Professional Documents
Culture Documents
Hand Book On Foundation, Formwork, Rebar & Concrete (PDFDrive)
Hand Book On Foundation, Formwork, Rebar & Concrete (PDFDrive)
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 OC’s 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 & DON’Ts
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 FORM WORK
Introduction............................................................................................6
Worksite Management............................................................................6
Assembly & Dismantling Process..............................................................9
Flowchart for Aluform...........................................................................32
SLIP FORM
Introduction..........................................................................................34
Type of Slipform....................................................................................36
Assembly procedures............................................................................36
Tapering Slipform.................................................................................38
Assembly of stair tower..........................................................................39
Dismantling procedure..........................................................................40
Summary of Labour Productivity Norms..................................................43
Slipform Planning.................................................................................44
TUNNEL FORM
Aluminium Formwork Refurbishment......................................................47
Plywood...............................................................................................71
Form Release agent..............................................................................73
Formwork lift........................................................................................74
Automatic Climbing System...................................................................75
Hand tools required..............................................................................76
Guidelines for Formwork Engineer ........................................................33
Guidelines for Foreman/Charge hand...................................................78
System Formwork Functions, applications& Safety...................................79
REINFORCEMENT WORKS
Category of Reinforcements...................................................................91
Reference Indian standards...................................................................91
Reference International Standards..........................................................91
2
Hook & Bend Allowance........................................................................92
Bar bending Schedule Format................................................................93
Minimum diameter required for Bending Former....................................98
Cross-sectional area & Mass of Rebar....................................................99
Checks...............................................................................................100
Testing of Rebar..................................................................................101
Nominal cover....................................................................................104
Tips on Cover.....................................................................................104
Tolerance of cover...............................................................................104
Material for cover...............................................................................105
Photographs (Rebar)...........................................................................106
Prefabricated cage photos...................................................................109
Rebar tying machine...........................................................................109
Splicing methods................................................................................110
Precautions.........................................................................................110
Splicing strengths................................................................................110
Reinforcement couplers.......................................................................110
Coupler photographs..........................................................................111
Classification of test for Reinforcement couplers....................................112
Reinforcement Binding........................................................................113
Welding of Reinforcements..................................................................115
Precautions in Rebar activity.................................................................117
PILNG WORKS
Pile....................................................................................................119
Classification......................................................................................120
Factor governing Pile selection.............................................................112
List of Reference Codes.......................................................................125
Installation sequence
Driven cast in-situ piles...................................................................126
Bore cast in-situ piles......................................................................127
Characteristics of Bentonite suspension for BCIS piles...........................128
Important things to be followed...........................................................130
3
Driven cast in-situ piles...................................................................130
Bore cast in-situ piles......................................................................131
Driven precast...............................................................................132
Load test on Piles................................................................................134
Types of Arrangements........................................................................134
Vertical load test Arrangements.......................................................135
Lateral load test Arrangements.......................................................137
Pullout test arrangements...............................................................138
Pile Integrity test..................................................................................140
PDA Test.............................................................................................140
‘O’ Cell Test........................................................................................142
CONCRETE WORKS
Cement..............................................................................................145
Physical requirement of Cement...........................................................149
Mineral Admixtures.............................................................................150
Fly ash..........................................................................................150
GGBFS..........................................................................................154
Micro silica& Metakoline.................................................................154
Aggregates.........................................................................................155
Mechanical Properties....................................................................158
Grading Requirements...................................................................159
Mixing of water...................................................................................161
Admixture...........................................................................................162
Concrete............................................................................................163
Grades of concrete........................................................................164
Exposure conditions.......................................................................165
Batching.............................................................................................168
Mixing Time........................................................................................170
Transporting Concrete.........................................................................171
Planning.............................................................................................172
Compaction.......................................................................................173
Vibration............................................................................................173
4
Points to remembered in Compaction..................................................174
Finishing............................................................................................175
Curing...............................................................................................177
Common defects in Concrete..............................................................179
Types of Surface defects.......................................................................180
Special concrete..................................................................................186
PRESTRESSING
Introduction........................................................................................187
Definition...........................................................................................187
Advantages of Prestressing..................................................................188
Application.........................................................................................188
Materials management.......................................................................189
Reference Standard & codes................................................................191
Elongation & Modified Elongation Calculations....................................192
Jack Pressure calculations....................................................................192
Losses in Prestressing..........................................................................193
Properties of HT strand (IS: 14268-1995).............................................193
Methodology of Post Tensioning works.................................................194
Prestressing Equipments......................................................................197
Tendon Profile.....................................................................................198
Case study.........................................................................................199
Photos................................................................................................201
5
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,
¾¾ Wall panel Layout,
¾¾ Slab Panel Layout,
¾¾ Starter Block Layout,
¾¾ Corner Layouts,
¾¾ Beam Panel Layout,
¾¾ Soffit Layout,
¾¾ Staircase Layout,
¾¾ Bracket and Soldier layout,
¾¾ 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 re-
adjustable 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.
7
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.
8
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.
¾¾ 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.
¾¾ Do not over apply. Excess Formoil can adversely affect performance
and should be picked up promptly with rags.
¾¾ 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.
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.
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.
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.
Aluspan
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
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
Flow Chart for
Aluform Work at Site
FLOW CHART FOR ALUFORM WORK AT SITE:-
1 1a, 1b, 1c
If not suitable
2a, 2b 2 3 3a
5 4 4a
7 7a
`
8
11
13
14 15 15a
16a 16 17 18
23 22 21 20
32
Activity for the Flow
Chart Numbers
1. Receive Aluform materials.
1a. Packing list, BOQ, and Formwork layout.
1b. Tools.
1c. Additional accessories.
2. Visual inspection.
2a. Packing list & schemes.
2b. Acceptance criteria.
3. Inform concern for any defects
3a. Details of report.
4. Collect modification details.
4a. Fabrication drawings.
5. Stock the material as per packing list.
6. Room wise segregation.
7. Dry mock-up.
7a. Schemes.
8. Room wise numbering for identification.
9. Dismantling of mock-up.
10. Setting out.
11. Shift to work location.
12. Shift to stock yard.
13. Actual assembly at work location.
14. Slab rebars & M&E works.
15. Final checking (Pre pour check)
15a. Check list.
16. Concreting.
16a. Pour card.
17. Post pour check.
18. Leveling and finishing.
19. De-shuttering
19a. Removing pins and wedges.
19b. Removing wall ties.
19c. Removal of wall panels.
19d. Removal of deck panels.
20. Cleaning of panels.
21. Fixing of working platforms with brackets.
22. Erection of Safety posts / rails.
23. Applying Form release agent.
33
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
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
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
Check starter for the correctness in level and diameter.
Fix the inside and outside staging brackets/erect scaffold pipes, if
required.
Fix timber runners connecting the walkway brackets. / Level the surface
using cement mortar.
Check the level.
Tie the vertical and horizontal reinforcement upto shutter top height.
ark the position of inside and outside yokes in the starter, starting from
M
the tower location.
nsure that three sets of yokes are located in between two tower
E
verticals.
lign the panels and introduce steel washers at regular intervals to
A
maintain
4mm slope both inner & outer faces.
ix top and bottom waler pipe. Fix external supports, both horizontal and
F
inclined to align the shutter.
Fix filler panels.
Repeat the operation 10 to 12 for outside and make sure that washers are
introduced at the bottom of shutters to achieve 4mm slope towards inside.
ix the waler shoes, inside and outside yoke legs. Adjust waler shoe and
F
check the verticality on both faces
Keep timber supports between top & bottom walers at yoke location.
Align the form panel by external supports.
ix the yoke beam generally two numbers at the bottom and one number
F
at top.
Check the level of yoke beams with spirit levels.
Fix the inside and outside walkway brackets.
inish the final alignment by suitably adjusting the waler shoe bolts. Ensure
F
that all walers are touching the form panels. Provide packing wherever
required.
Fix the flying tie rod assembly and support the center rings. Ensure uniform
tightness is maintained in all the spokes.
37
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 form supports with pre assembled
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.
Stair tower shall be checked for verticality at every support location. If any
deviation is found it shall be corrected then and there, by adjusting support
length. The deviation in verticality shall not be more than 10mm for every
10M of height and maximum 50mm for the overall height.
39
17. Consistent quality of concrete.
18. Periodical checking of concrete slump.
19. Fixing of required setting time for concrete based on slipping speed.
Dismantling Procedure
Stright Slipform:
Tapering Slipform:
40
7. Remove all the hydraulic hoses, manifolds and the jacks.
8. Remove the intermediate form supports, spindles, turnbuckle, shutters,
form supports, wall thickness screws, radius screws and yoke beams.
9. Remove inside & outside yoke legs.
10. Dismantle the truss assembly.
11. Extract the jack rods and grout the hole
12. Lower the materials then and there.
13. Remove the dismantling platform.
Slipform Reinforcement:
The total requirement of reinforcement should be cut / bent and kept near
the slipform structure before starting slipform. The stocks should be kept with
proper tag for easy identification.
41
3. ACI 313-77 R83 - Recommended practice for design and construction
of concrete bins, silos and bunkers for storage of granular materials.
42
Summary of Labour
Productivity Norms
Sl. Norms
Type of Work Unit
No. In M.Hrs
1 Erection of Access Tower (2.5 X 2.5 M) RM 32
2 Dismantling of Access Tower (2.5 X 2.5 M) RM 15
3 Erection of Stair Tower (2.5 X 2.5 M) RM 16
4 Dismantling of Stair Tower (2.5 X 2.5 M) RM 8
5 Straight Slipform Assembly YOKE SET 75
6 Straight Slipform Dismantling YOKE SET 55
7 Slipform Operation - Straight Slipform M2 1.22
8 Assembly of Pre-Stressed Silo YOKE SET 92
9 Slipform Concrete - Manual M 3
22
10 Slipform Concrete - Rmc With Pump M3 15
11 Slipform Concrete - Rmc With Hoist M3 25
12 Slipform Reinforcement - Straight Slipform MT 65
13 Extraction of Climbing Rod RM 0.34
14 Taper Slipform Assembly - Upto 24 Yoke Set MT 56
15 Taper Slipform Assembly - 16 To 48 Yoke Set MT 49
16 Taper Slipform Dismantling - Upto 24 Yoke Set MT 49
17 Taper Slipform Dismantling - 16 to 48 Yoke Set MT 46
18 Re-Assembly of Slipform - Taper Slipform MT 78
19 Re-Assembly of Slipform - Straight Slipform YOKE SET 90
20 Slipform Operation - Taper Slipform M 2
2.45
21 Slipform Reinforcement - Taper Slipform 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 Pre-Stressing Works in Silos 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.
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.
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:
Basic Loads:
Live Loads
Weight of Equipment
Note:- Jack shall not be loaded more than 80% of its capacity.
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
wire rope required for hoisting to be calculated separately based on height of
the structure.
Timber Requirement
The requirement of timber is for the following areas.
1) Working platform 2) Mason’s platform 3) Runners for supports
4) Planks for the bracket platform if assembly is taken up from higher
elevation.
Working Platforms
Timber platform consisting of four parts
a) Supporting runners 5”x 3”x7’ long & 6’ long
b) Wooden planks 6” x 1½” x 6’ long.
c) Toe board size: 4” x 1½” 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
a.1) Tools Required
Ball Pein Hammer
Chisel
Scrapper
b) Machine Cleaning
c) Dent Removal
68
d) Welding
e) Surface cleaning
69
e.1) Tools Required
AG7 & AG4 GrindingMachine ( RPM – 5000)
Sander Disc (80/120 Grade)
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 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
Repetitions – 8 to 10
71
72
Form Release Agent
Approved Form Release Agents
It’s 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&T’s 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 BSCC-
HQ which further eliminated the crane requirement for floor to floor shifting
of RCS.
74
ACS - Automatic Climbing System
Self Climbing System ACS - Fields of Application
75
Hand tools required (work place)
76
ROLES & RESPONSIBILITIESOF FORMWORK
ENGINEER AT SITE
1. Preparation of Formwork programme based on the overall construction
programme
10. Maintain close interaction with stores and site people for proper
accounting of materials
12. Making of purchase requisition for Plywood and Timber after thoroughly
analyzing the number of repetitions
77
16. Ensuring that despatched materials are in usable condition.
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.
78
1.Foundation formwork(All steel)
Functions/Salient features
2. No timber is used
3. Easy to assemble
Sequences of assembly
1. Materials stocking near to layout
2. Cleaning and oiling
3. Layout marking
4. Floor forms positioning
5. Accessories fixing
6. Line and verticality checking
7. Concreting
8. Deshuttering
1. Safety helmet
2. Manila rope 20 mm or 25 mm
Safety precautions
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
3. High strength tie system bear large concrete pressure and avoid load
bearing struts
Sequences of assembly
4. Panel positioning
7. Concreting
8. Deshuttering
1. Safety helmet
2. Safety belt
80
4. Manila rope 20 mm or 25 mm
Safety precautions
Crane operation
5. Before lifting the panel, necessary pre checking has to be done on the
panels.
Manual operation
2. Use the proper tool for adjusting the panel height and line
3. Flex system
Functions/Salient features
81
Sequences of assembly
7. Placing of plywood.
10. Concreting
11. Dismantling
12. Cleaning
1. Safety helmet
2. Safety belt
Safety precautions
82
3. Do not use tor steel in place of locking pin
Sequences of assembly
6. Levelling of beams
7. Placing of bottom/sheathing
8. Leveling of bottm/sheathing
83
10. Cleaning and oiling
11. Concreting
12. Dismantling
13. Cleaning
1. Safety helmet
2. Safety belt
Safety precautions
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
84
Sequences of assembly
3. Frame fixing with necessary accessories at bottom with foot plate , spring
locking pin and tower spindle
8. Dismantling
9. Cleaning
1. Safety helmet
2. Safety belt
3. Safety net for taller structures whereever it is necessary
4. Manila rope 20 mm or 25 mm wherever it is necessary
Safety precautions
4. Do not use coir string or binding wire in place of M 10 bolt and nut with
grid iron
85
6. Access scaffolding
Functions/Salient features
3. This provides free movement for workmen without any obstuction at all
levels
Sequences of assembly
8. Dismantling
9. Cleaning
1. Safety helmet
2. Safety belt
86
3. Safety net for taller structures whereever it is necessary
Safety precautions
1. 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
Sequences of assembly
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. Erection of outer panels with necessary accessories
7. Concreting
1. Safety helmet
2. Safety belt
Safety precautions
5. Before lifting the panel , necessary pre checking has to be done on the
panels.
88
2. Hot-dip galvanished for high Durabilty
3. High grade 15 mm thick film coated sheathing for high wear resistance
Sequences of assembly
4. Concreting
1. Safety helmet
2. Safety belt
Safety precautions
1. Provide the tierod only where the given the provision is given
89
9.Climbing formwork
Functions/Salient features
1. Safety helmet
2. Safety belt
Safety precautions
1. Platform timbers should be free from cracks ,fungus attack and dead
knots
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
Note:
92
Calculated Hook & Bend Allowance:
5 75 - 75 - 75 - 75 - 75 - 75 -
6 75 - 75 - 75 - 75 - 75 - 75 -
8 75 - 90 - 105 - 75 - 75 - 75 -
10 90 - 110 - 130 - 75 - 75 - 75 -
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
LARSEN & TOUBRO LIMITED -ECC DIVISION
QUALITY FORMAT
TOTAL
BAR DIA. OF NO.PER NO.OF No. OF CUT NET
MEMBER NO. BAR MEMBER MEMBER BARS LENGTH LENGTH SHAPE
TOTAL Wt.
REMARKS :
94
95
96
97
Minimum Diameter Required for Bending Former
Bending Former
Bending Former
Minimum dia. (mm).
Bar diameter ‘d’ (mm) Minimum dia. (mm).
[As per IS 2502-1963]
[As per BS-8666-2005]
for cold worked steel.
6 48 (8d) 24 (4d)
8 64(8d) 32(4d)
10 80 (8d) 40 (4d)
12 96 (8d) 48 (4d)
98
Cross-Sectional Area and Mass of Rebar
5 19.6 0.154
6 28.3 0.222
7 38.5 0.302
8 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
¾¾ Check the brand isapproved or not.
¾¾ Check Grade of reinforcement
¾¾ Check the Quantity requirement and duration
¾¾ If new vendor collect sample and check for conformity
On receipt at site
¾¾ S
tack various diameter bars separately over wooden sleepers ( avoid
contact with soil)
¾¾ Identify the stack with a tag number
¾¾ 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
¾¾ 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
Check Rolling margin ( at site lab)
Weigh the mass (measure to a precision of +0.5%) of the rebar
samples.
Calculate the nominal mass = Mass of the sample
Actual length of sample
The nominal mass should satisfy the Table 2 of IS1786-2008
102
Rebar Mechanical properties should satisfy Table 3 IS 1786 requirements
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
Nominal Cover for Durability requirement:
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:
TOLERANCE OF COVER
+10 mm
ACTUAL COVER = OF NOMINAL COVER
-0mm
104
Material for Cover
105
Photographs
Plain Rebars
Deformed Rebars
106
Stainless Steel Rebar
107
Hot Dip Galvanised Rebar
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:
Reinforcment couplers:
Classification according to IS Code (Draft):
Class L +H
Class L.
110
Coupling with injected sleeve
¾¾ Molten metal injection
¾¾ Grout (or) epoxy resin injection
Butt splices
Welded couplers
Other patented type
111
Classification of test for reinforcment couplers
Slip test
112
The above data is based on draft published by Indian Standard.
Reinforcement Binding
113
Hair Pin Tie:
Crown Tie:
Splice Tie:
114
Welding of Reinforcments:
References Standards:
IS 9417-1989
SP-34(S&T)-1987
Lap Welding
115
Quality Control Test on Welded Rebars
Samples of Lap welded joints to be tested for Mechanical properties like
Tensile. The failure should occur in the bars outside weld area and not on
the weld.
Samples of Butt weld joints to be tested for Tensile and Bend test. The failure
should occur in the bars outside weld area and not on the weld in tensile and
no sign of crack in the weld portion in bend test.
116
Precautions in Rebar Actvity:
117
Do not position laps in beam column junctions.
Do not position laps in the midspan of the beam at bottom
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
¾¾ Bored cast-in-situ piles
¾¾ Driven cast- in-situ piles
¾¾ Driven precast piles
Steel piles
120
Sheet Pile Vibro Hammer
Test on piles
¾¾ Pile load test (vertical compression,lateral & pull out )
¾¾ Pile integrity test (low strain dynamic test)
¾¾ PDA test (high strain dynamic test)
¾¾ Lateral dynamic test
¾¾ Ultrasonic logging test
¾¾ “O” cell load test method.
121
To be inserted in Page 88-(Continued from above)
FACTORS GOVERNING PILE SELECTION
FACTORS GOVERNING PILE SELECTION
SL.No. FACTOR BORED CAST DRIVEN CAST IN SITU DRIVEN PRECAST
INSITU
TECHNICAL CONSIDERATIONS
I SOIL BEHAVIOUR DUE TO
CONSTRUCTION
b PILE LATERAL MOVEMENT DOES NOT OCCUR CAN OCCUR CAN OCCUR
CANNOT BE CORRECTED CANNOT BE CORRECTED
c LOOSE MATERIALS AT PILE CAN OCCUR DOES NOT OCCUR DOES NOT OCCUR
TIP
d DENSIFICATION OF SILTY DOES NOT OCCUR OCCURS IMPROVES OCCURS IMPROVES
FINE SAND SHEAR STRENGTH SHEAR STRENGTH
e DEVELOPMENT OF EXCESS MAY FORM DUE WILL FORM RESULTS IN WILL FORM NO AFTER
PORE PRESSURE TO TEMPORARY WASHING OF CEMENT EFFECT
CASING SLURRY AND WASHING
RESULTING OF OF PILE SHAFT
CEMENT SLURRY
AT THE TIME OF
WITHDRAWAL
f SUB SURFACE WATER UNCASED BORE WILL WASH CEMENT UNAFFECTED
CURRENTS WILL COLLAPSE SLURRY
AND IN CASED,THE
CEMENT SLURRY
WILL GET WASHED
OFF
g STRUCTURAL INTEGRITY NECKING CAN NECKING CAN OCCUR NOT APPLICABLE
DUE TO TEMPORARY OCCUR
CASING
h QULAITY OF CONCRETING QUALITY OF BOUND TO GET QUALITY CAN BE
CONCRETE IN PILE SEGREGATED .QUALITY GURANTEED
SHAFT CANNOT BE CANNOT BE GURANTEED
GUARANTEED
II PILE/ SOIL INTERACTION IF BENTONITE IS FULL FRICTION AND END FULL FRICTION AND END
NOT CIRCULATED BEARING WILL BE BEARING WILL BE
CONTINUOSLY MOBILISED MOBILISED
SLUDGE CAN BE
FORMED AT
BOTTOM AND
SKIN FRICTION
MAY BE AFFECTED
122
SL.No. FACTOR BORED CAST DRIVEN CAST IN SITU DRIVEN PRECAST
INSITU
123
SL.No. FACTOR BORED CAST DRIVEN CAST IN SITU DRIVEN PRECAST
INSITU
5 GESTATION TIME 7 DAYS FOR EACH 7 DAYS FOR EACH PILE 28 DAYS FOR FIRST
PILE ADDITIONAL CASTING FIRST SET UP
PRECAUTION OF PILES IN YARD AFTER
NECESSARY.DUE TO SOIL MOBILISATION.
DIFFERENCE HEAVE
WHILE DRIVING
ADJACENT.
A SITE CONGESTION NOT LIKELY FLEXIBLE FLEXIBLE
B GROUND CONDITION PREFERABLY DRY DRY & LEVEL GROUND DRY & LEVEL GROUND
& LEVEL ABOVE DESIRABLE ESSENTIAL
WATER TABLE
C ENVIRONMENTAL MESSY DUE TO CLEAN CLEAN
BENTONITE
D NOISE LEVEL LOW HIGH HIGH
(EAR PLUGS/EAR MUFFS (EAR PLUGS/EAR MUFFS
IS MUST) IS MUST)
6 PILE CONSTRUCTION & DOES NOT OCCUR CAN OCCUR CAN OCCUR BUT CAN BE
SUB SURFACE REMIDED BY REDRIVING.
INTERACTION GROUND
HEAVE
7 RESTRICTION ON PILE
SIZES
A CROSS SECTION ONLY CIRCULAR. DIFFICULT TO DRIVE DIFFICULT TO HANDLE >
DIFFICULT TO LARGE DIA > 600 MM 600MM DIA.
CONCRETE LESS DIA
THAN 400 MM DIA
B LENGTH ANY LENGTH DIFFICULT FOR VERY GENERALLY LIMITED TO
LONG LENGTH 20-22 M.GREATER
LENGTH CAN BE
ACHIEVED BY JOINED
SECTION.
COMMERCIAL CONSIDERATIONS
1 TOTAL COST LEAST COSTLIER THAN BCIS COSTLIEST
2 INFRASTRUCTURES AT SITE NORMAL NORMAL NORMAL
3 EQUIPMENT SIMPLE/ SIMPLE/ SIMPLE/
SOPHISTICATED SOPHISTICATED SOPHISTICATED
124
List of reference codes
¾¾ I S 2911 part -1 (sec 1) - Design & construction of pile foundation
(DCIS)
¾¾ I S 2911 part -1 (sec 2) - Design & construction of pile foundation
(BCIS)
¾¾ I S 2911 part -1 (sec 3) - design & construction of pile foundation
(Driven precast))
¾¾ IS 2911 part-4 –Load test on piles.
¾¾ I S 14593 –Design & construction of bored cast-in-situ piles founded
on rocks.
¾¾ IS 14893 – Non destructive integrity testing of piles
¾¾ BS-8004 –1996 code of practice for foundations
¾¾ A
STM d 5882 -07 – standard test method for low strain impact integrity
testing of deep foundations
¾¾ A
STM d 4945 – 00 - standard test method for high-strain dynamic
testing of piles.
125
INSTALLATION SEQUENCES - DRIVEN CAST-IN-SITU PILES.
126
INSTALLATION SEQUENCES - BORED CAST-IN-SITU PILES
127
CONCRETING OPERATION IN A BCIS PILE.
128
Characteristics of bentonite suspensions for Bored Cast in Situ Piles:
129
IMPORTANT THINGS TO BE FOLLOWED
130
aintain a gap of “6d” between construction of successive piles.(where “d
M
“= diameter of pile )
Piling sequence is to be followed.
ile Driving shall normally be from the center to periphery or from one
P
side to other of a pile group.
ackfill the Empty bore (unconcreted portion above COL) of the pile with
B
sand or with approved materials.
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.
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
133
LOAD TEST ON PILES
Type of Arrangements:
entledge Method (Placing of Concrete blocks or Sandbags over
K
platform)
Anchor Method
¾¾ By Rock anchors.
¾¾ By Anchor piles.
134
VERTICAL LOAD TEST ARRANGEMENTS:
135
Arrangement for Vertical Load Test
136
Vertical Load Test Photograph
137
PULLOUT (OR) UPLIFT TEST ARRANGEMENTS:
138
Pull Out Test Photograph
139
PILE INTEGRITY TEST:
This test evaluates the pile integrity and pile physical dimensions (that is,
cross-sectional area, length), continuity, and consistency of the pile material,
although evaluation is approximate and not exact. This test method will not
give information regarding the pile bearing capacity.
Good Pile
Defective Pile
140
PDA test (High strain Dynamic test)
141
O-CELL TEST :
142
143
O-CELL TEST ARRANGEMENT:
144
Cement and Mineral
Admixtures
1. Cement
As per IS 456-2000 the cement used shall be any of the following and the
type selected should be appropriate for the intended use:
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-in-
charge. Specialist literature may be consulted for guidance regarding the use
of these types of cements.
145
Test Certificates : Sampling requirements.
a) 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.
a) 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 ,
Concrete with pozzolana cement and slag cement hardens at slower rate.
Therefore, prolonged curing is necessary.
146
Simple Physical tests and Interpretations.
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.
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.
147
Le Chatelier test reveals the soundness caused by excess amount of
uncombined(free) lime. Autoclave tests reveal the soundness caused by
excess amount of percales crystals(MgO)It is not necessary to perform tests
for soundness at site.
This is the average compressive strength of three mortar cubes of size 70.7
x 70.7 x 70.7 mm prepared using one part of cement with three parts of
standard sand confirming to IS 650 with( P/4+ 3 .0) percent (of combined
mass of cement and sand) water.
Supplementary Notes
a. ISI certification , week and year of manufacture are printed on the bag
148
Physical requirements of cement
149
Mineral admixtures:
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 ESP’s. 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.
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
Sl.
Characteristic Requirements
No
Siliceous Calcareous
Silicon dioxide(SiO2) plus aluminium
1 oxide (Al2O3) plus iron oxide 70.0 50
(Fe2O3) percent by mass ( Min)
Silicon dioxide (SiO2) percent by
2 35.0 25
mass (Min)
Reactive Silica in percent by mass,
3 20 20
Min *
Magnesium oxide (MgO) percent by
4 5.0 5.0
mass ( Max)
Total sulphur as sulphur trioxide
5 3.0 3.0
(SO3), percent by mass (Max)
Available alkalis as sodium oxide
6 1.5 1.5
(Na2O) , percent by mass (Max) •
Total chlorides in percent by mass,
7 0.05 0.05
Max **
Loss on ignition, percent by mass
8 5.0 5.0
(Max)
* Optional Test
** For the purpose of this test, wherever reference to cement has been made,
it may be read as pulverized fuel ash.
151
Physical requirements of fly ash (tested as per IS 1727-1967)
Not withstanding to the strength requirements specified above the fly ash
incorporated shall show a progressive increase in strength.
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” .
152
2) Reduced Segregation: The improved cohesiveness of Fly ash concrete
provides added body to plastic state concrete which resist segregation.
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.
153
GGBFS: (Ground Granulated Blast Furnace Slag)
154
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-in-
aggregate. Aggregates used in concrete should satisfy the requirement of IS
383 Specification for Coarse and Fine aggregates from natural sources for
concrete.
The following are the types of fine aggregates in general used for production
of concrete
155
3. All-in-aggregate : Material composed of fine and coarse aggregates.
As per IS 4082 – Aggregates shall be stored at site on a hard dry and level
patch of ground. If such a surface is not available , a platform of planks or
old corrugated iron sheets, or a floor of bricks, or a thin layer of lean concrete
shall be made so as to prevent contamination with clay, dust, vegetation and
other foreign matter.
156
a) Store sand and coarse aggregates of different size fractions in separate
stock piles, on firm ground or platform.
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).
e) Do not allow wheel loaders, trucks and bull dozers over the stock piles.
157
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.
Mechanical properties
158
Grading requirement of Single size coarse aggregate (IS 383)
159
Grading requirement of sand ( IS 383)
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.
160
All-in aggregate grading
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
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 workmen’s consumption
may be estimated on the basis of 370 to 500 litres / m3 of concrete.
161
a) To neutralize 100 ml sample of water, using phenolphthalein as an
indicator, it should not require more than 5 ml of 0.02 normal NaOH.
In case of doubt regarding the usage of water the same can be tested for
setting time and compressive strength test as mentioned below.
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
Admixtures are of four types:
1. Accelerating admixtures
2. Retarding admixtures
Concrete
163
so designed (not the method of design) shall be approved by the employer
within the limitations of parameters and other stipulations laid down by the
standard IS 456-2000”.
Concrete mix design for the grades of concrete used in project site can be
designed by considering the durability, Workability, Minimum cement content,
maximum water cement ratio, maximum size of aggregate and cement type
to used, method of placement, reinforcement congestion etc. Mix designed
asper10262, ACI or any other accepted method and mixes so designed
should satisfy the parameters laid down by IS 456.
Ordinary Concrete M 10 10
M 15 15
M 20 20
Standard concrete M 25 25
M 30 30
M 35 35
M 40 40
M 45 45
M 50 50
M 55 55
High strength concrete M 60 60
M 65 65
M 70 70
M 75 75
M 80 80
164
Note :
1. In the designation of concrete mix M refers to the mix and number to
the specified compressive strength of 150 mm size cube at 28 days
expressed in N/mm2
2. For concrete of compressive strength greater than M 55 design
parameters given in the standard may not be applicable and the values
may be obtained from specialized literature and experimental results.
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 Reinforced concrete
Minimum Minimum
S. Maximum Minimum Maximum Minimum
Exposure cement cement
No free w/c grade of free w/c grade of
content content
ratio concrete ratio concrete
(kg/cum) (kg/cum)
1 Mild 220 0.60 - 300 0.55 M 20
Note:
1. Cement content prescribed in this table is irrespective of the grade of
cement and inclusive of additions like fly ash and GGBFS and their
content also to be taken into account in the concrete composition with
respect to cement content and water cement ratio if the suitability is
established as long as the maximum amounts taken into account do not
exceed the limit of pozzolana and slag specified in IS 1489 Part I and IS
455 respectively.
2. Minimum grade for plain concrete under mild exposure condition is not
specified
Requirement of concrete exposed to Sulphate attack
166
Concentration of sulphates, Dense fully
Expressed as SO3 compacted concrete
made with 20mm
Nominal MSA
complying IS 383
Class Type of cement
In soil In Minimum Maximu
Ground cement m free
Total SO3 in 2:1 water content w/c
SO3 water : ratio
soil
extract
3
330
Supersulphated cement or Sulphate 0.50
167
Notes:
Batching
Cement
168
e) Keep a record of number of bags consumed. Received and in stock, The
stock should be checked regularly.
Aggregates
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.
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.
169
Water:
(a) When charging the skip or hopper with dry materials, first place the
coarse aggregate at the bottom followed by sand and cement.
(b) If the sand to be used is damp, first place half the coarse aggregate
in the skip, then the cement , followed by the fine aggregate and the
remainder of the coarse aggregate to prevent the mount of the skip
getting choked with the damp sand.
(c) Do not place materials in the skip unless they are to be mixed and used
immediately.
(b) See that hoppers, fulcrums, knife edges , and all moving parts are free
from binding, rubbing and friction. Knife edge bearing must be centered
and knife edges must be sharp.
(c) Balance scales on zero , dial scales should be checked atleast once daily
to ascertain that the hand returns to zero when batcher is emptied.
(d) In volume batching check if appropriate boxes are used for feeding the
aggregates. Also check if corrected quantity is being batched. Check if
correction for bulkage of moist sand is being done.
(e) Check for moisture content in sand and coarse aggregate daily. Do
necessary corrections before batching, if moisture is present.
Mixing time
In general the mixing time is 2 minutes. For automatic control plants the mixing
time can be as stated by manufacture. At the end of mixing time the concrete
from plant should have uniform colour, cohesive and free from segregation.
170
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.
(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 ½ 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.
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.
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.
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
This is why low slump concrete requires more vibration or longer time or more
poker needles compared to concrete with higher slump.
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.
173
With a properly designed cohesive mix, segregation and bleeding will be
minimized. With an over-wet mix the larger aggregates may settle during
compaction with the result that a weak layer of laitance will finish up on top
surface.
Process of compaction
1. 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.
4. Withdraw the needle slowly. The main thing is to see the hole made by
vibrator head is closed.
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
174
reiniforcement and also will decrease the bond between the reinforcement
and concrete
VIBRATING DON’TS
Don’t let a vibrator run very long outside concrete; it will overheat
Don’t use a vibrator to move concrete horizontally
on’t force pr push a vibrator into concrete it won’t remain vertical and
D
may get caught in the reinforcement
Don’t start a job without a spare vibrator
FINISHING
Initial finishing:
Strike off:
¾¾ P
roperly done removes excess concrete and brings top surface to
grade
¾¾ Start as soon as possible after placing concrete
¾¾ End before bleed water appears
¾¾ Straight edge uses can be of wood or magnesium
Straight edge
¾¾ Use a side-to-side sawing motion while pulling forward
¾¾ Tilt it slightly backward to create a single cutting edge
¾¾ Keep about an inch of concrete in front to fill low spots
¾¾ Make a second pass if the surface is not to grade
¾¾ Pull concrete into end edge forms.
175
BULL FLOATS AND DARBIES
¾¾ Use to level ridges and fill voids left by straightedge
¾¾ Start immediately after strike off and finish before bleed water
appears
¾¾ Use at right angle to the direction of strike off
¾¾ P
ush the bull float with the front edge slightly off the surface to cut
bumps; pull the bull float with the back edge slightly off the surface to
fill voids
¾¾ Use magnesium tools for sir entrained concrete
¾¾ D
arbies serve the same purpose as bull floats but for smaller areas;
use in a sawing arc motion
WAITING PERIOD
¾¾ B
egin further finishing when all the bleed water has evaporated and
concrete is firm enough to leave only ¼ inch foot prints
¾¾ F
inishing while bleed water is present can cause surface crazing,
dusting or scalling
Final finishing
Edgers
¾¾ Use to produce a clean slab edge that is less likely to chip
¾¾ A
n edger is less likely to dig into concrete or leave a bumpy surface
if a trowel is used in a vertical sawing motion to dislodge aggregate
particles away from the edge forms
¾¾ Run back and forth with the leading edge slightly raised
¾¾ D
on’t start in a corner and don’t raise the edger off the concrete unless
the tool is in motion
¾¾ U
se a wide edger for the first pass, then a narrow edger for the second
pass
Groovers
¾¾ U
se to control crack location by cutting joints to a depth of atleast one-
fourth the slab thickness
¾¾ P
ush the groover into the concrete then move it forward while applying
pressure to the back of the tool
176
¾¾ A
fter joint is cut, turn the groover around, running it back over the cut
to give as smoother finish
¾¾ For a straight cut, use a chalk line or a straight edge as a guide
Floats
¾¾ U
se to remove imperfections and to bring mortar to the surface for
troweling
¾¾ H
old flot flat and at arm’s length, moving it in awide semicircular
motion until surface is smooth
¾¾ Use magnesium tools for air entrained concrete
¾¾ More than one float pass may be required
Trowels
¾¾ Use to produce a hard, dense surface
¾¾ T
rowel only after floating, starting with a wide trowel then moving to
smaller trowels on the later passes
¾¾ H
old trowel at a slight tilt at arm’s 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.
177
¾¾ U
se curing water at a temperature within 20 ° F ( i.e -6 deg) of concrete
temperature
¾¾ A
void premature or sudden release of ponded water which can
damage the surrounding environment
Sprinkling or fog spraying
¾¾ K
eep the surface continuously wet, alternate wetting and frying causes
craze cracking
¾¾ U
se low water pressure and flow to avoid washing away the fresh
concrete surface
¾¾ U
se curing water at a temperature within 20 ° F ( i.e -6 deg) of concrete
temperature
¾¾ Avoid if water runoff can damage the surrounding environment.
Using wet materials
¾¾ Cover the concrete with wet burlap, straw, sawdust, or sand
¾¾ Wet continuously, or cover with plastic sheet and wet frequently
¾¾ Avoid materials that discolor concrete
¾¾ Prevent materials from blowing away.
Using Plastic sheet or water proof paper
¾¾ Lay flat , lap edges 6 inches, and cover exposed concrete edges
¾¾ U
se minimum 4 mm thick plastic sheet white in hot weather and black
in cold weather
¾¾ Don’t use on architectural concrete
¾¾ Secure covering to prevent concrete exposure
Using curing compounds
¾¾ Apply after finishing when bleedwater disappears in slab or flat surface
¾¾ I n vertical faces apply in two applications, at right angles to from a
continuous film
¾¾ The efficiency will be 80% to that of water curing.
¾¾ 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
COMMON DEFECTS IN CONCRETE
Any defects in the finished concrete surface observed after removal of form
work
b. Equipment-related causes
Improper equipment
Improper equipment maintenance
Equipment failure (crane, pump, concrete plant)
Interruption of utility service
c. Material-related causes
Improper selection of release agent
Cement characteristics
Variation in mixture components
Inappropriate use of admixtures
Inappropriate use of release agents
d. Environmental causes
Extreme weather conditions
179
Types of surface defects
Surface defects which can result from ineffective consolidation procedures are
discussed below.
1 Honeycomb
Bugholes on vertical faces are normally caused by air bubbles, but occasionally
by water entrapped between the concrete mass and the form, especially in
sticky or stiff concrete mixtures of low workability which may have an excessive
sand and/or entrapped air content. Also, the use of vibrators of too large an
amplitude or the lack of complete insertion of the vibrator head may result in
increased air-void formation. Air voids vary insize from microscopic to about
1 in. (25 mm). Rarely will water create bugholes on formed surfaces. Excess
water normally manifests itself in other textural defects such as bleeding
channels or sand streaks on vertical formed surfaces. Bleed water voids can
form at the top of a column and on battered formed surfaces. Surface voids
can be minimized by procedures which are discussed in section 4.
3 Form-streaking
180
4 Aggregate transparency
5 Subsidence cracking
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.
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
181
forms and proper mixture proportioning, using well-graded fines to minimize
bleeding. Although the characteristics of portland cement and pozzolans, if
used, have some influence on bleeding, the grading of the fine aggregate is
of greater importance. Streaking tendencies increase when the ratio of sand
to cementing materials increases, such as in lean mixtures.
8 Layer lines
Layer lines are dark horizontal lines on formed surfaces which indicate the
boundary between concrete placements. Layer lines are caused by stiffening
or insufficient consolidation of the lower level due to lack of penetration of the
vibrator into the lower level.
9 Form offsets
10 Cold joints
Cold joints frequently occur in concrete for many reasons. Cold joints can
often be avoided by contingency planning, back-up equipment, working to
keep the concrete surface alive, and working to vibrate into lower lifts.
To minimize the size and number of bugholes and other defects, arising out of
the consolidation the following practices should be followed:
Vibration period should be of sufficient duration
ibrator insertions should be properly spaced and overlapped and the
V
vibrator removed slowly
Each concrete layer should be consolidated from the bottom upward
Vibration periods should be increased when using impermeable forms
I nward sloping forms and other complex design details should be
avoided
Depth of placement layers should be limited
Vibrator should penetrate into the previous layer
182
ightening devices and gaskets to prevent leakage at form joints should
T
be provided as necessary
Placing ports should be designed into the forms as necessary
In areas where voids are most prevalent, revibration may be used to reduce
bugholes. Revibration is more effective if it is done at the latest possible time
at which the vibrator head will penetrate the concrete under its own weight.
Greater benefits are obtained with wetter concrete mixtures, especially in the
top few feet of a placement where air and water voids are most prevalent.
183
Defects Causes
Name Description Design of Forms Construction Properties of Placement Consolidation
member conditions fresh concrete
Honeycomb Stony surface with Highly Leaking at High Insufficient fines, Excessive free Vibrator too small , too
air voids; lacking in congested joints, severe temperature , low workability, fall, excessive low a frequency too
fines reinforcement, grout loss wind, early stiffening, travel of small an amplitude ,
narrow reinforcement excessive mixing concrete in short immersion time,
section, too close to too large an forms, too high excessive spacing
configuration forms, aggregate for a lift, drop between immersions,
internal accessibility placing conditions chute omitted inadequate penetration.
interference, or insufficient
reinforcement length , too
splices small a tremie,
segregation
Air surface Small individual Battered or Form face Excessive Low FM sand, Too slow , Too large an amplitude
voids holes, irregular , interfering impermeable, release agent , lean , sand with a caused by , external vibration
ranging up to 1inch construction poor wetting high high FM, low inadequate inadequate, head of
(25mm)In diameter characteristics, temperature workability, pumping rate, vibrator partially
form work too excessive cement undersized immersed
184
flexible, use of content or bucket
improper form pozzolana ,
release agent particle
degradation ,
excessive sand ,
high air content
Form streaking Sand or gravel Leaking at Excess water or Excessive amplitude or
textured areas joints, tie high slump frequency
lacking cement, holes, etc.
usually associated
with dark color on
adjacent surface
Cold joint Unintended Internal Poor planning of Too dry , early Delayed Failure to vibrate into
discontinuity, off interference insufficient stiffening delivery lower lift. Insufficient
coloured concrete backup vibration
equipment
mottled appearance porous ,
excessive coarse
aggregate ,
excessive slump
with light weight
concrete
Aggregate Dark or light areas Too flexible, Low sand Excessive or external
Defects
transparency of similar size and high density Causes content, vibration; over vibration
shape to that of the surface finish gapgraded, of light weight concrete
coarse aggregate, Design of Construction aggregate
Properties dryofor
Name Description
mottled appearance Forms porous , Placement Consolidation
member conditions fresh concrete
excessive coarse
Aggregate
Aggregate
Aggregate
Aggregate
Subsidence Dark
Dark
Dark
Darkor
Short or
or
or
light
light
light
lightareas
cracks areas
areas
areas Interference Too
Too
Too
PoorTooflexible,
flexible,
flexible,
flexible,
thermal Insufficient Low Low
Low
Low
Low
sand,
aggregate sand
sand
sand
sand
high, Too rapid Excessive
Excessive
Excessive
Excessiveor
Insufficient or
or
or
external
external
external
external
vibration
transparency
transparency
transparency
transparency
cracking of
of
of
ofsimilar
similar
similar
similar
varying size
insize
size
sizeand
and
and
and
width, to access high
high
high
highdensity
density
insulation,density
density interval between watercontent,
excessivecontent,
content,
content,
content
slump vibration;
vibration;
vibration;
vibration;over
over
over
overvibration
vibration
vibration
vibration
shape
shape
shape
shapeto
more to
to
tothat
often that
that
thatof
of
of
ofthe
the
the
the surface
surface
surface
surface
irregular finish
finish
finish
finish topout of with gapgraded,
gapgraded,
gapgraded,
gapgraded,
light weight of
of
of
oflight
light
light
lightweight
weight
weight
weightconcrete
concrete
concrete
concrete
coarse
coarse
coarse
coarseaggregate,
aggregate,
aggregate,
horizontalaggregate,
than shape columns and aggregate
aggregate
aggregate
aggregate
concrete dry
dry
dry
dryoror
or
or
mottled
mottled
mottled
mottledappearance
vertical appearance
appearance
appearance restraining placement of porous
porous
porous
porous, ,,,
Defects settlement, slab or beam, Causes
excessive
excessive
excessive
excessivecoarse coarse
coarse
coarse
excessive low humidity aggregate
aggregate
aggregate
aggregate, ,,,
Design of absorbency Construction excessive
excessive
excessive
excessiveslump
Properties slump
slump
slump
of
Name
Sand streaking Description
Variation in colour Forms
Low Low with
with
with
withlight
Lean light
light
light weight
weight
mixture, weight
weight Too Placement
rapid for Consolidation
Excessive vibration ,
member conditions fresh concrete
or shade due to absorbency temperature, overconcrete
concrete
concrete
concrete
sanded type of mix Excessive amplitude ,
Subsidence Short cracks
separation of fine Interference Poor thermal wetInsufficient
mixtures Low
bleeding
sand,mix, high Too rapid Insufficient vibration
Over manipulation
Defects
Defects
Defects
Defects
cracking varying width, to access insulation, interval between Causes Causes
Causes
Causes
water
particlesincaused sand deficient
contentin
more often
by bleeding irregular topout of fines, low air
horizontal
parallel to the than Design
Design
Design
Designof of
of
of shape columns
Construction
Construction
Construction
Construction and Properties
Properties
Properties
Properties
content of of
of
of
Name
Name
Name
Name Description
Description
Description
Description Forms
Forms
Forms
Forms Placement
Placement
Placement
Placement Consolidation
Consolidation
Consolidation
Consolidation
vertical
form face member
member
member
member restraining placement
conditions
conditions
conditions
conditions of fresh
fresh
fresh
freshconcrete
concrete
concrete
concrete
Layer lines Dark coloured Internal settlement, slab or beam,
Insufficient Wet mixture with Slow Lack of vibration,
Subsidence
Subsidence
Subsidence
Subsidence Short
Short
Short
Shortcracks
zones cracks
cracks
cracks
between Interference
Interference
Interference
Interference
interference Poor
Poor
Poor
Poor thermal
excessivethermal
thermal
thermal Insufficient
lowInsufficient
Insufficient
Insufficient
planning, humidity
high Low
Low
Low
Lowsand,
tendency sand,
sand,
sand,
to highhigh
high
bleed Too
Too
high Placement,Too
Toorapid
rapid
rapid
rapid
lack Insufficient
Insufficient
Insufficient
Insufficient
failure vibration
vibration
vibration
vibration
to penetrate into
185
cracking
cracking
cracking
cracking varying
varying
varying
varyingin
concrete in
in
inwidth,
width,
layerswidth,
width, to
to
to
toaccess
access
access
access insulation,
insulation,
insulation,
insulation,
absorbency interval
interval
interval
interval between
temperaturebetween
between
between waterwater
water
watercontent
content
content
content of equipment previous layer
Sand streaking more
more
more
more often
often
often
often
Variation in colour irregular
irregular
irregular
irregular
Low topout
topout
topout
topout
Low of
of
of
of Lean mixture, Too
or rapid for
manpower Excessive vibration ,
horizontal
horizontal
horizontal
horizontal
or shade duethan than
than
than
to shape
shape
shape
shape
absorbency columns
columns
columns
columnsand
temperature, and
and
and over sanded type of mix Excessive amplitude ,
Form offsets Abrupt
vertical
vertical
vertical
vertical
separation to gradual
of fine Inadequate
restraining
restraining
restraining
restraining placement
placement
wetplacement
placement
mixturesof
of
of
of Excessive
bleeding mix, Rate too high Excessive amplitude,
Over manipulation
particles
surface caused stiffness
settlement,
settlement,
settlement,
settlement, or slab
slab
slab
slabor or
or
orbeam,
beam,
beam,
beam, retardation
sand deficientofin nonuniform spacing of
irregularities
by bleeding anchorage,
excessive
excessive
excessive
excessive low
low
low
lowhumidity
humidity
humidity
humidity fines,mixeslow air immersion
parallel to the weak forming
absorbency
absorbency
absorbency
absorbency content
Sand
Sand
Sand
Sandstreaking
streaking
streaking
streaking Variation
Variation
Variation
Variation
form facein in
in
incolour
colour
colour
colour 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 Excessive
Excessive
Excessive
Excessivevibration
vibration
vibration
vibration, ,,,
Layer lines or
or
or
orshade
Dark shade
shade
shade due
coloured due
due
dueto to
to
to Internal irregular
absorbency
absorbency
absorbency
absorbency temperature,
temperature,
temperature,
temperature,
Insufficient Wet over
over
over
over sanded
mixturesanded
sanded
sanded with type
type
type
type of
Slow of
of
ofmix
mix
mix
mix Excessive
Excessive
Excessive
Excessive
amplitude
amplitude
amplitude
amplitude, ,,,
Lack of vibration,
separation
separation
separation
separation
zones between ofof
of
offine
fine
fine
fine interference lumber, poor wet
wet
wet
wetmixtures
planning, mixtures
mixtures
mixtures
high bleeding
bleeding
bleeding
bleeding
tendency mix,
tomix,mix,
mix,
bleed Placement, lack Over
Over
Over
Over
failure manipulation
manipulation
manipulation
tomanipulation
penetrate into
particles
particles
particles
particlescaused
concrete caused
caused
caused
layers carpentry temperature sand
sand
sand
sanddeficient
deficient
deficient
deficientin in
in
in of equipment previous layer
by
by
by
bybleeding
bleeding
bleeding
bleeding fines,
fines,
fines,
fines,lowlow
low
lowair air
air
air or manpower
parallel
parallel
parallel
parallelto to
to
tothe
the
the
the content
content
content
content
Form offsets Abrupt
form
form
form
formface to gradual
face
face
face Inadequate Excessive Rate too high Excessive amplitude,
Layer
Layer
Layer
Layerlines
lines
lines
lines surface
Dark
Dark
Dark
Darkcoloured
coloured
coloured
coloured Internal
Internal
Internal
Internal stiffness or Insufficient
Insufficient
Insufficient
Insufficient Wet
Wetretardation
Wet
Wet mixture
mixture
mixture
mixturewith of
with
with
with Slow
Slow
Slow
Slow nonuniform
Lack
Lack
Lack
Lackofof
of spacing of
ofvibration,
vibration,
vibration,
vibration,
irregularities
zones
zones
zones
zonesbetween
between
between
between interference
interference
interference
interference anchorage, planning,
planning,
planning,
planning,highhigh
high
high tendency
tendency
tendency
tendencymixes toto
to
tobleed
bleed
bleed
bleed Placement,
Placement,
Placement,
Placement,lack lack
lack
lack failure
failure
failureimmersion
failure
to
to
to
topenetrate
penetrate
penetrate
penetrateinto
into
into
into
concrete
concrete
concrete
concretelayerslayers
layers
layers weak forming temperature
temperature
temperature
temperature of
of
of
ofequipment
equipment
equipment
equipment previous
previous
previous
previouslayer
layer
layer
layer
material, or
or
or
ormanpower
manpower
manpower
manpower
irregular
Form
Form
Form
Formoffsets
offsets
offsets
offsets Abrupt
Abrupt
Abrupt
Abruptto
to
to
togradual
gradual
gradual
gradual Inadequate
Inadequate
Inadequate
Inadequate
lumber, poor Excessive
Excessive
Excessive
Excessive Rate
Rate
Rate
Ratetootoo
too
toohigh
high
high
high Excessive
Excessive
Excessive
Excessiveamplitude,
amplitude,
amplitude,
amplitude,
surface
surface
surface
surface stiffness
stiffness
stiffness
stiffnessor
carpentry or
or
or retardation
retardation
retardation
retardationof of
of
of nonuniform
nonuniform
nonuniform
nonuniformspacing
spacing
spacing
spacingof
of
of
of
irregularities
irregularities
irregularities
irregularities anchorage,
anchorage,
anchorage,
anchorage, mixes
mixes
mixes
mixes immersion
immersion
immersion
immersion
weak
weak
weak
weakforming
forming
forming
forming
material,
material,
material,
material,
irregular
irregular
irregular
irregular
lumber,
lumber,
lumber,
lumber,poor poor
poor
poor
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:
DEFINITIONS:
1. Pre- tensioning
2. Post-tensioning.
1. Pre-tensioning:
2. Post- tensioning:
Post-tensioning is a
method of reinforcing
concrete or other materials
with high strength steel
187
strands or bars, typically referred to as tendons. Post-tensioning applications
include office and apartment buildings, parking structures, bridges, stadiums,
soil anchors and water tanks.
ADVANTAGES OF PRESTRESSING
¾¾ Minimizes the concrete crakes.
¾¾ Allows reducing beam depth.
¾¾ Allows greater degree of loading than any structural material.
¾¾ Lighter elements permit the use of longer span.
¾¾ Ability to control deflection in beams and slab.
¾¾ Permits efficient usage of steel and reduces cost.
¾¾ Speed in construction.
APPLICATION
¾¾ Bridges
¾¾ Nuclear Structures.
188
¾¾ Building frames and floor slabs.
¾¾ Marine and waterside Structures.
¾¾ Ground anchor.
¾¾ Heavy lifting.
¾¾ Foundation.
Materials
Management
1) HT Strand
2) Anchorages
189
3) Wedges:
4) Sheathing:
190
MATERIAL ORDERING:
RECEPIT AT SITE:
H.T. Strand:
PT Hardware:
¾¾ Check for the test/mill certificate
¾¾ IS Code references
¾¾ Size/ dimensions.
¾¾ Quantity
¾¾ Visual inspection for any crake
191
TESTING FOR PRESTRESSING SYSTEM : BS 4447 -1973
a) Elongation Calculation:
a) Single-pull Stressing:
192
b) Multi-pull Stressing:
3. Losses due to Jack Efficiency “%” (add as per Jack Calibration Report)
Class Nominal Tolerance in Nominal Nominal Breaking 0.2% Proof Minimum Modulus of
of HT diameter Dia (mm) Area Mass Strength Load (KN) Tensile Elasticity
Strand (mm) (mm2) (Kg/M) (KN) Strength (N/mm2)
(N/mm2)
9.5 +/-0.4 51.6 0.405 89.0 80.1
11.1 +/-0.4 69.7 0.548 120.1 108.1
I 1860 195000
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
II 1860 195000
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
1. 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 self-
adhesive 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
at high profile locations and seal it properly.
ie Bursting and Spiral reinforcements at the anchorages zones as per the
T
details given in drawing.
inal checking of all Tendons for profiling, supporting and sealing after the
F
completion of reinforcement and formwork works and before concreting.
2) Stressing:
tressing shall be carried out only after the concrete has attainedthe
S
required Compressive Strength and age of concrete as specified in the
drawing.
heck the Stressing equipments and hoses before stressing to ensure
C
proper/smooth functioning.
T Strand/Wire/Bars shall be completely cleaned (oil, dust & etc.) for
H
gripping of Jacks. Stressing can be carried out stage by stage if required,
as per drawing.
alculate the Elongation or Modified Elongation for each tendon as per
C
the physical values in TC.
alculate the Jack Pressure for the Design Load including Jack & Anchorage
C
losses.
tressing shall be carried out only as per the specified sequence. Load
S
shall be applied to the tendons by using calibrated hydraulic pumps and
jacks and monitored through calibrated Pressure gauges.
ix the Bearing plate to the tube unit and lock it by wedges and mark
F
a reference point on Strand to measure elongation. Stressing can be
performed in single / multi strokes depend on Jack piston length.
ix the Hydraulic Jack (Mono/Multi) at stressing end (Single/Double) and
F
ensure proper seating of jack with bearing plate and also connect the Jack
& Pump by hydraulic hosepipes.
pply the calculated pressure (load) gradually in incremental basis on
A
each strand or tendon by using hydraulic Jack and Pump. Apply jack
pressure at both ends simultaneously for double-end stressing.
hile applying load check for required elongation & jack pressure during
W
stressing and also note the Jack pressure & Elongation reading at every
interval / stage in stressing format.
195
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:
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:
Designer.
200
Photos
201
202
Environment,
Health and Safety
Introduction
Larsen & Toubro , Health, Safety & Environment Department had been
certified ISO 9001:2000. We are the first company in India to have such
accreditation. The company’s management gives utmost importance to safety
in the company’s 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.
Rules:
Head Protection:-
All personals engaged for this job shall wear Safety Helmet of Class ‘B’ type.
Hand Protection:-
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:-
Suitable nose mask, face shield / cloth are to be used by the individuals to
protect them from dust, fumes, poisonous and toxic gases.
Body Protection:-
Appropriate body protection like Boiler Suit, Aprons must be used by the
concern personnel at site.
Fall Protection:-
Foot Protection:-
Housekeeping:
Electrical:
b. Cranes & equipments shall be used after inspected & approved by the
Safety engg. Dept.
204
Others:
¾¾ 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.
¾¾ 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.
¾¾ B
arricade is required around the shaft circumference at a distance of
10m.
¾¾ I nside the chimney, at the locations where perpendicularly is checked
by laser beam, is to be sheltered with a small hole.
¾¾ D
eploy minimum number of workmen on the platform and as far as
possible have them scattered.
¾¾ S
afety posters and caution boards shall be displayed on the platform
and at ground level.
¾¾ Intercom for communication is very much required.
¾¾ I t is important to give a safety talk to workers by the concerned engineer
briefing on procedures before the slipform starts.
¾¾ A
viation warning lights are necessary when the structure reaches
height of 50M
¾¾ It is part of each employee’s job to report all unsafe act / unsafe
condition and accident immediately to his supervisor.
¾¾ At No Smoking areas smoking is prohibited.
¾¾ Horseplay like practical jokes, running etc. is strictly to be avoided.
¾¾ Observe all working & hazard notice.
¾¾ 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.
¾¾ 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:
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.
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&T’s 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:
Safety Inspection:
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:
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.
Fire Safety:
1. Once in three months the fire extinguishers installed in the site premises
shall be maintained and recorded in a register.
All the relevant work permit systems shall be followed as per L&T / Client’s
procedure. viz,
a. Excavation Permit.
b. Electrical work Permit.
c. Confined space entry permit. Etc.
208
Accident Reports, Investigation and Analysis:
All minor injuries should be brought to the notice of the Site management and
recorded.
Lost Time Accidents, fatal accident, vehicle accident or damage to L&T plants,
facilities or equipment should be reported to the site management. The
contact phone nos. is given in Emergency Response Program. Subsequently,
reports of the accident shall be given in the L&T format.
All accidents and near misses shall be investigated by the Safety engineer &
Safety committee of the site and recorded.
Safety Motivations:
The company has the following reward schemes to encourage the employees
to follow safety.
1. 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
a) First Aid : First Aid Facility to be available in accordance with L&T policy
requirement. It is intent of the L&T management that the project is
self sufficient in terms of dealing minor first aid injuries and medical
requirements. In the event of a Serious Injury or an individual requiring
professional medical advice and care, are referred immediately to the
local hospital.
209
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:
PLATFORM:
4. Both inside and outside hanging scaffold platforms will be covered with
safety nets.
210
5. Access ladders will be provided to access top platform and hanging
platform.
ELECTRICAL:
1. All electrical equipment will be earthen.
2. Earth leakage circuit breaker (ELCB) will be fixed.
3. The electrical cable will be neatly traced along the platform and
handrail.
REINFORCEMENT GANG:
HOUSE KEEPING:
1. Housekeeping on platform will be maintained stringently. No material
will be dropped from height.
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.
Safety is everybody’s business. Slipform in-charge, in co-ordination with site
safety engineer should conduct safety demonstration / meetings.
1. Daily pep talk.
2. Weekly safety meeting for staff, departmental, subcontractor and other
workmen.
211
3. Fire extinguisher demonstration.
GENERAL SAFETY
¾¾ Toe boards.
¾¾ Tying of safety nets.
¾¾ Hand rails.
¾¾ Fire extinguishers (DCP) at top and bottom.
¾¾ First aid box at top.
¾¾ Emergency lights.
¾¾ Safety signboards.
¾¾ Protective shed.
¾¾ Prevent overloading of safety nets. Periodic cleaning is necessary.
¾¾ Wind protection cloth.
¾¾ Safety belts, safety helmets, goggles and gloves to be used properly.
¾¾ Proper earthling. Earthing for lights (ELCB)
¾¾ P
roper illumination at the top as well as around the slipform
structure.
¾¾ Built in safety systems in the equipment to be tested.
¾¾ Lightening arrestors./ Aviation lamps wherever required.
212
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.
Engineering Construction & Contracts Division
Mount Poonamallee Road,
Manapakkam, Chennai – 600 089.
Phone: 044-22526561 August 2010