Storage of Construction Material- Steel Bars, Cement, Bricks &

Aggregate At Construction Site

Cement- Storage and Transportation

Ordinary Portland Cement is a very finely ground chemical. It is

hygroscopic in nature and therefore it can easily absorb moisture from
the air. Cement should therefore be protected from dampness and high
humidity as it can rapidly lose its strength and get transformed into lumps
rendering it unsuitable for use.
During the monsoon, every year there considerable damage to cement due to
incorrect storage and transportation. It is therefore important to have a proper
storage arrangement at the consumer's end.

Storage Shed
The building where the cement bags are to be stored must be a totally watertight
structure
 The sidewall of the shed should have a minimum 9" brick masonry
plastered on both faces.
 The roof of cement shed/godown can be either of a leak-proof reinforced
concrete slab or of adequately sloped water tight galvanized/asbestos
sheets.
 The small windows are provided at the sill level and normally kept tightly
shut. Due to this, the moisture or rainwater is prevented from entering into
the shed.

The bottom level of the truck and the plinth of the cement
godown is of the same height.
 The height of the plinth of the cement godown should be built in such a
way that the bottom level of the truck is of the same height as that of the
godown so that, the loading/unloading operations of the bags are done
conveniently.

 The floor of the shed should be of a minimum 150 mm thick densely

compacted concrete slab on rubble soling. It should be in the proper line,
level, and slope. All necessary precautions must be taken to keep the floor
completely dry.

Precautions While Storing/Transporting Cement Bags

 Bags should not be stacked more than 8 bags high if the adequate storage
area is available. If the storage area is not adequate than higher stacking,
but not more than 15 bags high, can be permitted.

 If the stack is more than 8 bags should be arranged in layers with an

alternate layer of bags arranged in header and stretcher fashion to give the
stack better stability.

 All bags must be stored at least 0.3 m away from the walls. For better and
easy handling 1 m wide passages are required to be kept in such a manner
that old stock of cement can be removed without disturbing the fresher
stocks stored in the godown.

 Wooden planks or sleepers covered with plastic sheets should be kept on

the floor and then the cement bags stored on top of it. This is a must if the
godown has a low plinth.

 If wooden sleepers/planks are not provided two layers of plastic sheets

must be spread on the entire floor area in a crosswise manner and
repeatedly checked if it needs replacement. It is also recommended to
cover the cement bags with 700 gauge plastic sheets especially in humid
areas or in monsoons. Plastic sheets should be handled with care so that
they are not damaged.

 To reduce the air circulation the stacks of cement bags must be uce stored
as close as as close as possible.

 Install the strip on walls at suitable locations if humidity is very high.

 Install exhaust fans on blank walls to improve ventilation.

 It is absolutely necessary that the old stock (with earlier week number)
should be removed for consumption first and fresh stock later. Each
consignment should be stacked separately and a placard bearing the date
of arrival, week number should be displayed for proper and easy
identification.

 When the bags are to be removed, care should be taken that all bags are
not removed from the top layer. It is recommended that bags should be
removed from two or three layers in a stepwise manner so that the pile is
stable and will not topple easily.

Bags are removed from the stock pile in stepwise manner.

 Owing to the pressure on the lower layers of bags the cement lumps
together within the bag. If there is moisture ingress from the floor and if
the bags in lower layers are not properly protected as suggested in points
hard set cement lumps will be formed in the bags. If there is no moisture
ingress caking of cement particles will develop within the bags and will
 cause what is called a "Warehouse pack". This can be easily removed by
rolling the bag just before removing it from the storage shed.

 Trucks should not be allowed to enter the storage sheds if the plinth of the
shade is at the road level. Dirt and moisture or even water will create
problems of cement contamination and damage.
 Loading and unloading of cement bags onto the trucks should be done
under proper cover during the monsoons.

 Cement should not be loaded onto the trucks directly. The plastic sheet
must be spread on the truck's floor and then cement bags unloaded over it.
Due to huge gaps between the wooden planks on the truck's floor water
often gets splashed onto the lower layers of bags thereby damaging the
cement in it.

 Tarpaulin sheets are not waterproof. Water can seep through them if
collects on the top. It is therefore recommended that cement bags after
being loaded onto the trucks should be properly covered with plastic heets
and if 1 second layer tarpaulin cover over the if required i plastic sheet can
be given for more rigidity.

 Trucks without proper plastic sheets/tarpaulins should not be permitted to

carry cement. This is extremely important during the monsoons. Many
times cement bags have to be stored at the worksites in the open. In such
cases, minimum bags should be taken out for each day's work and the
balance bags, which are not consumed, should be returned back to the
proper storage shed at the end of the day.

 The open stockpile should be well covered with polyethylene sheets and
sheets be properly weighed down. This protects cement against moisture
ingress from the atmosphere. An additional layer of tarpaulin over the
 plastic sheet can give better protection to cement and reduce the chances
of damage to the plastic sheet.

Open cement bags stock pile covered with polyethylene

sheet and stacked on wooden platform.

 Open storage must be avoided during monsoon in any case.

Storage of Construction Materials (Cement) at Construction Site.

Storage of Construction Materials in such a way that it will prevent deterioration

and also improves the quality of material and work. At the construction site,
proper planning of stacking and storage of material should require. Not only
Material but also construction components and equipment shall be stored
properly. Stored Material shall be protected from rain, sun, winds, moisture in
order to remove damages. On-site there are different wooden and inflammable
materials such as timber; wooden planks, Paint, diesel, petrol, kerosene, etc
should be stored in such a way that there may not be any chances of catching fire.

In this article, you will know the guideline or the techniques to be used for the
stacking and storage of cement. Following are the guideline to be followed for the
storage of cement.
 Cement should be stored at the construction site only in an industrial shed or
in a building. Ensure that the shed or building should be dry, leakproof, and
having no moisture present. The shed or Building should have a minimum
number of doors, close-fitting, and windows and keep closed as far as possible.
 Cement Bags should be stacked off on wooden planks in order to prevent
them from dampness or moisture. It should be store in such a manner that at
any point in time it can be inspected by an individual.
 Cement shall be stored at least 6 inches to 8 inches above from PCC Bed or
some alternatives like Two flat bricks or wooden planks can be used.
 Stacked Cement Bags should be placed at a distance of at least 600 mm from
all external walls.
 Cement Bags should be kept close together in order to reduce the circulation
of air as much as possible.
 The stacked height of cement Bags shall not be more than 10 bags in order to
prevent the chances of lumping up under pressure.
 Stacked shall be stored in such a way that the First in First out (FIFO) system of
materials issue can be adopted.
 Cement shall be issued for construction only after testing and confirming the
specification as per requirement.
 Cement bags in store for more than 3 months shall be used only after testing
and confirming with objectives.
 There should be a gap of a minimum of 600 mm between two stacked cement
Bags.
 During the Rainy season or intend to store for a longer period in that situation,
cement bags shall be covered with a polythene sheet.
 Cement bags shall be stacked in a manner to facilitate their removal and use in
the order in which they are received; a label showing date of receipt of cement
bags shall put on each stage to know the age of cement.
15. To guarantee the top quality of your cement, you should take the following precautions.

(a) Check the freshness of the cement before buying. It should be free from any lumps which cannot be
pulverized between thumb and forefinger.

(b) Bring on site only the number of sacks needed for a short period.
(c) Protect your cement from humidity. Store it off the ground (a simple wooden platform is suitable) in
a dry, well-sheltered place.

(d) Use the cement while it is as fresh as possible, and rotate your stocks properly.

(e) Never use hardened cement, but throw it away.

What are the points to be checked before buying a cement?/14 things to consider before buying a
cement bag.

Following are the 14 points that should be observed, before buying a cement bag.

1. Brand name :

While purchasing the cement, you should always go for the branded cement having good popularity (5
🌟). The branded cement may cost 5 to 15% more, in comparison to other local cement, but they are
worth that price as there is no compromise in their quality. Check for the correct spelling of the printed
brand name, to confirm the originality of cement bags.

2. Trademark/logo:

All type of branded cement has their unique trademark logo printed on the bag as shown above. Look
out for those logos to avoid duplication.

3. ISI mark:

If the cement bag has no ISI mark (India ) printed over them, then stand apart from such bags to have a
longer life span for your construction works. If the manufactured cement bags are not according to the
industrial standards compliance( ISI ), don't buy such bags to maintain the quality of construction works.
4. IS code :

While manufacturing the cement, different types of IS codes are followed to meet the required
standards. You should check for the type of IS code ( as shown above ), to know the specification &
cement characteristics.

5. Grade of cement:

Cement bags are manufactured in various grades like 33, 43, 53, etc. to denote the cement cube
strength after 28 days of curing. You should look out for the required grade, that suits your work, to get
better results.

6. Type of cement:

Different types of cement are manufactured, to match the type of structural work, working situation,
and climatic conditions. Check over the bag, to know the type of cement you are dealing with.

7. Net quantity/Weight of cement:

The most common weight of the cement bags that are available in the market is 50kg. You can check
over the bags mentioned as net Qty -50kg., for the confirmation of actual weight.

The white cement bags are packed in different weights like 1kg, 10kg, 25kg, 50kg, etc. for purchasers'
convenience. Calculating the weight vs price for each type of bag, before buying, helps you to save
money.
8. Company address:

You do require the manufacturer's address for communication, in case you have any complaints to
register against the dealer or the quality of supplied cement.

9. Use no hooks:

MS hooks are used by some workers while loading & unloading the cement bags for transportation.
Although using hooks make them work fast, these hooks create small openings in the cement bags. You
have to look for such openings if any, while buying the cement bags. These openings give a passage for
the air to circulate in the bags, which ultimately decreases the cement strength. Strictly avoid such bags,
to maintain the cement standards.

10. The expiry date:

Cement loses its original strength gradually as the day progresses from its production date. Any bags
older than 3 months from the manufactured date are unfit for the construction works. So, check the
manufactured week and month, to know the expiry date of cement. Always go for the fresh cement to
utilize its full specified strength.
11.The printed price (MRP ) :

Observing the MRP of the cement bag helps you to know, whether you are paying the right amount of
money or the delivered bags are overpriced.

12.Stitching of cement bag:

Refilling the cement by mixing with other components in the factory-made bags can be found out by
checking the bag stitchings. To avoid duplicate adulterated cement, check the cement bag stitchings
precisely. The restitched bags certainly look different, as they cannot mimic the original factory-made
stitching.

13. Authorized outlet:

Always, try to buy the cement from the authorized outlet in your locality, to avoid duplication and to get
a fresh stock of cement.

14. Lumps in the bag:

If the bags in the godowns are not stored according to the procedure, the cement in the bags may
develop tiny grain-like lumps due to the absorption of atmospheric moisture. Press the bag hardly and
pinch the corner end of the bags with your fingers, to feel the powdery softness of cement. If you feel
stiff bag with grainy feelings, avoid such bags.

Note:

1. The printed location over the cement bags are not alike, & they are unique to each brand. For your
observation, the MRP & manufactured date of the cement bags of two different companies are shown in
checklists no. 10. & 11.

Field test for good quality of cement

field test for good quality of cement/field test for cement/cement tests/different site test for cement

Following are some field tests, that should be carried out to know the quality of cement.

1. Date of packing:

It should be within 3 months at the time of purchase.

2. Lumps test:

It should be free from any lumps which might be formed due to the atmospheric moisture.

3. Colour test:

Cement should be of uniform grey color, with a light green shade.

4. Float test:

When little quantity of cement is poured into a bucket of water, some part of it should float on water for
a few seconds, forming pockets before sinking.

5. Setting test:

A thick paste of cement should be applied evenly over the piece of a glass. After an initial setting time of
30 minutes, it should be kept in water for 24 hours. Next day, when you test the cement, it should be
hard in a single piece, if it breaks into several pieces then the cement is not of good quality.

6. Adulteration test:

When cement is rubbed between two fingers, you should get the smooth feeling of fine powders. If you
feel the rough grainy texture, then there is a possibility of adulteration.

7. Temperature test:

When kept over the palm, you should feel the normal atmospheric heat. It should not be much warmer.
Selecting the water to use

16. The water should be clean and neutral or slightly alkaline (pH 7 to 8.5). It should be free from organic
matter, oil, alkali or acid. Avoid using saltwater or a water too rich in sulphates (more than 250 ppm).

17. If you have to use brackish water or dirty water, add a tablespoon of soap powder for every sack of
cement used. Dissolve the soap into a small amount of water and add it to the mix.

Reinforcement Steel – Bar Types, Site Storage, Cutting and Bending

Reinforcement plays a very important role in construction; it takes most of the

tensile forces which are faced by reinforced concrete structures while concrete
takes care of the compressive loads.

Reinforced concrete construction (RCC) faces several types of environmental

attacks during its lifetime. Chemicals like sulfates and carbonate attack the
concrete while chlorides and moisture (water) attack the steel in RCC. It is,
therefore, necessary to take all precautions to prevent such attacks on RCC
structures for high performance. The selection of the correct type and quality of
steel and its procurement from a reliable source is important. The success of an
RCC job depends to a large extent on the reinforcement being correctly and
rigidly fixed in the concrete with the right spacing and cover. The cover to the
reinforcement is extremely important for the protection of steel in concrete. The
cover should not only be adequate in thickness but the concrete quality in the
cover itself should be dense and well compacted.

Accurate cutting, bending, and fixing of steel bars are a must, so that correct
cover is maintained and steel is adequately protected.

Bars Types and Identification

The reinforcement steel is generally available in three forms.

 Mild steel rounded bars

 High strength deformed
 Corrosion resistant steel

While the rounded mild steel bars are manufactured by hot rolling of mild steel,
the high yield steel is made by either hot rolling a low alloy steel or by cold
twisting and stretching of the mild steel bar.

By visual inspection the engineer can know if the bar is plain mild steel, hot rolled
deformed, cold worked deformed ribbed (TOR) or cold worked twisted (TOR).

TOR steel is available in several types/grades. TOR-40 is identified by a registered

trademark 'TOR' on every meter of bars. TOR-50 is identified by a registered
trademark as stated above, plus mark a '50' or '0' or * (star) between the two
TOR' trademarks at times at 300 mm spacing. The TOR 50 bars are also painted
'green' for the length of 10 cm at both ends for easy identification.

Checklist for Buying Reinforcement

Site Arrangements

The work of storing, cutting,bending, and fixing reinforcement becomes easier

with proper planning and careful selection of storage and working area. The
requirement will differ from job to job depending on the quantum of work and
whether or not all the above activities are to be executed at the site.

Storage

The points to be borne in mind regarding storage are as follows:

 The bars must be laid, so that the correct type,size,and length are located
easily without double handling.
 The bars must not get contaminated by materials like mud,oil, and grease.
 The bars should be stored on a raised platform or wooden sleeper/precast
concrete supports, so that,they do not get contaminated with mud,water,
moisture,or humidity and start rusting. The supports should lose enough so
that,bars do not develop a band on account of improper storage. In
addition, a suitable all-around protective cover of polythene sheeting is
preferred and it remarkably improves the performance of reinforcement
steel as it prevents rusting to a great extent during storage.
 Long storage periods especially in high humidity conditions and monsoon
periods should be avoided. Alternatively, steel reinforcement must be
properly covered and protected from rain and moisture.

Improper storage of steel reinforcement at site

Proper storage of steel reinforcement at site

Cutting and Bending

Generally, in our country, and bending of steel bars is done manually. Even coiled
steel is straightened manually at the site. Equipment is now easily available for
cutting, bending, and straightening reinforcement steel. The job can be done must
faster, giving better quality and economy.

The cutting area should be as close to the storing area as far as possible.

So that handling is simple and does not require long leads to transport. The
handling of the bars had to be done properly and carefully during each and every
operation. Avoid throwing the bars as bends and kinks will develop at undesired
locations which will be difficult to straighten at a later stage.

Before cutting, the bars should be correctly selected. The type of steel, diameter,
and length should be properly checked and verified. Proper planning of cutting
schedules is necessary. This can prevent unnecessary wastage and scrap
formation.

It is recommended to use steel tapes for measuring bars as there are fewer
chances of an error when steel taps are used.
The cutting length must be properly established from the bar bending schedules.
This is extremely necessary when bars required for stirrups are cut. If the length
cut is short, then the stirrups may not fit properly or may create problems of
increased cover or decreased effective depth. Similarly, if the length cut is more,
then the stirrup will be fixed in a skew manner and result in less cover or
congestion of reinforcement at certain locations.

Bending should be carried out with proper machines whether hand operated or
powered. The use of manual makeshift methods will produce poor results and are
dangerous.

Some precautions required for bending are listed below:

 Before bending a large complicated bar shape, prepare a full-scale drawing

that can be used for checking or alternately prepare a jig or gauge for
checking bar diameters and shapes before cutting and bending. Visual
identification of bar sizes should be avoided.
 Bending machines or jigs may cause variations, so before bending a
number of bars with several bends, especially with critical dimensions, the
first finished bar should be properly checked to see that it is of correct
dimensions.
 Check the diameter of the mandrel before bending. The inside radius of
the bend should not exceed '2d' for mild steel bars and '3d' for high - yield
bars ('d' being bar diameter). Too tight a radius will break weaken the bar.
 Always bend high-yield bars cold. Mild steel bars of large diameter may be
heated to a cherry red heat but must not be quenched in water to cool
them.
 During cold weather, the speed of bending be reduced for high-yield bars
as steel becomes more brittle below 5°C. This reduced speed of bending
also applies to dowel bars that have been bent already and require
straightening. Bending of high-yield steel bars by 90° for the diameter
above the 10mm for the dowels is generally not recommended as at a later
stage while straightening it is likely to break.
  Make sure that the latest revision of drawings and schedules are available
and referred. Superseded drawings and schedules must be destroyed once
revisions are received at the site.
 The bar to be bent must be properly gripped while being bent. If support is
not firm then the bar may bend in the wrong place.
 Cut and bend bars must be bundled and labeled before stacking so that
fitters can easily spot them and fix them at the correct location. Each
bundle should not weigh more than 75kg, it should have bars of identical
shape and size, and have a label that indicates the length, size, shape, and
type of bar used.

Cleanliness and Rust

The reinforced concrete structure is a composite mass whose performance
greatly depends on the bond between the steel bars and the concrete placed and
compacted around them. The quality of the bond will greatly depend on the
cleanliness of the steel bar surface and the quality of concrete around it. It is,
therefore absolutely necessary that bar surfaces are free from grease, oil, mud,
mould oll, loose mill scales, excessive rust, loose concrete, and/or ice.

It is also recommended not to leave the steel bars exposed for a long period of
time (more than two weeks) after they are fixed. This will cause rusting of steel
and subsequent staining of concrete.

The effect of rust on the bond between steel and concrete is often a debatable
issue on site. A little rust or brownish tinge on the bar is not harmful to reinforced
concrete. However, loose mill scales or excess flaky rust must be removed by firm
tapping or scraping. Reinforcement steel, before it is placed and embedded in
concrete, reacts with oxygen and moisture in the atmosphere while it is being
transported and stored. This causes the formation of a thin film of rust which is
reddish-brown in color. This reddish-brown film, so long as it is skin deep, is
considered desirable.
This brownish coating is said to improve bond quality and is not easily removable
even after wire brushing or scraping. The brownish tinge can remain and it needs
not to be removed. Besides improved bond quality,

this thin brownish film on the surface of the reinforcement also offers passivation
to the steel surface against corrosion.

Steel that is stored for a long period of time also needs to be checked for
cleanliness and excessive rusting before cutting and bending is done.

Fixing of Reinforcement Steel

Cover and Spacers

To protect the reinforcement from corrosion and for the composite action of the
reinforcement and concrete to be effective, it is absolutely necessary for the steel
bars to be surrounded by sufficiently impermeable strong concrete. If moisture
and chlorides penetrate into concrete the steel bars will rust and due to the
formation of ferrous oxide or ferrous hydroxide, there will be an expansion in the
volume of steel nearly 7 to 8 times its original size. This increase in the volume of
steel creates tensile forces in concrete and exposes the concrete to further attack.

All reinforcement steel has to be embedded to a certain minimum. distance from

the surface. This distance is called 'cover' and is specified by the structural
Engineer, in the drawings, depending on the following factors:

 Quality and grade of concrete.

 The environment in which concrete is located.
 The thickness of the structure and its location.
 Special provision to resist fire.

The correct cover is achieved by using mortar or plastic blocks/shapes. Generally,

cover blocks at the site are made out of the mortar, without proper compaction
or using correct size moulds. These results in porous cover blocks of low strength
which instead of protecting steel against Ingress of moisture and/or other harmful
chemicals give an easy passage causing rusting of steel and spalling of concrete.
The mortar blocks should be of good strength (in the range of main concrete).
They should also be well cured and most important, they should be dense and
well compacted. Similarly, plastic covers of poor quality often break as they are
not made from good quality special plastic.

It is important to use the correct size cover blocks to give the required depth of
protection to steel reinforcement. The cover blocks should be spaced at the
correct distance to ensure adequate and uniform protection to steel
reinforcement throughout. It is equally important to provide adequate cover to
both, main reinforcement as well as stirrups and ties which generally project
beyond the main reinforcement.

Mortar cover blocks are best made using cement mortar in 1:2 cement to sand
proportion, and water is added just sufficient enough to give dense concrete with
low permeability. Adequate precaution must be taken so that any wire cast into
the blocks is kept away from the exposed surface. If this is not done there will be
a risk of rusting or rust stains on the concrete surface.

Metal spacers should not be used when the structure is located in a corrosive
environment or is in contact with water. Do not use the stone chip timber pieces
as permanent covers/spacers.

The top and bottom reinforcement in suspended slabs have to be placed and
fixed correctly before concrete placing starts. They have to be properly secured so
that they are not displaced changing the effective depth and cover at the top and
bottom. Smaller cover blocks have to be used bottom. Mild steel chairs of
adequate size, the shape must be placed at such spacing that it can carry the top
steel and keep the required effective depth between the top and bottom steel,
uniformly and correctly. The cover blocks at the bottom of the steel cage should
be strong enough to take the foot load of workers.
In cantilever slabs, due to inadequate cover, it is observed that the top
reinforcement shifts to the bottom due poor fixing and movement of workers
over the bars during the concrete placing and compacting process. This often
results in failures, as the steel which is required at the top of the slab to take up
the required tensile forces and moments collapses or settles below due to the
reasons given above.

In the case of the slabs on grade which are singly reinforced, it is often convenient
to place the concrete up to a given level and then place the steel bars or steel
fabric before placing the rest of the concrete above the steel.

Never attempt to place the reinforcement age on the formwork and later try to
raise it as the concrete is being placed. This will never give the correct cover of
effective depth.

If spacers are allowed on the face of a beam or wall but not on the opposite face,
the reinforcing cage must be held in position by pulling it towards the formwork
on one side by means of wires attached to the cage and passing through holes in
the formwork. The wires are pulled towards the formwork so that the spacers on
this side prevent reinforcement from actually touching the formwork, thereby
giving a correct cover. This will also ensure proper cover on the side without
spacers. However, all wires must be removed soon after concrete is placed or it
will cause rust strains and future durability problems.

Storage of Construction Materials (Steel Bar) at Construction Site.

As we know that steel bars cover 25 -30% of the overall cost of the building so it is
very crucial that steel bars must be handled and stored with precaution on the
site. There are different processes or operations where laborers need to take care
of steel bar such as unloading, Stacking, Cutting, Bending, Fabrication, etc.
Reinforcement has the capability to resist lateral forces and provide strength and
ductility to the buildings, so it is very necessary that all these loading and
unloading operations should be done properly on site. Steel reinforcement is
highly corrosion in nature when it comes to direct contact with water and
moisture.

Following points to be considered during the Storage of Construction Materials

i.e. Steel bars at the construction site:

 A separate area with fencing wire should construct at the site in order to
store the reinforcement.
 Make ensure that area should be free from moisture and dust in order to
avoid rusting.
 Ensure that the storage area should have proper drainage facilities.
 Steel bar should be stored on the basis of diameter and length in order to
avoid confusion for identification.
 All-steel bar tags or Mark should be at the same end because it will help the
person to identify the particular Bars.
 Place the steel Bars on wooden sleepers so that they cannot touch the
ground.
 Storage of Construction Materials
 Cover the steel bar with a polythene sheet during nighttime that prevents
the reinforcement from moisture.
 In order to protect the steel bar from scaling and rusting, coat the steel
reinforcement with cement wash.
 If we stored the reinforcement for long period, then it should be stack at
least 6 inches above the ground level.
 There should be separate storage for cut pieces of steel.

Storage of Construction Materials (Aggregate) at the construction site.

Following are the guidance regarding stacking and storage of Aggregate at site.

 Aggregate should be stored on a dry hard surface.

  Aggregate shall be stored corrugated iron sheets, a wooden platform,
concrete surface or floor of bricks, etc.
 Storage of Construction Materials
 There should be separate stacks for Fine aggregate and coarse aggregate.

For Coarse Aggregate, the suggested size of stacks are as follows;

Material Length (m) Breadth (m) Height (m)

Coarse Aggregate 2 2 0.5

or. 5 5 1

or 5 1 0.5

For Fine Aggregate (sand), the suggested size of stacks are as follows;

Storage of Construction Materials

Material Length (m) Breadth (m) Height (m)

Coarse Aggregate 2 2 0.5

or 5 5 1

or 5 1 0.5

Storage of Bricks at the construction site.

Stacking and storage of Bricks at the site involves proper planning for space and
Location. The storage location of Bricks shall be near to the site because it will
reduce transportation time. While allocating the place, make sure that there
should be space for the vehicle to unload the Bricks. During unloading or handling
of bricks, there is a possibility of damage to corners, edges, or other parts of the
bricks that shall not be allowed. Following are the guideline to be followed for the
storage and stacking of

 Bricks should be stacked to a maximum height of 1 meter.

  Bricks should be stack on a dry hard surface.
 In order to reduce the breakage and defacement at the time of unloading,
Bricks should be stacked in regular tiers.
 Clay containing Bricks shall be immersed in water to prevent bursting.
 Bricks should be stacked to a maximum of 10 Bricks in Height.
 Bricks shall be stacked to 50 Bricks in Length and not more than 4 Bricks in
width.
 The Clear gap between the two adjacent Stacked Bricks should not be less
than 800 mm.
 Bricks of each tractor or Truck shall be stored in a separate stack.
 On the basis of types such as clay bricks, fly ash bricks shall be stacked or
stored separately.
 Bricks of different classification based on strength and size shall be stacked
separately.

Bricks: Properties Composition and Composition of Good Quality of Bricks

Properties/ Characteristics of Good quality Clay bricks

 A good clay brick should have uniform Rectangular shape and size.
 It shall be manufactured either hand or by machined.
 All the arris should be straight edges.
 It has to be well burnt.
 Brick should have a uniform in deep red color that shows the uniformity in
chemical composition.
 It should be hard enough to resist the compressive load.
 It should be free from holes, lumps, or grit.
 The surface of the bricks should not be smooth because mortar will not
stick to it.
 It should be free from any kind of cracks.
 Brick should have a uniform texture.
 It should have surfaced so hard that cannot be scratched by the fingernail.
 Good quality of bricks should have a metallic ring when one brick stuck
against another brick.
  It should not break when it falls from a height of about 1.5 m on the
ground.
 Water absorption of bricks shall be less than 20% of its dry weight when
immersed in water for 24 hours.
 The percentage of soluble salt should not exceed 2.5 percent in burnt
bricks.

Composition or Ingredients of Clay Bricks

Ingredients Composition value in Percentage

Silica (SiO2) 50-60

Alumina (Al2O3) 20-30

Lime (CaO) Less than 10%.

Ferric oxide (Fe2O3) Less than 7%.

Alkalis Less than 10%.

Magnesia (MgO) Less than 1%.

Major ingredients of clay Bricks and its functions

Silica (SiO2)

Good quality of bricks contains 50-60% silica. The presence of Silica controls
cracking, shrinkage, and warping of raw bricks. Aluminosilicate is formed when
Silica (SiO2) reacts with Alumina (Al2O3). If the amount of silica is more than
required then clay brick particles lose its cohesion between them. Due to the
excess amount of silica, a brick becomes brittle in nature.

Alumina (Al2O3)

Alumina is one of the compositions of bricks which play majors role in terms of
plasticity. Due to its plasticity property bricks can be molded into a rectangular
shape. If the amount of Alumina present in bricks is more than required, Crack
occurs in bricks when clay gets dried.
Lime (CaO)

In brick, the amount of lime is less than 10%. Lime prevent the brick from
shrinkage when it is under drying conditions. Excess amount of lime makes the
brick melt and it may lose its shape and size.

Iron Oxide ((Fe2O3)

The main Function of Iron oxide is to provide red color to the bricks. The presence
of oxygen on burning helps the brick to achieve the red color and due to the
absence of oxygen, it will achieve dark brown or black color. If the amount of Iron
oxide is more than required that makes the bricks dark blue. Iron oxide enhances
the properties of impermeability, strength, durability, and hardness.

Magnesia (MgO)

The main function of magnesia is to provide yellow tint if it presents in small

quantities. Magnesia content is less than 1% in brick. Due to the small quantity,
magnesia decreases the amount of shrinkage after drying. If the amount of
magnesia is more than required that causes the decay of brick.

Field Test

A field test is more important than laboratory results because it gives immediate
results. It plays a crucial role in terms of strength and durability. There is a
different practice to test the cement on site. Here is some applied method to
check the quality of cement.

Check the Color:

Once the cement bags carrying vehicles are unloaded, Engineers should check the
color. Make sure that the color should be uniform and grey.

The color of OPC is grey.

The color of PPC is Blackish.

Insert your palms inside the Bags:

Once you insert your hand in cement bags, you will feel smooth or cool when
touched or rubbed in between fingers. If you feel cool then it indicates the quality
of cement is good, if not which means it is not suitable for construction work.

Throw a small quantity of cement in Bucket:

If a small quantity of cement is thrown in a bucket of water, it should sink means

the quality of cement is good. If it won’t sink that shows that it is not suitable for
the preparation of concrete.

Check the lumps inside the bags:

It should be free from lumps because it affects the strength of concrete. IF bags
containing lumps should be rejected for construction work.

Storage Specification

 Keep the bags 1 foot from wall for the protection from moistures.
 15 Numbers of bags should be placed in one row.
 Cement bags should be placed 15- 25 cm from the floor level. Make sure
that it should be kept on wooden sleepers.
 Bags should be stacked in 10-12 layers.
 There should not be any opening in the storage room because to reduce
the moisture.

Strength versus age of concrete

Concrete strength is directly proportional with time. As the time duration

increasing, strength gained by concrete also increasing.

 1 days = 16% compressive strength.

 3 days = 45% of its Specified strength.
 7 days = 60% compressive strength.
 14 days = 90% compressive strength.
  28 days = 85% compressive strength.

Some Known Facts or information

 1 ton of cement: 20 Bags.

 No of bags carrying capacity of Trucks: 250-300 Bags.
 Density of cement: 1450 Kg/cum.
 Specific Gravity : 3.15.
 Color of OPC : Gray
 Color of PPC : Blackish.
 Grade of OPC : Grade 33, Grade 43, Grade 53
 Grade of PPC : Grade 33.
 Initial setting time : 30 minutes
 Final setting time of : 600 minutes.
 Percentage of Gypsum added in Cement: 2-3%.
 Acceptance Criteria of consistency of OPC is 25% – 33% of weight of the
bag.
 Soundness should not be more than 10 mm.

15 Points to Remember For Civil Engineer about Fine Aggregate or Sand

Following are the 15 Important points about Fine Aggregates.

1. Different sizes of Coarse Grained soil

 Boulders Greater than 300 mm.

 Cobble 80 mm – 300 mm.
 Gravel 4.75 mm – 80 mm.
 Sand 75 micron – 4.75 micron.

2. Size of Fine Grained soil

 Silt 2 micron – 75 micron.

 Clay less than 2 micron.
3. Specific Gravity

 Specific gravity of Fine Aggregate is ranges from 2.55 to 2.65.

4. Impurities available in Fine Aggregates

 Silt.
 Clay.
 Salts.
 Organic matter.

5. Sieve used for grading of Coarse Aggregates

80 mm, 63 mm, 40 mm, 20 mm, 16 mm, 12.5 mm 10 mm, 4.75 mm, 2.36 mm.

6. IS Sieve used for grading of Fine Aggregates

10 mm, 4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron, 150 micron.

7. Fine Modulus of Fine Aggregates

Type of sand fineness Modulus Range

Fine sand 2.2-2.6

Medium 2.6-2.9

Coarse Sand 2.9- 3.2

8. Field Test of Fine aggregate

 Fine Aggregate will not stick with hand. If it contains clay will stick and if
the color of the palm changes that indicate fine aggregate has clay and silt.
 If you add a small quantity of sand in a glass of water if it settles
immediately which means it is suitable for construction work if the sand
form different layer at the top that indicates that sand has a layer of silt at
the top. The thickness of the silt layer should not be more than the
thickness of the layer by 8%.
  If we add caustic soda in a glass of water and later add sand inside the
glass, if water changes the color to brown then it shows that it has some
organic impurities which are not suitable for construction work.
 It should be free from lumps, vegetable matter, organic impurities, etc.

9. Test of Fine Aggregate

 Bulking of sand.
 Silt content
 Fineness modulus
 Sieve analysis

10. Bulking of Sand

It is obtained from the following formula

% Bulkling of sand= (H1-H2/H2) x 100.

Where H1= Height of sand in one container

H1= height of water in another container. Add the sand in water and measure the
height of sand in water is H2.

11. Silt Content Test(IS 2386)

It is obtained by

Silt content= (V1/V2) x100

V1= Volume of sand layer alone.

V2= volume of Volume of sand below the silt.

12. Fineness modulus of Fine aggregate

Fineness modulus is obtained adding the percentage of the weight of fine

aggregate retained on each sieve and dividing by 100.
Fine modulus= cumulative weight of fine aggregate retained on each sieve/100.

13. Important information obtained from the different tests of Fine Aggregates.

Less than 5% moisture content in the fine aggregate is preferred for construction
work.

If Fine Aggregate having Fineness modulus greater than 3.2, then it is not suitable
for concrete.

Permissible silt content in Fine Aggregate = 6%.

14. Moisture content and Percentage of bulking with respect to volume

S.No. % Moisture content % Bulking w.r.t. Bulking

a. 2% 15%

b. 3% 20%

c 4% 25%

d. 5%. 30%

15. Characteristics of good quality of Fine Aggregate

 Habitats, Vegetable matter, grass, etc which affect the setting and binding
property of concrete.
 It should be chemically inert.
 Fine Aggregate should be free from silt and clay.
 Fine Aggregates should not contain more than 3 percent of silt.
 It should not contain salts that contain sodium chloride that causes
corrosion to reinforcement.

The following are the 11 Important Points to Remember for Civil Engineer about
Aggregates.

Definition of Aggregates.
Coarse Aggregates are the particles which are retained on 4.75 mm sieve. Coarse
Aggregates are larger in size as compared to fine aggregates. It obtained by the
processing of igneous rocks such as pumice, scoria, and tuff. Some of the most
common natural aggregates are silica sand, gravel, crushed lightweight stone, etc.
It is used to produce concrete and any other stonework.

IS Sieve used for Grading of Aggregates

The I.S. sieve used for grading of Aggregates is different sizes such as 80 mm, 63
mm, 40 mm, 20 mm, 16 mm, 12.5 mm, 10 mm, 4.75 mm, 2.36 mm.

Size of Coarse aggregate used for Concreting

The Size of Coarse aggregates ranges from 4.5 mm to 80 mm. The sizes of
aggregates depend on the grade of concrete is to be made. For normal house or
Residential building, 10 to 20 mm aggregates sizes are used. The angular shape of
the aggregate is best for concrete making. The other sizes of aggregates used for
concrete making are 40mm, 20mm, 12.5 mm and 10mm, etc.

Fineness Modulus

Fineness modulus is obtained by adding the percentage of the weight of material

retained on each of the prescribed I.S. sieves and divided by 100.

For Coarse Particles Sizes Fineness Modulus

20mm 6 to 6.9

40mm 6.9 to 7.5

75mm 7.5 to 8

Specific Gravity

The specific aggregates particles ranges from 2.55 to 2.65.

Qualities of Good aggregates that are suitable for construction Work

  Aggregate should be free from silt, Lumps, Clay, and organic impurities like
Vegetation, grass, etc. which affects the setting, strength, and durability of
concrete.
 It should not absorb water more the 10% of their weight after 24 hours
immersion in water.
 Flakey and Elongated aggregate is not used generally but it can be used in
very less amount.
 It is best for concrete making or the aggregates obtained from the river.
 Angular aggregates are best for Concrete preparation than the rounded
aggregates because of the following reasons
 Angular aggregates possess a high surface area with rough surface higher
bond strength with aggregate than the rounded aggregate.

Types of Coarse Aggregates

On the Basis of Shape

Angular Aggregate

Angular particles have sharp, angular and rough and have High Surface area. Due
to the rough surface, It has a strong bond between the surface of angular
Aggregate and cement paste. It requires more water due to rough surface. It has a
high W/C ratio. Coarse Aggregate has low strength as compared to Rounded
aggregates. It is good in workability.

Flaky Aggregate

Flaky aggregates are one of the types of aggregate which is flat and elongated in
shape. Elongated aggregates are those aggregate whose length is 1.8 times its
mean dimension.

Rounded Aggregates

These aggregates are generally found in rivers and seashore. It has a smooth
texture. Less surface area. Due to the smooth surface, it gives poor concrete
because due to the lack of bonding between the surface aggregate and cement
paste. It requires less water due to the smooth surface. It has a low W/c ratio.
Due to the low W/C ratio results in higher strength as compared to angular
aggregates.

On the Basis of unit weight.

 Light weight coarse Aggregates whose unit weight 12 KN/m3

 Normal weight coarse Aggregate whose unit weight is 12 KN/m3
 Heavy weight aggregate whose unit weight is 20 KN/m3

Characteristics of Aggregates

 Bond strength.
 Shape and texture.
 Moisture content.
 Bulk density.
 Specific gravity.
 Fine modulus.
 Soundness.

What are the stages of RCC construction?

Hi…

Generally, Any construction required following 12 stages, to complete RCC

building work. This stages may be varies accordingly, region to region because of
large country area.
For different prespective, someone making it's into 3 stages, 5 stages or any
number. We are making it into 12 stages from excavation to lock & key project as
follows

1.Footings concrete

1 excavation and dressing

2 PCC bed concreting

3 footing bar bending work

4 footings concrete casting

2.Plinth beam concreting

1 Starters concreting

2 Neck columns casting

3 soil backfilling

4 water consolidation

5 PCC bed concreting

6 marking on PCC

7 bar bending and shuttering

8 checking and casting

3.Floor PCC bed concreting

1 soil back filling

2 water consolidation

3 soil preparion and compacting

4 Anti termite treatment and PCC bed concreting

4.Slab casting work

1 Starters concreting

2 columns casting

3 staicase concrete

4 shuttering and barbending

5 checking and casting and curing bunds

5.Brick work

1 Hacking

2 cleaning & Marking

3 brickwork upto lintel level

4 terrace parapit wall

5 Lintel chajjas concrete

6 Up to beam bottom level

6.Plastering work

1 Electrical conduting

2 internal cleaning, jali fixing & bull marks checking

3 internal 1st coat plastering

4 internal plumbing lines fixing(cpvc and pvc lines)

5 External scaffolding fixing

6 external jali fixing& bullmarks checking

7 external 1st coat plastering

8 external 2nd coat plastering

7.Waterproofing

1 terrace dead morter chipping

2 checking & applying chemical

3 Genal raw material shifting

4 concrete screed& groove formaation

5 curing bunds and water stocking & seepage checking

8.Painting work

1 shelves with bison panels

2 internal 2 coats lappam apply(normal & cement based wall putty)

3 emery paper cut & light checking

4 internal 1 coat primer apply

5 external waterproofing chemical apply

6 elevation 2 coats putty apply

7 emri paper cut

8 externnal 1 coat primar apply

9.Tiles work

1 internal Plumbing lines pressure test

2 toilets wall tiles dadoing

3 tiles flooring work

4 kitchen wall tiles dadoing & kitchen platform

5 parking tiles laying

6 staircase tandoor stone laying

7 staircse and terrace ms railing fixing

8 raillings locksets and redoxide apply

10.Joinery works

1 door frames fixing

2 window UPVC frames fixing

3 all patch& touch up works

4 door shutters and window grills fixing

5 electrical wiring , CP , sanitary & all final fittings

6 checking, cleaning & locking

11.External final works

1 wall piles &plinth beam concreting

2 compound wall brick work

3 compound wall 2 sides 2 coats plastering

4 external plumbing main lines inlets and out lets

5 hume pipes & PVC pipes laying under the ramp

6 Ramp making, Gully flooring & chambers fixing

12.Final Handover procedure

1 internal final

2 coats painting 2 external final 2 coats painting

3 inside and outside cleaning

4 rechecking technically inside and outside

5 requesting validation team

6 attending all validation points

7 requesting 2nd validation team

8 requisting customer for WCC

9 handover key

Source:- my company WBS, internet & observation.

What is the reason behind cracks in cement plaster?

Typical defects in plaster, its reason and its remedies :-

1. Defect Observed = Swelling of small patches in plastering (Blistering)

Reason

This is due to faulty slacking of lime / sanla

Remedies / Care to be taken

The lime / sanla should be properly stacked before use. Slacked lime should be
left for some week to cool before use.

2. Defect Observed= Cracks on plastered surface

Reason

a) Movement of background

b) Shrinkage movement of

plastering mixes

c) Excessive trowelling

d) Varying thermal expansion

Remedies / Care to be taken

a) Proper mixing of mortar

b) Control on mix proportion of mortor

c) Avoid excess trowelling

d) Suitable control over variations in temperature

subsequent to plastering
3. Defect Observed= Falling of plaster

Reason

a) The adhesion / key of the plaster to the background is not perfect

b) Excessive moisture in background

c) Rapid drying of successive coats

d) Absorption of water from mortar which is turn loose the strength of mortar

Remedies / Care to be taken

a) To ensure proper key by racking out joints and roughening of background

material on base coat

b) Watering of base coat atleast one day before plastering

c) Fresh surface should be kept wet and cool for

atleast 7 days

d) Surface should be kept semi wet as per exact

requirement

4. Defect Observed= Stalatite (Whitish crystalline substance on plastered

surface)

Reason

a) Presence of salt in lime, cement, sand, bricks or water used in plastering

Remedies / Care to be taken

a) Only washed sand to be used in plastering used

b) Burnt bricks and clean water (free from salt) to be used

c) Small proportion of alum and salt soap to be added in mix

d) Damp proof coat should be provided

5. Defect Observed= Cracks on plastered surface within few days

Reason

a) Background surface not being properly prepared

b) Movements in the backing either on account of the thermal expansion or due

to shrinkage caused by the drying of the backing material

c) Movement in the plaster itself on account of the expansion (in case of lime
sand plaster) during drying

d) Excessive shrinkage of plaster due to application of mortar in thick coats or

very rich cement mortar with fast setting cement 53 grade

e) Poor workmanship and method of application of the plaster

Remedies / Care to be taken

a) Preparation of surface should be done properly

b) Backing surface should be semi dry before plastering

c) Keep plaster cool which is directly exposed to sun heat during its young age by
the help of wet gunny bags or by sprinkling water over it.

d) During preparation of surface, necessary chiseling should be done in

accordance with level dots before plastering

e) Improve the workmanship by training programmes

6. Defect Observed= Long term cracks on plaster observed after long period

a) Crack at junction of masonry & beam / column

b) Cracks due to excessive silt content in sand

c) Cracking in the form of closed net and shrinkage cracks in honeycomb form

d) Structural cracking

Reason

a) These cracks appear due to the different coefficients of thermal expansion of

two different material viz. R.C.C. & masonry. Also poor joint filling at junction
leads to cracking

b) These cracks appear due to movement of excessive silt after repeated dry &
wet conditions

c) This is due to excessive cement content in plastering mortar

d) This is due to unequal settlements in foundation

Remedies / Care to be taken

a) Chicken mesh is applied on junction after carefully sealing the joint by rich
mortar & khadi maal is applied at junctions

b) If the silt content in sand is mare than 7% wash the sand before use

c) Correctly mix the ingredients & consider bulkage of sand

7. Defect Observed= Peeling off ceiling plaster

Reason

This is due to bond failure between ceiling concrete & coat of plaster

Remedies / Care to be taken

Closely hacking (tacha) @ Nos. notches/sft (500 nos./m2) & cleaning the ceiling
for making it free oily substances will sort out the problem

8. Defect Observed= Rust stains

Reason

These appear on surface when plaster is applied on chicken mesh which is loosely
placed

Remedies / Care to be taken

Tight fixing of chicken mesh & cutting the excess projections of the mesh which
are coming out of plaster will sort out the problem

9. Defect Observed= Softness

Reason

This is due to excessive dampness at certain points which make it soft. Reason of
such softness is undue thickness of the finishing coat, presence of deliquescent
salts & excessive suction of the undercoat

Remedies / Care to be taken

Keep minimum thickness of plaster & wash the san

10.. Defect Observed= Uneven surface of plaster

Reason

Poor workmanship of the work

Remedies / Care to be taken

Improve the quality of workmanship & train the masons for good work

11.. Defect Observed= Peeling off top finish layer of internal plaster (Sanla /
Neeru finish)

Reason

a) Bad quality of sanla may lead to peeling off the top layer

b) If neeru finishing is done after setting of base coat

c) Excessive thickness of top finished layer

Remedies / Care to be taken

a) Carryout all the quality checks on sanla before using it

b) Immediately apply the neeru on the base coat before setting of mortar

c) Keep minimum thickness of top layer

What is Shuttering or Formwork ? |15 Steps to Execute.

What is Shuttering Work or Formwork?

Formwork or shuttering work is a temporary ancillary construction used as a mold
for the structure, in which concrete is placed and in which it hardens and
matures. The construction of formwork involves a considerable expenditure of
time and material. The cost of formwork may be up to 20 to 25% of the cost of
the structure in building works, and even higher in bridges. In order to reduce the
expenditure, it is necessary to design economical types of formwork and to
mechanize its construction. When the concrete has reached a certain required
strength, the form is no longer needed and it is removed. The operation of
removing the shuttering or formwork is commonly known as de shuttering.

Requirement of Good Shuttering Work or Formwork

Formwork or shuttering work is a very delicate and precise job. A good shape or
size of a concrete structure depends on the precision of the shuttering, hence it is
a very important activity in construction that shall be carried out carefully

good formwork should satisfy the following requirements:

1. The material of the formwork should be cheap and it should be suitable for
re-use several times.
2. It should be practically waterproof so that it does not absorb water from
Concrete, Also, its shrinkage and swelling should be minimal.
3. It should be strong enough to withstand all loads coming on it, such as a
dead load of concrete and live load during its pouring, compaction, and
curing.
4. Shuttering should be stiff enough so that deflection is minimum.
5. It should be as to be light as possible.
6. The surface of the formwork should be smooth, and it should afford easy
stripping.
7. All joints of the formwork should be stiff so that lateral deformation under
loads is minimum. Also, these joints should be leakproof.
8. The formwork should rest on non-yielding supports.

Tools & Materials Required For Shuttering Works

Shuttering work in construction is a vital activity that involves various tools,

materials, and manpower. The required resources for shuttering are listed below.
Manpower Type Required for Shuttering

 Engineer.
 Formwork/shuttering Supervisor
 Skilled- Carpenter.
 Semi-skilled Carpenter or Helper.

Tools Required For Shuttering Work

Tools-Used-In-Shuttering

1) Line thread 2) Plumb Bob 3) Hammer 4) Measuring Tape 5) Right Angle 6)

Cover Block 7) Wrench

 Line Thread– Required to check the vertical alignment.

 Plumb Bob– Required to check the vertical alignment.
 Carpentry Hammer– Required to assemble the formwork sheet/ply
 Measuring Tape– Required to measure the dimension of Shuttering.
 Right angle Tool – Required to check the right angle.
 Cover Blocks– Cover blocks are used to keep the gap between the face of
shuttering to the reinforcing bars.
 Wrench– Wrench is used to tightening the nut bolts.

Materials Required For Shuttering Work.

The requirement of materials in shuttering work may vary according to the

structure in this post I am going to list out the common material used in
shuttering work or formwork.
Materials used in shuttering

1) Hard Wood 2) Plywood 3) Steel Plate 4) Stagging Material 5) Stirrup Head 6)

Prop Jack 7) Telescopic Beam 8) Tie Bolt

 Hard Wood (batten)- Battens are required to make the shuttering board.
there are different sizes of battens required for different purposes.
 Shuttering Ply– Plywood is the very common material used in shuttering
work to make the form. The standard size of a shuttering ply is 2400mm X
1200mm and 12mm thick.
 Shuttering Steel Plate– There are different sizes of steel shuttering plates
available but the standard sizes are 1200mm X 600mm, 1200mm X 500mm,
1200mm X 250mm.
 Scaffolding or Stagging – scaffolding material is required for formwork
stagging means formwork for slabs
 Stirrup Heads– A stirrup head is a “U” shaped head used to support the
shuttering or formwork. It is attached in front of a scaffolding pipe.
 Telescopic Prop– Telescopic props are the vertical members available in
different sizes used below the beam or slab to support the formwork
structure.
 Telescopic Beam – Telescopic beams are the steel adjustable steel beams
provided below the slab shuttering in case of heavily loaded or larger spans.
This beam is used to carry and distribute the load of the temporary
formwork.
 Tie Rod & Bolt– Tie rod and blots are used to tie up the formwork.
The list does not end here, but these are the most commonly used shuttering
equipment in construction work. There are many more types of shuttering
materials that are used depending on the construction duration, budgets, and
quality needs. Such as Aluminum Shuttering, Plastic shuttering, Fabric shuttering,
etc.

Types of Shuttering [ Formwork ]

Forms are classified as wooden, plywood, steel, combined wood-steel, used for
reinforced concrete, and plain concrete structures. Timber is the most common
material used for formwork. The disadvantage of the wooden formwork is the
possibility of warping, swelling, and shrinkage of the timber. However, those
defects can be overcome by applying them to the shuttering water-impermeable
coatings. This coating also prevents the shuttering from adhering to concrete and
hence makes the stripping easier.

Steel shuttering is used for major work where everything is mechanized. Steel
formwork has many advantages, such (i) it can be put to a high number of uses,
(ii) it provides ease of stripping, as follows : (iii) it ensures an even and smooth
concrete surface, (iv) it possesses greater rigidity, (v) it is not liable to shrinkage or
distortion. However, steel formwork is comparatively more costly.

However, the classification of the shuttering can be made in two ways. One is in
terms of Material Used another in terms of Technique Used in shuttering.

Types of Shuttering Based on Material Used.

 Plywood Shuttering– Plywood shuttering is a standard and widely used

shuttering material, it is used by making shuttering board using batten with
it.
  Timber Shuttering – Timber shuttering is used in general or local
construction, not in a large project. There are timber logs and lumbers are
used as a shuttering material timbers shutters do not provide a smooth and
even surface.
 Steel Plate Stuttering – Steel plates are very durable and also commonly
used shuttering materials
 Aluminum Shuttering – Aluminium is a lightweight flexible material that
gives a smooth and even concrete surface.
 Plastic Shuttering– Plastic shutters are used in some projects, it is a
comparatively new shuttering material in the industry. It is also lightweight
and durable materials which are made of glass-reinforced plastics (GRP)
 Magnesium board Shuttering – Magnesium is another heard and smooth
metal element which is used as a shuttering board, these boards are
lightweight and eco-friendly materials which is suitable for use in green
buildings.
 Gypsum fiber Board Shuttering– Gypsum boards are made with glass fiber
and gypsum which is very smooth and lightweight as well it is generally
used as partition walls and false ceilings but can also be used as shuttering
material.
 Fabric shuttering – Fabric formwork is contemporary materials that are
used to obtain some specials curved architectural shape.

Types of Shuttering Based on Technique Used

Standard formwork / shuttering– Standard formwork means the conventional

type of formwork that is used in almost every construction work.

Maivan formwork– Maivan formwork is a special type of formwork that is used in

a building having a typical floor plan. The full structure (internal & external wall,
slabs) is made with RCC in maivan shuttering. The maivan shuttering helps to
complete a building structure in very little time.

Slipform– Slipform is a unique and mechanized form of shuttering that is used in

large vertical structures like water tanks, chimnies, etc. It helps to construct the
structure in one go, after finishing a certain level it slips up above using a
hydraulic jack and builds another level and the process continues till the structure
is completed.

Step By Step Shuttering/ Formwork Procedure To Execute

I am going to guide you through the step-by-step procedure to execute a

shuttering properly. This list you can use as a shuttering checklist as well.

1. One use good quality of Film faced Plywood, Partially Seasoned Plywood,
Curved Plywood for formwork which is rigid and closely fitted, with
sufficient strength to support wet concrete.
2. We shall ensure the centering plates, planks, or plywood are properly
cleaned
3. We shall take care of Proper checks for line, level, plumb, dimensions,
Reinforcements tied and placed as per drawing, and supports placed
outside of formwork before starting concreting activity.
4. We shall ensure the proper placing of cover blocks on the forms.
5. We shall ensure Shuttering to be checked in stage-wise.
6. We shall ensure the Position of pockets, Anchor Bolts, and Insert to be
carefully placed and tied before placement of concrete.
7. We shall take care to apply a suitable release agent for forms before the
placement of reinforcement and after de-shuttering, proper cleaning of
formwork shall be made.
8. We shall use tape or foam sheets for filling the Gaps.
9. The area inside the formwork shall be cleaned by hand, blower, or other
means before the start of concrete.
10.We shall ensure the top level of the concrete is marked on the form and the
same level is carried out throughout the form.
11.We shall take care in providing extra supports to prevent the bulging of
formwork.
12.We shall Leave slab formwork undisturbed till concrete gains 70% of the
required strength.
13.We shall take care not to damage the concrete while stripping the forms
off.
 14.Removal of shuttering in view of time period should be as detailed below.

Removal Of Formwork

When de shuttering takes place, the components of formwork are removed and
then reused for the forms of another part of the structure. Such forms, whose
components can be reused several times are known as panel forms. In contrast to
this are stationary forms which are made for individual non-standard members
and structures, which have no repeatable elements, and also for structural
members, the form of work that cannot be stripped.

SL NO DESCRIPTION REMOVAL OF SHUTTER ABOVE 40 oC REMOVAL OF

SHUTTER BETWEEN 20 TO 40 oC

1 Vertical Formwork to Columns, walls, and Beams 2 days 16 to 24 hrs

2 Beam sides and pile cap sides 3 days 2 days

3 Slabs 125mm thick( Props to refixed immediately after Removal of

formwork) 10days 7 days

4 Slabs over 125mm thick and soffit formwork of Minor Beams (Props to
refixed immediately after Removal of formwork) 18 days 14 days
To conclude,

Shuttering is the most essential activity in construction, in this article we have

tried to explain the basic definition of shuttering, types of shuttering, and guide to
execution of quality shuttering works.

Frequently Asked Questions

What is difference between formwork and shuttering?

Shuttering can be explained as a temporary mold to hold the concrete mix until it
gets heard. Formwork is synonymous with shuttering.

What is the purpose of shuttering?

There is only one purpose of shuttering is to act as a mold of concrete to impart a

desired shape to the concrete.

Which shuttering is best?

Plywood shuttering gives the best surface finish to the concrete but, ply cannot
be used multiple times hence, it is costly. On the other hand, steel plates are cost-
effective can be used multiple times. Finally, aluminum shuttering become the
preferred choice of builders that is lightweight, cost-effective, and convenient
formwork material.

How do you use shuttering oil?

Shuttering oils are used to lubricate the shuttering board or plate which makes it
easier to remove the shutter after concreting. And it shall be applied to the
shuttering board or plate properly, first by scrubbing and cleaning the shuttering
board or plate then applying the Shuttering Oil using a brush evenly throughout
the board or shuttering plate.

Tags: Formworkshuttering

TESTING OF CONCRETE.

1. FIELD TESTS ON FRESH CONCRETE

(a) SLUMP TEST

A slump test is performed to determine the workability of fresh concrete and to

check the uniformity of concrete from batch to batch. The test is conducted
where the nominal size of the aggregate does not exceed 40mm, The apparatus
consists of a mold shaped like the frustum of a cone, with the following
dimensions.

 Bottom diameter 200mm.

 100mm.
 300mm.

Tamping rod of steel 16mm in diameter, 600mm long and rounded at one end.

slump test results

 slump test results

PROCEDURE OF MEASURING SLUMP

1. The rod should penetrate every underlying layer.

2. Strike off excess concrete clean the internal surface of the mould.
3. Fill the mould with concrete in 4 layers.
4. Tamp each layer with 25 strokes of the rod.
5. Distribute the strokes uniformly over the entire cross-section of the mould.
after the top layer, with a trowel.
6. Remove the mould slowly and vertically.
7. The concrete will slump or slide.
8. Measure the height of the slump in mm.
9. For normal workability, the slump should not exceed 50mm.
10.Clean the slump cone.

(b) TEMPERATURE OF FRESH CONCRETE

This test is carried out to determine if fresh concrete is too hot or too cold. Hot
concrete stiffens rapidly and develops lower strengths at later stages. As per the
I.S., in hot weather, the temperature of hot concrete should not exceed 38
degrees centigrade while placing. In cold weather, a minimum temperature of 4.5
degrees centigrade is prescribed for the concrete at the time of placing.

Minimum 3 liters of fresh concrete is required for the test. At least 3 readings in
different parts of the batch should be taken. If the concrete is too hot. the
subsequent batches can be mixed by using cold water. Also, cool the aggregates
by sprinkling them with water.

2. LABORATORY TESTS OF HARDENED CONCRETE

Making cubes & curing for the required period.

This test is carried out for the following purposes.

1. To check that the mix proportions are adequate for the strength prescribed as
a basis for acceptance for quality control.
2. To determine the time of removal of forms when a structure may be put into
service.
3. To assess the 28 days compressive strength of the concrete in 24 hours, using
accelerated curing methods such as the boiling or warm water method.

A. FREQUENCY OF THE TEST For quality control of concrete for major

construction projects, the number of samples is proportionate to the quantity of
concrete produced, subject to a minimum of three samples.

B. PROCEDURE FOR CASTING OF CUBES

1. Clean the standard cube moulds, 6 Nos. thoroughly & tighten all the nut-
bolts properly.
2. Apply oil to all contact surfaces of the mould. The size of the mould is
normally 150mm x 150mm x 150mm.
3. Take random samples from the mix in a ghamela, while concreting.
4. Pour concrete into the cubes in 3 layers.
5. Compact each layer with 35 Nos. of strokes with the tamping rod.
6. Finish the top surface by thapi trowel after compaction of the last layer.
7. Cover the mould by a damp Hessian cloth immediately to prevent loss of
water.
8. Each specimen should be taken from different locations of the proposed
concreting.
9. After 24 hours, remove the specimen from the control of the quantity of
three the mould.
10.While removing, take care to avoid breaking of the edges.
11.Code the cubes with paint or marker. Coding should be self-explanatory,
showing the site name, concrete location, building no., and the date of
casting.
12.Submerge the specimen in clean, freshwater until the time of testing.
13.Test 3 specimens for 7 days & 3 specimens for 28 days curing concrete.
C. TESTING OF CONCRETE CUBES

For testing the cubes in the in-house lab of the organization, observe the
following procedures

1. Check the coding & numbers of cubes received.

2. Enter the details of the cubes in the testing register.
3. Weigh the cubes & note the figures in the register.
4. Inform the concerned person about any damages.
5. Check the dates of casting & testing for 7 & 28 days.
6. Place the cubes in the testing machine, so that the load is applied to the
opposite side of the cube as case i:e, not on top & bottom. (Opposite sides
of the cube surfaces are in contact with sides of the metal mould).
7. Apply the load without interruptions & increase the load continuously, at a
rate of approximately 400kg/min until the resistance of the specimen
breaks down & no additional load can be sustained.
8. Record the maximum load applied to the specimen.
9. Observe the appearance of concrete connection with the failure & note the
same.
10.Calculate
compressive strength = (Maximum load at failure.) / (Contact Area of the
cube.)
11.Take average strength of 3 specimen cubes.
12.This average strength represents the strength of concrete of a particular
portion of the structure.
13.Prepare the test report & submit to higher authorities.
14.Cubes of the same lot should not vary.
15.Inspect the particular portion of the structure immediately, if results are
considerably below normal.

D. AGE ATTEST
Tests shall be carried out at ages prescribed for the test, the most usual being 7
days and 28 days.

E. PRECAUTIONS

 Remove the mould after 24 hours and store the specimens in clean,
freshwater.
 The place where specimens are stored shall be free of vibrations.
 The water in which the specimens are submerged shall be replaced every 7
days.
 Specimens shall not be allowed to dry out at any time before testing.

3. NON DESTRUCTIVE TESTS ON HARDENED CONCRETE

A non-destructive test is defined as one that does not damage the structural
element or member under investigation.

Following are a few non-destructive tests generally performed

1. The ultrasonic pulse velocity test

2. Rebound hammer test
3. Test on cores cut from hardened concrete.

The purpose of carrying out these tests are

 To determine the uniformity of concrete in/between members.

 To detect the presence and approximate extent of cracks, voids, and other
defects.

PLINTH BEAM: MEANING AND PURPOSE OF PLINTH BEAM

WHAT IS A PLINTH BEAM?

Plinth beam is a reinforced concrete beam constructed between the wall and its
foundation. It is a framed structure provided at or above/below ground level that
takes the load of the wall built on top of it.
Plinth beam is provided to prevent the extension or propagation of cracks from
the foundation into the wall above when the foundation suffers from settlement.
Plinth beams distributes the load of the wall over the foundation evenly.

Plinth Beam

PURPOSE OF PLINTH BEAM

 Plinth Beam helps prevents differential settlement in structures because all

the load coming on the plinth beam is uniformly transferred to the
foundation.
 It prevents the dampness from foundation to enter the building.
 Plinth Beams distribute the load uniformly.
 It prevents cracks from foundation to reach the wall.
 It ties all the column.
 It prevents the building to collapse during an earthquake.

CHECKLIST FOR CONCRETING WORK

1. COLUMN CONCRETING ABOVE PLINTH FLOOR SLAB

1. Plotting of grid lines for the center of the column above the plinth floor
slab.
2. Locating and marking the centers of columns.
 3. Binding & placing column reinforcement above the upper floor slab, as per
the required height, considering lap length of the bar.
4. Check for column reinforcement & their arrangements as per the drawing.
5. Ring spacing and their arrangements as per the R.C.C. drawing.
6. Proper binding of reinforcement with binding wire.
7. Fixing concrete or P.V.C. cover blocks to reinforcement.

CHECKING OF SHUTTERING FOR COLUMNS

1. Check the quality of shuttering before placing it.

2. Applying de-shuttering oil to plywood shuttering.
3. Fixing of shikanjas (M.S. clamps) at every 60cm (2′.00″) interval.
4. Checking the stiffness of side supports, applied to the form-work in plumb.

CHECKING OF COLUMNS BEFORE CONCRETING

1. Size as per drawing

2. To check diagonals.
3. Oiling of shuttering
4. Plumb on both sides
5. Line
6. Level marking up to which concrete is to be done
7. Supports.
8. Reinforcement cover on top
9. The spacing of reinforcement above the concrete level.

11. Sufficient lap length.

12. Proper filling of gaps from outside with soil paste

CHECKING OF COLUMN WHILE CONCRETING

1. Check the quality of the material.

2. To check the proportion and mixing of material.
3. To ensure that six cube moulds are kept ready to cast cubes from different
batches.
4. Controlled water-cement ratio.
 5. Availability of vibrator or labour for tamping.
6. To ensure proper cover after concreting on the top level.
7. Casting of concrete cubes as required.
8. To ensure proper numbering on cubes.
9. Check all joints to ensure that no slurry flows from anywhere.
10.To check for the required concrete level.
11.Check the cleaning of the mixing platform.

CHECKING OF COLUMNS AFTER CONCRETING

1. De-shuttering of columns after 36 hours.

2. To submit the de-shuttering report to higher authorities.
3. Finishing the honeycombing carefully.
4. Date of casting and column number to be written on the column.
5. Hacking (Tacha) of columns 50 numbers in 1s.ft. (500 Nos. in 1sq.m.).
6. Cubes to be removed the next day and kept for curing, with a code number,
casting date, and site name.
7. Curing of columns to be done for a minimum of 15 days, with wet Hessian
cloth rapped around them.
8. Testing of cubes on due dates, i.e., after the 7th and 28th days.

Hacking of column

Things to be check-in Beam Reinforcement Before the Construction of

Slab
In this article, you will learn the general checklist of Beam reinforcement that is
practicing on the construction site before the concreting of the slab. The beam is
monolithically cast with a slab, so it is important to check the reinforcement of
the beam with the slab.

Checklist of Beam Reinforcement Before the construction of Slab

The following are the checklist of Beam Reinforcement that I personally follow on
Construction Site.

General Checklist for Beam Reinforcement

 Reinforcement bars shall be free from rust, mud, oil, slurry, loose materials,
etc.
 The grade of the steel Bar (Both for Main Reinforcement and Transverse
Reinforcement) shall be checked as per Structural drawings.
 Before going to check the reinforcement, identify Grid Name such Along
with Grid A, B, C,1, 2.3, etc, and Beam Name such as B1, B2, etc.

Checklist for Top and Bottom Main Bars

 The diameter of the Top and Bottom Main bar of the beam shall be
checked.
 Ensure the main reinforcement of the beam shall be passed through the
Column.
  Check the horizontal clear distance between the Top main bars and Bottom
main Bars. Clear gaps shall be such that vibrators can immerse in order to
get proper compaction.
 Check the vertical clear distance between the main bars (Both Top and
Bottom) if the Main bars are provided in two layers.

Checklist for Top and Bottom Extra Bars

 The diameter of Top and Bottom Extra Reinforcement of the beam shall be
checked.
 The location of Top extra shall be checked.
 Ensure proper position of Bottom extra reinforcement.
 The length of Top extra bars shall be checked as per drawings.
 Length of top extra bars beyond the column shall also be checked as per
structural drawings.
 The length of the bottom extra reinforcement shall be measured.
 Check the vertical clear distance between the top Main bars and Top extra
bar. To maintain the gap, the Pin bar is placed.
 Make sure that the diameter of the Pin bar or Spacer shall be greater than
the size or aggregate that is used for concrete.

Checklist for Stirrups

 The diameter of the stirrups shall be checked.
 Check the spacing between the stirrups near the support as well as mid-
span of the entire beam.
 The end of the stirrups or hook shall be at 135 degrees.
 Extra stirrups shall be provided at the junction of beams.

The following practices is done on-site to check the spacing between the stirrups
thought the beam.

 First, find the spacing between stirrups from the drawings. (Let’s say 4
inches).
 Measure the length of Main bars from face up to 6 feet (let’s say).
  Find the Number of stirrups.
 Number of stirrups = Length/Spacing +1
= 6 x 12/4+1 = 19 Nos.
 Now check the number of stirrups. IF the number of stirrups is matching
with 19 till 6 feet length, then the spacing between the stirrups is correct.

Checklist for Cover Block

 Check the Thickness of the cover block as per drawings given by Structural
Consultants.
 The grade of the concrete cover block shall be the same as of Grade of
concrete.
 Cover blocks shall be placed on the bottom of beams and Sides of beams.
 Make sure that the cover blocks shall not be broken.
 Ensure the position of the cover blocks is intact. It should not get disturbed
while concreting of the slab.
 Cover Block shall be placed below between the intersection of Main bars
and Stirrups.
 It should be located away from each other by 1 m along the bottom of the
Beam formwork.
 Make sure that Reinforcement shall not touch the formwork. If so cover
block shall be placed immediately.

Checklist for Lapping

 The position of Lapping of the Top Main bar shall be checked as per
structural drawings.
 The position of the Lapping of the Bottom Main bar shall also be checked as
per structural drawings.
 Proper binding of Lapped bars shall be checked.
 Bottom bars Lapping should not be placed at the middle span of the beam.
It is because of the maximum bending moment.
 Top Main lapping should not be placed near the support of the beam. It is
because of the maximum shear force.
  Make sure the lap should be placed in a staggered manner.
 Lap length shall be checked as per drawings.
 Proper binding of laps in the beam shall be checked.

Checklist for development length

 Measure the development length of Top Main reinforcement.
 Make sure that the Main bars shall be extending into the columns.
 Development length of Top Extra and Bottom Main bars (L shape
reinforcement) shall be checked.

Checklist for Bar Binding

 Ensure the proper binding of reinforcement at the junction of main bars
and stirrups.
 Bottom extra and Top extra shall be bind properly using binding wire.
 The binding wire should not be loose or remove from steel bars while
concreting.
 Check that oil should not come in contact with the surface of
Reinforcement.
 Temporary ties in column reinforcement shall be provided.

Checklist for dowel Bars

 Dowel bars shall be provided for a future extension for the upper story
column.
 Check the reinforcement shall be left for the upper floor staircase or not.
 Ensure the reinforcement shall be left for balconies.
 Check the diameter of the dowels bars.
 Check the length of dowel bars as per approved drawings.
 Dowel bars of the beam shall be checked.
Checklist of Slab and Beam Formwork Before Casting of SLab
Formwork is a temporary structure that is used to shape and support the concrete
to achieve sufficient strength. Wooden, steel, Plastics, aluminum formworks are
the most common formwork material. In this article, I have explained a checklist
that is generally done by the civil site engineer on construction for beam and slab
formwork.

Checklist of Slab and Beam Formwork

General Checklist of formwork

Formwork plates shall be uniform in the surface. Uneven surface in the shuttering
board shall not be allowed.

Wooden shuttering shall be properly cleaned and free form concrete particles if it
is used formwork

The shuttering plate shall be rigid, firm, and durable so that it can carry
movement load.

Checklist of Slab Formwork

 The size of the formwork of each slab panel must be checked as per
Approved drawings.
 Check the Slope and level of formwork of each slab panel.
 Shuttering oil shall be used on shuttering plates in order to remove the
formwork after concrete gets strength.
 Check the diagonal of slab formworks.
  Check that vertical formwork shall be used along all the edges of the slab,
staircase void, internal voids, etc.
 All the shuttering gaps shall be properly sealed or closed so that there is no
flow of slurry through those gaps.
 The entire gap shall be made leakage proof by masking tape.
 Before concreting of the slab, shuttering gaps such as beam-slab junction,
beam junction, columns, etc shall be supervised.
 Mark the thickness level of the slab on each and every column.
 Water tightness shall be done near column junctions.
 The side plank of the slab along the periphery has to be supervised.
 Slab shuttering board should be supported by Wooden batten also called
Chavis at an interval of 2 feet.
 Ensure the steel props shall be tightened properly.
 Check the sizes of wooden props, plumb, and soundness.
 Runner spacing for slab formwork shall not be more than 1 feet.
 Butt spliced on wooden props shall not be allowed.
 Check the nut-bolt/shuttering clip is properly tightened or not.

Checklist of beam Formwork

 Line, Level of the bottom of the beam formwork has to be checked.

 Vertical alignment or plumb, line of sides of beam formwork shall be
properly checked.
 Measure the length of beam formwork as per structural beam plan or
Architectural drawings.
  Check the width of the beam bottom plank as per drawings.
 Joints of bottom beam formwork must have to checked.
 Beam bottom Vertical props or plank should be straight.
 Vertical proper should not overlap or jointed.
 Placing of vertical props on bricks or blocks shall be avoided.
 Vertical props subjected to inclined must be avoided.
 M.S. props must be used when staging height is more than 12 feet.
 The maximum horizontal distance between the two vertical props shall be 2
feet to 3 feet.
 At the junction of beam and column, shuttering shall be in plumb and has
no voids.
 All the vertical props must have wedges and cross bracing.

Responsibilities Of Civil Site Engineer before Construction of concrete

Floor Slab

A Reinforced concrete slab is horizontal members made of concrete which is used

to resist the flexural bending stress when it is subjected to loads. Generally, the
minimum thickness of the slab is 4 inches and the maximum thickness depends
upon the span and loads acts on the slab. For Normal residential Building, 5 inches
thickness is generally recommended. As we know that checking of slab
reinforcement is very important. It is because the wrong layout of reinforcement
on site creates a great loss for the client, so the first duties of a civil engineer to
read the complete drawing of beam and Slab. The followings are a checklist of a
concrete slab that needs to be carried before casting.

Checklist of Reinforcement of concrete Slab

 Check the diameter of Main Bars and Distribution along with Shorter Span
as per approved drawings.
 Check the diameter of Main Bars and Distribution along with Longer Span
as per approved drawings.
 Spacing between Main Bar and Distribution along the Shorter span and
longer span of slab as per approved drawings.
 Check the depth of the cover block as per structural drawings.
 Ensure that spacing between the cover block shall be at 1 m spacing.
 The depth or thickness of the slab should be checked.
 A proper layout of chair Bars shall be provided for a slab.
 Check the dowel bars, if provided for future extensions.
 Make sure that the Main reinforcement of slab( both long span and short
span) shall be passed through the beam in order to transfer loads of slab.
 Ensure that the reinforcement bar that is lapped should be located in a low-
stress zone.
 Proper lap length shall be checked for Main Bars.
 Check diameter and Spacing of Extra Reinforcement in Slab.

Checklist for Reinforcement of Beam.

 Check the width, depth, and length of Beam as per approved structural
drawings.
 The diameter of the Top and Bottom main Reinforcement shall be ensured.
 Check the Spacing between the Top Bars and also between the bottoms
bare maintained equally along the length of the beam.
 Check whether the beam has top Extra and bottom extra bars or not.
 Ensure the diameter of Top and Bottom extra reinforcement.
  Check the Spacing between the stirrups in confinement zone as per
structural drawings or not.
 The proper cover block is provided for the bottom and sides of the beam
shall be checked.
 Make ensure that the cover blocks shall be maintained at 1 m spacing both
the bottom and sides of the beam.
 Check the proper development length (L-shape) which directly insert into
column or beam.
 Proper lap length shall be checked for Main Bars.
 Confirm that the lapped reinforcement shall be in lower bending moment
and shear zone.
 Ensure that the main reinforcement of the beam shall pass through
columns.

Checklist of Beam formwork

 Check the Horizontal alignment, Level, and width of the bottom of the
beam.
 Proper check the Vertical alignment or plumb, line, and level of Sides of
Beam formworks.
 Check the length of beam formwork as per approved Structural and
Architectural drawings.
 Ensure the depth and width of the beam shall be as per approved drawings.
 Check the Shuttering oil shall be properly coated on beam formworks or
not.
 Gaps between the beam bottom and side formworks should be checked.
 Make sure all the gaps in the formworks shall be properly sealed in order to
prevent slurry leakage.

Checklist for Slab formwork

 Check the dimension of the formwork of each slab panel.
 The level and diagonal of each slab panel shall be checked.
 Check the thickness of the slab.
  Ensure the formworks shall provide all-round the slab edges, openings, etc.
 Ensure the Support props of Slab should be in proper alignment and also
check the plumb.
 Vertical props or support of each slab panel shall be checked.
 Make sure all the gaps in the formworks shall be properly sealed in order to
prevent slurry leakage.

Checklist prior to casting of slab and Beam

 Depth of Beam shall be marked on formworks with nails. Mark shall be
done in all the beam formworks.
 The finishing concrete level shall also be marked.
 All the Conduit work, Electrical points, Fan Boxes, etc shall be checked as
per approved electrical drawings.
 The arrangement shall be made for Vibrators in case of broken of needle
shall be checked.
 Check Extra vibrators shall be kept in standby or not in case of breaking of
the needle.
 Arrangement of water shall be made in case of power failure should be
checked.
 Ensure the arrangement of lights if concreting is continued till the night
time.
 Ensure the arrangement of tarpaulin, plastic, etc sheet if the rain comes
while casting of beam and slabs.
 Make sure the wooden pieces, papers, binding wires, nails, etc should be
removed prior to casting of the slab.
 Make sure the arrangement of labor is sufficient for casting.

2. SLAB BEAM CONCRETING

Points to be noted for checking of slabs before casting,

CHECKING OF SHUTTERING
1. Height of slab from the plinth slab level.
2. Quality of shuttering material.
3. To ensure fixing of the cap on the column to take the load.
4. Width of the beam bottom plank. To ensure proper fixing of the beam
bottom over the cap.
5. Line and level of the beam bottom.
6. Depth of beam as per the R.C.C. drawing.
7. Proper fixing of props for the bottom in line and plumb, at every 2’0″ (0.60m)
interval.
8. For packing the below props, only one or two wooden plank pieces are
allowed. (Brick or blocks are not permitted).
9. Bamboo bracing for joining, prop to prop, at 4’0″ (1.2m) height from the
floor.
10.Proper fixing of the side of the beam in line, level, and plumb.
11.Support to the vertical joint of shuttering for 24″ (0.60m) beam or 3O”
(0.75m) beam.
12.Gaps in beam sides should be filled.
13.Ensure fixing of the steel plates over beam sides, in flush position.
14.Slab plates should be supported by 3″ x 3″ (75mm x 75mm) chawis at 2’0″
(0.60m) distance, centre to centre.
15.“Side plank’ for slab panel periphery.
16.Individual-level of each bay of the slab.
17.Mark the thickness of the slab.
18.Check if the joints of the plate and ghabadi work is watertight.
19.Oil the slab plates.
20.Internal panel measurements, beam to beam & diagonal of the panel.
21.Location and depth of the sunken slab.
22.The outer line of beam sides.
23.Check for room sizes & diagonals.
24.Check if the junctions of columns and beams are watertight.

CHECKING OF REINFORCEMENT FOR BEAMS

 1. Bottom bars, top bars, bent-up bars, stirrups, a distance of bent supports,
extra bars over the supports, the spacing of the stirrups as per the R.C.C.
drawing, proper tying of the stirrups.
2. The diameter of bars, binding of stirrups in plumb.
3. Length of bent-up bars continuing in adjacent beams.
4. ‘L’ for bent-up bars at discontinuous ends.
5. Side covers and bottom covers for beams.
6. Check if a pin is provided at required places, i.e. more than 3 bars in one
layer, for 15cm (6″) wide beam. Also, check the spacing and diameter of the
pin provided.
7. Proper binding of laps in beams, if provided with the required length.
8. Extra stirrups at the junction of the beam.
9. detail slab reinforcement

STEEL FOR SLAB

1. Spacing, a diameter of bent-up bars, and main bars.

2. The distance of bent-up bars from the face of the beam.
3. Length of bent-up bars projecting in the adjacent panel.
4. Height of the bent-up bars.
5. The chair below every bent-up bars.
6. Covering for the slab at the bottom.
7. Proper binding of laps of the required length.
8. Distribution steel diameters, spacing, and ties.
9. Check dowels of slab & beam.
10.Location, proper binding diameter & length of fan hook, and quality of the
fan hook box.
11.Put stirrups in the column for upper floor column size.

3. CARE TO BE TAKEN AND MANAGEMENT BEFORE AFTER CASTING OF SLAB

To check the concealed electric conduit work for the slab, as per the drawing and
I.S.I. mark on the P.V.C. pipes. Note down the length of all pipes for billing
purposes.
 1. Check the junctions and all electrical points as per the electric layout, the
position of fan points, M.S. boxes, junction boxes.
2. Avoid breaking of pipes during concreting.
3. Check the slab & the certificate from the architect.
4. Check the slab & obtain a certificate from the R.C.C. consultant.
5. Sieve analysis for sand to be carried out in advance, for the concrete mix
design.
6. To measure the silt content of sand.

CHECKLIST AFTER CONCRETING

1. De-shuttering of outer beams after 24 hours.

2. Make small ponds in sand and cement mortar (1:10) for the pounding
method of curing for the slab with a minimum size of 2.0 m x 2.0 m (6’0″ x
6’0″).
3. Check any waste of material like sand, metal, and steel cut-pieces.
4. De-shuttering of internal beam sides after 48 hours.
5. Curing of a slab for 28 days.
6. Paint work the date of the casting of a slab, on the front beam.
7. Register the slab in the head office, the day
8. after casting.
9. De-shuttering of the slab after 7 days, 10 days, or 15 days, depending on
the span.
10.Hacking of beam sides, bottom, slab bottom.
11.Checking all honeycombing surfaces & if finishing is to be done with rich
mortar.
12.For more honeycombing, consult the R.C.C. consultant.

4. BAR BENDING SCHEDULE

(a) NECESSITY OF BAR BENDING SCHEDULE

Bar bending schedules help the site engineer and R.C.C. fitters to give the exact cutting length
of steel, required for each member, i.e., beam, slab, column, etc. This reduces the wastage of
steel. With the help of a bar bending schedule, the site engineer can calculate the exact
quantity of steel required for slabs and beams. A counter check on quantities, calculated by the
site engineer is also easy.

when it is accompanied by the bar bending schedule. R.C.C. fitter gets familiar with the bar
cuttings and bent-up bar lengths before cutting of steel and mistakes in bending can be
avoided. Bar bending schedules also help in checking the slab reinforcement. With rapid
increases in the cost of steel, cost-effectiveness during construction can be maintained with the
use of a bar bending schedule. Every kilogram of extra steel used is a national waste and can be
avoided with the help of bar bending schedules.

5. PROCEDURE FOR REINFORCEMENT WORK

(a) PROCEDURE FOR FOOTING REINFORCEMENT

1. Cutting should be done for the footing mesh (jali) bars considering the allowance for ‘L’
and covers on all the sides.
2. Footing jail should be prepared by tying the bars. Care should be taken to tie each and
every junction with a binding wire.
3. Cut the column bars to the required length considering the allowance for base ‘L’.
4. Cut the bars for column rings, single or double, as per the requirement of the length
accordingly.
5. Rings should be prepared on the fitters’ platform, considering the width and breadth of
the column and deduct the cover from the same, e.g. for a column of 150mm width and
300mm breadth, the ring can be of size 100mm x 250mm, considering 25mm cover on
both faces.
6. Footing jali should be kept in the footing shuttering with a column base tied to its
center, with binding wire. The center of the footing should be matched with the jali of
footing.
7. The proper cover should be maintained from the sides as well as from the bottom.

(b) PROCEDURE FOR COLUMN REINFORCEMENT

1. Consider floor to floor height and lap length 45D to be added into the length. (D is the
diameter of the bar).
2. Cutting should be done first for the main reinforcement.
3. Cut the bars for rings of the column, to the required length as explained earlier.
 4. For lapping, make the joggle if the bar diameter is more than 12 mm.
5. Prepare column on the fitters’ platform by tying the rings to the main reinforcement, if
the size & No. of bars are not heavier.
6. Shift the column to the slab and erect it in the required position and tie it to the dowels
below the floor columns.
7. Care should be taken to tie the dowels of the below floor columns firmly, to the upper
floor columns.

lapping bar column

lapping bar column

(c) PROCEDURE FOR BEAM REINFORCEMENT

1. In R.C.C. drawings, the number of bottom bars, bent-up bars, and top bars along with
details of rings is normally mentioned.
2. Fitters generally take the actual measurements of the beam after shuttering and then
proceed for the cutting of the steel.
3. Cutting should be done beam-wise & for the total number of beams, required for the
slab.
4. Tie a chit of paper for easy identification, to the bunch of bars.
5. Then cutting of the rings should be done. Rings should be prepared out of these cut
bars.
6. The beam can be bound on the fitter’s platform along with the bent-up bars.
7. Shift the bound beams to the shuttering of the slab.
8. Place these beams to the position with proper anchorage in the end columns.
9. For continuous beams, bent-up bars should be properly extended in the adjacent beams
and tied with binding wire.
10. The proper cover should be provided to the bottom and sides of the reinforcement.

(d) PROCEDURE FOR SLAB REINFORCEMENT

1. Take the measurement of the cutting length of the slab reinforcement and accordingly
the cutting can be done.
2. For continuous slabs, consider the projection of the bent-up bars in the adjacent slab
while calculating the cutting lengths of the slabs.
3. The cut bars should be stored in bunches slab-wise and can be transferred on the slabs
accordingly.
4. Marking for the c/c distance of the bars should be done on the slab plates with the help
of chalk.
5. Lay the main reinforcement as per the marking.
 6. Place the distribution steel on the main reinforcement and every junction should be tied
with binding wire.
7. Bent-up bars should be bent at the required length from support as per the type of slab,
i.e. continuous or simply supported, etc.
8. Place the chairs under every bent-up bar to maintain the top reinforcement at the top.
9. Bent-up should be lifted considering the slab cover and slab thickness.
10. All hidden beams should be placed such that the center of the hidden beam should be
considered the center of the proposed wall on that beam.
11. The ring of the hidden beam should be bound such that it is just 1″ (25mm) less than the
thickness of the slab. e.g. for 5″ (125mm) thick slab, the ring for H.B. should be 4″
(100mm) in height.

slab reinforcement details

slab reinforcement details

(e) PROCEDURE FOR WATER TANK REINFORCEMENT

1. For the water tank, reinforcement of the bottom slab, along with the beams, should be
placed and bound properly.
2. Through this slab reinforcement of vertical pardi (R.C.C. thin wall) should be taken with
necessary anchorage. Vertical bars of the pardi are normally erected first.
3. Provide Chamber bars at the corner as per the design.
4. Generally, double jali is provided to the bottom slab.
5. After casting of the bottom slab, horizontal reinforcement of the vertical pardi should be
bound with due care, on anchorage inside the pardi.
6. Provide horizontal reinforcement at both the faces of Pardi. Ensure a proper cover to
this reinforcement. Side chamber bars to be provided as per the specified spacing.
7. After casting off the side Pardi, the form-work of the top slab should be bound as per
the design.
8. Provide a manhole for the top slab along with a vent pipe hole. For the manhole, extra
bars should be provided along the periphery of the opening.
9. If cut-pieces are to be used for the top slab, the lap length of the same should be 69D,
where D is the diameter of the bar. Care should be taken to provide laps in a staggered
manner.

(f) PROCEDURE FOR CHAJJA CANTILEVER REINFORCEMENT

 1. For chajjas and cantilever slabs the main reinforcement should be provided at the top of
the slab.
2. Every alternate bar or as specified by the R.C.C. designer should be bent back at the
bottom.
3. The anchorage of the top reinforcement should be provided either in the beam,
adjacent slab, or column, as the case may be.
4. For beams and lintels, the reinforcement should be anchored around the beam with the
required anchorage.
5. For slabs, the reinforcement should be continued in the adjacent panels for the required
anchorage length.
6. The anchorage length should be a minimum 69D or the span of the cantilever,
whichever is more.
7. Chairs should be provided below every bar of the slab, to keep the top reinforcement in
position.
8. Distribution bais should be provided as per the required spacing.

reinforcement-details-for-chajja

reinforcement details for chajja

6. NORMAL MISTAKES ON-SITE BY R.C.C. FITTERS.

NEGLIGENCE IN FOOTING JALI

 The spacing of bars differs.

 Each alternate junction of bars is tied with binding wire.
 The column base is not tied to footing jali properly.
 Column main corner bars are not laid in a 45° position with the plan.

NEGLIGENCE IN COLUMN REINFORCEMENT

 Stirrups for main reinforcement are not bound to each bar.

 Spacing between the stirrups is found to be unequal.
 Main reinforcing bars and stirrups are not tied tightly to each other.

NEGLIGENCE IN BEAM REINFORCEMENT

1. The top bars of beams are not bent in 90 degrees. The distance of bent-up from the face
of support differs.
2. The spacing of stirrups differs with specified drawings.
3. For the end support of beam bent up bars are not bent into beam or column up to the
required depth.
 4. For 150mm wide beams, the pin is not provided to the bottom bars when the number of
bars exceeds two.
5. Side face reinforcement is not provided to the beams having a depth of more than
750mm.
6. Beam bars are not passing through column reinforcement.
7. The full bearing of beam bars is not given on the column.
8. The angle of 45° is not maintained for a bent-up bar in a beam.

NEGLIGENCE IN SLAB REINFORCEMENT

1. The spacing of the main reinforcement.

2. A distance of bent-up from the face of support differs from typical bar bending.
3. Every junction of the main and distribution bars is not tied to each other properly.
4. For the end support of the slab, bent-up bars are not bent or hooked into the beam.
5. Insufficient chairs are provided under the bent-up bars.
6. Laps for slabs are not provided in a staggered manner.
7. Lap lengths provided are insufficient.
8. Length of projection of bent-up bars, in case of the continuous slab, is not found as per
the requirement, i.e., L/4.
9. The height of the bent-up bars is always found to be the same for different thicknesses
of slabs.
10. The extra length of cutting bars at the ends leads to improper end cover.
11. Insufficient chairs are provided to cantilever slabs, due to which top reinforcement is
not properly maintained at the top position.
12. Same lap length for all diameter of bars.

CHECKLIST & CERTIFICATE BEFORE CASTING SLAB

1. Do not cast: he s.ab before checking is done by the concerned higher

authorities.
2. The checklist should be written by J.E. & checked by the concerned higher
authorities.
3. Send one copy of the checklist to the head office after the necessary
checking.
4. Refer to the checklist as a guideline for checking work.
MANAGEMENT BEFORE AND AT THE TIME OF SLAB CASTING

Slab casting is the major concreting work, involving the use of high-cost materials
such as cement, steel, sand, metal, etc. along with substantial labor. The activity
must be managed properly, to prevent problems at a later stage.

MANAGEMENT BEFORE SLAB CASTING

1. Sieve analysis of the sand and metal should be carried out to decide the
volumetric mix design.
2. According to the importance of the structural member, the method of
mixing, i.e., volumetric by weight should be decided.
3. Levels of the slabs and their dimensions should be checked, well in
advance.
4. Slabs should be checked by the architect and R.C.C. consultants for the
correctness of dimensions and reinforcement.
5. The concealed electric conduit work should be checked for its quality as per
the requirements.
6. Arrangement for water and standby arrangements for the same should be
made.
7. A sufficient number of laborers should be present for concreting.
8. The contractor should be informed of the time of commencing the slab and
the maximum time allowed for slab casting, well in advance.
9. Decide the position of the reinforced cement concrete joints for a large slab
with the prior consent of the R.C.C. consultant.
10.Check all the machines for proper operation.
11.Check the availability of fuel for the machines such as mixers, vibrators,
lifts, etc.
12.Check whether a sufficient number of measuring boxes (farmas) are ready
or not.
13.Check a sufficient number of cube moulds for casting the cubes for
checking.
 14.Ensure removal of wooden pieces, papers, dust, etc. from the slab and
beam before casting.
15.Check the arrangement of planks and M.S. walkways over the slab, for easy
labour movement; without disturbing concrete & reinforcement.
16.Ensure sufficient light arrangement for late-night concreting.
17.Ensure for the arrangement of staff & allot their duties.

MANAGEMENT AT THE TIME OF SLAB CASTING

 Check that all the fan hooks boxes are placed in position.
 Check whether the vibrator is properly placed over the stand for use during
concreting.
 Ensure that one supervisor is present near the mixer for checking proper
mixing and the correct quantity of water for mixing the concrete. This
supervisor should maintain the register batchwise and control the
proportion of the ingredients. The slump cone & cube moulds must be
available with the supervisor.
 Check whether the M.S. platform is placed over the slab, for delivery of the
reinforced cement concrete on the platform.
 Buttering of the mixer should be done before starting the regular slab work.
 Quality and consistency of the concrete mix is checked for the first batch
and alterations, if any, should be made in the mix proportion as per the
ingredients available.
 Care should be taken first to cast the beams and compact layer-wise with
the help of the vibrator. Though vibrator is applied to beams, reinforced
cement concrete should be also compacted manually with the help of
tamping rods.
 For the initial batch, the slump test should be carried out to find out the
consistency and workability of the concrete mix. The alterations in the
proportion of ingredients should be made if the mix is not consistent and
workable.
 “Beams first and then slabs’: This method should be applied for concreting.
  Ensure the proper level of the slab after finishing by the mason, by visual
inspection.
 Ensure proper thickness and finishing of staircase steps and waste slab.
 Do not allow anyone to walk over fresh and finished concrete.
 Ensure the presence of a carpenter below the slab shuttering, during
casting, is in progress.
 Ensure a proper bottom and side cover for slabs and beams at every stage
of concrete.
 Ensure a proper finish to the slab panel, where lift delivers the concrete.
 For concreting in hot weather conditions, cover the fresh slab by wet gunny
bags, to prevent drying of the top surface of the reinforced cement
concrete.
 In case of rains, cover the slab with a big plastic turpentine sheet to protect
it.

Things to be Checked by the Client, Contractor and Engineer before and after
Concreting of Slab

In any construction project, there are three major entities i.e. Client, Contractor,
and consultant. The inspection of the project shall be done by three entities in
order to improve the quality of structure at their own level. IF the size of the
project is small then, material procurement, etc shall be managed by the clients
itself. Checklist of slab helps to reduce construction mistake and enhance the
quality of projects.

Things to be Checked by the Client and Contractor’s before and after Concreting
of the slab

Checklist that has to be adopted by the client, contractor, and engineers before
and after casting of the slab.

Checklist for Client before and after casting of slab

  Cement Bags Shall be kept in stock as per Project Requirement at least one
day before the casting.
 The client should arrange light if the casting is done until night time.
 Coarse Aggregate and Sand shall be kept in stock as per the requirement of
the project.
 Once the casting starts, the consumption of aggregates and sand decreases
so in that situation client should inform the supplier to bring materials.
 Cement bags shall be kept on standby in case of extra need.
 Arrangement of Water shall be done in case of power failure.
 Arrangement of Diesel and Petrol for Concrete mixer or vibrator shall be
done by the client.
 The client shall arrange a tarpaulin if concreting is done in the rainy season.

Checklist for Contractor before and after casting of slab

 The contractor should check the availability of strength of labors and

mason as per the project size.
 The concrete mixer machine should be arranged by the contractor itself.
 The concrete mixture machine shall be arriving on the construction site at
least 4 hrs before casting.
 Additional 3 internal Vibrators shall be arranged by either contractor or
client.
 The concrete mixture and Vibrator operator shall be arranged by the
contractor.
 The number of Mortar Pan (Tasala or Gamla), Spade (Kudaal), Measuring
Box, etc. shall be checked by the Contractor.
 Mark the finishing level of concrete.
 The starting time of slab casting shall be informed by the contractor to the
Consultant.
 Engineer-in-charge or supervisor should check the reinforcement position,
formworks level of the slab, etc.
 Curing of slab shall be done after 12 hrs of concreting. Curing of shall be
done by ponding method.
  The supervisor of the contractor shall be checked reinforcement work,
formwork, etc before informing the consultant.

Checklist for Engineers before and after casting of slab

 Mix Proportion of cement, sand, Aggregate, water, and admixtures if used

shall be checked by Engineer.
 Ensure the Standby arrangement of the internal vibrator.
 The water-cement ration shall be checked.
 Check the shuttering props displacement or settlement while moving.
 Make sure the availability of labors and masons are good enough for slab
casting.
 Check all the reinforcement of the slab.
 Segregation of concrete is not allowed.
 The water stopper shall be located in the proper position if the concrete is
done in two days.
 Ensure the Quality of cement.
 Check the quality of fine aggregates (sand) and Aggregates.
 The location of Construction joints in the slab shall be checked.
 Check all the reinforcement of the slab.
 Ensure the finishing level of concrete as per structural drawings.
 The formwork of the slab and Beam shall be checked by engineers.
 The reinforcement of the beam shall be checked.
 Cubes shall be cast for testing the concrete.
 A slump test is done prior to the concreting in order to check the
workability.
 Broken Wood, papers, etc shall be removed from the surface of the slab
and Beam formwork.
 Quality of water shall be ensured before mixing the concrete.
 Check the leveling of the slab done by the mason.
 Ensure the planks that shall be made for Labor movement over the slab
reinforcement.
 Check the electrical conduits work on the slab as per Electrical drawings.
  Check the pipeline arrangement.
 Ensure all the junction and electrical layout, the position of fan points, M.S.
boxes, and junction boxes.
 Make sure the arrangement of light in case of late-night concreting.
 Air voids, Bug holes, and honeycombing shall be checked after the removal
of formworks.
 Check the height of the free fall of concrete while placing the concrete.
 Support and stability of shuttering shall be checked.
 Check that vibrators should not be immersed in more than 15 seconds in
concrete.

Checklist of Slab Reinforcement Done By the Civil Engineer at Construction Site

Checklist of Slab Reinforcement

Checklist for Main and Distribution Bar

 Reinforcement bars shall be free from rust, mud, oil, slurry, loose materials,
etc.
 Grade of steel (for Example Fe 500 or Fe 500 D) for both main and
Distribution bars shall be checked as per approved drawings.
 The diameter of Main Bars and Distribution along Shorter Span shall be
checked.
 Diameter of Main Bars and Distribution along longer Span shall be checked.
  Ensure the main reinforcement of the slab shall be passed through the
beam.
 Reinforcement shall be bent up as per the approved structural drawings.
 Length of bent up Bars shall be checked.
 Length of bent up bars projecting in adjacent bays.

Check for spacing between Main and Distribution Bar

 Check the Spacing between Main Bars and Distribution bars in both shorter
and longer span of each slab panel.

To confirm the spacing between the bars shall be done as per the following steps.
At first, let’s assume the spacing between the mains bars is 6″ (Refer to the slab
reinforcement plan).

Take the measurement of 5 feet length and count the number of bars. If the
number of bars shall be matched with the below-calculated value using the
formula, then the spacing between the bar is correct.

Number of bar = Length of Bar/ Spacing +1

= 5’/6″ +1 = (5 x 12)/6+1 =11 Nos. (This value should

be matched with number of bars present on the site.

Checklist for Extra Bars

 The diameter of Extra Bars shall be checked.

 Make sure the length of the extra top reinforcement on the slab as per
Drawing.
 Spacing between the Extra bars shall be checked.
 Check the Position of extra reinforcement. Extra Reinforcement is provided
on the discontinuous edge of the slab or simply supported end.
 The diameter of Extra Bars shall be checked.

Checklist for dowel Bars

  Dowel bars shall be provided for a future extension for the upper story
column.
 Check the reinforcement shall be left for the upper floor staircase or not.
 Ensure the reinforcement shall be left for balconies.

Check the diameter of the dowels bars.

 Check the length of dowel bars as per approved drawings.

 Dowel bars of slab and beam shall be checked.

Checklist for Cover Block

 The depth of the cover block shall be checked as per Structural drawings.
 Ensure that the cover blocks have the same grade as of concrete slab grade.
 Ensure the position of the cover blocks is intact.
 Cover Block shall be placed below between the intersection of Main Bars in
x-direction and Y-direction.
 Cover Block shall be placed at a distance of 1 m from each other. It shall be
placed everywhere on the slab.
 Make sure that Reinforcement shall not touch the formwork. If it touched,
the cover block shall be placed immediately.

Checklist for Chair Bar.

 Ensure the diameter of chairs bars as per approved drawings.

 Depth of Chair Bars shall be checked.
 Ensure that leg of the chair shall be rested on the Main bars of the slab.
 Chair Bars are used in the slab in order to lift the Crank Bars.

Checklist for lapping

 Ensure the lap location of slab reinforcement.

 Proper binding of Lapped bars should be checked.
 Lapping should not be placed in the middle of the slab.
 Make sure the lap is placed in a staggered manner.
 Lap length shall be checked as per drawings.
Checklist for development length

 In the end, the Main reinforcement of Slab shall have L-bend.

 Development length (L-Shape main Reinforcement of the slab shall be up to
the bottom of the beam).

Checklist for Bar Binding

 Ensure the proper binding of reinforcement at the intersection point.

 Make sure the binding wire should not be loose its tightness while
concreting of the slab.
 When slab reinforcement passes through the beam, at the junction, slab
reinforcement shall be tied properly by binding wire with beam
reinforcement.
 Check that oil should not come in contact with the surface of
Reinforcement.
 Temporary ties in column reinforcement shall be provided.

Checklist for Electrical Items.

 Check the electrical conduits work of slab as per Electrical drawings.

 Check the proper position of fan points, M.S. box, PVC pipers, And Junction
box, etc.

CHECKLISTS
EXCAVATION & P.C.C.

 Final plinth levels of all buildings.

  Strata as per consultant’s specifications.
 Size of pits is more than size of P.C.C., & depth as desired.
 Shuttering provided, if required.
 Uniformity & thickness of soling.
 Compaction of concrete.
 Thickness of P.C.C. as specified.
 Curing for 7 days.

FOOTING & PLINTH BEAM

Final plinth level of building.

Footing number, size, column number & orientation.

Reinforcement of footing & plinth beams.

Cover for reinforcement.

Layout of plinth beams.

Shuttering of plinth beams.

Compaction of concrete.

Cubes taken with identification.

Test report of cubes. (7 days& 28 days)

BACKFILLING

Assorted material made available for backfilling.

Filling in layers & proper compaction.

Watering.

COLUMNS
General & reinforcement

Plotting of gridline for center of column above plinth / floor slab.

Locating & marking the centers of columns.

Binding & placing column reinforcement above upper floor slab as per required
height, considering lap length of the bar.

Column reinforcement & its arrangement as per drawing.

Ring spacing & their arrangement as per R.C.C. drawings.

Proper binding of reinforcement with binding wire.

Fixing of concrete or P.V.C. cover blocks to reinforcement.

Checking of shuttering for columns

The quality of shuttering before placing.

Applying deshuttering oil to plywood shuttering.

Fixing M.S.clamps (shinkanjas) at every 0.6 m (2’0″) internal.

Stiffness of side supports to have formwork in plumb.

Checking of column before concreting

Size as per drawing.

Diagonals as required.

Oiling of shuttering.

Plumb on both sides.

Line of columns as desired.

Sufficient Marking level up to which concreting to be done.

Supports.

Reinforcement cover provided.

Spacing of reinforcement above concrete level, maintained as required.

Proper filling of gaps from outside by soil paste.

Checking of column while concreting.

Quality of materials of concrete.

The proportion & mixing of material.

Six cube mould are kept ready to cast cubes from different batches.

Controlled water cement ratio.

Availability of vibrator or labour for tamping.

Proper cover after concreting on top level.

Casting of concrete cubes as required.

Proper numbering on cubes.

Fill joints if slurry flows from anywhere.

Maintain required concrete level.

Cleaning of mixing platform.

Checking of columns after concreting.

Deshuttering of columns after 24 hrs-48 hrs.

Submission of the deshuttering report to higher authority.

Finishing of honey combing, if any, with proper care.

Date of casting written on column.

Hacking of columns.

Cubes removed next day & kept for curing, with code numbers, cast code, site
name on cubes.
Curing of columns done for minimum 15 days. Wet nesian cloth wrapped around
it.

Testing of cubes on due dates i.e. after seventh & twenty eighth day.

SLAB & BEAMS

Checking of shuttering material

Height of slab from plinth / slab level.

Quality of shuttering material.

Proper fixing of cap on column to take load of beam & slab shuttering.

Width of beam bottom plank.

Proper fixing of beam bottom cap.

Line & level of beam bottoms.

Depth of beam as per R.C.C. drawings.

Proper fixing of props for bottom in line & plumb at every 0.6 m internal.

Packing below props only one or two wooden plank pieces is allowed. (No bricks
or blocks are allowed).

Proper fixing of side beam in line, level & plumb.

Support to vertical joint of shuttering for 0.6 m beam or 0.75 m beam.

Gaps in beam sides to be filled.

Ensure fixing of steel plates over beam sides in flush position.

Slab plates should be supported by 3″x3″ chavis at 2’0″ (0.60 m).distance center
to center.

‘Side plank’ for slab panel periphery (Dhar falee).

Individual level of each bay of slab.

Marking thickness of slab.

Water tightening of plates joints & ghabadi work.

Oiling of slab shuttering.

Internal panel measurement, beam-to-beam & diagonal of panel.

Location & depth of sunken slab.

Outer line of beam sides.

Room sides & diagonals.

Water tightness near junctions of columns & beams.

Bamboo bracing for joining, prop to prop at 4’0″ height from floor.

Checking of reinforcement for Beams.

Bottom bars, top bars, bentup bars, stirrups, distance of bentup bars from face of
supports, spacing of the stirrups as per R.C.C. drawing, proper tying of stirrups.

Diameter of bars, binding of stirrups in plumb.

Length of bentup bars projecting in the adjacent beams.

L for bentup at discontinuous end.

Side covers & bottom covers for beams.

Pin is provided at required places between reinforcement.

Proper binding of laps in beam if provided with required length.

Extra stirrups at the junction of beams.

Steel for slab.

Spacing, diameter of bent up bars & main bars.

Distance of bent ups from face of beam.

Length of bent up bars projecting in adjacent bays.

Height of the bent up bars.

Chair below each & every bent up bar.

Covering for slab at bottom.

Proper binding of laps of required length.

Distribution steel diameters, spacing & ties.

Dowels of slab & beam.

Location, proper binding diameter & length of fan hook & quality of the hook box.

Stirrups in column for upper floor column size.

Care to be taken before / after casting of slab

To check the concealed electrical conduit work for slabs as per drawing; check I.S.I
mark on P.V.C. pipes& note down the length of all pipes for billing purpose.

Check the junctions & all electrical layout, position of fan points, M,S, boxes,
junction boxes.

Avoid breaking of pipes during concreting.

Certificate from Architect.

Certificate from R.C.C. consultants.

Management before / after casting of slab.

The stock of cement , sand & metal required for casting of slab.

Arrangement of water & standby arrangement of water in case of electrical

failure.

Labour strength required & available for slab casting.

Inform contractor about starting time of slab & maximum allowable time for slab
casting.

Decide the position of concrete joints in case of big slab after consulting &
approval of R.C.C. Consultant.

Casting of slab with the help of mixer ,vibrator & measuring box.

Machine operator for mixer & vibrator is present on site.

Proportion of aggregate decided.

Casting of six cube moulds of various batches for testing.

Ensure cleaning of wooden pieces, papers etc. from slab, beam before casting.

Proper levelling of slab by mason.

Maintaining slab register.

Arrangement of planks over slab for labour movement along with the M.S. walk
ways for avoiding the disturbance to top reinforcement.

Arrange petrol & diesel for vibrator & mixer.

Ensure the working of materials lift before commencement of work. Ensure for
rigid scaffolding of lift.

Sufficient light arrangement in case of late night concreting.

Checklist after concreting

Deshuttering of outer beams after 24 hours.

Making small bonds in sand & cement mortar (1:10) for ponding method of curing
for slab, with each bay having maximum size of 2.0 m x 2.0 m.

Removal of waste material like sand, metal & steel pieces?

Deshuttering of internal beam sides after 48 hours?

Curing of slab for 28 days.

Painting the date of casting of slab on front & side beam.

Register in head office, next day after casting.

Deshuttering of slab after 7 days, 10 days or 15 days depending on spans.

Hacking of beam sides, beam bottom, slab bottom.

Minor honey combing surfaces, finished with rich mortar.

Major honeycombing shall be brought to the notice of R.C.C.Consultant.

Floor Tiling Work

Flooring is something which a owner of that house sees daily and feels
it. if it have damages, watta, bends, chips, color variation or any other
damages, its not a good sign.

A engineer incharge should check the floor tiling and tick all the points
in checklist if done correctly to ensure good quality work.

Checklist of Floor Tiling Work consist of following checkpoints in it;

Procedures to be followed before floor tiling

 Latest Architectural Drawings available on site

 All electrical conduting works on slab surface (if any) to be
complete in all respects
 Slab surface cleaned by chipping and wetted thoroughly
 Thiyas of tiles to be taken at all four corners of room
  Thiyas of tiles to be taken with reference to stair landing and
required offsets
 Tile layout marked on floor( tile edges being kept at right angles
to plastered faces of walls)
 Finished floor level marked on wall (reference line marked on all
walls )
 Sorting of tiles done for color and shade variation( if any)

Procedures to be followed during floor tiling

 Recommended mix proportion for mortar bed ( ) used

 Fixing of tiles started from starting point as per architectural
drawing
 Use of arrow marks at the back of tiles for proper fixing
 Tile fixing done by tamping of tiles by rubber mallet
 Proper slopes and offsets maintained as per specification
 Straightness of tile joints to be maintained throughout

Procedures to be followed after floor tiling

 Next day joints of tiles slightly raked and filled with matching
approved grout
 Curing of tiles done for 3 days
 Joints of tiles covered with masking tape to avoid entry of
dust/dirt
 Tiles covered for protection( POP cover with paper underneath
recommended )
  Skirting tiles fixed over floor tiles.(skirting fixed generally after
masking of joints is complete)
 Skirting tile to be fixed in plumb
 Skirting tile edges and floor tile edges perfectly match
 Skirting at offsets shall match at 45 degree to show a clean edge
 Gap above skirting to be filled / trowelled perfectly matching with
wall finish surface

BRICK MASONRY
Cleaning the entire floor, before starting the line out of masonry.

Confirm dimensions & diagonals of room after first layer (line out).

First layer checked with beam top / bottom edge, offset & plumb.

Opening to be provided at first layer for doors & at sill level for windows & A.C.
units.

Screening of sand,mortar proportion & soaking of bricks.

Erection of door & window frames with necessary number of holdfast.

Fixing of holdfasts to frames & to R.C.C. Columns if any.

Racking of joints & surface cleaning after completion of day-to-day work.

Verticality of walls & corners.

Thickness of joints not more than 12 mm.

20 mm metal chips filling in R.C.C.& masonry junction.

Cleaning of room

Curing for 7 days.

PLASTERING INTERNAL PLASTER ITEMS TO BE CHECKED: –

Service line like electrical & plumbing line chasing & filling of voids (Ghabadi).

Sufficient hacking (tacha) to all R.C.C. work.

Checking leakage (Toilets, W.C., passage).

Height & location of electrical points, switch boards, T.V. & Telephone frames.

Verticality of all door & window frames.

Hold fasting, fixing of doorframes in concrete.

Cleaning of all R.C.C. & masonry surfaces.

‘Khadi maal’ at beam bottom, column & masonry joints.

Chicken mesh fixing at joints of RCC & masonry work.

Watering of surface before one day of plastering.

Level dots (Thiyya) to be marked.

Sand measured by farma.

Silt content of sand (permissible limit).

Arrangement of M.S.chairs and planks.

Extra amenities, if any.

Covering of electrical boxes by dummy plates.

Soaking of sanala ( * if not instant).

AFTER PLASTERING

Fan hook at its position.

Line, level, right angle of plastered area.

Sanala application after 2 hours.

Trowelling the surface on next day for smooth finish.

Sills, column beam edges in plumb.

Cleaning of plastered surface.

Curing for minimum 10 days.

150 mm cutting of plaster in level for fixing skirting.

No sanala application at glazed or ceramic dado positions.

Edges to be made adding cement in sanala.

Cleaning of windows & door frames.

Cleaning floor exposed to slab top.

Finishing ghabadi work.

Provision for window sill fixing.

I.P.S. on loft top.

EXTERNAL PLASTER

Use of measuring farma according to the mix proportion.

Smoothness of concrete surface hacked with tacha.

Water the surface to be plastered one day in advance.

Verticality & stability of the provided scaffolding.

Mark dots (thiyya) before plastering, to ensure minimum specified thickness.

The cement sand mortar between junction of bottom beam & the last layer of
masonry shall be filled well in advance before plastering.

Chicken mesh of minimum 23 cm in width on either side of junction of different

surfaces (junction of masonry to R.C.C.).

3 to 4 days gap between two successive coats for double coat plaster.

Finishing of scaffolding holes properly & immediately.

Verticality of window opening jamb as well as horizontality of its bottom sills and
top to be checked during plastering work.

For parapet wall, leave a margin of 0.4m ht. in plaster at bottom level from
terrace side.

Clean the terrace after plastering work.

Curing the plaster for minimum 15 days.

Plaster checked for its thickness, line , level & plumb.

WATERPROOFING

CHECKLIST FOR ‘BOX TYPE’ WATERPROOFING

Finalise required levels.

Decide grade of mortar.

Mixing of waterproof compound

Ensure thickness of mortar

Ensure thickness of shahabad stone.

Grouting of cement mortar.

Metal grouting in joints.

Check plumb of dado

Proper filling & finishing of joints

Proper curing

CHECKLIST BEFORE WATERPROOFING FOR TOILET

Internal plaster of walls, leaving margin of 450mm from the final floor level be
completed.

Grooving / chasing for concealed G.I. piping / electrical conduit pipe be

completed.

All concealed G.I. & Electrical work in bathroom / toilet be completed.

Removal of all debris from toilet/ bathroom & chiseling of extra mortar, if any, to
expose the slab.

Completion of making holes in external walls for connecting nahani trap, p trap
etc. to external drainage line.

Thorough cleaning of bathroom/ toilet with sufficient quantity of water is done.

Marking levels on walls with respect to floor level.

CHECKLIST FOR ‘BASE COAT’ FOR TOILET / BATHROOM WATERPROOFING

Any leakage in base slab.

Maintain slope of 1:100 from entrance door towards water escape pipe (drainage
pipe) with cement mortar 1:4, thickness 25 mm to 40 mm.

Complete the base coat on walls up to height of 300 mm above toilet finish floor
level covering all beam top junction etc. properly.

Flood the base coat with water, upto slab drop top, for minimum 4 days for curing
& testing of leakage, if any.
Provide 25 mm G.I. / P.V.C. pipe for water escape outlet just above the base coat
of W.C./Bath/Toilet.

CHECKLIST FOR ‘BRICKBAT COBA’ COAT FOR TOILET / BATHROOM

WATERPROOFING

Lay well burnt brick bats, thoroughly soaked in water, on edge and fill the joint
cement mortar in 1:6 proportion with slope of 1:100 ,with waterproofing.

Fill the holes in wall for P.V.C./G.I. pipe connection is filled with waterproofing
coba.

Curing for 4 days & confirm that there is no leakages

CHECKLIST FOR TOPPING COAT FOR TOILET/ BATHROOM WATERPROOFING

Topping with 1:4 cement mortar with waterproofing compound and maintain
proper slope from entrance to nahani trap & finish with neat cement slurry.

Provide curing for minimum 7 days with water. Minimum 7.5 cm depth of water
to be maintained.

CHECKLIST FOR TERRACE WATERPROOFING PREPARATION CHECKS

Remove extra mortar accumulated on terrace and clean the surface clean with
water.

Mix and apply cement slurry on terrace.

Leave sufficient margin (approx. 150mm) w/p from terrace door bottom level.

Mark the levels on parapet wall all round.

Provide rain water pipe outlet bend in correct position.

Make available well burnt brick bats, properly soaked in water.

CHECKLIST FOR BRICKBAT COBA COAT FOR TERRACE WATERPROOFING

Check for levels & proper slope towards, rain water pipe outlet.
Fix the bricks & fill the joints of brick bats with C.M. 1:6 and maintain a slope of
1:150 with waterproofing

Compound.

Proper round shape to the mortar near water pipe.

Curing of brickbat coba for 7 days.

CHECKLIST OF FINAL COAT OF TERRACE WATERPROOFING

Spread the cement mortar of 1:4 proportion along with waterproofing compound
over brick bat coba.

Apply cement slurry over the surface along with waterproofing compound for
smooth finish.

Mark lines on polished surface.

Construct projected edge between the parapet & the watta on the next day.

Clean & cure the final coat atleast 21 days by ponding 150mm high water,
standing on it.

CHECKLIST FOR CHAJJA WATERPROOFING (before plastering work) Ensure &

confirm:

Cleaning the top of the chajja and chiselling out any extra mortar.

Top of chajja applying thick cement slurry.

Metal screen coat 1:1, 1:2,1:3 as specified.

Watta rounding at the junction of chajja & wall.

Curing for atleast 7 days.

CHECKLIST FOR SLOPPING TERRACE WATERPROOFING (before any other

architectural treatment) Ensure & confirm:

Cleaning sloping surface of slab properly.

Making metal screen coat 1:1,1:2 properly.

Applying finishing coat with C.M. 1:4 & water proofing method.

Making edge between parapet wall & sloping slab.

Curing the waterproofing for atleast 15 days.

CHECKLIST FOR PLUMBING

Ensure that all fixtures like bibcocks, mixers etc. are fixed properly.

Confirm that there is no leakage from cocks/ other C.P. fixtures.

Confirm that there is proper pressure to all the cocks / other C.P. fixtures.

Ensure that the half turn flush cock is operating properly.

Ensure that there is not any choke up in W.C. after continuous flow of water from
half turn flush cock.

Confirm that there not any cement lump observed in P-trap of W.C.

Ensure that there is not any choke up of Nahani trap of bath room after
continuous flow of water for five minutes.

Ensure that the hot & cold water mixer is operating properly.

Ensure that the boiler connections are properly plugged .

Ensure that the low level water tank of E.W.C. is operating properly.

Confirm that the seat cover of E.W.C. fixed properly.

Ensure that proper cleaning is done for all sanitary fixtures.

Confirm that the brackets of W.H.B. are painted with oil paint.

Confirm that open G.I. pipes fitting connected to E.W.C.are painted .

W.H.B. is fitted properly. ( It should not shake).

Are there any cracks/ breakages for any of the sanitary fittings.

Confirm that there is no leakage from G.I. lines in duct after continuous water
flow for fifteen minutes.

Confirm that the fixing of G.I. / C.I./ P.V.C. lines in plumb and with proper
clamping.

Confirm that there is no leakage in the drainage chambers.

Confirm that there are no cracks on white cement filled between wash basin and
wall.

Confirm that there is no leakage in the main inlet and outlet G.I. lines or water
tanks.

Ensure that the P.V.C. outlet pipes for wash hand basin and kitchen sink are fixed
properly.

Ensure that the escape spouts from W.C. and bath are provided.

CHECKLIST FOR DOORS & WINDOWS DOORS

Ensure & confirm:

Customer changes if any.

Size & specification of shutter.

Side of opening.

Slots & spacing of hinges.

Frames for plumb & alignment

Lipping provided or not.

Fixtures as per specifications and standard position(heights) of fittings.

Painting or polishing done properly to shutters, lipping etc.

All screws are fitted with screw driver & not hammered.

Clearance from all sides of shutters.

ALUMINUM WINDOWS

Ensure & confirm:

Right angle for the window.

Diagonal of the window

Details of tracks as per drawings

Weight range of sections.

Gap between the window and the walls.

Holes in the tracks are inside or outside.

Operation of the shutters.

Provision of screws to all four sides of windows.

Cleanliness of the track

Covering paper

Sealout filing on gaps.

Thickness of glass.

Quality & defects of glass.

Quality and operation of rollers

Handles and locking system fitted properly.

Intactness of rubber packing all around.

CHECKLIST FOR PAINTING

Internal wall painting Ensure & confirm:

Check that curing period is completed.

Wall has been scrapped for all unwanted material like excess cement, mortar,
nails, dust etc.

The mix and application of donga is done properly.

Donga has been removed completely and wall surface is rubbed by fine grade
paper 120 No.

Mix, preparation and application of primer.

Primer allowed to dry for atleast 24 hours before application of putty.

All the undulations of minor nature, dents, cracks, etc. are filled up with putty and
surface is smooth to receive paint.

Surface has been rubbed with fine paper to get smooth finish after 24 hours of
application of putty.

Mix, preparation and application of first coat of distemper.

The floor has been cleaned immediately and first coat is allowed to dry for atleast
24 hours, before application of successive coat.

Cleaning of the window glass, terrace, floor, pipes, doors, fixtures, electrical
switches etc. has been done properly.

Oil paint
For M.S. Windows, doors, gates, grills & railings etc. Ensure & confirm:

All cement mortar, unwanted welding burr etc. are removed before application of
primer.

Free movement of hinges, working systems before application of primer.

Application of zinc cromite metal primer before application of first coat of oil
paint.
Application of first coat of oil paint.

Application of second coat of oil paint after 24 hours drying of first coat.

Cleaning of the window glass, terrace, floor, pipes, doors, fixtures, electrical
switches etc. has been done properly.

For wooden Doors

The door frames for its line, level, plumb, quality and door shutter for its free
movement, bent, termite attack etc.

Wood primer is applied.

Putty has been filled in all the holes, gaps, depressions, etc. and the surface is
ready to get first coat.

First coat for colour, mix and application.

Application of second coat after 24 hours drying of first coat and application of
putty.

Cleaning of floor and fittings has been done properly.

Cleaning of the window glass, terrace, floor, pipes, doors, fixtures, electrical
switches etc. has been done properly.

EXTERNAL WALL PAINTING (CEMENT PAINT)

Ensure & confirm:

External wall surface is cleaned properly.

All the electrical and plumbing holes are finished properly before the application
of the first coat.

The surface is watered for 12 hours before application of the first coat

The first coat for proper mix, preparation, thickness & finishing of surface.

Curing for 7 days has been done.

Second coat for proper mix, preparation, thickness & finishing of surface.

Cleaning of the window glass, terrace, floor, pipes, doors, fixtures, electrical
switches etc. has been done properly.

CHECKLIST FOR ELECTRICAL WORK

Ensure & confirm:

No. of points in each rooms as per drawing.

Location of the points.

Height of all boards and points as required.

Line, level and alignment of casing caping /switch boards/ light points.

All material is of approved quality and specifications.

Size of boards as per the fixtures on it.

Internal connections in board for phase and neutral distribution is proper.

Colour codes and size of wires used for various points are as specified.

Operation of all the switches for smooth working.

The quality and tightening of all the screws with required spacing and with proper
gripes /rawal plugs.

The earthing connections for its proper working.

The supply of all the points by megger or test lamp and final testing report is
prepared.

The wiring in meter cabinet for quality, colour codes of wires, gauge of wire, main
switches, connections in bus bar etc.

The name of the flat holder painted on concerned meter and main switch.

The size of cables for required capacity.

The main supply for sufficient voltage.

The parking, street lightening and all common supply.

CHECKLIST FOR ELEVATORS (LIFTS)

Ensure & confirm:

Lift pit & shaft size as per lift manufacturer’s specification.

Waterproofing to the lift shaft & top of the machine room slab.

Size of the lift shaft, size of all door openings, floor levels & height of machine
room as per manufacturer’s requirement.

Cleaning of lift pit, shafts & ducts.

All material produced is as per the specification.

Angles and channels drooping in the lift shaft/ duct.

Scaffolding is made in the lift shafts is steady and approved by the lift erector.

Fixing of template.

All the door frames (Except ground floor ) are kept in the plumb line fixed by the
erector.

Rope hole in the bottom slab of machine room & pockets are made in the side
walls for clamping of angles.

Grouting of brackets & its rigidity

Whitewash in the lift shaft.

For the machine room :- I.P.S.Flooring, Ventilation/ exhaust fan, shutter fixing &
painting of machine room.

Angles (rails) fixing and roping.

Machine of the lift is fixed with proper bolting, grouting and anti vibration pads
are fixed below it.

Flooring in the landing is done as per levels fixed previously and slope of the
flooring is always away from the lift.

Button box holes are marked and made properly.

Three-phase meter exclusively for each lift.

All safety arrangement as

a) ladder for pit

b) weld mesh guard to the motor

c) weld mesh guard to the window to avoid entry of the birds.

d) all safety indicators working properly

e) Effective key operations

f) Emergency key operations

g) Instruction plates for the passengers’ guidance

h) Earthing done properly.

While the trial run of the lift that, there are no jerks and sudden stops, floor level
matching to the lift level at all floors.

Ensure about the guarantee period and certification from P.W.D.

CHECKLIST FOR FIREFIGHTING

Ensure & confirm:

The capacity of O.H.W.T. & a separate provision in that tank for fire fighting water
storage.
Other requirements as per Municipal Authorities mentioned in the provisional
N.O.C.

Authorised agency for fire fighting installation work.

Quality of material supplied by the contractor; refer work order.

Civil work like excavation, making holes to the bricks, wall, concrete and
refinishing is done properly as per the requirement of working agency.

Scaffolding fixed in such a way that no work in fire fighting system erection is
disturbed.

Testing done before inspection by Municipal Authorities.

All G.I. / M.S. pipelines for straightness, level, plumb etc. for perfectness.

G.I./M.S line painted in red colour.

All fire Extinguishers are working and are installed at proper locations.

Fire hydrants are easily accessible.

General

Demarcation of road on the layout plan and type of road to be provided.

Distinguish roads, ramps, open parkings areas, pavings etc.

Longitudinal and cross section of the existing ground level with respect to T.B.M.

The layers in foundation (sub base) and base course and thickness of wearing
surface.

The formation level with respect to plinth level of buildings and approach road.

Balancing of cutting and filling.

The longitudinal slope, camber, super elevation etc.

The cross Drains, Service line ducts.

Sub base

Initial ground level.

Excavated final ground level.

Murum filling in layers and rolling by 10 to 12 T roller.

Record final sub grade levels

Base coat

Record initial levels of sub base.

The pipes are laid for cross drain, electrical, drainage, water line and any other
service line.

Soling with stone laid on their edges and chips filled in voids properly.

Width of soling 0.3m more than the width of the road.

Rolling of the road by 10 to 12 T roller.

Record final formation levels.

Bituminous Road (On base course)

Record initial levels.

Spreading the grit as per specification

Proper slope, gradient, camber.

Grouting pattern (semi grout/ full grout) & weight of bitumen per square meter
area.

Spreading of grit when bitumen is hot. Ensure the compaction by rolling.

Final levels.

Tack coat, Carpet & Seal coat (On base course)

Record initial levels.

Weight of bitumen per Sq.meter area.

Mixing of 20 mm & 12 mm, metal with bitumen.

Spreading the mixture in uniform thickness.

Rolling when mix is hot

Same procedure to be adopted for seal coat. (Metal size smaller).

Record final levels.

Provision of speed breakers.

Concrete Road (On base Course)

Initial level of the base course.

Drawing showing lay out of concrete panels, expansion joints, construction joints.

Proper cleaning.

Channel thickness to match concrete thickness.

Grade of concrete/ mix design.

Concreting in alternate bays.

Filler for expansion joints.

Needle vibrator and screed vibrator.

Mechanical trovelling and vacuum dewatering

Broom finish

Curing by ponding

Filling bitumen 25 mm thick and deep, in joints.

Provision for speed breakers.

Paving Blocks (On base Course)

Approved drawing

Levels

Pattern of fixing

Blocks fixed in proper line, level and pattern with compaction.

CHECKLIST FOR STORM WATER SYSTEM

Ensure & confirm:

Approved drawing

Ensure that the storm water drain is not connected to sewage line in any case.

Ensure that no turbulence is created at junctions.

Periodic cleaning/pre monsoon precautions.

CHECKLIST FOR FABRICATION

Ensure & confirm:

The approved drawings, customer changes with N.O.C.

The material for the approved specifications prior to placing the order.

The material as per specifications.

a) Diagonal/Angles b) plumb c) Design d) joints welding e) Grounding of joints

Painting a) primer coat b) paint as per specification

Any damages created during erection, to be rectified.

Final touch ups.

Topics for Quantity Survey Course

1. Land Survey

2. Excavation

3. Backfilling

4. Compaction

5. Rubble Soling

6. Plain Cement Concrete ( PCC)

7. Reinforced Cement Concrete (RCC)

8. Brunt Brick Masonry (BBM)

9. Internal Plaster

10. External Plaster

11. Waterproofing

12. Flooring

13. Door

14. Windows

15. Window Grill and Railing

16. Internal Electrification

17. External Electrification

18. Internal Plumbing

19. External Plumbing

20. Concrete Road

21. Bitumen Road

22. Landscape and Gardening

23. Structural Steel

24. Other Agencies Work like Solar Water System, Fire fighting Work, Gas
Pipeline, CCTV Camera, Video Door Phone, Ventilation System, Garbage Chute,
Lift, Sewage Treatment Plant, Organic Waste Unit, Vermiculture Pit, Children Play
Equipment, Swimming Pool, Etc.

All the Above subject will be cover under this Course, and all topics will be cover
step by step with all information including the procedure of work and details
process to work out the Quantity and Estimation also we are trying to provide the
Checklists of each work.

Some of the above topics may not be cover in 1 session and might need more
than 1 session, suppose Reinforced Cement Concrete (RCC) can not be possible to
cover under one session so we are dividing this topic in the following Session.

The topics are as follows.

1. Footing/Raft

2. Pile

3. Plinth Beam

4. Pile Cap

5. Column

6. Beam

7. Slabs

8. Retaining Wall

9. Shear Wall
10. Mivon System

11. Precast System

12. Conventional System

13. Tremix

14. Concrete Road

This is just an example of how we distribute all the topics to understand easily to
our followers.

We are trying to cover all the topics under the following head's which can be
easily understood to all.

1. Name of Work

2. IS Code No.

3. The drawing needs to read.

4. Location of Work

5. Standard Procedure of Work (Step by Step)

6. Checkpoints

7. Equipment and Machinery

8. Measurement and Quantity Survey

9. Checklist

10. On-site Experience

EXCAVATION WORK

1. Name of Work & Description

Excavation Work is required to prepare the foundation of the building or any

structure on a hard surface. Sometimes we need to excavate hard rock also due
to level difference, or for road, bridges, need to cut the mountain for tunnel or to
prepare roads from the valley.

Before excavation work, we need to find out the SBC (Soil Bearing Capacity) with
the help of SBC we can easily prepare or assume how much excavation will be
done or what is an approximate depth of our structure foundation.

Types of Ground we are founding when excavation is going on.

1. Soft Soil

2. Compacted Soil

3. Soft Murum

4. Hard Murum

5. Soft Rock

6. Hard Rock

7. Shade/ Mud Soil

8. Boulders

2. IS Code No.

IS Code For Excavation Work Code of Safety: IS 3764-1992

IS Code For Sheet Piling Section: IS 2314:1986

IS Code For Scaffolds & Ladders Code of Safety: 3696: 1991

IS Code for Blasting and Related Drilling Work Code of Safety: IS 4081:1986

3. The Drawing Needs to Read.

Excavation work is needed to do before building or any structure foundation.

The following drawing needs to read before excavation work, or before starting to
excavation.

Building Foundation Plan

Bridge Foundation Plan

Plinth Section

Reduced Level Plan

Plot Layout Drawing

4. Location of Work

Excavation can be done with the following Locations.

1. Building Foundation

2. Podium Foundation

3. Basement

4. Under Ground Water Tanks

5. Bridge Foundation

6. Culvert

7. Dam

8. Trench

9. Storm Water Drain

10. Retaining Wall

5. Standard Procedure of Work (Step by Step)

Work Procedure before Start the Excavation

1. Read Plot Layout Drawing Carefully.

2. Read the building foundation Plan and Calculate the building outer to outer
measurement.

3. Read Foundation drawing plan, where Footing and A raft of the building are
outside than building the line.

4. Calculate Outer to outer distance from foundation drawing of building or bridge

structure.

5. Check SBC Report, we need to know what approximate depth of excavation or

hard surface is?

6. If Depth of foundation is up to 1.5m then add 1.5m in foundation outer to

outer distance both sides.

7. If the Depth of foundation is More than 1.5m then add 3.0m in foundation
outer to outer distance both sides.

8. Mark line for excavation as per building outer to outer distance plus 1.5m or
3.0m both sides for foundation workspace.

Example : If Building outer to outer Distance is: 30m X 20m

 Foundation Plan (Footing Size 1.50m X 1.50m ) : 30.00m + 0.75m+0.75m=
31.50m

: 20.00m + 0.75m+0.75m= 21.50m

Foundation Outer to Outer Distance is = 31.50m X 21.50m

Now if Depth of Foundation is 4.0m :

Excavation Size is : 31.50m + 3.0m + 3.0m : 37.50m

: 21.50m + 3.0m + 3.0m : 27.50m

9. Check and Note down actual ground level with the help of Auto Level with the
same interval of 2m to 5m, Take 4 reading of each interval.

Work Procedure during the Excavation

1. Excavate as per Marking

2. Excavate up to desired height as instructed by a designer with the help of the

SBC report.

3. Do not excavate more that limit.

4. Stop when hard strata are shown to responsible peoples.

5. If there is mud or loose soil then us instruction of IS 3764:1992.

6. If excavation is done for a trench or only footing pit then use sheathing with the
help of cleat, strut & Wales for support to soil.

7. Barricade the area after the excavation is completed.

8. Check and Note down excavated area levels with help of Auto level by the
same interval as you have done during taking an actual ground level reading, Take
a minimum of 4 reading of each area.

6. Checkpoints

1. Check Machine Capacity as well as which type of machine is Required.

2. Instruct to machine operator regarding the depth of Excavation as well as the
size and marking of excavation. As well as show the marking line of excavation.

3. Instruct to Operator to prepare the excavation area angle of 45 degrees of

slope.

4. Keep all workers Safe distance from the Machine.

5. If using the breaker to break the rock up to the desired level keep taking
reading and level on time to time to avoid extra excavation than required.

6. After Shown, the hard strata arrange the RCC Designer visit to inspect the SBC.

7. Check the Plinth Level and desired level before complete the excavation.

8. Please check Depth of Soling, PCC, Footing/Raft, and Plinth Beam before
complete the excavation.

For Example: If Plinth Level is Given 0.5m Above GL

Then Calculate Minimum Excavation Depth

Soling for Footing: 0.23m

PCC for Footing: 0.15m

Depth of Footing: 1.00m

Depth of Plinth Beam: 0.6m

Then Minimum Depth of The footing is 1.98m below from GL

If permission is given by RCC Designer then you can keep the plinth
beam and the footing level is the same.

7. Equipment and Machinery

There are two types of excavation is done

1. Manual Excavation

Manual Excavation can be done with the worker by using hand tools like shovels,
etc. but for mass excavation can not be possible manually. It will be too costly and
time consumable.

2. Mechanical Excavation.

With the help of advance technology excavation is made too much easy and cost-
effective as well as time-saving.

The machine is using for excavation

1. Backhoe Loader (JCB)

2. Excavator (Poclian)

3. Mini Excavator (Mini Poclain, Bob-Cat)

4. Air Compressor Breaker

5. Poclain/ JCB Breaker

6. Blasting

7. Tunnel Cutter

8. Hywa: For excavated material Shifting

9. Dumper: For excavated material shifting

10. Tractor : For excavated material shifting

8. Measurement and Quantity Survey

For the Calculation of the excavated area and quantity of excavated material, we
need the following points.

1. Actual Ground Level Reading: Average Level of each interval.

2. Excavated Ground Level Reading: Average level of each interval.

3. Actual Excavated Area: Prepare geometrical shapes as per level interval as we

can find an exact excavated area as well as the depth of excavation.

Depth of Excavation = RL of Actual GL – RL of Excavated GL

Quantity of Excavated Area = Actual Excavated Area X Depth of Excavation

Please prepare the chart as per the picture.

9. Checklist

Excavation Work Checkpoints

1. Mark Exact area of Excavation

2. Keep Working space after excavation

3. The slope at edges is 45 degree

4. The sheathing is done or Not.

5. Barricading is done or not to the excavated area.

6. Heavy equipment, such as excavating machinery and road traffic shall be kept
back from the excavated sides at a distance not less than the depth of trench or at
least 6 m for trench deeper than 6 m.

7.The use of power shovels or draglines in a trench, because of his violent thrust
or blows delivered, rapidly render the banks of the trench unstable and
dangerous to people working nearby. These conditions shall be watched for and
suitably remedied or eliminated.

8. Pathways shall be non-slippery and shall be of adequate width not less than 75
cm. They shall be strong enough to withstand the intended use.

9. Excavation areas shall be adequately lighted for night work.

10. On-site Experience

Readers Experience: in year 2009, we were work at near thane creek. We know
about the ground situation, strata and soil condition also. we started to excavate
building foundation which is only one building of one footing, another building
has a pile foundation. We completed 80% of excavation and guessed to no need
of support to soil or sheathing to side, but we are doing work near to full moon,
and during full moon, seawater level is increasing, and our excavator machine is
parked at same place where excavation is going on, on next day morning we all
has shocked, machine is going under the water. We had tried to out from this
area but the machine is clogged due to mud. After too much struggle we escape
this machine from this area.

Mr. Umesh (Engineer)

BACKFILLING WORK

1. Name of Work & Description

Backfilling Work is required to fill the excavated area of the foundation of the
building or any structure from a hard surface. Sometimes we need to do more
backfilling more than ground level due to increase the height of plinth level, on
infrastructure field backfilling, is most important part because the top level of
road and highways is calculated as per nearest dams or nearest river HFL (Highest
Flood Level).
Before excavation work, we need to find out the material quality of backfilling
work. With some laboratory tests and physical tests.

Types of using of Material for Backfilling Work.

1 Soft Soil

2 Murum (Same Gravels)

3 Murum (Brown Stone Color uniform size)

4 Murum (60-100mm size)

5 Boulders

6 Debris

2. IS Code No.

IS Code For Excavation & Backfilling Work Code of Safety: IS 3764-1992

There is No Specific Code for Backfilling

3. The Drawing Needs to Read.

Backfilling work is need to do after building the foundation completed or after top
level of structure final.

Following drawing need to read before Backfilling work, or before starting to

backfilling.

1 Building Foundation Plan

2 Bridge Foundation Plan

3 Plinth Section

4 Reduced Level Plan

5 Plot Layout Drawing

6 Road Level

7. Road Section

8. Foundation Sectional Drawing

4. Location of Work

Backfilling can be done with the following Locations.

1 Building Foundation

2 Podium Foundation

3 Basement

4 Under Ground Water Tanks

5 Bridge Foundation

6 Culvert

7 Dam
 8 Trench

9 Road

5. Standard Procedure of Work (Step by Step)

Work Procedure before Start the Backfilling

1 Read Plot Layout Drawing Carefully.

2 Calculate Approximate measurement to get the idea of required backfill

material.

3 Read Foundation drawing plan, where Footing and Raft of the building are
outside then building lines.

4 Calculate Outer to outer distance from foundation drawing of building or bridge

structure.

5 Do site visit of Backfill material quarry. Please keep quarry distance nearest
form your site.

6 Finalize material as per your requirement.

7 Finalize the rate as per your budgeted amount for backfilling work.

Work Procedure during the Backfilling

1 Remove all the Material from Pit, or Backfilling Area.

2 Fill loose material with help of machine up to 300mm height.

3 Do not backfill murum more than 300mm.

4 Do not allow boulders in Backfill murum.

5 Do not allow any vegetation/twigs

6 Do not allow keep the boulders near RCC structure, it can be damaged RCC
member.
7 Backfilling must be done by first filling the excavated soils in layers of 300–
500mm and tamping it with a vibrator. Till the desired level. The soil is moistened
up to the optimum moisture content to establish optimum compaction and best
results.

8 Barricade the area backfilling area when machinery is working.

9 Check and Note down backfilled area levels with help of Auto level by the same
interval as you have done during taking an actual ground level reading.

6. Checkpoints

1 Check Machine Capacity as well as which type of machine is Required.

2 Instruct to machine operator regarding the depth of Backfilling Material as well

as the thickness of each layer.

3 Instruct to Operator to compact each layer properly.

4 Compact each layer of the earth not exceeding 200mm.

5 Earth/soil should be free of vegetation/twigs if any.

6 Earth/soil should be free of boulders if any.

7 Rolling should be done with a 5-ton mechanical roller after sprinkling enough
water and core cutter samples taken for every 150sq.m

8 Proceed to the next layer after achieving a minimum of 95 % of MDD(maximum

dry density).

9 Keep all workers Safe distance from Machine.

10 Back the filling must be done by first filling the excavated soils in layers of 30–
50 mm and tamping it with a vibrator. Till the desired level. The soil is moistened
up to the optimum moisture content to establish optimum compaction and best
results.
11 After completion of compaction arrange the architect visit to inspect the level
as per Sections.

Check the Plinth Level and desired level before complete the backfilling, also keep
down the level of backfilling area for Soling, PCC & Flooring, or for Road work
keep the level down for WBM, Tack Coat, Seal Coat Etc.

12 Please check Depth of Soling, PCC, Footing/Raft, and Plinth Beam before
complete the excavation.

For Example: If Plinth Level is Given 1.0m Above GL.

Then Calculate Minimum Backfilling Depth

Soling for Footing: 0.23m

PCC for Footing: 0.15m

Tiling Work : 0.050m

Then Top Level of Compacted Backfilling Area is 0.57m below from

Plinth Level.

7. Equipment and Machinery

There are two types of Backfilling is done

Manual Backfilling
Manual Backfilling can be done with the worker by using hand tools like shovels,
etc. and 250-1000kg The compactor can be used for Compaction, Generally
manual backfilling must be done at the not accessible area for big machines like at
Parking, Under the Building, at Basement, Under the bridge, etc. but for mass
Backfilling can not be possible by manually. It will be too costly and time
consumable.

Mechanical Backfilling.

With the help of advance technology excavation is made too much easy and cost-
effective as well as time-saving.

Following The machine is using for excavation

1 Backhoe Loader (JCB)

2 Excavator (Poklain)

3 Mini Excavator (Mini poclain, Bob-Cat)

4 Mini Compactor

5 Plate Compactor

6 Road Roller

7 Grader

8 Vibro Roller

9 Hywa : For murum Shifting

10 Dumper: For murum shifting

11 Tractor: For murum shifting

12 Water Tanker

13 Dozer
8. Measurement and Quantity Survey

For Calculation of backfilling area and quantity of backfilled material we need the
following points.

1 Excavated ground Level Reading: Average Level of each interval.

2 Backfilled Ground Level Reading: Average level of each interval.

3 Actual backfilled Area: Prepare geometrical shapes as per level interval as we

can find exact backfilled the area as well as the depth of backfilling.

Depth of Backfilling = RL of excavated GL – RL of backfilled GL

Quantity of Backfilled Area = Actual backfilled Area X Depth of Backfilling

Please prepare the chart as per the Excavation work Session.

9. Checklist

Backfilling Work Checkpoints

1 Mark Exact area of Backfilling

2 Keep RCC Structure, Pipe Line, Chambers, Electrical Wire, etc. Safe

3 Compact up to 95 % of MDD(maximum dry density).

4 Use Vibro Roller as per your requirement.

5 Barricading is done when machines are working.

6 Keep exact 300mm Layers to compaction.

7 Heavy equipment, such as backfilling machinery and road traffic shall be kept
back from the excavated sides at a distance not less than the depth of backfilling
or at least 6 m for area deeper then 6 m.

8 The use of power shovels or draglines in a trench, because of his violent thrust
or blows delivered, rapidly renders the banks of the trench unstable and
dangerous to people working nearby. These conditions shall be watched for and
suitably remedied or eliminated.

9 Pathways shall be non-slippery and shall be of adequate width of not less than
75 cm. They shall be strong enough to withstand the intended use.

10 Backfilling areas shall be adequately lighted for night work.

10. On-site Experience

Readers Experience: At an MNC Project the work order is for industrial plant shed
and area of the shed is approximate 30000 Sqft, but movable area and road this
plant plinth area is approximate 72000Sqft and height are approximately 7m from
the existing ground level. Total work completion time is given by the client is 6
months including Monsoon season. And the site location is in the hilly area. But
our bad luck is after cutting of grass and murum backfilling completed up to 2
meters, rain is started, and continuously falling up to more than 40 days. And for
dry this area again give 40 days. But when we have to restart the work, the
murum is not as much dry as we think, at that site we did a lot of work on it, we
removed 2 layers of that murum and refill it. Obviously, the client gives us 90
days extra as well as they understood the exact situation of work.

Mr. Ashok (Sr. Supervisor)

Rate analysis for Back filling Work

Now a day we are releasing all rate analysis series as per our best readers
demands, in last blog we got detailed rate analysis about excavation work. Now in
this blog we are going to get detailed analysis about back filling work.

There are two types of rate analysis, but you are going to study some government
rates, we can found many types of back filling work which are depend on various
types are as follows

1. Back filling Material

There are many types of back filling materials which are using at various types of
sites. In some important projects like Bridges foundations, metro projects
foundations are using crush sand for back filling, on railway track there are using
60-90 mm course aggregates, somewhere 10-20 mm course aggregates are using
for back filling, for earthen dams there is using soil for back filling, and some
projects of roads, embankments of bridges, building foundations, etc. are using
murum. In all world there are commonly using murum for back filling.

2. onsite material

Commonly back filling work is done after excavation work, so therefore lot of
excavated material is stock at site, and lot of times to avoid extra cost to buy
outside material there are using excavated material to back filling, this method is
very commonly using in all over world but sometimes the location of site, type of
excavated material, etc. need to buy outside materials.

3. outside material

In some projects which are located are near creek, near ocean, near sea, near
dam, near river, water land, there are water table is up to 5ft from ground level
and lot of black cotton soil is there so in these cases after excavation there need
to buy outside back filling materials.
4. Distance

When we are going to buy outside material to back filling work there is distance
factor is very affected on the rate of the material.

5. Manual

Sometimes need back filling work manually due to site condition or site location.
Like hilly area, under the building, small building in crowded public place, no
roads for machine travel. Etc.

6. Machine

Now a days we are using all work is done by machine, back filling work is on of
from those, now a days lot of types of mini machines are available which are
going every were on site like under the building. On road work there is lot of work
is done machines.

Now today we are just giving formal information about back filling work. Now we
will analyse the common using rate analysis of back filling work which can give
idea to how to work out the rate analysis.

There are main 2 types of rate analysis which are using commonly in society.

1. Back filling with site material.

2. Back filling with excavated site material.

We are giving just these 2 types of analysis which are very useful to analyse to get
basic knowledge of analysis. After that you can also work on it as per your
material types and distance, etc. as we have given some differentiation factor
above.

1. Back filling with site material.

In given table you can get easily idea about how we can prepare the analysis of
back filling work,

Know the constants required to desired unit to work. He are we are giving you
rate analysis details in Cum only, which are using comely in construction industry
but material procurement unit might be different than out rate analysis unit. You
need to focus on that. If out rate analysis unit is in Cum, but material
procurement unit is Brass, so you need to prepare the rate analysis according to
that and conversion of material constant will be according to it.
2. Back filling with outside material

As we discussed above as why need outside material, but outside material rate is
depend on distance from site. As well as type of material as discussed.

As per basic information from local source and local contractors practice of rate
for distance is considered with mutual understanding and previous business
relations with contractors.
But in general there are using a practice as follows

0-10 km: Rs. 0.00/Cum

10-20 Km: Rs. 20.00/Cum

20-30 Km: Rs. 40.00/Cum

30-50 Km: Rs. 60.00/Cum

But lot of times this is depend on quantity of work, if there is huge quantity of
work, and then there is no one considering this distance factor.

Back filling rate analysis are generally as per given formats but rates are decided
are as per quantity of work, if there is huge quantity of work there will be rate are
decided as per the quantum of work.

Sometimes distance doesn’t matter if regular contractor is working, as well as

sometimes if murum or other quarry material is need to excavate and dump
outside that time lot of contractors are directly meet to this land owner and
directly deal with him with minimum rates, because both peoples need will fulfil
with this procedure. Like if Land Owner wants to do Excavation of a building or
plot and other contractor want to back filling material to his site. I these type o
cases contractor can get god benefits as he can do excavation of this plot as back
filling to another plot but in this work he want heavy machinery like excavator,
hywa, dumper, JCB, compactor, roller, dosser, grader, breaker, etc.

In back filling work Compaction factor also affecting on rates if any clients given to
show the proctor test up to 95% then back filling work need to do very carefully.
The back filling work wants to do in layers in 300 mm to 600 mm thickness. As
well as back filling need to do under observation to avoid the using of boulders or
any other hard materials if using murum. As well as while compaction of murum
need to spray the water on compacted surface and then again need to do
compaction to achieve the 95% proctor test.
If anyone want to do rate analysis follow these processes and take care while
checking the rate of material and labour because it will directly affecting your
budget and may be face the losses.

Plain Cement Concrete

(PCC)
1 Name of Work & Description

PCC (Plain Cement Concrete) : This is a sub-base structure of any foundation to

ease the foundation work like Shuttering, Reinforcement, concreting, etc. PCC
work is required to maintain the bottom level of a foundation in a level. Below
PCC we need to do excavation, cleaning, rubble soling, compaction, plum
concrete, etc. PCC can prevent termites as well as riotous insects, etc. below PCC
we need to do anti-termite treatment, to prevent all insects like Mouse, ant, frog,
etc.

PCC is not a reinforced structure; this is just a part of sub-base structure to work
easily before foundation.

Types of Plain Cement Concrete

1 Cast in situ PCC

2 Ready mix PCC

3 Hand Mix PCC

4 Screeding

5 slab Cushioning

6 Lime Concrete

7 Topping on Slab

8 Plum Concrete

2 IS Code No.

Plain and Reinforced Cement Concrete IS Code: IS456:2000

Code of Practice for laying in-situ Cement Concrete Flooring: IS2571:1970

Methods of tests for aggregate for concrete: IS: 2386

Compressive strength test for cement mortar cubes: IS: 2250

Methods of sampling and analysis of concrete: IS: 1199

Specifications for fine & coarse aggregate from natural sources for concrete: IS:
383

3 The Drawing Needs to Read.

As we discussed earlier PCC is a base structure which not taking the load, so no
separate drawing will be provided by any agency, in all drawing, there is only
mentioned thickness, offset of PCC and grade of concrete.

But sometimes in schedule drawing there are details motioned as well as sizes
and thickness are also given in the schedule. (As per Picture).

Following the drawing needs to study before start PCC Work.

1 Footing Sectional Drawing

2 Plinth Sectional Drawing

3 Layout of Foundation

4 Footing layout and Schedule.

5 Level Drawing.

4 Location of Work

Plain Cement concrete is the mandatory base before starting any foundation, the
following are some locations where we are found PCC Work.

1 PCC below footing

2 PCC below plinth beam

3 PCC below Raft

4 Floor PCC

5 PCC Below Tremix

6 Screeding on Slab

7 Plum Concrete was more level difference in-ground.

5 Standard Procedure of Work (Step by Step)

Following procedures need to follow before start PCC Work.

1 Checking of Excavation Level and Foundation depth, depth of PCC, plinth Level,
etc.

2 Checking of Hard Strata after Excavation.

3 Removal of all loose material.

4 Cleaning of the excavated area before start PCC.

5 Marking of Corner Point with fixing of a rod, and marking of top-level of PCC on
it.

6 Fixing of shuttering ply side as per the size given in drawing, or keep offset to
the foundation at least 150mm to smooth working space.

7 Keep The top-level of PCC is uniform. If the excavated ground is not is level then
do plum concrete after discussing it with the RCC consultant. But keep PCC in
level.

8 Fill Concrete as per the given design mix. Which can be generally given in
drawing is M10 & M15.

9 Keep the thickness of the PCC uniform which is nearing 150mm or 100 mm as
per given in drawing.

10 The next day remove shuttering and regular curing to be done.

11 Now PCC is Ready to Marking of Footing/Foundation and works further
according to drawing.

6 Checkpoints

PCC Checkpoints are as follows

1 Excavation level

2 Plinth Top-level

3 Depth of Foundation

4 Cleaning of Loose Material

5 Marking of Outer size of PCC

6 Shuttering of PCC

7 Thickness of PCC

8 Grade of Concrete

9 Quality of Concrete

10 Curing

7 Equipment and Machinery

Cast in situ PCC required following Material

1 0.5 Bag/1 Bag Manual or semi-automatic Concrete Mixer.

2 Weight batcher

3 Wheel Borrow

4 Shovel & Ghamela

5 Thapi,

6 Line Dori
7 Measurement Tape

7 Auto level and staff.

8 Measurements and Quantity Survey

Plain Cement Concrete is measuring in 2 units as Square Meter and Cubic Meter.

Following are the procedures to take and write the measurements of PCC.

If Size of Footing is 1500mm X1500mm and thickness is given 150mm,

Then we can calculate two types of measurements.

1 Square Meter:

Size of Footing: 1500mm X1500mm

One side length of PCC: (1500mm +150mm (Offset) + 150mm (Offset)): 1800mm

Size of PCC: 1800mm X 1800mm: i.e.:1.800mX1.800m

Area of PCC: 3.240 Square Meters

2 Cubic Meters:

Size of Footing: 1500mm X1500mm

Size of PCC (Including Offset):1800 mm X 1800mm: 1.800mX1.800m

Thickness of PCC: 150mm

Concrete Quantity of Footing PCC: 1.800mX1.800mX0.150: 0.486 Cubic Meters

9 Checklists

Checklist for Plain Cement Concrete is called Pour Card.

1 Excavation Level, Plinth Top Level, Thickness of PCC is Checked.

2 All Loose Material Removed and Cleaned the PCC base surface.
3 Marking is Done including offset to foundation

4 Formwork is cleaned and oiled

5 Formwork free from holes and gaps.

6 Formwork size is as per drawing.

7 Formwork is inline-level and plumb.

Footing PCC

10 Quality Tests

Compression test of Cube

Testing of Cement

Testing of Aggregate

11 On-site Experiences

Importance of Plain Cement Concrete: We executed a industrial renowned

beverages company project, before that we are assuming PCC is not as much
important structure, but after working on this site we understood the importance
of PCC, because there is some cold room made, and we did all the PUF panel
(polyurethane foam) work below concrete, now if you got to visit this site you can
see this normal, but below Tremix we did a lot of work and PCC and trimix are
cushioning to those hidden things.

Mr. Shankar

Plinth Beam

1 Name of Work & Description

RCC (Reinforced Cement Concrete) Plinth Beam: Plinth Beam is a Structural which
is located at Plinth level and shearing a load of structures an transfer it to footing.
Plinth beam is necessary when foundation depth is more than 1m, as well as if
foundation depth is more than 3m, need to design tie beam below plinth beam
level. because Columns are vertical member and they are not capable to bear
vertical load more than 6m, in a column if reinforced steel is not more than 4m,
so need to design tie beam at 3m level and then plinth beam at plinth level.

Generally Size of Plinth beam is 300x600 but it is depend on Design of building or

structure as well as it is depend on location of building and also depend on
structural designer.

Types of Plinth Beam

1 Tie Beam

2 Plinth Beam

2 IS Code No.

Plain and Reinforced Cement Concrete IS Code: IS456:2000

Code of Practice for laying in-situ Cement Concrete Flooring: IS2571:1970

Methods of tests for aggregate for concrete: IS: 2386

Compressive strength test for cement mortar cubes: IS: 2250

Methods of sampling and analysis of concrete: IS: 1199

Specifications for fine & coarse aggregate from natural sources for concrete: IS:
383

3 The Drawing Needs to Read.

Following drawing need to study before start Plinth Beam Work.

1 Footing Sectional Drawing

2 Plinth Beam Sectional Drawing

3 Layout of Foundation

4 Plinth Beam layout and Schedule.

5 Level Drawing.

4 Location of Work

Plinth beam is Located at below plinth level, that mean Plinth beam location is
Below Finish Floor Level, and tie beam location is 1m below ground level.

5 Standard Procedure of Work (Step by Step)

Following procedures need to follow before start Plinth Beam Work.

1 Checking of Excavation Level and Foundation depth, depth of PCC, plinth Beam
Level, etc.

2 Checking of PCC Level

3 Fix the Reinforcement as per schedule drawing.

4 Fixing of shuttering ply side as per the size given in drawing,

5 Keep Top level of plinth beam is uniform.

6 Fill Concrete as per given design mix.

7 On next day remove shuttering and regular curing to be done.

6 Checkpoints

Plinth Beam Checkpoints is as follows

1 Excavation level

2 Plinth Top level

3 Depth of Foundation

4 Cutting of Steel

5 Reinforcement of Steel

6 Shuttering of Plinth Beam

7 Thickness and Size of Plinth beam

8 Grade of Concrete

9 Quality of Concrete

10 Curing

7 Equipments and Machinery

Cast in situ concrete required following Material

1 0.5 Bag/1 Bag Manual or semi automatic Concrete Mixure.

2 Weight batcher

3 Wheel Borrow

4 Shovel & Ghamela

5 Thapi,

6 Line dori

7 Measurement Tape

8 Auto level and staff.

8 Measurements and Quantity Survey

Pinth Beam Concrete is measuring in Cubic Meter and Shuttering is in Square

Meter.

Following are the procedures to take and write the measurements of Plinth Beam.

If Size of Plinth Beam is 300mm X 600mm

Now we need to find out lenght of plinth beam from structural drawing or
architecture drawing, now a days we should we need to found autocad drawing
soft copy of structural drawing, with the help of this drawing we should be
measure length of beam.

Now we need to know about shuttering Quantity

Shuttering Quantity in Square Meter:

Size of Plinth Beam: 300mm X 600mm

length of Plinth Beam: 3m

Shuttering Quantity : 3m x0.6m x 2 Sides = 3.60 Sqm

Area of Shuttering : 3600 Square Meters

Concrete Quantity in Cubic Meters:

Size of Plinth Beam: 300mm X 600mm

Length of Plinth Beam : 3m

Concrete Quantity : 3m x0.3mx0.6 =0.540 Cum

Concrete Quantity of Plinth Beam :0.540 Cubic Meters

9 Checklists

Checklist for Concrete is called Pour Card.

1 Excavation Level, Plinth Top Level is Checked.

2 Steel cutting as per schedule

3 Steel reinforcement is checked and found as per drawing.

4 Formwork is cleaned and oiled

5 Formwork free from holes and gaps.

6 Formwork size is as per drawing.

7 Formwork is in line level and plumb.

10 Quality Tests

Compression test of Cube

Testing of Cement

Testing of Aggregate

11 On-site Experiences

Focous of Dowel bar installation process: we are generally follow typical process
of dowels bar installation process as lot of contractor follow wrong procedure
installation of dowels. they are using Ld(Development Length)+10d+lap lentgh of
bar in footing concrete after completion of footing concreting they are doing
plinth beam work, while plinth beam reinforment work, the steel need to rebend
and start the reinforcement but while rebending of steel there are lot of chances
of minor cracks on steel at bend, or many times steel will cut. so we need to
follow standard procedure as need to pass dowel bars from footing stuttering so
we should keep straight bar in plinth beam.which will be easier than old typical
procedure.

RCC COLUMN WORK

1 Name of Work & Description

RCC (Reinforced Cement Concrete) Column: The vertical Member of any structure
called as Column, Column is a very important member in any structure, this
member is the main load transferring member, from building to the footing. All
RCC Structure need to design RCC Designer, they are calculating all the details
about the load calculation as well as per design the details of reinforcement steel.

Types of Column

1 Column

2 Y Columns

3. Inclined Columns

2 IS Code No.

Plain and Reinforced Cement Concrete IS Code: IS 456:2000

Methods of tests for aggregate for concrete: IS: 2386

Compressive strength test for cement mortar cubes: IS: 2250

Methods of sampling and analysis of concrete: IS: 1199

Specifications for fine & coarse aggregate from natural sources for concrete: IS:
383

3 The Drawing Needs to Read.

Following the drawing needs to study before start Column Work.

1 Column Section Drawing

2 Column Centre Line

3 Layout of Column Position

4 Column and Schedule.

5 Section (Floor to Floor Height)

4 Location of Work

The column is the important part of any structural work, as the column is started
from Footing, Pile cap Foundation.

1 Column is Located at Footing Centre

2 Column is Located at as per centerline drawing on Raft foundation.

3 Each and Every Floor Column Position is Different as per schedule

4 Stub columns on Cantilever Beam

5 Y Shape column is Located to support at cantilever position.

5 Standard Procedure of Work (Step by Step)

Following procedures need to follow before starting the Column Work.

1 Checking Column Centre as per Column Layout Drawing

2 Checking of Column Size as per Drawing

3 Checking of Column Position and alignment as per Drawing

4 Marking of Column Position on Slab, Footing, Beam Etc.

5 Checking of Steel Reinforcement as per schedule.

6 As per Marking of Column Position Fix the Starter properly

7 Fix and Binding of steel as per given schedule to column up to the middle of
next floor as per drawing.

8 Concreting of Starter with given concrete grade with compaction.

9 Fixing the cover block to stirrups of the column and fix the shuttering.

10 Check the Supports of Columns, Size of Column at the top level.

11 Check the Plumb Bob of Column as per Given Drawing.

12 Pour the Concrete as per given concrete grade with proper compaction,
tamping, without disturbing the column position of the column. This may
decenter the column or chances of bulging.

13 The next day remove shuttering and regular curing to be done.

14 The next day needs to hacking the column because after the final setting time
completed hacking can not be more effective after 28 days.
6 Equipment and Machinery

Cast in situ Column Concreting required following Material

1 0.5 Bag/1 Bag Manual or Semi-Automatic Concrete Mixture.

2 Weight batcher

3 Wheel Borrow

4 Shovel & Ghamela

5 Trowel

6 Line Dori

7 Measurement Tape

7 Auto level and staff.

7 Measurements and Quantity Survey

Reinforced Cement Concrete is measuring in Cubic Meter.

Following are the procedures to take and write the measurements of Column
Concreting.

If Size of Column is 600mm X 300mm and Height is given 3000mm (Floor to Floor),

If column height is given 3m Floor to Floor We need to calculate the Beam Depth
which is resting on this column, suppose beam depth is 0.45m Then We need to
cast Column up to 2.55m but standard plywood height is 1.22m X 2.44m i.e. We
can do shuttering of column up to maximum 2.40m height, so we need to
calculate the column concrete requirement as per the required height.

There are 2 points, If you are doing concrete you need to calculate the column
height as per your requirement like if 1st stage of column concreting then column
height need to calculate as per plywood height i.e 2.44m

If you are calculating the all over building quantities you need to calculate the
column height in 2.55m because beam and slab need to consider separately.

1 Cubic Meter:

Size of column: 600mm X 300mm

Height: 2.44m

Concrete Quantity Column: 0.60m X 0.30m X 2.44: 0.439 Cubic Meters

8 Checklists

Checklist for Column Concrete is called Pour Card.

1 Excavation Level, Plinth Top Level, Column Size.

2 All Loose Material Removed and Cleaned the PCC base surface.

3 Marking is Done including offset to foundation

4 Formwork is cleaned and oiled

5 Formwork free from holes and gaps.

6 Formwork size is as per drawing.

7 Formwork is inline-level and plumb.

9 Quality Tests
Compression test of Cube

Testing of Cement

Testing of Aggregate

10 On-site Experiences

The column is the most important structure of any structure but when we actually
execute the work, some of the engineers ignore the importance of this structure,
due to this negligence lot of times may chance to bare huge cost to contractor,
client, and time will require more to do rework if possible.

During the execution of column work, there are 3 steps

1.Reinforcement:

Column shuttering should be checked carefully the checkpoint of the column are
as follows like the diameter of steel, the spacing of bar as well as spacing of
stirrups, link position, and most important part is checking of lap length or if the
lap is not possible need to check coupler joint done properly. After all the
checking needs to check the position of the column as well as the position of a bar
that the mean center is shifted or not. If the center is shifted please take advice
from RCC consultant, do not joggle the bar, this is reducing the life and strength
of the structure. Also, check the cover is placed or not, some covers are inserting
in the bar, some covers are from the external side of the bar. So please check all
the points of column reinforcement and do the actual bar bending schedule to
claim in client bill.

2.Shuttering:

Before shuttering of the column we need to check the quality of plywood, as well
as please check the oil is applied to internal side or not, if not applied please apply
it and the place and fix it as per size, please take precautions while supporting the
column, like supporting by props, fixing of shikanja (MS Shuttering Clamp), anchor
bolt, and tie rods, etc. while checking of column shuttering need to check the size
of the column is proper or not, and line-level with the centerline of column, as
well as most important part is checking of plumb bob of column this check is very
very important to reduce the errors in the decentralization of the column on the
next floor. If you will put 5mm error while checking of column plumb bob, then
next upper floor column will be shift 5mm from its position. So please take proper
precautions while checking the column positions, the same criteria will be
applicable to retaining wall, Pardi, shear wall, etc. internal side should be smooth,
as well as oiled.

3.Concreting:

Before starting the concreting of the column we supposed to all above checks was
done and found clear and rectified if found any error, after that we should make a
proper scaffolding around the column to fill the concrete in it, do not apply more
force of column shuttering because this is a temporary structure and all positions,
size, plumb bob checking has been completed if we apply this more force on the
column shuttering may chance to decentralize the column. This practice is not
good. So please prepare the scaffold to do the concreting of the column. Also
please check the concrete slump cone while concreting. Also, Fill the Concrete
Cube for Compression test after 7 days, 15 days, and 28 days this is very good
practice to know the concrete strength is achieved or not. If possible please keep
a concrete cube near to the same column which is very useful, how may time
actual curing was done to column and cube will know by the strength report.

Mr. Somnath

(Project Co-Ordinator)
 Soling Works

Name of Structure : Date :

Reference Drawings : Location:

Sr. Particulars Yes / No / Remarks

No. N.A.

1 Quality of the available stone acceptable

2 Compaction of the sub base material done
and checked
3 Level of sub base checked
4 Thickness of soling checked
5 Small "Kapchi" stone filled in gaps of laid
stone soling
6 Murum spread over the top of soling,watered
and compacted
7 Top level of the soling checked

Conclusion by Civil4M Representative - Activities Are Satisfactory / Not satisfactory

Contractor's Representative Civil4M Representative

Signature Signature