizeof
aggregate) the possibility of bond failure will tilt the balance in favour of angular
aggregate with more surfacearea.
Flaky and elongated coarseaggregate particles not only increasethe water
demand but also increasethe tendency of segregation. Flakiness and elongation
also reducethe flexural strength of concrete. Specifications by Ministry of Surface
Transportrestrictthe combined flakiness and elongation to 30% by weight of
coarseaggregates.
d) Strengthof coarse aggregate: Material strength of coarseaggregate is
indicated by crushing strength of rock, aggregatecrushing value, aggregate
impact value, aggregate abrasion value. In Maharashtra the coarseaggregates are
made of basalt rock, which has strengths in excess of 100 N/mm2. Hence
aggregates rarely fail in strength.
e) Aggregate Absorption: Aggregatecan absorb water up to 2 % by weight when
in bone dry state, however, in some cases the aggregate absorption can be as
high as 5%.
Aggregate absorption is used for applying a correction factor for aggregates in dry
condition and determining water demand of concrete in saturated surfacedry
condition.

55
DecisionVariables inMix Design
A. Water/cement ratio
B. Cement content
C. Relative proportion of fine & coarse
aggregates
D. Use of admixtures
A. Water/cement ratio
Water to cement ratio (W/C ratio) is the single most important factor governing
the strength and durability of concrete. Strength of concrete depends upon W/C
ratio rather than the cement content. Abram’s law states that higher the
water/cement ratio, lower is the strength of concrete. As a thumb rule every 1%
increase in quantity of water added, reduces the strength of concrete by 5%. A
water/cement ratio of only 0.38 is required for complete hydration of cement.
(Although this is the theoretical limit, water cement ratio lower than 0.38 will also
increase the strength, since all the cement that is added, does not hydrate) Water
added for workability over and above this water/cement ratio of 0.38, evaporates
leaving cavities in the concrete. These cavities are in the form of thin capillaries.
They reduce the strength and durability of concrete. Hence, it is very important to
control the water/cement ratio on site. Every extralit of water will approx.
reduce the strengthof concrete by 2 to 3 N/mm2
and increase the workability
by 25 mm. As stated earlier, the water/cement ratio strongly influences the
permeability of concrete and durability of concrete.
B. Cement content
Cement is the core material in concrete, which acts as a binding agent and
imparts strength to the concrete. Fromdurability considerations cement content
should not be reduced below 300Kg/m3 for RCC. IS 456 –2000 recommends
higher cement contents for more severe conditions of exposureof weathering
agents to the concrete. Itis not necessary that higher cement content would
result in higher strength. In fact latest findings show that for the same
water/cement ratio, a leaner mix will give better strength. However, this does not
mean that we can achieve higher grades of concrete by just lowering the
water/cement ratio. This is becauselower water/cement ratios will mean lower
water contents and result in lower workability. In factfor achieving a
given workability, a certain quantity of water will be required. If lower
water/cement ratio is to be achieved without disturbing the workability, cement

56
content will have to be increased. Higher cement content helps us in getting the
desired workability at a lower water/cement ratio. In most of the mix design
methods, the water contents to achieve different workability levels are given in
formof empirical relations. Water/cement ratios required to achieve target mean
strengths are interpolated from graphs given in IS 10262 Clause3.1 and 3.2 . The
cement content is found as follows:
Cement content (Kg/m3) =
Water required achieving required workability (Lit/m3)
Water/cement ratio
Thus, we see that higher the workability of concrete, greater is cement content
required and vice versa. Also, greater the water/cement ratio, lower is the
cement content required and vice versa.
C. Relative proportionof fine, coarse aggregates gradationof aggregates
Aggregates are of twotypes as below:
a. Coarseaggregate(Metal): These are particles retained on standard IS 4.75mm
sieve.
b. Fine aggregate(Sand): Theseare particles passing standard IS 4.75mmsieve.
Proportion of fine aggregates to coarseaggregate depends on following:
i. Fineness of sand: Generally, when the sand is fine, smaller proportion of it is
enough to get a cohesivemix; while coarser the sand, greater has to be its
proportion with respectto coarseaggregate.
ii. Size &shape of coarse aggregates:Greater the sizeof coarseaggregate lesser
is the surfacearea and lesser is the proportion of fine aggregate required and vice
versa.
Flaky aggregates have more surfacearea and require greater proportion of fine
aggregates to get cohesivemix. Similarly, rounded aggregate have lesser surface
area and requirelesser proportion of fine aggregateto get a cohesive mix.
iii. Cement content: Leaner mixes require more proportion of fine aggregates
than richer mixes. This is because cement particles also contribute to the fines in
concrete.

57
D. Use of admixtures
Now days, admixtures are rightly considered as the fifth ingredient of concrete.
The admixtures can change the properties of concrete. Commonly used
admixtures are as follows:
i. Plasticisers & super plasticisers
ii. Retarders
iii. Accelerators
iv. Air entraining agents
v. Shrinkagecompensating admixtures
vi. Water proofing admixtures
i. Plasticisers &super plasticisers
Plasticisers help us in increasing the workability of concrete without addition of
water. Itmeans that we can achieve lower water/cement ratio without reducing
the workability at the same cement content. Cement particles tend to formflocs
trapping a partof mixing water in them. Hence not all the water added is useful
for generating workability. Plasticisers work as dispersion agents (de flocculent)
releasing the water trapped in the flocs resulting in workability. Useof plasticisers
is economical as the cost incurred on them is less than the cost of cement saved;
this is moreso in concrete designed for higher workability.
Compatibility of plasticisers with the cement brand should be checked beforeuse.
Also plasticiser should not be added in dry concrete mix. Plasticizers are used for
moderate increase of workability whereas super plasticizers are used where very
large increase in workability is required. Plasticizers arenormally
lignosulphonated formaldehydes and are normally added in small dosages. This is
because large dosagecan causepermanent retardation in concrete and adversely
affect its strength. Super plasticizers are naphthalene or melamine based
formaldehyde.
They can be used in large dosages withoutany adverseeffect on concrete. This is
contrary to popular perception that term super plasticizers means more potent,
hence lower dosageis required when compared to normal plasticizers. In practice
super plasticizers are used in large dosages for generating higher workability and
better slump retention. Compatibility of plasticizers with cement should be
ascertained beforeuse in concrete. Since action of plasticizers is based on ionic
dispersion certain plasticizers aremore effective with certain cements, thus
requiring lower dosages. Non-compatibleplasticizers if used, will not adversely
affect the concrete, but its high dosage will make it uneconomical for use.

58
ii. Retarders:
They are used for retarding (delaying) the initial setting time of concrete. This is
particularly required when longer placing times are desired as in caseof ready
mixed concrete. Retarders are commonly used to preventformation of cold joints
when casting large concrete. Retarders are normally added in lower dosages as
large dosages can cause permanent retardation in concrete. Retarders are
recommended in case of hot weather concreting to prevent early loss of slump. It
is important to note that retarders reduceearly strength of concrete e.g. 1-day
and 3-day strength. However, 28 days strength is not affected.
iii. Accelerators
They are used for accelerating the initial strength of concrete. Typical accelerators
increase the 1-day (up to 50 %) and 3-days (up to 30 %) strength of concrete.
Most of the accelerators show little increasefor 7 days strength. For this reason,
accelerators are commonly used in precastconcrete elements for early removal
of moulds. Accelerators may not be much useful for early deshuttering where
early strengths arerequired in range of 5 to 7 days. This is because accelerators
are expensive and their ability to increasestrengths decreases after 3-5 days. A
better option for early deshuttering would be the use of plasticizers, reducing the
water/cement ratio and achieving a higher gradeof concrete. Itis believed that
accelerators may causeretrogression of strength after 28 days when compared
with normalconcrete.
Concrete Mix DesignMethods
The basic objective of concrete mix design is to find the most economical
proportions (Optimization) to achieve the desired end results (strength, cohesion,
workability, durability, As mentioned earlier the proportioning of concrete is
based on certain material properties of cement, sand and aggregates. Concrete
mix design is basically a process of taking trials with certain proportions. Methods
have been developed to arriveat these proportions in a scientific manner. Nomix
designmethoddirectly gives the exact proportions that will most economically
achieve endresults. These methods only serve as abase to start and achieve the
end results inthe fewest possibletrials.
The code of practice for mix design-IS 10262clearly states following: - The basic
assumption made in mix design is that the compressivestrength of workable

59
concretes, by and large, governed by the water/cement ratio. Another most
convenient relationship applicable to normalconcrete is that for a given type,
shape, size and grading of aggregates, the amountof water determines its
workability. However, there are various other factors which affect the properties
of concrete, for example the quality & quantity of cement, water and aggregates;
batching; transportation; placing; compaction; curing; etc. Therefore, the specific
relationships that are used in proportioning concrete mixes should be considered
only as the basis for trial, subject to modifications in the light of experience as
well as for the particular materials used at the site in each case. Differentmix
design methods help us to arriveat the trial mix that will give us required
strength, workability, cohesion etc. These mix design methods havesame
common threads in arriving at proportions buttheir method of calculation is
different. Basic steps in mix design are as follows:
Findthe target meanstrength.
Determine the curve of cement basedonits strength.
Determine water/cementratio.
Determine cement content.
Determine fine andcoarse aggregate proportion

60
PROJECT EXECUTION
METHOD STATEMENTS:
METHOD STATEMENTFOR SURVEYING
OBJECTIVE: To formulate guidelines for Setting out and routine survey
Works.
REFERENCE:
1. Drawing
2. Technical Specifications for Civil works
3. Inspection and test plan
4. Survey Layoutshowing controlstations
MAJOR EQUIPMENTS: Calibrated Auto- level, Theodolite (LC-1"), Total
Station and necessary measuring tools
METHOD STATEMENTFOR REINFORCEMENTWORK
1. OBJECTIVE: This procedurecovers method for cutting, bending and
tying of reinforcementand inspection of works.
2. REFERENCE: Reinforcement placing and handling shall be as per IS-456
MAJOR EQUIPMENTS: Bar cutting & bending machines, rebar tying tool.
METHOD STATEMENTFOR FORMWORK
1. OBJECTIVE: This Procedurecovers fixing and removalof formwork and
checking of formwork.
2. REFERENCE:
1. Approved Drawings
2. IS 456 & IS 6461(Part5)
3. Tender Document
METHOD STATEMENTFOR BOLTS PROCUREMENT& FIXATION
1. OBJECTIVE: This Procedurecovers procuring and fixing of bolts.
2. REFERENCE:
1. Tender Specification

61
METHOD STATEMENTFOR CONCRETING WORKS
1. OBJECTIVE: This Procedurecovers fixing and removalof formwork and
checking of formwork.
2. REFERENCE:
1. Tender Specification
3. IS 10262, IS 3370 & IS 456
4. IS 383
METHOD STATEMENTFOR BACKFILLING
1.OBJECTIVE: The scopeof back-filling covers the filling in plinths, pits,
trends, depressions in layers 200mmthick including watering and compaction
by Roller / plate compactor.
2. REFERENCE:
1. Drawing
2. Bill of Quantities
METHOD FOR REINFORCEMENTWORK
1.All reinforcement shall be placed above the ground by using wooden sleepers or
concrete blocks.
2.For reinforcement, care shall be taken to protect the reinforcement from
exposureto saline atmosphereduring storage, fabrication and use.
3.Againstrequirement fromsite, bars shallbe cut and bent to shapeand
dimension as shown in bar bending schedule based on Good For Construction
(GFC) drawings.
4.Reinforcementshall be tied as per the latest GFC drawing and any extra bars
provided at site shall be recorded in the pour card/ lap register.
5.Unusablecut rods and scrap reinforcement shall be properly placed at yard.
Bar Bending Schedule:
1.Preparebar bending schedulebased on the latest GFCdrawings and to be
submitted to Engineer for review
2.Bar bending schedule shallclearly specify the following:
a) Bar dia.
b) Numbers.
c) Cut-lengths.
d) Shapes.
3.Bar bending schedule shalltake into account the following field/ design

62
requirement.
a) Desirablelap locations and staggering of laps.
b) Lap lengths.
c) Development length/ Anchoragelength.
Cutting, Bending andPlacing:
1.All reinforcementshall be free fromloose mill scales, looserustand coats of
paints, oil, mud or any other substances which may destroy or reduce bond. Use
wire brush to clean the reinforcement.
2.Cutting and bending shall conformto the details given in the approved bar
bending schedule.
a) Cutting of Rebar by heat is not permitted, only cutting by grinding or shearing is
permitted.
b) No heating is allowed to facilitate bending of Rebar.
3.Placethe reinforcement as per GFC drawings ensuring thefollowing aspects
properly.
a) Type & sizeof bar. b) Number of bars.
c) Location and lengths of laps, splices.
d) Curtailment of bars.
e) In two way reinforcement, check the direction of reinforcement in various
layers.
f) Adequate number of chairs, spacer bars and cover blocks.
50
g) Sizeof cover blocks.
h) All the bars shall be tied with double fold 18g softGI annealed binding wire.
4.Reinforcementmay be placed with in the following tolerance whenever
required:
a) for effective depth 200mmor less ±10mm.
b) for effective depth morethan 200mm±15mm.
c) The cover shall in no case be reduced by morethan one third of the specified
cover or 0 /+ 10mm.
d) The cover should suit various cover requirement as per Drawing Notes.
5.The sequenceof reinforcement shall be correlated with fixing of inserts, sleeves,
conduits, anchors and formworks.
6.In walls, placeaccurately bent spacer bars wired to vertical or horizontalbars
between successiverows.

63
7.No steel parts of spacers sureallowed inside the concrete cover. Spacer blocks
made fromcement, sand and small aggregateshall match the mix proportion of
the surrounding concrete. Alternatively PVCcover blocks of approved make can
be used.
8.Spacers, cover blocks should beof concrete of same strength or PVC
9.Spacers, chairs and other supports detailed on drawings, together with such
other supports as may be necessary, should beused to maintain the specified
nominal cover to the steel reinforcement.
10.Spacers or chairs should beplaced at a maximum spacing of 1.0m and closer
spacing may sometimes be necessary.
11.Allreinforcement shall be placed and maintained in the positions shown in the
drawing by providing proper cover blocks, spacers, Supporting bars.
12.Rough handling, shock loading (Prior to embedment) and the dropping of
reinforcement froma height should be avoided. Reinforcement should be secured
against displacement.
METHOD FOR FORMWORK
Pre Check
1.Check if the shutters areproperly cleaned by removing the concrete/ mortar
and protruding nails.
2.Formworkshallbe made to the exact dimensions within the permissible
tolerances as mentioned below.
3.Required thickness and quality of plywood conforming to IS 6461 shallbe used
to meet the requirements of design and surfacefinish.
4.For beam bottom & sides, proper sizeof timber at required spacing shall be
provided to take the design loads/pressureconsidering sleeves, conduitanchors
& inserts.
Erectionof formwork
5.Sufficiently rigid and tight to prevent the loss of grout or mortar fromthe
concrete.
6.Capableof providing concrete of the correct shapeand surfacefinish within the
specified tolerance limits.
7.Soffits forms capableof imparting a camber if required.
8.The formwork may beof timber, plywood, steel, plastic or concrete depending
upon the type of finish specified.
9.Erectstaging/shuttering as per drawing/sketches in such a way that
deshuttering can be done easily including provision for repropping, if planned.

64
10.Check the location, line, level, plumb and dimensions of the formwork to
ensurethat the deviations are within the permissible limits.
11.Providebracing atproper places & intervals as specified by the manufacturer
or as per formwork schemeto take careof lateral loads.
12.Apply mould oil/other coatings as release agents before reinforcementsteel is
placed.
13.Wireties passing through beams, columns and walls shall not be allowed .In
their place bolts passing through sleeves shallbe used. For liquid retaining
structures, sleeves shallnot be provided for through bolts.
14.Check all the shutters areproperly aligned and fixed firmly with required
lateral supports and ties.
15.Check all the spanning members haveproper bearing at the supports.
16.Wedges or jacks shallbe secured in position after the final check of alignment.
17.Forms shallbethoroughly cleaned of all dirt, mortar and other matters such as
metals, blocks, saw dustand foreign materials before concreting if required
through clean-out openings.
18.Check all the gaps/openings areproperly closed to avoid leakages.
19.Check all the inserts/embedmentand openings are exactly placed as per the
drawings.
20.In caseof leakages, bulging and sagging immediate actions shall be taken by
tightening wedges or adjusting by jacks which must be done before the concrete
takes its initial set.
Removal of Forms
21.Formwork components shallnotbe dropped but shall be lowered without
damage to the components and structures. Allthe removed formwork materials
shall be thoroughly scraped, cleaned immediately and stacked properly for reuse.
22. All forms shall be removed after the minimum period stipulated mentioned
below without damage to the concrete including removalwithout shock as per IS
456
METHOD FOR BACKFILLING
1. Backfilling area shall be free fromforeign matters ( i.e. wooden scraps ,
plywood pieces rebar bits etc. and tie rods recesses shallbe rendered with
polymer based non shrink compound with a subsequentapplication of curing
compound on them.
2.Filling around foundation or other places indicated shall be done with approved
material obtained fromexcavation or approved materials broughtfrom outside.

65
3.The material shall be good quality softor hard murrumor Panna sand or other
approved back filling material. Back filling soil shall be free fromblack cotton soil.
4.Filling shall be done in layers not exceeding 20cm thick and each layer shall be
watered adequately and consolidated properly by rollers or pneumatic rammers 8
to 10 tonnes wherever conditions permit. If it is not possible, the consolidation
shall be done by hand rollers/ heavy pneumatic/ hand rammers/plate compactor.
5.The surfaceof the filling shall be finished to lines and levels as required.
6.The approved materials shall be placed in layers, not exceeding 200mmin depth
before compaction and shall be compacted to minimum 95% dry density. Layers
placed in the top 300mmof the fill shall be compacted to 98% of maximum dry
density.
No of Samples:
(i)For foundation filling - one for every 10 foundation for each compacted layer.
(ii)For area filling one for every 1000 m2
area for each compacted layer.
METHOD FOR CONCRETING
1.Concretemix design for DifferentStructureshould be as per Notes in the
specific approved drawing
2.For Design Mix Concrete, the mix shall be designed to providethe gradeof
concrete having the required strength, workability & durability requirements
given in IS: 456 for each gradeof concrete taking into account the type of cement,
minimum cement content and maximum W/C ratio conforming to exposure
conditions as per tender specifications.
3.Mix design and preliminary tests are not necessary for Nominal Mix concrete
(M5, M7.5, M10, M15, M20, M25, M30, M45, M60 as Specified in IS 456 - Table 9)
.However works tests shallbe carried out as per IS:456
4.No concreting shall be done without the approvalof engineer. Prior notice shall
be given before startof concreting.
5. Cement shall be measured by weight in weigh batching machines of an
approved type, aggregate shall be measured by volume / weight. The machines
shall be kept clean and in good condition and shall be checked adjusted for
accuracy at regular intervals when required by the engineer. Material shallbe
weighed within 2.5% tolerances, inclusiveof scale and operating errors. The
weigh batching machines / Measuring Boes shall dischargeefficiently so that no
materials are retained.

66
6.Concreteshall be mixed in mechanical mixers of an approved type. In no case
shall the mixing of each batch of concrete continue for less than 2 minutes. The
water to be added in concrete shall be adjusted based on moisturecontents in
fine and coarseaggregates. During hot and cold weather, suitable methods to
reduce the loss of water by evaporation in hot weather and heat loss in cold
weather will be adopted as per procedureset out in IS: 7861.
7.The compaction of concrete will be done by immersion type needle vibrator
which shall be inserted into concrete in vertical position not more than 450 mm
apart. Vibration will be applied systematically to cover all areas immediately after
placing concrete and will be stopped when the concrete flattens and takes up a
glistening appearance or rise of entrapped air ceases or coarseaggregate blends
into the surfacebut does not completely disappear. The vibrator shall be slowly
withdrawn to ensureclosing of the hole resulting from insertion.
8.Unless otherwiseapproved, continuous concreting shallbe done to the full
thickness of foundation rafts, slabs, beams & similar members. For placing on
slope, concreting will be started at the bottom and moved upwards. Concrete
shall not fall from a height of more than 1mto avoid segregation.
9.Special careshall be taken to guarantee the finish and Water-Tightness of
concrete for liquid retaining structures, underground structures and thoseif
specifically mentioned. The minimum 3.9 level of surfacefinish for liquid retaining
structures shall be Type F-2 and it shall be Hydrotested to approved procedure.
Any leakage during hydrotestor subsequently during direct liability period, if
occurred shall be effectively stopped either by cement /epoxy pressuregrouting
or any other approved method.
10.Curing of concrete with approved water shall startafter completion of Initial
setting time of concrete and in hot weather after 3 hours. Concretewill be cured
for a minimum period of seven days when OPCwith high water cement ratio is
used, curing for minimum 10 days in hot weather or low water cement ratio is
used and where mineral admixture used minimum curing period is 14 days.
Freshly laid concrete shall be protected from rain by suitable covering. Curing
shall be done by continuous sprays or ponded water or continuously saturated
coverings of sacking canvas, hessain or other absorbentmaterial for the period of
complete hydration with a minimum of 7 days. Curing shallalso be done by
covering the surfacewith an impermeable material such as Polyethylene ,which
shall be well sealed and fastened. Alternatively Curing compound of approved
make can be applied immediately after stripping of formwork.
11.Theworkability of concrete shallbe checked by the site engineer. 3.12 The

67
prepared surfaceshall be inspected and certified in pour card.
12.Staining or discoloration shall be washed out. If surfaceis not up to the
acceptable standard, as 3.13 per IS 456, cementwash is to be provided on
exposed concrete surfaceof foundation, beam, column, wall etc.
13.Allblemishes and defect if any, shall be rectified immediately after the
removalof formwork.
14.For each sample of concrete pour 150mm cubes shallbe prepared and cured.3
no. shallbe crushed at 7days and other 3 no. at 28 days. Record shall be made for
each test in enclose dormats as per ITP.
15.PVC water stoppers shallbe provided in construction joints as per AFCdrawing
confirming to IS-12200. Prior approvalshallbe taken for location & material.
PLANNING DEPARTMENT
Construction planning is a fundamentaland challenging activity in the
management and execution of construction projects. Itinvolves thechoice of
technology, the definition of work tasks, theestimation 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. Developing the construction
plan is a critical task in the management of construction, even if the plan is not
written or otherwiseformally recorded. In addition to these technical aspects of
construction planning, it may also be necessary to make organizationaldecisions
about the relationships between project participants and even which
organizations to include in a project.
Essential aspects of construction planning include the generation of required
activities, analysis of the implications of these activities, and choice among the
various alternative means of performing activities.
In developing a construction plan, it is common to adopt a primary emphasis on
either costcontrol or on schedule control. Some projects are primarily divided
into expense categories with associated costs. In these cases, construction
planning is costor expense oriented. Within the categories of expenditure, a
distinction is made between costs incurred directly in the performanceof an
activity and indirectly for the accomplishmentof the project. For example,
borrowing expenses for project financing and overhead items are commonly
treated as indirect costs. For other projects, scheduling of work activities over
time is critical and is emphasized in the planning process. In this case, the planner

68
insures that the proper precedence’s among activities are maintained and that
efficient scheduling of the available resources prevails. Traditionalscheduling
procedures emphasizethe maintenance of task precedence’s (resulting in critical
path scheduling procedures) or efficient use of resources over time (resulting in
job shop scheduling procedures). Finally, most complex projects require
consideration of costand scheduling over time, so that planning, monitoring and
record keeping must consider both dimensions. In these cases, the integration of
schedule and budget information is a major concern.
A parallel step in the planning process is to define the various work tasks that
must be accomplished. These work tasks representthe necessary framework to
permit scheduling of construction activities, along with estimating the resources
required by the individual work tasks, and any necessary precedence’sor required
sequence among the tasks. The terms work "tasks" or "activities" areoften used
interchangeably in construction plans to refer to specific, defined items of work.
Planning department in L&T uses MicrosoftProject as a powering tool for
reducing risk. MicrosoftProjectgives efficiency to plan a project, identify the
resources required and identify the tasks required in a sequence, increasing
probability of delivery of the project to the time, cost and quality objectives.
MicrosoftProjectgives you a powerful, visually enhanced way to effectively
manage a wide range of projects and programs. Frommeeting crucial deadlines,
to selecting the right resources, Microsoftprojectempowering your teams.
The initial schedule of major construction activities S0 is prepared according to
the Clients preference. S0 is the basis for all types of scheduling. Preliminary
schedules representing the monthly work estimates are prepared based on
experience considering local climate conditions, environment, learning curve,
pace of work, mobilization, etc. in MicrosoftProject. Productivities of different
activities are estimated and validated during the courseof execution. Man power
requirement calculated based on these productivities. Drawings released by the
Client. Revisions and changeorders are issued as and when there is a change and
distributed to all the units. The planning systemis updated in the first week of
every month. Two progress schedules aremaintained – original schedule
prepared in the starting of the project, planned schedule which is modified
according to the requirements and conditions. Actual progress is compared with
the planned scheduleand in case any delay in progress is then a Catch up
schedule is prepared and executed accordingly to overcomethe delay.

69
L&T FORMWORK
 L&T Formwork Business Unit, offers “TotalFormwork Solutions” for alltypes of
reinforced concrete structures for varied applications. Formwork gives formor
shapeto concrete and also it supports theweight of concrete until it attains
sufficient strength to carry its own weight.
 L&T formwork ensures speedy construction with high levels of accuracy and
superlativeconcrete finish together with enhanced productivity.
 L&T Formwork Systemis an engineered, fully compatible arrangement of
different components with an optimal number of individual elements having
inbuilt safety features, for various forming requirements of Concrete
Construction. These components are freely interchangeable for different
applications, lending considerableflexibility apart fromminimizing investment.
 Systems marketed include Large-area Wall formwork, Column formwork, Flex
systems for RC floors, Heavy duty towers for heavy and tall floors, Advanced
Automatic & Semi-automatic Climbing formwork systemand Modular panel
systems like Framiused for casting RC walls and columns.
 The Formwork Business Unitalso undertakes design, fabrication and supply of
custom-builtFormwork assemblies for specialized applications like Slipformfor
tall structures like Chimneys, Silos, Cores of high-risebuildings; Tunnel forms for
multi-storied buildings, Aluminium Formwork for Slabs and Walls , etc.,
 L&T’s modern factory at Pondicherry has a capacity to manufacture20,000 TPA
of L&T Formwork. Theunit also has facilities for manufacturing 12 lakh running
metres per annumof H-16/H-20 timber beams.

70
FOUNDATION FORMWORK
Floor Form Form clip Floor Form Corner
Lapping Plate Pipe Waler Pipe Waler Clamp
Waler Connector Threaded plug for floor form

71
WALL AND COLUMN FORMWORK
AdjustableSplice Plate AdjustableWaling Splice Plate
Angle Plate Assembly Angle Lifting Bracket
Anchor Plate Foot Adapter Assembly Head Adapter Assembly

72
FLEX SYSTEM
Floor Prop CT Assembly Wedge Clamp Beam Forming Head
4-way head Folding Tripod Beam forming support
AdjustableBeam side Beam forming support Star Grip Nut
Extension Extension

73
CONCLUSION
Working as a part of RMZ-Galleria projectwas an enlightening experience for me
as a budding civil engineer. I consider myself really fortunate and proud to have
become part of this wonderfullearning opportunity. The internship programme
offered me vastsite experience which I couldn’thave acquired elsewhere.
Sophisticated construction equipments, modern construction techniques bound
with immaculate theoretical know-how was whatI cameacross in the project.
Application of text book knowledge in the field, testing, learning about
components and parts and construction planning are among the various elements
I mastered during my time.
This was solely due to the full co-operation and guidance of all the officials,
engineers, staff and workers who arepart of L&T to whomI’mindebted to.
This was an unforgettablelearning experience!

Internship Report_Vishak

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