Casagrande Internship Report

INTERNSHIP REPORT (APRIL-JUNE 2016)
1 | P a g e N I C M A R M A S S E Y S
CASA GRANDE MASSEYS
Internship Report (April-June 2016)
By
NICMAR GOA STUDENTS
Vasireddy Venkat Raghav

ACKNOWLEDGEMENT
We would like to thank the Management of Casa Grande company, who gave us a
Privilege to work in company for two months, thanks to Mr. Raja Durai sir, who
Organised our presentations effectively and gave us a freedom to learn what we want.
Special thanks to Mr.Reddy sir (VP of Casa Grande Civil Engineering Department)
for giving his Valuable suggestions in presentations.
Thanks to our Masseys project GM sir (Mr. Rajiv Kumar) and
PM (Mr. Chandra Bommu) who monitored our work and gave a support to do work
in this Project. Special thanks to all the Staff of MASSEYS project of various
Departments who gave us valuable information by sharing their experiences with the
project, without them the report would not be possible.
By getting all the information from various departments, we
Made some Recommendations in the report which can be improved in their areas,
These recommendations are purely based on our study. We gone through every depar
tment of the project and took suggestions from them, some of the recommendations
mentioned in the report are reflected from the ideas of employees, which may be
Useful for the development of the company.
We are Thankful to our NICMAR institute and faculty for their
contribution by giving us ideas and techniques which made our work easier in
Internship.

TABLE OF CONTENTS
1) OVERVIEW OF THE COMPANY...................................................................... 5
2) ABOUT THE PROJECT....................................................................................... 6
2.1) PROJECT HIGHLIGHTS.................................................................................. 7
2.2) CONTRACTORS AND CONSULTANTS....................................................... 9
2.3) TYPICAL FLOOR PLAN................................................................................ 10
2.4) SPECIFICATIONS OF THE PROJECT ......................................................... 11
2.5) LABOUR & EMPLOYEES............................................................................. 13
2.6) RMC PLANT (READY MIX CONCRETE)................................................... 16
2.7) TECHNICAL DETAILS.................................................................................. 20
3) SPECIFICATIONS AND METHODOLOGY .................................................. 23
3.1) FOUNDATION................................................................................................ 23
3.2) BEAMS ............................................................................................................ 30
3.3) SLAB................................................................................................................ 32
3.4) COLUMNS....................................................................................................... 34
3.5) BLOCKWORK ................................................................................................ 37
3.5.1) FLEXCRETE (THE BONDING AGENT)................................................ 42
3.5.2) LINTELS AND BAND CONCRETE ....................................................... 44
3.6) PLASTERING.................................................................................................. 46
3.7) FLOORING...................................................................................................... 51
3.8) FORMWORK ERECTION (COLUMN)......................................................... 55
3.9) QUANTITY CONSUMPTION IN MASSEYS PROJECT............................. 57
4) LEARNINGS FROM PROJECT ....................................................................... 60
5) VARIOUS DEPARTMENTS IN PROJECT..................................................... 61
5.1) STORES DEPARTMENT ............................................................................... 62
5.2) MARKETING DEPARTMENT...................................................................... 65
5.3) QUALITY DEPARTMENT ............................................................................ 67
5.4) SAFETY DEPARTMENT............................................................................... 75
5.5) EXECUTION DEPARTMENT ....................................................................... 87
5.6) PLANNING DEPARTMENT.......................................................................... 91

6) DELAYS IN MASSEYS PROJECT................................................................... 93
6.1) MEASURES TO BE TAKEN TO OVERCOME DELAYS........................... 96
6.2) METHODOLOGY ADOPTED TO OVERCOME DELAYS ........................ 97
7) RECOMMENDATIONS ..................................................................................... 98
7.1) VARIOUS COST REDUCTION TECHNIQUES IN HIGH RISE
BUILDINGS............................................................................................................ 98
7.2) JIT TECHNIQUE........................................................................................... 104
7.3) QUALITY CIRCLES CONCEPT.................................................................. 107
7.4) PDCA APPROACH....................................................................................... 110

1) OVERVIEW OF THE COMPANY
Casa Grande private limited established in 2004 is an ISO –certified real estate
enterprise committed to building aspirations and delivering value. In the last eleven
years the company developed over 3 million sft of prime real estate across Chennai,
Bangalore and Coimbatore. Over 3000 happy families across 64 landmark properties
stand testimony to their commitment.
Casa Grande is all set to take the leap with projects in pipeline netting over 2500
crores.so far the company has completed 41 successful projects over various regions
of Chennai and Coimbatore. The company is trademark for Luxury Villas, it is
famous for on time delivery and quality, hence leading the construction industry as
Number 1 Villa developer in Chennai.
Some of the projects of Casa Grande are THE ADDRESS, RITZ, CHERRY
PICK, ELAN, PAVILION, ARISTO, and VIVANT etc. In few years it is going to
launch projects in Hyderabad, Bangalore, cochin and some parts of south India.Casa
Grande is counted as the best builders in Chennai, with projects worth Rs 2500 crores
Mission:
 To be a 3000 Crore Turnover Company by 2019
 To be a PAN South India Player through a position of Dominance/ Relevance
in each of the geography
 Continue to be the Most Preferred employer
 To be the most trusted Real Estate brand by 2019
Vision:
Customer Delight through Excellence in product, highest standards in Quality, and
On-time Delivery.

2) ABOUT THE PROJECT
CASA GRANDE MASSEYS
The first ever luxury multi-storied condominium in North Chennai takes shape at
Masseys. 91 exclusive apartments, the only high rise of 14 floors at a prime location
and with a magnificent sea view.
Muti-storied lifestyle condominium with a magnificent sea view.
Location: In Royapuram, the business hub of Chennai, Tamil Nadu.
Present status of site (10th
June 2016)

2.1) PROJECT HIGHLIGHTS
 Pile foundation.
 Post Tensioning Slab for Basement &Stilt floor, Post Tensioning for beams of
1st
floor.
 91 exclusive luxury apartments spread over 14 floors.
 Stilt + 14 storey structure with contemporary new age design.
 Basement, stilt &1st
floor are for car parking.
 Started on July 2015 and about to complete on July 2017. (2 years).
 Each floor consists of 7 Flats.
 Residential flats starts from 2nd
floor and continue up to 14th
floor, they are
named as A,B,C,D,E,F,G,H,I,J,K,L,M .
 All together residential floors are 13. (13x7=91 flats).
 2 BHK flats for single Floor is 3, & 3 BHK flats are 4. (Total=7/floor)
 Area: 2 BHK of 1152-1165 sft, 3 BHK of 1429-1589 sft.
 Total plinth area 10,500 sft.
 Project cost is around 30 crores.
 Imported vitrified tiles and high end Kohler fittings.
 Located on main road near Royapuram Bridge. (3 min to beach station & 10
min to central railway station.)
 Close to reputed school and colleges.

Elevation view of the structure (East Facing)
Amenities and features:
Gymnasium.
Grand lobby with fountain.
Association conventional hall.
Gazebo at terrace with pleasing landscaping.
2 Elevators and 2 Stair cases.
Security features like intercom and CCTV.
Common washrooms.
Rain water harvesting.

2.2) CONTRACTORS AND CONSULTANTS
Consultants (structural) is Universal consultants.
Consultants (Architectural) is Naksha Consultants.
Contractor for RCC & Plastering Work is CG SKYWORLD.
Type of contract is Turnkey, only Labour contract.
Material is supplied by the company itself.
Contractor for Electrical works is BL Electricals.
RMC plant Contractor is Southern Engineers.
Sea view from the project

2.3) TYPICAL FLOOR PLAN
Unit no. A1 to M 1. Size 1436 sft.
Typical floor plan

2.4) SPECIFICATIONS OF THE PROJECT
Structure:
 RCC framed structure with pile foundation.
 Anti-termite treatment.
 8 inch solid block work for outer wall and 4 inch Solid Aerocon for internal
wall.
 Roof height is 10feet from slab to slab.
Wall finishes:
 Internal wall in the living ,dining, bedrooms , kitchen and lobby with 1 coat of
primer , 2 coats of putty and 2 coats of plastic emulsion ( ace/apex )
 Ceiling with cement paint.
 Exterior faces of the building with 1 coat of primer and 2 coats of emulsion.
 Utility and toilets with 1 coat of primer and 2 coats of cement paint.
 Toilet walls with glazed ceramic tiles up to 7 feet height for aesthetic finish.
 Utility walls with glazed ceramic tiles for aesthetics up to 4 feet height.
Flooring:
 2x2 feet imported double loaded vitrified tiles in living, kitchen, dining.
 Anti-skid ceramic tiles in bathrooms, balconies and utility.
 Interlocking paver blocks in the driveway.
 Grano tiles in car parking.
 Tile/granite/marble in common areas and staircase.
Kitchen:
 Provision for LPG cylinder in utility.
 Provision for water purifier.
 Provision for chimney.
 Plumbing and electrical provisions for modular kitchen.
Bathrooms:
 Concealed diverter in all bathrooms.
 CP fittings and sanitary fitting will be Kohler/ Roca or equivalent brand.
Entrance Doors:
Main door of 7 feet height with teak wood frame and double side veneer finish skein.

Bedroom Doors:
Seasoned good quality wooden frame panelled skein doors with enamel finish of 7
feet height.
Windows:
 UPVC window with see through plain glass.
 French doors to access balcony, with high end aluminium frame and
toughened glass.
 Ventilators of aluminium frame with suitable louvered glass panes and iron
bars.
 MS- grills for windows wherever required.
Electricals:
 Finolex cables and wiring.
 Modular plate switches, MCB and ELCB (Earth leakage circuit breaker).
 MK switches and sockets.
Elevator:
 2 lifts are there in project.
 1 lift of capacity 15 passenger & other is of 10 passengers.
Power Supply:
3- Phase power supply for all apartments.
Generator backup:
 750 watts of 24x7 power back up to all apartments.
 100 % power backup for all common areas.
Fire safety Norms:
Sprinkler system is provided for entire building.

2.5) LABOUR & EMPLOYEES
Labour
Almost 120 labour from CG sky world (contractor) is working every day.
The labour are mostly from West Bengal, Orissa, and Bihar.
Labour type contract is Turnkey Basis.
Skilled labour =450rupees / day.
Unskilled Labour=350 rupees /day.
No women and child Labour in site.
No labour from Tamil Nadu is employed in site, since they are charging 650
rupees/day, which is expensive.
Every day there is provision in site to note down labour in time and out time in time
office.
Extra payment is also made when the labour are working overtime when the schedule
is under progress.
Daily Labour Attendance
89 91 92
106
79
93
82
107
62
112
91
100
No of Workers CG Sky world
No of Workers

Employees
In Casa Grande there are 22 employees in Masseys Project.
General Manager (Rajiv Kumar .M)
Project Manager (Chandra Bomu)
Project Engineers (4).
Site engineers (2).
Senior engineers (2).
Safety Engineers (2).
Quality engineers (3).
Stores Manager (2).
Senior Foreman (3).
Electrical Engineer (1).

RECOMMENDATIONS (labour and Employee benefits)
Labour scarcity, there should be some more labour employed in site.
For plastering only 4 members are there, hence work is getting delayed.
Labour is not following few of the safety and SOP practices, which should be
avoided.
Labour is getting tired because of the overtime work in few cases, to avoid that
Pleasant Music is recommended in site during their work.
Labour shifts to be followed.
Employees are assigned multiple tasks like…
(Planning dept., assigned work of quantity estimation, Safety dept. assigned work of
Time Office entry.) Which creates more burden on the employees, so separate
supervisors/engineers are employed for particular work.
Due to continuous work without any holidays the employees are feeling stressed, so
at least once in a week should be Holiday.
Employees are working for more than 12 hours in a day, and when the concreting in
night takes place even they are staying for late nights, which creates less enthusiasm
in work in the next day. So there should be a holiday, the next day of overtime or
there should be Employee shifts to make the employees active during work.
Temporary Lift should be provided for Staff to monitor the work effectively, since
it is a 14 floor structure, it’s getting difficult for the staff to go up to the working
area several number of times and check the progress of work.
Rewards for employees to be given to recognise their services to the company.
There should be coordination between the employees of various Departments in
project, daily or weekly the employees are to be bought to a single area and
discussions are to be carried out. Daily meetings should be there.
Health check-ups quarterly once should be done to employees, since Employee
Health increase the productivity of work.

2.6) RMC PLANT (READY MIX CONCRETE)
The site MASSEYS is having a RMC plant installed at site.
The contractor for Plant is Southern Engineers.
RMC Plant
Salient features of RMC (Ready mix concrete):
 The plant has a capacity to deliver 8 cu.m of concrete per hour.
 For casting the entire slab area of plinth area 10,500 sft, it requires 150-
160cu.m of concrete.
 Admixture veraplast MC 543 is used.
 M sand (manufacture sand) is used in concreting.
 River sand is used for mortar mix. (1:3)
 GGBS (Ground-granulated blast-furnace slag) is used as replacement for
cement, along with cement.
 Water cement ratio: 0.34.
 Admixture dosage: 0.3 %.
 The aggregates are watered before mixing.

Standard operating procedure for RMC plant
Don’t accept the concrete after 3 hours of Mixing.
The horizontal section of pipe should be at least 7 metres before the vertical bend is
put.
Reduce the length of pipe to the minimum to reduce frictional losses and excessive
strain on the pump.
The pipeline should be independently supported on vertical segment and not on the
shuttering.
Pump rich slurry (1 bag) before pumping concrete to lubricate the inner surface of
pipes.
Advantages in using GGBS:
GGBS perfectly suited to our site MASSEYS (A high rise building) and it is giving
better results when compared to the conventional concrete when tested at site during
cube strength.
 Ensures higher durability of structure.
 Reduces the temperature rise and helps to avoid early-age thermal cracking.
 Improved workability.
 It is off-white in colour and substantially lighter than Portland cement. Resultantly it
helps soften the visual impact of large structures such as bridges and retaining walls.
 Very economical and reduces the cement cost.
Concrete( all quantities
in kgs)
M 30 grade M 40 grade
Cement 240 270
GGBS 160 180
20mm( CA ) 658 669
12.5 mm (CA) 434 446
M-Sand 816 775
Water 160 155
Admixture - 1350

Concrete supply by RMC plant report
CONCRETE SUPPLY FOR THE PERIOD OF 22/05/2016 TO 30/05/2016
DATE DC.NO Vehicle GRADE UNIT QTY REMARKS
21-05-2015 213 Pump M40 Cum 3.50
22-05-2015 214 Pump M40 Cum 6.51
23-05-2016 215 Pump M40 Cum 5.20
23-05-2016 216 Pump M30 Cum 1.50
23-05-2016 217 Pump M30 Cum 1.00
24-05-2016 218 Pump M40 Cum 4.50
24-05-2016 219 Pump M30 Cum 84.50
27-05-2016 220 Pump M40 Cum 1.50
28-05-2016 221 Pump M40 Cum 7.30
28-05-2016 222 Pump M30 Cum 2.30
29-05-2016 223 Pump M40 Cum 5.05
30-05-2016 224 Pump M40 Cum 3.00
30-05-2016 225 Pump M30 Cum 75.00
200.86
M30 m3 164.30
M40 m3 36.56

RECOMMENDATIONS
 The present RMC plant has a capacity to pump concrete of 8 cu.m per hour.
Which takes more time for concreting the slab.
 The slab (including beams) requires 160 cu.m of concrete for casting, so it
takes almost 20 hours for casting a slab. It became a prime factor in delay of
project.
 It is recommended to increase the capacity of plant which should pump at
least 20 cu.m of concrete per hour.
 Maintenance of RMC plant is not proper, it is recommended to clean the plant
and inspect for every one week.
 Pumps which carries concrete should also be cleaned after used.

2.7) TECHNICAL DETAILS
Clear cover spacing
Footing, Raft slabs & Raft beams 50
Columns 40
Lintels & beams 25
Sunshade & slabs 15
Pile & pile cap 50
For earth Quake analysis zone -3 is taken as per IS 1893-2002 code.
 M 40 Grade is used for Columns, Parapet Walls, Shear walls and M30
Grade is used for remaining RCC structures.
 Lintels, band concrete grade is M30.
 Grade of steel used is Fe500 for all members.
 Pile concrete grade is M30.
 Screed concrete & PCC grade is M10.
 Grade of cement used is 53 grade.
 PT beam of 1st
floor Roof M50 grade concrete is used.
 PT slab M40 grade is used.
 In concreting works M-sand (Manufacture sand/Robot sand) is used.
 Aggregates are of 20mm and 12mm.
 Reinforcement bars are available at various sizes 32, 25, 20, 16, 12,
10&8mm bars are used in project.
 ISMB 100 sections are used for beam supports.
Lap joints for reinforcement bars:
 At any cross-section of member not more than 40% of bars should be lapped.
 Lap length shall be 50 times the diameter of bar for both compression and
tension members.
 Laps in columns are placed at mid height of floor and not at slab level.
 Laps in beams and slabs are provided at point of contra flexure.

Bar bending
Props to slabs:
Slabs spanning up to 4.5 M (15’ -0”) – 7 days.
Slabs spanning over 4.5 M (15’-0”) - 14 days.
Props to beams & arches:
Slabs spanning up to 6 M (20’ -0”) – 14 days.
Slabs spanning over 6 M (20’-0”) - 21 days.
Reinforcement details:
 Spacer bar is provided in between two layers of reinforcement of same
diameter at every 1000 c/c.
 Hook length of stirrups are 10 diameter (>75 mm).
 Stirrups diameter is 8 mm, and they are placed at 200mm c/c & 120
mm c/c depending on the structural design and length of beam.

 Reinforcement bars in slabs used are 8mm and 10 mm at spacing of 150mm,
180mm & 200 mm as per drawing, which differs from slab to slab.
 Reinforcement bars in columns used are 32 mm, 25mm, 20mm, 16mm, and
12mm.
 Ties used in columns are of 8 mm of 200 mm c/c spacing.
Some of the practices in site for reinforcement.
 Tolerances for cutting of reinforcement =+75 or -25 mm.
 Bending tolerance=+0 or -10 mm
 Bar spacing = + or – 10 mm.
 Spacer bars are maintained vertical distance between successive layers of bars.
 A separate engineer with prior experience in reinforcement works is employed
at site to supervise works.
 Binding wire is turned inside and it didn’t stick out to the surface.
 At the time of concreting, reinforcement bars are free from mud, oil, grease or
other foreign material.
 Mechanical splicing and welding of rods are done only after proper details and
instructions are available from structural consultant.
 Rods are cut as per BBS.
 Before placing rods, the plywood is cleaned and oiled.

3) SPECIFICATIONS AND METHODOLOGY
3.1) FOUNDATION
Foundation is the element of an architectural structure which connects it to
the ground, and transfers loads from structure to the ground. Foundation is generally
considered either shallow or deep.
At Masseys site, deep foundation is used. In deep foundation, pile foundation
is used. Total no of piles is 114.Various types of piles are shown below.
M30 Grade concrete is used for piles.
Pile layout

There are 2 types of piles used, each of diameter 750
mm and 900 mm.
 900Ø-62 piles
 750Ø-52 piles
 Total no of piles is 114.
It almost took 2 hours for casting a single pile.
REINFORCEMENT DETAILS FOR 750Ø
 Main rod -16mm , 13 no’s
 Inner ring -16mm, 200mm c/c
 Helical ring -8mm, 200mm c/c.
REINFORCEMENT DETAILS FOR 900Ø
 Main rod - 20mm, 13 no’s
 Inner ring -16mm, 200mm c/c
 Helical ring - 8mm, 200mm c/c.
Type
of
pile
cap
No.
of
piles
Diameter
of each
pile
P1 2 750ø
P3 12 900 ø
P4 2 900 ø
P5 7 900 ø
P6 20 900 ø
P7 4 900 ø
P8 7 900 ø
P9 5 900 ø
P9(A) 1 750 ø
P10 5 900 ø
P11 12 750 ø
P12 10 750 ø
P13 11 750 ø
P14 10 750 ø
P15 6 750 ø

Pile cap(P1)
Reinforcement detail for P1 pile cap
Top rod 16 ø 8 no’s
Bottom rod 25 ø 8 no’s
Binders - Top & Bottom 10 ø @180 mm
Binder – Outer 12 ø @150 mm
Lapping 12 ø @150 mm

Pile cap (P3)
Reinforcement detail for P3 pile cap
Top rod 16ø 5no’s
Bottom rod 25 ø 8 no’s
Binders - Top & Bottom 10 ø @180 mm
Binder – Outer 12 ø @150 mm
Lapping 12 ø @150 mm

PILE LOAD TEST PROCEDURE
Test pile preparation
The test pile is cut at the proper level by removing casing and chipping the concrete
and reinforcement bar up to proper level. Reinforcement bars are cut below 75 mm
from proper level where proper finishing of top surface is done with GP2 and stone
chips mortar and the same is allowed for curing for days.
Excavation for Test Pile pit shall be done up to pile cut of level by keeping
sufficient working area around the Pile. Wherever water table is above the Cut off
Level, the test pit shall be kept dry throughout the test period by suitable dewatering
methods.
Equipment and test set up
A steel plate of sufficient thickness shall be placed centrally on the pile head to prevent
it from crushing under applied load. The size of the plate shall not be less than the pile
size or less than the area covered by the base of the hydraulic jack(s).
The datum bars are placed on immovable supports of concrete pillars placed at
3 m away from edge of test pile on both ends. The dial gauges of 0.01mm least count
are fixed to the datum bar duly using magnetic base and the plunger is placed on glass
plates fixed to the bottom plate 4 dial gauges of MITUTOYO make with a least count
of 0.01 mm are placed diametrically opposite location suspended on datum bar
supported on concrete pillar around the pile with the plunger toughing on the glass
plates fixing to the bottom plate. The load is applied to the pile top in increments (steps)
of about 20% of safe load on the pile. Each increment of load is applied as smoothly
and expeditiously as possible. Settlement reading were taken before and immediately
after the application of next increment and at 30 minutes until application of the next
load increment.
Each stage of loading was maintained until the rate of displacement of the pile top is
either 0.1mm in 30minutes or 0.2mm in one hour or till 2 hours whichever occur first.
Loading on pile shall be continued till Applied load reaches two and half times the
assumed safe load or the settlement of pile exceeds a value equivalent to 10% of pile
diameter.
Where yielding of the soil does not occur the full test load shall be maintained on the
pile head for a minimum period of 24 hrs after the last increment of load and settlement
shall be recorded at hourly intervals during this period, however the interval can be
increased to 6 hours to suit the actual site conditions encountered. Unloading shall be
carried out in the same steps as loading. A minimum period of 15 minutes shall be
allowed to elapse between two successive stages of load decrement.

The final rebound shall be recorded 2 hours after the entire test load has been
removed.4 dial gauges of MITUTOYO make with a least count of 0.01 mm are placed
diametrically opposite location suspended on datum bar supported on concrete pillar
around the pile with the plunger toughing on the glass plates fixing to the bottom plate.
The load is applied to the pile top in increments (steps) of about 20% of safe load on
the pile. Each increment of load is applied as smoothly and expeditiously as possible.
Settlement reading were taken before and immediately after the application of next
increment and at 30 minutes until application of the next load increment. Each stage
of loading was maintained until the rate of displacement of the pile top is either 0.1mm
in 30minutes or 0.2mm in one hour or till 2 hours whichever occur first.
Loading on pile shall be continued till Applied load reaches two and half times
the assumed safe load or the settlement of pile exceeds a value equivalent to 10% of
pile diameter. Where yielding of the soil does not occur the full test load shall be
maintained on the pile head for a minimum period of 24 hrs after the last increment of
load and settlement shall be recorded at hourly intervals during this period, however
the interval can be increased to 6 hours to suit the actual site conditions encountered.
Unloading shall be carried out in the same steps as loading. A minimum period of 15
minutes shall be allowed to elapse between two successive stages of load decrement.
The final rebound shall be recorded 2 hours after the entire test load has been removed.
Loading method:
 The load shall be applied to the pile in increments of about 20% of the safe
capacity of pile.
 Each stage of loading shall be maintained till rate of movement of pile top is not
more than 0.1mm/30 min or 0.2mm /hrs or until 2 hrs have elapsed.
 Increment of loading continued till
1) Applied load reaches 3 times the safe vertical load carrying capacity or
2) The maximum l settlement of pile exceeds 10% of dia of pile.
 Full test load shall be maintained on the pile head for a minimum period of 24
hrs after the last increment of load has been applied.
 Unloading shall be carried out in the same steps as loading minimum of 30
minutes shall be allowed to elapse between two successive stages of load
decrement.
 The final rebound shall be recorded 6 hours after entire test load has been
removed.

Assessment of Safe Load:
The safe vertical load carrying capacity of single pile shall be least of
1. Two-third of the final load, at which the total settlement is 12 mm and
2. 50 % of the final load, at which the total settlement equals to 10% of pile
diameter.
Pile load checking
Result of Pile load test
S.No Description Result Remarks
1 Settlement on working load 0.695 mm (387.840MT)
2 Settlement on test load 4.968 mm (601.520MT)
3 Rebound 1.896 mm 4.968-3.072
4 Final settlement 3.072 mm Final settlement
Conclusion: At 900 ø pile, 750 ton of load is applied. Final settlement of pile is 3mm
but the allowable final settlement of pile is 20 mm. Based on the pile load test it ensure
that foundation is at good strength.

3.2) BEAMS
A total of 149 beams are there for a typical floor.
The cross-section of beam is 200x600mm.
 Reinforcement bars in beams used are 12mm, 16mm, 20mm, and 25 mm
diameter.
 Note: 25 mm rod is used for a critical span, this rod is used as an extra
reinforcement in compression zone, along with 12mm or 16mm bars. Which is
provided at the intersection of column and beam.
(12mm rods in compression zone, 16 &20 mm rods are placed in tension zone
in beam.)
 Stirrups diameter is 8 mm, and they are placed at 200mm c/c & 120 mm c/c
depending on the structural design and length of beam.
Typical cross-section of beam.

Concrete consumption for Beam.
Reinforcement consumption in Roof beams

3.3) SLAB
Slabs are designed as 1-way and 2-way slabs.
Concrete required for casting entire slab is 112 cu.m for a plinth area of 10,500 sft.
Reinforcement for slab
Cover blocks are provided at adequate distance.
Cover used for slab is 15mm.
Thickness of slab is 130mm.
 Reinforcement bars in slabs used are 8mm and 10 mm at spacing of 150mm,
180mm & 200 mm as per drawing, which differs from slab to slab.
 Needle vibrator of 50 mm diameter is used for compaction of concrete in slab.
 The level of concrete is checked after pouring the concrete.
 During slab casting SOP is followed.
 Curing is done for 7 days, method of curing adopted is ponding.

Typical slab layout
Recommendation:
 It is better to cast slab in night than in afternoon, since the freshly casted
concrete has chances of getting cracks when it is exposed to sunlight.
 Filler slab technique to be followed to reduce the concrete quantity.
 Curing should be done properly for 7 days.

3.4) COLUMNS
Number of columns for basement, stilt and 1st
floor=31 each floor.
Number of columns for 2nd
to 14th
floor =62 each floor.
Various Diameters of Reinforcement used in columns are 32, 25, 20, 16&12mm.
Maximum diameter used in column is 32mm.
Lap length of rod for a column is 50(dia).
Curing for column is done by curing compound POLY CURE-R.
DE shuttering for columns is done after 8 hours.
Typical column details

Column layout

Column concrete consumption
Column reinforcement consumption

3.5) BLOCKWORK
Aerocon Blocks are used for the entire structure.
Autoclaved aerated concrete (ACC) blocks. These blocks are light weight, easy to
handle and have high thermal insulation and sound absorption properties.
Aerocon Block
Instructions for using Aerocon blocks:
Unload blocks on a dry level surface raised above ground and cover them to prevent
exposure to rain or severe weather conditions.
Blocks can be easily cut/sawn, drilled, nailed and routed at site using recommended
tools. Cutting of blocks can be done by using handsaw.
Mortar for construction:
Recommended mortar for construction is 1:1:6 (cement, lime, sand) or 1:6 (cement,
sand).
The mortar shall not be spread so much ahead of the actual laying of blocks as it tends
to stiffen and lose its plasticity there by resulting poor adhesion to bond.
Maximum thickness of mortar should be 15mm.
Mortar consistency to be maintained at time of laying block masonry.

Laying of block work:
Do not soak the blocks during laying. All surfaces of blocks are to be moistened, using
wet brush, to prevent absorption of water from mortar. Best way is to dip and remove
the blocks.
For walls above ground floor, provide bed cement mortar 1:8, before starting the first
course of blocks .check the height.
Block sizes are 8 inch and 4 inch, hollow blocks.
Length of block is 60 cm.
Type of bond pattern used is stretcher bond.
Place the marker course of block (1st course) after checking the vertical & horizontal
alignment.
First measure if the given area is to plan as per correct and updated drawings.
The first course in blockwork is most important one. Using the spirit levels, check if
the erected wall is perfect –the surface should be free from undulations and cracks.
All concrete surfaces of beams and columns in contact with blockwork is to be
hacked. Since hacking is not used in our project. In place of hacking flexcrete is been
used.
Using the tape ensure the diagonals are equal.
Use Mesh for every 800mm height (4 layers of blocks) .the mesh used in project is
punching plate. Punching plate is used for only 4” inch block work (100 mm).
For bonding of block work to columns, Band concrete is provided at 1.2 m height
from floor level, wall ties are used to cast into columns at a vertical spacing not greater
than 500mm and is aligned with the horizontal mortar band. This is used for 4”
blockwork (100mm).
Note: For 8 inch walls band concrete and punching plate both are not used. Since the
8inch block itself gives the stability to wall.
Hollow blocks are used to fill the lowest (1st
course) with concrete 1:3:6 using 12mm
jelly to give a firm base for chipping to fix skirting.

Punching plate
Mix mortar in proportion of 1:5 on MS sheet using Farma Box for measuring sand
and a measuring can to standardize quantum of water to get a consistent mix.
Mix well for uniformity. Mix mortar in small manageable quantities and use it
within ½ an hour.
Mortar joints shouldn’t be more than 10 mm for both vertical & horizontal joints.
The joints should be neatly pointed using an aluminium straight edge or German
pointing trowel.
Don’t construct more than 1 m in a day.
Don’t place the topmost block under the beam until the immediate upper floor block is
raised up to the beam bottom, less one course.
In the top floor, build the parapet wall and do the water proofing and screed concrete
before placing and packing the last course.
Adjuster course in concrete 1:2:4 should be laid two in courses below the beam and
not above the topmost course.
Use hollow blocks at the location of electrical conduit and raise the conduit along with
the block work.
Dowel blocks to be left for further extension of block masonry.
Continuous horizontal chasing should be avoided. Chase block work using chasing
machines.
Start chasing after 21 days of block work construction.

For tiled surfaces it is a better option to chase after rough plaster is done and cured for
21 days.
All nibs adjacent to columns and less than 200 mm, should be cast in RCC at site using
M20 grade of concrete and curing for 7 days by covering with hessian clothes.
For mortar joints more than 10mm, packing of chasing for pipes, junction box etc.
Should be done in PCC 1:2:4 using 12mm jelly and cured for min 3 days.
Write down the date of work in paint on the block work and monitor the curing
accordingly.
Cure the block work by spraying water on the mortar joints only for at least 7 days.
Fibre Mesh
Cast the cut lintel, sill and chejjas over large openings, place them as end-to-end beam
type.
If bearing cannot the reinforcement be given as required lockset the reinforcement of
lintel into the column for a depth of 4d for cast insitu works.
Check chejjas and sills for toppling effect. If suspect, build counterweight courses for
lintel, sill and chajjas.
Continuous vertical mortar joints should be staggered and vertical movement joints to
be given every 12m.

Blockwork Check Using Plumbob
CARE AFTER BLOCK WORK:
 Do not entertain excessive chasing as it disturbs the mortar joints causing
hairline cracks and weakening the work.
 Don’t soak the blocks with water while curing. The moisture absorbed by the
blocks will be released subsequently causing volumetric variations and
shrinkage cracks.
 The interface between block and concrete is the most critical zone and needs
special care. This is due to incompatibility between two heterogeneous
materials.
 Before plastering these zones should be given special treatment.
 After 7 days curing of mortar joints drive a nail into the joint to test the
strength of joints at random.

3.5.1) FLEXCRETE (THE BONDING AGENT)
In our project Masseys, no hacking is done, instead of that a chemical called
flexcrete is applied.
 The outdated method of hacking concrete surfaces for plaster bonding is an
inefficient, slow and unreliable method.
 Modern construction methods specify the use of chemical bonding by polymer
dispersion bonding agents.
 It is applied at the junction of block work and RCC work.
 Flexcrete is a specially formulated pure acrylic polymer dispersion with
extraordinary adhesion and compatibility with concrete, plaster and masonry
surfaces.
Flexcrete compound (Along with mortar (1:1) on column)

ADVANTAGES OF FLEXCRETE:
 No need for hacking with Flexcrete.
 Flexcrete is quick and easy to apply; provides exceptional bond strength and
has a very long working time. And it is cheaper than hacking!
 Long working time means plaster can be applied up to 3 days after the bond
coat without compromising on bond. Other bonding agents require plaster to
be applied before they lose tackiness. Thus work scheduling flexibility is
greatly increased.
 Bonds new plaster/concrete, new /old concrete, new plaster/masonry.
Product specification:
Specific gravity : 1.05 kg/lt
Application : brush
Solid content : 45+2%
Expiry time : 6 months from manufacturing.

3.5.2) LINTELS AND BAND CONCRETE
Lintels are erected from 7ft above floor level.
Concrete Grade used in lintels is M30.
But aggregates size is 12 mm, we are not using 20 mm aggregates.
Lintels are Precasted and they are directly placed in that particular location.
Reinforcement bars used are 12mm, 8mm stirrups are placed at uniform placing.
Curing is done for 3 days.
Recommendation:
During erection of Lintel, it is getting difficult to cast in its position because of heavy
weight, since crane services can’t be utilised inside in the room, its is better to cast
lintel in cast-insitu
Reinforcement for lintel

Band Concrete
It is casted for every 1.2 metres from floor level, to a 4 inch wall block work.
Thickness of band concrete is 100 mm.
Main purpose of this concrete is to get more strength to blockwork and reduce cracks.
2 Reinforcement Bars of 12mm diameter is used for band concrete and they are
penetrated through some portion of column.
M30 grade concrete is used with 12mm aggregates.
It is not used for 8 inch Block work.
Band concrete Lintel

3.6) PLASTERING
All surfaces for plastering should be wet to prevent absorption of water from plaster.
Mix shall be generally CM (cement mortar) 1:4 for ceiling and 1:6 for wall plastering.
The CM mix should be used within ½ to 1 hour of mix.
All cut-outs such as fan, junction box, electrical box and skirting line should be finished
to perfection.
The blockwork should have been cured for 7 days and dry before plastering is started.
Button mark the surface to be plastered keeping the bull minimum. 12mm plaster is
desired thickness. Distance of button marks should be within an aluminium edge
length.
Plastering mesh should be 8 inch wide and fixed rigidly before plastering on the
junction between concrete and masonry surface with steel nails. The strip has to be
plastered and cured for min of 3 days before entire wall is plastered.
If thickness exceeds 15 mm, then plastering is done in 2 coats.
The first layer applied should be cured for a day before applying next coat.
In the project, for ceiling – putty finish, bathroom – cement plaster and for other
rooms gypsum plastering is been used.
For internal walls gypsum coating, followed by putty, primer and finally emulsion is
used.
Quantity estimation:
As per BOQ, 15mm thick internal plastering with gypsum plaster for Entire floor
required is 26,084 sq.ft
12mm tk. Ceiling Plastering in C.M 1:3 – for a floor required is 8,254.45 sq.ft.
Advantages of Gypsum Plastering:
No Curing is required.
Room will be cool.
Gives an excellent finishing to surface.
Cracks formation probability is less.
Gives aesthetic appearance to the surface.

Step-1) Application of Gypbond to RCC structures and Fibre Mesh fixing
Gypbond (for Beam)
Step-2) Button Marking
Button marking

Step-3) Levelling (connecting two button markings)
Step-4) finishing
Plastering work with gypsum

VANS GYPSUM :( Used in Masseys Site)
It is a pure gypsum based plaster suitable for most internal and partition surfaces
including brick, block and concrete. It consists essentially of pure gypsum hemihydrate
formulated with special additives to control application and setting characteristics. It
contains pure gypsum in natural form, eliminated from all impurities.
Advantages of using VANS GYPLAST:
 It gives plaster an unmatched workability because of its smoothness, coverage
and ease of application.
 When dried it provides a super white, smooth and fine finish (excellent strength
on drying).
 Thermal resistance & fungus free.
 Lightweight.
 Fire resistant.
 Humidity resistant.
 High coverage up to 92sq.m/t.
 Enhanced light reflection
imparting true colour one.
 Compatible with any type of
paint.
 Thickness can go up to 32mm.
 6 months shelf life.
 Mix ratio-1:1 water & gypsum by
volume.
 Crack free.
 No powdering.
 Gives cool atmosphere inside the
room.
Parameters Units
Dry bulk density 667-695 kg/m3
Wet bulk density 1.32-1.46gm/cm3
Initial setting time 14-18 min
Final setting time 24-26 min
Compressive strength(24 hours) 43.8 kgf/cm2
Compressive strength (48 hours ) 44.12 kgf/cm2
Approx. coverage 87-92 m2/t

Inference and Recommendations:
For plastering one room, it is taking 2 days of time, to complete the entire flat it is
taking around 10 days to complete work, which can be improved.
Out of 10 bags of gypsum, 2-3 bags of gypsum is going as wastage, there is more
wastage than required, which should be controlled.
Proper supervision for plastering work is not there, so there are chances for improper
work and errors in finishing.
Mixing of gypsum and water is not as per ratio.
Recommendation
During my interaction with labour, they said they are going to use gypsum plaster,
putty finish, primer and emulsion paint for internal walls of bedrooms and hall.
Since gypsum plaster itself is giving smooth finish to surface, putty finish is not
required, so that cost and time can be saved.

3.7) FLOORING
Vitrified tiles are used for the project.
Kajaria company tiles are being used.
 The tiles shall be ordered in sizes as determined by site dimensions to avoid
cutting at site.
 The floor drawing is given by the Architects (Naksha Consultants) based on the
drawing, they manufacture the tiles according to the size prescribed in drawing.
 The drawing is useful to ensure from where to start the tiles.
 The material received at site shall be checked for the following defects prior to
acceptance.
 Tiles of same type but with distinctly different color or texture shall be
rejected outright.
 Tiles shall be free from holes, seams, shakes, pockets, stains and other
effects and shall be of uniform color and texture.
 Dimensional tolerances shall be restricted to
Length + 0.5mm Width + 0.5mm
Aries + 0.5mm Plane + 1 / 500
 Ensure that the site is cleaned, taking care to remove any loose concrete, mortar
or other substances
 All chasing for the concealed piping, and electrical conduiting etc. shall be
carried out before commencement of work
 Make bull mark levels according to architectural specifications
 Design mix of Cement Mortar (1:6 or 1:8) to be followed.
 The thickness of mortar allowed is 25 mm from floor level.
 Ensure that the tiles to be laid are matched, numbered and available in the
required number for laying on the site
 Tiles are dry matched in the yard. They are then cut to the exact size required,
and numbered in the sequence and are laid at site in exactly the same order.
 As per drawing, work should be started by taking right angles for existing walls.
 Laying starts as per the previously numbered tiles
 The surface on which tile is to be laid is watered. A bed of mortar is placed on
the floor, and tiles are put into position with white cement slurry.
 Levelling is done with an aluminium straight edge and rubber hammer.
 If there is any slope, it has to be decided in the bull itself.
 Joint filler should make a joint filling material as per colour of the tiles

 Putty blade is used to rake all joints and fill the joint material neatly as the joints
will be paper joints.
 For fixing tiles to wall, suitable stainless steel mechanical anchors shall be used.
 Cure all tiling works and joint filling works for 3 days.
 After work is complete, ensure that it is covered with plastic sheet and Plaster
of Paris.
SKIRTING
 10 mm tiles are used for skirting, and the height of the tile is 100 mm.
 Skirting is chamfered at the edge to 4 mm. and fixed so that after fixing the tile
4 mm of straight edge and 4 mm chamfered edge is seen outside. The skirting
goes into the plaster by about 2 mm.
 Check the right angle that the skirting makes with the floor tile.
Step-1) Marking on the wall (level check) from floor level
Step-2) Button Marking

Step-3) Mortar preparation
Step-4) Finishing Tile works
Finishing tile work

Recommendations:
 The tiles laying is not done as per SOP of Casa Grande Company.
 They are laying mortar thickness of 50 mm, which is not recommendable.
 The allowable thickness is 25 mm.
Because of 50mm thickness mortar, the problems encountered are...
 Wastage of cement and sand quantity.
 Cost overruns
 Time taking.
 Hollow sound is caused when walked, since there are more voids in the mortar
thickness, chance of sinking the tiles.
If thickness is more, then it is better to do concreting of M10 grade (screed concrete)
instead of mortar for more stability.

3.8) FORMWORK ERECTION (COLUMN)
Timber formwork is used.
Plywood thickness 25mm.
Steps in erecting column formwork
 Check the steel reinforcement before starting formwork.
 Construct a starter for column at base level which is of 100 mm depth around
the reinforcement bars, by taking the cover for column as 40 mm.
 Position formwork from predetermined grids.
 Plumb formwork in both the ways and support using adjustable steel props.
 Propping angle should be 45 degrees to floor.
 The formwork bearers directly supports formwork sheeting. The formwork
bearers consists of squared timbers.
 Formwork ties :
 Tieing the two form-work faces to each other by formwork ties. It is done by
guiding it through boreholes in the formwork sheeting and tightening it by
twisting.
 Brace the formwork for more support to the floor.
Curing for shear wall by using curing compound

Shuttering for columns
INSPECTION OF FORMWORK: (Methodology adopted in Masseys site)
Checking the shuttering work for surface cleanliness, water tightness.
Checking for plumb horizontally & vertically using 1m/2m spirit level to formwork
at various points.
Spirit level
Checking of diagonals using a measuring tape.

3.9) QUANTITY CONSUMPTION IN MASSEYS PROJECT
IOW CODES Description Unit BOQ Qty ACTUAL QTY
EARTH WORK
EXCAVATION
1.1.18 Earth work excavation for Basement Cft 2,05,750.00 1,82,192.108
1.2.2 Dewatering & Shoring during earthwork
excavation
LS 1.00
-
1.1.2 Earth work Excavation for Pile cap Cft 23,315.84 23,315.78
18,15,355.72 -
FILLING WORK -
2.1.7 Earth Brought from outside for
Backfilling
Cft 66,311.38
53,864.67
2.1.33 Carting away the surplus earth Cft 2,20,454.26 -
2.1.36 6"tk.Quarry dust filling for Raft, Pile cap
& Under Ramp
Cft 7,785.44
6,224.65
36,89,635.60 -
PLAIN CEMENT
CONCRETE
-
3.1.1 P.C.C 1: 5: 10 - 5" tk. For pile cap, lift
well & Raft slab
Cft 4,962.57
4,791.10
6,90,293.49 -
PRE
CONSTRUCTION
WORK
-
23.5.3 Supply and Fixing of Measurement Box No 3.00 -
23.6.1 Soil Nailing & Guinting work Sft 6,470.00
-
Sample Quantity Consumption For Second Floor
8.1.98 M40 (Site mix ) for Column from Second
floor to Second floor roof
Cft 1,163.01
1,090.07
8.2.67 M40 200 mm thick Shear wall from
Second Floor to Second Floor roof.
Cft 347.68
441.76
8.1.114 M30 200 mm thick Lift Wall from
Second Floor to Second Floor roof.
Cft 262.55
307.52
8.2.5 M30 Roof beam in Second floor Roof Cft 1,760.03 2,125.17
8.2.16 M30 Roof slab in Second floor Cft 3,942.72 3,188.16
8.2.27 M30 Staircase Waist slab concrete from
Second floor to Second floor.
Cft 136.70
168.74
8.1.130 M30 Lintel & Sill Concrete in Second
floor.
Cft 153.24
8.38
9.1.14 For Roof beam in Second floor Roof Sft 5,195.96 5,257.01
9.1.74 For Lift core wall Second floor to
second floor
Sft 858.39
760.58
9.1.40 For Lintel Concrete in Second floor. Sft 799.71 -
9.5.21 Formwork for Staircase - Second floor Sft 296.80 351.71
9.1.204 For M25 200mm thick shear wall from
second floor to second floor roof
Sft 1,136.71
1,273.55

10.1.49 8" Light weight block work up to Second
floor roof level.
Sft 6,193.89
4,672.98
10.1.57 4" Light weight block work in Second
floor
Sft 4,933.95
3,760.67
10.1.100 8" tk. Light wt. Elevation block work -
Second floor
Cft 375.30
-
11.1.13 Railing for Balcony - Second floor Rft 82.54 -
11.1.53 Staircase MS-railing - Second floor Rft 38.27 -
17.1.39 Cladding works - Second floor. Sft 64.61 -
17.1.52 Elevation Louvers works - Second floor. Sft 296.96 -
16.1.5 Second floor - Vitrified tiles.(For Living,
Dining, kitchen, bed rooms and balcony)
Sft 5,883.62
-
16.1.9 Second floor - Anti -Skid ceramic tiles.
(For Bath room & Utility.)
Sft 618.50
-
16.1.13 Second floor - Vitrified tile skirting. Rft 1,624.56 -
16.1.24 Wall dado Up to Roof ht. for Toilet -
Second floor.
Sft 2,465.69
-
16.1.276 Wall dado Up to Roof 4' ht. utility-
second floor
Sft 565.56
-
16.1.46 Common area flooring Marble/Granite -
Second floor.
Sft 671.35
-
16.1.52 Common area Skirting - Marble/Granite
- Second floor
Rft 179.08
-
16.1.97 Staircase flooring Marble / Granite -
Second floor
Sft 225.08
-
16.1.103 Staircase skirting Marble / Granite -
Second floor
Rft 85.40
-
16.2.31 Lift Facia Dado Works (Granite/Marble)-
Second floor
Sft 105.69
-
16.1.19 Kitchen Dadoo Up to 2' - Second floor Sft 1,180.17 -
16.1.28 Granite Kitchen Counter Top - Second
floor
Sft 290.09
-
16.1.129 Second floor - Anti -Skid Vitrified tiles.
Skirting –Balcony
Rft 199.81
-
16.2.27 Second floor - Anti -Skid Vitrified tiles.-
Balcony
Sft 478.03
-
19.3.9 Internal Wall painting - Second floor Sft 25,911.24 -
19.3.55 Cement paint for Ceiling painting -
Second floor
Sft 8,176.47
-
14.1.5 12mm tk. Ceiling Plastering in C.M 1:3 -
In Second floor.
Sft 8,226.92
-
14.1.75 15mm tk internal plastering with gypsum
plaster in second floor
Sft 26,084.20
2,700.25
15.1.2 2Coats of Brush bond Fosroc Chemical
on Toilet Sunken (10") areas Bottom &
Sides including cleaning, Groove
cutting,Haunching etc., - Second floor
Sft 1,158.38
-
15.1.90 Vermiculite concrete 1:3 filling in Toilet
sunken portions - Second floor
Cft 405.83
235.43
15.18.2 2" tk. Screed for ODU for Second floor Sft 66.74 -
15.1.98 Vermiculite concrete 1:3 filling in Drying
balcony / Utility sunken portions -
Second floor
Cft 72.78
-
15.1.18 2Coats of Brush bond Fosroc Chemical
on Balcony & Utility. (3") areas
Bottom & Sides including cleaning,
Sft 1,196.70
-

Groove cutting,Haunching etc., -
Second floor
38.9 Gypsum Board false ceiling Supply &
Fixing work-Second Floor
Sft 1,289.85
-
25.28.29 Reinforcement for Lift Wall - Second
floor
Mt 1.36
-
25.1.27 Lintel reinforcement - Second floor Mt 0.39 -
25.1.22 Column reinforcement - Second floor Mt 15.96 -
25.1.23 Roof beam reinforcement - Second floor Mt 9.91 -
25.1.24 Roof slab reinforcement - Second floor Mt 5.90 -
25.1.25 Staircase waist slab reinforcement -
Second floor
Mt 0.48
-
25.1.110 Shear wall reinforcement - Second floor Mt 1.18 -
134.1.25 Material with labour for 4.5" tk. Brick
work for Toilet ledge wall - second floor
Sft 165.31
134.1.26 Material with labour for 2" thick kandi
brickwork for ledge wall - second floor
Sft 222.99

4) LEARNINGS FROM PROJECT
 Erection of formwork.
 Shuttering to column and slab.
 Studied Soil investigation report completely.
 Gone through floor plan drawing and Structural drawing.
 Methodology for every work.
 Complete Quantity Estimation for a project(Includes Bar bending)
 Basic idea of BSF software.
 Usage of mesh and banned concrete.
 Checks for blockwork, plastering work, flooring work.
 Application of chemicals like flexcrete, gypbond, poly cure-R.
 Testing Cube Strength and Workability (Slump Test).
 Plastering work.
 Flooring Work.
 Blockwork.
 Concreting and finishing.
 Basic idea of planning.
 Identification of various quality issues and remedies to overcome
Them.
 Identification of delays in project.

5) VARIOUS DEPARTMENTS IN PROJECT
1. Stores department.
2. Quality department.
3. Safety department.
4. Execution department.
5. Planning department.
6. Marketing / sales department.

5.1) STORES DEPARTMENT
Number of employees – 2.
Role of stores department:
Issue of purchase order.
Procedure:
Responsible engineers will give the requirement of various quantities to store
manager.
The store manager in site will create manual indent.
He sends the indent to the office store in charge.
Then the head of stores department will create indent by using BSF software and by
Coordination with Quantity Estimation Department.
The indent goes to purchase department.
The purchase department will look for vendors and make purchase order.
After the cycle procedure, the required quantity will come to stores department of
respective site.
The store manager will check the quantity received and the remaining quantity to be
received.
He checks the quality and quantity arrived and note down the time, date and vehicle
number and make entry.
He is responsible for storing items till utilised.

Cement storage
Cement, steel, aggregates will get to site after 1 week from purchase order.
1 vehicle has capacity of transporting 300 bags of cement at 1 stretch.
So there by taking that 7 days also into consideration, without affecting delay of
project, they are issuing purchase order, when the quantity is reaching to reorder
level. (I.e. 7 days before consumption)
Cement, aggregates are stored for 1 month.

Inference and Recommendations:
From the store in charge various material rates and their quantities came to know.
There is proper listing of materials in project about their consumption.
Materials are stored properly in proper alignment.
Material unit Cost(in
rupees)
Cement Kg 6
Gypsum
plaster
Kg 12
Aerocon
blocks
Inches 72-8” block
36-4”block
Steel Kg 38
Recommendations:
 Since there is very less space in the project, storage of materials is getting big
hectic job for store in charge, and JCB is also getting difficult to move. So JIT
(Just in Time) technique should be followed, the uses of this technique is
clearly illustrated in separate recommendations page (please refer that).
 Issue slips should be issued by store in charge to concerned responsible
engineer.
 There should be extra or spare materials available in site for sudden
requirement.
 Metric tapes are shortage, problem for engineers to inspect.
 Additional Safety equipment is not available in site. Helmets, safety shoes etc.
are in limited number.

5.2) MARKETING DEPARTMENT
Number of employees =80 for entire Casa Grande company.
Role of marketing department:
Stalls in corporate sector.
Promotional activities.
Advertisements in local and national newspapers.
Pamphlets.
Banners in ongoing construction project.
When I interacted with the marketing executive, they said they are having least
pressure because the company Casa Grande is a well-known company in Chennai
and 9 out of 10 people knew about the reputation of the company.
There are Facebook pages for company, having more that 1 million likes, the page
mainly focusses on the publicity activities and details of every project by staying in
touch with public.
So no more marketing strategies are required to go through the public.
INFERENCE:
In the project of Masseys so far 66 % of sales took place (61/91) till the date.
The sale is pre sale that shows the confidence on casa Grande Company by public.
For pre-sale there is 1% discount on total flat cost.
The company is having tie up with banks like HDFC and other reputed banks in
Chennai.
In addition to this there is recovery department in the company, the main motive or
objective of the company is not losing the customers.
If the customer feels that they can’t afford the amount, this department will show the
other project which is as per the budget and explains them the details and amenities.
The cost of Masseys flat varies from 98.5L -99.61L for double bedroom and 1.22C -
1.35 C for triple bedroom flats.
As most of the customers are preferring for upper floor flats for better scenery of sea
view, there is more demand for higher floor flats and rates are slightly higher for
higher floor flats compared to lower floors.

By using Buddy Neighbour Scheme, which is a good marketing strategy followed
in Casa Grande Company, made the bookings faster.
RECOMMENDATION:
Since many customers are visiting the site and interacting with marketing department
about the project, the marketing department is unaware of the technical details about
project, they are calling to the engineers who are busy in some other work, to know
the technical details.
So the customers are feeling little uncomfortable for the delay .so I recommend in
place of MBA candidates in marketing department , there should be techno-
management employees to sort out the issue.
Advertising through television should be implemented.
Shortage of marketing employees in Masseys site.
Temporary lift should be erected in site, for the convenience of customers to avoid
walking to 14 floors.

5.3) QUALITY DEPARTMENT
Number of employees in site = 3.
Role of Quality Department:
Responsible for various quality issues in the project like honey combing of concrete,
bulging of column, level of roof beam etc. .
The various checks are carried out by the department using quality checklist.
They write various issues in the project on the notice board, those are to be sought
out by the respective department.
At least one of them are to be in concreting in slabs , beams ,columns ( RCC works )
, they have to sought out the issue immediately by taking them to responsible
engineer.
Testing the cubes and finding the compressive strength and slump value and
checking whether the deshuttering work is to be carry or not.
Since by rectifying the issue on spot, there won’t be any quality issues further.
Checking the works whether they are done as per standard operating procedure
(SOP) or not.
They are finding the latest advanced methodologies that can be implemented in site
to minimize the quality issues, which is a good sign.
QUALITY ISSUES
HONEY COMBING
Honeycombs are hollow spaces and cavities left in concrete mass on surface or
inside the concrete mass where concrete could not reach. These look like honey bees
nest.
Honeycombs which are on sides are visible to naked eyes and can be detected easily
as soon shuttering is removed. Honey combs which are inside mass of concrete can
only be detected by advanced techniques like ultrasonic testing etc.
Reasons for Honey Combing:
Improper vibration during concrete.
Less cover to reinforcement bars.

Use of very stiff concrete (this can be avoided by controlling water as per slump test)
Places like junction of beam to beam to column and to one or more beams are the
typical spots where honey combs are observed. This is due to jumbling of
reinforcement of beams and column rods at one place; special attention is required at
such place during concreting and vibrating.
Presence of more percentage of bigger size of aggregate in concrete also prevents
concrete to fill narrow spaces between the reinforcement rods.
Placing too much concrete in one area at a time can result in incomplete
consolidation, causing a honey comb.

Effects of honey combing:
1) Honeycombs reduces the load bearing capacity of the structure.
2) Corrosion problem
Water finds an easy way to reinforcement rods and rusting and corrosion starts.
Corrosion is a process which continues through reinforcement rods even in good
concrete, this result in loosing grip between rods and concrete, which is very
dangerous to safety and life of concrete structures.
R.C.C. structures have failed with in 20 or 30 years of their construction which is
less than half their projected life. Especially no risk should be taken in case of
columns, Machine foundations, Rafts, Beams etc., where breaking and recasting is
the only best way.
Honeycombing
Remedies for Honeycombs in Concrete
In case of honey combs on surface pressure grouting with cement based chemicals
which are non-shrinkable can be adopted after taking opinion of the designer and
acting as per his advice.
At places of junction of columns and beams concrete with strictly 20mm and down
aggregates should be used with slightly more water and cement to avoid
honeycombs.
 Taping with wooden hammer the sides of shuttering from outs side during
concreting and vibrating will help minimizing honeycombs to a great extent in
case of columns and beams.

 Use of thinner needle say 25mm or less with vibrator at intricate places of
concreting will also help in reducing honey combs.
Plastic Shrinkage:
Plastic shrinkage occurs when a high rate of water evaporates from the concrete
surface and is affected by temperature, humidity, velocity and temperature of
concrete. While it is not possible to control the temperature or humidity at the
location where we are pouring concrete, we can prevent shrinkage by:
Remedies for shrinkage cracks:
 Dampening the surface
 Erecting windbreaks to reduce wind velocity.
 Minimizing placing and finishing time.
 Curing as soon as possible after finishing Using membrane curing compound,
curing paper, and wet burlap, sand.
Quality issues

Scaling problem
Scaling generally starts with a small area but expands as the concrete surface begins to
flake or peel away.
Scaling is caused by:
Faulty concrete finishing or workmanship.
Water seeping into porous, non-air entrained concrete that is exposed to freezing and
thawing cycles.
Scaling can be prevented by:
Specifying a proper mix design for exterior flat work which should be low slump and
air entrained.
Delaying finishing operations until all standing water has evaporated or been removed.
Once concreting has been finished, continue proper concrete care tips by avoiding the
use of salt or other harsh chemicals.
Some other quality issues occurred in site are beam and column bulging, dampness
on surface.

Inference:
The quality issues are almost rectified in time itself, there is no delay in rectifying out
the issues.
There is training for employees in various quality issues for once in a month.
Curing is done properly.
Many of the works are going as per SOP.
Various tests done for concrete in site Masseys:
COMPRESSION TEST:
A total of 9 cubes were prepared for testing which are of 15x15x15 cm.
3 cubes are tested at 3 days, 7 days and 28 days.
Average of the values from 3 cubes are considered as characteristic strength of
concrete.
In our site we achieved 105 -110 % strength in 28 days.
Cubes
SIEVE ANALYSIS:
Sieve analysis test is used for M-sand, many a times resulting the sand is good for
construction. Various sizes of sieves used are 4.75, 2.36, 1.18, 0.6, 0.3, 0.15 mm.

Cube test results 8th
floor column (M40) for 3 days
Sl.no Weight
of
cube(kg)
Maximum
load(KN)
Compressive
strength(N/mm2)
AVG comp
strength(N/mm2)
1 8.28 525 23.33
2 8.355 550 24.44 24.36
(60.91%)
3 8.375 570 25.33
Cube test results (M40) for 7 days
Sl.no Weight
of
cube(kg)
Maximum
load(KN)
Compressive
strength(N/mm2)
AVG comp
strength(N/mm2)
1 8.495 790 35.11
2 8.140 740 32.88 34.66
(86.65%)
3 8.256 810 36
Cube test results (M40) for 28 days
Sl.no Weight
of
cube(kg)
Maximum
load(KN)
Compressive
strength(N/mm2)
AVG comp
strength(N/mm2)
1 8.38 1060 46.9
2 8.42 1025 45.35 46.08
(115.21%)
3 8.5 1040 46.01

SLUMP TEST
USING SLUMP CONE:
Done to determine workability of concrete.
A slump of cone of 30 cm height and bottom dia 20 cm, top dia 10 cm is used.
Concrete is poured in 3 layers by proper compacting.
Later the cone is removed.
Inference:
The concrete is true slump having a slump value of 120 mm.
Slump cone
Recommendation:
There should be training for labourers also specially in concreting works.
Daily inspection for works should be strictly followed.
Issues in quality are to be noted immediately to the higher official for proper remedy.
During plastering work skilled labour is required.
SOP (Standard Operating Procedure) should be strictly followed during working.
Honey combing, dampness etc. issues are to be taken special care.

5.4) SAFETY DEPARTMENT
Number of employees is 2.
Role of Safety Department:
Ensuring the safety for employees and workers.
Ensuring Safety Practices in site.
Security department is under the control of safety Team.
BSF entries are done by the team on Time Office entries of Labourers and
Employees.
Ensuring Future safety Requirements for customers.
Conducting safety awareness programs for labours.
Methodology of using the Safety Equipment.
Safety statistics Report
SL.
NO.
DESCRIPTION STATUS REMARKS
1 Safe Man Hours
Staff 4,860 Hours Total Safe Man Hours
23,452 Hours
CG Sky world Staff 1,960 Hours
Workers 13,698 Hours Cumulative safe man
Hours
20,5005 Hours
Security Guards 2,904 Hours

2 First aid Cases.  02 No’s Of First
Aid Cases
identified and
First aid was
given
3 No. of workers Attended-
Safety Screening Induction
/ Toolbox talk
 45 New workers
are attended for
Safety Screening
induction
4 No. of Violations/ Safety
Note
 Nil
5 List of Safety PPE’, Tools &
accessories
Maintained the
safety PPE’s stock
by store and report
attached
6 Work permit details  02 No’ s W ork
permit followed
 02 No’s of Night
work permit
issued
7 Corrective Action Taken Ensured the below
 22 No’s of
Unsafe
Act/Conditions
identified
 20 No’s
corrective
actions taken
8 Near Misses. NIL
9 No. of Accident/ Incident
Wheel
NIL

10 Safety Meeting conducted  Safety Meeting
was conducted
on 23th
MAY‘16
11 House Keeping status @
stores / Labour shed /Site
office
 Housekeeping
was conducted
on Daily Basis
12 Electrical Inspection
(ELCB,RCCB,DG)
 Electrical
Rccb/Elcb
Inspection done
as on 14t h
MAY’16 and 23r d
MAY’16
 DG inspection
done as on 16t h
MAY’16
13 Hoist inspection Not Applicable @
Present.
14 Vehicle inspection  Jcb inspection
done as on 10th
MAY’16 and
Report attached
15 Machineries/equipment’s
inspection
 Rod Cutting and
bending machine
inspection was
done as on 28th
May’16
16 Mock Drills status Mock Drill
conduct on 12t h
March’16
16 Medical surveillance  Medical Health
check-up
conducted as on
03rd
March’16

17 HIRA report  HIRA for working
@ Electrical
Work maintained.
18 Screening of Occupational
Diseases
 Drinking water test
 Environment test
 Noise Monitoring
 Ambient Air Quality
 DG Stock Monitoring
Inspection
conducted once in
six month and
Reports are
maintained
NEXT DUE
PLANNED AS ON :
June 2016
Some of the Safe Practices adopted in site
Health & Hygienic protective controls
Effective health measures include fumigation to kill adult mosquitoes and elimination
of mosquito breeding was done at site.

Fire Extinguisher Inspection
JCB Inspection

Construction Waste / Scarp Collection
Safety Induction Training to CG SKY WORLD

Safety protective measures

Fencing rope around the corners

Safety Net Erection
Builder Hoist To carry out Waste from various floors

Safety First Aid/incident Status
0 0 0
1
0 0
1
0
3
2
4
3
4
1
2 2
11
7
5
15
17
18
12
22
October'15 November'15 December'15 January'16 February'16 March'16 April'16 May'16
0
5
10
15
20
25
Safety Incident Chart
Nearmiss First Aid Cases Unsafe Act/ Conditions

First Aid Register

Inferences and Recommendations
In the project, safety is as per OSHA standards, most of the safety norms are
followed in site.
Workers are using PFAS, Helmets, Gumboots, safety jackets, eye protectors while
working.
Safety nets are erected where as required, which has the capacity of 100 kgs, debris
in safety nets are cleared for every alternate days.
Barricades, fencing, fire extinguishers, sign boards are present in the site.
Temporary handrails are erected for stair case.
Monthly induction training for new workers is implemented and health check-up is
done for every 6months.
Some of the staff from Casa Grande & contractor side are also not following safety.
Recommendations:
During night work, lighting is not adequate, chances of danger is risk is more.
Some of the areas are not covered with safety nets.
Due to additional work like BSF entries of time office and security room monitoring
to the employees of safety department, they are not able to spend their time in
monitoring the safety norms in site.so it is recommended to implement 100% safety
supervision to employees by employing additional worker to assign other duties
like BSF entries and security room supervision.
Although the labour are provided with good safety equipment, they are not using to
full extent, so a video presentation about the accidents that occur while working
should be demonstrated to employees.
Rebar bars should be provided with rebar caps for avoiding injury.
Issuing of cards system, like the worker who is violates the safety norms should be
awarded with yellow cards, if get three cards in same month, then he should be
warned and given red card, in six months if he receive 3 red cards then he should be
terminated from job.
Rewards should be given to workers, who is following 100% safety.
Additional safety equipment should be readily available for labours and employees.
SAFETY FIRST ANYTHING NEXT

5.5) EXECUTION DEPARTMENT
Number of employees=4.
Role of the Department:
Inspects the reinforcement work, concreting work, blockwork, plastering, tiling,
painting etc. Which are executed by labour.
Their role is to look whether the work is going good or not. They coordinate with the
staff of contractor and are responsible for perfect execution of work.
If any issue happened in site, they convey that to their higher authority.
They act as a mediator between labour and higher official.
They do modifications to drawings if any client wants special requirements.
They coordinate with various departments like plumbing, electrical, carpenters etc.
for carrying concreting in slab.
Inspects every work carried out in site and sends DPR (Daily progress Report) to
higher authority.
Recommendations
Employees should be trained well to execute the specialised work like plastering,
tiling.
Communication gap between contractor employees and company employees is there,
so proper coordination between them should be there to do a particular task, so it is
recommended that they should assemble together and discuss about the methodology
adopted to carry out the work.
Since there is communication between contractor (sky world) and Casa Grande, the
procedure which contractor is following is not as per SOP of Casa Grande in some
cases. So the execution department is unware of the procedure and lacking of
technical skills, so proper training should be given to employees.

Concreting for slab

20
28
26
19
12
10 11
20
13
Column Completion Days
16
47
28
12 10 11
17 16
11
Slab Completion Days
Series1

Analysis from Graphs
The first floor roof slab took 47 days to complete, which consumed more days than
other floor slabs because, the first floor beams are PT (Post Tensioned) beams
which are complicated and unique . There are other 62 columns erected from the 1st
floor, which are floating columns that means they have no foundation on ground
level.
The first floor roof slab is heart of the structure, Due to the complexity of
design it took extra days to complete the work.
Apart from this, almost every slab is completed for an interval of 12-13 days.
Column completion days, the first floor columns took more days than other, the
reason as stated above.
Due to some other issues, which stated in delays of project the column completion
days got varied.

5.6) PLANNING DEPARTMENT
No of employees: 2
Planning engineer:
A planning engineer works with a site manager to develop suitable construction
Methods and sequences for a project.
Job description:
Planning engineers determine and develop the most suitable and economically viable
Construction and engineering methods for projects. They are involved throughout the
stages, and are present on site during the build to oversee procedures. It is the respons
ibility of the planning engineer to estimate a timescale for a project and to ensure that
The outlined deadlines are met. They work closely with site managers and
Other Engineers to ensure a project runs on schedule and that material supplies are
Sufficient.
Planning Engineer Roles and Responsibilities:
 Prepare and update project schedule based on the contract.
 Set work program and target milestones for each phase based on the project
Plan.
 Monitor critical activities based on the project schedule and advise project
management.
 Prepares and submit updated work program and cash flow curve showing
Actual progress and identify areas of weakness and establishes means and meth
ods for recovery, if any, as well as new critical activities.
 Monitor day to day work progress and prepare the weekly and monthly
Program and report.
 Maintain and record update of site work progress obtained from Project
Manager.
 Prepares monthly report reflecting work progress summary.
 Report to the Project Manager about the current work progress and make comp
arison between plan and actual progress and study impact of alternative

Approaches to work.
 Participate in project meetings and discussions with the Client as required.
 Assists in preparing work program, cash flow and manpower histogram for
Tenders.
 Performs other duties and responsibilities as may be assigned from time to time
& Prepares Daily Progress Report.
Recommendations:
Presently in site, the planning engineers are using EXCEL for planning as a tool fo
r tracking. But by EXCEL proper tracking is not possible. So by using PRIMAVE
RA or MSP tracking is possible in a better way.
So the employees should be trained in primavera or MSP for better results.
(Please refer the hyper link project file for reference, which is attached below, for opening file hold
ctrl button)
ms project planning.pdf

6) DELAYS IN MASSEYS PROJECT
A project Team comes together to create a unique development on a particular site
under circumstances that will never be repeated. They are very complex, requiring
the co-ordination of permissions, people, goods, plant and materials and construction
can begin despite many ‘unknown’ matters such as incomplete design information,
uncertain site conditions, Suppliers and so on. As a consequence delays are common.
Some of the Delays in MASSEYS project which encountered are ….
1) Delay in drawings
Delay in drawings from consultant for basement and stilt floor, which are typical and
complicated delayed. Many a time’s modifications are done to the drawings as per
site conditions, which led to the delay of work.
2) Poor safety Practices in site.
Since there is no safety net erected in site , some of the concrete while pumping
during casting slab gone to the surrounding apartment due to excess pressure in
pumping plant, due to this objections made by surrounding people delayed the work
for 1 week.
3) Pile Foundation:
There are almost 114 piles were used in the site, pile depth is 30 meters , while
casting a pile due to Vibrations and sound , objections from local people raised,
which led to the delay of almost 3 months.
4) Local Issues:
Some of the miscellaneous issues like general elections, followed by some of the
holidays led to delay in project.
5) Weather conditions:
Since the site is situated in coastal region near beach, heavy breeze and winds spoiled
the work, like… during blockwork checking using plumbob, due to continuous winds
they were unable to erect the blockwork, because plumbob is continuously moving
and giving negative correction. They have waited for long time till the wind to stop.
Although there is less temperature in Chennai than other places, the humidity that
caused Labour to dehydrate and the efficiency of work got reduced.
Untimely rains (cyclone) in Chennai that led to delay in construction work several
times in months of December as well as in May.

6) Uniqueness of Project:
As every project is unique in nature, the Masseys project is much more unique, since
there is very less repetitive work involved.
 The pile foundation work.
 Post tensioning for slabs and beams of 1st
floor, stilt & basement floor.
 Extra 31 floating columns on 1st
floor roof, which are erected from PT beams of
1st
floor.
 Additional complicated design and modifications for stilt floor made it much
more complicated and unique.
7) Poor or unrealistic schedule:
Unrealistic schedule from planning department or improper coordination between site
executives and planning department led to the delays in project.
Like for example, the planning department prepares the schedule without considering
various factors like weather, labour problems, local issues which are variant to the site,
will make the delays.
8) Lack of information and poor communication:
Lack of information and poor communication between the contractor’s side and
company’s side led to the delay of project. Meetings between the contractor and
company is not frequent.
9) Labour productivity:
Labour absenteeism, there is no control whether how much labour turned out, labour
stress because of continuous work, labour skill etc, Effected the productivity of work.

6.1) MEASURES TO BE TAKEN TO OVERCOME DELAYS
 Additional resources of manpower, plant and materials directly employed
or subcontracted.
 Revised methodologies including off-site prefabrication, extra scaffolding, and
temporary weatherproofing and so on.
 Proposals for phased completion.
 Increasing working hours on and off site, including weekends, holidays, night
working and shift working.
 Additional supervision.
 Changes to the design or specification .
 Reduction in scope (for example transferring work to a separate post-contract
agreement for occupational works).
 Low technical and managerial skills of contractors are the problems that faced by
contractors which might cause construction delays. Therefore, contractors should
organize some training programs for their workers in order to update their
knowledge and improve their management skill.
 Frequent progress meeting.
 Use up-to-date technology utilization.
 Use proper and modern construction.
 Proper emphasis on past experience.
 Effective strategic planning.
 Clear information and communication channels.
 Complete and proper design at the right time.
 Site management and supervision.
 Collaborative working in construction.
 Frequent coordination between the parties involved.
 Compressing construction durations.
 Proper project planning and scheduling.
 Proper material procurement.
 Use appropriate construction methods.
 Accurate initial cost estimates.
 Preparing the checklists of safety and quality by considering all the measures.

6.2) METHODOLOGY ADOPTED TO OVERCOME DELAYS
Ranking of delays
The causes, effects and minimisation of construction delays were ranked by using
relative important index.
The data analysis is determined to establish the relative importance of various
factors that contribute to causes, effects, and minimization if construction delays.
Analysis of data consists of the following:
1) Calculating the Relative Importance Index (RII)
2) Ranking of factors in each category based on the Relative Importance Index (RII)
RII= (∑W/AxN) Where,
RII is the Relative Importance Index,
W = weighting given to each factor by the respondents (ranging from 1 to 5),
A = highest weight (i.e. 5), N = total number of respondents.
In this way the most important cause for the delay is considered and necessary
planning is done to avoid that cause, so that the project will complete in time.

7) RECOMMENDATIONS
7.1) VARIOUS COST REDUCTION TECHNIQUES IN HIGH RISE
BUILDINGS
A) FILLER SLAB TECHNIQUE
In a conventional RCC slab which is used from many years as a ritual practice
consuming more and more resources by employing more labour and material cost.
Due to this unnecessary cost for additional reinforcement due to added load of
concrete is consuming most of the part in project cost.
ALTERNATIVE TO RCC SLAB
Conventional RCC slab can be replaced by low cost and light weight filler material,
which will reduce the dead load and cost of the slab by 22-28% (40% less steel is
used and 30 % less concrete)
PRINCIPLE OF FILLER SLAB
The filler slab is based on the principle that for roofs which are simply supported, the
upper part of slab is subjected to compressive forces and lower part of slab is
subjected to tensile forces. Concrete is good in compression and weak in tension,
thus the lower part of slab doesn’t need any concrete except for holding steel
reinforcements together. Thus by replacing the concrete in tension zone with any
filler material gives the same characteristics of conventional concrete.

Concrete cross-section
Filler material in tension zone.
MECHANISM OF FILLER SLAB
The filler slab is a mechanism to replace concrete in tension zone. The filler material
thus is not a structural part of slab, by reducing the quantity and weight of material,
the roof becomes less expensive, yet retains the strength of conventional slab. The
most popular type of filling material is roofing tile. Mangalore tiles are placed
between steel ribs and concrete is poured into gap to make filler slab. The structure
requires less steel and cement and it is also a good insulator.
Tiles alignment in filler slab
FILLER MATERIAL SELECTION
 Filler material should be inert in nature. It shouldn’t react with concrete or
steel in RCC slab construction.
 Filler material should be light in weight, so that overall weight of slab reduces.
 Filler material texture should match with desired ceiling finish requirements.
 Filler material should be of a size, cross section and thickness which can be
accommodated within spacing of reinforcement and cross section of slab.
 Filler material absorption should be checked, since it may absorb the water
from concrete.

INSTALLATION OF FILLER MATERIAL
 Filler materials shouldn’t be installed at shear zone.
 Clear distance of 150mm from end supports in all directions.
 Gap of about 75mm between each unit of filler material.
Normal spacing of filler tiles
EFFICIENCY OF FILLER SLAB
Conventional Tests By Different Institutions And Laboratories Has Proved The Load
Bearing Capacity Of Filler Slab And Found It No Less In Performance From
Conventional RCC Slab. Since Filler Tiles Are Firmly Bonded To And Covered By
The Concrete, It Doesn’t Collapse Under The Impact.
BENEFITS
The Savings On Cost Can Be Up To 22-28 %. But Designing A Filler Slab Requires
A Structural Engineer To Determine The Spacing Between Reinforcement Bars.

THERMAL INSULATION
The Air Pocket Formed By Contours Of Tiles Makes An Excellent Thermal
Insulation Layer. The Design Integrity Of Filler Slab Involves Careful Planning
Taking Into Account The Negative Zones And Reinforcement Areas.
PATTERENED CEILINGS
Filler slabs provide aesthetically pleasing patterned ceilings. In most houses the filler
material is left open without plastering to form aesthetic design.
B) Lintels and Chajjas
The Traditional RCC Lintels Which Are Costly Can Be Replaced By Brick Arches
For Small Spans And Save Construction Cost Up to 30-40% Over The Traditional
Method Of Construction. Arches are Economical and Aesthetic.
.

Building Cost:
Building material cost: 65 to 70 %
Labour cost: 65 to 70 %.
Cost of reduction is achieved by selection of more efficient material or by an
improved design.
C) Doors and windows:
It is suggested not to use wood for doors and windows and in its place concrete or
steel section frames shall be used for achieving saving in cost up to 30 to 40%..By
adopting brick jelly work and precast components effective ventilation could be
provided to the building and also the construction cost could be saved up to 50% over
the window components.
D) Amalgamating services:
Locating bathrooms kitchens and laundry’s etc. adjacent or above each other, can
reduce the cost of providing services (particularly plumbing) as the length of
concealed pipe work and conduit is reduced. Similarly amalgamating several services
in the same trench or duct can reduce costs...
E) Speed of Construction:
A building construction method that is faster not only utilises labour more efficiently
but also reduces the daily on-site costs such as building foreman, fencing,
scaffolding, site services, insurances etc.
F) Prefabrication Fabricating:
Items in a factory is always faster and cheaper than on site. This is because there is
not always a good supply of shelter, materials, specialised machinery and labour on
site. The extent of prefabrication can range from individual components, right up to a
totally prefabricated home.

MATERIAL SELECTION CRITERIA
Conclusion
However it is necessary that good planning and design methods shall be adopted by
utilizing the services of an experienced engineer or an architect for supervising the
work, thereby achieving overall cost effectiveness to the extent of 25% in actual
practice.

7.2) JIT TECHNIQUE
Just in time (JIT) is an inventory management system, used to manage the stock that
is kept in storage. It involves receiving goods from suppliers as and when they are
required, rather than carrying a large inventory at once.
Advantages
Lower Warehouse Costs:
Storing excess inventory can cost a lot of money, and reducing the amount of
inventory you keep on hand can reduce your carrying costs as well. Companies that
implement the just-in-time inventory model may be able to reduce the number of
warehouses they maintain, or even allow them to eliminate those warehouses
altogether.
Better Supply Chain Management:
The just-in-time inventory model can also help companies be more efficient and
competitive in the way they handle their supply chains.
A more efficient supply chain can provide lower costs throughout the construction
process, and those lower costs can then be passed on to the customer. Those lower

costs can make the company's products more affordable, and help the company gain a
larger market share and stay ahead of its competitors.
Less Waste:
When companies use the traditional method of inventory management and control,
they can end up with pallets of unused items that simply go to waste. The company
many need to slash prices on that unsold inventory just to get rid of it. The just-in-
time inventory model reduces this waste and helps the company respond more
quickly to what its customers need.
Smaller investments: JIT inventory management is ideal for smaller companies that
don’t have the funds available to purchase huge amounts of stock at once. Ordering
stock as and when it’s needed helps to maintain a healthy cash flow.
All of these advantages will save the company money.
Explaining With an Example:
Suppose if you have a sum of 1 lakh rupees, if you spend the entire amount in buying
Aggregates, cement and other materials which is necessary for 1 month , if any delay
occurs or some extra budget needed for other items ,to carry out the work money will
be on hold . So by using JIT technique, the day on which concreting takes place, on
that day itself if we get raw materials, money won’t get hold for much time, and
instead they can be used for other purposes.
Security for items not required:
For larger inventory there are chances for theft of raw materials, so CCTV Supervision
or any other supervisor is employed to check the materials, which requires additional
cost, in case of JIT technique, that problem won’t be there since the material will be
arrived at just on time. Supervision cost will be reduced.
Quality of raw materials:
Since we are ordering the materials just on time, the damage of the material will be
very very less compared to conventional method of storage.
Cement tends to lose its strength as the days are passing i.e. from date of manufacturing
to usage of cement, so immediate usage of cement gives extra strength to concrete, this
is only possible by JIT technique.

Disadvantages of just in time inventory management:
Risk of running out of stock: By not carrying much stock, it is imperative to have
the correct procedures in place to ensure stock can become readily available, and
quickly. To do this, it is better to have a good relationship with your supplier(s). It is
needed to form an exclusive agreement with suppliers that specifies supplying
goods within a certain time frame, prioritising the company. JIT means extremely
reliant on the consistency of supply chain. There is chance that supplier struggles
with our requirements, or goes out of business, then question arises that how to get
the products quickly from somewhere else?
Lack of control over time frame: Having to rely on the timeliness of suppliers for
each order puts us at risk of delaying customers’ expectations. If you don’t meet
customers’ expectations, they could take their business elsewhere, which would
have a huge impact on business if this occurs often.

7.3) QUALITY CIRCLES CONCEPT
During my discussion with Employees of Casa Grande, the employees have given a
valuable information with respective to their field. They have stated a few of the issues
which can be improved from their valuable work experience. But they are hesitated to
speak to the top management, and they didn’t get a platform to express their views. So
quality circle concept comes into the picture.
Quality circle:
A Quality Circle is a small group of between 6 to 12 employees in the same or similar
work area doing similar work who voluntarily meet together on a regular basis to
identify improvements in their work areas.
Purpose of Quality Circle:
The Quality Circle usually meets under the leadership of their own supervisor or leader,
and gets trained to identify, analyse and solve problems in their work areas, presenting
solutions to management.
Quality Circle Organizational Structure Consists of….

Concept of quality circle:
Principle of Quality Circles:
Principle of Quality Circles is that the responsibility of Quality rests with every
worker and every department. This responsibility should be accepted by each worker
voluntarily for realizing the overall vision and objectives of the organization.

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