Internship report with background

Department of civil engineering,SCOE,Pune-41 Page 1

ACKNOWLEDGEMENT

I express my deepest gratitude to our Principal Dr. S. D. Lokhande and Head of Civil

Engineering Department Dr. S. S. Shastri for providing facilities for an internship. My special

thanks to Asst. Prof. M. S. Injal, guidance of internship in Civil Engineering Department whose

valuable guidance and constant inspiration lead me towards the successful completion of

report.


INTRODUCTION OF COMPANY

Idea:

At Vaichal Group, we believe in creating value for our customers helping them build their long

term assets. We are at the beginning of the journey when our customers envision the future of

their companies, businesses and industries. We help them realize their visions by being their

partners in this process.

History:

The Vaichal Group story begins back in 1990. With a humble beginning of executing various

small scale jobs in the public sectors like irrigation and MSEB, Sanjay Vaichal begun his works

in civil engineering back in 1990. It was with his vision and determination that they entered

into main stream contracting for industrial and residential sectors. they started their building

team and enhancing their capabilities. Vaichal Constructions Pvt. Ltd. was incepted in 2000

with the same passion and vision, to create structures and provide a service with the best

possible knowledge, expertise and collaboration. With a rich experience of more than 20 years

in the industry, Vaichal Constructions has had an opportunity of executing a wide variety of

works in several sectors.

Core Ideology:

We hold a strong commitment to quality, integrity, team work and customer satisfaction as our

core ideals. This has earned the trust of our customers, several of whom have given us repeat

orders based on our performance. We do business with the highest standards of fairness and

professional ethics. We believe in proactive learning, innovation and change for the betterment

of our working standards. We care.

Office Address:- Off No 1, Ideal Chamber, 8-ideal Colony, Paud Road, Kothrud, Pune,

Maharashtra 411038

Sites Address:- 1. Chakan mahalunge MIDC and

2. Wakad bridge police chawky bhujbal chowk wakad pune 411057


Chakan Project: 15/12/14 to 15/01/15

Introduction of Construction Site

The chakan project is starting at 01/12/2013 in an area of 75*26 m2 plus 9 m roads in all sides and with a small security cabin in front side and transformer footing with 2 m height. This is

compound building which is from two parts office building and workshop site. Office building

has made in three floors basement floor which is store, ground, first and second floors are

offices and conference hall and work shop building is can provide parking area and

manufacturing area. This building is built for manufacturing of vehicles and electrical

machineries. In this project each facility is provided like toilet blocks for each floor separately

in each parts, parking, drinking water, water tank, water pump for water supply, electric

transformer for electricity connections and store area. Both buildings are joint together with

camprol treatment and also used some chemical liquid for leakage of water on the surface of

columns, beams and slabs and expansion material is used between two structures for controlling

of contraction and expansion of concrete and making compact both buildings. All columns sizes

are 600*600 mm and most of beams also 600*600 mm except plinth beam which is 600*300

mm sizes and thickness of each slab is 200 mm in workshop and in 150 mm and some of beams

are 600*750 mm sizes.

Floor to floor height is 3.85 m. Steel bars which used for columns 25 mm Ø, for beams 16, 18,

20 and 25 mm Ø, for slabs 8, 10 and 12 mm Ø, for lift 12 mm Ø and for water tank 10 and 12

mm Ø, Also all walls are concrete brick with thickness 230 mm except lift and lift walls are

provided as shearing RCC wall with 230 mm thick. This large building is located in a slope


area which footing height about 10 m below the ground surface. Before of construction filling

process is performed.

The material which is used for filling is murum is done layer wise such that each layer is 300

mm thick and rolling compaction machines are used in each layer and height of filling in back

side of building is about 10 m and front side is about 5. Tremix concrete is used for all floors.

For basement floor tremix plus steel reinforced is poured with mm thick and for others only

tremix is used about 7.5 mm thick.

It is also provided with two doglegged staircase, one straight staircase and one electrical lift

with shearing wall. In each roof they used red brick as water proofing material in radially shape

for water flowing purpose. Drainage pipes are provided underground surface which is RCC

hume pipe with facility of manhole or chamber and rain water is also can flow to ground surface

with the help of gutter which is from made plastic pipe. And finally a water tank is made in

front side of building which has one lakh litter capacity walls are RCC with 275 mm thick. And

at final the value of this project is a bout 100.5 million.


Hydraulic Pumping Machine

This machine is made from tow parts one is body of generator which is supply the air compres

for pushing of concrete mortar to the steel pipes second part is steel pipes with diameter of

about 15 cm which is connected to the machine and concrete mortar is transported by this to

the site. This machine is used mostly for heavy works or for transportation of more amount of

concrete.

Leveling Vibration Machine

This is made from girder frame which is connected with a electric motor this motor is connects

to the electiricity and producing vibration is used for mortar leveling.length is 4.5 m and width

is 40cm. this machine is used for heavy work and large area of mortar. After this mchine

dewatering and finidhing machine will used. This is locally manufactured it means which some

changing is happened to the main shap of brand and this machine is two types one is using for

for leveling of fresh concrete and other is for compaction of filling material and asphalt progress

is used.


Fly ash Brick Machine

This brick machine which is visible above is locally manufactured in pune area. Locally

manufactured means some changing is happened to main shape of the company brand. This

consist of three main parts mixing bucket, electric motor and brick mould. The mixing bucket

can mix cement, sand, fly ash and water. This machine machines produces standard brick size

with frog is optional. and has mould of size 230*100*70mm or it can mould the of

230*100*70mm which is called 4 inches bricks. Each moulding mechanism produces three

bricks per cycle. Grade of mix design for bricks which is produced is M20. Mix design is 1:4

or 1:6 means 1 bag cement, 6 farma sand and water as per required. And produced bricks should

keep 8 days minimum and after 1 day curing process is start. And finally bricks are ready for

testing. Testing is perform for compressive strength of bricks in compressive test machine (CT)

and in each test min 3 bricks should be used.

Floater Machine or Finishing Machine

Floater and finishing machine has same frame but only two type of plate is used for flatness.

When a steel plate is installed to the electric motor is used only for rough finishing. This plate

is a steel circular plate. Then when some absorption is done in mortar they can use other plate

which is in the form of steel blade plate and it can done final finishing. This machine is work

by electric motor and governed by a handle.


Dewatering Machine

Dewatering machine is other type of electric machine which is used for large civil engineering

project for absorption of water from concrete mortar purpose. Facility of this machine is

making fast drying of concrete mortar for finishing. It has three main parts car bucket,

transportation pipe and absorption net. Water is absorbed by net and transports to the bucket

car by plastic pipe.

Dewatering is the removal of water from solid material or soil by wet classification,

centrifugation, filtration, or similar solid-liquid separation processes, such as removal of

residual liquid from a filter cake by a filter press as part of various industrial

processes.Construction dewatering, unwatering, or water control are common terms used to

describe removal or draining groundwater or surface water from a riverbed, construction site,

caisson, or mine shaft, by pumping or evaporation. On a construction site, this dewatering may

be implemented before subsurface excavation for foundations, shoring, or cellar space to lower

the water table. This frequently involves the use of submersible "dewatering" pumps,

centrifugal ("trash") pumps, educators, or application of vacuum to well points.

Grove Cutting Machine

Grove cutting machine is used for making partition in concrete surface for purpose of removing

of cracks in floor surface. It is working by electric motor and has one steel blade which can

make grove in surface by rotation. During working some amount of water is also used for

lubrication purpose.


Tower Crane Machine

This machine is used for lifting of materials from ground surface to higher floors. All heavy

transportation is perform by this method of transportation. It make the works easy and fast.

Mostly this method is used for large projects. This machine is tow way supply which can work

by electricity and itself has also power generator. Activity of this machine is perform according

to remote controlling. At any other time which is not required it can fold to 3 parts and

transportation is doing by tractor vehicle. Balancing is going by two steel cabin which is filled

by sand.

Minilift

Minilift is other machine that can work by electric motor and is used for light lifting of material

for some less hieght and this is an one way supply mchine for its ballacing is required some

heavy material for lifting materials.


Transit Mixer

Transit mixer has different purposes once it take the mixed concrete from mix plan it can keep

fresh the mortar for some times because of rotation which is applied by generator motor. And

it is transports by track to the site. This rotation of transit mixer can mix the concrete and can

make out to the hydraulic pumping machine. This can transport 6.5 meter cube of fresh

concrete. Some times this machine is provided with gutter for some long distances.

One Bag Mixer Machine (10*7)

This is other type of mixer which is used for mixing of cement, sand, admixchers and water.

This machine is used for small work or light work. This is also called diesel mixer because it

is working diesel engin. Main component of this machine is mixer bucket, transfer chain and

diesel engin. When concrete mortar is mixed the bucket is rotated 90 degree and mortar is

transported to gitter. Transfer chain is for transfer of power from engin to the mixer bucket. It

is also called as one bag machine. This mixer perform heavy duty concrete mixer 10/7 cu. Ft

280/200 litters (0. 25mtr cube) capacity with loading hopper complete with heavy duty drum


using thick 10 gauge m. S sheet, bearings, blades, pulley, v-belts, wire ropes complete on heavy

duty structure on 4 pneumatic jeep type tires fitted with kirloskar 5 h. P*1440 rpm

Ready Mix Concrete (RMC) Plant

Location of RMC plan is also in Chakan mahalunge MIDC only 2 km distance with side of

construction area. In this plan mixing of cement, sand and water is performing in some specific

steps. The main components of RMC plan are mixing machinery, cement, cabin, bucket area

for course aggregate, fine aggregate and sand, conveyor, air compressor and pumping

machinery. Aggregates are coming down from duck of basin and are transported by conveyor

belt to inside of mixer and from right side cement is pumped to the transportation pipes to in

side of mixer, and water is pumped as per required from down side. All these operations

perform by electricity which is supplied by DG or diesel generator. Other main component of

plan is PC and panel board which is located to cabin of mixer. Set up of timing is done on PC

eg how match time is required for mixing. And job is doing operation for mixing. Finally it is

a computerised system.


Main Components of RMC Plant

Concrete Block Test on CT Machine

The below result is testing of concrete cube blocks which is tested in concrete test machine

sizes of each cubic block is 150*150*150 mm3. These blocks which is casted in steel moulds

and after 24 hours they keep in water basin for 7 days for curing purpose. And finally we have

done a testing in CT machine for determination of compressive strength of blocks the result is

shown in N per 1 mm squire of area it means this mix design which is used for structure is

suitable or no. the steel moulds are filled in three layers and in each layer 25 NO of blows are

performed.

In the study of strength of materials, the compressive strength is the capacity of a material or

structure to withstand loads tending to reduce size. It can be measured by plotting applied

force against deformation in a testing machine. Some materials fracture at their compressive


strength limit; others deform irreversibly, so a given amount of deformation may be

considered as the limit for compressive load. Compressive strength is a key value for design

of structures. Compressive strength is often measured on a universal testing machine these

range from very small table-top systems to ones with over 53 MN capacity. Measurements

of compressive strength are affected by the specific test method and conditions of

measurement. Compressive strengths are usually reported in relationship to a specific

technical standard.

For the preparation and compaction of 70.7 mm mortar cube specimens. The mould table is

mounted on four springs attached to an eccentric shaft which allows each sample to be vibrated

at 12000 cycles per minute in accordance with the specifications. The cube mould is not

included and has to be ordered separately. See accessories.

Electric motor: 375 W

Overall dimensions: 960x320x560 mm

Weight approx.: 70 kg


Result of Concrete Block Test on CT Machine

NO Date of Grade of Date of

Adge in Wt of Sizes in Density

Load Appl

Comp Strng

Avg Comp

Casting Concrete Testing Day Cube in

Kg mm3 Kg/m3 in KN In N/mm2

Strng in N/mm2

1 5/12/20

14 M30 17/12/14 7 Days

A 8.764 150X150

X150 2596.74 620 27.55

B 8.723 2584.59 615 27.33 27.47

C 8.759 2595.25 620 27.55

M20

a 8.354 150X150

X150 2475.25 525 23.33

b 8.494 2516.74 540 24 23.33

c 8.77 2598.5 510 22.67

M20

a 8.748 2947.64 639.9 28.1

b 8.811 2565.94 500.2 21.94 24.93

c 8.77 2588.97 573.4 24.9

2 6/12/20

14 M20 18/12/14 7 Days

a 8.45 150X150

X150 2503.7 590 26.22

b 8.532 2528 595 26.44 26.44

c 8.517 2523.55 600 26.66


Procedure of Project

1. Foundation:-

Foundation is the lowest and so important part of building that can transfer the load from higher

floors to the soil strata. Before laying of foundation to the subsurface some engineering surveys

should be done. For the above project diffrerent types of footings are used compound footings,

combined footings and individual footings with different sizes. 75 number of culomns are layed

with a thickness 150 mm of PCC and area of PCC is different like 2900*2700 mm2, 3000*2800

mm2 and thickness of footing is mostly 750 mm. sizes of footing is differ some of them with

3200*3200 mm2. All footings are RCC with 12 mm Ø bars starting. back side footings are

filled about 10 m under the ground and fornt side of structure is about 5 m filled.

2. Columns:-

Columns are second part of building that all portion of structure is hold by columns from

ground surface. Columns are hold over the footing. In this project different types of columns

are used with different of sizes eg squire columns has sizes 600*600 mm and 4500*600 mm.

the steel bars which is used for columns are 16 mm, 20 mm, 22 mm and 25 mm Ø. Firstly

formworks are held and concrete mortar is poured in to it and removing of formwork got 28

days for column. And 21 days curing processes is performed. And hacking process is start for

column about 100 hack is done per ft2. Hacking is provide rough surface to structure for

plastering purpose.


3. Beams:-

Beams are used for this structure is provided in different sizes for example plinth beams having

dimensions of 600*300 mm size and others are 600*550 mm, 600*200 mm and etc. the steel

bars which is used as follow 16 mm, 18 mm, 20 mm and 25 mm. mostly are coast in rectangular

shape. Beams and slabs are monolithically coasted and at junctions all columns, beams and

slabs are coasted monolithically and dimensions of beams for staircase is unique is not match

with others and of concrete which is provided is M20, M25 and M30.

4. Slabs:-

Dimensions of slabs and thickness of slabs are different together because two are joint one can

support light load that is office building and other is faced to heavy loads that is workshop.

Area of slabs for workshop is constant about 5000*7650 mm2 and thickness of slab for

workshop is 200 mm and for office building is 150 mm. steel bars which is used for slabs are

12 mm, 16 mm, 18 mm and 25 mm Ø. And removing of form work for beams and slabs are 7

days and curing process is required 21 days and of concrete which is provided is M20, M25

and M30.

5. Staircase:-

In this structure three staircases are used that tow one doglegged staircase and one is straight

with a landing at center. For each stairs rise=150 mm and tread=300 mm and landing thickness

is 230 mm height of landing= 1800 mm width of landing is 1500 mm length of doglegged

staircase is 3200 mm and length of straight one is 9000 mm and thickness of inclined slab is

1500 mm. all stairs are provided with steel hand rail and of concrete which is provided is M20,

M25 and M30.


Brick Work

Brick work is done between columns and beam to beam in external wall and in partition wall.

The bricks which is used in this structure is called 4 inche bricks or size of that is

230*100*70 mm with 20 mm joint thickness. According to my calcullations 138 number of

bricks are used per m2 and tickness of all walls are 230 mm.


Plastering

Plastering process is done after completion of all foolrs and curing of structure. Plaster is

compulsary for any type of structre it is performed in three steps single code, double code and

plaster of parise (POP). For all external walls, partation walls, outter sides, inner sides,

columns, beams and slabs are covered siglecode and doulecode in case of outter side and inner

side is also used (POP). Thicknees of singlecode and doublecod is 12 mm analytically and in

practical is maximum 20 mm and POP is 5 mm analyticll and miximum 10 mm practical. The

below figure is shown the numer 1 is brick wall without plaster and numer 2 is used mortar as

plaster is called singlecode numer 3 is wall which is covered totally is called doublecode and

finally numeber 4 is finall step of plaster process is called POP. Plaster of parise is place 25 kg

per bag.

Some times gypsum is used instead of POP. And laimond mish is provided as a junction

between brick wall and concrete portions it make a joint the gap and it can prevent the cracks

on wall surface the laimond mish is steel net which is hardly protected against corrosion or it

is made it is made from compound metal elements which can remain safe safe againdt effect

of oxigen of air and shipe of net is made such that which should be suitable for junction and it

has squer shape of 2*2 cm. And plaster is curing after 1 to 2 days of work. Minimum curing

time is 7 days. Mix design for concrete plaster is 1:4 it means 1 bag of cement and 4 farma of

sieved sand and water is as per required grade of this mix is called M20. The sand which is

uesd for plaster is river sand. And for other portions of building crushed sand is uesd.


Mixed Concrete on Floors

In workshop site all floors are covered with mortar concrete which is mixed and provided in

RMC plant and is called trimix concrete. And is poured by hydraulic pumping machine in floor.

According to my calculations the surface area of basement floor of workshop building is

1188.25 m2 excluding of columns, ducks and staircase the requirement of fresh concrete is 176

m3 and with a thickness of 150 mm. due to estimation of heavy load will come on parking area

they provided 8 mm steel Ø bars in a steel design of 200*200 mm net area. For first floor and

second floor and this mixed concrete is used with a thickness of 75 mm and according to my

calculations surface area is 1185 m2 excluding of columns, ducks and staircase and requirement

of fresh concrete is 176 m3 but no usage of steel bars.

Roofs and Water Proofing

Water proof is a material which is absorb the water and prevent water leakage to the down side

this is different types some times some material is used as water proofing material. But in this

structure red brick is used as water proof material in roofs and toilet blocks these bricks are

called 4 inches bricks.


For laying of bricks they provided a lame concrete of mix design 1:12 it means amount of

cement is so less but they used only for pasting of bricks on surface. These bricks are laded in

radial direction to gutter. And over the bricks laim mortar is poured grade of that is M20 mixed

concrete.

Conplast

Canplast is a chemical material in liquid form which is mixed with mortar cement and used in

joint of each layer of concrete for preventation of leaksge of water purposes. During a period

wrok of a day some unhomogenety of the structure is growt and starting of wrok from that level

some voids are remain between two working level. In this case it is require to some chemical

material for coverage of that as shown in figure.

Mullein Columns

Mullein columns are those columns that are not connected to the beams and main columns.

These columns are using only for partition area a long beam and the significant of this columns

making more safe that area and removing the vibration of structure is wind season. And

connection between column to column is easy and these are joint with a parapet wall. These

type columns are used in structure with a size of 300*300 mm in a distance of 3 m from each

others. These are provided as with 8 mm steel Ø bars. And in parapet of structure all mullein

columns and main columns are connected together by a inclined beam. These beams provided

connections of all columns for removing of vibration in wind season.


Curing

After one day of concreting or plastring curing is necessary for better live of structure different

types of curing is done water spreading by pipes to the wall srface, by covring of cotton and

stop of water on roofs surfaces. Curing is done for all parts of structures up to 15 days but

actually it is curing time is 21 to 25 days. This process is also perfomed for cubic concrete for

testing of compressive strenght of concrete for 28 days. And also curing is done for conrete

bricks up to 7 days and for red bricks for 5 days on roof surface.


Guide lines of Roads Marking

Leveling work is done for all parts of building starting from foundation up to basement of

structure and road lines. Main road is as a reference they used. And leveling is based on height

of instrument (HI). Gypsum is spread as marking over the Murom. And Road surface marking

is any kind of device or material that is used on a road surface in order to convey official

information. They can also be applied in other facilities used by vehicles to mark parking spaces

or designate areas for other uses. Road surface markings are used on paved roadways to provide

guidance and information to drivers and pedestrians. Uniformity of the markings is an

important factor in minimizing confusion and uncertainty about their meaning, and efforts exist

to standardize such markings across borders. However, countries and areas categorize and

specify road surface markings in different ways. Road surface markings are either mechanical,

non-mechanical, or temporary. They can be used to delineate traffic lanes inform motorists and

pedestrians or serve as noise generators when run across a road, or attempt to wake a sleeping

driver when installed in the shoulders of a road. Road surface marking can also indicate

regulation for parking and stopping. They are using also trimix concrete for surrounding roads.


Photos

PCC for Drainage Pipes

RCC Hume Pipes for Drainage


Cover Chamber

Frame Chamber


Base Plate for Fabricated Column

Foundation for Transfermmer


Conclusion:-

The goal of this report is provide information about duration of internship and got knowledge

of practical works and provided procedure of all project practically in site work and behaviour

of engineers with labours and attitude of PM with all stuffs. Entire works are performing by a

regularity or schedule which is provided by PM.
