COST SAVING TECHNIQUES

1. STIFFENING WORK OF BRICK WALLS :

Considerable economy has been achived by using brick-on-edge ( Kodi bricks) in CM 1:4
instead of 6'' thick RCC band ( RCC patli ) for 6'' thick brick work.
The details are as per following :

COMPARATIVE STATEMENT SHOWING COST COMPARISON FOR STIFFENING

100MM THICK BRICKWORK USING -
a) Provision of brick-on-edge(Kodi brick) brickwork in CM 1:4

b) Provision of 6" thick R.C.C. band(R.C.C. Patli)

DETAILS:-
A) Rate Analysis for Item a) as mentioned above
For analysis 1 unit measuring 4.55m x 3.25m is considered
Total Length= 15.2 RMT
Volume of brickwork = 0.35 Cum
No. of Bricks required= 180 bricks
Volume of mortar(1:4)= 0.3804 Cum
Cement Required = 2.85 bags
Volume of Sand= 14.12 Cft.
Material Cost:- Labour Cost:-
Bricks:- 180x1.60=288/- Mason :- 1no. x 200 = 200/-
Cement:- 2.85x150=428/- M/C:- 2nos. x 100 = 200/-
Sand:- 14.12x13.4=190/-
Total:- 906/- Total:- 400/-

Total Material + Labour Cost = 1306/- for 15.2m length

So cost per unit length for the above item is Rs. 86/- per Rmt.

B) Rate analysis for item b) as mentioned above:-

Length Considered = 15.2 Rm.
Volume of Concrete= 0.23 Cum
No. of Cement bags=0.7 bags
Volume of Sand = 3.5 Cft.
Volume of Aggregate=6.92 Cft.
Steel Nominal = 2nos. of 8mm dia. with 8 laps
Total length of steel = 38.4 Rmt.
Total wt. of steel = 0.015 MT
Shuttering = 4.56 M2
Material Cost :- Labour Cost:-
Cement:- 105/- Mason:-1no. x 200= 200/-
Sand:- 47/- M/C:-2.5no. x 100= 250/-
Metal:- 98/- Fitter:- 1no. x 150= 150/-
Steel:- 263/- Helper:- 1no. x 100= 100/-
Shuttering:- 684/- Carpenter:-1no.x175= 175/-
Helper:- 1no. x 100= 100/-

Total:- 1197/- Total:- 975/-

Approximate Cost/Rmt.(1197+975)/15.2 = 143/-

Conclusion : From above calculations it can be seen that Stiffening by brickwork

is cheaper than R.C.C. Stiffener by 60%

2. VALUE ANALYSIS FOR REINFORCEMENT STEEL

The usual conventional practice for indenting & procurement of the Reinforcement
Steel bars for dia. from 6mm onwards is in the form of bend bars as 'U' shaped coils.
As far as bar dia. from 6mm to 12mm the supply in 'U' shape coils gives convenience in loading
Un-loading & transportation. Furthermore bar dias. upto 12mm in coil shape can be easily
straightened up at site even with less space before cutting.
But when the bars of dia. above 16mm are received in coil shape their is wastage of
6 to 12 % due to following reasons :

At many sites there is acute shortage of working space, particularly in Steel yards,hence it is
very difficult & some times even impossible to straighten the bars above 16mm received in 'U'
shaped coil & hence a recourse is taken to cut the coiled bar at both ends of bend as shown
in fig. below. This results into loss of 6' to 7' per coil which sometimes cannot be used anywhere
& results into unusable scrap.

At our Cresent Developer Site the above shortcoming has been rectified as the indenting
& procurement for bar dias. 16mm & above is done in the form of straight bars. This not only
reduces wastage but also less storage space is required with increased convenience in handling
with or without use of bar bending & cutting machines.
At this site an attempt has been made to reduce the quantity of unusable scrap by
adopting following simple but innovative measures :

1. The cut pieces resulting from cutting the straight bars are stacked dia. & length wise & as per
site requirements, these cut pieces are used in window sill slabs, lofts,lintels with due regards
to bearing,development & lap lengths as per structural requirements.
2. The cut pieces of dia. 16mm & above have been effectively used to as small as 6" length as
shear pins,column & fan hooks as per length available & as required.
3. The items like stands required for Brickwork & Plastering supports have been prepared entirely
from the cut pieces instead of utilizing full length bars.
3. COST SAVING ACHIEVED BY EXECUTING WATERPROOFING WORK
DEPARTMENTALY

The waterproofing work of C-bldg. Residential wing of 1st floor, 2nd floor & 7th floor was
executed by engaging depzartmental labour instead of giving the work to waterproofing
sub-contractor

ITEM OF WORK :- WATERPROOFING FOR TOILET BLOCK

Quantity of work executed :-

Item A :- Waterproofing Plaster -----67.88 Sqm.

Item B :- Sunken filling ----------------14.96 Cum.

Material Cost :-

1. Cement = 22 bags x 165/- = 3630 /-

2. Sand = 80.3 Cft x 16/- = 1300 /-
3. Bricks= 2750 nos. x 1.45 = 4000 /-

Total Material Cost = 8930 /-

Labour Cost for the above work :-

1. Mason = 70.5 x 150/- = 10575 /-

2. M/C = 101.75 x 75/- = 7631.25

Total Labour Cost = 18206.25 /-

Total Cost for the waterproofing work executed :-

= Material Cost + Labour Cost
= 8930 + 18206.25
= 27136.25 /-

Cost that would have incurred if the work was given to sub-contractor :-
A. Water-proof plaster = 67.88 x 150 10182
B . Sunk filing = 14.96 x1500= 22440
Total = 32622 /-

Cost Saving Achieved =32622 - 27136.25 / 32622

= 16.81%
Say 17 %

Conclusion :-
From the above it can be conluded that cost saving of about17 % can be
achieved by engaging departmental labour for waterproofing actitity instead of
sub-contracting the item, but ofcourse one should have expert waterproofing
personnel at site to execute the work
4. COST COMPARISON BETWEEN CONVENTIONAL BRICKWORK USING MORTAR
OF SCREENED RIVER SAND WITH CEMENT AND NON-CONVENTIONAL
BRICKWORK USING UN-SCREENED GRIT WITH CEMENT (1:6)

For Comparison in both the cases Mortar proportion considered is 1:6 & quantity of
Brickwork = 10 Cum.
Only the Material cost of Mortar is considered in both the cases with other parameters
remaining same for both.

ITEM "A" :

Brickwork using Mortar of Cement & Screened River sand ( 1:6 )

Cement Required = 15 bags
River Sand ( Screened ) = 4 Cum.
As 23 % of Sand is wasted during screening, actual quantity of sand required
= 4 x 1.23 = 4.92 Cum. Say 5 Cum.

COSTING:-

Cement ------------15 bags x Rs 145/- bag = 2175.00

River Sand --------5 Cum. x Rs 460/- Cum = 2300.00
4475.00

Cost of Mortar only for 10 Cum. = Rs 4475

for 1 Cum. = Rs 447.5
Add Labour Charges for Screening of Sand = Rs 70 /- Cum

Total Cost per Cum. = Rs. 517.50 Say Rs 518.00

ITEM "B" :
Non-conventional Brickwork using Cement+Un-screened Grit (1:6)
Quantities Required :
Cement = 15 bags + 5% extra for maintaining workability & w/c ratio due to slightly higher water
demand due to use of Grit = 15 + 0.75 = say 16 bags
Grit = 4 Cum. ( No Screening required )
Plasticizer (Optional) :-
To reduce the extra water demand & maintain workability the Plasticizer like
Vamiplas-302 @ 150 ml per bag may be used.
Quantity required = 150 * 16 / 1000 = 2.4 lit.

COSTING :-

Cement-------------16 bags x Rs 145/- bag = 2320.00

Grit------------------4 Cum x Rs 300/- Cum = 1200.00
Plasticizer----------2.4 lit x Rs 30/- lit = 72.00

Total cost of Mortar for 10 cum. = 3592.00

Cost per Cum. = Rs 359 /-

CONCLUSION :

From the above calculations it can be seen that by usingGrit instead of River Sand
in Mortar for Brick Masonry the overall cost can be reduced by31 % in comparison
Hence it is proposed to implement the above practice in near future.
5. COST COMPARISON BETWEEN CONVENTIONAL PLAIN CEMENT
CONCRETE USING RIVER SAND & NON-CONVENTIONAL P.C.C.
USING GRIT

Considering 1:3:6 proportion & quantity considered 10 Cum. the comparison has been made
for the cost of Sand Vs Grit with other parameters remaining constant for both the cases.

ITEM "A":
P.C.C. using River Sand

Quantity of P.C.C. = 10 Cum.

Cement = 45 bags at 145/- bag = 6525.00
Sand = 5 Cum. at Rs 460/- Cum= 2300.00
Cost for 10 Cum 8825.00

Cost per Cum =Rs 882.5 = Say Rs 883/-

ITEM "B" :
P.C.C. using Grit -

Cement = 45 bags + 3% extra due to increase water demand for Grit

= 46 bags at Rs 145/- bag = 6670.00
Grit = 5 Cum. at Rs 300/- Cum. = 1500.00
Total for 10 Cum. = 8170.00

Cost per Cum. = Rs 817.00 /-

CONCLUSION:
From the above calculations it can be concluded that by usingGrit instead of Sand
in P.C.C. overall saving above7% in material cost can be achieved.
Hence it is proposed to implement theabove practice in near future.
6. COST COMPARISON BETWEEN CONVENTIONAL & MODULAR M.S. FRAME SHUTTERING
For cost comparisoshuttering area of size 8' x 4' will be considered.
A) Conventional Shuttering using 12 mm thick shuttering grade plywood of size 8' x 4' with backing
support of wooden runners ( Chavis ) of size 2" x 3" in both the directions fixed together by 2 1/2"
long nails.
a ) Material Cost Including Labour charges for making:-
1 ) Plywood 1nos X Rs. 1857= 1857.00
2 ) 2"x 4" Chavis
Long direction=8'x4 nos=32'
Short direction=4' x5 nos. =20'
Total length = 52'
Total Cft volume=52x0.17x0.34=3 cftxRs.290/cft=870.00
3 ) Nails - 2 1/2'" long - 0,06 Kg xRs.30/Kg =1.80
4 ) Making charges- Rs.270.00 (Departmentaly)
Total=Rs. 2998..80 say Rs.2999.00
Nos. of repetitions = 8
Cost per repetition =2999/8= Rs.374.87 say Rs.375/- ( If 100% Depreciation is considered )
Considering 30 % material re-use the cost per repeatition=Rs.260/-

B ) Modular M.S. frame type shuttering fabricated ,using MSA-40x40x5mm &12 mm thick plywood
fixed together with 60 nos. 25mm long galvanized nut-bolts.
a ) Material cost including fabrication,fixing charges-
1. Angle frame = 0.051 M.T x Rs.22500=1147.50
2. 8'x4' Plywood 1 nos. x Rs.1857=1857.00
3. Nut-Bolts 6o nos. x Rs.0.85 =51.00
4. Labour for fixing Plywood = 35.00
Total=Rs3090.50
Note that the initial cost of this type of shuttering is abut 3.5 % Higher than the conventional type
of shuttering but it is highly economical in the long run due to increased number of repetitions
which is evident from the following calculations.
Nos. of repetitions obtained=14
In this case it is to be noted that after 14 repetitions only the plywood with some bolts needs
replacement as the supporting M.S. angle frame remains intact without any major repairs.
Cost of 1 plywood seet+30 nut-bolts & fixing charges=1857+25+35=1917
Number of repetitions = 14
Cost per repeatition=1917/14=136.92 say Rs.137

Conclusion:-
Thus it can be seen that there is an net saving of abou48% in the shuttering cost per repetition
when Modular type M.S. Angle frame shuttering is used instead of Conventional Shuttering.
7. Minimizing the wastage of white cement at the time of issuing from stores
Usually white cement is issued directly from the bag in multiples of 1/2 kg., this results into wastage of
white cement as the bag once opened is exposed to moisture, resulting in to setting of the cement, thereby
deteriorating the quality. To avoid this at our site the contents of the cement bag once opened are immediately
repacked in to pvc bags of capacity ranginf from 1/2 kg. To 1 kg. & issed accordingly.

8. Use of 43 grade OPC cement for non-structural works :-

At our site the 53 grade OPC cement isonly used for structural concreting of RCC works, while for other
works like masonry, PCC, plastering, drainage, flooring, tiling etc. 43 grad Opc cement is used.

9. In Raft foundation cost saving was achieved by using Fe-500 grade reinforcement steel instead of Fe-415 :

Dia. of bar Rates of Fe-415 Rates of Fe-500

16 16750 17588
20 16750 17588
25 16750 17588
28 17900 18795

The top layer of reinfoecement steel for raft according to old drawing was to be in Fe-415 at a spacing of 6" c/c
but later it was decided to use Fe-500 bars at a spacing of 8" c/c.

Consumption of 25 mm dia, Fe-415 @ 6" c/c = 33.5 M.T.

Consumption of 25 mm dia, Fe-500 @ 8" c/c = 25.11 M.T.
As seen above there is saving of 25% in reinforcement steel if Fe-500 bars are used.

Cost of 25 mm Fe-415 bars = 33.5 M.T. x 16750 = 561125.00 /-

Cost of 25 mm Fe-500 bars = 25.11 M.T. x 17588 = 441635 /-
Cost Saving = 561125-441625 = 119490 /-

From the above calculation it is clear that there is saving Rs. 119490/- Say @ 22 % if Fe-500
reinforcement bars are used instead ofFe-415 bars

10. At this site an attempt has been made to reduce the quantity of unusable scrap by adopting
following simple but innovative measures:
a) The cut pieces resulting from cutting the straight bars are stacked dia. & length wise & as per
site requirements, these cut pieces are used in window sill slabs, lofts,lintels with due regards
to bearing,developement & lap lengths as per structural requirements.
b) The cut pieces of dia. 16mm & above have been effectively used to as small as 6" length as
shear pins,column & fan hooks as per length available & required.
c) The items like stands required for Brickwork & Plastering supports have been prepared entirely
from the cut pieces instead of utilizing full length bars.