THE CONSTRUCTION OF G+12 RESEDENTIAL

HOUSES FOR GROUP I, GROUP II & GROUP D

OFFICERS AT NELAPADU.
A INTERNSHIP REPORT

Submitted by

D.V.S. PHANEENDRA SARMA (151FA03043)

YESHWANTH PANDAY (151FA03040)

UNDER THE GUIDANCE OF Mr D.Y. VAMSI

In partial fulfilment for the award of the degree

of
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING

DEPARTMENT OF CIVIL ENGINEERING

VIGNAN’S FOUNDATION FOR SCIENCE TECHNOLOGY
AND RESEARCH, VADLAMUDI, GUNTUR
ANDHRA PRADESH, INDIA 522213
MAY 2019

i
 VIGNAN’S UNIVERSITY: VADLAMUDI 522 213

BONAFIDE CERTIFICATE

Certified that this project report “THE CONSTRUCTION OF G+12

RESEDENTIAL HOUSES FOR GAZETTED OFFICERS GROUP I,
GROUP II AND GROUP D, AT NELAPADU” is the bonafide work of
“D.V.S. PHANEENDRA SARMA & YESHWANTH PANDAY” who
carried out the project work under my supervision.

Mr D.Y. VAMSI Mr N. RUBEN

(UNIVERSITY GUIDE) (HEAD OF DEPT)
(Assistant Professor) Dept of Civil Engineering
Department of Civil Engineering VFSTRU
VFSTRU

ii
CHAPTER TITLE PAGE
NO NO
Abstract Iv
List of figures V
List of tables Vi
Overview of vii
APCRDA
1 Introduction 1
2 Foundation 7
2.1 Types of foundation 7
2.1.1 Types of shallow 7
foundation
2.1.2 Types of deep foundation 8
2.2 Foundation type in site 9
2.2.1 Type of pile used at site 11
2.2.2 Spacing given between 12
piles
2.2.3 Method of bored in situ 12
piling
2.2.4 Materials for piling 13
2.3 Mix design of M30 14
3 Podium 21
4 Formwork 23
4.1 Introduction to 23
formwork
4.2 Types of formwork 24
4.3 Mivan aluminium 26
formwork
4.3.1 Wall components 29
4.3.2 Beam components 31
4.3.3 Slab components 33
4.3.4 Other components 34
5 Reinforcement 36
5.1 Carbon steel 36
5.1.1 Low carbon steel 36
6 Finishing 39
works
6.1 Putty works 39
6.2 Water proofing 39
6.3 Floor tiling works 40
7 Conclusion 41
8 References 42

iii
 ABSTRACT

After the separation of Telangana from Andhra Pradesh, there is need for a new capital in
Andhra Pradesh. And our new capital is decided finally as Amaravati. There is a need to
develop infrastructure over there. Therefore many projects were started there. This is one
of those projects, apartments for group I, group II and group D officers. This is a small
report of internship done at Nelapadu, Thullur. Technology they adopted for the
construction was shear wall technology and the concrete is SCC (Self compacted concrete).

Group I consists of 384 flats, 8 towers and the project duration is 15 months. Group II
consists of 336 flats, 7 towers and the project duration is 15 months. Group D consists of
720 flats, 6 towers and the project duration is 15 months.

iv
 LIST OF FIGURES

FIGURE NO TITLE PAGE NO

1.1 TYPE 1 3D VIEW NORTH SIDE 2

1.2 TYPE 2 3D VIEW NORTH SIDE 3
1.3 TYPICAL FLOOR PLAN 4
1.4 TYPE D 3D VIEW EAST SIDE 5
1.5 TYPICAL FLOOR PLAN TYPE D 6
2.1 INSERTING CAGE 11
2.2 METHOD OF BORED IN SITU PILING 12
2.3 REINFORCEMENT CAGE 20
2.4 TREMIE PIPE 20
4.1 ALUMINIUM SHUTTERING 27
4.2 FIXING OF ALUMINIUM BOARDS 27
4.3 WALL COMPONENTS 29
4.4 STUB PIN 30
4.5 ROCKER 30
4.6 KICKERS 31
4.7 BEAM COMPONENTS 31
4.8 BEAM SOFFIT PANEL 32
4.9 PROP HEAD 32
4.10 SLAB COMPONENT 33
4.11 PROP 33
4.12 INTERNAL SOFFIT CORNER 34
4.13 EXTERNAL SOFFIT CORNER 34
4.14 EXTERNAL CORNER 35
5.1 STEEL REINFORCEMENT 37

v
 LIST OF TABLES

Table No Name Page no

2.1 Test results on cement 14
2.2 Test results on CA 16
2.3 Test results on FA 17
2.4 Mix Proportion 19

vi
 OVERVIEW OF APCRDA

The Andhra Pradesh Capital Region Development Authority is an urban planning agency
of the capital, Amaravati. It was notified on 30 December 2014 by the Government of
Andhra Pradesh as per Andhra Pradesh Capital Region Development Authority Act, 2014,
it replaced the Vijayawada Guntur Tenali Mangalagiri Urban Development Authority.

The Andhra Pradesh Capital Region Development Authority is an urban planning agency
of the capital, Amaravati. It was notified on 30 December 2014 by the Government of
Andhra Pradesh as per Andhra Pradesh Capital Region Development Authority Act, 2014,
it replaced the Vijayawada Guntur Tenali Mangalagiri Urban Development Authority.

APCRDA has set up 4 offices in AP Capital Region, although headquarters is located in

Vijayawada, a regional (sub-registrar) offices are administered
from Thullur, Ananthavaram and Mandadam. The present commissioner of the authority
is Mr. Sreedhar Cherukuri.

The authority has a jurisdictional area of 8,352.69 km2 (3,224.99 sq mi) and covers the
districts of Guntur and Krishna, including 217 km2 (84 sq mi) of the state
capital, Amaravati.

vii
 CHAPTER . 1
INTRODUCTION
PROJECT DETAILS
GAZETTED OFFICERS: - 01 (1800 sq. Feet)
Project in brief: -
 Site area :- 27,356.75 sq. ft (6.76 acres)
 No. of Towers :- 8
 No. of Floors :- STILT + 12
 No. of Flats :- 384
 Each Flat Area :- 1800 Sq. ft
 Total Build-up Area :- 888368 Sq. ft
 NO. of piles :- 1608
 Podium area in sq. Feet:- 73500 sq. ft
 Project Duration :- 15 months

1
Fig 1.13D VIEW North Side

2
GAZETTED OFFICERS: - 02 (1500 sq. Feet)
Project in brief: -
 Site area :- 17,725.23 sq. ft (4.38 acres)
 No. of Towers :- 7
 No. of Floors :- STILT + 12
 No. of Flats :- 336
 Each Flat Area :- 1500 Sq. ft
 Total Build-up Area :- 504000 Sq. ft
 NO. of piles :- 1232
 Podium area :- 64843 sq. ft
 Project Duration :- 15 months

Fig 1.2 3D VIEW North Side

3
Fig 1.3 TYPICAL FLOOR PLAN

4
Group-D :- (900 sq. Feet)
Project in brief: -
 Site area :- 45081.981 sq. ft (11.14 acres)
 No. of Towers :- 6
 No. of Floors :- STILT + 12
 No. of Flats :- 720
 Each Flat Area :- 900 Sq. ft
 Total Build-up Area :- 888732 Sq. ft
 NO. of piles :- 2100
 Podium area :- 133417 sq. ft
 Project Duration :- 15 month

Fig 1.4 3D VIEW East Side

5
Fig 1.5 TYPICAL FLOOR PLAN

6
 CHAPTER 2
FOUNDATION
A foundation is the element of a structure which connects it to the ground, and
transfers loads from the structure to the ground.

2.1 TYPES OF FOUNDATION:

I) SHALLOW FOUNDATION:

A shallow foundation is a type of building foundation that transfers building loads to the
earth very near to the surface. Shallow foundations include spread footing foundations,
mat-slab foundations, slab-on-grade foundations, pad foundations, rubble trench
foundations and earthbag foundations.

2.1.1 TYPES OF SHALLOW FOUNDATION:

1) ISOLATED SPREAD FOOTINGS:

A spread footing foundation, which is common in residential buildings, has a wider

bottom portion than the load-bearing foundation walls it supports. This wider part
"spreads" the weight of the structure over more area for greater stability.

2) WALL FOOTINGS:

A wall footing or strip footing is a continuous strip of concrete that serves to spread the
weight of a load-bearing wall across an area of soil.

7
3) COMBINED FOOTINGS:

Combined footing is basically a combination of various footings, which utilizes the

properties of different footing in a single footing based on the requirement of the
structure. It carries two or more columns along a straight line.

4) CANTILEVER FOOTINGS:

A cantilever footing is a component of a building’s foundation. It is a type of combined

footing, consisting of two or more column footings connected by a concrete beam. This
type of beam is called a strap beam. It is used to help distribute the weight of either
heavily or eccentrically loaded column footings to adjacent footings.

5) RAFT OR MAT FOUNDATION:

Raft foundations (sometimes known as Mat Foundations) are a large concrete slab
which can support a number of columns and walls. The slab is spread out under the
entire building or at least a large part of it which lowers the contact pressure compared
to the traditionally used strip or trench footings.

II DEEP FOUNDATION:

A deep foundation is a type of foundation that transfers building loads to the earth
farther down from the surface than a shallow foundation does to a subsurface layer or
a range of depths.

2.1.2TYPES OF DEEP FOUNDATION:

1) PILE FOUNDATION:

Pile foundation, a kind of deep foundation, is actually a slender column or long cylinder
made of materials such as concrete or steel which are used to support the structure and
transfer the load at desired depth either by end bearing or skin friction.

2) PIER FOUNDATION:

A pier foundation is a collection of large diameter cylindrical columns to support the

superstructure and transfer large super-imposed loads to the firm strata below. It stood
several feet above the ground. It is also known as “post foundation”.

8
2.2 FOUNDATION TYPE IN SITE:

PILING

PILE FOUNDATION:

Pile foundation, a kind of deep foundation, is actually a slender column or long cylinder
made of materials such as concrete or steel which are used to support the structure and
transfer the load at desired depth either by end bearing or skin friction. A foundation is
described as 'piled' when its depth is more than three times its breadth.

Pile foundations are principally used to transfer the loads from superstructures, through
weak, compressible strata or water onto stronger, more compact, less compressible and
stiffer soil or rock at depth, increasing the effective size of a foundation and
resisting horizontal loads

Pile foundations are used in the following situations:

1. When there is a layer of weak soil at the surface. This layer cannot support the
weight of the building, so the loads of the building have to bypass this layer and be
transferred to the layer of stronger soil or rock that is below the weak layer.
2. When a building has very heavy, concentrated loads, such as in a high rise structure,
bridge, or water tank.

Pile foundations can take higher loads than of spread footings.

Types of pile foundation:

I) Based upon method of construction

II) Based upon functioning

Pile foundations based upon method of construction

1. Driven piles
2. Bored piles

Pile foundations based upon their basic function

1. End bearing piles

2. Friction piles

9
 1) DRIVEN PILES:

Driven (or displacement) piles are driven, jacked, vibrated or screwed into the ground,
displacing the material around the pile shaft outwards and downwards instead of removing
it.

Driven piles are useful in offshore applications, are stable in soft squeezing soils and can
densify loose soil.

There are two groups of driven piles:

 Driven in situ: Either with a permanent concrete or steel casing, or with temporary
casing.
 Preformed: Prefabricated off-site from timber, concrete or steel.

2) BORED PILES:

Bored (or replacement) piles remove spoil to form a hole for the pile which is poured in
situ. They are used primarily in cohesive subsoils for the formation of friction piles and
when forming pile foundations close to existing buildings.

Bored piles are more popular in urban areas as there is minimal vibration, they can be used
where headroom is limited, there is no risk of heave and where it may be necessary to vary
their length.\

3) END BEARING PILES:

End-bearing piles develop most of their load-bearing capacity at the toe of the pile, bearing
on a hard layer of rock or very dense soil and gravel. The pile transmits the load through
soft, compressible strata directly onto firm strata. This type of pile therefore acts in the
same way as a column.

4) FRICTION PILES:

Friction (or floating) piles develop most of the pile-bearing capacity by shear stresses
along the sides of the pile, and are suitable where harder layers are too deep to reach
economically. The pile transmits the load to surrounding soil by adhesion or friction

10
between the surface of the pile and soil, which in effect lowers the bulb of pressure. In
other words, the whole surface of the pile (cylindrical in shape) works to transfer
the forces to the soil.

2.2.1 Type of Pile used at site:

Depending upon the soil investigation report, site ground conditions and taking into
consideration the cost of the project it was decided that Bored cast in-situ piles will be
suitable for the process of pile foundation.

In my project where my internship is going on, bored cast in-situ concrete piles were being
used for the construction of pile foundation as it is most suitable for swelling type of soils.

The construction of bored cast in-situ concrete piles is formed by drilling and auguring and
then reinforcement is placed and concrete is poured into hole, For bored cast in-situ piles
foundation in stiff clays, the toe can be enlarged by under-reaming to provide greater end
bearing capacity for the piles. Once the pile shaft has been formed, reinforcement is placed
and concrete poured into the hole. To combat difficulties caused by groundwater during
pilling, the hole can be lined with a casing which is driven ahead of the bore.

Fig 2.1 Inserting Cage

11
2.2.2 Spacing adopted at site between the piles:

The minimum centre- to-centre spacing of piles is considered from three aspects, namely:

1) Practical aspects of installing the piles

2) Diameter of the pile

3) Nature of the load transfer to the soil and possible reduction in the load capacity of
piles group.

The max spacing between the piles adopted at site is as follows:

S= 4d (As d=600mm)

S=4×600=2400mm

Therefore, max spacing adopted at site is 2400mm.

As the soil is black cotton soil and they exhibit high rate of swelling and shrinkage when
exposed to changes in moisture content. So piles where designed and spaced accordingly
so that structure can withstand and overcome all the forces.

2.2.3 METHOD OF “BORED IN-SITU PILING”

The construction of bored cast in-situ concrete pile consists of 4 primary phases-

1) Pile boring

2) Reinforcement cage lowering

3) Flushing

4) Pile concreting

12
 Fig 2.2 Method of Bored in-situ piling:

2.2.4 Materials used for bored cast in-situ piling:

BENTONITE: -Bentonite is commonly used as support fluid. In its natural form

as sodiummontmorillonite exhibits thixotropic properties, where by it forms a gel
under quiescent /static conditions & regains its fluidity under dynamic conditions.
The action of bentonite in stabilizing the side of bore holes is primarily due to
thixotropic property of bentonite suspension, it permits the material to have the
consistency of a fluid when introduced into the excavation & when undisturbed
forms a jelly which when agitated becomes a fluid again. Slurry containing bentonite
is pumped into outer casing of rig and slurry with cutting soil come out and they are
allowed to settle to re-circulate soil removed fairly fresh bentonite slurry to the
previous process. The specific gravity of bentonite should be 1.1 to 1.2 gm/cc.

CONCRETE:- M-30 mix design concrete is used for piling works in site. It is
mixture of following contents:

 Cement = 400 kg/m3

 Coarse Aggregate 20 mm = 744 kg/m3

 Coarse Aggregate 12.5 mm = 496 kg/m3

 Sand = 640 kg/m3

 Water =180 kg/m3

13
  Admixture = 0.60%

2.3MIX DESIGN OF M30:

MATERIALS:

Cement: Ultra Tech Cement OPC 53 Grade

Additive(s): Fly Ash

Coarse aggregate: 12.5 mm (Source: Nallapadu/Perecherla/Donabanda)

Fine aggregate: sand (Source: Lingayapalem)

Admixture: FOSROC Aromix 450 & BASF Master Glinium 8630

SI. Req. as per IS: Test Results

No. NAME OF THE TEST 12269:1987

1 Fineness of cement(Sieve Not more than 10% 4.8%

Analysis)

2 Standard Consistency(Water %) ------ 26.5%

3 Setting Times(Min)
 Initial setting time Not more than 30 115
 Final setting time min 230
Not more than 600
min

14
4 Compressive strength(N/mm^2)
 3 day strength Not less than 27 30
 7 day strength Not less than 37 41
 28 day strength Not less than 53 57

5 Specific gravity ---- 3.15

6 Unit weight ---- 1440(kg/m^3)

TEST RESULTS ON CEMENT:

Table 2.1 Test results on cement

The Cement – Ultra Tech OPC 53 Grade supplied by the client was tested as per IS:

12269: 1987 specification and the results are given below:

Sample Designation as per Client: Ultra Tech OPC 53 Grade

TEST RESULTS ON COARSE AGGREGATE:

The coarse aggregate sample 20 mm and 12 mm size supplied by the client were

tested according to IS: 2386(Part 1) – 1963 and the results are given in the following

table:

15
 12 mm

Sieve size Reinforcement as per Percentage passing

IS:383-1970

40 -- --

20 -- --

16 100% 100%

12.5 85 – 100% 85-100%

10 00 – 45% 00-45%

4.75 00 – 10% 00-10%

Flakiness & Elongation Index% 24.00

Abrasion Value% 21.60

Aggregate Crushing Value% 19.00

Deleterious material Nil

Specific Gravity 2.70

Loose Density(kg/m^3) 1470

Rodded Density(kg/m^3) 1560

Table 2.2 Test results on coarse aggregate

16
TEST RESULTS ON FINE AGGREGATE:
The fine aggregate smaple supplied by the client was tested according to IS: 2386
(Part 1) – 1963 and the results are given in the following table

Sieve size (mm) Percentage passing or

percentage finer than

4.75 100 Fineness modulus – 2.29

2.36 98.20 Specific gravity – 2.65

1.18 90.20 Bulking 09%

0.600 63.70 Silt & clay – 1.2%

0.300 11.70 Loose Density – 1460 kg/m^3

0.150 7.70 Rodded density – 1540

kg/m^3

Pan Nil

Table 2.3 Test results on Fine Aggregate

17
 MIX DESIGN FOR CONCRETE

DESIGN STIPULATIONS:

1. Characteristic compressive strength required in the field at 28 days

Fck: 30N/mm^2(M30)
2. Maximum size of coarse aggregate
3. Degree of workability
4. Degree of quality control
5. Type of exposure
6. Quality of cement
7. Maximum water cement ratio
IS:456:2000)
8. Maximum water content
10262:2009)
: 12 mm
: 100 – 150 mm slump
: Good
: Moderate to severe
: Ultra tech cement OPC 53 grade
: 0.45(According to Table 5 of
: 208lts(From Table 2 of IS

DESIGN PROCEDURE:

Target mean strength, Ft=Fck+1.65S : 30+(1.65*5)= 38.25N/mm^2

Selected water cement Ration : 0.38(<0.45, Hence OK)

Selected water content : 190lts(<208lts. Hence OK)

Selected Cementitious content : 450Kg/m^3(>320 Kg/m^3. Hence

. OK)

Coarse aggregate content : 875Kg/m^3

Fine aggregate content : 850Kg/m^3

Super Plasticizer : 7 ml/Kg of cement

The following mix proportions according to IS: 10262 – 2009 were proposed using Ultra
Tech cement OPC 53 grade, Fly Ash, 12.5 mm coarse aggregate for M30 grade SCC.
The cubes were casted to determine the compressive strength at the age of 7 days and 28
days.

18
Trail Binder Water Sand CA Mix W/B Flow Compressive Remarks
Strength,
No Kg Lt Proportion in
N/mm^2(28days)
mm
1 500 190 850 875 1:1.70:1.75 0.38 640 41.56 FOSROC
Aromix
450
2 500 190 850 875 1:1.70:1.75 0.38 640 42.00 BASF
Master
Glinium
8630
Table 2.4 Mix proportion

RECOMMENDATIONS:

The following Mix Design is recommended for M30 Grade SCC

Mix proportion by weight for M30 Grade SSConcrete = 1:1.70:1.75

Concrete: 340 Kg

Fly Ash: 160 Kg

W/C ratio: 0.38

Plasticizer: 7ml/Kg of cement

12 mm CA: 100%

Water:-Water is also one of the major material in construction. In piling work, it used

by mixing with mud and bentonite for creating slurry and poured into the boring rig. It is

also used to cute the concrete of the pile top.

19
Reinforcement Cage:- Pile reinforcement cage is cylindrical in shape which is about

12m length and consist of 12 no. of bars with 16mm dia. Stiffener consist of 16mm

diameter bars with 1500mmc/c spacing and there is also 8mm pitched spiral ties with

200mm spacing this all in the first section. The second section has 6 no. of 16 mm diameter

bars and stiffeners with 16mm diameter 1500mm c/c spacing and also pitched spiral ties

8mm diameter bars with 200mm spacing.

Tremie Pipe:- A Tremie is a watertight pipe which is used for concreting of the piles

bore drilled by hydraulic rig, it is usually of about 250mm inside dia (150 to 300mm), with

conical hopper at its upper end above the water level. It has a valve at the bottom end. The

Tremie is often supported by a working platform, above the bore.

Fig 2.3 Reinforcement Cage

20
 Fig 2.4 Tremie Pipe

CHAPTER 3
PODIUM

Podium slabs are special type of floor system that transfers loads from a steel or wood
frame structure above the slab to walls and columns below.

Load bearing elements such as walls and columns of superstructure above the podium slab
may not align with substructure load bearing elements below. Typically, the superstructure
built from wood, metal studs or structural steel.

Generally, this type of slab constructed and placed at ground level parking with 3-4 levels
of conventional residential construction above. The name is derived from the “podium”
that separates the two occupancies.

FUNCTIONS OF PODIUM SLAB:

 It works as a structural floor and transfer slab for loads from the above superstructure
to the walls and columns below.
 As a horizontal separation, podium slab works as a fire separation between different
building occupancy types.

ADVANTAGES OF PODIUM SLAB:

 Provide solid separation between parking areas and living spaces and consequently
offers sound and fire protection.
 The application of post-tensioned two-way podium slab permits the decrease of overall
thickness of the frame. This will cause the reduction of excavation because the parking
is below grade.

21
 Flat soffit does not need extra fire protection provided that adequate cover for rebars
and post tensioning are provided. Additionally, the flat soffit permits efficient lighting,
electrical, heating, ventilation, and air conditioning.
 Forms can be stripped two to three days after the post tensioning application.
 It is proven to be cost effective.
 It provides large open spaces at or below grade for example parking and retail.
 In single family and multi-family residential structures, podium slab provides high fire
rating, decline sound transmission and floor vibration.

DISADVANTAGES OF PODIUM SLAB:

 In the case of precast hollow podium slab, provision of proper connections is not easy,
the unit may damage in the case of improper handling and transportation, and need
special equipment and machines to move and lift precast units.
 In the case of post-tensions cast in place podium slab, construction work is complex,
low quality workmanship could cause accidents, and there is a possibility of tendon
corrosion.

22
 CHAPTER 4

FORMWORK

4.1 INTRODUCTION TO FORMWORK:

Formwork (shuttering) in concrete construction is used as a mould for a structure in which

fresh concrete is poured only to harden subsequently. Types of concrete formwork
construction depend on formwork material and type of structural element.

Formworks can also be named based on the type of structural member construction such
as slab formwork for use in slab, beam formwork, column formwork for use in beams
and columns respectively etc.

The construction of formwork takes time and involves expenditure up to 20 to 25% of the
cost of the structure or even more. Design of these temporary structures is made to
economic expenditure. The operation of removing the formwork is known as stripping.
Stripped formwork can be reused. Reusable forms are known as panel forms and non-
usable are called stationary forms.

Timber is the most common material used for formwork. The disadvantage with timber
formwork is that it will warp, swell and shrink. Application of water impermeable cost to
the surface of wood mitigates these defects.

A good formwork should satisfy the following requirements:

23
  It should be strong enough to withstand all types of dead and live loads.
 It should be rigidly constructed and efficiently propped and braced both
horizontally and vertically, so as to retain its shape.
 The joints in the formwork should be tight against leakage of cement grout.
 Construction of formwork should permit removal of various parts in desired
sequences without damage to the concrete.
 The material of the formwork should be cheap, easily available and should be
suitable for reuse.
 The formwork should be set accurately to the desired line and levels should
have plane surface.
 It should be as light as possible.
 The material of the formwork should not warp or get distorted when exposed
to the elements.

Economy in Formwork

The following points are to be kept in view to effect economy in the cost of formwork

 The plan of the building should imply minimum number of variations in the size of
rooms, floor area etc. so as to permit reuse of the formwork repeatedly.
 Design should be perfect to use slender sections only in a most economical way.
 Minimum sawing and cutting of wooden pieces should be made to enable reuse of
the material a number of times. The quantity of surface finish depends on the
quality of the formwork

Formwork can be made out of timber, plywood, steel, precast concrete or fiberglass used
separately or in combination. Steel forms are used in situation where large numbers of re-
use of the same forms are necessary. For small works, timber formwork proves useful.
Fiber glass made of precast concrete and aluminum are used in cast-in-situ construction
such as slabs or members involving curved surfaces.

4.2 TYPES OF FORMWORK

1) Timber Formwork: Timber for formwork should satisfy the following

requirement:

It should be

 Well seasoned

24
  Light in weight
 Easily workable with nails without splitting
 Free from loose knots

Timber used for shuttering for exposed concrete work should have smooth and even
surface on all faces which come in contact with concrete

2) Steel Formwork

This consists of panels fabricated out of thin steel plates stiffened along the edges by
small steel angles. The panel units can be held together through the use of suitable
clamps or bolts and nuts. The panels can be fabricated in large number in any desired
modular shape or size. Steel forms are largely used in large projects or in situation
where large number reuses of the shuttering is possible. This type of shuttering is
considered most suitable for circular or curved structures.

3) Aluminum Formwork.

Aluminum Formwork system is very cost effective. Aluminum Formwork panels can
be designed for any condition/component of building such as bay windows, stairs,
balconies and special architectural features. This system is unique as all the
components in a building, including slabs, floors, walls, columns, beams, staircases,
balconies and window hood, are concrete and there is no need for block works or brick
works. As all the periphery of resulting structure/component is concrete and at the same
time we can control the concrete quality, the durability of the structure increases. It
gives form finish, eliminates the need for external and internal plaster and the walls can
be directly painted with a minimal skim coat, all these ultimately resulting in cost
saving.

Aluminum Formwork System is highly suited to load bearing wall construction

whereas traditional formwork consisting of plywood and timber is not suitable to the
high pressures of fresh concrete on the wall. Use of this formwork in load bearing
design gives an average of 15 per cent cost saving in the structure of the building and
increased usable floor spaces of 8 per cent over RCC design.

Construction of Concrete formwork:

25
This normally involves the following operations:

 Propping and centering

 Shuttering
 Provision of camber
 Cleaning and surface treatment.

Order and Method of Removing Formwork:

The sequence of orders and method of removal of formwork are as follows:

 Shuttering forming the vertical faces of walls beams and column sides should be
removed first as they bear no load but only retain the concrete.
 Shuttering forming soffit of slabs should be removed next.
 Shuttering forming soffit of beams, girders or other heavily loaded shuttering
should be removed in the end.

Rapid hardening cement, warm weather and light loading conditions allow early removal
of formwork. The formwork should under no circumstances be allowed to be removed until
all the concrete reaches strength of at least twice the stresses to which the concrete may be
subjected at the time of removal of formwork. All formworks should be eased gradually
and carefully in order to prevent the load being suddenly transferred to concrete.

4.3 MIVAN ALUMINIUM FORMWORK:

Mivan is an aluminum formwork system developed by a European construction company.

In 1990, the Mivan Company Ltd. from Malaysia started manufacturing these formwork
systems. Today, more than 30,000sqm of formwork from Mivan Co. Ltd. is used across
the world. The MIVAN formwork has proven economical as well as satisfactory for the
overall construction environment.

Mivan technology is suitable for constructing large number of houses in a short span of
time using room size forms to construct walls and slabs in one continuous pour on concrete.

Aluminum formwork is very cost effective for repetitive Buildings layouts and for above
the plinth work. This system is very unique as all the components in a buildings, including

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slabs, beams, walls, columns, staircases, balconies and special window hood are of
concrete and there is no need for block works or brick works

Fig 4.1 Aluminum Shuttering

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 Fig 4.2 Fixing of aluminum boards

The modular nature of the Mivan aluminum formwork system allows easy fixing and
removal of formwork and the construction can proceed speedily with very little deviation
in dimensional tolerances. System is quite flexible and can be easily adapted for any
variations in the layout. It consists of four components Beam components, Deck
components and wall components these all are made of high strength aluminum alloy

Formwork Assembly:

MIVAN aims in using modern construction techniques and equipment in all its projects.
On leaving the MIVAN factory all panels are clearly labeled to ensure that they are easily
identifiable on site and can be smoothly fitted together using the formwork modulation
drawings. All formwork begins at a corner and proceeds from there.

Simplicity – pins and wedge system in MIVAN aluminum formwork:

The beams are held in position by a simple pin and wedge system that passes through holes
in the outside rib of each panel. The panels fit precisely, simply and securely and require
no bracing.

Work Cycle of Mivan shuttering

 The first activity consists of erection of vertical reinforcement bars and one side of
the vertical formwork for the entire floor or a part of one floor.
 The second activity involves erection of the second side of the vertical formwork
and formwork for the floor
 Fixing reinforcement bars for floor slabs and casting of walls and slabs.
 Removal of vertical form work panels after 24hours, leaving the props in place for
7 days and floor slab formwork in place for 2.5 days. MIVAN Formwork:

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Object of Mivan Shuttering

Formwork is not a permanent construction but it required careful attention to avoid

damages of permanent construction.The formwork design and construction are controlled
by three principles

 Safety: It depends on the formwork strength substantially. Life of labors and public
might be in danger if the formwork does not possess adequate strength.
 Quality: Concrete shape accuracy and quality of final finished surface of concrete
element
 Economy: The structural frame, which is the most critical factor during
construction, is most crucial cots component.

Components of mivan shuttering are

 Wall components

 Beam components

 Slab components

 Other components

4.3.1 WALL COMPONENTS:

Wall Panel: It forms the face of the wall. It is an aluminum sheet properly cut to fit the
exact size of the wall.

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 Fig 4.3 Wall components

Stub pin: It helps in joining two wall panels. It helps in joining two joints.

Fig 4.4 stub pin

Rockers: It is a supporting component of wall. It is L-shaped panel having allotment holes

for stub pin.

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 Fig 4.5Rocker

Kickers: It forms the wall face at the top of the panels and acts as a ledge to support.

Fig 4.6 Kickers

4.3.2 BEAM COMPONENTS:

• Beam side panel: It forms the side of the beams. It is a rectangular

structure and is cut according to the size of the beam.

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 Fig 4.7 Beam component

Beam Soffit Panel: It supports the soffit beam. It is a plain rectangular structure of
aluminium.

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 Fig 4.8 Beam soffit panel

Prop Head for Soffit Beam: It forms the soffit beam. It is a V shaped head for easy
dislodging of the formwork.

Fig 4.9 Prop head

4.3.3 SLAB OR DECK COMPONENTS:

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Deck Panel: It forms the horizontal surface for casting of slabs. It is built
for proper safety of workers.

Fig 4.10 slab component

Deck Prop: It supports the deck and bears the load coming on the deck panel.

Fig 4.11 Prop

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 • Prop Length: It is the length of the prop. It depends upon the length of the slab.

• Deck mid – Beam: It supports the middle portion of the beam. It holds the concrete.

• Soffit Length: It provides support to the edge of the deck panels at their perimeter
of the room.

4.3.4 OTHER COMPONENTS:

Internal Soffit Corner: It forms the vertical internal corner between the walls and the
beams, slabs, and the horizontal internal cornice between the walls and the beam slabs and
the beam soffit.

Fig 4.12Internal soffit corner

External Soffit Corner: It forms the external corner between the components.

Fig 4.13 External soffit corner

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External Corner: It forms the external corner of the formwork system.

Fig 4.14 External corner

Advantages of Mivan Shuttering

 MIVAN Formwork
 Ease of construction and easy to remove formwork
 Same formwork may be used for whole project.
 No need of plastering
 High seismic resistance
 Faster in completion of formwork

Features of aluminum formwork technique are as follows: -

 Versatility
 Speed
 Quality
 Durability
 Cost

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 CHAPTER 5
REINFORCEMENT:
Steel is an alloy of iron and carbon, and sometimes other elements. Because of its
high tensile strength and low cost, it is a major component used in buildings, infrastructure,
tools, ships, automobiles, machines, appliances, and weapons.

The carbon in typical steel alloys may contribute up to 2.14% of its weight. Varying the
amount of carbon and many other alloying elements, as well as controlling their chemical
and physical makeup in the final steel.

Steel can be broadly categorized into four groups based on their chemical compositions:

1. Carbon Steels
2. Alloy Steels
3. Stainless Steels
4. Tool Steels

5.1 CARBON STEEL:

Carbon steels contain trace amounts of alloying elements and account for 90% of total steel
production. Carbon steels can be further categorized into three groups depending on their
carbon content:

 Low Carbon Steels/Mild Steels contain up to 0.3% carbon

 Medium Carbon Steels contain 0.3-0.6% carbon
 High Carbon Steels contain more than 0.6% carbon

5.1.1 LOW CARBON STEEL/MILD STEEL:

Mild steel (iron containing a small percentage of carbon, strong and tough but not readily
tempered), also known as plain-carbon steel and low-carbon steel, is now the most common
form of steel because its price is relatively low while it provides material properties that
are acceptable for many applications.

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PROPERTIES OF MILD STEEL:

Carbon content --- 0.05-0.25%

Density --- 7.85 g/cm^3

Young’s modulus--- 200 GPa

Low-carbon steels contain less carbon than other steels and are easier to cold-form, making
them easier to handle.

CHECKING THE STEEL REINFORCEMENT:

1) Make sure that cover block used for casting of walls have the same grade as of
concrete. They are not broken and properly positioned and should not get disturbed
during concreting operations.
2) Minimum 25 mm cover should be provided in wall.

Fig 5.1 Steel Reinforcement

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 3) Spacing above 450 mm is not allowed
4) The minimum lap length should be 40D, D is the diameter of the bar. Lap provided
at site is 45D.
5) Before placing the concrete, Check the reinforcement details with bar bending
schedule and get an approval from structural consultant.

CONCRETING:

After giving clearance of civil, MEP and safety concreting starts.

 At first line pump or boom placer is fixed

 Line pump is for more than 5th floor and boom placer is used upto 5 floors
 At first slurry is passed to make the pipes free of any particles inside it
 Then the concrete is pumped.

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 CHAPTER 6

FINISHING WORKS

6.1 PUTTY WORKS

1) Surface preparation should be done

2) Grinding the concrete joints and wall ties, removal of dust, grease etc.

3) Take the required quantity of wall putty, and 35 to 40% of water by volume

4) Mix it vigorously by puddle mixer

5) Apply putty using putty blade in 2 coats

6) Total thickness should be 1.5 mm

7) Final coat should be applied after proper drying of preceding coat

6.2 WATER PROOFING

1) The surface to be coated should be cleaned first

2) Any pipes, opening should be provided prior

3) Water pond/Flood test shall be conducted for a period of 24 hrs

4) At dripping points Pressure Grouting should be done and surface is cleaned

5) Two layers of Acrylic polymer modified cementitious Dr. Fixit Pidfin is applied in 2 coats
perpendicular to each other @ 0.75 kg/coat/sqm

6) Second is applied after the first is dried

7) Waterproof plastering with cm 1:3 with Dr. Fixit pidiprooofLW +@200ml per bag

8) Final ponding test should be done for 72 hours

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6.3 FLOOR TILING WORKS

1) Before laying tiles, floor need to be wet and cement motar bed of 1:8 mix proportion
tobe laid of thickneses 12 mm

2) Cement slurry shall be applied over cement mortar and back of tile with 2 mm spacer
joint

3) After 24 hrs, the joints can be grouted with white cement.

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 7.CONCLUSION

From this Internship Program in APCRDA at Nelapadu we have learnt many things
like……

 Shear wall technology.

 Reading and understanding Slab drawings, Beam drawings and other structural
drawings.
 I have also learnt how to handle workers.
 Also precautions to be taken during concreting like checking flow, maintaining slab
level, maintaining required no. of workers, minimising wastage of concrete by shutter
leakage, over flow from corner of slab etc
 Observed some problems during concreting like bulging of wall, leakage of concrete
from shuttering, choking of pipes, flow changes due to variation in temperature of site,
worker shift changes, plant failures etc.
 Authority levels and their responsibilities at site.
 Some specifications like slab covers, podium covers and their thickness,

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 8. REFERENCES:
 Method of Statements of Company
 Company Hand book
 https://theconstructor.org/building/podium-slab-functions-advantages-
disadvantages/23102/
 site engineers
 Drawings

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