15 Days Industrial Training Report

On
Various working on a high-rise construction site using
Aluminum Formwork Shuttering Material
February 28, 2021
Primarc Groups & PS Groups

Submitted By:
Aritro Roy Mitra (001910601067)

Remaining Group:
Debabrata Garai (001910601047)
Md Sahil Ali (001910601004)
Soumik Maji (001910601069)
Sk Upahar Ali (101810601066)

DEPARTMENT OF CONSTRUCTION ENGINEERING

JADAVPUR UNIVERSITY
 Certificate
It is to certify that Aritro Roy Mitra, student at
Undergraduate Level of Department of Construction
Engineering, Faculty of Engineering and Technology,
Jadavpur University, Kolkata has completed the
Vocational Training at “The Soul, Primarc” for the partial
fulfillment of the requirement for the award of Bachelors of
Engineering (Construction Engineering) Degree of
Jadavpur University, Kolkata. This is a record of
student’s own study carried under my supervision &
guidance.

_____________________ _____________________
Guide for the Group Head of the Department
Dr. Dipesh Majumdar Construction Engineering
Jadavpur University Jadavpur University

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 ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude & deep regards to
our training in charge for his exemplary guidance, monitoring and constant
encouragement throughout the course of this thesis. The blessing, help and
guidance given by him time to time shall carry me a long way in the
journey of life on which I’m about to embark.

I also take this opportunity to express a deep sense of gratitude to

Mr. Kingshuk Mazumdar, DGM – Projects, Primarc Industries for his
cordial support, valuable information and guidance, which helped me in
completing this task through various stages.

I’m obliged to staff members of Primarc Group, for the valuable

information provided by them in their respective fields. I’m grateful for
their cooperation during the period of my assignment.

Lastly, I thank almighty, my parents, professors for their constant

encouragement without which this assignment would not be possible.

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TRAINING LETTER FROM
THE DEPARTMENT

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 ABSTRACT
In our training report, we discuss about all technical description which
we’re getting during our training duration at “The Soul, Primarc”, Rajarhat
Newtown, Action Area – III.
In our project we discuss about studying drawings of the site, testing
compression strength of concrete, different use of timber on the site,
conventional form of shuttering and aluminum formwork shuttering.
The concrete cube test is performed for the purpose of determining the
compressive strength of a concrete element. We can use the results from the
compressive strength to determine the strength of the concrete. If the test
results are inconclusive or show that your concrete isn’t curing as quickly
as it should, we shouldn’t risk using it in our project.
Use of aluminum formwork shuttering is a recent technology and gives
edge in both fast progression and premium finish to the conventional mode
of shuttering using timber.

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 CONTENTS
Sl. No. Items Page Number
1 Certificate 02
2 Acknowledgement 03
3 Training Letter from the department 04
4 Abstract 05
5 Company Profile 07
6 Project Profile 08
7 Site Safety 09
8 Aluminum Formwork Systems 11
9 Self-Compacting Concrete 13
10 Sieve Analysis 18
11 Jacketing 19
12 Wall Finishing 23
13 Cube Testing Method 24
14 Conclusion 26

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 COMPANY PROFILE

Primarc is a leading business group with diversified interests in retail,

realty, omnichannel logistics & angel investments. Founded three decades
ago as Pansari Group of Enterprises, it is recognized as one of the finest
entrepreneur-driven corporate houses in East India today.
Primarc Projects is the real estate arm of the group that prides in creating
more than 38 lakh sqft. of prime real estate products. A Certified member
of CREDAI & Indian Green Building Council.
Their core mission lies in delivering relevant, best in class, products,
solutions & experiences; Primarc is revered for its customer-first approach.
Headquartered in Kolkata, Primarc has expanded operations across key
cities in India.

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 PROJECT PROFILE

Highlights of the Project:

Total Area of the site: 27883 m2 (Phase 1: 20345 m2 & Phase 2: 7538 m2)
No. of Blocks: 3 (A, B & C)
No. of Buildings: 10 (4 in Block A & B each and 2 in Block C
Open Area: Near 60%
Total Area of the podium: Nearly 400m2
Superstructure: G+16
No. of rooms: 704

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 SITE SAFETY
On our vocational presentation regarding safety induction, we came to
know about various safety norms at a construction site.
Personal Protective Equipments to be used on site:

➢ Head Protection: Colour coded Helmets in accordance to IS:2925.

Color Designated Person

White Managers, Engineers, Supervisors and Foremen
Electricians, Carpenters and other technical
Blue
operators apart from civil workers
Green Safety Officers
Red Fire Fighters
Yellow Laborers
Brown Welders and workers with high heat application
Grey Site Visitors
➢ Protective equipment for body:
Steel-toe boots and reflective safety vests (following proper color
coding) are perhaps the most common personal protective equipment
worn by construction workers across the country. A risk assessment
may deem that other protective equipment is appropriate, such as
gloves, goggles, or high-visibility clothing. Leather Gloves are
preferred while working in high temperature zones like welding.

Site Preparations for safety:

A badly planned and untidy construction site can lead to many accidents at
construction sites, which may arise from: (i) fall of materials, (ii) collision
between the workers, (iii) plant or equipment. To avoid the above causes of
accidents, a good layout of the site is a must. While preparing the site
layout, at-most care should be taken to avoid overcrowding the site. Also
enough space should be provided for the movement of men, material and
construction equipment within the site.
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The construction sites should have easy and safe access. In this respect, the
following parameters should be taken into consideration:
• Everyone should be able to get into the work site safely.
• Edges of Scaffolds/Platforms from where people could fall are
provided with double guard rails or other suitable edge protection.
• Holes and pits are protected with clearly marked and fixed covers and
barricades to prevent falls.
• Site should be kept tidy and good housekeeping should be practiced.
• Provide good/adequate lighting in all locations of the site.
• The site should be fenced off from the public.
Electricity can cause great damage to both people working in the
construction sites and property. Contact with the electric current can trigger
other accidents, like falls from ladders or scaffolding. Electrical shocks or
flashes can cause serious injuries such as burns. Electric shock may also
cause the victim to stop breathing and nerve centers may be temporarily
paralyzed.
Make sure that the workers at the construction site understand the
importance of electrical safety and recognize, that abusing or misusing
electrical equipment is an invitation to an accident. The workers should also
make sure that the work area is safe and free from all electrical hazards.
Provide necessary personal protective equipment in particular, electrical
gloves & breathing apparatus.

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Aluminum Formwork System
Aluminum Formwork System is a construction system for forming cast in
place concrete structure of a building. It’s also a system for controlling and
scheduling the work of other construction trades such as steel
reinforcement, concrete placement and electrical & mechanical conduits.
This is highly suited for load bearing walls construction whereas traditional
formwork using plywood & timber isn’t suitable for high pressure of fresh
concrete on the wall.
Advantages of Aluminum Formworks: -
o It’s a fast, simple and easily adaptable system.
o The use of this formwork in load-bearing design gives an average of
15% costs saving in the structure of the building and & increased
usable floor space of 8% over RCC Design.
o Strengthens the structure & makes it more durable because of lesser
number of joints. Provides form finish and also eliminates need of
external & internal plaster.
o Casting in-situ concrete wall & floor slabs cast monolithic provides
the structural system in one concrete pour.
o Seismic Resistance – Box type construction.
o Eco Friendly because the formwork can be reused after recasting
unlike traditional one which needs to be disposed after few uses.
Various components of Aluminum Formwork: -
1) Slab Components
a) Slab/Deck Panel
b) Slab Prop Beam
c) Mid / End Beam
d) Slab Corner
e) Beam Splice Bar
f) Prop Length
2) Wall Components
a) Wall Panel
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 b) External Corner
c) Rocker
d) Internal Corner
e) Kicker
f) Pin & Wedge
3) Beam Components
a) Beam Panel
b) Bulk Head Horizontal
c) Beam Prop Head
d) Soffit Corner Internal
e) Beam Soffit Panel
f) Soffit Corner External
Limitations of Aluminum Formwork: -
o High Initial Investment Cost
o More number of components.
o High repairment cost of Aluminum Forms
o The probability of theft is more
o Segregation & Stocking requires more space
On Site Aluminum Formwork was provided by S-Form, Seoul, South
Korea.

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 SELF COMPACTING
CONCRETE
Japan Concrete Institute defines SCC as “A concrete having self-
compatibility; compactability of concrete is its ability related to the
placeability, with which it can be uniformly filled and compacted in every
corner of formwork by its own weight without vibration during placing.”

Necessity to Choose SCC: -

SCC is considered as a preferred option due to its well-known properties of
flowability, passing ability and compatibility. SCC is an excellent repair
material for concrete encasement because of its ability to flow through
narrow openings. Care shall be taken to avoid shrinkage of concrete by
adding shrinkage compensating admixtures since bonding of new concrete
with the old concrete is a requirement in repair works.

Few Advantages of Self Compacting Concrete

1. Self-compacting concrete (SCC) is a concrete which is able to flow
under its own weight, completely filling formwork & achieving full
compaction, even in the congested places. The SCC mixes have these
attributes because of their good deformability enabling them to
maintain homogeneity at a fresh state. It can be placed & compacted
under its self-weight with little or no vibration effort & which is at the
same time is cohesive enough to be handled without segregation &
bleeding.
2. Self-compacting concrete offers a rapid rate of concrete placement with
faster construction times & ease of flow around congested
reinforcement. The fluidity & segregation resistance of SCC ensures a
high level of homogeneity, minimal concrete voids & uniform concrete
strength in situ, providing the potential for a superior level of finish &
durability to the structure.

Few Limitations of SCC

1. Absence of internal and external bleeding in SCC, however is one of
the causes for their higher plastic shrinkage compared to traditional
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 vibrated concrete. Hence, SCC should be cured as soon as practicable
after placement to prevent surface shrinkage cracking.
2. SCC requires good and leak proof formwork due to presence of more
fines and
flowable concrete. Special attention is needed in design of the
formwork for pressures based on the flowability, cohesiveness, rate and
method of placing or pumping (from top/from bottom) etc.

TEST METHODS FOR SCC

METHOD PROPERTY
Slump-flow by Abrams cone Filling ability

T500mm slump flow Filling ability

V-funnel Filling ability

L-box Passing ability

I. Test 1- Slump flow & Test 2: T500 Time

The slump flow is used to assess the horizontal free flow of SCC in the
absence of obstructions. It was first developed in Japan for use in
assessment of underwater concrete. The test method is based on the test
method for determining the slump. The diameter of the concrete circle
is a measure for the filling ability of the concrete.

The higher the slump flow (SF) value, the greater its ability to fill
formwork under its own weight. A value of at least 650mm is required
for SCC. There is no generally accepted advice on what are reasonable
tolerances about a specified value, though ± 50mm, as with the related
flow table test, might be appropriate.

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 The T500 time is a secondary indication of flow. A lower time indicates
greater flowability. The Brite EuRam research suggested that a time of
3-7 seconds is acceptable for civil engineering applications and 2-5
seconds for housing applications.

II. Test 3: V- funnel test

The test was developed in Japan and used by Ozawa et al. The
equipment consists of a V-shaped funnel, shown in Fig.8. An
alternative type of V-funnel, the O funnel, with a circular section is also
used in Japan. The described V-funnel test is used to determine the
filling ability (flowability) of the concrete with a maximum aggregate
size of 20mm. The funnel is filled with about 12 liter of concrete and
the time taken for it to flow through the apparatus is measured. After
this the funnel can be refilled concrete and left for 5 minutes to settle.
If the concrete shows segregation then the flow time will increase
significantly.

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 This test measures the ease of flow of the concrete; shorter flow times
indicate greater flowability. For SCC a flow time of 10 seconds is
considered appropriate. The inverted cone shape restricts flow and
prolonged flow times may give some indication of the susceptibility of
the mix to blocking.

III. Test 4: L- box

The apparatus consists of a rectangular-section box in the shape of an

‘L’, with a
vertical and horizontal section, separated by a moveable gate, in front
of which vertical lengths of reinforcement bar are fitted. The vertical
section is filled with concrete, then the gate lifted to let the concrete
flow into the horizontal section. When the flow has stopped, the height
of the concrete at the end of the horizontal section is expressed as a
proportion of that remaining in the vertical section (H2/H1in the
diagram). It indicates the slope of the concrete when at rest. This is an
indication of passing ability, or the degree to which the passage of
concrete through the bars is restricted. 74 The horizontal section of the
box can be marked at 200mm and 400mm from the gate and the times
taken to reach these points measured. These are known as the T20 and
T40 times and are an indication for the filling ability. The sections of
bar can be of different diameters and spaced at different intervals: in
accordance with normal reinforcement considerations, 3x the
maximum aggregate size might be appropriate. The bars can principally
be set at any spacing to impose a more or less severe test of the passing
ability of the concrete.

Figure 10 Dimensions and typical design of L-box

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If the concrete flows as freely as water, at rest it will be horizontal, so
H2/H1 = 1.
Therefore, the nearer this test value, the ‘blocking ratio’, is to unity, the
better the flow of the concrete. The EU research team suggested a
minimum acceptable value of 0.8. T20 and T40 times can give some
indication of ease of flow, but no suitable values have been generally
agreed. Obvious blocking of coarse aggregate behind the reinforcing
bars can be detected visually.

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 SIEVE ANALYSIS
1Kg of sand is taken as a sample and then oven-dried at 105 to 110°C. The
sieve or sieves shall be agitated so that the sample rolls in irregular motion
over the sieve. No particle shall be pushed through the sieve. The material
retained on the sieve shall be rubbed with the rubber pestle in mortar in re-
sieved to make sure that only individual particles are retained on the sieve.
The amount retained on the sieve shall be weighed.
The cumulative mass of sand retained on each sieve shall be calculated.
The percentage of sand retained on each sieve shall be calculated on the
basis of the mass of the sample passing 4.75-mm IS Sieve taken for the
initial analysis. The combined gradation on the basis of the total sand
sample taken for analysis shall then be calculated.
Here is the table for the sieve analysis that we have done on the site.
WT. OF REMARKS
SIEVE SAMPLE % OF CUMULATIVE % OF IS 383-1970
SIZE RETAINED RETAINED % RETAINED PASSING (ZONE II
(g) LIMIT)
10 mm 0 0 0 100 100
4.75 mm 0 0 0 100 90-100
2.36 mm 31 3.1 3.1 96.9 75-100
1.18 mm 342 34.2 37.3 62.7 55-90
600 μm 334 33.4 70.7 29.3 35-59
300 μm 214 21.4 92.1 7.9 8-30
150 μm 70 7 99.1 0.9 0-10
PAN 9 0.9 100 0

In this project mostly Zone II sand is used.

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 JACKETING
Jacketing is the most popularly used method for strengthening of building
columns
▪ Jacketing consists of added concrete with longitudinal and transverse
reinforcement around the existing column.
▪ It improves axial and shear strength of column and major
strengthening of foundation may be avoided.
It’s necessarily done when:
• The load carried by column is increased.
• When there is error in design.
• Deterioration of column due to weathering action.
• Dilapidation of column.
• Heavy damage due to other causes like earthquake, fire etc.
Major Types of Jacketing are:
• Reinforced concrete jacketing
• Steel jacketing
• FRP composite jacket
• Jacket with high tension materials like carbon fiber, glass fiber etc.
In our Vocational Training we have witnessed the Jacketing work of RCC
columns. The following are the steps:-
Step-1: Remove Concrete Cover.
• Remove the RCC concrete cover of the column and expose all the
longitudinal bars.
• Remove any loose material and clean the exposed surface for
subsequent treatment
Step-2: Install Dowels
• Install L-Dowels on all faces of Col. using appropriate epoxy Grout.
This is to provide sufficient anchoring of new concrete with the old
concrete.
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 • Install required dowel bars in Raft using appropriate epoxy grout for
connection with new longitudinal rebars.
Step-3: Install Bent Bars
• Install bent bars at Top, Middle and Bottom of column, welded with
existing longitudinal rebars.
Step-4: Install Jacketing Reinforcement and Concreting.
• Provide new rebars on the corners of the column and connect
with existing bars by welded Bent Bars. New bars should be
provided in the corners to avoid puncturing the beams.
• Connect the New Rebars with the Raft by providing Dowels in
the Raft and welding them with the new rebars.
• Connect New Rebars with the slab by punching holes for
pouring concrete and providing hooks in the Rebars.
• Before pouring Jacketing Concrete, completely wet the existing
concrete surfaces. A bonding agent may also be used to form a
bond between old and new concrete; however, this is not
necessary.
• Concreting should be done in two stages to avoid segregation.
For bottom half of the column, concreting may be done through
opening in the formwork and for top half of the column,
concreting may be done through punctured openings in the slab.
• For jacketing, concrete strength should be more than existing
column concrete strength, or at least equal to it.
• Minimum Jacketing Concrete thickness should be 4 in, all
around the column.
• Ensure provision of appropriate cover to new rebars.

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HILTI Process of Rebarring
➢ What Is Rebarring ?
• Adding reinforcement to an existing concrete structure such that the
structure behaves as a cast in structure.

➢ How Is Rebarring Done?

• Drill Hole in Concrete based on design
• Fill it with chemical
• Insert rebar and allow for chemical curing
Applications
A. Simply Supported Connections
• Adding beam between columns
• Casting slab in a cutout

B. Spliced Connections
• Extension of column
• Extension of beam/ slab
• Casting slab in a cutout

C. Moment Connections
• Column from Raft/ Pile cap
• Cantilever beam from column
• Bracket on column

D. Shear Connectors
• Thickening of slabs/ raft
• J bolting while jacketing

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Need for rebarring:-
• Post-installation is necessary when there is a rebar misplaced or
completely missing due to error in construction
• Additional rebars Corrections or additions to be made due to
architectural changes or for additional strength

Rebar Grouting Outcome

• No damage to existing concrete (Cost saving on prepare & repair)
• Precise controlled application (Quality of work & Speed)
• Flexibility in designs.

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 WALL FINISHING
Application of Wall Putty: -
➢ Ensure that the surface is totally clean. It should be free from dust,
loose particles, residual paints, grease, oil or any other contamination.
➢ Remove all loose and poorly adhered materials from the surface by
rubbing down them with the help of sandpaper or with a wire brush or
with a putty blade, and wipe them out afterwards.
➢ Let the wall get wet with water before application of initial layer of
putty.
➢ Make sure that it does not create lumps while mixing.
➢ Apply the initial coat of putty in a vertical “bottom to top” manner by
using a putty blade/spatula/ trowel or any finishing tool.
➢ Once the first coat is dry, just rub the surface gently with sandpaper in
order to remove the loose and small particles.
➢ Once it’s ready to apply second coating, we do it in a simultaneously
from Top & Bottom, so that merging in the middle is easy and
without lump.

Advantages of Wall Putty

• It improves the tensile strength of the wall.
• Wall putty increases the lifespan of the wall paint.
• It is resistant to moisture.
• Wall putty provides a smoother finish.
• Wall putty doesn’t flake or get easily damaged.

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 CUBE TESTING METHOD
(Compressive Strength of Concrete)

Compressive strength is the ability of material or structure to carry the

loads on its surface without any crack or deflection. A material under
compression tends to reduce the size, while in tension, size elongates.
Compressive strength formula for any material is the load applied at the
point of failure to the cross-section area of the face on which load was
applied.
𝐿𝑜𝑎𝑑 (𝑘𝑁)
𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝑀𝑃𝑎) =
𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐴𝑟𝑒𝑎 (𝑚2 )
Specimen: - Cubes of 15 cm size
Sampling of Cubes for Test: -
➢ Clean the mounds and apply oil.
➢ Fill the concrete in the molds in layers approximately 5 cm thick.
➢ Compact each layer with not less than 35 strokes per layer using a
tamping rod (steel bar 16mm diameter and 60cm long, bullet-pointed
at lower end).
➢ Level the top surface and smoothen it with a trowel.
Curing of Cubes for test: -
The test specimens are stored in moist air for 24 hours and after this period
the specimens are marked and removed from the molds and kept
submerged in clear freshwater until taken out prior to the test. The water for
curing should be tested every 7 days and the temperature of the water must
be at 27±2°C.
Procedure for Concrete Cube Test: -
➢ Remove the specimen from the water after specified curing time and
wipe out excess water from the surface.
➢ Take the dimension of the specimen to the nearest 0.2m
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 ➢ Clean the bearing surface of the testing machine
➢ Place the specimen in the machine in such a manner that the load shall
be applied to the opposite sides of the cube cast.
➢ Align the specimen centrally on the base plate of the machine.
➢ Rotate the movable portion gently by hand so that it touches the top
surface of the specimen.
➢ Apply the load gradually without shock and continuously at the rate
of 140 kg/cm2/minute till the specimen fails
➢ Record the maximum load and note any unusual features in the type
of failure.
Calculations of Compressive Strength
Size of the cube =15cm × 15cm × 15cm

Area of the specimen (calculated from the mean size of the specimen) =
225 cm2

Characteristic compressive strength at 7 days = 41.9 MPa

Compressive strength at 28 days (fck) = 48.16 MPa

𝐿𝑜𝑎𝑑 (𝑘𝑁)
𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝑀𝑃𝑎) =
𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐴𝑟𝑒𝑎 (𝑚2 )

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 CONCLUSION
I was extremely overwhelmed for the opportunity provided to us from the
department’s end under strictest supervision of our guide and Head of the
Department. The 18 days long span was exciting and educational in equal
manner. The industrial knowledge accumulated in the short span was really
enriched and wouldn’t be possible without my classmates in the group and
the esteemed professor’s guidance.

I’d also like to extend my sincere gratitude to the respected engineers on

site who had been by us along the whole period of training. Their
cooperation and guidance across the period of training was impeccable.

I’d like to thank everyone sincerely contribution for everyone to prepare me

as a suitable engineer for the industry.

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