1.

INTRODUCTION
1.1 Introduction
Ramky Infrastructure Ltd, is a multi-disciplinary consulting firm, a reputation for
responsive, innovative yet practical design approaches to complex Architectural and
Engineering problems. Through their experience and dedication to the construction
industry Ramky consulting firm is committed to provide with the most professional,
efficient and cost effective consultancy services. The goal of the company is to satisfy the
most demanding construction needs in the world.
Ramky Infrastructure Ltd partnership providing design, supervision, consultancy
and project management services and engineering firms, and the use of the most recent
information technology in the production if contract information, medium to large scale
project from feasibility through design and contract administration to completion and
project administration.
RAMKY Infrastructure Ltd is a dynamic organization of innovative professionals
who share a common goal to render the best and most effective services to the demanding
construction industry, which is sensitive services to the demanding construction industry,
which is sensitive to both cost containment and service levels.

1
1.2 Organization and Management
In every organization, the most important asset is the people that play essential role in
the performance of the companys functions and responsibilities. Thus, Ramky Infrastructure
Ltd is fortunate to have highly qualified and experienced personnel. Reciprocally, Ramky
Infrastructure Ltd has aimed to provide its employees all the basic necessities while
performing theory assigned tasks and at the same time equip them through training and
seminars to enhance their capabilities. The company as organization and employees, because
of mutual benefits that simultaneously being enjoyed by, has grown tremendously and has
blazed a track record of fulfilling its obligation and commitment both then customers and the
community. They would like to be on the level where they should be. Having confidence in
the organization, they aim high. The teamwork that has been developed through the years of
hard work has reaped a harvest of opportunities and wealth. They will continue to improve
and develop new concepts both in management and technology.

The firm is capable of furnishing well coordinating Architectural and Civil

engineering design services by utilizing its in-house staff as well as its professional
associates. All engineering services carry the quality control assurance and guaranty of the
company firm.

Ramky Infrastructure Ltd. Carries out any project by forming a dedicated project
team. Each team is headed by a senior design engineer and draftsmen enough to complete the
project in schedule. Design teams are dynamically managed to accommodate necessary and
fluctuating workload and tight schedules. Flexibility teaming capability enables RAMKY to
undertake large and small project with the lowest overhead coasts has providing the best
value to the client.

1.3 Mission
Guided by their vision, they shall provide quality services exceeding clients expectations
while adhering to the highest standards of technical and individual excellence through
continuous improvement training and innovation.

Adding value to clients

Nurturing and promoting talents.

Respecting employees and intense efforts and contribution.

2
 2. Safety Precautions Taken At RAMKY
It is the objective of RAMKY is to ensure that the contract is completed on time, within
budget and conforming to international standards of Health and Safety aspects.

Policy:

Every contract should aim at zero fatal accidents.

Every contract should aim at zero dangerous occurrences.

Every contract should aim at an Accident Frequency Rate (AFR) of less than 0.5
per 100,000 hours worked on the contract.

Safety training: Induction training shall be given to all persons prior to permitting them to
go to the worksite.

Safety inspections: Weekly site safety inspections are carried out and reports of such
inspections are prepared.

Follow up actions: Follow up actions for any deficiency identified or unsafe practices
discovered should be implemented immediately.

Reporting of accidents: All accidents and dangerous occurrences shall be recorded

regardless of whether or not personnel injury occurs.

Safety signage: All safety signage that is displayed in and around the sites shall be in both
Telugu and English.

Working at height: It is the single largest cause of serious accidents in construction

industry. Edge protection shall be provided at the leading edges. It shall meet the
minimum standard of main guard rail at least 1m above the edge, toe board at least
150mm high and intermediate guard rail so that no gap exists more than 470mm.

Care should be taken so that materials should not fall on the public areas such as
footpaths, roads, etc.

Safety harnesses and fall arrestors are used so that workers working at height are safe.

Excavations: Preventing the sides from collapse by supporting them with timber or
sheeting and unsupported excavations should be avoided.

3
 Proper barricading of the work site should be done.

Firefighting equipment should be available at all work places.

PPE or the Personal Protection Equipment should be used compulsorily which includes
the helmet, jacket and shoes.

Machines and equipment should be used by the workers only under the supervision of the
person in charge.

Safety goggles or face shields must be worn during welding, cutting or grinding.

Housekeeping: All unnecessary waste is cleared off and the equipment used should be
kept at their places after their use, thereby providing a first-line of defense against
accidents and injuries.

Safety helmets, hearing protection, respiratory protection, eye protection, gloves and
footwear are to be used by the workers.

First aid and ambulance services are provided at every work site.

Environment friendly construction activities and activities are adopted so as to cause

minimum inconvenience to public and protection from ecological degradation.

Solid waste management is an important aspect. The waste from work site should be
collected and disposed of properly.

4
3. Construction methodology & Building materials:
3.1 construction methodology:

Earth work excavation

P.C.C (plain cement concrete / profile corrective course)

Raft foundation

Columns

Beams and Slabs

Block work

Internal and external plaster

Doors and windows

Putty, Painting, Water proofing, Flooring

Earth work: First the area when we want to build has to be steady. We have to carry
out demolition if there is any building and we have to level the soil with special
machinery.

Foundation: It is the placement some structures under the ground to withstand the
building.

Column: It is the construction of the pillars and the plates which form the support of
the building, they can be of reinforced concrete.

Beams and slabs: It is the construction of the beams which provide support to the
slabs and the plates which form the floors of the building, they can be of steel or of
reinforced concrete.

Block work: In this stage the walls and partitions which close the building are built.
These walls are used to isolate it from the exterior and to distribute the space of the
interior. The walls are usually built with bricks.

Internal and external plaster: It consists on covering the building with materials
like tiles or sheets of slate or zinc depending on the characteristics of the climate of
the zone.

5
 Finishing works: This stage includes water proofing, painting, placing windows,
doors, wardrobes.

3.2 Building materials

Building material is any material which is used for construction purposes. Many
naturally occurring substances, such as clay, rocks, sand, and wood, even twigs and leaves,
have been used to construct buildings. Apart from naturally occurring materials, many man-
made products are in use, some more and some less synthetic. The manufacture of building
materials is an established industry in many countries and the use of these materials is
typically segmented into specific specialty trades, such as carpentry, insulation, plumbing,
and roofing work. They provide the make-up of habitats and structures including homes.

3.2.1 Cement
A Cement is a powdery substance made by calcining lime and clay, mixed with water to
form mortar or mixed with sand, gravel, and water to make concrete. Cement is the binder
that holds concrete and mortars together. Which is why it play the most critical role in giving
strength and durability to your building. Cement uses for domestic building such as home.

Ordinary Portland Cement:

Ordinary Portland cement (OPC) 33 grade conforming to IS: 269, 43 grade
conforming to IS: 8112 and 53 grade conforming to IS: 12269 A combination of clinker and
gypsum of good quality. Ordinary Portland cement is manufactured by first burning at a very
high temperature the mixture of calcareous (mainly calcium carbonate) and argillaceous
(mainly clay) and then grinding the calcite product (i.e. clinker) with small amount of
gypsum in to a fine power known as ordinary Portland cement.

Good quality cement has the following features: Reduced water requirement Improve
Workability Less permissible to moisture Improved resistance to acid and chlorides Reduced
heat of hydration Easier to finish Reduced Shrinkage Reduced leaching problems because it
is low as Free lime.

3.2.2 Aggregates
Aggregate is a granular material, such as sand, gravel, crushed stone, crushed
hydraulic-cement concrete, or iron blast-furnace slag, used with a hydraulic cementing
medium to produce either concrete or mortar.

Coarse aggregates:
6
 The coarse aggregates grading should be done as per IS 383 code. The coarse
aggregates are river gravel or crushed stone. They are 40mm, 20mm, 10mm depending upon
the requirement. Coarse aggregates like flaky and elongated should be rejected.

Aggregates of size 40-60mm are used in foundation and 10mm are used in concrete at Ramky

Fine aggregates:
Fine aggregates are which pass through 4.75mm IS sieve. These are added to
the concrete to assist workability and to bring uniformity in mixture. Usually natural river
sand is used as the fine aggregate. Now-a-days robot sand is used as the fine aggregate
(which is prepared by crushing of stone) due to scarcity of natural river sand and to reduce
the cost.

We have seen combination of Sand and Robo sand in 1:2 ratio at Ramky which gives
better Binding property, more strength and reduces the cost of construction.

3.2.3 Bricks
A brick is building material used to make walls, pavements and other elements in
masonry construction. Traditionally, the term brick referred to a unit composed of clay, but it
is now used to denote any rectangular units laid in mortar. A brick can be composed of clay-
bearing soil, sand, and lime, or concrete materials.

Autoclaved aerated concrete (AAC) blocks are used in Ramky constructions

7
3.2.4 Water
Water is one of the most important elements in construction but people still ignore
quality aspect of this element. The water is required for preparation of mortar, mixing of
cement concrete and for curing work etc. during construction work. The quality and quantity
of water has much effect on the strength of mortar and cement concrete in construction work.
The water used for mixing and curing should be clean and free from injurious quantities of
alkalis, acid, oils, salt, sugar, organic materials, vegetable growth and other substances that
may be deleterious to bricks, stone, concrete or steel. Potable water is generally considered
satisfactory for mixing. The pH value of water should be not less than 6.

3.2.5 Admixtures
Admixtures are those ingredients/materials that are added to cement, water and
aggregates during mixing in order to modify or improve the properties of concrete for a
required application. The admixture used in Ramky is CONBEXTRA GP2 is a blend of
Portland cement, graded filler sand chemical additives which impart controlled expansion in
the plastic state whilst minimizing water demand. It is also used for precision grouting where
it is essential to withstand static and dynamic loads.

3.2.6 Concrete
Concrete is the mixture of cement, fine aggregate, coarse aggregate and water.
Also in some cases, admixtures are added to enhance the properties of concrete and to
increase its workability. Admixtures are accelerators to increase the setting time,
Retarders to decrease the setting time, etc.
There are two types of mixes.

8
 Nominal mix:
Nominal mix concrete is a prescribed concrete. Nominal mix is used to produce the
concrete grade up to M20. It is in ratios like Cement: Fine: Coarse
Nominal mix ratios for different grades of concrete
TABLE 1
Grade of concrete Nominal Mix Ratio
M5 1:5:10
M7.5 1:4:8
M10 1:3:6
M15 1:2:4
M20 1:1.5:3

Design mix:
Design mix is used to produce the concrete more than M20. It represents in kgs. The main
purpose of design mix concrete is to mixing the different proportions in order to get the more
than required strength of concrete. A good concrete should have three basic qualities they are
strength, workability and durability

Types of concrete vibrators for compaction:

Concrete contains particles of varying sizes, the most satisfactory compaction would perhaps
be obtained by using vibrators with different speeds of vibration. Polyfrequency vibrators
used for compacting concrete of stiff consistency are being developed. The vibrators for
compacting concrete are manufactured with frequencies of vibration from 2800 to 15000
rpm.

Immersion or Needle Vibrators:

9
 Immersion or Needle Vibrators are most commonly used vibrator for concrete. It consists
of a steel tube (with one end closed and rounded) having an eccentric vibrating element
inside it. This steel tube called poker is connected to an electric motor or a diesel engine
through a flexible tube. They are available in size varying from 40 to 100 mm diameter. The
diameter of the poker is decided from the consideration of the spacing between the
reinforcing bars in the form-work.

The frequency of vibration varies up to 15000 rpm. However a range between 3000 to 6000
rpm is suggested as a desirable minimum with an acceleration of 4g to 10g.

The normal radius of action of an immersion vibrator is 0.50 to 1.0m. However, it would be
preferable to immerse the vibrator into concrete at intervals of not more than 600mm or 8 to
10 times the diameter of the poker.

The period of vibration required may be of the order of 30 seconds to 2 minute. The concrete
should be placed in layers not more than 600mm high.

Concrete Grade and Mix Ratio Table

As per IS 456:2000, the grades less than M20 should not be used in RCC works

10
 Characteristic Compressive Strength
Group Concrete Grade Mix Ratio
(N/mm2)

M5 1 : 5 : 10 5 N/mm2

M7.5 1:4:8 7.5 N/mm2

Ordinary Concrete M10 1:3:6 10 N/mm2

M15 1:2:4 15 N/mm2

M20 1 : 1.5 : 3 20 N/mm2

M25 1:1:2 25 N/mm2

M30 Design Mix 30 N/mm2

M35 Design Mix 35 N/mm2

Standard Concrete
M40 Design Mix 40 N/mm2

M45 Design Mix 45 N/mm2

M50 Design Mix 50 N/mm2

M55 Design Mix 55 N/mm2

M60 Design Mix 60 N/mm2

High Strength Concrete
M65 Design Mix 65 N/mm2

M70 Design Mix 70 N/mm2

TABLE 2 Mix Ratio Table

11
4. CONSTRUCTION WORKS
4.1 FOUNDATION
4.1.1 Functions of Foundations:
Reduction of load intensity

Even distribution of load

Provision of level surface

Lateral stability

Safety against undermining

Protection against soil movements

4.1.2 Essential requirements of foundations:

The foundations shall be constructed to sustain the dead and imposed loads and
transmit these to the subsoil in such a way that pressure on it will not be cause
settlement which would impair the stability of building or adjoining structures.

Foundation base should be rigid so that differential settlements are minimized,

especially for the case when superimposed loads are not evenly distributed.

Foundations should be taken sufficiently deep to guard the building against the
damage or shrinkage of subsoil.

Foundation should be so located that its performance may not be affected due to any
unexpected future influence.

4.1.3 TYPES OF FOUNDATIONS:

Shallow foundations:

1. Strip footing.

2. Spread or isolated footing.

3. Combined footing Strap or cantilever footing.
4. Mat or raft Foundation.

12
Spread footing:
A shallow foundation is a type of foundation which transfers building loads to the earth
very near to the surface, rather than to a subsurface layer or a range of depths as does a deep
foundation. Shallow foundations include spread footing foundations, mat-slab foundations,
slab-on-grade foundations, pad foundations, rubble trench foundations and earth bag
foundations.

4.1.4 Footing PCC

After done with excavation, a PCC bed is to be laid as per the plan.
Ratio used for this PCC is 1:4:8
Space should be provided around the bed in the pit for the free movement of labor.
PCC beds are laid for given no. of (drawing) pits as per the engineer plan.
Curing is done.

4.1.5 Column & Footing Marking

Marking is the very essential stage for any construction
Centering is done with the help of plum bob
Then marking is done as per the given plan
As marking is done, diagonal checks should be made.
The same procedure is done for both footing and column.

13
4.2 Form work
As fresh concrete is in plastic state when it is placed for construction purpose so, it
becomes necessary to provide some temporary structure to confine and support the concrete
till it gains sufficient strength for self-supporting. This temporary structure is called form
work. In the site the formwork material we use was the plywood material which have a good
surface finish

Plywood is used extensively for concrete forms and provides the following
advantages:

It is economical in large panels

It is available in various thickness

It creates smooth, finished surfaces on concrete

The general step used to construct a formwork in the site is:

Prepare the false works in the desired position and level.

Preparing the formwork in a desired shape based on the drawing or the size of the
structure that is going to be cast.

Painting with a releasing agent if needed.

Nailing it with appropriate bracing element and false work.

14
4.3. EARTH FILL:
Fill work will follow the erection of foundation column. bulk, pit and trench excavations
need to be back filled with a better soil type, which will have better compaction character
and would bring the minimum required proctor density.in order to attain the minimum
standard as mentioned on the bill of quantity, they deploy appropriate machineries .

4.4. CRS masonry

CRS (coursed rubble stone)

CRS masonry is only done along with the external column.

Before CRS masonry PCC bed has to be placed along with the external column.

Height of the CRS masonry depends on the natural ground level.

Width of the CRS masonry is 400 mm.

DPC is placed above the CRS masonry.

4.5 Design of slab

Definition:
It is a horizontal structural component, with top and bottom surfaces parallel or near
so.

15
Functions of Concrete:
Provide a flat surface.

To support load.

Sound, heat and fire insulator.

Act as a divider (privacy) for the occupants.

Upper slab became the ceiling for the storey below.

Space between slab and ceiling can be used to place building facilities.

Design Considerations in Slab:

Locate position of wall to maximize the structural stiffness for lateral loads.

Facilitates the rigidity to be located to the center of building.

Its necessary to check the slab deflection for all load cases both for short and long
term basis. In general, under full service load, Deflection (d) or 40 mm whichever is
smaller

Its preferable to perform crack width calculations based on spacing of reinforcement.

Restrict the crack width to within acceptable tolerances as specified in the codes.

Reduce future maintenance cost of the building.

Take care of punching shear i.e., use more steel or thickness of concrete where there
is chance of punching shear in the concrete slab. To increase shear capacity at the
edges of walls and columns embed shear studs or stirrup cages in the slab.

Check for lateral stability.

Classification of slabs:
In general slabs are classified into two types. They are;

One - way slabs

Two - way slabs

One - way slabs :

16
 The slabs which are supported continuously on the two opposite sides so that the
loads carried along one direction only are called "One - way slabs".

The ratio of longer span panel (L) to shorter span panel (B) is greater than or equal to "2"

Thus 2

Main reinforcement is provided in only one direction for one - way slabs

Verandah slab is a type of one way slab, where the slab is spanning in the shorter
direction with main reinforcement and the distribution of reinforcement in the transverse
direction.

In one way slab, the loads are carried along one direction. They are designed to
transfer their general loads to the opposite support walls. The actual structural support of a
one way slab is found on the shortest spans.

Two - way slabs :

Slabs which are supported on unyielding supports like walls on all four sides are
called "Two - way slabs ".The ratio of longer span panel (L) to shorter span panel (B) is less
than "2".

Main reinforcement is provided in both the direction for two - way slabs.

This type of slabs are mostly used in the floor of multi - storey buildings.

In two - way slabs the loads are carried along both directions.

17
The transfer of the load is on all of the walls, all four become support walls. The supports will
run perpendicular to each other.

The actual structural support of a two way slab is found on two directions or on all four
spans.

4.6 BEAMS
RCC beams are the structural elements designed to carry transverse external loads that
cause bending moments, shear forces and in some cases torsion across their
length. Concrete is strong in compression and very weak in tension. Steel reinforcement is
used to take up tensile stresses in reinforced concrete beams.

Good detailing of reinforcements with proper drawings are essential at the site to
provide good construction process. These drawing generally also include a bar bending
schedule. The bar bending schedule describes the length and number, position and the shape
of the bar.

18
4.7 Designing of Columns:
Members in compression are called columns

The term 'Column' is reserved for members which transfers loads to the ground.

Columns when centrally loaded, fail in one of the three following modes, depending on the
slenderness ratio.

MODE 1: Pure compression failure

MODE 2:Combined compression and bending failure

MODE 3: Failure by elastic instability

5. FINISHING WORKS:

5.1 BRICK WORK

19
 Brickwork is masonry produced by a bricklayer, using bricks and mortar. Typically,
rows of bricks called courses are laid on top of one another to build up a structure such as a
brick wall.

In RAMKY they have AAC (Autoclaved aerated concrete) blocks as bricks.

5.1.1 AAC BRICKS

Reduces at least 30% of environmental waste

Consume less energy.

Greenhouse radiation decreased by 50%.

Over 60% decrease in integrated energy on the surface of brick. Easy and cheaper
transportation.

Easy and cheaper transportation.

Not affected by extreme climatic conditions

Do not degrade under normal atmospheric conditions.

BLOCKS PER CUBIC METER

DIMENSIONS BLOCKS

100 MM (4 ") 83

110MM (4.5") 72

150MM (6") 55

200MM (8") 41

225MM (9") 37

5.1.2 Brick work in Cement or Lime Mortar:

20
 Cement mortar consists of Cement and sand with water in appropriate proportions and
the lime mortar consist of lime and Surkhi with water in appropriate proportions. The
thickness of the joint in this type of work is kept not more than 10.0 mm.

Following are the tips for construction of brick masonry buildings or structures:

In the brick work, the bricks should be laid on their beds with the frogs pointing
upwards.

The brick courses should be laid truly horizontal and should have truly horizontal and
should have truly vertical joints.

As far as possible the use of brick-bats should be discouraged.

As far a possible the brick walls should be raised uniformly with proper bond.
Generally the height of brick masonry construction in a day should be less than 1.5m.
The maximum difference in rise of the wall between the different portions should not
be more than one meter.

When the mortar is green, the face joints should be raked to a depth of 12 to 19mm in
order to have a proper key for plastering or pointing. The mortar joints should be
stuck flush and finished if no plastering or pointing is to be done.

In order to ensure continuous bond between the old and the new, the walls should be
stopped with a toothed end.

Finished brickwork in lime mortar should be cured for a period of 2 to 3 weeks. This
period can be reduced to 1 to 2 weeks in case of brickwork with cement mortar.

In order to carry out the brickwork at higher level, a single scaffolding is used.

5.2 FLEMISH BOND

In Flemish bond, each course consists of alternate headers and stretchers. The
alternate headers of each course are centered over the stretchers in the course below. Every
alternate course starts with a header at the corner. For the breaking of vertical joints in the
successive courses, closers are inserted in alternate courses next to the quoin header. In walls
having their thickness equal to odd number of half bricks, bats are essentially used to achieve
the bond.

21
5.3 PLASTERING

5.3.1 INTRODUCTION

Plastering is a process of obtaining smooth surface on the rough surfaces of walls,

roofs, columns and ceilings etc. for long lasting purposes and to meet its estimated design life
period. Also plastering make the rough surfaces smooth thereby make it good looking and
attractive. Also it helps in preventing damp proofing. The coat formed on the rough surface is
called plaster when applied inside of the building and its called as rendering when applied
outside of the building i.e. at outer wall exposed to direct environmental condition.

5.3.2 Tools:

Floating Rule: Its used for checking the plastering surface whether its leveled or
not.

22
 Float: Its used for applying and spreading mortar on the surface. Its made up of
either by wood or steel. Steel or metal float is also known as laying trowel. The
wooden float is known as skimming float and mainly used for finishing plaster work.
The blade size of steel float generally is 1030 cm2 and the wooden float blade size
varies from 1030 to 1133 cm2. Sometimes the devil float having nail projection of 3
mm is used for making zigzag on the plaster surface for further work upon it.

Trowel: A trowel is used for throwing the mortar on to the plastering surface by the
mason. Its also used for gauging small quantities of material and applying mortar to
moldings, corners etc. The end of the trowel blade may be pointed or may be of bull
nose type.

Other Miscellaneous Tools: In this type other tools like steel plate (used for
discharging mortar from one place to the working place), set square (used for
measurement works), plumb line (used by mason to know the leveling), edge brushes
(used for cleaning the plaster surface) etc. are used.

5.3.3 Objectives:

Protection of surface against environmental condition and rain water as well as sun
light.

Protection against insects and fungus etc.

Provides aesthetically beautified construction.

Defective construction is patched and a little strength is gained.

5.3.4 Requirements:

It should stick to the back ground and should not spall off during bad weather.

It should be inert and should not chemically react with reinforcement or other
decorative finishing or floorings.

It should be economical and easily available.

It should possess water resistance nature and should be environmental friendly as far
as possible.

23
5.3.5 Materials:

The materials used for plastering is commonly of two types. These are categorized as
general plastering material and special plastering material. General plastering materials are
the materials used for plastering everywhere and irrespective of any special requirement and
these forms the parent material even for special plastering materials and commonly used in
residential as well as commercial buildings. Special materials are used as per requirement of
the environment, radiation, atmospheric exposure and type of decoration etc.

General plastering materials are as follows

1. LIME:

Lime used for plaster is of basically two types i.e. flat lime and hydraulic lime. Fat
lime can be slaked wet and easy to use. Lime mortar can be used with proportion as follows

Lime: sand = 1:3 to 1:4

For hydraulic lime mortar as follows,

Lime : sand = 1:2

Cement : lime : sand as 1:1:8 to 1:2:8

For purely lime mortar with no cement, a binding material named gugal can be added @ 1.6
kg/m3 to the mortar. Also the tensile properties of lime is increased with the addition of
chopped hemp @ 1kg/m3 of mortar which ultimately prevents the formation of tensile cracks.

2. SAND:

In plastering works, coarse sand and medium sand is used and not fine sand. Silt is not
used any type of construction work. For plastering of roofs or heavy duty floors, where
greater hardness is desired, instead of fine sand, broken granite chips of smaller size is used.
But sand is a major material for all type of plasters and even on heavy duty floors, coarse
sand can replace the smaller broken granite chips.

3. WATER:

24
 Water is another constituent in plastering. Desired amount of water is added to
plastering for making the mortar workable. Also after plastering is hardened, for obtaining
harder surface and adequate performance of heat of hydration reaction, water is used for
curing. The water used should not have a pH below 6.0 and should be free from debris and
other materials like chloride, Sulphur etc. should remain within acceptable limits as per IS
code.

4. CEMENT:

The commonly used cement for building works is Portland Pozzolana Cement or PPC
of grade 43 or 53 as available in the market. Also Portland slag cements (PSC) is used for the
purpose. The ratio of cement to sand varies from 1:4 to 1:6 in cement plaster and for lime-
cement plaster, its ratio varies between cement: lime: sand as 1:1:6 to 1:2:8.

5.3.6 NUMBER OF COATS OF PLASTER:

The back ground over which plaster is to be made decide the number of coats like
random rubble, brick masonry, stone masonry, coarse rubble masonry, cement block etc.
Therefore plastering is applied in 1 or 2 or 3 coats. Generally lime plaster is applied in 3 coats
and cement plaster in two coats.

TABLE 3 (PLASTER COATING NUMBERS)

BACKGROUND OF PLSATER NUMBER OF COATS

Stone work 3or 2

Concrete cast in situ 2or 1

Brick work or Hollow clay tile 3, 2 or 1

Building blocks 3, 2 or 1

Fiber building board 2 or 1

Wood wool slabs 3or 2

Wood or metal lath 3

Cork slabs 2 or 1

25
5.4 FLOORING

Flooring is the general term for a permanent covering of a floor, or for the work of
installing floor cover such a in. Floor covering is a term to generically describe any finish
material applied over a floor structure to provide a walking surface. Both terms are used
interchangeably but floor covering refers more to lose-laid materials. Flooring is done as
follows:

Step 1: Prepare the Surface

Make sure your surfaces are clean, smooth, and dry for best results. Take time to
repair, patch, and level any damaged or uneven areas. Double check to make sure the surface
is structurally sound and the area free of wax, soap scum, and grease.

Remove any moldings, trim, or appliances that may interfere with tile application, and check
the doorjambs to make sure tile has clearance when installed beneath. Identifying these
potential complications in advance will help your installation run smoothly.

Step 2: Begin the Layout

For an efficient layout, start by marking the center point of each of the walls in the
room. Next, snap chalk lines between the centers points of opposite walls to pinpoint the
center of the room. Make any necessary adjustments to ensure that the intersection creates
perfect squares.

Starting at the center point, lay a row of loose tiles along the center lines in both directions,
using tile spacers as you go to for even, uniform joints. Once you reach the walls, you'll need
to cut tiles for a proper fit. If the cuts needed are smaller than half of a tile, you can adjust the
center line by snapping a new line a half-tile size closer to the wall. If necessary, repeat this
step along the intersecting center line for a precise design.

Step 3: Apply the Adhesive:

As a general rule of thumb, be mindful to mix only enough of the adhesive to be used
within 30 minutes. Using the flat side of the trowel type recommended on the adhesive
package, spread a 1/4" coat on the surface of one grid area without covering the guidelines.

26
After doing so, hold the trowel at a 45-degree angle and use the notched side to comb
adhesive into standing ridges. When you remove the excess adhesive, you leave behind a
uniform, ridged setting bed for your tile. As another rule of thumb, do not spread a larger area
of your adhesive than can be set in 15 minutes. Stick to the script and facilitate your tile
installation with the perfect adhesive application.

Step 4: Cut Tile as Needed:

Start by marking carefully measured cuts-to-be with a pencil or felt-tip pen on the tile
surface. You can use a tile cutter to achieve pinpoint straight or diagonal cuts. Make
masterful curved cuts with a nipper, chipping away small pieces for best results. For any full-
length curved cuts, a rod saw is most properly suited to handle the task. After your cuts are
made, smooth out any sharp edges with a carborundum stone to give a soft finish to your tile.

Step 5: Set the Tile:

Begin by installing tiles in the center of the room, one grid at a time, finishing each
grid before moving to the next. Within each grid, it will help to start with the first tile in the
corner and work outward. Using a slight twisting motion, set tiles one at a time and avoid
sliding them into place. Be sure to either insert spacers as each tile is set or leave equal joints
between tiles.

Once a grid is completely installed, tap in all tiles with a rubber mallet or hammer and wood
block to ensure a solid bond and level plane. Remove excess adhesive from joints with a
putty knife and from tile with a damp sponge to prevent an uneven appearance. Lastly, allow
your hard work at least 24 hours to set before walking on it. And of course, take at least 20
minutes to admire the time and care you have put in to your new floor!

Step 6: Grouting joints:

As you remove the tile spacers and spread grout on the tile surface, use a rubber grout
float or a squeegee to force it down into the joints. Tilt the float at a 45-degree angle and with
the edge of the float, remove the excess grout from the surface immediately. Now tilt the float
at a 90-degree angle and scrape it diagonally across the tiles.

Once you've let the grout set slightly for around 15 to 20 minutes, use a damp sponge to clean
any residue from the surface and smooth the grout joints Polish with a soft cloth when the

27
grout has dried and haze forms on the tile surface, and rinse again with sponge and clean
water.

5.5 PAINTING

5.5.1 Surface dryness

If possible, the plastered surface should be left unpainted for the first few months to
allow it to carbonate, harden and dry thoroughly. If not possible to leave the plaster bare, a
temporary decoration of soft distemper (non-washable) or a coat of lime may be applied. No
attempt should be made to apply solvent based paint (especially gloss finishes) until the
plastered surfaces of new brickwork, concrete or building blocks are thoroughly dry.

5.5.2 Cleaning & Treatment

Before painting, the surface should be thoroughly brushed to remove all dirt and
remains of loose or powered materials to provide a mechanical key between surface and paint
for satisfactory adhesion. Treatment of the surface with solution of acids or salts such as zinc
sulphate is not advisable as the risk of alkali attack is not reduced appreciably and
efflorescence may be increased.

White Wash: White wash on both interior and external surfaces with lime fat u/s of
approved quality to get the final finish for which one coat of white wash as primer coat and
two coats as finishing coat are provided. The actual Coverage may vary from the quoted
coverage due to factors such as method and condition of application and surface roughness.

Color Wash: on both interior and external surfaces with lime fat u/s and any approve color
on old/new surfaces to get the final finish for which one coat of color wash as primer coat and
two coats as finishing coat are provided. The actual Coverage may vary from the quoted
coverage due to factors such as method and condition of application and surface roughness.

5.6 QUALITY ASSURANCE AND QUALITY CONTROL

Selection of materials like sand, cement and aggregates is called quality assurance.

During the construction quality control is maintained.

28
 The various types of grades that are generally used in the construction process are:

M15

M20

M25

M30

M35

M40

M40 grade is called cold concrete and the temperature is reduced by using ice blocks
to 10 degrees

R is poured on aggregates to reduce the temperature of aggregates.

With the thermometers we can notice the temperature of aggregate and the concrete
should be at 15 20 degrees and the production should be done.

At laying time of concrete the temperature of 25 26 degrees should be maintained.

To remove the entrapped air vibration should be done for settlement of concrete.

In nuclear plants grade is M60 and everything is cold concrete.

Care should be taken that curing is efficiently done.

Any designer will take care factor of safety and it is taken twice or thrice

6.1 THE VARIOUS TESTS THAT ARE DONE AT SITE ARE:

6.1.1 Consistency of cement

6.1.2 Compression test for concrete cube

6.1.3 Compression test for cement cube

6.1.1 CONSISTENCY OF CEMENT

Standard consistency as per IS: 4031 (Part 4) - 1988.

29
 The standard consistency of a cement paste is defined as that consistency which will
permit the Vic at plunger to penetrate to a point 5 to 7mm from the bottom of the Vic
at mould.

APPARATUS:
i) Vicat apparatus conforming to IS: 5513 - 1976

ii) Balance, whose permissible variation at a load of 1000g should be +1.0g

iii) Gauging trowel conforming to IS: 10086 1982

VICATS APPARATUS

PROCEDURE:
i) Weigh approximately 400g of cement and mix it with a weighed quantity of water. The
time of gauging should be between 3 to 5 minutes.

ii) Fill the vicat mould with paste and level it with a trowel.

iii) Lower the plunger gently till it touches the cement surface.

iv) Release the plunger allowing it to sink into the paste.

v) Note the reading on the gauge.

vi) Repeat the above procedure taking fresh samples of cement and different quantities of
water until the reading on the gauge is 5 to 7mm.

RESULT OBTAINED: The normal consistency obtained in the laboratory is 29%.

6.1.2 COMPRESSION TEST FOR CONCRETE CUBE

Compressive strength test of concrete as per IS:516-1959

30
 APPARATUS:
i) Compression testing machine (2000 KN)

ii) Curing tank/Accelerated curing tank

iii) Balance (0-10 Kg)

COMPRESSION TESTING MACHINE

PROCEDURE:
i) Representative samples of concrete shall be taken and used for casting cubes 15 cm x 15
cm x 15 cm or cylindrical specimens of 15 cm dia x 30 cm long.

ii) The concrete shall be filled into the moulds in layers approximately 5 cm deep. It would be
distributed evenly and compacted either by vibration or by hand tamping. After the top layer
has been compacted, the surface of concrete shall be finished level with the top of the mould
using a trowel; and covered with a glass plate to prevent evaporation.

iii) The specimen shall be stored at site for 24+ hr under damp matting or sack. After that,
the samples shall be stored in clean water at 27+20C; until the time of test. The ends of all
cylindrical specimens that are not plane within 0.05 mm shall be capped.

iv) Specimen shall be tested immediately on removal from water and while they are still in
wet condition.

v) The bearing surface of the testing specimen shall be wiped clean and any loose material
removed from the surface. In the case of cubes, the specimen shall be placed in the machine
in such a manner that the load cube as cast, that is, not to the top and bottom.

31
vi) Align the axis of the specimen with the steel plates, do not use any packing.

vii) The load shall be applied slowly without shock and increased continuously at a rate of
approximately 140 kg/sq.cm/min until the resistance of the specimen to the increased load
breaks down and no greater load can be sustained. The maximum load applied to the
specimen shall then be recorded.

OBSERVATIONS:

Size of cube Area Weight Volume Density Load (N) Strength

(mm) (mm2) (kg) (mm3) (kg/m3) (N/mm2)

150x150x150 22500 8.195 3375000 2428.14 1258.3x103 55.92

150x150x150 22500 8.230 3375000 2438.51 1209.3x103 53.7

150x150x150 22500 8.152 3375000 2415.40 1236.3x103 56.1

TABLE 4

RESULT OBTAINED: Average strength of the concrete cube =55.2Mpa.

6.1.3 COMPRESSIVE TEST FOR CEMENT

Compressive strength of cement as per IS 4031 part-6

APPARATUS:
i) Compression testing machine (2000 KN)

ii) Curing tank/Accelerated curing tank

iii) Balance (0-10 Kg)

32
 PROCEDURE:
i) Mixing of material for each test cube shall be separately prepared. The quantities of
cement, standard sand and water shall be as follows: Cement 200 gms, Standard sand 600
gms water (p/4+3) % of mass (cement +sand) where P = % of water required to make
cement paste of standard consistency.

ii) All ingredients shall be dry mixed for one minute. After that, water is gradually added till
paste is formed of uniform color. Mixing time shall be between 3-4 minutes. If uniform color
of paste is not achieved after mixing more than 4 minutes, fresh mortar shall be prepared.

iii) Apply mould oil on interior surface of mould and place the mould on vibrating table.
Immediately after preparing mortar as describe in point 2, place the mortar inside cube
moulds. Rod 20 times for approximate 8 sec to ensure full compaction of mortar.

iv) Further compaction shall be done by using vibrating machine. The period of vibration
shall be two minutes at the specified speed of 12 000 400

v) After completion of vibration, remove moulds along with base plate and finish the top
surface by trowel.

vi) Keep moulds filled with specimen for 24 1 hr in moist environment. Remove samples
from mould and immediately submerge in clean water.

vii) After curing period is over, remove cubes from water and immediately place in testing
machine with side facing upwards. Cubes shall be tested without packing between steel plates

33
of the testing machine and cubes surface. Load shall be steadily and uniformly applied,
starting from zero at a rate of 35 N/mm2/min. till failure of sample.

TABLE 5

Size of cube Area Weight Volume Density Load (N) Strength

(mm) (mm2) (kg) (mm3) (kg/m3) (N/mm2)

70x70x70 4900 0.846 343000 2466.47 210x103 42.85

70x70x70 4900 0.844 343000 2460.64 335.6x103 68.48

70x70x70 4900 0.834 343000 2431.48 229.7x103 46.87

RESULT OBTAINED: Average strength of the cement cube =52.7Mpa

34
 7. CONCLUSION

During the internship on execution of villas at Ramky we gained practical knowledge

regarding the sequence of steps that are taken place during the construction such as
reinforcement, block work, plastering. We also conducted the various experiments regarding
quality assurance and quality control in the laboratory and we gained a good knowledge
regarding the above topics.

We also observed safety precautions to be taken care in construction. IS codes have been
followed during the entire construction. We had undergone various drawings during the
construction. We had done internship for 2 weeks and got a brief view regarding the
construction. Finally I would to thank everyone who had supported in making this project
successful.

35