MAJOR PROJECT ON ISCON
COMMERCIAL BUILDING
Prepared by : 19BCL124 (Priyam Shah) Faculty Guide: Dr. Sonal Thakkar
1
INTRODUCTION
Iscon Commercial is a G+7 and 2 basements, commercial building.
It is contract based project where client ( Mr. Baljeetsingh Baggha) has gives
contract to firm ( Divine Construction Pvt. Ltd ), where contractor has to
complete this project under certain time and under specific terms and
conditions.
Contract is of only civil work.
There are five partners in this firm namely Mr. Nilesh Mewada, Mr. Mukesh
Mewada, Mr. Akhil Rah, Mr. Umesh Thakkar and Mr. Maulik Shah.
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FRONT VIEW SIDE VIEW 3
SITE LOCATION
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PROJECT DETAILS
Name of the project Iscon Commercial
Name of the company Divine Construction Pvt. Ltd & Allied
Engineering Pvt. Ltd
Location of project Near Parmeshwar Bunglow, Behind Shivalika-
Shilp building, Iscon cross road, Satellite,
Ahmedabad
Type of building Commercial
No. of floors G+7
No. of basements 2
FSI 2.7
Plot Area 92,592 sq. ft
Super built-up Area 3,12,500 sq. ft
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CONT.
Built-up Area
Estimated time of the project 15 months ( Feb 2022 – July 2023)
Estimated cost of the project 45 crores – 50 crores
Floor Height G.F to F.F – 11’8”
F.F to SE.F – 9’10”
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AGENCIES INVOLVED
Architecture : ADS architect Pvt. Ltd.
Structural Engineer : Shreeji Infrastructure Pvt. Ltd.
Contractor : Allied Engineering & Infrastructure Pvt. Ltd
Post Tension Agency : CNS Infrastructure Pvt. Ltd
Concrete Agency : ConPlus
Shuttering Agency : Lalchand
Steel Agency : Steefo Steels
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SITE LAYOUT
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OBJECTIVE OF MAJOR PROJECT
• To improve the knowledge about various construction process.
• To learn how to solve the rising problem and unexpected events.
• To get insight into various aspects of construction and how things are executed
at the construction site.
• To understand the assumptions and approximations adopted in practice while
dealing with live engineering issues.
• To learn how to apply theoretical knowledge to practical work.
• To work closely with Site Engineer and observe various tasks and get to know
about the execution.
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WORKS OBSERVED
1. AAC Block Masonry.
2. Shuttering of Column.
3. Casting of Column.
4. De-shuttering of Column.
5. Shuttering of Slab.
6. Post Tensioning system.
7. Safety Equipments
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MATERIALS & EQUIPMENTS
USED AT SITE
• Water
• Cement (OPC, PPC & white cement)
• Sand
• Steel
• Jakmister
• Vibrator machine
• Muster
• Ledger
• Cable Pipe
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• PT cable ( Tendon)
CONT.
• Prism
• Spirit level
• Bar bending machine
• Bar cutting machine
• AAC block
• Plumb bob
• Shikanja
• Couplers
• Tie rods
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CONT.
• Battens
• Wooden ply sheets
• Hammer and nails
• Binding wire
• Trowel
• Concrete pump
• Ready Mixed Concrete (RMC)
• Total Station
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1) SPECIFICATION OF AAC
BLOCK
According to IS:2185 (Part 3)-1984 ,
• The nominal dimensions of the concrete block shall be as follows:
• Length: 400, 500 or 600mm
• Height :200, 250 or 360 mm
• Width : 100, 150, 200 or 250 mm
• AAC Blocks Composition : Fly-ash (59%), Cement (33%), Lime (8%),
Aluminium powder (0.07%)
• Cost of AAC block is 54 Rs/piece.
• At our site AAC block of dimensions 600x200x100 mm is used. 14
CONT.
Minimum Compressive Strength 3 - 4.5 N/mm2
Minimum Dry Density 450 – 650 Kg/m3
Thermal Resistance 0.9 – 1.25 per inch of thickness
Allowable Shear Stress 8 – 22 psi
Sound Absorption Up to 42 De
Fire Resistance 4-6 hours
Thermal Conductivity 0.16 – 0.18 w/Mk
Density 750 kg/m3
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PROCEDURE FOR LAYING
AAC BRICK MASONRY
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CONT.
• The surface of application must be properly cleaned for loose particles, dust,
dirt, oil, and grease.
• The base on which the adhesive is applied must be cured.
• Make a line out of whole floor as per drawing with line dori and angle.
• After that, mixture is prepared by keeping ratio of 1:6 ( 1 cement + 6 sand + 1
cup SBR)
• The Thin Bed Mortar: Water ratio for mortar mix should be 10kg: 6 liter or as
prescribed by the manufacturer. Mix should be done in clean vessels.
• Apply a thin layer of mixed adhesive on the AAC blocks in the thickness of 3
to 5mm by using a proper trowel on which the block work is to be carried out.
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CONT.
• For walls above ground floor, a layer of mortar (cement: sand-1:6) should be
used before starting the first course of blocks; this is to level the foundation
before the first course.
• Each block needs to be made wet with a sponge on all sides of mortar contact
surface, and place them one by one, pressing it firmly to have proper bond
without any level difference and fill joints between the blocks by same mortar
• The blocks for first course shall first be laid with mortar along a string
stretched between properly located corners of the wall.
• This helps to determine the correct position of the blocks. It also includes
those of the cross walls jointing it and adjust their spacing.
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CONT.
• For second course, the string shall then be stretched tightly along the faces of
two corner blocks and the faces of the intermediate ones should be adjusted to
coincide with the line.
• As each course is laid at the corner, it shall be checked for alignment and level
and for being plumb.
• Use tool like hacksaw or rotary cutter or hand wood saw to cut AAC block.
• In this way block wall is constructed up to coping level.
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COPING
20
CONT.
• For AAC Block it is necessary to provide Coping above the height greater then
4 feet.
• It is provided to distribute load and to prevent cracks.
• Thickness :100 mm
• For the construction of copping 8 -100mm , Fe 500 Reinforcement bars is
used. Four no’s of 8 mm dia. rods and 6 mm stirrups at 200 mm c/c are used in
coping.
• Binding wires of MS 18 Gauge are also used.
21
CONT.
The grade of concrete for coping is M15 (1:2:4)
The formwork of coping can be remove after next day of concreting.
After 2 days of coping further wall is constructed.
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FORMWORK
Formwork is a mould or open box into which fresh concrete is poured and
compacted.
It provides support to horizontal, vertical, and inclined surfaces or also
provides support to cast concrete according to the required shape and size.
The formwork also produces a desired finish concrete surface.
Dimensions : 8’x4’x and thickness is10mm
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CONT.
Types of Formwork :
1. Timber Formwork.
2. Steel Formwork.
3. Plywood Formwork.
4. Plastic Formwork.
5. Aluminium Formwork.
Among these we have used plywood formwork at our construction site.
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CONT.
Plywood Formwork are further classified into :
1. Film faced plywood.
2. HDO plywood.
3. MDO plywood
Among these we have used Film faced plywood at our construction site.
The below mentioned are the plywood companies that we have used at our
construction site :
1. Heer (mirror finished)
2. Birla (Film Faced)
3. Unified (Film Faced) 25
COMPONENTS OF
SHUTTERING
1. Plywood sheets
2. Wing Nuts
3. Tie Rods
4. Props
5. Channels
6. U Jack
7. Wooden Battern
8. Ledger
9. C – channel
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10. Base plate
2) SHUTTERING OF COLUMN
• First of all, starters have to be casted before shuttering. This starters should be
cured for a day or 2 so that it is hard enough to fix the shuttering around it.
• Before the installation of the column formwork shuttering, oil should be
applied to the inner plywood surface. The oil helps in easy de-shuttering work
& provides a good surface finish to the casted concrete.
• Appropriate space is to be provided in the inner face of the shutter and
reinforcement by fixing cover blocks of about 40mm.
• Formwork should be properly supported with props size prior to pouring the
concrete to resist it’s movement horizontally or vertically throughout
concreting.
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CONT.
• A shutter clamp ( Shikanja ) or nut bolt system can be used to hold the Chavi
that are opposite to each other.
• The plywood should be fastened with adequate wooden batten ( Patti ) & yoke
(Chavi) at the appropriate intervals as shown below.
panel
wedges
channel
Check nut
profile
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CONT.
• Any two adjacent shutter sides should be checked for verticality by using the
plumb bob.
• Also, diagonals are to be checked from the inner corner of plywood.
• The position of the column shutter should be checked by measuring the
required length from the neighboring columns.
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3) CASTING OF COLUMN
• M40 grade of concrete was used during casting of column.
• Casting was done using Concrete pump.
• Ready Mixed Concrete was used in casting.
• Mechanical vibrator having needle 40 mm were used.
• Mechanical vibrator machine used to remove air avoid present between the
concrete ingredients and prevent from concrete forming honeycomb.
• Slump of concrete was kept 160.
• Around 2-3 people are require for casting of one column. It takes around 15
minutes to cast 1 column.
• To achieve a smooth and shiny concrete finish, proper leveling, floating, and
troweling is done before it cures. 30
CONT.
• Mix Design of M40 :
Quantity of Item’s in 6 CMT RMC Truck
Items Quantity
10 mm Aggregate 226 Kg
20 mm Aggregate 353 Kg
Sand 37O Kg
Cement 220 Kg
Water 83 Litres
Admixture 1.8 Litres
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4) DE-SHUTTERING OF
COLUMN
• De-shuttering is done carefully, so that edges of the column are not spoiled.
• De-shuttering of column is done after 24 hours in summers and in winters it is
done after 48 hours.
• After de-shuttering concrete should be cured with fresh water immediately.
• Curing should continue for 14 days.
• Date of casting is written on the column in order to maintain curing.
• Columns are wrapped with gunny bags, so that column can retain water for
longer period of time, and can attain desired strength.
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5) SHUTTERING OF SLAB
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CONT.
• Shuttering of slab is done using plywood
• Base plates are connected with props (verticals) of desired length.
• Props are further connected horizontally with ledger.
• U-jacks are connected vertically with pros.
• Above U-jacks C- channel is provided which acts as support for box pipe.
• Above box pipe plywood of desired length are placed.
• Two adjoining plywoods are joined by nails and cello tapes.
• Slabs levels are checked by plum bob.
• This process is also called staging of slab.
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COMPONENTS OF
SHUTTERING
1. Plywood sheets
2. Wing Nuts
3. Tie Rods
4. Props
5. Channels
6. U Jack
7. Wooden Battern
8. Ledger
9. C – channel
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10. Base plate
6) POST TENSION (PT) BARS
• A single PT bar is known as Tendon.
• A single Pt bar consist of 7 wires.
• Tendons today are seven high-strength steel wires wound together and placed
inside a plastic duct (HDPE) and are coated with grease.
• When a heavy live load is brought upon a structure, its concrete slab undergoes
tension, which leads to the formation of cracks and ultimately deformation
occurs.
• To mitigate this problem, post tensioned steel tendons are inserted at the time
of concreting and tensioned after concreting with conventional rebars.
• They are used at sites where slab reinforcement shows double mesh i.e. top
mesh and bottom mesh. 36
COMPONENTS OF POST
TENSION SLAB
The components of post tension slab are :
• Ducts
• Tendon
• Anchor
Tendon
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POST TENSIONING SYSTEM
• There are two types of post tensioning system :
1. Bounded :- Bounded Post-Tensioning comprises tendons from one to
multiple strands (multistrand) or bars.
2. Unbounded :- Unbounded Post-Tensioning typically consists of single
(mono) strands or threaded bars that remain unbonded to the surrounding
concrete giving them the freedom to move locally relative to the structural
member
• At our site we have used unbounded post tensioning system
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KEY POINTS FOR POST
TENSIONING
PT bars are especially used for slabs having span greater than 6 meter.
They are used at sites where slab reinforcement shows double mesh i.e. top
mesh and bottom mesh.
Diameter of Pt bars used at our site is 16mm with HDPE coating.
Pt bars are also used in continuous cantilever slab.
Minimum M35 grade is require for post tensioning system.
Maximum length of tendon is 60 meter.
If 1 meter cable is stressed at 5500 psi then elongation will be 6.4mm.
Tendons could break due to pressure caused by over stressing.
Elongation tolerance is 5mm.
For dia 16mm tendon, cost of tendon is Rs 135/m.
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7) SAFETY EQUIPMENTS
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PROGRESS CHART
40
36
35
30
25
20
20
15 15
15
10
8
7
5
5
2 1.5
1
0
AAC Block Masonry Shuttering of Column Casting of column De-shuttering of column Shuttering of slab
Manpower Days 41
FUTURE WORKS
1. Slab Casting
2. Slab de-shuttering
3. Detailed Post Tensioning system.
4. Construction of post tensioned slab.
5. Estimating quantity of Concrete for slabs, beams and columns.
6. Bar bending schedule of slabs, beams and columns.
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REFERENCES
• IS:2185 (Part 3)-1984 Specification For Concrete Masonry Units Part 3
Autoclaved Aerated Concrete Blocks
• IS:6041-1985 Code Of Practice For Construction Of Autoclaved Cellular
Concrete Block Masonry
• IS : 456 – 2000 Plain And Reinforced Concrete - Code Of Practice
• Post Tension Slab: Working, Components, Construction & Advantages Of Post
Tension Slab (dreamcivil.com)
• PROCEDURE FOR LAYING AAC BLOCK MASONRY WORK [A HOW T
O GUIDE] -
CivilBlog.Org
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THANK YOU
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