1.

INTRODUCTION

1.1 About the Organization:

Himalaya Society is a redevelopment project by New India Construction

Company (NICCO). The Mumbai based company was established in 1972 by
Mr. Ashok Shah they believe in improving their customers lifestyle by providing
them with better amenities and the best infrastructure. NICCO deals in making
residential, commercial buildings and row houses. They have completed over 50
Projects and have 24 Projects currently going on in Mumbai.

1.2 About the project:

Himalaya Society is a redevelopment project by New India Construction
Company (NICCO). The site is situated in Andheri East, Next to the Andheri
Court, Court lane. Mumbai 400053. Himalaya consists of two residential towers
G+16 stories also provided with a car parking tower and a part podium. Which
consists of the following amenities provided on the podium terrace and the
building terrace:

Car Parking podium terrace:

 Basketball Court
 Toddlers Play area.
 Podium Garden
Terrace:
 Stargazing deck
 Jogging track
 Senior Citizen sitting area.
 Swimming Pool
 Informal Sitting

Internal Amenities:
 2000 sq.ft gym and meditation area
 Earthquake resistant structure
 Fire Fighting System
 CCTV surveillance

Car Parks are provided in the following way:

1. Car Parking tower consisting of mechanical parking’s - 48 Nos.
2. Stilt parking provided below the A wing & B wing -19 Nos.
3. G+2 Podium consisting of single parking, double stack, and triple stack parking -
89 Nos.
4. Visitors’ car parking - 6 Nos

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Fig 1.2 Terrace Amenities Fig 1.3 Building Elevation

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2. LAYOUT OF THE PROJECT

The project is constructed on a plot area of 3373.1 sq.mt of land which is

connected to a road of width 13.4 m. HIMALAYA SOCIETY consists of
approx. 96,000 RERA carpet area. Total number of flats are 118 and 4 refuge area
for both the wings provided on the 7 th and 14th floor. Both wings consist of 4 flats
on each floor having RERA carpet area as follows

A wing –

Flat no. 1 – 3 BHK (969 sq.ft)

Flat no. 2 – 2 BHK (697 sq.ft)
Flat no. 3 – 2 BHK (697 sq.ft)
Flat no. 4 – 3 BHK (1194sq.ft)

B wing –
Flat no. 1 – 1 BHK (474 sq.ft)
Flat no. 2 – 2 BHK (763 sq.ft)
Flat no. 3 – 3 BHK (1195 sq.ft)
Flat no. 4 – 3 BHK (969 sq.ft)

2.1 Various Organizations associated.

There are numerous organizations involved in the development of the project. The
following organizations involved are:

Contractors - United One Constructions

Sub Contractors - Suhana Constructions
Architect – Kulin Patrawala
Consulting Architect - Somaiya and associates
RCC Consultant - Neel Solutions
Legal Advisors - Mehta and company

There are many other agencies involved such as internal plaster (gypsum),
waterproofing, plumbing, false celling, excavation, electrical, window fixing, railing
fixing, door fixing.

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 Fig 2.1 A- wing Layout

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Fig 2.2 B - wing Layout
 3. SITE LAYOUT

5 Fig 3.1 Ground Floor Layout

 Fig 3.2 Floor Layout

4. SLAB CYCLE
 Slab cycle is the process of casting of slab at each level in the construction
site.
 First the column projections are made on site with the help of line dori made
with the help of center line drawing.
 Then the starter shuttering is done. Height of each starter is 200mm.
 Column mivan shuttering is done above starter of height 200mm.
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  After the casting of columns and lift wall, beam bottoms are placed at a level
of 2200mm from slab.
 Beam steel is placed at the beam bottom and after that the slab steel
placement starts.
 Spacers are place in slab & beam steel and ply shuttering.
 After the checking by contractors & engineer from developer & consultant
engineer the casting is done.
 The slab cycle is repeated accordingly.

Himalaya Society has a total of 16 floors and 17 slabs to be constructed. It

has a floor-to-floor height of 2.9m. The types of footing used were Isolated
and combine footing. The depth of excavation was 4.2 m and the grade of
concrete used for the foundation of M40. 300 mm of soling at 230 mm of
PCC was done at the base.
The total of the slab cycle is between 18 to 20 days for 2.9 m floor height
height.

5.
Fig 4.1 IN
ENTERING STAGE R.C.C Schedule
THE PROJECT
The project started in March 2022 and the work upto the 11 th slab for the residential
tower and the 4th slab for the car parking tower had been completed till June 2023.
I started the internship in June 2023 from where the work for the casting of the 12 th
slab was going on and the internal blockwork had been completed till the 5 th floor

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and other work such as internal plaster, tile work, plumbing, electrical fittings, false
ceiling, Granite fixing, waterproofing etc work was being done at the same time.

5.1 List of Agencies:

The project was given on a labor contract for the RCC structure to United One and
the material is provided by the builder. Every Monday there is a weekly meeting held
with all the contractors to resolve the issues and tasks to be completed in the
following week. The meeting is held in the presence of the builders site engineers
and supervisors along with the main contractor’s engineers and supervisors with the
other agency contractors.

 RCC (Blockwork, Gypsum, External Plaster)

 Plumbing
 Waterproofing
 Electrical
 False ceiling
 Tile and granite
 Window and Glass Railing
 Firefighting

5.2 List of Materials:

After the material is ordered, when they arrive in a few days time (depending on the
material). When they arrive they are checked by the supervisor and tests are
performed on them by the engineer and are accepted or rejected accordingly. All the
challans are collected by the supervisor and the entries in the register are made by the
site engineers to keep a record of the materials on the site.

 Steel
 Cement 53 OPC and PPC (JK Lakshmi and India cement)
 AAC blocks of 3,4 and 6 inches (Godrej)
 Aggregates 10 and 20 mm
 Crush, River Sand and Plaster sand
 Tile, Marble, and Granite
 Plumbing
 Door Fittings

5.3 List of supervisors (Foremen):

Almost all agencies have their supervisors to monitor their work so that they can
finish their work in their respective time so that the slab cycle does not extend.
The foremen from different agencies are:
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  Carpenter
 Fitter (steel management)
 Labour
 Gypsum
 External Plaster
 Electrical
 Plumbing
 Tile
 False Ceiling
 Fire Fighting

6.

OBSERVATIONS AND FINDINGS

Fig 5.1 Building when the Fig 5.2 Car Parking tower
6.1 CHECKING:
internship started.

6.1.1 Checking of starter:

Starters are of 100 and 200 mm and they are casted to check if the shuttering Is
proper and in line so that when the column is casted it doesn’t bulge. They are casted
with the help of ply wood.
They are checked in three steps:
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  The horizontal and vertical length is measured.
 With the help of plum bob check if the shuttering is in line.
 And with the help of line dori the right angle is to be checked.

When all the three points are checked and if they are correct then the columns
are to be casted.

6.1.2 Checking of Columns:

A column is casted on a starter with the help of mivan shuttering. Mivan shuttering is
faster and a very accurate material for shuttering is reduces the average time of slab
cycle.
They are checked in the following way:
 For Steel checking the number of bars are to be checked along with the
diameter of the bars by referring to the Schedule of columns drawings.
 Plum bob are released from the top of the column face vertically and any 3
points are measured using measuring tape. If the measurements are same,
then they pass the check.
 Columns are also checked for position by measuring from other columns.

6.1.3 Checking of Beams and Slab:

Beams and slab are very important to be checked thoroughly because they are the
ones to start the load distribution process.
They are checked in the following way:
 The length, width and the depth of the beam are checked thoroughly.
 The beams number of bars are counted and are cross checked in the schedule.
 There shouldn’t be any
gap in the beam (Gabdi)
 The slab is checked by
counting the number of
bars in the short and long
span.
 The indication of the
level of the slab is marked
with the help of line dori
and steel bars.
Before every casting the R.C.C
consultant sends their engineer to
check all the above-mentioned
points.

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 Fig 6.1.1 Beam Checking

Fig 6.1 Beam Checking

Fig 6.1.2 Column Side Checking

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Fig 6.1.4 Slab Drawing with Schedule

 6.2 R.C.C

Himalaya Society is a 16 Floor building which has a total of 17 slabs to be casted.

SHUTTERING & CONCRETE

Type of footing used in the society is Isolated & combined footing. A total of 4200
mm deep excavation was done.
Grade of concrete used in the foundation casting is M-40.
300 mm soling was done & 230 mm P.C.C was done at the base.

After the casting of plinth beam, the total duration of slab cycle was 18-20 days. Slab
to slab height is 2900mm typical followed for every slab. Columns casting are done
by Mivan shuttering. Beams & Slab decking is done by wooden shuttering which
uses Avron plywood.

Grade of concrete used are as follows:

1-3 floor - M-40
4-9 floor - M-35
10-16 floor - M-30

Sub-structure concreting, 1 & 2nd slab was casted by Ready mix concrete & 3rd slab
onwards on-site mix was done.

M30 Grade includes following material & quantity.

 Crush Sand- 52 lit
 River Sand- 52 lit
 Metal 1- 50 lit
 Metal 2- 88 lit
 Cement- 75 kgs
 BASF Admixture- 200 ml

Diameter of steel used in column & beams are 12, 16, 20, 25 & 32mm.
Diameter of steel used in slab are 8, 10 & 12mm.
Diameter of steel used in stirrups are 8,10 and 12mm.

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 Fig 6.2.3 Slab Casting

6.3 BLOCK WORK

A.A.C is a foam concrete material that is up to three times more lightweight than
regular bricks, and hence, is easy to handle and use too.
There are three types of blocks used at Himalaya site.
75 x 200 x 600 mm
100 x 200 x 600 mm
150 x 200 x 600 mm

External walls & partition walls of each flat are made by 150 mm A.A.C blocks &
internal walls like washroom and bedroom partition walls are made by 100 mm AAC
blocks.
 First 200mm DPC is casted along the wall line.
 Blocks are placed on DPC & is aligned with the help of plum bob.
 Tuff fix chemical is applied between the joints.

Fig 6.3.1 and 6.3.2 Internal and External Blockwork

6.4 ELECTRICAL

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The electrical system in a building is a crucial component that provides power for
various devices and systems. It consists of several key elements designed to ensure
the safe and efficient distribution of electricity throughout the building.

 The electrical pipes are distributed in the specific way in which they are
put on the steel, so they get concealed while the concrete is casted. They
are also concealed in the columns of the structure.

 After the pipes are distributed, they connect the lobby, the building and are
connected from the houses.

 After all the pipes are connected according to the plan they are checked by
the engineer and the wires are put in them, which will be connected to a
power source and then it will get functional.

Fig 6.4.1 Electrical wiring Fig 6.4.2 Electrical wiring

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 Fig 6.4.3 Electrical layout

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6.5 WATERPROOFING

Bathroom waterproofing is the process of adding a protective barrier to bathroom

surfaces to prevent water damage. It helps to stop water from getting into the floors
and walls, which can cause problems like mold growth and structural damage.
Waterproofing keeps your bathroom safe and prevents expensive repairs later on.

The waterproofing for the washrooms in this project is done in the following way -

 Before starting the waterproofing work, it is important to clean the

washroom, which is known as "GHADAI" work in site language.
 This involves applying a chemical called Polyalk WP by Sunanda
waterproofing to the surfaces and walls of the washroom.
 A base coat of 20 mm layer consisting of sand, cement mortar, and
waterproofing chemical is then applied in a ratio of 1:3

 The washroom is filled with water for 2 days to check for any leakage.
 Once this is done, the plumbing agency installs the required pipes.
 The voids in the piping area are filled with sand and then Brick Bat Coba is
done by placing red bricks and filling gaps with cement mortar.
 After the Brick Bat Coba process, a waterproofing chemical is applied again,
and water is kept in the washroom for 2 days.
 Finally, IPS (Interior Plaster Solution) is done, which is the final coat of
waterproofing.

The whole process of waterproofing is performed in 7-8 days for each washroom.

The process of the waterproofing in the Kitchen is done in a similar way as it is done
for the washrooms.

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 Fig 6.5.1 Base Coat work

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 Fig 6.5.2 Brick Bat Coba Fig 6.5.3 Final Coat Done

6.6. PLUMBING

Plumbing System in a building included

installation of pipes and plumbing fixtures for
providing potable water, flushing water and to
provide a good quality drainage for
wastewater.

Plumbing includes the following:

 CP fittings
 Ceramic fittings
 Concealed fittings

CP fittings include chrome plated fittings as

follows:
 Bib cock or taps
 2 in 1 bib cock
 Angle cock
 Pillar cock
 Basin mixer
 Concealed stop cock
 Swan neck sink cock
 Wall mixer
 Diverter
 Shower
 Health faucet
 washing machine bib tap
 Ball Valve
 Float valve
 Flush valve

Ceramic fittings include the following:

 Ceramic Basin
 Ceramic WC Fig 6.6.1 Distribution of Pipes

Concealed fittings include the following:

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  Astral PVC Pipes 40mm Diameter
 Astral PVC Pipes 110mm Diameter
 Astral PVC Pipes 75mm Diameter
 Astral PVC Pipes 20mm Diameter

6.7 GYPSUM FINISHING AND FALSE CEILING WORK

Fig 6.6.2 Pressure Testing
Plaster of Paris is a dry powder made from low-moisture gypsum or calcium sulfate.
When mixed with water, it rehydrates and hardens into a solid form that takes the
shape of the mold. Within about 10 minutes, the mixture starts to set and the particles
interweave, creating a strong and resilient material.

In the past, a 6 mm layer of cement sand mortar was applied to the wall, followed by
a coating of Plaster of Paris. However, this method is now being replaced by a more
modern approach where a single coat of gypsum plaster is directly applied to the
surface.

Gypsum board false ceilings are made from gypsum plasterboards, which are
screwed to a metal frame that is attached to the soffit.
Distance between gypsum board and R.C.C slab is approximately 100mm.

 Gypsum boards are easy to install and clean.

 These boards can provide a seamless look to the ceiling without too many
joints.
 Since these are manufactured in factory machines, the consistency of the
product’s finish and quality is maintained.
 All the light fittings are concealed in the false ceiling, so that no wires or
lights are seen hanging in the apartment. Giving it a clean and neat finish.

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 Fig 6.7.1 Gypsum Sheet

Fig 6.7.2 Gypsum work

going on

6.8 GRANITE AND MARBLE INSTALLATION

Kitchen platform work-

Kitchen platform is constructed with the help of both Marble Patti and Granite Patti .
For making the kitchen platform the following procedure is followed :

 Jhari work is done in the wall where the main platform and service platform
is going to placed which is about one and a half inches.
 Sand is applied on the Indian Marble as it is a very smooth surface and needs
to be rough for better bonding.
 Two Indian marbles are joined and used for the vertical support of the granite
platform. Araldite is the adhesive used to join the two Indian marbles.
 After the vertical supports are created, Araldite is applied on the top of it to
place the Indian marble again as the support for the top platform.
 After the Indian marble is place on top. Materials such as black sand and
cement mortar is applied on the top surface and then the granite is placed.

Washrooms and Kitchen –

Granite Patti is placed as the doorframe of the

washroom and kitchen.
The granite is cut with the help of a cutting
machine according to the measurements
provided to them by the engineers. Then sand
and araldite are applied on the Patti and after
letting it dry for a time period it is then placed
on the doorframe.

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 Fig 6.8.1 Marble Cutting Fig 6.8.2 Granite Cutting

6.9 EXTERNAL PLASTER

Plaster serves as a thin layer of mortar that is applied to the surface of masonry work.
Its primary purpose is to act as a damp-proof coating over the brickwork.
Additionally, plastering provides a smooth and firm finish, enhancing the overall
appearance of the building.
 To begin, we start by applying a layer of cement and sand mortar onto the
R.C.C surface to create a rough texture.
 Once the mortar has fully dried, we proceed to water the surface for a period
of 2-3 days to ensure its hardness.
 Following that, we apply a first coat of plastering measuring approximately
12mm in thickness. This coat is then allowed to dry completely.
 Continuing the process, we water the surface for the next 4-5 days.
 We then proceed to apply a final coat of plastering, measuring around 5-6mm
in thickness, and utilize an aluminum patti to achieve a smooth finish.
 Lastly, we use a plum bob and a tile to ensure that a 90-degree angle is
achieved during the inspection phase.

Materials required for external plastering work:

1. Cement
2. Sand
3. Water
4. Admixtures
5. Glass Fiber

External Plaster mix:

Sand- 5 bags
Cement- 1 bag

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Recron 3S- 1 bag

Fig 6.9.1
6.10 Levelling the final Coat
TILING Fig 6.9.2 Final coat work

The most important part in the process of tiling work is marking off the level
throughout the house with help level pipe.

A Piece of tile also known as DHADA is placed at entrance of the house and each
rooms, kitchens so that a level can be marked thought the house. Here at site the
level is marked at 600mm level so the procedure of tile work can be done easily.

Now for the flooring tile work the following work procedure is followed :

 The process begins with the placement of a small piece of tile used for
marking a level.
 Next, the cleaning work (GHADAI) is carried out inside the apartment to
ensure a smooth and clean surface for the placement of materials required for
tiling.
 A layer of sand, approximately 50-55mm in thickness, is spread throughout
the house in the areas where tiling will be done.
 Cement is then mixed with water to create a slurry, which is applied over the
sand layer.
 The placement of tiles starts from the corner of the room to ensure ease of
placement throughout the apartment.
 Once the tiles are placed, grouting work is done to fill the gaps between the
tiles, often referred to as filling of SANDHA.
 After completing all the necessary procedures, the placement of tiles is
checked for accuracy. Any remaining SANDHA is filled, and a final cleaning
is carried out.

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 Process for the tiling work on the walls of kitchen and washrooms is done in the
following way :
For the tilling walls only cement mortar is used.
 Marking is done for the placement of tiles on the wall .
 Cement Mortar is applied on the back surface of the tile, and it is placed on
the walls.
 Grouting process is applied and all the sandhas are filled up.

In the following ways it’s checked if tiles are placed correctly:

 Tiles that are installed correctly will be even with each other, with no gaps.
This ensures a level surface and a seamless look.
 Sound test is done by knocking on tiles. There would be issue in the sound if
there any gap left behind the tiles.
 Grout lines should be consistent and straight, with no gaps between the tiles.
 There should be no excess grout on tile surfaces.
 Tiles are firmly attached to the floor.
 Tiles are not chipped or cracked.

Fig 6.10.2 Placement of Tiles

Fig 6.10.1 Placement of Tiles

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 Fig 6.10.4 Application of tiles

Fig 6.10.3 Application of mortar

6.11 DOOR

The doors that have been provided are fire-resistant doors that adhere to the
guidelines set by the Chief Fire Officer (CFO).

The door frames have dimensions of 45x900 mm and 45x2100 mm, while the doors
themselves have dimensions of 810x2000 mm. The process of installation:

 The first layer of the door frame is securely fastened to the wall using anchor
fasteners.
 The second layer of the frame is then affixed to the first layer using adhesive
and left to dry for a full day.
 On the following day, the hinges are carefully drilled, and the door is attached
to the frame.
 Lastly, the door is checked for alignment and functionality to ensure a
successful installation.

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Fig 6.11.1 Application of a FRD Door

6.12 ALUMINUM WINDOW

Aluminum window frames offer numerous benefits for buildings due to their
strength, lightweight nature, and resistance to rust. These frames are highly
favored for both residential and commercial settings as they provide
durability, aesthetic appeal, and are easy to maintain.

In the case of the four-track aluminum window used in Himalaya, three of the
tracks are designated for the windows, while the fourth track serves as a
mosquito net.

Here is the step-by-step process for installing an aluminum window:

 Start by placing the aluminum track over the marble frame at the top
and bottom.
 Next, Position the window along with the mosquito net on the marble
frame.
 Ensure smooth sliding of the window without any obstructions before
placing the tracks on the side frame.
 Once the tracks are in position, mark and cut them accordingly to
accommodate the window locking system.
 Install the locks, completing the installation process and making the
window fully functional.

Fig 6.12.1 Application of Window

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6.13 OVERHEAD TANK

An overhead tank is crucial for consistent water supply by utilizing gravity, ensuring
reliable water pressure in buildings. It facilitates uninterrupted water access during
power outages and emergencies. Essential for residential, industrial, and agricultural
use, overhead tanks contribute to water efficiency and support daily activities.
The capacity of the overhead tank is:

WING-A WING-B
OHT Domestic 18000 Liters 17000 Liters
OHT Flushing 20000 Liters 20000 Liters
Fire Tank 15000 Liters 15000 Litres

Fig 6.13.2 Distribution of Steel

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Fig 6.13.1 Drawing of Overhead Tank

6.14 UNDERGROUND TANK

For the underground tank casting we had excavated soil of 580 brass which made the
construction of the UGT possible.
Underground tanks are vital for water storage, especially in areas with limited space
or aesthetic considerations. They provide discreet storage while preventing water
contamination and temperature fluctuations. Commonly used in urban settings, these
tanks enhance water conservation, ensuring a reliable and hidden solution for diverse
water storage needs.

The capacity of the underground tank is:

WING-A WING-B
Underground Domestic 42000 Liters 42000 Liters
Underground Flushing 15000 Liters 15000 Liters
Fire Tank 75000 Liters 75000 Liters

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 Fig 6.14.1 PCC for Underground Tank
6.15 SOFTWARES

AutoCAD:
Autodesk AutoCAD is one of the Computer Aided Design software tools used for
Technical Drawing in the construction industry. It is mainly used by architect and
drafter to design blueprints, bridges, and roads. It helps us to find the length or size
of footing, column, retaining wall, beam, and slab. It also helps us to visualize and
understand how the building will look after completion of construction.

Microsoft Excel:

Microsoft excel is a helpful and powerful program for documentation and data
analysis. It’s a spread sheet program with number of column and rows. Onsite it
helps to maintain all the data of work completed on each day, material entry and
most importantly for preparing Bill of Quantity (BOQ) and Bar Bending Schedule
(BBS) and during calculations for ordering and cross checking all the materials.

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6.16 CUBE TESTING

Compressive strength in a concrete cube indicates its ability to resist squeezing

forces. Determined through testing, it reflects the maximum load the cube can endure
before failure. This parameter is vital in construction, guiding engineers to ensure
concrete meets necessary strength standards for safe and durable structures.
The following cube tests were conducted after curing of 7 and 28 days.
The grades were M30 and M40.

Fig 6.16.1 M-30 Cubes 28 Days Report

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 Fig 6.16.2 M-40 Cubes 7 Days Report

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 Fig 6.16.3 M-30 Cubes 28 Days Report

31
7. IN PLANT TRAINING OUTCOME

Throughout my internship, I gained valuable knowledge and experience in various

areas. I was exposed to the slab cycle, learned how to check steel using architectural
drawings, and became familiar with the internal activities involved in construction
projects, including calculations for materials such as cement, sand, aggregates, and
steel.

In addition to that, I had the privilege of being part of the sales team, where I learned
how to effectively present the site and showcase sample flats to potential clients.

One of the most valuable aspects of this internship was the opportunity to handle
real-world situations and find solutions. The presence of experienced individuals on
the site, including laborers, site engineers, supervisors, and foremen, greatly
contributed to my learning experience as they were always available to guide and
clarify any doubts I had.

Overall, this internship has provided me with practical knowledge and a deeper
understanding of the construction industry.

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8. REFERENCES

 New India Construction Company website

 AutoCAD Drawings provided by site engineers.
 Check List provided from the Company.

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