Professional Documents
Culture Documents
Building Structure
Competency Center
PREFACE
Construction industry in India is growing at faster pace
and the Buildings & Factories Operating Company (B&F
OC) is no exception in terms of number, size and volume
of projects. This growth throws challenges in terms of
delivery without compromising on Quality, Safety and
Sustainability. To meet this challenge, human resource is
the prime mover and it is essential to upgrade the skill and
knowledge level of engineers and front line supervisors to
the latest technology that our company adopts to sustain our leadership in the
market.
B&F OCs entire business is grouped into three disciplines namely Structure,
Finishes and MEP. Building Structure Competency Cell (BSCC) of B&F OC
is created to provide total solutions to structure discipline in the areas of
Foundation, Formwork, reinforcement, Concrete and Pre-stressing.
BSCC has come out with a reference hand book on the methods and processes
adopted in construction of structure. I have gone through the book and found
it very useful for site engineers especially in
Understanding the basics
Application in respective field
DOs & DONTs
Specifications & Standards
With this handbook they will be able to largely address the day to day issues
that they face and thereby become self-sufficient.
I am sure that the BSCC site engineers and Supervisors will make use of this
hand book to improve the operational efficiency which should translate into
improved quality at optimum cost.
I appreciate the entire BSCC teams who have put inefforts to make this book
a comprehensive tool.
(A.L.Sekar)
Vice President & Head RBBU.
INDEX
CONTENTS
Page No.
Aluminium Formwork
Introduction
Formwork Drawings
Site will be provided with a set of formwork drawings which entailed the
followings: Shell Plan Layout
Formwork layout drawings,
Wall panel Layout,
Slab Panel Layout,
Starter Block Layout,
Corner Layouts,
Beam Panel Layout,
Soffit Layout,
Staircase Layout,
Bracket and Soldier layout,
Miscellaneous Layout which includes sunken portion, upstand portion
etc,
Elevations and sections drawings indicating the location of formwork
panels and component,
Typical Fixing Detail drawings,
Location of Box outs and Transfer Box out drawings for transfer of
Formwork, etc.
Worksite Management
Logistic
Prior to the arrival of the containers from the disembarking point to the
project work site; a Stock Yard is to be properly allocated and set up for
the unloading of the formwork material and accessories.
This Stock Yard should preferably be located at close proximity or within
the compound of the project work site, properly fenced up and security
6
shall be of up most priority due to the high residue value in the secondary
market for aluminum formwork material.
A Workshop area for maintenance of formwork material is recommended
to be set up at the project site to minimize the downtime in requisition of
replacement panels.
The proposed Stock Yard and Workshop area shall be flexible and readjustable to suit the working environment and project work site. As a
result of the far away Stock Yard or Workshop area the project progress
will affect the targeted construction cycle time. (Ref Layout Drg No.:
)
Upon arrival of formwork panels at Project Site, Site personnel shall ensure
that the panels are stacked and stored according to sizes and marking using
proper separator such as pallets for easy identification and allocation for
subsequent distribution. (Dry Mockup will be assembled as per schemes
at factory; this will eliminate the usual problematic discrepancies of odd
size panels which need to be fabricated at project site).
Manpower
BSCC - HQ shall provide the estimated manpower requirement for the
Project based on the quantity of formwork panels to be supplied to achieve
the required cycle time. This manpower requirement shall vary according
to the size of formwork use on the building.
However, the manpower requirement for other supplementary trades which
complement the formwork installation such as Mechanical & Electrical
(M&E) services and rebar works need to be taken into consideration also.
A joint effort of all operations from formwork installer, rebar, plumbing,
electrical and concreting workers need to be synchronized to achieve the
required cycle time.
Segregation and systematically allocation of duties for each formwork team
are required in ensuring optimization of productivity. Hence, each team
shall be delegated or assigned to do specific job tasks on a daily basis to
resemble a manufacturing production line. However, due consideration
should be used in determining the level of experience and compatibility of
persons when allocating tasks to minimize the risks.
Safety
Control measures should be taken to identify and minimize the hazards
associated with work involving the assembly and dismantling of formwork
equipment such as falls from height, slips, falling objects, noise, dust and
manual tasks.
The external working brackets/platforms or scaffoldings should not be
used to stack materials or equipment. This will lead to the persons working
on it expose to additional hazards in relation to trips and slips or collapse
of the external working brackets / platforms or scaffolding.
Minimize the working heights for persons performing the assembly and
dismantling formwork.
Mixing of formwork components should be avoided to prevent unsafe
installation such as mixing pins and braces which may lead to collapse of
the formwork.
Do not allow drop stripping of formwork as it is an unsafe practice.
Partially assembled or dismantled formwork should be secured during
break time to prevent against overturning or collapsing due to strong wind
or accidentally / unintentionally knock over by workers.
Electrical safety should be implemented for the safe use of electrical
equipment.
Protruding flat ties or projecting nails should be removed immediately
with appropriate tools at dismantling stage.
Use of personal protective equipment by all persons working at work
areas (such as safety hardness, safety helmets, eye protection etc) should
be strictly implemented.
Accessories & Tools
Accessories (10%) extra will be supplied for the assembly and dismantling
of the formwork panels.
Sufficient tools required for assembling and dismantling will also be
supplied as per the attached list.
Assembly Process
Setting Up Level & Marking Of Position
The project surveyor shall mark based on the approved construction drawings
to ensure that the gridline and level of the foundation level is properly set up,
marked for walls, column etc. Leveling must be checked prior to commencement
of formwork installation to ensure accurate positioning.
Formwork Panels
Cleaning of the surface and side panel of the formwork after each usage
shall be done immediately using proper tools.
Ensure that all front and side panel of formwork is properly coated with
recommended Form release agent that prevents from sticking and concrete
buildup aluminium form surfaces. It protects and prolongs the useful lives
of the aluminium formwork.
The following precautions shall be taken when applying the Formoil on
the aluminium panels.
The best results are obtained when a uniform application of Formoil is
applied immediately following stripping and subsequent cleaning of
the panels. Always ensure that the coated form surfaces are allowed
to dry prior to placing concrete.
Do not over apply. Excess Formoil can adversely affect performance
and should be picked up promptly with rags.
Prevent Formoil overspray from contacting reinforcing steel bars and/
or tensioning cables.
Installation Works of Rebar, M&E & Plumbing
The support works such as rebar, Mechanical & Electrical (M&E) and
plumbing are to commence immediately once the set up is done. The
same is to be ensured before installing the Aluminium formwork.
The support works for the slab section commence after the slab formwork
panels are assembled.
Cover Blocks should be fixed on both sides of the rebar section for
positioning and eliminate the rebar from resting on the surface of the
formwork panels.
9
Positioning of outlets for electrical switch boxes to its correct alignment can
be done by riveting the appropriate fit size mould to the formwork panels.
The electrical switch boxes are then securely cap to the fit size mould and
fasten by way of wiring to the formwork panels. Ensure that it is properly
secured to prevent grouting from building up in the switch boxes.
Assembly of Wall Formworks
Always commence wall erection from the external corner of the wall
section to ensure both joint external corner wall panels will support each
other for standing position. Pin and wedges are to be used to secure the
panels together. Always insert the pin from the inside out for easy removal
of pin after concreting.
The formwork panels wall positioning is securely placed on the marked
gridlines and level by way of fixing timber stoppers at the base of the
outer side of the formwork panels at interval of one (1) meter. This would
ensure that the formwork panels are not disposition during the concreting
process.
Once the initial wall corner panels are assembled, place the wall corner
panels on the allotted set up position.
Commence to erect simultaneously the balance of the wall panels from
either side of the external wall panel.
Proceed to assemble the internal wall corner. Place these panels into the
correct position on the lines which were set up by the surveyor. Proceed to
assemble the balance of the internal wall at both sides.
The internal and external walls are to be held together by flat wall tie with
wall tie sleeve and PVC cover. These wall tie sleeve and PVC cover are
to be cut for the exact length of the wall thickness. Flat wall tie are to be
coated with the Form Oil before each usage.
To determine and achieve the vertical accuracy of the formwork panels
assembled before concreting process, several methods such as plumb
bob, spirit level, theodolite equipment etc can be used. The simplified
method of using a plumb bob with a string attached to it which is then
suspended from the upper part of the formwork panels is used as a guide
to determine the deviation from the vertical alignment of the panels.
Additional wall panels or starter blocks (kickers) are fixed on the external
wall panels in accordance to the required height for the formation of the
10
slab concrete. Check to ensure that the verticality of the Starter Blocks
(kickers) is correctly aligned.
The Starter Blocks (kickers) shall remain at its position for the subsequent
forming of next level wall.
Assembly of Beam & Slab Formworks
Fix the slab corner on top of the wall panels with round pins and wedges.
The position of the pins should be from top down to ease the dislodging
process.
The prop length and prop head is to be connected together for beam and
slab support.
Alu span mid beam and Alu span cantilever end beam are connected to
the Slab prop head using Beam Splice Bars. They are connected together
by long pins and wedges at bottom section.
The Aluspan mid beam sections are accurately position to enable the slab
panels to be connected systematically.
Commence to assemble the slab panels from the corner section of the
slab. Subsequently, fixed the whole slab area by pinning the slab panels
together with the Aluspan mid beam.
Assembly of External Working Brackets
External working platform brackets are used to provide a work area at the
external wall section.
Once the first level is completed and external formwork panels are
removed, fix the external working brackets to the first floor level at position
slightly below the kickers which are fixed on first floor external slab.
The external working brackets are secured to the external wall section
from the inside using tie rods, nuts and bolts.
Once all the external working brackets are put in place, timber planks
and strips are placed on the floors and railings respectively to create an
external working platform for the assembly of the subsequent level of the
external formwork panels and kickers.
Another set of external working brackets are later fixed on the subsequent
level using the method as prescribed above.
Once the subsequent level of external formwork panels are fixed, the
11
external working brackets at one level below are removed and moved to
the subsequent level. This process is repeated until the completion of the
subsequent floors.
Identification of Formwork Assembled
A numbering sequence / stenciling shall be given for each panel and is
identified in accordance to unit area such as living rooms, Kitchens, Bed
rooms, bathrooms, common areas etc.
Color identification scheme while numbering on each section or area will
also eliminate the confusion that may arise due to the size. It can be
identified such that Blue is for Room 1, Red is for Room 2, Green is for
Living area etc.,
By practicing the use of numbering system in combination with the color
identification scheme, it have been proven to avoid confusion and assist
in the process of identification of panels position once they are transferred
to the next level/floor.
CONCRETING PROCESS
Pre-Check Before Concreting
Ensure that the position of the walls and column formwork are in
accordance with the set up marking.
Check to ensure correct spacing of props for slab formwork.
Check the verticality and horizontality level of the wall and slab panels
respectively.
Ensure that all pins, wedges and ties are properly secured and tightened.
Re-check the opening such as door and window panels are correct.
Re-check all propping stands to ensure its height are in accordance to
drawings.
Adequate bracing (if necessary) to ensure stability.
Ensure cover blocks are placed correctly.
Monitoring During Concreting Process
Ensure site coordinators are available and on stand-by during the
concreting process.
Always ensure that concrete pouring is distributed evenly throughout the
12
wall sections before commencing to cast the slab level areas. This is to
prevent loading pressure on the formwork panels due to uneven casting.
Recheck the areas whenever cement slurry leakage is noted to determine
the cause of it. Remedy work should be done immediately to ensure the
concreting process is not affected.
During concreting, always ensure that immediate step is taken to remove
/ clean all the excess concrete that is stuck on the back of the formwork
panels. Non removal will result in the formwork panels getting too heavy
and also the scrapping task after the concrete has dried up becomes more
tedious.
13
Dismantling Process
Dismantling of Wall, Column & Beam Formwork
Formwork panels shall be removed without damaging the concrete.
Reinforcement Bars or other tools shall not be used as a lever against the
concrete in removing the formwork panels. Only panel puller shall be
used for removing the wall panels.
The appropriate time for the stripping of formwork panels will vary
according to the environment and type of concrete used. The formwork
panels of the wall, column and beam section can be usually dismantled
after 12 hours. However, this process shall subject to approval of the
project structural engineer after taking into consideration the grade of
concrete used, additional props stand ordered, etc.
lways ensure that the wall section panels are removed first follow by the
A
column and beam sections.
For precautionary step, ensure that formwork panels are removed
systematically and due care is to be taken to prevent any damages to the
formwork panels and also finish surface of the concrete whenever possible.
or safety reason, ensure that no workers are facing the pin and wedges
F
when removing using hammer. Pin and wedges removed are to be
collected and placed in containers to minimize lost and replacement.
he dismantle formwork panels shall be transferred to the next level/floor
T
for subsequent assembly process via the slab opening or staircase areas
in an orderly manner and to the appropriate section/area immediately.
This will eliminate the confusion and congestion in the dismantling area
or level as a result of too many dismantled formwork panels lying on the
floor area.
s the formwork panels are pre-numbered and if color identification
A
scheme is implemented, the transfer of panels can be determined and
planned ahead according to the various sections / areas of one level/floor
to the subsequent level/floor.
lways ensure that all the formwork panels are to be properly cleaned
A
and applied with the Form release agent to protect the surface of the
formworks before re-used.
14
or the external wall section, the Starter Blocks (kickers) on the upper
F
portion of the floor level shall remain intact to support and align the
next level/floor of formwork panels that are going to be assembled.
The assembly of the external formwork panels can be done by using the
external working platforms that are fixed to the wall areas.
Dismantling of Slab Formwork
he appropriate time for the stripping of formwork panels will vary
T
according to the environment and type of concrete used. The formwork
panels of the slabs section are usually dismantled after 36 hours. However,
this process shall subject to approval of the project structural engineer
after taking into consideration the grade of concrete used, additional
props stand ordered, etc.
he Aluspans mid beams / end beams have to be removed first after
T
dismantling the wall panels. Proceed by removing the long pins and
wedges on the joint bars for the end and middle beams. However, the
prop lengths are to remain undisturbed during this process to lend support
for the weight of the concrete slab.
here shall be 2 sets of prop lengths to support the concrete slab. The first
T
set of the prop stands will only be removed when the assembly of the third
level/floor commences and also upon approval and consultation with the
project structural engineer.
roceed to dismantle the slab panels by commencing from the end of the
P
slab area. Once the slab panels are dismantled, continue to remove the
slab corners.
Removal of Flat Wall Tie & Wall Tie Sleeve
Flat wall Ties are used for the purpose of ensuring the thickness of the walls
and column are consistent. Flat wall ties are to be removed by using special
called Wall tie remover / extractor.
Subsequently, proceed to remove the wall tie sleeve which is embedded in the
walls and columns section by using nose player.
15
Assembly Process
Sequence No. 1
Form Release agent (Solvent based) to be applied on the surface of all the
panels before the assembly process.
16
Assembly Process
Sequence No. 2
Outer Corner is fixed to External Wall Corner panel by round pin and
wedge.
17
Assembly Process
Sequence No. 3
Inner Corner is fixed to the Internal Wall panels by round pin & wedge. The
Internal and External Wall Panels are hold by Flat Tie with Tie Bar Shield in
between the panels.
VERTICAL CORNER INTERNAL
18
Assembly Process
Sequence No. 4
Repeat Sequence No. 3 to complete the assembly of both the Internal and
External Wall Panels.
19
Assembly Process
Sequence No. 5
Install Slab Corner on the top portion of the Wall Panels with round pin &
wedge.
20
Assembly Process
Sequence No. 6
Aluspans mid beams / end beams and Prop head are combined by Beam
splice bar with long pin and wedge at the bottom section.
21
Assembly Process
Sequence No. 7
Start the assembly of the Slab Panels from the Slab corner Internal.
Subsequently, fill out the whole slab area by pinning the slab panels together
with the Aluspans (Comprises of Aluspans and cantilevers). Mid Beams / End
Beams
22
Assembly Process
Sequence No. 8
Additional Wall Panels (or Kickers) are fixed to the external Wall Panels to raise
to the appropriate height to contain the slab concrete when it is poured.
ADDITIONAL WALL
PANEL / STARTER
BLOCK
23
Assembly Process
Sequence No. 9
Upon completion of the installation and fixing of the Wall and Slab Panels,
a numbering sequence will be made for each of these panels with colour
identification scheme to differentiate each of the unit area such as bedrooms,
living room, bathroom etc. This numbering and colour identification scheme
will ensure that each panels can be determined as to their exact location once
they are tansferred to the next level for installation.
Sequence No. 10
Always ensure that wall ties, pins and wedges are properly installed and
secured before pouring concrete into the forms. Ensure that concrete pouring
is distribute evenly throughout the Wall Panels section before commencing to
cast the slabs level area.
24
Dismantling Process
Sequence No. 1
After 12 hours, remove the Internal Wall panels by knocking out the wedges
and pins. The Wall Panels are to be moved to upper floor through the slab
opening as shown. The transferring of the panels should be done in a
systematically and orderly manner to ensure that the next cycle or level is not
affected. Since all the panels are numbered with different colour identification
scheme, these transfer process can be determined and planned in advance
according to section of the building such as Room 1, Room 2, Bathroom are
etc.
25
Dismantling Process
Sequence No. 2
After removing the External Wall Forms (the starter Block (kicker) should
remain undisturbed), the dismantled wall forms are moved to upper floor.
Access Scaffolding is use for transferring of external wall panels from the
ground floor level. For level 1 and above, an external working platform is
fixed to the external wall. The external wall forms from level 1onward shall
be supported by the kickers. (These steps are to be repeated from one floor
to another floor.)
Starter Block
Super plate
26
Dismantling Process
Sequence No. 3
After removing the Wall Panels, proceed to the Slab Panels after 36 hours
by removing the long pins and wedges on the joint bars the end and middle
beam section.
27
Dismantling Process
Sequence No. 4
Upon removing the Aluspans Mid Beams and Aluspan cantilevers End Beams,
the prop shall remained undisturbed during this process to support the
concrete slab.
28
Dismantling Process
Sequence No. 5
Proceed to strip the Slab Panels and transfer to the next level according to the
designated area and installation sequence.
29
Dismantling Process
Sequence No. 6
Strip the Slab Corner.
30
Dismantling Process
Sequence No. 7
Pull out Wall flat Tie using Wall Tie puller and remove the Wall tie sleeve using
Nose player.
Sequence No. 8
When the cube tests show that the slab concrete is sufficiently strong, the prop
together with the prop heads are removed and transferred to the next level.
31
1a, 1b, 1c
If not suitable
2a, 2b
3a
If suitable
If not suitable
4a
6
7
7a
8
If work front is not ready
12
10
11
13
14
23
15a
15
16a
16
19
22
21
17
20
32
18
Slipform
Introduction
Slipform has been accepted as a precise construction technique within a
comparatively short period of time an indication of its considerable popularity.
This popularity has in turn encouraged further research ensuring the adoption
of new methods and modern materials, which have firmly established
slipforming as an economical, rapid and accurate form of construction.
Now that it is properly developed, the technique can be applied to many
different forms of structure, including tapering formations with straight
or parabolic profiles incorporating constant reductions in wall thickness.
Traditional applications for slipforming are silos, chimneys, bridge piers,
water towers, special application like construction of pylons, lift core wall of
building, lining for tunnel shaft, framed structures etc.,
Principles of Slipform
Slipform construction, also referred to as sliding form construction, is similar
to an extrusion process. Plastic concrete is placed in the forms, and the forms
act as moving die to shape the concrete. Once the form has been filled with
fresh concrete and hardening has started the form is gradually raised by the
lifting devices on which it is suspended. The rate of movement of the form
is regulated, so that the forms leave the concrete after it is strong enough to
retain its shape while supporting its own weight. Pouring of concrete, tying of
reinforcement, fixing of openings/inserts etc are performed gradually from a
working platform.
An average sliding speed of 200mm an hour is common, rising to 300mm
an hour under the best conditions and 100 to 150mm an hour when large or
complicated structures are being slipformed.
Design Considerations:
The slipform should be designed so that the loads to which its various
component parts are subjected are uniformly distributed, and the yokes are
loaded as uniformly and axially as possible to avoid their overturning. The
jacks should not be located in wall openings as for as possible. The loading
should not exceed the lifting capacity of the jacks. The loads acting on slipform
can be classified as follows,
34
BASIC LOADS
Dead load due to the components
Live loads due to Concrete
Friction between form and concrete
Workmen
Materials
Machinery
Other installations
Auxiliary load due to the way of application of live loads,
Crowds of workmen
Piles of materials
Shocks produced by material unloading
Accidental Loads
Wind pressure
Adhesion between concrete and form due to long interruption.
Friction due to incorrect position of form
Failure of one jack
Extraordinary Loads
Breaking of certain members of the slipform
Failure of two adjacent jacks
Minimum concrete strength required for slipform application,
2
35
Type of Slipform
The slipform can be broadly classified into,
Straight slipform.
Tapering slipform.
Slipform for special applications
Typical structures that are constructed using straight slipform technique are,
Silos
Cylindrical chimneys
Water tank shafts
Columns
Typical structures that are constructed using Tapering slipform are,
Conical chimneys
Ventilation stack
Tapered bridge piers
Typical structures that are constructed using Special slipform are,
Lift cores
Framed structures
Preheater building
RCC Pylons
Construction of block of flats, lifts and stair- well, bridge piers, preheater and
RCC pylons for boiler supporting structure using slipform techniques comes
under special applications because of their complex sizes, shapes and loads
to be lifted along with slipform, like walkway trusses, etc. which is essential
for construction.
Assembly Procedures
Stright Slipform
Position the vertical and horizontal reinforcement with correct cover.
Casting of the starter. (min: 150 - 200mm)
36
Tapering Slipform
Position the vertical and horizontal reinforcement with correct cover.
asting the starter. (Provide pocket or pipe sleeve in yoke locations to
C
accommodate tapered sleeves )
heck starter for the correctness in inclination level and diameter. Chip
C
and finish the same, if required.
rect central tower using L&T HDT system and fix planks on the top after
E
aligning the top construction accurately.
Fix the centre frames with the help of scaffold pipes, if required.
re assemble the trusses and spiders after marking the location of inside
P
yoke leg, assemble with yoke legs, yoke beams, adjusting screws as per
initial setting diagram , erect them and provide support.
Check the level of truss.
ark the position of inside and outside yokes in the starter starting from
M
the tower location.
ssemble the panels along with
A
condition.
ix top and bottom waler. Fix external supports both horizontal and inclined
F
to align the shutter.
ix inside and outside consoles and upper outside console and fix
F
planks.
Fix the yoke beams at top & bottom.
Check the level of yoke beams with spirit levels.
Fix the top platform pipes with guard railings.
Fix the jacks & turnbuckle jacks and finish the hydraulic connections.
Test for leakage in the line and jacks and replace, if required.
Fix water level tubes & check the platform level. Adjust if required.
Check the the final adjustment as per the initial setting diagram.
Fix the handrails.
Fix the tapered sleeves & jack rods.
nergise the slipform before filling the form and removing temporary
E
supports.
38
tart the concreting after completion of all activities and checking the
S
availability of all materials as given in the planning for slipform.
Fix the inside and outside hanging scaffold and do the decking.
Tie the safety net.
2.
3.
4.
5.
6.
7.
8.
9.
Dismantling Procedure
Stright Slipform:
1.
2.
Fix dismantling brackets, handrails, finish planking and transfer the load
of slipform assembly to the brackets.
3.
Remove the flying tie rod assembly and lower the same.
4.
Remove the inside and outside hanging scaffold and shift the planks to
the staging brackets.
5.
6.
7.
8.
9.
yoke beams
2.
3.
4.
Transfer the load of slipform assembly and main truss to the wall.
5.
Remove & re-fix the safety net with the temporary platform.
6.
7.
8.
9.
42
Summary of Labour
Productivity Norms
Sl.
No.
Type of Work
Unit
Norms
In M.Hrs
RM
32
RM
15
RM
16
RM
YOKE SET
75
YOKE SET
55
M2
1.22
YOKE SET
92
22
10
M3
15
11
M3
25
12
MT
65
13
RM
0.34
14
MT
56
15
MT
49
16
MT
49
17
MT
46
18
MT
78
19
YOKE SET
90
20
2.45
21
MT
90
22
Erection of R.G.Hoist
NOS.
827
23
Re-Location of R.G.Hoist
NOS.
1365
24
Dismantling of R.G.Hoist
NOS.
675
25
MT
170
Note: The productivity norms will vary based on volume of work involved and number
of structures to be constructed in the project.
43
Slipform Planning
The execution of slipform job requires a complete and detailed preparation
as many simultaneous and successive operations are involved. The method
of construction, preparation of scheme drgs., calculating the requirement of
slipform materials, equipment, tools & tackles, consumable, manpower etc
needs thorough planning.
It also involve mix design, admixtures to be added for the concrete,
reinforcement around openings and planning for other related works on the
slipformed structure.
Straight Slipform
On large site with several structures built with the same slipform, planning
includes
Work below slip form level
Detailed programme for the wall
Work involved in intermediate floors, if any.
Embedment/ pockets and other installations during slipform
Slipform Materials
The number of yokes for each silo is calculated based on the diameter of the
silo. The yoke to yoke distance is normally kept between 1.25 and 1.35 m.
Once the number of yokes required is calculated the list of materials can be
prepared from the master list. The requirement of jack rods depends on the
height of structure. Always keep 5% extra material as spare.
The length of yoke beams = Wall thickness + 1000 mm.
Normally 2Nos. Yoke beams at the bottom and 1 at the top are fixed.
Wherever yokes are used for supporting some lifting arrangements, there the
top yoke beams also shall be 2 no back to back.
Slipform Equipment:
The capacity of Jacks to be deployed is depends on the following loads:
Basic Loads:
Dead weight of yokes,
44
=X
Live Loads
Live load over platform @ 200kg/sqm
Weight of Concrete 0.5 cum
Weight of Steel (reinforcement, jack rod stacked on platform)
Weight of Equipment
Total Live load
L = (X+Y+Z) * t
Concrete Equipment
The quantity of concrete required per meter height should be calculated
first. The slipping speed can be assumed based on the quantity of concrete ,
reinforcement, pre-stressing and other related items. Rate of rise depends on
the above and setting time of concrete. Once the slipping speed is assumed
the concrete requirement per shift can be calculated.
Once the quantity per shift is known, with 25% spare capacity, the size and
number of mixing and lifting equipment shall be decided.
Consumable:
The standard list of consumable is given along with master material list. The
quantity of electrodes, gas, grease, oil etc. can be given approximately. The
45
Timber Requirement
The requirement of timber is for the following areas.
1) Working platform
2) Masons platform
Working Platforms
Timber platform consisting of four parts
a) Supporting runners 5x 3x7 long & 6 long
b) Wooden planks 6 x 1 x 6 long.
c) Toe board
size: 4 x 1 x 6 long
Manpower Requirement:
The requirement of labour for various activities can be calculated based on the
productivity norms, site conditions and type of structure.It is preferable to engage
one single agency for the entire slipform works in a project to have better control
over productivity and also optimum use of workmen with multi skill.
46
Tunnel Form
Description of Half Tunnel Form
47
48
49
50
51
52
53
54
55
56
57
Movement of Formwork
58
Movement of Formwork
Movement of Formwork
Movement of Formwork
59
60
Kickers
61
62
Ties
63
Protection Platforms
64
65
66
Aluminium formwork
Refurbishment
A) Process involved
a) Manual cleaning
A working table to be made and the Concrete lumps, dirt shall be cleaned by
the scrapper and wire brush.
67
68
d) Welding
69
Safety items
Hand gloves
Nose mask
Ear plug / ear muff
Apron
Goggles white
70
Plywood
Plywood is an important commodity which plays a key role in the formwork
both in terms of quality and cost (10-13% of formwork cost). The finish of
the concrete surface where plywood is used as sheathing members is purely
dependent on the quality of the plywood. Plywood is a manufactured wood
made up of thin sheets of woods and compressed together with a glue which
gives higher strength when compared to a normal wood.
Indian government has put stringent rules for cutting of wood which has
initiated the local ply manufactures to import the logs (poplar and birch wood)
from various foreign countries for the production of plywood. The performance
of the plywood (for formwork application) is mainly based on the glue which
they use for binding (mostly wood species used by all the manufactures are
common).
Plywood shall be tested at site premises before accepting. The testing facilities
are established in all major projects. Incase if the same is not available
respective site representative can contact the Cluster BSCC in charge for
extending the support.
Plywood procurement is centralized in order to deliver a quality product to the
projects at a competitive rate.
Plywood request format shall be filled and sent to the respective cluster BSCC
in-charge for clearing the procurement. Cluster BSCC in-charge will in turn
take concurrence from Head BSCC.
Now about 60 to 70% of the plywood requirements for the projects are serviced
from china and the following
are the details pertaining to the
same
Item Code 765610020
Repetitions 8 to 10
Price approx 20% cheaper
than domestic ply
Delivery period 60 to 65 days
71
72
Its a management decision that apart from these solvet based form release
agent other products cannot be used until unless it is approved by Cluster /
HQ BSCC.
73
Formwork Lift
A system which complements the ability of Table form to do faster construction.
It is turning out to be one of the most important equipments which will be
extremely useful in improving the functional aspect of L&Ts trademark Table
form System. Till now, our Table form System was totally dependent on Crane,
especially while shifting the Table vertically from one Floor to the next. RCS
would not only help in drastically reducing this dependability on Crane but
also have a positive impact on the Labour Productivity subsequently helping in
reduction of Cycle time. Though the system was procured from the formwork
supplier the self climbing equipment was indigenously developed by BSCCHQ which further eliminated the crane requirement for floor to floor shifting
of RCS.
A project site will be debited with a internal hire charges of ` / Month
Cycle time
Labour Productivity -
74
75
76
2.
3.
4.
5.
6.
7.
8.
9.
10. Maintain close interaction with stores and site people for proper
accounting of materials
11. Despatch and receipt notes to be sent to Cluster Office
12. Making of purchase requisition for Plywood and Timber after thoroughly
analyzing the number of repetitions
13. Receipts of plywood / formwork materials to be acknowledged after
quality checks to Cluster Office on monthly basis
14. 100% materials reconciliation at the end of the job
15. Looking after pre-despatch maintenance
77
2.
Small items have to be issued to the sub contractors from stores and
make them responsible for those items. For their sake, tool box can be
issued. These items have to reconcile after the completion of the job.
3.
Proper usage of the formwork materials and avoid the misuse (using
bracing as leverage) of the same.
4.
5.
6.
7.
8.
9.
78
Easy to assemble
79
2. While lowering the materials from ground level to down level additional
care has to be taken
2.Wall/Column formwork
Functions/Salient features
1. System can be done by Crane and Manual
2. Using standard component wide range of plan configurations are
possible
3. High strength tie system bear large concrete pressure and avoid load
bearing struts
4. Provisions for fixing scaffolding platform and alignment units built-in
5. Offsetseliminated producing good concrete finish
Sequences of assembly
1. Materials stocking near to layout
2. Cleaning and oiling
3. Layout marking/starter casting and layout checking
4. Panel positioning
5. Accessories fixing and alignment
6. Line, level and verticality checking
7. Concreting
8. Deshuttering
Safety appliances required
1. Safety helmet
2. Safety belt
3. Safetynet for taller structures
80
4. Manila rope 20 mm or 25 mm
Safety precautions
Crane operation
1. Sling capacity and quality of sling has to be checked
2. D Shackle capacity has to be checked
3. Experienced signal man has to be engaged for propersignaling to the
crane operator
4. Ensure that there is no loose material on the panels or platforms
5. Before lifting the panel, necessary pre checking has to be done on the
panels.
Manual operation
1. Use the necessary personal protection appliances such as helmet and
belt.
2. Use the proper tool for adjusting the panel height and line
3. Flex system
Functions/Salient features
1. System can be used up to floor height of 4.40 mtr.
2. Removable folding tripods make selected individual props self
-standing
3. Flexibility in adjusting the individual prop height and spacing between
props
4. Components are easy to handle manually
5. Steel members can also be used for decking
7. Eliminating the skilled labour at site
81
Sequences of assembly
1. Materials stocking near to layout
2. Prop layout marking
3. Main Prop positioning with tripod
4. Intermediate props positioning with supporting head
5. Placing of fourway head, primary layer beam and secondary layer
beam
6. Levelingof beams with the help of props
7. Placing of plywood.
8. Levelling of seathing and checking
9. Cleaning and oiling
10. Concreting
11. Dismantling
12. Cleaning
13. Transporting and stocking
Safety appliances required
1.
Safety helmet
2.
Safety belt
3.
4.
Safety precautions
1.
2.
82
3.
4.
2.
3.
4.
5.
Sequences of assembly
1.
2.
3.
4.
5.
6.
Levelling of beams
7.
Placing of bottom/sheathing
8.
Leveling of bottm/sheathing
9.
Safety helmet
2.
Safety belt
3.
4.
Safety precautions
1.
2.
3.
4.
5. Stair tower
Functions/Salient features
1.
Safe and convenient access up to 100 mtr height in the form of stair with
suitablebracing with bracing with permanent structures every 6 mtr
2.
3.
84
Sequences of assembly
1.
2.
3.
Frame fixing with necessary accessories at bottom with foot plate , spring
locking pin and tower spindle
4.
5.
6.
7.
8.
Dismantling
9.
Cleaning
Safety helmet
2.
Safety belt
3.
4.
Safety precautions
1.
2.
3.
4.
Do not use coir string or binding wire in place of M 10 bolt and nut with
grid iron
5.
6. Access scaffolding
Functions/Salient features
1.
2.
3.
This provides free movement for workmen without any obstuction at all
levels
4.
Sequences of assembly
1.
2.
3.
4.
5.
6.
7.
8.
Dismantling
9.
Cleaning
Safety helmet
2.
Safety belt
86
3.
4.
Safety precautions
1.
2.
3.
4.
5.
Provides a platform for shutter and workmen inside the closed area of
liftwell and a deshuttering mechanism for stripping of formwork without
dismantling the panels and seathing
2.
3.
Sequences of assembly
1.
2.
Erect the platform in the pocket loations in the inside wall face with
climbing pawl arrangements
3.
Level the platform with the help of bolt given in the climbing pawl
4.
Erection of inner wall panels with the necessary accessories including tie
arrangements
87
5.
6.
7.
Concreting
8.
9.
Safety helmet
2.
Safety belt
3.
4.
Safety precautions
1.
2.
2.
3.
High grade 15 mm thick film coated sheathing for high wear resistance
4.
5.
6.
7.
Sequences of assembly
1.
2.
3.
4.
Concreting
5.
6.
7.
8.
Safety helmet
2.
Safety belt
3.
Safety precautions
1.
Provide the tierod only where the given the provision is given
2.
3.
9.Climbing formwork
Functions/Salient features
1.
2.
3.
4.
5.
6.
Safety helmet
2.
Safety belt
3.
Safety precautions
1.
Platform timbers should be free from cracks ,fungus attack and dead
knots
2.
3.
4.
5.
90
REINFORCEMENT WORKS
Category of Reinforcements
Carbon steel bars (plain and deformed).
Cold reduced plain and deformed steel wire fabric.
Stainless steel bars and fabric.
Galvanized carbon steel bars and fabric.
Epoxy coated carbon steel bars.
Fiber Reinforced Polymer (FRP) rebar- [Non steel reinforcement]
Reference Indian Standards:
IS 1786 - 2008 - Specification for High Strength Deformed bar and Wires
for Concrete Reinforcement.
IS 432 PART 1- 1982 - Specification for Mild steel and Medium tensile
steel bars and hard drawn steel wire for concrete reinforcement
IS 432 PART 2 -1982-Specification for Mild steel and Medium tensile steel
bars and hard drawn steel wire for concrete reinforcement.
IS 2502 -1963 - Code of practice for Bending and Fixing Bars for Concrete
Reinforcement.
SP 34 -1987 Hand book on Concrete Reinforcement and Detailing
Reference International Standards.
BS 4449 Carbon steel bars for concrete.
BS 7295 Fusion bonded epoxy coated steel
BS6744 Stainless steel
BS 4483 Steel fabric
BS 4482 Hard drawn wire
BS 8666 Scheduling dimensioning, bending and cutting of steel
reinforcement for concrete - Specification
ASTM A 615 for carbon steel rebar.
ASTM A 706 for seismic rebar.
ASTM A 955 for stainless steel rebar.
ACI 440 for FRP bars
DIN 488 Reinforcing steels
91
REBAR TYPE
Bar Diameter,
d 25mm
k
Value
Hook
Bar Diameter,
d > 25mm
Bend
k
Value
Hook
Bend
Mild Steel
9d
5d
11d
5.5d
11d
5.5d
13d
6d
13d
6d
17d
7d
Note:
92
Mild Steel
Min
Rec
om
md.
75
Medium
Tensile
Steel
Min
Rec
om
md.
75
75
75
10
Min
Rec
om
md.
75
75
90
90
12
110
16
Mild Steel
Min
Rec
om
md.
75
75
105
110
130
145
20
180
22
Medium
Tensile
Steel
Cold
Worked
Steel
Min
Rec
om
md.
Min
Rec
om
md.
75
75
75
75
75
75
75
75
130
75
75
75
155
75
75
75
175
210
80
90
95
220
260
100
110
120
200
240
285
110
120
130
25
225
275
325
125
140
150
28
250 310 310 365 365 475 146 155 155 170 170 195
32
290 350 350 415 415 545 160 175 175 190 190 225
36
325 395 395 470 470 610 180 200 200 215 215 250
40
360 440 440 520 520 680 200 220 220 240 240 280
45
405 495 495 585 585 765 225 250 250 270 270 315
50
450 550 550 650 650 850 250 275 275 300 300 350
93
:
:
DESCRIPTION OF WORK
DRG.REF .
:
:
MEMBER
BAR
NO.
DIA. OF
BAR
NO.PER
MEMBER
NO.OF
MEMBER
TOTAL
No. OF
BARS
CUT
LENGTH
DATE
TIME
:
NET
LENGTH
SHAPE
TOTAL Wt.
REMARKS :
SITE ENGINEER
REINFORCEMENT ENGINEER
94
CLIENT
95
96
97
Bending Former
Minimum dia. (mm).
[As per IS 2502-1963]
for cold worked steel.
Bending Former
Minimum dia. (mm).
[As per BS-8666-2005]
48 (8d)
24 (4d)
64(8d)
32(4d)
10
80 (8d)
40 (4d)
12
96 (8d)
48 (4d)
16
128 (8d)
64 (4d)
20
160 (8d)
140 (7d)
25
200 (8d)
175 (7d)
28
336 (12d )
196 ( 7d)
32
384 (12d)
224 (7d)
40
480 (12 d)
280 (7d)
50
600 (12 d)
350 (7d)
98
CROSS-SECTIONAL
AREA (Sq mm)
12.6
0.099
19.6
0.154
28.3
0.222
38.5
0.302
50.3
0.395
10
78.6
0.617
12
113.1
0.888
16
201.2
1.58
18
254.6
2.00
20
314.3
2.47
22
380.3
2.98
25
491.1
3.85
28
616
4.83
32
804.6
6.31
36
1018.3
7.99
40
1257.2
9.86
45
1591.1
12.50
50
1964.3
15.42
99
CHECKS
During procurement of Rebar
Check the brand isapproved or not.
Check Grade of reinforcement
Check the Quantity requirement and duration
If new vendor collect sample and check for conformity
On receipt at site
S
tack various diameter bars separately over wooden sleepers ( avoid
contact with soil)
Identify the stack with a tag number
Collect sample for test
inding Wires for tying rebar should be as per Technical specification /
B
BOQ [black soft annealed wire or GI wire of 16 gauge (1.6mm dia.)]
Rebar Stacking
100
TESTING OF REBAR
Sample collection
S
amples of 1 m length (quantity as per below table) taken randomly
per lot for each diameter.
Breaking of bars :
If rebars breaks during bending then check the carbon content of the lot.
Ensure bars of 25mm and above are free from cracking while bending 90
deg . If observed then straighten the bars again to know they are not
breaking. Collect samples and send for chemical analysis. Mark and identify
the lot till results available and lot is cleared of doubt.
Sample Testing on receipt at site
Samples of rebars collected from the lots received at site 2 sets of samples ( 3
specimens each) for 100 MT per Lot or Heat number and tested for mechanical
properties as above. If one sample fails to meet the requirement 2 additional samples
to be collected from the same lot and tested for conformity. If one specimen fails to
meet the physical requirement of Table 3 IS 1786 the whole lot is rejected.
Cover blocks
Cover blocks used shall be of same grade of concrete or made up of PVC
101
For Bend and Rebend test there should be not any rupture or cracks visible
in the bent portion.
If any one of the test sample fails then collect 2 more sample of 3 Nos
each.
If any one sample fails LOT REJECTED.
103
Mild
20
Moderate
30
Severe
45
Very Severe
50
Extreme
75
Note:
main reinforcement up to 12mm dia bar for mid exposure the nominal cover
For
may be reduced upto 5mm.
nless specified otherwise, actual cover should not deviate from the required
U
nominal cover by +10mm
F or exposure condition severe & very severe ,reduction of 5mm may be made,
where concrete grade is M35 and above.
TIPS ON COVER:
DESCRIPTION
In no Case
Column
Bar
NOMINAL COVER
Less than Dia of Bar
Longitudinal
Minimum Cover is 50 mm
TOLERANCE OF COVER
+10 mm
-0mm
ACTUAL COVER =
OF NOMINAL COVER
104
Photographs
Plain Rebars
Deformed Rebars
106
107
FRP Rebar
108
Pre-fabricated cages
109
Splicing Methods
Lap Splicing
Welding
Mechanical Coupler
Precautions:
plicing should not be done at the area where the max. Bending moment
S
is more than 50% of moment resistance.
L ap splicing is not permitted for reinforcing bar > 32mm. (Clause
26.2.5.1(A), is 456 -2000 amendment 3).
Bars >32mm shall be welded or mechanically spliced.
hen two different dia. Bars is to be spliced, then the lap length calculation
W
is to be made on basis of smaller dia rod.
SPLICE-STRENGTH:
Description
Compression
Tension
Welded splice
Mechanical splice
Reinforcment couplers:
Classification according to IS Code (Draft):
Class L +H
Class L.
Different mechanical splicing systems based on type of reinforcment
coupler used:
Threaded couplers
Parallel threaded couplers
Tapered threaded couplers
Upset parallel threaded couplers
Coupler with crimped sleeve
110
111
112
113
Crown Tie:
The crown tie, again a most secure
tie, and is used in much same way
as the hairpin tie.
It has one further use that it can
be used to tighten bars together
that have a tendency to spring.
Splice Tie:
The splice tie, is used exactly as
the name indicates for joining
laps of splices in bars.
It is in fact, exactly the same as the
crown tie. And as the same useful
qualities
114
Welding of Reinforcments:
References Standards:
IS 9417-1989
SP-34(S&T)-1987
Lap Welding
Rebar Dia. Vs Electrode size
Sl.No.
NOMINAL BAR
DIAMETER (mm)
SIZE OF ELECTRODE,
MAX (mm)
Up to and including 10 mm
2.50
3.15
4.00
Over 28 mm
5.00
115
117
118
Piling Works
119
What is a Pile?
Pile is a conduit through which load from the structure is transferred to soil
either by friction or by bearing or by both.
CLASSIFICATION
Concrete
Bored cast-in-situ piles
Driven cast- in-situ piles
Driven precast piles
Steel piles
120
FACTOR
BORED CAST
INSITU
DRIVEN PRECAST
TECHNICAL CONSIDERATIONS
I
PILE HEAVE
OCCURS
OCCURS
CAN OCCUR
CAN OCCUR
CANNOT BE CORRECTED
DOES NOT OCCUR
CAN OCCUR
CANNOT BE CORRECTED
DOES NOT OCCUR
OCCURS IMPROVES
SHEAR STRENGTH
WILL FORM RESULTS IN
WASHING OF CEMENT
SLURRY AND WASHING
OF PILE SHAFT
OCCURS IMPROVES
SHEAR STRENGTH
WILL FORM NO AFTER
EFFECT
UNAFFECTED
NOT APPLICABLE
BOUND TO GET
SEGREGATED .QUALITY
CANNOT BE GURANTEED
QUALITY CAN BE
GURANTEED
CAN BE AFFECTED
NO EFFECT PROTECTIVE
COAT CAN BE APPLIED
d
e
g
h
STRUCTURAL INTEGRITY
DUE TO TEMPORARY
CASING
QULAITY OF CONCRETING
II
III
CORROSION DUE TO
SULPHATE AND
CHLORIDES
122
SL.No.
FACTOR
BORED CAST
INSITU
DRIVEN PRECAST
IV
CANNOT
OVERCOME.NET
PILE CAPACITY
REDUCES.
CANNOT
OVERCOME.NET PILE
CAPACITY REDUCES.
ADDITIONAL
REINFORCMENT
TO BE PROVIDED
WHICH MAY
CREATE PROBLEM
WHILE
CONCRETING
MAXIMUM RAKE
1H :8V
LONGER
ADDITIONAL
REINFORCMENT TO BE
PROVIDED. THIS MAY
HINDER CONCRETING
CAN BE EFFECTIVELY
REDUCED TO A VERY
LOW VALUE AT
MINIMUM COST BY
PROVIDING
BITUMINUOS COATING
SINCE CONCRETEIMG IS
DONE IN CASTING YARD
,ADDL REINFORCMENT
WILL NOT CREATE
PRBLEM FOR
CONCRETING.
SHORTER
VI
LENGTH OF PILE
MAXIMUM RAKE
1H :4V
SHORTER
PRACTICAL CONSIDERATIONS
1
N.A
N.A
CAN OCCUR.BUT
PRECAUTIONS
AND SUPERVISION
CAN MINIMISE
THE PROBLEM.
N.A
ACCURACY IN:
a) VERTICAL
b) RAKER
ACCURATE
NOT TOO
ACCURATE
ACCURATE
ACCURATE
N.A
MOBILISATION
OPERATOR SKILLS
1 MONTH
EXPERIENCED
OPERATOR &
CLOSE
SUPERVISION
1 MONTH
EXPERIENCED OPERATOR
& CLOSE SUPERVISION
1 MONTH
PARTICULAR SKILLS NOT
NECESSARY.
CONSTRUCTION METHOD
& SPEED
RATHER SLOW
MEDIUM SPEED
FASTEST
LENGTH OF PILE
MOST FLEXIBLE
FLEXIBLE
FLEXIBLE
123
SL.No.
FACTOR
BORED CAST
INSITU
DRIVEN PRECAST
GESTATION TIME
A
B
SITE CONGESTION
GROUND CONDITION
FLEXIBLE
DRY & LEVEL GROUND
ESSENTIAL
ENVIRONMENTAL
CLEAN
CLEAN
NOISE LEVEL
NOT LIKELY
PREFERABLY DRY
& LEVEL ABOVE
WATER TABLE
MESSY DUE TO
BENTONITE
LOW
HIGH
(EAR PLUGS/EAR MUFFS
IS MUST)
CAN OCCUR BUT CAN BE
REMIDED BY REDRIVING.
HIGH
(EAR PLUGS/EAR MUFFS
IS MUST)
CAN OCCUR
DIFFICULT TO DRIVE
LARGE DIA > 600 MM
DIA
LENGTH
GENERALLY LIMITED TO
20-22 M.GREATER
LENGTH CAN BE
ACHIEVED BY JOINED
SECTION.
COSTLIEST
NORMAL
SIMPLE/
SOPHISTICATED
ONLY CIRCULAR.
DIFFICULT TO
CONCRETE LESS
THAN 400 MM DIA
ANY LENGTH
COMMERCIAL CONSIDERATIONS
1
2
3
TOTAL COST
LEAST
INFRASTRUCTURES AT SITE NORMAL
EQUIPMENT
SIMPLE/
SOPHISTICATED
124
125
126
127
128
129
131
I nsert Tremie pipe to the required length leaving a gap of 100mm from
pile toe level and Record.
remie pipe diameter should be >200 mm for concrete mix having 20mm
T
size aggregates.
Check the Capacity of Concrete Hopper.
tart concrete operation after flushing and after checking the specific
S
gravity of slurry.
eep the concrete slump between 150mm and 180 mm. Grade of
K
concrete as per approved Mix Design.
remie pipe should be always 2 to 3 m inside the concrete during concreting
T
operation
hile removal of Tremie shake the same to ensure proper compaction
W
of concrete , ensuring that the Tremie pipe does not leave the concrete
surface
Maintain the Record of Tremie Removal during operation.
he concrete pressure > overburden pressure always during concreting
T
with Tremie.
All concrete operation should be completed within six hours.
ackfill the Empty bore if any(unconcreted top portion, i.e., from COLto
B
EGL) of the pile with sand or with approved materials.
Muck shall be disposed at designated area/dump yard.
DRIVEN PRECAST PILES
Prepare a neat leveled casting bed free from undulations.
Check the alignment during and after casting the piles.
The pile shoe should be properly aligned during casting.
Lifting hooks should be properly positioned.
nsure concrete has flown inside and well compacted near pile shoe and
E
end points.
se Concrete(grade as specified in GFC drawing) with a slump of 80 to
U
130mm for casting
132
heck whether the precast piles have attained the required strength before
C
lifting it.
Lift the pile with Lifting arrangements (Strand back)
Cross check the location of piles with reference points.
Check for verticality during driving.
Take extra precaution for splice joints.
ile driving sequence should be properly followed. Pile driving shall be
P
from Centre towards outside or from one end to other end in a pile
group.
Use stress band at the top of the pile during pile driving.
If the precast pile length exceeds 22m length, then joints are required
MALE JOINT
FEMALE JOINT
133
Test load = 2.5 times of design load Test load = 1.5 times of design load
or upto failure whichever is earlier.
or 12mm whichever is earlier
Load test will be carried on Initial Load test will be conducted on
test piles seperately casted especially working piles. The quantity will be
during beginning of project.
generally 1.5% to 2% of total number
of piles.
Type of Arrangements:
entledge Method (Placing of Concrete blocks or Sandbags over
K
platform)
Anchor Method
By Rock anchors.
By Anchor piles.
134
135
136
137
138
139
Good Pile
Defective Pile
140
141
O-CELL TEST :
142
143
144
1.
Cement
b)
c)
d)
e)
f)
g)
h)
i)
j)
Other combinations of Portland cement with mineral admixtures like Fly ash,
Silica fume, Rice husk ash, Metakaoline and GGBFS of quality confirming
with relevant Indian standards may also be used in the manufacture of
concrete provided that there are satisfactory data on their suitability, such as
performance test on concrete containing them.
Low heat Portland cement confirming to IS 12600 shall be used with adequate
precautions with regard to removal of formwork, etc, Highalumina cement
confirming to IS 6452 and Supersulphated cement confirming to IS 6909
may be used under special circumstances with prior approval of Engineer-incharge. Specialist literature may be consulted for guidance regarding the use
of these types of cements.
145
When the cement has ISI Certification mark, or when it comes with
manufactures certificate, no further testing is usually required.
b)
If clients still insist, one sample for every 250 tonnes or batch of cement
may be tested for physical properties or sent for testing to an external
agency.
c)
Take the samples within one week from receipt of cement and arrange
to test within one week from the date of sampling.
d)
Send the sample for testing atleast 10 days before the cement is to be
used.
e)
False set : Concrete may stiffen too early say with 5 to 20 minutes
after mixing. This problem arises because of inadequate cooling during
grinding of cement or because cement is fresh and hot from the mill. If
false set occurs remix the concrete without adding water. Plasticity will
return and concrete will set in the normal manner. ( IS 4031 part 14
Method of test for determination of false set.)
b)
Flash set : If concrete stiffens too early and does not regain plasticity on
re-mixing, flash set might have occurred. The cause may be ,
1)
2)
3)
c)
Concrete with pozzolana cement and slag cement hardens at slower rate.
Therefore, prolonged curing is necessary.
146
The cement paste made with 85 % of standard consistency water, the initial
setting time should not be less than 30 minutes and final setting time should
not be more than 10 hours. However the limits of setting time for different
types of cement should confirm to the respective Indian standards.
d) Loss on Ignition : IS 4032 Method of Chemical Analysis of Hydraulic
cement
This shows the amount of moisture and carbon dioxide absorbed by the cement.
If cement is stored for a longer time (say three months) or if deterioration is
suspected, check the cement for loss on ignition. This test can be done in an
outside laboratory. The value should not be more than four or five percent by
weight of cement.
e) Insoluble Residue : IS 4032 Method of Chemical Analysis of Hydraulic
cement
Insoluble residue is found by dissolving cement in hydrochloric acid. For
ordinary PortlandCement this should not be more than 2 to 4 % by weight of
cement. For pozzolana cement this may amount to 15% to 20 %
f) Test for Soundness: IS 4031 part 3 Determination of soundness for
hydraulic cement.
147
ISI certification , week and year of manufacture are printed on the bag
b.
c.
d.
e.
f.
g.
h.
148
OPC
OPC
33
43
Grade Grade
OPC
53
Grade
269
8112
12269 12330
1489
part 1
455
Fineness (Blaine)
2250
(sq. cm / gm ) Min
2250
2250
2250
3000
2250 3700
30
600
30
600
30
600
30
600
30
600
60
600
Soundness
10
1)Le Chatelier (mm)
10
10
10
10
10
2) Autoclave (%)
0.8
0.8
0.8
0.8
0.8
0.8
0.8
160
230
270
100
160
160
7 Days
220
330
370
160
220
220
375
28 Days
330
430
530
330
330
330
0.15
Type of cement
IS Code No
Compressive
strength (Kg/
Sq.cm) Min
3 Days
Drying shrinkage
(max %)
149
SRC
PPC
(Flyash
Based)
PSC
Sleeper
53 S
12269
Mineral admixtures:
IS 456-2000 permits the usage of the following pozzolanic materials confirming
the relevant standard specification can be used in concrete as admixtures with
the permission of the deciding authorities.
Fly ash (pulverized fuel ash ) confirming IS 3812-1981
Ground granulated blast furnace slag (GGBFS) confirming IS 12089 &
BS 6699
Silica fume confirming IS 15388
Rice husk ash
Metakaoline having fineness between 700 to 900 m2/kg. confirming IS
In general fly ash , GGBFS and in some cases Silica fume is used depends on
project requirement. But fly ash is used in major quantity in concrete making
as part replacement to cement.
FLY ASH:
Fly ash is the by product of coal fired power plants. The ash which is very small
in size is collected by the ESPs. The chemical composition mainly depends up
on the type of coal used for firing in the boilers.
The details of requirement of Chemical and Physical properties of Fly ash for
use as a pozzolana for part eplacement of cement , for use as an admixture
is given below.
Grade designation : As per IS 3812- Part 1 - 2003 fly ash is designated as
Siliceous Pulverized Fuel Ash Pulverized fuel ash with reactive calcium
oxide less than 10 percent,by mass. Such fly ash are normally produced from
burning anthracite or bituminous coal and has pozzolanic properties.
Calcareous Pulverized Fuel Ash Pulverized fuel ash with reactive calcium
oxide not less than 10 percent by mass. Such fly ash are normally produced
from lignite or sub-bituminous coal and have both pozzolanic and hydraulic
properties
150
Chemical requirements
When tested according to IS 1727-1967 fly ash to confirm the following
requirements.
Chemical requirements of fly ash
Sl.
No
Characteristic
Siliceous
Calcareous
70.0
50
35.0
25
20
20
5.0
5.0
3.0
3.0
1.5
1.5
0.05
0.05
5.0
5.0
Requirements
* Optional Test
** For the purpose of this test, wherever reference to cement has been made,
it may be read as pulverized fuel ash.
151
Characteristic
Requirements
320
34
4.5
0.8
Not withstanding to the strength requirements specified above the fly ash
incorporated shall show a progressive increase in strength.
In case of fly ash is used as replacement to cement a maximum of 35 % is
permitted. But field trials to be conducted to estimate the strength development
before the concrete mix is used. An optimum dosage of 20% to 25 % is found
to give satisfactory results.
Note : Fly ash in general classified as Calcareous ( class C) & Siliceous
(Class F). Fly ash of Class C is obtained from power plant where Lignite
is used as fuel and Class F obtained from power plants where bituminous
coal is used as fuel. In general in India , majority availability is fly ash of
Class F .
Advantages of using fly ash in concrete
In plastic state concrete:
1)
2)
3)
Reduces Bleed water: The lower water content required for workability in
fly ash concrete reduces bleeding.
4)
Increased pumpability : The spherical shape of fly ash acts like a tiny
ball bearing, reducing internal friction, thereby producing a mix that is
easier to pump.
5)
2)
3)
Reduced permeability: The packing effect of the spherical fly ash particles
helps to reduce permeability. The chemical reaction between fly ash and
lime forms additional (C-S-H) bonds that block bleed channels and fill
pore space.
4)
5)
6)
Aggregates:
Aggregates in general are inert material and occupy nearly more than 75
percent of concrete volume. The quality of aggregate is more important since
it is concerned with the durability of concrete. Aggregates in general are
classified into three types as coarse aggregate, fine aggregate and all-inaggregate. Aggregates used in concrete should satisfy the requirement of IS
383 Specification for Coarse and Fine aggregates from natural sources for
concrete.
1.
The following are the types of fine aggregates in general used for production
of concrete
2.
1.
2.
3.
b)
c)
3.
2.
3.
4.
b)
c)
d)
a)
b)
If aggregates are stored directly over firm ground, do not use the material
in the bottom 10 cm portion( This will be a Dead storage)
c)
Provide ample space between adjacent stock piles ( about one meter).
d)
e)
Do not allow wheel loaders, trucks and bull dozers over the stock piles.
f)
g)
h)
i)
j)
Plums above 160 mm and up to any reasonable size may be used in plain
concrete work up to a maximum limit of 20 percent by volume of concrete
when specifically permitted. The plums shall be distributed evenly and shall be
not closer than 150mm from the surface.
For heavily reinforced concrete members as in the case of ribs of main beams,
the nominal maximum size of the aggregate should usually be restricted to
5 mm less than the minimum clear distance between the main bars or 5 mm
less than the minimum cover to the reinforcement which ever is less.
The aggregate used should satisfy the following requirements given in IS
383
Limits of the content of Deleterious Materials (IS 383)
Percentage by weight of aggregate
Deleterious
substance
Fine aggregates
Coarse aggregates
Uncrushed
Crushed
Uncrushed
Crushed
1.00
1.00
1.00
1.00
Clay lumps
1.00
1.00
1.00
1.00
3.00
3.00
15.00
3.00
3.00
Shale
1.00
5.00
2.00
5.00
5.00
Soft fragments
* Excluding Mica
Mechanical properties
Test
Wearing surface
Impact Value
30% Max
45 % Max
Crushing Value
30% Max
45 % Max
Abrasion Value
30% Max
50 % Max
158
40 mm
25 mm
20 mm
16 mm
12.5 mm
10 mm
80 mm
100
63 mm
85100
100
40 mm
0 30
85100
100
25 mm
85100
100
20 mm
05
020
85100
100
16 mm
85100
100
12.5 mm
0 20
85100
100
10 mm
0 5
0 5
020
0-30
045
85100
4.75 mm
05
05
0-5
0 10
0 20
2.36 mm
05
25 mm
20 mm
16 mm
12.5 mm
80 mm
100
40 mm
95 100
100
100
25 mm
90 100
20 mm
30 70
95 100
100
100
16 mm
90 - 100
12.5 mm
25- 55
25 -55
90 100
10 35
30 70
40 85
0 5
05
05
0 - 10
0 10
10 mm
4.75 mm
159
II
III
IV
100
100
100
100
4.75 mm
90 100
90 100
90 100
95 100
2.36 mm
60 95
75 - 100
85 - 100
95 100
1.18 mm
30 70
55 - 90
75 - 100
90 - 100
600 micron
15 - 34
35 - 59
60 - 79
80 - 100
300 micron
5 - 20
8 - 30
12 - 40
15 - 50
150 micron
0 - 10
0 - 10
0 - 10
0 - 15
75 micron
0 - 3
0 - 3
0 - 3
0 - 3
10 mm
Note : If the grading falls outside the limits of any particular sieve other than 600 micron IS
sieve by a total amount of 5 percent it shall be regarded falling within the zone. This limit is not
applicable for coarser limits of zone I and finer limits of zone IV. For crushed sand 150 microns
parsing increased to 20 percent.
Crushed Sand
100
100
4.75 mm
90 100
90 100
2.36 mm
75 100
75 100
1.18 mm
55 100
55 100
600 micron
30 70
30 70
300 micron
8 40
8 40
150 micron
0 20
0 15
75 micron
0 - 15
09
160
IS Sieve
25 mm
20 mm
12.5 mm
80 mm
100
40 mm
95 100
100
100
95 100
95 100
100
95 100
25 mm
20 mm
45 75
12.5 mm
4.75 mm
25 45
30 50
30 50
35 55
600 micron
8 30
10 35
10 35
12 40
150 micron
06
0 10
0 - 10
0 12
1.
The relaxed limits for crushed sand are applicable only if the boulders
used for crushing in the crusher are free from natural over burden soil /
muck.
2.
The following Table13 is the guidance for selecting the percentage 4.75
mm passing in all-in-aggregate grading precisely.
Mixing Water
a)
b)
Water should be free from oils, acids, alkalis, salts, sugar and organic
materials.
c)
In general , do not use sea water either for mixing or for curing . However
IS 456-2000 permits use of sea water for Plain concrete and reinforced
concrete permanently immersed in sea water.
d)
The total requirement of water, for all purposes such as mixing, curing,
washing of shutters, washing of aggregates and workmens consumption
may be estimated on the basis of 370 to 500 litres / m3 of concrete.
a)
b)
c)
Permissible Solids
Organic
200 mg/l
Inorganic
3000 mg/l
400 mg/l
Suspended matter
2000 mg /l
In case of doubt regarding the usage of water the same can be tested for
setting time and compressive strength test as mentioned below.
1)
2)
The initial setting time of test block made with the appropriate cement
and the water proposed to be used shall not be less than 30 min and
shall not differ by 30 min from the initial setting time of control test
block prepared with the same cement and distilled water.
Admixture
Admixtures are the fourth ingredients in concrete making, which are added
to cement, aggregate and mixing water. Admixtures are added to concrete
mix immediately before or during its mixing , to modify one or more of the
properties of concrete in the plastic and hardened states. Admixtures used in
concrete should satisfy the requirement of IS 9103.
162
Accelerating admixtures
2.
Retarding admixtures
3.
4.
Grade Designation
(1)
Ordinary Concrete
Strength of150 mm
28 days in N/mm2
(2)
M 10
cube
at
(3)
10
M 15
15
M 20
20
Standard concrete
M 25
25
M 30
30
M 35
35
M 40
M 45
40
45
M 50
50
M 55
55
60
M 65
65
M 70
70
M 75
75
M 80
80
164
Note :
1.
2.
Mild
Moderate
Severe
Very Severe
Extreme
Minimum cement content , Maximum water cement ratio and Minimum grade
of concrete for different exposure condition with normal weight aggregates of
20mm nominal size.
165
Plain concrete
Minimum
S.
No
Exposure
cement
content
(kg/cum)
Mild
Maximum Minimum
Reinforced concrete
Minimum
Maximum Minimum
free w/c
ratio
grade of
concrete
cement
content
(kg/cum)
220
0.60
300
0.55
M 20
Moderate 240
0.60
M 15
300
0.50
M 25
Severe
250
0.50
M 20
320
0.45
M 30
Very
Severe
260
0.45
M 20
340
0.45
M 35
Extreme
280
0.40
M 25
360
0.40
M 40
free w/c
ratio
grade of
concrete
Note:
1.
2.
Minimum grade for plain concrete under mild exposure condition is not
specified
166
Concentration of
Expressed as SO3
Class
In soil
sulphates,
In
Ground
water
Total
SO3
SO3 in 2:1
water
:
soil
extract
Percent
g/l
g/l
Traces
(<0.2)
Less than
1.0
Less
than 0.3
to
1.0 to 1.9
0.3
1.2
Type of cement
Minimum
cement
content
to
Ordinary
portland
cement
or
Portland slag cement or portland
pozzolana cement
Ordinary
portland
cement
or
Portland slag cement or Portland
pozzolana cement
1.0
2.0
More
than
2.0
to
1.2
2.5
to
3.1 to 5.0
2.5
5.0
to
More than
5.0
More
than 5.0
1.9 to 3.1
Maximu
m free
w/c
ratio
(Kg/cum)
0.2
0.5
Dense
fully
compacted concrete
made with 20mm
Nominal
MSA
complying IS 383
cement
or
167
280
0.55
330
0.50
310
0.50
330
350
0.50
0.45
370
0.45
400
0.40
Notes:
Cement content given in this table is irrespective of grades of cement.
1.
2.
3.
4.
5.
Portland slag cement confirming to IS 455 with slag content more than
50 percent exhibits better sulphate resisting properties.
6.
Batching
Cement
a)
b)
c)
d)
e)
f)
Aggregates
a)
b)
If the mix proportions, are given by weight (in case designed mixes) but
only volume batching could be done at site, then convert the weight to
volume by dividing the weights by loose bulk density.
Use only loose bulk density and not rodded bulk density for conversion. Loose
bulk density is determined by filling a known volume container loosely without
compacting and finding the weight and volume.
Weight of material loosely packed in the container
Loose bulk density =
----------------------------------------------------------
c)
Do not heap the sand or aggregates in the batch box. It should always
be struck level, so that constant volumes are measured out.
d)
Use separate batch boxes for different grades of concrete and different
aggregates. It is advisable to mark on the box with paint the grade
of concrete and type of aggregate, whether fine or coarse, over the
respective boxes for easy identification, Marking also helps in avoiding
use of wrong boxes.
e)
f)
g)
Water:
a)
b)
If mineral admixtures like microsilica, high volume fly ash , GGBFS used to
get uniform blending of the material the mixing time needs to be increased ,
normal experience shows it is 60 seconds to 90 seconds depend on quantity
of mineral admixture used.
In central control plant the mixing time for 0.5 cum batch should not be
less than 30 seconds. Refer to the cycle time diagram of the batching plant
manufacture for this.
Transporting concrete
(a) The method of conveying concrete should not cause segregation, loss of
part of the concrete and loss of slump.
(b) Do not add extra water to the concrete (in addition to what is required as
per the W/c ratio) for the purpose of easy handling / transporting.
(c) Properly designed and operated buckets are an excellent means of
transporting concrete. But they should be capable of discharging
low slump concrete and the discharge rate should be controllable.
Cylindrical buckets with proper center discharge gates are the most
efficient
(d) When using chutes for transporting , take care to avoid segregation.
The chutes should be of rounded cross-section and of smooth metal
to avoid sticking of concrete. They should be of correct slope so that
concrete of the required slump will slide without flowing. Usually,
the slope is 1 vertical to 2 or 2 horizontal but the best slope for a
particular concrete can be fixed after a few trials. Control should be
provided at the end of the chute so that concrete will drop vertically
without segregation.Flush the chute with water before starting to
transport the concrete.
(e) Wheel barrows can be effectively used for transporting concrete
horizontally over a short distance of about 60 meters. Provide a smooth
path for the wheelbarrows using planks or sheets to transport the concrete
without shaking or spilling.
171
Placing
(a) Preparation
1)
Do not place the concrete until the place of deposit has been thoroughly
inspected and approved. Check whether the formwork has been oiled
and the supports are rigid. Also, check whether the reinforcement ,
cover blocks, inserts and embedded plates have been properly secured
in position.
2)
3)
Keep the dry surface saturated with water for not less than 24 hours .
Before placing fresh concrete, remove the standing water from depressions
and spread about 1.5 cm thick mortar layer (in same proportion as in
original concrete but not greater than 1:2) over the contact surface of the
old concrete.
4)
b) During Placement
Deposit the concrete at, or as near as possible to its final position
lace the concrete in uniform layers. Avoid placing in large heaps or
P
sloping layers which will lead to segregation.
I n walls and columns no layer should be more than about450mm thick. As
more layer thickness make the concrete impossible to vibrate the bottom
layer and will lead to air entrapment at bottom and surface blemishes on
vertical surface.
In thin slabs place concrete thickness of 150mm.
here good finish is required on columns and walls restrict the pour
W
height to 2m per hour.
nsure every layer of concrete is fully compacted before placing successive
E
layer.
172
nsure the vibrator head penetrates the previous layer this will eliminate
E
layer lines.
Always make sure that you can see the concrete being deposited.
I n columns and walls the placing must be done in such a way that the
concrete does not strike the face of the formwork, similarly, avoid heavy
impact against reinforcement as the force could displace it.
Compaction
The object of compaction is to get rid of as much as possible of entrapped
air, down to less than 1% is the aim.(This does not apply with deliberate air
entrainment, but in that case the air is uniformly distributed and stable)
The amount of air is related to workability. Concrete with a slump of 75mm
contains about 5% air while concrete with 25mm has 20%.
This is why low slump concrete requires more vibration or longer time or more
poker needles compared to concrete with higher slump.
It is important to remove this entrapped air for the following reasons:
Voids reduces the strength of the concrete. Every 1% of entrapped air the
strength falls by about 5 to 6 % . So a concrete with 3% voids will be about
15 to 20% weaker than it should be.
Voids increased permeability, which in turn reduces the durability.
oid reduces the contact between concrete and reinforcement and other
V
embedded metals. The required bond will then not be achieved and the
reinforced member will not be as strong as it should be.
oids produces visual blemishes such as blowholes and honeycombing
V
and porosity on the struck surface.
Vibration
Rodding , spading-even using foot- are all ways of removing air from concrete
to compact it, but the best and quickest method is vibration.
When concrete is vibrated it is fluidized which reduces the internal friction
between the aggregate particle and removes the entrapped air , make them
to get packed well to become a dense member.
173
Process of compaction
Make sure the concrete surface being vibrated is seen. Light is need for
thin section columns and walls.
2.
Insert the needle quickly this makes the concrete liquefies and fill the
forms and allow the vibrator to penetrate to the previous layer.
3.
4.
Withdraw the needle slowly. The main thing is to see the hole made by
vibrator head is closed.
5.
6.
Excess vibration not to be done this may lead to Segregate the concrete
7.
Place the poker needle in not more than 500mm away from its last
position.
8.
Avoid touching the form face with poker needle. This will result in colour
variation
9.
reiniforcement and also will decrease the bond between the reinforcement
and concrete
10. Avoid moving concrete to flow using poker.
STOP VIBRATION WHEN
The concrete surface takes on a sheen
Large air bubbles no longer escape
You hear the vibrator change pitch or tone
You feel a change in vibration action
VIBRATING DONTS
Dont let a vibrator run very long outside concrete; it will overheat
Dont use a vibrator to move concrete horizontally
ont force pr push a vibrator into concrete it wont remain vertical and
D
may get caught in the reinforcement
Dont start a job without a spare vibrator
FINISHING
Initial finishing:
Strike off:
P
roperly done removes excess concrete and brings top surface to
grade
Start as soon as possible after placing concrete
End before bleed water appears
Straight edge uses can be of wood or magnesium
Straight edge
Use a side-to-side sawing motion while pulling forward
Tilt it slightly backward to create a single cutting edge
Keep about an inch of concrete in front to fill low spots
Make a second pass if the surface is not to grade
Pull concrete into end edge forms.
175
A
fter joint is cut, turn the groover around, running it back over the cut
to give as smoother finish
For a straight cut, use a chalk line or a straight edge as a guide
Floats
U
se to remove imperfections and to bring mortar to the surface for
troweling
H
old flot flat and at arms length, moving it in awide semicircular
motion until surface is smooth
Use magnesium tools for air entrained concrete
More than one float pass may be required
Trowels
Use to produce a hard, dense surface
T
rowel only after floating, starting with a wide trowel then moving to
smaller trowels on the later passes
H
old trowel at a slight tilt at arms length and move it in a semicircular
motion , overlapping each pass by one half until surface finish is
smooth.
CURING
When cement is mixed with water, a chemical reaction takes place, called
hydration, it is this reaction which causes the cement and hence the concrete to
harden and then develop strength. This strength development can take place
only if the concrete is kept moist and at a favorable temperature, especially
during the first few days.
A properly cured concrete is superior in many ways. It is stronger and more
durable to chemical attack, but it is also more resistant to traffic wear and
more water- tight , further more the accidental knocks it is bound to receive
well probably cause less damage.
Cure concrete immediately after finishing by
Ponding
Build dike, then fill with water to cover the entire concrete slab
Avoid water or dike material that can stain the concrete
177
U
se curing water at a temperature within 20 F ( i.e -6 deg) of concrete
temperature
A
void premature or sudden release of ponded water which can
damage the surrounding environment
Sprinkling or fog spraying
K
eep the surface continuously wet, alternate wetting and frying causes
craze cracking
U
se low water pressure and flow to avoid washing away the fresh
concrete surface
U
se curing water at a temperature within 20 F ( i.e -6 deg) of concrete
temperature
Avoid if water runoff can damage the surrounding environment.
Using wet materials
Cover the concrete with wet burlap, straw, sawdust, or sand
Wet continuously, or cover with plastic sheet and wet frequently
Avoid materials that discolor concrete
Prevent materials from blowing away.
Using Plastic sheet or water proof paper
Lay flat , lap edges 6 inches, and cover exposed concrete edges
U
se minimum 4 mm thick plastic sheet white in hot weather and black
in cold weather
Dont use on architectural concrete
Secure covering to prevent concrete exposure
Using curing compounds
Apply after finishing when bleedwater disappears in slab or flat surface
I n vertical faces apply in two applications, at right angles to from a
continuous film
The efficiency will be 80% to that of water curing.
I f further painting or surface finishing required select compound which
will not harm secondary finishes. Otherwise paints will not stick to the
surface.
178
Honeycomb
4 Aggregate transparency
Aggregate transparency is a condition characterized by a mottled coloring
on the surface which results from deficiencies in the mortar. It may result
when concrete mixtures have low sand content, dry or porous aggregates, or
high slump with some lightweight and normal weight aggregates. Also, high
density or glossy form surfaces may cause aggregate transparency.
5 Subsidence cracking
Subsidence cracking results from the development of tension when the
concrete settles after or near initial set.
The cracks are caused because the upper concrete bridges between the forms
while the lower concrete settles. These cracks may occur when there is an
insufficient interval between placement of concrete in columns and placement
of concrete for slabs or beams. They may also occur adjacent to block outs or
over reinforcing bars with shallow cover.
To prevent subsidence cracking, the concrete can be revibrated. Revibration
is most effective when done at the latest time at which the vibrator head
will penetrate the concrete under its own weight. Subsidence cracking over
reinforcing bars can be controlled by increasing concrete cover during the
design phase and by using well-consolidated, low-slump concrete.
6 Color variation
Color variation may occur within a placement if the concrete is not uniform
or is incompletely mixed. Vibrators inserted too close to the form destroy the
release agent or mar the form surface. External vibration used haphazardly
may also cause color variation. Furthermore, color variations may result from
nonuniform absorption and/or nonuniform application of the release agent.
7 Sand streaking
Sand streaking is a streak of exposed fine aggregate in the surface of the
formed concrete caused by heavy bleeding along the form. It frequently
results from the use of harsh, wet mixtures, particularly those deficient in 0.30
to 0.15 mm and smaller sizes. Sand streaking is controlled by the use of tight
181
183
184
Small individual
holes, irregular ,
ranging up to 1inch
(25mm)In diameter
Sand or gravel
textured areas
lacking cement,
usually associated
with dark color on
adjacent surface
Unintended
discontinuity, off
coloured concrete
Air surface
voids
Form streaking
Cold joint
Defects
Description
Honeycomb
Name
Internal
interference
Battered or
interfering
construction
Design of
member
Highly
congested
reinforcement,
narrow
section,
configuration
internal
interference,
reinforcement
splices
Leaking at
joints, tie
holes, etc.
Form face
impermeable,
poor wetting
characteristics,
form work too
flexible, use of
improper form
release agent
Leaking at
joints, severe
grout loss
Forms
Poor planning of
insufficient
backup
equipment
Excessive
release agent ,
high
temperature
Construction
conditions
High
temperature ,
wind,
reinforcement
too close to
forms,
accessibility
Low FM sand,
lean , sand with a
high FM, low
workability,
excessive cement
content or
pozzolana ,
particle
degradation ,
excessive sand ,
high air content
Excess water or
high slump
Causes
Properties of
fresh concrete
Insufficient fines,
low workability,
early stiffening,
excessive mixing
too
large
an
aggregate
for
placing conditions
Delayed
delivery
Excessive free
fall, excessive
travel
of
concrete
in
forms, too high
a
lift,
drop
chute omitted
or insufficient
length , too
small a tremie,
segregation
Too slow ,
caused by
inadequate
pumping rate,
undersized
bucket
Placement
Excessive amplitude or
frequency
Consolidation
185
Description
Variation
in colour
or shade due to
Short
cracks
separation
of fine
varying
width,
particlesincaused
more
often
by bleeding
horizontal
than
parallel to the
Description
Description
Description
Description
vertical
form face
Dark coloured
Short
Short
Short
Shortcracks
cracks
cracks
cracks
zones
between
varying
varying
varying
varyingin
in
in
inwidth,
width,
width,
width,
concrete
layers
more
more
more
more
often
often
often
often
Variation in colour
horizontal
horizontal
horizontal
horizontal
than
than
than
or shade duethan
to
Abrupt
to gradual
vertical
vertical
vertical
vertical
separation
of fine
surface caused
particles
irregularities
by
bleeding
parallel to the
Variation
Variation
Variation
Variation
in
in
incolour
colour
colour
colour
form
facein
or
or
or
orshade
shade
shade
shade
due
due
due
dueto
to
to
to
Dark
coloured
separation
separation
separation
separation
of
of
of
offine
fine
fine
fine
zones
between
particles
particles
particles
particlescaused
caused
caused
caused
concrete
layers
by
by
by
bybleeding
bleeding
bleeding
bleeding
parallel
parallel
parallel
parallelto
to
to
tothe
the
the
the
Abrupt
to gradual
form
form
form
formface
face
face
face
surface
Dark
Dark
Dark
Darkcoloured
coloured
coloured
coloured
irregularities
zones
zones
zones
zonesbetween
between
between
between
concrete
concrete
concrete
concretelayers
layers
layers
layers
Name
Sand streaking
Form
Form
Form
Formoffsets
offsets
offsets
offsets
Form offsets
Layer
Layer
Layer
Layerlines
lines
lines
lines
Sand
Sand
Sand
Sandstreaking
streaking
streaking
streaking
Layer lines
Form offsets
Layer lines
Subsidence
Subsidence
Subsidence
Subsidence
cracking
cracking
cracking
cracking
Sand streaking
Name
Name
Name
Name
Subsidence
Defects
Defects
Defects
Defects
cracking
Defects
Abrupt
Abrupt
Abrupt
Abruptto
to
to
togradual
gradual
gradual
gradual
surface
surface
surface
surface
irregularities
irregularities
irregularities
irregularities
Dark
Dark
Dark
Darkor
or
or
or
light
light
light
lightareas
areas
areas
areas
Short
cracks
of
of
of
ofsimilar
similar
similar
similar
size
size
size
size
and
and
and
and
varying
in
width,
shape
shape
shape
shapeto
to
to
tothat
that
that
thatof
of
of
ofthe
the
the
the
more
often
coarse
coarse
coarse
coarseaggregate,
aggregate,
aggregate,
aggregate,
horizontal
than
mottled
mottled
mottled
mottledappearance
appearance
appearance
appearance
vertical
Aggregate
Aggregate
Aggregate
Aggregate
Subsidence
transparency
transparency
transparency
transparency
cracking
Name
Aggregate
Defects
transparency
mottled appearance
Internal
Internal
Internal
Internal
interference
interference
interference
interference
Internal
interference
Design
Design
Design
Designof
of
of
of
member
member
member
member
Internal
Interference
Interference
Interference
Interference
interference
to
to
to
toaccess
access
access
access
Interference
to access
Design of
member
Interference
to access
Design of
member
porous ,
excessive coarse
aggregate ,
excessive slump
with light weight
concrete
Too flexible,
Low sand
Causes
high density
content,
surface finish
gapgraded,
aggregate
dryofor
Construction
Properties
Forms
Placement
porous
,
conditions
fresh
concrete
excessive coarse
Too
Too
Too
Tooflexible,
flexible,
flexible,
flexible,
Low
Low
Low
Low
sand
sand
sand
sand
Poor
thermal
Insufficient
Low
sand,
high
Too rapid
aggregate
,
high
high
high
highdensity
density
density
density interval between
content,
content,
content,
content,
insulation,
water
content
excessive
slump
surface
surface
surface
surface
finish
finish
finish
finish
gapgraded,
gapgraded,
gapgraded,
gapgraded,
irregular
topout of
with
light weight
aggregate
aggregate
aggregate
aggregate
dry
dry
dry
dryor
or
or
or
shape
columns and
concrete
porous
porous
porous
porous, ,,,
restraining
placement of
Causes
excessive
excessive
excessive
excessivecoarse
coarse
coarse
coarse
settlement,
slab or beam,
aggregate
aggregate
aggregate
aggregate, ,,,
excessive
low humidity
excessive
excessive
excessive
excessiveslump
slump
slump
slump
absorbency
Construction
Properties
of
Forms
Placement
with
with
with
withlight
light
light
light
weight
weight
weight
weight Too
Low
Low
Lean
mixture,
rapid for
conditions
fresh
concrete
concrete
concrete
concrete
concrete
absorbency
temperature,
over
sanded
type of mix
Poor thermal
Insufficient
Low
sand,mix,
high
Too rapid
wet
mixtures
bleeding
Causes
Causes
Causes
insulation,
interval between Causes
water
contentin
sand
deficient
irregular
topout of
fines, low air
shape
columns
and
content of
Construction
Construction
Construction
Construction
Properties
Properties
Properties
Properties
of
of
of
Forms
Forms
Forms
Forms
Placement
Placement
Placement
Placement
restraining
placement
of
conditions
conditions
conditions
conditions
fresh
fresh
fresh
freshconcrete
concrete
concrete
concrete
settlement,
slab
or beam,
Insufficient
Wet mixture with
Slow
Poor
Poor
Poor
Poor
thermal
thermal
thermal
thermal
Insufficient
Insufficient
Insufficient
Insufficient
Low
Low
Low
Lowsand,
sand,
sand,
sand,
high
high
high Placement,
Too
Too
Too
Toorapid
rapid
rapid
rapid
excessive
low
humidity
planning,
high
tendency
to high
bleed
lack
insulation,
insulation,
insulation,
insulation,
interval
interval
interval
interval
between
between
between
between water
water
water
watercontent
content
content
content
absorbency
temperature
of equipment
irregular
irregular
irregular
irregular
topout
topout
topout
topout
of
of
of
of
Low
Low
Lean mixture,
Too
rapid for
or
manpower
shape
shape
shape
shape
columns
columns
columns
columnsand
and
and
and
absorbency
temperature,
over sanded
type of mix
Inadequate
Excessive
Rate too high
restraining
restraining
restraining
restraining
placement
placement
placement
placement
of
of
of
of
wet
mixtures
bleeding
mix,
stiffness
or
retardation
settlement,
settlement,
settlement,
settlement,
slab
slab
slab
slabor
or
or
orbeam,
beam,
beam,
beam,
sand
deficientofin
anchorage,
mixes
excessive
excessive
excessive
excessive
low
low
low
lowhumidity
humidity
humidity
humidity
fines,
low air
weak
forming
absorbency
absorbency
absorbency
absorbency
content
material,
Low
Low
Low
Low
Low
Low
Low
Low
Lean
Lean
Lean
Leanmixture,
mixture,
mixture,
mixture,
Too
Too
Too
Toorapid
rapid
rapid
rapidfor
for
for
for
irregular
absorbency
absorbency
absorbency
absorbency
temperature,
temperature,
temperature,
temperature,
over
over
over
over
sanded
sanded
sanded
sanded
type
type
type
type
of
of
of
ofmix
mix
mix
mix
Insufficient
Wet
mixture
with
Slow
lumber, poor
wet
wet
wet
wetmixtures
mixtures
mixtures
mixtures
bleeding
bleeding
bleeding
bleeding
mix,
mix,
mix,
planning,
high
tendency
tomix,
bleed
Placement, lack
carpentry
sand
sand
sand
sanddeficient
deficient
deficient
deficientin
in
in
in of equipment
temperature
fines,
fines,
fines,
fines,low
low
low
lowair
air
air
air
or manpower
content
content
content
content
Inadequate
Excessive
Rate too high
stiffness or
retardation
of
Insufficient
Insufficient
Insufficient
Insufficient
Wet
Wet
Wet
Wet
mixture
mixture
mixture
mixturewith
with
with
with
Slow
Slow
Slow
Slow
anchorage,
mixes
planning,
planning,
planning,
planning,high
high
high
high tendency
tendency
tendency
tendency
to
to
to
tobleed
bleed
bleed
bleed Placement,
Placement,
Placement,
Placement,lack
lack
lack
lack
weak forming
temperature
temperature
temperature
temperature
of
of
of
ofequipment
equipment
equipment
equipment
material,
or
or
or
ormanpower
manpower
manpower
manpower
irregular
Inadequate
Inadequate
Inadequate
Inadequate
Excessive
Excessive
Excessive
Excessive
Rate
Rate
Rate
Ratetoo
too
too
toohigh
high
high
high
lumber,
poor
stiffness
stiffness
stiffness
stiffnessor
or
or
or
retardation
retardation
retardation
retardationof
of
of
of
carpentry
anchorage,
anchorage,
anchorage,
anchorage,
mixes
mixes
mixes
mixes
weak
weak
weak
weakforming
forming
forming
forming
material,
material,
material,
material,
irregular
irregular
irregular
irregular
lumber,
lumber,
lumber,
lumber,poor
poor
poor
poor
Excessive
Excessive
Excessive
Excessiveamplitude,
amplitude,
amplitude,
amplitude,
nonuniform
nonuniform
nonuniform
nonuniformspacing
spacing
spacing
spacingof
of
of
of
immersion
immersion
immersion
immersion
Excessive amplitude,
nonuniform
spacing of
Lack
Lack
Lack
Lackof
of
of
ofvibration,
vibration,
vibration,
vibration,
immersion
failure
failure
failure
failure
to
to
to
topenetrate
penetrate
penetrate
penetrateinto
into
into
into
previous
previous
previous
previouslayer
layer
layer
layer
Excessive
Excessive
Excessive
Excessivevibration
vibration
vibration
vibration, ,,,
Excessive
Excessive
Excessive
Excessive
amplitude
amplitude
amplitude
amplitude, ,,,
Lack of vibration,
Over
Over
Over
Over
manipulation
manipulation
manipulation
failure
tomanipulation
penetrate
into
previous layer
Lack of vibration,
Insufficient
Insufficient
Insufficient
Insufficient
vibration
vibration
vibration
vibration
failure
to penetrate
into
previous layer
Excessive vibration ,
Excessive amplitude ,
Excessive
amplitude,
Over manipulation
nonuniform spacing of
immersion
Consolidation
Consolidation
Consolidation
Consolidation
Consolidation
Excessive
vibration ,
Excessive amplitude ,
Insufficient
vibration
Over manipulation
Excessive
Excessive
Excessive
Excessiveor
or
or
or
external
external
external
external
Insufficient
vibration
vibration;
vibration;
vibration;
vibration;over
over
over
overvibration
vibration
vibration
vibration
of
of
of
oflight
light
light
lightweight
weight
weight
weightconcrete
concrete
concrete
concrete
Consolidation
Excessive or external
vibration; over vibration
of light weight concrete
SPECIAL CONCRETE
Concrete used for ALUFORM and Tunnel form has to be designed considering
the following to avoid surface defects and to get form finish
The concrete mix should be slightly over sanded and cohesive
he concrete mix at placement should have a slump of 150mm to 200
T
mm (like tremie concrete)
he maximum size of aggregate may be 12.5mm or 10mm considering
T
the reinforcement, electrical conduits and electrical boxes and other
boxouts provided
he concrete should attain the required strength of 15 N/mm2 at 36
T
hours for Mivan formwork and 8 to 10 N/mm2 after 18 hours for tunnel
forms
he cubes used to check the form removal strength shall be cured along
T
with structure and tested at specified time.
hen Self compacting concrete is used the concrete shall have a flow of
W
600 mm to 700mm flow at placement.
oncrete placement shall be commenced from pouring in walls and
C
finished along with slab covering room by room
hen concrete is placed in walls the form work shall be shirked with
W
wooden mallet to ensure air removal from surface
xcess malleting to be avoided after full placement in walls , if continued
E
will lead to formation of mild gap between form and concrete and will
entrap bleed water and lead to bug holes.
hile placing in walls having windows, electrical boxes concrete need to
W
be placed from one side ensuring the concrete placed flow to the other
side and get lifted up passing boxes or cutouts. Both side placement will
lead to air entrapment under boxes and lead to void or cavity.
186
Prestressing
INTRODUCTION:
The prestressing and precasting of concrete are inter-related features of
the modern building industry. Prestressing concrete is the application of
compressive force to concrete members and may be achieved by either pretensioning high tensile steel strands before the concrete has set, or by the
post-tensioning the strands after the concrete has set.
DEFINITIONS:
Prestressing of concrete is defined as the application of compressive stresses
to concrete members. Those zones of the member ultimately required to carry
tensile stresses under working load conditions are given an initial compressive
stress before the application of working loads so that the tensile stress
developed by these working loads are balanced by induced compressive
strength. Prestress can be applied in two ways.
1. Pre- tensioning
2. Post-tensioning.
1. Pre-tensioning:
Pre-tensioning is the application, before casting, of a tensile force to high
tensile steel tendons around which the concrete is to be cast. When the
placed concrete has developed sufficient compressive strength a compressive
force is imparted to it by
releasing the tendons, so
that the concrete member
is in a permanent state of
prestress.
2. Post- tensioning:
Post-tensioning
is
a
method of reinforcing
concrete or other materials
with high strength steel
187
ADVANTAGES OF PRESTRESSING
Minimizes the concrete crakes.
Allows reducing beam depth.
Allows greater degree of loading than any structural material.
Lighter elements permit the use of longer span.
Ability to control deflection in beams and slab.
Permits efficient usage of steel and reduces cost.
Speed in construction.
APPLICATION
Bridges
Nuclear Structures.
188
Materials
Management
1) HT Strand
2) Anchorages
189
3) Wedges:
4) Sheathing:
190
MATERIAL ORDERING:
The followings are to be specified in MR.
Client Specification
IS code references
Type of material
Delivery schedule
Type of packing
RECEPIT AT SITE:
H.T. Strand:
Check the following:
Size of Strand.
Coil No/Heat No.
IS Specifications and class of strand.
Weight/ Length.
Test certificate.
PT Hardware:
Check for the test/mill certificate
IS Code references
Size/ dimensions.
Quantity
Visual inspection for any crake
REFRENCE STANDARDS &CODES:
HT STRAND : IS : 14268 -1995
IS: 6006 -1983
ASTM A 146 -1998
TEST FOR SHEATHING : IRC : 18 -2000
191
BS 4447 -1973
GROUTING :
IRC : 18 -2000
2.
3.
4.
2.
3.
Elongation in mm --- e
4.
5.
2.
3.
4.
5.
b) Multi-pull Stressing:
1.
2.
3.
4.
5.
6.
Losses in Prestress:
Losses due to Elastic Shortening of Concrete
Creep in Concrete (Creep Strain)
Shrinkage in Concrete
Relaxation of Prestressing Steel
Losses due to seating of Anchorages
Friction Losses
Properties of HT Strand (IS: 14268 - 1995):
Class
Nominal
Tolerance
of HT
diameter
Dia (mm)
Strand
(mm)
in
Nominal
Nominal
Breaking
0.2% Proof
Minimum
Modulus of
Area
Mass
Strength
Load (KN)
Tensile
Elasticity
(mm2)
(Kg/M)
(KN)
Strength
(N/mm2)
(N/mm2)
II
9.5
+/-0.4
51.6
0.405
89.0
80.1
11.1
+/-0.4
69.7
0.548
120.1
108.1
12.7
+/-0.4
92.9
0.73
160.1
144.1
15.2
+/-0.4
139.4
1.094
240.2
216.2
9.5
+0.66 / -0.15
54.8
0.432
102.3
92.1
11.1
+0.66 / -0.15
74.2
0.582
137.9
124.1
12.7
+0.66 / -0.15
98.7
0.775
183.7
165.3
15.2
+0.66 / -0.15
140
1.102
260.7
234.6
1860
195000
1860
195000
193
Profiling.
2.
Stressing.
3.
Grouting.
1) Profiling:
ead the drawings and identify type of tendons, layout, locations, and
R
number of strands per tendon, sequence of laying, number of tendons per
pour, etc.
alculate the materials requirement such as Tube Units, Bearing Plates,
C
Wedges, Sheathing and Prestressing Steel (HTS).
alculate the cut length of Strand inclusive of Jack Grip length & profile
C
for each tendon and prepare Strand cutting schedule as per drawing. HT
Strand must be cut by using cut-off wheel/abrasion blade.
T Strand shall be uncoiled using coil dispenser and it should not contact
H
soil or dust while cutting.
ark the Tendons as per Tendon layout drawing, after the completion of
M
formwork& reinforcement.
ix the fabricated tendon support bars (bar chairs) rigidly at every 1m
F
(max.) interval according to the tendon layout and profile drawings.
L ay the sheathing over the tendon support bars as per the tendon layout
drawing and jointhe ducts using couplers and seal the joint using selfadhesive tape.
hread therequired number of Strands into Sheathing according to the
T
Tendon type (strand schedule) and tie thesheathing with Bar Chairs using
Binding wires rigidly.
rofiling of Tendons, both horizontally and vertically as per drawingsand
P
arresting it rigidly to avoid any disturbances in profile during concreting.
ix the Stressing anchorages and make Dead-end anchorages position as
F
per the layout drawing. Fix the Grout vents at end portions and Air vents
194
ompute the total Jack Pressure applied and the total elongation arrived
C
during stressing.
I f elongation reached, but pressure not reached apply 5% additional
elongation. If pressure reached, but elongation not reached apply 5%
additional pressure.
fter applying the additional pressure / elongation, if the Stressing result
A
is within +/-5%, release the jack pressure slowly and then proceed for
next stressing.
I f the stressing result / value is more than +/-5% inform the Design
Engineer for further instruction. Same method shall be followed for all
other Strands / Tendons.
2 hours after the completion of stressing of all tendons, cut the strands
1
leaving 25mm from the face of wedges by using angle grinder.
fter cutting fill the recess pockets (Stressing pocket) in layers using
A
approved materials.
3) Grouting:
fter the setting / curing time of recess pockets, flush the tendons
A
(sheathing) completely by water and then by compressed air.
otable water and OPC Cement should be used for preparation of grout.
P
Suitable admixture (Non-Aluminium / Non-Chloride based) may be
added to the grout as per specification.
Fix the valves at all grout and air vents and also fix the pressure gauge.
Mix Water followed by Cement of ratio 0.40 in the grouting machine.
he grout shall be mixed in mixture for 2-3 minutes and until pumping of
T
grout.
rout should be colloidal mixture and free from any lumps and it should
G
passed through sieve.
ump the grout into the tendon through grout vent pipe (inlet) and release
P
the air inside the tendon through air vents.
lug all air vent pipes and also the outlet vent pipe after consistent grout
P
is passed.
After plugging all the vents pipes tightly, built the pressure of 5kg/cm2
196
and maintain for one minute. Then close the inlet valve also. The same
method shall be followed for all other tendons.
routing should be performed continuously to avoid grout setting. Any
G
breakage occurred during grouting, flush the tendon with water and
compressed air and do fresh grouting.
Clean the vicinity by water after the grouting is completed.
Cut all vent pipes projecting outside the surface after the grout is set.
PRESTRESSING EQUIPMENTS
197
GROUTING MACHINE
TENDON PROFILING:
198
CASE STUDY
Problem:
Breaking of concrete near anchorage area.
Probable reason:
Poor quality of concrete
Improper vibration of concrete near anchorage zone
Poor workmanship
199
Strand snap
Actual reason:
Honey comb near anchorage area
Improper vibration.
Correct alignments of anchorage
Remedial action:
De-stress the tendon
Chip the crack area and remove the loose concrete.
Remove the broken anchorage
Fix the new anchorage and connect the duct.
Fill the area with epoxy or approved material
After getting the strength stress the tendon.
Note:
All this remedial works carried out the consultation with
Designer.
200
Photos
201
202
Introduction
Environment,
Health and Safety
Larsen & Toubro , Health, Safety & Environment Department had been
certified ISO 9001:2000. We are the first company in India to have such
accreditation. The companys management gives utmost importance to safety
in the companys function. The Safety Engineering Department has bagged
many commendations from various clients.
GOALS
Maintaining a safe and healthy working environment.
Preventing fatalities and lost time injuries.
reventing damage to the equipment, facilities and potential effects on
P
progress.
Eliminating risk to the environment.
No fires.A Safe and Productive Project, in Scheduled time.
Safety Rule and Procedure.
Rules:
Head Protection:All personals engaged for this job shall wear Safety Helmet of Class B type.
Hand Protection:Appropriate Hand Gloves will be used for Materials handling , Concreting,
Welding , Grinding , Gas cutting , Chemical Handling & Electrical work.
Eye Protection:Suitable goggles must be ensured for the personnel deployed for Welding
(Face Shield), Grinding, Gas cutting, Concreting, Chipping etc. Staff should
wear safety spectacle.
Ear Protection:The personnel engaged in the noise zone such as Compressor Operator.
Pneumatic Vibrators & Breakers, DG Operator etc. will be equipped with
suitable ear protection.
203
2.
3.
4.
Electrical:
1.
2.
3.
b.
Cranes & equipments shall be used after inspected & approved by the
Safety engg. Dept.
204
Others:
I t is preferable to have one entrance to enter the chimney. One security
guard shall be posted to prohibit anyone entering without helmet and
trespassers.
T
he entrance shall be sheltered to a length of 15m outside the chimney
and inside upto R. G. Hoist so that entrant will be saved from falling
material.
B
arricade is required around the shaft circumference at a distance of
10m.
I nside the chimney, at the locations where perpendicularly is checked
by laser beam, is to be sheltered with a small hole.
D
eploy minimum number of workmen on the platform and as far as
possible have them scattered.
S
afety posters and caution boards shall be displayed on the platform
and at ground level.
Intercom for communication is very much required.
I t is important to give a safety talk to workers by the concerned engineer
briefing on procedures before the slipform starts.
A
viation warning lights are necessary when the structure reaches
height of 50M
It is part of each employees job to report all unsafe act / unsafe
condition and accident immediately to his supervisor.
At No Smoking areas smoking is prohibited.
Horseplay like practical jokes, running etc. is strictly to be avoided.
Observe all working & hazard notice.
A
ll are requested to follow instructions from their immediate supervisors.
If instructions are not clear or are confusing, the employee has a
responsibility to clarify with the supervisor and obtain clear instructions
before commencement of works.
A
ppropriate fire extinguishers are to be kept on the platform. The
distance to reach a fire extinguisher should be maximum 25m.
205
PROCEDURE:
Safety Committee:
Safety Committee is formed at site whose function is to troubleshoot safety
problems and conduct a weekly safety walk down . Not more than five to six
members would be in the committee and they are mainly section in charges.
Safe Work Method.
A written Safe Work Method for a job is prepared by the Safety Personnel
in consultation with the concerned engineers. The Work Method helps to
foresee the risk involved in the job, take precautionary action for the risk
involved and plan the materials required for the safety cause. The safe work
method is methodically done as followed:
a.
Approach Safety.
b.
c.
d.
On receiving the safe work method, the line engineers brief it to their
subordinate and implement them.
Safety Meeting:
Safety meeting shall be held once in a week for staff and sub- contracors
representatives. The meeting is convened by the safety engineer and chaired
by the project manager / site superintendent. Minutes of the meeting are
minuted in L&Ts Safety Meeting Format. Copies are sent to GM/ DGM/ RSC,
PM/ Site staff, once in a fortnight.
Screening System:
All workmen before deploying at site shall be screened by the site in charge/
engineer and safety engineer.
Orientation :
Orientation on safety is given to the new staff and workmen before they go
to work place.
206
Training:
Training programmes conducted by the Safety engineer for staff and
workmen
General Safety
Safety in Welding & Gas Cutting Operation
Material Handling
Fire Safety
Working at Heights
Electrical Safety
Work Permit systems
Personnel Protective Equipments & Job based training programmes
Safety Inspection:
Daily Safety Inspection is conducted by safety engineer. .Weekly Safety
Inspection by the safety committee and the findings are minuted.
Tool Box Meeting / Safety Task Assignment (STA):
Tool box meeting is conducted everyday by gathering the workmen before
starting the job. Concerned engineer talks for 5 to 10 minutes on Safety to the
workmen. In Tool Box Meeting, general safety, case studies or job knowledge
is imparted to the workmen.
STA is conducted whenever a new activity is taken up and the concerned
engineer details the workmen the safe work method to carryout the job. This
safety procedure helps to keep the safety consciousness among the workmen
at constant level.
Ladder Inspection:
The ladders used in the site are numbered and inspected once in a month.
The inspection is recorded in a register.
207
Scaffolding:
Scaffolding is erected by an experienced scaffolders and under the supervision
of a competent authority. Tag system shall be followed to indicate whether the
scaffold is permitted to use or not. Red tag indicates, only scaffolders are
allowed to work on it and the scaffold is not ready to use. Green tag indicates
the scaffold is for use by all.
Wire ropes, Tools & Tackles inspection:
A competent person identified at the site first inspects the above materials.
The said materials are coded and coloured to indicate whether they are good
for use. Visual Inspection is carried out once in a month and recorded the
findings.
Electrical Inspection:
Monthly Inspection is done for the total electrical installation at the site and
recorded.
Equipment fitness certificate:
Any equipment arriving to the site is inspected and authorized by the
P & M engineer and safety engineer on its fitness to use. Based on their
recommendation the equipment is deployed / rejected / used after a minor
repair. The inspection is recorded.
Fire Safety:
1.
Once in three months the fire extinguishers installed in the site premises
shall be maintained and recorded in a register.
2.
Excavation Permit.
b.
c.
Million Safe Manhours: The jobsite which achieves One million safe
manhours or more a certificate of merit is given to the jobsite signed by
the President of the company.
2.
Annual Safety Award: Given to the Best Safety performed jobsite in the
Company as a whole.
3.
Best safety workman: This is given at site level on monthly basis. The site
safety committee selects the most safety conscious workman among the
workforce , for the month and rewards him
c) Working hours: Working hours may vary due to time of year and
particular peak workloads. In general work will be restricted to a ten
hours day with one-hour lunch break. Working on Fridays, the normal
rest day is discouraged but may be required from time to time.
Welfare facilities encompass both the site facilities and those of the company
accommodation.
SAFETY IN SLIPFORM:
GENERAL:
1.
2.
3.
4.
5.
6.
7.
Fire extinguishers will be kept on the platform and the distance to reach
a fire extinguisher will be max. of 25 mtrs.
8.
Safety posters and caution boards will be displayed on the platform and
at ground level.
PLATFORM:
1.
2.
3.
4.
Both inside and outside hanging scaffold platforms will be covered with
safety nets.
210
5.
ELECTRICAL:
1.
2.
3.
The electrical cable will be neatly traced along the platform and
handrail.
REINFORCEMENT GANG:
1.
2.
The access to pick the rebar from the winch bucket will be safe and easy
reach.
3.
4.
HOUSE KEEPING:
1.
2.
The shutter cleaning gang will be instructed to clear the platform at the
end of the shift and the collected debris will be brought down.
3.
Bit rods cut by gas cutter or electrode bits generated by welders will be
collected by the respective helpers and brought down at the end of each
shift.
2.
3.
4.
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This Handbook is the property of Larsen & Toubro Limited Construction Group and must
not be passed on to any unauthorized person or body for reproduction or reference
without prior permission sought in writing from L&T ECC Division.
August 2010