Summer Internship Report

`

Prepared by:

SUMMER INTERNSHIP REPORT

JULY 2014

Mihir Rambhia

3rd Year Civil Engineering

Pandit Deendayal Petroleum University

Gandhinagar

Hardik Soni

3rd Year Civil Engineering

Pandit Deendayal Petroleum University

Gandhinagar

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DECLARATION

This is to declare that the report submitted regarding the Summer

Internship undergone in the project entitled “FEASIBILITY ANALYSIS OF

USING ALUMINIUM FORMWORK FOR RESIDENTIAL PROJECTS” is a

bonafide work carried out by us, under the guidance of Mr. Aniket Save,

Managing Director, Dan Aluform Consultancy Limited and Mr. Nilesh

Nikam, Design Head, Dan Aluform Consultancy Limited.

Further, we declare that the data and information collected

during our Summer Internship will not been submitted or used

anywhere else.

Mihir Rambhia

3rd Year Civil Engineering,

Pandit Deendayal Petroleum University,

Gandhinagar.

Hardik Soni

3rd Year Civil Engineering,

Pandit Deendayal Petroleum University,

Gandhinagar.

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ACKNOWLEDGEMENT

This training owes its completion to the guidance and contributions of

many without whose help it would not have been possible for us to learn and

understand so many things.

We are truly thankful to DAN ALUFORM CONSULTANCY LIMITED for

providing us with the opportunity to undertake our Summer Training.

We would like to convey our sincere thanks to Mr. Aniket Save,

Managing Director, DAN for his constant support which helped us in achieving

our learning objectives successfully. Also, we would like to extend our gratitude

to Mr. Nilesh Nikam, Design Head who guided and encouraged us throughout

the summer training and imparted in-depth knowledge of the project.

Also we would like to convey our special thanks to Mr. Dayanand

Poojari, Production Head for devoting his precious time to assist and advise us

whenever we needed help.

We are also highly indebted to Mr. Imran Shaikh, Officer, Accounts &

Admin for generously helping us throughout the training period.

The Managers, Engineers and the support staff working at DAN have

always extended their warm support and helped us in every possible way.

Entire staff is so friendly and cheerful that work stress was never experienced.

So we extend our sincere thanks to each and every one of them.

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PROJECT TITLE – FEASIBILITY ANALYSIS

OF USING ALUMINIUM FORMWORK FOR

RESIDENTIAL PROJECTS.

Under the guidance of:

Mr. Aniket Save, Managing Director, DAN

Mr. Nilesh Nikam, Design Head, DAN

Mr. Dayanand Poojari, Production Head, DAN

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CONTENTS

1. SUMMARY ...................................................................................................... 6

1.1 BACKGROUND .............................................................................................. 6

1.2 OBJECTIVE OF THE STUDY ......................................................................... 6

2. COMPANY PROFILE ...................................................................................... 7

2.1. BACKGROUND OF DAN ALUFORM ............................................................. 7

2.2. QUALITY POLICY .......................................................................................... 8

2.3. QUALITY OBJECTIVES ................................................................................. 8

2.4. MANAGEMENT HIERARCHY ........................................................................ 8

2.5. PROJECTS COMPLETED.............................................................................. 9

2.6. SERVICES OFFERED .................................................................................... 9

3. JOB DESCRIPTION ...................................................................................... 10

3.1. ROLES AND RESPONSIBILITIES ................................................................ 10

3.2. ESSENTIAL DUTIES .................................................................................... 10

3.3. ANCILLARY DUTIES .................................................................................... 10

4. PROJECT ..................................................................................................... 11

4.1 PROJECT RATIONALE ................................................................................ 11

4.2 WHAT IS FORMWORK? .............................................................................. 11

4.3 LOADS ACTING ON FORMWORK .............................................................. 12

4.4 TYPES OF FORMWORK ............................................................................. 13

4.5 ALUMINIUM FORMWORK SYSTEM ............................................................ 13

4.6 FORMWORK COMPONENTS ...................................................................... 15

4.7 PRODUCTION LINE ..................................................................................... 21

4.8 ADVANTAGES OF THE SYSTEM ................................................................ 23

4.9 WORK FLOWCHART ................................................................................... 23

4.10 METHODOLOGY OF CALCULATION .......................................................... 24

4.11 CALCULATIONS FOR ALUMINIUM FORMWORK SYSTEM ....................... 25

4.12 CALCULATIONS FOR TRADITIONAL FORMWORK SYSTEM .................... 31

5. COMPARATIVE ANALYSIS .......................................................................... 42

5.1. COST COMPARISON .................................................................................. 42

5.2. CONCLUSION .............................................................................................. 44

6. ANNEXURES ................................................................................................ 45

7. REFERENCES .............................................................................................. 71

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1. SUMMARY

1.1 BACKGROUND The report has been prepared to summarize the things learnt during the

summer internship undertaken at DAN. The primary goal of this

internship program is to provide an opportunity for translation of

theoretical concepts in real life situation. This practical exposure helps

the students in refining their knowledge and exploring there area of

interest. For this, students are placed in enterprises, organizations,

research institutions as well as development projects.

1.2 OBJECTIVE OF THE STUDY To enhance our academic knowledge by working on real time

projects.

To gain practical experience of working in a corporate environment.

To improve our understanding and know-how regarding Aluminium

formwork technology.

To find out whether Aluminium formwork is an economic viable

solution for speedy construction or not.

Improving our know-how regarding the technologies available for

constructing Low Cost Houses and effective solutions for delivering

Mass Housing Projects on time.

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2. COMPANY PROFILE

2.1. BACKGROUND OF DAN ALUFORM

The DAN Aluminium Formwork System for concreting is

probably the most versatile modern construction system. Unlike other

systems it is equally suited to both high and low rise construction.

Specifically designed to allow the rapid construction of

multiple unit projects at optimum productivity, the DAN Aluminium

Formwork can be used for a broad range of applications, from

straightforward panels to more complicated structures involving bay

windows, stairs and A/C hoods.

The degree of pre engineering and inherent simplicity of

the DAN Aluminium Formwork enables unskilled labour to be used.

Every component is light enough to be handled by one operative,

minimizing the need for heavy lifting equipment.

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2.2. QUALITY POLICY

DAN Aluform consultancy service to achieve customer satisfaction by

delivering quality product in specified time. We are committed for

continual improvement to achieve TOTAL QUALITY MANAGEMENT.

2.3. QUALITY OBJECTIVES

To deliver quality product by adopting set specifications.

To achieve customer satisfaction through cost-effective and timely

completion.

To motivate and train staff for continual improvement of quality

standards.

2.4. MANAGEMENT HIERARCHY

Managing Director

Accounts & Admin Officer

Marketing Officer

Production Head

Production Supervisor

Welders and Fitters

Unskilled Worker

Design Head

Draftsmen and Quantity Surveyor

Site

Technician

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2.5. PROJECTS COMPLETED

Aliens Space Station – I ,

Hyderabad

BSUP, Nasik Municipal

Corporation

Veda by Omkar-phase I

Prakashwadi Andheri, SRA

Project by Omkar

MAN Opus at Mira Road

EWS Housing - Thipasandra

BSUP Housing by Pawar

Patkar

Veda by Omkar-phase II

EWS Housing by AMC

EWS Housing - Gunjur

DSIIDC Project - Substructure

DSIIDC Project - Superstructure I

The Jewel of NOIDA

EWS Housing at Kaniminike

EWS Housing at Gunjur-II

VERTU, Wadala

Vishrani, Matunga

2.6. SERVICES OFFERED

END TO END FORMWORK SOLUTIONS

DESIGNING

MANUFACTURING

ONSITE ERECTION

REFURBISHING

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3. JOB DESCRIPTION

3.1. ROLES AND RESPONSIBILITIES

1. Understanding Aluminium Formwork system and its applicability

for mass housing and residential projects.

2. To learn how the system is designed, produced and erected on

construction site.

3. Collection of data from DAN-Chinchani project for performing a

comparative analysis between Plywood formwork system

(referred as traditional formwork system) and aluminium

formwork system.

3.2. ESSENTIAL DUTIES

1. Discussion with production engineers and site supervisors for

understanding the system.

2. Calculating the quantity of formwork required for any project.

3. Estimating the quantity of materials required for any project.

4. Perform a study between Aluminium Formwork System and

Traditional formwork for an identical plan.

5. Draft a comparative study report of the respective project clearly

describing advantages, disadvantages and limitations of this

system.

3.3. ANCILLARY DUTIES

1. Observing and interacting with employees working at Production

unit.

2. Understanding how day to day issues are handled in an industry.

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4. PROJECT

4.1 PROJECT RATIONALE

Objective: The objective of this project is to examine the financial

viability and feasibility of using Aluminium formwork system for different

residential projects. The project comprises of cost comparative study

between projects constructed with traditional formwork system vs with

aluminium formwork system.

Scope: The scope of the study includes the following activities:

Different types of formwork system.

Aluminium formwork system, its designing, production and

erection.

Quantity of formwork required by any project.

Cost estimation for constructing any project, including material,

labour and formwork cost.

Assess major advantages of using Aluminium formwork system in

terms of savings in money, time and improved quality.

4.2 WHAT IS FORMWORK?

Formwork is the term given to either temporary or permanent moulds

into which concrete or similar materials are poured.

Forms or moulds or shutters are the receptacles in which concrete is

placed, so that it will have desired shape or outline when hardened. Once

concrete develops the adequate strength to support its own weight they

can be taken out.

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When concrete is placed, it is in plastic state. It requires to be supported

by temporary supports and castings of desired shape till it becomes

sufficiently strong to support its own weight. This temporary casting is

known as formwork or forms or shuttering or false work.

4.3 LOADS ACTING ON FORMWORK

During the construction formwork has to bear the following loads:

Self-weight

Weight of concrete

Live load due to labour

Impact load due to pouring of concrete

Impact due to workmen working on it

Vibration caused due to vibrators used for compaction of the

concrete

Thus, proper designing of formwork system is an essential and important

part of any building project.

For the design of planks and joists in bending & shear, a live load including

the impact may be taken as 370kg/m². It is however, usual to work with

a small factor of safety in the design of formwork. The surfaces of

formwork should be dressed in such a manner that after deflection due

to weight of concrete and reinforcement, the surface remains horizontal,

or as desired by the designer. The sheathing with full live load of 370

kg/m² should not deflect more than 0.25 cm and the joists with 200kg/m²

of live load should not deflect more than 0.25cm.

In the design of formwork for columns or walls, the hydrostatic pressure

of the concrete should be taken into account. This pressure depends

upon the quantity of water in the concrete, rate of pouring and the

temperature

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4.4 TYPES OF FORMWORK

Timber formwork

Plywood formwork

Steel formwork

Aluminium formwork

Composite formwork

Plastic formwork

4.5 ALUMINIUM FORMWORK SYSTEM

The basic element of Aluminium Formwork System is the panel made

from a high strength aluminium alloy. This aluminium panel is produced

from specially designed extruded sections welded to 4 mm thick sheet to

form a robust component framework. This produces a lightweight panel

with an excellent stiffness to weight ratio, yielding minimal deflections

under concrete loading. Panels are manufactured in standard sizes with

non-standard elements made in the sizes and shapes to suit the

requirements of specific projects.

The panels are held in position by a simple pin and wedge arrangement

system that passes through holes in the outside rib of each panel. The

panel fits precisely, securely and requires no bracing. The walls are held

together with high strength wall ties, while the decks are supported by

beams and props.

Since the equipment is made of aluminium, it has sections that are large

enough to be effective, yet light enough in the weight to be handled by a

single worker. Individual workers can handle all the elements necessary

for forming the system with no requirement for heavy lifting equipment

or skilled labour.

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By ensuring repetition of work tasks on daily basis it is possible for the

system to bring assembly line techniques to construction site and to

ensure quality work, by unskilled or semi-skilled workers. Trial erection

of the formwork is carried out in factory conditions which ensure that all

components are correctly manufactured and no components are missed

out. Also, they are numbered and packed in such a manner so as to

enable easy site erection and dismantling.

The steel reinforcement is placed within the formwork as they are being

erected and concrete is poured into the moulds. When the concrete is

set according to the required strength, the moulds are dismantled. Its

advantages over the traditional construction method include, low skill

requirement, speedy construction, low maintenance, durable structure

and less cost.

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4.6 FORMWORK COMPONENTS

1. Wall Components:

1.1 Standard Wall Panel – It forms the face of the wall. It is an

extruded aluminium sheet precisely cut to the dimension to fit

the exact size of the wall.

1.2 Rocker – It is a supporting component of the wall panel. It is L-

shaped panel having allotment holes for stub pin.

1.3 Kicker – It forms the wall face at the top of the panels and acts

as a ledge to support.

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1.4 Stub pin – It helps in joining two wall panels through joints made

as per the design.

2. Slab Components:

2.1 Deck panel – It forms the horizontal surface for casting of slabs.

It will be used to support the concrete weight during concrete

pouring and casting.

2.2 Deck prop – It forms a V – shaped prop head. It supports the

deck and bears the load coming on the deck panel. The pipe

support will be placed under the prop head.

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2.3 Prop length – It is the length of the prop. Total length depends

on the floor to floor height of the project.

2.4 Deck Mid beam – Used to join the prop heads, the middle beam

supports the slab panels.

2.5 Soffit length (Slab Corner) – It provides support to the edge of

the deck panels at their perimeter of the room. It will act as a

connection between wall panel and slab panel

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2.6 Deck beam bar – It is the deck for the beam. The component

supports the deck and beam.

3. Beam Components:

3.1 Beam side panel – It forms the side of the beams. It is a

rectangular structure and is cut according to the size of the beam.

3.2 Prop head for Soffit beam – It forms the soffit beam. It is a V-

shaped head for easy dislodging of the formwork.

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3.3 Beam Soffit panel – It supports the soffit beam. It is a plain

rectangular structure of aluminium.

4. Other Components:

4.1 Internal Soffit corner (Slab in-corner) – It forms the internal

corner and act as a connection between the Wall panel and Slab

panel (inside).

4.2 External Soffit corner (Slab out-corner) – It forms the external

corner and act as a connection between the Wall panel and Slab

panel (outside).

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4.3 External corner – It forms the external corner of the formwork

system.

4.4 Internal corner – It connects two pieces of vertical formwork

pieces at their exterior intersections.

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4.7 PRODUCTION LINE

Raw Material

Cutting

Punching

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Welding

Cleaning

Labeling

Packing &

Dispatch

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4.8 ADVANTAGES OF THE SYSTEM

The Formwork is specifically designed to allow rapid construction on all types of architectural layouts.

Total system forms the complete concrete structure.

Custom designed to suit project requirements.

Unsurpassed construction speed.

High rigidity so deflection is within permissible limits.

High quality finish.

Cost effective for mass production.

Panels can be reused over 150 times.

Erected using unskilled labour.

Light weight, easy to handle.

Low waste generation.

High recycle ability makes it environment friendly.

4.9 WORK FLOWCHART

PROJECT DRAWING

COLLECTION

QUANTITY ESTIMATION BY

EXPERTS

QUOTATION GIVEN TO CLIENTS

FORMWORK DESIGN

PRODUCTION

ON SITE ERECTION UNDER

EXPERIENCED SUPERVISOR

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4.10 METHODOLOGY OF CALCULATION

For performing a feasibility analysis of using Aluminium formwork system

for residential projects, we selected one project. Project details are as

follows:

Site Location – Chinchani

Client Name- Dan Aluform

Built up Area per flat – 514 ft2

Type of Building – G + 4

Total number of buildings to be constructed – 20

Total built up area of Project – 205456 sq2

Now for comparative study we will select the same plan but with

different type of structures. Load bearing structure is to be constructed

in case of Aluminium Formwork system and Framed Structure will be

constructed in case of Traditional Formwork system (Plywood).

Load bearing structure will be constructed entirely using concrete,

whereas framed structure will be constructed using concrete (for beams,

columns, chajja and slab) and brickwork for the walls.

All the assumptions in the calculations are taken after referring to

Schedule of Rates (2012-13) published by Maharashtra Jeevan

Pradhikaran for pune region (Refer – Annexure 15). Some assumptions

were also derived based on the experience of guide, reliable online and

offline sources and market research.

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4.11 CALCULATIONS FOR ALUMINIUM FORMWORK SYSTEM

(Plan of the Building – Load Bearing Structure)

Data available from the plan are as follows:

Total Floors (Including G) - 5.00

Total Flats on each floor - 4.00

Total number of Buildings - 20.00

Type of Structure - Load Bearing

Type of Formwork - Aluminium

Built-up Area/ Flat 513.64 ft2

Built-up Area/ Floor 2054.56 ft2

Built-up Area/ Building 10272.80 ft2

Total Built up area of Project 205455.94 ft2

Length Width Height

Slab Thickness - 100.00 mm

Floor to Floor Height - 2900.00 mm

Living Entrance Door - 1000.00 2100.00 mm

Bedroom, Kitchen Door - 900.00 2100.00 mm

Bath, Toilet, WC Door - 750.00 2100.00 mm

Living to Passage Door - 1150.00 2100.00 mm

Living Window - 2000.00 1200.00 mm

Bedroom, Kitchen Window - 1200.00 1200.00 mm

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Toilet, WC Ventilation - 600.00 900.00 mm

First & Second Floor Bed - 1200.00 2100.00 mm

Wall thickness 1 - 100.00 mm

Wall thickness 2 - 125.00 mm

Following assumptions were taken for performing detailed cost

calculation of the super structure:

Material Assumptions :

1) Grade of Concrete used = 20.00 Mpa

2) Cement : Sand : Aggregate = 1.00 1.50 3.00

3) Density of Cement = 1440.00 kg/m3

4) Cost of Cement bag - 53 Grade OPC = 310.00 INR/bag

Bag size = 50.00 kg

5) Cost of sand = 1150.00 INR/m3

6) Density of Aggregates = 1670.00 kg/m3

7) Cost of Aggregates = 850.00 INR/m3

8) % of Steel per unit volume of Concrete = 1.00 %

9) Density of steel = 7850.00 kg/m3

10) Cost of Steel = 48000.00 INR/tonne

Aluminium Formwork Cost Assumptions :

1 Cost of Aluminium Formwork = 8500.00 INR/m2

2 No of expected Repetitions = 100.00 times

3 Scrap Value = 130.00 INR/kg

4 Weight of Aluminium/m2 25.00 kg

5 Material Available for Scrap = 100.00 %

Assumptions- Formwork Accessories/Consumables:

Unit Loss

Assumption Unit Cost /Unit

1 Pin-Wedge 14.00 pcs/m2 2.00 % per floor 15.00

2 Wall ties 5.00 pcs/m2 2.00 % per floor 20.00

3 Shuttering Oil 0.06 litres/m2 100.00 % per floor 230.00

4 Corrugated Sheet 800.00 mm2 / tie 100.00 % per floor 60.00

5 PVC roll 100.00 mm / tie 100.00 % per floor 1.75

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Cost Calculation Assumptions :

Electric Fitting Including Wiring @ % of Total Cost 10.00 %

Water Supply Fitting And Sanitary Fitting @ % of Total Cost 10.00 %

Sewerage @ % of Total Cost 5.00 %

Assumptions- Labour Cost:

Rate per

Formwork 150.00 sqm

Steel 8000.00 ton

Concrete 350.00 cum

Skilled 350.00 day

M/C 275.00 day

F/C 270.00 day

BHISHTI 270.00 day

Now taking this asusmptions detailed cost analysis of each component

was done.

1.1 Total quantity of wet concrete required for monolithically

concreting a unit floor of the building will be : 61 m3 (as per

calculations shown in Annexure -2 )

Thus total quantity of dry concrete required will be:

= 61 x 1.54

= 94 m3

So for producing this much concrete, the amount of materials that

will be required is as follows:

Materials required:

1 Cement = 492.22 Bags

2 Sand = 25.64 m3

3 Aggregates = 51.27 m3

4 Steel = 7.38 tonnes

(as per calculations shown in Annexure -3)

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Thus, total cost of materials required for concreting will be as follows:

Sr No Material Material Required Cost of Material (INR) Total cost

1 Cement 492.22 310.00 152587.64

2 Sand 25.64 1000.00 25636.36

3 Aggregates 51.27 850.00 43581.82

4 Steel 7.38 48000.00 354192.00

Total Material cost of one floor = 575997.82

Total Material cost of project = 57599781.82

2.1 Total material cost for concreting of the super stucture of one floor

will be 5,75,998 INR

3.1 Total formwork quantity required for a unit floor will be : 1031 m2

(as per calculations shown in Annexure -1 )

4.1 Cost incurred due to formwork consumables for the entire project

will be 13,26,501 INR (as per calculations shown in Annexure – 4 )

5.1 Total cost incurred for the grouting of entire project will be 85,885

INR (as per calculations shown in Annexure -5 ).

6.1 Number of labours required for achieving a 4 Day Slab cycle:

Work Description Skilled M/C F/C BHISHTI

Concreting 3 6 18 12

Reinforcement 14

Formwork 8 24

Grouting 1

Thus, Labour Cost per day will be 26,833 INR (as per calculations

shown in Annexure -6 ).

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Now for constructing this project, using one set of Aluminium formwork

system is suggested as follows:

Formwork Cycle Assumptions:

Initial set up time required 15.00 days

Floor cycle = 4.00 days

Section to Section work cycle = 2.00 days

No of Buildings to be constructed using Aluminium formwork = 20.00

Transfer time between building 8.00 days

Working days in Month 26.00 days

Set Proposal

Block Typical floor /

building

Total No of

buildings Repetition

Initial Set up time

(days)

Cycle time (days per

floor)

Time for Transfer

B/w Building (Days)

Total days

Months (Considering

Working days)

Set 1 Typical Floor 5 20 100 15 4 8 487 18.73

Total Built up Area

Formwork Quantity Required

Formwork Cost (Formwork +

Consumables) Cost/ft2

Estimated Scrap Value

Net Cost (Formwork + Consumables – Scrap)

Net Cost/ft2

205455.94 1030.63 10086837.91 49.09 3349540.74 6737297.17 32.79

Total sets required = 1.00

Repetitions per set = 100.00 times

Initial Expense = 8760337.33 INR

Total Expense = 6737297.17 INR

Time period required for completing the concrete work of all the Buildings = 487 days

Time period required for completing the concrete work of all the Buildings = 18.73 months

So with using one Aluminium formwork set concreting work of

superstructure of entire project can be completed within 487 days or

18.73 months.

Total formwork cost is estimated to be 32.79 INR/ft2 (Considering the

return on scrap).

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TOTAL COST BREAK UP OF THE SUPERSTRUCTURE IS AS FOLLOWING:

Description Unit

Total Built up Area/ floor 2054.56 ft2

Formwork/Built-up ratio 5.40

Cost Calculations per Built up Area

Category Total

Concreting Material Cost 280.35 INR/ft2

Formwork Cost 42.64 INR/ft2

Formwork Consumables 6.46 INR/ft2

Grouting Material Cost 0.42 INR/ft2

Labour Cost 63.60 INR/ft2

Subtotal 393.47 INR/ft2

Electric Fitting Including Wiring @ 10% of Total Cost 39.35 INR/ft2

Water Supply Fitting And Sanitary Fitting @ 10% of Total Cost 39.35 INR/ft2

Sewerage @ 5% of Total Cost 19.67 INR/ft2

Total 491.83 INR/ft2

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4.12 CALCULATIONS FOR TRADITIONAL FORMWORK SYSTEM

(Plan of the Building – Framed Structure)

Data available from the plan are as follows:


Total Flats on each floor - 4.00


Type of Structure - Framed Structure

Type of Formwork - Traditional

Built-up Area/ Flat 513.64 ft2

Built-up Area/ Floor 2054.56 ft2

Built-up Area/ Building 10272.80 ft2

Total Built up area of Project 205455.94 ft2

Length Width Height

Slab Thickness - 0.00 0.00 100.00 mm

Floor to Floor Height - 0.00 0.00 2900.00 mm

Living Entrance Door - 1000.00 0.00 2100.00 mm

Bedroom, Kitchen Door - 900.00 0.00 2100.00 mm

Bath, Toilet, WC Door - 750.00 0.00 2100.00 mm

Living to Passage Door - 1150.00 0.00 2100.00 mm

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Living Window - 2000.00 0.00 1200.00 mm

Bedroom, Kitchen Window - 1200.00 0.00 1200.00 mm

Toilet, WC Ventilation - 600.00 0.00 900.00 mm

First & Second Floor Bed - 1200.00 0.00 2100.00 mm

Wall thickness - 0.00 150.00 0.00 mm

Column dimension 900.00 230.00 0.00 mm

Beam dimension 0.00 230.00 600.00 mm

Balcony Beam dimension 700.00 200.00 450.00 mm

Following assumptions were taken for performing detailed cost

calculation of the super structure:

Material Assumptions :





Bag size = 50.00 kg







11) Assumed Brick Wastage = 10.00 %

12) Mortar mixture ( Cement : Sand) = 1.00 4.00

13) Bricks density = 500.00 pcs/m3

14) Cost of Brick = 6.90 INR/pc

Traditional Formwork Cost Assumptions :

1 Cost of Traditional Formwork = 750.00 INR/m2

2 No of expected Repetitions = 10.00 times

3 Scrap Value = 0.00 INR/kg

4 Material Available for Scrap = 0.00 %

Formwork Accessories/Consumables Assumptions:

Unit Loss Assumption Unit Cost /Unit

1.00 Nails 0.22 kg/m2 100.00 % per floor 80.00

2.00 Shuttering Oil 0.06 litres/m2 100.00 % per floor 50.00

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Cost Calculation Assumptions :

Electric Fitting Including Wiring @ % of Total Cost 10.00 %

Water Supply Fitting And Sanitary Fitting @ % of Total Cost 10.00 %

Sewerage @ % of Total Cost 5.00 %

Assumptions- Labour Cost:

Rate per

Formwork 150.00 sqm

Steel 8000.00 ton

Concrete 350.00 cum

Skilled 350.00 day

M/C 275.00 day

F/C 270.00 day

BHISHTI 270.00 day

Now taking this asusmptions detailed cost analysis of each component

was done as following:

1.1 Total quantity of wet concrete required for monolithically

concreting a unit floor of the building will be : 54 m3 (as per

calculations shown in Annexure - 8 )

Thus total quantity of dry concrete required will be:

= 54 x 1.54

= 84 m3

So for producing this much concrete, the amount of materials that

will be required are as follows:

So materials required:


2 Sand = 22.91 m3



(as per calculations shown in Annexure - 9)

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Thus, total cost of materials required for concreting will be as follows:

Sr No Material Material Required

Cost of Material (INR) Total cost

1 Cement 439.85 310.00 136354.91

2 Sand 22.91 1150.00 26345.45

3 Aggregates 45.82 850.00 38945.45

4 Steel 6.59 48000.00 316512.00

Total Material cost per floor = 518157.82


2.1 Total material cost for concreting of the super stucture of one

floor will be 5,18,157 INR

3.1 Total formwork quantity required for a unit floor will be : 434 m2

(as per calculations shown in Annexure -7 )

4.1 Cost incurred due to formwork consumables for the entire project

will be 8,87,200 INR (as per calculations shown in Annexure – 12 )

5.1 Total quantity of brickwork required per floor will be : 34 m3 (as per

calculations shown in Annexure - 10 )

So for doing this quantity of brickwork, the amount of materials

that will be required are as follows:

Materials required:


2 Sand = 10.89 m3

3 Bricks = 18718.47 pcs


MIHIR

35

Thus, total cost of materials required for brickwork will be as follows:


Cost of Material (INR) Total cost

1.00 Cement 80.66 310.00 25004.47

2.00 Sand 10.89 1150.00 12524.36

3.00 Bricks 18718.47 6.90 129157.45



6.1 Total material cost for brickwork of the super stucture of one floor


7.1 Total material required for plastering of one floor will be as

follows:


1.00 Cement = 452.00 Bags

2.00 Sand = 72.73 m3


Thus, total cost of materials required for plastering will be as follows:

Sr No Material Material Required Cost of Material (INR) Total cost

1.00 Cement 452.00 310.00 140120.95

2.00 Sand 72.73 1150.00 83642.85

Subtotal = 223763.81

3.00 Labour 10% of cost (Subtotal) 22376.38



MIHIR

36

8.1 Total material cost for plastering of the super stucture of one floor


9.1 Now for doing Comparative analysis, following two cases are

taken:

1. Buying one set of traditional formwork at a time.

2. Buying sufficient sets of traditional formwork to complete the

project in same amount of time as Aluminium formwork system.

CASE 1:

i. Number of labours required/day for achieving a 25 Day Slab cycle:

Work Description Skilled M/C F/C BHISHTI

Concreting 0.43 0.87 2.61 1.74

Reinforcement 3.96

Formwork 0.84 2.51

Brickwork 1.50 1.50

Thus, Labour Cost per day will be 5,106 INR (as per calculations shown

in Annexure -13 ).

ii. For constructing this project, using one set of Traditional formwork

system at a time:

Formwork Cycle Assumptions :



No of Buildings to be constructed using traditional formwork = 20.00



MIHIR

37

Block Typical floor /

building

Total No of

buildings Repetition

Initial Set up

time (days)


floor)

Time for

Transfer B/w

Building (Days)

Total days

Months (Considering

Working days)

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Typical Floor 5 2 10 25 25 25 250 10

Total Built up

Area


Formwork Cost

Cost/ft2 Estimated

Scrap Value

Net Cost Net

Cost/ft2

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17





Time period required for completing the concrete work of all the Buildings = 2500 days


So with using one set of traditional formwork set, concreting work of

superstructure of entire project can be completed within 2500 days

or 96.15 months. Total formwork cost is estimated to be 20.17 INR/ft2

(Considering the return on scrap).

MIHIR

38

TOTAL COST BREAK UP OF THE SUPERSTRUCTURE FOR CASE 1 IS AS

FOLLOWING:

Description Unit




Category Total

Material Cost

Concrete 252 INR/ft2

Brickwork and Plaster 190 INR/ft2




SUBTOTAL 524.54 INR/ft2




TOTAL 655.68 INR/ft2

MIHIR

39

CASE 2:

For constructing this project, in similar time as Aluminium formwork

system we require five sets of traditional formwork system at a time.

i. Number of labours required/day for for working with five sets at a

time and achieving 25 Day Slab cycle:

Labour Required/ Day:

Sr No Work Description Skilled M/C F/C BHISHTI

1 Concreting 2.17 4.34 13.03 8.68

2 Reinforcement 19.78

3 Formwork 4.18 12.53

4 Brickwork 7.49 7.49

Thus, Labour Cost per day will be 24,874 INR (as per calculations shown in

Annexure -14 ).

ii. For constructing this project, using five set of Traditional formwork

system at a time:

Formwork Cycle Assumptions :



No of Buildings to be constructed using traditional formwork = 20.00



MIHIR

40

Set Propos

al Block

Typical floor /

building

Total No of buildi

ngs

Repetition

Initial Set up time

(days)


floor)

Time for Transfer

B/w Building (Days)

Total days

Months (Consid

ering Working days)

Set 1 Typical Floor 5 2 10 25 25 25 250 10










Total Built up

Area


Formwork Cost

Cost/ft2 Estimated

Scrap Value

Net Cost Net

Cost/ft2

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17

20550 434 414418 20.17 0 414418 20.17





Time period required for completing the concrete work of all the Buildings = 500.00 days


So with using five set of traditional formwork set, concreting work of

superstructure of entire project can be completed within 500 days or

19.23 months. Total formwork cost is estimated to be 20.17 INR/ft2

(Considering the return on scrap).

MIHIR

41

TOTAL COST BREAK UP OF THE SUPERSTRUCTURE FOR CASE 2 IS AS

FOLLOWING:

Description Unit




Category Total

Material Cost

Concrete 252 INR/ft2

Brickwork and Plaster 190 INR/ft2




SUBTOTAL 522.94 INR/ft2




TOTAL 653.68 INR/ft2

MIHIR

42

5. COMPARATIVE ANALYSIS

5.1. COST COMPARISON

Cost when constructed using Aluminium formwork system:

Formwork Repetition 100

Days 487.00

Cost

Formwork 8760337.33

Consumables 1326500.58

Material 57599781.82

Labour 13067804.93

Grouting 85884.78

Cost when constructed using Traditional formwork system Case 1:


Days 2500.00

Cost

Formwork 4144176.72


Concrete 51815781.82

Brickwork & Plaster 39045009.16

Labour 12765207.48

Cost when constructed using Aluminium formwork system Case 2:


Days 500.00

Cost

Formwork 3256976.36


Concrete 51815781.82

Brickwork & Plaster 41282647.21

Labour 497482.44

MIHIR

43

Graph: Time required vs Cost incurred for different formwork system

- Denotes the Break-Even point of Aluminium formwork system

(40 Repetitions)

Observations

Description Aluminium Formwork

Traditional Formwork Case-1

Traditional Formwork Case 2

Initial Cost Very High Very low Low

Floor to Floor cycle Very fast ( 4 days) Slow ( 25 days) Slow ( 25 days)

Approx. Repetitions High (100) Less (10) Less (10)

Time taken to complete project Fast (487 days) Very slow (2500 days) Fast (500 days)

Labour required Unskilled Skilled Skilled

Overall Cost of Project (Comparison)

7,74,90,769 (Lowest)

10,43,02,386 (Highest)

9,41,83,579 (Medium)

Remarks: Suitable for large scale construction (Repetitions - >50)

Suitable for small scale project

(Repetitions - <20)

Suitable for medium scale projects

(Repetitions – 20-50)

77490769

104302386

94183579

0

20000000

40000000

60000000

80000000

100000000

12000000025

125

225

325

425

525

625

725

825

925

1025

1125

1225

1325

1425

1525

1625

1725

1825

1925

2025

2125

2225

2325

2425

2500

Cost Comparative Analysis

Aluminium FormworkTraditional Formwork Case 1Traditional Formwork Case 2

Days

Cost

MIHIR

44

5.2. CONCLUSION

COST: Use of this formwork in load bearing design gives an average

of 25 per cent cost saving in the structure of the building and

increased usable floor space of 8 per cent over RCC design.

TIME: For 100 per cent work, construction through slab beam wall

construction takes X time and through Aluminium Formwork

technology the time required is 1/5th of the X time.

ENVIRONMENT FRIENDLY: The technology is environment friendly

as there is no use of timber. Also aluminium is a recyclable product,

hence it is highly eco-friendly.

EARTHQUAKE RESISTANCE: The formwork gives the box or cellular

design resulting in the walls giving support to the super structure

in two directions. As a result, the structures are more resistant to

earthquakes than the traditional RCC column and beam designs.

LIFTING: As the Aluminium Formwork is lightweight and easy to

handle, no tower cranes are required for the same. Even high rise

towers can be constructed very easily without help of any lifting

mechanisms.

LABOURS: Due to simplicity of the assembly, only unskilled labours

are required with minimal supervision.

REPETITIONS: The Aluminium Formwork System is removable and

can be reused over hundred times with little maintenance.

MIHIR

45

6.ANNEXURES

Annexure - 1 – Formwork Quantity for Aluminium Formwork System

Length Width Height

Total Floors (Including G) - 5 Slab Thickness - 0 0 100 mm

Total Flats on each floor - 4 Floor to Floor Height - 0 0 2900 mm

Total number of Buildings - 20 Living Entrance Door - 1000 0 2100 mm

Type of Structure -

Load Bearing Bedroom, Kitchen Door - 900 0 2100 mm

Type of Formwork - Aluminium Bath, Toilet, WC Door - 750 0 2100 mm

Living to Passage Door - 1150 0 2100 mm

Living Window - 2000 0 1200 mm

Bedroom, Kitchen Window - 1200 0 1200 mm

Toilet, WC Ventilation - 600 0 900 mm

First & Second Floor Bed - 1200 0 2100 mm

Wall thickness 1 - 0 100 0 mm


Total Formwork Area Requirement

Sr Part of

Building Component Length Width Height Quantity Area

Total Flats

Net Quantity Required

1 Bed Room Internal Wall 3050 2800 2 17080000 4 68320000

Bed Room Internal Wall 3050 2800 2 17080000 4 68320000

Bed Room Window 1200 1200 2 2880000 4 -11520000

Bed Room Jamb 1200 100 4 480000 4 1920000

Bed Room Jamb 100 1200 4 480000 4 1920000

Bed Room Door 900 2100 1 1890000 4 -7560000

Bed Room Jamb 900 100 1 90000 4 360000

Bed Room Jamb 100 2100 2 420000 4 1680000

Bed Room Slab 3050 3050 1 9302500 4 37210000

Bed Room Chajja 1400 450 1 630000 4 2520000

Bed Room Chajja 1400 100 1 140000 4 560000

Bed Room Chajja 450 100 2 90000 4 360000

MIHIR

46

2 Living Room Internal Wall 5000 2800 2 28000000 4 112000000

Living Room Internal Wall 3050 2800 2 17080000 4 68320000

Living Room Window 2000 1200 1 2400000 4 -9600000

Living Room Jamb 2000 100 2 400000 4 1600000

Living Room Jamb 100 1200 2 240000 4 960000

Living Room Main Door 1000 2100 1 2100000 4 -8400000

Living Room Jamb 1000 125 1 125000 4 500000

Living Room Jamb 125 2100 2 525000 4 2100000

Living Room Passage Door 1150 2100 1 2415000 4 -9660000

Living Room Jamb 1150 100 1 115000 4 460000

Living Room Jamb 100 2100 2 420000 4 1680000

Living Room Slab 5000 3050 1 15250000 4 61000000

Living Room Chajja 2200 450 1 990000 4 3960000



3 Kitchen Internal Wall 2200 2800 2 12320000 4 49280000

Kitchen Internal Wall 1850 2800 2 10360000 4 41440000

Kitchen Window 1200 1200 1 1440000 4 -5760000

Kitchen Jamb 1200 100 2 240000 4 960000

Kitchen Jamb 100 1200 2 240000 4 960000

Kitchen Door 900 2100 1 1890000 4 -7560000

Kitchen Jamb 900 100 1 90000 4 360000

Kitchen Jamb 100 2100 2 420000 4 1680000

Kitchen Slab 2200 1850 1 4070000 4 16280000

Kitchen Chajja 3800 450 1 1710000 2 3420000

Kitchen Chajja 3800 100 1 380000 2 760000

4 Bathroom Internal Wall 1500 2800 2 8400000 4 33600000

Bathroom Internal Wall 1100 2800 2 6160000 4 24640000

Bathroom Ventilation 600 900 1 540000 4 -2160000

Bathroom Jamb 600 100 2 120000 4 480000

Bathroom Jamb 100 900 2 180000 4 720000

Bathroom Door 750 2100 1 1575000 4 -6300000

Bathroom Jamb 750 100 2 150000 4 600000

Bathroom Jamb 100 2100 2 420000 4 1680000

Bathroom Slab 1500 1100 1 1650000 4 6600000

Bathroom Chajja 2200 300 1 660000 4 2640000

Bathroom Chajja 2200 100 1 220000 4 880000

5 W.C. Internal Wall 1000 2800 2 5600000 4 22400000

W.C. Internal Wall 1000 2800 2 5600000 4 22400000

W.C. Ventilation 600 900 1 540000 4 -2160000

MIHIR

47

W.C. Jamb 600 100 2 120000 4 480000

W.C. Jamb 100 900 2 180000 4 720000

W.C. Door 750 2100 1 1575000 4 -6300000

W.C. Jamb 750 100 2 150000 4 600000

W.C. Jamb 100 2100 2 420000 4 1680000

W.C. Slab 1000 1000 1 1000000 4 4000000

6 Passage Internal Wall 1650 2800 2 9240000 4 36960000

Passage Internal Wall 1000 2800 2 5600000 4 22400000

Passage Bed room Door 900 2100 1 1890000 4 -7560000

Passage W.C. Door 750 2100 1 1575000 4 -6300000

Passage Slab 1650 1000 1 1650000 4 6600000

Passage Passage Door 1150 2800 1 3220000 4 -12880000



Passage Living-Passage

Door 1150 2100 1 2415000 4 -9660000

Passage Bath Door 750 2100 1 1575000 4 -6300000

Passage Slab 1200 1150 1 1380000 4 5520000

7 Balcony Beam 3250 450 1 1462500 4 5850000

Balcony Beam 3250 200 1 650000 4 2600000

Balcony Beam 3250 350 1 1137500 4 4550000

Balcony Slab 200 450 2 180000 4 720000

Balcony Slab 3250 700 2 4550000 4 18200000

8 Floor Passage Internal Wall 2500 2800 2 14000000 1 14000000

Floor Passage Internal Wall 2300 2800 1 6440000 1 6440000

Floor Passage Slab 2500 2300 1 5750000 1 5750000

Floor Passage Main Door 1000 2100 1 2100000 4 -8400000

Floor Passage Window 2300 1200 1 2760000 4 -11040000

Floor Passage Jamb 2300 100 2 460000 4 1840000

Floor Passage Jamb 100 1200 2 240000 4 960000

9 Staircase Tread 250 1100 8 2200000 2 4400000

Staircase Riser 161 1100 9 1593900 2 3187800

Staircase Mid-Landing 813 2300 1 1869900 1 1869900

Staircase Internal Wall 3200 2900 2 18560000 2 37120000

Staircase Stair 1175099 1 1175099 1 -1175099

Staircase Wall 2300 900 1 2070000 1 2070000

2300 1225 1 2817500 1 2817500

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48

Staircase Inclined Slab 2446 1100 1 2690600 1 2690600

2677 1100 1 2944700 1 2944700

Beam 2300 200 1 460000 1 460000

2300 200 1 460000 1 460000

10 External Wall Wall 83900 2900 1 243310000 1 243310000

External Wall Kitchen Chajja 3800 2900 1 11020000 2 -22040000

External Wall Kitchen Chajja 3800 2800 1 10640000 2 21280000

External Wall Bath-W.C. Chajja 2800 2900 1 8120000 4 -32480000

External Wall Bath-W.C. Chajja 2800 2800 1 7840000 4 31360000

External Wall Living Window 2000 1200 1 2400000 4 -9600000

External Wall Window 1200 1200 3 4320000 4 -17280000

External Wall Ventilation 600 900 2 1080000 4 -4320000

External Wall Staircase 2300 1675 1 3852500 1 -3852500

External Wall Staircase 1200 1200 1 1440000 1 -1440000

11 Kicker External wall 83900 125 1 10487500 1 10487500

Column1 SUMMARY QUANTITY (m2) 5 % Inc.

1.00 Bed Room 164.09 172.29

2.00 Living Room 226.16 237.47

3.00 Kitchen 101.82 106.91

4.00 Bathroom 63.38 66.55

5.00 W.C. 43.82 46.01

6.00 Passage 68.54 71.97

7.00 Balcony 31.92 33.52

8.00 Floor Passage 9.55 10.03

9.00 Staircase 56.85 59.69

10.00 External Wall 204.94 215.18

11.00 Kicker 10.49 11.01

981.55 1030.63

MIHIR

49

Annexure - 2 – Concrete Quantity for Aluminium Formwork System

Length Width Height




Type of Structure - Load

Bearing Bedroom, Kitchen Door - 900 0 2100 mm

Type of Formwork - Aluminium Bath, Toilet, WC Door - 750 0 2100 mm

Construction time (Months) - 24 Living to Passage Door - 1150 0 2100 mm







Total Concrete Requirement

Sr No

Part of Building Component Length

Width

Height

Quantity Volume

Total Flats


1 Bed Room Internal Wall 3250 50 2800 2 910000000 4 3640000000

Bed Room Internal Wall 50 3050 2800 2 854000000 4 3416000000

Bed Room Window 1200 50 1200 2 144000000 4 -576000000

Bed Room Door 900 50 2100 1 94500000 4 -378000000

Bed Room Slab 3050 3050 100 1 930250000 4 3721000000

Bed Room Chajja 1400 450 100 1 63000000 4 252000000

2 Living Room Internal Wall 5000 50 2800 1 700000000 4 2800000000

Living Room Internal Wall 5000 63 2800 1 875000000 4 3500000000


Living Room Window 2000 50 1200 1 120000000 4 -480000000

Living Room Main Door 1000 63 2100 1 131250000 4 -525000000

Living Room Passage Door 1150 50 2100 1 120750000 4 -483000000

Living Room Slab 5000 3050 100 1 1525000000 4 6100000000

Living Room Chajja 2200 450 100 1 99000000 4 396000000

3 Kitchen Internal Wall 2200 50 2800 2 616000000 4 2464000000

Kitchen Internal Wall 50 1850 2800 2 518000000 4 2072000000

MIHIR

50

Kitchen Window 1200 50 1200 1 72000000 4 -288000000

Kitchen Door 900 50 2100 1 94500000 4 -378000000

Kitchen Slab 2200 1850 100 1 407000000 4 1628000000

Kitchen Chajja 3800 450 100 1 171000000 2 342000000

4 Bathroom Internal Wall 1500 50 2800 2 420000000 4 1680000000

Bathroom Internal Wall 50 1100 2800 2 308000000 4 1232000000

Bathroom Ventilation 600 50 900 1 27000000 4 -108000000

Bathroom Door 750 50 2100 1 78750000 4 -315000000

Bathroom Slab 1500 1100 100 1 165000000 4 660000000

Bathroom Chajja 2200 300 100 1 66000000 4 264000000

5 W.C. Internal Wall 1000 50 2800 2 280000000 4 1120000000

W.C. Internal Wall 50 1000 2800 2 280000000 4 1120000000

W.C. Ventilation 600 50 900 1 27000000 4 -108000000

W.C. Door 750 50 2100 1 78750000 4 -315000000

W.C. Slab 1000 1000 100 1 100000000 4 400000000

6 Passage Internal Wall 1650 50 2800 2 462000000 4 1848000000

Passage Internal Wall 50 1000 2800 2 280000000 4 1120000000

Passage Bed room Door 900 50 2100 1 94500000 4 -378000000

Passage W.C. Door 750 50 2100 1 78750000 4 -315000000

Passage Slab 1650 1000 100 1 165000000 4 660000000

Passage Passage Door 1150 50 2800 1 161000000 4 -644000000




Door 1150 50 2100 1 120750000 4 -483000000

Passage Bath Door 750 50 2100 1 78750000 4 -315000000

Passage Slab 1200 1150 100 1 138000000 4 552000000

7 Balcony Beam 3250 200 450 1 292500000 4 1170000000

700 200 450 2 126000000 4 504000000

Balcony Slab 3250 700 100 1 227500000 4 910000000

8 Floor Passage Internal Wall 2500 63 2800 2 875000000 1 875000000

Floor Passage Internal Wall 50 2300 2800 1 322000000 1 322000000

Floor Passage Slab 2500 2300 100 1 575000000 1 575000000

Floor Passage Main Door 1000 63 2100 1 131250000 4 -525000000

Floor Passage Window 2300 50 1200 1 138000000 4 -552000000

9 Staircase Left 484603 1100 1 533063300 1 533063300

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51

Staircase Right 484603 1100 1 533062860 1 533062860

Staircase Mid-Landing 150000 2300 1 345000000 1 345000000

Staircase Internal Wall 3200 63 2900 2 1160000000 2 2320000000

Staircase Landing Wall 2300 50 900 1 103500000 1 103500000

Staircase 2300 50 1225 1 140875000 1 140875000

Staircase Beam 2300 200 100 1 46000000 1 46000000

10 External Wall Wall 83900 50 2900 1 1216550000

0 1 12165500000

External Wall Kitchen Chajja 3800 50 2900 1 551000000 2 -1102000000

External Wall Kitchen Chajja 3800 50 2800 1 532000000 2 1064000000

External Wall Bath-W.C. Chajja 2800 50 2900 1 406000000 4 -1624000000

External Wall Bath-W.C. Chajja 2800 50 2800 1 392000000 4 1568000000

External Wall Living Window 2000 50 1200 1 120000000 4 -480000000

External Wall Window 1200 50 1200 3 216000000 4 -864000000

External Wall Ventilation 600 50 900 2 54000000 4 -216000000

External Wall Staircase 2300 50 1675 1 192625000 1 -192625000

External Wall Staircase Window 1200 50 1200 1 72000000 1 -72000000

Sr No SUMMARY QUANTITY (m3) 5 % inc

1.00 Bed Room 10.08 10.58

2.00 Living Room 14.98 15.72

3.00 Kitchen 5.84 6.13

4.00 Bathroom 3.41 3.58

5.00 W.C. 2.22 2.33

6.00 Passage 4.03 4.23

7.00 Balcony 2.58 2.71

8.00 Floor Passage 0.70 0.73

9.00 Staircase 4.02 4.22

10.00 External Wall 10.25 10.76

58.10 61.01

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52

Annexure - 3 – Materials required for concreting in Aluminium Formwork System

Assumptions- Materials:

Unit





Bag size = 50.00 kg







So, total volume of dry concrete required = 94.00 m3


(m3) Density of Material

(kg/m3) Material Required

(kg) No. of Bags

1 Cement 17.09 1440.00 24610.91 492.22

2 Sand 25.64

3 Aggregates 51.27 1670.00 85625.45

4 Steel 0.94 7850.00 7379.00



2 Sand = 25.64 m3



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53

Annexure - 4 – Consumables required in Aluminium Formwork System and its cost

incurred



1 Pin-Wedge 14.00 pcs/m2 2.00 % per floor 15

2 Wall ties 5.00 pcs/m2 2.00 % per floor 20

3 Shuttering Oil 0.06 litres/m2 87

4 Corrugated Sheet 800.00 mm2 / tie 60

5 PVC roll 100.00 mm / tie 1.75

Total Formwork quantity = 1030.63 m2

Total Floors (Including G) - 5.00 1st Supply

from Company


Sr Material Material Required

Total quantity required

Additional Material/Floor

Total Additional Material Unit

1 Pin-Wedge 14.00 14428.79 288.58 28569.01 pcs

2 Wall ties 5.00 5153.14 103.06 10203.22 pcs

3 Shuttering Oil 0.06 66.58 66.58 6657.86 litres

4 Corrugated Sheet 800.00 4122511.68 4122511.68 408.13 m2

5 PVC roll 100.00 515313.96 515313.96 51531.40 m

So additional cost incurred due to consumables:

Sr Material Additional Material Cost/Unit Total Cost

1 Pin-Wedge 28569.01 15.00 428535.09

2 Wall ties 10203.22 20.00 204064.33

3 Shuttering Oil 6657.86 87.00 579233.50

4 Grease 0.00 0.00 0.00

5 Corrugated Sheet 408.13 60.00 24487.72

6 PVC roll 51531.40 1.75 90179.94

13,26,500.58

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54

Annexure - 5 – Cost incurred due to Grouting in Aluminium Formwork System

Grouting Assumptions:

Length Width Height

1 Grout Dimension = 100.00 50.00 8.00

2 Cost of grouting material per mm3 =

3 Grouting to be done with mortar(Cement : Sand) = 1.00 4.00

Sr No Material Material Required/ Grout (mm3)

Total Material (m3)

Cost of Material

Total cost

1 Grouting 40000.00 20.61

31.74

1 Cement 6.35 310.00 56680.91

2 Sand 25.39 1150.00 29203.87

85884.78

Net Grouting Cost = 85884.78

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55

Annexure - 6 – Labors required to achieve 4 day work cycle in Aluminium Formwork

System and cost calculations

Work to be done in one day:

Total volume of concreting to be done = 15.25 m3

Total volume of Reinforcement to be done = 0.60 tonnes

Total formwork quantity to be done = 257.66 m2

Total grouting quantity to be done = 0.01 m3 Skilled M/C F/C BHISHTI Unit

Worker output for Concreting = 5.00 m3 1.00 2.00 6.00 4.00 Man/day

Worker output for Reinforcement = 1.00 tonnes 15.00 Man/day

Worker output for formwork = 8.00 m2 1.00 Man/day

Worker output for grouting = 0.01 m3 1.00 Man/day

Slab to Slab Work cycle = 4.00 days

Section to Section Work cycle = 2.00 days

Labour Required/ Day

Sr Work to be done Material Skilled M/C F/C BHISHTI

1 15.25 Concreting 3.05 6.10 18.30 12.20

2 0.60 Reinforcement 8.98

3 128.83 Formwork 8.05 24.16

4 0.01 Grouting 1.00

Labour Cost / Day

Sr No Material Skilled M/C F/C BHISHTI TOTAL

1 Concreting 1067.50 1677.50 4941.00 3294.00 10980.00

2 Reinforcement 4844.00 4844.00

3 Formwork 2817.50 6644.00 9461.50

4 Grouting 270.00 270.00

Per day Labour Cost = 25555.50

Per day Labour Cost (5%inc) = 26833.28

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56

Annexure - 7 – Formwork Quantity required for Traditional Formwork System

Length Width Height




Type of Structure - Framed

Structure Bedroom, Kitchen Door - 900 0 2100 mm

Type of Formwork - Traditional Bath, Toilet, WC Door - 750 0 2100 mm

Column Formwork Set Use 3 times Living to Passage Door - 1150 0 2100 mm






Column dimension 900 230 0

Beam dimension 0 230 600 mm

Balcony Beam dimension 700 200 450 mm

Total Formwork Area Requirement

Sr Compone

nt Part of Building Length Width Height

Quantity

Total Area Total Flats


1 Columns Bedroom 900 2300 2 4 16560000 4 66240000

230 2300 2 4 4232000 4 16928000

Kitchen 900 2300 2 1 4140000 4 16560000

230 2300 2 1 1058000 4 4232000

Living Room 900 2300 2 2 8280000 4 33120000

230 2300 2 2 2116000 4 8464000

Staircase Passage 900 2300 2 2 8280000 1 8280000

230 2300 2 2 2116000 1 2116000

2 Beams Vertical Bedroom 3250 230 1 1 747500 4 2990000

2120 600 1 1 1272000 4 5088000

2120 500 1 1 1060000 4 4240000

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57

Vertical Flat to Flat 7600 230 1 1 1748000 2 3496000

7600 600 1 1 4560000 2 9120000

7600 500 1 1 3800000 2 7600000


8335 600 1 1 5001000 2 10002000

8335 500 1 1 4167500 2 8335000


7140 600 1 1 4284000 2 8568000

7140 500 1 1 3570000 2 7140000

Horizontal 5680 230 1 1 1306400 4 5225600

5680 600 1 1 3408000 4 13632000

5680 500 1 1 2840000 4 11360000

Horizontal Bedroom 2250 230 1 2 1035000 4 4140000

2250 600 1 2 2700000 4 10800000

2250 500 1 2 2250000 4 9000000

Horizontal Passage

+ Kitchen 2070 230 1 5 2380500 2 4761000

2070 600 1 5 6210000 2 12420000

2070 500 1 5 5175000 2 10350000

Horizontal Living

Room 2815 230 1 2 1294900 2 2589800

2815 600 1 2 3378000 2 6756000

2815 500 1 2 2815000 2 5630000

2145 230 1 1 493350 2 986700

2145 600 1 1 1287000 2 2574000

2145 500 1 1 1072500 2 2145000

Staircase 2300 230 1 3 1587000 1 1587000

2300 600 1 3 4140000 1 4140000

2300 500 1 3 3450000 1 3450000

3 Slab Bedroom 2790 2920 1 1 8146800 4 32587200

Kitchen 2070 1625 1 1 3363750 4 13455000

Living Room 4805 2815 1 1 13526075 4 54104300

Bath + WC +

Passage 2490 2070 1 1 5154300 4 20617200

Staircase 1265 2300 1 1 2909500 1 2909500

1005 2300 1 1 2311500 1 2311500

4 Staircase Riser 161 1100 9 1 1593900 2 3187800

Mid-Landing 813 2300 1 1 1869900 1 1869900

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Inclined Slab 2446 1100 1 1 2690600 1 2690600

2677 1100 1 1 2944700 1 2944700

5 Chajja Bedroom 1400 450 1 1 630000 4 2520000

Bedroom 1400 100 1 1 140000 4 560000

Bedroom 450 100 2 1 90000 4 360000

Living Room 2200 450 1 1 990000 4 3960000

Living Room 2200 100 1 1 220000 4 880000

Living Room 450 100 2 1 90000 4 360000

Kitchen 3800 450 1 1 1710000 2 3420000

Kitchen 3800 100 1 1 380000 2 760000

Kitchen 450 100 2 1 90000 2 180000

WC + Bath 2070 300 1 1 621000 4 2484000

WC + Bath 2070 100 1 1 207000 4 828000

WC + Bath 300 100 2 1 60000 4 240000

6 Balcony Vertical Beam 3250 200 1 1 650000 4 2600000

3250 450 1 1 1462500 4 5850000

2850 350 1 1 997500 4 3990000

Horizontal Beam 200 700 1 2 280000 4 1120000

700 450 1 2 630000 4 2520000

700 450 1 2 630000 4 2520000

Slab 2850 700 1 1 1995000 4 7980000

Column1 SUMMARY QUANTITY

(m2) 5 % inc

1 Columns 52 55

2 Beams 182 191

3 Slab 126 132

4 Staircase 11 11

5 Chajja 17 17

6 Balcony 27 28

414 434

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Annexure - 8 – Concrete Quantity required for Traditional Formwork System

Lengt

h Width Heig

ht




Type of Structure - Framed

Structure Bedroom, Kitchen Door - 900 0 2100 mm

Type of Formwork - Traditional Bath, Toilet, WC Door - 750 0 2100 mm

Construction time (Months) - 3 Living to Passage Door - 1150 0 2100 mm





Wall thickness - 0 150 0 mm

Column dimension 900 230 0

Beam dimension 0 230 600 mm

Balcony Beam dimension 700 200 450 mm

Total Concrete Requirement

Sr No

Component Part of Building Length

Width

Height Total Volume

Total Flats


1 Columns Bedroom 900 230 2300 4 1904400000 4 7617600000

Kitchen 900 230 2300 1 476100000 4 1904400000

Living Room 900 230 2300 2 952200000 4 3808800000

Staircase Passage 900 230 2300 2 952200000 1 952200000

2 Beams Vertical Bedroom 3250 230 600 1 448500000 4 1794000000




Horizontal 5680 230 600 1 783840000 4 3135360000

Horizontal Bedroom 2250 230 600 2 621000000 4 2484000000

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Horizontal Passage +

Kitchen 2070 230 600 5 1428300000 2 2856600000

Horizontal Living Room 2815 230 600 2 776940000 2 1553880000

2145 230 600 1 296010000 2 592020000

Staircase 2300 230 600 3 952200000 1 952200000

3 Slab Bedroom 2790 2920 100 1 814680000 4 3258720000

Kitchen 2070 1625 100 1 336375000 4 1345500000

Living Room 4805 2815 100 1 1352607500 4 5410430000

Bath + WC + Passage 2490 2070 100 1 515430000 4 2061720000

Staircase 1265 2300 100 1 290950000 1 290950000

1005 2300 100 1 231150000 1 231150000

4 Staircase Steps up 467881 1100 1 1 514669100 1 514669100

Mid-Landing 137250 2300 1 1 315675000 1 315675000

Steps down 484602 1100 1 1 533062200 1 533062200

5 Chajja Bedroom 1400 450 100 1 63000000 4 252000000

Living Room 2200 450 100 1 99000000 4 396000000

Kitchen 3800 450 100 1 171000000 2 342000000

WC + Bath 2070 300 100 1 62100000 4 248400000

6 Balcony Vertical Beam 3250 200 450 1 292500000 4 1170000000

Horizontal Beam 200 700 450 2 126000000 4 504000000

Slab 2850 700 100 1 199500000 4 798000000

Sr no SUMMARY QUANTITY (m3) 5 % Inc.

1 Columns 14 15

2 Beams 20 21

3 Slab 13 13

4 Staircase 1 1

5 Chajja 1 1

6 Balcony 2 3

52 54

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Annexure - 9 – Materials required for concreting in Traditional Formwork System

Assumptions- Materials:

Unit





Bag size = 50.00 kg







So, total volume of dry concrete required = 84.00 m3

Sr Material Material Required (m3) Density of

Material (kg/m3) Material Required

(kg) No. of Bags

1.00 Cement 15.27 1440.00 21992.73 439.85

2.00 Sand 22.91

3.00 Aggregates 45.82 1670.00 76516.36

4.00 Steel 0.84 7850.00 6594.00



2.00 Sand = 22.91 m3

3.00 Aggregates = 45.82 tonnes

4.00 Steel = 6.59 tonnes

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Annexure - 10 – Quantity of Brickwork required in Traditional Formwork System

Total Brickwork Requirement

Sr No

Part of Building Component

Length

Width

Height

Quantity Volume

Total Flats


1 Bed Room Internal Wall 2120 150 2300 2 731400000 4 2925600000

Bed Room Internal Wall 2250 150 2300 2 776250000 4 3105000000

Bed Room Window 1200 150 1200 2 216000000 4 -864000000

Bed Room Door 900 150 2100 1 141750000 4 -567000000

2 Living Room Internal Wall 2815 150 2300 1 485587500 4 1942350000




Living Room Window 2000 150 1200 1 180000000 4 -720000000

Living Room Main Door 1000 150 2100 1 157500000 4 -630000000

Living Room Passage Door 1150 150 2100 1 181125000 4 -724500000

3 Kitchen Internal Wall 1450 150 2300 2 500250000 4 2001000000

Kitchen Internal Wall 2070 150 2300 2 714150000 4 2856600000

Kitchen Window 1200 150 1200 1 108000000 4 -432000000

Kitchen Door 900 150 2100 1 141750000 4 -567000000

4 Bathroom Internal Wall 1500 150 2300 1 258750000 4 1035000000




Bathroom Ventilation 600 150 900 1 40500000 4 -162000000

Bathroom Door 750 150 2100 1 118125000 4 -472500000

5 W.C. Internal Wall 1000 150 2300 1 172500000 4 690000000

W.C. Internal Wall 500 150 2300 1 86250000 4 345000000

W.C. Internal Wall 1000 150 2300 1 172500000 4 690000000

W.C. Internal Wall 870 150 2300 1 150075000 4 600300000

W.C. Internal Wall 1740 150 600 1 78300000 4 313200000

W.C. Ventilation 600 150 900 1 40500000 4 -162000000

6 Passage Internal Wall 1520 150 2300 2 524400000 4 2097600000

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Passage Bed room Door 900 150 2100 1 141750000 4 -567000000

Passage W.C. Door 750 150 2100 1 118125000 4 -472500000

Passage Passage Door 1020 150 2800 1 214200000 4 -856800000




Door 1020 150 2800 1 214200000 4 -856800000

Passage Bath Door 750 150 2100 1 118125000 4 -472500000

8 Floor Passage Internal Wall 2300 150 2300 2 793500000 1 793500000

Floor Passage Internal Wall 5135 150 2300 2 177157500

0 1 1771575000

Floor Passage Main Door 1000 150 2100 1 157500000 4 -630000000

Floor Passage Window 2300 150 1200 1 207000000 4 -828000000

10 External Wall Wall 6254

0 150 2300 1 107881500

00 1 10788150000

External Wall Living Window 2000 150 1200 1 180000000 4 -720000000

External Wall Window 1200 150 1200 3 324000000 4 -1296000000

External Wall Ventilation 600 150 900 2 81000000 4 -324000000

External Wall Staircase 2300 150 1675 1 288937500 1 -288937500

External Wall Staircase Window 2300 150 1200 1 207000000 1 -207000000

Sr no SUMMARY QUANTITY

(m3) 5 % inc

1 Bed Room 5 5

2 Living Room 7 7

3 Kitchen 4 4

4 Bathroom 3 3

5 W.C. 2 3

6 Passage 3 3

7 Floor Passage 1 1

8 External Wall 8 8

32 34

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Annexure - 11 – Quantity of materials required for Brickwork and Plastering in

Traditional Formwork System

Assumed Brick Wastage = 10.00 %

Mortar mixture ( Cement : Sand) = 1.00 4.00

Bricks density = 500.00 pcs/m3

Cost of Brick = 5.00 INR/pc

So, total volume of bricks required = 34.03 m3

BRICKWORK

Sr No Material Material Required Unit

1.00 Cement 80.66 bags

2.00 Sand 10.89 m3

3.00 Bricks 18718.47 pcs



2.00 Sand = 10.89 m3

3.00 Bricks = 18718.47 pcs

INTERNAL PLASTERING



2.00 Sand 43.64 m3

EXTERNAL PLASTERING



2.00 Sand 29.09 m3



2.00 Sand = 72.73 m3

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Annexure - 12 – Consumables required for in Traditional Formwork System and its

cost incurred



1 Nails 0.22 kg/m2 100.00 % per floor 80.00

2 Shuttering Oil 0.06 litres/m2 100.00 % per floor 50.00

Total Formwork quantity = 434.26 m2



Sr No

Material Material Required

Total quantity required

Additional Material/Floor

Total Additional Material

Unit

1 Nails 0.22 93.37 93.37 9336.67 kg/m2

2 Shuttering

Oil 0.06 28.05 28.05 2805.34 litres/m2

So additional cost incurred due to consumables:

Additional Material Cost/Unit Total Cost

1 Nails 9336.67 80.00 746933.25

2 Shuttering Oil 2805.34 50.00 140267.12

3 Grease 0.00 0.00 0.00

8,87,200.36

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Annexure - 13 – Labour required in Traditional Formwork System for 25 days cycle

with one set a time





Total brickwork to be done = 748.74 pcs

Total Plastering to be done =

Skilled M/C F/C BHISHTI

Worker output for Concreting = 5.00 m3 1 2 6 4 man per day

Worker output for Reinforcement = 1.00 tonnes 15 man per day

Worker output for formwork = 5.20 m2 1 man per day

Worker output for brickwork = 500 pcs 1 1 man per day

Slab to Slab Work cycle = 25.00 days


Sr No Work to be done Material Skilled M/C F/C BHISHTI

1 2.17 Concreting 0.43 0.87 2.61 1.74


3 8.69 Formwork 0.84 2.51

4 748.74 Brickwork 1.50 1.50

Labour Cost / Day


1 Concreting 150.50 239.25 704.70 469.80 1564.25


3 Formwork 294.00 690.25 984.25

4 Brickwork 524.12 404.32 928.44


Per day Labour Cost (5%inc) = 5,106.08

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Annexure - 14 – Labour required in Traditional Formwork System for 25 days cycle

with five set a time





Total brickwork to be done = 3743.69 pcs

Skilled M/C F/C BHISHTI

Worker output for Concreting = 5.00 m3 1 2 6 4 man per day

Worker output for Reinforcement = 1.00 tonnes 15 man per day

Worker output for formwork = 5.20 m2 1 man per day

Worker output for brickwork = 500 pcs 1 1 man per day


Sr No Work to be done Material Skilled M/C F/C BHISHTI

1 10.86 Concreting 2.17 4.34 13.03 8.68


3 43.43 Formwork 4.18 12.53

4 3743.69 Brickwork 7.49 7.49

Labour Cost / Day


1 Concreting 759.50 1193.50 3518.10 2343.60 7814.70


3 Formwork 1463.00 3445.75 4908.75

4 Brickwork 2021.59 2021.59 4043.19


Per day Labour Cost (5%inc) = 24,874.12

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Annexure - 15 – Schedule of Rates (2012-13) Applicable for Pune Region by

Maharashtra Jeevan Pradhikaran

Sr. No.

Description Unit Rate (Rs.)

2012-13

MATERIALS

1 Acetylene gas No 506.00

2 Alum Grade-I ( ex-factory ) MT 8000.00

3 Binding wire Kg 57.00

4 Black enamel paint ( anti-corrosive ) Lit 193.00

5 Bricks No 6.90

6 Bullies, struts ( 125 mm dia 1.5 M long ) RMT 194.00

7 C.C.T.W. planks ( 3" x 6" ) Cum 7400.00

8 Cement ( bags ) Bags 310.00

9 Cement ( MT ) MT 6200.00

10 Cement sulphur resistant MT 6840.00

11 Charcoal Kg 33.00

12 Corrosion resistant steel MT 48300.00

13 Diesel Lit 51.75

14 Epoxy paint Kg 435.00

15 Fuse No 25.00

16 Gun powder Kg 132.00

17 Liquid chlorine ( 100 Kg. Dept. container )

No --

18 Liquid chlorine ( 100 Kg. Supplier container )

No --

19 Liquid chlorine ( 900 Kg. Dept. container )

No 16000.00

20 Lubricant oil Lit 230.00

21 M.S. angle ( 50 mm x 50 mm x 6 mm ) Kg 48.30

22 M.S. bars MT 48000.00

23 M.S. bars (in Kgs. ) Kg 48.00

24 M.S. flats ( 40 mm x 3 mm ) Kg 48.30

25 M.S. plate Kg 49.00

26 Mild steel grill ready Kg 70.00

27 Mild steel grill railing MT 70.00

28 Mobile oil Lit 230.00

29 Murum Cum 340.00

30 Nails Kg 74.00

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31 Nut bolts Kg 90.00

32 Oxygen gas ( refill ) Cylndr 345.00

33 Poling boards Cum 20000.00

34 Quarry spalls Cum 200.00

35 R.S. joists, channels, etc. MT 51000.00

36 Rapid sand gravity filter media at source ( Godhra sand )

Cum 1265.00

37 Rapid sand gravity filter gravel at source ( Godhra )

Cum 1265.00

38 Ready mixed lead / zinc paint Lit 231.00

39 Ready mixed oil paint Lit 231.00

40 Ready mixed primer for steel Lit 165.00

41 Rubber gasket ( 6 mm thick ) Kg 99.00

42 Sand Cum 1150.00

43 Godhra sand for mortar lining work @ source

Cum 1265.00

44 Spun yarn Kg 88.00

45 Stone aggregate – 10 mm Cum 900.00



48 Stone at quarry Cum 405.00

49 Structural steel MT 5100.00

50 TCL ( bleaching powder ) Grade - I ( 5 kg pack )

Kg 25.00


Kg 25.00


Kg 25.00

53 Teak wood Cum 69200.00

54 Tor steel MT 48500.00

55 Walling ( 100 mm x 100 mm ) Cum 16500.00

56 Welding rod having weight 5.25 kg Box 1450.00

57 Welding rod having weight 5.25 kg - 4.0 M

Box --

58 White cement Kg 33.00

59 White lead Kg 150.00

60 Wire Kg 71.00

61 Plywood commercial (12 mm thk.

Waterproof for centering )

Sqm 720.00

(Taken in analysis for RCC items only)

LABOUR

1 Assistant fitter No 352.00

2 Bandhani No 351.00

3 Bhisti with pakahal No 267.00

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4 Blacksmith ( IInd class ) No 303.00

5 Breaker No 339.00

6 Carpenter ( Ist class ) No 399.00

7 Carpenter ( IInd class ) No 363.00

8 Chiseller No 339.00

9 Excavator No 303.00

10 Fitter ( Ist class ) No 399.00

11 Glazier No 303.00

12 Helper No 267.00

13 Hole driller No 339.00

14 Mason ( Ist class ) No 436.00

15 Mason ( IInd class ) No 399.00

16 Mazdoor ( female ) No 267.00

17 Mazdoor ( heavy ) No 303.00

18 Mazdoor ( light ) No 267.00

19 Mazdoor ( male ) No 267.00

20 Mistri No 363.00

21 Mukadam No 363.00

22 Painter ( for colouring ) No 333.00

23 Painter No 351.00

24 Polisher No 333.00

25 Pump driver No 339.00

26 Stone cutter or dresser No 399.00

27 Tile layer No 399.00

28 Welder No 399.00

29 Welder for pipeline No 399.00

30 Whitewasher No 333.00

31 Tile turner No 363.00

32 L.M.V. driver No 339.00

33 Electrician No 339.00

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7.REFERENCES

i. Dan Aluform Consultancy Limited (www.danaluform.com)

ii. Building cost comparison between conventional and formwork system by Nuzul

Azam Haron, Salihuddin Hassim, Mohd Razaliabd Kadir, Mohd Saleh Jaafar.

iii. IS 4990:1993 - Indian Standard “Plywood for concrete shuttering work –

Specification (2nd Revision)” published by Bureau of Indian Standards.

iv. Seminar report on “Mivan – A versatile formwork” by Tilak Bhattacharya,

Rajarambapu Institue of Technology.

v. Report on “Aluminium Formwork System – An Introduction” by Prasanth s,

Grand Edifice Developers.

vi. Maharashtra Jeevan Pradhikaran – Schedule of Rates (2012-13) – Pune Region

vii. Book: “The A to Z of Practical Building Construction and its Management” by

Sandeep Mantri

http://www.danaluform.com/

Summer Internship Report

Documents

Transcript of Summer Internship Report