Internship report with background

Department of civil engineering,SCOE,Pune-41
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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.

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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

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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

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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.

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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.

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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.

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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.

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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.

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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

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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.

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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

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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

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Result of Concrete Block Test on CT Machine
N
O 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

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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Photos
PCC for Drainage Pipes
RCC Hume Pipes for Drainage

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Cover Chamber
Frame Chamber

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Base Plate for Fabricated Column
Foundation for Transfermmer

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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.

Page 26

Internship report with background

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