Tests on concrete

Compression test
The Compression Test is a laboratory test to determine the characteristic strength of the concrete but the making of test cubes is sometimes carried out by the supervisor on site. This cube test result is very important to the acceptance of insitu concrete work since it demonstrates the strength of the design mix. The procedure of making the test cubes is as follows: 1.150 mm standard cube mold is to be used for concrete mix and 100 mm standard cube mold is to be used for grout mix. 2. Arrange adequate numbers of required cube molds to site in respect with the sampling sequence for the proposed pour. 3. Make sure the apparatus and associated equipment are clean before test and free from hardened concrete and superfluous water . 4. Assemble the cube mold correctly and ensure all nuts are tightened. 5. Apply a light coat of proprietary mold oil on the internal faces of the mold. 6. Place the mold on level firm ground and fill with sampled concrete to a layer of about 50 mm thick. 7. Compact the layer of concrete thoroughly by tamping the whole surface area with the Standard Tamping Bar. (Note that no less than 35 tamps / layer for 150 mm mold and no less than 25 tamps / layer for 100 mm mold). 8. Repeat Steps 5 & 6 until the mold is all filled. (Note that 3 layers to be proceeded for 150 mm mold and 2 layers for 100 mm mold). 9. Remove the surplus concrete after the mold is fully filled and trowel the top surface flush with the mold. 10. Mark the cube surface with an identification number (say simply 1, 2, 3, etc) with a nail or match stick and record these numbers in respect with the concrete truck and location of pour where the sampled concrete is obtained. 11. Cover the cube surface with a piece of damp cloth or polythene sheeting and keep the cube in a place free from vibration for about 24 hours to allow initial set . 12. Strip off the mold pieces in about 24 hours after the respective pour is cast. Press the concrete surface with the thumb to see any denting to ensure the concrete is sufficiently hardened, or otherwise de-molding has to be delayed for one more day and this occurrence should be stated clearly in the Test Report. 13. Mark the test cube a reference number with waterproof felt pen on the molded side, in respect with the previous identification number. 14. Place the cube and submerge in a clean water bath or preferably a thermostatically controlled curing tank until it is delivered to the accredited laboratory for testing 15.Test the cube sample under compression testing machine, the factored load divided by the cross sectional area will give the compressive strength of concrete

Slump test
The concrete slump test is used for the measurement of a property of fresh concrete. The test is an emprical test that measures the workability of fresh concrete. More specifically, it measures consistency between batches. The test is popular due to the simplicity of apparatus used and simple procedure. The slump test is used to ensure uniformity for different batches of similar concrete under field conditions and to ascertain the effects of plasticizers on their introduction. The slump test result is a measure of the behaviour of a compacted inverted cone of concrete under the action of gravity. It measures the consistency or the wetness of concrete. The slump is termed as true slump, shear slump or collapse slump. If a shear or collapse slump is achieved, a fresh sample should be taken and the test repeated. A collapse slump is an indication of too wet a mix. Only a true slump is of any use in the test. A collapse slump will generally mean that the mix is too wet or that it is a high workability mix, for which slump test is not appropriate. Very dry mixes; having slump 0 25 mm are used in road making, low workability mixes; having slump 10 - 40 mm are used for foundations with light reinforcement, medium workability mixes; 50 - 90 for normal reinforced concrete placed with vibration, high workability concrete; > 100 mm.

Curing
Curing is the process of controlling the rate and extent of moisture loss from concrete during cement hydration.

It may be either after it has been placed in position (or during the manufacture of concrete products),thereby providing time for the hydration of cement to occur. Since the hydration of cement does take time in days, and even in weeks rather than in hours, curing must be done for a reasonable period of time if concrete is to achieve its potential strength and durability. Curing may also encompass the control of temperature since this affects the rate at which cement hydrates.

Purpose

Curing serves two main purposes.

It retains moisture in the slab so that concrete continues to gain strength It delays drying shrinkage until the concrete is strong enough to resist shrinkage cracking.

Properly curing concrete improves strength,durability,water tightness, and water resistance.

PROCESSES OF CURING
Water cure: The concrete is flooded,ponded or mist sprayed. This is the most effective curing method for preventing mix water evaporation.

Water retaining methods: Use coverings such as sand,canvas,burlap,or straw that are kept continuously wet. The material used must be kept damped during the curing period.

Water proof paper or plastic film seal: These are applied as soon as the concrete is hard enough to resist the surface damage. Plastic films may cause discolouration of concrete. So do not apply to concrete where appearance is important.

Chemical membranes: The concrete application should be made as soon as the concrete is finished.

Following methods are to be adopted for CURING different parts of buildings: Walls-Water should be sprinkled from the top such that it covers the whole area of the wall and it should remain wet. Slab-Ponding should be done on the slab by constructing bunds of mortar. Beams and columns-The beams and columns can be maintained wet by tying gunny bags /Hessian clothes around the periphery and by maintaining it wet always.

Compaction
Compacting reinforced concrete work is very important and is done using iron rods. In case the thickness of concrete is more than 15cm,the most satisfactory method for compacting concrete properly is to consolidate each layer separately so that its top surface become level and fairly smooth before the next layer is placed. While tamping is carried out, care should be taken that rod should penetrate the full layer of last layer placed and to some extent into lying to ensure proper bond between them. Secondly the reinforcement and formwork should not be disturbed from their positions. Mechanical compaction is done by use of vibrators.Compaction of concrete done by vibration is considered essential for all important works especially in situations where reinforcements are congested or the member is required to have exposed concrete finish. When vibrators are used, leaner but stiff concrete mix should be used to obtain greater durability and highest strength, mixes which are too stiff to be compacted by hand compaction can be easily compacted by mechanical compaction, in case the concrete is compacted by vibrations , during which the vibrator communicates rapid vibrations to the particles, increases the futility of concrete.Due to vibrations, the particles occupy a more stable position and concrete fills all the space.

Types of vibrators
Following are the type of vibrators usually used to compact the concrete: 1. Internal vibrators 2. External vibrators 3. Surface vibrators 4. Vibrating table Internal vibrator consists of metal rod like vibrating head which is immersed in the full depth of concrete layer. It is also known as poker or needle vibrator and is considered as most effective type of vibrator as it comes in to intimate contact with concrete. External vibrators are placed against the concrete foam- work and vibrating force for compaction is conveyed to the concrete through the foam work. These vibrators are also called form vibrators. The vibrator is rigidly

clamped to form work resting on an elastic spot, so that both the form and concrete are vibrated.

Concrete Mix Design

The process of selecting suitable ingredients of concrete and determining their relative amounts with the object of producing a concrete of the required strength, durability, and workability as economically as possible, is termed the concrete mix design.

Types of Mixes

Nominal mix
In the past the specifications for concrete prescribed the proportions of cement, fine and coarse aggregates. These mixes of fixed cement aggregate ratio which ensures adequate strength are termed nominal mixes.

Standard mix
The nominal mixes of fixed cement aggregate ratio (by volume) vary widely in strength and may result in under or over rich mixes. For this reason, the minimum compressive strength has been included in many specifications. These mixes are termed standard mixes. IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M25, M30, M35, M40. In this designation the letter m refers to the mix and the number to the specified 28 day cube strength of mix in N/mm2.

Designed mixes

In these mixes the performance of the concrete is specified by the designer but the mix proportions are determined by the producer of concrete, except that the minimum cement content can be laid down. This is the most rational approach to the selection of mix proportions with specific materials in mind possessing more or less unique characteristics. The approach results in the production of concrete with the appropriate properties most economically.

Factors affecting the choice of mix proportions

The various factors affecting the mix design are:

1.Compessive strength

The compressive strength required at a specific age, usually 28 days, determines the nominal water cement ratio of the mix.

2.Workability

The degree of workability required depends on three factors. These are size of the section to be concreted, the amount of reinforcement, and the method of compaction to be used. For the narrow & complicated section with numerous corners or inaccessible parts, the concrete must have a high workability so that full compaction can be achieved with reasonable effort.

3.Durability
The durability of concrete is its resistance to the aggressive environment conditions. High strength concrete is generally more durable than low strength concrete. In the situations when high strength is not necessary but the conditions of exposure are such that high durability is vital, the durability requirement will determine the water cement ratio to be used.

4.Maximum nominal size of aggregate

In general, larger the maximum size of aggregate, smaller is the cement required for a particular water-cement ratio, because the workability of concrete increases with in size of the aggregate.

5.Grading and type of aggregate

The grading of aggregate influences the mix proportions for a specified workability and water cement ratio. Coarser the grading, leaner will be mix which can be used. very lean mix is not desirable since it does not contain enough finer material to make the concrete cohesive.

Design mix for M40(for 1cum-concrete)

Water Cement Fine agg. Coarse agg. 20mm 10mm 154kg 440kg 627kg 1182kg 709kg 473kg

Design mix for M30(For 1 cum concrete)

Water Cement 168kg 390kg

Fine agg. Coarse agg. 20mm 10mm

683kg 1131kg 679kg 452kg

ACKNOWLEDGEMENT
. JKPCC is one of the leading construction corporation in J & K. It was a great experience to be a part of this esteemed organization as a trainee. During this short training of 6 weeks, I have been guided by many staff members here at the site. I am highly thankful to all the staff to have taken the time off from their busy schedule for explaining each and every minor detail. First and foremost, I am highly obliged to DGM , JKPCC UNIT-12 for permitting me to actually join the training, and his constant supervision due to which I have come a long way in building a sound practical knowledge. Next, I would like to thank managers who gave me vital details about the project, relating it to the theoretical concepts and also gave me inputs on how to manage things for optimal output owing to their vast experience, and their timely inputs and checks have actually helped me go into every detail of the project. I am very much thankful to Mr. khurshid sb (AEE/Civil), Mr. (jEE/CIVIL), and others who very selflessly gave me all the details of the construction methodology, and would take out their valuable time to answer all my queries. They have really guided me all along the project and have taken pains so as to make this training period worthwhile for me. Last, but not the least, I would like to thank all the JKPCC (Contractor) members and staff at the site for their cooperation

PROJECT OVERVIEW

Name of Work :Construction of district hospital at anantnag Owner: R & B division anantnag

Project Consultant: Structural & Geotechnical consulttants Estimated Cost: Contractor: No of stories Coverd area: grade of concrete: M25 : 61 crs JKPCC G+3 50,228 sft

steel reinforcement used : 10 mm, 25 mm

IMPORTANCE OF PRACTICAL TRAINING:

Engineering science is quite different from other academic studies, and the biggest cause of difference is importance of its practical field . The main aim of practical training is to make students aware of the practical happenings.The academic course of civil engineer is meant to learn fundamentals and know how to apply results of these basics on practical problems.

INFORMATION REGARDING PROJECT:

The hospital consists of 300 beds and is being accomplished by JKPCC in district anantnag of kashmir valley to serve the people of that region.it also includes the modern facilities not found in other hospitals.

LOCATION OF PROJECT:
The hospital was located in anantnag and is going to serve Not only the people of that district but the othert districts too.it has easir connectivity with far flung areas of anantnag and also with other districts like pulwama,shopian and kulgam.

ESTIMATED COST AND PERIOD OF COMPLETION:

The cost of the project was estimated to be about 61 crore rupees but no deadline was given to working company.The construction of bridge started in november 2007,the construction is going on smoothly and is expected to be completed very soon.

IMPORTANCE OF THIS PROJECT:

It will reduce the load on the existng hospital and will provide the better medicare facilities to the people. its construction will reduce the rush of the patients to the existing hospital and will increase its capacity.its latest design and facilities avaliable will serve for the betterment of people.

SITE SAFETY RULES

Manager/Engineer/Supervisors Responsibilities at the site

-Understand the companys and clients safety plan fully and follow the same in their day to day work activities. -Be familiar and show commitment to the implementation of our companys Health & Safety Plan. -Ensure that all persons undergo Health & Safety training before they are deployed at the site. -Ensure that employees working under them implement relevant requirements of this safety plan -Giving safety instructions to their workmen on a daily basis as a part of the job instructions, highlighting the possible hazards of the days work and the precautions to be taken. -Ensuring that the technicians under them are issued with necessary PPEs and they use the same.

-Identify weakness and deficiencies in job procedures, rectified these if possible and where necessary refer these to the Project Manager / Safety Representatives. -Keep their work area neat and clean, especially at heights free from loose materials -Promote the continuous improvement of Health & Safety performance. -Verifying the third party test certificates while hiring cranes of any lifting appliances for their validity. -Preventing horseplay of workmen. -Organizing and conducting tool box talks to their workmen every day. -Identifying and eliminating all unsafe conditions in their respective work area by carrying out safety inspection every day. -Take suitable corrective measures to rectify the unsafe observations pointed out by safety Engineers in his inspection report. -Inform their Respective Manager & Safety Representatives about ACCIDENT, NEARMISS & FIRST AID Case.

SITE SAFETY RULES OPERATIVES

-Make sure you attend a site safety introduction prior to commencing work. -Safety Helmets, High visibility vests and safety footwear are mandatory on site. -Possession and consumption to Alcohol/drugs is prohibited. -Smoking prohibited at work areas.

WORK AREAS

-Do not cross barriers or no entry areas. -Keep your work area clean, tidy and maintain good housekeeping. -All openings should be covered. -Scaffolding only to be erected dismantled or altered by an authorized competent person. -Use ladder, never climb on scaffolds. -Never remove guard rails. -Never tamper with Electrics. -Only authorized person should operate electrical power tools.

UNPLANNED EVENTS -Report all accidents including near misses. -Know the best means of escape from your work area and your assembly point in case of emergency. -Use proper fire extinguisher to extinguish the fire.

PLANT & EQUIPMENT -Only authorized operators and drivers should operate plant/equipment /vehicle. -Always use the right tool for the right job.

GENERAL -Follow safety signs, instructions and site safety rule. -Inform your supervisor, if something is in unsafe in your activity.

-Never carry out any operations, which may cause danger or injury to any person or loss of property.

WE TAKE PRIDE IN EVERYONE RETURNING HOME SAFELY EVERYDAY

SAFETY IS THE RESPONSIBILITY OF EVERYBODY BE SAFE ALWAYS

GO FOR ZERO ACCIDENT

CONSTRUCTION PROCESS

Construction process undergoes by this series. 1. 2. 3. 4. 5. 6. 7. 8. 9. Site clearance & decommissioning Demarcation of site Positioning of central coordinate & layout Excavation Plain cement concrete Water proofing Layout of foundation Column erection Beam and slab

Site Clearance & Decommissioning - Site clearance means removing all the buildings and facilities from a site. It might also include ground remediation where soil has been

contaminated radiologically or by other agents. Decommissioning is the process related to decontaminating and removing buildings or other structures; and clean up is concerned with ground remediation of contaminated land. Site clearance is, therefore, a combination of decommissioning and cleans up. Demarcation of Site- The whole area on which construction is to be done is marked so as to identify the construction zone. In our project, area was chosen and the respective marking was done. The marking is done on bases of points given by surveyors. Positioning of Central coordinate and layout- The centre point was marked with the help of a thread and plumb bob as per the grid drawing. With respect to this center point, all the other points of columns were to be decided so its exact position is very critical.

EXCAVATION

Excavation was carried out both manually as well as mechanically. Normally 1-2 earth excavators were used for excavating the soil. Adequate precautions are taken to see that the excavation operations do not damage the adjoining structures. Excavation is carried out providing adequate side slopes and dressing of excavation bottom. The soil present beneath the surface was too clayey so it was dumped and was not used for back filling. The filling is done in layer not exceeding 20 cm layer and then its compactedThe excavation is done by excavators and the excavated soil is transported by truck.

Drawings Required
1. Centerline Drawing 2. Layout Plan Removal of Excess Soil

Estimate the excavated stuff to be re-utilized in filling, gardening, preparing roads, etc. As far as possible try to carry excavation and filling simultaneously to avoid double handling. Select and stack the required material in such a place that it should not obstruct other construction activities. The excess or unwanted material should immediately be carried away and disposed off by employing any of the following methods. Departmental labour. Tractor. Trucks.

QUALITY CHECKS FOR EXCAVATION

Recording initial ground level and check size of bottom. Disposal of unsuitable material for filling. Stacking suitable material for backfilling to avoid double handling. Strata classification approval by competent authority. Dressing bottom and sides of pits as per drawing with respect to centerline. Necessary safety measures observed.

QUALITY CHECKS FOR FILLING

Recording initial ground level Sample is approved for back filling. Necessary marking/ reference points are established for final level of backfilling. Back filling is being carried out in layers (15cm to 20cm). Required watering, compaction is done. Required density is achieved.

PLAIN CEMENT CONCRETE (P.C.C)

After the process of excavation, laying of plain cement concrete that is PCC is done. A layer of 75mm was made in such a manner that it was not mixed with the soil. It

provides a solid base for the raft foundation and a mix of 1:4:8 that is, 1 part of cement to 4 parts of fine aggregates and 8 parts of coarse aggregates by volume were used in it. Plain concrete is vibrated to achieve full compaction. Concrete placed below ground should be protected from falling earth during and after placing. Concrete placed in ground containing deleterious substances should be kept free from contact with such a ground and with water draining there from during placing and for a period of seven days. When joint in a layer of concrete are unavoidable, and end is sloped at an angle of 30 and junctions of different layers break joint in laying upper layer of concrete. The lower surface is made rough and clean watered before upper layer is laid Materials and Tools used . Auto level instrument Wooden /Steel rammer Mixer machine

WATER-PROOFING
The moisture present in the ground or rain water may penetrate into the building from below, from side and also sometimes from the top of its roof, causing the structure to remain in damp condition and thus deteriorating the structure as a whole. It is therefore, very essential to prevent any moisture penetrating into a building now-a-days, care is taken while designing and constructing any building so that dampness can be prevented from affecting it and its inhabitants. There are various methods of water-proofing but at our site Kota stone with grouting is used as water-proofing because they are very impervious. METHODS OF WATER-PROOFING After laying P.C.C (100 mm thick) first we clean the surface by the help of blower. After cleaning the surface the cement sand mortar is prepared.

We add 1 liter. Siko in 1 bag cement and the same is applied in 25 mm thick layer.

Then Kota stone is laid in cement mortar (1:4) (25 mm thick). After laying Kota stone gap between stone and P.C.C is filled with slurry. And then 25 mm protection coat of cement plaster is applied.

KOTA STONE IS USED AS WATER-PROOFING MATERIAL BECAUSE 1. 2. 3. 4. 5. It is impervious to moisture. It is durable. It does not disintegrate under loading. It provide uniform and homogeneous layer. It is easily available.

LAYING OF FOUNDATION
At our site, isolated square foundations are used to spread the load from a structure over a large area, normally the entire area of the structure. foundations are used to distribute heavy column and wall loads across the entire building area, to lower the contact pressure compared to conventional spread footings.Isolated foundations are used where the load expected from superstructure is not heavy enough .

METHOD OF LAYING OF FOUNDING First we study the drawing.

After study the drawing B.B.S. (BAR BENDING SCHEDULE) is prepared by the engineer. Then the B.B.S. is passed at senior level.

 After B.B.S. is passed reinforcement is prepared by reinforcement gang at steel yard with the help of bar bending machine, bar cutting machine etc. When reinforcement is prepared it is taken to the site (at working place) with the help of tractor, tower crane, manually. Then formwork is prepared for foundation by carpenter gang.

Then the reinforce bar is tied as per drawing specifications by reinforcement gang under supervision of engineer. Cover blocks are providing at bottom, sides and ends of foundation of 50mm. After completing the reinforcement it is checked by the senior officers. When the reinforcement is passed, we ready for next step of concreting. Concrete Grade used in foundation: - M30

COLUMN ERECTION AND CONCRETING

Concrete columns are used for carrying loads of a building. They transfer the same to a suitable soil bearing capacity. They carry loads horizontally, vertically and laterally. They can be erected as free standing, used for hanging gates. Alternatively they can be incorporated within the walls of a building structure. Concrete columns are made from steel and concrete cast in a formwork. These are done in circular, rectangular or square shapes.

METHODS OF COLUMN ERECTION:

In erecting concrete columns the load to be carried is considered. This determines the size of column and type of reinforcement to use. After that surveyor give us some point for starter of column. Then the starter is provided as per points. Formwork of the required column size is formed first aside.

The steel should be free from oils and rust. Use binding wire to tie together all steel. Its important to cast concrete in lifts. This should not exceed two thousand five

hundred millimeters in height. When the steel work is complete, then form work assembly starts. The formwork for erecting a column is fixed by opening the sides. Its then slid to have the steel inside the box. Once the box is upright, the form work is then fastened and supported on all sides. Concrete is then poured and vibrated until it reaches the top of the box. It is left for seven days. Curing is done from the top. After seven days the form work is then removed to expose the cast column. This is continuously cured for another seven days.

COLUMN REINFORCEMENT

TIE BEAM REINFORCEMENT

CARE TAKEN WHILE COLUMN ERECTION

A proper tie of reinforcement is done. Lap length should by according to drawing. Cover blocks are provided at suitable intervals. Board used should not be in damage condition. Staging should be done properly. Alignment should be proper.

BEAM AND SLAB CASTING MATERIALS AND MACHINERY USED

mixers. Vibrators

REINFORCEMENT
It shall be as per BBS prepared according to approved drawing. The R/F shifting and binding shall be started as soon as shuttering is completed. R/F binding shall continue as formwork and shuttering work is progresses.

PRODUCTION AND PLACEMENT OF CONCRETE

Stock of material shall be sufficient to start the concrete. It shall be ensured by stores/purchase dept that concreting is not stopped on account of materials. All plant and machinery are checked and made in working conditions.

Proper walkways/platforms shall be arranged so that the supports of the pipeline and manpower are not directly stand on reinforcement. Sufficient carpenters along with supervisor shall inspect the behavior of supports below the slab during the casting. Extra Props shall be stocked below slab to provide additional supports in case of any failure of supports.

CURING
The curing shall be started immediately after thumb set of the concrete laid. Final curing shall be done by ponding and stacking water for minimum period of 7 days.

SCAFFOLDING
Scaffolding is a temporary structure used to support people and material in the construction or repair of buildings and other large structures. It is usually a modular system of metal pipes or tubes, although it can be made out of other materials. Bamboo is still used in some Asian countries. The purpose of a working scaffold is to provide a safe place of work with safe access suitable for the work being done.

SHUTTERING

Shuttering or form work is the term used for temporary timber, plywood, metal or other material used to provide support to wet concrete mix till it gets strength for self support. It provides supports to horizontal, vertical and inclined surfaces or also provides support to cast concrete according to required shape and size. The form work also produces desired finish concrete surface. Shuttering or form work should be strong enough to support the weight of wet concrete mix and the pressure for placing and compacting concrete inside or on the top of form work/shuttering. It should be rigid to prevent any deflection in surface after laying cement concrete and be also sufficient tight to prevent loss of water and mortar form cement concrete. Shuttering should be easy in handling, erection at site and easy to remove when cement concrete is sufficient hard. Generally there are three types of shuttering. Steel Shuttering Wooden Planks Shuttering Temporary Brick Masonry Shuttering

WOODEN PLANK SHUTTERING:Generally wooden planks shuttering is used by contractors because this shuttering is cheap and easily available. But this type of shuttering affects the strength of concrete and has some disadvantages which are given below. DISADVANTAGES This is not water tight shuttering as the size and thickness of planks differ and are not of same size. Due to this difference the water and cement flow to the ground from joints and reduce the strength of concrete. Bottom level of RCC slab is not in straight line and the surface being uneven, the thickness of plaster is more which remains weak. Due to leakage of cement slurry through joints, earth work below 'Ballies may settle and create problems. In some cases wooden planks cannot bear the weight of concrete. Due to low strength there is bending or deflection in wooden planks. Sometimes the planks may break.

PRECAUTIONS FOR VERTICAL SUPPORTS FOR RCC BEAMS, SLABS ETC The 'Ballies used for vertical support should not be less than 6'' dia and these should be in one length without joints. Never allow bricks support of more than one or two bricks below a 'balli' to make required height. Cross Ballies or bracing should be done for better support to beam as well as slab. The wooden batten used below the plate should not be less than 5'' in height.

At the time of concreting one carpenter with helper having spare ballies, nails etc. should be deputed for watching any disturbances in ballies under shuttering. REMOVAL OF SHUTTERING As a guideline, with temperature above 20 degree following time limits should be followed: STRUCTURAL COMPONENT Footings Sides of beams, columns, lintels, wall Underside of beams spanning less than 6m Underside of beams spanning over 6m Underside of slabs spanning less than 4m Underside of slabs spanning more than 4m Flat slab bottom Age 1 day 2 days 14 days 21 days 7 days 14 days 21 days