CHAPTER 4

PRACTICAL EXPERIENCE ON SITE/ ACTUAL WORK ON

SITE

While being on site we got to learn about the construction process carried out on site. The project
comprise of construction of auditorium, the facility is designed as a multi-functional auditorium for
the community of Airoli. The plot area of the site is around 2896 sq.m. The comprises of four floors
each having its unique functionality. The total built up of the auditorium is 2861.279 sq.m, the built
up area of ground floor is 212.146 sq.m, built up area of first floor is 1221.554 sq.m, built up area of
second floor is 411.790 sq.m, built up area of third floor is 912.403 sq.m, built up area of fourth floor
is 103.384 sq.m. During our internship, we experienced various things and we got to see the one-
floor rise.

The various operations which we learned and observed on site are as follows:

 Casting of slab, beams and columns

 Filling of starter

 Shuttering and de-shuttering

 Concrete vibrator

 Curing method

 Blockwork/ brickwork

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CASTING OF SLAB, BEAMS & COLUMNS

M 40 GRADE OF CONCRETE MIX WAS USED FOR WHOLE CASTING

PROCESS
Casting of columns is done separate and casting of beam is done at time of casting of slab.

 CASTING OF COLUMNS
The process of casting involves pouring of concrete into the formwork. It is a crucial
process because handling the concrete is itself a difficult job.
The RMC truck filled with concrete starts and concrete flows through the conveyor.

After concrete flows through conveyor Bucket was used to transport concrete and a
person controls the working of truck. Thereafter with the help of crane the bucket is sent
to the above floor where concreting is going on. The labour then takes the bucket and
pours the concrete into a wide container. Then the other labourer with the help of
powrah starts pouring the concrete into the column formwork. The process continues
until desired depth and vibrator is continued after every 1 meter.

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BEFORE CONCRETEING, a solution/ admixture is added to the RMC truck and it is
mixed well. It is a bonding agent used to bond the constituents of concrete and also it
increases the flexibility of which helps in handling of concrete. The name of this
admixture is SBR.

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 CASTING OF BEAM AND SLAB
The process of casting of beam and slab is different from casting of column. The casting
of beam is done together with slab.
Here the concrete was transported through concrete pump. The concrete pump is
connected with pipes the pump pushes the concrete and flows through pipe. The
concrete flows and then it is spread over the formwork.

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 FILLING OF STARTER
Filling of starters refers to the process of covering or embedding the starter bars (also
known as dowel bars) with concrete to prepare for the next phase of construction.
Ensures that the new structural elements, such as columns or walls, are properly
anchored to the existing concrete. Facilitates the transfer of loads from new to existing
concrete elements. Ensures that starter bars are properly aligned and embedded to
maintain structural strength. Provides a stable foundation for the addition of new
construction elements. The formwork is about 15 to 20 cm height. Starters are needed to
cast the column in proper alignment. Column starter marking is the process of casting
the first 50 to 100 mm height of column for the alignment of rest of the column.
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 SHUTTERING AND DE-SHUTTERING

Shuttering or formwork is a temporary structure used to mold concrete into desired

shapes and support it until it gains sufficient strength. The shuttering is commonly made
using wood and steel. On our site we saw wooden shuttering. The carpenters are
responsible for all shuttering work going out. Wooden formwork is one of the oldest and
most commonly used methods for creating concrete structures. This work is done with
proper caution because little deflection in formwork or if cover or concrete ring which
keeps gap between ply and concrete is not installed the concrete after getting solid
deflection occurs which is not safe.

De-shuttering is the process of removing formwork or shuttering after concrete has set
and gained sufficient strength. It involves the careful disassembly of the temporary
structures used to mold concrete elements like beam, slabs, and columns.
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 (SHUTTERING OF BEAM)

(REMOVAL OF SHUTTERING) 22
 CONCRETE VIBRATOR

A concrete vibrator is a device used to consolidate freshly poured concrete. It works by

vibrating the concrete mixture to eliminate air bubbles and voids, ensuring a more
uniform and dense concrete surface. It consists of a vibrating head or needle attached
to a motor or a flexible shaft. The vibrating head is inserted into the freshly poured
concrete. The motor generates high-frequency vibrations that travel through the shaft
and head. Vibrations cause the concrete to flow and settle, allowing trapped air
bubbles to escape and filling voids. The vibrator is withdrawn from the concrete once
the desired level of compaction is achieved.
Concrete needle vibrators are valuable tools in the construction industry for achieving
high-quality concrete structures. They help in improving compaction, reducing air
bubbles and voids, and ensuring the longevity of concrete projects.
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 CURING METHOD

Curing is a critical process in construction, especially in the context of concrete work.

It involves maintaining adequate moisture, temperature, and time conditions to ensure
that concrete achieves its desired strength and durability.
Curing helps in the development of the desired compressive strength of
concrete.Proper curing improves the durability of concrete by preventing cracking,
scaling, and surface defects.It enhances the surface finish of concrete and helps in
achieving a smooth and even texture.It prevents the premature drying of the concrete
surface which can lead to shrinkage cracks.
On the site we got to see two curing methods namely, PONDING METHOD AND
GUNNY BAGS METHOD. Ponding method and gunny bags method was familiar to
us.
Ponding method was incorporated for curing of slab. A series of small square ponds
are made with the help of cement and water is filled inside the squares.
The Gunny Bag method uses burlap or gunny bags to cover the concrete surface,
which is then kept wet to ensure proper curing.
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(CURING OF SLAB/ PREPARATION FOR PONDING)

 (CURING OF STARTER)
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 BLOCKWORK/ BRICKWORK

Blocks that were used on our site was Autoclaved Aerated Concrete (AAC) blocks
commonly called as C4X blocks.AAC blocks are significantly lighter than traditional
clay bricks, making them easier to handle and transport on-site. This reduces labor
costs and speeds up construction. It can be easily cut to size using basic tools like
saws. This flexibility allows for precise fitting and reduces construction waste. It has
good thermal insulation, sound insulation and it is fire resistance. Due to their larger
size compared to traditional bricks, AAC blocks can cover more area quickly,
accelerating the construction process. While AAC blocks are lightweight, they
provide adequate structural strength.
Construction time is reduced by these blocks, but the con of these blocks is that they
are expensive than traditional burnt clay brick.
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CHAPTER 5

TESTING OF RAW MATERIALS

Quality assurance of building materials is very essential in order to build strong

durable and cost-effective structures. When construction is planned building
materials should be selected to fulfil the functions expected from them.
Testing for quality of construction materials is very important. Objective of testing
construction materials is to provide an assurance to the user on the reliability of the
materials. Thus, construction materials testing laboratories make a useful contribution to
national development through the estimation of the quality of construction materials.
Testing of raw materials are done in labs. The materials are tested in labs and then
assured for use. As such testing of raw material was not done on our site.
Testing of concrete cubes were performed on site which is not a raw material but
testing of these were done.
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