742548

“SITE EXECUTION & COST ESTIMATION

RESIDENTIAL BUILDING”
AN INTERNSHIP REPORT
2025

Submitted By

GAMIT VIRALKUMAR VIPULBHAI

210170106012

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

In

CIVIL ENGINEERING

Vishwakarma Government Engineering College, Ahmedabad

Gujarat Technological University, Ahmedabad

Civil Engineering
[April, 2025]
8th Semester

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Vishwakarma Government Engineering College, Ahmedabad

(Nr. Visat Roads, Sabarmati-Koba Highway, Nigam Nagar, Chandkheda,

Ahmedabad, Gujarat 382424)

CERTIFICATE

This is to certify that the project report submitted along with the project
entitled “Site Execution & Cost Estimation of Residential Building” has been
carried out by Gamit Viralkumar Vipulbhai under my guidance in partial
fulfilment for the degree of Bachelor of Engineering in Civil, 8th Semester of
Gujarat Technological University, Ahmadabad during the academic year
2024-25.

Prof. Y. J. Patel Dr. N. P. Singh

(Internal Guide) (Head Of Dept.)

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Vishwakarma Government Engineering College, Ahmedabad

(Nr. Visat Roads, Sabarmati-Koba Highway, Nigam Nagar, Chandkheda,

Ahmedabad, Gujarat 382424)

DECLARATION

I hereby declare that the Internship Report submitted along with the Internship
entitled “Site Execution & Cost Estimation of Residential Building” submitted
in partial fulfilment for the degree of Bachelor of Engineering in Civil to
Gujarat Technological University, Ahmedabad, is a Bonafide record of
original project work carried out by me at Emboss Construction Pvt. Ltd.
under the supervision of Prof. Yamini J. Patel and that no part of this report
has been directly copied from any students’ reports or taken from any other
source, without providing due reference.

Name: Gamit Viral V.

Enrolment No.: 210170106012 Sign of Student

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ACKNOWLEDGEMENT

The Internship opportunity I had with Standard Infrastructure was a great chance for
learning and professional knowledge development. Therefore, an opportunity provided to
me may be a part of it. I am also very grateful for having a chance to meet so many
wonderful, knowledgeable people and professionals who led me though this internship
period.

First, I thanks to Gujarat technological university to give us this opportunity in summer

internship to gain practical knowledge of our stream.

I express my profound thanks to Mr. Param Shah (CEO), Mr. Yogesh Mewada (Senior
Engineer) & Miss. Medhavi Dave (Head of Billing) partner of Emboss Construction
Pt. Ltd. who giving me opportunity to intern the company.

Special thanks to the Mr. Yogesh Mewada (Senior Engineer) who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct
path and allowing me to carry out my project at their organization and extending during the
training.

I am thankful to the head of department Dr. N P Singh for his valuable inputs throughout
the internship.

I am thankful to my internal guide Prof. Y J Patel who help me during internship and report
preparation and also share some extraordinary his site experience and practical knowledge
which help me a lot during internship. Finally, I am thankful to all the workers at the site
including: labours, masons and other technical personnel engaged at the ground level of the
project for making me understand about the small details which need to be taken care of
for the completion of the project.

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ABSTRACT

This report documents a 12-week industrial training internship undertaken at Emboss

Construction Pvt. Ltd. from January 20, 2025, to April 19, 2025, focusing on the
construction of their 3BHK high-rise residential building.

The internship provided practical experience in various aspects of the construction process,
from excavation and foundation work to superstructure development. Key skills acquired
include interpreting construction drawings, quality control of steel reinforcement,
preparing Bar Bending Schedules (BBS), and site supervision, including team management
and task delegation.

This training significantly enhanced the understanding of real-world civil engineering

practices and construction management specific to high-rise residential projects.

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LIST OF FIGURES
Figure 1.6 Elevation Of Adani Agusta ................................................................................. 4
Figure 1.8 Logistic Plan Of Site .......................................................................................... 6
Figure 1.9.3 Safety Tools And Equipment ........................................................................... 8
Figure 2.1.1 Plumb Bob ..................................................................................................... 10
Figure 2.1.2 Tube Level ..................................................................................................... 10
Figure 2.1.3 Spirit Level .................................................................................................... 11
Figure 2.1.4 Showel ........................................................................................................... 11
Figure 2.1.5 Needle Vibrator ............................................................................................. 12
Figure 2.1.6 Hammer ......................................................................................................... 12
Figure 2.1.7 Bar Cutting Machine ..................................................................................... 13
Figure 2.1.8 Bar Bending Machine .................................................................................... 13
Figure 2.1.9 Bar Threading Machine ................................................................................. 14
Figure 2.1.10 Aluminium Patti .......................................................................................... 14
Figure 2.1.11 Right Angle .................................................................................................. 15
Figure 2.1.12 Grinding Machine........................................................................................ 15
Figure 2.1.13 Drill Machine .............................................................................................. 16
Figure 2.1.14 Mortar Mixing Machine .............................................................................. 16
Figure 2.1.15 Plastering Float ............................................................................................ 17
Figure 2.1.16 Dumpy Level ............................................................................................... 17
Figure 2.1.21 Finishing Trowel.......................................................................................... 18
Figure 2.1.22 Sand Measuring Box ................................................................................... 19
Figure 2.1.23 Shuttering, Centering And Scaffolding ....................................................... 19
Figure 2.1.24 Rotary Sand Sieve ....................................................................................... 20
Figure 2.1.25 Binding Wire Hook ..................................................................................... 20
Figure 2.1.26 Blower ......................................................................................................... 21
Figure 2.1.27 Tiles Cutting Machine ................................................................................. 21
Figure 2.1.28 Bar Bent Up Tool ......................................................................................... 21
Figure 2.1.29 Injecting Mortar Equipment ........................................................................ 22
Figure 2.1.30 Electric Board .............................................................................................. 22
Figure 2.2.1 Aac Block ...................................................................................................... 23
Figure 2.2.2 Block Joint Mortar......................................................................................... 23
Figure 2.2.4 Ambuja Ppc Cement Bag .............................................................................. 24

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Figure 2.2.5 Chicken Mess ................................................................................................ 25

Figure 2.2.7 Roff Flooring Chemical ................................................................................. 26
Figure 2.2.9 Tiles Spacer ................................................................................................... 27
Figure 2.2.10 Water Proofing Chemical ............................................................................ 28
Figure 2.2.12 Plumbing Pipes ............................................................................................ 29
Figure 2.2.14 Coupler ........................................................................................................ 30
Figure 2.2.16 Putty............................................................................................................. 31
Figure 2.2.17 Reinforcement bar ....................................................................................... 31
Figure 2.3.2 Slump And Cube Test .................................................................................... 33
Figure 2.3.4 Sand Silt Content Test ................................................................................... 35
Figure 3.3.1 Column Steel Details ..................................................................................... 45
Figure 3.4.1 Beam Steel Details ........................................................................................ 47
Figure 4.3.1 Bar Cutting And Bending .............................................................................. 55
Figure 4.3.2 Scaffolding .................................................................................................... 56
Figure [Link] Column Casting .......................................................................................... 59
Figure [Link] Slab And Beam Casting .............................................................................. 60
Figure [Link] Staircase Casting ........................................................................................ 61
Figure [Link] Curing ......................................................................................................... 62
Figure 4.3.7 Masonry Work ............................................................................................... 64
Figure [Link] Conduit In Slab ........................................................................................... 66
Figure [Link] Conduit Before Flooring ............................................................................ 67
Figure [Link] Plumbing Drilling In Wall .......................................................................... 69
Figure [Link] Installation Of Plumbing ............................................................................ 69

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LIST OF TABLES
Table 1.5.1 Completed Projects Of Company ................................................................................... 3
Table 1.5.2 Ongoing Projects Of Company ...................................................................................... 3
Table 1.9.2 Is Codes Of Safety At Site.............................................................................................. 7
Table 1.9.3 Safety Equipment Used At Site ...................................................................................... 7
Table 1.9.4 Safety Helmet ................................................................................................................. 9
Table 2.3.1 sieve Analysis (Is 1542: 1977....................................................................................... 32
Table 2.3.2 Slump Values For Different Types Of Concrete ........................................................... 33
Table 2.3.3 Minimum Compressive Strength Of Cubes ................................................................. 33
Table 2.3.4 Acceptable Silt Content In Sand................................................................................... 34
Table 3.6.1 Reinforcement Quantity For Typical Floor .................................................................. 51
Table 3.6.2 Concrete Quantity For Typical Floor ........................................................................... 52
Table 3.6.3 Masonry Quantity For Typical Floor............................................................................ 52
Table 3.6.4 Plaster Quantity For Typical Floor ............................................................................... 53
Table 4.3.2 Shuttering Removal Periods Of Rcc ............................................................................ 58
Table 4.3.4 Period Of Curing As Per Is 456:2000........................................................................... 62

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ABBRAVIATION
1. IS-Indian Standards
2. RCC-Reinforced Cement Concrete
3. PCC-Plain Cement Concrete
4. OPC-Ordinary Portland Cement
5. PPC-Portland Pozzolana Cement
6. PVC- Polyvinyl Chloride
7. CPVC-Chlorinated Polyvinyl Chloride
8. UPVC-Unplasticized Polyvinyl chloride
9. AAC-Autoclaved Aerated concrete
10. TMT- Thermo-Mechanically Treated
11. BBS-Bar Bending Schedule
12. RMC-Ready Mix Concrete
13. SSD-Saturated Surface Dry
14. RL-Reduce Level
15. FS-Fore sight
16. BS-Back sight
17. IS-Inter-mediate sight
18. CTM-Compression Testing Machine
19. BOQ-Bill of Quantity
20. MEP-Mechanical Electrical and Plumbing
21. CMT-Cubic Meter
22. SQM-Square Meter
23. C/C- Centre to Centre
24. mm-Millimetre
25. m-Meter
26. Kg-Kilogram

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INDEX

ACKNOWLEDGEMENT .............................................................................................................. v
ABSTRACT ....................................................................................................................................vi
LIST OF FIGURES ......................................................................................................................vii
LIST OF TABLES .........................................................................................................................ix
ABBRAVIATION ........................................................................................................................... x
CHAPTER 1 INTRODUCTION ................................................................................................... 1
1.1 OVERVIEW OF ORGANIZATION .................................................................................. 1
1.2 PURPOSE OF COMPANY.................................................................................................. 1
1.3 SCOPE OF ORGANIZATION ............................................................................................ 2
1.4 OBJECTIVES OF INTERNSHIP ....................................................................................... 2
1.5 ABOUT COMPANY PROJECTS ....................................................................................... 3
1.5.1 Completed project of company ..................................................................................... 3
1.5.2 On Going Projects of Company .................................................................................... 3
1.6 SITE INFORMATION ......................................................................................................... 4
1.7 WORK BREAKDOWN STRUCTURE .............................................................................. 5
1.8 LOGISTIC PLAN OF SITE ................................................................................................ 6
1.9 SAFETY MEASURE ............................................................................................................ 6
1.9.1 General ............................................................................................................................ 6
1.9.2 IS codes for safety at site ............................................................................................... 6
1.9.3 Safety equipment used at site ........................................................................................ 7
1.9.4 Safety helmet used at site............................................................................................... 9
CHAPTER 2 EQUIPMENT, MATERIAL & TEST ................................................................. 10
2.1 EQUIPMENTS .................................................................................................................... 10
2.1.1 Plumb bob .....................................................................................................................10
2.1.2 Tube level ......................................................................................................................10
2.1.3 Spirit Level....................................................................................................................11
2.1.4 Shovel ............................................................................................................................11
2.1.5 Needle Vibrator ............................................................................................................12
2.1.6 Hammer ........................................................................................................................12
2.1.7 Bar Cutting Machine ...................................................................................................13
2.1.8 Bar Bending Machine ..................................................................................................13
2.1.9 Bar Threading Machine ..............................................................................................14
2.1.10 Aluminium Patti .........................................................................................................14
2.1.11 Right Angle .................................................................................................................15

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2.1.12 Grinding Machine ......................................................................................................15

2.1.13 Drill Machine ..............................................................................................................16
2.1.14 Mortar Mixing Machine ............................................................................................16
2.1.15 Plastering Float...........................................................................................................17
2.1.16 Dumpy Level...............................................................................................................17
2.1.17 Staff for Dumpy Level ...............................................................................................18
2.1.18 Chisels..........................................................................................................................18
2.1.19 Wooden Mallet ...........................................................................................................18
2.1.20 Pointing Trowel ..........................................................................................................18
2.1.21 Finishing Trowel.........................................................................................................18
2.1.22 Sand Measuring box for plaster and flooring .........................................................19
2.1.23 Shuttering and scaffolding Equipment ....................................................................19
2.1.24 Rotary Sand Sieving Machine ...................................................................................20
2.1.25 Binding wire hook ......................................................................................................20
2.1.26 Blower..........................................................................................................................21
2.1.27 Tiles cutting Machine.................................................................................................21
2.1.28 Bar Bent up tool .........................................................................................................21
2.1.29 Fischer FIS EM Plus 585s Injection mortar Equipment ........................................22
2.1.30 Electric board .............................................................................................................22
2.2 MATERIAL ......................................................................................................................... 23
2.2.1 Autoclaved Aerated Concrete Blocks (Eco-Green)-sand base .................................23
2.2.2 Block Joint Mortar (Eco-Green).................................................................................23
2.2.3 Ambuja OPC ................................................................................................................24
2.2.4 Ambuja PPC .................................................................................................................24
2.2.5 Chicken Mess ................................................................................................................25
2.2.6 River Sand.....................................................................................................................25
2.2.7 Roff Flooring chemicals ...............................................................................................26
2.2.8 Flooring Tiles ................................................................................................................26
2.2.9Tiles Spacer ....................................................................................................................27
2.2.10 Sika Latex Power........................................................................................................27
2.2.11 Sika Latex Pink ..........................................................................................................28
2.2.12 Plumbing Material .....................................................................................................28
2.2.13 Cover Block (Concrete Spacers for Reinforcement)...............................................30
2.2.14 coupler .........................................................................................................................30
2.2.15 steel formwork panel..................................................................................................30
2.2.16 White Cement (JK cement wall-max)30kg bag.......................................................31

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2.2.17 Reinforcement Bar .....................................................................................................31

2.3 MATERIAL TEST ............................................................................................................. 32
2.3.1 Sieve analysis (IS 1542: 1977) – Sand for Plaster ......................................................32
2.3.2 Slump Test (IS 1199:1959)- workability classification .............................................32
2.3.3 Cube test (IS 456:2000)- Compressive strength Requirements ...............................33
2.3.4 Silt content test (IS 2386 Part 2:1963)- Permissible Limits ......................................34
CHAPTER 3 BBS AND QUANTITY ESTIMATION .............................................................. 44
3.1 OVERVIEW ........................................................................................................................ 44
3.1.1Bar Bending Schedule (BBS): ......................................................................................44
3.1.2 QUANTITY ESTIMATION .......................................................................................44
3.2 BAR BENDING SCHEDULE FORMAT ......................................................................... 44
3.3 COLUMN BBS .................................................................................................................... 45
3.3.1 Cutting Length .............................................................................................................45
3.3.2 Total weight ..................................................................................................................46
3.4 BEAM BBS .......................................................................................................................... 47
3.4.1 Cutting Length .............................................................................................................47
3.4.2 Total weight ..................................................................................................................49
3.5 SLAB BBS ............................................................................................................................ 49
3.5.1 Cutting Length .............................................................................................................49
3.5.2 Total weight ..................................................................................................................50
3.6 QUANTITY ESTIMATE FOR TYPICAL FLOOR ....................................................... 51
3.6.1 Reinforcement Quantity for Typical floor .................................................................51
3.6.2 Concrete Quantity for Typical floor...........................................................................51
3.6.3 Masonry Quantity for Typical floor ...........................................................................52
3.6.4 Plaster Quantity for Typical floor ..............................................................................53
CHAPTER 4 SITE ACTIVITIES ............................................................................................... 54
4.1 OVERVIEW OF SITE ACTIVITIES ............................................................................... 54
4.2 OBSERVED SITE ACTIVITIES ON SITE FOR A RESIDENTIAL BUILDING ...... 54
4.3 SITE ACTIVITIES ............................................................................................................. 54
4.3.1 Bar cutting, Bending and threading ...........................................................................54
4.3.2 Shuttering, Centering and scaffolding .......................................................................55
4.3.3 Reinforcement and casting of RCC members ...........................................................59
4.3.4 Curing............................................................................................................................61
4.3.5 Leveling of shuttering and centering..........................................................................63
4.3.6 Reinforcement inspection as per structural drawing ...............................................63
4.3.7 Masonry work...............................................................................................................64

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4.3.8 Electric Work ...............................................................................................................66

4.3.9 Plumbing .......................................................................................................................68
4.3.10 Waterproofing ............................................................................................................70
4.3.11 Plaster work ................................................................................................................71
4.3.12 Flooring Work ............................................................................................................73
4.3.15 Finishing by White Cement .......................................................................................74
CHAPTER 5 CONCLUSION ...................................................................................................... 76
REFERENCES ......................................................................................................................77

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742548 INTRODUCTION

CHAPTER 1 INTRODUCTION

1.1 OVERVIEW OF ORGANIZATION

Emboss Construction Private Limited, established in Ahmedabad, Gujarat, on June 21,

2021, is an active private limited company operating within the real estate and
construction sector, primarily engaged in specialized construction activities and
building completion and finishing, holding an MSME "Small enterprise" classification,
with an authorized and paid-up capital of ₹1.50 Cr, and displaying active open charges,
notably with major lending from the State Bank of India, and is managed by directors
Liza Shah, Jagadish Kumar Shah, and Param Shah.

❖ Organization Details

▪ Company Name: Emboss Construction Private Limited

▪ Incorporation Date: June 21, 2021
▪ Location: Ahmedabad, Gujarat, India
▪ Company Status: Active
▪ Industry: Real Estate and Construction
▪ Company Type: Private Limited Company

1.2 PURPOSE OF COMPANY

➢ Enhancing Operational Efficiency: Streamlining processes to reduce costs and

improve productivity.
➢ Expanding Market Presence: Growing their portfolio in Ahmedabad and other
regions.
➢ Maintaining Safety Standards: Ensuring workplace safety for workers and
compliance with regulatory norms.
➢ Building Long-Term Client Relationships: Focusing on post-construction
services and customer satisfaction.
➢ Continuous Improvement: Investing in workforce training and technological
advancements for better project execution.

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742548 INTRODUCTION

1.3 SCOPE OF ORGANIZATION

Emboss Construction Pvt. Ltd. operates in the construction and infrastructure

development sector, providing end-to-end project management solutions. Their scope
covers:
➢ Residential Projects: Construction of high-rise apartments, luxury villas, and
gated communities.
➢ Commercial Buildings: Development of office spaces, retail outlets, and business
centres.
➢ Industrial & Institutional Projects: Infrastructure for factories, pharmaceutical
plants, and educational institutions.
➢ MEP Services: Integration of mechanical, electrical, and plumbing systems.
Turnkey Construction Solutions: Handling projects from concept to completion,
including planning, execution, and finishing.

1.4 OBJECTIVES OF INTERNSHIP

➢ The primary objective of this internship at Emboss Construction Ltd. in Ahmedabad

was to bridge the gap between academic theory and practical application within the
dynamic construction industry.
➢ This experience aimed to provide a comprehensive understanding of the day-to-day
operations of a construction company, focusing on site management, project
planning, and execution.
➢ By actively participating in ongoing projects, I sought to gain firsthand knowledge
of the various processes involved, from initial planning to final completion, while
also observing and learning about crucial aspects such as construction safety,
quality control, and material management.
➢ This internship aimed to enhance my professional skills, including communication,
teamwork, and problem-solving, through direct interaction with experienced
professionals.
➢ Ultimately, the objective was to document and analyse these experiences to create
a detailed project report that reflects the practical insights gained and the application
of theoretical knowledge in a real-world construction setting, while also
understanding the administrative and financial aspects of the company.

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1.5 ABOUT COMPANY PROJECTS

1.5.1 Completed project of company

Sr. Project Type Location Built up Area

No. (Sq. Ft)
1. Residential Kensville 1,00,000
2. Residential Billonaires Street 3,00,000
3. Serenity Villas Kadi 5,00,000
4. Residential High Rise Central Bopal 3,90,000
5. Parijaat Adani 3,60,000
Shanti gram
6. Industrial (Infinity Factory) Changodar 30,000
7. Stallion RM Plant Kerela GIDC 50,000

Table 1.5.1 Completed projects of company

1.5.2 On Going Projects of Company

Sr. Project Type Location Built up Area

No. (Sq. Ft)
1. Residential High Rise Tragad 1,70,000
(Adani Augusta)
2. RE 45 Link-in Road, 4,50,000
Shantipura
3. Industrial Changodar 40,000
(Zydus Mumps Facility)
4. Healthcare (Medico House) Adani 1,60,000
Shanti Dram
5. Institutional (MNIMS School) Sanand 4,22,000

Table 1.5.2 ongoing projects of company

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1.6 SITE INFORMATION

overview of the residential building project:

➢ Project Name: Adani Augusta
➢ Location: Tragad, Ahmedabad, specifically near Adani Pratham and behind Nirma
University.
➢ Developer: Adani Reality
➢ Project status:
1. A block
➢ Masonry:5th floor completed
➢ Plaster:4th floor completed
➢ RCC:7th floor Completed
2. B block
➢ Masonry:2nd floor completed
➢ Plaster: Ground floor completed
➢ RCC:6th floor completed

➢ Project Details:
• It's an "under construction" residential project.
• It features 3 BHK apartments.
• The project consists of 2 buildings.
• There are a total of 80 units.
• The expected possession date is December 2026.
• The project is located on roughly .81 acres of land.

Figure 1.6 Elevation of Adani Augusta

➢ Amenities:
•
The project includes modern amenities such as power backup and 24/7 security.
•
Also listed are things like: Event lawn, Banquet Hall, Indoor game room, Kids
play area, and a Gymnasium.
➢ Key Features:

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742548 INTRODUCTION

• The project emphasizes spacious living areas.

• The towers are designed to provide open views for each apartment.
• It is a RERA registered project.
➢ Target audience:
➢ The project is designed to provide a blend of luxury and comfort, aimed at
families and professionals.

1.7 WORK BREAKDOWN STRUCTURE

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742548 INTRODUCTION

1.8 LOGISTIC PLAN OF SITE

Figure 1.8 Logistic plan of site

1.9 SAFETY MEASURE

1.9.1 General

There is the perception that a site which is concerned for the safety of workers and
engineers is a good site just as a safety is important during the transportation and
construction.
1.9.2 IS codes for safety at site

IS Code IS Code Name

Number

SP 70: 2001 Handbook on construction practices

IS 3764 :1992 Code of safety for excavation

IS 3696: 1991 Safety code of scaffolds and ladders

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742548 INTRODUCTION

IS 4081: 2013 Blasting and realated drilling operation

IS 7969: 1975 Storage code for handling and storage of building materials

IS 7293: 1974 Safety code for working with construction machinery

IS 4912: 1978 Safety requirements floor and wall openings and toe boards

IS 3764: 1992 Code of safety for excavation work

IS 13416: 1992 Recommendations for Preventive Measures against Hazards at

Workplace

IS 13415: 1992 Protective Barriers in and arounds buildings

IS 4082: 1996 Stacking and storage of construction materials and components at site

Table 1.9.2 IS codes of safety at site

1.9.3 Safety equipment used at site

Name Uses

Safety Safety of head and face from hazardous

Helmet

Safety Should be used while transporting heavy materials like reinforcement bars
Gloves

Safety Should be used while welding or working with wooden in hazardous

Goggles condition

Safety Should be used all the time on site to get protection from pointed things
Shoes lying on the site

Safety Belt Should be used above while working 1.8m height

Safety Should be used mainly during the night to know the person’s presence on
Jacket site in darkness or during any accident

Table 1.9.3 Safety Equipment used at site

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742548 INTRODUCTION

Figure 1.9.3 Safety Tools and Equipment

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742548 INTRODUCTION

1.9.4 Safety helmet used at site

Sr. No. Color Used By

1. White Managers, Engineers, Supervisor

2. Green Safety Engineer

3. Grey Visitors

4. Blue Foreman

5. Red Electrician

6. Yellow Labour
Table 1.9.4 Safety helmet

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742548 EQUIPMENT, MATERIAL & TEST

CHAPTER 2 EQUIPMENT, MATERIAL & TEST

2.1 EQUIPMENTS

2.1.1 Plumb bob

Figure 2.1.1 Plumb bob

➢ Uses: Ensures vertical alignment in construction.

➢ Justification: A pointed weight attached to a string, used to check if a structure is
perfectly vertical (plumb).

2.1.2 Tube level

Figure 2.1.2 Tube level

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742548 EQUIPMENT, MATERIAL & TEST

➢ Use: Checks the level of plastered surfaces.

➢ Justification: A tool with a liquid-filled tube and bubble indicator that ensures the
surface is perfectly horizontal or vertical.

2.1.3 Spirit Level

Figure 2.1.3 spirit level

➢ Use: Checks horizontal and vertical alignment.

➢ Justification: A tool with a liquid-filled vial and an air bubble that indicates level
positioning. Used in masonry, carpentry, and plumbing.

2.1.4 Shovel

Figure 2.1.4 Showel

➢ Use: Moves loose materials like sand, gravel, and cement.

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742548 EQUIPMENT, MATERIAL & TEST

➢ Justification: A hand tool with a broad blade and handle, used for digging, mixing,
and loading materials.

2.1.5 Needle Vibrator

Figure 2.1.5 Needle Vibrator

➢ Use: Removes air bubbles and ensures proper compaction of concrete.

➢ Justification: A long, flexible shaft with a vibrating needle inserted into wet
concrete. Helps achieve a dense and strong concrete structure. Prevents
honeycombing and improves durability.

2.1.6 Hammer

Figure 2.1.6 Hammer

➢ Use: Used for fixing nails and minor chipping work in plaster.

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742548 EQUIPMENT, MATERIAL & TEST

➢ Justification: A hand tool with a heavy head, used for driving nails into wooden
frameworks before plastering.
2.1.7 Bar Cutting Machine

Figure 2.1.7 Bar Cutting machine

➢ Use: Cuts steel reinforcement bars (rebars) to required lengths for construction.
➢ Justification: Uses a strong, sharp blade to cut rebars of different diameters. Works
with hydraulic or mechanical power for precision cutting.

2.1.8 Bar Bending Machine

Figure 2.1.8 Bar Bending Machine

➢ Use: Bends reinforcement bars (rebars) into different shapes as per construction
requirements.

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742548 EQUIPMENT, MATERIAL & TEST

➢ Justification: Uses mechanical or hydraulic power to bend bars [Link] bend

bars to different angles, such as 45°, 90°, or 135°.

2.1.9 Bar Threading Machine

Figure 2.1.9 Bar Threading machine

➢ Use: Creates threads on the ends of reinforcement bars for joining with couplers.
➢ Justification: Uses a rotating die to cut precise threads on steel bars. Ensures a strong
mechanical connection between rebars without welding. Commonly used in high-
rise buildings and infrastructure projects for strong reinforcement joints.

2.1.10 Aluminium Patti

Figure 2.1.10 Aluminium Patti

➢ Use: Used to level and smooth freshly applied plaster.

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742548 EQUIPMENT, MATERIAL & TEST

➢ Justification: A long, straight aluminium strip that spreads and evens out plaster,
ensuring a uniform surface finish.
2.1.11 Right Angle

Figure 2.1.11 Right Angle

➢ Use: Ensures walls and corners are at a perfect 90-degree angle.

➢ Justification: A metal or plastic tool that checks and aligns plastered surfaces to
achieve straight edges and correct angular measurements.

2.1.12 Grinding Machine

Figure 2.1.12 Grinding machine

➢ Use: Used for smoothing rough plaster surfaces.

➢ Justification: A power tool with an abrasive disc that grinds and polishes hardened
plaster to remove imperfections and create a fine finish.

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2.1.13 Drill Machine

➢ Use: Creates holes in walls, metal, concrete, and wood for fittings and installations.
➢ Justification: Comes in electric or battery-powered models. Equipped with different
drill bits for various materials. Used for installing fixtures, anchors, and fasteners.

Figure 2.1.13 Drill machine

2.1.14 Mortar Mixing Machine

Figure 2.1.14 Mortar Mixing machine

➢ Use: Mixes cement, sand, and water to create mortar for brickwork and plastering.
➢ Justification: Ensures a uniform and consistent mortar mix. Available in manual,
electric, or diesel-powered models. Reduces labour effort and improves efficiency
compared to manual mixing.

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2.1.15 Plastering Float

Figure 2.1.15 Plastering float

➢ Use: Smoothens plastered surfaces.

➢ Justification: A flat tool, often with a wooden or plastic base, used to spread and
level plaster, cement, or mortar.

2.1.16 Dumpy Level (for Leveling)

Figure 2.1.16 Dumpy level

➢ Use: Measures and maintains levels during construction.

➢ Justification: A telescope-like instrument mounted on a tripod. Used to check height
differences and ensure even surfaces. Essential for road construction, foundations,
and landscape grading.

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742548 EQUIPMENT, MATERIAL & TEST

2.1.17 Staff for Dumpy Level

➢ A graduated measuring rod (leveling staff) used to read height differences.

➢ Placed at different points to measure elevation changes.

2.1.18 Chisels

➢ Use: Removes excess plaster and shapes decorative elements.

➢ Justification: A sharp-edged metal tool, used manually with a hammer or mallet to
cut or remove hardened plaster in detailed work.

2.1.19 Wooden Mallet

➢ Use: Used in conjunction with chisels for controlled plaster removal.

➢ Justification: A wooden hammer that delivers softer impacts compared to a metal
hammer, preventing damage to delicate surfaces.

2.1.20 Pointing Trowel

➢ Use: Used for small-scale plastering and repair work.

➢ Justification: A small, pointed metal tool with a handle, ideal for applying and
shaping plaster in corners, joints, and narrow spaces.
2.1.21 Finishing Trowel

Figure 2.1.21 Finishing trowel

➢ Use: Provides a smooth and even finish to the plaster surface.

➢ Justification: A flat, rectangular metal blade with a handle, used to spread and level
the final coat of plaster.

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742548 EQUIPMENT, MATERIAL & TEST

2.1.22 Sand Measuring box for plaster and flooring

Figure 2.1.22 sand measuring box

➢ Use: Helps maintain the correct sand-cement ratio. Reduces wastage and ensures
uniform strength in construction.
➢ Justification: Ensures accurate proportioning of sand in construction works,
preventing inconsistencies in plastering and flooring.
2.1.23 Shuttering and scaffolding Equipment

Figure 2.1.23 Shuttering, centering and scaffolding

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➢ Use: Supports concrete until it gains [Link] shape structural elements like
columns, beams, and slabs.
➢ Justification: Provides temporary support to structures during construction,
ensuring safety and stability.

2.1.24 Rotary Sand Sieving Machine

Figure 2.1.24 Rotary sand sieve

➢ Use: Ensures uniform particle size for consistent plastering and concrete mix.
➢ Justification: Helps in filtering fine and coarse sand to ensure better quality in
construction.

2.1.25 Binding wire hook

Figure 2.1.25 Binding wire hook

➢ Use: Helps in tying steel reinforcement bars quickly and securely. Reduces manual
effort and increases work efficiency.
➢ Justification: A tool designed to tie reinforcement bars efficiently.

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742548 EQUIPMENT, MATERIAL & TEST

2.1.26 Blower

Figure 2.1.26 blower

➢ Use: Keeps surfaces clean before applying finishes like paint or plaster.
➢ Justification: Used to clean construction areas by removing dust and debris.

2.1.27 Tiles cutting Machine

Figure 2.1.27 Tiles cutting machine

➢ Use: Helps achieve clean edges and customized shapes for flooring and wall tiling.
Cuts ceramic, porcelain, and other types of tiles efficiently.
➢ Justification: Ensures precise cutting of tiles to fit specific dimensions.

2.1.28 Bar Bent up tool

Figure 2.1.28 bar bent up tool

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742548 EQUIPMENT, MATERIAL & TEST

➢ Use: bend steel rebars at required angles (typically 45° or 60°) as per design
specifications.
➢ Justification: Used to bend reinforcement bars (rebars) accurately according to
structural design requirements.

2.1.29 Fischer FIS EM Plus 585s Injection mortar Equipment

Figure 2.1.29 injecting mortar Equipment

➢ Justification: Fischer FIS EM Plus 585 S is a high-performance epoxy injection

mortar used for heavy-duty anchoring in concrete and masonry. It provides
exceptional load-bearing capacity, corrosion resistance, and long-term durability,
making it ideal for structural strengthening and retrofitting applications.

2.1.30 Electric board

Figure 2.1.30 Electric board

➢ Use: Power Distribution, Safe Connection Points, Temporary Power Supply

➢ Justification: a power distribution unit used on construction sites to safely distribute
electricity to multiple tools and equipment.

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2.2 MATERIAL

2.2.1 Autoclaved Aerated Concrete Blocks (Eco-Green)-sand base

Figure 2.2.1 AAC Block

➢ Composition: Cement, Fly Ash, Lime, Aluminium Powder, Water

➢ Properties: Lightweight (1/3rd weight of bricks) → Reduces dead load on
structures.
➢ Thermal insulation → Keeps buildings cool.
➢ Fire resistance → Up to 6 hours.
➢ Soundproofing → Good for residential & commercial buildings.
➢ Common Sizes: 600 × 200 × 100 mm
600 × 200 × 150 mm
600 × 200 × 200 mm
600 × 200 × 230 mm
Uses: High-rise buildings, commercial complexes, hospitals, industrial sheds.

2.2.2 Block Joint Mortar (Eco-Green)

Figure 2.2.2 Block joint mortar

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Use: Special adhesive for AAC blocks to ensure strong bonding.

IS Code: IS 2250:1981 (Code for Masonry Mortars)

Composition: Cement, Polymers, Sand, and Chemical Additives.

➢ Properties: Pre-mixed, ready-to-use → Just add water and apply.

➢ Thin joint application (2-3mm thick) → Saves material.
➢ Faster construction → Reduces labor and curing time.
➢ High bonding strength → Prevents cracks in masonry.
➢ Advantages Over Traditional Cement Mortar:
Less material consumption (Reduces usage by 75%).
Stronger bonding than conventional cement-sand mortar.
No curing required, saving water and labor costs.
➢ Uses: AAC block wall construction, lightweight block masonry, and partition walls.

2.2.3 Ambuja OPC

➢ Full Form: Ordinary Portland Cement

➢ Available Grades: OPC 33 (IS 269:2015) → Rarely used now.
OPC 43 (IS 8112:2013) → Used for plastering, masonry, and non-structural works.
OPC 53 (IS 12269:2013) → Used in RCC, high-strength structures, and bridges.
➢ Properties:
High early strength, fast setting time.
Ideal for large-scale construction projects.

2.2.4 Ambuja PPC

Figure 2.2.4 Ambuja PPC cement bag

➢ Full Form: Portland Pozzolana Cement

➢ IS Code: IS 1489 (Part 1):2015
➢ Composition: 65-80% Clinker + 15-35% Pozzolanic Material (Fly Ash) + Gypsum
➢ Properties: Better durability, lower heat of hydration, more resistant to chemical
attacks.

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2.2.5 Chicken Mess

Figure 2.2.5 Chicken mess

➢ Purpose: Used to prevent plaster cracks at joints between concrete & brickwork.
➢ Material: PVC-coated mesh or Galvanized Iron (GI) mesh.
➢ Sizes: Mesh ½ inch – 1 inch
➢ Wire Thickness 0.5 mm – 1.5 mm
➢ Uses:
1. Plastering to avoid cracks.
2. Ceiling works for better bonding.
3. Tile fixing on walls.
4. Fencing purposes.

2.2.6 River Sand

➢ Source: Sabarmati River

➢ Use: Concrete Mix, Plastering & Masonry, Flooring & Tiling for Acts as a stable
bedding material, Foundation & Backfilling
➢ Justification: High-strength, well-graded, and impurity-free natural fine aggregate,
ensuring durability and workability in construction.

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2.2.7 Roff Flooring chemicals

Figure 2.2.7 Roff Flooring chemical

ROFF T03 (Cementitious Tile Adhesive)

➢ Use: Fixing ceramic tiles, mosaic tiles, vitrified tiles on walls & floors.
➢ Composition: Cement-based polymer adhesive.
➢ Advantages: High bond strength & Water-resistant. Can be used for internal &
external walls.
➢ ROFF T07 (Heavy-Duty Tile Adhesive)
➢ Use: Fixing large-size vitrified tiles, marble, granite, and stone tiles.
➢ Composition: High-polymer modified adhesive.
➢ Advantages: Extra strong adhesion for heavy stones & tiles.

2.2.8 Flooring Tiles

[Link] Granite Vitrified Tiles

➢ Uses: Long lifespan, reducing the need for frequent replacements.
➢ Available in a wide range of colours, patterns, and finishes to suit various design
preferences.
➢ Non-porous surface resists stains and moisture, making cleaning easy.
➢ Requires minimal maintenance, typically just regular sweeping and mopping.
➢ Different Size of Tiles: 600*600 mm
: 600*1200 mm
: 800*800 mm
: 200*300 mm
[Link] Granite Marble
➢ Uses: They provide a sophisticated and water-resistant surface.
➢ They provide a sophisticated and water-resistant surface.

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➢ Both granite and marble are used for flooring in various areas, including entryways,
living rooms, and hallways, adding a sense of grandeur.
➢ It is also use for stair treads and risers, creating durable and visually appealing
staircases.

2.2.9Tiles Spacer

Figure 2.2.9 Tiles spacer

➢ Purpose: Used to maintain uniform gaps between tiles for grouting.

➢ Material: Plastic (PVC/PP), sometimes rubber-based.
➢ Common Sizes: 1 mm – For wall tiles (minimal gap).

2.2.10 Sika Latex Power

➢ Purpose: Its primary functions are to improve adhesion and provide water
resistance.
➢ It serves as a bonding agent, waterproofing additive, and mortar modifier.
➢ Advantage:
➢ Waterproofing: It makes the mortar or concrete more water-resistant, protecting
structures from moisture damage.

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Figure 2.2.10 water proofing chemical

2.2.11 Sika Latex Pink

➢ Purpose: Improve adhesion.

1. Enhance water resistance.
2. Increase strength and flexibility
2.2.12 Plumbing Material
[Link] PVC Pipes for Normal Water Supply
➢ Material: Polyvinyl Chloride (PVC) – Lightweight, corrosion-resistant.
➢ IS Code: IS 4985:2000 (PVC pipes for potable water supply).
➢ Pressure Ratings (Class):
➢ Class 2 (2.5 kg/cm²) → Low-pressure supply.
➢ Class 3 (4 kg/cm²) → Medium-pressure supply.
➢ Class 4 (6 kg/cm²) → High-pressure applications.
➢ Sizes: 20mm – 250mm diameter
➢ Uses: Drinking water supply in homes & buildings.
1. Irrigation & agricultural pipelines.
2. Underground water supply.
➢ Advantages:
1. Rust-proof, lightweight, and easy to install.
2. Low maintenance & long lifespan (up to 50 years).

[Link] CPVC Pipes for Hot Water Supply

➢ Material: Chlorinated Polyvinyl Chloride (CPVC) – Heat-resistant up to 93°C.

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742548 EQUIPMENT, MATERIAL & TEST

➢ IS Code: IS 15778:2007 (CPVC pipes for hot & cold water).

➢ Pressure Ratings: SDR 11 → Higher pressure applications.
➢ SDR 13.5 → Normal household use.
➢ Sizes: 15mm – 100mm diameter
➢ Uses: Hot & cold-water supply in residential & commercial buildings.
1. Solar water heater connections.
2. Industrial hot water lines.
➢ Advantages: Does not corrode or scale like metal pipes.
1. Handles high temperature & pressure well.
2. Less thermal expansion compared to normal PVC.

[Link] UPVC Pipes for Sewer & Drainage Lines

➢ Material: Unplasticized PVC (UPVC) – More rigid & durable than PVC.
➢ IS Code: IS 15328:2003 (UPVC pipes for sewerage & drainage).
➢ Types of Sewer Pipes: Solid Wall UPVC Pipes → Normal underground drainage.
➢ Structured Wall uPVC Pipes (Ribbed/Corrugated) → Heavy-duty sewer lines.
➢ Sizes: 110mm – 315mm diameter
➢ Uses:
1. Wastewater disposal from buildings.
2. Municipal sewage lines.
3. Stormwater drainage.
➢ Advantages:
1. Chemical & corrosion-resistant.
2. Smooth inner surface prevents clogging

Figure 2.2.12 plumbing pipes

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2.2.13 Cover Block (Concrete Spacers for Reinforcement)

➢ Purpose: Maintains correct cover thickness between rebar & concrete to prevent
corrosion.
➢ Material: Concrete, PVC, Plastic, Fiber-reinforced plastic.
➢ Sizes & Cover Thickness as per IS 456:2000
Structure Type Cover Block Thickness
1. Slabs-15 mm – 20 mm
2. Beams & Columns-25 mm – 40 mm
3. Footings: 40 mm -75 mm
4. Retaining Walls-20 mm – 50 mm
5. Raft Foundations-50 mm – 75 mm

2.2.14 coupler

Figure 2.2.14 coupler

➢ Purpose: Threaded couplers are used to connect two rebars end-to-end by threading
the ends and securing them with a coupler
➢ Material: steel
➢ Structure Type coupler Size
16mm,20mm,25mm,32mm

2.2.15 steel formwork panel

➢ Purpose: Maintains correct cover thickness between rebar & concrete to prevent
corrosion.
➢ Material: Concrete, PVC, Plastic, Fiber-reinforced plastic.

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2.2.16 White Cement (JK cement wall-max)30kg bag

➢ Purpose: Used for decorative and architectural applications.
Acts as a base for coloured concrete and aesthetic coatings.

Figure 2.2.16 Putty

2.2.17 Reinforcement Bar

➢ Purpose: Provides tensile strength to concrete, which is weak in tension.
➢ Types of Rebars:
1. Mild Steel Bars (plain surface – rarely used now)
2. Deformed Bars TMT – with ribs for better bonding)
➢ Common Grades
1. Fe 415, Fe 500, Fe 500D, Fe 550
(Higher number = higher yield strength in N/mm²)
➢ Standard Bar Diameters
1. 6mm, 8mm, 10mm, 12mm, 16mm, 20mm, 25mm, 32mm, 36mm

Figure 2.2.17 Reinforcement Bar

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2.3 MATERIAL TEST

2.3.1 Sieve analysis (IS 1542: 1977) – Sand for Plaster

Sieve size Percentage passing limits

10mm 100
4.75mm 95-100
2.36mm 95-100
1.18mm 90-100
600µ 80-100
300µ 20-65
150µ 0-15
Table 2.3.1Sieve Analysis (IS 1542: 1977

Procedure of sieve analysis

1. Take 1000 Gms of fine aggregates sample.
2. Arrange the sieve set from top to bottom as follows 10mm, 4.75 mm, 2.36 mm, 1.18
mm, 600 micron, 300 micron, 150 micron and Pan.
3. After weighing the sample, transfer the sample to 4.75 mm sieve and cover it with
lid.
4. Sieve Shaking for 5 minutes
5. Weight the sample retained on each sieve, simultaneously note down in
observation sheet.
Sand test table

IS sieve Weight Cumulative Cumulative Percentage Percentage

size retained(gm) weight percentage passing passing
retained(gm) retained limits
10mm 100
4.75mm 95-100
2.36mm 95-100
1.18mm 90-100
600µ 80-100
300µ 20-65
150µ 0-15

𝑇𝑜𝑡𝑎𝑙 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑟𝑒𝑡𝑎𝑖𝑛𝑒𝑑

𝐹𝑖𝑛𝑒𝑛𝑒𝑠𝑠 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 =
100
2.3.2 Slump Test (IS 1199:1959)- workability classification

Types of concrete Slump range(mm) Workability classification

PCC Roads 0-25 Very low
RCC Foundation 25-50 Low

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Normal RCC 50-100 Medium

Pumped Concrete 100-150 High
Self-compacting >150 Very high
Table 2.3.2 Slump values for different types of concrete

Procedure of slump test

1. Ensure the mold is clean and place it on a flat, non-absorbent surface

2. Moisten the base plate and inside of the mold
3. Fill the mold in three layers
4. Tamp each layer 25 times with a rod
5. Strike off the concrete level with the top of the mold
6. Remove any excess concrete from the top and base of the mold
7. Raise the mold vertically in a slow and steady motion
8. Measure the slump by determining the difference between the height of the mold
and the highest point of the concrete
9. Record the slump in millimeters

Figure 2.3.2 Slump and cube Test

2.3.3 Cube test (IS 456:2000)- Compressive strength Requirements

Grade of concrete Compressive strength Compressive strength

(MPa) at 7 days (MPa) at 28 days
M10 7 10
M15 10 15
M20 13.5 20
M25 17 25
M30 20 30
M35 23 35
M40 27 40
M50 33 50

Table 2.3.3 Minimum compressive strength of cubes

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Material & Equipment required

1. Cement, sand, aggregates, and water (as per mix design).

2. Standard cube molds (150mm × 150mm × 150mm).
3. Tamping rod (16mm diameter, 600mm length).
4. Trowel, steel float, and weighing balance.
Procedure of cube test

1. Prepare the Molds: Clean and apply a thin layer of oil inside the cube moulds to
prevent sticking.
2. Mixing Concrete: Prepare concrete as per the designed mix proportions. Ensure
proper water-cement ratio and uniform mixing.
3. Fill the mould in three layers, each approximately 50mm thick. After placing each
layer, compact it properly using a tamping rod (35 strokes per layer).
4. Leveling the Surface: After filling and compacting, level the top surface using a
trowel.
5. Identification Marking: Each cube should be labelled with a unique identification
number (date, batch, and mix details).
6. Remove cubes from the Mould after 24 hours and submerge them in clean water for
curing.
7. Remove cubes from water and wipe off excess moisture.
8. Place the cube on the compression testing machine (CTM) with the cast surface
facing down.
9. Apply load gradually at a rate of 140 kg/cm² per minute (or 5.2 kN/sec) until failure.
10. Note down the maximum load (P) at failure.

Calculate compressive strength:

𝑁 𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑙𝑜𝑎𝑑(𝑃)
𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ( ) =
𝑚𝑚2 𝐶𝑢𝑏𝑒 𝑎𝑟𝑒𝑎(150𝑚𝑚 × 150𝑚𝑚)

2.3.4 Silt content test (IS 2386 Part 2:1963)- Permissible Limits

Type of work Maximum permissible silt content (%)

Concrete work 3
Plastering work 7
Table 2.3.4 acceptable silt content in sand

Procedure of silt content test:

1. The measuring cylinder is filled with the salt-water solution (the concentration of
the solution will be a teaspoon full of common salt for every 570 ml) up to the 50
ml mark on the cylinder.
2. Add sand until the level of the sand is reached the 100 ml mark.
3. Add further salt-water solution till the 150 ml mark is reached.
4. Place the palm on the mouth of the glass cylinder and shake it vigorously.

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5. Place the measuring cylinder on a hard level surface and tap it all around so that
the sand is level.
6. Wait for three hours for the silt to settle on top of the sand.
7. Measure the thickness of the silt layer and the height of the sand.

𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠𝑖𝑙𝑡 𝑙𝑎𝑦𝑒𝑟

𝑠𝑖𝑙𝑡 𝑐𝑜𝑛𝑡𝑒𝑛𝑡 𝑖𝑛 𝑠𝑎𝑛𝑑(%) = × 100%
(ℎ𝑖𝑔ℎ𝑡 𝑜𝑓 𝑠𝑎𝑛𝑑 + 𝑠𝑖𝑙𝑡)

Figure 2.3.4 Sand silt content test

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CHAPTER 3 BBS AND QUANTITY ESTIMATION

3.1 OVERVIEW

3.1.1Bar Bending Schedule (BBS): Bar Bending Schedule (BBS) is a detailed document
that provides the cutting, bending, and placement details of reinforcement bars in
Reinforced Cement Concrete (RCC) structures. It helps in:
1. Material Estimation: Accurate calculation of reinforcement steel required.
2. Cost Control: Avoids wastage and ensures economic use of steel.
3. Ease of Execution: Guides site engineers and workers for proper reinforcement
placement.
4. Key Components of BBS

➢ Bar Marking: Identifies each bar type.

➢ Shape Code: Indicates the bending shape.
➢ Diameter & Length: Specifies bar dimensions.
➢ Cutting Length: Determines bar length after bending.
𝐷2
➢ Weight Calculation: Weight = ×Length (m) (for mild steel in kg)
162

5. Hook length: as per IS 2502: 1963 (Indian Standard for Bending & Fixing of
Bars), the standard hook length is 9d (where d is the diameter of the bar).
However, infield practice, many engineers and site supervisors consider 10d for
ease of calculation and safety margin.
6. Bend Deduction: When a bar is bent, the effective length is reduced due to the
curvature. This deduction is considered while calculating cutting length.

➢ Bend Deduction Formula:

For 45° bend: Deduct 1d
For 90° bend: Deduct 2d
For 135° bend: Deduct 3d
For 180° bend: Deduct 4d
(where d is diameter of bar)

3.1.2 QUANTITY ESTIMATION

1. Concrete quantity for RCC
2. Block quantity
3. Plaster quantity

3.2 BAR BENDING SCHEDULE FORMAT

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3.3 COLUMN BBS

3.3.1 Cutting Length

➢ Vertical bar: Height of column + lap length

➢ Stirrups: Perimeter of stirrup + hook length – Bend Deduction as per Angles

Ex.

Figure 3.3.1 Column steel details

[Link] length for vertical bar for column

Height of column consider 3m and lap length as per 50d

1. For 16mm diameter

=3 + 50(0.016) =3.8m
2. For 12mm diameter
=3 + 50(0.012) =3.6m

[Link] length for Stirrups

2.1 Main stirrup cutting length (8mm dia.)

=2(length + width) + 10d (hook length) - 3×2d-2×3d

=2(1.120 + 0.150) + 0.160 -0.048-0.048

=2.604m

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2.2 stirrup-1 cutting length(8mm)

=2(length + width) + 10d (hook length) - 3×2d-2×3d

=2(0.235 + 0.150) + 0.160 -0.048-0.048

=0.834m

2.3 Stirrup-2 cutting length

=2(length + width) + 10d(hook length) - 3×2d-2×3d

=2(0.130 + 0.150) + 0.160 -0.048-0.048

=0.624m

3.3.2 Total weight

Cutting length×No. of bars×unit weight of bar

1. for 16mm dia. of bar

=3.8×16×1.580
=96.064kg
2. for 12mm dia. of bar
=3.6×8×0.888
=25.57kg
3. Stirrups
No. of stirrup calculation:
In confined Zone L/4=3000/4=750mm
In confined zone set stirrups at both ends at 100c/c=14 no. of set
Rest Zone set of stirrups at 150c/c =1500/150+1=11 no. of set
Total set:25
Total no of stirrups in one set=5nos

Total Weight=no. of set×no of stirrup in one set×cutting length×unit weight

[Link] Stirrup
=25×1×2.604×0.395
=25.71kg
[Link]-1

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=25×2×0.834×0.395
=16.47kg
[Link]-2
=25×2×0.624×0.395
=12.32kg

3.4 BEAM BBS

3.4.1 Cutting Length

1. Top bar
2. Bottom bar
3. Top extra
4. Bottom extra
5. Fork (if given)
6. Stirrups
Ex.

Beam length consider:6.780m

Bend in beam: Beam Depth-150mm (as per client specification)

Figure 3.4.1 Beam Steel details

[Link] Bar Cutting length

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=Beam length + 2(End beam width-cover of beam) +0.425(Bend in beam at both end)-bend
deduction

=6.790+2(0.230-0.025) +2(0.425)-2×2(0.016)

=6.790+0.410+0.850-0.064

=7.99m

[Link] Bar Cutting length

=Beam length + 2(End beam width-cover of beam) +0.425(Bend in beam at both end)-bend
deduction

=6.790+2(0.230-0.025) +2(0.425)-2×2(0.016)

=6.790+0.410+0.850-0.064

=7.99m

[Link] Extra (20mm dia.)

=1.700+0.205+0.375-0.040

=2.24m

[Link] Extra (16mm dia.)

=1.700+0.205+0.375-0.032

=2.25m

5. Bottom Extra (16mm dia.)

=6.790-0.950-0.950

=4.89m

[Link]

=2(length + width) + 10d(hook length) - 3×2d-2×3d

=2(0.525+0.18) + 0.2-0.120

=1.49m

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3.4.2 Total weight

cutting length×No. of bars×unit weight of bar

1. Top bar(2-20T+1-16T)
=2.24×4×2.47+2.25×2×1.58
=29.23kg
2. Bottom bar(3-16T)
=4.89×3×1.58
=23.17kg
3. Stirrups
No. of stirrup calculation:
Spacing:100c/c
Total no. of stirrups=6.790/0.1+1=69nos
4. Total Weight=no. of stirrups×cutting length×unit weight
[Link] Stirrup
=69×1×1.49×0.617
=63.43kg

3.5 SLAB BBS

3.5.1 Cutting Length

1. Main steel
2. Distribution steel
3. Top distribution bar along shorter span
4. Top extra bar(L/3) along shorter span
5. Top extra bar(L/3) along longer span
6. Chairs
Ex.

➢ Slab (3215×4605)
➢ Top extra length: L/3
➢ Bent-up: L/4
➢ Steel use in slab: 8mm diameter
1. Main steel: length+410(both ends in beam) + crank length(0.42×d=0.02814)-
bend deduction
Where d=Depth of slab-both side cover-dia. of bar(8mm) =0.067m

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=3.215+0.205+0.205+0.02814-0.016
=3.637m
2. Distribution steel
=4.605+0.205+0.205+0.02814-0.016
=5.027m

3. Top distribution along shorter span

=3.625m
4. Top extra(L/3) along shorter span
=4.605+0.205
=4.81m
5. Top extra(L/3) along shorter span
=1.071+0.205
=1.2767m

3.5.2 Total weight

cutting length×No. of bars×unit weight of bar

No of bars=Length/spacing+1

1. Main steel
=3.637×32×0.395
=45.97kg
2. Distribution steel
=5.027×22×0.395
=43.68kg
3. Top distribution along shorter span
=3.625×8×0.395
=11.46kg
4. Top extra along shorter span
=1.74× 32 ×0.395
=21.99kg
5. Top extra along longer span
=1.2767× 12 ×0.395

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=6.05kg

3.6 QUANTITY ESTIMATE FOR TYPICAL FLOOR

3.6.1 Reinforcement Quantity for Typical floor

Sr. Description 8mm 10mm 12mm 16mm 20mm 25mm 32mm Total
No. (Kg)
1 1st Floor
Slab 4423.36 4435.91
Beam and 2723.10 1459.28 236.10 4846.37 960.07 1493.51 11718.42
Chhajja
Column(1st 1816.21 85.248 1858.08 2489.76 185.184 6434.48
to 2nd floor)
Lift(1st to 2nd 847.85 103.36 70.10 407.64 355.68 1784.62
floor)
Total:24360.89kg

Table 3.6.1 Reinforcement Quantity for typical floor

❖ Link of Estimation
AGUSTA [Link]
❖ Link of Drawing
beam and [Link]
column drw 1at [Link]
3.6.2 Concrete Quantity for Typical floor
[Link] Column
=length×width×Height

3.6.2.2Beam
=length×width×Height

[Link] Slab
=length×width×Thickness

[Link] PCC
=length×width×Height

[Link] Footing
a) for rectangular
=length×width×Height

b) Trapezoidal

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1
= × (area of “a” face+ area of “b” face+√area of “a” face× area of “b” face) ×h
3

Sr. Description Quantity of concrete Grade of concrete

No. (Cubic Meter)
1 1st Floor
Slab 71.63 M25
Beam and Chhajja 26.86 M25
Column and Lift in slab (450mm 5.96 M25
height)
Column and Lift in slab (2425mm 32.14 M30
height)
Staircase 6.031 M25
Total Concrete require 142.621 CMT
for typical floor

Table 3.6.2 Concrete Quantity for Typical floor

❖ Link of Estimation
(concrete Quantity typical [Link])
❖ Column Drawing
column drw 1at [Link]
beam and [Link]
3.6.3 Masonry Quantity for Typical floor
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑊𝑎𝑙𝑙
= 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑏𝑙𝑜𝑐𝑘 𝑤𝑖𝑡ℎ 𝑚𝑜𝑟𝑡𝑎𝑟

Sr NO. Description Area of Area of AAC Block with Quantity of Block

Masonry mortar (Nos)
1 100mm 732.5 0.122409 5984.04
2 150mm 26.16 0.122409 213.71
3 200mm 15.61 0.122409 127.52
4 230mm 18.98 0.122409 155.05
Total No. 6480.32

Table 3.6.3 Masonry quantity for typical floor

❖ Link of Estimation
Masonry [Link]
❖ Architectural Drawing
Architectural Drw of [Link]

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3.6.4 Plaster Quantity for Typical floor

Sr NO. Description Total Area (Square Meter)

1 Wall plaster(12mm) 1173.915
2 Ceiling plaster(6mm) 414.043
Total Quantity 1587.958(SQM)
Table 3.6.4 Plaster Quantity for Typical floor

❖ link of Estimation
([Link])

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CHAPTER 4 SITE ACTIVITIES

4.1 OVERVIEW OF SITE ACTIVITIES

Construction projects involve a wide range of site activities, each playing a crucial role in
ensuring successful project completion. These activities are necessary to maintain
efficiency, safety, and quality while adhering to project timelines and budgets. Each of these
activities is interdependent, and their systematic execution ensures the smooth completion
of a project within the specified timeframe.

4.2 OBSERVED SITE ACTIVITIES ON SITE FOR A RESIDENTIAL

BUILDING

1. Bar bending, Cutting and threading

2. Shuttering, centering and scaffolding
3. Reinforcement and casting of RCC members
4. Curing
5. Leveling by dumpy level and staff
6. Checking of reinforcement as per Drawings
7. Masonry work
8. Electric work
9. Plumbing
10. Water-proofing
11. Plaster work
12. Flooring
13. Door and Window Framing
14. Fabrication
15. Finishing by White cement
4.3 SITE ACTIVITIES
4.3.1 Bar cutting, Bending and threading
[Link] Overview
➢ Bar Cutting: Bar cutting is the process of cutting steel reinforcement bars (rebars)
or metal bars to required lengths. It’s done using bar cutting machines, shears, or cutting
torches depending on bar thickness. Precision in cutting is essential to meet structural
requirements and minimize material waste.
➢ Bending of bars: Bar bending involves shaping steel bars to specific angles and
forms based on structural design. Bar bending machines or manual bar benders are
used to achieve accurate shapes. Proper bending ensures the bar fits into the
concrete framework, maintaining structural integrity.
➢ Threading of bars: Bar threading is the process of creating threads (spiral grooves)
on the ends of steel bars. Threaded bars are used for mechanical splicing, allowing

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two bars to connect with couplers. Threading is done using threading machines
and ensures strong, secure bar connections without weld

Figure 4.3.1 Bar Cutting and Bending

[Link] Process:
1. Understanding the BBS
2. Marking – Mark the required lengths on the steel bars based on the BBS.
3. Cutting – Use a bar cutting machine, cutting torch, or shears to cut bars
accurately to the specified lengths.
4. Setup – Set the bar bending machine according to specified angles and shapes in
the BBS.
5. Bending – Place each cut bar in the bending machine or manual bending tool and
bend according to the given shape codes (standard shapes as per IS 2502 or
project drawings).
6. Checking – Verify the bent bar against the template or measurement for accuracy.

4.3.2 Shuttering, Centering and scaffolding

[Link] Shuttering and Centering materials
1 Wooden Ply
➢ Used as formwork panels to hold and shape wet concrete.
➢ Helps achieve smooth concrete surfaces after de-shuttering.
➢ Can be cut and adjusted to various shapes and sizes for custom formwork
2 Steel channel
➢ Provides structural support to the shuttering framework.
➢ Used as beams or ledgers in scaffolding to hold loads and support platforms.
➢ Helps maintain alignment and rigidity in formwork systems.

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3 Sello tap
➢ Used to seal joints and gaps between formwork panels to prevent concrete
leakage.
4 Sika Separol plus modified vegetable oil base (230 L)
➢ Acts as a form-release agent in shuttering work.
➢ Prevents concrete from sticking to the wooden ply and steel formwork,
ensuring easy removal

[Link] Scaffolding materials:

Figure 4.3.2 Scaffolding

1. Ledger
➢ Horizontal component in scaffolding systems.

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➢ Connects the standards (vertical pipes) and supports planks or platforms.

➢ Maintains horizontal stability.
2. Standards
➢ Vertical steel pipes or posts in scaffolding.
➢ Carry the load from the scaffold to the ground via base jacks.
➢ Key structural element for height and load distribution.
3. Tie Rod
➢ Used in shuttering to hold formwork panels together.
➢ Resists lateral pressure from wet concrete.
➢ Maintains the correct spacing and alignment of formwork.
4. Shuttering clamp
➢ Fastens and secures formwork panels or plates.
➢ Ensures panels are tightly held without displacement.
➢ Reduces formwork leakage and increases safety.
5. Wing nut
➢ Used with tie rods to tighten or release formwork connections quickly.
6. Base Jack
➢ Adjustable base component placed under the standards.
➢ Used to level and support scaffolding on uneven ground.
➢ Transfers load from standards to the ground safely.
7. U-jack
➢ Placed at the top of scaffolding standards.
➢ Holds beams or ledgers in place for secure positioning.
➢ Used to adjust height and support formwork or slabs.
8. Cup lock
➢ A quick locking system for scaffolding pipes.
➢ Allows easy, secure connection of ledgers and standards.
➢ Provides strong, stable joints in scaffolding structures.
9. Tata box
➢ Used for safe storage of scaffolding accessories, clamps, bolts, nuts, and tools.
➢ Helps maintain site organization and reduces material loss.

[Link] Process of Shuttering, Centering and scaffolding

1. Site Preparation

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➢ Clear and level the site.

➢ Mark layout lines as per the
2. Erection of Scaffolding
➢ Fix base jacks on the ground.
➢ Erect vertical standards (pipes) on base jacks.
➢ Connect ledgers (horizontal members) and tighten with cup lock or clamps.
➢ Add bracings and transoms to ensure rigidity and stability.
➢ Install working platforms for safe access at required heights
3. Centering Setup
➢ On top of scaffolding, place main beams and secondary joists to create the
support frame.
➢ Adjust height and level using U-jacks.
➢ Ensure all members are tightly fixed, aligned, and can bear the concrete load.
4. Shuttering/Formwork Installation
➢ Fix formwork panels (wooden ply/steel plates) over the centering structure.
Secure the panels using tie rods, shuttering clamps, and wing nuts.
➢ Apply form oil/release agent to the formwork (e.g., Sika Separol Plus).
➢ Close all joints using sellotape to prevent concrete leakage.
➢ Check alignment, level, and dimensions carefully
5. Pre-Pour Inspection
➢ Check scaffolding stability and centering supports.
➢ Ensure all shuttering is properly fixed, oiled, and level.
➢ Confirm there are no gaps or weak connections.
6. De-Shuttering and Dismantling
➢ After the concrete has gained sufficient strength, dismantle shuttering panels.
➢ Remove centering and scaffolding carefully in reverse order.
➢ Store materials (tie rods, wing nuts, clamps) in a Tata box or designated
area for future use
❖ Here’s the shuttering removal time as per IS 456:2000 (Clause 11.3)
Member Shuttering Removal Time
Column (Vertical formwork) 16 to 24 hours
Slab (Soffit formwork only) 3 days
Slab props (if span<4.5m) 7 days
Slab props (if span<4.5m) 14 days
Beam sides (only side shutter) 16 to 24 hours
Beam Bottom formwork 7 days
Beam props (if span <6m) 14 days
Beam props (if span >6m) 21 days
Staircase side formwork (riser, 16 to 24 hours
side, panel)
Staircase bottom formwork 7 days

Table 4.3.2 Shuttering removal periods of RCC

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4.3.3 Reinforcement and casting of RCC members

[Link] Column and Footing

1. Bar Placement
➢ Mark column centerlines on footing or slab.
➢ Fix vertical main bars with proper lap length.
➢ Tie stirrups with specified spacing (closer spacing near ends).
Maintain 40mm cover using cover blocks.
➢ Check vertical alignment (plumb) and secure bars with ties.
2. Shuttering & Scaffolding
➢ Use steel or wooden shuttering as per design.
➢ Ensure inside surface is clean and apply shuttering oil.
➢ Check dimensions and column alignment with plumb line.
➢ Tighten joints to avoid leakage.
➢ Provide scaffolding around the column for safe access.
3. Casting Process
➢ Pour concrete in layers (not exceeding 1m height).
➢ Use needle vibrators carefully.
➢ Provide shier key for next casting.

Figure [Link] column casting

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[Link] Slab and Beam

Figure [Link] Slab and beam casting

1. Shuttering & Scaffolding

➢ Start with staging and scaffolding for slab and beams.
➢ Fix beam bottom formwork first and then side formwork.
➢ Place slab shuttering (plywood or steel sheets) over beams.
➢ Check levels and alignment.
➢ Apply shuttering oil on all surfaces.
2. Reinforcement placing
Bream:
➢ Fix beam bottom shuttering first and support it with strong props/scaffolding.
➢ Place beam bottom bars as per design with required cover.
➢ Tie stirrups with correct spacing.

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➢ Place top bars and extra bars at supports and openings.

Slab:
➢ Lay slab bottom bars (main and distribution bars)
➢ Place cranked bars and top bars at support area
➢ Use chairs to maintain top reinforcement spacing
➢ Keep 20-25mm cover with cover blocks
3. Casting Process
➢ Pour concrete starting from beams, then move to the slab.
➢ Vibrate beams and slab carefully.
➢ Finish slab surface (troweling and leveling).
➢ Providing Brooms on surface of slab.
➢ Curing

[Link] Staircase
1. Shuttering & Scaffolding
➢ Construct riser and tread shuttering with wood or steel.
➢ Provide tight joints to avoid leakage.
➢ Strong scaffolding underneath the entire flight and landing
➢ Apply shuttering oil.
2. Bar Placement
➢ Place main longitudinal bars anchored into landing beams.
➢ Tie distribution bars perpendicular to main bars.
➢ Maintain cover (25-30mm) using cover blocks
3. Casting of stairs with the help of Bucket.

Figure [Link] staircase casting

4.3.4 Curing

[Link] Curing Overview as per IS 456:2000 (Clause 13.5)

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Figure [Link] curing

1. Purpose of Curing
➢ Prevent loss of moisture from concrete.
➢ Maintain temperature for hydration.
➢ Ensure proper strength development.
➢ Minimize shrinkage cracks
2. Methods of curing
➢ Water curing (ponding, spraying, wet covering).
➢ Membrane curing (application of curing compounds).
➢ Steam curing (in special conditions/precast).
➢ Covering with wet hessian or polythene sheets.
Member Curing period Curing period
(OPC) (PPC)
Column 7 days 10 days
Beam & slab 7-10 days 10-12 days
Staircase 7 days 10-12 days
Plaster (internal) 7 days 7 days
Plaster (external) 10 days 10-14 days

Table 4.3.4 period of curing as per IS 456:2000

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4.3.5 Leveling of shuttering and centering

[Link] Instruments
➢ Auto level
➢ Levelling Staff
➢ Tripod

[Link] Process of levelling by Auto level

1. Set up the Auto Level on firm ground, ensure the bubble is centered, and the tripod
is stable.
2. Identify Benchmark (BM) elevation on site (given by surveyor/engineer).
Take Backsight (BS) reading on the benchmark to calculate Instrument Height (HI
= BM + BS).
3. Move the staff to the shuttering/centering points (corners, center, edges) and take
Foresight (FS) readings.
4. Calculate level for each shuttering point by subtracting FS from HI (Point Elevation
= HI – FS).
5. Compare the measured elevation with the design level.
a) If the level is low, raise the shuttering by adjusting supports or packing.
b) If it is high, reduce height by lowering the supports or trimming.
6. Re-check all points after adjustments to ensure uniform and correct levels.

4.3.6 Reinforcement inspection as per structural drawing

[Link] Steel checking for column and footing

1. Column
➢ Vertical bar
➢ Stirrups
➢ Lap length or Coupler
➢ Binding wire at joints
➢ Stirrups alternate Hook
2. Footing
➢ Top Jali
➢ Bottom Jali
➢ Vertical Bar with bottom L
➢ Spacer Bar

[Link] Steel Checking for Slab

➢ Main steel
➢ Distribution steel
➢ Top extra
➢ Top distribution
➢ Chairs

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[Link] Steel checking for Beam

➢ Top bar
➢ Bottom bar
➢ Top extra
➢ Bottom extra
➢ Fork
➢ Stirrups
➢ Spacer bar

[Link] Staircase steel checking

➢ Main steel
➢ Distribution steel
➢ Top extra at bottom
➢ Top extra at landing
➢ chairs

4.3.7 Masonry work

Figure 4.3.7 Masonry work

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[Link] Material
➢ AAC Block
➢ Block joint mortar
➢ Solid block
➢ Chicken mesh
➢ Coping and Mullion in wall

[Link] Process of work

1. Check drawings & materials -Verify line, level, and positions of wall, mullions,
and coping. Ensure block joint mortar bags are approved and stored in a dry place.
2. Mark layout -Mark wall lines and mullion centre lines (in the middle of wall
length) on the slab or footing.
3. Preparation of block joint mortar -
➢ Mix pre-packed block joint mortar with clean water (as per manufacturer’s ratio,
typically 3:1 water to mortar by volume or as specified).
➢ Use a mechanical stirrer for uniform mix.
➢ Keep consistency like thick paste, with no lumps.
➢ Use within the pot life (usually 30–40 minutes).
4. Lay first course
➢ Start from corners with a 10mm bedding layer of block mortar.
➢ Check line, level, and plumb.
5. Build wall and mullion up to half height
➢ Lay each block with 3mm thick horizontal and vertical mortar joints (use
notched trowel for uniform thickness).
➢ Maintain proper staggered joints and bonding pattern.
➢ Build mullions (vertical members) in center of wall, maintaining plumb and
straightness with each course.
6. Mid-wall coping
➢ Once half height is reached, clean the top surface.
➢ Place coping stone or concrete coping with a slight outward slope.
➢ Finish edges neatly and ensure proper curing of coping.
7. Cure coping -Keep coping moist for a minimum of 7 days.
8. Continue masonry above coping

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➢ Continue laying blocks with 3mm thick mortar joints above the coping.
➢ Extend mullions upward, ensuring vertical accuracy.
9. Complete full wall and mullion height
➢ Finish at specified wall height, keeping mullions aligned with the wall face.
10. Final finishing
➢ Clean joints, edges, and remove any excess mortar. Plaster or finish as per
specifications.
11. Curing
➢ Curing of block masonry is generally minimal due to thin joint mortar, but light
water misting for 2–3 days is recommended.
➢ Coping concrete requires proper curing for at least 7 days.

4.3.8 Electric Work

[Link] Material
➢ PVC Conduit Pipe & Fitting (25mm size)
➢ KEI 1100v wiring cable
➢ Electrical panel box
➢ Switch board
➢ Fiber distribution box
[Link] Process
1. Drawing Verification & Material Preparation

➢ Verify approved electrical drawings (power, lighting, conduit layouts).

➢ Arrange materials: PVC conduits, bends, junction boxes, switch boxes, KEI electric
wires, fish spring, chicken mesh, cement mortar, and accessories.
➢ Check tools readiness: pipe bender, cutter, spring, drill machine, measurement tape.

2. Conduit Laying in Slab (Before RCC)

Figure [Link] conduit in slab

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742548 SITE ACTIVITIES

➢ Mark conduit paths on slab shuttering as per layout.

➢ Lay conduits with bends, junction boxes, and fan boxes.
➢ Fix conduits to rebar using tie wire to avoid movement during concreting.
➢ Seal pipe ends with tape to prevent blockage from concrete.
➢ Get pre-casting inspection approval.
➢ After clearance, proceed with slab casting.
3. Conduit Laying in Masonry Walls (Before Plaster)

➢ Mark switch points, plug points, and conduit lines on the masonry wall.
Cut wall chases neatly using a chase cutter or chiselling.
➢ Lay conduits in chases and fix junction boxes/switch boxes with clamps.
➢ Ensure boxes are in level and plumb.
➢ After conduit laying, place chicken mesh over all chases (drill lines) to prevent
future cracking.
➢ Apply cement mortar to cover conduit lines flush with wall surface.
Allow to set before plastering.

4. Conduit Laying in Flooring (Before Tiles)

Figure [Link] conduit before flooring

➢ Mark conduit layout on floor for power points and floor boxes.
➢ Lay conduits with proper slopes and bends as required.
➢ Fix boxes at floor level and protect them with covers or caution tape.
➢ Obtain approval before tile laying.

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5. Wire Pulling (KEI Electric Wire) After Wall Plaster & Floor Finish

➢ Clean all conduits with compressed air or draw wire.

➢ Insert fish spring (cable pulling spring) through conduits.
➢ Tie KEI electric wires (color coded: phase - red/yellow, neutral - black, earth -
green) to the spring.
➢ Pull wires gently without damaging insulation; use lubricant if needed for long runs.
➢ Group wires neatly in junction boxes.

6. Fixing Switchboards, Sockets, and MCBs

➢ Terminate KEI wires in switch boxes and DB as per load schedule.

➢ Fix switches, sockets, and faceplates at the correct heights.
➢ Tighten terminals properly and fix faceplates neatly.
➢ Label circuits in DB panel for easy identification.

7. Testing & Commissioning

➢ Perform insulation resistance testing (megger test) on all circuits.
➢ Check continuity, earthing, and polarity.
➢ Test all points and loads for proper functioning

4.3.9 Plumbing

[Link] Material
➢ Prince CPVC 28.6mm potable hot & cold-water pipe
➢ Prince SDR11 (Flow guard plus)
➢ Prince Aquafit UPVC pipe
➢ U-bolt and Bracket with adjustable clamp
➢ Concealed cistern for wall-hung toilet
➢ Plumbing fixture rough-in protruding part

[Link] Process
1. Material to be Used
➢ Potable hot & cold-water supply:
a) Prince CPVC 28.6mm pipe
b) Prince SDR11 (Flow Guard Plus)
➢ Waste & drain lines:
a) Prince Aquafit UPVC pipe
➢ Support system:
a) U-bolt and bracket with adjustable clamp
➢ Sanitary ware:
a) Concealed cistern for wall-hung toilet
2. Execution Steps

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742548 SITE ACTIVITIES

a) Marking & Layout

➢ Mark plumbing lines as per approved drawings.
➢ Confirm pipe routes, fixture locations, and wall-hung toilet frame placement.

Figure [Link] plumbing drilling in wall

b) Pipe Installation (Before Plaster & Waterproofing)

Figure [Link] Installation of plumbing

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742548 SITE ACTIVITIES

➢ Install Prince CPVC 28.6mm for hot & cold lines from risers to fixture points using
appropriate fittings (elbows, tees, reducers).
➢ Use Prince SDR11 Flow Guard Plus pipe for high-pressure areas or main branches.
➢ Install Prince Aquafit UPVC pipes for waste and vent lines.

c) Mounting & Support

➢ All vertical and horizontal pipes to be secured with U-bolt and bracket adjustable
clamps at intervals per standards (not exceeding 1.2m for vertical, 1.5m for
horizontal).

d) Concealed Cistern Installation

➢ Fix concealed cistern frames for wall-hung toilets at designated height and
locations.
➢ Ensure cistern inlets, outlets, and flush points are accessible for future connections.

e) Fixture Rough-in Protrusion

➢ Extend all rough-in protruding pipe ends (hot, cold, drain lines) with protective end-
caps to avoid blockages.
➢ Check pipe pressure and leakage before plastering.

f) Testing
➢ Conduct hydro testing for CPVC lines (1.5 times working pressure) and leakage
testing for waste lines before covering.
➢ Ensure all lines are flushed clean.

3. Pre-Plaster & Waterproofing Checklist

➢ Verify alignment, supports, and levels.

➢ Confirm concealed cistern and pipe protrusions are correctly placed and secured.
➢ Obtain inspection clearance before plastering and waterproofing.

4.3.10 Waterproofing

[Link] Preparation
➢ Clean the surface thoroughly to remove dust, grease, oil, and loose particles.
➢ Dampen the surface slightly (avoid standing water).
2. Waterproof Coating (Using Sika Latex Power + Sika Latex Solid Compound)
➢ Preparation of Waterproof Coating Mix:
➢ 1 part Sika Latex Power (liquid)
➢ 1 part water
➢ 1 parts cement
➢ 3% Sika Latex Solid (powder) by cement weight (Approx. 1.5 kg per 50 kg cement)
➢ Mix to a smooth paste.

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Application:
➢ Apply 2 coats using a brush.
➢ First coat: Apply evenly and allow it to dry for 6–8 hours.
➢ Second coat: Apply in a perpendicular direction to the first coat.
➢ Allow 24–48 hours of curing.
Testing:
➢ After drying, conduct a water ponding test for at least 24 hours to check for leaks.
➢ If there’s leakage, apply an extra coat of the waterproofing mix.
3. Plaster & Screed Application (Using Sika Latex Pink in Mortar & Plaster Work)
➢ Mixing for Plaster/Screed:
➢ Cement: Sand = 1:4 (for plaster), 1:3 (for screed)
➢ Add Sika Latex Pink at 10% by weight of cement (5 kg for 50 kg cement)
➢ Add water gradually and mix thoroughly.
Application:
➢ Apply plaster/screed above the waterproofed surface.
➢ Maintain a minimum 12 mm thickness.
➢ Finish smoothly and allow it to set.
4. Curing
➢ Start curing after 24 hours.
➢ Keep the surface moist for at least 7 days.
4.3.11 Plaster work
[Link] Material
5 PPC Cement
6 Sand
[Link] Ratio of plaster
➢ Ceiling-1:3
➢ Wall-1:4
[Link] Quantity calculation for plaster work
Ex.
[Link] dimensions
L=5000mm
H=3000mm
Thickness of plaster=12mm
Dry volume factor:1.33
Volume=5×3×0.012
=0.18×1.33=0.24𝑚3

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For 1:4 Ratio of cement and sand

1
1. Cement= × 0.24=0.048𝑚3
5
𝑣𝑜𝑙𝑢𝑚𝑒 0.048
No of bag require= = =1.37Bag
0.035 0.035
4 3
2. Sand= × 0.24=0.19𝑚
5

[Link] Process
1. Surface Preparation
➢ Clean the wall surface by removing dust, loose materials, and stains.
➢ Fill any cracks and holes to make the surface smooth and even.
➢ Sprinkle water on the surface to keep it damp before plastering.
➢ Prepared Bull mark for proper reference plaster level.
2. Material Preparation
➢ Prepare a smooth paste by mixing PPC cement, clean fine sand, and water in the
correct proportion (commonly 1:4 or 1:6).
➢ Mix thoroughly until the mixture is uniform and lump-free.
3. Applying the First Coat (Scratch Coat)
➢ Apply the first coat of plaster with a trowel, approximately 10-12 mm thick.
➢ Roughly level the surface and scratch it with a comb to create bonding for the
second coat, if required.
4. Applying the Second Coat (if required)
➢ If a smooth or thicker finish is needed, apply the second coat after the first coat has
set (usually after 24 hours).
➢ This coat should be 6-8 mm thick and applied evenly.
5. Finishing
➢ Use an aluminium patti to level and straighten the plastered surface.
➢ Then, use a wooden or sponge float to smooth the surface and remove any lines or
imperfections.
6. Inspection
➢ After finishing, inspect the plastered surface for uniformity, cracks, hollow sounds,
and smoothness.
➢ Check for proper alignment, level, and thickness using a spirit level and plumb bob.
➢ Any defects found should be rectified immediately before curing.
7. Curing
➢ The plastered surface should be cured by sprinkling water 2–3 times daily for at
least 7 days.
➢ Proper curing ensures strength, prevents shrinkage cracks, and increases durability.
[Link] Inspection
Equipment Used for Inspection of Plaster:
1. Aluminum Rectangular Floater- Used for checking the evenness, smoothness,
and uniformity of plaster surfaces.
2. Plumb Bob- Used to check the verticality of plastered walls and surfaces.
3. Right Angle- Used to ensure the corners and edges are at perfect 90-degree
angles.

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4. Measure Tap- Used for measuring the dimensions, thickness, and overall area of
the plastered surfaces.
5. Level Tube- Used to check the level of plastered surfaces across large spans and
ensure horizontal alignment.

4.3.12 Flooring Work

[Link] Material to be used
1. Glazed Vitrified Tiles
600×600
600×1200
800×800
200×300
2. Roff Vitro-fix Grey T03
3. Roff Extro-fix Adhesive Grey T07
4. PEARL Black Marble
5. P- White Marble
6. Bubble Guard Sheet

[Link] Ratio for Bedding

➢ For Flooring – 1: 6

[Link] Process of Flooring Work

1. Surface Preparation
➢ Clean the surface by removing dust, loose particles, and debris.
➢ Check the surface level using leveling tools.
➢ Fill any gaps or uneven areas with appropriate material to ensure a smooth and even
base.
➢ Apply a coat of cement slurry (cement and water mix) on the surface for better
adhesion.
2. Preparation of Mortar for Bedding (1:6 Ratio)
➢ Prepare a cement-sand mortar with a mix ratio of 1 part cement and 6 parts sand.
➢ Mix thoroughly with water to achieve the desired consistency, ensuring it is
workable but not too watery.
3. Apply Mortar Process
➢ Spread the mortar bed uniformly on the prepared surface to the required thickness
(generally 20-25 mm).
➢ Ensure proper slope or level using a straight edge or level tube.
➢ Allow the mortar to set slightly before placing the tiles.

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4. Placing of Tiles
➢ Before placing, soak tiles in water for 15-20 minutes.
➢ Start placing tiles from one corner or as per layout line.
➢ Press each tile gently into the mortar bed and tap with a rubber mallet to ensure
proper bonding and leveling.
➢ Use spacers if required to maintain uniform gaps between tiles.
5. Used Chemical for Tile Joints
➢ After the mortar and tiles have set (generally after 24 hours), clean the joints and
apply tile joint grout or epoxy grout.
➢ Commonly used brands are Roff, Weber, or Fosroc Tile Joint Grout depending
on site preference.
➢ Mix the grout material as per manufacturer’s instructions and fill the tile joints using
a rubber float.
6. Finishing
➢ Wipe the tile surface with a damp sponge to remove excess grout and mortar.
➢ Clean thoroughly with water after the grout has hardened.
➢ Final polish can be done if required, and protection covers can be placed over tiles
to avoid damage during subsequent work.

4.3.13 Door and Window Framing

[Link] Material to be used

4.3.15 Finishing by White Cement

[Link] Material to be Used
➢ JK Cement wall-max (White Cement Based Putty)

[Link] Process of Finishing by White Cement (2mm)

1. Surface Preparation
➢ Clean the surface thoroughly to remove dust, dirt, loose particles, grease, or oil.
➢ Wet the surface lightly with water to avoid absorption of moisture from the white
cement.
➢ Repair cracks or uneven areas with mortar or plaster before starting
2. Mixing of White Cement
➢ Take high-quality white cement.

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➢ Mix with clean water in the ratio specified by the manufacturer (generally 1 part
cement to 2 parts water or as needed to make a smooth paste).
➢ Stir well to make a lump-free, uniform slurry or paste.

3. Application of First Coat

➢ Apply the first coat with a trowel or putty knife evenly.
➢ The thickness of the first coat is usually around 1–2 mm.
➢ Make sure the surface is smooth and level.
➢ Allow it to set for 2–3 hours (depending on temperature and humidity).

4. Application of Second Coat

➢ Apply a second coat (if needed) for additional smoothness and to cover minor
imperfections.
➢ Maintain a uniform thickness and finish.
➢ Smooth out the surface with a trowel or putty blade.

5. Curing
➢ Light curing by sprinkling water over the surface may be done for 2–3 days if used
as an exterior or plaster finish.
➢ For interior putty finish, generally, curing is not required, but check manufacturer
instructions.

6. Final Finishing
➢ After drying, gently rub the surface with fine sandpaper (400–600 grit) to get a
perfectly smooth finish.
➢ Wipe down to remove dust.
➢ The surface is now ready for paint or can be left as a natural white cement finis

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CHAPTER 5 CONCLUSION

The internship at Emboss Construction Pvt. Ltd. provided me with invaluable hands-on exposure
to the real-world applications of civil engineering. Throughout the internship period, I gained a
deep understanding of various construction processes, including site execution, material
management, structural drawing interpretation, reinforcement detailing, and Bar Bending Schedule
(BBS) preparation. I also observed and learned about the importance of quality control, safety
measures, and compliance with industry standards.
Working closely with site engineers and supervisors allowed me to enhance my technical and
managerial skills, as well as improve my ability to work in a team-oriented environment. This
experience helped bridge the gap between theoretical knowledge and its practical implementation
on-site. It has also contributed significantly to shaping my understanding of project planning,
execution, and the coordination required to complete a residential building successfully.
Overall, this internship was a vital step in my journey as a civil engineer, equipping me with the
confidence and competence to take on real-time challenges in the construction industry.

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REFERENCES
1. IS 456:2000 – Plain and Reinforced Concrete Code of Practice
2. IS 10262:2019 – Concrete Mix Design Guidelines
3. IS 4926:2003 – Ready Mixed Concrete
4. IS 14687:1999 – Guidelines for falsework and formwork
5. IS 2502:1963 – Bending and fixing of bars
6. SP 34:1987 – Handbook on reinforcement and detailing
7. IS 2250:1981 – Code of Practice for Preparation and Use of Masonry Mortars
8. IS 2185 (Part 3):1984 – AAC Blocks
9. IS 1661:1972 – Code of practice for application of cement and cement-lime plaster
10. IS 2402:1963 – Code of practice for external finishing
11. IS 1443:1972 – Laying and finishing cement concrete flooring tiles
12. IS 15622:2017 – Vitrified ceramic tiles
13. IS 2645:2003 – Integral waterproofing compounds
14. IS 3764:1992 – Excavation Safety
15. IS 3696:1991 – Scaffolding Safety
16. IS 7293:1974 – Machinery Safety
17. IS 2386 (Part 1-8):1963 – Aggregate testing
18. IS 516:1959 – Concrete compressive strength (cube test)
19. IS 1199:1959 – Sampling and testing of fresh concrete
20. IS 383- Specifications for fine & Coarse aggregate for concrete

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GTU 78 VGEC