A

Internship Report

On

CONSTRUCTION OF G+6 COMMERCIAL BUILDING, AUDITORIUM

AND CULTURAL HALL AT, KALAMANDIR, DIST. NANDED,
MAHARASHTRA STATE.

A report submitted in partial fulfillment of the requirements

for the degree of

B. Tech (Civil Engineering)

Submitted by
KHAN FAISAL YUSUF KHAN
MOHAMMAD ASHHAD
MOHAMMAD REHAN
SHAIKH AJIM

Department of Civil Engineering

M.G.M’s

College of Engineering, Nanded

Affiliated to

Dr. Babasaheb Ambedkar Technological University, Lonere, Maharashtra state,

India

2025-2026
Add CERTIFICATE (from company)
 CERTIFICATE

This is to certify that, the Internship entitled —Construction Of G+6 Commercial

Building,Auditorium and Cultural Hall submitted by —Khan Faisal Yusuf Khan”
“23021271191507” is a Bonafide record of work done by him and submitted during 2025 –
2026 academic year, in partial fulfillment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY in CIVIL ENGINEERING.

Prof.A.A. Bhore Prof. Alurwad Rajeshwarreddy Dr.A.K.

Hashmi Internship Guide Internship In charge HOD

Director,
Dr. Mrs. Geeta. S. Lathkar
MGM’s College of
Engineering Nanded

Place: NANDED
Date:
 CERTIFICATE

This is to certify that, the Internship entitled —Construction Of G+6 Commercial

Building, Auditorium and Cultural Hall submitted by —Mohammed Ashhad Md Akhtar
Quasmi” “23021271191508” is a Bonafide record of work done by him and submitted
during 2025 – 2026 academic year, in partial fulfillment of the requirements for the award of
the degree of BACHELOR OF TECHNOLOGY in CIVIL ENGINEERING.

Prof. [Link] Prof. Alurwad Rajeshwarreddy Dr. A.K.

Hashmi Internship Guide Internship In charge HOD

Director,
Dr. Mrs. Geeta. S. Lathkar
MGM’s College of
Engineering Nanded

Place: NANDED
Date:
 CERTIFICATE

This is to certify that, the Internship entitled —Construction Of G+6 Commercial

Building, Auditorium and Cultural Hall submitted by —Mohammed Rehan Mohammed
Asif Khan” “23021271191511” is a Bonafide record of work done by him and submitted
during 2025 – 2026 academic year, in partial fulfillment of the requirements for the award of
the degree of BACHELOR OF TECHNOLOGY in CIVIL ENGINEERING.

[Link] Prof. Alurwad Rajeshwarreddy Dr. A.K.

Hashmi Internship Guide Internship In charge HOD

Director,
Dr. Mrs. Geeta. S. Lathkar
MGM’s College of
Engineering Nanded

Place: NANDED
Date:
 CERTIFICATE

This is to certify that, the Internship entitled —Construction Of G+6 Commercial

Building, Auditorium and Cultural Hall submitted by —Shaikh Ajim Shaikh Mohiddin
” “23021271191528” is a Bonafide record of work done by him and submitted during 2025 –
2026 academic year, in partial fulfillment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY in CIVIL ENGINEERING.

[Link] Prof. Alurwad Rajeshwarreddy Dr. A.K.

Hashmi Internship Guide Internship In charge HOD

Director,
Dr. Mrs. Geeta. S. Lathkar
MGM’s College of
Engineering Nanded

Place: NANDED
Date:
 ACKNOWLEDGEMENT

The internship opportunity I had with SANMAN BUILDCON PVT LTD. Nanded
was a great chance for learning and professional development. I was provided with an
opportunity to be a part of it. I am grateful for having a chance to meet so many professionals
who led me though this internship period.

I express my deepest gratitude and special thanks to the ADIL SIR Project manager
with his designated post in company who guided us on site, 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 internship at their esteemed organization and extending
during the training. He provided precious guidance which was extremely valuable for my
study both theoretically and practically. I choose this moment to acknowledge his
contribution gratefully.

I would also like to take this opportunity to thank all projects team for their precious
guidance and administration staff for their help.

I would like to also convey my deepest thanks to Prof R. R. Alurwad, Internship In

charge and Dr. A.K. Hashmi, Head of Department for providing necessary support, advice
and guidance to me during the internship.

I also express my deepest gratitude to our Institute Director Dr. Mrs. Geeta Lathkar,
for providing this precise guidance and valuable support for the internship.

Khan faisal Yusuf Khan PRN: 23021271191507

Mohammed Ashhad PRN: 23021271191508
Mohammed Rehan PRN:
23021271191511
Shaikh Ajim PRN: 23021271191528
 DECLARATION

We hereby declare that the summer Internship report titled —Construction Of G+6
Commercial Building, Auditorium and Cultural Hall‖ is Bonafide work carried out by us
under guidance of project team at Sanman Buildcon. Nanded. Further we declare that this
report has not previously formed the basis of award of any associate ship or other similar
degrees or diplomas, has not been submitted anywhere else.

Date: -

Khan Faisal Yusuf Khan PRN: 23021271191507

Mohammad Ashhad PRN: 23021271191508
Mohammed Rehan PRN: 23021271191511
Shaikh Ajim PRN: 23021271191528
 INDEX

Sr Content Pg No.
No.
1 Company Profile 1-2
2 Project Details 3-5
3 Internship Work 6-7
4 Structural Drawings 8-19
5 Excavation 20-21
6 Footing 22-24
7 Formwork 25-28
8 Column 29-31
9 Beam And slab 32-36
10 Post-Tension Beam 37-40
11 Retaining Wall 41-43
12 Lift and Staircase 44-47
13 Tools And Equipment 48-67
14 Benefits 68
15 Photos Gallery 69
 1. Company Profile
Sanman Buildcon Pvt. Ltd. is a renowned construction company based in Nanded,
Maharashtra, dedicated to shaping the skyline of the city with innovative and sustainable
infrastructure solutions. Since its inception, the company has been a key player in the
construction and real estate industry, specializing in both residential and commercial projects.

Founded by Mr. Satish Maheshwari, a visionary entrepreneur with a strong passion for
architecture and construction, Sanman Buildcon quickly became synonymous with excellence,
reliability, and on-time project delivery. With a team of highly skilled professionals, including
architects, engineers, project managers, and construction experts, the company has successfully
completed numerous landmark projects across various sectors, including commercial
complexes, residential developments, cultural spaces, and institutional buildings.

Sanman Buildcon Pvt. Ltd. is committed to creating spaces that are not only functional
but also aesthetically pleasing, safe, and sustainable. The company’s core values revolve
around quality, integrity, customer satisfaction, and a deep respect for the environment.

The company has earned a reputation for its high standards in construction, backed by
advanced engineering practices, the latest technology, and meticulous attention to detail. Their
approach to project management ensures that each project is completed efficiently, within
budget, and in accordance with client specifications.

Through years of dedication and innovation, Sanman Buildcon Pvt. Ltd. has positioned
itself as a leader in the region’s construction industry, continuously pushing the boundaries of
design and engineering to deliver transformative spaces that improve the quality of life for its
customers.

1.1. Company History:

Sanman Buildcon Pvt. Ltd. is a leading construction company based in Nanded,

Maharashtra. Established with the vision to contribute to the development of high-quality
infrastructure, the company has over a decade of experience in the construction and real estate
industry. Known for delivering a variety of residential, commercial, and institutional projects,
Sanman Buildcon has grown to be a trusted name in the region.

1.2. Services Offered:

Sanman Buildcon Pvt. Ltd. provides a wide array of services related to construction
and real estate development, including:

Residential & Commercial Construction

Project Management & Consultancy
Architectural Design & Planning
Interior Design & Civil Works
1.3. Vision & Mission:
Vision: To be the premier construction company recognized for quality, integrity, and
innovative solutions in building sustainable environments.

Mission: To deliver exceptional, sustainable, and innovative projects that meet the
diverse needs of clients, while adhering to the highest standards of safety, quality, and customer
Satisfaction.

1.4. Project Details:

Awards:
Awarded the Best Construction Company in Nanded in 2023.
Recognized for outstanding Innovative Architectural Design in 2022.

1.5. Key Persons:

Managing Director: Mr. Satish Maheshwari
Chief Architect: Mr. Sehal Kapasi
Chief Engineer: Mr. M. Adil
Project Manager for Kalamandir Trust Project: Mr. M. Adil
Structural Engineer: Mr R.G. Birla

1.6. Organizational Structure:

Sanman Buildcon operates with a hierarchical structure, organized to ensure smooth
execution of all projects. Key divisions include:
Project Management Division
Design & Architecture Division
Engineering Division (Civil, Structural, MEP)
Quality Control and Safety Department
Accounts and Admin Department

1.7 Location the company:

Fig:1LocationofCompany
 2. Project Details

2.1. Name of Project:

Kalamandir Trust Project (G+6 Floor Commercial Building, Cultural Hall & Auditorium)

2.2. Owner of Project:

Kalamandir Trust (A non-profit trust dedicated to the promotion of culture, art, and
community events in Nanded.)

2.3. Consultants Involved:

Architect: Mr. Sehal Kapasi Mumbai
Structural Consultants: Mr. R.G. Birla
MEP Consultants: Saphalya Environs Pune

2.4. Address & Location:

Project Address:
Kalamandir Trust, Khadakpura, Nanded, Maharashtra 431601, India.

Location Map:

Fig:2LocationofSite
2.5. 3D Image of Project:

Fig:3 3DImageoftheProject
2.6. Area Statement:

Area of Land: 9757 square meters

Total Construction Area: 16000 square meters
Number of Floors: 7 (Ground + 6 floors)
Total Built-up Area of the Project: 16000 square meters

2.7. Building Details:

The Kalamandir Trust Project consists of a G+6 commercial building, which will
Commercial Office Spaces.
Cultural Hall (for art exhibitions, cultural events, etc.)
Auditorium (with seating capacity of 750)
Parking Area: 10832 square meters
Lobbies, Cafeteria, and Support Spaces

2.8. Architectural and Structural Drawing of Project:

Architectural Design:

The design of the building combines modern aesthetics with functionality, featuring
expansive glass facades, a spacious cultural hall, and a large auditorium for public events. The
ground floor consists of retail outlets, and the upper floors will serve as commercial office
spaces. The overall theme reflects Nanded's rich cultural heritage blended with contemporary
architecture.

Structural Design:

The structure is designed with a reinforced concrete frame and also have Post Tensioned
Beams, ensuring high durability and safety standards. The building includes a basement
parking area, with an efficient layout that maximizes space.

MEP Design: The building will include state-of-the-art electrical, plumbing, HVAC, and fire
safety systems, all designed to ensure energy efficiency and sustainability.
 3. Internship work

Visited Commercial building construction site for practical insights, and observe the
various stages of work in practically and learn from it how the actual work is going on the site.
And how the labors are work on site. And Interact with them on site to know more about the
actual work going on site how they work.

3.1 Stage of work at joining:

Project Type: Commercial Complex. A
Site Location: Kalamandir, Khadakpura, Nanded.
Stage of Work at Joining:
Excavation work was done of auditorium .
Foundation marking was done. of auditorium
Initial levelling and site clearance were in progress.
The second floor slab work was in process of G+6
commercial building
Reinforcement fixing work was being carried out as per structural drawings.
Site preparations for slab concreting were underway.
3.2 work allocation:
a. Assisting in Site Supervision
- Supported the site engineer in monitoring daily construction activities.
- Ensured that the work was progressing as per the drawings and schedule.
- Observed health and safety practices being followed on-site.
b. Layout and Level Checking
- Helped in layout marking for foundations, columns, and walls using measuring tape and
theodolite/auto level.
- Verified line, level, and plumb of structural elements under supervision.
c. Reinforcement Checking
- Checked placement of steel bars as per structural drawings and bar bending schedule.
- Verified bar diameters, spacing, lap length, anchorage, and cover block placement.
d. Post-Tensioned Beam Monitoring
– Observed the complete cycle of PT beam construction:
▪ Duct (sheathing) placement inside the beam formwork.
▪ Installation of anchorages at both ends.
▪ Placement and threading of high-tensile steel tendons (cables).
▪ Ensured correct positioning and support of ducts using spacers.
– Checked the cable profile and position as per structural drawings.
– Attended the stressing process after concrete gain strength (usually after 7–10 days).
– Observed grouting operation after stressing.
e. Reinforcement Checking (Conventional and PT)
– Verified conventional steel bars in slabs and beams along with PT cable layout.
– Checked the use of chair bars, stirrups, and cable spacing.
f. Concrete Work for PT Beams and Slabs
– Supervised casting of PT members ensuring no movement of ducts or tendons.
– Assisted with slump testing and cube testing of concrete.
– Ensured vibration and surface finishing were done properly.
g. Stressing Operation Observation
– Observed post-tensioning using hydraulic jack and pump system. Recorded elongation
values of tendons and compared them with theoretical values.
– Ensured safety measures were followed during stressing.
h. Grouting of Ducts
– Saw the grouting process using cement-sand slurry after tensioning.
– Verified that no air pockets remained and ducts were completely filled.
i. Concrete Work Assistance
- Supervised mixing, transportation, pouring, compaction, and curing of concrete.
- Participated in quality control activities like cube casting for compressive strength tests.
- Noted down batch numbers and mix ratios used at site.
j. Formwork Inspection
- Assisted in checking the alignment and tightness of shuttering before concreting.
- Observed removal timing and sequence of formwork for slabs, beams, and columns.
k. Material Management Support
- Assisted in recording incoming materials like cement, sand, aggregates, steel, bricks, etc.
- Maintained stock register and noted quantities used in daily work.
- Coordinated with suppliers and site storekeeper.
l. Documentation and Reporting
- Maintained daily progress reports (DPRs).
- Collected and filed site photographs for record keeping.
- Took notes of changes and instructions given during site meetings.
m. Learning from Drawings and Site Plans
- Regularly referred to architectural and structural drawings to understand the sequence of
construction.
- Compared drawings with actual on-site construction for better learning.

3.3 Role and responsibility allocated to Intern:

a. Site Supervision Assistance
– Assisted the Site Engineer in supervising day-to-day construction activities.
– Monitored the execution of work to ensure it followed technical drawings and
specifications.
– Conducted routine inspections of work such as excavation, concreting, reinforcement,
masonry, and plastering.
b. Checking Construction Layout and Levels
– Supported the layout marking of footings, columns, and walls using measuring tape and
level instruments.
– Verified the accuracy of plumb and level for structural and masonry works.
c. Reinforcement Inspection
– Cross-checked reinforcement placement as per bar bending schedules (BBS).
– Ensured proper diameter, spacing, cover blocks, lapping, and tying of rebars.
– Recorded and reported discrepancies in rebar arrangements to the site engineer.
d. Post-Tensioned (PT) Beam Work Observation
– Monitored the installation of PT ducts, tendons, anchorages, and stressing jacks.
– Ensured the PT cable profile followed design drawings.
– Recorded elongation and grouting data after tensioning was completed.
e. Concrete Work Monitoring
– Observed batching, mixing, transporting, pouring, compacting, and curing of concrete.
– Conducted or assisted in slump testing and cube casting for strength verification.
– Ensured proper use of vibrators and curing methods were followed.
f. Formwork Inspection
– Verified the alignment, stability, and cleanliness of shuttering before concrete work.
– Ensured joints were sealed properly to prevent leakage.
 4. Structural Drawings
4.1. Footing Plan:
`

Fig:4FootingPlanofG+6commrcialbuilding
4.2 Column Details Plan:

Fig:5ColumnLayoutPlan
Fig:6ScheduleofColumnandFooting
Fig:7 Detail of Column and Ring Plan
4.3 Beams and Slab Detail Plans:

Fig:8 Beam and Slab Plan at Second Floor level

Fig:9 Beam and Slab Plan at Second Floor Level
Fig:10 Schedule of Beam Plan at Second Floor Level
Fig:11 Schedule of Slab Plan at Second Floor Level
4.4 RCC Pardi Detail Plans:

Fig:12DetailsPlanofRCCPardiForRamp
4.5 All Drainage Channels Detail Plans:

Fig:13DetailsPlanofDrainage
4.6 Post Tensioned Beam Layout Detail Plans:

Fig:14PTBeamLayoutPlan
Fig:15ScheduleofPTBeamPlan
 5. Footing Of

5.1. Definition of Footing:

Footing is the lowermost part of a building structure that transfers the load from
columns or walls safely to the underlying soil. It spreads the structural load over a larger area
to prevent excessive settlement or failure of the soil. Footings are a critical component of the
foundation system.

5.2. Purpose of Footing:

– To distribute the load of the structure uniformly over the soil.
– To prevent structural settlement and maintain stability.
– To increase the bearing area and reduce pressure on the ground.

5.3. Types of Footings Observed on Site:

During the internship, the Isolated Box footings were used, based on soil conditions
and structural requirements:
a) Isolated Footing
– Used to support individual columns.
– Typically square or rectangular in shape.
– Common size observed: 2.35 m × 2.80 m, depth 2.4 m.
– Provided where columns are spaced far apart.
b) Raft (Mat) Foundation.
– A large continuous slab covering the entire building footprint.
– Used when soil bearing capacity is low or for basements.

Fig:18FootingPlanDrawing
Fig:19IsolatedBoxFooting
6.4 Following are the various sizes of footings:
Total Number of footings=80.
F1= 2.65mx2.80mx2.4m, Numbers of footings= 40.
F2= 2.30mx2.65mx1.9m, Number of footings= 1.
F3= 2.35mx2.50mx1.9m, Numbers of footings= 31.
F4= 2.25mx2.10mx1.5m, Numbers of footings= 4.
F5= 2.10mx1.95mx1.2m, Numbers of footings= 3.
F6= 2.10mx2.10mx0.9m, Number of footings= 1.

6.5 Formwork details:

1. Definition of Formwork:
Formwork is a temporary mold made of materials such as wood, plywood, or steel used
to hold wet concrete in place until it hardens and gains sufficient strength. In the case of footing
construction, formwork defines the size and shape of the concrete footings.

2. Type of Formwork Used on Site:

– Plywood formwork was used for constructing isolated and combined footings.
– Plywood boards were supported by wooden battens and braced using timber props.
– Plywood sheets provided a smooth surface finish and were reusable for multiple footings.
3. Materials Used:
– Plywood sheets (18 mm thick, waterproof shuttering grade)
– Timber battens (for support and bracing)
– Nails, screws, clamps, and corner angles
– Shuttering oil (mould release agent)
– Wire ties or steel clamps (to hold joints tightly)
– Wooden stakes or props for external bracing

4. Procedure of Plywood Formwork Installation for Footing:

a) Surface Preparation:
– Excavated footing pit was cleaned and leveled.
– A 100 mm thick PCC layer was laid to provide a flat base.
b) Assembly and Installation:
– Plywood sheets were cut according to the footing dimensions (length, width, and height).
– Sheets were nailed or screwed to vertical timber battens to form rigid panels.
– Panels were placed along the perimeter of the footing and fixed in position.
– Internal corners were supported with wooden cleats or L-angles to prevent leakage.
c) Alignment and Level Check:
– Formwork was checked for plumb (vertical alignment) and horizontal level using a spirit
level.
– Diagonal measurements were verified to maintain squareness.
d) Bracing and Support:
– External supports such as props, wooden stakes, or horizontal struts were installed.
– This ensured that the formwork did not move or bulge during concreting.
e) Surface Preparation of Formwork:
– Plywood surfaces were coated with shuttering oil to prevent concrete from sticking.
– Gaps and joints were sealed to avoid leakage.

5. De-shuttering (Formwork Removal):

– Formwork was removed after 24 to 48 hours, depending on weather and concrete strength.
– Plywood was carefully removed to avoid damaging edges or corners of the footing.
– Sheets were cleaned and stored properly for reuse.

6. Advantages of Using Plywood Formwork:

– Provides a smooth and uniform finish to concrete surfaces.
– Lightweight and easy to handle.
– Reusable for multiple footing castings.
– Faster assembly and disassembly compared to traditional timber.

7. Site Observations:
– Plywood formwork was used for most of the isolated footings (sizes ranging from 1.5 m ×
1.5 m to 2.5 m × 2.5 m).
– Bracing was done using wooden stakes and diagonal supports.
– No major leakage was observed during concreting due to tight joints and proper sealing.
– After de-shuttering, the plywood was reused for other footing castings.
 6. Formwork

Formwork is a temporary or permanent mold used to hold wet concrete in place until
it hardens and gains sufficient strength.

Purpose:
To shape the concrete as per the design (slabs, beams, columns, foundations, etc.) To
support the weight of fresh concrete until it hardens.

Stage Observed During Internship:

 Column formwork.
 Beam & slab formwork.
 Staircase formwork.

 Types of Formworks:
1. Timber Formwork – Made of wood; easy to use but less durable.
2. Plywood Formwork – Smooth finish; reusable up to 20–25 times.
3. Steel Formwork – Strong, durable, and reusable; gives excellent finish.
4. Aluminium Formwork – Lightweight and used for mass housing projects.
5. Plastic Formwork – Lightweight and good for small projects.

 Components:
Sheeting or panels: For contact surface with concrete. Supports:
Props, jacks, or scaffolding to bear load.
Ties and clamps: To hold formwork together.
Spacers and cover blocks: To ensure proper concrete cover.

 Key Requirements:
Strong enough to carry the load of wet concrete.
Leak-proof to prevent slurry loss.
Easy to remove without damaging concrete. Should
be reusable and economical.

 Stripping Time (General):

Vertical surfaces (columns, walls): 24–48 hours. Slabs
(props left under): 3–7 days.
Beams and slabs (complete removal): 7–14 days.

Key Details of Formwork:

1. Type of Formwork Used:
 Steel plates.
 Plywood with wooden supports.
 Modular formwork systems.

2. Materials Used:
 Plywood sheets (12mm thickness)
 Wooden battens and planks
 Steel props (Adjustable)
 Shikanja (clamps), tie rods, wing nuts
 3. Tools and Equipment:
 Measuring tape, plumb bob, spirit level.
 Hammer, nails, saw.
 Pipe wrench/spanners for tightening tie rods.
 Lifting equipment.

4. Procedure Followed:
a. Surface cleaned and leveled before formwork installation.
b. Base plates laid, verticals (props or soldiers) positioned.
c. Shuttering sheets fixed with clamps or nails.
d. Alignment and leveling checked with spirit level and plumb.
e. Form release agent applied.
f. Formwork inspected before pouring concrete.

Key Points Checked:

 Tight joints to avoid leakage
 Correct cover to reinforcement (spacers used)
 Stability of supports
 Proper alignment (vertical and horizontal)
 Gaps sealed to prevent slurry loss

6. Stripping (De-shuttering) Time:

 Columns: 24–36 hours
 Slabs: 7–14 days (depending on span and curing)
 Beams: 7 days (bottom), sides after 24–48 hours

7. Safety Measures Observed:

 Scaffolding properly braced.
 Personnel using PPE (helmet, gloves, shoes).
 Supervision during formwork removal

 Types of Formworks:
1. Timber Formwork – Made of wood; easy to use but less durable.
2. Plywood Formwork – Smooth finish; reusable up to 20–25 times.
3. Steel Formwork – Strong, durable, and reusable; gives excellent finish.
4. Aluminium Formwork – Lightweight and used for mass housing projects.
5. Plastic Formwork – Lightweight and good for small projects.

 Components:
Sheeting or panels: For contact surface with concrete. Supports:
Props, jacks, or scaffolding to bear load.
Ties and clamps: To hold formwork together.
Spacers and cover blocks: To ensure proper concrete cover.

 Key Requirements:
Strong enough to carry the load of wet concrete.
Leak-proof to prevent slurry loss.
Easy to remove without damaging concrete. Should
be reusable and economical.
 Stripping Time (General):
Vertical surfaces (columns, walls): 24–48 hours.
Slabs (props left under): 3–7 days.
Beams and slabs (complete removal): 7–14 days.

 Safety & Quality:

Proper alignment and support.
Use of release agent (oil) for easy removal.
Inspected before concreting for gaps, level, and plumb.

Fig:20 Plywood Sheet

Fig:21 Installation of Slab and Beam Formwork

 Fig:22 Column Shuttering

Fig:23 Staircase Formwork

 7. Column
A column is a vertical structural member in a building or structure that primarily carries
compressive loads from the slab, beam, or roof above and transfers them to the foundation
below.

There are different types of columns were utilized. The column sizes are specified as
follows:
0.30m x 0.75m and 0.23m x 0.75m with 8mm Dia stirrups made at 120mm spacing. A
concrete cover of 40mm was maintained, and M35 grade concrete was used. The concrete was
ready mixed and placed with the aid of a vibrator machine. The workforce consisted of three
laborers. Curing was achieved by covering the columns with gunny bags and periodically
pouring water over them. De-shuttering was performed after 48 hours using a crowbar. This
process ensured proper setting and strength development of the columns within the specified
construction parameters.

Fig:24Column
8.1 Column Steel details:
Total no. of Columns: 80.
Height of column at each floor: 3.5 m.

Fig:25ColumnSteelDetail

8.2 Following are the Step-by-step procedure for Column casting:

a. Check Layout & Centreline:

Use total station or theodolite to mark the centreline of the column on the slab or foundation.
Verify the position, orientation, and dimensions as per the structural drawing.

b. Surface Preparation:

Clean the foundation or footing top where the column will be cast.
Remove dust, oil, debris, or standing water.
Roughen the surface for better bonding (if cold joint exists).
Apply cement slurry or bonding agent before casting (optional).
c. Reinforcement Placement:

Fix vertical bars as per bar bending schedule (BBS).

Tie lateral ties/stirrups at specified spacing.
Maintain clear cover using plastic or concrete spacers (usually 25–40 mm).
Ensure proper lap lengths (if continuing from lower column) and bar positions.

d. Formwork Fixing:

Fix plywood or steel shuttering around the reinforcement cage.

Ensure dimensions and alignment match the drawing.
Apply shuttering oil on the inner face to prevent sticking.
Seal all joints with tape or foam to prevent leakage of slurry.

e. Final Checks Before Concreting:

Column alignment (verticality).

Dimensions.
Reinforcement details.
Formwork tightness and support.
Ensure concrete of required grade is ready.

f. Concrete Pouring:
Pour concrete into the column in layers of 300–500 mm.
Use mechanical vibrator to compact each layer and avoid honeycombing.
Ensure proper flow of concrete around bars and corners.
Monitor concrete level during pouring using formwork openings.

g. Surface Finishing & Protection:

Finish the top surface of the column flat if another beam/slab will connect.
Cover the top immediately after finishing with wet hessian or plastic.

h. Curing:

Start curing after 10–12 hours (or when surface hardens).

Remove shuttering after 24–48 hours (depending on height and weather).
Continue curing for at least 7 days (preferably 14 days for better strength gain).

i. Inspection & Records:

Document:
Concrete pouring time.
Cube test samples.
Curing schedule.
Inspect for honeycombs, alignment, surface finish.
 8. Beams & Slabs work
9.1 Beam:
A beam is a horizontal structural element that resists loads applied perpendicular to its
length. It transfers the load from the slab or wall above to the columns or vertical supports
below. Beams are designed to withstand bending and shear forces.

Following are the step-by-step procedure of beam casting:

Step 1: Marking Beam Layout on Site:

 Using the structural drawing, the exact location and dimensions of the beam are
marked on the supporting structure (usually the slab or column).
 Chalk lines or marking tools are used to define the beam's centreline and width.
 Accuracy is crucial to ensure correct alignment and proper integration with slabs and
columns.
 Levels are checked using spirit level or auto level instruments.

Step 2: Installing Formwork (Bottom and Sides):

 The bottom shutter (soffit) is fixed first using plywood or steel sheets supported on
vertical props or steel jacks.
 Side formwork panels are then installed on both sides of the beam, creating a mold of
the beam cross-section.
 Props, bracing, and clamps are used to support the entire formwork system, ensuring
stability and resistance against concrete pressure.
 Form release agent (shuttering oil) is applied on the inner face to prevent sticking of
concrete.
 The formwork must be leak-proof and properly aligned both vertically and
horizontally.

Step 3: Placing Reinforcement (Main Bars and Stirrups):

 Reinforcement is placed as per the bar bending schedule (BBS) and structural
drawing.
 Main longitudinal bars (top and bottom) are fixed first.
 Stirrups (rings) are then placed at specified intervals to resist shear forces.
 Cover blocks are used to maintain the required concrete cover (usually 25–40 mm).
 Binding wire is used to tie bars securely to prevent displacement during concreting.
 Extra bars may be provided at beam-column junctions for added strength.

Step 4: Pouring and Compacting Concrete:

 Concrete of the required grade (e.g., M25 or M35) is poured into the formwork in
layers.
 Pouring is done from one end to the other to avoid cold joints.
 Mechanical vibrators are used to compact the concrete and remove air voids
(honeycombs).
 Care is taken not to displace the reinforcement during pouring.
 The top surface is leveled and finished after concreting.
 Step 5: Curing for Proper Strength Development:
After initial setting, curing begins to keep the concrete moist and ensure strength gain.
Curing can be done by:
Covering with wet burlap or gunny bags
Sprinkling water regularly
Using curing compound (for vertical surfaces)
Curing is continued for at least 7 to 14 days depending on temperature and humidity.

Step 6: De-shuttering (Formwork Removal):

Side shutters can be removed after 24–48 hours, as these do not bear direct loads. Bottom
formwork is removed after 7 to 14 days depending on beam span and concrete strength.
Removal is done carefully to avoid damage to the concrete edges.
After de-shuttering, any surface defects are repaired, and the beam is checked for
alignment and cracks.

Safety Measures During Beam Work:

Scaffoldings and working platforms for safe access
Proper handling and storage of materials

Fig:26 Beam Steel Detail

Fig:27 Beam and Slab Formwork
9.2 Slab:
A slab is a flat, horizontal structural component, typically made of reinforced concrete,
that forms floors and ceilings in buildings. It distributes live and dead loads to the supporting
beams or directly to columns and walls.
Only two-way slab is construct on site
 Supported on all four sides
 Load transfers in both directions
 Main bars in both directions

9.2.1 Construction Procedure of Slab:

1. Formwork / Shuttering:
 Plywood or steel plates supported by props and scaffolding
 Proper levelling and tight joints are ensured
2. Reinforcement Placement:
 Main bars and distribution bars placed as per design
 Cover blocks provided to maintain proper cover (20–25 mm)
 Additional reinforcement at column junctions (negative reinforcement)
3. Electrical & Plumbing Conduits:
 Pipes for lighting, fans, and drains laid before concreting.

4. Concreting:
 Concrete of specified grade (e.g., M20, M25) poured
 Compacted using mechanical vibrators to remove air voids
 Surface is leveled and finished

5. Curing:
 Begins 24 hours after casting
 Water ponding or wet hessian cloth used
 Continued for 7 to 14 days
6. De-shuttering:
 Side shutters: 1–2 days after casting.
 Bottom shuttering: 7–14 days (depending on span and load).00
 9. Post Tensioned Beam
A post-tensioned beam is a type of reinforced concrete beam where high-strength steel
tendons or cables are tensioned after the concrete has been cast and has gained sufficient
strength. This process helps counteract the tensile stresses imposed by loads, improving
performance and allowing longer spans, thinner members, and reduced material use.

Following are the Components of the Post-tensioned beam:

1. Concrete Beam – The structural member shaped and cast from concrete.
2. Ducts – Plastic or steel tubes cast into the beam to house the tendons.
3. Tendons – High-strength steel cables or strands placed in the ducts.
4. Anchorage System – Devices at the ends of the beam that anchor the tendons after
tensioning.
5. Grout (optional) – In bonded post-tensioning, the ducts are filled with grout after
tensioning to bond the tendons to the concrete.

Following are the step-by-step procedure for casting of post-tensioned beam:

1. Formwork & Staging:

 Set up formwork as per beam dimensions and support layout.
 Ensure formwork can resist tendon forces during tensioning and concreting.
 Provide camber (if specified) to counteract expected deflection.

2. Duct & Anchorage Placement:

 Install ducts (HDPE or metallic) according to tendon profile (parabolic or straight).
 Fix anchorage assemblies at both ends of the beam.
 Place spacers and supports to hold ducts in position during concreting.
 Ensure all ducts are properly sealed to prevent concrete ingress.

3. Tendon Installation
 Insert strands (tendons) through the ducts.
 Maintain identification tags for each tendon.
 Avoid damage, kinks, or corrosion.
 Leave required tendon length protruding beyond anchorages for stressing.

4. Concreting
 Check duct alignment and stability before pouring.
 Pour concrete carefully to avoid disturbing the ducts.
 Use vibrators to ensure proper compaction around ducts and anchorages.
 Maintain cover to ducts as specified (typically 25–50 mm).

5. Curing
 Allow concrete to cure properly for the duration specified (usually 5–7 days or until
strength >75% of design strength).
 Keep concrete moist using wet hessian, water spraying, or curing compound.
6. Stressing (Tensioning) of Tendons
 Perform a concrete strength test (cylinder/cube) to confirm required strength.

 Use hydraulic jacks and a pump to tension the tendons.

 Apply force gradually as per the tensioning schedule.

 Monitor elongation and jack pressure; compare with theoretical values.

 Anchor tendons at the designed elongation.

7. Grouting
 Mix cement grout (typically cement + water + admixtures).
 Pump grout into the ducts from the lowest point until it flows out from the other end.

 Seal the ducts after grouting is complete.

 Allow grout to harden (1–2 days).

8. Finishing Works
 Cut and seal the protruding tendons at the anchor ends.

 Patch up anchor recesses with non-shrink grout.

 Remove formwork once all operations are done and curing is complete.

 Perform any required surface finishing or protection (e.g., epoxy coating).

Fig:28 post-tension beam Tendons

 Fig:29Layingofpost-tensionbeamgrout.

Fig:30Layingofpost-tensionbeamDuct.
Fig:31post-tensionbeamDuct.
 10. Retaining Wall

A retaining wall is a structure designed to hold or retain soil, preventing it from sliding
or eroding away due to gravity or water action. It supports vertical or near-vertical grade
changes and is commonly used in landscaping, road construction, and building foundations.

11.1 Retaining wall dimension and reinforcement details:

 Thickness of wall: 300 mm
 Height of wall: 3 m
 Mian bar: 10 mm at 100 mm c/c
 Secondary bar: 8 mm at 150 mm c/c

11.2 Step-by-Step Procedure for Casting a Retaining Wall:

1. Site Preparation:
 Clear the area: Remove vegetation, rocks, and debris.

 Excavation: Excavate soil according to the foundation depth as per structural drawings.

 Check soil bearing: Ensure the soil can support the wall

2. Base Preparation:
 Levelling and compacting: Compact the excavated base with a mechanical compactor.

 Mark layout: Mark dimensions using line and pegs per design.

3. Reinforcement Placement:
 Cut and bend: Cut steel reinforcement bars according to bending schedule.

 Fix reinforcement:

a. Place bottom and top reinforcements with cover blocks.

b. Tie vertical and horizontal bars as per drawing.

 Install spacers: Use cover blocks to ensure concrete cover (cover provided 40 mm).

4. Formwork:
 Install shuttering: Set up formwork for the base and wall using Aluminum Shuttering.

 Check alignment: Ensure verticality and dimensions are accurate.

 Apply form oil: To prevent concrete sticking to the forms.

5. Concrete Pouring:
 Mix design: Use M 35 grade of concrete.

 Place concrete: Pour in layers and use a vibrator to avoid air pockets.

6. Curing:
 Initial curing: Cover with wet bunny bags.

 Final curing: Continue water curing for at least 7–14 days.

7. Backfilling:
 Wait for strength gain: Backfill only after concrete gains sufficient strength (usually
after 7 days).

 Provide drainage:

a. Place a layer of gravel or crushed stone behind the wall.

b. Install weep holes (at regular intervals) or drainage pipes to relieve hydro static
pressure.
Fig:33 RCC Retaining Wall (Pardi)
 11. Lift and Staircase

12.1 Lift Definition:

A Lift or Elevator is a vertical transportation system used to move people or goods
between different levels of a building using a motor-driven cabin or platform within a lift shaft.

No. of lift at our site is 7.

Purpose:

 Provides vertical mobility in multi-storey buildings.

 Essential for elderly and disabled accessibility.
 Facilitates quick transport of goods and people.
 Required in high-rise residential and commercial structures.

Following are the Step-by-Step Procedure for Lift Shaft Casting:

1. Site Layout:

 Mark the location of the lift pit as per architectural and structural drawings.

 Ensure alignment with staircase and floor landings.

2. Excavation:

 Excavate to the required depth for the lift pit (generally deeper than the basement or
ground floor level).
3. Lean Concrete:

 Place a 75–100 mm thick PCC (Plain Cement Concrete) bed to provide a clean, level
base.
4. Reinforcement and Shuttering (Pit):

 Place reinforcement for the pit slab and walls according to the structural drawing.

 Provide proper concrete cover 40 mm.

 Fix shuttering for pit walls and base.

5. Concrete Pouring (Pit):

 Pour concrete into the pit base and walls.

 Use vibrators to ensure compaction.

6. Wall Construction (Lift Shaft):

 Build shaft walls with RCC columns.

 Provide guide rails insert positions and leave openings for doors.
12.2 Staircase Definition:
A staircase is a structural element that provides a vertical circulation path through a
series of steps, allowing people to move between floors.

No. of staircase at our site is 2.

Purpose:
 Enables manual access between floors.
 Acts as an emergency exit.
 Provides fire escape route.
 Adds architectural design value.

Following are the Step-by-Step Procedure for Staircase Casting:

1. Layout:

 Set out the dimensions of flight, riser, tread, and landing as per architectural design.
 Confirm alignment with lift shaft and floor levels.

2. Formwork:

 Fabricate and fix shuttering for steps and landing slab.

 Use plywood and steel props for support.
 Form each step shape correctly, including nosing, riser, and tread.

3. Reinforcement:

 Cut and place steel as per structural drawings.

 Provide cover blocks of 25 mm.

4. Concreting:

 Mix and pour concrete of M 30 grade.

 Start from the bottom step upward for proper compaction.
 Use needle vibrators and compact carefully around edges and corners.

5. Finishing:
 Screed the surface and smooth treads.
 Provide nosing finish for slip resistance.
 Use a steel trowel for neatness.

6. Curing

 After de-shuttering (after 2–3 days), begin water curing for at least 7 days.

7. Tiling or Final Finish

 Apply tiles, stone, or anti-skid flooring material as per design.
 Fig:36 Staircase Formwork.

Fig:37 Staircase After Construction.

 12. Brick work
Definition .

AAC (Autoclaved Aerated Concrete) blocks are lightweight, precast building materials made from
cement, lime, sand/fly ash, water, and aluminum powder. They are cured in an autoclave under high
pressure and temperature, resulting in a strong and lightweight block used for wall construction.

Purpose and Necessity of AAC Block Work in Buildings

1. Lightweight Construction & Reduced Dead Load

AAC (Autoclaved Aerated Concrete) blocks are significantly lighter than conventional clay bricks. Their low
density reduces the dead load on beams, columns, and foundations, resulting in economical structural design
and improved seismic performance.

2. High Thermal Insulation

AAC blocks contain millions of tiny air pores that provide excellent thermal insulation. They reduce heat
transfer through walls, helping maintain comfortable indoor temperatures and lowering energy consumption
for cooling and heating.

3. Fire Resistance & Safety

AAC blocks are non-combustible and offer excellent fire resistance. Depending on wall thickness, they can
withstand fire exposure for several hours, enhancing building safety and protecting occupants during
emergencies.

4. Sound Insulation
The porous structure of AAC blocks effectively absorbs sound and reduces noise transmission. This makes
them suitable for residential buildings, schools, hospitals, offices, and other structures where acoustic comfort
is important.

5. Faster Construction
AAC blocks are larger in size and lighter in weight than traditional bricks. Fewer units are required per square
meter of wall area, leading to faster construction, reduced labor requirements, and improved project
efficiency.

6. Durability & Strength

AAC blocks possess adequate compressive strength and are resistant to weathering, termites, pests, and
fungal growth. Properly constructed AAC masonry provides long-lasting and reliable performance with
minimal deterioration.

7. Smooth Surface Finish

AAC blocks are manufactured with precise dimensions and smooth surfaces. This results in uniform masonry,
thinner mortar joints, and reduced plaster thickness, saving both material and finishing costs.

8. Eco-Friendly & Sustainable

AAC blocks are manufactured using materials such as cement, lime, sand, and fly ash. They consume fewer
natural resources, generate less construction waste, and contribute to sustainable and environmentally friendly
building practices.

9. Cost Efficiency
Although AAC blocks may have a higher initial unit cost, savings in structural steel, cement, mortar, plaster,
labor, transportation, and energy consumption make them economical over the building's life cycle.
10. Earthquake Resistance
Due to their lightweight nature, AAC blocks reduce the seismic load acting on a structure. This improves the
building's overall resistance to earthquake forces and enhances structural safety.

Block Size:

Standard size: 600 × 200 × 100 mm, 600 × 200 × 150 mm, or 600 × 200 × 200 mm
Size may vary depending on wall thickness requirements.
• Wall Thickness & Height:
Common wall thickness: 100 mm, 150 mm, or 200 mm
Maximum wall height constructed in one day should be controlled to avoid settlement and ensure proper
alignment.

• Materials:
AAC blocks
Ready-mix AAC block jointing mortar
Clean water
Reinforcement mesh (where required)

Procedure:

Clean the surface and mark wall layout as per drawings.

Prepare AAC block adhesive/jointing mortar as per manufacturer's instructions.
Apply a thin layer of mortar (approximately 3–5 mm thick).
Place AAC blocks carefully and align them using a string line.
Maintain staggered vertical joints for better bonding.
Check level and plumb regularly during construction.
Fill joints completely and remove excess mortar.
Cure the masonry as required.

• Instruments Used:

Spirit level
Plumb bob
Measuring tape
Mason's line
AAC block cutter
Fig 38 .Brick Work
 13. Plastering

Definition

Plastering is the process of covering rough surfaces of walls, ceilings, columns, and other structural
members with a layer of mortar (cement mortar, lime mortar, or gypsum mortar) to obtain a smooth,
durable, and protective finish.

Plastering on AAC (Autoclaved Aerated Concrete) block walls provides a protective and decorative finish while
improving the performance and durability of the masonry.

Creates a Smooth and Uniform Finish

AAC block surfaces may contain minor joints and surface irregularities. Plastering fills these imperfections and
provides a smooth, level surface suitable for painting, putty, or decorative finishes.

Enhances Durability
The plaster layer acts as a protective coating that safeguards AAC blocks from abrasion, impact, and surface
damage. It also helps prevent the formation of small cracks and improves the longevity of the wall.

Moisture & Weather Protection

AAC blocks are porous and can absorb moisture. Plastering seals the surface, reducing water penetration and
protecting the wall from dampness, efflorescence, and weather-related deterioration.

Improves Thermal Performance

AAC blocks already possess excellent thermal insulation properties. A plaster layer further enhances thermal
resistance, helping maintain comfortable indoor temperatures and reducing energy consumption.

Improves Acoustic Insulation

Plaster adds density to the wall surface, reducing sound transmission and improving acoustic comfort within the
building.

Aesthetic Enhancement
Plastered AAC walls provide an attractive appearance and allow various decorative finishes such as paint, texture
coatings, and wall coverings.

Protection Against Environmental Effects

The plaster coat protects AAC block masonry from sunlight, rain, dust, pollution, and other environmental factors,
preserving the wall's strength and appearance.

Procedure

-Clean the AAC block surface and remove dust, loose particles, and debris.
-Wet the wall lightly before plastering to control water absorption.
-Apply a bonding coat or slurry where required.
-Fix dots and screeds at suitable intervals to maintain uniform thickness.
-Apply the base coat evenly between screeds and level it using a straightedge.
-Scratch the base coat lightly to create a key for the finish coat.
-After the base coat has partially set, lightly wet the surface.
-Apply the finish coat from top to bottom and smooth it using a steel float.
-Cure the plaster adequately for at least 7 days to achieve proper strength.
Fig.39 Plastering
 14. Tools & Equipment

13.1. Auto Level:

An Auto Level is a precision optical instrument used in surveying and construction to

measure height differences and to transfer, measure, or set horizontal levels.

Following are the main Components of an Auto Level:

Telescope: - Fixed to the instrument; used to view the levelling staff.

Levelling Screws: - Used to adjust the instrument’s position horizontally.

Circular Bubble (Spirit Level): - Ensures horizontal alignment manually.

Compensator: - Automatically maintains a horizontal line of sight (key difference from dumpy
level).

Tripod: - Stand on which the auto level is mounted.

Levelling Staff: - A graduated staff (in meters or feet) used to read elevation.

Following are the procedure of taking out levelling:

 Set up the auto level on a tripod and roughly level it using foot screws.
 Sight the back sight (BS) on a known elevation (e.g., benchmark).
 Sight the intermediate sight (IS) or fore sight (FS) on the point(s) to be measured.
 Use the readings to compute Reduced Levels (RL) using.

How It Works:

 The instrument is mounted on a tripod and roughly levelled using foot screws.
 The internal compensator adjusts the line of sight to be perfectly horizontal.
 The operator sights a graduated staff held at a distant point and reads the value.
 This reading is used to calculate the height difference between points.
Fig.40 Takimg out leveling with the help of auto-level
13.1.2. Levelling Staff:
A levelling staff (also called a level staff or surveyor’s staff) is a graduated rod used
with a levelling instrument (like an auto level, dumpy level, or total station) to determine height
differences between points on the earth’s surface.
Graduation and Measurement Units:
Staff is usually marked in meters or feet, divided into:

 Meters: Typically marked in decimetres (dm), centimetres (cm), and millimetres (mm)

 Alternating black/red and white patterns to increase visibility

 Major divisions (e.g., 1.000 m, 2.000 m) are clearly labelled

Uses of a Levelling Staff:

 Height Measurement: Determines height difference between two points

 Setting Out Levels: For foundations, slabs, beams, and other structural works
 Topographic Surveying: - Measures ground elevations for mapping
How It Works (with an Auto Level):

Place the levelling instrument on a tripod at a stable point.

Place the levelling staff vertically on the ground point to be measured.

Through the instrument, read the value at the horizontal crosshair on the staff.

Record readings:

 Backsight (BS): First reading on a known benchmark (BM)

 Foresight (FS): Reading on a new point

 Intermediate Sight (IS): Reading between BS and FS

Fig.41 Takimg out leveling with the help of leveling staff
13.2. Double Drum Roller:
A Double Drum Roller, also known as a tandem roller, is a compaction machine with
two steel drums, one in the front and one at the rear, used to compact soil, asphalt, gravel, or
other materials in construction.

It is widely used in road construction and other large-scale compaction tasks.

Main Features and Components:

 Front Drum: - Smooth steel drum used for compacting the surface.
 Rear Drum: - Identical to front drum, works simultaneously.
 Vibratory System: - Provides vibration to enhance compaction efficiency.
 Operator Cabin: - Seat and control panel to steer and operate the roller.
 Water Tank & Sprinkler: - Sprays water to prevent asphalt from sticking to the drum.
How It Works:

 The drums roll over the surface, applying static and dynamic (vibratory) pressure.
 Both drums can apply vibration, which reduces air voids and increases material density.
 The machine moves forward and backward, ensuring uniform compaction.

Fig.42 Double Drum Roller

13.4. Compression Testing Machine:
It is a mechanical or digital machine used to test the compressive strength of materials
such as concrete cubes, cylinders, bricks, blocks, and other structural materials.

The CTM machine helps determine whether a construction material (like concrete)
can withstand the compressive loads it will face in real-world conditions. It’s a crucial tool in
quality control and material testing.

Testing Procedure (Using CTM):

 Switch ON the CTM machine (manual, digital, or computerized).

 Clean the platens of the machine.
 Place the concrete cube on the lower platen centrally and without tilting.
 Ensure the cube is aligned properly under the loading axis.
 Close the machine safety doors (if any).

Loading: -

 Start the machine.

 Apply load gradually and uniformly at a rate of:

o 0.5 MPa to 0.75 MPa/sec (per IS code)

o Or 2.5 kN/sec to 5 kN/sec (as per machine calibration)

 Continue loading until the specimen fails (cracks or crushes).
 Note the maximum load (in kN) displayed before failure.
Fig:43 Compressive Testing Machine (Digital and Manual)
13.5. Bar Bending Machine:
A Bar Bending Machine is a mechanical device used to bend steel reinforcement bars
(rebars) into desired shapes and angles for use in reinforced concrete construction. It ensures
accurate, consistent, and efficient bending of bars as per structural design requirements.
Following are the main Features & Specifications:

 Material Handled: - Steel reinforcement bars (TMT bars)

 Bar Diameter Range: - 6 mm to 40 mm (varies by model)
 Power Source: - Electric motor (usually 3-phase)
 Bending Angle Range: - 0° to 180°

Working Principle: -

 The rebar is placed on the machine with one end fixed.

 The bending disc rotates, forcing the bar around a bending pin.
 The angle selector stops the machine at the desired angle.
 The bar is then removed, now bent to the required shape.

Fig.44 Bar Bending Machine

13.6. Jack & Spanners:
13.6.1. Jack:

A Jack in construction formwork refers to a mechanical or adjustable device used to

support and level formwork structures like beams, slabs, and columns. It helps transfer loads
during concrete casting and maintains the formwork in position.

Types of Jacks Used in Formwork:

 Adjustable Base Jack: -A threaded jack used at the bottom of vertical supports (like
props or scaffolding) to level the height.
 Adjustable U-Head Jack: - Supports beams or soffits from the top; allows adjustment
and load transfer.
 Telescopic Jack (Prop): - A steel pipe system that can extend or shrink to desired height
to support slab or beam formwork.

Uses of Jacks in Formwork:

 To adjust and align vertical supports accurately.
 To transfer vertical loads from slabs and beams.
 To level uneven ground during shuttering setup.
 To maintain height of slab formwork while casting concrete.
 To support heavy loads safely during curing time.
13.6.2. Spanner:
A Spanner is a hand tool used to tighten or loosen bolts, nuts, and clamps that secure
formwork components like steel plates, panels, or pipe connections.

Common Types Used in Formwork:

 Ring Spanner: - Encloses the nut completely for firm grip (used for continuous
tightening).
 Open-End Spanner: - U-shaped ends to quickly engage/disengage nuts.
 Adjustable Spanner (Crescent Wrench): - Jaw width can be adjusted for multiple bolt
sizes.
 Box Spanner: - Cylindrical tool for deep-set bolts in formwork clamps or joints.

Uses of Spanners in Formwork:

 Tightening formwork clamps, joints, and bolts.

 Assembling and dismantling shuttering panels and scaffolding.
 Securing adjustable jacks or screw heads.
 Used during alignment to keep formwork rigid.
 Helps ensure leak-proof joints before concrete pouring.

Safety Tips:
 Always check the jack threads for wear or damage.
 Use correct spanner size to avoid bolt stripping.
 Ensure jacks are on firm base plates or sole pads.
 Do not overtighten with spanners as it may damage formwork.

Fig:46 Spanner
13.7. Tower Crane:
A Tower Crane is a tall, fixed crane used on large construction sites for lifting and
moving heavy materials like steel, concrete, formwork, and machinery. It provides a
combination of height and lifting capacity and is anchored to the ground or structure for
stability.

Key Features and Specifications:

 Type: - Fixed (anchored), Self-erecting, or Climbing
 Height: - 20 m to 265 m (or more, if tied to the structure)
 Jib (Arm) Length: - 30 to 80 meters (horizontal reach)
 Lifting Capacity: - 1 to 25 tons (varies by model)
 Rotation Range: - 360° slewing
 Power Source: - Electric motor or diesel generator

Main Components of a Tower Crane:

 Mast (Tower): - Vertical structure that gives the crane its height
 Jib (Working Arm): - Horizontal arm that carries the load
 Counter Jib: - Short arm that holds counterweights to balance the load
 Slewing Unit: - Allows 360° rotation of the jib
 Trolley: - Moves the load horizontally along the jib
 Hook: - Attached to wire rope for lifting materials
 Cabin: - Operator’s control station, usually near the top
 Counter weights: - Concrete or steel blocks to prevent tipping
 Base/Foundation: - Anchored to the ground or building for stability.

Working Process of a Tower Crane:

1. Installation:
 Installed on a concrete foundation (with anchor bolts).
 Crane sections are assembled vertically using mobile cranes.
 For tall buildings, the crane may be self-climbing (builds itself upward through the
structure).

2. Operation:
1. Load is attached to the crane hook using slings or shackles.
2. The operator in the cabin (or remote control) uses joysticks to:
o Raise/lower the hook (hoisting)
o Move the trolley (horizontal movement)
o Rotate the jib (slewing)
3. Counterweights balance the crane to avoid tipping.
4. Materials are safely moved to desired height and location.
5. Once the task is done, the hook is returned to rest near the mast.
Fig.47 Tower Crane:
13.8. Boom Pump:

A Boom Pump is a concrete pumping machine mounted on a truck or trailer, equipped

with a remote-controlled robotic arm (boom) used to deliver concrete precisely and efficiently
at elevated or difficult-to-reach construction sites. It is ideal for high-rise buildings, bridges,
overpasses, and large slabs where manual concrete pouring is not practical.

Key Features of a Boom Pump:

 Mounted on: - Truck or stationary platform.
 Pump Type: - Hydraulic piston-type or twin-cylinder.
 Reach Height: - 20 to 70+ meters (depending on boom length).
 Concrete Output: - 50 to 170 m³/hour.
 Boom Sections: - 3 to 6 articulating sections for flexible movement.
 Control: - Remote wireless or cable-operated joystick.
 Operation: - Automatic, with hydraulic support stabilizers.

Main Parts of Boom Pump:

 Boom Arm: - Articulated robotic arm that delivers concrete to height or distance.
 Concrete Pump: - Moves the concrete through pipes.
 Hopper: - Holds concrete from the mixer truck before pumping.
 Hydraulic System: - Powers the boom movement and pumping action.
 Outriggers (Stabilizers): - Provide base support during pumping.
 Remote Control Unit: - Allows the operator to control boom position and pump
remotely.

Working Process of Boom Pump Step-by-Step Procedure:

 Site Preparation.
 Position the truck at a safe and accessible location.
 Deploy outriggers (stabilizers) for a level and secure setup.
 Connecting the Mixer.
 A concrete transit mixer pours concrete into the hopper of the boom pump.
 Concrete Pumping.
 The pump uses hydraulic pressure to move concrete through steel pipes.
 Concrete travels from the hopper into the pipeline via twin-piston pumping system.

Boom Operation:
 The boom arm is extended and positioned to the pouring area using remote control.
 The operator directs the hose for accurate placement.
 Continuous Pouring
 Concrete flows steadily without the need for manual transportation.
 Flow rate and boom position are adjusted in real-time by the operator.
 Completion & Cleaning
 Once pouring is complete, the system is flushed with water.
Fig:48 Concrete Pump
13.9. Transit Mixer:
A Transit Mixer (also known as a concrete mixer truck) is a vehicle used to transport
ready-mix concrete from a batching plant to the construction site. It has a rotating drum
mounted on the back, which continuously mixes the concrete during transit to keep it fresh,
uniform, and workable.
Key Features of a Transit Mixer:

 Mounted On: - Truck chassis

 Drum Capacity: - Typically, 4 to 12 cubic meters (m³)
 Power Source: - Diesel engine or hydraulic PTO (Power Take-Off)
 Mixing Method: - Rotating spiral blades inside the drum
 Drum Rotation: - Clockwise to mix, counter-clockwise to discharge

Working Process of a Transit Mixer Step-by-Step Procedure:

1. Loading:

 The truck arrives at the concrete batching plant.

 Measured quantities of cement, sand, aggregate, water, and admixtures are
loaded into the drum through the hopper.

2. Mixing in Transit:

 The drum rotates continuously (clockwise) to keep the concrete well mixed
during travel.

 If required, water is added from the onboard tank to adjust the slump.
3. Transporting:

 The mixer truck transports the concrete to the construction site.

 The drum keeps rotating during the journey to prevent setting.

4. Discharging:

 At the site, the drum is rotated in reverse (counter-clockwise) to push the

concrete towards the chute.

 The concrete is discharged directly into buckets, pumps, or forms.

5. Cleaning:

 After discharge, the drum and chute are washed with water to prevent
hardened concrete buildup.

 Regular cleaning increases machine life and reduces blockages.

13.10. Backhoe Loader:
A Backhoe Loader is a versatile construction machine that combines the functions of a
tractor, a front loader, and a backhoe. It is commonly used in construction, road work, digging,
and material handling operations.
 A front bucket (loader) for lifting and loading materials.

 A rear arm (backhoe) for digging trenches or foundations.

Following are the main Components of a Backhoe Loader:

Front Loader Bucket: - Used to lift, carry, and load materials like soil, gravel, or debris.
Backhoe Arm: - A hydraulic arm with a bucket used for digging.
Cab: - Operator’s station with controls for loader and backhoe.
Stabilizer Legs: - Provide stability during backhoe operations.
Wheels/Tracks: - Used for movement; usually wheel-mounted for road use.

Working Process of a Backhoe Loader:

1. Site Preparation:

 Position the machine on a stable surface.

 Deploy stabilizer legs for backhoe operations to avoid tipping.

2. Loader Operation (Front Side):

 The loader bucket is used to scoop, carry, and dump materials.

 It is operated with hydraulic levers from within the cab.

3. Backhoe Operation (Rear Side):

 The operator turns the seat to the rear control panel.

 Uses the hydraulic backhoe arm to dig and lift soil.

 Digging depth typically ranges from 2.5 to 6 meters, depending on machine size.

4. Mobility:

 The machine moves on wheels (ideal for urban jobs).

 Can travel short distances between sites without a trailer.

Key Features:

 4-in-1 bucket (optional for multiple tasks)

 Compact and mobile—great for small to medium sites

 Hydraulic system for smooth control

 Can be fitted with attachments like hammers, augers, and forks

Fig:50 Backhoe Loader
13.11. Needle Vibrator:
A Needle Vibrator (also known as an internal vibrator or poker vibrator) is a mechanical
device used in construction to compact freshly poured concrete. It consists of a steel vibrating
needle (poker) that is inserted into wet concrete to remove air bubbles, improve bonding, and
ensure a dense and uniform mix.
 Slabs

 Beams

 Columns

 Foundations

Following are the main components of a needle vibrator:

 Needle (Poker Head): - A steel tube with an eccentric vibrating weight inside.
 Flexible Shaft: - Connects the needle to the motor and transmits rotary motion.
 Drive Unit (Motor): - Provides mechanical power—electric, petrol, diesel.
 Handle/Frame: - For carrying and controlling the device.

Following Typical Specifications:

 Needle Diameter: - 25 mm to 60 mm.

 Vibration Frequency: - 4000 – 12000 vibrations per minute.
 Power Source: - 1 – 2 HP motor (electric/diesel).
 Shaft Length: - 1.5 – 6 meters.

Uses of a Needle Vibrator in Construction:

 Concrete Compaction: - Removes air voids from wet concrete.

 Improves Strength: - Ensures proper bonding of concrete with reinforcement.
 Reduces Honeycombing: - Prevents surface defects and weak zones.
 Foundation Work: - Compacts deep concrete pours like footings and pile caps.
 Beam and Column Work: - Suitable for narrow, reinforced formworks.

Working Process of a Needle Vibrator Step-by-Step Procedure:

1. Preparation:

 Connect the needle and flexible shaft to the motor.

 Ensure proper power supply (electricity or fuel).

 Position the vibrator close to the concrete pour.

2. Insertion into Concrete:

 Insert the needle vertically into the freshly poured concrete.

 Allow it to vibrate in one spot for 5 to 15 seconds (until air bubbles stop rising).
3. Compacting the Concrete:

 Move the vibrator to the next position, overlapping slightly with the previous.

 Maintain a spacing of 8–10 times the needle diameter for uniform compaction.

4. Withdrawal:

 Withdraw the needle slowly to avoid leaving voids or holes.

 Repeat the process across the entire formwork.

5. Cleaning:

 After use, clean the needle and shaft to remove concrete residue and prevent
hardening.

Fig:51 NiddleVibrator
 15. Benefits

 Apply classroom knowledge to real-world engineering problems.

 Improve technical skills like AutoCAD, Excell.

 Understand construction site operations and daily workflows.

 Understand site work, safety, and material handling procedures.

 Learn to read and work with drawings.

 Work under experienced engineers and supervisors.

 Learn to handle quality checks and material testing.

 Understand bar bending schedules (BBS) and quantity estimation.

 Develop report writing and documentation skills.

 Gain experience in surveying instruments like Auto level.

 Understand billing, estimation, and DPR (Daily Progress Reports).

 Build confidence to handle real engineering challenges.

 Develop a strong work ethic, responsibility, and professionalism.

 Develop soft skills – communication, teamwork, time management.

 Build a professional network for future job opportunities.

 Get clarity on your career path or specialization area.

 Strengthen your resume with internship certification.

 CONCLUSION

From the past internship time I conclude the following based on practical and theoretical knowledge that
gained from my internship time:

In my internship period I got the chance to improve both my theoretical and practical knowledge When I stay
in the site, I was learned how to communicate with the site workers. I Believed that the skills gained from
the internship will actually help me for my future career, because I was familiar with the skills, which
are essential in the working environment. More supports me to learn the different hierarchs of the
projects. During these past internship time, I have been able to see the different theoretical and practical
aspects, methodologies. I have been fulfilling our curiosity in learning practically building construction
well in this

internship program.

Generally, the internship program creates a vital role in our four years theoretical lessons. The internship
program connects me to the real construction works and made me to hold a vital confidence.